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Service Information

Document Title: Function Group: Information Type: Date:


Crank mechanism, 030 Service Information 4/21/2013
specifications
Profile:
Engine, D16E [GB]

Crank mechanism, specifications


Crankshaft
Length 1256 mm (49.4 in)
Crankshaft, axial clearance 0.15 mm (0.006 in)
Max. permitted ovality of main bearing and connecting rod < 0.01 mm (< 0.004 in)
(big-end) bearing journals
Max. permitted conicity of main bearing and connecting rod < 0.02 mm (< 0.0008 in)
(big-end) bearing journals
Pitch on middle bearing < 0.15 mm (< 0.0059 in)

Figure 1

Main bearing journal


Diameter () standard for reworking
Undersize:
0.25 mm (0.0098 in) 117.75 mm (4.636 in)
0.50 mm (0.0197 in) 117.50 mm (4.626 in)
0.75 mm (0.0295 in) 117.25 mm (4.616 in)
1.00 mm (0.0394 in) 117.00 mm (4.606 in)
1.25 mm (0.0492 in) 116.75 mm (4.596 in)
surface finish, main bearing journal
surface finish, radius
Width, thrust bearing journal (a), standard 49.0 mm (1.929 in)
Oversize:
0.2 mm (0.00787 in) 49.2 mm (1.937 in)
0.4 mm (0.0157 in) 49.4 mm (1.945 in)
0.6 mm (0.0236 in) 49.6 mm (1.953 in)
Fillet (hollow) radius (r) 4.5 mm (0.177 in)

Thrust washer (thrust bearing)


Width (b), standard 3.18 mm (0.125 in)
Oversize:
0.1 mm (0.0039 in) 3.28 mm (0.129 in)
0.2 mm (0.0079 in) 3.38 mm (0.133 in)
0.3 mm (0.0118 in) 3.48 mm (0.137 in)
0.4 mm (0.0157 in) 3.58 mm (0.141 in)

Main bearing cups


Type Replaceable
Outer diameter (c) 123.12 mm (4.847 in)
Thickness (d), standard 2.51 mm (0.099 in)
Oversize:
0.25 mm (0.0098 in) 2.64 mm (0.1039 in)
0.50 mm (0.0197 in) 2.76 mm (0.1087 in)
0.75 mm (0.0295 in) 2.89 mm (0.1138 in)
1.00 mm (0.0394 in) 3.01 mm (0.1185 in)
1.25 mm (0.0492 in) 3.14 mm (0.1236 in)

Figure 2

Big-end bearing journals


Diameter () standard for reworking 112 mm (4.409 in)
Undersize:
0.25 mm (0.0098 in) 111.75 mm (4.400 in)
0.50 mm (0.0197 in) 111.50 mm (4.390 in)
0.75 mm (0.0295 in) 111.25 mm (4.380 in)
1.00 mm (0.0394 in) 111.00 mm (4.370 in)
1.25 mm (0.0492 in) 110.75 mm (4.400 in)
Surface finish, crankshaft bearing journal Ra 0.25
Surface finish, radius Ra 0.4
Width (A) 60 mm (2.362 in)
Fillet (hollow) radius (R) 4.5 mm (0.177 in)

Connecting rods' bearing cups


Outer diameter (B) 116.8 mm (4.598 in)
Thickness (C), standard 2.35 mm (0.100 in)
Oversize:
0.25 mm (0.0098 in) 2.48 mm (0.098 in)
0.50 mm (0.0295 in) 2.60 mm (0.102 in)
0.75 mm (0.0295 in) 2.73 mm (0.107 in)
1.00 mm (0.0394 in) 2.85 mm (0.112 in)
1.25 mm (0.0492 in) 2.98 mm (117 in)
Diameter, bearing cup's bearing seat (D) 116.8 mm (4.598 in)

Connecting rod
Length centre centre (E) 280 mm (11.02 in)
Marking:
"FRONT" on shaft turned Forward

Connecting rod and cap are pair-marked with a three-digit


running number.
Connecting rod bushing's inside diameter (G)
63 mm (2.480 in)
Axial clearance, connecting rod crankshaft, with marking
directly opposite each other
< 0.35 mm (<0.014 in)
Connecting rod (big-end) bearing, radial clearance, oiled part
< 0.10 mm (0.0039 in)
Straightness (max.) deviation per 100 mm measured length
0.06 mm (0.0024 in)
Rotation (max.) deviation per 100 mm measured length
0.15 mm (0.0059 in)

Piston
Height above cylinder block face 0.18 0.03 mm (0.007 0.001 in)
Number of ring grooves 3
Front marking Arrow facing forward

Piston rings
Compression rings
Quantity 2
Piston ring clearance in grooves:
upper compression ring Trapezius-shaped profile
lower compression ring 0.07 mm (0.0028 in)
Piston ring gap:
upper compression ring 0.62 mm (0.0244 in)
lower compression ring 1.1 mm (0.043 in)
Oil scraper ring
Quantity 1
Width, incl. spring 4.55 mm (0.1791 in)
Piston ring clearance in grooves 0.10 mm (0.039 in)
Piston ring gap 0.9 mm (0.035 in)