Libro de Tallaer V Gas Ingles PDF

S A F E T Y
REPAIR AND OVERHAUL S E G U R I D A D
MANUAL
DISASSEMBLY
GAS ENGINES
SF/FG IN " V "
DESMONTAJE
I N S P E C T I O N
Ref: 19.09.531
Edition: May 2003
I N S P E C C I O N
A S S E M B L Y
M O N T A J E
T O O L S
U T I L E S
REPAIR AND OVERHAUL
MANUAL
SF/FG IN “V”
Ref.: 19.09.531
Edition: May 2003
GUASCOR, S.A. Barrio Olkia 44.

20759 ZUMAIA (GIPUZKOA)
Spain, P.O. Box 30
www.guascor.com
GENERAL INDEX
SAFETY
DISASSEMBLY
INSPECTION
ASSEMBLY
TOOLS
NOMENCLATURE
PAGE
DISASSEMBLY D- - x/y EXAMPLE: D-T-2/3
SECTION PAGE NUMBER

SECTION
PAGE
ASSEMBLY A- - x/y EXAMPLE: A-50-1/2
SECTION PAGE NUMBER

OPERATION NUMBER
ASSEMBLY
SUB-UNITS S-
EXAMPLE: S-6
SECTION NUMBER
PAGE
TOOLS T- - x/y EXAMPLE: T-10-2/7
SECTION PAGE NUMBER

PHOTO NUMBER
PAGE
INSPECTION I- - x/y EXAMPLE: I-5-1/7
SECTION PAGE NUMBER
SECTION NUMBER
REF. 19.09.531 1/1 REPAIR AND OVERHAUL MANUAL GAS ENGINES SF/FG IN “V”
S A F E T Y
SEGURIDAD
SAFETY
REPAIR ANDOVERHAUL MANUAL
SF/FG IN “V”
Ref.: 19.09.531
Edition: May 2003

SAFETY INDEX
1. SAFETY REGULATIONS
* EUROPEAN SAFETY REGULATION FOR "CE" TYPE BRAND MACHINERY

COMPLIANCE REVIEW
* SAFETY RULES AND REGULATIONS IN THE UNITED STATES
1.- ENGINE DESIGN

READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS
2.- ENGINE ROOM/AREA

3.- RISK ANALYSIS
3.1. MOVING PARTS
3.2. HEAT PROTECTION
3.2.1. COOLING WATER
3.2.2. OIL & LUBRICATION
3.2.3. AIR-FUEL MIXTURE FOR SUPERCHARGING
3.2.4. MANIFOLDS AND EXHAUST PIPE
3.3. VIBRATIONS
3.4. NOISE
3.5. ELECTRICAL INSTALLATION
3.6. GAS INSTALLATION
3.7. CRANKCASE GAS
3.8. EXHAUST GAS
4.- CONTROL & SAFETY DEVICES
5.- IDENTIFICATION & FEATURES
6.- INSTALLATION, OPERATION & MAINTENANCE MANUALS
7.- TRANSPORTATION
8.- MALFUNCTION PROTECTION
9.- SAFETY PRECAUTIONS
10.- CONCLUSION
2. SAFETY PRECAUTIONS FOR GUASCOR GAS ENGINES
3. STANDARDS FOR PROPERLY LIFTING GUASCOR GAS ENGINES
- INTRODUCTION
- GENERAL STANDARDS
- LIFTING ENGINES
REF. 19.09.531 REPAIR AND OVERHAUL MANUAL GAS ENGINES SF/FG IN “V”
SAFETY REGULATIONS
EUROPEAN SAFETY REGULATION FOR "CE" TYPE BRAND

MACHINERY COMPLIANCE REVIEW
The purpose of this "G-60-002 Product Information" document is to describe all aspects
of engine design and peripherals, as well as technical solutions envisaged to comply with
the machinery safety regulation, contained in the UNE EN 292-1 & UNE EN 292-2
standards, which are mandatory for Compliance with the European regulation and
utilization of the CE stamp to Royal Decree 1435/1992 of November 27, 1992 and its
amendments.
SAFETY RULES AND REGULATIONS IN THE UNITED STATES
For details on safety rules and regulations in the United States, contact your local
Occupational Safety and Health Administration (OSHA).
These safety precautions are published for your information. GUASCOR does not, by the
publication of these precautions, imply or in any way represent that these published
precautions are the sum of all dangers present near industrial engines. If you are
operating industrial engines, it is your responsibility to ensure that such operation is in
full accordance with all applicable safety requirements and codes. All requirements of the
United States Federal Occupational Safety and Health
Administration Act must be met when GUASCOR engines are operated in areas that are
under the jurisdiction of that United States department. Engines operated in countries
other than the United States of America must be installed, operated and seviced in
accordance and compliance with any and all safety requirements of that country which
may be applicable.
1.- ENGINE DESIGN
The engines under review for machinery safety in this document are GUASCOR Gas-
Fueled Engines.
These are a development of the respective Diesel versions whose design has been the
subject of technical audit for marine applications by prestigious classification agencies
such as Lloyd's Register, Bureau Veritas, Germanischer Lloyd's, Rina, Det Norske
Veritas, Helenic Register of Shipping and others, earning the TYPE APPROVAL rating
which guarantees the suitability of its basic manufacturing design.
2.- ENGINE ROOM/AREA

According to the standard, the engine room or the area surrounding the engine cannot be
rated as dangerous since there are no instances when solid, liquid or heat emissions are
produced that may endanger operator safety. However, since operators need not be
close to the engine to monitor it, it is recommended that they maintain a safe distance to
avoid any unforeseen fatal failures that may take place.
Adjustment or fine tuning operations (valve adjustment, oil, water level control, etc.) are
to be performed with the engine off.
Carburetion setup operations performed with the engine on must be performed according
to established procedures by trained personnel without it entailing any risk to operators.
1
REGULATIONS SAFETY
3.- RISK ANALISIS

Technical options or solutions that avoid inherent and intrinsic engine operation risks
were taken into consideration when designing these engines. However, due to the very
concept of the engine and its operation, there are some inevitable danger aspects, and,
hence, risk to the operator.
In this section, applied design solutions to be overcome in light of potential dangers

inherent to the engine are analyzed.
3.1.- MOVING PARTS
All engine external moving parts have been protected with covers (fixed guards according
to standard) due to possible inadvertent contact.
3.2.- HEAT PROTECTION

There are several fluids in the engine with various characteristics at various heat levels.
3.2.1.- COOLING WATER

The water circuit has been designed so that all connections are by O-ring gaskets and
mechanical seals suitable for high temperature cooling system engines (120°C/250°F);
therefore, no rubber hoses are used.
3.2.2.- OIL & LUBRICATION

The oil system design is integrated to the engine so the only outlets are those discharging
and return to the oil cooler. All lines are sealed by mechanical seals and O-rings;
therefore, no rubber hoses are used.
3.2.3.- AIR-FUEL MIXTURE FOR SUPERCHARGING

By design, the components of the supercharging circuit (downstream of the turbo) are
sealed with mechanical seals including Viton O-ring gaskets; therefore, no rubber or other
hoses are used.
3.2.4.- MANIFOLDS & EXHAUST PIPE

The engine exhaust manifolds are mechanically sealed with mechanically reinforced
special joints to avoid risks.
Insofar as protection, in order to avoid potential inadvertent contact by people, the
exhaust manifolds have been especially designed with water cooling so on the outer
surface of the exhaust manifold the engine water is re-circulated thus diminishing the heat
level on the manifold surface from 400 to 500 ºC/750 to 930°F to water heat level of 80
a 90 ºC/175 to 195°F.
As for the turbocharger, its turbine casing (exhaust side), which also has a high
temperature and it is not cooled, it is protected by a heat insulating cover (or jacket) that
limits the surface temperature to under 90°C/175°F.
The pipe or outlet elbow is also protected as well as the exhaust pipe installation flexible
joint connecting flange placed outside the engine. This exhaust pipe protection is detailed
in the installation project.
REPAIR AND OVERHAUL MANUAL GAS ENGINES SF/FG IN “V” 2/7 REF. 19.09.531
SAFETY REGULATIONS
3.3.- VIBRATIONS
Engine vibrations do not affect operator safety, although they could indeed be transmitted
through the engine foundation to other machines or buildings, thus affecting the comfort
of people in nearby buildings.
In the engine application in instances where this happens, an engine vibration isolation
system is designed with respect to its seat by means of elastic shock absorbers.
Likewise, all peripheral engine devices (water, fuel, oil, etc.) are connected through
flexible elements.
3.4.- NOISE
Noise is inherent to the engine itself, and, in general, unavoidable, although engine
design itself also provides the necessary protection for an admissible operational noise
level.
Acoustic protection for operators in engine areas when engines are in operation is a must
and, consequently, the need for operators to wear acoustic protection should be noted
clearly and conspicuously at the entrance of all engine areas.
The type of protection is not specified as those usually available in the retail market will
suffice.
Insofar as external engine area noise (noise pollution), silencers and mufflers suitable for
complying with local regulations or site surroundings must be installed in engines.
3.5.- ELECTRICAL INSTALLATION

The engine electrical installation is limited to one terminal box with 24Vdc & 220 V
elements such as sensors, contacts, etc. connected to it. This terminal box and the
installation of said elements comply with low voltage electro-technical regulations. On the
front of said box there is an emergency switch for immediate engine stop.
3.6.- GAS INSTALLATION

Gas installation is performed according to the relevant standards currently in force (UNE
60 - 620 - 88) and it always includes the following items:
· ERM. Control and Measurement Station to applicable design standards. Engine-

specific, it must ensure gas supply at the specified working pressure.
· VALVE TRAIN or set composed of: hand-operated shutoff valve, gas filters, pressure
gauge, twin normally-closed gas supply stop solenoid valve, venting line for leak
monitoring, all of them in conformity with standard specifications.
· CONNECTIONS TO ENGINE, always made with DIN flanges or approved hoses.
· ENGINE-MOUNTED PRE-CARBURATION PIPING designed with a minimum of

1
REGULATIONS SAFETY
development and connections. In any case, the pipes are made to the installer's
standards and checked for leaks during the engine tests.
· POST-CARBURATION AIR/GAS MIXTURE PIPING. The whole circuit has been
mechanically-sealed with Viton O-rings (therefore, no rubber or silicone hoses are
used).
· "BACKFIRING" or "DETONATION" PROTECTION. In a gas engine, backfiring may

happen when burning of the fuel mixture takes place in the intake manifold because
damaged valves do not seal the combustion chamber hermetically. Detonation
occurs if the mixture strength vary out of control or when the mixture autoignites in
contact with hot surfaces.
As a direct protection against these instances, two types of measures or safeties have
been adopted. The mechanical resistance of the equipment (as regards intake manifold
joints, ribs, etc.) has been increased with respect to the normal design specification
(diesel type) and two spring-loaded valves, rated at 2 bars, have been installed in the
intake manifold to permit pressure leak while preventing any overload of the manifolds.
Indirect protection is provided by the engine's own control and regulating systems which
have been designed to protect the engine against erratic or abnormal operation.
3.7.- CRANKCASE GASES

Due to the impossibility of completely sealing the combustion chamber, there is always
an accumulation of combustion gases that may cause oil gases to leak due to
overpressure in the crankcase. To avoid this possibility, all engines have a crankcase vent
that allows their evacuation, and, after proper filtering, these gases in some cases are re-
circulated back into the engine air intake for environmental protection reasons.
3.8.- EXHAUST GASE

Exhaust gases emission is intrinsic to engine operation and thus unavoidable.
There are clear and specific instructions for installing exhaust gas piping that eliminate
the risk of contaminating the engine room.
In these instructions, conditions for installing exhaust devices, pipe diameter
specifications calculation, expansion joints location standards, etc. are indicated.
4.- CONTROL AND SAFETY DEVICES

All engines are delivered with a minimum of safety devices and operational controls, and
although their primary function may not be to protect operators, they do protect them
indirectly by preventing malfunctions or inadequate operation.
These controls or alarms include:
· Engine outlet water temperature.

· Low oil pressure.
· Exhaust temperature.
· Intake air manometer / vacuometer (on supercharged engines).
· and others related to engine operation as a generator.
SAFETY REGULATIONS
5.- IDENTIFICATION AND FEATURES

Identification and characteristic nameplates are installed on the engines for the purpose
of:
· Identifying and ensuring engine recognition and tracing in the production system.
· Indicating its features in order to ascertain safe operating conditions for which they
were built and strict compliance thereof, especially those relating to the FUEL GAS
quality, GAS PRESSURE and equipment power rating.
6.- INSTALLATION, OPERATION & MAINTENANCE MANUALS

Engines are installed according to an installation manual specific for each application. In
this manual we'll find:
· Engine general dimensions diagram.

· Engine peripherals diagram (it includes necessary information for installing all the
necessary peripherals for engine operation: water, oil, fuel, exhaust…).
· Specific installation instructions for each peripheral.
· Specific instructions for engine complements or optional and additional devices (not
mandatory).
The operation and maintenance manuals for each engine are written so the operator has
readily available information for::
· Identification of the machine and its components.

· Instructions for proper adjustment and startup.
· Operational instructions.
· Maintenance instructions (frequency of maintenance operations) are of major
importance as a direct safety element to insure proper engine condition and
operation.
In order to comply with the regulation in effect for using the "CE" stamp, the engine
service manuals must be available in the official language of the member countries where
equipment shall be installed. Fulfilment of these regulations will be achieved by
translating the current Installation, Operation and Maintenance Manuals as and when our
engines are sold to the different countries of the European Union.
REGULATIONS SAFETY
7.- TRANSPORTATION
The engines are provided with solid lifting parts that allow their safe handling by
conventional freight lifting. Likewise, engine weights are clearly stated in the product
information so that they are transported appropriately.
8.- MALFUNCTION PROTECTION

Control and safety systems that allow detection of the operating condition of the engine
vis-à-vis its principal parameters activate PREVENTIVE warning signals when certain
preset values are exceeded, or they simply STOP THE ENGINE when alarm signals are
exceeded.
In any event and in light of any potential control system failure, all GAS engines have a
MASTER CONTROL BOX indicating connections and communication with all electrical
control panels. This Master Control Box has an EMERGENCY SHUT OFF SWITCH for
immediate and sudden engine stop.
Moreover and in all cases, the engine has an EMERGENCY STOP LEVER, which, once
operated MANUALLY and deliberately, blocks the air/gas charge to the engine
immediately, causing the engine to stop at once.
9.- SAFETY PRECAUTIONS

In all instances, we deliver operation and maintenance information together with the
product datasheet (G-60-004) regarding GUASCOR GAS engine safety precautions
indicating necessary preventive measures for handling our engines and their
environment.
SAFETY REGULATIONS
10.-CONCLUSION
In conclusion, as a result of all the above analysis, it can be stated that Series "F"
GUASCOR GAS engines have been designed with knowledge and in compliance
with machine safety regulation requirements included in UNE EN 292-1 & UNE EN
292-2 adjusted standards. Hence, they are in compliance with the requirements that
certify the use of "CE" type brand.
ENCLOSURE
Enclosed with this report:
"G-00-100 Product Information" entitled "GUASCOR GAS ENGINES

MANUFACTURING GENERAL DESCRIPTION".
"G-60-004 Product Information" entitled "GUASCOR GAS ENGINE SAFETY

PRECAUTIONS".
NOTE
All certifications that support the statements and conclusions in this report have been
documented and submitted to external auditing.
SAFETY SAFETY PRECAUTIONS FOR
GUASCOR GAS ENGINES
2 - SAFETY PRECAUTIONS FOR

GUASCOR GAS ENGINES
OBJECT
This product information establishes the precautions to be taken by people handling or
operating gas engines, according to prevailing safety guidelines.
INTRODUCTION
All GUASCOR engines have been designed as far as security is concerned in
accordance with European Standards for machines, contained in royal decree 1435/1992
of Nov. 92, and the unified norms UNE EN 192-1 and UNE EN 292-2. Therefore, they
are supplied under the "CE" mark and with the mandatory statement of compliance with
European regulations.
The intention thereby has been to design a dependable engine, although the very nature
of the machine might not prevent the presence of potential risks, in light of which it is
necessary to adopt certain safety measures.
The purpose of this information is to inform the user of these engines of safety measures
to be adopted that are necessary in the handling and operation of these engines.
The installation of these engines and in particular fuel installations must at all times
comply with local existing regulations at the place of installation.
PRELIMINARY OBSERVATIONS
At the time the "GUASCOR" engine is received it is necessary to read these instructions
relative to the safety precautions that are always included in the user and maintenance
manual, in which are also included:
· A technical description of the engines

· A preventative maintenance manual, where such periodical operations as monitoring
and verification, adjustments, and corrective maintenance operations are described
with full details.
Therefore, it is recommended that the manual be maintained in good condition (clean),

available for use by the operator and those persons responsible for the maintenance of
the engines.
SAFETY PRECAUTIONS FOR SAFETY
GUASCOR GAS ENGINES
Given the easy maintenance of the engines, it has been possible to simplify the manual.
Therefore, all paragraphs are important and must be faithfully applied during
maintenance operations.
Our Network of Service Shops is available to conduct inspections and repairs under
optimal conditions, applying the norms established by GUASCOR.

The use of original replacement parts guarantees continuity in service after long periods
of operation. These parts have been manufactured in accordance with the same rigorous
quality control that is applied in the manufacturing of the original equipment.
BODY PROTECTION
CAREFUL
Use necessary protection for your body, eyes, ears, and respiratory system. When
working in or close to an engine, do not use loosely-fitting clothing, do not wear hanging
jewelry, and be careful if you have long hair.
EXAHUST FUMES
CAREFUL
Internal combustion engine exhaust products are toxic and can cause injury or death if
inhaled. All engines installed must be equipped with an exhaust pipe, so that exhaust
fumes may exit the engine room. Any enclosed area must have adequate ventilation, and
must have a constant supply of air to the outside.
ENGINE FUEL
CAREFUL
If an engine does not start in spite of cranking it a number of times, close the gas shutoff
valve and continue barring the engine until all unburnt gas has been removed from the
cylinders. Failure to do this may lead to gas ignition by a spark plug and to an explosion.
Engine fuel is inflammable and may explode. It must be carried to the engine through an
adequate pipe system free of leaks and openings and designed to withstand ruptures
caused by vibration.
GUASCOR GAS ENGINES
FUEL SHUT-OFF
CAREFUL
All installed engines must be equipped with a dependable means of completely cutting off
the fuel supply during an emergency.
Intake lines of pressurized fuels such as natural gas or digester gas must be fitted with a
manual gas cut-off system (hand-operated valve, automatic valve or valve train) separate
from the carburettor or gas regulating system.
The user is the person responsible for verifying that the installed engine is free of fuel and
exhaust gases leaks and that the installed engine is in compliance with all regulations.
SAFETY PROTECTORS (GUARDS)
CAREFUL
Internal combustion engines must be equipped with certain defense mechanisms in order
to protect people or structures that may be near rotating or hot parts. It is the engine
user's responsibility to install the appropriate protectors.
PRESSURE PLUGS AND CONNECTIONS FOR THE COOLING

SYSTEM.
CAREFUL
Do not remove pressure plugs while the engine is operational or if the water is hot. The
cooling system is pressurized and serious burns caused by boiling water that will come
out when the plug is removed may occur. Wait until the engine and the water have cooled
down before removing the heat exchanger plugs, expansion tanks, or radiator. Always
replace hoses, pipes and connections that are not in good operating condition or have
deteriorated.
IGNITION SYSTEM
CAREFUL
The ignition system may cause electric discharges. Avoid touching this system and its
wiring.
GUASCOR GAS ENGINES
A spark plug will generate sparks if the discharge condenser of the electronic ignition
module is on. This may occur even when the wires have been disconnected. Once you
connect the wires, the condenser will discharge and energize the spark plug that will
ignite the gas accumulated in a cylinder. As a result, the crankshaft and timing gear will
rotate, which may cause damage to the equipment and/or its operators. The gas
accumulated in the exhaust system could catch fire, too.

Before reconnecting the wires of the electronic ignition module, disconnect this module
from the power source.
Protect spark plugs, coils and wires from rain and snow.
GENERATORS
DANGER
The voltage generated by a generator is dangerous for any person who touches any part
of the electrical system while it is operational, since he may receive a very serious, if not
fatal shock. Verify that the electrical system is grounded prior to putting it into operation.
Be extremely cautious when the unit or the surrounding area is moist or wet. Upon
servicing any part of the electrical system or upon making any connection, verify that the
main switch is off. In order to clean or service the generator, the engine must be turned
off.
In case of an emergency caused by an electric shock, turn off the generator immediately.
If it can not be turned off, move the victim away from the live current.
Avoid direct contact with the victim. Use a dry board, a dry chord, or any non-conducting
tool to free the victim. If the victim is unconscious, apply cardiopulmonary resuscitation
and a heart massage and request medical assistance.
Do not operate the generator with current transformers in an open system. Dangerous
voltage may be generated for personnel and the equipment in a secondary open system
or in a current transformer.
If the generator has stopped because a circuit breaker has been activated, do not attempt
to start the generator without locating and correcting the problem.
When the generator stops after having been operational, disconnect all switches to all
electrical external and parallel circuits.
GUASCOR GAS ENGINES
NEATNESS AND CLEANLINESS
WARNING
Neatness and cleanliness are indispensable in order to have a safe workplace. A neat
workplace, with clean handrails and well-organized equipment and tools, allows for better
work performance and is an important factor in the prevention of accidents.
ENGINE AND EQUIPMENT, REPAIR AND SERVICE
CAREFUL
Always turn off the engine before cleaning, servicing, or repairing it or the accompanying
equipment. Place all controls in the disconnected or stop position in order to prevent
accidental start-up. If possible, place all controls in the disconnected position and
remove the key. Place a sign on the instrument panel to announce that the engine is
being serviced. Before turning the engine on again, verify that all tools and engine and
equipment materials have been removed.
Service and repair are important for the safe and dependable operation of the engines
and accompanying equipment. The procedures recommended by GUASCOR in this
manual are effective methods for conducting service and repair operations. Some of
these procedures require the use of special tools, which must be used how and when
they are recommended. Any person applying a service, reapir, or installation procedure
not recommended by GUASCOR must first verify that he will not jeopardize his safety
upon using the service methods that he selects
ENGINE FAN BLADES
CAREFUL
· Do not operate the engine if the fan has been bent, is missing a piece, has been
altered or damaged in any way.
· Do not operate the engine if the fan comes into contact with any engine accessory or
with the internal mechanism or nucleus of the radiator.
· Do not try to balance the fan. If it is necessary to balance it again, consult the supplier
of the fan.
· Verify that all of the fan's pressure screws are tight, with the torque specified by the
engine's, vehicle's, or ship's manufacturer.
· Install the fan in such a way that it will be properly facing the radiator.
GUASCOR GAS ENGINES
· Conduct all required maintenance for the friction drive, as described in this manual.
· Do not alter or replace any engine part without the approval of the GUASCOR
Technical Department. Be especially careful to not make any alterations that might
increase the speed of the fan.
· Install the fan only if the engine is of the kind that requires a fan. In addition, install

only the drive that is specified by GUASCOR.
· If the fan or the fan propeller has any plastic or rubber component part, only an
authorized mechanic may inspect the fan and the propeller after the fan has been
operating or has been exposed to excessively high temperatures (air temperature of
120ºC).
· For reverse-action or adjustable pitch fans, verify that the blades are in their proper
position prior to starting the engine. Also, inspect the fan before starting the engine
in order to determine if there has been an accumulation of ice or dirt in the fan, which
might cause a potential imbalance in the fan.
· Verify that all fans, drives and belts have adequate protectors (guards).
TURBOCHARGERS
CAREFUL
Turbochargers are specifically designed for each application. They operate at high
temperatures; therefore, they must be kept a safe distance away from inflammable
materials. The engines must be stopped and left to cool down to room temperature prior
to working on the turbochargers, in order to avoid serious burns.
Keep all material and parts away from the turbochargers openings.
CHEMICAL PRODUCTS FOR STORAGE OF ENGINES
DANGER
Protective oils contain a petroleum distillate that may be harmful or fatal if ingested. Avoid
contact with the skin. The fumes are harmful; they cause irritation to the eyes, nose,
throat, and skin. They should only be used in well-ventilated areas.
Avoid breathing in the fumes. Avoid contact with the skin, the eyes, and clothing.
Do not swallow.
Keep the container closed and away from heat. Read and observe the "PRECAUTION"
labels on the cans. Do not destroy the labels.
GUASCOR GAS ENGINES
In general, the temperature of the protective oils should not exceed 93ºC. In order to
arrive at this temperature, the cans should be placed in a container of hot water. The top
should be removed or a hole should be made in the can in order to reduce the danger of
explosion. Direct heat or heating is an unnecessary fire risk.
PROTECTION AGAINST FIRE

WARNING
Fire extinguishers should be placed in an easily accessible location, close to possible fire
spots. They must show fire extinguisher inspection registration and refill labels so that
they may be used when needed.
Consult the appropriate supplier of fire extinguishers or the fire department in order to
install the engine. It is also recommended that there be well-identified emergency exits
when any engines is being installed, in accordance with regulations governing incidents
of fires.
CLEANING SOLVENT
CAREFUL
Use appropriate solvents approved for the cleaning in well-ventilated places; do not
inhale the fumes, since some may be fatal. Keep them away from flames or sparks. Do
not use gasoline, solvents, or other very volatile liquids for cleaning. Read and observe
the "PRECAUTION" labels on the cans. Do not destroy the labels.
Cleaning sovents may cause various skin irritations.
WELDING EQUIPMENT
CAREFUL
If a welding bottle is damaged because it is dropped or hit, it may explode and cause
great damage. These bottles must be stored in accordance with safety regulations and
the manufacturer's instructions.
When welding or cutting with Acetylene, retention valves must be installed, between the
regulators and the hoses in order to prevent the backward movement of flames toward
the regulators and tanks. Backward flame movement may cause the regulators and tanks
to explode.
GUASCOR GAS ENGINES
Keep all greasy or oily materials away from valves, hoses, etc…, for oxygen. Oxygen
can combine with these materials to produce violent combustion.
Always use a protective mask to weld, cut, and observe this work. Protective clothing
must be worn. Do not weld or cut close to inflammable materials
GROUNDING FOR ELECTRICAL WELDING

CAREFUL
When electrical welding is used on an engine, affix the ground cable as close as possible
to the welding location. If the ground cable is connected too far to the welding location,
arcs may be created throughout the bearings, which might fuse in the crankshaft.
ELECTRICAL TOOLS
CAREFUL
Verify that all tools are properly grounded. Use eye protection. Do not work in moist or
wet locations. Verify that electrical tools are in good condition and that necessary
protective devices are in place. Portable electrical emergency lamps must also be
grounded. Do not move electrical tools hanging from the cable. Do not pull on the cable
to disconnect it. Pull from the connector to disconnect it from the socket.
BATTERIES
CAREFUL
Always disconnect the ground connection from the batteries prior to working on the
engine or equipment. This will prevent sparks or damage in case of an accidental short
circuit in a connection.
Never expose a battery to an open flame or sparks. The battery's chemical action
generates hydrogen gas, which is inflammable and explosive. Do not permit the battery's
electrolyte to touch your skin, eyes, clothes, or painted surfaces. The electrolyte is a
sulfuric acid solution that can produce serious burns or damage to equipment. Use
protective goggles when working on the battery
GUASCOR GAS ENGINES
PRECAUTIONS WHEN USING BATTERIES AND AUXILIARY CABLES

(REINFORCED) FOR START-UP
CAREFUL
Do not attempt to start the engine with an auxiliary battery when the battery is frozen,
because a frozen battery may break or explode. If it is suspected that the battery is
frozen, examine all filled openings. If there is ice or the electrolyte cannot be seen, do
not attempt to start the engine with an auxiliary battery or auxiliary cables. Batteries,
charged or uncharged, must be treated with care when using auxiliary batteries and
cables.
The following procedures will help to reduce sparks and the risk of explosion that always
exists when connecting a good battery to an uncharged battery.
Disconnect all electrical charges. Remove the covers from the cells and cover the upper
part of the battery with a moist rag. The auxiliary battery or batteries must have the same
total voltage as the dead battery or batteries
The positive terminal is marked with the " + " sign, is usually painted red, and has a
larger diameter than the negative terminal.
· Battery with Negative Ground
First :
Connect a bridge cable from the positive terminal of the charged battery (auxiliary) to
the positive terminal of the dead battery. If there are more than one battery,
connected in series or in parallel series, connect the bridge cable to the positive
terminal where the cable is connected to the starter.
Second :
Connect another bridge cable from the negative terminal of the charged battery
(auxiliary) to a good ground location on the engine, not to the dead battery. When
disconnecting the bridge cables, first disconnect the grounded cable on the engine
prior to disconnecting the positive cable.
· Battery with Positive Ground

Use the same procedure for the battery with positive ground, except the cable to the
starter motor is connected to the negative terminal and the positive terminal is the one
that must be grounded.
COMPRESSED AIR
Compressed air or gas should never be used to clean clothes or the body. A stream of
water at high pressure entering through a small opening can perforate the skin and cause
serious and very painful injury. Never test the circulation or pressure of air, gas, or liquid
on your hand. Never "fool around" with air, gas, or liquid hoses. Observe all regulations
for the use of compressed gas.
2
GUASCOR GAS ENGINES
INTOXICATING BEVERAGES OR DRUGS
CAREFUL
Any person who is intoxicated or under the influence of drugs is a hazard for himself
and for all personnel.

SAFE PRACTICES FOR THE HANDLING OF ACIDS
Cleaning with acid is common for certain cast parts or equipment parts.
CAREFUL
· Avoid contact with the skin, eyes, or clothing.

· Scaling (removal of rust) must be done far away from flames, sparks, or other
possible sources of ignition.
· Do not leave acid on concrete floors, because it attacks the limestone in the cement.
If the solution spills onto the concrete floor, apply an alkaline solution to neutralize it.
· Acid may react with metals and form various gases. In general, acid solutions that
come into contact with limy and rusty incrustations produce carbon dioxide, which is
harmless. However, when the acid comes into contact with aluminum, zinc, cadmium,
tin, sulfur, arsenic, and cyanaide, highly poisonous and explosive gases can be the
result. When an acid solution is used to clean in an enclosed place, adequate
ventilation should be provided to sweep away the vapors.
· Always keep closed containers in their normal position.
· Verify that there are no leaks in the component part or container that is cleaned with
acid. These leaks might allow the solution to move to the opposite side of the
equipment. It is advisable to fill the opposite side of the equipment that is being
cleaned with water up to a higher level than that of the acid solution.
· Use an acid-proof pump or a cheap throw-away pump.
· Always add acid to water; never add water to acid when mixing a solution.
· Do not shake up acid solutions with compressed air.
· The application of acid should be followed by careful rinsing and then neutralization
with an alkaline solution in order to eliminate all acid residues and prevent further
action by the acid.
· Store acid solutions in steel containers with acid-proof wood or synthetic rubber
linings.
· Examine to see if steel equipment that is to be cleaned with the acid solution has
copper connections, brass, or metallic fuse caps. If possible, unequal metals should
be removed prior to cleaning with acid so as to prevent the action of the electrolyte,
which would hinder the action of the inhibitor solution. Do not use acid to clean
aluminum parts.
STANDARDS
SAFETY FOR PROPER LIFTING OF
GUASCOR GAS ENGINES
3 - STANDARDS FOR PROPER LIFTING OF

GUASCOR GAS ENGINES
INTRODUCTION
This product datasheet aims to diffuse the general standards for proper lifting of
GUASCOR gas engines, indicating the engine lifting points
GENERAL NORMS
CAREFUL
· When lifting an engine or its components, be careful.
· Keep all personnel away when the assembly is in the air.
WARNING
· Correctly inspect all anchor points so that there is no defective welding, loose screws,
etc. that might jeopardize the lifting of the equipment.
· Verify that all pertinent structures have been inspected, are in good condition, and can
support at least the weight of the equipment plus 10%. If you are not sure, weigh the
equipment prior to lifting it.
· The use of cloth slings is recommended so as not to damage equipment with rough
movements.
· Assure that the slings do not come into contact with sensitive parts of the equipment.
· Prior to lifting it, be sure to balance the equipment to the maximum, using slings of
different lengths if necessary.
· Do not lift the equipment further than necessary.
STANDARDS FOR PROPER LIFTING OF
GUASCOR GAS ENGINES
SAFETY
LIFTING ENGINES
GAS-fueled "V" engines are lifted at four points, two at front of the engine block, and two
at the rear.
A special hoisting accessory is required for this operation.

Fig.1 Lifting Gas-fueled "V" engines
D I S A S S E M B LY
DESMONTAJE
DISASSEMBLY
SF/FG IN “V”
Ref.: 19.09.531
Edition: May 2003

DISASSEMBLY INDEX
A.- REMOVING THE ENGINE FROM ITS LOCATION
1. Connections and external components disassembly.

2. Removing the engine from its location.
B.- DISASSEMBLY OF AIR FILTER ADAPTOR AND GAS INTAKE.

CARBURATION
1. Disassembling the Air Filter Adaptor.

2. Disassembling the Gas Supply Lines.
3 Disassembly of the carburetor.
C.- DISASSEMBLY OF THE TURBOCHARGERS
1. Disassembly of the exhaust gas outlet elbows.

2. Disassembly of the air discharge piping from the turbocharger to the air cooler
(Intercooler).
3. Disassembly of the oil inlet and outlet piping from the turbocharger.
4. Removal of turbocharger from engine and disassembly of turbocharger
adaptor.
4.1. Sub-assembly: Turbocharger-----------------------------------------------------------------
S - 22
5. Turbocharger inspection.
5.1. Turbocharger inspection-------------------------------------------------------------- I - 9
6. Cleaning of components-----------------------------------------------------------------------------
I-0 A-0
D.- DISASSEMBLY OF WATER PUMP(S) AND PIPING FROM COOLING

CIRCUIT(S)
1. Disassembly of the Water Preheating System.
2.- ENGINE WITH COOLING CIRCUITS WITH MECHANICAL PUMPS
1. Disassembly of the auxiliary cooling circuit.
1.1. Disassembling the auxiliary circuit piping.

1.2. Disassembling the water discharge pipe from intercooler (toward oil cooler).
1.3. Disassembling the water flange and by-pass pipe.
1.4. Removing the auxiliary circuit pump.
1.4.1. Sub-assembly: Mechanical Pump of
Auxiliary Circuit.--------------------------------------------------- S - 10
INDEX DISASSEMBLY
2. Disassembly of the main cooling circuit.
a) MAIN CIRCUIT WITH ADAPTOR TO REMOTE COOLER.

a.1. Disassembling the water flange and by-pass pipe
b) MAIN CIRCUIT WITH ADAPTOR TO REMOTE RADIATOR.

b.1. Disassembling the water flange and by-pass pipe.
b.2. Disassembling the fan adaptor.
c) MAIN CIRCUIT WITH ADAPTOR FOR HEAT EXCHANGER.

c.1. Disassembling the heat exchanger
c.1.1. Sub-assembly: Heat Exchanger.---------------------------------------
S - 12
c.1.2. Hydraulic testing of Heat Exchanger.---------------------------- I - 12
c.2. Disassembling the water flange and by-pass pipe.
1. Disassembly of the water discharge pipe.
2. Removing the main circuit water pump.
2.1. Sub-assembly: Mechanical
Pump of Main Circuit-------------------------------------------------
S-9
3. ENGINE WITH COOLING CIRCUITS WITH ELECTRIC PUMPS.
1. Disassembly of the auxiliary cooling circuit.

a) Disassembling the water inlet line to the intercooler.
b) Disassembling the water discharge line from the intercooler.
2. Disassembly of the main cooling circuit.
E.- DISASSEMBLING THE THERMOSTAT HOUSING OF THE MAIN CIRCUIT.
1. Sub-assembly: Thermostat Housing of Main Circuit---------------------------------

S - 11
F.- DISASSEMBLING THE IGNITION SYSTEM.
1. Disassembly of the high-voltage coils and wires.

2. Removing the electronic ignition module.
DISASSEMBLY INDEX
G. DISASSEMBLING THE ENGINE REGULATION SYSTEM
FGLD ENGINE. Mechanical Regulation System
1. Disassembling the main control rod of the regulation system.

2. Disassembling the hydraulic regulator.
2.1. Disassembly of the electric control.

2.1.1. Sub-assembly: Electric Control-------------------------------------------------
S - 24
2.2. Disassembly of the regulator lubricating lines.
2.3. Removal of the body of the hydraulic regulator.
2.4. Removal of the regulator drive housing.
2.4.1. Sub-assembly: Hydraulic
Regulator Housing---------------------------------------------------------
S - 23
SFGLD ENGINE. Electronic Regulation System
H.- DISASSEMBLING THE INTAKE MANIFOLD
1. Disassembly of probes and sensors.

2. Disassembly of the gauge panel.
2.1. Sub-assembly: Gauge Panel.------------------------------------------------ S - 25
3. Disassembling the oil filling elbow.
4. Disassembling the gas/oil separating filter for gas recirculation.
5. Disassembly of the Engine Intake Circuit.
5.1. Disassembling the intake elbow and connector to the intercooler.
FGLD ENGINE. Intake elbow with Mechanically-operated Butterfly Valve.
SFGLD ENGINE. Intake elbow with Flo-Tech Electronic Butterfly Valve.
5.2. Disassembling the Y-pipe and inlet elbows to intake manifolds.
5.3. Removal of intake manifolds.
5.3.1. Cleaning.-----------------------------------------------------------------------------
I-0 A -0
I.- DISASSEMBLING THE INTERCOOLER
1. Sub-assembly: Intercooler.-------------------------------------------------------------------------
S - 21
2. Hydraulic testing of the Intercooler.-------------------------------------------------------------
I - 12
INDEX DISASSEMBLY
J.- DISASSEMBLING THE EXHAUST MANIFOLDS
1. Removal of water outlet elbows from cylinder heads.

2. Removal of exhaust manifolds.
2.1. Cleaning------------------------------------------------------------------------------------------
I-0 A -0
2.2. Sub-assembly: Exhaust Manifold-------------------------------------------------------------
S - 20

2.3. Hydro test of exhaust manifold.------------------------------------------------- I - 12
K.- DISASSEMBLING THE ROCKER ARM COVERS
1. Extracting the spark plugs.

1.1. Checking the spark plugs and wires.----------------------------------------------------I - 10
2. Disassembling the rocker arm covers.
3. Disassembling the spark plug holders.
L.- DISASSEMBLING THE MAIN ROCKER ARM ASSEMBLY
1. Disassembling the main rocker arm support.

1.1. Sub-assembly: Main Rocker Arm Support.----------------------------------------------- S-4
2. Disassembling the push rods.
3. Disassembling the valve lifters.
3.1. Sub-assembly: Valve Lifters.---------------------------------------------------------- S-5
4. Cleaning the lubricating holes.---------------------------------------------------------------
I-0 A-0
5. Checking elements.--------------------------------------------------------------------------I - 8
M.- DISASSEMBLING THE CYLINDER HEADS
1. Removal of cylinder heads.

2. Disassembling the Cylinder Head Gasket, Bushing and Oil Passing O-ring.
3. Visual checking of the surface of the cylinder block on which the cylinder head
rests.
4. Sub-assembly: Cylinder Heads.-------------------------------------------------------------------
S-3
5. I-7
Inspection of Cylinder Heads.---------------------------------------------------------------------
N.- DISASSEMBLING COMPONENTS ON THE FRONT OF THE ENGINE AND

THE FRONT GEAR TRAIN.
1. Pulley disassembly
2. Disassembling the vibration damper.
3. Disassembling the crankshaft front flange.
DISASSEMBLY INDEX
4. Disassembling the crankshaft front seal.

5. Disassembling the front cover of the front gear housing.
5.1. Cleaning.-----------------------------------------------------------------------------------------
I-0 A-0
6. Disassembling the water pumps intermediate drive gears.
6.1. Gear check.----------------------------------------------------------------------
I-0 I-1
7. Disassembling the intermediate cover of the front gear housing.
7.1. Sub-assembly: Jets Control Valve.------------------------------------------ S - 26

7.2. Cleaning.-----------------------------------------------------------------------------------------
I-0 A-0
O.- DISASSEMBLING COMPONENTS ON THE BACK PART OF THE ENGINE

AND THE REAR GEAR TRAIN
1. Disassembling the flywheel.

1.1. Inspection.
1.2. Sub-assembly: Flywheel.--------------------------------------------------------------- S-8
2. Disassembling the seal holder unit, gasket and rear seal.
2.1. Sub-assembly: Rear Seal Holder.---------------------------------------------------------- S-7
3. Disassembling the flywheel housing.
3.1. Disassembling the electric starter.
3.2. Disassembling the flywheel housing.
3.3 Cleaning.------------------------------------------------------------------------------------------
I-0 A-0
4. Disassembling the hydraulic regulator drive gear.
4.1. Gear check.-------------------------------------------------------------------------
I-0 I-1
5. Disassembling the camshaft gears.
5.1. Gear check.----------------------------------------------------------------------
I-0 I-1
6. Disassembling the thrust drive disk of the camshaft.
7. Disassembling the intermediate gear of the back gear train.
7.1. Gear check.----------------------------------------------------------------------
I-0 I-1
8. Disassembling the oil pipe to the engine block central gallery.
9. Disassembling the back timing gear intermediate housing cover.
9.1. Disassembly of the oil line from the external oil circuit.
9.2. Disassembling the back timing gear intermediate housing cover.
9.2.1.Cleaning.-------------------------------------------------------------------------------
I-0 A-0
P.- INSTALLATION OF ENGINE ROTATING TOOL. DISASSEMBLING PHASE

ON A SUPPORT TOOL.
Q.- DISASSEMBLING THE PISTON CONNECTING ROD ASSEMBLY.
1. Disassembling the components interfering with the disassembly operation.

1.1. Disassembling the dipstick
INDEX DISASSEMBLY
1.1.1. Sub-assembly: Oil Dipstick.-------------------------------------- S - 19

1.2. Disassembling the crankcase breather.
1.2.1. Sub-assembly: Crankcase Breather.---------------------------- S - 6
1.3. Disassembly of electrically-operated pre-lube and oil drain pump.
1.4. Disassembling the oil level alarm.
1.5. Disassembling the oil level control.

1.6. Disassembling the oil distributor and piping.
1.7. Disassembling the oil filter support.
1.7.1. Sub-assembly: Filter Support.----------------------------------------------- S - 18
2. Disassembling the connecting rod inspection covers.
I-0
2.1. Cleaning.------------------------------------------------------------------------------------
A-0
3. Removing the piston connecting rod unit.
3.1. Disassembling the oil jets
3.2. Removing the piston connecting rod unit.
3.3. Disassembling the piston connecting rod unit.
3.4. Disassembling the piston rings.
3.5. Checking elements-----------------------------------------------------------------------I - 5
R.- DISASSEMBLING THE CYLINDER LINERS
1. Inspection.----------------------------------------------------------------------------------------------
I-2 I - 11
S.- DISASSEMBLY OF CAMSHAFTS AND AUXILIARY ROCKER ARMS
1. Disassembling the auxiliary rocker arm covers.

I-0 A-0
1.1. Cleaning.--------------------------------------------------------------------------------------------
2. Disassembling the camshaft covers.
2.1.Cleaning.---------------------------------------------------------------------------------------------
I-0 A-0
3. Removal of auxiliary rocker arms.
3.1. Sub-assembly: Auxiliary Rocker Arms.-------------------------------------------------------S-1
3.2. Cleaning.--------------------------------------------------------------------------------------
I-0 A-0
3.3. Inspection.------------------------------------------------------------------------------------------
I-8
4. Disassembling the camshaft.
4.1. Inspection.--------------------------------------------------------------------------------------
I-4
5. Disassembling the camshaft bushings.
5.1. Inspection.----------------------------------------------------------------------------------------
I-2
DISASSEMBLY INDEX
T.- DISASSEMBLING THE OIL PAN
1. Disassembling the oil pre-heating system.

2. Disassembling the oil pan covers.
2.1. Sub-assembly: Oil Pan Cover (oil dipstick
support unit). --------------------------------------------------------------------- S - 17
3. Removal of thermostatic oil control valve.

3.1. Sub-assembly: Thermostatic Oil Control Valve.--------------------------- S - 16
4. Removing the oil pan.
4.1. Cleaning-------------------------------------------------------------------------------------------
I-0 A-0
U.- DISASSEMBLING THE OIL PUMP AND OIL CIRCUIT INSIDE THE OIL PAN
1. Disassembling the suction strainer - oil pump connecting piping.

1.1. Sub-assembly: Oil Suction Hood----------------------------------------- S - 13
2. Disassembling the oil discharge pipe.
3. Disassembling the oil pump outlet elbow with pressure safety valve.
3.1. Sub-assembly: Pressure Safety Valve.-------------------------------------- S - 15
4. Disassembling the oil pump.
4.1. Sub-assembly: Oil Pump.----------------------------------------------------------------
S - 14
4.2. Checking elements.-----------------------------------------------------------------------
I-6
4.3. Check the oil pump gear---------------------------------------------------------
I-0 I-1
5. Removal of the oil pump intermediate drive gear.
5.1. Gear check.-----------------------------------------------------------------------
I-0 I-1
V.- DISASSEMBLING OF CRANKSHAFT
1. Disassembling the pump gear drive.

1.1. Gear check.---------------------------------------------------------------------
I-0 I-1
2. Disassembling the beams.
3. Disassembling the caps and thrust bearings
3.1. Cleaning of caps.-------------------------------------------------------------------
I-0 A-0
3.2. Inspection.------------------------------------------------------------------------------------------
I-2
4. Removal of the crankshaft.
5. Disassembling the half bearings.
INDEX DISASSEMBLY
6. Control and testing of the

engine block and the crankshaft---------------------------------------------------------------
I-2 I-3
6.1. Hydro test of engine block with liners on.------------------------------------------------
I - 12
7. Crankshaft Recovery.------------------------------------------------------------------------
I - 11
8. Cleaning.-----------------------------------------------------------------------------------------------
I-0 A-0

8.1. Block.
8.2. Crankshaft.
DISASSEMBLY REMOVING THE ENGINE
FROM ITS LOCATION
A.-REMOVING THE ENGINE FROM ITS LOCATION

1.CONNECTIONS AND EXTERNAL COMPONENTS DISASSEMBLY.
1. Before removing the engine from the frame, all engine connections to the external
components must be disassembled first, as well as any couplings and piping, which
may include:
- Gas supply line: Disassemble all the pipes upstream of the nearest flange to the
engine (i.e. just before the gas regulating screws for FGLD engines and the
TecJet valve for SFGLD engines).
- Water pipes: Remove the water supply / discharge pipes from the engine.
Where cooling is by means of mechanical pumps (*) on the engine, loosen the
external water lines to the nearest flange of the engine (inlet to the water flange
and discharge connection at the thermostat housing). If cooling is by means of
electric pumps (external to the engine), detach the external pipe connecting
flanges from the engine flanges (water inlet to block, water inlet to auxiliary
circuit, main and auxiliary circuit discharge pipes).
- Oil pipes: In the case of engines with connections to a remote oil cooler, loosen
the oil supply and return pipes to the thermostat and oil regulation housing.
2. Power and control cables: Disconnect all kinds of electric cables from the engine
to external components (like electrical cabinets) as well as to engine-mounted
components (control panel, batteries, electric starter, etc.).
3. Also disassemble any coupling the engine may be fitted with, including any coupling
to the flywheel (alternators, etc.) and coupling to the crankshaft pulley (used as a
power take-off for driving an external piece of equipment).
(*) There exists one configuration in which the engine's auxiliary cooling circuit includes
an engine-driven mechanical pump that is not mounted on the engine, but on the frame.
In this event, it will be necessary to disassemble the pump's drive coupling / adaptor. To
do so:
1. Loosen the fixing screws from the pump coupling guard to the front cover of the front
gear housing. Remove the coupling guard.
2. Loosen the screws from the coupling to the pump shaft.
3. Loosen the screws fastening the pump to the frame. Remove the mechanical pump
of the auxiliary circuit from the frame.
REMOVING THE ENGINE DISASSEMBLY
FROM ITS LOCATION
4. Remove the half coupling (attached to the gear shaft) as well as the intermediate
elastic element of the coupling.
5. Loosen the nut from the other half coupling to the pump drive shaft. Remove the nut,
half coupling and drive shaft key.
6. Now left on the engine is the pump drive unit that will be disassembled later on.
2. REMOVING THE ENGINE FROM ITS LOCATION.

Once all the above mentioned elements external to the engine have been disconnected
or disassembled, proceed with the removal of the engine from its "usual" location and
place it in a more "appropriate" location for easier disassembly of the engine components.
For that purpose:
Loosen the engine supports fastening screws from the frame.

Set the engine lifting brackets in their respective supports, as specified. (**).
Secure the engine with slings and a crane. Attach the slings in the lifting brackets of the
engine.
NOTE
Appropriate equipment to undertake the hoisting has to be used in order to hold the
weight of the engine with all other installed components.
Move the engine from its location and set it on the ground on the oil pan.
(**) See section on safety: “Lifting of engines / Guidelines for the correct lifting of
Guascor equipment.”
DISASSEMBLY AIR FILTER ADAPTOR AND GAS
INTAKE. CARBURATION
B. - DISASSEMBLY OF AIR FILTER ADAPTOR AND GAS INTAKE. CARBURATION
1. DISASSEMBLING THE AIR FILTER ADAPTOR.
1. Loosen the clamps from the connecting hose between the air filter outlet and the
piping to the carburetor. Remove the two clamps and the hose.
2. Detach the belts holding the Air Filter assembly to its support. Remove the Air Filter
assembly and the belts
3. Repeat steps 1 and 2, in order to disassemble the air filter from the engine's second
bank of cylinders
CLAMPS AND HOSE

CONNECTING THE AIR FILTER
TO THE AIR PIPING TO THE
CARBURETOR
AIR FILTER FIXING BELTS TO
SUPPORT
When the engine has a crankcase breather with a gas recirculating pipe and separating
NOTE
filter, it will be necessary to disassemble the pipes (hose and Y-pipe) between the
separating filter and the two air inlet pipes to the carburetors.
4. Loosen the clamps from the connecting

hose between the air recirculating pipe
(from the separating filter) and the Y-pipe
to the two banks of cylinders. At the other
end of the hose, loosen the connector to
the separating filter. Remove the hose.
5. Loosen the clamps from the hose between

the Y-pipe and the air inlet pipe to the
carburetor (on one side of the engine).
Remove the hose and two clamps.
PIPE SUPPORT
RECIRCULATED GAS Y-PIPE TO THE

TWO BANKS OF CYLINDERS. HOSE FROM FEEDBACK
CONNECTION BY MEANS OF HOSE AND FILTER
B CLAMPS
AIR FILTER ADAPTOR AND GAS DISASSEMBLY
INTAKE. CARBURATION
6. Repeat step 5, disassembling the Y-pipe connection to the air inlet pipe to the
carburetor on the second side of the engine.
7. Remove the Y-pipe.
8. Loosen the nuts from the clamps holding the carburetor's air inlet pipe to its support
on the intercooler. Remove the clamps.

9. Loosen the clamps from the hose between the air inlet pipe to the carburetor and the
carburetor. Remove the clamps, hose and air inlet pipe to the carburetor.
10. Loosen the screws fastening the support of the carburetor's air inlet pipe to the
intercooler. Remove this support.
11. Repeat operations 8 through 10, disassembling the air inlet pipe to the carburetor on
the other side of the engine
HOSE AND CLAMPS CONNECTING THE AIR

PIPE SUPPORT TIED TO
PIPING TO THE AIR INLET TO THE
INTERCOOLER
CARBURETOR
12. Loosen the screws from the air filter supports to the flywheel housing. Remove the
air filter supports.
INTAKE. CARBURATION
2. DISASSEMBLING THE GAS SUPPLY LINES.

FGLD ENGINES.
1. Loosen the bolts and nuts holding the gas inlet flange to the gas supply hose.
Remove the gas inlet flange and flat gasket.
2. Loosen the screws fastening the gas supply hose to the gas regulating valve.
Remove the gas supply hose and the gasket located between the hose and the gas
regulating valve.
3. Loosen the threaded connection between the gas regulating valve and the T-branch
that deviates gas to either sides of the engine. Remove the gas regulating valve
(screw type).
4. Loosen the male-female connectors between the T-branch and the gas inlet elbows
to the carburetors. Remove the connectors and T-branch.
5. Loosen the threaded connectors between the gas inlet elbows and the carburetors.
Remove the gas inlet elbows.
T-BRANCH
MALE-FEMALE
CONNECTORS
GAS INLET ELBOW

TO CARBURETOR
GAS SUPPLY LINE WITH SINGLE-RUN GAS INLET
REGULATING SCREW VALVE ELBOW TO CARBURETOR
SFGLD ENGINES
1. Loosen the fixing screws of the TecJet valve to its adaptor.
2. Loosen the fixing screws of the TecJet valve to its support, on the underside of the
support.
3. Remove the TecJet valve and the gasket inserted between the valve and the adaptor.
4. Soltar la unión roscada y la reducción de unión de la "T" roscada (tubo bifurcación
de gas hacia las dos bandas del motor) con los codos de entrada de gas a los
carburadores.
5. Remove the T-branch/TecJect adaptor assembly as well as the threaded connectors
and reducers.
6. Disassemble the gas inlet elbows from the carburetors. For this purpose, loosen the
threaded connectors between the gas pipes and the gas inlets to the carburetors.
Remove the gas inlet elbows.
7. Loosen the fixing screws of the TecJet valve support to the intercooler. Remove the
TecJet valve support
AIR FILTER ADAPTOR AND GAS DISASSEMBLY
INTAKE. CARBURATION
TECJET VALVE
TECJET VALVE SUPPORT

FASTENED TO THE

INTERCOOLER
GAS SUPPLY LINE WITH

TECJET VALVE
As for SFGLD engines with turbo at 1500rpm, gas is fed into the carburetors through
one single branch pipe (single-run pipe) that is flanged to the carburetors. In order to
NOTE
disassemble this gas inlet pipe, after removing the TecJet valve, it will be necessary to
loosen the fixing screws from the pipe flange to the gas inlet to the carburetors.
Then, remove the gas supply pipe to the carburetors.
SINGLE-RUN GAS SUPPLY PIPE

TO CARBURETORS
FLANGE CONNECTION TO
CARBURETOR: LOOSEN THE
FIXING SCREWS.
3. DISASSEMBLY OF THE CARBURETORS.

1. Loosen the carburetor coupling nuts to the carburetor pipe connection to the
turbocharger.
2. Remove the carburetor
3. Repeat this process to disassemble the carburetor on the other cylinder bank.
4. Loosen the connection - consisting of an O-ring, split ring and clamp (FGLD 360 &
480 engines and SFGLD 560 engines) - from the carburetor connecting pipe to the
turbocharger.
5. Remove the carburetor connecting pipe to the turbocharger.
6. Repeat these operations, disassembling the pipe from the other cylinder bank.
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS INTAKE. CARBURATION
CARBURETOR. FIXING CARBURETOR PIPE CONNECTION

SCREWS OF CONNECTING PIPE
CONNECTION TO TURBO BY
TO TURBOCHARGER
MEANS OF O-RING, SPLIT
TO TURBO
RING AND CLAMP
NOTE
On SFGLD 360 and 480 engines, the connection of the carburetor connecting pipe to
the turbocharger is by means of O-rings only.
DISASSEMBLY TURBOCHARGER
C.- DISASSEMBLY OF THE TURBOCHARGERS
1. DISASSEMBLY OF THE EXHAUST GAS OUTLET ELBOW.

1. Loosen the screws from the exhaust gas outlet elbow to its support.
2. Loosen the screws holding the gas outlet elbow support to the exhaust manifold.
LEFT SIDE ELBOW SUPPORT

RIGHT SIDE ELBOW SUPPORT
FASTENED TO THE EXHAUST
FASTENED TO THE TURBO
MANIFOLD
On the right side, the exhaust gas outlet elbow support is not fastened to the exhaust
NOTE
manifold, but to the nuts fixing the turbocharger to its adaptor. In order to remove the
elbow support, it will be necessary to loosen the two nuts securing the support and turbo
to the turbo adaptor.
3. Remove the exhaust gas outlet elbow support.

4. Loosen the connection (hose and clamp) between the exhaust gas outlet elbow and
the turbocharger.
5. Remove the exhaust gas outlet elbow, as well as the clamp and connecting hose to
the turbocharger.
6. Repeat this process, disassembling the exhaust gas outlet elbow from the other
turbocharger.
EXHAUST GAS OUTLET ELBOW
TURBOCHARGER DISASSEMBLY
2. DISASSEMBLY OF THE DISCHARGE PIPING FROM THE TURBOCHARGER TO THE

INTERCOOLER.
1. Loosen the (air + gas mixture) discharge elbow screws from the intercooler inlet.
2. Loosen the connection - consisting of a tie and two O-rings - between the discharge
elbow and the turbocharger.
3. Remove the mixture discharge elbow, tie, two O-rings and gasket from the intercooler

inlet.
4. Repeat this process, disassembling the discharge piping from the other turbocharger.
MIXTURE DISCHARGE ELBOW

TO INTERCOOLER.
CONNECTION TO
TURBOCHARGER BY MEANS OF
O-RINGS
On SFGLD engines with turbocharger at 1800rpm, the connection between the mixture
NOTE
discharge elbow and the turbocharger is by means of two O-rings (there is no tie
between the elbow and the turbocharger).
3. DISASSEMBLY OF THE OIL INLET AND OUTLET PIPING FROM THE TURBOCHARGER.
a) Disassembly of the oil outlet pipe from the turbocharger.
1. On the turbocharger side, loosen the connecting flange of the 1st oil outlet pipe
section from the bottom of the turbocharger.
2. Loosen the twin connector from the two sections of the oil outlet line.
3. Remove the 1st oil outlet pipe section, the twin connector and the gasket inserted in
the connection to the turbocharger.
4. Loosen the screws holding the flange of the 2nd oil outlet pipe section to the engine
block (oil inlet to block, just under the intake manifold). Remove the 2nd oil outlet pipe
section as well as the gasket from the oil inlet to the block.
5. Repeat steps 1 to 4, disassembling the oil outlet pipe from the other turbocharger.
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS DISASSEMBLY TURBOCHARGER
OIL OUTLET PIPE FROM TURBO. OIL OUTLET PIPE FROM

CONNECTION TO TURBO WITH TURBO.2ND SECTION .
FLANGE AND GASKET CONNECTION TO BLOCK
b) Disassembly of the oil inlet pipe to the turbocharger.
1. On the turbocharger side, upper part, loosen the connection - consisting of

connector, bicone and O-ring - between the oil inlet pipe and the turbocharger.
2. Loosen the fixing screws of the oil inlet pipe clamp and clamp support to the
turbocharger.
3. At the other end of the turbo lubricating pipe, loosen the elbow (connector) from the
pipe to the oil distributor (on the upper part of the engine block)..
4. Remove the turbocharger lubricating pipe.
5. Repeat operations 1 to 4, disassembling the other turbocharger lubricating pipe.
TURBO LUBRICATING PIPES.

TURBO LUBRICATING PIPE
CONNECTION TO OIL DISTRIBUTOR
TURBOCHARGER DISASSEMBLY
4. REMOVAL OF TURBOCHARGER FROM ENGINE AND DISASSEMBLY OF THE

TURBOCHARGER ADAPTOR.
1. Loosen the screws holding the turbocharger to the turbocharger adaptor.

TURBOCHARGER INSTALLED ON
ITS ADAPTOR.
BOLTS/NUTS SECURING
TURBO TO ITS ADAPTOR
NOTE
On the right side, the turbocharger is secured to its adpator with studs and nuts instead
of screws. In this case, loosen the turbo fixing nuts.
2. Remove the turbocharger and the gasket

situated between the turbocharger and its
adaptor.
3. Loosen the screws holding the
turbocharger adaptor to the exhaust gas
outlet of the exhaust manifold.
4. Remove the turbocharger adaptor and the
gasket inserted between the adaptor and
the gas outlet of the exhaust manifold.
5. Repeat this process, to remove the
turbocharger and turbocharger adaptor
from the other cylinder bank.
TURBO ADAPTOR MOUNTED ON EXHAUST
MANIFOLD. ADAPTOR FIXING SCREWS.
4.1. Sub-assembly: Turbocharger.-----------------------------------------------------------------------

S - 22
5. TURBOCHARGER INSPECTION.
1. Clean and check the turbocharger.
If the turbocharger has to be inspected to control its degree of efficiency, the inspection
process must be done BEFORE it is disassembled.
5.1. Turbocharger Inspection.--------------------------------------------------------------------I - 9

6. CLEANING OF COMPONENTS.---------------------------------------------------------------
I-0 A-0
1. Clean all the sticky material in the connectors that have been disassembled, by using
a flat scraper.
DISASSEMBLY WATER PUMP(S) AND PIPING
FROM COOLING CIRCUIT(S)
D.- DISASSEMBLY OF WATER PUMP(S) AND PIPING FROM COOLING CIRCUITS
1. DISASSEMBLY OF THE WATER PREHEATING SYSTEM.

NOTE
Only SFGLD 560 engines include a water preheating system.

1. Remove the water preheating system from the front left side of the engine. For this
purpose:
2. Loosen the pipe reduction connector of the water intake pipe from the engine block.
Remove the copper gasket.
3. Loosen the pipe connecting elbow from the resistance pre-heater. Remove the water
intake pipe.
4. Disassemble the preheated water pipe between the resistance pre-heater and the
water outlet elbow of the left exhaust manifold (water inlet elbow to the thermostat
housing).
5. To do so, loosen the pipe connecting elbow to the water outlet elbow from the left
exhaust manifold.
6. On the resistance pre-heater side, loosen the threaded outlet of preheated water.
Remove the preheated water pipe.
7. Loosen the screws from the pre-heater support to the oil pan.
8. Remove the pre-heater and its support as a whole.
9. Repeat those operations to disassemble the other water preheating system, whose
resistance pre-heater lies on the right side of the engine.
PREHEATED WATER RETURN WATER INTAKE PIPE

WATER RESISTANCE PRE-HEATER
LINE TO THE THERMOSTAT FROM BLOCK
HOUSING INLET
WATER PUMP(S) AND PIPING DISASSEMBLY
ENGINE WITH COOLING CIRCUITS WITH MECHANICAL PUMPS
1. DISASSEMBLY OF THE AUXILIARY COOLING CIRCUIT.
1.1. Disassembling the auxiliary circuit discharge piping.
1. Loosen the connection - consisting of a hose and two clamps - between the water

pump discharge pipe and the water inlet line to the intercooler.
2. Loosen the connecting flange between the two sections of the water line to the
intercooler.
3. Remove pipe section 1 as well as the flat gasket placed in the connection to pipe
section 2.
4. Loosen the screws holding the pipe section 2 to the intercooler water manifold.
Remove pipe section 2 and the gasket placed in the connection to the intercooler
water manifold.
HOSE AND CLAMP

CONNECTION OF DISCHARGE
PIPE TO PUMP
GENERAL VIEW OF THE

AUXILIARY CIRCUIT'S
DISCHARGE PIPING
DETAIL OF THE COUPLING

BETWEEN THE TWO PIPE
SECTIONS AND CONNECTION TO
THE INTERCOOLER
1.2. Disassembling the water discharge pipe from the intercooler

(toward the oil cooler).
1. Remove the 4 water outlet pipe sections from the intercooler toward the oil coiler. For
this purpose, start disassembling the last pipe section (that farther from the
intercooler).
NOTE
The water line from the last section (on the engine) to the remote oil cooler would have
been removed in a previous operation, when removing the engine from its location.
2. Loosen the flange connection between pipe sections 4 and 3.

3. Remove the pipe section 4 and the gasket placed in the connection to section 3.
4. Loosen the flange connection between pipe section 3 and section 2 (running from the
upper part of the engine - between the cylinder heads - to the auxiliary rocker arm
covers).
5. Remove the pipe section 3 and the gasket placed in the connection to section 2.
6. Loosen the flange connection between pipe section 2 and section 1, water outlet from
the intercooler.
7. Remove the pipe section 2 and the gasket placed in the connection to section 1
8. Loosen the screws fastening the intercooler water outlet pipe (section 1) to the water
manifold of the intercooler.
9 Remove the water oultet pipe (section 1) and the gasket placed between this pipe
and the water manifold of the intercooler.
INTERCOOLER WATER
INTERCOOLER WATER SECTION 1 SECTION 3 SECTION 4
OUTLET. SECTION 1,
OUTLET. SECTION 2 AND
CONNECTION TO
CONNECTIÓN TO SECTION 1. INTERCOOLER WATER OUTLET.
INTERCOOLER
SECTIONS 2, 3 & 4
1.3. Disassembling the water flange and by-pass pipe.
In general, the thermostat housing of the auxiliary circuit is located off the engine,
NOTE
mounted on the frame, and consequently the by-pass pipe and the thermostat housing
connecting pipe to the water flange also run off the engine. So, they should have been
removed during the disassembly of all the external lines to the engine, before removing
the engine from its location.

1. In order to disassemble the auxiliary circuit water flange, loosen its fixing screws to
the auxiliary circuit. water pump.
2. Insert two screws in the removal points of the water flange.
3. Then, screw against the pump in order to separate the water flange, since an applied
sealing liquid exists between the flange and the pump.
4. Remove the flange and the O-ring gasket.
EXTERNAL WATER
INLET
BY-PASS PIPE CONNECTING AUXILIARY CIRCUIT WATER

FLANGE FLANGE
REMOVAL POINT OF WATER

FLANGE
1.4. Removing the auxiliary circuit water pump.
1. At the back of the front gear train cover, on the left side, remove the water pump
lubricating pipe.
2. To do so, loosen the hollow screws holding the lubricating pipe to the back cover of
the pump.
3. At the other end of the pipe, loosen the hollow screw from the oil distributor.
4. Remove the water pump lubricating pipe and all the gaskets
5. Loosen the screws of the pump cover to the back of the gear train cover. Remove the
pump cover and the O-ring.
6. Loosen the nuts securing the water pump to the gear train cover.
7. Manually extract the pump from its supporting studs.
8. Remove the water pump and the O-ring placed between the pump and its housing.
9. Remove the studs from the gear train cover.
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS FROM COOLING CIRCUIT(S)
MECHANICAL PUMP OF THE

PUMP FIXING NUTS
AUXILIARY CIRCUIT
BACK COVER OF THE PUMP AND

LUBRICATING PIPE
1.4.1. Sub-assembly: Mechanical Pump

of the Auxiliary Circuit.------------------------------------------- S - 10
2. DISASSEMBLY OF THE MAIN COOLING CIRCUIT
a) MAIN CIRCUIT WITH ADAPTOR TO REMOTE COOLER.
a.1. Disassembling the water flange and by-pass pipe.
1. Loosen the connection - consisting of a hose and two clamps - between the
thermostat housing water outlet and the by-pass pipe. Remove the hose and two
clamps.
2. Loosen the connection - consisting of a hose and two clamps - between the by-
pass pipe and the water inlet elbow to the water flange.
3. Remove the by-pass pipe, hose and two clamps.
4. Loosen the water flange screws from the water pump..
5. Insert two screws in the removal points of the water flange. Then, screw against
the pump in order to separate the water flange, since an applied sealing liquid
exists between the flange and the pump
6. Remove the water flange and the O-ring placed between the flange and the
pump.
BY-PASS PIPE
BY-PASS PIPE
WATER INLET

ELBOW TO WATER
FLANGE
WATER FLANGE
REMOVAL POINT OF
WATER FLANGE WATER INLET
ELBOW TO
WATER FLANGE
b) MAIN CIRCUIT WITH ADAPTOR TO REMOTE RADIATOR.
The cooling system with remote radiator needs a pulley coupled to the crankshaft
to transmit themovement to the fan through a driving belt. Therefore, in addition
NOTE
to dismounting the water lines, it will be necessary to disassemble the fan

adaptor.
b.1. Disassembling the water flange and by-pass pipe.
Although the components are physically different,

NOTE
disassembling the water flange and by-pass pipe

will be done in the same way as for the adaptor
with remote cooler.
1. Follow the procedure described for

disassembling the water flange and by-pass pipe
of a circuit with adaptor to a remote cooler.
FAN ADAPTOR
BY-PASS PIPE
WATER FLANGE
b.2. Disassembling the fan adaptor.
1. Loosen the screws securing the fan to the fan pulley - driving flange. Remove the
fan.
2. Remove the fan driving belt both from the crankshaft pulley and from the fan
pulley.
3. Loosen the nut of the fan clamping flange. Remove the pulley and driving flange.
4. Loosen the screws from the fan bearing to its support. Remove the bearings and
shaft.
5. Loosen the screws from the bearing support to the front gear housing cover.
6. Remove this support and support bracket.
c) MAIN CIRCUIT WITH ADAPTOR FOR HEAT EXCHANGER.
In installations where the main circuit water is cooled in a heat exchanger, the
NOTE
"coolant" is supplied by an external circuit. Therefore, it is necessary to

disassemble the piping of this external circuit before disassembling the main
circuit
c.1. Disassembling the heat exchanger.
1. Disassemble the water line from the heat

exchanger to the water inlet flange into the main
circuit. For that purpose, loosen the clamps of the
coupling sleeve between the water outlet elbow
of the heat exchanger and the water inlet flange.
Remove the coupling sleeve (hose) and clamps.
2. Set the exchanger lifting tool Ref. 16.75.247 on
the top of the heat exchanger. Attach a crane to
this tool, which will hold the heat exchanger once
this has been removed from its supports.
3. Loosen the screws between the water inlet to the exchanger and the thermostat
housing of the main circuit.
4. Loosen the screws holding the heat exchanger to its support.
5. Remove the heat exchanger with the help of a crane.
Use hoisting equipment with adequate capacity
NOTE
to hold the weight of the heat exchanger and its

support.

6. Loosen the screws retaining the heat exchanger
supports to the gear housing cover.
HEAT EXCHANGER SUPPORT
c.1.1. Sub-assembly: Heat Exchanger---------------------------------------S - 12
c.1.2. Hydraulic testing of heat exchanger---------------------------- I-12
c.2. Disassembling the water flange and by-pass pipe.

As is the case with the previous configuration, in spite of the physical differences
existing between the components, the disassembling procedure both for the
NOTE
water flange to the main circuit and for the by-pass pipe is identical to that
described for a main circuit with remote cooling.
1. Follow the procedure described for disassembling the water flange and by-pass
pipe of a circuit with adaptor to a remote cooler.
BY.PASS PIPE
WATER FLANGE
INLET ELBOW TO WATER

FLANGE
REMOVAL POINT OF
WATER FLANGE
1. Disassembly of the water discharge pipe into the engine block
1. Loosen the clamps of the hose between the water discharge pipe into the engine
block and the water outlet elbow of the main circuit pump.
2. Remove the hose and two clamps.
3. Loosen the screws from the water discharge pipe into the water inlet to the
engine block.
4. Remove the water discharge pipe and the O-ring placed in the engine block water
inlet
5. Loosen the screws fastening the water outlet elbow to the pump.
6. Remove the water outlet elbow and the O-ring situated between the elbow and
the pump.
WATER DISCHARGE PIPE

INTO THE ENGINE BLOCK
WATER OUTLET ELBOW OF THE

MAIN CIRCUIT
2. Removing the main circuit water pump.
1. Disassemble the lubricating pipe of the main circuit water pump.

2. For this purpose, loosen the hollow screw of the pump lubricating pipe at the back
of the front gear housing cover.
3. At the other end of the lubricating pipe, loosen the hollow screw holding the
lubricating pipe to the engine block.
4. Remove the pump lubricating pipe and the gaskets placed at its ends.
5. Loosen the screws from the back cover of the water pump to the middle cover of
the front gear housing.
6. Remove the pump back cover as well as the O-ring.
7. Loosen the nuts of the water pump to the gear housing cover.
8. Manually remove the water pump from the studs on the front gear train cover.
Also, remove the O-ring gasket between the pump and its housing.
9. Remove the studs from the front gear train cover.
LUBRICATING PIPE OF
WATER PUMP

BACK COVER OF THE WATER
PUMP OF MAIN CIRCUIT
MECHANICAL PUMP OF MAIN

CIRCUIT
S-9
2.1. Sub-assembly: Mechanical Pump of Main Circuit-----------------------------
ENGINE WITH COOLING CIRCUITS WITH ELECTRIC PUMPS.
1. DISASSEMBLY OF THE AUXILIARY COOLING CIRCUIT
a) Disassembling the water inlet line to the intercooler.

1. Loosen the nuts from the pipe clamp to the pipe support. Remove the clamp.
2. Loosen the screws that fasten the support of the intercooler's water inlet line to
the engine block. Remove the support.
3. Loosen the screws from the water inlet line to the intercooler.
4. Remove the water inlet line to the intercooler and its O-ring.
WATER INLET LINE TO

INTERCOOLER.
AUXILIARY CIRCUIT
PIPE CONNECTION TO
WATER MANIFOLD OF
INTERCOOLER
PIPE SUPPORT
The water inlet line to the intercooler comprises two sections and can be
NOTE
disassembled either as a whole unit as described previously or by section after
loosening the connection between the two pipe sections.
b) Disassembling the water discharge line from the intercooler (to the oil cooler)
In this case, the water discharge line from the intercooler consists of 4 pipe
NOTE
sections. However, due to the form and layout of the line, in order to remove it, it
will be necessary to loosen all its sections, starting from that farther away from
the intercooler.
1. Disassemble section 4 of the water discharge line. To do so, loosen the fixing
screws of pipe section 4 to section 3
2. Remove the pipe section 4 and the gasket situated between the connecting
flanges of the two sections
3. Disassemble section 3 of the water discharge line. For this purpose, loosen the
fixing screws of pipe section 3 to section 2 (inclined section).
4. Remove the pipe section 3 and the gasket placed between the connecting
flanges of the two sections.
5. Disassemble section 2 (inclined section). Loosen the fixing screws of pipe section
2 to section 1 (water outlet from intercooler).
6. Remove section 2 and the gasket placed between the two sections.
7. Loosen the fixing screws of section 1 (intercooler water outlet) to the intercooler.
8. Remove section 1 as well as the gasket from the connection to the intercooler.
INTERCOOLER DISCHARGE INTERCOOLER DISCHARGE SECTION 2 SECTION 3 SECTION 4

LINE. SECTION 2 AND LINE. SECTION 1,
CONNECTION TO SECTION 1. CONNECTION TO INTERCOOLER
INTERCOOLER DISCHARGE LINE.

SECTIONS 2, 3 AND 4S
2. DISASSEMBLY OF THE MAIN COOLING CIRCUIT.
1. Disassemble the water inlet pipe to the engine block. For this purpose, loosen the
screws holding the water inlet pipe to the water inlet on the cylinder block.
2. Remove the water inlet pipe to the block and the O-ring situated between the pipe
and the block.

WATER INLET PIPE AND FLANGE TO
CYLINDER BLOCK. ASSEMBLY OF MAIN
CIRCUIT WITH ELECTRIC PUMPS
3. Disassemble the water outlet system from the engine.

4. Engines with a main cooling circuit with (remote) electric pump have an engine
water outlet consisting of a box collecting water from both cylinder banks. In order
to disassemble this system, loosen the screws fastening the exhaust manifold
water outlet elbows to the said collecting box.
5. Remove the water collecting box and the gaskets.
6. Loosen the screws from the water outlet elbows to the exhaust manifolds.
Remove the outlet elbows and the gaskets.
BOX COLLECTING WATER FROM THE TWO EXHAUST MANIFOLD CONNECTING ELBOW TO
CYLINDER BANKS. WATER OUTLET ENGINE WATER OUTLET
In the case of engines having a main cooling circuit with (remote) electric pumps,
NOTE
the thermostat housing of the main circuit usually lies off the engine, fitted to the
external water lines.
DISASSEMBLY THERMOSTAT HOUSING OF
THE MAIN CIRCUIT
E.- DISASSEMBLING THE THERMOSTAT HOUSING OF THE MAIN

CIRCUIT
1. Before disassembling the thermostat housing, it will be necessary to remove the

temperature switch cable and the cooling water temperature control cable from the
control panel to the thermostat housing.
2. Disassemble the thermostat from the thermostat housing.
TEMPERATURE CONTROL
CABLE
THERMOSTAT HOUSING OF
THE MAIN CIRCUIT
3. Loosen the screws of the water inlet elbows to the thermostat housing (one elbow
per exhaust manifold).
4. Remove the thermostat housing and the gaskets placed at the water inlets, i.e. at the
connections with the water inlet elbows (water outlet from exhaust manifolds).
5. Loosen the screws retaining the water outlet elbows to the exhaust manifolds. (These
elbows are the water inlet elbows to the thermostat housing.)
6. Remove the two elbows and the gaskets situated between the elbows and the
exhaust manifolds.
SCREWS SECURING THE

ELBOWS TO THE ELBOW BETWEEN EXHAUST
THERMOSTAT HOUSING MANIFOLD OUTLET AND WATER
INLET TO THERMOSTAT
HOUSING
SCREWS SECURING THE
ELBOWS TO THE EXHAUST
MANIFOLD
As for engines with a main cooling circuit with (remote) electric pumps, the
NOTE
thermostat housing is located in a piping external to the engine and should have
been removed earlier, during the disassembly of the external water circuit.
1. Sub-assembly: Thermostat Housing of the Main Circuit.---------------------------------------

S - 11
DISASSEMBLY IGNITION SYSTEM
F.- DISASSEMBLING THE ENGINE IGNITION SYSTEM.
1. DISASSEMBLY OF THE HIGH-VOLTAGE COILS AND WIRES.
1. Disconnect the high-voltage coil strips from the electronic ignition cable.
2. Disconnect the grounds of the coil strip.
3. Remove the links between the high-voltage coils and the spark plugs. Loosen the
spark plug wires.
ENLACE LLNK BETWEEN

COIL & SPARK PLUG
4. Disassemble the high-voltage coil sets by removing their supporting strips..

5. To do so, loosen the screws from the strips to their supports (brackets fitted to the
engine intake manifolds).
6. Remove the two strips with the high-voltage coils (one strip per cylinder bank).
7. Loosen the screws retaining the coil strip supports to the intake manifolds and
remove the support. Also remove the studs from the intake manifolds.
STRIP SUPPORTS ON THE INTAKE

MANIFOLD
HIGH-VOLTAGE COIL SET ON A STRIP
IGNITION SYSTEM DISASSEMBLY
2. REMOVING THE ELECTRONIC IGNITION MODULE.
1. Disassemble the electronic ignition pickups from the flywheel housing.

2. Loosen the pickup cables from the terminals of the electronic ignition module and
remove the pickups.
The cables between the electronic ignition module and the high-voltage coil strip should

NOTE
have been disconnected in a previous operation, before removing the high-voltage

coils.
3. Loosen the lock nuts of the electronic ignition module to its support. Remove the
electronic ignition module and the elastic inserts placed between the ignition module
and its supports.
4. Loosen the screws retaining the electronic ignition module support to the back of the
intermediate cover of the back timing gear housing.
5. Remove the ignition module support and the gasket placed between this support and
the intermediate cover of the back timing gear housing.
ELECTRONIC IGNITION MODULE

ON ITS SUPPORT
ELECTRONIC IGNITION PICKUPS
ELECTRONIC IGNITION MODULE SUPPORT

ON THE INTERMEDIATE COVER OF BACK
TIMING GEAR HOUSING
F
DISASSEMBLY REGULATION SYSTEM
G.- DISASSEMBLING THE ENGINE REGULATION SYSTEM.
FGLD ENGINES. Mechanical Regulation System.
1. DISASSEMBLING THE MAIN CONTROL ROD.

1. Loosen the lock nut holding the control rod joint to the lever of the mechanical
regulation butterfly.
2. At the other end of the control rod, loosen the nut holding the control rod joint to the
hydraulic regulator lever.
3. Remove the control rod assembly of the regulation system.
DETAIL OF CONTROL ROD UNION
WITH LEVER OF MECHANICAL
BUTTERFLY
DETAIL OF ROD
ATTACHMENT TO
REGULATOR LEVER
MAIN CONTROL ROD OF REGULATION SYSTEM
2. DISASSEMBLING THE HYDRAULIC REGULATOR.
2.1. Disassembly of the Electric Control.
This device only exists when the hydraulic regulator

NOTE
fitted on the engine is the PSG type.
1. Loosen the screws from the electric control cover.

Remove the cover.
2. Loosen the nuts holding the electric control
varispeed drive to the body of the hydraulic regulator.
Remove the varispeed drive and the washers,
separator and elastic inserts
3. Remove the manual control.
2.1.1. Sub-assembly: Electric Control.---------------------

S - 24
REGULATION SYSTEM DISASSEMBLY
2.2. Disassembly of the regulator lubricating lines.
1. Loosen the lubricating pipe hollow screw from the hydraulic regulator casing.
2. At the other end of the lubricating pipe, loosen the hollow screws from the upper oil
distributor.
3. Remove the regulator casing lubricating pipe as well as the hollow screws and the
copper gaskets from both ends of the lubricating pipe.

4. Loosen the lubricating pipe hollow screw from the hydraulic regulator casing.
5. At the other end of the lubricating pipe, loosen the reducing connector of the said
lubricating pipe to the hydraulic regulator (regulator body).
6. Remove the hydraulic regulator lubricating pipe and the copper gaskets.
Where the regulator is the EG3P (actuator) type, there will be only a lubricating pipe to
NOTE
the actuator casing (drive housing), i.e. an oil pipe from the oil distributor to the regulator
casing. Disassemble this pipe, as described above.
HYDRAULIC REGULATOR
REGULATOR CASING LUBRICATING PIPE
LUBRICATING PIPE
2.3. Disassembling the hydraulic regulator body.
1. Loosen the nuts from the hydraulic regulator body to the regulator drive casing.
2. Remove the regulator body, regulator drive, bushing and bearing splitter.
2.4. Disassembling the regulator drive casing.
1. Loosen the screws that secure the regulator drive casing to the flywheel housing in
which it is mounted.
2. Remove the Regulator Casing assembly as well as the O-ring gasket situated
between the regulator casing and its location in the flywheel housing.
DISASSEMBLY REGULATION SYSTEM
SCREWS FASTENING THE DRIVE

TO THE FLYWHEEL HOUSING
REGULATOR DRIVE
2.4.1. Sub-assembly: Hydraulic Regulator Drive Housing.------------------------ S - 23
SFGLD. Electronic Regulation System.
SFGLD engines have an electronic type of regulation consisting of a remote electronic

NOTE
control unit (EGS) and an Electronic Intake Butterfly Valve (Flo-Tech Butterfly Valve)
The electronic control (EGS) is installed in a stand-alone cabinet external to the engine;
therefore, all the connections and cables between this element and the engine should
have been removed in a previous operation, before starting the disassembly of the
engine components.
The Flo-Tech electronic butterfly valve will be removed later, during the disassembly of
the engine intake system.
DISASSEMBLY INTAKE MANIFOLD
H.- DISASSEMBLY OF INTAKE MANIFOLDS

1. DISASSEMBLY OF PROBES AND SENSORS.
1. Disconnect the cables from the thermoswitch wells and the pressure switch tubes
mounted on the engine.
2. Remove the temperature and pressure switch panel from the engine. For this
purpose, once the cables have been disconnected, loosen the screws fixing the
panel to the engine block, etc.
Depending on the engine configuration and on the type and use of installed probes and
sensors, the temperature and pressure switch panels will be mounted either on the
NOTE
cylinder block (usually on the left side) or on one of the intake manifolds, or at another
place.
NOTE
As for SFGLD engines, it will be necessary to disconnect the tube for the MAP (EGS).
2. DISASSEMBLY OF THE GAUGE PANEL.
Removing the gauge panel from the engine, although not a requirement for
disassembling the intake manifolds (and particularly the right-hand intake manifold), will
NOTE
greatly facilitate this operation, by providing easier access to the manifold fixing screws
to the cylinder heads.
1. The connections between the Gauge Panel and the different measurement and
control devices on the engine should have been released in a previous operation.
2. Loosen the nuts from the Gauge Panel bracket. Remove the gauge panel and the
elastic spacers.
3. Loosen the screws fastening the gauge panel bracket to the auxiliary rocker arm
cover. Remove the gauge panel bracket. So, there will be space enough to reach the
screws of the intake manifold to the cylinder heads, for disassembly at a later stage.
2.1. Sub-assembly: Gauge Panel.------------------------------------------------------- S - 25
INTAKE MANIFOLD DISASSEMBLY

3. DISASSEMBLING THE OIL FILLING ELBOW
Disassembling the oil filling elbow is not necessary for being able to remove the intake
NOTE
manifold, but will help significantly.
1. Loosen the nuts retaining the oil filling elbow to the auxiliary rocker arm inspection
cover (normally the first cover on the right-hand side of the engine).
2. Remove the oil filling elbow and its O-ring.
3. Loosen the studs mounted on the auxiliary rocker arm inspection cover.
OIL FILLING ELBOW
OIL FILLING ELBOW FIXING

SCREWS
4. DISASSEMBLING THE GAS/OIL SEPARATING FILTER FOR

CRANKCASE GAS RECIRCULATION
This section describes how to disassemble only one of the two types of separating filters
used in recirculating crankcase gases on gas-fueled V-engines. The said filter is the so-
NOTE
called "bottle" type which rests on brackets above the auxiliary rocker arm inspection
covers, on one flank of the cylinder block.
Disassembling the separating filter will ease the disassembly of the intake manifolds at
a later stage.
For this purpose:
1. Loosen the screws from the clamp of the gas inlet hose to the separating filter (for
gas recirculation).
2. Loosen the screws securing the flanges of the gas outlet pipe from the decanters of
the crankcase gas breather.
3. Remove the gas outlet pipe from the decanters and the gas inlet hose to the
separating filter.
4. Loosen the connector of the oil drain pipe to the bottom of the separating filter.
5. Loosen the connector of the gas recirculating hose to the separating filter outlet.
6. Remove the gas recirculating hose.
7. Loosen the screws retaining the separating filter supports to the auxiliary rocker arm
inspection covers.
8. Remove the separating filter and its supports.
GAS / OIL SEPARATING

FILTER FILTER OIL DRAIN PIPE
GAS PIPE FROM BREATHER TOWARD

SEPARATING FILTER
5. DISASSEMBLY OF THE ENGINE INTAKE CIRCUIT.
5.1. Disassembling the Intake Elbow and Connector to the Intercooler.
FGLD ENGINE. Intake Elbow with mechanically-operated butterfly valve
The main control rod of the regulation system, which operates the mechanical butterfly
NOTE
valve, should have been removed previously, during the disassembly of the engine
regulation system.
1. Loosen the screws of the intercooler outlet pipe to the intake elbow with
mechanically-operated butterfly valve.
H
2. Extract the outlet pipe from the intercooler, connection made with O-rings.
3. Remove the intercooler outlet pipe, its O-rings and the flat gasket situated at the
connection to the intake elbow.
4. Loosen the screws of the intake elbow to the intake distributor (Y-pipe toward the two
intake lines).
5. Remove the intake elbow (with the mechanical regulating valve mounted in it) as well
as the flat gasket placed at the connection to the intake distributor (Y-pipe toward the

two cylinder banks).
INTERCOOLER OUTLET
INTAKE INLET ELBOW WITH
PIPE
BUTTERFLY VALVE
INTAKE INLET ELBOW WITH

MECHANICALLY-OPERATED
BUTTERFLY VALVE
SFGLD ENGINE. Intake Elbow with Flo-Tech electronic regulating butterfly valve.
1. Loosen the screws holding the Flo-Tech electronic valve to the A/F mixture outlet of
the Intercooler.
2. Loosen the screws and nuts fastening the electronic valve to the connection pipe to
the intake elbow.
3. Remove the Flo-Tech valve and the gaskets placed at both ends, in the unions with
the intercooler and the connection pipe.
4. Loosen the screws of the pipe (Flo-Tech connection to the intake elbow) to the intake
elbow.
5. Remove the pipe and the gasket placed at the union with the intake elbow.
6. Loosen the screws of the intake elbow to the intake distributor (Y-pipe toward the
manifolds of the two cylinder banks).
7. Remove the inlet elbow to the intake manifold, and the flat gasket situated in the
union of the intake elbow with the intake distributor (Y-pipe toward the two cylinder
banks).
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS DISASSEMBLY INTAKE MANIFOLD
INLET ELBOW TO INTAKE CONNECTION PIPE TO FLO-TECH ELECTRONIC

MANIFOLD INTERCOOLER REGULATING VALVE
5.2. Disassembling the Y-pipe and inlet elbows to the intake manifolds.
FGLD engines have two manually-operated safety butterfly valves mounted in the inlet
NOTE
elbows to the intake manifolds. In order to disassemble the inlet elbows to the intake
manifolds, it will be necessary to remove the linkage of the two butterfly valves first. For
this purpose:
1. Loosen the nuts securing the ball joints of the rod (linkage of the two safety valves)
to the valve levers (one in each inlet elbow to the intake manifold).
2. Remove the rod.
3. Loosen the screws from the control levers of the butterfly valves, in order to be able
to reach the inlet elbow fixing nuts more comfortably.
4. Remove the safety valve control levers.
MANUAL SAFETY VALVE CONTROL DETAIL OF SAFETY VALVE

LEVER LINKAGE

DETAIL OF SAFETY VALVE
LINKAGE
1. In the upper part of the intake distributor, screw a hoisting tool that will retain and
prevent this distributor from falling when we loosen the connections to the inlet
elbows to the intake manifolds.
2. Set a crane or similar equipment on the tool and hold it.
NOTE Appropriate equipment must be used to hoist the assembly in order to support
the weight of the intake distributor.
3. Loosen the bolts and nuts fastening the inlet elbow of the left intake manifold to the
intake distributor.
4. Loosen the bolts and nuts fastening the inlet elbow of the right intake manifold to the
intake distributor.
5. Remove the intake distributor (Y-pipe toward the intake manifolds of the two cylinder
banks) and the gaskets placed at the unions with the two inlet elbows.
6. Loosen the screws holding the inlet elbow to the left intake manifold.
7. Remove the inlet elbow to the left intake manifold and the gasket inserted between
the elbow and the manifold.
8. Loosen the screws holding the inlet elbow to the right intake manifold.
9. Remove the inlet elbow to the right intake manifold and the gasket inserted between
the elbow and the manifold.
FIXING SCREWS OF ELBOW

FIXING SCREWS OF ELBOW TO INTAKE DISTRIBUTOR
TO INTAKE MANIFOLD
5.3. Removal of Intake Manifolds.
1. Install the intake manifold lifting tool on the left intake manifold to support it once the
screws from the manifold to the cylinder heads have been removed.
2. Tie the lifting tool to a crane.
3. Loosen the screws from the left intake manifold to the cylinder heads.
4. Remove the intake manifold with the crane, removing the gaskets from the manifold
connection to the cylinder heads.

NOTE
Appropriate equipment must be used to hoist the assembly in order to support the
weight of the intake manifold.
5. Repeat this procedure, disassembling the

intake manifold of the other cylinder bank
(right intake manifold).
INTAKE MANIFOLD. FIXING SCREWS TO

CYLINDER HEADS
5.3.1. Cleaning---------------------------------------------------------------------------------------
I-0 A-0
DISASSEMBLY INTERCOOLER
I.- DISASSEMBLING THE INTERCOOLER (A/F MIXTURE COOLER)
1. Install the intercooler lifting tool in its housing.

2. Tie a crane on the lifting tool to remove the intercooler when the fixing screws to its
supports have been released.
3. Loosen the intercooler fixing screws to its supports.
4. Remove the intercooler (with the water distributor mounted in its lower part) using the
crane and lifting tool
INTERCOOLER SUPPORTS MOUNTED

ON THE EXHAUST MANIFOLD
LIFTING OF INTERCOOLER WITH

ADEQUATE LIFTING TOOL AND CRANE
Appropriate equipment must be used to hoist the assembly in order to support the
NOTE
weight of the intercooler.
5. Loosen the screws fixing the intercooler supports to the exhaust manifolds (2
intercooler supports per exhaust manifold).
6. Remove the intercooler supports.
1. SUB-ASSEMBLY: S - 21
INTERCOOLER (AIR/FUEL MIXTURE COOLER).-----------------------
2. HYDRAULIC TESTING OF THE INTERCOOLER.---------------------------------------------

I-12
DISASSEMBLY EXHAUST MANIFOLDS
J.- DISASSEMBLING THE EXHAUST MANIFOLDS
1. REMOVAL OF WATER OUTLET ELBOWS FROM CYLINDER HEADS.
1. Remove the water outlet elbows from the cylinder heads. For this purpose, loosen
the bolts from the elbows to the cylinder heads and the exhaust manifold. Use a
special wrench to disassemble the water outlet elbows.

2. Remove the water outlet elbows and the O-rings from the connections to the cylinder
heads and to the exhaust manifolds.
3. Disassemble the elbow-flange assembly, removing the O-ring.
4. Repeat the above steps, disassembling the water outlet elbows from the cylinder
heads on the other bank.
WATER OUTLET ELBOW FROM CYLINDER

HEAD. REMOVE GASKETS FROM ELBOW,
MANIFOLD AND CYLINDER HEAD.
2. REMOVAL OF EXHAUST MANIFOLDS
1. Set the exhaust manifold lifting tool (ref. 16.75.166) to secure it once the exhaust
manifold screws have been removed from the cylinder heads.
2. Place a crane on the exhaust manifold lifting tool.
Appropriate equipment must be used to hoist the

NOTE
assembly in order to support the weight of the exhaust

manifold.
MANIFOLD LIFTING TOOL REF.

16.75.166, MOUNTED ON THE
MANIFOLD
EXHAUST MANIFOLDS DISASSEMBLY
3. Disassemble the exhaust manifold by loosening the exhaust manifold union screws
to the cylinder heads. Remove the gaskets located on the cylinder heads.
4. Repeat the previous operations to remove the exhaust manifold from the other
cylinder bank.

2.1. Cleaning.--------------------------------------------------------------------------------------------------
I-0 A-0
- Clean the disassembled connecting surfaces, cleaning the possible remains from
gaskets.
- Use a flat scraper to remove any remaining pieces.
- Clean the exhaust manifold flanges and the water outlet elbows.
- General cleaning of the exhaust manifolds.
- All gaskets and O-rings will be replaced when it is assembled
2.2. Sub-assembly: Exhaust Manifold------------------------------------------------------------------

S - 20
2.3. Hydro Test of Exhaust Manifold------------------------------------------------------- I - 12
DISASSEMBLY ROCKER ARM COVERS
K.- DISASSEMBLING THE ROCKER ARMS COVERS
1. EXTRACTING THE SPARK PLUGS

1. Extract the spark plugs from each cylinder head, using the spark plug wrench.
MANUAL REMOVAL OF SPARK PLUGS

WITH THE SPARK PLUG WRENCH
1.1. Checking the spark plugs and wires.------------------------------------------- I-10
1. Check the gap and, if necessary, recalibrate to the specified setting for each type of
spark plug (1 electrode / 4 electrodes).
2. Do a diagnosis of the spark plug condition, watching their color, the electrodes, etc.
2. DISASSEMBLING THE ROCKER ARM COVERS
1. Loosen the nuts and washers from each cover.

2. Remove the rocker arm covers and the O-rings placed between the covers and the
cylinder heads.
3. During the subsequent assembly, the O-rings of the rocker arms covers shall be
replaced.
ROCKER ARM COVERS DISASSEMBLY
3. DISASSEMBLING THE SPARK PLUG HOLDERS
1. Remove the spark plug holder from the cylinder head, using the special spark plug
holder assembly/disassembly wrench ref.16.75.009.
2. Verify that the spark plug holder O-ring has been removed from the housing in the
cylinder head.
3. This O-ring shall be replaced, when re-assembling the spark plug holder.

REMOVAL OF SPARK PLUG HOLDERS
WITH TOOL REF. 16.75.009
DISASSEMBLY MAIN ROCKER ARM ASSEMBLY
L.- DISASSEMBLING THE MAIN ROCKER ARM ASSEMBLY
1. DISASSEMBLING THE MAIN ROCKER ARM SUPPORT
1. Perform the disassembly of the main rockers support assembly to gain access to the
cylinder head retaining nut located under the main rockers.
2. To do this, loosen the 4 retaining screws of the main rocker-arms axle support.
Mark all the rocker´s supports before removing them if they are NOT going to be
NOTE
replaced so they are set in the same location when re-installed later on.
MAIN ROCKER ARM

SUPPORT
SUPPORT FIXING SCREWS
1.1. Sub-assembly: Main Rocker Arm Support-----------------------------------------------

S-4
2. DISASSEMBLING THE PUSH RODS
1. Remove the 2 push rods by hand (they just rest on the cam followers, as the main
rockers have been disassembled).
3. DISASSEMBLING THE VALVE LIFTERS
1. Remove the 2 valve lifters (2 per cylinder head) from their guides.
3.1. Sub-assembly: Valve Lifters.---------------------------------------------------------- S-5
PUSH ROD VALVE LIFTER
MAIN ROCKER ARM ASSEMBLY DISASSEMBLY
4. CLEANING THE LUBRICATING HOLES
5. CHECKING ELEMENTS-------------------------------------- I-8
DISASSEMBLY CYLINDER HEADS
M.- DISASSEMBLING THE CYLINDER HEADS
1. REMOVAL OF CYLINDER HEADS.
To avoid damaging the upper oil distributor (mounted

NOTE
between the two banks of cylinder heads) during the

removal of the cylinder heads, we shall first remove this
oil distributor.
For this purpose:
1. Loosen the screws fastening the oil distributor

support to the engine block.
2. Remove the oil distributor and the O-ring situated
between the distributor support and the block.
OIL DISTRIBUTOR SUPPORT FIXING

SCREWS
Now, disassemble the cylinder heads.
1. Loosen the cylinder head fastening nuts and remove washers.

2. Set the cylinder head removal / assembly tool (ref. 19.75.234), mounted where the
spark plug holders are located.
3. Tie a crane (or hoisting equipment) on the tool and remove the cylinder head. When
removing the cylinder head, be careful not to hit the cylinder head studs.
NOTE
Appropriate lifting equipment must be used to support the weight of the cylinder head.
If the cylinder head is being taken apart for an inspection of the valve retainers, valves,
NOTE
etc. it must be numbered to ensure consistent wear and tear among components
REMOVAL OF CYLINDER HEAD

WITH TOOL REF. 19.75.234 AND
CRANE.
CYLINDER HEADS DISASSEMBLY
2. DISASSEMBLING THE CYLINDER HEAD GASKET,

BUSHING AND OIL PASSING O-RING
1. Remove the cylinder head gasket, bushing and the oil passing O-ring that will be
replaced in a subsequent step of assembly.

DISASSEMBLY OF CYLINDER
BUSHING AND OIL PASSING O-RING
HEAD GASKET
Clean and dry any water and dust off the surface of the engine block that might exist on
the upper face where the cylinder heads are mounted in order to avoid the
DANGER
possible formation of scab.

In the disassembling process of each cylinder head, once the cylinder head is
disassembled, place a rag over the piston brace to prevent any type of element from
entering.
2. Check the hole of the gasket guiding pin in each cylinder head since if this seat is too
big or deteriorated, the cylinder head will be rejected.
3. Now, remove the cylinder head studs from the engine block.
3. VISUAL CHECKING OF THE SURFACE OF THE ENGINE BLOCK ON WHICH THE

CYLINDER HEAD RESTS: PERFECTLY CLEAN AND SMOOTH.
4. SUB-ASSEMBLY: CYLINDER HEADS---------------------------------------------------------

S-3
5. INSPECTION OF THE CYLINDER HEADS----------------------------------------------------

I-7
DISASSEMBLY COMPONENTS ON THE FRONT OF THE
ENGINE AND FRONT GEAR TRAIN
N.- DISASSEMBLING COMPONENTS ON THE FRONT OF THE ENGINE AND THE

FRONT GEAR TRAIN.
1. PULLEY DISASSEMBLY.
NOTE
There will be a pulley coupled to the front of the crankshaft only if the engine has had
a water cooling system with remote radiator.
1. Loosen the nuts retaining the pulley to the vibration damper.

NOTE
If the engine has two dampers, the pulley will be attached to the external damper.
2. Remove the pulley.

3. Remove the pulley studs from the damper.
PULLEY MOUNTED ON THE

FRONT END OF THE
ENGINE
2. DISASSEMBLING THE VIBRATION DAMPERS.
If there is no pulley-type coupling mounted on the front end of the engine, it will be
NOTE
necessary to remove the damper guard before the vibration damper can be
disassembled. Thus, loosen the fixing screws from the front timing gear housing cover
and remove the damper guard.
DAMPER GUARD
COMPONENTS ON THE FRONT OF THE DISASSEMBLY
1. Loosen the screws fastening the dampers to the front flange of the crankshaft.
2. In doing this, first remove two diametrically opposed screws and insert the guides
used to remove the Dampers in their holes. Then, loosen all remaining damper fixing
screws.
Make sure the guides are properly secured once installed.

3. Introduce a sling in the central hole of the vibration damper and tie it to a crane.
4. Remove the dampers off the guides previously mounted in the front flange of the
crankshaft.
DAMPER FIXING SCREWS TO

FRONT FLANGE OF
CRANKSHAFT. TWIN DAMPER ASSEMBLY
3. DISASSEMBLING THE CRANKSHAFT FRONT FLANGE.
1. Loosen the screws fastening the crankshaft front flange to the front gear of the
crankshaft.
2. To remove the flange, use the hydraulic gun and the disassembly tool ref. 16.75.135
(same tool as was used for assembling the flange).
Verify that the hydraulic flange disassembly

CAREFUL
tool is mounted correctly; otherwise, the

flange under pressure could get out like a
shot, causing injury and damage.
3. Remove the front flange from the

crankshaft with great care.
4. DISASSEMBLING THE CRANKSHAFT FRONT SEAL.
1. Remove the crankshaft front seal from the housing where it is mounted, on the gear
train front housing cover.
5. DISASSEMBLING THE FRONT COVER OF THE FRONT GEAR HOUSING.

1. Place the lifting tool (ref. 16.75.157) on the front

cover of the front gear housing.
2. Set the crane (or hoisting equipment) on this tool so
it holds the cover when the cover fixing screws are
removed.
REMOVAL OF FRONT COVER WITH

LIFTING TOOL REF. 16.75.175 AND A
CRANE
NOTE
The proper equipment should be used to do the lifting so it can withstand the weight of
the front cover of the gear train.
3. Loosen the screws that fasten the front cover to the oil pan.
4. Loosen the screws holding the front cover of the gear train to the gear housing
intermediate cover. To prevent the cover from falling, the last screws to be removed
should be the two on top of the front cover.
5. Detach the front cover of the gear train from the intermediate cover. Since that there
is a liquid seal applied to it, X screws would be used, placing them in the removal
holes of the front cover of the gear train.
6. Screw the different screws alternately against the intermediate cover. This way, it will
be possible to separate both covers.
7. Remove the front cover of the front gear train with the aid of a crane (hoisting
equipment) and the cover lifting tool.
5.1. Cleaning.--------------------------------------------------------------------------------------------------
I-0 A-0
COMPONENTS ON THE FRONT OF THE DISASSEMBLY
6. DISASSEMBLING THE WATER PUMPS INTERMEDIATE DRIVE GEARS.
1. Loosen the screws from the axial thrust washer (clamp disk) that is mounted on the
gear shaft, just in front of the gear.
2. Remove the axial thrust washer (clamp disk).
3. Remove the intermediate gear from its shaft, using the gear extracting tool. The gear
bushing (mounted between the gear and the shaft) should come out at the same

time.
4. Extract the bushing from the inside of the gear, so that a new bushing can be inserted
at the assembly stage.
5. Loosen the screws fastening the intermediate gear shaft to the intermediate cover of
the front gear train.
6. Remove the gear shaft.
HOUSING IN INTERMEDIATE
COVER FOR WATER PUMP INTERMEDIATE DRIVE GEAR OF
INTERMEDIATE DRIVE GEAR MAIN CIRCUIT WATER PUMP
In the event there are two pumps on the engine (one for the main cooling circuit and
NOTE
one for the auxiliary circuit), it will be necessary to repeat the above procedure in order
to disassemble the other water pump intermediate drive gear.
DANGER
After removing the gear shaft from its bore in the intermediate cover of the gear train,
check the bore condition.
6.1. Gear check.----------------------------------------------------------------------------

I-0 I-1
7. DISASSEMBLING THE INTERMEDIATE COVER OF THE FRONT GEAR HOUSING.
1. Remove the jets control valve from its housing in the upper part of the front timing
gear intermediate cover.
2. Loosen the screws holding the top cover to the front timing gear intermediate cover.
Remove the top cover and install the intermediate cover lifting tool (ref. 16.75.168) in
its place.
3. Place a crane (or hoisting equipment) over the tool to hold the intermediate cover
once its fixing screws have been removed from the engine block.
NOTE
Appropriate lifting equipment must be used, to support the weight of the front timing
gear intermediate cover.
4. Loosen the screws holding the intermediate cover to the cylinder block.
5. Separate the intermediate cover from the engine block. To do this, and since there is
a liquid seal applied to it, X screws will be inserted into the removal points of the
timing gear intermediate cover.
6. Screw onto the engine block, alternating, the different screws inserted into the
removal points of the intermediate housing. This way this timing gear intermediate
housing cover can be separated from the engine block.
7. Remove the timing gear intermediate housing cover with the lifting tool and a crane.
8. Remove the guide pins from the engine block.
JETS CONTROL VALVE INSTALLED IN REMOVAL OF INTERMEDIATE COVER WITH LIFTING

INTERMEDIATE COVER TOOL REF. 16.75.168
INTERMEDIATE COVER FIXING

SCREWS TO CYLINDER
BLOCK
7.1. Sub-assembly: Jets Control Valve.----------------------------------------------- S - 26
7.2. Cleaning.--------------------------------------------------------------------------------------------------
I-0 A-0
DISASSEMBLY COMPONENTS ON THE BACK PART OF
THE ENGINE AND REAR GEAR TRAIN
O.- DISASSEMBLING COMPONENTS ON THE BACK PART OF THE ENGINE AND

THE REAR GEAR TRAIN.
1. DISASSEMBLING THE FLYWHEEL.
In the event the engine has a coupling secured to the flywheel, this should have been
NOTE
removed previously, before starting the disassembly of engine components.
1. Assure a minimal amount of space to allow easy removal of the flywheel.

2. Loosen a couple of flywheel anchor bolts facing each other diametrically into the
flywheel adaptor piece.
3. Assemble two flywheel tool guides on this adaptor piece, in the holes of the bolts
previously removed.
CAREFUL
Make sure that the guides are correctly installed.
4. Loosen the rest of the flywheel mounting screws.

5. Remove the flywheel gently and manually, on the previously installed guides, to be
able to place the flywheel fastening tool (ref. 16.75.017) on the wheel.
NOTE
Check ahead of time that the hole for the wheel fastening / lifting tool is in the correct
position. Otherwise, use a barring tool to place the flywheel in the desired position.
6. Install the flywheel lifting tool with a crane through the use of slings.
7. Remove the flywheel off the previously installed guides with the help of the crane and
a lifting tool.
Appropriate equipment must be used for hoisting so that it supports the weight of the
NOTE
flywheel.
8. Remove the two guides previously mounted on the flywheel adaptor piece.
1.1. Inspection.
1. Check the gear mounted on the outside of the flywheel. Test its correct condition,
confirming that there are no burrs in the ring teeth. Use grinding wheels to recondition
the gear ring when there are burrs.
COMPONENTS ON THE BACK PART OF DISASSEMBLY
1.2. Sub-assembly: Flywheel.--------------------------------------------------------------------

S- 8
FLYWHEEL DISASSEMBLY WITH A

CRANE AND LIFTING TOOL REF.
16.75.017

GUIDES MOUNTED ON FLYWHEEL
ADAPTOR PIECE FOR FLYWHEEL
REMOVAL
2. DISASSEMBLING THE SEAL HOLDER UNIT, GASKET AND REAR SEAL.
1. Remove the crankshaft rear seal,

assembled on the seal support unit. For
this purpose, introduce two jackscrews in
the taps of the seal.
2. Loosen the bolts of the rear seal support
unit to the flywheel case.
3. Remove both the seal holder unit support
and the gasket.
4. The seal and gasket will be replaced in the
rear seal assembly.
2.1. Sub-assembly: Back Seal Holder----------------------------------------------------------------

S-7
3. DISASSEMBLING THE FLYWHEEL HOUSING.
3.1. Disassembling the Electric Starter.
If the engine is not disassembled completely, it is necessary to disconnect the power

CAREFUL
and control lines before disassembling the electric starter. In case of complete
disassembly of the engine, all cables should have been removed prior to starting the
disassembly of the engine components.
1. Loosen the electric starter anchor bolts to the flywheel housing.

2. Remove the starter from its housing in the flywheel housing.
3.2. Disassembling the Flywheel Housing.
1. Place the ear screw ref. 16.75.017 in the flywheel housing. This ear screw will serve
as a lifting tool.
2. Secure the flywheel housing with a crane or lifting component, using the previously
mounted ear screw.
DANGER
Do not damage the existing guides on the flywheel housing when securing the casing
with the crane.
3. Loosen the flywheel housing bolts to the oil pan.

4. Loosen the flywheel housing bolts to the engine block.
5. To detach the engine block flywheel housing, and because a sealing liquid has been
applied, use X screws on the removal points of the flywheel housing.
6. Screw the different screws placed in the removal points of the flywheel housing
alternately against the engine block.
7. Remove the flywheel housing with the help of a crane.
NOTE
Appropriate equipment must be used for hoisting so that it supports the weight of the
flywheel housing.
8. Remove the installed pins (guides) on the engine block.
3.3. Cleaning.--------------------------------------------------------------------------------------------------
I-0 A-0
1. The flywheel casing shall be cleaned thoroughly prior to its re-assembly.

2. With a flat scraper, eliminate all gasket remains adhering to the area in which the
liquid seal has to be installed during the assembly procedure.

4. DISASSEMBLING THE HYDRAULIC REGULATOR DRIVE GEAR.
1. Loosen the screws of the locking disk to the gear shaft. Remove the locking disk.
2. Extract the gear of the hydraulic regulator drive from its mounting shaft, removing the
bearings mounted on the gear at the same time.
3. Remove the calibration washer.
4. Loosen the anchor bolts of the gear shaft to the intermediate cover of the back timing
gear train.
5. Remove the gear shaft.
NOTE
The existing gear bearings must be disassembled and shall be replaced by new ones
during the re-assembly process.
DRIVE GEAR OF
WOODWARD HYDRAULIC
REGULATOR
4.1. Gear Check.------------------------------------------------------------------------------

I-0 I-1
5. DISASSEMBLING THE CAMSHAFT GEARS.
1. Loosen the fastening screws of the camshaft gear to the camshaft.

2. Remove the camshaft gear.
3. Repeat these two operations, to disassemble the other camshaft gear.
CAMSHAFT GEARS
I-0
5.1. Gear Check.------------------------------------------------------------------------------ I-1
6. DISASSEMBLING THE THRUST DRIVE DISKS OF THE CAMSHAFT.
1. Loosen the bolts fastening the thrust drive disks of the camshaft to the intermediate
cover of the back timing gear housing.
2. Remove the thrust drive disks from both camshafts.
3. Also remove the lock washers.
THRUST DRIVE DISK OF

CAMSHAFT
7. DISASSEMBLING THE INTERMEDIATE GEAR OF THE BACK TIMING GEAR TRAIN.
1. Loosen the screws from the axial thrust washer and remove this washer.
2. Remove the gear with the extractor, removing the gear bushing at the same time.
3. Remove the bushing from the gear, so that a new bushing can be mounted during re-
assembly.
4. Loosen the screws holding the shaft of the intermediate gear to the intermediate
cover of the back gear train.
5. Remove the gear shaft from its housing in the intermediate cover of the back gear
train.
DANGER
Check the housing of the intermediate gear shaft in the timing gear cover.
INTERMEDIATE GEAR OF
BACK TIMING GEAR TRAIN

I-0
7.1. Gear Check.------------------------------------------------------------------------------ I-1
8. DISASSEMBLING THE OIL PIPE TO THE ENGINE BLOCK CENTRAL GALLERY.
1. Loosen the screws of the oil pipe to the

intermediate cover of the back gear train.
2. Loosen the screws of the oil pipe to the oil
inlet into the engine block central gallery.
3. Remove the oil pipe and its O-rings. The
O-rings must be changed in the
subsequent re-assembly process.
OIL PIPE TO THE ENGINE

BLOCK CENTRAL GALLERY
8.1. Cleaning.--------------------------------------------------------------------------------------------------
I-0 A-0
9. DISASSEMBLING THE BACK TIMING GEAR INTERMEDIATE HOUSING COVER.
9.1. Disassembly of the oil line from the external oil circuit.
1. Before removing the back timing gear intermediate housing cover, it will be
necessary to disassemble the external oil circuit line attached to it and to the filter
support.
2. For this purpose, loosen the screws securing this oil line to the side of the back timing
gear intermediate housing cover.
3. At the other end of the pipe, loosen the screws from the oil filter support.
4. Remove the oil line of the external circuit and the gaskets placed at both ends of the
line.
NOTE
Although the oil line of the external circuit consists of two (2) sections, it can be removed
a whole, without disassembling the intermediate connection of the two sections.
9.1.1. Cleaning.----------------------------------------------------------------------------------------
I-0 A-0
9.2. Disassembling the back timing gear intermediate housing cover.
1. Set the intermediate housing cover holding tool. Place the crane over the tool to hold
the intermediate cover.
NOTE
The proper equipment should be used for the lifting, so it can withstand the weight of
the timing gear intermediate housing.
2. Loosen the fastening screws between the oil pan and the intermediate cover.
3. Loosen the fastening screws between the intermediate cover and the engine block.
4. Separate the intermediate cover from the engine block. To do this, and since there is
a liquid seal applied to it, X screws will be inserted into the removal points of the
timing gear intermediate housing.
5. Screw onto the engine block, alternating, the different screws inserted into the
removal points of the intermediate housing. This way this timing gear intermediate
housing cover can be separated from the engine block.
6. Remove the timing gear intermediate housing cover with the lifting tool and the crane.
7. Remove the guide pins from the engine block.

REMOVAL OF INTERMEDIATE HOUSING
COVER WITH EXTRACTION SCREWS AND A
CRANE
9.2.1. Cleaning---------------------------------------------------------------------------------------
I-0 A-0
1. The back timing gear intermediate cover shall be cleaned thoroughly before its re-
assembly.
2. With a flat scraper, eliminate all gasket remains adhering to the area in which the
liquid seal has to be installed during the assembly procedure.
DISASSEMBLY ENGINE ROTATING TOOL. DISASSEMBLING
PHASE ON A SUPPORT TOOL
P.- INSTALLATION OF ENGINE ROTATING TOOL. DISASSEMBLING PHASE ON A

SUPPORT TOOL.
Once the engine rotating tool (ref. 16.75.213) has been placed, begins the
NOTE
disassembling phase on the support. It will facilitate, to a great extent, the disassembly
of most of the elements.
If the engine is not being completely disassembled, then disassembling these
components could be done outside of the support tool.

However, if the engine is being completely disassembled, it is advisable to continue on
disassembling on a support tool.
1. Place the front rotating tool on the front part of the engine block. Set the tool anchor
bolts on the engine block.
2. Place the back rotating tool on the back part of the engine block. Set the tool anchor
bolts on the engine block.
3. Place the eye-screws for lifting the engine in the appropriate locations for that
purpose.
4. Secure the eye-screws for lifting and using a crane so as to move the engine block
to the support tool, supporting the engine on them by the previously mounted rotating
tools.
ENGINE ROTATING TOOL. DISASSEMBLING DISASSEMBLY
PHASE ON A SUPPORT TOOL
Appropriate equipment (slings and crane) must be used to hoist and move the engine
NOTE
block to the tool so that the crane supports the weight of the engine block along with its
assembled components.
5. Once we have the engine block installed on the support tool, we will be able to
continue disassembling the engine, and may turn the engine on its longitudinal axis,

which will facilitate, to a great extent, disassembling any of the components still left
to be disassembled.
For a correct holding and lifting of the engine, see section on safety: “SAFETY /
DANGER
GUIDELINES FOR THE CORRECT LIFTING OF GUASCOR EQUIPMENT/

3 - LIFTING OF ENGINES.”
DISASSEMBLY PISTON CONNECTING ROD ASSEMBLY
Q.- DISASSEMBLING THE PISTON CONNECTING ROD ASSEMBLY
1. DISASSEMBLING THE COMPONENTS INTERFERING WITH THE CON ROD

DISASSEMBLY OPERATION.
1. Remove all the components that prevent access to the connecting rods through the
connecting rod inspection covers:

- Oil level dipstick.
- Crankcase breather
- Electric pre-lube and oil drain pump. Oil level warning alarm
- Oil level control
- Oil distributors and pipes.
- Oil filter support.
1.1. Disassembling the Oil Level Dipstick
1. Loosen the oil level dipstick hollow plug to the oil-pan cover.
2. Remove the complete dipstick.
3. Remove the gasket placed between the hollow plug and the oil-pan cover.
LOOSEN HOLLOW PLUG

AND REMOVE THE
ASSEMBLY
OIL LEVEL DIPSTICK

INSTALLED IN OIL PAN
COVER
1.1.1. Sub-assembly: Oil Level Dipstick.---------------------------------------------------

S - 19
1.2. Disassembling the Crankcase Breather.
1. Loosen the oil outlet elbow from the lower body of the crankcase breather.
2. Loosen the hollow screw at the other end of the crankcase breather drain pipe (to the
oil pan cover) and remove the breather oil outlet pipe toward the oil pan.
PISTON CONNECTING ROD ASSEMBLY DISASSEMBLY
If the crankcase breather comprises two decanters, each decanter has its own drain
NOTE
pipe and the two drain pipes are joined with a T-connector to a common discharge pipe
toward the oil pan.
3. Loosen the nuts from the breather gas outlet pipe. Remove the gas outlet elbow and
the gasket placed between the elbow and the decanter.

NOTE
If there are two decanters, their gas outlets will be joined to a single gas discharge
(elbow) pipe to the atmosphere.
Where the crankcase breather(s) system has been fitted with a gas recirculation pipe
NOTE
instead of the gas discharge elbow to the atmosphere, this recirculation pipe should
have been removed earlier, during the disassembly of the gas recirculation system filter.
4. Loosen the nuts of the breather(s) to the connecting rod inspection cover.
5. Remove the crankcase breather and the gasket situated between the breather and
the connection rod inspection cover.
DRAIN PIPE. CONNECTION OF

BOTH DECANTERS AND TO CRANKCASE BREATHER WITH
THE OIL PAN COVER TWO DECANTERS
1.2.1. Sub-assembly: Crankcase Breather----------------------------------------- S-6
1.3. Disassembly of electrically-operated pre-lube and oil drain
1. Disassemble the oil discharge pipe from the pre-lube pump. To do this, on the side
of the pre-lube pump, loosen the connector between the discharge pipe to the three-
way valve from the pump.
2. On the other end of the discharge pipe, loosen the connector between the discharge
pipe and the thermostat and oil regulator housing.
3. Remove the oil discharge pipe from the pump.
4. Disassemble the oil suction pipe from the pre-lube pump. To do this, on the side of
the pre-lube pump, loosen the elbow connector and the reducing connector.
5. On the other end of the suction pipe, loosen the reducing connector of the oil-suction
piping to the oil-pan cover (oil intake under the flywheel housing).
6. Remove the oil suction pipe and its gaskets.

7. Loosen the bolts from the support of the pre-lube pump to the connecting rod
inspection cover. Remove the electrically-operated pre-lube and drain pump
complete with its support.
ELECTRIC PUMP SUPPORT

FIXED TO THE CONNECTING
ROD INSPECTION COVER
PIPE TO OIL PAN
ELECTRICALLY-OPERATED
PRE-LUBE AND OIL DRAIN
PUMP
OIL SUCTION PIPE FROM

THERMOSTAT AND OIL
REGULATOR HOUSING
1.4. Disassembling the oil level alarm.
1. Remove the pipe between the oil pan cover and the oil level. To do this, disassemble
the inlet elbow on the side of the oil level.
2. On the side of the oil pan cover, loosen the reducing connector.
3. Remove the connector- two-way valve -
pipe assembly unit
4. Remove the vent pipe between the oil
level and the connecting rod inspection
cover. On the connecting rod inspection
cover, loosen the vent pipe connector
elbow to the connecting rod inspection
cover.
5. On the other end of the vent pipe, in the
upper part of the oil level, loosen the
connector of the vent pipe to the oil level
alarm. Remove the vent pipe.
6. Loosen the oil level alarm supporting assembly bolts to the engine block.
Remove the oil level alarm - support assembly.
1.5. Disassembling the oil level control.
1. Disassemble the hose between the oil level control and the oil pan cover. For this
purpose, on the side of the oil pan cover, loosen the hose connector.
2. On the other end of the hose, loosen the straight connector to the oil level control.
3. Remove the hose.
4. Disassemble the hose between the oil level control and the connecting rod inspection
cover. For this purpose, on the side of the oil level control, loosen the straight
connector.
5. On the side of the connecting rod inspection cover, loosen the right-angle connector
installed through the cover.

6. Remove the hose.
7. Loosen the nuts of the oil level control support to the oil pan cover.
8. Remove the oil level control + support unit. Also remove the washers and spacers
mounted with the support.
9. Remove the studs from the oil pan cover.
OIL LEVEL CONTROL
1.6. Oil Distributor and Piping.
The oil distributor in the upper part of the engine block (between the cylinder heads
NOTE
housings) should have been removed before disassembling the cylinder heads, in order
not to get damaged during the cylinder heads disassembly process.
1. To disassemble the oil distributor from the oil filter support, it will first be necessary
to disassemble all the oil distributor outlet pipes.
2. Loosen the hollow screw of the oil supply line (from the oil filter support) to the oil
distributor. In doing this, we also loosen the connection of another pipe connected to
the oil distributor: that which runs to the oil regulator.
3. At the other end of the oil supply line, loosen the connector to the oil outlet of the filter
support.
4. Remove the oil supply line and the copper gaskets.
5. On the side of the regulator (in the thermostat and oil regulator housing), loosen the
hollow screw of the regulator's pilot pipe from the distributor.
6. Remove the pilot pipe and its gaskets.
The water pump lubricating pipe, running from the distributor to the back cover of the
NOTE
pump, should have been removed when disassembling the water pump.
The pipes from the pressure switches to the oil distributor should have been removed
NOTE
during the disassembly of the pressure and temperature switches supporting plates.
7. Loosen the screws of the oil distributor to the filter support. Remove the oil distributor.
OIL DISTRIBUTOR
OIL OUTLET PIPES FROM

DISTRIBUTOR
1.7. Disassembling the Oil Filter Support.
Before disassembling the oil filter support, the three filters must be removed from it. For
NOTE
this purpose, use the oil filter disassembly tool, as shown on the photos.
1. Disassemble the oil discharge pipe of the safety valve to the connecting rod
inspection cover. To do so, on the side of the connecting rod cover, loosen the hollow
screw of the oil discharge pipe to the cover. On the side of the filter support, loosen
the safety valve outlet connector. Remove the oil discharge pipe and the copper
gaskets.
2. At the bottom of the filter support, loosen the oil pipe to the thermostat and oil
regulator housing. This implies removing the pipe screws to the bottom of the filter
support.
3. At the other end of the pipe (side of oil regulator), loosen the screws holding the pipe
to the thermostat and oil regulator housing. Remove the pipe and its gaskets.
4. Loosen the screws securing the filter support to its bracket (access to the screws is
from under the bracket). Remove the oil filter support and the seals.
The oil line from the oil filter support to the intermediate cover of the back timing gear
NOTE
housing should have been disassembled during the disassembly of the back timing

gear train.
1.7.1. Sub-assembly: Filter Support.--------------------------------------------------------

S - 18
2. DISASSEMBLING THE CONNECTING ROD INSPECTION COVERS.
1. Remove the bolts from the connecting rod inspection covers on one side of the
engine
2. Remove the connecting rod inspection covers as well as their gaskets.
3. Clean any gaskets left on the covers and on the engine block.
4. Repeat this procedure, disassembling the connecting rod inspection covers on the
other side of the engine.
CONNECTING ROD
INSPECTION COVERS
2.1. Cleaning.-----------------------------------------------------------------------------------------
I-0 A-0
3. REMOVING THE PISTON CONNECTING ROD UNIT
1. Perform the disassembly process on each piston connecting rod unit. The complete
disassembly of one piston connecting rod unit must be done before beginning with
the following unit.
3.1. Disassembling the Oil Jets.
1. It is advisable to remove the oil jet for each piston connecting rod that is going to be
disassembled ahead of time. This will prevent the jet from being damaged when the
piston is removed.
2. To do this, it will be necessary to loosen the nuts on each jet, and then remove the
jet.
PISTON COOLING JETS
JETS FIXING NUTS
3.2. Removing the Piston Connecting Rod Unit.
1. Turn the crankshaft, with the tool, until it is located so the crankshaft journal of the
piston that is to be disassembled is located in the appropriate position vis-à-vis the
inspection door of the connecting rods (a little after the TDC).
2. Place the removal tool (ref. 74.44.026) on the piston. Engage the pump to grip the
piston with this tool. This will prevent the piston connecting rod unit to fall when its
union to the crankshaft is released.
If any of the pistons to be removed is damaged in any way (deformed, pitted, broken,
NOTE
etc.), use alternative removal tool ref. 16.75.153 screwed into the top of the piston in
order to remove it. For this purpose, it will be necessary to previously drill 2 threaded
holes in the top edge of the piston.

INSTALLATION OF DAMAGED
PISTON REMOVAL TOOL REF.
16.75.153
3. Loosen and remove the connecting rod screws from the connecting rod table, using
the special tool for the connecting rod bolts. As a result, the connecting rod is
disassembled from the crankpin and the piston connecting rod unit is held only by the
piston removal tool.
REMOVING PISTON CONNECTING

ROD UNIT WITH TOOL REF.
16.75.153
DANGER
Mark the connecting rod bolts in the end to keep the number of times that they have
been loosened. Connecting rod bolts must be replaced after the 3rd tightening or after
27000 hours of service.
4. Remove the connecting rod cap and the bearing, leaving it on a bench.
Be specially careful when cleaning them to prevent any impurities, such as metallic
CAREFUL
shavings, from getting in the engine. Cleanliness of the bench on which the connecting
rods and pistons have been left as well as of the area nearby the engine is of special
importance in order to prevent the introduction of dirt inside the engine through the
connecting rod inspection covers that have been disassembled.
5. Remove the piston connecting rod unit carefully by using the removal tool. The
connecting rod end bearing must be removed simultaneously with the piston
connecting rod unit. Otherwise, it must be taken out afterwards manually.
The piston removal process must be done very carefully. To do this, hold the connecting
CAREFUL
rod to avoid hitting the crankshaft when the connecting rod is no longer supported by
the crankshaft. Later, place the connecting rod parallel to the liner, in order to prevent
the connecting rod from hitting the liners during removal.
6. Once the piston and connecting rod are removed, put them on a bench, together with
their corresponding cap.
Each cap has to be placed with its corresponding connecting rod. To avoid any
CAREFUL
confusion, place the cap and piston connecting rod on the bench together. The
connecting rods and their caps are marked with a matching number, and also have the
cylinder number to which they belong for later assembly.
3.3. Disassembling the Piston - Connecting Rod Unit.
1. Disassembly of the Piston - Connecting Rod

Assembly Unit. Remove the snap rings and the
piston pin.
2. To remove the pin, it will be necessary to heat up the
piston. This heating can be done through the use of
a grill with controlled heating of the piston. In the
event there is no grill available, alternatively, alcohol
can be poured and burnt in the piston's combustion
chamber.
3. Once the piston has been heated, the pin will easily
come out of its box in the piston.
4. Now, we can separate the connecting rod and the
piston.
EXTRACTING THE PISTON PIN

AND DISASSEMBLING THE
PISTON CON ROD UNIT
3.4. Disassembling the piston rings.
1. Remove the piston rings by using the assembly tool for the rings (ref. 16.75.750).

DISASSEMBLING THE
PISTON RINGS
3.5. Checking Elements.----------------------------------------------------------------------------

I-5
DISASSEMBLY CYLINDER LINERS
R.- DISASSEMBLING THE CYLINDER LINERS

DANGER
Before disassembling the liners, water should have been drained through the engine
block plugs (if the engine is going to be completely disassembled, this is normally done
before starting disassembly; otherwise do it now.).
1. Remove the liners by using the liner removal tool (ref. 16.75.530).
LINER REMOVAL TOOL REF.

16.75.530
2. To do this, insert the tool along the side, through the inside of the liner. Position the
tool.
DANGER
Be careful, do not damage the inside walls of the liners with the liner removal tool.
3. Remove the initial section of the liner, where the gaskets are set on the engine block,
with the liner removal tool.
4. Finally remove the line completely by hand.
5. Repeat this process on all liners.
LINER REMOVAL TOOL PLACED ON THE BLOCK.

REMOVING THE INTITIAL SECTION OF THE LINER
WITH THE TOOL.
CYLINDER LINERS DISASSEMBLY

REMOVE THE GASKET FROM THE LINER.
PLACE NEW GASKETS DURING RE-
ASSEMBLY
1. INSPECTION.
1. Test the condition of the setting in the engine block where the flange of the liner is
set.
DANGER
It is important to check both the concentricity of the housing and the flange seat. Review
the flange housing in the engine block with a cutting tool in order to maintain the flange
housing in the engine block at 90 degrees.
2. Check that the surface of the engine block where the cylinder head supports is
completely clean and smooth, and that it has no grooves or small marks on it.
3. Inspection of liners-------------------------------------------------------------------------------
I-2
4. Visually inspect the internal surface of the liners to see if it has scratches or rust on
it.
5. Check wear of the cylinder liner according to preset limits----------------------------------- I - 11
DISASSEMBLY CAMSHAFTS AND AUXILIARY
ROCKER ARMS
S.- DISASSEMBLY OF CAMSHAFTS AND AUXILIARY ROCKER ARMS
1. DISASSEMBLING THE AUXILIARY ROCKER ARM COVERS.
1. Loosen the auxiliary rocker arm cover

bolts (located in the upper portion of the
engine, on either side).

2. Remove the rocker arm covers as well as
the O-ring gaskets from the covers.
AUXILIARY ROCKER ARM

COVERS
1.1. Cleaning---------------------------------------------------------------------------------------
I-0 A-0
2. DISASSEMBLING THE CAMSHAFT COVERS.
1. Loosen the screws from the detachable

lifting brackets mounted on the camshaft
covers, in the front part of the engine.
Remove the detachable lifting bracket.
2. Loosen the camshaft cover screws
(located in the front area of the engine).
3. Remove the covers (2 covers per
camshaft).
CAMSHAFT COVER
2.1. Cleaning-----------------------------------------
I-0 A-0
3. DISASSEMBLING THE AUXILIARY ROCKER ARMS.
1. Once the auxiliary rocker arm covers have been removed in a previous operation,
disassemble the auxiliary rocker arms.
2. For this purpose, loosen the nut covering the screw in each one of the two auxiliary
rocker arm shafts.
3. Loosen the screw on each shaft by using an Allen wrench.
CAMSHAFTS AND AUXILIARY DISASSEMBLY
ROCKER ARMS
4. Remove the different components mounted on each shaft (washers, springs, spacers
and auxiliary rocker arms) through the inspection doors, as the auxiliary rocker arms
shaft is being removed.
5. Finally, remove the auxiliary rocker arms shaft.
6. Repeat this process on each auxiliary rocker arm, on both sides of the engine.

REMOVAL OF AUXILIARY ROCKER SET OF COMPONENTS MOUNTED ON EACH
ARM AUXILIARY ROCKER ARM SHAFT
3.1. Sub-assembly: Auxiliary Rocker Arm.--------------------------------------------------------------

S-1
3.2. Inspection-----------------------------------------------------------------------------------------------
I-8
4. DISASSEMBLING THE CAMSHAFTS
1. Manually remove the camshaft, through the rear area of the engine block (side of
flywheel housing).
2. Inspection.
3. Check the camshaft wear limits, with a Pass/Fail gauge, at the places marked on the
camshaft (following the instructions given in the "Inspection" chapter of this Manual).
4.1. Inspection.-----------------------------------------------------------------------------------------------
I-4 I-4
DISASSEMBLY CAMSHAFTS AND AUXILIARY
ROCKER ARMS
5. DISASSMEBLING THE CAMSHAFT BUSHINGS.
1. To remove all the camshaft bearings, use the tool ref. 16.75.116 and the thrust plates.
2. Insert the tool in the camshaft bore in the engine block. Place the thrust plates in the
tool.
3. Remove the tool by using a pneumatic cylinder. While removing the tool, the
camshaft bushings (bearings) will also be removed.
4. Once the bushings have been removed from their housings in the engine block,
remove the thrust plates from the tool grooves.
5. Manually remove the tool, and while the tool is being removed, remove the bushings
through the auxiliary rocker arm inspection doors.
In the event it is not necessary to remove all the bushings, an identical process will be
NOTE
done, that is, inserting the tool in the camshaft bore and mounting thrust plates only in
the grooves corresponding to the camshaft bushings to be removed.
MOUNTING OF THRUST PLATES IN THE BUSHING

BUSHING MOUNTING / REMOVAL TOOL AND
REMOVAL TOOL GROOVES
THRUST PLATE
5.1. Inspection: Pass / Fail.------------------------------------------------------------------------

I-4 I-4
DISASSEMBLY OIL PAN
T.- DISASSEMBLING THE OIL PAN.
1. DISASSEMBLING THE OIL PRE-HEATING SYSTEM.
1. Disassemble the oil pre-heating system.

2. Rotate the engine block until the oil pan is on the upper part.
3. Loosen the screws from the oil pre-heater (pre-heater casing and resistance)
attached to the lower part of the oil pan.
4. Remove the oil pre-heater.
OIL PRE-HEATER ON OIL PAN
2. DISASSEMBLING THE OIL PAN COVERS.

1. Disassemble the two oil pan covers. For this purpose : Loosen the nuts from the two
oil pan covers.
2. Loosen the nuts from the two oil pan covers. Once the nuts are removed, we will be
able to remove the two oil pan covers easily.
3. Likewise remove the gasket located between the covers and the oil pan. Finally,
remove the studs placed on the oil pan.
SEAT OF OIL PAN COVER IN OIL OIL PAN COVER, FASTENING TO OIL PAN WITH
PAN OIL LEVEL DIPSTICK SUPPORT STUDS AND NUTS
2.1. Sub-assembly: Oil Pan Cover

(oil level dipstick support unit).--------------------------------------------------------- S - 17
OIL PAN DISASSEMBLY
3. REMOVAL OF THE THERMOSTATIC OIL CONTROL VALVE
1. Set the thermostatic valve lifting tool (ref. 16.75.172) screwed on the thermostatic
valve and tie the tool to a crane in order to hold the valve when its fixing nuts are
removed from the oil pan.
2. Disassemble the oil discharge pipe from the regulator, to ease the removal of the
thermostatic valve. For this purpose, loosen the connectors from both ends of the

discharge pipe and remove the pipe.
3. Loosen the nuts of the thermostatic valve to the oil
pan
4. Gently separate the thermostatic valve from the oil
pan, to be able to loosen the connection between the
oil supply pipe and the oil inlet to the thermostatic
valve (inside the oil pan).
5. Remove the thermostatic oil control valve, with the
crane. Also remove the gasket between the valve
and the oil pan.
NOTE
Appropriate lifting equipment must be used, to support

the weight of the thermostatic oil control valve.
DISASSEMBLING THE THERMOSTATIC

VALVE WITH TOOL REF. 16.75.172
AND A CRANE
3.1. Sub-assembly: Thermostatic Oil Control Valve.-------------------------------- S - 16
4. REMOVING THE OIL PAN.
1. Set the oil pan disassembling tools (tools for lifting the pan) (ref. 16.75.171), screwing
them into the oil pan.
2. Hoist the pan by placing a pair of slings in the oil pan lifting tools.
Appropriate equipment must be used to do the hoisting so that it supports the weight of
NOTE
the oil container.
3. Loosen the oil pan anchor bolts to the engine block.

4. Detach the oil pan from the engine block. Since there is a liquid seal, X screws
located at the points of removal of the oil pan will be used to detach the oil pan from
the engine block.
5. Several screws will be placed on the removal points of the oil pan in the engine block
in an alternate way so that the oil pan detaches simultaneously from the engine
block.
T
DISASSEMBLY OIL PAN
6. Remove the pan with a hoisting device.
DISASSEMBLY AND REMOVAL OF OIL PAN

WITH TOOL REF. 16.75.171 AND A CRANE
4.1. Cleaning--------------------------------------------------------------------------------------------------
I-0 A-0
1. Thoroughly clean the inside of the pan (removing oil residues).

2. Scrape the area in where the liquid seal was used. Use a smooth scraper to remove
possible gasket remains.
DISASSEMBLY OIL PUMP AND OIL CIRCUIT
INSIDE THE OIL PAN
U.- DISASSEMBLING THE OIL PUMP AND OIL CIRCUIT INSIDE THE OIL PAN.
1. DISASSEMBLING THE SUCTION STRAINER AND OIL PUMP CONNECTING PIPE.
1. Disassemble the suction hood unit and its support, together with the oil piping and
pump inlet elbow.
2. Loosen the screws of the inlet elbow to the oil pump.

3. Loosen suction hood fixing screws to its support.
4. Remove the assembly formed by:
- Suction hood.
- Suction hood support.
- Oil inlet elbow to the pump.
5. Remove the O-ring between the inlet elbow and the oil pump.
6. Loosen the screws of the suction hood support to the cross-beams of the engine
block.
7. Remove the suction hood support.
8. Now, disassemble the assembly previously removed from the engine. This means,
loosen the screws fastening the suction hood to the oil suction piping. Separate both
components and remove the O-rings placed at their union.
9. Clean the screen (strainer) of the suction hood.
REMOVAL OF SUCTION HOOD - SUPPORT FIXING SCREWS

SUCTION HOOD SUPPORTS
OIL SUCTION PIPING ASSEMBLY TO BLOCK
1.1. Sub-assembly: Oil Suction Hood------------------------------------------------- S - 13
OIL PUMP AND OIL CIRCUIT DISASSEMBLY
INSIDE THE OIL PAN
2. DISASSEMBLING THE OIL DISCHARGE PIPE.
1. Loosen the oil discharge pipe bolts attached to the engine block.
2. Remove the discharge outlet pipe from the oil pump elbow.
3. Remove the two O-ring gaskets between the discharge pipe and the pump outlet
elbow.

3. DISASSEMBLING THE OIL OUTLET ELBOW WITH PRESSURE SAFETY VALVE.
1. Loosen the connection between the oil pump outlet elbow and the oil discharge pipe.
2. Remove the oil discharge pipe and the two O-rings placed at the connection to the
oil outlet elbow.
3. Loosen the screws of the oil outlet elbow to the oil pump. Remove the oil outlet elbow.
4. Remove the pressure safety valve from the inside of the outlet elbow.
5. Remove the gaskets (O-ring and copper gasket) that are mounted to the pressure
valve.
OIL PUMP OUTLET ELBOW

PRESSURE SAFETY VALVE
3.1. Sub-assembly: Pressure Safety Valve.----------------------------------------- S - 15
4. DISASSEMBLING THE OIL PUMP.
1. Install the oil pump lifting tool (ref. 16.75.174). Set a crane to the oil pump lifting tool.
2. Loosen the oil pump bolts to the engine block.
3. Remove oil pump from engine block with the help of the previously installed tool and
crane.
DISASSEMBLY OIL PUMP AND OIL CIRCUIT
INSIDE THE OIL PAN
Appropriate equipment must be used to hoist

the oil pump so that the hoisting device
supports the weight of the oil pump.
4. Remove the two guide pins from the

engine block.
REMOVAL OF OIL PUMP WITH

TOOL REF. 16.75.174 AND A
CRANE
4.1. Sub-assembly: Oil Pump.---------------------------------------------------------------------

S - 14
4.2. Checking elements.-----------------------------------------------------------------------------
I-6
4.3. Check the oil pump gear -----------------------------------------------------------
I-0 I-1
5. REMOVAL OF THE OIL PUMP INTERMEDIATE DRIVE GEAR

(MOUNTED ON THE FRONT CAP).
1. Loosen the screw between the washer (or blocking washer) and the gear shaft.
2. Use the gear removal tool for removing the oil pump intermediate gear. Likewise, the
bearing will be removed so that a new bearing will be subsequently installed.
3. Loosen the bolts from the intermediate drive shaft to the front cap.
4. Remove shaft from its housing in the cap.
OIL PUMP INTERMEDIATE

DRIVE GEAR
5.1. Gear Check-----------------------------------------------------------------------------

I-0 I-1
DISASSEMBLY CRANKSHAFT
V.- DISASSEMBLING THE CRANKSHAFT.
1. DISASSEMBLING THE PUMP GEAR DRIVE
1. Remove the pump drive gear from the

engine crankshaft. To do this, it will be
necessary to heat the gear.

NOTE
Wear safety gloves to protect your hands

from burns, when handling hot parts.
2. Remove the pin mounted on the

crankshaft that guides the pump drive
gear.
REMOVAL OF PUMP GEAR

DRIVE
1.1. Gear Check.-----------------------------------------------------------------------------

I-0 I-1
2. DISASSEMBLING THE BEAMS
1. Loosen the screws of the beams to the engine block.

2. Remove the beams.
BEAMS MOUNTED ON THE

CYLINDER BLOCK. REMOVE
THE SCREWS
3. DISASSEMBLING THE CAPS AND THRUST BEARINGS.

1. Loosen the cap lateral screws.
2. Loosen the upper cap bolts.
3. To remove the caps, it will be necessary to use the spreader tool (ref. 16.75.005) to
separate the two sides of the engine frame, and ease the removal of the caps.
4. The caps will be removed in pairs, placing the spreader tool between the caps that
are going to be removed. Place the spreader tool between two caps (those that are
going to be removed), and separate the sides from the engine frame.
V
CRANKSHAFT DISASSEMBLY
5. Remove the caps (the two located on both sides of the spreader tool). Upon
removing each cap, the skid half bearings (cap half bearing) must be removed at the
same time. Place them on a clean table.
In the event that the half bearing of the cap that has been removed remains in the inside
NOTE
of the engine, on the crankshaft, this half bearing must be removed manually.

REMOVING THE CAPS
MANUALLY
SPREADER TOOL
REF. 16.75.005
6. Repeat the process, until all caps have been

removed.
7. Once the intermediate (central) cap has been
removed, the crankshaft thrust bearings, which are
installed on it (one on each side of the cap), must
also be removed.
8. Remove the pin from the caps.
9. Once all the caps have been removed, gently move
the crankshaft in its bore, using the connecting rod
inspection doors as a lever, in order to be able to
remove the other half of the thrust bearings.
REMOVAL OF THRUST
BEARINGS
I-0
3.1. Cleaning the caps.----------------------------------------------------------------------------
A-0
3.2. Inspection.-----------------------------------------------------------------------------------------------
I-2
DISASSEMBLY CRANKSHAFT
4. REMOVAL OF THE CRANKSHAFT

1. Place two screws at each end of the crankshaft so that these screws may be used
as a holding tool when hoisting the crankshaft.
2. Place a sling on the screws located at the ends of the crankshaft, and, with the help
of a crane, lifting and removal of the crankshaft can be done.
Appropriate lifting equipment must be used so that the crane supports the weight of the
NOTE
crankshaft.
3. Remove the crankshaft very carefully, making sure it does not bump into anything.
CRANKSHAFT REMOVAL
WITH SLINGS AND A CRANE
5. DISASSEMBLING THE HALF BEARINGS.
1. Remove the half-bearings from the engine block

housing.
2. Remove the half-bearings from the caps. They
should have been disassembled from the engine and
placed on a table in a previous procedure.
3. Place the various half-bearings that have been
removed on a clean table.
4. Check half-bearing housing alignment.
REMOVAL OF HALF-
BEARINGS
CRANKSHAFT DISASSEMBLY
6. ENGINE BLOCK AND CRANKSHAFT CONTROL

AND ANALYSIS --------------------------
I-2 I-3
1. Perform a dimensional check of the engine block, as well as a dimensional check of

the crankshaft bores on the engine block.
2. Likewise, check crankshaft bore alignment in the engine block.

3. Check the out of round of the bore to check their oval shape by using an out of round
control tool.
4. Check the dimensions both on the mains as well as on the journals.
DANGER
Pay particular attention to any indication of annealing or rotation of the main bearings
6.1. Hydro test of engine block (with new liners on) ---------------------------- I - 12
7. CRANKSHAFT RECOVERY.--------------------------------- I - 11
8. CLEANING.------------------------------------------------------------------------------------
I-0 A-0
DANGER
The section on CLEANING is particularly important to the different components that are
assembled in the engine as well as cleaning while performing engine procedures.
8.1. Block.
1. A thorough wash all the circuits in the engine will be done (different oil and water
galleries on the engine block).
2. Wash out the oil passages to eliminate oil that accumulates, and consequently,
becomes hard.
3. Insert a rod to ensure that none of the circuits is clogged.
4. Likewise wash the water passages in the engine to eliminate the possible rust that
might have been formed in these circuits.
5. The engine block must be thoroughly washed in a machine to eliminate any particles
that might be present so as to fully assure that the engine block is PARTICLE FREE.
6. Washing of the different engine passages will be done either with water or with
degreasing liquid. It is very important to dry all pipes thoroughly after the washing of
the engine passages. To do this, compressed air will be used.
8.2. Crankshaft.
1. An engine component whose cleaning is very important is the crankshaft, since oil
can accumulate in the inside oil passages of the crankshaft.
2. For an appropriate cleaning of the crankshaft, remove the plugs on the final section
of each one of the inside circuits, cleaning these passages by using a degreasing
liquid. Afterwards, dry the conduits thoroughly and replace the plugs previously
removed with new ones.
INSPECTION
INSPECCION
INSPECTION
SF/FG IN “V”
Ref.: 19.09.531
Edition: May 2003

INSPECTION INDEX
0. GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(5 PAGES)

1. DISTRIBUTION GEAR CLEARANCES . . . . . . . . . . . . . . . . . . . .(2 PAGES)
2. ENGINE BLOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(7 PAGES)
3. CRANKSHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(1 PAGE)
4. CAMSHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
5. CONNECTING RODS AND PISTONS. . . . . . . . . . . . . . . . . . . . .(7 PAGES)
6. OIL PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(3 PAGES)

7. CYLINDER HEADS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(20 PAGES)
8. TAPPETS AND ROCKER ARMS. . . . . . . . . . . . . . . . . . . . . . . .(7 PAGES)
9. TURBOCHARGER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(7 PAGES)
10. HIGH-VOLTAGE WIRES AND SPARK PLUGS. . . . . . . . . . . . . . . .(3 PAGES)
11. TIGHTENING TORQUES. . . . . . . . . . . . . . . . . . . . . . . . . . . . .(5 PAGES)
12. HYDRAULIC TESTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(14 PAGES)
- ENGINE BLOCK AND LINERS . . . . . . . . . . . . . . . . . . . . . . .(4 PAGES)
- EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . .(4 PAGES)
- HEAT EXCHANGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
- INTERCOOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
- OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
INSPECTION GENERAL
GENERAL INSPECTION PROCEDURE
Procedure.
The procedure for cleaning, inspection, repairing, and assembly of the different parts,
kits and sub-assemblies that make up the engine, will be the same for most of them.
Any cleaning, inspection, repair, and assembly procedures specific to a part or one of
its components, are discussed in the specific paragraph to this component.
Cleaning Instructions.
The maintenance personnel must clearly understand the importance of cleaning. Great
care and conscientious work are required in all the cleaning operations. The presence
of dirt or foreign matter is a constant threat for satisfactory operation and maintenance
of the engine. The following general instructions shall be applied to all the cleaning
operations:
- Clean all the parts before inspections, after repair and before assembly.
- Hands must be free of grease which can collect dust and impurities.
- After cleaning, all the parts must be covered or wrapped to protect them from dust
and dirt.
Casting.
- Using a hard brush, remove residues and the carbon deposits in the castings.
- Clean the inside and outside surfaces of the castings, in all areas exposed to oil
and grease, with dry cleaning solvent or with a petroleum based paint solvent.
- Blow all the threaded holes with compressed air .
- After cleaning, dry the castings with compressed air.
THE PARTICLES CARRIED BY THE COMPRESSED AIR ARE DANGEROUS.

CAREFUL
USING ADEQUATE SAFETY PROTECTION (GLOVES, MASKS, ETC...), ENSURE

THE AIR FLOW IS DIRECTED AWAY FROM THE EQUIPMENT OPERATOR AND
OTHER PERSONNEL .
Oil Passages.
Special attention shall be given to the oil passages in the castings and in all mechanical
parts. All the passages shall be free from obstructions, and the following shall be taken
into account:
- Clean the passages with a wire cable to break up carbon deposits or dirt.
- Clean the passages with dry cleaning solvent or with a mineral paint solvent.
- After cleaning the passages, dry them by blowing compressed air.
GENERAL INSPECTION
CAUTION - AIR
DO NOT ALLOW THE SOLVENT TO COME IN CONTACT WITH THE FASTENERS,

CAREFUL
CABLES, AND FLEXIBLE TUBING. THESE CLEANING AGENTS CAUSE THE

RUBBER AND SYNTHETIC MATERIALS TO DETERIORATE AND LOOSE
FLEXIBILITY, LEAVING THEM USELESS.

Oil Seals, Electric Cables and Flexible Tubing.
Clean the oil seals, electric cables, and flexible tubing with compressed air.
(SEE PREVIOUS .
CAREFUL
PARAGRAPH)
Ball and Needle Roller Bearings.
The bearings require special attention for cleaning and lubrication. After the dirt, oil or
grease has been removed, the bearings , with exception of the sealed bearings
(permanently greased) must be placed in a hot oil bath (approximately 140ºF) to loosen
the solid residues of oil and grease. After the cleaning, the bearings shall be covered
with a lubricating film and wrapped in a lubricated coated paraffin paper for inspection
and assembly.
DO NOT SUBMERGE THE SEALED BALL BEARINGS IN CLEANING SOLVENT OR

CAREFUL
IN A HOT OIL BATH. THE INTRODUCTION OF CLEANING SOLVENT OR OF ANY

CLEANING SUBSTANCE, WILL DESTROY THE LUBRICANT THAT WAS
INTRODUCED DURING THE MANUFACTURING.
- The cleaning of the sealed ball bearings will be done only on the outside surfaces,
with a clean cloth impregnated with dry cleaning solvent.
- The compressed air shall never be used in the cleaning or in the drying of the ball
or needle roller bearings. Due to the abrasive particulates the air carries, damage
can be done to the bearing tracks.
INSPECTION GENERAL
INSPECTION.
General.
The engines are built with precision, therefore all the repair standards and
reconstruction of the pieces that make up the engine have been established with very
strict tolerances. The following general instructions shall be applied to all inspection
procedures.
- Use adequate inspection equipment to inspect the different components in which

the cracks or other defects cannot be seen with the naked eye.
- Extreme care shall be taken in all inspection phases. Inspect the components,
following the instructions provided in the next paragraphs.
Castings.
Inspect all the ferric pieces (cast iron, steel, etc...) looking for possible cracks with the
magnaflux equipment. Inspect al the non-ferric parts (Aluminum) looking for cracks with
a magnifying lens and a powerful light. Inspect especially around the stud bolts, line
plugs, threaded inserts or heli-coil and in the threaded corners or holes. Inspect the
machined surfaces in the castings for scratches, burrs, or protruding excess metal.
Mark the defective areas for repair.
Check with a ruler, if there is any warping in the set up flat surfaces.
Check for different color shades in the surface area that indicates oil leaks or lack of
sealing.
Inspect the line openings and their plugs, in case there are damaged or stripped
threads.
Verify that all the castings are in good condition. If they are not, they need to be replaced
Studs.
Inspect all the assembly stud bolts, in case they are loose or bent, have damaged
threads or show signs of elongation.
Pinions.
THERE ARE NO ESTABLISHED LIMITS FOR THE WEAR OF THE PINION TEETH
NOTE
AND OF THE KEY SEAT. TO DETERMINE THE NEED OF REPLACEMENT,

CERTAIN CRITERIA MUST BE MET.
Inspect all the pinions, using the magnaflux equipment for cracks. If magnaflux
equipment is not available, use a magnifying lens and a powerful light.
Inspect all the pinion teeth for wear spots, protruding edges, burrs, and decayed
surfaces
GENERAL INSPECTION
Inspect the pinion groove bushings for damages, wear and check their adjustments
over the coupling shaft. The pinion grooves shall firmly fit the ones on the shaft, without
clearances or tightness.
Make sure that all the pinions comply with the repair and construction standards.
Shafts.

Inspect all shafts for cracks, using magnaflux equipment
When this equipment is not available, use a magnifying lens and a powerful light.
Inspect all shafts for scratches, burrs, notches or particulates of protruding metal.
Inspect the shaft grooves for damage, defects while observing the fit with the pinion
grooves to which it is connected. The fitting of the shaft grooves and the pinion shall be
without clearance nor tightening.
Make sure all the shafts are in good condition. If not, replace them.
Friction Bearings.
Make sure all the friction bearings are safely adjusted with their respective connecting
parts and research possible signs of overheating by observing the different color shades
of the friction surfaces.
Inspect the different types of friction bearings, looking for wear, burrs, bites, and
possible deformation to an oval shape.
Make sure there is no dirt in the orifices and lubrication grooves in the different types of
friction bearings. The orifices and grooves shall be clean and without defects in order to
assure adequate lubrication.
Check the thrust bearing faces of the thrust bearings for damage and wear. The wear
can be determined by mounting the assembly and verifying the longitudinal movement
with calipers, inserted between the push surfaces.
Verify that all friction bearings are inside the established parameters in the inspection
section.
Oil Seals.
The oil seals covered with a metal box are durable parts and shall not be substituted
when the inspection indicates that the seal is in good condition.
Make sure the edge of the oil seal that comes in contact with the piece that turns is not
damaged.
Verify the smoothness and flexibility of the seal material.
INSPECTION GENERAL
Threaded Inserts and Heli-Coil Threads.
In order to allow greater stress to be applied on the bolts and screws that are fastened
to cast aluminum, it is a common practice to install inserts of a stronger metal in which
the studs and pins are screwed.
The heli-coil and the threaded inserts are designed for this function. The heli-coil inserts
are steel cylindrical spiral springs, where the wire section is in the shape of a fillet, that
screws in the inside as well as the outside. The end of the wire in the bottom crosses
the spring diametrically, allowing by means of a special tool fitted at the end of the
threaded wire, to be introduced screwing it in the casting.
The threaded inserts are cylindrically threaded in the inside and outside (the top surface
in the shape of a star), allowing them to be set in the casting.
One type of heli-coil fillet have the center spiral forming an hexagon, providing a locking
effect on the stud or screw, when the threaded insert is screwed.
Inspect all the heli-coil fillets and screw threaded inserts, making sure they have a tight
fit on the casting and that there are no stripped or damaged threads.
NEVER USE HELI-COIL INSERTS IN THE THREADED ORIFICES OF: CYLINDER

CAREFUL
HEADS STUDS, ENGINE BLOCK MAIN BEARING CAPS, ALL IN THE

CRANKSHAFT, COUNTERWEIGHTS, FASTENING OF FLYWHEEL, VIBRATION
DAMPER, FRONT COUPLING.
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS INSPECTION DISTRIBUTION GEAR CLEARANCES
DISTRIBUTION GEAR CLEARANCES INSPECTION
INSPECTION BLOCK
Ø167 H6
Ømax. 167.025
Ø167.025
+0.059
Ø160.12 0.000
Ømax.160.179
Tightening 0.025
Bearing – Block ∅int Bearing Cap = ∅ Block. ∅ 167 H6
0.000
0.000
Tightening of the bearing cap - block (-)
0.025
∅ext lower half-bearing (cap) / upper (block) ∅ 167.025
∅ of the housing of the half-bearing in the 167 H6

0.025
Calculation of the
block. ∅
0.000
∅int of the half-
bearing (mounted) 0.000
Wall thickness of half-bearing. 3.44
-0.017
∅int of the half- 160.12

0.059
bearing (mounted) ∅
0.000
BLOCK INSPECTION
54.4
Emin. 54.36
5.05
Emin. 5.05

64.5
Emin. 64.460
Axial Clearance:
Jmax=0.586
Jmin= 0.340
Calculation for the 0.040

Width of the center bearing cap 54.4
width of the cap -0.040
assembly + 2 thrust 0.060
bearings Width of the lower thrust bearing 5.05
0.000
Width of the bearing cap + 0.160

∅ 64.5
thrust bearing -0.040
0.046
Axial Clearance Width of bearing cap 65 H8
0.000
Axial clearance: Housing of the cap in the 0.586
crankshaft and the mounted cap + thrust (+)
bearings assembly 0.340
0.160
Width of cap + 2 thrust bearings 64.5
-0.040
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS INSPECTION BLOCK
Ø104 H6
Ømax. 104.022
Ø104 r6
Ømin. 104.054
Fitting bushings in 0.022

engine block ∅ bore in engine block ∅ 104 H6
0.000
Front camshaft bearing tightened in the engine 0.076
(-)
block 0.032
0.076
∅ext front camshaft bearing ∅ 104 r6
0.054
BLOCK INSPECTION

Ø
Øm98 H6
ax
.9
8.0
22
Setting of Center
bushing
in engine block
Ø98
Ømin. 98.071

block ∅ bore in engine block ∅ 98 H6
0.000
Center camshaft bearing tightened in the 0.115
engine (-)
block 0.049
0.115
∅ext center camshaft bearing ∅ 98
0.071
INSPECTION BLOCK
Ø98
Ømin. 98.071
Left side:
1 Center Bearing + 1
Ø98
Front Bearing
Ømin. 98.071
(Tightened)
Ø98 H6
Ømax. 98.022
Right Side:
1 Center Bearing
Fitting Front Bearings in

Block

0.000
Narrow back camshaft bearing tightened in the 0.115
(-)
engine block 0.049
0.115
∅ext of narrow back camshaft bearing ∅ 98
0.071

0.000
Wide back camshaft bearing tightened in the 0.115
(-)
engine block 0.049
0.115
∅ext of wide back camshaft bearing ∅ 98
0.071
BLOCK INSPECTION
Ø175.5
Ømin. 175.435
Ø172 f6
Ømin. 171.932

Ø172 H7 Ømax. 172.040
Ø175.5 H7
Ømax. 175.54 * Value in the lower
portion of the cylinder
* Value of the upper bore on the engine
section of the block
cylinder bore on the
engine block
Cylinder / Block 0.040

clearance ∅ cylinder bore in block ∅ 172 H7
0.000
Clearance between the block and cylinder 0.108
(+)
jacket (lower section of the jacket) 0.043
-0.043
∅ext of the cylinder jacket in the lower section ∅ 172 f6
-0.068
Cylinder / Block 0.040

clearance ∅ cylinder bore in block ∅ 175.5 H7
0.000
Clearance between the block and cylinder 0.105
(+)
jacket (upper section of the jacket) 0.030
-0.030
∅ext of the cylinder jacket in the upper section ∅ 175.5
-0.065
INSPECTION BLOCK
* Height of the cylinder

DETAIL A jacket collar
h14
h min. 14.0
h14.09
h min. 14.070
Ø152 H6
* Height of the cylinder Ømax. 152.025
jacket collar support in
the engine block
Height of the 0.010

cylinder jacket collar Height of the cylinder jacket collar 14.09
over the block -0.020
0.100
Fit of camshaft front bearing in block (+)
0.040
Height of the cylinder jacket support in the 0.030
14
engine block 0.000
0.025
∅int of the cylinder jacket 152 H6
0.000
INSPECTION CRANKSHAFT
Half-bearing
Crankshaft
Ø160.12 Ømax. 160.179
Ø160h7
Ømin.159.960
Clearance between 0.059

int of half-bearing (mounted) 160.12
bearing and crankshaft ∅ ∅
0.000
0.219
Clearance of crankshaft set in half bearing (+)
0.120
0.000
∅ main bearing / ∅ crankpins ∅ 160 h7
-0.040
INSPECTION CAMSHAFT
Left Camshaft Ø92e7

Ømin. 91.893
Ø92
Ømin. 92.057
Ø92
Ømin. 92.057
Ø92 e7 Front part:
Ømin. 91.893 1 Center Bearing + 1
Front Bearing
Ø92
Ø92 e7 Ømax. 92.057
Ømin. 91.893 Center Bearings (6)
* All the bearings installed in

Ø92 their engine block bores
Ømax. 92.110
Back Bearing (1)

int of back bearing (mounted) 92
bushings and camshaft ∅ ∅
0.020
Camshaft clearances in the back bearing 0.217
(+)
(mounted). 0.092
-0.072
∅ camshaft ∅ 92 e7
-0.107

int center bearing (mounted) 92
0.000
Camshaft clearances in the center bearing 0.164
(+)
(mounted). 0.072
-0.072
-0.107

int of narrow center bearing (mounted) 92
0.000
0.164
Crankshaft clearance in half-bearing (+)
0.072
-0.072
∅ main bearing / ∅ crankpins ∅ 92 e7
-0.107
CAMSHAFT INSPECTION
Right Camshaft Ø92 e7

Ømin. 91.893

Ø92
Ømax. 92.057
Ø92 e7 Front Part:
Ømin. 91.893 1 Center Bearing
Ø92
Ø92 e7 Ømax. 92.057
Ømin. 91.893
Center Bearings (6)
Ø92
* All the bearings installed in their
Ømax. 92.110 engine block bores
Back Bearing (1)

int of back bearing (mounted) 92
bearings and crankshaft ∅ ∅
0.020
Camshaft clearance in back bearing 0.217
(+)
(mounted) 0.092
-0.072
-0.107

int center bearing (mounted) 92
bearings and crankshaft ∅ ∅
0.000
Camshaft clearance in center bearing 0.164
(+)
(mounted) 0.072
-0.072
-0.107
INSPECTION CAMSHAFT
INSPECTION OF THE CAMSHAFT BEARINGS

(VERIFICATION PASS / FAIL)
Verify the internal diameter of the camshaft bearings once they are mounted in their
bores.
When checking the bearings, it is necessary to perform the Pass / Fail verification
process, using the specific tool for verification (See photo).
It is necessary to check the 9 camshaft bearings (1 in front + 7 in the center + 1 in

back).
CHECKING THE FRONT CAMSHAFT BEARING

GO / NO GO GAUGE
(MOUNTED IN ITS BORE) WITH THE GO / NO GO
GAUGE
To perform the Pass/Fail test of the rest of the camshaft bearings it is necessary to
follow the procedures above, using the same tool. (Pass/Fail).
If there is no specific tool available for the Pass / Fail test of the camshaft bearing bore
diameter, use an internal micrometer, making different measurements along the bore.
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS INSPECTION CONNECTING RODS & PISTONS
Ø121 H6
Ømax. 121.025
Ø121.05
Ø115.1 +0.035
-0.01
Tightening bearing / ∅int of connecting rod = ∅ connecting rod 0.025

bearing bore ∅ 121 H6
connecting rod 0.000
Tightening of the bearing in the connecting 3.025
(-)
rod bore 1.500
3
∅ext bearing for connecting rod. ∅ 121.025
1.5
0.025
Calculation of the ∅int ∅int of connecting rod = ∅ bearing bore ∅ 121 H6
0.000
of the connecting rod
bearing (mounted) 0.005
Bearing wall thickness ∅ 2.95
-0.005
∅int of the connecting 115.1

0.035
rod bearing (mounted) ∅
-0.01
CONNECTING RODS & PISTONS INSPECTION
Measurement and Calibration Equipment:
1. Use an inside diameter measuring caliper with a dial indicator as shown, with a dial
reading gauge of 0.002 mm. The measurement range will be for inside diameters
between 100 and 150 mm ( see photo 1 to the left).

2. Use a 121mm in diameter ring for the zero adjustment (See Photo 2 to the left).
3. If for instance a ring of 121.005 mm is available for a specific diameter, to measure a

diameter of 121 H6 (121.000 - 121.025), the ring measurements can be compensated
by moving the gage dial 0.005 mm. This way when the dial reads zero, in reality it is
measuring 121.005 mm. The system works by comparison. (See Photo 3 to the left).
INSPECTION CONNECTING RODS & PISTONS
4. To perform the connecting rod measurements, first:

Verify the bearing bore is dry and clean, verify the serrated unions of the connecting
rod and cap are clean and without burrs or blows, place the caps against the
connecting rod, making sure that the position of the pin guides match in both pieces,
apply engine oil to the teeth and the bolt threads, tighten the bolts with an pneumatic
gun, starting with the through bolt to 18+/-2 mKg (this operation serves to seat the
threaded surfaces and the bolt head), tighten the bolts in the same order previously
indicated to 35 +/- 2 mKg and proceed with the measurement.
5. To make the measurements, insert the bore measuring device inside the diameter to
be measured (once zero calibration has been done as indicated in items 1, 2, and 3
above). Read the dial indicator (thousandth of millimeter over zero). (For example: If
after calibrating the dial reads 22, the dimension is 121.022 mm).
6. This measurement is repeated two times for each diameter at two different depths
(zones 1 and 2) and in five different diameters A, B, C, D, and E. (See attached
sketch).
ACCEPTANCE CRITERIA
The measurement is performed for each connecting rod over 5 diameters at two depths (ten
measurements per connecting rod). The manufacturing specification for the connecting rod
diameter is of 121 H6 (121.000-121.025 mm ). The connecting rod will be accepted after
operation when the measurements are between 120.995 and 121.030 mm.

Sketches for verification points:
- Diameters A, B, C, D and E in zones 1 and 2.
INTERIOR IN ZONES
ZONE 2
ZONE 1
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS INSPECTION CONNECTING RODS & PISTONS
+0.035
Ø115.1 -0.01
Ø115 j6
Ømin. 114.991
Jmax. 0.54
Jmin.0.28
Clearance 0.035
int of connecting rod bearing (mounted) 115.1
Bearing / Crankshaft ∅ ∅
-0.01
0.144
Crank Throw clearances in the bearing. (+)
0.077
0.013
∅ Crank Throw. ∅ 115 j6
-0.009
FGLD 360/480 SFGLD 360/480

SFGLD 560
Ø65
Ømax. 65.080
Ø66
Ømax. 66.078
Ø65
Ømin. 64.992
Ø66
Ømin. 65.992
Clearance ∅int Connecting Rod Bushing (set and 0.080

∅ 65
Bushing / Piston pin. machined) 0.035
Clearance of Piston Pin in connecting rod 0.088
(+)
bushing. 0.035
0.000
∅ext of piston pin. ∅ 65
-0.008
Clearance ∅int Connecting Rod Bushing (set and 0.078

∅ 66
Bushing / Piston pin. machined) 0.059
Clearance of Piston Pin in connecting rod 0.086
(+)
bushing. 0.059
0.000
∅ext of piston pin. ∅ 66
-0.008
INSPECTION CONNECTING RODS & PISTONS
Compression ring (1)
Scraper ring (2)

Oil control ring (3)
CLEARANCE AND LIMITS IN THE PISTON AND PISTON RINGS
ITEM NORMAL LIMIT
Height No. 1 groove (compression ring) 3.54 to 3.56 3.7
Height No. 2 groove (scraper ring) 3.54 to 3.56 3.7
Height No. 3 groove (oil control ring) 4.02 to 4.04 4.15
Ring clearances No. 1 groove 0.05 to 0.085 0.15
INSPECTION OIL PUMP
Ø50
Ømin 50.05
Ø45
Ømax. 45.089
Ø45 f6
Ømin. 44.959
Ø50 H6
Ømax. 50.016
Bushing bore in
pump body
Fitting the bushing 0.016

in the bore ∅ of bushing bore in the pump body ∅ 50 H6
0.000
0.090
Bushing fit in the bore of the pump body. (-)
0.034
0.090
∅ext of bushing ∅ 50
0.050
Clearance of the 0.089

pinion shaft
int of bushing 45
installed in the ∅ ∅
0.050
bushing
0.130
Clearance of the pinion shaft in the bushing (+)
0.075
-0.025
∅ext of pinions ∅ 45 f6
-0.041
OIL PUMP INSPECTION

Ø45 f6
Ømax 44.975
Ø45
Ømax 45.089
Ø50
Ømax 50.05
Ø50 H6
Ømax 50.016
Fitting the bushing 0.016

in the bore ∅ of bushing bore in pump cover. ∅ 50 H6
0.000
0.090
Bushing fit in the bore of the pump cover. (-)
0.034
0.090
∅ext of bushing ∅ 50
0.050
Clearance of the 0.089

pinion shaft
int of bushing (mounted). 45
installed in the ∅ ∅
0.050
bushing
0.130
Clearance of the pinion shaft in the bushing. (+)
0.075
-0.025
∅ of pinion shaft. ∅ 45 f6
-0.041
INSPECTION OIL PUMP
CLEARANCES
Axial clearance of 0.087

Axial length of pump body 110 H9
pinions in pump body 0.000
0.237
Axial clearance of pinions in pump body (+)
0.100
-0.100
Axial length of pinion shaft 110

-0.150
Radial clearance of the 0.100

∅ of pump body housing ∅ 121
oil pump 0.000
Radial clearance between pump body and 0.310
(+)
pinion 0.150
-0.150
∅ of gear (pinion) ∅ 121
-0.210
CLEARANCE VALUES
0.500
Clearance between sides of the pinion teeth
0.300
0.310
Radial clearances of pinions in the pump body
0.150
Axial clearances for pinions between pump 0.237
body
and cover plate 0.100
Radial clearance of pinion shaft in bushings 0.130
0.075
DISTRIBUTION DRIVING GEARS
0.345
Clearance between sides
0.238
INSPECTION CYLINDER HEADS
Ø20
Ømin. 20.022
Ø14 u6
Ømin. 14.033 Ø20 H6

Ømax. 20.013
Cylinder head bore
for valve guide
Cylinder head Ø 14 H8
bore for tapped Ømax. 14.018
guide
Inlet /Exhaust Valve ∅ Inlet/Exhaust Valve Guide bore in cylinder 0.013

∅ 20 H6
Guide head 0.000
Fit of inlet/exhaust valve guides in cylinder 0.035
(-)
head bores. 0.009
0.035
∅ext of valve guide (not mounted) ∅ 20
0.022
0.018
Tappet Guide ∅ tappet guide bore in cylinder head. ∅ 14 H8
0.000
0.044
Fit of tappet guide in cylinder head bore. (-)
0.015
0.044
∅ext of tappet guide ∅ 14 u6
0.033
CYLINDER HEADS INSPECTION
Intake / Exhaust
Valve Guide
assembled

Ø 11
Ømax. 11.037
Ø 10.95
Ømin. 10.935
Intake / Exhaust Valve
Valve guide/valve ∅int Valve Guide (intake/exhaust) 0.037

∅ 11
(intake/exhaust) (mounted) 0.027
Clearance between valve guide and 0.102
(+)
intake / exhaust valve 0.077
0.000
∅ext intake / exhaust valve ∅ 10.95
-0.015
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS INSPECTION CYLINDER HEADS
Intake/exhaust valve
seats
Ø 55 v6
Ømin. 55.102 Ø 55 H7
Ømax. 55.030
Valve seat bore in

cylinder
head(intake/exhaust) in
cylinder
head
Intake/exhaust valve 0.030

∅Valve seat bore in cylinder head ∅ 55 H7
seats 0.000
0.121
Valve seats fit in cylinder head (-)
0.072
0.121
∅ext (intake/exhaust) valve seat ∅ 55 v6
0.102
Ø46.8 +0.050
+0.010
(2)
Ømin. 46.81

(1)
Ø45.9 +0.040
+0.000
Ømin. 45.9
Ø47.03 +0.030
-0.030
(2) Ømax. 47.06
(1)
Ø46 +0.030
-0.030
Ømax. 46.03
(1) Value under the o-ring bore

(2) Value above the o-ring bore
0.030
∅ under the O-ring ∅ spark plug tube bore in cylinder head ∅ 46
-0.030
Clearance between spark plug tube and bore 0.130
(+)
in cylinder head, under the O-ring 0.030
0.040
∅ spark plug tube under the O-ring ∅ 45.9
0.000
0.030
∅ above the O-ring ∅ spark plug tube bore in cylinder head ∅ 47.03
-0.030
Clearance between spark plug tube and bore 0.250
(+)
in cylinder head, above the O-ring 0.015
0.050
∅ spark plug tube above the O-ring ∅ 46.8
0.010
ADJUSTMENTS
NOTE
Refer to the information shown in this section and on the Tightening Torque tables
included in this chapter for specifications and tolerances.
The readjustment of the valves and the retightening of the cylinder heads, after
NOTE
operation of a new or rebuilt engine, is not required in accordance with the

specifications, however, it can be considered as a good general practice.
Valve Adjustment (Figures 1 through 4)
1. Loosen the mounting screws of the cover of the opening for the marks in the
flywheel, on the right side of the flywheel housing, and rotate the cover until the
flywheel mark is seen (marks on the flywheel of the cylinder positions).
2. Disassemble and remove the cover of the barring assembly, on the right side of the
front part of the flywheel housing.
The push rods of the cylinder to be adjusted will be loosened when the cylinder is at
CAREFUL
the top dead center (TDC) of the compression stroke. If the push rods are not loose,
rotate the engine one complete turn until it is placed in the correct position. If this
procedure is not performed correctly, it will result in an incorrect valve adjustment and
engine malfunctioning.
3. Rotate the engine, using the engine barring tool, until the number one cylinder is
placed in the top dead center (TDC) in the compression stroke.
NOTE
Verify this through the flywheel markings, on the right side of the flywheel housing.
FIGURE 1

FIGURE 2
4. Loosen the locking nut of the push rods and the adjusting nut, until the push rod
moves freely.
5. Loosen the locking nut and the adjustment nut of the corresponding tappet.
6. Verify appropriate contact between the tappet and the tappet seat (friction seat).
NOTE
The tappet shall always be in contact with the valves and at the same time.
7. Rotate the tappet-adjusting nut clockwise; until it makes contact with the seat while
pressure is applied to the fixed side of the tappet.
8. Tighten the locking nut of the tappet to the specified torque, making sure the
adjusting screw does not move.
FIGURE 3
9. Insert the required feeler gauge to verify the clearance between the non-adjustable
end of the tappet and its seat.
This action can cause a slight elongation of the filler gauge when it is placed between
NOTE
the tappet and the seat.
10. Tighten the locking nut of the rocker arm, while it is in contact with the seat of the
tappet.
11. Tighten the locking nut to the specified torque, making sure the adjusting screw does
not move.
FIGURE 4
12. Repeat steps 4 through 11 for the rest of the valve clearances.
13. Rotate the engine (by means of the barring tool) until the next cylinder is, in the firing
order, at the top dead center of the compression stroke.
14. Repeat steps 4 through 13, for the rest of the cylinders.
15. Reposition the barring tool cover, on the right side of the front part of the flywheel
housing.
16. Rotate the flywheel cover to close the opening.
17. Tighten the screws of the cover, located on the right side (lateral) of the flywheel
housing.
Refer to the information shown in this section and on the Tightening Torque tables
NOTE
included in this chapter for specifications and tolerances.
The cylinder heads shall be tested by means of a pressure or the Magnaflux test, when
NOTE
disassembled from the engine. Consult the information provided in the "Pressure test"
and "Magnaflux test" in this Section (Diagnostic Systems).
Cylinder Heads- Surfaces (Figure 1)
1. Place the cylinder head on a rigid and clean table with its lower face facing up.
2. Clean the lower face of the cylinder head.
3. Check the surface for deformations and warpings, using a precision ruler and a feeler
gauge.
4. Repair the surface or replace the cylinder head if the deformations (warping) exceed

the specifications.
The cylinder heads shall not exceed the

CAREFUL
specifications to prevent serious damage to

the engine due to contact of the piston or the
valves.
FIGURE 1
Cylinder Heads Inspection - Valve Recess (Figure 2)

CAREFUL
Care must be taken to avoid serious damage to the engine, if the cylinder head does
not meet the specifications due to the contact of the piston or of the valves.
1. Place the cylinder head on a rigid and clean table, with its lower part facing upwards.
2. Before taking measurements, make sure that the valves are well seated.
3. Measure the recess of the valves in the cylinder head, with a depth micrometer.
4. Repeat steps 2 and 3 for the rest of the valves.
5. Remove all the valves, following their numbered positions.
If the measurement of the recess of the valve is greater than the tolerance, replace the
NOTE
valve, the valve guide and the valve seat.
If the measurement is less that the allowed tolerances, repair the valve seat until the
NOTE
required tolerance is achieved, following the instructions for the Correction of Valve
Seats in this Section.
FIGURE 2
Cylinder Heads Inspection - Valve Closure. (Figure 3)
1. Make sure that the valve seats, valve guides and the valves are clean.
2. Place the cylinder head on a rigid and clean table, on its base.
3. Apply Prussian Blue to the valves.
4. Insert the valves in the cylinder head, applying pressure in the center of the head of
the valve.
5. Rotate the valve a quarter turn in the valve seat.
6. Remove the valve and look at the contact area to determine if the contact guidelines
are met, in the valve as well as in the valve seat.
7. Check several times to avoid errors.
If the valve contact is not correct at the center of the valve surface, or it is not shown
around the entire valve seat, repair the valve seat (not the valve) following the
NOTE
instructions in " Valve Contact Diagnostics" of this Section.
8. Repeat steps 3 to 7 for each of the remaining valves.

9. Remove all the valves, following their numbered position.
Inspection of Components (Pass / Fail, Failure and Diagnostic Analysis)
The Prussian Blue will be removed from the valve surface once contact has been made
NOTE
with the valve seat and the contact criteria has been checked.
NOTE
The valve seats shall be replaced if the valve guides have been replaced.

FIGURE 3
Inspection of Cylinder Heads - Valve Guides Bores (Figures 4 & 5)
1. Place the cylinder head on a rigid and clean table on its base.
2. Before taking measurements, make sure the valves have been removed.
3. Measure the valve guides, at the top and lower section of its seat, using telescopic
feeler gauges.
4. Measure the feeler gauges with a micrometer (0-1 inches, or metric equivalent),
according to the specifications.
5. Repeat steps 3 and 4 for the rest of the valve guides.
If the measurement of the valve guides does not meet the specifications, replace the
NOTE
valve guide, the valve and repair or replace the valve seat
FIGURE 4 FIGURE 5
Inspection of the Cylinder Heads - Valves. (Figure 6)

DANGER
It is necessary to wear a mask, when working with a wire brush.
1. Clean the valves with a wire brush, being careful not to break the valve stem.
2. Inspect the valve for abrasive surfaces, porous surfaces, scratches, fractures, etc.
3. Measure the valve stem between different points. Use a micrometer, rotating the
valve, to measure the surface of the valve stem.
4. Repeat steps 1 to 3 for the rest of the valves.
FIGURE 6
NOTE
If the valve measurements do not meet the specifications, or if wear is detected, replace
the valve, the valve guide and repair or replace the valve seat
Inspection of the Cylinder Heads - Valve Seats.
Inspect the valve seats for surfaces with holes (porous), burnt surfaces, etc.
Follow the procedure indicated in the section "Inspection of Cylinder Heads- Valve
Recess" and "Inspection of Cylinder Heads - Valve Closure".
If the measurements of the valve seats do not meet the specifications or other defects
NOTE
are detected, replace or repair the valve seat. Perform the procedure indicated in the
Section "Inspection of Cylinder Heads- Valve Recess" and "Inspection of Cylinder
Heads - Valve Closure" again.
Inspection of Cylinder Heads - Valve Springs. (Figures 7 & 8)
1. Clean the valve springs, spring seats and the spring seals in a mild solution.
2. Inspect the springs, seats and seals for rust, porous surfaces, cracks, etc.
3. Measure the length of the internal spring with a micrometer, according to the
specifications.
4. Measure the tension of the inner spring, compressed, using a valve spring testing
equipment.
5. Repeat steps 3 and 4 for the rest of the inner springs.
6. Measure the length of the outer spring with a micrometer, according to the
specifications.
7. Measure the spring tension with a micrometer, according to the specifications.

8. Measure the tension of the outer spring, compressed, using valve spring testing
equipment.
9. Repeat steps 6 and 7 for the rest of the outer springs.

FIGURE 7
Replace any rusted spring that has porous surfaces, broken or springs which cannot
NOTE
perform the specific functions.
FIGURE 8
A B CHARGE
OUTER VALVE SPRING 67,1±2,03 39,01 43 kg ± 3,03
INNER VALVE SPRING 56,6 34,1 26,3 kg ±1,86
NOTE: A y B mm
Inspection of Cylinder Heads- Valve Spring Cup.
1. Clean the spring cup in a mild chemical solution.

2. Inspect the inside surface of the cup looking for wear that can result in a loose fit.
3. Inspect the external portion of the cup for wear that can cause the valve seals to
come over the spring flanges.
The wear of the outer part of the spring flanges can be caused by overspeed of the
NOTE
engine.
Analysis of Cylinder Heads Failures - Main Causes of Valve Failure. (Figure 9)
1. The deformation of the valve seat can be derived from burned valves and are usually
caused by:
- Failure in the cooling system.

- Loose valve seats (with clearance) can reduce or interrupt heat transfer
between the valve and the cylinder head.

- Deformed surfaces (warped) in the cylinder head or in the block can deform
the valve seats when the cylinder head is assembled.
- A wrong tightening, a higher tightening torque, or wrong sequence of
tightening can deform the valve seats.
2. Valve residues can provoke high temperature in the valve stem, due to the presence
of unsuitable oils. Refer to oil specifications. These valve residues can reduce the
heat transfer of the cylinder head and cause valve failure. Other factors can cause
an accumulation of residues and then valve failure.
3. Too small tolerances can cause the valve to come out (from the seat) thus causing
the valve surface to burn. Small tolerances can be a result of:
- Valve tolerances not meeting the specifications.

- Valve tolerances not verified and modified after an overhaul and remounting
of the cylinder heads.
4. Surface defects in the valve stem can cause a lubrication defect, too much or too
little clearance between the stem and the valve guide, or surface defects in the stem
or in the valve guide.
5. Accumulation of residues in the valve guide can cause defects in the guide / valve
stem, and the valve to remain open.
6. The wear of the stem, under the valve head, can cause the valve to break. Possible
causes of valve wear are:
- High levels of Hydrogen Sulfide (H2S).

- Defective combustion.
- Excessively high valve temperature.
- Inadequate air/fuel ratio that can cause high temperatures and wear in the
valves.
7. Stress due to heat (overheating) can cause the valves to fracture. Causes for stress
are:
- Defective valve guide.

- Valve seats out of shape.
- Inadequate air/fuel ratio.

8. The fractures are generally of two types:
- Fracture because of fatigue, is the gradual fracture due to high temperatures

or pressures.
- Mechanical fractures by impact, are caused by the valve closing with too
much pressure.
9. The wear of the valve stem and the valve guide can be caused by surface abrasion.
Defective valve guides can cause the valve to fail.
- Defective guides result in a defective closing and produce surface abrasion.

- Defective guides make the valve close at an incorrect angle, damaging the
closing surface and producing surface abrasion.
- Excessive clearance between the valve stem and the guide can produce an
excessive oil accumulation on the stem with subsequent accumulation of
deposits (solidified oil) over the stem.
Causes of defective guides are:
- Defective rocker arms.

- Poor lubrication.
- Carbon deposits on the valve stem that wears the valve guide.
FIGURE 9
Failure of Cylinder Heads - Principal causes of the rocker arms failure (Figure 10)
A poor lubrication of the rocker arm can produce the wear of the rocker arm pushing
surface. The effects can be:
- Collapsing of the valves.

- Difficulty in measuring the clearance between the rocker arm and the pusher
with a conventional feeler gauge.
Whenever the rocker arm is installed, the lubrication screw should be tightened
according to the specifications. Rocker arm ball screws and rocker arms seats with
surface defects can cause failure of the valves.
FIGURE 10
Failure Analysis of the Cylinder Heads - Principal causes for tappets failure.
When the seat on the tappet is defective or broken, this can cause a failure of the valves.
An incorrect alignment of the tappet with the adjustment nut of the rocker arm is a
common cause of fracture of the seat. A careful reinstallation of the rocker arm set
prevents this from occurring.
Analysis of the failure of the Cylinder Heads - Principal causes of failure of the
auxiliary rockers (Figure 11).
The auxiliary rocker arms can present signs of wear, surface defects, and stress, due to
engine malfunctioning under rigorous conditions and high velocities. They are described
as follows:
- Gradual and mild wear due to friction.

- The surface defects are the most severe form of wear and they are identified
by the presence of deep fractures, surface roughness, etc., on the metal
surface.
- Fatigue is the tendency of the metal to break under severe working
conditions.
Dirt in the lubrication oil can produce wear by abrasion.

FIGURE 11
Diagnostic of the valve contact standards. (Figures 12 to 16)
If the valve contact surface is different, verify them with the diagnostic surface contact
NOTE
patterns shown in the following pages.
A resurfacing of the valve and valve seats can facilitate the diagnostic of the contact
NOTE
standards between valves and seats.
Exhaust / Intake Valve: 20º

A 19º 30' ±15'
B 0.5º
FIGURE 12
FIGURE 13 FIGURE 14
FIGURE 15 FIGURE 16
7
REPAIR OF COMPONENTS
To obtain specifications and tolerances, consult the information provided in this section
NOTE
and the Tightening Torque Tables included in this chapter.
Grinding of Valves. (Figure 1)

1. Place a grinding stone in the grinding machine.
2. Place the grinding machine at the appropriate angle.
3. Begin to grind the valve with smooth cuts.
When finished, move the grinding stone to the outside. If we move the grinding stone
NOTE
towards the outside when still in contact with the valve surface, we could cause a
fracture in the valve surface.
4. Continue grinding the valve, with light cuts,

until all the irregularities of the valve surface
are removed and leaving it according to the
specifications.
5. If the ground material in the valve angle is very
thick, replace the valve. The valve margins are
determined by the specifications.
6. Check the valve surface after it is grounded.
FIGURE 1
7. Replace the valve, if the valve exceeds the specifications (after grinding).
Check the valve stem surface after grinding, using the information provided in
NOTE
"Inspection of Cylinder Heads- Valves".
Grinding of the Valve Seats. (Figure 2)

NOTE
Use a precision instrument, whenever possible. Make light cuts, with the grinding tool
to remove the minimum material. This will help assure a good finish of the valve seat.
1. Place the cylinder head, with its lower face upwards.

2. Insert the tool guide in the valve guide, while the grinding tool cleans the valve seat.
3. Apply the grinding stone smoothly onto the valve seat, applying small pressure over
the grinding tool.
4. Repeatedly lift the grinding tool to avoid overheating.
5. Smoothly grind the valve seat until a good surface finish is obtained.
6. Inspect the valve seats, specially its concentricity, cylindricity and valve contact,
using Prussian Blue in accordance with the procedures shown in "Cylinder Head
Inspection - Valve Recess" and "Cylinder Head Inspection- Valve Closure".
FIGURE 2
DIAGNOSTIC SYSTEMS
BORESCOPE TEST
Generally, visual inspection of the combustion chamber is accepted, before

disassembling, because it is a good diagnostic system. If no evidence of water is found
in the combustion chamber, the cylinder can be pressure or Magnaflux tested, in search

of fractures.
The borescope test can be performed to determine the cause of low pressure, if possible,
before dismantling the engine.
This type of test shall be performed by qualified personnel.
PRESSURE TEST
The pressure test of the water circuit, or any of its components, after dismantling of the
NOTE
engine, is necessary to prove the integrity of the system. If no evidence is found of

water in the lubrication system or in the combustion chamber, the cylinder head can be
tested for fractures by the Magnaflux method.
MAGNAFLUX TEST
The cylinder heads shall be Magnaflux tested, as long as they have been dismounted
from the engine. This test allows to discover defects that are not visible to the naked eye,
in normal conditions.
Qualified personnel shall perform the Magnaflux test.
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS INSPECTION TAPPETS AND ROCKER ARMS
Clearance of tappet 0.018

seats (pad) ∅int bore of tappet seat ∅ 18 H7
0.000
0.052
Clearance in tappet seats (pad) (+)
0.016
-0.016
∅ext tappet seat (pad) ∅ 18 f7
-0.034
0.077
Tappet guide ∅int bore of tappet guide ∅ 14 D8
0.050
0.044
Clearance of tappet guide in bore (+)
0.006
0.044
∅ext of pistons ∅ 14 u6
0.033
TAPPETS AND ROCKER ARMS INSPECTION

Auxiliary Rocker Arm 0.025
∅ 36 H7
Assembly ∅int auxiliary rocker arm 0.000
0.100
Fit of the bushing in the auxiliary rocker arm (-)
0.025
0.100
∅ 36
∅ext of bushing 0.050
Operational clearance of 0.034

∅ 32 G7
shaft in bushing ∅int of bushing (machined). 0.009
Clearance of auxiliary rocker arm shaft in 0.068
(+)
detachable bushing 0.018
-0.009
∅ 32 g7
∅ of rocker arm shaft. -0.034
Fit of the auxiliary rocker ∅int bore of the auxiliary rocker arm seat. 0.021
arm seat in the auxiliary ∅ 22 H7
rocker arm 0.000
Fit between auxiliary rocker arm seat and bore (+) 0.013
in the auxiliary rocker arm (-) 0.021
0.021
∅ 22 m6
∅ext. of auxiliary rocker arm seat 0.008
Operational clearance 0.049

of the push rod seat ∅int of auxiliary rocker arm seat ∅ 16 G9
0.006
Operational Clearance of the rod seat in the 0.092
(+)
spherical end. 0.006
0.000
∅ext of spherical end of push rod. ∅ 16
-0.043
Operational clearance 0.049

of the push rod ∅int of concave end of push rod ∅ 16 G9
concave spherical end 0.006
Clearance of rocker arm spherical seat in 0.062
(+)
the push rod concave spherical end 0.006
0.000
∅ Rocker arm spherical end. ∅ 16
-0.013

Clearance of external- 0.098
internal roller ∅int external roller. ∅ 23 D8
0.065
Clearance between external and internal 0.119
(+)
rollers. 0.065
0.000
∅ext internal roller. ∅ 23 h7
-0.021
Clearance of internal 0.043

roller - auxiliary rocker ∅int internal roller. ∅ 16 F8
arm shaft. 0.016
Clearance between internal roller – auxiliary 0.077
(+)
rocker arm shaft. 0.032
-0.016
∅ext roller shaft ∅ 16 f7
-0.034
Clearance roller shaft 0.010

- aux. rocker arm. ∅ bore for shaft in the auxiliary rocker arm. ∅ 16 J7
-0.008
Clearance of roller shaft in the bore of the 0.044
(+)
auxiliary rocker arm. 0.008
-0.016
∅ext roller shaft ∅ 16 f7
-0.034
Exhaust rocker 0.025

arm ∅int. exhaust rocker arm. ∅ 36 H7
0.000
0.100
Fit of the bushing in the exhaust rocker arm. (-)
0.025
0.100
∅ext bushing ∅ 36
0.050
0.034
∅int bushing (mounted). ∅ 32 G7
0.009
Clearance of the exhaust rocker arm shaft in the 0.059
(+)
bushing. 0.018
-0.009
∅ exhaust rocker arm shaft ∅ 32 g6
-0.025

0.025
Intake rocker arm ∅ 36 H7
∅int. intake rocker arm. 0.000
0.100
Fit of the bushing in the intake rocker arm (-)
0.025
0.100
∅ 36
∅ext bushing 0.050
0.034
∅ 32 G7
∅int bushing (mounted). 0.009
Clearance of the intake rocker arm shaft 0.059
(+)
in the bushing. 0.018
-0.009
∅ 32 g6
∅ intake rocker arm shaft. -0.025
0.016
∅int rocker arm shaft support. ∅ 32 H6
0.000
Clearance of the shaft in the rocker arm shaft 0.041
(+)
support 0.009
-0.009
∅ rocker arm shaft (intake and exhaust). ∅ 32 g6
-0.025
INSPECTION TURBOCHARGER
Cleaning and Inspection of Components

(Dimensional check, Failure and Diagnostic Analysis).
Consult the information provided in the specifications and tolerances table of Section A
NOTE
(Illustration / List of Components/ List of Tools / Table of Specifications and Tolerances) for
specifications and tolerances.
CLEANING
Use a NON-FLAMMABLE solution. In place of a solution, a NEUTRAL soap can be used.

NOTE
In either case, make sure that the product used for cleaning is chemically neutral and does
not attack the metal.
1. Perform a visual inspection of the components, for signs of wear and abrasion by friction
and other damages to obtain the greatest amount of information, before cleaning the
turbocharger.
CAREFUL
Carefully wash and dry the components by hand, avoiding deformation and/or impacting
them.
2. Submerge the components in a tub filled with liquid (solution or soap) and wash them
one by one, leaving them completely clean and free of oil.
Never use compressed air or gases for cleaning clothes or the body. The compressed air
DANGER
can be very dangerous, because it can produce damage to the skin, dangerous injuries
and even death. Never use your hands to verify the air pressure or to detect leaks.
NEVER PLAY WITH COMPRESSED AIR, GASES OR LIQUID.
3. Initially, manually dry the clean parts, as a last step dry them totally with compressed air.
4. Remove any particulates that adhered using a plastic scraper or a wire brush.
5. Repeat steps 2 and 3 for each one of the components that have any type of adhesion.
6. Protect from dust the surfaces of the components which are subject to displacements
(possible friction, machined surfaces) by applying oil.
TURBOCHARGER INSPECTION
INSPECTION OF THE TURBOCHARGER - BUSHING BORE
1. Measure the inside diameter of the bushing bore using a micrometer or telescopic
caliper.
2. If the measurements are outside the limits of the specifications, replace the bushing
housing of the turbocharger body.

INSPECTION OF THE TURBOCHARGER- BUSHINGS
1. Measure the outside diameter of the bushings using a micrometer.

2. Measure the inside diameter of the bushings using a micrometer and/or a telescopic
caliper.
3. Measure the length of the bushing, using a micrometer.
4. If the measurements are outside of the specifications limits, replace the bushings.
INSPECTION OF THE TURBOCHARGER- SHAFT AND TURBINE WHEEL
1. Using a micrometer, measure the outside diameter of the shaft journal.

2. Using a dial gauge and a V Block, measure the outside part of the shaft.
CAREFUL
Do not try to straighten a bent shaft. Make sure to replace the shaft and the turbine wheel
, when the shaft is bent and outside the limits of the specifications.
3. If the measurements are outside the limits, substitute the lock ring (snap ring), the shaft,
and the turbine wheel.
4. Verify the condition of the surface of the shaft journal.

5. If the finish of the surface of the shaft is outside the specifications, repair the shaft
(lightly polish) using sand paper and oil (rotating the shaft at 300/600 rpm).
6. If the shaft correction has been performed (step 5), repeat steps 1 to 3.
INSPECTION OFTHE TURBOCHARGER - SEPARATOR.
1. Place a new lock ring (snap ring) in the groove of the separator.
2. Measure the closing zone of the snap ring with a feeler gauge.
3. If the measurement is outside of the specification limits, replace the separator.
INSPECTION OF THE TURBOCHARGER - CLEARANCE OF THE SHAFT AND OF

THE TURBINE WHEEL IN THE TURBINE BODY
1. Install a dial indicator to measure the clearance of the shaft and of the turbine wheel

in the body of the turbine.
2. Measure the clearance by moving the shaft between its top and bottom ends.
3. If the measurement is outside of the specification limits, disassemble and check for
possible causes.
INSPECTION OF THE TURBOCHARGER - AXIAL CLEARANCE OF THE SHAFT

AND THE TURBINE WHEEL
1. Install a dial indicator to measure the clearance between the shaft and turbine wheel.
2. Measure the clearance, moving the shaft between its top and bottom ends.
3. If the measurement is outside of the specification limits, disassemble and check for
possible causes.
INSPECTION OF THE TURBOCHARGER - CLEARANCE OF THE TURBINE WHEEL

AND THE REAR COVER OF THE TURBINE
1. Disassemble the bushing housing of the turbine body and place it on the compressor
cover.
2. Measure the clearance of the turbine wheel in the rear cover of the turbine by using two
feeler gauges placed on the sides, on two diametrically opposed blades.
3. If the measurements are outside of the specifications, disassemble and check for
possible causes.
ANALYSIS OF THE FAILURES OF THE TURBOCHARGER - ABNORMAL NOISE

AND VIBRATIONS.
1. The most frequent causes of this type of failure generally are bushings in bad
conditions, or parts subject to movement, in particular bearings, that touch adjoining
components. This type of problems are often caused by lack of oil maintenance in
service, for insufficient oil, caused by an obstruction of oil lines or of a filter, starting the
engine cold, or by a sudden stop of the engine.
2. A sign of friction of moving parts indicates a defect in the distribution of the rotating
mass, or a bent shaft, caused by a defective bushing or by an object, that carried by the
gas flow in the turbine, hits the turbine wheel or the compressor, thus causing an
unbalance in the mass distribution.
3. In these cases, the turbocharger must be taken off, inspected and in most cases, will
need to be repaired.
ANALYSIS OF THE FAILURES OF THE TURBOCHARGER - APPARENTLY IN

GOOD CONDITION, THE ENGINE LACKS POWER.
1. The exhaust gases can leak. Verify the exhaust line from the engine manifold up to
the inlet of the turbocharger.
2. An abnormal back pressure in the gas exhaust from the turbocharger can also be the
cause. Verify the muffler (exhaust muffler), in search of obstructions by the

accumulation of carbon (derived from the combustion and present in the exhaust
gases).
3. The air intake can leak, or the air filter can be plugged. If it is plugged, clean it or
replace the air filter.
4. The inside of the turbocharger can be dirty, with excessive accumulated dust. If this
is the case, remove the compressor cover and clean it.
5. After the engine has stopped, try to manually turn the rotor of the turbocharger. If the
rotor does not turn freely, disassemble the turbocharger and clean it.
ANALYSIS OF THE FAILURE OF THE TURBOCHARGER-OIL LEAKS IN THE

EXHAUST GAS OUTLET OR IN THE AIR INLET, WHITE OR BLUE SMOKE .
1. An obstruction of the air filters can be responsible for creating a negative pressure
that can favor, in the suction area, the entrance of oil. Clean and/or replace the air
filters.
2. Verify that the return oil pipe is free of defects. An oil tube that has been dented
and/or deformed must be replaced.
3. Verify if the locking ring (snap ring) is defective, or if the snap ring loosens up due to
the poor condition of the groove. In this case, replace the defective parts.
4. If the turbocharger is allowed to run with its bushings in bad condition, the snap ring
can be damaged, causing oil leaks towards the air inlet and gas outlet.
Nominal Values and tolerances. Tolerance and Clearance

Service
Nominal value Assembly value
Limit
(mm) (mm)
(mm)
Inside diameter of the TD 09 22.26 22.268
bushing bore inside the
body (Figure 1) TD 10 – TD 13 30 30.006
Outside Diameter bushings TD 09 22.144

(Figure 2) TD 10 – TD 13 29.876
Inside Diameter bushings TD 09 13.542

(Figure 2) TD 10 – TD 13 18.050
Length of Bushings (width) TD 09 14.440

(Figure 2) TD 10 – TD 13 17.440
Clearance between shaft TD 09 0.05 – 0.15
assembly and turbine wheel
and turbine body
(Figure 6) TD 10 – TD 13 0.05 – 0.25
Axial clearance of shaft TD 09 0.6 – 1.2

assembly and turbine wheel
(Figure 7) TD 10 – TD 13 0.6 – 1.2
TD 09 0.6 – 1.2
Clearance between rear
cover of turbine and turbine TD 10 0.65 – 1.25
(Figure 8)
TD 13 0.55 – 1.15
Tightening Torques
Tightening Torque (Nm)
TD 09 25.5 – 27.5
Fastening nuts
compressor wheel Metric Thread 50 - 54
TD 10 – TD 13
Helical Thread 86.3 – 90.2
TD 09 7.8 – 9.8
Coupling clamp Nuts
TD 10 – TD 13 7.8 – 9.8
INSPECTION HIGH VOLTAGE WIRES AND
SPARK PLUGS
SPARK PLUG CHECKING AND CHANGING INSTRUCTIONS.
POLARITY
Checking the ignition system polarity mainly aims to establish that a negative voltage is fed
to the center electrode of the spark plug. If a positive voltage were fed to this electrode due
to incorrect wiring, the necessary voltage to create the electric arc across the gap would
rise by 45%, which could lead to misfiring or ignition failures, since the ignition system is
not able to generate such a high voltage level and the plug would not produce any spark.
The reason for feeding a negative voltage to the spark plug is because the electron drift
must go from negative to positive.
As soon as the center electrode works normally at a higher temperature than the rest, it is
much likely to produce a spark before any other colder electrode.
If polarity is correct, the center electrode will wear faster than peripheral ones.
PERIODICITY
· Clean and adjust every 700 hours of operation.

· Change every 1400 hours of operation.
VISUAL INSPECTION OF THE SPARK PLUG CONDITION
CONDITION CAUSE
Small deposits of white ashes on the electrodes NORMAL
Electrodes or casing fused PREMATURE DETONATION OR IGNITION
Orange-color residues on spark plug end ANTIFREEZE RESIDUES
Granular red deposits on insulator or spark plug end IRON OXIDE DEPOSITS
Rough white deposits on spark plug end DEPOSITS OF CALCIUM OR BARIUM
Black specks on the spark plug end CINDER DEPOSITS
CHANGING SPARK PLUGS
1. Change all the spark plugs at the same time.

2. Adjust all the electrodes correctly, following the installation instructions.
3. Inspect each wire to see if the insulation is broken or burnt.
4. The terminals at both ends must be securely fit and their contacts clean. Replace, as
necessary.
10
HIGH VOLTAGE WIRES AND INSPECTION
SPARK PLUGS
INSTALLATION INSTRUCTIONS
1. Installation of dry spark plugs (without MOLYKOTE).
2. First, clean the spark plugs with a degreaser (trichloroethylene).
3. Make sure the ceramic portion is flawless.
4. Adjust the electrode gap as per specifications (4 electrodes (Figure 1) / 1 electrode
(Figure 3)). Use the special electrode adjusting tool to obtain the required gap. For
4-electrode spark plug, use tool ref. 16.75.016 (see Figure 2) and for one-electrode

spark plug, use precision feeler gauges.
5. Introduce the spark plugs in their housing, carefully, to avoid breaking the ceramic
element (see Tightening Torques).
6. Connect the wire to the spark plugs, with a small pressure to click it in place..
7. Change the gaskets at the same time as you change the spark plugs.
FIGURE 1:OUTLINE AND CALIBRATION

OF 4-ELECTRODE SPARK PLUG
FIGURE 2: GAP ADJUSTING TOOL FOR

4-ELECTRODE SPARK PLUGS
REF. 16.75.016
FIGURE 3:OUTLINE AND CALIBRATION

OF 1-ELECTRODE SPARK PLUG
10
INSPECTION HIGH VOLTAGE WIRES AND
SPARK PLUGS
CHECKING THE HIGH VOLTAGE WIRES

HIGH VOLTAGE WIRES
Check the high voltage coil wires to see if there are fractures in the insulation, damages or
signs of burn, etc.
Any wire showing such damage need to be changed.
10
INSPECTION TIGHTENING TORQUES, GAPS AND
WEAR LIMITS
TIGHTENING TORQUES
ITEM FGLD 360 / 480

SFGLD 360 / 480 / 560
Nm. Kgm.
ENGINE BLOCK
Fastening studs for bearing cap 100 10.2

Fastening nuts of bearing cap 1000 102
Lateral bolt bearing cap 270 27.54
Fastening studs cylinder head 50 5.1.
Fastening studs cylinder head SFGLD 560 50 5.1
MOVING PARTS
Bolts for counterweight of crankshaft 285 29.07
Damper mounting bolts 140 14.28
Connecting rod bolt. 500 51
Screws crankshaft companion flange back. 520 51
Flywheel mounting bolt 370 37.74
CYLINDER HEAD
Cylinder head nut 480 48.96
Cylinder head nut SFGLD 560 450 45.9
Spark plugs jacket 230 23.46
Spark plug 30 6.12
Rocker arms adjusting nut 110 11.22
TIMING GEAR
Oil pump gear nut 350 35.7
VARIOUS
Fastening nut for water pump impeller 100 10.2
Tightening bolts for water pump gear drive 180 18.36
Bolt engine to skid /subbase M20 330 33.66
Screw for exhaust pipe to cylinder head 60 6.12
Screw for intake pipe to cylinder head 47 / 78 4.79 / 7.96
Nut for turbocharger to manifold 60 6.12
11
TIGHTENING TORQUES, GAPS AND INSPECTION
WEAR LIMITS
GAPS & LIMITS (mm)
ITEM GAS FGLD / SFGLD 360 / 480

Normal Limit

TIMING
Intermediate / Front / Back
∅ Camshaft bushings 92
+0 +0
/ 92 +0.057 / 92
+0.110
+0.057 +0.020
End play of camshaft (locked pinion) 0.15 to 0.20 0.30
OIL CIRCUIT
Axial clearance of internal pump gears 0.100 to 0.237
Radial clearance of internal pump gears 0.075 to 0.155
Gap between gear tooth faces 0.3 to 0.5

Diametral clearance of drive shaft in bushing of pump
0.075 to 0.130
body and pump cover
Oil pump safety valve rating 8 bar
Lube oil pressure control valve rating 4.5 bar
Piston coolant pressure control valve rating 3 bar
Relief valve rating because of filter obstruction 6 bar
VALVE TAPPET
∅int. bore of valve tappet guide 14.05 to 14.077
Clearance between bore and tappet 0.006 to 0.044
∅ tappet guide 14.033 to 14.044
Clearance between tappet and intake rocker arm 0.3
Clearance between tappet and exhaust rocker arm 0.8
CYLINDER
Liner inside ∅ (top) 152.0 to 152.025 152.4
Maximum out-of-roundness 0.025 0.2
Upper ∅ of bore (liner housing) 175.5 to 175.54
Lower ∅ of bore (liner housing) 172.00 to 172.04
Protrusion of liner over cylinder block 0.64 to 0.90
CONNECTING ROD
Width of connecting rod big end 52.82 to 52.78
Clearance between piston pin and connecting rod
0.035 to 0.088
bearing insert
Diametral crankpin-to-bearing clearance 0.077 to 0.144
11
WEAR LIMITS
GAPS & LIMITS (mm)
ITEM GAS FGLD / SFGLD 360 / 480

Normal Limit
PISTON - RINGS
Height of piston groove 1 (compression ring) 3.56 to 3.54 3.7

Height of piston groove 2 (scraper ring) 3.56 to 3.54 3.7
Height of piston groove 3 (oil control ring) 4.04 to 4.02 4.15
Height of compression ring 1 3.475 to 3.490 3.4
Height of scraper ring 2 3.478 to .3490 3.4
Height of oil control ring 3 3.978 to 3.990 3.9
Protrusion of the piston over the liner (dwell) -1.0 to –1.8
Clearance of ring 1 in groove 1 0.05 to 0.085 0.15
End-to-end clearance of compression ring (1) 0.5 to 0.75 1.7
End-to-end clearance of scraper ring (2) 0.6 to 0.85 1.7
End-to-end clearance of oil control ring (3) 0.5 to 0.8 1.7
CRANKSHAFT
Crankpin ∅ 114.991 to 115.013 114.9
Crankpin ∅ 1st repair size 114.491 to 114.513 114.4
Crankpin ∅ 2nd repair size 113.991 to 114.013 113.9
Crankshaft journal ∅ 159.96 to 160.00 159.84
Crankshaft journal ∅ 1st repair size 159.46 to 159.50 159.34

Crankshaft journal ∅ 2nd repair size 158.96 to 159.00 158.84
Diametral gap between journal and bearing 0.120 to 0.219
Axial check ring thickness 5.05 to 5.11 4.85
End play of crankshaft 0.34 to 0.586 0.8
VALVES
Head angle, intake / exhaust valves 141º ±0º 15’
Milling angle, intake / exhaust valve seats 140º ±0º 15’
Free length of external spring 67.1 65
Free length of internal spring 56.6 55
Clearance of valve stem in removable guide (exhaust) 0.077 to 0.102 0.15
Clearance of valve stem in removable guide (intake) 0.077 to 0.102 0.15

Depression of valve with regard to cylinder head
1.15 to 1.50 1.75
plane
ROCKER ARM
Rocker arm shaft 31.975 to 31.991 31.9
Clearance of rocker arm shaft in removable bushing 0.018 to 0.059 0.1
11
TIGHTENING TORQUES, GAPS AND INSPECTION
WEAR LIMITS
GAPS & LIMITS (mm)
ITEM GAS SFGLD 560

Normal Limit
TIMING GEAR

Intermediate / Front / Back
∅ Camshaft bushings 92
+0 +0
/ 92 +0.057 / 92
+0.110
+0.057 +0.020
End play of camshaft (locked pinion) 0.15 to 0.20 0.30
OIL CIRCUIT
Axial clearance of internal pump gears 0.100 to 0.237
Radial clearance of internal pump gears 0.075 to 0.155
Gap between gear tooth faces 0.3 to 0.5

Diametral clearance of drive shaft in bushing of pump
0.075 to 0.130
body and pump cover
Oil pump safety valve rating 8 bar
Lube oil pressure control valve rating 4.5 bar
Piston coolant pressure control valve rating 3 bar
Relief valve rating because of filter obstruction 6 bar
VALVE TAPPET
∅int. bore of valve tappet guide 14.050 to 14.077
Clearance between bore and tappet 0.006 to 0.044
∅ tappet guide 14.033 to 14.044
Clearance between tappet and intake rocker arm 0.3
Clearance between tappet and exhaust rocker arm 0.8
CYLINDER
Liner inside ∅ (top) 160.000 to 160.025 160.4
Maximum out-of-roundness 0.025 0.2
Upper ∅ of bore (liner housing) 181.50 to 181.54
Lower ∅ of bore (liner housing) 180.00 to 180.04
Protrusion of liner over cylinder block 0.68 to 0.94
CONNECTING ROD
Width of connecting rod big end 52.82 to 52.78
Clearance between piston pin and connecting rod
0.030 to 0.087
bearing insert
Diametral crankpin-to-bearing clearance 0.077 to 0.144
11
WEAR LIMITS
GAPS & LIMITS (mm)
ITEM GAS SFGLD 560

Normal Limit
PISTON - RINGS
Height of piston groove 1 (compression ring)

Height of piston groove 2 (scraper ring) 3.56 to 3.54 3.7
Height of piston groove 3 (oil control ring) 4.04 to 4.02 4.15
Height of compression ring 1
Height of scraper ring 2 3.475 to 3.490 3.4
Height of oil control ring 3 3.975 to 3.990 3.9
Protrusion of the piston over the liner (dwell) -1.0 to –1.8
Clearance of ring 1 in groove 1
End-to-end clearance of compression ring (1) 0.40 to 0.65 1.6
End-to-end clearance of scraper ring (2) 0.80 to 1.05 1.9
End-to-end clearance of oil control ring (3) 0.50 to 0.80 1.7
CRANKSHAFT
Crankpin ∅ 114.991 to 115.013 114.9
Crankpin ∅ 1st repair size 114.491 to 114.513 114.4
Crankpin ∅ 2nd repair size 113.991 to 114.013 113.9

Crankshaft journal ∅ 159.975 to 160.000 159.84
Crankshaft journal ∅ 1st repair size 159.475 to 159.500 159.34
Crankshaft journal ∅ 2nd repair size 158.975 to 159.000 158.84
Diametral gap between journal and bearing 0.120 to 0.204
Axial check ring thickness 5.05 to 5.11 4.85
End play of crankshaft 0.34 to 0.586 0.8
VALVES
Head angle, intake / exhaust valves 141º ±0º15’
Milling angle, intake / exhaust valve seats 140º ±0º15’
Free length of external spring 67.1 65
Free length of internal spring 56.6 55
Clearance of valve stem in removable guide (exhaust) 0.077 to 0.102 0.15
Clearance of valve stem in removable guide (intake) 0.077 to 0.102 0.15

Depression of valve with regard to cylinder head
1.15 to 1.50 1.75
plane
ROCKER ARM
Rocker arm shaft 31.975 to 31.991 31.9
Clearance of rocker arm shaft in removable bushing 0.018 to 0.059 0.10
11
INSPECTION HYDRAULIC TESTS
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS BLOCK & LINERS
LIST OF COMPONENTS
NUMBER DESCRIPTION F360 F480
1 Block, hydraulic test 1 1
2 Cylinder liner ready 12 16
3 Set of cylinder liner gaskets 12 16
4 O-ring, cylinder liner, upper and middle 24 32
5 O-ring, cylinder liner, lower 12 16
6 O-ring gasket, cylinder liner, square 12 16
TOOLS
Liners assembly tool Ref. 16.78.730
Hydro test set-up tool Ref. 16.75.228
12
HYDRAULIC TESTS INSPECTION
BLOCK & LINERS
1. VISUAL INSPECTION
1.1. Free of Oxidation.

1.2. Free of Burrs.
1.3. Free of Blows.
1.4. Free of Dirt.

2. PREPARE THE LINERS
2.1. Install O-rings with animal grease in the liner slots.
3. INTRODUCING LINERS IN THE ENGINE BLOCK
3.1. Introduce all the liners in the engine block.
3.2. With the aid of the tool: Ref.: 16.75.228, introduce the liners in the engine block
making sure they set well.
4. DO THE HYDRAULIC TEST
4.1. Install the covers with the filling and drain valves on the water inlets to the engine block.
12
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS BLOCK & LINERS
LIST OF COMPONENTS
1 Block, hydraulic test 1 1
2 Cylinder liner ready 12 16
3 Set of cylinder liner gaskets 12 16
4 O-ring, cylinder liner, upper and middle 24 32
5 O-ring, cylinder liner, lower 12 16
6 O-ring gasket, cylinder liner, square 12 16
TOOLS
Liners assembly tool Ref. 16.78.730
Hydro test set-up tool Ref. 16.75.228
12
BLOCK & LINERS
4.2. Mount the covers on the cylinder head face of the engine block.

4.3. Allow water to flow in through the cover of cylinder 1 at a maximum pressure of 6 bar
and drain the circuit through the last cylinder.
MANOMETER
4.4. Keep water flowing for some time, making sure there occurs no pressure losses
(recorded by the manometer mounted on the block) and visually check for no water
leakage in the engine block.
4.5. Drain the circuit from all water and remove the items used for making the test.
4.6. Dry the components and apply rust-preventor.
12
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS EXHAUST MANIFOLD
LIST OF COMPONENTS
1 Exhaust manifold 1 1
2 Covers on Water Inlet from Cylinder Head 4 4
3 Cover with filling plug 1 1
4 Cover with vent valve 1 1
5 Screws for Gas Inlets to Manifold 6 8
6 Drain cock 1 1
TOOLS
Special manifold lifting tool for hydraulic testing.
Hydro test set-up tool.
12
EXHAUST MANIFOLD
1. Set the lifting tool to the manifold and place the manifold on a skid with a crane.
2. Close each one of the gas entry to the manifold with a screw and washer, so that all air
can be drained out of the manifold.

3. Place covers with gaskets over the water inlets. Set the vent valve at the highest
elevation on the manifold and the water drain cock on the lower cover.
4. Turn the manifold and set the covers on each end of the manifold. Mount the water
filling plug on the cover for the lower part of the manifold.
5. Install the water supply hose and fill the manifold with pressurized water (at 7Kg) with
a water pump.
Purge the entire manifold, with the previously mounted screws, until water comes out
(start from the lower part of the manifold). Take care that no water enters the zone of
the manifold in which air will pass (so that it is not mistaken for a water leak later).
12
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS EXHAUST MANIFOLD
LIST OF COMPONENTS
1 Exhaust manifold 1 1
2 Covers on Water Inlet from Cylinder Head 4 4
3 Cover with filling plug 1 1
4 Cover with vent valve 1 1
5 Screws for Gas Inlets to Manifold 6 8
6 Drain cock 1 1
TOOLS
Special manifold lifting tool for hydraulic testing.
12
EXHAUST MANIFOLD

6. Watch the gas orifices and the manifold unions for possible leaks (during 5 minutes).
7. Once it has been confirmed that the manifold does not leak through any part, remove
the supply hose and empty the manifold. Open the screws and vent valve for a quicker
drainage.
8. Finally, remove the covers and screws.
Paint and stamp the letter B (good) on each manifold section (in the part that will not face
the engine block) and place the manifold on a pallet.
12
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS HEAT EXCHANGER
LIST OF COMPONENTS
1 HEAT EXCHANGER 1 1
2 INLET WATER VALVE 1 1
3 VENT VALVE & PRESSURE GAUGE SET 1 1
4 PRESSURE PLUG 1 1
5 COVER 1 1
TOOLS
Heat Exchanger Lifting Tool Ref. 16.75.247
12
HEAT EXCHANGER
1. Secure the heat exchanger with tool (ref. 16.75.247) and lift it with a crane.
2. Set it on a mounting.
3. The hydraulic test of the heat exchanger is performed by checking the water tightness
of the fresh water system.

4. For this purpose, set the hydraulic test tools consisting of an inlet water valve (2), a
drain cock and a pressure gauge (3) for the outlet of the heat exchanger water system.
5. Set an inlet water valve (2) at the fresh water system inlet (connecting flange to the
thermostat housing).
6. Place the cover with the drain cock and pressure gauge at the outlet of the heat
exchanger water system (lower part of the heat exchanger).
7. In the upper part of the heat exchanger, if it is new, set a cover (4) in such a way that
we will introduce a gasket thru the orifice and with a stud, an O-ring and the top upper
cover, we will close the orifice by the tightening with a nut and its copper gasket.
NOTE
In the case that the heat exchanger has been dismantled from an operational engine, for
the performance of the test the pressure plug mounted (5) will be left in place.
8. Fill with pressurized water at (6Kg) with an hydraulic test pump thru the valve, checking
that the pressure is constant during a time interval.
9. Leaks in the fresh water system (thru the bundle of the heat exchanger) will result in a
pressure loss in the system that will be detected in the pressure gauge readings.
10. After a reasonable amount of time, observe using a flashlight the joints of the heat
exchanger (lateral covers) and perform a general review of plugs, drills and cover. Once
it has been checked that the heat exchanger does not loose water thru any place,
reduce the water pressure.
Allowable leakage 0.
11. Empty the heat exchanger, by opening the drain plug at the lower part of heat
exchanger.
NOTE
The water in the hydraulic test shall have lime-inhibiting and non-rusting components..
12
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS INTERCOOLER
LIST OF COMPONENTS
1 INTERCOOLER, Hydraulic Test 1 1
2 WATER MANIFOLD OF THE INTERCOOLER 1 1
3 FILL IN VALVE 1 1
4 MANOMETER 1 1
5 DRAIN VALVE 1 1
TOOLS
Intercooler lifting tool.
Hydraulic test set-up tools.
12
INTERCOOLER
1. Secure the intercooler (air cooler) with the lifting tool.
2. Lift with hoist and place it on a skid.
3. The hydro test of the air cooler consists of testing the water tightness of the water
cooling system.

4. Set a filling valve (3) at the water inlet to the water manifold (2) of the intercooler.
5. Set a drain valve (5) and a manometer (4) on the outlet of the air cooler water manifold.
6. Fill with pressurized water (6kg) the water cooling side. Leaks in the system will be
detected in the form of a pressure loss that will be checked by the manometer installed
at the water circuit outlet.
7. Maintain the water pressure during a certain time while all the unions of the intercooler
(lateral covers, plugs, etc.) are checked. Verify the air circuit of the intercooler. Water
leaks also will be shown by the presence of water in the air cooler side (outside the
intercooler bundle).
0 loss of pressure allowed
8. Once the water tightness of the system has been verified, remove the water pressure
and proceed to empty the air cooler using the drain valve installed on the outlet of the
intercooler water manifold.
NOTE
The water in the hydraulic test shall have lime-inhibiting and non-rusting components.
12
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS OIL COOLER
LIST OF COMPONENTS
1 Oi Cooler, hydraulic test 1 1
2 Air inlet 1 1
3 Air outlet 1 1
TOOLS
Hydro test set-up tools.
12
OIL COOLER
1. The hydraulic test of the oil cooler is performed by verifying the water tightness of the
oil cooler system.
2. Through the introduction of pressurized air in the oil circulation system and submerging
the cooler in a water bath, we can check if there are any leaks in the oil system.
3. Set the air inlet pipe at the cooler oil inlet. Set the air outlet pipe at the outlet of the oil

cooler.
4. Secure with tool and lift with crane. Submerge the oil cooler in a tub with water.
5. Pressurize with air at (6 Kg) the oil system in the cooler. Leaks in the cooler oil system
will be noticed by the appearance of air bubbles in the bath where the cooler is
submerged.
6. The air pressure will be controlled through the pressure gauge of the compressed air
system.
7. After a period of time and after verifying the water tightness of the system, remove the
air pressure, remove the oil cooler from the tub. Remove the inlet and outlet air cooler
hoses and carefully dry the oil cooler..
NOTE
The water in the hydraulic test shall have lime-inhibiting and non-rusting components.
12
ASSEMBLY
MONTAJE
ASSEMBLY
SF/FG IN “V”
Ref.: 19.09.531
Edition: May 2003

ASSEMBLY INDEX
0. GENERAL COMMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(9 PAGES)

1. TRANSFER OF ENGINE BLOCK TO FIXTURE . . . . . . . . . . . . . . . .(2 PAGES)
2. CAMSHAFT BUSHINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(4 PAGES)
3. CRANKSHAFT CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
4. PREPARATION OF CAPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
5. CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
6. CAPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
7. BACK GEAR TRAIN DRIVE GEAR . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
8. FRONT CAP, INTERMEDIATE PUMP GEAR ASSEMBLY . . . . . . . . . .(8 PAGES)
9. DRIVE GEAR PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)

10. PISTON PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(4 PAGES)
11. CONNECTING ROD PREPARATION . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
12. PISTON CONNECTING ROD UNIT . . . . . . . . . . . . . . . . . . . . . . . .(4 PAGES)
13. JETS ASSEMBLY AND VERIFICATION . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
14. OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
15. BEAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
16. OIL PIPING INSIDE THE OIL PAN . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
17. OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
18. OIL PAN COVER AND OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
19. OIL PRE-HEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
20. CONNECTING RODS INSPECTION COVERS . . . . . . . . . . . . . . . . .(2 PAGES)
21. CRANKCASE BREATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
22. THERMOSTAT AND OIL REGULATION HOUSING . . . . . . . . . . . . . .(2 PAGES)
23. FILTERS SUPPORT AND CONNECTING PIPE
TO THERMOSTAT VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
24. ROCKER ARM SHAFT AND AUXILIARY ROCKER ARM . . . . . . . . . .(2 PAGES)
25. CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
26. AUXILIARY ROCKER ARM INSPECTION COVERS . . . . . . . . . . . . .(2 PAGES)
27. FRONT INTERMEDIATE COVER . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
28. GEAR FOR PUMPS DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . .(4 PAGES)
29. FRONT COVER WITH SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
30. FRONT FLANGE (HYDRAULIC) . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
31. DAMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
32. WATER PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
33. WATER INLET TO BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
34. RAW WATER PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
35. INTERMEDIATE COVER ON BACK GEAR TRAIN HOUSING . . . . . . . .(2 PAGES)
36. CAMSHAFT THRUST DISKS . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
37. DISTRIBUTION MIDDLE GEAR . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
38. CAMSHAFT GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
39. REGULATOR GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
40. FLYWHEEL HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
41. REAR SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
42. BACK FLANGE AND FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
43. TIMING INDICATOR COVER AND FLYWHEEL MARKING . . . . . . . . .(2 PAGES)
44. FRONT LIFTING BACKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
45. EXTERNAL OIL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
46. OIL DISTRIBUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
47. CYLINDER HEAD STUDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
48. CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
49. PUSH RODS, PUSHER SET AND ROCKER ARMS . . . . . . . . . . . . . .(2 PAGES)
50. ADJUSTING ROCKER ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
51. SPARK PLUG PROTECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
52. ROCKER ARM COVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
53. SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
54. EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
55. THERMOSTAT HOUSING AND CONNECTION TO WATER PUMP . . . . (6 PAGES)
56. HEAT EXCHANGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
57. INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
INDEX ASSEMBLY
58. INTAKE AIR CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .(4 PAGES)

59. AIR COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
60. BUTTERFLY VALVE AND CONNECTION TO COOLER . . . . . . . . . . .(4 PAGES)
61. WATER PIPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(6 PAGES)
62. TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
63. TURBO OIL INLET AND OUTLET PIPES . . . . . . . . . . . . . . . . . . . .(2 PAGES)
64. AIR GALLERY BETWEEN COOLER AND TURBOS . . . . . . . . . . . . .(2 PAGES)
65. ELBOWS TO TURBO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
66. CARBURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(4 PAGES)

67. AIR FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
68. 6-GAUGE CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
69. TEMPERATURE AND PRESSURE SWITCHES . . . . . . . . . . . . . . . .(4 PAGES)
70. REGULATOR - ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
71. REGULATOR LUBRICATING PIPES . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
72. REGULATOR - BUTTERFLY OPERATION LINKAGE . . . . . . . . . . . . .(2 PAGES)
73. PRE-LUBE AND OIL DRAINING SYSTEM . . . . . . . . . . . . . . . . . . .(2 PAGES)
74. OIL PAN LEVEL ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(4 PAGES)
75. ELECTRONIC IGNITION MODULE AND PICKUPS . . . . . . . . . . . . . .(2 PAGES)
76. HIGH VOLTAGE COILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
SUB-UNITS-ASSEMBLY
1. AUXILIARY ROCKER ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
2. AUXILIARY ROCKER ARM SHAFT . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
3. CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(5 PAGES)
4. ROCKER ARM SETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
5. VALVE PUSH RODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
6. CRANKCASE BREATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
7. REAR SEAL HOLDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
8. FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
9. CENTRIFUGAL FRESH WATER PUMP . . . . . . . . . . . . . . . . . . . . .(7 PAGES)
10. CENTRIFUGAL RAW WATER PUMP . . . . . . . . . . . . . . . . . . . . . . .(6 PAGES)
11. THERMOSTAT HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
12. HEAT EXCHANGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(4 PAGES)
13. SUCTION BELL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
14. OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(4 PAGES)
15. OVERPRESSURE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
16. THERMOSTATIC AND OIL REGULATING VALVE . . . . . . . . . . . . . . .(4 PAGES)
17. OIL PAN COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
18. FILTER SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
19. OIL LEVEL DIPSTICK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
20. WATER-COOLED EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . .(2 PAGES)
21. AIR COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
22. TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(6 PAGES)
23. HYDRAULIC REGULATOR HOUSING . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
24. 24/220V ELECTRIC DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
25. 6-GAUGE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
26. JETS CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
27. BLOCK WITH LINERS AND HYDRAULIC TEST . . . . . . . . . . . . . . . .(4 PAGES)
28. B UTTERFLY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
ASSEMBLY GENERAL COMMENTS
PROCEDURE FOR GENERAL CLEANING
Procedure
The procedure for cleaning, inspection, repair and installation of different parts, units
and sub-units that make up the engine, will be the same for the great majority of them.
Any installation, cleaning, inspection, repair or procedure that is particular to a given part
or component, is dealt with in the appropriate paragraph of this article.
Cleaning Instructions
The maintenance staff has to completely understand the importance of cleaning.

Great care and conscious work are necessary in every cleaning operation. The presence
of dirt or unknown material is a constant threat against the satisfactory running and
maintenance of the engine.
The following general instructions have to be applied in all cleaning operations:
· CLEAN ALL PARTS BEFORE INSPECTION, AFTER REPAIR AND BEFORE

INSTALLATION
NOTE
· YOUR HANDS CANNOT HAVE ANY OIL THAT MIGHT PICK UP DUST OR OTHER
IMPURITIES.
· AFTER CLEANING, ALL PARTS HAVE TO BE COVERED OR WRAPPED TO
PROTECT THEM FROM DUST AND DIRT.
Castings
· Remove the dirt and other carbon deposits from the castings, using a hard brush.
· Clean the inside and outside surfaces of the castings, in all the areas subjected to
oil and grease, with moisture-free cleaning solvent or an oil-based solvent for paint.
· Blow all the threaded holes with air pressure.
· After cleaning, dry the castings with compressed air.
THE PARTICLES PULLED BY THE AIR PRESSURE ARE DANGEROUS.

CAREFUL
MAKE SURE THE AIR CURRENT IS IN THE OPPOSITE DIRECTION OF THE

OPERATOR AND NOT IN THE DIRECTION OF OTHERS.
USE APPROPRIATE SAFETY PROTECTION (GOGGLES, A MASK, GLOVES …).
GENERAL COMMENTS ASSEMBLY
Oil conduits
Particular attention has to be given to all the oil conduits in castings and all the
machined parts. All the oil conduits have to be free of obstructions, meaning the following
will be kept in mind:
· Clean the conduits with wires, to break up the carbon deposits and dirt.

· Clean the pipes with moisture-free cleaning solvent or with mineral solvent like those
used for paint.
· After cleaning the conduits, dry them with compressed air.
(SEE CAREFUL THE PREVIOUS PAGE)
Oil seals, electric cables and flexible piping
Clean the seals, cables and flexible piping, with water and soap, air-drying them.
DO NOT LEAVE THE SOLVENT IN CONTACT FOR A LONG TIME WITH THE
CAREFUL
SEALS, CABLES AND FLEXIBLE PIPING. THESE CLEANING AGENTS ARE THE
REASON THAT THE LEATHER, RUBBER AND SYNTHETIC MATERIAL WHEN DRY
ROT AND LOOSE THE FLEXIBILITY, MAKING THEM USELESS.
Ball and Needle Bearings
Bearings require particular care for their cleaning and lubrication. After removing dirt,
oil or grease from their surface, bearings, with the exception of those that are sealed
(permanently greased), have to be inserted in a warm oil solution (around 140º F) in order
to release the solidified oil and grease residuals. After cleaning, the bearings must be
covered in a lubricant film and wrapped in a greased or waxed paper, until inspection and
installation
DO NOT SUBMERGE THE "SEALED" TYPE BALL BEARINGS IN CLEANING

CAREFUL
SOLVENT OR IN WARM OIL SOLUTION. THE CONTACT WITH A SOLVENT OR

ANY CLEANING COMPONENT WILL DESTROY THE LUBRICANT THAT WAS
INSERTED AT THE TIME OF MANUFACTURE.
· The cleaning of sealed ball bearings will only be done on the outside surfaces, with a
clean cloth soaked in moisture-free cleaning solvent.
Air pressure must never be used in the cleaning or in the drying of ball or needle bearings.
Air, because of the abrasives it pulls could cause damage in the bearing tracks.
INSPECTION
Generalities
Engines are built with complete precision and repair and rebuilt standards for parts
have been set with extremely rigorous tolerances. The following general instructions must
be applied to all inspection processes.
· Use modern inspection equipment, to inspect different components in which cracks or

other defects cannot be discovered through sight alone.
· It is necessary to be careful in all inspection stages. Inspect components, following the
instructions contained in the following paragraphs.
The majority of engine parts and components can be repaired as indicated below.
After repair, clean all the parts completely to prevent metal shavings, coming from the
repair operations or the abrasive tools used, get into the engine parts.
Casting
Inspect all the iron-containing parts (cast iron, steel, etc.), looking for possible cracks
with the magnaflux equipment. Inspect all the non iron-containing parts (aluminum),
searching for cracks with a magnifying lens and a strong light.
Particularly verify zones near studs, piping plugs, thread or helicoil insets and in the
corners or in threaded holes. Inspect the machined surfaces in casting, to see if there are
any scratches, burrs or metallic particles, sticking up. Mark the defective areas to be
repaired.
Verify, with a ruler, if there is any bending on the adjustment flat surfaces.
Inspect if there are any different color tones in adjustments surfaces that indicate oil
leaks or lack of sealing.
Inspect the piping opening and their corresponding plugs, just in case there are
damaged or coated threads.
Verify if all the castings are in good condition and if not replace them.
Replace the castings that are cracked.
Replace all the castings that do not conform to the tolerances set forth.
Replace all the castings in which there are burrs or scratches on the machined
surfaces making their installation or smooth operation difficult. Repair the minor defects
on the machined surfaces with a fine flat file and emery cloth, wet with moisture-free
cleaning solvent or mineral solvent for paint.
Replace all castings that indicate significant bending in their faces.

Repair sides of parts indicating minor bending in their faces, wiping them repeatedly
with an emery cloth that is kept tight on a flat surface.
Repair the damaged threads, refacing them with screw plate or used screw tap.
CONDUITS PLUG THREADS IN CASTINGS HAVE TO BE IN GOOD CONDITION

NOTE
TO PREVENT LEAKS.
Ball and Needle Bearings
Make certain all bearings conform to repair and reconstruction standards.
Replace all damaged or pitted bearings.
Replace all bearings not conforming to the tolerances specified in the repair and
reconstruction standards.
Studs
Inspect all installation studs, to see if any is loose or bent, has damaged threads or
show signs of stretching.
Replace all bent, loose studs or those that show obvious stretch indications. Repair
minor thread defects.
Replace all studs that have damaged threads. Remove and replace the studs, as
indicated in the two following paragraphs.
a- Removal
By using a puller, unscrew the studs by slowly turning them to prevent reheating and
jamming. When the studs are broken and the stem is not long enough to use the puller,
drill the stud in the center of its upper end and proceed with its removal, by using the set
of taps for that purpose.
Short studs can be removed by welding a hexagonal rod or nut on its end and removing
it with the appropriate wrench.
CAREFUL
PREVENT DAMAGING THE CAST PART WHEN THE SOLDERING METHOD OF

THE STUD IS USED
b- Replacement
When the threads of the parts are in good condition, use a tap screw to clean the
original thread.
When the threads are damaged or coated, or when the stud is removed because it
is loose, replace it with another one that has the next higher size diameter.
The chart shows the available studs with oversize. Markings on the end of the thread
with the larger diameter of the stud indicate if the diameter is the original one or with
oversize. Whenever replacing a stud on an aluminum casting, use the immediate higher
size.
WHEN THE THREAD SIZE ON THE ENDS OF THE STUD IS DIFFERENT, THE END
NOTE
WITH THE GREATER SIZE HAS TO BE SCREWED INTO THE CAST ALUMINUM
PART.
Apply a small amount of non-stick paste of mica base, before installing the stud.
Slowly insert the stud in the threaded hole, to prevent heating it up.
When the threaded holes in the cast parts do not allow oversized studs, a helicoil
insert can be placed; in this situation, use a stud of the original size.
Pinions
NO LIMITS ARE SET FORTH FOR THE WEAR AND TEAR OF PINION TEETH. TO
NOTE
DETERMINE THE NEED FOR THEIR REPLACEMENT, CHECK IF THE

INSTALLATION CLEARANCE EXCEEDS WHAT IS ESTABLISHED.
Inspect all the pinions, using the magaflux equipment, just in case there are any cracks.
When there is no magnaflux equipment available, use a magnifying lens and strong light.
Inspect all the pinion teeth, looking for wear and tear, sharp edges, burrs.
Inspect the pinion bushing grooves, looking for damage, wear and tear and reviewing
their adjustment to the coupling shaft. Pinion grooves have to adjust on the shaft, without
clearance or jamming.
Replace all pinions in which cracks are observed.
Replace pinions that do not conform to the installation clearances.
Replace pinion that have worn, scratched or pitted teeth.
Remove teeth burrs with emery cloth soaked in moisture-free cleaning solvent or with
mineral solvent for paint.

Replace the pinions that have the grooves or key-slot damaged to the point it could
prevent its installation or its operation. Replace all the pinions in which the grooves or key
slot does not match with their corresponding pair.
Remove any burrs, scratches or pitting of the grooved surface of the pinion, with a
special stone with oil or emery cloth, soaked in moisture-free cleaning solvent or to
mineral solvent for paint.
Shafts
Inspect all shafts, looking for cracks, using magnaflux equipment. When this
equipment is not available, use a magnifying lens and a strong light.
Inspect all the shafts, looking for scratches, burrs, raised metallic nicks or particles.
Inspect the grooves of the shafts, looking for damage, defects and observing the
conformity with the pinion grooves into which it is coupled. Matching between the shaft
and pinion grooves has to be done without clearance or jamming.
Make sure all the shafts are in good condition and when they are not, replace them.
Replace all cracked, bent or curved shafts.
Replace all the shafts not conforming to the specified tolerance levels.
Replace all shafts that are scratched, burred or pitted to the point of preventing their
installation or operation. Remove the burrs, scratches or pitting that are minor, with an
emery cloth soaked in moisture-free cleaning solvent or with mineral solvent for paint.
Replace all the shafts that have the grooves, slots or key holes, as appropriate, damaged
to the point of preventing their installation or operation. Replace all the shafts in which the
grooves or key-hole does not match with its coupling pair. Remove the scratches, burrs
and pitting that is less serious, from the grooves or the key holes, with an emery cloth
soaked in moisture-free cleaning solvent or with mineral solvent for paint.
Friction Bearings (for bushings, locators, etc.)
Make sure all the friction bearings comply with the safety of their respective coupling
parts, and research possible symptoms of heating, observing the different shades of red
of the bearing surfaces.
Inspect the different types of friction bearings, looking for wear and tear, burrs, bites
and possible oval shapes.
Check to see if there is dirt in the holes and lubricating slots of the different types of
friction bearings. The holes and slots have to be clean and with no defects, to make sure
of appropriate lubrication. Check to see if the axial friction faces of the friction bearings
were damaged or worn out. Wear can be determined by installing the set and verifying
the longitudinal clearance with some feeler gauges inserted between the thrust faces.
Verify all the friction bearings conform to the repair and reconstruction standards.
Whenever any type of friction bearing is damaged or worn beyond its tolerance limits,
the parts associated with it have to also be replaced in most cases. In the following
paragraphs the disassembly and the installation are specified whenever replacement of
any kind of friction bearing or repair on the part on which they are seated might be
required.
a- Disassembly
Remove the friction bearings, pressuring toward the outside with the adapter piece
or with an appropriate special tool. Drill the bearing retainer pin when this procedure is
used to secure them in the castings or on the retainer boxes.
b- Installation
Align the bearing on the cast part or on the retaining housing. Insert it by pressing
with an adapter piece or with an appropriate special tool.
Check the position of the bearing to make sure the greased drill holes are not
covered.
Clean the parts before their assembly or installation.
Oil Seals
Oil seals, covered in a metallic casing, are parts that last long and they must not be
replaced if the inspection indicates that the retainer is in good condition.
Make sure the oil retainer sealing edge that seats on the rotating part is not
damaged.

Inspect the retainer material to verify its softness and flexibility.
Replace the oil retainer whenever the sealing edge becomes damaged or its material
becomes hard or brittle.
a- Disassembly
Put pressure on the damaged oil retainer and push it out of the cast part or the
adapter, being careful not to damage the cast part or the adapter part.
b- Repair
When the oil retainer seat has burrs or is damaged to the degree that is impossible
to have an airtight seal, replace the cast part or adapter piece.
Eliminate minor pitting, burrs and scratches in the housing of the oil retainer on the
cast parts or on the adapter piece, with an emery cloth soaked in moisture-free cleaning
solvent or with mineral solvent for paint.
c- Installation
Install a new retainer in the housing of the cast part or on the adapter piece, by using
the tool for its installation.
Threaded insets and Heli-Coil Threads
In order to allow greater force on the studs and screws that are secured on the cast
aluminum, it is a common practice to install inserts from a stronger metal, where the studs
and screws are installed. The heli-coil and threaded inserts are designed for this purpose.
The heli-coil inserts are spiral-shaped cylindrical springs, made out of steel, right-handed,
with the threaded section in the shape of a filet, that screws both on the inside portion as
well as the outside part of it. The end of the thread, in the lower part, diametrically crosses
the spring; thus allowing, through a special tool, fitting on the end of the thread insert, to
screw it into the cast section. The threaded inserts are screwed inserts on the lower outer
part, with the upper section of the face being star-shaped; this allows securing it on the
casting.
One type of heli-coil thread has the central turn shaped as an hexagon; this provides a
self-blocking effect on the stud and screw, when the insert is screwed in. Inspect all the
heli-coil threads and the threaded inserts, making sure that they are securely set on the
cast portion and that there are no damaged threads.
Replace all the heli-coil inserts and the threaded inserts that cannot be snugly
adjusted on the cast part or whenever the screw threads in the casting are damaged or
worn.
Whenever the threaded holes in the cast parts do not accept oversize studs it is
possible to insert heli-coil inserts; in this situation, use a stud with its original size.
DO NOT EVER USE HELI-COIL INSERTS IN THE THREADED HOLES OF: STUDS
CAREFUL
CLAMPING CYLINDER HEADS, CYLINDER ENGINE BLOCK CAPS, ALL OF THE

CRANKSHAFT, BALANCE WEIGHTS, FLYWHEEL HOLDER, VIBRATION DAMPER,
AND FRONT COMPANION FLANGE.
ASSEMBLY TRANSFER OF THE ENGINE
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS BLOCK TO THE FIXTURE
LIST OF COMPONENTS
TOOLS
Rotating tool - assembly phase 1, FV Ref.16.75.213
TRANSFER OF THE ENGINE ASSEMBLY
BLOCK TO THE FIXTURE
1. Set lifting brackets on engine block.

2. Set tools (Ref.:16.75.213) on engine block to secure it to the fixture.
3. Set engine block on fixture with help of a crane.
4. Secure tools with flanges on the fixture.
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY CAMSHAFT BUSHINGS
LIST OF COMPONENTS
NUMBER DESCRIPTION SF/FG...360 SF/FG...480
1 BLOCK, HYDRAULIC TEST 1 1
2 FRONT BUSHING OF CAMSHAFT 1 1
3 BUSHING OF CAMSHAFT 13 17
4 BACK BUSHING OF CAMSHAFT 2 2
TOOLS
Camshaft bushing assembly tool: Ref. 16.75.116
Go gauge: Ref. 92.32.199
Go no go gauge: Ref. 92.32.692
CAMSHAFT BUSHINGS ASSEMBLY
1. Place the engine block in the crankshaft assembly position (cylinder head seat facing
downward).
2. Rotate block 90° (counterclockwise when looking at the flywheel) so as to be able to

introduce the camshaft bushings from the right-hand side of the engine.

- Set the bushings guide (Ref.:16.75.116).
- Insert the shaft (Ref.: 16.75.116) while the bushings are alternated.
- Place the shaft grooves even with the hole.
- When assembling the bushings, turn the bushing connection up and rotate two
holes upwards.
- Set the half moon pushing tool into the shaft ( Ref.:16.75.116) and pressurize the
piston.
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY CAMSHAFT BUSHINGS
LIST OF COMPONENTS
2 FRONT BUSHING OF CAMSHAFT 1 1
3 BUSHING OF CAMSHAFT 13 17
4 BACK BUSHING OF CAMSHAFT 2 2
TOOLS
Camshaft bushing assembly tool: Ref. 16.75.116
Go gauge: Ref. 92.32.199
Go no go gauge: Ref. 92.32.692
CAMSHAFT BUSHINGS ASSEMBLY
- The bushing oil hole has to be even with the engine block hole.
- The smallest bushing is put in last removing the bearing guide, at the end closer
to the flywheel.

DANGER
Positioning the bushing for a match between the oil hole and the hole in the block is a
critical operation that must be carried out very carefully. In the remotest housing, install
1+1 bushings, making sure their position will not obstruct the oil hole.
3. Inspect the bushings with the go gauge (Ref.: 92.32.199) and the no go gauge
(ref.: 92.32.692).
4. Rotate the engine block 180°.
5. Introduce 8 camshaft bushings (SF/FG...480) or 6 camshaft bushings (SF/FG...360)
and 1 narrow bushing with tool (Ref.: 16.75.116).
- Set the bushings guide (Ref.:16.75.116).

- Insert the shaft (Ref.: 16.75.116) while the bushings are alternated.
- Place the shaft grooves even with the hole.
- When assembling the bushings, turn the bushing connection up and rotate two
holes upwards.
- Set the half moon pushing tool into the shaft ( Ref.:16.75.116) and pressurize the
piston.
- The bushing oil hole has to be even with the engine block hole.
- The smallest bushing is put in last removing the bearing guide, at the end closer
to the flywheel.
DANGER
Positioning the bushing for a match between the oil hole and the hole in the block is a
critical operation that must be carried out very carefully. In the remotest housing, install
1+1 bushings, making sure their position will not obstruct the oil hole.
6. Inspect the bushings with the go gauge (Ref.: 92.32.199) and the no go gauge
(ref.: 92.32.692).
7. Assemble the 2 end bushings, close to the flywheel side, aligning the flange on the
eccentric in the housing in the block.
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY CRANKSHAFT CLEANING
LIST OF COMPONENTS
1 CRANKSHAFT 1 1
2 CRANKSHAFT COUNTERWEIGHT 6 8
3 WASHER 12 16
4 COUNTERWEIGHT FIXING SCREW 12 16
5 SCREW 10 10
TOOLS
CRANKSHAFT CLEANING ASSEMBLY
1. Unpack the crankshaft, place slings and carry it to the washing machine.
2. Clean in a tub with gas-oil. Remove and allow it to drain.

3. Inspect oil holes and crank-pins for burr. Place plugs and clean the crankshaft with a
cloth.
4. Move to the assembly shop. Cover until installed in the engine.
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY PREPARATION OF CAPS
LIST OF COMPONENTS
2 SET OF MAIN HALF-BEARINGS 7 9
3 WASHER 14 18
4 CAP FIXING NUT 14 18
5 STUD 24 32
6 CAP FIXING STUD 14 18
7 BACK CAP 5 7
8 MIDDLE CAP 1 1
9 FRONT CAP 1 1
TOOLS
PREPARATION OF CAPS ASSEMBLY
1. Inspect cap seats and bearing housings for burr or hits. Clean with compressed air
2. Take the caps to the table and remove burrs.
3. Place in the washer together with the studs, nuts and washers. Dry with compressed
air.

4. Mount the jet fixing studs with Loctite 270. Tighten
and remove Loctite residues from base.
5. Set the cap fixing studs, with some oil at the base to
make screwing easier, and tighten to a torque of 10
Kg.m. Remove oil residues from the base.
We recommend that the block is inclined when
screwing the studs, in order to prevent damage to
the cylinder liner if the stud falls.
6. Unpack and clean with absorbent paper 7 half-

bearings for SF/FG...360 engines or 9 half-bearings
for SF/FG480... engines, (those with a groove in
them). Install them in the engine block, making sure
their back is clean and dry. Also check that they do
not protrude excessively from their housing.
7. Unpack and clean with absorbent paper the

remaining half-bearings and install them, verifying
that their back is clean and dry.
DANGER
The absence of abrasive particles is very important during this stage of assembly.
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY CRANKSHAFT
LIST OF COMPONENTS
1 CRANKSHAFT 1 1
2 PLUG 6 8
SET OF AXIAL THRUST BEARINGS FOR
3 2 2
CRANKSHAFT
4 STUDS 14 18
5 SET OF MAIN HALF-BEARINGS 7 9
TOOLS
Crankshaft rotating tool: Ref. 16.75.176
CRANKSHAFT ASSEMBLY
1. Check oil holes, seats and crankshaft journals in the engine block.
2. Rinse, dry and check the crankshaft.
3. Set the threaded plugs in the drilled holes for the oil gallery.
4. Apply abundant motor oil on the crankshaft as well as on the main bearings and the

caps.
5. Carefully set the crankshaft on the engine block. This procedure is preferably done
by two operators.
6. File the thrust bearings (to remove the burrs from the letters so they do not distort the
measurement of the axial clearance).
7. Move the crankshaft forward and backward to set the thrust bearings on the flywheel
side.
DANGER
The faces with oil slots must be oriented towards the crankshaft.
8. Once the crankshaft is in place, rotate it one full turn,

using the tool (Ref.: 16.75.176) and check for any
interference.
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY CAPS
LIST OF COMPONENTS
1 FRONT CAP 1 1
2 CENTRAL CAP 1 1
3 INTERMEDIATE CAP 5 7
4 WASHER 13 17
5 SCREW 13 17
6 WASHER 14 18
7 CAP FIXING NUT 28 36
SET OF AXIAL THRUST BEARINGS FOR
8 2 2
CRANKSHAFT
TOOLS
Extensor: Ref. 16.75.005
CAPS ASSEMBLY
1. Install caps in 2's on the engine block, by using the stretcher (Ref.: 16.75.005).
Secure with washers and previously oiled nuts.

2. Set the axial thrust bearings on the cap on the flywheel side (back part of engine).
3. Tighten the screws.
- Insert and tighten the right lateral fixing screws to 5 Kg.m. in this order:
SF/FG...360 engines: 4-6-2-5-3-7-1; SF/FG...480 engines: 5-7-3-9-1-6-4-8-2.
- Tighten the fixing nuts of each cap to 40 Kg.m. with an electric screwdriver or a
torque wrench, always starting from the right side and following the above order.
- Tighten the screws on the right side to 27 Kg.m. in the above order.
- Insert the left lateral screws, tightening first to 5 Kg.m. and then to 27 Kg.m., in
the order indicated above.
- Tighten the cap fixing nuts to 60 Kg.m. in the indicated order. Apply an
intermediate torque of 80 Kg.m. and finally tighten to 100 Kg.m. Keep the
aforementioned order throughout this tightening process.
8. Check shaft thrust clearance: 0.34 to 0.58 mm.

9. Verify the crankshaft counterweight screw pressure at
3 Kg.m.
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY BACK GEAR TRAIN DRIVE GEAR
LIST OF COMPONENTS
1 BACK GEAR TRAIN DRIVE GEAR 1 1
TOOLS
Tool to fit guide studs in crankshaft: Ref. 16.75.167
BACK GEAR TRAIN DRIVE GEAR ASSEMBLY
1. Introduce the gear guide stud in the crankshaft's asymmetrical hole, with tool
(Ref.: 16.75.167).
2. Clean and heat the gear on a grill. Mount on the crankshaft, with letter "A" toward the
outside.
ASSEMBLY FRONT CAP, INTERMEDIATE
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS PUMP GEAR ASSEMBLY
LIST OF COMPONENTS
1 SCREW 3 3
2 AXIAL THRUST WASHER 1 1
3 BEARING SPACER 1 1
4 INTERMEDIATE PUMP GEAR 1 1
5 GEAR SHAFT 1 1
6 SCREW 3 3
7 BEARING 2 2
8 ADJUSTING WASHER 3/6 3/6
9 SCREW 3 3
12 INTERM. GEAR, AUX. WATER CIRC. PUMP 1 1
13 GEAR SHAFT 1 1
14 SCREW 3 3
15 BEARING 2 2
TOOLS
Tool to fit bearing runner in middle gear: Ref. 16.75.177.
FRONT CAP, INTERMEDIATE ASSEMBLY
PUMP GEAR ASSEMBLY
a.) Main circuit with mechanical pump
1. Set the gear shaft on the cap, securing it with 3 screws with Loctite 242 at 8 Kg.m.

2. Heat the conical bearing body and mount it on the shaft (so as to be able to mount
the outer runner).
DANGER
Do not mix bearing runners and bodies.
3. Set bearing spacer and adjusting shims.
4. In the middle gear, place the bearing outer runners, using the tool Ref.: 16.75.177.
5. Set the gear on the shaft, supported on

the first bearing.
6. Heat a second bearing and set it on the

shaft.
7. Set the axial thrust washer, securing it

with 3 screws with Loctite 270 and
tightened at 4 Kg.m.
LIST OF COMPONENTS
1 SCREW 3 3
5 GEAR SHAFT 1 1
6 SCREW 3 3
7 BEARING 2 2
9 SCREW 3 3
13 GEAR SHAFT 1 1
14 SCREW 3 3
15 BEARING 2 2
TOOLS
PUMP GEAR ASSEMBLY
8. Check axial clearance of the gear with a dial gauge: 0.07 to 0.11 mm. This gear
must be installed, even when there is no main circuit water pump.

b.) With mechanical raw water pump
1. Set the gear shaft on the cap, securing it with 3 screws with Loctite 242 at 5 Kg.m.
2. Heat the conical bearing body to 100 º (max. 120º) and mount it on the shaft (so
as to be able to mount the outer runner).
DANGER
LIST OF COMPONENTS
1 SCREW 3 3
5 GEAR SHAFT 1 1
6 SCREW 3 3
7 BEARING 2 2
9 SCREW 3 3
13 GEAR SHAFT 1 1
14 SCREW 3 3
15 BEARING 2 2
TOOLS
PUMP GEAR ASSEMBLY
4. In the middle gear, place the bearing outer runner, using the tool Ref.: 16.75.177.
5. Set the gear on the shaft, supported on the first bearing.
6. Heat a second bearing to 100º (max. 120º) and set it on the shaft.
7. Set the axial thrust washer, securing it with 3 screws with Loctite 270 and tightened

at 4 Kg.m.
8. Check axial clearance of the gear with a dial gauge: 0.06 to 0.10 mm.
c.) No mechanical pump installed
If there is no pump installed, the middle gear for the raw water pump drive will not be
mounted.
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY GEAR FOR PUMP DRIVE
LIST OF COMPONENTS
1 GEAR FOR PUMP DRIVE 1 1
TOOLS
GEAR FOR PUMP DRIVE ASSEMBLY
1. Heat the gear on an electric plate.
2. Set the gear on the front end of the crankshaft, to a stop.
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY PISTON PREPARATION
LIST OF COMPONENTS
1 PISTON 12 16
2 SET OF PISTON RINGS 12 16
TOOLS
Tool to install piston rings on pistons: Ref.16.75.750
10
PISTON PREPARATION ASSEMBLY
1. Unpack, clean and take the pistons to the electric plate with a contact temperature
between 50º C and 75º C.
2. Each one of these pistons will be marked with a number, from 1 to 12 in the
SF/FG...360 engines and from 1 to 16 in the SF/FG...480 engines.
3. Unpack the complete rings and install them on the pistons.

- The spring has one of its ends L-shaped to 90º to be inserted in one of its
windows. In the drawing the correct position of the stretcher spring is indicated
vis-a-vis the ring.
- It is necessary to install all the rings with numbering toward the head of the
piston.
- Introduce the scrapper ring (ring with spring) into the farthest slot from the piston
head with the appropriate tool. (Ref.: 16.75.750).
10
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY PISTON PREPARATION
LIST OF COMPONENTS
1 PISTON 12 16
2 SET OF PISTON RINGS 12 16
TOOLS
Tool to install piston rings on pistons: Ref.16.75.750
10
PISTON PREPARATION ASSEMBLY
- Then insert the compression ring (the black one, which is the one that cleans the
dirt from the explosion), with tool (Ref.:16.75.750).
- To finish, insert the head ring (the one with the silver-plated edge, which is the
one that withstands the impact), with tool (Ref.:16.75.750).
NOTE
In all rings install the mark "TOP" toward the firing face of the piston.

4. Inspect clearance spaces.
10
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY CONNECTING ROD PREPARATION
LIST OF COMPONENTS
1 CONNECTING ROD ASSEMBLY 12 16
2 WRIST PIN END BUSHING 12 16
3 SNAP RING 12 16
4 CONNECTING ROD BEARING 12 16
5 PISTON SHAFT 12 16
6 PIN 24 32
7 CONNECTING ROD SCREW 24 32
8 PISTON 12 18
TOOLS
Tool for safety rings (snap rings): Ref. 16.75.156
11
CONNECTING ROD PREPARATION ASSEMBLY
1. Visual control of the inside of the bushing of the wrist pin end and caps (bumps,
burrs). If it is necessary sand it.
2. Unpack, clean and install set of connecting rod bearings.
3. Mark caps and connecting rods, each one with its corresponding cylinder number.

4. Install half bearings into caps:
- Inspect the bearing housing is clean and dry. Verify the connecting rod and cap
serrated connections are clean and without burrs or bumps.
- Clean the back of the bearing with a cloth, without using dissolvent and avoid
touching the rolling surface as much as possible. Verify there are no marks either
on the back or on the bearing surface.
- Set the half bearings in their connecting rod and cap housing, pressing on the
bearing edges to make sure there is correct contact in all its perimeter.
- Oil the inside of the bearings, the serrated connections, the screw thread and the
seat area of the screw heads abundantly with engine oil.
5. Install the safety ring (snap ring) in the pin hole with the tool (Ref.:16.75.156).
6. Install the connecting rod

in the piston and insert
the pin. Install the second
safety ring (snap ring)
with the tool
(Ref.:16.75.156).
Some pistons have a

symbol showing the piston
NOTE
area that must face toward

the flywheel (back part of
the engine).
11
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY PISTON CONNECTING ROD ASSEMBLY
LIST OF COMPONENTS
2 PIN 24 32
3 PISTON 12 16
TOOLS
Holding Tool: Ref. 74.44.026
Tool for installation of piston on liners: Ref. 16.75.009
12
PISTON CONNECTING ROD ASSEMBLY ASSEMBLY
1. On all units, verify that the number on the machined surface of connecting rod and
cap corresponds to the number on the piston.
2. Rotate the engine block to a horizontal position (auxiliary rocker arms inspection
doors facing up).
3. Move the crankshaft to the position suitable for assembling the first piston, using the

crankshaft rotating tool.
4. Set the holding tool Ref.: 74.44.026 and the piston to liner installation tool
Ref.: 16.75.009 on the piston.
5. Apply abundant oil onto the liner, crank-pin and bearings.
6. Carefully introduce the piston in the liner. At the other end, position the connecting
rod on the crank-pin by hand.
CAREFUL
This is a critical operation, since neither the liner nor the crankshaft may be damaged.
For a safe assembly, the help of a second operator is absolutely indispensable.
7. Place the cap against the connecting rod.
12
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY PISTON CONNECTING ROD ASSEMBLY
LIST OF COMPONENTS
2 PIN 24 32
3 PISTON 12 16
TOOLS
Holding Tool: Ref. 74.44.026
Tool for installation of piston on liners: Ref. 16.75.009
12
PISTON CONNECTING ROD ASSEMBLY ASSEMBLY
CAREFUL
Check for mating number on the two elements (rod and cap).
8. Tighten the connecting rod screws to a torque of 25 Kg.m.

NOTE
Screwing the screws shall be done preferably by hand, to make sure they enter the
connecting rod body without difficulty.
9. Repeat assembly steps 3 to 8 for each one of the pistons.
10. Rotate the engine block 180°, so the auxiliary rocker arm inspection doors for the
other cylinder bank are facing up.
11. Carry out the assembly steps 3 to 8 for each one of the pistons on this cylinder bank.
12. After installing the 2nd connecting rod on each crank-pin, verify the connecting rod
thrust clearance: 0.28 to 0.54 mm.
13. Tighten the screws to the connecting rod big end at 50 Kg.m.
14. Check if the pistons and rings scratch the liners, by rotating the crankshaft a couple
of revolutions.
12
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY JETS
LIST OF COMPONENTS
1 PISTON COOLING JET 12 16
2 NUT 24 32
TOOLS
Crankshaft rotating tool: Ref. 16.75.176
13
JETS ASSEMBLY
1. Set the piston cooling jets, making sure they are clean and unobstructed.
2. Secure each jet with two nuts with Loctite 242 at 3 Kg.m.

3. Rotate the crankshaft, checking the jets do not collide with the crankshaft
counterweight, connecting rod or piston. Use the crankshaft rotating tool
Ref.: 16.75.176.
13
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY OIL PUMP
LIST OF COMPONENTS
1 OIL PUMP 1 1
2 SCREW 4 4
3 WASHER 4 4
TOOLS
Oil pump lifting tool: Ref. 16.75.174
14
OIL PUMP ASSEMBLY
1. Lift the oil pump with the tool Ref.:16.75.174 and clean it with oil and compressed air.
2. Mount oil pump with 2 guiding pins on the engine block; bolt with 4 screws with
Loctite 270 and washers, and torque to 31 Kg.m.

3. Check the clearance in respect of intermediate drive gear with a dial indicator.
Allowable clearance between gears is 0.2 to 0.31 mm, with the oil pan upward.
4. If necessary, lock the pump with adjusting shims.
14
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY BEAMS
LIST OF COMPONENTS
1 SCREW 12 16
2 BEAM 5 7
3 BEAM 1 1
TOOLS
15
BEAMS ASSEMBLY
1. On SF/FG...360 engines: Mount 5 beams in the block, placing the offset beam in
position 2 (starting from the pump side). On SF/FG...480 engines: Mount 7 beams in
the block, placing the offset beam in position 2 (starting from the pump side).

2. Secure each beam with 2 screws with Loctite 242, tightening to a torque of 31 Kg.m.
15
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY OIL PIPING INSIDE THE OIL PAN
LIST OF COMPONENTS
1 OIL PUMP DISCHARGE PIPING 1 1
2 O-RING 2 2
3 O-RING 1 1
4 WASHER 2 2
5 SAFETY VALVE 1 1
6 SCREW 5 5
7 WASHER 2 2
8 SPACER 2 2
9 SAFETY VALVE SUPPORT 1 1
10 SUCTION BELL 1 1
11 OIL SUCTION BELL BRACKET 2 2
12 NUT 4 4
13 NUT 4 4
14 SCREW 4 4
15 O-RING 4 4
16 OIL INLET PIPE 1 1
17 OIL INLET ELBOW TO OIL PAN 1 1
18 SCREW 4 4
TOOLS
16
OIL PIPING INSIDE THE OIL PAN ASSEMBLY
1. Fasten 2 suction bell brackets on 2 beams with washers, bolts with Loctite 270 and
nuts. Bolt the unit in the block, in positions 3 and 5 of the beams (starting from the
pump).
2. Hold the inlet suction pipe in the workbench vice, grease both ends of the tube and
set 2 O-ring gaskets in each end.
3. Introduce the inlet elbow in one end of the oil suction pipe and the suction bell in the

other, tapping with a mallet.
4. Set an O-ring with grease in the oil inlet elbow.
5. Offer the suction bell + pipe + elbow assembly on the supports. Bolt this assembly to
the oil pump with 4 screws with Loctite 242 at 5 Kg.m. Fasten the bell to the supports
with washers and nuts.
6. Assemble the pressure safety valve and bolt it to the oil pump with screws with
Loctite 242 at 6 Kg.m. Secure the rear bracket of the valve to the beam with bolts,
washers and nuts.
7. Clean and dry the oil discharge pipe, put an O-ring with grease in each end.
Introduce the discharge pipe in the safety valve.
8. Set the last beam close to the oil pump and secure it with washers and screws
tightened to a torque of 31 Kg.m.
WARNING
It is very important that all the components are clean before their assembly.
16
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY OIL PAN
LIST OF COMPONENTS
1 OIL PAN 1 1
2 PLUG 1 1
3 OIL PAN DOOR 1 1
4 GASKET FOR OIL PAN DOOR 1 1
5 SCREW 70
6 JUNTA 1 1
7 PLUG 1 1
8 COPPER GASKET 2 2
9 SCREW 2 2
10 PLUG 4? 4?
11 GASKET 4? 4?
12 STUD 10 10
13 NUT 22? 22?
14 STUD 10 10
15 GASKET 1 1
TOOLS
Oil pan lifting tool: Ref. 16.75.171
Oil pan guide screws: Ref. 16.75.169
17
OIL PAN ASSEMBLY
1. File support surface to remove burrs and improve support. Clean with degreaser and
air.
2. Lift the oil pan with the tool Ref.: 16.75.171 and a crane.
3. Apply Loctite 5368 liquid seal to the bottom of the cylinder block.

4. Place oil pan over the block.
- Bolt it to the block with 52 screws at 8 Kg.m.

CAREFUL
Locate oil pan correctly, using two special guide screws Ref.: 16.75.169 in the third hole
on each side.
5. Set the drain plug in the oil pan with Loctite 242 and a copper gasket.
6. Insert 10 studs on which oil pan inspection cover with its gasket will be mounted and
bolted with 10 nuts at 4 Kg.m.
7. Insert 10 studs for the assembly of the oil level indicator cover with Loctite 270.
8. Set 16 studs in oil pan, which will be used later for the assembly of the thermostat
and oil regulation housing.
9. Set 2 plugs with 2 copper gaskets.

DANGER
17
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY OIL PAN COVER AND OIL LEVEL
LIST OF COMPONENTS
1 OIL LEVEL 1 1
2 OIL PAN COVER GASKET 1 1
3 OIL PAN COVER 1 1

4 GASKET 1 1
5 NUT 10 10
TOOLS
18
OIL PAN COVER AND OIL LEVEL ASSEMBLY
1. Rotate block 90º, with oil pan downwards.
2. Set oil pan cover with nuts.

3. Install the provisional oil level.
18
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY OIL PRE-HEATING
LIST OF COMPONENTS
1 NUT 8 8
2 NUT 2 2
3 PRE-HEATING RESISTANCE BOX 2 2
4 CLAMP 2 2
5 BOX FIXING BOLT 8 8
6 WASHER 8 8
7 PRE-HEATING RESISTANCE 2 2
8 BEARING STRIP 4 4
9 SCREW 8 8
10 SCREW 2 2
TOOLS
19
OIL PRE-HEATING ASSEMBLY
1. Bolt 2 boxes to the pre-heater mounting plate with bolts, washers and nuts.
2. Bolt bearing strips to the boxes with bolts, washers and nuts.
3. Secure the pre-heating resistors to the box by means of a clamp, bolt and nut.
4. Set the 2 resistance guards, fixing them to the boxes with screws.

5. Bolt the pre-heater assembly to the oil pan with screws.
19
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY CONNECTING RODS INSPECTION COVERS
LIST OF COMPONENTS
GASKET FOR CONNECTING ROD INSPECTION
1 12 16
COVER
2 CONNECTING ROD INSPECTION COVER 1 1
3 SCREW 110 150
CONNECTING ROD INSPECTION COVER AND
4 1 1
BRACKET
5 SCREW 10 10
6 CONNECTING ROD INSPECTION COVER 7 14
TOOLS
20
CONNECTING RODS INSPECTION COVERS ASSEMBLY
1. Mount the connecting rods inspection covers, each with its gasket and 10 screws.
Tighten to 5 kg.m.

2. Set 1 cover with its gasket and screws at cylinder number 4. Introduce 4 studs in the
cover (for fastening the crankcase breather).
3. Mount the bracket for the filter support on the connecting rods inspection covers, with
a gasket and secure with 10 screws.
4. Mount 1 cover with a threaded hole in it.
20
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY CRANKCASE BREATHER
LIST OF COMPONENTS
1 PIPE -/1 -/1
2 BREATHER SUPPORT COVER 1/2 1/2
3 STUDS 4/8 4/8
4 NUT 4/8 4/8
5 WASHER 4/8 4/8
6 BREATHER OUTLET PIPING 1 1
7 ELBOW 1 1
8 CRANKCASE BREATHER 1/2 1/2
9 COPPER GASKET 2 2
10 HOLLOW SCREW 1 1
11 GASKET 1/2 1/2
12 T-BRANCH -/1 -/1
13 O-RING 2 2
TOOLS
21
CRANKCASE BREATHER ASSEMBLY
1. Set 1 or 2 crankcase breathers with gaskets in the connecting rods inspection cover
with studs, secure with nuts.
2. Assemble an elbow at the lower part of the breather.

3. Assemble pipe to elbow and to oil pan with hollow screws.
21
ASSEMBLY THERMOSTAT AND OIL
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS REGULATION HOUSING
LIST OF COMPONENTS
1 THERMOSTAT AND OIL REGULATION HOUSING 1 1
2 STUD 16 16
3 NUT 16 16
GASKET FOR THERMOSTAT AND OIL
4 1 1
REGULATION HOUSING
TOOLS
Thermostat and oil regulation housing lifting tool: Ref. 16.75.172
22
THERMOSTAT AND OIL ASSEMBLY
REGULATION HOUSING
1. Lift the unit with tool Ref.: 16.75.172 and a crane. Clean by blowing air.

2. Set greased gasket.
3. Place the housing over the oil pan, using the 16 studs already inserted in the oil pan
in a previous operation, and secure with 16 nuts. Tighten to a torque of 5 Kg.m.
4 Remove the lubricating pipe with the tool, before driving the nuts. Then, replace the
lubricating pipe.
5. Set the reducing plug with a copper gasket to the thermostat.

DANGER
22
ASSEMBLY FILTER SUPPORT AND CONNECTING
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS PIPE TO THERMOSTATIC VALVE
LIST OF COMPONENTS
1 SCREW 2 2
2 SCREW 4 4
3 OIL FILTER SUPPORT 1 1

4 O-RING 2 2
5 OIL INLET/OUTLET ELBOW 2 2
6 O-RING 2 2
7 OIL PIPE BETWEEN ELBOWS 1 1
TOOLS
23
FILTER SUPPORT AND CONNECTING ASSEMBLY
PIPE TO THERMOSTATIC VALVE
1. Clean holes in filter support by blowing air.

2. Secure filter support to bracket with 4 nuts at 5 Kg.m.

3. Insert O-rings and apply grease to the ends of the oil inlet and outlet elbows and
assemble them to the oil pipe between filter support and thermostatic valve.
4. Bolt the assembly to the thermostatic valve and to the filter support with screws and
gaskets.
5. Set 3 elbows to the filter support with Loctite 242.
DANGER
It is very important that all the components

are clean before their assembly.
23
ASSEMBLY ROCKER ARM SHAFT AND
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS AUXILIARY ROCKER ARM
LIST OF COMPONENTS
1 AUXILIARY ROCKER ARM 24 32
2 AUXILIARY ROCKER ARM SPACER 12 16
3 WASHER 24 32
4 SPRING 12 16
5 AUXILIARY ROCKER ARM SHAFT 24 32
6 AUXILIARY ROCKER ARM SPACER 12 16
7 GASKET 12 16
8 SCREW 12 16
9 NUT 12 16
10 ROCKER ARM BUSHING 24 32
TOOLS
24
ROCKER ARM SHAFT AND ASSEMBLY
AUXILIARY ROCKER ARM
1. Clean all the parts to be assembled.

- Inspect and blow the oil holes in the auxiliary rocker arm shafts.
- Inspect the oil hole in the auxiliary rocker arms.

2. Lubricate the shaft bores and the shafts, for the right bank of the engine. Set all the
shafts for the right bank of the engine.
3. For the right bank (left-hand side facing the flywheel, with the engine in inverted
position), start assembly from the flywheel side. On the shaft put: washer, spring,
washer, thick spacer, auxiliary rocker arm, medium spacer, auxiliary rocker arm and
fine spacer.
4. Rotate the shaft so that the setscrew fits both in the shaft and in the cylinder block.
5. Repeat steps 3 and 4 for each one of the existing rocker arm doors.
6. For the left bank, set all the shafts and start assembly from the side opposite the
flywheel, putting on the shaft: washer, spring, washer, thick spacer, auxiliary rocker
arm, medium spacer, auxiliary rocker arm and fine spacer.
7. Rotate the shaft so that the setscrew fits both in the shaft and in the cylinder block.
8. Repeat steps 6 and 7 for each one of the existing rocker arm doors.
9. Lock the assembly with a special bolt, copper washer and lock nut.
24
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY CAMSHAFT
LIST OF COMPONENTS
1 RIGHT CAMSHAFT 1 1
2 LEFT CAMSHAFT 1 1
3 SCREW 14 14
4 PLUG 4 4
5 LEFT CAMSHAFT COVER 1 1
6 RIGHT CAMSHAFT COVER 1 1
TOOLS
Camshaft mounting tool: Ref. 16.75.173
25
CAMSHAFT ASSEMBLY
1. Clean and check the camshaft.

2. Set the left side camshaft with the help of mounting tool Ref.:16.75.173.

3. Set the right side camshaft with the help of mounting tool Ref.: 16.75.173.
4. Apply Molykote 42204 to the whole surface of the cams.
5. At both ends of the camshafts, set a screw plug with Loctite 542. Break the thread,
using a chisel and a hammer, to prevent the plug unscrewing.
WARNING
The plug of the right camshaft, i.e. the one on the side opposite the flywheel, must be
screwed until there is one thread left. Otherwise, it will block the oil hole.
6. Mount the camshaft covers on the side opposite the flywheel.

WARNING
25
ASSEMBLY AUXILIARY ROCKER ARM
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS INSPECTION COVERS
LIST OF COMPONENTS
1 ELBOW (OIL FILLING) 1 1
2 ROCKER ARM COVER WITH OIL FILLING HOLE 1 1
3 STUD 4 4
4 GASKET, ROCKER ARM INSPECTION COVER 12 16
5 ROCKER ARM INSPECTION COVER 11 15
6 FLAT WASHER 48 64
7 SCREW 48 64
8 O-RING 1 1
9 PLUG WITH SEAL 1 1
TOOLS
26
AUXILIARY ROCKER ARM ASSEMBLY
INSPECTION COVERS
1. Place one cover at cylinder nº 6 (SF/FG...360... engines) or cylinder nº 8

(SF/FG...480 engines), with O-ring with grease, and fasten with 4 screws and
washers. Insert 4 studs with Loctite 270 into the cover (which will be used for
retaining the oil filling elbow).
2. Remove burrs from the covers. Mount the remaining covers with O-rings with grease,
bolting them with washers and screws at 5 Kg.m.

3. Set the oil filling elbow with O-ring and plug to the relevant cover, fixing it with nuts.
26
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY FRONT INTERMEDIATE COVER
LIST OF COMPONENTS
1 INTERMEDIATE COVER 1 1
2 OIL PRESSURE CONTROL VALVE 1 1
3 SCREW 5 5
4 SCREW 6 6
5 TOP CLOSING COVER 1 1
6 GASKET FOR TOP CLOSING COVER 1 1
7 CENTERING BUSH 1 1
8 O-RING 1 1
9 O-RING 2 2
10 COUPLING, OIL PIPE TO JET 2 2
11 GASKET 1 1
12 REDUCTION SCREW 1 1
13 GASKET 1 1
14 CONNECTOR 1 1
15 PIN 2 2
TOOLS
Front intermediate cover lifting tool: Ref.: 16.75.168
27
FRONT INTERMEDIATE COVER ASSEMBLY
1. Set the cover centering bush and the couplings for the oil lines to the jets.
2. Apply Loctite 5368 on the cover bearing surface on the engine block. Place the front
intermediate housing cover on the block, using the tool Ref.: 16.75.168. Bolt the
cover with screws with Loctite 242.

3. Tighten the screws to 8 Kg.m.
4. Set the top closing cover with a gasket over the intermediate housing and fasten it
with screws, tightening to 3 Kg.m.
5. Install the oil pressure control valve (for oil supply to the jets) with grease.
27
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY GEAR FOR PUMPS DRIVE
LIST OF COMPONENTS
1 MIDDLE GEAR, MAIN WATER PUMP DRIVE 1 1
2 BEARING 2 2
4 ADJUSTING WASHER 2 2
6 SCREW 3 3
7 MIDDLE GEAR SHAFT 1 1
8 SCREW 1 1
9 SCREW 3 3
10 SCREW 1 1
TOOLS
Tool to fit bearings runner in middle gear: Ref. 16.75.177
28
GEAR FOR PUMPS DRIVE ASSEMBLY
a.) Engine with two mechanically driven pumps:
1. Set the gear shaft in the block, with screws with Loctite 242 at 5 Kg.m.
2. Heat the conical bearing body and mount it on the shaft (so as to be able to
mount the outer runner).
WARNING

Do not mix bearing runners and bodies
6. Press fit the inner runner.
7. Set the axial thrust washer, securing it with 3 screws with Loctite 270 and
8. Check axial clearance with a dial gauge: 0.06 to 0.10 mm. Adjust by adding or
removing shims as appropriate.
9. Repeat steps 1 to 8 with the second gear for raw water pump drive.
NOTE
In this case, there will be a heat exchanger.
b.) Engine with mechanically driven fresh water pump and electric raw water pump.
1. Set the gear shaft in the block, securing it with screws with Loctite 242 at 5 Kg.m.
2. Heat the conical bearing body and mount it on the shaft (so as to be able to
mount the outer runner).
WARNING
28
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY GEAR FOR PUMPS DRIVE
LIST OF COMPONENTS
1 MIDDLE GEAR, MAIN WATER PUMP DRIVE 1 1
2 BEARING 2 2
6 SCREW 3 3
7 MIDDLE GEAR SHAFT 1 1
8 SCREW 1 1
9 SCREW 3 3
10 SCREW 1 1
TOOLS
Tool to fit bearings runner in middle gear: Ref. 16.75.177
28
GEAR FOR PUMPS DRIVE ASSEMBLY
6. Press fit the inner runner.
7. Set the axial thrust washer, securing it with 3 screws with Loctite 270 and
8. Check axial clearance with a dial gauge: 0.06 to 0.10 mm. Adjust by adding or
removing shims as appropriate.

9. Set and bolt the cover on the bore for the raw water pump drive gear shaft.
c.) Engine with two electric pumps
1. Set and bolt the cover on the bore for the main water pump drive gear shaft.
2. Set and bolt the cover on the bore for the raw water pump drive gear shaft.
28
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY FRONT COVER WITH SEAL
LIST OF COMPONENTS
1 COVER 1 1
2 PIN 2 2
3 CRANKSHAFT FRONT SEAL 1 1
4 SCREW 2 2
5 AUXILIARY WATER PUMP HOUSING COVER 1 1
6 SCREW 8 8
7 NUT 1 1
8 O-RING 1 1
9 FRONT COVER 1 1
10 SCREW 3 3
11 SCREW 2 2
12 SCREW 9 9
13 SCREW 7 7
14 STUD 1 1
TOOLS
Front seal assembly tool: Ref. 16.75.141
Pump support front cover lifting tool: Ref. 16.75.175
29
FRONT COVER WITH SEAL ASSEMBLY
1. Set seal, with grease between lips, in the front closing cover using tool
Ref.: 16.75.141.
2. Set 2 guide pins on the front intermediate cover and apply Loctite 5368 on oil pan
and intermediate cover.
3. Lift the front cover with tool Ref.: 16.75.175 and place it over the intermediate cover.

4. Bolt closing cover to intermediate cover and to oil pan with screws at 8 Kg.m.
29
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY FRONT FLANGE (HYDRAULIC)
LIST OF COMPONENTS
1 COMPANION FLANGE ON CRANKSHAFT 1 1
2 SCREW 10 10
TOOLS
Companion flange assembly tool (hydraulic): Ref. 16.75.135
30
FRONT FLANGE (HYDRAULIC) ASSEMBLY
1. Set companion flange on crankshaft and measure the distance between the flange
and the crankshaft end (*).
2. Install connector to flange and connect the hydraulic pump.
3. Install tool Ref.:16.75.135 on the crankshaft and operate the hydraulic pump.

4. Press with the pneumatic tool or air gun until the measured distance (*) decreases
by 5mm.
30
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY DAMPER
LIST OF COMPONENTS
1 DRIVE FLANGE 1 1
2 SCREW 12 12
3 DAMPER 1 1/2
4 SCREW 4 4 / 16
5 TWIN DAMPER SPACER - 1
6 ENGINE TURNING GEAR 1 1
7 TWIN DAMPER TURNING GEAR - 1
8 DAMPER PROTECTION 1 1
9 FLAT WASHER 3 3
10 SCREW 1 1
11 SCREW 12 12
12 SPACER 2 2
13 SCREW 2 2
14 PULLEY 1 1
15 PULLEY MOUNTING STUD 12 12
16 WASHER 12 12
TOOLS
Damper mounting tool: Ref. 16.75.183
31
DAMPER ASSEMBLY
1. Take damper, wipe with a rag and assemble with tool Ref.: 16.75.183. Bolt with 12
screws with Loctite 270 at 14 Kg.m.
2. If there are 2 dampers, insert 12 studs with Loctite 242 inside the companion flange.
Insert the spacer and the second vibration damper. Secure with nuts at 14 kg.m.
3. Assemble turning gear to damper with 4 screws.

4. Assemble damper protection with spacers and screws. Fasten protection to block
with 3 screws.
5. If the engine has a pulley, install it with gaskets, and fasten with bolts and nuts with
Loctite 270 at 8 Kg.m.
NOTE
If the engine has a crankshaft pulley, it does not have a turning gear or a cover.
31
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY WATER PUMPS
LIST OF COMPONENTS
1 FRESH WATER PUMP (MAIN CIRCUIT) 1 1
2 O-RING 1 1
3 STUD 2 2
4 STUD 5 5
5 O-RING 1 1
6 PUMP BACK COVER 1 1
7 SCREW 4 4
8 NUT 7 7
9 WASHER 4 4
10 SCREW 4 4
11 SCREW 2 2
12 MAIN WATER PUMP COVER 1 1
13 PUMP CLOSING COVER 1 1
14 SCREW 4 4
TOOLS
32
WATER PUMPS ASSEMBLY
a.) Main circuit with mechanical water pump
1. Set the previously greased O-ring on the pump.
2. Mount the fresh water pump to the front gear train cover, with screws at 8 Kg.m.
3. Install the cover on the pump shaft and connect the lubricating pipe from the oil

distributor. .
b.) Main circuit with electric pump
1. Set the cover on the timing gear housing with Loctite 5368 and secure with
screws.
32
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY WATER INLET TO CYLINDER BLOCK
LIST OF COMPONENTS
1 COPPER GASKET 1 1
2 WATER INLET PIPE TO BLOCK 1 1
3 WATER OUTLET ELBOW 1 1
4 O-RING 2 2
5 SCREW 4 4
6 SCREW 2 2
7 HOSE 1 1
8 CLAMP 2 2
9 PLUG 2 2
10 COPPER GASKET 2 2
11 PLUG 1 1
12 WASHER 6 6
TOOLS
33
WATER INLET TO CYLINDER BLOCK ASSEMBLY
1. Assemble water outlet elbow to pump with O-ring and screws.
2. Assemble water inlet pipe to water pump outlet elbow with hose.

3. Set assembly on the engine block and fasten it with clamps.
4. Install 2 plugs with copper gaskets.
5. Assemble water inlet flange to pump with O-ring and screws.
6. Assemble water inlet elbow to inlet flange with O-ring and screws.
33
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY RAW WATER PUMPS
LIST OF COMPONENTS
1 RAW WATER PUMP (AUXILIARY CIRCUIT) 1 1
2 O-RING 1 1
3 SCREW 4 4
4 STUD 6 6
5 NUT 6 6
6 O-RING 1 1
7 PUMP BACK COVER 1 1
8 SCREW 4 4
9 WATER PUMP LUBRICATING PIPE 1 1
10 ELBOW 1 1
11 SCREW 1 1
12 GASKET 2 2
13 SCREW 2 2
14 RAW WATER PUMP HOUSING COVER 1 1
15 PUMP CLOSING COVER 1 1
16 SCREW 4 4
TOOLS
34
RAW WATER PUMPS ASSEMBLY
c.) Auxiliary (raw) water circuit with mechanical pump
1. Assemble raw water pump on front closing cover with O-ring, studs and nuts.

2. Install pump shaft cover and connect the lubricating pipe from the oil distributor.
d.) Auxiliary (raw) water circuit with electric pump
1. Set the cover on the timing gear housing with Loctite 5368 and secure with
screws.
34
ASSEMBLY INTERMEDIATE COVER ON
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS BACK GEAR TRAIN HOUSING
LIST OF COMPONENTS
INTERMEDIATE COVER, BACK GEAR TRAIN
1 1 1
HOUSING
2 PIN 2 2
3 O-RING 2 2
4 BLING OVAL FLANGE 1 1
5 SCREW 2 2
TOOLS
35
INTERMEDIATE COVER ON ASSEMBLY
BACK GEAR TRAIN HOUSING
1. Clean the oil passage and the inside of the cover.
2. Insert 2 guide pins on the engine block.
3. Lift the cover with screws in its sides. Place the cover over the block and apply Loctite
5360 on the contact surface with the block and the oil pan.

4. Fasten cover to block with 16 screws (placing the guide protection in one of them) at
8 Kg.m. Bolt to the oil pan with screws at 8 Kg.m.
5. Clean the inside of the connecting pipe between oil pump and cylinder block.
6. Assemble one end of this connecting pipe to the intermediate cover with a greased
O-ring gasket and 2 screws (tightening torque: 8 Kg.m.). Assemble the other end to
the block with a greased O-ring gasket and 3 screws at 5 Kg.m.
7. Bolt the oil inlet rectangular blind flange (with greased O-ring). Torque to 4 Kg.m.
35
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY CAMSHAFT THRUST DISKS
LIST OF COMPONENTS
1 ADJUSTING WASHER 1/... 1/...
2 CAMSHAFT THRUST DISK 2 2
3 SCREW 10 10
4 WASHER 10 10
TOOLS
36
CAMSHAFT THRUST DISKS ASSEMBLY
1. Set the axial thrust disk on the left camshaft, inserting adjusting washers (shims).

2. Measure the axial clearance with a dial gauge. It must be 0.15 to 0.20 mm.
3. If necessary, adjust the clearance by adding or removing shims.
4. Once the axial clearance has been set, bolt the thrust disk with washers and screws
with Loctite 242 with a tightening torque of 8 Kg.m.
DANGER
Check that axial thrust disk is centered and does not touch the camshaft.
5. Repeat this process on the right side camshaft.
36
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY DISTRIBUTION MIDDLE GEAR
LIST OF COMPONENTS
1 MIDDLE GEAR, REGULATOR DRIVE 1 1
2 SHAFT FOR DISTRIBUTION MIDDLE GEAR 1 1
3 SCREW 4 4
4 BEARING 2 2
7 SCREW 3 3
TOOLS
Tool to fit outer bearing runner in timing middle gear: Ref. 16.75.178
37
DISTRIBUTION MIDDLE GEAR ASSEMBLY
1. Install shaft for timing middle gear in the block. Bolt with screws to 5 Kg.m.

2. Heat the bearings (inner runner) and assemble them to the shaft.
3. Fit the outer bearing runner in the gear with tool Ref.:16.75.178.
DANGER
4. Insert the gear over the shaft, so that letters A-A coincide with letter A on the timing
master gear.
5. The inner runner must be pressed on the

shaft.
6. Bolt the axial thrust washer to the shaft

with 3 screws with Loctite 270 at a
tightening torque of 4 Kg.m.
7. Measure the axial clearance and adjust

with shims if necessary. Allowable
clearance: 0.148 to 0.234 mm.
37
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY CAMSHAFT GEAR
LIST OF COMPONENTS
1 CAMSHAFT GEAR AND ELEC. IGNITION 2 2
2 SCREW 12 12
3 PIN 2 2
4 IGNITION CONTROL SENSOR 1 1
TOOLS
38
CAMSHAFT GEAR ASSEMBLY
Left camshaft
1. Wash the gears, then mount the ignition control sensor on the left camshaft gear, with
Loctite 270.
2. Insert 2 pins in the camshaft.

3. Using the pins as guides, set the gear over the camshaft.
- Verify that mark B on the camshaft gear coincides with mark B on the timing
middle gear.
4. Bolt the gear with 6 screws with green Loctite with a torque of 14 kg.m.
Left camshaft
1. Insert 2 pins in the camshaft.
2. Using the pins as guides, set the gear over the camshaft.
- Verify that mark C on the camshaft gear coincides with mark C on the timing
middle gear.
3. Bolt the gear with 6 screws with green Loctite with a torque of 14 kg.m.
4. Check gear clearance with a dial gauge.

38
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY REGULATOR GEAR
LIST OF COMPONENTS
1 INTERMEDIATE GEAR, REGULATOR DRIVE 1 1
3 SCREW 6 6
4 INTERMEDIATE GEAR SHAFT 1 1
5 SCREW 4 4
6 BEARING 2 2
TOOLS
39
REGULATOR GEAR ASSEMBLY
1. Secure the shaft of the regulator intermediate drive gear with 3 screws.
2. Heat the inner bearing runner and place it over the shaft.
3. Insert the two outer bearing runners in the gear.

DANGER

Do not mix the bearing runners
4. Introduce the gear over the shaft. Set the adjusting washers and bearing spacer.
5. Assemble the inner runner of the other bearing and secure the gear with axial thrust
washer and screws.
6. Bolt the regulator drive gear to the regulator intermediate drive gear with screws.
7. If there is no mechanical regulator, install a cover with screws.
39
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY FLYWHEEL HOUSING
LIST OF COMPONENTS
1 FLYWHEEL HOUSING 1 1
2 NUT 4 4
3 STUD 4 4
4 SCREW 2 2
5 PIN 2 2
6 GASKET, PTO COVER 2 2
7 PTO COVER 2 2
8 SCREW 2 2
9 STUD 10 10
10 NUT 10 10
11 SCREW 28 28
12 SCREW 6/3 6/3
13 ELECTRIC STARTER 2/1 2/1
14 SPACER 2/1 2/1
15 MAGNETIC PICKUP AND CONNECTOR 1 1
TOOLS
40
FLYWHEEL HOUSING ASSEMBLY
1. Insert 2 guide pins in the back intermediate cover. Apply Loctite 5368 to housing and
support base of oil pan.
2. Bolt electric starter to the left side of the flywheel housing with screws at 16 Kg.m.
Bolt a cover to the right side. (When there are two starters, one is to be mounted on
the right side instead of the cover.).

3. Set flywheel housing to the block (lifting the housing with a crane and two eyebolts
in the sides).
4. Install one plug and two magnetic pick-ups on the flywheel housing.
5. Bolt covers with screws.

NOTE
If the engine has a pneumatic starter, this will be mounted later.
6. Install a pick-up on the support in the flywheel housing.
40
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY REAR SEAL
LIST OF COMPONENTS
1 GASKET, BACK SEAL SUPPORT 1 1
2 CRANKSHAFT BACK SEAL UNIT 1 1

3 SCREW 6 6
TOOLS
Rear seal assembly tool: Ref. 16.75.103
41
REAR SEAL ASSEMBLY
1. Install gasket in rear seal and apply Molykote between the lips. Set the rear seal
support, using the rear seal assembly tool Ref.: 16.75.103.

2. Bolt rear seal support to flywheel housing with screws at 3 Kg.m.
41
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY BACK COMPANION FLANGE AND FLYWHEEL
LIST OF COMPONENTS
1 FLYWHEEL 1 1
2 FLYWHEEL SCREW 10 10
3 WASHER FOR FLYWHEEL SCREW 10 10

4 SCREW 12 12
5 ADAPTER, FLYWHEEL 1 1
TOOLS
Flywheel lifting tool: Ref. 16.75.017
Flywheel guide: Ref. 16.75.162
Flywheel fixing tool: Ref. 16.78.670
Flywheel rotating tool: Ref. 16.75.031
42
BACK COMPANION FLANGE AND FLYWHEEL ASSEMBLY
1. Bolt the back companion flange or flywheel flange to the timing gear with screws at
43.8 Kg.m.

2. Lift the flywheel with tool Ref.:16.75.017 and offer it to the companion flange with
guides Ref.:16.75.162.
3. Install tool Ref.:16.78.670 to prevent flywheel rotation when tightening the screws
and bolt the flywheel to the flange with washer and screws with a torque of 27 Kg.m.
4. Install the flywheel rotating tool Ref.:16.75.031.
42
ASSEMBLY TIMING INDICATOR COVER
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS AND FLYWHEEL MARKING
LIST OF COMPONENTS
1 TIMING INDICATOR COVER 2 2
2 TIMING INDICATOR 1 1
3 SCREW 4 4
4 WASHER 4 4
TOOLS
Flywheel rotating tool: Ref. 16.75.031
43
TIMING INDICATOR COVER ASSEMBLY
AND FLYWHEEL MARKING
1. Bolt the timing indicator covers to each side of the flywheel housing with washers and
screws at 5 Kg.m.

2. Mark the top dead center for cylinders 1-6 (SF/FG...360) or 1-8 (SF/FG...480), with
the help of a dial gauge.
· Place dial gauge at zero over piston number 1.
· Start turning the crankshaft with tool Ref.:16.75.031, so that piston 1 rises until
dial gauge reads 1 mm. Mark it on flywheel.
· Turn flywheel in the same direction until it goes below 1 mm.
· Turn flywheel in opposite direction until it reaches the 1 mm height. Mark it on
flywheel.
· The mid point between the 2 marks is the top dead center (TDC) for pistons 1 and
6 in SF/FG...360 engines or for pistons 1-8 in SF/FG...480 engines.
3. Mark top dead centers for cylinders 5-2,3-4,8-11,10-9,7-12 on SF/FG...360 engines

and for cylinders 4-5,2-7,6-3,12-13,10-15,14-11,16-9 on SF/FG...480 engines, when
either of the pistons in each pair is at the highest point with dial gauge.
4. Loosen the flywheel and mark the TDC

numbers.
5. Place the timing plate.
6. Bolt the flywheel with a tightening torque

of 27 Kg.m.
43
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY FRONT LIFTING BRACKETS
LIST OF COMPONENTS
1 RIGHT FRONT LIFTING BRACKET 1 1
2 LEFT FRONT LIFTING BRACKET 1 1

3 SCREW 6 6
TOOLS
44
FRONT LIFTING BRACKETS ASSEMBLY
1. Bolt the flat lifting bracket to the left side of the engine block.

2. Bolt the offset lifting bracket to the right side of the engine block.
44
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY EXTERNAL OIL CIRCUIT
LIST OF COMPONENTS
1 ELBOW 1 1
2 FLANGE 1 1
3 O-RING 2 2
4 PIPE 1 1
5 SCREW 4 4
6 FLANGE 1 1
7 O-RING 1 1
8 O-RING 2 2
9 SCREW 4 4
10 PIPE, OIL PUMP TO CYLINDER BLOCK 1 1
11 SCREW 3 3
12 SCREW 2 2
13 O-RING 1 1
14 O-RING 1 1
TOOLS
45
EXTERNAL OIL CIRCUIT ASSEMBLY
1. Assemble oil inlet pipe to cylinder block with greased O-ring and 4 screws at 4 Kg.m.
2. Insert 2 O-rings with grease in the flange and set the flange to the filter support outlet
pipe.
3. Assemble this set to the oil inlet pipe to the block with one O-ring and 2 screws.

4. Assemble the outlet pipe to the filter support with O-ring and 2 screws at 5 Kg.m.
5. Assemble safety valve discharge pipe to elbow.
6. Bolt pipe to block with 2 copper gaskets and hollow screw.
45
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY OIL DISTRIBUTION
LIST OF COMPONENTS
1 R-500 OIL VALVE 1 1
2 REDUCING COUPLING 2 2
3 COPPER GASKET 2 2
4 PLUG 2 2
5 COPPER GASKET 2 2
6 PLUG 1 1
7 GASKET 1 1
8 PLUG 6 6
9 COPPER GASKET 6 6
10 SCREW 2 2
11 TOP FLANGE, BLOCK 1 1
12 O-RING 1 1
13 SCREW 3 3
14 OIL VALVE 1 1
15 PLUG 1 1
TOOLS
46
OIL DISTRIBUTION ASSEMBLY
Upper Oil Valve
1. Assemble top flange with grease-coated

O-ring to block with 2 screws at 5 Kg.m.
2. Install 2 plugs, each with a copper gasket,
on the oil valve. Mount 2 elbows.
3. Introduce oil valve in top flange with

Loctite 270 and Teflon.
4. Over the R-500 oil valve body, place the
following items:
1 reducing plug with copper gasket. 1 long
hollow screw over the reducing coupling.
Plug with copper gasket. Reducing plug
with copper gasket. Reducing connector.
Plug with copper gasket. 6 plugs with
copper gasket. Elbow.
Oil Valve on Filter Support
1. Assemble 2 elbows with Loctite 242 to

valve.
2. Place plug on valve.
3. Bolt valve.
4. Assemble valve pipe (left elbow) to oil
discharge pipe from filters with coupling.
5. Assemble two pipes with double hollow
screw to oil valve:
- One with elbow to the filter support.

- The other one to the thermostatic valve.
46
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY CYLINDER HEAD STUDS
LIST OF COMPONENTS
1 CYLINDER HEAD STUD 84 112
2 CYLINDER HEAD GASKET 12 16
3 O-RING 12 16
4 OIL CONDUIT BUSHING 12 16
TOOLS
47
CYLINDER HEAD STUDS ASSEMBLY
1. Set 12 bushings with O-rings and 24 pins in the upper portion of the engine block.
2. Wash, dry and set 72 studs (oiled) at 6 Kg.m.

3. Set the cylinder head gaskets (one per cylinder head).
WARNING
Gaskets are to be correctly located over the guide pins.
47
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY CYLINDER HEADS
LIST OF COMPONENTS
1 COMPLETE CYLINDER HEAD 12 16
2 CYLINDER HEAD FIXING NUT 84 112

3 WASHER 84 112
TOOLS
Cylinder head lifting tool: Ref.: 16.75.234
Cylinder head aligning tool: Ref. 16.75.109
48
CYLINDER HEADS ASSEMBLY
1. Clean cylinder head oil holes and support base with air.
2. Install the complete cylinder heads, using lifting tool Ref.:16.75.234 and a crane.

3. Align the cylinder heads with tool Ref.:16.75.109.
4. Secure cylinder heads with 72 washers and previously oiled nuts to 48 Kg.m.
5. Loosen alignment tool from cylinder heads.
48
ASSEMBLY PUSH RODS, PUSHER SET
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS AND ROCKER ARMS
LIST OF COMPONENTS
1 ROCKER ARMS ASSEMBLY 12 16
2 COMPLETE INTAKE ROCKER ARM 12 16
3 COMPLETE EXHAUST ROCKER ARM 12 16

4 PUSHER 24 32
5 PUSH ROD 24 32
6 AUXILIARY ROCKER ARM AND FIXED PARTS 24 32
TOOLS
Wrench for clamping rocker arm mounting plate: Ref. 16.75.121
49
PUSH RODS, PUSHER SET ASSEMBLY
AND ROCKER ARMS
1. Clean the rods and place them, by twos, in their respective bores, with their round
ends against the auxiliary rocker arms (cam followers).

2. Set the pushers. Apply Molykote or molybdenum disulfide to the clampers and adjust
them (so the 2 sides push at the same time).
3. Fasten the rocker arms to the bracket, 1 per cylinder head, with screws at 8 kg.m.
For this purpose, use tool Ref.:16.75.121.
49
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY ADJUSTING ROCKER ARMS
50
ADJUSTING ROCKER ARMS ASSEMBLY
1. Set flywheel on the upper dead center of cylinder number 1.
2. Set shims:
- For intake (shorter rocker arm): 0.3 mm

- For exhaust (longer rocker arm): 0.8 mm
WARNING

Correct measurement will be obtained when the shim is almost captive between the
rocker arm and the pusher.
3. Tighten intake and exhaust rocker arm nuts to10 Kg.m.
EXHAUST
INTAKE
4. Follow this order:
- On SF/FG...360 engines: 1, 8, 5, 10, 3, 7, 6, 11, 2, 9, 4, 12.

- On SF/FG...480 engines: 1, 2, 4, 10, 2, 14, 6, 16, 8, 13, 5, 15, 7, 11, 3, 9.
rotating the flywheel to the left, counterclockwise (looking at the flywheel).
50
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY SPARK PLUG PROTECTOR
LIST OF COMPONENTS
1 O-RING 12 16
2 SPARK PLUG TUBE 12 16

3 GASKET 12 16
TOOLS
Spark plug housing tightening wrench: Ref. 19.75.009
51
SPARK PLUG PROTECTOR ASSEMBLY
1. Set 2 O-rings on the spark plug housing tube with grease.
2. Insert spark plug housing tube in cylinder head with tool (Ref.: 19.75.009) at 5 Kg.
51
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY ROCKER ARM COVERS
LIST OF COMPONENTS
1 ROCKER ARM COVER 12 16
2 O-RING 12 16
3 FLAT WASHER 48 64
4 NUT 48 64
TOOLS
52
ROCKER ARM COVERS ASSEMBLY
1. Remove burrs on covers. Set O-ring with grease to 12 covers.
2. Fasten covers to cylinder heads with studs (already placed), nuts and washers.
52
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY SPARK PLUGS
LIST OF COMPONENTS
1 SPARK PLUG 12 16
2 SPARK PLUG WIRE 12 16
TOOLS
Spark plug wrench: Ref. 19.75.030
53
SPARK PLUGS ASSEMBLY
1. Unpack the spark plugs.
2. Check the gap. Regauge to 0.3mm if necessary.
3. Introduce the spark plug in its housing tube with tool (Ref.: 19.75.030) at 3 Kg.m. Do
not grease, oil, etc. the spark plugs; so, contact will be optimum.

4. Repeat this process with all remaining spark plugs.
53
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY EXHAUST MANIFOLD
LIST OF COMPONENTS
1 WATER-COOLED EXHAUST MANIFOLD 2 2
2 GASKET, OUTLET TO TURBO 2 4
3 COVER, OUTLET TO TURBO 2 2
4 SCREW 16 16
5 GASKET, EXHAUST MANIFOLD 12 16
6 SCREW 32 32
7 WASHER 64 64
8 SCREW, EXHAUST MANIFOLD 64 64
9 GASKET, OUTLET TO WATER MANIFOLD 4 4
10 COVER, OUTLET TO WATER MANIFOLD 2 2
11 GASKET 16 16
12 WATER OUTLET ELBOW 12 16
13 SCREW 24 32
14 O-RING 12 16
15 WATER OUTLET FLANGE 12 16
16 GASKET, WATER INLET MANIFOLD 12 16
17 PLUG 3 3
18 RIGHT MANIFOLD OUTLET ELBOW 1 1
19 LEFT MANIFOLD OUTLET ELBOW 1 1
TOOLS
Exhaust manifold lifting tool: Ref. 16.75.179
54
EXHAUST MANIFOLD ASSEMBLY
1. Lift the right exhaust manifold with the help of tool Ref.:16.75.179 and a crane.
2. Set right exhaust manifold on cylinder heads with gaskets and bolt with washers and
screws.

3. Lift the left exhaust manifold with the help of tool Ref.:16.75.179 and a crane.
4. Fasten left exhaust manifold with 4 guides.
5. Set the water outlet elbows (12 on SF/FG...360 engines and 16 on SF/FG...480
models.) Fasten the elbows to the manifolds with gaskets and screws and to the
engine block with O-rings, flanges, gaskets and screws.
6. Place 1 cover with its gasket on each manifold and secure it with screws.
7. Install the outlet elbows to the left and right manifolds, with gaskets.
54
ASSEMBLY THERMOSTAT HOUSING AND
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS CONNECTION TO WATER PUMP
LIST OF COMPONENTS
1 THERMOSTAT HOUSING 1 1
2 NUT 4 4
3 GASKET 2 2
4 SCREW 4 4
5 SCREW 2 2
TOOLS
55
THERMOSTAT HOUSING AND ASSEMBLY
CONNECTION TO WATER PUMP
1. Assemble the thermostat housing on the exhaust manifold water outlet elbows, with
screws, washers and nuts.

MANIFOLD WATER
OUTLET ELBOW
THERMOSTAT HOUSING
55
LIST OF COMPONENTS
1 OUTLET FLANGE 1 1
2 SCREW 7 7
3 ELBOW GASKET 1 1
4 CLAMP 4 4
5 HOSE 2 2
6 BY-PASS PIPE 1 1
7 COPPER GASKET 3 3
8 PLUG 3 3
9 WATER INLET ELBOW 1 1
10 SCREW 3 3
11 SCREW 6 6
12 WATER FLANGE 1 1
13 O-RING 3 3
14 SCREW 2 2
15 PLUG 3 3
16 GASKET 3 3
17 O-RING 1 1
18 PLUG 7 7
19 GASKET 7 7
20 STUD 4 4
21 SCREW 4 4
22 GASKET 2 2
23 SCREW 16 16
24 FLANGE 2 2
TOOLS
55
1. Assemble water flange to fresh water pump, with greased O-ring and screws.
2. Set a counterflange to the water flange, with gasket and screws.
3. Set a greased O-ring in the water inlet elbow and fasten the elbow to the top of the
water flange with screws.

WATER INLET ELBOW
WATER FLANGE
COUNTERFLANGE
4. Assemble the by-pass pipe to the water inlet elbow at one end and to the thermostat
housing at the other, with hose and clamps. Tighten the clamps.
5. Introduce one plug with its copper gasket in the by-pass tube.
6. Assemble the water outlet flange to the thermostat housing, with elbow gasket, studs
and nuts.
7. Introduce plugs with gaskets in the flange.
8. Assemble a counterflange to the water outlet flange, with gasket and screws.
WATER OUTLET FLANGE
BY-PASS PIPE
55
LIST OF COMPONENTS
1 O-RING 1 1
2 SCREW 3 3
3 WATER OUTLET HOSE 1 1
4 O-RING 1 1
5 CLAMP 2 2
6 HOSE 2 2
7 WATER INLET FLANGE TO PUMP 1 1
8 SCREW 5 5
9 CLAMP 4 4
10 HOSE 2 2
11 BY-PASS PIPE 1 1
13 PLUG 1 1
14 SCREW 3 3
15 WATER INLET ELBOW 1 1
TOOLS
55
With heat exchanger
1. Bolt water flange to water pump.
2. Set a greased O-ring in the water inlet elbow. Assemble the elbow to the water flange
with screws.

3. Put one hose and 2 clamps on both ends of the by-pass pipe.
4. Assemble the by-pass pipe to the water inlet elbow and to the thermostat housing,
fixing it by tightening the clamps.
5. Introduce 4 studs with Loctite 270 into the thermostat housing, for assembly to heat
exchanger at a later stage.
55
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY HEAT EXCHANGER
LIST OF COMPONENTS
1 WATER HEAT EXCHANGER 1 1
2 HEAT EXCHANGER BRACKET 1 1
3 SCREW 2 2
4 SCREW 2 2
5 WASHER 2 2
6 NUT 2 2
7 O-RING 1 1
8 STUD 4 4
9 NUT 4 4
10 SCREW 2 2
11 WASHER 2 2
12 WASHER 2 2
13 O-RING 1 1
14 SCREW 3 3
TOOLS
56
HEAT EXCHANGER ASSEMBLY
1. Bolt heat exchange bracket to engine block and front cover.
2. Place heat exchanger on its bracket and fasten it with washers and screws.
3. Secure with nuts to the studs previously mounted in the thermostat housing, inserting
an O-ring.

4. Connect the heat exchanger to the water pump inlet flange, with O-ring and screws.
56
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY INTAKE MANIFOLD
LIST OF COMPONENTS
1 SCREW 12 12
2 LEFT MANIFOLD COVER 1 1
3 GASKET 2 2
4 INTAKE MANIFOLD 2 2
5 O-RING 32 32
6 GASKET 4 4
7 SCREW 14 14
8 WASHER 12 16
9 SCREW 12 16
10 SCREW 24 32
11 SCREW 14 14
12 PLUG 1 1
13 RIGHT MANIFOLD COVER 2 2
14 INTAKE MANIFOLD - 2
15 PLUG 24 32
16 WASHER 4 4
17 SAFETY VALVE 4 4
TOOLS
57
INTAKE MANIFOLD ASSEMBLY
1. Set greased O-rings in the right intake manifold. Fasten the manifold to the cylinder
heads with screws and washers. (On SF/FG...480 engines, install 1 manifold
complete with the short manifold assembled to its front end during the "Sub-unit"
assembly stage.)
2. Install the safety valve in the front portion of the intake manifold, with gasket and
screws.

3. Assemble a cover with its gasket to the manifold, with 6 screws. Insert 2 plugs in the
manifold cover.
4. Set greased O-rings in the left intake manifold. Fasten the manifold to the cylinder
heads with screws and washers. (On SF/FG...480 engines, install 1 manifold
complete with the short manifold assembled to its front end during the "Sub-unit"
assembly stage.)
5. Install the safety valve in the front portion of the intake manifold, with gasket and
screws.
6. Assemble a cover with its gasket to the manifold, with 6 screws. Insert 2 plugs in the
manifold cover.
57
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY INTAKE AIR CONNECTION
LIST OF COMPONENTS
NUMBER DESCRIPTION SFGLD 360 SFGLD 480
1 T-BRANCH TO BUTTERFLY 1 1
2 T-BRANCH GASKET 2 2
3 RIGHT INTAKE ELBOW 1 1
4 LEFT INTAKE ELBOW 1 1
5 GASKET, INTAKE MANIFOLD 2 2
6 SCREW 14 14
7 GASKET 4 4
8 PLUG 4 4
9 GASKET 3 3
10 PLUG 3 3
11 SCREW 16 16
12 GASKET 2 2
13 PLUG 2 2
14 GASKET, BUTTERFLY BODY 1 1
15 ELBOW 1 1
16 SCREW 6 6
TOOLS
58
INTAKE AIR CONNECTION ASSEMBLY
SFGLD Engines
1. Assemble the air intake elbows, with gaskets and screws, to both intake manifolds.

2. Carefully set the T-branch, with gaskets, between the two elbows and secure with
screws.
3. Fasten the elbows to the manifolds and fix the T-branch to the elbows.
4. Place 4 plugs with their respective gaskets at the connection of the elbows.
ELBOW TO BUTTERFLY
CONNECTION BRANCH
INTAKE ELBOW
5. Assemble 1 elbow to the top of the T-branch, with the butterfly body gasket and
screws.
58
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY INTAKE AIR CONNECTION
LIST OF COMPONENTS
NUMBER DESCRIPTION FGLD 360 FGLD 480
1 T-BRANCH TO BUTTERFLY 1 1
2 T-BRANCH GASKET 2 2
3 ELBOW, REGULATION 1 1
4 ELBOW 1 1
5 GASKET 2 2
6 SCREW 16 16
7 GASKET 4 4
8 PLUG 4 4
9 GASKET 3 3
10 PLUG 3 3
11 SCREW 16 16
12 GASKET 2 2
13 PLUG 2 2
14 GASKET 1 1
15 GAS INLET VALVE BODY 1 1
16 SCREW 6 6
17 BALL JOINT 4 4
18 NUT 8 8
19 STUD 4 4
20 ROD 1 1
21 ROD 1 1
TOOLS
58
INTAKE AIR CONNECTION ASSEMBLY
FGLD Engines
1. Assemble the intake elbows, with gasket and screws, to both intake manifolds.
2. Set 1 rod between the two elbows:
- Assemble the ball joint to the butterfly valve lever, on one of the elbows (the lever

between the block and the elbow).
- Assemble the rod to the ball joint with studs and nuts.
- Proceed likewise to assemble the rod to the butterfly valve lever, on the other
elbow.
BUTTERFLY VALVE
LEVER, RIGHT ELBOW
3. Set 1 rod to the side of the left elbow:
- Assemble the ball joint to the butterfly valve lever (which is outside the elbow).
- Fasten the rod to the ball joint with studs and nuts.
- Fasten the rod to the lever on the elbow, in a similar manner.
4. Carefully set the T-branch, with gaskets, between the two elbows and secure with
screws.
5. Fasten the elbows to the manifolds and fix the T-branch to the elbows.
6. Place 4 plugs with their respective gaskets at the connection of the elbows.
7. Install the gas intake valve body on the T-branch, with gasket, and secure with
screws.
58
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY AIR COOLER
LIST OF COMPONENTS
1 AIR COOLER UNIT 1 1
2 BACK SUPPORT 2 2
3 SCREW 8 8
4 SCREW 4 4
5 WASHER 12 12
6 SCREW 2 4
7 PIPE 1 2
8 GASKET 1 2
TOOLS
FV gas engine air cooler lifting tool: Ref. 19.75.017
59
AIR COOLER ASSEMBLY
1. Set the air cooler supports on the exhaust manifolds, with gaskets and screws.

2. Hoist the cooler with tool Ref.:19.75.017.
3. Assemble 2 water pipes, with their gaskets, to the bottom of the cooler and secure
with screws. On SF/FG...360 engines, assemble only the front pipe.
4. Place the oil cooler on its supports and assemble it to the butterfly valve, or otherwise
to the appropriate elbow, with gasket and screws.
5. Fasten all elements securely.
CONNECTION TO INTAKE
SUPPORTS
WATER PIPE
59
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY BUTTERFLY AND CONNECTION TO COOLER
LIST OF COMPONENTS
1 SCREW 8 14
2 GASKET - 1
3 ELBOW TO BUTTERFLY CONNECTION - 1

4 BUTTERFLY VALVE 1 1
5 O-RING 2 2
TOOLS
60
BUTTERFLY AND CONNECTION TO COOLER ASSEMBLY
SFGLD Engines
1. On SFGLD 480 engines, assemble the elbow-to-butterfly connection to the elbow,

with gasket and screws.

2. Set the butterfly valve in the connection pipe with O-ring and screws.
3. On SFGLD 360 engines, assemble the butterfly direct to the elbow, with O-ring and
screws.
60
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY BUTTERFLY AND CONNECTION TO COOLER
LIST OF COMPONENTS
1 SCREW 6 6
2 GASKET 1 1
3 CONNECTION PIPE 1 1
TOOLS
60
BUTTERFLY AND CONNECTION TO COOLER ASSEMBLY
FGLD Engines
1. Assemble the connection pipe to the elbow, with gasket and screws.
60
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY WATER PIPES
LIST OF COMPONENTS
1 PIPE 1 1
2 SCREW 2 4
3 GASKET 2 3
4 NUT 2 6
5 PIPE - 1
6 SCREW 2 -
7 HOSE CONEXION FLEXIBLE 1 1
8 PIPE 1 1
9 CLAMP - 1
10 WASHER - 1
11 SCREW - 1
TOOLS
61
WATER PIPES ASSEMBLY
1. Assemble a long pipe, with gasket, to the line already mounted at the back of the
cooler, and secure with bolts and nuts. (On SF/FG...360 engines, this pipe is
assembled direct to the cooler.)

LINECONNECTED TO
THE COOLER HOSE
2. On SF/FG...480 engines, assemble 1 straight pipe section, with gasket, to the end of
the former pipe and secure with bolts and nuts. Fasten the pipe to the rocker arm
cover, with clamp, washer and screw.
3. Assemble the pipe - that will lie on the right side of the engine - with gasket, bolts and
nuts, to the last pipe you have installed.
4. Set a hose to the former pipe.
HOSE CONEXION
FLEXIBLE
61
LIST OF COMPONENTS
1 PIPE 1 1
2 CLAMP 1 1
3 WATER INLET PIPE SUPPORT 1 1
4 NUT 2 2
5 WASHER 2 2
6 SCREW 2 2
7 WATER INLET FLANGE TO BLOCK 1 1
8 GASKET 1 1
9 PLUG 1 1
10 O-RING 3 3
11 SCREW 20 20
12 WATER INLET FLANGE 1 1
13 GASKET 1 1
14 SCREW 3 3
15 GASKET 1 1
16 COUNTERFLANGE 1 1
17 SCREW 8 8
18 GASKET 2 2
20 NUT 2 2
21 GASKET 1 1
23 SCREW 2 2
24 WASHER 2 2
TOOLS
61
Coolant system with electric pumps
1. Secure the water inlet pipe support on the block with washers and screws.
2. Set the water outlet pipe, with clamp, on the support.
3. Assemble the pipe, with cardboard gasket, bolts and nuts, to the line already present
on the cooler.

4. Assemble a counterflange with gasket and screws to the pipe.
5. Set the water inlet flange to the thermostat

housing, with O-ring and screws.
6. Mount plugs, with gaskets, in the water

inlet flange.
7. Assemble a counterflange with gasket and

screws to the water inlet flange..
8. Install the water inlet flange, with gasket

and screws, on the front part of the block.
9. Assemble a counterflange with gasket and screws to the pipe.
61
LIST OF COMPONENTS
1 PIPE 1 1
2 SCREW 2 2
3 GASKET 1 1
4 NUT 2 2
5 CLAMP 2 2
6 HOSE 1 1
TOOLS
61
Coolant System with mechanical pumps
1. Assemble the pipe, with gasket, bolts and nuts, to the piping at the front of the cooler.
2. Connect the pipe to the pump by means of a hose and clamps.

PIPE FROM COOLER
TO MECHANICAL
PUMP
61
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY TURBOCHARGER
LIST OF COMPONENTS
1 TURBO 2 2
2 BY-PASS COVER GASKET 2 2
3 BY-PASS HOUSING COVER 2 2
4 SCREW 10 10
5 SCREW 6 6
6 SCREW 2 2
7 WASHER 6 6
8 GASKET 2 2
9 TURBO INLET ADAPTER 2 2
10 GASKET 2 2
11 SCREW 8 8
12 WASHER 8 8
TOOLS
62
TURBOCHARGER ASSEMBLY
1. Assemble turbo inlet adapter to right exhaust manifold with gasket, washers and
screws. Torque screws to 8 Kg.m.
2. Bolt by-pass housing cover with by-pass cover gasket and screws with red Molykote.
3. Assemble right turbo to adapter with gasket, washers, screws and nuts. Screws to be
smeared with red Molykote.

4. Repeat these operations on the left turbo.
TURBOCHARGER
ADAPTER
62
ASSEMBLY TURBO OIL INLET AND
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS OUTLET PIPES
LIST OF COMPONENTS
1 CLAMP 2 2
2 O-RING 2 2
3 RIGHT TURBO LUBRICATING PIPE 1 1
4 ELBOW 2 2
5 CONNECTOR, LUBRICATING FLANGE 2 2
6 SCREW 4 4
7 NUT 2 2
8 OIL PIPING FOR LEFT TURBOCHARGER 1 1
9 RIGHT TURBO OIL OUTLET PIPE (1ST SECTION) 1 1
10 LEFT TURBO OIL OUTLET PIPE (1ST SECTION) 1 1
11 DUAL CONNECTOR 2 2
12 GASKET 4 4
13 SCREW 4 4
14 TURBO OIL OUTLET PIPE (2ND SECTION) 2 2
15 CLAMP BRACKET 2 2
16 CLAMP 2 2
17 SCREW 2 2
18 NUT 2 2
19 WASHER 2 2
20 BICONE 2 2
TOOLS
63
TURBO OIL INLET AND ASSEMBLY
OUTLET PIPES
1. Bolt bracket to front of cylinder block with screws and washers.
2. Set a flange to left turbo for connection of the oil inlet pipe.
3. Assemble oil inlet pipe to turbo and to oil valve with connector.

4. Fasten to the bracket with clamp, rubber gasket, bolt and nut.
5. Assemble outlet pipe to elbow with connector and to turbo with gasket and screws.
6. Fasten pipe elements to each other with clamps, rubber gasket, bolts and nuts.
7. Bolt bracket to right front area of cylinder block with screws and washers.
8. Set a flange to right turbo for connection of the oil inlet pipe.
9. Assemble oil inlet pipe to turbo and to oil valve with connector.
10. Fasten to the bracket with clamp and rubber gasket.
11. Assemble outlet pipe to elbow with connector and to turbo with gasket and screws.
12. Fasten pipe elements to each other and to the engine block with clamps.
WARNING Be careful that oil pipes do not touch any surface of the engine.
63
ASSEMBLY AIR GALLERY BETWEEN
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS COOLER AND TURBOS
LIST OF COMPONENTS
1 TURBO OUTLET ELBOW 2 2
2 O-RING 2 2
3 GASKET 2 2
4 PLUG 2 2
5 WASHER 10 10
6 SCREW 6 6
7 O-RING 4 4
TOOLS
64
AIRGALLERY BETWEEN ASSEMBLY
COOLER AND TURBOS
1. Assemble the two turbo outlet elbows to the cooler, with O-ring, screws and washers.
2. Set 2 O-rings in the other end of the two elbows and mount them on the turbos.
3. Insert 1 plug with gasket in each elbow.
64
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY ELBOWS TO TURBO
LIST OF COMPONENTS
1 EXHAUST GAS OUTLET ELBOW 2 2
2 CLAMP 2 2
3 FLAT GASKET 2 2
4 COVER 2 2
5 GASKET 4 4
6 PLUG 4 4
7 SCREW 8 8
8 GASKET 2 2
9 PLUG 2 2
10 RHS ELBOW SUPPORT 1 1
11 LHS ELBOW SUPPORT 1 1
12 SCREW 4 4
13 FLAT WASHER 4 4
14 WASHER 4 4
15 SCREW 4 4
TOOLS
65
ELBOWS TO TURBO ASSEMBLY
1. Set gas outlet elbow on turbocharger.
2. Secure elbow to turbocharger with a clamp.
3. Bolt the RHS elbow support to the exhaust manifold with screws and washers.
4. Fasten RHS elbow to its support with 2 screws and flat washers.

RHS ELBOW
SUPPORT
5. Bolt LHS elbow support to turbo adapter with screws.
LHS ELBOW
SUPPORT
6. Fasten LHS elbow to its support with 2 screws and flat washers.
7. Place 1 cover, with flat gasket and screws, on each elbow.
8. Insert 2 plugs with gasket in each of

the elbow covers.
9. Place 1 plug with gasket in each

elbow. TURBO GAS
EXHAUST ELBOW
LHS ELBOW
SUPPORT
65
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY CARBURATION
LIST OF COMPONENTS
1 FILTER-CARBURETOR CONNECTING PIPE 2 2
2 COUPLING 2 2
3 INDUSTRIAL CLAMP 4 4
4 CARBURETOR (NATURAL GAS) 2 2
5 CARBURETOR-TURBO CONNECTING PIPE 2 2
6 O-RING 2 2
8 TURBO INLET CLAMP 2 2
9 ELBOW, CARBURETOR 2 2
10 "T" CONNECTOR 1 1
11 GAS REGULATING SCREW 1 1
12 GAS INLET HOSE 1 1
13 FLANGE 1 1
14 SCREW 4 4
15 NUT 4 4
16 FLAT GASKET DN 65 1 1
17 SCREW 8 8
18 MALE-FEMALE CONNECTOR 2 2
19 THREADED CLAMP 2 2
20 NUT 8 8
21 WASHER 8 8
22 BRACKET FOR FILTER-CARBURETOR PIPE 2 2
23 GASKET 1 1
24 SCREW 4 4
25 WASHER 4 4
26 SPACER 4 4
27 NUT 8 8
28 WASHER 8 8
TOOLS
66
CARBURATION ASSEMBLY
FGLD Engines
1. Set 1 turbo-carburetor connecting pipe in each turbocharger, with greased O-ring,

industrial clamp and turbo inlet clamp.
2. Assemble 1 carburetor with its studs and gasket to each pipe, fastening it loosely with
nuts and washers.

3. Check horizontality of both carburetors with a spirit level.
4. Set the carburetors connecting pipe. Fasten it to the studs mounted on the
carburetors with washers and nuts, inserting cardboard gaskets.
5. Check carburetors to be level.
6. Place 1 coupling on each carburetor and fasten each with 1 clamp.
7. Introduce 1 filter-carburetor connecting pipe in each coupling and fasten with another
clamp. Verify that the pipe is in a correct position.
8. Set 1 filter-carburetor pipe support on the sides of the air cooler, with screws, spacers
and washers.
9. Fasten the pipes to the supports with braces, washers, nuts and lock nuts.
10. Install the gas regulating screw in the carburetors connecting pipe.
11. Place the gas inlet hose to the regulating screw with gasket and screws. Assemble
one flange to the hose with flat gasket, bolts and nuts.
CARBURETOR ELBOWS GAS REGULATING SCREW
FILTER-CARBURETOR CARBURETOR
PIPE & SUPPORT
66
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY CARBURATION
LIST OF COMPONENTS
1 TECJET VALVE 1 1
2 GASKET 2 2
3 CARBURETOR CONNECTING PIPE 1 1
5 COUPLING 2 2
6 FILTER-CARBURETOR CONNECTING PIPE 2 2
7 GAS CARBURETOR 2 2
8 TURBO-CARBURETOR CONNECTING PIPE 2 2
9 O-RING 2 2
10 SUPPORT 1 1
11 FILTER-CARBURETOR PIPE SUPPORT 2 2
12 STUD 4 4
13 WASHER 8 8
14 NUT 12 12
15 FLANGE 1 1
16 SCREW 16 16
17 NUT 16 16
18 THREADED CLAMP 2 2
19 SPACER 3 3
20 FLAT WASHER 3 3
21 SCREW 3 3
22 WASHER 8 8
23 SPACER 4 4
24 SCREW 4 4
25 NUT 8 8
26 WASHER 8 8
TOOLS
66
CARBURATION ASSEMBLY
SFGLD Engines
1. Set 1 turbo-carburetor connecting pipe in each turbocharger, with greased O-ring.
2. Assemble 1 carburetor with its studs and gasket to each pipe, fastening it loosely with
nuts and washers.

3. Check horizontality of both carburetors with a spirit level.
4. Install the Tecjet valve support, with 3 screws, on the upper surface of the air cooler.
5. Assemble the Tecjet valve to its support with studs, spacers and fast-on nuts.
Place a flange with gasket, bolts and nuts on the external side of the Tecjet valve.
6. Set the carburetors connecting pipe. Fasten it to the studs mounted on the
carburetors with washers and nuts, inserting cardboard gaskets.
7. Check carburetors connecting pipe and Tecjet valve to be level.
8. Place 1 coupling on each carburetor and fasten each with 1 clamp.
9. Introduce 1 filter-carburetor connecting pipe in each coupling and fasten with another
clamp. Verify that the pipe is in a correct position.
10. Set 1 filter-carburetor pipe support on the sides of the air cooler, with screws, spacers
and washers.
11. Fasten the pipes to the supports with braces, washers, nuts and lock nuts.
12. Assemble the Tecjet valve to the carburetors connecting pipe, with gasket, bolts and
nuts. Tighten firmly.
CARBURETOR CONNECTING PIPE TECJET VALVE
CARBURETOR
66
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY AIR FILTERS
LIST OF COMPONENTS
1 AIR FILTERS 2 2
2 COLLAR 4 4
3 CLAMP 4 4
4 HOSE 2 2
5 RIGHT SUPPORT 1 1
6 LEFT SUPPORT 1 1
7 SCREW 8 8
8 WASHER 8 8
9 NUT 8 8
10 WASHER 10 26
11 SCREW 10 18
12 NUT - 8
13 FILTER FIXING PLATE - 4
14 FILTER CAP 2 2
15 CLAMP 1 1
16 FLOW RESTRICTION INDICATOR 2 2
17 INSERT FOR FILTER 2 -
TOOLS
67
AIR FILTERS ASSEMBLY
1. Assemble the support on the flywheel housing with bolts, nuts and washers.

LHS FILTER SUPPORT
2. Set the filter fixing plates on the supports, with 4 screws with spacer.
3. Set the collars to the filters, without tightening.
4. Secure the filters to the fixing plates on the supports, by locking the collars with bolts,
nuts and washers.
5. Assemble the filters to the carburetor pipes, with hoses and clamps.
FILTER-CARBURETOR
CONNECTION
67
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY 6-GAUGE CONTROL PANEL
LIST OF COMPONENTS
1 6-GAUGE CONTROL PANEL 1 1
2 6-GAUGE PANEL BRACKET 1 1
3 SCREW 4 4
4 ELASTIC ELEMENT 4 4
5 FLAT WASHER 8 8
6 NUT 8 8
TOOLS
68
6-GAUGE CONTROL PANEL ASSEMBLY
1. On a table, assemble 4 elastic elements to the control panel.
2. Fasten the control panel to its bracket with nuts going through the elastic elements.
3. Set bracket on camshaft cover and fasten with screws and washers.
4. Connect tubes/cables to the gauges:

- Oil temperature to flywheel housing.
- Air temperature to intake manifold.
- Oil pressure to connector in intermediate front gear housing cover, with gasket,
reducing connector, copper gasket and connector.
- Air pressure to intake manifold
- Raw water temperature cable to water inlet pipe to air cooler.
- Fresh water temperature cable to thermostat housing.
68
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY PRESSURE AND TEMPERATURE SWITCHES
LIST OF COMPONENTS
1 PRESSURE SWITCH (2.5KG) 1 1
2 SPACER 2 2
PRESSURE/TEMPERATURE SWITCHES
3 2 2
SUPPORT PLATE
4 SCREW 2 2
5 PRESSURE SWITCH (6KG/CM2) 1 1
6 R-000 ELASTIC ELEMENT 16 16
7 NUT 32 32
8 FLAT WASHER 16 16
9 1/4" SIMPLE STEEL ELBOW, PIPE 6 2 2
10 1/4" FEMALE COUPLING 2 2
11 TEMPERATURE SWITCH (125º) 1 1
12 6X4 FILTER PLUGGING CONTROL LINE 1 1
13 TEMPERATURE SWITCH (100º) 1 1
14 SCREW M4X8 DIN 7991 4 4
15 PRESSURE/TEMPERATURE SWITCH SUPPORT 2 2
LOW OIL PRESSURE PIPE TO PRESSURE
16 1 1
SWITCH
17 CLAMP 3 3
18 PROTECTIVE SHEATHING 4 4
19 CLAMP 4 4
TOOLS
69
PRESSURE AND TEMPERATURE SWITCHES ASSEMBLY
The number of control devices (pressure switches and temperature switches) depends
NOTE
on the application of each engine. This chapter describes the assembly procedure for
1 pressure switch and for 1 temperature switch.
1. Set the switch support plate on the engine. (On this plate, we shall fasten as many
pressure and temperature switches as required in each case.)

2. Assembly of pressure switch:
- Set a pressure switch on its support with 4 screws.

- Install 1 connector to the pressure switch inlet.
- Connect the pressure switch pipe to the engine parameter check point (water
pressure, oil pressure, ...).
3. Assembly of temperature switch:
- Set the temperature switch on its support.

- Place the bulb in the circuit whose temperature is to be monitored.
- Introduce the bulb of the temperature switch in the former bulb.
- Lay out the line correctly, bunch any excess length, and fasten it with plastic
clamps.
TEMPERATURE SWITCHES
TEMPERATURE SWITCHES
PRESSURE SWITCHES
69
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY REGULATOR -ACTUATOR
LIST OF COMPONENTS
1 ACTUATOR 1 1
2 O-RING 2 2
3 ADJUSTING SHIM 6 6
6 REGULATOR DRIVE SHAFT 1 1
7 STUD 2 2
8 NUT 2 2
9 CONNECTOR 1 1
10 SCREW 4 4
11 REGULATOR SUPPORT 1 1
12 BEARING SUPPORT 1 1
13 SEPARADOR 1 1
14 SCREW 2 2
15 SCREW 2 2
16 SCREW 4 4
17 REGULATOR COVER 1 1
18 PICK-UP AND ACTUATOR 1 1
TOOLS
70
REGULATOR -ACTUATOR ASSEMBLY
Actuator
1. Set a gasket on the actuator support and

bolt this support to the flywheel housing.
2. Set 2 plugs with washers.

3. Install actuator drive shaft with spacer on
support and adjust clearance by inserting
as many adjusting shims as necessary.
4. Fasten actuator to support with studs and nuts.
5. Install the valve needle with an O-ring in the regulator.
6. Place the connector on the actuator and connect the cable to the pick-up on the
flywheel housing.
CONNECTOR ACTUATOR
Without a regulator
1. When the engine has another regulation system, the regulator support housing shall
be closed with the regulator cover fastened with screws and Loctite 5368.
REGULATOR COVER
70
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY REGULATOR -ACTUATOR
LIST OF COMPONENTS
1 REGULADOR PSG 1 1
2 VALVE NEEDLE 1 1
3 O RING 2 2
4 REGULATOR GOVERNOR 1 1
5 NUT 4 4
6 STUD 4 4
7 ROLLERS SPACER 1 1
8 PITON REGULADOR 1 1
9 SCREW 4 4
11 PLUG 2 2
12 ADJUSTING 0,10 3 3
13 ADJUSTING 0,50 3 3
14 O RING 1 1
15 REGULATOR CONTROL GEARING 1 1
16 SCREW 6 6
17 SCREW 2 2
18 REGULATOR SUPPORT 1 1
19 SCREW 2 2
20 SCREW 4 4
21 REGULATOR COVER 1 1
TOOLS
70
REGULATOR -ACTUATOR ASSEMBLY
Hydraulic regulator
1. Set a gasket on the regulator support and bolt this support to the flywheel housing.
2. Set 2 plugs with washers.
3. Install regulator drive shaft with spacer on support and adjust clearance by inserting

as many adjusting shims as necessary.
4. Fasten regulator to support with studs and nuts.
5. Install the valve needle with an O-ring in the regulator.
Without a regulator
1. When the engine has another regulation system, the regulator support housing shall
be closed with the regulator cover fastened with screws and Loctite 5368.
70
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY REGULATOR LUBRICATING PIPES
LIST OF COMPONENTS
1 REDUCING CONNECTOR 2 2
2 REGULATOR LUBRICATING PIPE 1 1
3 REGULATOR LUBRICATING PIPE 1 1
4 HOLLOW SCREW 2 2
5 COPPER GASKET 6 6
6 COPPER GASKET 6 6
7 SCREW 1 1
8 SIMPLE ELBOW 1 1
TOOLS
71
REGULATOR LUBRICATING PIPES ASSEMBLY
1. Assemble 1 pipe from the oil distributor to the regulator support.
- Fasten it to the distributor with a hollow screw and copper gaskets.

- Fasten it to the regulator support with a reducing connector, copper gaskets and
screw.
2. Assemble 1 pipe from the regulator support to the regulator inlet.

- Fasten to the regulator support with reducing connector, copper gasket and
screw.
- Introduce into the regulator by means of a simple elbow.
SUPPORT -
DISTRIBUTOR - REGULATOR REGULATOR LINE
SUPPORT LINE
71
ASSEMBLY REGULATOR - BUTTERFLY
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS OPERATION LINKAGE
LIST OF COMPONENTS
1 LEVER, REGULATOR 1 1
2 LEVER, BUTTERFLY VALVE 1 1
3 WASHER 1 1
4 SCREW 2 2
5 BALL JOINT 2 2
6 NUT 2 2
7 STUD 2 2
8 MAIN ROD 1 1
9 SCREW 2 2
TOOLS
72
REGULATOR - BUTTERFLY ASSEMBLY
OPERATION LINKAGE
1. Set butterfly valve lever with screw and washer.
2. Assemble regulator lever with screw.
MAIN ROD

REGULATOR LEVER
3. Connect the two levers by means of the main rod, studs, nuts and ball joints and
screws.
BUTTERFLY LEVER
72
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY PRE-LUBE AND OIL DRAINING SYSTEM
LIST OF COMPONENTS
1 OYE 0.75HP MOTOR-DRIVEN PUMP 1 1
2 PRE-LUBE PUMP BRACKET 1 1
3 2-WAY VALVE 1 1
4 TUBO ASPIRACION 1 1
5 SUCTION PIPE 1 1
6 SCREW 4 4
7 SCREW 5 5
8 WASHER 4 4
9 NUT 4 4
10 GASKET 1 1
11 CONNECTOR 1 1
12 SIMPLE ELBOW 3 3
TOOLS
73
PRE-LUBE AND OIL DRAINING SYSTEM ASSEMBLY
220V/24V.
1. Secure pump bracket to engine block with 4 screws.
2. Assemble reducing couplings to pump.
3. Assemble elbow and valve on reducing couplings.

4. Set hoses with connector to valve and elbow.
5. Mount a connector, valve and reducing coupling on the pipe in the lower part.
6. Assemble it to the oil pan with a gasket and reducing coupling.
The pre-lube pump is generally housed on the engine. In some applications, the pump
NOTE
may be installed on the bedplate.
73
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY OIL PAN LEVEL ALARM
LIST OF COMPONENTS
1 LEVEL 1 1
3 PIPE 1 1
4 CONNECTOR 1 1
5 PIPE 1 1
6 CONECTOR 2 2
7 GASKET 1 1
8 VALVE 1 1
9 ADAPTER 1 1
10 ELBOW 1 1
TOOLS
74
OIL PAN LEVEL ALARM ASSEMBLY
1. Set reducing coupling with Loctite 242 on oil pan cover.
2. Assemble a shutoff valve with Loctite 242 to the reducing coupling, the valve
remaining in the upper area.
3. Bolt oil level alarm to support.

4. Bolt alarm support in oil pan. The alarm must be vertical. Check with an air level.
5. Set connecting pipe between elbow and oil level, with connector.
6. Set connecting pipe between oil level and connecting rod inspection cover, with
connectors with Loctite 242, on both ends.
WARNING
Check that oil level alarm is still vertical. Correct position if necessary.
74
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY ELECTRONIC IGNITION MODULE
LIST OF COMPONENTS
1 CEC IGNITION MODULE 1 1
3 NUT 8 8
4 CEC IGNITION MODULE SUPPORT 1 1
5 GASKET FOR IGNITION MODULE 1 1
6 SCREW 6 6
7 PICK-UP 1 1
8 PICK-UP CABLE 1 1
9 PIN 2 2
TOOLS
75
ELECTRONIC IGNITION MODULE ASSEMBLY
FGLD Engines
1. Set support on back intermediate housing cover.
2. Fasten the elastic elements (dynaflex) to the support with nuts.
3. Install the electronic ignition system on the dynaflex and secure it with nuts.

4. Install the pick-up on the back of the support in the gear train cover and connect the
cable to the ignition module.
5. Connect the spark plug cable to the ignition module.
PICK-UP CABLE
SPARK PLUG CABLE
75
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY ELECTRONIC IGNITION MODULE
LIST OF COMPONENTS
1 CEC IGNITION MODULE 1 1
3 NUT 8 8
4 CEC IGNITION MODULE SUPPORT 1 1
5 GASKET FOR IGNITION MODULE 1 1
6 SCREW 6 6
7 PICK-UP 2 2
8 CABLE 2 2
9 PIN 2 2
10 PICK-UP 1 1
11 PICK-UP CABLE 1 1
TOOLS
75
ELECTRONIC IGNITION MODULE ASSEMBLY
SFGLD Engines
1. Set support on back intermediate housing

cover.
2. Fasten the elastic elements (dynaflex) to

the support with nuts.

3. Install the electronic ignition system on the
dynaflex and secure it with nuts.
4. Install the pick-up on the back of the support in the gear train cover and connect the
cable to the ignition module.
PICK-UP TO GEAR
TRAIN COVER
5. Install 2 pick-ups in the flywheel housing and connect their cables to the ignition
module.
6. Connect the spark plug cable to the ignition module.
SPARK PLUG CABLE
PICK-UPS TO
FLYWHEEL HOUSING
75
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY HIGH VOLTAGE COILS SET
LIST OF COMPONENTS
1 SHIELDED LOW-VOLTAGE WIRE STRIP 1 1
2 SPARK PLUG WIRE 12 16
3 COIL 12 16
4 CABLES CONDUIT SUPPORT 4 6
5 SCREW 8 8
6 WASHER 8 8
7 SCREW 8 8
8 WASHER 8 8
9 SCREW 24 32
TOOLS
76
HIGH VOLTAGE COILS SET ASSEMBLY
1. Bolt three low-voltage wire supports on the intake manifold with screws and washer.
2. Secure the low-voltage wire strip on the supports with screws.
3. Set the spark plugs in the engine, to 2 Kg.m.

DANGER

Before installing the spark plugs, check the gap.
4. Set the coils on the strip with screws.
5. Connect the spark plug wire to the coils, until you hear it make two clicks.
6. Connect the said wire to the spark plugs.
SPARK PLUG CONNECTION

HIGH-VOLTAGE COILS
LOW VOLTAGE WIRE STRIP
SUPPORT
76
ASSEMBLY-SUB-UNITS INDEX
1. AUXILIARY ROCKER ARMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)

2. AUXILIARY ROCKER ARM SHAFT. . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
3. CYLINDER HEAD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(5 PAGES)
4. ROCKER ARM SETS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
5. VALVE PUSH RODS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
6. CRANKCASE BREATHER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
7. REAR SEAL HOLDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)

8. FLYWHEEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
9. CENTRIFUGAL FRESH WATER PUMP. . . . . . . . . . . . . . . . . . . . . .(7 PAGES)
10. CENTRIFUGAL RAW WATER PUMP. . . . . . . . . . . . . . . . . . . . . . . .(6 PAGES)
11. THERMOSTAT HOUSING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
12. HEAT EXCHANGER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(4 PAGES)
13. SUCTION BELL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
14. OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(4 PAGES)
15. OVERPRESSURE VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
16. THERMOSTATIC AND OIL REGULATING VALVE. . . . . . . . . . . . . . . .(4 PAGES)
17. OIL PAN COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)

18. FILTER SUPPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
19. OIL LEVEL DIPSTICK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
20. WATER-COOLED EXHAUST MANIFOLD. . . . . . . . . . . . . . . . . . . . .(2 PAGES)
21. AIR COOLER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
22. TURBOCHARGER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(6 PAGES)
23. HYDRAULIC REGULATOR HOUSING. . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
24. 24/220V ELECTRIC DRIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
25. 6-GAUGE CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
26. JETS CONTROL VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
27. BLOCK WITH LINERS AND HYDRAULIC TEST. . . . . . . . . . . . . . . . .(4 PAGES)
28. BUTTERFLY VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(2 PAGES)
REF. 19.09.530 1/1

READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY SUB-UNITS AUXILIARY ROCKER ARM
LIST OF COMPONENTS
2 AUXILIARY ROCKER 1 1
3 SAFETY WASHER 1 1
4 SPHERICAL SEAT AUXILIARY ROCKER ARM 1 1
5 OUTER SKID AUXILIARY ROCKER ARM 1 1
6 SCREW 1 1
7 INTERIOR SKID AUXILIARY ROCKER ARM 1 1
TOOLS
Auxiliary rocker arm holding tool: Ref. 16.75.214
Spherical seat mounting tool: Ref. 16.75.215
AUXILIARY ROCKER ARM ASSEMBLY SUB-UNITS
1.2. Free of Burrs.
1.3. Free of Blows.
1.4. Free of Dirt.

2. ASSEMBLE THE SPHERICAL SEAT WITH THE TOOLS REF.16.75.214 AND
REF.16.75.215
3. ASSEMBLE THE AUXILIARY ROCKER ARM SHAFT

3.1. Assemble the shaft on the interior skid and on the outer skid with black
Molikote.
3.2. Insert the shaft in the auxiliary rocker arm and screw it in.
3.3. Set a safety washer on the end of the shaft.
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY SUB-UNITS AUXILIARY ROCKER ARM SHAFT
LIST OF COMPONENTS
2 PLUG SCREW 4 4
TOOLS
AUXILIARY ROCKER ARM SHAFT ASSEMBLY SUB-UNITS
1.2. Free of Burrs.
1.3. Free of Blows.
1.4. Free of Dirt.
2. DEGREASE ALLEN PLUG SCREWS

3. CHECK THE INSIDE OF THE SHAFT FREE OF BURRS AND DIRT
4. INSTALL PLUG SCREWS

4.1. Set plug screws on top of thread of the shaft, with Loctite 270, Allen wrench
and a pneumatic tool.
4.2. Make sure none of the oil holes is blocked by the plugs.
4.3. Put antioxidants on the shaft.
ASSEMBLY SUB-UNITS CYLINDER HEAD
ASSEMBLING COMPONENTS
Regarding the specifications and tolerances, consult the information provided in the
tolerance and specification table in section A (Illustration / List of Components / List of
Tools / Table of Specifications and Tolerances).
Installation of the injector holder liner (Figures 1 and 2)

The injector holder liner must be installed before doing the required hydraulic test with
NOTE
the cylinder head, since the liner is water cooled and is part and parcel of the cylinder
head water tightness.
1. Make sure the holes and injector

holder liners are clean and without
burrs.
2. Set the cylinder head, face up, on a
clean table.
3. Install new compression O-rings and
washers on the injector holder liners.
4. Apply clean motor oil to the thread of
the injector holder liners.
5. Install the injector holder liner in the
cylinder head, using the injector
holder insert/removal tool.
6. Tighten the liner according to
specifications by using the injector
holder insert/removal tool.
CYLINDER HEAD ASSEMBLY SUB-UNITS
Installation for Valve Guides (Figures 3 and 4)
If the cylinder head is taken apart only for inspection, the valves, valve seals, valve
NOTE
guides, etc., must be installed in their original positions (numbered). This is the way to
make sure the assembly maintains the same guidelines of wear among the
components.

1. Make sure the guide holes and guides are clean and without burrs.
2. Place the cylinder head, face up, on a clean table.
3. Insert an inlet valve guide, with the conical portion face up, in an inlet valve guide
hole, from the upper part of the cylinder head.
CAREFUL
When we use a mallet to install the valve guide, use moderate blows.
4. Place the tool for inserting valve guides in the guide to be installed and set it by
using a press or a mallet, being careful not to harm the valve guide, its hole or
other parts of the cylinder head.
5. Repeat steps 3 and 4 for the rest of the inlet valve guides.
6. Insert an exhaust valve guide, with the conical portion face up, in an exhaust
valve guide, from the upper part of the cylinder head.
7. Place the tool for inserting valve guides in the guide to be installed and set it by
using a press or a mallet, being careful not to harm the valve guide, its hole or
other parts of the cylinder head.
8. Repeat steps 6 and 7 for the rest of the exhaust valve guides.
ASSEMBLY SUB-UNITS CYLINDER HEAD
Installation of Valve Seats (Figures 5 and 6)
1. Make sure the valve seats and their bores are clean and without burrs.
2. Place the cylinder head, with its lower portion face up, on a clean table.
NOTE
Before the installation of the valve seats, it will be necessary to cool the valve seats in
freezing water for approximately 5 minutes. Make sure the valve seats are dry before
their installation.
3. Position the valve seats, with the beveled edge face up, in the valve seat boxes.
CAREFUL
When we use a mallet to install the valve seats, use moderate blows, rotating the insert
tool for the seats, between mallet blows.
4. Place the valve holder insert tool on top of the seat that is going to be installed
and set it by using a press or a mallet, being careful not to harm the valve seat,
its assembly or another part of the cylinder head.
5. Repeat steps 3 and 4 to install the rest of the valve seats.
Verify the valve heads in the setback area of the cylinder head
Verification of the valve movement within the cylinder head according to information
NOTE
provided in "Inspection of Cylinder Heads - Valve Clearance" in Section E (component

inspection).
Verification of Valve Seats
Verify the valve seats according to the information supplied in "Inspection of Cylinder
NOTE
Heads, Shutoff of Valves" in section E (inspection of components).
CYLINDER HEAD ASSEMBLY SUB-UNITS
Valve Installation
1. Make sure the valve rods, guides and rod seals are clean and without burrs.
2. Place the cylinder head on its face on a clean table.
3. Apply clean motor oil to the valve rod that is going to be installed, and install the
valve.
4. Repeat step 3 for the rest of the valve rods.

Installation of valve rod seals (Figures 7 and 8)
1. Make sure the valve guides and valve rod seals are clean and without burrs.
2. Place the cylinder head, with its upper portion face up, on a clean table.
3. Manually adjust the valve rod seal to the valve guide.
CAREFUL
When we use a mallet for the installation of the valve rod seals, use the least amount
of force required to secure the seals.
4. Place the rod seal insert tool in the seal that is going to be installed, and secure
it by using a mallet, being careful not to harm the seal, the guide or any other
component of the cylinder head.
5. Repeat steps 3 and 4 to install the rest of the seals.
Installation of valve spring seats (Figure 9)

1. Make sure the spring seats and their holes are clean and without burrs.
2. Place the cylinder head on its base, on a clean table.
3. Insert the spring in its housing, with the stepping face up.
4. Repeat step 3 to install the rest of the spring seats.
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY SUB-UNITS CYLINDER HEAD
Installation of the inside and outside springs, spring locks and valve
seals (Figure 10)
Valve springs must be tested or replaced in the maintenance process of cylinder heads,
NOTE
according to the information provided in "Inspection of Valve Spring Cylinder Heads" in

section E (inspection of components).
1. Make sure that all the components that make up the valve unit are clean and
without burrs.
2. Place the cylinder head, with its upper panel face up, on a clean table.
3. Position the inside and outside springs in the valve rod, so that they are
supported on the staggered surface of the spring hole.
4. Place the spring seal, with the stepping down, above the valve springs, in a way
that the staggered surface holds the springs.
6. Screw the base of the spring compressor tool in the spark plug holder liner.
7. Position the spring compression tool and compress the spring unit.
8. Insert two spring stops, with the conical portion face down, its inside surface in a
form that will match the slot of the valve rod.
10. Remove the valve spring compressor tool.
11. Hit the upper part of each spring stop to make sure they are properly secured.
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY SUB-UNITS ROCKER ARM SET
LIST OF COMPONENTS
1 COMPLETE INLET ROCKER ARM 1 1
2 COMPLETE EXHAUST ROCKER ARM 1 1
3 ROCKER ARM SUPPORT 1 1
4 SCREW 2 2
5 SCREW 2 2
6 SUPPORT CENTERING PIN 1 1
7 SAFETY WASHER 1 1
8 ROCKER ARM SHAFT 1 1
9 ROCKER ARM CLAMPING WASHER 1 1
TOOLS
Snap ring wrench: 16.75.194
ROCKER ARM SET ASSEMBLY SUB-UNITS

1.2. Free of Burrs.
1.3. Free of Blows.
1.4. Free of Dirt.

2. SET CENTERING PIN
2.1. Set centering pin on rocker arm support.
2.2. Secure the unit support to the screw of the work table.
3. PLACE SHORT SCREWS ON THE ROCKER ARM SUPPORT
4. INSTALL THE EXHAUST ROCKER ARM

4.1. Insert the exhaust rocker arm in the rocker arm shaft.
5. INSTALL THE INLET ROCKER ARM

5.1. Secure the inlet rocker arm on the support with your hand.
5.2. Insert the exhaust rocker arm shaft in the support and the inlet rocker arm.
5.3. Secure the rocker arm with a clamping washer and a safety washer, using tool
ref.: 16.75.194.
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY SUB-UNITS VALVE PUSH-RODS
LIST OF COMPONENTS
1 VALVE PUSH ROD BODY 1 1
2 PUSH ROD SEAT 1 1
3 NUT 1 1
4 PUSH ROD ADJUSTMENT SCREW 1 1
TOOLS
VALVE PUSH-RODS ASSEMBLY SUB-UNITS
1.2. Free of Burrs.
1.3. Free of Blows.
1.4. Free of Dirt.

2. DEGREASING OF PARTS
3. INSTALLATION OF ADJUSTMENT SCREW

3.1. Install adjustment screw on rod and place nut.
4. INSTALLATION OF SEAT
4.1. Install seat with grease on its outside. Verify if it rotates correctly (important).
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY SUB-UNITS CRANKCASE BREATHER
LIST OF COMPONENTS
1 GAS EXHAUST TUBE FLANGE 1 1
2 O-RING 2 2
3 BREATHER FIXING STUD 1 1
4 NUT 4 4
5 WASHER 4 4
6 SCREW 4 4
7 O-RING 1 1
8 NUT 1 1
9 GASKET 1 1
10 UPPER BODY, BREATHER 1 1
11 METALLlC MESH 1 1
12 LOWER BODY, BREATHER 1 1
TOOLS
CRANKCASE BREATHER ASSEMBLY SUB-UNITS
1.2. Free of Burrs.
1.3. Free of Blows.
1.4. Free of Dirt.

2. DEGREASING OF STUD
3. FITTING OF STUD IN LOWER BODY

3.1. Introduce stud with Loctite 270 in the lower body and tighten it with a
pneumatic wrench.
4. SETTING OF O-RING (PREVIOUSLY GREASED) IN THE UPPER BODY
5. CUTTING OF METALLIC MESH

5.1. Cut a piece of metallic mesh (filter screen) about 800mm in length.
6. ASSEMBLY OF LOWER AND UPPER BODIES

6.1. Assemble the lower body, complete with filter screen, to the upper body, with
a blind nut and copper gasket.
7. ASSEMBLY OF FLANGE TO GAS EXHAUST TUBE

7.1. Pre-assemble flange and O-ring to the tube with bolts and nuts (final assembly
will be carried out on the assembly line).
8. LABELLING AND STORING
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY SUB-UNITS REAR SEAL HOLDER
LIST OF COMPONENTS
1 REAR SEAL HOLDER 1 1
2 CRANKSHAFT REAR SEAL 1 1
TOOLS
REAR SEAL HOLDER ASSEMBLY SUB-UNITS
1.2. Free of Burrs.
1.3. Free of Blows.
1.4. Free of Dirt.

2. HYDRAULIC PRESS PREPARATIONS
2.1. Prepare the hydraulic press with its appropriate tool.
3. SET SEAL IN THE SEAL HOLDER

3.1. Oil the seal.
3.2. Set the seal on the tool and hydraulically insert it into the holder.
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY SUB-UNITS FLYWHEEL
LIST OF COMPONENTS
1 FLYWHEEL 1 1
2 FLYWHEEL GEAR RING 1 1
TOOLS
FLYWHEEL ASSEMBLY SUB-UNITS
1.2. Free of Burrs.
1.3. Free of Blows.
1.4. Free of Dirt.
2. GEAR RING EXPANSION

2.1. Put the gear ring in the oven and leave it for a period of 30' at 230°C for it to
expand sufficiently.
3. INSTALLATION OF GEAR RING ON FLYWHEEL

3.1. Install gear ring on flywheel and observe that beveled side remains toward the
outside.
3.2. Verify the right setting of the gear ring on the flywheel.
4. LABELING AND STORAGE
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY SUB-UNITS CENTRIFUGAL FRESH WATER PUMP
LIST OF COMPONENTS
2 FRESH WATER PUMP BEARING SUPPORT 1 1
3 BEARING 1 1
4 GEAR DISTANCE TUBE 1 1
5 KEY 1 1
6 FRESH WATER PUMP CONTROL GEAR 1 1
7 BEARING SPLITTER 2 2
8 BEARING 1 1
9 LOCK WASHER 1 1
10 NUT 1 1
11 SAFETY WASHER 1 1
12 BODY OF FRESH WATER PUMP 1 1
13 FRESH WATER PUMP IMPELLER 1 1
14 AXIAL SEAL 1 1
15 NUT 1 1
16 PLUG 1 1
TOOLS
Water seal adjustment tool: Ref. 16.75.187
Bearing fitting tool (hot): Ref. 16.75.189
Bushing punching fitting tool: Ref. 16.75.191
CENTRIFUGAL FRESH WATER PUMP ASSEMBLY SUB-UNITS
Regarding specifications and tolerances, consult the information provided in the table
NOTE
of tolerances and specification in Section A (Illustration / List of Components / List of

WARNING
Make sure all the components are clean and without rust, before being installed.

NOTE
Replace O-rings, oil seals and seals (bushings) during the re-assembly.
1. Installation of Cap Screws and Allen Screws (Figure 1).
1. Place the body of the water pump, with

the side that faces the engine face up,
on a clean and rigid table.
2. Install 2 cap screws in the pump body.
3. Apply Loctite 270 to the thread of the
Allen screws.
4. Set the Allen screws in the pump body
with an Allen wrench.
5. Make sure there are no leftovers of
Loctite 270 on the pump body.
2. Installation of pump shaft assembly.(Figure 2). FIGURE 1
1. Expand the bushing and bearings, placing them in an oven or heating surface.
CAREFUL
Wear appropriate gloves to protect your hands from burns, when using an oven or
handling hot parts.
2. Manually place the bushing on the

shaft.
3. Place the bearings in the shaft, in such
position as they butt against the
bushing, by using the bearing
installation tool.
4. Set the shaft spacer.
5. Position the key in the shaft key-slot.
Seat the key completely, by
hammering it moderately with the
mallet.
FIGURE 2
9
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY SUB-UNITS CENTRIFUGAL FRESH WATER PUMP
LIST OF COMPONENTS
18 FRESH WATER PUMP SHAFT ASSEMBLY 1 1
19 PUMP SHAFT 1 1
20 BUSHING 1 1
21 PUMP SEAL HOLDER COVER 1 1
22 RADIAL SEAL 1 1
23 SCREW 6 6
24 O-RING 1 1
25 STOP BUSHING 1 1
26 SCREW 1 1
27 FLAT WASHER 4 4
28 PIN 1 1
29 O-RING 1 1
31 TAPON 1 1
32 SCREW 2 2
33 O-RING 1 1
TOOLS
Water seal adjustment tool: Ref. 16.75.187
Bearing fitting tool (hot): Ref. 16.75.189
Bushing punching fitting tool: Ref. 16.75.191
9
3. Preparation of the pump bearing support
a) Setting of seal and O-ring in the seal holder (Figures 3 & 4).
1. Clean the seal holder and its mounting screws in a washer.

2. Grease the seal and set it in the seal holder with the seal adjustment tool.
3. Place the O-ring on the contact surface of the seal holder.

FIGURE 3
b) Assembly of pump shaft, control gear and

seal holder in the bearing support (Figures
5 & 6) FIGURE 4
1. Set the bearing support in a clamp.

2. Mount the pump control gear in the support.
3. Introduce the pump shaft in the bearing support, aligning the key with the gear
slot.
4. Set the seal holder on the support. Apply Loctite 270 to the threads of the seal
holder mounting screws.
5. Tighten the 6 screws (in diametrically opposed pairs) to 2 kg.m.
FIGURE 5 FIGURE 6
ASSEMBLY SUB-UNITS CENTRIFUGAL FRESH WATER PUMP
c) Assembling the bearing, bearing splitter, washer and nut (Figures 7 to 12).
1. Rotate the pump support until the end
of the pump shaft points upward.
2. Insert an O-ring in the slot in the pump
support.
3. Place the control gear in its correct
position (close to the shaft spacer).
4. Install the bearing splitter, with the step

up, inside the support.
5. Install the external track of the bearing.
6. Place the snap ring in the slot that is
just over the bearing, using the snap
ring installation tool.
FIGURE 7
FIGURE 8 FIGURE 9
Secure the snap rings with your hand, secure the ends with the snap ring tool.
This will prevent it from flying if it gets loose from the tool.
7. Install the internal track of the bearing, by hammering it moderately with a mallet.
FIGURE 10 FIGURE 11
8. Set the bearing splitter with the plain surface facing up.
9. Install the spacer and washer.
10. Apply Loctite 270 to the thread of the nut and tighten the nut at a pressure of
18 kg.m.

FIGURE 12
4. Assembly of pump support and body (Figures 13 to 17).
1. Apply Loctite 270 to the pump body mounting screws and assemble the two parts
(bearing support and pump body).
FIGURE 13 FIGURE 14
ASSEMBLY SUB-UNITS CENTRIFUGAL FRESH WATER PUMP
2. Place the unit in a clamping tool and prepare the seal, axial seal, impeller and
nut.
3. Grease the exterior surface of the seal and place it inside the pump body.
4. Install the axial seal with the spring oriented upwards.
5. Introduce the impeller inside the pump body, rotating it smoothly until the impeller
is perfectly seated inside the pump body.
FIGURE 15 FIGURE 16
FIGURE 17
6. Apply Loctite 270 to the thread of the nut and tighten the nut to a torque of
10 kg.m.
7. Install the oil retainer in the pump body.
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY SUB-UNITS CENTRIFUGAL RAW WATER PUMP
LIST OF COMPONENTS
3 BEARING 1 1
4 GEAR SPACER 1 1
5 KEY 1 1
6 WATER PUMP GEAR 1 1
8 BEARING 1 1
9 LOCK WASHER 1 1
10 NUT 1 1
12 PUMP BODY 1 1
13 PUMP WHEEL 1 1
14 NUT 1 1
15 PLUG 1 1
TOOLS
Snap ring wrench: Ref.: 16.75.194
10
CENTRIFUGAL RAW WATER PUMP ASSEMBLY SUB-UNITS
1. VISUAL INSPECTION.
1.2. Free of Burrs.
1.3. Free of Blows.
1.4. Free of Dirt.

2. PREPARARE PUMP SHAFT.
3. ASSEMBLE BEARING SUPPORT
3.1. Install the external track of the bearing inside the support with the bearing
fitting tool.
3.2. Set a snap ring (safety washer), with tool Ref.: 16.75.194, in the slot in the
bearing support.
4. ASSEMBLE PUMP GEAR AND PUMP SHAFT.
4.1. Clamp the bearing support in a vice. Clean it with compressed air to remove
any residual dirt.
10
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY SUB-UNITS CENTRIFUGAL RAW WATER PUMP
LIST OF COMPONENTS
17 O-RING 1 1
22 SHAFT 1 1
23 BUSHING 1 1
24 AXIAL SEAL 1 1
25 STOP BUSHING 1 1
26 SEAL RETAINER COVER 1 1
27 SEAL 1 1
28 SCREW 6 6
29 O-RING 1 1
30 SCREW 4 4
31 WASHER 4 4
TOOLS
10
4.2. Install the internal track of the bearing in the bearing support.
4.3. Set the bearing splitter in the lower part of the bearing support. Place the pump
gear inside the bearing support.
4.4. Insert the pump shaft, aligning the shaft's key with the gear slot.
4.5. Hammer the shaft down until the splitter runs into the pump gear.
4.6. Verify that the area surrounding the gear slot is free of burrs, after the shaft has

been set in place.
BEARING SPLITTER
GEAR SPACER
WATER PUMP GEAR
5. INSTALLATION OF SEAL AND SEAL RETAINER COVER.
5.1. Grease the seal and set it in the seal retainer cover with the seal mounting tool.
5.2. Apply sealing paste (Loctite 573) to the contact surface of the seal retainer
cover.
5.3. Apply sealing paste (Loctite 573) to the contact surface of the seal retainer
cover.
5.4. Clean sealing paste and Loctite leftovers, once the screws have been
tightened in the seal retainer cover.
10
ASSEMBLY SUB-UNITS CENTRIFUGAL RAW WATER PUMP
6. INSTALLATION OF SPLITTER, WASHER AND FASTENING NUT.
6.1. Turn the bearing support in the vice

and install a splitter, washer and
fastening nut over the end of the
shaft.
6.2. Apply Loctite 270 to the nut and

tighten the nut at 18 kg.m.
7. ASSEMBLY OF THE PUMP BODY.
7.1. Clean the pump body with

compressed air.
7.2. Insert 2 setscrews with Loctite 270,
using an Allen wrench.
7.3. Set pump body on tool and clamp it

in a vice. Position the bearing
support on the pump body and
fasten it with 4 screws and washers.
Tighten the screws by hand.
10
7.4. Install axial seal inside the pump body.

7.5. Install the wheel inside the pump body. Apply Loctite 242 to the fastening nut
and tighten the nut at 10 kg.m.

AXIAL SEAL FASTENING NUT PUMP WHEEL
7.6. Verify that the whole assembly (wheel, shaft, gear) rotates freely inside the
pump body.
8. LABELING AND STORING.
10
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY SUB-UNITS THERMOSTAT HOUSING
LIST OF COMPONENTS
1 THERMOSTAT HOUSING 1 1
2 THERMOSTAT HOUSING COVER 1 1
3 BODY OF THERMOSTAT HOUSING 1 1
4 THERMOSTAT 7 7
5 SEAL 7 7
6 SNAP RING 7 7
7 WASHER, THERMOSTAT HOUSING 7 7
8 STUD 4 4
9 FLANGE 1 1
10 SIMPLE ELBOW 1 1
13 SCREW 2 2
14 SCREW 9 9
15 GASKET, THERMOSTAT HOUSING 1 1
16 PLUG 1 1
18 GASKET 3 3
20 PRESSURE PLUG 3 3
21 PLUG 3 3
22 VENT VALVE 1 1
23 O-RING 1 1
24 SCREW 3 3
TOOLS
Snap ring wrench : Ref.: 16.75.194
Seal inset tool: Ref.: 16.75.186
11
THERMOSTAT HOUSING ASSEMBLY SUB-UNITS
1.2. Free of Burrs.
1.3. Free of Blows.
1.4. Free of Dirt.

2. DEGREASING VENT VALVES AND M10 STUDS
3. INSTALLATION OF PRESSURE PLUG AND M10 STUDS

3.1. In the back part of the box, insert pressure plugs and M10 studs with Loctite
270, using the appropriate tools.
4. INSTALLATION OF SEALS, THERMOSTATS, WASHERS AND SNAP RINGS
4.1. In the front part of the housing, install seals, thermostats, washers and snap
rings with tool Ref.: 16.75.194.
5. INSTALLATION OF VENT VALVE (with Loctite 270 and double open-ended
spanner)
5.1. Install seals on thermostat box with tool Ref.: 16.75.186 and a hammer.
6. INSTALLING THE COVER
6.1. On the front part, install the cover with its gasket and secure it with M10 Allen
screws.
7. INSTALLING HEXAGON PLUGS
7.1. Install hexagon plugs with their copper gaskets on the cover, using a
pneumatic wrench.
8. INSTALLING THE FLANGE
8.1. Bolt a flange with its O-ring (previously greased) to the back part with 3 M10
screws.
8.2. Install a 1/2" plug with its copper gasket, using a pneumatic wrench.
11
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY SUB-UNITS HEAT EXCHANGER
LIST OF COMPONENTS
1 COMPLETE HEAT EXCHANGER 1 1
2 HEAT EXCHANGER BUNDLE 2 2
3 WATER INLET AND OUTLET COVER 4 4
4 HOUSING COVER 1 1
5 GASKET 1 1
6 PLUG 4 4
7 HEAT EXCHANGER BODY 1 1
8 SCREW 3 3
9 FLAT WASHER 16 16
10 NUT 16 16
11 STUD 16 16
12 O-RING 4 4
14 FLANGE 1 1
15 PLUG 1 1
TOOLS
12
HEAT EXCHANGER ASSEMBLY SUB-UNITS
1. VISUAL INSPECTION.
1.2. Free of Burrs.
1.3. Free of Blows.
1.4. Free of Dirt.

2. INSTALLING STUDS.
2.1. Set 16 M10 studs with Loctite 270.
3. INSTALLING THE HEAT EXCHANGER BUNDLES (AS SHOWN ON DRAWING)
4. INSTALLING O-RINGS ON THE BUNDLE

4.1. Place O-rings, previously greased, on the bundle.
12
ASSEMBLY SUB-UNITS HEAT EXCHANGER
5. INSTALLING SIDE COVERS

5.1. Install the side covers with nuts and washers, using a pneumatic wrench.
5.2. Set sealing plugs on the side covers.
6. INSTALLING THE FILLING PLUG AND FLANGE (with Loctite 270TM).
12
HEAT EXCHANGER ASSEMBLY SUB-UNITS
7. INSTALLING THE TOP COVER.

12
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY SUB-UNITS SUCTION BELL
LIST OF COMPONENTS
1 SUCTION BELL 1 1
2 STRAINER 1 1
3 SCREW 10 10
4 STUD 4 4
TOOLS
13
SUCTION BELL ASSEMBLY SUB-UNITS
1.2. Free of Burrs.
1.3. Free of Blows.
1.4. Free of Dirt.
2. DEGREASING OF M10 STUDS AND M6 SCREWS.

3. INSTALLING STUDS
3.1. Insert the studs with Loctite 270, using a pneumatic wrench and the stud fitting
tool.
4. STRAINER ASSEMBLY ON BELL

4.1. Set strainer on bell and fasten it with M6 screws with Loctite 270, using a
pneumatic screwdriver.
13
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY SUB-UNITS OIL PUMP
LIST OF COMPONENTS
1 OIL PUMP BODY 1 1
2 OIL PUMP DRIVE PINION 1 1
3 OIL PUMP DRIVEN PINION 1 1
4 OIL PUMP COVER 1 1
5 HOLLOW CENTRING PIN 2 2
6 KEY 1 1
7 NUT 1 1
8 BUSHING, OIL PUMP COVER 2 2
9 PIN 2 2
10 SCREW 12 12
11 OIL PUMP GEAR 1 1
TOOLS
Oil pump unit assembly tool: Ref.: 16.26.340 M01
14
OIL PUMP ASSEMBLY SUB-UNITS
1.2. Free of Burrs.
1.3. Free of Blows.
1.4. Free of Dirt.
2. COVER BUSHING ASSEMBLY

2.1. Set two bushings on the pump cover (placing the bushings in the correct
position, with the contact area facing the oil discharge), using the mounting
tool and a press.
2.2. Subject bushing to a pass fail inspection (dimensional check).
3. ASSEMBLY OF BUSHINGS ON BODY

3.1. Place the pump body on the tool in the press.
3.2. Set 2 bushings on the pump body (in the correct position) with the help of the
tool.
3.3. Subject bushings to a pass fail inspection (dimensional check).
4. INSTALLING GUIDE PINS

4.1. Introduce 2 guide pins in the pump body, with a hammer.
4.2. Identify the pump body according as it is for an SF/FG...360 engine or an
SF/FG...480 engine.
5. DEGREASING BOLTS AND NUTS
6. ASSEMBLY OF PINIONS ON THE PUMP BODY

6.1. Set pump body on tool Ref.: 16.26.340 M01 and clean the inside with
compressed air.
6.2. Polish the pinions.
6.3. Grease and apply Molykote BR2 to the inside of the pump body and set the
pinions.
6.4. Grease and apply Molykote BR2 to the pinions
7. INSTALLING THE PUMP COVER

7.1. Apply Loctite 573 on contact surface between the cover and body and set the
cover on the pump body.
7.2. Introduce two guide pins.
7.3. Secure the pump cover with 12 screws to 4.7 kg.m. of pressure with Loctite
270.
14
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY SUB-UNITS OIL PUMP
LIST OF COMPONENTS
1 OIL PUMP BODY 1 1
2 OIL PUMP DRIVE PINION 1 1
3 OIL PUMP DRIVEN PINION 1 1
4 OIL PUMP COVER 1 1
5 HOLLOW CENTRING PIN 2 2
6 KEY 1 1
7 NUT 1 1
8 BUSHING, OIL PUMP COVER 2 2
9 PIN 2 2
10 SCREW 12 12
11 OIL PUMP GEAR 1 1
TOOLS
Oil pump unit assembly tool: Ref.: 16.26.340 M01
14
OIL PUMP ASSEMBLY SUB-UNITS
8. GEAR INSTALLATION
8.1. Set key in the shaft of the oil pump pinion.
8.2. Install the oil pump gear.
8.3 Apply Loctite 270 to the nut and tighten it to 35 kg.m.
9. CHECK CLEARANCES

9.1. Check gear and shaft clearances with a dial gauge (Maximum permissible
clearance is 0.15mm in both cases).
10. LABELING AND STORING
14
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY SUB-UNITS OVERPRESSURE VALVE
LIST OF COMPONENTS
1 SCREW 3 3
2 VALVE COVER 1 1
3 VALVE BODY 1 1
4 PISTON CYLINDER 1 1
5 PISTON 1 1
6 VALVE SPRING 1 1
7 VALVE BRACKET 1 1
8 SPLITTER 2 2
9 WASHER 2 2
10 SCREW 2 2
TOOLS
Overpressure valve cover mounting tool: Ref.: 16.27.280 M01
15
OVERPRESSURE VALVE ASSEMBLY SUB-UNITS
1.2. Free of Burrs.
1.3. Free of Blows.
1.4. Free of Dirt.

2. IDENTIFYING THE PARTS TO BE DEGREASED AND DEGREASING
2.1. The parts that will be fastened with Loctite 270 must be degreased to improve
adherence.
3. INSTALLING PISTON AND SPRING

3.1. Oil the piston and the spring.
3.2. Set piston and spring inside the valve body
4. INSTALLING THE TOP COVER

4.1. Place the unit in tool Ref.: 16.27.280 M01 to keep the spring compressed.
4.2. Set the cover in the correct position.
4.3. Secure the cover with M8X25 screws with Loctite 270.
5. ASSEMBLING BRACKETS TO VALVE BODY

5.1. Assemble the brackets on the valve body with splitters, washers and
screws.
6. LABELLING AND STORING.
15
ASSEMBLY SUB-UNITS THERMOSTATIC AND OIL
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS REGULATING VALVE
LIST OF COMPONENTS
1 BODY, THERMOSTATIC & REGULATING VALVE 1 1
2 O-RING 2 2
3 CLOSING COVER 2 2
4 SCREW 10 10
5 STUD 8 8
6 NUT 8 8
7 GASKET, THERMOSTAT INSPECTION COVER 1 1
8 THERMOSTAT INSPECTION COVER 1 1
9 SCREW 6 6
10 GASKET 2 2
11 PLUG 2 2
12 GASKET 1 1
13 PLUG 1 1
14 SCREW 2 2
15 THERMOSTATIC VALVE FLANGE 1 1
16 O-RING 1 1
17 OIL REGULATING VALVE PISTON 1 1
18 SCREW 4 4
TOOLS
16
THERMOSTATIC AND OIL ASSEMBLY SUB-UNITS
REGULATING VALVE
1.2. Free of Burrs.
1.3. Free of Blows.
1.4. Free of Dirt.
2. DEGREASING STUDS AND SCREWS

3. INSTALLING REGULATING VALVE COVER AND THERMOSTAT COVER
3.1. Set the oil regulating valve cover in the lower part with M8 screws with Loctite
270.
3.2. Set the thermostat cover with a gasket (previously greased) and 4 M8 screws.
4. INSTALLING M12 STUDS (with Loctite 270 and the appropriate tool).
5. INSTALLING THE THERMOSTAT INSPECTION COVER

(with greased gasket and M8 screws).
6. INSTALLING THE SIDE COVER

6.1. Install the side cover with O-ring, 2 M10 screws and the non-return valve with
its seal.
7. INSTALLING THE SECOND SIDE COVER

7.1. Install the side cover on the opposite side, with its O-ring and M10 screws
tightened with a pneumatic screwdriver.
8. ASSEMBLY OF SPRING, TUBE, COVER AND PISTON OF THE REGULATING

VALVE
8.1. On the lower cover, place a spring, tube and cover with their O-rings; inside
install the regulating valve piston, properly greased. Verify the correct sliding
of the piston inside of the valve body.
9. ASSEMBLY OF SEAL (with seal fitting tool 16.75.197), THERMOSTAT, WASHER

AND SNAP RING
9.1. Close the mechanism with a cover, O-ring and M10 screws tightened with a
10. INSTALLATION OF PLUGS, REDUCING COUPLINGS AND ANGLE HOLLOW

SCREW
10.1. Install the plugs, the reducing couplings with their washers, and the angle
hollow screw with Loctite 270.
16
ASSEMBLY SUB-UNITS THERMOSTATIC AND OIL
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS REGULATING VALVE
LIST OF COMPONENTS
19 O-RING 1 1
20 THERMOSTAT 1 1
21 WASHER, THERMOSTATIC VALVE 1 1
22 SNAP RING 1 1
23 SPRING 1 1
24 OIL REGULATING VALVE COVER 1 1
25 SCREW 3 3
26 PISTON, OIL REGULATING VALVE 1 1
27 O-RING 2 2
28 COVER, REGULATING VALVE 1 1
29 SCREW 4 4
30 REGULATING VALVE DISCHARGE PIPE 1 1
31 ELBOW CONNECTOR 1 1
32 SCREW 1 1
33 WASHER 1 1
34 3/8 A REDUCING COUPLING 1 1
36 SEAL 1 1
37 THERMOSTAT COVER 1 1
38 VALVE 1 1
TOOLS
16
THERMOSTATIC AND OIL ASSEMBLY SUB-UNITS
REGULATING VALVE
11. INSTALLING THE REGULATING VALVE DISCHARGE PIPE

11.1 Install the discharge pipe to the regulating valve with an angle hollow screw
and 2 gaskets.
16
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY SUB-UNITS OIL PAN COVER
LIST OF COMPONENTS
1 PLUG 1 1
2 OIL PAN COVER 1 1
3 GASKET 2 2
4 GASKET 1 1
5 PLUG 1 1
6 GASKET 5 5
7 PLUG 5 5
8 PLUG 1 1
9 OIL SUCTION PIPE 1 1
10 GASKET 2 2
11 PLUG 2 2
TOOLS
17
OIL PAN COVER ASSEMBLY SUB-UNITS
1.2. Free of Burrs.
1.3. Free of Blows.
1.4. Free of Dirt.
2. DEGREASING THE OIL SUCTION PIPE

3. INSTALLATION OF PLUGS
3.1. Install plugs with their corresponding gaskets in the oil pan cover, with a
pneumatic wrench.
4. INSTALLING THE "ALLEN" PLUG

4.1. Install the "Allen" plug (cap screw) in the correct position, with Loctite 242.
5. INSTALLING THE OIL SUCTION PIPE

5.1. Apply Loctite 270 to the thread of the oil suction pipe.
5.2. Install oil suction pipe on the back side of the oil pan cover.
5.3. Screw the pipe by hand.
17
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY SUB-UNITS FILTER SUPPORT
LIST OF COMPONENTS
1 FILTER SUPPORT 1 1
2 ANGLE CONNECTOR 1 1
3 SAFETY VALVE 1 1
4 O-RING 5 5
5 SCREW 3 3
6 FLANGE 1 1
7 SCREW 2 2
8 OIL FILTER CONNECTOR 3 3
9 SCREW 4 4
TOOLS
Connectors fitting tool:Ref.:16.75.243
18
FILTER SUPPORT ASSEMBLY SUB-UNITS
1.2. Free of Burrs.
1.3. Free of Blows.
1.4. Free of Dirt.

2. DEGREASING STUDS AND HOLLOW SCREW CONNECTORS TO FILTERS
3. INSTALLATION OF SIDE COVER AND SAFETY VALVE

3.1. Install the side cover and the safety valve on the filter support, with their
corresponding gaskets (previously greased) and tightening the screws with a
4. INSTALLING STUDS (with Loctite 270 and a pneumatic wrench).
5. INSTALLING HOLLOW SCREWS (with Loctite 242, using the connectors fitting
tool Ref:16.75.243).
6. INSTALLING THE ANGLE CONNECTOR.
18
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY SUB-UNITS OIL LEVEL DIPSTICK
LIST OF COMPONENTS
1 DIPSTICK TUBE 1 1
2 OIL LEVEL DIPSTICK 1 1
3 DIPSTICK PLUG 1 1
TOOLS
19
OIL LEVEL DIPSTICK ASSEMBLY SUB-UNITS
1.2. Free of Burrs.
1.3. Free of Blows.
1.4. Free of Dirt.
2. CUTTING ROD

2.1. A rod will be cut to the size indicated in the drawing.
2.2. Smooth the sharp edges.
3. MAKING LEVEL HOLES

3.1. Locations where these holes will be located will be marked.
3.2. Previously marked spots will be drilled with a Ø2 mm bit.
3.3. Sharp edges will be eliminated with a higher Ø bit or reamer.
4. ROD SURFACE FINISH

4.1. The rod surface will be polished through sanding or Scotch Brite.
5. ENGRAVING OF ROD REFERENCE

5.1. Reference will be engraved on one of the rod sides with a manual engraving
(letter height 3 mm).
6. OIL UNIT WITH ANTIOXIDANT
19
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY SUB-UNITS WATER-COOLED EXHAUST MANIFOLD
LIST OF COMPONENTS
2 MANIFOLD GASKET 1 2
3 WATER-COOLED EXHAUST MANIFOLD - 1
5 SCREW 6 12
6 WASHER 6 12
TOOLS
FV-engine water-cooled exhaust manifold alignment tool: Ref. 16.75.233
20
WATER-COOLED EXHAUST MANIFOLD ASSEMBLY SUB-UNITS
1.2. Free of Burrs.
1.3. Free of Blows.
1.4. Free of Dirt.
1.5. Correctly painted.

2. PLACING MANIFOLD ON TOOL
2.1. Place manifolds on alignment tool
Ref.:16.75.233 and fasten their lower
faces with the tool screws.
2.2. Allow for sufficient separation
between the manifolds for inserting
the gaskets.
3. INSERTING GASKETS AND ASSEMBLING OF MANIFOLDS

3.1. Insert the gaskets between the manifolds. Gaskets have a concrete position.
3.2. Assemble the manifolds with washers and screws, tightening to 14 kg.m.
4. REMOVE ASSEMBLED MANIFOLDS FROM TOOL

5. HYDRAULIC TESTING
5.1. If found OK, mark with letter B (manifold line "good").
6. LABELING AND STORING ON A PALLET
20
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY SUB-UNITS AIR COOLER
LIST OF COMPONENTS
1 AIR COOLER BODY 1 1
2 AIR COOLER GASKET 2 2
3 AIR COOLER OUTLET 1 1
4 COOLER INLET ELBOW, COVER 1 1
5 SCREW 44 44
6 GASKET 1 1
7 DRAIN VALVE 2 2
8 GASKET 4 4
9 PLUG 4 4
10 PLUG 1 1
11 PLUG 1 1
12 WATER MANIFOLD OUTLET/INLET 1 1
13 GASKET 1 1
14 LIFTING EYEBOLT 2 2
15 SCREW 8 8
16 COMPLETE COOLER 2 2
17 SCREW 4 4
18 SCREW 4 4
TOOLS
21
AIR COOLER ASSEMBLY SUB-UNITS
1.2. Free of Burrs.
1.3. Free of Blows.
1.4. Free of Dirt.

2. ASSEMBLY OF WATER MANIFOLD INLET/OUTLET
2.1. Hoist the cooler through the lifting eyebolts, placing the bottom face up.
2.2. Set the water inlet/outlet pipe on the air cooler, with gasket and screws,
tightening to 5 kg.m.
3. ASSEMBLY OF AIR INLET/OUTLET COVERS

3.1. Assemble the air inlet and outlet covers to the cooler body, with gaskets and
screws, using an air screwdriver. Mind the correct position of the covers.
4. FITTING OF WATER DRAIN COCKS, PLUGS AND LIFTING EYEBOLTS

4.1. Overturn the air cooler (the water pipe facing downward).
4.2. Remove 2 plugs existing on the air cooler and install 2 drain cocks instead.
4.3. Set the remaining plugs and eyebolts.
5. LABELING AND TRANSFER TO FINISHED PRODUCT STORE
21
ASSEMBLY SUB-UNITS TURBOCHARGER
ASSEMBLING COMPONENTS
Regarding the specifications and tolerances, consult the information provided in the
NOTE
Tolerance and Specification table in section A (illustration / List of Components / List of

The wheel blades from the compressor and the turbine are weak and can easily be
CAREFUL
deformed. When the turbine and compressor blades are handled, be careful and do not
let them drop or get hit.
CAREFUL
Replace the wheel and/or shaft of both the compressor and the turbine, if the blades are
deformed or broken. One solitary blade with a small deformation or a slight breakage is
not sufficient to replace the wheel; in this case never wait to repair this blade.
CAREFUL
Before installing them again, make sure the all the components are clean.
NOTE
Replace all the gaskets and O-rings during the re-assembly.
TURBINE INSTALLATION - BUSHINGS AND SNAP RINGS (SAFETY RINGS)

(FIGURE 1).
Secure the snap ring with your hand while we
DANGER
secure the ends with the snap ring installation

tool; this will prevent the snap ring from flying
in the event it gets loose from the tool.
When installing the snap rings, be careful not

CAREFUL
to harm the inside surface of the bearing

bracket and the gasket seal surface. After
installing the snap rings, verify that it rotates
freely when we rotate it with our fingers. FIGURE 1
1. Set the bearing bracket on a sturdy and clean table.

2. Apply clean motor oil to the inside and outside surfaces of the bushing.
3. Install the bearing bracket, the snap rings (on the turbine side), the bushing (on the
turbine side), and the safety ring (on the compressor side).
22
TURBOCHARGER ASSEMBLY SUB-UNITS
INSTALLATION OF SHAFT, TURBINE WHEEL AND GASKETS (RINGS) (FIGURE 2).

1. Place the bushing bracket, with the turbine
wheel face up, on the compressor cover.
CAREFUL
When installing the ring (gasket), be careful

not to give way the ring more than necessary

or to twist its ends.
2. Install the ring (gasket) in the shaft slot -

turbine wheel.
3. Apply MolykoteTM on the installed ring
(gasket).
4. Position the ring (gasket) on the shaft. FIGURE 2
CAREFUL
Never force the turbine-wheel shaft. Verify the correct alignment of the shaft, the turbine
wheel, the back cover of the turbine, the bearing bracket, if possible before applying
pressure.
5. Install the turbine wheel and shaft unit with the gasket introduced inside the bushing
bracket rotating it and moving it back and forth.
INSTALLATION OF BUSHING ON THE COMPRESSOR SIDE (FIGURE 3).
1. Place the body flange of the turbine on the

screw (clamp), being careful not to
damage the surface of the flange.
2. After installing the turbine-wheel shaft unit
on the bearing bracket, secure the shaft
with your hand and rotate it, so that the
compressor side remains face up.
3. Apply clean oil on the inside and outside
surfaces of the bushing.
4. Install the bushing on the compressor
side.
5 Place the bearing bracket on the turbine
body and tighten the coupling clamp
FIGURE 3
temporarily.
22
INSTALLATION OF THRUST BEARING BUSHING. (FIGURE 4)

1. Apply clean motor oil to the outside and
inside surfaces of the axial collar and the
thrust bearing bushing.
2. Install the axial collar and the thrust
bearing bushing, positioning it to make
sure the guide remains in the hole of the

housing.
FIGURE 4
INSTALLATION OF O-RING. (FIGURE 5)

1. Apply grease to the O-Ring.
2. Install the O-Ring.
FIGURE 5
INSTALLATION OF OIL THROWER

(FIGURE 6).
1. Apply clean motor oil to both sides of the
axial collar and to the oil thrower.
2. Install the axial collar.
3. Install the oil thrower with the lip down.
FIGURE 6
22
REF. 19.09.531 X/6 REPAIR AND OVERHAUL MANUAL GAS ENGINES SF/FG IN “V”
INSTALLATION OF THE SUB-UNIT. (FIGURES OF 7 TO 9).

1. Assemble the unit formed by the threaded
stud, the gasket and the thrust shoulder
(slave).
2. Apply MolykoteTM to the previously
installed sub-unit.

When we are ready to install the gasket on
CAREFUL
the thrust shoulder, be careful not to give way

the ring more than necessary or to fold its
ends.
3. Install the subunit on the bearing bracket.

FIGURE 7
Secure the snap ring with your hand while we
DANGER
secure the ends with the snap ring

installation tool; we will prevent the snap ring
from flying if it gets loose from the tool.
4. Install the snap ring on the bearing

bracket with its stepping face up.
CAREFUL
When we hit the snap ring lightly with the

mallet (for its installation), be careful not to
harm the bearing bracket.
5. Hit it lightly with a mallet, by using a screw FIGURE 8

driver, to make sure the snap ring is
perfectly set.
FIGURE 9
VERIFY THE TURBINE-WHEEL SHAFT CLEARANCE SET INSIDE OF THE
TURBINE BODY.
Verify the turbine-wheel shaft unit clearance according to the information provided in
NOTE
"Inspection of the Turbocharger - Turbine-Wheel Shaft Clearance inside the Turbine

Body" of section E (inspection of components).
22
REPAIR AND OVERHAUL MANUAL GAS ENGINES SF/FG IN “V” X/6 REF. 19.09.531
INSTALLATION OF COMPRESSOR WHEEL (FIGURE 10).
1. Place the compressor wheel on the shaft.

2. Apply MolykoteTM to the thread of the
fastening nut.
3. Tighten the fastening nut to the specified
torque.
FIGURE 10
VERIFY THE AXIAL CLEARANCE OF THE TURBINE WHEEL SHAFT UNIT.
Verify the clearance of the shaft unit and turbine wheel according to the information
NOTE
provided in "Inspection of the Turbocharger - Axial Clearance of the Shaft Unit and
Turbine Wheel" in section E (Inspection of Components).
VERIFY THE CLEARANCE BETWEEN THE REAR COVER OF THE TURBINE AND
THE TURBINE WHEEL.
Verify the clearance between the rear lid of the turbine and the turbine wheel according
NOTE
to the information provided in "Inspection of the Turbocharger - Clearance between the

Rear Lid of the Turbine and the Turbine Wheel" in section E (Inspection of Components).
INSTALLATION OF THE TURBINE BODY (FIGURE 11).

1. Install the bearing bracket on the turbine
body.
2. Align the installation marks, made before
the disassembly.
3. Apply MolykoteTM to the threads of
coupling clamp.
4. Tighten the clamp to the specified torque.
FIGURE 11
22
INSTALLATION OF THE COMPRESSOR COVER (FIGURE 12).
1. Install the compressor cover on the bearing bracket.

2. Align the installation marks, done in two pieces before the disassembly.
3. Apply grease to the O-ring.
4. Install the O-ring on the bearing bracket.
5. Install the compressor cover seals and fastening nuts to the bearing bracket.

6. Tighten the compressor cover fastening nuts to the specified torque.
FIGURE 12
CAREFUL
After installing the previously examined turbocharger, pre-oil the motor to allow the
motor oil to flow to the turbocharger.
22
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY SUB-UNITS HYDRAULIC REGULATOR HOUSING
LIST OF COMPONENTS
16 REGULATOR GEAR 1 1
18 REGULATOR DRIVE GEAR 1 1
20 BEARING 1 1
21 BEARING 1 1
TOOLS
23
HYDRAULIC REGULATOR HOUSING ASSEMBLY SUB-UNITS
1.2. Free of Burrs.
1.3. Free of Blows.
1.4. Free of Dirt.

2. ASSEMBLY OF BEARINGS
2.1. Install bearing in the support with
snap ring and retainer.
2.2. Install the bearings, hammering
them moderately.
3. INSTALLING THE SHAFT

3.1. Install the shaft in the correct position as shown on the drawing, setting
splitters, bearings and snap rings with tool Ref.: 16.75.194.
4. LABELLING AND STORING.
23
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY SUB-UNITS 24/220V ELECTRIC DRIVE
LIST OF COMPONENTS
1 24/220V ELECTRIC DRIVE 1 1
6 NUT 3 3
13 MANUAL CONTROL 1 1
41 STUFFING BOX 1 1
42 SCREW 4 4
43 COVER 1 1
44 O-RING 1 1
45 NUT 3 3
46 24VDC / 220V SPEED-SETTING MOTOR 1 1
48 SPLITTER 3 3
TOOLS
24
24/220V ELECTRIC DRIVE ASSEMBLY SUB-UNITS
1.2. Free of Burrs.
1.3. Free of Blows.
1.4. Free of Dirt.

2. INSTALL STUFFING BOX AND O-RING (with grease) IN THE FINE REGULATOR
COVER
3. ASSEMBLE COVER TO SPEED-SETTING MOTOR (with 3 Allen screw)
4. SET ELASTIC ELEMENT TO SPLITTER
5. INSTALLING THE ELASTIC ELEMENT AND SPLITTER ON THE SPEED-SETTING

MOTOR
5.1. Provisionally install the elastic element and splitter assembly on the speed-
setting motor with 3 nuts and 3 Exnor washers.
6. ASSEMBLE REGULATOR CONTROL TO SPEED-SETTING MOTOR

(provisionally)
24
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY SUB-UNITS 6-GAUGE CONTROL PANEL
LIST OF COMPONENTS
1 VACUUM METER 1 1
2 THERMOMETER (0º-71º) *2/0 *2/0
3 THERMOMETER (60º-121º) *2/4 *2/4
4 MANOMETER 1 1
5 MAIN CIRCUIT WATER TEMPERATURE PLATE 1 1
6 AIR TEMPERATURE PLATE 1 1
7 OIL TEMPERATURE PLATE 1 1
8 AUX. CIRCUIT WATER TEMPERATURE PLATE 1 1
9 AIR PRESSURE PLATE 1 1
10 OIL PRESSURE PLATE 1 1
11 PUNCHED CONTROL PANEL 1 1
12 NUT 4 4
13 WASHER 3 3
14 TUBE FOR MANOMETER 2 2
15 DOUBLE PIPE COUPLING 2 2
16 FEMALE CONNECTOR 1 1
17 GAUGE SUPPORT 1 1
18 PYROMETER THERMOCOUPLE TUBE 4 4
20 6-GAUGE PANEL BRACKET 1 1
21 NUT 8 8
22 FLEXIBLE ELEMENT 4 4
23 SCREW 4 4
TOOLS
25
6-GAUGE CONTROL PANEL ASSEMBLY SUB-UNITS
1.2. Free of Burrs.
1.3. Free of Blows.
1.4. Free of Dirt.
2. BOX ASSEMBLY

2.1. Flexible components are installed in casing and secured with their
corresponding nuts and washers.
3. INSTALLATION OF GAUGES
3.1. Gauges for revolutions, temperature and pressure (per drawing), are mounted,
with the gauge support, starting with the central gauge.
3.2. Set the previously prepared oil pressure piping to the pressure gauge.
Assemble the double coupling to the pipe.
3.3. Place the gauges for main circuit water, air and oil temperature, with their
respective washers. Secure with nuts.
4. INSTALLATION OF OIL PRESSURE PIPING

4.1. Connectors are installed on the ends of oil pressure piping.
5. FITTING OF THE GAUGE NAMEPLATES

5.1. Fit the gauge nameplates with glue above their respective gauge
6. CONNECTION OF COVER WITH CASING

6.1. The cover and casing are connected with 4 screws already inserted in the
casing.
7. INSTALLATION OF CASING ON ENGINE BRACKET

7.1. Fasten the casing, with the flexible components, to the engine bracket with nuts
and washers.
25
ASSEMBLY SUB-UNITS JET PRESSURE ADJUSTMENT
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS VALVE
LIST OF COMPONENTS
1 VALVE BODY 1 1
2 SPRING 1 1
3 PISTON 1 1
4 SNAP RING 1 1
5 O-RING 1 1
6 O-RING 1 1
TOOLS
26
JET PRESSURE ADJUSTMENT ASSEMBLY SUB-UNITS
VALVE
1.2. Free of Burrs.
1.3. Free of Blows.
1.4. Free of Dirt.
2. ASSEMBLY OF VALVE BODY

2.1. Oil the piston adequately.
2.2. Insert spring and piston inside the valve body.
2.3. Swing valve body to observe the correct sliding of the piston.
3 SNAP RING INSTALLATION

3.1. Compress piston and spring with a press and set snap rings in the appropriate
position, with the tool Ref.: 16.75.194.
4. O-RING INSTALLATION
4.1. Set the O-rings in their grooves (these can be seen on the picture).
26
ASSEMBLY SUB-UNITS ENGINE BLOCK WITH LINERS AND
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS HYDRAULIC TEST
LIST OF COMPONENTS
1 ENGINE BLOCK FOR HYDRAULIC TEST 1 1
2 PREPARED LINER 12 16
3 CYLINDER LINER 12 16
4 SET OF LINER GASKETS 12 16
5 UPPER & CENTRAL O-RING, CYLINDER LINER 24 32
6 LOWER O-RING, CYLINDER LINER 12 16
7 SQUARE O-RING, LINER 12 16
8 TOP COVER OF BLOCK 1 1
9 GASKET, TOP COVER OF BLOCK 1 1
10 SCREW 44 56
11 STUD 4 4
12 NUT 4 4
13 PLUG 1 1
14 WASHER 1 1
15 FLANGE 1 1
16 GASKET 1 1
18 PLUG 2 2
TOOLS
Tool to insert liners: Ref. 16.75.228
Hydraulic test set up tools: Ref. 16.78.760
27
ENGINE BLOCK WITH LINERS AND ASSEMBLY SUB-UNITS
HYDRAULIC TEST
1.2. Free of Burrs.
1.3. Free of Blows.
1.4. Free of Dirt.
2. PREPARE THE LINERS

2.1. Install O-rings with animal grease in
the liner slots.
3. INTRODUCING LINERS IN THE ENGINE BLOCK

3.1. Introduce all the liners in the engine block.
3.2. With the aid of the tool: Ref.: 16.75.228, introduce the liners in the engine block
making sure they set well.
4. DO THE HYDRAULIC TEST
4.1. Smear the upper surface of the

engine block with black silicone. Set
the gasket and apply silicone again.
Install the cover tightening the
screws to 5 kg.m.
4.2. Insert studs for flanges in the cover.
Set the back flange with black
silicone, gasket, washers, nuts and
plug.
27
ASSEMBLY SUB-UNITS ENGINE BLOCK WITH LINERS AND
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS HYDRAULIC TEST
LIST OF COMPONENTS
1 ENGINE BLOCK FOR HYDRAULIC TEST 1 1
2 PREPARED LINER 12 16
3 CYLINDER LINER 12 16
4 SET OF LINER GASKETS 12 16
5 UPPER & CENTRAL O-RING, CYLINDER LINER 24 32
6 LOWER O-RING, CYLINDER LINER 12 16
7 SQUARE O-RING, LINER 12 16
8 TOP COVER OF BLOCK 1 1
9 GASKET, TOP COVER OF BLOCK 1 1
10 SCREW 44 56
11 STUD 4 4
12 NUT 4 4
13 PLUG 1 1
14 WASHER 1 1
15 FLANGE 1 1
16 GASKET 1 1
18 PLUG 2 2
TOOLS
Tool to insert liners: Ref. 16.75.228
Hydraulic test set up tools: Ref. 16.78.760
27
ENGINE BLOCK WITH LINERS AND ASSEMBLY SUB-UNITS
HYDRAULIC TEST
4.3. Instead of the front flange, momentarily install a vented flange with grease,
gasket, washers and nuts (the front flange similar to the back flange will be
installed after completing the test).
4.4. Place the covers (Ref.: 16.78.760) on the engine block cylinder head face with
screws and washers.
- Place a cover with a cock and hose on cylinder 8 in the case of an
F480... engine or on cylinder 6 for an F360... engine.

- Place a cover with pressure gauge on cylinder 7 in the case of an
F480... engine or on cylinder 6 for an F360... engine.
4.5. Place the cover with a cock over the water inlet at the front of the engine.
4.6. Place a drain plug on either side of the back portion of the engine.
4.7. Colored hydraulic fluid comes in through the cock at the front of the engine,
with a maximum pressure of 8 kg.m. and the system is discharged through the
last cylinder.
4.8. Maintain the water current during a period of time making sure there is no loss
of pressure and verify with the naked eye and the aid of a lamp, that there are
no water leaks in the engine block (areas in contact with water, liners, water
circuit, ...).
4.9. Open the drain plugs at the back of the engine block and empty the water
system. Install the engine block lifting tool and hoist the block in order to
eliminate any hydraulic fluid leftovers.
4.10. Take apart the tools used for the test, dry the engine block and apply
antioxidant.
27
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS ASSEMBLY SUB-UNITS BUTTERFLY VALVE
LIST OF COMPONENTS
1 ELBOW, REGULATION 1 1
2 RETAINER 4 4
3 BUSHNG 4 4
4 BUTTERFLY VALVE SHAFT 2 2
5 BUTTERFLY VALVE 2 2
6 SCREW 4 4
7 SCREW 4 4
8 BUTTERFLY LEVER 3 3
9 GASKET 4 4
10 WASHER 3 3
11 SCREW 2 2
12 GASKET 2 2
13 ELBOW 1 1
14 PIN 1 1
15 SCREW 2 2
16 SCREW 1 1
17 PIN 1 1
18 BUTTERFLY STOP LEVER 1 1
19 NUT 1 1
20 SCREW 1 1
21 LEVER 1 1
22 SCREW 2 2
TOOLS
28
BUTTERFLY VALVE ASSEMBLY SUB-UNITS
1. Introduce the bushings in both sides of the elbow with appropriate tools.
2. Set retainers at both ends with tools.
3. Insert the butterfly valve shaft in correct position (one of the ends is longer).
4. Introduce the butterfly valve into the elbow

and fasten it to the shaft with screws with
Loctite 242.
5. Set one pin in the side of the elbow.
6. On the valve stop lever, assemble 1 screw

with washer and 1 screw with nut.
7. Set the valve stop lever on the elbow and

secure it with the screw carrying the
washer.
8. Widen the hole in the stop lever with a

Metric-3 drill. Introduce one pin in this hole
in order to block the stop lever in relation
to the shaft.
9. Assemble 1 valve lever to each side of the

shaft with washers and screws.
10. Set one lever (for rod) with 2 screws.
11. Repeat steps 1, 2, 3 and 4 on the right elbow.
12. Assemble 1 valve lever to the shaft in the right elbow, with washer and screw.
13. Set 3 screws with gaskets in each elbow; these will act as plugs.
28
T O O L S
U T I L E S
TOOLS
SF/FG IN “V”
Ref.: 19.09.531
Edition: May 2003

TOOLS INDEX
NUMBER DESIGNATION REFERENCE PAGE
1 Oil pump assembly tool 16.26.340 M01 1

2 Overpressure relief valve cover mounting tool 16.27.280 M01 1
3 Tension tool 16.75.005 1
4 Piston to liner installation tool 16.75.009 1

5 Flywheel housing lifting tool 16.75.017 1
6 Flywheel turning tool 16.75.031 1
7 Cylinder head alignment tool 16.75.109 1
8 Camshaft bushings mounting tool 16.75.116 1
9 Wrench for clamping rocker arms to bracket 16.75.121 2
10 Companion flange assembly tool (hydraulic) 16.75.135 2
11 Front seal assembly tool 16.75.141 2
12 Safety rings (circlips) tool 16.75.156 2
13 Flywheel guide tool 16.75.162 2
14 Tool to fit guide studs in crankshaft 16.75.167 2
15 Front intermediate cover lifting tool 16.75.168 2
16 Oil pan guide screws 16.75.169 2
17 Oil pan lifting tool 16.75.171 3
18 Thermostat and oil regulation 16.75.172 3
housing lifting tool
19 Camshaft mounting tool 16.75.173 3
20 Oil pump lifting tool 16.75.174 3
21 Pump support front cover lifting tool 16.75.175 3
22 Crankshaft rotating tool 16.75.176 3
23 Tool to fit bearing runner in middle gear 16.75.177 3
24 Tool to fit outer bearing runner in timing middle 16.75.178 3
gear
25 Exhaust manifold lifting tool 16.75.179 4
REF. 19.09.531 REPAIR AND OVERHAUL MANUAL GAS ENGINES SF/FG IN “V”
INDEX TOOLS
NUMBER DESIGNATION REFERENCE PAGE
26 Damper mounting tool 16.75.183 4

27 Seal fitting tool 16.75.186 4
28 Water seal adjustment tool 16.75.187 4

29 Bearing fitting tool (hot) 16.75.189 4
30 Bushing punching fitting tool 16.75.191 4
31 Snap ring wrench 16.75.194 4
32 Connectors fitting tool (hot process) 16.75.195 4
33 Seal mounting tool 16.75.197 5
34 Rotating tool - assembly phase 1, FV 16.75.213 5
35 Auxiliary rocker holding tool 16.75.214 5
36 Auxiliary rocker spherical seat mounting tool 16.75.215 5
37 Liners assembly tool 16.75.228 5
38 Water cooled exhaust manifold 16.75.233 5
alignment tool FV
39 Cylinder head lifting tool F & V 16.75.234 5
40 Tool to install piston rings on pistons 16.75.750 5
41 Flywheel fixing tool 16.78.670 6
42 Hydraulic test set up tools engines FV 16.78.760 6
43 Holding tool 74.44.026 6
44 Go gauge 92.32.199 6
45 Go no go gauge 92.32.692 6
46 Rear seal assembly tool 16.75.103 6
47 Connectors fitting tool 16.75.243 7
48 Air cooler lifting tool - gas FV engine 19.75.017 7
49 Spark plug wrench 19.75.030 7
REPAIR AND OVERHAUL MANUAL GAS ENGINES SF/FG IN “V” REF. 19.09.531
READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS TOOLS
1 2
Ref.:16.26.340 M01 Ref.:16.27.280 M01
3 4 Ref.:16.75.009
Ref.:16.75.005
5 6 Ref.:16.75.031
Ref.:16.75.017
7 Ref.:16.75.109 8
Ref.:16.75.116
TOOLS

9 Ref.:16.75.121 10 Ref.:16.75.135
11 12
Ref.:16.75.141 Ref.:16.75.156
13 14
Ref.:16.75.162 Ref.:16.75.167
15 Ref.:16.75.168 16
Ref.:16.75.169
17 18
Ref.:16.75.171 Ref.:16.75.172
19 20
Ref.:16.75.173 Ref.:16.75.174
21 22 Ref.:16.75.176
Ref.:16.75.175
23 Ref.:16.75.177 24 Ref.:16.75.178
TOOLS

25 26
Ref.:16.75.179 Ref.:16.75.183
27 28 Ref.:16.75.187
Ref.:16.75.186
29 Ref.:16.75.189 30 Ref.:16.75.191
31 Ref.:16.75.194 32 Ref.:16.75.195
33 34
Ref.:16.75.197 Ref.:16.75.213
35 Ref.:16.75.214 36
Ref.:16.75.215
37 Ref.:16.75.228 38 Ref.:16.75.233
39 40
Ref.:16.75.234 Ref.:16.75.750
TOOLS

41 43 Ref.:74.44.026
Ref.:16.78.670
42 Ref.:16.78.760
45 Ref.:92.32.692
44 Ref.:92.32.199 46 Ref.:16.75.103
47 48
Ref.:16.75.243 Ref.:19.75.017
49
Ref.:19.75.030
GUASCOR, S.A. Barrio Oikia 44
20759 ZUMAIA (GIPUZKOA) SPAIN
www.guascor.com

Libro de Tallaer V Gas Ingles PDF

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S A F E T Y

REPAIR AND OVERHAUL S E G U R I D A D

Edition: May 2003

GUASCOR, S.A. Barrio Olkia 44.

DISASSEMBLY D- - x/y EXAMPLE: D-T-2/3

SECTION PAGE NUMBER

ASSEMBLY A- - x/y EXAMPLE: A-50-1/2

SECTION PAGE NUMBER

TOOLS T- - x/y EXAMPLE: T-10-2/7

SECTION PAGE NUMBER

INSPECTION I- - x/y EXAMPLE: I-5-1/7

SECTION PAGE NUMBER

Edition: May 2003

* EUROPEAN SAFETY REGULATION FOR "CE" TYPE BRAND MACHINERY

* SAFETY RULES AND REGULATIONS IN THE UNITED STATES

1.- ENGINE DESIGN

2.- ENGINE ROOM/AREA

2. SAFETY PRECAUTIONS FOR GUASCOR GAS ENGINES

3. STANDARDS FOR PROPERLY LIFTING GUASCOR GAS ENGINES

EUROPEAN SAFETY REGULATION FOR "CE" TYPE BRAND

2.- ENGINE ROOM/AREA

3.- RISK ANALISIS

READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS

3.2.- HEAT PROTECTION

3.2.1.- COOLING WATER

3.2.2.- OIL & LUBRICATION

3.2.3.- AIR-FUEL MIXTURE FOR SUPERCHARGING

3.2.4.- MANIFOLDS & EXHAUST PIPE

3.5.- ELECTRICAL INSTALLATION

3.6.- GAS INSTALLATION

· ERM. Control and Measurement Station to applicable design standards. Engine-

· CONNECTIONS TO ENGINE, always made with DIN flanges or approved hoses.

· ENGINE-MOUNTED PRE-CARBURATION PIPING designed with a minimum of

· "BACKFIRING" or "DETONATION" PROTECTION. In a gas engine, backfiring may

READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS

3.7.- CRANKCASE GASES

3.8.- EXHAUST GASE

4.- CONTROL AND SAFETY DEVICES

· Engine outlet water temperature.

5.- IDENTIFICATION AND FEATURES

6.- INSTALLATION, OPERATION & MAINTENANCE MANUALS

· Engine general dimensions diagram.

· Identification of the machine and its components.

8.- MALFUNCTION PROTECTION

READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS

9.- SAFETY PRECAUTIONS

"G-00-100 Product Information" entitled "GUASCOR GAS ENGINES

"G-60-004 Product Information" entitled "GUASCOR GAS ENGINE SAFETY

2 - SAFETY PRECAUTIONS FOR

· A technical description of the engines

Therefore, it is recommended that the manual be maintained in good condition (clean),

READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS

SAFETY PROTECTORS (GUARDS)

PRESSURE PLUGS AND CONNECTIONS FOR THE COOLING

READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS

NEATNESS AND CLEANLINESS

ENGINE AND EQUIPMENT, REPAIR AND SERVICE

ENGINE FAN BLADES

READ ALL SAFETY PRECAUTIONS BEFORE OPERATING OR PERFORMING REPAIRS

CHEMICAL PRODUCTS FOR STORAGE OF ENGINES

PROTECTION AGAINST FIRE

GROUNDING FOR ELECTRICAL WELDING