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Number of items in cart:. The part tightening torques are given on page 9. When total or partial engine disassembly is carried out, all the seals must be changed. Lubricate rotating parts and seals with engine oil before putting them in place. When fitting the oil filter, lubricate the seal with engine oil.
Never put your hands between one part and another and use the most appropriate tools for aligning bores. Disassembly operation NOTE: At assembly the bushings 1 should be directed so that the lubrication holes coincide with those on the crankcase housings. Place the plate 1 retaining the camshaft 2 with the slot facing the top part of the crankcase and the stamping facing the operator, tighten the screws 3 to the torque specified on page 9.
If the main journals and connecting rod pins show signs of seizure, scores or excessive ovalisation, regrind them. Before grinding the pins 1 , use a micrometric gauge 2 to measure the shaft pins and establish, according to the spare undersizes given on page 5, the diameter to which the pins are to be reduced. Check that the toothing of the gear 1 , keyed onto the crankshaft 2 is not damaged or worn, if so, remove it using a suitable puller tool 3.
NOTE: If the crankshaft main journals are undersized, the main bearings should be replaced with those of the same undersize class. NOTE: Do not do any adaptation work on the bearings. Carefully clean the main half bearings 1 with hole for lubrication and fit them in their housings. Insert the screws 1 lubricated beforehand and tighten them in three steps. The clearance between the main bearings and the respective journals is measured comparing the width of the calibrated wire 2 , in the point mostly squeezed, with the graduated the scale on the packet 1 containing the calibrated wire.
The numbers on the scale indicate the coupling clearance in millimetres. Check that the clearance is as specified on page 5, then lubricate the main bearings and definitively assemble the supports tightening the fixing screws as described previously. Disassembly operations Spare part number and design change number.
Arrow showing the direction of assembly of the piston in the cylinder liner, it must be faced towards the crankcase front auxiliary components side. Date of manufacture. With the pin 3 connect the piston 2 to the connecting rod 4 so that the reference arrow 1 for assembling the piston 2 in the cylinder liner is directed as described in point 2. NOTE: If the crankshaft connecting rod pins are undersized, the connecting rod bearings should be replaced with those of the same undersize class.
Do not do any adaptation work on the half bearings. Apply tool 1 on the socket spanner and further tighten the screws 2 as specified on page 9. Remove the cap and find the clearance, comparing the width of the calibrated wire 1 with the graduation of the scale on the packet 2 that contained the wire. Check that the clearance is as specified on page 5, then lubricate the connecting rod half bearings and definitively assemble them tightening the connecting rod cap fixing screws as described on page 9.
NOTE: Before final assembly of the connecting rod cap fixing screws, check that their diameter, measured at the centre of the thread length, is not 0. Check by hand that the connecting rods 1 slide axially on the crankshaft journals and that their end play measured with thickness gauge 2 is as specified on page 5. Cleaning the surface to be sealed is absolutely necessary to obtain effective tightness. It must be even no lumps , with no bubbles, thin or discontinuous areas.
Any imperfections should be corrected in the shortest time possible. Avoid using excess material for sealing the joint. Too much sealant would tend to come out on both sides of the joint and obstruct the passages of the lubricant. Fit the bracket 4. On the cylinder head position: the spring 4 and the upper plate 3 ; use tool 1 to compress the spring 4 and restrain the parts to the valve 5 through the cotters 2.
Check that the cylinder head surface 1 and the one on the crankcase are clean. Do not dirty the cylinder head gasket. As two types of head gasket exist, to choose the thickness 1. After installing the gasket, fit the cylinder head on the crankcase tightening the screws 1 without locking to the torque. Before every assembly, always check that the threads of the holes and screws reveal no signs of wear or traces of dirt.
Fit a new seal ring 2 lubricated with vaseline and a new seal washer 3 on the electroinjector 1. Tighten the electroinjector fixing screws without locking them. Install a new seal ring 3 , lubricated with vaseline, on the fuel manifold 2 and insert it in the housing on the cylinder head so that the positioning balls 5 coincide with the corresponding housing 4.
The fuel manifolds 2 in F4HE engines have 2 positioning balls. During this operation move the electroinjector 1 so that the fuel manifold 2, fig. Use a torque spanner to gradually and alternately tighten the electroinjector fixing screws 1 to a torque of 8.
Tighten the nuts 2 fixing the fuel manifolds 3 to a torque of 50 Nm. Assemble the rocker unit after checking the parts. The rods that control the intake and exhaust valves are identical and therefore interchangeable.
Check that the tappet adjustment screws 1 are slackened to prevent them from sticking on the rods 2, fig. Then assemble the rocker units formed by the support 5 , rockers 3 , spindles 4 and fasten them to the cylinder head tightening the screws to a torque of 36 Nm.
Check the clearance between the rockers and valves using an Allen wrench 1 , polygonal wrench 3 and thickness gauge 2. Every cylinder must be checked taking it to the T.
Apply on the connection surface of the intake manifold 1 complete with heater 2 a sufficient coating of LOCTITE and tighten the screws to the specified torque. Fit the sensor 3 with a new seal. Fit the rail 2 and tighten the fixing screws 1 to the specified torque, connect the ground cable 3 to the intake manifold 4 tightening the fixing nut to the specified torque.
The pipe fittings 7 should be tightened to a torque of 20 Nm, using the special spanner 5 and torque spanner 4. The fittings 6 should be tightened keeping the flow limiting valves still using the special hexagon spanner 1. Check the conditions of the electrical cables 5 , change them if damaged cutting the clamps that fasten them to the support 2 and removing the screws 4 fastening them to the connectors 3.
Install a new seal 1 on the support 2. Fit the tappet cover tightening the nuts and lock them to the specified torque. Direct the crankshaft and camshaft so that when the driven gear is fitted on the latter, the marks stamped on the gears coincide. Tighten the screws 1 fastening the gear 2 to the camshaft 3 and lock them to the specified torque.
Assembly operation Check that the clutch plate resting surface shows no signs of scores, if so, face it. Check the conditions of the ring gear teeth 2 , if breakage or excessive wear is noted, change it. Tighten two pins 2 of suitable length in the holes of the shaft 3 and assemble the engine flywheel 1 using a suitable sling. Key the flywheel 1 onto the crankshaft tightening the screws 2 by hand. Suitably block the flywheel before tightening the screws to their torque. Carefully clean the front cover connection surface on the crankcase 2 and install the front cover.
Insert the screws 1 and tighten them to the torque specified on page 9. Position part 1 on part 4 and tighten the nut 7 until completely fitting the seal ring 6 in the front cover 2.
Key the pulley 1 and damper flywheel 2 on the crankshaft. Fit the rpm sensor 3 in the front cover 1 and tighten the fixing screw 2 to the specified torque. On the crankcase install: a new seal 1 , the heat exchanger 2 , a new seal 3 and the oil filter support 4. Tighten the screws 5 and lock them to the specified torque. Position a new seal ring 6 in the crankcase housing. Tighten the screws 2 and lock them to the specified torque.
Reconnect the alternator 1 and fit the guard. Tighten the fixing screws to the specified torque. Refit the automatic belt tensioner 2. Tighten the screw 3 and lock it to the specified torque. Turn the automatic belt tensioner 2 to fit the belt 1 on the pulleys and guide rollers. Fit the support 4 with a new seal ring, the rpm sensor 2 with a new seal ring and tighten the corresponding fixing nut 1 to the specified torque.
Connect the pipe 6 and fasten the oil vapour recovery pipe 5 using the clamp; tighten the nut fastening it to the top end. Connect the pipe 2 to the pressure limiter 1.
Suitably support the engine using the lift, release it from the rotary stand, remove the brackets and rest it on a suitable support for the completion operations. Fit the oil filter.
Fit the starter motor 2 on the inner part of the flywheel cover. Fit the oil filler pipe with a new O-ring. Fasten with the three M12x25 screws. Then connect in sequence the pipes 9, 3, 4 and 5 of the support 1 to the high pressure pump 8. Connect the pipe 7 from the high pressure pump to the electronic control unit exchanger.
Connect the pipe 10 from the high pressure pump to the rail diffuser. All the fuel pipes are fastened with the clamps illustrated. To connect the pipes press the clip 1 in the direction of the arrow Fig. B and connect the pipe to the high pressure pump or to the fuel filter support. Make sure that the fuel line is connected properly. Fit the engine electric cable connecting all the sensors, the control unit and the rail diffuser. Checks and measurements After engine disassembly, clean the parts of the crankcase unit thoroughly.
Use the special lifting rings to handle the unit. Carefully check that the crankcase is not cracked. Check the conditions of the plugs 3, fig.
Change them if they are rusted or in the slightest doubt of their tightness. Examine the cylinder liner surfaces; they should not show signs of scores, ovalisation, taper or excessive wear. Checking the inside diameter of cylinder liners to find the amount of ovalisation, taper and wear is carried out using the bore gauge 1 fitted with dial gauge, reset beforehand on a ring gauge 2 of the diameter of the cylinder liner.
The measurements are to be carried out on every single cylinder liner at three different heights of the cylinder and on two perpendicular planes: one parallel with the longitudinal axis of the engine A and the other perpendicular B ; generally the highest amount of wear is noted on the latter plane in correspondence with the first measurement.
If ovalisation, taper or in any case wear is noted beyond the tolerances given on page 4, bore and grind the cylinder liners. Regrinding the cylinder liners must be carried out in relation to the diameter of the pistons supplied as spare oversized by 0. NOTE: In the event of regrinding, all the liners must have the same oversize 0. If a higher value is noted, change the crankcase.
Examine the resting surface of the head on the cylinder unit for distortion. This check can be carried out after removing the dowels 2 with a calibrated rule 1 and thickness gauge 4.
After having ascertained the distortion areas, reface the resting surface using a grinder. The flatness error may not be over 0. NOTE: Crankcase refacing may be carried out only after making sure that, at the end of the work, the protrusion of the piston from the cylinder liner is not over the value specified on page 6.
Check the conditions of the machining plugs 3 of the crankcase unit; if rusted, or in the slightest doubt as to their tightness change them. Upon completing refacing restore the chamfer of the cylinder liners as shown in fig.
Crankshaft Before carrying out any operation, clean the various parts thoroughly. Carefully examine the crankshaft, which should be changed in the case of even slight cracks. Before grinding the pins 1 , use a micrometric gauge 2 to measure the shaft pins and establish the diameter to which the pins are to be reduced.
NOTE: The main journals and connecting rod pins must always be ground to the same undersize. The undersize carried out on main journals and connecting rod pins should marked by a special stamping on the side of the arm of crank no. The letter M for undersized connecting rod pins. The letter B for undersized main journals. Let us know if you have any catalog for exchange.
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