C-63
35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08
Crankcase, Crankshaft, Main Bearings & Flywheel
1. PREPARATION :
Check and fill the cooling system. Check the level
of oil in the crankcase. Bleed the fuel system using
the hand primer pump located on fuel filter. Start
the engine and run with the throttle at 1/4 position
until the engine attains the operating temperature.
2. DISMANTLING
a) Remove the crankshaft spin-on and clutch
shaft pilot bearing if inspection proves this
necessary.
b) Remove the oil seal from the rear oil seal
retainer.
3. INSPECTION AND REPAIR
a) Check the main journals and crankpins for
wear and taper. Grind if necessary to the
dimensions shown in Fig. 7.
b) Check the dowels for wear or damage, replace
if necessary pressing into the dimension
shown in Fig. 5.
c) Check the clutch shaft pilot bearing for wear
or damage, replace if necessary pressing into
the dimension shown in Fig. 5.
d) Check that the oil ways are clear.
4. ASSEMBLY
a) Install the clutch shaft pilot bearing if it was
removed.
b) Install the dowels if they were removed.
c) Install a new key and the crankshaft spin-on
if they were removed.
d) Press a new oil seal into the rear oil seal
retainer with the lip toward the front of the
crankcase. The seal must be pressed hard
against the shoulders of the retainer.
5. INSTALLATION
a) Install the upper half bearing inserts and
lubricate them.
b) Carefully install the crankshaft and spin it by
hand.
c) Install the main bearing caps.
d) Install the connecting rods, connecting rod
bearings and bearing caps to the crankshaft
with the identification numbers to the fuel
injection pump side then tighten the bolts to
the specified torque.
e) Check the connecting rod side clearance to
specifications.
f) Use jointing compound and fit a new
horseshoe gasket to the rear face of the
crankcase lining up the holes in the gasket
with the bolt holes.
g) Apply a light coating of grease to the oil seal
and fit the oil seal retainer over the end of
the crankshaft taking care not to damage the
lip of the seal. If possible use a sleeve for this
operation. Ensure that the seal garter spring
is in position.
h) Locate the retainer on the dowels, install the
bolts and to ensure even seating of the gasket,
tighten the bolts by stages to the specified
torque.
NOTE: The bottom face of the retainer, after
installation, must be in line with the
bottom face of the crankcase within
0.020”.
(i) Trim the horseshoe gasket flush with the
bottom of the crankcase.
(j) Install adapter plate and oil pan, use liquid
gasket (loctite 584) for these joints.
(k) Install the flywheel.
(l) Install the oil pump.
(m) Invert the engine.
(n) Install the crankcase front cover.
E. HELI-COIL THREAD INSERTS
1. REMOVAL
a) Place the extractor into the insert and turn
in an anti-clockwise direction.
2. INSTALLATION
NOTE: Never use an insert that has been removed.
a) Place a new insert in the driver with the
driving lug to the bottom.
b) Screw the insert into the tool guide until
it is flush with the end of the tool.
c) Place the driver over the tapped hole and
turn the handle clockwise until the insert
leaves the tools, then break off the driving
lug. Ensure that inserts are driven into the
specified depth.
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