Vectra Fitness 175 Engine Technical Manual Download Page 1

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Summary of Contents for 175

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Page 2: ...ENGINE TECHNICAL MANUAL...

Page 4: ...ENTIVE MAINTENANCE 21 F FUEL SYSTEM 27 G COOLING SYSTEM WATER PUMP 33 H FRONT OIL SEAL 35 I FLY WHEEL AND REAR END OIL SEAL 37 J LUB OIL SUMP BALANCER UNIT AND OIL PUMP 40 K CYLINDER HEAD 45 ASPIRATIO...

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Page 6: ...or malfunction of the product Note It is used to draw attention to important information to facilitate procedure or handling Section A GENERAL INFORMATION TOOLS AND MEASURING EQUIPMENT Be sure that a...

Page 7: ...Page No 6 Section B ENGINE VIEW...

Page 8: ...Page No 7 ENGINE VIEW...

Page 9: ...stamped on the Camshaft Tunnel of the Block When requesting information regarding the engine please quote complete engine number T SJ436 E 00027 T SJ 4 3 6 E 000 27 Turbocharged Serial Number Simpsons...

Page 10: ...side 65 6 6 M10 x 1 0 Cylinder head setscrew Refer Section K X X M12 x 1 5 Connecting rod nuts 80 8 3 7 16 20 UNF Main bearing setscrews 155 15 9 M14 x 2 Idler gear hub nut lower and upper 28 2 9 M10...

Page 11: ...operated fitted on Fuel Filter mounting Bracket by Tractor Manufacturing Provision for plunger type fuel lift pump fitted on cam tunnel driven by engine cam shaft also is available Application Tracto...

Page 12: ...pe Production liner Dry Interference fit Service liner Dry pre finished transition fit Outside diameter of liner 3 861 3 860 inch 98 075 98 047 mm Interference fit of liner in Cylinder Block 0 003 0 0...

Page 13: ...e diameter Gudgeon Pin Type Fully Floating Outside dia of gudgeon pin 1 2497 1 2500 inch 31 74 31 75 mm Fit in piston boss Transition Clearance fit in Small end Bush 0 0005 0 0017 inch 0 013 0 044 mm...

Page 14: ...ed 1 2275 inch 31 1785 mm maximum The maximum permissible undersize is 0 030 inch 0 76 mm Crankshaft main and connecting rod journals are nitrided and requires nitriding when reground to undersize bey...

Page 15: ...311 0 312 inch 7 90 7 92 mm Outside Dia 0 5127 0 513 inch 13 023 13 034 mm Overall Length 2 323 2 315 inch 59 00 58 80 mm Guide Protrusion above Cyl head Top Face 0 392 0 396 inch 9 95 10 05 mm Interf...

Page 16: ...ing the bushes in the gear bore Crankshaft Gear Diameter of Bore 1 499 1 501 inch 38 09 38 13 mm Spigot Dia of crankshaft 1 5005 1 5000 inch 38 11 38 10 mm Transition fit of Gear on Crankshaft 0 011 0...

Page 17: ...y pass blanking Opening temperature 167 35 6 F 75 2 C Fully open 192 2 35 6 F 89 2 C Water Pump Type Centrifugal Impeller to Body Clearance 0 010 0 020 inch 0 25 0 51 mm Distance between impeller rear...

Page 18: ...can vary with individual application Cold Starting Aid Device Glow plugs fitted in each cylinder Voltage 12 volts Location Cylinder Head Cylinder Block water heater provision is also available Atomise...

Page 19: ...seconds By setting the starter switch to heat position H the heat wire in glow plugs preheats the air in combution chamber cylinders Then turn the starter switch to the Heat and Start position thereb...

Page 20: ...radiator water level 9 Check fan belt for tension 10 Carry out test to check general performance of engine 11 Check engine mounting bolts for tightness 12 Check the electrical equipment such as rate o...

Page 21: ...cent anti freeze manufactured to BS 3151 in water in a properly maintained engine should maintain its anti freeze and anti corrosive properties throughout the winter season and in general a safe life...

Page 22: ...emove and clean Flush radiator with clean water COOLING SYSTEM MAINTENANCE Check the condition of coolant every year at the beginning of winter Renew the coolant every 2 years DRY TYPE AIR CLEANER MAI...

Page 23: ...warm 2 Turn off the engine 3 Open the oil filler cap 1 4 Place an oil pan below the sump loosen and remove the drain plug 3 Drain the engine oil 5 Loosen the oil filter 6 Once the oil drained complet...

Page 24: ...Check for any leakage Cautions a It is important that only genuine fuel filter element is used b Do not allow dirt to enter into the fuel system c Do not over tighten fuel line joints d Use genuine wa...

Page 25: ...new belt and adjust the belt tension Note Over tensioning of belt will cause pre mature failure of alternator and water pump bearings Loose belt can cause over heating of the engine THERMOSTAT ASSEMBL...

Page 26: ...direction and bring No 1 Cylinder piston to TDC at the end of compression stroke Check the No 4 cylinder inlet valve has just opened and exhaust valve about to close overlap position i e both valves...

Page 27: ...spective pipes for identification Warning Cover the fuel pump delivery ports and automiser ports against the ingress of dirt with suitable protective caps To Fit 1 Clean and check for any crack or dam...

Page 28: ...Page No 27 Section F FUEL SYSTEM VE TYPE FUEL INJECTION PUMP TYPICAL FUEL PIPE LAYOUT BOSCH VE TYPE PUMP...

Page 29: ...ve terminal to KSB and ve to body Then wait for few minutes 8 Remove the distributor cap setscrew 3 from fuel pump 9 Fit the dial gauge with adopter on FIP as show in Figure 10 Turn the crankshaft in...

Page 30: ...ing No 1 cylinder piston to T D C on compression stroke marking on the crankshaft pulley to be aligned with pointer Check that the No 1 cylinder push rods are free to rotate 6 Remove the high pressure...

Page 31: ...but do not tighten the nuts Caution While installing the FIP the key should be aligned properly and see that the key doesn t fall inside the timing case 4 Position the washer and screw the nut on the...

Page 32: ...the cylinder head and remove the atomiser and washer Use 24 mm tubular spanner Warning Cover the fuel pump delivery ports and automiser ports against the ingress of dirt with suitable protective caps...

Page 33: ...EL LIFT PUMP Electrically operated Fuel lift pump is supplied along with the Tractor by the OEM A Hand primer is provided on the Primary fuel filter mounting bracket for Hand priming to Air vent in th...

Page 34: ...radiator 2 Remove Fan 4 3 Slacken alternator securing setscrews and remove fan belt 4 Loosen the hose clips and disconnect water pump inlet and outlet hoses 2 5 Remove by pass hose connection 6 Loosen...

Page 35: ...010 0 020 Check the clearance using feeler guage dial guage 4 Replace the four setscrews used for securing the water pump on to the timing case cover 5 Supporting the shaft at the impeller end press o...

Page 36: ...haft if required use suitable puller as shown 5 Clean the components and check for damage Renew damaged components To Refit 1 Lubricate the timing case cover oil seal lip with clean engine oil 2 Lubri...

Page 37: ...ove the radiator and water pump 3 Remove the crankshaft pulley 4 Loosen the screws fixing timing case cover to case and remove the timing case cover INSPECTION 1 Check the front case for cracks and da...

Page 38: ...the flywheel and crankshaft flange is clean and free from burrs 3 Position the flywheel on the crankshaft using a suitable rod as shown 3 4 Screw in the setscrews complete with tab washers into the f...

Page 39: ...ve the starter 2 Remove the flywheel 3 Loosen and remove the flywheel back plate 2 fixing setscrews using suitable wrench 4 Hold and hit the back plate rear side evenly using soft face hammer Ensure b...

Page 40: ...ten the screws 4 Apply molykote 111 compounds uniformly on the OD of the crankshaft flange and ID of the oil seal 5 Position the new oil seal 2 over the adaptor Note Seal surface with the part number...

Page 41: ...umpunitisapproximately 25 kg 55 lb 8 Clean the sump 9 Clean the mating face of the sump and of the cylinder block To Fit 1 Fit new sump joint front and rear neck packings to cylinder block 2 Position...

Page 42: ...it is driven by the engine crank gear through an idler gear 4 Lub oil pump is an integral part of balancer unit and it is driven by a drive shaft of balancer unit 5 Lub oil pump is not serviceable sep...

Page 43: ...t 1 After thorough inspection and cleaning of balancer unit check that balance weights are parallel and at the bottom This can be checked only after removing the cover 2 Use the special tool to ensure...

Page 44: ...be repaired How ever the pump rotors can be checked for its serviceability To Inspect 1 Remove sump 2 Loosen and remove strainer pipe securing screws Remove the strainer pipe 3 Using a suitable wrench...

Page 45: ...tween the outer rotor and the pump body 3 0 28 0 33 mm 0 011 0 013 11 Check the clearance between the top of the inner rotor and the end of the pump body with feeler gauges and straight edge 4 0 04 0...

Page 46: ...ylinder Head Cover 2 Stud Cylinder Head Cover 3 Cylinder Head Cover 4 Joint Cylinder Head Cover 5 Screw Rocker Bracket 6 Screw Tappet Adjusting 7 Bracket Rocker Shaft 8 Tappet 9 Push Rod 10 Spring Roc...

Page 47: ...losed Loop Breathing system ensures Positive Crankcase Ventilation PCV with oil mist separator and connecting hoses as shown in figure PCV OPERATION The blow by gases reaches to the Oil Mist Separator...

Page 48: ...EXHAUST MANIFOLD 1 Setscrew Exhaust Manifold 2 Washer 3 Exhaust Manifold 4 Joint Exhaust Manifold 5 Joint Inlet manifold 6 Intake manifold 7 Washer 8 Setscrew Intake Manifold 9 Washer 10 Plug For The...

Page 49: ...7 Cover the inlet ports to prevent dirt entry To Refit 1 Remove covers from cylinder head inlet ports and clean thoroughly 2 Refit inlet manifold with a new joint sealant applied on both sides and tig...

Page 50: ...xhaust manifold carefully with joint 6 Check turbocharger compressor and turbine wheels and housings for any damage or wear To Fit 1 After thorough cleaning refit exhaust manifold with a new joint and...

Page 51: ...careful note of the order of assembly 3 Clean and inspect all the components for wear and any other damages If required renew the component 4 Lubricate the components and reassemble in the correct ord...

Page 52: ...Valve Spring 1 Place the new spring in position and install the valve spring cap 2 Fit the valve spring compressor compress the valve spring and fit the collets Remove the valve spring compressor 3 Fi...

Page 53: ...Connection 4 Body Water Outlet 5 Thermostat 6 Valve Seat Inlet Valve 7 Inlet Valve 8 Exhaust Valve 9 Valve Seat Exhaust Valve 10 Cylinder Head 11 Plate Engine Lifting Rear 12 Valve Spring 13 Cap Valv...

Page 54: ...Use 24 mm tubular spanner 12 Remove the rocker shaft assembly 13 Remove the push rods 14 Remove VE glow plugs 15 Loosen and release the cylinder head setscrews as per the sequence shown Remove the se...

Page 55: ...EQUENCE CYLINDER HEAD SETSCREW TIGHTENING SEQUENCE TORQUE TO BE APPLIED A 11 15 M10x1 TORQUE 65 Nm 8 3 kgm Sl No 1 10 HOLES M12 X 1 5 IN THE FIRST TURN TORQUE to 45 Nm IN THE SECOND TURN 180o ANGULAR...

Page 56: ...n the stop against a suitable protrusion on the cylinder head to prevent movement Rotate the pointer to align with the relevant angle Tighten the setscrew until the pointer on the tool is aligned with...

Page 57: ...3 Check the cylinder head surface for flatness in seven directions as shown If flatness exceeds the limit in any direction either replace the cylinder head or machine head surface Cylinder head bow li...

Page 58: ...let 0 023 0 052 mm 0 0009 0 002 in Exhaust 0 036 0 065mm 0 0014 0 0025 in 5 Renew the valve if clearance is more CYLINDER HEAD REASSEMBLY Note Clean each part before assembly Apply engine oil to the s...

Page 59: ...r cleaner hose at compressor inlet 3 Remove the exhaust elbow from the turbo charger after releasing nuts with gasket If fitted with sleeve pull out the same 4 Release the banjo bolt from the flange o...

Page 60: ...hated to prevent seizure Fit the nuts and tighten them to 44 Nm 33 lbf ft 4 5 kgf m 4 Lubricatethebearinghousingoftheturbocharger with clean engine lubricating oil Fit the oil supply pipe together wit...

Page 61: ...he elbow 8 Slide the hose on the induction manifold on to the compressor outlet and tighten the hose clips 9 Check that there is no restriction in the air filter to turbocharger hose Fit the hose and...

Page 62: ...or casing in a suitable container that contains a non caustic solution Allow the dirt to become soft and then clean the casing with a hard brush and or a soft scraper Dry the casing with clean compres...

Page 63: ...08 0 23 mm 0 003 0 008 To Replace the Hubs and Timing Gears 1 The studs on which the hubs locate are so positioned that the hubs will fit in one position only and the boss at the rear of the hub locat...

Page 64: ...gear 4 Remove camshaft thrust washer 5 Lift all the tappets and keep them in lift position using tappets holding sticks 6 Remove the camshaft from its location in the cylinder block taking care not to...

Page 65: ...by camshaft thrust washer sintered which is retained by two setscrews Camshaft End Float Measure with dial Gauge 0 10 0 40 mm 0 004 0 016 in Note Ensure dowel pin and a dowel hole on the camshaft gear...

Page 66: ...r and camshaft 8 Remove the VE pump 9 Remove the driving gear from the VE pump as detailed appropriate section 10 Loosen the mounting bolts and remove 11 Remove the Timing Case INSPECTION 1 Check the...

Page 67: ...ned on No 4 cylinder Inlet valve In this position set the clearance between rocker lever and No 1 inlet valve to 1 2 mm 0 047 in Now turn the engine in the normal direction of rotation until the No 1...

Page 68: ...assembly 5 Turn the engine until number one connecting rod is at bottom centre Remove bolts and nuts securing the connecting rod cap 6 Remove the connecting rod cap and both top and bottom half bearin...

Page 69: ...Measure the piston ring end clearance Piston ring end clearance Standard Value Top ring 0 30 0 55 mm 0 0015 0 0216 in 2nd ring 0 80 1 00 mm 0 0314 0 0393 in 3rd ring 0 30 0 55 mm 0 0015 0 003 in 6 Me...

Page 70: ...wards fuel injection pump side Ensure that the notches for holding the bearing in place is on the FIP side Offer the connecting rod to the pistons and insert the gudgeon pin Fit the circlips on both s...

Page 71: ...they are inserted into cylinder 9 Make sure that the word F or arrow mark on the piston crown is towards the front of the engine Offset of combustion bowl in the crown toward fuel injection pump side...

Page 72: ...Bush Connecting Rod Small End 3 Connecting Rod 4 Bolt Connecting Rod Cap 5 Crankshaft 6 Gear Crankshaft 7 Pulley 8 Setscrew Pulley Retaining 9 Cap Connecting Rod 10 Main Bearing 11 Thrust Washer Main...

Page 73: ...nd idler gears 2 Remove the starter motor 3 Remove the flywheel flywheel housing rear end oil seal housing and oil seal 4 Remove turbocharger and pipe connections 5 Remove the cylinder head assembly 6...

Page 74: ...ameters Main bearing inside Dia bearing fitted 69 90 69 94 mm 2 7519 2 7535 in Running clearance 0 07 0 13 mm 0 003 0 005 in Plastic gauge may be used to measure the clearance Notes It is important th...

Page 75: ...ointing Compound only coat outboard of the grooves machined in the cap butt faces and ensure that the grooves are free from jointing compound 8 When replacing the main bearing caps ensure that they ar...

Page 76: ...4 Water Inlet Connection 5 Setscrew 6 Main Bearing Cap Front 7 Main Bearing Cap Inter 8 Oil separator Pipe Assy 9 Setscrew main bearing cap 10 Main Bearing Cap Rear 11 Adapter Lub oil Pressure gauge 1...

Page 77: ...ng no damage is done to the parent bores INSPECTION 1 Check the cylinder block liner for cracks scores rust and any other defects 2 Measure the cylinder bore with the cylinder gauge at the three level...

Page 78: ...Liners Unbored Cast Iron Liners 1 Lubricate the outside diameter of the liners with engine oil 2 Press or draw in the new liners using special tool When fully home the top face of the liner flange sho...

Page 79: ...Page No 78 Section P LUBRICATION SYSTEM...

Page 80: ...mance A fuel with a low cetane number can cause cold start problems and affect combustion Viscosity Is the resistance to flow and engine performance can be affected if it is outside the limits Density...

Page 81: ...remove the drive belt 3 Remove the adjustment link and pivot bolt Make note of the position of the washers and distance pieces to ensure they are fitted correctly 4 Remove the alternator 5 Clean and...

Page 82: ...e lists problems and their possible causes with recommended action IMPORTANT When attending performing a repair the cause of the problem must also be investigated and corrected to avoid repeat failure...

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Page 91: ...19 20 22 28 30 31 32 Too much lubricating oil at compressor end 1 2 4 5 6 8 19 20 21 28 31 32 Not enough lubrication 8 12 14 15 16 23 24 29 32 33 37 38 Lubricating oil in the exhaust manifold 2 7 17...

Page 92: ...cted lubricating oil supply pipe 17 Restricted lubricating oil drain pipe 18 Turbine housing damaged or restricted 19 Leakage from turbocharger seals 20 Worn turbocharger bearings 21 Excessive dirt in...

Page 93: ...Page No 92 Section S SERVICE TOOLS...

Page 94: ...Page No 93 SERVICE TOOLS...

Page 95: ...Page No 94 SERVICE TOOLS...

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Summary of Contents for 175

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Vectra Fitness 175, Engine Technical Manual, Page: 1 / 96

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Summary of Contents for 175

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