REMOVAL AND INSTALLATION

Removal steps <<A>> >>G<< 1. Flywheel bolt <M/T> 2. Ball bearing <M/T> 3. Flywheel <M/T> <<A>> >>G<< 4. Drive plate bolt <A/T> >>F<< 5. Adapter plate <A/T> 6. Drive plate <A/T> 7. Inertia ring <A/T> 8. Rear plate 9. Bell housing cover >>E<< 10. Oil seal case >>D<< 11. Crankshaft rear oil seal >>C<< 12. Bearing cap bolt >>C<< 13. Bearing cap >>C<< 14. Bearing cap No.3 >>C<< 15. Bearing cap No.4 >>B<< 16. Crankshaft bearing, lower 17. Crankshaft >>B<< 18. Crankshaft bearing, upper >>B<< 19. Crankshaft thrust bearing 20. Check valve >>A<< 21. Oil jet 22. Engine support bracket, right 23. Engine support bracket, left 24. Cylinder block

1.Use special tool flywheel stopper (MB991883) to secure the flywheel <M/T> or inertia ring <A/T>. 2.Remove the flywheel bolts <M/T> or drive plate bolts <A/T>.

There are two types of oil jets installed. one for No. 1 and No. 3 and the other for No. 2 and No. 4. Make sure that the correct one is installed with correct direction as shown.

1.When the bearing needs replacing, select a proper bearing by the following procedure. note If the crankshaft is machined to an undersized, bearings for undersized crankshaft should be used and therefore the following selection procedure is unnecessary. (1) Measure the crankshaft journal diameter and confirm its classification from the following table. In the case of a crankshaft supplied as a service part, identification colours and marks of its journals and painted at the positions shown in the illustration. (2) The cylinder block bore diameter identification marks are stamped at the position shown in the illustration from front to rear beginning at No. 1. (3) Select proper bearings from the below table on the basis of the identification data confirmed under Items (1) and (2). Example If the measured value of a crankshaft journal outer diameter is 65.997 mm, the journal is classified as "1" or "Yellow" in the table. In case the crankshaft is also replaced by a spare part, check the identification colours of the journals painted on the new crankshaft. Next, check the cylinder block bearing bore identification mark stamped on the cylinder block. If it is "A" read the "Bearing identification mark" column to find the identification mark of the bearing to be used. In this case, it is "1" or "Green" Combination of crankshaft journal diameter and cylinder block bearing bore diameter Bearing identification mark Crankshaft journal Classification Cylinder block bearing bore diameter identification mark Identification colour or mark Using both ID (mark and colour) or either one O.D. mm 1 Yellow 65.994 - 66.000 A 1 or Green B 2 or Yellow C 3 or None 2 None 65.988 - 65.994 A 2 or Yellow B 3 or None C 4 or Blue 3 White 65.982 - 65.988 A 3 or None B 4 or Blue C 5 or Red

2.Crankshaft bearing (1) Install the bearings having an oil groove to the cylinder block. (2) Install the bearings having no oil groove to the bearing cap.

3.Crankshaft thrust bearing installation (1) Install the two thrust bearing in the number 3 bearing bore in the cylinder block. For easier installation, apply engine oil to the bearings; this will help hold them in position. (2) The thrust bearings must be installed with their groove side toward the crankshaft web.

1.Install according to the front mark and cap No. 2.Apply engine oil to the threaded portion and seating face of the bolt. 3.Tighten the bearing cap bolts in the illustrated sequence to 40 ± 2 N·m.

4. caution When the tightening angle is smaller than the specified tightening angle, the appropriate tightening capacity cannot be secured. When the tightening angle is larger than the specified tightening angle, remove the bolt to start from the beginning again according to the procedure. Using special tool angle gauge (MB991614), tighten the bearing cap bolts in the illustrated sequence by a further 35° to 39°.

5.After installing the bearing caps, make sure that the crankshaft turns smoothly and the axial play is correct. If the axial play exceeds the limit, replace crankshaft bearings. Standard value: 0.05 - 0.25 mm Limit: 0.45 mm

2.Use special tool oil seal installer (MB992147) to press-fit the crankshaft rear oil seal. 3.Press-fit the crankshaft rear oil seal into the oil seal case assembly to have the dimension shown in the illustration.

2.Apply a continuous bead of the specified sealant (Φ2.3 ± 0.3 mm) to the oil seal case mating surface as shown. Specified sealant: ThreeBond 1207F or equivalent note Install the oil seal case immediately applying sealant. 3. caution After the installation, until a sufficient period of time (one hour or more) elapses, do not apply the oil or water to the sealant application area or start the engine. Applying an appropriate amount of engine oil to the entire circumference of its crankshaft oil seal rear lip portion, and then set the oil seal case to the cylinder block and tighten the mounting bolts to the specified torque. Tightening torque: 11 ± 1 N·m

Install the adapter plate in the direction shown in the illustration.

2.Use special tool flywheel stopper (MB991883) to secure the flywheel <M/T> or inertia ring <A/T> in the same manner as removal.

3.Tighten the flywheel bolts <M/T> or drive plate bolts <A/T> to the specified torque in the order shown in the illustration. Tightening torque: <M/T> 133 ± 4 N·m <A/T> 135 ± 5 N·m