Service Specifications

Pistons and connecting rods





1. 30 Nm + 1/4 turn (90°) further
^ To measure radial clearance, tighten 30 Nm but not further

2. Pressure relief valve, 27 Nm
^ Opens at 2.5...3.2 bar

5. Bearing shell
^ Axial clearance
New 0.10...0.35 mm
Wear limit 0.40 mm

^ Check radial clearance with Plastigage
New 0.01...0.05 mm
Wear limit 0.12 mm

^ Do not rotate crankshaft when checking radial clearance
^ To measure radial clearance, tighten nut -1- 30 Nm but not further

7. Bearing shell
^ Axial clearance
New 0.10...0.35 mm
Wear limit 0.40 mm

^ Check radial clearance with Plastigage
New 0.01...0.05 mm
Wear limit 0.12 mm

^ Do not rotate crankshaft when checking radial clearance
^ To measure radial clearance, tighten nut -1- 30 Nm but not further

11. Piston rings
^ Offset gaps by 120°
^ Checking ring gap Fig. 1
^ Checking ring to groove clearance Fig. 2





Fig. 1 Checking piston ring gap
- Push ring squarely from above down to lower cylinder bore, approximately 15 mm from cylinder edge. To do this use a piston without rings.








Fig. 2 Checking ring to groove clearance
- Clean groove before checking clearance.








Fig. 3 Checking piston
- Measure pistons approximately 10 mm from lower edge of skirt, at 90° to piston pin axis.
^ Deviation from nominal dimension: max. 0.04 mm





Fig. 4 Checking cylinder bore

Special tools and repair equipment required
^ Internal dial gauge 50...100 mm
- Take measurements at 3 positions in both lateral -A- and longitudinal -B- directions.
^ Deviation from nominal dimension: max. 0.08 mm


Crankshaft





2. 65 Nm + 1/4 turn (90°) further
^ When measuring radial clearance of crankshaft, tighten 65 Nm but do not turn further

3. Bearing caps
^ Bearing cap 1: pulley end
^ Bearing shell retaining lugs of cylinder block/bearing cap must be on same side





4. Bearing shell 3 (top)
^ For bearing cap without oil groove For cylinder block with oil groove Do not interchange used bearing shells (mark)

5. Thrust washers
^ For bearing cap, bearing 3
^ Note fixing arrangement






8. Pilot needle bearing
^ Pulling out and driving in

9. Crankshaft
^ Axial clearance
New 0.07...0.23 mm
Wear limit 0.30 mm

Check radial clearance with Plastigage
^ New 0.02...0.04 mm
^ Wear limit 0.15 mm

^ Do not rotate crankshaft when checking radial clearance
^ It is only possible to install the sensor wheel in one position, mounting holes are offset.

Bearing shell identification by color codes





Lower crankshaft bearing shells supplied as replacement parts are always color-coded yellow.