service repair manual download

1. 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
Foreword
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
15 - 3 9813/6750-1 15 - 3
00 - General
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
Introduction
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.

3. 15 - Engine
00 - General
00 - General
15 - 4 9813/6750-1 15 - 4
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

4. 15 - Engine
00 - General
00 - General
15 - 5 9813/6750-1 15 - 5
accordance with local regulations. Use authorised
waste disposal sites.
Technical Data
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 23.3:1
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

5. 15 - Engine
00 - General
00 - General
15 - 6 9813/6750-1 15 - 6
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
A
M
B
C
D
E
F
L
K
J
H
G
A Fuel shutoff solenoid B Number one fuel injector
C Water pump D Lower engine oil filler cap
E Throttle lever F Cover plate for the accessory drive
G Engine oil level gauge H Engine oil cooler
J Engine oil filter K Fuel injection pump
L Transfer pump M Fuel filter

6. 15 - Engine
00 - General
00 - General
15 - 7 9813/6750-1 15 - 7
Figure 91. Front and left side view
N
S
R
Q
U
T
V
W
X
Y
Z
AA
AB
AC
AD
P
N Top engine oil filler cap P Crankcase breather
Q Rear Lifting eye R Air inlet elbow
S Valve mechanism cover T Turbocharger
U Water temperature regulator housing V Starting motor solenoid
W Electric starting motor X Alternator
Y Engine oil pan Z Engine oil drain plug
AA Fan drive belt AB Crankshaft pulley
AC Coolant temperature switch AD Cooling fan

7. 15 - Engine
00 - General
00 - General
15 - 8 9813/6750-1 15 - 8
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

8. 15 - Engine
00 - General
00 - General
15 - 9 9813/6750-1 15 - 9
Figure 92. Typical Four Cylinder Engine
745620
CYL1 CYL2 CYL3 CYL4
A A A A
B
F
C
B
C
B
B
C
C
C B
G
G
H
H
J
J
K
K
C B C B C B
4
5
2
3
A
1
745620
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

9. 15 - Engine
00 - General
00 - General
15 - 10 9813/6750-1 15 - 10
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.
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).
Power
The piston continues to rise after the start of fuel
injection, causing a further increase in pressure and
temperature.
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.
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.
Figure 93.
3
2
41
B
C
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

10. 15 - Engine
00 - General
00 - General
15 - 11 9813/6750-1 15 - 11
Figure 94.
717620
1 2 3 4
A A A A
B C
BC B BC
C
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

11. 15 - Engine
03 - Crankcase
00 - General
15 - 31 9813/6750-1 15 - 31
00 - General
Introduction .................................................... 15-31
Technical Data ............................................... 15-32
Check (Condition) .......................................... 15-32
Introduction
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

12. 15 - Engine
03 - Crankcase
00 - General
15 - 32 9813/6750-1 15 - 32
Technical Data
Table 42. Cylinder bore data
Description Data
Diameter of bore 84–84.019mm
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
Figure 98.
A B
A Tappet
B Tappet bore
Check (Condition)
1. Check the six positions for flatness with a straight
edge and the feeler gauge. Refer to Figure 99.
Figure 99.
C
2
65
3 4
1
B
A
A Crankcase
B Straight edge
C Feeler gauge
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.
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.

13. 15 - Engine
06 - Cylinder Head
00 - General
15 - 36 9813/6750-1 15 - 36
Technical Data
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
0–0.05mm
Maximum service limit 0.12mm
Maximum limit for re-
grinding the cylinder
head
0.15mm
Check (Condition)
1. Make the machine safe. Refer to (PIL 01-03).
2. Get access to the engine. Refer to (PIL 06-06).
3. 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
17
18
1027
918
11 3 6 14
16
15
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.

14. 15 - Engine
06 - Cylinder Head
00 - General
15 - 37 9813/6750-1 15 - 37
Figure 102.
6
1
4
2
5
3
Calibrate
• 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 5 13
17
18
1027
918
11 3 6 14
16
15
• Use a straight edge and a feeler gauge to check
the six positions for distortion. Refer to Figure
105.
Figure 105.
6
1
4
2
5
3

15. 15 - Engine
06 - Cylinder Head
00 - General
15 - 38 9813/6750-1 15 - 38
• 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 13
17
18
1027
918
11 3 6 14
16
15
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.

16. 15 - Engine
06 - Cylinder Head
00 - General
15 - 39 9813/6750-1 15 - 39
15. Make a note of the position of the dowels. Do not
remove the dowels unless they are damaged.
16. If necessary, remove the thermostat from the
cylinder head. Refer to (PIL 21-12).
Figure 107.
A
B
A Bolt
B Cylinder head
Figure 108.
C
C
D
D
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.
6. Make sure that the new gasket is of the same
thickness as the old gasket.
7. Align the gasket with the guide bolt and the
dowels. Install the gasket onto the crankcase.
8. Lift the cylinder head with a suitable lifting device.
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.
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).
16. Install the rocker shaft and the push rods. Refer
to (PIL 15-42).
17. Install the glow plugs. Refer to (PIL 15-80).
18. Install the fuel injectors. Refer to (PIL 18-18).
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 Description Nm
A Bolt 100

17. 15 - Engine
12 - Crankshaft
00 - General
15 - 42 9813/6750-1 15 - 42
Technical Data
Table 46.
DataDescription
Standard Service limit
Thrust washer
thickness
2.95–3mm 0.5mm
Crankshaft end
play
0.1–0.3mm 0.5mm
• Make sure that the oil grooves of all of the thrust
washers are toward the crankshaft.
Figure 109.
BA
D
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.
A
E
F
A Crankshaft
E Allen head screw
F Retaining bolt
Table 47. Torque Values
Item Description Nm
B Main bearing holder bolt 52
E Allen head screw 27
F Retaining bolt 52
Component Identification
Figure 111.
B
A
A Crankcase
B Crankshaft

18. 15 - Engine
12 - Crankshaft
00 - General
15 - 43 9813/6750-1 15 - 43
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 and Install
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.

19. 15 - Engine
12 - Crankshaft
00 - General
15 - 44 9813/6750-1 15 - 44
Figure 112.
C
D
A
B
A Crankshaft
B Crankcase
C Bolt
D Allen screw
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.
3. Tighten the bolts and the screws to the correct
torque value.
4. Check the crankshaft end play.
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).
Table 48. Torque Values
Item Description Nm
C Bolt 52
D Allen screw 27

20. 15 - Engine
12 - Crankshaft
03 - Main Bearing
15 - 45 9813/6750-1 15 - 45
03 - Main Bearing
Introduction .................................................... 15-45
Check (Condition) .......................................... 15-46
Remove and Install ....................................... 15-47
Introduction
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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22. 15 - Engine
12 - Crankshaft
03 - Main Bearing
15 - 46 9813/6750-1 15 - 46
Check (Condition)
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 Dimensions
Green 0.025–0.076mm
Red 0.051–0.152mm
Blue 0.102–0.229mm
Yellow 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.
Figure 115.
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.

23. 15 - Engine
12 - Crankshaft
03 - Main Bearing
15 - 47 9813/6750-1 15 - 47
Remove and Install
Remove
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.
5. Remove the upper main bearing and the lower
main bearing from the upper main bearing cap
and the lower main bearing cap respectively.
6. Keep the main bearings with the respective
bearing caps.
7. Do not remove the dowels from the main bearing
caps.
8. Remove the front bearing with the driver tool.
Figure 116.
B
B
G
H
F
A
A
D
F
E
G
C
A Bolt B Upper main bearing cap
C Thrust washer1 D Upper main bearing
E Lower main bearing F Lower main bearing cap
G Thrust washer2 H Dowel

24. 15 - Engine
12 - Crankshaft
03 - Main Bearing
15 - 48 9813/6750-1 15 - 48
Figure 117.
J K
L
M
J
N
J Front bearing
K Joint
L Chamfer
M Oil supply hole
N Driver tool
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.
11. Install the thrust washer1 and thrust washer2
12. Make sure that the thrust washers are aligned
correctly and the oil grooves are facing the
crankshaft.
13. Install the bolt and tighten to the correct torque
value.
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.
14.2.Make sure that the joint is facing upwards.
14.3.Make sure that the chamfer faces towards
the crankcase.
15. Install the crankshaft. Refer to (PIL 15-12).