Table of Contents
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This manual gives the main instructions on how to repair LOMBARDINI diesel engines LDW 1503 - 1603 - 2004 -
2004/T - 2204 - 2204/T, fluid cooling circuit
General service manual notes ......................................................................................................................................... 3
Glossary and terminology ................................................................................................................................................ 3
Preface ............................................................................................................................................................................. 3
1
GENERAL REMARKS AND SAFETY INFORMATION ........................................................................12 - 17
California Proposition 65 WARNING ................................................................................................................................ 9
Explanation of the safety pictograms that can be found on the engine or in the Workshop manual .............................. 12
General remarks and safety information .......................................................................................................................... 8
General safety during operating phases ........................................................................................................................ 10
Indications regarding the points on the engine where the safety pictograms are placed ............................................... 12
Information and safety signals ....................................................................................................................................... 11
Regulations for lifting the engine ...................................................................................................................................... 9
Safety and enviromental impact ..................................................................................................................................... 10
Safety regulation .............................................................................................................................................................. 8
2
TECHNICAL INFORMATION ...............................................................................................................18 - 27
Manuifacturer and Motor identification data ................................................................................................................... 14
Name plate for EPA rules applied on rocker-arm cap .................................................................................................... 15
Overall dimensions .................................................................................................................................................... 22-24
Performance diagrams .............................................................................................................................................. 20-21
Possible causes and trouble shooting ....................................................................................................................... 18-19
Technical data ........................................................................................................................................................... 16-17
3
MAINTENANCE - PRESCRIBED LUBRICANT - REFILLING ............................................................28 - 31
ACEA regulations - sequences ...................................................................................................................................... 29
Coolant ........................................................................................................................................................................... 31
Extraordinary maintenance ............................................................................................................................................ 28
Fuel recommendation .................................................................................................................................................... 31
International specifications ............................................................................................................................................. 29
Lubricant ........................................................................................................................................................................ 29
Ordinary maintenance .................................................................................................................................................... 28
Prescribed lubricant ....................................................................................................................................................... 30
Routine engine maintenance ......................................................................................................................................... 28
SAE classification ........................................................................................................................................................... 29
4
DISASSEMBLY/REASSEMBLY ...........................................................................................................34 - 67
Air filter clogging indicator .............................................................................................................................................. 36
Assembling and tightening the cylinder head on engines with hydraulic tappets .......................................................... 49
Camshaft ........................................................................................................................................................................ 61
Camshaft bushing replacement ..................................................................................................................................... 62
Camshaft end play ......................................................................................................................................................... 66
Camshaft gear - Speed governor counter weights ........................................................................................................ 60
Camshaft journals and bushings in model LDW 1503 -1603 ......................................................................................... 62
Camshaft journals and bushings in models LDW 2004-2204-2004/T-2204/T ................................................................ 62
Camshaft timing ............................................................................................................................................................. 64
Center main bearings ..................................................................................................................................................... 52
Check clearance between main bearings and journals .................................................................................................. 53
Checking camshaft bushing internal diameter ................................................................................................................ 62
Checking main journals and crank pins ......................................................................................................................... 56
Connecting rod ............................................................................................................................................................... 50
Connecting rod alignment .............................................................................................................................................. 51
Connecting rod and piston pin ....................................................................................................................................... 50
Connecting rod weights .................................................................................................................................................. 50
Connecting rod/piston assemblies ................................................................................................................................. 51
Cooling fan ..................................................................................................................................................................... 37
Crankshaft end play ....................................................................................................................................................... 54
Crankshaft for engines with dynamic equalizer (only four-cylinder engines). ................................................................ 57
Crankshaft front and rear oil seal ................................................................................................................................... 55
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CHAPTER INDEX
Workshop Manual LDW CHD _ cod.
ED0053031210 - 1° ed_rev. 00
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