For 1990-2009 cars

#### Special Tools

J 41818 Crankshaft Bearing Cap Remover

Important: If the crankshaft bearings have been used in a running engine, replace them with new crankshaft bearings for reassembly.

1. Clean the crankcase crank bore with a lint-free cloth.
2. Clean all the oil from the backside of new bearing halves.
3. Install the new upper crankshaft bearings into position. The thrust bearing (1) belongs in the number 3 journal (2). Ensure the upper bearing insert contains the oil transfer hole and groove. Roll the bearing into position so the lock tang engages the crank slot. The bearing must fit flush with the upper crankcase.
4. Install the new lower crankshaft bearings (2) into position in the main bearing caps (1). The lower crankshaft bearings are identified by no grooves or holes. The bearings must fit flush with the crankshaft bearing caps.
5. Place a length of fresh, room temperature plastic gaging material all the way across all the crankshaft bearing journals.
6. Install the crankshaft main bearing caps.
7. Loosely install the original inner main cap bolts (1).
8. Loosely install the original outer main cap bolts (2).
9. Loosely install the original short/inner side main cap bolts.
10. Loosely install the original long/outer side main cap bolts (3).
11. Gently tap the crankshaft main bearing caps with a soft-faced hammer to help seat the caps.

Notice: Refer to Fastener Notice in the Preface section.

12. Tighten the main caps bolts.

Tighten

• | Tighten the crankshaft main bearing cap inboard attaching bolt to 20 N·m (15 lb ft) plus another 80 degrees.

• | Tighten the crankshaft main bearing cap outboard attaching bolt to 15 N·m (11 lb ft) plus another 110 degrees.

• | Tighten the crankshaft main bearing cap side attaching bolt to 30 N·m(22 lb ft) plus another 60 degrees.

Important: Do not rotate the crankshaft.

13. Allow the assembly to sit for 2 minutes.
14. Remove the crankshaft bearing cap side bolts.
15. Remove the crankshaft bearing cap outer bolts (2).
16. Remove the crankshaft bearing cap inner bolts (1).
17. Install the J 41818 as previously described and remove the crankshaft bearing cap.
18. Repeat steps 10 to 13 for the remaining crankshaft bearing caps.
19. Determine the crankshaft bearing clearance by comparing the width of the flattened plastic gauging material (1) at its widest point with the graduation on the gauging material scale (2).
20. Compare the measurements listed in the specifications. If the new bearings do not provide the correct crankshaft to bearing clearance, inspect the following:

• | Measure the crankshaft journals for the correct specified size and ensure new bearings are being installed. If the crankshaft journals are incorrectly sized, replace or regrind the crankshaft. Crankshaft machining is permitted and undersized bearings are available.

• | Measure the engine block crankshaft bearing bore diameter to ensure correct size. The engine block crankshaft bearing bore is not machinable and the block must be replaced if out of specification. Refer to Engine Mechanical Specifications.

21. Clean the plastic gauging material from the crankshaft bearing journals with a soft, lint-free cloth.
22. If removed, install the crankshaft sprocket drive pin (1). Lightly tap the pin in place with a small soft face, bronze/plastic, hammer until it bottoms in the hole.

Important: Ensure the crankshaft position sensor has been removed from the cylinder block prior to loading the crankshaft.

23. Apply a liberal amount of clean engine oil to the upper and lower bearing surfaces.
24. Gently lower the crankshaft (1) into position in the cylinder block (2).
25. Install the crankshaft main bearing caps.
26. Loosely install the original inner main cap bolts (1).

Important: The outer crankshaft bearing cap bolts (2) are yield tightened during assembly and must be replaced prior to reassembly. Outer crankshaft bearing cap bolts that are not replaced will not torque to the correct clamp load and can lead to serious engine damage.

27. Loosely install the new outer main bearing cap bolts (2).
28. Gently tap the crankshaft main bearing caps with a soft-faced hammer to help seat the caps.

Important: The short/inner side main cap bolts originally have a sealant on the flange of the bolt head. New bolts must be used. If new bolts are not used, oil can leak from the crankcase past the bolts.

29. Loosely install new short/inner side main cap bolts (4).

Important: The long/outer side main cap bolts originally have a sealant on the flange of the bolt head. New bolts must be used. If new bolts are not used, oil can leak from the crankcase past the bolts.

30. Loosely install the new long/outer side main cap bolts (3).
31. Tighten the main caps bolts.

Tighten

• | Tighten the crankshaft main bearing cap inboard attaching bolt to 20 N·m (15 lb ft) plus another 80 degrees .

• | Tighten the crankshaft main bearing cap outboard attaching bolt to 15 N·m (11 lb ft) plus another 110 degrees .

• | Tighten the crankshaft main bearing cap side attaching bolt to 30 N·m (22 lb ft) plus another 60 degrees .

32. Ensure the crankshaft turns without binding or noise.
33. Install the remaining components in the reverse order to removal.