Dismantling
1. Remove the cylinder head gaskets.
V8 Engine, ENGINE OVERHAUL, Cylinder Head Gasket.
2. Remove the rear crankshaft oil seal.
V8 Engine, ENGINE OVERHAUL, Rear Crankshaft Oil Seal.
3. Remove the lower front timing cover.
V8 Engine, ENGINE OVERHAUL, Lower Timing Belt Cover.
4. Remove the connecting rod bearings.
V8 engine, ENGINE OVERHAUL, Connecting rod bearings.
5. Remove the timing chain from the crankshaft sprocket.
6. Remove the oil pump drive chain from the crankshaft sprocket.
7. Loosen the oil injector mounting bolts and remove the injectors.
8. Push the connecting rods upward so that the piston crowns are level with the top plane of the cylinder block.
Disassembly
1. Remove the 10 main cap bolts with adjustable spacers. Discard the bolts.
2. Remove the 10 bolts securing the main caps to the cylinder block and save them for future use.
3. Using adjustable spacers, loosen and remove the 5 main caps.
NOTE: The locating tabs on the main bearings must be aligned with the slots. Main bearing caps 1 through 3 are marked, main bearing cap 5 has thrust washers. Main bearing cap #4 is not marked.
4. Remove the crankshaft from the cylinder block.
5. Remove the liners from the cylinder block and main caps and dispose of them.
6. Remove the thrust rings.
7. Using a puller, remove the sprocket from the crankshaft.
8. Remove the key from the crankshaft.
Examination
1. Check the color mark on the front cheek of the crankshaft to see if the shaft has been ground to the repair size.
TECHNICAL SPECIFICATIONS, Engine - V8.
2. Measure the diameter of each main journal and record the measurement results. Take 4 measurements at 90° on each main journal to determine the size and out-of-roundness.
TECHNICAL SPECIFICATIONS, Engine - V8.
3. If wear and/or out-of-roundness exceed the permissible values, the main journals must be ground to a repair size.
TECHNICAL SPECIFICATIONS, Engine - V8.
4. Wipe the crankshaft, thoroughly blow out the oil channels.
5. Wipe the main caps and bearing beds in the cylinder block, blow dry the main bolt seats.
6. Wipe the old main bolts and lightly oil their threads.
7. If the crankshaft or main bearings are replaced, regardless of the color coding of the old bearings, use only bearings of the appropriate size with a yellow code.
TECHNICAL SPECIFICATIONS, Engine - V8.
8. Lubricate the bearings with engine oil.
9. Carefully install the crankshaft into the cylinder block.
10. Fully thread the adjustable spacers into the main caps.
11. Install the correct size and color coded main bearings into the main cap.
TECHNICAL SPECIFICATIONS, Engine - V8.
12. Place a strip of deformable gauging material (Plastigage) on the main journal.
13. Install the main caps and screw in the old bolts. Tighten the bolts evenly and sequentially to a torque of 20 N·m, and then, using a protractor torque wrench, tighten the bolts a further 100°.
CAUTION: Do not rotate the crankshaft while using the calibration material.
14. Loosen and remove the main bolts in sequence, remove the main caps and liners.
15. Using a special ruler, measure the width of the calibration strip and, based on this value, determine the gap size on each main journal.
TECHNICAL SPECIFICATIONS, Engine - V8.
16. If the values do not correspond to the permissible values, then you need to select another insert(s) from the size group and repeat the gap measurement.
TECHNICAL SPECIFICATIONS, Engine - V8.
17. Remove the crankshaft and remove all traces of calibration strips from the main journals using clean engine oil and a cloth.
18. Install the bearing shells found to be good into the main caps.
19. Lubricate the main journals and main bearings that have been found to be in good condition with clean engine oil.
20. Install the crankshaft and main caps 1 through 4.
21. Wipe the thrust rings.
22. Lubricate the thrust rings with clean engine oil.
23. Insert the thrust rings found to be of good quality into the cylinder block.
CAUTION: The grooves on the thrust washers must face the crankshaft.
24. Install the thrust rings found to be good into the 5th main cap and install the cap onto the cylinder block.
CAUTION: The grooves on the thrust washers must face the crankshaft.
25. Screw in the old main bolts, tighten the bolts evenly and consistently to a torque of 20 Nm and, using a bevel torque wrench, turn them an additional 100°.
26. Install the indicator with the stand as shown in the figure. If the axial movement of the crankshaft does not correspond to the permissible value, then unscrew the bolts of the 5th main cover and remove the thrust rings.
TECHNICAL SPECIFICATIONS, Engine - V8.
27. Select thrust rings of the required thickness and ensure that the axial movement of the shaft is within the permissible limits.
TECHNICAL SPECIFICATIONS, Engine - V8.
28. Lubricate the thrust rings that have been found to be suitable.
29. Insert the thrust rings found to be of good quality into the cylinder block.
CAUTION: The grooves on the thrust washers must face the crankshaft.
30. Install the thrust rings found to be good into the 5th main cap and install the cap onto the cylinder block.
31. Remove and discard old main cap bolts 1 through 4.
Assembly
1. Screw in new main bolts. Tighten the bolts to 20 Nm, then tighten them an additional 100°.
CAUTION: Do not attempt to remove the special coating from new bolts.
2. Tighten the adjustable spacers to 10 Nm.
3. Screw the new tie bolts through the adjustable spacers and tighten them to 20 Nm and turn them a further 45°.
4. Wipe the crankshaft sprocket and the seating surface on the shaft nose.
5. Wipe the keys and keyways.
6. Install the key into the crankshaft groove.
7. Heat the crankshaft sprocket to at least 150°Celsius and place the sprocket on the shaft.
Assembly
1. Wipe the oil nozzles and mating surfaces.
2. Install the oil injectors and tighten the mounting bolts to a torque of 10 Nm.
3. Install the connecting rod bearings.
V8 engine, ENGINE OVERHAUL, Connecting rod bearings.
4. Wipe the oil pump drive chain
5. Lubricate the oil pump drive chain with clean engine oil.
6. Install the oil pump drive chain onto the crankshaft sprocket.
7. Place the timing chain on the crankshaft sprocket.
8. Install the lower front timing cover.
V8 Engine, ENGINE OVERHAUL, Lower Timing Belt Cover.
9. Install the rear crankshaft oil seal.
V8 Engine, ENGINE OVERHAUL, Rear Crankshaft Oil Seal.
10. Install the cylinder head gaskets.
V8 Engine, ENGINE OVERHAUL, Cylinder Head Gasket.
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