Cylinder Block Assembly: Specifications

Connecting Rod
Install connecting rod bearing caps and tighten to 30 Nm.
Clearance when new 0.015 to 0.062 mm
Wear limit 0.12 mm
Final Assembly Tightening Specifications
Rod Cap Bolt 30 Nm (22 ft. lbs.) plus 1/4 turn (90°)





Crankshaft bearing caps
- Replace bolts -A- and nuts -1 to 8-.
- Inserting alignment bushings into cylinder block
- Tighten bearing cap nuts or bolts in the following sequence:
1. Tighten bolts -A- by hand.
2. Tighten nuts -1 to 8- to 35 Nm.
3. Using rigid wrench turn nuts -1 to 8 an additional 90° (1/4 turn.
4. At the same time, tighten bolts -A- to 20 Nm.
5. Using rigid wrench turn nuts -A- an additional 90° (1/4 turn.





Piston and cylinder measurements
1) Measurements without graphite coating (thickness = 0.02 mm) Graphite coating wears away.

Harmonic balancer to crankshaft 23 Nm





Crankshaft measurements
(Distance in mm)








Piston ring-Checking end gap
- Insert ring at a right angle to cylinder wall from above to lower cylinder opening approximately 15 mm cylinder edge. When inserting, use pistons without rings








Piston ring-Checking height play
- Before measuring, clean piston ring groove








Checking piston
Special Tools and Equipment
External micrometer 75 - 100 mm
- Measure approximately 10 mm from lower edge, at a 90° angle to piston pin axis.
^ Deviation from nominal dimension: max. 0.04 mm
Specified dimension piston and cylinder measurements, Refer to Piston, Engine, Service and Repair.





Checking cylinder bore
Special Tools and Equipment
Inner bore gauge 50 - 100 mm
- Measure diagonally at 3 positions horizontally -A- and lengthwise -B-.
^ Deviation from nominal dimension: max. 0.08 mm
Specified dimension piston and cylinder measurements, Refer to Piston, Engine, Service and Repair.





Installed position and allocation piston/cylinder
- Mark installed position and allocation to cylinder on piston head using chalk or waterproof felt pen.

Note: Do not use a center punch or scribe, since the piston head coating will be damaged.

^ Installation position: Arrow on piston head points to belt pulley side





Identification of crankshaft bearing caps
^ Bearing 1 is located on the belt pulley side





Allocation of crankshaft bearing shells for cylinder block
Bearing shells with the correct thickness are allocated to the cylinder block in the factory. Colored dots on the bearing shells serve for identifying bearing shell thickness.

Note: The arrow points to the belt pulley side.





Allocation of bearing shells to cylinder block is marked by a letter beside the respective bearing.





Allocation of crankshaft bearing shells for bearing caps
Bearing shells with the correct thickness are allocated to the bearing caps in the factory. Colored dots on the bearing shells serve for identifying bearing shell thickness.





Allocation of bearing shells to crankshaft is marked with a letter sequence at the crankshaft flank. The first digit, "1" (arrow) identifies the color coding for bearing 1.