Page 1969 of 5267

Camshaft Bushing/Bores
Camshaft bores No. 2–7do notuse a bushing.
1. Inspect the camshaft bushing and bores for signs
of excessive wear.
2. Measure the camshaft bushing and bores with a
telescoping bore gauge and micrometer. If out of
specification, (Refer to 9 - ENGINE/ENGINE
BLOCK/CAMSHAFT & BEARINGS (IN BLOCK) -
REMOVAL).
3. Inspect the camshaft bushing (1) oil holes for align-
ment with cylinder block.
Camshaft Gear
Inspect the camshaft gear for cracks (gear and hub), and chipped/broken/fretted teeth. If replacement is necessary,
camshaft and gear are replaced as an assembly. (Refer to 9 - ENGINE/ENGINE BLOCK/CAMSHAFT & BEARINGS
(IN BLOCK) - REMOVAL).
Thrust Plate
CAMSHAFT THRUST PLATE THICKNESS CHART
MIN. 9.34 mm (0.368 in.)
MAX. 9.60 mm (0.378 in.)
Inspect the camshaft thrust plate for excessive wear in the camshaft contact area. Measure thrust plate thickness
using the CAMSHAFT THRUST PLATE THICKNESS CHART . Replace any thrust platethat falls outside of these
specifications:
Page 1970 of 5267

INSTALLATION
CAMSHAFT BEARINGS
1. Apply a coating of Loctite640 Adhesive to the
backside of the new bushing. Avoid getting adhe-
sive in the oil hole.
2. Use a universal cam bushing installation tool and
install the front bushing (1) so that it is even with
the front face of the cylinder block. The oil hole
must be aligned. A 3.2 mm (0.128 inch) diameter
rod must be able to pass through the hole.
3. Measure the installed bushings at the front bore.
The minimum inside diameter is 54.083 mm
(2.1293 inch), and the maximum inside diameter is
is 54.147 mm. (2.1318 in.).
CAMSHAFT
1. Lubricate the camshaft bushing and bores with
fresh engine oil or suitable equivalent.
2. Liberally coat the camshaft lobes, journals, and
thrust washer with fresh engine oil or suitable
equivalent.
CAUTION: When installing the camshaft, DO NOT
push it in farther than it will go with the thrust
washer in place.
3. Install the camshaft and thrust plate. Align the tim-
ing marks as shown.
BACKLASH - 0.075 - 0.250 mm (0.003 - 0.010 inch)
CLEARANCE - 0.025 - 0.500 mm (0.001 - 0.020 inch)
4. Install the thrust plate bolts and tighten to 24 Nꞏm (18 ft. lbs.) torque.
5. Measure camshaft back lash and end clearance.
6. Remove the wooden dowel rods and rubber bands from the tappets.
7. Lubricate the push rods with engine oil and install in their original location.Verify that they are seated in the
tappets.
8. Lubricate the valve tips with engine oil and install the crossheads in their original locations.
9. Lubricate the crossheads and push rod sockets with engine oil and install the rocker arms and pedestals in their
original locations. Tighten bolts to 36 Nꞏm (27 ft. lbs.) torque.
10.Verify valve lash adjustment (Refer to 9 - ENGINE/CYLINDER HEAD/INTAKE/EXHAUST VALVES & SEATS
- STANDARD PROCEDURE).
11. Install the cylinder head cover. (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) -
INSTALLATION)
Page 1971 of 5267

12. Install gear housing cover (Refer to 9 - ENGINE/VALVE TIMING/GEAR HOUSING COVER - INSTALLATION).
Install front crankshaft dust seal.
13. Install the crankshaft damper with the speed indicator ring (Refer to 9- ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - INSTALLATION).
14. Install the fan support/hub assembly Refer to (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTALLA-
TION).
15. Install the power steering pump.
16. Install accessory drive belt tensioner. Torque bolt to 43 Nꞏm (32 ft. lbs.).
17. Install the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
18. Install the charge air cooler (with a/c condenser and auxiliary transmission oil cooler, if equipped) and tighten
the mounting bolts to 2 Nꞏm (17 in. lbs.) torque.
19. Connect charge air cooler inlet and outlet pipes. Tighten clamps to 11 Nꞏm (95 in. lbs.) torque.
20. Install the radiator upper support panel.
21. Close radiator petcock and lower the radiator into the engine compartment. Tighten the mounting bolts to 11
Nꞏm (95 in. lbs.) torque.
22. Raise vehicle on hoist.
23. Connect radiator lower hose and install clamp.
24. Connect transmission auxiliary oil cooler lines (if equipped).
25. Lower vehicle.
26. Install the fandrive/shroud assembly. (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTALLATION)
27. Install the coolant recovery and windshield washer fluid reservoirs to the fan shroud.
28. Connect the coolant recovery hose to the radiator filler neck.
29. Add engine coolant (Refer to 7 - COOLING - STANDARD PROCEDURE).
30. Charge A/C system with refrigerant (if A/C equipped) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING - STANDARD PROCEDURE).
31. Connect the battery negative cables.
32. Start engine and check for engine oil and coolant leaks.
Page 1972 of 5267

BEARINGS - CONNECTING ROD
STANDARD PROCEDURE - CONNECTING ROD BEARING AND CRANKSHAFT
JOURNAL CLEARANCE
DESCRIPTION MEASUREMENT
CONNECTING ROD BORE, BEARINGS REMOVED MIN. 72.99 mm (2.874 in.)
MAX. 73.01 mm (2.875 in.)
CONNECTING ROD BORE, BEARINGS INSTALLED MIN. 69.05 mm (2.719 in.)
MAX. 69.10 mm (2.720 in.)
1. Measure the connecting rod bore with bearings
removedand the bolts tightened to 100 Nꞏm (73 ft.
lbs.) torque..
2. Measure the connecting rod bore with the bearings
installedand the bolts tightened to 100 Nꞏm (73 ft.
lbs.) torque.
Measure within 20° arc from each side of the parting
line. Also measure 90° from parting line.
Record the smallest and largest diameter.
Measure the diameter of the rod journal at the location
shown. Calculate the average diameter for each side
of the journal.
Determine minimum bearing clearance by calculating
thedifferancebetweenthesmallestconnectingrod
borediameterwiththebearinginstalledandtheaver-
age diameter for each side of the crankshaft journal.
Determine the maximum bearing clearance by calculating the difference between the largest connecting rod bore
diameter and the average diameter with the bearing installed for each sideof the crankshaft journal.
If the crankshaft is within limits, replace the bearing. If the crankshaftis out of limits, grind the crankshaft to the next
smaller size and use oversize rod bearings.
Page 1973 of 5267

CRANKSHAFT & GEAR
DESCRIPTION
The crankshaft is a forged steel, integrally balanced
unit. It is supported by seven main bearings, with posi-
tion number six designated as the thrust journal. The
crankshaft is held in place by main caps and 12 mm
capscrews. The crankshaft also has internal cross
drillings to supply the connecting rods with engine oil.
REMOVAL - GEAR
1. Remove the gear housing cover. (Refer to 9 - ENGINE/VALVE TIMING/GEAR HOUSING COVER - REMOVAL)
2. Split the gear and remove it from the crankshaft.
INSTALLATION - GEAR
1. Remove all burrs and make sure the gear surface
on the end of the crankshaft is smooth.
2. If removed, install a new alignment pin. Drive the
pin in using a ball- peen hammer, leaving it pro-
truding 1.0 mm (0.039 inch) to 1.5 mm (0.059 inch)
above the crankshaft.
WARNING: WEAR PROTECTIVE GLOVES TO PRE-
VENT INJURY.
CAUTION: DO NOT heat the gear longer than 45
minutes.
3. Heat the crankshaft gear for 45 minutes at a temperature of 149°C (300°F).Do not use torch, gear failure will
occur.
4. Apply a thin coat of lubricant to the nose of the crankshaft.
5. Position the gear with the timing mark out and install it on the crankshaft using the alignment pin. Make sure the
gear contacts the shoulder.
Page 1974 of 5267

BEARINGS - CRANKSHAFT MAIN
STANDARD PROCEDURE - MAIN BEARING CLEARANCE
MAIN BEARING BORE DIAMETER CHART
ITEM MAIN BEARING BORE DIAMETER (MAXIMUM)
BEARINGS INSTALLED 83.106 mm (3.2719 in.)
BEARINGS REMOVED Min 87.983 mm (3.4639 in.)
Max. 88.019 mm (3.4653 in.)
Inspect the main bearing bores for damage or abnormal wear.
1. Remove bearings and measure main bearing bore diameter after torquing main bearing cap bolts to 176 Nꞏm
(130 ft. lbs.).
2. Install the crankshaft main bearings and measure main bearing bore diameter with the main bolts tightened to
176 Nꞏm (130 ft. lbs.) torque.
CRANKSHAFT MAIN JOURNAL DIAMETER CHART
ITEM SPECIFICATION
Minimum diameter 82.962 mm (3.2662 in.)
Maximum diameter 83.013 mm (3.2682 in.)
Maximum out of roundness 0.050 mm (.002 in.)
Maximum taper 0.013 mm (.0005 in.)
Thrust distance (at No.6 position) Min. 0.065 mm (.003 in.)
Max. 0.432 mm (.017 in.)
3. Measure the diameter of the main journal at the locations shown. Calculate the average diameter for each side
of the journal.
Page 1975 of 5267
4. Calculate the main bearing journal to bearing clearance. Maximum clearance is 0.119 mm (0.00475 inch). If the
crankshaft journal is within limits, replace the main bearings. If not within specifications, grind the crankshaft to
next size and use oversize bearings.
5. Measure thrust distance at the No.6 position.
Page 1976 of 5267

SEAL - CRANKSHAFT OIL - FRONT
REMOVAL
1. Disconnect both battery negative cables.
2. Raise vehicle on hoist.
3. Partially drain engine coolant into container suitable for re-use (Refer to 7 - COOLING - STANDARD PROCE-
DURE).
4. Lower vehicle.
5. Remove radiator upper hose.
6. Disconnect coolant recovery bottle hose from radiator filler neck.
7. Disconnect windshield washer pump supply hose and electrical connections and lift washer bottle off of fan
shroud.
8. Remove viscous fan/drive assembly. (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - REMOVAL).
9. Remove cooling fan shroud and fan assembly from the vehicle.
10. Remove the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
11. Remove the cooling fan support/hub from the front of the engine.
12. Raisethevehicleonhoist.
13. Remove the crankshaft damper and speed indicator ring.
14. Remove power steering pump.
15. Remove accessory drive belt tensioner.
16. Remove the gear cover-to-housing bolts and gen-
tly pry the cover away from the housing, taking
care not to mar the gasket surfaces. Remove
crank seal dust shield with cover.
17. Support the cover on a flat work surface with
wooden blocks, and using a suitable punch (1)
and hammer, drive the old seal out of the cover
from the back side of the cover to the front side.