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Portable Fire Pump

Workshop Manual

Publication: GP/291
Issue 4, January 2016

Содержание PowerFlow 12/10

Страница 1: ...Portable Fire Pump Workshop Manual Publication GP 291 Issue 4 January 2016...

Страница 2: ...ligation AMENDMENT RECORD Model 12 10 17 10 Portable Fire Pumps Mod No Date Page s Amendment New Issue No 1 May 2012 All New publication 1 2 November 2012 8 18 19 Revised oil level check procedure 2 3...

Страница 3: ...ONENTS AND CONTROLS 17 10 AND 12 10 MODELS 11 GENERAL ARRANGEMENT LEFT HAND VIEW FROM FRONT 11 GENERAL ARRANGEMENT RIGHT HAND SIDE FROM REAR 12 GENERAL ARRANGEMENT CONTROLS AND INSTRUMENTS 13 ENGINE F...

Страница 4: ...STALLATION 30 INTRODUCTION 30 PRECAUTIONS 30 POST REPAIR AND ASSEMBLY 30 INSTALLATION 30 1 SUCTION TUBE REMOVAL WEAR RING RE ASSEMBLY 31 2 IMPELLER MECHANICAL SEAL AND REAR WEAR RING 34 3 PRIMING VALV...

Страница 5: ...4 Godiva Ltd Our policy is one of continuous development We therefore reserve the right to amend specifications without notice or obligation Page intentionally left blank...

Страница 6: ...ed from the suction tube end For specific engine information please refer to the Weber Operating and Maintenance Instructions Fuel system Care To ensure availability and reliability of gasoline powere...

Страница 7: ...ns 1998 applies Training It is ESSENTIAL that Godiva pumps are operated ONLY by TRAINED PERSONNEL Please contact Godiva Ltd to discuss your training needs To avoid damage and personal injury operating...

Страница 8: ...eights without assistance DO NOT remove protective guards or shields When cleaning the pump and engine use hot soapy water do not use flammable degreasers When cleaning the pump and engine use hot soa...

Страница 9: ...y for operation under ambient conditions 0 C Oil Filter Metal spin on type Fuel Type Unleaded gasoline EU 95 RON US 91 RON MON Fuel Feed Electric pump Fuel Capacity 18 litres Run Time 17 10 model 60 m...

Страница 10: ...7 10 1500 l min FPN 10 1500 12 10 1000 l min FPN 10 1000 Maximum Flow 17 10 2450 l min at 3 bar 12 10 2150 l min at 3 bar Maximum Pump Discharge Pressure 17 10 12 10 17 bar with boosted suction 17 bar...

Страница 11: ...damage Optional Equipment Detachable floodlight rated 55w Detachable wheel assembly for transporting pump over long distances Frame with extendable handles Additional fuel tank with quick release conn...

Страница 12: ...TROLS 17 10 AND 12 10 MODELS General Arrangement Left Hand View from front 1 Priming valve automatic operation 2 Engine oil filter 3 Coolant fill 4 Battery 5 Fuel filler cap 6 Delivery valve 7 Carryin...

Страница 13: ...d Our policy is one of continuous development We therefore reserve the right to amend specifications without notice or obligation General Arrangement Right Hand Side from rear 12 Air filter 13 Oil fil...

Страница 14: ...gauge 17 10 80mm dia 12 10 60mm dia 25 Pressure gauge 17 10 80mm dia 12 10 60mm dia 26 Throttle controls pump speed 27 Engine start Warning Lights Indicator Meaning Action Fuel level Shows fuel level...

Страница 15: ...for aluminium engines Suitable additives BASF Glysantin G 30 Chevron Havoline Extended Life Coolant XLC B Valvoline Zerex G 30 The coolant acts as anti freeze in the winter and coolant in the summer...

Страница 16: ...d or removed from the unit this procedure must be followed to restart 4 1 Reconnect the battery red lead to positive terminal black to negative terminal in that order 4 2 Place throttle in closed posi...

Страница 17: ...ngine Check oil level Yes 1 Engine Check coolant level Yes 1 Engine Change engine oil and oil filter Yes 2 Yes 2 Yes Engine Check clean air filter Yes 2 Engine Check and adjust valve play Yes Yes 3 En...

Страница 18: ...seawater Ensure the pump is drained Frost If frost is expected drain the pump volute by opening the drain valve at the bottom of the volute Engine Coolant Level Fill the cooling system with a 4 litre...

Страница 19: ...ot to let the coolant spill on to the exhaust insulation below the coolant is a flammable liquid Coolant Change Coolant is drained through the drain tap at the lowest point in the system which is loca...

Страница 20: ...dipstick Remove the oil tank cap dipstick 1 wipe the dipstick with a clean cloth and re insert Always screw the dipstick fully down to achieve a correct reading Remove the dipstick and note where the...

Страница 21: ...seal is lubricated Stop the engine and check the oil level with the dipstick as described in the previous section If necessary top up the oil level or drain off some oil to achieve the correct level...

Страница 22: ...s and below the fuse box The fuel filter can be removed by disconnecting the hoses on both sides and loosening the two clips holding the filter to the engine Air Filter Element The air filter is locat...

Страница 23: ...on Sparking Plugs This procedure is described in the Weber Service Manual Section 6 5 Preparing the unit for storage See Weber Service Manual section 8 9 Change oil and oil filter Add fuel stabiliser...

Страница 24: ...must be maintained for a minimum of 15 seconds If vacuum retention fails proceed to a pressure test to identify the cause Should the pump be incapable of developing a vacuum of 0 6 bar but hold whate...

Страница 25: ...s of the gauges with abrasive or solvent cleaners These will cloud the glass surface use a mild detergent and water FAULT TRACING Engine For specific engine related information please refer to the Web...

Страница 26: ...jet uneven Suction strainers not completely immersed Submerge Leakage in suction side Check and secure joints In the event of the above information not leading to a solution carry out the Monthly pum...

Страница 27: ...ontinuous development We therefore reserve the right to amend specifications without notice or obligation schedules of Godiva Ltd and Weber This information may be useful should you need to contact th...

Страница 28: ...pment We therefore reserve the right to amend specifications without notice or obligation PUMP LOG SHEET Model __________ Serial No ___________ Date Entered Service _______ Date Location Hours run Ins...

Страница 29: ...er Primer 12 10 4inch RT 2 x 2 Instantaneous connection Electric and recoil handstart Exhaust gas prime 17 10 4inch RT 2 x 2 Instantaneous connection Electric and recoil handstart Exhaust gas prime Ot...

Страница 30: ...ump shaft to crankshaft 1 10 O ring priming valve to volute 1 11 Dowty seal strainer 2 12 Dowty seal fuel drain plug Fuel Tank 1 13 Sealing washer for oil drain Oil Tank 2 Weber Engine Spares Kit Part...

Страница 31: ...lease refer to the Spare Manual GP 292 for the relevant assembly and part numbers Precautions Before carrying out repair work take the following precautions o Drain the fuel tank o Drain the engine oi...

Страница 32: ...ess to the volute impeller and mechanical seal behind 1 1 Disconnect the compound gauge tubing from the top of the suction tube 16mm spanner 1 2 Disconnect rubber hose from heat exchanger to suction t...

Страница 33: ...be to come forward 1 6 Remove the panel on the left hand side to gain better access to the priming valve Undo 7 x M6 socket head screws 1 7 This will allow the priming valve to be removed completely f...

Страница 34: ...f the suction tube by turning the screws evenly into the three holes on the face of the suction tube 1 9 The front wear ring 68026 can now be inspected for wear and damage Measure the ring across the...

Страница 35: ...the suction tube removed the impeller main shaft seal and the rear wear ring will be accessible in this sequence 2 1 Remove the M16 nyloc nut retaining the impeller onto the shaft Carefully move the i...

Страница 36: ...hten to 2Nm 2 4 While the impeller is removed from the pump the front and rear wearing dimensions can be checked This dimension should be no less than 114mm This dimension must be measured on the fron...

Страница 37: ...seal is mounted on a backing plate with a retaining washer Check the condition of the seal 55669 If the seal is worn replace it The retaining washer must be flat To release the seal undo the M6 screw...

Страница 38: ...assembly is complete it can be re attached to the suction tube if required at this stage by reversing instructions in section 1 3 1 7 4 Priming Valve Heat Shield When the priming valve is removed fro...

Страница 39: ...ulation blanket on manifold 5 1 To remove the exhaust priming assembly First follow the procedure in sections 1 3 1 7 to disconnect and remove the priming valve including the removal of the side panel...

Страница 40: ...r the internal parts 5 6 Undo and remove 4 x M8 Thick nuts and 4 x M8 thin nuts retaining the exhaust exit to the exhaust primer housing 5 7 Removing the exhaust exit reveals the exhaust primer housin...

Страница 41: ...on exhaust gases are diverted through the adjacent venture channel to create the pump priming action 5 9 The butterfly valve can removed from the exhaust primer housing while the housing is attached t...

Страница 42: ...al in the primer housing 5 11 The exhaust primer housing can now be detached from the silencer by undoing the single M8 socket head screw in the corner 5 12 Removing the exhaust primer housing allows...

Страница 43: ...t insulation on the exhaust is permanent 5 14 When all the internal parts have been checked the exhaust primer system can be reassembled a reversal of the dismantling process Ensure the gasket is repl...

Страница 44: ...43 Godiva Ltd Our policy is one of continuous development We therefore reserve the right to amend specifications without notice or obligation...

Страница 45: ...olant from the system A drain tap is provided on the side of the engine Attach a suitable hose to the tap before opening Be careful not to spill or splash the coolant on any components as it is a flam...

Страница 46: ...eserve the right to amend specifications without notice or obligation Engine coolant into heat exchanger at the heat exchanger Engine coolant return to engine at the heat exchanger 6 3 To release the...

Страница 47: ...e the removal operation Note that the 2 x M6 screws on the rear bracket require a small amount of Loctite 243 on the threads to secure 7 Oil Tank The oil tank is located at the rear of the pump Please...

Страница 48: ...is one of continuous development We therefore reserve the right to amend specifications without notice or obligation 7 2 Undo the two hoses feeding oil to and from the tank 7 3 Undo the 1 x M6 bolt o...

Страница 49: ...to remove it from the bottom of the pump frame 7 5 To release the oil tank form the pump the breather hose connected to the top of the tank needs to be removed from the elbow It may be necessary to cu...

Страница 50: ...removing the major assemblies should be followed first remove the oil tank section 7 instrument panel section 14 heat exchanger section 6 Separate the engine from the panel wiring harness Disconnect...

Страница 51: ...engine mount 8 4 To allow the pump engine assembly to be lifted clear of the frame the two sides of the frame must be separated The exhaust side of the frame hot side is secured to the fuel tank side...

Страница 52: ...frame it is advisable to remove the air filter assembly from the throttle body on the air intake 8 7 With the pump engine assembly removed the fuel tank is exposed Continue to remove the fuel tank by...

Страница 53: ...it does not obstruct or snag when replacing the tank Note the M6 bolts at each end of the fuel tank are longer than the ones under the tank Apply a small amount of Loctite 243 to the threads of all t...

Страница 54: ...53 Godiva Ltd Our policy is one of continuous development We therefore reserve the right to amend specifications without notice or obligation...

Страница 55: ...uts on studs retaining the pump to the engine 9 2 The pump assembly can now be moved forward from the engine gently tap the pump body with a plastic hammer to dislodge it from the engine 9 2 This reve...

Страница 56: ...eing careful not to disturb the location of the stub shaft The teeth on the outer edge of the rotor will engage with teeth on the starter motor 9 7 Apply a sealant Loctite 243 or equivalent to the 6 o...

Страница 57: ...ap the pump body gently against the engine Tap evenly around the outer edge of the pump 10 4 Replace the 9 x M6 nuts and 2 x M10 nuts around the outside edge of the pump Tighten the 2 x M10 nuts first...

Страница 58: ...or obligation 11 3 Press the seal into the pump volute evenly Ensure it is pressed to the bottom of the recess and is flush with the surface of the pump volute 11 4 Clean the surface of the seal with...

Страница 59: ...he right to amend specifications without notice or obligation 11 7 Press bearing 68170 onto the shaft Also place O ring 57044 into the groove next to the shaft splines 11 8 Use a press to move the bea...

Страница 60: ...e right to amend specifications without notice or obligation 11 10 Fit the flinger 68033 on to the shaft 11 11 Fit the shaft with the collar and flinger facing down into the rear of the pump 11 12 Tap...

Страница 61: ...gation 11 13 Use a suitable ring tool to push the bearing and shaft further into the pump 11 14 Push the bearing into the pump body until it passes the internal circlip groove 11 15 Insert the circlip...

Страница 62: ...e right to amend specifications without notice or obligation 11 17 Fit the O ring to the impeller end of the shaft 11 18 Place the key MS179 36 into the slot on the shaft 11 19 Apply a soft soap solut...

Страница 63: ...ce the spring from the seal kit over the impeller rear central section 11 21 Apply a soft soap solution to the internal part of the seal 11 22 Push the seal onto the impeller and press down against th...

Страница 64: ...be fitted to the shaft Grease the end of the shaft and inside impeller 11 25 Press the impeller down on to the shaft Ensure the slot in the impeller lines up with the key on the shaft 11 26 Fit the wa...

Страница 65: ...64 Godiva Ltd Our policy is one of continuous development We therefore reserve the right to amend specifications without notice or obligation...

Страница 66: ...chieved when the pump end is separated from the engine 12 1 The recoil start mechanism is retained in the rear of the volute by a circlip Remove the circlip with circlip pliers to access the reel 12 2...

Страница 67: ...elopment We therefore reserve the right to amend specifications without notice or obligation 12 4 Pull most of the rope through the reel 12 5 Tie a knot in the rope end 12 6 Pull the rope back through...

Страница 68: ...ly around the reel in a clockwise direction for four turns 12 8 Thread the other end of the rope through the hole the volute to the outside 12 9 Place the complete reel back over the shaft and onto th...

Страница 69: ...right to amend specifications without notice or obligation 12 11 Place the Straight end of the Clip through the ratchet guide hole as shown below 12 12 Line the Plate grooves up with the Block grooves...

Страница 70: ...ce or obligation 12 14 Pull the other end of the rope right through the handle length should be 1800mm Make a mark where the 1800mm length should be 12 15 Tie a secure slip knot in the end of the rope...

Страница 71: ...igation 12 17 Burn the end of the rope to prevent it fraying and push it back into the handle This should make the rope the correct length for the recoil action 12 18 When the rope is released the rec...

Страница 72: ...therefore reserve the right to amend specifications without notice or obligation 12 19 Before assembling the volute with the recoil starter fixed inside to the engine Fully extend Rope check the Pulle...

Страница 73: ...he 1 x M10 nut fixing the hand wheel to the Spindle 13 2 Rotate the Spindle Clockwise and remove from the delivery valve housing Note Do NOT attempt to remove the Valve Seal Plate assembly from the St...

Страница 74: ...ay from the Plate Locking Nut and release the nut to allow the Stem to be separated from the Valve Plate 13 5 Re assembly is a reversal of the dismantling Check condition of and renew as necessary the...

Страница 75: ...aced with a small amount of Loctite 243 applied to the thread 15 Electrical System The pump and engine electrical system is checked by diagnostic software connected to the unit through the main wiring...

Страница 76: ...derside of the instrument panel provides engine calibration and management according to pre programmed data and is accessed by the diagnostic software mentioned above In normal operation it is not nec...

Страница 77: ...n the instrument panel First undo and lift the instrument panel from the frame see section 12 Instrument Panel It is not necessary to disconnect any of the wiring harness or gauge connections 15 6 The...

Страница 78: ...77 Godiva Ltd Our policy is one of continuous development We therefore reserve the right to amend specifications without notice or obligation 15 8 Engine wiring harness...

Страница 79: ...78 Godiva Ltd Our policy is one of continuous development We therefore reserve the right to amend specifications without notice or obligation 15 9 Control Panel Wiring Harness...

Страница 80: ...79 Godiva Ltd Our policy is one of continuous development We therefore reserve the right to amend specifications without notice or obligation 15 10 Fuel Tank Harness...

Страница 81: ...e 243 46 Skid plate retaining screws Loctite 243 50 Fuel tank retaining screws Loctite 243 50 Fuel tank connections fuel filter equal tee Loctite 410 and Activator 770 52 Stub shaft on six screws reta...

Страница 82: ...elopment We therefore reserve the right to amend specifications without notice or obligation Godiva Limited A Unit of IDEX Corporation Charles St Warwick CV34 5LR England Tel 44 0 1926 623600 Fax 44 0...

Страница 83: ...IND NA 406555 This repair manual is valid for the following engine variants en_English REPAIR MANUAL 4 Stroke Engine Read the introductory chapter before performing the task on the engine Pay particu...

Страница 84: ......

Страница 85: ...s to make continual improvements as part of the ongoing technical development of its products All documentation is therefore subject to technical modifications Reprints and translations in whole or in...

Страница 86: ...ve side of the engine stand 18 3 3 2 Mount the engine across from the drive side of the engine stand 19 3 4 While working 20 3 4 1 Tightening torque 20 3 4 2 Cleaning 20 3 4 3 Disposal 20 3 5 Checking...

Страница 87: ...ain bearing play 136 020 02 Stub shaft 142 020 02 01 Removing stub shaft 143 020 02 02 Installing stub shaft 145 020 03 Crankshaft cover 147 020 03 01 Removing crankshaft cover 148 020 03 02 Installin...

Страница 88: ...tem 234 050 01 Thermostat housing 234 050 01 01 Removing thermostat housing 235 050 01 02 Installing thermostat housing 236 050 01 03 Removing fitting 238 050 01 04 Installing fitting 239 050 01 05 Re...

Страница 89: ...starter 285 090 01 02 Installing starter 286 090 01 03 Replacing starter 287 090 02 Generator 289 090 02 01 Removing generator 290 090 02 02 Installing generator 293 090 03 Voltage regulator 296 See t...

Страница 90: ...8 120 Engine mount 329 120 01 Lifting eye 329 120 01 01 Removing bracket on the drive side 330 120 01 02 Installing bracket on the drive side 331 120 01 03 Removing pipe clamp 332 120 01 04 Installing...

Страница 91: ...res and recommendations These chapters are required for tasks covered in the following chapter Tools and supplies required for tasks covered in the chapter The chapter structure in the repair manual i...

Страница 92: ...ons in the repair manual are changed or amended All changes are described in the chapter Overview of revisions Observe the following information Always use the most current repair manual from the prot...

Страница 93: ...personnel have read and understand all introductory chapters and in particular the chapter on safety Observe all generally applicable laws and regulations in addition to the information in this repai...

Страница 94: ...the engine on the brackets provided See chapter 3 2 Lift and transport the engine Lift and transport the engine Securing the engine Crush injuries due to the engine overturning Mount the engine to the...

Страница 95: ...er s documentation Engine power supply Protective equipment Missing protective equipment poses a safety risk to personnel Attach all protective equipment after completing the tasks Tools and accessori...

Страница 96: ...e engine or the fuel system Never fill with fuel while the engine is running Do not start the engine if there is a smell of fuel or you suspect that fuel is leaking Have a workshop authorized by Weber...

Страница 97: ...The following requirements must be met before performing any tasks The engine has been removed from the portable fire pump The engine has been disconnected from the power supply There is no engine oi...

Страница 98: ...ct lifting of heavy loads Always lift the engine using a workshop crane NOTICE Components can break Lift the engine only using the brackets Lift the engine using the brackets 1 3 Basic instructions fo...

Страница 99: ...ss from the drive side Mount the engine on the drive side 1 of the engine stand See chapter 3 3 1 Mount the engine on the drive side of the engine stand or Mount the engine across from the drive side...

Страница 100: ...kshop crane Engine stand WARNING Spinal column injury due to incorrect lifting of heavy loads Always lift the engine using a workshop crane NOTICE Breakage Lift the engine only using the brackets Lift...

Страница 101: ...e stand WARNING Spinal column injury due to incorrect lifting of heavy loads Always lift the engine using a workshop crane NOTICE Breakage Lift the engine only using the brackets Lift the engine using...

Страница 102: ...s about tightening torque in this repair manual observe the following information The thread is dry and free of engine oil For components with coated threads the tightening torques always refer to new...

Страница 103: ...d then back off Allow the engine to warm up as described in the portable fire pump manufacturer s documentation You should not hear any unusual noises Perform a visual inspection No fluids should be e...

Страница 104: ...or com for more information 4 1 Weber Motor tool case 4 Tools and accessories 4 1 Weber Motor tool case Figure Description Locking tool crankshaft Chain breaking tool Installation spike valve stem sea...

Страница 105: ...ewdriver T20 T30 T45 Torx screwdriver socket T20 T30 T45 Hexagon screwdriver 4 5 6 7 8 In addition to the tool case you will require the following tools and accessories The figures are only examples o...

Страница 106: ...ins maximum 3 mm Bar magnet Universal pliers Plastic hammer Universal strap wrench Lockring pliers bore holes Figure Description Valve refacer Piston ring compressor Cylinder liner puller Oil seal sli...

Страница 107: ...25 RLF MPE850 Rev 1 2 406555 Figure Description Precision clearance gauges 0 025 mm 0 04 mm 4 Tools and accessories 4 2 Equipment workshop...

Страница 108: ...nti Seize assembly paste for lubricating threaded connections Weicon Anti Seize High Tech ASW 040 P Loctite 8150 Thread sealant Loctite 542 Valve grinding compound Teroson valve grinding compound Seal...

Страница 109: ...27 RLF MPE850 Rev 1 2 406555 010 010 01 1 Crankcase 010 01 1 Crankcase 010 Crankcase...

Страница 110: ...end wrench 12 Crown wrench Cylinder liner puller Torque wrench Hexagon screwdriver socket 5 6 8 Torx screwdriver socket T30 Insert open end wrench 12 Petroleum jelly Pin punch axle intermediate gear...

Страница 111: ...2 406555 010 5 6 6 7 3 4 Turn the lower case 180 Remove the sleeves 6 Unscrew the fitting 5 Unscrew the bolts 3 Remove the intake manifold bracket 4 010 01 1 Crankcase 010 01 1 01 Replacing crankcase...

Страница 112: ...8 Unscrew the bolts 12 Remove the chain rail 13 Remove the sleeves 11 010 01 1 Crankcase 010 01 1 01 Replacing crankcase Remove the intermediate gear suction pump 10 Punch the axle 9 out using the pin...

Страница 113: ...strap wrench Unscrew the threaded sleeve 14 using a crown wrench Unscrew 10 bolts 16 The thermostat housing is caulked with a silicone liquid seal Remove the thermostat housing 18 010 01 1 Crankcase 0...

Страница 114: ...1 Remove the cylinder liners 22 using a cylinder liner puller Prepare the new crankcase Replace the crankcase The plug can be found in the spare parts catalog in chapter 010 01 2 Crankcase Screw in a...

Страница 115: ...eves 26 The plugs can be found in the spare parts catalog in chapter 010 01 3 Crankcase Screw in new plugs 27 Tightening torque 20 Nm 4 Nm 14 8 lbf ft 3 lbf ft Two threaded holes M18 28 remain open Th...

Страница 116: ...g points M10 31 Depth of thread 30 mm Suitable mounting points M6 32 Screw in the threaded sleeve 33 using a crown wrench Tightening torque 17 Nm 3 Nm 12 5 lbf ft 2 2 lbf ft 010 01 1 Crankcase 010 01...

Страница 117: ...39 Screw in the oil filter 37 by hand Tightening torque 10 Nm 7 4 lbf ft Clean the sealing surface 38 with sealing surface cleaner 010 01 1 Crankcase 010 01 1 01 Replacing crankcase Clean the sealing...

Страница 118: ...ed Hold the thermostat housing 41 in position 010 01 1 Crankcase 010 01 1 01 Replacing crankcase Screw in 10 bolts 42 Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft The bolt is an additional part a...

Страница 119: ...torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft 010 01 1 Crankcase 010 01 1 01 Replacing crankcase Hold the intake manifold bracket 46 in position Screw in the bolts 47 Tightening torque 20 Nm 4 Nm 14 8 lbf f...

Страница 120: ...se 180 Hold the intermediate gear suction pump 52 in position Slide in the axle 53 Observe the position of the bevel 54 The plug and seal can be found in the spare parts catalog in chapter 010 01 3 Cr...

Страница 121: ...2 60 60 010 01 1 Crankcase 010 01 1 01 Replacing crankcase Unscrew the bolt 58 Remove the lower case 59 Insert the chain guide 62 Screw in the bolts 61 Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf f...

Страница 122: ...chain rail 64 Screw in the bolt 63 Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft The o rings can be found in the spare parts catalog in chapter 010 01 2 Crankcase Replace the o rings 66 Coat the o...

Страница 123: ...from the crankcase Welch plug 1st cylinder 1 Welch plug 2nd cylinder 2 Unscrew the banjo bolt 3 Remove the welch plug 4 010 01 1 Crankcase 010 01 1 02 Replacing welch plugs 010 01 1 02 Replacing welch...

Страница 124: ...case is disconnected from the crankcase Unscrew the tie rod 1 using a stud extractor Replace tie rod Apply Anti Seize assembly paste to all threads 2 Screw in the tie rod using a stud extractor Tighte...

Страница 125: ...bf ft Hexagon screwdriver 5 8 Torque wrench Hexagon screwdriver socket 5 8 Plug M18x1 5 exhaust side 1 Plug M18x1 5 intake side 2 Plug M10x1 3 Replacing plug M18x1 5 intake side The rotor is removed U...

Страница 126: ...v 1 2 406555 010 1 Replacing plug M10x1 The generator is removed Unscrew the plug 1 Replace the plug Screw in the plug Tightening torque 9 Nm 2 Nm 6 6 lbf ft 1 5 lbf ft 010 01 1 Crankcase 010 01 1 04...

Страница 127: ...45 RLF MPE850 Rev 1 2 406555 010 010 01 2 Crankcase 010 01 2 Crankcase...

Страница 128: ...e stand Mount the engine across from the drive side 1 of the engine stand See chapter 3 3 2 Mount the engine across from the drive side of the engine stand 070 01 01 Removing intake manifold 030 01 04...

Страница 129: ...ead Install the valve cover See chapter 030 01 02 Installing valve cover Install the ignition coils See chapter 030 01 05 Installing ignition coils Install the intake manifold See chapter 070 01 02 In...

Страница 130: ...ee chapter 3 3 2 Mount the engine across from the drive side of the engine stand Preparation Remove the generator See chapter 090 02 01 Removing generator 090 02 01 Removing generator 090 02 02 Instal...

Страница 131: ...de sleeve 4 Slide the guiding sleeve 6 onto crankshaft 7 Use the M10x1x35 bolts you removed on the rotor Screw in the bolts 8 Hold the sliding sleeve 9 in position on the oil seal 10 Use the M10x1x35...

Страница 132: ...tor See chapter 090 02 02 Installing generator Unscrew the bolt 14 Remove the sliding sleeve 13 Unscrew the bolts 17 Remove the guiding sleeve 15 Check if the oil seal 16 is tilted If the oil seal is...

Страница 133: ...crew the plug 1 Replace the plug Screw in the plug Tightening torque 20 Nm 4 Nm 14 8 lbf ft 3 lbf ft Hexagon screwdriver 8 Torque wrench Hexagon screwdriver socket 8 010 01 2 Crankcase 010 01 2 03 Rep...

Страница 134: ...52 RLF MPE850 Rev 1 2 406555 010 010 01 3 Crankcase 010 01 3 Crankcase...

Страница 135: ...Mount the engine on the engine stand Mount the engine on the drive side 1 of the engine stand See chapter 3 3 1 Mount the engine on the drive side of the engine stand 010 01 3 Crankcase 010 01 3 01 R...

Страница 136: ...406555 010 2 1 Torque wrench Hexagon screwdriver socket 8 010 01 3 Crankcase 010 01 3 02 Installing plug 010 01 3 02 Installing plug Replace the seal 1 Screw in the plug 2 Tightening torque 20 Nm 4 Nm...

Страница 137: ...side The oil cooler bracket is removed Two threaded holes M18 1 remain open Unscrew the plugs 2 Replace the plugs Screw in the the plugs Tightening torque 20 Nm 4 Nm 14 8 lbf ft 3 lbf ft Plugs across...

Страница 138: ...he plug 1 Replace the plug Screw in the plug Tightening torque 20 Nm 4 Nm 14 8 lbf ft 3 lbf ft Replacing lower plug intake side Unscrew the plug 1 Replace the plug Screw in the plug Tightening torque...

Страница 139: ...7 RLF MPE850 Rev 1 2 406555 010 1 Open end wrench 12 Unscrew the fitting 1 Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft 010 01 3 Crankcase 010 01 3 04 Removing fitting 010 01 3 04 Removing fittin...

Страница 140: ...555 010 2 1 Torque wrench Insert open end wrench 12 Replace the seal 1 Screw in the fitting 2 Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft 010 01 3 Crankcase 010 01 3 05 Installing fitting 010 01...

Страница 141: ...RLF MPE850 Rev 1 2 406555 010 1 2 Unscrew the bolt 1 Pull the sensor crankshaft 2 out Torx screwdriver T30 010 01 3 Crankcase 010 01 3 06 Removing sensor crankshaft 010 01 3 06 Removing sensor cranksh...

Страница 142: ...ket T30 Petroleum jelly 010 01 3 Crankcase 010 01 3 07 Installing sensor crankshaft 010 01 3 07 Installing sensor crankshaft Coat the o ring 1 lightly with petroleum jelly Insert the sensor crankshaft...

Страница 143: ...61 RLF MPE850 Rev 1 2 406555 010 010 02 1 Oil cooler bracket 010 02 1 Oil cooler bracket...

Страница 144: ...3 3 1 Mount the engine on the drive side of the engine stand Removing oil cooler bracket Unscrew 15 bolts 2 Preparation Remove the oil cooler See chapter 050 03 01 Removing oil cooler 050 03 01 Removi...

Страница 145: ...63 RLF MPE850 Rev 1 2 406555 010 3 4 Remove the oil cooler bracket 3 010 02 1 Oil cooler bracket 010 02 1 01 Removing oil cooler bracket Remove the sleeve 4...

Страница 146: ...the groove and lightly coat with petroleum jelly Insert the sleeve 2 Hold the oil cooler bracket 3 in position 050 03 02 Installing oil cooler Petroleum jelly Torque wrench Hexagon screwdriver socket...

Страница 147: ...55 010 4 Screw in 15 bolts 4 Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft Completion Install the oil cooler See chapter 050 03 02 Installing oil cooler 010 02 1 Oil cooler bracket 010 02 1 02 Ins...

Страница 148: ...66 RLF MPE850 Rev 1 2 406555 010 010 02 2 Oil cooler bracket 010 02 2 Oil cooler bracket...

Страница 149: ...iver socket T30 Mount the engine on the engine stand Mount the engine on the drive side 1 of the engine stand See chapter 3 3 1 Mount the engine on the drive side of the engine stand Replace the blank...

Страница 150: ...v 1 2 406555 010 8 9 7 Insert the blanking cover 9 Hold the bracket 8 in position Screw in the bolt 7 Tightening torque 9 Nm 2 Nm 6 6 lbf ft 1 5 lbf ft 010 02 2 Oil cooler bracket 010 02 2 01 Replacin...

Страница 151: ...m 10 3 lbf ft 1 5 lbf ft Hexagon screwdriver 6 Torque wrench Hexagon screwdriver socket 6 Mount the engine on the engine stand Mount the engine on the drive side 1 of the engine stand See chapter 3 3...

Страница 152: ...r 3 3 1 Mount the engine on the drive side of the engine stand Preparation Remove the oil cooler See chapter 050 03 01 Removing oil cooler 050 03 01 Removing oil cooler 050 03 02 Installing oil cooler...

Страница 153: ...3 Sealing cover oil cooler bracket Unscrew 14 bolts 2 The cover oil cooler bracket is caulked with a silicone liquid seal Remove the cover oil cooler bracket 3 010 02 2 Oil cooler bracket 010 02 2 03...

Страница 154: ...0 Rev 1 2 406555 010 5 4 Clean the sealing surface 5 with sealing surface cleaner Clean the sealing surface 4 with sealing surface cleaner 010 02 2 Oil cooler bracket 010 02 2 03 Sealing cover oil coo...

Страница 155: ...E850 Rev 1 2 406555 010 6 7 Apply the silicone liquid seal 6 without gaps as illustrated Hold the cover oil cooler bracket 7 in position 010 02 2 Oil cooler bracket 010 02 2 03 Sealing cover oil coole...

Страница 156: ...ing torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft Screw in 13 bolts 9 Tightening torque 5 Nm 1 Nm 3 7 lbf ft 0 7 lbf ft Completion Install the oil cooler See chapter 050 03 02 Installing oil cooler 010 02 2...

Страница 157: ...75 RLF MPE850 Rev 1 2 406555 020 020 01 Crankshaft 020 01 Crankshaft 020 Crank drive...

Страница 158: ...ing ignition coils 030 01 01 Removing valve cover 050 03 01 Removing oil cooler 010 02 1 01 Removing oil cooler bracket 020 03 01 Removing crankshaft cover 050 02 03 Removing coolant pump 090 02 01 Re...

Страница 159: ...Remove the intake manifold See chapter 070 01 01 Removing intake manifold Remove the starter See chapter 090 01 01 Removing starter 020 01 Crankshaft 020 01 01 Removing crank drive Remove the oil cool...

Страница 160: ...5 Remove the generator See chapter 090 02 01 Removing generator Remove the oil pressure pump See chapter 110 02 01 Removing oil pressure pump 020 01 Crankshaft 020 01 01 Removing crank drive Turning e...

Страница 161: ...rection shown 6 until the marking 9 ends flush with the crankcase halves 8 Check whether the camshaft is at the crossing point The position of the camshaft is as illustrated 11 The marking 10 ends flu...

Страница 162: ...firmly attached to the cylinder head Do not turn the cylinder head Remove the cylinder head 17 Turning engine in the engine stand Lift the engine See chapter 3 2 Lift and transport the engine Remove...

Страница 163: ...LF MPE850 Rev 1 2 406555 020 18 19 20 Turn the engine 180 Unscrew 4 bolts M6 18 020 01 Crankshaft 020 01 01 Removing crank drive Unscrew 5 bolts M8 19 Pull the oil pressure valve 20 out using a bar ma...

Страница 164: ...ne liquid seal Remove the lower case 21 020 01 Crankshaft 020 01 01 Removing crank drive Turn the crankshaft 22 180 Mark the cylinder assignment and installation position on the piston con rod con rod...

Страница 165: ...83 RLF MPE850 Rev 1 2 406555 020 25 26 27 28 Pull the pistons 25 out 020 01 Crankshaft 020 01 01 Removing crank drive Remove the balance shaft 26 Remove the crankshaft 27 Remove the oil seal 28...

Страница 166: ...Installing chain tensioner 110 02 02 Installing oil pressure pump 090 02 02 Installing generator 050 02 04 Installing coolant pump 020 03 02 Installing crankshaft cover 010 02 1 02 Installing oil coo...

Страница 167: ...the con rod bearing 020 01 Crankshaft 020 01 02 Installing crank drive Installation instructions for the con rod bearings NOTICE Serious damage to bearings due to con rod bearing shells being install...

Страница 168: ...ressor Displace the ring joints 6 of the three piston rings 120 Turn the engine 180 When replacing the crankshaft check the main bearing play and con rod bearing play See chapter 020 01 09 Checking co...

Страница 169: ...rt the balance shaft Observe the marking 11 The marking ends flush with the crankcase 020 01 Crankshaft 020 01 02 Installing crank drive Insert con rod covers 10 Replace the con rod bolts 9 Tighten th...

Страница 170: ...rn the crankshaft 14 180 Clean the sealing surface 15 with sealing surface cleaner 020 01 Crankshaft 020 01 02 Installing crank drive Aligning the balance shaft to the crankshaft Observe the marking 1...

Страница 171: ...17 17 18 18 18 18 Clean the sealing surface 16 with sealing surface cleaner Check if the centering pins 17 are installed Apply the silicone liquid seal 18 without gaps as illustrated 020 01 Crankshaf...

Страница 172: ...20 on Checking the alignment of the balance shaft crankshaft Check the markings 19 Both markings appear as shown Assemble the oil pressure valve in the sequence as illustrated 21 Insert the oil press...

Страница 173: ...5 bolts M8 23 Tightening torque 23 Nm 2 Nm 17 lbf ft 1 5 lbf ft Screw in 4 bolts M6 24 Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft Turn the engine 180 Check if the centering pins 25 are install...

Страница 174: ...on Observe the installation position Exhaust side 27 Inscription 28 Centering pins 29 Oil filter 30 Tighten the nuts 34 in the sequence as illustrated 35 in three stages Tightening torque First stage...

Страница 175: ...d transport the engine Remove the engine from the engine stand Turn the engine and mount on the engine stand Suitable mounting points M10 36 Depth of thread 30 mm The oil seal 37 can be found in the s...

Страница 176: ...the guiding sleeve 41 onto crankshaft 42 Use the M10x1x35 bolts you removed on the rotor Screw in the bolts 43 Hold the sliding sleeve 44 in position on the oil seal 45 Use a M10x1x35 bolt that you r...

Страница 177: ...e sliding sleeve 48 Unscrew the bolts 52 Remove the guiding sleeve 50 Check if the oil seal 51 is tilted If the oil seal is tilted it must be replaced Setting valve timing Hold the TDC adjusting tool...

Страница 178: ...ction shown 56 until the marking 59 ends flush with the crankcase halves 58 Install the timing chain See chapter 040 01 07 Installing timing chain Install the chain tensioner See chapter 040 01 03 Ins...

Страница 179: ...urn the crankshaft on the TDC adjusting tool 63 several times in the direction shown 62 The crankshaft can be turned If the crankshaft does not turn check the alignment of the balance shaft crankshaft...

Страница 180: ...lush with the cross bar If the camshaft does not appear as shown set the valve timing again or If the camshaft does not appear as shown several times replace the timing chain See chapter 040 01 08 Rep...

Страница 181: ...thread 74 34 mm Install the coolant pump See chapter 050 02 04 Installing coolant pump Install the crankshaft cover See chapter 020 03 02 Installing crankshaft cover Install the oil cooler bracket Se...

Страница 182: ...850 Rev 1 2 406555 020 020 01 Crankshaft 020 01 02 Installing crank drive Install the starter See chapter 090 01 02 Installing starter Install the intake manifold See chapter 070 01 02 Installing inta...

Страница 183: ...Checking main bearing play Check the con rod bearing play See chapter 020 01 09 Checking con rod bearing play Completion Install the crank drive See chapter 020 01 02 Installing crank drive 020 01 01...

Страница 184: ...tensioner 040 01 06 Removing timing chain 050 02 04 Installing coolant pump 020 03 02 Installing crankshaft cover 010 02 1 02 Installing oil cooler bracket 050 03 02 Installing oil cooler 040 01 07 In...

Страница 185: ...e cover See chapter 030 01 01 Removing valve cover Remove the intake manifold See chapter 070 01 01 Removing intake manifold Remove the starter See chapter 090 01 01 Removing starter Remove the oil co...

Страница 186: ...bolts you removed on the rotor Screw in the bolts 5 Remove the generator See chapter 090 02 01 Removing generator Remove the oil pressure pump See chapter 110 02 01 Removing oil pressure pump Turning...

Страница 187: ...direction shown 6 until the marking 9 ends flush with the crankcase halves 8 Check whether the camshaft is at the crossing point The position of the camshaft is as illustrated 11 The marking 10 ends f...

Страница 188: ...er firmly attached to the cylinder head Do not turn the cylinder head Remove the cylinder head 17 Turning engine in the engine stand Lift the engine See chapter 3 2 Lift and transport the engine Remov...

Страница 189: ...F MPE850 Rev 1 2 406555 020 18 19 20 020 01 Crankshaft 020 01 04 Replacing balance shaft Turn the engine 180 Unscrew 4 bolts M6 18 Unscrew 5 bolts M8 19 Pull the oil pressure valve 20 out using a bar...

Страница 190: ...2 23 21 21 Remove the balance shaft 22 Remove the bearing shells balance shaft 23 Remove the oil seal 21 020 01 Crankshaft 020 01 04 Replacing balance shaft The crankcase is caulked with a silicone li...

Страница 191: ...ightly with engine oil Insert the main bearing shells in crankcase Replace the balance shaft 25 Insert the balance shaft Aligning the balance shaft to the crankshaft Observe the markings 26 Both marki...

Страница 192: ...29 28 30 30 30 30 Check if the centering pins 29 are installed Clean the sealing surface 28 with sealing surface cleaner 020 01 Crankshaft 020 01 04 Replacing balance shaft Apply the silicone liquid...

Страница 193: ...32 on Checking the alignment of the balance shaft crankshaft Check the markings 31 Both markings appear as shown 020 01 Crankshaft 020 01 04 Replacing balance shaft Assemble the oil pressure valve in...

Страница 194: ...5 bolts M8 35 Tightening torque 23 Nm 2 Nm 17 lbf ft 1 5 lbf ft 020 01 Crankshaft 020 01 04 Replacing balance shaft Screw in 4 bolts M6 36 Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft Turn the e...

Страница 195: ...on Observe the installation position Exhaust side 39 Inscription 40 Centering pins 41 Oil filter 42 020 01 Crankshaft 020 01 04 Replacing balance shaft Put the cylinder head 43 on Observe the installa...

Страница 196: ...nd transport the engine Remove the engine from the engine stand Turn the engine and mount on the engine stand Suitable mounting points M10 48 Depth of thread 30 mm The oil seal 49 can be found in the...

Страница 197: ...the sliding sleeve 56 in position on the oil seal 57 Use a M10x1x35 bolt that you removed from the rotor Screw in the bolt 58 Screw in the bolt 59 until the oil seal is flush with the crankcase Slide...

Страница 198: ...he sliding sleeve 60 Unscrew the bolts 64 Remove the guiding sleeve 62 Check if the oil seal 63 is tilted If the oil seal is tilted it must be replaced Setting valve timing Hold the TDC adjusting tool...

Страница 199: ...ection shown 68 until the marking 71 ends flush with the crankcase halves 70 Install the timing chain See chapter 040 01 07 Installing timing chain Install the chain tensioner See chapter 040 01 03 In...

Страница 200: ...Turn the crankshaft on the TDC adjusting tool 75 several times in the direction shown 74 The crankshaft can be turned If the crankshaft does not turn check the alignment of the balance shaft crankshaf...

Страница 201: ...flush with the cross bar If the camshaft does not appear as shown set the valve timing again or If the camshaft does not appear as shown several times replace the timing chain See chapter 040 01 08 Re...

Страница 202: ...f thread 86 34 mm Install the coolant pump See chapter 050 02 04 Installing coolant pump Install the crankshaft cover See chapter 020 03 02 Installing crankshaft cover Install the oil cooler bracket S...

Страница 203: ...50 Rev 1 2 406555 020 020 01 Crankshaft 020 01 04 Replacing balance shaft Install the starter See chapter 090 01 02 Installing starter Install the intake manifold See chapter 070 01 02 Installing inta...

Страница 204: ...components are installed swapped over they no longer fit together well When removing the components mark the cylinder assignment and installation position Install all components back into the place f...

Страница 205: ...10 01 01 Removing suction pump cover Turn the engine 180 Remove the cylinder head See chapter 030 02 01 Removing cylinder head Removing pistons and con rods Turn the engine 180 Turn the crankshaft on...

Страница 206: ...124 RLF MPE850 Rev 1 2 406555 020 6 Pull the pistons 6 out 020 01 Crankshaft 020 01 05 Removing pistons and con rods...

Страница 207: ...e components are installed swapped over they no longer fit together well When removing the components mark the cylinder assignment and installation position Install all components back into the place...

Страница 208: ...tallation instructions for the con rod bearings NOTICE Serious damage to bearings due to con rod bearing shells being installed incorrectly Insert the con rod bearing shells 2 centered on the con rod...

Страница 209: ...ngine 180 Install the cylinder head See chapter 030 02 02 Installing cylinder head Turn the engine 180 Install the suction pump cover See chapter 110 01 02 Installing suction pump cover Install the va...

Страница 210: ...serious eye injuries Wear protective glasses along with any bystanders Bearing damage increased wear and leaks due to installing components swapped over All components in the crank drive are inserted...

Страница 211: ...row on top 8 and inside arrow 9 in the direction of the starter 10 Replace the piston 5 Install the circlip 7 using a litte screwdriver Pull the piston pin 6 out Hold the con rod 4 in position Observe...

Страница 212: ...0 RLF MPE850 Rev 1 2 406555 020 12 11 Coat the piston pin 12 lightly with engine oil Slide in the piston pin Install the circlip 11 using a litte screwdriver 020 01 Crankshaft 020 01 07 Replacing pist...

Страница 213: ...ve glasses along with any bystanders Bearing damage increased wear and leaks due to installing components swapped over All components in the crank drive are inserted together If the components are ins...

Страница 214: ...e con rod in position Coat the piston pin 5 lightly with engine oil Slide in the piston pin Install the circlip 6 using a litte screwdriver Check the con rod bearing play See chapter 020 01 09 Checkin...

Страница 215: ...ue wrench Reversible ratchet 12 point socket wrench 12 Angle indicator Information Con rod bolts are extension bolt and must be replaced after removal However when measuring the con rod bearing play y...

Страница 216: ...Tightening torque First stage 10 Nm 7 4 lbf ft Second stage 20 Nm 14 8 lbf ft Third stage 115 Unscrew the con rod bolts Remove the con rod Installation instructions for the con rod bearings NOTICE Se...

Страница 217: ...con rod bearing play is incorrect repeat the process using another con rod bearing shell thickness The con rod bearing shells are marked on the side 9 in color Each color represent a specific thickne...

Страница 218: ...hells 1 in crankcase Affix the precision clearance gauges to all bearing positions of the crankshaft 2 according to the manufacturer s instructions Insert the crankshaft 3 Bearing damage increased wea...

Страница 219: ...MPE850 Rev 1 2 406555 020 4 6 5 Put the lower case 4 on Insert the oil pressure valve 6 Assemble the oil pressure valve in the sequence as illustrated 5 020 01 Crankshaft 020 01 10 Checking main beari...

Страница 220: ...asuring the main bearing play you can use the removed cylinder head gasket Put the cylinder head gasket on Observe the installation position 8 Exhaust side 9 Inscription 10 Centering pins 11 Oil filte...

Страница 221: ...nuts 16 in the sequence as illustrated 17 in three stages Tightening torque First stage 20 Nm 3 Nm 14 8 lbf ft 2 2 lbf ft Second stage 40 Nm 3 Nm 29 5 lbf ft 2 2 lbf ft Third stage 180 4 Unscrew the n...

Страница 222: ...40 RLF MPE850 Rev 1 2 406555 020 21 20 19 Pull the oil pressure valve 21 out using a bar magnet Unscrew 5 bolts M8 20 Remove the cylinder head 19 020 01 Crankshaft 020 01 10 Checking main bearing play...

Страница 223: ...04 mm 0 06 mm If the main bearing play is incorrect repeat the process using another main bearing shell thickness The main bearing shells are marked on the side 24 in color Each color represent a spe...

Страница 224: ...142 RLF MPE850 Rev 1 2 406555 020 020 02 Stub shaft 020 02 Stub shaft...

Страница 225: ...ft Hexagon screwdriver 8 Reversible ratchet Hexagon screwdriver socket 7 Mount the engine on the engine stand Mount the engine across from the drive side 1 of the engine stand See chapter 3 3 2 Mount...

Страница 226: ...144 RLF MPE850 Rev 1 2 406555 020 6 7 4 5 Remove the rotor 6 Remove the stub shaft 7 Unscrew the bolts 4 Remove the locking tool crankshaft 5 020 02 Stub shaft 020 02 01 Removing stub shaft...

Страница 227: ...olts on the rotor have a micro encapsulated coating During fastening the bolt the microcapsules will burst and the contained adhesive and curing agent are released and mixed The coating begins to cure...

Страница 228: ...ning torque 60 Nm 10 Nm 44 3 lbf ft 7 4 lbf ft Remove the locking tool crankshaft 9 Replace the bolts 5 Screw in the bolts by hand Do not tighten Hold the locking tool crankshaft 6 on rotor Screw in t...

Страница 229: ...147 RLF MPE850 Rev 1 2 406555 020 020 03 Crankshaft cover 020 03 Crankshaft cover...

Страница 230: ...the engine stand Mount the engine on the drive side 1 of the engine stand See chapter 3 3 1 Mount the engine on the drive side of the engine stand Unscrew the bolt 3 Remove the cover 2 020 03 Cranksha...

Страница 231: ...crewdriver socket T30 Insert the cover 2 Screw in the bolt 3 Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft Replace the gasket 1 Coat the gasket lightly with petroleum jelly 020 03 Crankshaft cover...

Страница 232: ...150 RLF MPE850 Rev 1 2 406555 030 030 01 Valve cover 030 01 Valve cover 030 Cylinder head...

Страница 233: ...crew the bolts 1 Remove the valve cover 2 Preparation Remove the ignition coils See chapter 030 01 04 Removing ignition coils 030 01 04 Removing ignition coils Hexagon screwdriver 5 030 01 Valve cover...

Страница 234: ...1 5 lbf ft Installing valve cover Replace the valve cover seals 1 Completion Install the ignition coils See chapter 030 01 05 Installing ignition coils 030 01 05 Installing ignition coils Torque wrenc...

Страница 235: ...ping These bolts can be removed and installed again at any time after the initial installation Coat the o ring 4 on the sensor camshaft 3 lightly with petroleum jelly Replace the valve cover 1 Affix t...

Страница 236: ...ress down on the bolt 5 and screw in Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft Put the valve cover 9 on Apply Anti Seize assembly paste to all bolts 10 Screw in the bolts in the sequence as il...

Страница 237: ...No threads are cut in the new valve cover Use the self tapping bolts included with the valve cover Lightly press down on the bolts 13 and screw in Observe the arrangement of the serrated lock washers...

Страница 238: ...156 RLF MPE850 Rev 1 2 406555 030 1 2 Unscrew the bolts 1 Pull the ignition coils 2 out Hexagon screwdriver 5 030 01 Valve cover 030 01 04 Removing ignition coils 030 01 04 Removing ignition coils...

Страница 239: ...ert the ignition coils 3 Replace the serrated lock washers 1 Screw in the bolts 2 Observe the arrangement of the serrated lock washers and washers Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft 030...

Страница 240: ...158 RLF MPE850 Rev 1 2 406555 030 1 2 Unscrew the bolt 1 Pull the sensor camshaft 2 out Hexagon screwdriver 5 030 01 06 Removing sensor camshaft 030 01 Valve cover 030 01 06 Removing sensor camshaft...

Страница 241: ...Hexagon screwdriver socket 5 Insert the sensor camshaft 3 Screw in the bolt 2 Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft Coat the o ring 1 lightly with petroleum jelly 030 01 07 Installing sen...

Страница 242: ...160 RLF MPE850 Rev 1 2 406555 030 030 02 Cylinder head 030 02 Cylinder head...

Страница 243: ...amage and cause the crank drive to seize When removing small components always cover the chain channel Mount the engine on the engine stand Mount the engine across from the drive side 1 of the engine...

Страница 244: ...following figure Remove the chain tensioner See chapter 040 01 02 Removing chain tensioner Open the timing chain See chapter 040 01 04 Opening timing chain with chain breaking tool Secure the ends of...

Страница 245: ...06555 030 8 9 Remove the cylinder head 9 Unscrew the nuts 8 The rocker arm and cross bars are no longer firmly attached to the cylinder head Do not turn the cylinder head 030 02 Cylinder head 030 02 0...

Страница 246: ...centering pins 1 are installed Replace the cylinder head gasket 2 Put the cylinder head gasket on Observe the installation position Exhaust side 3 Inscription 4 Centering pins 5 Oil filter 6 040 01 05...

Страница 247: ...lbf ft 2 2 lbf ft Second stage 40 Nm 3 Nm 29 5 lbf ft 2 2 lbf ft Third stage 180 4 Setting valve timing Check whether the crankshaft is at TDC Top Dead Center The markings 13 fit together If the mark...

Страница 248: ...hown set the valve timing again or If the camshaft does not appear as shown replace the timing chain See chapter 040 01 08 Replacing timing chain Checking valve timing Turn the crankshaft on a bolt 17...

Страница 249: ...e cover See chapter 030 01 02 Installing valve cover Install the ignition coils See chapter 030 01 05 Installing ignition coils Install the intake manifold See chapter 070 01 02 Installing intake mani...

Страница 250: ...or cylinder head Operating the engine when there are small components in the crankcase and cylinder head can result in serious damage and cause the crank drive to seize When removing small components...

Страница 251: ...ew the bolt 5 Remove the bracket 4 Unscrew the fitting 6 Replacing cylinder head Unscrew the bolts 1 Remove the bracket 2 Unscrew the switch oil pressure 3 Unscrew the studs 7 using a stud extractor 0...

Страница 252: ...170 RLF MPE850 Rev 1 2 406555 030 10 9 8 Remove the sleeves 10 Remove the fuel rail 9 Unscrew the bolts 8 030 02 Cylinder head 030 02 03 Replacing cylinder head...

Страница 253: ...olts 11 Remove the camshaft 14 Replace the cylinder head 15 Remove the bearing cap 13 using the remover bearing cap 12 Information The hole in the remover bearing cap is provided for mounting a slide...

Страница 254: ...the 2nd cylinder end only Observe the installation position Inscription 20 Intake side 21 Coat the camshaft on the bearing surfaces 19 lightly with engine oil Unscrew the bolts 16 Remove the bearing...

Страница 255: ...he bearing cap being installed incorrectly The bearing surfaces for supporting the camshaft in the cylinder head and in the bearing cap are processed together Therefore only use the bearing cap origin...

Страница 256: ...i Seize assembly paste to all studs 30 Screw in the studs using a stud extractor Tightening torque 16 Nm 4 Nm 11 8 lbf ft 3 lbf ft Screw in the bolts 28 Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf...

Страница 257: ...rque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft 030 02 Cylinder head 030 02 03 Replacing cylinder head Screw in a new plug 35 Tightening torque 6 Nm 2 Nm 4 4 lbf ft 1 5 lbf ft Coat the thread on the switch oil p...

Страница 258: ...ad See chapter 030 02 02 Installing cylinder head Install the valve cover See chapter 030 01 02 Installing valve cover Install the ignition coils See chapter 030 01 05 Installing ignition coils Instal...

Страница 259: ...See chapter 030 01 04 Removing ignition coils 030 01 04 Removing ignition coils Reversible ratchet Spark plug wrench 030 02 Cylinder head 030 02 04 Removing spark plugs 030 02 04 Removing spark plugs...

Страница 260: ...ing ignition coils 030 01 05 Installing ignition coils Torque wrench Spark plug wrench 030 02 Cylinder head 030 02 05 Installing spark plugs 030 02 05 Installing spark plugs Installing spark plugs Scr...

Страница 261: ...179 RLF MPE850 Rev 1 2 406555 030 1 Unscrew the switch oil pressure 1 Open end wrench 24 030 02 Cylinder head 030 02 06 Removing switch oil pressure 030 02 06 Removing switch oil pressure...

Страница 262: ...h 24 Thread sealant 030 02 Cylinder head 030 02 07 Installing switch oil pressure 030 02 07 Installing switch oil pressure Coat the thread on the switch oil pressure 1 with thread sealant Screw in the...

Страница 263: ...181 RLF MPE850 Rev 1 2 406555 030 1 Unscrew the fitting 1 Open end wrench 12 030 02 08 Removing fitting 030 02 Cylinder head 030 02 08 Removing fitting...

Страница 264: ...06555 030 2 1 Replace the seal 1 Screw in the fitting 2 Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft Torque wrench Insert open end wrench 12 030 02 09 Installing fitting 030 02 Cylinder head 030...

Страница 265: ...ocket 4 5 Plug across from the drive side 1 Plugs 2 exhaust side 030 02 Cylinder head 030 02 10 Replacing plugs 030 02 10 Replacing plugs Replacing plug across from the drive side Unscrew the plug 1 R...

Страница 266: ...cing plugs Replacing plugs drive side Unscrew the plugs 1 Replace the plugs Screw in the plugs Tightening torque 6 Nm 2 Nm 4 4 lbf ft 1 5 lbf ft Replacing plug drive side Unscrew the plug 1 Replace th...

Страница 267: ...185 RLF MPE850 Rev 1 2 406555 030 See chapter 040 01 01 Replacing camshaft 030 02 Cylinder head 030 02 11 Mounting camshaft 030 02 11 Mounting camshaft...

Страница 268: ...186 RLF MPE850 Rev 1 2 406555 040 040 01 Camshaft 040 Valve train 040 01 Camshaft...

Страница 269: ...valve train are inserted together If the components are installed swapped over they no longer fit together well Install all components back into the place from which they were removed 070 01 01 Remov...

Страница 270: ...ng figure Check whether the camshaft is at the crossing point The position of the camshaft is as illustrated 5 The marking 4 ends flush with the cross bar Preparation Remove the intake manifold See ch...

Страница 271: ...e valve adjustment shims 10 using a bar magnet Unscrew the bolts 11 Remove the chain tensioner See chapter 040 01 02 Removing chain tensioner Open the timing chain See chapter 040 01 04 Opening timing...

Страница 272: ...190 RLF MPE850 Rev 1 2 406555 040 12 13 14 15 Remove the bearing cap 12 using the remover bearing cap 13 Remove the camshaft 14 Remove the cylinder head 15 040 01 Camshaft 040 01 01 Replacing camshaft...

Страница 273: ...4 The cylinder head gasket can be found in the spare parts catalog in chapter 030 02 Cylinder head Replace the cylinder head gasket 17 Put the cylinder head gasket on Observe the installation position...

Страница 274: ...bearing surfaces 25 lightly with engine oil NOTICE Bearing damage due to the bearing cap being installed incorrectly The bearing surfaces for supporting the camshaft in the cylinder head and in the be...

Страница 275: ...tages Tightening torque First stage 20 Nm 3 Nm 14 8 lbf ft 2 2 lbf ft Second stage 40 Nm 3 Nm 29 5 lbf ft 2 2 lbf ft Third stage 180 4 Screw in the bolts 30 Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5...

Страница 276: ...n tensioner See chapter 040 01 03 Installing chain tensioner Check whether the camshaft is at the crossing point The position of the camshaft is as illustrated 38 The marking 37 ends flush with the cr...

Страница 277: ...See chapter 070 01 02 Installing intake manifold Check whether the camshaft is at the crossing point The position of the camshaft is as illustrated 42 The marking 41 ends flush with the cross bar If t...

Страница 278: ...n end wrench 27 If the chain tensioner is not accessible remove the throttle body See chapter 070 02 01 Removing throttle body Unscrew the chain tensioner 1 Information The following chapter only desc...

Страница 279: ...ch 27 Replace the chain tensioner 1 Screw in the chain tensioner Tightening torque 40 Nm 5 Nm 29 5 lbf ft 3 7 lbf ft Information The following chapter only describes how to install the chain tensioner...

Страница 280: ...r see the spike 4 Screw in the bolt 5 slightly into the chain breaking tool 6 Hold the chain breaking tool in position on a bolt 7 of the chain link Information The following chapter only describes ho...

Страница 281: ...ly seated Screw in the bolt 9 using a open end wrench until the bolt of the chain link is pushed out Unscrew the bolt Unscrew the bolt 10 and remove chain breaking tool Repeat the process on the secon...

Страница 282: ...Insert the chain link 5 Press the plate 6 onto the chain link using the universal pliers Hold the chain breaking tool on a bolt 7 of the timing chain link Information The following chapter only descri...

Страница 283: ...ool Repeat the process on the second bolt 10 of the chain link Screw in the bolt 8 until the chain breaking tool is firmly seated Screw in the bolt using a open end wrench until the bolt of the chain...

Страница 284: ...are removed Mark the running direction of the timing chain 1 Remove the chain tensioner See chapter 040 01 02 Removing chain tensioner Open the timing chain See chapter 040 01 04 Opening timing chain...

Страница 285: ...the open ends of the timing chain Information The following chapter only describes how to install the timing chain Always observe the instructions in the chapters for the timing chain and valve timin...

Страница 286: ...rn the engine 180 Close the timing chain See chapter 040 01 05 Closing timing chain with chain breaking tool Install the chain tensioner See chapter 040 01 03 Installing chain tensioner 040 01 Camshaf...

Страница 287: ...and See chapter 3 3 2 Mount the engine across from the drive side of the engine stand 110 01 01 Removing suction pump cover 030 01 04 Removing ignition coils 030 01 01 Removing valve cover 040 01 02 R...

Страница 288: ...e chapter 040 01 04 Opening timing chain with chain breaking tool Check whether the camshaft is at the crossing point The position of the camshaft is as illustrated 5 The marking 4 ends flush with the...

Страница 289: ...nsert the timing chain as illustrated Insert the chain link 9 on the open ends of the timing chain Turn the engine 180 Setting valve timing Check if the crankshaft is at TDC Top Dead Center The markin...

Страница 290: ...t in the direction shown until the camshaft stops as shown in the following figure Check whether the camshaft is at the crossing point The position of the camshaft is as illustrated 13 The marking 12...

Страница 291: ...ee chapter 030 01 02 Installing valve cover Install the ignition coils See chapter 030 01 05 Installing ignition coils Turn the engine 180 Install the suction pump cover See chapter 110 01 02 Installi...

Страница 292: ...t 1 Remove the chain rail 2 Replace the chain rail Insert the chain rail Screw in the bolt Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft Torx screwdriver T30 Torque wrench Torx screwdriver socket...

Страница 293: ...the bolts 1 Remove the chain guide 2 Replace the chain guide Insert the chain guide Screw in the bolts Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft Hexagon screwdriver 5 Torque wrench Hexagon scr...

Страница 294: ...er See chapter 030 01 01 Removing valve cover Checking valve timing Hold the TDC adjusting tool 3 in position Observe the positioning pin and positioning bore 2 Use the M10x1x35 bolts you removed on t...

Страница 295: ...r the camshaft is at the crossing point The position of the camshaft is as illustrated 10 The marking 9 ends flush with the cross bar If the camshaft does not appear as shown set the valve timing See...

Страница 296: ...l the valve cover See chapter 030 01 02 Installing valve cover Install the ignition coils See chapter 030 01 05 Installing ignition coils Install the generator See chapter 090 02 02 Installing generat...

Страница 297: ...on Observe the positioning pin and positioning bore 2 Use the M10x1x35 bolts you removed on the rotor Screw in the bolts 4 090 02 01 Removing generator 030 01 04 Removing ignition coils 030 01 01 Remo...

Страница 298: ...the chain tensioner See chapter 040 01 02 Removing chain tensioner Open the timing chain See chapter 040 01 04 Opening timing chain with chain breaking tool Use a hexagon screwdriver socket 8 and rev...

Страница 299: ...tall the valve cover See chapter 030 01 02 Installing valve cover Install the ignition coils See chapter 030 01 05 Installing ignition coils Install the generator See chapter 090 02 02 Installing gene...

Страница 300: ...218 RLF MPE850 Rev 1 2 406555 040 040 02 Rocker arms 040 02 Rocker arms...

Страница 301: ...nk drive to seize When removing small components always cover the chain channel Preparation Remove the ignition coils See chapter 030 01 04 Removing ignition coils Remove the valve cover See chapter 0...

Страница 302: ...k whether the camshaft is at the crossing point The position of the camshaft is as illustrated The marking 4 ends flush with the cross bar All rocker arms 5 on the cylinder have a certain amount of pl...

Страница 303: ...he 2nd cylinder end only Check whether the camshaft is at the crossing point The position of the camshaft is as illustrated The inscription 8 is not visible All rocker arms 9 on the cylinder have a ce...

Страница 304: ...with the section Checking valve play on the 1st cylinder Checking valve play on the 2nd cylinder Turn the crankshaft on a bolt 16 in the direction shown 15 until the camshaft stops as shown in the fol...

Страница 305: ...shim Checking valve play on the 1st cylinder Turn the crankshaft on a bolt 21 in the direction shown 20 until the camshaft stops as shown in the following figure The camshaft is marked at the 2nd cyli...

Страница 306: ...0 2 0 3 mm If the valve play of one or more valves is not right remove the rocker arm and replace the valve adjustment shim Completion Install the valve cover See chapter 030 01 02 Installing valve c...

Страница 307: ...225 RLF MPE850 Rev 1 2 406555 040 040 03 Valves 040 03 Valves...

Страница 308: ...mall components in the engine or cylinder head Operating the engine when there are small components in the crankcase and cylinder head can result in serious damage and cause the crank drive to seize W...

Страница 309: ...linder head See chapter 030 02 01 Removing cylinder head Removing valve Remove the rocker arms and cross bars 2 Remove the valve adjustment shim 3 using a bar magnet Install the valve spring compresso...

Страница 310: ...228 RLF MPE850 Rev 1 2 406555 040 6 7 8 10 9 Remove the spring cup 6 valve spring 7 and spring pad 8 Pull the valve 10 out Remove the valve stem seal 9 040 03 Valves 040 03 01 Removing valve...

Страница 311: ...ll all components back into the place from which they were removed Engine damage from small components in the engine or cylinder head Operating the engine when there are small components in the crankc...

Страница 312: ...Insert the spring pad 6 valve spring 5 and spring cup 4 Install the valve spring compressor according to the manufacturer s instructions Press the valve spring 8 together using the valve spring compre...

Страница 313: ...th the section Checking valve play on the 2nd cylinder or Continue with the section Checking valve play on the 1st cylinder Checking valve play on the 2nd cylinder Turn the crankshaft on a bolt 12 in...

Страница 314: ...shim Checking valve play on the 1st cylinder Turn the crankshaft on a bolt 17 in the direction shown 16 until the camshaft stops as shown in the following figure The camshaft is marked at the 2nd cyli...

Страница 315: ...over See chapter 030 01 02 Installing valve cover Install the ignition coils See chapter 030 01 05 Installing ignition coils Install the intake manifold See chapter 070 01 02 Installing intake manifol...

Страница 316: ...234 RLF MPE850 Rev 1 2 406555 050 050 01 Thermostat housing 050 01 Thermostat housing 050 Cooling system...

Страница 317: ...The thermostat housing is caulked with a silicone liquid seal Remove the thermostat housing 3 050 01 01 Removing thermostat housing 050 01 Thermostat housing 050 01 01 Removing thermostat housing The...

Страница 318: ...er Silicone liquid seal Clean the sealing surface 1 with sealing surface cleaner Clean the sealing surface 2 with sealing surface cleaner Apply the silicone liquid seal 3 without gaps as illustrated 0...

Страница 319: ...ition Screw in 10 bolts 5 Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft 050 01 Thermostat housing 050 01 02 Installing thermostat housing The bolt is an additional part and not installed in every...

Страница 320: ...238 RLF MPE850 Rev 1 2 406555 050 1 2 Unscrew 2 bolts 1 Torx screwdriver T30 Remove the fitting 2 050 01 Thermostat housing 050 01 03 Removing fitting 050 01 03 Removing fitting...

Страница 321: ...torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft Petroleum jelly Torque wrench Torx screwdriver socket T30 Replace the o ring 1 Coat the o ring lightly with petroleum jelly Insert the fitting 2 050 01 Thermost...

Страница 322: ...ing thermostat Remove the thermostat 1 and distance washer 2 Preparation Remove the fitting See chapter 050 01 03 Removing fitting 050 01 Thermostat housing 050 01 05 Removing thermostat 050 01 05 Rem...

Страница 323: ...4 Installing fitting 050 01 Thermostat housing 050 01 06 Installing thermostat 050 01 06 Installing thermostat Installing thermostat Put a new distance washer 2 on thermostat 1 Insert the thermostat 4...

Страница 324: ...or coolant temperature Screw in the sensor coolant temperature Tightening torque 18 Nm 7 Nm 13 3 lbf ft 5 2 lbf ft Open end wrench 19 Torque wrench Insert open end wrench 19 050 01 Thermostat housing...

Страница 325: ...ce the plug Screw in the plug Tightening torque 14 Nm 2 Nm 10 3 lbf ft 1 5 lbf ft Hexagon screwdriver 7 Torque wrench Hexagon screwdriver socket 7 050 01 Thermostat housing 050 01 08 Replacing plug th...

Страница 326: ...ev 1 2 406555 050 1 2 Open the hose clamp 1 Remove the closing cap 2 Hexagon nut driver 7 050 01 09 Removing closing cap thermostat housing 050 01 Thermostat housing 050 01 09 Removing closing cap the...

Страница 327: ...ing cap 2 Close the hose clamp 1 Tightening torque 3 Nm 0 5 Nm 2 2 lbf ft 0 4 lbf ft Torque wrench 6 point socket wrench 7 050 01 Thermostat housing 050 01 10 Installing closing cap thermostat housing...

Страница 328: ...246 RLF MPE850 Rev 1 2 406555 050 050 02 Coolant pump 050 02 Coolant pump...

Страница 329: ...ter 010 02 1 01 Removing oil cooler bracket Mount the engine on the engine stand Mount the engine on the drive side 1 of the engine stand See chapter 3 3 1 Mount the engine on the drive side of the en...

Страница 330: ...248 RLF MPE850 Rev 1 2 406555 050 5 4 6 Unscrew the nut 4 Remove the impeller 5 Remove the locking tool crankshaft 6 050 02 Coolant pump 050 02 01 Removing impeller...

Страница 331: ...Installing impeller Hold the locking tool crankshaft 1 on rotor Screw in the bolt 2 and washer 010 02 1 02 Installing oil cooler bracket 050 03 02 Installing oil cooler Locking tool crankshaft Hexagon...

Страница 332: ...ion Install the oil cooler bracket See chapter 010 02 1 02 Installing oil cooler bracket Install the oil cooler See chapter 050 03 02 Installing oil cooler Remove the locking tool crankshaft 5 050 02...

Страница 333: ...2 on rotor Screw in the bolt 3 and washer Preparation Remove the oil cooler See chapter 050 03 01 Removing oil cooler Remove the oil cooler bracket See chapter 010 02 1 01 Removing oil cooler bracket...

Страница 334: ...50 Rev 1 2 406555 050 6 5 4 7 Unscrew the nut 4 Remove the impeller 5 Unscrew the water pump axle 6 using a open end wrench Remove the locking tool crankshaft 7 050 02 Coolant pump 050 02 03 Removing...

Страница 335: ...ocking tool crankshaft 1 on rotor Screw in the bolt 2 and washer 010 02 1 02 Installing oil cooler bracket 050 03 02 Installing oil cooler Petroleum jelly Locking tool crankshaft Hexagon screwdriver 8...

Страница 336: ...ng bracket 4 Coat the gasket 5 and o ring 6 lightly with petroleum jelly Coat the inside of the oil seal 7 lightly with petroleum jelly Insert the sealing bracket 8 Screw in the guide 9 using a open e...

Страница 337: ...10 onto guide Hold the sliding sleeve 11 in position Screw on the nut 12 Screw in the nut 13 using a open end wrench until the slide ring seal is inserted completely Tightening torque 10 Nm 1 Nm 7 4...

Страница 338: ...4 16 Insert the impeller 17 Screw on the nut 18 Tightening torque 9 Nm 2 Nm 6 6 lbf ft 1 5 lbf ft Unscrew the nut 15 Remove the sliding sleeve 14 Unscrew the guide 16 using a open end wrench 050 02 Co...

Страница 339: ...e locking tool crankshaft 19 Completion Install the oil cooler bracket See chapter 010 02 1 02 Installing oil cooler bracket Install the oil cooler See chapter 050 03 02 Installing oil cooler 050 02 C...

Страница 340: ...258 RLF MPE850 Rev 1 2 406555 050 050 03 Oil cooler 050 03 Oil cooler...

Страница 341: ...r T30 Remove the oil cooler 3 Mount the engine on the engine stand Mount the engine on the drive side 1 of the engine stand See chapter 3 3 1 Mount the engine on the drive side of the engine stand 050...

Страница 342: ...ts 3 Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft Petroleum jelly Torque wrench Torx screwdriver socket T30 Replace the gaskets 1 Insert the gaskets into the grooves and lightly coat with petrole...

Страница 343: ...261 RLF MPE850 Rev 1 2 406555 062 062 01 Mounting exhaust manifold 062 01 Mounting exhaust manifold 062 Exhaust system...

Страница 344: ...place the nuts 1 Apply Anti Seize assembly paste thoroughly to all studs 2 Screw on the nuts Tightening torque 22 Nm 4 Nm 16 2 lbf ft 3 lbf ft Replace the exhaust gaskets 3 062 01 01 Instructions for...

Страница 345: ...assembly paste Unscrew the studs 1 using a stud extractor Replace the studs Apply Anti Seize assembly paste to all studs Screw in the studs using a stud extractor Tightening torque 16 Nm 4 Nm 11 8 lbf...

Страница 346: ...264 RLF MPE850 Rev 1 2 406555 070 070 Intake area 070 01 Intake manifold 070 01 Intake manifold...

Страница 347: ...F MPE850 Rev 1 2 406555 070 1 2 Unscrew 4 bolts 1 Hexagon screwdriver 5 Torx screwdriver T45 Unscrew the bolts 2 070 01 01 Removing intake manifold 070 01 Intake manifold 070 01 01 Removing intake man...

Страница 348: ...266 RLF MPE850 Rev 1 2 406555 070 3 Remove the intake manifold 3 070 01 Intake manifold 070 01 01 Removing intake manifold...

Страница 349: ...osition Screw in the bolts 4 lightly Do not tighten Petroleum jelly Torque wrench Hexagon screwdriver socket 5 Torx screwdriver socket T45 Screw in 4 bolts 5 Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5...

Страница 350: ...70 01 01 Removing intake manifold 070 01 01 Removing intake manifold Hexagon screwdriver 6 070 01 03 Removing intake manifold bracket 070 01 Intake manifold 070 01 03 Removing intake manifold bracket...

Страница 351: ...Installing intake manifold Torque wrench Hexagon screwdriver socket 6 070 01 04 Installing intake manifold bracket 070 01 Intake manifold 070 01 04 Installing intake manifold bracket Screw in the bolt...

Страница 352: ...screwdriver T30 070 01 05 Removing sensor intake manifold pressure temperature 070 01 Intake manifold 070 01 05 Removing sensor intake manifold pressure temperature Unscrew the bolt 1 Pull the sensor...

Страница 353: ...anifold 070 01 06 Installing sensor intake manifold pressure temperature 070 01 06 Installing sensor intake manifold pressure temperature Coat the o ring 1 lightly with petroleum jelly Insert the sens...

Страница 354: ...272 RLF MPE850 Rev 1 2 406555 070 070 02 Mounting throttle body 070 02 Mounting throttle body...

Страница 355: ...3 RLF MPE850 Rev 1 2 406555 070 2 1 Open the hose clamp 1 Hexagon nut driver 7 Remove the throttle body 2 070 02 01 Removing throttle body 070 02 Mounting throttle body 070 02 01 Removing throttle bod...

Страница 356: ...e hose clamp 3 Tightening torque 1 5 Nm 1 Nm 1 1 lbf ft 0 7 lbf ft Torque wrench 6 point socket wrench 7 Insert the hose clamp 2 and throttle body 1 070 02 Mounting throttle body 070 02 02 Installing...

Страница 357: ...socket wrench 7 Information When replacing the throttle body it must be recalibrated Before putting the engine into operation again turn on the ignition for a minute and then off again 070 02 03 Repla...

Страница 358: ...070 02 Mounting throttle body 070 02 03 Replacing throttle body Unscrew the bolts 3 Remove the rubber mount 4 Replace the throttle body 6 Hold the rubber mount 7 in position Screw in the bolts 5 Tight...

Страница 359: ...50 Rev 1 2 406555 070 8 10 9 070 02 Mounting throttle body 070 02 03 Replacing throttle body Close the hose clamp 10 Tightening torque 1 5 Nm 1 Nm 1 1 lbf ft 0 7 lbf ft Insert the hose clamp 9 and thr...

Страница 360: ...nut driver 7 Hexagon screwdriver 5 Torque wrench Hexagon screwdriver socket 5 6 point socket wrench 7 070 02 Mounting throttle body 070 02 04 Replacing rubber mount 070 02 04 Replacing rubber mount Op...

Страница 361: ...070 02 Mounting throttle body 070 02 04 Replacing rubber mount Screw in the bolts 6 Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft Unscrew the bolts 3 Remove the rubber mount 4 Replace the rubber...

Страница 362: ...850 Rev 1 2 406555 070 7 9 8 070 02 Mounting throttle body 070 02 04 Replacing rubber mount Close the hose clamp 9 Tightening torque 1 5 Nm 1 Nm 1 1 lbf ft 0 7 lbf ft Insert the hose clamp 8 and throt...

Страница 363: ...l the spark plugs See chapter 030 02 05 Installing spark plugs Sensor coolant temperature 2 Replace the sensor coolant temperature See chapter 050 01 07 Replacing sensor coolant temperature Informatio...

Страница 364: ...body 6 Remove the throttle body See chapter 070 02 01 Removing throttle body Install the throttle body See chapter 070 02 02 Installing throttle body Sensor intake manifold pressure temperature 7 Remo...

Страница 365: ...gine control unit the throttle body must be recalibrated Before putting the engine into operation again turn on the ignition for a minute and then off again See the portable fire pump manufacturer s d...

Страница 366: ...284 RLF MPE850 Rev 1 2 406555 090 090 01 Starter 090 01 Starter 090 Starter generator...

Страница 367: ...Unscrew the bolt 3 Remove the starter 2 Preparation Remove the intake manifold See chapter 070 01 01 Removing intake manifold 070 01 01 Removing intake manifold Hexagon screwdriver 8 Torx screwdriver...

Страница 368: ...40 Nm 8 Nm 29 5 lbf ft 5 9 lbf ft Tighten the bolt 4 Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft Completion Install the intake manifold See chapter 070 01 02 Installing intake manifold 070 01 02...

Страница 369: ...anifold See chapter 070 01 01 Removing intake manifold 070 01 01 Removing intake manifold 070 01 02 Installing intake manifold Hexagon screwdriver 8 Torx screwdriver T30 Torque wrench Hexagon screwdri...

Страница 370: ...t 1 5 lbf ft Hold the starter 9 in position Screw in the bolt 10 lightly Do not tighten Screw in 2 bolts 11 Tightening torque 40 Nm 8 Nm 29 5 lbf ft 5 9 lbf ft Tighten the bolt 12 Tightening torque 8...

Страница 371: ...289 RLF MPE850 Rev 1 2 406555 090 090 02 Generator 090 02 Generator...

Страница 372: ...e engine stand Mount the engine across from the drive side 1 of the engine stand See chapter 3 3 2 Mount the engine across from the drive side of the engine stand Hold the locking tool crankshaft 2 on...

Страница 373: ...LF MPE850 Rev 1 2 406555 090 6 7 4 5 8 Remove the rotor 6 Remove the stub shaft 7 Unscrew the bolts 4 Remove the locking tool crankshaft 5 Unscrew the bolts 8 090 02 Generator 090 02 01 Removing gener...

Страница 374: ...292 RLF MPE850 Rev 1 2 406555 090 9 10 Remove the stator 9 Remove the distance washer 10 090 02 Generator 090 02 01 Removing generator...

Страница 375: ...ng fastening the bolt the microcapsules will burst and the contained adhesive and curing agent are released and mixed The coating begins to cure within a short time If the bolts are moved again later...

Страница 376: ...4 3 2 Hold the stub shaft 5 in position Slide on the rotor 6 Screw in the bolts 4 Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft 090 02 Generator 090 02 02 Installing generator Insert the distance...

Страница 377: ...4 lbf ft Remove the locking tool crankshaft 11 Hold the locking tool crankshaft 8 on rotor Screw in the bolt 9 and washer 090 02 Generator 090 02 02 Installing generator The bolts can be found in the...

Страница 378: ...296 RLF MPE850 Rev 1 2 406555 090 See the portable fire pump manufacturer s documentation 090 03 Voltage regulator 090 03 Voltage regulator...

Страница 379: ...297 RLF MPE850 Rev 1 2 406555 100 100 Fuel unit 100 01 Fuel rail 100 01 Fuel rail...

Страница 380: ...g on the fuel system observe the safety messages in chapter 2 2 Important safety messages Only remove the fuel rail if absolutely necessary If you find that the fuel rail or injectors are defective re...

Страница 381: ...299 RLF MPE850 Rev 1 2 406555 100 2 Remove the fuel rail 2 100 01 Fuel rail 100 01 01 Removing fuel rail...

Страница 382: ...ly with lubricant Insert the fuel rail 1 Lubricant for o ring injectors Torque wrench Torx screwdriver socket T30 Screw in the bolts 3 Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft 100 01 Fuel rai...

Страница 383: ...n the fuel system observe the safety messages in chapter 2 2 Important safety messages Only remove the injectors if you have to replace them If you find that the fuel rail or injectors are defective r...

Страница 384: ...ng 3 lightly with lubricant Insert the injector until it engages in the bracket Check that the injector is engaged in the bracket 5 Completion Install the fuel rail See chapter 100 01 02 Installing fu...

Страница 385: ...303 RLF MPE850 Rev 1 2 406555 110 110 01 Dry sump 110 01 Dry sump 110 Lubrication system...

Страница 386: ...4 bolts 1 Hexagon screwdriver 5 110 01 01 Removing suction pump cover 110 01 Dry sump 110 01 01 Removing suction pump cover Remove the suction pump cover 3 The suction pump cover is caulked with a sil...

Страница 387: ...ling surface cleaner Silicone liquid seal Clean the sealing surface 1 with sealing surface cleaner Clean the sealing surface 2 with sealing surface cleaner Check if the sleeves 3 are installed 110 01...

Страница 388: ...2 406555 110 4 5 6 Apply the silicone liquid seal 4 without gaps as illustrated Put the suction pump cover 5 on Screw in 14 bolts 6 Observe the arrangement of the bolts Tightening torque 8 Nm 2 Nm 5...

Страница 389: ...307 RLF MPE850 Rev 1 2 406555 110 A B B B B B A A A A A B B A Arrangement of the bolts A 7 Bolts M6x20 B 7 Bolts M6x30 Turn the engine 180 110 01 Dry sump 110 01 02 Installing suction pump cover...

Страница 390: ...03 Replacing suction pump cover Preparation Remove the suction pump cover See chapter 110 01 01 Removing suction pump cover Remove the oil suction pump See chapter 110 01 04 Removing oil suction pump...

Страница 391: ...il screen 2 Unscrew the bolts 3 Remove the oil suction pump 4 110 01 01 Removing suction pump cover Torx screwdriver T30 110 01 04 Removing oil suction pump 110 01 Dry sump 110 01 04 Removing oil suct...

Страница 392: ...ft Insert the oil screen 4 Screw in the bolts 3 Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft 110 01 02 Installing suction pump cover Torque wrench Torx screwdriver socket T30 110 01 05 Installin...

Страница 393: ...wrench Insert open end wrench 24 Turn the engine 180 Unscrew the fitting 1 Replace the fitting Screw in the fitting Tightening torque 36 Nm 8 Nm 26 6 lbf ft 5 9 lbf ft Turn the engine 180 110 01 06 R...

Страница 394: ...drive side 1 of the engine stand See chapter 3 3 1 Mount the engine on the drive side of the engine stand 110 01 01 Removing suction pump cover Pin punch axle intermediate gear Plastic hammer Hexagon...

Страница 395: ...v 1 2 406555 110 5 4 3 110 01 Dry sump 110 01 07 Removing intermediate gear suction pump Remove the intermediate gear suction pump 5 Punch the axle 4 out using the pin punch axle intermediate gear 3 a...

Страница 396: ...uction pump The plug and seal can be found in the spare parts catalog in chapter 010 01 3 Crankcase Replace the seal 4 Screw in the plug 5 Tightening torque 20 Nm 4 Nm 14 8 lbf ft 3 lbf ft Installing...

Страница 397: ...315 RLF MPE850 Rev 1 2 406555 110 110 02 Oil pressure pump 110 02 Oil pressure pump...

Страница 398: ...the engine stand See chapter 3 3 2 Mount the engine across from the drive side of the engine stand 090 02 01 Removing generator Lockring pliers bore holes Universal pliers 110 02 Oil pressure pump 110...

Страница 399: ...06555 110 5 4 6 7 110 02 Oil pressure pump 110 02 01 Removing oil pressure pump Remove the outer rotor 4 of the oil pressure pump Remove the inner rotor 5 of the oil pressure pump Remove the key 6 Rem...

Страница 400: ...install the key Replace the key Insert the key Insert the inner rotor 4 of the oil pressure pump Insert the outer rotor 5 of the oil pressure pump Replace the o rings 6 Coat the o rings lightly with p...

Страница 401: ...319 RLF MPE850 Rev 1 2 406555 110 Completion Install the generator See chapter 090 02 02 Installing generator 110 02 Oil pressure pump 110 02 02 Installing oil pressure pump...

Страница 402: ...320 RLF MPE850 Rev 1 2 406555 110 110 03 Oil pressure valve 110 03 Oil pressure valve...

Страница 403: ...ssure valve 2 out using a bar magnet Preparation Remove the suction pump cover See chapter 110 01 01 Removing suction pump cover 110 01 01 Removing suction pump cover Hexagon screwdriver 6 Bar magnet...

Страница 404: ...ert the oil pressure valve 2 Installing oil pressure valve Assemble the oil pressure valve in the sequence as illustrated 1 110 01 02 Installing suction pump cover Torque wrench Hexagon screwdriver so...

Страница 405: ...323 RLF MPE850 Rev 1 2 406555 110 Completion Install the suction pump cover See chapter 110 01 02 Installing suction pump cover 110 03 Oil pressure valve 110 03 02 Installing oil pressure valve...

Страница 406: ...324 RLF MPE850 Rev 1 2 406555 110 110 04 Oil filter 110 04 Oil filter...

Страница 407: ...325 RLF MPE850 Rev 1 2 406555 110 1 Unscrew the oil filter 1 using a universal strap wrench Universal strap wrench 110 04 Oil filter 110 04 01 Removing oil filter 110 04 01 Removing oil filter...

Страница 408: ...e sealing surface 2 with sealing surface cleaner Coat the oil filter seal 3 lightly with engine oil Sealing surface cleaner Screw in the oil filter 4 by hand Tightening torque 10 Nm 7 4 lbf ft 110 04...

Страница 409: ...the threaded sleeve 1 using a crown wrench Preparation Remove the oil filter See chapter 110 04 01 Removing oil filter 110 04 01 Removing oil filter Reversible ratchet Crown wrench 110 04 Oil filter 1...

Страница 410: ...g a crown wrench Tightening torque 17 Nm 3 Nm 12 5 lbf ft 2 2 lbf ft Completion Install the oil filter See chapter 110 04 02 Installing oil filter 110 04 02 Installing oil filter Torque wrench Crown w...

Страница 411: ...329 RLF MPE850 Rev 1 2 406555 120 120 01 Lifting eye 120 01 Lifting eye 120 Engine mount...

Страница 412: ...LF MPE850 Rev 1 2 406555 120 1 2 Unscrew the bolts 2 Remove the bracket 1 Hexagon screwdriver 5 120 01 01 Removing bracket on the drive side 120 01 Lifting eye 120 01 01 Removing bracket on the drive...

Страница 413: ...racket 1 in position Screw in the bolts 2 Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft Torque wrench Hexagon screwdriver socket 5 120 01 02 Installing bracket on the drive side 120 01 Lifting eye...

Страница 414: ...332 RLF MPE850 Rev 1 2 406555 120 1 2 Unscrew the bolt 2 Remove the pipe clamp 1 Torx screwdriver socket T30 120 01 Lifting eye 120 01 03 Removing pipe clamp 120 01 03 Removing pipe clamp...

Страница 415: ...1 2 Hold the pipe clamp 1 in position Screw in the bolt 2 Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft Torque wrench Torx screwdriver socket T30 120 01 04 Installing pipe clamp 120 01 Lifting ey...

Страница 416: ...0 Rev 1 2 406555 120 1 2 Unscrew the bolt 2 Remove the bracket 1 Hexagon screwdriver 5 120 01 Lifting eye 120 01 05 Removing bracket across from the drive side 120 01 05 Removing bracket across from t...

Страница 417: ...in position Screw in the bolt 2 Tightening torque 8 Nm 2 Nm 5 9 lbf ft 1 5 lbf ft Torque wrench Hexagon screwdriver socket 5 120 01 06 Installing bracket across from the drive side 120 01 Lifting eye...

Страница 418: ...336 RLF MPE850 Rev 1 2 406555 910 910 01 Long block 910 Repair kits 910 01 Long block...

Страница 419: ...e the intake manifold bracket See chapter 070 01 03 Removing intake manifold bracket Remove the starter See chapter 090 01 01 Removing starter 070 01 01 Removing intake manifold 070 01 03 Removing int...

Страница 420: ...See chapter 090 02 01 Removing generator 910 01 Long block 910 01 01 Installing long block Mount the long block on the engine stand Mount the engine across from the drive side 3 of the engine stand Se...

Страница 421: ...all the intake manifold bracket See chapter 070 01 04 Installing intake manifold bracket Install the intake manifold See chapter 070 01 02 Installing intake manifold Install the generator See chapter...

Страница 422: ...ev 1 2 11 10 2012 050 01 04 Installing fitting Rev 1 2 11 10 2012 050 01 06 Removing thermostat Removal modified to the new distance washer Rev 1 2 11 10 2012 050 01 07 Installing thermostat Installat...

Страница 423: ...3 remove 57 Fitting 030 02 install 182 Fitting 030 02 remove 181 Fitting 050 01 install 239 Fitting 050 01 remove 238 Fitting 110 01 replace 311 Fuel rail install 300 Fuel rail remove 298 G Generator...

Страница 424: ...rter replace 287 Stub shaft install 145 Stub shaft remove 143 Studs replace 263 Suction pump cover install 305 Suction pump cover remove 304 Suction pump cover replace 308 Supplies overview 26 Switch...

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