JCB 205 Skid Steer Loader Service Repair Manual (From 2473501 To 2473800)

Foreword The Operator's Manual

SERVICE MANUAL

You and others can be killed or seriously injured if you operate or maintain the machine without first studying the Operator's Manual. You must understand and follow the instructions in the Operator's Manual. If you do not understand anything, ask your employer or JCB dealer to explain it.

Do not operate the machine without an Operator's Manual, or if there is anything on the machine you do not understand.

Treat the Operator's Manual as part of the machine.

Keep it clean and in good condition. Replace the Operator's Manual immediately if it is lost, damaged or becomes unreadable.

SKIDSTEER LOADER

135, 155, 175, 190, 205

Contents 01 - Machine 03 - Attachments and Options

EN - 9813/6750 - ISSUE 1 - 04/2016

06 - Body and Framework 09 - Operator Station 12 - Heating, Ventilating Conditioning (HVAC) 15 - Engine 18 - Fuel and Exhaust System 21 - Cooling System 24 - Brakes

This manual contains original instructions, verified by the manufacturer (or their authorized representative).

27 - Driveline 30 - Hydraulic System 33 - Electrical System

Copyright 2016 Š JCB SERVICE All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.

www.jcb.com

72 - Fasteners and Fixings 75 - Consumable Products 78 - After Sales

and

Air-

15 - Engine

00 - General 00 - General

00 - General

Introduction

Introduction ...................................................... 15-3 Health and Safety ........................................... 15-4 Technical Data ................................................. 15-5 Component Identification ................................. 15-6 Operation ......................................................... 15-8 Fault-Finding .................................................. 15-12 Clean ............................................................. 15-22 Check (Leaks) ............................................... 15-23 Check (Pressure) .......................................... 15-24 Remove and Install ....................................... 15-25 Store and Recommission .............................. 15-26

This section contains information about the complete engine assembly. For specific engine technical information refer to the technical data section.

Make sure that the correct engine service tools, consumables and torque figures are used when you perform service procedures.

Replacement of oil seals, gaskets, etc., and any component that show signs of wear or damage, is expected as a matter of course.

It is expected that components will be cleaned and lubricated where required, and that any opened hose or pipe connections will be blanked to prevent excessive loss of hydraulic fluid, engine oil and ingress of dirt.

Basic Description The Perkins 400 series engines are indirect injection engines. The engines are controlled with a mechanically actuated fuel injection pump. The engine cylinders are arranged in-line. The cylinder head assembly has one inlet valve and one exhaust valve for each cylinder. Each cylinder valve has a single valve spring.

The crankshaft for the four cylinder engine has five main bearing journals. End play is controlled by the thrust washers that are located on the rear main bearing.

The timing gears are stamped with timing marks in order to ensure the correct assembly of the gears.

When the No. 1 piston is at top center compression stroke, the teeth that are stamped on the crankshaft gear and the camshaft gear will be in alignment with the idler gear.

The crankshaft gear turns the idler gear which then turns the camshaft gear and the gear for the engine oil pump.

The fuel injection pump is mounted in the crankcase.

The fuel injection pump is operated by lobes on the camshaft. The fuel transfer pump is located on the right hand side of the crankcase. The fuel transfer pump is also operated by lobes on the camshaft.

The fuel injection pump conforms to requirements for emissions. If any adjustments to the fuel injection pump timing and high idle are required you must refer to a Perkins distributor or a Perkins dealer. Some fuel injection pumps have mechanical governors that control the engine rpm. Some fuel injection pumps have a governor that is electrically controlled.

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15 - Engine

00 - General 00 - General

A gerotor oil pump is located in the centre of the idler gear. The engine oil pump sends lubricating oil to the main oil gallery through a pressure relief valve and an engine oil filter. The rocker arms receive pressurized oil through an externally located oil line that runs from the main oil gallery to the cylinder head.

Coolant from the bottom of the radiator passes through the belt driven centrifugal cooling pump. The coolant is cooled by the radiator and the temperature is regulated by a water temperature regulator.

Engine efficiency, efficiency of emission controls, and engine performance depend on adherence to correct operation and maintenance recommendations.

Engine performance and efficiency also depend on the use of recommended fuels, lubrication oils, and coolants. Refer to the Maintenance Schedules (PIL 78-24).

Health and Safety Hot Components Touching hot surfaces can burn skin. The engine and machine components will be hot after the unit has been running. Allow the engine and components to cool before servicing the unit.

Turning the Engine Do not try to turn the engine by pulling the fan or fan belt. This could cause injury or premature component failure.

Notice: The engine and other components could be damaged by high pressure washing systems.

Special precautions must be taken if the machine is to be washed using a high pressure system.Make sure that the alternator, starter motor and any other electrical components are shielded and not directly cleaned by the high pressure cleaning system. Do not aim the water jet directly at bearings, oil seals or the engine air induction system.

WARNING! To bleed the injectors you must turn the engine. When the engine is turning, there are parts rotating in the engine compartment.Before starting this job make sure that you have no loose clothing (cuffs, ties etc) which could get caught in rotating parts.When the engine is turning, keep clear of rotating parts.

Notice: Clean the engine before you start engine maintenance. Obey the correct procedures.

Contamination of the fuel system will cause damage and possible failure of the engine.

Notice: Do not exceed the correct level of engine oil in the sump. If there is too much engine oil, the excess must be drained to the correct level. An excess of engine oil could cause the engine speed to increase rapidly without control.

WARNING! The engine has exposed rotating parts.

Switch off the engine before working in the engine compartment. Do not use the machine with the engine cover open.

WARNING! Hot oil and engine components can burn you. Make sure the engine is cool before doing this job.Used engine crankcase lubricants contain harmful contaminants. In laboratory tests it was shown that used engine oils can cause skin cancer.

Notice: A drive belt that is loose can cause damage to itself and/or other engine parts.

WARNING! Do not open the high pressure fuel system with the engine running. Engine operation causes high fuel pressure. High pressure fuel spray can cause serious injury or death.

CAUTION! It is illegal to pollute drains, sewers or the ground. Clean up all spilt fluids and/or lubricants.Used fluids and/or lubricants, filters and contaminated materials must be disposed of in

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15 - Engine

00 - General 00 - General

accordance with local regulations. Use authorised waste disposal sites.

Technical Data Table 18.

Description Engine type Emission compliance Number of cylinders Nominal bore size Stroke Cylinder arrangement Combustion Cycle Firing order Compression ratio Swept volume Valve clearance (cold) Idling speed

Data GN 404D-22 Tier 3 4 88mm 102mm Vertical In-line 4-stroke 1-3-4-2 23.3:1 2.216L 0.2mm 1400 RPM (Revolutions Per Minute) Maximum no-load speed 2800 RPM Power output 34kW at 2600 RPM

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00 - General 00 - General

Component Identification External The following identifies the main components of a typical engine assembly visible from the exterior.

Some variants may differ in detail.

Figure 90. Front and right side view

B

C

A

M

D L E K

F J H G

A C E G J L

Fuel shutoff solenoid Water pump Throttle lever Engine oil level gauge Engine oil filter Transfer pump

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B D F H K M

Number one fuel injector Lower engine oil filler cap Cover plate for the accessory drive Engine oil cooler Fuel injection pump Fuel filter

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15 - Engine

00 - General 00 - General

Figure 91. Front and left side view Q

P

N

R S T U

V

AD

W X

AC AB

Y Z AA

N Q S U W Y AA AC

Top engine oil filler cap Rear Lifting eye Valve mechanism cover Water temperature regulator housing Electric starting motor Engine oil pan Fan drive belt Coolant temperature switch

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P R T V X Z AB AD

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Crankcase breather Air inlet elbow Turbocharger Starting motor solenoid Alternator Engine oil drain plug Crankshaft pulley Cooling fan

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00 - General 00 - General

Operation The Four Cylinder Cycle

Firing Order

This section describes the cycle sequence for the 4 cylinder engine.

A cylinder is said to be firing, when the fuel/air mixture ignites and the piston is about to start its power stroke.

With the crankshaft positioned as shown, the pistons in numbers 1 and 4 cylinders are at top dead centre and pistons in numbers 2 and 3 cylinders are at bottom dead centre.

It is important to note that number 1 cylinder is firing and about to start its Power stroke. Rotating the crankshaft a further full rotation would position the pistons as described but the engine would be at a different stage in its four stroke cycle, with number 1 cylinder about to start its Induction stroke.

From the stages described, it can be seen that number 1 cylinder will be next to fire. Number 3 cylinder is starting its compression stroke and is next in the cycle, followed by cylinders 4 and 2. The firing order is therefore; 1, 3, 4, 2.

The stages in the four stroke cycle for each cylinder are as follows:

Table 19. The Four Stroke Cycle Cylinder number 1 2 3 4

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Piston operation The piston is at the top of its Compression stroke and is about to start its Power stroke.

The piston is at the bottom of its Power stroke and is about to start its Exhaust stroke.

The piston is at the bottom of its Induction stroke and is about to start its Compression stroke.

The piston is at the top of its Exhaust stroke and is about to start its Induction stroke.

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Valve operation Inlet and exhaust valves closed Inlet valves closed, exhaust valves about to open Exhaust valves closed, inlet valves about to close.

Valve Operation Exhaust valves about to close, inlet valves about to open

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15 - Engine

00 - General 00 - General

CYL1

Figure 92. Typical Four Cylinder Engine CYL2

1

CYL3

CYL4

2

5

A C

B

C G

B

C

B

H

C

B

J

K 4

3

F

745620 745620

G

H

J

K

C

A C

CYL1 CYL3 A C 1 3 5

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B

A B

A

B

C

A

C

B

Cylinder number 1 Cylinder number 3 Camshaft Camshaft lobe - Exhaust valve operation Exhaust valves Crankshaft Camshaft drive gear

CYL2 CYL4 B F 2 4

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Cylinder number 2 Cylinder number 4 Camshaft lobe - Inlet valve operation Front of engine Inlet valves Crankshaft gear

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15 - Engine

00 - General 00 - General

Four Stroke Cycle Induction

The temperature rises to a point at which the fuel/air mixture ignites. A cylinder is said to be firing when the fuel/air mixture ignites.

As the piston travels down the cylinder, it draws filtered air at atmospheric pressure and ambient temperature through an air filter and inlet valves into the cylinder.

This combustion causes a very rapid rise in both temperature and pressure. The high pressure generated propels the piston downwards turning the crankshaft and producing energy.

Compression

Exhaust

When the piston reaches the bottom of its stroke, the inlet valves close. The piston then starts to rise up the cylinder compressing the air trapped in the cylinder.

This causes the temperature and pressure of the air to rise. Fuel is injected into the cylinder when the piston is near to TDC (Top Dead Centre).

Once the piston has reached the bottom of its travel, the exhaust valves open and momentum stored in the flywheel forces the piston up the cylinder expelling the exhaust gases.

Power

In a running engine, these four phases are continuously repeated. Each stroke is half a revolution of the crankshaft, thus, in one cycle of a four stroke engine, the crankshaft revolves twice.

The piston continues to rise after the start of fuel injection, causing a further increase in pressure and temperature.

Figure 93.

3

2

B

C

4

1

746030

1 3 A C TDC

Induction stroke Power stroke Camshaft Camshaft lobe - Exhaust valve operation TDC

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2 4 B BDC

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Compression stroke Exhaust stroke Camshaft lobe - Inlet valve operation Bottom dead centre

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15 - Engine

00 - General 00 - General

Figure 94.

717620

1

2

3

4

B

C

A

C

A

B

A

B

A

C

B

C

1 3 A C

Induction stroke Power stroke Camshaft Camshaft lobe - Exhaust valve operation

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2 Compression stroke 4 Exhaust stroke B Camshaft lobe - Inlet valve operation

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15 - Engine

03 - Crankcase 00 - General

00 - General

Introduction

Introduction .................................................... 15-31 Technical Data ............................................... 15-32 Check (Condition) .......................................... 15-32

The crankcase is the housing for the crankshaft.

The enclosure forms the largest cavity in the engine and is located below the cylinders. It is integral with the cylinder bank and forms an engine block. It has an opening in the bottom to which an oil sump is attached with a gasket and bolted joint.

The crankcase protects the crankshaft and connecting rods from foreign objects it also keeps the engine oil contained and allows the oil to be pressurised and also provide the rigid structure with which to join the engine to the transmission.

Figure 97.

B

A A Crankcase B Crankshaft

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03 - Crankcase 00 - General

Technical Data

Check (Condition)

Table 42. Cylinder bore data Description Diameter of bore Bore service limit Flatness of the top of the cylinder Service limit for the flatness Clearance between the tappet and the tappet bore (Maximum) Clearance between the tappet and the tappet bore (Service limit)

Data 84–84.019mm 84.2mm Less than 0.05mm

1. Check the six positions for flatness with a straight edge and the feeler gauge. Refer to Figure 99.

Figure 99.

B

A

0.12mm 0.058mm C

0.08mm

Figure 98.

3

1 5

A Crankcase B Straight edge C Feeler gauge A

B

2

6

4

2. Inspect the top of the crankcase for cracks, damage and warping.

3. Inspect each cylinder bore.

3.1. Make sure that there are no signs of scoring or corrosion.

A Tappet B Tappet bore

3.2. Measure each cylinder bore with a suitable gauge.

3.3. Measure the area of each cylinder bore that is in contact with the top, middle and bottom piston rings.

3.4. Make sure that you measure each cylinder bore at right angles to the crankshaft.

3.5. Do NOT use the flex-hone process on this engine.

4. Make sure that the cylinder bore dimensions do not exceed the specified service limits. Refer to Technical data (PIL 15-03).

5. If the service limit for the crankcase is exceeded, you must replace the crankcase.

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15 - Engine

06 - Cylinder Head 00 - General

Technical Data

Check (Condition)

Table 43. Cylinder head gasket Piston height below top face of crankcase +0.35mm to +0.5mm +0.5mm to +0.6mm

1. Make the machine safe. Refer to (PIL 01-03).

Gasket Thickness

2. Get access to the engine. Refer to (PIL 06-06).

1.2mm 1.3mm

3. Remove the cylinder head bolts in the reverse numerical order. This will prevent distortion of the cylinder head. Refer to Figure 100.

Table 44. Distortion of the cylinder head Description Distortion of the cylinder head Maximum service limit Maximum limit for regrinding the cylinder head

Figure 100.

Data 0–0.05mm

12

4 8

16

0.12mm 0.15mm

5 1

7

15

11

13 9

2

3

17

10

6

18

14

4. Remove the cylinder head from the engine.

5. Clean the cylinder head thoroughly.

6. Make sure that the contact surface of the cylinder head and the contact surface of the crankcase are clean, smooth and flat.

7. Inspect the bottom surface of the cylinder head for pitting, corrosion and cracks.

8. Inspect the area around the valve seats and the holes for the fuel injectors.

9. Put the cylinder head on a suitable support.

Figure 101.

A

B A Cylinder head B Support 10. Use a straight edge and a feeler gauge to check the six positions for distortion. Refer to Figure 102.

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15 - Engine

06 - Cylinder Head 00 - General

Calibrate

Figure 102.

•

1 4

3 5

6

•

2

The dowel pins in the crankcase hold the cylinder head gasket in the correct position when the cylinder head is installed. Refer to Figure 103.

The stamped marking on the cylinder head gasket must face upward. This makes sure that the cylinder head gasket is installed correctly.

Refer to Figure 103.

Figure 103.

A

•

B

C

A Dowel pins B Gasket C Stamped marking Before you tighten the bolts, apply clean engine oil on the threads of the bolts. The bolts must be tightened to the torque of 101N·m in the specified numerical sequence only. Refer to Figure 104.

Figure 104.

12

4 8

16

11

13

1

7

15

•

5 9

2

3

17

10

18

6

14

Use a straight edge and a feeler gauge to check the six positions for distortion. Refer to Figure 105.

Figure 105.

1 4

3 5

6 2

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15 - Engine

06 - Cylinder Head 00 - General

•

If you grind the cylinder head, check the valve depth below the cylinder head face. Refer to (PIL 15-30).

Remove and Install CAUTION This component is heavy. It must only be removed or handled using a suitable lifting method and device.

Remove 1. Make the machine safe. Refer to (PIL 01-03).

2. Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start the service work.

3. Remove the exhaust manifold. Refer to (PIL 18-24).

4. Remove the fuel filter. Refer to (PIL 18-09).

5. Remove the fuel injectors. Refer to (PIL 18-18).

6. Remove the glow plugs. Refer to (PIL 15-80).

7. Remove the rocker shaft and the push rods.

Refer to (PIL 15-42).

8. Remove the cooling pump. Refer to (PIL 21-09).

9. Drain the cooling system. Refer to (PIL 21-00).

10. Gradually loosen the bolts in reverse numerical order. This will prevent distortion of the cylinder head. Refer to Figure 106.

Figure 106.

12

4

5

8

16

1

7

15

11

13 9

2

3

17

10

6

18

14

11. Remove the bolts from the cylinder head.

12. Carefully lift the cylinder head off the crankcase with a suitable lifting device.

13. Make sure of the following: 13.1.Do not use a lever to separate the cylinder head from the crankcase.

13.2.Take care not to damage the machined surfaces of the cylinder head.

13.3.Avoid contamination of the cylinder bores with coolant or with debris.

13.4.Place the cylinder head on a surface that will not scratch the face of the cylinder head.

14. Remove the cylinder head gasket. Retain the old gasket to help identification.

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15 - Engine

06 - Cylinder Head 00 - General

15. Make a note of the position of the dowels. Do not remove the dowels unless they are damaged.

6. Make sure that the new gasket is of the same thickness as the old gasket.

16. If necessary, remove the thermostat from the cylinder head. Refer to (PIL 21-12).

7. Align the gasket with the guide bolt and the dowels. Install the gasket onto the crankcase.

Figure 107.

8. Lift the cylinder head with a suitable lifting device.

A

9. Align the cylinder head with the guide bolts on the crankcase. Install the cylinder head onto the crankcase.

10. Make sure that the cylinder head is correctly positioned on the dowels.

11. Remove the guide bolts.

12. Install the bolts to the cylinder head.

13. Tighten the bolts to the correct torque value in the specified numerical sequence only. Refer to Figure 106.

B

14. If removed, install the thermostat to the cylinder head. Refer to (PIL 21-12).

15. Install the cooling pump. Refer to (PIL 21-09).

A Bolt B Cylinder head

16. Install the rocker shaft and the push rods. Refer to (PIL 15-42).

Figure 108.

D

C

17. Install the glow plugs. Refer to (PIL 15-80).

18. Install the fuel injectors. Refer to (PIL 18-18).

D C

19. Install the fuel filter. Refer to (PIL 18-09).

20. Install the exhaust manifold. Refer to (PIL 18-24).

Table 45. Torque Values Item A

Description Bolt

Nm 100

C Dowel D Guide bolt (M11 by 100mm)

Install 1. Clean the mating surfaces of the cylinder head and the crankcase.

2. Make sure that no debris enters the cylinder bores, the coolant passages, or the lubricant passages.

3. Inspect the mating surface of the cylinder head for distortion. If the mating surface of the cylinder head is distorted beyond the maximum permitted limits, replace the cylinder head.

4. Inspect dowels for damage. If necessary, replace the dowels in the crankcase.

5. Install the guide bolts to the crankcase.

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15 - Engine

12 - Crankshaft 00 - General

Technical Data

Component Identification Figure 111.

Table 46.

Description

Data Standard 2.95–3mm

Service limit 0.5mm

Thrust washer thickness Crankshaft end 0.1–0.3mm play •

0.5mm

Make sure that the oil grooves of all of the thrust washers are toward the crankshaft.

Figure 109.

B

B

A

D

A A Crankcase B Crankshaft

C

•

A Crankshaft B Main bearing holder bolt C Thrust washer D Top thrust washer If the crankshaft end play exceeds the service limit, check the thrust washers for wear.

Figure 110.

F E

A A Crankshaft E Allen head screw F Retaining bolt Table 47. Torque Values Item B E F 15 - 42

Description Main bearing holder bolt Allen head screw Retaining bolt

Nm 52 27 52 9813/6750-1

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15 - Engine

12 - Crankshaft 00 - General

Check (Condition)

Remove and Install

1. Check the main bearing surfaces for damage and excessive wear.

2. Measure the crankshaft diameters to confirm they are within service limits. Refer to Crankshaft- Technical Data (PIL 15-12).

3. Check that the oilway cross drillings in the crankshaft are clear and free from debris.

Blocked or restricted oilways will cause oil starvation at the big end bearings.

CAUTION This component is heavy. It must only be removed or handled using a suitable lifting method and device.

Remove 1. Remove the engine oil relief valve. Refer to (PIL 15-60).

2. Remove the crankshaft rear seal. Refer to (PIL 15-12).

3. Remove the engine oil pump and the suction pipe. Refer to (PIL 15-60).

4. Remove the pistons and the connecting rods.

Refer to (PIL 15-36).

5. Mount the engine in a suitable stand with the rear end facing upwards.

6. Remove the bolts from the crankcase.

7. Remove the Allen screws from the crankcase.

8. Attach a suitable lifting device to the crankshaft assembly.

9. Carefully lift the crankshaft assembly from the crankcase.

10. If necessary, gently tap the nose of the crankshaft with a soft faced hammer.

11. Install the nut for the crankshaft pulley to protect the nose of the crankshaft. Do not scratch the finished surfaces of the crankshaft.

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12 - Crankshaft 00 - General

Figure 112.

3. Tighten the bolts and the screws to the correct torque value.

C D

4. Check the crankshaft end play.

B

4.1. Push the crankshaft towards the front of the engine.

4.2. Install a DTI (Dial Test Indicator) to the crankcase and the rear face of the crankshaft.

4.3. Push the crankshaft toward the rear of the engine.

4.4. Measure the crankshaft end play with the DTI. 4.5. Make sure that the end play does not exceed the maximum permissible crankshaft end play. Refer to Crankshaft Technical Data - (PIL 15-12).

A A B C D

Table 48. Torque Values Item C D

Crankshaft Crankcase Bolt Allen screw

Description Bolt Allen screw

Nm 52 27

Figure 113.

E

A

B

A Crankshaft B Crankcase E Lifting device

Install 1. Installation is the opposite of the removal procedure. Additionally do the following steps.

2. Before installation make sure that all the components are clean and free from damage.

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15 - Engine

12 - Crankshaft

03 - Main Bearing

03 - Main Bearing

Introduction

Introduction .................................................... 15-45 Check (Condition) .......................................... 15-46 Remove and Install ....................................... 15-47

In a piston engine, the main bearings are the bearings on which the crankshaft rotates.

The bearings hold the crankshaft in place and prevent the forces created by the piston and transmitted to the crankshaft by the connecting rods from dislodging the crankshaft, instead forcing the crank to convert the reciprocating movement into rotation.

Figure 114.

A

B A Main bearing B Main bearing bolts

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15 - Engine

12 - Crankshaft

03 - Main Bearing

Check (Condition)

Figure 115.

Check the condition of the main bearings by measuring the clearance between the two bearing halves.

If the crankshaft journals and the bores for the crankcase and connecting rods were measured, no further checks are necessary. If the bearing clearance measurement is necessary, the use of the plastic gauge is an acceptable method. The plastic gauge is less accurate on journals with small diameters if the clearances are less than 0.1mm.

When you use the plastic gauge make a note of the following: • • •

Make sure that the backs of the bearings and the bores are clean and dry.

Make sure that the bearing locking tabs are properly seated in the tab grooves.

The crankshaft must be free of oil at the contact points of the plastic gauge.

Table 49. Plastic Gauges

Colour code Green Red Blue Yellow

A

B A Plastic gauge B Bearing 7. Measure the width of plastic gauge while the plastic gauge is in the bearing cap or on the crankshaft journal.

8. Remove all of plastic gauges before you install the bearing cap.

Dimensions 0.025–0.076mm 0.051–0.152mm 0.102–0.229mm 0.23–0.51mm

Measurement Procedure 1. Put the plastic gauge on the crown of the bearing that is in the cap.

2. Do not allow the plastic gauge to extend over the edge of the bearing.

3. Use the correct torque-turn specifications in order to install the bearing cap.

4. Do not use an impact wrench. Be careful not to dislodge the bearing when the cap is installed.

5. Do not turn the crankshaft when the plastic gauge is installed.

6. Carefully remove the cap, but do not remove the plastic gauge.

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15 - Engine

12 - Crankshaft

03 - Main Bearing

Remove and Install Remove 1. Remove the crankshaft. Refer to (PIL 15-12).

5. Remove the upper main bearing and the lower main bearing from the upper main bearing cap and the lower main bearing cap respectively.

2. Make sure that the bearing caps are marked for orientation and the correct position.

6. Keep the main bearings with the respective bearing caps.

3. Remove the bolt and the upper main bearing cap from the lower main bearing cap.

7. Do not remove the dowels from the main bearing caps.

4. Remove the thrust washer1 and the thrust washer2.

8. Remove the front bearing with the driver tool.

Figure 116.

A

A

B

C

D

B

E F

F G

G H

A C E G

Bolt Thrust washer1 Lower main bearing Thrust washer2

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B D F H

Upper main bearing cap Upper main bearing Lower main bearing cap Dowel

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15 - Engine

12 - Crankshaft

03 - Main Bearing

Figure 117.

K

J

11. Install the thrust washer1 and thrust washer2

L

12. Make sure that the thrust washers are aligned correctly and the oil grooves are facing the crankshaft.

M

13. Install the bolt and tighten to the correct torque value.

J

14. Install the front bearing with the driver tool as follows: 14.1.Make sure that the oil supply hole is aligned with the oil gallery in the crankcase.

N

14.2.Make sure that the joint is facing upwards.

J K L M N

14.3.Make sure that the chamfer faces towards the crankcase.

Front bearing Joint Chamfer Oil supply hole Driver tool

15. Install the crankshaft. Refer to (PIL 15-12).

Install 1. Clean the crankshaft thoroughly. Check the condition of the crankshaft. Refer to (PIL 15-12).

2. Clean all the bearings and thrust washers.

Inspect all the components for wear or damage.

3. Install the upper main bearing to the upper main bearing cap.

4. Make sure that the locating tab for the upper main bearing is seated in the slot in the upper main bearing cap.

4.1. The upper bearing has a groove.

5. Install the lower main bearing to the lower main bearing cap.

6. Make sure that the locating tab for the lower main bearing is seated in the slot in the lower main bearing cap.

6.1. The lower bearing is a plain bearing that has oil holes.

7. Lubricate the main bearings with clean engine oil.

8. Keep the upper and the lower main bearing cap in position on the crankshaft.

9. Make sure that the bearing caps are installed in the correct location and orientation. The locating tabs for the upper and the lower bearings should be on the same side of the engine.

10. Make sure that the dowels are in the correct position. This is to make sure that the two halves of the main bearing caps are aligned.

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9813/6750-1

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