Farmall 90 Manual Download

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SECTION 10 -- ENGINE -- CHAPTER 1

SECTION 10 -- ENGINE

Chapter 1 -- Engine

CONTENTS

Section

Description

Page

Specifications

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Torques

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Special Tools

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Sectional Views

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting

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Overhaul

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 001 10

Engine

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Removal

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation

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10 001 53

Disassembly

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Engine Assembly on the Bench

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fitting the Bushings

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fitting the Tappets

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fitting the Camshaft

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Fitting the Oil Nozzles

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Fitting the Crankshaft

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fitting the Connecting Rod -- Piston Assembly

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fitting the Piston Connecting Rod Assemblies in the Cylinder Liners

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Big End Cap Assembly

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fitting the Thermostat Valve

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fitting the Cylinder Head

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fitting the Injectors

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fitting the Rocker Arm Assembly

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fitting the Timing Gear

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fitting the Injection Pump

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fitting the Additional Counterweights

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fitting the Hydraulic Pump Drive Gear

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fitting the Timing Gear Casing

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fitting the Crankshaft Rear Seal

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Fitting the Flywheel

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fitting the Oil Pump

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fitting the Oil Sump

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Summary of Contents for 90

Page 1: ...Oil Nozzles 58 Fitting the Crankshaft 58 Fitting the Connecting Rod Piston Assembly 61 Fitting the Piston Connecting Rod Assemblies in the Cylinder Liners 63 Big End Cap Assembly 64 Fitting the Thermostat Valve 65 Fitting the Cylinder Head 66 Fitting the Injectors 68 Fitting the Rocker Arm Assembly 69 Fitting the Timing Gear 69 Fitting the Injection Pump 72 Fitting the Additional Counterweights 73...

Page 2: ...uel Supply and Injection Pumps Pre heating System and Tappet Cover 82 Fitting the Starter Motor 82 10 102 70 Crankshaft Front Seal 83 Removal 83 Installation 86 10 102 74 Crankshaft Rear Seal 86 Removal 86 Installation 88 10 106 12 Valve rocker Arm Clearance 89 Removal 89 Installation 92 10 218 30 Engine Injector 93 Removal 93 Installation 94 10 246 14 Bosch Injection Pump 95 Removal 95 Installati...

Page 3: ...ing Bending 121 Pistons 121 Measuring the Piston Diameter 122 Piston Pins 122 Conditions for Correct Pin piston Coupling 123 Piston Rings 123 Valves and Camshaft 124 Valves 124 Tappets 127 Camshaft 128 Cylinder Head 129 Cylinder Head Mating Surface Check 129 Cylinder Head Thickness 129 Cylinder Head Hydraulic Seal Check 129 Low Oil Pressure Indicator 130 Functional Checks 130 Oil Filter 130 Replac...

Page 4: ...Compression ratio for Models Farmall 90 Farmall 95 17 5 1 Maximum power model Farmall 90 type F4CE9487M J 65 kW 88 HP model Farmall 95 type F4CE9487N J 70 kW 95 HP Maximum torque Farmall 90 type F4CE9487M J 375 Nm 277 ft lbs Maximum torque Farmall 95 type F4CE9487N J 390 Nm 288 ft lbs Maximum torque speed 1300 rev min Number of main bearings 5 Sump structural cast iron Lubrication forced with lobe...

Page 5: ...stem overhead valves operated by tappets rods and rocker arms via the camshaft located in the engine block the camshaft is driven by the crankshaft using straight tooth gears Intake start before T D C 10 30 end after B D C 10 30 Exhaust start before B D C 64 end after B D C 26 Valve rocker arm clearance with engine cold intake 0 25 0 05 mm 0 0098 0 002 in exhaust 0 50 0 05 mm 0 0197 0 002 in For f...

Page 6: ...e HOLSET HX25W TB11H A085BXL For versions F4CE9487N J type HOLSET HX25W TB11K A11CXL Injection pump rotating distributor with speed governor and advance regulator incorporated BOSCH pump Farmall 90 model type F4CE9487M J VE 4 12 F1250 L2043 S N 504218826 Farmall 95 model type F4CE9487N J VE 4 12 F1250 L2023 S N 504218827 Direction of rotation counter clockwise Injection order 1 3 4 2 For all model...

Page 7: ...87 to 83 013 3 2671 to 3 2682 Journal undersizes 0 250 to 0 500 0 0098 to 0 0196 Main journal half bearing thickness 2 456 to 2 464 0 0966 to 0 0970 Main half bearing undersizes internal diameter 0 250 to 0 500 0 0098 to 0 0196 Clearance between bearings and main journal no 1 5 0 041 to 0 119 0 0016 to 0 0046 n 2 3 4 0 041 to 0 103 0 0016 to 0 0040 Standard crankpin diameter 68 987 to 69 013 2 716...

Page 8: ... seal rings and one scrap er ring Standard piston diameter measured at 2 4015 in 61 mm from skirt base and perpendicularly to the gudgeon pin axis 104 000 to 104 024 4 0944 to 4 0954 Piston clearance in cylinder liner 0 268 to 0 310 0 0105 to 0 0122 Piston oversizes 0 500 0 0196 Piston protrusion at T D C from cylinder block face 0 280 to 0 520 0 0110 to 0 0204 Gudgeon pin diameter 37 994 to 38 00...

Page 9: ...o 54 147 2 1292 to 2 1317 intermediate 54 083 to 54 147 2 1292 to 2 1317 rear 54 083 to 54 147 2 1292 to 2 1317 Diameter of camshaft journals front 53 995 to 54 045 2 1257 to 2 1277 intermediate 53 995 to 54 045 2 1257 to 2 1277 rear 53 995 to 54 045 2 1257 to 2 1277 Clearance between camshaft journals and bushings 0 038 to 0 152 0 0014 to 0 0059 Camshaft end float 0 230 0 130 0 0090 0 0051 Cranks...

Page 10: ... clearance between valve stem and seat 0 039 to 0 079 0 0015 to 0 0031 Valve seat angle in head inlet valve 60 exhaust valve 45 Valve face angle inlet valve 60 exhaust valve 45 Diameter on head for fitting valve seat inlet valve 46 987 to 47 013 1 8498 to 1 8509 exhaust valve 43 637 to 43 663 1 7178 to 1 7190 Valve seat insert outside diameter inlet valve 47 063 to 47 089 1 8528 to 1 8538 exhaust ...

Page 11: ...d mm in Inlet and exhaust valve springs free length 63 500 2 4999 length under load of 329 N 49 020 1 9299 length under load of 641 N 38 200 1 5039 Injector protrusion relative to head face D injectors BOSCH DLLA 145 P 1338 BOSCH DSLA 145 P 1255 Not adjustable ...

Page 12: ... 18 4 Oil cooler retaining bolts M 8 x 1 25 25 5 18 4 Coolant pump retaining bolts M 8 x 1 25 25 5 18 4 Coolant inlet manifold retaining bolts M 10 x 1 50 45 10 33 7 Thermostat valve assembly retaining bolts M 8 x 1 25 25 5 18 4 Fan support retaining bolts M 8 x 1 25 x 50 M 10 x 1 50 x 25 25 5 45 5 18 4 33 7 Injector fastener 60 5 44 7 Fuel pump retaining bolts M 8 x 1 25 25 5 18 4 Nuts securing t...

Page 13: ...0 6 37 4 phase 2 M 12 x 1 5 80 6 59 4 phase 3 M 12 x 1 5 90 5 Big end cap bolts phase 1 M 10 x 1 25 30 5 22 4 phase 2 M 10 x 1 25 50 5 37 4 phase 3 M 10 x 1 25 60 5 Cylinder head bolts M 12 x 1 75 x 70 50 5 37 4 90 M 12 x 1 75 x 140 40 5 30 4 180 M 12 x 1 75 x 180 70 5 52 4 180 Bolts fastening pulley on crankshaft M 12 x 1 25 50 5 37 4 90 5 Engine flywheel retaining bolts M 12 x 1 25 30 5 22 4 60 ...

Page 14: ...r various measurements use with 380000228 380000569 Movable tool for dismantling tractors with bracket 380000500 and adapter plate 380000844 X 380000661 Engine mounting brackets for rotating stand 380000301 X 380000663 Tool to extract crankshaft rear seal X 380000664 Splining tool for fitting rear seal on crankshaft X 380000665 Tool to extract crankshaft front seal X 380000666 Splining tool for fi...

Page 15: ...SECTION 10 ENGINE CHAPTER 1 15 SECTIONAL VIEWS MIF1097A 1 View of Farmall 90 tractor engines of 65 kW 88 HP and Farmall 95 of 70 kW 95 HP ...

Page 16: ... lubrication is accomplished by the following components oil pump housed at the front of the crankcase driven by the grooved bushing keyed onto the shank of the crankshaft water oil cooler housed in the crankcase oil pressure control valve incorporated in the cooler assembly by pass valve to cut off clogged oil filter incorpo rated in the cooler assembly cartridge oil filter ...

Page 17: ...nt entering the pump 3 Cooling system diagram The forced circulation closed circuit engine cooling system is composed of the following components a lubricating oil cooler a centrifugal coolant pump housed at the front of the crankcase a thermostat valve governing coolant circulation ...

Page 18: ... ENGINE CHAPTER 1 MIF1101A 4 Detail of cylinder head with valve seats fitted in engines mod Farmall 90 Farmall 95 1 Exhaust manifold 2 Intake manifold 3 Air heater 4 Fitted valve seats 5 Thermostat valve 6 Injector ...

Page 19: ...SECTION 10 ENGINE CHAPTER 1 19 MIF1102A 5 Additional counterweights 1 Retaining bolts 2 Support 3 Retaining bolts 4 Gear 5 Balancing weight 6 Half bearings 7 Counter shaft 8 Gear 9 Ring 10 O Ring ...

Page 20: ...ons supply pump filters and injection pump for air then bleed the air from the circuit 8 Starter motor faulty Repair or replace starter motor 9 Thermostarter faulty Check and replace thermostarter if necessary Engine stalls 1 Idle speed too low Adjust idle speed 2 Injection pump delivery irregular Check injection pump delivery on test bench 3 Impurities or water in fuel lines Disconnect fuel lines...

Page 21: ...n tables 9 Air filter clogged Clean filter unit and replace filter el ement if necessary Engine lacks power and runs unevenly 1 Injection pump timing incorrect Adjust injection pump timing 2 Auto advance regulator in injec tion pump damaged Overhaul injection pump and adjust on test bench to values specified in calibration table 3 Control valve journal worn Overhaul injection pump and adjust on te...

Page 22: ...if necessary 3 Injection pump timing incorrect Adjust injection pump timing 4 Crankshaft knocking due to ex cessive play in one or more main or big end bearings or excessive endfloat Re grind crankshaft journals and crankpins Fit oversize shell bearings and thrust washers 5 Crankshaft out of balance Check crankshaft alignment and bal ance replace if necessary 6 Flywheel bolts loose Replace any bol...

Page 23: ...ear worn or incorrectly adjusted valves Replace damaged parts or if necess ary overhaul the engine 7 High pressure fuel lines dam aged Inspect and replace if necessary Blue grey blue or grey white smoke 1 Injection pump delivery excess ively retarded or automatic ad vance regulator damaged Adjust injection pump timing or check automatic advance regulator 2 Injectors obstructed or damaged Clean ove...

Page 24: ...f suitable slings and hooks Check that no one is in the vicinity of the load to be lifted WARNING Always use appropriate tools to align fixing holes NEVER USE FINGERS OR HANDS 1 Disconnect the battery negative lead 1 2 Drain the oil from the transmission gearbox housing 3 Drain the cooling system 1 6 4 Remove the exhaust pipe attach lifting chains 2 to the hood 1 and attach the chain to the hoist ...

Page 25: ...SECTION 10 ENGINE CHAPTER 1 25 5 Disconnect the electrical connection 1 of hood 8 6 Detach the gas struts 1 from the hood 9 7 Remove the four hood hinge bolts 1 and lift the hood clear 10 ...

Page 26: ...nd the guard 2 on the right left hand side of the fan 11 9 Unscrew the nut 1 from the weight retaining pin Remove the weights from the front support 12 10 Unscrew the front central and rear retaining bolts on the front axle shaft guard then remove the guard 1 25038 1 13 ...

Page 27: ...s released from the groove on the front axle 1 2 25039 14 12 Remove the circlip 2 and move the rear sleeve 1 in the direction indicated by the arrow until it is released from the groove on the drive 1 2 25040 15 13 Remove the propeller shaft central support 1 retaining bolts and extract the shaft together with the support 1 25041 16 ...

Page 28: ...10 ENGINE CHAPTER 1 14 Remove the retaining bolts 1 of the suction pipe 2 of the lift pump 17 15 Disconnect the delivery and return lines from the hydraulic lift pump 18 16 Detach the cab heating pipes 1 and 2 19 ...

Page 29: ...xtract the plastic fasteners 2 and detach the diesel recovery pipe 3 and delivery pipe 4 to the diesel pump 1 21 19 Remove two metal clamps 2 and the rigid pipe of drawing oil from the transmission housing via lift pump 1 and power steering pump Remove the fitting of the delivery pipe 22 ...

Page 30: ... the electrical connection from the brake fluid reservoir and take the brake fluid reservoir 1 from the bracket 23 21 Disconnect the steering oil delivery and return hoses 1 and 2 24 22 Disconnect A C compressor inlet 2 and outlet 1 hoses 25 ...

Page 31: ... electrical connections of tempera ture sender 1 and oil switch 2 27 25 Remove the retaining retaining clips 1 and de tach the flexible cables governing the hand throttle and pedal throttle 26 Remove the retaining clip 2 and detach the throttle control tie rod connected to the injection pump 28 ...

Page 32: ...ct the electrical connection 1 between the cab and the engine 29 28 Disconnect the electrical connections from alter nator 1 and starter motor 2 30 29 Disconnect the electrical connections of dryer fil ter sensor 1 and water in fuel sensor 2 31 ...

Page 33: ...e the electrical connection 1 and air filter clogging sensor 2 32 31 Remove the two retaining bolts and the support together with relays protecting system 1 33 32 Loosen the corresponding retaining clamps and extract the pipes 1 2 and 3 3 34 ...

Page 34: ...a fixed stand under the over drive clutch housing near the engine attachment flanging and apply the hand brake 36 35 Position the movable tool for dismantling tractors 380000569 with the bracket 380000500 and adapter plate 380000844 under the engine and place a wooden block in between the points of contact between the tool and tractor 1 2 37 ...

Page 35: ...ning pin from the drive shaft 1 remove the pedal and footboard 2 25043 1 2 38 37 Unscrew the nuts 1 and the bolts securing the engine to the transmission Access is through the two slots in the cab floor 1 39 38 Remove the remaining six retaining bolts at the bottom and side 40 ...

Page 36: ...ate the engine from the transmission with the tool 380000569 1 2 41 40 Remove the spacer located between the engine and the transmission 42 41 Insert the fixed under the ballast support and se cure the front wheels with wooden blocks 1 2 43 ...

Page 37: ...HAPTER 1 37 42 Loosen the corresponding retaining clamp 1 and extract the pipes And remove the bracket 2 44 43 Disconnect the delivery and return lines 1 to the power steering cylinders 45 44 Remove the hood support 1 46 ...

Page 38: ... the pipe 1 joining the coolant pump to the bottom of the radiator 47 46 Position a fixed stand 3 under the support of the groove 1 of the front axle drive placing a wood en plug 2 between the parts 3 and 1 48 47 Fit the lifting eyelet 1 in the threading on the support 2 49 ...

Page 39: ...he lifting chains 1 in the eye lets shown in the figure afterwards tensioning the chains with the hoist 51 50 Detach the engine 2 from the front axle 3 try ing to avoid incorrect operations with the hoist so as not to let the engine fan damage the fins of the radiator 1 left on the axle 3 51 Then rest the engine on a platform support 52 ...

Page 40: ...surfaces 14 Position wooden blocks under the rear wheels make sure that the hand brake is fully applied and that all fixed and mobile stands are safely posi tioned 15 The installation phase described here requires the presence of two or three workers to use the movable tool for dismantling tractors 380000569 to move the engine front axle assembly close to the overdrive clutch casing 16 In the phas...

Page 41: ...y and return hoses 42 Install the electrical connections between the cab and the engine 43 Reconnect the diesel delivery and return pipes to the diesel pump and install the relevant plastic fasteners 44 Working on the left hand side of the engine install the lift pump draw pipe and tighten the re taining bolts 45 Install the delivery pipe of the services pump on the right hand side of the engine a...

Page 42: ...the plug from the sump and the oil filler plug 3 Detach the fan unit from the fan pulley 4 To be able to fit the bracket 380000661 for fixing the engine to the overhaul stand to the crank case it is necessary to remove the wiring 1 from the left hand side of the engine MIF1103A 53 5 To be able to fit the bracket 380000661 to the crankcase on the right hand side remove the starter motor 5 oil filte...

Page 43: ...ove the fuel filter support 9 MIF1105A 55 16 Act on the fork 1 as shown in the figure 56 part B and remove the fitting To avoid deforma tion with the fitting removed put the fork 1 back in the locking position part A NOTE Figure 56 shows the connectors for the low pressure pipes 6 and 8 figure 55 A Pipe locking position on connector B Pipe removal position on connector MIF0909A 56 17 Remove the in...

Page 44: ... the exhaust manifold 3 24 Remove the belt 3 fig 60 of the auxiliary mem bers by loosening the tightener MIF1109A 59 25 Remove the alternator 6 fan pulley 2 and tightener 8 Remove the support 1 of the pulley 2 and the oil cooler 7 26 Remove the coolant pump 5 27 Remove the engine cooling system fitting 4 from the crankcase NOTE The coolant pump 5 cannot be overhauled It must be replaced if there i...

Page 45: ...aft 30 Perforate the inner seal 1 with a drill bit 0 1377 in 3 5 mm through the guide holes of the tool 380000665 4 for a depth of 0 1968 in 5 mm 31 Secure the tool 380000665 4 to the seal 1 with the screws 3 provided 32 Extract the seal 1 by screwing down the screw 5 MIF0916A 62 33 Fit the tie rod 3 of the tool 380000669 to the out er seal 1 as shown in the figure 63 and with the lever 4 extract ...

Page 46: ...4 35 Take out the bolts 2 and remove the oil pump 1 NOTE The oil pump 1 cannot be overhauled It must be replaced if there is any irregular operation MIF1112A 65 36 Using the pin 1 lock the additional counter weights 2 at the T D C Unscrew the retaining bolts 3 and remove the additional counterweights 2 MIF1113A 66 ...

Page 47: ...00732 Then loosen the bolt 2 remove the L spacer 1 and lock the screw 2 in order to keep the pump in time with the engine flywheel NOTE Keep the L spacer with the pump casing MIF0920A 67 38 Remove the three nuts 2 3 5 securing the in jection pump 1 to the crankcase 4 and extract it from its housing MIF0922A 68 39 Remove the screws 2 fixing the engine flywheel 1 to the crankshaft MIF1115A 69 ...

Page 48: ...3 3 onto the rear shank 1 of the crankshaft 43 Perforate the inner seal 5 with a drill bit 0 1377 in 3 5 mm through the guide holes of the tool 380000663 3 for a depth of 0 1968 in 5 mm 44 Secure the tool 380000663 3 to the seal 5 by screwing down the screws 2 supplied 45 Extract the seal 5 by screwing down the screw 4 MIF0927A 71 46 Take out the screws 2 and remove the timing gear box 1 retrievin...

Page 49: ...e gears 3 and 4 from the camshaft 2 MIF1118A 73 48 Take out the bolts 1 and remove the hydraulic pump drive gear 2 MIF1119A 74 49 For each cylinder remove the rocker arm assem bly 1 loosen the adjuster nuts 3 unscrew the adjusters 4 and take out the screws 2 MIF0933A 75 ...

Page 50: ...F0934A 76 51 Take out the screws 1 fixing the head to the crankcase MIF1120A 1 77 52 After fitting the brackets 1 and 2 hook the met al cables and detach the cylinder head from the crankcase with the hoist NOTE After removing the cylinder head remove the brackets 1 and 2 MIF1121A 78 ...

Page 51: ...t this operation on all valves 5 MIF1122A 79 54 Remove the intake manifold cover and extract the oil seals 1 fitted on the valve stems To remove the valves turn the head over NOTE Mark the inlet and exhaust valves before re moving them MIF1123A 80 NOTE The inlet valves differ from the exhaust valves in the size of the head and there being an addi tional reference mark 1 on the stem A Inlet valve B...

Page 52: ... the connecting rod caps 2 and remove them 57 Extract the pistons together with the connecting rods from the top of the crankcase NOTE Keep the half bearings in their respective housings since if they are used they must be mounted in the position found upon disassembly MIF0938A 83 58 Remove the rings 1 from the piston 3 with the pliers 380000221 2 MIF0950A 84 ...

Page 53: ...he main bearing caps 2 MIF1126A 86 61 The penultimate main bearing cap 1 and the re lated mounting have the half bearing 2 equipped with a shoulder Remove the pistons with the connecting rods NOTE Note down the assembly position of the top and bottom half bearings since if they are reused they must be mounted in the position found upon dis assembly MIF0940A 87 ...

Page 54: ...crankshaft 2 from the crankcase MIF1127A 88 63 Remove the main half bearings 1 64 Take out the screws 2 and remove the oil nozzles 3 MIF0942A 89 65 Take out the screws 1 and remove the plate 3 retaining the camshaft 2 NOTE Note down the assembly position of the plate 3 MIF1128A 90 ...

Page 55: ...lly extract the camshaft 1 from the crank case MIF1129A 91 67 Extract the tappets 1 from the crankcase MIF0945A 92 68 To remove and renew the front and rear bushings 1 of the camshaft use the drift 380000667 2 and grip 380000668 3 MIF1130A 93 ...

Page 56: ...ith engine oil When fitting the oil filter lubricate the seal with engine oil CAUTION Handle all parts carefully Do not put your hands or fingers between parts and use appropriate tools to align fixing holes Wear the prescribed safety clothing including goggles gloves and safety footwear ENGINE ASSEMBLY ON THE BENCH Fitting the Bushings Disassembly operation 68 To remove and renew the front and re...

Page 57: ...65 to 66 Lubricate the bushings supporting the camshaft and mount the camshaft 1 taking care that dur ing this process the bushings or the supporting seats do not get damaged MIF1129A 96 Position the plate 1 retaining the camshaft 2 with the slot facing towards the top of the crank case and the punchmark facing the operator Tighten the screws 3 to the prescribed torque stated on page 12 MIF1132A 9...

Page 58: ... tighten the retaining bolts 1 MIF0957A 99 Fitting the Crankshaft Disassembly operations 60 to 63 If any sign of seizure scoring or too much ovality is found on the main journals or crankpins they must be reground Before reconditioning the pins 1 use a micrometer 2 to measure the pins of the shaft and according to the undersizes given on page 8 define the diameter to which the pins must be reduced...

Page 59: ...f the main journals of the crankshaft are un dersized it is necessary to replace the main bearings of the same undersize class made Do not modify the bearings in any way The main bearings 1 are supplied as spare parts with an undersized inside diameter of 0 250 0 500 mm 0 0098 0 0196 in Carefully clean the main half bearings 1 with a lu brication hole and fit them into their respective seats The p...

Page 60: ...rated wire 3 on the crankshaft journals 4 parallel to the crank shaft centerline Fit the caps 1 complete with half bearings 2 on the relevant supports MIF0964A 104 Insert the pre lubricated screws 1 and tighten them in three successive stages 1st and 2nd phase with a torque wrench to the torque given on page 13 MIF0965A 105 3rd phase with tool 380000304 1 positioned as in the figure further tighte...

Page 61: ...y set ting a dial gauge 2 with a magnetic base on the crankshaft 3 as shown in the figure the normal as sembly clearance must come within the tolerance prescribed on page 8 If the clearance is found to be any greater change the main half bearings of the penultimate rear thrust bear ing support 1 and check the clearance again between the crankshaft journals and main half bearings MIF1076A 108 Fitti...

Page 62: ...liner is fac ing as described in point 2 MIF0968A 110 2 Insert the rings 2 retaining the pin 1 MIF1060A 111 3 To fit the rings 1 on the piston 3 use tool 380000221 2 NOTE The piston rings see page 8 to 9 are sup plied as spare parts in the following sizes standard marked with yellow paint oversized by 0 5 mm 0 0196 in and marked with yellow green paint MIF0969A 112 ...

Page 63: ...mbly operation 57 1 Lubricate the pistons well including the piston rings and the inside of the cylinder liners 2 With the aid of the ring clamp 380000220 2 fit the connecting rod piston assemblies 1 in the cylinder liners MIF0971A 114 3 The ring openings must be staggered apart by 120 4 The connecting rod piston assemblies must all have the same weight 5 The arrow 1 stamped on the crown of the pi...

Page 64: ...aft journals 1 Fit the connecting rod caps 3 with the relevant half bearings 4 MIF1077A 116 Big End Cap Assembly Disassembly operation 56 1 Tighten the screws 1 previously lubricated with engine oil with a torque wrench 2 to the torque prescribed on page 13 MIF0973A 117 2 Fit tool 380000304 1 on the socket wrench and further tighten the bolts 2 as prescribed on page 13 MIF0974A 118 ...

Page 65: ...bed on page 13 NOTE Before permanently fitting the connecting rod cap retaining bolts check that their diameter mea sured at the center of the length of the thread is no less than 0 1 mm 0 0039 in of the diameter mea sured at approximately 10 mm 0 3937 in from the end of the bolt 5 Check by hand that the connecting rods 1 run axially on the crankshaft journals and their end float measured with a f...

Page 66: ...ion the following parts on the cylinder head spring 4 and top cap 3 using tool 380000302 1 compress the spring 4 and retain the parts to the valve 5 with the cotters 2 MIF1138A 123 4 Check that the mating surfaces 1 of the cylinder head and crankcase are clean 5 Do not dirty the cylinder head gasket NOTE Before reusing the cylinder head retaining bolts check they show no sign of deterioration or d...

Page 67: ...piston as shown in the figure at a dis tance of 45 mm 1 7716 in from the center of the piston measure its protrusions S1 and S2 from the top face of the crankcase and then calculate the mean S l S1 S2 Scyl1 2 Repeat this operation for pistons 2 3 and 4 and calculate the mean value S Scyl1 Scyl2 Scyl3 Scyl4 S 4 If S is 0 40 mm 0 0157 in use the gasket type A If S is 0 40 mm 0 0157 in use the gasket...

Page 68: ...ve control rods are identical and can therefore be interchanged MIF1011A 128 Spread LOCTITE 5999 sealant between the cov er 2 and the manifold 3 and tighten the screws 1 to the torque prescribed on page 12 MIF1094A 129 Fitting the Injectors Disassembly operation 50 1 On the injector 1 mount a new seal 2 lubri cated with Vaseline and a new washer 3 2 Fit the injectors 2 3 4 in the seats on the cyli...

Page 69: ...ng on the rods when fitting the rocker arm assembly 1 3 Then mount the rocker arm assembly comprising the support and spindles and secure them to the head without tightening the bolts 2 to torque They will be tightened to torque together with those fixing the cylinder head MIF1013A 132 Fitting the Timing Gear Disassembly operation 47 1 Use a marker pen to mark the tooth of the driving gear 1 mount...

Page 70: ... stamped on the gears 1 and 2 coincide MIF0978A 134 3 Place the dial gauge 1 on the timing gear 2 and check that the clearance between the gears 2 and 3 is between 0 076 to 0 280 mm 0 0029 to 0 0110 in MIF1140A 135 4 Insert the screws 1 fixing the gears 2 to the camshaft 3 and tighten them to the torque pre scribed on page 12 MIF1141A 136 ...

Page 71: ... angle of 90 for all the screws 3rd stage additional tightening to an angle of 90 for 140 and 180 mm 5 5118 and 7 0866 in long bolts only A fan side MIF1015A 138 6 Adjust the clearance between the rocker arms and valves using an Allen wrench 1 box wrench 2 and feeler gauge 3 The working clearance is given on page 10 7 Move the cylinder to the exhaust stroke and mea sure the clearance the valves in...

Page 72: ...on 37 using tools 380000988 and 380000732 2 Do the timing for the injection pump 1 fig 141 in relation to the drive gear proceeding as de scribed on page 101 3 Then loosen bolt 2 insert the L spacer 1 and lock bolt 2 to make the fuel pump spindle free to turn MIF0920A 140 4 Fix the injection pump casing 1 to the seat of the gear box 2 with the screws 3 MIF0981A 141 5 Spline the gear 1 transmitting...

Page 73: ...timing of the additional counterweights making the marks A stamped on the gears coincide as shown in the figure MIF1142A 143 2 Insert the retaining pin in the hole B on the addi tional counterweight assembly to block rotation during the subsequent installation phase MIF1143A 144 3 Fit the additional counterweights 2 tighten the screws 3 to the torque prescribed on page 12 and remove the retaining ...

Page 74: ...ve seal Apply LOCTITE 5999 sealant onto the box to form a bead with a diameter of a few mm as shown in fig 147 It must be uniform no lumps with no air bubbles thin areas or breaks Any flaws must be corrected in as short a time as possible Avoid using excess material to seal the joint Too much sealant would tend to come out on both sides of the joint and clog the lubricant passage ways After applyi...

Page 75: ...9 Fitting the Flywheel Disassembly operations 39 to 41 1 Check the clutch plate mating surface turning is required if there is any scoring 2 Check the state of the teeth of the crown gear 2 If you find any breakage or excessively worn teeth replace it Mount the new one previously heated to a temperature of 150 C for 15 to 20 min NOTE The nominal thickness of the engine flywheel is 70 5 mm 2 7755 i...

Page 76: ... securing the engine flywheel 2 in two stages as described on page 13 1st phase tightening with torque wrench to a torque of 30 5 Nm 2nd phase tightening to an angle of 60 5 NOTE Tightening to an angle is done with tool 380000304 MIF1146A 153 Fitting the Oil Pump Disassembly operation 35 1 Insert the seal 2 Fit the oil pump 1 3 Insert the tightening screws 2 and tighten them to the torque prescrib...

Page 77: ...he Crankshaft Front Seal Disassembly operations 29 to 33 1 Fit part 4 of tool 380000666 on the front shank 3 of the crankshaft 2 Secure it with the screws 5 and spline the new seal 6 onto it 3 Position part 1 on part 4 screw down the nut 7 until the seal 6 is completely fitted in the front cover 2 MIF1001A 156 Fitting the Crankshaft Front Pulley Disassembly operation 28 1 Spline the pulley 2 onto ...

Page 78: ...tting so that the pins 3 and 4 are against the crankcase 2 Tighten the screws 1 and 2 MIF1005A 158 Fitting the Coolant Pump Assembly operation 26 1 Fit a new seal 2 onto the coolant pump 1 MIF0997A 159 2 Mount the coolant pump 1 3 Screw down the screws 2 and tighten them to the torque prescribed on page 12 MIF1150A 160 ...

Page 79: ...e screws 3 tightening them to the torque given on page 12 MIF1151A 161 3 Fit on the crankcase a new gasket 1 the cooler 2 a new gasket 3 and the oil filter mounting 5 4 Insert the screws 4 and tighten them to the torque prescribed on page 12 MIF1152A 162 5 Refit the bracket 1 to secure the alternator 2 to the crankcase Tighten the alternator fixing screws 3 to the torque specified on page 12 MIF10...

Page 80: ...r 1 tightening the bolts 2 and the tightener nut as directed on page 112 MIF1154A 165 Fitting the Auxiliary Member Drive Belt Disassembly operation 24 1 Fit the Poly V belt 3 on the pulleys of the crank shaft tightener 5 of the coolant pump 4 alter nator 1 and fan 2 NOTE Tension the belt correctly as indicated in op eration 10 414 10 MIF1155A 166 ...

Page 81: ...A 167 Fitting the Injector Feed Pipes Assembly operations 20 to 21 1 Fit the injector feed pipe assembly 1 2 Fit the injector fuel outlet pipes 2 using the seals 4 and tighten the screws 3 MIF1108A 168 Fitting the Priming Pump Feed Pipes Disassembly operations 17 to 19 1 Fit the priming pump 5 2 Fit the injector feed pipes 4 of the injection pump 3 secure the brackets fixing the pipe as sembly 1 2...

Page 82: ... tappet covers 1 8 Connect the engine oil vapor recovery pipe to the blow by 3 9 Fit the intake manifold 2 MIF1105A 170 10 Press the clip 1 in the direction of the arrow part B and connect the low pressure pipe Put the clip back in its locking position part A NOTE Figure 171 shows the connectors for the low pressure pipes 6 and 8 of figure 170 A Pipe locking position on connector B Coupling pipe r...

Page 83: ...RONT SEAL Removal DANGER Lift and handle all heavy parts using suitable lifting equipment Make sure that assemblies or parts are supported by means of suitable slings and hooks Check that no one is in the vicinity of the load to be lifted To access the seal proceed as follows 1 Lift the hood 1 and disconnect the battery nega tive cable 174 2 Remove air filter 3 and the radiators of the con denser ...

Page 84: ...NE CHAPTER 1 3 Remove the engine radiator 1 as indicated in operation 10 406 10 176 4 Loosen the pivot screws 2 and lock screws 1 of the tightener 3 177 5 Loosen the bolt 2 tensioning the belt 1 and re move the belt 178 ...

Page 85: ...e guide holes of the tool 380000665 4 for a depth of 0 1968 in 5 mm 9 Secure the tool 380000665 4 to the seal 1 by screwing down the screws 3 supplied 10 Extract the seal 1 by screwing down the screw 5 MIF0916A 180 11 Fit the tie rod 3 of the tool 380000669 to the out er seal 1 as shown in the figure and with the le ver 4 extract it from the front cover 2 12 To assemble and install proceed as foll...

Page 86: ...mission belt on the pulleys adjust it with the tensioning screw and lock the tighten er tightening the two retaining and pivot screws 4 Refit the engine radiator as described in opera tion 10 406 10 5 Refit the condenser radiator see opera tion 50 200 72 6 Reconnect the negative battery cable and close the hood Op 10 102 74 CRANKSHAFT REAR SEAL Removal DANGER Lift and handle all heavy parts using ...

Page 87: ... and then and put down in a specific wooden container with the hoist MIF1116A 185 4 Apply tool 380000663 3 on the rear shank 1 of the crankshaft 5 Perforate the inner seal 5 with a drill bit 0 1377 in 3 5 mm through the guide holes of the tool 380000663 3 for a depth of 0 1968 in 5 mm 6 Secure the tool 380000663 3 to the seal 5 by screwing down the screws 2 supplied 7 Extract the seal 5 by screwin...

Page 88: ...d as fol lows 1 Fit part 6 of tool 380000664 on the rear shank 3 of the crankshaft Secure it with the screws 1 and spline the new seal 2 onto it Position part 5 on part 6 screw down the nut 4 until the seal 2 is completely fitted in the flywheel casing MIF1145A 187 2 With a hoist and appropriate slinging insert the engine flywheel 1 on the pins 2 described above pushing it into contact with the cr...

Page 89: ...5 Nm 2nd phase tightening to an angle of 60 5 NOTE Tightening to an angle is done with tool 380001001 MIF1146A 190 5 Refit the clutch as described in opera tion 18 110 10 Op 10 106 12 VALVE ROCKER ARM CLEARANCE Removal WARNING Handle all parts carefully Do not put your hands or fingers between parts Wear the prescribed safety clothing including goggles gloves and safety footwear 1 Remove the hood ...

Page 90: ...r filter 192 4 Remove the plastic retaining clamps from the cab heater water delivery return pipes 2 and those of the electric cables 1 moving the pipes and cables on the compressor as described in the figure 193 5 Remove the retaining bolt and the front tappet in spection cover 1 together with the cover base seal 194 ...

Page 91: ...5 7 Remove the retaining bolt and the rear tappet in spection cover 1 together with the cover base seal 196 8 After taking off the covers adjust the clearance between the rocker arms and valves using an Al len wrench 1 box wrench 2 and feeler gauge 3 The working clearance should be inlet valves 0 30 0 05 mm 0 0118 0 019 in exhaust valves 0 55 0 05 mm 0 0216 0 0019 in MIF1016A 197 ...

Page 92: ...he retaining bolt to the torque stated on page 12 2 Fit the central tappet inspection cover together with the engine vapor inlet pipe and the cover base seal then tighten the retaining bolts to the torque stated on page 12 3 Fit the front tappet inspection cover together with the cover base seal and tighten the retaining bolt to the torque stated on page 12 4 Reposition the cab water delivery retu...

Page 93: ...ncluding goggles gloves and safety footwear CAUTION Always use appropriate tools to align fixing holes NEVER USE FINGERS OR HANDS Proceed as follows 1 Lift the hood and disconnect the battery negative cable 2 Disconnect the electrical connection of hood and remove the hood 1 198 3 Remove the diesel delivery 1 and recovery 2 fittings from the injectors then remove the rele vant pipes 199 ...

Page 94: ... 1 mount a new seal 2 lubri cated with Vaseline and a new washer 3 3 Fit the injectors in the seats on the cylinder head and tighten them with a torque wrench to the torque prescribed on page 12 4 Fit the new seals on the fuel manifolds 5 Fit the diesel delivery and recovery pipes and fit tings on the injectors 6 Fit the air filter dust ejector pipe its clamp and the four rear nuts retaining the s...

Page 95: ...bed safety clothing including goggles gloves and safety footwear CAUTION Always use appropriate tools to align fixing holes NEVER USE FINGERS OR HANDS Proceed as follows 1 Lift the hood and disconnect the battery negative cable 2 Disconnect the electrical connection of hood and remove the hood 1 202 3 Remove the accelerator retaining spring 1 and extract the lever 2 203 ...

Page 96: ...quick couplers 1 on the filter and 2 on the injection pump remove the injec tion pump supply pipe Remove the pipe 3 coming from the tank CAUTION Make the vehicle safe and put the gear into neutral MIF1161A 205 6 Remove the quick couplers and pipe 1 installed between the fuel filter and fuel pump 206 ...

Page 97: ...ectors the pipe 1 con nected to the thermostarter device and the elec trical connection of the engine stop device 3 MIF1163A 207 8 Disconnect the electrical connection 1 for mea suring the engine oil pressure 208 9 Remove the four fittings 2 connecting the injec tion pump injectors and the pipes 1 209 ...

Page 98: ...jection pump diesel return pipe then detach the pipes 12 Lock the engine flywheel with appropriate means 211 13 Before removing the injection pump do the tim ing and lock the engine flywheel with cylinder no 1 at T D C as indicated on page 100 using tools 380000988 and 380000732 Then loosen the bolt 2 remove the L spacer 1 and lock the screw 2 in order to keep the pump in time with the engine flyw...

Page 99: ...d safety bolt of the injection pump timing 5 Reinsert the L spacer and tighten the retaining bolts 6 Free the engine flywheel take out the tools 380000988 and 380000732 and refit the starter motor 7 Reconnect the pipes and the fittings of the diesel delivery pipes to the injectors and the fittings of the diesel return pipe to the injection pump 8 Fit the three retaining brackets insert the pipes o...

Page 100: ...g clip 17 Install the hood 18 Reconnect the battery negative cable and lower the hood Timing When replacing the injection pump bear in mind that it is supplied as a spare part already set for cylinder No 1 at T D C Proceed as follows 1 Unscrew the bolts 1 and remove the starter mo tor 2 MIF1172A 214 2 Fit the bracket tool 380000988 1 retaining the gear for turning the engine flywheel tool 38000073...

Page 101: ...n 4 fig 215 from the flywheel and turn this through 360 so that the reference marks 2 are visible as shown in the figure alongside then reinsert the locking pin 4 fig 215 MIF1175A 217 6 Fit the injection pump casing 1 already set in the seat of the gear box 2 without tightening the retaining bolts 3 With the injection pump fitted in its seat take the cyl inder No 1 to T D C as follows CAUTION The ...

Page 102: ...it equivalent to the lowest indication of the dial gauge pointer 13 In these conditions reset the dial gauge and turn the crankshaft in the opposite direction to go back into the condition of the 1 cylinder at the TDC in the phase of the end of compression In this position the dial gauge on the pump must read off a value of 1 mm 0 0393 in 14 Turn the pump anticlockwise if the stroke is any less or...

Page 103: ...MIF1167A 222 Op 10 402 10 COOLANT PUMP Removal DANGER Lift and handle all heavy parts using suitable lifting equipment Make sure that assemblies or parts are sup ported by means of suitable slings and hooks Check that no one is in the vicinity of the load to be lifted 1 Raise the hood 1 2 Disconnect the battery negative cable 223 3 Remove the three retaining bolts 1 and the guard 2 on the right ha...

Page 104: ...26 CAUTION Always use appropriate tools to align fixing holes NEVER USE FINGERS OR HANDS 1 Respect the tightening torques prescribed on page 12 and on page 112 2 Fit a new seal 2 onto the coolant pump 1 3 Fit the coolant pump tightening the two retaining bolts 4 Fit the belt and adjust it with the tensioning screw 5 Tighten the screws retaining and pivoting the tightener to the cover 6 Reconnect t...

Page 105: ... footwear 1 Raise the hood 1 2 Disconnect the battery negative cable 227 3 Remove the three retaining bolts 1 and the guard 2 on the right hand side of the fan 228 4 Detach the fitting of the return pipe for the coolant from the cab heater radiator connected to the un derside of the coolant pump and drain off the en gine coolant 5 Remove the clamp 2 and extract the sleeve 1 connecting the radiator...

Page 106: ...he tightening torques prescribed on page 12 2 Refit the thermostatic valve after positioning the thermostat valve seal 3 Fit the thermostat valve body and the retaining bolts 4 Fit the radiator thermostat valve connecting sleeve and the clamp 5 Install the fitting of the cab heater radiator coolant return pipe connected to the bottom of the cool ant pump and refill the engine coolant 6 Fit the gua...

Page 107: ...no one is in the vicinity of the load to be lifted 1 Raise the hood 1 232 2 Remove the three retaining bolts 1 and the guard 2 on the right hand side of the fan 233 3 Detach the fitting of the return pipe for the cool ant from the cab heater radiator connected to the underside of the coolant pump and drain off the engine coolant 4 Loosen the retaining clamp and extract the pipe 1 joining the coola...

Page 108: ...sponding retaining clamp 1 and extract the pipes And remove the bracket 2 235 6 Loosen the corresponding retaining clamps and extract the pipes 1 2 and 3 remove the bracket 4 4 3 236 7 Remove the clamp securing the sleeve 1 to the air filter 2 1 2 237 ...

Page 109: ...r 1 238 9 Remove the clamp 1 and extract the radiator coolant compensation reservoir 2 1 239 10 Remove the radiator of air cooler 1 and bracket 3 11 Remove the condenser 2 without however re moving the condenser gas delivery return pipes so as not to recover recharge the system refrig erant gas 3 240 ...

Page 110: ...ake out the two radiator retaining bolts 2 installed under the front axle support 1 remov ing the bolts washers and lower rubber blocks 241 13 Remove the radiator 1 242 14 Remove the rubber blocks 1 washers and up per rubber blocks 2 243 ...

Page 111: ...thermostat valve connect ing sleeve and the relevant clamp 8 Fit the sleeve connected to the bottom of the wa ter radiator and its clamp 9 Fit the engine oil vapor suction pipe and its clamp 10 Fit the air filter and tighten the two lower retaining bolts 11 Fit the air filter exhaust ejector connecting pipe and its clamp 12 Fit the sleeve connected to the intake manifold and its clamp 13 Fit the s...

Page 112: ...itioned on the belt tensioning device and on the pulleys 2 Loosen the screws 2 and 3 retaining and piv oting the tightener to the cover 6 3 Loosen the locking nut 5 and the screw for ten sioning the belt 4 checking that its thread is not defective and has no oxidized painted parts that would affect its rotation in its seat in the cover 6 244 4 Turn the screw 4 and lightly tension the belt 1 with t...

Page 113: ...7 to 292 lbs f Frequency measured with CLAVIS 158 to 170 Hz With the cooling fan with viscostatic cou pling Assembly tension 1250 to 1450 N 281 to 326 lbs f Frequency measured with CLAVIS 177 to 191 Hz 246 8 If the measured data are out of tolerance repeat operations 5 to 7 described above and check that the measurements come within the prescribed tolerances 9 Using a torque wrench tighten the M 1...

Page 114: ...heck the internal diameter of the cylinder liners for ovality taper and wear use the bore gauge 1 fitted with a dial gauge zero set on the ring gauge 2 of the diameter of the cylinder liner NOTE If the ring gauge is not available use a mi crometer MIF1030A 247 Measurements must be taken for each single liner at three different heights on the liner and on two ortho gonal faces one parallel to the l...

Page 115: ...ng all the liners must have the same oversize 0 5 mm 0 0196 in Check the main bearing seats proceeding as follows fit the main bearing caps on the supports without bearings tighten the retaining bolts to the prescribed torque using an appropriate dial gauge for interiors check that the diameter of the seats is as pre scribed on page 8 If the measurement is any greater change the crank case ...

Page 116: ...ing a grinding machine The flatness error must be no greater than 0 075 mm 0 0029 in NOTE The crankcase can be faced only after mak ing sure that after machining the protrusion of the piston from the cylinder liner is no greater than as prescribed on page 9 Check the condition of the cylinder block plugs 3 if they are rusty or if there is the slightest doubt about their seal change them After faci...

Page 117: ...use a micrometer 2 to measure the pins of the shaft 1 to define the diameter to which the pins must be reduced NOTE It is advised to note the values on a chart See figure 252 The undersize classes are 0 250 0 500 mm 0 0098 0 0196 in MIF0958A 251 MIF0959A 252 Chart on which to note the measurements of the main journals and crankpins Nominal value All the main journals and crankpins must be ground t...

Page 118: ...ANCES TOLERANCES CHARACTERISTIC SUBJECT OF TOLERANCE GRAPHIC SYMBOL SHAPE Circularity f SHAPE Cilindricity f Parallelism ORIENTATION Perpendicularity Straightness POSITION Concentricity or coaxiality Circular oscillation OSCILLATION Total oscillation Taper CLASS OF IMPORTANCE ASSIGNED TO PRODUCT CHARACTERISTICS GRAPHIC SYMBOL CRITICAL IMPORTANT SECONDARY ...

Page 119: ...he cylinder in which it is mounted In the event of replacement number the new rod with the same number as the replaced connect ing rod On the body of the connecting rod with a letter indicating the weight class of the connect ing rod mounted in production V 1600g to 1640g marked in yellow W 1641g to 1680g marked in green X 1681g to 1720g marked in blue Connecting rods are supplied as spare parts i...

Page 120: ... on the stop bar 1 MIF1045A 256 Checking Twisting Check the twist of the connecting rod 2 by compar ing two points A and B of the pin 4 on the horizon tal plane of the connecting rod axis Position the support 1 of the dial gauge 5 so that this pre loads by 0 5 mm 0 0196 in on the pin 4 at point A and reset the dial gauge 5 Move the spindle 3 with the connecting rod 2 and on the op posite side B of...

Page 121: ...t this rests on the pin 4 at point C as shown in the figure Swing the connecting rod to and fro seeking the highest posi tion of the pin and reset the dial gauge 1 in this con dition Move the spindle with the connecting rod 3 and on the opposite side D of the pin 4 repeat the check for the highest point The difference between points C and D must be no greater than 0 08 mm 0 0031 in MIF1047A 258 PI...

Page 122: ... pages 8 and 9 If the clearance is not within the tolerances stated on page 9 it will be necessary to ream rebore the liners and fit oversize pistons and rings see pages 8 and 9 NOTE The diameter must be measured at a distance of 61 mm 2 4015 in from the base of the piston skirt MIF1035A 260 Clearance between the piston and the cylinder liner can be measured with a feeler gauge 1 as shown in the f...

Page 123: ...ton with a light pressure of the fingers and must not drop out MIF1038A 263 Piston Rings Using a micrometer 1 check that the thickness of the 1 2 3 ring 2 comes within the tolerances stated on page 8 MIF1039A 264 Using a feeler gauge 2 check that the clearance between the rings and their seats on the piston come within the tolerances prescribed on page 9 MIF1040A 265 ...

Page 124: ...between the ring and the groove this clear ance must be as prescribed on page 9 MIF1041A 266 Measure the clearance between the ends of the pis ton rings 2 introduced in the cylinder liner 3 using a feeler gauge 1 checking it is as prescribed on page 9 MIF1042A 267 VALVES AND CAMSHAFT Valves CAUTION Handle all parts carefully Do not put your hands or fingers between parts Wear the prescribed safety...

Page 125: ...ire brush 1 Check that the valves show no signs of seizure cracking or burning If necessary grind the bevels on the valve heads us ing a grinding machine removing as little material as possible MIF1049A 269 Using a micrometer 2 measure the valve stem 1 and check it comes within the range of tolerance giv en on page 9 MIF1050A 270 ...

Page 126: ...parts Using a specific tool and taking care not to nick the cylinder head remove as much mate rial as possible from the valve seats until it is possible to extract them from the cylinder head with the aid of a punch Heat the cylinder head to 80 to 100 C 176 to 212 F and using a suitable drift insert the new valve seats previously cooled Then regrind the valve seats according to the values given in...

Page 127: ...the main data for checking the inlet and exhaust valve springs Before assembly check the valve spring flexibility us ing tool 380000976 Compare the elastic deforma tion and load data with those of the new springs stated in the following table Height Under a load of mm in N lbs f H free 63 50 2 50 No load H1 49 02 1 93 P1 329 73 96 H2 38 20 1 50 P2 641 144 10 MIF1054A 274 Tappets The figure gives t...

Page 128: ...signs of seizing or scoring replace the shaft and relative bushings Checking Cam Lift and Pin Alignment Set the shaft on tailstocks and using a dial gauge with a 1 100 mm scale placed on the central support check that the alignment error is no greater than 0 04 mm 0 0015 in change the shaft if it is Check the diameter of the supporting pins of the camshaft 2 with the micrometer 1 on two orthogo na...

Page 129: ...ng figure MIF1058A 278 Cylinder Head Thickness The nominal thickness A of the cylinder head is 95 0 25 mm 3 7401 0 0098 in the maximum permis sible amount of metal removed must not exceed the thickness B of 0 13 mm 0 0051 in NOTE After regrinding check the valve recessing and if necessary regrind the valve seats to obtain the recessing prescribed on page 9 MIF1059A 279 TOLERANCES CHARACTERISTIC SU...

Page 130: ...ible causes are blown fuse blown lamp interruption in wire to the control switch NOTE When the engine oil pressure is too low the indicator light comes on with the ignition key on B ready for starting OIL FILTER Replacement The oil filter 3 fig 54 is the paper integral cartridge type If the filter gets too clogged the safety valve opens to enable the oil to by pass the filter keeping the en gine l...

Page 131: ... lime scale in the radiator by means of a solution of water and descaling agent in the proportions shown on the container It is never advisable to limit flushing to the radiator only always extend it to the entire cooling circuit and top up the engine with the solution referred to above Run the engine for about an hour with the engine off in order to drain the solution through the drain plug In th...

Page 132: ...132 SECTION 10 ENGINE CHAPTER 1 ...

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