Cylinder block
Identification marking
Mark (at "a")
- Engraving of the crankshaft bearings diameter category
- Bearing orientation (clutch to timing)
Mark (at "b")
- Machining reference
- Year of manufacture
Engine flywheel immobilisation hole (at "c")
Mark (at "d")
- Constructor's reference
- Legislation type
- Component marque
- Serial number
The cylinders are marked from 1 to 4 (cylinder no 1; flywheel side)
Data
Cylinder block
- Material: aluminium alloy
- Cast iron liners inserted during casting (foundry)
- Cylinder bore, diameter: 75 mm
Crankshaft main bearing cap casing
- Material: aluminium alloy
- Cast iron bearing caps inserted during casting
- Fixing: 26 bolts (10 bolts: M9 x 125, 16 bolts: M6 x 100) 10 solid pins
Aluminium alloy cylinder block with cast iron liners inserted at the foundry
Aluminium alloy bearing cap housing with cast iron bearing caps inserted during the casting process
The cylinder block has removable piston head spray jets
The cylinder block has 5 bearings
"e": top of cylinder coolant hole; diameter: 2,5 mm
The cylinder block is non-repairable
Cylinder block height and flatness
"f" cylinder block flatness checking zone (cylinder head sealing face)
"g" "reconditioning" marking zone
| DV6 engines all types | nominal dimension | repair size |
|---|---|---|
| diameter "A" | 75 mm (+0,018; 0 mm) | 75,4 mm (+0,018; 0 mm) |
| height "B" | 221,9 mm ± 0,05 mm | 221,66 mm ± 0,05 mm |
| overall flatness (at "f") | 0,042 mm | - |
NoteChecking the flatness is done with the aid of a checking ruler and a set of shims (see figure below)
Crankshaft
Identification
| reference | repair reference |
|---|---|
| "M" | 4 crankshaft big end journals |
| "T" | 5 crankshaft main bearing journals |
| "FB | 2 contact faces of the stop bearing |
| "JE" | seal surface (clutch side) |
| "JD" | seal surface (timing side) |
"h" classes of crankshaft main bearing journals (marking by ink jet)
"j" machining marking (marking by electric pencil)
Data
| diameter "C" | DV6 engine |
|---|---|
| nominal dimension | 49,981 mm (0; 0,19 mm) |
| repair size | 49,681 mm (0; 0,19 mm) |
| diameter "D" | DV6 engine |
|---|---|
| nominal dimension | 40 mm (0; -0,16 mm) |
| repair size | 39,8 mm (0; -0,16 mm) |
NoteThe regrinding of diameter "B", necessitates the fitting of a new sealing ring
| diameter "E" | DV6 engine |
|---|---|
| nominal dimension | 85 mm (0; -0,22 mm) |
| repair size | 84,8 mm (0; -0,22 mm) |
NoteThe regrinding of diameter "c", necessitates the fitting of a new sealing ring
| width "F" | DV6 engine |
|---|---|
| nominal dimension | 23,39 mm (+0,052; 0 mm) |
| repair size | without |
| diameter "G" | DV6 engine |
|---|---|
| nominal dimension | 47 mm (+0.009; -0,025 mm) |
| repair size | 46,7 mm (+0.009; -0,025 mm) |
Crankshaft end float
The endfloat is adjusted by 2 thrust washers on bearing n°2
| thickness | DV6 engine |
|---|---|
| nominal dimension | 2,4 ± 0,05 mm |
| repair size | without |
Crankshaft half bearing shells
"h" marking of the crankshaft bearing classes on the crankshaft
"j" marking of the classes of crankshaft bearings on a reground crankshaft
"k" marking of the classes of crankshaft bearings on the crankshaft and cylinder block
The operating clearances of the crankshaft bearings are obtained from the creation of 3 classes of smooth lower bearing shell (crankshaft bearing cap casing side)
Upper bearing shells (grooved)
"H" = thickness of the crankshaft bearing upper half-shells
"J" = thickness of the crankshaft bearing lower half-shells
NoteThere is only one class of grooved upper crankshaft bearing shell (cylinder block side)
The grooved upper half-shells are marked at "l" by a product number
The crankshaft bearing lower half-shells are marked at "m" by a colour mark
| - | nominal dimension | repair size |
|---|---|---|
| distance "H" | 1,834 ± 0,003 mm | 1,984 ± 0,003 mm |
| reference "l" | 371606 | 844592 |
| colour | orange | without |
Lower bearing shells (smooth)
NoteThe positioning of the lower bearing shells necessitates use of a specific tool, Part No. [0194-Q]
The selection of the appropriate half-shell must be carried out using a pairing table with the marks "j" and "k"
The first character corresponds to bearing N°5, the second to bearing N°4, and so on
NoteThe crankshaft main bearings are marked from 1 to 5 (bearing n°1; flywheel side)
Matching table
| - | nominal dimension | repair size |
|---|---|---|
| distance "J" | 1,822 ± 0,003 mm | 1,972 ± 0,003 mm |
| colour (at "m") | white or blue | blue |
| - | nominal dimension | repair size |
|---|---|---|
| distance "J" | 1,834 ± 0,003 mm | 1,984 ± 0,003 mm |
| colour (at "m") | yellow or black | black |
| - | nominal dimension | repair size |
|---|---|---|
| distance "J" | 1,846 ± 0,003 mm | 1,996 ± 0,003 mm |
| colour (at "m") | brown or green | Green |
Thrust washers
"n" positioning pin
"N" thickness of the thrust bearings
The grooves are oriented towards the crankshaft
The crankshaft endfloat is adjusted using thrust washers on bearing Nº2
There should be a 0,07 to 0,32 mm endfloat
NoteThe crankshaft main bearings are marked from 1 to 5 (bearing N°1, flywheel side)
| designation | nominal dimension |
|---|---|
| thickness of the thrust washers "N" | 2,40 mm (+ 0,05; 0) |
Conrods - connecting rod half shells
Conrods
| - | DV6 engines |
|---|---|
| "P" length | 136,8 ± 0,025 mm |
| diameter "Q" | 26 (+ 0,020; 0,007) mm |
| diameter "R" | 50,655 (+0,019; 0) mm |
Connecting rod half shells
REFERENCE (at "p"): area of marking
| DV6 engine | |
|---|---|
| nominal dimension "T" | 1,815 ± 0,05 mm |
| repair size "T" | 1,965 ± 0,05 mm |
| width "S" | 17 (0; - 0,25) mm |
Pistons; piston rings; the piston shaft
Identification
Mark (at "q"): piston orientation
(1) aluminium alloy piston
(2) trapezoidal upper ring
(3) tapered lower ring
(4) trapezoidal scraper ring with spring
Piston
| dimensions | DV6 engine |
|---|---|
| diameter "U": nominal dimension | 74,945 ± 0,075 mm |
| diameter "U": repair size | 75,345 ± 0,075 mm |
| height "V" | 41,7 ± 0,025 mm |
| piston gudgeon pin offset | 0,4 ± 0,075 mm |
Piston rings
| DV6 engine | compression ring | sealing ring | scraper ring |
|---|---|---|---|
| make / colour: nominal dimension | red | green - light blue | yellow - Green |
| make / colour: repair size | orange | pink | mauve |
| ring gap | 0,15 to 0,25 mm | 0,3 to 0,5 mm | 0,35 to 0,55 mm |
| thickness | 2,83 mm | 1,95 mm | 2,50 mm |
The piston shaft
| dimensions | DV6 engine |
|---|---|
| "Y" length | 61 (0; -0,3) mm |
| diameter "X" | 26 (0; -0,005) mm |
NoteThe gudgeons pins are fitted free in the little ends and in the pistons. the gudgeon pins are immobilised in translatory motion by two stop rings
Piston head spray jets
The piston head spray jets (5) are removable and replaceable