MWM Acteon Workshop Manual Download Page 69

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Pistons and Connecting Rods

7 - 1

9.612.0.006.7160 - 05/04

Pistons and Connecting Rods

Disassembly Notes ........................................................................................................................... 7-2

Pre-Assembly Inspections and Measurements ............................................................................... 7-4

Piston Grooves Specifications .................................................................................... 7-6

Ring Ends Gaps Specification ..................................................................................... 7-7

Connecting Rod Bearings Specification ..................................................................... 7-7

Connecting Rods Specification ................................................................................... 7-9

Piston and Pin ............................................................................................................ 7-10

Pre-Assembly Inspections and Measurements ............................................................................. 7-11

Connecting Rod Bolts Tightening Specification ....................................................... 7-16

Assembly ......................................................................................................................................... 7-17

Summary of Contents for Acteon

Page 1: ...Workshop Manual...

Page 2: ...liente Customer Assistance Fax Av das Na es Unidas 22 002 CEP 04795 915 S o Paulo SP Brasil 55 11 3882 3574 9 612 0 006 7160 11 06 Internet e mail Fone DDG www mwm international com br mwm mwm com br...

Page 3: ...5 04 Presentation Introduction 1 2 How to Use thisWorkshop Manual 1 2 Important Safety Remarks 1 3 General Instructions 1 4 Cleaning General Instructions 1 5 Engine Serial Number Identification and Lo...

Page 4: ...ced with last generation technology components and with high level quality standards When parts changes are necessary it is recommended to use only MWM genuine spare parts These parts can be identifie...

Page 5: ...ration and the cooling fluid is hot leave the engine to cold down before slowly open the cover of the reservoir to relief the pressure of the cooling system Do not work with materials that are lifted...

Page 6: ...he engine electronic injection system General Instructions This engine has been manufactured with the most advanced technology nevertheless it was designed to be repaired using regular techniques comp...

Page 7: ...oduct Remove all gaskets sealing rings and with a brush of steel or rasper the sludge deposits carbon etc before placing the parts in the cleaning tank Be careful to do not damage the surfaces of the...

Page 8: ...ftercooler Identification and Location of the Serial Number The engine identification and serial number can be found in the following places 1 Identification plate on the water pipe 2 Engraving on the...

Page 9: ...s Numeration The numeration of the cylinders starts from the flywheel according to the illustration below During the assembly check the numbers on the block A and on the bearings B which indicates the...

Page 10: ...NOTES 1 8 9 612 0 006 7160 05 04...

Page 11: ...Technical Data 2 1 9 612 0 006 7160 05 04 Technical Data Technical Data 2 2 Fuel System 2 2 Lubrication System 2 3 Cooling System 2 3 Thermostat 2 3...

Page 12: ...nder bore 105 mm Cylinder stroke 137 mm Unit displacement 1 2 l 4 745 litres 7 118 litres Total displacement 4 6 Quantity of cylinders Compression rate Firing order 1 3 4 2 1 5 3 6 2 4 Rotation sense...

Page 13: ...e without radiator Water temperature Nominal Maximum Cooling System 4 12TCE 6 12TCE 5 l 8 l 9 2 l 4 12TCE 6 12TCE 80 90 C 100 C 13 l 17 l 18 7 l 7 l 9 l Variation pressure of the filter to open by pas...

Page 14: ...2 4 9 612 0 006 7160 05 04 NOTES...

Page 15: ...0 05 04 Operation and Maintenance Engine Operation 3 2 Cooling fluid and Coolant 3 5 Level Check 3 5 Cooling Fluid Filling Procedure 3 6 MaintenanceTable 3 7 MWM Acteon Engines Vehicular 3 7 Conservat...

Page 16: ...vailable it is necessary that the filter has a heater on the cylinder head to allow fuel flow before the start TurbochargerCares Almost all failures in turbochargers are caused by lubrication deficien...

Page 17: ...ormal operation temperature yet Avoid operating over the limit of 3 4 75 of the maximum load of the vehicle or equipment Avoid operating the engine at constant speeds for long periods of time Avoid le...

Page 18: ...levelled vehicle the oil level must reach the upper mark of the dipstick Run the engine checking the sealing of the filter and carter plug Stop the engine and after 30 minutes check oil level again f...

Page 19: ...ngine is cold Check the level of the cooling system daily If the level is not correct add clean water MWM coolant according to the proportion recommended on the bottle Carefully open the first stage o...

Page 20: ...gtotherecommendedproportion 9 Operate the engine up to the normal operation temperature and leave it running for 15 minutes Remark If the vehicle has hot air conditioning turn the button in hot positi...

Page 21: ...and temperature water temperature sensors are free of maintenance and checked by recommended diagnose scanner with errors stored in failure memory 15 000 Km 80 000 Km 40 000 Km 20 000 Km 10 000 Km 5 0...

Page 22: ...he springs and rocker arms Reinstall covers 10 Remove fuel injectors and spray 10 to 15 cm of protective oil in each cylinder with the respective piston at bottom dead centre position Turn crankshaft...

Page 23: ...ucts Castrol Rustilo 652 SAE 20 Texaco Engine Oil DBH 20 W 20 Ipiranga UltramoTurbo SAE 20 Graxas Other products with similar technical features could be used with a previous approval of MWM Manufactu...

Page 24: ...NOTES 3 10 9 612 0 006 7160 05 04...

Page 25: ...Disassembly Notes 4 2 Pre Assembly Inspections and Measurements 4 3 Liner Protrusion Specification 4 3 Liners Specification 4 4 Liners and Pistons Assembly Specifications 4 5 Engine Block Specificatio...

Page 26: ...liners removal must be made with the special tool MWM nr 9 610 0 690 017 6 in order to do not damage the engine block or the liners The lower part of the tool must be fitted on the lower edge of the...

Page 27: ...on Specification ProtrusionAdjustmentShims whennecessary Thickness mm 9 612 8 340 004 4 0 05 9 612 8 340 005 4 0 10 9 612 8 340 006 4 0 20 9 612 8 340 007 4 0 50 Liner over Engine Block Surface Measur...

Page 28: ...4 4 Engine Block 9 612 0 006 7160 05 04 Pre Assembly Inspections and Measurements Liners Specification Liners Measure mm Maximum waste 0 06 Out of roundness 0 02 Inner 105 000 105 022...

Page 29: ...0 05 04 Liners and Pistons Assembly Specifications 1 Piston 2 Liner 3 Engine Block 4 Gasket LinersAssembly W X Y Z Gasket nr Application 0 23 to 0 59 8 04 to 8 06 0 95 to 1 10 1 35 to 1 69 9 612 0 854...

Page 30: ...Block Specifications Main Bearings A Diameter mm Inner 92 000 92 022 TappetsHousing B Inner mm standard nominal 18 000 18 018 standard maximum 18 020 1st repair 18 500 18 518 Measure main bearings bol...

Page 31: ...50 025 maximum 50 045 1st repair withoutbushing 54 000 54 030 withbushing 49 990 50 050 CamshaftBearing D inner mm withoutbushing 54 000 54 030 withbushing 49 990 50 050 Remark Camshaft bearing D has...

Page 32: ...Clean liner housing and installTombak ring A Measure liner protrusion in relation to the upper surface of the engine block with a dial indicator gauge As a bracket to the dial indicator gauge it can...

Page 33: ...ing but without the rubber sealing rings Lubricate with engine oil the contact area of the liner with the sealing rings if they are assembled in the engine block To measure liner protrusion with the s...

Page 34: ...tely clean to avoid torsion or cut during the assembly causing lubricant oil contamination with water Measure the liner protrusion in relation to the upper surface of the engine block with a dial indi...

Page 35: ...Engine Block 4 11 9 612 0 006 7160 05 04 Install the Tombak ring Assembly Install the sealing rings Install the liners according to the procedure described previously...

Page 36: ...4 12 Engine Block 9 612 0 006 7160 05 04 Rings correct position with the assembled liner...

Page 37: ...5 5 Out of roundness andTaper Specification 5 6 Radial Clearance 5 7 Fillets 5 8 Pre Assembly Inspections and Measurements 5 9 Crankshaft 5 9 Engine Block Bearings 5 10 Bearing Shells 5 12 Main Bearin...

Page 38: ...upright position and loosen the main bearing caps To remove the bearing caps use the fixation bolts Remove the axial thrust ring from bearing 1 flywheel side Carefully remove crankshaft in order to d...

Page 39: ...Crankshaft 5 3 9 612 0 006 7160 05 04 Gear Diameter mm Seat 60 020 60 059 Crankshaft Specification...

Page 40: ...rankshaft 9 612 0 006 7160 05 04 Main Journals Specification Main Journal Diameter mm Standard 85 942 85 964 1st repair 85 692 85 714 2ndrepair 85 442 85 464 3rdrepair 85 192 85 214 4threpair 84 942 8...

Page 41: ...ankshaft 5 5 9 612 0 006 7160 05 04 Crankpins Specification Crankpins Diameter mm Standard 62 951 62 970 1st repair 62 701 62 720 2ndrepair 62 451 62 470 3rdrepair 62 201 62 220 4threpair 61 951 61 97...

Page 42: ...5 6 Crankshaft 9 612 0 006 7160 05 04 Out of roundness and Taper Specification MaximumOut of roundness mm A x C and B x D 0 01 Maximum Taper mm A x B and C x D 0 01...

Page 43: ...Crankshaft 5 7 9 612 0 006 7160 05 04 Radial Clearance RadialClearance mm nominal 0 036 0 096 maximum 0 245...

Page 44: ...5 8 Crankshaft 9 612 0 006 7160 05 04 Fillets Fillet mm Nominal 3 8 4 0...

Page 45: ...hecked It is necessary to check for overheating signs deep scratches cracks or other types of damage Presenting anyone of these damages it is necessary to check the possibility of machining and to use...

Page 46: ...e that the numeration engraved on the engine block corresponds to the bearing cap Install bearing caps and tighten according to the specification Measure bearings diameter out of roundness and taper w...

Page 47: ...ing shells Main Bearings Specifications Engine Block Diameter mm Withoutbearingshell 92 000 92 022 Bearingshell Diameter mm Standard 86 000 86 038 1st repair 85 750 85 788 2ndrepair 85 500 85 538 3rdr...

Page 48: ...cted by the reduction of the lubricant oil pressure Theprolongedoperationwithlowoilpressurecancause beats and vibrations in crankshaft and consequently early deterioration of the bearing shells To per...

Page 49: ...on the crankshaft through the bore gauge Position the bearing shells with the aid of the expansion pin Measure the crankshaft The measurements must be taken twice at 90 and in the two edges of the be...

Page 50: ...aring pre tension Pre tension 0 025 0 060 mm Assembly bearing caps and tighten according specification Perform the measurements in the same way that they were performed for the bearings without bearin...

Page 51: ...and measure warping Check crankshaft thrust rings Check for damages existence or excessive waste In the assembly the side with two grooves must be toward the shaft When necessary it can be used over...

Page 52: ...5 16 Crankshaft 9 612 0 006 7160 05 04 Bolts Tighten Torque Specification Torque Angle Step 1st 45 Nm 5 2nd 90 5 Lmax 133 50 mm 10 1 5 Nm Main Bearing Caps Piston Oil Injector...

Page 53: ...Crankshaft 5 17 9 612 0 006 7160 05 04 Install crankshaft Install and oil all bearing shells Assembly Install piston cooling oil injectors Apply torque of 10 1 5 Nm...

Page 54: ...18 Crankshaft 9 612 0 006 7160 05 04 Install first bearing lower thrust ring Assembly bearing caps with the upper thrust ring Attention Thrust rings grooves must stay towards the crankshaft mobile sid...

Page 55: ...Crankshaft 5 19 9 612 0 006 7160 05 04 Tighten bolts in two steps and tighten according the specification The torque must be applied from the center to the extremities...

Page 56: ...5 20 Crankshaft 9 612 0 006 7160 05 04 Measurements After Assembly Axial Clearance Specification Axialclearance A mm Nominal 0 08 0 25 Maximum 0 4 Measure the crankshaft axial clearance A...

Page 57: ...612 0 006 7160 05 04 Camshaft Disassembly Notes 6 2 Camshaft Specifications 6 3 Tappets and Lock Plate Specification 6 4 Pre Assembly Inspections and Measurements 6 5 BoltsTightening Specifications 6...

Page 58: ...aft lock Turn the engine keeping the carter side upwards Remove camshaft with the hands and through the front of the engine making a movement of rotation Take care to do not damage the bearings of the...

Page 59: ...ft Specifications Gearseat Diameter A mm Nominal 51 971 51 990 AxialClearanceLimitationGroove Width B mm Nominal 7 100 7 190 Maximum 7 275 Main journals Diameter C mm Standard 49 920 49 940 BearingCle...

Page 60: ...shaft 9 612 0 006 7160 05 04 Tappets and Lock Plate Specification Lock Plate Thickness Nominal Tappets Diameter mm Standard Nominal 17 983 17 994 Minimum 17 975 1st repair Nominal 18 483 18 494 mm 7 0...

Page 61: ...ste on the contact area with the cams of the camshaft Attention During its operation the tappets perform a rotating movement responsible for a uniform distribution of the force uniforming the waste It...

Page 62: ...6 6 Camshaft 9 612 0 006 7160 05 04 Measure the tappets diameter Measure the diameter and out of roundness of the tappets housing Measure the camshaft bearing diameters...

Page 63: ...006 7160 05 04 Comparing the performed measurements obtain the clearance between the bearing and the housing Measure the camshaft bearing housing bores Measure the camshaft warping 6 cyl Maximum warpi...

Page 64: ...6 8 Camshaft 9 612 0 006 7160 05 04 Bolts Tightening Specification 35 5 Nm 20 3 Nm 8 5 1 0 Nm...

Page 65: ...bricate the tappets and the tappets housing Install them with the hands If it is not necessary to change the tappets check the original position in that they were installed and reinstall them in the s...

Page 66: ...0 05 04 Install it with the hands making rotating movements Take care to do not damage the bushings in the engine block After camshaft installation install the axial lock and tighten fixation bolts ac...

Page 67: ...Measure the camshaft axial clearance Repeat the operation sometimes to make sure of the measurement View of the assembled camshaft and lock Assembly the pulse wheel Attention to the expansion bushing...

Page 68: ...12 0 006 7160 05 04 Install camshaft gear Pay attention to the difference between the pulse wheels of the 4 and 6 cylinders engines Assembly pulse wheel fixation bolts and tighten according the specif...

Page 69: ...embly Inspections and Measurements 7 4 Piston Grooves Specifications 7 6 Ring Ends Gaps Specification 7 7 Connecting Rod Bearings Specification 7 7 Connecting Rods Specification 7 9 Piston and Pin 7 1...

Page 70: ...loosen the screw of one side and later loosen other Before removing the piston clean the inner part of the liner to remove residues of coal and impurities With the connecting rod caps out carefully r...

Page 71: ...Connecting Rods 7 3 9 612 0 006 7160 05 04 Remove piston rings with an appropriate device Aten o No ato da retirada do conjunto pist o biela observar a posi o do ejetor de leo para evitar batidas e a...

Page 72: ...Weight Strip Application X 1625g 1666g Production Y 1667g 1707g Production Z 1708g 1748g Spare Part The difference of weight between all pistons connecting rods sets in the same engine must be of at...

Page 73: ...re part it is only available connecting rods of the Y strip mass that is used to replace connecting rods of any other strips Important Do not assembly connecting rods of X and Z mass strip in the same...

Page 74: ...ecifications Remark The rings of the 10 Series engines are identified by a red strip on the outer diameter Rings Dimensions and Clearances in the Grooves Groove Dimensions mm Clearance mm 1st 103 0 x...

Page 75: ...Rod Bearing bore Diameter mm standard 62 992 to 63 037 repair1 62 746 to 62 791 repair2 62 496 to 62 541 repair3 62 246 to 62 291 repair4 61 996 to 62 041 Ends Gap mm 1st and 2nd groove Nominal 0 40...

Page 76: ...7 8 Pistons and Connecting Rods 9 612 0 006 7160 05 04 Connecting Rod Warping Maximum Torsion Maximum Warping 0 10 0 03...

Page 77: ...Pistons and Connecting Rods 7 9 9 612 0 006 7160 05 04 RadialClearance mm Nominal 0 022 0 087 Maximum 0 178 Connecting Rods Specifications SideClearance mm Nominal 0 30 0 50 Maximum 0 90...

Page 78: ...ton Pin Diameter mm Nominal 37 994 to 38 000 Maximum 37 900 B ConnectingRodBushing assembled Diameter mm Nominal 38 030 to 38 080 Maximum 38 140 C ConnectingRodBushing housing Diameter mm Nominal 41 0...

Page 79: ...g rods Check piston pin for marks scratches or excessive waste Measure the diameter of the pin Check pins taper and out of roundness Check connecting rod possible damages marks or waste Damages on the...

Page 80: ...ating of the bearing shells in the assembly Loosen the bolts of the connecting rod disassembling the connecting rod bearing and cap With the bushing assembled measure the diameter of the housing of th...

Page 81: ...ting Rods 7 13 9 612 0 006 7160 05 04 Turn the bore gauge 90 and perform the second measurement of the diameter Check connecting rod torsion Maximum Torsion 0 10 mm Check connecting rod warping Maximu...

Page 82: ...embly the bearing shells with the aid of the expansion pin assembly again the connecting rod cap and tighten according to Compare the clearances obtained from the crankpins with the bore gauge Measure...

Page 83: ...Rods 7 15 9 612 0 006 7160 05 04 With the bore gauge at 90 from the partition of the connecting rod reset the dial indicator gauge remove one of the connecting rod bolts and measure its pre tension Pr...

Page 84: ...7 16 Pistons and Connecting Rods 9 612 0 006 7160 05 04 Connecting Rod Bolts Tightening Specification Torque Angle Etep 1st 30 5 Nm 2nd 60 3 Lmax 59 20 mm...

Page 85: ...rings Lubricate piston pin assembly the piston in the connecting rod observing the correct positioning between them The arrow on the top of the piston must be toward the side of the 3 holes of the co...

Page 86: ...he piston grooves Lubricate the liners and piston rings When installing the piston connecting rod set in the cylinder mind the correct assembly position The arrow on to top of the piston must point to...

Page 87: ...nside the cylinder Never hit directly on the top of the piston Install the device for piston assembly to close the rings Note Position the engine flywheel upward This avoids the contact of the connect...

Page 88: ...ent Measure the side clearance With the piston on TDC measure the surface height in relation with the engine block surface Check the positions of the piston arrows Position the connecting rod stem in...

Page 89: ...Specification 8 4 Valve Guides Specification 8 5 Specification of Guide Height and Distance to Cylinder Head Surface 8 6 Valves Course 8 7 Rocker Arm Cold Clearance 8 8 Valves Diagram 8 10 Pre Assembl...

Page 90: ...l and valves To remove valve guides and seats send them to a specialized authorized workshop Loosen cylinder head fixation bolts in 3 steps and crosswise With the aid of the fixation bolts remove cyli...

Page 91: ...ts Specification B Outer mm Standard Intake 46 152 46 168 Exhaust 43 097 43 113 A Housing mm Standard Intake 46 046 46 086 Exhaust 42 976 43 016 C SeatWidth mm Standard Intake 1 90 2 00 Exhaust 2 17 2...

Page 92: ...s 9 612 0 006 7160 05 04 Valves Specification A Stem mm Nominal 8 952 8 970 Minimum 8 949 B Headheight mm Intake 2 7 Exhaust 2 1 C Surfacewidth mm Intake 3 60 Exhaust 3 11 D Head mm Intake 44 9 45 1 E...

Page 93: ...05 04 Valve Guides Specification A Afterassembly mm Nominal 9 000 9 022 Repair 9 013 9 028 Maximum 9 060 B Outer mm Nominal 15 028 15 039 C Housing mm Nominal 14 991 15 021 D Clearance at the Stem mm...

Page 94: ...Height and Distance to Cylinder Head Surface Guide Height A mm Intake and Exhaust 11 3 12 6 Distancetocylinder headsurface B Nominal Intake 0 8 1 1 Exhaust 1 30 1 60 Maximum Intake 1 35 Exhaust 1 85 G...

Page 95: ...Cylinder heads 8 7 9 612 0 006 7160 05 04 Valves Course and Clearance A Course mm Intake 11 10 11 34 Exhaust 11 22 11 46 B Clearance mm Intake Exhaust 0 40...

Page 96: ...8 8 Cylinder heads 9 612 0 006 7160 05 04 Rocker arm Cold Clearance Diameters mm Rocker arm A 16 000 16 018 Shaft B 15 966 15 984 Clearance mm Radial C 0 016 0 052 Axial D 0 050 0 260 B A C D...

Page 97: ...he following table The intake valves springs are single only one spring and exhaust valves springs are double Intake valve spring and outer exhaust valve spring wire 3 50 mm Load Kgf Length mm 0 0 71...

Page 98: ...eads 9 612 0 006 7160 05 04 Valves Diagram Valves clearance 1 mm After the check readjust the clearance to 0 40 mm Intake Open 3 after TDC Close 23 after PMI Exhaust Open 33 before PMI Close 1 after T...

Page 99: ...easurements Visually check cylinder heads for leaks Check push rods The push rods ends must not be loosen or cracked Check for excessive waste and if the lubrication hole is not obstructed Check if th...

Page 100: ...7160 05 04 Measure the outer diameter of the valve stem in 3 different points Upper part Central part Lower part Measure the outer diameter of the valve guide Attention Do not measure the diameter on...

Page 101: ...er heads 8 13 9 612 0 006 7160 05 04 Measure valve guide housing bore After the measurements install valve guides with the special tool MWM nr 9 610 0 690 014 6 Measure the bore of the assembled valve...

Page 102: ...8 14 Cylinder heads 9 612 0 006 7160 05 04 Measure the width of the valves seat Measure the width of the valve contact surface Measure the valve guide height in relation to the cylinder head...

Page 103: ...arm ends do not present excessive waste or cracks in the shaft housing or on the contact area with the valve stem After removing the rocker arms check for grip signs Measure the rocker arm shaft ovali...

Page 104: ...8 16 Cylinder heads 9 612 0 006 7160 05 04 Measure the shaft housing bore Check rocker arms ends axial clearance in the shafts e deforma es como conicidade e ovaliza o...

Page 105: ...Cylinder heads 8 17 9 612 0 006 7160 05 04 Bolts Tighten Torques Specifications 56 8 Nm 20 6 Nm 15 5 Nm 15 5 Nm 110 15 Nm Torque Angle Step 1st 60 10 Nm 2nd 60 3 3rd 60 3 Lmax 148 50 mm...

Page 106: ...eat of the valves on the respective seats new seats are provided semi finished Make sure if the seat obtained between the valve and seat is uniform Install springs plates Remark Before beginning the a...

Page 107: ...ompress the springs and assembly the valves locks Install a dial indicator gauge in the special measurement device MWM nr 9 407 0 690 031 6 and reset on the flat surface of the cylinder head Measure t...

Page 108: ...07 0 690 030 4 in the place of two diametrically opposite bolts Install cylinder head gasket with the TOP mark upward The cylinder head gasket must be perfectly clean and must never be assembled with...

Page 109: ...and its main characteristic is its double assembly that is to say for two cylinder heads Attention Use only MWM genuine gaskets The thickness of the cylinder head gasket for replacement is only of 1...

Page 110: ...cylinder heads with the help of the intake manifold Assembly intake manifold with gaskets and tighten manifold fixation bolts according to the specification With the cylinder heads aligned by the int...

Page 111: ...5 04 Install pushrods checking their correct seat on the tappets Install rocker arms set assembled tightening according to the specification Attention Totally unscrew the valve clearance adjustment sc...

Page 112: ...eads and valves covers for leaks 4 Cylinders 6 Cylinders 4 2 1 3 6 2 4 1 5 3 To swing 1 3 4 2 1 5 3 6 2 4 To adjust Adjust valves clearances Position the last cylinder in swinging and adjust the valve...

Page 113: ...1 9 612 0 006 7160 05 04 Gearing Carcass Disassembly Notes 9 2 Inspections and Measurements 9 3 Specifications 9 3 Gears Backlashes and Clearances Specification 9 6 BoltsTightenTorques Specification...

Page 114: ...until that the lever touches the pulley This way the crankshaft will stay locked making possible the loosening of the crankshaft pulley bolts Loosen the bolts of the crankshaft pulley Remove the pulle...

Page 115: ...Check for waste signs or cracks on the base of the teeth Presenting such as those defects the gears must be replaced Measure the components of the gearing carcass according to the following illustrat...

Page 116: ...nkshaftfrontgear hole mm 60 000 60 025 quantity of teeth 36 Idle gear furo mm Withoutbushing 50 000 50 015 With bushing 45 024 45 070 No s de dentes 6 Thrust ring E mm MWM nr 3 46 3 48 9 610 0 433 004...

Page 117: ...9 612 0 006 7160 05 04 Camshaftgear hole mm 52 00 52 03 quantity of teeth 72 Specifications High pressure pump gear hole mm 20 000 20 033 quantity of teeth 27 Air compressor gear hole mm 30 00 30 033...

Page 118: ...shaft gear A Idle gear B High pressure fuel pump gear C Camshaft gear D Water pump gear E Air compressor gear F Oil pump gear G Balancer unit driving gear H Balancer unit gears I J For 4 12 engines Ge...

Page 119: ...Gearing Carcass 9 7 9 612 0 006 7160 05 04 Bolts Tightening Torques Specification 5 5 Nm 20 3 Nm 60 5 Nm 5 5 Nm 20 3 Nm 20 3 Nm Tightening sequence 8 5 1 Nm...

Page 120: ...9 8 Gearing Carcass 9 612 0 006 7160 05 04 Bolts Tightening Torques Specification Coincide hole for cotter pin 45 5 Nm 105 5 Nm 200 50 Nm 40 6 Nm...

Page 121: ...Gearing Carcass 9 9 9 612 0 006 7160 05 04 Bolts Tightening Torques Specification 60 5 Nm 60 5 Nm 1st 100 10 Nm 2nd 275 15 Nm Lmax 66 00 mm 8 5 1 Nm...

Page 122: ...9 10 Gearing Carcass 9 612 0 006 7160 05 04 Bolts Tightening Torques Specification 40 6 Nm 30 5 Nm 20 3 Nm 30 5 Nm 30 5 Nm...

Page 123: ...mbly Install the idle bearing without the disk and the thrust ring for a perfect centralization of the intermediary piece Install the intermediary piece tightening the fixation bolts crosswise accordi...

Page 124: ...ication Take care to do not damage the sealing ring Install lubricant oil pump tightening according to the specification Take care to do not damage the sealing ring Attention The centralization of the...

Page 125: ...s 9 13 9 612 0 006 7160 05 04 Install lubrication pipes tightening according to the specification Assembly camshaft gear and tighten the bolts according to the specification Detail of the gears timing...

Page 126: ...bolts of the idle bearing and install the thrust ring of the idle gear The two grooves must stay towards the side of the shaft There are 3 different thickness of thrust ring in order to guarantee the...

Page 127: ...Gearing Carcass 9 15 9 612 0 006 7160 05 04 Tighten all fixation bolts of the gears with the specified torques View of the assembled gears set Install high pressure pump...

Page 128: ...gasket Centre the front cover with the special tool MWM nr 9 610 0 690 019 6 Place the bolts without tightening to allow the movement of the cover Attntion During the engine operation there must not...

Page 129: ...9 612 0 006 7160 05 04 Install the crankshaft seal with the special tool MWM nr 9 610 0 690 019 6 Assembly the temperature and oil pressure sensor Apply the specified torque Tighten the fixation bolt...

Page 130: ...6 7160 05 04 Check the housing of the camshaft phase sensor Clean it if necessary Assembly the front pulley with the damper Tighten the bolts crosswise with the specified torque Lock the engine with t...

Page 131: ...embly the adapter then the sensor of phase and apply the specified torque Before assembling the air compressor put on a layer of Vaseline on the o ring area in order to facilitate the assembly Assembl...

Page 132: ...NOTES 9 20 9 612 0 006 7160 05 04...

Page 133: ...lywheel Housing 10 1 9 612 0 006 7160 05 04 Flywheel and Flywheel Housing Disassembly Notes 10 2 Pre Assembly Inspections 10 3 BoltsTighteningTorques Specification 10 4 Assembly 10 5 Inspections After...

Page 134: ...he engine crankshaft with the special tool MWM nr 9 610 0 690 026 4 The engine could also be locked with a lever positioned on the nut of the water pump gear until that it touches the pulley This way...

Page 135: ...lly check flywheel and gear ring Failures in the starter motor gearing can be caused by broken gear ring or damaged teeth Check if the sensor holes are clean and in good conditions Pre Assembly Inspec...

Page 136: ...612 0 006 7160 05 04 Bolts Tightening Torques Specification Pre torque 100 10 Nm Lmax 36 00 mm Final 275 15 Nm 100 15 Nm 100 15 Nm 100 15 Nm Tighten sequence 100 15 Nm 8 2 Nm 250 20 Nm For the applic...

Page 137: ...embly paying attention to the assembly position of the chamfer indicated by an arrow Well clean the carcass and the engine block Apply a layer of Loctite 515 on the contact surface between the engine...

Page 138: ...en the crankshaft fixation bolts according to the specification Inspections After Assembly After the flywheel installation measure the concentricity of the fitting of the shaft pilot in relation to th...

Page 139: ...he flywheel Maximum side oscillation 0 30 mm Check the parallelism of the flywheel in relation to the housing Maximum parallelism 0 20 mm Dynamic Balancing Holes 10 x 12 mm maximum in a ray of 197 mm...

Page 140: ...NOTES 10 8 9 612 0 006 7160 05 04...

Page 141: ...Balancer Unit 11 1 9 612 0 006 7160 05 04 Balancer Unit Remark 11 2 Disassembly Notes 11 2 Assembly 11 3 BoltsTighteningTorques Specification 11 4 Measurements After Assembly 11 5...

Page 142: ...r unit Loosen the balancer bolts and carefully remove it to do not loosen the bearing Keep the guide pins on their positions Remark The balancer unit is an exclusive item of the 4 cylinders engines es...

Page 143: ...arings with the specified torque leaving the other bearing free for the balancer adjustment Assembly Loosen the bolts of the bearing caps correspondent to the balancer unit and with a rubber hammer mo...

Page 144: ...4 Balancer Unit 9 612 0 006 7160 05 04 Observe the marks 00 and 0 on the balancer gear and on the crankshaft gear ring to guarantee the timing of the system Bolts Tightening Torques Specification 60 5...

Page 145: ...0 20 mm Lean the bearing to eliminate the clearance and slightly move the bearing that is free There are three thicknesses of thrust ring 9 226 0 433 001 4 3 45 to 3 50 mm 3 5 6 208 0 433 003 4 3 55 t...

Page 146: ...ar ring Determine the necessary amount of shims between the balancer and the bearing caps so that that clearance is between 0 05 and 0 18 mm The shims are available with 0 1 mm of thickness Use the sa...

Page 147: ...Balancer Unit 11 7 9 612 0 006 7160 05 04 Reinstall balancer deflector oil suction pipe and carter tightening the bolts according to the specification...

Page 148: ...NOTES 11 8 9 612 0 006 7160 05 04...

Page 149: ...cuit 12 2 Disassembly Notes 12 3 Inspections and Measurements 12 3 TighteningTorques Specification for Components of the Lubrication System 12 5 TighteningTorques Specification for Oil Cooler Connecti...

Page 150: ...12 2 Lubrication System 9 612 0 006 7160 05 04 Lubrication System Lubrication Circuit...

Page 151: ...he Torx bolts avoiding the mixture of lubricant oil in the cooling system The bolts Torx types require a special driver for their removal and if necessary only can be removed when the oil cooler is re...

Page 152: ...t of the carcass and the rotor for damages or excessive waste Check the clearance between oil pump rotors Clearance between rotors 0 05 0 10 mm Check the radial clearance between the outer rotor and t...

Page 153: ...ing Torques Specification for Components of the Lubrication System 25 4 Nm 25 5 Nm 65 10 Nm 16 14 8 6 2 4 12 18 10 15 13 7 5 1 3 11 17 9 Tighten sequence Tightening Torques Specification for Oil Coole...

Page 154: ...12 6 Lubrication System 9 612 0 006 7160 05 04 Tightening Torques Specification for Lubrication Connections of the Compressor 20 6 Nm 20 6 Nm 20 6 Nm 20 6 Nm 10 2 Nm...

Page 155: ...he oil suction pipe in order to do not let the sealing ring to fall inside the suction gallery Install a new carter gasket The gasket must be assembled without glues or adhesives Assembly the carter t...

Page 156: ...12 8 Lubrication System 9 612 0 006 7160 05 04 Clean the sealing surfaces and carefully assembly reinstalling the oil cooler Tighten the sextavado bolts crosswise applying the specified torque...

Page 157: ...oling System 13 1 9 612 0 006 7160 05 04 Cooling System Cooling Circuit 13 2 Disassembly Notes 13 3 Inspections 13 3 ThermostatTest Procedure 13 4 BoltsTighteningTorques Specification 13 5 Assembly 13...

Page 158: ...13 2 Cooling System 9 612 0 006 7160 05 04 Cooling Circuit...

Page 159: ...ter pump carcass and rotor Attention Never perform a service in any component of the cooling system while the engine is running Avoid touching the components of the cooling system soon after the opera...

Page 160: ...f the temperatures at the beginning and final of the thermostat opening course beginning and end of the dial indicator gauge movement and the final total course of the dial indicator gauge fully open...

Page 161: ...Cooling System 13 5 9 612 0 006 7160 05 04 Bolts Tightening Torques Specification 20 3 Nm 8 5 1 Nm 20 5 Nm 40 6 Nm 20 3 Nm 20 3 Nm 20 3 Nm 25 4 Nm 20 6 Nm 8 5 1 Nm...

Page 162: ...ghten all bolts with the specified torque Assembly Assembly the thermostat in the carcass with a new sealing ring Cautions Never operate the engine without the thermostat because the engine will not r...

Page 163: ...7160 05 04 Assembly the thermostat set and tighten the bolts according to the specification Assembly the sensor of temperature Apply the specified torque Assembly all hoses and components of the syst...

Page 164: ...cooling system it is necessary that all the water passages inside the engine are properly filled up The aeration of the cooling system can cause high temperature spots on the cylinder heads and engine...

Page 165: ...3 Common Rail Harness 4 12 14 4 CP 3 3 Pump Rear Part View 14 5 High Pressure Pump Removal 14 7 BoltsTighteningTorques Specification 14 8 Electronic Control Module ECM Disassembly Assembly 14 14 Inspe...

Page 166: ...ies if disassembled The ECM under no circumstances can be disassembled for any kind of service Only the Bosch authorized service station can check or repair any problem in this component after analyze...

Page 167: ...Fuel Injection System 14 3 9 612 0 006 7160 05 04 Common Rail Modulated Pressure Fuel Injection System...

Page 168: ...14 4 Fuel Injection System 9 612 0 006 7160 05 04 Common Rail Harness 4 12...

Page 169: ...p C Fuel return to the tank D Fuel outlet to filter E ECM cooler fuel inlet F Fuel outlet to the Rail G Fuel lift pump BCP 3 3 Identification Plate The identification plate of the high pressure fuel p...

Page 170: ...soltura da tubula o de alta press o recomenda se fixar a conex o de alta press o do injetor com uma chave de boca e s ent o aplicar o torque de desaperto Essa medida se faz necess rio para evitar risc...

Page 171: ...er removing the locks remove fuel injectors using the tool MWM nr 9 612 0 690 001 4 and put them away The solenoid must be protected against impacts Aten o A retirada da conex o de alta press o do inj...

Page 172: ...ning and removing the pipes loosen high pressure pump fixation bolts on the intermediary piece Loosen and remove the fixation nut of the high pressure pump gear by the side of the gearing cover Remove...

Page 173: ...l Injection System 14 9 9 612 0 006 7160 05 04 30 3 Nm 20 6 Nm 20 3 Nm 25 2 Nm 25 2 Nm 30 3 Nm 30 3 Nm 30 3 Nm 25 4 Nm 40 6 Nm 25 2 Nm Tightening Torques Specification 6 12 Fuel Piping 10 1 5 Nm 20 6...

Page 174: ...lts Tightening Torques Specification 1 2 3 4 5 1 Fuel return 2 Fuel filter CP 3 3 Pump 3 Cooler CP 3 3 Pump 4 CP 3 3 Pump Fuel Filter 5 CP 3 3 Pump Rail 25 2 Nm 25 2 Nm 25 2 Nm 25 2 Nm 1st 14 1 Nm 2nd...

Page 175: ...Fuel Injection System 14 11 9 612 0 006 7160 05 04 Tightening Torques Specification ECM Tightening Sequence...

Page 176: ...14 12 Fuel Injection System 9 612 0 006 7160 05 04 Tightening Torques Specification 4 12 Fuel Piping 25 2 Nm 10 1 5 Nm 30 3 Nm 25 4 Nm 40 6 Nm 30 3 Nm 25 2 Nm 25 2 Nm 30 3 Nm 30 3 Nm 30 3 Nm 40 6 Nm...

Page 177: ...Fuel Injection System 14 13 9 612 0 006 7160 05 04 Tightening Torques Specification Harness Brackets 10 1 5 Nm 10 1 5 Nm 10 1 5 Nm 10 1 5 Nm 10 1 5 Nm 10 1 5 Nm 10 1 5 Nm 10 1 5 Nm 10 1 5 Nm 10 1 5 Nm...

Page 178: ...housing of the pump can difficult its removal As it is a component that requires extreme care keep it in a reserved place and far from accidents Attention The high pressure pump must never be disassem...

Page 179: ...ring Clean the residues from the cooler Attention The ECM is a Black Box and must never be disassembled for any reason Antes de fazer a substitui o do componente constatado atrav s da an lise do diagn...

Page 180: ...check the condition of the nipples If necessary change them Apply the specified torque The cooler has a drain plug If the change is necessary first apply liquid gasket and then apply the specified tor...

Page 181: ...Fuel Injection System 14 17 9 612 0 006 7160 05 04 Visually check the ECM pins set Check for dirt and clean if necessary...

Page 182: ...2 0 006 7160 05 04 Assembly Assembly the cooler bracket Apply the specified torque After assembling the bracket assembly cushions on the bracket and apply the specified torque Assembly the cooler with...

Page 183: ...Apply the specified torque Assembly the ECM Attention to the centralization of the fixation bolts in the cooler After positioning the ECM tighten the bolts and apply the specified torque Assembly the...

Page 184: ...yer on the contact area of the o ring with the housing on the intermediary piece Install high pressure pump Perform tightening with care in order to the o ring to do not bite the lateral of the pump P...

Page 185: ...he piping assembly avoiding contaminations Attention The cone of the high pressure pump shaft and the gear must be clean and free of oil and grease before the fixation The materials for cleaning can b...

Page 186: ...ection System Assembly First position new o ring on the injector and put on a Vaseline layer on the ring area Install sealing washers Install injector in cylinder head Assembly the fixation locks of t...

Page 187: ...sembly keep the nut caps inlet and return pipe protected After positioning the injectors assembly the return pipe The assembly must be performed carefully in the connector tightening sense to avoid lo...

Page 188: ...e previous procedure If the fuel filter is assembled use also an articulated tool to tighten and remove the screw Assembly the fuel filter head Apply the specified torque After assembling the Rail beg...

Page 189: ...cket Assembly the high pressure pipe on the Rail Apply the specified torque The high pressure piping must be assembled free of tension avoiding damages and deformations in the piping and nut caps Afte...

Page 190: ...connection on the bracket Assembly the cooler fuel outlet pipe to the high pressure pump Assembly the cooler pipe nut cap of the high pressure pump and apply the specified torque The assembly of the...

Page 191: ...el outlet pipe Keep the same procedure used in the fuel inlet pipe assembly Assembly fuel inlet and outlet pipes of the filter head First visually check the condition of the nipples If necessary chang...

Page 192: ...006 7160 05 04 Assembly the fast connector of the return pipe on the pressure limiter valve Fit the return pipe on the injector Apply the specified tightening torques on the nut caps of the fuel lift...

Page 193: ...tem 14 29 9 612 0 006 7160 05 04 General view of the fuel injection system assembled Assembly the high pressure pipe of the pump to the Rail Apply the specified torque General view of the high pressur...

Page 194: ...om aux lio de uma bomba manual bombear at haver uma pequena restri o ao movimento e logo ap s dar partida no motor Caso o motor n o parta escorvar novamente o sistema com ajuda da bomba manual e tenta...

Page 195: ...5 04 Intake Exhaust and Turbocharger System Disassembly Notes 15 2 Inspections 15 2 Intake Manifold and ElbowTighteningTorques Specification 15 3 Exhaust ManifoldTighteningTorques Specification 15 4 T...

Page 196: ...he engine in operation inside rooms without appropriate ventilation because exhaust gases are extremely toxic Inspections Check the general condition of the turbo blades The contamination of the intak...

Page 197: ...Intake Exhaust andTurbocharger System 15 3 9 612 0 006 7160 05 04 Intake Manifold and Elbow Tightening Torques Specification 25 4 Nm 56 8 Nm 25 4 Nm 56 8 Nm 25 4 Nm 3 0 5 Nm 3 0 5 Nm 25 4 Nm...

Page 198: ...10 Nm 6 2 Nm 20 3 Nm 20 6 Nm 20 6 Nm Exhaust Manifold Tightening Torques Specification Turbocharger Tightening Torques Specification Retighten after the 1st operation of the engine Retighten after the...

Page 199: ...s so that the drying occurs with the manifold already assembled Assembly exhaust manifold with all new gaskets Tighten the bolts according to the specification from the centre to the edges After assem...

Page 200: ...aust andTurbocharger System 9 612 0 006 7160 05 04 Assembly turbocharger lubrication piping Assembly exhaust elbow Tighten nuts according to the specification Retighten the nuts after the 1st operatio...

Page 201: ...urbocharger System 15 7 9 612 0 006 7160 05 04 Tighten the bolts according to the specification Assembly return pipe spacer Apply the specified torque Assembly intake elbow on intake manifold Apply th...

Page 202: ...15 8 Intake Exhaust andTurbocharger System 9 612 0 006 7160 05 04 Assembly air temperature sensor Apply the specified torque...

Page 203: ...Failure Diagnosis 16 1 9 612 0 006 7160 05 04 Failures Diagnosis Introduction 16 2 SymptomTable 16 3 Symptoms 16 3 Probable CausesTable 16 5 Probable Causes 16 5...

Page 204: ...resented some typical problems which the engine may present their probable causes and possible corrections for these problems Attention Study in full detail the problem before trying any action First...

Page 205: ...44 53 Excessive fuel consumption 09 14 15 17 18 21 22 23 25 26 27 29 57 60 Black smoke 09 14 15 17 18 21 22 23 25 26 27 29 53 54 57 60 White bluish smoke 04 14 15 17 19 21 22 23 25 26 27 28 29 39 40 4...

Page 206: ...igh lubricant oil consumption 04 12 13 15 25 27 28 39 49 54 55 58 59 60 66 Water mixed to lubricating oil 10 19 50 Water mixed to lubricating oil 50 Irregular idle speed 07 08 09 10 16 17 29 59 Engine...

Page 207: ...Clean fuel filters or change elements 09 Restriction in the air intake system Free the intake system or clean air filter element dry type 10 Air in fuel system Bleed the system 11 Leakages through se...

Page 208: ...nge 28 Valves stems and guides worn Change 29 Failure in electronic fuel injection system Perform Diagnosis on the system according to the Diagnosis Manual of the engine 30 Damaged or worn bearings Ch...

Page 209: ...7 Radiator blocked outside or inside Clean 48 Defective water pump Change 49 Carter breathe blocked Clean 50 Oil cooler leakage Correct 51 Lack of water in the cooling system Complete level 52 Oil pum...

Page 210: ...er unit out of position Correct 4 cylinders engines 62 Defective damper Change 63 Liner protrusion below specification Correct leakage through liner collar 64 Thermostat bad seating Change 65 Lack or...

Page 211: ...04 GUIDE PIN FOR EXHAUST AND INTAKE MANIFOLD 9 407 0 690 027 4 9 407 0 690 030 4 GUIDE PIN FOR CYLINDER HEAD AND BEARINGS DEVICE TO MEASURE PISTON POSITION AND HEIGHT TO LINER 9 610 0 690 025 4 DEVICE...

Page 212: ...7160 05 04 ADAPTORS FOR ENGINE STAND 9 610 0 690 011 6 DEVICE TO DISASSEMBLY AND ASSEMBLY VALVE SPRINGS 9 407 0 690 044 6 CONNECTOR FOR CYLINDER COMPRESSION TEST 9 612 0 690 003 4 9 610 0 690 014 6 DE...

Page 213: ...612 0 006 7160 05 04 9 610 0 690 019 6 DEVICE TO ASSEMBLY VALVE SEAL DEVICE TO DISASSEMBLY CYLINDER LINER 9 610 0 690 017 6 9 610 0 690 015 4 DEVICE TO ASSEMBLY FRONT SEAL 9 610 0 690 020 6 DEVICE TO...

Page 214: ...05 04 9 612 0 690 002 4 HEXAGONAL ARTICULATED DEVICE FOR EXHAUST MANIFOLD DEVICE TO LOCK ENGINE FLYWHEEL DEVICE TO ASSEMBLY CYLINDER LINERS 9 610 0 690 026 4 9 610 0 690 024 6 DISPOSITIVO PARA APERTAR...

Page 215: ...ASC Comunica o T cnica www asccomunicacao com br Produzido por...

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