The following tools are needed to perform this procedure:
• Drill ream fixture, Part No. ST-1232, which contains:
(1) Plate, Part No. ST-1232-1
(2) Locator pin, Part No. 3375052
(3) Spacer washer, Part No. ST-1232-2
(4) Drill/ream Actual sizes depend on the dowel size
Bushing set Part No. 3376495
(5) Drill adapter Locally obtained; use to adapt openshank reamers to drill-chuck
(6) Reamer Locally obtained
(7) Drill bit Locally obtained
Remove the flywheel housing. If necessary, refer to Engine Disassembly, Group 00-01.
Use dowel pin extractor, Part No. ST-1134, or its equivalent to remove the two dowel pins from the cylinder
block.
Measure and record the diameter of one of the dowel pins which was removed to determine the next oversize dowel
to be installed after the housing is aligned.
Install the flywheel housing without the dowel pins.
Tighten the capscrews.
Torque Value: 7 N•m [5 ft-lb]
NOTE: Do not tighten the capscrews to the final torque value until the flywheel housing is aligned.
Use chalk to mark the housing at the 12:00 o’clock, 3:00 o’clock, 6:00 o’clock, and 9:00 o’clock positions.
Attach the dial indicator to the crankshaft as shown.
Use the accessory drive to rotate the crankshaft until the dial indicator is at the 3:00 o’clock position. Adjust the dial
indicator until the needle points to ′′0.′′
Rotate the crankshaft until the indicator is at the 9:00 o’clock position. Check the total indicator reading.
If the total indicator reading exceeds the limits listed in Section 00-02 ‘‘Flywheel Housing Installation,’’ use a
mallet to horizontally move the housing one-half the distance of the total indicator reading.
Rotate the crankshaft until the indicator is at the 12:00 o’clock position. Adjust the dial until the needle points to
‘‘0.’’
Rotate the crankshaft until the indicator is at the 6:00 o’clock position. Check the total indicator reading.
If the total indicator reading exceeds the limits listed in Section 00-02 ‘‘Flywheel Housing Installation,’’ use a
mallet to vertically move the housing one-half the distance of the total indicator reading.
Rotate the crankshaft until the indicator is at the 12:00 o’clock position. Adjust the dial until the needle points to
′′0.′′
Rotate the crankshaft, and record the indicator reading at the 3:00 o’clock, 6:00 o’clock, and 9:00 o’clock positions.
If the total indicator reading exceeds the limits listed in Section 00-02 ‘‘Flywheel Housing Installation,’’ repeat
the previous steps.
After the housing bore is aligned, check to make sure the surface of the housing is in alignment. Refer to Section
00-02 ‘‘Flywheel Housing Installation – Face Alignment.’’
Tighten the mounting capscrews in the sequence shown.
Torque Value: 203 N•m [150 ft-lb]
After the capscrews are torqued, check the housing bore and the surface alignment again before doweling the
housing.
Use the appropriate size capscrews. Attach a plate, Part No. ST-1232-1, which is contained in drill ream fixture,
Part No. ST-1232.
NOTE: Do not tighten the capscrews so tightly that the plate will not move.
Use the locator pin to align the plate with the hole for the dowel pin. Tighten the capscrews. The taper on the pin
must engage the dowel pin hole.
The locator pin must rotate easily after the capscrews are tightened.
Measure the dowel pins which are to be installed.
Obtain a reamer (1) that is 0.013 mm to 0.02 mm [0.0005-inch to 0.001-inch] smaller than the dowel.
The dowel must be long enough to protrude from the block one-half of the flywheel housing wall thickness but
must not protrude past the housing wall.
NOTE: There are three oversize dowel pins available:
Install the appropriate drill bushings. The Table shows the bushings available in Part No. 3376495.
The drill bushing used must be the same size as the reamer (or the drill) which is used.
If the new dowel pins are more than 0.38 mm [0.015-inch] larger than the old dowels, drill the hole to a size that is
slightly smaller than the reamer. Then the reamer will not have to remove an excessive amount of material.
Caution: Do not allow metal chips to enter the engine.
Damage to the engine will result.
Ream the hole until the reamer touches the bottom of the hole in the block.
After reaming one hole, turn the plate and align it with the second dowel hole. Repeat the procedure in the second
hole.
Remove the plate from the crankshaft.
Caution: To avoid possible engine damage, make sure the dowel hole does not contain any metal chips.
Use a square nose drift. Drive each dowel in until it touches the bottom of the hole in the block.
After the dowels are installed, measure the bore and the surface alignment again.
Use a square nose drift. Stake the dowel holes to prevent the dowels from coming out.
