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MBE 900 Compression Testing

ADDITIONAL INFORMATION

SPECIFICATIONS

This section contains the specifications for servicing the engine. ‪

The specifications for compressions testing are listed in Table and listed in Table . ‪

Description ‪

Pressure ‪

Compression Pressure at Starter Speed ‪

2800 kPa (406 psi) ‪

Permissible Difference Between Individual Cylinders ‪

400 kPa (58 psi) ‪

Compression Pressure Test Data

Description ‪

Torque Value ‪

Hex-head Bolt ‪

30 Nm (22 lbft) ‪

12-point Head Bolt with Spherical Collar ‪

35 Nm (26 lbft) ‪

Torque Values, Tensioning Arm Bolts

The torque specifications for the cylinder head cover are listed in Table . ‪

Description ‪

Torque Value ‪

Hexagon Socket Bolt ‪

30 Nm (22 lbft) ‪

Torque Values, Cylinder Head Cover

The cylinder head warpage limits are listed in Table (6cylinder engine), listed in Table (4cylinder engine) and listed in Table (cylinder block). Cylinder head bolt length is listed in Table . The tightening stages are listed in Table (exhaust manifold bolts) and listed in Table (cylinder head bolts). Oil pressure readings are listed in Table . There are miscellaneous torque values listed in Table . ‪

Description ‪

Limit ‪

Over entire length ‪

0.07 mm (0.003 in.) ‪

Over a length of 150 mm (6 in.) ‪

0.02 mm (0.001 in.) ‪

Head Warpage Limits, 6-Cylinder Engine

Description ‪

Limit ‪

Over entire length ‪

0.05 mm (0.002 in.) ‪

Over a length of 150 mm (6 in.) ‪

0.02 mm (0.001 in.) ‪

Head Warpage Limits, 4-Cylinder Engine

Description ‪

Limit ‪

Over entire length ‪

.030 mm (00.0012 in.) ‪

Over a length of 150 mm (6 in.) ‪

.015 mm (0.0006 in.) ‪

Cylinder Block Warpage Limits, 4 and 6Cylinder Engines

Description ‪

Length ‪

Shaft length when new ‪

149.0 mm (5.87 in. ) ‪

Maximum shaft length ‪

151.0 mm (5.94 in.) ‪

Cylinder Head Bolts, Length

Size ‪

Maximum Shaft Length ‪

Tightening Stage ‪

Torque Value ‪

M10 ‪

47.5 mm (1.87 in.) ‪

Stage 1 ‪

10 Nm (7 lbft) ‪

Stage 2 ‪

55 Nm (41 lbft) ‪

Stage 3 ‪

additional 90 degrees ‪

Tightening Stages, Exhaust Manifold Bolts

Size ‪

Max. Shaft Length ‪

Tightening Stage ‪

Torque Values ‪

M16 ‪

151.0 mm (5.94 inches) ‪

Stage 1 ‪

20 Nm (15 lbfft) ‪

Stage 2 ‪

70 Nm (52 lbfft) ‪

Stage 3 ‪

170 Nm (125 lbfft) ‪

Stage 4 ‪

280 Nm (207 lbfft ) ‪

Stage 5 ‪

additional 90 degrees ‪

Stage 6 ‪

additional 90 degrees ‪

Tightening Stages, Cylinder Head

Description ‪

Minimum Oil Pressure Reading ‪

Engine at Idle Speed ‪

50 kPa (7 psi) ‪

Engine at Max. rpm ‪

250 kPa (36 psi) ‪

Oil Pressure Readings

Description ‪

Torque Value ‪

High-Pressure Fuel Injection Lines ‪

25 Nm (18 lbft) ‪

Charge-Air Manifold Fasteners ‪

25 Nm (18 lbft) ‪

Rocker Arm Mounting Bolts ‪

30 Nm (22 lbft) ‪

Inspection Cover on Flywheel Housing ‪

25 Nm (18 lbft) ‪

Protective Sleeve ‪

45 Nm (33 lbft) ‪

Miscellaneous Torque Values

For the crankshaft specifications, see Figure 42282 . Crankshaft repair specifications are listed in Table . The main bearing repair specifications are listed in Table . The main bearing-cap tightening stages are listed in Table . ‪

Description ‪

Specification ‪

Main and Connecting-Rod Bearing Journals Permissible Difference In Out-Of-Roundness ‪

0.005 mm ‪

( 0.0002 in.) ‪

Permissible Taper at Main Bearing Journals and Connecting-Rod Bearing Journals ‪

0.005 mm ‪

( 0.0002 in.) ‪

Fillet Radii of Main Bearing and Connecting-Rod Bearing Journals ‪

2.5 to 3.0 mm ‪

(0.0984 to 0.1181 in.) ‪

Radial Runout Measured at Middle Main Journal* ‪

0.15 mm ‪

(0.0059 in.) ‪

Lateral Runout (End Play) Measured at Thrust washer Bearing Journal ‪

0.160.38 mm ‪

(0.0060.015 in.) ‪

Crown of Main Bearing Journals and Connecting-Rod Journals ‪

0.000 to 0.004 mm ‪

(0.000 to 0.0002 in.) ‪

Main Bearing and Connecting Rod Journal Hardness (Rockwell hardness) ‪

52 HRC ‪

Permissible Imbalance of Crankshaft ‪

30 gcm ‪

(0.4162 in.-ounce) ‪

Crankshaft Specifications


Size ‪

mm (in.) ‪

Main Bearing Journal Diameter ‪

mm (in.) ‪

Main Bearing Journal Width ‪

mm (in.) ‪

Thrustwasher Bearing Journal Width ‪

mm (in.) ‪

Connecting-Rod Bearing Journal Diameter ‪

mm (in.) ‪

Connecting-Rod Bearing Journal Width ‪

mm (in.) ‪

All Sizes ‪

31.031.2 ‪

(1.2201.228) ‪

34.034.2 mm ‪

(1.3391.346 in.) ‪

Standard ‪

85.99086.010 ‪

(3.38543.3862) ‪

31.00031.062 ‪

(1.22051.2229) ‪

69.99570.015 ‪

(2.75572.7565) ‪

Undersize ‪

0.10 (0.004) ‪

85.89085.910 ‪

(.3.38153.3823) ‪

69.89569.915 ‪

(2.75182.7526) ‪

Undersize ‪

0.25 (0.010) ‪

85.74085.760 ‪

(3.37563.3764) ‪

69.74569.765 ‪

(2.74592.7466) ‪

Undersize ‪

0.30 (0.012) ‪

31.30031.362 ‪

(1.23231.2347) ‪

Undersize ‪

0.50 (0.020) ‪

85.49085.510 ‪

(3.36583.3665) ‪

31.50031.562 ‪

(1.24021.2426) ‪

69.49569.515 ‪

(2.73602.7368) ‪

Undersize ‪

0.75 (0.030) ‪

85.24085.260 ‪

(3.35593.3567) ‪

69.24569.265 ‪

(2.72622.7270) ‪

Undersize ‪

1.00 (0.040) ‪

84.99085.010 ‪

(3.34613.3469) ‪

68.995069.015 ‪

(2.71632.7171) ‪

Crankshaft Repair Specifications

Size ‪

mm (in.) ‪

Main Bearing Inner Diameter ‪

mm (in.) ‪

Standard ‪

86.066 to 86.108 (3.388 to 3.390) ‪

Undersize 0.1 (0.0039) ‪

85.966 to 86.008 (3.384 to 3.386) ‪

Undersize 0.25 (0.0098) ‪

85.816 to 85.858 (3.379 to 3.380) ‪

Undersize 0.5 (0.0197) ‪

85.566 to 85.608 (3.369 to 3.370) ‪

Undersize 0.75 (0.0295) ‪

85.316 to 85.358 (3.359 to 3.361) ‪

Undersize 1.0 (0.0394) ‪

85.066 to 85.108 (3.349 to 3.351) ‪

Main Bearing Repair Specifications

Max. Shaft Length ‪

Tightening Stage ‪

Torque Value ‪

4.57 in (116.0 mm) ‪

Stage 1 ‪

30 Nm (22 lbft) ‪

Stage 2 ‪

80 Nm (59 lbft) ‪

Stage 3 ‪

155 Nm (114 lbft) ‪

Stage 4 ‪

additional 90 degrees ‪

Tightening Stages, Main Bearing-Cap Bolts

The tightening stages for the vibration damper mounting bolts are listed in Table . ‪

Maximum Shank Length ‪

Tightening Stage ‪

Torque Value ‪

61.0 mm (2.40 in.) ‪

Stage 1 ‪

50 Nm (37 lbft) ‪

Stage 2 ‪

125 Nm (92 lbft) ‪

Stage 3 ‪

additional 90 degrees ‪

Tightening Stages, Vibration Damper Mounting Bolts

Flywheel specifications are listed in Table . Ring Gear Specifications are listed in Table . The Flywheel Tightening Stages are listed in Table . ‪

Description ‪

Four and Six Cylinder Engines ‪

Specification mm (in.) ‪

Flywheel Outer Diameter ‪

443 (17.4) ‪

Flywheel Shoulder Diameter ‪

392.435392.575 (15.450215.4557 ) ‪

Flywheel Diameter at Crankshaft Flange ‪

114.960115.020 (4.52604.5283 ) ‪

Flywheel Diameter for Mounting Clutch ‪

435.000435.063 (17.126017.1285 ) ‪

Flywheel Minimum Width Between Friction Surface and Mounting Flange After Repairs ‪

55 (2.17) ‪

Flywheel Maximum Overall Width ‪

56 (2.20) ‪

Pitch Circle Diameter for Clutch ‪

373.7 (14.71) ‪

Peak-to-Valley Height (Rz ) of Clutch Friction Surface ‪

16 m (630 in) ‪

Flywheel Permissible Deviation From True (radial and lateral) ‪

0.05 (0.002) ‪

Flywheel Specifications

Description ‪

Four- and Six-Cylinder Engines ‪

Flywheel Shoulder Diameter (for ring gear mounting ) ‪

392.435392.575 mm (15.450215.4557 in.) ‪

Hole for Mounting Clutch Pressure Plate ‪

3/816 UNC ‪

Thread Depth ‪

24 mm (15/16 in.) minimum ‪

Ring Gear Inner Diameter ‪

392.000392.140 mm (15.433115.4386 in) ‪

Ring Gear/Flywheel Overhang ‪

0.2950.575 mm (0.01160.0226 in.) ‪

Ring Gear/Flywheel Permissible Radial Runout ‪

0.5 mm (0.02 in) ‪

Ring Gear Width ‪

15.616.0 mm (0.6140.630 in.) ‪

Ring Gear Fitting Temperature ‪

250280C (480540F) ‪

Ring Gear Specifications

Size ‪

Max. Shank Length ‪

Tightening Stage ‪

Torque Value Nm (lbft) ‪

M14 x 1.5 ‪

61.0 mm (2.40 in.) ‪

Stage 1 ‪

50 (37) ‪

Stage 2 ‪

125 (92) ‪

Stage 3 ‪

additional 90 degrees ‪

Tightening Stages, Flywheel Mounting Bolts

The specification for piston protrusion specifications is listed in Table . The connecting rod stretch bolts tightening stages are listed in Table . The piston ring end-gap dimensions are listed in Table . The connecting rod inspection specifications are listed in Table . The bearing journal specifications are listed in Table . ‪

Description ‪

mm (in.) ‪

Piston Protrusion (from top dead center) ‪

0.28 to 0.50 (0.011 to 0.020) ‪

Piston Protrusion Specifications

Size ‪

Max. Shaft Length ‪

Tightening Stage ‪

Torque Value ‪

Nm (lbft) ‪

M12 x 1.25 ‪

57.0 mm (2.24 in.) ‪

Stage 1 ‪

11 (8) ‪

Stage 2 ‪

45 (33) ‪

Stage 3 ‪

additional 90 degrees ‪

Tightening Stages, Connecting Rod Stretch Bolts

Ring Designation ‪

Groove ‪

Gap When New ‪

mm (in.) ‪

Maximum End Gap ‪

mm (in.) ‪

Keystone ‪

I ‪

0.35 to 0.55 (0.014 to 0.022) ‪

1 (.039) ‪

Taper-Faced with Internal Angle ‪

II ‪

0.40 to 0.60 (0.016 to 0.024 ) ‪

1 (.039) ‪

Double-Chamfered Oil Control with Garter Spring ‪

III ‪

0.25 to 0.50 (0.010 to 0.020 ) ‪

1 (.039) ‪

Piston Ring End-Gap Dimensions

Description ‪

Dimensions, ‪

mm (in.) ‪

Distance Between Connecting Rod Bearing Bore and Bushing Inner Surface ‪

157.445157.510 (6.19866.2012 ) ‪

Maximum Difference in Axial Parallelism Between Bearing Bore and Bushing Inner Surface ‪

0.025 (0.0010) ‪

Distance from Connecting Rod Center Line for Measuring Parallelism ‪

50 (2) ‪

Bushing Inner Diameter ‪

40.0340.04 (1.57601.5764) ‪

Bearing Seat Inner Diameter with Bearing Shells Installed ‪

Standard ‪

70.05470.093 (2.75802.7596 ) ‪

Repair Stage: Undersize 0.1 mm ‪

69.95469.993 (2.75412.7556 ) ‪

Repair Stage: Undersize 0.25 mm ‪

69.80469.843 (2.74822.7497) ‪

Repair Stage: Undersize 0.5 mm ‪

69.55469.593 (2.73832.7399) ‪

Repair Stage: Undersize 0.75 mm ‪

69.30469.343 (2.72852.7300) ‪

Repair Stage: Undersize 1.0 mm ‪

69.05469.093 (2.71872.7202) ‪

Basic Bore Diameter for Connecting Rod Bearings ‪

75.00075.019 (2.95282.9535) ‪

Connecting-Rod Bearing Play ‪

Radial ‪

0.0390.098 (0.00150.0039) ‪

Axial (end play) ‪

0.1700.470 (0.00670.0185) ‪

Permissible Out-of-Roundness of Basic Bores ‪

Bearing Bore ‪

0.008 (0.0003) ‪

Bushing Bore ‪

0.006 (0.0002) ‪

Connecting Rod Bolt ‪

Thread Diameter ‪

M12 x 1.25 ‪

Shank Length When New ‪

56.0 (2.20) ‪

Maximum Shank Length ‪

57.0 (2.24) ‪

Connecting Rod Inspection Specifications

Repair Stage ‪

Diameter mm (in.) ‪

Standard ‪

69.99570.015 ( 2.75572.7565) ‪

Undersize 0.1 mm ‪

69.89569.915 (2.75182.7526) ‪

Undersize 0.25 mm ‪

69.74569.765 (2.74592.7467) ‪

Undersize 0.5 mm ‪

69.49569.515 (2.73602.7368) ‪

Undersize 0.75 mm ‪

69.24569.265 (2.72622.7270) ‪

Undersize 1.0 mm ‪

68.99569.015 (2.71632.7171) ‪

Bearing Journal Specifications

The general valve specifications are listed in Table . The valve lift specifications are listed in Table . The specifications for valve lash checking and adjustment are listed in Table . The specifications for the valve seat bore machining are listed in Table . The general specifications for valve seats are listed in Table . ‪

Description ‪

Intake ‪

in. (mm) ‪

Exhaust ‪

in. (mm) ‪

Valve Stem Diameter ‪

7.9357.950 (0.31240.3130) ‪

7.9257.940 (0.31200.3126) ‪

Valve Seat Diameter, at Head Mating Surface ‪

31.0 (1.22) ‪

36.0 (1.42) ‪

Valve Head Diameter ‪

33.934.1 (1.331.34) ‪

37.938.1 (1.491.50) ‪

Valve Seat HeightAfter Grinding ‪

2.73.1 (0.1060.122) ‪

2.53.2 (0.0980.126 ) ‪

Valve Seat Width, at Valve Head ‪

3.34.3 (0.1300.169) ‪

3.54.2 (0.1380.165) ‪

Valve Seat Angle ‪

20 degrees ‪

45 degrees ‪

Valve Length ‪

125.7126.1 (4.9484.998) ‪

152.5152.9 (6.0046.020) ‪

Valve Stem Hardness ‪

54-60 HRC ‪

Maximum Concentricity of Valve Seat to Stem ‪

0.03 (0.0012) ‪

Difference in Height Between the Two Intake Valves as Measured From the End of the Stem ‪

0.20 (0.008) ‪

N/A ‪

Valve Standback from Cylinder Head ‪

1.1-1.5 (0.04-0.08) ‪

General Valve Specifications

Description ‪

Specification ‪

Specified Dial Gauge Preload for Checking Valve Lift ‪

15 mm (0.60 in.) ‪

Valve Lift with Intake Valves Completely Open ‪

at least 9.7 mm (0.38 in.) ‪

Valve Lift with Exhaust Valves Completely Open ‪

at least 10.7 mm (0.42 in.) ‪

Inspection Cover Bolt Torque ‪

25 Nm (18 lbft) ‪

Valve Lift Specifications

Valve Type ‪

Check For: ‪

mm (in.) ‪

Adjust To: ‪

mm (in.) ‪

Intake ‪

0.30 to 0.60 (0.012 to 0.024 ) ‪

0.40 (0.016) ‪

Exhaust ‪

0.50 to 0.80 (0.020 to 0.032) ‪

0.60 (0.024) ‪

Valve Lash Checking and Adjustment

Repair Stage ‪

Basic Bore in Cylinder Head ‪

Outside Diameter of Valve Seat Insert ‪

Intake ‪

mm (in.) ‪

Exhaust ‪

mm (in.) ‪

Intake ‪

mm (in.) ‪

Exhaust ‪

mm (in.) ‪

Standard ‪

35.00035.025 ‪

(1.3781.379) ‪

40.00040.025 ‪

(1.5751.576) ‪

35.0735.08 ‪

(1.38071.3811) ‪

40.0740.08 ‪

(1.57751.5779) ‪

Standard I ‪

35.30035.325 ‪

(1.3901.391) ‪

40.30040.325 ‪

(1.5751.588) ‪

35.3735.38 ‪

(1.39251.3929) ‪

40.3740.38 ‪

(1.58931.589) ‪

Stage I ‪

35.50035.525 ‪

(1.3981.399) ‪

40.50040.525 ‪

(1.5941.595) ‪

35.5735.58 ‪

(1.40041.4008) ‪

40.5740.58 ‪

(1.59721.5976) ‪

Valve Seat Bore Machining Repair Stage Specifications

Description ‪

Specification ‪

mm (in.) ‪

Valve Seat Interference Fit ‪

0.045-0.080 ‪

(0.0018-0.0031) ‪

Depth of Bore in Cylinder Head ‪

(see Figure , E) ‪

11.4-11.6 ‪

(0.449-0.457) ‪

Height of Valve Seat Insert ‪

(see Figure , C) ‪

Intake ‪

7.6-7.7 ‪

(0.299-0.303) ‪

Exhaust ‪

8.0-8.1 ‪

(0.315-0.319) ‪

Clearance Between Head mating Surface and Valve Seat Insert Face ‪

(see Figure , D) ‪

Intake ‪

3.7-4.0 ‪

(0.146-0.157) ‪

Exhaust ‪

3.3-3.6 ‪

(0.130-0.142) ‪

Valve Seat General Specifications

Rocker arm specifications are listed in Table . ‪

Description ‪

Specifications ‪

Bushing Inside Diameter (when installed) ‪

22.00-22.021 mm (0.8661-0.8670 in.) ‪

Shaft Diameter ‪

21.967-21.980 mm (0.8648-0.8654 in.) ‪

Rocker Arm Mounting Bolt Torque ‪

30 Nm (22 lbft) ‪

Distance from Front Bracket to First Inside Bracket (see Figure , A) ‪

122 mm (4.80 in.) ‪

Distance from Last Inside Bracket to Rear Bracket (see Figure , B) ‪

110 mm (4.33 in.) ‪

Rocker Arm Specifications

Camshaft specifications are listed in Table . The valve tappet specifications are listed in Table . ‪

Description ‪

6-Cylinder ‪

mm (in.) ‪

4-Cylinder ‪

mm (in.) ‪

Camshaft Radial Runout When Mounted on Outer Bearing Journals ‪

Timing Gear Seat Maximum ‪

0.020 ‪

(0.0001 ) ‪

0.020 ‪

(0.0001 ) ‪

Cam Base Circle Maximum ‪

0.025 ‪

(0.0010 ) ‪

0.025 ‪

(0.0010 ) ‪

All Bearing Points Maximum ‪

0.030 ‪

(0.0012) ‪

0.030 ‪

(0.0012) ‪

Cam RiseValve Lobes Over Base Circle Diameter ‪

Inlet Minimum ‪

7.3 ‪

(0.3) ‪

7.3 ‪

(0.3) ‪

Exhaust Minimum ‪

8.2 ‪

(0.32) ‪

8.2 ‪

(0.32) ‪

Cam RiseUnit Pump Over Base Circle Diameter ‪

Minimum ‪

13.8 ‪

(0.54) ‪

13.8 ‪

(0.54) ‪

Hardness of Cams and Bearing Journals HRc ‪

5460 HRc ‪

Camshaft Specifications

Description ‪

4- and 6-Cylinder: ‪

mm (in.) ‪

Valve Tappet Outer Diameter ‪

Standard ‪

17.94417.965 ‪

(0.70650.7073 ) ‪

Oversize 0.25 ‪

18.19418.215 ‪

(0.7163 0.7171 ) ‪

Valve Tappet Bore in Crankcase Diameter ‪

Standard ‪

18.00018.018 ‪

(0.70870.7094 ) ‪

Oversize 0.25 ‪

18.25018.268 ‪

(0.71850.7192 ) ‪

Valve Tappet Specifications