Page 1
code 1.5302.727
SERVICE MANUAL
Page 2
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
Page 3
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
Page 4
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
Page 5
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
Page 6
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
Page 7
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
Page 8
GENERAL REMARKS AND SAFETY
Notes :
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- 8 - Service Manual LW 502 automotive _ cod. 1.5302.727 - 2° ed_rev. 01
Page 9
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
Page 10
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
Page 11
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
Page 12
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
Page 13
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 **
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Page 14
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
Page 15
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
Page 16
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
Page 17
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
Page 18
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
Page 19
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
Page 20
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
Page 21
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
Page 22
TECHNICAL INFORMA TION
Notes :
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- 22 - Service Manual LW 502 automotive _ cod. 1.5302.727 - 2° ed_rev. 01
Page 23
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
Page 24
MALFUNCTIONS
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- 24 - Service Manual LW 502 automotive _ cod. 1.5302.727 - 2° ed_rev. 01
Page 25
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
Page 26
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
Page 27
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
Page 28
STORING THE ENGINE
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- 28 - Service Manual LW 502 automotive _ cod. 1.5302.727 - 2° ed_rev. 01
Page 29
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
Page 30
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
Page 31
5.3.1 Disassembling the cooling fan belt
(with external alternator)
1 - Loosen the nuts (B - B1).
REMOVING THE ASSEMBLIES
5
2 - Loosen the belt (D) by adjusting the
alternator (C) manually.
3 - Remove the belt (D).
4 - Remove the hub (E) and flange.
5 - Remove the pulley (F), washers and
spacer.
5.3.2 Disassembling the cooling fan belt
(with internal alternator)
1 - Remove the hub (E) and flange.
pulley flange
E
B
C
D
B1
D
F
2 - Remove the belt (D).
3 - Remove the pulley (F), washers and
spacer.
5.4 REMOVING THE TIMING BEL T
5.4.1 Disassembling the timing belt casing
1 - Disassemble the starter motor.
2 - Install tool “7107-1460-051” to inhibit
rotation of the crankshaft.
3 - Loosen the screw (G).
Caution - Warning
The screw is left-handed. Turn clockwise
to unscrew.
pulley flange
E
D
tool 7107-1460-051
GH
- 31 -Service Manual LDW 502 automotive _ cod. 1.5302.727 - 2° ed_rev. 01
Page 32
4 - Loosen the screws and remove the pulley
(H).
5 - Remove the casing (L).
5.4.2 Disassembling the timing belt
REMOVING THE ASSEMBLIES
L
H
5
1 - Twist the pulley nut (M) to fully loosen
the belt (N).
2 - Remove the belt (N), working it away in
sequence first from the pulley and (P) and
then from the others.
Important
The timing belt must always be replaced
with an original spare part whenever it is
removed.
5.4.3 Disassembling the pulleys (camshaft
and crankshaft)
1 - Remove the pulley (P).
2 - Remove the pulley (Q).
P
M
N
P
Q
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Page 33
5.5 REMOVING THE CYLINDER HEAD
5.5.1 Disassebling the rocker arm cover
1 - Remove the negative-pressure vent valve
(A).
2 - Remove the rocker arm cover (B).
REMOVING THE ASSEMBLIES
B
5
3 - Remove the gasket (C).
5.5.2 Disassebling the rocker arms
1 - Press the rocker arm to fully push the
drive rod down (E).
2 - Introduce a pin to interrupt the injector
stroke in order to be able to extract the
drive rod.
3 - Let go of the rocker arm and remove
the drive rod.
4 - Repeat the same operation on the
other injector.
C
A
D
E
5 - Remove the rocker arm pin and
support (D).
5.5.3 Disassebling the fuel pump
1 - Disconnect the supply pipe (G1) from the
union.
2 - Remove the supply pump (G).
3 - Remove the O-ring (G2).
4 - Extract the drive rod (H).
H
G1
G2
G
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Page 34
5.5.4 Disassembling the injection-pumps
1 - Remove the fuel rail (F).
Important
Make sura that the injector gaskets remain
in position.
2 - Unhook the spring (L).
Important
If injector pumps are to be used during
installation, do not loosen the screws (L1)
in order to not balance injector pump
deliveries during tuning.
3 - Unscrew the screws (M).
4 - Remove the connecting rod (M1).
L1
M1
REMOVING THE ASSEMBLIES
F
M
L1
L
5
N
5 - Dismount the injection-pumps (N).
5.5.5 Disassembling precombustion
chamber
1 - Disconnect the electric cable (P).
2 - Remove the preheating glow plugs (Q).
3 - Unscrew the ring nut (R) using the special
pin wrench “7107-1460-027”.
Q
P
R
pin wrench 7107-1460-027
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Page 35
4 - Screw the extractor “7107-1460-030” onto
the precombustion chamber (S) and
remove it.
5.5.6 Disassembling the speed governor
and flow limiter
1 - Remover the cover (T).
extractor 7107-1460-027
S
T
REMOVING THE ASSEMBLIES
U
5
2 - Extract the weights assembly (U) from
the camshaft.
3 - Remove the fuel flow limiter (V).
4 - Unscrew the pin and extract the governor
tinkage adjustment pin (W).
V
W
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Page 36
5.5.7 Disassembling the camshaft
REMOVING THE ASSEMBLIES
5
1 - Remove the cover (X).
2 - Extract the camshaft (Y) from the cylinder
head.
Important
Make sure the drive rod has been
removed and rotate the camshaft gently
to remove it easily.
5.5.8 Disassembling the cylinder head
1 - Remove the cylinder head (A).
2 - Take off the gasket (B).
Y
X
5.6 REMOVING THE CRANK GEAR AND CRANKCASE
5.6.1 Disassembling the flywheel
1 - Disassemble the starter motor (A).
2 - Install tool “7107-1460-051” to inhibit
rotation of the crankshaft.
3 - Remove the flywheel (B).
A
B
A
tool 7107-1460-027
B
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Page 37
4 - Remove the support (C).
5.6.2 Disassembling the oil pump
1 - Remove the flange (D).
REMOVING THE ASSEMBLIES
C
D
5
2 - Extract the key (E) from the crankshaft.
3 - Bring piston number one (flywheel side)
to the top dead centre, with the oil pump
activation key in line with break in the
flange, in order to be able to remove it.
Important
You should in no way try to force removal
of the pump, if its activation key is not lined
up with the break in the flange.
4 - Remove the oil pump (F).
E
oil pump
activation key
crankshaft
F
5 - Take off the gasket (G).
G
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Page 38
5.6.3 Disassembling the crankcase and
crankshaft
1 - Remove the flange (H).
REMOVING THE ASSEMBLIES
5
2 - Tske off the gasket (L).
3 - Remove the crankcase (M).
L
H
M
4 - Remove the connecting rod cap (N).
Caution - Warning
Before removing the cap, mark the area of
contact with the connecting rod, in order
to recognise the right position during
reassembly.
5 - Remove the crankshaft (P) and place it
in a container for washing.
N
- 38 - Service Manual LW 502 automotive _ cod. 1.5302.727 - 2° ed_rev. 01
P
Page 39
5.6.4 Disassembling connecting rod and
piston
1 - Extract the connecting rod/piston
assembly (Q).
2 - Remove the crankshaft half bearings.
Caution - Warning
Before removing the crankshaft half
bearings, mark the seat position, in order
to recognise and match it up during
reassembly.
Important
REMOVING THE ASSEMBLIES
Q
bearings
5
Be careful not to damage the half bearing
during removal.
5.7 DISASSEMBLING THE V ALVES
1 - Place the cylinder head on the workbench.
2 - Press down hard on the cup (A), using the
special tool.
3 - Remove the half collets (B) blocking the
cup (A), the spring (C), the collar (D) and
the gasket (E).
thrust bearings
B
A
C
D
E
4 - Remove the valves (F).
Important
Keep components together during the
disassembly phase, in order to be able to
reassemble correctly.
F
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Page 40
5.8 DISASSEMBLING THE PISTON
1 - Remove the stop ring (B).
2 - Extract the wrist pin (C) to separate the
piston (D) from the connecting rod (E).
Important
Keep each connecting rod together with its
piston and wrist pin.
REMOVING THE ASSEMBLIES
E
B
D
C
5
3 - Remove the stop rings (F).
F
Notes :
. ..........................................................................................................................................................................
. ..........................................................................................................................................................................
. ..........................................................................................................................................................................
. ..........................................................................................................................................................................
...........................................................................................................................................................................
. ..........................................................................................................................................................................
. ..........................................................................................................................................................................
. ..........................................................................................................................................................................
. ..........................................................................................................................................................................
.
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Page 41
6.1 RECOMMENDA TIONS FOR OVERHAULS AND TUNING
OVERHAULS AND TUNING
6
– 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 controlling,
overhauling and tuning assemblies and/or individual
components.
Important
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.
– The operator must comply with the specific measures
described in order to avoid errors that might cause
damage to the engine.
– Before carrying out any operation, clean the
assemblies and/or components thoroughly and
eliminate any deposits or residual material.
– Wash the components with special detergent and do
not use steam or hot water.
– Do not use flammable products (petrol, diesel, etc.) to
degrease or wash components. Use special products.
– Dry all washed surfaces and components thoroughly
with a jet of air or special cloths before reassembling
them.
– Apply a layer of lubricant over all surfaces to protect
them against oxidation.
– Check all components for intactness, wear and tear,
seizure, cracks and/or faults to be sure that the engine
is in good working condition.
– Some mechanical parts must be replaced en bloc,
together with their coupled parts (e.g. valve guide/valve
etc.) as specified in the spare parts catalogue.
6.1.1 Shaft seals
– Clean the shaft thoroughly and make sure that it is
not damaged or scored or has become oval-shaped
in the areas of contact with the seals.
– Lubricate the seal lips, and pointing them in the right
direction, place them in their seat using a special pad.
6.1.2 O-Rings
– Lubricate the seal before introducing it to its seat.
– Avoid “rolling” the gasket during the attachment phase.
6.1.3 Bearings
– Use special extractors or plugs to remove bearings.
– Clean the bearings thoroughly. Check their condition
and, if they are fully intact, lubricate all over , otherwise
replace with original spares.
6.2 OVERHAULING THE CRANK GEARS AND CRANK CASE
– Do not use a hammer directly on the gaskets during
– Be careful not to damage the gaskets while joining
assembly, to avoid damaging them.
them to the shaft.
– Do not use a hammer directly on the bearings during
assembly, to avoid damaging them.
6.2.1 Overhauling cylinders and pistons
Before deciding what kind of overhaul needs to be done,
it is important to carry out a dimensional check and verify
the correspondence of cylinders, pistons, sealing rings,
crankshaft and connecting rods.
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Page 42
6.2.2 Dimensional check and overhaul of
cylinders
1 - Place the engine block on the
workbench.
2 - Using a micrometer, measure the
diameter at points 1-2-3 (see diagram).
3 - Rotate the micrometer 90° and
remeasure. If ovalization or wear is
greater than 0.05mm, the cylinder must
be ground .
Important
– The increases recommended by the
manufacturer for the cylinder head 0.5
and 1 mm.
– When grinding make sure that the
working angle is 45-55° and that the
average roughness is Ra=0.5-1.
– Do not sand the internal surfaces of the
cylinders using emery cloth.
– Protect the contact surfaces with
lubricant oil, to prevent them from
rusting
The table shows the reference values and their class (only
applies to new engines).
OVERHAULS AND TUNING
6
Important
Pistons with nominal diameter are supplied only in
class (A) spares. Those uprated by 0.5 and 1 mm have
the uprating referance (ø72.5 e ø73) engraved on the
upper part of the piston (see “T able of cylinder - piston
classes and dimensions”).
Table of cylinder - piston classes and dimensions
Dimension
class
A000,27÷099,17049,17÷039,17
Ø Cylinders
(mm)
Ø Pistons
(mm)
clearance
(mm)
6.2.3 Dimensional check and overhaul of
pistons
1 - Clean the piston thoroughly (D).
2 - Using a micrometer, measure the piston
9mm from the base of the skirt.
3 - Check the table to identify the class from
the values detected.The class letter is
engraved on the piston,
If clearance between cylinder and piston
is greater than 0.05mm, the piston and
sealing rings must be replaced, and
rematched according to the diameter of
the ground cylinders “see Table of
cylinder-piston classes and dimensions”).
Important
B010,27÷000,27059,17÷049,17
70,0÷50,0
C020,27÷010,27069,17÷059,17
R021,27÷001,27940,27÷130,27
D
Before replacing the pistons, check that
the weight difference does not exceed 4g
Protect the contact surfaces with lubricant oil, to prevent them
from rusting.
to prevent weight imbalances.
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Page 43
6.2.4 Dimensional check of sealing rings
1 - Place a sealing ring in the cylinder and
measure the distance between the two
tips using a thickness gauge (H).
2 - Repeat for all the sealing rings.
If the distance between the tips does not
correspond to the indicated values,
replace the sealing ring with an original
spare (see “Dimensional table of sealing
rings”).
Dimensional table of sealing rings
OVERHAULS AND TUNING
6
Sealing rings
°154,0÷52,0
°254,0÷52,0
°354,0÷02,0
distance between
tips (mm)
Wear & tear limit
(mm)
0,1
3 - Put the sealing rings on the piston in the
order shown in the figure.
Important
Place the sealing rings with the markings
facing up towards the upper part of the
piston (crown).
4 - Using a thickness gauge, measure the
clearance of each sealing ring. If
clearance does not correspond to the
values shown, replace the sealing rings
with original spares.
Table of sealing rings clearance
Sealing rings
Clearance (mm)
°1=1L521,0÷090,0
°2=2L580,0÷050,0
°3=3L570,0÷040,0
Important
– Sealing rings cannot be replaced
separately.
– Protect the contact surfaces with
lubricant oil, to prevent them from
rusting.
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Page 44
6.2.5 Dimensional check and overhaul of
crankshaft
1 - Wash the crankshaft thoroughly using
suitable detergent.
2 - Introduce a pipe cleaner into the
lubrication ducts to remove any residual
dirt.
3 - Blow compressed air into the points
indicated to free the ducts from oil.
4 - Check the surfaces of the main journals
and crank pins for wear and tear to see
whether grinding is necessary.
5 - Using a micrometer, measure the diameter
of the main journals (A1) and crank pins
(B1).
6 - Using a dial indicator, measure the
inside diameters of the crankshaft
(A2) and connecting rod (B2) half
bearings .
OVERHAULS AND TUNING
6
Table of diameters of connecting rods and half bearings
Ref.
Dimensions
(mm)
1A000,84÷489,74009,74
2A850,84÷220,84550,84
Wear &
tear limit
(mm)
Clearance (mm)
=1A-2A610,0÷230,0002,0
wear &
tear lim
(mm)
Important
– Crankshaft half bearings cannot be
replaced separately.
– If the crankshaft needs to be ground,
establish the diameters of the
connecting rod and crank pins, in order
to choose the matching measurements
available of connecting rod and half
bearing spare parts (see “Table of
diameters of connecting rods and half
bearings”).
– When grinding the crankshaft it is
possible to downrate the crankshaft
and connecting rod pins by 0,25 mm
and 0,50 mm.
– When grinding the crankshaft it is also
necessary to consider grinding the
sides (shoulder) to be able to choose
uprated ring replacements (see “Table
of uprated shoulder half-rings”).
Important
1B000,04÷498,93009,93
2B530,04÷020,04001,04
Table of diameters of connecting rods and half bearings PROGRESS
Réf.
Dimensions
(mm)
1A000,84÷489,7459,74
2A170,84÷520,841,84
1B000,04÷489,9359,93
2B50,04÷120,0480,04
Wear and
tear limit
(mm)
=1B-2B660,0÷120,0031,0
Clearance (mm)
=1A-2A780,0÷520,021,0
=1B-2B660,0÷120,001,0
Max
clear.
(mm)
Table of uprated shoulder half-rings
Dimensions (mm)
Half-rings
Standard
1° increase
2° increase
3° increase
AB
029,22÷787,22001,32÷050,32
021,32÷789,22003,32÷052,32
022,32÷780,32004,32÷053,32
023,32÷781,32005,32÷054,32
Clearance
B-A=C
313,0÷031,0
Protect the contact surfaces with lubricant
oil, to prevent them from rusting.
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Page 45
d520,011÷579,901
cØ-bØ
520,0÷010,0
04,0
bØ020,02÷010,02
cØ000,02÷599,91
aØ530,04÷020,04
e020,55÷000,55
OVERHAULS AND TUNING
6
6.2.6 Dimensional check and overhaul of
connecting rods
1 - Check that the contact surfaces are
perfectly clean and intact.
2 - Assemble the cap (D) onto the
connecting rod big end and tighten the
screws to a torque of 38 Nm ( 40 Nm x
PROGRESS).
3 - Using a micrometer, measure diameters
øa-b.
Important
– If the diameter of the conncting rod
small end does not match the diameter
of the wrist pin, the connecting rods
must be replaced to achieve the right
match (see “Table of connecting rod
dimensions”).
– The half-bearings are supplied smaller
than the nominal dimensions, by 0,25
mm and 0,50 mm.
– Before replacing the connecting rods,
check that the weight difference does
not exceed 10g to prevent weight
imbalances (see “Table of connecting
rod dimensions”).
– Protect the contact surfaces with
lubricant oil, to prevent them from
rusting.
D
Table of connecting rod dimensions
Ref.
Dimensions
Clearance
(mm)
Table of connecting rod dimensions PROGRESS
Dimensions (mm)
Réf.
A20,701÷89,601
Clearance
(mm)
connecting
rod
wear &
tear limit
(mm)
Wear
and tear
limit(mm)
6.2.7 Checking parallelism of the
connecting rod axes
1 - Insert the wrist pin (V) in the connecting
rod small end.
2 - Use a dial indicator to check that there is
parallelism between the small end and
big end axes. Parallel deviation,
measured at the very tip of the wrist pin,
must not exceed 0.015-0.030mm. If
parallel values do not correspond to those
indicated, replace the connecting rod with
an original spare.
3 - After carrying out all checks and
overhauls, remount the connecting rods,
pistons and sealing rings (see “Preassembly of sealing rings - pistons” and
“Pre-assembly of connecting rods pistons”).
Important
Protect the contact surfaces with lubricant
oil, to prevent them from rusting.
B520,81÷510,81
D81÷599,71
C50,04÷120,04
E1,15÷9,05
V
connecting rod
small end
connecting
rod
connecting rod
big end
D-B
30,0÷510,0
60,0
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Page 46
6.2.8 Check and overhaul of the fuel pump
Disassemble the oil pump before checking or
overhauling. See “Disassembling the oil
pump” for the correct procedure.
1 - Remove the plate (A).
2 - Remove the O-ring (B).
OVERHAULS AND TUNING
A
6
3 - Remove the sealing ring (C) from the
flange and clean the seat.
4 - Unscrew the oil (D) and extract the gasket
(E), the spring (F) and the valve (G).
5 - Disassemble the rotors (H).
6 - Blow compressed air into the valve seat
to clean it.
7 - Thoroughly clean all the components.
8 - Measure the length of the spring (F).
If the length of the spring is not
between 27.50 and 27.75mm, replace it
with an original spare.
9 - Replace the valve (G), the spring (F),
the gasket (E) and the plug (D).
10 - Fill the sealing ring (C) with grease and
lubricate the rim with oil.
B
G
H
D
F
E
C
A
L
B
C
H
11 - Mount the new sealing ring (C) using a
special tool.
Important
Given the particular function played by this sealing
ring, it is important to use only original spares.
12 - Mount the rotors (H) with the referance notches
facing upwards so that they are visible.
13 - Using a thickness gauge, measure the clearance
between the rotor teeth.
If clearance is above the 0.25mm limit for wear,
replace the rotors with original spares.
14 - Check that the contact surfaces are perfectly
clean, intact and not deformed.
15 - Mount the new O-ring.
Important
The O-ring must always be replaced with an original
spare part whenever the pump is disassembled.
16 - Replace the plate (A) and put in the screws (L).
17 - Tighten the screws (L) to a torque of 10 Nm.
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Page 47
6.2.9 Overhauling the decanting device
OVERHAULS AND TUNING
6
In order to overhaul the decanting device, it
is necessary to disassemble the starter motor .
See “Replacing the starter motor” for the
correct procedure.
1 - Loosen the clamp and extract the pipe
(A).
2 - Remove the cover (B).
3 - Thoroughly clean the inside of the cover
and blow compressed air on the
decanting device (C) to eliminate residues.
4 - Check that the decanting device is intact
and, if necessary, replace it with an
original spare.
5 - Slip ona new gasket (D).
6 - Replace the cover (B) and fix it using the screws.
7 - Replace the pipe (A) and fasten it using the clamp.
A
B
D
C
8 - Mount the starter motor and tighten the screws to a
torque 45 Nm.
6.3 OVERHAUL OF CYLINDER HEAD AND RELA TED COMPONENTS
6.3.1 Checking and overhauling the
cylinder head
1 - Place the cylinder head on a surface
plate and position it with the corners on
the stud bolts.
2 - Using a dial indicator make sure the
cylinder head is level.
Important
If the level deviation is above 0.1mm, the
cylinder head must be ground, removing
not more than 0.2mm.
3 - Before grinding, remove the valves (see
“Disassembling the valves”) and the
precombustion chambers (see
“Disassembling the precombustion
chamber”).
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Page 48
6.3.2 Checking and overhauling the rocker
arm pin
1 - In order to carry out a control of the rocker
arm assembly, it is necessary to
disassemble the cylinder head.
See “Disassembling the rocker arms” for
the correct procedure.
2 - Bore a hole in the blocking pin (A), using
a 4mm bit to remove it.
3 - Extract the supports and the rocker arm
from the pivot pin (B).
OVERHAULS AND TUNING
B
6
4 - Thoroughly clean the components.
5 - Using a micrometer measure, the
diameters of the pivot pin and the rocker
arms (see “Table of dimensions pin-
rocker arm”).
Table of dimensions pin-rocker arm
=bØ-aØ
140,0÷510,0
T ear & wear
limit (mm)
090.0
Ref.
aØ000,81÷989,71
bØ030,81÷510,81
Dimensions
Clearance
(mm)
If the diameters do not correspond to the
values shown, replace the pin and, if
necessary, the rocker arms with original
spares.
If the pin can be re-used, remove the plugs
and clean the inside carefully, to eliminate
residual dirt.
A
6 - Place the new plugs in the pin.
7 - Carefully clean and lubricate the supports
and rocker arms and remount on the pin.
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Page 49
8 - Insert a new pin (E) and drive it in 0÷1
mm from the flat part of the support.
9 - Reassemble the rocker arm assembly in
the cylinder head (see “Assembling the
rocker arms”).
6.3.3 Checking and replacing the camshaft
OVERHAULS AND TUNING
E
6
In order to carry out a control of the camshaft,
it is necessary to disassemble it from the
cylinder head.
See “Disassembling the camshaft” for the
correct procedure.
1 - Using a dial indicator, measure the
diameters of the seats ( Ø X ) and, with a
micrometer, find out the diameters of the
camshaft ( Ø Y ) (see “Table of camshaft
dimensions”).
Table of camshaft dimensions
Ref.
aØ060,73÷530,73
bØ000,73÷579,63
Dimensions
Clearance
(mm)
=bØ-aØ
580,0÷530,0
T ear & wear
limit (mm)
071.0
If the diameters do not correspond to the
values shown, replace the camshaft with an
original spare.
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Page 50
2 - Use a micrometer to measure the
maximum dimensions of the involutes of
the intake, exhaust and injection cams
(see “Table of cam dimensions”).
Table of cam dimensions
OVERHAULS AND TUNING
6
Ref.
H056,92÷895,92
1H000,92÷849,82
If the dimensions of cam involutes are lower
than the values shown by 0.1mm (maximum
dimension), replace the camshaft with an
original spare.
Important
Protect the contact surfaces with lubricant
oil, to prevent them from rusting.
3 - Replace the camshaft (see “Assembling
tha camshaft”).
Dimensions (mm)
6.3.4 Checking and replacing the fuel
pump drive rod
To check the drive rod it is necessary to
disassemble the fuel pump.
See “Disassembling the fuel pump” for the
correct procedure.
1 - Rotate the camshaft until the drive rod is
at the most indented point.
2 - Check that the distance between the
drive rod (A) and the cylinder head is
between 1.66 and 2.18mm. If the
distance does not correspond to this
value, replace the drive rod with an
original spare.
3 - Assemble the fuel pump (see
“Assembling the fuel pump”).
Fuel pump
A
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Page 51
6.3.5 Checking and overhaulimg the valves
OVERHAULS AND TUNING
6
In order to carry out a control of the valves, it
is necessary to remove them from the cylinder
head. See “Disassembling the valves” for the
correct procedure.
1 - Use a gauge to measure the length of the
springs (see “Table of dimensions for
springs – valve stems – valve guides”).
Table of dimensions for springs - valve
stems - valve guides
Ref.
Z0,64÷5,34
W8,0÷5,01,1
J7,1÷6,10,2
Dimensions
(mm)
xØ020,7÷500,7
Clearance
(mm)
Wear &
tear limit
(mm)
01,0yØ099,6÷069,6
cØ-bØ
500,0÷50,0
If the length does not correspond to the value
shown, replace the springs with original
spares.
valve guide
valve
guide
valve guide
2 - Use a micrometer to measure the
diameters of the valve stems and guides
(see “Table of dimensions for springs –
valve stems – valve guides”). If the
diameters do not correspond to the
values show, replace the valves and
guides with original spares.
Important
Take measurements in several places in
order to discover possible ovalization and/
or wear.
3 - Thoroughly clean the valves and their seats.
4 - Measure the width of the seal for each valve (J) and
the indentation (W) from the flat part of the cylinder
head (see “Table of dimensions for springs – valve
stems – valve guides”). If the dimensions do not
correspond to the values shown, replace the valve
seat ring with an original spare.
5 - Use a pointed tool to take out the valve seats.
6 - Remove any debris, clean the valve seat holder
carefully and scrape the mouth.
7 - Lubricate the new valve seats and put them into the
holder manually.
valve seat
8 - Use the special tool to put the valve seats in the
holder.
9 - Slide the valves into their seats.
10 - Measure the degree of indentation of each valve from
the flat part of the cylinder head (see “Table of
dimensions for springs – valve stems – valve
guides”).
Se le dimensioni rilevate corrispondono ai valori
indicati, smerigliare ogni valvola nella propria sede.
Important
Protect the contact surfaces with lubricant oil, to
prevent them from rusting.
11 - Assemble the valves (see “Assembling the flywheel”).
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Page 52
6.3.6 Adjusting valve-rocker arm clearance
In order to make the adjustment, it is
necessary to remove the rocker arm cover.
See “Disassembling the rocker arm cover” for
the correct procedure.
Important
Adjustment of valve clearance must be
done when the engine is cold.
1 - Place the pistons at the compression top
dead centre.
2 - Turn the screw and the lock nut to adjust
clearance. Adjustment can be made in
two different points: the contact area
between the rocker arm and the camshaft
(0.15mm) and/or the contact area
between the rocker arm and the valve
(0.2mm).
OVERHAULS AND TUNING
6
3 - Repeat the same operation on the other
valves.
6.3.7 Checking clearance volume
1 - Position the pistons at the top dead
centre.
2 - Measure the distance in four diametrically
opposite points on the piston crown.
3 - Repeat the operation on all pistons.
The maximum value determines the
measurement (A).
Choose the gasket corresponding to the
measured value. This match determines the
value of the clearance volume (see “Table of
head gasket and clearance volume values”).
A
Table of head gasket and clearance volume values
A (mm)
60,1÷79,00
61,1÷70,11
52,1÷71,12 84,0÷04,0
Number of holes
Clearance
volume (mm)
84,0÷93,0
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Page 53
6.3.8 Calibrating the injector
To carry out setting, the injector pump must
be disassembled from the engine.
Per conoscere la procedura corretta, vedi
“Smontaggio pompe-iniettori”.
1 - Remove the non-return valve (A) and
replace it with the plug supplied with the
“7107-1460-074” tool.
2 - Mount the tool head (B) and fasten with
the screws.
3 - Connect the pump for calibrating the
diesel injectors to the head union.
4 - Press the pump and bring to a pressure
of 130 bars for 10 sec, in order to check
the needle seal. Replace the nozzle (see
“Nozzle-injector replacement”) if there is
any dripping.
5 - Press the pump again and check to see whether the
fuel comes out at a pressure of 140-155 bars (optimal
operating calibration).
6 - If calibration is not optimal, it is possible to modify
the action of spring, using the adjustment shims. The
adjustment shims are available in 11 sizes between
1mm and 2mm, uprated at 0.1mm gaps.
If after inserting the largest adjustment shim (2mm)
optimal calibration is still not achieved, the spring
(see “Nozzle-injector replacement”) must be replaced.
OVERHAULS AND TUNING
Pump
A
Union
B
6
7 - After replacing the spring, calibrate at 10 bars higher
than the optimal operating calibration of 140-155
bars. When the spring settles, the calibration will level
at the optimal value.
8 - Remove the tool “7107-1460-074”.
9 - Replace the non-return valve.
10 - Assemble the injection-pump on the engine (see
“Assemble injection –pumps”).
6.3.9 Checking and overhauling the speed governor
Disassemble the speed governor before checking or
overhauling.
See “Disassembling the speed governor and flow limiter”
for the correct procedure.
Exploded diagram of the speed governor
Caption
1) Oil seal
2) Screw
3) Cover
4) O-ring
5) Ball bearing
6) Plate
7) Screw
8) Weighted support
9) Spacing collar
10) Fith wheel coupling
11) Nut
12) Idle spring
13) Maximum speed ring
14) Barrel
15) Thrust washer
16) Stop ring
17) Pivot
18) Leverage assembly
19) Clearance ring
20) Hose (in some versions)
1 - Use a gauge to make sure that the distance (A) is
between 45 and 46 mm.
2 - Make sure that the contact surfaces (B) are perfectly
level with a deviation of no more than 0.05 mm.
If the deviation is greater than this, replace the speed
governor with an original spare.
A
B
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Page 54
6.4 CHECKING TIMING BEL T RATING
6.4.1 Valve adjustments
OVERHAULS AND TUNING
6
1 - Bring the piston to the compression top
dead centre.
2 - Adjust the screw (A) and the lock nut in
order to adjust the rocker arm valve
clearance to 2 mm.
3 - Rotate the crankshaft clockwise through
360° in order to make the piston reaching
the balancing top dead centre.
4 - Apply a magnetic goniometer on the
crankshaft pulley and set it to zero.
Fan drive pulley
magnetic
goniometer
A
5 - Place two dial indicators on the collars of
the intake and exhaust valves, then set
them to zero.
6 - Rotate the crankshaft clockwise until the
dial indicator moves away from zero.
7 - Measure the rotation angle of the
crankshaft by using the magnetic
goniometer.
The value registered indicates when the
intake valve starts opening.
8 - Go on rotating the crankshaft clockwise
until the dial indicator stops at point “0”.
9 - Measure the rotation angle of the
crankshaft by using the magnetic
goniometer.
The value registered indicates when the
intake valve starts closing.
The values registered must coincide with
those indicated on the timing angle
diagrams (see “Distribution timing angle
diagram”).
Intake
valve
Exhaust
valve
10 - Repeat these procedures on the other
valves.
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Page 55
6.5 DIAGRAM OF TIMING BEL T RATES
Rotate the crankshaft clockwise to find out the
timing rates of the entire cycle in each cylinder
(operation and control).
Timing belt operating angles
(valve clearance 0.25 mm)
αα
α = 14° before S (top dead center)
αα
ββ
β = 38° after I (bottom dead center)
ββ
γγ
γ = 34° before I (bottom dead center)
γγ
δδ
δ = 18° after S (top dead center)
δδ
OVERHAULS AND TUNING
6
Timing belt control angles
(valve clearance 2 mm)
αα
α = 25° after S (top dead center)
αα
ββ
β = closes 2° after I (bottom dead center)
ββ
γγ
γ = 5° after I (bottom dead center)
γγ
δδ
δ = 18° before S (top dead center)
δδ
6.6 ADJUSTING ST ATIC INJECTION TIMING
In order to adjust injection timing, it is
necessary to remove the rocker arm cover.
See “Disassembling rocker arm cover” for the
correct procedure.
1 - Disassemble the injector pump fuel rail
(A).
2 - Select the cylinder on which the injection
static advance adjustment will be carried
out.
Legenda
S = piston at top dead center
I = piston at bottom dead center
α =α =
α = intake valve open
α =α =
β =β =
β = intake valve closed
β =β =
γ =γ =
γ = exhaust valve open
γ =γ =
δ =δ =
δ = exhaust valve closed
δ =δ =
A
B
3 - Unscrew the rocker arm support nut (B)
corresponding to the cylinder on which
the procedure will be carried out.
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Page 56
4 - Assemble the dial indicator on stud bolt
(C).
5 - Place the dial indicator tracer on the
exhaust valve collar.
OVERHAULS AND TUNING
E
D
6
6 - Remove the O-ring (D) from the little non-
return valve and replace it with the suitable
rubber cap (E) (part of tool “7107-1460048”).
7 - Install the tool metal base plate (F).
8 - Remove the rocker arm cover gasket.
9 - Fix the tool lever base (G) on cylinder
head.
10 - Rotate the crankshaft clockwise until the
injection cam acts on the rocker arm that
controls the injector pump.
In these conditions, the piston is near the
compression top dead centre.
11 - Place the auxiliary tank at a height higher
than that of the injectors (~30-40) cm.
12 - Connect the tank to union (H).
dial indicator
C
G
dial indicator tracer
F
H
13 - Rotate slowly the crankshaft clockwise
keeping the lever (L) lowered and the
valve set on the piston crown, until the
dial indicator shows the maximum
L
L
measurement.
14 - Set the dial indicator to zero. In these
conditions, the compression top dead
centre can be identified.
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Page 57
16 - Rotate the crankshaft anticlockwise until
liquid leaks from the pipe (M), and then
stop turning when the flow is constant
and without air bubbles.
17 - Then turn slowly the crankshaft clockwise
in order to identify the exact point at
which liquid stops leaking.
In these conditions, the point which
coincides with the static injection timing
can be identified.
18 - Act again on lever (L) to lower the valve
and bring it again on the piston.
19 - Measure the piston lowering value by
using the dial indicator.
20 - Convert the value registered from
millimetres to degrees (see “Conversion
table for establishing injection timing”).
Important
– When converting, refer to the table value that is
nearest to the registered one (see “Conversion
table for establishing injection timing”).
– For a good engine operation, the injection static
advance must be as follows:
– Engine with maximum speed up to 3000 rpm: 13°
(± 1°)
– Engine with maximum speed above 3000 rpm: 15°
(± 1°)
OVERHAULS AND TUNING
L
M
Conversion table for establishing injection timing
injection advance angle injection advance angle
mm
749,1
937,1
345,1
853,1
481,1
220,1
178,0
°81
°71
°61
°51
°41
°31
°21
mm
337,0
606,0
194,0
883,0
792,0
812,0
°11
°01
°9
°8
°7
°6
6
If the static advance does not correspond to
the ideal values, change the adjustment by
means of the screw (N).
To increase the angular value (higher static
advance), turn the screw clockwise.
To decrease the angular value (lower static
advance), turn the screw anticlockwise.
Important
Half turn of the screw equals approximately
5° of static angular advance.
21 - Disassemble all equipment when the
injection static advance is reached.
22 - Fasten and tighten the nut (B) to a final
torque of 40 Nm.
Important
Repeat on the other cylinder.
N
B
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Page 58
23 - Once adjustment is finished, assemble
the new O-rings (D) on the injector
pumps.
Important
The O-rings must always be replaced with
original spare p arts whenever the fuel rail
is disassembled.
24 - Apply some silicone sealant on the fuel
rail seat.
25 - Assemble the fuel rail and fasten the
screws without tightening them.
26 - Tighten the screws to a final torque of 4
Nm.
27 - Slip on a new gasket (P).
28 - Reassemble the rocker arm cover (see
“Assembling the rocker arm cover”).
OVERHAULS AND TUNING
P
D
6
6.7 BALANCING THE INJECTION-PUMP DELIVERY
Importante
It is necessary to balance delivery whenever
the injection-pump is replaced.
In order to work on the injector, it is necessary
to remove the rocker arm cover.
See “Disassembling the rocker arm cover” for
the correct procedure.
1 - Remove the fuel rail (A).
2 - Mount the “7107-1460-127” tool heads
(B).
A
B
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Page 59
3 - Position the assembly “7107-1460-127"
above the height of the injectors.
4 - Connect the outlet and intake pipes of
the assembly to the test heads.
Important
Be careful not to reverse the intake and
outlet pipes when connecting.
assembly
7107-1460-127
fuel filter
OVERHAULS AND TUNING
C
6
5 - Open the cocks (C).
6 - Start the engine and keep it at minimum
idle speed (~ 1150÷1250 Rpm).
7 - Turn the equipment switching valve by
means of the lever (D).
(The engine is supplied by tubes and no
more by tool tank).
8 - Check the level of the test heads after 1 minute.
9 - Make sure the difference in volume is no greater than
1 cm³.
Important
If the difference is greater, increase
delivery of the injector pump with the
highest level, or reduce the one with the
lowest level.
D
F
E
10 - Loosen the screw (E) to adjust delivery
at the injector.
11 - Shift the plate (F) gently in one of the
two directions. Shift the plate towards the
flywheel to increase delivery. Shift the
plate towards the timing belt to reduce
delivery.
12 - Tighten the screw (E) to a torque of
1.1Nm.
13 - Close the cocks and disconnect the
assembly.
14 - Put the new O-rings on the injector
pumps.
15 - Apply sealant to the seat of the fuel rail.
Important
The O-rings must always be replaced with original
spares whenever the fuel rail is disassembled.
16 - Assemble the fuel rail and fasten the screws without
tightening them completely.
17 - Tighten the screws to a torque of 4Nm.
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Page 60
6.8 ADJUSTING MINIMUM AND MAXIMUM IDLE SPEED RPMS
1 - Connect a revolution counter to the
engine.
2 - Run the engine and bring it to the
operating temperature.
OVERHAULS AND TUNING
C
6
3 - Turn the idle adjusting screw (A) and set
the engine to the minimum speed
required.
4 - Tighten the lock nut (B) when finished.
Important
To decrease the rpm number, loosen the
screw. To increase it, tighten the screw.
5 - Turn the peak-rpm adjusting screw (D)
and set the engine to the maximum speed
required.
6 - Tighten the lock nut (C) when finished.
Important
To decrease the rpm number, tighten the screw
whereas to increase it loosen the screw.
6.9 ADJUSTING INJECTION DELIVER Y
BD
A
The adjustment may be performed with the
dynamometric brake (accurate adjustment) or without it
(approximate adjustment).
6.9.1 Adjusting injection delivery (without
dyno break)
1 - Loosen locknut (A).
2 - Firmly tighten the screw (B) of the flow
limiter.
3 - Start the engine and bring it to the
operating temperature.
4 - Bring the engine to maximim rpm allowed.
5 - Loosen the screw (B) of the flow limiter
until the engine speed starts to decrease.
6 - Retighten the screw rotating it 2.5
revolutions, then fasten with the lock nut
(A).
A
B
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Page 61
6.9.2 Adjusting injection delivery (with
dyno break)
1 - Start the engine and bring it to the
operating temperature.
OVERHAULS AND TUNING
A
6
2 - Bring the engine to maximim rpm
allowed.
3 - Loosen the locknut (A).
4 - Firmly tighten the screw (B) of the flow
limiter.
5 - Activate the dyno brake to bring the
engine to maximum power and speed.
6 - Make sure that fuel consumption
corresponds to the recommended values
(see “Table of specific fuel
consumption”).
If fuel consumption does not correspond to the values
shown, reduce the load of the dyno brake.
7 - After a few minutes of running the engine and when
it has “stabilised”, slowly unscrew the limiter screw
(B) until the speed starts to decrease.
8 - Fasten the screw (B) with the locknut (A).
9 - Deactivate the dyno brake and take note of the
“stabilized” engine speed.
10 - Switch off the engine and leave to cool.
11 - Check the valve-rocker arm clearance (see
“Adjusting valve/rocker arm clearance”).
B
Important
If the engine gives off too many fumes at maximum
load, loosen the flow limiter screw. If it gives off no
fumes or does not achieve maximum power, tighten
the flow limiter screw.
Table of specific fuel consumption
Motor speed
Rpm
002215,5381÷291992÷582
000383,7921÷521523÷513
006327,7511÷021043÷623
Power curve
(a)
NB
wKhwK/g
Specific fuel consumption
Time-secs.
per 100 cc
6.10 CHECKING OIL PREASSURE
1 - Remove the preassure switch (A).
2 - Mount a union in the hole (B) and
connect to a 10-bar pressure gauge (C).
3 - Start the engine and bring it to the
operating temperature.
4 - Start the engine and bring it to a speed
of 900 RPM, while at the same time
making sure that the pressure gauge
shows a pressure of 1 bar (oil
temperature 80÷120 °C).
5 - Switch off the engine.
6 - Remove the pressure gauge (C) and the
union (B).
7 - Replace the pressure switch (A) and
tighten it to a torque of 25Nm.
A
C
B
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Page 62
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Page 63
7.1 RECOMMENDATIONS FOR INSTALLING THE ASSEMBLIES
INST ALLA TION OF ASSEMBLIES
7
– 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 installing
assemblies and/or individual components that have
been checked, overhauled or replaced with original
spare parts.
Important
To locate specific topics, the reader should refer to
the index.
– The operator must wash, clean and dry components
and assemblies before installing them.
– The operator must make sure that the contact surfaces
are intact, lubricate the coupling parts and protect those
that are prone to oxidation.
– 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.
– For safety and convenience, you are advised to place
the engine on a special rotating stand for engine
overhauls.
– Before proceeding with operations, make sure that
appropriate safety conditions are in place, in order to
safeguard the operator and any persons involved.
– In order to fix assemblies and/or components securely ,
the operator must tighten the fastening parts in a crisscross or alternating pattern.
– Assemblies and/or components with a specific
tightening torque must initially be fastened at a level
lower than the assigned value, and then subsequently
tightened to the final torque.
7.2 PRE-ASSEMBL Y OF SEALING RINGS-PISTONS
– Thoroughly clean the pistons and lubricate
the coupling areas.
– Put the sealing rings on the piston in the
order shown in the figure.
Important
– Place the sealing rings with the markings
facing up towards the upper part of the
piston (crown).
– Keep the pistons together with their own
connecting rods and wrist pins.
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Page 64
7.3 PRE-ASSEMBL Y OF CONNECTING RODS - PISTONS
Important
Before pre-assembly , check that the weight
difference between the two connecting
rod-piston-wrist pin assemblies does not
exceed 10 g to prevent weight imbalances.
1 - Lubrificate the wrist pin (A) and the seat
of the small end of the connecting rod
(B).
2 - Place the lock ring (C) on the piston
complete with sealing rings (D).
INST ALLA TION OF ASSEMBLIES
A
B
connecting rod cap
7
Important
Insert the lock rings with the tips pointing
towards the base of the piston with a
tolerance of 15°.
3 - Insert the wrist pin (A) into the piston (D) and install
the connecting rod (B) (complete with cap).
4 - Insert the wrist pin completely and fasten with the
lock ring.
Important
– Make sure the lock rings are positioned correctly
in their seats.
– Lubricate the coupling parts and those that are
prone to oxidation.
7.4 INSTALLING VALVES
D
C
7.4.1 Assembling the valves
Important
tool
717-1460-047
– Make sure that the cylinder head is
perfectly clean and dry.
– Check that all components are intact
and, if necessary, replace them with
original spares.
A
1 - Lubrificate the valve stem sealing ring
(A), insert it into tool “717-1460-047”, and
mount it right into the seat of the valve
guide.
B
2 - Lubrificate the vale stem (B).
3 - Slip the valve into the seats.
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Page 65
4 - Mount the collar (C), the spring (D), the
cup (E) and the half collets (F).
INST ALLA TION OF ASSEMBLIES
F
7
5 - Press down hard on the cup (E), using
the special tool “7107-1460-047” to insert
the half collets (F) into the valve stem
groove.
6 - Release the tool and check that the half
collets are positioned correctly.
If the half collets are not correctly
positioned, repeat the operation.
7 - Repeat the same operation on the other
valves.
7.5 INST ALLA TION OF CRANK GEAR AND CRANKCASE
7.5.1 Installing piston/connecting rod -
engine block
Important
Make sure that the engine block and the
crankcase are perfectly clean and dry.
E
D
C
A1
1 - Assemble the pipe (A) with the oil
suction filter.
2 - Mount the new O-rings (A1).
3 - Carefully clean and lubricate the
cylinders and the connecting rod-piston
assembly (B).
4 - Rotate the sealing rings so that the cuts
have a displacement of about 120°
between them.
Important
In order not to damage the sealing rings
and the contact areas while inserting the
piston into the cylinder, use the special
containment device.
5 - Mount the connecting rod-piston
assembly (B) onto the engine block and
position the connecting rod big ends
along the axis of the crankshaft.
A
B
Important
The piston combustion chamber must be
assembled on the precombustion
chamber.
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7.5.2 Assembling the crankshaft
1 - Mount the half-bearings (C) and the
standard shoulder half-rings (E)
(flywheel side).
Important
– Follow the marks made during the
removal phase.
– The shoulder half-rings must be placed
with the lubrication grooves facing
outwards.
INST ALLA TION OF ASSEMBLIES
E
D
C
C
E
7
C
2 - Lubrificate the half-bearings (C), the
connecting rod big ends (D) and caps
(F).
3 - Carefully lubricate the crankshaft main
journals and crank pins.
4 - Assemble the crankshaft (G).
5 - Replace the connecting rod caps (F) and
put in the screws.
6 - Tighten the connecting rod cap screws
to a temporary torque of 25Nm.
7 - Tighten the connecting rod cap screws
to a final torque of 30 Nm ( 50 Nm x
PROGRESS ).
8 - Assemble the crankcase (see
“Assembling the crankcase”).
9 - Measure the axial clearance of the
crankshaft (see “Measuring crankshaft
axial clearance”).
E
E
C
D
G
F
7.5.3 Assembling the crankcase
Important
– Make sure that the contact surfaces and
engine block
H1
M
related pins are perfectly intact and
clean.
– Make sure there are no foreign bodies
or residual material in the engine block
and crankcase.
1 - Mount the new gaskets (H1- H2) for the
L
engine block contact surface with the
crankcase.
2 - Replace the crankcase (H) and put in
the screws (L-M).
3 - Tighten the screws (L) temporarily in a
crisscross pattern.
H2
H
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4 - Tighten the screws (M) temporarily in
alternating pattern.
5 - Tighten the screws (L) in a crisscross
pattern to a final torque of 50Nm.
6 - Tighten the screws (M) in an alternating
pattern to a final torque of 10Nm.
engine block
H1
INST ALLA TION OF ASSEMBLIES
M
L
7
7.5.4 Measuring crankshaft axial clearance
To measure the axial clearance of the
crankshaft, it is necessary to assemble the
shaft complete with crankcase.
See “Assembling the crankcase” for the
correct procedure.
1 - Using a dial indicator, measure the axial
shift of the crankshaft.
Axial shift must be between 0.130 and
0.313mm. If axial shift is above these
values, it is necessary to insert uprated
shoulder half-rings and once again
disassemble the crankcase (see
“Dimensional check and overhaul of
crankshaft”).
H2
H
7.5.5 Assembling the crankshaft flange
(flywheel side)
1 - Clean the flange and the sealing ring seat
(N).
2 - Using the special pad, insert a new
sealing ring (N) into the flange (Q).
Important
Given the particular function played by this
sealing ring, it is important to use only
original spares.
3 - Check that the contact surfaces are
perfectly clean and intact.
P
Q
R
N
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4 - Slip on a new gasket (P).
5 - Replace the falnge (Q) and put in the
screws (R).
Important
INST ALLA TION OF ASSEMBLIES
P
7
Be careful not to damage the sealing rings
during this operation.
6 - Tighten the screws (R), in a crisscross
pattern to a final torque of 12Nm.
7.5.6 Installing the oil pump
Before installing the oil pump, make sure there
are no malfunctions (see “Check and overhaul
the oil pump”).
Important
Check that the contact surfaces are
perfectly clean and intact.
Q
R
N
A
B
1 - Slip on a new gasket (A).
2 - Insert the oil pump activation key into the
crankshaft.
3 - Bring piston number one (flywheel side)
to the top dead centre, with the oil pump
activation key in line with break in the
flange, in order to be able to assemble
the pump.
4 - Install the pump (B) and put in the screws
(C).
Important
Be careful not to damage the sealing rings
during this operation.
C
E
D
oil pump activation
key
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5 - Tighten the screws in a crisscross pattern,
and tighten each of them to their
respective final torques (see image).
6 - Insert the key (D) into the crankshaft.
7 - Install the alternator support (E) and
tighten the screws to a torque of 2.2Nm.
7.5.7 Assembling the flywheel
INST ALLA TION OF ASSEMBLIES
E
D
oil pump activation
key
7
1 - Install the support (F) and tighten the
screws to a torque of 25 Nm.
2 - Install the flywheel (G) and put in the
screws (H).
3 - Tighten the screws temporarily in a
crisscross pattern.
F
4 - Tighten the screws in a crisscross pattern
to a final torque of 80Nm.
Important
Turn the flywheel manually to check the
movement of the mechanical parts.
G
H
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7.6 INSTALLATION OF CYLINDER HEAD AND COMPONENTS
7.6.1 Assembling the precombustion
chamber
Important
INST ALLA TION OF ASSEMBLIES
7
Check that the contact surfaces are
perfectly clean and intact.
1 - Install the precombustion chamber (A),
so that its hole (H) coincides with the one
on the pre-heating glow plug.
2 - Insert tool “7107-1460-031” into the seat
of the preheating glow plug in order to
lock the chamber while the ring nut (B)
is being tightened.
3 - Apply some anti-seize product to the ring
nut thread (B) and to the surface that is
in contact with the precombustion
chamber.
4 - Mount the ring nut (B).
5 - Tighten the ring nut to a temporary torque
of 100Nm.
6 - Make sure that the precombustion
chamber protrusion (C) is between
3.56÷4,04 mm. If the protrusion (C)
exceeds the recommended value, insert
a shim (D) (provied ad spare part)
beneath the precombustion chamber (A).
A
tool 7170-1460-031
H
C
D
B
7 - Tighten the ring nut to a final torque of
180Nm.
8 - Remove the tool and install the
preheating glow plug (E).
9 - Tighten the glow plug to a torque of 20
Nm.
10 - Repeat the same operations on the other
chamber.
11 - Connect the glow plug power supply
cable (F).
F
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E
Page 71
7.6.2 Assembling cylinder head
Important
– Make sure there are no foreign bodies
or residual material in the cylinder head
cavity.
– Check that the contact surfaces are
perfectly clean and intact.
1 - Slip on a new gasket (G).
2 - Choose the gasket shim to be installed
(see “Check clearance volume”)
INST ALLA TION OF ASSEMBLIES
L
H
7
3 - Make sure that the length of the screws
(H) does not exceed 92mm, otherwise
replace.
4 - Lubricate the screws copiously (H).
5 - Mount the cylinder head (L) and put in
the screws (H).
6 - Tighten the screws in sequence (see
diagram) to a temporary torque of 40
Nm.
Important
Use a torque wrench with an angle torque tool to
tighten the screws.
7 - Tighten the screws further clockwise, rotating 90°.
8 - Tighten the screws to their final torque, rotating 90.
G
Important
If the screws (H) belong to 10.9 class, the tightening
torque is 60Nm and it is not necessary to tighten them
further.
7.6.3 Assembling the camshaft
Important
Make sure that the camshaft and it’s
housing are perfectly intact and clean.
1 - Lubricate the camshaft (A) and its
housing.
2 - Insert the camshaft into its housing.
3 - Mount a new O-ring onto the cover (B).
4 - Mount the cover (B) and tighten the
screws to a torque of 10 Nm.
A
B
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7.6.4 Assembling the speed governor and
flow limiter
INST ALLA TION OF ASSEMBLIES
7
Important
– Make sure that all components are
perfectly clean and dry.
– Check that all components are intact
and, if necessary, replace them with
original spares.
1 - Mount the levers (C) and pivot them with
the screw (D) to a torque of 0.70 Nm.
2 - Install the flow limiter.
3 - Mount the rotation components onto the
camshaft.
Important
The rotation components are produced in
several versions. Consult the diagram
when mounting.
D
flow limiter
C
H
1 - Mount the weights assembly (H) onto the
camshaft.
Carry out this operation with the weights
open so that they close on the flat part of
the spacing collar.
2 - Check that all the components of the
cover (L) are intact and, if necessary,
replace them with original spares.
Important
Make sure that the contact surfaces are
perfectly intact and clean.
3 - Mount the new O-ring on the cover (L).
4 - Mount the cover (L) and fasten the
screws without tightening them.
5 - Tighten the screws in an alternating
pattern to a final torque of 10 Nm.
hose
hose
Governor counterweight
entire support
L
L
Important
Check that the camshaft has no axial
clearance.
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7.6.5 Assembling injection-pumps
INST ALLA TION OF ASSEMBLIES
7
Important
– Check that all components are intact
and, if necessary, replace them with
original spares.
– Before replacing the injectors it is
always necessary to replace the
flameproof bulkhead, the copper gasket
and the oil and diesel O-ring seals.
– Always make sure that the injectors are
calibrated correctly (see “Calibrating
and replacing the injector”).
1 - Insert the flameproof bulkhead (M) in the
injector seat, with the flat part directed
as in the drawing.
2 - Grease the copper gasket (N) and the
oil O-ring seals (N1) copiously.
3 - Install the injector pumps (Q) and fasten
the nuts without tightening them.
4 - Tighten the nuts to a temporary torque
of 10 Nm.
5 - Tighten the nuts to a final torque of 20
Nm.
6 - Hook the connecting rod (R) to the
adjustment levers and, fasten the injector
pumps without fully tightening the
screws.
7 - Tighten the screws to a final torque of
1,1 Nm.
8 - Hook the spring (S).
P
M
N1
N
R
S
Q
Important
The following procedures must be
performed only if pumps have been
replaced. Otherwise, go directly to point
13.
Prepare the injector pumps for running the
engine, as explained below.
9 - Loosen the screws (T) of every injection
pump.
10 - Move the plates (U) fully towards the
flywheel side in order to maximise the
injector delivery.
U
R
T
S
S
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Page 74
11 - Tighten the screws (T) to a torque of 1,1
Nm.
INST ALLA TION OF ASSEMBLIES
U
7
12 - Balance the injector deliveries (see
“Balancing injector pump deliveries”).
13 - Put the new O-rings on the injector
pumps.
14 - Apply sealant to the seat of the fuel rail.
15 - Assemble the fuel rail and fasten the
screws without tightening them.
R
T
S
S
fuel rail
16 - Tighten the screws to a final torque of
4Nm.
17 -Mount the rocker arm cover (see
“Assembling the rocker arm cover”).
7.6.6 Assembling the mechanical fuel pump
Important
– Check that the contact surfaces are
perfectly clean and intact.
– Make sure that the length of the drive
rod is between 153,15÷153,25 mm,
otherwise replace it.
1 - Insert the drive rod (V).
2 - Mount a new O-ring (W).
3 - Install the fuel pump (Z) and fasten the
nuts without tightening them.
4 - Tighten the nuts to a final torque of
22Nm.
5 - Connect the pipes to the pump.
V
W
Z
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7.6.7 Assembling the rocker arms
Important
Check that the contact surfaces are
perfectly clean and intact.
1 - Press down hard on the pump stroke to
insert the pin, which facilitates assembly
of the drive rods (B).
2 - Mount the rocker arm assembly (A).
3 - Insert the pump injector activation drive
rods (B).
4 - Tighten the nuts by hand.
5 - Tighten the nuts to a temporary torque
of 20 Nm.
6 - Tighten the screws in an alternating
pattern to a final torque of 40 Nm.
INST ALLA TION OF ASSEMBLIES
A
B
7
7 - Remove the pins and check that the
rocker arms (B) have been inserted
correctly.
7.6.8 Assembling the rocker arm cover
Important
– Make sure that the rocker arm cover is
perfectly clean and dry.
– Check that the contact surfaces are
perfectly clean and intact.
1 - Slip on a new gasket (C).
2 - Apply some silicone sealant on the fuel
rail seat (D).
3 - Mount the cover (E) and fasten the
screws without tightening them.
E
F
C
D
4 - Tighten the screws in a crisscross pattern
to a final torque of 9 Nm.
5 - Assemble the negative-pressure vent
valve (F).
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7.7 INST ALLING THE TIMING BELT DRIVE
7.7.1 Assembling the timing belt pulley
INST ALLA TION OF ASSEMBLIES
7
1 - Insert the key (B) into the crankshaft.
2 - Mount the pulley (A).
3 - Mount the pulley (C) and tighten the
screw to a torque 80 Nm.
Important
To ensure the correct timing, line up the
reference notches on the pulley (A-C) with
the respective gear timing notches (X-Y).
7.7.2 Assembling the timing belt
1 - Insert the belt into the pulley (C). Keeping
it taut, insert into pulley (A).
C
B
A
X
A
C
G
Y
C
C
G
Important
– Keep the reference arrows (G) directed
E
as shown in the diagram.
– The timing belt must always be replaced
F
with an original spare part whenever it
is removed.
2 - Keep the belt inserted into the two pulleys
and then mount it onto pulley (E) and the
pulley nut (F).
3 - Tighten the belt using the pulley nut (F)
and fasten temporarily.
Important
To maintain engine timing while the timing belt is
being installed, keep it slotted onto the two pulleys
(A-C), which must remain lined up with their notches.
belt
A
A
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Page 77
4 - Insert tool “7107-1460-049” in the
tensioner holder lever.
5 - Calibrate the torque wrench to 20 Nm
and insert it into the tool, with the lever
perpendicular to the belt.
6 - Loosen the nut slightly (D).
7 - Turn the torque wrench clockwise to
tighten the belt to 20 Nm. Once the
specified torque is reached (20 Nm),
tighten the nut (D) temporarily without
allowing the belt tension to loose.
8 - Mount the pulley (G1).
tool
7107-1460-049
D
INST ALLA TION OF ASSEMBLIES
tensioner
holder
7
9 - Tighten the nut (D) to a final torque of
40Nm.
10 - Rotate the crankshaft a few times to
settle and position the belt correctly.
11 - Before doing so, make sure that the
pulley notches (crankshaft and camshaft)
are lined up with their respective timing
notches.
12 - Insert the tool again into the lever on the
pulley nut support and repeat all the steps
to check belt tension.
13 - Disassemble the pulley (G1).
7.7.3 Assembling the belt drive cover
1 - Mount the guard (G), without tightening
the screws completely.
2 - Tighten the screws in an alternating
pattern to a final torque of 10 Nm.
D
G1
H1
Important
If replacement of the optional dust guard
rings (H-H1) and the peripheral sleeve
becomes necessary for technical or
construction reasons, please request the
pre-assembled guard (G) complete with
rings and gaskets.
G
H
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Page 78
7.8 INST ALLATION OF THE COOLING FAN BEL T DRIVE
7.8.1 Assembling the fan belt drive pulleys
1 - Check that all components are intact
and, if necessary, replace them with
original spares.
2 - Mount the pulley (G1) and fasten the
screws without tightening them.
3 - Tighten the screws in a crisscross
pattern to a final torque of 10 Nm.
4 - Mount tool “7107-1460-051” to inhibit
rotation of the crankshaft.
INST ALLA TION OF ASSEMBLIES
G1
7
5 - Apply some anti-seize product to the
screw thread (L).
Caution - Warning
The screw is left-handed. Turn
anticlockwise to screw.
6 - Tighten the screw (L) to a torque of 180
Nm.
7 - Remove the tool (M).
8 - Install the starter motor (N) and tighten
the screws to a torque of 45 Nm.
M
L
N
M
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9 - Mount the pulley (P), washers and
spacer.
INST ALLA TION OF ASSEMBLIES
7
10 - Tighten the screw (Q) to a torque of 25
Nm.
7.8.2 Assembling the fan belt drive
The engine may have an external or internal
alternator.
With internal alternator
P
Q
With internal alternator With external alternator
R
R
1 - Install the belt, flange and the pulley hub
(R).
2 - Tighten the screws (S) to a torque of 10
Nm.
3 - Carry out belt tension (see “Replacing
alternator/fan belt”).
With external alternator
1 - Install the flange and the pulley hub (R).
2 - Tighten the screws (S) to a torque of 10
Nm.
3 - Install the belt (T).
4 - Tighten the belt (T) (see “Replacing the
alternator – fan belt”).
S
T
S
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7.8.3 Assembling the cooling fan
INST ALLA TION OF ASSEMBLIES
7
1 - Check that the fan is intact and, if
necessary, replace it with an original
spare.
2 - Install the cooling fan (U).
3 - Tighten the screws to a torque of 10 Nm.
screw
7.9 INST ALLING INT AKE AND EXHAUST MANIFOLDS
7.9.1 Assembling exhaust manifold
1 - Make sure that the manifold ducts are
clean and intact.
2 - Check that the contact surfaces are
perfectly clean and intact.
3 - Eliminate any blockages in the ducts.
4 - Put on the new gaskets (A).
5 - Mount the manifold (B) without tightening
the nuts completely.
6 - Tighten the screws in an alternating
pattern to a final torque of 25 Nm.
U
A
B
7.9.2 Assembling the intake manifold
minimum-maximum
Air filter (square type)
1 - Check that the contact surfaces are
C
D
device
perfectly clean and intact.
2 - Eliminate any blockages in the ducts.
3 - Slip on a new gasket (D).
4 - Bring the manifold (C) up to the cylinder
F
governor spring
head and hook on the minimum-
maximum device or the governor spring.
5 - Install the manifold (C) without tightening
the screws (F) completely.
6 - Tighten the screws in an alternating
pattern to a final torque of 25 Nm.
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7 - Clean the cover (H) witha a jet of air.
8 - Check the state of the filter cartridge (G).
If necessary , remove the cartridge, knock
it repeatedly against a flat surface to
eliminate dirt and clean with a jet of air.
9 - Return the cleaned filter cartridge or
replace it with an original spare.
Caution - Warning
Do not use liquids to clean the filter
cartridge.
10 - Replace the cover (H) and re-hook it
carefully into place.
INST ALLA TION OF ASSEMBLIES
H
G
7
Air filter (cylindrical type)
1 - Check that the contact surfaces are
perfectly clean and intact.
2 - Eliminate any blockages in the ducts.
3 - Slip on a new gasket (L).
4 - Bring the manifold (M) up to the cylinder
head and hook on the minimum-
maximum device.
5 - Install the manifold (M) without
tightening the screws (N) completely.
6 - Tighten the screws in an alternating
pattern to a final torque of 25Nm.
7 - Check the state of the filter cartridge.
If necessary, remove the cartridge and
clean with a jet of air.
8 - Return the cleaned filter cartridge or
replace it with an original spare.
P
L
M
N
minimum-maximum
device
governor spring
Caution - Warning
Do not use liquids to clean the filter cartridge.
9 - Replace the filter housing.
10 - Mount the cover (P).
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Page 82
INST ALLA TION OF ASSEMBLIES
Notes :
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8.1 RACCOMMENDA TIONS FOR REPLACING P ARTS
REPLACING P ARTS
8
– This chapter describes the procedures for replacing a
number of components and/or assemblies which are
not recommended for repairs.
– Some of these operations are also contained in the
user’s operation and maintenance manual.
– 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.
8.2 REPLACING THE AL TERNATOR - F AN BEL T
Important
Replacement may be carried out with the
engine installed on the machine.
The engine may have an external or internal
alternator.
– 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.
Important
To locate specific topics, the reader should refer to
the index.
With external alternator
1 - Switch off the engine and leave to cool.
2 - Loosen the nuts (B - B1).
3 - Loosen the belt by adjusting the
alternator manually and tighten the nut
(B1).
4 - Slip off the belt (D) and replace it with an
original spare.
B
B1
D
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Page 84
5 - Adjust the alternator manually while at
the same time tightening the screw to
regulate belt tension.
Important
REPLACING P ARTS
8
Use the method shown in the diagram to
check belt tension. The resultant (R) must
be 10÷15 mm.
6 - Tighten the nuts (B -B1) to a final torque
of 40 Nm and 25 Nm respectively.
With internal alternator
1 - Switch off the engine and leave to cool.
2 - Remove the cooling fan.
3 - Remove the hub and flange.
4 - Slip off the belt and replace it with an
original spare.
B
R
belt
alternator
B1
flange
cooling fan
fan hub pulley
5 - Install the flange and pulley hub.
6 - Manually rotate the fan to make sure the
belt is fitted correctly.
7 - Tighten the screws to a torque of 10 Nm.
8 - Regolare la tensione della cinghia.
flange
fan hub pulley
cooling fan
Important
– To check the belt tension, follow the
procedure explained in the figure. The
resultant (R) must be 10÷15 mm.
– If the belt is too tense, insert a spacer
between the flange and the pulley, or
remove a spacer if it is too slack.
R
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Page 85
9 - Install the cooling fan.
REPLACING P ARTS
8
10 - Tighten the screws to a torque of 10 Nm.
fan hub pulley
8.3 REPLACING THE TIMING BELT
Important
Replacement may be carried out with the engine
installed on the machine.
1 - Switch off the engine and leave to cool.
cooling fan
flange
R
4 - Replace the timing belt with an original spare (see
“Assembling the timing belt drive”).
5 - Check the timing belt rating (see “Checking timing
belt rating”).
2 - Disassemble the cooling fan belt drive (see
“Removing the cooling fan belt drive”).
3 - Disassemble the timing belt drive (see “Removing
the timing belt drive”).
8.4 REPLACING THE OIL FILTER
Important
Replacement may be carried out with the
engine installed on the machine.
1 - Switch off the engine and leave to cool.
2 - Prepare a receptacle to catch leaks.
3 - Remove the filter (A) using the special tool.
4 - Lubricate the new filter seal with engine
oil.
5 - Install and tighten the filter manually.
6 - Mount the belt drive cover (see “Assembling the belt
drive cover”).
7 - Replace the cooling fan belt drive (see “Installation
of the cooling fan belt drive”).
A
Important
Polluting substances should be disposed
of properly , in full compliance with the law.
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Page 86
8.5 REPLACING THE AIR FILTER
Important
– Polluting substances should be disposed
of properly, in full compliance with the
law.
– Replacement may be carried out with the
engine installed on the machine.
Air filter (square type)
1 - Switch off the engine and leave to cool.
2 - Remove the cover (A).
REPLACING P ARTS
B
8
3 - Extract the cover that is to be replaced (B).
4 - Clean the cover with a jet of air.
5 - Replace the cartridge with an original
spare.
6 - Mount the cover and hook it carefully into
place.
Air filter (cylindrical type)
1 - Switch off the engine and leave to cool.
2 - Remove the cover (C).
3 - Extract the cover that is to be replaced (D).
4 - Clean the cover with a jet of air.
5 - Replace the cartridge with an original
spare.
A
C
D
6 - Mount the cover and hook it carefully into
place.
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Page 87
8.6 REPLACING THE AL TERNA TOR
Caution - Warning
Replacement may be carried out with the
engine installed on the machine.
REPLACING P ARTS
8
1 - Switch off the engine and leave to cool.
2 - Disconnect the battery.
3 - Disconnect the electrical connectors.
4 - Loosen the nut (A).
5 - Loosen the belt (C) by adjusting the
alternator (B) manually.
6 - Slip the belt (C) off the alternator pulley.
7 - Remove the alternator and replace it with
a new one.
8 - Insert the belt into the alternator pulley.
8.7 REPLACING THE ST ARTER MOTOR
Caution - Warning
C
9 - Regulate belt (C) tension (see “Replacing alternator
– fan belt”).
10 - Reconnect the electrical connectors.
A
C
B
B
Replacement may be carried out with the
engine installed on the machine.
1 - Switch off the engine and leave to cool.
2 - Disconnect the electrical connectors.
3 - Remove the starter motor.
Important
If in order to take care of the problem it is
necessary to remove the motor, please
refer to an authorised BOSCH service
centre.
4 - Install the starter motor (A) and tighten the screws.
5 - Tighten the screws to a final torque of 40 Nm.
6 - Make sure that the distance (B) is between 17,5÷19,5
mm.
7 - Reconnect the electrical connectors.
B
A
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Page 88
8.8 REPLACING THE FL YWHEEL RING GEAR
In order to replace the ring gear, it is necessary
to disassemble the flywheel.
See “Disassembling the flywheel” for the
correct procedure.
1 - Cut the ring gear (A) in several places
using a chisel and remove it.
Important
Remove any debris and carefully clean the
ring gear.
2 - Heat the new ring gear uniformly and
keep it at a temperature of 300°C
for15÷20 minuti.
Caution - Warning
Risk of burning: be careful of hot surfaces.
REPLACING P ARTS
A
B
4 - Leave to the ring gear to cool gently before
reassembling the flywheel.
8
3 - Insert the ring gear into its seat and place it carefully
on the rim of the flywheel (B).
8.9 REPLACING THE COOLANT THERMOST A T
Important
Replacement may be carried out with the
engine installed on the machine.
1 - Switch off the engine and leave to cool.
2 - Disconnect the electrical connectors.
3 - Remove the thermostat.
Important
The screw is left-handed, turn clockwise
to unscrew.
4 - Install the new thermostat.
thermostat
5 - Tighten the thermostat to a torque of 30 Nm.
Important
The screw is left-handed, turn anti-clockwise to
tighten.
6 - Reconnect the electrical connectors.
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Page 89
8.10 REPLACING THE COOLANT PUMP
Important
Replacement may be carried out with the
engine installed on the machine.
1 - Switch off the engine and leave to cool.
2 - Disassemble the cooling fan (see
“Removing the cooling fan belt drive”).
3 - Disassemble the timing belt drive (see
“Removing the timing belt drive”).
4 - Disassemble the coolant pump.
5 - Install a new pump and tighten the
screws to a torque of 20 Nm.
Important
Coolant pump
REPLACING P ARTS
8
Following a failure, the coolant pump cannot be
repaired and must be replaced with an original spare.
8.11 REPLACING THE THERMOSTA TIC V AL V E
Important
Replacement may be carried out with the
engine installed on the machine.
1 - Switch off the engine and leave to cool.
2 - Remove the cover.
3 - Remove the valve and make sure it is
working properly.
Important
The valve must be heated in order to check
weather it is functioning correctly.
- Dip the thermostatic valve in a metal
container of water.
- Use a thermometer with a full scale of
150°C to monitor the temperature of the
water in the container.
- Heat the water and, using the thermometer, make
sure that the temperature at which the valve begins
to open is between 78 and 82°C.
- If the thermostatic valve opens at a different
temperature, it must be replaced.
- Maintaining the conditions described above, heat
the water to 94°C and check whether or not the valve
is completely open at this temperature, i.e. that it
has lifted to 7mm.
cover
spring
thermostatic valve
- Check whether the valve is completely shut once it
has cooled down.
If the length does not correspond to the value shown,
replace the valve spring with an original spare.
4 - Mount the cover and fasten the screws.
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Page 90
8.12 REPLACING THE NEGATIVE-PRESSURE VENT VAL VE
REPLACING P ARTS
8
Important
Replacement may be carried out with the
engine installed on the machine.
1 - Switch off the engine and leave to cool.
2 - Loosen nut (A).
3 - Loosen the clamps and disconnect the
pipes.
4 - T ake off the negative-pressure vent valve
(B).
5 - Install the negative-pressure vent valve.
6 - Tighten the nut to a final torque of 22Nm.
7 - Connect the pipe to the coupling.
B
A
Caption
1) Nut
2) Bushing
3) V alve body
4) Diaphram
5) Bottom plate
6) Quicklock ring
7) O-ring
8) Collar
9) O-ring
10)Seal collar
11) Spring
12)Gas vent pipe
8.13 REPLACING THE PREHEA TING GLOW PLUGS
Important
Replacement may be carried out with the
engine installed on the machine.
1 - Switch off the engine and leave to cool.
2 - Remove the intake manifold (see
“Disassembling the intake manifold”).
3 - Disconnect the electric cable.
4 - Disconnect the preheating glow plugs.
5 - Install the new preheating glow plugs and
tighten the screws to a torque of 20 Nm.
6 - Reconnect the electric cable.
7 - Mount the intake manifold (see
“Assembling the intake manifold”).
pre-heating glow plugs
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Page 91
8.14 REPLACING INJECTOR PUMP PARTS
Exploded diagram of the injector pump
The figure shows the injector pump parts.
Caption
1) T ension washer
2) T appet
3) Stop collar
4) Plunger
5) Spring
6) Screw
7) Support
8) Lever
9) Ring nut
10) O-ring
11) Barrel
12) Delivery valve
13) Gland
14) Spring
15) Filler
16) Pin
17) O-ring
18) Non-return valve
19) O-ring
20) Metal gland
(new type)
21) Ring nut
23) Nozzle
24) Spacer
25) Preassure rod
26) Spring
27) Setting adjusting shim
28) Injector case
29) Control blade
REPLACING P ARTS
30) Plunger guide
31) O-ring
32) Copper gland
8
8.14.1 Pumping element replacement
1 - Press down hard on the pump collar to fit
the pin (A).
2 - Disassemble the lock ring (1).
3 - Press down hard on the pump collar to
remove the pin (A).
4 - Remove the parts (2-3-4-5).
5 - Loosen the screws (6).
6 - Disassemble the support (7) and the lever
(8).
7 - Insert tool “7107-1460-029” and
disassemble the ring nut (9).
Important
Rotate in an alternating way the ring nut
during disassembling to avoid damaging
the O-ring (10).
8 - Extract the barrel (11), the valve (12) as
well as the parts (13-14-15).
tool “7107-1460-029”
9
delivery valve (12)
sealing surfaces
B
G
1
A
3
5
6
10
11
13
15
2
4
7
8
9
12
14
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Page 92
9 - Check the good seal of the delivery
valve (12) as well as of the pumping
element (parts 4-11). If necessary,
replace them with original spare parts.
10 - Assemble all parts (15-14-13).
REPLACING P ARTS
1
A
3
2
4
8
11 - Assemble the delivery valve (12).
Important
The needle (B) and the valve seat (C) must
be assembled as shown in the figure.
12 - Assemble the barrel (11) and tighten the
ring nut (9) provided with a new O-ring
(10).
Important
Rotate in an alternating way the ring nut
during assembling to avoid damaging the
O-ring (10).
13 - Assemble in sequence all parts (5-4-3-
2) on the support (7).
14 - Press down part (2) to fit the pin (A).
15 - Reassemble the stop ring (1).
tool 7107-1460-029
9
delivery valve (12)
sealing surfaces
B
5
6
10
11
13
15
C
7
8
9
12
14
16 - Rotate the plunger (4) by means of the
control blade (29) as shown in the figure.
17 - Insert the lever (8) and engage it in the
plunger (4).
Caution - Warning
Check that the position of both lever (8)
and plunger control blade (29) is the same
as that shown in the figure.
If the control blade is positioned in a
different way, the engine may not run.
18 - Tighten the screws (6) to join the support
to the injector pump case .
19 - Press down hard on the pump collar to
remove the pin (A).
8
9
29
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Page 93
8.14.2 Replacing nozzle-injector
REPLACING P ARTS
8
Important
Replacement may be carried out with the
engine installed on the machine.
1 - Disassemble the injection pump (see
“Disassembling injection pumps”).
2 - Loosen the ring-nut (21 ).
3 - Extract the nozzle (23) and the parts (24-
25-26-27).
4 - Check that all components are intact and,
if necessary, replace them with original
spare parts.
5 - Reassemble the parts (27-26-25-24).
6 - Assemble a new nozzle (23).
7 - Tighten the ring nut (21) to a final torque
of 70 Nm.
Important
Check the setting (see “Injector pump setting”) since
it could be necessary to replace the adjusting shim
(27) and the spring (26).
21
23
24
25
26
27
21
8 - Repeat the same operation on the other injector.
9 - Assemble the injector pump (see “Injector pump
assembly”).
8.15 REPLACING THE COOLING FAN SUPPORT
Important
Replacement may be carried out with the
engine installed on the machine.
1 - Switch off the engine and leave to cool.
2 - Disassemble the cooling fan belt drive
(see “Removing the cooling fan belt
drive”).
3 - Remove the belt drive cover (see
“Disassembling timing belt casing”).
4 - Remove the support (A).
5 - Install the new support.
6 - Tighten the screws (B) to a torque of 20
Nm.
7 - Mount the belt drive cover (see “Assembling the belt
drive cover”).
B
A
8 - Replace the cooling fan belt drive (see “Installation
of the cooling fan belt drive”)
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Page 94
REPLACING P ARTS
Notes :
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Page 95
A
ACEA S tandards, .............................................................................. 14
Adjusting injection delivery, .............................................................. 60
Adjusting injection delivery (with dyno brake) .................................. 61
Adjusting injection delivery (without dyno brake), ............................ 60
Adjusting minimum and maximum idle speed rpms, ....................... 60
Adjusting static injection timing,....................................................... 55
Adjusting valve-rocker arm clearance,.............................................. 52
Air filter, replacing,............................................................................ 86
Alternator - fan blet, replacing, ......................................................... 83
Alternator load curve diagrams, ........................................................ 13
Alternator, replacing,......................................................................... 87
API/MIL sequences,.......................................................................... 14
Assembling injection – pumps,......................................................... 73
Assembling the belt drive cover,....................................................... 77
Assembling the camshaft, ................................................................ 71
Assembling the cooling fan,.............................................................. 80
Assembling the crankcase,............................................................... 66
Assembling the crankshaft,............................................................... 66
Assembling the crankshaft flange (flywheel side),............................ 67
Assembling the cylinder head,.......................................................... 71
Assembling the exhaust manifold , ................................................... 80
Assembling the fan belt drive , ......................................................... 79
Assembling the fan belt drive pulleys, .............................................. 78
Assembling the flywheel, .................................................................. 69
Assembling the intake manifold,....................................................... 80
Assembling the mechanical fuel pump, ........................................... 74
Assembling the precombustion chamber, ........................................ 70
Assembling the rocker arm cover, .................................................... 75
Assembling the rocker arms, .............. ...... ...... .................................. 75
Assembling the speed governor and flow limiter, ............................. 72
Assembling the timing belt , ............................................................. 76
Assembling the timing belt pulley,.................................................... 76
Assembling the valves, ..................................................................... 64
B
Balancing injection-pump delivery, ................................................... 58
Bearings, ........................................................................................... 41
Belt drive cover, assembling,............................................................ 77
C
Calibrating the injector, ..................................................................... 53
Cam dimensions, table, .................................................................... 50
Camshaft dimensions, table, ............................................................ 49
Camshaft, assembling, ..................................................................... 71
Camshaft, checking and replacing, .................................................. 49
Camshaft, disassembling,................................................................. 36
Characteristic curve diagrams, ......................................................... 12
Checking and overhauling the cylinder head, ................................... 47
Checking and overhauling the fuel pump, ........................................ 46
Checking and overhauling the rocker arm pin, ................................. 48
Checking and overhauling the speed governor,................................ 53
Checking and overhauling the valves, .............................................. 51
Checking and replacing the camshaft, ............................................. 49
Checking and replacing the fuel pump drive rod, ............................. 50
Checking clearance volume,............................................................. 52
Checking oil preassure,..................................................................... 61
Checking parallelism of the connecting rod axes, ............................ 45
Checking the timing belt rating,........................................................ 54
Clearance table of sealing rings,....................................................... 43
Clearance volume and head gasket values, table,............................ 52
Clearance volume, checking,............................................................ 52
Clearance, valve - rocker arm, adjusting, ......................................... 52
Connecting rod / piston - engine block, installing,............................ 65
Connecting rod and piston, disassembling,...................................... 39
Connecting rod axes, checking parallelism, ..................................... 45
Connecting rod dimensions, table, ................................................... 45
Connecting rods - pistons, pre-assembly,......................................... 64
Connecting rods and half bearings, table of diameters,.................... 44
Connecting rods, dimensional check and overhaul, ......................... 45
Conversion table for establishing injection timing,............................ 57
Coolant pump, replacing,.................................................................. 89
Coolant thermostat, replacing,.......................................................... 88
Coolinf fan belt drive, removing, ....................................................... 30
Cooling fan belt drive, installation, .................................................... 78
Cooling fan blet (with external alternator), disassembling, ............... 31
Cooling fan blet (with internal alternator), disassembling,................ 31
Cooling fan support, replacing, ......................................................... 93
Cooling fan, assembling, .................................................................. 80
Cooling, operating principle, ............................................................. 15
Crank gear and crankcase, removing, .............................................. 36
Crank gears and crankcase, overhauling,......................................... 41
Crankcase and crank gear, removing, .............................................. 36
Crankcase and crank gears, overhauling,......................................... 41
Crankcase and crankgear, ................................................................ 65
Crankcase and crankshaft, disassembling, ...................................... 38
Crankcase, assembling,.................................................................... 66
Crankgear and crankcase, installation, ............................................. 65
Crankshaft and crankcase, disassembling, ...................................... 38
Crankshaft axial clearanca, measuring, ............................................ 67
Crankshaft flange (flywheel side), assembling,................................. 67
Crankshaft, assembling, ................................................................... 66
Crankshaft, dimensional check and overhaul, .................................. 44
Cylinder - piston classes and dimensions, table,.............................. 42
Cylinder head and components, installation, .................................... 70
Cylinder head and components, overhaul, ....................................... 47
Cylinder head, assembling, .............................................................. 71
Cylinder head, checking and overhauling, ........................................ 47
Cylinder head, disassembling, .......................................................... 36
Cylinder head, removing, .................................................................. 33
Cylinders and pistons, overhauling, .................................................. 41
Cylinders, dimensional check and overhaul, .................................... 42
D
Decanting device, overhauling,......................................................... 47
Diagram of timing belt rates, ............................................................ 55
Dimensional check and overhaul of connecting rods, ...................... 45
Dimensional check and overhaul of crankshaft,................................ 44
Dimensional check and overhaul of cylinders,.................................. 42
Dimensional check and overhaul of pistons,..................................... 42
Dimensional check of sealing rings, ................................................. 43
Dimensional table of sealing rings, ................................................... 43
Disassembling the camshaft,............................................................ 36
Disassembling the connecting rod and piston, ................................. 39
Disassembling the cooling fan belt (with external alternator), .......... 31
Disassembling the cooling fan belt (with internal alternator), ........... 31
Disassembling the crankcase and crankshaft,.................................. 38
Disassembling the cylinder head, ..................................................... 36
Disassembling the exhaust manifold, ............................................... 30
Disassembling the flywheel, ............................................................. 36
Disassembling the fuel pump, .......................................................... 33
Disassembling the injection-pumps,................................................. 34
Disassembling the intake manifold, .................................................. 29
Disassembling the oil pump, ............................................................ 37
Disassembling the piston,................................................................. 40
Disassembling the precombustion chamber,.................................... 34
Disassembling the pulleys (camshaft and crankshaft),..................... 32
Disassembling the rocker arm cover,................................................ 33
Disassembling the rocker arms, ....................................................... 33
Disassembling the speed governor and flow limiter,......................... 35
Disassembling the timing belt, ......................................................... 32
Disassembling the timing belt casing, .............................................. 31
Disassembling the valves, ................................................................ 39
E
Engine and manufacturer identification, ............................................. 5
Engine block - piston/connecting rod, installing, .............................. 65
Establishing injetion timing, conversion table,.................................. 57
Exhasut and intake manifolds, installing,.......................................... 80
Exhaust and intake manifolds, removing, .................. ......... ......... ..... 29
Exhaust manifold, assembling, ......................................................... 80
Exhaust manifold, disassembling, .................................................... 30
Exploded diagram of the Injector pump,........................................... 91
Exploded diagram of the speed governor,......................................... 53
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Page 96
F
Fan belt drive pulleys, assembling, .................................................. 78
Fan belt drive, assembling,............................................................... 79
Flow limiter and speed governor, assembling, ................................. 72
Flow limiter and speed governor, disassembling,............................. 35
Flywheel ring gear, replacing,........................................................... 88
Flywheel, assembling, ...................................................................... 69
Flywheel, disassembling,.................................................................. 36
Fuel injection, operating principle, .................................................... 16
Fuel pump drive rod, checking and replacing, ................................. 50
Fuel pump, checking and overhauling,............................................. 46
Fuel pump, disassembling,............................................................... 33
Fuel pump, mechanical, assembling,............................................... 74
G
General description of the engine, ...................................................... 9
General safety during operating phases, ............................................ 6
General safety regulations, ................................................................. 6
Glossary and terminology,................................................................... 6
H
Half bearings and connecting rods, table of diameters,.................... 44
Handling and lifting, .......................................................................... 25
Head gasket and clearance volume values, table,............................ 52
I
IIdle speed rpms, minimum and maximum, adjusting, .................... 60
Injection - pumps, assembling,......................................................... 73
Injection delivery (with dyno brake), adjusting,................................. 61
Injection delivery (without dyno brake), adjusting,............................ 60
Injection delivery, adjusting,.............................................................. 60
Injection-pump delivery, balancing, .................................................. 58
Injection-pumps, disassembling, ...................................................... 34
Injector pump parts, replacing, ......................................................... 91
Injector pump, exploded diagram, .................................................... 91
Injector, calibrating,........................................................................... 53
Injetion timing, conversion table for establishing,............................. 57
Installation of crankgear and crankcase,........................................... 65
Installation of cylinder head and components,.................................. 70
Installation of the cooling fan belt drive, ........................................... 78
Installing piston/connecting rod - engine block, ............................... 65
Installing the assemblies, recommendations,................................... 63
Installing the intake and exhaust manifolds, ..................................... 80
Installing the oil pump,...................................................................... 68
Installing the timing belt drive,.......................................................... 76
Installing valves,................................................................................ 64
Intake and exhaust manifolds, installing, .......................................... 80
Intake and exhaust manifolds, removing, ......................................... 29
Intake manifold, assembling, ..................... ......... ......... ......... .......... .. 80
Intake manifold, disassembling, ....................................................... 29
L
Looking for malfunctions, .................................................................. 23
Lubricants, ........................................................................................ 14
Lubrification, operating principle,...................................................... 15
M
Maggiorazioni semianelli di spallamento, tabella,............................. 42
Maintenance, engine, routine,........................................................... 21
Maintenance, special tools and equipment,...................................... 19
Malfunctions, looking for, .................................................................. 23
Manufacturer and engine identification, .............................................. 5
Measuring crankshaft axial clearance, .............................................. 67
Mechanical fuel pump, assembling, ................................................. 74
N
Negative-preassure vent valve, replacing, ........................................ 90
Nozzle-injector, replacing,................................................................. 93
O
Oil filter, replacing,............................................................................ 85
Oil preassure, checking, ................................................................... 61
Oil pump, disassembling, ................................................................. 37
Oil pump, installing,.......................................................................... 68
Operating phases, general safety,....................................................... 6
Operating principle for cooling, ......................................................... 15
Operating principle for fuel injection, ................................................ 16
Operating principle for lubrification, .................................................. 15
O-rings, ............................................................................................. 41
Overhaul and dimensional check of connecting rods, ...................... 45
Overhaul and dimensional check, Cylinders,.................................... 42
Overhaul and dimensional check, pistons, ....................................... 42
Overhaul and dimensionalcheck, crankshaft, ................................... 44
Overhaul of cylinder head and components, .................................... 47
Overhauling and checking the cylinder head,................................... 47
Overhauling and checking the fuel pump, ........................................ 46
Overhauling and checking the rocker arm pin, ................................. 48
Overhauling cylinders and pistons, ................................................... 41
Overhauling the crank gears and crankcase,.................................... 41
Overhauling the decanting device, ................................................... 47
Overhauls and tuning, recommendations, ........................................ 41
P
Parallelismo assi biella, controllo,..................................................... 45
Pin - rocker arm dimensions, table, .................................................. 48
Piston - cylinder classes and dimensions, table, .............................. 42
Piston / connecting rod - engine block, installing, ............................ 65
Piston and connecting rod, disassembling, ...................................... 39
Piston, disassembling, ...................................................................... 40
Pistons - connecting rods, pre-assembly,.................. ........ ........ ....... 64
Pistons - sealing rings, pre-assembly, .............................................. 63
Pistons and cylinders, overhauling, .................................................. 41
Pistons, dimensional check and overhaul,........................................ 42
Pre-assembly of connecting rods - pistons,...................................... 64
Pre-assembly of sealing rings - pistons, ........................................... 63
Precautions when the engine is installed on the machine,................. 7
Precautions when the engine is on the rotating stand,....................... 7
Precombustion chamber, assembling, ............................................. 70
Precombustion chamber, disassembling,....................... ........... ....... 34
Pre-heating glow plugs, replacing, ................................................... 90
Preparing the engine for operation (istalled), .................................... 27
Preparing the engine for operation (unistalled), ................................ 26
Protective treatment,......................................................................... 26
Pulleys (camshaft and crankshaft), disassembling,.......................... 32
Pumping element replacement,........................................................ 91
Purpose of the manual,....................................................................... 5
R
Raccomandazioni per l’installazione dei gruppi,............................... 63
Recommendations for installing the assemblies, ............................. 63
Recommendations for overhauls and tuning, ................................... 41
Recommendations for removing the assemblies, ............................. 29
Recommendations for replacing parts, ............................................. 83
Recommended oil,............................................................................ 14
Removing the assemblies, recommendations, ................................. 29
Removing the cooling fan belt drive, ................................................ 30
Removing the crank gear and crank case, ....................................... 36
Removing the cylinder head, ............................................................ 33
Removing the exhaust and intake manifolds, ................................... 29
Removing the timing belt drive, ........................................................ 31
Replaceing the pre-heating glow plugs,............................................ 90
Replacing and checking the camshaft,............................................. 49
Replacing injector pump parts,......................................................... 91
Replacing parts, recommendations, ................................................. 83
Replacing the air filter, ...................................................................... 86
Replacing the alternator, ................................................................... 87
Replacing the alternator - fan belt,.................................................... 83
Replacing the coolant pump, ............................................................ 89
Replacing the coolant thermostat, .................................................... 88
Replacing the cooling fan support, ................................................... 93
Replacing the flywheel ring gear,...................................................... 88
Replacing the negative-preassure vent valve, .................................. 90
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Replacing the nozzle-injector,........................................................... 93
Replacing the oil filter, ...................................................................... 85
Replacing the starter motor, .............................................................. 87
Replacing the theromstatic valve,..................................................... 89
Replacing the timing belt, ................................................................. 85
Rocker arm - pin dimensions, table, ................................................. 48
Rocker arm - valve clearance, adjusting,.......................................... 52
Rocker arm cover, assembling, ........................................................ 75
Rocker arm cover, disassembling,.................................................... 33
Rocker arm pin, checking and overhauling, ..................................... 48
Rocker arm, disassembling, ............................................................. 33
Rocker arms, assembling, ................................................................ 75
Routine engine maintenance, ........................................................... 21
S
SAE Classification, ........................................................................... 14
Safety and environmental impact, ...................................................... 7
Sealants, table, ................................................................................. 21
Sealing rings - pistons, pre-assembly,.............................................. 63
Sealing rings, clearance table,.......................................................... 43
Sealing rings, dimensional check, .................................................... 43
Sealing rings, dimensional table, ...................................................... 43
Shaft seals, ....................................................................................... 41
Special tools and equipment for maintenance,................................. 19
Specific fuel consumption, table,...................................................... 61
Speed governor and flow limiter , assembling, .................................. 72
Speed governor and flow limiter , disassembling,.............................. 35
Speed governor , checking and overhauling, ..................................... 53
Speed governor , exploded diagram,.................................................. 53
Springs - valve stems - valve guides dimensions, table, .................. 51
Starter motor , replacing, ................................................................... 87
Static injection timing, adjusting,...................................................... 55
Storing the engine (installed), ........................................................... 25
Storing the engine (uninstalled), ....................................................... 25
V
Valve - rocker arm clearance, adjusting,........................................... 52
Valve adjustment s,............................................................................ 54
Valve guides - springs - valve stems dimensions, t able, .................. 51
Valve stems - springs - valve guides dimensions, t able, .................. 51
Valves, assembling, .......................................................................... 64
Valves, checking and overhauling,.................................................... 51
Valves, disassembling,...................................................................... 39
Valves, inst alling, .............................................................................. 64
W
Warranty clauses, ............................................................................... 6
Wiring diagram, ................................................................................ 17
T
T abella classi e dimensioni cilindri - pistoni,..................................... 42
T able of cam dimensions, ................................................................. 50
T able of camshaft dimensions, ......................................................... 49
T able of connecting rod dimensions, ................................................ 45
T able of cylinder - piston classes and dimensions,........................... 42
T able of diameters of connecting rods and half bearings,................. 44
T able of dimensions for springs - valve stems - valve guides,.......... 51
T able of dimensions pin-rocker arm,................................................. 48
T able of head gasket and clearance volume values,......................... 52
T able of sealants, .............................................................................. 21
T able of sealing rings clearance,....................................................... 43
T able of specific fuel consumption,................................................... 61
T able of tightening torques,............................................................... 19
T able of uprated shoulder half-rings,................................................. 44
T echnical specifications, ................................................................... 10
T erminology and glossary ,................................................................... 6
Thermostatic valve, replacing, .......................................................... 89
Tightening torques, table, ................................................................. 19
Timing belt casting, disassembling, ................................................. 31
Timing belt drive, installing,.............................................................. 76
Timing belt drive, removing, ............................................................. 31
Timing belt pulley , assembling, ........................................................ 76
Timing belt rates, diagram,............................................................... 55
Timing belt rating, checking, .... .. ... .. ... ... .. ... .. ... ................................. 54
Timing belt, assembling,................................................................... 76
Timing belt, disassembling,.............................................................. 32
Timing belt, replacing, ...................................................................... 85
U
Uprated shoulder half-rings, table,.................................................... 44
Using this manual, .............................................................................. 5
- 97 -Service Manual LDW 502 automotive _ cod. 1.5302.727 - 2° ed_rev. 01
Page 98
SERVICE MANUAL -
code 1.5302.727
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