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ZEXEL
105402-1620
1054021620
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105402-1620
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Start By:a. remove cylinder head assemblyb. remove front housing groupc. remove flywheel housingd. remove crankshaft rear seal assemblye. remove piston and connecting rod assemblies 1. Remove bolts (1). Remove main bearing caps (2). Remove thrust bearings (3) from the center main. Main bearing caps are identified by numbers one through seven. Unmarked caps should be marked by stamping the appropriate number toward the right side on the bottom prior to the removal. 2. Install a suitable size bolt in each end of the crankshaft as shown. Fasten two lifting straps (4) to the bolts in the crankshaft and to a hoist as shown. Carefully, remove the crankshaft. The appropriate weight of the crankshaft is 129 kg (285 lb).3. Remove the upper portions of the main bearings. The following steps are for the installation of the crankshaft.
Be sure the main bearing tabs engage with the grooves in the block and cap.
4. Position the upper portion of the main bearings in the cylinder block. Lower the main bearing portion in caps (2). Be sure everything is clean and only the bearing face is lubricated with clean engine oil.5. Fasten a hoist to the crankshaft, and position it in the cylinder block. 6. Install thrust bearings (3).7. Install main bearing caps (2) with the part numbers toward the right hand side of the cylinder block. Take care to ensure the caps are numbered one through seven from the front of the engine. Put clean engine oil or molylube on the bolt threads and the washer face; then install bolts (1). Tighten the bolts on the side where the main bearing tabs are located to a torque of 95 5 N m (70 4 lb ft). Tighten the bolts on the opposite side to a torque of 95 5 N m (70 4 lb ft).8. Put a mark on each bolt head and the bearing caps. Turn the bolts that are opposite the main bearing tabs an additional 90° 5° turn. Then turn the bolts on the side where the main bearing tabs are located an additional 90° 5° turn.
Typical Example9. Use tooling (A) to measure crankshaft end play. The crankshaft end play must be 0.10 to 0.50 mm (.004 to .020 in).End By:a. install piston and connecting rod assembliesb. install crankshaft rear seal assemblyc. install flywheel housingd. install front housing groupe. install cylinder head assembly
Be sure the main bearing tabs engage with the grooves in the block and cap.
4. Position the upper portion of the main bearings in the cylinder block. Lower the main bearing portion in caps (2). Be sure everything is clean and only the bearing face is lubricated with clean engine oil.5. Fasten a hoist to the crankshaft, and position it in the cylinder block. 6. Install thrust bearings (3).7. Install main bearing caps (2) with the part numbers toward the right hand side of the cylinder block. Take care to ensure the caps are numbered one through seven from the front of the engine. Put clean engine oil or molylube on the bolt threads and the washer face; then install bolts (1). Tighten the bolts on the side where the main bearing tabs are located to a torque of 95 5 N m (70 4 lb ft). Tighten the bolts on the opposite side to a torque of 95 5 N m (70 4 lb ft).8. Put a mark on each bolt head and the bearing caps. Turn the bolts that are opposite the main bearing tabs an additional 90° 5° turn. Then turn the bolts on the side where the main bearing tabs are located an additional 90° 5° turn.
Typical Example9. Use tooling (A) to measure crankshaft end play. The crankshaft end play must be 0.10 to 0.50 mm (.004 to .020 in).End By:a. install piston and connecting rod assembliesb. install crankshaft rear seal assemblyc. install flywheel housingd. install front housing groupe. install cylinder head assembly
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105402-1620