Crankshaft pin diameters

Diameter mm (in)

Engine model/Pin type

Standard

Service limit

102-05, 103-07

Standard

34,964 - 34,975 (1.37653 - 1.37697)

34,714 - 34,725 (1.36669 - 1.36712)

34,464 - 34,475 (1.35685 - 1.35728)

34,90 (1.374)

34,65 (1.364)

Undersize 0,25 mm (0.01 in)

Undersize 0,50 mm (0.02 in)

103-10

34,40 (1.354) (1)

Standard

38,964 - 38,975 (1.53401 - 1.53445)

38,714 - 38,725 (1.52417 - 1.52460)

38,464 - 38,475 (1.51433 - 1.51476)

38,90 (1.531)

38,65 (1.5216)

Undersize 0,25 mm (0.01 in)

Undersize 0,50 mm (0.02 in)

103-13

38,40 (1.5118) (1)

Standard

43,964 - 43,975 (1.73090 - 1.73130)

43,714 - 43,725 (1.72102 - 1.72145)

43,464 - 43,475 (1.71120 - 1.71161)

43,90 (1.728)

43,65 (1.719)

Undersize 0,25 mm (0.01 in)

Undersize 0,50 mm (0.02 in )

103-15, 104-19, 104-22

Standard

43,40 (1.709) (1)

51,964 - 51,975 (2.04582 - 2.04626)

51,714 - 51,725 (2.03598 - 2.03641)

51,464 - 51,475 (2.02614 - 2.02660)

51,90 (2.0433)

51,65 (2.0335)

51,40 (2.0236) (1)

Undersize 0,25 mm (0.01 in)

Undersize 0,50 mm (0.02 in)

(1) If the diameter is less than this value, the crankshaft must be renewed.

Workshop Manual, TPD 1377E, issue 4

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2

100 Series

Bearing holder

Centre bearing

1  Remove the bearing holder and check it for stepped wear and other damage. If it is excessively damaged

renew.

2  Using the Plastigauge ®, measure the oil clearance between the crankshaft centre journal and the bearing.

If the oil clearance is more than the service limit, renew the bearing or grind the crankshaft centre journal and

use an undersize bearing.

Clearance mm (in)

Engine model/Journal No.

Standard

Service limit

102-05

No. 1

0,035 - 0,088 (0.00140 - 0.00350)

0,039 - 0,092 (0.00154 - 0.00362)

0,20 (0.0078)

0,20 (0.0078)

No. 2

103-07

No. 1, 2

0,035 - 0,088 (0.00140 - 0.00350)

0,039 - 0,092 (0.00154 - 0.00362)

0,20 (0.0078)

0,20 (0.0078)

No. 3

103-10

No. 1, 2, 3

103-13, 103-15

No. 1, 2, 3

104-19, 104-22

No. 1, 2, 3, 4

0,039 - 0,092 (0.00154 - 0.00362)

0,044 - 0,102 (0.00173 - 0.00401)

0,044 - 0,102 (0.00173 - 0.00401)

0,20 (0.0078)

0,20 (0.0078)

0,20 (0.0078)

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Workshop Manual, TPD 1377E, issue 4

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2

100 Series

Undersize bearing shell chart

Journal

No.

Crankshaft centre

journal diameter mm (in)

Engine model/Bearing size

102-05

1

2

1

2

1

2

42,964 - 42,975 (1.69150 - 1.69193)

45,948 - 45,959 (1.80897 - 1.80941)

42,714 - 42,725 (1.68165 - 1.68210)

45,698 - 45,709 (1.79913 - 1.79956)

42,464 - 42,475 (1.67181 - 1.67224)

45,448 - 45,459 (1.78930 - 1.78972)

Standard

Undersize 0,25 mm (0.01 in)

Undersize 0,50 mm (0.02 in)

103-07

1, 2

3

42,964 - 42,975 (1.69150 - 1.69193)

45,948 - 45,959 (1.80897 - 1.80941)

42,714 - 42,725 (1.68165 - 1.68210)

45,698 - 45,709 (1.79913 - 1.79956)

42,464 - 42,475 (1.67181 - 1.67224)

45,448 - 45,459 (1.78930 - 1.78972)

Standard

1, 2

3

Undersize 0,25 mm (0.01 in)

Undersize 0,50 mm (0.02 in)

1, 2

3

103-10

Standard

1, 2, 3

1, 2, 3

1, 2, 3

45,964 - 45,975 (1.80960 - 1.81004)

45,714 - 45,725 (1.79976 - 1.80019)

45,464 - 45,475 (1.78992 - 1.79035)

Undersize 0,25 mm (0.01 in)

Undersize 0,50 mm (0.02 in)

103-13

Standard

1, 2, 3

1, 2, 3

1, 2, 3

57,957 - 57,970 (2.28177 - 2.28228)

57,707 - 57,720 (2.27192 - 2.27244)

57,457 - 57,470 (2.26210 - 2.26260)

Undersize 0,25 mm (0.01 in)

Undersize 0,50 mm (0.02 in)

103-15

Standard

1, 2, 3

1, 2, 3

1, 2, 3

67,957 - 67,970 (2.67550 - 2.67597)

67,707 - 67,720 (2.66563 - 2.66614)

67,457 - 67,470 (2.65579 - 2.65630)

Undersize 0,25 mm (0.01 in)

Undersize 0,50 mm (0.02 in)

104-19, 104-22

Standard

1, 2, 3, 4

1, 2, 3, 4

1, 2, 3, 4

67,957 - 67,970 (2.67550 - 2.67597)

67,707 - 67,720 (2.66563 - 2.66614)

67,457 - 67,470 (2.65579 - 2.65630)

Undersize 0,25 mm (0.01 in)

Undersize 0,50 mm (0.02 in)

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2

100 Series

Crankshaft bearing bush

1  Check the bearing (bush) for damage or poor contact. If found to be defective, renew.

2  Using a cylinder gauge and micrometer, measure the clearance between the bearing (bush) and the

crankshaft journal (B).

3  Measure inside diameters at positions (A1) and (A2). At each position measure in both directions (A3) and

(A4) as shown. The oil clearance can be obtained by subtracting this value from the maximum crankshaft

journal diameter.

Clearance mm (in)

Engine model

Standard

Service limit

0,20 (0.0078)

0,20 (0.0078)

0,20 (0.0078)

102-05, 103-07

0,035 - 0,102 (0.00140 - 0.00401)

0,039 - 0,106 (0.00154 - 0.00420)

0,044 - 0,116 (0.00173 - 0.00456)

103-10

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

4  If the oil clearance exceeds the service limit renew the bearing (bush), or grind the crankshaft journal to the

required specifications. In this case use an undersize bearing (bush).

5  To renew the crankshaft journal (bush), use a press to install.

Crankshaft journal

Engine model/Bush size

O.D. finished size mm (in)

102-05, 103-07

Standard

42,964 - 42,975 (1.69150 - 1.69193)

42,714 - 45,725 (1.68165 - 1.68210)

42,464 - 42,475 (1.67181 - 1.67224)

Undersize 0,25 mm (0.01 in)

Undersize 0,50 mm (0.02 in)

103-10

Standard

45,964 - 45,975 (1.80960 - 1.81004)

45,714 - 45,725 (1.79980 - 1.80020)

45,464 - 45,475 (1.78992 - 1.79035)

Undersize 0,25 mm (0.01 in)

Undersize 0,50 mm (0.02 in)

103-13

Standard

57,957 - 57,970 (2.28177 - 2.28228)

57,707 - 57,720 (2.27192 - 2.27244)

57,457 - 57,470 (2.26210 - 2.26260)

Undersize 0,25 mm (0.01 in)

Undersize 0,50 mm (0.02 in)

103-15, 104-19, 104-22

Standard

67,957 - 67,970 (2.67550 - 2.67597)

67,707 - 67,720 (2.66563 - 2.66614)

67,457 - 67,470 (2.65579 - 2.65630)

Undersize 0,25 mm (0.01 in)

Undersize 0,50 mm (0.02 in)

3

1

2

4

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Workshop Manual, TPD 1377E, issue 4

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100 Series

3

Cylinder head assembly

3

Rocker cover and inlet manifold

To remove and to fit

Operation 3-1

Special requirements

Torque Nm (lbf ft) kgf m

102-05, 103-07, 103-10

103-13, 103-15

11 (8) 1,1

10 (7) 1,0

14 (10) 1,4

104-19, 104-22

Note:  Inspect the joint, renew if necessary.

102-05

103-07

103-10

103-13

103-15

104-19

104-20

103-13

103-15

104-19

104-20

Workshop Manual, TPD 1377E, issue 4

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