Electrical System

General Information

Central Fuse/Relay Board "

Central Warning System

Wiring Diagrams ;

The aluminium crankcase is split horizontally with a separate bolt-an cast aluminium oil sump.

The 95 mm dia. cylinder bores are surrounded by coolant.

The material used for the case upper section is an aluminium alloy with a high silicone content which makes liners made of gray cast iron or steel unnecessary. The cylinder bores are finished 50 that the pistons and rings only rub against the silicone particles.

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The crankcase lower section — made of silunrin — is bolted to the upper section with M 10/M 12 studs and M 8 bolts. Loctite 573 is used as a sealant for the mating surface.

The lower portion of the oil pan is divided into four sections and covered with a screen.

The oil drain plug, located on the lefthancd of the oil sump, has been changed to use a 15 mm wrench. The oil filler tube is now bent and mourned with two 6x10 mm bolts and sealed with an 0*r ng. The oil pan has a steeper angle on the top side to the right of the oil level sendinc unit.

Crankshaft

The crankshaft runs on 5 main bearings and has 6 counterweights.

Main bearing # 3 is the thrust bearing. The mam bearing journals have a diameter of 70 mm; 52 mm for the conrod journals.

The toothed belt sprocket and vibration damper are mounted on the front end of the crankshaft with an M 18 x 1.5 bolt and a spring washer, and located with a woodruff key. Degree marks are stamped along the circumference of the vibration damper

The flywheel for the twin-disc clutch is mounted with 9 Allen head bolts. A grooved ball bearing ¡s pressed into the crankshaft as a guide bearing for the drive shaft.

Connecting Rods

The connecting roas are made of sinter-forged steel. Two connecting roas are mounted on sach con red journal icyi. 1/5; ?/6 3/7; 4/8).

Make sura that conrcdsare instailec correctly when assembling

The connecting rod ends are offset. Make sure that the narrow side With the smail chamfer faces the neighboring connecting rod, while the wide side the large chamfer faces the crankshaft web.

Thi? conrod bolts have locating spi nes and mu.;! be li'jhuired to a torque of 5 8 Mkprn ;-i2 ff/lbst Luo'ioate threads and thrust sup face ,-ilth oil.

Pistons

The aluminium pistons (compression ratio 8.5 : 1) have a coated friction surface.

Mahle pistons — chrome plated KS pistons — iron coated

Cut-outs for the exhaust and intake valves are cast into the piston crown at an angle of 20", The piston pin bore is offset from center by 1.5 mm.

Piston rings:

Groove 1 — Taper faced ring Groove 2 - Taper faced oil scraper ring Groove 3 - 3-piece steel band ring

Piston Assembly

The piston must be installed with the valve pockets facing toward the exhaust manifold, important! Make .sure that the connecting rods are correctly installed to the pistons.

Cylinder bores and piston diameters come in 3 tolerance croups.

Tolerance Group Cylinder Bore Piston Dia. ± 0.007

0 95.000 94.964

1 95.010 94.974

2 95.020 94.984

Tolerance groups are stamped in the piston crown or cylinder block.

Cylinder Heads

The aluminium cylinder heads have 2 dowel pins each for location and 10 studs for mounting on the crankcase. The in line valves are operated by a single overhead camshaft per cylinder head via bucket type hydraulic valve lifters.

Intake port size:

38 mm dia. at intake manifold flange 37 mm dia. at insert

Exhaust port size: -

32.5 mm dia. at insert 34 mm dia. at exhaust flange

Cylinder Head Gaskets

Left and right cylinder head gaskets are different. When installing make sure thai "TOP/OBEN" faces up and the arrow faces in driving direction.

Cylinder head tightening specifications:

The cylinder heads must be tightened in 3 steps.

Cylinder head tightening specifications:

The cylinder heads must be tightened in 3 steps.

A) 1st step to 2.0 Mkp (14 ft/lbs} 2nd steD to 5.0 Mkp (36 ft/lbs) 3rd step to 3.5 Mkp (61 ft/lbs)

B) Leave cylinder head under pressure of 3rd step tightness for at least 30 minutes.

C) After 30 minutes, loosen nuts by 1/4 turn and tighten to final torque of 3.5 Mkp (61 ft/lbs) Cylinder heads do not have to be retightened later

Camshaft Drive

A toothed belt drives both camshafts (4), the distributor (6), the water pump (5) and the oil pump (7),

The toothed belt is tightened with a temperature sensitive mechanical tensioner (2) and guided by a roller (3).

1 — Crankshaft sprocket

3 - Roller Guide

4 - Camshafts

6 — Distributor

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