SAFARI

ENGINE

100

Fig. 12

Fig. 11

INSTALLATION OF CRANKSHAFT

1 Install new crankshaft gear together with new key

using drift, 2574 5890 35 03.

Thoroughly clean crankcase and crankshaft using

kerosene. Use suitable wire brushes for cleaning oil

passages in crankcase and crankshaft. Blowdrywith

moist free compressed air.

2 Install 5thmain bearing oil seal in crankcase and 5th

main bearing cap with special tool, 2574 5890 02 03

Fig. 11&12. Ensure that seal holdingpin is inposition.

3 Install bearing shells in crankcase and main bearing

caps. Make sure that locating lugs of bearing shells

are properly seated in slots of crankcase and main

bearingcap. Incaseoldbearingsarebeingused, install

marked shells in their respective positions.

4 Bearing shells with oil groove and holes should be

fitted incrankcaseand thosewithout holeandgroove

should be fitted in main bearing caps. Ensure that

holes of bearing shellsmatchwithdrilledholes in the

block.

5 Apply clean engine oil to bearing surfaces and

crankshaft journals

6 Install upper half of thrustwashers as per size selected

to suit ground width of crankshaft 2ndmain journal

and then lower crankshaft oncrankcase carefully after

installing all bearing shells in crankcase.

NOTE

: Insert one of the thrust washers without lug

(where provided on the block) into the groove

providedonthe2ndmainbearingshoulder,androtate

the same. Push the crankshaft against this thrust

washer so that there is no clearance between

crankshaft thrust collar and thiswasher.Insert second

thrust washer (of the block) and rotate the same.

Matchparting surfaces of thewasher with that of the

block.

7 Install other half of thrust washers on 2nd main

bearing cap and install cap.

NOTE

: Place tongued thrust washers on 2nd main

bearing cap and install cap on crankcase taking care

that locating lugs for bearing shells are on the same

side. Screw in cap mounting bolts. Apply oil to

thrust faces.

Slots on thrust faces of washers should face

crankshaft thrust collars. Flat side of washers

should face crankcase/main bearing cap.

8 Install other main bearing caps with shells taking

care that locating lugs of bearing shells are on

same side and caps are fitted in their respective

positions i.e. No. 1 cap fitted to the No. 1 main

bearing and so on. Screw in main bearing cap

mounting bolts.