Cylinder Block Assembly: Service and Repair
Cylinder Block, Crankshaft and Flywheel/Drive Plate
Disassembling and Assembling
1. Crankshaft
- Axial clearance new: 0.07-0.23 mm
- Wear limit: 0.25 mm
- Measure radial clearance with Plastigage
- New: 0.018-0.045 mm
- Wear limit: 0.10 mm
- Do not rotate the crankshaft when checking the radial clearance
- For vehicles with automatic transmission with bearing bushings for torque converter see Fig. 3
2. Bearing cap
- Installation position see Fig. 1
- Bearing cap 4 with recesses for thrust washers
3. 60 Nm + 1/4 turn (90°) further
- To measure radial clearance, tighten to 60 Nm but do not turn further
4. Thrust washer
- For bearing cap 4
- Note fixing arrangement
5. Flywheel/drive plate
- Removing and installing needle bearing in flywheel see Fig. 2
6. For flywheel: 60 Nm + 1/2 turn (180°) further For drive plate: 60 Nm +l/4 turn (90°) further
- Lock with clamping bolt 3242 when loosening and tightening Fig. 4
7. Bearing caps
- Do not interchange used bearing shells (mark)
8. Sealing flange with oil seal
- Only replace complete
- Drain coolant before removing
- Fit spare part sealing flange with supplied sleeve
9. Gasket
- Always replace
10. 10 Nm
11. Thrust washer
- For cylinder block, bearing 4
12. 25 Nm
- Tighten by hand before tightening the bearing cap bolts
13. Cylinder block
14. Guide sleeve
Fig. 1 Bearing cap installation position
- Bearing cap 1 - Belt pulley side
- Bearing cap 4 - Flywheel side
Fig. 2 Removing and installing needle bearing
- Pull out needle bearing with commercially available puller e.g. KUKKO 21/2 or KUKKO 22-1.
- Drive in needle bearing with fitting drift 3264.
Fig. 3 Bearing bushing for torque converter
Note: Short and exchange engines as well as new and exchange crankshafts are supplied without bushings. The bushings must be driven in before installing the drive plate.
Fig. 4 Locking crankshaft with clamping bolt 3242
Remove sealing plugs and bring crankshaft to TDC No. 3 cylinder, then screw clamping bolt into TDC hole.