Connecting rod half shells
NoteThe operating clearance of the rods, between 0.030 and 0.054, is obtained by the creation of categories of conrod half shells (big end caps side)
Top half shells
There is only one category for upper conrod shells fitted with a lubrication hole (little end side)
| engine code | EW7J4 | EW10J4 | EW10D |
|---|---|---|---|
| (B) nominal dimension | 1.825 ± 0.003 mm | 1.825 ± 0.003 mm | 1.825 ± 0.003 mm |
| (B) repair size | 1.975 ± 0.003 mm | 1.975 ± 0.003 mm | 1.975 ± 0.003 mm |
| (G) colour identification: nominal dimension | orange | yellow | orange |
| (G) colour identification: repair size | orange + orange | yellow + yellow | orange + orange |
Bottom half shells
The categories of conrod shells are also used on the conrod (lug side) at (M) and on the crankshaft (engine flywheel side) at (E)
The categories of bearing shells are determined by the measurement of each main bearing
(J) bar code used in plant
(K) characters read on the crankshaft (in service)
The first character corresponds to bearing no 1, the second to bearing no 2 and so on
NoteThe big end caps are marked from 1 to 4 on the engine flywheel side
Example
- Characters read on the crankshaft 37BF
- Raised character on conrod no. 1F
- Raised character on conrod no. 2C
For bearing no. 1 (3 F): the lower half shell to be fitted is category (B)
For bearing no. 2 (7 C): the lower half shell to be fitted is category (A)
Proceed in the same way for the 2 other assemblies
| engine code | EW7J4 | EW10J4 | EW10D |
|---|---|---|---|
| (A) nominal dimension + colour identification (F) | 1.815 ± 0.003 mm - blue | 1.815 ± 0.003 mm - Green | 1.815 ± 0.003 mm - Green |
| (A) repair size + colour identification (F) | 1.965 ± 0.003 mm - blue + blue | 1.965 ± 0.003 mm - Green + Green | 1.965 ± 0.003 mm - Green + Green |
| (A) nominal dimension + colour identification (F) | 1.825 ± 0.003 mm - orange | 1.825 ± 0.003 mm - yellow | 1.825 ± 0.003 mm - yellow |
| (A) repair size + colour identification (F) | 1.975 ± 0.003 mm - orange + orange | 1.975 ± 0.003 mm - yellow + yellow | 1.975 ± 0.003 mm - yellow + yellow |
| (A) nominal dimension + colour identification (F) | 1.835 ± 0.003 mm - black | 1.835 ± 0.003 mm - white | 1.835 ± 0.003 mm - white |
| (A) repair size + colour identification (F) | 1.985 ± 0.003 mm - black + black | 1.985 ± 0.003 mm - white + white | 1.985 ± 0.003 mm - white + white |
NoteIf the measuring equipment is faulty, fit category (A) lower half-shells; this practice must only occur in exceptional cases, since the engine may prove to be noisy
Crankshaft half shells
To enable adjustment for the whole range of engines EW: the operating tolerance of the crankshaft bearings is obtained by the creation of 3 categories of uipper half shells (cylinder block side) and 8 categories of lower half-shells (crankshaft bearings caps housing side)
The classes of bearing shells are grouped according to engine type
| production serial number | EW7J4 | EW10J4 | EW10D |
|---|---|---|---|
| to 107 214 | 1 + 4 | ||
| from 107 215 to 174 878 | 1 + 4 | 2 + 4 | |
| from 174 879 | 1 + 5 | ||
Number of upper half-shells + number of lower half-shells
Top half shells
There are 3 categories of grooved upper crankshaft bearing half-shells
Choice of crankshaft upper main bearing shells
- 1 + 4 assembly: On all the upper bearings, fit the bearing shell with the nominal size 1.854 or repair size 2.004
- 2 + 4 assembly: On the upper bearings 1 and 5, fit the bearing shell with the nominal size 1.861 or repair size 2.011; On the upper bearings 2, 3 and 4, fit the bearing shell with the nominal size 1.854 or repair size 2.004
- 1 + 5 assembly: On all the upper bearings, fit the bearing shell with the nominal size 1.859 or repair size 2.009
Identification of crankshaft upper main bearing shells
| distance | distance C | distance C | distance C | engine type |
|---|---|---|---|---|
| nominal dimension | 1.854 ± 0.003 mm | 1.861 ± 0.003 mm | 1.859 ± 0.003 mm | EW7J4, EW10J4, EW10D engines |
| repair size | 2.004 ± 0.003 mm | 2.011 ± 0.003 mm | 2.009 ± 0.003 mm | |
| colour identification (H); nominal dimension | without | black | yellow | EW10J4, EW10D engines |
| colour identification (H); nominal dimension | yellow - violet | orange | yellow | EW7J4 engines |
Bottom half shells
The categories of crankshaft bearing shells are also used on the cylinder block at (A) and on the crankshaft at (B)
Bar code used in plant
(C) caractères Alphanumériques: utilisé en après-vente
The first character corresponds to bearing no 1, the second to bearing no 2 and so on
The crankshaft bearings are marked from 1 to 5, No. 1 at flywheel end
All engines since the series launch up to the manufacturing serial no. 174 878
The operating clearance of the crankshaft main bearings, between 0.022 and 0.045 mm, is obtained by the creation of 4 categories of lower smooth half shells (cap side)
Example
Characters read on the crankshaft A7H6D
Characters on the cylinder block EPTG6
For bearing no. 1 (AE): the lower half shell to be fitted is category (F)
For bearing no. 2 (7P): the lower half shell to be fitted is category (G)
Proceed in the same way for the 3 other assemblies
| engine code | EW7J4 | EW10J4 | EW10D |
|---|---|---|---|
| (D) nominal dimension + colour identification (I) | 1.841 mm - without | 1.841 mm - blue | 1.841 mm - blue |
| (D) repair size + colour identification (I) | 1.991 mm - without | 1.991 ± 0.003 mm - blue + blue | 1.991 ± 0.003 mm - blue + blue |
| (D) nominal dimension + colour identification (I) | 1.850 ± 0.003 mm - brown | 1.850 ± 0.003 mm - black | 1.850 ± 0.003 mm - black |
| (D) repair size + colour identification (I) | 2.00 ± 0.003 mm - brown + brown | 2.00 ± 0.003 mm - black + black | 2.00 ± 0.003 mm - black + black |
| (D) nominal dimension + colour identification (I) | 1.858 ± 0.003 mm - yellow | 1.858 ± 0.003 mm - Green | 1.858 ± 0.003 mm - Green |
| (D) repair size + colour identification (I) | 2.008 ± 0.003 mm - yellow + yellow | 2.008 ± 0.003 mm - Green + Green | 2.008 ± 0.003 mm - Green + Green |
| (D) nominal dimension + colour identification (I) | 1.867 ± 0.003 mm - orange | 1.867 ± 0.003 mm - red | 1.867 ± 0.003 mm - red |
| (D) repair size + colour identification (I) | 2.017 ± 0.003 mm - orange + orange | 2.017 ± 0.003 mm - red + red | 2.017 ± 0.003 mm - red + red |
WarningThere are 2 types of assembly of half-shells on the engines of this section 1 + 4 - 2 + 4; replace the new half-shells when assembling type 2 + 4
NoteIf the measuring equipment is faulty, fit category (D) lower half-shells; this practice must only occur in exceptional cases, since the engine may prove to be noisy
All engines from manufacturing number 174 879
The operating clearance of the crankshaft main bearings, between 0.019 and 0.049 mm, is obtained by the creation of 5 categories of lower smooth half shells (cap side)
| zone | H | I | J | K | L |
|---|---|---|---|---|---|
| nominal dimension (mm) | 1,846 ± 0,003 | 1,853 ± 0,003 | 1,858 ± 0,003 | 1,864 ± 0,003 | 1,870 ± 0,003 |
| colour identification | blue | black | Green | orange | brown |
Thrust washers
Crankshaft endfloat is adjusted by flanges on no. 2 main bearing shells
There should be an endfloat of 0.06 to 0.15 mm
Nominal dimension: E = 2.28 to 2.33 mm
NoteThere are no identification marks on the thrust washers