Crankshaft retainer setscrews and crankshaft

To remove and to fit

Operation 5-3

Special requirements

Hex hole setscrews (A1) : Torque Nm (lbf ft) kgf m

Hex setscrews (A2) : Torque Nm (lbf ft) kgf m

102-05, 103-07, 103-10

27 (20) 2,7

27 (20) 2,7

102-05, 103-07, 103-10

27 (20) 2,7

51 (38) 5,2

103-13, 103-15, 104-19, 104-22

103-13, 103-15, 104-19, 104-22

Check that the oil ways of the bearings match up with the oil ways in the block.

Caution:  Before removal and fitting of the crankshaft ensure that the pressure relief valve has been removed.

Notes:

For emissions approved engines. The fuel adjustment screw must not be altered from the original setting.

The maximum No Load Speed must be checked after assembly.

If a new crankshaft is fitted, see Operation 3-13.

Continued

Workshop Manual, TPD 1377E, issue 4

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5

100 Series

1

2

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Workshop Manual, TPD 1377E, issue 4

This document has been printed from SPI². Not for Resale

5

100 Series

Bearing clearance

To check

Operation 5-4

Special requirements

Clearance mm (in)

Engine model

Standard

Service limit

0,20 (0.0079)

0,20 (0.0079)

0,20 (0.0079)

102-05, 103-07

0,031 - 0,079 (0.00122 - 0.00311)

0,035 - 0,083 (0.00138 - 0.00327)

0,035 - 0,085 (0.00138 - 0.00335)

103-10

103-13, 103-15, 104-19, 104-22

Use Plastigauge® to check the bearing clearance.

Tighten the main bearings to the torque settings given in Operation 5-5 for two and three cylinder engines or

Operation 5-6 for four cylinder engines.

1.0

2.0

2.5

3.0

4.0

5.0

6.0

7.0

INCH

Workshop Manual, TPD 1377E, issue 4

61

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5

100 Series

Main bearings

To dismantle and to assemble (two and three cylinder engines)

Operation 5-5

Special requirements

Bearing holder (Aluminium) : Thickness mm (in)

Torque Nm (lbf ft) kgf m

Standard

Service limit

102-05, 103-07, 103-10

Aluminium Bearings

22 (16) 2,2

21,85 - 21,95 (0.8602 - 0.8641)

21,6 (0.8503)

102-05, 103-07, 103-10

Cast Iron Bearings

27 (19.9) 2,7

N/A

N/A

End Float : Clearance mm (in)

Engine model

Standard

Service limit

0,50 (0.0197)

0,50 (0.0197)

102-05, 103-07

103-10

0,10 - 0,30 (0.0040 - 0.0120)

0,05 - 0,30 (0.0020 - 0.0120)

1  Identify position of bearing carriers on shaft.

2  Install bearing carriers on the crankshaft ensuring oil holes align with feed holes in cylinder block.

3  Check end float.

4  Check number 2 bearing holder on 102-05 engines and number 3 bearing holder on 103-07 and 103-10

engines for wear, poor contact, look burnt or other defects. Defective bearing holders must be renewed.

Notes:

For emissions approved engines. The fuel adjustment screw must not be altered from the original setting.

The maximum No Load Speed must be checked after assembly.

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Workshop Manual, TPD 1377E, issue 4

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5

100 Series

To dismantle and to assemble (four cylinder engines)

Operation 5-6

Special requirements

Torque Nm (lbf ft) kgf m

103-13, 103-15, 104-19, 104-22

51 (38) 5,2

End float : Clearance mm (in)

Thrust washer : Thickness mm (in)

Standard

Service limit

Standard

Service limit

0,10 - 0,40 (0.0040 - 0.0160)

0,50 (0.0197) max

2,95 - 3,00 (0.1161 - 0.1181)

2,80 (0.1102) max

1  Identify position of bearing carriers on shaft.

2  Install bearing carriers on shaft ensuring oil holes align with feed holes in cylinder block.

3  Check end float clearance (A2).

Note:  Ensure that the thrust washers are aligned correctly, and are fitted with their oil grooves towards the

crankshaft.

4  Check the thrust washers for wear, poor contact, look burnt, or have any other defects. Defective washers

must be renewed.

Note:  Item (A1) is only used on 104-19 and 104-22 engines.

1

2

Workshop Manual, TPD 1377E, issue 4

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