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Vectra Fitness 175 Engine Technical Manual

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  • Page 2 ENGINE TECHNICAL MANUAL...
  • Page 3 Page No. : 2...

  • Page 4: Table Of Contents

    CONTENTS Section Description Page No. GENERAL INFORMATION ENGINE VIEW … ENGINE SERIAL NUMBER LOCATION … THREADS AND TORQUE SPECIFICATION … TECHNICAL DATA … MANUFACTURING DATA AND DIMENSIONS … OPERATION AND MAINTENANCE … PREVENTIVE MAINTENANCE … FUEL SYSTEM … COOLING SYSTEM – WATER PUMP …...
  • Page 5 Page No. : 4...

  • Page 6: General Information

    Section A GENERAL INFORMATION SAFETY PRECAUTIONS: TOOLS AND MEASURING EQUIPMENT The safety measures that always should be sure that necessary tools performed in order to avoid risks that is always equipments are available before starting work. present. Use special tools where they are specified.

  • Page 7: Engine View

    Section B ENGINE VIEW Page No. : 6...
  • Page 8 ENGINE VIEW Page No. : 7...

  • Page 9: Engine Serial Number Location

    ENGINE SERIAL NUMBER LOCATION The Engine Number is stamped on the Camshaft Tunnel of the Block T SJ436 E 00027 T SJ 4 3 6 E 000 27 Turbocharged Serial Number Simpsons Export 'J' Series 4 Cylinder 3.6 Litres Engine Cubic Capacity When requesting information regarding the engine, please quote complete engine number.

  • Page 10: Threads And Torque Specification

    SIMPSONS ‘SJ’ SERIES DIESEL ENGINES ALL THREADS USED IN T SJ436 E ENGINES ARE METRIC SERIES Except for the components indicated below : Bolt and Nut, connecting rod 7/16" – 20 UNF De-aerator plug on water outlet body … … 1/4"...

  • Page 11: Technical Data

    Section C TECHNICAL DATA Engine Type 4 Cylinder, 4 Stroke, Inline, Water Cooled Aspiration Turbo Charged Combustion Direct Injection Bore (Nominal dia.) 3.74 inch (95.0 mm) Stroke 5.00 inch (127 mm) Cubic Capacity 0.952 gal (3.6 Lts.) Compression ratio 18.3 : 1 Rotation Anti-clock wise from the flywheel end Firing order...

  • Page 12: Manufacturing Data And Dimensions

    MANUFACTURING DATA AND DIMENSIONS The following data of clearances and tolerances are given as a guide for personnel engaged in major overhauls and the figures are those used in the factory for production purposes. Cylinder Block Height of cylinder block (Top to bottom faces) …...
  • Page 13 Piston Rings Top Compression … Chromium inlaid, Half Keystone (Symetric barrel on periphery) 2nd Compression … Cast Iron, Taper land 3rd Oil Control … Conformable oil control ring Piston Ring Width Top ring width … 0.118 inch (3.0 mm) (Nominal) 2nd ring width …...
  • Page 14 Crankshaft Refer Figure from Page No. 70 A – Main Journal Dia. (Std.) … 2.748 / 2.749 inch (69.81 / 69.83 mm) B – Crank Pin Dia. (Std.) … 2.248 / 2.249 inch (57.11 / 57.13 mm) C – Main Journal length Nos. 2 and 4 …...
  • Page 15 Running Clearance – All Camshaft Journals … 0.004 / 0.0055 inch (0.10 / 0.141 mm) Oil way for rocker shaft lubrication … From head to 1st rocker bracket top face Cam Lift – Inlet … 0.251 inch (6.3814 mm) – Exhaust …...
  • Page 16 Rocker Shaft Outside Diameter … 0.748 / 0.747 inch (19.000 / 18.979 mm) Rocker Lever Bush Bore Diameter … 0.748 / 0.750 inch (19.01 / 19.06 mm) Running clearance of Bush on Shaft … 0.004 / 0.003 inch (0.01 / 0.08 mm) Timing Gears Crankshaft gear –...
  • Page 17 Lubricating System Pressure Lubricating Oil Pressure … 29.87 / 59.74 psi (2.1 / 4.2 kg per cm²) at maximum engine speed and normal working temperature Lub. Oil delivery at 800 pump rpm with pressure setting 40 lbf/ in² (2.8 Kg/cm²) For Balancer type …...
  • Page 18 Starter Motor Make … Lucas-TVS. India Type … 3SM114. 12 V Solenoid operated No. of teeth on pinion … 10 Starter Cable Resistance … 0.002 ohms maximum Rotation … Normally clockwise NOTE : The above electrical data is general and can vary with individual application Cold Starting Aid Device …...

  • Page 19: Operation And Maintenance

    Section D OPERATION AND MAINTENANCE PREPARATION FOR STARTING Check the coolant level with radiator. Check the oil level in engine sump. Check the fuel oil level in the tank. Check the fan belt tension. Check the battery is fully charged and that all electrical connections are properly made and all circuits in order.
  • Page 20 TO STOP THE ENGINE 10. Carry out test to check general performance of engine. Turn start switch to the ‘Off’ position. 11. Check engine mounting bolts for tightness. Note : A mechanical stop lever is also provided in the FIP as an alternative in case of fault in 12.
  • Page 21 light is extinguished. Do not rapidly accelerate the engine after initial start; allow it to run at slow speed for approximately two minutes to ensure good oil circulation before accelerating to higher speeds. Note: Where a preservative is used in the lubricating oil sump, this should be drained off and replaced by normal lubricant prior to restarting the engine at the end of the storage period.

  • Page 22: Preventive Maintenance

    Section E PREVENTIVE MAINTENANCE DAILY OR EVERY 8 HOURS OR 240 KMS COOLING SYSTEM MAINTENANCE : WHICHEVER OCCURS FIRST: Check the condition of coolant every year at the Keep Engine Clean. beginning of winter Check level of coolant. Renew the coolant every 2 years. Check oil level in sump.
  • Page 23 CHECKING ENGINE OIL Park the vehicle on a level surface Turn off the engine Note: If the engine has not been operated for a prolonged period, run the engine for 10 minutes in fast idle. Turn off the engine and wait for 5 minutes and then check the oil level.
  • Page 24 FUEL FILTER ELEMENT To Renew Close the fuel tank cock (1), If fuel tank is above the engine level. Clean the filter assembly externally Drain the fuel from fuel filter by loosening the drain plug (3). Remove and discard the filter/ filters. Apply clean engine oil to the surface of the rubber gasket (oil seal) in the new fuel filter.
  • Page 25 FAN BELT ADJUSTMENT Press down the belt with thumb at the centre of the longest free length and check the deflection. The correct deflection with moderate thumb pressure 4.5 kgf (45N) is 10 mm ( 0.4"). To Adjust Loosen the alternator bottom mounting bolt/nut (2) and the adjusting link fixing bolt/nut (1).
  • Page 26 ROCK COVER To Remove Remove Turbocharger hose pipe connections to inlet manifold. Disconnect the flexible hose (2) from rocker cover. Remove rocker cover securing nuts (1) shown in figure – (Use Spanner 13mm A/F). Lift off the rocker cover along with the joint. To Refit Check the condition of the rocker cover and joint.
  • Page 27 HIGH PRESSURE PIPES To Remove Remove turbocharger hose pipe connection to inlet manifold. Disconnect the flexible hose (1) from rocker cover to oil separator assembly. Remove the high pressure pipe clamps (2). Refit turbocharger hose pipe connection. Loosen the high pressure pipe line union nuts from automiser side (19 mm A/F) and fuel pump side (17 mm A/F).

  • Page 28: Fuel System

    Section F FUEL SYSTEM VE TYPE FUEL INJECTION PUMP TYPICAL FUEL PIPE LAYOUT (BOSCH VE TYPE PUMP) Page No. : 27...
  • Page 29 BOSCH VE TYPE FUEL INJECTION PUMP (FIP) TO CHECK & RESET FIP TIMING (VE Pump) Disconnect the battery terminals. Disconnect the throttle linkages. Remove hose connection from Turbocharger to Inlet manifold. Remove breather hose from tappet cover and remove the tappet cover. Turn the engine and bring No.
  • Page 30 14. Tighten the FIP retaining nuts to the torque 13 Nm (1.3 kgf.m). 15. Remove the dial gauge with adopter and fit back the setscrew (screw plug). 16. Remove 12V source connection from KSB unit and give regular connection. 17. Refit tappet cover and breather hose. 18.
  • Page 31 11. Loosen and remove the three nuts (1) and washers securing the flange of the FIP to the timing case. 12. Remove the Fuel Injection Pump. Caution: After the removal of FIP, don’t rotate the engine. The pump setting is to be carried out by trained personnel only.
  • Page 32 AUTOMISER To Remove Loosen the clip and disconnect the flexible hose from rocker cover to oil mist separator assembly. Remove Turbocharger hose connection to Inlet manifold. Remove LDA Pipe connection between FIP and Inlet manifold. Loosen the cap nuts and remove the high pressure pipes.
  • Page 33 FUEL LIFT PUMP Electrically operated Fuel lift pump is supplied along with the Tractor by the OEM A Hand primer is provided on the Primary fuel filter mounting bracket for Hand priming to Air vent in the fuel system. Page No. : 32...

  • Page 34: Cooling System - Water Pump

    Section G COOLING SYSTEM – WATER PUMP TO REMOVE AND REFIT FAN Loosen and remove the set screws (1) securing the fan and remove the fan and fan extension. If necessary, fit the set screws to retain the fan extension to the pulley hub. Clean the fan extension and fan thoroughly.
  • Page 35 Note: The water pump shaft and bearings are integral component cannot dismantled. TO RE-ASSEMBLE WATER PUMP With the shorter end foremost, press the shaft and bearing assembly into the rear of the water pump. Press the unitised seal into shaft. Fit the impeller with blades inwards on to the rear of the shaft.

  • Page 36: Front Oil Seal

    Section H FRONT OIL SEAL CRANKSHAFT PULLEY To remove Remove the fan belt. Lock the flywheel so as to avoid the engine rotation. Loosen the bolt mounting the pulley on the crankshaft and remove. Pull the pulley out of crankshaft, if required use suitable puller as shown.
  • Page 37 TIMING CASE COVER To Renew the Crankshaft Front Oil Seal Remove the crankshaft pulley. Carefully pull out the oil seal from the timing case cover using a suitable drift. Clean the timing case cover seal area. Position the new seal in the timing case cover with the lip of the seal towards the inside of the timing case cover.

  • Page 38: Fly Wheel And Rear End Oil Seal

    Section I FLY WHEEL AND REAR END OIL SEAL FLY WHEEL To remove Remove the starter assembly. Rotate the crankshaft bring the hole (A) to the top position. With suitable chisel unfold the tab washers (1) on the flywheel mounting setscrews (2). Loosen the setscrews uniformly.
  • Page 39 FLY WHEEL RING GEAR To Renew the Flywheel Ring Gear Remove the flywheel. Check the position of the chamfer on the teeth. Break and remove the ring gear (1) using chisel and hammer. Ensure no damages to the flywheel. Warning: Wear eye protection while removing flywheel ring gear from flywheel.
  • Page 40 To Fit oil seal Clean the oil seal housing fixing surface. Fit the rear end oil seal retainer housing on to the cylinder block rear face with joint aligning with the dowl pin and tighten all bolts 13 mm A/F as per sequence using a torque wrench.

  • Page 41: Lub Oil Sump, Balancer Unit And Oil Pump

    Section J LUB OIL SUMP, BALANCER UNIT (MID MOUNTED) AND OIL PUMP SUMP To remove Operate the engine until it is warm. Loosen and remove the sump drain plug (1). Disconnect Turbo oil drain pipe connection. Drain the oil completely. If necessary remove the dipstick and dipstick tube.
  • Page 42 BALANCER UNIT AND OIL PUMP (MID MOUNTED) T SJ 436 E Engines are fitted with mid mounted balancer unit. Balancer unit is secured to the engine crank case by six set screws (Torque 55MM). Balancer unit is driven by the engine crank gear through an idler gear. Lub oil pump is an integral part of balancer unit and it is driven by a drive shaft of balancer unit.
  • Page 43 BALANCER UNIT (MID MOUNTED) To remove Bring piston of 1st cylinder to TDC (Pointer on timing cover in line with TDC mark on crank pulley). Drain oil in sump Remove turbo charger oil drain pipe Remove the sump assembly from the engine. Remove lub oil pump suction pipe from balancer unit.
  • Page 44 OIL STRAINER AND SUCTION PIPE The oil strainer is an integral part of the suction pipe. No regular services are necessary but wash the strainer when it is removed. The suction pipe is normally a short pipe which is fastened to the balancer frame. OIL PUMP Note: The oil pump is an integral part of the balancer assembly, it should not be repaired.
  • Page 45 Pull and remove the outer rotor (1). Thoroughly clean all parts and inspect the rotors for cracks or scores. Install the outer rotor in the pump body making sure the chamfered edge of the outer rotor enters the pump body first. Check the clearance between the inner rotor (2) and the outer rotor at all points 0.01/ 0.06 mm (0.0004/ 0.0023")

  • Page 46: Cylinder Head

    Section K CYLINDER HEAD Nut Cylinder Head Cover Bracket Rocker Shaft Stud Cylinder Head Cover Tappet Cylinder Head Cover Push Rod Joint Cylinder Head Cover 10. Spring Rocker Shaft Screw Rocker Bracket 11. Lever Rocker Screw Tappet Adjusting 12. Shaft Rocker Page No.
  • Page 47 OIL MIST SEPARATOR ASSEMBLY To Remove and Refit Loosen the clips (5). Remove the flexible hose (2) from rocker cover to oil mist separator assembly (1). Remove the oil drain hose (3) from oil mist separator assembly. Remove the hose (4) from air cleaner to oil mist separator assembly.
  • Page 48 INLET & EXHAUST MANIFOLD Setscrew Exhaust Manifold Intake manifold Washer Washer Exhaust Manifold Setscrew Intake Manifold Joint Exhaust Manifold Washer Joint Inlet manifold 10. Plug (For Therostart Assembly) Page No. : 47...
  • Page 49 INLET MANIFOLD To Remove Remove hose pipe and clamps connecting turbocharger air out let to inlet manifold. Remove booster control device (LDA) pipe connection from inlet manifold. Remove high pressure pipes. Remove oil mist separator (PCV), hose pipe connections to cylinder head cover, oil drain to sump etc.
  • Page 50 INLET MANIFOLD To Remove EXHAUST MANIFOLD To Remove Remove exhaust pipe elbow from turbocharger assembly. Remove hose pipe connecting air cleaner and inlet manifold from turbocharger. Release oil supply and drain pipe flange from turbocharger bearing housing. Remove four nuts and take out turbocharger assembly from exhaust manifold flange and cover turbo openings.
  • Page 51 ROCKER SHAFT ASSEMBLY To Remove Shaft Rocker Assembly Remove Turbocharger to inlet manifold hose connection. Remove the rocker cover. Loosen evenly and gradually the screws securing rocker shaft brackets to cylinder head; begin with the end and move towards the centre. 4. Remove the screws and washers and lift off the rocker assembly.
  • Page 52 VALVE SPRINGS To Remove the Valve Spring Remove the rocker cover. Remove the rocker assembly. Rotate the crankshaft in the normal direction of rotation until the relevant piston is approximately at top dead centre (TDC). Fit the valve spring Compressor (1) as shown. Compress the valve spring and remove the cotters.
  • Page 53 CYLINDER HEAD Stud - Water Outlet Connection 11. Plate Engine Lifting Rear Water Outlet Connection 12. Valve Spring Joint - Connection 13. Cap Valve Spring Body Water Outlet 14. Collets Valve Spring Thermostat 15. Setscrew Valve Seat – Inlet Valve 16.
  • Page 54 CYLINDER HEAD ASSEMBLY To Replace Cylinder Head Gasket Disconnect the battery terminals. Drain coolant from radiator and cylinder block. Detach coolant hose connections from thermostat housing on front of cylinder head. Remove air cleaner and hose connection. Disconnect cold starting equipment connections (if fitted).
  • Page 55 CYLINDER HEAD SETSCREW RELEASING SEQUENCE CYLINDER HEAD SETSCREW TIGHTENING SEQUENCE TORQUE TO BE APPLIED A (11 ~ 15) – M10x1 – TORQUE 65 Nm (8.3 kgm) Sl. No.1 ~ 10 - HOLES – M12 X 1.5 – IN THE FIRST TURN TORQUE to 45 Nm IN THE SECOND TURN – 180 ANGULAR TORQUE IN THE THIRD TURN – 180 ANGULAR TORQUE Page No. : 54...
  • Page 56 21. Place the cylinder head properly on locating dowels. Cylinder Head Tightening Procedure : (a) Screw the cylinder head mounting bolts and tighten the setscrews uniformly in sequence (as shown in page 55) to 45 Nm (33 lbf.ft) in first turn using torque wrench.
  • Page 57 CYLINDER HEAD DISMANTLING To Remove Valves Remove cylinder head. Remove the valves by depressing the spring cap and spring by means of a valve spring compressor. Refer page 52. Remove the two half conical collets. Remove the spring caps, springs and washers. Take out the valves.
  • Page 58 Valve Guides Examine the valve guides for wear, if necessary replace with new guides. When pressing in a valve guide, care must be taken to ensure it is fitted the right way round. Both the guides inlet and exhaust are interchangeable. The stepped end of this guide should protrude 9.95/10.05mm (0.3917/0.3956 inch) above cylinder head top face.

  • Page 59: Aspiration System

    ASPIRATION SYSTEM WARNING: Turbochargers operate at high speed and at high temperatures. Keep fingers, tools and other objects away from the inlet and outlet ports of the turbocharger and avoid contact with hot surfaces. A turbocharger is fitted between the exhaust and induction manifolds.
  • Page 60 ASPIRATION SYSTEM To Fit: Remove the covers from the pipes, manifolds and the turbocharger. Check that the turbocharger inlets and outlets are clean and free from restriction and that the turbocharger shaft rotates freely. Also check that the openings in the manifolds and the exhaust pipe are clean and free from restriction.
  • Page 61 Where the exhaust elbow has a flange, clean the threads of the studs in the flange of the turbocharger. Apply a suitable compound to the studs to prevent seizure of the nuts. Put a new gasket in position on the flange and fit the elbow. Fully tighten the setscrews that hold the elbow. Slide the hose on the induction manifold on to the compressor outlet and tighten the hose clips.
  • Page 62 ASPIRATION SYSTEM towards the compressor casing. Fit the casing to the turbocharger and align the marks on the To Clean the Impeller and the Compressor Casing casing and on the bearing housing. Fit the circlip Generally, it is not necessary to remove the turbo in its groove.

  • Page 63: Timing Case And Drive

    Section L TIMING CASE AND DRIVE To Remove the Timing Gears and Hubs Fix the oil pipe and banjo bolt to the lower idler gear retaining plate. The closed end of the oil Remove the drive belt, Alternator Assembly, pipe must locate in a hole in the back of the Crankshaft pulley and Timing cover.
  • Page 64 CAMSHAFT GEAR AND CAMSHAFT To Remove the Camshaft Gear and Camshaft Remove the rocker shaft assembly. Remove the timing case cover. Release the securing bolt 15 mm A/F from the camshaft and remove the camshaft gear. Remove camshaft thrust washer. Lift all the tappets and keep them in lift position using tappets holding sticks.
  • Page 65 To Replace the Camshaft Gear and Camshaft Lift all the tappets and keep them in lift position using tappet holding sticks and carefully fit the camshaft and gear continually turning the camshaft. Take care not to damage the journals, cams and tappets. Fit camshaft thrust washer. Camshaft Thrust The camshaft end float is taken up by camshaft thrust washer (sintered) which is retained by...
  • Page 66 REMOVE THE TIMING CASE Remove the timing case cover as previously detailed. Release remove rocker shaft assembly. Remove the sump. Remove timing case bottom cover. Release the banjo bolt fitted on lower idler hub and remove the oil pipe. Remove the locking washer, idler gear and spigot. Remove the camshaft gear, thrust washer and camshaft.
  • Page 67 TIMING When the engine is timed at the factory, timing marks are stamped on the gears. To Reset Engine Timing Remove atomisers. Bring No. 1 piston to T.D.C. on its compression stroke. The T.D.C that has been obtained can be checked by examining the valve position.

  • Page 68: Pistons And Connecting Rods

    Section M PISTONS AND CONNECTING RODS PISTON The Alfin Pistons are of special light aluminium alloy with a re-entrant bowl in the crown. They are secured to the connecting rods by means of fully floating gudgeon pins which work in thin wall steel backed lead bronze lined bushes fitted in the small ends of the connecting rods. The connecting rod big end bearings are of the thin wall type consisting of a thin steel shell lined with aluminium tin.
  • Page 69 INSPECTION Check each piston for scuffing, scoring, wear and other defects. Replace any piston that is defective. Check each piston rings for breakage, damage and abnormal wear. Replace the defective rings. If piston to be replaced, replace piston with ring assembly.
  • Page 70 REASSEMBLY Install New Small End Bushes The small end bushes are a press fit in the connecting rods. Press out the old bushes using a suitable drift. Press in the new bushes using a suitable dolly/ drift, aline ensuring that the oil holes in the bushes coincide with the holes in the top of the connecting rods.
  • Page 71 Fit the outer C.I. ring over the coil spring. Ensure coil spring gets seated properly inside the ring groove and the coil spring latch is on the opposite side of the ring open end gap. Using piston ring expander, install the No.2 ring (Chromium inlaid, Half Keystone with ‘Top’...

  • Page 72: Crankshaft Assembly

    Section N CRANKSHAFT ASSEMBLY Piston Assembly Setscrew Pulley Retaining Bush – Connecting Rod Small End Cap Connecting Rod Connecting Rod 10. Main Bearing Bolt Connecting Rod Cap 11. Thrust Washer Main Bearing Crankshaft 12. Ring Starter Gear Crankshaft 13. Flywheel Pulley 14.
  • Page 73 CRANKSHAFT ASSEMBLY The crankshaft runs in five pre-finished re-placeable shell bearings lined with aluminium tin/copper lead. The seal at the rear end of the crankshaft is a cassette type seal fitted in a one-piece housing. REMOVAL Remove the fan belt, water pump, crankshaft pulley, timing case front cover and idler gears. Remove the starter motor. Remove the flywheel, flywheel housing, rear end oil seal housing and oil seal.
  • Page 74 INSPECTION Crankshaft Check the crankshaft journals and pins for damage, uneven wear and cracks. Check the oil holes for restriction. Inspect the crankshaft journal for taper and out-of- round. Crankshaft journal outer diameter: Standard 69.81/ 69.83 mm (2.748/ 2.479 in.) Crankpin outer diameter: Standard 57.11/ 57.13 mm ( 2.248/ 2.249 in.) Main Bearing and Connecting Rod Bearing Visually inspect bearing for pealing, melting, seizure and improper contact, replace if defective.
  • Page 75 REASSEMBLY Ensure that no blockage in oil-ways. Clean block main bearing housing and place half bearing in position. Spray oil on the bearing and Place crankshaft in position. Lightly smear the two upper thrust washers with lubricating oil and slide in to the recesses provided on either side of the rear main bearing housing, with the steel side or plain surface of the washers towards the housing.

  • Page 76: Cylinder Block And Liners

    Section O CYLINDER BLOCK AND LINERS Gasket Cylinder Head Setscrew main bearing cap Liner Cylinder Block 10. Main Bearing Cap – Rear Plug 11. Adapter Lub. oil Pressure gauge Water Inlet Connection 12. Drain Plug Setscrew 13. Rear End Oil Seal & Housing Main Bearing Cap – Front 14. Plate Flywheel Housing Adapter Main Bearing Cap – Inter 15.
  • Page 77 The cylinder block is fitted with renewable thin wall cast iron dry cylinder liners. The cast iron cylinder liners are an interference fit and are not recommended to rebore. When they are worn to an extent whereby engine performance is affected, they should be renewed. To Remove Liners Remove cylinder head, pistons, connecting rod assemblies, crankshaft and all component parts of the cylinder block as detailed in the...
  • Page 78 Preparation for Fitting New Liners After removal of the old liners, the parent bore must be thoroughly cleaned. Ensure that the new liner is thoroughly cleaned and dried. To Fit New Liners (Unbored Cast Iron Liners) Lubricate the outside diameter of the liners with engine oil.

  • Page 79: Lubrication System

    Section P LUBRICATION SYSTEM Page No. : 78...

  • Page 80: Approved Lubricating Oils

    LUBRICATING OIL SPECIFICATION Use only a good quality lubricating oil to the relevant specification as shown in the table below. Attention : The type of lubricating oil to be used may be affected by the quality of the fuel which is available. Always ensure that the correct viscosity grade of lubricating oil is used for the ambient temperature range in which the engine will run as shown in the chart below. Lubricating oil specification Recommended SAE viscosity grades (1) Not recommended for the first 25/50 hours of Ambient temperature operation, nor for light load applications.

  • Page 81: Electrical Equipment

    Section Q ELECTRICAL EQUIPMENT STARTER MOTOR To Remove Disconnect the battery. Disconnect the starter motor cables. Release the fasteners and remove the starter motor and, if necessary, remove the distance piece. To Fit Fit the starter motor and tighten the fasteners. Connect the starter motor cables.

  • Page 82: Trouble Shooting

    Section R TROUBLE SHOOTING The following table lists problems and their possible causes with recommended action. IMPORTANT : When attending/performing a repair, the cause of the problem must also be investigated and corrected to avoid repeat failures. Page No. : 81...
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  • Page 91 ASPIRATION SYSTEM Turbocharger Faults The chart below is given to assist in the correct diagnosis of turbocharger faults. If the inside of the induction manifold is wet, check that there is not a fuel leak from the fuelled starting aid, if there is one fitted. Problems Possible causes code numbers Not enough power 1, 4, 5, 6, 7, 8, 9, 10, 11, 18, 20, 21, 22, 25, 26, 27, 28, 34, 35, 36 Black smoke 1, 4, 5, 6, 7, 8, 9, 10, 11, 18, 20, 21, 22, 25, 26, 27, 28, 34, 35, 36 Blue smoke 1, 2, 4, 6, 8, 9, 17, 19, 20, 21, 22, 30, 31, 32, 34 High lubricating oil consumption...
  • Page 92 ASPIRATION SYSTEM Element of the air filter dirty. Restricted crankcase breather. Element of the air filter missing, leaking or not sealing correctly, loose connection to turbocharger. Internal distortion or restriction in pipe from air filter to turbocharger. Damaged/restricted crossover pipe, turbocharger to induction manifold. Restriction between air filter and turbocharger. Restriction in exhaust system. Turbocharger loose or clamps/setscrews loose. Induction manifold cracked or loose, flanges distorted. 10. Exhaust manifold cracked or loose, flanges distorted. 11. Restricted exhaust system. 12. Delay of lubricating oil to turbocharger at engine start. 13. Insufficient lubrication. 14. Dirty lubricating oil. 15. Incorrect lubricating oil. 16.

  • Page 93: Service Tools

    Section S SERVICE TOOLS Page No. : 92...
  • Page 94 SERVICE TOOLS Page No. : 93...
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