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Nanni 4.380 TDI Workshop Manual

Other manuals for 4.380 TDI: Instruction Manual
Manual is about: Toyota engine base

Summary of 4.380 TDI

  • Page 1

    60300140( indice a ) 4 cylinders workshop manual 1/191 t4.155 4.380 tdi 4.390 tdi w w o o r r k k s s h h o o p p m m a a n n u u a a l l 4 4 c c y y l l i i n n d d e e r r s s engine base nanni industries 11 av mariotte 33260 la teste france tel: +33 5 56 22 30 60 fax: +33 5 56 22 30 79 e-mail: co...

  • Page 2: Sommaire Du Manuel D'Atelier

    60300140( indice a ) 4 cylinders workshop manual 2/191 sommaire du manuel d'atelier nanni diesel base m1kz t 4.155 / 4.380 tdi / 4.390 tdi all tightening torques are indicated in nm and in kgf/cm 1st part: maintenance manual 4 main components 28 setting injection timing 7 safety information 31 repla...

  • Page 3: Manuel De Maintenance

    60300140( indice a ) 4 cylinders workshop manual 3/191 manuel de maintenance moteur base m1kz t4.155 4.380 tdi 4.390 tdi t4.155 4.380 tdi 4.390 tdi (part one).

  • Page 4

    60300140( indice a ) 4 cylinders workshop manual 4/191.

  • Page 5

    60300140( indice a ) 4 cylinders workshop manual 5/191.

  • Page 6: Safety Information

    60300140( indice a ) 4 cylinders workshop manual 6/191 safety information this operating manual has been published to help you use your engine and its equipment. Numerous important instructions are given in this manual and need to be observed when operating the engine. The operator must read this ma...

  • Page 7

    60300140( indice a ) 4 cylinders workshop manual 7/191 fuels and lubricants - stop the engine before topping up with fuel and lubricants. - do not smoke close to the engine and keep any naked flames away when filling with fuel - wear gloves to detect a possible leakage. - hot oil can burn. Allow the...

  • Page 8: 1. General Information

    60300140( indice a ) 4 cylinders workshop manual 8/191 1. General information your nanni diesel engine is a high quality nanni industries designed and manufactured product. This engine is manufactured with the best materials according to precise specifications and strictly controlled manufacturing m...

  • Page 9

    60300140( indice a ) 4 cylinders workshop manual 9/191 identification of main components 1. Temperature exchanger 2. Coolant filling port 3. Block drain plug 4. Fresh water pump 5. Sea water pump 6. Alternator 7. Flexible suspension 8. Electrical connector 9. Starter 10. Oil filling port 11. Suction...

  • Page 10

    60300140( indice a ) 4 cylinders workshop manual 10/191 danger: do not bring a flame or sparks close to the battery. An extremely explosive detonating gas forms during battery charging. Do not cause a short circuit. The battery electrolyte is highly corrosive. If the acid is spilt on skin, immediate...

  • Page 11

    60300140( indice a ) 4 cylinders workshop manual 11/191 danger: do not smoke or bring a flame or sparks close to fuel. Always wipe up spilled fuel. Cooling system the system comprises two different circuits: the closed coolant circuit and the seawater circuit. Closed coolant circuit this circuit com...

  • Page 12: 4. Engine Operation

    60300140( indice a ) 4 cylinders workshop manual 12/191 4. Engine operation starting dangers - correctly close the engine cover and fit all protection guards before starting the engine. - check the fuel level. - open the fuel supply valve. - open the seawater intake valve. - check the engine and rev...

  • Page 13: 5. Servicing

    60300140( indice a ) 4 cylinders workshop manual 13/191 twin engine boats: when navigating with a single engine, close the seawater intake of the engine shut down. Do not forget to open it before restarting the engine. Caution: check the engine and the engine compartment to detect any possible leaks...

  • Page 14

    60300140( indice a ) 4 cylinders workshop manual 14/191 danger – shut down the engine and turn off the battery isolation valve before performing any work on the electrical system battery - check the condition of battery elements once per season. - the density of the electrolyte must be between 1.270...

  • Page 15

    60300140( indice a ) 4 cylinders workshop manual 15/191 seawater circuit - close the seawater intake valve. - drain all seawater intake pipes, the filter, the seawater pump, the temperature exchanger and pipe by loosening the attachment collars. - drain the exhaust circuit, as a certain quantity of ...

  • Page 16

    60300140( indice a ) 4 cylinders workshop manual 16/191 oil filter replacement - the cartridge is of the disposable type. - connect a pipe to the sleeve of the filter head bowl and connect to a recipient. - unscrew the filter head cartridge. - coat the gasket of the cartridge with clean oil. - screw...

  • Page 17: Fiche Technique

    60300140( indice a ) 4 cylinders workshop manual 17/191 fiche technique moteurs type: t4.155 / 4.380 tdi / 4.390 tdi characteristics lubrication number of cylinders: 4 total displacement: 2982 cm 3 bore-stroke: 96 x 103 mm cylinder ratio: 19.7/1 compression pressure: 3 mpa minimum maximum difference...

  • Page 18: Recommendations

    60300140( indice a ) 4 cylinders workshop manual 18/191 recommendations lubrication and cooling e e n n g g i i n n e e o o i i l l api -cd~cf 15 w 40 mineral ( motul tekma mega or motul marine 4t ) c c o o o o l l a a n n t t 50% pure antifreeze 50% fresh water ( motul antifreeze ).

  • Page 19: Alternator Belts

    60300140( indice a ) 4 cylinders workshop manual 19/191 alternator belts glow plugs checking the alternator drive belt check the alternator drive belt a) check the drive belt and verify the amount of fraying, clogging or wear. Check that the top of the drive belt does not touch the bottom of the pul...

  • Page 20

    60300140( indice a ) 4 cylinders workshop manual 20/191 warning: • "new belt" means a belt that is installed in an engine and that has rotated for less than 5 minutes. • "worn belt" means a belt that is rotated in an engine and that has turned for at least 5 minutes. • after installing a new drive b...

  • Page 21

    60300140( indice a ) 4 cylinders workshop manual 21/191 checking and adjusting valve clearance (engine cold) 1. Remove the rocker cover remove the ten assembly bolts, the two attachment nuts, the rocker cover and the gasket. Cylinder no.4 is on fly wheel side 2. Put cylinder no.4 in top dead positio...

  • Page 22

    60300140( indice a ) 4 cylinders workshop manual 22/191 c) only measure the clearance of the valves illustrated opposite. Measure the valve clearance . D) remove the thickness shim. - turn the crankshaft so as to position the peak of the cam shaft cam of the valve to adjust at the peak. - use specia...

  • Page 23

    60300140( indice a ) 4 cylinders workshop manual 23/191 selection table for thickness shims intake thickness shim no. Thickness thickness shim no. Thickness 01 2.50 46 2.95 42 2.55 26 3.00 06 2.60 47 3.05 43 2.65 31 3.10 11 2.70 48 3.15 44 2.75 36 3.20 16 2.80 49 3.25 45 2.85 41 3.30 21 2.90 thickne...

  • Page 24

    60300140( indice a ) 4 cylinders workshop manual 24/191 selection table for thickness shims exhaust thickness shim no. Thickness thickness shim no. Thickness 01 2.50 46 2.95 42 2.55 26 3.00 06 2.60 47 3.05 43 2.65 31 3.10 11 2.70 48 3.15 44 2.75 36 3.20 16 2.80 49 3.25 45 2.85 41 3.30 21 2.90 thickn...

  • Page 25

    60300140( indice a ) 4 cylinders workshop manual 25/191 f) install a new thickness shim. - install the new thickness shim on the valve lifter. - remove the special maintenance tool sst. G) verify the valve operating clearance 4. Installation of the rocker cover a) remove any signs of former gasket o...

  • Page 26

    60300140( indice a ) 4 cylinders workshop manual 26/191 setting the injection advance checking and setting the injection timing 1 install the special maintenance tool sst and the dial gauge. A) remove the bolt from the injection pump timing cap plug. B) install the special maintenance tool sst (plun...

  • Page 27

    60300140( indice a ) 4 cylinders workshop manual 27/191 if the recorded value is not within the tolerances : e) loose the following assembly bolts and nuts. 1) the 4 attachment nuts of the injection pipe coupling on injection pump side. 2) the bolts securing the injection pump to the injection pump ...

  • Page 28

    60300140( indice a ) 4 cylinders workshop manual 28/191 to remove the injection pump it is necessary to use the pulley extractor reference: 970 312 374 2) the bolts securing the injection pump on the injection pump space. Recommended tightening torque: 32 n.M (330 kgf.Cm) * verify the travel of the ...

  • Page 29: Replacing The Timing Belt

    60300140( indice a ) 4 cylinders workshop manual 29/191 replacing the timing belt every 1000 hours or 2 years removing the timing belt (refer to the component part illustration for removal and reinstallation) 1) remove the timing belt protection cover remove the four assembly bolts, the sealing wash...

  • Page 30

    60300140( indice a ) 4 cylinders workshop manual 30/191 check of the timing belt equipments 2) check the intermediate pulley verify whether the timing belt intermediate pulley turns without any excessive friction. If necessary, replace the intermediate pulleys. Precaution: replace the intermediate p...

  • Page 31

    60300140( indice a ) 4 cylinders workshop manual 31/191 several examples of belt damage requiring immediate replacement (do not wait until it breaks) tearing off of 1 tooth (engine blocking...) cracking (intermediate pulley deformation...) side torn off (pulley alignment...) surface torn off (waste,...

  • Page 32

    60300140( indice a ) 4 cylinders workshop manual 32/191 reinstallation of timing belt 1) reinstall the timing belt remark: the engine must be cold advice: if the timing belt is re-used, make the marks made during removal coincide, then reinstall the timing belt, taking care to point the arrow in the...

  • Page 33

    60300140( indice a ) 4 cylinders workshop manual 33/191 5) check turn the crankshaft clockwise and verify that each pulley coincides with the alignment marks (top dead center mark) as illustrated opposite. If the marks do not coincide, remove the timing belt and reinstall once more. 6) reinstall the...

  • Page 34: Compression Measurement

    60300140( indice a ) 4 cylinders workshop manual 34/191 compression measurement checking the compression advice: measure cylinder compression pressure when the engine efficiency is low, oil consumption excessive or fuel consumption uneconomical. 1) warm the engine, then stop it allow the engine to h...

  • Page 35

    60300140( indice a ) 4 cylinders workshop manual 35/191 compression pressure: 3.040 kpa (31.0 kgf/cm²) or more minimum pressure: 1.961 kpa (20.0 kgf/cm²) pressure difference between cylinders: less than or equal to 490 kpa (5.0 kgf/cm²) e) if the compression pressure of one or more cylinders is less...

  • Page 36: Piston Protrusion

    60300140( indice a ) 4 cylinders workshop manual 36/191 piston protrusion selection of the cylinder head gasket reinstallation and tightening of the cylinder head 1) check the protruding part of the piston and choose an appropriate cylinder head joint a) check the protruding part of the piston of ea...

  • Page 37

    60300140( indice a ) 4 cylinders workshop manual 37/191 b) select a new cylinder head gasket. Warning: there are 5 types of cylinder head gaskets (hole no.1 to 5) which are installed in the factory but only 3 types as procurement parts (hole no. "1", "3", and "5") so that when replacing a cylinder h...

  • Page 38

    60300140( indice a ) 4 cylinders workshop manual 38/191 b) reinstall cylinder head bolts. Warning: - cylinder bolts must be tightened gradually in three step (step (b), (d) and (e)). - any broken or deformed cylinder head bolt must be replaced. A) put a drop of engine oil on bolt threads and under b...

  • Page 39

    60300140( indice a ) 4 cylinders workshop manual 39/191 b) reinstall the five bearing caps at their respective locations. C) reinstall and evenly tighten the ten bearing cap bolts to the recommended torque, in the tightening order indicated opposite. Recommended tightening torque: 18 n.M (185 kgf.Cm...

  • Page 40

    60300140( indice a ) 4 cylinders workshop manual 40/191 checking the cooling system components frequency: refer to maintenance plan hardware in direct contact with sea water must be made of a4.70 stainless steel sea water pump: replacing the rotor and cover gasket thermostat: opening temperature che...

  • Page 41

    60300140( indice a ) 4 cylinders workshop manual 41/191 exchanger: clean the core and replace o-rings caution: core securing screw in exchanger body. Intercooler: clean the core and replace o-rings.

  • Page 42: Coolant:

    60300140( indice a ) 4 cylinders workshop manual 42/191 anode on exhaust elbow: check and replace coolant: 50% pure antifreeze, 50% fresh water important: bleed the fresh water circuit on the turbo charger.

  • Page 43

    60300140( indice a ) 4 cylinders workshop manual 43/191 indicators: pre-heating water in fuel and water alarm oil alarm battery charging panel c3: rectangular connector panel c3: round connector indicators: water in fuel water alarm oil alarm battery charging.

  • Page 44

    60300140( indice a ) 4 cylinders workshop manual 44/191.

  • Page 45

    60300140( indice a ) 4 cylinders workshop manual 45/191 toyota 4 cylinder base panel connectors male connectors lug side view 4 cylinders toyota square connector 11 terminals + 2 terminals terminal no. Wire colour function 1 red battery + 2 black battery - 3 brown starter 4 brown 1 pre-heating 5 whi...

  • Page 46

    60300140( indice a ) 4 cylinders workshop manual 46/191.

  • Page 47

    60300140( indice a ) 4 cylinders workshop manual 47/191 1 red battery + 2 purple charge indicator 3 grey oil pressure probe 4 yellow pre-heating 5 pink / black oil alarm 6 yellow / green water alarm 7 brown starting 8 orange / blue water temperature probe 9 green pre-heating timeout probe 10 white e...

  • Page 48: Electrical Drawing

    60300140( indice a ) 4 cylinders workshop manual 48/191 electrical drawing rectangular connector.

  • Page 49

    60300140( indice a ) 4 cylinders workshop manual 49/191.

  • Page 50: List of Essential Special

    60300140( indice a ) 4 cylinders workshop manual 50/191 list of essential special tools • alternator belt tension controller - 970 312 375 • valve adjustment tool: - 970 312 377 • injection pump dial gauge support - 970 312 378 • pulley / pinion extractor box (usable on all nanni models) - 970 312 3...

  • Page 51: Contents Exploded View of

    60300140( indice a ) 4 cylinders workshop manual 51/191 contents exploded view of the 4 cylinders toyota base engine timing belt timing casing timing pinions cylinder head cylinder block glow plugs injectors injection pump thermostat fresh water pump oil pump oil radiator oil injectors turbo charger.

  • Page 52: Timing Belt

    60300140( indice a ) 4 cylinders workshop manual 52/191 timing belt component parts removal and reinstallation cylinder head cover cam shaft no.1 tightening pulley gasket fastener timing belt specified tightening torque - non-reusable part intermediate timing pulley timing belt tensioner cam shaft n...

  • Page 53

    60300140( indice a ) 4 cylinders workshop manual 53/191.

  • Page 54

    60300140( indice a ) 4 cylinders workshop manual 54/191.

  • Page 55

    60300140( indice a ) 4 cylinders workshop manual 55/191.

  • Page 56

    60300140( indice a ) 4 cylinders workshop manual 56/191.

  • Page 57

    60300140( indice a ) 4 cylinders workshop manual 57/191.

  • Page 58

    60300140( indice a ) 4 cylinders workshop manual 58/191.

  • Page 59

    60300140( indice a ) 4 cylinders workshop manual 59/191.

  • Page 60

    60300140( indice a ) 4 cylinders workshop manual 60/191.

  • Page 61

    60300140( indice a ) 4 cylinders workshop manual 61/191.

  • Page 62

    60300140( indice a ) 4 cylinders workshop manual 62/191.

  • Page 63

    60300140( indice a ) 4 cylinders workshop manual 63/191.

  • Page 64

    60300140( indice a ) 4 cylinders workshop manual 64/191.

  • Page 65

    60300140( indice a ) 4 cylinders workshop manual 65/191.

  • Page 66: Manuel De Maintenance

    60300140( indice a ) 4 cylinders workshop manual 66/191 manuel de maintenance moteur base m1kz t4.155 4.380 tdi 4.390 tdi t4.155 4.380 tdi 4.390 tdi (part two).

  • Page 67

    60300140( indice a ) 4 cylinders workshop manual 67/191 c c o o n n t t e e n n t t s s : : tightening torques (standard) specific tightening torques characteristics special tooling timing pinions cylinder head injection pump and injector fresh water pump and sender, thermostat pre-heating oil press...

  • Page 68

    60300140( indice a ) 4 cylinders workshop manual 68/191.

  • Page 69: Category

    60300140( indice a ) 4 cylinders workshop manual 69/191 specific standard bolt torque category diameter mm pitch mm tightening torque hex head bolt hex head bolt with collar n.M kgf.Cm n.M kgf.Cm 4t 6 8 10 12 14 16 1 1.25 1.25 1.25 1.5 1.5 5 12.5 26 47 74 115 55 130 260 480 760 1150 6 14 29 53 84 - ...

  • Page 70: Specific Tightening Torques

    60300140( indice a ) 4 cylinders workshop manual 70/191 specific tightening torques tightening torques component to tighten n.M kgf.Cm intake pipe x intake manifold 12 120 injection pump x timing gear casing 21 210 injection pump x injection pump spacer 15 150 injection pump tightening head cap bolt...

  • Page 71: Engine Characteristics

    60300140( indice a ) 4 cylinders workshop manual 71/191 engine characteristics maintenance characteristics maintenance data engine tuning api quality engine oil alternator drive belt sag under a 98 n (10kgf) force new belt worn belt alternator drive belt tension with special maintenance tool sst new...

  • Page 72

    60300140( indice a ) 4 cylinders workshop manual 72/191 cylinder head deformation limit valve seat grinding angle contact angle contact width intake exhaust outside diameter of the cylinder head assembly bolts std limited installed cylinder head gasket thickness hole no. "1" hole no. "3" hole no. "5...

  • Page 73

    60300140( indice a ) 4 cylinders workshop manual 73/191 combustion chamber protrusion thickness shim thickness less 0.03 – more 0.02 mm 0.05 mm 0.10 mm cylinder block cylinder head surface warp limit cylinder bore diameter std (item 1) (mark 2) (mark 3) limit (std) crankshaft bearing trunnion bore d...

  • Page 74

    60300140( indice a ) 4 cylinders workshop manual 74/191 connecting rod piston pin lubrication clearance std limit connecting rod small end inner diameter (reference) std (item 1) (item 2) (item 3) 0.008 – 0.016 mm 0.03 mm 62.014 – 62.020 mm 62.020 – 62.026 mm 62.026 – 62.032 mm crankshaft stop clear...

  • Page 75: 970 312 375

    60300140( indice a ) 4 cylinders workshop manual 75/191 b b a a s s i i c c s s p p e e c c i i a a l l t t o o o o l l s s • alternator belt tension controller - 970 312 375 • valve adjustment tool: - 970 312 377 • injection pump dial gauge support - 970 312 378 • pulley/pinion extractor box (usabl...

  • Page 76

    60300140( indice a ) 4 cylinders workshop manual 76/191.

  • Page 77

    60300140( indice a ) 4 cylinders workshop manual 77/191.

  • Page 78

    60300140( indice a ) 4 cylinders workshop manual 78/191 r r e e m m o o v v i i n n g g t t h h e e t t i i m m i i n n g g b b e e l l t t 1. Remove the timing belt protection cover remove the four assembly bolts, the sealing washers, the two fasteners, the timing belt protection cover and the gask...

  • Page 79

    60300140( indice a ) 4 cylinders workshop manual 79/191 6. Remove the timing belt 7. Remove cam shaft no.2 timing pulley remove the four assembly bolts, the cam shaft no.2 timing pulley flange and the cam shaft no.2 timing pulley. 8. Remove the rocker cover remove the ten assembly bolts, the two att...

  • Page 80

    60300140( indice a ) 4 cylinders workshop manual 80/191 removing the timing pinions (refer to component part illustration for disassembly and reassembly) 1. Remove the timing belt 2. Remove the timing belt and pulleys 3. Remove the cam shaft oil gasket retainer remove the seven assembly bolts and ca...

  • Page 81

    60300140( indice a ) 4 cylinders workshop manual 81/191 c. Remove the thirteen assembly bolts and the two attachment nuts. C. Prise opens the timing cover. D. Remove the o-ring 6. Check the axial clearance of the intermediate toothed wheel use a dial gauge to measure the axial clearance of the inter...

  • Page 82

    60300140( indice a ) 4 cylinders workshop manual 82/191 7. Remove the timing toothed wheels remark: * the alignment mark engraved on the surface of each toothed wheel is directed towards the front of the engine * make sure not to damage the teeth of the toothed wheels when removing and reinstalling ...

  • Page 83

    60300140( indice a ) 4 cylinders workshop manual 83/191 c. Remove the injection pump drive pinion using the special maintenance tool. Remark: * tighten the two assembly bolts of the special maintenance tool sst on more than 8mm * install the special maintenance tool sst so that it is balanced 8. Rem...

  • Page 84

    60300140( indice a ) 4 cylinders workshop manual 84/191 f. Install the intermediate toothed wheel in a vice. Remark: make sure not to damage the toothed wheels during this operation. G. Remove the snap ring with snap ring pliers. H. Remove the following parts: (1) star washer (2) no.2 secondary inte...

  • Page 85

    60300140( indice a ) 4 cylinders workshop manual 85/191 checking the toothed wheel timing 1. Verify intermediate toothed wheels a. Measure the inside diameter of each intermediate toothed wheel using a bore gauge. Intermediate toothed wheel inside diameter: 44.000 – 44.025 mm b. Measure the outside ...

  • Page 86

    60300140( indice a ) 4 cylinders workshop manual 86/191 b. Reinstall the bearing use the special maintenance tool sst and a press to fit the bearing. 4. Check the reactive clearance of the timing toothed wheel teeth install the dial gauge to measure the teething reactive clearance between each tooth...

  • Page 87

    60300140( indice a ) 4 cylinders workshop manual 87/191 replacing the crankshaft oil gasket advice: there are two methods of replacing the oil gasket (a and b) as described below replace the crankshaft oil gasket a. When the timing casing cover is separate from the cylinder block: a. Use a screw dri...

  • Page 88

    60300140( indice a ) 4 cylinders workshop manual 88/191 replacing the injection pump oil seal warning: there are two methods of replacing the oil gasket (a and b) as described below replace the injection pump pinion oil gasket a. When the timing casing cover is separate from the cylinder block: a. U...

  • Page 89: Reinstalling The Timing

    60300140( indice a ) 4 cylinders workshop manual 89/191 reinstalling the timing pinions (refer to component part illustration for disassembly and reassembly) 1. Remove the intermediate toothed wheel a. Install the intermediate toothed wheel in a vice. Warning: install the intermediate toothed wheel ...

  • Page 90

    60300140( indice a ) 4 cylinders workshop manual 90/191 g. Remove the service bolt. H. Reinstall the following parts: (1) intermediate toothed wheel spring (2) no.1 secondary intermediate toothed wheel (3) star washer advice: make the pawls of the toothed wheels coincide with the spring ends. I. Rei...

  • Page 91

    60300140( indice a ) 4 cylinders workshop manual 91/191 a. Reinstall the crankshaft timing toothed wheel a. Verify that the crankshaft assembly key is correctly positioned upwards to reinstall the crankshaft timing toothed wheel on the crankshaft. B. When this is done, the alignment marks of the oil...

  • Page 92

    60300140( indice a ) 4 cylinders workshop manual 92/191 b. Reinstall the cylinder block intermediate toothed wheel shaft. C. Make the timing adjustment marks "5" and "4" of the intermediated toothed wheel assembly, coincide respectively with the timing setting mark "5" of the crankshaft and the timi...

  • Page 93

    60300140( indice a ) 4 cylinders workshop manual 93/191 3. Reinstall the timing casing cover a. Reinstall a new o-ring on the timing casing cover b. Carefully remove any signs of former sealant (fipg) from application surfaces and take care not to dirty the assembly surfaces between the timing casin...

  • Page 94

    60300140( indice a ) 4 cylinders workshop manual 94/191 4. Check the axial clearance of the injection pump drive gear a. Temporarily remove the flange and the no.2 cam shaft timing pulley with the four assembly bolts. B. Move cam shaft no.2 timing pulley from the front to the back and check the axia...

  • Page 95

    60300140( indice a ) 4 cylinders workshop manual 95/191 r r e e f f e e r r t t o o t t h h e e m m a a i i n n t t e e n n a a n n c c e e m m a a n n u u a a l l f f o o r r r r e e i i n n s s t t a a l l l l a a t t i i o o n n a a n n d d s s e e t t t t i i n n g g o o f f t t h h e e t t i i ...

  • Page 96

    60300140( indice a ) 4 cylinders workshop manual 96/191.

  • Page 97

    60300140( indice a ) 4 cylinders workshop manual 97/191 remove the intake manifold a. Disconnect the following wiring connection block * water temperature sender gauge wiring connection block b. Disconnect the flexible pipe from the injection pump. C. Remove the rubber insulating washer, the attachm...

  • Page 98

    60300140( indice a ) 4 cylinders workshop manual 98/191 remark: * this engine is fitted with ceramic glow plugs. To prevent damaging the glow plugs, do not remove them unless it is absolutely necessary. * before removing the glow plugs, refer to the page in this manual discussing how glow plugs must...

  • Page 99

    60300140( indice a ) 4 cylinders workshop manual 99/191 remove the timing belt and the pulleys remove the cam shaft oil seal retainer a. Remove the seven assembly bolts securing the camshaft oil seal retainer to the cylinder head. B. Remove the cam shaft oil seal retainer to separate it. Remove the ...

  • Page 100

    60300140( indice a ) 4 cylinders workshop manual 100/191 remove the cylinder head a. Uniformly and gradually loosen the eighteen cylinder head bolts in several stages and in the order indicated on the illustration. Remark: cylinder head warping or cracking may occur if the bolts are not loosened and...

  • Page 101

    60300140( indice a ) 4 cylinders workshop manual 101/191 advice: remove the valve lifters and thickness shims in the disassembly order. Remove valves a. Compress valve springs using special maintenance tool sst and remove the two half-keys. B. Remove the spring cup retainer, the valve spring, the va...

  • Page 102

    60300140( indice a ) 4 cylinders workshop manual 102/191 advice: lay out the combustion chambers in the logical disassembly order. Remove the semi-circular cap checking, maintenance and reconditioning of component parts of the cylinder head 1. Clean the top of the piston and the top surface of the c...

  • Page 103

    60300140( indice a ) 4 cylinders workshop manual 103/191 c. Clean valve guide bushes use a valve guide bush brush and a solvent to carefully clean the valve guide bushes. D. Clean the cylinder head use a flexible bristle brush and solvent to carefully clean the cylinder heads. 3. Checking the cylind...

  • Page 104

    60300140( indice a ) 4 cylinders workshop manual 104/191 4. Clean the valves a. Use a gasket scraper to separate any accumulation of carbon deposits on the tops of valves. B. Use a metal brush to carefully clean valves. 5. Check rods and valve guides a. Measure the inside diameter of each valve guid...

  • Page 105

    60300140( indice a ) 4 cylinders workshop manual 105/191 6. If necessary, replace valve guide bushes a. Drive out the valve guide using the special maintenance tool sst and a hammer. B. Use an inside micrometer to measure the bore of the cylinder head valve guide bushes c. Select a new valve guide b...

  • Page 106

    60300140( indice a ) 4 cylinders workshop manual 106/191 7. Examine and grind valves a. Only grind valves with an electric grinder if surface pitting or carbon deposits need to be removed. B. Make sure that the angle of the sealing surface of valves is ground to the indicated dimension. Valve sealin...

  • Page 107

    60300140( indice a ) 4 cylinders workshop manual 107/191 8. Examine and clean the valve seats a. Re-bore the valve seats using a 45° carbide reamer and essentially remove the amount of material making it possible to return the seats to good condition. B. Check the bearing surface of the valve on its...

  • Page 108

    60300140( indice a ) 4 cylinders workshop manual 108/191 9. Checking valve springs a. Use a metal square to measure the squareness of the valve springs. Squaring limit: 2.0 mm replace the valve spring if the maximum squaring is exceeded. B. Use a slide caliper to measure the length of the valve spri...

  • Page 109

    60300140( indice a ) 4 cylinders workshop manual 109/191 minimum cam peak height: intake : 54.39 mm exhaust: 55.72 mm replace the camshaft if the height of the cam peak is less than the minimum limit. C. Check cam shaft pivot measure the diameter of the pivot using a micrometer. Nominal diameter: 27...

  • Page 110

    60300140( indice a ) 4 cylinders workshop manual 110/191 e. Remove the bearing caps. F. Measure the widest part of the plastigage. Nominal lubrication clearance: 0.025 – 0.062 mm lubrication clearance limit: 0.10 mm only replace the cam shaft if the maximum limit is exceeded. Replace bearing caps an...

  • Page 111

    60300140( indice a ) 4 cylinders workshop manual 111/191 c. Subtract the valve lifter diameter measurement from the valve bore diameter. Nominal lubrication clearance: 0.038 – 0.063 mm lubrication clearance limit: 0.08 mm replace the valve lifter if the lubrication clearance limit is exceeded. If ne...

  • Page 112

    60300140( indice a ) 4 cylinders workshop manual 112/191 replacing the cam shaft oil gasket advice: there are two methods of replacing the oil gasket (a and b) as described below . Replace the cam shaft oil gasket a. When the cam shaft oil gasket retainer is taken off the cylinder head: a. Use a scr...

  • Page 113

    60300140( indice a ) 4 cylinders workshop manual 113/191 reinstall the cylinder head (refer to the component part illustration for disassembly and reassembly) advice: * carefully clean all parts to assemble. * before starting to assemble the parts, coat all rotating and sliding surfaces with fresh e...

  • Page 114

    60300140( indice a ) 4 cylinders workshop manual 114/191 2. Reinstall the combustion chambers a. Make the combustion chamber position pin coincide with the corresponding recess in the cylinder head. B. Use a plastic mallet to fit the combustion chambers and position them. C. Use a dial gauge to veri...

  • Page 115

    60300140( indice a ) 4 cylinders workshop manual 115/191 c. Lightly strike the end of the valve stem with the plastic mallet to verify that it is correctly positioned. 4. Reinstall the valve lifters with their thickness shims a. Reinstall the valve lifters and thickness shims. B. Check that the valv...

  • Page 116

    60300140( indice a ) 4 cylinders workshop manual 116/191 reinstalling the cylinder head 1. Verify the protruding part of the piston and choose the corresponding cylinder head gasket a. Verify the protruding part of the piston of each cylinder. A. Carefully clean the cylinder block assembly surface w...

  • Page 117

    60300140( indice a ) 4 cylinders workshop manual 117/191 b. Select a new cylinder head gasket. Advice: there are 5 types of cylinder head gaskets (hole no.1 to 5) which are installed in the factory but only 3 types as procurement parts (hole no. "1", "3", and "5") so that when replacing a cylinder h...

  • Page 118

    60300140( indice a ) 4 cylinders workshop manual 118/191 b. Reinstall cylinder head bolts. Advice: * cylinder bolts must be tightened gradually in three stages (stages (b), (d) and (e)). * any broken or deformed cylinder head bolt must be replaced. A. Put a drop of engine oil on bolt threads and und...

  • Page 119

    60300140( indice a ) 4 cylinders workshop manual 119/191 b. Reinstall the five bearing caps at their respective locations. C. Reinstall and evenly tighten the ten bearing cap bolts to the recommended torque, in the tightening order indicated opposite. Recommended tightening torque: 18 n.M (185 kgf.C...

  • Page 120

    60300140( indice a ) 4 cylinders workshop manual 120/191 r r e e f f e e r r t t o o t t h h e e m m a a i i n n t t e e n n a a n n c c e e m m a a n n u u a a l l t t o o a a d d j j u u s s t t v v a a l l v v e e s s * parts must be assembled within 5 minutes of the product being applied. Otherw...

  • Page 121

    60300140( indice a ) 4 cylinders workshop manual 121/191.

  • Page 122

    60300140( indice a ) 4 cylinders workshop manual 122/191.

  • Page 123

    60300140( indice a ) 4 cylinders workshop manual 123/191 remove the injection pipes a. Loosen the two nuts securing fasteners (a) on the intake manifold. B. Use a screwdriver to prise off the fastener (b). C. Loosen the eight injection pipe attachment coupling nuts. D. Remove the four injection pipe...

  • Page 124

    60300140( indice a ) 4 cylinders workshop manual 124/191 advice: remove the injectors in the logical order corresponding to the cylinders injector test injection pressure test a. Install the injector to check on an injector test bench and bleed out the air by the coupling nut precaution: never put a...

  • Page 125

    60300140( indice a ) 4 cylinders workshop manual 125/191 advice: * modifying the thickness of the thickness shim by 0.025 mm makes the injection pressure change by approx. 471 kpa (4.8 kgf/cm²). * only one thickness shim should be used. E. Verify that no fuel drops are found during post-detection dr...

  • Page 126

    60300140( indice a ) 4 cylinders workshop manual 126/191 component part disassembly and reassembly disassembling the injectors disassemble the injectors a. Use special maintenance tool sst to loosen the injector carrier attachment nut. Remark: when disassembling the injector, make sure not to let an...

  • Page 127

    60300140( indice a ) 4 cylinders workshop manual 127/191 b. Remove the carbon deposits accumulated at the end of the injector needle valve with the bar c. Use a brass bristle brush to remove the carbon deposits from the external parts of the injector nozzle (without touching the lapped surface). D. ...

  • Page 128

    60300140( indice a ) 4 cylinders workshop manual 128/191 reassembling the injectors ( refer to the component part illustration for disassembly and reassembly operations) reinstall the injector a. Reinstall the injector carrier attachment nut, the complete injector, the spacing part, the pressure pin...

  • Page 129

    60300140( indice a ) 4 cylinders workshop manual 129/191 start the engine and check whether there are any leaks reinstall the injector pipes a. Temporarily reinstall the four injection pipes and the two fasteners (a) b. Reinstall the two attachment nuts securing the fasteners (a) to the intake manif...

  • Page 130

    60300140( indice a ) 4 cylinders workshop manual 130/191.

  • Page 131

    60300140( indice a ) 4 cylinders workshop manual 131/191 r r e e f f e e r r t t o o t t h h e e m m a a i i n n t t e e n n a a n n c c e e m m a a n n u u a a l l t t o o s s e e t t t t h h e e i i n n j j e e c c t t i i o o n n p p u u m m p p t t i i m m i i n n g g a) immobilize the crankshaf...

  • Page 132

    60300140( indice a ) 4 cylinders workshop manual 132/191 checking the water temperature sensor 1. Remove the water temperature sensor 2. Verify the water temperature sensor use the special maintenance tool sst to verify the resistance between the terminals using an ohmmeter. Resistance: (refer to th...

  • Page 133

    60300140( indice a ) 4 cylinders workshop manual 133/191.

  • Page 134

    60300140( indice a ) 4 cylinders workshop manual 134/191 removing the water pump (refer to component part illustration for disassembly and reassembly) 1. Drain the engine coolant 2. Remove the drive belt and the water pump pulley a. Pull the drive belt as much as possible and loosen the four water p...

  • Page 135

    60300140( indice a ) 4 cylinders workshop manual 135/191 d. Remove the assembly bolt, the water pump cover and the gasket. Reassembling the water pump (refer to component part illustration for removal and reinstallation) 1. Reinstall the complete water pump a. Install a new gasket on the water pump ...

  • Page 136

    60300140( indice a ) 4 cylinders workshop manual 136/191 r r e e f f e e r r t t o o t t h h e e m m a a i i n n t t e e n n a a n n c c e e m m a a n n u u a a l l f f o o r r c c o o o o l l i i n n g g c c i i r r c c u u i i t t b b l l e e e e d d i i n n g g f. Reinstall the alternator with th...

  • Page 137

    60300140( indice a ) 4 cylinders workshop manual 137/191 removing the thermostat (refer to component part illustration for removal and reinstallation) advice: simply removing the thermostat may have a negative effect and cause a decrease to cooling system efficiency. Do not remove the thermostat, ev...

  • Page 138

    60300140( indice a ) 4 cylinders workshop manual 138/191 checking the thermostat check the thermostat advice: the thermostat is marked with a number according to the valve opening temperature. A. Dip the thermostat into water and heat the water gradually. B. Verify the valve opening temperature. Val...

  • Page 139

    60300140( indice a ) 4 cylinders workshop manual 139/191 glow plugs component part (removal and reinstallation) remark: * cylinder head seizing and opening of glow plugs may occur if carbon deposits accumulate. Also, twisting the glow plugs excessively when removing them may cause the ceramic to spl...

  • Page 140

    60300140( indice a ) 4 cylinders workshop manual 140/191 remove the glow plugs a. Remove the four screw insulating washers. B. Remove the four attachment nuts and the connection plate of the glow plugs c. Use a box spanner, depth 12 mm, to remove the four glow plugs. Reinstalling the glow plugs (ref...

  • Page 141

    60300140( indice a ) 4 cylinders workshop manual 141/191 d. Use a 12 mm deep box spanner to reinstall the four glow plugs. Recommended tightening torque: 13 n.M (130 kgf.Cm) checking on board remark: when checking the glow plug resistance, the engine must on board. Avoid removing and reinstalling gl...

  • Page 142: Oil Cooler

    60300140( indice a ) 4 cylinders workshop manual 142/191 oil pressure, oil injectors, oil pump, oil cooler checking the oil pressure 1. Check the engine oil quality check the level of quality of the oil, infiltration of water in the oil, its colour and its lubrication capacity. Drain the engine oil ...

  • Page 143

    60300140( indice a ) 4 cylinders workshop manual 143/191 remove oil jets 1. Drain the engine oil 2. Remove the engine bottom casing 3. Remove the check valve and the oil jets remove the four check valves and the oil jets. Checking oil jets 1. Check the check valves press the check valve with a piece...

  • Page 144

    60300140( indice a ) 4 cylinders workshop manual 144/191 2. Check oil jets check the degree of damage or clogging of oil jets. If necessary, replace it. Reinstalling oil jets (refer to component part illustration for removal and reinstallation) 1. Reinstall oil jets and the check valves a. Make the ...

  • Page 145

    60300140( indice a ) 4 cylinders workshop manual 145/191.

  • Page 146

    60300140( indice a ) 4 cylinders workshop manual 146/191 removing the oil pump (refer to component part illustration for removal and reinstallation) advice: when repairing the oil pump, carefully clean the engine bottom casing and remove the oil strainer to clean it. 1. Drain the engine coolant 2. D...

  • Page 147

    60300140( indice a ) 4 cylinders workshop manual 147/191 10. Remove the oil strainer remove the two attachment bolts, two nuts and the oil strainer and gasket 11. Remove the oil pump timing casing before removing the two nuts securing the injection pump flange on the timing casing, verify that the t...

  • Page 148

    60300140( indice a ) 4 cylinders workshop manual 148/191 disassembling the oil pump (refer to component part illustration for removal and reinstallation) 1. Remove the driven rotor. 2. Remove the discharge valve. Remove the threaded cap, the gasket, the spring and the discharge valve. Checking the o...

  • Page 149

    60300140( indice a ) 4 cylinders workshop manual 149/191 c. Verify the rotor side clearance use a set of thickness shims and a ground precision rule to measure the side clearance between the rotor and the ground precision rule. Nominal side clearance: 0.030 – 0.090 mm limit side clearance: 0.15 mm r...

  • Page 150

    60300140( indice a ) 4 cylinders workshop manual 150/191 reinstalling the oil pump ( refer to component part illustration for removal and reinstallation) reinstalling the oil pump (timing casing) a. Remove all signs of former sealant (fipg) and take care not to dirty contact surfaces of the timing c...

  • Page 151

    60300140( indice a ) 4 cylinders workshop manual 151/191 e. Reinstall the distribution casing. F. Make the mark made on the driven pinion of no.1 balancing shaft correspond with mark "2". G. Make the mark made on the oil pump drive pinion coincide with the mark made on the timing casing. H. Reinstal...

  • Page 152

    60300140( indice a ) 4 cylinders workshop manual 152/191 c. Coat two or three threads of the threaded section of the tapered threaded plug with sealant. Adhesive product: loctite 242 or similar product. D. Reinstall the tapered threaded plug reinstall the oil strainer reinstall a new gasket at the o...

  • Page 153

    60300140( indice a ) 4 cylinders workshop manual 153/191 reinstall the water pump reinstall the alternator and the alternator attachment plate reinstall the alternator adjustment bar reinstall the adjustment bar with the assembly bolt and the lock bolt. Recommended tightening torque: 21 n.M (210kgf....

  • Page 154

    60300140( indice a ) 4 cylinders workshop manual 154/191.

  • Page 155

    60300140( indice a ) 4 cylinders workshop manual 155/191 removing the oil radiator and the discharge valve 1. Drain the coolant from the engine 2. Remove the timing belt 3. Remove the injection pipelines 4. Remove the injection pump 5. Remove the oil level gauge and its guide a. Remove the attachmen...

  • Page 156

    60300140( indice a ) 4 cylinders workshop manual 156/191 9. Separate the oil radiator from the oil radiator casing remove the four nuts, the oil radiator, and the two seals from the oil radiator cover. 10. Remove the discharge valve 11. Remove the oil drain plug checking the oil cooler and the disch...

  • Page 157

    60300140( indice a ) 4 cylinders workshop manual 157/191 reinstalling the oil radiator and the discharge valve (refer to component part illustration for removal and reinstallation) 1. Reinstall the engine oil plug recommended tightening torque: 8 n.M (80 kgf.Cm) 2. Reinstall the discharge valve rein...

  • Page 158

    60300140( indice a ) 4 cylinders workshop manual 158/191 5. Reinstall the oil cooler and the oil cooler casing assembly a. Reinstall a new gasket, the oil radiator casing assembled to the oil radiator with the thirteen bolts. Recommended tightening torque: 13 n.M (130 kgf.Cm) 6. Reinstall the oil le...

  • Page 159

    60300140( indice a ) 4 cylinders workshop manual 159/191.

  • Page 160

    60300140( indice a ) 4 cylinders workshop manual 160/191 checking the turbo charger 1. Check rotation of the impeller take the edge of the turbine impeller and rotate it. Verify that the impeller turns without offering any resistance. If the impeller does not turn, or if it turns and rubs, replace t...

  • Page 161

    60300140( indice a ) 4 cylinders workshop manual 161/191.

  • Page 162

    60300140( indice a ) 4 cylinders workshop manual 162/191 removal preparation 1- remove the engine fly wheel 2- install the complete engine on an appropriate support in order to disassemble it 3- remove the timing belt and the timing pulleys 4- remove the cylinder head 5- remove the alternator and th...

  • Page 163

    60300140( indice a ) 4 cylinders workshop manual 163/191 disassembling the cylinder block (refer to component part illustration for disassembly and reassembly) 1. Remove the rear oil gasket retaining cage remove the five assembly bolts and the rear oil gasket retaining cage. 2. Measure the axial cle...

  • Page 164

    60300140( indice a ) 4 cylinders workshop manual 164/191 5. Measure the connecting rod axial clearance measure the connecting rod axial clearance using a dial gauge while moving the connecting rod forwards and backwards. Nominal axial clearance: 0.10 – 0.30 mm axial clearance limit: 0.40 mm replace ...

  • Page 165

    60300140( indice a ) 4 cylinders workshop manual 165/191 f. Put a piece of plastigage over the crank pin of the crankshaft. G. Reinstall the connecting rod cap with the two assembly bolts. Recommended tightening torque: first stage: 29 n.M (300kgf.Cm) 2nd stage: turn 90° remark: make sure not to tur...

  • Page 166

    60300140( indice a ) 4 cylinders workshop manual 166/191 numbered mark cylinder block 1 2 3 crankshaft 1 2 3 1 2 3 1 2 3 shell bearing used 2 3 4 3 4 5 4 5 6 example: cylinder block "2" + crankshaft "1" = total number 3 (use shell bearing "3") reference connecting rod small end inner diameter: mark ...

  • Page 167

    60300140( indice a ) 4 cylinders workshop manual 167/191 advice: * never separate the shell bearing from the connecting rod and the connecting rod cap. * lay out piston-connecting rod assemblies in the disassembly order. 8. Measure the crankshaft axial clearance use a dial gauge to measure the crank...

  • Page 168

    60300140( indice a ) 4 cylinders workshop manual 168/191 c. Lift and remove the crankshaft. Advice: keep the upper shell bearings and the upper end shims in place in the cylinder block. D. Carefully clean the pivot and the shell bearings. E. Examine each pivot and the shell bearings for signs of pit...

  • Page 169

    60300140( indice a ) 4 cylinders workshop manual 169/191 j. Measure the widest part of the plastigage. Lubrication clearance nominal: 0.036 – 0.054 mm dimension less than 0.25 and dimension less than 0.50: 0.037 – 0.077 mm clearance limit: 0.10 mm advice: if the cylinder block sub-assembly is replac...

  • Page 170

    60300140( indice a ) 4 cylinders workshop manual 170/191 thickness of the nominal shell bearing centre wall: mark "2" 2.479 – 2.482 mm mark "3" 2.482 – 2.485 mm mark "4" 2.485 – 2.488 mm mark "5" 2.488 – 2.491 mm mark "6" 2.491 – 2.494 mm k. Carefully remove any signs of plastigage 10. Remove the cr...

  • Page 171

    60300140( indice a ) 4 cylinders workshop manual 171/191 checking the cylinder block 1. Clean the cylinder block a. Remove all signs of gasket use a scraper to remove all signs of sealant material, gasket, especially on the cylinder block assembly surface . B. Clean the cylinder block carefully clea...

  • Page 172

    60300140( indice a ) 4 cylinders workshop manual 172/191 use a cylinder diameter and measure the diameter of the bores of the cylinders at positions a, b and c and in the axial and stop directions. Nominal diameter: nominal mark "1" 96.000 – 96.010 mm mark "2" 96.010 - 96.020 mm mark "3" 96.020 – 96...

  • Page 173

    60300140( indice a ) 4 cylinders workshop manual 173/191 disassembling connecting-rod piston assemblies 1. Verify the assembly clearance between the piston and the pin move the piston backwards and forwards on its pin. Replace the piston and its pin as a matched assembly when the clearance is record...

  • Page 174

    60300140( indice a ) 4 cylinders workshop manual 174/191 c. Gently strike the piston pin to drive it from the piston using a plastic mallet and a brass mandrel advice: * piston and pin make up a matched pair. * lay out pistons, piston pins, rings and connecting rods in groups in compliance with the ...

  • Page 175

    60300140( indice a ) 4 cylinders workshop manual 175/191 2. Verify the pistons and the piston segments a. Verify the piston diameter and the piston lubrication clearance. Advice: there are three nominal piston diameters, respectively identified "1", "2" and "3". The mark is stamped on the top surfac...

  • Page 176

    60300140( indice a ) 4 cylinders workshop manual 176/191 compression ring and oil scraper ring. Use a set of thickness shims and measure the gap between the new ring and the side of the piston groove. Piston groove spacing: compression ring 0.060 – 0.100 mm oil scraper ring 0.020 – 0.060 mm replace ...

  • Page 177

    60300140( indice a ) 4 cylinders workshop manual 177/191 4. Checking the connecting rods a. Checking connecting rod straightness check the straightness of connecting rods with a set of thickness shims by installing them on the connecting rod square. A) check whether there is any bending. Bending lim...

  • Page 178

    60300140( indice a ) 4 cylinders workshop manual 178/191 c. Subtract the piston pin diameter measurement from the connecting rod small end bush internal diameter measurement. Nominal lubrication clearance: 0.008 – 0.016 mm lubrication limits clearance: 0.03 mm if the lubrication clearance is greater...

  • Page 179

    60300140( indice a ) 4 cylinders workshop manual 179/191 e. Fit the connecting rod small end nozzle in the connecting rod using special maintenance tool sst and a press. F. Use the piston pin bore reamer to ream the connecting rod small end nozzle to bring it to the nominal dimension between the noz...

  • Page 180

    60300140( indice a ) 4 cylinders workshop manual 180/191 checking balancing shafts check right and left balancing shafts a. Use a bore checker to measure the inside diameter of the balancing rod bearing. Bearing inside diameter (measured from the front of the engine). No.1: 42.000 – 42.020 mm no.2: ...

  • Page 181

    60300140( indice a ) 4 cylinders workshop manual 181/191 cylinder bore advice: * ream the four cylinders to bring them to the top diameter of the piston external diameter. * replace worn rings to match them with the pistons at top diameter. 1. Select pistons at top dimension top dimension piston dia...

  • Page 182

    60300140( indice a ) 4 cylinders workshop manual 182/191 checking and reconditioning of the crankshaft 1. Measure the crankshaft out of roundness a. Install the crankshaft on v blocks b. Use a dial gauge to measure the circular out of roundness of the centre pivot . Out of roundness limit: 0.06 mm r...

  • Page 183

    60300140( indice a ) 4 cylinders workshop manual 183/191 replacing the crankshaft oil gasket advice: there are two methods for replacement of oil seals (a and b) as described below: replacing the crankshaft rear oil gasket a. When the rear oil gasket retaining cage is separated from the cylinder blo...

  • Page 184

    60300140( indice a ) 4 cylinders workshop manual 184/191 reassemblying the piston- connecting rod assemblies 1. Reinstall the piston-connecting rod assembly a. Reinstall the new spring on one side of the piston pin hole. B. Gradually heat the piston until it reaches a temperature of approximately 80...

  • Page 185

    60300140( indice a ) 4 cylinders workshop manual 185/191 c. Use the expanding ring spacing tool and install the two compression rings, taking care to position their identification marks upwards. Identification mark: top compression ring: 1n compression ring: 2n d. Position the rings so that the ring...

  • Page 186

    60300140( indice a ) 4 cylinders workshop manual 186/191 reassembling the cylinder block (refer to component part illustration for disassembly and reassembly) advice: * carefully clean all parts to reinstall. * before reassembling parts, coat all sliding and rotating surfaces with fresh engine oil. ...

  • Page 187

    60300140( indice a ) 4 cylinders workshop manual 187/191 4. Reinstall the crankshaft on the cylinder block 5. Reinstall the thrust bearing bushes a. Push the crankshaft forward (backward). B. Reinstall the two stop bushes under the crankshaft no.5 bearing cap on the cylinder block, taking care to or...

  • Page 188

    60300140( indice a ) 4 cylinders workshop manual 188/191 a. Lightly coat the threading and the top of crankshaft bearing cap assembly bolts with engine oil. B. Reinstall and evenly tighten the ten assembly bolts of the crankshaft bearing caps to the torque indicated in compliance with the numbered t...

  • Page 189

    60300140( indice a ) 4 cylinders workshop manual 189/191 8. Reinstall crankshaft bearing caps a. Reinstall the connecting rod cap on the crankshaft. A. Match the numbered caps with numbered connecting rods b. Make the front mark correspond to the front and reinstall the connecting rod cap. B. Reinst...

  • Page 190

    60300140( indice a ) 4 cylinders workshop manual 190/191 9. Reinstall the rear gasket retaining cage a. Remove all signs of the material making up the gasket (fipg) taking care not to let oil fall onto the contact surfaces of the gasket retaining cage and the cylinder block. * use a razor blade and ...

  • Page 191

    60300140( indice a ) 4 cylinders workshop manual 191/191 post-assembly 1. Reinstall the plug 2. Reinstall the motor suspension attachment plate 3. Reinstall the water temperature sensor 4. Reinstall the thermostat and the water intake pipes 5. Reinstall the oil radiators 6. Reinstall the engine lowe...