General Specifications
Surface Variation
Check cylinder head at multiple points for distortion, using straight edge and feeler gauges.
Max. permissible distortion 0.1 mm
It is only permitted to reface cylinder head to minimum dimension -a-.
Min. dimension: -a- 139.25 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 Dimension
Axial clearance
New 0.090 to 0.251 mm
Radial clearance
New 0.010 to 0.039 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)
Torque bolts 9 Nm in diagonal sequence.
(dark hatching in the illustration)
Allocation of main bearing shells for new crankshafts
Allocation of crankshaft bearing shells for cylinder block
Bearing shells with correct thickness are allocated to cylinder block in 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 left front 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 - crankshaft manufactured by Alfing
Bearing shells with correct thickness are allocated to 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.
Crankshafts manufactured by Alfing have no manufacturers identification.
Allocation of crankshaft bearing shells for guide frame - crankshaft manufactured by Weber
Bearing shells with correct thickness are allocated to 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).
Crankshafts manufactured by Weber have a manufacturers identification -A- on front crankshaft counterweight.
The letter series begins at left with bearing 5 (flywheel 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 matching bearing shells.
Basic dimension of main crankshaft journals = 65 mm dia.
Repair stage of main crankshaft journals = 64.75 mm dia.
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 determined diameter of main crankshaft journals according to the following table.
Connecting Rod
Torque 30 Nm + 90 degrees (1/4 turn)
Axial play
New 0.20 to 0.38 mm
Wear limit 0.60 mm
Connecting Rod Bearing
Radial clearance
New 0.028 to 0.077 mm
Wear limit 0.012 mm
Piston Ring
Vibration Damper/Crankshaft Pulley
Torque Specifications
