3239063 - 1004E20 engine - dismantle and re-build following operation 1004e10 - wash and check dismantled parts - re-fit cylinder head and oil sump - does not include repairs to cylinder head and auxiliary unit
Dismantling
(
Reassembling
)
Rotate the crankcase through 180° on the
overhauling stand.1. Undo the bolts (1a) and remove the alternator (1b).
| Name | Connector |
|---|
| 1b | Alternator | A10 |
2. Undo bolts (2a) and remove rear alternator bracket (2b).3. Undobolts (3a) and remove intermediate shaft mount (3b).
1. Undo bolts (1a) and remove air conditioner compressor (1b).2. Undo the bolts (2a) and remove the air conditioner compressor
mounting (2b).3. Remove the oil filter.4. Undo the bolts (4a) and remove the heat exchanger (4b) complete
with pipes.
1. Fit the tool.
| Name | Country |
|---|
| 1 | Counter-torque | 1.820.624.000 |
1. Undo the bolts (1a) and remove the crankshaft pulley (1b).2. Remove the timing belt.3. Undo bolt (anticlockwise) (2a) and remove toothed drive pulley
(2b).
1. Undo the bolts (1a) and remove the flywheel (1b).2. Remove the tool.
| Name | Country |
|---|
| 2 | Counter-torque | 1.820.624.000 |
1. Undo bolts (1a) and remove the power unit mount, timing gear
side (1b).2. Undo bolts (2a) and remove fixed timing belt tensioner (2b).3. Undo bolts (3a) and remove the automatic auxiliary drivebelt
tensioner (2b).4. Undo bolts (4a) and remove the mount (4b) together with power
steering pump (4c) and timing belt tensioner.
1. Undo the bolts (1a) and remove the crankcase front cover with
built in oil pump (1b) and intake housing.Remove the gasket.
Fit the tool.
| Name | Country |
|---|
| - | Flange | 1.820.618.000 |
Rotate the crankcase through 180° on the
overhauling stand.1. Undo the bolts (1a) and remove the connecting rod cap (1b).2. Remove the lower big end bearing shell.3. Remove the connecting rod - piston assembly.4. Remove the upper big end bearing shell.Proceed in the same way with the removal
of the pistons and connecting rods for the remaining cylinders.Remove the tool.
| Name | Country |
|---|
| - | Flange | 1.820.618.000 |
5. Undo the bolts (5a) and remove the crankcase rear cover (5b)
with built-in oil seal.Check that the crankshaft end float is
within the recommended values using a magnetic base fitted with
a dial gauge.
| Measurement | | Value |
|---|
| - | End float (mm) | | 0.049 - 0.211 |
If the end float of the crankshaft is not
within the recommended values, when refitting, reface the seat in the
cylinder block/crankcase and use suitable oversize thrust washers.6. Undo bolts (6a) and remove connecting rod caps (6b).7. Remove the lower main journal half-bearings.8. Remove the crankshaft.9. Remove the upper main journal half-bearings.10. Remove the thrust washers.11. Undo the bolts (11a) and remove the jets (11b) from the crankcase.12. Undo the bolt (12a) and remove the rpm and timing sensor (12b).13. Remove the mininum engine oil pressure warning light sensor.
1. Undo bolts (1a) and remove flange (1b) with the oil return pipe
to the sump from the turbocharger.2. Undo connector (2a) and remove the oil supply pipe to the turbocharger
(2b).3. Undo bolts (3a) and remove the turbocharger bracket (3b).
Rotate the cylinder block/crankcase through
90° on the overhauling stand.Undo the bolts and remove the crankcase
from the mounting brackets, then place it on a workbench.Unscrew the bolts and remove the flywheel
protection. - 1028H60 piston, pin set - replaceUndo the bolts and remove the oil inlet
from the oil pump. - 1084B18 engine oil pump, removed - check at bench
Reassembling
(
Dismantling
)
Wash the dismantled components.Fit the water/oil sealing plugs in the
crankcase, using suitable fitting tools.Lubricate all the components for the mechanical
couplings using engine oil.Check that there are no superficial cracks
or grooves in the cylinder head support surface.Check that the planarity of the cylinder
head support surface is within the recommended values; if this is
not the case, regrind the cylinder head support surface.
| Measurement | | Value |
|---|
| - | Flatness of cylinder head supporting surface
(mm) | | < 0.1 |
1. Measure the diameter of the cylinder liners/bores following the
diagram illustrated.
| Measurement | | Value |
|---|
| 1 | Cylinder bore diameter (mm) | Category B | 82.010 - 82.020 |
| Category C | 82.020 - 82.030 |
| Classe A | 82.000 - 82.010 |
Check that the conicity of the cylinder
liners/bores is within the recommended values.
| Measurement | | Value |
|---|
| - | Cylinder bore taper (mm) | | < 0.005 |
Check that the ovality of the cylinder
liners is within the recommended values.
| Measurement | | Value |
|---|
| - | Cylinder bore ovalization (mm) | | < 0.05 |
If the diameter of the cylinder liners/bores
is not within the recommended values, ream the cylinder liners/bores
in accordance with the recommended oversizes. | In the case of reaming, all liners/bores
must be the same oversize. |
| Measurement | | Value |
|---|
| - | Cylinder liner oversize (mm) | | 0.1 |
1. Fit the bearing caps. | The bearing caps have progressive
references (from zero to four starting from the front of the engine)
which define their fitting position. |
1. Tighten the bearing cap bolts (1a) to the recommended torque
using the angular tightening tool (1b).
| Fastening | Component | Ø | Value(daNm) |
|---|
| 1A | Bolt | MAIN BEARING CAPS | M12 | (Engine crankcase side) 2.4 ÷ 2.6 +100? |
| Name | Country |
|---|
| 1b | Protractor | 1.860.942.000 |
2. Check that the diameter of the bearing seats is within the recommended
values.
| Measurement | | Value |
|---|
| 2 | Main bearing seat diameter (mm) | | 63.691 ÷ 63.732 |
Check that the crankshaft lubrication ducts
are free from deposits.Check that the diameter of the main journals
is within the recommended values.
| Measurement | | Value |
|---|
| - | Main bearing journal diameter (mm) | Category B | 59.987 ÷ 59.993 |
| Category C | 59.982 ÷ 59.986 |
| Classe A | 59.994 ÷ 60.000 |
If the diameter of the main journals is
not within the recommended values, regrind them in accordance with the
recommended undersize.
| Measurement | | Value |
|---|
| - | Main bearing journal undersize (mm) | | 0.127 |
| Undersizes for big end bearings
above the value mentioned adversely affect the structural strength
of the crankshaft (as a result of contact between the tool and the
connectors). As far as the above is concerned, if the regrinding requires
undersizes above 0.127 mm, the crankshaft must be replaced with
a new one ordered from the Parts Dept. The half-bearings used for undersizes
above 0.127 mm should no longer be requested from the Parts Dept.
(even if the number is still shown). |
Check that the diameter of the crankpins
is within the recommended values.
| Measurement | | Value |
|---|
| - | Crankpin diameter (mm) | Category B | 50.793 - 50.799 |
| Category C | 50.787 - 50.793 |
| Classe A | 50.799 - 50.805 |
If the diameter of the crankpins is not
within the recommended values, regrind them in accordance with the
recommended undersize.
| Measurement | | Value |
|---|
| - | Crankpin undersize (mm) | | 0.127 |
| Undersizes for bearings above
the value mentioned adversely affect the structural resistance of
the crankshaft (as a result of contact between the tool and the
connectors). As far as the above is concerned, if the regrinding
requires undersizes above 0.127 mm, the crankshaft must be replaced
with a new one ordered from the Parts Dept. The half-bearings used
for undersizes above 0.127 mm should no longer be requested from
the Parts Dept. (even if the number is still shown). |
Check that the inner diameter of the small
end bushes is within the recommended limits; if this is not the case,
replace the worn small end bush (refer to op.
1028H58 connecting rod small end bush - replace
).
| Measurement | | Value |
|---|
| - | Inner diameter (mm) | | 26.006 - 26.012 |
Check that the inner diameter of the small
end bushes is within the recommended limits; if this is not the case,
replace the piston complete with rings, gudgeon pin and bushes.
| Measurement | | Value |
|---|
| - | Piston bush bore (mm) | | 25.999 - 26.004 |
Check that the outer diameter of the gudgeon
pins is within the recommended values. if this is not the case, replace
the worn gudgeon pins.
| Measurement | | Value |
|---|
| - | Outer diameter (mm) | | 25.982 - 25.988 |
Fit the seals in the cylinder liner/bore
and check that the opening between the ends is within the recommended
values; if this is not the case, replace the piston seals.
| Measurement | | Value |
|---|
| - | 1° sealing ring gap (mm) | | 0.25 - 0.40 |
| Measurement | | Value |
|---|
| - | 2° sealing ring gap (mm) | | 0.25 - 0.50 |
| Measurement | | Value |
|---|
| - | Scraper ring gap (mm) | | 0.25 - 0.50 |
Check that the outer diameter of the pistons
is within the recommended values; if this is not the case, replace the
piston complete with seals and gudgeon pin.
| Measurement | | Value |
|---|
| - | Outer diameter (mm) | Category B | 81.930 ÷ 81.940 |
| Category C | 81.940 ÷ 81.950 |
| Classe A | 81.920 ÷ 81.930 |
| The measurement should be made
perpendicular to the gudgeon pin axis, 8 mm from the skirt lower
edge. |
1. Check that the end float (1a) between the second piston ring
(1b) and the groove in the piston (1c) is within the recommended
limits.
| Measurement | | Value |
|---|
| 1a | End float (mm) | | 0.020 ÷ 0.060 |
Check that the end float between the oil
scraper ring and the groove in the piston is within the recommended
limits.
| Measurement | | Value |
|---|
| - | End float (mm) | | 0.030 - 0.065 |
1. Fit the caps (1b) on the connecting rods (1a) and fix them tightening
the bolts (1c) to torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| 1c | Bolt | BIG END BEARING CAPS | M9 | 2.4 ÷ 2.6 + 60? |
Use the tool for angular tightening of
the connecting rod cap bolts.
| Name | Country |
|---|
| - | Protractor | 1.860.942.000 |
2. Check that the diameter of the big end is within the recommended
values; if this is not the case, replace the connecting rods.
| Measurement | | Value |
|---|
| 2 | Big end diameter (mm) | | 53.883 ÷ 53.923 |
- 1028H60 piston, pin set - replace - 1084B18 engine oil pump, removed - check at benchFit the inlet and fix it using the bolts.Check that there are no signs of seizing
on the flywheel ring gear teeth; if this is not the case, replace
it.Fit the flywheel protection to the crankcase
and tighten the bolts.Fit the cylinder block/crankcase on the
rotating stand and fix it using the bolts.Fit the turbocharger bracket and secure
it using the bolts.Fit the engine oil delivery pipe to the
turbocharger and tighten the connector.Fit the flange together with the oil return
pipe from the turbocharger to the sump and secure it using the bolts.Fit the minimum engine oil pressure warning
light sensor and tighten it to the recommended torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| - | - | OIL PRESSURE W/L | - | 1.9 - 2.3 |
Fit the rpm and timing sensor and fix it
with its bolts.Fit the jets in the cylinder block/crankcase
and fix them using the bolt.Fit the thrust washers on the third main
bearing.Starting from engine number 02030116, main
journal half-bearings have been fitted on crankshafts which have
been selected so that the matching clearance is optimum. | The crankshaft is supplied,bythe
Parts Dept.,without the appropriate half-bearingsfor 'normal' dimension
main journals and crank pins; it is therefore necessary to select
the main journal half-bearings to be fitted identifying the grade
for each main journal and crank pin for the new crankshaft. |
The following is needed for selecting the
main journal half-bearings: the code number stamped on the flywheel;the paint mark, if present, next to the
main journals.Below is an example of the identification
of main journal grades.
1. Crank pin identification number: the number on the left refers
to the first timing side bearing; the final 'N' is a code that does
not matter for 4 cylinder engines; for 5 cylinder engines the numerical
code for the 5th crank pin is found in place of the 'N'.2. Main journal identification code: the first number on the left
refers to the first timing side bearing; the final 'N' is a code
that does not matter for 4 cylinder engines; for 5 cylinder engines
the numerical code for the 6th main journal is found in place of
the 'N'.3. Set of numbers (if present), in groups of two digits, which indicate
the dimensions (thousandth part) of the main journals: the first
two numbers on the left refer to the first bearing on the timing
side. | Only use the codes in the key,
all other codes on the flywheel should not be used. |
For the identification of the main journal
grade, reer to the numerical code for reference 2.In the case of the example, the numbers
11111N indicate that all five bearings are Grade A (red colour)
as described below.A further method for identifying the grade
of the bearings is to read reference 3 in the figure (if present).In the case of the example, the number
94 (first on the left) corresponds to the dimension 59.994 for the
first bearing on the timing side which identifies Grade A (red colour);
the same method can be used for all the other groups of two digits
for the same reference 3 (97 - 95 - 95 - 94). Grade A bearing - Normal, diameter 59.994
60.000 mm, RED paint mark, code number 1 (94 00)°Grade B bearing - Normal, diameter 59.987
59.993 mm, BLUE paint mark, code number 2 (87 93)°Grade C bearing - Normal, diameter 59.982
52.986 mm, YELLOW paint mark, code number 3 (82 86)°Grade D bearing - Undersize, diameter 59.867
59.873 (*) mm, BROWN paint mark, code number 6 (67 73)°Grade E bearing - Undersize, diameter
59.860 59.866 (*) mm, GREEN paint mark, code 7 (60 66)°Grade F bearing - Undersize, diameter 59.855
59.859 (*) mm, BLACK paint mark, code number 8 (55 59)° (*) 0.127 mm undersize (°) Last two numbers (thousandth part)
of the dimensions of the main journalsIf a crankshaft is being used where the
maximum bearing undersize through regrinding is 0.127 mm, then the
grade should be selected by measuring the dimensions of the diameter
of the bearing with reference to the above. Having defined the grade and colour for
each new or reground crankshaft bearing, it is necessary to select the
pair and the size for the bearings which should be the same colour
as the corresponding bearing; at the Parts Dept. it is possible
to go back to the part no. of the pair of half-bearings required. The above is designed to ensure the optimum
operating clearance for all bearings.Lastly, we wish to point out that, generally,
the clearance between the main journal and the half-bearing, obtained
using the selection method indicated, should be between the following
values:Minimum: 0.025 mm - Maximum: 0.052 mm;
this value can be measured, as a final check, using the Plastic
Gauge. Fit the main journal half-bearings in the
cylinder block/crankcase.Fit the crankshaft on the cylinder block/crankcase.1. Fit the main journal caps complete with half-bearings. | The bearing caps have progressive
references (from zero to four starting from the front of the engine)
which define their fitting position. |
1. Tighten the bearing cap bolts (1a) to the recommended torque
using the angular tightening tool (1b).
| Fastening | Component | Ø | Value(daNm) |
|---|
| 1a | Bolt | MAIN BEARING CAPS | M12 | 2.4 ÷ 2.6 + 100? |
| Name | Country |
|---|
| 1b | Protractor | 1.860.942.000 |
1. Fit the tool.
| Name | Country |
|---|
| 1 | Flange | 1.820.618.000 |
Rotate the crankshaft using the tool fitted
previously until the cylinder concerned is at B.D.C.1. Fit the connecting rod-piston assembly (1a), complete with half-bearing,
using the tool (1b). | To select the connecting rod half-bearings, follow
the procedure described previously for the main journal half-bearings. |
| The piston - connecting rod assemblies
are fitted in the cylinder block/crankcase so that the explosion
chamber in the piston is facing the inlet side. |
2. Fit the big end bearing cap (2a) complete with half-bearing and
fix it using the bolts (2b) without tightening them. | The connecting rod caps are fitted
so that the number stamped on them is facing the same side as the
one stamped on the big end (inlet side). |
Work in the same way when refitting the
pistons and connecting rods for the remaining cylinders.
1. Tighten the bearing cap bolts (1a) to the recommended torque;
use the tool (1b) for the angular tightening.
| Fastening | Component | Ø | Value(daNm) |
|---|
| 1a | Bolt | BIG END BEARING CAPS | M9 | 2.4 - 2.6 + 60° |
| Name | Country |
|---|
| 1b | Protractor | 1.860.942.000 |
Remove the tool.
| Name | Country |
|---|
| - | Flange | 1.820.618.000 |
1. Fit the crankcase rear cover (1a) with the oil seal integrated
using the tool (1b).
| Name | Country |
|---|
| 1b | Fitting tool | 1.820.619.000 |
2. Tighten the bolts securing the crankcase rear cover to the recommended
torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| 2 | Bolt | FLYWHEEL SIDE COVER | M6 | (Engine crankcase side) 0.8 ÷ 1.0 |
Remove the tool.
| Name | Country |
|---|
| - | Fitting tool | 1.820.619.000 |
1. Fit the crankcase front cover with the built-in oil pump (1a),
complete with intake (1b).2. Tighten the bolts for the crankcase front cover complete with
oil pump to the recommended torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| 2 | Bolt | CRANKSHAFT FRONT COVER | M6 | (engine crankcase side) 0.8 ÷ 1.0 |
Apply sealant to the entire perimeter of
the crankcase sump.
| Type | Component | Name | Qty. |
|---|
| - | Silicon sealant | OIL SUMP | - | - |
1. Fit the crankcase sump.2. Tighten the side bolts (2a) for the crankcase sump to the recommended
torque using the tool (2b).
| Fastening | Component | Ø | Value(daNm) |
|---|
| 2a | Side bolts | OIL SUMP | M6 | (engine crankcase side) 0.7 ÷ 0.9 |
| Name | Country |
|---|
| 2b | Key | 1.822.144.000 |
3. Tighten the front and rear bolts (3a) for the crankcase sump
to the recommended torque using the tool (3b).
| Fastening | Component | Ø | Value(daNm) |
|---|
| 3a | Front and rear bolt | OIL SUMP | M8 | (Engine crankcase side) 2.1 ÷ 2.6 |
| Name | Country |
|---|
| 3b | Key | 1.822.145.000 |
Rotate the engine through 180° on the
overhauling stand.1. Fit the tool.
| Name | Country |
|---|
| 1 | Counter-torque | 1.820.624.000 |
2. Fit the flywheel (2a) and tighten the bolts (2b) to the recommended
torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| 2b | Bolt | FLYWHEEL | M12 | 13.6 - 16.8 |
1. Fit toothed drive pulley (1a) and tighten bolt (anticlockwise)
(1b) to torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| 1b | Bolt | TOOTHED DRIVE PULLEY | M16 | 30.6 - 37.8 |
Remove the tool.
| Name | Country |
|---|
| - | Counter-torque | 1.820.624.000 |
Fit the oil supply pipe to the turbocharger
on the crankcase.Fit the power steering pump with its bracket.Fit the fixed timing belt tensioner and
secure it using the bolts.Fit the timing end power unit mount .Fit the auxiliary shaft belt tensioner
and fix it using the relevant bolt.Place the heat exchanger, complete with
pipes, back in its housing.Tighten the connector securing the heat
exchanger to the specified torque. | For versions prior to engine n° 1586000,
replace the connector securing the heat exchanger with the one supplied
by the Parts Dept. which has a tapered spring washer in addition
to the O-Ring. |
| Fastening | Component | Ø | Value(daNm) |
|---|
| - | Connector | ENGINE OIL HEAT EXCHANGER | - | 6.0 |
Fit the oil filter, tightening it fully
by hand, after having lubricated the gasket using engine oil.Fit the air conditioner compressor mount
and secure using the relevant bolts.Fit the air conditioning compressor and
fix it without tightening the bolts.Fit the intermediate shaft support and
fix it using the bolts.Fit the bolt securing the intermediate
shaft mounting to the crankcase sump.Fit the alternator rear bracket and secure
with bolts, without tightening.Fit the alternator and fix it using the
bolts.Tighten the rear alternator bracket bolts.Fit the support complete with pressure
pump and fix it without tightening the side bolts.1. Measure the projection of the pistons at two points at 180° on
the gudgeon pin axis using the tool and take the average of the
two figures measured for each piston.
| Name | Country |
|---|
| 1 | Dial gauge mounting | 1.820.253.000 |
Select the correct size cylinder head gasket,
according to the maximum value of the averages of the projection
for each individual piston.
| Measurement | | Value |
|---|
| - | Maximum average piston projection (mm) | | 0.795 - 0.881 |
| Gasket thickness (no references)
(mm) | 1.55 - 1.65 |
| Measurement | | Value |
|---|
| - | Maximum average piston projection (mm) | | 0.881 - 0.967 |
| Gasket thickness (one reference)
(mm) | 1.65 - 1.75 |
| Measurement | | Value |
|---|
| - | Maximum average piston projection (mm) | | 0.987 - 1.055 |
| Gasket thickness (two references)
(mm) | 1.75 - 1.85 |
Position the cylinder head centring bushes
on the cylinder block/crankcase.Fit the cylinder head gasket selected. | ASTADUR type cylinder head gaskets
are fitted. The material from which these gaskets are made undergoes
a polymerization process during the operation of the engine so that
they become considerably harder during usage. |
In order for the polymerization process
to take place it is necessary to:
- keep the gasket in its sealed container until fitting
- not lubricate or get oil on the gasket and the contact
surfaces.
Position the cylinder head on the crankcase.1. Tighten the cylinder head bolts (1a) to the recommended torque,
using the angular tightening tool (1b). Follow the order shown
in the diagram for each sequence.
| Fastening | Component | Ø | Value(daNm) |
|---|
| 1a | Bolt | CYLINDER HEAD | M10 | (Engine block side) 2.0 + 4.5 + 90° + 90°
+ 90° |
| Name | Country |
|---|
| 1b | Protractor | 1.860.942.000 |
Fit the tappet cover, complete with seal,
and fix it tightening the bolts to torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| - | Bolt | CAM COVER | M6 | 0.8 ÷ 1.0 |
Fit the pressure pump mounting front bolts
and tighten them together with the side bolts fitted previously.1. Undo the oil pump bolt shown in the diagram.Temporarily fit the timing drive belt on
the drive pulley.2. Fit the tool (2a) and secure it with the calibrated screw (2b) | To allow the engagement of the
locating dowel on the timing drive belt drive pulley in the opening
in the tool, rotate the crankshaft using small movements. |
| Name | Country |
|---|
| 2a | Template | 1.860.905.000 |
| Name | Country |
|---|
| 2b | Calibrated screw | 1.860.905.010 |
1. Rotate the driven pulley so that the timing references line up.2. Completely fit the timing belt.3. Use a screwdriver to lever in the hole (3a) until the reference
on the tensioner (3b) lines up with the reference hole (3c) and,
in this position, tighten the belt tensioner nut (3d) to torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| 3d | Nut | MOBILE TIMING TENSIONER | M10 | (cylinder head side) 4.2 ÷ 5.2 |
Remove the tools.
| Name | Country |
|---|
| - | Template | 1.860.905.000 |
| Name | Country |
|---|
| - | Calibrated screw | 1.860.905.010 |
Tighten the bolt on the oil pump removed
previously.
Rotate the crankshaft through two revolutions.Check once again that the timing references
and the tensioning references on the timing belt tensioner coincide.Fit the timing drive belt guards and fix
them using the bolts.Fit the power unit reaction rod mounting
bracketFit the crankshaft pulley and secure it
with the bolts.Fit the exhaust manifold gasket.Fit the exhaust manifold, complete with
turbocharger and E.G.R. valve, and fix it tightening the nuts to torque.
| Fastening | Component | Ø | Value(daNm) |
|---|
| - | Nut | EXHAUST MANIFOLD/S | M8 | 2.1 - 2.6 |
Connect the oil intake pipe to the turbocharger.Connect the oil return pipe to the sump
to the turbocharger.Fit the protection for the oil return pipe
from the turbocharger to the sump and secure it using the bolts.Tighten the nut securing the exhaust manifold
bracket to the crankcase.Fit the gasket.Connect the exhaust gas recirculation pipe
and secure using the nuts.Tighten the bolt securing the exhaust gas
pipe recirculation bracket.Fit the turbocharger protective heat shield
and secure using the bolts.Connect the water outlet pipe connector
from the heat exchanger to the manifold.Tighten the bolt securing the water outlet
pipe from the heat exchanger.Connect the water supply pipe to the heat
exchanger.Fit the bracket.Replace the oil vapour separator complete
with bracket and secure using the nuts.Connect the condensed oil recovery pipe
to the crankcase sump.Connect the oil vapour recovery pipe to
the crankcase.Connect the fuel supply pipe to the pressure
pump.Place the pipe from the pressure pump to
the single fuel manifold back in its housing and fix it using the connectors
without tightening them.Tighten the connector for the pipe from
the pressure pump to the single fuel manifold, pump side, to the recommended
torque using a suitable spanner.
| Fastening | Component | Ø | Value(daNm) |
|---|
| - | Connector | PRESSURE PUMP LINE TO FUEL MANIFOLD | M12 | (Pressure pump side) 2.2 |
Tighten the connector for the pipe from
the pressure pump to the single fuel manifold, fuel manifold side, to
the recommended torque using a suitable spanner.
| Fastening | Component | Ø | Value(daNm) |
|---|
| - | Connector | PRESSURE PUMP LINE TO FUEL MANIFOLD | M14 | (Fuel manifold side) 2.2 |
Fit the engine oil dipstick assembly and
secure it using the bolts.Fit the engine component single drive belt
guide pulley and fix it using the bolt.Fit the single engine component belt by
adjusting the automatic belt tensioner using a wrench. - 1004D40 engine - position on stand and remove
