Cylinder Block, Crankshaft and Flywheel, Servicing

WARNING:
- Do not re-use fasteners that are worn or deformed in normal use.
- Some fasteners are designed to be used only once, and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts, washers, circlips and cotter pins. Always follow recommendations - replace these fasteners with new parts where indicated, and any other time it is deemed necessary by inspection.

Note:
- Always replace all gaskets and seals.
- The engine speed sensor is located in the transmission bell-housing, and installed together with a spacer.





1. Main bearing cap bolts
- Always replace
- 60 Nm (44 ft. lbs.) + 1/2-turn (180°)
2. Main bearing caps
- Marking -1- on oil pump side
- Always replace bolts
- Checking bearing clearance.
3. Connecting rod bearing bolts
- Always replace
- 30 Nm (22 ft. lbs.) + 1/4-turn (90°)
- When measuring radial clearance, tighten to 20 Nm (15 ft. lbs.) but do not turn further
4. Connecting rod bearing shells
- Do not interchange used bearing shells
- Checking connecting rods and connecting rod bearing clearance.
5. Piston rings
- Refer To Piston Ring, Engine.
6. Pistons
- Refer To Piston, Engine.
7. Crankshaft
- Measuring clearance.
- Oil pump, removing, refer to Engine Lubrication; Oil Pump, Engine.
Oil Pan

- For vehicles with automatic transmission always install bushing as pilot for converter
- Remove bushing using KUKO 21/2 and 21/1
8. Oil passage with seal
- Always replace seal
9. Sealing flange, front
10. Bolt
- 10 Nm (7 ft. lbs.)
11. Bolt
- 30 Nm (22 ft. lbs.)
12. Thrust washer
- Only on 4th crankshaft bearing
- Measuring crankshaft axial clearance.
13. Bolt
- Automatic transmission (drive plate): 60 Nm (44 ft. lbs.) + 1/4-turn (90°)
- Manual transmission (dual mass flywheel): 60 Nm (44 ft. lbs.) + 1/2-turn (180°)
14. Dual-mass flywheel or drive plate
- Removing and installing.
- Needle bearing, removing and installing.
15. Crankshaft bearing
- Axial and radial clearance, checking.
16. Bolt
- 10 Nm (7 ft. lbs.)
17. Oil jet
- To cool piston
18. Seal for flange
- Replace.
19. Bolt
- 10 Nm (7 ft. lbs.)
20. Bolt
- 20 - 25 Nm (14 - 18 ft. lbs.)
- Install hand-tight before fully tightening
21. Cylinder block