09800-01040 PUMP ASSY, INJECTI Denso Cross

1. Loosen the bolts (2) that hold main bearing caps (1) to cylinder block.2. Install one of the bolts for flywheel in each end of the crankshaft.3. Fasten a hoist and remove the main bearing caps. Remove bearings from bearing caps.4. Remove crankshaft from engine. Weight is 350 lb. (159 kg).5. Remove crankshaft main bearings from cylinder block. If new main bearings are not to be installed, keep old bearings with identification as to their location in cylinder block. 6. Use tooling (A) to remove crankshaft outer gear. Use a hammer and a chisel to remove spacer. 7. Use tooling (B) to remove dowel.8. Use tooling (A) to remove crankshaft inner gear.Install Crankshaft
1. Heat the crankshaft gears to a maximum temperature of 400°F (204°C). 2. The centerline of inner gear key way must be in alignment with the centerline of the dowel hole within .020 in. (0.51 mm). Install crankshaft inner gear (2) on the crankshaft.3. Install the spacer on the crankshaft.4. Install the dowel in the crankshaft. The dowel must be extended no more than .19 in. (4.83 mm) from the surface of the crankshaft. The dowel in the crankshaft must be in alignment with the notch in crankshaft gear (1).5. Make sure the "V" mark on the crankshaft gear is toward the outside and install crankshaft gear (1).6. Clean the cylinder block and main bearing caps thoroughly. Install the bearings dry when the clearance checks are made. Put clean engine oil on the bearings for final assembly. 7. Install upper half of main bearings (3) in the block.8. Install one bolt for flywheel on each end of crankshaft.9. Fasten a hoist and put crankshaft in position in block. Be sure the "V" mark on the crankshaft gear is in alignment with "V" mark on the idler gear. The "K" marks on the camshaft gear can be seen at the outer edges of the idler gear when the timing gears are in the correct position.10. Install main bearings in bearing caps. Be sure the tabs (4) on back of bearings fit in the grooves of caps and cylinder block.11. Use Plastigate (B) to check bearing clearance.12. Put Plastigage (B) on the bearing.
Be sure main bearing caps (5) are installed so the numbers on the side of the cylinder block are the same as the numbers on the bearing caps, and the arrows on the caps are toward the front of the cylinder block.
When the bearing clearance is checked and the engine is in a vertical position, such as in the vehicle, the crankshaft will have to be lifted up with a force equal to the weight of the crankshaft and held against the upper halves of the main bearings to get a correct measurement with Plastigage (B). The Plastigage will not hold the weight of the crankshaft and give a correct indication. If the engine is in a horizontal position, such as on an engine stand, it is not necessary to hold the crankshaft up. Do