Opel Insignia: Crankshaft & Main Bearings

REMOVAL

NOTE: Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Ensure all main bearing caps are marked for location on cylinder block. Some main bearing caps have an arrow stamped on them. The arrow must face timing belt or timing chain end of engine. Remove main bearing cap bolts. Remove main bearing caps. Carefully remove crankshaft. Use care not to bind crankshaft in cylinder block during removal.

CLEANING & INSPECTION

NOTE: Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Thoroughly clean crankshaft using solvent. Dry with compressed air. Ensure all oil passages are clear and free of sludge, rust, dirt and metal chips.

Inspect crankshaft for scoring and nicks. Inspect crankshaft for cracks using Magnaflux procedure.

Inspect rear seal area for grooving or damage. Inspect bolt hole threads for damage. If pilot bearing or bushing is used, check pilot bearing or bushing fit in crankshaft. Inspect crankshaft gear for damaged or cracked teeth. Replace gear if damaged. Ensure oil passage plugs are tight (if equipped).

Using micrometer, measure all journals in 4 areas to determine journal taper, out-of-round and undersize. See Fig. 20. Some crankshafts can be reground to the next largest undersize, depending on the amount of wear or damage. Crankshafts with rolled fillet cannot be reground and must be replaced.

Fig. 20: Measuring Crankshaft Journals

Crankshaft journal runout should be checked. Install crankshaft in "V" blocks or bench center. Position dial indicator with tip resting on the main bearing journal area. See Fig. 21. Rotate crankshaft and note reading. Journal runout must not exceed specification. Repeat procedure on all main bearing journals.

Crankshaft must be replaced if runout exceeds specification.

Fig. 21: Measuring Crankshaft Main Bearing Journal Runout

INSTALLATION

NOTE: Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Install upper main bearing in cylinder block. Ensure lock tab is properly located in cylinder block. Install bearings in main bearing caps. Ensure all oil passages are aligned. Install rear seal (if removed).

Ensure crankshaft journals are clean. Lubricate upper main bearings with clean engine oil. Carefully install crankshaft. Check each main bearing clearance using Plastigage method. See MAIN & CONNECTING ROD BEARING CLEARANCE.

Once clearance is checked, lubricate lower main bearing and journals. Install main bearing caps in original location. Install rear seal in rear main bearing cap (if removed). Some rear main bearing caps require sealant to be applied in corners to prevent oil leakage.

Install and tighten all bolts except thrust bearing cap to specification. Tighten thrust bearing cap bolts finger tight only. Some models require that thrust bearing be aligned. On most applications, crankshaft must be moved rearward then forward. Procedure may vary with manufacturer. Thrust bearing cap is then tightened to specification. Ensure crankshaft rotates freely. Crankshaft end play should be checked.

See CRANKSHAFT END PLAY.

CRANKSHAFT END PLAY

NOTE: Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Dial Indicator Method

Crankshaft end play can be checked using dial indicator. Mount dial indicator on rear of cylinder block.

Position dial indicator tip against rear of crankshaft. Ensure tip is resting against flat surface.

Pry crankshaft rearward. Adjust dial indicator to zero. Pry crankshaft forward and note reading.

Crankshaft end play must be within specification. If end play is not within specification, check for faulty thrust bearing installation or worn crankshaft. Some applications offer oversize thrust bearings.

Feeler Gauge Method

Crankshaft end play can be checked using feeler gauge. Pry crankshaft rearward. Pry crankshaft forward. Using feeler gauge, measure clearance between crankshaft and thrust bearing surface. See Fig. 22.

Fig. 22: Checking Crankshaft End Play

Crankshaft end play must be within specification. If end play is not within specification, check for faulty thrust bearing installation or worn crankshaft. Some applications offer oversize thrust bearings.

CYLINDER BLOCK

NOTE: Examples used in this article are general in nature and do not necessarily relate to a specific engine or system. Illustrations and procedures have been chosen to guide mechanic through engine overhaul process.

Always refer to appropriate engine overhaul article, if available, in the ENGINES section for complete overhaul procedures and specifications for the vehicle being repaired.

Block Cleaning

Only cast cylinder blocks should be hot tank cleaned. Aluminum cylinder blocks should be cleaned using cold tank method. Cylinder block is cleaned in order to remove carbon deposits, gasket residue and water jacket scale. Remove oil gallery plugs, freeze plugs and cam bearings before cleaning block.

Block Inspection

Visually inspect the block. Check suspected areas for cracks using the Dye Penetrant inspection method.

Block may be checked for cracks using the Magnaflux method.

Cracks are most commonly found at the bottom of cylinders, main bearing saddles, near expansion plugs and between cylinders and water jackets. Inspect lifter bores for damage. Inspect all head bolt holes for damaged threads. Threads should be cleaned using tap to ensure proper head bolt torque. Consult machine shop concerning possible welding and machining (if required).

Cylinder Bore Inspection

Inspect bore for scoring or roughness. Cylinder bore is dimensionally checked for out-of-round and taper using dial bore gauge. For determining out-of-round, measure cylinder parallel and perpendicular to the block center line. Difference in the 2 readings is the bore out-of-round. Cylinder bore must be checked at top, middle and bottom of piston travel area.

Bore taper is obtained by measuring bore at the top and bottom. If wear has exceeded allowable limits, block must be honed or bored to next available oversize piston dimension.

Cylinder Honing

Cylinder must be properly honed to allow new piston rings to properly seat. Cross-hatching at correct angle and depth is critical to lubrication of cylinder walls and pistons.

A flexible drive hone and power drill are commonly used. Drive hone must be lubricated during operation. Mix equal parts of kerosene and SAE 20W engine oil for lubrication.

Apply lubrication to cylinder wall. Operate cylinder hone from top to bottom of cylinder using even strokes to produce 45 degree cross-hatch pattern on the cylinder wall. DO NOT allow cylinder hone to extend below cylinder during operation.

Recheck bore dimension after final honing. Wash cylinder wall with hot soapy water to remove abrasive particles. Blow dry with compressed air. Coat cleaned cylinder walls with lubricating oil.

Deck Warpage

Check deck for damage or warped gasket surface. Place a straightedge across gasket surface of the deck.

Using feeler gauge, measure clearance at center of straightedge. Measure across width and length of cylinder block at several points.

If warpage exceeds specifications, deck must be resurfaced. If warpage exceeds manufacturer's maximum tolerance for material removal, replace block.

NOTE: Some manufacturers recommend that a total amount of material (cylinder head and cylinder block) can only be removed before components must be replaced.

Deck Height

Distance from crankshaft center line to block deck is called the deck height. Measure and record front and rear main journals of crankshaft. To compute this distance, install crankshaft and retain with center main bearing and cap only. Measure distance from crankshaft journal to block deck, parallel to cylinder center line.

Add one half of main bearing journal diameter to distance from crankshaft journal to block deck. This dimension should be checked at front and rear of cylinder block. Both readings should be the same.

If difference exceeds specification, cylinder block must be repaired or replaced. Deck height and warpage should be corrected at the same time.

Main Bearing Bore & Alignment

For checking main bearing bore, remove all bearings from cylinder block and main bearing caps. Install main bearing caps in original location. Tighten bolts to specification. Using inside micrometer, measure main bearing bore in 2 areas 90 degrees apart. Determine bore size and out-of-round. If diameter is not within specification, block must be align-bored.

For checking alignment, place a straightedge along center line of main bearing saddles. Check for clearance between straightedge and main bearing saddles. Block must be align-bored if clearance exists.

Expansion Plug Removal

Drill hole in center of expansion plug. Remove with screwdriver or punch. Use care not to damage sealing surface.

Expansion Plug Installation

Ensure sealing surface is free of burrs. Coat expansion plug with sealer. Using wooden dowel or pipe of slightly smaller diameter, install expansion plug. Ensure expansion plug is evenly located.

Oil Gallery Plug Removal

Remove threaded oil gallery plugs using appropriate wrench. Soft press-in plugs are removed by drilling into plug and installing a sheet metal screw. Remove plug with slide hammer or pliers.

Oil Gallery Plug Installation

Ensure threads or sealing surface is clean. Coat threaded oil gallery plugs with sealer and install.

Replacement soft press-in plugs are installed with a hammer and drift.

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