Engine Specifications and Clearances
Engine SpecificationsSome Torque and design specifications are combined in this section
2.8L V6
Engine Code Stamps Location:
Engine Specifications:
WARNING!
^ Do not reuse 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 notlimfted 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.
CAUTION!
Do not rotate the crankshaft when checking radial clearance.
1 - Crankshaft
Checking axial play:
^ New: 0.07-0.23 mm (0.003-0.009 in.)
^ Wear limit: 0.25 mm (0.010 in.)
Check radial clearance with Plastigage:
^ 0.018-0.045 mm (0.0007-0.0017 in.)
^ Wear limit: 0.10 mm (0.0039 in.)
^ Crankshaft dimensions
^ For vehicles with automatic transmission with bearing bushing for torque converter
2 - Bearing cap
^ Installation position
^ Bearing cap 4 with recesses for thrust washers
3 - Bolt
^ Always replace
^ 60 Nm (44ft lb) + 1/4 turn (90°)
^ To measure radial clearance tighten to 60 Nm (44 ft lb) but not further
4 - Thrust washer
^ For bearing cap 4
Note:
fixed arrangement
5 - Flywheel/Driveplate
^ Removing and installing needle bearing in flywheel
^ Removing and installing driveplate
6 - Bolt for flywheel/driveplate
^ Always replace
^ Flywheel: 60 Nm (44 ft lb) + 1/2 turn (180°)
^ Driveplate: 60 Nm (44 ft lb) + 1/4 turn (90°)
^ Lock with 3242 crankshaft holder when loosening and tightening
7 - Bearing shells
Do not interchange used bearing shells
8 - Sealing flange with oil seal
^ Only replace complete
^ Drain coolant before removing
^ Install spare part sealing flange with supplied sleeve
9 - Gasket
^ Always replace
10 - Bolt
^ 10 Nm (7 ft lb)
11 - Thrust washer
^ For cylinder block, bearing 4
12 - Bolt
^ 25 Nm (18 ft lb)
^ Tighten by hand before tightening the bearing cap bolts
13 - Cylinder block
14 - Guide sleeve
Crankshaft Dimensions:
Connecting Rod:
Connecting Rod Bolt
^ Always replace
^ 30 Nm (22 ftlb) + 1/4 turn (90°)
^ Oil threads and contact surface
^ To measure radial clearance tighten to 20 Nm (15 ft lb) but not further
Bearing shell
^ Note installation position
^ Do not interchange used bearing shells
Check radial clearance using Plastigage
^ New: 0.015-0.062 mm (0.0006-0.0024 in.)
^ Wear limit: 0.120 mm (0.0047 in.)
CAUTION!
Do not rotate the crankshaft when checking radial clearance.
Piston Ring Gap:
Piston Ring Specifications:
Checking piston ring gap
^ Feeler gauge
^ Push piston ring into lower end of cylinder at right angle to approx. 15 mm (0.590 in.) from bottom edge of cylinder.
Piston Ring Side Clearance:
Checking piston ring side clearance
^ Feeler gauge
^ Clean piston ring groove before checking.
Piston Specifications:
Piston Ring Side Clearance Specifications:
Measure piston approx. 10 mm (0.400 in.) from bottom of skirt, at 90° angIe to piston pin.
Maximum deviation from nominal dimension: 0.04 mm (0.0015 in.)
Cylinder Bore Specifications:
^ Internal dial gauge 50-100 mm (2-4 in.)
^ Take measurements at 3 positions in both lateral -A- and longitudinal -B- directions, as illustrated. Deviation from nominat dimension max. 0.08 mm (0.003 in.)
CAUTION!
DO NOT have the cylinder block mounted to the assembly stand while measuring the cylinder bores. The block is deformed by its own weight under these conditions, and this stress will result in false measurements that are not accurate after the tension has been relieved.
Piston And Cylinder Dimensions:
Cylinder Head Overview:
Cylinder Head Overview
1 - Upper toothed belt guard, right
2 - Toothed belt guard, center
3 - Upper toothed belt guard, left
4 - Hex nut
^ 10 Nm (7 ft lb)
5 - Rear toothed belt guard
6 - Lifting eye
7 - Bolt
^ 25 Nm (18 ft lb)
8 - Cylinder head cover gasket
^ Replace if damaged
^ Before installing gasket coat sealing surface between bearing cap and cylinder head with D 454 300 A3 sealant
9 - Cylinder head cover
10 - Seal
11 - Cap
^ Replace seal if damaged
12 - Bracket
^ For engine cover
13 - Hex nut
^ 10 Nm (7 ft lb)
^ Tighten from center outward
14 - Cylinder head bolt
^ Replace
15 - Cylinder head
^ Check for distortion
^ After replacing replace all the coolant
16 - Oil deflector
17 - Cylinder head gasket
^ Always replace
^ Metal gasket
^ After replacing replace the complete coolant
18 - Camshaft sprocket
^ Note position when installing the toothed belt
19 - Securing plate
20 - Bolt
^ 55 Nm (41 ft lb)
Cylinder Head Distortion Specifications:
Checking Cylinder Head For Distortion
Max. permissible distortion: 0.05 mm (0.002 in.)
Cylinder Head Loosening Sequence:
- Loosen socket head bolts in sequence given and then re move completely.
Cylinder Head Torque Specifications
Cylinder Head Torque Specifications:
- Tighten cylinder head in tightening sequence
- GTighten all bolts to 60 Nm (44 ft lb).
- Using ridged wrench tighten all bolts 1/4 turn (90°) further.
- GTighten all bolts again 1/4 turn (90°) further.
Tightening torque for front exhaust pipe with catalvtic converter to exhaust manifold: 25 Nm (18 ft lb)
Compression Pressure:
Permissible difference between all cylinders: 3 bar (43 psi)
Valve Specifications:
Note:
Valves must not be reworked Only lapping-in is permitted.
WARNING!
Sodium-filled exhaust valves must not be disposed of until they have been properly treated as follows:
^ Saw the valves into two sections using a metal saw at a point between the center of the valve stem and the valve head. The valves must not come into contact wfth water when this is done.
^ Throw the valves into a bucket of water (not more than ten at a time) and step back. A sudden chemical reaction will occur during which the sodium filling burns. After this treatment the valves can be disposed of as normal scrap.
Valve Seat Specifications:
Refacing inlet valve seat
a = 26.2 mm (10.031 in) diameter
b = Max. permissible refacing dimension
C = 1.5-1.8 mm (0.0394-0.1063 in.)
Z = Cylinder head lower edge
= 45° valve seat angle
= 30° upper correction angle
= 60° lower correction angle
Refacing exhaust valve seat
a = 29.0 mm (1.142 in.) diameter
b = Max. permissible refacing dimension
C = Approx. 1.8 mm (0.1063 in.)
Z = Cylinder head lower edge
G = 45° valve seatangle
B = 30° upper correction angle
Y = 60° lower correction angle
Valve Guide Specifications:
- Determine side to side play.
- Wear limit 0.8 mm (0.031 in)
Oil Pump, Crankcase Breather Housing And Oil Spray Jets
Oil Pump, Crankcase Specifications:
1 - Oil pump
^ Only replace complete
2 - Spray jet valve, 40 Nm (30 ft lb)
3 - 0-ring
^ Always replace
4 - Bolt
^ 45 Nm (33 ft lb)
5 - Idler roller
6 - Bolt
^ 10 Nm (7 ft lb)
7 - Bolt
^ 10 Nm (7 ft lb)
8 - Crankcase breather housing
9 - Gasket/breather plate, Always replace
10 - Oil check valve
^ 25 Nm (18 ft lb)
11 - Connector
12 - Bolt
^ 15 Nm (11 ft lb)
13 - Oil distribution pipe
^ For oil spray jets for piston cooling
14 - Cylinder block
15 - Bolt
^ 10 Nm (7 ft lb)
^ Use locking fluid -D6- when installing
16 - Oil spray let
^ For piston cooling
17 - Gasket
^ Always replace
^ Metal gasket
18 Engine oil temperature sensor -GS-
^ 10 Nm (7 ft lb)
^ For oil temperature gauge
^ White
^ If sealing washer is leaking cut open and replace.
20 - Tensioner
^ Secure before removing
21 - Bolt
^ 10 Nm (7 ft lb)
^ Use locking fluid -D6- when installing
22 - 0-ring
23 - Washer
24 - Bearing bushing
25 - Bolt
^ 25 Nm (18 ft lb)
26 - Tensioning lever