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Godiva PowerFlow 12/10, Workshop Manual

The Godiva PowerFlow 12/10 Workshop Manual is a comprehensive guide to understanding and maintaining your power pump. This essential manual is available for free download from manualshive.com, providing users with detailed instructions and troubleshooting tips to ensure optimal performance of this rugged and reliable product.

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RLF MPE850 Rev 1.2 | 406555 |

Table of contents

070.01.01 Removing intake manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
070.01.02 Installing intake manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
070.01.03 Removing intake manifold bracket  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
070.01.04 Installing intake manifold bracket  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
070.01.05 Removing sensor intake manifold pressure/temperature . . . . . . . . . . . . . . . . . 270
070.01.06 Installing sensor intake manifold pressure/temperature . . . . . . . . . . . . . . . . . . 271

070.02 Mounting throttle body  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272

070.02.01 Removing throttle body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
070.02.02 Installing throttle body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
070.02.03 Replacing throttle body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
070.02.04 Replacing rubber mount  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278

080 

Engine management system 

281

080.01 Engine management components overview  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
080.02 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283

See the portable fire pump manufacturer‘s documentation.

090 

Starter, generator 

284

090.01 Starter  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284

090.01.01 Removing starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
090.01.02 Installing starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
090.01.03 Replacing starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

090.02 Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289

090.02.01 Removing generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
090.02.02 Installing generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293

090.03 Voltage regulator  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296

See the portable fire pump manufacturer‘s documentation.

100 

Fuel unit 

297

100.01 Fuel rail  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297

100.01.01 Removing fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
100.01.02 Installing fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
100.01.03 Replacing injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301

110 

Lubrication system 

303

110.01 Dry sump  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303

110.01.01 Removing suction pump cover  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
110.01.02 Installing suction pump cover  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
110.01.03 Replacing suction pump cover  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
110.01.04 Removing oil suction pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
110.01.05 Installing oil suction pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
110.01.06 Replacing fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
110.01.07 Removing intermediate gear suction pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
110.01.08 Installing intermediate gear suction pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314

110.02 Oil pressure pump  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315

110.02.01 Removing oil pressure pump  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
110.02.02 Installing oil pressure pump  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318

110.03 Oil pressure valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320

110.03.01 Removing oil pressure valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321

Summary of Contents for PowerFlow 12/10

Page 1: ...Portable Fire Pump Workshop Manual Publication GP 291 Issue 4 January 2016...

Page 2: ...ligation AMENDMENT RECORD Model 12 10 17 10 Portable Fire Pumps Mod No Date Page s Amendment New Issue No 1 May 2012 All New publication 1 2 November 2012 8 18 19 Revised oil level check procedure 2 3...

Page 3: ...ONENTS AND CONTROLS 17 10 AND 12 10 MODELS 11 GENERAL ARRANGEMENT LEFT HAND VIEW FROM FRONT 11 GENERAL ARRANGEMENT RIGHT HAND SIDE FROM REAR 12 GENERAL ARRANGEMENT CONTROLS AND INSTRUMENTS 13 ENGINE F...

Page 4: ...STALLATION 30 INTRODUCTION 30 PRECAUTIONS 30 POST REPAIR AND ASSEMBLY 30 INSTALLATION 30 1 SUCTION TUBE REMOVAL WEAR RING RE ASSEMBLY 31 2 IMPELLER MECHANICAL SEAL AND REAR WEAR RING 34 3 PRIMING VALV...

Page 5: ...4 Godiva Ltd Our policy is one of continuous development We therefore reserve the right to amend specifications without notice or obligation Page intentionally left blank...

Page 6: ...ed from the suction tube end For specific engine information please refer to the Weber Operating and Maintenance Instructions Fuel system Care To ensure availability and reliability of gasoline powere...

Page 7: ...ns 1998 applies Training It is ESSENTIAL that Godiva pumps are operated ONLY by TRAINED PERSONNEL Please contact Godiva Ltd to discuss your training needs To avoid damage and personal injury operating...

Page 8: ...eights without assistance DO NOT remove protective guards or shields When cleaning the pump and engine use hot soapy water do not use flammable degreasers When cleaning the pump and engine use hot soa...

Page 9: ...y for operation under ambient conditions 0 C Oil Filter Metal spin on type Fuel Type Unleaded gasoline EU 95 RON US 91 RON MON Fuel Feed Electric pump Fuel Capacity 18 litres Run Time 17 10 model 60 m...

Page 10: ...7 10 1500 l min FPN 10 1500 12 10 1000 l min FPN 10 1000 Maximum Flow 17 10 2450 l min at 3 bar 12 10 2150 l min at 3 bar Maximum Pump Discharge Pressure 17 10 12 10 17 bar with boosted suction 17 bar...

Page 11: ...damage Optional Equipment Detachable floodlight rated 55w Detachable wheel assembly for transporting pump over long distances Frame with extendable handles Additional fuel tank with quick release conn...

Page 12: ...TROLS 17 10 AND 12 10 MODELS General Arrangement Left Hand View from front 1 Priming valve automatic operation 2 Engine oil filter 3 Coolant fill 4 Battery 5 Fuel filler cap 6 Delivery valve 7 Carryin...

Page 13: ...d Our policy is one of continuous development We therefore reserve the right to amend specifications without notice or obligation General Arrangement Right Hand Side from rear 12 Air filter 13 Oil fil...

Page 14: ...gauge 17 10 80mm dia 12 10 60mm dia 25 Pressure gauge 17 10 80mm dia 12 10 60mm dia 26 Throttle controls pump speed 27 Engine start Warning Lights Indicator Meaning Action Fuel level Shows fuel level...

Page 15: ...for aluminium engines Suitable additives BASF Glysantin G 30 Chevron Havoline Extended Life Coolant XLC B Valvoline Zerex G 30 The coolant acts as anti freeze in the winter and coolant in the summer...

Page 16: ...d or removed from the unit this procedure must be followed to restart 4 1 Reconnect the battery red lead to positive terminal black to negative terminal in that order 4 2 Place throttle in closed posi...

Page 17: ...ngine Check oil level Yes 1 Engine Check coolant level Yes 1 Engine Change engine oil and oil filter Yes 2 Yes 2 Yes Engine Check clean air filter Yes 2 Engine Check and adjust valve play Yes Yes 3 En...

Page 18: ...seawater Ensure the pump is drained Frost If frost is expected drain the pump volute by opening the drain valve at the bottom of the volute Engine Coolant Level Fill the cooling system with a 4 litre...

Page 19: ...ot to let the coolant spill on to the exhaust insulation below the coolant is a flammable liquid Coolant Change Coolant is drained through the drain tap at the lowest point in the system which is loca...

Page 20: ...dipstick Remove the oil tank cap dipstick 1 wipe the dipstick with a clean cloth and re insert Always screw the dipstick fully down to achieve a correct reading Remove the dipstick and note where the...

Page 21: ...seal is lubricated Stop the engine and check the oil level with the dipstick as described in the previous section If necessary top up the oil level or drain off some oil to achieve the correct level...

Page 22: ...s and below the fuse box The fuel filter can be removed by disconnecting the hoses on both sides and loosening the two clips holding the filter to the engine Air Filter Element The air filter is locat...

Page 23: ...on Sparking Plugs This procedure is described in the Weber Service Manual Section 6 5 Preparing the unit for storage See Weber Service Manual section 8 9 Change oil and oil filter Add fuel stabiliser...

Page 24: ...must be maintained for a minimum of 15 seconds If vacuum retention fails proceed to a pressure test to identify the cause Should the pump be incapable of developing a vacuum of 0 6 bar but hold whate...

Page 25: ...s of the gauges with abrasive or solvent cleaners These will cloud the glass surface use a mild detergent and water FAULT TRACING Engine For specific engine related information please refer to the Web...

Page 26: ...jet uneven Suction strainers not completely immersed Submerge Leakage in suction side Check and secure joints In the event of the above information not leading to a solution carry out the Monthly pum...

Page 27: ...ontinuous development We therefore reserve the right to amend specifications without notice or obligation schedules of Godiva Ltd and Weber This information may be useful should you need to contact th...

Page 28: ...pment We therefore reserve the right to amend specifications without notice or obligation PUMP LOG SHEET Model __________ Serial No ___________ Date Entered Service _______ Date Location Hours run Ins...

Page 29: ...er Primer 12 10 4inch RT 2 x 2 Instantaneous connection Electric and recoil handstart Exhaust gas prime 17 10 4inch RT 2 x 2 Instantaneous connection Electric and recoil handstart Exhaust gas prime Ot...

Page 30: ...ump shaft to crankshaft 1 10 O ring priming valve to volute 1 11 Dowty seal strainer 2 12 Dowty seal fuel drain plug Fuel Tank 1 13 Sealing washer for oil drain Oil Tank 2 Weber Engine Spares Kit Part...

Page 31: ...lease refer to the Spare Manual GP 292 for the relevant assembly and part numbers Precautions Before carrying out repair work take the following precautions o Drain the fuel tank o Drain the engine oi...

Page 32: ...ess to the volute impeller and mechanical seal behind 1 1 Disconnect the compound gauge tubing from the top of the suction tube 16mm spanner 1 2 Disconnect rubber hose from heat exchanger to suction t...

Page 33: ...be to come forward 1 6 Remove the panel on the left hand side to gain better access to the priming valve Undo 7 x M6 socket head screws 1 7 This will allow the priming valve to be removed completely f...

Page 34: ...f the suction tube by turning the screws evenly into the three holes on the face of the suction tube 1 9 The front wear ring 68026 can now be inspected for wear and damage Measure the ring across the...

Page 35: ...the suction tube removed the impeller main shaft seal and the rear wear ring will be accessible in this sequence 2 1 Remove the M16 nyloc nut retaining the impeller onto the shaft Carefully move the i...

Page 36: ...hten to 2Nm 2 4 While the impeller is removed from the pump the front and rear wearing dimensions can be checked This dimension should be no less than 114mm This dimension must be measured on the fron...

Page 37: ...seal is mounted on a backing plate with a retaining washer Check the condition of the seal 55669 If the seal is worn replace it The retaining washer must be flat To release the seal undo the M6 screw...

Page 38: ...assembly is complete it can be re attached to the suction tube if required at this stage by reversing instructions in section 1 3 1 7 4 Priming Valve Heat Shield When the priming valve is removed fro...

Page 39: ...ulation blanket on manifold 5 1 To remove the exhaust priming assembly First follow the procedure in sections 1 3 1 7 to disconnect and remove the priming valve including the removal of the side panel...

Page 40: ...r the internal parts 5 6 Undo and remove 4 x M8 Thick nuts and 4 x M8 thin nuts retaining the exhaust exit to the exhaust primer housing 5 7 Removing the exhaust exit reveals the exhaust primer housin...

Page 41: ...on exhaust gases are diverted through the adjacent venture channel to create the pump priming action 5 9 The butterfly valve can removed from the exhaust primer housing while the housing is attached t...

Page 42: ...al in the primer housing 5 11 The exhaust primer housing can now be detached from the silencer by undoing the single M8 socket head screw in the corner 5 12 Removing the exhaust primer housing allows...

Page 43: ...t insulation on the exhaust is permanent 5 14 When all the internal parts have been checked the exhaust primer system can be reassembled a reversal of the dismantling process Ensure the gasket is repl...

Page 44: ...43 Godiva Ltd Our policy is one of continuous development We therefore reserve the right to amend specifications without notice or obligation...

Page 45: ...olant from the system A drain tap is provided on the side of the engine Attach a suitable hose to the tap before opening Be careful not to spill or splash the coolant on any components as it is a flam...

Page 46: ...eserve the right to amend specifications without notice or obligation Engine coolant into heat exchanger at the heat exchanger Engine coolant return to engine at the heat exchanger 6 3 To release the...

Page 47: ...e the removal operation Note that the 2 x M6 screws on the rear bracket require a small amount of Loctite 243 on the threads to secure 7 Oil Tank The oil tank is located at the rear of the pump Please...

Page 48: ...is one of continuous development We therefore reserve the right to amend specifications without notice or obligation 7 2 Undo the two hoses feeding oil to and from the tank 7 3 Undo the 1 x M6 bolt o...

Page 49: ...to remove it from the bottom of the pump frame 7 5 To release the oil tank form the pump the breather hose connected to the top of the tank needs to be removed from the elbow It may be necessary to cu...

Page 50: ...removing the major assemblies should be followed first remove the oil tank section 7 instrument panel section 14 heat exchanger section 6 Separate the engine from the panel wiring harness Disconnect...

Page 51: ...engine mount 8 4 To allow the pump engine assembly to be lifted clear of the frame the two sides of the frame must be separated The exhaust side of the frame hot side is secured to the fuel tank side...

Page 52: ...frame it is advisable to remove the air filter assembly from the throttle body on the air intake 8 7 With the pump engine assembly removed the fuel tank is exposed Continue to remove the fuel tank by...

Page 53: ...it does not obstruct or snag when replacing the tank Note the M6 bolts at each end of the fuel tank are longer than the ones under the tank Apply a small amount of Loctite 243 to the threads of all t...

Page 54: ...53 Godiva Ltd Our policy is one of continuous development We therefore reserve the right to amend specifications without notice or obligation...

Page 55: ...uts on studs retaining the pump to the engine 9 2 The pump assembly can now be moved forward from the engine gently tap the pump body with a plastic hammer to dislodge it from the engine 9 2 This reve...

Page 56: ...eing careful not to disturb the location of the stub shaft The teeth on the outer edge of the rotor will engage with teeth on the starter motor 9 7 Apply a sealant Loctite 243 or equivalent to the 6 o...

Page 57: ...ap the pump body gently against the engine Tap evenly around the outer edge of the pump 10 4 Replace the 9 x M6 nuts and 2 x M10 nuts around the outside edge of the pump Tighten the 2 x M10 nuts first...

Page 58: ...or obligation 11 3 Press the seal into the pump volute evenly Ensure it is pressed to the bottom of the recess and is flush with the surface of the pump volute 11 4 Clean the surface of the seal with...

Page 59: ...he right to amend specifications without notice or obligation 11 7 Press bearing 68170 onto the shaft Also place O ring 57044 into the groove next to the shaft splines 11 8 Use a press to move the bea...

Page 60: ...e right to amend specifications without notice or obligation 11 10 Fit the flinger 68033 on to the shaft 11 11 Fit the shaft with the collar and flinger facing down into the rear of the pump 11 12 Tap...

Page 61: ...gation 11 13 Use a suitable ring tool to push the bearing and shaft further into the pump 11 14 Push the bearing into the pump body until it passes the internal circlip groove 11 15 Insert the circlip...

Page 62: ...e right to amend specifications without notice or obligation 11 17 Fit the O ring to the impeller end of the shaft 11 18 Place the key MS179 36 into the slot on the shaft 11 19 Apply a soft soap solut...

Page 63: ...ce the spring from the seal kit over the impeller rear central section 11 21 Apply a soft soap solution to the internal part of the seal 11 22 Push the seal onto the impeller and press down against th...

Page 64: ...be fitted to the shaft Grease the end of the shaft and inside impeller 11 25 Press the impeller down on to the shaft Ensure the slot in the impeller lines up with the key on the shaft 11 26 Fit the wa...

Page 65: ...64 Godiva Ltd Our policy is one of continuous development We therefore reserve the right to amend specifications without notice or obligation...

Page 66: ...chieved when the pump end is separated from the engine 12 1 The recoil start mechanism is retained in the rear of the volute by a circlip Remove the circlip with circlip pliers to access the reel 12 2...

Page 67: ...elopment We therefore reserve the right to amend specifications without notice or obligation 12 4 Pull most of the rope through the reel 12 5 Tie a knot in the rope end 12 6 Pull the rope back through...

Page 68: ...ly around the reel in a clockwise direction for four turns 12 8 Thread the other end of the rope through the hole the volute to the outside 12 9 Place the complete reel back over the shaft and onto th...

Page 69: ...right to amend specifications without notice or obligation 12 11 Place the Straight end of the Clip through the ratchet guide hole as shown below 12 12 Line the Plate grooves up with the Block grooves...

Page 70: ...ce or obligation 12 14 Pull the other end of the rope right through the handle length should be 1800mm Make a mark where the 1800mm length should be 12 15 Tie a secure slip knot in the end of the rope...

Page 71: ...igation 12 17 Burn the end of the rope to prevent it fraying and push it back into the handle This should make the rope the correct length for the recoil action 12 18 When the rope is released the rec...

Page 72: ...therefore reserve the right to amend specifications without notice or obligation 12 19 Before assembling the volute with the recoil starter fixed inside to the engine Fully extend Rope check the Pulle...

Page 73: ...he 1 x M10 nut fixing the hand wheel to the Spindle 13 2 Rotate the Spindle Clockwise and remove from the delivery valve housing Note Do NOT attempt to remove the Valve Seal Plate assembly from the St...

Page 74: ...ay from the Plate Locking Nut and release the nut to allow the Stem to be separated from the Valve Plate 13 5 Re assembly is a reversal of the dismantling Check condition of and renew as necessary the...

Page 75: ...aced with a small amount of Loctite 243 applied to the thread 15 Electrical System The pump and engine electrical system is checked by diagnostic software connected to the unit through the main wiring...

Page 76: ...derside of the instrument panel provides engine calibration and management according to pre programmed data and is accessed by the diagnostic software mentioned above In normal operation it is not nec...

Page 77: ...n the instrument panel First undo and lift the instrument panel from the frame see section 12 Instrument Panel It is not necessary to disconnect any of the wiring harness or gauge connections 15 6 The...

Page 78: ...77 Godiva Ltd Our policy is one of continuous development We therefore reserve the right to amend specifications without notice or obligation 15 8 Engine wiring harness...

Page 79: ...78 Godiva Ltd Our policy is one of continuous development We therefore reserve the right to amend specifications without notice or obligation 15 9 Control Panel Wiring Harness...

Page 80: ...79 Godiva Ltd Our policy is one of continuous development We therefore reserve the right to amend specifications without notice or obligation 15 10 Fuel Tank Harness...

Page 81: ...e 243 46 Skid plate retaining screws Loctite 243 50 Fuel tank retaining screws Loctite 243 50 Fuel tank connections fuel filter equal tee Loctite 410 and Activator 770 52 Stub shaft on six screws reta...

Page 82: ...elopment We therefore reserve the right to amend specifications without notice or obligation Godiva Limited A Unit of IDEX Corporation Charles St Warwick CV34 5LR England Tel 44 0 1926 623600 Fax 44 0...

Page 83: ...IND NA 406555 This repair manual is valid for the following engine variants en_English REPAIR MANUAL 4 Stroke Engine Read the introductory chapter before performing the task on the engine Pay particu...

Page 84: ......

Page 85: ...s to make continual improvements as part of the ongoing technical development of its products All documentation is therefore subject to technical modifications Reprints and translations in whole or in...

Page 86: ...ve side of the engine stand 18 3 3 2 Mount the engine across from the drive side of the engine stand 19 3 4 While working 20 3 4 1 Tightening torque 20 3 4 2 Cleaning 20 3 4 3 Disposal 20 3 5 Checking...

Page 87: ...ain bearing play 136 020 02 Stub shaft 142 020 02 01 Removing stub shaft 143 020 02 02 Installing stub shaft 145 020 03 Crankshaft cover 147 020 03 01 Removing crankshaft cover 148 020 03 02 Installin...

Page 88: ...tem 234 050 01 Thermostat housing 234 050 01 01 Removing thermostat housing 235 050 01 02 Installing thermostat housing 236 050 01 03 Removing fitting 238 050 01 04 Installing fitting 239 050 01 05 Re...

Page 89: ...starter 285 090 01 02 Installing starter 286 090 01 03 Replacing starter 287 090 02 Generator 289 090 02 01 Removing generator 290 090 02 02 Installing generator 293 090 03 Voltage regulator 296 See t...

Page 90: ...8 120 Engine mount 329 120 01 Lifting eye 329 120 01 01 Removing bracket on the drive side 330 120 01 02 Installing bracket on the drive side 331 120 01 03 Removing pipe clamp 332 120 01 04 Installing...

Page 91: ...res and recommendations These chapters are required for tasks covered in the following chapter Tools and supplies required for tasks covered in the chapter The chapter structure in the repair manual i...

Page 92: ...ons in the repair manual are changed or amended All changes are described in the chapter Overview of revisions Observe the following information Always use the most current repair manual from the prot...

Page 93: ...personnel have read and understand all introductory chapters and in particular the chapter on safety Observe all generally applicable laws and regulations in addition to the information in this repai...

Page 94: ...the engine on the brackets provided See chapter 3 2 Lift and transport the engine Lift and transport the engine Securing the engine Crush injuries due to the engine overturning Mount the engine to the...

Page 95: ...er s documentation Engine power supply Protective equipment Missing protective equipment poses a safety risk to personnel Attach all protective equipment after completing the tasks Tools and accessori...

Page 96: ...e engine or the fuel system Never fill with fuel while the engine is running Do not start the engine if there is a smell of fuel or you suspect that fuel is leaking Have a workshop authorized by Weber...

Page 97: ...The following requirements must be met before performing any tasks The engine has been removed from the portable fire pump The engine has been disconnected from the power supply There is no engine oi...

Page 98: ...ct lifting of heavy loads Always lift the engine using a workshop crane NOTICE Components can break Lift the engine only using the brackets Lift the engine using the brackets 1 3 Basic instructions fo...

Page 99: ...ss from the drive side Mount the engine on the drive side 1 of the engine stand See chapter 3 3 1 Mount the engine on the drive side of the engine stand or Mount the engine across from the drive side...

Page 100: ...kshop crane Engine stand WARNING Spinal column injury due to incorrect lifting of heavy loads Always lift the engine using a workshop crane NOTICE Breakage Lift the engine only using the brackets Lift...

Page 101: ...e stand WARNING Spinal column injury due to incorrect lifting of heavy loads Always lift the engine using a workshop crane NOTICE Breakage Lift the engine only using the brackets Lift the engine using...

Page 102: ...s about tightening torque in this repair manual observe the following information The thread is dry and free of engine oil For components with coated threads the tightening torques always refer to new...

Page 103: ...d then back off Allow the engine to warm up as described in the portable fire pump manufacturer s documentation You should not hear any unusual noises Perform a visual inspection No fluids should be e...

Page 104: ...or com for more information 4 1 Weber Motor tool case 4 Tools and accessories 4 1 Weber Motor tool case Figure Description Locking tool crankshaft Chain breaking tool Installation spike valve stem sea...

Page 105: ...ewdriver T20 T30 T45 Torx screwdriver socket T20 T30 T45 Hexagon screwdriver 4 5 6 7 8 In addition to the tool case you will require the following tools and accessories The figures are only examples o...

Page 106: ...ins maximum 3 mm Bar magnet Universal pliers Plastic hammer Universal strap wrench Lockring pliers bore holes Figure Description Valve refacer Piston ring compressor Cylinder liner puller Oil seal sli...

Page 107: ...25 RLF MPE850 Rev 1 2 406555 Figure Description Precision clearance gauges 0 025 mm 0 04 mm 4 Tools and accessories 4 2 Equipment workshop...

Page 108: ...nti Seize assembly paste for lubricating threaded connections Weicon Anti Seize High Tech ASW 040 P Loctite 8150 Thread sealant Loctite 542 Valve grinding compound Teroson valve grinding compound Seal...

Page 109: ...27 RLF MPE850 Rev 1 2 406555 010 010 01 1 Crankcase 010 01 1 Crankcase 010 Crankcase...

Page 110: ...end wrench 12 Crown wrench Cylinder liner puller Torque wrench Hexagon screwdriver socket 5 6 8 Torx screwdriver socket T30 Insert open end wrench 12 Petroleum jelly Pin punch axle intermediate gear...

Page 111: ...2 406555 010 5 6 6 7 3 4 Turn the lower case 180 Remove the sleeves 6 Unscrew the fitting 5 Unscrew the bolts 3 Remove the intake manifold bracket 4 010 01 1 Crankcase 010 01 1 01 Replacing crankcase...

Page 112: ...8 Unscrew the bolts 12 Remove the chain rail 13 Remove the sleeves 11 010 01 1 Crankcase 010 01 1 01 Replacing crankcase Remove the intermediate gear suction pump 10 Punch the axle 9 out using the pin...

Page 113: ...strap wrench Unscrew the threaded sleeve 14 using a crown wrench Unscrew 10 bolts 16 The thermostat housing is caulked with a silicone liquid seal Remove the thermostat housing 18 010 01 1 Crankcase 0...

Page 114: ...1 Remove the cylinder liners 22 using a cylinder liner puller Prepare the new crankcase Replace the crankcase The plug can be found in the spare parts catalog in chapter 010 01 2 Crankcase Screw in a...

Page 115: ...eves 26 The plugs can be found in the spare parts catalog in chapter 010 01 3 Crankcase Screw in new plugs 27 Tightening torque 20 Nm 4 Nm 14 8 lbf ft 3 lbf ft Two threaded holes M18 28 remain open Th...

Page 116: ...g points M10 31 Depth of thread 30 mm Suitable mounting points M6 32 Screw in the threaded sleeve 33 using a crown wrench Tightening torque 17 Nm 3 Nm 12 5 lbf ft 2 2 lbf ft 010 01 1 Crankcase 010 01...

Page 117: ...39 Screw in the oil filter 37 by hand Tightening torque 10 Nm 7 4 lbf ft Clean the sealing surface 38 with sealing surface cleaner 010 01 1 Crankcase 010 01 1 01 Replacing crankcase Clean the sealing...

Page 118: ...ed Hold the thermostat housing 41 in position 010 01 1 Crankcase 010 01 1 01 Replacing crankcase Screw in 10 bolts 42 Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft The bolt is an additional part a...

Page 119: ...torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft 010 01 1 Crankcase 010 01 1 01 Replacing crankcase Hold the intake manifold bracket 46 in position Screw in the bolts 47 Tightening torque 20 Nm 4 Nm 14 8 lbf f...

Page 120: ...se 180 Hold the intermediate gear suction pump 52 in position Slide in the axle 53 Observe the position of the bevel 54 The plug and seal can be found in the spare parts catalog in chapter 010 01 3 Cr...

Page 121: ...2 60 60 010 01 1 Crankcase 010 01 1 01 Replacing crankcase Unscrew the bolt 58 Remove the lower case 59 Insert the chain guide 62 Screw in the bolts 61 Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf f...

Page 122: ...chain rail 64 Screw in the bolt 63 Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft The o rings can be found in the spare parts catalog in chapter 010 01 2 Crankcase Replace the o rings 66 Coat the o...

Page 123: ...from the crankcase Welch plug 1st cylinder 1 Welch plug 2nd cylinder 2 Unscrew the banjo bolt 3 Remove the welch plug 4 010 01 1 Crankcase 010 01 1 02 Replacing welch plugs 010 01 1 02 Replacing welch...

Page 124: ...case is disconnected from the crankcase Unscrew the tie rod 1 using a stud extractor Replace tie rod Apply Anti Seize assembly paste to all threads 2 Screw in the tie rod using a stud extractor Tighte...

Page 125: ...bf ft Hexagon screwdriver 5 8 Torque wrench Hexagon screwdriver socket 5 8 Plug M18x1 5 exhaust side 1 Plug M18x1 5 intake side 2 Plug M10x1 3 Replacing plug M18x1 5 intake side The rotor is removed U...

Page 126: ...v 1 2 406555 010 1 Replacing plug M10x1 The generator is removed Unscrew the plug 1 Replace the plug Screw in the plug Tightening torque 9 Nm 2 Nm 6 6 lbf ft 1 5 lbf ft 010 01 1 Crankcase 010 01 1 04...

Page 127: ...45 RLF MPE850 Rev 1 2 406555 010 010 01 2 Crankcase 010 01 2 Crankcase...

Page 128: ...e stand Mount the engine across from the drive side 1 of the engine stand See chapter 3 3 2 Mount the engine across from the drive side of the engine stand 070 01 01 Removing intake manifold 030 01 04...

Page 129: ...ead Install the valve cover See chapter 030 01 02 Installing valve cover Install the ignition coils See chapter 030 01 05 Installing ignition coils Install the intake manifold See chapter 070 01 02 In...

Page 130: ...ee chapter 3 3 2 Mount the engine across from the drive side of the engine stand Preparation Remove the generator See chapter 090 02 01 Removing generator 090 02 01 Removing generator 090 02 02 Instal...

Page 131: ...de sleeve 4 Slide the guiding sleeve 6 onto crankshaft 7 Use the M10x1x35 bolts you removed on the rotor Screw in the bolts 8 Hold the sliding sleeve 9 in position on the oil seal 10 Use the M10x1x35...

Page 132: ...tor See chapter 090 02 02 Installing generator Unscrew the bolt 14 Remove the sliding sleeve 13 Unscrew the bolts 17 Remove the guiding sleeve 15 Check if the oil seal 16 is tilted If the oil seal is...

Page 133: ...crew the plug 1 Replace the plug Screw in the plug Tightening torque 20 Nm 4 Nm 14 8 lbf ft 3 lbf ft Hexagon screwdriver 8 Torque wrench Hexagon screwdriver socket 8 010 01 2 Crankcase 010 01 2 03 Rep...

Page 134: ...52 RLF MPE850 Rev 1 2 406555 010 010 01 3 Crankcase 010 01 3 Crankcase...

Page 135: ...Mount the engine on the engine stand Mount the engine on the drive side 1 of the engine stand See chapter 3 3 1 Mount the engine on the drive side of the engine stand 010 01 3 Crankcase 010 01 3 01 R...

Page 136: ...406555 010 2 1 Torque wrench Hexagon screwdriver socket 8 010 01 3 Crankcase 010 01 3 02 Installing plug 010 01 3 02 Installing plug Replace the seal 1 Screw in the plug 2 Tightening torque 20 Nm 4 Nm...

Page 137: ...side The oil cooler bracket is removed Two threaded holes M18 1 remain open Unscrew the plugs 2 Replace the plugs Screw in the the plugs Tightening torque 20 Nm 4 Nm 14 8 lbf ft 3 lbf ft Plugs across...

Page 138: ...he plug 1 Replace the plug Screw in the plug Tightening torque 20 Nm 4 Nm 14 8 lbf ft 3 lbf ft Replacing lower plug intake side Unscrew the plug 1 Replace the plug Screw in the plug Tightening torque...

Page 139: ...7 RLF MPE850 Rev 1 2 406555 010 1 Open end wrench 12 Unscrew the fitting 1 Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft 010 01 3 Crankcase 010 01 3 04 Removing fitting 010 01 3 04 Removing fittin...

Page 140: ...555 010 2 1 Torque wrench Insert open end wrench 12 Replace the seal 1 Screw in the fitting 2 Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft 010 01 3 Crankcase 010 01 3 05 Installing fitting 010 01...

Page 141: ...RLF MPE850 Rev 1 2 406555 010 1 2 Unscrew the bolt 1 Pull the sensor crankshaft 2 out Torx screwdriver T30 010 01 3 Crankcase 010 01 3 06 Removing sensor crankshaft 010 01 3 06 Removing sensor cranksh...

Page 142: ...ket T30 Petroleum jelly 010 01 3 Crankcase 010 01 3 07 Installing sensor crankshaft 010 01 3 07 Installing sensor crankshaft Coat the o ring 1 lightly with petroleum jelly Insert the sensor crankshaft...

Page 143: ...61 RLF MPE850 Rev 1 2 406555 010 010 02 1 Oil cooler bracket 010 02 1 Oil cooler bracket...

Page 144: ...3 3 1 Mount the engine on the drive side of the engine stand Removing oil cooler bracket Unscrew 15 bolts 2 Preparation Remove the oil cooler See chapter 050 03 01 Removing oil cooler 050 03 01 Removi...

Page 145: ...63 RLF MPE850 Rev 1 2 406555 010 3 4 Remove the oil cooler bracket 3 010 02 1 Oil cooler bracket 010 02 1 01 Removing oil cooler bracket Remove the sleeve 4...

Page 146: ...the groove and lightly coat with petroleum jelly Insert the sleeve 2 Hold the oil cooler bracket 3 in position 050 03 02 Installing oil cooler Petroleum jelly Torque wrench Hexagon screwdriver socket...

Page 147: ...55 010 4 Screw in 15 bolts 4 Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft Completion Install the oil cooler See chapter 050 03 02 Installing oil cooler 010 02 1 Oil cooler bracket 010 02 1 02 Ins...

Page 148: ...66 RLF MPE850 Rev 1 2 406555 010 010 02 2 Oil cooler bracket 010 02 2 Oil cooler bracket...

Page 149: ...iver socket T30 Mount the engine on the engine stand Mount the engine on the drive side 1 of the engine stand See chapter 3 3 1 Mount the engine on the drive side of the engine stand Replace the blank...

Page 150: ...v 1 2 406555 010 8 9 7 Insert the blanking cover 9 Hold the bracket 8 in position Screw in the bolt 7 Tightening torque 9 Nm 2 Nm 6 6 lbf ft 1 5 lbf ft 010 02 2 Oil cooler bracket 010 02 2 01 Replacin...

Page 151: ...m 10 3 lbf ft 1 5 lbf ft Hexagon screwdriver 6 Torque wrench Hexagon screwdriver socket 6 Mount the engine on the engine stand Mount the engine on the drive side 1 of the engine stand See chapter 3 3...

Page 152: ...r 3 3 1 Mount the engine on the drive side of the engine stand Preparation Remove the oil cooler See chapter 050 03 01 Removing oil cooler 050 03 01 Removing oil cooler 050 03 02 Installing oil cooler...

Page 153: ...3 Sealing cover oil cooler bracket Unscrew 14 bolts 2 The cover oil cooler bracket is caulked with a silicone liquid seal Remove the cover oil cooler bracket 3 010 02 2 Oil cooler bracket 010 02 2 03...

Page 154: ...0 Rev 1 2 406555 010 5 4 Clean the sealing surface 5 with sealing surface cleaner Clean the sealing surface 4 with sealing surface cleaner 010 02 2 Oil cooler bracket 010 02 2 03 Sealing cover oil coo...

Page 155: ...E850 Rev 1 2 406555 010 6 7 Apply the silicone liquid seal 6 without gaps as illustrated Hold the cover oil cooler bracket 7 in position 010 02 2 Oil cooler bracket 010 02 2 03 Sealing cover oil coole...

Page 156: ...ing torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft Screw in 13 bolts 9 Tightening torque 5 Nm 1 Nm 3 7 lbf ft 0 7 lbf ft Completion Install the oil cooler See chapter 050 03 02 Installing oil cooler 010 02 2...

Page 157: ...75 RLF MPE850 Rev 1 2 406555 020 020 01 Crankshaft 020 01 Crankshaft 020 Crank drive...

Page 158: ...ing ignition coils 030 01 01 Removing valve cover 050 03 01 Removing oil cooler 010 02 1 01 Removing oil cooler bracket 020 03 01 Removing crankshaft cover 050 02 03 Removing coolant pump 090 02 01 Re...

Page 159: ...Remove the intake manifold See chapter 070 01 01 Removing intake manifold Remove the starter See chapter 090 01 01 Removing starter 020 01 Crankshaft 020 01 01 Removing crank drive Remove the oil cool...

Page 160: ...5 Remove the generator See chapter 090 02 01 Removing generator Remove the oil pressure pump See chapter 110 02 01 Removing oil pressure pump 020 01 Crankshaft 020 01 01 Removing crank drive Turning e...

Page 161: ...rection shown 6 until the marking 9 ends flush with the crankcase halves 8 Check whether the camshaft is at the crossing point The position of the camshaft is as illustrated 11 The marking 10 ends flu...

Page 162: ...firmly attached to the cylinder head Do not turn the cylinder head Remove the cylinder head 17 Turning engine in the engine stand Lift the engine See chapter 3 2 Lift and transport the engine Remove...

Page 163: ...LF MPE850 Rev 1 2 406555 020 18 19 20 Turn the engine 180 Unscrew 4 bolts M6 18 020 01 Crankshaft 020 01 01 Removing crank drive Unscrew 5 bolts M8 19 Pull the oil pressure valve 20 out using a bar ma...

Page 164: ...ne liquid seal Remove the lower case 21 020 01 Crankshaft 020 01 01 Removing crank drive Turn the crankshaft 22 180 Mark the cylinder assignment and installation position on the piston con rod con rod...

Page 165: ...83 RLF MPE850 Rev 1 2 406555 020 25 26 27 28 Pull the pistons 25 out 020 01 Crankshaft 020 01 01 Removing crank drive Remove the balance shaft 26 Remove the crankshaft 27 Remove the oil seal 28...

Page 166: ...Installing chain tensioner 110 02 02 Installing oil pressure pump 090 02 02 Installing generator 050 02 04 Installing coolant pump 020 03 02 Installing crankshaft cover 010 02 1 02 Installing oil coo...

Page 167: ...the con rod bearing 020 01 Crankshaft 020 01 02 Installing crank drive Installation instructions for the con rod bearings NOTICE Serious damage to bearings due to con rod bearing shells being install...

Page 168: ...ressor Displace the ring joints 6 of the three piston rings 120 Turn the engine 180 When replacing the crankshaft check the main bearing play and con rod bearing play See chapter 020 01 09 Checking co...

Page 169: ...rt the balance shaft Observe the marking 11 The marking ends flush with the crankcase 020 01 Crankshaft 020 01 02 Installing crank drive Insert con rod covers 10 Replace the con rod bolts 9 Tighten th...

Page 170: ...rn the crankshaft 14 180 Clean the sealing surface 15 with sealing surface cleaner 020 01 Crankshaft 020 01 02 Installing crank drive Aligning the balance shaft to the crankshaft Observe the marking 1...

Page 171: ...17 17 18 18 18 18 Clean the sealing surface 16 with sealing surface cleaner Check if the centering pins 17 are installed Apply the silicone liquid seal 18 without gaps as illustrated 020 01 Crankshaf...

Page 172: ...20 on Checking the alignment of the balance shaft crankshaft Check the markings 19 Both markings appear as shown Assemble the oil pressure valve in the sequence as illustrated 21 Insert the oil press...

Page 173: ...5 bolts M8 23 Tightening torque 23 Nm 2 Nm 17 lbf ft 1 5 lbf ft Screw in 4 bolts M6 24 Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft Turn the engine 180 Check if the centering pins 25 are install...

Page 174: ...on Observe the installation position Exhaust side 27 Inscription 28 Centering pins 29 Oil filter 30 Tighten the nuts 34 in the sequence as illustrated 35 in three stages Tightening torque First stage...

Page 175: ...d transport the engine Remove the engine from the engine stand Turn the engine and mount on the engine stand Suitable mounting points M10 36 Depth of thread 30 mm The oil seal 37 can be found in the s...

Page 176: ...the guiding sleeve 41 onto crankshaft 42 Use the M10x1x35 bolts you removed on the rotor Screw in the bolts 43 Hold the sliding sleeve 44 in position on the oil seal 45 Use a M10x1x35 bolt that you r...

Page 177: ...e sliding sleeve 48 Unscrew the bolts 52 Remove the guiding sleeve 50 Check if the oil seal 51 is tilted If the oil seal is tilted it must be replaced Setting valve timing Hold the TDC adjusting tool...

Page 178: ...ction shown 56 until the marking 59 ends flush with the crankcase halves 58 Install the timing chain See chapter 040 01 07 Installing timing chain Install the chain tensioner See chapter 040 01 03 Ins...

Page 179: ...urn the crankshaft on the TDC adjusting tool 63 several times in the direction shown 62 The crankshaft can be turned If the crankshaft does not turn check the alignment of the balance shaft crankshaft...

Page 180: ...lush with the cross bar If the camshaft does not appear as shown set the valve timing again or If the camshaft does not appear as shown several times replace the timing chain See chapter 040 01 08 Rep...

Page 181: ...thread 74 34 mm Install the coolant pump See chapter 050 02 04 Installing coolant pump Install the crankshaft cover See chapter 020 03 02 Installing crankshaft cover Install the oil cooler bracket Se...

Page 182: ...850 Rev 1 2 406555 020 020 01 Crankshaft 020 01 02 Installing crank drive Install the starter See chapter 090 01 02 Installing starter Install the intake manifold See chapter 070 01 02 Installing inta...

Page 183: ...Checking main bearing play Check the con rod bearing play See chapter 020 01 09 Checking con rod bearing play Completion Install the crank drive See chapter 020 01 02 Installing crank drive 020 01 01...

Page 184: ...tensioner 040 01 06 Removing timing chain 050 02 04 Installing coolant pump 020 03 02 Installing crankshaft cover 010 02 1 02 Installing oil cooler bracket 050 03 02 Installing oil cooler 040 01 07 In...

Page 185: ...e cover See chapter 030 01 01 Removing valve cover Remove the intake manifold See chapter 070 01 01 Removing intake manifold Remove the starter See chapter 090 01 01 Removing starter Remove the oil co...

Page 186: ...bolts you removed on the rotor Screw in the bolts 5 Remove the generator See chapter 090 02 01 Removing generator Remove the oil pressure pump See chapter 110 02 01 Removing oil pressure pump Turning...

Page 187: ...direction shown 6 until the marking 9 ends flush with the crankcase halves 8 Check whether the camshaft is at the crossing point The position of the camshaft is as illustrated 11 The marking 10 ends f...

Page 188: ...er firmly attached to the cylinder head Do not turn the cylinder head Remove the cylinder head 17 Turning engine in the engine stand Lift the engine See chapter 3 2 Lift and transport the engine Remov...

Page 189: ...F MPE850 Rev 1 2 406555 020 18 19 20 020 01 Crankshaft 020 01 04 Replacing balance shaft Turn the engine 180 Unscrew 4 bolts M6 18 Unscrew 5 bolts M8 19 Pull the oil pressure valve 20 out using a bar...

Page 190: ...2 23 21 21 Remove the balance shaft 22 Remove the bearing shells balance shaft 23 Remove the oil seal 21 020 01 Crankshaft 020 01 04 Replacing balance shaft The crankcase is caulked with a silicone li...

Page 191: ...ightly with engine oil Insert the main bearing shells in crankcase Replace the balance shaft 25 Insert the balance shaft Aligning the balance shaft to the crankshaft Observe the markings 26 Both marki...

Page 192: ...29 28 30 30 30 30 Check if the centering pins 29 are installed Clean the sealing surface 28 with sealing surface cleaner 020 01 Crankshaft 020 01 04 Replacing balance shaft Apply the silicone liquid...

Page 193: ...32 on Checking the alignment of the balance shaft crankshaft Check the markings 31 Both markings appear as shown 020 01 Crankshaft 020 01 04 Replacing balance shaft Assemble the oil pressure valve in...

Page 194: ...5 bolts M8 35 Tightening torque 23 Nm 2 Nm 17 lbf ft 1 5 lbf ft 020 01 Crankshaft 020 01 04 Replacing balance shaft Screw in 4 bolts M6 36 Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft Turn the e...

Page 195: ...on Observe the installation position Exhaust side 39 Inscription 40 Centering pins 41 Oil filter 42 020 01 Crankshaft 020 01 04 Replacing balance shaft Put the cylinder head 43 on Observe the installa...

Page 196: ...nd transport the engine Remove the engine from the engine stand Turn the engine and mount on the engine stand Suitable mounting points M10 48 Depth of thread 30 mm The oil seal 49 can be found in the...

Page 197: ...the sliding sleeve 56 in position on the oil seal 57 Use a M10x1x35 bolt that you removed from the rotor Screw in the bolt 58 Screw in the bolt 59 until the oil seal is flush with the crankcase Slide...

Page 198: ...he sliding sleeve 60 Unscrew the bolts 64 Remove the guiding sleeve 62 Check if the oil seal 63 is tilted If the oil seal is tilted it must be replaced Setting valve timing Hold the TDC adjusting tool...

Page 199: ...ection shown 68 until the marking 71 ends flush with the crankcase halves 70 Install the timing chain See chapter 040 01 07 Installing timing chain Install the chain tensioner See chapter 040 01 03 In...

Page 200: ...Turn the crankshaft on the TDC adjusting tool 75 several times in the direction shown 74 The crankshaft can be turned If the crankshaft does not turn check the alignment of the balance shaft crankshaf...

Page 201: ...flush with the cross bar If the camshaft does not appear as shown set the valve timing again or If the camshaft does not appear as shown several times replace the timing chain See chapter 040 01 08 Re...

Page 202: ...f thread 86 34 mm Install the coolant pump See chapter 050 02 04 Installing coolant pump Install the crankshaft cover See chapter 020 03 02 Installing crankshaft cover Install the oil cooler bracket S...

Page 203: ...50 Rev 1 2 406555 020 020 01 Crankshaft 020 01 04 Replacing balance shaft Install the starter See chapter 090 01 02 Installing starter Install the intake manifold See chapter 070 01 02 Installing inta...

Page 204: ...components are installed swapped over they no longer fit together well When removing the components mark the cylinder assignment and installation position Install all components back into the place f...

Page 205: ...10 01 01 Removing suction pump cover Turn the engine 180 Remove the cylinder head See chapter 030 02 01 Removing cylinder head Removing pistons and con rods Turn the engine 180 Turn the crankshaft on...

Page 206: ...124 RLF MPE850 Rev 1 2 406555 020 6 Pull the pistons 6 out 020 01 Crankshaft 020 01 05 Removing pistons and con rods...

Page 207: ...e components are installed swapped over they no longer fit together well When removing the components mark the cylinder assignment and installation position Install all components back into the place...

Page 208: ...tallation instructions for the con rod bearings NOTICE Serious damage to bearings due to con rod bearing shells being installed incorrectly Insert the con rod bearing shells 2 centered on the con rod...

Page 209: ...ngine 180 Install the cylinder head See chapter 030 02 02 Installing cylinder head Turn the engine 180 Install the suction pump cover See chapter 110 01 02 Installing suction pump cover Install the va...

Page 210: ...serious eye injuries Wear protective glasses along with any bystanders Bearing damage increased wear and leaks due to installing components swapped over All components in the crank drive are inserted...

Page 211: ...row on top 8 and inside arrow 9 in the direction of the starter 10 Replace the piston 5 Install the circlip 7 using a litte screwdriver Pull the piston pin 6 out Hold the con rod 4 in position Observe...

Page 212: ...0 RLF MPE850 Rev 1 2 406555 020 12 11 Coat the piston pin 12 lightly with engine oil Slide in the piston pin Install the circlip 11 using a litte screwdriver 020 01 Crankshaft 020 01 07 Replacing pist...

Page 213: ...ve glasses along with any bystanders Bearing damage increased wear and leaks due to installing components swapped over All components in the crank drive are inserted together If the components are ins...

Page 214: ...e con rod in position Coat the piston pin 5 lightly with engine oil Slide in the piston pin Install the circlip 6 using a litte screwdriver Check the con rod bearing play See chapter 020 01 09 Checkin...

Page 215: ...ue wrench Reversible ratchet 12 point socket wrench 12 Angle indicator Information Con rod bolts are extension bolt and must be replaced after removal However when measuring the con rod bearing play y...

Page 216: ...Tightening torque First stage 10 Nm 7 4 lbf ft Second stage 20 Nm 14 8 lbf ft Third stage 115 Unscrew the con rod bolts Remove the con rod Installation instructions for the con rod bearings NOTICE Se...

Page 217: ...con rod bearing play is incorrect repeat the process using another con rod bearing shell thickness The con rod bearing shells are marked on the side 9 in color Each color represent a specific thickne...

Page 218: ...hells 1 in crankcase Affix the precision clearance gauges to all bearing positions of the crankshaft 2 according to the manufacturer s instructions Insert the crankshaft 3 Bearing damage increased wea...

Page 219: ...MPE850 Rev 1 2 406555 020 4 6 5 Put the lower case 4 on Insert the oil pressure valve 6 Assemble the oil pressure valve in the sequence as illustrated 5 020 01 Crankshaft 020 01 10 Checking main beari...

Page 220: ...asuring the main bearing play you can use the removed cylinder head gasket Put the cylinder head gasket on Observe the installation position 8 Exhaust side 9 Inscription 10 Centering pins 11 Oil filte...

Page 221: ...nuts 16 in the sequence as illustrated 17 in three stages Tightening torque First stage 20 Nm 3 Nm 14 8 lbf ft 2 2 lbf ft Second stage 40 Nm 3 Nm 29 5 lbf ft 2 2 lbf ft Third stage 180 4 Unscrew the n...

Page 222: ...40 RLF MPE850 Rev 1 2 406555 020 21 20 19 Pull the oil pressure valve 21 out using a bar magnet Unscrew 5 bolts M8 20 Remove the cylinder head 19 020 01 Crankshaft 020 01 10 Checking main bearing play...

Page 223: ...04 mm 0 06 mm If the main bearing play is incorrect repeat the process using another main bearing shell thickness The main bearing shells are marked on the side 24 in color Each color represent a spe...

Page 224: ...142 RLF MPE850 Rev 1 2 406555 020 020 02 Stub shaft 020 02 Stub shaft...

Page 225: ...ft Hexagon screwdriver 8 Reversible ratchet Hexagon screwdriver socket 7 Mount the engine on the engine stand Mount the engine across from the drive side 1 of the engine stand See chapter 3 3 2 Mount...

Page 226: ...144 RLF MPE850 Rev 1 2 406555 020 6 7 4 5 Remove the rotor 6 Remove the stub shaft 7 Unscrew the bolts 4 Remove the locking tool crankshaft 5 020 02 Stub shaft 020 02 01 Removing stub shaft...

Page 227: ...olts on the rotor have a micro encapsulated coating During fastening the bolt the microcapsules will burst and the contained adhesive and curing agent are released and mixed The coating begins to cure...

Page 228: ...ning torque 60 Nm 10 Nm 44 3 lbf ft 7 4 lbf ft Remove the locking tool crankshaft 9 Replace the bolts 5 Screw in the bolts by hand Do not tighten Hold the locking tool crankshaft 6 on rotor Screw in t...

Page 229: ...147 RLF MPE850 Rev 1 2 406555 020 020 03 Crankshaft cover 020 03 Crankshaft cover...

Page 230: ...the engine stand Mount the engine on the drive side 1 of the engine stand See chapter 3 3 1 Mount the engine on the drive side of the engine stand Unscrew the bolt 3 Remove the cover 2 020 03 Cranksha...

Page 231: ...crewdriver socket T30 Insert the cover 2 Screw in the bolt 3 Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft Replace the gasket 1 Coat the gasket lightly with petroleum jelly 020 03 Crankshaft cover...

Page 232: ...150 RLF MPE850 Rev 1 2 406555 030 030 01 Valve cover 030 01 Valve cover 030 Cylinder head...

Page 233: ...crew the bolts 1 Remove the valve cover 2 Preparation Remove the ignition coils See chapter 030 01 04 Removing ignition coils 030 01 04 Removing ignition coils Hexagon screwdriver 5 030 01 Valve cover...

Page 234: ...1 5 lbf ft Installing valve cover Replace the valve cover seals 1 Completion Install the ignition coils See chapter 030 01 05 Installing ignition coils 030 01 05 Installing ignition coils Torque wrenc...

Page 235: ...ping These bolts can be removed and installed again at any time after the initial installation Coat the o ring 4 on the sensor camshaft 3 lightly with petroleum jelly Replace the valve cover 1 Affix t...

Page 236: ...ress down on the bolt 5 and screw in Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft Put the valve cover 9 on Apply Anti Seize assembly paste to all bolts 10 Screw in the bolts in the sequence as il...

Page 237: ...No threads are cut in the new valve cover Use the self tapping bolts included with the valve cover Lightly press down on the bolts 13 and screw in Observe the arrangement of the serrated lock washers...

Page 238: ...156 RLF MPE850 Rev 1 2 406555 030 1 2 Unscrew the bolts 1 Pull the ignition coils 2 out Hexagon screwdriver 5 030 01 Valve cover 030 01 04 Removing ignition coils 030 01 04 Removing ignition coils...

Page 239: ...ert the ignition coils 3 Replace the serrated lock washers 1 Screw in the bolts 2 Observe the arrangement of the serrated lock washers and washers Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft 030...

Page 240: ...158 RLF MPE850 Rev 1 2 406555 030 1 2 Unscrew the bolt 1 Pull the sensor camshaft 2 out Hexagon screwdriver 5 030 01 06 Removing sensor camshaft 030 01 Valve cover 030 01 06 Removing sensor camshaft...

Page 241: ...Hexagon screwdriver socket 5 Insert the sensor camshaft 3 Screw in the bolt 2 Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft Coat the o ring 1 lightly with petroleum jelly 030 01 07 Installing sen...

Page 242: ...160 RLF MPE850 Rev 1 2 406555 030 030 02 Cylinder head 030 02 Cylinder head...

Page 243: ...amage and cause the crank drive to seize When removing small components always cover the chain channel Mount the engine on the engine stand Mount the engine across from the drive side 1 of the engine...

Page 244: ...following figure Remove the chain tensioner See chapter 040 01 02 Removing chain tensioner Open the timing chain See chapter 040 01 04 Opening timing chain with chain breaking tool Secure the ends of...

Page 245: ...06555 030 8 9 Remove the cylinder head 9 Unscrew the nuts 8 The rocker arm and cross bars are no longer firmly attached to the cylinder head Do not turn the cylinder head 030 02 Cylinder head 030 02 0...

Page 246: ...centering pins 1 are installed Replace the cylinder head gasket 2 Put the cylinder head gasket on Observe the installation position Exhaust side 3 Inscription 4 Centering pins 5 Oil filter 6 040 01 05...

Page 247: ...lbf ft 2 2 lbf ft Second stage 40 Nm 3 Nm 29 5 lbf ft 2 2 lbf ft Third stage 180 4 Setting valve timing Check whether the crankshaft is at TDC Top Dead Center The markings 13 fit together If the mark...

Page 248: ...hown set the valve timing again or If the camshaft does not appear as shown replace the timing chain See chapter 040 01 08 Replacing timing chain Checking valve timing Turn the crankshaft on a bolt 17...

Page 249: ...e cover See chapter 030 01 02 Installing valve cover Install the ignition coils See chapter 030 01 05 Installing ignition coils Install the intake manifold See chapter 070 01 02 Installing intake mani...

Page 250: ...or cylinder head Operating the engine when there are small components in the crankcase and cylinder head can result in serious damage and cause the crank drive to seize When removing small components...

Page 251: ...ew the bolt 5 Remove the bracket 4 Unscrew the fitting 6 Replacing cylinder head Unscrew the bolts 1 Remove the bracket 2 Unscrew the switch oil pressure 3 Unscrew the studs 7 using a stud extractor 0...

Page 252: ...170 RLF MPE850 Rev 1 2 406555 030 10 9 8 Remove the sleeves 10 Remove the fuel rail 9 Unscrew the bolts 8 030 02 Cylinder head 030 02 03 Replacing cylinder head...

Page 253: ...olts 11 Remove the camshaft 14 Replace the cylinder head 15 Remove the bearing cap 13 using the remover bearing cap 12 Information The hole in the remover bearing cap is provided for mounting a slide...

Page 254: ...the 2nd cylinder end only Observe the installation position Inscription 20 Intake side 21 Coat the camshaft on the bearing surfaces 19 lightly with engine oil Unscrew the bolts 16 Remove the bearing...

Page 255: ...he bearing cap being installed incorrectly The bearing surfaces for supporting the camshaft in the cylinder head and in the bearing cap are processed together Therefore only use the bearing cap origin...

Page 256: ...i Seize assembly paste to all studs 30 Screw in the studs using a stud extractor Tightening torque 16 Nm 4 Nm 11 8 lbf ft 3 lbf ft Screw in the bolts 28 Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf...

Page 257: ...rque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft 030 02 Cylinder head 030 02 03 Replacing cylinder head Screw in a new plug 35 Tightening torque 6 Nm 2 Nm 4 4 lbf ft 1 5 lbf ft Coat the thread on the switch oil p...

Page 258: ...ad See chapter 030 02 02 Installing cylinder head Install the valve cover See chapter 030 01 02 Installing valve cover Install the ignition coils See chapter 030 01 05 Installing ignition coils Instal...

Page 259: ...See chapter 030 01 04 Removing ignition coils 030 01 04 Removing ignition coils Reversible ratchet Spark plug wrench 030 02 Cylinder head 030 02 04 Removing spark plugs 030 02 04 Removing spark plugs...

Page 260: ...ing ignition coils 030 01 05 Installing ignition coils Torque wrench Spark plug wrench 030 02 Cylinder head 030 02 05 Installing spark plugs 030 02 05 Installing spark plugs Installing spark plugs Scr...

Page 261: ...179 RLF MPE850 Rev 1 2 406555 030 1 Unscrew the switch oil pressure 1 Open end wrench 24 030 02 Cylinder head 030 02 06 Removing switch oil pressure 030 02 06 Removing switch oil pressure...

Page 262: ...h 24 Thread sealant 030 02 Cylinder head 030 02 07 Installing switch oil pressure 030 02 07 Installing switch oil pressure Coat the thread on the switch oil pressure 1 with thread sealant Screw in the...

Page 263: ...181 RLF MPE850 Rev 1 2 406555 030 1 Unscrew the fitting 1 Open end wrench 12 030 02 08 Removing fitting 030 02 Cylinder head 030 02 08 Removing fitting...

Page 264: ...06555 030 2 1 Replace the seal 1 Screw in the fitting 2 Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft Torque wrench Insert open end wrench 12 030 02 09 Installing fitting 030 02 Cylinder head 030...

Page 265: ...ocket 4 5 Plug across from the drive side 1 Plugs 2 exhaust side 030 02 Cylinder head 030 02 10 Replacing plugs 030 02 10 Replacing plugs Replacing plug across from the drive side Unscrew the plug 1 R...

Page 266: ...cing plugs Replacing plugs drive side Unscrew the plugs 1 Replace the plugs Screw in the plugs Tightening torque 6 Nm 2 Nm 4 4 lbf ft 1 5 lbf ft Replacing plug drive side Unscrew the plug 1 Replace th...

Page 267: ...185 RLF MPE850 Rev 1 2 406555 030 See chapter 040 01 01 Replacing camshaft 030 02 Cylinder head 030 02 11 Mounting camshaft 030 02 11 Mounting camshaft...

Page 268: ...186 RLF MPE850 Rev 1 2 406555 040 040 01 Camshaft 040 Valve train 040 01 Camshaft...

Page 269: ...valve train are inserted together If the components are installed swapped over they no longer fit together well Install all components back into the place from which they were removed 070 01 01 Remov...

Page 270: ...ng figure Check whether the camshaft is at the crossing point The position of the camshaft is as illustrated 5 The marking 4 ends flush with the cross bar Preparation Remove the intake manifold See ch...

Page 271: ...e valve adjustment shims 10 using a bar magnet Unscrew the bolts 11 Remove the chain tensioner See chapter 040 01 02 Removing chain tensioner Open the timing chain See chapter 040 01 04 Opening timing...

Page 272: ...190 RLF MPE850 Rev 1 2 406555 040 12 13 14 15 Remove the bearing cap 12 using the remover bearing cap 13 Remove the camshaft 14 Remove the cylinder head 15 040 01 Camshaft 040 01 01 Replacing camshaft...

Page 273: ...4 The cylinder head gasket can be found in the spare parts catalog in chapter 030 02 Cylinder head Replace the cylinder head gasket 17 Put the cylinder head gasket on Observe the installation position...

Page 274: ...bearing surfaces 25 lightly with engine oil NOTICE Bearing damage due to the bearing cap being installed incorrectly The bearing surfaces for supporting the camshaft in the cylinder head and in the be...

Page 275: ...tages Tightening torque First stage 20 Nm 3 Nm 14 8 lbf ft 2 2 lbf ft Second stage 40 Nm 3 Nm 29 5 lbf ft 2 2 lbf ft Third stage 180 4 Screw in the bolts 30 Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5...

Page 276: ...n tensioner See chapter 040 01 03 Installing chain tensioner Check whether the camshaft is at the crossing point The position of the camshaft is as illustrated 38 The marking 37 ends flush with the cr...

Page 277: ...See chapter 070 01 02 Installing intake manifold Check whether the camshaft is at the crossing point The position of the camshaft is as illustrated 42 The marking 41 ends flush with the cross bar If t...

Page 278: ...n end wrench 27 If the chain tensioner is not accessible remove the throttle body See chapter 070 02 01 Removing throttle body Unscrew the chain tensioner 1 Information The following chapter only desc...

Page 279: ...ch 27 Replace the chain tensioner 1 Screw in the chain tensioner Tightening torque 40 Nm 5 Nm 29 5 lbf ft 3 7 lbf ft Information The following chapter only describes how to install the chain tensioner...

Page 280: ...r see the spike 4 Screw in the bolt 5 slightly into the chain breaking tool 6 Hold the chain breaking tool in position on a bolt 7 of the chain link Information The following chapter only describes ho...

Page 281: ...ly seated Screw in the bolt 9 using a open end wrench until the bolt of the chain link is pushed out Unscrew the bolt Unscrew the bolt 10 and remove chain breaking tool Repeat the process on the secon...

Page 282: ...Insert the chain link 5 Press the plate 6 onto the chain link using the universal pliers Hold the chain breaking tool on a bolt 7 of the timing chain link Information The following chapter only descri...

Page 283: ...ool Repeat the process on the second bolt 10 of the chain link Screw in the bolt 8 until the chain breaking tool is firmly seated Screw in the bolt using a open end wrench until the bolt of the chain...

Page 284: ...are removed Mark the running direction of the timing chain 1 Remove the chain tensioner See chapter 040 01 02 Removing chain tensioner Open the timing chain See chapter 040 01 04 Opening timing chain...

Page 285: ...the open ends of the timing chain Information The following chapter only describes how to install the timing chain Always observe the instructions in the chapters for the timing chain and valve timin...

Page 286: ...rn the engine 180 Close the timing chain See chapter 040 01 05 Closing timing chain with chain breaking tool Install the chain tensioner See chapter 040 01 03 Installing chain tensioner 040 01 Camshaf...

Page 287: ...and See chapter 3 3 2 Mount the engine across from the drive side of the engine stand 110 01 01 Removing suction pump cover 030 01 04 Removing ignition coils 030 01 01 Removing valve cover 040 01 02 R...

Page 288: ...e chapter 040 01 04 Opening timing chain with chain breaking tool Check whether the camshaft is at the crossing point The position of the camshaft is as illustrated 5 The marking 4 ends flush with the...

Page 289: ...nsert the timing chain as illustrated Insert the chain link 9 on the open ends of the timing chain Turn the engine 180 Setting valve timing Check if the crankshaft is at TDC Top Dead Center The markin...

Page 290: ...t in the direction shown until the camshaft stops as shown in the following figure Check whether the camshaft is at the crossing point The position of the camshaft is as illustrated 13 The marking 12...

Page 291: ...ee chapter 030 01 02 Installing valve cover Install the ignition coils See chapter 030 01 05 Installing ignition coils Turn the engine 180 Install the suction pump cover See chapter 110 01 02 Installi...

Page 292: ...t 1 Remove the chain rail 2 Replace the chain rail Insert the chain rail Screw in the bolt Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft Torx screwdriver T30 Torque wrench Torx screwdriver socket...

Page 293: ...the bolts 1 Remove the chain guide 2 Replace the chain guide Insert the chain guide Screw in the bolts Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft Hexagon screwdriver 5 Torque wrench Hexagon scr...

Page 294: ...er See chapter 030 01 01 Removing valve cover Checking valve timing Hold the TDC adjusting tool 3 in position Observe the positioning pin and positioning bore 2 Use the M10x1x35 bolts you removed on t...

Page 295: ...r the camshaft is at the crossing point The position of the camshaft is as illustrated 10 The marking 9 ends flush with the cross bar If the camshaft does not appear as shown set the valve timing See...

Page 296: ...l the valve cover See chapter 030 01 02 Installing valve cover Install the ignition coils See chapter 030 01 05 Installing ignition coils Install the generator See chapter 090 02 02 Installing generat...

Page 297: ...on Observe the positioning pin and positioning bore 2 Use the M10x1x35 bolts you removed on the rotor Screw in the bolts 4 090 02 01 Removing generator 030 01 04 Removing ignition coils 030 01 01 Remo...

Page 298: ...the chain tensioner See chapter 040 01 02 Removing chain tensioner Open the timing chain See chapter 040 01 04 Opening timing chain with chain breaking tool Use a hexagon screwdriver socket 8 and rev...

Page 299: ...tall the valve cover See chapter 030 01 02 Installing valve cover Install the ignition coils See chapter 030 01 05 Installing ignition coils Install the generator See chapter 090 02 02 Installing gene...

Page 300: ...218 RLF MPE850 Rev 1 2 406555 040 040 02 Rocker arms 040 02 Rocker arms...

Page 301: ...nk drive to seize When removing small components always cover the chain channel Preparation Remove the ignition coils See chapter 030 01 04 Removing ignition coils Remove the valve cover See chapter 0...

Page 302: ...k whether the camshaft is at the crossing point The position of the camshaft is as illustrated The marking 4 ends flush with the cross bar All rocker arms 5 on the cylinder have a certain amount of pl...

Page 303: ...he 2nd cylinder end only Check whether the camshaft is at the crossing point The position of the camshaft is as illustrated The inscription 8 is not visible All rocker arms 9 on the cylinder have a ce...

Page 304: ...with the section Checking valve play on the 1st cylinder Checking valve play on the 2nd cylinder Turn the crankshaft on a bolt 16 in the direction shown 15 until the camshaft stops as shown in the fol...

Page 305: ...shim Checking valve play on the 1st cylinder Turn the crankshaft on a bolt 21 in the direction shown 20 until the camshaft stops as shown in the following figure The camshaft is marked at the 2nd cyli...

Page 306: ...0 2 0 3 mm If the valve play of one or more valves is not right remove the rocker arm and replace the valve adjustment shim Completion Install the valve cover See chapter 030 01 02 Installing valve c...

Page 307: ...225 RLF MPE850 Rev 1 2 406555 040 040 03 Valves 040 03 Valves...

Page 308: ...mall components in the engine or cylinder head Operating the engine when there are small components in the crankcase and cylinder head can result in serious damage and cause the crank drive to seize W...

Page 309: ...linder head See chapter 030 02 01 Removing cylinder head Removing valve Remove the rocker arms and cross bars 2 Remove the valve adjustment shim 3 using a bar magnet Install the valve spring compresso...

Page 310: ...228 RLF MPE850 Rev 1 2 406555 040 6 7 8 10 9 Remove the spring cup 6 valve spring 7 and spring pad 8 Pull the valve 10 out Remove the valve stem seal 9 040 03 Valves 040 03 01 Removing valve...

Page 311: ...ll all components back into the place from which they were removed Engine damage from small components in the engine or cylinder head Operating the engine when there are small components in the crankc...

Page 312: ...Insert the spring pad 6 valve spring 5 and spring cup 4 Install the valve spring compressor according to the manufacturer s instructions Press the valve spring 8 together using the valve spring compre...

Page 313: ...th the section Checking valve play on the 2nd cylinder or Continue with the section Checking valve play on the 1st cylinder Checking valve play on the 2nd cylinder Turn the crankshaft on a bolt 12 in...

Page 314: ...shim Checking valve play on the 1st cylinder Turn the crankshaft on a bolt 17 in the direction shown 16 until the camshaft stops as shown in the following figure The camshaft is marked at the 2nd cyli...

Page 315: ...over See chapter 030 01 02 Installing valve cover Install the ignition coils See chapter 030 01 05 Installing ignition coils Install the intake manifold See chapter 070 01 02 Installing intake manifol...

Page 316: ...234 RLF MPE850 Rev 1 2 406555 050 050 01 Thermostat housing 050 01 Thermostat housing 050 Cooling system...

Page 317: ...The thermostat housing is caulked with a silicone liquid seal Remove the thermostat housing 3 050 01 01 Removing thermostat housing 050 01 Thermostat housing 050 01 01 Removing thermostat housing The...

Page 318: ...er Silicone liquid seal Clean the sealing surface 1 with sealing surface cleaner Clean the sealing surface 2 with sealing surface cleaner Apply the silicone liquid seal 3 without gaps as illustrated 0...

Page 319: ...ition Screw in 10 bolts 5 Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft 050 01 Thermostat housing 050 01 02 Installing thermostat housing The bolt is an additional part and not installed in every...

Page 320: ...238 RLF MPE850 Rev 1 2 406555 050 1 2 Unscrew 2 bolts 1 Torx screwdriver T30 Remove the fitting 2 050 01 Thermostat housing 050 01 03 Removing fitting 050 01 03 Removing fitting...

Page 321: ...torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft Petroleum jelly Torque wrench Torx screwdriver socket T30 Replace the o ring 1 Coat the o ring lightly with petroleum jelly Insert the fitting 2 050 01 Thermost...

Page 322: ...ing thermostat Remove the thermostat 1 and distance washer 2 Preparation Remove the fitting See chapter 050 01 03 Removing fitting 050 01 Thermostat housing 050 01 05 Removing thermostat 050 01 05 Rem...

Page 323: ...4 Installing fitting 050 01 Thermostat housing 050 01 06 Installing thermostat 050 01 06 Installing thermostat Installing thermostat Put a new distance washer 2 on thermostat 1 Insert the thermostat 4...

Page 324: ...or coolant temperature Screw in the sensor coolant temperature Tightening torque 18 Nm 7 Nm 13 3 lbf ft 5 2 lbf ft Open end wrench 19 Torque wrench Insert open end wrench 19 050 01 Thermostat housing...

Page 325: ...ce the plug Screw in the plug Tightening torque 14 Nm 2 Nm 10 3 lbf ft 1 5 lbf ft Hexagon screwdriver 7 Torque wrench Hexagon screwdriver socket 7 050 01 Thermostat housing 050 01 08 Replacing plug th...

Page 326: ...ev 1 2 406555 050 1 2 Open the hose clamp 1 Remove the closing cap 2 Hexagon nut driver 7 050 01 09 Removing closing cap thermostat housing 050 01 Thermostat housing 050 01 09 Removing closing cap the...

Page 327: ...ing cap 2 Close the hose clamp 1 Tightening torque 3 Nm 0 5 Nm 2 2 lbf ft 0 4 lbf ft Torque wrench 6 point socket wrench 7 050 01 Thermostat housing 050 01 10 Installing closing cap thermostat housing...

Page 328: ...246 RLF MPE850 Rev 1 2 406555 050 050 02 Coolant pump 050 02 Coolant pump...

Page 329: ...ter 010 02 1 01 Removing oil cooler bracket Mount the engine on the engine stand Mount the engine on the drive side 1 of the engine stand See chapter 3 3 1 Mount the engine on the drive side of the en...

Page 330: ...248 RLF MPE850 Rev 1 2 406555 050 5 4 6 Unscrew the nut 4 Remove the impeller 5 Remove the locking tool crankshaft 6 050 02 Coolant pump 050 02 01 Removing impeller...

Page 331: ...Installing impeller Hold the locking tool crankshaft 1 on rotor Screw in the bolt 2 and washer 010 02 1 02 Installing oil cooler bracket 050 03 02 Installing oil cooler Locking tool crankshaft Hexagon...

Page 332: ...ion Install the oil cooler bracket See chapter 010 02 1 02 Installing oil cooler bracket Install the oil cooler See chapter 050 03 02 Installing oil cooler Remove the locking tool crankshaft 5 050 02...

Page 333: ...2 on rotor Screw in the bolt 3 and washer Preparation Remove the oil cooler See chapter 050 03 01 Removing oil cooler Remove the oil cooler bracket See chapter 010 02 1 01 Removing oil cooler bracket...

Page 334: ...50 Rev 1 2 406555 050 6 5 4 7 Unscrew the nut 4 Remove the impeller 5 Unscrew the water pump axle 6 using a open end wrench Remove the locking tool crankshaft 7 050 02 Coolant pump 050 02 03 Removing...

Page 335: ...ocking tool crankshaft 1 on rotor Screw in the bolt 2 and washer 010 02 1 02 Installing oil cooler bracket 050 03 02 Installing oil cooler Petroleum jelly Locking tool crankshaft Hexagon screwdriver 8...

Page 336: ...ng bracket 4 Coat the gasket 5 and o ring 6 lightly with petroleum jelly Coat the inside of the oil seal 7 lightly with petroleum jelly Insert the sealing bracket 8 Screw in the guide 9 using a open e...

Page 337: ...10 onto guide Hold the sliding sleeve 11 in position Screw on the nut 12 Screw in the nut 13 using a open end wrench until the slide ring seal is inserted completely Tightening torque 10 Nm 1 Nm 7 4...

Page 338: ...4 16 Insert the impeller 17 Screw on the nut 18 Tightening torque 9 Nm 2 Nm 6 6 lbf ft 1 5 lbf ft Unscrew the nut 15 Remove the sliding sleeve 14 Unscrew the guide 16 using a open end wrench 050 02 Co...

Page 339: ...e locking tool crankshaft 19 Completion Install the oil cooler bracket See chapter 010 02 1 02 Installing oil cooler bracket Install the oil cooler See chapter 050 03 02 Installing oil cooler 050 02 C...

Page 340: ...258 RLF MPE850 Rev 1 2 406555 050 050 03 Oil cooler 050 03 Oil cooler...

Page 341: ...r T30 Remove the oil cooler 3 Mount the engine on the engine stand Mount the engine on the drive side 1 of the engine stand See chapter 3 3 1 Mount the engine on the drive side of the engine stand 050...

Page 342: ...ts 3 Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft Petroleum jelly Torque wrench Torx screwdriver socket T30 Replace the gaskets 1 Insert the gaskets into the grooves and lightly coat with petrole...

Page 343: ...261 RLF MPE850 Rev 1 2 406555 062 062 01 Mounting exhaust manifold 062 01 Mounting exhaust manifold 062 Exhaust system...

Page 344: ...place the nuts 1 Apply Anti Seize assembly paste thoroughly to all studs 2 Screw on the nuts Tightening torque 22 Nm 4 Nm 16 2 lbf ft 3 lbf ft Replace the exhaust gaskets 3 062 01 01 Instructions for...

Page 345: ...assembly paste Unscrew the studs 1 using a stud extractor Replace the studs Apply Anti Seize assembly paste to all studs Screw in the studs using a stud extractor Tightening torque 16 Nm 4 Nm 11 8 lbf...

Page 346: ...264 RLF MPE850 Rev 1 2 406555 070 070 Intake area 070 01 Intake manifold 070 01 Intake manifold...

Page 347: ...F MPE850 Rev 1 2 406555 070 1 2 Unscrew 4 bolts 1 Hexagon screwdriver 5 Torx screwdriver T45 Unscrew the bolts 2 070 01 01 Removing intake manifold 070 01 Intake manifold 070 01 01 Removing intake man...

Page 348: ...266 RLF MPE850 Rev 1 2 406555 070 3 Remove the intake manifold 3 070 01 Intake manifold 070 01 01 Removing intake manifold...

Page 349: ...osition Screw in the bolts 4 lightly Do not tighten Petroleum jelly Torque wrench Hexagon screwdriver socket 5 Torx screwdriver socket T45 Screw in 4 bolts 5 Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5...

Page 350: ...70 01 01 Removing intake manifold 070 01 01 Removing intake manifold Hexagon screwdriver 6 070 01 03 Removing intake manifold bracket 070 01 Intake manifold 070 01 03 Removing intake manifold bracket...

Page 351: ...Installing intake manifold Torque wrench Hexagon screwdriver socket 6 070 01 04 Installing intake manifold bracket 070 01 Intake manifold 070 01 04 Installing intake manifold bracket Screw in the bolt...

Page 352: ...screwdriver T30 070 01 05 Removing sensor intake manifold pressure temperature 070 01 Intake manifold 070 01 05 Removing sensor intake manifold pressure temperature Unscrew the bolt 1 Pull the sensor...

Page 353: ...anifold 070 01 06 Installing sensor intake manifold pressure temperature 070 01 06 Installing sensor intake manifold pressure temperature Coat the o ring 1 lightly with petroleum jelly Insert the sens...

Page 354: ...272 RLF MPE850 Rev 1 2 406555 070 070 02 Mounting throttle body 070 02 Mounting throttle body...

Page 355: ...3 RLF MPE850 Rev 1 2 406555 070 2 1 Open the hose clamp 1 Hexagon nut driver 7 Remove the throttle body 2 070 02 01 Removing throttle body 070 02 Mounting throttle body 070 02 01 Removing throttle bod...

Page 356: ...e hose clamp 3 Tightening torque 1 5 Nm 1 Nm 1 1 lbf ft 0 7 lbf ft Torque wrench 6 point socket wrench 7 Insert the hose clamp 2 and throttle body 1 070 02 Mounting throttle body 070 02 02 Installing...

Page 357: ...socket wrench 7 Information When replacing the throttle body it must be recalibrated Before putting the engine into operation again turn on the ignition for a minute and then off again 070 02 03 Repla...

Page 358: ...070 02 Mounting throttle body 070 02 03 Replacing throttle body Unscrew the bolts 3 Remove the rubber mount 4 Replace the throttle body 6 Hold the rubber mount 7 in position Screw in the bolts 5 Tight...

Page 359: ...50 Rev 1 2 406555 070 8 10 9 070 02 Mounting throttle body 070 02 03 Replacing throttle body Close the hose clamp 10 Tightening torque 1 5 Nm 1 Nm 1 1 lbf ft 0 7 lbf ft Insert the hose clamp 9 and thr...

Page 360: ...nut driver 7 Hexagon screwdriver 5 Torque wrench Hexagon screwdriver socket 5 6 point socket wrench 7 070 02 Mounting throttle body 070 02 04 Replacing rubber mount 070 02 04 Replacing rubber mount Op...

Page 361: ...070 02 Mounting throttle body 070 02 04 Replacing rubber mount Screw in the bolts 6 Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft Unscrew the bolts 3 Remove the rubber mount 4 Replace the rubber...

Page 362: ...850 Rev 1 2 406555 070 7 9 8 070 02 Mounting throttle body 070 02 04 Replacing rubber mount Close the hose clamp 9 Tightening torque 1 5 Nm 1 Nm 1 1 lbf ft 0 7 lbf ft Insert the hose clamp 8 and throt...

Page 363: ...l the spark plugs See chapter 030 02 05 Installing spark plugs Sensor coolant temperature 2 Replace the sensor coolant temperature See chapter 050 01 07 Replacing sensor coolant temperature Informatio...

Page 364: ...body 6 Remove the throttle body See chapter 070 02 01 Removing throttle body Install the throttle body See chapter 070 02 02 Installing throttle body Sensor intake manifold pressure temperature 7 Remo...

Page 365: ...gine control unit the throttle body must be recalibrated Before putting the engine into operation again turn on the ignition for a minute and then off again See the portable fire pump manufacturer s d...

Page 366: ...284 RLF MPE850 Rev 1 2 406555 090 090 01 Starter 090 01 Starter 090 Starter generator...

Page 367: ...Unscrew the bolt 3 Remove the starter 2 Preparation Remove the intake manifold See chapter 070 01 01 Removing intake manifold 070 01 01 Removing intake manifold Hexagon screwdriver 8 Torx screwdriver...

Page 368: ...40 Nm 8 Nm 29 5 lbf ft 5 9 lbf ft Tighten the bolt 4 Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft Completion Install the intake manifold See chapter 070 01 02 Installing intake manifold 070 01 02...

Page 369: ...anifold See chapter 070 01 01 Removing intake manifold 070 01 01 Removing intake manifold 070 01 02 Installing intake manifold Hexagon screwdriver 8 Torx screwdriver T30 Torque wrench Hexagon screwdri...

Page 370: ...t 1 5 lbf ft Hold the starter 9 in position Screw in the bolt 10 lightly Do not tighten Screw in 2 bolts 11 Tightening torque 40 Nm 8 Nm 29 5 lbf ft 5 9 lbf ft Tighten the bolt 12 Tightening torque 8...

Page 371: ...289 RLF MPE850 Rev 1 2 406555 090 090 02 Generator 090 02 Generator...

Page 372: ...e engine stand Mount the engine across from the drive side 1 of the engine stand See chapter 3 3 2 Mount the engine across from the drive side of the engine stand Hold the locking tool crankshaft 2 on...

Page 373: ...LF MPE850 Rev 1 2 406555 090 6 7 4 5 8 Remove the rotor 6 Remove the stub shaft 7 Unscrew the bolts 4 Remove the locking tool crankshaft 5 Unscrew the bolts 8 090 02 Generator 090 02 01 Removing gener...

Page 374: ...292 RLF MPE850 Rev 1 2 406555 090 9 10 Remove the stator 9 Remove the distance washer 10 090 02 Generator 090 02 01 Removing generator...

Page 375: ...ng fastening the bolt the microcapsules will burst and the contained adhesive and curing agent are released and mixed The coating begins to cure within a short time If the bolts are moved again later...

Page 376: ...4 3 2 Hold the stub shaft 5 in position Slide on the rotor 6 Screw in the bolts 4 Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft 090 02 Generator 090 02 02 Installing generator Insert the distance...

Page 377: ...4 lbf ft Remove the locking tool crankshaft 11 Hold the locking tool crankshaft 8 on rotor Screw in the bolt 9 and washer 090 02 Generator 090 02 02 Installing generator The bolts can be found in the...

Page 378: ...296 RLF MPE850 Rev 1 2 406555 090 See the portable fire pump manufacturer s documentation 090 03 Voltage regulator 090 03 Voltage regulator...

Page 379: ...297 RLF MPE850 Rev 1 2 406555 100 100 Fuel unit 100 01 Fuel rail 100 01 Fuel rail...

Page 380: ...g on the fuel system observe the safety messages in chapter 2 2 Important safety messages Only remove the fuel rail if absolutely necessary If you find that the fuel rail or injectors are defective re...

Page 381: ...299 RLF MPE850 Rev 1 2 406555 100 2 Remove the fuel rail 2 100 01 Fuel rail 100 01 01 Removing fuel rail...

Page 382: ...ly with lubricant Insert the fuel rail 1 Lubricant for o ring injectors Torque wrench Torx screwdriver socket T30 Screw in the bolts 3 Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft 100 01 Fuel rai...

Page 383: ...n the fuel system observe the safety messages in chapter 2 2 Important safety messages Only remove the injectors if you have to replace them If you find that the fuel rail or injectors are defective r...

Page 384: ...ng 3 lightly with lubricant Insert the injector until it engages in the bracket Check that the injector is engaged in the bracket 5 Completion Install the fuel rail See chapter 100 01 02 Installing fu...

Page 385: ...303 RLF MPE850 Rev 1 2 406555 110 110 01 Dry sump 110 01 Dry sump 110 Lubrication system...

Page 386: ...4 bolts 1 Hexagon screwdriver 5 110 01 01 Removing suction pump cover 110 01 Dry sump 110 01 01 Removing suction pump cover Remove the suction pump cover 3 The suction pump cover is caulked with a sil...

Page 387: ...ling surface cleaner Silicone liquid seal Clean the sealing surface 1 with sealing surface cleaner Clean the sealing surface 2 with sealing surface cleaner Check if the sleeves 3 are installed 110 01...

Page 388: ...2 406555 110 4 5 6 Apply the silicone liquid seal 4 without gaps as illustrated Put the suction pump cover 5 on Screw in 14 bolts 6 Observe the arrangement of the bolts Tightening torque 8 Nm 2 Nm 5...

Page 389: ...307 RLF MPE850 Rev 1 2 406555 110 A B B B B B A A A A A B B A Arrangement of the bolts A 7 Bolts M6x20 B 7 Bolts M6x30 Turn the engine 180 110 01 Dry sump 110 01 02 Installing suction pump cover...

Page 390: ...03 Replacing suction pump cover Preparation Remove the suction pump cover See chapter 110 01 01 Removing suction pump cover Remove the oil suction pump See chapter 110 01 04 Removing oil suction pump...

Page 391: ...il screen 2 Unscrew the bolts 3 Remove the oil suction pump 4 110 01 01 Removing suction pump cover Torx screwdriver T30 110 01 04 Removing oil suction pump 110 01 Dry sump 110 01 04 Removing oil suct...

Page 392: ...ft Insert the oil screen 4 Screw in the bolts 3 Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft 110 01 02 Installing suction pump cover Torque wrench Torx screwdriver socket T30 110 01 05 Installin...

Page 393: ...wrench Insert open end wrench 24 Turn the engine 180 Unscrew the fitting 1 Replace the fitting Screw in the fitting Tightening torque 36 Nm 8 Nm 26 6 lbf ft 5 9 lbf ft Turn the engine 180 110 01 06 R...

Page 394: ...drive side 1 of the engine stand See chapter 3 3 1 Mount the engine on the drive side of the engine stand 110 01 01 Removing suction pump cover Pin punch axle intermediate gear Plastic hammer Hexagon...

Page 395: ...v 1 2 406555 110 5 4 3 110 01 Dry sump 110 01 07 Removing intermediate gear suction pump Remove the intermediate gear suction pump 5 Punch the axle 4 out using the pin punch axle intermediate gear 3 a...

Page 396: ...uction pump The plug and seal can be found in the spare parts catalog in chapter 010 01 3 Crankcase Replace the seal 4 Screw in the plug 5 Tightening torque 20 Nm 4 Nm 14 8 lbf ft 3 lbf ft Installing...

Page 397: ...315 RLF MPE850 Rev 1 2 406555 110 110 02 Oil pressure pump 110 02 Oil pressure pump...

Page 398: ...the engine stand See chapter 3 3 2 Mount the engine across from the drive side of the engine stand 090 02 01 Removing generator Lockring pliers bore holes Universal pliers 110 02 Oil pressure pump 110...

Page 399: ...06555 110 5 4 6 7 110 02 Oil pressure pump 110 02 01 Removing oil pressure pump Remove the outer rotor 4 of the oil pressure pump Remove the inner rotor 5 of the oil pressure pump Remove the key 6 Rem...

Page 400: ...install the key Replace the key Insert the key Insert the inner rotor 4 of the oil pressure pump Insert the outer rotor 5 of the oil pressure pump Replace the o rings 6 Coat the o rings lightly with p...

Page 401: ...319 RLF MPE850 Rev 1 2 406555 110 Completion Install the generator See chapter 090 02 02 Installing generator 110 02 Oil pressure pump 110 02 02 Installing oil pressure pump...

Page 402: ...320 RLF MPE850 Rev 1 2 406555 110 110 03 Oil pressure valve 110 03 Oil pressure valve...

Page 403: ...ssure valve 2 out using a bar magnet Preparation Remove the suction pump cover See chapter 110 01 01 Removing suction pump cover 110 01 01 Removing suction pump cover Hexagon screwdriver 6 Bar magnet...

Page 404: ...ert the oil pressure valve 2 Installing oil pressure valve Assemble the oil pressure valve in the sequence as illustrated 1 110 01 02 Installing suction pump cover Torque wrench Hexagon screwdriver so...

Page 405: ...323 RLF MPE850 Rev 1 2 406555 110 Completion Install the suction pump cover See chapter 110 01 02 Installing suction pump cover 110 03 Oil pressure valve 110 03 02 Installing oil pressure valve...

Page 406: ...324 RLF MPE850 Rev 1 2 406555 110 110 04 Oil filter 110 04 Oil filter...

Page 407: ...325 RLF MPE850 Rev 1 2 406555 110 1 Unscrew the oil filter 1 using a universal strap wrench Universal strap wrench 110 04 Oil filter 110 04 01 Removing oil filter 110 04 01 Removing oil filter...

Page 408: ...e sealing surface 2 with sealing surface cleaner Coat the oil filter seal 3 lightly with engine oil Sealing surface cleaner Screw in the oil filter 4 by hand Tightening torque 10 Nm 7 4 lbf ft 110 04...

Page 409: ...the threaded sleeve 1 using a crown wrench Preparation Remove the oil filter See chapter 110 04 01 Removing oil filter 110 04 01 Removing oil filter Reversible ratchet Crown wrench 110 04 Oil filter 1...

Page 410: ...g a crown wrench Tightening torque 17 Nm 3 Nm 12 5 lbf ft 2 2 lbf ft Completion Install the oil filter See chapter 110 04 02 Installing oil filter 110 04 02 Installing oil filter Torque wrench Crown w...

Page 411: ...329 RLF MPE850 Rev 1 2 406555 120 120 01 Lifting eye 120 01 Lifting eye 120 Engine mount...

Page 412: ...LF MPE850 Rev 1 2 406555 120 1 2 Unscrew the bolts 2 Remove the bracket 1 Hexagon screwdriver 5 120 01 01 Removing bracket on the drive side 120 01 Lifting eye 120 01 01 Removing bracket on the drive...

Page 413: ...racket 1 in position Screw in the bolts 2 Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft Torque wrench Hexagon screwdriver socket 5 120 01 02 Installing bracket on the drive side 120 01 Lifting eye...

Page 414: ...332 RLF MPE850 Rev 1 2 406555 120 1 2 Unscrew the bolt 2 Remove the pipe clamp 1 Torx screwdriver socket T30 120 01 Lifting eye 120 01 03 Removing pipe clamp 120 01 03 Removing pipe clamp...

Page 415: ...1 2 Hold the pipe clamp 1 in position Screw in the bolt 2 Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft Torque wrench Torx screwdriver socket T30 120 01 04 Installing pipe clamp 120 01 Lifting ey...

Page 416: ...0 Rev 1 2 406555 120 1 2 Unscrew the bolt 2 Remove the bracket 1 Hexagon screwdriver 5 120 01 Lifting eye 120 01 05 Removing bracket across from the drive side 120 01 05 Removing bracket across from t...

Page 417: ...in position Screw in the bolt 2 Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft Torque wrench Hexagon screwdriver socket 5 120 01 06 Installing bracket across from the drive side 120 01 Lifting eye...

Page 418: ...336 RLF MPE850 Rev 1 2 406555 910 910 01 Long block 910 Repair kits 910 01 Long block...

Page 419: ...e the intake manifold bracket See chapter 070 01 03 Removing intake manifold bracket Remove the starter See chapter 090 01 01 Removing starter 070 01 01 Removing intake manifold 070 01 03 Removing int...

Page 420: ...See chapter 090 02 01 Removing generator 910 01 Long block 910 01 01 Installing long block Mount the long block on the engine stand Mount the engine across from the drive side 3 of the engine stand Se...

Page 421: ...all the intake manifold bracket See chapter 070 01 04 Installing intake manifold bracket Install the intake manifold See chapter 070 01 02 Installing intake manifold Install the generator See chapter...

Page 422: ...ev 1 2 11 10 2012 050 01 04 Installing fitting Rev 1 2 11 10 2012 050 01 06 Removing thermostat Removal modified to the new distance washer Rev 1 2 11 10 2012 050 01 07 Installing thermostat Installat...

Page 423: ...3 remove 57 Fitting 030 02 install 182 Fitting 030 02 remove 181 Fitting 050 01 install 239 Fitting 050 01 remove 238 Fitting 110 01 replace 311 Fuel rail install 300 Fuel rail remove 298 G Generator...

Page 424: ...rter replace 287 Stub shaft install 145 Stub shaft remove 143 Studs replace 263 Suction pump cover install 305 Suction pump cover remove 304 Suction pump cover replace 308 Supplies overview 26 Switch...

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