Service Workbook

2.5 DI Diesel Engine

 2.5 DI DIESEL ENGINE
Service Workbook
This Service Workbook covers the 2.5 DI Diesel engine fitted to LDV vehicles. It is primarily
designed to assist skilled technicians in the efficient repair and maintenance of this engine, but
can also be used as a reference workbook for training purposes.
This Service Workbook should always be consulted prior to servicing or repair work.

SPECIFICATION
LDV (the Company) reserves the right to change the procedures, material, specification,
dimensions or design of the vehicles shown, described or referred to herein at any time and
without prior notice in accordance with the Company’s policy of constant product improvement.
Every reasonable effort is made to ensure that the Company’s publications are accurate,
but nothing shown, described or referred to herein should be regarded as an infallible
guide to the procedures, materials, specifications, dimensions, design or availability of
any particular vehicle, nor does this publication constitute an offer for the sale of any
particular vehicle. No liability can be accepted by the Company or any Distributor or
Dealer for any malfunction, damage, loss, injury, or death caused by the use of incorrect
or misinterpreted information, omissions or errors that may have arisen during the
preparation of this workbook.
Purchasers are advised that the specification details set out in this publication apply to a
range of vehicles and not to any particular vehicle. For the specification of any particular
vehicle, purchasers should consult their LDV Distributor or Dealer. Please note that LDV
Distributors and Dealers are not agents of the Company, and have no right or authority
whatsoever to bind the Company in any way, or to assume on its behalf any obligation
expressed or implied.

COPYRIGHT
 LDV 1997
All rights reserved. No part of this publication may be reproduced, stored in a retrieval
system or transmitted, in any form, whether electronic, or mechanical, or by
photocopying, recording or other means without prior permission in writing of LDV.
Published by LDV, from whom further copies may be obtained through your normal
literature ordering procedure.

LDV
Training & Publications
Bromford House
Drews Lane
Birmingham
B8 2QG

Publication Part No. DW03962102

CONTENTS
Page
Introduction and General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

TORQUE WRENCH
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

SETTINGS
Lubricants and Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Service summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Torque wrench settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Engine illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Cylinder head:
Rocker cover – remove refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

CYLINDER HEAD
Valve clearances – check / adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Cylinder head – remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
– overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
– re–build . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
– rocker shaft overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
– refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Front end:
External drive belts – remove, refit, adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

FRONT END
Power assisted steering drive belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Alternator drive belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Timing belt – remove / fit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Camshaft oil seal – renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Crankshaft front oil seal – renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Flywheel end:
FLYWHEEL END

Clutch and spigot bearing – remove and refit . . . . . . . . . . . . . . . . . . . . . . . . 62

Flywheel – remove and refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Camshaft rear oil seal – renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Crankshaft rear oil seal – renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Flywheel Timing socket setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
 Page
Crankcase:
Sump – remove / refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Crankcase overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

CRANKCASE
Inspection and overhaul – Cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . 80
– Camshaft bearings . . . . . . . . . . . . . . . . . . . . 81
– Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
– Camshaft and cam followers . . . . . . . . . . . . 83
– Pistons & connecting rods . . . . . . . . . . . . . . 83
– Revised connecting rod bolts/nuts . . . . . . . 86
Re–build . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

LUBRICATION
SYSTEM
Lubrication system:
Oil circulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Oil filter – renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Oil pressure relief valve – remove / refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Oil pump – remove / inspect / refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Fuel system:
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

FUEL SYSTEM
Adjustments – Throttle cable (N/A engine) . . . . . . . . . . . . . . . . . . . . . . . . . 107
– Idle speed (N/A engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Fuel filter element – renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Fuel lift pump – remove / refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Injectors – remove / refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Fuel injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Timing – check and adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Remove and refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
EGR SYSTEM

Exhaust gas recirculation system:

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
EGR valve – remove / refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
 Page

Cooling system:
Coolant circulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

COOLING
SYSTEM
Coolant drain and refill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Water pump – remove and refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Thermostat – remove and refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

TURBOCHARGER
Turbocharger: – remove and refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
INTRODUCTION

WARNINGS and CAUTIONS are given throughout this Service Workbook in the following
form:
WARNING: Procedures which must be followed precisely to avoid the possibility
of personal injury.
CAUTION: This calls attention to procedures which must be followed to avoid damage to
components.
NOTE: This calls attention to methods which make a job easier to perform.

REFERENCES
References to the left or right hand side in this Service Workbook are made when
viewing the vehicle from the rear, unless instructed otherwise.
To reduce repetition, operations covered in this Service Workbook do not always include
reference to testing the vehicle after repair. It is essential that work is inspected and
tested after completion and, if necessary, a road test of the vehicle is carried out
particularly where safety related items are concerned.

GENERAL PRECAUTIONS
1. When disconnecting the vehicle battery, always disconnect the earth return
(negative) cable first, and then the positive cable. On twin battery installations,
disconnect both earth return (negative) cables first, and then the positive cables.
When reconnecting the battery(s), connect the positive cable(s) first, then the
negative cable(s).
2. Absolute cleanliness is essential when working on fuel injection components.
3. Always plug fuel injection system connectors when disconnected to avoid the
possibility of dirt ingress.
4. Always turn the engine in a clockwise direction unless instructed otherwise.
5. The mating faces of all pulleys contained within the timing case must be assembled
clean and dry.
6. The timing belt must be renewed if for any reason its tension is slackened or the belt
removed.

9
7. Correct storage and handling of timing belts is most important, and the following
points must be observed:
• Timing belts must be stored flat and circular; never hang on a peg.
• Do not crimp or bend to a diameter of less than 25 mm (1 in.).
• A timing belt is constructed with a reinforcement of fibre running circumferentially
inside it. Do not attempt to lever a belt on or off its pulleys as this may damage
the fibres; use finger pressure only.
• A belt must be renewed if contaminated with oil, fuel, coolant or other detrimental
fluids. The pulleys must be cleaned if the belt has been contaminated, and the
cause of the contamination identified and rectified.
• Timing belt pulleys have a smooth finish to prolong belt life. Prior to fitting a belt,
ensure the pulleys have no burrs or rough surfaces.

• Correct tensioning procedures are essential to ensure full service life of the belt.
• During the time a timing belt is removed, to prevent damage to components it is
important that neither crankshaft nor camshaft are turned unless instructed to do
so.
8. Care must be taken when working underbonnet to avoid rotating pulleys and drive
belts.
9. Use only the approved LDV anti–freeze.
10. Before using special tools to check alignment / concentricity of oil seal housings,
ensure there are no burrs on the tool diameters which could affect the checks.
11. Many securing bolts on this engine use micro–encapsulation (patch–lock) for locking
purposes. The threads of these bolts should be cleaned and Loctite 270 applied
before re–use.
12. A number of security–critical bolts are used on this engine which can only be re–used
a specified number of times e.g. cylinder head, flywheel etc.
The workbook identifies the bolts affected, which must be punch marked on each
occasion they are removed to indicate the usage. The bolts are not marked on initial
build, therefore e.g. one punch mark indicates twice used, three punch marks
indicates four times used etc.

REPAIRS AND REPLACEMENTS

When replacement parts are required, it is essential that only genuine LDV parts are
used.

10
DATA

Engine
Type Diesel, 4 cylinder in line OHV, direct
injection
Bore 93,70 mm
Stroke 90,50 mm
Capacity 2496 cm3
Injection sequence 1 – 2 – 4 – 3 (cylinders numbered front to
rear)
Compression ratio N/A 20.8 : 1
Turbo 18.0 : 1
Naturally aspirated (N/A)
Power output 76 PS at 4000 rpm
Torque 168 Nm at 2500 rpm
Idle speed 825 ± 25 rpm
Maximum continuous engine speed 4000 rpm
Maximum intermittent engine speed 4400 +160 –80 rpm
Turbo
Power output 100 PS at 4000 rpm
Torque 226 Nm at 2100 rpm
Idle speed 850 ± 25 rpm
Maximum continuous engine speed 4000 rpm
Maximum intermittent engine speed 4400 ± 80 rpm

Cylinder Head
Height 89,93 mm 3.541 in.
Max. permissible distortion Flatness to be within 0,15 mm (0.006 in.)
overall, and within 0,07 mm (0.003 in) in
any 150 mm (6 in.). Also must not
exceed 0,025 mm (0.001 in.) in any
25 mm (1 in.).

Valve Seats
Valve seat angle to horizontal
Inlet 30° – 30°30’
Exhaust 45° – 45°30’
Valve seat inserts (service fitment)
Recess diameter:
Inlet 43,50 mm max. 1.713 in. max.
Exhaust 37,96 mm max. 1.494 in. max.
Recess depth (inlet and exhaust) 9,00 mm max. 0.354 in. max.

11
Valve Guides
Length 56,50 mm 2.2224 in.
Diameters
Standard:
Outer diameter 14,738 – 14,725 mm 0.5802 – 0.5997 in.
Inner diameter 8,982 – 9,013 mm 0.3536 – 0.3548 in.
Oversize:
Outer diameter 15,238 – 15,225 mm 0.600 – 0.5994 in.
Inner diameter 8,982 – 9,013 mm 0.3536 – 0.3548 in.
Fitted height 1,80 – 2,30 mm 0.071 – 0.091 in.
(above rocker cover mounting face)

Inlet Valves
Seat angle 29°30’ – 30°
Stem diameter 8,941 – 8,966 mm 0.3520 – 0.3530 in.
Stem clearance in valve guides: 0,010 – 0,066 mm 0.0004 – 0.0026 in.
Head diameter 41,90 – 42,10 mm 1.6496 – 1.6577 in.
Valve recession in head 0,35 – 0,65 mm 0.014 – 0.025 in
Valve clearance (hot) 0,20 mm 0.008 in.

Exhaust Valves
Seat angle 44°30’ – 45°
Stem diameter 8,923 – 8,948 mm 0.3513 – 0.3530 in.
Stem clearance in valve guides: 0,024 – 0,084 mm 0.0009 – 0.0033 in.
Head diameter 36,20 – 36,40 mm 1.425 – 1.433 in.
Valve recession in head 0,50 – 0,80 mm 0.020 – 0.031 in.
Valve clearance (hot) 0,38 mm 0.015 in.

Valve springs
Colour code:
N/A Green & Yellow
Turbo Inlet Red
Exhaust Green & Yellow
Specification:
Red coded spring
Number of coils – total (effective) 6.95 (5.45)
Free length 51.00 mm 2.008 in.
Wire diameter 4.60 mm 0.181 in
Spring rate 46.8 N/mm
Green / yellow coded spring
Number of coils – total (effective) 6.8 (5.3)
Free length 51.00 mm 2.008 in.
Wire diameter 4.60 mm 0.181 in
Spring rate 48.4 N/mm

12
Rocker shaft and rocker arms
Rocker shaft diameter 18,87 – 18,90 mm 0.743 – 0.744 in.
Number of springs on rocker shaft 4
Rocker arm clearance on shaft 0,02 – 0,08 mm 0.0008 – 0.0031 in.

Push rods and tappets

Push rod length 154,87 – 153,87 mm 6.097 – 6.058 in.
Push rod diameter 7,72 – 8,03 mm 0.304 – 0.316 in.
Tappet stem diameter 17,475 – 17,488 mm 0.6880 – 0.6885 in.
Total tappet length, measured over a
9,5 mm ball in socket for push rod 66,60 ± 0,25 mm 2.62 ± 0.01 in.

Camshaft
End float 0,10 – 0,25 mm 0.004 – 0.010 in.
Cam lift N/A Inlet 7,3 ± 0.038 mm 0.287 ± 0.0015 in.
Exhaust 7,6 ± 0.038 mm 0.299 ± 0.0015 in.
Turbo Inlet 6,3 ± 0.038 mm 0.248 ± 0.0015 in.
Exhaust 7,6 ± 0.038 mm 0.299 ± 0.0015 in.
Number of bearings 5
Bearing journal diameter 55,966 – 55,941 mm 2.2034 – 2.2024 in.
Bearing bore 56,032 – 56,058 mm 2.2060 – 2.2070 in.
Bearing clearance 0,072 – 0,116 mm 0.0028 – 0.0046 in.
Oversize bearing (outer diameter) +0,50 mm +0.0197 in.

Valve timing
Nominal valve timings with a clearance of 0,5 mm:
N/A T/C
Inlet valve opens 7° before TDC 5° before TDC
Inlet valve closes 45° after BDC 27° after TDC
Exhaust valve opens 57° before BDC 57° before TDC
Exhaust valve closes 7° after TDC 7° after TDC

13
Cylinder block
Cylinder bore diameters:
Grade 1 93,648 – 93,660 mm 3.6869 – 3.6874 in.
Grade 2 93,660 – 93,672 mm 3.6874 – 3.6879 in.
Grade 3 93,672 – 93,684 mm 3.6879 – 3.6883 in.
Grade 4 93,684 – 93,696 mm 3.6883 – 3.6888 in.
Measuring point 80 mm (3.15 in.) below cylinder head
mating face.
Main bearing bore in cylinder block
Rear Red 81,00 – 81,01 mm 3.1890 – 3.1894 in.
Blue 81.01 – 81,02 mm 3.1894 – 3.1898 in.
Others Red 74,00 – 74,01 mm 2.9134 – 2.9138 in.
Blue 74,01 – 74,02 mm 2.9138 – 2.9142 in.
Camshaft bearing bore in cylinder block:
Standard 61,000 – 61,046 mm 2.4016 – 2.4034 in.
Oversize 61,500 – 61,546 mm 2.4213 – 2.4231 in.

Pistons
Number of piston rings 3 (2 compression, 1 oil scraper)
Standard piston diameter:
Class 1 93,621 – 93,633 mm 3.6859 – 3.6863 in.
Class 2 93,633 – 93,645 mm 3.6863 – 3.6868 in.
Class 3 93,645 – 93,657 mm 3.6868 – 3.6873 in.
Class 4 93,657 – 93,669 mm 3.6873 – 3.6877 in.
Piston clearance in bore 0,015 – 0,039 mm 0.0006 – 0.0015 in.
Height of measuring point for piston 81,5 mm 3.21 in.
clearance in bore, measured from the
piston crown at right angles to gudgeon
pin bore.
Piston oversizes 0.65 mm 0.0256 in.
1.00 mm 0.0394 in.
Piston protrusion relative to cylinder N/A 0,301 – 0,503 mm 0.012 – 0.02 in.
block face at TDC in production T/C 0.201 – 0.403 mm 0.008 – 0.016 in.
Gudgeon pin length N/A 76,750 – 77,000 mm 3.0216 – 3.0315 in.
T/C 79,000 – 79,400 mm 3.1102 – 3.1260 in.
Gudgeon pin clearance in bore 0,002 – 0,010 mm 0.0001 – 0.0004 in.
Ring groove width:
Upper compression ring 2,13 – 2,15 mm 0.084 – 0.085 in.
Lower compression ring 2,08 – 2,10 mm 0.082 – 0.083 in.
Oil scraper ring 4,03 – 4,055 mm 0.159 – 0.160 in.
Piston rings:
Ring gaps (in 93,67 mm / 3.688 in. bore):
Upper compression ring 0,30 – 0,50 mm 0.012 – 0.020 in.
Lower compression ring 0,40 – 0,60 mm 0.016 – 0.024 in.
Oil scraper ring (3–piece) 0,38 – 1,14 mm 0.015 – 0.045 in.

14
Ring widths:
Upper compression ring 2,313 – 2,333 mm 0.0911 – 0.0919 in.
Lower compression ring 1,975 – 1,990 mm 0.0778 – 0.0783 in.
Oil scraper ring 3,978 – 3,990 mm 0.1566 – 0.1571 in.
Ring lateral clearance in grooves:
Upper compression ring 0,14 – 0,172 mm 0.0055 – 0.0068 in.
Lower compression ring 0,06 – 0,092 mm 0.0024 – 0.0036 in.
Oil scraper ring 3–piece assembly to fit groove

Crankshaft
Crankshaft end float 0,075 – 0,328 mm 0.003 – 0.013 in.
End float thrust washer thickness (standard) 2,811 – 2,862 mm 0.1107 – 0.1127 in.
End float thrust washer oversizes 0,06 mm, 0,12 mm, 0,18 mm, 0,25 mm.
(0.0024, 0.0047, 0.0071, 0.0098 in.)
Number of main bearing journals 5
Main bearings
Journal diameters: Rear Blue 76,980 – 76,990 mm 3.0307 – 3.0311 in.
Red 76,990 – 77,000 mm 3.0311 – 3.0315 in.
Others Blue 69,980 – 69,990 mm 2.7551 – 2.7555 in.
Red 69,990 – 70,000 mm 2.7555 – 2.7559 in.
Regrind undersize (nominal, service
diameter) Rear Size 3 76,490 – 76,500 mm 3.0114 – 3.0118 in.
Size 4 76,240 – 76,250 mm 3.0016 – 3.0020 in.
Regrind undersize (nominal, service
diameter) Others Size 3 69,490 – 69,500 mm 2.7358 – 2.7362 in
Size 4 69,240 – 69,250 mm 2.7260 – 2.7264 in.
Centre bearing journal length 35,635 – 35,675 mm 1.4029 – 1.4045 in.
Main bearing clearance Nos. 1 to 4 0,052 – 0,090 mm 0.0020 – 0.0035 in.
No.5 0,056 – 0,094 mm 0.0022 – 0.0037 in.
Shell widths:
Front and intermediate bearings 22,85 – 23,10 mm 0.900 – 0.909 in.
Centre bearing 26,85 – 27,10 mm 1.057 – 1.067 in.
Rear bearing 21,90 – 22,10 mm 0.862 – 0.870 in.
Regrind undersizes 0,25 mm, 0,50 mm, 0,75 mm
(0.0098, 0.0197, 0.0295 in.)
Big end bearings:
Journal diameters 60,000 – 59,980 mm 2.3622 – 2.3614 in.
Regrind undersizes 0,25 mm, 0,50 mm, 0,75 mm
(0.0098, 0.0197, 0.0295 in.)
Maximum turning torques:
Crankshaft on its own (without 2,9 Nm 2.14 lbf ft.
connecting rods and pistons)
Crankshaft (with rear oil seal, connecting 50 Nm 37 lbf ft
rods and pistons, without cylinder head
and timing cover)

15
Connecting Rods
Connecting rod lengths between bore
centres 1A 153,862 – 153,931 mm 6.0575 – 6.0603 in.
2A 153,931 – 154,000 mm 6.0603 – 6.0630 in.
3A 154,000 – 154,069 mm 6.0630 – 6.0657 in.
4A 154,069 – 154,138 mm 6.0657 – 6.0684 in.
Small end bush bore 29,010 – 29,022 mm 1.1421 – 1.1426 in.
Gudgeon pin clearance in bush 0,006 – 0,026 mm 0.0002 – 0.0010 in.
Big ends:
Bore (excluding bearing shells) 63,503 – 63,523 mm 2.5001 – 2.5009 in.
Bearing shell thickness (standard) 1,738 – 1,729 mm 0.0684 – 0.0681 in.
Bearing shell oversizes 0,25 mm, 0,50 mm, 0,75 mm
(0.0098, 0.0197, 0.0295 in.)
Bearing shell width 25,87 – 26,13 mm 1.0185 – 1.0287 in.
Bearing clearance 0,030 – 0,095 mm 0.0012 – 0.0037 in.
Maximum ovality of journals 0,035 mm 0.0014 in.
Connecting rod end float on big end
journal 0,140 – 0,420 mm 0.0055 – 0.0165 in.

Flywheel
Maximum run–out of friction surfaces 0,130 mm (0.005 in.) at radius of 120 mm
(4.68 in.)

Lubrication System
Oil pressure (oil at 80°C):
Idle speed 1,0 bar (14.5 psi) minimum
Maximum pressure 4.5 bar (65 psi)
Oil pump
Driving gear backlash 0,050 – 0,330 mm 0.002 – 0.013 in.
Clearance between inner & outer rotors 0,150 mm (max) 0.006 in. (max)
Clearance between outer rotor & housing 0,130 – 0,300 mm 0.005 – 0.012 in.
Rotor end float 0,010 – 0,090 mm 0.0004 – 0.0035 in.

16
Fuel System
Fuel injection pump
Naturally aspirated engine Bosch VE
Turbocharged engine Lucas (‘EPIC’)
Injection pump timing (static) 11° BTDC
Timing belt tension 220 – 345 N 50 – 78 lbf.
Injector type Stanadyne

Cooling System
Water pump type Centrifugal
Thermostat opening temperature 88°C 190°F
fully open temperature 102°C 235°F
Pressure cap setting 1 bar

Alternator drive belt

New belt Belt tension 578 – 623 N 129.5 – 139.5 lbf
Deflection 4,5 mm 0.175 in.
New belt (after 15 Belt tension 378 – 423 N 84.6 – 94.8 lbf
minutes running) Deflection 5,5 mm 0.215 in.
Used belt Belt tension 378 – 423 N 84.6 – 98.4 lbf
Deflection 5,5 mm 0.215 in.
Power steering pump drive belt
New belt Belt tension 578 – 623 N 129.5 – 139.5 lbf
New belt (after 15 Belt tension 378 – 423 N 84.6 – 94.8 lbf
minutes running)
Used belt 378 – 423 N 84.6 – 94.8 lbf

17
LUBRICANTS
Engine oil: Multigrade 10W–40, conforming to specification ACEA A3/96, B3/96 or
E3/96.

Engine oil capacity

Initial fill (including filter) 7 litres (12.3 pints)
Oil change (including filter change) 6 litres (10.6 pints)
Dipstick ‘MIN’ and ‘MAX’ 1.5 litres (2.6 pints)

COOLANT
Capacity 11 litres (19.5 pints)
Only approved anti–freeze must be used for this engine, and the correct coolant
proportions are 50% anti–freeze, 50% water.

SEALANTS
Thread locking Loctite 270
Sealer, non–hardening Hylomar PL32M

18
SERVICE SUMMARY

MILEAGE
12,000 24,000 36,000 48,000 60,000

RENEW ENGINE OIL & FILTER • • • • •

CHECK/ADJUST VALVE
CLEARANCES • • • • •
CHECK CONDITION & TENSION OF
EXTERNAL DRIVE BELTS. ADJUST
OR RENEW IF NECESSARY
• • • • •
VISUALLY CHECK CRANKCASE
BREATHER SYSTEM • • • • •
CHECK COOLING SYSTEM, HOSES
& CONNECTIONS FOR LEAKS • • • • •
CHECK OPERATION OF COOLING
FANS (when fitted) • • • • •
CHECK COOLANT SOLUTION
STRENGTH. RECORD READING Renew Renew Renew Renew
BY REFRACTOMETER. TOP UP
WITH SPECIFIED ANTIFREEZE
• every
2 years or
72,000 m*
every
2 years or
72,000 m*
every
2 years or
72,000 m*
every
2 years or
72,000 m*
(50% SOLUTION)
CHECK COOLING SYSTEM
PRESSURE CAP. RENEW IF
EVIDENCE OF SEAL •
DETERIORATION

DRAIN WATER FROM FUEL FILTER

• • •
RENEW FUEL FILTER
• •
RENEW AIR CLEANER ELEMENT
• •
Important Renew
Note every
RENEW TIMING BELT 5 years or
N/A 60,000 m*
Engine #

# The preferred renewal interval for naturally aspirated engine (i.e. non–turbo) is 36,000 miles / 3 years*,
particularly if the vehicle is subject to frequent high engine speed use.

* Whichever comes first

NOTE: The timing belt must NOT be re–tensioned; it must be renewed.

19
SPECIAL TOOLS

15–072 21–102–03

• Crankshaft rear seal centraliser/replacer (for

• Camshaft seal remover replacer use with 21–102–01 & 21–02–02A)
21–036A 21–122

090198

• Crankshaft spigot bearing remover • Flywheel holding tool

21–102–01 21–123

• Crankshaft rear seal replacer (use with

21–102–02A & 21–02–03) • Camshaft timing pin
21–102–02A 21–151

• Crankshaft rear seal replacer (use with

21–102–01 & 21–02–03) • Crankshaft rear seal remover
• denotes new tool

20
21–159 0480054 (18G 1205)

• Camshaft seal replacer / centraliser Flange holder (alternative to LDV 118)

23–019 0480080 (LST 122)

INC 10
RE °
ME
NT
S

• Fuel injection pump timing pin (Turbo engine) Angular torque gauge
23–020 1210507 (18G 1519A)

• Flywheel timing pin Valve spring compressor

23–029 LDV 118

• Fuel injection pump timing pin (N/A engine) Flange holder (alternative to 0480054 18G 1205)

• denotes new tool

21
 LDV 119 LDV 130

Clutch aligner • Injector seal replacer / EGR valve setting block

LDV 129 18G 1577

• Crankshaft front seal replacer / centraliser Valve stem seal remover

• denotes new tool

22
 DIAGNOSTIC TOOLS

0484976 (DX 710) 1210524 (DX 801)

Injector tester Optical tachometer

1210513 (DX 511) DA.102–116

Compression tester Compression tester adaptor (use with DX–511)

23
 TORQUE WRENCH SETTINGS
TORQUE WRENCH

Component Nm Lbf ft
SETTINGS

Inlet manifold to cylinder head . . . . . . . . . . . . . . . . . . . . . . 23 17

Left hand & right hand inlet manifold joint (N/A) . . . . . . . 23 17
Inlet manifold to exhaust manifold bracket (N/A) . . . . . . . 23 17
Front exhaust pipe to exhaust manifold (N/A) . . . . . . . . . 40 30
Exhaust manifold to cylinder head . . . . . . . . . . . . . . . . . . 52 39
Turbocharger to exhaust manifold (Turbo) . . . . . . . . . . . . 30 22
Turbocharger exhaust outlet . . . . . . . . . . . . . . . . . . . . . . . . 30 22
Throttle body to inlet manifold . . . . . . . . . . . . . . . . . . . . . . 23 17
Alternator belt tensioner security bolt . . . . . . . . . . . . . . . . 24 18
Alternator tensioning / adjusting bracket . . . . . . . . . . . . . . 24 18
Alternator mounting bracket / bolt . . . . . . . . . . . . . . . . . . . 24 18
Vacuum pump to alternator . . . . . . . . . . . . . . . . . . . . . . . . . 13 9
Power steering pump mounting bolt . . . . . . . . . . . . . . . . . 23 17
Power steering adjustment clamp bolt bolt . . . . . . . . . . . . 23 17
Starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 26
Water pump pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 8
Coolant drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 17
Temperature gauge sender unit . . . . . . . . . . . . . . . . . . . . . . 6 4.5
Temperature sensor (Turbo) . . . . . . . . . . . . . . . . . . . . . . . . 15 11
Coolant inlet pipe to engine plate . . . . . . . . . . . . . . . . . . . . 23 17
Water pump to engine front plate – M8 bolts . . . . . . 23 17
– M10 bolts . . . . . 46 34
Thermostat housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 17
Oil feed and return lines to adaptor . . . . . . . . . . . . . . . . . . 23 17
Oil feed and return lines to turbocharger (Turbo) . . . . . . 23 17
Main oil gallery plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 17
Camshaft oil gallery plug . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 15
Oil pressure sensor / switch . . . . . . . . . . . . . . . . . . . . . . . . 14 10
Oil pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 41
Oil pick–up pipe to cylinder block . . . . . . . . . . . . . . . . . . . . 18 13
Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 14
Oil pump cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 17
Oil drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 18
Oil cooler adaptor (Turbo) . . . . . . . . . . . . . . . . . . . . . . . . . . 70 53
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 11
Oil pressure pipe to vacuum pump . . . . . . . . . . . . . . . . . . 21 15
Sump to cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 10
EGR valve to throttle housing . . . . . . . . . . . . . . . . . . . . . . . 23 17
EGR pipe to exhaust manifold . . . . . . . . . . . . . . . . . . . . . . 23 17
Clutch pressure plate to flywheel . . . . . . . . . . . . . . . . . . . . 24 18
Flywheel timing socket bolt . . . . . . . . . . . . . . . . . . . . . . . . . 24 18
Flywheel to crankshaft – Stage 1 . . . . . . . 21 15
– Stage 2 . . . . . . . 30° 30°

24
Component Nm Lbf ft
Engine mounting bracket to cylinder block . . . . . . . . . . . . 55 41

TORQUE WRENCH
Crankshaft main bearing caps – Stage 1 . . . . . . . 84 62
– Stage 2 . . . . . . . 170 127

SETTINGS
Big end bearing caps
Early bolt/nut * – Stage 1 . . . . . . . 55 40
– Stage 2 . . . . . . . 70 50
Later bolt/nut * – Stage 1 . . . . . . . 30 20
– Stage 2 . . . . . . . 40 30
– Stage 3 . . . . . . Tighten nuts a further 90°
* See ‘Crankcase Overhaul – Pistons & Connecting Rods’
Crankshaft pulley / vibration damper bolt . . . . . . . . . . . . . 163 120
Camshaft rear cover plate to cylinder block . . . . . . . . . . . 23 17
Camshaft thrust plate to cylinder block . . . . . . . . . . . . . . . 23 17
Engine front plate to cylinder block – bolts 1 to 8 . . . . 36 27
– bolt 9 . . . . . . . . . 23 17
Front plate to support bracket . . . . . . . . . . . . . . . . . . . . . . . 23 17
Front plate support bracket to cylinder block . . . . . . . . . . 46 34
Crankshaft rear oil seal carrier . . . . . . . . . . . . . . . . . . . . . . 19 14
Camshaft pulley bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 88
Cylinder head to cylinder block – Stage 1 . . . . . . . 70 52
– Stage 2 . . . . . . . 70 52
– Stage 3 . . . . . . . 90° 90°
Rocker cover – Stage 1 . . . . . . . . 7 5
– Stage 2 . . . . . . . . 7 5
Rocker shaft pedestal–to–shaft bolts – M6 . . . . . . . . . . . 13 9
Rocker shaft pedestal bolts – M8 . . . . . . . . . . . 29 21
– M10 . . . . . . . . . . 66 49
Rocker arm adjusting screw . . . . . . . . . . . . . . . . . . . . . . . 12–48 9–36
Coolant outlet to cylinder head . . . . . . . . . . . . . . . . . . . . . . 23 17
Engine lifting eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18
Fuel lift pump to cylinder block . . . . . . . . . . . . . . . . . . . . . . 23 17
Fuel lift pump heat shield . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 17
Fuel filter housing to inlet manifold . . . . . . . . . . . . . . . . . . 17 13
Fuel injection pump to engine front plate . . . . . . . . . . . . . 23 18
Fuel injection pump timing belt pulley bolts . . . . . . . . . . . 25 19
Fuel injection pump rear support bracket . . . . . . . . . . . . . 24 18
Fuel injection high pressure pipe nuts . . . . . . . . . . . . . . . . 19 14
Fuel injection pump banjo union connections . . . . . . . . . 17 13
Injector retaining plate bolt . . . . . . . . . . . . . . . . . . . . . . . . . 40 29
Timing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 5
Idler and water pump pulley bolts . . . . . . . . . . . . . . . . . . . 11 8
Timing belt tensioner mounting bracket bolt (M8) . . . . . . 24 18
Timing belt tensioner pulley centre bolt (M10) . . . . . . . . . 58 43
Vacuum pump oil supply pipe to cylinder block . . . . . . . . 12 9
Gearbox to cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . 50 40

25
 EXTERNAL COMPONENTS (Turbo)
2 3
5
6

26
1

13 12 11
7
4 14

16 15
8
40

17 19 10
18
20
39

21
38
37 22 24
23
25

36
26

32
33
27
31 30
34
35 29 28
040966
 EXTERNAL COMPONENTS (Turbo engine illustrated)

1. Throttle body 14. Engine lifting eye 27. Sump drain plug
2. EGR valve 15. Fuel injection pump support bracket 28. Sump reinforcing strips
3. Inlet manifold 16. Fuel injection pump 29. Power steering pump
4. Inlet manifold gasket 17. Oil filter 30. Front plate
5. High pressure fuel pipes 18. Adaptor 31. Front plate bracket
6. Rocket cover 19. Oil cooler 32. Water pump gasket
7. Rocket cover gasket 20. Oil pressure relief valve 33. Water pump
8. Cylinder head 21. Front plate gasket 34. Oil pump cover gasket
9. Cylinder head gasket 22. Oil gallery sealing ring 35. Oil pump cover
10. Cylinder block 23. Fuel lift pump 36. Alternator mounting bracket
11. Coolant outlet 24. Heat shield 37. Alternator
12. Thermostat 25. Sump gasket 38. Vacuum pump
13. Thermostat housing 26. Sump 39. Coolant inlet pipe
40. Timing cover
27
 INTERNAL COMPONENTS

28
5

6
8
2 3 9 28
1 10
27
26
11 29
15 7 25
12 30
17 16 31
13 32
34

14 39
35 33
37 36
18
38
24
23 50
21 22 51
48

19 20 41
42 40
43
44

45
49 46
47
53 52 45
54
55

56 040971
57
 INTERNAL COMPONENTS

1. Rocker pedestal 20. Camshaft pulley 39. Crankshaft thrust washers (upper)
2. Rocker arm 21. `O' ring 40. Flywheel
3. Spring 22. Spacer sleeve 41. Crankshaft rear oil seal
4. Adjusting screw 23. Seal 42. Seal carrier
5. Shaft 24. Camshaft thrust plate 43. Seal carrier gasket
6. Push rod 25. Camshaft 44. Crankshaft
7. Cam follower 26. Camshaft bearing 45. Crankshaft thrust washers (lower)
8. Valve stem cap 27. `O' ring 46. Centre main bearing (lower)
9. Valve collets 28. Cover plate 47. Centre main bearing cap
10. Spring cap 29. Compression ring 48. Main bearing (upper)
11. Valve spring 30. Compression ring 49. Main bearing (lower)
12. Valve stem seal 31. Oil control ring 50. Oil pump ‘O’ rings
13. Valve guide 32. Piston 51. Oil pump
14. Valve 33. Connecting rod 52. Main bearing cap
15. Fuel injection pump pulley 34. Gudgeon pin 53. Oil pump drive gear
16. Plate 35. Small end bearing 54. Oil seal
17. Timing belt 36. Connecting rod cap 55. Timing belt guide (inner)
18. Tensioner spring 37. Big end bearings 56. Crankshaft pulley/damper
19. Timing belt tensioner 38. Centre main bearing (upper) 57. Rubber plug
29
CYLINDER HEAD

ROCKER COVER
Remove / Refit
Tools required: None
Remove 5 4 3 2 1

1A. N/A Engine:

– Remove the oil filler cap.
– Detach the air intake duct from the
throttle housing.
– Disconnect the EGR pipe from the 9 8 7 6
exhaust manifold. 041010

Discard the gasket and plug the Fig.1 Rocker cover tightening
apertures. sequence
– Disconnect the EGR throttle link at

CYLINDER HEAD
4. Clean and fit the rocker cover gasket
the throttle housing.
and the cover. Tighten the cover
– Remove the inlet manifold support securing bolts in the sequence
bracket bolts from the exhaust illustrated to 7 Nm (5 lbf ft).
manifold. Re–torque in the same sequence and
to the same torque.
– Remove the bolts/nuts securing
the left hand inlet manifold section, 5. Refit the components removed to gain
remove the manifold and discard access to the rocker cover, using new
the gasket. Plug the apertures. gaskets as required.
1B. Turbo engine:
6. N/A engine:
– Remove the oil filler cap. Check the setting of the throttle butterfly
link rod (see section ‘EGR System
– Disconnect the air charge Adjustments – Control Linkage’).
temperature sensor.
– Detach the air intake duct from the
throttle housing.
– Remove the EGR pipe and plug
the apertures.
2. Unclip the heater hose from the
rocker cover.
3. Remove the rocker cover. Inspect the
gasket for damage and renew if
necessary.

31
 VALVE CLEARANCES Valve clearances (hot)
Check / Adjust Inlet 0,20 mm (0.008 in.)
Exhaust 0,38 mm (0.015 in.)
Tools required: None
Using a socket and ‘T’ handle, adjust
1. Remove the rocker cover (see ‘Rocker incorrect clearances by turning the
Cover – Remove’). rocker adjusting screw.
Ex. Ex. Ex. Ex. 3. Refit the rubber plug in the crankshaft
F pulley / damper.

4. Refit the rocker cover (see ‘Rocker

Cover – Refit’).
In. In. In. In.
CYLINDER HEAD

041016

Fig.1 Adjusting valve clearance

2. To check / adjust the valve

clearances, remove the rubber plug
from the crankshaft pulley / damper
and use the securing bolt to turn the
crankshaft clockwise until the valves
in the following table are open.

Check the valve clearances by

inserting a feeler gauge between the
valve rocker arm and the valve stem
cap. The gauge should be a sliding
fit.
Open Valves to be
valves adjusted
1 and 6 4 and 7
2 and 3 5 and 8
4 and 7 1 and 6
5 and 8 2 and 3

32
CYLINDER HEAD REMOVE / 6. Detach the fuel filter housing from the
OVERHAUL / REFIT inlet manifold.

REMOVE 7. Remove the rocker cover (see

Tools required: None
The cylinder head can be removed with
the engine in situ by first carrying out the
following operations.
‘Rocker Cover – Remove’).
8. CAUTION: Care must be taken to
ensure the plastic connectors on
the injectors do not break.
Disconnect the spill return pipes.

1. Disconnect the battery(s), negative

terminal(s) first.
2. WARNING: Use caution if the
coolant is hot.
Drain the coolant into a suitable
container by disconnecting the bottom
radiator hose.
3. Disconnect the top hose and

CYLINDER HEAD
thermostat housing vent hose.
Disconnect the heater supply hose.
4A. N/A engine:
– Detach the exhaust down pipe
from the manifold.
041023

4B. Turbo engine:

Fig.1 Slackening fuel injector pipe
– Disconnect EGR system vacuum
pipes and electrical connections as 9. Remove the fuel injector high
necessary. pressure pipes, making sure each
union is restrained from turning while
– Detach the exhaust manifold from slackening the nut.
the cylinder head. To prevent ingress of dirt:
5. – Detach the wiring harness bracket – Plug the injector pipe ends , or
on the inlet manifold, and disconnect place the assembly in a clean
cables from: plastic bag.
Water trap sensor – Plug the injector and pump
Alternator connections.
Oil pressure switch
Starter solenoid
Coolant temperature transmitter
Coolant temperature sensor (Turbo
only)
Reverse light switch
Fuel injection pump (Turbo engine:
fit protector cap to socket)

33
 1
4
2
3

2
1

041029

Fig.3 Injector seals

1. PTFE compression seal
2. Water / dust seal
– Remove and discard the injector
041027
seals.
Fig.2 Injector – Fit a protective cap on the nozzle
CYLINDER HEAD

1. Injector tip.
2. Securing plate
3. Clamp
4. Bolt
10. To remove the injectors:
– Clean the area around each
injector. 2

– Before removing an injector, note

the relative positions of the
securing plate, and the position of
the injector feed pipe relative to
the recess in the cylinder head.
– Working on one injector at a time,
remove the injector securing bolt 1
and clamp.
– Pull the injector out of the cylinder 041072
head, and plug the hole.
Fig.4 Removing rocker shaft
1. Push rods
2. Valve stem caps

34
11. Remove the rocker shaft assembly, 2 6 10 14 18 15 11 7 3
releasing the pedestal securing bolts
progressively to release the valve
spring tension.
12. Remove each push rod and its
associated valve stem cap,
identifying them in a numbered
sequence for correct refitting later. 1 5 9 13 17 16 12 8 4
13. Disconnect the coolant by–pass hose
from the coolant return pipe, and
detach the hose from the inlet
manifold.
14. Remove the two bolts securing the
coolant outlet to the cylinder head.
Detach the outlet and discard the ‘O’
ring. A

041037

CYLINDER HEAD
Fig.6 Cylinder head bolt loosening
sequence
A. Torx bolt

16. To remove the cylinder head:

041033
Fig.5 Marking cylinder head bolts
15. NOTE: The cylinder head bolts can
only be used three times.
Mark each bolt head with a punch
mark to indicate its removal. If the
bolts already have 2 marks they
should be renewed (see ‘General
Precautions, note 12’).
– Remove the torx bolt securing the
timing cover to the cylinder head.
– Slacken the cylinder head bolts in
the sequence shown.
Remove the bolts and discard any
that show signs of damage,
stretch, etc.
If any are binding on their threads,
investigate the cause, and rectify
as necessary.
17. Using suitable lifting tackle, remove
the cylinder head.
Place it on clean blocks of wood to
protect machined surfaces.
18. Note the two ring dowels which locate
the cylinder head on the block.
Remove and discard the cylinder
head gasket.

35
 2 1 OVERHAUL
3 Tools required: 1210507 (18G 1519A)
4 Dismantling
5 1. Place the cylinder head, cylinder block
face down, on two blocks of wood to
avoid damaging the mating face.
2. Remove the inlet manifold and
discard the gasket
3. Remove the exhaust manifold (if not
6 already removed).

041114
CYLINDER HEAD

Fig.1 Cylinder Head Components

1. Valve stem cap
2. Valve collets 041101

3. Spring cap
Fig.2 Removing valves
4. Valve spring
5. Spring seat / valve stem seal NOTE: During dismantling, keep all
6. Valve guide components from each valve assembly
7. Valve in identifiable sets to ensure they will be
refitted in the same locations.
4. Working on each valve in turn:
CAUTION: Take care not to damage
the valve stems when removing the
valve collets. The valve stem oil
seals will only be effective if the
stems are free from score marks or
other damage.
– Compress the valve spring using
1210507 (18G 1519A) or other
suitable valve spring compressor and
withdraw the valve collets.
Carefully release the valve spring
compressor.
– Remove the spring cap and
spring, noting the spring
identification colour(s).
– Remove the valve.

36
 CYLINDER HEAD
Examine the cylinder head particularly
carefully for damage (e.g. discolouration
1 or cracks) which may indicate that the
engine is overheating. If such damage is
found, check that the cooling system is
operating satisfactorily. Only parts that are
in good condition may be used again.
2 Before proceeding with overhaul work,
check the cylinder head for distortion.

041102

Fig.3 Removing valve stem oil seal

1. Tool 18G 1577
2. Valve stem oil seal
– Remove and discard the combined
stem seal and spring seat. Tool

CYLINDER HEAD
18G 1577 can be used for this
purpose.

Inspection / Overhaul
Clean the cylinder head and block mating
faces (the surfaces must not be a
polished finish).
041097

Remove all carbon deposits and
combustion residues from the valves and
cylinder head.
Check the valve guides for carbon
deposits and clean as necessary.
Examine all components for wear and
damage.
Fig.4 Checking for cylinder head
distortion
Use a straight edge and feeler gauge to
check for distortion in a number of planes
across the cylinder head face.
See ‘Data’ for distortion dimensions.

37
 VALVE GUIDES
Check each valve guide for wear or
damage (see ‘Data’ for guide
X
dimensions).
Guides are available with an oversize
outer diameter.
If renewal is necessary, fit the new
guide(s) as follows:

041064

Fig.6 Fitting valve guide

3. To fit the new guide(s), invert the
cylinder head (lower face
downwards). Press in each guide
from above (grooved end uppermost)
CYLINDER HEAD

using a suitable size mandrel.

When fitted, the valve guides should
protrude by 1.8 to 2.3 mm (0.071 –
0.091 in.) above the rocker cover
041063
sealing face (dimension ‘X’ in
Fig.5 Removing valve guide illustration).

1. CAUTION: Ensure machined 4. When new valve guides have been

surfaces are protected against
damage by resting on wooden
blocks.
Position the cylinder head on the
press bed (lower face upwards) and
press the old guide(s) out using a
suitable size mandrel.
fitted, the valve seats must be re–cut
or new seat inserts fitted to ensure
concentricity between the valve stem
and its seat (see ‘Valve Seats’).
NOTE: Care must be taken to
maintain the correct valve recession
(see ‘Valves’).

2. If oversize guides are to be fitted, the

cylinder head must be accurately
machined to accept them in a
workshop properly equipped for this
work (see ‘Data’ for dimensions).

38
VALVES
Check the valves for cracks, pits and
signs of burning. Check the stems for
wear (see ‘Data’ for dimensions) and for
correct fit in their guides.
Check the valves for concentricity.
1 2
041068
Fig.7 Exhaust valve identification
1. N/A exhaust valve
2. Turbo exhaust valve
The exhaust valves used in the
turbocharged engine have a Stellite ring
on their seating faces. The exhaust
valves fitted in the naturally aspirated
engine can be identified by the additional
groove in the valve stem.
Do not attempt to re–face Stellite valves.
Minor imperfections on other valve faces
can be rectified by re–facing. Then lap
the valve into its seat using a fine paste
until a satisfactory seal is obtained.
A minimum seating width of 1 mm (0.040
in.) is recommended around the full
circumference (360°).
Ensure all paste is removed from the
valve and seat area after lapping.
041048
Fig.8 Valve recession
After rectification the valve recession in
the cylinder head must be checked and
the valve(s) renewed if outside tolerance.
Inlet 0,35 – 0,65 mm
(0.014 – 0.025 in.)
Exhaust 0,50 – 0,80 mm
(0.020 – 0.031 in.)
CYLINDER HEAD
If renewal of the valve(s) fails to give the
correct recession, the valve seat can be
renewed (see ‘Valve Seats’).
VALVE SEATS
Examine the seats for damage and pitting.
Fit each valve in turn and check its
recession by measuring the depth of the
valve below the face of the cylinder head
(see ‘Valves’).
Compare the measured depth with the
valve recession information given in
‘Data’, and rectify as necessary.
39

30° Inlet
Exhaust
45°
041051
Fig.9 Valve seats
When cutting valve seats, note that the
inlet and exhaust valve angles are
different:
Inlet 30° to 30°30’
Exhaust 45° to 45°30’
After re–cutting valve seats, the valve
CYLINDER HEAD
recession must be checked.
If valve recession is excessive and cannot
be rectified by renewing the valve(s), one
size of valve seat insert is available.
WARNING: Wear eye protection.
Fit the new valve seat by machining the
cylinder head to the dimensions given in
‘Data’. The replacement seat must be
chilled (typically using liquid Nitrogen)
prior to installation.
Precision work of this nature is best
carried out by a properly equipped
specialist workshop.
SPRINGS
Inspect the springs for damage.
NOTE: On the turbocharged engine,
different colour coded springs are fitted.
Inlet – Red
Exhaust – Green / yellow
Spring condition can be checked against
information in ‘Data’ (free length, force to
open valve).
40
REBUILD
Before starting to assemble the cylinder
head, ensure all swarf, grinding paste,
etc. has been removed.
1. Working on each valve in turn:
– Check that there are no burrs / sharp
edges on the collet grooves on the
valve stem which could damage the
oil seal during installation.
– Lightly oil the valve stem and insert it
in the corresponding valve guide.
– Slide a new combined stem seal
and spring seat over the valve
stem and press it fully onto the
valve guide.
– Fit the valve spring and spring cap
on the valve stem.
NOTE: On Turbo engines, red
colour coded springs are fitted to
inlet valves.
– Carefully compress the valve spring
using 1210507 (18G 1519A) or other
suitable valve spring compressor and
insert the valve collets. Make sure
that the collets are correctly seated in
the grooves.
Release the valve spring
compressor.
– Fit the remaining valves in the
same way.
2. Naturally aspirated engine:
Apply Hylomar PL32M to the exhaust
manifold mating face with the cylinder
head.
Fit the manifold, apply Loctite 270 to
the securing bolts, then fit and tighten
to 52 Nm (39 lbf ft).
3. Fit the inlet manifold to the cylinder
head using a new gasket.
Apply Loctite 270 to the securing
bolts, then fit and tighten
progressively from the centre
outwards to 23 Nm (17 lbf ft).
ROCKER SHAFT

5
7

3
2 4
8
1

CYLINDER HEAD
041103

Fig.1 Rocker shaft assembly

1. Pedestal 5. Pedestal securing bolt
2. Rocker arm 6. Pedestal–to–shaft securing bolt
3. Adjusting screw 7. End plug
4. Spring 8. Shaft

Overhaul
Temporarily mark the components prior to PEDESTALS
dismantling to ensure replacement in the D Check that pedestals are a snug fit on
same location. the shaft.

Progressively remove the D Centre pedestal – check that oil

pedestal–to–shaft securing bolts and drilling is clear.
remove the components. Maintain them
in the dismantling sequence. SPRINGS
D Inspect for wear / damage.
Inspect as follows:
SHAFT
D Inspect for wear / damage.
D Check that end–plugs are securely
fitted, and are positioned inboard of
outer pedestal–to–shaft securing bolt
holes.
D Check that shaft bore and oil drillings
are clear.

41
 ROCKER ARMS
D Check pads for wear.
D Check bores for wear / damage and
for fit on shaft (see ‘Data’ for
dimension). If necessary, compare fit
with new rocker.
D Check that oil drillings are clear.
CYLINDER HEAD REFIT
Tool required: LDV 130
1. Ensure that the mating faces of the
cylinder head and block are clean and
dry.
Check that the two locating ring
dowels are correctly located.
2. Fit a new cylinder head gasket.
NOTE: Two gasket sizes are
available; a standard size, and an
oversize for fitting to an engine that
has been rebored.
3. Carefully fit the cylinder head,
guiding it over the locating dowels.

17 13 9 5 1 4 8 12 16
CYLINDER HEAD

041014

Fig.2 Checking residual torque of

rocker arm adjusting screw 18 14 10 6 2 3 7 11 15
D Clamp each rocker arm in turn in a
soft–jawed vice.
Use a torque meter and socket to
check that valve clearance adjusting
screw has a residual torque of
12 – 48 Nm (9 – 36 lbf ft.).

Assembly of the rocker shaft is the

A
reverse of dismantling, noting the
following:
041049

D Lubricate each component prior to

fitting. Fig.1 Cylinder head bolt tightening
sequence
D Fit but do not tighten the A. Torx bolt
pedestal–to–shaft securing bolts at
this stage. They should only be
tightened after the assembly has
been fitted to the engine to ensure
correct alignment.

42
4. Lightly oil the cylinder head bolt
threads and contact surfaces before
fitting them.
Tighten the bolts as follows in the
sequence illustrated.
Stage 1 – Pre–tighten in sequence to
70 Nm (52 lbf ft.)
Stage 2 – Re–torque in sequence to
70 Nm (52 lbf ft.)
Stage 3 – Tighten in sequence by a
further 90°.
7. Fit each injector as follows:
NOTE: The seals fitted to N/A and
Turbo injectors are different sizes.
– Fit a new dirt seal.
– Position a new compression seal
on the injector, ensuring the
externally grooved end is
downwards.
– Press the seal into place using tool
LDV 130 as illustrated.

5. Fit the torx bolt securing the timing – Lightly grease the barrel of the
cover to the cylinder head. injector in the area between the
two seals.
6. Fit the water outlet on the cylinder
head, using a new sealing ‘O’ ring.
2
Connect the coolant by–pass hose to
the return pipe, and secure the
bracket to the inlet manifold.

CYLINDER HEAD
3 1

041091
2
1 Fig.3 Fitting injector
1. Securing plate
3
2. Downward facing lug
3. Securing clamp
041030
– Fit the injector in the cylinder
Fig.2 Fitting injector seals head, ensuring that the feed pipe
1. Compression seal locates correctly in the recess in
2. Dirt seal the head.
3. Tool LDV 130 – Position the securing plate as
illustrated so that its two downward
facing lugs are on either side of
the feed pipe, and the slot aligns
with the securing bolt hole in the
head.

43
 – Fit the securing clamp and bolt. 11. To check / adjust the valve
Tighten the bolt to 40 Nm (29 lbf ft). clearances, turn the crankshaft until
the valves in the following table are
8. Fit the push rods and valve stem caps open and then check the valves
in their original positions. indicated in the following table by
9. Fit the rocker shaft assembly, inserting a feeler gauge between the
locating the adjusters in the pushrods. valve rocker arm and the valve stem
Progressively tighten the M10 cap. The gauge should be a sliding
pedestal securing bolts to the correct fit.
torque, followed by the M8 bolts: Open Valves to be
M10 bolts 66 Nm (49 lbf ft) valves adjusted
M8 bolts 29 Nm (21 lbf ft) 1 and 6 4 and 7
2 and 3 5 and 8
10. If the rocker assembly pedestal–to–shaft
4 and 7 1 and 6
retaining bolts were slackened /
5 and 8 2 and 3
removed, tighten them to 13 Nm
(9 lbf ft). Valve clearances (hot)
Ex. Ex. Ex. Ex. Inlet 0,20 mm (0.008 in.)
F Exhaust 0,38 mm (0.015 in.)
CYLINDER HEAD

Using a socket and ‘T’ handle, adjust

incorrect clearances by turning the
In. In. In. In.
rocker adjusting screw.

041016

Fig.4 Adjusting valve clearance

041023

Fig.5 Tightening injector pipe

44
12. CAUTION: It is important to use
two spanners to tighten high
pressure fuel pipes: one to hold
the injector while tightening the
gland nut with the other.
Fit and tighten the injector high
pressure pipes.
13. Fit the spill return pipes.
14. Turbo engine:
Apply Hylomar PL32M to the exhaust
manifold mating face with the cylinder
head, and fit the manifold. Apply
Loctite 270 to the securing bolts and
tighten to 47 Nm (35 lbf ft).
15. Fit the fuel filter housing to the inlet
manifold and connect the fuel pipes.
16. Fit the rocker cover (see ‘Rocker
Cover Refit’).
If the engine is in situ, complete the
installation by carrying out the following
operations:
17. Refit the components removed during
dismantling, and reconnect electrical
cables as appropriate.
18. Refill with coolant (50% antifreeze) –
see ‘Cooling System’ for correct filling
procedure.
19. Connect the battery(s), positive
terminal(s) first.
20. Start the engine and run until normal
operating temperature is reached.
Check for coolant leaks.
WARNING: Place a thick
cloth over the cap and
CYLINDER HEAD
expansion tank before attempting
to remove the cap slowly, to avoid
the possibility of scalding if the
engine is hot.
Check the coolant level and top up as
necessary.
45
EXTERNAL DRIVE BELTS Refit / Adjust
Remove / Refit / Adjust 3. Fit the belt and tension as follows:
POWER ASSISTED STEERING DRIVE – Pull the pump away from the
BELT engine until the belt deflection at
mid point under firm thumb
Remove pressure is:
New belt 4.5 mm
Used belt 5.5 mm
– Tighten the pump bracket clamp
bolt, then tighten the pivot bolt.
– Re–check the tension and adjust
2 as necessary.
1 – Run the engine for 5 minutes, then
check that the belt tension is correct
(see used belt tension data above).

041099

Fig.1 Power assisted steering pump

1. Bracket clamp bolt
2. Pivot bolt

FRONT END
1. Slacken the pump bracket clamp bolt
and the pivot bolt.
2. Push the pump towards the engine
and remove the drive belt.

47
 ALTERNATOR DRIVE BELT Refit / Adjust
Remove

1. Remove the power assisted steering

drive belt (see ‘Power Assisted
Steering Drive Belt’).

041028

Fig.2 Alternator drive belt

5. Fit the drive belt.

3 6. Tighten the tensioner bolt until the
041020 belt deflection at the mid–point of the
longest run is:
Fig.1 Alternator mountings
1. Belt tensioner security bolt New belt 4.5 mm
2. Belt tensioner bolt Used belt 5.5 mm
3. Alternator pivot bolt
7. Tighten the tensioner security bolt,
FRONT END

2. Slacken the belt tensioner security and the pivot nut and bolt.
bolt, and the alternator pivot nut and
bolt.
3. Release belt tension by slackening
the belt tensioner bolt.
4. Remove the drive belt.

48
TIMING BELT
Remove / Fit
Tools required: 23–020, 21–123,
23–019 (turbo engine), 23–029 (naturally
aspirated engine), MS 1517 (if viscous fan
fitted).
Remove
1
The timing belt can be removed with the
engine in situ after first carrying out the
following operations:
WARNING: If the engine has
been running recently, cooling 1
system components may be
sufficiently hot to cause burning to
skin on contact.
CAUTION: A new timing belt must only
be fitted when the engine is cold. (If 041019

the engine has been running it must be

allowed to cool for 4 hours before Fig.1 Timing belt cover
fitting the new belt). 1. Dirt shield screws

1. Ensure the ignition is switched off. 7. To remove the timing cover:

Disconnect the battery(s), negative
(earth) terminal(s) first.
2. Access will be improved by removing
the bonnet closing panel and the
– Slacken the 2 dirt shield screws
(5 mm spanner) and slide the
shield upwards.
– Remove the 7 torx screws
securing the cover.

FRONT END
radiator (if required). – Hinge the lower section down and
remove the cover.
3. Remove the viscous fan (if fitted)
using tool MS 1517 (right hand
thread).
NOTE: On engines built for hot
climates the viscous fan is fitted to the
water pump and has a left hand
thread.
4. Slacken the bolts on the water pump
and fan / idler pulleys (4 bolts on
each).
5. Remove the external drive belts (see
section ‘External Drive Belts’).
6. Remove the water pump pulley and
the fan / idler pulley.

49
 8. Remove the rubber plug from the
2 crankshaft pulley and use the pulley
securing bolt (18 mm spanner) to turn
the engine clockwise until the hole in
the camshaft pulley (arrowed) and its
1 timing hole in the engine front plate
3
are approximately 6 mm from
7 alignment.
4

6 041021

Fig.2 Timing belt and pulleys

1. Fuel injection pump drive pulley
2. Timing belt
3. Water pump 041015

4. Engine front plate

5. Camshaft drive pulley Fig.4 Flywheel timing pin
6. Crankshaft pulley / damper
7. Oil pump cover 9. N/A engine:
8. Timing belt tensioner Remove the blanking plug from the
crankcase adjacent to the starter
motor.
Turbo engine:
Remove the engine speed sensor
FRONT END

(torx bolt), ensuring that any shim

fitted is retained for refitting.
Continue to turn the crankshaft until
the flywheel timing pin 23–020 can be
fitted through the hole in the
crankcase and into the flywheel.
The crankshaft is now in its correct
timing position (11° BTDC, No. 1
041025
cylinder firing).

Fig.3 Camshaft pulley timing locations

50
 1
2 041024
Fig.5 Timing pins
1. Fuel injection pump timing pin
2. Camshaft timing pin
10. Fit timing pin 21–123 through the hole
in the camshaft pulley and into the
hole in the engine front plate.
Fit the appropriate fuel injection pump
timing pin (23–029 for N/A engines,
23–019 for turbo engines) through the
hole in the pump pulley and into the
hole in the pump drive.
NOTE: If it is not possible to fit both
timing pins, this would indicate that
the timing is incorrectly set.
11. Slacken the 4 fuel injection pump
pulley securing bolts by 1/4 to 1/2
turn.
1
1
2
040994
Fig.6 Releasing timing belt tension
1. Securing bolts
2. Pry bar
12. Slacken the timing belt tensioner
securing bolts. Use a suitable pry bar
as illustrated to push the tensioner
away from the camshaft pulley, and
release the tension on the belt.
Tighten the smaller securing bolt (M8)
to lock the tensioner in the ’retract’
position.
13. Remove the larger tensioner securing
FRONT END
bolt (M10) and its large, flat washer.
14. Remove the timing belt by first easing
it off the fuel injection pump pulley.
DISCARD THE TIMING BELT.
CAUTION: Unless instructed, do
not turn the camshaft or crankshaft
when the timing belt is not fitted.
51
 2 17. Lightly lubricate the back face of the
1 tensioner mounting bracket and the
spring with a high melting point
lubricant.

040991

Fig.7 Timing belt tensioner

1. Tensioner spring
2. Spring seat
15. Remove the M8 tensioner securing
bolt to detach the tensioner.
16. Clean the back face of the tensioner 3
mounting bracket.
Remove any evident damage or burrs
on the mating faces of the mounting
bracket and the engine front plate.

Fit
1
CAUTION 2
a. Never fit a used timing belt. A046-001
b. A new timing belt must only be
fitted when the engine is cold. Fig.8 Fitting tensioner
FRONT END

(If the engine has been running 1. M8 bolt

it must be allowed to cool for 4 2. M10 bolt
hours before fitting the new 3. Water pump pulley
belt).
c. If any pulley is contaminated it 18. Fit the tensioner, checking that it can
must be cleaned before fitting a slide freely on the engine front plate.
replacement belt. Note that both Push the tensioner back by using a
oil and antifreeze will suitable lever as illustrated, and
contaminate the belt. temporarily tighten the smaller (M8)
d. Take care not to contaminate securing bolt.
the belt or the pulleys when
handling them.
e. Always observe all the belt
handling precautions listed in
‘General Precautions’.

52
 1
3 041026
Fig.9 Timing pins
1. Flywheel timing pin
2. Fuel injection pump timing pin
3. Camshaft timing pin
19. Check that the three timing pins
(flywheel, camshaft and fuel injection
pump) remain in their fitted position.
20. A new timing belt must be fitted.
Check that all the pulley teeth are
clean and dry. Ensure that the
direction of rotation arrows on the belt
will point in the correct direction when
it is fitted, then ease the belt between
the crankshaft pulley and the
tensioner pulley.
1 4 041031
Fig.10 Timing belt pulleys
1. Crankshaft pulley
2. Camshaft pulley
3. Fuel injection pump pulley
4. Tensioner pulley
21. To fit the timing belt:
– Engage it on the crankshaft pulley.
Ensure it is central to the
crankshaft and camshaft pulleys.
NOTE: If necessary, remove the
tensioner M10 bolt and large
washer to allow the belt to pass
FRONT END
freely between the crankshaft and
idler pulleys, then refit the bolt
and washer.
– Keeping the belt taut on the drive
side, engage it on the camshaft
pulley.
– Position the fuel injection pump
pulley central on its mounting
slots.
Engage the belt on the pulley,
keeping it taut on the camshaft
pulley side.
NOTE: If necessary, rotate the
injection pump pulley clockwise
on its slots to allow the belt teeth
to engage.
53
 – Finally place the belt around the
tensioner pulley.
22. Release the tensioner securing bolts
and allow the tensioner to spring into
its working position.
041032
Fig.11 Activating tensioner
23. Press down on the timing belt midway
between the fuel injection pump and
camshaft pulleys, and check that
there is free tensioner movement.
Temporarily tighten the tensioner
FRONT END
securing bolts.
24. Temporarily tighten the fuel injection
pump pulley securing bolts.
25. Remove all three timing pins.
54
A046-002
Fig.12 Aligning fuel injection pump
pulley
26. CAUTION: Failure to position the
crankshaft at 1 7/8 turns alignment
position, so that the correct
tension is set, can result in
premature engine failure.
Turn the crankshaft clockwise until the
fuel injection pump pulley aligns with
the engine front plate feature as
illustrated. This is equivalent to 1 7/8
crankshaft turns.
27. Slacken the two bolts securing the
timing belt tensioner.
28. Press down on the timing belt midway
between the fuel injection pump and
camshaft pulleys, and check that
there is free tensioner movement.
29. Remove the two tensioner mounting
bolts one at a time, apply Loctite 270
to the threads and refit the bolts.
Torque tighten to:
M10 centre bolt 58 Nm (43 lbf ft)
M8 mounting bolt 24 Nm (18 lbf ft)

041015
Fig.13 Flywheel timing pin
30. Rotate the crankshaft clockwise until
the flywheel timing pin 23–020 can be
inserted.
1 with the torx bolts.
2 041024
Fig.14 Timing pins
1. Fuel injection pump timing pin
2. Camshaft timing pin
31. Re–fit the fuel injection pump and
camshaft timing pins to check that the
timing is still correct.
If the injection pump timing pin will not
enter, slacken the four fuel injection
pump pulley bolts and rotate the
pump hub using its centre nut until the
pin will enter.
Remove the four pulley bolts one at a
time, apply Loctite 270 to the
threads, refit and torque tighten to 25
Nm (19 lbf ft).
32. Remove the three timing pins.
33. Refit the rubber plug in the crankshaft
pulley.
N/A engine:
Refit the sealing plug in the flywheel
timing hole.
Turbo engine:
Refit the engine speed sensor and
shim (if fitted).
34. Fit the timing belt cover and secure
Slide the dirt shield down and tighten
the securing screws.
35. Fit the water pump pulley and the
FRONT END
idler / fan pulley.
36. Fit the two external drive belts,
adjusting them to the correct tension
(see section ‘External Drive Belts’).
37. Fit the viscous fan (if fitted) and
tighten with tool MS 1517.
If working with the engine in situ:
38. Fit the radiator and bonnet closing
panel (if removed). Fill with 50%
anti–freeze / water (see ‘Cooling
System’).
39. Connect the battery(s), positive
terminal(s) first.
55
 CAMSHAFT FRONT OIL SEAL –
RENEW
Tools required: 23–020, 21–123,
23–019 (turbo engine), 23–029 (naturally
aspirated engine), either 0480054
(18G 1205) or LDV 118, 21–159, MS 1517
(turbo engine), 15–072, 21–159.
4. CAUTION: The camshaft pulley
securing bolt can only be used a
maximum of 6 times. Discard it if
marked with 5 punch marks.
(For explanation, see ‘General
Precautions, note 12’.)
Make a punch mark on the head of
the camshaft pulley securing bolt.

Remove
1. The camshaft oil seal can be removed
in situ after removing the timing belt
cover, and removing and discarding
the timing belt (see section ‘Timing
Belt Remove’).
Then proceed as follows.

CAUTION: Do not allow the timing

belt pulleys to become
contaminated by dirt or oil.
1 041040

Fig.2 Removing camshaft pulley

1. 0480054 (18G 1205)

5. Using tool 0480054 (18G 1205) or

LDV 118 to restrain the camshaft
pulley as illustrated, remove the
pulley securing bolt and extract the
90° pulley.
FRONT END

040250

Fig.1 Pistons in ‘safe’ position

2. Remove the flywheel timing pin

23–020 and turn the crankshaft
anti–clockwise by 1/4 turn (90°) to
position the pistons in the ’safe’
position.
3. Remove the camshaft timing pin
21–123.

56
 1 2
4 1
3 041060

040997

Fig.5 Removing camshaft oil seal

Fig.3 Camshaft front seal 1. Tool 15–072
1. Woodruff key
2. ‘O’ ring 8. Remove the camshaft oil seal using
3. Spacer sleeve tool 15–072.
4. Seal
Inspection
6. Remove the woodruff key from the
9. Clean all parts and examine for wear
camshaft.
or damage. Renew as necessary.

FRONT END
041059 041003

Fig.4 Removing camshaft spacer Fig.6 Checking centralisation

sleeve
7. Taking care not to damage the
surface of the spacer sleeve, engage
two suitable levers in the sleeve
groove as illustrated, and carefully
prise off the sleeve together with the
‘O’ ring.
Discard the ‘O’ ring.
1. Tool 21–159
10. Check the centralisation of the engine
front plate around the camshaft by
fitting tool 21–159. If the tool will not
fit, the front plate must be centred
(see ‘Crankcase – Rebuild’).
IMPORTANT: It is essential that the
front plate is centred correctly to
avoid creating an oil leak past the
seal.

57
 1 1
041050
041076

Fig.7 Fitting camshaft front seal Fig.8 Tightening camshaft pulley

1. Tool 21–159
11. NOTE: Do not apply lubricant to the
oil seal.
To fit the camshaft front seal:
– Remove the protector supplied
with the seal.
– Position the seal, lip towards the
camshaft, and carefully tap it into
the front plate using tool 21–159.
Finally position the seal by drawing
it into place using tool 21–159 and
the camshaft pulley bolt.
– Remove the tool.
FRONT END
1. 0480054 (18G 1205)
14. Fit the camshaft pulley and restrain it
with tool 0480054 (18G 1205) or
LDV 118 as illustrated.
Apply a light smear of oil to the
underside of the securing bolt flange.
Fit the bolt and torque tighten to
120 Nm (88 lbf ft).
15. Fit the camshaft timing pin 21–123.
16. Turn the crankshaft clockwise until the
flywheel timing pin 23–020 can be
fitted.
17. Fit a new timing belt as described in

12. Fit the spacer sleeve, first ensuring it

the section ‘Timing Belt – Fit’, and
is clean and dry.
then complete the rebuild as
Fit a new ‘O’ ring, pressing it into described in the same section.
place with tool 21–159.

13. Fit the woodruff key.

58
CRANKSHAFT FRONT OIL SEAL –
RENEW
Tools required: 23–020, 21–123, 23–029
(N/A engines), 23–019 (turbo engines),
21–159, MS 1517 (turbo engines),
21–122 (engine in situ) or 0480054
(18G 1205) / LDV 118, LDV 129
Remove
1. The crankshaft oil seal can be
removed in situ after removing the
timing belt cover and timing belt (see
section ‘Timing Belt Remove’).
Discard the timing belt.
Then proceed as follows.
CAUTION: Do not allow the timing
belt pulleys to become
contaminated by dirt or oil.
90°
040250
Fig.1 Pistons in ‘safe’ position
2. Remove the flywheel timing pin
23–020 and turn the crankshaft
anti–clockwise by 1/4 turn (90°) to
position the pistons in the ‘safe’
position.
3. CAUTION: Do not attempt to use
the flywheel timing tool and / or its
locating socket in the crankcase to
restrain the flywheel from turning.
Remove the starter motor and install
Tool No. 21–122 in its place.
NOTE: If the engine is out of the
vehicle, the crankshaft can be
restrained from turning by attaching
tool 0480054 (18G 1205) or LDV 118
to the flywheel using suitable bolts.
3
4
5
1 2
041039
Fig.2 Crankshaft pulley / damper
1. Rubber plug
2. Securing bolt
FRONT END
3. Crankshaft pulley / damper
4. Woodruff key
5. Timing belt inner guide
4. Remove:
– Crankshaft pulley / damper
securing bolt
– Crankshaft pulley / damper
– Timing belt inner guide
5. Disconnect the vacuum pump oil
drain pipe.
6. CAUTION: Do not allow alternator
to hang on its cables or the
vacuum pump oil supply pipe.
Remove the alternator mounting pivot
bolt, and support the alternator on its
adjuster bracket.
59
 7. Slacken the timing belt tensioner
securing bolts to allow the tensioner
to slide towards the camshaft.
8. Remove the bolts securing the oil
pump cover, noting the position of the
alternator mounting bracket before
removing it.
Remove the cover and discard the
gasket.
9. Inspect the oil pump cover for
damage.
Install
10. NOTE: Do not apply lubricant to the
oil seal.
Renew the crankshaft seal as follows:
– Press the old seal out of the cover.
– Temporarily removing the seal
protector, offer a new seal into the
cover, ensuring the seal lip will
face the engine.
FRONT END
041022
Fig.3 Fitting crankshaft front oil seal
– Place the assembly on a clean, flat
surface and press down on the
cover as illustrated to press the
seal squarely into position.
Check that the outer diameter of
the seal is flush with the machined
face of the cover.
– Refit the seal protector supplied
with the seal from the rear.
60
11. To fit the oil pump cover:
– Fit a new oil pump cover gasket.
– Ensure the seal journal on the oil
pump drive gear is clean and dry.
– Carefully place the front cover in
position, allowing the seal protector
to be pushed out through the seal.
– Fit the cover securing bolts finger
tight; do not fit the alternator
mounting bracket.
6
3 8
9 4
1
2 5 7
A 041058
Fig.4 Fitting oil pump cover
A. Tool LDV 129
– Fit tool LDV 129 as illustrated to
centralise the cover over the
crankshaft.
– Tighten the securing bolts in the
sequence illustrated to 23 Nm
(17 lbf ft).
 – Remove and re–fit the tool
LDV 129 using hand pressure
only; it must enter the oil seal
location easily. If not, slacken the
cover securing bolts and repeat
the cover fitting procedure.
IMPORTANT: It is essential that
the cover is centralised
correctly to avoid creating an oil
leak past the seal.
– Remove the tool.
12. Fit the alternator mounting bracket,
ensuring the coolant pipe mounting is
correctly located.
13. Loosely secure the alternator, and fit
the vacuum pump drain pipe.
3 and refit the starter motor (if
4 removed).
5
1 2
041039
Fig.5 Crankshaft pulley / damper
1. Rubber plug
2. Securing bolt
3. Crankshaft pulley / damper
4. Woodruff key
5. Timing belt inner guide
14. Fit to the crankshaft:
– Timing belt inner guide, concave
face towards the seal.
– Crankshaft pulley / damper.
– Pulley securing bolt, first
lubricating the threads and the
larger diameter head of the bolt
with clean engine oil.
15. Restrain the flywheel from turning
using tool 21–122 (engine in situ), or
0480054 (18G 1205) or LDV 118,
and tighten the pulley securing bolt to
163 Nm (120 lbf ft.)
CAUTION: Do not attempt to use
the flywheel timing tool and/or its
locating hole to restrain the
flywheel from turning.
Remove the flywheel restraining tool
16. Turn the crankshaft clockwise until the
flywheel timing pin 23–020 can be
fitted.
17. Fit a new timing belt and rebuild the
engine as described in the section
‘Timing Belt Fit’.
FRONT END
61
 FLYWHEEL
CLUTCH & SPIGOT BEARING
Remove / Refit
Tools required: 21–122 (engine in situ)
or 0480054 (18G 1205) / LDV 118,
LDV 119, 21–036A (for spigot bearing).
Remove
The clutch can be removed with the
engine in situ, after removing the gearbox.
1. Remove the starter motor.
2. Remove the gearbox and temporarily
secure the mounting plate with
suitable bolts.
1
041065
Fig.1 Restraining the Flywheel
1. LDV 118
3. Secure the flywheel from turning with
tool LDV 118.
4. If the clutch is to be refitted,
temporarily make correlation marks
FLYWHEEL END
on the clutch and flywheel to maintain
the balance on refitting.
5. Progressively remove the clutch
pressure plate securing bolts to
release the clutch, noting which way
round the friction plate is fitted.
62
Inspection
6. Inspect the flywheel friction face and
starter ring gear teeth for wear or
damage.
Renew as necessary; see ‘Flywheel’.
7. Examine the clutch release
mechanism for serviceability, and
rectify as necessary.
8. Check the crankshaft spigot bearing
for wear or damage.
If renewal is necessary, proceed as
follows:
Spigot Bearing Renewal
1
041078
Fig.2 Removing spigot bearing
1. Tool 21–036A
9. If the spigot bearing is to be renewed,
remove it using tool 21–036A.
Carefully fit the replacement bearing
fully home, using a suitably sized drift
against the bearing outer track.
Clutch Refit FLYWHEEL

10. Fit the clutch friction plate and Remove / Refit

pressure plate, aligning the
correlation marks if refitting the Tools required: 21–044A, 21–122 or
original clutch. 0480054 (18G 1205) / LDV 118.

Centralise the friction plate with tool Remove

LDV 119.
1. Remove the clutch as detailed in
Progressively tighten the securing
‘Clutch Remove / Refit’.
bolts, and finally torque tighten them
to 30 Nm (22 lbf ft).
11. Remove the flywheel restraining tool.
12. Remove the mounting plate
temporary securing bolts and fit the

0.01mm
gearbox.
13. Fit the starter motor. 120 mm

041061

Fig.1 Checking flywheel run–out

2. Unless the flywheel is being renewed,

its run–out should be checked before
removal if considered necessary.
Position the stylus of a dial gauge
120 mm (4.68 in.) from the centre of
the flywheel as illustrated.
The run–out should be a maximum of
FLYWHEEL END

0,13 mm (0.005 in.).

If excessive, the cause should be
established.

63
 1 Ring Gear Renew
041065
Fig.2 Restraining the flywheel
1. LDV 118
3. Restrain the flywheel;
– In situ: fit tool 21–122.
– On the bench: attach flange holder
0480054 (18G 1205) or LDV 118
to the flywheel as illustrated.
4. CAUTION: The flywheel securing
bolts can only be used a maximum
of 6 times. Discard any bolts with 5
punch marks.
(For explanation, see ‘General
Precautions, note 12’.)
Make a punch mark on the head of
each bolt.
WARNING: The flywheel is
heavy; support it during
removal.
Support the flywheel and remove the
flywheel securing bolts.
Remove the flywheel, noting the roll
pin.
5. Examine the camshaft rear cover
FLYWHEEL END
plate and the crankshaft rear oil seal
for signs of leakage. If renewal is
necessary, see ‘Camshaft Rear Oil
Seal’ or ‘Crankshaft Rear Oil Seal’ as
appropriate.
64
1
3
3
041077
Fig.3 Removing starter ring gear
1. Drilled hole
2. Chisel
3. Protective cloth
6. If the starter ring gear requires
renewal, drill a hole at the root of any
tooth and the inner diameter of the
ring gear, deep enough to weaken
the gear. Do not drill into the
flywheel.
WARNING: Wear goggles.
Cover the chisel and ring
gear area with a cloth to prevent
injury from metal fragments.
Secure the flywheel in a soft jawed
vice. Use a chisel to split the ring gear
at the point at which the hole has
been drilled.
7. Fit the replacement ring gear as follows:
– Heat it uniformly to 170°C (340°F).
– Making sure the chamfered side of
the teeth will point towards the
chamfered teeth on the starter motor
pinion when fitted, press the ring
gear up to the shoulder on the
flywheel.
– Hold the ring gear in place until it
has cooled sufficiently to contract
and grip the flywheel.
– Allow the ring gear to cool gradually;
do not quench in cold water.
Flywheel Refit CAMSHAFT REAR OIL SEAL

8. Thoroughly clean the mating faces of Renew

the crankshaft and flywheel. Check
that the dowel pin is correctly located Tools required: 21–122 or 0480054 (18G
in the crankshaft. 1205) / LDV 118, LDV 119.

9. Fit the flywheel. The camshaft rear oil seal can be

Fit the securing bolts and tighten
diagonally in two stages:
– Tighten to 21 Nm (15 lbf ft)
– Tighten a further 30°
renewed with the engine in situ, after
removing the gearbox.
1. Remove the flywheel as detailed in
‘Flywheel Remove / Refit’.

2 1
0.01mm

120 mm

040977

041061
Fig.1 Camshaft rear cover plate
1. Cover plate
Fig.4 Checking flywheel run–out
2. ‘O’ ring
10. Check the flywheel run–out as before, 2. Remove the camshaft rear cover
positioning the stylus of a dial gauge plate and discard the ‘O’ ring.
120 mm (4.68 in.) from the centre of
the flywheel as illustrated. 3. Clean all mating surfaces and inspect
The run–out should be a maximum of for signs of damage.
0,13 mm (0.005 in.).
4. Fit the cover plate using a new ’O’
If run–out is excessive, establish the
ring. Tighten the securing bolts to
FLYWHEEL END

cause.
23 Nm (17 lbf ft).
11. Fit the clutch and gearbox (see
5. Fit the flywheel (see ‘Flywheel
‘Clutch Remove / Refit’).
Remove / Refit’).
6. Fit the clutch and gearbox (see
‘Clutch Remove / Refit’).

65
 CRANKSHAFT REAR OIL SEAL – Secure tool 21–151 to the
crankshaft using two M10 x 38 mm
Renew long screws through the inner pair
Tools required: 21–122, 21–151, of holes.
21–102–01, 21–102–02, 21–102–03,
– Use the punch supplied to mark
LDV 119.
the seal at 4 points through the
Remove inner ring of holes in the tool
The crankshaft rear oil seal can be flange.
renewed with the engine in situ, after
– Remove the tool.
removing the gearbox.
– CAUTION: Do not allow the
1. Remove the flywheel as detailed in punch to damage the seal
‘Flywheel Remove / Refit’. carrier.
2. Remove the crankshaft rear oil seal Use the punch to make holes in
as follows: the seal at the points marked, just
large enough to ensure that the
1 2 self–tapping screws supplied with
the tool will grip the seal.
– Attach tool 21–151 (without the
two bolts) to the seal using 4
self–tapping screws supplied.
3 – Turn the centre screw of the tool to
extract the seal.
2
– Discard the seal.
3. Clean out any swarf or dirt from the
seal carrier, and examine for damage.

4
FLYWHEEL END

4
040972

Fig.1 Removing crankshaft rear seal

1. Tool 21–151
2. Punch
3. Securing bolts
4. Screws

66
Install
1 Fig.3 Rear oil seal carrier sealant
040992
Fig.2 Checking centralisation of rear
oil seal carrier
1. Tool 21–102–03
4. Before fitting a new seal, check the
centralisation of the seal carrier using
the alignment side of tool 21–102–03
(the side with the smaller internal
diameter).
If the tool is difficult to fit:
– Remove the seal carrier (4
securing bolts + 2 sump bolts) and
discard the gasket.
– Thoroughly clean the carrier,
cylinder block and sump gasket
mating faces.
041087
– Apply Hylomar PL32M sealant at
the points arrowed in the
illustration.
– Locate a new seal carrier gasket
on the cylinder block face, dry.
Ensure its lower ends contact the
sealant just applied.
– Position the seal carrier over the
end of the crankshaft, ensuring the
sump gasket is not displaced. Fit
the carrier securing bolts and sump
allen screws but do not tighten.
– Fit tool 21–102–03 to centralise
the carrier.
– Carefully align the carrier with the
sump mating faces of the cylinder
block. Progressively tighten the
carrier securing bolts, checking the
alignment.
– Tighten the carrier securing bolts
to 19 Nm (14 lbf ft).
FLYWHEEL END
– Tighten the two sump allen screws
to 14 Nm (10 lbf ft).
– Remove the centralising tool
21–102–03.
67
 1

5
4
3

041017

2
Fig.4 Tool 21–102–02 fitted to
crankshaft
5. NOTE: Do not apply lubricant to the
oil seal. 041018

Fit a new crankshaft rear seal as

Fig.5 Fitting crankshaft rear seal
follows:
1. Tool 21–102–02
– Ensure the crankshaft rear oil seal 2. Nut
journal is clean and dry. 3. Tool 21–102–01
– Fit tool 21–102–02 to the rear of 4. Tool 21–102–03
the crankshaft using the two 5. Seal
screws supplied (arrowed).
– Locate the new seal, together with
its protector sleeve into the seal
aperture, ensuring that when fitted,
the seal lip will face towards the
cylinder block.
– Fit tool 21–102–03 with its larger
internal diameter towards the seal.
– Fit tool 21–102–01 onto the
spindle of tool 21–102–02 and fit
the washer and nut supplied.
FLYWHEEL END

– Carefully tighten the nut to pull the

seal squarely into the carrier until it
bottoms.
– Remove the tools and the
protector sleeve.
6. Fit the flywheel (see ‘Flywheel
Remove / Refit’).
7. Fit the clutch (See ‘Clutch Remove /
Refit’) and the gearbox.

68
FLYWHEEL TIMING SOCKET SETTING
The flywheel timing is obtained via a
socket bolted to the cylinder block. If the
block is renewed, or the position of the
socket disturbed, the socket has to be
‘timed’ to the replacement block.
If the crankshaft or flywheel is changed,
the position of the socket should be
checked.
Checking Flywheel Timing Socket
Position
(With cylinder head removed)
Tool required: 23–020.
1. Turn the crankshaft to position
numbers 1 and 4 pistons at the top of
their bores.

041066

Fig.2 Positioning dial gauge

2. Place a dial gauge with the stylus

041069
resting centrally and vertically on the
Fig.1 Flywheel timing socket top of number 1 or 4 piston, at a
1. Flywheel point directly above the gudgeon pin.
2. Timing socket Pre–load the gauge by
The socket is accurately positioned during approximately 3 mm.
assembly, and secured by a conventional
bolt and a shear bolt.
The socket serves two purposes:
– Location for flywheel timing pin
23–020 to position the crankshaft at
FLYWHEEL END

the timing position of 11° BTDC.

– On Turbo engines to locate the
electronic engine speed sensor.
(The sensor is removed to allow the
timing pin to be inserted for static
timing.)
The position of the socket can be checked
either with the cylinder head removed or
fitted as follows.

69

040987
Fig.3 Dial gauge reading
(position ‘A’)
3. ‘Rock’ the crankshaft so that the
gauge registers the rise and fall of the
piston. Accurately find the highest
point reached by the piston as it
passes TDC, and zero the gauge at
that point (position ‘A’).
2mm
040986
Fig.4 Dial gauge reading
FLYWHEEL END
(position ‘B’)
4. Turn the crankshaft anti–clockwise
(seen from the front) until the gauge
reads approximately 2 mm (0.080 in.)
before TDC (position ‘B’).
70
1.04mm
041079
Fig.5 Dial gauge reading
(position ‘C’)
5. Slowly turn the crankshaft clockwise
until the gauge records the piston
position 1.04 " 0.04 mm (0.041 "
0.0015 in) before TDC (position ’C’).
The crankshaft is now positioned at
11° BTDC.
041080
Fig.3 Flywheel timing pin
1. Tool 23–020
6. N/A engine:
Remove the plug from the flywheel
timing hole.
Turbo engine:
Remove the engine speed sensor
(and shim if fitted).
Fit the timing pin 23–020, which should
be able to enter the hole in the flywheel.
If it will not enter, the timing socket is
incorrectly positioned and must be
moved.
7. To re–position the timing socket,
remove the flywheel to gain access to
the two socket securing bolts (see the
section ‘Flywheel’).
8. NOTE: One of the securing bolts is a
shear bolt.
Slacken the hexagon headed bolt and
fit a new shear bolt finger tight.
Checking Flywheel Timing Socket
Position
(With cylinder head fitted)
Tools required: 0480056, 18G 1577,
23–020.
1. Remove the rocker cover (see section
‘Rocker Cover Remove / Refit’).

9. Refit the flywheel (see the section 2. Turn the crankshaft until valves 7 and
‘Flywheel’). 8 are ‘on the rock’ (i.e. No.1 cylinder
is approximately at TDC on its firing
10. Check / re–adjust the position of the stroke).
crankshaft so that the dial gauge
reads 1.04 " 0.04 mm (0.041 " 3. Fully slacken No. 2 tappet adjuster,
0.0015 in.) before TDC as before. slide the rocker to one side and
remove the valve stem cap.
11. Fit the timing pin through the timing
socket and into the hole in the 1
flywheel
12. NOTE: While tightening the bolts,
continually check that the dial gauge
still reads 1,04 " 0,04 mm (0.041 "
0.0015 in.), and that the flywheel
timing pin will still enter the flywheel.
Lightly tighten the shear bolt.
Fully tighten the socket hexagon headed
securing bolt to 24 Nm (18 lbf ft)
Tighten the shear bolt until it shears.
Check the gauge reading and timing
pin entry again.
The flywheel timing pin socket is now
correctly positioned. 041011

13. N/A engine: Fig.1 Releasing valve spring collets

Fit the sealing plug
1. Tool 0480056
Turbo engine:
Fit the speed sensor (and shim if 4. Carefully hook valve spring compressor
fitted). 0480056 at a convenient point around
FLYWHEEL END

the rocker shaft where it will not cause

14. If removed, refit the clutch and
damage, and can be used to press
gearbox (see section ‘Clutch remove /
down on No.2 valve spring cap.
Refit’).

71
 5. Use the compressor to press down on
No.2 valve spring cap; the valve will be
restrained by No.1 piston at TDC below
it. Remove the valve spring retaining
collets.
6. Remove the valve spring cap and
spring.

041013

Fig.3 Establishing the crankshaft

timing position

8. Position the dial gauge on top of the

valve stem and pre–load it by
approximately 3 mm.
9. Carry out the timing procedure as
041012
detailed in operations 3 to 14 –
‘Checking Flywheel Timing Socket
Fig.2 Removing valve stem seal Position (with cylinder head
1. Tool 18G 1577 removed)’.

7. Remove and discard the valve stem 10. Fit a new valve stem oil seal.
seal using tool 18G 1577. 11. Refit the valve spring and spring cap.
Compress the valve spring using tool
0480056 and refit the collets.
12. Fit the valve stem cap, re–position the
rocker and adjust the valve clearance.
13. Refit the rocker cover (see section
‘Rocker Cover Remove / Refit’).
FLYWHEEL END

72
SUMP Refit

Remove / Refit 4
2
Tools required: None

Remove

CRANKCASE
NOTE: It is possible to remove the sump 4
in situ.

1. Remove the sump plug and drain the 1

oil into a suitable receptacle.
2. Turbo engine:
Disconnect the turbocharger oil drain 3
pipe.
3. Note which way round the sump is
fitted before removing the sump
securing bolts / allen screws. Note the
position of the 4 allen screws.
Remove the sump.
040984

Inspection
Fig.1 Sump
4. Clean the sump and its mating face 1. Sump
on the cylinder block. Examine the 2. Reinforcing strips
sump mating face for damage and 3. Gasket
dress if necessary. 4. Allen screws
5. Check that the engine front plate and 7. Apply Hylomar PL32M to the joints
crankshaft rear oil seal carrier are (arrowed):
fitted so that their lower faces align
– between the cylinder block and the
with the bottom face of the cylinder
engine front plate
block.
– between the cylinder block and the
If misaligned, see relevant
rear oil seal carrier.
instructions in ‘Crankcase Rebuild’.
8. Fit the one–piece rubber gasket,
6. Clean and examine the sump rubber
ensuring that the lipped edges at the
gasket and renew if damaged.
front and rear face towards the sump.
9. Check that the sump reinforcing strips
are correctly located to the sump,
then fit the sump and secure with the
bolts and allen screws, ensuring the
allen screws are positioned at the
front and rear.
Tighten all the fixings to 14 Nm
(10 lbf ft).

73
 10. Turbo engine:
Connect the turbocharger oil drain
pipe.

11. Fit the sump drain plug using a new

washer. Tighten the plug to 24 Nm
(18 lbf ft).
CRANKCASE

12. Fill with the correct grade of oil.

Start the engine and check for leaks.

74
 7

6
5

CRANKCASE
8
4 9
3

1 2
10
12

13

14

11
18

19

15

14

18
16

16 17

20

041071

Fig.1 Crankshaft, connecting rods and pistons

1. Rubber plug 11. Connecting rod assembly
2. Securing bolt 12. Crankshaft thrust washers (upper)
3. Crankshaft pulley / damper 13. Big end bearing shells
4. Timing belt inner guide 14. Main bearing shells
5. Oil seal 15. Crankshaft
6. Oil pump drive gear 16. Crankshaft thrust washers (lower)
7. Piston rings 17. Main bearing cap
8. Piston 18. Main bearing shells
9. Gudgeon pin 19. Woodruff key
10. Small end bearing bush 20. Main bearing cap

75
 CRANKCASE OVERHAUL
Tools required: 21–151, 21–123,
21–159, 23–019, 23–029, 23–020,
21–102–01, 21–102–02, 21–102–03,
LDV 129, LDV 119, 0480054 (18G 1205)
or LDV 118, 0480080 (LST 122).
CRANKCASE

CAUTION: Ensure that if a suitable

engine stand is not being used, the
machined surfaces of the cylinder
head and sump mating faces are not 1 041040
damaged. Place on wooden blocks.
Fig.2 Removing camshaft pulley
DISMANTLING 1. 0480054 (18G 1205)
The following operations assume that the 6. Using tool 0480054 (18G 1205) or
engine has been removed from the LDV 118 to restrain the camshaft
vehicle. pulley as illustrated, remove the
pulley securing bolt and extract the
1. Remove the cylinder head (see pulley.
section ‘Cylinder Head Remove’).
7. Remove the woodruff key from the
2. Remove and discard the timing belt camshaft.
(see section ‘Timing Belt Remove’).
3. Disconnect the fuel supply pipe from
the lift pump and remove the fuel
injection pump (see section ‘Fuel
Injection Pump Remove’).
4. Remove six bolts to release the water
pump, and discard the gasket.
5. CAUTION: The camshaft pulley
securing bolt can only be used a
maximum of 6 times. Discard it if
marked with 5 punch marks.
(For explanation, see ‘General 041059

Precautions, note 12’.)

Remove the camshaft timing pin and
make a punch mark on the head of
the camshaft pulley securing bolt.
Fig.3 Removing camshaft spacer
sleeve
8. Taking care not to damage the
surface of the spacer sleeve, engage
two suitable levers in the sleeve
groove as illustrated, and carefully
prise off the sleeve together with the
‘O’ ring.
Discard the ‘O’ ring.

76
9. To remove the alternator:
3
– Disconnect the vacuum pipe and 4
the oil supply pipe from the
vacuum pump.
– Disconnect the vacuum pump oil
drain pipe from the oil pump 5

CRANKCASE
housing.
– Support the alternator while
removing its adjuster bolt and pivot
bolt. 1 2

1
041039

Fig.5 Crankshaft pulley / damper

1. Rubber plug
2. Securing bolt
3. Crankshaft pulley / damper
4. Woodruff key
5. Timing belt inner guide

041065
Fig.4 Restraining the flywheel
1. LDV 118
10. Restrain the crankshaft from turning
by attaching tool 0480054 (18G 1205)
or LDV 118 to the flywheel using
suitable bolts.
11. Remove from the crankshaft:
– Crankshaft pulley / damper
securing bolt
– Crankshaft pulley / damper.
– Woodruff key.
– Timing belt inner guide.
12. Slacken the timing belt tensioner
securing bolts to allow the tensioner
to slide towards the camshaft.
If required, remove the tensioner and
recover the spring and its seat.
13. Remove the oil pump and pump drive
gear (see section ‘Lubrication – Oil
Pump Remove’).
14. Remove the oil filter and the oil cooler
(if fitted).
15. Remove the fuel lift pump shield and
the pump. Discard the ‘O’ ring seal.

77
 16. Remove the clutch and flywheel (see
section ‘Flywheel – Remove’).
17. Remove the sump (see ‘Sump –
Remove’).
18. Remove the pick–up pipe and
strainer.
CRANKCASE
Remove and discard the ‘O’ ring.
1 23. Remove 4 bolts to detach the
041046
Fig.6 Engine front plate
1. OIl gallery sealing ring
19. Remove the engine front plate.
Discard the gasket and the oil gallery
sealing ring.
20. Remove from the engine front plate:
– The coolant inlet pipe, discard the
gasket.
– N/A engine: the accelerator cable
bracket.
21. Press out and discard the camshaft
oil seal.
78
22. Remove:
– Oil pressure relief valve (see
section ‘Lubrication – Oil
Pressure Relief Valve’).
– Oil pressure switch.
– Vacuum pump oil supply pipe.
– Engine front plate support bracket.
– Turbo engine: Turbocharger oil
supply pipe adaptor.
crankshaft rear oil seal carrier.
Discard the gasket.
Use a suitable tube to press out and
discard the oil seal.
040982
Fig.7 Connecting rod / big end cap
marks
NOTE: During the following
dismantling operations,
temporarily mark any components
that are likely to be refitted to
identify their locations. These may
include:
Cam followers
Big end shells
Pistons
Connecting rods
Main bearing shells
Thrust washers
24. Note the identification markings on
the connecting rods and caps (No.1 is
at the front of the engine). If not
marked, temporarily identify them.
Before removal, use feeler gauges to
check the clearance / end float of
each connecting rod on its journal,
26. Before removing the main bearing
cap bolts, examine each bolt head for
a centre punch mark. If a mark
exists, this indicates that the bolts
have already been re–used once and
must therefore be discarded when
removed.

CRANKCASE
If no marks exist, mark each bolt
and compare with the dimensions once ready for re–fitting.
given in ‘Data’.
27. Working on one main bearing cap at a
Working on one assembly at a time, time, remove the securing bolts and
remove the big end cap securing nuts pull off the caps, noting the
and pull off the caps. crankshaft thrust washers located in
Retain each shell bearing with its cap. No.3 cap.
Fit protective sleeves to the big end Retain each lower shell bearing with
bolts. its cap.
28. Lift out the crankshaft.
29. Remove the 5 upper main bearing
shells and the upper halves of the
centre main thrust washers.
30. Carefully remove the piston and
connecting rod assemblies, and place
them with their caps.

2 1

041082

Fig.8 Main bearing cap marks

25. Note the identification markings

(position number, and arrow to
indicate front) cast on the main
bearing caps. 040977

Fig.9 Camshaft rear cover plate

1. Cover plate
2. ‘O’ ring
31. Remove the camshaft rear cover
plate and discard the sealing ‘O’ ring.

79
 INSPECTION & OVERHAUL
Thoroughly clean all components prior to
inspection / overhaul

Cylinder Block

1. Check core plugs and threaded plugs

CRANKCASE

for signs of leakage. Rectify as

necessary.
2. Degrease the block and remove all
traces of old sealant.
3. Inspect for cracks and other damage,
particularly on mating surfaces.
040976

Fig.10 Camshaft thrust plate

32. Temporarily mark and then remove

the camshaft front thrust / retaining
plate.
Withdraw the camshaft.
33. Remove the 8 cam followers from the
cylinder block, maintaining them in
041070
order.
Fig.1 Piston oil cooling jet hole

4. Flush out the oil and coolant

passages, paying particular attention
to the piston oil cooling jet holes.
5. Assess the cylinder bores for signs of
excessive scoring. Check for wear as
follows:

80
 Top
A see ‘Data’.
80 mm
B oversize cylinder head gasket
165 mm
041092
Fig.2 Cylinder bore measurement
points
– Working on one cylinder at a time,
measure the diameter of each
cylinder in line with, and at right
angles to the crankshaft axis at
three different points as illustrated;
the highest point (A) being
immediately below the lip caused
by the top piston ring.
– At each point, calculate the
average diameter.
– Subtract the average diameter at
point ‘C’ from the average at point
‘A’.
If the difference exceeds 0,15 mm
(0.006 in.), the cylinders can be
rebored and oversize pistons
fitted.
– If the cylinder bores are within
specification (see ‘Data’).
Establish the smallest diameter
and note for use when checking
the pistons for serviceability (see
‘Pistons and Connecting Rods’).
Two oversizes of piston are
available for rebored cylinders –
NOTE: If the engine has been
bored oversize from standard, an
must be fitted. It has larger
CRANKCASE
cylinder bore apertures.
041073
Fig.3 Cylinder bore grades
NOTE: During production the four
bore diameters are measured and
their grades (1, 2, 3 or 4) stamped
on the cylinder block.
Pistons are selectively fitted to suit
the bore sizes (see ‘Pistons and
Connecting Rods’).
Camshaft Bearings
6. Examine the cam follower bores for
wear or damage.
7. Examine the camshaft bearings. If
worn or damaged, replacement
bearings are available. A special tool
21–022 can be used to remove / refit
the bearings.
81
 Crankshaft 11. Main bearing and / or big end journal
clearances can be checked using
8. CAUTION: Take care not to damage Plastigage as follows:
the journals. NOTE: Assemble components dry.
Degrease the crankshaft and check
that the oilways are not restricted or – Fit the upper main bearing shells,
blocked. and fit the crankshaft.
CRANKCASE

– Place a piece of Plastigage across

Check that the oil passage plugs are the full width of the journal being
secure. measured.
9. Examine the spigot bearing for wear – Fit the lower shell bearing to its
and renew if necessary. Tool appropriate cap and tighten the
21–036A can be used to extract the securing nuts / bolts to the correct
old bearing (see section ‘Flywheel’ for torque. Do not rotate the
details). crankshaft or connecting rod.
10. Examine the main bearing journals, – Carefully remove the cap and
thrust washer bearing faces and bearing shell.
crankpins for signs of wear, scores, – Use the scale supplied to measure
grooves and signs of overheating. the flattened Plastigage at its
Assess for serviceability. widest point. The graduation that
most closely corresponds to the
width of the Plastigage indicates
.07
.0 6
A

.03 51
US

8
IN

.02
mm 5
DE

the bearing clearance. Compare it

MA
6

.07
.0 6
.07

.03 51
8
.02
mm 5

with the dimensions given in

TO

.07
5

.0 6
.03 51
.02

‘Data’.
.02
mm 5

.07
.0 6
.03 51
8

– Wipe off the Plastigage with an oily

-1

.02
P E

mm 5
G

.07
A

.0 6
G

.03 51

rag.
IG

8
.02
ST

mm 5
PEA

.07
.0 6
.03 51
L

Big end journal clearances can be

8
P

.02
Y

mm 5
T

.07
.0 6

measured in a similar way.

.03 51
8
.02
mm 5

Journal re–grinding is permissible

.07
E

.0 6
NG

.03 51
8
.02
RA

mm 5
.07
and two undersizes are available
CE

.0 6
.03 51
8
AN

.02

for both main and big end journals

mm 5
9m m
m
AR
22 m
2
TO 15

.07
E

.0 6
TO

.03 51
CL

.02
mm 5
8
(see ‘Data’ for undersizes).
Four oversizes of end–float thrust
040978 washer are also available.

Fig.4 Measuring flattened Plastigage

82
Camshaft and Cam Followers
12. Examine the camshaft for wear;
compare dimensions with those given
in ‘Data’.
13. Examine the steel balls located in the
ends of the camshaft. They seal the oil
drilling and must seat correctly to ensure
the correct oil supply to the camshaft
bearings and to the rocker shaft.
041067
Fig.5 Checking camshaft end–float
14. To check camshaft end–float:
Fit to the camshaft:–
– Thrust plate (fitted same way
round as removed from cylinder
block).
– Spacer sleeve.
– Pulley.
– Securing bolt.
Lightly nip the securing bolt.
Use two feeler gauges positioned as
illustrated to measure the gap
between the thrust plate and the
camshaft front bearing. it should be
0,10 to 0,25 mm (0.004 to 0.010 in.).
If excessive, renew parts as necessary.
15. Examine the cam followers for signs
of damage or excessive wear. Renew
as necessary.
Pistons and Connecting Rods
16. De–grease the piston and connecting
rod assemblies.
A B
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041004
Fig.6 Piston crowns
A Piston – Naturally aspirated engine
B Piston – Turbo engine
NOTE: Turbo and naturally aspirated
pistons are not the same.
17. Before dismantling, check for wear in
the gudgeon pin area. If the pistons
are to be re–fitted, make temporary
marks to indicate the cylinder number,
and note which way round the pistons
are fitted.
18. The pistons are fully floating on their
gudgeon pins and can be detached
after removal of one of the circlips to
allow the gudgeon pin to be removed.
Discard the circlips.
19. Examine the connecting rods for
damage, and check for bend or twist.
Examine the small end bushes and
renew if worn (see ‘Connecting
Rods’).
83
 20. Carefully examine the pistons and
their rings for wear, damage, scuffing
etc.
Check the lateral clearance of the
rings in the grooves and compare with
the information in ‘Data’. If excessive,
remove the rings and measure the
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breadth of the grooves. If any are
greater than permissible, renew the
piston(s).
Always fit new rings (see ‘Piston
Rings’).
21. When considering the correct course
of action to be taken, the following
must be borne in mind:
Fig.7 Piston grading diameter
CONNECTING RODS
During production, the connecting
rods are measured for length and
selectively fitted as a set of four.
Small end bushes are renewable;
press out the old bush using a
suitable mandrel. Press in the
replacement bush which must be
fitted with its oil hole in alignment with
the hole in the connecting rod.
After fitting, the small end bore must
be accurately machined to the correct
size; its bore must be parallel with
the big end bore to within 0,013 mm
per 25 mm (0.0005 in. per 1 in.), and
in the same plane to within 0,038 mm
per 25 mm (0.0015 in. per 1 in.).
PISTONS
During production, the pistons are
weighed and a balanced set of four
are fitted.
In addition, their diameters are
measured and graded into four
grades which are marked on the
piston crowns (1, 2, 3 or 4).They are
then selectively fitted to suit the bore
sizes (see ‘Cylinder Block’).
84
These four standard size grades are
available in Service, and the correct
size must be fitted if replacement is
necessary as follows:
81.5 mm
041093
– Establish the smallest cylinder
bore diameter for the piston being
checked (see ‘Cylinder Block’,
operation 5).
– Measure the diameter of the piston
at right angles to the gudgeon pin
and at a point 81.5 mm below the
piston crown.
– Subtract the piston diameter from
the smallest bore diameter to
calculate the clearance.
– The clearance should be 0,015 to
0,039 mm (0.0006 to 0.0015 in.)
If the clearance is greater, it may
be possible to fit a larger grade
piston.
A grade 1 piston is the smallest
size; (see ‘Data’ for details).
– If the clearance is excessive, the
cylinders can be rebored and
oversize pistons fitted. 0,65 mm
and 1,00 mm (0.0256 and 0.0394
in.) oversize pistons are available.
PISTON RINGS
– Ensure that the piston ring grooves
are clean.

CRANKCASE
041094

Fig.9 Piston rings

Fit the piston rings using a suitable

041062
ring expander;
– The bottom (oil control) scraper
Fig.8 Checking piston ring gap
and spring rings can be fitted
Before fitting new rings, check the either way round.
ring gaps as follows: – The middle (compression) ring has
a stepped section.
– Fit each ring in turn into the bore in – The top (compression) ring is
the cylinder to which it will be tapered in section (8° half
fitted. keystone).
– Push it squarely into the bore – The middle and top rings are
using the crown of an inverted marked TOP, and must be fitted
piston until it is approximately with the word TOP to the top.
15 mm (0.5 in.) down (i.e. below
the ‘lip’ made by the top ring).
– Measure the ring gap with feeler
gauges and compare with the
figures given in ‘Data’.
– If the gap is too large, check for
bore wear (see ‘Cylinder Block’ –
operation 5).

85
 Revised Connecting Rod Bolts / Nuts The revised 10 mm bolts are designed to
be ‘torqued to yield’ and can only be
New connecting rod big end bolts and
re–used once. When dismantling an
nuts have been fitted from mid 1999.
engine containing these bolts, examine
Incorporation took place at 99A–04 as
each bolt tip for a centre punch mark. If
shown on the label on the timing cover.
present, this indicates that the bolts have
Service requirements are different to the already been re–used and must therefore
CRANKCASE

original bolts / nuts and therefore be renewed.

identification is important (see diagram
below).

1 A

A046-003

2 B

A046-004

Fig.10 Connecting rod bolts

A. Early type bolt
B. Revised bolt
1. View on head of early type bolt
2. View on head of revised bolt
The bolts can be identified by the shape
of the head and the splines on the shank.
NOTE: The nuts are also changed:
Early nuts – 7/16–20 UNF thread
Revised nuts – 10 mm
The revised bolts / nuts are
interchangeable, but only as a set of 2.

86
REBUILD
Lightly lubricate components before fitting.
Ensure complete cleanliness at all times.

CRANKCASE
1

3
4

040976

Fig.2 Camshaft thrust plate

040974
3. Fit the camshaft.
Fig.1 Oil pressure relief valve Noting the temporary mark made
1. Valve body during dismantling, fit the camshaft
2. ‘O’ ring front thrust / retaining plate.
3. Valve plunger
4. Spring Tighten the securing torx bolts to
23 Nm (17 lbf ft).
1. Assemble the oil pressure relief valve
as illustrated. Fit the ‘O’ ring in the Using a new ‘O’ ring, fit the camshaft
cylinder block, and fit the valve rear cover plate and tighten the
assembly and tighten to 56 Nm securing torx bolts to 23 Nm
(41 lbf ft). (17 lbf ft).

2. Fit the cam followers in the cylinder

block in their original positions.

87
 A
CRANKCASE

B 040979

Fig.4 Applying sealant to rear main

040975 bearing cap
Fig.3 Main bearing shells 6. CAUTION: Do not allow sealant to
A. Bearings in cylinder block spread onto the crankshaft bearing
B. Bearings in main bearing caps journal.
Before fitting the rear main bearing
4. Locate the upper halves of the main
cap, apply Hylomar PL32M sealant to
bearing shells in the cylinder block
its mating faces on the cylinder block.
and the lower halves in their bearing
caps in the correct positions. Check
that the oil drilling in each upper shell
aligns with the hole in the cylinder
block.
NOTE: The bearings are not all
identical, and their locating lugs are
positioned differently to ensure
correct positioning.
5. Lubricate the journals and fit the
crankshaft.

041082

Fig.5 Main bearing cap marks

7 Fit Nos. 1, 2, 4 and 5 main bearing

caps, noting the direction arrows and
numbers on them. Lubricate the
threads and contact faces of the bolts
before fitting them.
Secure the bolts, finger tighten only.

88
 CRANKCASE
50
60
40
4 5 6
7
2
3 70
8 1
0 9
30

040980 20
80

90
10
0

Fig.6 Crankshaft thrust washers

040981

8. Fit the upper halves of the crankshaft

thrust washers in the block, ensuring Fig.7 Measuring crankshaft end–float
the grooved thrust faces are towards
the crankshaft. 10. Measure the crankshaft end float; it
NOTE: If two different size thickness should be 0,075 to 0,328 mm (0.003
thrust washers are fitted, ensure the to 0.013 in.).
thicker washer is fitted in the rear If excessive, fit new thrust washers to
location. reduce the float by the same amount
in each direction.
Locate the lower halves of the thrust Oversize thrust washers are available:
washers on the centre main bearing 0,06 mm, 0,12 mm, 0,18 mm, 0,25 mm
cap (grooved thrust faces outwards) (0.0024, 0.0047, 0.007, 0.0098 in.).
and fit the cap, securing it finger tight
with new bolts.
Tighten the main bearing cap bolts in
two stages as follows:
– Tighten all bolts to 84 Nm (62 lbf ft).
– Re–tighten all bolts to 170 Nm
(127 lbf ft).
9. Temporarily fit the crankshaft pulley
bolt and use it to check the
crankshaft turning torque. It should
be no more than 2,9 Nm (2.14 lbf ft).

89
 A 13. To fit each piston and connecting rod
CRANKCASE
FRONT
B and lower ‘rails’ must be at 90°
FRONT 040983
Fig.8 Piston and connecting rod
assembly
A. Turbo piston crown
B. N/A piston crown
11. Assemble each piston to its
connecting rod so that the arrow mark
on the piston aligns with the side of
the connecting rod marked ‘FRONT’.
If the arrow mark on the piston is
obscured, the piston must be fitted so
that the offset of the combustion
chamber is away from the camshaft
side.
Use new circlips to secure the
gudgeon pins.
12. If not already checked, measure the
piston ring gaps and fit the rings as
described in ‘Pistons and Connecting
Rods’.
90
assembly:
– Fit protective sleeves to the big
end bolts.
– Fit the big end shells.
– Position the oil control ring
expander spring gap at the front of
the piston. The gaps in the upper
and 270° respectively to the gap in
the expander spring.
– Position the two compression rings
so that their gaps are located on
opposite sides of the piston and in
line with the gudgeon pin.
– Using a suitable compressor to
compress the piston rings, fit the
assembly into its original bore,
ensuring the ‘Front’ marks are to
the front of the engine.
14. Fit the big end bearing caps the
correct way round (as numbered).
NOTE: See section ‘Pistons and
Connecting Rods – Revised
Connecting Rod Bolts/Nuts’ for details
of bolt/nut changes.
Secure with new self–locking nuts,
and torque tighten them using the
appropriate 2 or 3 stage procedure
(see Torque Wrench Settings).
15. Measure the piston protrusion of each
piston as follows:
– Clean all traces of carbon from a
small area as near the centre of
each piston as possible.

040988
Fig.9 Zeroing gauge
– Position a dial gauge so that its
stylus rests vertically on a flat part
of the cylinder block adjacent to
the piston to be checked.
– Pre–load and zero the gauge.
– Turn the crankshaft to position the
piston at the top of its bore.
16. If a new crankshaft or connecting rods
17. If a new cylinder block is being
040989
Fig.10 Measuring piston protrusion
– Carefully move the gauge without
disturbing its setting until the stylus
rests on the previously cleaned
area of the piston.
– ‘Rock’ the crankshaft so that the
gauge registers the rise and fall of
the piston. Note the gauge reading
CRANKCASE
at the highest point reached by the
piston.
– This reading is the piston
protrusion and the figure should be
compared with the specified
protrusion:
N/A 0,301 – 0,503 mm
(0.012 – 0.02 in.)
T/C 0,201 – 0,403 mm
(0.008 – 0.016 in.)
– Repeat the procedure for the other
three pistons.
– If incorrect, the piston and
connecting rod assembly should
be removed and a suitable length
rod selected from the four lengths
available.
have been fitted, use feeler gauges to
check the end–float between each
connecting rod big end bearing and
the crankshaft.
The end–float should be 0,140 to
0,420 mm (0.0055 to 0.0165 in.).
Make sure that the connecting rods
have clearance on both sides of the
bearing.
installed, fit the timing socket on the
rear face using a new shear bolt, and
tighten finger tight.
91
 22. If a new cylinder block is being
installed, or if the crankshaft or
flywheel is being renewed, the
position of the flywheel timing socket
should be checked /adjusted at this
stage (see section ‘Flywheel Timing
Socket Setting’).
CRANKCASE

1
1

041130

Fig.11 Centralising crankshaft rear oil

seal carrier
1. Tool 21–102–03
18. Fit the crankshaft rear oil seal carrier
(without the seal) using a new gasket.
Fit tool 21–102–03 to centralise the 041046
carrier, and using a straight edge as
illustrated, align the carrier with the Fig.12 Engine front plate
sump mounting face and tighten the 1. Oil gallery sealing ring
securing bolts to 19 Nm (14 lbf ft).
Remove the tool 21–102–03. 23. Fit a new oil gallery sealing ring.
IMPORTANT: It is essential that the
oil seal carrier is centralised
correctly to avoid creating an oil
leak past the seal.
19. Fit the crankshaft rear oil seal as
described in the section ‘Flywheel –
Crankshaft Rear Oil Seal Install’.
20. Temporarily fit the crankshaft pulley
bolt and use it to check the crankshaft
turning torque. It should be no more
than 50 Nm (37 lbf ft).
21. Fit the flywheel (see section ‘Flywheel
Remove / Refit’).
If not already fitted, fit the crankshaft
spigot bearing (see section – Clutch
and Spigot Bearing Remove / Refit).

92
 – Check that the plate remains
central around the camshaft, and
the lower edge of the plate aligns
with the sump mounting face of
4 5 the block. If not, slacken the
8 securing bolts and repeat the
2
A centralising / tightening procedure.

CRANKCASE
Remove tool 21–159.
IMPORTANT: It is essential that
7
the engine plate is centralised
correctly to avoid creating an oil
6 leak past the camshaft oil seal.

1
3
9 041053

Fig.13 Fitting engine front plate

A. Tool 21–159
24. To fit the engine front plate:
041000

– Fit the coolant inlet pipe to the rear

of the plate using a new gasket.
– Fit a new gasket and loosely
secure the front plate.
– Fit tool 21–159 over the camshaft
nose to centralise the front plate
around the camshaft.
– Use a straight edge to align the
lower edge of the front plate with
the sump face of the cylinder
block.
– Tighten bolts 1 to 8 in the
sequence illustrated to 36 Nm
(27 lbf ft).
Tighten bolt 9 to 23 Nm (17 lbf ft).
Fig.14 Front plate bracket
25. Fit the engine front plate bracket.
Tighten the securing bolts / nut
progressively to ensure the plate is
not distorted.
Tighten the bolt / nut securing the
bracket to the plate to 23 Nm
(17 lbf ft).
Tighten the bolts securing the bracket
to the block to 46 Nm (34 lbf ft).
26. N/A engine:
Fit the accelerator cable bracket to
the engine front plate.

93

CRANKCASE
040996
Fig.15 Fitting camshaft front seal
1. Tool 21–159
27. NOTE: Do not apply lubricant to the
oil seal.
To fit a new camshaft front seal:
– Remove the protector supplied
with the seal.
– Position the seal, lip towards the
camshaft, and carefully tap it into
the front plate using tool 21–159.
Finally position the seal by drawing
it into place using tool 21–159 and
the camshaft pulley bolt until the
tool bottoms.
– Remove the tool.
28. Fit the camshaft spacer sleeve, first
ensuring the sleeve is clean and dry.
Fit a new ‘O’ ring, pressing it into
place with tool 21–159.
29. Fit the woodruff key.
94
1
041081
Fig.16 Tightening camshaft pulley
1. 0480054 (18G 1205)
30. Fit the camshaft pulley and restrain it
with tool 0480054 (18G 1205) or
LDV 118 as illustrated.
Apply a light smear of oil to the
underside of the securing bolt flange.
Fit the bolt and torque tighten to
120 Nm (88 lbf ft).
31. Fit the oil pick–up pipe and strainer
using a new ‘O’ ring. Tighten the
securing bolts to 18 Nm (13 lbf ft).
32. Fit the sump gasket and sump (see
section ‘Sump Remove / Refit’).
If removed, fit the sump drain plug
using a new washer. Tighten the plug
to 24 Nm (18 lbf ft).
33. Fit the fuel lift pump using a new ‘O’
ring; tighten the securing nuts to
23 Nm (17 lbf ft).
Fit the pump heat shield, tightening
the securing nuts to 23 Nm (17 lbf ft).
34. Fit two new ‘O’ rings in the engine
front plate.
Fit the oil pump and pump drive gear.
(See section ‘Lubrication – Oil Pump
Remove / Refit’).
 6
3 8 3
4
9 4

CRANKCASE
2 5 7
1 2

041039

Fig.18 Crankshaft pulley / damper

1. Rubber plug
2. Securing bolt
3. Crankshaft pulley / damper
4. Woodruff key
A 041058
5. Timing belt inner guide

Fig.17 Fitting oil pump cover 36. Fit to the crankshaft:

A. Tool LDV 129
35. Fit a new crankshaft front seal in the
oil pump cover and fit the cover using
tool LDV 129 for centralisation (see
section ‘Crankshaft Front Seal –
Install’).
37. Restrain the flywheel from turning
– Timing belt inner guide, concave
face towards the seal.
– Woodruff key.
– Crankshaft pulley / damper.
– Pulley securing bolt, first
lubricating the threads and the
larger diameter head of the bolt
with clean engine oil.
using tool 0480054 (18G 1205) or
LDV 118, and tighten the pulley
securing bolt to 163 Nm (120 lbf ft.)
CAUTION: Do not attempt to use
the flywheel timing tool and/or its
locating hole to restrain the
flywheel from turning.
Remove the flywheel restraining tool.

95
 2
1
CRANKCASE

040991

Fig.19 Timing belt tensioner

1. Tensioner spring
2. Spring seat 3

38. Lightly lubricate the back face of the

tensioner mounting bracket and the
spring with a high melting point
lubricant.
Fit the tensioner assenbly, checking 1
that it can slide freely on the engine 2
front plate. Tighten the 2 securing
A046-001
bolts finger tight.
Fig.20 Retracting tensioner
1. M8 bolt
2. M10 bolt
3. Water pump pulley

Press the tensioner back against the

spring by using a suitable lever as
illustrated, and temporarily tighten the
M8 bolt.
39. Fit the water pump using a new
gasket. Tighten the securing bolts as
follows:
M8 bolts 23 Nm (17 lbf ft)
M10 bolts 46 Nm (34 lbf ft)

40. Fit the fuel injection pump to the

engine front plate and tighten the
three securing bolts to 23 Nm
(18 lbf ft).

96
 1

CRANKCASE
3

041038
040990

Fig.21 Fuel injection pump rear Fig.22 Fuel injection pump pulley
support bracket 1. Pulley
2. Plate
41. CAUTION: Tighten the bolts evenly, 3. Fuel injection pump securing bolts
ensuring that while doing so the
bracket does not force the pump 42. Fit the fuel injection pump pulley and
out of alignment or cause the loosely fit the retaining plate and
engine plate to distort. bolts, ensuring the word FRONT on
Fit the injection pump rear support the plate is to the front.
bracket. Tighten the bolts to 24 Nm
(18 lbf ft).

041055

Fig.23 Fuel injection pump timing pin

43. Fit the fuel injection pump timing pin

(23–029 for N/A engines, 23–019 for
Turbo engines) through the hole in
the pulley and into the pump flange.

97
 47. Fit the alternator mounting bracket.
Loosely secure the alternator /
vacuum pump assembly, and connect
the vacuum pump drain pipe.
Applying Hylomar PL32M to the
threads, fit the vacuum pump oil
supply pipe to the cylinder block.
CRANKCASE

Connect the pipe to the vacuum pump

and tighten using two spanners.
48. Fit the water pump pulley, and the
idler pulley (N/A engine) or viscous
fan pulley (Turbo engine).

2
041085
1

Fig.24 Camshaft timing pin

44. Turn the camshaft until the timing
holes align and fit the camshaft timing
pin 21–123.
5

1
4
3 041104

Fig.26 Turbo oil cooler and filter

1. Oil filter
2. Adaptor
041080 3. Oil cooler
4. Locating spigot
Fig.25 Flywheel timing pin 5. Oil seal
45. Turn the crankshaft until flywheel 49. Turbo engine:
timing pin 23–020 can be fitted.
– Using a new oil seal, fit the oil
46. Fit a new timing belt and time the cooler ensuring its locating spigot
engine as described in the section is correctly positioned.
‘Timing Belt Fit’. Tighten the adaptor to 70 Nm
Fit the timing belt cover. (53 lbf ft).
– Fit the turbocharger oil supply pipe
adaptor to the cylinder block.

98
50. Fit the oil filter (see ‘Oil Filter Renew’).
51. If removed, fit the oil pressure switch.
52. Fit the cylinder head, rocker shaft,
injectors, injector pipes, manifolds etc.
(See section ‘Cylinder Head Refit’.)

CRANKCASE
53. Fit and tension the alternator and
power steering pump drive belts (see
section ‘External drive belts’).

99
 LUBRICATION SYSTEM

11

10

9
5

8
LUBRICATION
SYSTEM

7 3
12

040973

Fig.1 Lubrication system

1. Oil pump 7. Crankshaft
2. Strainer 8. Piston lubrication
3. Filter 9. Camshaft centre bearing
4. Pressure relief valve 10. Rocker shaft centre pedestal
5. Main oil gallery 11. Turbocharger
6. Vacuum pump 12. Oil cooler

100
OIL CIRCULATION Oil cooling
On Turbo engines an oil cooler (12) is
The rotary type oil pump (1) is located at fitted between the oil filter canister and the
the front of the engine and is driven off the cylinder block. Coolant is circulated
nose of the crankshaft by a gear. It draws through the oil cooler to cool the oil as it
oil from the sump via a fine mesh oil
passes through the filter.
strainer (2).
The oil is pumped to the full flow oil filter
(3) via a pressure relief valve (4) located
in the cylinder block. This valve bleeds off
surplus oil and returns it to the inlet side of
the pump.
After passing through the filter, the
pressurised oil is directed to the main oil
gallery (5) which runs the length of the
cylinder block. A tapping in the oil gallery

LUBRICATION
allows oil to be piped to the vacuum pump

SYSTEM
(6) for lubrication.
Individual drillings in the cylinder block
direct oil from the main oil gallery to each
of the five crankshaft main bearings (7),
and internal drillings in the crankshaft
provide lubrication to the big end journals.
Additional drillings (8) in the cylinder block
supply jets which spray oil to the
underside of the pistons for lubrication
and cooling purposes.
An oilway from the centre main bearing
takes oil to the camshaft centre bearing
(9), where it enters a drilling which runs
the length of the camshaft to lubricate the
other four bearings.
Another oilway from the centre main
bearing bypasses the camshaft centre
bearing and takes oil up to the rocker
shaft centre pedestal (10). This oil is
forced through the hollow rocker shaft to
lubricate the rockers.
On the Turbo engine, an external pipe
takes oil from the supply to the rocker
shaft, and delivers it to the turbocharger
bearings (11), and a second pipe returns
the oil to the crankcase.

101
 WARNING: Prolonged and OIL PRESSURE RELIEF VALVE
repeated contact with used
Remove / refit
engine oils can be injurious to health

OIL FILTER
Renew 1

1. Position a drain pan directly

underneath the oil filter, and unscrew 2
the canister using a suitable strap 3
wrench. 4
2. Thoroughly clean the oil filter mating
face.
3. Partly pre–fill the new filter with clean
engine oil of the correct type and
LUBRICATION

grade. Apply a thin film of clean

SYSTEM

engine oil to the oil filter sealing ring. 040974

4. Screw on the new oil filter until Fig.1 Oil pressure relief valve
sealing ring abuts the mating face and 1. Valve body
tighten a further 3/4 turn. Do NOT use 2. ‘O’ ring
a strap wrench or similar tool to 3. Plunger
tighten the filter. 4. Spring

5. Run the engine and check for leaks.
6. Stop the engine, allow the oil to settle
and top up as necessary.
1. Unscrew and remove the oil pressure
relief valve components, and extract
the ‘O’ ring seal.
2. Carefully inspect all parts for damage
or excessive wear. Renew as
necessary.
3. Lubricate the spring and valve
plunger with new clean engine oil.
Insert the spring in the cylinder block,
and the plunger in the valve casing.
Ensure the plunger is fitted the correct
way round.
4. Fit a new ‘O’ ring seal in the recess in
the cylinder block. Screw the valve body
into the cylinder block and tighten it to
56 Nm (41 lbf ft).

102
OIL PUMP

Remove, Inspect, Refit

Tools required: MS 1517 (Turbo),
23–020, 21–123, 23–029 (N/A) 23–019 2
(Turbo), 21–122, 21 (engine in situ) or
0480054 (18G 1205) / LDV 118, LDV 129.
The oil pump can be removed and
replaced with the engine ‘in–situ’. 1
041002

Remove
Fig.2 Oil pump
1. Remove and discard the timing belt 1. Oil pump
as described in the section ‘Timing 2. ‘O’ rings
Belt – Remove’.
5. Turn the oil pump gear to allow

LUBRICATION
2. Remove the oil pump cover as access to the pump retaining bolts.

SYSTEM
described in the section ‘Crankshaft Unscrew the bolts, lift out the oil pump
Front Oil Seal – Remove’. and discard the ‘O’ rings.
Discard the gasket.

041045

Fig.1 Measuring oil pump gear backlash

3. Before removing the oil pump, use

feeler gauges to measure the
backlash between the gear and the oil
pump teeth at four different points.
Backlash – 0,050 to 0,330 mm
(0.002 to 0.013 in.)
If the backlash is excessive, renew
the drive gear. If it is still excessive,
renew the oil pump.
4. Remove the oil pump drive gear.

103
 Dismantling & Inspection
6. Thoroughly clean all components.

2
041043

3
Fig.4 Checking clearance between
rotors
LUBRICATION

– Position the rotors as illustrated

SYSTEM

and measure the clearance

between the inner and outer
rotors.
041041
Maximum clearance 0,15 mm
Fig.3 Oil pump (0.006 in.)
1. Pump housing
2. Outer rotor
3. Inner rotor

7. Remove the retaining screw and

detach the pump cover plate.
8. Examine the pump component parts
for wear / damage, and carry out the
clearance checks as follows:

041042

Fig.5 Checking clearance between

outer rotor and pump casing
– Measure the clearance between
the outer rotor and the casing. it
should be 0,13 to 0,30 mm (0.005
to 0.012 in.).

104
 Refit

041044

Fig.6 Checking outer rotor end–float

1
– Place a straight–edge across the 041002

face of the pump casing as

Fig.7 Oil pump
illustrated, and measure the
1. Oil pump
clearance between the outer rotor
2. ‘O’ rings
and the straight–edge. It should be

LUBRICATION
0,01 to 0,09 mm (0.0004 to 12. To fit the oil pump:

SYSTEM
0.0035 in.). – Fit 2 new ‘O’ rings in the engine
– If any of the above clearances are front plate.
outside tolerance, the oil pump – Fill the pump with clean engine oil.
should be renewed.
– Fit the oil pump, aligning the ports
9. If the outer rotor has been removed, and fixing holes.
refit it chamfered side first. NOTE: Insert the oil pump by hand
until it is full home against the
10. Coat the mating face of the cover cylinder block. Do not tilt the pump
plate with Hylomar PL32M, locate it and then attempt to pull it into place
on the pump casing and secure with with the securing bolts; damage will
the retaining screw, ensuring the result.
screw lines up with the slot in the Fit and tighten the 5 securing torx
retaining plate. screws to 19 Nm (14 lbf ft).
13. Apply Hylomar PL32M sealant on the
11. Check that the pump can turn freely.
pump drive gear face that will contact
the crankshaft flange, then fit the gear.
14. Fit a new crankshaft oil seal in the oil
pump cover and fit the crankshaft
pulley etc., as described in the section
‘Crankshaft Front Oil Seal – Install’.
IMPORTANT: It is essential that the
cover is centralised correctly as
described to avoid creating an oil
leak past the seal.
15. Turn the crankshaft clockwise until the
flywheel timing pin 23–020 can be fitted.
16. Fit a new timing belt and rebuild the
engine as described in the section
‘Timing Belt – Fit’.

105
 FUEL SYSTEM

4 1
3

041098

Fig.1 Fuel system

1. Fuel tank 4. Fuel injection pump
2. Fuel lift pump 5. Injector
3. Filter
DESCRIPTION The Bosch fuel injection pump fitted to
FUEL SYSTEM

naturally aspirated engines is a

The basic fuel injection system consists of
conventional rotary type pump, controlled
the fuel tank (1), a fuel lift pump (2), a
by throttle position and engine speed.
filter (3), an injection pump (4) and
injectors (5). Fuel used for lubrication and The CAV fuel injection pump fitted to the
cooling of the injectors and the fuel turbocharged engine is controlled
injection pump is returned to the fuel tank. electronically by an engine management
system (EPIC). An electronic control unit
The mechanical fuel lift pump is mounted
(ECU) receives signals from sensors
on the cylinder block and is operated by a
which record throttle position, engine
lobe on the camshaft. It pumps fuel
speed, fuel temperature etc. The ECU
through the fuel filter to the fuel injection
programmes the fuel injection pump to
pump.
provide automatically the correct fuelling
Two types of fuel injection pump are fitted, under all driving conditions.
a Bosch rotary type pump is fitted to the
The fuel injection pump supplies a
naturally aspirated engine, and a CAV
metered amount of fuel to the four
rotary pump is fitted to the turbocharged
Stanadyne ‘slim tip’ fuel injectors, which
engine. The pump is driven at half engine
inject fuel directly into the combustion
speed by the timing belt.
chambers. The injectors fitted to the N/A
engine are the 2–stage type.

106
ADJUSTMENTS Throttle Cable
Idle Speed (Naturally aspirated engine)
(Naturally aspirated engine)

041110

Fig.1 Adjusting throttle cable

1
041109
1. Check that a small amount of free
Fig.1 Adjusting idle speed play exists at the throttle cable.
1. Idle speed screw 2. Get an assistant to depress the
1. Prepare suitable equipment to enable throttle pedal fully. Check for full
engine speed to be measured movement of the throttle lever against
accurately e.g. Dieseltune DX 801 the maximum speed stop. Rectify as
(1210514). necessary.

2. Start the engine and warm to normal 3. Check the throttle butterfly link rod
running temperature. setting and adjust if necessary (see
section ‘Exhaust Gas Recirculation
3. Check that a small amount of free System’).

FUEL SYSTEM
play exists at the throttle cable. Adjust
if necessary.
4. Check the idle speed; it should be
825 RPM ± 25 RPM. If incorrect,
adjust as follows:
– Loosen the locknut and adjust the
idle speed screw to set the correct
idle speed.
– Tighten the locknut and re–check the
speed.
5. Stop the engine.
6. Check the throttle cable adjustment
(see ‘Throttle Cable’).
7. Check the throttle butterfly link rod
setting and adjust if necessary (see
section ‘Exhaust Gas Recirculation
System’).

107
 FUEL FILTER ELEMENT Install

Renew 6. Locate the sealing washer, and

screw the water trap sensor into the
base of the new element canister.
7. Clean the inside of the filter housing
with a non–fluffy rag.
Smear the canister sealing ring with
clean fuel.

3
1
4

041047

Fig.1 Fuel filter

1. Sealing washers
2. Element canister
FUEL SYSTEM

3. Securing ring
4. Water trap sensor

Remove
1. Press in the wire clip and disconnect
the electrical connector from the
water trap sensor.
2. Place a suitable drain container under
the filter canister.
3. Unscrew the canister securing ring
and remove the canister. 041234

4. Unscrew the water trap sensor from Fig.2 Securing ring alignment marks
the base of the canister and capture
the sealing washer. 8. Position the canister into the filter
housing, turning it until the locating
5. Discard the canister. lugs (arrowed) engage.
Fit the securing ring and tighten it by
hand until the marks (circled) align.

108
9. Connect the water trap sensor wiring
plug.
10. Turn the ignition switch to position ‘II’.
Check that the water trap warning
light illuminates.
11. Start the engine. Check that the
water trap warning light goes out after
approximately 2 seconds.
NOTE: (Turbo only) If the fuel
management system warning light
remains on after starting, the system
will have sensed the presence of air.
The fault has to be erased from the
E.C.U. memory (see Workbook ‘EPIC
DI Engine Management System’).
12. Check for fuel leaks.

FUEL SYSTEM

109
 FUEL LIFT PUMP 6. Fit the lift pump, using a new ‘O’ ring,
and tighten the the two nuts
Remove progessively to 23 Nm (17 lbf ft).
The fuel lift pump can be removed with 7. Connect the fuel pipes by carefully
the engine in situ. pushing them fully home.
NOTE: It may be necessary to first
8. Fit the heat shield, tightening the
remove the brake pipe heat shield.
securing nuts to 23 Nm (17 lbf ft).
9. NOTE: The system should not require
bleeding; it will self–bleed during
cranking.
3 Start the engine and check for leaks.
NOTE: (Turbo only) If the fuel
2
management system warning light
remains on after starting, the system
will have sensed the presence of air.
The fault has to be erased from the
E.C.U. memory (see Workbook ‘EPIC
1 DI Engine Management System’).

041057

Fig.1 Fuel lift pump

1. Heat shield
FUEL SYSTEM

2. Lift pump
3. ‘O’ ring

1. Place a suitable drip tray under the lift

pump.
2. Remove two retaining bolts to detach
the pump heat shield.
3. To disconnect each fuel pipe,
squeeze together the two lugs on the
fixing and pull the pipe off.
4. Progressively remove the two
securing nuts to release the pump.
Remove and discard the sealing ‘O’
ring.

Refit

5. Clean the mating surfaces of the lift

pump and the cylinder block.

110
INJECTORS
Remove / Refit
Remove

NOTE: All injectors are removed from the

cylinder head in the same way, but the
components to be removed to gain
access to the injectors is different on
naturally aspirated and turbo engines.

1. On naturally aspirated engines:

– Disconnect the EGR control rod.
On turbo engines:
– Disconnect the air intake duct from
the throttle housing. 041023

– Disconnect vacuum pipes as

necessary.
– Detach the EGR pipe at the EGR
valve.
– Remove the 3 bolts securing the
throttle housing to the inlet
manifold, move the housing to
one side and suitably support it.
2. CAUTION: Take care not to break
the plastic connectors on the
Fig.1 Disconnecting fuel pipe from
injector
3. CAUTION: It is important to use
two spanners to detach high
pressure fuel pipes: one to hold
the connector while slackening the
gland nut with the other.
Remove all the injector pipes.
Plug all connections and pipe ends to

FUEL SYSTEM
prevent the ingress of dirt.
injectors.
Pull off the spill return pipes from the
injectors.

111
 1
4
2
3

2
1

041029

Fig.3. Injector
1. Compression seal
2. Water / dust seal

5. If the injector is to be refitted, remove

041027
and discard the injector compression
seal and water / dust seal.
Fig.2 Injector
1. Injector Testing
2. Clamp
3. Securing plate The spray pattern and leak back of an
4. Bolt injector can be checked using an
approved injector tester; for example
4. To remove the injectors: 0484976 (DX 710) or Dieseltune 111.
– Clean the area around the
FUEL SYSTEM

Injector overhaul is not possible.

injectors.
– Before removing each injector,
note the relative positions of the
securing plate, and the position of
the injector feed pipe relative to
the recess in the cylinder head.
– Working on one injector at a time,
remove the injector securing bolt
and clamp.
– Pull the injector out of the cylinder
head.
– Fit a protective cap on the nozzle
tip and plug the injector location in
the cylinder head.

112
Refit
2

3 1

3 1
041091

041131 Fig.5 Fitting injector

1. Securing plate
Fig.4 Fitting compression seal to 2. Downward facing lug
injector 3. Securing clamp
1. Tool LDV 130
2. Compression seal 7. Fit each injector as follows:
3. Groove in seal
– Remove the plug from the cylinder
6. To fit new seals: head.
NOTE: The seals fitted to N/A and – Fit the injector in the cylinder
Turbo injectors are different sizes and head, ensuring that the feed pipe

are colour coded:
N/A engine – White
T/C engine – Blue
– Fit a new dirt seal.
– Position a new compression seal on
the injector, ensuring the externally
grooved end is downwards.
– Press the seal into place using tool
LDV 130 as illustrated.
– Lightly grease the barrel of the
injector in the area between the two
seals.
FUEL SYSTEM
locates correctly in the recess in
the head.
– Position the securing plate as
illustrated so that its two downward
facing lugs are on either side of
the feed pipe, and the slot aligns
with the securing bolt hole in the
head.
– Fit the securing clamp and bolt.
Tighten the bolt to 40 Nm
(29 lbf ft).

113

041023
Fig.6 Tightening injector pipe
8. CAUTION: It is important to use
two spanners to tighten high
pressure fuel pipes: one to hold
the connector while tightening the
gland nut with the other.
Fit and tighten the injector high
pressure pipes.
9. Fit the spill return pipes.
FUEL SYSTEM
10. Fit the components removed to gain
access to the injectors
11. N/A engines only:
Check / adjust the throttle butterfly
link rod (see section ‘Exhaust Gas
Recirculation System’).
12. Start the engine and check for leaks.
114
FUEL INJECTION PUMP
Pump Timing – Check and Adjust
Checking Pump Timing
Tools required: 23–020, 21–123, 23–019
(turbo engine), 23–029 (N/A engine).
CAUTION: If there is evidence that the
flywheel timing pin socket has moved,
it must be reset before proceeding to
check pump timing (see section
‘Flywheel Timing Socket Setting’).
1. N/A engine:
Remove the blanking plug from the
timing pin socket adjacent to the
starter motor
Turbo engine:
Remove the engine speed sensor,
ensuring that any shim fitted is
retained for refitting.
2. Remove the rubber plug from the
crankshaft pulley.
3. Remove the rubber plug from the
engine timing belt cover. Using a
suitable mirror, note the position of
the injection pump pulley through the
hole in the cover.

041035
Fig.1 Fuel injection pump timing slot
4. Turn the crankshaft clockwise using
the crankshaft pulley bolt until a ‘U’
shaped slot just becomes visible
through the timing cover hole.
041015
Fig.2 Flywheel timing pin
5. Slowly continue to turn the crankshaft
until the flywheel timing pin 23–020
can be fitted through the hole in the
timing pin socket and into the
flywheel. The crankshaft is now set at
the timing position of 11° BTDC, No. 1
cylinder firing.
041036
Fig.3 Fuel injection pump timing pin
6. Check the injection pump timing by
fitting the timing pin 23–029 (for N/A
engine) or 23–019 (for turbo engine)
through the hole in the pump pulley
and into the pump body.
NOTE: The timing pin should slide
easily through the hole in the pulley
flange and locate fully and squarely
into the hole in the pump body.
If the timing pin does fit correctly, the
pump timing is correct.
FUEL SYSTEM
Remove both timing pins, replace the
crankshaft and timing cover rubber
plugs.
N/A engine:
Refit the sealing plug in the flywheel
timing socket.
Turbo engine:
Refit the speed sensor (and shim, if
fitted).
If the timing is incorrect. Proceed as
follows.
115
 Adjusting Pump Timing
Tools required: 23–020, 21–123, 23–019
(turbo engine), 23–029 (N/A engine),
MS 1517 (turbo engine).
7. Remove the viscous fan (if fitted)
using tool MS 1517 (right hand
thread).
NOTE: On engines built for hot 1
climates the viscous fan is fitted to the
water pump and has a left hand
thread.
8. Remove the external drive belts.
Remove the water pump pulley and
the idler / viscous fan pulley. 041084

Fig.5 Camshaft timing pin

1. Tool 21–123

10. Check that the flywheel timing pin

23–020 remains in position.
Fit the camshaft timing pin 21–123
through the hole in the camshaft
pulley and into the hole in the front
engine plate.
1
FUEL SYSTEM

041019

Fig.4 Timing belt cover

1. Dirt shield screws
041052
9. To remove the timing cover:
– Slacken the 2 dirt shield screws Fig.6 Fuel injection pump pulley
and slide the shield upwards. 1. Fuel injection pump timing tool
– Remove the 7 cover securing torx
screws. 11. Slacken the four bolts (arrowed)
– Hinge the lower section down and which secure the injection pump
remove the cover. pulley to its hub.
CAUTION: Do not allow the
timing belt to become
contaminated while the timing
cover is removed.

116
 Rotate the injection pump hub using
the centre nut (movement is limited by
the slotted bolt holes in the pulley)
until the timing pin 23–029 (for N/A
engine) or 23–019 (for turbo engine)
will enter fully.
FUEL INJECTION PUMP REMOVE /
REFIT
Tools required: 23–020, 21–123, 23–019
(turbo engine), 23–029 (naturally aspirated
engine), MS 1517 (turbo engine).

Tighten the four pulley securing bolts Remove

to 25 Nm (19 lbf ft).
NOTE: If the correct adjustment
cannot be obtained by rotating the
injection pump hub as detailed above,
the timing belt must be removed and
discarded, a new timing belt fitted,
and the timing procedure carried out
in full (see ‘Timing Belt Remove / Fit’).
12. Remove all three timing pins.
13. Turn the engine clockwise two
revolutions and refit the flywheel
timing pin.
Fit the camshaft and injection pump
timing pins to check that the timing
remains correct.
Remove all three timing pins.
14. Fit the timing belt cover and secure
The fuel injection pump can be removed
with the engine in situ:
WARNING: If the engine has
been running recently, cooling
system components may be
sufficiently hot to cause burning to
skin on contact.
1. Remove the timing belt as described
in the section ‘Timing Belt –
Remove / Fit’.
Discard the timing belt.
1
2

FUEL SYSTEM
with the torx bolts.
3
Slide the dirt shield down and tighten
the securing screws.
15. Refit the rubber plug in the crankshaft
pulley.
041038

16. N/A engine: Fig.1 Fuel injection pump pulley

Refit the flywheel timing socket
1. Pulley
blanking plug.
2. Plate
Turbo engine:
3. Fuel injection pump securing bolts
Refit the engine speed sensor (and
shim, if fitted). 2. Remove the fuel injection pump
timing pin.
17. Fit the water pump pulley and the
Remove the four securing bolts to
idler pulley.
detach the plate and the fuel injection
18. Fit the two external drive belts, pump pulley.
adjusting them to the correct tension. Note the word ‘FRONT’ on the plate.

19. Refit viscous fan (if removed).

117
 3. Disconnect from the fuel injection pump:
N/A engine – the throttle cable and
the throttle butterfly link rod.
Turbo engine – the multiplug
connector. Fit the blanking plug.
041117
Fig.2 Releasing high pressure fuel
pipe
4. Ensuring that each union is restrained
from turning while slackening its pipe
nut, remove the high pressure pipes.
FUEL SYSTEM
Seal all connections to prevent the
ingress of dirt.
5. Disconnect the low pressure and fuel
leak off pipes from the injection pump
and seal all the connections.
118
040990
Fig.3 Injection pump rear support
bracket.
6. Remove the injection pump rear
support bracket.
7. Support the fuel injection pump while
removing the three bolts securing it to
the engine front plate.
Refit
8. Fit the fuel injection pump to the engine
front plate and tighten the three securing
bolts to 24 Nm (18 lbf ft).
9. Fit the injection pump rear support
bracket.
CAUTION: Tighten the bolts evenly,
ensuring that while doing so the
bracket is not forcing the pump out
of alignment or causing the engine
plate to distort.
Tighten the bolts to 24 Nm (18 lbf ft).
 11. Fit the fuel injection pump timing pin
(23–029 for N/A engines, 23–019 for
1 Turbo engines) through the hole in
the pulley and into the pump flange.

041038

Fig.4 Fuel injection pump pulley

1. Pulley
2. Plate
3. Fuel injection pump securing bolts
041117

10. Fit the injection pump pulley and

loosely fit the retaining plate and
bolts, ensuring the word FRONT on
the plate is to the front.
1
Fig.6 Tightening high pressure pipes
12. Connect the high pressure pipes to
the injection pump, ensuring that each
union is restrained from turning while
tightening its nut.
13. Connect the low pressure and fuel
leak off pipes.

FUEL SYSTEM
2 14. Connect to the fuel injection pump:
N/A engine – the throttle cable and
the throttle butterfly link rod.
Turbo engine – the multiplug
connector.
15. Fit a new timing belt, the timing belt
cover and external drive belts etc. as
described in the section ‘Timing Belt
Fit’.
16. Refit any other components removed
3 041026
during dismantling.
Fig.5 Timing pins 17. Connect the battery(s), positive
1. Flywheel timing pin terminal(s) first.
2. Fuel injection pump timing pin
18. Start the engine and run until normal
3. Camshaft timing pin
operating temperature is reached.

119
 19. Check the fuel system for leaks.
20. N/A engine:
Check the following settings and
adjust as necessary:
– idle speed
– throttle cable
– throttle butterfly link rod.
FUEL SYSTEM

120
EXHAUST GAS RECIRCULATION SYSTEM (EGR)

CLEAN AIR EXHAUST GAS VACUUM

041086

Fig.1 EGR system (N/A engine)

1. Throttle butterfly valve
2. EGR valve

OPERATION Oxygen; there is sufficient for complete

EGR SYSTEM
The EGR system is fitted to reduce noxious combustiion of the fuel, but little or none
Nitrogen Oxide exhaust emissions. remaining to combine with Nitrogen.

Under idle and light acceleration Thus the NOx emissions are reduced.
conditions, more Oxygen can enter the
combustion chambers than is required for
burning. As a result it combines with
Nitrogen to form Nitrogen Oxide (NOx)
The EGR valve is fitted between the exhaust
and inlet manifolds. On naturally aspirated
engines it is operated by inlet manifold
vacuum created under low load conditions.
On turbo engines the EGR valve is operated
automatically, under the control of the
engine management system.
When the EGR valve is opened, exhaust
gases which contain very little Oxygen are
allowed into the inlet manifold to mix with the
incoming air; this has the effect of ‘diluting’ it.
The air entering the cylinder now has less

121
 ADJUSTMENT 3. Check that tool 23–019 can be
inserted through the hole in the EGR
EGR Control Linkage
cam and into the throttle body.
(Naturally aspirated engine)
If it enters easily, the EGR control
1. Run the engine until it reaches normal linkage is adjusted correctly.
operating temperature.
Turn off the engine. If not, slacken the lock nuts on the link
rod and adjust the length of the rod.
Tighten the lock nuts.
1
4. Remove tools 23–019 and LDV 130.

2
EGR SYSTEM

041088

Fig.1 Adjusting throttle butterfly valve

link rod
1. Tool 23–019
2. LDV 130

2. Fit tool LDV 130 between the throttle

lever and the 3rd stop screw on the
fuel injection pump as shown, to hold
the throttle lever 20 mm away from
the 3rd stop screw.

122
EGR VALVE

Remove / Refit

041116

Fig.1 EGR valve (N/A engine shown)

1. Detach the EGR pipe at the EGR

valve by releasing the flange clamp
with a suitable screwdriver blade as
illustrated.
2. Disconnect from the EGR valve:

EGR SYSTEM
– Rubber pipe(s).
– Multiplug (Turbo engine).

3. Remove 2 torx screws to detach the

EGR valve.

4. Refitting is the reverse of removal,

using a new gasket.
The EGR valve flange clamp can be
fitted using suitable pliers to snap the
two ends together as illustrated.

123
 COOLING SYSTEM
1 3

4
2
COOLING
SYSTEM

7
15
14 8 6

10
13
12
11 9

1
14 5
6
14
8

4 3
9 7 10 2

15

13
12
11 041005

Fig.1 Cooling system circulation

1. Expansion tank 6. Heater supply pipe 11. Radiator
2. Heater return pipe 7. By–pass hose 12.Radiator bottom hose
3. Heater 8. Thermostat housing 13.Oil cooler (turbo only)
4. Heater control valve 9. Radiator top hose 14.Air vent pipes
5. Heater by–pass valve 10.Water pump 15.Filler pipe

124
DESCRIPTION COOLANT DRAIN AND REFILL
Coolant circulating in the engine is Drain
directed by the water pump (10) into the
WARNING: Use caution if the
thermostat housing (8). If the thermostat
coolant is hot.
is closed, the coolant is directed back to

COOLING
the engine via the by–pass hose (7).

SYSTEM
1. Set the cab heater control to the ‘hot’
When the thermostat is open, coolant can position.
pass through the radiator (11) via the top 2. Remove the expansion tank pressure
hose (9) and the bottom hose (12). cap.
Coolant is directed into the heater (3) from 3. Position a suitable drain container
the front of the cylinder head via a under the vehicle.
separate supply pipe (6) and the heater
by–pass valve (5). This can only take
place if the heater control valve (4) has
been opened manually to allow the
coolant to circulate through the heater.
If the heater control valve is closed,
coolant circulation pressure opens the
heater by–pass valve, allowing coolant to
pass directly into the heater return pipe
(2) and back to the engine via the filler
pipe (15).
041108

An oil cooler (13) is fitted on turbo

engines, and is connected into the heater
return pipe.
Fig.1 Cylinder block drain plug
4. Remove the cylinder block drain plug.
5. Disconnect the radiator bottom hose
at the radiator.

Refill

6. Apply Hylomar PL32M to the drain

plug, fit and tighten to 23 Nm
(17 lbf ft).
7. Connect the radiator bottom hose.

125
 WATER PUMP

Remove / Refit
Tools required: MS 1517 (turbo only)
The water pump can be removed with the
COOLING
SYSTEM

engine in situ after first carrying out the

following operations:
1. Disconnect the battery(s), negative
(earth) terminal(s) first.

041008

041108

040840
Fig.1 Cylinder block drain plug
Fig.2 Expansion tank
2. WARNING: If the engine has
8. Fill the system slowly through the been running recently, the
expansion tank with the correct coolant may be sufficiently hot to
coolant (50% anti–freeze), to the MAX cause scalding.
mark on the expansion tank. Fit the Set the cab heater control to the ‘hot’
cap. position.
Position a suitable container to drain
9. WARNING: Place a thick the coolant.
cloth over the cap and Disconnect the lower radiator hose
expansion tank before attempting and remove the cylinder block drain
to remove the cap slowly, to avoid plug.
the possibility of scalding. After draining, refit the hose and the
Warm the engine to normal operating drain plug.
temperature and top up as necessary.
3. Remove the viscous fan (if fitted)
10. Check the system for leaks. using tool MS 1517 (right hand
thread).
NOTE: On engines built for hot
climates the viscous fan is fitted to the
water pump and has a left hand
thread.
4. Remove the external drive belts.
5. Remove the water pump pulley and
the idler / fan pulley.

126
 Refit

8. Thoroughly clean all mating faces.

9. Locate a new gasket and fit the water
pump.
Torque tighten the six securing bolts:

COOLING
SYSTEM
M8 bolts 23 Nm (17 lbf ft)
M10 bolts 46 Nm (34 lbf ft)
1
10. Fit the timing belt cover and secure
with the torx bolts.
Slide the dirt shield down and tighten
the securing screws.
1 11. Fit the water pump pulley and the
idler / fan pulley.
12. Fit the two external drive belts,
adjusting them to the correct tension.

041019
Fig.2 Timing belt cover
1. Dirt shield screws
6. To remove the timing cover:
– Slacken the 2 dirt shield screws
and slide the shield upwards.
– Remove the 7 cover securing torx
screws.
– Hinge the lower section down and
remove the cover.
13. Refit viscous fan (if removed).
14. Refill with coolant (50% antifreeze)
– see ‘Coolant Drain and Refill’ for
correct filling procedure.
15. Connect the battery(s), positive
terminal(s) first.
16. Start the engine and check for coolant
leaks. Run until normal operating
temperature is reached.
WARNING: Place a thick
cloth over the cap and
expansion tank before attempting
to remove the cap slowly, to avoid
the possibility of scalding if the
engine is hot.
Check the coolant level and top up as
necessary.

041056

Fig.3 Water pump

7. Remove six bolts to remove the water
pump.
Discard the gasket.

127
 THERMOSTAT 9. Refill with coolant (50% antifreeze)
– see ‘Coolant Drain and Refill’ for
Remove and refit correct filling procedure.
Remove 10. Start the engine and check for coolant
1. WARNING: If the engine has leaks. Run until normal operating
COOLING

temperature is reached.
SYSTEM

been running recently, the

coolant may be sufficiently hot to
cause scalding.
Position a suitable drain container,
disconnect the top radiator hose and
allow the coolant to drain.
1 4
2 3
WARNING: Place a thick
cloth over the cap and
expansion tank before attempting
to remove the cap slowly, to avoid
the possibility of scalding if the
engine is hot.
Check the coolant level and top up as
necessary.

041054

Fig.1 Thermostat
1. Thermostat housing
2. Thermostat
3. Sealing ring
4. Coolant outlet
2. Unscrew the coolant outlet.
3. Remove the thermostat.
4. Examine the sealing ring and renew if
necessary.

Refit
5 Thoroughly clean all mating surfaces.
6. Fit the sealing ring to the thermostat.
7. Fit the thermostat in the housing, and
fit and tighten the coolant outlet.
8. Connect the coolant top hose.

128
TURBOCHARGER

Remove / Refit

Remove
The turbocharger can be removed with
the engine in situ by first carrying out the
following operations.

1. Disconnect the exhaust down pipe.

2. Disconnect the air intake duct.
3. Disconnect the air outlet pipe from the
turbocharger.
4. Disconnect the turbocharger oil drain
pipe from the sump, and the oil
supply pipe from the cylinder block.
5. Support the turbocharger while
detaching it, by removing the 3 nuts
securing it to the exhaust manifold.

TURBOCHARGER
Refit
6. CAUTION: Ensure the turbocharger
is primed with clean engine oil
prior to fitting.
Refitting is the reverse of removal.

129
Part Number DW 03962102