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ENGINE MECHANICAL (C24SE) 6A-51
OPERATIONS ON CRANK DRIVE
Con-Rod Bearing
Removal
1. Remove oil pan and bearing bridge according to the corresponding operation.
2. Remove con-rod bearing cap and con-rod bearing after marking both sides.
Clean
Con-rod journal, con-rod bearing cap
Installation
1. Install new bearing shafts lightly coated with engine oil.
2. Install con-rod bearing cap.
Torque-Angle Method
Con-rod bearing cap to con-rod - 35N ⋅m (3.5 kgf ⋅m) +45 ° to
60 °
Important!
Use new bolts.
3. Install oil pan and bearing bridge according to the corresponding operation.
Piston with Con-Rod
Removal
1. Remove cylinder head and oil pan according to the corresponding operations.
2. Remove piston with con-rod after marking con-rod bearing cap.
Inspection
Remove and install all parts, if applicable.
Important!
Ring gap offset:
Piston rings - 180 °.
Oil scraper rings - 25 to 50 mm/1 to 2 in. from gap of
intermediate ring to the left and to the right.
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Page 2066 of 6020

6A-52 ENGINE MECHANICAL (C24SE)
Installation
1. Install piston with con-rod by inserting with engine oil.
2. Coat piston rings with engine oil and compress with piston ring compressor.
Important!
Installation position:
Arrow / notch on piston head on timing side of engine
Beads on con-rod on clutch side
Torque-Angle Method
Piston to cylinder block.
Con-rod bearing cap to con-rod-35N ⋅m (3.5 kgf ⋅m) +45 ° to 60 °
Important!
Use new bolts.
Installation
1. Install oil pan and cylinder head according to the corresponding operations.
2. Install sealing Gasket or replace if damaged.
3. Install camshaft housing to cylinder head.
4. Install cylinder head according to the corresponding operation.
Con-Rod
Removal
1. Remove piston with con-rod according to the corresponding operation.
2. Disassemble con-rod piston assembly by pressing out piston pin, using 5-8840-0468-0.
Installation
1. Slide guide drift (5-8840-0468-0) in horizontal position through piston and con-rod as far as side plate stops.
2. Tighten bolts evenly so that the piston rests flush on the rear plate.
3. Remove centre piece from guide drift and insert piston bolts (lubricated) into guide drift.
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Page 2067 of 6020
ENGINE MECHANICAL (C24SE) 6A-53
4. Heat a new con-rod to 280
°C in the oil bath.
5. Install the con-rod to the piston and insert the piston pin.
Important!
Since the con-rods have no weight balancing studs, re-working
is not possible.
Exchange con-rods in sets only.
Installation position, beads on con-rod point to the flattening on
the piston pin eye.
Firmly seated piston pin cannot be pushed in. Carry out
installation quickly.
Piston Rings
Removal
1. Remove piston with con-rod according to the corresponding operation.
2. Remove piston rings using commercially available ring installer or piston ring clamp pliers.
Clean
Piston ring grooves - ground piece of old piston ring
Inspection
Piston ring gap
For piston ring sizes, permissible piston ring gaps - see
"Technical Data"
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Page 2068 of 6020
6A-54 ENGINE MECHANICAL (C24SE)
RTW 46ASH002401
Installation
1. Install oil scraper ring.
2. Offset ring gaps of steel band rings each 25 to 50 mm/1 to 2in. to the left or right of the intermediate ring gap.
3. Install piston rings.
4. Offset ring gaps by approx. 180 °.
5. Install second piston ring with identification mark "TOP" facing upwards.
6. Install piston with con-rod according to the corresponding operation.
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Page 2069 of 6020

ENGINE MECHANICAL (C24SE) 6A-55
OPERATIONS ON REMOVED ENGINE
Crankshaft
Removal
1. Mount the engine on an engine overhaul stand with appropriate adapters.
2. Remove the aggregates, flywheel/drive disc, oil pan, bearing bridge and oil pump according to the
corresponding operation.
3. Mark the con-rod bearing cover.
4. Remove the crankshaft bearing cover.
5. Remove the crankshaft from cylinder block.
Inspection
Remove and install all parts if necessary.
Crankshaft pulse pickup sensor rotor inspection and repair.
Inspect the crankshaft pulse pickup sensor rotor for excessive
wear and damage.
Replace the crankshaft pulse pickup rotor if the inspection
results exceed wear and damage limits.
Installation
1. Install the crankshaft pulse pickup sensor. Torque: 13N !
!!
!
m (1.3 kgf !
!!
!
m)
2. Install new bearing shells into the cylinder block and bearing cover.
3. Coat the bearing shafts with engine oil. For oversizes-see “Technical Data”
4. Install a new crankshaft into the cylinder block.
Note
The sealing of the crankshaft can be corrected with light
blows with a rubber hammer on the crank arm (arrowed).
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Page 2070 of 6020

6A-56 ENGINE MECHANICAL (C24SE)
5. Apply a bead of sealant (TB-1207C or equivalent) in the grooves of both bearing shells.
Important!
After installation of bearing cover, press in sealing compound
again from above, until compound emerges at the joints.
Torque - Angle Method
Bearing cover to cylinder block - 50 N ⋅m (5.1 kgf ⋅m) +40 ° to
50 °
Con-rod bearing cover to con-rod - 35 N ⋅m (3.5 kgf ⋅m) +45 ° to
60 °.
Use new bolts.
6. Install oil pump, oil pan, bearing bridge rear crankshaft
sealing, flywheel/drive plate, and aggregates according to
the corresponding operations.
Inspection
Bearing play - bearing cover removed
Measure
W ith "Plastigage" (ductile plastic threads)
Cut threads to length of bearing width and lay axiaity between
crankshaft journal and bearing shell (arrowed).
Install bearing cover with correct torque.
Important!
Grease crankshaft journal and lubricate bearing shell slightly
so that the thread does not tear when the bearing cover is
moved.
Crankshaft
Inspection
End play when bearing shells are installed.
Front end contact surfaces of flywheel/flexible plate.
Permissible end play - see "Technical Data "
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Page 2071 of 6020

ENGINE MECHANICAL (C24SE) 6A-57
Inspection
Out-of-round (run-out)-middle bearing shell removed when
mounting on front and rear bearing.
Permissible out-of-round - see "Technical Data"
Bearing Free Play Measurement
Two methods for measuring bearing free play are described -
1. Plastigage method and 2. micrometer and gauge method.
The two procedures are suitable for measuring both con-rod
and main bearing free play.
For both methods ensure con-rod and main bearing caps are
identified (1) prior to removal as they are machine matched.
1.Plastigage Method
Removal
1. Remove bearing cap and shell.
2. Lightly coat journals and bearings with engine oil to prevent Plastigage from tearing when cap is removed.
Installation
1. Lay a length of Plastigage across width of crank pin and fit bearing cap and shell using old bolts at this stage.
Important!
Do not allow crankshaft to rotate.
Torque - Angle Method
Main bearing cap bolt - 60 N ⋅m (6.1 kgf ⋅m) +40 ° + to 50 °.
Con-rod bearing cap bolts - 35 N ⋅m (3.6 kgf ⋅m) +45 °.
Removal
1. Remove bearing cap and shell.
Measure
W idth of Plastigage -use scale supplied with Plastigage.
If con-rod bearing clearance exceeds 0.031mm/0.001in or
main journal bearing clearance exceeds 0.04mm/0.02in. -
check crankshaft journal diameters - see corresponding
operation.
Replace bearing if crankshaft is within specification - see
"Technical Data"
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6A-58 ENGINE MECHANICAL (C24SE)
Clean
Plastigage from journals.
Lightly coat journals and bearings with engine oil.
Installation
Install bearing cap and shell using new bolts.
Torque - Angle Method
Main bearing cap bolt - 60 N ⋅m (6.1 kgf ⋅m) +40 ° to 50 °.
Con-rod bearing cap bolts - 35 N ⋅m (3.9 kgf ⋅m) +45 °.
2.Micrometer and gauge method.
Crankshaft removed.
Installation
1. Install caps and bearing shells to con-rods and cylinder block.
Measure
Con-rod and main bearing diameters at three points I, II, III
(arrowed).
Divide the sum of the three measurements by three to obtain a
mean diameter.
The top illustration shows con-rod measuring points.
The second illustration shows main bearing measuring points.
Measure
Crankshaft main and con-rod bearing journals at points I and
II. Divide the sum of both measurements to obtain a mean
diameter.
Crankshaft must be replaced if mean diameter of main or con-
rod journals is below specified limit - see "Technical Data".
If crankshaft is serviceable subtract crankshaft mean journal
diameters from corresponding shell bearing mean diameters to
determine bearing clearance.
Permissible main bearing clearance - 0.015 to 0.04mm/0.0006
to 0.002in.
Permissible con-rod bearing clearance - 0.006 to
0.031mm/0.002 to 0.001in.
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