Section Title

Engine – Dismantle and Assemble (21 134 8)

Special Tools
21-137
21-036A Oil seal installer/aligner
Remover for pilot bearing
21137

21036A
21-144
21-044A Inlet manifold wrench
Installer/Aligner, Pilot
Bearing/Clutch Plate 21144
21044A

21-147
21-059C Remover, vibration damper
Installer for radial seal
21147

21059C
21-168
21-064 Crankshaft locking tool
Mounting bracket
21168

21064
21-540
21-075 B Bolt tightening angle gauge
Remover for vibration
damper 21540

21075B

21-092 A
Inlet manifold wrench

21092A

Workshop Equipment Proprietary Tools

Assembly stand Oil filter strap wrench
Dial indicator
Materials Magnetic fixture
Plastigage Obtainable through: Micrometer screw
Replacement Piston ring pliers
Services Limited,
Piston ring compressor
30 Euston Street,
Freemans Industrial V-belt tension gauge
Estate,
Leicester, LE2 7ST.
M8 threaded rod
Spark plug thread
lubricant ESE-M1244-A
(Never Seez)
Loctite 518 ESKM-4G-269-A
Wellseal SPM-4G-9112-H
Sealer SPM-2G-3121-A

xx/xx Model 00-01-1

 Section Title

Dismantle
1. Remove the heat shield from the
right-hand exhaust manifold.
2. Remove the bracket with the right-hand
engine mounting bracket (four bolts).

ELS2104164

3. Detach the right-hand exhaust manifold.

ELS2104163

4. Attach the engine to the assembly stand.

21–064
Attach the mounting bracket.

Attach the engine to the assembly stand.

Drain off the engine oil.

Withdraw the oil dipstick.

ELS2104162

5. Remove the distributor arc shield.

1 Pull off all spark plug connectors.
2 Remove the arc shield.
1

IAS2104150

xx/xx Model 00-01-2

 Section Title

6. Remove the distributor cap (two bolts).

7. Remove the distributor and the spark
plugs.

IAS2104151

8. Remove the alternator (two bolts).

IAS2104155

9. Detach the alternator bracket.

IAS2104156

10. Remove the coolant pump belt pulley.

S2104008

xx/xx Model 00-01-3

 Section Title

11. Remove the intake air plenum chamber

with the throttle housing.

CAUTION: Do not use a steel scraper.

Remove the gaskets.

Pull the positive crankcase ventilation (PCV)
hose and valve from the cylinder head cover.

IAS2104160

12. Detach the fuel rail (four bolts).

IAS2104152

13. Remove the injectors.

IAS2104153

14. Remove the cylinder head covers (eight

bolts and extended washers on each).
Remove the gaskets.

IAS2104154

xx/xx Model 00-01-4

 Section Title

15. Detach the two rocker shafts.

NOTE: Do not mix up the rocker shafts and the
push rods.
Withdraw the push rods in the correct
sequence and keep them in order.

S2104013

xx/xx Model 00-01-5

 Section Title

16. Detach the inlet manifold.

6 4 2 7

Disconnect the connecting hose running to
the thermostat housing.
NOTE: Bolt-slackening sequence.

Detach the inlet manifold (seven bolts, one
nut).

Remove the gasket.

8 3 1 5
IAS2104159

3 4 2 1

5 8 6 7

7 6 5
8

1 2 4 3

S2104054

NOTE: Bolt-slackening sequence.

17. Remove the cylinder heads.
The cylinder head bolts may only be used
once.

xx/xx Model 00-01-6

 Section Title

18. Remove the oil pressure switch.

IS2104019

19. Detach the belt pulley with the crankshaft

vibration damper.

Lock the flywheel.

Remove the bolt.

IAS2104170 21–168

20. Detach the belt pulley with the crankshaft

21–147 vibration damper (continued).

Screw in the bolt fifteen turns.

Insert the special tool and pull off the
vibration damper.

Remove the bolt and the Woodruff key.

IAS2104157

21. Detach the flywheel.

3 1 Six bolts.
2 Pressure plate.
2 3 Flywheel.
4 Adaptor plate.
22. Detach the oil filter.

4
1
ELS2104161

xx/xx Model 00-01-7

 Section Title

23. Remove the crankshaft pilot bearing.

21–036 A

S2104035

CAUTION: Oil sludge and abraded

particles must not get into the engine.
24. Remove the sump downwards
(18 bolts/six nuts).

S2104025

CAUTION: Take care not to damage the

cylinder liners.
25. Remove the carbon from the upper edges
of the cylinder bores.

S2104026

xx/xx Model 00-01-8

 Section Title

26. Remove the hydraulic tappets.

Place a suitable drain tray under the cylinder
block.

Place the cylinder block in the vertical
position.
NOTE: Do not mix up the tappets when
removing and installing them and do not
dismantle them. They are only available as a
single part for servicing.

Press out the hydraulic tappets with a bent
S2104027
piece of brass wire.

27. Detach the oil baffle.

S2104028

28. Detach the oil pump with the intake

pipe.
Remove the oil pump drive shaft.

S2104029

xx/xx Model 00-01-9

 Section Title

29. Detach the coolant pump.

S2104030

30. Detach the timing cover.

Remove the oil seal from the timing cover.

S2104031

31. Remove the camshaft chain drive

complete.

CAUTION: The oil-filled plunger of the

chain tensioner is spring-loaded.
3
1 Chain tensioner (two bolts)
2 Camshaft sprocket
3 Timing chain
2
4 Crankshaft sprocket
5 Chain guide (two bolts)

1 5

S2104032

xx/xx Model 00-01-10

 Section Title

32. Remove the camshaft.

1 Detach the thrust plate (two bolts).
2 Carefully withdraw the camshaft with the
sprocket bolt.

Swivel the engine.
2

S2104033

CAUTION: Do not damage the crankshaft

bearing journal.
33. Remove the pistons.
4
Detach the big-end bearing caps.
4
5

Remove the bearing shells from the big-end
bearing caps and the connecting rods and
5
mark them.

Press out the pistons with the connecting
rods.
D2105203

xx/xx Model 00-01-11

 Section Title

34. Remove the crankshaft.

NOTE: Four special bolts for securing the oil
baffle.

Detach the main bearing caps.

Lift out the crankshaft.

Remove the rear oil seal.

Remove the bearing shells and mark them
for reuse.

S2104166

Assemble
35. Preparatory measures.
Thoroughly clean all mating and bearing
surfaces and re-usable parts and check
them for damage.

xx/xx Model 00-01-12

 Section Title

Measure the cylinder bores

NOTE: Machine or renew the cylinder block as
necessary.
36. Measure the cylinder bores.

Measure dimensions A, B, and X-Y and
compare them with the values in the
Technical Data.

Ovality = X-Y

Conicity = A-B

10mm

XY

10mm
D2105206

Measure the piston diameter

NOTE: Piston classification, if a piston has to be
renewed.
37. Measure the piston diameter.

Measure the piston diameter at the top of
the piston pin bore.

D2105207

xx/xx Model 00-01-13

 Section Title

CAUTION: Do not mix up the piston rings.

Refit the piston rings in the same position
as before.
38. Check the piston ring gaps.
The figures indicated in the Technical Data
are for a gauge ring used in production. The
figures measured in the cylinder can exceed
these by 0,15 mm.

D2105208

39. Measure the diameter of the main and

big-end bearing journals.

Repeat each measurement at 90
.

Overhaul or renew the crankshaft as
necessary.

D2105214

Measure the bearing clearance

40. Paint marks on the main bearing caps.

If the parent bore in the cylinder block has
standard dimensions, it does not have a
mark.

Bearing caps for a 0,38 mm oversize parent
bore have a white paint mark.

S2104556

41. Paint marks on the main and big-end

bearing shells.

Standard bearing shells do not have a mark.

Bearing shells for an oversize cylinder block
and an undersize crankshaft are marked on
the back as appropriate (see Parts
Microfiche).

If a repair is carried out in production, the
bearing shells are provided with paint marks
as shown.
S2104540

xx/xx Model 00-01-14

 Section Title

42. Paint marks on the main and big-end

bearing journals.

Main bearing journals with the standard
diameter are not marked.

In the case of bearing journals with 0,25 mm
undersize, the first counterweight on the
crankshaft has a green paint mark.

Big-end bearing journals with the standard
diameter are not marked.

In the case of big-end bearing journals with
S2104541
0,25 mm undersize, the first crankshaft web
in relation to the big-end bearing journal is
marked with a green spot.

CAUTION: Do not damage the crankshaft

bearings during fitment.
43. Fit the crankshaft.

Fit the main bearing shells in the cylinder
block.

Fit the crankshaft without lubrication.

S2104537

44. Measure the crankshaft main bearing

clearance.

Measure the clearance of the bearings in
turn in numerical order (1 – 4). The
numbering starts at the timing chain end.

Lay a length of Plastigage thread on the
bearing journal across the bearing.

M2101727

xx/xx Model 00-01-15

 Section Title

45. Measure the crankshaft main bearing

clearance (continued).
97 Nm
Fit the bearing cap with the associated
bearing shell and tighten it.

CAUTION: The crankshaft must not be

turned during the measuring operation. Do
not hit the bearing caps.

Detach the bearing caps.

S2104538

NOTE: If the measured bearing clearance is

outside the specification of 0,008 - 0,062 mm,
then the bearing shells should be renewed and
the measurement procedure repeated from
step 44.
46. Measure the crankshaft main bearing
clearance (continued).

Compare the Plastigage thread with the
Plastigage scale.

The reading corresponds to the bearing
M2101728 clearance.

47. Fit the crankshaft.

97 Nm

Coat all main bearing journals, all bearing
shells, the threads of all bolts and all bolt
contact faces with oil.

Arrange the bearing shells and fit the
crankshaft.

Thinly coat the seat of the rear main
bearing cap with sealer (Loctite 518,
ESKM-4G-269-A).

Fit the main bearing caps with the
associated bearing shells.
NOTE: The arrows point to the timing chain
end. The numbering starts at the timing chain
end.

Tighten the bolts.

S2104671

xx/xx Model 00-01-16

 Section Title

48. Check the crankshaft end float.

Set up a dial indicator.

Measure the end float by lifting the
crankshaft with the aid of a screwdriver.

Correct the end float as necessary by
fitting new flanged bearing shells.

S2104514

49. Fit the pistons with the connecting rods.

CAUTION: The upper piston rings are

coated with molybdenum. This coating
must not be damaged.
NOTE: The tapered face ring must be fitted so
that the “TOP” mark faces the piston crown.

Fit the piston rings on to the pistons using
proprietary piston ring pliers.

Lubricate the piston and cylinder bore with
engine oil.
S2102024

Distribute the ring gaps evenly around the
circumference (see Technical Data).

xx/xx Model 00-01-17

 Section Title

50. Fit the pistons with the connecting rods

(continued).

Compress the piston rings with a proprietary
piston ring compressor.
NOTE: The front mark on the piston (arrow)
must point in the direction of travel. The
numbering on the connecting rods starts at the
timing chain end.

Fit the pistons. The associated big-end
bearing journal must be at BDC.
S2104534

Place the appropriate bearing shells in the
connecting rod and bearing cap.

Fit the bearing caps.

1 2
9 7,5

21,8 23,3

6AA 5AB

54,3 0,5 54,3 0,5

39,35 1,25 30,75 0,25

15 19

KX 110 KX 900

ELZ9621176

xx/xx Model 00-01-18

 Section Title

51. Identification of the big-end bearing

bolts and connecting rods used.

Only engines with connecting rods and big-end

bearing journals with the respective
identification codes 6AA and KX110.
30 Nm
4 52. Measure the big-end bearing clearance.
4
Measure the big-end bearing clearance as
5 described in sub-operations 44. to 46.
5
Renew the bearing shell(s) as necessary.
NOTE: Check whether the connection rods
have the specified end float.
S2104524 53. Fit the big-end bearing caps.

Lubricate the bearing shells, bearing
journals, threads and contact faces of the
connecting rod nuts with engine oil.
NOTE: The connecting rods and their bearing
caps have the same numbers.

Fit the big-end bearing caps with the bearing
shells and tighten them.

xx/xx Model 00-01-19

 Section Title

Only engines with connecting rods and big-end

bearing journals with the respective
identification codes 5AB and KX900.
20 Nm NOTE: Use the old bolts to measure the
bearing clearance.
54. Measure the big-end bearing clearance.

Measure the big-end bearing clearance as
described in sub-operations 44. to 46.

Renew the bearing shell(s) as necessary.
ELS2105870 NOTE: Check whether the connection rods
have the specified end float.
NOTE: Use new bolts.
55. Fit the big-end bearing caps.

Lubricate the bearing shells, bearing
journals, threads and contact faces of the
connecting rod nuts with engine oil.
NOTE: The connecting rods and their bearing
caps have the same numbers.

Fit the big-end bearing caps with the bearing
shells and tighten them.

NOTE: The oil seal points outwards.

56. Install the crankshaft pilot bearing.

21–044 A
S2104535

xx/xx Model 00-01-20

 Section Title

57. Fit the crankshaft rear oil seal.

Lubricate the crankshaft running face and
oil seal lip with oil.

Support the special tool in a vice.

Insert the oil seal with the open side
upwards and drive it in carefully as far as it
will go using the handle of a hammer.

Fit the special tool with the oil seal to the
engine.

Drive in the oil seal evenly as far as it will
go.

Swivel the engine.

21–059 C

S2104515

58. Install the camshaft.

Lubricate the camshaft bearings, the
camshaft and the thrust plate with oil.

Screw in the sprocket bolt half way and fit
the camshaft.
NOTE: The oil bore in the thrust plate must be
at the bottom.
11 Nm
Fit the thrust plate.

Take out the sprocket bolt.

S2104533

xx/xx Model 00-01-21

 Section Title

59. Check the camshaft end float.

S2104539

Install the chain drive.

60. Attach the chain guide.
61. Align the camshaft and crankshaft in
relation to one another.
The recesses on both crankshaft journals
must be opposite one another.
11 Nm

S2104542

62. Preload the chain tensioner.

Press the spring and the oil-filled plunger
into the chain tensioner and fit the oil-filled
plunger in the sliding block.

S2104563

63. Preload the chain tensioner (continued).

Press the oil-filled plunger and sliding block
right into the chain tensioner and hold it in
this position.

S2104564

xx/xx Model 00-01-22

 Section Title

NOTE: A locking clip is supplied with new chain

tensioners. If necessary, fabricate a locking clip
from welding rod.
64. Preload the chain tensioner (continued).
Immobilise the sliding block in this position
with a locking clip.

S2104552

65. Fit the camshaft chain drive.

NOTE: The dots on the sprockets must be
exactly opposite each other on the inside.
64 Nm
4 1 Crankshaft sprocket.
2 Crankshaft Woodruff key.
3 Camshaft sprocket.
3 4 Timing chain.
5 Chain tensioner.
10 Nm
6 Remove the locking clip after tensioner has
been fitted.

5
11 Nm

6 2

S2104532

66. Fit the timing cover.

Fit the timing cover with a gasket and screw
the bolts in fingertight.

Centre the timing cover using the special
tool and align it to the sump mating face.
21–137

Tighten the nine bolts.

19 Nm
Remove the special tool.

S2104531

xx/xx Model 00-01-23

 Section Title

67. Fit the new crankshaft front oil seal.

Lubricate the oil seal lip and the crankshaft
21–137 with oil.

Insert the oil seal lip as far as it will go.

Remove the bolt and the special tool.

S2104545

68. Fit the adaptor plate in place and attach

2 15 Nm the flywheel.

CAUTION: Use new bolts.

3
Immobilise the crankshaft in the cylinder
block.
1 Place the adaptor plate on the guide
sleeves.

1 2 Flywheel.
30 Nm 85
4 3 Pressure plate.
ELS2104661
4 Bolts.
69. Attach the oil filter.
Lubricate the oil seal with clean engine oil.

70. Fit the belt pulley with the vibration

damper.
45 Nm 85

Immobilise the flywheel.

Lubricate the belt pulley bore with oil.

Fit the belt pulley with the bolt by means of
the Woodruff key on the crankshaft.

Loosen the bolt, apply sealer
(SPM-2G-3121-A) and re-tighten it.

IAS2104658

xx/xx Model 00-01-24

 Section Title

71. Fit the coolant pump.

9 Nm

Coat the coolant pump mating faces and the
timing cover with sealer (specification
ESKM-4G-269-A).

Fit the coolant pump with an oil seal.

S2104530

72. Fit the driveshaft and the oil pump with

the intake pipe.
2
NOTE: The short pointed end of the shaft
points towards the distributor.
128 mm
19 Nm 1 Set the retaining ring in its correct position
on the drive shaft and fit the shaft.
1
Fill the oil pump with oil through the intake
pipe and turn it by hand.
2 Fit the oil pump.

1
S2104529

xx/xx Model 00-01-25

 Section Title

73. Fit the oil baffle.

19 Nm

S2104528

Fit the sump.

25 Nm
74. Apply sealer (Loctite 518,
ESKM-4G-269-A) as follows:

To the gap at the cylinder block/timing
cover mating face.
5 Nm 8 Nm
To the groove in the rear main bearing cap.
75. Fit the sump with a new one-piece
gasket.

Fit the gasket over the studs on the
cylinder block.
5 Nm 8 Nm
NOTE: The knobs on the sump must engage
in the corresponding holes in the gasket.

Fit the sump and screw on the nuts.

Tighten the nuts and bolts in two stages.
76. Fit the oil drain plug using a new seal.

S2104525

77. Tighten the sump nuts and bolts.

1 Start – stage 1.
2 Start – stage 2.

2
1

S2104546

xx/xx Model 00-01-26

 Section Title

NOTE: Fit the hydraulic tappets in the correct

sequence.
NOTE: Hydraulic tappets that are new or
contain no oil should be pumped up manually in
oil before installation until they cannot be
compressed any more.
78. Fit the hydraulic tappets.

S2104527

Install the cylinder heads

79. Fit new cylinder head gaskets.

The cylinder block and cylinder head mating
faces must be dry and clean.

The gaskets are marked “TOP FRONT” and
are guided into place with the locating
sleeves.

The left and right-hand gaskets are different.
80. Fit the cylinder heads.
S2104553
The cylinder heads are guided into locating
sleeves.

xx/xx Model 00-01-27

 Section Title

6 5 7 8

73 Nm
4 3 2
38 Nm

2 3 4
1

8 7 5 6

S2104565

CAUTION: Use new bolts.

81. Pre-tighten the cylinder head bolts.

Oil the heads and the threads of the
cylinder head bolts and screw them in.

Pre-tighten the cylinder head bolts in two
stages and in the indicated sequence.

CAUTION: The cylinder head bolts must

not be retorqued.
21–540 90

82. Tighten the cylinder head bolts.
Wait five minutes after the second stage and
then tighten the bolts a further 90
.

J2105623

xx/xx Model 00-01-28

 Section Title

83. Fit the oil pressure switch.

27 Nm
S2104519

Install the inlet manifold.

84. Fit the gasket.

Apply sealer (Wellseal, SPM-4G-9112-H) to
the contact faces of the cylinder block and
cylinder heads and the inlet manifold flange.

Fit the gasket.

Apply sealer (SPM-4G-9112-H) to the four
projecting areas of the inlet manifold to
cylinder head gasket.
S2104547

85. Fit the inlet manifold (seven bolts, one

3 5 7 2 nut).
Tighten the inlet manifold in four stages as
illustrated.
23 Nm 18 Nm 12 Nm 6 Nm

1 6 8 4
IAS2104659

xx/xx Model 00-01-29

 Section Title

19 Nm
1 4

S2104672

86. Fit the distributor.

Set cylinder no. 1 to TDC.
1 Align the notches on the distributor base
and the cylinder block.
2 The distributor rotor points towards the
notch on the edge of the distributor.

Press the distributor down and engage the
pinion.

Crank the engine and bring the distributor
into engagement with the oil pump drive
assembly.
3 Position of the distributor rotor (cylinder
no. 1 in TDC position) with the distributor
installed.
4 Secure the distributor with the retaining
plate (one bolt).

xx/xx Model 00-01-30

 Section Title

87. Fit the rocker shafts.

32 Nm 90


Lubricate the push rods with oil and fit them.

CAUTION: Do not under any

circumstances adjust the rocker arms.

Fit the rocker shafts in their correct positions
and screw in the bolts.

Tighten the bolts.

S2104513

88. Fit the fuel rail (four bolts).

12 Nm

IAS2104652

NOTE: Use new rubber seals at the injectors.

89. Fit the injectors.

IAS2104153

Attach the cylinder head covers

NOTE: Stick the gaskets in place with the
adhesive-coated side facing the cylinder head
cover.
90. Coat the contact faces of the cylinder
head cover flange with sealer
(SPM-2G-3121-A).
Arrange the gaskets in position.

S2104549

xx/xx Model 00-01-31

 Section Title

91. Fit the cylinder head covers (eight bolts

7 Nm and washers each).

IAS2104654

92. Fit the inlet air plenum chamber and

9 Nm throttle housing.
Insert the positive crankcase ventilation
(PCV) hose into the left-hand cylinder head
cover.

IAS2104660

93. Attach the belt pulley to the coolant

25 Nm pump.

S2104508

94. Fit the alternator bracket.

25 Nm
IAS2104656

xx/xx Model 00-01-32

 Section Title

95. Fit the alternator.

25 Nm
IAS2104655

NOTE: Apply lubricant (Never Seez,

ESE-M1244-A) to the spark plug threads.
96. Fit the spark plugs.
Torque: 32 Nm
97. Fit the distributor cap and HT leads.

IAS2104151

98. Fit the distributor arc shield.

1 Push the arc shield on and ensure that it
engages correctly.
2 2 Join the spark plug connectors.

IAS2104650

NOTE: Use new gaskets.

28 Nm 99. Top up the engine oil and insert the

dipstick.
100. Remove the engine from the assembly
stand.
101. Fit the right-hand exhaust manifold.

ELS2104663

xx/xx Model 00-01-33

 Section Title

102. Fit the heat shield to the right-hand

exhaust manifold.
9 Nm
103. Fit the bracket with the engine mounting
bracket on the cylinder block (four bolts).

50 Nm

ELS2104664

NOTE: Bolt-tightening sequence.

104. Retorque the inlet manifold bolts.

Install the engine and let it run to operating
21–144 temperature.

Retorque the bolts.

23 Nm
Retorque the nuts using Special

Tool 21-092 A.

3 5 7 2

23 Nm

1 6 8 4
PZS2104668

xx/xx Model 00-01-34