0403 - Repair instructions for crankcase, cylinder head and gasket Engine 102 (except 102.983/99), single-belt drive

01-403 Repair instructions for crankcase, cylinder heads and cylinder head gaskets

Crankcase

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The tapped hole for attaching the power steering pump carrier (compared to engines with multi-belt drive) have been converted from M8 to M10.

The M 381.5 tapped hole for mounting the coolant preheater on the left side is shorter. It is sealed with a screw plug (5) and an O-ring of engines 116/117 and 601.

P01-2082-13

The crankshaft bearings in the crankcase have been modified (size "B").

Multi-belt drive =24 mm

Single-belt drive =20 mm

P01-0188-13

At the same time, the crankshaft bearing covers are 8 mm lower.

Engines with multi-belt drive

H=48 mm

P01-0052-13

Engines with single-belt drive

H=40 mm

P01-0053-13

Fastening bolts of the crankshaft bearing covers converted to M1162 twelve-side stretch bolts with collar (B). Previously, M1270 hexagon bolts (A).

A M1270 hexagon bolts

B M1162 twelve-side stretch bolt

P03-2061-13

Bolt projections (A, B, C) on crankcase for fastening bolts of timing case cover lengthened.

P01-0189-13

Because of the lengthened bolt extensions, the power steering pump carrier has been provided with a semi-circular cutout at the second reinforcing rib (arrow). Production breakpoint 06/1986.

P01-0190-13

Cylinder head

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The same cylinder head is fitted to engines 102.922/924 as to engines 102.962/982/985.

Only one cylinder head version is likewise supplied as a replacement part.

This cylinder head must not be fitted to the previous engines 102.921/938/961.

A core plug, Part No. 000 443 025 003 should

be inserted with the sealant 002 989 94 71 and

the fitting mandrel 102 589 02 15 00 for engines

102.962/963/982/985.



If the core hole is not closed (arrow), coolant may get into the cylinders on engines 102.962/982/985.

P01-2077-13

An oil pipe (A) is inserted in the oil feed passage at the rear of the cylinder head to prevent the oil passages running empty when the engine is switched off.

P01-0087-13

Since 07/1987 the oil nozzle return lock (A) has a stop collar, which prevents it "migrating upward" in the cylinder head. At the same time, the recess in the cylinder head has been modified.

When performing repairs, install the oil nozzle return lock (18-415).

P01-0191-13

Standard implementation: 07/87

No oil passage is provided at the 4th bearing point for camshaft lubrication (arrow).

P01-2083-13

Cylinder head gasket

The cylinder head gasket in the chain box area was modified with implementation of the double roller chain (B, arrow).

In addition, sealing surfaces with modified coating and widened combustion chamber chamfered faces (c) as well as silicone strips (d) running all round the outer edge. Production breakpoint 01/1988.

P01-2389-13

To achieve greater clearance for the double roller chain, the front wall at the cylinder head was lengthened (arrows). In addition, the bolt extensions were flattened off at the radius (f).

A Single roller chain

B Double roller chain

P01-2393-13

Double roller chain, production breakpoint:01/88

Engines with KAT except engines 102.99: the squish edge (arrows) in the cylinder head is discontinued as of model year 1990.

Combustion chamber with squish edge

P01-2153-13

The hydrocarbons in the exhaust are reduced as a result of the "open" combustion chamber.

The enlarged combustion chamber volume was compensated by modified pistons.

These pistons must only be used on engines with open combustion chamber.

"Open" combustion chamber

P01-2152-13