Cylinder Block - Replace Block Instead of Entire Engine
SECTION2
GROUP
21
NO.
817
DATE
June -96
Replacing cylinder block instead of complete engine
800
REFERENCE:
TP 2102201, SECTION 2 (21), RECONDITIONING, ENGINES B5202, B5204, B5234, B5252, B5254; 850 1992-
Replacing cylinder block instead of complete engine
Instead of replacing the complete engine, use a materials kit that includes cylinder block, pistons, gudgeon pins and piston rings.
When replacing the cylinder block new main bearings must be installed according to the table in section J in Service Manual:
Section 2 (21) Reconditioning,
Engines B 5202, B5204, B5234, B5252, 85254,
850 1992-
TP 2102201.
Note!
The new cylinder block (including pistons, gudgeon pins and piston rings) or the engine, will be the latest variants. (If parts from the older cylinder block do not match parts on the new cylinder block, then other parts may need replacing).
Content, variant and chassis number range:
The table describes the operation and other material required.
Replacing right engine mounting
When replacing the cylinder block a new engine mounting must be installed in model 854 with engines B5254S including chassis nos. -24259. Refer to Service Bulletin 2-21-825; 3/96.
Order the following material:
1 engine pad 9135178-3
1 engine mounting 9135179-1
1 bolt 978875-3
2 bolt 978425-7
2 bolt 965185-2
Replacing flame trap, naturally aspirated engine
When replacing the cylinder block a new flame trap must be installed in model 854 with naturally aspirated engines including chassis nos. -30699. This is because connectors have changed.
Order the following material:
1 flame trap 2-valve engine 1271652-8
1 flame trap 4-valve engine 9146756-3
1 hose 6642719-4
2 hose clamp 976584-3
1 hose 6842720-2
2 hose clamp 977964-6
Replacing the flame trap, turbocharged engines
When replacing the cylinder block a new 1995 model flame trap (including connectors) must be installed on cars model year 1994 with turbocharged engines.
Order the following material:
1 flame trap 1271988-6
1 hose inlet cylinder block 1271653-6
2 hose clamp 976584-3
Replacing timing belt and timing cover
Cars with an engine number lower than 131034 require a new 23 mm (29/32") timing belt (including covers).
Order the following material:
1 Upper timing cover for 4 valve engine 9146937-9
1 Lower timing cover for 4 valve engine 9135040-5
1 Timing belt for 4 valve engine 271834-4
1 Upper timing cover for 2 valve engine 6842991-9
1 Lower timing cover for 2 valve engine 9135043-9
1 Timing belt for 2 valve engine 271835-1
1 Idler pulley 9146376-0
1 Tension pulley with bolt 9135036-3
1 Vibration damper 9146693-8
1 Water pump kit 271855-9
Replacing drive shaft bearing seat
Cars with an engine number lower than 240985 require a new drive shaft bearing seat because of a change in the design of the cylinder block.
Order the following material for the new cylinder block:
1 bearing seat 9143465-4
2 bolt M10x35 946752-3
1 bolt M8x35 946470-2
Replacing main bearings
When replacing the cylinder block new main bearings must be installed according to the table and operations in Service Manual:
Section 2 (21) Reconditioning,
Engines B 5202, B5204, B5234, B5252, B5254,
850 1992-
TP 2102201
Use following section in the Service Manual:
Table see section J
Operation see section J
WARRANTY STATEMENT: Claims may be submiffed under the New Car Limited Warranty when a manufacturing defect is present using claim type: 01
Operation No. Labor description Time allowance
21238-2 Replacing cylinder block 21.2 hrs
21260-4 Replacing cylinder block with engine removed 15.2 hrs