CRANKCASE REMOVAL CRANKCASE 1. If required, matchmark position, and remove cil tubes from ‘the front of Figure 2.05-61). the crankcase (see Figure 2.05-61. Oil Tubes NOTE: A collet type stud driver grips the threads of the studs. This will prevent scratching and gouging of the studs, causing weak spots to be created. 2. Using a collet type stud driver, remove the main bearing studs from the crankcase (see Figure 2.05-62) = — FRONT MAIN rte BEARING SADDLE ye \ IDLER GEAR, os t See MAIN BEARING go” MANSTUDS SPINDLENUTS eS Figure 2.05-62. Crankease — Inside Front NOTE: The idler gear spindle nut is a left-hand thread. The idler gear spindie is a shrink fit o the crankcase. 3. If required, remove the nut and washer trom the idler gear spindles. A WARNING Heated parts can cause serious burns. Use caution when heating parts to prevent severe personal injury or death. Use caution when heat- A CAUTION | ing ie aren around tne Idler gear spindles. Applying tao much heat could cause damage to the crankcase or idler gear spindle. 4, Apply heat to the area around the idler gear spindle. 5, Remove the idler gear spindles from the crankcase. 6. Remove five capscrews, lock washers and upper retainer plate from crankcase, 7. Remove the wick type seal from retainer plate (see Figure 2,05-63) 2 UPreR RETAINER ieee Bore Figure 2.05-63. Upper Retainer Plate CRANKSHAFT NO. 1 MAIN BEARING REMOVAL IN FIELD CONDITIONS NOTE: This procedure applies to the No. 1 main bearing with current "T” Drilled crankshaft. Procedures for the remaining main bearings are similar, with the exception that Steps to remove the oil pump, of pickup screen and cil pump drive gear, do not apply. Refer to Main Bearing, Removal for procedures to remove the other main bearings. Refer to Service Bulletin 5-2326D for all previous crankshaft and bearing configurations. 205-24 FORM 6248 Frei EaiionCRANKCASE REMOVAL A WARNING Each main bearing cap weighs 46 Ibs. (21 kg). The bearing must be supported from underneath while removing or installing to avoid severe personal injury or death, A. CAUTION | 2enetsutiecttne crank shaft to any excessive ‘bending or flexing. Keep high heat sources, such as. cutting torches and welders, away from the crank- shaft, use care during handling, prevent scratching or marring the machined surfaces, especially the rod and main bearing journals. Disregarding this information could result in product damage. ‘A. CAUTION J Te main bearings con- LMa LAVIN sist of two half shells, fitted in the bearing saddle and bearing cap, respectively. The shells are precision machined. Do not file the joint faces, and do not scrape the running layer in any way. Disregarding this informa- tion could result in product damage. [_& WARNING L___ A WARNING | ‘Tho crankshaft weighs 1828 bs. (22949) foprovide ihe cramkanaft ith adequate suppor, never re- move more than two malnbearing cops atthe same foe the only ‘axcaption to tie Te when the Crankshattferemoved tomthe crankcase andboth tre properly supported wih adequate Itng de- tices, Failure te take adequate preceutlone. can reeult in severe personal injury of death, NOTE: The oil pan doors should afready be of. I not, remove the doors adjacent to the main bearing fo be replaced, 1. Refer to Chapter 5, and remove the oil pump assembly. A CAUTION] 22,721 leave an unat- tached oil pickup screen beneath any rod journals if the engine is to be barred over. Disregarding this information could result in product damage. 2. Refer to Chapter, and remove the oil pickup screen, from the oil sump. 3. Remove the two cross tie bolts from the No. 1 main bearing (see Figure 2.05-64) Figure 2.05-64. Cross Tie Bolts 4, Loosen the four lock nuts on the bottom of the bearing cap (see Figure 2.05-65) INSTALL EVE § SCREW (FOR REMOVAL) ° WN MARSDEN NUT acai Figure 2.05-65. No. 1 Main Bearing 6. To assist in the removal, install an eye screw in the center dling of the No.1 main bearing cap (see Figure 2.05-65) 6. Protect the idler gear by placing a block of wood under the oil pump idler gear so that when the bearing ‘cap and oil pump gear drop down, the gear will rest on the block of wood, 7. Carefully pry with pipe in eye screw to loosen cap (See Figure 2.05-65), Mark thrust bearing position 8. Using a socket to secure the oil pump bolt, remove the self-locking marsden nut and washer from the spindle (see Figure 2.05-65). 9. Remove the oil pump bolt and washer from the oil pump gear. FORM 6246 First Eaton 205-25CRANKCASE REMOVAL 10. Mark the gear spindle front side and remove the spindle through the oil pump opening, 11. While supporting the lower bearing cap, remove the four lock nuts and washers from the lower bearing cap. 12. Slide the cap out from under the studs. A. CAUTION | 7: eve screw is not required for installation, ‘The eye screw must be removed from the bearing cap prior to installation, or damage to equipment will result, 13. Remove the eye scrow from the bearing cap. 14. Mark the position of the thrust bearings f they are to be reused. Watch forthe position of Ay CAUTION |e per besrng rg Before rolling out the upper bearing, The bearing must be roled in the proper direction the tang accidently rolled through the upper bearing seat, damage tothe seat and crankshatt wil result. 15. Using a bearing rollout tool (P/N 494366), roll out the upper main bearing and thrust bearing (see Figure 2.05-66). Tag them for identification, " mate (LO ou BEARING ROLLOUT TOOL, FRONT MAIN BEARING SADDLE COUNTERWEIGHT. LOCATING TANG’ Figure 2.05-66. Bearing Rollout 16. Inspect the roll pins on the front of the bearing cap, insure that the split of the roll pins is assembled as shown (see Figure 2.05-67). 17. Thoroughly clean all parts as required. FOLL PINS AND HOLES IN CAP MUST BE CLEANED BEFORE ‘ASSEMBLING ROLL PINS “ik 0.180 =0.015" (47752 0.381 mm) ‘BOTH SIDES. MAIN BEARING CAP 12 CYL ~ FRONT. SPLIT OF ROLL PING (4) TBE ‘ASSEMBLED AS SHOWN. Figure 2.05-67. Roll Pin Installation 205-25 FORM 6248 Fist EaionCRANKCASE REMOVAL CRANKSHAFT NO. 1 MAIN BEARING INSTALLATION IN FIELD CONDITIONS NOTE: This procedure applies to the No. 1 main bearing with current "T" Drilled crankshatt. Procedures forall other main bearings are similar, with the exception that steps to remove the oll pump, ollpickup screen and il pump dive gear, do not apply, Refer to Main Bearing, Installation, for procedures to remove the other main bearings, Refer to Service Bulletin 5-2228D for all previous crankshaft and bearing configurations. ‘Thrust bearings come in Ay CAUTION | itched sets. Always install the thrust bearings in the same position. Failure to install thrust bearings in the correct, position can cause damage to equipment. 1. Lubricate the running side of the upper main bearing shell B. CAUTION | 2th 12° the position ot L@& VAY TION | the upper bearing tang before rolling in the upper bearing. The bearing must be rolled in the proper direction. If the tang is accidently rolled through the upper bearing seat, damage to the bearing seat and crankshaft will result. 2. Using the bearing rollout tool (P/N 494366) (see Figure 2.05-66), install the upper bearing shell (grooved ‘with elongated oil hole) and thrust bearing (Grease the thrust bearing to help hold it in place}. Insure the ungrooved By CAUTION | oer bonring shells installed on the bearing cap. Failure to follow proper procedures could cause damage to equip- ‘ment. 3. Lubricate the running surtace of the lower bearing, 4, Apply a small amount of grease to the thrust bearing roll pins (see Figure 2,05-68) to help hold the thrust bearing on the bearing cap. Figure 2.05-68, No. 1 Main Bearing Cap 5, Install the lower bearing shell and and thrust bearing on the bearing cap (see Figure 2.05-66). A WARNING Each main bearing cap weighs 46 Ibs. (21 kg). The bearing must be supported from underneath while removing or installing to avoid severe personal jury or death. NOTE: Each main bearing cap is matched to a main bearing saddle. Check the stamped number on the bearing cap before installing the cap (see Figure 2,05-69). Figure 2.05-69. Main Bearing Cap Stamped Identification Numbers. 6. Place the bearing cap on 2 inch x 6 inch (51 x 152 mm) ‘wood blocks on edge, with the bearing cap just started on the studs, FORM 6248 Fis Eaion 205-27CRANKCASE REMOVAL 7. Refer to reference mark on the oll pump gear and install the gear on the lower main bearing cap with outer washer, oll pump bolt, inner washer and self-locking ‘marsden nut (see Figure 2.05-70). Torque the nut to 175 ft-lb (287N-m), 11, Torque the bearing cap in the proper sequence listed below (see Figure 2.05-71): LEFT SIDE OF ENGINE 3 OIL PUMP GEAR FRONT. WASHER IDLER GEAR ei ‘SPINDLE | capscrew Figure 2.05-70, Oil Pump Gear Assembly 8. Generously apply engine oil to main bearing cap studs, nuts and washers before installing them. 9. Apply 3M Scotch-Grip” 847, Rubber and Gasket ‘Adhesive, to both sides of each cross tie bolt washer to prevent oil leaks. Install one washer on each cross tie bot. 10. Install the main bearing cap with the four washers, lock nuts, cross tie bolts and washers (see Figure 2.05-64 and Figure 2.05-65) FRONT OF ENGINE Figure 2.05-71. Main Bearing Cap Tightening/Torquing Pattern - As Viewed From Underside Of Crankease ‘+ Torque the bearing cap nuts one through four (in that order) to 75 ft-lb (102.N-m). Ifinstalling replacement caps that will be align bored, torque to only 30 ft-lb (40 N-m). When installing more than one cap, torque uts one through four to 75 ft-lb (102 N-m) on all caps before torquing side bolts ‘+ Torque all left side bolts (five) to 260 fb (339 Nm) starting from the front af the engine, ‘© Torque allright side bolts (six) to 250 ft-lo (339 Nm) starting from the front of the engine. + Torque nuts one through four to 275 ttib (373 Nem) to ‘wo steps: first 175 fib (287 Nim), and then 275 ftlb (373 Nm). 12. Check the crankshaft for free rotation after the bearing cap is torqued. 13. Refer to Chapter § and install the oil pump assembly. 14, Refer to Chapter 5 and install the oil pickup screen 20528 FOR 6246 Fist EatonCRANKCASE REMOVAL CRANKSHAFT MAIN BEARINGS REMOVAL IN FIELD CONDITIONS NOTE: This procedure applies to the main bearings ‘with current “T" Drilled crankshaft, with the exception of the No. 1 Main bearing. For procedures for the No. 1 ‘main bearing refer to Crankshaft, No, 1 Main Bearing, Removal In Field Conditions, A WARNING Each main bearing cap weighs 46 Ibs. (21 kg). The bearing must be supported from underneath while removing or installing to avoid severe personal injury or death. — A. CAUTION | 2enetsubiectine crank. [M& LAU TION | shatt to any excessive bending or flexing. Keep high heat sources, such as cutting torches and welders, away from the crank- shaft. use care during handling. prevent scratching or marring the machined surfaces, especially the tod and main bearing journals. Disregarding th information could result in product damage A CAUTION] Te 22 bearings con- sist of two half shells, fitted in the bearing saddle and bearing cap, respectively. The shells are precision machined. Do not file the joint faces, and do not scrape the running layer in any way. Disregarding this informa- tion could result in product damage A WARNING ‘The crankshaft weighs 1828 Ibs. (829 kg). to provide the crankshaft with adequate support, never re- move more than two main bearing caps at the same time. the only exception to this is when the crankshaft is removed from the crankcase and both are properly supported with adequate lifting de- vices. Failure to take adequate precautions can result in severe personal injury or death. NOTE: The oil pan doors should already be off. I not, remove the doors adjacent to the main bearing to be replaced. 1. Remove the two crosstie bolts from the main bearing (see Figure 2.05-64) 2. Loosen the four lock nuts (see Figure 2.05-72) on the bottom of the bearing cap WASHERS ™ | (stat eve screw | Ba (eon REMOVAL) Figure 2.05-72. Main Bearing 3. To assist in the removal, install an eye screw in the center filing of the main bearing cap (see Figure 2.05-72}, 4. Carefully pry with pipe in eye screw to loosen cap, A WARNING Each main bearing cap weighs 46 Ibs. (21 kg). The bearing must be supported from underneath while removing or installing avoid severe personal injury. 5. While supporting the lower main bearing cap, remove the four lock nuts and washers from the lower bearing cap (see Figure 2.05-72}, NOTE: Do not handle the bearing running surfaces with bare hands, 6. Slide the main bearing cap and lower bearing shell ut from under the studs, [AR CAUTION] The 272 s2r0m is not A CAUTION | ied tor instanton ‘The eye screw must be removed from the bearing cap prior to installation, or damage to equipment will result, 7. Remove the eye screw from the main bearing cap. [A CAUTION | "2" 10° the position of the upper bearing tang before rolling out the upper bearing. The bearing ‘must be rolled in the proper direction. If the tang is accidently rolled through the upper bearing seat, damage to the bearing seat and crankshaft will result. FORM 6248 Fret Eaton 205-28CRANKCASE REMOVAL 8, Usinga bearing rollout tool, rollout the upper bearing shell (see Figure 2.05-73), ‘BEARING SHELL \ mamseannc \J © Ko ‘SOURNAL BEARING ROLLOUT TOOL, ero © T s BEARING SADDLE ! COUNTERWEIGHT LOCATING TANG’ Figure 2.05-73. Bearing Rollout 9. Thoroughly clean all parts as required. CRANKSHAFT MAIN BEARINGS INSTALLATION IN FIELD CONDITIONS NOTE: This procedure applies to the main bearings with current "T” Drilled crankshatt, with the exception of the No. 1 Main bearing. For procedures for the No. 1 main bearing refer to Crankshatt, No. 1 Main Bearing, Installation In Field Conditions. 1. Lubricate the running side of the upper main bearing shell Zi. CAUTION | Wath tor the position of the upper bearing tang before rolling in the upper bearing. The bearing must be rolled in the proper direction. If the tang is accidently rolled through the upper bearing seat, damage to the bearing seat and crankshaft will result. 2. Using the bearing rollout tool, install the upper bearing shell (grooved with elongated oil hole) (see Figure 2,05-73). 3. Lubricate the running surface of the lower bearing shell A CAUTION] 222 the ungrooved lower bearing shell is installed on the bearing cap. Failure to follow proper procedures could cause damage to equip- ment. 4. Install the lower bearing shell on the main bearing cap. A WARNING Each main bearing cap weighs 46 Ibs. (21 kg). The bearing must be supported from underneath whi removing or installing to avoid severe personal injury or death. NOTE: Each main bearing cap is matched to a main bearing saddle, Check the stamped number on the bearing cap before installing the cap (see Figure 2.05-74), Figure 2.05-74. Main Bearing Cap Stamped dentition Numbers 5. Place the beating cap on 2 inch x 6 inch (51 x 152.mm) wood blacks on edge, with the bearing cap just started on the studs. 6. Apply 3M Scotch-Grip"” 847, Rubber and Gasket Adhesive, to both sides of each cross tie bolt washer to prevent cil leaks, Install one washer on each cross tie bolt 20530 FOR 6288 Fist EditonCRANKCASE REMOVAL 7. Install the main bearing cap with the four washers, lock nuts, Figure 2.05-75), Figure 2.05-75. Cross Tie Bolts 8. Torque the bearing cap in the proper sequence listed below (see Figure 2.05-76) ‘LEFT SIDE OF ENGINE LOCATING DOWEL. FRONT OF ENGINE Figure 2.05-76. Main Bearing Cap Tightening/Torquing Pattern ~ As Viewed From Underside Of Crankcase ++ Torque the bearing cap nuts one through four (inthat order) to 75 tt-1b (102 Nim). If installing replacement caps that will be align bored, torque to only 30 ft-lb (40 N-m). When installing more than one cap, torque nuts one through four to 75 ft-lb (102 Nem) on all caps before torquing side bolts, ‘+ Torque all left side bolts (five) to 250 tt1b (839 Nim) starting from the front of the engine. cross tie bolts and washers (see ‘© Torque all right side bolts (six) to 260 ft-lb (339 Nm) starting from the front of the engine. ‘Torque nuts one through four to 275 fib (373 Nm) to {wo steps: first 175 fb (237 Nm), and then 275 ttl (373. Nm) 9. Check the crankshaft for free rotation after each bearing cap is torqued. CAMSHAFT BEARING REMOVAL IN FIELD CONDITIONS NOTE: Replace one bearing ata time. 1. Remove the capserews and lock washers from the bearing cap (see Figure 2.05-77), cau Reick) BEARING CAP». | F | CAMSHAFT. Figure 2.05-77. Cam Bearing Cap 2, Remove the bearing cap and upper bearing shell 3. Remove and discard the O-ring from the cam bearing cap. A. CAUTION] Te camshatt bearings consist of two half ‘shells, fitted in the bearing saddle and bearing cap, respectively. The shells are precision machined. Do not file the joint faces, and do not scrape the running layer in any way. Disregarding this informa- tion could result in product damage. Za CAUTION | "2c 12 the position ot the lower bearing tang before rolling out the lower bearing. The bearing ‘must be rolled in the proper direction. If the tang is accidently rolled through the lower bearing seat, ‘damage to the bearing seat and camshaft will result. 4, Using the proper bearing rollout tool, P/N 474001 carefully roll out the lower camshaft bearing in the proper direction. 205-31CRANKCASE REMOVAL CAMSHAFT BEARING INSTALLATION IN FIELD CONDITIONS A. CAUTION | W2tsh 2° the position of the lower bearing tang before rolling in the lower bearing. The bearing ‘must be rolled in the proper direction. If the tang is accidently rolled through the lower bearing seat, ‘damage to the bearing seat and camshaft will result. 1. Lubricate the bearing shells. 2. Using the bearing rollout tool, P/N 474001, carefully rollin the lower bearing shell, 3. Install a new O-ring in the bearing cap. 4, Install the bearing cap and upper bearing shell, with the ferry head capscrews and lock washers. 5. Refer to Chapter 4 for procedures on replacing the valve lifter cover. Tee FORW 6268 Fis Eaton