General Specifications
Surface Variation
Check cylinder head at multiple points for distortion, using straight edge and feeler gauges.
Max. permissible distortion 0.1 mm
Resurfacing cylinder head (face grinding) is only permissible to minimum dimension -a-.
Min. dimension: -a- 139.5 mm
Measuring Cylinder Bore
Using an internal dial gauge 50 to 100 mm, measure at 3 points in diagonal sequence horizontally -A- and vertically -B-.
Max. deviation from nominal dimension 0.08 mm
Crankshaft Dimensions
Axial clearance
New 0.090 to 0.251 mm
Radial clearance
New 0.017 to 0.044 mm
Wear limit 0.08 mm
Main Bearing Guide
Replace bolts - 1 to 20 -.
Tighten bolts for guide frame as follows:
Torque wrench bolts - 1 to 10 - 30 Nm
Torque wrench bolts - 11 to 20 - 20 Nm
Torque wrench bolts - 1 to 10 - 50 Nm
Torque wrench bolts - 11 to 20 - 30 Nm
Rigid wrench bolts - 1 to 10 - + 90 degrees (1/4 turn)
Rigid wrench bolts - 11 to 20 - + 90 degrees (1/4 turn)
Tighten bolts 9 Nm. in a diagonal sequence
(highlighted in illustration but not numbered)
Allocation of main bearing shells for new crankshafts
Allocation of crankshaft bearing shells for cylinder block
Bearing shells with correct thickness are allocated to the cylinder block in the factory. Colored dots on sides of bearing shells serve for identifying bearing shell thickness.
Allocation of bearing shells to cylinder block is marked by one letter each at front left on cylinder block (can be read from outside) as shown in the illustration.
^ In addition, the letters are also stamped on the guide frame.
Allocation of crankshaft bearing shells for guide frame - Version I
Bearing shells with correct thickness are allocated to the guide frame in the factory. Colored dots on sides of bearing shells serve for identifying bearing shell thickness.
Allocation of bearing shells to guide frame is marked by one colored dot each on crankshaft counterweight as shown in the illustration.
Allocation of crankshaft bearing shells for guide frame - Version II
Bearing shells with correct thickness are allocated to the guide frame in the factory. Colored dots on sides of bearing shells serve for identifying bearing shell thickness.
Allocation of bearing shells to guide frame is marked by one colored dot each on front crankshaft counterweight as shown in the illustration. The "X" marks the end of the letter series and stand next to color identification for bearing 1, belt pulley side.
Allocation of main bearing shells for used and reworked crankshafts
Allocation of crankshaft bearing shells for cylinder block
Bearing shells are allocated to cylinder block corresponding to color markings stamped into cylinder block.
For used and reworked crankshafts, the main crankshaft journals must be measured in order to allocate the matching bearing shells.
Basic dimension of main crankshaft journals = dia. 65.00 mm.
Repair stage of main crankshaft journals = dia. 64.75 mm.
Thicker over-sized bearing shells are available for reworked crankshafts. These have the same color markings as the original-size bearing shells.
Allocation of crankshaft bearing shells for guide frame
For used and reworked crankshafts, the main crankshaft journals must be measured in order to allocate the matching bearing shells.
Any other markings on the crankshaft are invalid when reworking crankshafts.
Allocate bearing shells to the determined diameter of main crankshaft journals according to the following table.
Connecting Rod
Torque 40 Nm + 90 degrees (1/4 turn)
Axial play
New 0.20 to 0.27 mm
Wear limit 0.30 mm
Axial play
New 0.20 to 0.27 mm
Wear limit 0.30 mm
Connecting rod, allocating with connecting rod bearing shells to crankshaft
Allocating connecting rod (width of connecting rod base) to crankshaft
The crankshaft is allocated to a connecting rod of the proper width at the factory. Stamped letters on the narrow side of the base identify the width of the base.
The allocation of the connecting rod to the crankshaft is identified by a letter on the front crankshaft counterweight, as shown in the illustration.
The numbers under the sequence of letters indicate the allocation of the crank pins from front to rear.
Connecting Rod Bearing
Radial clearance
New 0.020 to 0.069 mm
Wear limit 0.120 mm
Allocation of connecting rod bearing shell thickness to crankshaft
The crankshaft is allocated to connecting rod bearing shells of the proper thickness at the factory. Colored dots on sides of bearing shells serve for identifying bearing shell thickness.
The allocation of bearing shells to crankshaft is identified by a letter on the front crankshaft counterweight, as shown in the illustration.
The numbers under the sequence of letters indicate the allocation of the crank pins from front to rear.
Piston Ring
Vibration Damper/Crankshaft Pulley
Tighten vibration damper bolts - arrow - diagonally in 3 stages.
Torque wrench 15 Nm.
Torque wrench 22 Nm.
Torx key + 90 degrees (1/4 turn).