ENGINE

Crank Assembly - Model 906

TESTING & REPAIR

TESTING & REPAIR WORK: LIGHT TRANSPORTERS: CRANK ASSEMBLY - AR03.00-Z-9642EB

ENGINE 642

TESTING & REPAIR WORK: LIGHT TRANSPORTERS: CRANK ASSEMBLY - ENGINE 642
Remove/install belt ENGINES 642 in MODEL 639 ENGINES AR03.30-S-1600SE
pulley/vibration damper 642.896 /898 /992 /993 in MODEL 906
Remove/install crankshaft ENGINES 642 in MODEL 639 ENGINES AR03.20-S-4351SE
642.896 /898 /992 /993 in MODEL 906

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Remove/install drive plate ENGINES 642.896 /898 /992 /993 in MODEL AR03.30-S-8003SE
906 with TRANSMISSION 722.683 ENGINES
642 in MODEL 639
Remove/install piston ENGINES 642 in MODEL 639 ENGINES AR03.10-S-7021SE
642.896 /898 /992 /993 in MODEL 906
Remove/install piston rings ENGINE 642 in MODEL 639 ENGINE AR03.10-S-7311SE
642.896 /898 /992 /993 in MODEL 906
Remove/install retaining lock for ENGINE 272, 642 ... AR03.30-S-5000SE
crankshaft/ ring gear
Replace front crankshaft radial ENGINES 642 in MODEL 639 ENGINES AR03.20-S-3000SE
sealing ring 642.896 /898 /992 /993 in MODEL 906

TESTING & REPAIR WORK: TRANSPORTERS: CRANK ASSEMBLY - AR03.00-Z-9642FB

ENGINE 642

TESTING & REPAIR WORK: TRANSPORTERS: CRANK ASSEMBLY - ENGINE 642

Inspect basic position of balancing ENGINES 642.896 /898 /992 /993 in MODEL AR03.20-D-3637SF
shaft 906
Remove/install a flywheel ENGINE 642 ... AR03.30-D-8002SF
Remove/install balance shaft ENGINE 642 ... AR03.20-D-1000SF
Remove/install belt ENGINES 642 in MODEL 639 ENGINES AR03.30-S-1600SE
pulley/vibration damper 642.896 /898 /992 /993 in MODEL 906
Remove/install crankshaft ENGINES 642 in MODEL 639 ENGINES AR03.20-S-4351SE
642.896 /898 /992 /993 in MODEL 906
Remove/install drive plate ENGINES 642.896 /898 /992 /993 in MODEL AR03.30-S-8003SE
906 with TRANSMISSION 722.683 ENGINES
642 in MODEL 639
Remove/install piston ENGINES 642 in MODEL 639 ENGINES AR03.10-S-7021SE
642.896 /898 /992 /993 in MODEL 906
Remove/install piston rings ENGINE 642 in MODEL 639 ENGINE AR03.10-S-7311SE
642.896 /898 /992 /993 in MODEL 906
Remove/install retaining lock for ENGINE 272, 642 ... AR03.30-S-5000SE
crankshaft/ ring gear
Replace front crankshaft radial ENGINES 642 in MODEL 639 ENGINES AR03.20-S-3000SE
sealing ring 642.896 /898 /992 /993 in MODEL 906
Replace rear crankshaft radial ENGINE 642 ... AR03.20-S-3063SE
sealing ring

MOUNT CONNECTING ROD BEARING - AR03.10-D-6111-08SF

MODIFICATION NOTES - CONNECTING ROD CAP BOLT TORQUE SPECIFICATION (ENGINE

642)
21.4.09 Value altered: bolt connecting, rod bearing cap to CONNECTING ROD CAP BOLT
connecting rod TORQUE SPECIFICATIONS

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CONNECTING ROD CAP BOLT TORQUE SPECIFICATIONS - ENGINE 642
Number Designation Engine 642
BA03.10-N-1001- Bolt, connecting rod bearing cap to 1. Short arm stage Nm 15
01P connecting rod 2. Long arm stage Nm 20
3rd Short arm Nm 30
stage
4th Long arm Nm 40
stage
5th stage short Nm 40
arm Degrees 90
6th stage long Degrees 90
arm
7th stage short Degrees 90
arm
8th stage long Degrees 90
arm
See picture Fig. 1

1. Clean the bearing points of conrod, conrod bearing caps and conrod bearing journals with a chamois
leather.

Never use hard objects for cleaning to prevent damage.

2. Blow out oil galleries with compressed air in direction of oil flow.
3. Install conrod bearing cap with conrod bearing shells.
4. Lubricate thread and bolt head contact surface of conrod bolts with engine oil.
5. Tighten connecting rod bolt.
 The connecting rod bolts must be replaced after removal. Otherwise engine damage can occur. The
conrods are supplied with assembly screws, which must be replaced by conrods with assembly clamps to
prevent loosening. Tighten connecting rod bolt in stages with the prescribed tightening torque. Observe
tightening instructions.

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Fig. 1: Identifying Connecting Rod Cap Bolt Torque Sequence - Engine 642

REMOVE/INSTALL PISTON - AR03.10-S-7021SE

ENGINES 642.896 /898 /992 /993 in MODEL 906

Fig. 2: Removing/Installing Piston - Engine 642 In Model 906

MODIFICATION NOTES - CONNECTING ROD CAP BOLT TORQUE SPECIFICATION (ENGINES

642.896 /898 /992 /993 IN MODEL 906)
21.4.09 Value altered: bolt connecting, rod bearing cap to CONNECTING ROD CAP BOLT
connecting rod, see picture TORQUE SPECIFICATIONS -
ENGINE 642

REMOVE/INSTALL PISTON - (ENGINES 642.896 /898 /992 /993 IN MODEL 906

Removing
1 Remove engine with Model 906 AR01.10-D-2401SF
transmission
2 Detach transmission from Model 906 with transmission AR27.10-D-0502B
engine 722.6
3 Install engine on engine repair Passenger car engine assembly
stand stand
4 Remove cylinder heads Model 906 AR01.30-D-5780SF
Right cylinder head
Model 906 AR01.30-D-5770SF

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Left cylinder head
5 Remove oil pump Model 906 AR18.10-D-6020SF
6 Mark pistons (4a, 4b) and Pistons (4a, 4b) on the right
cylinder liners to one another and left side must not be
as well as their installation swapped with each other.
position. If arrow for the installation
position of piston (4a, 4b) is no
longer visible on the piston
crown, remove carbonization
(arrow) and identify again if
necessary.
7 Unscrew connecting rod bolts The connecting rods (2) are
(3), remove connecting rod cracked (broken). The
bearing cap (1) and remove dimensional accuracy of the
connecting rods (2) with connecting rods (2) can no
pistons (4a, 4b) longer be guaranteed after
opening, therefore new
connecting rods must be fitted.
New connecting rods (2) are
supplied with assembly bolts.
Replace with connecting rod
bolts (3) with assembly locking
element.
8 Transfer marked installation
position of pistons (4a, 4b) to
new connecting rods (2)
9 Remove circlip (5) for piston Lay on a clean and soft base
pin (6) to protect pistons (4a, 4b) from
being damaged.
10 Remove piston pin (6)
 Install
11 Match pistons (4a, 4b) to
cylinder bore
12 Oil piston pin (6) and
connecting rod bush
13 Assemble pistons (4a, 4b) and
connecting rod (2) according to
marked installation position
14 Push in piston pin (6) by hand
15 Insert retaining (5) on piston Lay on a clean and soft base
pin (6) into groove (arrow A) to protect pistons (4a, 4b) from
on pistons (4a, 4b) being damaged.
16 Clean pistons (4a, 4b), oil
cylinder bores, connecting rod
journals and connecting rod

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bearing shells
17 Align piston rings and tension Joint on upper piston ring
with tensioning strap (7) must point in the direction of
travel towards the front. The
joints of other piston rings must
be offset by 120° in each case.
Fig. 3
18 Insert pistons (4a, 4b) into The arrow in the piston
cylinder bores crown must point in the
direction of travel. When
inserting pistons (4a, 4b) into
cylinder bores, ensure that
connecting rods (2) do not
make contact with the
crankshaft, turn crankshaft
accordingly.
19 Position connecting rod The contact surfaces must AR03.10-D-6111-
bearing cap (1) on connecting be devoid of any oil and grease 08SF
rod (2) and tighten with and must not be damaged.
connecting rod bolts (3)
20 Install oil pump Model 906 AR18.10-D-6020SF
21 Install cylinder heads Model 906 AR01.30-D-5780SF
Right cylinder head
Model 906 AR01.30-D-5770SF
Left cylinder head
22 Remove engine from engine
repair stand
23 Attach the transmission to the Model 906 with transmission AR27.10-D-0502B
engine. 722.6
24 Install engine with Model 906 AR01.10-D-2401SF
transmission

CONNECTING ROD CAP BOLT TORQUE SPECIFICATIONS - ENGINE 642

Number Designation Engine 642
BA03.10-N-1001- Bolt, connecting rod bearing cap to 1. Short arm stage Nm 15
01P connecting rod 2. Long arm stage Nm 20
3rd Short arm Nm 30
stage
4th Long arm Nm 40
stage
5th stage short Nm 40
arm Degrees 90
6th stage long Degrees 90
arm

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7th stage short Degrees 90
arm
8th stage long Degrees 90
arm
See picture -

Fig. 3: Identifying Tensioning Strap (000 589 04 14 00)

REMOVE/INSTALL PISTON RINGS - AR03.10-S-7311SE

ENGINE 642 in MODEL 639

ENGINE 642.896 /898 /992 /993 in MODEL 906

 cardiagn.com
Fig. 4: Identifying Piston Rings Installation Position - Engine 642

Measure side clearance

Fig. 5: Measuring Ring Side Clearance - Engine 642

Measure end gap

Fig. 6: Measuring Piston End Gap

REMOVE/INSTALL PISTON RINGS - ENGINE 642.896 /898 /992 /993 IN MODEL 906

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Remove/install
1 Remove pistons AR03.10-S-7021SE
2 Determine side clearance of Piston ring vertical clearance
piston rings (1, 2, 3) using a
feeler gauge
3 Remove piston rings (1, 2, 3) Installation: Observe
from piston installation position of piston
rings (1, 2, 3). The emblem
"Top" or the name of the
manufacturer must point
towards the piston crown.
Installation: Insert hook
spring (8) with spring expander
(4) offset by 180° to the ring
gap of the piston ring (3) and
insert piston rings (1, 2) with
the ring gaps offset by 120° to
each other.
Fig. 7
4 Determine ring gap of piston Insert respective piston ring
rings (1, 2, 3) using a feeler (1, 2, 3) into unused area of the
gauge cylinder contact surface.
Piston ring end gap
5 Install in the reverse order

PISTON RING VERTICAL CLEARANCE & END GAP - ENGINE 642 IN MODELS 639, 642
Engine 642 in Engine 642 in
Number Designation model 639 model 906
BE03.10-N- Piston ring vertical clearance Groove 1 mm 0.12 to 0.16 0.18 to 0.24
1003-02Q Groove 2 mm 0.065 to 0.110 0.05 to 0.10
 Groove 3 mm 0.03 to 0.07 0.03 to 0.07
BE03.10-N- Piston ring end gap Groove 1 mm 0.40 to 0.55 0.20...0.40
1004-02Q Groove 2 mm 0.25 to 0.50 0.40 to 0.60
Groove 3 mm 0.20...0.40 0.20...0.40

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Fig. 7: Identifying Pliers (000 589 51 37 00)

REMOVE/INSTALL BALANCE SHAFT - AR03.20-D-1000SF

ENGINE 642.896 in MODEL 906 with TRANSMISSION 711.685, 722.683

ENGINE 642.898 in MODEL 906 with TRANSMISSION 722.683

ENGINE 642.992 in MODEL 906 with TRANSMISSION 711.660, 722.683

ENGINE 642.993 in MODEL 906 with TRANSMISSION 722.683

Fig. 8: Balance Shaft Remove/Install Component Locations - Engine 642

REMOVE/INSTALL BALANCE SHAFT - ENGINE 642.898 IN MODEL 906 WITH TRANSMISSION

722.683
Remove/install
1.1 Remove flywheel Transmission 711 AR03.30-D-8002SF
1.2 Remove driven plate Transmission 722 AR03.30-S-8003SE
2 Remove cap (2) Installation: Install new
end cover (2).

Loctite sealant 5970

3 Remove front module AR88.30-D-1064SE
4 Remove right-hand camshaft Fix timing chain (11) onto AR05.20-D-6040SF
sprocket cylinder head. Do not lower
into timing chain chamber.

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5 Remove timing case cover AR01.40-S-8000SE
6 Attach timing chain (11) to Installation: The marking
crankshaft (10) using a cable (arrow) on balance shaft (1)
tie (12) and detach on must point vertically upwards
cylinder head then place timing chain (11) on
balance shaft (1).
If camshaft or crankshaft (10)
was turned the basic position
of balance shaft (1) must be
checked.
See:
Inspect basic position of AR03.20-D-3637SF
balance shaft (1)
7 Insert drill bit (7) with an 8.5 The drill bit (7) serves as an
mm diameter in the bore (5) assembly stop for correctional
weight (6).
8 Remove bolt (4) and
correctional weight (6)
9 Remove drill bit (7) from
bore (5) in crankcase (3)
10 Remove bolt (9) and remove
bracket (8)
11 Pull out balance shaft (1)
from crankcase (3) to the
front
12 Install in the reverse order

BALANCE SHAFT TORQUE SPECIFICATIONS - ENGINE 642

Number Designation Engine 642
BA03.20-N-1001- Correctional weight at rear balance Stage 1 Nm 20
02A shaft Stage 2 Degrees 90
BA03.20-N-1002- Balance shaft cover on crankcase at rear Nm 8
02A
BA03.20-N-1003- Bolt to crankcase at front to secure balance shaft Nm 9
02A

REPAIR MATERIALS - SEALANT

Number Designation Order number
BR00.45-Z-1013-01A Loctite sealant 5970 A 003 989 98 20

INSPECT BASIC POSITION OF BALANCING SHAFT - AR03.20-D-3637SF

ENGINES 642.896 /898 /992 /993 in MODEL 906

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Fig. 9: Identifying Balancing Shaft Basic Installation With Gear Timing Marks
 cardiagn.com
Fig. 10: Balancing Shaft & Timing Chain Basic Installed Position

INSPECT BASIC POSITION OF BALANCING SHAFT - ENGINES 642.896 /898 /992 /993 IN MODEL
906
Removing
1 Place camshafts (1) in basic AR05.20-D-6010SF
position
2 Remove timing case cover The crankshaft must not turn AR01.40-S-8000SE
(6) while the vibration damper (7)
is being removed.
Checking
3 Provisionally install timing Only perform if crankshaft
case cover (6) without was turned.
applying sealant
4 Provisionally install vibration Only perform if crankshaft
damper (7) was turned.
5 The top dead center marking Only perform if crankshaft
(arrow) of the vibration was turned.
damper (7) must be flush
with the stay on timing case
cover (6); align if necessary
6 Remove vibration damper (7) Only perform if crankshaft
and timing case cover (6) was turned.
7 Check whether markings (8) If markings (8) are no
on the camshafts (1) are aligned, or if markings (3), seen
aligned with each other and in the direction of travel, are not
the markings (3) on aligned on the left side to the
camshafts (1) must, seen in cylinder head upper edge, then
the direction of travel, be timing chain (9) must be placed
 aligned on the left side to the again on camshaft sprockets (4,
cylinder head upper edge 5).
Refer to:
Remove/install camshaft AR05.20-D-6040SF
sprocket
8 Check whether marking If marking (arrow A) does
(arrow A) on balance shaft not point vertically upwards,
(10) points vertically upward remove camshaft sprocket (4)
and place timing chain (9) again
on balance shaft (10).
Refer to:
Remove/install camshaft AR05.20-D-6040SF
sprocket
Install
9 Install timing case cover (6) AR01.40-S-8000SE

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INSTALL FRONT CRANKSHAFT RADIAL SEAL - AR03.20-S-3000-01SE

Fig. 11: Identifying Centering Sleeve (642 589 00 14 00)

1. Place radial shaft sealing ring-crankshaft (8) on timing case cover (10) and press on lightly.

Do not lubricate or grease crankshaft journal and sealing lip of radial shaft sealing ring-crankshaft (8).
Grease on the tilted stays of sealing lip of radial shaft sealing ring-crankshaft (8) prevents back transport
of engine oil into the crankcase.

2. Push centering sleeve (9) onto the crankshaft.

Turn centering sleeve (9) to ensure that the groove on the centering sleeve (9) is aligned with the
parallel key (7) in crankshaft.

3. Pull radial shaft sealing ring-crankshaft (8) over the centering sleeve (9) using the center bolt (4) and
washer (5).
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Fig. 12: Identifying Center Bolt, Washer, Parallel Key, Radial Shaft Sealing Ring-Crankshaft &
Centering Sleeve

REPLACE CRANKSHAFT FRONT RADIAL SEALING RING - AR03.20-S-3000SE

ENGINES 642 in MODEL 639

ENGINES 642.896 /898 /992 /993 in MODEL 906

 cardiagn.com
Fig. 13: Replacing Crankshaft Front Radial Sealing Ring - Engine 642 (Shown On Model 639)

REPLACE FRONT CRANKSHAFT RADIAL SEALING RING - ENGINES 642.896 /898 /992 /993 IN
MODEL 906
Removing
1 Remove belt AR03.30-S-1600SE
pulley/vibration damper
2 Pry radial shaft sealing ring Do not damage mounting
(1) out of timing case cover hole for radial shaft sealing
with suitable tool ring (1); use clean rag as base
to ensure that the radial shaft
sealing ring (1) is tight.
Install
3 Install radial shaft sealing AR03.20-S-3000-
ring (1) 01SE
Centering sleeve Fig. 11
4 Install belt pulley/vibration AR03.30-S-1600SE
damper
Checking
5 Check engine oil level, The engine oil level must
correct if necessary not be above the maximum
mark. This can lead to engine
damage.

Risk of accident caused by Secure vehicle to prevent it AS00.00-Z-0005-

vehicle starting off by itself from moving by itself. 01A
when engine is running. Wear closed and snug-fitting
Risk of injury caused by work clothes.
 contusions and burns during Do not touch hot or rotating
starting procedure or when parts.
working near the engine as
it is running
6 Check for leaks with engine Visual inspection only.
running

ENGINE OIL CAPACITY & SPECIFICATIONS - ENGINES 642 IN MODEL 906

Engine 642 in
model 906 Engine 642 in
without model 906 with
Number Designation particulate filter particulate filter
BF18.00-N-1001- Engine oil Filling capacity (oil and Liters 12.5 12.5
01L filter change)
Specifications for Sheet BB00.40-P-0228- -

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Operating Fluids 03A
Sheet BB00.40-P-0228- -
05A
Sheet BB00.40-P-0228- BB00.40-P-0228-
51A 51A
Sheet BB00.40-P-0229- -
03A
Sheet BB00.40-P-0229- -
05A
Sheet BB00.40-P-0229- BB00.40-P-0229-
31A 31A
Sheet BB00.40-P-0229- BB00.40-P-0229-
51A 51A

ENGINE OIL CAPACITY & SPECIFICATIONS - ENGINES 642 IN MODEL 639

Engine 642 in
Number Designation model 639
BF18.00-N-1001- Engine oil Filling capacity (oil and filter Liters 10
01L change)
Specifications for Operating Sheet -
Fluids Sheet -
Sheet BB00.40-P-0228-
51A
Sheet -
Sheet -
Sheet BB00.40-P-0229-
31A
Sheet -
Fig. 14: Identifying Centering Sleeve (642 589 00 14 00)

INSTALLING REAR CRANKSHAFT RADIAL SEALING RING - AR03.20-S-3063-01SE

CRANKCASE, TIMING CASE COVER, END COVER TORQUE SPECIFICATIONS - ENGINE

642 IN MODEL 906

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Engine 642 in
Number Designation model 906
BA01.40-N-1001- Bolt connecting rear end cover to Stage 1 Nm 8
01S crankcase Stage 2 Nm 10

Fig. 15: Identifying Insertion Tool (271 589 00 43 00)

REPAIR MATERIALS - REAR CRANKSHAFT RADIAL SEALING RING

Number Designation Order number
BR00.45-Z-1013-01A Loctite sealant 5970 A 003 989 98 20
BR00.45-Z-1028-04A Cleaner from package Adolf Wurth GmbH & Co. KG Reinhold-Wurth-
Str. 12-17
74653 Kunzelsau-Gaisbach
Germany
Tel. +49 7940 15-0
Fax +49 7940 15-1000
www.wuerth.de
BR00.45-Z-1038-04A Loctite 7200 Henkel Loctite Deutschland GmbH
Arabellastrasse 17
81925 Munchen
 Germany
Tel. +49 899268-0
Fax + 49 899101978
www.Loctite.de

Do not touch sealing lips on radial shaft sealing ring-crankshaft (1) and the contact surface (3a) on
crankshaft flange (3), since these must be oil and grease-free.

When using the insertion tool always ensure alignment of the sealing lips (1d, 1s) on the radial shaft sealing
ring-crankshaft (1). There is danger of poor sealing by the radial shaft sealing ring-crankshaft (1) if these
instructions are not observed.

Fig. 16: Identifying Rear Radial Shaft Sealing Ring, Crankshaft, Crankshaft Flange, Sealing Lips &
Contact Surface cardiagn.com
Cleaning

1. Clean and degrease crankcase (4) in area of sealant application as well as contact surface (3a) on
crankshaft flange (3).

The contact surface (3a) must not be processed with abrasive paper, since this will damage the user
interface of crankshaft flange (3).
2. Clean and degrease sealing surface on the new end cover (2).

Install

3. Apply sealant in the form of a bead (A) with a height of about 2 mm on the crankcase and to the oil pan.

Do not apply sealant (A). Mount end cover within 5 minutes after applying the sealant (A).

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Fig. 17: Sealant Application Area For Crankcase Rear End Cover

4. Fit insertion tool (271) and insertion tool (271a) together.

Upon subsequent assembly, the conical form of the insertion tool (271a) leads the lip (1d) in the
correct direction.

5. Slide end cover (2) with radial shaft sealing ring-crankshaft (1) onto the fitted together insertion tool
(271, 271a).

The sealing lip (1d) must point in the direction of the engine, the sealing lip (1s) in the direction of the
transmission (see arrows).

6. Detach insertion tool (271a) from insertion tool (271).

 cardiagn.com
Fig. 18: Identifying Rear Radial Shaft Sealing Ring, Crankshaft, End Cover, Sealing Lip &
Insertion Tool

7. Insert insertion tool (271) with preassembled end cover (2) on the crankshaft flange (3).
8. Slide end cover (2) with radial shaft sealing ring-crankshaft (1) carefully onto contact surface of the
crankshaft flange (3).

Check correct installation position of sealing lip (1d) in order to avoid leakage.

Sealing lip (1d) must point towards crankcase (4) all around the whole of its circumference.
 cardiagn.com
Fig. 19: Identifying Rear Radial Shaft Sealing Ring, Crankshaft, End Cover, Position Of Sealing
Lip & Crankshaft Flange

9. Detach insertion tool (271) from crankshaft flange (3).

Check correct installation position of the protective lip (1s) in order to avoid premature wear on the
radial shaft sealing ring-crankshaft (1).

The protective lip (1s) must point towards transmission housing around its entire circumference.

10. Tighten bolts (2a) on end cover (2) stepwise diagonally.

Observe tightening torque.

REPLACE REAR CRANKSHAFT RADIAL SEALING RING - AR03.20-S-3063SE

ENGINES 642.896 in MODEL 906 with TRANSMISSION 711.685, 722.683

ENGINES 642.898 in MODEL 906 with TRANSMISSION 722.683

ENGINES 642.992 in MODEL 906 with TRANSMISSION 711.660, 722.683

ENGINES 642.993 in MODEL 906 with TRANSMISSION 722.683

Fig. 20: Identifying Rear Radial Shaft Sealing Ring, Crankshaft, End Cover & Bolts

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REPLACE REAR CRANKSHAFT RADIAL SEALING RING - ENGINE 642 IN MODEL 906
Removing
1.1 Remove flywheel Transmission 711 AR03.30-D-8002SF
1.2 Remove driven plate Transmission 722 AR03.30-S-8003SE
2 Unscrew bolts (1) at end
cover (2)
3 Warm up end cover (2) Use a hot air blower.
and remove Hot air blower
Fig. 21
Install
4 Apply sealant on the end Replace end cover (2) with AR03.20-S-3063-
cover (2) and install end radial shaft sealing ring- 01SE
cover (2) with radial shaft crankshaft (3).
sealing ring-crankshaft (3) Clean sealing surfaces on
crankcase and oil pan.
Fig. 15

Loctite sealant 5970

Cleaner from package
Loctite 7200
5.1 Install flywheel Transmission 711 AR03.30-D-8002SF
5.2 Install drive plate Transmission 722 AR03.30-S-8003SE
Checking
6 Check engine oil level, The engine oil level must
correct if necessary not be above the maximum
mark. This can lead to engine
damage.
 Engine oil, Specifications
for Operating Fluids
Risk of accident caused Secure vehicle to prevent it AS00.00-Z-0005-
by vehicle starting off by from moving by itself. 01A
itself when engine is Wear closed and snug-fitting
running. Risk of injury work clothes.
caused by contusions and Do not touch hot or rotating
burns during starting parts.
procedure or when
working near the engine as
it is running
7 Conduct engine test run
and check engine in the
area of joint between
transmission and engine
for leaks

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CRANKCASE, TIMING CASE COVER, END COVER TORQUE SPECIFICATIONS - ENGINE
642 IN MODEL 906
Engine 642 in
Number Designation model 906
BA01.40-N-1001- Bolt connecting rear end cover to Stage 1 Nm 8
01S crankcase Stage 2 Nm 10

ENGINE OIL CAPACITY & SPECIFICATIONS - ENGINES 642 IN MODEL 906

Engine 642 in
model 906 Engine 642 in
without model 906 with
Number Designation particulate filter particulate filter
BF18.00-N- Engine oil Filling capacity (oil Liters 12.5 12.5
1001-01L and filter change)
Specifications for Sheet BB00.40-P-0228- -
Operating Fluids 03A
Sheet BB00.40-P-0228- -
05A
Sheet BB00.40-P-0228- BB00.40-P-0228-
51A 51A
Sheet BB00.40-P-0229- -
03A
Sheet BB00.40-P-0229- -
05A
Sheet BB00.40-P-0229- BB00.40-P-0229-
31A 31A
Sheet BB00.40-P-0229- BB00.40-P-0229-
51A 51A
Fig. 21: Identifying Removal & Installation Tool (116 589 01 62 00)

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Fig. 22: Identifying Insertion Tool (271 589 00 43 00)

REPAIR MATERIALS - REAR CRANKSHAFT RADIAL SEALING RING

Number Designation Order number
BR00.45-Z-1013-01A Loctite sealant 5970 A 003 989 98 20
BR00.45-Z-1028-04A Cleaner from package Adolf Wurth GmbH & Co. KG Reinhold-Wurth-
Str. 12-17
74653 Kunzelsau-Gaisbach
Germany
Tel. +49 7940 15-0
Fax +49 7940 15-1000
www.wuerth.de
BR00.45-Z-1038-04A Loctite 7200 Henkel Loctite Deutschland GmbH
Arabellastrasse 17
81925 Munchen
Germany
Tel. +49 899268-0
Fax + 49 899101978
www.Loctite.de

TIGHTENING PROCEDURE FOR CRANKSHAFT BEARING CAPS - AR03.20-S-4351-02SE

CRANKSHAFT MAIN BEARING CAP BOLT TORQUE SPECIFICATIONS - ENGINE 642 IN

MODELS 639, 906
 Engine 642 in Engine 642 in
Number Designation model 906 model 639
BA03.20-N- Bolt, crankshaft bearing cap to Stage 1 Nm 35 35
1002-01J crankshaft bearing body Stage 2 Degrees 95 95
Stage 3 Degrees 95 95
BA03.20-N- Lateral bolt, M10 Stage 1 Nm 53 53
1003-01J crankcase to
crankcase bearing Stage 2 Degrees 95 95
cap

1. Lubricate bolts (1 to 16) for crankshaft bearing cap (A, B, C, D) on thread and the bolt head contact
surface with engine oil.
2. Tighten bolts (1 to 16) for crankshaft bearing cap (A, B, C, D) as per tightening procedure.

Observe tightening torque for bolts (1 to 16)

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3. Tighten side bolts (1.1 to 8.1) for the crankshaft housing on crankshaft bearing cap (A, B, C, D) as per
tightening procedure.

Observe tightening torque for bolts (1.1 to 8.1)

4. Check crankshaft through turning freewheeling; remove crankshaft bearing cap (A, B, C, D) if necessary
and determine error.

Fig. 23: Crankshaft Bearing Cap Bolt Tightening Sequence - Engine 642

REMOVE/INSTALL CRANKSHAFT - AR03.20-S-4351SE

ENGINES 642 in MODEL 639

ENGINES 642.896 /898 /992 /993 in MODEL 906

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Fig. 24: Identifying Crankshaft Remove/Install Component Locations

REMOVE/INSTALL CRANKSHAFT - ENGINE 642 IN MODEL 906

Remove/install
1 Remove pistons AR03.10-S-7021SE
2 Remove timing case cover AR01.40-S-8000SE
3 Unscrew bolts (8, 9) in Installation: Replace AR03.20-S-4351-
opposite order of tightening bolts (8, 9). 02SE
torque Observe tightening
procedure.

4 Mark crankshaft bearing cap Installation: Observe

(4, 10) and fitted bearing (5) installation position of
and pry out carefully crankshaft bearing cap (4, 10)
and fitted bearing (5).
5 Remove crankshaft bearing
shells (3) from crankshaft (1)
if they do not stick in the
crankshaft bearing caps (4,
10) or fitted bearing (5)
6 Take crankshaft (1) out of
 crankcase
7 Remove crankshaft bearing The crankshaft bearing
shells (2) shells (2) are equipped with
an oil groove with oil hole in
contrast to the crankshaft
bearing shells (3)
Installation: Oil
crankshaft journals and
crankshaft bearing shells (2).
8 Remove thrust plates (6)
9 Install in the reverse order

CRANKSHAFT MAIN BEARING CAP BOLT TORQUE SPECIFICATIONS - ENGINE 642 IN

MODELS 639, 906
Engine 642

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in model Engine 642
Number Designation 906 in model 639
BA03.20-N-1002- Bolt, crankshaft bearing cap to Stage 1 Nm 35 35
01J crankshaft bearing body Stage 2 Degrees 95 95
Stage 3 Degrees 95 95
BA03.20-N-1003- Lateral bolt, crankcase to M10 Stage 1 Nm 53 53
01J crankcase bearing cap Stage 2 Degrees 95 95

REMOVE/INSTALL FLYWHEEL - AR03.30-D-8002SF

ENGINE 642.896 in MODEL 906 with TRANSMISSION 711.685

ENGINE 642.992 in MODEL 906 with TRANSMISSION 711.660

Shown on engine 642.992

Fig. 25: Identifying Flywheel, Guide Bearing, Bolt & Retaining Lock (Shown on Engine 642.992)
REMOVE/INSTALL A FLYWHEEL - ENGINE 642.896/.992 IN MODEL 906 WITH TRANSMISSION
711.6
Remove/install
1 Remove clutch AR25.10-S-0050SD
2 Install retaining lock (4) AR03.30-S-5000SE
3 Remove bolts (2) Installation: Replace bolts
(2).

4 Remove retaining lock (4) Fig. 26

5 Take off flywheel (1) Installation: Observe
correcting seating of flywheel
(1).
Checking
6 Check flywheel (1) for

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damage and friction surface
for wear; replace flywheel
(1) if necessary
7 Check guide bearing (3) for
damage and wear; replace
flywheel (1) if necessary
8 Install in the reverse order
9 Attach STAR DIAGNOSIS, Only if the flywheel (1) has
read out fault memory, been replaced.
delete if necessary and
perform sensor rotor
adaptation in menu item
Control unit adaptation
Connect STAR AD00.00-D-2000-
DIAGNOSIS and read out 04SD
fault memory

FLYWHEEL, DRIVE PLATE, VIBRATION DAMPER, STARTER RING GEAR TORQUE

SPECIFICATIONS - ENGINE 642
Number Designation Engine 642
BA03.30-N-1004- Bolt, two-mass flywheel/drive plate Stage 1 Nm 45
01S to crankshaft Stage 2 Degrees 90
Fig. 26: Identifying Retaining Lock (112 589 03 40 00)

REMOVE/INSTALL BELT PULLEY/VIBRATION DAMPER - AR03.30-S-1600SE

ENGINES 642 in MODEL 639

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ENGINES 642.896 /898 /992 /993 in MODEL 906

Fig. 27: Identifying Vibration Damper & Accessory Drive Belt Routing - Engine 642

REMOVE/INSTALL BELT PULLEY/VIBRATION DAMPER - ENGINES 642.896 /898 /992 /993 IN

MODELS 639, 906
Remove/install
1 Remove bottom engine On model
compartment paneling 639.701/703/705/711/713/811/813/815 as
of vehicle identification end number
055347
2.1 Remove fan poly-V belt Model 906 without code (H08) High AR13.22-D-
(2) performance air conditioning system 1302SF
2.2 Remove poly-V belt for Model 906 with code (H08) High AR13.21-D-
2nd refrigerant performance air conditioning 0160SF
compressor on air
conditioning system
3 Remove poly-V belt (3) Model 906 AR13.22-D-
1202HD
4 Install retaining lock for AR03.30-S-
starter ring gear 5000SE
5 Unscrew center bolt (4)
6 Remove vibration Installation: Check vibration damper
damper (1) from (1) for galling or damage; replace
crankshaft vibration damper (1) if necessary.
Die The installation position of vibration
damper (1) is defined by the feather key.
7 Replace front radial AR03.20-S-

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shaft sealing ring 3000SE
8 Install in the reverse
order
Risk of accident caused Secure vehicle to prevent it from moving AS00.00-Z-0005-
by vehicle starting off by itself. 01A
by itself when engine is Wear closed and snug-fitting work
running. Risk of injury clothes.
caused by contusions Do not touch hot or rotating parts.
and burns during
starting procedure or
when working near the
engine as it is running
9 Perform engine test run
and check engine in the
area of the vibration
damper (1) for leaks

VIBRATION DAMPER CENTRAL BOLT TORQUE SPECIFICATIONS - ENGINE 642

Number Designation Engine 642
BA03.30-N-1001- Central bolt of vibration 10.9 Stage 1 Nm 210
01S damper Stage 2 Degrees 180

REMOVE/INSTALL RETAINING LOCK FOR CRANKSHAFT/RING GEAR - AR03.30-S-5000SE

ENGINES 272, 642 in MODEL 639

ENGINES 642.896 /898 /992 /993 in MODEL 906

ENGINES 272 in MODEL 636

Engine 642 in model 639

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Fig. 28: Identifying Retaining Lock & Cover For Crankshaft/Ring Gear (Engine 642 In Model 639)

Engine 642 in model 906

Fig. 29: Identifying Retaining Lock & Cover For Crankshaft/Ring Gear (Engine 642 In Model 906)

Engine 272 in model 636 and model 639

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Fig. 30: Identifying Screw & Protective Cover (Engine 272 In Model 636 & Model 639)

REMOVE/INSTALL RETAINING LOCK FOR CRANKSHAFT/RING GEAR - ENGINES

642.896 /898 /992 /993 IN MODEL 906
Remove/install
1 Lift/jack up vehicle Model 906 AR00.60-D-1000H
2 Remove bottom engine On model 636 or on
compartment paneling Model 639.7/8 as of vehicle
identification end number
055347
3 Remove cover (1) On model 639 with engine 642
or on model 906 with engine
642

4 Remove protective cover (4) On model 636, 639 with engine

272
5 Remove screws (3) On model 636, 639 with engine
272

6 Insert retaining lock (2) in The retaining lock (2) must

opening engage in the ring gear of the
flywheel or clutch plate, if
necessary crank the engine at
the crankshaft in the direction
of engine rotation.
Retaining lock Fig. 26
7 Install in the reverse order
 STARTER COVER TORQUE SPECIFICATIONS - ENGINE 642
Number Designation Engine 642
BA15.30-N-1005-01G Cover on starter opening on crankcase Nm 40

AUTOMATIC TRANSMISSION-TO-ENGINE MOUNTING BOLTS - MODELS 636, 639 WITH

TRANSMISSION 722.6
Model 636, 639 with
Number Designation transmission 722.6
BA27.10-N-1001- Automatic transmission to engine M10 Nm 38
04A

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Fig. 31: Identifying Retaining Lock (112 589 03 40 00)

REMOVE/INSTALL DRIVE PLATE - AR03.30-S-8003SE

ENGINES 642.896 /898 /992 /993 in MODEL 906 with TRANSMISSION 722.683

ENGINES 642 in MODEL 639

Shown on engine 642.992 in model 906

Fig. 32: Identifying Drive Plate & Bolts (Shown On Engine 642.992 In Model 906 With Transmission
722.683)

REMOVE/INSTALL DRIVE PLATE - ENGINES 642.896 /898 /992 /993 IN MODEL 906 WITH
TRANSMISSION 722.683; ENGINE 642 IN MODEL 639
Remove/install
1 Remove transmission with Model 906 AR27.10-D-0502B
torque converter
2 Install retaining lock for AR03.30-S-5000SE
crankshaft or starter ring
gear
3 Unscrew bolts (2) and Installation: Replace bolts
remove clutch plate (1) (2).

Checking
4 Check clutch plate (1) for

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damage, if necessary replace
clutch plate (1)
5 Install in the reverse order
6 Attach STAR DIAGNOSIS, Only if the clutch plate (1)
read out fault memory, has been replaced.
delete if necessary and
perform sensor rotor
adaptation in menu item
Control unit adaptation
Connect STAR AD00.00-D-2000-
DIAGNOSIS and read out 04SD
fault memory

TWO-MASS FLYWHEEL/DRIVE PLATE-TO-CRANKSHAFT - ENGINE 642

Number Designation Engine 642
BA03.30-N-1004- Bolt, two-mass flywheel/drive plate to Stage 1 Nm 45
01S crankshaft Stage 2 Degrees 90

TEST & ADJUSTMENT VALUES

TEST & ADJUSTMENT VALUES: LIGHT TRANSPORTERS: CRANK ASSEMBLY - BE03.00-Z-
9999EZ

MODEL all

TEST & ADJUSTMENT VALUES: LIGHT TRANSPORTERS: CRANK ASSEMBLY

Belt pulley/vibration damper ENGINE 642 BE03.30-N-1000-02F
Check values for crankshaft ENGINE 642, 646, 651 ... BE03.20-N-1000-01G
bearing cap bolts
Check values for crankshaft main ENGINE 642 BE03.20-N-1000-03C
bearing shells
Check values for piston rings ENGINE 642 BE03.10-N-1000-05N
Check values for connecting rod ENGINE 642.890/990 in MODEL 639 BE03.10-N-1000-01S
ENGINE 642.896/898/992/993 in MODEL
906
Check values of crankshaft ENGINE 271, 272, 642, 646, 651 in MODEL BE03.20-N-1000-02S
906 ENGINE 651 ENGINE 651 in MODEL
900
Test specifications for connecting ENGINE 642, 646, 651 ... BE03.10-N-1000-03D
rod bolts
Test specifications for crankshaft ENGINE 642, 646, 651 ... BE03.20-N-1000-04B
bearing clearance
Test specifications for pistons ENGINE 642, 646 BE03.10-N-1000-02Q

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TEST & ADJUSTMENT VALUES: TRANSPORTERS: CRANK ASSEMBLY - BE03.00-Z-9999FZ

MODEL all

TEST & ADJUSTMENT VALUES: TRANSPORTERS: CRANK ASSEMBLY

Belt pulley/vibration damper ENGINE 642 BE03.30-N-1000-02F
Check values for crankshaft ENGINE 642, 646, 651 ... BE03.20-N-1000-01G
bearing cap bolts
Check values for crankshaft main ENGINE 642 BE03.20-N-1000-03C
bearing shells
Check values for piston rings ENGINE 642 BE03.10-N-1000-05N
Check values for connecting rod ENGINE 642.890/990 in MODEL 639 BE03.10-N-1000-01S
ENGINE 642.896/898/992/993 in MODEL
906
Check values of crankshaft ENGINE 271, 272, 642, 646, 651 in MODEL BE03.20-N-1000-02S
906 ENGINE 651 ENGINE 651 in MODEL
900
Test specifications for connecting ENGINE 642, 646, 651 ... BE03.10-N-1000-03D
rod bolts
Test specifications for connecting ENGINE 611, 612, 613, 628, 629, 642, 646, BE03.10-P-1000-03D
rod bolts 647, 648, 668 ...
Test specifications for crankshaft ENGINE 642, 646, 651 ... BE03.20-N-1000-04B
bearing clearance
Test specifications for pistons ENGINE 642, 646 BE03.10-N-1000-02Q

CHECK VALUES FOR CONNECTING ROD - BE03.10-N-1000-01S

ENGINE 642.890/990 in MODEL 639

ENGINE 642.896/898/992/993 in MODEL 906

CHECK VALUES FOR CONNECTING RODS - ENGINE 642.896/898/992/993 IN MODEL 906,
ENGINE 642.890/990 IN MODEL 639
ENGINE ENGINE
642.890/990 in 642.896/898/992/99
Number Designation MODEL 639 3 in MODEL 906
BE03.10-N- Dimension Distance from center of mm 167,97...168,03 167,97...168,03
1001-01S connecting rod bearing bore to
connecting rod bush bore (L)
Width of Connecting rod mm 18,1...18,6 18,1...18,6
connecting rod bearing bore (B)
Connecting rod mm 21,94...22,0 21,94...22,0
bush bore (b) -
BE03.10-N- Dimension Connecting rod bearing shells mm 67,600...67,614 67,600...67,614
1002-01S basic bore (D1) Diameter
Permissible out-of-roundness mm 0,007 0,007

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and conicity of basic bore -
BE03.10-N- Dimension Permissible twist of connecting mm 0,100 0,100
1003-01S rod bearing bore to connecting
rod bush bore over a length of
100
BE03.10-N- Dimension Permissible axial deviation from mm 0,045 0,045
1004-01S parallel of connecting rod
bearing bore to connecting rod
bush bore over a length of 100
BE03.10-N- Dimension Permissible weight difference g 2 2
1005-01S between complete connecting
rods in the same engine
BE03.10-N- Dimension Connecting rod bushing inner mm 30,038...30,044 30,038...30,044
1006-01S diameter (d) -
BE03.10-N- Dimension Connecting rod bush outside mm - -
1007-01S dia.
BE03.10-N- Dimension Connecting rod bushing basic mm 32,500...32,525 32,500...32,525
1008-01S bore diameter (d1) -
BE03.10-N- Dimension Piston pin play in connecting mm 0,028...0,039 0,028...0,039
1009-01S rod bushing
BE03.10-N- Dimension Peak-to-valley height (Rz) µm 5 5
1010-01S inside connecting rod bush
BE03.10-N- Connecting Thread dia. M 8,5X1 8,5X1
1011-01S rod bolt Shank length when new mm 47 (±0,3) 47 (±0,3)

TEST SPECIFICATIONS FOR PISTONS - BE03.10-N-1000-02Q

ENGINE 642, 646

TEST SPECIFICATIONS FOR PISTONS - ENGINES 642, 646 IN MODEL 906

 ENGINE 642 in ENGINE 646 in
Number Designation MODEL 906 MODEL 906
BE03.10-N- Piston ring vertical Groove 1 mm 0,18...0,24 0,12...0,16
1003-02Q clearance Groove 2 mm 0,05...0,10 0,05...0,09
Groove 3 mm 0,03...0,07 0,03...0,07
BE03.10-N- Piston ring end gap Groove 1 mm 0,20...0,40 0,22...0,42
1004-02Q Groove 2 mm 0,40...0,60 0,20...0,40
Groove 3 mm 0,20...0,40 0,20...0,40
BE03.10-N- Piston dia. Standard mm DN -
1005-02Q dimension
Piston group A mm 82,833...82,839 -
Piston group X mm 82,838...82,846 -
Piston group B mm 82,845...82,851 -
BE03.10-N- Piston dia. Repair stage 1 mm - -

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1006-02Q Piston group mm 82,876...82,890 -
+5
BE03.10-N- Piston dia. Repair stage 2 mm - -
1007-02Q Piston group mm 82,926...82,940 -
+10

TEST SPECIFICATIONS FOR CONNECTING ROD BOLTS - BE03.10-N-1000-03D

ENGINE 651.940 in MODEL 639

ENGINE 651.955 in MODEL 900

ENGINE 642.890/990 in MODEL 639

ENGINE 642.896/898/992/993, 646.984/985/986/989/990, 651.955/956/957 in MODEL 906

ENGINE 646.980/981/982/983 in MODEL 639

ENGINE 646.980 in MODEL 636

TEST SPECIFICATIONS FOR CONNECTING ROD BOLTS

Engine 646 in
model 636, Engine 646 in
Number Designation 639 model 906
BE03.10-N- Connecting rod bolt Thread diameter M 8X1 8X1
1001-03D Shank length New mm 47 (±0,3) 47 (±0,3)
max. mm 48 48

TEST SPECIFICATIONS FOR CONNECTING ROD BOLTS

ENGINE 642 ENGINE 651
 in MODEL in MODEL
Number Designation 639, 906 639, 900, 906
BE03.10-N- Connecting rod bolt Thread diameter M 8,5X1 8X1
1001-03D Shank length New mm 47 (±0,3) 47 (±0,3)
max. mm 47,8 48

CHECK VALUES FOR PISTON RINGS - BE03.10-N-1000-05N

ENGINE 642

CHECK VALUES FOR PISTON RINGS - ENGINE 642 IN MODELS 639, 906
ENGINE 642 in ENGINE 642 in
Number Designation MODEL 639 MODEL 906
BE03.10-N- Piston ring Bevel-edged ring mm 83X2,0X3,4 83X2,0X3,4
1001-05N height (DSF ring)

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Taper-faced ring (M- mm 83X2,0X3,45 83X2,0X3,45
ring)
Double-sided half- mm 83X2,0X3,3 83X2,0X3,4
keystone ring (DT
ring)

TEST SPECIFICATIONS FOR CONNECTING ROD BOLTS - BE03.10-P-1000-03D

ENGINE 611, 612.961/962/963/965/966/981/990, 613, 628.960/961/962/963, 629, 642, 646, 647/981, 648,
668.914/940/941/942

TEST SPECIFICATIONS FOR CONNECTING ROD BOLTS - ENGINE 611, 612, 613
ENGINE 611,
612.961/962/963/965 /966/981, ENGINE
Number Designation 613 612.990
BE03.10-P- Connecting Thread diameter M 8X1 8X1
1001-03D rod bolt Shank New mm 47 (±0,3) 47
length max. mm 48 48

TEST SPECIFICATIONS FOR CONNECTING ROD BOLTS - ENGINES 642, 646, 647, 648
ENGINE 646,
Number Designation ENGINE 642 647, 648
BE03.10-P-1001- Connecting rod bolt Thread diameter M 8,5X1 8X1
03D Shank length New mm 47 (±0,3) 47 (±0,3)
max. mm - 48

CHECK VALUES FOR CRANKSHAFT BEARING CAP BOLTS - BE03.20-N-1000-01G

ENGINE 642.896/898/992/993, 646.984/985/986/989/990, 651.955/956/957 in MODEL 906

ENGINE 646.980 in MODEL 636

ENGINE 651.955 in MODEL 900

ENGINE 642.890/990, 646.980/981/982/983, 651.940 in MODEL 639

CHECK VALUES FOR CRANKSHAFT BEARING CAP BOLTS - ENGINE 642.890/990 IN MODEL
639; ENGINE 646.980/981/982/98 3 IN MODEL 639; ENGINE 646.980 IN MODEL 636
ENGINE
646.980/981/982/98
ENGINE 3 in MODEL 639
642.890/990 in ENGINE 646.980 in
Number Designation MODEL 639 MODEL 636
BE03.20-N- Crankshaft M11 Thread M 11 11
1001-01G bearing cap bolts diameter
Length (L) mm 66 61,8...62,2

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when new
Max. length (L) mm 67,8 63,8

BE03.20-N- Crankshaft M10 Thread M - -

1002-01G bearing cap bolts diameter
Length (L) mm - -
when new
Max. length (L) mm - -
BE03.20-N- Crankshaft M12 Thread M - -
1003-01G bearing cap bolts diameter
Length (L) mm - -
when new
Max. length (L) mm - -
- -

CHECK VALUES FOR CRANKSHAFT BEARING CAP BOLTS - ENGINES 642, 646 IN MODEL 906
Engine 646 in Engine 642
Number Designation model 906 in model 906
BE03.20-N- Crankshaft bearing M11 Thread diameter M 11 11x1,5
1001-01G cap bolts Length (L) when mm 61,8...62,2 109
new
Max. length (L) mm 63,8 111
-
BE03.20-N- Crankshaft bearing M10 Thread diameter M - 10
1002-01G cap bolts Length (L) when mm - 40
new
Max. length (L) mm - 41
BE03.20-N- Crankshaft bearing M12 Thread diameter M - -
1003-01G cap bolts Length (L) when mm - -
new
Max. length (L) mm - -
-

CHECK VALUES OF CRANKSHAFT - BE03.20-N-1000-02S

Engines 271, 272, 642, 646, 651

CHECK VALUES OF CRANKSHAFT - ENGINES 642, 646

Number Designation Engine 642 Engine 646
BE03.20-N- Diameter-crankshaft Stage 1 (blue) mm 75.960 to 57.960 to
1001-02S main bearing journal 75.965 57.965
main bearings 1 to 5 Stage 2 (yellow) mm 75.955 to 57.955 to
75.960 57.960

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Stage 3 (red) mm 75.950 to 57.950 to
75.955 57.955
Stage 4 (white) mm 75.945 to 57.945 to
75.950 57.950
Stage 5 (violet) mm 75.940 to 57.940 to
75.945 57.945
BE03.20-N- Diameter-crankshaft Stage 1 (blue) mm - -
1002-02S main bearing journal Stage 2 (yellow) mm - -
Main bearings 1 Stage 3 (red) mm - -
Stage 4 (white) mm - -
Stage 5 (violet) mm - -
BE03.20-N- Diameter-crankshaft Stage 1 (blue) mm - -
1003-02S main bearing journal Stage 2 (yellow) mm - -
main bearings 2 to 5 Stage 3 (red) mm - -
Stage 4 (white) mm - -
Stage 5 (violet) mm - -
BE03.20-N- Diameter-crankshaft Standard size mm 63.940 to 47.940 to
1004-02S connecting rod journal 63.965 47.965
1st repair stage mm - -
Repair stage 2 mm - -
Repair stage 3 mm - -
Repair stage 4 mm - -
BE03.20-N- Width of the crankshaft N (colorless) mm 29.500 to 24.500 to
1005-02S fitted bearing journal 29.533 24.533
N1 (red) mm 29.600 to 24.600 to
29.633 24.633

CHECK VALUES FORCRANKSHAFT MAIN BEARING SHELLS - BE03.20-N-1000-03C

ENGINE 642

CHECK VALUES FOR CRANKSHAFT MAIN BEARING SHELLS - ENGINE 642

ENGINE 642 in ENGINE 642 in
Number Designation MODEL 639 MODEL 906
BE03.20-N- Main bearing Replacement part additional 52 52
1001-03C shells standard number (color coding blue)
dimension for
upper crankcase
section and Bearing shell mm 2,250...2,255 2,250...2,255
lower crankcase thickness
section diameter
70.00 mm
BE03.20-N- Main bearing Replacement part additional 54 54
1002-03C shells standard number (color coding yellow)
dimension for

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upper crankcase
section and Bearing shell mm 2,255...2,260 2,255...2,260
lower crankcase thickness
section diameter
70.00 mm
BE03.20-N- Main bearing Replacement part additional 56 56
1003-03C shells standard number (color coding red)
dimension for
upper crankcase
section and Bearing shell mm 2,260...2,265 2,260...2,265
lower crankcase thickness
section diameter
70.00 mm
BE03.20-N- Main bearing Replacement part additional 57 57
1004-03C shells standard number (color coding white)
dimension for
lower crankcase Bearing shell mm 2,265...2,270 2,265...2,270
section diameter thickness
70.00 mm
BE03.20-N- Main bearing Replacement part additional 58 58
1005-03C shells standard number (color coding violet)
dimension for
lower crankcase Bearing shell mm 2,270...2,275 2,270...2,275
section diameter thickness
70.00 mm
BE03.20-N- Crankshaft radial play (main mm - -
1006-03C bearing play)

TEST SPECIFICATIONS FORCRANKSHAFT BEARING CLEARANCE - BE03.20-N-1000-04B

Engine 642, 646, 651

TEST SPECIFICATIONS FOR CRANKSHAFT BEARING CLEARANCE - ENGINE 642 IN MODEL
639; ENGINE 646 IN MODELS 636, 639
Engine 642 in Engine 646 in
Number Designation model 639 model 636, 639
BE03.20-N- Crankshaft bearing Radial measurement mm 0.029 to 0.056 0.03 to 0.05
1001-04B clearance (when new
new) radial wear limit mm - 0.08
Axial measurement mm 0.100 to 0.254 0.10 to 0.25
when new
axial wear limit mm - 0.3
BE03.20-N- Connecting rod Radial measurement mm - -
1002-04B bearing play (new new
value) radial wear limit mm - -
Axial measurement mm - -
when new

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axial wear limit mm - -

TEST SPECIFICATIONS FOR CRANKSHAFT BEARING CLEARANCE - ENGINE 642 IN MODEL

906; ENGINE 646 IN MODEL 906
Engine 642 in Engine 646 in
Number Designation model 906 model 906
BE03.20-N- Crankshaft Radial measurement mm 0.029 to 0.056 0.027 to 0.051
1001-04B bearing clearance new
(when new) radial wear limit mm - 0.08
Axial measurement mm 0.100 to 0.254 0.100 to 0.254
when new
axial wear limit mm - 0.3
BE03.20-N- Connecting rod Radial measurement mm 0.015 to 0.060 0.021 to 0.062
1002-04B bearing play (new new
value) radial wear limit mm - -
Axial measurement mm - -
when new
axial wear limit mm - -

TEST SPECIFICATIONS FOR CRANKSHAFT BEARING CLEARANCE - ENGINE 651

Engine 651 in
model 639, 900,
Number Designation 906
BE03.20-N-1001- Crankshaft bearing Radial measurement new mm 0.028 to 0.063
04B clearance (when new) radial wear limit mm -
Axial measurement when mm 0.110 to 0.300
new
axial wear limit mm -
BE03.20-N-1002- Connecting rod bearing Radial measurement new mm 0.027 to 0.075
04B play (new value) radial wear limit mm -
Axial measurement when mm -
new
axial wear limit mm -

BELT PULLEY/VIBRATION DAMPER - BE03.30-N-1000-02F

ENGINE 642

TEST SPECIFICATIONS FOR BELT PULLEY/VIBRATION DAMPER (RUNOUT) - ENGINE 642 IN

MODELS 639, 906
ENGINE 642 in ENGINE 642 in
Number Designation MODEL 639 MODEL 906
BE03.30-N- Permissible difference on Radial runout mm 0,4 0,4
1001-02F vibration damper Lateral mm 0,4 0,4

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trueness

TORQUE SPECIFICATIONS
TIGHTENING TORQUES: LIGHT TRANSPORTERS: CRANK ASSEMBLY - BA03.00-Z-9999EZ

TIGHTENING TORQUES: LIGHT TRANSPORTERS: CRANK ASSEMBLY

Balance shaft ENGINE 642 in MODEL 906 ENGINE BA03.20-N-1000-02A
642 in MODEL 639
Connecting rods ENGINE 642 in MODEL 639 ENGINE BA03.10-N-1000-01P
642 in MODEL 906
Crankshaft ENGINE 642, 646, 651 ... BA03.20-N-1000-01J
Flywheel, driven plate, vibration ENGINE 271, 642, 646, 651 ... BA03.30-N-1000-01S
damper, starter ring gear

TIGHTENING TORQUES: TRANSPORTERS: CRANK ASSEMBLY - BA03.00-Z-9999FZ

TIGHTENING TORQUES: TRANSPORTERS: CRANK ASSEMBLY

Balance shaft ENGINE 642 in MODEL 906 ENGINE BA03.20-N-1000-02A
642 in MODEL 639
Connecting rods ENGINE 642 in MODEL 639 ENGINE BA03.10-N-1000-01P
642 in MODEL 906
Crankshaft ENGINE 642, 646, 651 ... BA03.20-N-1000-01J
Flywheel, driven plate, vibration ENGINE 271, 642, 646, 651 ... BA03.30-N-1000-01S
damper, starter ring gear

CONNECTING RODS - BA03.10-N-1000-01N

ENGINE 651.955 in MODEL 900

ENGINE 646.980 in MODEL 636

ENGINE 651.955/956/957 in MODEL 906

ENGINE 646.980/981/982/983 in MODEL 639

ENGINE 651.940 in MODEL 639

ENGINE 646.984/985/986/989/990, 647.981

CONNECTING ROD
ENGINE ENGINE
Number Designation 646.984/985/986/989/990 647.981
BA03.10-N- Screw/bolt, For initial Stage 1 Nm 5 5
1001-01N connecting tightening after Stage 2 Nm 30 25
rod bearing cracking

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Stage 3 Degrees 180 180
cap to
For subsequent Stage 1 Nm 5 5
connecting
tightening Stage 2 Nm 25 25
rod
Stage 3 Degrees 90 90

CONNECTING ROD
Engine 646 in Engine 651 in
model 636, model 639,
Number Designation 639 906
BA03.10-N- Screw/bolt, For initial Stage 1 Nm 5 5
1001-01N connecting tightening after Stage 2 Nm 25 25
rod bearing cracking Stage 3 Degrees 180 180
cap to
For subsequent Stage 1 Nm 5 5
connecting
tightening Stage 2 Nm 25 25
rod
Stage 3 Degrees 90 90

CONNECTING ROD
ENGINE
651.955 in
Number Designation MODEL 900
BA03.10-N- Screw/bolt, For initial tightening Stage 1 Nm 5
1001-01N connecting rod after cracking Stage 2 Nm 25
bearing cap to Stage 3 Degrees 180
connecting rod
For subsequent Stage 1 Nm 5
tightening Stage 2 Nm 25
Stage 3 Degrees 90

CONNECTING RODS - BA03.10-N-1000-01P

ENGINE 642 in MODEL 639

ENGINE 642 in MODEL 906

CONNECTING ROD TORQUE SPECIFICATIONS - ENGINE 642 IN MODELS 639, 906

Number Designation Engine 642
BA03.10-N-1001- Screw/bolt, connecting rod Stage 1 short arm Nm 15
01P bearing cap to connecting rod
Stage 2 long arm Nm 20
Stage 3 short arm Nm 30
Stage 4 long arm Nm 40
Stage 5 short arm Nm 40
Stage 5 short arm Degrees 90
Stage 6 long arm Degrees 90
Stage 7 short arm Degrees 90

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Stage 8 long arm Degrees 90

CRANKSHAFT - BA03.20-N-1000-01J

ENGINES 642, 646, 651

CRANKSHAFT TORQUE SPECIFICATIONS - ENGINE 646

Engine 646 in
model 636, Engine 646 in
Number Designation 639 model 906
BA03.20-N-1001- Bolt for crankshaft M11 Stage 1 Nm 50 50
01J bearing cap Stage 2 Degrees 95 95
M12 Stage 1 Nm - -
Stage 2 Degrees - -
BA03.20-N-1002- Bolt crankshaft bearing cap to Stage 1 Nm - -
01J crankshaft bearing body Stage 2 Degrees - -
Stage 3 Degrees - -
BA03.20-N-1003- Lateral bolt, crankcase M10 Stage 1 Nm - -
01J to crankcase bearing
cap Stage 2 Degrees - -

CRANKSHAFT TORQUE SPECIFICATIONS - ENGINE 642 IN MODELS 639, 642

Engine 642 in Engine 642 in
Number Designation model 906 model 639
BA03.20-N- Bolt for crankshaft M11 Stage 1 Nm - -
1001-01J bearing cap Stage 2 Degrees - -
M12 Stage 1 Nm - -
Stage 2 Degrees - -
BA03.20-N- Bolt crankshaft bearing cap to Stage 1 Nm 35 35
1002-01J crankshaft bearing body Stage 2 Degrees 95 95
Stage 3 Degrees 95 95
BA03.20-N- Lateral bolt, crankcase to M10 Stage 1 Nm 53 53
1003-01J crankcase bearing cap Stage 2 Degrees 95 95

CRANKSHAFT TORQUE SPECIFICATIONS - ENGINE 651

Engine 651 in
Engine 651 in model 639,
Number Designation model 900 906
BA03.20-N- Bolt for crankshaft M11 Stage 1 Nm - -
1001-01J bearing cap Stage 2 Degrees - -
M12 Stage 1 Nm 60 60
Stage 2 Degrees 90 90

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BA03.20-N- Bolt crankshaft bearing cap to Stage 1 Nm - -
1002-01J crankshaft bearing body Stage 2 Degrees - -
Stage 3 Degrees - -
BA03.20-N- Lateral bolt, M10 Stage 1 Nm - -
1003-01J crankcase to
crankcase bearing cap Stage 2 Degrees - -

BALANCE SHAFT - BA03.20-N-1000-02A

ENGINE 642 in MODEL 906

ENGINE 642 in MODEL 639

BALANCE SHAFT TORQUE SPECIFICATIONS - ENGINE 642

Number Designation Engine 642
BA03.20-N-1001- Correctional weight at rear balance Stage 1 Nm 20
02A shaft Stage 2 Degrees 90
BA03.20-N-1002- Balance shaft cover on crankcase at rear Nm 8
02A
BA03.20-N-1003- Bolt to crankcase at front to secure balance shaft Nm 9
02A

FLYWHEEL, DRIVEN PLATE, VIBRATION DAMPER, STARTER RING GEAR - BA03.30-N-1000-

01S

ENGINE 646 in MODEL 636, 639

ENGINE 642 in MODEL 639

ENGINE 271, 642, 646, 651 in MODEL 906

ENGINE 651 in MODEL 900

ENGINE 651 in MODEL 639

FLYWHEEL, DRIVEN PLATE, VIBRATION DAMPER, STARTER RING GEAR TORQUE

SPECIFICATIONS - ENGINES 271, 646
ENGINE 271 ENGINE 646
in MODEL in MODEL
Number Designation 906 636, 639
BA03.30-N- Central bolt of vibration 10.9 Stage 1 Nm 200 325
1001-01S damper Stage 2 Degrees 180 90
BA03.30-N- Stretch-thread bolt for Stage 1 Nm - 45
1002-01S flywheel or two-mass
flywheel to crankshaft Stage 2 Degrees - 90
BA03.30-N- Bolt, retaining lock to transmission Nm - 10

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1003-01S
BA03.30-N- Bolt, two-mass Stage 1 Nm 45 -
1004-01S flywheel/clutch plate to
crankshaft Stage 2 Degrees 90 -
BA03.30-N- Stretch-thread bolt for Stage 1 Nm - -
1005-01S drive plate to crankshaft Stage 2 Degrees - -
BA03.30-N- Bolt, vibration damper M12 Stage 1 Nm - -
1006-01S to crankshaft Stage 2 Degrees - -
BA03.30-N- Bolt, decoupler with Stage 1 Nm - -
1007-01S vibration damper to
crankshaft Stage 2 Degrees - -

FLYWHEEL, DRIVEN PLATE, VIBRATION DAMPER, STARTER RING GEAR TORQUE

SPECIFICATIONS - ENGINE 646 IN MODEL 906; ENGINE 642
ENGINE 646 in ENGINE
Number Designation MODEL 906 642
BA03.30-N- Central bolt of vibration damper 10.9 Stage Nm 200 210
1001-01S 1
Stage Degrees 180 180
2
BA03.30-N- Stretch-thread bolt for flywheel or Stage 1 Nm 45 -
1002-01S two-mass flywheel to crankshaft Stage 2 Degrees 90 -
BA03.30-N- Bolt, retaining lock to transmission Nm 10 -
1003-01S
BA03.30-N- Bolt, two-mass flywheel/clutch plate Stage 1 Nm - 45
1004-01S to crankshaft Stage 2 Degrees - 90
BA03.30-N- Stretch-thread bolt for drive plate to Stage 1 Nm 45 -
1005-01S crankshaft Stage 2 Degrees 90 -
BA03.30-N- Bolt, vibration damper to crankshaft M12 Stage Nm - -
1006-01S 1
Stage Degrees - -
2
BA03.30-N- Bolt, decoupler with vibration Stage 1 Nm - -
1007-01S damper to crankshaft Stage 2 Degrees - -

FLYWHEEL, DRIVEN PLATE, VIBRATION DAMPER, STARTER RING GEAR TORQUE

SPECIFICATIONS - ENGINE 651
Number Designation ENGINE 651
BA03.30-N-1001- Central bolt of vibration 10.9 Stage 1 Nm -
01S damper Stage 2 Degrees -
BA03.30-N-1002- Stretch-thread bolt for Stage 1 Nm -
01S flywheel or two-mass flywheel
to crankshaft Stage 2 Degrees -
BA03.30-N-1003- Bolt, retaining lock to transmission Nm -

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01S
BA03.30-N-1004- Bolt, two-mass flywheel/clutch Stage 1 Nm 45
01S plate to crankshaft Stage 2 Degrees 90
BA03.30-N-1005- Stretch-thread bolt for drive Stage 1 Nm -
01S plate to crankshaft Stage 2 Degrees -
BA03.30-N-1006- Bolt, vibration damper to M12 Stage 1 Nm 80
01S crankshaft Stage 2 Degrees 90
BA03.30-N-1007- Bolt, decoupler with vibration Stage 1 Nm 80
01S damper to crankshaft Stage 2 Degrees 180

SPECIAL TOOLS
000 589 04 14 00 TENSIONING STRAP - WS03.00-N-0001C

FG 03/Set C

ENGINE 111.948 /978, 601, 602, 616, 617, 161, 661, 662

ENGINE 611.981 /987, 612.981, 647.981

ENGINE 646

ENGINE 642

ENGINE 271, 272.979

ENGINE 651

Use:
Tensioning strap with a 60 - 125 mm diameter for compressing piston rings

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Fig. 33: Identifying Tensioning Strap (000 589 04 14 00)

000 589 51 37 00 PLIERS - WS03.00-N-0005C

FG 03/Set C

ENGINE 111.948 /978, 601, 602, 616, 617

ENGINE 611.981 /987, 612.981, 647.981

ENGINE 642, 646

ENGINE 271, 272.979

ENGINE 651

Use:

Pliers for spreading apart piston rings.

Fig. 34: Identifying Pliers (000 589 51 37 00)

000 589 37 37 00 PLIERS - WS03.00-N-3043C

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FG 03/13/Set C

ENGINE all

Use:

Pliers for removing and installing the piston rings.

Fig. 35: Identifying Pliers (000 589 37 37 00)

000 589 38 31 00 TENSIONING STRAP - WS03.00-N-3045C

FG 03/Set C

ENGINE all

Use:
Tensioning strap for piston rings diameter 90 to 175 mm

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Fig. 36: Identifying Tensioning Strap (000 589 38 31 00)

000 589 04 14 00 TENSIONING STRAP - WS03.00-P-0001C

FG 03/Set C

ENGINES all

Use:

Tensioning strap 60 - 125; mm dia. for compressing piston rings

Fig. 37: Identifying Tensioning Strap (00 589 04 14 00)

000 589 51 37 00 PLIERS - WS03.00-P-0005C

FG 03/Set C
ENGINE all

Use:

Pliers for expanding piston rings

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Fig. 38: Expanding Piston Rings

Fig. 39: Identifying Pliers (000 589 51 37 00)

001 589 65 09 00 SOCKET - WS03.00-P-0006B

FG 03/01/05/27Set B

ENGINE all

001 589 65 09 00 SOCKET

Further use FG 07/Set A

Use:
Bihexagonal socket, 27 mm, 1/2" square drive for loosening and tightening the center bolt on the crankshaft.

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Fig. 40: Identifying Socket (001 589 65 09 00)

001 589 32 21 00 DIAL GAGE - WS03.00-P-0007B

FG 01/03/Set B

ENGINE 601.943, 602.980 /982 /983 /984 /985, 612.965, 112, 113, 271, 272, 642, 646, 651, 272, 273

Use:

Dial indicator, stroke 1 mm, scale value 0.001 mm, for measuring crankshaft radial and axial bearing clearance
and cylinder bores.

Fig. 41: Identifying Dial Gage (001 589 32 21 00)

119 589 01 14 00 SLEEVE - WS03.00-P-0022B

FG 03/05/Set B
ENGINES 112, 113, 119, 120, 137, 152, 156, 157, 159, 271, 272, 273, 275, 276, 278, 642, 271.951

119 589 01 14 00 SLEEVE

6.3.12 Replacement for: 272 589 00 14 00 FG 03/Set B
insertion tool

Use:

Sleeve to press in front crankshaft radial sealing ring.

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Fig. 42: Identifying Sleeve (119 589 01 14 00)

112 589 03 40 00 RETAINING LOCK - WS03.00-P-0037B

FG 01/03/05/27/ Set B

ENGINE 112, 113, 137, 152, 155, 156, 157, 272 /979, 273, 276, 278, 629, 642

Use:

Retaining lock for holding crankshaft via ring gear for flywheel or clutch plate.
Fig. 43: Identifying Retaining Lock (112 589 03 40 00)

611 589 00 14 00 INSERTION TOOL - WS03.00-P-0042B

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FG 03/Set B

ENGINE 112, 113, 137, 156, 159, 601, 602, 603, 604, 605, 606, 611 /980, 612, 613, 612.965 /966, 629, 642 /,
646, 647 /981, 648

MODIFICATION NOTES - 611 589 00 14 00 INSERTION TOOL

7.10.97 Replacement for 606 589 00 14 00 FG 03/Set B C

Use:

Insertion tool for front crankshaft radial sealing ring.

Fig. 44: Identifying Insertion Tool (611 589 00 14 00)

613 589 00 33 00 PULLER - WS03.00-P-0044B

FG 03/Set B
ENGINE 611, 612, 613, 612.965 /966, 642 / /, 647

Use:

Puller for vibration damper

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Fig. 45: Identifying Puller (613 589 00 33 00)

642 589 00 14 00 CENTERING SLEEVE - WS03.00-P-0094B

FG 01/03/Set B

ENGINE 642

ENGINE 642 in MODEL 906

Use:

Centering sleeve for installing timing case cover and front crankshaft radial shaft sealing ring.
Fig. 46: Identifying Centering Sleeve (642 589 00 14 00)

112 589 07 40 00 COUNTERHOLDER - WS03.00-P-0102B

FG 03/Set B

ENGINE 112, 113, 271, 272 /, 273, 640, 642 /, 646 /

Use:

Counterholder for fixing in place and unfastening the belt pulley on the air conditioner compressor.

NOTE: Partially in combination with 112 589 02 09 00 socket

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Fig. 47: Identifying Counterholder (112 589 07 40 00)

SPECIAL TOOLS: COMMERCIAL VEHICLES: CRANK ASSEMBLY - WS03.00-Z-9999TZ

MODEL all

SPECIAL TOOLS: COMMERCIAL VEHICLES: CRANK ASSEMBLY

000 589 04 14 00 FG 03/Set C WS03.00-N-0001C
Tensioning strap
000 589 04 14 00 FG 03/Set C WS03.00-P-0001C
Tensioning strap
000 589 20 21 00 FG 00 FG 03/Set B FG 03/05/Set C WS00.00-N-3047Z
Hardness tester
000 589 20 21 00 FG 00 FG 03/Set B FG 03/05/Set C WS00.00-N-3047Z
Hardness tester
000 589 20 21 00 FG 03/Set B
Hardness tester
000 589 20 21 00 FG 03/Set C
Hardness tester
000 589 25 33 00 FG 03/Set C
Internal puller
000 589 26 33 00 FG 00 FG 03/Set C WS00.00-N-3024Z
Internal extractor
000 589 27 33 00 FG 00/Set Z FG 03/25/26/Set C WS00.00-N-3025Z
Internal extractor
000 589 28 33 00 Puller FG 00/03/05/26/27/ 28/33/43/46/Set B WS00.00-N-3026Z
dia. 28-37 mm
000 589 33 33 00 FG 03/Set B
Bracing tool
000 589 33 33 00 FG 00/03/05/26/27/ 28/33/43/46/Set B WS00.00-N-0051Z
Counter stay
000 589 34 33 00 FG 00 FG 03/05/13/18/25/26/28/33/35/42/46/ Set C WS00.00-N-3032Z
Counter stay

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000 589 37 37 00 Pliers FG 03/13/Set C WS03.00-N-3043C
000 589 38 31 00 FG 03/Set C WS03.00-N-3045C
Tensioning strap
000 589 39 21 00 FG 00/03/55 WS00.00-N-3015Z
Torque wrench
000 589 45 33 00 Puller FG 00/ 03/20/26/28/ 33/35/41 WS00.00-N-3036Z
000 589 51 37 00 Pliers FG 03/Set C WS03.00-N-0005C
000 589 51 37 00 Pliers FG 03/Set C WS03.00-P-0005C
000 589 65 33 00 Puller FG 00 FG 03/20/26/28/ Set B WS00.00-N-0007Z
000 589 65 33 00 Puller FG 00/03/27/33 WS00.00-P-0007Z
000 589 65 33 00 Puller FG 03/Set B
000 589 88 33 00 Puller, FG 03/Set A
two-arm
001 589 00 91 00 Set of FG 01/03/05/07/08/ WS01.00-N-0110B
protective covers 09/13/14/15/18/20/23/43/46/47/49/54/ Set B
001 589 01 91 00 Set of FG 01/03/05/07/08/ 09/13/14/15/18/20/23/43/47/49/Set
protective covers B
001 589 02 91 00 Set of FG 01/03/05/07/08/ WS01.00-N-0112B
protective covers 09/13/14/15/18/20/23/43/46/47/49/54/Set B
001 589 32 21 00 Dial FG 01/03/Set B WS03.00-P-0007B
gage
001 589 43 09 00 FG 03/Set B
Impact-type box wrench
001 589 43 09 01 Box FG 03/Set B
wrench
001 589 43 09 02 FG 03/Set B
Socket
001 589 53 21 00 Dial FG 00/01/03/05/09/ WS00.00-N-0013Z
gage 13/18/23/26/28/33/35/41/42/46/83/Set B
001 589 65 09 00 FG 03/01/05/27Set B WS03.00-P-0006B
Socket
001 589 65 09 00 FG 03/07/18/set A
Socket
001 589 65 09 00 FG 01/03/05/Set B
Socket wrench bit
001 589 78 21 00 FG 01/03/05/Set A WS01.00-N-0006A
Compression tester
003 589 01 16 00 Pry FG 00/01/03/Set C WS00.00-P-0180Z
bar
055 589 00 67 00
Processing tool
102 589 00 33 00 Puller FG 03/Set C
102 589 00 33 00 Puller FG 03/Set B
102 589 00 33 03 FG 03/Set C

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Spindle
102 589 01 40 00 FG 03/Set B
Retaining lock
102 589 05 33 00 Puller FG 03/Set C
103 589 00 33 00 Puller FG 03/Set B
103 589 00 33 00 Puller FG 03/Set B
104 589 01 40 00 FG 03/Kit C
Counterholder
110 589 00 40 00 FG 03/Set C
Retaining lock
111 589 03 15 00 FG 01/03/05/Set B WS05.00-N-0072B
Retaining pins
111 589 08 43 00 FG 03/Set B
Installation tool
111 589 08 43 00 FG 03/Set B B
Installation tool
112 589 00 40 00 FG 01/03/Set B
Counterholder
112 589 00 40 01 Set of FG03FG 03/Set B
sleeves
112 589 00 40 01 Set of FG03FG 03/Set B
sleeves
112 589 03 40 00 FG 01/03/05/27/ Set B WS03.00-P-0037B
Retaining lock
112 589 07 40 00 FG 03/Set B WS03.00-P-0102B
Counterholder
115 589 03 59 00 Long FG 03/Set C
wedge
116 589 01 34 00 FG 01/03/05/ Set B WS05.00-N-0083B
Threaded bolt
116 589 01 40 00 FG 03/Set D
Retaining lock
116 589 01 62 00 FG 42/01/03/26/27/ 28/29/33/35/54/68/77/88/91/ Set B WS42.00-P-0017B
Removal and
installation tool
116 589 20 33 00 FG 01/03/05/07/Sat B WS05.00-N-0089B
Impact extractor
119 589 00 21 00 FG 03/Set C
Locating tool
119 589 00 21 00 FG 03/Set C
Locating tool
119 589 01 14 00 Sleeve FG 03/05/Set B WS03.00-P-0022B
126 589 02 15 00 FG 03/33/Set C
Assembly mandrel

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130 589 00 61 00 Sleeve FG 03/Set B
130 589 00 61 00 Sleeve FG 03/Set B
163 589 00 37 00 Pliers FG
01/03/05/07/09/14/15/18/20/32/33/35/42/46/47/54/82/91/
Set B
166 589 00 40 00 FG 03/Set B
Retaining lock
166 589 01 40 00 FG 03/Set B
Retaining lock
266 589 01 40 00 FG 03/Set B
Retaining lock
271 589 00 15 00 Drift FG 03/05/Set C
271 589 00 40 00 FG 03/Set B
Counterholder
271 589 00 43 00 FG 01/03/Set B WS01.00-P-0120B
Installation tool
271 589 01 15 00 Drift FG 03/Set C
271 589 02 63 00 FG 03/05/Set C
Assembly inserts
271 589 09 63 00 FG 03/05/Set B WS05.00-P-0228B
Assembly element
272 589 00 07 00 FG 03/Set B
Counterholder
272 589 00 14 00 FG 03/Set B
Insertion tool
312 589 00 15 00 Thrust Group 03/Set C
piece
312 589 00 50 00 FG 03/Set D
Bushing
312 589 07 33 00 Puller FG 03/Set C
312 589 13 15 00 Drift FG 01/Set B FG 03/Set C
321 589 00 63 00 Thrust FG 03/Set B
element
321 589 00 63 00 Thrust FG 03/Set B FG 20/23/Set C
piece
352 589 01 31 00 FG 03/Set C
Locating plate
352 589 01 43 00 Sleeve FG 03/Set C
352 589 02 31 00 FG 03/Kit C
Locating plate
352 589 07 15 00 Drift FG 03/Set C
punch
352 589 12 63 00 FG 03/Set C
Clamping device

cardiagn.com
355 589 00 33 00 Puller FG 03/Set B
355 589 00 33 03 Thrust FG 03/set B
piece
363 589 02 21 00 Dial FG 00/01/03/05/09/ 13/18/26/28/33/35/41/42/ Set B WS00.00-N-0033Z
gage holder
364 589 00 63 00 Face FG 03/Set B
wrench
366 589 00 21 05 FG 00/01/03/05/09/13/18/23/26/28/33/35/41/42/83/Set B WS00.00-N-0013-
Extension 01Z
366 589 00 63 00 FG 03/05/Set B
Turning fork
402 589 03 03 00 Box FG 03/23/Set B
wrench
402 589 03 03 02 FG03/23/Set B
Adapter
403 589 00 33 00 FG 03/Set C
Removal and insertion
device
403 589 01 33 00 Puller FG 03/Set C
403 589 02 63 00 Drift FG 03/05/Set C
403 589 03 15 00 Drift FG 03/Set C
403 589 03 15 03 FG03/Set C
Adapter
403 589 04 15 00 Drift FG 03/01/Set C
403 589 05 15 00 Drift FG 03/Set C
403 589 06 15 00 Drift FG 03/Set C
407 589 00 63 00 FG 01/03/07/13/18/ 27/46/47/Set B
Turning device
407 589 01 63 00 FG 03/Set B
Turning device
415 589 01 62 00
Engine mount
422 589 02 09 00 FG 01/03/Set C
Socket
437 589 00 03 00 FG 03/Kit A
Special wrench, WAF
46 mm
437 589 00 15 00 FG 03/Kit C
Flywheel guide bolt
437 589 03 43 00 FG 03/Kit C
Connecting rod bushing
removal tool
437 589 07 43 00 FG 03/Kit C
Connecting rod bushing

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installation tool
437 589 08 43 00 Core FG 03/Kit C
hole cover drift punch
442 589 00 23 00 Gauge FG 03/Set C
442 589 00 33 00 Puller FG 03/Set C
442 589 07 63 00 V- FG 03/Set C
type support
447 589 00 15 00 Drift FG 03/01/Set C
457 589 00 43 00 FG 01/03/Set B
Removal and
installation tool
457 589 01 14 00 FG 03/Set C
Assembly sleeve
457 589 01 43 00
Installer
470 589 00 31 00 FG 03/05/Set C
Measuring bridge
470 589 00 91 00 FG 01/03/05/Set B
Adapter
470 589 00 91 04 Seal FG 03/01/05/Set B
set
470 589 01 21 00 FG 03/05/Set C
Adjustment tool
470 589 01 23 00 Fixing FG 03/05/Set B
device
470 589 02 33 00 Puller FG 03/Set C
470 589 02 43 00 FG 03/Set B
Assembly tool
470 589 02 59 00 FG 03/Set C
Assembly tool
470 589 04 09 00 FG 03/Set C
Socket
470 589 05 33 00 FG 01/03/Set C
Removal and
installation tool
470 589 05 61 00 Valve FG 03/05/Set C
tool case
541 589 00 34 00 FG 03/Set B
Spacer washer
541 589 00 40 00 Dial FG 01/03/05/Set C
indicator holder
541 589 01 21 00 FG 03/13/Set C
Measuring bridge
541 589 01 34 00

cardiagn.com
Spacer ring
541 589 02 14 00 FG 03/Set C
Assembly sleeve
541 589 02 33 00 FG 03/Set B
Removal and insertion
device
541 589 09 63 00 FG 03/Set C
Removal and
installation tool
601 589 02 40 00 FG 03/Set B
Retaining lock
601 589 03 14 00 Sleeve FG 03/Set B
601 589 03 43 00 FG 03/Set B
Installation tool
601 589 07 21 00 FG 03/Set C
Measuring device
601 589 07 21 00 FG 03/Set C
Measuring device
602 589 00 33 00 FG 01/03/07/18/Set B WS01.00-P-0039B
Impact extractor
602 589 00 33 02 FG 01/03/07/18 / Set B WS01.00-P-0039-01B
Threaded bolt
602 589 00 40 00 FG 03/Set B
Retaining lock
602 589 00 40 00 FG 01/03/05/27 / Set B
Retaining lock
602 589 00 98 00 Case FG 03/05/18/Set C WS05.00-P-0158C
602 589 04 63 00 Thrust FG 03/05/Set C WS05.00-P-0160C
spindle
602 589 04 63 01 FG 03/05/Set C WS05.00-P-0160-
Pressure pins 01C
603 589 01 21 00 FG 03/Set C
Locating tool
606 589 00 14 00 Sleeve FG 03/Set B
606 589 03 15 00 FG 03/Set C
Installation tool
606 589 03 15 01 Drift FG03/Set C
607 589 00 15 00 Drift
607 589 00 43 00
Adapter
607 589 01 40 00
Retaining lock
607 589 01 43 00 Puller
607 589 02 43 00 Puller

cardiagn.com
607 589 03 43 00
Insertion tool
607 589 04 43 00
Insertion tool
607 589 05 43 00
Insertion tool
611 589 00 14 00 FG 03/Set B WS03.00-P-0042B
Insertion tool
611 589 00 31 00 Base FG 03/Set B
611 589 00 40 00 FG 01/03/20/46/ Set B WS20.00-N-3032B
Counterholder
611 589 01 14 00 FG 03/01/Set B
Assembly sleeve
611 589 01 40 00 FG 03/05/Set B
Retainer device
613 589 00 33 00 Puller FG 03/Set B WS03.00-P-0044B
615 589 01 33 00 Puller FG 03/Set C
615 589 01 33 00 Puller FG 03/Set C
615 589 01 33 04 FG 03/Set C
Gripper
617 589 00 14 00 Sleeve FG 03/Set B
617 589 00 16 00 FG 03/Set B
Square drive
617 589 00 16 00 FG 03/Set B
Square drive
617 589 00 63 00 FG 03/Set C
Mounting fixture
617 589 02 63 00 FG 03/Set C
Mounting fixture
629 589 01 63 00 FG 01/03/05/27/ Set B WS01.00-P-0137B
Engine turning device
629 589 02 63 00 FG 01/03/05/27/ Set B WS01.00-P-0142B
Engine turning device
631 589 03 31 00 FG 03/Set B
Arresting device
639 589 00 40 00 FG 03/Set B
Retaining lock
639 589 01 63 00 Strut FG 01/03/22/31/32/33/ 46/60/Assembly B
639 589 03 62 00 FG 01/03/31/33/ 46/Set C
Adaptation
639 589 07 63 00 FG 01/03/27/Set B
Turning device
642 589 00 14 00 FG 01/03/Set B WS03.00-P-0094B
Centering sleeve

cardiagn.com
646 589 00 21 00 FG 03/Set C
Adjustment tool
651 589 00 40 00
Counterholder
651 589 00 43 00 FG 03/Set C
Extraction and insertion
tool
651 589 00 61 00 FG 01/03/Set B
Insertion tool
651 589 01 40 00 Tie- FG 03/05/Set C
down set
651 589 01 61 00 FG 03/Set B
Insertion tool
651 589 02 40 00 FG 01/03/05/Set B
Retaining lock
651 589 02 63 00 FG 03/05/18/Set C
Assembly tool
651 589 07 40 00 FG 03/Set B
Counterholder
651 589 08 40 00 FG 01, 03, 05, 27/Set B
Counterholder
655 589 00 63 00 FG 01/03/20/set A
Adapter
667 589 01 21 00 FG 03/Set C
Locating tool
900 589 00 15 00 Drift FG 03/Set C
901 589 02 63 00 FG 03/Set B
Arresting device
904 589 00 10 00 FG 03/Set C
Screwdriver bit
904 589 00 33 00 Puller FG 03/Set B
904 589 01 10 00 FG 03/Set B
Screwdriver bit
904 589 02 15 00 Drift FG 03/18/Set B
904 589 02 63 00 FG 03/05/Set C
Alignment punch
904 589 03 15 00 Drift FG 03/Set C
904 589 04 15 00 FG 03/18/Set B
Assembly tool
904 589 04 63 00 FG 01/03/05/07/13/ 15/18/23/Set B
Turning device
904 589 04 63 01 Plate FG 01/03/05/07/13/15/18/23/Set B
904 589 05 15 00 FG 03/Set B
Mounting ring

cardiagn.com
906 589 03 61 00 Strut FG 01/03/15/ 22/31/32/33/46 /Set B WS01.00-N-3110B
936 589 00 14 00 FG 03/Set B
Spacer washer
936 589 00 91 00
Adapter
936 589 01 14 00
Spacer ring
936 589 01 15 00 Drift
936 589 02 15 00 Guide
pin