SECTION 6A - ENGINE MECHANICAL

(C22NE MODELS)

GENERAL DESCRIPTION

ENGINE PICTORIAL

FRONT VIEW

INLET SIDE VIEW

REAR VIEW

EXHAUST SIDE VIEW

TOP VIEW

MAIN DATA AND SPECIFICATION

ENGINE SPECIFICATION MATRIX FOR AUSTRALIA

CRANK CASE VENTILATION SYSTEM

ENGINE ASSEMBLY & LOOSE PARTS

OPERATIONS ON ENGINE AGGREGATES

ENGINE MOUNTS (ENGINE WITHOUT TRANSMISSION)

TOOTHED BELT TENSION, CHECK

TOOTHED BELT TENSION, ADJUST

TOOTHED BELT, REPLACE

OPERATIONS ON INSTALLED ENGINE

SEALING OPERATIONS

GASKE T, EXHAUST MANIFOLD, CYLINDER HEAD

GASKE T, INTAKE MANIFOLD, CYLINDER HEAD

SEAL RING, CAMSHAFT HOUSING, TIMING SIDE

SEAL RING, THERMOSTAT HOUSING, CYLINDER HEAD

SEAL RING - FRONT CAMS HAFT HOUSING, REPLACE

TOOTHED BELT REAR COVER

TOOTHED BELT TENSION ROLLER

COMPONENT PARTS

CYLINDER HEAD

HYDRAULIC V ALVE LIFTER

OPERATIONS ON CYLINDER HEAD AND CAMS HAFT HOUSING

CAMSHAFT

CAMSHAFT HOUSING REMOVAL AND INSTALLATION

CYLINDER HEAD

HYDRAULIC V ALVE LIFERS, REPLACE

CAMS HAFT HOUSING, REPLACE

CAMS HAFT HOUSING, CHECK FOR PLANE SURFACE

CYLINDER HEAD, REMOVAL AND INSTALLATION

CYLINDER HEAD, DISASSEMBLE AND ASSEMBLE

VALVE, GRIND

VALVE SEATING, MILL

CYLINDER HEAD, OVERHAUL

VAVLE GRIND

FLYWHEEL

STARTE R RING GE AR (MANUAL TRANSMISSION)

SEAL RING, CRANKSHAFT (OIL PUMP HOUSING)

SEAL RING, CRANKSHAFT REAR

GASKET, OIL PAN

OPERATIONS ON CRANKSHAFT

CON-ROD BEARING

PISTON WITH CON-ROD

CON-ROD

PISTON RINGS

OPERATIONS ON REMOVED ENGINE

CRANKSHAFT

BEARING FREE PLAY MEASUREMENT

1.PLASTIGAGE METHOD

2.MICROMETER AND GAUGE METHOD

BYPASS VALVE

OIL FILTER

OIL PUMP

OIL PUMP SAFETY VALVE

OIL PUMP (OVERHAUL)

OPERATIONS ON OIL CIRCULATION

CYLINDER HEAD SAFETY VALVE

OPERATIONS ON COOLING SYSTEM

COOLING SYSTEM, CHECK FOR LEAKS

COOLING SYSTEM, FILL UP AND BLEED

REFILL COOLANT

IGNITION TIMING, CHECK

ENGINE EXTERNAL PARTS

RADIATOR

THERMOSTAT

WATER PUMP

COATING SEALING SURFACES WITH SILICONE GREASE

ALTERNATOR

STARTER

V-BELT TENSION OF ALTERNATOR

V-BELT TENSION OF POWER STEERING PUMP

FUEL INJECTION SYSTEM

MAP SENSOR

PRESSURE REGULATOR

ECM (ENGINE CONTROL MODULE)

ECT

IDLE AIR CONTROL (IAC) VALVE

IGNITION COIL

CRANK POSITION SENSOR

FUEL INJECTOR

KNOCK SENSOR

OXYGEN SENSOR (IF APPLICABLE)

THROTTLE VALVE POSITION SENSOR

ACCE LERATOR P EDAL AND CABLE

AI R CLE ANER FILTER

SPARK PLUG THREAD

TECHNICAL DATA

SOHC GASOLINE ENGINE C22NE

OIL PUMP

COOLING SYSTEM

IDLE SPEEDS, CO CONTENT, IGNITION ADJUSTMENT

CYLINDER HEAD

CAMSHAFT

CRANKS HAFT, CYLINDER BLOCK

RECOMMENDED TORQUE V ALUES

SPECIAL SERVICE TOOL

GENERAL DESCRI PTION

ENGINE CLEANLINESS AND CARE

An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that

are measured in the thousandths of a millimeter (ten thousandths of an inch). Accordingly, when any internal engine

parts are serviced, care and cleanliness are important. Throughout this section, it should be understood that proper

cleaning and protection of machined surfaces and friction areas is part of the repair procedure. This is considered

standard shop practice even if not specifically stated.

lA liberal coating of engine oil should be applied to all friction areas during assembly to protect and lubricate the

surfaces on initial operation.

lWhenever valve train components, pistons, piston rings, connecting rods, rod bearings, and crankshaft journal

bearings are removed for service, they should be retained in order.

lAt the time of installation, they should be installed in the same locations and with the same mating surfaced as

when removed.

lBattery cables should be disconnected before any major work is performed on the engine. Failure to disconnect

cables may result in damage to wire harness or other electrical parts.

lThe four cylinders of this engine are identified as 1, 2, 3 and 4, as counted from crankshaft pulley.

GENERAL INFORMATION ON ENGINE SERVICE

The following information on engine service should be noted carefully, as it is important in preventing damage and

contributing to reliable engine performance:

lWhen raising or supporting the engine for any reason, do not use a jack under the oil pan. Due to the small

clearance between the oil pan and the oil pump strainer, jacking against the oil pan may cause damage to the oil

pick up unit.

lThe 12-volt electrical system is capable of damaging circuits. When performing any work where electrical

terminals could possible be grounded, the ground cable of the battery should be disconnected at the battery.

lAny time the intake air duct or air cleaner is removed, the intake opening should be covered. This will protect

against accidental entrance of foreign material into the cylinder, which could cause extensive damage when the

engine is started.

CYLINDER BLOCK

The cylinder block is made of cast iron. The crankshaft is supported by five bearings. The bearing caps are made of

nodular cast iron.

CYLINDER HEAD

The cylinder head is made of aluminum alloy casting.

VALVE TRAIN

Valve system is a single over head camshaft.

Hydraulic valve lifters, no adjustment necessary.

INTAKE MANIFOLD

The intake manifold is made of aluminum alloy.

EXHAUST MANIFOLD

The exhaust manifold is made of high Si-Mo nodular iron.

PISTONS AND CONNECTING RODS

Aluminum pistons are used after selecting the grade that meets the cylinder bore diameter. Each piston has two

compression rings and one oil control ring. The piston pin is made of cast hardened steel. The connecting rod bearings

are made of modular cast iron. The connecting rod bearings are made of steel backed with tri-metal babbitt metal.

CRANKSHAFT AND BEARI NGS

The crankshaft is made of modular cast iron. Pins and journal are graded for correct size selection for their bearing.

ENGINE PICTORIAL

FRONT VIEW

INLET SIDE VIEW

REAR VI EW

EXHAUST SIDE VI EW

TOP VIEW

MAIN DATA AND SPECIFICATIONS

Engine - General C22NE

Engine type Four-cycle, water cooled cross-flow with single over head camshaft

Micro-computer control, fuel injection

Combustion chamber type (Volume) Hemispherical (43.3cm3)

Timing train system Belt drive

No.of cylinders-bore × stroke mm (in) 4-86.0×94.6 (3.39×3.72)

Bore Spacing (C/L to C/L) 93.0 mm

Firing Order 1-3-4-2

Bore×Stroke 86.0×94.6mm

Total piston displacement cm3 (in3) 2,198 (134.39)

Combustion Chamber Volume 43.3 cm

No.of piston ring compression ring : 2 ,oil ring :1

Compression pressure kg/cm2 (psi/pa) 17.8 (253/1746)

Ignition timing (BTDC) No adjustment

Idling speed :rpm (WO/AC,W/AC)

Acoff 825

Valve clearances (At cold)

Intake mm (in) 0 (0) (Hydraulic valve lash adjustment)

Exhaust mm (in) 0 (0) (Hydraulic valve lash adjustment )

Intake valves

Open at (BTDC) deg 29

Close at (ABDC) deg 65

Exhaust valves

Open at (BBDC) deg 66

Close at (ATDC) deg 29

Ignition system Fully transistorized battery ignition

Distributor type Not applicable, Electronic Spark Timing control

Distributor advance type Not applicable, Electronic Spark Timing control

Spark plug type RN9YC4

Spark plug gap mm (in) 1.0--1.1 (0.039--0.043)

Lubrication system

Lubricating method Fully flow pressure circulation

Special engine oil (API grade) SE,SF,SG or SH grade

Oil pressure (psi/Pa) rpm (21.3/147)/825 (SAE 10W-30/API SE grade) engine oil after warm-

Oil pump type Gear

Oil filter type Cartridge full flow

Oil capacity lit. (US/UK gal.) with Oil Filter change 4.5litres

without Oil Filter change 4.25 (1.07/0.93) litres

Cooling system

Radiator type Corrugated fin with reserve tank

Coolant capacity lit. (US/UK gal.) 2.3 (0.66/0.55)

Water pump type Centrifugal

Thermostat Wax pellet with jiggle hole

Fuel system Electronically controlled Multi Port Fuel Injection System

Fuel pump ty pe Electric

Engine - General C22NE

Fuel pressure psi/Pa 48.4/334

Fuel filter type Cartridge paper element

Air cleaner type Dry paper element

Battery Type/V-Ax No. of units 50D20L 306 CCA

Alternator

Capacity V-A(W) 12-70 (840)

Starter

Output V-kW 12-1.4

Exhaust system CO Adjustment (1) Applicable to Open Loop System (Not equipped H2OS)

(2) Not applicable to Closed Loop System (Equipped H2OS)

Compression Ratio (with Tolerance) 9.2:1±0.3

Cylinder Head Material Aluminum Alloy (gravity cast)

Cylinder Block Material Cast Iron

No.of Mounting Points (including

trans.) 3

Engine Installation Angles-Longitudinal 3° 30'

-Lateral 7° 50' (towards exhaust side)

Overall Dimensions (L × W × H): 610×550×744 mm

Engine Weight 136kg

Camshaft Type SOHC

No.of Valves per Cylinder - Inlet

- Exhaust 1

Spark Plug Location Side

Port Arrangement Cross Flow

Valve System C22NE

Actuation Type Direct-acting Inverted Bucked Tappet

Valve Clearance Adjustment Hydraulic

Valve Rotor Type None

Inlet-Valve Material Chromium Alloyed Steel

-Seat Insert Material Sintered Iron

Exhaust-Valve Material Head:Cr-Mn-Ni Alloyed

Shaft:Cr-Si Alloyed&Cr plated

-Seat Insert Material Sintered Iron

Valve Spring Material GME 06 100-C1

Valve Guide Material QS 13 MR 00

Valve Seal Type Lip

Water Pump C22NE

Type Centrifugal

Drive-Material&Type HNBR Toothed-belt

Bearing Type Double Row Ball

Shaft Seal Type Mechanical Ceramic

Thermostat-Coolant C22NE

Type Bypass

Oil Pump & Filter C22NE

Type Gear Pump

Location Front of Engine

Drive Direct Crankshaft Driven

Filter Type Full Flow with Bypass for blocked filter

Oil&Oil Reservoir C22NE

Reservoir-Description&Location 1-piece below Engine

Reservoir Material Aluminium Alloy (pressure cast)

Replacement Oil Fill Volume

-With FIlter change 4.5L

-without Filter change 4.5L

Recommended Oil - Normal use API SG or SH Engine oil with a viscosity of 20W/50

Prolonged use in snow areas API SG or SH Engine oil with a viscosity of 15W/40

Ignition Components C22NE

Spark Plugs Conventional

Type Electronic Spark Control

No.of Coils&Type 2 Solid State

Coil Location Engine-mounted

Ignition Lead Type Inductive (hi-resistance)

Crankshaft C22NE

Material Nodular Cast Iron

Bearing subjected to End Thrust Guide Bearing NO.3

Main Bearing-Material&Type Steel Backed Tri-metal Babbitt

Front Seal-Diameter&Type 35.0mm Lip Seal

Rear seal-Diameter&Type 90.0mm Micro-lip Seal

Crankshaft Balancing Individually Balanced

No.of Counterweights 8

Camshaft C22NE

Location Overhead(Cylinder Head)

Material Chilled Cast Iron

Bearing Material Aluminium

No.of Bearings HNB 5

Pistons C22NE

Material Aluminium Alloy

Finish & Type Tin-coated Strut-less

Piston Rings C22NE

Function (top to bottom) -Ring 1 Compression Ring

-Ring 2 Compression Ring

-Ring 3 Oil Ring

Description-Ring 1 Rectangular

-Ring 2 Taper Face

-Ring 3 3-piece (2 Scrapers&1 Expander)

Material-Ring 1 Molybdenum Inlay Nodular Cast Iron

-Ring 2 Cast Iron (individually cast)

-Ring 3 Steel

Piston Pins C22NE

Material Case Hardened Steel

Retention Locked in Rod

Bearing Machined in Piston Pin Boss

Connecting Rod C22NE

Material Nodular Cast Iron

Bearing-Material&Type S teel Backed Tri-metal Babbitt

Inlet Manifold C22NE

Material Aluminium Alloy

Exhaust Manifold C22NE

Description Dual Take-down

Material High Si-Mo Nodular Iron

ENGINE SPECI FICATION MATRIX FOR AUSTRALIA

HEC FOR TF MODEL:

AUSTRALIA

VEHICLE MODE L TFR/S (141)

2.2L

VEHICLE TYPE 4×2

VEHICLE IDENT. CODE TA

ENGINE TYPE C22NE

FUEL CONTROL

SYSYTEM OPEN LOOP

COMPRESSION RATIO 9.2:1

FUEL OCTANE 91RON

FUEL TYPE UN-LEADED

OXYGEN SENSOR NO

EVAP CANISTER YES

PURGE CONTROL

SOLENOID YES

CHECK & RELIEF VALVE YES

ECM YES

EXHAUST SYSTEM

FRONT PIPE

MUFFLER

TWC YES

CO ADJUSTMENT YES

Refer to 6A-78

CRANKCASE VENTILATION SYSTEM

The Engine Ventilation System passes crankcase vapours, via the Engine Vent Pipe, to the Cam Support Cover, where

separation of oil and exhaust gases occurs. The oil drains into the Cylinder Head, via the Camshaft Support. The gases

pass through the Primary and Secondary Vent Hoses to the intake system, and are consumed during the combustion

process.

ENGINE ASSEMBLY & ACCESSORIES

ACCESSORIES

1 Alternator

2 P/S Pivot Spacer

3 P/S Adjusting Screw

4 P/S Adjusting Plate

5 P/S Adjusting Nut

6 Alternator & Fan Drive Belt

7 A/C Compressor Drive Belt

8 P/S Pump Drive Belt

9 TENSIONER Bolt

10 TENSIONER Pulley

11 Pulley Dust Shield Cover

12 Pulley Spacer

13 A/C Compressor Bracket

14 Pulley Bolt

15 Fan Pulley

16 Cooling Fan

ENGINE ASSEMBLY

20 C22NE

OPERATIONS ON ENGINE AGGREGATES

ENGINE MOUNTS (ENGINE WITHOUT TRANSMISSION)

REMOVAL

1. Remove bonnet.

2. Remove radiator.

3. Remove air inlet hose.

4. Remove power steering pump drive belt and power

steering pump from engine.

5. Remove all cable connections, hoses and lines from

engine.

6. Remove accelerator cable from inlet pipe.

7. Remove exhaust pipe from manifold.

8. Remove lower nine bolts and transmission from engine

block.

9. Remove clutch slave cylinder and allow to hang free.

10. Remove starter from engine block.

11. Remove upper bolts of left and right engine mounting

from damping blocks.

12. Raise engine slightly.

13. Remove lower bolts of left and right damping blocks.

14. Remove damping blocks.

Attach engine to cable, support transmission with car jack and

remove upper transmission fastening bolt.

Press off engine from transmission and lift out of engine

compartment.

INSTALLATION

Lower engine into engine compartment and insert guide

bushings on cylinder block into transmission.

TIGHTEN (TORQUE)

Transmission to cylinder block (M10) -45 N⋅m (4.6 kgf⋅m)

Transmission to cylinder block (M12) -60 N⋅m (6.1 kgf⋅m)

INSTALLATION

1. Install engine to vehicle and transmission.

2. Install clutch slave cylinder.

TIGHTEN (TORQUE)

Transmission to engine block bolts - 76 N⋅m (7.6 kgf⋅m)

3. Install left engine-mounting block to sidemember.

4. Install left and right engine damping blocks to engine

brackets.

TIGHTEN (TORQUE)

Engine damper block to sidemember - 52 N⋅m (5.3 kgf⋅m)

Engine damper block to engine bracket - 85 N⋅m (8.6 kgf⋅m)

5. Install exhaust pipe to manifold.

6. Install power steering pump and V-belt.

ADJUST

Adjust power steering pump V-belt tension according to the

corresponding operation.

INSTALLATION

7. Install radiator according to the corresponding operation.

8. Install air inlet hose.

9. Install all electrical cable connections, hoses and lines to

engine.

10. Install accelerator cable from inlet pipe.

11. Install bonnet.

INSPECTION

1. Check engine oil level.

2. Fill up cooling system and bleed according to the

corresponding operation.

TOOTHED BELT AND TIMING CHECK

REMOVAL

1. Remove the belts on the bracket for alternator.

2. Remove the fan.

3. Remove the V-belt for power steering.

4. Remove the V-belt for A/C.

5. Remove the fan belt.

6. Remove the fan shroud.

7. Remove the crankshaft pulley while counterholding on

the fastening bolt of toothed belt drive gear.

8. Remove the toothed belt from cover.

INSPECTION

1. Turn the crankshaft in the engine rotational direction

mark (2) so that the notch (1) on the camshaft gear

aligns with the mark on toothed belt rear cover.

2. Check the timing belt for wear, cracks or oil adhesion.

3. Check that the cast on the water pump aligns with the

counterpart on cylinder block (arrowed).

4. The tension of a NEW toothed belt is correctly adjusted

when the pointer and the center of the notch are aligned

(I).

The tension of a RUN-IN toothed belt (regardless of

mileage covered) is correctly adjusted when the pointer

is positioned approx. 4mm (0.16 in.) to the left of the

center of the notch (2).

Check the condition of the run-in toothed belt for

suitability for reuse. Only toothed belts of the toothed

belt tension rollers must be replaced and the source of oil

contamination must be eliminated.

INSTALLATION

1. Install the toothed belt to the cover.

2. Install the crankshaft pulley while counterholding on the

fastening bolt of toothed belt drive gear.

3. Install the fan shroud.

TIGHTEN(TORQUE)

Crankshaft pulley bolts - 20 Nm (2.1 kgf.m)

4. Install the fan belt

5. Install the V-belt for A/C.

6. Install the V-belt for power steering.

7. Install the fan.

8. Install the belts on the bracket for alternator.

TOOTHED BELT TENSION, ADJUST (ENGINES WITH TOOTHED BELT TENSION ROLLER)

REMOVAL

Refer to 6A. Toothed Belt and Timing check and removal

steps.

ADJUST

1. Loosen the fastening bolt of the toothed belt tension

roller.

2. Turn the toothed belt tension roller at adjustment

eccentric (1) in the direction of arrow (counterclockwise),

until pointer (2) comes to the right stop.

3. If necessary tighten the fastening bolt of toothed belt

tension roller.

4. Rotate the crankshaft twice (720°) in the engine

rotational direction until marks (2) and (1) align again.

5. Turn the eccentric in the direction of arrow (clockwise)

until pointer (1) and notch (2) are positioned to suit age of

toothed belt. The tension of a NEW toothed belt is

correctly adjusted when the pointer and the centre of the

notch are aligned (I).

The tension of a RUN-IN toothed belt (regardless of

mileage covered) is correctly adjusted when the pointer

is positioned approx. 4mm (0.16 in.) to the left of the

centre of the notch (2).

6. Rotate the crankshaft twice (720°) in the engine

rotational direction again and correct adjustment if

necessary.

INSTALLATION

Refer to 6A Toothed Belt and Timing check and installation

steps.

TOOTHED BELT, REPLACE ( ENGINE WI TH TOOTHED BELT TENSION ROLLER)

REMOVAL

1. Remove the belts on the bracket for alternator.

2. Remove the fan.

3. Remove the V-belt for power steering.

4. Remove the V-belt for A/C.

5. Remove the fan belt.

6. Remove the fan shroud.

7. Remove the crankshaft pulley while counterholding on

the fastening bolt of toothed belt drive gear.

8. Remove the toothed belt from cover.

ADJUST

Turn the crankshaft in the engine rotational direction to mark

(2).

Align markings on toothed belt and on toothed belt rear cover.

Simultaneously, notch (1) on camshaft gear must align with the

mark on toothed belt rear cover.

Turn the crankshaft slowly and smoothly.

ADJUST

Loosen the fastening bolt of the toothed belt tension roller and

turn the adjustment eccentric in the direction of arrow

(clockwise) until pointer (1) comes to the left stop.

Remove the toothed belt.

INSTALLATION

1. Install a new toothed belt while keeping tension side taut.

ADJUST

Toothed belt tension - see operation " Toothed Belt Tension".

2. Install the toothed belt to the cover.

3. Install the crankshaft pulley while counterholding on the

fastening bolt of toothed belt drive gear.

4. Install the fan shroud.

5. Install the fan belt.

6. Install the V-belt for A/C.

7. Install the V-belt for power steering.

8. Install the fan.

9. Install the belts to the bracket for alternator.

OPERATIONS ON INSTALLED ENGINE

SEALING OPERATIONS

GASKET, EXHAUST MANIFOLD, CYLINDER HEAD

REMOVAL

1. Remove front exhaust pipe from exhaust manifold.

2. Remove exhaust manifold heat shield.

3. Remove exhaust manifold retaining nut.

4. Remove exhaust manifold from cylinder head.

CLEAN

Sealing surfaces.

TIGHTEN (TORQUE)

Exhaust manifold to cylinder head - 22 N⋅m (2.2 kgf⋅m)

Front exhaust pipe to exhaust manifold - 25 N⋅m (2.6 kgf⋅m)

GASKET, INTAKE MANIFOLD, CYLINDER HEAD

REMOVAL

1. Remove air intake hose.

2. Remove drives belt for alternator.

3. Remove bolt clamping bracket for alternator from intake

manifold.

4. Remove intake manifold from cylinder head.

CLEAN

Sealing surfaces

TIGHTEN (TORQUE)

Intake manifold to cylinder head - 22 N⋅m (2.2 kgf⋅m)

Clamping bracket for alternator to intake manifold - 25 N⋅m (2.5

kgf⋅m)

INSTALLATION

1. Install V-belt according to the corresponding operation.

2. Install air intake hose.

SEAL RING, CAMSHAFT HOUSI NG , TIMING SIDE

REMOVAL

1. Remove front toothed belt cover toothed belt from

camshaft timing gear according to the corresponding

operation.

2. Remove camshaft housing cover and camshaft timing

gear.

3. Remove sealing ring by making hole in middle of ring,

turning in self-tapping screw and edging out.

INSTALLATION

1. Install sealing ring by using 5-8840-0451-0 with camshaft

sprocket bolt and washer.

2. Install coat seal lips of shaft seal ring slightly.

SEAL RING, THERMO STAT HOUSING , CYLINDER

HEAD

REMOVAL

1. Open radiator drain tap and collect coolant.

2. Remove toothed belt rear cover and toothed belt

according to the corresponding operation.

3. Remove camshaft housing cover.

4. Remove camshaft timing gear by counterholding

camshaft with a flat spanner.

5. Remove cable from temperature sensor.

6. Remove upper inner hex bolts of rear toothed belt cover.

7. Turn rear toothed belt cover to one side.

8. Remove thermostat housing.

9. Remove sealing ring from cylinder head.

CLEAN

Sealing surfaces in cylinder head and thermostat housing.

INSTALLATION

1. Install sealing ring in recess of cylinder head.

2. Install cable to temperature sensor.

3. Install upper bolts of rear toothed belt rear cover.

4. Install camshaft timing gear then check timing according

to the corresponding operation.

5. Install camshaft housing cover.

6. Install toothed belt and front cover.

7. Fill up and bleed cooling system according to the

corresponding operation.

TIGHTEN (TORQUE)

Thermostat housing to cylinder head - 15 N⋅m/1.5 kgf⋅m.

SEAL RING - FRONT CAMSHAFT HOUSING,

REPLACE

REMOVAL

Mark running direction of toothed belt.

Remove toothed belt-see operation “Toothed Belt, Replace”.

Camshaft housing cover, camshaft pulley-counterhold on hex

of camshaft.

REMOVAL

Screw self-tapping screw into seal ring.

Edge out seal ring.

INSTALLATION

Lightly coat sealing lip of seal ring with protective grease.

Install seal ring with 5-8840-0451-0 into camshaft housing-use

screw and washer of camshaft pulley.

INSTALLATION

Camshaft pulley: counter-hold camshaft at hexagon, near

camshaft housing cover.

Toothed belt-see operation “Toothed Belt, Replace”.

Note operating direction of toothed belt.

TIGHTEN (TORQUE)

Camshaft pulley to camshaft-45 N⋅m (3.7 kgf⋅m)

TIGHTEN (TORQUE)

Camshaft housing cover to cover to housing-8 N⋅m (0.8 kgf⋅m)

TOOTHED BELT REAR COVER ( ENGINE WITH TOOTHED BELT TENSION ROLLER)

REMOVAL

1. Mark operating direction of toothed belt.

2. Remove toothed belt according to the operation "Toothed

Belt".

3. Remove toothed belt tension roller according to the

operation "Toothed Belt Tension Roller ".

4. Remove fastening bolt while counter-holding with 5-8840-

2598-0 (Holding wrench).

5. Remove toothed belt drive gear while counter-holding

with 5-8840-2598-0 (Holding wrench).

6. Remove camshaft housing cover.

7. Remove camshaft pulley while counter-holding camshaft

at hexagon.

8. Remove toothed belt rear cover (arrows) from oil pump

and camshaft housing.

INSTALLATION

1. Install toothed belt rear cover.

2. Install camshaft pulley while counter-holding at camshaft

hexagon.

3. Install camshaft housing cover.

TIGHTEN (TORQUE)

Toothed belt rear cover to oil pump and camshaft housing - 6

Nm/4 lb/ft.

Camshaft housing cover to housing - 6 N⋅m (0.6 kgf⋅m).

Camshaft pulley to camshaft - 45 N⋅m (4.6 kgf⋅m).

4. Install toothed belt drive gear to crankshaft - 130 N⋅m

(13.3 kgf⋅m).

5. Install toothed belt according to the operation "Toothed

Belt".

TOOTHED BELT TENSION ROLLER

REMOVAL

1. Mark operating direction of toothed belt.

2. Remove toothed belt according to the operation "Toothed

Belt”.

3. Remove toothed belt tension roller (1) from oil pump.

INSTALLATION

1. Install toothed belt tension roller and make sure that the

locking lever (1) engages in the guide lugs (arrowed) on

the oil pump housing.

2. Install toothed belt according to the operation "Toothed

Belt" with paying attention to the operating direction of

toothed belt.

TIGHTEN (TORQUE)

Toothed belt tension roller to oil pump - 25 N⋅m (2.5 kgf⋅m)

COMPONENT PARTS

CYLINDER HEAD

(A)

1. Camshaft Housing Cover

2. Camshaft Housing

3. Camshaft

4. Cylinder Head

(A) Valve Gear

HYDRAULI C VALVE LIFTER

1. Hydraulic Valve Lifter 1. Oil reservoir

2. Piston with ball head (moving)

3. Pressure Cylinder (fixed)

4. Check ball

5. Pressure chamber

6. Oil feed

OPERATI O NS ON CYLINDER HEAD AND CAM SHAFT HOUSING

CAMSHAFT

REMOVAL

1. Remove cylinder head according to the corresponding

operation.

2. Remove camshaft housing from cylinder head and lay

housing on base provided

3. Remove rear sealing gasket and plate camshaft housing

with taking care not to damage housing.

4. Remove thrust plate.

5. Remove camshaft.

6. Remove front sealing gasket and plate from camshaft

housing with taking care not to damage housing.

INSPECTION

All parts.

INSTALLATION

1. Install camshaft.

2. Coat sliding surfaces with molybdenum disulphide

grease.

TIGHTEN (TORQUE)

Thrust plate for camshaft housing - 8 N⋅m (0.8 kgf⋅m)

CAM SHAFT HOUSING, REMOVAL AND INSTALLATION

See operation Camshaft

CYLINDER HEAD

IMPORTANT:

Remove cylinder head only from cold engine (room

temperature).

REMOVAL

1. Remove ground cable from battery.

2. Open radiator drain tap and collect coolant.

3. Remove air intake hose.

4. Remove all cable connections, hoses and lines to the

cylinder head.

5. Remove accelerator cable on the throttle valve.

6. Remove V-belt for alternator.

7. Remove front toothed belt cover according to the

corresponding operation.

8. Bring piston of 1st cylinder to TDC and mark the position.

9. Remove camshaft housing cover.

10. Remove camshaft timing gear after releasing tension on

toothed belt.

11. Remove upper bolts of rear toothed belt cover.

12. Remove exhaust pipe from exhaust manifold.

13. Remove cylinder head after loosening bolts from outside

inwards (at first quarter turn then half turn) in a spiral

pattern.

14. Remove camshaft housing from cylinder head.

15. Remove rocker arm, pressure parts and hydraulic valve

lifter adjuster.

CLEAN

All sealing surfaces, drill holes in cylinder head bolts.

Check cylinder block and cylinder head for plane surface

according to the corresponding operations.

INSTALLATION

1. Install cylinder head sealing with marking "OBEN/TOP"

facing upwards and to right side of engine.

2. Install cylinder head on cylinder block.

3. Install hydraulic valve lash adjuster, pressure parts and

rocker arm - molybdenum disulphate paste.

4. Install camshaft housing-Sealing Compound TB-1207C

or equivalent.

IMPORTANT:

Use new cylinder head bolts.

Screw in bolts until they rest on cover.

TORQUE - ANGLE METHOD

Cylinder head to cylinder block - 25 N⋅m (2.5 kgf⋅m)

Further turn angle 90°+90°+ 90°.

Tighten cylinder head bolts from inside outwards. In four

stages in a spiral pattern.

5. Install rear toothed belt cover onto camshaft housing.

6. Install toothed belt and apply tension according to the

corresponding operation.

TIGHTEN (TORQUE)

Camshaft timing gear to camshaft - 45 N⋅m (4.6 kgf⋅m)

7. Install camshaft housing cover and front toothed belt

cover.

8. Install cable connections, all hoses and lines onto

cylinder head.

9. Adjust accelerator cable for free of play.

10. Install V-belt according to the corresponding operation.

11. Install air intake hose.

12. Install front exhaust pipe.

13. Install ground cable onto battery.

14. Fill up cooling system and bleed according to the

corresponding operation.

HYDRAULI C VALVE LIFTERS, REPLACE

REMOVAL

1. Remove the spark plug connectors and spark plugs.

2. Remove the camshaft housing cover.

3. Turn the crankshaft at fastening bolt of toothed belt drive

gear in the direction of the engine rotation until the cam

of hydraulic valve lifter being replaced stands vertically.

4. Apply 5-8840-0457-0 to the camshaft housing, valve

spring cap and tension valve spring.

5. Remove the cam follower from camshaft housing.

Note thrust pieces.

6. Remove hydraulic valve lifter from camshaft housing.

CAM SHAFT HOUSING, REPLACE

REMOVAL

Cylinder head-see operation “Cylinder Head. Remove and

Install”.

INSPECTION

All parts, if necessary replace.

When replacing camshaft, always replace all cam followers.

INSTALLATION

Insert hydraulic valve lifter (1) in camshaft housing.

Coat sliding surfaces of rocker arm with Molybdenum Grease

(HN1461 or equivalent) and insert in camshaft housing.

ADJUST

Adjustment of the hy draulic valve liters is not required.

Pretension is provided by the design.

INSTALLATION

1. Remove 5-8840-0457-0 and install the camshaft housing

cover.

2. Insert the spark plug connectors.

TIGHTEN (TORQUE)

Guide plate to camshaft housing.

Insert camshaft with MoS2 paste.

INSTALLATION

1. Install the front seal ring in camshaft housing with

5-8840-0451-0.

2. Install the camshaft housing rear cover.

3. Install the cylinder head.

CAM SHAFT HOUSING, CHECK FO R PLANE

SURFACE

CLEAN

Sealing surfaces.

INSPECTION

Check length and width of sealing surface for deformation and

diagnosis for warpage and use straight edge feeler gauge.

MEASURE

Height of camshaft housing (sealing surface to sealing

surface).

Dimension I: (74.0 mm)

CYLINDER HEAD, REMO VAL AND INSTALLATIO N

IMPORTANT:

Only remove cylinder head with engine cold (room

temperature).

REMOVAL

1. Remove the alternator, power steering and V-belts.

2. Loosen the fastening bolts from alternator.

3. Loosen the lower alternator fastening bolt by swinging

the alternator to the rear.

4. Remove the front toothed belt cover.

5. Remove the toothed belt from camshaft pulley.

See operation "Timing Check and Adjust".

6. Remove the camshaft housing cover and camshaft

pulley by counter-holding at the hex head of camshaft.

7. Remove the fastening bolts from camshaft housing.

8. Remove the exhaust pipe from exhaust manifold.

9. Loosen the cylinder head bolts spirally from the outside

inwards (first 1/4, then 1/2 revolution).

REMOVAL

1. Remove the camshaft housing from cylinder head.

2. Remove the cam followers, thrust pieces and hydraulic

valve lifters.

Note the allocation.

3. Remove the cylinder head.

CLEAN

Sealing surfaces, bores and threads of cylinder head bolts.

INSPECTION

Check cylinder head and cylinder block for plane Surface-see

operations “Cylinder Head. Check for Plane Surface” and

“Cylinder Block, Check for Plane Surface.”

INSTALLATION

1. Install the cylinder head gasket.

Mark "OBEN/TOP" on top and turn it towards timing side

of engine.

2. Place cylinder head on cylinder block.

INSTALLATION

1. Insert the hydraulic valve lifters (3), thrust pieces (2) and

cam followers (1) with MoS2 paste.

Note allocation.

2. Apply a bead of Sealing Compound TB1207C to sealing

surface of cylinder head.

3. Install the camshaft housing on cylinder head.

TORQUE-ANGLE METHOD

Cylinder head and camshaft housing with new cylinder head

bolts to cylinder block.

Cylinder head bolts in sequence shown.

INSTALLATION

1. Install the rear toothed belt cover to camshaft housing.

2. Install the camshaft pulley to camshaft.

3. Install the camshaft housing cover to housing.

INSTALLATION

1. Install the toothed belt on camshaft pulley.

See operation "Timing Adjust".

2. Install the front toothed belt cover.

INSTALLATION

1. Install the fastening bolts.

2. Loosen the lower alternator fastening bolt.

3. Install the alternator, power steering and V-belts.

CYLINDER HEAD, DISASSEMBLE AND ASSEMBLE

REMOVAL

1. Remove the hydraulic valve lifters.

Lay aside in installation positions.

2. Remove the spark plugs, exhaust manifold and intake

manifold from cylinder head.

REMOVAL

1. Mark valves.

2. Remove the tension valve springs with 5-8840-2594-0

(1).

3. Remove valve keepers, valve spring cap and valve

spring.

REMOVAL

1. Remove the valve and valve stem seal.

2. Remove the valve spacer ring (1-exhaust) and valve

spring seat (2-intake).

3. Remove valve from cylinder head.

CLEAN

Sealing surfaces.

INSPECTION

Sealing surfaces for plane surface, guides, sliding and bearing

points for wear-see operation “Cylinder Head. Overhaul”.

INSTALLATION

1. Coat the valves with engine oil and insert in cylinder

head.

2. Install the valve spacer ring or valve rotator (exhaust)

and valve spring seal (intake).

3. Push the accompanying assembly sleeve onto valve

stem and coat with engine oil.

4. Insert a new valve stem seal with 5-8840-2601-0 (1).

5. Drive the valve stem seal carefully in to stop with light

hammer blow.

INSTALLATION

1. Install the valve springs and valve spring caps.

2. Install the tension valve springs with 5-8840-2594-0 (1),

valve keeper.

IMPORTANT:

Note markings made on valves.

TIGHTEN (TORQUE)

Exhaust manifold and intake manifold with new gaskets to

cylinder head.

Thermostat housing with new seal ring to cylinder head:

TIGHTEN (TORQUE)

Spark plugs with spark plug wrench to cylinder head.

INSTALLATION

1. Coat hydraulic valves lifters (1) with oil.

2. Insert them in cylinder head.

Note installation position.

VALVE, GRIND

Valves can be reused once or twice after regrinding-only if

there are no crater-like burns on the valve cone.

Excessive grinding can cause the upper valve head edge to

become too thin.

IMPORTANT:

Valve stem protection must not exceed dimension “A”-use 5-

8840-2596-0.

Do not regrind valve stem ends.

For all valve reworking note that angle of valve head is 44° and

the valve seat 45°-see also “Technical Data”.

VALVE, GRIND IN

Grind-In the valve to improve valve seating.

Grind-In by rhythmically lifting valves and turning uniformly.

Use commercially available grinding tool.

IMPORTANT:

Use only fine-grained pastes for grinding.

Lubricate valve stem before grinding in.

CLEAN

After grinding, carefully clean valve and valve seat.

VALVE GUIDE, REAM

MEASURE

Diameter of valve guide-dial gauge and internal measuring

instrument.

IMPORTANT:

Valve oversizes are available ex-works.

Oversize identification, on the valve guide and on the valve

stem end with the following specified identification

flgures/letters-see also “Technical Data”.

IDENTIFICATION MARK

Size Production Customer Service Reamer

Normal none K

0.075 mm 1 K1

0.150mm 2 K2

Ream valve guide from the upper side of the cylinder head to

the next oversize (use 5-8840-2599-0).

After reaming, cross out identification mark and stamp in new

identification mark.

VALVE SEATING, MILL

Place cylinder head on block of wood.

Inlet and exhaust, Guide Drift and Valve Seat Cutter 5-8840-

2593-0.

Valve seat-45°, side face, upper correction-30°, side face

(arrows on cutter).

Valve seat width:

Inlet-1.0 to 1.5 mm/0.04 to 0.06 in.

Exhaust-1.7 to 2.2 mm/0.072 to 0.088 in.

INSPECTION

Valve stem projection-use 5-8840-2596-0.

IMPORTANT:

If dimension “A” is exceeded, use new valves.

Check valve stem projection again. If dimension “A” is

exceeded, replace cylinder head.

CYLINDER HEAD, OVERHAUL

Cylinder head disassembled.

VALVE, GRIND

IMPORTANT:

Ensure that there are no crater-like burns on the valve cone.

Regrinding possible once or twice.

Grinding of valve stem end is not permitted.

Angle at valve head-44°

INSPECTION

Check valve stem projection as shown 5-8840-2596-0

VALVE, LAP IN

Lubricate valve stem, use fine-graining grinding paste.

Lift up valve from seat rhythmically using valve grinding tool

(1)-for distribution of grinding paste.

INSPECTION

Check contact pattern (I) on valve seat and in cylinder head.

CLEAN

Valves, valve guides, cylinder head.

FLYWHEEL

REMOVAL

1. Remove transmission and clutch.

2. Remove flywheel while locking with 5-88400-446-0.

TORQUE - ANGLE METHOD

Flywheel to crankshaft - 65 Nm/6.5 kgf⋅m.+30° to 45°

IMPORTANT:

Use new bolts.

Do not apply grease to the thread.

INSTALLATION

1. Install clutch and transmission.

COMPONENT PARTS

Fly wheel and Ring gear. (Manual Transmission)

STARTER RING GEAR (MANUAL TRANSMI SSION)

REMOVAL

1. Remove flywheel according to the corresponding

operation.

2. Drill starter ring gear underneath tooth gap approx.

8mm/0.30in. deep with 8mm/0.25in. diameter drill.

3. Separate starter ring gear with chisel on the drilling point.

INSTALLATION

1. Install starter ring gear with inner chamfered edge to

flywheel.

2. Heat starter ring gear evenly to 180°C /356°F to 230°C

/446°F (yellow paint mark)

3. Install flywheel according to the corresponding operation.

INSPECTION

Lateral run-out of starter ring gear - max. 0.5mm/0.02in.

SEAL RING, CRANKSHAFT (OIL PUMP HOUSING)

REMOVAL

1. Remove toothed belt rear cover according to the

corresponding operation.

2. Remove sealing ring by making hole in middle of ring,

turning in self-tapping screw and edging out.

INSTALLATION

1 Install the protective sleeve to the crankshaft.

2. Coat the sealing lip with protective grease.

3. Install the sealing ring.

4. Install the sealing ring using 5-8840-0455-0.

5. Install the rear toothed belt cover and toothed belt

according to the corresponding operations.

6. Replace the sealing ring with a new one.

7. Tighten the belt to the crankshaft.

SEAL RING, CRANKSHAFT REAR

REMOVAL

1. Remove transmission and clutch.

2. Remove flywheel or flex plate according to the

corresponding operations.

3. Make hole in middle of sealing ring, turn in self-tapping

screw and edge out.

INSTALLATION

1. Install protective sleeve.

2. Coat sealing lip with Protective Grease.

3. Install sealing ring using 5-8840-0459-0 and 5-8840-

2597-0.

4. Install flywheel, clutch and transmission.

REASSEMBLY

Reassemble clutch assembly.

DISASSEMBLY

Disassemble clutch assembly to flywheel using 5-8840-2634-0

TORQUE ANGLE-METHOD

Clutch assembly to flywheel-17.6Nm/1.8 kgfm.

GASKET, OIL PAN

REMOVAL

1. Loosen fixing bolts.

2. Remove oil pan from oil pump and cylinder block.

3. Remove oil intake pipe, oil intake pipe bracket, and oil

baffle plate.

CLEAN

Sealing surfaces.

INSTALLATION

1. Apply a bead of Sealing Compound, TB120TC or

equivalent to joint of oil pump.

2. Install baffle plate, or reuse baffle plate with vulcanised

gasket.

CAUTION:

Baffle plates with vulcanised gasket can be retrofitted without

difficulty - replace baffle plate with gasket.

3. Install oil intake pipe to oil pump and oil intake pipe

bracket to cylinder block.

4. Install oil pan and new gasket to cylinder block and insert

bolts with Locking Compound 15 10 177 (90 167 347).

Maximum assembly time including torque check is 10

min.

TIGHTEN (TORQUE)

Oil intake pipe to oil pump -8N⋅m (0.8 kgf⋅m)

Oil intake pipe bracket to cylinder block - 6 N⋅m (0.6 kgf⋅m)

Oil pan to cylinder block - 8 N⋅m (0.8 kgf⋅m) with vulcanized

gasket - 15 N⋅m (1.5 kgf⋅m)

OPERATI O NS ON CRANKSHAFT

CON-ROD BEARING

REMOVAL

1. Remove oil pan according to the corresponding

operation.

2. Remove con-rod bearing cap and con-rod bearing after

marking both sides.

CLEAN

Con-rod journal, con-rod bearing cap

INSTALLATION

1. Install new bearing shafts lightly coated with engine oil.

2. Install con-rod bearing cap.

TORQUE-ANGLE METHOD

Con-rod bearing cap to con-rod - 35N⋅m (3.5 kgf⋅m) + 45° to

60°

IMPORTANT:

Use new bolts.

3. Install oil pan according to the corresponding operation.

PISTON WI TH CON-ROD

REMOVAL

1. Remove cylinder head and oil pan according to the

corresponding operations.

2. Remove piston with con-rod after marking con-rod

bearing cap.

INSPECTION

Remove and install all parts, if applicable.

IMPORTANT:

Ring gap offset:

Piston rings - 180°.

Oil scraper rings - 25 to 50 mm/1 to 2 in. from gap of

intermediate ring to the left and to the right.

INSTALLATION

1. Install piston with con-rod by inserting with engine oil.

2. Coat piston rings with engine oil and compress with

piston ring compressor.

IMPORTANT:

Installation position:

Arrow / notch on piston head on timing side of engine

Beads on con-rod on clutch side

TORQUE-ANGLE METHOD

Piston to cylinder block.

Con-rod bearing cap to con-rod-35N⋅m (3.5 kgf⋅m) + 45° to 60°

IMPORTANT:

Use new bolts.

INSTALLATION

1. Install oil pan and cylinder head according to the

corresponding operations.

2. Install sealing Gasket or replace if damaged.

3. Install camshaft housing to cylinder head.

4. Install cylinder head according to the corresponding

operation.

CON-ROD

REMOVAL

1. Remove piston with con-rod according to the

corresponding operation.

2. Disassemble con-rod piston assembly by pressing out

piston pin, using 5-8840-0468-0.

INSTALLATION

1. Slide guide drift (5-8840-0468-0) in horizontal position

through piston and con-rod as far as side plate stops.

2. Tighten bolts evenly so that the piston rests flush on the

rear plate.

3. Remove centre piece from guide drift and insert piston

bolts (lubricated) into guide drift.

4. Heat a new con-rod to 280°C in the oil bath.

5. Install the con-rod to the piston and insert the piston pin.

IMPORTANT:

Since the con-rods have no weight balancing studs, re-working

is not possible.

Exchange con-rods in sets only.

Installation position, beads on con-rod point to the flattening on

the piston pin eye.

Firmly seated piston pin cannot be pushed in. Carry out

installation quickly.

OPERATI O NS ON CRANKSHAFT

CON-ROD BEARING

REMOVAL

1. Remove oil pan according to the corresponding

operation.

2. Remove con-rod bearing cap and con-rod bearing after

marking both sides.

CLEAN

Con-rod journal, con-rod bearing cap

INSTALLATION

1. Install new bearing shafts lightly coated with engine oil.

2. Install con-rod bearing cap.

TORQUE-ANGLE METHOD

Con-rod bearing cap to con-rod - 35N⋅m (3.5 kgf⋅m) + 45° to

60°

IMPORTANT:

Use new bolts.

3. Install oil pan according to the corresponding operation.

PISTON WITH CON-ROD

REMOVAL

1. Remove cylinder head and oil pan according to the

corresponding operations.

2. Remove piston with con-rod after marking con-rod

bearing cap.

INSPECTION

Remove and install all parts, if applicable.

IMPORTANT:

Ring gap offset:

Piston rings - 180°.

Oil scraper rings - 25 to 50 mm/1 to 2 in. from gap of

intermediate ring to the left and to the right.

INSTALLATION

1. Install piston with con-rod by inserting with engine oil.

2. Coat piston rings with engine oil and compress with

piston ring compressor.

IMPORTANT:

Installation position:

Arrow / notch on piston head on timing side of engine

Beads on con-rod on clutch side

TORQUE-ANGLE METHOD

Piston to cylinder block.

Con-rod bearing cap to con-rod-35N⋅m (3.5 kgf⋅m) + 45° to 60°

IMPORTANT:

Use new bolts.

INSTALLATION

1. Install oil pan and cylinder head according to the

corresponding operations.

2. Install sealing Gasket or replace if damaged.

3. Install camshaft housing to cylinder head.

4. Install cylinder head according to the corresponding

operation.

CON-ROD

REMOVAL

1. Remove piston with con-rod according to the

corresponding operation.

2. Disassemble con-rod piston assembly by pressing out

piston pin, using 5-8840-0468-0.

INSTALLATION

1. Slide guide drift (5-8840-0468-0) in horizontal position

through piston and con-rod as far as side plate stops.

2. Tighten bolts evenly so that the piston rests flush on the

rear plate.

3. Remove centre piece from guide drift and insert piston

bolts (lubricated) into guide drift.

4. Heat a new con-rod to 280°C in the oil bath.

5. Install the con-rod to the piston and insert the piston pin.

IMPORTANT:

Since the con-rods have no weight balancing studs, re-working

is not possible.

Exchange con-rods in sets only.

Installation position, beads on con-rod point to the flattening on

the piston pin eye.

Firmly seated piston pin cannot be pushed in. Carry out

installation quickly.

PISTON RINGS

REMOVAL

1. Remove piston with con-rod according to the

corresponding operation.

2. Remove piston rings using commercially available ring

installer or piston ring clamp pliers.

CLEAN

Piston ring grooves - ground piece of old piston ring

INSPECTION

Piston ring gap

For piston ring sizes, permissible piston ring gaps - see

"Technical Data"

INSTALLATION

1. Install oil scraper ring.

2. Offset ring gaps of steel band rings each 25 to 50 mm/1

to 2in. to the left or right of the intermediate ring gap.

3. Install piston rings.

4. Offset ring gaps by approx. 180°.

5. Install second piston ring with identification mark "TOP"

facing upwards.

6. Install piston with con-rod according to the corresponding

operation.

OPERATIONS ON REMOVED ENGINE

CRANKSHAFT

REMOVAL

1. Mount the engine on an engine overhaul stand with

appropriate adapters.

2. Remove the aggregates, flywheel/drive disc, oil pan, and

oil pump according to the corresponding operation.

3. Mark the con-rod bearing cover.

4. Remove the crankshaft bearing cover.

5. Remove the crankshaft from cylinder block.

INSPECTION

Remove and install all parts if necessary

Crankshaft pulse pickup sensor rotor inspection and repair.

Inspect the crankshaft pulse pickup sensor rotor for excessive

wear and damage.

Replace the crankshaft pulse pickup rotor if the inspection

results exceed wear and damage limits.

INSTALLATION

1. Install the crankshaft pulse pickup sensor.

Torque: 13N



m (1.3 kgf



m)

2. Install new bearing shells into the cylinder block and

bearing cover.

3. Coat the bearing shafts with engine oil.

For oversizes-see “Technical Data”

4. Install a new crankshaft into the cylinder block.

NOTE

The sealing of the crankshaft can be corrected with light

blows with a rubber hammer on the crank arm (arrowed).

5. Apply a bead of sealant (TB-1207C or equivalent) in the

grooves of both bearing shells

IMPORTANT:

After installation of bearing cover, press in sealing compound

again from above, until compound emerges at the joints.

TORQUE - ANGLE METHOD

Bearing cover to cylinder block - 50 N⋅m (5.1 kgf⋅m) +40° to

50°

Con-rod bearing cover to con-rod - 35 N⋅m (3.5 kgf⋅m) +45° to

60°

Use new bolts.

6. Install oil pump, oil pan, rear crankshaft sealing,

flywheel/drive plate, and aggregates according to the

corresponding operations.

INSPECTION

Bearing play - bearing cover removed

MEASURE

With "Plastigage" (ductile plastic threads)

Cut threads to length of bearing width and lay axially between

crankshaft journal and bearing shell (arrowed).

Install bearing cover with correct torque.

IMPORTANT:

Grease crankshaft journal and lubricate bearing shell slightly

so that the thread does not tear when the bearing cover is

moved

INSPECTION

End play when bearing shells are installed.

Front end contact surfaces of flywheel/flexible plate.

Permissible end play - see "Technical Data "

INSPECTION

Out-of-round (run-out)-middle bearing shell removed when

mounting on front and rear bearing.

Permissible out-of-round - see "Technical Data"

BEARING FREE PLAY MEASUREMENT

Two methods for measuring bearing free play are described -

1. Plastigage method and 2. micrometer and gauge method.

The two procedures are suitable for measuring both con-rod

and main bearing free play.

For both methods ensure con-rod and main bearing caps are

identified (1) prior to removal as they are machine matched.

1. PLASTIGAGE METHOD

REMOVAL

1. Remove bearing cap and shell.

2. Lightly coat journals and bearings with engine oil to

prevent Plastigage from tearing when cap is removed.

INSTALLATION

1. Lay a length of Plastigage across width of crank pin and

fit bearing cap and shell using old bolts at this stage.

IMPORTANT:

Do not allow crankshaft to rotate.

TORQUE – ANGLE METHOD

Main bearing cap bolt - 60 N⋅m (6.1 kgf⋅m) +40° + to 50°.

Con-rod bearing cap bolts - 35 N⋅m (3.6 kgf⋅m) +45°.

REMOVAL

1. Remove bearing cap and shell.

MEASURE

Width of Plastigage -use scale supplied with Plastigage.

If con-rod bearing clearance exceeds 0.031mm/0.001in or

main journal bearing clearance exceeds 0.04mm/0.02in. -

check crankshaft journal diameters - see corresponding

operation.

Replace bearing if crankshaft is within specification - see

"Technical Data"

CLEAN

Plastigage from journals.

Lightly coat journals and bearings with engine oil.

INSTALLATION

Install bearing cap and shell using new bolts.

TORQUE – ANGLE METHOD

Main bearing cap bolt - 60 N⋅m (6.1 kgf⋅m) +40° to 50°.

Con-rod bearing cap bolts - 35 N⋅m (3.9 kgf⋅m) +45°.

2. MICROMETER AND GAUGE METHOD.

Crankshaft removed.

INSTALLATION

1. Install caps and bearing shells to con-rods and cylinder

block.

MEASURE

Con-rod and main bearing diameters at three points I, II, III

(arrowed).

Divide the sum of the three measurements by three to obtain a

mean diameter.

The top illustration shows con-rod measuring points.

The second illustration shows main bearing measuring points.

MEASURE

Crankshaft main and con-rod bearing journals at points II and

I. Divide the sum of both measurements to obtain a mean

diameter.

Crankshaft must be replaced if mean diameter of main or con-

rod journals is below specified limit - see "Technical Data".

If crankshaft is serviceable subtract crankshaft mean journal

diameters from corresponding shell bearing mean diameters to

determine bearing clearance.

Permissible main bearing clearance - 0.015 to 0.04mm/0.0006

to 0.002in.

Permissible con-rod bearing clearance - 0.006 to

0.031mm/0.002 to 0.001in.

BYPASS VALVE

REMOVAL

1. Remove oil filter.

2. Remove bypass valve by cutting thread in locking disc

with M 10 tap (3rd stage), turning in M 10 bolt and taking

out bypass valve from seating.

INSTALLATION

1. Install bypass valve using drift (diameter approx.

15mm/0.6in.).

OIL FILTER

REMOVAL

1. Remove oil filter using commercially available tool.

INSTALLATION

1. Install oil filter by hand and oil seal ring.

2. Fill up engine oil while preventing overflow.

OIL PUMP

REMOVAL

1. Remove rear toothed belt cover, and oil pan according to

the corresponding operations.

2. Remove oil filter, wiring plug from oil pressure switch, oil

pump from cylinder block, and oil pressure switch from

oil pump.

CLEAN

Sealing surfaces

INSTALLATION

1. Install oil pressure switch to oil pump, oil pump to cylinde

block, oil pan, wiring plug, oil filter and toothed belt cover.

TIGHTEN (TORQUE)

Oil pressure switch to oil pump - 30 N⋅m (3.2 kgf⋅m)

Oil pump to cylinder block - 8 to 12 N⋅m (0.6 kgf⋅m)

Oil intake pipe to oil pump - 8 N⋅m (0.8 kgf⋅m)

Intake pipe bracket to cylinder block - 8 N⋅m (0.8 kgf⋅m)

*Insert bolts with Loctite (Refer to

General Description Recommended Liquid Gasket)

OIL PUMP SAFETY VALVE

REMOVAL

1. Remove closure plug.

2. Remove seal ring.

3. Remove spring.

4. Remove piston.

INSTALLATION

1. Install piston (observe installation position).

2. Install spring.

3. Install seal ring.

4. Install closure plug.

TIGHTEN (TORQUE)

Closure plug - 30 N⋅m (3.0 kgf⋅m)

OIL PUMP (OVERHAUL)

REMOVAL

1. Remove oil pump according to the corresponding

operation.

2. Remove oil cover and pressure control valve.

INSPECT

Clearance between gear pair and housing upper edge - see

“Technical Data”.

Check housing, cover and pressure control valve.

INSTALLATION

1. Install pump cover with Sealing Compound 15 03 166 (90

094 714).

2. Install oil pump safety valve according to the

corresponding operation.

3. Install oil pump according to the corresponding operation.

OPERATI ONS ON OIL CIRCUI T

CYLINDER HEAD SAFETY VALVE

REMOVAL

1. Remove cylinder head according to the corresponding

operation.

2. Make hole in core plugs with pointed drift, turn in self

tapping screw and edge out.

IMPORTANT:

Cover oil duct in cylinder head with piece of cloth.

3. Pull out valve retainer, using commercially available tool.

4. Remove ball and spring.

5. Cut three threads in the ball seating with M 10 tap (3rd

stage).

6. Coat tap with grease.

7. Remove ball seating from cy linder head with

commercially available tool.

Do not damage cylinder head.

INSTALLATION

1. Install new pressure valve into cylinder head - with

suitable pipe until stop.

2. Install core hole plugs into cylinder head - with suitable

pipe to end of chamfer.

OPERATIONS ON COOLING SYSTEM

CAUTION:

Before working with the cooling system, be sure to confirm that

the temperature of the engine is cooled down.

Failure to observe this may cause burn.

COOLING SYSTEM, CHECK FOR LEAKS

INSTALLATION

1. Install commercially available coolant checking

instrument onto compensation tank (Refer to

Section 6B; Engine cooling).

2. Check coolant level.

INSPECTION

Use 5-8840-0277-0 tester & 5-8840-2603-0 adaptor.

COOLING SYSTEM, FILL UP AND BLEED

IMPORTANT:

Radiator and heater core are made from aluminium.

To avoid corrosion, use only anti-freeze with corrosion

protection.

REPLACE CO OLANT

1. Confirm the engine is cold enough.

2. Open the radiator cap, pour coolant to the filler neck level

and close the cap.

3. Pour coolant into the reservoir until MAX line is reached.

4. Start the engine, run 2 ∼ 3 minutes at idling speed and

switch off the engine.

5. Refill coolant if the coolant level is lowered.

IMPORTANT:

Do not loosen or open the radiator cap when coolant is hot.

Doing so may cause hot water or steam to splash out, resulting

in burn. When opening the radiator cap, be sure to confirm the

coolant is cold. Cover a thick cloth over the cap and loosen it

slowly to reduce pressure, then open the cap.

6. Close the radiator cap firmly and run the engine at

approx. 2000 rpm. In addition, set the heater temperature

adjuster to the max position to circulate coolant in the

heater conduit system.

7. Confirm that the temperature gauge reads half or more

of full scale and that the thermostat is activated.

Then continue idling 5 minutes more and switch off the

engine, and allow it to cool.

8. After the engine cools down, check the coolant level and

refill it if necessary. When the level is lowered extremely,

check the coolant conduit system and reservoir hose for

leak.

9. Pour coolant into the reservoir to MAX level.

REFILL COOLANT

IMPORTANT:

After closing the cooling system, let engine run warm until

thermostat opens (coolant approx. 92°C/197.6F)

INSPECTION

Coolant level

Allow engine to cool. If necessary, refill coolant.

Check that cooling system self-bleeds during engine warming-

up phase.

IGNITION TIMING, CHECK

NO ADJUSTMENT

ENGINE EXTERNAL PARTS

RADIATOR

REMOVAL

1. Remove the upper hose and lower hose.

2. Remove all V-belts.

3. Remove the cooling fan.

4. Remove the fan guide.

5. Remove the radiator.

INSTALLATION

1. Install the radiator.

2. Install the fan guide.

3. Install the cooling fan.

4. Install all V-belts.

5. Install the lower and upper hose.

THERMOSTAT

REMOVAL

1. Remove water outlet nozzles with thermostat from

thermostat housing.

2. Remove coolant hose and collect coolant.

IMPORTANT:

Remove and Install thermostat only together with water outlet

nozzles.

TIGHTEN (TORQUE)

Water outlet nozzles to thermostat housing - 8 N⋅m (0.8 kgf⋅m)

INSTALLATION

1. Install coolant hose.

2. Fill cooling system and bleed according to the

corresponding operation.

WATER PUMP

REMOVAL

1. Remove lower hose band from pipe band and collect

coolant.

2. Remove front toothed belt cover according to the

corresponding operation.

3. Remove water pump from cylinder block after releasing

tension on toothed belt.

CLEAN

Sealing surfaces

COATING SEALING SURFACES

WITH SILICONE GREASE

INSTALLATION

1. Install water pump to cylinder block with new rubber O-

ring.

2. Apply tension to toothed belt according to the

corresponding operation.

3. Install coolant hoses.

4. Fill cooling system and bleed according to the

corresponding operation.

ALTERNATOR

REMOVAL

1. Remove ground cable from battery.

2. Remove cable connection from alternator and V-belt.

3. Remove alternator from retaining strap and lower

fastening.

INSTALLATION

1. Install alternator by tightening firmly by hand.

2. Install V-belt and apply tension according to the

corresponding operation.

3. Install cable connections to alternator.

4. Install ground cable to battery.

STARTER

REMOVAL

1. Remove cable connections from starter.

2. Remove upper bolt of transmission side.

3. Remove lower bolt of engine side.

TIGHTEN (TORQUE)

Starter to cylinder block:

Engine side - 45 N⋅m (4.6 kgf⋅m)

Transmission side - 75 N⋅m (7.6 kgf⋅m)

Starter support to cylinder block - 25 N⋅m (2.5 kgf⋅m)

Re-connect cables.

V-BELT TENSION OF ALTERNATOR

MEASURE

Measure V-belt tension of alternator.

Permitted values for new V-belt are approx. 311-489N (31-50

kgf).

Note:

V-belt to deflection as loaded with 10kg : 8-12mm.

ADJUST

Adjust V-belt tension by loosening clamping bracket and lower

alternator bracket and moving alternator.

TIGHTEN (TORQUE)

Clamping bracket to alternator - 25 N⋅m (2.6 kgf⋅m)

Lower alternator bracket – 25 N⋅m (2.6 kgf⋅m)

V-BELT TENSION OF POWER STEERING PUMP

MEASURE

Measure V-belt tension of power steering pump. Permitted

values for new belt are approx. 578-712N (59-73 kgf) and 534-

667N (54-68 kgf) for used belt.

Note:

V-belt to deflection as loaded with 10kg : 8-12mm.

ADJUST

Adjust V-belt tension by loosening clamping bolt, lower pump

bracket, and adjusting nuts and moving steering pump.

TIGHTEN (TORQUE)

Adjusting nuts - 18 N⋅m (1.8 kgf⋅m)

Clamping bolt - 25 N⋅m (2.6 kgf⋅m)

Lower pump bracket - 26 N⋅m (2.6 kgf⋅m)

FUEL INJECTION SYSTEM

MAP SENSOR

REMOVAL

1. Disconnect the battery cable.

2. Disconnect the electrical connector from the sensor.

3. Remove the mounting bolts securing the sensor to the

manifold.

4. Remove the sensor from the intake manifold.

INSTALLATION

1. Push MAP sensor into the manifold.

2. Install the mounting bolts and tighten them.

3. Connect electrical connector.

4. Connect the battery cable.

PRESSURE REGULATOR

REMOVAL

1. Remove vacuum hose.

2. Remove fuel hoses.

3. Remove pressure regulator.

INSTALLATION

1. Install pressure regulator.

2. Install fuel hoses.

3. Install vacuum hoses.

ECM (ENGINE CONTROL MODULE)

REMOVAL

1. Remove the center console assembly.

2. Remove the ECM cover.

3. Remove 3 screws for the bracket.

4. Pull ECM out.

5. Disconnect the connectors.

INSTALLATION

1. Connect the connectors.

2. Install ECM to the proper position.

3. Tighten 4 screws to the bracket.

4. Install the ECM cover.

5. Install the center console assembly.

ECT

REMOVAL

1. Remove wiring harness plug and coolant temperature

sensor.

TIGHTEN (TORQUE)

Temperature sensor to intake pipe - 10 N⋅m (1.0 kgf⋅m)

Wiring harness plug to temperature sensor

INSPECTION

Coolant level

IDLE AIR CONTROL (IAC) VALVE

REMOVAL

1. Remove wiring harness plug, hose clamps and idle

speed adjuster.

INSTALLATION

1. Install idle speed adjuster, hose clamps and wiring

harness plug.

IGNITION COIL

REMOVAL

1. Remove 2 bolts, plug and ignition coil.

INSTALLATION

1. Install ignition coil, plug and bolts.

CRANK POSITION SENSOR

REMOVAL

1. Remove crank position sensor.

INSTALLATION

1. Install crank position sensor.

FUEL INJECTOR

REMOVAL

CAUTION: To reduce the risk of fire and personal injury, it

is necessary to relieve the fuel system pressure before

servicing the fuel system components.

CAUTION: After relieving the fuel system pressure, a small

amount of fuel may be released when servicing fuel lines

or connections. Reduce the chance of personal injury by

covering the fuel line fitting with a shop towel before

disconnecting the fittings. The towel will absorb any fuel

that may leak out. When the disconnect is completed,

place the towel in an approved container.

1. Depressurise the fuel system.

2. Disconnect the fuel inlet.

3. Disconnect the fuel return line.

4. Remove the fuel rail from the intake manifold.

5. Remove the fuel injector from the fuel rail by disengaging

claws.

INSTALLATION

1. Install the fuel injector to the fuel rail by engaging claws.

2. Install the fuel rail to the intake manifold.

3. Connect the fuel return line firmly.

4. Connect the fuel supply line firmly.

KNOCK SENSOR

REMOVAL

1. Remove fixing bolts.

2. Disconnect the connector at the other side.

TIGHTEN (TORQUE)

30N⋅m (3.2 kgf⋅m)

OXYGEN SENSOR (IF APPLICABLE)

REMOVAL

1. Remove wiring harness plug.

2. Remove oxygen sensor from the front exhaust pipe.

TIGHTEN (TORQUE)

Oxygen sensor in exhaust pipe - 30 N⋅m (3.1 kgf⋅m)

THROTTLE VALVE POSITION SENSOR

REMOVAL

1. Remove wiring harness connector.

2. Remove throttle valve position sensor.

INSTALLATION

1. Install throttle valve position sensor.

2. Install wiring harness connector.

ACCE LERATOR P EDAL AND CABLE

REMOVAL

1. Remove pad stopper from pedal stop bolt.

MEASURE

Dimension "A":

RD=15mm ± 0.5mm/0.59in. ± 0.02in.

LD=14mm ± 0.5mm/0.55in. ± 0.02in.

INSTALLATION

1. Install pad stopper.

INSPECTION

Ensure that accelerator pedal is fully in idle position and

accelerator level at engine is in closed position.

Pull outer sleeve of accelerator cable towards pedal and check

that clip on sleeve is in slot nearest to grommet.

Reposition clip if necessary, and check that full throttle and idle

positions are obtained at engine lever.

AI R CLE ANER FILTER

REMOVAL

1. Remove positive ventilation hose connector.

2. Remove intake air temperature sensor.

3. Remove mass air flow sensor.

4. Remove air cleaner duct assembly.

5. Remove air cleaner element.

INSPECTION

Check the air cleaner filter for damage or dust clogging.

Replace if it is damaged, or clean if it is clogged.

CLEANING METHOD

Tap the air cleaner filter gently so as not to damage the paper

filter, or clean the element by blowing with compressed air of

about 490 kPa (71 psi) from the clean side if it is extremely

dirty.

INSTALLATION

1. Install air cleaner element.

2. Attach the air cleaner duct cover to the body completely,

then clamp it with the clip.

3. Install mass air flow sensor.

4. Install mass air temperature sensor.

5. Install positive crankcase ventilation hose connector.

SPARK PLUG THREAD

RECONDITION

Ream thread and recut using commercially available spark

plug thread drill (observe manufacturer's instructions).

REMOVAL

Remove thread bush on spark plug. (Dimensions (A) =

17mm/0.67in.)

TIGHTEN (TORQUE)

Spark plug with thread bush into cylinder head - 25N⋅m (2.5

kgf⋅m) - use

TECHNICAL DATA

SOHC GASOLINE ENGINE C22NE

ENGINE OIL VISCOSITY

The following engine oils can be used:

A = single-grade oils

B = multigrade oils

C = easy run oils

Depending on the outside temperature.

ENGINE OIL QUALITY

It is important that the following API and CCMC classes are

used:

Engines Single and multigrade oils Easy run oils

Petrol API-SF/CC, SF/CD, SG/CC,

SG/CD, CCMC/G4 API-SF/CC, SF/CD, SG/CD

CCMC-G5/PD2

IMPORTANT:

CD engine oils designed by manufacturers especially for diesel

engines are not suitable for petrol engines, unless a sufficient

performance class for petrol engines (e.g. API-SF/CCMC-G4)

is also indicated.

DISPOSAL.

Observe the relevant national regulations when disposing of

used oil.

ENGINE OIL FILLING QUANTITIES

Initial filling

(litres) Filling quantity

with filter change*

(litres)

MIN to MAX

(litres)

4.25 4.5 1.00

*Up to mark "MAX" on oil dipstick

OIL PUMP

Backlash 0.1 to 0.2mm

Gaps in gears opposite housing 0.03 to 0.1mm

Oil pressure at idle speed Engine at operating

temperature (>70°C oil and

approx. 80°C coolant) 150

kPa/1.5 bar

Oil drain plug M14 × 1.5

COOLING SYSTEM

Radiator

Type: Cross-flow

Radiator core surface in cm2: 2000

Cooling system capacity (in litres): 7.2

COOLANT

50% HN2043 with wa ter

FAN

Type Visco Clutch Fan

Number of blades 5

Distribution of blades asymmetric

Diameter mm

RADIATOR CAP

Boiling point 123°C

Opening pressure kPa (bar) 120 to 135 (1.20 to 1.35)

THERMOSTAT

Start of opening 92°C

Fully opened 107°C

Type Bypassed

IDLE SPEEDS, CO CONTENT, IGNI TIO N

ADJUSTMENT

Appl i cabl e S yatem I dle speed in min -1 (rpm)

Manual CO content

in vol. % Ignition timing in CA BTDC (adjustment

ensues at able speed,

ignition marks must align) with TDC

sensor measuring instrum ent:

Closed Loop Syst em 825 *<0.4 *** 8 to 12

Open Loop System 825 **1.0+0.2

-0.5 *** 8 to 12

Note) * CO content adjustment not applicable.

** CO content adjustment refer to 6C1-93

*** Ignition timing adjustment not possible.

ADJUSTMENT VALUES/CHECKING VALUES

Valve clearance

Inlet Hydraulic valve lash adjustment

Outlet No adjustment necessary

Spark plugs - electrode gap 1.0 ∼ 1.1mm

Compression The difference in compression

between the individual cylinders

in the engine must not exceed

100 kPa (1 bar).

Pressure loss The pressure loss of an engine

in perfect condition per cylinder

is not more than max. 25%

CYLINDER HEAD

Cylinder Head Gasket

Thickness - installed mm 1.15 to 1.30

Valve seat width at cylinder head

inlet mm 1.0 to 1.5

outlet mm 1.7 to 2.2

Valve stem play inlet mm 0.018 to 0.052

outlet mm 0.038 to 0.072

Permissible valve stem to cone runout

inlet mm 0.03

outlet mm 0.33

Overall height of cylinder head

(Sealing surface to sealing surface) mm 96.00 ± 0.25

Installation height

inlet and

outlet valves mm 17.85 to 18.25

dimension "A" Distance Gauge

5-8840-2596-0

Installation height valve guide mm 83.50 to 83.80

Sealing surface peak-to-valley height mm max. 0.025

Valve System

Valve lifter valve play compensator

(hydraulic)

Valve rotators

(inlet or outlet) outlet

Valve play

(warm or cold) inlet mm 0

outlet mm 0

Valve Dimensions C 22 NE

A in mm B in

mm C(diameter in mm) and identification mark D

1) 2) Normal K Oversize K1

0.075 Oversize K2

0.150 Oversize A

0.250

Inlet valve 104.2 103.8 41.8 7.012

6.998 7.087

7.073 7.162

7.148 7.262

7.248 44°

Outlet valve 104.0 103.6 36.5 6.992

6.978 7.087

7.053 7.142

7.128 7.242

7.228 44°

Valve stem

bore - 7.050

7.030 7.125

7.105 7.200

7.180 7.300

7.280 -

1) Production

2) Customer service

The P and A department only supplies valves with a length of 103.8mm (inlet valve) and 103.6mm (outlet valve)

only

CAMSHAFT

Identification letter J

Colour code Normal size -

0.1mm undersize violet

Radial runout mm 0.03

End play mm 0.09 to 0.21

Cam lift Inlet and outlet valve mm 6.67

Grinding Dimension for Camshaft Bearing Position

Bearing Bearing journal

diameter in mm Diameter

in housing

normal -0.1mm normal -0.1mm

1 42.470

42.455 42.370

42.355 42.525

42.425 42.500

42.400

2 42.720

42.705 42.620

42.605 42.775

42.750 42.675

42.650

3 42.970

42.955 42.870

42.855 43.025

43.000 42.925

42.900

4 43.220

43.205 43.120

43.105 43.275

43.250 43.175

43.150

5 43.470

43.455 43.370

43.355 43.525

43.500 43.425

43.400

CRANKSHAFT, CYLINDER BLOCK

CYLINDER GRI NDING AND PISTON DIMENSIO NS

Cylinder Grinding and Piston Dimensions

Size Cylinde r bore dia. in mm Cylinder to Related pis ton dia. in mm Piston head

Crankshaft co- efficient

housing

co-efficient

over to over to

Production 1 85.97* 85.89 8 85.95 85.96 8

2 85.98

85.99

86.00

86.01

85.99

86.00

86.01

86.02

85.96

85.97

85.98

85.99

85.97

85.98

85.99

86.00

Customer

service Oversize

0.5mm 8.46 86.47 7+0.5 86.44 86.45 7+0.5

Piston diameter must be measured at the position "D".

*inclusive

CYLINDER BORE

Rebore cylinder Permissible oversize to 0.5mm (see parts

microfiche)

After reboring, invalidate original crankcase

housing coefficient and drive in new oversize

coefficient

Permissible out-of-round: 0.013mm

Permissible taper: 0.013mm

Measure out-of-round in bore at 4 different

heights

Piston projection above upper edge of cylinder block

0.40mm

Piston

Type Recessed pistons

Clearance For short-blocks and cylinder blocks with

complete pistons, the clearance is 0.02 to

0.04mm

For replacement (oversize), depending on

available pistons, a clearance of 0.02 to

0.04mm is permissible

PISTON RINGS

Square ring Height mm 1.5

Tapered ring Height mm 1.5

Oil scraper Height mm 3

Ring gap offset 180°

Note that the upper steel band ring gap is offset 25 to 50mm to

the left and the lower 25 to 50mm to the right opposite the

intermediate ring gap.

Piston Pin

Length mm 61.5

Diameter mm 21

Type Shrunk into con-rod

Play mm

in piston 0.011 to 0.014

in con-rod none

Installation When installing piston pins,

heat con-rods to approx.

280°C in oil bath. This

temperature should under no

circumstances be exceeded.

The permissible weight variation of con-rods without piston and

bearing shell inside an engine is 8 g.

As the con-rods do not have balancing studs, reworking is not

possible.

Con-rods can only be replaced in sets.

CRANKSHAFT GRINDING DI M E NSI ONS

Crankshaft

jounal

I, II, IV, V

Guide

bearing

III

Con-rod journal

1 to 4 Con-rod width

Diameter

mm Widtht

mm Diameter

mm Width

mm mm

Normal size

Bearing journal and colour code from 57.9820 green

to 57.9885

> 57.9885 brown

to 57.9950

25.900

25.850 48.988

48.970 26.580

26.460 26.390

26.338

Bearing shel l i dent i ficat i on mark

Colour code and embossed Crankshaft bearing

I, II, IV, V Guide bearing

III Con-rod bearing

1 to 4

Identif i cation mark brown-662N

green-663N brown-655N

green-658N

Crankshaft

jounal

I, II, IV, V

Guide

bearing

III

Con-rod journal

1 to 4 Con-rod width

Diameter

mm Widtht

mm Diameter

mm Width

mm mm

0.25m m Undersi ze f or Producti on and Custom er Service

Bearing journal and colour code from 57.7320 green/

to 57.7385 blue

> 57.7385 brown/

to 57.7450 blue

26.100

26.050 48.738

48.720 26.580

26.460

Bearing shel l i dent i ficat i on mark

Colour code and embossed Crankshaft bearing

I, II, IV, V Guide bearing

III Con-rod bearing

1 to 4

Identif i cation mark brown/blue-664 A

green/blue-655 A brown/ bl ue-657 A

green/blue-658 A

Crankshaft

jounal

I, II, IV, V

Guide

bearing

III

Con-rod journal

1 to 4 Con-rod width

Diameter

mm Widtht

mm Diameter

mm Width

mm mm

0.50m m Undersi ze Custom er Service

Bearing journal and colour code from 57.4820 green/

to 57.4885 blue

> 57.4885 brown/

to 57.4950 blue

26.300

26.250 48.488

48.470 26.580

26.460

Bearing shel l i dent i ficat i on mark

Colour code and embossed Crankshaft bearing

I, II, IV, V Guide bearing

III Con-rod bearing

1 to 4

Identif i cation mark brown/white-666 B

green/white-667 B brown/blue-659 B

green/blue-660 B

PISTON PINS

Dimensions

Length mm

Diameter mm 61.5

Type Shank-fit in con-rod

Clearance

In piston mm

In con-rod mm 0.011 to 0.014

Installation See operation “Con-rod, Replace”

CON-ROD

Permissible, weight variation of con-rods without pistons and bearing shells within an engine 8 g.

As the con-rods have no counterweights, re-working is not possible.

Con-rods must be replaced only as a set.

Crankshaft Grinding Dimensions

Crankshaft

bearing journals

I, II, III, IV, V

Guide bearings

III Con-Rod bearing journals

1 to 4 Con-rod

diameter in

mm/col our code width

in mm diameter

in mm

width

in mm width

in mm

Standard Si ze for Product i on and Service

from 57.974white

to 57.981

over 57.981

green

to 57.988

over 57.988

brown

to 57.995

26.002

25.950 48.988

48.970 26.580

26.450 26.390

26.338

Crankshaft and con-rod journal Permissible out-of-round:

0.04mm

Out-of-round Permissible variation of

middle crankshaft bearing

journal when seating shaft into

cylinder block: 0.03mm

Permissible end play 0.05 to 0.152mm

Permissible main bearing play Bearing I to V0.015 to

0.04mm

Permissible con-rod play 0.006 to 0.031mm

Permissible con-rod and play 0.07 to 0.24mm

6A-97-1

Crankshaft, Cylinder Block (continued)

Flywheel Starter ring gear:

Before fitting, heat ring gear to 180 – 230° C

Lateral run-out Permissible lateral run-out of installed

starter ring gear to flywheel: 0.5 mm.

Precision turning Permissible removal of material in clutch

disc lining surface area: 0.3mm

In order to achieve the functional

relationship again after removal of material,

the same removal of material must take

place on the fore part of the flywheel

(contact for clutch assembl y ).

Dimension ‘1’: 2.1 to 2.2mm

Cylinder block

Top Deck flatness 0.05 mm

Cylinder block height 271 ± 0.075 mm.

RECOMMENDED TORQUE VALUES

N m (kgf m)

Bearing cover to cylinder block..................................................... 60 1) 6.1 40° – 50 °

Bracket for alternator to cylinder block......................................... 40 4.1

Bracket for engine damping block to transmission....................... 60 2) 6.1

Bracket for engine damping block to engine block....................... 60 6.1

Bracket for pump/compressor to engine block............................. 40 4.1

Camshaft housing cover to housing............................................. 8 0.8

Camshaft timing gear to camshaft................................................ 45 4.6

Clamping bracket for alternator to intake manifold....................... 25 2.5

Clamping bracket to alternator. .................................................... 25 2.5

Con-rod bearing cap to con-rod.................................................... 35 1) 3.5 45° – 60°

Crankshaft pulley bolts................................................................. 20 2.0

Cylinder head to cylinder block..................................................... 25

1)2) 2.5 +90° +90° +90°

Engine damping block to engine bracket ..................................... 8.5 8.7

Engine damping block to side member ........................................ 52 1) 5.3

Exhaust manifold to cylinder head................................................ 22 2.2

Flywheel to crankshaft.................................................................. 65 1) 6.6 +30° – 45°

Front exhaust pipe to exhaust manifold ....................................... 25 2.5

Guide sleeve for pressure bearing to transmission...................... 22 2.2

Intake manifold to cylinder head................................................... 22 2.2

Lower alternator bracket............................................................... 25 2.5

Oil drain plug to oil pan................................................................. 45 4.6

Oil intake pipe bracket to cylinder block....................................... 6

2) 0.6

Oil intake pipe to oil pump............................................................ 8 0.8

Oil pan to cylinder block .............................................................. 8

2)3) 0.8

Oil pan to cylinder block (vulcanized gasket)............................... 15 2)3) 1.5

Oil pressure switch to oil pump..................................................... 30 3.2

Pump for power steering (ribbed V-belt) to engine block............. 30 3.2

Spark plugs in cylinder head ........................................................ 25 2.5

Starter support to cylinder block................................................... 25 2.5

Starter to cylinder block - engine side .......................................... 45 4.6

Starter to cylinder block - transmission side................................. 75 7.6

Thermostat housing to cylinder head........................................... 15 1.5

Toothed belt drive gear to crankshaft........................................... 130 1) 13.3

Toothed belt front cover................................................................ 4 0.4

Toothed belt rear cover ................................................................ 6 0.6

Toothed belt tension roller to oil pump......................................... 25 2.5

(M10)............................................ 45 4.6

Transmission to engine block....................................................... 76 7.7

(M12)............................................ 60 6.1

Water pump to cylinder block....................................................... 25 2.5

1) Use new bolts

2) Use Locking Compound

3) Maximum installation time - 10 minutes

SPECIAL SERVICE TOOLS

ITEM NO. I LLUSTRATION PART NO. PART NA ME

5-8840-2634-0 Aligner

5-8840-2593-0 Cutter set

5-8840-2594-0 Spring Compressor

5-8840-0451-0 Installer

5-8840-0452-0 Remover / Installer

5-8840-2596-0 Distance Gauge

5-8840-0455-0 Assembly Sleeves

5-8840-2597-0 Installer

5-8840-0457-0 Remover / Installer

5-8840-0468-0 Remover / Installer

ITEM NO. I LLUSTRATION PART NO. PART NA ME

5-8840-0459-0 Installer

5-8840-0460-0 Installer

5-8840-0446-0 Flywheel Holder

5-8840-2598-0 Holding Wrench

5-8840-2599-0 Reamer Set

5-8840-2600-0 Socket Wrench

5-8840-2601-0 Installer