industrial engines section 5 8460 INDUSTRIAL TURBOCHARGED INTERCOOLED 8460SRi10.00 8460SRi11.00 WORKSHOP MANUAL Publication No 32024007 Date 10-1986 IVECO aifaquawedinbs podsuen pue Buny!| 20M Ife Yo8uO “esn e10}9g “seous Aigjes ‘senoi6 ‘iewiey, ‘sasse|6 annoaioid :uoisinoid Arayes au Aq pareoipur Yeym Jeam pue YORYD B/O}@/eUL ‘ua!oWa PUB eIaelTene ee ssoInep LONUanald 1WapIoo® He eu eins 9q aq ‘swedes Aue BumUeIS 810}88 “squapiooe ajg1ssod je Woy suovesedo aun Sunoeioud ‘elu enp Ul PeUTeIgo aq jm eNpeoosd sledal 1984109 e ‘seunnay dyads iuazeuL! ain BuIsn pue suononasut paiddns eta BuMMolog “aui6ue Su Jo ]uavOod.I09 eiBuIs Yoee UO Ino Paleo aq oO} sUOREsedo rede! JO spouiew ajaeuns aun Lim seuT8601 e1ep Due sainieay saiddns uoReoyand SIL “seununos Snover ayy Ul me] 42 JO suauiaunbas ain 01 unojuoe } o87@ pure suOseA! [AI> reused J0 feo1uyoe1 JO} “awn Aue ye “vesnNoe|NUEW aut ‘Aq ino payiies suoneayinoi Buywolo} parepdn uaaq ‘aney you Aew uonesugnd siyi wi paureIUOD BIeP YL8460 INDUSTRIAL - TURBOCHARGED INTERCOOLED SRi11.00 ‘SRi10.00 GENERAL 1 1 ASSEMBLY CLEARANCE DATA 2 2 TIGHTENING TORQUE 8 a TooLs 9 9 DIAGNOSTIC 10 10 DISMANTLING THE ENGINE ON THE BENCH 20 20 SERVICING - CYLINDER UNIT 23 23 VALVE GEAR CAMSHAFT 26 26 REPLACING BUSHES: 28 28 TAPPETS 28 28 DRIVE SHAFT 20 20 MAIN JOURNALS 0 30 CRANKPINS 30 30 FITTING MAIN BEARINGS 2 2 FLYWHEEL - REPLACING THE FLYWHEEL RING GEAR 35 36 CONNECTING ROD/PISTON ASSEMBLY 36 35 PISTON RING 37 37 CONNECTING RODS 38 38 MEASURING CONNECTING ROD at 4 TIMING GEAR 42 42 INJECTION PUMP CONTROL 42 42 ASSEMBLING AND TIMING THE INJECTION PUMP 44 “4 CYLINDER HEADS 45, 45, VALVES - VALVE GUIDES 46 46 VALVE SPRINGS. 50 50 CYLINDER HEAD ASSEMBLY 50 50 PUSH RODS: 51 51 ROCKER SHAFT - ROCKERS 51 51 LUBRICATION - OIL PUMP - OIL FILTER 53 53 COOLING SYSTEM - WATER PUMP __ THERMOSTAT. 34 24 COMPLETING ASSEMBLY OF THE ENGINE ON THE BENCH. 54 54~ 8460 GENERAL Engine p.1 TIMING LUBRICATION Valve Timing ~ Minimun oil pressure- = Intake + al full throttle + 3kolem® opens - before T'D.C R atte"! | -when ting... 1,8 kglom* closes after 8 DC. ae 2 - Exhaust opens before BDC coon 54 closes : after TDC. 18° 28" STARTING Operating clearance between valves and rockers, cold engine, intake 0,25 mm exhaust... 7 0,50. mm FUEL SYSTEM In line nyection pump type Bosch PE Fixed injection pump delivery start advance. . 11° 30° Fuel injectors setting, . 260 + 8 bar| Finng oraer . sess A823 8-24 By starter motor ELECTRIC SYSTEM = Voltage. + Self regulated alternator . + Starting motor power. + Battery (optional. 24 24V, 558 5.4 KW 2X 143.An8460 ASSEMBLY CLEARANCE DATA CYUNDER HEAD AND CRANKSHAFTS COMPONENTS Engine p 2 oi Cylinder barrel housng x! a upper 137010 ~ 137038 lower 134000 = 134025 Cylinder barrels ‘owtemal dameter upper 136975 ~ 137000 a oF lower 133972 + 133990 : Length L . Cynder barrel { Upper 0010 ~ 0060 7 ousngs diameter {lower : fon engne block _ comics > Btemaldameter 2 - Cynder bare x Internal dameter A @ 3 119990 - 120015 | Protuson x 004 ~ 007 ~ Pistons a : a 119863 ~ 119877 0008 + 48012 Qe oar ous = 0152 Diameter piston Protrusion pstons Piston pins a Pistons pin - pin housing ei x 3033 = KL Somysots x2 306 + 308 COO UBSES 2 * The dimension is measured on a diameter of 117 mm 503 + $058460 Engine p 3 aie ~ 3075 — 3085 $2 2975 ~ 2990 0105 — 0155 | i ay 4975 ~ 4950 | Qe Sole rg - [ag b> hme Opening between the end spit ng in cyinder barre + ia a 040 = 065 3 xs x2 | 025 = 050 I 0070 - 0105 0040 - 0075 xa | 040 + 045 Gye Housng dameter for { smal end bush o1 | 52000 ~ s2025 Housing big end i OLfe: bbearmg 22 | 86213 + 86235, rameter bg end journal ik | OF ea as | 2110 + 2169 t\ s internal ah 93 48023 + 48033 oO} on Connecting rod ; J halfoeanng 3 2079 — 2089 a ‘Small end journal ~ housng (0085 = 0160 Qe Piston pin ~ journal 0030 + 0048 wea) | | Connecting rod half beanngs 02540508 ‘4a. cae : | Standards x 12s Max tolerance on 7 journal algament. = oo78460 Engine p. 4 ge Man journals a1 =_ oo 07950 — 07900 Man beanng shells 1978 + $2000 $1 s2 Sl =thcness] $1 2981 ~ 2991 J Big end beanng sets ae TT maetcenee Tee 23 ranveannghousngs O3 98000 - 96022 Qe panes 0038 + 0.102 eigac 0035 + 0089 Man beanng shes 0254-0508, Mar urna eux beanrg x! 3594-5600 Man beanng hovsag rust bearing x2 4800-4805 Thrust washer haves x3 3870-3920 Crankshaft end fost 005-026 “Trev washer halves 0 127~0254~05008460 Engine p.5 12 1 5005 } Abgrment ; 2 a. ‘Ovalizaton Oo 1-2 0010 | we (DS ooo CYLINDER FEAD VANE GEAR Bi Ve gue housngs 16000-16018 Bz a a2 9.025 -9085 ve gue @3 16028 - 16039 2s a — | 0010-0039 ee A Valve guides: - Za Taxes 24 3990-3955 | co a eorist 3 O4 8980-8995 fu aise 3 Qe Valve stem and ns guide ‘ousy 0065 Tong mead or wens oa a 80995-51020 Cisne danciaroPave sea _ een en ma 22 5107051085 OQ «g od 22 14060-44075 @ to ¢ reEngine p 6 ~ eS ae x Varesntrg x PO ie ay 0050 ~ eS Mating berween vave fod id) send my 004s ~ 090 Sprnghaght Free sonng u 833 Spring height under a load of HD Sige akg HI 33 TBkgt3g HD 40 Y Camshaft support pins X 12a 04 3 CYLINDER BLOCK AND CRANK MECHANISM COMPONENTS Camshaft beanng housngs in crankcase — 2 65000 + 65030 a] al a) Bz Camshaft beanng journals ° ond front aI 61910 — 61940 wmiermedate and rear 2-3 61870 = 61900 aT os = i Outside dameter of camshaft bushes 65110 + 65160 4 F Inside dameter of ed bushes: ah 62000 + 62030 Cashes andhowange = os ahaa 008 - 016 Bushes and heanng jure ae front 06 + a2 intermedate an cea 0.10 = 0:16 Carn if ao : ajo4 8 pu H 88460 Engine p. 7 Tappet cup housing vnverankeate a 19000 - 18027, Outsde diameter oF oa es | topean ¥-_ 2 17960-17892 @ 23 17938-17970 ae Between appets and hovangs (0030-0087 4 &> Tappers ost 1 =H Rocker shat a 25015-26036 oz aS Beween odes and a 02s = 004s Fenwe n TOC or = Q Mee poise presure . moe woe «0 Engne wenover sped. rom 200 ~ 250 (") The value for the pressures is recorded by turning the engne over with the electne starter motor, swith ol temperature at 40 ~ 50° C and the injecton pump in the stop condition8460 Engine p.8 TIGHTENING TORQUE DESCRIPTION TORQUE Na er ‘Cylinder head attachment bok # {ok sage prebrnary torque 100 (102) 2nd stage prelmnary torque 00 (102) 3rd stage angle 80° + 5° Man beanng cap attachment bolts @ Preliminary torque 175 (uy) Angle 90° 5° Big end cap attachment bolts @ Preliminary torque 45 a6) Ange 50° 5° Flywheel attachment bolts Prelimnary torque 00 (102) Angle 60? + 5° Fywheel cover attachment bolt 150 055) Bolt eétanng pully to crankshat ® Prelernary torque 200 (204) Angle 90° & 52 Inlet manfold atachment bok 75 3) Exhaust manifold atachment bolt 0 o Compressor gear allachiment nut 130 ay Rocker shaft mounting attachment bolt Prelennary tightening 7 ayn Angle 80° & 5° © Lubricate with UTOM ai before tightening8460 Engine p. 9 TOOLS TOOL NUMBER DESCRIPTION 99342145 Extractor for mector holder case 99350071 Socket wrench (19 mm) with 3/4” square attachment for ughtening cyinder head botts 99350108 Weench for vale gear clearance adjustment screw 99360184 —Phers for fting rings to engine pistons 99360263 Tool or remowng and refttng engine valves 99360314 Tool for remowng cartnge fi 99360320 Teal for turning fywhee! 99360351 Tool for retaning fywhee! 99360423 Teal for feung front crankshaft seal (use wit 99370006) 99360471 Adaptor for checlong cyinder compression (use wth 99395682) 99360475 Ont for rernovg an feng busing on nyecuon pump shaft mournng (use with 99370000) 99360481 Dnt for removing valve guide 99360494 Dnt for fing valve gure (une wh 9936048 1) 99360500 Crankshaft fong tool 99360504 Rang fo hing cylrder block 99360585. Hossong beam for removng and refitting engine 99360603 Ag clamp for mserung standard and oversize pions nto the cylinders 99360772 Threaded plate 99360775 Setof sues 99360778 Bcracton bolt 99360782 ny 99360790 Set of parts 99361032 Brackets for securing engine to swiveling anc 99322230 99365063 Tool for refitting mector holder cases 99370006 Handle for mnerchangeable deits 99370415 Tool for measunng cyinder Iner protrusion 99370454 eoLaling wo for tang crankshaft rear seal (use wah 99380006) 99390311 Reamng tool for valve gude 99390789 Set of ups for threacing injector holder cases to be exacted 99394017 Reamer for recondiuoning lower part of injector halder caze (use with 99394019) 99394019 lot Lash 99394020 Milling whee! for facing injector support housing (use with 99394019)8460 DIAGNOSTICS Engine p 10 Man engne troubles 6 — Exhaust fumes are blue 7 = The engne functions irregularly 8 ~The engne stops 9 ~The engine excites the macinum Tem | ~The engine does not start 2- The engine overheats 3 — The engine lacks power 4 — Exhaust fumes are black or dark grey 10 ~ Oil pressure 1s too high or too low 5 — Exhaust furnes are grey 11 = Fuel consumption is too high ‘THE ENGINE DOES NOT START [om the battery termmals — a | Clean. check and tghten the nuts onthe battery cips | = NO | or change them | " Barenes effeent Carry out the checks desenbed in the repar manual = NO | "Blectncal System! ves a =_ -, ——~ a Starter motor werleng Carry out the checks described = NO i - ! l ves y Gow plug werk Subsite \ NO ves y Injection pump delivering i ‘Gheckethe entre setup as descrbedin the approprate | = NO >| chapter | ves y Fuel pump workeng correctly Neo _pe | CS ane Frese replae = NO (conunved)8460 1 | Imectors serviceable? NO Engine p. 11 (Check operaton and adust as described Premnere | | Check and bleea —— | J y . __. — = v - ‘Compression ratio as specified? | Overhaul the engine or limit reparrs to the parts con- i | ered (valves, piston rings etc) | i ves _ Y = - Fuel ters serviceable? Replace = NO ‘Automabc aovance reguator and elecine STOP vale (Check and replace the parts concemed serwceable? = NO [-No Coolant level core” Check for leaks ard top up ] = NO vs ‘Water pump and belts serviceable? Check, adjust tension and replace parts ifnecessary |8460 Engine p. 12 ‘Water pump serwceable | [ Overhaul or replace the unt = NO ves y ~ = — Thermostat servceable Replace | Nom} | ves Faciator serwceable 1 Wash thoroughly, check condion replace iF |= NO | necessary ves ‘After arn orca ducts servieabie ‘Clean or replace defectve parts -NO | Yes Injection pump timing correct ‘Check correct ming as desenbed in the relevant | secv0n U = ves Cylinder head gasket serviceable Replace |= NO Yes Fan serwceable Replace NOEngine p.13 3 f Replace, followng the procedure descr bed | = NO} ves [ Feel ieed oreut eficene ‘Checkand cary out the necessary repars 1 = NO P| : Y I J ves y ener fa 1 | No>| t : ! Fuel pump efficent { Reiace i NO ves L ¥ . = Injectors eficent "Check and register as desenbes, | = NO | ves a if oe Iryecoon pump bring correct, ‘Check the regstration as desenbed inthe appropriate = no > | paragrpn | ves y 7 [ieecton pump reguated corecty { Check and calibrate the ryecion pump in the work] | = No | Shop = J (contoued)8460 Engine p. 14 ‘Turbocharger serviceable Repar or replace the unt ! = Nom i t . 4 vs Y —- = UDA crcur and dence serventbe Chece = Nom 4 : “iter erwceable [ Repiace -No >| ves y Starr heater serveeable Replace i = Noe i ve y . ‘Automate book dence cxting.n Check and replace fncestry = NO i ves Ines serveeabie (Check operon and adt as descrbed, |-No >} 1s y iyecbon pap omg correct [ Check correc rng as cesenbed nthe = NO >| relsvaesecvon ‘s LDA dewee servessle ‘jun te LDA dence ung i001 79300002 = No8460 LDA dence efficent - NO Engine p 15 | Check the setng of the LDA devce wang too! | >: 99508002 ‘Check and calibrate the injection pump in the work- sNom Sip ves Y - Compresion rato core ‘Check ang 00199595682 and cary out necemry ) chamber repace te canes has pe or oe | te eneneExcesswe oll consumption = NO Engine p. 16 ‘Check ol breathes cyinder compressions FFnecessary ovehaul the eyinder head or engne T 7 | ABNORMAL KNOCKING FROM THE ENGINE 2 OO vs \ Knockng coming from crankshat | = NO ves Y Knocking coming from connecting rods | ‘Check main journals for clearance and oval tightness {of main bearing cap bolts and fywheel bots ol pressure Replace parts Gr overhaul the engine | Check crankpins for clearance and ovaly ughtness of | wo me | conectng ou ap bots conmecing ens er esioe i {on Replace parts or vera the eopne Ys ¥ Knocking coming rom pions © Gheaccearance between tons and epnde” bers = No a! jon ngs fo treat gucgoon pf pon boss " Gearances Replace part of overhaul the ene ve _ __Y Knocking cong rom cinder head [ Cheacoperatng clearance between rocker ars and | = NO = | valees injecton pump timing valve tming Adjust ves Y [ Keone coming for rng gears Check ears and replace necessary = NO ves8460 | Knockng located nthe wjectors | Geka aris arene om Fuel inthe tank. Ys Fel fiters eficent. ves LE Engine brake wortang correctly i Fil tank and. necessary, fush Check and replace f necessary Engine p 17 | - NO | ves — —— _—_—. Fuel supply orcuteffcent (Check the ppes and fush = NO ves y - —— Engne ming correct i Calibrate = NO ae ves yi . - . -— ~. Injection pumps set correctiy (Check the flow rate nthe workshop = NO (contnued)Engine p.18 ~ 9 |> ENGINE EXCEEDS MAXIMUM RPM EXCEEDS ul | Speed governor opera corecty 1 ‘Check and epace worn parts ifnecessary =NOe : | 10} OIL PRESSURE TOO LOW | ORTOO HICH Y a a | Pressure relief valve operating. : Check and replace if necessary: - | |= No J ~ i: ys Y = - [ Ol punp and debvery ppes servceable 1 {Check and renlace necessary Nom vs 7 7 = [ Pan and’bg ene beanngs serwceable Replace beanngs and Fnecesary recond ~|| = NOD Sate i _ _ = vs y = Engne ol wscosty correc Replace engne ol wh one of stable wicosty = NO Fuel tank and pppes seruceable | Eheunate any leaks and replace parts showng de- = NO» | tenorston8460 Engine p.19 = eter con : ' — ' _ | = as . _ | Injectors calibrated correctly j Ceckand calibrate according. ' i “| i = v _ . = Se | [inemon pump carated conecty [ Cheat ane aia nthe worknop : oa . | : a = ly eee TDA dent eomre Calirte the LDA deve ving oo 90%002 co. = y - Inyecton pump adjusted correctly i Check static fit of the section pump | ao8460 Engine p 20 DISMANTLING THE ENGINE ON THE BENCH Secure the engine to swwveling stand 99322230 by means of| | Q) belts crwng aternator brackets 99361032, dran the iubncation ol from the engine | | O) alternator oll sume Q rem putey ang mount. Remove the ol level dipstick sleeve O water fiter Disconnect the wscostauc fan assembly ee ‘The iscostanc fan must be replaced in upright postion (Lippe from coolant pump to heat exchanger ‘water pump with thermostat, batt dive pulley and damping fywheet Continue dsmanting the engne by remowng Removing damping flywheel hub ssarter motor fuel hoses from iyecton pum, fuel fiters with mounts, Prevent crankshaft from rotating using toc! 99360351 Using sutable socket wrench (2), unscrew bolt retaring hub (1), screw reacton block 99340028 in place of the batt Ths el recovery ne Meine Bel BA crocs brecauton protects te opertoraganst the possi othe Fitment, fab sudan coming oote dung oval fel deer ine injection pump injectors, eemoving retaning brackets, ‘ylinder head coolant manifold rocker cover coococoooc00 ‘Apply extractor 99340030 (2) to hub (3) complete with hy- ‘Grate unit 99341033 Remove the damping fywheel hub with ‘the aid of hydraulic purnp 9934 034 (1.- Continue by deconnecen The ines for of delvery to (5) and retum fom (6) the supercharger the supercnarger (2) Cl filters (4) and bracket (3) complete wath the heat exchanger ar compressor and water ppes exhaust mansold (7) equaliser shaft (I) equalser control rods (8) valve stem caps Cyionder head using appropnate eyebolt two impulse transmtters (9) on the rear bracket and on the nection pump bracket ooooceo oO Rotate the angne and remove O theolsum (i) timing gear cover (2) ol pump complete wats engine ol suction rose Engine p 21 (ny forthe engine models with two oil pumps the ‘200 ll delvery and return pump: complete with engine ol suction rose ae ce RC NAP NR v A 1) bgend caps with half bearngs Bi connecting rod ~ piston unt (1) withdrawing them from the upper part of the pston barrels, ‘When removing the connecting od = piston unit check whether the connecting rods and relatve caps are numbered If they are not mark them with fapproprate manbers acurdig lo Une barrels they belong to Stripping the Engine Flywheel Usnigtool 9936035 (2) blockthe rotation ofthe fwhee!(). loosen the screws (3) remove the tool (2) and ernove the engne fywhes! CContinse by removing8460 Engine p 22 rear mourtng (1), Fo] tapers (1), cover (2) wth sealing ong Of spray ets (2), | | ovincer iners as desenbed on page 24 (Once the engine i csmantied clean the parts thoroughly and cheek for damage crankshaft (2) by means of tool 99360500 (1), ; | | rman bear cps wh bearng she | al | idler gear (2) and mounting: inyection pump drive gear (3), mounting with injection pump toothed coupling, camshaft (I)8460 Engine p 23 SERVICING CYLINDER UNIT ‘Checks and measurements Examine the surfaces ofthe piston barrels they must not show any sans of serzng, scare. ovalzaton or excessive taper intemal dameter of the prston barrels 1s checked for ovalz- hon, parece taper or wear using 2 100 bore dial gauge 99395687 (2) prewousy reset to rng gauge dameter 120 mm. Ifa. 120 mm ring gauge 1s not avalable use a micro DIAGRAM FOR PISTON BARREL DIAMETER CHECK The measurements must be taken for each cyinder at three different heights nthe cylinder and on two planes one paralet to the longtudinal aus of the engne (A) anc the other per- pendirnlar (B) Mavirune wear e usually found im plane (B) in correspondence with the fst measurement 119,990 ¥20015 Inthe case of maemum wear (0.150 mm) ae masaenum avai ation (0 100 mm) in companson with the values indicated in| figure 23 the barrels must be replaced Thebsrrelshave been subjected to "softrtnding-" treatment and cannot be ground, lapped or trued8460 REPLACING CYLINDER LINERS Remove cyinder liners (2) u 99300711 (3) applied as sho = Engine p. 24 Ses Qe ( CB. Check cylinder head mating surfaces (3) are fat using a cal brated rule (2) and feeer gauge Gennd any rough spots removing as Itle matenal as possible ater removing the locating dowels TA seca Carefully check cylinder liner seats the diagram shows the d= ameters of eyinder liners and seats (Cylinder ners may be removed and refitted in diferent seats several umes f necessary the seal appears to be poor | 4 | tale ‘Check the conditions of plugs (I) fitted n maching hoes and, associated wth cyinder unit Replace if found to be rusty orf j198,5-0.15 ‘After gnnang the cyinder Read surace, restore he depth of the gyinder liner border support base X to _—— h b= | =o 9 = i ‘Atwaysreplace water seals (I and2) each bme the cyl inder ners ae fitedFit the nng gauge (!) onthe piston barrel lubricate the lower part of the barrel and fit t using plate 99360782 (2), too! 199360799 (3) and rods 99360776 (4) Repeat the checks on the protrusion af the paston bacrale a6 cesenbed below ‘Checking and Calibrating Protrusion of Piston Barrels ‘The check on the protrusion of the piston barrels is carne ‘out using plate 9.360782 (3) and 001 99360799 tghrening the screw to torque 140 Nav Engine p 25 a C~) Ong | Usng toot 99370415 (2), ted wath a dal gauge, check that | the protrusion of the piston barrels (1) 5 0040 007 mm | ifte values regstered are not within these iis proceed as follows OD exact the pston bare remove the water sel (| and 2rgee 3) caine the hg gauge (|. Fg 30) § replace the barrel and setup the tool (I and 3 Figure 31) | tgnten the seews to torque |40 Nn to ensure thatthe edge ofthe Baral is stung cocrecty in the housing Oy esingt001 99370415 (2 Figure 22) feted wath aha gauge, measure the cnuty in han places (at 180°) and find tha average depth Then on the basis of the average depth use the table below to find the correct ring gauge to ft Depresson wha range | Thedness of hm to be | | | i EET Ert a i | | I I fied (mm) [ 008 0035 — 0054 o10 (0055 — vor viz 0075 — 0095 ol8460 VALVE GEAR CAMSHAFT Engine p. 26 (ST570 51310 GET 61900 Al a) MAIN CAMSH) 1ABT DATA (0 ‘The data guen refer to normal ournal diameter “The surfaces of shaft bearng journals and cam journals should be perfectly smooth, Its adwsable to replace the shaft and bushes ifthe journals show signs of binding and sconng CHECKING CAM LIFT AND JOURNAL ALIGNMENT. ‘Arrange the carnshaft (4) between the centres (|) and use dal gauge (2) check the lft of cams (3) which should be ‘8 mm for the let cam 18 mm for the exhaust cam Sull wath camshaft (4) arranged between centres (I), check | algnment of bearing journals (3) for makgnment usng dal gauge (2), this should not exceed 0020 mm Replace the shaft misalignment «found to be greater ‘To check the instalaton fi, measure the dameter of camshaft journals (2) usng merometer (I) and the msde clameters of bushes (3) using bore micrometer (4) The actual station ftis calculated asthe difference between the two values Tas should be U 60 ~ 0 120 mm forthe front bearing and 0 100 — 0.160 mm for termediate and rear beanngs Ifrugher clearances are found, enlace the hishes and ako the camshaft necessaryEngine p. 27 8460 Replacing Camshaft Gears = ‘Check that the teeth of the control gear (|) are not broken ‘or wom ifthe gear (|) sto be replaced t must be welded at 200°C and fted so that the distance between the shoulder (of the camshaft (2) and the shoulder ofthe gear is 8:3" mm BUSHINGS 1_{6500] 6503 eS in L [6200] 6203 CAMSHAFT AND RELATIVE HOUSING MAIN DATA FOR THE BUSHING OF THE * Value to be taken after ting the bushings with the bore dial gauge (Fgure 31) For the sinpping and refting ofthe bushings use an appropn= ate beater ‘The camshaft bushings must ft very ughtly in ther housings.” ‘The ntarnal surfaces must not show any traces of deag or wear Before replacing the bushings measure ther dameter8460 REPLACING BUSHES In order to replace dhe ar bush, rst removeseaing phug( I) on crankcase. Spread LOCTITE 275 over the surfaces of plug (!) when fitting, Fe the bushes so that ol feed holes (1) are aligned with crank case holes Engine p 28 TAPPETS. | Replacement tappetsare supplied. standard aes and 05 ~ | mm everane Replacing tappets ch. | When replacing loose tappets ft oversize tappets and cut housings (2) using a sutable reamer (1) MAIN DATA FOR TAPPETS AND HOUSINGS INTHE CRANKCASE Fitting tappets ~ Camshaft ‘Aft tng ream the camshaftbushes to speced values using ‘chuck (1) fitted wrth guide bush (2) and cutter (3) —<$—$$ _______ I In order to positon front plate (I) perfect Rtinter- mediate gear mounting (3) in its seat and tighten screws (2) t0 specified lorque8460 Engine p 29 | not to damage te syppars bushes when assembl | secure the camshaft to the tront plate wath the special plate The thread of the secunng screws s veated with a i thread locking product, "Esiok’. n the area indicated DRIVE SHAFT ae + = ES} — i dda fh MAIN DATA FOR THE DRIVE SHAFT PINS AND THE HALF BEARINGS. fo) ‘Check the condition ofthe journals and the big end pins, there must be no signs of scorng, ovalzation or excessive wear ‘The data guen refers to the normal dameter ofthe pins8460 MEASURING MAIN BEARING JOURNALS AND CRANKPINS. Before regnnding the journals, measure main journals and crank: pss (2) wath micrometer gauge (I) and artableh the diameter to.which the journals must be reground on the bass ofthe scale of beanng underszes Engine p 30 (Undersize categones are 0254 0 S08mm MEASURING MAIN JOURNALS \ weasurevenr orconnecrag | postekctcmnd Itsadmate to eterthe messes recordin tabeepee) ee | MAIN JOURNALS oe romana 1 MAXIMUM 2 — t | Tile tr ning man rt H pee tet C LN MINIMUM © — MAXIMUM CRANKPINS Se UEEveaeaEEte sree Main journals and crankpins are aways all ground to| ‘the same undersize category n order not to impair crankshaft balance, | Regrnding carned out on main journals or crankpins must be mncicatad by apprapaate marlange amped on the side of crank web n0 | For undersze crankpins the letter M1 For undersze main jours the lewer B For undersze crankpins and man journals the letters MB ————_—_—_————8460 ‘When grinding the journals and big end pins ts essential to ‘mamta the values shown in figures 52, §3 and 5+ Figure 52 - | | | I fs | | | ae = — _ | a > Figure, $3 _ Detail of the union ofthe big end pins Ret = gnnd “Figure'54. 7 Detalof tne union ofthe front. intermediate and rear journals Rett. = gred Engine p 31 Checking Alignment of Journals and Big End Pins | al | Thus check must be cared out after grinding the deve shaft fins Pace the eve shaft 2) on the taisock and use a 1/100 1 a gauge (1) Cy Alignment of journals marnum tolerance 0 10 ram between two Successwve pins and 0 20 mm overal reading D1 Aignment of the big end pins wth respect othe journal. the ax ofeach parmstbe on the same plane mairnur tolerance perpendicular to that plane = 025 mm The tolerance for the dstance between the aus of the deve shaft and the external surface of each bg end pins 0 10 mm.Frywheel attachment fange when the shaft 1 rotated, wth thel dal gauge resting as shown, over a ameter 2-4 rm less than the maxemum diameter of the support surface, the changes| should not exceed 002 rm REPLACING TIMING GEARS AND OIL PUMP Check that the teeth of gears (|-2) are not damaged or worn Otherwise remove Using an sppropnate extractor : ‘When fing new gears (I and 3) and bush (4), heat both for 10 mutes in an oven at 200°C and before fitting to shaft ‘When ftng gear (1), take particular care to algn hole (8) wth thehole onthe shaft. Use aémmilocabngpa forthe operation, Engine p. 32 | FITTING MAIN BEARINGS Replacement mam beanngs are supped in nse ameter underszes of 0254 - 0508 mm re re ener Do not attempt to adapt beanngs Postion bearing shells (1) 0 main bean housigs Fit oul spray jets (1)Lit the drve shaft (2) using to0! 99360500 (1) and vest it on the haifheaning ‘Checking Clearance of Main Bearings The check s earned out using calibrated wire, as follows 1D clean the parts carefully and a particular ebminate any sraces of a place apiece of calibrated ware (4) on the drve shaft pins @), parallel to wre longrudinal aes Or fitthe caps() complete with half-beanngs to the relative supports, G lubecate and positon the fang screws of the caps and ‘ughten them using a force gauge spanner to the pre serhed torque Remove the lower engne block and calculate the clear ance between the man half bearngs and the drve shaft bigend pins by companng the width ofthe cabbrated wire at the vadest point wit the scale on the envelope (2) Engine p 33 ‘Checking Driving Shaft Shoulder Clearance Ihe standard clearance 1s 0050 mm ~ 0260 If clearance | exceeds ths fgure replace the shoulder half ngs with new | ones of standard ar increased thieknese Engne block half ings are not interchangeable Pace the shoulder clearance nngs (I) on the central support, ‘wath the channels towards the shim of the drive shat der clearance half rings (2) with the ant-frcvon alloy auface towards the shun ofthe dnve shatTighten the hong screws. the beanng caps tothe prescrioed torque, check the shoulder clearance of the drwe shaft (I) Using a comparator The standard assembly clearance 1s 0050 ~ 0260 mm Instructions for the fitting of the self-centring of the shoulder clearance half rings. Tighten the screws (I) ofthe beanng caps to torque 80 Nem loosen the two screws o the central cap (2) and tighten them to torque 15 Nn ‘The fnang screws ofthe beanng caps can be re-used Unulthe ofthe threag sess than 17 4 mm measures ‘over the length of 50 mm. cs Pace an axal force (=) of 2500N on the front part of the | ‘dows shaft and ralaasa carry out the tame procedure on the ‘opposite end ofthe deve shaft Tighten the two screws ofthe Centra cap tothe presenbed tore (1175 Nm + 90" 5*) | Engine p 34 spanner 99395216(1) Rear Cover Drive Shaft Ff. the che rng on the rear cover (2) use the wrench 99370454 (I) and anp 9937006 (3) = Fit the rear cover (1) with relatve seal on the engine blockFitrear mounting (I) and tghten botts (2) toa torque of 1425 Nim (1445 kgm) using 2 torque wrench FLYWHEEL, CCheckthe clutch plate mating surface Skim or replace the f= wheel if sconng is present. REPLACING THE FLYWHEEL RING GEAR Ifthe teeth of the rng gear fitted to the flywheel are badly damaged, replace the rng gear Before feung, the rng gear ‘must be heated to a temperature of 80" C | Fiywheel atachment boits may be reused unt the diameter reduced to below (5S mm Installing the flywheel Engine p. 35 CONNECTING ROD/PISTON ASSEMBLY PISTON ~ CONNECTING ROD ASSEMBLY | Piston = 2 Retaning cips ~ 3 Sealing nng ~ 4 Oi scraper ring 5 Gudgeon pin § Circips~7 Bearing shels = 8 Connecung rod -9 Connacong red cap ~ 10 Screws ‘Checkthe pistons Replaceifthey show signs ofseizng sconng, crackng or excessive wear Fife (4); apply retaning tool 9936035! (2) and vghten retaining bots (3) to a torque of 100 Nev (102 kgm) using a ‘torque wrench. Further ughten through 60° 5° using grad- ated dence 99395216 (I) [Remove the piston nngs from the piston (2) usng pliers 99360184 (1)Removal of the spit rngs from the piston (2) using pers 99360184 (1) \¢ al Remeving the piston pin spit ngs (2) using the round upped pliers (I) Removing the piston px (1) Ifremoval is dificult use the appropate beater Engine p. 36 ‘Using a ericrometer (2) measure the diameter of the piston I) t0 find the assembly clearance The dameter should be | measured 20 mm fren tne hase Piston Measuring the Diameter of the Pistons The clearance between the piston and the piston barrel can| be checked ether by measuring the diameter of the pistons and of the barrels or using a feeler gauge (|) as ilstrated Piston Pins ‘The pins are fitted with clearance on both the bg end and on the pasion ‘Measuring the dameter of the pan (1) using a micrometer (2)8460 Engine p 37, 49008) ~~" (47989) (48012) Re MAIN DATA FOR THE PISTON, PISTON RINGS AND GUDGEON Pity ( Engine 6460SRI10.00 ) +The demanson s measured ata damete. of | 7 mn Ta 75) (2875) (as) CRSETIONTD) (288 3083) (Be fiass) (2828) (2338 : fea) MAIN DATA FOR THE PISTON. PISTON RINGS AND GUOGEON FIN (Engine @460SRi11.00 ) + The dmeneon et measwed at ameter of 117 mm Conditions for a correct gudgeon pin to PISTON RING piston fit (uss Lubreate pin (1) and rs housing inthe piston bosses with en- |__| Creck the thickness of pston rng (2) using micrometer (!) gee cal Pish the pan ina the pistan hy presing lghtiy wath 3 finger It should not drop out under is qwn weight.8460 Check the clearance between piston rngs (2) and the grooves ‘on piston (1) using eeer gauge (3) a] | Compreznonning 2) nthe frat groove swedge shaped Clary | ance X between the compresson reg and he groore treasured postonngpton (I) wrth beclevanrrgm yi Gere (3) nsocha way tat tbecompresson nrg hal projec frm the rand ner a eo o, S O20 08 » 2%2 © 2% ee Measure the clearance between the ends of piston nngs(!)in= | | serted nto cyinder liner (3) using feeler gauge (2) Replace the piston ngs ifthe gap between the bottom ortop lends s greater or lower than specined Engine p. 38 CONNECTING RODS 38 i Zi MAIN DATA FOR CONNECTING ROD, BUSH, GUDGEON PIN AND BEARING SHELLS Domension to be cotamea ater presiiting te bah Checking connecting rod for distortion Check that the connectng rod axes are parallel using tool 99395363 (|) and feel gauge (2) Permtted tolerance s 007 mm measured at 125 vn Fom the rod longrucinal xt Each connactng rod body and cap ara marked wth a number indicating that they ft together The connecting rod may aso be stamped with the number of the cyinder in whch 2s fitted In case of replacement, therefore, mark the new connecting rod with the same numher a the old ———$—8460 Bushings Engine p. 39 Remove and refit the bush (2) using the appropnate beater Q ‘After postuoning the bush n the smallend ofthe con- heubig rod machine Une bush to obtain the pre- senbed diameter Machne the small end of the connecting rod using goer 99301044, Fitting the Connecting Rod ~ Pi Connecting Rod - Piston Mating ton lhe mating between the connecting rod and the piston must be carried out according to the followang values Fit the piston (2) onthe connecting rod (3) so that the arrow (1) marked on the top is towards the operator Ft the per (I) and the choke rings8460 ‘Checking the Connecting Red ~ Piston Unit Checkthe alent of te conectngod—pstonuntuseg | 100199295361 @) anda bor gust (The mrace ons topo the ptr mast be perth pereraeuarta ne hace Soe too ‘The screws forthe connecting rad can be re-used as long as me diameter ofthe tread iat least [34mm ee RE RNAS Fitting the Split Rings To fit the split nngs (1) to the piston (2) use the pers 99360183 (3) Therngsmustbe ftted wth the word"TOP" (4) upwardsand the gaps must be turned through 120° | | Engine p. 40 e Fitthe half bearngs (1) on the connecting rod and onthe cap Do not ty to adaot the halfbeanngs Fitting the connecting rod - piston into the pis- ton barrel Say \ DIAGRAM OF THE MATING OF THE CONNECTING ROD AND THE PISTON READY FOR FITTING INTO THE PISTON BARREL | Maung number is printed here 2, Raised arrow showing. ‘direction n which engine rotates 3 Onve shaft8460 Fug coorevony rod-pstunt assembly (1) nto the eylner liner using ang damp 99360605 (2) Lubricate the parts concerned before fog ‘When fitting the connecting rodipiston assemies, check the followang ‘Arrow (1) stamped on the aston crowns faces toward the front of the engine. Connectng rod numbers (1 Fg 91) face away For the opposite end of camshaft (3) The piston ring gaps are staggered 120° apart MEASURING CONNECTING ROD Proceed as follows to measure the clearance” clean parts thoroughly and remove all traces of ol, Engine p 41 ostuona stnp of plastigage (3) on crankshaft journals (2). ftthe connectingrad cap and tghten the bolts tothe spectied torque “The bolts must be lubnieated, eemove the connecting rod cap and determine the clearance by comparing the widtn of plast- g2 (3) wath the scale divisions gen cn package (|) containing the plasugage Fitting big end caps lend caps (2) with beanng shel Tighten bots (I) toa torque of 5 Ne (4 6kgm) usngatorque | wrench Apply tool 99395216 (1) and tghten the bolts further through an angle of 0° & 5° ‘Checkthatthe connecting rods can be moved from sdeto side (on the crankshaft journals,8460 Engine p. 42 ~ Checking the Po: Replacing the Bush of the Intermediate Gear + ts ‘~ | When itungiscompletedcheckthe postionoftnepstons(2) | | Ftthe bush (fg 104) so that sts below the plane ofthe gear’ | weing 2 magnets base dal gauge (1), provuson nant vot | | byl-=1 Sem afer Reng grind the bush to cotam heceeerr exceeded 075 mm nominal dameter (98'000] Wi (97.978) TIMING GEAR ‘Checking and Replacing the | 4 = ‘ene ee ones | Check that the surface ofthe intermediate gear support snot ‘Check that the teeth of mtermedate gear are not damaged | | damaged or worn co worn, replace necessary Cheuk Uitte 01 noes are not dogged ees! INJECTION PUMP CONTROL Replacing the Support Bushes 3500 8503, i ss Ge) | = ‘Check the faying surface of the bush (I) f there are nay sgns ‘Check that the matng surfaces of the shaft and the bushes are of sacng or acorng replace the bush uang the epproprate | | rv damaged ana ina clearance not excessve beater The nomial dameter of the shafts 6500 + 65038460 = WWexcessive fit clearance not attributable to the shaft 1s found, | replace the bushes, using a sutable drift for removal and ref: | ing When the busheshave been ttc. ream them out so that her nomial dameter's '30025 ~ 50050 mn CE EEE Fitthe bushes so that they are recessed by | = | 2mm with regard to the mounting surface, Fr the injection pump control couping mount on the front plate after nterposing seaing nngs (1 ahd 2) Engine p 43 == Frethe iyecton pump shaft nto the mount Fitting the idler gear and setting the timing A ES) SA Gan Turn the feel unl the 0 (1) samoed on tindcang TOC ssinlne wn ponter @) Install terrediaue gear (2) wnt support (4), so thatthe marks stamped on it ine up with the corresponding marks on the {ears ofcamshat (2) and crankshaft(|) Ftiryecton pump gear (G), ensuring that reference marks (=>) are algned as before8460 Engine p 44 ‘ASSEMBLING AND TIMING THE INJECTION PUMP LL, JI Veo OT \e XY Wa \ | \ XARA a fetate ne eng hunt ne machined op) whch coresponste te uted enaciymatnes esa pore w Areva the vapcaen cap Fo the yecnen pure, ae thea to deer nan poseon Ft the injection pump matching the notches marked before| stngping to fx the injection pump in the relatwe susport pro-| ceed as follows screw-on the nuts ~ do not tighten to drving tongue (2) C1 positon the rear support (3) onthe engne block and poss tion the screws without tghtering them (4) fit screw (5) wethout locking it 1 tgnten the nuts (2) and the screws (5) to torque C2 tghten the screws (4) Ft tool 99365163 and dal gue tothe pecan pump (I) ‘mcg the rd af the tol oh teag peton soon Sethe dal gauge fo O when te tring ston at BOC Tum the fae! backby Raat Nozate the ee he oppose Greco and creck at | shen he sgn tre Saree (2 Fare 113) whch cores ‘Bond to he spar ad erat mates he metal pot Figze 113) the pump has covered the dolery art poe | vase Ths canbe determined cong te dl gage and oe table of ava eve vals re nt correct loosen the screws) and move the cams (@) nord to eect the presebed preva Repo ns reckon opeantne wees)8460 CYLINDER HEADS Hydraulic leak test Before dismanting the cylinder head, carry out the hydraulic leak test using the appropriate tool Pump water heated to approx 90° C and at a pressure of 4) Stbarsinto the cylinder head Under these conditars: no leaks should be found: they are replace the cyinder hi DISMANTLING VALVES Rest the cyinder head on the workbench and use tool | 99360357 (|) to apply pressure to spring cup (2 130) 50. ‘hat by compressing spring (4) vane colts (I) can be re- moved Then take off upper cup (2). spring (3) and lower cup (5) Repeat the operaton on all the valves, “Turn the cyinder head upside down and wahdraw valves | 8) COMPONENTS OF VALVE ASSEMBLY | Coll = 2. Upper cup = 3 Straus abe — 4 Value sprngs ‘5 Lower cups 6 inlet vale Engine p. 45 BOTTOM VIEW OF CYLINDER HEAD | Sxhaust vale 2 Inlet vale Checking mating surfaces on cylinder block ‘Check mating suace (1) ofthe head wth the eynder block using straght edge (2) and feler gauge (3) ifvaluesm excess of0.5 mm are found over the whale length cof the surface, rue up the head on a sutable utace gnoder reenowng a ila mataral a posse8460 VALVES Removing Carbon Deposits and Checking the Valves Grinding the valves, Hfnecessary eam thevalve gues unngtool 99301014 sextng the angle a 45° [5S tote ashauss vals and 60" 15° or the intake vaies removng the least matenal possible Figure (2b MAIN DATA VALVES AND VALVE GUIDES * value to be taken after fang the vale gudes Engine p 46 ‘Checking the clearance between the valve stem and the valve guide Using 2 magne base dal gauge (2) check the clearance Between the va stem (1) and rlatwe gues If clearance s ‘excessve replace the valves and if necessary the vale gues VALVE GUIDES. Figure 123 BE MAIN DATA CYLINDER HEAD AND VALVE GUIDES A= INTAKE. $= EXHAUSTRemove the valve guides using deft 99360481 (1) Frusing dnft 9936048 (I) equpped wath adapter 99360494 o Adapter 99360494 determines the correct ftng postion for the valve guides inthe cyinder head Ifths partis not avalabl, the guides must be installed m the cyinder head so that they protrude from by the amounts shown in fgure 123, Reaming the valve guides Engine p. 47 Replacing — Recutting the valve seats Sess = ene Wiha retang ab sets ue the appropnis tal oe a ae seas) ae peste by ooig the sus tak | conaring Nave nccpen 180%) and posta e di (I) Installation Gearance. | ile 0050-0090 | exhaust 0045-0090 Using Hunger too! 99360419 (|) to recutthe valve seats nthe cylinder head Recutthe vale seatsin the cyinder head whenever ‘the vaves or valve guides are recondrioned or 1 reolaced al After press ftung valve gudes (2), ream the holes in valve ‘udes (2) using reaming tool 99390311) ‘After recuttng the valve seats, use 100! 99370415 (1) so check that the positions of valves with respect tothe cylinder head faces Inlet valve protusion 035 — 0.60 men, exhaust valve recessing 080 ~ | 058460 Replacing Nozzle Sheaths Inmperfect mating between the Injectors and the sheaths! into the cylinder head or between the sheath and is seat wl cause ether loss of compression or water leaks i Inthe fist case the problem can be soled by reaming the seat | taf the sheath using 120199334020 (|) and the bush 99294019 | (2) —beanng in mind that the myectors must protrude | 2 — 04mm | I fers | In the second case repiace the sheath as follows. Oy thread the sheath using the set of tans 99390786 (1) using the extractor 99342145 (1) remove it from the finder head | Engine p 48 | Using the appropeate tool (1) remove any traces of copper | inthe grooves of te ryndor hood | Remove the upper choke ngs | Lubneate the choke angs (I) and pestica them n the relative seats | Fit the sheaths nto the seats on the cylinder head Cold head the lower seat of the sheath on the cylinder head \ i \ | ‘using tool 99365063 (1) IReam the bore n case (2) using reamer 99394017 (3) and bush 99394019 (1) Restore the protrusion of the injection in relation to the cyin= derhead plane using cutter 99394020 (4) and bush 99394019 (1) Ths should be 2 1-29 mm Checking injector protrusion Use dal gage wth magnetic base (|) to checkthe protruson of mecar (2) fom me jinder hea shee ou by reiting the setong Ung ct” 59394000 and Bush 98394019, Engine p 49 INECTION PROTRUSION8460 VALVE SPRINGS Before fitting check the fexbity ofthe vale springs using tool 99305049, compare data wath standards gen in Fgure 139 Free song, Closed vabe MAIN DATA FOR INTAKE AND EXHAUST VALVE ‘SPRING CHECK Fitting valves Lubneate the vale stems and introduce therm into the respective vale guides Postion the lower and upper spring ‘capsin the cylinder head Using too! 99360357 (1) press the sprng and ft the retarning cotters Engine p. 50 CYLINDER HEAD ASSEMBLY For mounting and tightening the cyinder heads proceed asf lows In order to re-use the head fixng screws (2) use a ‘micrometer to check that the dameter of the thread SS not less than |5 4 mm (measured between 45 and 70 mm from the bagreng of the theese (atherwge replace them) Poston the seals on the block, ft the cinder head (2) ft the screws after oling them and tighten them asexplaned in figure 139 stage pre-torque usng a force gauge spanner (I) to torque 100 No OP sage wen to torque 100 Nmsa) | ‘Stage 3 fttool 9939521 6 (1) to angle gauge wrench (2) and ‘ughten Uiraugh an angie of 180" (CYUNDER HEAD BOLT TIGHTENING DIAGRAM PUSH RODS <<. ‘The valve pushrods mustbe ree fram cstocian, the cup seat ings for the adjustment screws and the bal ends iocatngn the ‘appets (arrowed) must not show any signs of sezng or wear. IF they do, replace the rads. Pushrods for inlet and exhaust valves are ential and there- fore interchangeable Engine p. 51 Fr pushrods (1) into ther seatngs ROCKER SHAFT ROCKERS. (Check thatthe rockers, rocker shaft and pedestals do not dis- play sgns of wear scoring or sen, ‘Check Uiat Une plugs fitad 10 the ends of tne shat prowde a perfect seal (Checkethat the spacer spang dimensions are as showin figure i Free spring 12012 Kg 85 MAIN! OATA FOR CHECKING ROCKER SPACER SPRINGS8460 Engine p 52 MAIN DATA ~ SUPPORTS, EQUALISER SHAFT AND EQUALISERS ‘Assembly Equaliser Shafts and | Clearance Check | Fit the caps on the valve stems Fit the equaliser shafts as follows | bance the sabes of bare Nt fers equaser sho for bara 2,3 oghten the serene to pre torque 7 Nem Te) #101 939506 (I) na en | Sion ange 180" 5+ Balance the vahes for cyinder N° and ft the equaler shaft i for barrels 4,5, 6, ughten the screws as before | | I i ‘Aust clearance between equalsers and valves using too! 99350108 (|). spanner (2) and feeler gauge (3) ‘The working dearance 5025 mm for intake and 0.50 mm for the exhaust Take the barrel tobe checked to fring stroke the valves ofthis cyinder remain closed while balancing tose of the symmetne barrel Symmetne barrels are ! -6,2~S and 3-4 In order to carry out the checks more quekly proceed as follows Dy rotate the drve shaft, balance the valves of barrel IN®| and agust the barrels marked with an asters inthe table below barrel no. [23 4s 6 inate ot ha rotate the drve shaft, balance the valves of barrel N%6 and aust the valves marked with an astensk vn the table Below arrel 0 [i233 3 6 wreak va 78460 LUBRICATION Ibe engine is lubricated using a gear pump (Fg 146) applied to the lower partofthe base with the front support is dnven| from the camshaft using gears. OlL PUMP. am © Engine p.s3 (CROSS-SECTION THROUGH PRESSURE RELIEF VALVE (CROSS-SECTION THROUGH OL PUMP | Pump case ~2. Onving gear—3 Orven gear~ ‘4 Cover 5 Oi pump drve sear (Check that the gears (2-3-5) are not wom or showing de- erorauon and Ghat ther shafts do not dplay excessve play | in the housings incase (1) or cover (4) | Replace oll pump assembly if any faut found, Press. Sbar Ga] Kggeeog) Press. §bai Kgi41=07] Regulation valve Pressure relief valve ‘The reguiaton valves and pressure rele valves are fitted tothe cl fiter mousing (CROSS SECTION THROUGH REGULATION VALVE MAIN DATA FOR CHECKING REGULATION VALVE AND PRESSURE RELIEF VALVE SPRING ‘The regulation valve and pressure reef valves cifer ony in the gap between the four ol ports and the edge ofthe valve case Thisis |35 mm forthe regula [BOM valve ait! 25 am (Or Ure pressure rhe! valve ‘They are not therefore interchangeable upon i sallaton O1L FILTER | Two coublefitration ol fers are fttedto the engine Opennig | pressure forthe fitervave 25 # 0.2 bar I ‘When tng the ers observe the folowng esrucions vol the seas ~ sei thers n unl the seals contact the seatng bases = tigen through a further 34 tum8460 COOLING SYSTEM WATER PUMP (CROSS-SECTION THROUGH THE WATER PUMP. (Check that there are no cracks or leaks n the purnp bod, ifthere are replace the water pump assembly THERMOSTAT ‘Check thermostat operaton and replace n case of doubt Engine p. 54 COMPLETING ASSEMBLY OF THE ENGINE ON THE BENCH Complete engne assembly by nstallng or connecting Ni pump wath strane, — sealing rng 10 ming cover and tering cover to plate Prevent the fywheel from turning using tool 99360351 Fre damping flywheel hub (1) and tighten bott Stage | pretorque of 200 Nm (205 kgm) Stage 2 ughten through 90° st $° usng tool 99395216 2), = damping hpuhoel and akarnator dnve pulley water pump wrth thermostats and water pump-crankcase connection manifold, pulley retuen suppor ai pulley, ‘water manifold on cylinder head, injectors. Ughten to speciied torque by means of brackets, fuel delvery lines from jection pump to injectors. mounting with fuel lters and lines ‘sarter motor, Pulse sender unit and adjust postion as follows tighten Sender unt nto contact, unserew by one turn correspon ing to a | mm gap, tighten locknut to speaed torque rocker cover, exhaust maniol, coolant inhibtoon fiter and connecung pines.