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Nanni T4.155 seriers, Workshop Manual

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Nanni T4.155 seriers Workshop Manual Download Page 67

                          

                                      

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Tightening torques (standard) 
Specific tightening torques 
Characteristics 
Special tooling 
Timing pinions 
Cylinder head 
Injection pump and injector 
Fresh water pump and sender, thermostat 
Pre-heating 
Oil pressure, oil injectors, oil pump, oil radiator 
Turbo charger 
Cylinder block 
Your notes 

 
 
 
 
 
 
 
 
 

Setting, adjustment and maintenance operations are described in 

the 

MAINTENANCE MANUAL 

Summary of Contents for T4.155 seriers

Page 1: ...N NU UA AL L 4 4 C Cy yl li in nd de er rs s ENGINE BASE NANNI INDUSTRIES 11 Av MARIOTTE 33260 LA TESTE FRANCE Tel 33 5 56 22 30 60 Fax 33 5 56 22 30 79 E mail contact nannidiesel com Web www nannidie...

Page 2: ...anel C3 19 Technical sheet 51 Electricity engine harnesses 20 Recommendations 53 Special tools 21 Alternator belts 54 Exploded view of M1KZ base 22 Glow plugs 23 Adjusting valve clearance 2nd part Eng...

Page 3: ...60300140 indice A 4 CYLINDERS WORKSHOP MANUAL 3 191 Manuel de Maintenance MOTEUR Base M1KZ T4 155 4 380 TDI 4 390 TDI T4 155 4 380 TDI 4 390 TDI PART ONE...

Page 4: ...60300140 indice A 4 CYLINDERS WORKSHOP MANUAL 4 191...

Page 5: ...60300140 indice A 4 CYLINDERS WORKSHOP MANUAL 5 191...

Page 6: ...the safety steps or draws attention to dangerous practice that could cause injury to personnel or damage to the ship or its components The user will take all useful steps needed for operation and pro...

Page 7: ...with your bare hands Wear gloves Discharged fluids under pressure may cause severe injury If struck by a fluid jet have the injury checked by a physician BATTERY An extremely explosive flammable and v...

Page 8: ...ive in compliance with the in board installation instructions This operating manual contains all information required to ensure correct operation of the engine NANNI INDUSTRIES is represented in more...

Page 9: ...RVICE When the engine has been installed and before removing the protection devices blanking the different ports clean all outer surfaces of the engine These operations must be performed by the shipya...

Page 10: ...LUBRIFICATION Engine Oil pump lubrication system pressure adjusted by discharge valve Disposable cartridge oil filter Transmission Refer to separate specifications Engine oil filling Through the fill...

Page 11: ...visible Continue filling to maximum level Future top ups if necessary will be made with fresh water only engine cold Start the engine and top up the level Verify that there are no leaks Every two year...

Page 12: ...ate the cause before restarting the engine Allow the engine to run at idle speed for 2 or 3 minutes Verify that the seawater effectively flows out via the exhaust If the engine does not start first ti...

Page 13: ...ent protection instructions IMPORTANT These recommendations must be observed Observance of the recommendations will extend the service life of the engine and govern normal coverage of the engine guara...

Page 14: ...a NANNI DIESEL representative to use several batteries When starting with a spare battery and jumper leads proceed as follows Disregard the main battery circuit connect the spare battery to the main...

Page 15: ...Screw the new cartridge to the filter head then tighten by hand of a turn do not use tooling Open the fuel valve Bleed the circuit Start the engine and check sealing CAUTION Always wipe up spilled fue...

Page 16: ...he engine and check for leaks Stop the engine and top up the oil level if necessary WARNING Hot oil can burn Avoid any contact with the skin Observe environment protection rules Reverser Refer to deta...

Page 17: ...tting 0 46 0 02 mm Cold valve clearance Intake 0 20 0 30 Exh 0 25 0 35 Adjustment by shims thickness 0 05 mm Piston protrusion 0 08 0 33 mm TURBOCHARGER RINGS Delivered pressure T4 155 80 90 kPa 4 380...

Page 18: ...S WORKSHOP MANUAL 18 191 RECOMMENDATIONS LUBRICATION AND COOLING E EN NG GI IN NE E O OI IL L API CD CF 15 W 40 Mineral MOTUL TEKMA MEGA OR MOTUL MARINE 4T C CO OO OL LA AN NT T 50 PURE ANTIFREEZE 50...

Page 19: ...drive belts is defective replace both drive belts b Check the sag in the drive belt by pressing the belt with a finger at the locations indicated in the drawing with a force of 98 N 10 kgf Drive belt...

Page 20: ...a new drive belt run the engine for at least 5 minutes and verify the sag or the tension of the drive belt CHECKING GLOW PLUGS REMARK the resistance of glow plugs must be checked when the engine is fi...

Page 21: ...rs are blocked Otherwise turn the crankshaft one complete turn 360 to make the indicator mentioned above coincide 3 MEASURE THE VALVE OPERATING CLEARANCE a Only measure the clearance of the valves ill...

Page 22: ...tool reference 97031 2377 e Select the appropriate size of the thickness shim to make the replacement in compliance with the indications in the formula of the following tables Using a micrometer measu...

Page 23: ...6 2 80 49 3 25 45 2 85 41 3 30 21 2 90 Thickness of new thickness shim Intake valve clearance measured cold 0 20 0 30 EXAMPLE A 2 800 mm thickness shim is currently installed and the measured clearanc...

Page 24: ...5 36 3 20 16 2 80 49 3 25 45 2 85 41 3 30 21 2 90 Thickness of new shims Intake valve clearance 0 25 0 35 MM EXAMPLE A 2 800 mm thickness shim is currently installed and the measured clearance is 0 39...

Page 25: ...Verify the valve operating clearance 4 INSTALLATION OF THE ROCKER COVER a Remove any signs of former gasket on the joint FIPG b Coat the locations illustrated in the figure opposite with sealant c Put...

Page 26: ...e crankshaft pulley counter clockwise so that the notch in the pulley is at 25 or more from the timing cap indicator 3 Release the automatic cold start system a Use a screwdriver to turn the cold star...

Page 27: ...on pump to the timing gear casing f Adjust the plunger stroke by gradually inclining the injection pump body If the plunger stroke is less than the limits stipulated in the specifications incline the...

Page 28: ...ify the travel of the plunger piston 3 The four attachment nuts of the injection pipe coupling on injection pump side Recommended tightening torque 15 N m 150 kgf cm REMOVE THE STEEL PLATE 5 REMOVE TH...

Page 29: ...otches in No 1 and No 2 cam shaft pulleys coincide with the top dead center TDC timing marks 3 WHEN THE TIMING BELT IS RE USED MAKE A MARK ON THE TIMING BELT ADVICE If the timing belt is re used make...

Page 30: ...ight sign of oil is recorded on the lifter sealing gasket the timing rod tensioner is in good condition Replace the tightening belt tensioner if oil leaks are found b Immobilize the timing belt tensio...

Page 31: ...31 191 SEVERAL EXAMPLES OF BELT DAMAGE REQUIRING IMMEDIATE REPLACEMENT Do not wait until it breaks TEARING OFF OF 1 TOOTH Engine blocking CRACKING Intermediate pulley deformation SIDE TORN OFF Pulley...

Page 32: ...b Verify that the intermediate pulley moves normally Otherwise verify the intermediate pulley and the washer 3 POSITION THE TIMING BELT TENSIONER a Use a press and slightly compress the push rod under...

Page 33: ...do not coincide remove the timing belt and reinstall once more 6 REINSTALL THE TIMING BELT PROTECTION COVER a Remove signs of former sealant FIPG b Coat the timing gear cover and cam shaft oil gasket...

Page 34: ...CTION PUMP WIRING COUPLING UNIT POWER SUPPLY CUTOFF CONTROL SOLENOID 3 REMOVE THE INJECTORS 4 MEASURE THE COMPRESSION PRESSURE OF EACH CYLINDER a Install the accessory on the injector port b Connect t...

Page 35: ...and repeat checking operations a to c on the cylinder where the pressure is low If adding engine oil in the cylinders makes it possible to increase the compression pressure it is probable that the fa...

Page 36: ...wn on the figure opposite Verify that the sensor is perpendicular to the surface of the cylinder block gasket and piston head d Find the position corresponding to the greatest percentage of piston hea...

Page 37: ...select the most appropriate value and then choose the appropriate cylinder head gasket in compliance with the information given in the table below Piston protrusion in mm Gasket size 0 08 0 12 Use gas...

Page 38: ...ly tighten these eighteen cylinder head bolts in several steps in compliance with the order indicated in the figure opposite Recommended tightening torque 39 N m 400 kgf cm c Identify the front of the...

Page 39: ...the assembly surfaces of the cylinder head and cam shaft oil gasket retainer with oil Carefully remove all signs of former sealant FIPG from gasket application surfaces and from the sealing groove us...

Page 40: ...ARDWARE IN DIRECT CONTACT WITH SEA WATER MUST BE MADE OF A4 70 STAINLESS STEEL SEA WATER PUMP Replacing the rotor and cover gasket THERMOSTAT Opening temperature check replacement OPENING 71 C COOLERS...

Page 41: ...60300140 indice A 4 CYLINDERS WORKSHOP MANUAL 41 191 EXCHANGER Clean the core and replace o rings CAUTION Core securing screw in exchanger body INTERCOOLER Clean the core and replace o rings...

Page 42: ...60300140 indice A 4 CYLINDERS WORKSHOP MANUAL 42 191 ANODE ON EXHAUST ELBOW Check and replace COOLANT 50 PURE ANTIFREEZE 50 FRESH WATER IMPORTANT BLEED THE FRESH WATER CIRCUIT ON THE TURBO CHARGER...

Page 43: ...ERS WORKSHOP MANUAL 43 191 INDICATORS Pre heating Water in fuel and water alarm Oil alarm Battery charging PANEL C3 rectangular connector PANEL C3 round connector INDICATORS Water in fuel Water alarm...

Page 44: ...60300140 indice A 4 CYLINDERS WORKSHOP MANUAL 44 191...

Page 45: ...terminals 2 terminals TERMINAL No WIRE COLOUR FUNCTION 1 RED BATTERY 2 BLACK BATTERY 3 BROWN STARTER 4 BROWN 1 PRE HEATING 5 WHITE STOP 6 GREY OIL PRESSURE SWITCH 7 PURPLE ALTERNATOR LOAD 8 GREY 1 OIL...

Page 46: ...60300140 indice A 4 CYLINDERS WORKSHOP MANUAL 46 191...

Page 47: ...PINK BLACK OIL ALARM 6 YELLOW GREEN WATER ALARM 7 BROWN STARTING 8 ORANGE BLUE WATER TEMPERATURE PROBE 9 GREEN PRE HEATING TIMEOUT PROBE 10 WHITE ENGINE STOP 11 BLUE REV COUNTER 12 BLUE GREY REV COUNT...

Page 48: ...60300140 indice A 4 CYLINDERS WORKSHOP MANUAL 48 191 ELECTRICAL DRAWING Rectangular connector...

Page 49: ...60300140 indice A 4 CYLINDERS WORKSHOP MANUAL 49 191...

Page 50: ...nsion controller 970 312 375 Valve adjustment tool 970 312 377 Injection pump dial gauge support 970 312 378 Pulley pinion extractor box usable on all NANNI models 970 312 374 Valve spring compressor...

Page 51: ...191 CONTENTS EXPLODED VIEW OF THE 4 CYLINDERS TOYOTA base ENGINE TIMING BELT TIMING CASING TIMING PINIONS CYLINDER HEAD CYLINDER BLOCK GLOW PLUGS INJECTORS INJECTION PUMP THERMOSTAT FRESH WATER PUMP O...

Page 52: ...REMOVAL AND REINSTALLATION Cylinder Head cover Cam shaft No 1 tightening pulley Gasket Fastener Timing belt Specified tightening torque Non reusable part Intermediate timing pulley Timing belt tension...

Page 53: ...60300140 indice A 4 CYLINDERS WORKSHOP MANUAL 53 191...

Page 54: ...60300140 indice A 4 CYLINDERS WORKSHOP MANUAL 54 191...

Page 55: ...60300140 indice A 4 CYLINDERS WORKSHOP MANUAL 55 191...

Page 56: ...60300140 indice A 4 CYLINDERS WORKSHOP MANUAL 56 191...

Page 57: ...60300140 indice A 4 CYLINDERS WORKSHOP MANUAL 57 191...

Page 58: ...60300140 indice A 4 CYLINDERS WORKSHOP MANUAL 58 191...

Page 59: ...60300140 indice A 4 CYLINDERS WORKSHOP MANUAL 59 191...

Page 60: ...60300140 indice A 4 CYLINDERS WORKSHOP MANUAL 60 191...

Page 61: ...60300140 indice A 4 CYLINDERS WORKSHOP MANUAL 61 191...

Page 62: ...60300140 indice A 4 CYLINDERS WORKSHOP MANUAL 62 191...

Page 63: ...60300140 indice A 4 CYLINDERS WORKSHOP MANUAL 63 191...

Page 64: ...60300140 indice A 4 CYLINDERS WORKSHOP MANUAL 64 191...

Page 65: ...60300140 indice A 4 CYLINDERS WORKSHOP MANUAL 65 191...

Page 66: ...60300140 indice A 4 CYLINDERS WORKSHOP MANUAL 66 191 Manuel de Maintenance MOTEUR Base M1KZ T4 155 4 380 TDI 4 390 TDI T4 155 4 380 TDI 4 390 TDI PART TWO...

Page 67: ...g torques Characteristics Special tooling Timing pinions Cylinder head Injection pump and injector Fresh water pump and sender thermostat Pre heating Oil pressure oil injectors oil pump oil radiator T...

Page 68: ...60300140 indice A 4 CYLINDERS WORKSHOP MANUAL 68 191...

Page 69: ...0 930 1400 7 5 17 5 36 65 100 75 175 360 670 1050 6T 6 8 10 12 14 16 1 1 25 1 25 1 25 1 5 1 5 8 19 39 71 110 170 80 195 400 730 1100 1750 9 21 44 80 125 90 210 440 810 1250 7T 6 8 10 12 14 16 1 1 25 1...

Page 70: ...x crankshaft 363 3700 Cam shaft oil gasket retainer x cylinder head 9 90 Cam shaft bearing cap x cylinder head 18 185 Cylinder head x cylinder block 1st stage 2nd stage 3rd stage 39 Turn 90 Turn 90 4...

Page 71: ...2 60 mm 2 65 mm 2 70 mm 2 75 mm 2 80 mm 2 85 mm 2 90 mm 2 95 mm 3 00 mm 3 05 mm 3 10 mm 3 15 mm 3 20 mm 3 25 mm 3 30 mm 0 48 mm 800 50 rpm 4 200 50 rpm Compression pressure at 250 rpm STD Limited Pre...

Page 72: ...lubrication clearance STD Intake Exhaust Limit Intake Exhaust Valve head thickness STD Intake Exhaust Limit Intake Exhaust 103 29 103 69 mm 102 79 mm 45 5 7 975 7 990 mm 7 960 7 975 mm 0 020 0 055 mm...

Page 73: ...mit Top compression ring Sealing ring Oil scraper ring 95 940 95 950 mm 95 950 95 960 mm 95 960 95 970 mm 96 440 96 470 mm 96 690 96 720 mm 96 940 96 970 mm 0 050 0 070 mm 0 14 mm 0 060 0 110 mm 0 060...

Page 74: ...ity Limit Crank pin ovlization and conicity Limit Crankshaft bearing cap bolt external diameter STD Limit 0 04 0 240 mm 0 30 mm 2 430 2 480 mm 2 555 2 605 mm 2 493 2 543 mm 0 036 0 054 mm 0 037 0 077...

Page 75: ...tor belt tension controller 970 312 375 Valve adjustment tool 970 312 377 Injection pump dial gauge support 970 312 378 Pulley pinion extractor box Usable on all NANNI models 970 312 374 Valve spring...

Page 76: ...60300140 indice A 4 CYLINDERS WORKSHOP MANUAL 76 191...

Page 77: ...60300140 indice A 4 CYLINDERS WORKSHOP MANUAL 77 191...

Page 78: ...s coincide with the top dead center timing marks 3 WHEN THE TIMING BELT IS RE USED MAKE A MARK ON THE TIMING BELT WARNING If the timing belt is re used make a mark in the rotation direction on the tim...

Page 79: ...ulley flange and the cam shaft No 2 timing pulley 8 REMOVE THE ROCKER COVER Remove the ten assembly bolts the two attachment nuts the rocker cover and the gasket 9 REMOVE THE CAM SHAFT No 1 TIMING PUL...

Page 80: ...THE CAM SHAFT OIL GASKET RETAINER Remove the seven assembly bolts and cam shaft oil gasket retainer 4 REMOVE THE CRANKSHAFT PULLEY a Remove the assembly bolt and the crankshaft pulley plate using the...

Page 81: ...ANCE OF THE INTERMEDIATE TOOTHED WHEEL Use a dial gauge to measure the axial clearance of the intermediate toothed wheel Nominal axial clearance 0 05 0 15 mm Axial clearance limit 0 30 mm Replace the...

Page 82: ...ing the service bolt Recommended service bolt Thread diameter 6 mm Thread pitch 1 0 mm Bolt length 28 mm WARNING When removing the intermediate toothed wheel check that the twist force of the secondar...

Page 83: ...termediate toothed wheel and the secondary No 2 intermediate toothed wheel in a vice REMARK Make sure not to damage the toothed wheels during this operation b Use the special maintenance tool SST to t...

Page 84: ...mediate toothed wheel in a vice REMARK Make sure not to damage the toothed wheels during this operation g Remove the snap ring with snap ring pliers h Remove the following parts 1 Star washer 2 No 2 s...

Page 85: ...eter 43 965 44 000mm c Subtract the external diameter measurement of the intermediate toothed wheel shaft from the internal diameter of the intermediate toothed wheel measurement Nominal lubrication c...

Page 86: ...F THE TIMING TOOTHED WHEEL TEETH Install the dial gauge to measure the teething reactive clearance between each toothed wheel of the timing Nominal teething reactive clearance 0 02 0 15 mm Teething re...

Page 87: ...special maintenance tool SST and a hammer to fit the new oil gasket Enter the gasket until its surface is flush with the surface of the timing casing cover c Coat the oil gasket lip with grease MP B W...

Page 88: ...he new oil gasket Enter the gasket until its surface is flush with the surface of the timing casing cover c Coat the oil gasket lip with grease MP B When the timing case cover is installed on the cyli...

Page 89: ...ing 2 No 2 secondary intermediate toothed wheel 3 Star washer ADVICE Make the pawls of the toothed wheels coincide with the spring ends c Remove the snap ring with snap ring pliers d Use the special m...

Page 90: ...cial maintenance tool SST to make the holes in the intermediate toothed wheel and the No 1 secondary intermediate toothed wheel coincide by turning the No 2 secondary intermediate toothed wheel clockw...

Page 91: ...wheel B Reinstall the injection pump drive pinion a Put the assembly key in the front of the injection pump shaft groove b The alignment marks of the driven toothed wheel of the No 2 balancing shaft m...

Page 92: ...cide respectively with the timing setting mark 5 of the crankshaft and the timing setting mark 4 of the injection pump drive pinion then engage timing toothed wheels mesh d Make the stop washer assemb...

Page 93: ...for this purpose Carefully clean all removed parts to eliminate any signs of the product Clean the two sealing surfaces using a residue free solvent c Apply a bead of sealant on the timing casing cov...

Page 94: ...achment nuts of the injection pump and the three spacer assembly bolts securing the injection pump and re tighten them as necessary to obtain the necessary clearance If the axial clearance is still in...

Page 95: ...TI IO ON N A AN ND D S SE ET TT TI IN NG G O OF F T TH HE E T TI IM MI IN NG G B BE EL LT T 6 REINSTALL THE SEA WATER PUMP Recommended tightening torque 21 N m 210 kgf cm 7 REINSTALL THE CAM SHAFT OIL...

Page 96: ...60300140 indice A 4 CYLINDERS WORKSHOP MANUAL 96 191...

Page 97: ...ating washer the attachment nut and the cable d Remove the two electrical wire harness attachments of the engine e Remove the seven attachment nuts the intake manifold and the four seals REMOVE THE WA...

Page 98: ...ow plugs must be handled DRAIN THE ENGINE COOLANT REMOVE THE INTAKE PIPE REMOVE THE OIL LEVEL GAUGE AND ITS GUIDE a Remove the attachment nut and the oil level gauge guide assembly b Remove the guide...

Page 99: ...ring the camshaft oil seal retainer to the cylinder head b Remove the cam shaft oil seal retainer to separate it REMOVE THE CAMSHAFT a Uniformly loosen and remove the ten bearing cap assembly bolts in...

Page 100: ...n blocks placed on the bench ADVICE If the cylinder head is difficult to separate prise with a screwdriver pushed between the cylinder block and the cylinder head REMARK Pay attention not to damage th...

Page 101: ...ecial maintenance tool SST and remove the two half keys b Remove the spring cup retainer the valve spring the valve and the valve cup ADVICE Remove valves valve spring cups and spring cup keys in the...

Page 102: ...Also remove any particles of sealant from the surface of the cylinder block REMARK take care not to scratch the surfaces c Eliminate accumulation of carbon deposits and oil in bolt holes with compress...

Page 103: ...HEAD A Check flatness Use a precise straight edge and a set of thickness shims to measure the contact clearance of the surface between the cylinder block and the manifolds and to detect any possible w...

Page 104: ...ometer Guide inside diameter 8 010 8 030 mm b Use a micrometer to measure the diameter of valve stems Valve stem diameter Intake 7 975 7 990 mm Exhaust 7 960 7 975 mm c Subtract the measured value for...

Page 105: ...an 13 027 mm grind the valve guide bush valve bore to the dimensions indicated below Re bore dimension of the cylinder head valve guide bush 13 050 13 077 mm If the diameter of the cylinder head valve...

Page 106: ...e 1 1 mm Exhaust 1 2 mm If the thickness of the valve head is less than the minimum dimension replace the valve involved d Measure the overall length of the valves Nominal overall length of the valve...

Page 107: ...valve this means that the valve is concentric Replace the valve if it is not like this If the blue appears over 360 on the surface of the valve seat this means that the valve seat and guide are conce...

Page 108: ...ion of the valve spring at the installed and specified length Installed spring tension 301 332 N 30 7 33 9 kgf over a 37 0 mm length Replace the valve spring if the tension of the installed spring is...

Page 109: ...trunnion diameter is less than the indicated dimension D Check cam shaft bearings Check for flaking and scratching on bearings Replace bearing caps and the cylinder head as a matched pair if bearings...

Page 110: ...he cam shaft b Measure the cam shaft axial clearance with a dial gauge by moving the cam shaft from back to front Nominal axial clearance 0 08 0 18 mm Axial clearance limit 0 25 mm Replace the cam sha...

Page 111: ...D EXHAUST MANIFOLDS Use a ground straight edge and a set of thickness shims to verify the degree of warping of cylinder head contact surfaces Warping limit 0 40 mm If warping exceeds the limit stipula...

Page 112: ...t a new oil gasket until its surface is flush with the surface of the cam shaft oil gasket retainer c Coat the oil gasket lip with grease MP B When the cam shaft oil gasket retainer is installed on th...

Page 113: ...in a c Take the thickness of the new combustion chamber and subtract the thickness of the former combustion chamber to be able to select an appropriate thickness shim from amongst those listed in the...

Page 114: ...s 0 03 plus 0 02 mm If the protrusion of the combustion chamber is less than the specified dimension obtain this dimension with thickness shims Thickness shim thickness 0 05 mm 0 10 mm If the protrusi...

Page 115: ...e valve lifters turn normally when moved by hand 5 REINSTALL THE WATER TEMPERATURE SENDER GAUGE 6 REINSTALL THE CABLE ATTACHMENT PLATE 7 REINSTALL THE SEMI CIRCULAR CAP a remove signs of former gasket...

Page 116: ...t the sensor is perpendicular to the surface of the cylinder block gasket and the piston head d Find the position corresponding to the greatest percentage of piston head protrusion by slowly rotating...

Page 117: ...select the most appropriate value and then choose the appropriate cylinder head gasket in compliance with the information given in the table below Piston protrusion mm Gasket size 0 08 0 12 Use gaske...

Page 118: ...formly tighten these eighteen cylinder head bolts in several steps in compliance with the order indicated in the figure opposite Recommended tightening torque 39 N m 400 kgf cm c Identify the front of...

Page 119: ...the assembly surfaces of the cylinder head and cam shaft oil gasket retainer with oil Carefully remove all signs of former sealant FIPG from gasket application surfaces and from the sealing groove us...

Page 120: ...sing cap c Coat two or three threads at the end of assembly bolts with sealant d Reinstall the retainer using the seven assembly bolts Recommended tightening torque 9 N m 90kgf cm 6 REINSTALL THE TIMI...

Page 121: ...60300140 indice A 4 CYLINDERS WORKSHOP MANUAL 121 191...

Page 122: ...60300140 indice A 4 CYLINDERS WORKSHOP MANUAL 122 191...

Page 123: ...B c Loosen the eight injection pipe attachment coupling nuts d Remove the four injection pipes and the two pipe retainers A REMOVE THE FUEL RETURN PIPE a Disconnect the flexible supply pipe from the f...

Page 124: ...s at the injector nozzle c Operate the control lever more slowly and observe the pressure indicated by the pressure gauge d Interpret the pressure indicated by the pressure gauge as soon as the inject...

Page 125: ...and verify that no fuel drops occur for 10 seconds by the injector nozzle or around the attachment nut If a fuel drop is found in less than 10 seconds replace or disassemble the injector to clean it a...

Page 126: ...attachment nut REMARK When disassembling the injector make sure not to let any internal parts fall b Remove the pressure spring the thickness shim the pressure pin the spacing part and the injector C...

Page 127: ...lace complete injector when any one of the parts has the slightest defect CHECK THE INJECTORS a Carefully clean the injector in fresh diesel fuel ADVICE Never touch the assembly surfaces of the inject...

Page 128: ...RY OUT AN INJECTION PRESSURE TEST AND FUEL ATOMIZATION JET SHAPE TEST REINSTALL THE INJECTORS refer to the component part illustration for removal and reinstallation REINSTALLING THE INJECTORS a Reins...

Page 129: ...reinstall the four injection pipes and the two fasteners A b Reinstall the two attachment nuts securing the fasteners A to the intake manifold Recommended tightening torque 6 N m 65 kgf cm c Use a scr...

Page 130: ...60300140 indice A 4 CYLINDERS WORKSHOP MANUAL 130 191...

Page 131: ...check whether the timing lines are aligned If this is not the case make new alignment marks on the injection pump to facilitate reassembly Remove the two attachment nuts securing the injection pump to...

Page 132: ...SOR 2 VERIFY THE WATER TEMPERATURE SENSOR Use the special maintenance tool SST to verify the resistance between the terminals using an ohmmeter Resistance Refer to the diagram If the resistance is not...

Page 133: ...60300140 indice A 4 CYLINDERS WORKSHOP MANUAL 133 191...

Page 134: ...justment lock bolt c Loosen the adjustment bolt and remove the drive belt d Remove all four attachment nuts the fan and the hydraulic coupling and also the water pump drive pulley 3 REMOVE THE TIMING...

Page 135: ...tion 1 REINSTALL THE COMPLETE WATER PUMP a Install a new gasket on the water pump cover b Temporarily reinstall the water pump and the water pump cover with the assembly bolts c Install a new gasket o...

Page 136: ...REINSTALL THE CAM SHAFT OIL SEAL RETAINER 3 REINSTALL THE CAM SHAFT TIMING PULLEY 4 REINSTALL THE INTERMEDIATE PULLEY AND THE TIMING BELT 5 REINSTALL THE WATER PUMP PULLEY AND THE DRIVE BELT a Reinst...

Page 137: ...thermostat may have a negative effect and cause a decrease to cooling system efficiency Do not remove the thermostat even if the engine has a tendency to overheat 1 DRAIN THE ENGINE COOLANT 2 DISCONN...

Page 138: ...t when the valve lift is not within the limits complying with specifications d Check that the thermostat spring is fully stretched when the thermostat is fully closed Replace the thermostat if not ful...

Page 139: ...xcessively when removing them may cause the ceramic to split Consequently wherever possible avoid moving glow plugs The heating element is made of ceramic Consequently allowing the glow plug to fall o...

Page 140: ...on for removal and reinstallation REMARK before reinstalling the glow plugs first remove any accumulation of carbon deposit on the glow plug holes in compliance with the procedure described below a Pu...

Page 141: ...KING ON BOARD REMARK When checking the glow plug resistance the engine must on board Avoid removing and reinstalling glow plugs as far as possible CHECKING GLOW PLUGS Check that there is electrical co...

Page 142: ...any leaks and top up so that the oil level is at the F mark 3 REMOVE THE OIL SENDER GAUGE 4 INSTALL ING OIL PRESSURE GAUGE IN ITS PLACE 5 WARM UP THE ENGINE Start the engine and allow it to heat until...

Page 143: ...HE ENGINE OIL 2 REMOVE THE ENGINE BOTTOM CASING 3 REMOVE THE CHECK VALVE AND THE OIL JETS Remove the four check valves and the oil jets CHECKING OIL JETS 1 CHECK THE CHECK VALVES Press the check valve...

Page 144: ...reinstallation 1 REINSTALL OIL JETS AND THE CHECK VALVES a Make the lubrication injector pin coincide with the corresponding hole in the cylinder block b Reinstall the lubrication injector with the c...

Page 145: ...60300140 indice A 4 CYLINDERS WORKSHOP MANUAL 145 191...

Page 146: ...OVE THE TIMING BELT 5 REMOVE THE TIMING GEARS 6 REMOVE THE ALTERNATOR ADJUSTMENT BAR a Remove the lock bolt b Remove the assembly bolt and the adjustment bar 7 REMOVE THE ALTERNATOR AND THE ALTERNATOR...

Page 147: ...TIMING CASING Before removing the two nuts securing the injection pump flange on the timing casing verify that the timing lines coincide correctly Otherwise mark alignment marks to facilitate reassem...

Page 148: ...RS A Check the rotor clearance Measure the clearance between the driven rotor and the oil pump body using a set of thickness shims Nominal clearance of the rotor type oil pump body 0 100 0 170 mm Clea...

Page 149: ...nce 0 15 mm Replace rotors if the clearance recorded is greater than the indicated limit If necessary replace the complete oil pump REASSEMBLING THE OIL PUMP Refer to component part illustration for r...

Page 150: ...free solvent to clean the application surfaces REMARK do not let the sealant fall on painted surfaces b Coat the timing casing with sealant at the locations illustrated in the figure opposite Put an...

Page 151: ...he coupling bolt Recommended tightening torque 13 N m 130 kgf cm for the assembly bolt Recommended tightening torque 16 N m 160 kgf cm for the coupling bolt i Reinstall the two attachment nuts securin...

Page 152: ...alant formed at the time of installation on gasket application surfaces and the sealant groove Carefully clean all component parts so as to leave no sign of the former sealant Use a residue free solve...

Page 153: ...T BAR Reinstall the adjustment bar with the assembly bolt and the lock bolt Recommended tightening torque 21 N m 210kgf cm REINSTALL THE TIMING GEARS REINSTALL THE TIMING BELT REINSTALL THE WATER PUMP...

Page 154: ...60300140 indice A 4 CYLINDERS WORKSHOP MANUAL 154 191...

Page 155: ...REMOVE THE OIL LEVEL GAUGE AND ITS GUIDE a Remove the attachment nut and the oil level gauge guide assembly b Remove the o ring from the oil level gauge guide 6 REMOVE THE OIL FILTER 7 SEPARATE THE OI...

Page 156: ...il radiator cover 10 REMOVE THE DISCHARGE VALVE 11 REMOVE THE OIL DRAIN PLUG CHECKING THE OIL COOLER AND THE DISCHARGE VALVE 1 VERIFY THE DISCHARGE VALVE Push the discharge valve with a wooden stick a...

Page 157: ...ew gasket on the discharge valve Recommended tightening torque 39 N m 400 kgf cm 3 REINSTALL THE OIL COOLER AND THE OIL COOLER CASING Reinstall two new seals on the oil radiator and the oil radiator c...

Page 158: ...m 130 kgf cm 6 REINSTALL THE OIL LEVEL GUIDE AND THE OIL LEVEL GAUGE Reinstall a new o ring on the oil level gauge guide Reinstall the oil level gauge guide assembly with the attachment nut Recommend...

Page 159: ...60300140 indice A 4 CYLINDERS WORKSHOP MANUAL 159 191...

Page 160: ...ECK THE RADIAL CLEARANCE OF THE IMPELLER a Working from the oil delivery connector side fit the dial gauge in the centre part of the impeller shaft b Move the impeller shaft in the radial direction an...

Page 161: ...60300140 indice A 4 CYLINDERS WORKSHOP MANUAL 161 191...

Page 162: ...LLEYS 4 REMOVE THE CYLINDER HEAD 5 REMOVE THE ALTERNATOR AND THE ALTERNATOR ATTACHMENT PLATE 6 REMOVE THE WATER PUMP 7 REMOVE THE TIMING GEARS 8 REMOVE THE INJECTION PUMP 9 REMOVE THE ENGINE LOWER CAS...

Page 163: ...cing shaft backwards and forwards Nominal axial clearance 0 065 0 140 mm Axial clearance limit 0 25 mm Replace the balancing shaft stop bush if the axial clearance limit is exceeded If necessary repla...

Page 164: ...ring engraver to mark the alignment marks on the connecting rod and the connecting rod cap so as to prevent any confusion during reassembly b Remove the connecting rod cap assembly bolts c Use the two...

Page 165: ...cation Lubrication clearage Nominal 0 036 0 054 mm Dimension less than 0 25 and dimension less than 0 50 0 037 0 077 mm Clearance limit 0 10 mm Replace the shell bearings if the clearance limit is exc...

Page 166: ...kshaft crank pin diameter Mark 1 58 994 59 000 mm Mark 2 58 988 58 994 mm Mark 3 58 982 58 988 mm Thickness of the standard size shell bearing centre wall Mark 2 1 486 1 489 mm Mark 3 1 489 1 492 mm M...

Page 167: ...mm Dimension less than 0 25 2 555 2 605 mm Dimension less than 0 125 2 493 2 543 mm 9 REMOVE CRANKSHAFT BEARING CAPS AND VERIFY THE LUBRICATION CLEARANCE a Gradually loosen and remove the assembly bo...

Page 168: ...signs of pitting and scratching When a pivot or shell bearing is damaged grind it or replace the crankshaft f Reinstall the crankshaft in the cylinder block g Put a strip of plastigage across the cran...

Page 169: ...ng of the same number If it is not possible to determine the shell bearing number choose an appropriate one by adding the numbers stamped on the connecting cylinder head and the crankshaft then select...

Page 170: ...Carefully remove any signs of plastigage 10 REMOVE THE CRANKSHAFT a Remove the crankshaft by lifting it up straight b Remove the upper shell bearings and the upper end shims from the cylinder block AD...

Page 171: ...nd a set of thickness shims to measure the top contact surfaces of the cylinder block and check whether there is any deformation Warping limit 0 10 mm Replace the cylinder block when the amount of war...

Page 172: ...necessary replace the cylinder block 5 CUTTING CYLINDER COLLARS When wear is less than 0 2 mm obtain a collar lifter to grind the top edge of the cylinder involved 6 CHECK THE ASSEMBLY BOLTS OF THE CR...

Page 173: ...in as a matched assembly when the clearance is recorded 2 REMOVE THE PISTON RINGS a Use a ring remover and remove the two compression rings of the piston and the oil scraper ring b Remove the expander...

Page 174: ...ings and connecting rods in groups in compliance with the matched pair corresponding to each cylinder CHECKING THE CONNECTING ROD PISTON ASSEMBLIES 1 CLEAN THE PISTONS a Remove carbon deposits from th...

Page 175: ...mm b Measure the cylinder bore diameter in the stop direction c Subtract the piston diameter measurement from the cylinder bore diameter measurement Nominal lubrication clearance 0 050 0 070 mm Lubric...

Page 176: ...o 120 mm from the top surface of the cylinder block c Measure the ring gap using a set of thickness shims Nominal ring gap Top compression ring 0 350 0 570 mm Compression ring 0 400 0 600 mm Oil scrap...

Page 177: ...when twisting exceeds the indicated limit B Check the connecting rod assembly bolts Use a Vernier caliper to check the minimum diameter of the compressed section of the bolt thread at the location whe...

Page 178: ...ecting rod assembly D If necessary replace the connecting rod small end nozzles a Drive out the connecting rod small end nozzle using special maintenance tool SST and a press b Use a fine file to slig...

Page 179: ...e piston pin bore reamer to ream the connecting rod small end nozzle to bring it to the nominal dimension between the nozzle and the piston pin refer to operation C quoted above g Check the piston pin...

Page 180: ...the balancing shaft bearing pivot External diameter of the bearing trunnion measured from the front of the engine No 1 41 941 41 960 mm No 2 40 931 40 950 mm No 3 31 941 31 960 mm c Subtract the meas...

Page 181: ...TERIAL TO REAM OUT IN THE CYLINDERS a Using a micrometer measure the diameter of the piston at right angles to the geometrical centre line of the piston pin hole and at the specified distance of 58 8...

Page 182: ...han 0 50 mm 69 495 69 505 mm Diameter of the crankshaft crank pin Nominal 58 982 59 000 mm Dimension less than 0 25 58 745 58 755 Dimension less than 0 50 mm 58 495 58 505 mm Verify the lubrication cl...

Page 183: ...ool until the gasket is flush with the edge of the rear oil gasket retaining cage c Coat the lip of the gasket with MP grease B When the rear oil gasket retaining cage is installed in the cylinder blo...

Page 184: ...80 C c Coat the piston pin with engine oil d Make the front mark of the piston and the connecting rod in line and then push the piston pin into the piston with the pressure generated by the thumb e Re...

Page 185: ...mark Top compression ring 1N Compression ring 2N d Position the rings so that the ring gaps are positioned as illustrated in the figure REMARK Never put ring gaps in the same alignment 3 REINSTALL THE...

Page 186: ...STALL THE INJECTORS AND CHECK VALVES a Make the needle of the injector coincide with the cylinder block needle hole b Reinstall each injector with its check valve Reinstall the four injectors and chec...

Page 187: ...RUST BEARING BUSHES A Reinstall the crankshaft bearing caps and the lower stop bushes on the cylinder block a Reinstall the two stop bushes on the crankshaft No 5 bearing cap taking care to orient the...

Page 188: ...ications must be replaced c Identify the front of the crankshaft bearing cap assembly bolts with paint d Retighten the crankshaft bearing cap assembly bolts 90 working in the numbered order opposite e...

Page 189: ...deformed a Lightly coat the thread on the top of the connecting rod cap bolt heads with engine oil b Reinstall and alternately tighten the connecting rod cap assembly bolts to the tightening torque i...

Page 190: ...the applied sealant and start again When the product application operation is completely finished remove the nozzle and immediately put the cap back on the tube c reinstall the rear oil gasket retain...

Page 191: ...NSTALL THE CYLINDER HEAD 12 REINSTALL THE TIMING BELT AND THE TIMING PULLEYS 13 REMOVE THE COMPLETE ENGINE FROM THE ENGINE TEST BENCH 14 REINSTALL THE REAR CLOSING PLATE Reinstall the rear closing pla...

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