77
Repair instructions
12
Install a new rear crankshaft seal. Please refer to
items 2 and 3 in the “Crankshaft seal, rear” method
on page 83.
13
Clean the mating surface of the flywheel against the
crankshaft flange and install the flywheel. Torque the
screws to 190 ±10 Nm (19 ± 1.0 kpm).
14
Install the timing gear cover with a new string of seal-
ant. Please refer to the “Application of sealant, timing
gear cover” method on page 66.
15
Install the polygon hub, torsional damper and crank-
case pulley. Please refer to the “Polygon hub, instal-
lation” method on page 67.
16
Install the big end bearing caps, be careful with the
markings.
The markings specify the location of each bearing
cap.
17
Torque the bearing cap screws to 190 ±10 Nm
(19 ±1.0 kpm).
18
Install the sump and tighten the screws.
Please refer to the tightening sequence for each
engine in “Technical Data” in the workshop manual,
under the “Tightening torque” heading.
19
Check the injector settings and adjust if necessary.
Big end bearing replacement
(Crankshaft not removed)
Preparatory work
l
Drain or pump out the engine oil.
l
Remove the sump.
l
Remove the supply and suction pipes for the oil
pump, plus the baffle.
l
Remove the injectors, to make it easier to crank
the engine.
1
Turn the crankshaft round until the bearing caps for
cylinders 1 and 6 come into the positions where the
screws can be removed.
2
Remove the bearing caps for con rods 1 and 6.
NOTE! Make sure that you do not mix up bearing
caps nos. 1 and 6.
3
Remove the bearing shells and clean the bearing lo-
cations in the con rods and bearing caps.
4
Check the bearing journals and bearing shells for
damage.
If the bearing shells have seized, the reason must be
investigated before new bearing shells are installed.
5
Check measure the bearing journals with a microme-
ter which covers the range of 50–75 mm.
Max permitted ovality 0.08 mm
Max permitted taper 0.05 mm.
If any values exceed the permitted limits, the crank-
shaft must be removed and repaired.
NOTE! Check “Technical Data” in the workshop
manual to see whether the crankshaft journals have
standard or underdimensions.
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