Piston ring and block

To inspect

Operation 4-6

Note:   If the piston ring is worn or damaged, renew it.

Piston ring gap

Insert the rings into the cylinder at right angles to the cylinder bore and measure the gaps with a feeler gauge.

If the gap is more than the service limit, renew the ring.

102-05, 103-07

Gap mm (in)

Standard

103-10

Gap mm (in)

Standard

Piston ring

Service limit

Piston ring

Service limit

0,13 - 0,25

(0.0051 - 0.0100)

1,0

(0.040)

0,15 - 0,27

(0.0059 - 0.0106)

1,0

(0.040)

No. 01 ring

No. 01 ring

0,10 - 0,22

(0.0040 - 0.0087)

1,0

(0.040)

0,12 - 0,24

(0.0047 - 0.0094)

1,0

(0.040)

No. 02 ring

No. 02 ring

0,10 - 0,30

(0.0040 - 0.0120)

1,0

(0.040)

0,20 - 0,35

(0.0079 - 0.0138)

1,0

(0.040)

Oil control ring

Oil control ring

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

Gap mm (in)

Piston ring

Standard

Service limit

0,20 - 0,35

(0.0079 - 0.0138)

1,0

(0.040)

No. 01 ring

0,20 - 0,40

(0.0079 - 0.0158)

1,0

(0.040)

No. 02 ring

0,20 - 0,40

(0.0079 - 0.0158)

1,0

(0.040)

Oil control ring

54

Workshop Manual, TPD 1377E, issue 4

This document has been printed from SPI². Not for Resale

4

100 Series

Small end bush

To remove and to fit

Operation 4-7

Special requirements

Clearance mm (in)

Engine model

Standard

Service limit

0,1 (0.004)

0,1 (0.004)

0,1 (0.004)

102-05, 103-07

0,013 - 0,028 (0.00051 - 0.00110)

0,008 - 0,023 (0.00031 - 0.00091)

0,010 - 0,025 (0.00040 - 0.00099)

103-10

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

Calculate the clearance between the small end bush and the gudgeon pin. If the clearance exceeds the service

limit, renew.

Workshop Manual, TPD 1377E, issue 4

55

This document has been printed from SPI². Not for Resale

4

100 Series

Connecting rod

To inspect

Operation 4-8

Special requirements

Dimension mm (in)

Standard

Service limit

Distortion for 100 (3.937)

Parallel for 100 (3.937)

Less than 0,08 (0.0031)

0,20 (0.0079) max

0,15 (0.0059) max

Less than 0,05 (0.0020)

56

Workshop Manual, TPD 1377E, issue 4

This document has been printed from SPI². Not for Resale

100 Series

5

Crankshaft assembly

5

Crankshaft pulley

To remove and to fit

Operation 5-1

Special requirements

Special tools

Description

Torque Nm (lbf ft) kgf m

Part number

102-05, 103-07

93 (69) 9,5

123 (91) 12,5

304 (224) 31

103-10

Crankshaft pulley remover

21825619

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

Note:  Store the key (A1) in a safe place until assembly.

Workshop Manual, TPD 1377E, issue 4

57

This document has been printed from SPI². Not for Resale

5

100 Series

Flywheel, backplate and oil seal

To remove and to fit

Operation 5-2

Special requirements

POWERPART products

Description

Part number

Silicone RTV sealing and jointing compound

1861108

Flywheel setscrews : Torque Nm (lbf ft) kgf m

Backplate setscrews : Torque Nm (lbf ft) kgf m

102-05, 103-07

73 (54) 7,4

102-05, 103-07

15 (11) 1,5

50 (37) 5,1

15 (11) 1,5

103-10

73 (54) 7,4

73 (54) 7,4

103-10

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

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

Notes:

To remove and fit the flywheel, see Operation 13-1.

On assembly, apply Powerpart silicone RTV sealing and jointing compound to the block (around screw

holes) before the backplate is fitted.

103-10, 103-13 and 103-15 engines only: Remember the position of the dowel (A1).

1

POWERPART silicone

gasket sealant

58

Workshop Manual, TPD 1377E, issue 4

This document has been printed from SPI². Not for Resale