N14 Base Engine Troubleshooting and Repair Manual – 001-016   Crankshaft

Use only the accessory drive shaft to rotate the crankshaft.

Rotate the crankshaft clockwise through two complete revolutions.

If the engine does not turn freely, the equipment can have a malfunction. Refer to the manufacturer’s instructions. The engine can have internal problems. Reference the correct procedure for inspection and replacement of internal engine components.

Inspect the crankshaft for dirt or damage

NOTE: If the crankshaft is found to be damaged, replace it.

Inspect the flywheel mating face of the crankshaft for signs of pitting, fretting, or corrosion.

NOTE: If the crankshaft is found to be damaged, replace it.

Reference the Grind section of this procedure for guidelines for reuse and grinding mating faces of crankshafts for rail engines.

• Disconnect the batteries to prevent accidental engine starting.
• Make sure vehicle is immobilized and safe to work on. Refer to the end-user procedures.
• Remove the vehicle driveline and the transmission. Refer to the manufacturer’s instructions.
• Remove the engine from vehicle. Refer to the manufacturer’s instructions.
• Remove the lubricating oil pan. Refer to Procedure 007-025 in Section 7.
• Remove the flywheel housing. Refer to Procedure 016-006 in Section 16.

CAUTION  The main bearing caps must be marked for position and cylinder block identification.

The position number (1) of the cap is stamped on the camshaft side and the block identification number (2) is stamped on the exhaust side of the cap.

The cylinder block identification number is stamped on the front and the rear of the oil pan flange on the camshaft side of the engine.

Check and mark all caps that are not marked before removing them from the cylinder block.

NOTE: The number 7 main bearing cap has thrust bearings and dowel pins.

Remove the main bearing capscrews and the washers.

Use main bearing cap puller, Part Number ST-1178, or equivalent to remove the caps. The service tool must be centered on the main bearing cap.

NOTE: Mark the bearing shells with the journal number from which they were removed if they are to be used again or if failure analysis is required.

Remove the lower main bearing shell from the crankshaft journal.

Remove the dowel ring.

Remove the thrust bearings from the number 7 cap.

Mark these bearings as the front and rear thrust bearings.

CAUTION  Do not damage the crankshaft when removing the thrust bearings.

Use a blunt tool to remove the upper thrust bearings.

Mark the bearings in the notched area as the front and rear thrust bearings.

NOTE: If necessary, slide the crankshaft to the front or to the rear to allow the thrust bearings to be removed.

WARNING  This assembly weighs 23 kg [50 lb] or more. To reduce the possibility of personal injury, use a hoist or get assistance to lift this assembly.

Use a hoist and a lifting sling to remove the crankshaft.

Push the upper main bearing on the end that does not have the dowel ring groove.

NOTE: Mark the bearing shells with the journal number from which they were removed if they are to be used again or if failure analysis is required.

Use a soft bristle brush to clean the parts, and dry with compressed air.

NOTE: Refer to Parts Reuse Guidelines, Bulletin 3810303, for information on bearing inspection.

Plastigage

CAUTION  To reduce the possibility of the crankshaft falling, two evenly spaced main bearing caps must always be on the engine to support the engine crankshaft.

The inspection must be performed with the main cap bearings that will be used in the engine after the inspection and/or repair is completed.

The PR-1 (red) style Plastigage, clearance range of 0.05 to 0.152 mm [0.002 to 0.006 in], is required for this procedure.

Do not destroy useful evidence. Go slowly and observe all conditions.

To measure the main bearing journal clearance on an in-chassis engine, shims must be inserted into the main caps on both sides of the journal being checked.

Use a main bearing cap puller, Part Number ST-1178, or equivalent to remove the caps. The main bearing cap puller must be centered on the cap. Pull straight down to remove the cap.

Remove the lower bearings.

Shims push the crankshaft up against adjoining upper bearings so an accurate clearance measurement can be made on the lower bearing.

The shims can be manufactured from a piece of 4-inch-diameter, schedule 40 PVC pipe. The dimensions of the fabricated shims must be as follows:

Width = 38.1 mm [1.5 in]

Thickness = 6.35 mm 0.25 in] (approximate thickness of schedule 40 PVC pipe)

Diameter = 101.6 mm [4.0 in].

Cut the pipe in half. The shims must be fabricated to the above-specified dimensions and be less than 180 degrees in circumference.

NOTE: Two fabricated shims are required for this procedure.

Install the shims in the main bearing caps on both sides of the bore being checked. (For example, to check the number 4 main bearing cap, install the shims on the number 3 and number 5 main bearing caps. To check the number 6 main bearing cap, install the shims on the number 5 and number 7 main bearing caps.)

Install the main bearing caps.

Install and tighten the capscrews.

Remove the main bearing cap to be checked.

Wipe the oil from the bearing and crankshaft journal.

Cut or tear a piece of Plastigage the full width of the bearing.

Do not squeeze the gauge material as this can result in a false reading.

Tear through both the envelope and plastic thread at the same time. Open the envelope lengthwise by cutting the edge with scissors or a knife or by tearing.

With the envelope open, lift out the Plastigage by one end. Roll the material out with a thumb if the material is stuck lightly to the paper.

Occasionally, the color in the Plastigage material will transfer to the paper. This has no effect on accuracy.

Place the piece of Plastigage in the bearing shell approximately at the 6-o’clock position.

The Plastigage clearance check procedure must be performed with the original bearings.

Do not disturb the Plastigage before reading the measurement. Disturbing the Plastigage can result in an incorrect measurement.

Install the main bearing cap using the appropriate torque procedure.

Remove the main bearing cap. The compressed Plastigage will be located adhering to either the bearing shell or the crankshaft.

Compare the width of the compressed Plastigage at its widest point, to the graduations on the envelope (regardless of taper). The number within the graduation on the envelope indicates the bearing clearance in thousandths of an inch or millimeters, depending on which side of the envelope is used.

Taper does not affect the clearance measurement. Clearance is still measured at the widest point on the Plastigage strip.

If the compressed Plastigage is less than 0.051 mm [0.002 in] at its widest point, the block must be removed and repaired or replaced.

If the compressed Plastigage is greater than 0.051 mm [0.002 in], reassemble the main bearing caps with either the existing or new main bearings.

Inspect the main bearing cap and capscrews for damage.

Inspect the bearing shells and the thrust bearings for nicks, scratches, or other damage.

NOTE: If the main bearings are damaged, reference the N14 Shop Manual, Bulletin 3810487, to inspect the crankshaft main bearing journals. If the crankshaft is damaged, the engine must be removed for repair. Refer to Procedure 000-001 (Engine Removal) in the N14 Shop Manual, Bulletin 3810487.

Use an outside diameter ball tipped micrometer to measure the main bearing shell thickness.

Standard Main Bearing Shell Thickness

Discard a main bearing shell if its thickness is below the minimum specification.

NOTE: For more detailed information of bearing damage, refer to Analysis and Prevention of Bearing Failures, Bulletin 3810387.

NOTE: Bearing shells are available for crankshafts which are 0.25 mm [0.010 in], 0.51 mm [0.020 in], 0.76 mm [0.030 in], or 1.02 mm [0.040 in] undersize. Crankshafts which are ground undersize in the connecting rod and main bearing journals are marked on the front counter weight. If the crankshaft is marked, check the bearing shell part number to make sure the correct bearing size is used.

Use a lint free cloth to clean the crankshaft bearing journals.

WARNING  This assembly weighs 23 kg [50 lb] or more. To reduce the possibility of personal injury, use a hoist or get assistance to lift this assembly.

CAUTION  Use a lifting strap that will not damage the crankshaft. Do not drop the crankshaft on the bearings.

The end of the crankshaft with the smallest diameter must point toward the front of the block. Install the crankshaft.

Use a lint free cloth to clean the thrust bearings, the main bearing shells, and the main bearing caps.

NOTE: If used thrust bearings are to be installed, each must be installed in its original location in the engine. The bearing journal numbers must have been marked on the bearing during disassembly.

Use clean Lubriplate™ 105 or equivalent to lubricate the upper thrust bearings.

CAUTION  The grooves must be toward the crankshaft.

Install the upper thrust bearings in the number 7 main bearing saddle.

NOTE: Push the crankshaft toward the rear of the engine to install the front bearing and to the front of the engine to install the rear bearing.

The end of the thrust bearing must be even with the main bearing cap mounting surface.

Install the dowel ring in the dowel ring counterbore of the cylinder block.

Install the lower main bearing shells as follows:

• Use clean Lubriplate™ 105 or its equivalent to lubricate the bearing shell to the crankshaft journal mating surface.

Align the dowel ring groove in the bearing with the dowel ring.

The dowel ring grooves (1) and (2) in the bearings must be engaged with the dowel ring (3).

Push on the side of the bearing shell opposite the dowel ring to install the bearing shell.

The end of the lower main bearing shell opposite the dowel ring must be engaged between the crankshaft and the cylinder block and be seated against the end of the upper bearing shell.

NOTE: If installed correctly, the ends of the bearing shells (1) will meet approximately 1.50 mm [0.060 in] below the cylinder block main bearing mounting surface.

NOTE: If used thrust bearings are to be installed, each must be installed in its original location in the engine. The bearing journal numbers must have been marked on the bearing during disassembly.

Use Lubriplate® 105 or its equivalent to lubricate the lower thrust bearings.

Put the lower thrust bearings around the No. 7 main journal with the grooves facing the thrust surface on the crankshaft.

NOTE: The notch (1) on the outside diameter of the lower thrust bearings must align with the locating pins in the number 7 main bearing cap.

CAUTION  Drain the excess oil from the capscrews before installing them in the cylinder block to prevent hydraulic lock and possible damage to the cylinder block during the capscrew torquing operation.

Use clean 15W-40 oil to lubricate the capscrew threads and flat washers.

CAUTION  The main bearing caps are marked for position (1) on the camshaft side and the cylinder block identification (2) on the exhaust side. The cylinder block identification number (3) is stamped on the pan rail on the camshaft side of the block. Install the caps in the correct position with the position number to the camshaft side and its part number toward the rear of the engine.

Install the main bearing caps as follows:

• Align the capscrew holes in the cap with the holes in the cylinder block. Make sure the dowel ring and lower bearing shell are in position.

• Install the capscrews and the washers through the cap and into the cylinder block.
• Hand tighten the capscrews two to three threads.

CAUTION  Do not use impact wrenches. The main bearing shells can become dislocated.

Use both of the capscrews to pull the main bearing cap into position.

Use two wrenches. Tighten both of the capscrews at the same time.

Make sure the cap is touching the block. If it is not, check for a bearing out-of-location.

CAUTION  Do not rotate the crankshaft until the main bearing capscrews are tightened. This will keep the bearings in place.

Tighten the main bearing capscrews in the sequence shown in the illustration.

Tighten the main bearing capscrews on engines built with 1 inch diameter main bearing capscrews to the following torque values:

1. Tighten to 150 N•m [111 ft-lb].
2. Tighten to 285 N•m [210 ft-lb].
3. Tighten to 415 N•m [306 ft-lb].
4. Loosen completely.
5. Repeat steps a. through c.

Tighten the main bearing capscrews on engines built with ¾ inch diameter main bearing capscrews to the following torque values:

1. Tighten to 120 N•m [89 ft-lb].
2. Tighten to 230 N•m [170 ft-lb].
3. Tighten to 345 N•m [254 ft-lb].
4. Loosen completely.
5. Repeat steps a. through c.

Turn the crankshaft by hand. If it does not turn freely, loosen the main bearing capscrews one cap at a time. This will help locate the bearing that is too tight.

Remove the main bearing cap and the bearing. Check for an incorrect or mislocated bearing or main bearing cap, for incorrect oversize bearing, or debris between the main bearing and the cap.

Tighten the main bearing capscrews in the sequence shown and to the torque values shown above.

Measure the end clearance of the crankshaft as follows:

1. Install a dial indicator to the rear face of the cylinder block.
2. Put the tip of the gauge against the end of the crankshaft.
3. Push the crankshaft toward the rear of the cylinder block.

1. Set the dial indicator to “0”.
2. Push the crankshaft toward the front of the cylinder block.
3. If the end clearance is less than 0.18 mm [0.007 in], do the following:

• Loosen the main bearing capscrew one turn.
• Push the crankshaft toward the front and then toward the rear of the cylinder block.

• Tighten the main bearing capscrews in the sequence shown in the illustration.

Measure the crankshaft end clearance. The end clearance specification for a new or reground crankshaft with new thrust bearings is 0.18 mm [0.007 in] to 0.45 mm [0.018 in].

NOTE: Crankshafts that have been reground on the thrust bearing surfaces are marked for oversize thrust bearings on the rear crankshaft counter weight. If the crankshaft counter weight is marked, check the thrust ring part number to make sure the correct thrust ring size is used.

Example: F.-.010 – Front 0.25 mm [0.010-in]

Example: R.-.020 – Front 0.51 mm [0.020-in]

If the crankshaft end clearance is more than 0.56 mm [0.022 in], use oversize thrust bearings to adjust the end clearance to the correct specification.

• Install the flywheel housing. Refer to Procedure 016-006.
• Install the lubricating oil pan. Refer to Procedure 007-025.
• Install the engine into vehicle. Refer to the manufacturer’s instructions.
• Install the vehicle driveline and the transmission. Refer to the manufacturer’s instructions.
• Connect the batteries.
• Mobilize the vehicle. Reference the end-user procedures.

This procedure is designed to extend the usable life of the crankshaft and to maintain the integrity of the crankshaft/flywheel bolted joint.

In order to maintain maximum clamping loads, it is permissible to grind the flywheel mounting face of the crankshaft.

Following a re-grind, a minimum thickness of 54.483 mm [2.145 inch] from the thrust bearing face must remain.

If the grinding process reaches the minimum dimension, and there are still signs of imperfections, the crankshaft must be replaced.

The grinding process should be carried out in increments of 0.0254 mm [0.001 inch] or less, to avoid burn damage to the crankshaft or unnecessary removal of material.

The new crankcase surface finish must be 125 microns of an inch or better.