Kohler Lombardini LDW FOCS 502 Euro 2, Service Manual

Page: 5 / 98

5
Service Manual LDW FOCS 502 automotive _ cod. ED0053027270 - 3° ed_rev. 02
7.3 PRE-ASSEMBLY OF
CONNECTING RODS – PISTONS ........................... 66
7.4 INSTALLING VALVES ............................................... 66
7.4.1 Assembling the valves ............................................. 66
7.5
INSTALLATION OF CRANK GEAR
AND CRANKCASE … ................................................67
7.5.1 Installing piston/connecting rod - engine block .......67
7.5.2 Assembling the crankshaft ..................................... 68
7.5.3 Assembling the crankcase ....................................... 68
7.5.4. Measuring crankshaft axial clearance ..................... 69
7.5.5 Assembling the crankshaft flange (flywheel side) ... 69
7.5.6 Installing the oil pump ...............................................70
7.5.7 Assembling the flywheel ...........................................71
7.6
INSTALLATION OF CYLINDER HEAD
AND COMPONENTS…. ...........................................72
7.6.1 Assembling the precombustion chamber ................72
7.6.2 Assembling the cylinder head ...................................73
7.6.3 Assembling the camshaft .........................................73
7.6.4 Assembling the speed governor and flow limiter .....74
7.6.5 Assembling injection – pumps .................................75
7.6.6 Assembling the mechanical fuel pump .....................76
7.6.7 Assembling the rocker arms .................................... 77
7.6.8 Assembling the rocker arm cover ............................ 77
7.7
INSTALLING THE TIMING BELT DRIVE ....................78
7.7.1 Assembling the timing belt pulley .............................78
7.7.2 Assembling the timing belt .......................................78
7.7.3 Assembling the belt drive cover ............................... 79
7.8
INSTALLATION OF THE COOLING FAN
BELT DRIVE .............................................................. 80
7.8.1 Assembling the fan belt drive pulleys ...................... 80
7.8.2 Assembling the fan belt drive ..................................81
7.8.3 Assembling the cooling fan ...................................... 82
7.9
INSTALLING INTAKE AND EXHAUST MANIFOLDS 82
7.9.1 Assembling the exhaust manifold ........................... 82
7.9.2 Assembling the intake manifold ............................... 82
8 REPLACING PARTS
8.1 RECOMMENDATIONS FOR REPLACING PARTS ... 85
8.2 REPLACING THE ALTERNATOR – FAN BELT ........ 85
8.3 REPLACING THE TIMING BELT................................87
8.4 REPLACING THE OIL FILTER ..................................87
8.5 REPLACING THE AIR FILTER ................................. 88
8.6 REPLACING THE ALTERNATOR.............................. 89
8.7 REPLACING THE STARTER MOTOR ....................... 89
8.8 REPLACING THE FLYWHEEL RING GEAR ............. 90
8.9 REPLACING THE COOLANT THERMOSTAT .......... 90
8.10 REPLACING THE COOLANT PUMP .........................91
8.11 REPLACING THE THERMOSTATIC VALVE …. ........91
8.12 REPLACING THE NEGATIVE-PRESSURE
VENT VALVE ............................................................. 92
8.13 REPLACING THE PRE-HEATING GLOW PLUGS .... 92
8.14 REPLACING INJECTOR PUMP PARTS ................... 93
8.14.1 Pumping element replacement ................................ 93
8.14.2 Replacing the nozzle-injector .................................. 95
8.15 REPLACING THE COOLING FAN SUPPORT .......... 95