Service Manual
VF4.140E
VF4.170E
VF5.220E
VF5.250E
VF4
VF5
Marine Diesel Engine
2 402102.01
Service manual VF4 VF5
Copyright © 2009 Vetus N.V. Schiedam
Holland
Reproduction of text and illustrations,
in whole or in part, is strictly prohibited.
The information contained in this
manual is not binding and providing
the basic specication of the model
described herein is not aected VETUS
reserve the right to introduce any
changes in their products without
obligation immediately to update this
publication .
402102.01 3
Service manual VF4 VF5
Contents
1 Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Performance curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Values and ts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1 Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2 Cylinder head and valve gear. . . . . . . . . . . . . . . . . . . . . . . . 12
3.3 Valve timing diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.4 Cylinder head gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.5 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.6 Cooling system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.7 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.8 Supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4 Repair data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.1 Cylinder head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.1.1 Camshaft housing. . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.1.2 Lower cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.1.3 Camshaft housing. . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.2 Crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.2.1 Main journal identication . . . . . . . . . . . . . . . . . . . . . 41
4.3 Engine ywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.4 Crankshaft phonic wheel for rpm and timing sensor replace
with crankshaft removed . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.5 Connecting rod small end bush (one) replace . . . . . . . . . . . . . 57
4.6 Set of pistons, gudgeon pins and seals (replace) . . . . . . . . . . . 59
4.7 Toothed timing belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.8 Fuel lter assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.9 Engine coolant temperature sensor. . . . . . . . . . . . . . . . . . . . 66
4.10 Pressure relief sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.11 Engine rpm sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.12 Cam angle sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.13 Variable geometry turbocharger . . . . . . . . . . . . . . . . . . . . . 70
4.14 Pressure pump support VF4 . . . . . . . . . . . . . . . . . . . . . . . . 73
4.15 Pressure pump support VF5 . . . . . . . . . . . . . . . . . . . . . . . . 76
4 402102.01
Service manual VF4 VF5
Specications1
VF4.140E VF4.170E
Cycle Diesel 4 stroke
Valve gear
With 2 camshaft on the cylinder
head
Fuel system Direct injection common rail
Number of cylinder 4 in line 4 in line
∅
Bore mm 82 82
Stroke mm 90.4 90.4
+ + + . . . =
Total displacement cm
3
1910 1910
+
= CR
Compression ratio 18 : 1 18 : 1
Maximum output CEE
kW (CEE) 103 125
hp (CEE) 140 170
1/min 4000 4000
Maximum torque CEE
Nm (CEE) 301 345
kgm (CEE) 30.1 34.5
1/min 2400 2400
402102.01 5
Service manual VF4 VF5
VF5.220E VF5.250E
Cycle Diesel 4 stroke
Valve gear
With 2 camshaft on the cylinder
head
Fuel system Direct injection common rail
Number of cylinder 5 in line 5 in line
∅
Bore mm 82 82
Stroke mm 90.4 90.4
+ + + . . . =
Total displacement cm
3
2387 2387
+
= CR
Compression ratio 18 : 1 18 : 1
Maximum output CEE
kW (CEE) 162 184
hp (CEE) 220 250
1/min 4200 4200
Maximum torque CEE
Nm (CEE) 401 454
kgm (CEE) 40.1 45.4
1/min 2400 2600
6 402102.01
Service manual VF4 VF5
Performance curves2
kWhp
125
100
75
50
25
150
POWER
175
200
250
225
275
1000 20001500 2500 3000 40003500 4500
RPM
125
100
75
50
25
150
175
200
kWhp
125
100
75
50
25
150
POWER
175
200
250
225
275
1000 20001500 2500 3000 40003500 4500
RPM
125
100
75
50
25
150
175
200
VF4.140E VF4.170E
kWhp
125
100
75
50
25
150
POWER
175
200
250
225
275
1000 20001500 2500 3000 40003500 4500
RPM
125
100
75
50
25
150
175
200
kgmNm
350
300
250
200
150
400
TORQUE
450
500
1000 20001500 2500 3000 40003500 4500
35
30
25
20
15
40
45
50
RPM
kWhp
125
100
75
50
25
150
POWER
175
200
250
225
275
1000 20001500 2500 3000 40003500 4500
RPM
125
100
75
50
25
150
175
200
kgmNm
350
300
250
200
150
400
TORQUE
450
500
1000 20001500 2500 3000 40003500 4500
35
30
25
20
15
40
45
50
RPM
kWhp
125
100
75
50
25
150
POWER
175
200
250
225
275
g/hp·hg/kW·h
350
300
250
200
150
400
FUEL CONSUMPTION
1000 20001500 2500 3000 40003500 4500
RPM
1000 20001500 2500 3000 40003500 4500
RPM
125
100
75
50
25
150
175
200
kgmNm
350
300
250
200
150
400
TORQUE
450
500
1000 20001500 2500 3000 40003500 4500
35
30
25
20
15
40
45
50
RPM
250
200
150
275
125
175
225
kWhp
125
100
75
50
25
150
POWER
175
200
250
225
275
g/hp·hg/kW·h
350
300
250
200
150
400
FUEL CONSUMPTION
1000 20001500 2500 3000 40003500 4500
RPM
1000 20001500 2500 3000 40003500 4500
RPM
125
100
75
50
25
150
175
200
kgmNm
350
300
250
200
150
400
TORQUE
450
500
1000 20001500 2500 3000 40003500 4500
35
30
25
20
15
40
45
50
RPM
250
200
150
275
125
175
225
Performance curves according to ISO 8178.
402102.01 7
Service manual VF4 VF5
VF5.220E VF5.250E
kWhp
125
100
75
50
25
150
POWER
175
200
250
225
275
1000 20001500 2500 3000 40003500 4500
RPM
125
100
75
50
25
150
175
200
kWhp
125
100
75
50
25
150
POWER
175
200
250
225
275
1000 20001500 2500 3000 40003500 4500
RPM
125
100
75
50
25
150
175
200
kWhp
125
100
75
50
25
150
POWER
175
200
250
225
275
1000 20001500 2500 3000 40003500 4500
RPM
125
100
75
50
25
150
175
200
kgmNm
350
300
250
200
150
400
TORQUE
450
500
1000 20001500 2500 3000 40003500 4500
35
30
25
20
15
40
45
50
RPM
kWhp
125
100
75
50
25
150
POWER
175
200
250
225
275
1000 20001500 2500 3000 40003500 4500
RPM
125
100
75
50
25
150
175
200
kgmNm
350
300
250
200
150
400
TORQUE
450
500
1000 20001500 2500 3000 40003500 4500
35
30
25
20
15
40
45
50
RPM
kWhp
125
100
75
50
25
150
POWER
175
200
250
225
275
g/hp·hg/kW·h
350
300
250
200
150
400
FUEL CONSUMPTION
1000 20001500 2500 3000 40003500 4500
RPM
1000 20001500 2500 3000 40003500 4500
RPM
125
100
75
50
25
150
175
200
kgmNm
350
300
250
200
150
400
TORQUE
450
500
1000 20001500 2500 3000 40003500 4500
35
30
25
20
15
40
45
50
RPM
250
200
150
275
125
175
225
kWhp
125
100
75
50
25
150
POWER
175
200
250
225
275
g/hp·hg/kW·h
350
300
250
200
150
400
FUEL CONSUMPTION
1000 20001500 2500 3000 40003500 4500
RPM
1000 20001500 2500 3000 40003500 4500
RPM
125
100
75
50
25
150
175
200
kgmNm
350
300
250
200
150
400
TORQUE
450
500
1000 20001500 2500 3000 40003500 4500
35
30
25
20
15
40
45
50
RPM
250
200
150
275
125
175
225
Performance curves according to ISO 8178.
8 402102.01
Service manual VF4 VF5
Values and ts3
Crankcase3.1
Crankcase
Values [mm]
1
L
1
∅
L
2
L
Main bearing
housing
L 21.720 ÷ 21.800
L1 -
L2 -
Ø 63.705 ÷ 63.718
∅
Cylinder liner seat Ø -
∅
Cylinder liner
∅
A 82.000 ÷ 82.010
B 82.010 ÷ 82.020
C 82.020 ÷ 82.030
2
∅ 2
∅ 1
Cylinder liner
Ø1 -
Ø2 -
-
2 - 1
Cylinder liner - Crankcase -
1
2
3
11
10
9
8
7
6
5
4
402102.01 9
Service manual VF4 VF5
Crankcase
Values [mm]
3
X
∅
Piston
X 8
∅
A 81.920 ÷ 81.930
B 81.930 ÷ 81.940
C 81.940 ÷ 81.950
0.4
∅
Piston pin bore dia Ø 26.006 ÷ 26.014
Ring groove
width
1 2.080 ÷ 2.100
2 2.020 ÷ 2.040
3 2.020 ÷ 2.040
Piston weight dierence ± 5 gr
3 - 1
Piston protrusion - Crankcase 0.014 ÷ 0.294
3 - 2
Piston protrusion - Liner -
3 - 1
Piston – Cylinder liner 0.070 ÷ 0.090
3 - 2
Piston – Cylinder liner -
4
∅
Piston pin
Ø 25.982 ÷ 25.987
0.4
4 - 3
Piston pin - Seat pin 0.012 ÷ 0.022
10 402102.01
Service manual VF4 VF5
Crankcase
Values [mm]
5
L
∅
Piston ring
1 1.970 ÷ 1.995
2 1.970 ÷ 1.995
3 1.970 ÷ 1.990
0.4
5 - 3
Piston ring Ring clearance
in piston
1 0.105 ÷ 0.150
2 0.050 ÷ 0.090
3 0.030 ÷ 0.070
5 - 1
Piston ring gap
1 0.20÷ 0.35
2 0.60 ÷ 0.80
3 0.25 ÷ 0.50
5 - 2
Piston ring gap
1 -
2 -
3 -
6
∅
2
∅
1
Small end bore diameter Ø1 -
Big end bore
diameter
∅
2
1 -
2 -
3 -
Connecting rod weight dierence ± 2.5 g
6
∅
2
∅
1
Small end bush I.D. Ø1 26.006÷ 26.014
Big end I.D. Ø2 53.897 ÷ 53.909
Connecting rod weight dierence ± 2.5 g
7
∅
2
∅
1
Small end bush
Ø1 29.018 ÷ 29.038
∅
2
25.279 ÷ 25.512
402102.01 11
Service manual VF4 VF5
Crankcase
Values [mm]
4 - 7
Piston pin - Small end bush 0.018 ÷ 0.030
7 - 6
Small end bush - Bush seat 0.046 ÷ 0.099
8
L
∅
2
∅
1
L
1
Main journal
∅
1
1 59.994 ÷ 60.000
2 59.988 ÷ 59.994
3 59.982 ÷ 59.988
Crankpin
A 50.799 ÷ 50.805
B 50.793 ÷ 50.799
C 50.787 ÷ 50.793
L -
L1 26.829 ÷ 26.879
9
L
∅
Main bearing
1 1.831 ÷ 1.837
2 1.836 ÷ 1.844
3 1.843 ÷ 1.849
0.127
9 - 8
Main bearing - Journal 0.031 ÷ 0.051
10
L
∅
Connecting rod
bearing
L
A 1.527 ÷ 1.531
B 1.530 ÷ 1.534
C 1.533 ÷ 1.537
0.127
10 - 8
Connecting rod bearing - Pin 0.030 ÷ 0.056
11
s
Thrust washer S 2.469 ÷ 2.485
0.127
11 - 8
Thrust crankshaft 0.059 ÷ 0.221
12 402102.01
Service manual VF4 VF5
Cylinder head and valve gear3.2
Cylinder head and valve gear Values [mm]
12
∅
Intake valve guide housing Ø 29.600 ÷ 29.611
Exhaust valve guide housing Ø 27.600 ÷ 27.611
α
L
Valve housing
α
45° ±1’
45° ± 1’
L Circa 2.7
∅
Camshaft support end exhaust dia.
VF4
I 43.646 ÷ 43.671
II 43.446 ÷ 43.471
III 43.246 ÷ 43.271
IV 43.046 ÷ 43.071
V 30.045 ÷ 30.070
∅
Camshaft support end exhaust dia.
VF5
I 43.846 ÷ 43.871
II 43.646 ÷ 43.671
III 43.446 ÷ 43.471
IV 43.246 ÷ 43.271
V 43.046 ÷ 43.071
VI 30.045 ÷ 30.070
∅
Tappet housing bore dia. Ø 37.010 ÷ 37.030
12
16
15
17
20
13
14
19
402102.01 13
Service manual VF4 VF5
Cylinder head and valve gear Values [mm]
13
∅
2
∅
1
Valve guide
Ø1
∅
1
8.022 ÷ 8.040
14.010 ÷ 14.030
14.010 ÷ 14.030
0.05 - 0.10 - 0.25
13 - 12
Valve guide
0.033 ÷ 0.080
Seat in cylinder head
0.033 ÷ 0.080
14
∅
2
∅
1
α
Valve
Ø1 5.982 ÷ 6.000
Ø2 27.40 ÷ 27.60
α
45° 30’ ± 5’
Ø1 5.972 ÷ 5.990
Ø2 25.40 ÷ 25.60
α
45° 30’ ± 5’
14 - 13
Valve – Valve guide 0.030 ÷ 0.066
15
P1
P2
H
1
H
2
Internal valve spring
P1
daN
-
H1 -
P2
daN
-
H2 -
16
P1
P2
H
1
H
2
External valve spring
P1
daN
20.47 ÷ 21.84
H1 34.0
P2
daN
44.81 ÷ 47.59
H2 24.5
17
L
∅
Journal camshaft and exhaust
Ø 26.000 ÷ 26.015
L 19.250 ÷ 19.330
Cam lift intake / exhaust
8
8
14 402102.01
Service manual VF4 VF5
Cylinder head and valve gear Values [mm]
17 - 12
Journal camshaft - Seat in cylinder
head
VF4
I 43.600 ÷ 43.615
II 43.400 ÷ 43.415
III 43.200 ÷ 43.215
IV 43.000 ÷ 43.015
V 30.000 ÷ 30.015
Journal camshaft - Seat in cylinder
head
VF5
I 43.800 ÷ 43.815
II 43.600 ÷ 43.615
III 43.400 ÷ 43.415
IV 43.200 ÷ 43.215
V 43.000 ÷ 43.015
VI 30.000 ÷ 30.015
17-12
Journal camshaft - Cylinder head
support
radial 0.030 ÷ 0.070
axial 0.100 ÷ 0.230
19
∅
Tappet Ø 36.975 ÷ 36.991
19 - 12
Tappet - Cylinder head 0.019 ÷ 0.065
20
s
Shim
0.05
S
3.25 ÷ 4.90
17 - 20
For timing check
0.50
0.50
Normal cold
0.30 ± 0.05
0.35 ± 0.05
402102.01 15
Service manual VF4 VF5
Valve timing diagram3.3
A
B
D
C
A
Intake
Opens B.T.D.T. 10°
B Closes A.B.D.C. 18.5°
C
Exhaust
Opens B.B.D.C. 40°
D Closes A.T.D.C. 9°
Cylinder head gasket3.4
Fit the cylinder head, the gasket should have the thickness indicated below in order to maintain compression
ratio within the prescribed limits:
Piston protrusion (mm) Gasket thickness (mm) Identication notches
-0.020 ÷ +0.100 0.82 ± 0.05 0
+0.101 ÷ +0.200 0.92 ± 0.05 1
+0.201 ÷ +0.295 1.02 ± 0.05 2
16 402102.01
Service manual VF4 VF5
Lubrication3.5
Lubrication Values [mm]
Lubrication circuit engine
with forced circulation, by
means of pump to gears
with cartridge lter in
series.
Oil pump: type
With gears, located the
front cover crankshaft
Driving pump
With a chain command
from the crankshaft
Oil pressure regulation valve
Incorporated in the crank-
shaft front cover
Oil lter full ow With cartridges
Insucient oil pressure sender Electrical
Between the body pump and the
gear
-
Between the gears periphery and
the body pump
0.110 ÷ 0.180
Between the superior side of the
gears and the pump cover
-
Between the superior side of the
gears and the cover pump
0.016 ÷ 0.086
Between the gear and the conductor 0.30
bar
Operation pressure
temperature of
100°C
@ minimal rpm > 1 bar
@ 4000 / min > 4 ÷ 4.5 bar
@ maximum
rpm
-
402102.01 17
Service manual VF4 VF5
Lubrication Values [mm]
P1
P2
H
1
H
2
Valve spring oil
pressure regulation
P1
daN
12.19 ÷ 13.00
H1 35
P2
daN
-
H2 -
Cooling system3.6
Cooling system
Cooling system circuit
To circulation of coolant by means of pump command
from thermostatic switch.
Command coolant pump By means of timing belt
Engine coolant thermostat
Opening temperature
74° ÷ 83°C
Fully open at 101° ÷ 105°C
Valve stroke 12 mm
Pressure for held control system 1.08 bar
Exhaust valve control on the cap of the additional
expansion tank
1.08 bar
Fuel system3.7
Fuel system VF4 VF5
Firing order 1 - 3 - 4 - 2 1 - 2 - 4 - 5 - 3
Distributor type injection pump Bosch EDC 16 C39
Calibration pressure injectors 1800 bar
Rpm minimal engine 800 ± 20 1/min
Rpm maximal engine to empty 5000 ± 20 1/min
Supercharging3.8
Supercharging (Gas exhaust turbocharger) VF4 VF5
Turbocharger to variable geometry Garret GT 17 59V Garret GT 22 56 V
Pressure of the maximum supercharging to 2400/min 1.05 bar
18 402102.01
Service manual VF4 VF5
Repair data4
Position the camshaft housing (1 a) in a vice using the tool (1b)
Undo the bolt (1 a) and remove the cam angle sensor (1b).
Camshaft housing4.1.1
Cylinder head4.1
402102.01 19
Service manual VF4 VF5
Remove plugs (1 a) and t camshaft timing tools (1b) on the camshaft housing.
Check that the tools are correctly tted in the housings in the
camshaft.
Undo the bolts xing the camshaft gears (1)
Undo the bolt (1 a) and remove the exhaust side camshaft toothed
drive pulley (1b).
20 402102.01
Service manual VF4 VF5
Remove the camshaft timing tools from the cylinder head extension.
Withdraw the camshaft (1 a), as far as necessary and remove the
camshaft gears (1b)
Using a suitable drift, extract the inlet side camshaft (1 a) and plug
(1b).
Using suitable drift, extract the exhaust side camshaft (2 a) and oil
seal (2b).
Undo and remove the engine oil lubrication duct plugs (1).
402102.01 21
Service manual VF4 VF5
Lower cylinder head4.1.2
Position the cylinder head (1 a) in a vice using the tool (1b).
Remove the hydraulic tappets.
Loosen the band (1 a), undo the bolts (1b) and remove the thermostat (1c) complete with O-ring.
22 402102.01
Service manual VF4 VF5
Undo the bolts (1 a) and remove the water pump (1b).
Remove the gasket.
Fit a wooden stand on the cylinder head plane to support the
valves and secure it using bolts.
Fit the cotters (1 a) using the tools (1b lever) and (1c chamber)
Remove the valve upper shim.
Remove the valve spring.
Remove the shim (for exhaust valves only)
Remove the valve guide oil seal with integrated lower valve shim.
Carry out the same operations on the other valves.
Remove the wooden stand and recover the valves.
Remove the lower cylinder head from the support tool.
Replace the valve guide.
402102.01 23
Service manual VF4 VF5
Clean any residues of the old basket from the lower cylinder head
plane.
Check that the atness of the lower cylinder head plane corresponds to the recommended.
Cylinder head
Lower surface atness = 0.1 ± 0,05
If the planarity of the lower cylinder head plane does not correspond to the recommended gures, regrind it without exceeding
the minimum permitted height.
Cylinder head
Lower plane minimum permitted
height
= 107.0 ± 0.05
Check that the valves do not show signs of scoring or seizing.
Check that the diameter of the valve stems corresponds to the
recommended gures; if not, replace the worn valves.
Inlet valve stem diameter = 5.982 ÷ 6.000
Exhaust valve stem diameter = 5.972 ÷ 5.990
24 402102.01
Service manual VF4 VF5
Check that the length of the valve springs when released is within
the recommended values.
Valve spring free length = 43.1 mm
Using a torque wrench, check that the valve spring specications
correspond to the recommended gures; if not, replace the worn
components.
Length of valve springs under a load
of 20.47 ÷ 21.84 daN
= 34.0 mm
Length of valve springs under a load
of 44.81 ÷ 47.59 daN
= 24.5 mm
Check that the diameter of the camshaft bearings corresponds to
the recommended gure; if not, replace the worn camshaft/s.
Diameter of inlet and exhaust shaft bearings VF4
Diameter I bearing• = 43.600 ÷ 43.615
Diameter II bearing• = 43.400 ÷ 43.415
Diameter III bearing• = 43.200 ÷ 43.215
Diameter VI bearing• = 43.000 ÷ 43.015
Diameter V bearing• = 30.000 ÷ 30.015
Diameter of inlet and exhaust shaft bearings VF5
Diameter I bearing• = 43.800 ÷ 43.815
Diameter II bearing• = 43.600 ÷ 43.615
Diameter III bearing• = 43.400 ÷ 43.415
Diameter IV bearing• = 43.200 ÷ 43.215
Diameter V bearing• = 43.000 ÷ 43.015
Diameter VI bearing• = 30.000 ÷ 30.015
402102.01 25
Service manual VF4 VF5
Check that the nominal camshaft cam lift corresponds to the recommended gures; if not, replace the worn camshaft/s.
Nominal inlet/exhaust cam lift = 8.00 mm
Check that the diameter of the camshaft supports corresponds to
the recommended gures; if not, replace the cylinder head.
Diameter of inlet and exhaust shaft supports VF4
Diameter I support• = 43.646 ÷ 43.671
Diameter II support• = 43.446 ÷ 43.471
Diameter III support• = 43.246 ÷ 43.271
Diameter VI support• = 43.046 ÷ 43.071
Diameter V support• = 30.045 ÷ 30.070
Diameter of inlet and exhaust shaft supports VF5
Diameter I support• = 43.846 ÷ 43.871
Diameter II support• = 43.646 ÷ 43.671
Diameter III support• = 43.446 ÷ 43.471
Diameter IV support• = 43.246 ÷ 43.271
Diameter V support• = 43.046 ÷ 43.071
Diameter VI support• = 30.045 ÷ 30.070
26 402102.01
Service manual VF4 VF5
The outer diameter of the valve seats is as follows.
Inlet valve seat outer diameter = 29.600 ÷ 29.611
Exhaust valve seat outer diameter
= 27.600 ÷ 27.611
Position the lower cylinder head in the vice using the tool (support).
Fit the valves in the seats, then support them using the wooden
stand and secure it using suitable bolts.
Place the valve guide oil seal (1 a) in position using the tool (1b
extractor/tting tool).
Grind the valve seats to the recommended size.
Valve seat band
Angle in contact with valve = 45° +/- 1’
Grind the valve seats using a suitable tool.
402102.01 27
Service manual VF4 VF5
Place the shim in position (for exhaust valves only).
Fit the valve spring in its seat.
Ret the upper valve shim.
Place the cotters (4 a) in their housings using the tools (4b lever)
and (4c chamber).
Carry out the same operations on the other valves.
Remove the wooden stand for supporting the valves from the cylinder head plane.
Ret the water pump, complete with basket, in its housing and
secure it tightening the bolts to the recommended torque.
Water pump
Bolt M8 value (da Nm) cylinder head side 2.3 ÷ 2.8
Place the thermostat in its housing with the new O-ring and secure it to the cylinder head by tightening the bolts to the recommended torque.
Thermostat
Bolt M8 value (da Nm) cylinder head side 2.5
Place the hydraulic tappets in their housings.
Remove the lower cylinder head from the support tool.
28 402102.01
Service manual VF4 VF5
Camshaft housing.4.1.3
Position the camshaft housing in the vice using the tool (support).
Tighten the engine oil lubrication duct plugs.
Place the camshaft gears in their housings.
Place the camshaft gears in their housings and secure them without tightening the bolts.
Fit the camshaft timing tools (template)
Check that the tools are correctly tted in the housings in the
camshaft.
Tighten the camshaft gear xing bolts to the recommended
torque.
Camshaft gears
Bolt M12 (da Nm) camshaft side 2.9 ÷ 3.2 + 40°
402102.01 29
Service manual VF4 VF5
Fit the exhaust side camshaft front oil seal (1 a) using the tool (1b
tting tool).
Fit the intake side camshaft plug.
Ret the exhaust side camshaft toothed pulley and secure by
screwing in the bolt without tightening.
Position the cam angle sensor (1 a) in its housing and secure it
tightening the bolt (1b) to the recommended torque .
Cam angle sensor
Bolt M6 (da Nm) 0,8 ÷ 1,0
30 402102.01
Service manual VF4 VF5
Crankshaft4.2
Undo bolts (1 a) and remove oil intake duct (1b).
Fit the tool for rotating the crankshaft (ange)
Undo bolt (anti-clockwise) (1 a) and remove toothed drive pulley
(1b).
Undo bolts (2 a) and remove crankshaft front oil seal cover with
built-in oil pump (2b).
Remove the gasket.
Undo bolt (3 a) and remove timing belt xed tensioner (3b).
Undo bolt (4 a) and remove timing belt tensioners mounting (4b)
402102.01 31
Service manual VF4 VF5
Undo bolt (1 a) and remove rpm sensor (1b).
Rotate the camshaft using the tool tted previously until the cylinder concerned is at B.D.C.
Undo bolts (2 a) and remove connecting rod cap (2b).
Remove the lower connecting rod half-bearing.
Remove the connecting rod-piston assembly.
Remove the upper connecting rod half-bearing.
Carry out the same operations for removing the remaining pistons.
Check that the crankshaft end play corresponds to the recommended gures using a magnetic base and dial gauge.
Crankshaft end play
0.049 ÷ 0.211 mm
If the value for the crankshaft end play does not correspond with
the recommended gures, when retting, regrind the crankcase
seat and use suitable oversize thrust washer.
32 402102.01
Service manual VF4 VF5
VF4
Undo bolts (1 a) and remove crankcase rear cover (1b) with builtin oil seal.
Remove the lower main journal half-bearings.
Remove the crankshaft.
Remove the upper main journal half-bearings.
Remove the thrust washers.
Undo bolts (6 a) and remove jets (6b) from the crankcase.
VF5
Undo bolts (1 a) and remove crankcase rear cover (1b) with builtin oil seal.
Undo bolts (2 a) and remove bearing caps (2b).
Remove the lower main journal half-bearings.
Remove the crankshaft.
Remove the upper main journal half-bearings.
Remove the thrust washers.
Undo bolts (7 a) and remove jets (7b) from the crankcase.
Drill and remove the water/oil sealing plugs from the crankcase to
allow for washing.
Remove the engine block from the overhaul stand and place on a
suitable work bench.
Wash the dismantled components.
Fit the water/oil sealing plugs in the crankcase using suitable tting, tools.
Lubricate all the mechanical components with engine oil.
Check that the cylinder head support surface does not have cracks
or surface grooves.
402102.01 33
Service manual VF4 VF5
Check that the planarity of the cylinder head support surface
corresponds to the recommended gure; if this is not the case,
regrind the cylinder head support surface.
Cylinder head lower surface atness
0,1 mm
Measure the cylinder bore diameter using the diagram illustrated.
Cylinder liner inner diameter
Grade A 82.000 ÷ 82.010
Grade B 82.010 ÷ 82.020
Grade C 82.020 ÷ 82.030
Check that the taper and ovality of the cylinder liners/bores is
within the recommended limits.
Cylinder liner taper < 0.005 mm
Cylinder liner ovality < 0.05 mm
34 402102.01
Service manual VF4 VF5
If the cylinder bore measurements are not within the recommended limits, ream the cylinder bores following the recommended
oversize.
If reaming, ensure all the bores have the same oversize.
Cylinder liner bore diameter oversize
0.1 mm
Fit the bearing caps.
The bearing caps have progressive references (from zero to
ve VF4, or zero to six VF5, starting from the timing system
side) which dene the tting position.
Tighten bearing cap bolts (1 a) to the recommended torque, use
torque wrench (1b).
Bearing caps
Bolt M12 (da Nm) 2.4 ÷ 2.6 + 100°
Check that the diameter of the main journal seats is within specied limits.
Main journal seat diameter
63.705 ÷ 63.718 mm
402102.01 35
Service manual VF4 VF5
Check that there are no deposits or blockages in the crankshaft
lubrication ducts.
Check that the diameter of the main journals corresponds to the
recommended gures.
Main journal diameter
Category A 59.994 ÷ 60.000 mm
Category B 59.988 ÷ 59.994 mm
Category C 59.982 ÷ 59.988 mm
If the diameter of the main journals is not correct, they should be
reground to the recommended undersize.
Main journal diameter undersize
0.127 mm
Crankpin undersizes higher than the value mentioned will ad-
versely aect the structural resistance of the crankshaft (following contact between the tool and rolled connectors). As
far as the above is concerned, if the regrinding requires under
sizes greater than 0.127 mm, then the crankshaft must be replaced and a new one ordered from the parts dept.
Check that the diameter of the crank pins corresponds to the recommended gures.
Crankpin diameter
Category A 50.779 ÷ 50.805 mm
Category B 50.793 ÷ 50.799 mm
Category C 50.787 ÷ 50.793 mm
36 402102.01
Service manual VF4 VF5
If the diameter of the crank pins is not correct, they should be reground to the recommended undersize.
Crankpin diameter undersize
0.127 mm
Crankpin undersizes higher than the value mentioned will ad-
versely aect the structural resistance of the crankshaft (following contact between the tool and rolled connectors). As
far as the above is concerned, if the regrinding requires under
sizes greater than 0.127 mm, then the crankshaft must be replaced and a new one ordered from the parts dept.
Check the main bearings, noting that the half-bearings should
not be adapted. Replace them if scoring or signs of binding are
noted.
Fit the half-bearings, making sure they are scrupulously clean.
If the crankshaft has been round, t new oversize half- bear-
ings to restore the initial tolerance conditions.
Fit the crankshaft into its seat on the crankcase.
Fit the calibrated wire (plastigage) for measuring the bearing
clearance.
Check one journal at the time, without rotating the crank-
shaft.
Fit the bearing caps complete with half-bearings and tighten the
bolts to the recommended torque.
Bearing caps
Bolt M12 (da Nm) 2.4 ÷ 2.6 + 100°
The bearing caps have progressive references (from zero to ve
starting from the timing system side) which dene the tting position.
402102.01 37
Service manual VF4 VF5
Remove the bearing caps tted previously and, using a suitable
graduated measuring instrument (1 a), measure the clearance
shown by calibrate
Clearance between main bearings- crankshaft main journals
0.011 ÷ 0.071 mm
If the gure measured is outside of the tolerance, replace the
half-bearings with ones of the correct size and category.
Measure the clearance for all the bearings, being careful to take
the measurements one at a time without moving the crankshaft
at all.
Check that the outer diameter of the gudgeon pins is within the
recommended limits; if not, replace the worn gudgeon pins.
Gudgeon pin outer diameter
25.982 ÷ 25.987 mm
Check that the small end bush diameter is within the recommended limits; if not, replace the worn small end bush, refer to:
Small end bush inner diameter
26.006 ÷ 26.014 mm
38 402102.01
Service manual VF4 VF5
Fit the piston rings in the cylinder bore and check that the opening between the ends is within the recommended values; if this is
not the case, replace the cir-clips.
Cylinder compression piston ring gap
I piston ring gap 0.20 ÷ 0.35 mm
II piston ring gap 0.60 ÷ 0.80 mm
Scraper ring gap 0.25 ÷ 0.50 mm
Check that the outer diameter of the pistons corresponds to the
recommended gures; if not, replace the piston complete with
piston rings and gudgeon pin.
Piston outer diameter
Grade A 81.920 ÷ 81.930 mm
Grade B 81.930 ÷ 81.940 mm
Grade C 81.940 ÷ 81.950 mm
Measure perpendicular to the gudgeon pin axis, 9 mm from
the lower edge of the skirt.
Check that backlash (1 a) between rings (1b) and the seats in
pistons(1c) corresponds to the recommended gures.
Cylinder compression piston ring
I piston ring 0.105 ÷ 0.150 mm
II piston ring 0.050 ÷ 0.090 mm
Scraper ring 0.030 ÷ 0.070 mm
402102.01 39
Service manual VF4 VF5
Fit caps (1b) on connecting rods (1 a) and secure them by tightening bolts (1c) to the recommended torque.
Connecting rod big end bearing caps
Bolt M9 (da Nm) 2.4 ÷ 2.6 + 60°
Check that the diameter of the big end corresponds to the recommended gures; if not, replace the connecting rods.
Big end inner diameter
53.897 ÷ 53.909 mm
Check that there are no signs of seizing on the ywheel ring gear
teeth; if this is not the case, replace it.
Fit the crankcase on the overhaul stand and secure it using the
bolts.
Fit the thrust washers on the fourth bearing support.
The crankshaft supplied by the parts dept, comes without half-
bearings and the main journals and crankpins are the “normal”
size; the half-bearings to be tted must therefore be selected
identifying the class of each main journal crankpin for the new
crankshaft.
40 402102.01
Service manual VF4 VF5
The following must be determined for the selection of main journal half-bearings:
the numerical code stamped on the ywheel;•
the paint mark, if present, next to the main journals. •
Below is an example of the identication of main journal grades.
Crankpin identication numerical code: the number on the left 1
refers to the rst timing-side bearing,
Main journal identication numerical code: the rst number on 2
the left refers to the rst timing-side bearing.
Series of numbers (if present), in groups of two digits, which 3
indicate the dimensions (thousandth part) of the main journals:
the rst two numbers on the left refer to the rst timing-side
main journal.
Only use the codes that relate to the key, all other codes on
the ywheel should not be used.
For the identication of the main journal category, refer to the numerical code for reference 2.
In the case of the example, the numbers 111111 indicate that all
six bearings are grade A ( red ) as indicated in the table.
A further method for identifying the grade of the bearings is to
read reference 3 (if present) in the diagram.
In the case of the example, the number 94 (rst on the left) corresponds to the dimensions 59.994 for the rst timing-side bearing
which, as indicated in the table, identies Grade A (red); the same
method should be applied for other groups of two digits for the
same reference 3 (97 – 95 – 94 – 95).
402102.01 41
Service manual VF4 VF5
Main journal identication4.2.1
Bearing grade A Normal, diameter 59.994 ÷ 60.000 paint mark –, numerical code 1 (94 00)°
Bearing grade B Normal, diameter 59.988 ÷ 59.994 paint mark –, numerical code 2 (88 94)°
Bearing grade C Normal, diameter 59.982 ÷ 59.988 paint mark – numerical code 3 (82 88)°
Bearing grade D Normal, diameter 59.867 ÷ 59.873 (*) paint mark – numerical code 6 (67 73)°
Bearing grade E Normal, diameter 59.861 ÷ 59.867 (*) paint mark – numerical code 7 (61 67)°
Bearing grade F Normal, diameter 59.855 ÷ 59.861 (*) paint mark – numerical code 8 (55 61)°
(*) 0.127 mm undersize
(°) Last two numbers (thousandth part) of the main journal dimension.
In the case of using a crank shaft where the maximum undersize
for the bearings is 0.127 mm through grindings, the grade should
be selected through the measurement of the diameter of the
bearing using table as a reference.
Having dened the grade and the colour of each new or reground
crankshaft bearing, it is necessary to select the pair or thickness of
the bearings that should be the same colour as the corresponding
bearing; the pair of half-bearings required can be ordered from
the parts dept. By quoting the order no.
The above is designed to guarantee the optimum operational
clearances.
42 402102.01
Service manual VF4 VF5
Lastly, we wish to point out that the clearance between the main
journal and the half-bearing, obtained through the selection
method indicated above, should generally be within the following values:
Minimum: 0.025 mm – Maximum: 0,052 mm; this value can be
measured, as a nal check, using the calibrated wire (plastigage).
Place the lubrication jets back in their housings and secure them
to the crankcase using the bolts.
Fit the crankshaft in the crankcase.
Fit the bearing caps complete with half-bearings and tighten the
bolts to the recommended torque.
Bearing caps
VF4 Bolt M12 (da Nm) 1.9 ÷ 2.1 + 100°
VF5 Bolt M12 (da Nm) 2.4 ÷ 2.6 + 100°
The bearing caps have progressive references (from zero to
ve starting from the timing system side) which dene the tting position.
402102.01 43
Service manual VF4 VF5
Fit the tool for rotating the crankshaft.
Rotate the crankshaft using the tool tted previously until the cylinder concerned is at B.D.C.
Fit piston-connecting rod assembly (1 a) complete with half-bearing using tool (1b).
The piston-connecting rod assemblies are tted in the cylin-
der block/crankcase so that the combustion chamber in the
piston is facing the intake side.
For the selection of the connecting rod half-bearings, follow
the procedure described previously for the main journal halfbearings.
Fit connecting rod cap (2 a) complete with half-bearing and secure it without tightening bolts (2b).
Fit the connecting rods so that the number stamped on each
rod faces toward the same side as the number stamped on the
big end (inlet side).
For the remaining cylinders, carry out the same operations to ret
the pistons and connecting rods.
Test the crankpin clearance by applying plastigage to measure
crankpin installation clearance.
Tighten connecting rod cap bolts to the recommended torque.
Connecting rod big end bearing caps
Bolt M9 (da Nm) 2.4 ÷ 2.6 + 60°
44 402102.01
Service manual VF4 VF5
Undo the bolts and remove the connecting rod caps complete
with half-bearings.
Using an appropriate graduated measuring tool (1 a),measure the
clearance indicated by plastigage (1b).
Clearance between crankpins crankshaft bearings
VF4 0.030 ÷ 0.056 mm
VF5 0.016 ÷ 0.070 mm
If the value measured is not within the recommended gures, replace the connecting rod bearings.
Carry out this test on all the crankpins, one at a time, without ever
turning the crankshaft.
Fit the connecting rod caps complete with half bearings and
tighten the bolts.
Tighten connecting rod cap bolts to the recommended torque.
Connecting rod big end bearing caps
Bolt M9 (da Nm) 2.4 ÷ 2.6 +60°
Remove the ange for rotating the crankshaft.
Place the crankcase rear cover with integrated oil seal in position and secure it by tightening the bolts to the recommended
torque.
Flywheel side oil seal cover
Bolt (pre-treated to be replaced.) (engine block side)
M6 (daNm) 0.8 ÷1.0
402102.01 45
Service manual VF4 VF5
Place the crankcase front cover complete with oil pump and gasket in its seat and tighten the bolts to the recommended torque.
Crankshaft oil seal front cover
Bolt (pre-treated to be replaced) (engine block side)
M6 (daNm) 0.8 ÷1.0
Ret the engine oil intake duct complete with O-ring in its housing and secure it by tightening the bolts to the specied torque.
Engine oil intake
VF4 Bolt M6 (daNm) 0.8 (oil pump side)
VF5 Bolt M6 (daNm) 0.9 (oil pump side)
Apply silicon sealant to the entire perimeter of the oil sump.
Place the oil sump back in its housing.
Tighten the bolts securing the oil sump to the crankcase to the
recommended torque using the tool (spanner).
Engine oil sump
Bolts front and rear M8 (daNm) 2.5
46 402102.01
Service manual VF4 VF5
Tighten the bolts securing the oil sump to the crankcase front and
rear covers to the recommended torque using the tool.
Engine oil sump
Side bolts M6 (daNm) 0.9
Fit the tool for rotating the crankshaft (ange).
Position the timing belt toothed drive pulley in its housing and
tighten the bolt (anti-clockwise thread) to the recommended
torque.
Toothed drive pulley
Left hand bolt M16
(daNm)
32.3 ÷ 35.7 (crankshaft side)
Measure the piston projection in two places at 180° on the gudgeon pin axis using the tool and take the average of the two values
measured for each piston. (dial gauge support).
402102.01 47
Service manual VF4 VF5
Select the correct size cylinder head gasket depending on the
maximum value out of the averages of the projection for each individual piston.
Cylinder head gasket size with average maximum piston
projection
0
opening projection -0.020 ÷ +0.100 mm – thickness
0.82 ÷ 0.05 mm
1
opening projection +0.101 ÷ +0.200 mm – thickness
0.92 ÷ 0.05 mm
2
opening projection +0.201 ÷ +0.295 mm – thickness
1.02 ÷ 0.05 mm
VF4
VF5
Place the cylinder head centring bushes on the cylinder block.
Fit the cylinder head basket selected.
Position the cylinder head on the cylinder block/crankcase.
48 402102.01
Service manual VF4 VF5
Tighten the cylinder head bolts to the specied torque.
Follow the order shown in the diagram for each tightening se-
quence.
Camshaft housing
VF4 Bolt M12 (daNm)
6.2 ÷ 6.8 + 4.5+90°+90°+90°
(Crankcase side)
The value of 2 daNm in the table above is a tightening value
for all the bolts following the order illustrated in the diagram.
Camshaft housing
VF5 Bolt M12 (daNm)
2 + 4.5+90°+90°+90° (Crankcase side)
The value of 2 daNm in the table above is a tightening value
for all the bolts following the order illustrated in the diagram.
Position the rpm sensor in its housing and secure it using the
bolt.
Place the timing belt tensioner mount in its housing and secure it
using the bolt.
Place the timing belt xed tensioner in its housing and secure it
using the bolt.
Fit the pressure pump mounting complete with pump and secure
it using the bolts.
Place the timing belt side guard in its housing and secure it using
the bolts.
VF4
VF5
402102.01 49
Service manual VF4 VF5
Remove plugs (1 a) and t camshaft timing tools (1b) on the camshaft housing.
Check that the tools marked “A” are correctly tted in the seats
on the camshaft.
Remove the timing tool, (templates) camshaft side, and tighten
the plug.
Fit a new upper cylinder head basket in position.
Position the camshaft housing and secure it by tightening the
bolts to the recommended torque.
Camshaft housing
Bolt M8 (daNm) 2.3 ÷ 2.8 (cylinder head side
Loosen the bolt xing the exhaust side timing belt toothed drive
pulley.
Undo the bolt xing the crankcase front cover shown in the diagram.
Temporarily t the toothed timing drive belt on the toothed drive
pulley.
50 402102.01
Service manual VF4 VF5
Fit tool (2 a template) and fasten it using calibrated screw (2b).
Fully t the toothed timing drive belt.
Use a screwdriver for leverage in opening (2 a) until the reference
for tensioner (2b) is aligned with reference opening (2c). In this
position, tighten nut (2d) for the belt tensioner to the recommended torque.
Timing moving tensioner
Nut M8 (daNm) 2.3 ÷ 2.8
Tighten the bolt xing the exhaust side timing belt toothed drive
pulley to the specied torque.
Driver toothed pulley
Bolt M12 (daNm) 2.9 ÷ 3.2 + 40° (camshaft side)
Remove the camshaft timing tools, exhaust and crankshaft side.
402102.01 51
Service manual VF4 VF5
Rotate the crankshaft through two turns and check again that the
timing is correct by retting the timing tools removed previously.
Check the collimation of the reference marks for the tensioning of
the timing belt tensioner and remove the timing tools.
Tighten the bolt xing the crankcase front cover removed previously.
Tighten the plug on the upper cylinder head for tting the exhaust-side timing tool.
Fit the injectors and brackets in their seats and tighten the nuts.
VF4: Start the assembly with the injector on the fourth cylin-
der and follow the sequence until the rst cylinder.
VF5: Start the assembly with the injector on the fth cylinder
and follow the sequence until the rst cylinder.
Place the fuel return pipe back in place and connect it to the injectors and the return manifold pipe.
Place the single fuel manifold in its housing and secure it by tightening the bolts to the recommended torque.
Single fuel manifold pipe (rail)
Bolt M8 (daNm) 2.3 ÷ 2.8 ( cylinder head extension side )
Connect the return pipe to the single fuel manifold and secure it
with the band.
Lace new rigid pipes from the fuel manifold to the injectors in
their housing and tighten the connectors to the recommended
torque.
Pipes from fuel manifold to injectors
Connector M14 (daNm) 2.2 ÷ 2.4 (rail side)
Connector M12 (daNm) 2.4 ÷ 2.6 (injector side)
52 402102.01
Service manual VF4 VF5
Place a new rigid pipe between the pump and the single fuel
manifold back in its housing and tighten the connectors to the
recommended torque.
Pipes from pressure pump to fuel manifold
Connector M14 (daNm) 2.2 ÷ 2.4 (fuel manifold side)
Connector M12 (daNm) 2.2 ÷ 2.4 (pressure pump side)
Ret the auxiliary drive belt pulley and secure by tightening the
bolts to the recommended torque.
Services pulley on crankshaft
Bolt M8 (daNm) 2.3 ÷ 2.5 (crankshaft side)
Ret the timing belt guard and secure it using the bolts.
Place the exhaust manifold assembly, complete with new gasket,
back in its housing and secure it by tightening the nuts to the recommended torque.
Exhaust manifold
Nut M8 (daNm) 2.3 ÷ 2.8 (turbocharger side)
402102.01 53
Service manual VF4 VF5
Connect the turbocharger lubrication oil delivery pipe to the crankcase and tighten the connector to the recommended torque.
Engine oil supply pipe to turbo - crankcase
Connector M10 (daNm) 4.5 ÷ 5.5
Connect the turbocharger lubrication oil outlet pipe to the sump
and tighten the bolts to the recommended torque.
Engine oil supply pipe from turbo
Bolt M6 (daNm) 0.8 ÷ 1.0 (engine block side)
Place the alternator in position and secure it by tightening the
bolts to the recommended torque.
Alternator
Bolt M12x1.25x120 (daNm) 6.3 ÷ 7.7
Bolt M10x1,25x100 (daNm) 4.5 ÷ 5.5
54 402102.01
Service manual VF4 VF5
Place the auxiliary drive belt automatic tensioner in position and
tighten the bolts to the recommended torque.
Engine components single belt moving tensioner
Bolt M8 (daNm) 2.3 ÷ 2.5
Fit and tension the single auxiliary drive belt by working on the
automatic tensioner using the tool (spanner).
Secure the electrical connection for the engine oil pressure
switch.
Secure the electrical connection for the rpm sensor
Attach the electrical connection for the coolant temperature sensor.
Secure the electrical connection for the pressure relief sensor.
Secure the electrical connections for the spark plugs.
Secure the electrical connection for the pressure regulator on the
single fuel manifold.
Secure the electrical connections for the injectors.
Secure the electrical connection for the timing sensor.
Secure the electrical connection for the alternator.
Place the alternator power supply cable back in its housing and
secure it using the nut.
Secure the engine wiring using the various retaining clips.
402102.01 55
Service manual VF4 VF5
Engine ywheel4.3
With the ywheel lock (1 a) tted, undo the bolts (1b) and remove
the ywheel (1c).
The bolts xing, the ywheel have been treated with a special agent;
therefore they should be replaced each time they are removed.
Place the ywheel (1 a) in its housing and secure it tightening the
new bolts (1b) to the recommended torque.
Engine ywheel
Bolt M12 (daNm) 16.0
56 402102.01
Service manual VF4 VF5
Crankshaft phonic wheel for rpm and timing sensor re-4.4
place with crankshaft removed
Undo the bolts (1 a) and remove the phonic wheel for the rpm and
timing sensor (1b) from the crankshaft.
Fit a new rpm and timing sensor ywheel on the crankshaft and
secure it tightening the bolts to the recommended torque.
Phonic wheel on crankshaft
Bolt M5 (daNm) 2.3 ÷ 3.3
402102.01 57
Service manual VF4 VF5
Connecting rod small end bush (one) replace4.5
Remove the bush (1 a) from the small end using a hydraulic press,
a suitable plate (1b) and the tool (1c extractor/tting tool) constructed as illustrated in the diagram.
Fit a new bush (1 a) in the small end using a hydraulic press, a suitable plate (1b) and the tool (1c extractor/tting tool) constructed
as illustrated in the diagram.
The bush should be tted in the small end so that the lubrica-
tion port is aligned with the one in the small end.
58 402102.01
Service manual VF4 VF5
Ream the inner diameter of the small end bush to the recommended gure.
Small end bush
Inner diameter 26.006 ÷ 26.014 mm
402102.01 59
Service manual VF4 VF5
Set of pistons, gudgeon pins and seals (replace)4.6
Remove the piston rings.
Release the pin (2 a) and separate the connecting rods (2b) from
the piston (2c).
Remove the piston rings (1 a) from the pistons using a suitable
tool (1b).
60 402102.01
Service manual VF4 VF5
Check the alignment of the connecting rods using suitable equipment; if it is not correct, replace the connecting rod.
Check that the weight dierence between the pistons corresponds to the recommended gures.
The arrows in the diagram illustrate where material can be re-
moved from the to equalize the weight.
Engine piston set
Weight dierence between pistons
± 5g
Weight dierence between connecting rods
± 2.5g
Join the connecting rods to the pistons so that the number printed on the connecting rod head (1 a) is facing notch (1b) on the
piston skirt for the oil jet housing.
Fit the pins and secure them using the cir-clips.
402102.01 61
Service manual VF4 VF5
Toothed timing belt4.7
Position the ywheel retaining tool in its seat (ywheel lock).
Undo bolts (1 a) securing crankshaft pulley (1b) and remove.
Undo the xing bolt (2 a) and remove the single drive belt xed
tensioner (2b).
62 402102.01
Service manual VF4 VF5
Undo bolts (1 a) and remove the protective timing covers (1b).
Loosen the moving timing tensioner nut.
Remove the toothed timing belt.
Remove plug (1 a) and t camshaft timing tool ( 1b templates) to
the cylinder head extension.
Check the tools marked “A” are correctly tted in the seat on
the camshaft.
Undo the bolt xing the crankcase front cover shown in the diagram.
Temporarily t the toothed timing drive belt on the drive pulley.
Fit the tool (2 a template) and fasten it using the calibrated screw
(2b).
The crankshaft must be rotated, using small movements to
allow the locating dowel on the timing drive pulley to be inserted in the opening in the tool.
402102.01 63
Service manual VF4 VF5
Fully t the toothed timing drive belt.
Use a screwdriver on the tensioner (3 a) tab for leverage until the
reference (3b) is in the maximum tension position, then lock the
nut (3c) xing the moving tensioner in this position
Remove the tools used to ad just the timing.
Rotate the crankshaft through two revolutions.
Re-check the alignment of the timing references, loosen the nut
securing the mobile tensioner and align mobile indicator (4 a) with
hole (4b), i.e. ad just to nominal tension position, then tighten nut
(4c) securing the belt tensioner to torque.
Mobile timing tensioner
Nut M8 (daNm) 2.5
Loosen the bolt retaining the timing pulley.
Rotate the crankshaft through two revolutions.
Recheck the timing by retting the timing tools
64 402102.01
Service manual VF4 VF5
Check the timing belt tensioner references are aligned.
Tighten the bolt xing the crankcase front cover removed previously.
Tighten the plug on the cylinder head extension for tting the exhaust side timing tool.
Fit the toothed timing belt protective guards and tighten the retaining bolts.
Position the ywheel retaining tool in its seat.
Fit the crankshaft pulley in position and tighten the xing bolts.
Flywheel lock
Bolt M8 (daNm) 2.5
Fit the xed timing belt tensioner for the single engine component drive belt and tighten the retaining bolt to torque.
Remove the ywheel lock.
Tighten the bolt xing the exhaust side camshaft toothed pulley
to the recommended torque.
402102.01 65
Service manual VF4 VF5
Fuel lter assembly4.8
Make sure that the ignition key is in the OFF position then, disconnect the battery terminal (-) .
Disconnect the rapid connectors from the fuel lter, fuel lter
side.
Unscrew the fuel lter from the bracket.
Raise the fuel lter assembly (3 a) by the required amount and
disconnect the electrical connection (3b) from the water presence
sensor, then remove.
Working at the bench, unscrew the water presence sensor in the
fuel lter and remove.
Ret the water sensor in its seat on the fuel lter.
Connect the electrical connection to the water presence sensor,
then ret the fuel lter assembly in its seat.
To screw the lter in its seat of the bracket.
Connect the rapid connectors for the fuel pipes, fuel lter side.
Connect the negative battery terminal (-).
66 402102.01
Service manual VF4 VF5
Engine coolant temperature sensor4.9
Disconnect the electrical connection from the engine coolant
temperature sensor (1).
Undo the engine coolant temperature sensor and remove it.
Place the engine coolant temperature sensor in its housing and
tighten it to the recommended.
Engine coolant temperature sensor
M ... (daNm) 0.8 Thermostat side
Connect the electrical connection to the engine coolant temperature sensor.
402102.01 67
Service manual VF4 VF5
Pressure relief sensor4.10
Make sure that the ignition key is it in the OFF position, then disconnect the battery terminal (-).
Undo bolts (2 a) and remove the pressure relief sensor (2b).
Position the excess pressure sensor (1 a) in its housing and secure
it tightening the bolt(1b) to the recommended torque.
Excess pressure sensor
Bolt M ... (daNm) 0.9
Connect the electrical connection for the pressure relief sensor.
Connect the negative (-) battery terminal.
68 402102.01
Service manual VF4 VF5
Engine rpm sensor4.11
Make sure that the ignition key is in the OFF position, then disconnect the battery terminal (-).
Disconnect the electrical connection from the engine rpm sensor
(1).
Undo the bolt (2 a) and remove the rpm sensor (2b).
Position the engine rpm sensor (1 a) in its housing and secure it
tightening the bolt (1b) to the recommended torque .
Rpm sensor
Bolt M6 (daNm) 0.6 ÷ 1.0 (engine block side)
Connect the electrical connection for the engine rpm sensor.
Connect the negative battery terminal (-) .
402102.01 69
Service manual VF4 VF5
Cam angle sensor4.12
Make sure that the ignition key is in the OFF position, then disconnect the battery terminal (-).
Disconnect the electrical connection from the cam angle sensor.
Undo the bolts (2 a) and remove the cam angle sensor (2b).
Position the cam angle sensor (1 a) in its housing and secure it
tightening the bolt (1b) to the recommended torque.
Cam angle sensor
Bolt M6 (daNm) 0.8 ÷ 1.0 (cylinder head extension side)
Connect the electrical connection to the cam angle sensor.
Connect the negative battery terminal (-).
70 402102.01
Service manual VF4 VF5
Variable geometry turbocharger4.13
Loosen collar (2 a) and disconnect exhaust pipe (2b) from the turbocharger.
Undo the engine oil delivery pipe connector turbocharger side.
402102.01 71
Service manual VF4 VF5
Loosen the collar on the sleeve the engine oil return pipe, turbocharger side.
Undo the nuts securing the turbocharger on the exhaust manifold.
Remove the gasket.
Undo connector (1 a) and remove turbocharger engine oil supply
pipe (1b).
Undo bolts (2 a) and remove turbocharger oil return pipe (2b).
72 402102.01
Service manual VF4 VF5
Place the turbocharger engine oil return pipe back in position and
tighten the turbocharger-side bolts to the recommended torque.
Engine oil supply pipe from turbocharger
Bolt M6 (daNm) 0.8 ÷ 1.0 (turbocharger side)
Place the engine oil supply pipe back in position and tighten the
turbocharger-side connector to the recommended torque.
Engine oil supply pipe from turbocharger
Connector M10 (daNm) 1.5 (turbocharger side)
Tighten the nuts securing the turbocharger to the exhaust manifold to the recommended torque.
Turbocharger fastening
Nut M8 (daNm) 2.3 ÷ 2.8 (turbocharger side)
Tighten the bolts securing the engine oil return pipe, turbocharger side, to the specied torque.
Engine oil supply pipe from turbocharger
Bolt M6 (daNm) 0.8 ÷ 1.0 (turbocharger side)
402102.01 73
Service manual VF4 VF5
Pressure pump support VF44.14
Position the pressure pimp support in a vice tted with protective
jaws.
Lock the rotation of the pressure pump drive pulley using two
bolts.
Undo the pressure pump drive pulley nut.
Undo the two bolts for locking the rotation of the pressure pump
drive pulley tted previously.
74 402102.01
Service manual VF4 VF5
Remove the pressure pump drive pulley (1 a) using the tools (1b
extractor).
Undo the nuts (1 a) and remove the pressure pump (1b) from the
support.
Place the pressure pump (1 a) on the support and secure it tightening the nuts (1b) to the recommended torque .
Injection pressure pump mount
Nut M8 (daNm) 2.3 ÷ 2.8
402102.01 75
Service manual VF4 VF5
Place the pressure pump drive pulley back in its housing.
Lock the rotation of the pressure pump drive pulley using two
bolts.
Tighten the nut xing the pressure pump drive pulley to the recommended torque.
Pressure pump control pulley
Nut M14 (daNm) 4.2 ÷ 6.6
Undo the two bolts for locking the rotation of the pressure pump
drive pulley tted previously.
76 402102.01
Service manual VF4 VF5
Pressure pump support VF54.15
Position the pressure pimp support in a vice tted with protective
jaws.
Lock the rotation of the pressure pump drive pulley using two
bolts.
Undo the pressure pump drive pulley nut.
Undo the two bolts for locking the rotation of the pressure pump
drive pulley tted previously.
Remove the pressure pump drive pulley (1 a) using the tools (1b
extractor).
402102.01 77
Service manual VF4 VF5
Undo the nuts (1 a) and remove the pressure pump (1b) from the
support.
Place the pressure pump (1 a) on the support and secure it tightening the nuts (1b) to the recommended torque.
Injection pressure pump mount
Nut M8 (daNm) 2.3 ÷ 3.3
Place the pressure pump drive pulley back in its housing.
Lock the rotation of the pressure pump drive pulley using two
bolts.
Tighten the nut xing the pressure pump drive pulley to the recommended torque.
Pressure pump control pulley
Nut M14 (daNm) 4.2 ÷ 6.6
Undo the two bolts for locking the rotation of the pressure pump
drive pulley tted previously.
78 402102.01
Service manual VF4 VF5
402102.01 79
Service manual VF4 VF5
VF4 VF5
402102.01 12-09 Printed in the Netherlands
FOKKERSTRAAT 571 - 3125 BD SCHIEDAM - HOLLAND
TEL.: +31 (10) 4377700 - TELEFAX: +31 (10) 4372673 - 4621286
E-MAIL: sales@vetus.nl - INTERNET: http://www.vetus.com
vetus n.v.
Loading...