Ligier Ambra 2001 User Manual
code 1.5302.727
SERVICE MANUAL
REGISTERING DOCUMENT MODIFICATIONS
This document is made up of 98 pages (-sides - excluding the
cover and title page). Pages are numbered in progressive order
from 051135.01 to 051 135.98.
Any modifications to this document must be registered by the
drafting body and approved by the head of the Quality
Management System, with completion of the table below .
Drafting body
A TLO
Document
Code
1-5302-727
Edition
2°
Issue date Review date
30/06/05 10/01/2007
Replaced
Pages
Added
Pages
Eliminated
pages
Copyright 2005 - Lombardini. Reproduction, even partial, of this document is subject to the manufacturer’s written authorisation. The manufacturer is committed to a policy of continuing improvement and reserves the right to modify the
document, with no obligation to notify, providing that omission to do so constitutes no safety risk. The text may be reproduced in part or in whole, providing that the author is cited. Text and graphics by: IDM Esperti in
Comunicazione Tecnica - Forlì
- 2 - Service Manual LW 502 automotive _ cod. 1.5302.727 - 2° ed_rev. 01
GENERAL INDEX
1 GENERAL REMARKS AND SAFETY
1.1 PURPOSE OF THE MANUAL.....................................5
1.2 USING THIS MANUAL................................................5
1.3 MANUFACTURER AND ENGINE IDENTIFICA TION ..5
1.4 GLOSSARY AND TERMINOLOGY.............................6
1.5 WARRANTY CLAUSES.............................................. 6
1.6 GENERAL SAFETY REGULATIONS.......................... 6
1.7 GENERAL SAFETY DURING OPERA TING PHASES 6
1.8 SAFETY AND ENVIRONMENTAL IMPACT ................7
1.9 PRECAUTIONS WHEN THE ENGINE IS INSTALLED
ON THE MACHINE .....................................................7
1.10 PRECAUTIONS WHEN THE ENGINE IS ON THE
ROTATING STAND ..................................................... 7
2 TECHNICAL INFORMATION
2.1 GENERAL DESCRIPTION OF THE ENGINE.............9
2.2 TECHNICAL SPECIFICATIONS................................ 10
2.3 CHARACTERISTIC CURVE DIAGRAMS ................. 12
2.4 ALTERNA T OR LOAD CURVE DIAGRAMS ..............13
2.5 LUBRICANTS ........................................................... 14
2.5.1 SAE Classification ..................................................... 14
2.5.2 API/MIL sequences ................................................... 14
2.5.3 ACEA S tandards ....................................................... 14
2.5.4 Recommended oil......................................................14
2.6 OPERATING PRINCIPLE FOR LUBRICA TION ........15
2.7 OPERATING PRINCIPLE FOR COOLING ............... 15
2.8 OPERATING PRINCIPLE FOR FUEL INJECTION ... 1 6
2.9 WIRING DIAGRAM...................................................17
2.10 SPECIAL TOOLS AND EQUIPMENT FOR
MAINTENANCE ........................................................19
2.1 1 TABLE OF TIGHTENING TORQUES........................19
2.12 TABLE OF SEALANTS ............................................. 21
2.13 ROUTINE ENGINE MAINTENANCE ........................ 21
3 MALFUNCTIONS
3.1 LOOKING FOR MALFUNCTIONS ........................... 23
4 STORING THE ENGINE
4.1 HANDLING AND LIFTING ......................................... 25
4.2 STORING THE ENGINE (UNINST ALLED) ...............25
4.3 STORING THE ENGINE (INST ALLED) .................... 25
4.4 PROTECTIVE TREATMENT..................................... 26
4.5 PREPARING THE ENGINE FOR OPERA TION
(UNINSTALLED) ....................................................... 26
4.7 PREPARING THE ENGINE FOR OPERA TION
(INSTALLED) ............................................................27
5 REMOVING THE ASSEMBLIES
5.1 RECOMMENDATIONS FOR REMOVING THE
ASSEMBLIES ........................................................... 29
5.2 REMOVING THE EXHAUST AND INT AKE
MANIFOLDS .............................................................29
5.2.1 Disassembling the intake manifold ............................ 29
5.2.2 Disassembling the exhaust manifold ......................... 30
5.3 REMOVING THE COOLING FAN BEL T DRIVE........30
5.3.1 Disassembling the cooling fan belt
(with external alternator) ............................................ 31
5.3.2 Disassembling the cooling fan belt
(with internal alternator).............................................31
5.4 REMOVING THE TIMING BELT DRIVE.................... 31
5.4.1 Disassembling the timing belt casing ........................ 31
5.4.2 Disassembling the timing belt.................................... 3 2
5.4.3 Disassembling the pulleys
(camshaft and crankshaft) ........................................ 32
5.5 REMOVING THE CYLINDER HEAD......................... 33
5.5.1 Disassembling the rocker arm cover ......................... 33
5.5.2 Disassembling the rocker arms ................................. 33
5.5.3 Disassembling the fuel pump ....................................33
5.5.4 Disassembling the injection-pumps........................... 34
5.5.5 Disassembling the precombustion chamber..............34
5.5.6 Disassembling the speed governor
and flow limiter .......................................................... 35
5.5.7 Disassembling the camshaft ..................................... 36
5.5.8 Disassembling the cylinder head ............................... 36
5.6 REMOVING THE CRANK GEAR
AND CRANKCASE ................................................... 36
5.6.1 Disassembling the flywheel ....................................... 36
5.6.2 Disassembling the oil pump....................................... 37
5.6.3 Disassembling the crankcase and crankshaft ........... 38
5.6.4 Disassembling the connecting rod and piston ...........39
5.7 DISASSEMBLING THE VALVES .............................. 39
5.8 DISASSEMBLING THE PISTON............................... 40
6 OVERHAULS AND TUNING
6.1 RECOMMENDATIONS FOR OVERHAULS
AND TUNING............................................................ 41
6.1.1 Shaft seals ................................................................ 41
6.1.2 O-rings ......................................................................41
6.1.3 Bearings ....................................................................41
6.2 OVERHAULING THE CRANK GEARS AND
CRANKCASE............................................................ 41
6.2.1 Overhauling cylinders and pistons............................. 4 1
6.2.2 Dimensional check and overhaul of cylinders ............ 42
6.2.3 Dimensional check and overhaul of pistons............... 42
6.2.4 Dimensional check of sealing rings ........................... 43
6.2.5 Dimensional check and overhaul of crankshaft ......... 44
6.2.6 Dimensional check and overhaul of
connecting rods......................................................... 45
6.2.7 Checking parallelism of the connecting rod axes.......45
6.2.8 Checking and overhauling the fuel pump................... 46
6.2.9 Overhauling the decanting device.............................. 47
6.3 OVERHAUL OF CYLINDER HEAD AND RELA TED
COMPONENTS ........................................................ 47
6.3.1 Checking and overhauling the cylinder head ............. 47
6.3.2 Checking and overhauling the rocker arm pin ........... 48
6.3.3 Checking and replacing the camshaft ....................... 49
6.3.4 Checking and replacing the fuel pump drive rod........ 50
6.3.5 Checking and overhauling the valves ........................ 51
6.3.6 Adjusting valve-rocker arm clearance ....................... 52
6.3.7 Checking clearance volume....................................... 52
6.3.8 Calibrating the injector............................................... 53
6.3.9 Checking and overhauling the speed governor.......... 53
6.4 CHECKING TIMING BELT RA TING .......................... 54
6.4.1 Valve adjustment s .....................................................54
6.5 DIAGRAM OF TIMING BEL T RA TES........................ 55
6.6 ADJUSTING STA TIC INJECTION TIMING ...............55
6.7 BALANCING INJECTION-PUMP DELIVERY............ 58
- 3 -Service Manual LDW 502 automotive _ cod. 1.5302.727 - 2° ed_rev. 01
GENERAL INDEX
6.8 ADJUSTING MINIMUM AND MAXIMUM
IDLE SPEED RPMS.................................................. 60
6.9 ADJUSTING INJECTION DELIVERY ....................... 60
6.9.1 Adjusting injection delivery (without dyno brake).......60
6.9.2 Adjusting injection delivery (with dyno brake)............61
6.10 CHECKING OIL PRESSURE ....................................61
7 INSTALLATION OF ASSEMBLIES
7.1 RECOMMENDATIONS FOR INST ALLING THE
ASSEMBLIES ........................................................... 63
7.2 PRE-ASSEMBLY OF
SEALING RINGS – PISTONS.................................. 63
7.3 PRE-ASSEMBLY OF
CONNECTING RODS – PISTONS ........................... 64
7.4 INSTALLING V ALVES ...............................................64
7.4.1 Assembling the valves...............................................64
7.5 INSTALLA TION OF CRANK GEAR
AND CRANKCASE …............................................... 65
7.5.1 Installing piston/connecting rod - engine block .......... 6 5
7.5.2 Assembling the crankshaft ........................................ 66
7.5.3 Assembling the crankcase ........................................ 66
7.5.4. Measuring crankshaft axial clearance........................ 67
7.5.5 Assembling the crankshaft flange (flywheel side)......67
7.5.6 Installing the oil pump................................................68
7.5.7 Assembling the flywheel ............................................ 69
7.6 INSTALLA TION OF CYLINDER HEAD AND
COMPONENTS….....................................................70
7.6.1 Assembling the precombustion chamber .................. 70
7.6.2 Assembling the cylinder head....................................71
7.6.3 Assembling the camshaft .......................................... 71
7.6.4 Assembling the speed governor and flow limiter........ 72
7.6.5 Assembling injection – pumps................................... 73
7.6.6 Assembling the mechanical fuel pump ......................74
7.6.7 Assembling the rocker arms...................................... 75
7.6.8 Assembling the rocker arm cover..............................75
7.7 INSTALLING THE TIMING BEL T DRIVE...................76
7.7.1 Assembling the timing belt pulley ..............................76
7.7.2 Assembling the timing belt ........................................ 76
7.7.3 Assembling the belt drive cover................................. 77
7.8 INSTALLA TION OF THE COOLING F AN
BEL T DRIVE ............................................................. 78
7.8.1 Assembling the fan belt drive pulleys ........................78
7.8.2 Assembling the fan belt drive .................................... 79
7.8.3 Assembling the cooling fan........................................ 80
7.9 INSTALLING INT AKE AND EXHAUST MANIFOLDS 80
7.9.1 Assembling the exhaust manifold ..............................80
7.9.2 Assembling the intake manifold ................................. 80
8 REPLACING PARTS
8.1 RECOMMENDATIONS FOR REPLACING P AR TS .. 83
8.2 REPLACING THE ALTERNA TOR – FAN BEL T......... 83
8.3 REPLACING THE TIMING BELT ..............................85
8.4 REPLACING THE OIL FILTER.................................. 85
8.5 REPLACING THE AIR FILTER.................................. 86
8.6 REPLACING THE ALTERNA TO R .............................87
8.7 REPLACING THE STARTER MOTOR...................... 87
8.8 REPLACING THE FLYWHEEL RING GEAR ............ 88
8.9 REPLACING THE COOLANT THERMOSTA T .......... 8 8
8.10 REPLACING THE COOLANT PUMP........................ 89
8.1 1 REPLACING THE THERMOSTA TIC VAL VE …. .......89
8.12 REPLACING THE NEGATIVE-PRESSURE VENT
VALVE....................................................................... 90
8.13 REPLACING THE PRE-HEATING GLOW PLUGS... 90
8.14 REPLACING INJECTOR PUMP PARTS................... 91
8.14.1 Pumping element replacement .................................. 91
8.14.2 Replacing the nozzle-injector..................................... 93
8.15 REPLACING THE COOLING FAN SUPPORT.......... 93
INDEX ................................................................ 95
- 4 - Service Manual LW 502 automotive _ cod. 1.5302.727 - 2° ed_rev. 01
1.1 PURPOSE OF THE MANUAL
GENERAL REMARKS AND SAFETY
1
- This manual was written by the manufacturer to provide
technical and operating information to authorised
LOMBARDINI after-sales service centres to carry out
assembly, disassembly, overhauling, replacement and
tuning operations.
- This information is provided by the manufacturer in its
own language (Italian) and may be translated into other
languages to satisfy legislative and/or commercial
requirements.
- As well as employing good operating techniques and
observing the right timing for operations, operators must
read the information very carefully and comply with it
scrupulously.
- Time spent reading this information will help to prevent
health and safety risks and financial damage.
- Written information is accompanied by illustrations in
order to facilitate your understanding of every step in
the operating phases.
- Important remarks and features of the text are
highlighted using symbols, which are explained below.
Danger – Attention
This indicates situations of grave danger, which, if
ignored, may seriously threaten the health, and safety
of individuals.
Caution – Warning
This indicates that it is necessary to take proper
precautions to prevent any risk to the health and
safety of individuals and avoid financial damage.
Important
This indicates particularly important technical
information that should not be ignored.
1.2 USING THIS MANUAL
- This manual is divided into several chapters.
- The first chapter gives general information and details
about safety (purpose of the manual, safety, etc.).
- The second, third and fourth chapters provide general
technical information (technical specifications,
diagrams, tightening torques, malfunctions, etc.).
- The fifth, sixth, seventh and eighth chapters describe
the most important operating procedures (removal,
overhaul and tuning, installation, replacements, etc.).
1.3 MANUFACTURER AND ENGINE IDENTIFICA TION
The identification plate shown in the figure
can be found directly on the engine. It
contains the model, engine identity and all
information needed to operate safely.
A) Manufacturer’s identity
B) Engine type
C) Engine serial number
D) Maximum speed
E) Customer code
E) Approval data
- This final section, which is reserved specifically for
LOMBARDINI after-sales service centres, has been
prepared with technical and practical considerations in
mind.
- However, the actual sequence of operations that
LOMBARDINI service centres must use may in some
cases be different from the ones described in this
manual. For this reason, the reader should refer to the
index to find his/her topic of interest quickly.
- 5 -Service Manual LDW 502 automotive _ cod. 1.5302.727 - 2° ed_rev. 01
1.4 GLOSSARY AND TERMINOLOGY
GENERAL REMARKS AND SAFETY
1
For clarity, here are the definitions of a number of terms
used recurrently in the manual.
1.5 WARRANTY CLAUSES
LOMBARDINI issues a warranty certificate for each
engine giving details of all relevant general terms.
1.6 GENERAL SAFETY REGULA TIONS
- In designing and building its product, the manufacturer
has paid particular attention to those aspects posing
a risk to the health and safety of persons handling the
engine. In addition to legislative requirements, all “rules
for good technical construction” have been applied.
- The purpose of this information is to invite operators
to pay particular attention in order to prevent any form
of risk. Caution is always the best policy. Safety is
also the responsibility of all operators who handle the
1.7 GENERAL SAFETY DURING OPERA TING PHASES
- Piston number one: first piston “viewed from the
flywheel side of the engine”.
- Rotation direction: clockwise or anticlockwise “viewed
from the timing belt side of the engine”..
engine.
- All persons carrying out work on the engine at any
point in its life must possess precise technical
qualifications and skills, as well as experience
recognised and gained in the specific sector. Noncompliance with these requirements may cause
damage to the health and safety of individuals.
- Do not tamper with, sidestep, eliminate or bypass the
installed safety devices. Non-compliance with this
requirement may be hazardous to the health and
safety of individuals.
- The procedures contained in this manual have been
tested and selected by the manufacturer’s technical
experts, and hence are to be recognised as authorised
operating methods.
- A number of procedures must be carried out with the
aid of equipment and tools that simplify and improve
the timing of operations.
- Some of these tools are normal workshop equipment,
while others are specific instruments that have been
constructed by the engine manufacturer.
- All tools must be in good working condition so that
engine components are not damaged and that
operations are carried out properly and safely.
- It is important to wear the personal safety devices
prescribed by work safety laws and also by the
standards of this manual.
- Holes must be lined up methodically and with the aid
of suitable equipment. Do not use your fingers to carry
out this operation to avoid the risk of amputation.
- Some phases may require the assistance of more than
one operator. If so, it is important to inform and
exercise them regarding the type of activity they will
be performing in order to prevent risks to the health
and safety of all persons involved.
- Do not use flammable liquids (petrol, diesel, etc.) to
degrease or wash components. Use special products.
- Keep flames away from the engine to avoid the risk
of fire.
- Replace worn or damaged parts exclusively with
original LOMBARDINI spare parts. This will contribute
to ensuring better performance and longer product
life.
- 6 - Service Manual LW 502 automotive _ cod. 1.5302.727 - 2° ed_rev. 01
GENERAL REMARKS AND SAFETY
GENERAL REMARKS AND SAFETY
1
- Use the oils and greases recommended by the
manufacturer. Do not mix different brands or oils with
different characteristics.
- Use a torque wrench to tighten the main fixing points
of engine components. S tick to the tightening torques
indicated by the manufacturer.
1.8 SAFETY AND ENVIRONMENTAL IMP ACT
Every organisation has a duty to implement procedures
to identify, assess and monitor the influence of its own
activities (products, services, etc.) on the environment.
Procedures for identifying the extent of the impact on
the environment must consider the following factors:
- Liquid waste
- Waste management
- Soil contamination
- Atmospheric emissions
- Use of raw materials and natural resources
- Regulations and directives regarding environmental
impact
- Discontinue use of the engine if any irregularities
arise, particularly in the case of unusual vibrations.
- The engine has been designed and built to satisfy
all the operating conditions described by the
manufacturer.
- Do not tamper with any devices to alter the level
of performance guaranteed by the manufacturer.
In order to minimise the impact on the environment, the
manufacturer now provides a number of indications to
be followed by all persons handling the engine, for any
reason, during its expected lifetime.
- All packaging components must be disposed of in
accordance with the laws of the country in which
disposal is taking place.
- Keep exhaust pipes in efficient working order to limit
the noise level of the engine and reduce
environmental pollution.
- When discontinuing use of the engine, select all
components according to their chemical
characteristics and dispose of separately.
1.9 PRECAUTIONS WHEN THE ENGINE IS INSTALLED ON THE MACHINE
- All operations, except where expressly stated
otherwise, must be carried out when the engine is not
running and has cooled sufficiently to avoid the risk of
burns.
- Do not keep the engine running in areas that are closed
and inadequately ventilated. Take all necessary
precautions to prevent a build up of exhaust fumes.
1.10 PRECAUTIONS WHEN THE ENGINE IS ON THE ROT A TING STAND
- Before removing the engine from the machine on
which it is installed, disconnect the electric current,
the fuel supply, coolant and all connections including
mechanical ones.
- To lift the engine, attach the lifting device at the points
(eyebolts) specified by the manufacturer.
- Close all engine openings carefully (exhaust, intake,
etc.) wash the outside and dry with a jet of compressed
air.
- Anchor the engine to the rotating stand to facilitate
all operations.
Note:the engine may also be placed on the
workbench, depending on the type of work to
be carried out.
- 7 -Service Manual LDW 502 automotive _ cod. 1.5302.727 - 2° ed_rev. 01
GENERAL REMARKS AND SAFETY
Notes :
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- 8 - Service Manual LW 502 automotive _ cod. 1.5302.727 - 2° ed_rev. 01
2.1 GENERAL DESCRIPTION OF THE ENGINE
Main components
BQDSHAN
TECHNICAL INFORMA TION
2
EPF GRTCM
A) Cylinder head
B) Engine block
C) Crankcase
D) Timing belt assembly
E) Flywheel and crankshaft assembly
F) Air intake assembly
G) Cooling fan
H) Negative-pressure vent valve
L
L) Alternator
M) Oil filter
N) Exhaust manifold
P) Starter motor
Q) Camshaft
R) Coolant pump
S) Fuel supply pump
T) Oil pump
- 9 -Service Manual LDW 502 automotive _ cod. 1.5302.727 - 2° ed_rev. 01
2.2 TECHNICAL SPECIFICA TIONS
A
B
(1) with suction fan
(2) with blower fan
451
491
C
D
353
238
E
G
DIMENSIONS (mm)
181
213
H
M
36
280
TECHNICAL INFORMA TION
N
340
Q
P
151
51(
52(
1
2
R
)
S
)
2
182
160
Operating cycle
Number of cylinders
Bore x stroke
Displacements
Compression rate
Intake
Filter capacity
Filtering surface
Cooling
Driving shaft rotation
Combustion sequence
Timing system
Dry weight of engine
Maximum tilt while operating
Maximum tilt while operating
Volume of air flow (at 3600 RPM)
Volume of cooling air (at 3600 RPM)
Maximum operating speed
Max. power (N 80/1269/EEC - ISO 1585 - DIN 7020)
Max. power (NB ISO 3046 - 1 IFN - DIN 6270)
Max. power (NA ISO 3046 - 1 ICXN - DIN 6270)
Maximum torque (at 2400 RPM)
Axial load allowed on driving shaft
GENERAL DET AILS
no more than 1 minute
no more than 30 minutes
POWER AND TORQUE
4-stroke diesel
n°
mm
3
cm
22,8:1
Air filter (dry)
µm
2
cm
Water
Clockwise (from distribution side)
1:2
Synchronous toothed belt
Kg 60
Nl/min
m3/min
RPM
kW (CV)
kW (CV)
kW (CV)
Nm
Kg
2
72x62
505
13÷14
4470
35°
25°
910
36
3600
9.8 (13.4)
9.1 (12.4)
8.2 (11.2)
28.7
300
- 10 - Service Manual LW 502 automotive _ cod. 1.5302.727 - 2° ed_rev. 01
CONSUMPTION AT MAXIMUM POWER
Specific fuel onsumption
Specific oil consumption
SUPPL Y CIRCUIT
Supply type
Fuel type
Fuel supply
Fuel filter
Filter paper
Filtering surface
Filter capacity
Maximum operating pressure
LUBRIFICA TION CIRCUIT
Type of lubrication
Circuit supply
Maximum oil quantity
Maximum oil quantity
Oil pressure at minimum speed (with oil temperature of 120°C)
Oil filter cartridge
Maximum operating pressure
Maximum combustion pressure
Filter capacity
By-pass valve setting
Filtering surface
COOLING CIRCUIT
Coolant
Thermostatic valve
Opening temperature
Max stroke (at 94°C)
Liquid return
ELECTRICAL EQUIPMENT
Nominal voltage
Alternator (nominal voltage)
Internal/external alternator (nominal current) (see “Alternator load
curve diagrams”)
Starter motor power
Preheating glow plugs
Nominal voltage
Absorption (after 5 seconds)
Surface temperature of the sheath
Control unit temperature sensor
Working field
Voltage
Max. temperature
Oil pressure switch
Operating pressure
Coolant temperature monitoring sensor
Electric circuit
Supply voltage
Absorbed power
Closed circuit temperature
g/kWh
Kg/h
Electric or membrane pump
Screw-on or in-line “fispino”
m
2
cm
µ
bar
including filter (I)
excluding filter (I)
bar
bar
µ
bar
2
cm
50% water - 50% antifreeze fluid
°C
mm
l/h
V
V
Kw
V
A
°C
°C
V
°C
bar
V
W
°C
TECHNICAL INFORMA TION
326
0,007
Indirect injection
Car diesel
PF905
2400
2÷3
4
Completely forced
Trochoid pump
1,4
1,3
no lower than 1 bar
7
20
15
1,5÷1,7
730
83°÷87°
7
30÷80
12
14
40A
1,1
12,5
12÷14
850°
-30°÷80°
6+24
150°
0,15÷0,45
Unipolar system
6÷24
3
107°÷113°
2
- 11 -Service Manual LDW 502 automotive _ cod. 1.5302.727 - 2° ed_rev. 01
2.3 CHARACTERISTIC CURVE DIAGRAMS
TECHNICAL INFORMA TION
Power curve diagram 80/1269/CEE - 95/1/CE (3000 rpm)
2
Caption
NB = Power curve
MB = Torque curve
C= Specific consumption curve
Power curve diagram 80/1269/CEE - 95/1/CE (3600 rpm)
- 12 - Service Manual LW 502 automotive _ cod. 1.5302.727 - 2° ed_rev. 01
2.4 ALTERNATOR LOAD CURVE DIAGRAMS
Reading taken after heat stabilisation at 25°C and
constant voltage 13,5V.
TECHNICAL INFORMA TION
Internal load curve diagram
Current supplied (A)
2
* To determine engine r.p.m.s, check the gear ratio
adapted to pulleys.
Reading taken after heat stabilisation at 20°C and
constant voltage 12,5V.
Alternator RPM *
External load curve diagram
Current supplied (A)
** The alternator turns at the same rate as the engines.
Alternator RPM **
- 13 -Service Manual LDW 502 automotive _ cod. 1.5302.727 - 2° ed_rev. 01
2
2
123456789012345678
1
8
1
8
123456789012345678
9
2.5 LUBRIFICANTS
2.5.1 SAE Classification
TECHNICAL INFORMA TION
2
In the SAE classification, oils differ on the basis
of their viscosity, and no other qualitative
characteristic is taken into account.
40
-35-
-30-25-
-
20
15
SAE 10W*
The first number refers to the viscosity when
the engine is cold (symbol W = winter), while
the second considers viscosity with the engine
at régime.
The criteria for choosing must consider, during
winter, the lowest outside temperature to which
the engine will be subject and the highest
functioning temperature during summer.
Single-degree oils are normally used when the
running temperature varies scarcely.
Multi-degree oil is less sensitive to temperature
changes.
* Mineral base
** Semi-synthetic base
*** Sythetic base
Key to abbreviations
A.P.I. : (American Petroleum Institute)
MIL : USA military specifications for engine oils issued for logistic reasons
ACEA : European Automobile Manufacturers Association
2.5.2 API/MIL Sequences
-100+5+10+15+20
5
SAE 20W*
SAE 10W-30**
SAE 10W-40**
SAE 10W-60**
SAE 15W-40 **
SAE 15W-40 **
SAE 20W-60 **
SAE 5W-30 ***
SAE 5W-40 ***
SAE 0W-30 ***
SAE 30*
+
+30+
25
SAE 40*
35
+40+
45
+
50
DIESEL
API SJ
CF CE CD C C CB CA SA S B SC SD SE SF SG
MIL
2.5.3 ACEA Standards - ACEA Sequences
PETROL
A1 = Low-viscosity,
B1 = Low-viscosity,
for friction reduction
A2 = Standard
A3 = High performance
B2 = Standard
B3 = High performance (indirect
B4 = High quality (direct injection)
2.5.4 Recommended oil
2345678901234567
2345678901234567
L - 2104 D / E
CORRENTI - CURRENT
23456789012345678901
23456789012345678901
23456789012345678
LIGHT DUTY DIESELS
for friction reduction
injection)
BENZINA - ESSENCE - PETROL
BENZIN - GASOLINA - GASOLINA
SH
L - 46152 B / C / D / E
OBSOLETI - OBSOLETE
HEAVY DUTY DIESELS
E1 = OBSOLETE
E2 = Standard
E3 = Heavy conditions (Euro1 -
Euro2 engines)
E4 = Heavy conditions (Euro1 -
Euro2 - Euro3)
E5 = High performance in heavy
conditions (Euro1 - Euro2 Euro3 engines)
SLCH-4 CG-4 CF-4 CF-2
- 14 - Service Manual LW 502 automotive _ cod. 1.5302.727 - 2° ed_rev. 01
Description
Engine oil
Oil type
Agip SINT
2000 5W40
Oil characteristics
API SJ/CF ACEA
A3-96 B3-96
MIL-L-4615 D/E
2.6 OPERATING PRINCIPLE FOR LUBRIFICATION
Ref.
Description
Pressure switch
1
Rocker-arm pin
2
Connecting rod big end pin
3
Oil filter cartridge
4
Main jurnal
5
Oil drain plug
6
Oil dipstick
7
Air vent
8
Oil refilling pump
9
Camshaft
10
Oil pressure regulating valve
11
Oil pump
12
Crankshaft
13
Oil suction filter
14
TECHNICAL INFORMA TION
2
2.7 OPERATING PRINCIPLE FOR COOLING
Ref.
Description
Coolant refilling plug
1
Compensation tank
2
Thermostatic valve
3
Cylinder block
4
Liquid temperature monitoring thermostat
5
Circulating pump
6
Fan
7
Radiator
8
- 15 -Service Manual LDW 502 automotive _ cod. 1.5302.727 - 2° ed_rev. 01
2.8 OPERATING PRINCIPLE FOR FUEL INJECTION
With mechanical supply pump
Ref.
Description
Tank
1
Fuel filter
2
Supply pipe
3
Supply pump
4
Injection pump
5
Injector
6
Fuel rail
7
Exhaust pipe
8
Plug
9
Solenoid valve
10
Note: the tank is supplied complete with
filter on request.
TECHNICAL INFORMA TION
2
With electrical supply pump
Ref.
Description
Tank
1
Fuel filter
2
Supply pipe
3
Electrical supply pump
4
Pump
5
Injector
6
Fuel rail
7
Exhaust pipe
8
Plug
9
- 16 - Service Manual LW 502 automotive _ cod. 1.5302.727 - 2° ed_rev. 01
2.9 WIRING DIAGRAM
With external alternator
TECHNICAL INFORMA TION
2
Electric pump version
Ref.
Description
1
40A alternator
2
Starter motor
3
Battery (recommended 44Ah-210A-DIN)
4
Preheating glow plugs
5
Coolant temperature monitoring sensor
6
Glow plug pre-heating control box
7
Ignition switch
8
50A fuses
9
5A fuses
10
Electrostop device or electrical fuel lift pump
11
Glow plugs indicator
12
Coolant temperature indicator
Ref.
Description
13
Coolant thermostat indicator light
14
Engine oil preassure lamp
15
Oil preassure gauge
16
Battery load indicator
18
Coolant thermometer
19
Coolant thermomenter sensor
20
Fuel level light
21
Fuel level indicator
22
Relay (normally closed with a 3 second delay) 40÷50 A
Electrical fuel lift pump
23
- 17 -Service Manual LDW 502 automotive _ cod. 1.5302.727 - 2° ed_rev. 01
With internal alternator
TECHNICAL INFORMA TION
2
Electric pump version
Ref.
Description
1
40A alternator
2
Starter motor
3
Battery (recommended 44Ah-210A-DIN)
4
Preheating glow plugs
5
Coolant temperature monitoring sensor
6
Glow plug pre-heating control box
7
Ignition switch
8
50A fuses
9
5A fuses
10
Electrostop device or electrical fuel lift pump
11
Glow plugs indicator
12
Coolant temperature indicator
Ref.
Description
Coolant thermostat indicator light
13
Engine oil preassure lamp
14
Oil preassure gauge
15
Battery load indicator
16
Volt age regulator
17
Coolant thermometer
18
Coolant thermomenter sensor
19
Fuel level light
20
Fuel level indicator
21
25 V - 10000 µF condensator
22
Electrical fuel lift pump
23
- 18 - Service Manual LW 502 automotive _ cod. 1.5302.727 - 2° ed_rev. 01
2.10 SPECIAL TOOLS AND EQUIPMENT FOR MAINT ANANCE
Serial number Serial numberDescription Description
TECHNICAL INFORMA TION
2
Instrument for balancing injection pump
delivery
Precombustion chamber extractor
Pin wrench for ring nut on pump/
injector pumping element
Precombustion chamber pin wrench
T ool for mounting intake/exhaust valve
guide gasket
2.11 TABLE FOR TIGHTENING TORQUES
The table shows the tightening torques for standard
screws and the main components.
T ool for lowering injection advance control valve
Equipment for injection advance control and
injector calibration
Driving shaft clamping tool
Pivot pin precombustion chamber
T ool for adjusting timing belt tension
Tightening torques are provided again, along with method
and sequence, in the instructions for assembling
components and/or assemblies.
Tightening torques for standard screws (coarse thread)
Resistance class (R)
Quality /
Dimensions
Diameter
M3
M4
M5
M6
M8
M10
M12
M14
M16
M18
M20
M22
M24
M27
M30
4.6 4.8 5.6 5.8 6.8 8.8
R>400N/mm
Nm
0,5
1,1
2,3
3,8
9,4
18
32
51
79
109
154
206
266
394
544
2
Nm
0,7
1,5
3
5
13
25
43
68
105
145
205
275
355
525
725
R>500N/mm
Nm
0,6
1,4
2,8
4,7
12
23
40
63
98
135
193
260
333
500
680
2
Nm
0,9
1,8
3,8
6,3
16
31
54
84
131
181
256
344
444
656
906
10.9 12.9
R>600N/mm2R>800N/mm2R>1000N/mm
Nm
1
2,2
4,5
7,5
19
37
65
101
158
218
308
413
533
788
1088
Nm
1,4
2,9
6
10
25
49
86
135
210
290
410
550
710
1050
1450
Nm
1,9
4,1
8,5
14
35
69
120
190
295
405
580
780
1000
1500
2000
2
R>1200N/mm
Nm
145
230
355
485
690
930
1200
1800
2400
2
2,3
4,9
10
17
41
83
- 19 -Service Manual LDW 502 automotive _ cod. 1.5302.727 - 2° ed_rev. 01
Tightening torques for standard screws (fine threads)
Resistance class (R)
TECHNICAL INFORMA TION
2
Quality /
4.6 4.8 5.6 5.8 6.8 8.8
Dimensions
2
Nm
14
28
26
48
45
75
113
163
157
230
218
305
390
575
800
Diameter
M 8x1
M 10x1
M 10x1,25
M 12x1,25
M 12x1,5
M 14x1,5
M 16x1,5
M 18x1,5
M 18x2
M 20x1,5
M 20x2
M 22x1,5
M 24x2
M 27x2
M 30x2
R>400N/mm
Nm
10
21
20
36
38
56
84
122
117
173
164
229
293
431
600
Tightening torques for main components
R>500N/mm
Nm
13
26
24
45
42
70
105
153
147
213
204
287
367
533
750
2
Nm
17
35
33
59
56
94
141
203
196
288
273
381
488
719
1000
10.9 12.9
R>600N/mm2R>800N/mm2R>1000N/mm
Nm
20
42
39
71
68
113
169
244
235
345
327
458
585
863
1200
Nm
27
56
52
95
90
150
225
325
313
460
436
610
780
1150
1600
Nm
38
79
73
135
125
210
315
460
440
640
615
860
1 100
1600
2250
2
R>1200N/mm
Nm
160
150
250
380
550
530
770
740
1050
1300
1950
2700
2
45
95
88
Description
Injector pump connecting rod
Aluminium connecting rod
Steel connecting rod
Preheating glow plugs
Rocker-arm cover
Crankcase (screws for fixing crankshaft)
Crankcase (screws for fixing engine block)
Screw for speed governor bearing support cover
Preheating glow plugs cable nuts
Fuel supply pump nuts
Nut for synchronous timing belt pulley
Injector pump nut
Rocker arm support nuts
Fuel pump control eccentric
Oil sealing ring flange screws (flywheel side)
Precombustion chamber ring nut
Governor tinkage adjustment pin
Crankshaft pulley screw (timing belt side)
Camshaft pulley screw
Oil pressure switch
Oil plug
Cylinder head screws
Injector pump head screws
Flywheel screws
Coolant thermostat / Control unit sensor
Control unit temperature sensor
Diameter x thread Tightening torque (Nm)
M 3 spéc.
8x1
8x1
12x1,25
6x1
M 10
M 6
M 6
5x0,8
8x1,5
M 10
8x1,25
10x1,5
10x1,25
M 6
30x1,5
6x1
16x1,5 gauche
10x1,25
12x1,5
12x1,5
TCEI 4x1,5
10x1,5
1,2
30
50
25
9
30
10
10
5
24
40
20
40
80
12
180
7
180
80
25
40
(1)
4
80
30
30
(1)
For more detailed information see “Assembling the cylinder head”
- 20 - Service Manual LW 502 automotive _ cod. 1.5302.727 - 2° ed_rev. 01
2.12 TABLE OF SEALANTS
TECHNICAL INFORMA TION
2
Area of application
Fuel rail attachment
Oil filter cartridge union (M 20X1,5)
Camshaft bearing screw (M 6)
Stud bolt for tightening pulley (M 10)
Cylinder head plug (ø 18)
Engine and engine block cylinder head plug (ø 30)
2.13 ROUTINE ENGINE MAINTENANCE
After the first
500 Km
Sealant
Loctite 638
Loctite 601
Loctite 270
Loctite 601
Loctite 510
Loctite 510
REGULARITY KM ( per 1000 Km )
5 101520253035404550556065707580859095100
PROCEDURE
CLEANING
CHECK
CHANGE
DETAIL
Pump injectors
Radiator fan
V alve and rocker arm
clearance
Engine oil
Solenoid valve
operation
Oil vapor
recovery
Fuel pipe and
connections
Coolant
Alternator belt
Timing belt
Alternator
Air filter element
Engine oil
Oil filter
Fuel filter
Coolant
Alternator belt
Timing belt
Fuel pipes
EVERY 2500 Km
EVERY 25000 Km
EVERY 5000 Km
EVERY 50000 Km ( or at every disassembly)
EVERY 4 years
- 21 -Service Manual LDW 502 automotive _ cod. 1.5302.727 - 2° ed_rev. 01
TECHNICAL INFORMA TION
Notes :
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- 22 - Service Manual LW 502 automotive _ cod. 1.5302.727 - 2° ed_rev. 01
MALFUNCTIONS
3.1 LOOKING FOR MALFUNCTIONS
The following information is provided to help identify and correct any irregularities and malfunctions that
may arise during use.
Problem
Probable cause
3
Clogged pipes
Clogged fuel filter
Air in the fuel circuit
Clogged tank breather
Faulty fuel pump
Blocked injector
Blocked injection pump valve
Injector not adjusted
FUEL CIRCUIT
Excess leaking in the plunger
Jammed injection pump delivery control
Wrong injection pump delivery setting
High oil level
Blocked pressure relief valve
Worn oil pump
Air in the oil intake pipe
Faulty pressure gauge or switch
Clogged oil suction hose
LUBRIFICATION
Burnt fuse on pre-heating glow plugs
Failure in glow plugs control unit
Discharged battery
Inefficient or wrong cable connection
SYSTEM
Faulty ignition switch
ELECTRICAL
Faulty starter motor
Air filter clogged
Excessive idle operation
Incomplete running-in
Overloaded engine
Clogged cooling circuit
Slack or broken fan control belt
MAINTENANCE
Incorrect injection timing
Delayed injection
Incorrect governor linkage adjustment
Broken or loose governor spring
Low idle setting
Worn or stuck piston rings
Worn or scored cylinders
Worn valve guides
Valves stuck
Worn crankshaft/connecting rod bearings
Non-sliding speed governor leverage
Driving shaft not turning freely
ADJUSTMENTS / REPAIRS
Damaged head gasket
Slack pump/injector control rod
Incorrect pump/injector delivery balancing
Engine does not start
Inconsistent rpm
Does not accelerate
Engine starts and then stops
Black smoke
White smoke
Low oil preassure
Oil consumption too high
Consommation huile en excès
Oil and condensation dripping from
the exhaust
Coolant overheats
- 23 -Service Manual LDW 502 automotive _ cod. 1.5302.727 - 2° ed_rev. 01
MALFUNCTIONS
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- 24 - Service Manual LW 502 automotive _ cod. 1.5302.727 - 2° ed_rev. 01
4.1 HANDLING AND LIFTING
- Secure the engine using a lifting device
(lifting beam) of suitable capacity.
- Hook the lifting device to the points indicated
in the drawing.
- Before lifting, check the load’s centre of
gravity.
Important
The dimensions of the brackets on the
fastening points have been specially
conceived to lift the engine and have not
been tested for lifting additional weights.
Do not lift the engine using different
methods from those described. Nonobservance of this requirement will
invalidate the insurance warranty from any
damages caused in this way.
STORING THE ENGINE
4
4.2 STORING THE ENGINE (UNINST ALLED)
- If the engine is not to be used for extensive periods,
check the surroundings and the type of packaging and
make sure that they are suitable for correct storage.
If necessary, cover the engine with a protective sheet.
- Avoid storing the engine directly on the ground or in an
environment that is humid, exposed to bad weather or
close to sources of danger, including less visible ones,
such as high-voltage power lines etc.
4.3 STORING THE ENGINE (INST ALLED)
If the engine has been installed on a machine and is not
due to be used for extensive periods, it is necessary to
carry out a few maintenance measures in order to ensure
it remains efficient and to protect its components. If the
engine is installed on the machine and is not to be used
for short periods of time, the following measures must
be carried out:
- Check the condition of the electrical contacts and
protect them, if necessary, using an anti-rust spray.
- Disconnect the battery.
- Empty the fuel tank to prevent the risk of fire.
- If the engine is not to be used for more than 1 month, it
is necessary to apply the protective measures that are
valid for 6 months (see “Protective treatment (first 6
months of inactivity)”)
- If, after the first 6 months, the engine is still not to be
used, it is necessary to carry out a further measure to
extend the protection period (see “Protective treatment
(after 6 months of inactivity)”).
- Remove the key from the dashboard and put it in a
safe place to avoid acts of vandalism.
- Lock the cabin and the cowls to prevent strangers
getting access.
If the engine is not to be used for more than 1 month, it is
necessary to apply protective measures that are valid for
6 months (see “Protective treatment”).
If, after the first 6 months, the engine is still not to be
used, it is necessary to carry out a further measure to
extend the protection period (see “Protective
treatment”).
- 25 -Service Manual LDW 502 automotive _ cod. 1.5302.727 - 2° ed_rev. 01
4.4 PROTECTIVE TREA TMENT
STORING THE ENGINE
4
1- Check that the engine oil and coolant are up to
level.
2 - Start the engine and keep idle at minimum speed
for 15 minutes.
3 - Switch off the engine and leave to cool.
4 - Take out the lubricant
5 - Fill the casing with AGIP RUSTIA C protective oil
6 - Empty the fuel tank completely.
7 - Replace fuel filter.
8 - Fill the fuel tank with a mixture made up of 10%
AGIP RUSTIA NT protective oil and 90% fuel.
9 - Release the air from the fuel supply circuit.
10 - Start the engine and check for fuel leaks.
11 - Start the engine and bring to ¾ of the maximum
speed for 5-10 minutes.
12 -Switch off the engine.
13 - Spray SAE 10W oil on the exhaust and intake
4.5 PREPARING THE ENGINE FOR OPERATION (UNINST ALLED)
manifolds.
14 - Close all openings to prevent foreign bodies from
entering.
15 - Thoroughly clean all external parts of the engine
using suitable products.
16 - Treat non-painted parts with protective products
(AGIP RUSTIA 100/F).
17 - Loosen the alternator-fan belt.
18 - If necessary, cover the engine with a protective
sheet.
After a year of engine inactivity, the coolant loses its
properties and must be replaced
Important
After a period of inactivity and before installing and
running the engine, it is necessary to carry out a few
measures in order to ensure that it runs at maximum
efficiency.
1 - Remove the protective treatment.
2 - Remove any blockages from the exhaust and intake
ducts.
3 - Use a cloth soaked in degreasing product to remove
the external protective treatment.
4 - Remove the intake manifold.
5 - Inject lubrication oil (no more than 2 cm3 ) into the
valves and replace the intake manifold.
6 - Adjust the alternator-fan belt tension.
7 - Turn the flywheel manually to check the movement
of the mechanical parts.
8 - S tart the engine and run at ¾ of the maximum speed
for 5-10 minutes.
9 - Switch off the engine.
10 - Remove the protective oil to replace with engine oil.
11 - Introduce new oil (see “Table of lubricants”) up to
the correct level marked on the dipstick.
12 - Check the filters for aging (air, oil, fuel) and, if
necessary, replace them with original spares.
Important
Over time, a number of engine components and
lubricants lose their properties, even when the engine
is not in use, and so it is important to consider
whether they need replacing, based not only on the
number of hours of use, but also on age and wear.
13 - Install the engine onto the machine and make the
necessary connections and unions.
14 - Make sure that electrical contacts are intact and
efficient.
15 - Check that the engine oil and coolant are up to level.
16 -Start the engine and keep at minimum speed for a
few minutes.
17 - Check for leaks and, if necessary , find and eliminate
the cause.
18 -Switch off the engine.
- 26 - Service Manual LW 502 automotive _ cod. 1.5302.727 - 2° ed_rev. 01
4.6 PREP ARING THE ENGINE FOR OPERA TION (INST ALLED)
After a period of inactivity and before installing and
running the engine, it is necessary to carry out a few
measures in order to ensure that it runs at maximum
efficiency.
1 - Use a cloth soaked in degreasing product to remove
the external protective treatment.
2 - Adjust the alternator-fan belt tension.
3 - Make sure that electrical contacts are intact and
efficient.
4 - Check the filters for aging (air, oil, fuel) and, if
necessary, replace them with original spares.
Over time, a number of engine components and
lubricants lose their properties, even when the engine
is not in use, and so it is important to consider
whether they need replacing, based not only on the
number of hours of use, but also on age and wear.
5 - Check that the engine oil and coolant are up to
6 - Start the engine and keep at minimum speed for a
7 - Check for leaks and, if necessary, find and
8 - Switch off the engine.
Important
level.
few minutes.
eliminate the cause.
STORING THE ENGINE
4
- 27 -Service Manual LDW 502 automotive _ cod. 1.5302.727 - 2° ed_rev. 01
STORING THE ENGINE
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- 28 - Service Manual LW 502 automotive _ cod. 1.5302.727 - 2° ed_rev. 01
5.1 RACCOMENDATIONS FOR REMOVING THE ASSEMBLIES
REMOVING THE ASSEMBLIES
5
- Information is given in a logical order in terms of timing
and sequence of operations. The methods have been
selected, tested and approved by the manufacturer’s
technical experts.
- This chapter describes procedures for removing
assemblies and/or individual components, in order to
carry out work on specific parts of the engine.
- See the chapter entitled “Overhauls and tuning” for
operations involving checks, overhauls and tuning of
assemblies and/or components.
- See the chapter entitled “Installation of assemblies” for
operations involving the installation of assemblies and/
or components.
5.2 REMOVING THE EXHAUST AND INT AKE MANIFLODS
5.2.1 Disassembling the intake manifold
Air filter (square type)
1 - Remove the cover (A).
2 - Remove the intake manifold (B)
D
Important
Importante
To locate specific topics, the reader should refer to
the index.
- Before any intervention, the operator should lay out all
equipment and tools in such a way as to enable him to
carry out operations correctly and safely.
- Before proceeding with operations, make sure that
appropriate safety conditions are in place, in order to
safeguard the operator and any persons involved.
- For safety and convenience, you are advised to place
the engine on a special rotating stand for engine
overhauls.
B
C
C1
3 - Unhook the minimum-maximum device
(C) or the spring (C1).
4 - Remove the gasket (D).
5 - Close the openings and ducts to
prevent foreign bodies from entering.
Air filter (cylindrical type)
1 - Remove the cover (E).
2 - Disconnect the intake and air vent
pipes.
3 - Remove the intake manifold (F).
4 - Unhook the minimum-maximum
device or the spring.
5 - Remove the gasket (G).
A
E
G
6 - Close the openings and ducts to
prevent foreign bodies from entering.
F
- 29 -Service Manual LDW 502 automotive _ cod. 1.5302.727 - 2° ed_rev. 01
5.2.2 Disassembling the exhaust
manifold
REMOVING THE ASSEMBLIES
H
5
1 - Remove the dipstick tube (H).
2 - Remove the exhaust manifold (L).
3- Remove the gaskets (M).
4 - Close the openings and ducts to
prevent foreign bodies from entering.
5.3 REMOVING THE COOLING FAN BELT DRIVE
1 - Remove the cooling fan (A).
M
L
A
Important
The cooling fan belt drive comes in more
than one version: with external or internal
alternator.
- 30 - Service Manual LW 502 automotive _ cod. 1.5302.727 - 2° ed_rev. 01
with internal alternatorwith external alternator
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