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Maintenance chart

SCHEDULED MAINTENANCE TABLE

I: CHECK AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY.
C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE
* Clean more frequently in cases of intensive use on gravel roads

km x 1,000 (mi x 1,000)

1 (0.6)

10 (6.2)

20

(12.4)

30

(18.6)

40

(24.8)

50

(31.0)

EVERY

12

MONTH

S

EVERY

24

MONTH

S

Safety blocks

I

I

I

I

Spark plug

R

R

Centre stand

L

L

L

L

L

L

L

Roll lock calliper control cable

A

A

A

A

A

Drive belt

R

R

Throttle control

A

A

A

A

A

A

I

I

Complete roller housing

I

I

Diagnosis by tool

I

I

I

I

I

I

I

I

Air filter *

R

R

R

R

R

CVT Filter *

C

C

C

C

C

Engine oil filter

R

R

R

R

R

R

R

R

Valve clearance

A

A

Electrical system and Battery

I

I

I

I

I

I

Braking system

I

I

I

I

I

I

Coolant

I

I

I

I

I

I

I

R

Brake Fluid

I

I

I

I

I

I

I

R

Engine oil

R

R

R

R

R

R

R

R

Hub oil

R

R

R

I

I

Headlight direction adjustment

I

I

I

Brake pads

I

I

I

I

I

I

I

I

Sliding shoes / CVT rollers

R

R

Tire pressure and wear

I

I

I

I

I

I

I

I

Test drive

I

I

I

I

I

I

I

I

Suspensions

I

I

I

I

I

I

I

Centre and side steering

A

A

A

A

A

A

I

I

Transmission

I

I

I

I

I

I

I

Labour time (minutes)

120

160

290

160

290

160

40

140

N.B.

AT EACH SCHEDULED MAINTENANCE MUST BE VERIFIED WITH THE DIAGNOSTIC TOOL IF
THERE ARE ERRORS AND THE IF THE PARAMETERS ARE CORRECT.
ENSURE THAT THE VEHICLE CALIBRATION IS UP TO DATE AFTER UPDATING THE DIAGNOS-
TIC TOOL.

CAUTION

AFTER THE SCHEDULED MAINTENANCE PROGRAM IS FINISHED YOU ARE TOLD TO PRO-
CEED WITH THE MAINTENANCE OF THE VEHICLE STARTING FROM THE SERVICE COUPON
OF 10,000 km (6,214 miles) OR 10 MONTHS.

Recommended products

Piaggio Group recommends the use of prod-

ucts from its Castrol official partner for the

scheduled maintenance of its vehicles.

Only use lubricants and fluids which meet or ex-

ceed the performance characteristics specified.

This also applies when topping up only.

MP3 400 hpe E5

Maintenance

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Содержание MP3 400 hpe E5 2021

Страница 1: ...MANUALE STAZIONE DI SERVIZIO 1Q000906 MP3 400 hpe E5...

Страница 2: ...any changes to components parts or accessory supplies which it deems necessary to improve the product or which are required for manufacturing or commercial reasons Not all the versions shown in this p...

Страница 3: ...degli impianti e delle attrezzature necessarie ed per questo che vi invitiamo a consultare le pagine di questo manuale riguardanti l attrezzatura specifica e il catalogo degli attrezzi specifici N B P...

Страница 4: ......

Страница 5: ...INDEX OF TOPICS GENERAL MANDATORY REQUIREMENTS NORM PRE DELIVERY PRE DE TECHNICAL DATA DT TOOLING TOOL MAINTENANCE MAIN ENGINE ENG...

Страница 6: ...INDEX OF TOPICS GENERAL MANDATORY REQUIREMENTS NORM...

Страница 7: ...f the PROFESSIONAL CLIENT as provided by the EC Regulation No 1907 2006 REACh 2000 53 EC END of LIFE VEHICLES SCIP Database Directive art 9 par 1 lett i of the framework directive regarding waste as m...

Страница 8: ...h as the radiator exhaust manifold exhaust pipe catalytic converter and silencer 8 Do not smoke during maintenance operations 9 To avoid any injuries do not wear rings watches jewellery and loose clot...

Страница 9: ...INDEX OF TOPICS PRE DELIVERY PRE DE...

Страница 10: ...PROCEDURE The calibration procedure of the system must be carried out according to what is indicated below riding on a straight flat stretch of road In order to maintain the effectiveness of the ASR s...

Страница 11: ...nd wait for at least 60 seconds before being able to switch again to ON In case of failure to complete the procedure within 5 minutes the ASR warning light 2 will stay on steady and the ASR will remai...

Страница 12: ...rature indicator Instrument panel lights Horn Electric starter Engine stopping with emergency stop switch Electric opening of saddle with solenoid Tilting system locking unlocking button TO ENSURE MAX...

Страница 13: ...l level Engine coolant level Engine oil level Road test Test ride Cold start Instrument operations Response to the gas command Stability on acceleration and braking Front and rear brake efficiency Par...

Страница 14: ...late fitting lock check tyre pressure check rear view mirror and any accessory fitting Specific operations for the vehicle TOOLKIT The toolkit comprises a shock absorber pre load adjusting wrench One...

Страница 15: ...so that it does not fall the windshield on the top fair ing aligning the holes and making sure that the spacers are in place Insert the bushing Put in place the cover cap Insert the screw and tighten...

Страница 16: ...NCE PLATE HOLDER CAUTION N B ONLY FIT THE LICENCE PLATE HOLDER SUPPLIED AS STANDARD WITH THE VEHICLE SINCE IT HAS TYPE AP PROVED AND OBLIGATORY SIDE REFLECTORS If the reflectors need to be removed and...

Страница 17: ...INDEX OF TOPICS TECHNICAL DATA DT...

Страница 18: ...ith a hydraulic lock system Rear suspension Two double acting shock absorbers adjustable to four posi tions at pre loading Front brake Dual 258 mm hydraulically operated disc brakes controlled from RH...

Страница 19: ...ic clutch oil bath centrifuge Final drive reduction gear Gear reduction unit in oil bath Lubrication Engine lubrication with trochoidal pump inside the crankcase oil filter and pressure adjustment by...

Страница 20: ...INDEX OF TOPICS TOOLING TOOL...

Страница 21: ...LS Stores code Description 001330Y Tool for fitting steering seats 001467Y Extractor for bearings for holes 001467Y002 Driver for OD 73 mm bearing 001467Y003 Nut 001467Y004 Lug Taper pin 001467Y005 Sc...

Страница 22: ...mm bearings 001467Y014 Calliper to extract 15 mm bearings 001467Y017 Bearing housing external 36 mm 001467Y035 Bearing housing external 47 mm 006029Y Punch for fitting steering bearing on the steering...

Страница 23: ...ription 020055Y Wrench for steering tube ring nut 020074Y Support base for checking crankshaft alignment 020084Y punch 20 020115Y punch 18 020128Y Piston fitting ring 020151Y Air heater MP3 400 hpe E5...

Страница 24: ...Crankcase splitting plate 020193Y Oil pressure gauge 020234y extractor 020244Y punch 15 020271Y Tool for removing fitting silent bloc 020306Y Punch valve seal rings fitting 020329Y Mity Vac vacuum pum...

Страница 25: ...res code Description 020331Y Digital multimeter 020332Y Digital rpm indicator 020335Y Magnetic mounting for dial gauge 020357Y 32 x 35 mm Adaptor 020358Y 37 x 40 mm Adaptor MP3 400 hpe E5 Tooling TOOL...

Страница 26: ...Stores code Description 020359S 42 x 47 mm Adaptor 020360S 52 x 55 mm adaptor 020362Y 12 mm guide 020363Y 20 mm guide 020364Y 25 mm guide 020375Y 28 x 30 mm adaptor Tooling MP3 400 hpe E5 TOOL 26...

Страница 27: ...aptor handle 020382Y Valve cotters equipped with part 012 re moval tool 020382Y011 adapter for valve removal tool 020382Y012 bush valve removing tool 020412Y 15 mm guide 020431Y Valve oil seal extract...

Страница 28: ...20434Y Union for oil pressure measurement 020439Y 17 mm guide 020441S 26 x 28 mm adaptor 020442Y Pulley lock wrench 020444Y009 wrench 46 x 55 020454Y Tool for fitting the pin snap rings 200 250 Toolin...

Страница 29: ...Description 020456Y 24 mm adaptor 020467Y Flywheel extractor 020477Y Adapter 37 mm 020480Y Fuel pressure measurement kit 020483Y 30 mm guide 020489Y Hub cover support stud bolt kit MP3 400 hpe E5 Tool...

Страница 30: ...heel lock tool 020648Y Single battery charger 020661Y Water pump overall seal replacement kit 020892y Steering side headstock ring nut key 020916Y Magneto flywheel blocking tool 020917Y Driven pulley...

Страница 31: ...918Y Clutch lock 020919Y Clutch discs disassembly tool 020921Y Piston position checking tool 020922Y Diagnosis Tool 020924Y Bluetooth for the PADS diagnostic tool 021017Y EOBD E5 diagnostics cable MP3...

Страница 32: ...INDEX OF TOPICS MAINTENANCE MAIN...

Страница 33: ...justment I I I Brake pads I I I I I I I I Sliding shoes CVT rollers R R Tire pressure and wear I I I I I I I I Test drive I I I I I I I I Suspensions I I I I I I I Centre and side steering A A A A A A...

Страница 34: ...dium fibre yellow brown coloured grease suitable for various uses ISO L X BCHA 3 DIN 51 825 K3K 20 Water repellent spray grease Water repellent pouring calcium spray grease White soap base spray greas...

Страница 35: ...INDEX OF TOPICS ENGINE ENG...

Страница 36: ...This section describes the operations to be carried out on the engine and the tools to be used N B Engine MP3 400 hpe E5 ENG 36...

Страница 37: ...ENT UNITS REFER TO THE CONVERSION TABLE IN CHAP SPECIFICATIONS Automatic transmission Transmission cover Insert the special tool Rotate the engine until the driven pulley stops Specific tooling 020917...

Страница 38: ...and remove the central screw from the transmission cover Remove the transmission cover Air duct Unscrew and remove the cooling cover fastening screws Remove the cooling cover Engine MP3 400 hpe E5 EN...

Страница 39: ...le 020358Y 37 x 40 mm Adaptor 020439Y 17 mm guide 001467Y002 Driver for OD 73 mm bearing Refitting the driven pulley shaft bearing Use the heat gun to heat the inner part of the lid CAUTION DO NOT HEA...

Страница 40: ...e belt WARNING AS A RESULT OF THE OPERATION THERE MAY BE A LIGHT HAMMERING BETWEEN THE KNURLING OF THE PULLEY AXLE THIS CAN MAKE REMOVAL BY HAND DIF FICULT IN CASE OF NEED USE AN EXTRACTOR Inspecting...

Страница 41: ...iven pulley stop Remove the housing from the shaft To fit follow the removal steps but in reverse order being careful to tighten to the specified torque CAUTION ALWAYS USE A NEW NUT FOR RETAINING THE...

Страница 42: ...ibed in the section Dismount ing the hub cover Working from the automatic transmission side remove the driven pulley Unscrew the six fixing screws from the clutch cover By using two screwdrivers work...

Страница 43: ...or handle 020358Y 37 x 40 mm Adaptor Heat the crankcase by means of specific tools and then insert a new bearing Using the equipment plant a new bearing apply grease on the adapter and guide in order...

Страница 44: ...IRST LUBRICATING THE SEAL RING STOPS WITH A BRUSH DISASSEMBLY Insert the clutch assembly in the special tool and tighten the three wing nuts until you hear the end of stroke Prepare two aluminium prot...

Страница 45: ...the lock circlips Disengage the upper ring of the specific tool Remove the outer ring with the seat for the Bel leville spring Remove the Belleville spring Remove the spring door upper disc MP3 400 h...

Страница 46: ...pring Remove the semi trimmed duct disc trimmed on one side Remove a conductor disc Remove the discs clearance recovery spring Remove a duct metallic disc Remove a conductor disc trimmed on both sides...

Страница 47: ...recovery spring Remove a non trimmed duct metallic disc Remove a conductor disc trimmed on both sides Remove the discs clearance recovery spring Remove the semi trimmed duct disc trimmed on one side M...

Страница 48: ...ANCE RECOVERY SPRING DISCS ARE FIT TED INDIVIDUALLY THE FIRST IN THE ASSEMBLY PHASE MUST BE POSI TIONED TOWARDS THE INSIDE OF THE HOUSING AS SHOWN IN FIGURE Remove the hub Remove the shaft Engine MP3...

Страница 49: ...e lower spring holder disc complete with the six springs Remove the rollers Check that there is no abnormal wear on the roll ers the support channels for rollers and those for discs MP3 400 hpe E5 Eng...

Страница 50: ...s 3 2 0 1 mm Clearance recovery spring wear limit 2 8 mm CLUTCH DISCS REVISION Check the clutch discs for damage or signs of wear In this case replace them all Measure the thickness of the discs in fo...

Страница 51: ...mm Trimmed duct wear limit C 1 7 mm CLUTCH DISCS REVISION MAXIMUM DEFOR MATION Measure the maximum deformation of the discs by positioning them on a reference plane and check ing with a feeler gauge I...

Страница 52: ...ir has its opposite for proper balance Lubricate the parts of the clutch pack with the recommended product Recommended products Transmission oil 80W 90 Lubricant for gear boxes and transmissions SAE 8...

Страница 53: ...overy spring CAUTION THE CLEARANCE RECOVERY SPRING DISCS ARE FIT TED INDIVIDUALLY THE LAST IN THE ASSEMBLY PHASE MUST BE POSI TIONED TOWARDS THE INSIDE OF THE HOUSING AS SHOWN IN FIGURE Insert the sem...

Страница 54: ...retaining ring at the specified loca tion Specific tooling 020919Y Clutch discs disassembly tool FINAL CHECK Once the clutch is assembled turn by hand the exit axis to the final reduction The rotatio...

Страница 55: ...fic tools remove the roller casing Specific tooling 001467Y006 Pliers to extract 20 mm bearings 001467Y007 Driver for OD 54 mm bearings Insert a new roller casing and set it with specific tools Specif...

Страница 56: ...ng the support of an appendix against a pin Ensure the centring of the driven pulley by means of the key inserted on the nut Specific tooling 020444Y Tool for installing removing clutch on from driven...

Страница 57: ...ve the following components in this order upper cap spring lower spring support synthetic ring Using two screwdrivers lift the locking sheath of the torque server and remove it MP3 400 hpe E5 Engine E...

Страница 58: ...irectly into the holes in the bushing CAUTION THE TORQUE SERVER PINS ARE SET ON THE BUSHING WITH INTERFERENCE AND ARE THEREFORE NOT RE MOVABLE WHEN IT IS NECESSARY TO REPLACE THE INTERNAL SEAL RINGS O...

Страница 59: ...ver taking care to respect the positioning of the ap pendices in their corresponding seats Refitting the driven pulley Insert the synthetic ring Insert the lower spring support Insert the spring lubri...

Страница 60: ...pecific tool and spring preloading Insert the fixing nut and using the specific wrench tighten to torque Specific tooling 020444Y009 wrench 46 x 55 Locking torques N m Driven pulley nut 50 60 Inspecti...

Страница 61: ...NG MUST BE PROPERLY GREASED DUE TO THE HIGH STRENGTH OF THE O RING IT IS REC OMMENDED TO TIGHTEN IN CROSSED SEQUENCE UN TIL COMPLETING THE INSERTION Locking torques N m Clutch cover retainer screws 11...

Страница 62: ...g specific tools lock the driving pulley and loosen the flanged nut Specific tooling 020442Y Pulley lock wrench remove the flat washer and the cup washer remove the stationary half pulley and the wash...

Страница 63: ...of the belt facing surfaces on both pulley halves Check that stationary driving pulley does not show signs of abnormal wear on the grooved edge and on the surface in contact with the belt CAUTION DO N...

Страница 64: ...se the specific tool to lock the pulley tightening to the prescribed torque Specific tooling 020442Y Pulley lock wrench Locking torques N m Nut M14x1 5 securing the driving pulley 120 130 CAUTION DURI...

Страница 65: ...nsmission cover to the crankcase to the pre scribed torque Locking torques N m Transmission cover screws 11 13 Insert the nut Insert the special tool Rotate the pulley axle until the pulley stops Spec...

Страница 66: ...iner large enough to recover the final reduction oil Unscrew the indicated screw and re cover the aluminium seal Unscrew the oil filler screw in order to facilitate bleeding Unscrew the seven hub cap...

Страница 67: ...eduction cap complete with the wheel axle being careful not to drop the inter mediate gear Remove the final reduction cap Turn the shaft of the driven pulley until aligning a slot with the axis of the...

Страница 68: ...on is symmetrical mark the outer surface to avoid reversed reassembly Remove the pinion and the specific tool CAUTION CLEAN THE THREAD FROM ANY RESIDUAL THREAD LOCK Removing the wheel axle Remove the...

Страница 69: ...g removal Using the specific tools remove the bearing Specific tooling 020376Y Adaptor handle 020357Y 32 x 35 mm Adaptor 020363Y 20 mm guide Removing the intermediate gear bearing Using the specific t...

Страница 70: ...g Using the equipment set a new bearing N B IF THE BEARING HAS AN ASYMMETRICAL BALL RETAIN ER PLACE IT SO THAT THE BALLS ARE VISIBLE FROM THE HUB INNER SIDE Specific tooling 020376Y Adaptor handle 020...

Страница 71: ...n case of faults replace the damaged parts Characteristic Driven pulley shaft standard sizes A 25mm 0 01 0 02 B 19 6mm 0 20 0 33 Clutch output shaft standard sizes C 20mm 0 0 013 D 20mm 0 01 0 02 Whee...

Страница 72: ...ng Using the specific tools support the hub cover Using the specific tools remove the bearing N B TO FIT THE BEARING ON THE COVER ADEQUATELY SUPPORT THE COVER WITH THE STUD BOLT KIT Specific tooling 0...

Страница 73: ...the specific tool and then insert the bearings Specific tooling 020151Y Air heater Using the equipment set a new bearing Specific tooling 020376Y Adaptor handle 020359S 42 x 47 mm Adaptor 020363Y 20 m...

Страница 74: ...iate tool Grease the sealing lips Specific tooling 020376Y Adaptor handle 020360S 52 x 55 mm adaptor Refitting the hub bearings Insert the gears in the cover in order to prevent abnormal movements dur...

Страница 75: ...round the entire outer perimeter of the duct that leads to the breather CAUTION AN IMPROPER SEALING OF THE VENTILATION CIRCUIT MEANS A LOSS OF OIL INTO THE AUTOMATIC TRANS MISSION HOUSING Recommended...

Страница 76: ...l 80W 90 Lubricant for gear boxes and transmissions SAE 80W 90 API GL 4 Characteristic Final reduction unit oil about 500 cc Locking torques N m Oil relief screw 15 17 Flywheel cover Removing the hub...

Страница 77: ...ponents Disconnect the spark plug cap Undo the two fixing screws of the coil Loosen the two clamps and remove the coolant internal recirculation pipe Undo the four screws A and the fixing screw B of t...

Страница 78: ...HER THAN THE NORMAL LOCKING TORQUE REF ERENCE SHOULD BE MADE TO THE REMOVAL OF THE DISMOUNTED FLYWHEEL COVER IMPELLER FAILURE TO FOLLOW THIS WARNING WILL CAUSE AB NORMAL AXIAL THRUST THAT CAN CAUSE DA...

Страница 79: ...taking care to tighten to specified torque Locking torques N m Pick up screws 3 to 4 Coil fixing screw 11 to 13 Oil drain screw 20 to 24 Refitting the flywheel cover Fit the gasket and be careful with...

Страница 80: ...or Undo the two fixing screws and remove the start er motor Removing the flywheel magneto Undo the screw indicated and remove the plate Install the support plate Specific tooling 020916Y Magneto flywh...

Страница 81: ...to the flywheel and extract it as shown in the picture CAUTION SCREWING UP THE NUT WITHOUT WASHER HELPS PRO TECT THE THREAD AGAINST THE STRAIN EXERTED BY THE EXTRACTOR AND ALSO PREVENTS DROPPING THE F...

Страница 82: ...egrease the threading of the holes in the free wheel and the clamping screws Apply the recommended product to the end of the screws Recommended products Loctite 243 Medium strength thread locking seal...

Страница 83: ...ate gear Lubricate the sliding surfaces and insert the in termediate gear in its seat Refitting the flywheel magneto Place the tab Insert the magneto flywheel on the crankshaft Insert the washer MP3 4...

Страница 84: ...ied torque Specific tooling 020627Y Flywheel lock tool Locking torques N m Flywheel fixing nut 100 to 110 Refitting the starter motor Fit a new O ring on the starter motor and lubricate it Fit the sta...

Страница 85: ...the big end loosen the clamps to remove the sleeve Remove the sleeve connecting the throttle body Removing the rocker arms cover Support the big end cover Unscrew and remove the special cover fastenin...

Страница 86: ...e timing system it is recom mended to place the engine at TDC in compres sion aligning the references as shown in the figure First loosen the tensioner and unscrew the fixing screws Remove the tension...

Страница 87: ...Undo the fixing screw and remove the washer Remove the complete mass of the return spring Loosen the screw Remove the counterweight fixing screw MP3 400 hpe E5 Engine ENG 87...

Страница 88: ...ngage the chain from the sprocket and re move the camshaft control sprocket Removing the cam shaft Remove the big end cover Remove the timing system control Unscrew the two screws of the camshaft lock...

Страница 89: ...to access the calibrated pads Remove the calibrated pads CAUTION PROPERLY REPLACE THE PADS AND ROCKERS SO AS TO PRESERVE THE COUPLINGS CAUTION IF NECESSARY USE A TELESCOPIC MAGNET TO RE MOVE THE PADS...

Страница 90: ...ng the cylinder head Undo the two external screws Gradually loosen the four columns in crossed se quence recovering the washers Remove the cylinder head N B IF NEEDED THE HEAD MAY BE REMOVED WITH THE...

Страница 91: ...pecific tool to remove the cotters cap and spring CAUTION PROPERLY REPLACE THE PADS AND ROCKERS SO AS TO PRESERVE THE COUPLINGS Specific tooling 020382Y Tool to extract valve cotters 020382Y012 bush v...

Страница 92: ...Use the specific tool to remove the valve oil seal Specific tooling 020431Y Valve oil seal extractor Slide off the valve and remove the lower support Engine MP3 400 hpe E5 ENG 92...

Страница 93: ...ng attention to the cyl inder head alignment dowels N B IN ORDER NOT TO DAMAGE THE BASE GASKET WITH THE PISTON LOCK FORK 020512Y DURING THE MOUNT ING PHASE IT IS RECOMMENDED TO INSERT THE ALIGNMENT DO...

Страница 94: ...G CLEARANCES SEE THE SPECIFICATIONS CHAP TER Inspecting the wrist pin N B TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES SEE THE SPECIFICATIONS CHAP TER Inspecting the piston N B TO MEASURE WEAR LIMIT...

Страница 95: ...load of a few millimetres Finally fix the dial gauge Check the perfect sliding of the feeler pin Install the tool on the cylinder without changing the dial gauge position Lock the tool using the origi...

Страница 96: ...ston Fit the sealing rings with the word TOP or the identification letter facing upwards In any case the step must be facing opposite the piston crown Sealing rings are manufactured with a cylinder co...

Страница 97: ...base gasket Fit the specific tool Specific tooling 020426Y Piston fitting fork Place the seal rings as indicated in the figure Place the cylinder and the specific tool Specific tooling 020128Y Piston...

Страница 98: ...camshaft control pulley chain as sembly and the sprocket wheel are not worn If you detect wear replace the parts or if the chain sprocket wheel and pulley are worn replace the whole unit Remove the ce...

Страница 99: ...ERALLY IN LINE WITH THE VALVES IN ORDER TO PREVENT ACCIDENTAL BENDING OF THE BLADE THAT MAY AFFECT THE MEAS UREMENTS Characteristic Valve clearance cold engine Intake 0 10 mm Exhaust 0 15 mm Detecting...

Страница 100: ...ORDER TO PRESERVE THE INDICATION OF THICKNESS OVER TIME THE OUTLET ROCKER SLIDES ON THE AXIS ONLY AF TER THE INTAKE ROCKER HAS BEEN MOVED MAKE SURE THAT THE PADS DO NOT FALL INSIDE THE ENGINE COMPART...

Страница 101: ...al punch fit the four valve seal rings Fit the valves the springs and the caps Using the appropriate tool with adapter compress the springs and insert the cotters in their seats N B DO NOT CHANGE THE...

Страница 102: ...D BOLTS FOR FITTING QUOTA SEE THE SECTION MOTOR STUD BOLT SHAFT CRANKCASE Position the crankshaft to the TDC in compres sion Insert the head gasket and check the correct op eration of the alignment do...

Страница 103: ...to 9 11 Nm then proceed for 270 0 5 0 of rotation Fit the pins and rocking levers Lubricate the two rockers through the upper holes Lubricate the two housings and insert the cam shaft in the cylinder...

Страница 104: ...st position Fit the chain tensioner on the cylinder using a new gasket and tight the two screws to the specified torque Insert the chain tensioning screw together with the spring and washer tightening...

Страница 105: ...screws 6 7 Refitting the intake manifold Connect the rubber sleeve complete with throttle body to the intake manifold Place the clamps and tighten them to the speci fied torque Locking torques N m Th...

Страница 106: ...RANKCASES AND REMOVING THE CRANKSHAFT CHECK THAT THE THREADED SHAFT ENDS DO NOT INTERFERE WITH THE MAIN BUSH INGS FAILURE TO OBSERVE THIS PRECAUTION CAN DAMAGE THE MAIN BUSHINGS CAUTION KEEP THE CRANK...

Страница 107: ...and oil ducts On the transmission side crankcase half take particular care when handling the oil pump com partment and the oil ducts the by pass duct the main bushings and the cooling jet on the trans...

Страница 108: ...AS EFFECTS THAT ARE DIFFICULT TO DETECT PISTON TEMPERATURE IN CREASE FAILURE OR LEAKS CAN CAUSE A CONSID ERABLE DROP IN THE LUBRICATION PRESSURE FOR MAIN BUSHINGS AND CONNECTING ROD N B THE HEAD LUBRI...

Страница 109: ...B TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES SEE THE SPECIFICATIONS CHAP TER See also Crankcase crankshaft connecting rod Coupling chart N B TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES SEE THE...

Страница 110: ...ts during inser tion of the crankcase half which could cause collision with the oil pump control toothing on the crankshaft and consequently damage the bush ings insert the crankcase fastening screws...

Страница 111: ...20163Y Crankcase splitting plate 020335Y Magnetic mounting for dial gauge Characteristic Crankshaft crankcase axial clearance H 0 15 0 43 mm Studs Using two nuts fitted as nut and lock nut type remove...

Страница 112: ...function is to reduce the flow rate reaches the timing system where it lubricates the camshaft A and from there the valves and rockers The oil passes through the timing chain duct and returns to the s...

Страница 113: ...not within the specified limits in the following order check the oil filter the oil by pass valve the oil pump and the crankshaft seals N B THE CHECK MUST BE CARRIED OUT WITH OIL AT THE CORRECT LEVEL...

Страница 114: ...Using pliers remove the door by acting on the appendices Remove the spacer and the O ring Engine MP3 400 hpe E5 ENG 114...

Страница 115: ...R TO PREVENT ABNORMAL FORMATIONS OF DIRT DUE TO THE RELEASE OF GREASE WE RECOM MEND FIRST LUBRICATING THE SEAL RING STOPS WITH A BRUSH Locking torques N m Crankcase timing cover screws 3 5 4 5 Oil pum...

Страница 116: ...two screws and remove the ten sioner pad Remove the oil pump command sprocket com plete with chain Undo the fastening screws of the oil pump Remove the oil pump and collect the gasket Engine MP3 400 h...

Страница 117: ...the two reference marks visible Using a feeler gauge check the distance be tween the rotors in the position shown in the figure Check the distance between the outer rotor and pump body see figure Chec...

Страница 118: ...Admissible limit clearance 0 12 mm Refitting Insert the oil pump with the corresponding gas ket in the seat Engine MP3 400 hpe E5 ENG 118...

Страница 119: ...5 6 Insert the oil pump driving sprocket and chain fit the tensioner pad place the spring washer and insert the water pump control screw Preventing rotation tighten the water pump com mand screw CAUT...

Страница 120: ...sen the impeller CAUTION THE THREAD IS ANTICLOCKWISE CAUTION IF THE LOCKING TORQUE IS EXCESSIVE DO NOT INSIST WITH THE OPERATION BUT CARRY IT OUT AFTER THE REMOVAL OF THE FLYWHEEL COVER AFTER REMOV IN...

Страница 121: ...plug of diameter less than 8 mm and being careful not to damage the shaft seat remove the shaft and ceramic seal Specific tooling 001467Y002 Driver for OD 73 mm bearing Supporting the ceramic seal pro...

Страница 122: ...not show abnormal wear Make sure the ceramic seal seat does not show signs of scoring Check the cleaning of the drain and lubrication holes Fitting Lubricate the new seal ring with grease and insert...

Страница 123: ...he drive Locking the drive in a vice properly lock the shaft Check that the shaft rotates freely considering the friction of the oil seal and that the axial clear ance is noticeable but not excessive...

Страница 124: ...l and tighten the nut with a wrench while holding the central pin locked Screw until the seal stops on the crankcase The special tool provides for processing that en sures the proper preloading of the...

Страница 125: ...Insert and screw the impeller to the specified tor que Locking torques N m Impeller on the pump shaft 4 6 MP3 400 hpe E5 Engine ENG 125...

Страница 126: ...I Identification 18 M Maintenance 33 R Recommended products 33 T Technical Data 18 Transmission 37 64 V Vehicle 14 18...

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