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Vetus VF4 Service Manual Download Page 36

36

402102.01

Service manual VF4 VF5

If the diameter of the crank pins is not correct, they should be re-
ground to the recommended undersize.

Crankpin diameter undersize

0.127 mm

Crankpin undersizes higher than the value mentioned will ad-

versely affect the structural resistance of the crankshaft (fol-
lowing contact between the tool and rolled connectors). As
far as the above is concerned, if the regrinding requires under
sizes greater than 0.127 mm, then the crankshaft must be re-
placed and a new one ordered from the parts dept.

Check the main bearings, noting that the half-bearings should
not be adapted. Replace them if scoring or signs of binding are
noted.

Fit the half-bearings, making sure they are scrupulously clean.

If the crankshaft has been round, fit new oversize half- bear-

ings to restore the initial tolerance conditions.

Fit the crankshaft into its seat on the crankcase.

Fit the calibrated wire (plastigage) for measuring the bearing
clearance.

Check one journal at the time, without rotating the crank-

shaft.

Fit the bearing caps complete with half-bearings and tighten the
bolts to the recommended torque.

Bearing caps

Bolt M12 (da Nm)

2.4 ÷ 2.6 + 100°

The bearing caps have progressive references (from zero to five
starting from the timing system side) which define the fitting po-
sition.

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Summary of Contents for VF4

Page 1: ...Service Manual VF4 140E VF4 170E VF5 220E VF5 250E VF4 VF5 Marine Diesel Engine ...

Page 2: ...ions in whole or in part is strictly prohib ited The information contained in this manual is not binding and providing the basic specification of the model described herein is not affected VETUS reserve the right to introduce any changes in their products without obligation immediately to update this publication ...

Page 3: ...d 21 4 1 3 Camshaft housing 28 4 2 Crankshaft 30 4 2 1 Main journal identification 41 4 3 Engine flywheel 55 4 4 Crankshaft phonic wheel for rpm and timing sensor replace with crankshaft removed 56 4 5 Connecting rod small end bush one replace 57 4 6 Set of pistons gudgeon pins and seals replace 59 4 7 Toothed timing belt 61 4 8 Fuel filter assembly 65 4 9 Engine coolant temperature sensor 66 4 10...

Page 4: ...e cylinder head Fuel system Direct injection common rail Number of cylinder 4 in line 4 in line Bore mm 82 82 Stroke mm 90 4 90 4 Total displacement cm3 1910 1910 CR Compression ratio 18 1 18 1 Maximum output CEE kW CEE 103 125 hp CEE 140 170 1 min 4000 4000 Maximum torque CEE Nm CEE 301 345 kgm CEE 30 1 34 5 1 min 2400 2400 ...

Page 5: ...r head Fuel system Direct injection common rail Number of cylinder 5 in line 5 in line Bore mm 82 82 Stroke mm 90 4 90 4 Total displacement cm3 2387 2387 CR Compression ratio 18 1 18 1 Maximum output CEE kW CEE 162 184 hp CEE 220 250 1 min 4200 4200 Maximum torque CEE Nm CEE 401 454 kgm CEE 40 1 45 4 1 min 2400 2600 ...

Page 6: ...50 400 TORQUE 450 500 1000 2000 1500 2500 3000 4000 3500 4500 35 30 25 20 15 40 45 50 RPM 250 200 150 275 125 175 225 kW hp 125 100 75 50 25 150 POWER 175 200 250 225 275 g hp h g kW h 350 300 250 200 150 400 FUEL CONSUMPTION 1000 2000 1500 2500 3000 4000 3500 4500 RPM 1000 2000 1500 2500 3000 4000 3500 4500 RPM 125 100 75 50 25 150 175 200 kgm Nm 350 300 250 200 150 400 TORQUE 450 500 1000 2000 1...

Page 7: ...UE 450 500 1000 2000 1500 2500 3000 4000 3500 4500 35 30 25 20 15 40 45 50 RPM 250 200 150 275 125 175 225 kW hp 125 100 75 50 25 150 POWER 175 200 250 225 275 g hp h g kW h 350 300 250 200 150 400 FUEL CONSUMPTION 1000 2000 1500 2500 3000 4000 3500 4500 RPM 1000 2000 1500 2500 3000 4000 3500 4500 RPM 125 100 75 50 25 150 175 200 kgm Nm 350 300 250 200 150 400 TORQUE 450 500 1000 2000 1500 2500 30...

Page 8: ...ase 3 1 Crankcase Values mm 1 L1 L2 L Main bearing housing L 21 720 21 800 L1 L2 Ø 63 705 63 718 Cylinder liner seat Ø Cylinder liner A 82 000 82 010 B 82 010 82 020 C 82 020 82 030 2 2 1 Cylinder liner Ø1 Ø2 2 1 Cylinder liner Crankcase 1 2 3 11 10 9 8 7 6 5 4 ...

Page 9: ...ton pin bore dia Ø 26 006 26 014 Ring groove width 1 2 080 2 100 2 2 020 2 040 3 2 020 2 040 Piston weight difference 5 gr 3 1 Piston protrusion Crankcase 0 014 0 294 3 2 Piston protrusion Liner 3 1 Piston Cylinder liner 0 070 0 090 3 2 Piston Cylinder liner 4 Piston pin Ø 25 982 25 987 0 4 4 3 Piston pin Seat pin 0 012 0 022 ...

Page 10: ...2 0 050 0 090 3 0 030 0 070 5 1 Piston ring gap 1 0 20 0 35 2 0 60 0 80 3 0 25 0 50 5 2 Piston ring gap 1 2 3 6 2 1 Small end bore diameter Ø1 Big end bore diameter 2 1 2 3 Connecting rod weight difference 2 5 g 6 2 1 Small end bush I D Ø1 26 006 26 014 Big end I D Ø2 53 897 53 909 Connecting rod weight difference 2 5 g 7 2 1 Small end bush Ø1 29 018 29 038 2 25 279 25 512 ...

Page 11: ... 994 3 59 982 59 988 Crankpin A 50 799 50 805 B 50 793 50 799 C 50 787 50 793 L L1 26 829 26 879 9 L Main bearing 1 1 831 1 837 2 1 836 1 844 3 1 843 1 849 0 127 9 8 Main bearing Journal 0 031 0 051 10 L Connecting rod bearing L A 1 527 1 531 B 1 530 1 534 C 1 533 1 537 0 127 10 8 Connecting rod bearing Pin 0 030 0 056 11 s Thrust washer S 2 469 2 485 0 127 11 8 Thrust crankshaft 0 059 0 221 ...

Page 12: ...g Ø 27 600 27 611 α L Valve housing α 45 1 45 1 L Circa 2 7 Camshaft support end exhaust dia VF4 I 43 646 43 671 II 43 446 43 471 III 43 246 43 271 IV 43 046 43 071 V 30 045 30 070 Camshaft support end exhaust dia VF5 I 43 846 43 871 II 43 646 43 671 III 43 446 43 471 IV 43 246 43 271 V 43 046 43 071 VI 30 045 30 070 Tappet housing bore dia Ø 37 010 37 030 12 16 15 17 20 13 14 19 ...

Page 13: ...linder head 0 033 0 080 14 2 1 α Valve Ø1 5 982 6 000 Ø2 27 40 27 60 α 45 30 5 Ø1 5 972 5 990 Ø2 25 40 25 60 α 45 30 5 14 13 Valve Valve guide 0 030 0 066 15 P1 P2 H1 H2 Internal valve spring P1 daN H1 P2 daN H2 16 P1 P2 H1 H2 External valve spring P1 daN 20 47 21 84 H1 34 0 P2 daN 44 81 47 59 H2 24 5 17 L Journal camshaft and exhaust Ø 26 000 26 015 L 19 250 19 330 Cam lift intake exhaust 8 8 ...

Page 14: ...30 000 30 015 Journal camshaft Seat in cylinder head VF5 I 43 800 43 815 II 43 600 43 615 III 43 400 43 415 IV 43 200 43 215 V 43 000 43 015 VI 30 000 30 015 17 12 Journal camshaft Cylinder head support radial 0 030 0 070 axial 0 100 0 230 19 Tappet Ø 36 975 36 991 19 12 Tappet Cylinder head 0 019 0 065 20 s Shim 0 05 S 3 25 4 90 17 20 For timing check 0 50 0 50 Normal cold 0 30 0 05 0 35 0 05 ...

Page 15: ... B B D C 40 D Closes A T D C 9 Cylinder head gasket 3 4 Fit the cylinder head the gasket should have the thickness indicated below in order to maintain compression ratio within the prescribed limits Piston protrusion mm Gasket thickness mm Identification notches 0 020 0 100 0 82 0 05 0 0 101 0 200 0 92 0 05 1 0 201 0 295 1 02 0 05 2 ...

Page 16: ...ressure regulation valve Incorporated in the crank shaft front cover Oil filter full flow With cartridges Insufficient oil pressure sender Electrical Between the body pump and the gear Between the gears periphery and the body pump 0 110 0 180 Between the superior side of the gears and the pump cover Between the superior side of the gears and the cover pump 0 016 0 086 Between the gear and the cond...

Page 17: ...ly open at 101 105 C Valve stroke 12 mm Pressure for held control system 1 08 bar Exhaust valve control on the cap of the additional expansion tank 1 08 bar Fuel system 3 7 Fuel system VF4 VF5 Firing order 1 3 4 2 1 2 4 5 3 Distributor type injection pump Bosch EDC 16 C39 Calibration pressure injectors 1800 bar Rpm minimal engine 800 20 1 min Rpm maximal engine to empty 5000 20 1 min Supercharging...

Page 18: ... 402102 01 Service manual VF4 VF5 Repair data 4 Position the camshaft housing 1 a in a vice using the tool 1b Undo the bolt 1 a and remove the cam angle sensor 1b Camshaft housing 4 1 1 Cylinder head 4 1 ...

Page 19: ... and fit camshaft timing tools 1b on the cam shaft housing Check that the tools are correctly fitted in the housings in the camshaft Undo the bolts fixing the camshaft gears 1 Undo the bolt 1 a and remove the exhaust side camshaft toothed drive pulley 1b ...

Page 20: ... exten sion Withdraw the camshaft 1 a as far as necessary and remove the camshaft gears 1b Using a suitable drift extract the inlet side camshaft 1 a and plug 1b Using suitable drift extract the exhaust side camshaft 2 a and oil seal 2b Undo and remove the engine oil lubrication duct plugs 1 ...

Page 21: ...ce manual VF4 VF5 Lower cylinder head 4 1 2 Position the cylinder head 1 a in a vice using the tool 1b Remove the hydraulic tappets Loosen the band 1 a undo the bolts 1b and remove the ther mostat 1c complete with O ring ...

Page 22: ...lts Fit the cotters 1 a using the tools 1b lever and 1c chamber Remove the valve upper shim Remove the valve spring Remove the shim for exhaust valves only Remove the valve guide oil seal with integrated lower valve shim Carry out the same operations on the other valves Remove the wooden stand and recover the valves Remove the lower cylinder head from the support tool Replace the valve guide ...

Page 23: ...ity of the lower cylinder head plane does not corre spond to the recommended figures regrind it without exceeding the minimum permitted height Cylinder head Lower plane minimum permitted height 107 0 0 05 Check that the valves do not show signs of scoring or seizing Check that the diameter of the valve stems corresponds to the recommended figures if not replace the worn valves Inlet valve stem dia...

Page 24: ...47 59 daN 24 5 mm Check that the diameter of the camshaft bearings corresponds to the recommended figure if not replace the worn camshaft s Diameter of inlet and exhaust shaft bearings VF4 Diameter I bearing 43 600 43 615 Diameter II bearing 43 400 43 415 Diameter III bearing 43 200 43 215 Diameter VI bearing 43 000 43 015 Diameter V bearing 30 000 30 015 Diameter of inlet and exhaust shaft bearin...

Page 25: ...ace the cylinder head Diameter of inlet and exhaust shaft supports VF4 Diameter I support 43 646 43 671 Diameter II support 43 446 43 471 Diameter III support 43 246 43 271 Diameter VI support 43 046 43 071 Diameter V support 30 045 30 070 Diameter of inlet and exhaust shaft supports VF5 Diameter I support 43 846 43 871 Diameter II support 43 646 43 671 Diameter III support 43 446 43 471 Diameter ...

Page 26: ...n the lower cylinder head in the vice using the tool sup port Fit the valves in the seats then support them using the wooden stand and secure it using suitable bolts Place the valve guide oil seal 1 a in position using the tool 1b extractor fitting tool Grind the valve seats to the recommended size Valve seat band Angle in contact with valve 45 1 Grind the valve seats using a suitable tool ...

Page 27: ...ng the valves from the cyl inder head plane Refit the water pump complete with basket in its housing and secure it tightening the bolts to the recommended torque Water pump Bolt M8 value da Nm cylinder head side 2 3 2 8 Place the thermostat in its housing with the new O ring and se cure it to the cylinder head by tightening the bolts to the recom mended torque Thermostat Bolt M8 value da Nm cylind...

Page 28: ...ugs Place the camshaft gears in their housings Place the camshaft gears in their housings and secure them with out tightening the bolts Fit the camshaft timing tools template Check that the tools are correctly fitted in the housings in the camshaft Tighten the camshaft gear fixing bolts to the recommended torque Camshaft gears Bolt M12 da Nm camshaft side 2 9 3 2 40 ...

Page 29: ...1b fitting tool Fit the intake side camshaft plug Refit the exhaust side camshaft toothed pulley and secure by screwing in the bolt without tightening Position the cam angle sensor 1 a in its housing and secure it tightening the bolt 1b to the recommended torque Cam angle sensor Bolt M6 da Nm 0 8 1 0 ...

Page 30: ... rotating the crankshaft flange Undo bolt anti clockwise 1 a and remove toothed drive pulley 1b Undo bolts 2 a and remove crankshaft front oil seal cover with built in oil pump 2b Remove the gasket Undo bolt 3 a and remove timing belt fixed tensioner 3b Undo bolt 4 a and remove timing belt tensioners mounting 4b ...

Page 31: ...ove the connecting rod piston assembly Remove the upper connecting rod half bearing Carry out the same operations for removing the remaining pis tons Check that the crankshaft end play corresponds to the recom mended figures using a magnetic base and dial gauge Crankshaft end play 0 049 0 211 mm If the value for the crankshaft end play does not correspond with the recommended figures when refittin...

Page 32: ...caps 2b Remove the lower main journal half bearings Remove the crankshaft Remove the upper main journal half bearings Remove the thrust washers Undo bolts 7 a and remove jets 7b from the crankcase Drill and remove the water oil sealing plugs from the crankcase to allow for washing Remove the engine block from the overhaul stand and place on a suitable work bench Wash the dismantled components Fit ...

Page 33: ...head support surface Cylinder head lower surface flatness 0 1 mm Measure the cylinder bore diameter using the diagram illustrat ed Cylinder liner inner diameter Grade A 82 000 82 010 Grade B 82 010 82 020 Grade C 82 020 82 030 Check that the taper and ovality of the cylinder liners bores is within the recommended limits Cylinder liner taper 0 005 mm Cylinder liner ovality 0 05 mm ...

Page 34: ...e diameter oversize 0 1 mm Fit the bearing caps The bearing caps have progressive references from zero to five VF4 or zero to six VF5 starting from the timing system side which define the fitting position Tighten bearing cap bolts 1 a to the recommended torque use torque wrench 1b Bearing caps Bolt M12 da Nm 2 4 2 6 100 Check that the diameter of the main journal seats is within speci fied limits ...

Page 35: ...commended undersize Main journal diameter undersize 0 127 mm Crankpin undersizes higher than the value mentioned will ad versely affect the structural resistance of the crankshaft fol lowing contact between the tool and rolled connectors As far as the above is concerned if the regrinding requires under sizes greater than 0 127 mm then the crankshaft must be re placed and a new one ordered from the...

Page 36: ... bearings noting that the half bearings should not be adapted Replace them if scoring or signs of binding are noted Fit the half bearings making sure they are scrupulously clean If the crankshaft has been round fit new oversize half bear ings to restore the initial tolerance conditions Fit the crankshaft into its seat on the crankcase Fit the calibrated wire plastigage for measuring the bearing cl...

Page 37: ... bearings with ones of the correct size and category Measure the clearance for all the bearings being careful to take the measurements one at a time without moving the crankshaft at all Check that the outer diameter of the gudgeon pins is within the recommended limits if not replace the worn gudgeon pins Gudgeon pin outer diameter 25 982 25 987 mm Check that the small end bush diameter is within t...

Page 38: ... outer diameter of the pistons corresponds to the recommended figures if not replace the piston complete with piston rings and gudgeon pin Piston outer diameter Grade A 81 920 81 930 mm Grade B 81 930 81 940 mm Grade C 81 940 81 950 mm Measure perpendicular to the gudgeon pin axis 9 mm from the lower edge of the skirt Check that backlash 1 a between rings 1b and the seats in pistons 1c corresponds...

Page 39: ...inner diameter 53 897 53 909 mm Check that there are no signs of seizing on the flywheel ring gear teeth if this is not the case replace it Fit the crankcase on the overhaul stand and secure it using the bolts Fit the thrust washers on the fourth bearing support The crankshaft supplied by the parts dept comes without half bearings and the main journals and crankpins are the normal size the half be...

Page 40: ... the main journals the first two numbers on the left refer to the first timing side main journal Only use the codes that relate to the key all other codes on the flywheel should not be used For the identification of the main journal category refer to the nu merical code for reference 2 In the case of the example the numbers 111111 indicate that all six bearings are grade A red as indicated in the ...

Page 41: ... 861 paint mark numerical code 8 55 61 0 127 mm undersize Last two numbers thousandth part of the main journal dimen sion In the case of using a crank shaft where the maximum undersize for the bearings is 0 127 mm through grindings the grade should be selected through the measurement of the diameter of the bearing using table as a reference Having defined the grade and the colour of each new or re...

Page 42: ...as a final check using the calibrated wire plastigage Place the lubrication jets back in their housings and secure them to the crankcase using the bolts Fit the crankshaft in the crankcase Fit the bearing caps complete with half bearings and tighten the bolts to the recommended torque Bearing caps VF4 Bolt M12 da Nm 1 9 2 1 100 VF5 Bolt M12 da Nm 2 4 2 6 100 The bearing caps have progressive refer...

Page 43: ... rod half bearings follow the procedure described previously for the main journal half bearings Fit connecting rod cap 2 a complete with half bearing and se cure it without tightening bolts 2b Fit the connecting rods so that the number stamped on each rod faces toward the same side as the number stamped on the big end inlet side For the remaining cylinders carry out the same operations to refit th...

Page 44: ...ing rod bearings Carry out this test on all the crankpins one at a time without ever turning the crankshaft Fit the connecting rod caps complete with half bearings and tighten the bolts Tighten connecting rod cap bolts to the recommended torque Connecting rod big end bearing caps Bolt M9 da Nm 2 4 2 6 60 Remove the flange for rotating the crankshaft Place the crankcase rear cover with integrated o...

Page 45: ...the engine oil intake duct complete with O ring in its hous ing and secure it by tightening the bolts to the specified torque Engine oil intake VF4 Bolt M6 daNm 0 8 oil pump side VF5 Bolt M6 daNm 0 9 oil pump side Apply silicon sealant to the entire perimeter of the oil sump Place the oil sump back in its housing Tighten the bolts securing the oil sump to the crankcase to the recommended torque us...

Page 46: ...for rotating the crankshaft flange Position the timing belt toothed drive pulley in its housing and tighten the bolt anti clockwise thread to the recommended torque Toothed drive pulley Left hand bolt M16 daNm 32 3 35 7 crankshaft side Measure the piston projection in two places at 180 on the gudg eon pin axis using the tool and take the average of the two values measured for each piston dial gaug...

Page 47: ...gasket size with average maximum piston projection 0 opening projection 0 020 0 100 mm thickness 0 82 0 05 mm 1 opening projection 0 101 0 200 mm thickness 0 92 0 05 mm 2 opening projection 0 201 0 295 mm thickness 1 02 0 05 mm VF4 VF5 Place the cylinder head centring bushes on the cylinder block Fit the cylinder head basket selected Position the cylinder head on the cylinder block crankcase ...

Page 48: ...g VF5 Bolt M12 daNm 2 4 5 90 90 90 Crank case side The value of 2 daNm in the table above is a tightening value for all the bolts following the order illustrated in the diagram Position the rpm sensor in its housing and secure it using the bolt Place the timing belt tensioner mount in its housing and secure it using the bolt Place the timing belt fixed tensioner in its housing and secure it using ...

Page 49: ...e and tighten the plug Fit a new upper cylinder head basket in position Position the camshaft housing and secure it by tightening the bolts to the recommended torque Camshaft housing Bolt M8 daNm 2 3 2 8 cylinder head side Loosen the bolt fixing the exhaust side timing belt toothed drive pulley Undo the bolt fixing the crankcase front cover shown in the dia gram Temporarily fit the toothed timing ...

Page 50: ...ce for tensioner 2b is aligned with reference opening 2c In this position tighten nut 2d for the belt tensioner to the recom mended torque Timing moving tensioner Nut M8 daNm 2 3 2 8 Tighten the bolt fixing the exhaust side timing belt toothed drive pulley to the specified torque Driver toothed pulley Bolt M12 daNm 2 9 3 2 40 camshaft side Remove the camshaft timing tools exhaust and crankshaft si...

Page 51: ...d follow the sequence until the first cylinder VF5 Start the assembly with the injector on the fifth cylinder and follow the sequence until the first cylinder Place the fuel return pipe back in place and connect it to the injec tors and the return manifold pipe Place the single fuel manifold in its housing and secure it by tight ening the bolts to the recommended torque Single fuel manifold pipe r...

Page 52: ...onnector M12 daNm 2 2 2 4 pressure pump side Refit the auxiliary drive belt pulley and secure by tightening the bolts to the recommended torque Services pulley on crankshaft Bolt M8 daNm 2 3 2 5 crankshaft side Refit the timing belt guard and secure it using the bolts Place the exhaust manifold assembly complete with new gasket back in its housing and secure it by tightening the nuts to the rec om...

Page 53: ...nkcase Connector M10 daNm 4 5 5 5 Connect the turbocharger lubrication oil outlet pipe to the sump and tighten the bolts to the recommended torque Engine oil supply pipe from turbo Bolt M6 daNm 0 8 1 0 engine block side Place the alternator in position and secure it by tightening the bolts to the recommended torque Alternator Bolt M12x1 25x120 daNm 6 3 7 7 Bolt M10x1 25x100 daNm 4 5 5 5 ...

Page 54: ...al connection for the rpm sensor Attach the electrical connection for the coolant temperature sen sor Secure the electrical connection for the pressure relief sensor Secure the electrical connections for the spark plugs Secure the electrical connection for the pressure regulator on the single fuel manifold Secure the electrical connections for the injectors Secure the electrical connection for the...

Page 55: ...ts 1b and remove the flywheel 1c The bolts fixing the flywheel have been treated with a special agent therefore they should be replaced each time they are removed Place the flywheel 1 a in its housing and secure it tightening the new bolts 1b to the recommended torque Engine flywheel Bolt M12 daNm 16 0 ...

Page 56: ...lace with crankshaft removed Undo the bolts 1 a and remove the phonic wheel for the rpm and timing sensor 1b from the crankshaft Fit a new rpm and timing sensor flywheel on the crankshaft and secure it tightening the bolts to the recommended torque Phonic wheel on crankshaft Bolt M5 daNm 2 3 3 3 ...

Page 57: ...e 1b and the tool 1c extractor fitting tool con structed as illustrated in the diagram Fit a new bush 1 a in the small end using a hydraulic press a suit able plate 1b and the tool 1c extractor fitting tool constructed as illustrated in the diagram The bush should be fitted in the small end so that the lubrica tion port is aligned with the one in the small end ...

Page 58: ...58 402102 01 Service manual VF4 VF5 Ream the inner diameter of the small end bush to the recom mended figure Small end bush Inner diameter 26 006 26 014 mm ...

Page 59: ...l VF4 VF5 Set of pistons gudgeon pins and seals replace 4 6 Remove the piston rings Release the pin 2 a and separate the connecting rods 2b from the piston 2c Remove the piston rings 1 a from the pistons using a suitable tool 1b ...

Page 60: ...commended figures The arrows in the diagram illustrate where material can be re moved from the to equalize the weight Engine piston set Weight difference between pistons 5g Weight difference between connecting rods 2 5g Join the connecting rods to the pistons so that the number print ed on the connecting rod head 1 a is facing notch 1b on the piston skirt for the oil jet housing Fit the pins and s...

Page 61: ... VF4 VF5 Toothed timing belt 4 7 Position the flywheel retaining tool in its seat flywheel lock Undo bolts 1 a securing crankshaft pulley 1b and remove Undo the fixing bolt 2 a and remove the single drive belt fixed tensioner 2b ...

Page 62: ...ad extension Check the tools marked A are correctly fitted in the seat on the camshaft Undo the bolt fixing the crankcase front cover shown in the dia gram Temporarily fit the toothed timing drive belt on the drive pulley Fit the tool 2 a template and fasten it using the calibrated screw 2b The crankshaft must be rotated using small movements to allow the locating dowel on the timing drive pulley ...

Page 63: ...o ad just the timing Rotate the crankshaft through two revolutions Re check the alignment of the timing references loosen the nut securing the mobile tensioner and align mobile indicator 4 a with hole 4b i e ad just to nominal tension position then tighten nut 4c securing the belt tensioner to torque Mobile timing tensioner Nut M8 daNm 2 5 Loosen the bolt retaining the timing pulley Rotate the cra...

Page 64: ...he toothed timing belt protective guards and tighten the re taining bolts Position the flywheel retaining tool in its seat Fit the crankshaft pulley in position and tighten the fixing bolts Flywheel lock Bolt M8 daNm 2 5 Fit the fixed timing belt tensioner for the single engine compo nent drive belt and tighten the retaining bolt to torque Remove the flywheel lock Tighten the bolt fixing the exhau...

Page 65: ...he required amount and disconnect the electrical connection 3b from the water presence sensor then remove Working at the bench unscrew the water presence sensor in the fuel filter and remove Refit the water sensor in its seat on the fuel filter Connect the electrical connection to the water presence sensor then refit the fuel filter assembly in its seat To screw the filter in its seat of the brack...

Page 66: ...engine coolant temperature sensor 1 Undo the engine coolant temperature sensor and remove it Place the engine coolant temperature sensor in its housing and tighten it to the recommended Engine coolant temperature sensor M daNm 0 8 Thermostat side Connect the electrical connection to the engine coolant tempera ture sensor ...

Page 67: ...t the battery terminal Undo bolts 2 a and remove the pressure relief sensor 2b Position the excess pressure sensor 1 a in its housing and secure it tightening the bolt 1b to the recommended torque Excess pressure sensor Bolt M daNm 0 9 Connect the electrical connection for the pressure relief sensor Connect the negative battery terminal ...

Page 68: ... the electrical connection from the engine rpm sensor 1 Undo the bolt 2 a and remove the rpm sensor 2b Position the engine rpm sensor 1 a in its housing and secure it tightening the bolt 1b to the recommended torque Rpm sensor Bolt M6 daNm 0 6 1 0 engine block side Connect the electrical connection for the engine rpm sensor Connect the negative battery terminal ...

Page 69: ...trical connection from the cam angle sensor Undo the bolts 2 a and remove the cam angle sensor 2b Position the cam angle sensor 1 a in its housing and secure it tightening the bolt 1b to the recommended torque Cam angle sensor Bolt M6 daNm 0 8 1 0 cylinder head extension side Connect the electrical connection to the cam angle sensor Connect the negative battery terminal ...

Page 70: ... 402102 01 Service manual VF4 VF5 Variable geometry turbocharger 4 13 Loosen collar 2 a and disconnect exhaust pipe 2b from the tur bocharger Undo the engine oil delivery pipe connector turbocharger side ...

Page 71: ...sleeve the engine oil return pipe turbo charger side Undo the nuts securing the turbocharger on the exhaust mani fold Remove the gasket Undo connector 1 a and remove turbocharger engine oil supply pipe 1b Undo bolts 2 a and remove turbocharger oil return pipe 2b ...

Page 72: ...sition and tighten the turbocharger side connector to the recommended torque Engine oil supply pipe from turbocharger Connector M10 daNm 1 5 turbocharger side Tighten the nuts securing the turbocharger to the exhaust mani fold to the recommended torque Turbocharger fastening Nut M8 daNm 2 3 2 8 turbocharger side Tighten the bolts securing the engine oil return pipe turbocharg er side to the specif...

Page 73: ...tion the pressure pimp support in a vice fitted with protective jaws Lock the rotation of the pressure pump drive pulley using two bolts Undo the pressure pump drive pulley nut Undo the two bolts for locking the rotation of the pressure pump drive pulley fitted previously ...

Page 74: ...ve pulley 1 a using the tools 1b extractor Undo the nuts 1 a and remove the pressure pump 1b from the support Place the pressure pump 1 a on the support and secure it tight ening the nuts 1b to the recommended torque Injection pressure pump mount Nut M8 daNm 2 3 2 8 ...

Page 75: ...Lock the rotation of the pressure pump drive pulley using two bolts Tighten the nut fixing the pressure pump drive pulley to the rec ommended torque Pressure pump control pulley Nut M14 daNm 4 2 6 6 Undo the two bolts for locking the rotation of the pressure pump drive pulley fitted previously ...

Page 76: ... vice fitted with protective jaws Lock the rotation of the pressure pump drive pulley using two bolts Undo the pressure pump drive pulley nut Undo the two bolts for locking the rotation of the pressure pump drive pulley fitted previously Remove the pressure pump drive pulley 1 a using the tools 1b extractor ...

Page 77: ...rque Injection pressure pump mount Nut M8 daNm 2 3 3 3 Place the pressure pump drive pulley back in its housing Lock the rotation of the pressure pump drive pulley using two bolts Tighten the nut fixing the pressure pump drive pulley to the rec ommended torque Pressure pump control pulley Nut M14 daNm 4 2 6 6 Undo the two bolts for locking the rotation of the pressure pump drive pulley fitted prev...

Page 78: ...78 402102 01 Service manual VF4 VF5 ...

Page 79: ...402102 01 79 Service manual VF4 VF5 ...

Page 80: ...VF4 VF5 402102 01 12 09 Printed in the Netherlands FOKKERSTRAAT 571 3125 BD SCHIEDAM HOLLAND TEL 31 10 4377700 TELEFAX 31 10 4372673 4621286 E MAIL sales vetus nl INTERNET http www vetus com vetus n v ...

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