JCB 135, 155, 175, 190, 205 Skid Steer Loader Service Repair Manual Instant Download (From 2473501 To 2473800)

1
Foreword
SERVICE MANUAL SKIDSTEER LOADER 135, 155,
175, 190, 205 EN - 9813/6750 - ISSUE 1 -
04/2016 This manual contains original
instructions, verified by the manufacturer (or
their authorized representative). Copyright
2016 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
The Operator's 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.
Contents 01 - Machine
03 - Attachments and Options
06 - Body and Framework
09 - Operator Station
12 - Heating, Ventilating and Air- Conditioning
(HVAC)
15 - Engine 18 - Fuel and Exhaust System 21 -
Cooling System
24 - Brakes
27 - Driveline
30 - Hydraulic System
33 - Electrical System
72 - Fasteners and Fixings
75 - Consumable Products
78 - After Sales
2
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.
9813/6750-1
15 - 3
3
15 - Engine 00 - General 00 - General
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
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).
9813/6750-1
15 - 4
4
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5
15 - Engine 00 - General 00 - General
Technical Data
accordance with local regulations. Use authorised
waste disposal sites.
Table 18.
Description Data
Engine type GN 404D-22
Emission compliance Tier 3
Number of cylinders 4
Nominal bore size 88mm
Stroke 102mm
Cylinder arrangement Vertical In-line
Combustion Cycle 4-stroke
Firing order 1-3-4-2
Compression ratio 23.31
Swept volume 2.216L
Valve clearance (cold) 0.2mm
Idling speed 1400 RPM (Revolutions Per Minute)
Maximum no-load speed 2800 RPM
Power output 34kW at 2600 RPM
6
15 - Engine 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 Fuel shutoff solenoid C Water pump E Throttle
lever G Engine oil level gauge J Engine oil
filter L Transfer pump
B Number one fuel injector D Lower engine oil
filler cap F Cover plate for the accessory
drive H Engine oil cooler K Fuel injection pump M
Fuel filter
7
15 - Engine 00 - General 00 - General
Figure 91. Front and left side view Q
P
R
N
S
T U
V
AD
W
X
AC
AB
Y
Z
AA
N Top engine oil filler cap Q Rear Lifting
eye S Valve mechanism cover U Water temperature
regulator housing W Electric starting
motor Y Engine oil pan AA Fan drive belt AC
Coolant temperature switch
P Crankcase breather R Air inlet
elbow T Turbocharger V Starting motor
solenoid X Alternator
Z Engine oil drain plug
AB Crankshaft pulley AD Cooling fan
8
15 - Engine 00 - General 00 - General
Operation
The Four Cylinder Cycle This section describes
the cycle sequence for the 4 cylinder
engine. 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.
Firing Order A cylinder is said to be firing,
when the fuel/air mixture ignites and the piston
is about to start its power 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 Piston operation Valve operation
1 The piston is at the top of its Compression stroke and is about to start its Power stroke. Inlet and exhaust valves closed
2 The piston is at the bottom of its Power stroke and is about to start its Exhaust stroke. Inlet valves closed, exhaust valves about to open
3 The piston is at the bottom of its Induction stroke and is about to start its Compression stroke. Exhaust valves closed, inlet valves about to close.
4 The piston is at the top of its Exhaust stroke and is about to start its Induction stroke. Valve Operation Exhaust valves about to close, inlet valves about to open
9
15 - Engine 00 - General 00 - General
Figure 92. Typical Four Cylinder
Engine CYL2 CYL3 CYL4
CYL1
1
2
5
A
C B
C B
C B
C B
G
H
J
K
4
3
F
745620
745620
G
H
J
K
C
B
B
C
A
A
A
A
B
C
C
B
CYL1 Cylinder number 1 CYL2 Cylinder number 2
CYL3 Cylinder number 3 CYL4 Cylinder number 4
A Camshaft B Camshaft lobe - Inlet valve operation
C Camshaft lobe - Exhaust valve operation F Front of engine
1 Exhaust valves 2 Inlet valves
3 Crankshaft 4 Crankshaft gear
5 Camshaft drive gear
10
15 - Engine 00 - General 00 - General
Four Stroke Cycle Induction 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.
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.
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.
Exhaust 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.
Compression 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).
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.
Power The piston continues to rise after the
start of fuel injection, causing a further
increase in pressure and temperature.
Figure 93.
3
2
C
B
4
1
746030
1 Induction stroke 2 Compression stroke
3 Power stroke 4 Exhaust stroke
A Camshaft B Camshaft lobe - Inlet valve operation
C Camshaft lobe - Exhaust valve operation BDC Bottom dead centre
TDC TDC
11
15 - Engine 00 - General 00 - General
Figure 94.
717620
1
2
3
4
B
C
A
A
A
A
B C
B
C
B
C
1 Induction stroke 3 Power stroke A Camshaft C
Camshaft lobe - Exhaust valve operation
2 Compression stroke 4 Exhaust stroke B Camshaft
lobe - Inlet valve operation
12
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

1. Crankcase
2. Crankshaft

9813/6750-1
15 - 31
13
15 - Engine 03 - Crankcase 00 - General
Technical Data
Check (Condition)
1. Check the six positions for flatness with a
straight edge and the feeler gauge. Refer to
Figure 99. Figure 99.
Table 42. Cylinder bore data
Description Data
Diameter of bore 8484.019mm
Bore service limit 84.2mm
Flatness of the top of the cylinder Less than 0.05mm
Service limit for the flat- ness 0.12mm
Clearance between the tappet and the tappet bore (Maximum) 0.058mm
Clearance between the tappet and the tappet bore (Service limit) 0.08mm
B
A
C
1
Figure 98.
3 4
5 6
2

• Crankcase
• Straight edge
• Feeler gauge
• Inspect the top of the crankcase for cracks,
  damage and warping.
• Inspect each cylinder bore.
• Make sure that there are no signs of scoring or
  corrosion.
• Measure each cylinder bore with a suitable
  gauge.
• Measure the area of each cylinder bore that is
  in contact with the top, middle and bottom
  piston rings.
• Make sure that you measure each cylinder bore at
  right angles to the crankshaft.
• Do NOT use the flex-hone process on this engine.
• Make sure that the cylinder bore dimensions do
  not exceed the specified service limits. Refer
  to Technical data (PIL 15-03).
• If the service limit for the crankcase is
  exceeded, you must replace the crankcase.

A
B

1. Tappet
2. Tappet bore

9813/6750-1
15 - 32
14
15 - Engine 06 - Cylinder Head 00 - General
Technical Data
Check (Condition)

• Make the machine safe. Refer to (PIL 01-03).
• Get access to the engine. Refer to (PIL 06-06).
• Remove the cylinder head bolts in the reverse
  numerical order. This will prevent distortion of
  the cylinder head. Refer to Figure 100.
• Figure 100.
• 12 4 5 13

Table 43. Cylinder head gasket
Piston height below top face of crankcase Gasket Thickness
0.35mm to 0.5mm 1.2mm
0.5mm to 0.6mm 1.3mm
Table 44. Distortion of the cylinder head
Description Data
Distortion of the cylinder head 00.05mm
Maximum service limit 0.12mm
Maximum limit for re- grinding the cylinder head 0.15mm
9
1
8
17
16
7
10
2
18
15

• 11 3 6 14
• Remove the cylinder head from the engine.
• Clean the cylinder head thoroughly.
• Make sure that the contact surface of the
  cylinder head and the contact surface of the
  crankcase are clean, smooth and flat.
• Inspect the bottom surface of the cylinder head
  for pitting, corrosion and cracks.
• Inspect the area around the valve seats and the
  holes for the fuel injectors.
• Put the cylinder head on a suitable support.
• Figure 101.
• A

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

9813/6750-1
15 - 36
15
15 - Engine 06 - Cylinder Head 00 - General
Calibrate
Figure 102.

• 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

1
4
3
6
5
2

• Dowel pins
• Gasket
• 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 101Nm in the
  specified numerical sequence only. Refer to
  Figure 104.
• Figure 104.
• 12 4 5 13

9
1
8
17
16
7
10
2
18
15

• 11 3 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
6
5
2
9813/6750-1
15 - 37
16
15 - Engine 06 - Cylinder Head 00 - General
Remove and Install CAUTION This component is
heavy. It must only be removed or handled using a
suitable lifting method and device.

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

• Remove
• Make the machine safe. Refer to (PIL 01-03).
• 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.
• Remove the exhaust manifold. Refer to (PIL
  18-24).
• Remove the fuel filter. Refer to (PIL 18-09).
• Remove the fuel injectors. Refer to (PIL 18-18).
• Remove the glow plugs. Refer to (PIL 15-80).
• Remove the rocker shaft and the push rods. Refer
  to (PIL 15-42).
• Remove the cooling pump. Refer to (PIL 21-09).
• Drain the cooling system. Refer to (PIL 21-00).
• 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 13

17
9
1
8
16
10
2
7
18
15

• 11 3 6 14
• Remove the bolts from the cylinder head.
• Carefully lift the cylinder head off the
  crankcase with a suitable lifting device.
• Make sure of the following
• Do not use a lever to separate the cylinder head
  from the crankcase.
• Take care not to damage the machined surfaces of
  the cylinder head.
• Avoid contamination of the cylinder bores with
  coolant or with debris.
• Place the cylinder head on a surface that will
  not scratch the face of the cylinder head.
• Remove the cylinder head gasket. Retain the old
  gasket to help identification.

9813/6750-1
15 - 38
17
15 - Engine 06 - Cylinder Head 00 - General

• Make a note of the position of the dowels. Do not
  remove the dowels unless they are damaged.
• If necessary, remove the thermostat from the
  cylinder head. Refer to (PIL 21-12).
• Figure 107.
• A

1. Make sure that the new gasket is of the same
   thickness as the old gasket.
2. Align the gasket with the guide bolt and the
   dowels. Install the gasket onto the crankcase.
3. Lift the cylinder head with a suitable lifting
   device.
4. Align the cylinder head with the guide bolts on
   the crankcase. Install the cylinder head onto
   the crankcase.

1. Make sure that the cylinder head is correctly
   positioned on the dowels.
2. Remove the guide bolts.
3. Install the bolts to the cylinder head.
4. Tighten the bolts to the correct torque value in
   the specified numerical sequence only. Refer to
   Figure 106.
5. If removed, install the thermostat to the
   cylinder head. Refer to (PIL 21-12).
6. Install the cooling pump. Refer to (PIL 21-09).
7. Install the rocker shaft and the push rods. Refer
   to (PIL 15-42).
8. Install the glow plugs. Refer to (PIL 15-80).

B

1. Bolt
2. Cylinder head

Figure 108.
D
C
18. Install the fuel injectors. Refer to (PIL
18-18).
D

1. Install the fuel filter. Refer to (PIL 18-09).
2. Install the exhaust manifold. Refer to (PIL
   18-24).

C
Table 45. Torque Values
Item Description Nm
A Bolt 100

• Dowel
• Guide bolt (M11 by 100mm)
• Install
• Clean the mating surfaces of the cylinder head
  and the crankcase.
• Make sure that no debris enters the cylinder
  bores, the coolant passages, or the lubricant
  passages.
• 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.
• Inspect dowels for damage. If necessary, replace
  the dowels in the crankcase.
• Install the guide bolts to the crankcase.

9813/6750-1
15 - 39
18
15 - Engine 12 - Crankshaft 00 - General
Technical Data
Component Identification
Figure 111.
Table 46.
Description Data Data
Description Standard Service limit
Thrust washer thickness 2.953mm 0.5mm
Crankshaft end play 0.10.3mm 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

1. Crankcase
2. Crankshaft

• C
• Crankshaft
• Main bearing holder bolt
• Thrust washer
• 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
• Allen head screw
• Retaining bolt
• Table 47. Torque Values

Item Description Nm
B Main bearing holder bolt 52
E Allen head screw 27
F Retaining bolt 52
9813/6750-1
15 - 42
19
15 - Engine 12 - Crankshaft 00 - General
Remove and Install CAUTION This component is
heavy. It must only be removed or handled using a
suitable lifting method and device.
Check (Condition)

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.

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.

1. If necessary, gently tap the nose of the
   crankshaft with a soft faced hammer.
2. Install the nut for the crankshaft pulley to
   protect the nose of the crankshaft. Do not
   scratch the finished surfaces of the crankshaft.

9813/6750-1
15 - 43
20
15 - Engine 12 - Crankshaft 00 - General
Figure 112.

• Tighten the bolts and the screws to the correct
  torque value.
• Check the crankshaft end play.
• Push the crankshaft towards the front of the
  engine.
• Install a DTI (Dial Test Indicator) to the
  crankcase and the rear face of the crankshaft.
• Push the crankshaft toward the rear of the
  engine.
• Measure the crankshaft end play with the DTI.
• Make sure that the end play does not
  exceed the maximum permissible crankshaft end
  play. Refer to Crankshaft - Technical Data -
  (PIL 15-12).
• Table 48. Torque Values

C
D
B
A
Item Description Nm
C Bolt 52
D Allen screw 27

• Crankshaft
• Crankcase
• Bolt
• Allen screw
• Figure 113.
• E

A
B

• A Crankshaft
• B Crankcase
• E Lifting device
• Install
• Installation is the opposite of the removal
  procedure. Additionally do the following steps.
• Before installation make sure that all the
  components are clean and free from damage.

9813/6750-1
15 - 44
21
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
• Main bearing
• Main bearing bolts

9813/6750-1
15 - 45
22
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
A
B

• 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.

• Plastic gauge
• Bearing
• Measure the width of plastic gauge while the
  plastic gauge is in the bearing cap or on the
  crankshaft journal.
• Remove all of plastic gauges before you install
  the bearing cap.

Table 49. Plastic Gauges
Colour code Dimensions
Green 0.0250.076mm
Red 0.0510.152mm
Blue 0.1020.229mm
Yellow 0.230.51mm

• Measurement Procedure
• Put the plastic gauge on the crown of the bearing
  that is in the cap.
• Do not allow the plastic gauge to extend over the
  edge of the bearing.
• Use the correct torque-turn specifications in
  order to install the bearing cap.
• Do not use an impact wrench. Be careful not to
  dislodge the bearing when the cap is installed.
• Do not turn the crankshaft when the plastic gauge
  is installed.
• Carefully remove the cap, but do not remove the
  plastic gauge.

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23
15 - Engine 12 - Crankshaft 03 - Main Bearing
Remove and Install
Remove

1. Remove the upper main bearing and the lower main
   bearing from the upper main bearing cap and the
   lower main bearing cap respectively.
2. Keep the main bearings with the respective
   bearing caps.
3. Do not remove the dowels from the main bearing
   caps.
4. Remove the front bearing with the driver tool.

1. Remove the crankshaft. Refer to (PIL 15-12).
2. Make sure that the bearing caps are marked for
   orientation and the correct position.
3. Remove the bolt and the upper main bearing cap
   from the lower main bearing cap.
4. Remove the thrust washer1 and the thrust washer2.

Figure 116.
A
A
B
C
D
B
E
F
F
G
G
H
A Bolt C Thrust washer1 E Lower main bearing G
Thrust washer2
B Upper main bearing cap D Upper main bearing F
Lower main bearing cap H Dowel
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24
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15 - Engine 12 - Crankshaft 03 - Main Bearing
Figure 117. K L

• Install the thrust washer1 and thrust washer2
• Make sure that the thrust washers are aligned
  correctly and the oil grooves are facing the
  crankshaft.
• Install the bolt and tighten to the correct
  torque value.
• Install the front bearing with the driver tool as
  follows
• Make sure that the oil supply hole is aligned
  with the oil gallery in the crankcase.
• Make sure that the joint is facing upwards.
• Make sure that the chamfer faces towards the
  crankcase.
• Install the crankshaft. Refer to (PIL 15-12).

J
M
J
N

1. Front bearing
2. Joint
3. Chamfer
4. Oil supply hole
5. Driver tool

• Install
• Clean the crankshaft thoroughly. Check the
  condition of the crankshaft. Refer to (PIL
  15-12).
• Clean all the bearings and thrust washers.
  Inspect all the components for wear or damage.
• Install the upper main bearing to the upper main
  bearing cap.
• Make sure that the locating tab for the upper
  main bearing is seated in the slot in the upper
  main bearing cap.
• The upper bearing has a groove.
• Install the lower main bearing to the lower main
  bearing cap.
• Make sure that the locating tab for the lower
  main bearing is seated in the slot in the lower
  main bearing cap.
• The lower bearing is a plain bearing that has
  oil holes.
• Lubricate the main bearings with clean engine
  oil.
• Keep the upper and the lower main bearing cap in
  position on the crankshaft.
• 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.
• 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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