Godiva PowerFlow 17/10 Workshop Manual
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Godiva PowerFlow 17/10 Workshop Manual

Portable fire pump
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Table of Contents

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Portable Fire Pump
Workshop Manual
Publication: GP/291
Issue 4, January 2016

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May 22, 2025

I’m after the flow chart for a 1700 The one with the 1.8 ford engine in

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Summary of Contents for Godiva PowerFlow 17/10

  • Page 1 Portable Fire Pump Workshop Manual Publication: GP/291 Issue 4, January 2016...

  • Page 2: Amendment Record

    Addition of Adhesives, Solvents and 2013 Greases List Impeller nut – torque figure of 45Nm January 35, 63 2016 specified ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 3: Table Of Contents

    ........................23 ATTERY Safety ..............................23 Terminals ............................24 Charging ............................24 Gauges .............................. 24 FAULT TRACING ......................24 ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 4 15. E ......................74 LECTRICAL YSTEM 16. E ..................... 80 NGINE AINTENANCE 17. A ............... 80 DHESIVES OLVENTS AND REASES ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 5 Page intentionally left blank. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 6: Important Notes

    The serial number, model specification and year of manufacture can be found on the instrument panel on the top of the pump. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 7: Safety Relevant Data

    ENSURE that exhaust fumes are safely ventilated. DO NOT SMOKE while operating the unit. DO NOT inhale fumes or gases. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 8: Environmental Protection

    End of life disposal – please dispose of the pump according to local regulations relating to recycling of materials. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 9: General Data

    180Kg 177Kg Note: The wet weight is inclusive of the full capacity of engine oil, fuel, coolant and battery. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 10: C Onstruction M Aterials

    45°C maximum for water in pump Dangerous goods identification category Class 9 UN3166 Data source: Godiva 17/10, 12/10 light alloy pump with 4" suction; 2 x 2½" delivery valve (typical connector configuration) ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the...

  • Page 11: R Ecommended O Perating P Ressure

    Connect the plug to the equipment according to the equipment manufacturer’s instructions. Associated Publications Publication Part Operation Manual GP/282 Pump Parts List GP/292 ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 12: G Eneral A Rrangement - L Eft H And V Iew ( From Front )

    Carrying handle – shown in stored position Suction tube (shown with Round Thread connection) Engine exhaust Hand pulled recoil starter (behind volute) ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 13 General Arrangement - Right Hand Side (from rear) Air filter Oil fill cap ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 14: G Eneral A Rrangement – C Ontrols And Instruments

    Unblock filter. Battery Charge insufficient Charge battery Malfunction indicator lamp Engine management Refer to workshop manual system fault identified ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 15: Engine Fluids

    Use a battery meter to check that the battery has retained a charge during transit and storage, if necessary re-charge the battery until 12.4 volts are available. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 16 4.4 Wait one minute - a click will be heard from the throttle body after precisely one minute. 4.5 The unit is ready to be used. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 17: Maintenance Schedule

    3 Or at least every two years if the specified hours of operation are not reached before that 4 If the pump is not to be used for more than 30 days ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 18: Maintenance Operations

    Heat exchanger cross section, as viewed from rear of pump See page 14 for the list of suitable additives. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 19: Coolant Change

    Attach drain hose here ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 20: Engine Oil Fill And Level Check

    Specification – 0W/40, completely synthetic, API SH. Alternative oil is 15W/50 multi-grade but only for use in temperatures above 0°C. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 21: Change Engine Oil And Filter

    Further information about changing the oil filter is provided in the Weber Repair Manual section 110.04.01. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 22: Engine Fuel Filter

    Check and Adjust Valve play This procedure is described in the Weber Service Manual, Section 8.4. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 23: Sparking Plugs

    Check spark plugs While spark plugs are removed, add preservative into cylinders Replace spark plugs Do not run the engine ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 24: Pump Test

    The absorbent glass material (AGM) battery is a sealed unit and requires no fluid top up during its life. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 25: Terminals

    Do NOT crank the engine with the spark plug removed. When tilting the engine, keep the spark plug side uppermost. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 26: Engine

    Use the following log sheet (or photocopy) to keep an historical record of your maintenance and parts renewals, in accordance with the recommended maintenance ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 27 Godiva Ltd and Weber. This information may be useful should you need to contact the manufacturer on any related matter. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 28: Pump Log Sheet

    Model __________ Serial No. ___________ Date Entered Service _______ Date Location Hours Inspection / Fault Parts Reason for Initials used renewal ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 29: Workshop Manual

    Repair and Spare Parts Policy Pump Godiva products may only be repaired or serviced by persons trained in said procedures by either Godiva Ltd., or their approved agents. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the...
  • Page 30 Valve adjustment shim 3.20mm Valve adjustment shim 3.25mm Valve adjustment shim 3.30mm Valve adjustment shim 3.35mm Valve adjustment kit Feeler gauges 0.05-2mm ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 31: I Ntroduction

    Complete the maintenance log. Installation Do NOT allow oil, grease or silicone products to contaminate Mechanical Seal mating (ceramic / carbon) faces. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 32: Removal, Wear Ring, Re-Assembly

    1.4 Remove the 6 x M8 nuts and washers retaining the suction tube to pump volute. Use a 13mm socket and extension bar. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 33 Be careful not to lose the O ring in the priming valve connecting port. If necessary remove the guard plate, below and to rear of priming valve to allow full access. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 34 To remove the ring, undo 2 x M5 screws. When fitting the new ring apply a small amount of threadlock – Loctite 243 or similar - to the screw threads. Tighten to 2Nm. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 35 The seal faces can be cleaned with a solvent cleaner, Loctite 7076 or equivalent. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 36 3. Priming valve To inspect and repair the Priming Valve, remove the complete assembly as described in sections 1.3 to 1.7. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 37 3.4 When replacing the cover, ensure the small air hole is facing downwards, this allows the atmosphere to act on the diaphragm. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 38 Undo the two screws below the shield. 4.2 Undo the top screw and the shield will come away from the pump. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 39 5.4 Undo the bracket on the right, 1 x M6 bolt. The exhaust system can now be lifted clear of the engine and pump. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 40 5.8 Before dismantling the exhaust primer housing, mark the position of the butterfly valve in relation to the housing. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 41 5.10 Undo the two screws retaining the valve flap to the spindle and lift flap out of housing. The spindle can now be pulled away from the housing. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 42 The nozzle is a push fit in the housing and should drop out when the housing is tapped on a hard surface. Check the nozzle for damage and replace if necessary. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 43 5.15 Do not forget to reconnect the priming rod to the lever on the side of the exhaust priming valve housing. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 44 ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 45 Detach water supply hose to heat exchanger – detach at heat exchanger Detach the water return to suction hose at the suction tube. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 46 6.3 To release the heat exchange unit undo the 2 x M6 socket head screws on the top bracket. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 47 The plug is accessible through the skid plate on the bottom of the frame. 13mm socket is required. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 48 7.2 Undo the two hoses feeding oil to and from the tank. 7.3 Undo the 1 x M6 bolt on the side of the frame. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 49 Note: when replacing the skid plate apply a small amount of Loctite 243 to the threads of the 4 x M6 socket head screws retaining the plate to the pump frame. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 50: Fuel Tank

    M10 bolt. The front two mounting points are studs inserted in the pump secured to the frame by 2 x M10 nuts. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 51 2 x M6 60mm bolts and 2 x M6 20mm bolts. Undoing these bolts allows the hot side of the frame to be removed. 8.5 Using a powered hoist lift the pump/engine assembly clear of the frame. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 52 8.8 The fuel pump can be removed by undoing the 3 x M6 bolts and nuts holding the pump to the frame. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 53 The combination of the two Loctite applications will form a secure seal. Note the orientation of the fixings in the tank. Equal tee Fuel filter (65572) (68158) ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 54 ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 55 The stub shaft also retains the rotor and recoil starter pulley. 9.3 The stub shaft can then be removed from the engine by gently knocking with a hammer. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 56: Pump On To Engine

    At the same time the pump shaft which is splined, can be located into the internal splines of the stubb shaft. Grease all the splines with CV grease. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 57 11.2 Apply a soft soap solution to the outside of this seal part. Do not allow grease to touch the sealing surfaces seal as this will ruin the sealing capability. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 58 11.5 Fit the rear wear ring, Apply Loctite 243 to the retaining screws 11.6 Tighten the retaining screws to 2 Nm. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 59 11.8 Use a press to move the bearing down to the shoulder on the shaft 11.9 Fit the collar (68024) on to the shaft ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 60 11.11 Fit the shaft, with the collar and flinger facing down, into the rear of the pump. 11.12 Tap evenly around the edge of the bearing to force the assembly into the pump volute. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 61 11.15 Insert the circlip (53527) using suitable circlip pliers to retain the bearing and shaft 11.16 Turn the volute over. Smear grease all over the O ring (57129) ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 62 11.19 Apply a soft soap solution, or Rubber Lube, to the impeller inside and outside on the rear central section ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 63 11.23 Clean the carbon surface of the seal with solvent cleaner (Loctite 7063 or similar) ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 64 45 Nm, this is sufficient to push the impeller back into position. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 65 ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 66 12.3 When the reel is free from the pump volute. A new rope can be threaded through the hole in the reel. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 67 12.5 Tie a knot in the rope end. 12.6 Pull the rope back through the reel until the knot is retained in the slot ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 68 12.10 Fit Clip to the plate making sure the straight end of the Clip is on the right side looking from the back ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 69 12.12 Line the Plate grooves up with the Block grooves as shown below 12.13 Secure the plate to the block and the volute with the circlip ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 70 12.15 Tie a secure slip knot in the end of the rope that has gone through the handle 12.16 Tighten the knot as close as possible top the black mark and cut off the excess rope. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 71 12.18 When the rope is released the recoil spring will pull the handle right up to the volute casing. If it is loose, then re-tie the knot until it is tight against the volute. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 72 12.19 Before assembling the volute (with the recoil starter fixed inside) to the engine. Fully extend Rope & check the Pulley will Rotate a further 360° before Spring becomes coil bound. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 73: Alve

    13.3 Using a suitable chisel, bend the tab away from the Locking Nut and release the nut to allow the Stem to be separated from the Spindle. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 74 13.6 Lubricate the Spindle, valve body threads and O Ring with suitable water-proof grease; Shell Alvania WR2, or similar. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 75: Panel

    15. Electrical System The pump and engine electrical system is checked by diagnostic software connected to the unit through the main wiring harness. Contact Godiva Ltd. or your approved local distributor for more details concerning the diagnostic software. Electric system data -...
  • Page 76 15.4 The fuses and relays are a push fit in the housing. This diagram shows the location and purpose of the fuses and relays ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 77 15.7 The light units push into the panel from the top side. ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 78 15.8 Engine wiring harness ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 79 15.9 Control Panel Wiring Harness ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 80 15.10 Fuel Tank Harness ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.

  • Page 81: Olvents And G Reases L Ist

    If fitting a new grip to a handle, spread Loctite 410 along handle. Instrument panel, retaining screws Loctite 243 ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 82 A Unit of IDEX Corporation Charles St Warwick CV34 5LR England Tel:+44 (0)1926 623600 Fax: +44 (0)1926 623666 www.godiva.co.uk godiva@idexcorp.com ©Godiva Ltd. Our policy is one of continuous development. We therefore reserve the right to amend specifications without notice or obligation.
  • Page 83 REPAIR MANUAL 4-Stroke Engine MPE 850 IND NA This repair manual is valid for the following engine variants: – 406555 406555_RLF Rev 1.2 Read the introductory chapter before performing the task on the engine. 11.10.2012 Pay particular attention to the safety messages. en_English...
  • Page 85 Weber Motor GmbH strives to make continual improvements as part of the ongoing technical development of its products. All documentation is therefore subject to technical modifications. Reprints and translations, in whole or in part, require written permission from Weber Motor GmbH. All rights reserved according to the copyright law.
  • Page 86 Table of contents Table of contents About this document 1.1 Meaning of the symbols and signal words ......... 9 1.2 Finding the required information .
  • Page 87 Table of contents 010.01-3.06 Removing sensor crankshaft ........59 010.01-3.07 Installing sensor crankshaft .
  • Page 88 Table of contents Valve train 040.01 Camshaft ............. 186 040.01.01 Replacing camshaft .
  • Page 89 Table of contents 070.01.01 Removing intake manifold......... 265 070.01.02 Installing intake manifold.
  • Page 90 Table of contents 110.03.02 Installing oil pressure valve ........322 110.04 Oil filter .
  • Page 91 1 About this document 1.1 Meaning of the symbols and signal words | … About this document This repair manual describes how to safely and correctly remove, install and replace engine components. Observe the following information: – Read through the service manual before performing any tasks. –...
  • Page 92 1 About this document 1.3 Change management 1.3 Change management Weber Motor GmbH strives to make continual improvements as part of the ongoing technical development of its products. You may find that descriptions in the repair manual are changed or amended. All changes are described in the chapter Overview of revisions.
  • Page 93 2 Safety 2.1 Meaning of the safety alert symbol and signal words Safety This engine is state-of-the-art and built according to recognized safety-technical regulations. Ignoring the information in this repair manual may result in personal injury or property damage. This repair manual is solely intended for use in a workshop authorized by Weber Motor or the portable fire pump manufacturer.
  • Page 94 2 Safety 2.2 Important safety messages 2.2 Important safety messages Work specifications You endanger the safety of personnel if you do not perform work exactly as described in this repair manual. ► Only deviate from the work specifications in this repair manual when prompted to do so by the portable fire pump manufacturer.
  • Page 95 2 Safety 2.2 Important safety messages Tools and accessories Unsuitable tools and accessories pose a safety risk to personnel. ► Always use tools listed in chapter 4 Tools and accessories. Engine power supply The engine must be disconnected from the power supply before any work is carried out.
  • Page 96 2 Safety 2.2 Important safety messages Fuel Fuel is highly flammable. Vapors may ignite and cause an explosion. ► Do not smoke in the vicinity of the engine and do not allow naked flames or sparks near the engine or the fuel system. ►...
  • Page 97 3 Basic instructions for working on the engine 3.1 Before you begin working Basic instructions for working on the engine 3.1 Before you begin working The following requirements must be met before performing any tasks: – The engine has been removed from the portable fire pump. –...
  • Page 98 3 Basic instructions for working on the engine 3.2 Lift and transport the engine. 3.2 Lift and transport the engine. – Workshop crane WARNING! Spinal column injury due to incorrect lifting of heavy loads. Always lift the engine using a workshop crane. NOTICE! Components can break.
  • Page 99 3 Basic instructions for working on the engine 3.3 Mount the engine on the engine stand 3.3 Mount the engine on the engine stand WARNING! Crush injuries due to the engine overturning. Mount the engine to the engine stand before starting any work. If not otherwise specified in the chapter, mount the engine on the drive side or across from the drive side.
  • Page 100 3 Basic instructions for working on the engine 3.3 Mount the engine on the engine stand 3.3.1 Mount the engine on the drive side of the engine stand – Workshop crane – Engine stand WARNING! Spinal column injury due to incorrect lifting of heavy loads.
  • Page 101 3 Basic instructions for working on the engine 3.3 Mount the engine on the engine stand 3.3.2 Mount the engine across from the drive side of the engine stand – Workshop crane – Engine stand WARNING! Spinal column injury due to incorrect lifting of heavy loads.
  • Page 102 3 Basic instructions for working on the engine 3.4 While working 3.4 While working 3.4.1 Tightening torque For all details about tightening torque in this repair manual, observe the following information: – The thread is dry and free of engine oil. –...
  • Page 103 3 Basic instructions for working on the engine 3.5 Checking the work carried out 3.5 Checking the work carried out Check the engine when installed again in the portable fire pump. Observe the following information: – Turn the ignition on for one minute and then back off. –...
  • Page 104 4 Tools and accessories 4.1 Weber Motor tool case Tools and accessories 4.1 Weber Motor tool case Weber Motor offers a tool case that contains the following special tools. Visit our web site www.weber-motor.com for more information. Figure Description Figure Description Pin punch axle Locking tool crankshaft...
  • Page 105 4 Tools and accessories 4.2 Equipment workshop 4.2 Equipment workshop In addition to the tool case, you will require the following tools and accessories. The figures are only examples of suitable tools. All tools and accessories are available from specialist retailers. Figure Description Figure...
  • Page 106 4 Tools and accessories 4.2 Equipment workshop Figure Description Figure Description Spark plug wrench Wrench size 16 mm [5/8“] Diameter: maximum 22 mm [0.87 in] Valve refacer Angle indicator Piston ring compressor Crown wrench Width of pins maximum 3 mm Cylinder liner puller Bar magnet Oil seal slide hammer...
  • Page 107 4 Tools and accessories 4.2 Equipment workshop Figure Description Precision clearance gauges 0,025 mm - 0,04 mm RLF MPE850 Rev 1.2 | 406555 |...
  • Page 108 4 Tools and accessories 4.3 Supplies 4.3 Supplies You need the following supplies when working on the engine. Unless otherwise specified, use the products as directed by the manufacturer. All supplies are available from specialist retailers. Supplies Recommended products Commercial petroleum jelly for industrial Petroleum jelly for fitting o-rings and gaskets applications Mobil DTE-24, DTE-25, DTE-26...
  • Page 109 010.01-1 Crankcase Crankcase 010.01-1 Crankcase RLF MPE850 Rev 1.2 | 406555 |...
  • Page 110 010.01-1 Crankcase 010.01-1.01 Replacing crankcase 010.01-1.01 Replacing crankcase – 020.01.01 Removing crank drive. – 020.01.02 Installing crank drive. – Reversible ratchet – Torx® screwdriver socket T30 – Hexagon screwdriver 5, 6, 8 – Insert open-end wrench 12 – Torx® screwdriver T30 –...
  • Page 111 010.01-1 Crankcase 010.01-1.01 Replacing crankcase ► Unscrew the bolts ► Remove the intake manifold bracket ► Unscrew the fitting ► Turn the lower case 180°. ► Remove the sleeves ► Unscrew the plug RLF MPE850 Rev 1.2 | 406555 |...
  • Page 112 010.01-1 Crankcase 010.01-1.01 Replacing crankcase ► Punch the axle out using the pin punch axle intermediate gear and plastic hammer. ► Remove the intermediate gear suction pump ► Remove the sleeves ► Unscrew the bolts ► Remove the chain rail RLF MPE850 Rev 1.2 | 406555 |...
  • Page 113 010.01-1 Crankcase 010.01-1.01 Replacing crankcase ► Turn the upper case 180°. ► Unscrew the oil filter using a universal strap wrench. ► Unscrew the threaded sleeve using a crown wrench. ► Unscrew 10 bolts The bolt is an additional part and not installed in every engine.
  • Page 114 010.01-1 Crankcase 010.01-1.01 Replacing crankcase ► Remove the sleeve ► Unscrew the bolt ► Remove the chain rail ► Remove the cylinder liners using a cylinder liner puller. Prepare the new crankcase ► Replace the crankcase. The plug can be found in the spare parts catalog in chapter 010.01-2 Crankcase.
  • Page 115 010.01-1 Crankcase 010.01-1.01 Replacing crankcase ► Screw in new plugs Tightening torque: 20 Nm +4 Nm [14.8 lbf ft +3 lbf ft] ► Screw in a new plug Tightening torque: 9 Nm +2 Nm [6.6 lbf ft +1.5 lbf ft] ►...
  • Page 116 010.01-1 Crankcase 010.01-1.01 Replacing crankcase Mount the crankcase on the engine stand WARNING! Crush injuries due to a dropped crankcase. ► Lift the crankcase using a carrying strap. ► Mount the crankcase on the engine stand. Suitable mounting points M10 –...
  • Page 117 010.01-1 Crankcase 010.01-1.01 Replacing crankcase ► Screw in the oil filter by hand. Tightening torque: 10 Nm [7.4 lbf ft] ► Clean the sealing surface with sealing surface cleaner. ► Clean the sealing surface with sealing surface cleaner. RLF MPE850 Rev 1.2 | 406555 |...
  • Page 118 010.01-1 Crankcase 010.01-1.01 Replacing crankcase ► Apply the silicone liquid seal without gaps as illustrated. ► Hold the thermostat housing in position. ► Screw in 10 bolts Tightening torque: 8 Nm +2 Nm [5.9 lbf ft +1.5 lbf ft] The bolt is an additional part and not installed in every engine.
  • Page 119 010.01-1 Crankcase 010.01-1.01 Replacing crankcase The seal can be found in the spare parts catalog in chapter 010.01-3 Crankcase. ► Replace the seal ► Screw in the fitting Tightening torque: 8 Nm +2 Nm [5.9 lbf ft +1.5 lbf ft] ►...
  • Page 120 010.01-1 Crankcase 010.01-1.01 Replacing crankcase ► Turn the crankcase 180°. ► Hold the intermediate gear suction pump in position. ► Slide in the axle . Observe the position of the bevel The plug and seal can be found in the spare parts catalog in chapter 010.01-3 Crankcase.
  • Page 121 010.01-1 Crankcase 010.01-1.01 Replacing crankcase ► Unscrew the bolt ► Remove the lower case ► Check if the welch plugs are installed. ► Insert the chain guide ► Screw in the bolts Tightening torque: 8 Nm +2 Nm [5.9 lbf ft +1.5 lbf ft] RLF MPE850 Rev 1.2 | 406555 |...
  • Page 122 010.01-1 Crankcase 010.01-1.01 Replacing crankcase ► Turn the upper case 180°. ► Insert the chain rail ► Screw in the bolt Tightening torque: 8 Nm +2 Nm [5.9 lbf ft +1.5 lbf ft] The o-rings can be found in the spare parts catalog in chapter 010.01-2 Crankcase.
  • Page 123 010.01-1 Crankcase 010.01-1.02 Replacing welch plugs 010.01-1.02 Replacing welch plugs – Hexagon screwdriver 6 – Hexagon screwdriver socket 6 – Torque wrench The upper case is disconnected from the crankcase. – Welch plug 1st cylinder – Welch plug 2nd cylinder ►...
  • Page 124 010.01-1 Crankcase 010.01-1.03 Replacing tie rod 010.01-1.03 Replacing tie rod – Reversible ratchet – Stud extractor 10 – Torque wrench – Anti-Seize assembly paste The lower case is disconnected from the crankcase. ► Unscrew the tie rod using a stud extractor.
  • Page 125 010.01-1 Crankcase 010.01-1.04 Replacing plugs 010.01-1.04 Replacing plugs – Hexagon screwdriver 5, 8 – Hexagon screwdriver socket 5, 8 – Torque wrench – Plug M18x1.5 exhaust side – Plug M18x1.5 intake side – Plug M10x1 Replacing plug M18x1.5 exhaust side ►...
  • Page 126 010.01-1 Crankcase 010.01-1.04 Replacing plugs Replacing plug M10x1 The generator is removed. ► Unscrew the plug ► Replace the plug. ► Screw in the plug. Tightening torque: 9 Nm +2 Nm [6.6 lbf ft +1.5 lbf ft] RLF MPE850 Rev 1.2 | 406555 |...
  • Page 127 010.01-2 Crankcase 010.01-2 Crankcase RLF MPE850 Rev 1.2 | 406555 |...
  • Page 128 010.01-2 Crankcase 010.01-2.01 Replacing cylinder liners 010.01-2.01 Replacing cylinder liners – 070.01.01 Removing intake manifold – 020.01.06 Installing pistons and con rods – 030.01.04 Removing ignition coils – 110.01.02 Installing suction pump cover – 030.01.01 Removing valve cover – 030.02.02 Installing cylinder head –...
  • Page 129 010.01-2 Crankcase 010.01-2.01 Replacing cylinder liners Replacing cylinder liners ► Turn the engine 180°. ► Remove the cylinder liners using a cylinder liner puller. ► Replace the cylinder liners. ► Coat the o-rings lightly with petroleum jelly. ► Insert the cylinder liners. Completion ►...
  • Page 130 010.01-2 Crankcase 010.01-2.02 Replacing oil seal 010.01-2.02 Replacing oil seal – 090.02.01 Removing generator – 090.02.02 Installing generator – Oil seal slide hammer – Hexagon screwdriver socket 7 – Assembling kit oil seal crankshaft – Petroleum jelly – Reversible ratchet Mount the engine on the engine stand ►...
  • Page 131 010.01-2 Crankcase 010.01-2.02 Replacing oil seal ► Replace the oil seal ► Coat the inside of the oil seal lightly with petroleum jelly. ► Slide the oil seal onto guide sleeve ► Slide the guiding sleeve onto crankshaft Use the M10x1x35 bolts you removed on the rotor. ►...
  • Page 132 010.01-2 Crankcase 010.01-2.02 Replacing oil seal ► Unscrew the bolt ► Remove the sliding sleeve ► Unscrew the bolts ► Remove the guiding sleeve ► Check if the oil seal is tilted. ► If the oil seal is tilted, it must be replaced. Completion ►...
  • Page 133 010.01-2 Crankcase 010.01-2.03 Replacing plug 010.01-2.03 Replacing plug – Hexagon screwdriver 8 – Hexagon screwdriver socket 8 – Torque wrench ► Unscrew the plug ► Replace the plug. ► Screw in the plug. Tightening torque: 20 Nm +4 Nm [14.8 lbf ft +3 lbf ft] RLF MPE850 Rev 1.2 | 406555 |...
  • Page 134 010.01-3 Crankcase 010.01-3 Crankcase RLF MPE850 Rev 1.2 | 406555 |...
  • Page 135 010.01-3 Crankcase 010.01-3.01 Removing plug 010.01-3.01 Removing plug – Hexagon screwdriver 8 Mount the engine on the engine stand ► Mount the engine on the drive side the engine stand. (See chapter 3.3.1 Mount the engine on the drive side of the engine stand.) ►...
  • Page 136 010.01-3 Crankcase 010.01-3.02 Installing plug 010.01-3.02 Installing plug – Torque wrench – Hexagon screwdriver socket 8 ► Replace the seal ► Screw in the plug Tightening torque: 20 Nm +4 Nm [14.8 lbf ft +3 lbf ft] RLF MPE850 Rev 1.2 | 406555 |...
  • Page 137 010.01-3 Crankcase 010.01-3.03 Replacing plugs 010.01-3.03 Replacing plugs – Hexagon screwdriver 8 – Hexagon screwdriver socket 8 – Torque wrench – Plugs across from the drive side – Upper plug intake side – Lower plug intake side Replacing plugs across from the drive side The oil cooler bracket is removed.
  • Page 138 010.01-3 Crankcase 010.01-3.03 Replacing plugs Replacing upper plug intake side ► Unscrew the plug ► Replace the plug. ► Screw in the plug. Tightening torque: 20 Nm +4 Nm [14.8 lbf ft +3 lbf ft] Replacing lower plug intake side ►...
  • Page 139 010.01-3 Crankcase 010.01-3.04 Removing fitting 010.01-3.04 Removing fitting – Open-end wrench 12 ► Unscrew the fitting Tightening torque: 8 Nm +2 Nm [5.9 lbf ft +1.5 lbf ft] RLF MPE850 Rev 1.2 | 406555 |...
  • Page 140 010.01-3 Crankcase 010.01-3.05 Installing fitting 010.01-3.05 Installing fitting – Torque wrench – Insert open-end wrench 12 ► Replace the seal ► Screw in the fitting Tightening torque: 8 Nm +2 Nm [5.9 lbf ft +1.5 lbf ft] RLF MPE850 Rev 1.2 | 406555 |...

  • Page 141: 3.06 Removing Sensor Crankshaft

    010.01-3 Crankcase 010.01-3.06 Removing sensor crankshaft 010.01-3.06 Removing sensor crankshaft – Torx® screwdriver T30 ► Unscrew the bolt ► Pull the sensor crankshaft out. RLF MPE850 Rev 1.2 | 406555 |...

  • Page 142: 3.07 Installing Sensor Crankshaft

    010.01-3 Crankcase 010.01-3.07 Installing sensor crankshaft 010.01-3.07 Installing sensor crankshaft – Torque wrench – Petroleum jelly – Torx® screwdriver socket T30 ► Coat the o-ring lightly with petroleum jelly. ► Insert the sensor crankshaft ► Screw in the bolt Tightening torque: 8 Nm +2 Nm [5.9 lbf ft +1.5 lbf ft] RLF MPE850 Rev 1.2 | 406555 |...

  • Page 143: Oil Cooler Bracket

    010.02-1 Oil cooler bracket 010.02-1 Oil cooler bracket RLF MPE850 Rev 1.2 | 406555 |...

  • Page 144: 1.01 Removing Oil Cooler Bracket

    010.02-1 Oil cooler bracket 010.02-1.01 Removing oil cooler bracket 010.02-1.01 Removing oil cooler bracket – 050.03.01 Removing oil cooler – Hexagon screwdriver 5 Mount the engine on the engine stand ► Mount the engine on the drive side the engine stand. (See chapter 3.3.1 Mount the engine on the drive side of the engine stand.) Preparation...
  • Page 145 010.02-1 Oil cooler bracket 010.02-1.01 Removing oil cooler bracket ► Remove the oil cooler bracket ► Remove the sleeve RLF MPE850 Rev 1.2 | 406555 |...

  • Page 146: 1.02 Installing Oil Cooler Bracket

    010.02-1 Oil cooler bracket 010.02-1.02 Installing oil cooler bracket 010.02-1.02 Installing oil cooler bracket – 050.03.02 Installing oil cooler – Petroleum jelly – Hexagon screwdriver socket 5 – Torque wrench Installing oil cooler bracket ► Replace the gasket ► Insert the gasket into the groove and lightly coat with petroleum jelly.
  • Page 147 010.02-1 Oil cooler bracket 010.02-1.02 Installing oil cooler bracket ► Screw in 15 bolts Tightening torque: 8 Nm +2 Nm [5.9 lbf ft +1.5 lbf ft] Completion ► Install the oil cooler. (See chapter 050.03.02 Installing oil cooler.) RLF MPE850 Rev 1.2 | 406555 |...

  • Page 148: Oil Cooler Bracket

    010.02-2 Oil cooler bracket 010.02-2 Oil cooler bracket RLF MPE850 Rev 1.2 | 406555 |...

  • Page 149: 2.01 Replacing Blanking Cover

    010.02-2 Oil cooler bracket 010.02-2.01 Replacing blanking cover 010.02-2.01 Replacing blanking cover – Petroleum jelly – Torx® screwdriver T30 – Torque wrench – Torx® screwdriver socket T30 Mount the engine on the engine stand ► Mount the engine on the drive side the engine stand.
  • Page 150 010.02-2 Oil cooler bracket 010.02-2.01 Replacing blanking cover ► Insert the blanking cover ► Hold the bracket in position. ► Screw in the bolt Tightening torque: 9 Nm +2 Nm [6.6 lbf ft +1.5 lbf ft] RLF MPE850 Rev 1.2 | 406555 |...

  • Page 151: 2.02 Replacing Plug

    010.02-2 Oil cooler bracket 010.02-2.02 Replacing plug 010.02-2.02 Replacing plug – Hexagon screwdriver 6 – Hexagon screwdriver socket 6 – Torque wrench Mount the engine on the engine stand ► Mount the engine on the drive side the engine stand. (See chapter 3.3.1 Mount the engine on the drive side of the engine stand.) ►...

  • Page 152: 2.03 Sealing Cover Oil Cooler Bracket

    010.02-2 Oil cooler bracket 010.02-2.03 Sealing cover oil cooler bracket 010.02-2.03 Sealing cover oil cooler bracket – 050.03.01 Removing oil cooler – 050.03.02 Installing oil cooler – Torx® screwdriver T20 – Hexagon screwdriver socket 5 – Hexagon screwdriver 5 – Sealing surface cleaner –...
  • Page 153 010.02-2 Oil cooler bracket 010.02-2.03 Sealing cover oil cooler bracket Sealing cover oil cooler bracket ► Unscrew 14 bolts The cover oil cooler bracket is caulked with a silicone liquid seal. ► Remove the cover oil cooler bracket RLF MPE850 Rev 1.2 | 406555 |...
  • Page 154 010.02-2 Oil cooler bracket 010.02-2.03 Sealing cover oil cooler bracket ► Clean the sealing surface with sealing surface cleaner. ► Clean the sealing surface with sealing surface cleaner. RLF MPE850 Rev 1.2 | 406555 |...
  • Page 155 010.02-2 Oil cooler bracket 010.02-2.03 Sealing cover oil cooler bracket ► Apply the silicone liquid seal without gaps as illustrated. ► Hold the cover oil cooler bracket position. RLF MPE850 Rev 1.2 | 406555 |...
  • Page 156 010.02-2 Oil cooler bracket 010.02-2.03 Sealing cover oil cooler bracket ► Screw in the bolt Tightening torque: 8 Nm +2 Nm [5.9 lbf ft +1.5 lbf ft] ► Screw in 13 bolts Tightening torque: 5 Nm +1 Nm [3.7 lbf ft +0.7 lbf ft] Completion ►...

  • Page 157: Crank Drive

    020.01 Crankshaft Crank drive 020.01 Crankshaft RLF MPE850 Rev 1.2 | 406555 |...

  • Page 158: Removing Crank Drive

    020.01 Crankshaft 020.01.01 Removing crank drive. 020.01.01 Removing crank drive. – 070.01.01 Removing intake manifold – 020.03.01 Removing crankshaft cover – 090.01.01 Removing starter – 050.02.03 Removing coolant pump – 110.01.01 Removing suction pump cover – 090.02.01 Removing generator – 030.01.04 Removing ignition coils –...
  • Page 159 020.01 Crankshaft 020.01.01 Removing crank drive. ► Remove the intake manifold. (See chapter 070.01.01 Removing intake manifold.) ► Remove the starter. (See chapter 090.01.01 Removing starter.) ► Remove the suction pump cover. (See chapter 110.01.01 Removing suction pump cover.) ► Turn the engine 180°.
  • Page 160 020.01 Crankshaft 020.01.01 Removing crank drive. Turning engine in the engine stand ► Lift the engine. (See chapter 3.2 Lift and transport the engine.) ► Remove the engine from the engine stand. ► Turn the engine and mount on the engine stand.
  • Page 161 020.01 Crankshaft 020.01.01 Removing crank drive. Use a hexagon screwdriver socket 8 and reversible ratchet. ► Turn the crankshaft on the TDC-adjusting tool in the direction shown until the marking ends flush with the crankcase halves ► Check whether the camshaft is at the crossing point.
  • Page 162 020.01 Crankshaft 020.01.01 Removing crank drive. Turning engine in the engine stand ► Lift the engine. (See chapter 3.2 Lift and transport the engine.) ► Remove the engine from the engine stand. ► Turn the engine and mount on the engine stand.
  • Page 163 020.01 Crankshaft 020.01.01 Removing crank drive. ► Turn the engine 180°. ► Unscrew 4 bolts M6 ► Unscrew 5 bolts M8 ► Pull the oil pressure valve out using a bar magnet. RLF MPE850 Rev 1.2 | 406555 |...
  • Page 164 020.01 Crankshaft 020.01.01 Removing crank drive. The crankcase is caulked with a silicone liquid seal. ► Remove the lower case ► Turn the crankshaft 180°. ► Mark the cylinder assignment and installation position on the piston, con rod, con rod cover and bearing shells. ►...
  • Page 165 020.01 Crankshaft 020.01.01 Removing crank drive. ► Pull the pistons out. ► Remove the balance shaft ► Remove the crankshaft ► Remove the oil seal RLF MPE850 Rev 1.2 | 406555 |...

  • Page 166: Installing Crank Drive

    020.01 Crankshaft 020.01.02 Installing crank drive. 020.01.02 Installing crank drive. – 040.01.07 Installing timing chain – 050.03.02 Installing oil cooler – 040.01.03 Installing chain tensioner – 110.01.02 Installing suction pump cover – 110.02.02 Installing oil pressure pump – 030.01.02 Installing valve cover –...
  • Page 167 020.01 Crankshaft 020.01.02 Installing crank drive. ► Coat the con rod bearing shells lightly with engine oil. ► Insert con rod bearing shells in con rod and con rod cover. Observe the installation instructions for the con rod bearing. Installation instructions for the con rod bearings NOTICE! Serious damage to bearings due to con rod bearing shells being installed incorrectly.
  • Page 168 020.01 Crankshaft 020.01.02 Installing crank drive. ► Displace the ring joints of the three piston rings 120°. ► Turn the engine 180°. ► Coat the pistons lightly with engine oil. ► Slide in the pistons using a piston ring compressor. ►...
  • Page 169 020.01 Crankshaft 020.01.02 Installing crank drive. ► Insert con-rod covers ► Replace the con-rod bolts ► Tighten the con-rod bolts in three stages. Tightening torque: First stage 10 Nm [7.4 lbf ft] Second stage 20 Nm [14.8 lbf ft] Third stage +115° ►...
  • Page 170 020.01 Crankshaft 020.01.02 Installing crank drive. Aligning the balance shaft to the crankshaft ► Observe the marking The marking ends flush with the crankcase. ► Turn the crankshaft 180°. ► Clean the sealing surface with sealing surface cleaner. RLF MPE850 Rev 1.2 | 406555 |...
  • Page 171 020.01 Crankshaft 020.01.02 Installing crank drive. ► Clean the sealing surface with sealing surface cleaner. ► Check if the centering pins are installed. ► Apply the silicone liquid seal without gaps as illustrated. RLF MPE850 Rev 1.2 | 406555 |...
  • Page 172 020.01 Crankshaft 020.01.02 Installing crank drive. Checking the alignment of the balance shaft / crankshaft ► Check the markings Both markings appear as shown. ► Put the lower case ► Assemble the oil pressure valve in the sequence as illustrated ►...
  • Page 173 020.01 Crankshaft 020.01.02 Installing crank drive. ► Screw in 5 bolts M8 Tightening torque: 23 Nm +2 Nm [17 lbf ft +1.5 lbf ft] ► Screw in 4 bolts M6 Tightening torque: 8 Nm +2 Nm [5.9 lbf ft +1.5 lbf ft] ►...
  • Page 174 020.01 Crankshaft 020.01.02 Installing crank drive. The cylinder head gasket can be found in the spare parts catalog in chapter 030.02 Cylinder head. ► Replace the cylinder head gasket ► Put the cylinder head gasket on. Observe the installation position: –...
  • Page 175 020.01 Crankshaft 020.01.02 Installing crank drive. Turning engine in the engine stand ► Lift the engine. (See chapter 3.2 Lift and transport the engine.) ► Remove the engine from the engine stand. ► Turn the engine and mount on the engine stand.
  • Page 176 020.01 Crankshaft 020.01.02 Installing crank drive. ► Slide the guiding sleeve onto crankshaft Use the M10x1x35 bolts you removed on the rotor. ► Screw in the bolts ► Hold the sliding sleeve in position on the oil seal Use a M10x1x35 bolt that you removed from the rotor.
  • Page 177 020.01 Crankshaft 020.01.02 Installing crank drive. ► Unscrew the bolt ► Remove the sliding sleeve ► Unscrew the bolts ► Remove the guiding sleeve ► Check if the oil seal is tilted. ► If the oil seal is tilted, it must be replaced. Setting valve timing ►...
  • Page 178 020.01 Crankshaft 020.01.02 Installing crank drive. Use a hexagon screwdriver socket 8 and reversible ratchet. ► Turn the crankshaft on the TDC-adjusting tool in the direction shown until the marking ends flush with the crankcase halves ► Check whether the camshaft is at the crossing point.
  • Page 179 020.01 Crankshaft 020.01.02 Installing crank drive. Checking the alignment of the balance shaft / crankshaft Use a hexagon screwdriver socket 8 and reversible ratchet. ► Turn the crankshaft on the TDC-adjusting tool several times in the direction shown The crankshaft can be turned. ►...
  • Page 180 020.01 Crankshaft 020.01.02 Installing crank drive. ► Check whether the camshaft is at the crossing point. The position of the camshaft is as illustrated The marking ends flush with the cross bar. ► If the camshaft does not appear as shown, set the valve timing again.
  • Page 181 020.01 Crankshaft 020.01.02 Installing crank drive. Turning engine in the engine stand ► Lift the engine. (See chapter 3.2 Lift and transport the engine.) ► Remove the engine from the engine stand. ► Turn the engine and mount on the engine stand.
  • Page 182 020.01 Crankshaft 020.01.02 Installing crank drive. ► Install the starter. (See chapter 090.01.02 Installing starter.) ► Install the intake manifold. (See chapter 070.01.02 Installing intake manifold.) RLF MPE850 Rev 1.2 | 406555 |...

  • Page 183: Replacing Crankshaft

    020.01 Crankshaft 020.01.03 Replacing crankshaft 020.01.03 Replacing crankshaft – 020.01.01 Removing crank drive. – 020.01.09 Checking con rod bearing play – 020.01.10 Checking main bearing play – 020.01.02 Installing crank drive. Preparation ► Remove the crank drive. (See chapter 020.01.01 Removing crank drive.) Replacing crankshaft ►...

  • Page 184: Replacing Balance Shaft

    020.01 Crankshaft 020.01.04 Replacing balance shaft 020.01.04 Replacing balance shaft – 070.01.01 Removing intake manifold – 050.02.04 Installing coolant pump – 090.01.01 Removing starter – 020.03.02 Installing crankshaft cover – 110.01.01 Removing suction pump cover – 010.02-1.02 Installing oil cooler bracket –...
  • Page 185 020.01 Crankshaft 020.01.04 Replacing balance shaft ► Remove the intake manifold. (See chapter 070.01.01 Removing intake manifold.) ► Remove the starter. (See chapter 090.01.01 Removing starter.) ► Remove the suction pump cover. (See chapter 110.01.01 Removing suction pump cover.) ► Turn the engine 180°.
  • Page 186 020.01 Crankshaft 020.01.04 Replacing balance shaft Turning engine in the engine stand ► Lift the engine. (See chapter 3.2 Lift and transport the engine.) ► Remove the engine from the engine stand. ► Turn the engine and mount on the engine stand.
  • Page 187 020.01 Crankshaft 020.01.04 Replacing balance shaft Use a hexagon screwdriver socket 8 and reversible ratchet. ► Turn the crankshaft on the TDC-adjusting tool in the direction shown until the marking ends flush with the crankcase halves ► Check whether the camshaft is at the crossing point.
  • Page 188 020.01 Crankshaft 020.01.04 Replacing balance shaft Turning engine in the engine stand ► Lift the engine. (See chapter 3.2 Lift and transport the engine.) ► Remove the engine from the engine stand. ► Turn the engine and mount on the engine stand.
  • Page 189 020.01 Crankshaft 020.01.04 Replacing balance shaft ► Turn the engine 180°. ► Unscrew 4 bolts M6 ► Unscrew 5 bolts M8 ► Pull the oil pressure valve out using a bar magnet. RLF MPE850 Rev 1.2 | 406555 |...
  • Page 190 020.01 Crankshaft 020.01.04 Replacing balance shaft The crankcase is caulked with a silicone liquid seal. ► Remove the lower case ► Remove the oil seal ► Remove the balance shaft ► Remove the bearing shells balance shaft RLF MPE850 Rev 1.2 | 406555 |...
  • Page 191 020.01 Crankshaft 020.01.04 Replacing balance shaft ► Replace the bearing shells balance shaft ► Coat the bearing shells balance shaft lightly with engine oil. ► Insert the main bearing shells in crankcase. ► Replace the balance shaft ► Insert the balance shaft. Aligning the balance shaft to the crankshaft ►...
  • Page 192 020.01 Crankshaft 020.01.04 Replacing balance shaft ► Clean the sealing surface with sealing surface cleaner. ► Check if the centering pins are installed. ► Apply the silicone liquid seal without gaps as illustrated. RLF MPE850 Rev 1.2 | 406555 |...
  • Page 193 020.01 Crankshaft 020.01.04 Replacing balance shaft Checking the alignment of the balance shaft / crankshaft ► Check the markings Both markings appear as shown. ► Put the lower case ► Assemble the oil pressure valve in the sequence as illustrated ►...
  • Page 194 020.01 Crankshaft 020.01.04 Replacing balance shaft ► Screw in 5 bolts M8 Tightening torque: 23 Nm +2 Nm [17 lbf ft +1.5 lbf ft] ► Screw in 4 bolts M6 Tightening torque: 8 Nm +2 Nm [5.9 lbf ft +1.5 lbf ft] ►...
  • Page 195 020.01 Crankshaft 020.01.04 Replacing balance shaft The cylinder head gasket can be found in the spare parts catalog in chapter 030.02 Cylinder head. ► Replace the cylinder head gasket ► Put the cylinder head gasket on. Observe the installation position: –...
  • Page 196 020.01 Crankshaft 020.01.04 Replacing balance shaft Turning engine in the engine stand ► Lift the engine. (See chapter 3.2 Lift and transport the engine.) ► Remove the engine from the engine stand. ► Turn the engine and mount on the engine stand.
  • Page 197 020.01 Crankshaft 020.01.04 Replacing balance shaft ► Slide the guiding sleeve onto crankshaft Use the M10x1x35 bolts you removed on the rotor. ► Screw in the bolts ► Hold the sliding sleeve in position on the oil seal Use a M10x1x35 bolt that you removed from the rotor.
  • Page 198 020.01 Crankshaft 020.01.04 Replacing balance shaft ► Unscrew the bolt ► Remove the sliding sleeve ► Unscrew the bolts ► Remove the guiding sleeve ► Check if the oil seal is tilted. ► If the oil seal is tilted, it must be replaced. Setting valve timing ►...
  • Page 199 020.01 Crankshaft 020.01.04 Replacing balance shaft Use a hexagon screwdriver socket 8 and reversible ratchet. ► Turn the crankshaft on the TDC-adjusting tool in the direction shown until the marking ends flush with the crankcase halves ► Check whether the camshaft is at the crossing point.
  • Page 200 020.01 Crankshaft 020.01.04 Replacing balance shaft Checking the alignment of the balance shaft / crankshaft Use a hexagon screwdriver socket 8 and reversible ratchet. ► Turn the crankshaft on the TDC-adjusting tool several times in the direction shown The crankshaft can be turned. ►...
  • Page 201 020.01 Crankshaft 020.01.04 Replacing balance shaft ► Check whether the camshaft is at the crossing point. The position of the camshaft is as illustrated The marking ends flush with the cross bar. ► If the camshaft does not appear as shown, set the valve timing again.
  • Page 202 020.01 Crankshaft 020.01.04 Replacing balance shaft Turning engine in the engine stand ► Lift the engine. (See chapter 3.2 Lift and transport the engine.) ► Remove the engine from the engine stand. ► Turn the engine and mount on the engine stand.
  • Page 203 020.01 Crankshaft 020.01.04 Replacing balance shaft ► Install the starter. (See chapter 090.01.02 Installing starter.) ► Install the intake manifold. (See chapter 070.01.02 Installing intake manifold.) RLF MPE850 Rev 1.2 | 406555 |...

  • Page 204: Removing Pistons And Con Rods

    020.01 Crankshaft 020.01.05 Removing pistons and con rods 020.01.05 Removing pistons and con rods – 070.01.01 Removing intake manifold – 110.01.01 Removing suction pump cover – 030.01.04 Removing ignition coils – 030.02.01 Removing cylinder head – 030.01.01 Removing valve cover –...
  • Page 205 020.01 Crankshaft 020.01.05 Removing pistons and con rods Preparation ► Remove the intake manifold. (See chapter 070.01.01 Removing intake manifold.) ► Remove the ignition coils. (See chapter 030.01.04 Removing ignition coils.) ► Remove the valve cover. (See chapter 030.01.01 Removing valve cover.) ►...
  • Page 206 020.01 Crankshaft 020.01.05 Removing pistons and con rods ► Pull the pistons out. RLF MPE850 Rev 1.2 | 406555 |...

  • Page 207: Installing Pistons And Con Rods

    020.01 Crankshaft 020.01.06 Installing pistons and con rods 020.01.06 Installing pistons and con rods – 030.02.02 Installing cylinder head – 030.01.05 Installing ignition coils – 110.01.02 Installing suction pump cover – 070.01.02 Installing intake manifold – 030.01.02 Installing valve cover –...
  • Page 208 020.01 Crankshaft 020.01.06 Installing pistons and con rods Installation instructions for the con rod bearings NOTICE! Serious damage to bearings due to con rod bearing shells being installed incorrectly. ► Insert the con rod bearing shells centered on the con rod. ►...
  • Page 209 020.01 Crankshaft 020.01.06 Installing pistons and con rods ► Turn the engine 180°. ► Insert con-rod covers ► Replace the con-rod bolts ► Tighten the con-rod bolts in three stages. Tightening torque: First stage 10 Nm [7.4 lbf ft] Second stage 20 Nm [14.8 lbf ft] Third stage +115°...

  • Page 210: Replacing Piston

    020.01 Crankshaft 020.01.07 Replacing piston 020.01.07 Replacing piston – Protective glasses Serious eye injuries due to a flying circlip. When installing or removing the circlip, it can be thrown at great speed and cause serious eye injuries. ► Wear protective glasses, along with any bystanders. Bearing damage, increased wear and leaks due to installing components swapped over.
  • Page 211 020.01 Crankshaft 020.01.07 Replacing piston ► Replace the piston ► Install the circlip using a litte screwdriver. ► Pull the piston pin out. ► Hold the con rod in position. Observe the piston's installation position. Installation position piston Arrow on top and inside arrow in the direction of the starter...
  • Page 212 020.01 Crankshaft 020.01.07 Replacing piston ► Coat the piston pin lightly with engine oil. ► Slide in the piston pin. ► Install the circlip using a litte screwdriver. RLF MPE850 Rev 1.2 | 406555 |...

  • Page 213: Replacing Con Rod

    020.01 Crankshaft 020.01.08 Replacing con rod 020.01.08 Replacing con rod – 020.01.09 Checking con rod bearing play – Protective glasses Serious eye injuries due to a flying circlip. When installing or removing the circlip, it can be thrown at great speed and cause serious eye injuries.
  • Page 214 020.01 Crankshaft 020.01.08 Replacing con rod ► Replace the con rod ► Hold the con rod in position. ► Coat the piston pin lightly with engine oil. ► Slide in the piston pin. ► Install the circlip using a litte screwdriver.

  • Page 215: Checking Con Rod Bearing Play

    020.01 Crankshaft 020.01.09 Checking con rod bearing play 020.01.09 Checking con rod bearing play – Precision clearance gauges – 12-point socket wrench 12 – Torque wrench – Angle indicator – Reversible ratchet Info rmatio n ! Con rod bolts are extension bolt and must be replaced after removal. However, when measuring the con rod bearing play, you can use the removed con rod bolts.
  • Page 216 020.01 Crankshaft 020.01.09 Checking con rod bearing play Installation instructions for the con rod bearings NOTICE! Serious damage to bearings due to con rod bearing shells being installed incorrectly. ► Insert the con rod bearing shells centered on the con rod. ►...
  • Page 217 020.01 Crankshaft 020.01.09 Checking con rod bearing play ► Read con rod bearing play "A" on the precision clearance gauges according to the manufacturer's instructions. Required con rod bearing play: 0,025 – 0,040 mm ► If the con rod bearing play is incorrect, repeat the process using another con rod bearing shell thickness.

  • Page 218: Checking Main Bearing Play

    020.01 Crankshaft 020.01.10 Checking main bearing play 020.01.10 Checking main bearing play – Precision clearance gauges – Reversible ratchet – Hexagon screwdriver 5, 6 – Torque wrench – Hexagon screwdriver – 6-point socket wrench 14 socket 5, 6 – Bar magnet Bearing damage, increased wear and leaks due to installing components swapped over.
  • Page 219 020.01 Crankshaft 020.01.10 Checking main bearing play ► Put the lower case ► Assemble the oil pressure valve in the sequence as illustrated ► Insert the oil pressure valve RLF MPE850 Rev 1.2 | 406555 |...
  • Page 220 020.01 Crankshaft 020.01.10 Checking main bearing play ► Screw in 5 bolts M8 Tightening torque: 23 Nm +2 Nm [17 lbf ft +1.5 lbf ft] Info rmatio n ! The cylinder head gasket must be replaced after removal. However, when measuring the main bearing play, you can use the removed cylinder head gasket.
  • Page 221 020.01 Crankshaft 020.01.10 Checking main bearing play ► Put the cylinder head Observe the installation position: – Exhaust side – Oil filter ► Tighten the nuts in the sequence as illustrated in three stages. Tightening torque: First stage 20 Nm ±3 Nm [14.8 lbf ft ±2.2 lbf ft] Second stage 40 Nm ±3 Nm [29.5 lbf ft ±2.2 lbf ft] Third stage...
  • Page 222 020.01 Crankshaft 020.01.10 Checking main bearing play ► Remove the cylinder head ► Unscrew 5 bolts M8 ► Pull the oil pressure valve out using a bar magnet. RLF MPE850 Rev 1.2 | 406555 |...
  • Page 223 020.01 Crankshaft 020.01.10 Checking main bearing play ► Remove the lower case ► Read main bearing play "B" on the precision clearance gauges according to the manufacturer's instructions. x 23 Required main bearing play: 0,04 mm - 0,06 mm ► If the main bearing play is incorrect, repeat the process using another main bearing shell thickness.

  • Page 224: Stub Shaft

    020.02 Stub shaft 020.02 Stub shaft RLF MPE850 Rev 1.2 | 406555 |...

  • Page 225: Removing Stub Shaft

    020.02 Stub shaft 020.02.01 Removing stub shaft 020.02.01 Removing stub shaft – Locking tool crankshaft – Reversible ratchet – Hexagon screwdriver 8 – Hexagon screwdriver socket 7 Mount the engine on the engine stand ► Mount the engine across from the drive side of the engine stand.
  • Page 226 020.02 Stub shaft 020.02.01 Removing stub shaft ► Unscrew the bolts ► Remove the locking tool crankshaft ► Remove the rotor ► Remove the stub shaft RLF MPE850 Rev 1.2 | 406555 |...

  • Page 227: Installing Stub Shaft

    020.02 Stub shaft 020.02.02 Installing stub shaft 020.02.02 Installing stub shaft – Locking tool crankshaft – Torque wrench – Hexagon screwdriver 8 – Hexagon screwdriver socket 7 Leaks due to damage to the coating on the bolts. The threads of the 6 bolts on the rotor have a micro encapsulated coating. During fastening the bolt, the microcapsules will burst and the contained adhesive and curing agent are released and mixed.
  • Page 228 020.02 Stub shaft 020.02.02 Installing stub shaft ► Replace the bolts ► Screw in the bolts by hand. Do not tighten. ► Hold the locking tool crankshaft on rotor. ► Screw in the bolt and washer. ► Tighten the bolts Tightening torque: 60 Nm +10 Nm [44.3 lbf ft +7.4 lbf ft] ►...

  • Page 229: Crankshaft Cover

    020.03 Crankshaft cover 020.03 Crankshaft cover RLF MPE850 Rev 1.2 | 406555 |...

  • Page 230: Removing Crankshaft Cover

    020.03 Crankshaft cover 020.03.01 Removing crankshaft cover 020.03.01 Removing crankshaft cover – Torx® screwdriver T30 Mount the engine on the engine stand ► Mount the engine on the drive side the engine stand. (See chapter 3.3.1 Mount the engine on the drive side of the engine stand.) ►...

  • Page 231: Installing Crankshaft Cover

    020.03 Crankshaft cover 020.03.02 Installing crankshaft cover 020.03.02 Installing crankshaft cover – Petroleum jelly – Torx® screwdriver socket T30 – Torque wrench ► Replace the gasket ► Coat the gasket lightly with petroleum jelly. ► Insert the cover ► Screw in the bolt Tightening torque: 8 Nm +2 Nm [5.9 lbf ft +1.5 lbf ft] RLF MPE850 Rev 1.2 | 406555 |...

  • Page 232: Cylinder Head

    030.01 Valve cover Cylinder head 030.01 Valve cover RLF MPE850 Rev 1.2 | 406555 |...

  • Page 233: Removing Valve Cover

    030.01 Valve cover 030.01.01 Removing valve cover 030.01.01 Removing valve cover – 030.01.04 Removing ignition coils – Hexagon screwdriver 5 Preparation ► Remove the ignition coils. (See chapter 030.01.04 Removing ignition coils.) Removing valve cover ► Unscrew the bolts ► Remove the valve cover RLF MPE850 Rev 1.2 | 406555 |...

  • Page 234: Installing Valve Cover

    030.01 Valve cover 030.01.02 Installing valve cover 030.01.02 Installing valve cover – 030.01.05 Installing ignition coils – Torque wrench – Anti-Seize assembly paste – Hexagon screwdriver socket 5 – Sealing surface cleaner Installing valve cover ► Replace the valve cover seals ►...

  • Page 235: Replacing Valve Cover

    030.01 Valve cover 030.01.03 Replacing valve cover 030.01.03 Replacing valve cover – 030.01.04 Removing ignition coils – 030.01.01 Removing valve cover – 030.01.06 Removing sensor camshaft – Hexagon screwdriver 5 – Petroleum jelly – Hexagon screwdriver socket 5 – Sealing surface cleaner –...
  • Page 236 030.01 Valve cover 030.01.03 Replacing valve cover ► Insert the sensor camshaft No threads are cut in the new valve cover. Use the self-tapping bolts included with the valve cover. ► Lightly press down on the bolt screw in. Tightening torque: 8 Nm +2 Nm [5.9 lbf ft +1.5 lbf ft] ►...
  • Page 237 030.01 Valve cover 030.01.03 Replacing valve cover ► Insert the ignition coils ► Replace the serrated lock washers No threads are cut in the new valve cover. Use the self-tapping bolts included with the valve cover. ► Lightly press down on the bolts screw in.

  • Page 238: Removing Ignition Coils

    030.01 Valve cover 030.01.04 Removing ignition coils 030.01.04 Removing ignition coils – Hexagon screwdriver 5 ► Unscrew the bolts ► Pull the ignition coils out. RLF MPE850 Rev 1.2 | 406555 |...

  • Page 239: Installing Ignition Coils

    030.01 Valve cover 030.01.05 Installing ignition coils 030.01.05 Installing ignition coils – Torque wrench – Hexagon screwdriver socket 5 ► Insert the ignition coils ► Replace the serrated lock washers ► Screw in the bolts . Observe the arrangement of the serrated lock washers and washers.

  • Page 240: Removing Sensor Camshaft

    030.01 Valve cover 030.01.06 Removing sensor camshaft 030.01.06 Removing sensor camshaft – Hexagon screwdriver 5 ► Unscrew the bolt ► Pull the sensor camshaft out. RLF MPE850 Rev 1.2 | 406555 |...

  • Page 241: Installing Sensor Camshaft

    030.01 Valve cover 030.01.07 Installing sensor camshaft 030.01.07 Installing sensor camshaft – Petroleum jelly – Hexagon screwdriver socket 5 – Torque wrench ► Coat the o-ring lightly with petroleum jelly. ► Insert the sensor camshaft ► Screw in the bolt Tightening torque: 8 Nm +2 Nm [5.9 lbf ft +1.5 lbf ft] RLF MPE850 Rev 1.2 | 406555 |...

  • Page 242: Cylinder Head

    030.02 Cylinder head 030.02 Cylinder head RLF MPE850 Rev 1.2 | 406555 |...

  • Page 243: Removing Cylinder Head

    030.02 Cylinder head 030.02.01 Removing cylinder head 030.02.01 Removing cylinder head – 070.01.01 Removing intake manifold – 040.01.02 Removing chain tensioner – 030.01.04 Removing ignition coils – 040.01.04 Opening timing chain with chain – 030.01.01 Removing valve cover breaking tool –...
  • Page 244 030.02 Cylinder head 030.02.01 Removing cylinder head Setting valve timing ► Turn the crankshaft on a bolt in the direction shown until the camshaft stops as shown in the following figure. ► Check whether the camshaft is at the crossing point. The position of the camshaft is as illustrated The marking ends flush with the cross...
  • Page 245 030.02 Cylinder head 030.02.01 Removing cylinder head ► Unscrew the nuts The rocker arm and cross bars are no longer firmly attached to the cylinder head. Do not turn the cylinder head. ► Remove the cylinder head RLF MPE850 Rev 1.2 | 406555 |...

  • Page 246: Installing Cylinder Head

    030.02 Cylinder head 030.02.02 Installing cylinder head 030.02.02 Installing cylinder head – 040.01.05 Closing timing chain with chain – 030.01.02 Installing valve cover breaking tool – 030.01.05 Installing ignition coils – 040.01.03 Installing chain tensioner – 070.01.02 Installing intake manifold –...
  • Page 247 030.02 Cylinder head 030.02.02 Installing cylinder head ► Put the cylinder head Observe the installation position: – Exhaust side – Oil filter ► Tighten the nuts in the sequence as illustrated in three stages. Tightening torque: First stage 20 Nm ±3 Nm [14.8 lbf ft ±2.2 lbf ft] Second stage 40 Nm ±3 Nm [29.5 lbf ft ±2.2 lbf ft] Third stage...
  • Page 248 030.02 Cylinder head 030.02.02 Installing cylinder head ► Check whether the camshaft is at the crossing point. The position of the camshaft is as illustrated The marking ends flush with the cross bar. ► If the camshaft does not appear as shown, turn it.
  • Page 249 030.02 Cylinder head 030.02.02 Installing cylinder head Completion ► Install the valve cover. (See chapter 030.01.02 Installing valve cover.) ► Install the ignition coils. (See chapter 030.01.05 Installing ignition coils.) ► Install the intake manifold. (See chapter 070.01.02 Installing intake manifold.) RLF MPE850 Rev 1.2 | 406555 |...

  • Page 250: Replacing Cylinder Head

    030.02 Cylinder head 030.02.03 Replacing cylinder head 030.02.03 Replacing cylinder head – 070.01.01 Removing intake manifold – 040.03.02 Installing valve – 030.01.04 Removing ignition coils – 030.02.02 Installing cylinder head – 030.01.01 Removing valve cover – 030.01.02 Installing valve cover –...
  • Page 251 030.02 Cylinder head 030.02.03 Replacing cylinder head Replacing cylinder head ► Unscrew the bolts ► Remove the bracket ► Unscrew the switch oil pressure ► Unscrew the bolt ► Remove the bracket ► Unscrew the fitting ► Unscrew the studs using a stud extractor.
  • Page 252 030.02 Cylinder head 030.02.03 Replacing cylinder head ► Unscrew the bolts ► Remove the fuel rail ► Remove the sleeves RLF MPE850 Rev 1.2 | 406555 |...
  • Page 253 030.02 Cylinder head 030.02.03 Replacing cylinder head ► Unscrew the bolts Info rmatio n ! The hole in the remover bearing cap is provided for mounting a slide hammer. ► Remove the bearing cap using the remover bearing cap ► Remove the camshaft ►...
  • Page 254 030.02 Cylinder head 030.02.03 Replacing cylinder head ► Unscrew the bolts ► Remove the bearing cap ► Check if the sleeves are installed. ► Coat the camshaft on the bearing surfaces lightly with engine oil. ► Insert the camshaft. The camshaft is marked at the 2nd cylinder end only.
  • Page 255 030.02 Cylinder head 030.02.03 Replacing cylinder head NOTICE! Bearing damage due to the bearing cap being installed incorrectly. The bearing surfaces for supporting the camshaft in the cylinder head and in the bearing cap are processed together. Therefore, only use the bearing cap originally installed. Observe the markings during installation.
  • Page 256 030.02 Cylinder head 030.02.03 Replacing cylinder head ► Coat the o-rings lightly with petroleum jelly. ► Insert the fuel rail ► Screw in the bolts Tightening torque: 8 Nm +2 Nm [5.9 lbf ft +1.5 lbf ft] ► Screw in a new plug Tightening torque: 9 Nm +2 Nm [6.6 lbf ft +1.5 lbf ft] ►...
  • Page 257 030.02 Cylinder head 030.02.03 Replacing cylinder head ► Hold the bracket in position. ► Screw in the bolt Tightening torque: 8 Nm +2 Nm [5.9 lbf ft +1.5 lbf ft] ► Replace the seal ► Screw in the fitting Tightening torque: 8 Nm +2 Nm [5.9 lbf ft +1.5 lbf ft] ►...
  • Page 258 030.02 Cylinder head 030.02.03 Replacing cylinder head Completion ► Install all valves. (See chapter 040.03.02 Installing valve.) ► Install the cylinder head. (See chapter 030.02.02 Installing cylinder head.) ► Install the valve cover. (See chapter 030.01.02 Installing valve cover.) ► Install the ignition coils.

  • Page 259: Removing Spark Plugs

    030.02 Cylinder head 030.02.04 Removing spark plugs 030.02.04 Removing spark plugs – 030.01.04 Removing ignition coils – Reversible ratchet – Spark plug wrench Preparation ► Remove the ignition coils. (See chapter 030.01.04 Removing ignition coils.) Removing spark plugs ► Unscrew the spark plugs using a spark plug wrench.

  • Page 260: Installing Spark Plugs

    030.02 Cylinder head 030.02.05 Installing spark plugs 030.02.05 Installing spark plugs – 030.01.05 Installing ignition coils – Torque wrench – Spark plug wrench Installing spark plugs ► Screw in the spark plugs using a spark plug wrench. Tightening torque: 22 Nm +10 Nm [16.2 lbf ft +7.4 lbf ft] Completion ►...

  • Page 261: Removing Switch Oil Pressure

    030.02 Cylinder head 030.02.06 Removing switch oil pressure 030.02.06 Removing switch oil pressure – Open-end wrench 24 ► Unscrew the switch oil pressure RLF MPE850 Rev 1.2 | 406555 |...

  • Page 262: Installing Switch Oil Pressure

    030.02 Cylinder head 030.02.07 Installing switch oil pressure 030.02.07 Installing switch oil pressure – Torque wrench – Thread sealant – Insert open-end wrench 24 ► Coat the thread on the switch oil pressure with thread sealant. ► Screw in the switch oil pressure. Tightening torque: 9 Nm +2 Nm [6.6 lbf ft +1.5 lbf ft] RLF MPE850 Rev 1.2 | 406555 |...

  • Page 263: Removing Fitting

    030.02 Cylinder head 030.02.08 Removing fitting 030.02.08 Removing fitting – Open-end wrench 12 ► Unscrew the fitting RLF MPE850 Rev 1.2 | 406555 |...

  • Page 264: Installing Fitting

    030.02 Cylinder head 030.02.09 Installing fitting 030.02.09 Installing fitting – Torque wrench – Insert open-end wrench 12 ► Replace the seal ► Screw in the fitting Tightening torque: 8 Nm +2 Nm [5.9 lbf ft +1.5 lbf ft] RLF MPE850 Rev 1.2 | 406555 |...

  • Page 265: Replacing Plugs

    030.02 Cylinder head 030.02.10 Replacing plugs 030.02.10 Replacing plugs – Hexagon screwdriver 4, 5 – Hexagon screwdriver socket 4, 5 – Torque wrench – Plug across from the drive side – Plugs exhaust side – Plug drive side Replacing plug across from the drive side ►...
  • Page 266 030.02 Cylinder head 030.02.10 Replacing plugs Replacing plugs drive side ► Unscrew the plugs ► Replace the plugs. ► Screw in the plugs. Tightening torque: 6 Nm +2 Nm [4.4 lbf ft +1.5 lbf ft] Replacing plug drive side ► Unscrew the plug ►...

  • Page 267: Mounting Camshaft

    030.02 Cylinder head 030.02.11 Mounting camshaft 030.02.11 Mounting camshaft See chapter 040.01.01 Replacing camshaft. RLF MPE850 Rev 1.2 | 406555 |...

  • Page 268: Valve Train

    040.01 Camshaft Valve train 040.01 Camshaft RLF MPE850 Rev 1.2 | 406555 |...

  • Page 269: Replacing Camshaft

    040.01 Camshaft 040.01.01 Replacing camshaft 040.01.01 Replacing camshaft – 070.01.01 Removing intake manifold – 040.01.05 Closing timing chain with chain – 030.01.04 Removing ignition coils breaking tool – 030.01.01 Removing valve cover – 040.01.03 Installing chain tensioner – 040.01.02 Removing chain tensioner –...
  • Page 270 040.01 Camshaft 040.01.01 Replacing camshaft Preparation ► Remove the intake manifold. (See chapter 070.01.01 Removing intake manifold.) ► Remove the ignition coils. (See chapter 030.01.04 Removing ignition coils.) ► Remove the valve cover. (See chapter 030.01.01 Removing valve cover.) Setting valve timing ►...
  • Page 271 040.01 Camshaft 040.01.01 Replacing camshaft ► Remove the chain tensioner. (See chapter 040.01.02 Removing chain tensioner.) ► Open the timing chain. (See chapter 040.01.04 Opening timing chain with chain breaking tool.) ► Secure the ends of the timing chain. ► Unscrew the nuts ►...
  • Page 272 040.01 Camshaft 040.01.01 Replacing camshaft ► Remove the bearing cap using the remover bearing cap ► Remove the camshaft ► Remove the cylinder head RLF MPE850 Rev 1.2 | 406555 |...
  • Page 273 040.01 Camshaft 040.01.01 Replacing camshaft ► Check if the centering pins are installed. The cylinder head gasket can be found in the spare parts catalog in chapter 030.02 Cylinder head. ► Replace the cylinder head gasket ► Put the cylinder head gasket on. Observe the installation position.
  • Page 274 040.01 Camshaft 040.01.01 Replacing camshaft ► Replace the camshaft. ► Coat the camshaft on the bearing surfaces lightly with engine oil. ► Insert the camshaft. The camshaft is marked at the 2nd cylinder end only. Observe the installation position. – Inscription –...
  • Page 275 040.01 Camshaft 040.01.01 Replacing camshaft ► Screw in the bolts Tightening torque: 8 Nm +2 Nm [5.9 lbf ft +1.5 lbf ft] ► Insert the valve adjustment shims ► Insert the rocker arms and cross bars ► Tighten the nuts in the sequence as illustrated in three stages.
  • Page 276 040.01 Camshaft 040.01.01 Replacing camshaft Setting valve timing ► Check if the crankshaft is at TDC (Top Dead Center). The markings fit together. ► If the markings do not line up, turn the rotor ► Check whether the camshaft is at the crossing point.
  • Page 277 040.01 Camshaft 040.01.01 Replacing camshaft ► Check whether the camshaft is at the crossing point. The position of the camshaft is as illustrated The marking ends flush with the cross bar. ► If the camshaft does not appear as shown, set the valve timing again.

  • Page 278: Removing Chain Tensioner

    040.01 Camshaft 040.01.02 Removing chain tensioner 040.01.02 Removing chain tensioner – Open-end wrench 27 Info rmatio n ! The following chapter only describes how to remove the chain tensioner. Always observe the instructions in the chapters for the timing chain and valve timing. ►...

  • Page 279: Installing Chain Tensioner

    040.01 Camshaft 040.01.03 Installing chain tensioner 040.01.03 Installing chain tensioner – Torque wrench – Insert open-end wrench 27 Info rmatio n ! The following chapter only describes how to install the chain tensioner. Always observe the instructions in the chapters for the timing chain and valve timing. ►...

  • Page 280: Opening Timing Chain With Chain Breaking Tool

    040.01 Camshaft 040.01.04 Opening timing chain with chain breaking tool 040.01.04 Opening timing chain with chain breaking tool – Chain breaking tool – Hexagon screwdriver 5 – Reversible ratchet – Insert open-end wrench 16, 24 Info rmatio n ! The following chapter only describes how to open the timing chain using the chain breaking tool.
  • Page 281 040.01 Camshaft 040.01.04 Opening timing chain with chain breaking tool ► Screw in the bolt until the chain braking tool is firmly seated. ► Screw in the bolt using a open-end wrench until the bolt of the chain link is pushed out.

  • Page 282: Closing Timing Chain With Chain Breaking Tool

    040.01 Camshaft 040.01.05 Closing timing chain with chain breaking tool 040.01.05 Closing timing chain with chain breaking tool – Chain breaking tool – Hexagon screwdriver 5 – Universal pliers – Insert open-end wrench 24 – Reversible ratchet Info rmatio n ! The following chapter only describes how to close the timing chain using the chain breaking tool.
  • Page 283 040.01 Camshaft 040.01.05 Closing timing chain with chain breaking tool ► Screw in the bolt until the chain breaking tool is firmly seated. ► Screw in the bolt using a open-end wrench until the bolt of the chain link is rivited. ►...

  • Page 284: Removing Timing Chain

    040.01 Camshaft 040.01.06 Removing timing chain 040.01.06 Removing timing chain – 040.01.02 Removing chain tensioner – 040.01.04 Opening timing chain with chain breaking tool Info rmatio n ! The following chapter only describes how to remove the timing chain. Always observe the instructions in the chapters for the timing chain and valve timing.

  • Page 285: Installing Timing Chain

    040.01 Camshaft 040.01.07 Installing timing chain 040.01.07 Installing timing chain – 040.01.05 Closing timing chain with chain – 040.01.03 Installing chain tensioner breaking tool Info rmatio n ! The following chapter only describes how to install the timing chain. Always observe the instructions in the chapters for the timing chain and valve timing.
  • Page 286 040.01 Camshaft 040.01.07 Installing timing chain ► Turn the engine 180°. ► Close the timing chain. (See chapter 040.01.05 Closing timing chain with chain breaking tool.) ► Install the chain tensioner. (See chapter 040.01.03 Installing chain tensioner.) RLF MPE850 Rev 1.2 | 406555 |...

  • Page 287: Replacing Timing Chain

    040.01 Camshaft 040.01.08 Replacing timing chain 040.01.08 Replacing timing chain – 110.01.01 Removing suction pump cover – 040.01.05 Closing timing chain with chain – 030.01.04 Removing ignition coils breaking tool – 030.01.01 Removing valve cover – 040.01.03 Installing chain tensioner –...
  • Page 288 040.01 Camshaft 040.01.08 Replacing timing chain Setting valve timing ► Turn the crankshaft on a bolt in the direction shown until the camshaft stops as shown in the following figure. ► Check whether the camshaft is at the crossing point. The position of the camshaft is as illustrated The marking ends flush with the cross...
  • Page 289 040.01 Camshaft 040.01.08 Replacing timing chain ► Turn the engine 180°. ► Remove the timing chain ► Replace the timing chain. ► Insert the timing chain as illustrated. ► Insert the chain link on the open ends of the timing chain. ►...
  • Page 290 040.01 Camshaft 040.01.08 Replacing timing chain ► Check whether the camshaft is at the crossing point. The position of the camshaft is as illustrated The marking ends flush with the cross bar. ► If the camshaft does not appear as shown, turn it.
  • Page 291 040.01 Camshaft 040.01.08 Replacing timing chain Completion ► Install the valve cover. (See chapter 030.01.02 Installing valve cover.) ► Install the ignition coils. (See chapter 030.01.05 Installing ignition coils.) ► Turn the engine 180°. ► Install the suction pump cover. (See chapter 110.01.02 Installing suction pump cover.) RLF MPE850 Rev 1.2 | 406555 |...

  • Page 292: Replacing Chain Rail

    040.01 Camshaft 040.01.09 Replacing chain rail 040.01.09 Replacing chain rail – Torx® screwdriver T30 – Torx® screwdriver socket T30 – Torque wrench The cylinder head is removed. ► Unscrew the bolt ► Remove the chain rail ► Replace the chain rail. ►...

  • Page 293: Replacing Chain Guide

    040.01 Camshaft 040.01.10 Replacing chain guide 040.01.10 Replacing chain guide – Hexagon screwdriver 5 – Hexagon screwdriver socket 5 – Torque wrench The upper case is disconnected from the lower case. ► Unscrew the bolts ► Remove the chain guide ►...

  • Page 294: Checking Valve Timing

    040.01 Camshaft 040.01.11 Checking valve timing 040.01.11 Checking valve timing – 090.02.01 Removing generator – 030.01.02 Installing valve cover – 030.01.04 Removing ignition coils – 030.01.05 Installing ignition coils – 030.01.01 Removing valve cover – 090.02.02 Installing generator – Hexagon screwdriver 7 –...
  • Page 295 040.01 Camshaft 040.01.11 Checking valve timing Use a hexagon screwdriver socket 8 and reversible ratchet. ► Turn the crankshaft on the TDC-adjusting tool in the direction shown until the marking ends flush with the crankcase halves ► Check whether the camshaft is at the crossing point.
  • Page 296 040.01 Camshaft 040.01.11 Checking valve timing Completion ► Install the valve cover. (See chapter 030.01.02 Installing valve cover.) ► Install the ignition coils. (See chapter 030.01.05 Installing ignition coils.) ► Install the generator. (See chapter 090.02.02 Installing generator.) RLF MPE850 Rev 1.2 | 406555 |...

  • Page 297: Setting Valve Timing

    040.01 Camshaft 040.01.12 Setting valve timing 040.01.12 Setting valve timing – 090.02.01 Removing generator – 040.01.05 Closing timing chain with chain – 030.01.04 Removing ignition coils breaking tool – 030.01.01 Removing valve cover – 040.01.03 Installing chain tensioner – 040.01.02 Removing chain tensioner –...
  • Page 298 040.01 Camshaft 040.01.12 Setting valve timing Use a hexagon screwdriver socket 8 and reversible ratchet. ► Turn the crankshaft on the TDC-adjusting tool in the direction shown until the camshaft stops as shown in the following figure. ► Check whether the camshaft is at the crossing point.
  • Page 299 040.01 Camshaft 040.01.12 Setting valve timing Use a hexagon screwdriver socket 8 and reversible ratchet. ► Turn the crankshaft on the TDC-adjusting tool in the direction shown until the marking ends flush with the crankcase halves ► Close the timing chain. (See chapter 040.01.05 Closing timing chain with chain breaking tool.) ►...

  • Page 300: Rocker Arms

    040.02 Rocker arms 040.02 Rocker arms RLF MPE850 Rev 1.2 | 406555 |...

  • Page 301: Replacing Rocker Arms

    040.02 Rocker arms 040.02.01 Replacing rocker arms 040.02.01 Replacing rocker arms – 030.01.04 Removing ignition coils – 030.01.05 Installing ignition coils – 030.01.01 Removing valve cover – 030.01.02 Installing valve cover – Universal pliers – Hexagon screwdriver socket 7 – Reversible ratchet –...
  • Page 302 040.02 Rocker arms 040.02.01 Replacing rocker arms Replacing a rocker arm on the 2nd cylinder ► Turn the crankshaft on a bolt in the direction shown until the camshaft stops as shown in the following figure. The camshaft is marked at the 2nd cylinder end only.
  • Page 303 040.02 Rocker arms 040.02.01 Replacing rocker arms The camshaft is marked at the 2nd cylinder end only. ► Check whether the camshaft is at the crossing point. The position of the camshaft is as illustrated. The inscription is not visible. All rocker arms on the cylinder have a certain amount of play.
  • Page 304 040.02 Rocker arms 040.02.01 Replacing rocker arms ► Replace the rocker arm ► Hold the rocker arm in position. ► Check if the circlip is installed. ► Slide in the rocker axle NOTICE! Valve breakage due to insufficient valve play. ►...
  • Page 305 040.02 Rocker arms 040.02.01 Replacing rocker arms ► Check the valve play of all valves on the cylinder using a feeler gauge. Required valve play: 0,2 – 0,3 mm ► If the valve play of one or more valves is not right, remove the rocker arm and replace the valve adjustment shim.
  • Page 306 040.02 Rocker arms 040.02.01 Replacing rocker arms ► Check the valve play of all valves on the cylinder using a feeler gauge. Required valve play: 0,2 – 0,3 mm ► If the valve play of one or more valves is not right, remove the rocker arm and replace the valve adjustment shim.

  • Page 307: Valves

    040.03 Valves 040.03 Valves RLF MPE850 Rev 1.2 | 406555 |...

  • Page 308: Removing Valve

    040.03 Valves 040.03.01 Removing valve 040.03.01 Removing valve – 070.01.01 Removing intake manifold – 030.01.01 Removing valve cover – 030.01.04 Removing ignition coils – 030.02.01 Removing cylinder head – Valve spring compressor – Bar magnet Info rmatio n ! The following chapter describes how to remove a valve. If you want to remove several valves, apply the procedure for any number of valves.
  • Page 309 040.03 Valves 040.03.01 Removing valve Preparation ► Remove the intake manifold. (See chapter 070.01.01 Removing intake manifold.) ► Remove the ignition coils. (See chapter 030.01.04 Removing ignition coils.) ► Remove the valve cover. (See chapter 030.01.01 Removing valve cover.) ► Remove the cylinder head.
  • Page 310 040.03 Valves 040.03.01 Removing valve ► Remove the spring cup , valve spring and spring pad ► Remove the valve stem seal ► Pull the valve out. RLF MPE850 Rev 1.2 | 406555 |...

  • Page 311: Installing Valve

    040.03 Valves 040.03.02 Installing valve 040.03.02 Installing valve – 030.02.02 Installing cylinder head – 030.01.05 Installing ignition coils – 030.01.02 Installing valve cover – 070.01.02 Installing intake manifold – Valve spring compressor – Reversible ratchet – Valve refacer – Hexagon screwdriver socket 7 –...
  • Page 312 040.03 Valves 040.03.02 Installing valve ► Coat the valve stem lightly with engine oil. ► Slide in the valve. ► Insert the valve using the valve refacer. ► Insert the spring pad , valve spring and spring cup ► Install the valve spring compressor according to the manufacturer's instructions.
  • Page 313 040.03 Valves 040.03.02 Installing valve ► Insert the valve adjustment shims ► Insert the rocker arms and cross bars ► Install the cylinder head. (See chapter 030.02.02 Installing cylinder head.) NOTICE! Valve breakage due to insufficient valve play. ► Check valve play. Continue with the section Checking valve play on the 2nd cylinder.
  • Page 314 040.03 Valves 040.03.02 Installing valve The camshaft is marked at the 2nd cylinder end only. ► Check whether the camshaft is at the crossing point. The position of the camshaft is as illustrated. The marking ends flush with the cross bar.
  • Page 315 040.03 Valves 040.03.02 Installing valve The camshaft is marked at the 2nd cylinder end only. ► Check whether the camshaft is at the crossing point. The position of the camshaft is as illustrated. The inscription is not visible. All rocker arms on the cylinder have a certain amount of play.

  • Page 316: Cooling System

    050.01 Thermostat housing Cooling system 050.01 Thermostat housing RLF MPE850 Rev 1.2 | 406555 |...

  • Page 317: Removing Thermostat Housing

    050.01 Thermostat housing 050.01.01 Removing thermostat housing 050.01.01 Removing thermostat housing – Hexagon screwdriver 5 ► Unscrew 10 bolts The bolt is an additional part and not installed in every engine. ► Unscrew the bolt The thermostat housing is caulked with a silicone liquid seal.

  • Page 318: Installing Thermostat Housing

    050.01 Thermostat housing 050.01.02 Installing thermostat housing 050.01.02 Installing thermostat housing – Torque wrench – Hexagon screwdriver – Sealing surface cleaner socket 5 – Silicone liquid seal ► Clean the sealing surface with sealing surface cleaner. ► Clean the sealing surface with sealing surface cleaner.
  • Page 319 050.01 Thermostat housing 050.01.02 Installing thermostat housing ► Hold the thermostat housing in position. ► Screw in 10 bolts Tightening torque: 8 Nm +2 Nm [5.9 lbf ft +1.5 lbf ft] The bolt is an additional part and not installed in every engine.

  • Page 320: Removing Fitting

    050.01 Thermostat housing 050.01.03 Removing fitting 050.01.03 Removing fitting – Torx® screwdriver T30 ► Unscrew 2 bolts ► Remove the fitting RLF MPE850 Rev 1.2 | 406555 |...

  • Page 321: Installing Fitting

    050.01 Thermostat housing 050.01.04 Installing fitting 050.01.04 Installing fitting – Petroleum jelly – Torx® screwdriver socket – Torque wrench ► Replace the o-ring ► Coat the o-ring lightly with petroleum jelly. ► Insert the fitting ► Screw in 2 bolts Tightening torque: 8 Nm +2 Nm [5.9 lbf ft +1.5 lbf ft] RLF MPE850 Rev 1.2 | 406555 |...

  • Page 322: Removing Thermostat

    050.01 Thermostat housing 050.01.05 Removing thermostat 050.01.05 Removing thermostat – 050.01.03 Removing fitting Preparation ► Remove the fitting. (See chapter 050.01.03 Removing fitting.) Removing thermostat ► Remove the thermostat and distance washer RLF MPE850 Rev 1.2 | 406555 |...

  • Page 323: Installing Thermostat

    050.01 Thermostat housing 050.01.06 Installing thermostat 050.01.06 Installing thermostat – 050.01.04 Installing fitting Installing thermostat ► Put a new distance washer thermostat ► Insert the thermostat Observe the installation position: – Locating tab at thermostat Completion ► Install the fitting. (See chapter 050.01.04 Installing fitting.) RLF MPE850 Rev 1.2 | 406555 |...

  • Page 324: Replacing Sensor Coolant Temperature

    050.01 Thermostat housing 050.01.07 Replacing sensor coolant temperature 050.01.07 Replacing sensor coolant temperature – Open-end wrench 19 – Insert open-end wrench 19 – Torque wrench ► Unscrew the sensor coolant temperature ► Replace the sensor coolant temperature. ► Screw in the sensor coolant temperature. Tightening torque: 18 Nm +7 Nm [13.3 lbf ft +5.2 lbf ft] RLF MPE850 Rev 1.2 | 406555 |...

  • Page 325: Replacing Plug Thermostat Housing

    050.01 Thermostat housing 050.01.08 Replacing plug thermostat housing 050.01.08 Replacing plug thermostat housing – Hexagon screwdriver 7 – Hexagon screwdriver – Torque wrench socket 7 ► Unscrew the plug ► Replace the plug. ► Screw in the plug. Tightening torque: 14 Nm +2 Nm [10.3 lbf ft +1.5 lbf ft] RLF MPE850 Rev 1.2 | 406555 |...

  • Page 326: Removing Closing Cap Thermostat Housing

    050.01 Thermostat housing 050.01.09 Removing closing cap thermostat housing 050.01.09 Removing closing cap thermostat housing – Hexagon nut-driver 7 ► Open the hose clamp ► Remove the closing cap RLF MPE850 Rev 1.2 | 406555 |...

  • Page 327: Installing Closing Cap Thermostat Housing

    050.01 Thermostat housing 050.01.10 Installing closing cap thermostat housing 050.01.10 Installing closing cap thermostat housing – Torque wrench – 6-point socket wrench 7 ► Insert the closing cap ► Close the hose clamp Tightening torque: 3 Nm +0,5 Nm [2.2 lbf ft +0.4 lbf ft] RLF MPE850 Rev 1.2 | 406555 |...

  • Page 328: Coolant Pump

    050.02 Coolant pump 050.02 Coolant pump RLF MPE850 Rev 1.2 | 406555 |...

  • Page 329: Removing Impeller

    050.02 Coolant pump 050.02.01 Removing impeller 050.02.01 Removing impeller – 050.03.01 Removing oil cooler – 010.02-1.01 Removing oil cooler bracket – Locking tool crankshaft – 6-point socket wrench 10 – Reversible ratchet – Hexagon screwdriver 8 Mount the engine on the engine stand ►...
  • Page 330 050.02 Coolant pump 050.02.01 Removing impeller ► Unscrew the nut ► Remove the impeller ► Remove the locking tool crankshaft RLF MPE850 Rev 1.2 | 406555 |...

  • Page 331: Installing Impeller

    050.02 Coolant pump 050.02.02 Installing impeller 050.02.02 Installing impeller – 010.02-1.02 Installing oil cooler bracket – 050.03.02 Installing oil cooler – Locking tool crankshaft – Torque wrench – Hexagon screwdriver 8 – 6-point socket wrench 10 Installing impeller ► Hold the locking tool crankshaft on rotor.
  • Page 332 050.02 Coolant pump 050.02.02 Installing impeller ► Remove the locking tool crankshaft Completion ► Install the oil cooler bracket. (See chapter 010.02-1.02 Installing oil cooler bracket.) ► Install the oil cooler. (See chapter 050.03.02 Installing oil cooler.) RLF MPE850 Rev 1.2 | 406555 |...

  • Page 333: Removing Coolant Pump

    050.02 Coolant pump 050.02.03 Removing coolant pump 050.02.03 Removing coolant pump – 050.03.01 Removing oil cooler – 010.02-1.01 Removing oil cooler bracket – Locking tool crankshaft – Open-end wrench 7 – Reversible ratchet – 6-point socket wrench 10 – Hexagon screwdriver 8 Mount the engine on the engine stand ►...
  • Page 334 050.02 Coolant pump 050.02.03 Removing coolant pump ► Unscrew the nut ► Remove the impeller ► Unscrew the water pump axle using a open-end wrench. ► Remove the locking tool crankshaft RLF MPE850 Rev 1.2 | 406555 |...

  • Page 335: Installing Coolant Pump

    050.02 Coolant pump 050.02.04 Installing coolant pump 050.02.04 Installing coolant pump – 010.02-1.02 Installing oil cooler bracket – 050.03.02 Installing oil cooler – Petroleum jelly – Torque wrench – Locking tool crankshaft – Open-end wrench 7, 15 – Hexagon screwdriver 8 –...
  • Page 336 050.02 Coolant pump 050.02.04 Installing coolant pump ► Replace the sealing bracket ► Coat the gasket and o-ring lightly with petroleum jelly. ► Coat the inside of the oil seal lightly with petroleum jelly. ► Insert the sealing bracket ► Screw in the guide using a open-end wrench.
  • Page 337 050.02 Coolant pump 050.02.04 Installing coolant pump ► Slide the slide ring seal onto guide. ► Hold the sliding sleeve in position. ► Screw on the nut ► Screw in the nut using a open-end wrench until the slide ring seal is inserted completely.
  • Page 338 050.02 Coolant pump 050.02.04 Installing coolant pump ► Unscrew the nut ► Remove the sliding sleeve ► Unscrew the guide using a open-end wrench. ► Insert the impeller ► Screw on the nut Tightening torque: 9 Nm +2 Nm [6.6 lbf ft +1.5 lbf ft] RLF MPE850 Rev 1.2 | 406555 |...
  • Page 339 050.02 Coolant pump 050.02.04 Installing coolant pump ► Remove the locking tool crankshaft Completion ► Install the oil cooler bracket. (See chapter 010.02-1.02 Installing oil cooler bracket.) ► Install the oil cooler. (See chapter 050.03.02 Installing oil cooler.) RLF MPE850 Rev 1.2 | 406555 |...

  • Page 340: Oil Cooler

    050.03 Oil cooler 050.03 Oil cooler RLF MPE850 Rev 1.2 | 406555 |...

  • Page 341: Removing Oil Cooler

    050.03 Oil cooler 050.03.01 Removing oil cooler 050.03.01 Removing oil cooler – Torx® screwdriver T30 Mount the engine on the engine stand ► Mount the engine on the drive side the engine stand. (See chapter 3.3.1 Mount the engine on the drive side of the engine stand.) ►...

  • Page 342: Installing Oil Cooler

    050.03 Oil cooler 050.03.02 Installing oil cooler 050.03.02 Installing oil cooler – Petroleum jelly – Torx® screwdriver socket T30 – Torque wrench ► Replace the gaskets ► Insert the gaskets into the grooves and lightly coat with petroleum jelly. ► Hold the oil cooler in position.

  • Page 343: Exhaust System

    062.01 Mounting exhaust manifold Exhaust system 062.01 Mounting exhaust manifold RLF MPE850 Rev 1.2 | 406555 |...

  • Page 344: Instructions For Mounting Nuts And Exhaust Gasket

    062.01 Mounting exhaust manifold 062.01.01 Instructions for mounting nuts and exhaust gasket 062.01.01 Instructions for mounting nuts and exhaust gasket – Anti-Seize assembly paste – Torque wrench – Reversible ratchet – 6-point socket wrench 12 ► Replace the nuts ► Apply Anti-Seize assembly paste thoroughly to all studs ►...

  • Page 345: Replacing Studs

    062.01 Mounting exhaust manifold 062.01.02 Replacing studs 062.01.02 Replacing studs – Reversible ratchet – Stud extractor 8 – Torque wrench – Anti-Seize assembly paste ► Unscrew the studs using a stud extractor. ► Replace the studs. ► Apply Anti-Seize assembly paste to all studs. ►...

  • Page 346: Intake Area

    070.01 Intake manifold Intake area 070.01 Intake manifold RLF MPE850 Rev 1.2 | 406555 |...

  • Page 347: Removing Intake Manifold

    070.01 Intake manifold 070.01.01 Removing intake manifold 070.01.01 Removing intake manifold – Hexagon screwdriver 5 – Torx® screwdriver T45 ► Unscrew 4 bolts ► Unscrew the bolts RLF MPE850 Rev 1.2 | 406555 |...
  • Page 348 070.01 Intake manifold 070.01.01 Removing intake manifold ► Remove the intake manifold RLF MPE850 Rev 1.2 | 406555 |...

  • Page 349: Installing Intake Manifold

    070.01 Intake manifold 070.01.02 Installing intake manifold 070.01.02 Installing intake manifold – Petroleum jelly – Hexagon screwdriver socket 5 – Torque wrench – Torx® screwdriver socket T45 ► Replace the o-rings ► Insert the o-rings into the grooves lightly coat with petroleum jelly. ►...

  • Page 350: Removing Intake Manifold Bracket

    070.01 Intake manifold 070.01.03 Removing intake manifold bracket 070.01.03 Removing intake manifold bracket – 070.01.01 Removing intake manifold – Hexagon screwdriver 6 Preparation ► Remove the intake manifold. (See chapter 070.01.01 Removing intake manifold.) Removing intake manifold bracket ► Unscrew the bolts ►...

  • Page 351: Installing Intake Manifold Bracket

    070.01 Intake manifold 070.01.04 Installing intake manifold bracket 070.01.04 Installing intake manifold bracket – 070.01.02 Installing intake manifold – Torque wrench – Hexagon screwdriver socket 6 Installing intake manifold bracket ► Hold the intake manifold bracket position. ► Screw in the bolts Tightening torque: 20 Nm +4 Nm [14.8 lbf ft +3 lbf ft] Completion...

  • Page 352: Removing Sensor Intake Manifold Pressure/Temperature

    070.01 Intake manifold 070.01.05 Removing sensor intake manifold pressure/temperature 070.01.05 Removing sensor intake manifold pressure/temperature – Torx® screwdriver T30 ► Unscrew the bolt ► Pull the sensor intake manifold pressure/ temperature out. RLF MPE850 Rev 1.2 | 406555 |...

  • Page 353: Installing Sensor Intake Manifold Pressure/Temperature

    070.01 Intake manifold 070.01.06 Installing sensor intake manifold pressure/temperature 070.01.06 Installing sensor intake manifold pressure/temperature – Petroleum jelly – Torx® screwdriver socket T30 – Torque wrench ► Coat the o-ring lightly with petroleum jelly. ► Insert the sensor intake manifold pressure/ temperature ►...

  • Page 354: Mounting Throttle Body

    070.02 Mounting throttle body 070.02 Mounting throttle body RLF MPE850 Rev 1.2 | 406555 |...

  • Page 355: Removing Throttle Body

    070.02 Mounting throttle body 070.02.01 Removing throttle body 070.02.01 Removing throttle body – Hexagon nut-driver 7 ► Open the hose clamp ► Remove the throttle body RLF MPE850 Rev 1.2 | 406555 |...

  • Page 356: Installing Throttle Body

    070.02 Mounting throttle body 070.02.02 Installing throttle body 070.02.02 Installing throttle body – Torque wrench – 6-point socket wrench 7 ► Insert the hose clamp and throttle body ► Close the hose clamp Tightening torque: 1,5 Nm +1 Nm [1.1 lbf ft +0.7 lbf ft] RLF MPE850 Rev 1.2 | 406555 |...

  • Page 357: Replacing Throttle Body

    070.02 Mounting throttle body 070.02.03 Replacing throttle body 070.02.03 Replacing throttle body – Hexagon nut-driver 7 – Hexagon screwdriver socket 5 – Hexagon screwdriver 5 – 6-point socket wrench 7 – Torque wrench Info rmatio n ! When replacing the throttle body, it must be recalibrated. Before putting the engine into operation again, turn on the ignition for a minute and then off again.
  • Page 358 070.02 Mounting throttle body 070.02.03 Replacing throttle body ► Unscrew the bolts ► Remove the rubber mount ► Replace the throttle body ► Hold the rubber mount in position. ► Screw in the bolts Tightening torque: 8 Nm +2 Nm [5.9 lbf ft +1.5 lbf ft] RLF MPE850 Rev 1.2 | 406555 |...
  • Page 359 070.02 Mounting throttle body 070.02.03 Replacing throttle body ► Insert the hose clamp and throttle body ► Close the hose clamp Tightening torque: 1,5 Nm +1 Nm [1.1 lbf ft +0.7 lbf ft] RLF MPE850 Rev 1.2 | 406555 |...

  • Page 360: Replacing Rubber Mount

    070.02 Mounting throttle body 070.02.04 Replacing rubber mount 070.02.04 Replacing rubber mount – Hexagon nut-driver 7 – Hexagon screwdriver socket 5 – Hexagon screwdriver 5 – 6-point socket wrench 7 – Torque wrench ► Open the hose clamp ► Remove the throttle body RLF MPE850 Rev 1.2 | 406555 |...
  • Page 361 070.02 Mounting throttle body 070.02.04 Replacing rubber mount ► Unscrew the bolts ► Remove the rubber mount ► Replace the rubber mount ► Hold the rubber mount in position. ► Screw in the bolts Tightening torque: 8 Nm +2 Nm [5.9 lbf ft +1.5 lbf ft] RLF MPE850 Rev 1.2 | 406555 |...
  • Page 362 070.02 Mounting throttle body 070.02.04 Replacing rubber mount ► Insert the hose clamp and throttle body ► Close the hose clamp Tightening torque: 1,5 Nm +1 Nm [1.1 lbf ft +0.7 lbf ft] RLF MPE850 Rev 1.2 | 406555 |...

  • Page 363: Engine Management System

    080.01 Engine management components overview Engine management system 080.01 Engine management components overview Info rmatio n ! The engine control unit and throttle request unit are not shown. See the portable fire pump manufacturer‘s documentation. The wire harness is not supplied with the engine. –...
  • Page 364 080.01 Engine management components overview – Sensor camshaft Remove the sensor camshaft. (See chapter 030.01.06 Removing sensor camshaft.) Install the sensor camshaft. (See chapter 030.01.07 Installing sensor camshaft.) – Injectors Replace the injector. (See chapter 100.01.03 Replacing injector.) – Switch oil pressure Remove the switch oil pressure.

  • Page 365: Engine Control Unit

    080.02 Engine control unit 080.02 Engine control unit See the portable fire pump manufacturer‘s documentation. Info rmatio n ! When replacing the engine control unit, the throttle body must be recalibrated. Before putting the engine into operation again, turn on the ignition for a minute and then off again. RLF MPE850 Rev 1.2 | 406555 |...

  • Page 366: Starter, Generator

    090.01 Starter Starter, generator 090.01 Starter RLF MPE850 Rev 1.2 | 406555 |...

  • Page 367: Removing Starter

    090.01 Starter 090.01.01 Removing starter 090.01.01 Removing starter – 070.01.01 Removing intake manifold – Hexagon screwdriver 8 – Torx® screwdriver T30 Preparation ► Remove the intake manifold. (See chapter 070.01.01 Removing intake manifold.) Removing starter ► Unscrew 2 bolts ► Unscrew the bolt ►...

  • Page 368: Installing Starter

    090.01 Starter 090.01.02 Installing starter 090.01.02 Installing starter – 070.01.02 Installing intake manifold – Torque wrench – Torx® screwdriver socket T30 – Hexagon screwdriver socket 8 Installing starter ► Hold the starter in position. ► Screw in the bolt lightly. Do not tighten. ►...

  • Page 369: Replacing Starter

    090.01 Starter 090.01.03 Replacing starter 090.01.03 Replacing starter – 070.01.01 Removing intake manifold – 070.01.02 Installing intake manifold – Hexagon screwdriver 8 – Hexagon screwdriver socket 8 – Torx® screwdriver T30 – Torx® screwdriver socket T30 – Torque wrench Preparation ►...
  • Page 370 090.01 Starter 090.01.03 Replacing starter ► Replace the starter. ► Hold the bracket in position. ► Screw in the bolt Tightening torque: 8 Nm +2 Nm [5.9 lbf ft +1.5 lbf ft] ► Hold the starter in position. ► Screw in the bolt lightly.

  • Page 371: Generator

    090.02 Generator 090.02 Generator RLF MPE850 Rev 1.2 | 406555 |...

  • Page 372: Removing Generator

    090.02 Generator 090.02.01 Removing generator 090.02.01 Removing generator – Locking tool crankshaft – Hexagon screwdriver 5, 7, 8 Mount the engine on the engine stand ► Mount the engine across from the drive side of the engine stand. (See chapter 3.3.2 Mount the engine across from the drive side of the engine stand.) ►...
  • Page 373 090.02 Generator 090.02.01 Removing generator ► Unscrew the bolts ► Remove the locking tool crankshaft ► Remove the rotor ► Remove the stub shaft ► Unscrew the bolts RLF MPE850 Rev 1.2 | 406555 |...
  • Page 374 090.02 Generator 090.02.01 Removing generator ► Remove the stator ► Remove the distance washer RLF MPE850 Rev 1.2 | 406555 |...

  • Page 375: Installing Generator

    090.02 Generator 090.02.02 Installing generator 090.02.02 Installing generator – Locking tool crankshaft – Hexagon screwdriver socket 5, 7 – Torque wrench – Hexagon screwdriver 8 Leaks due to damage to the coating on the bolts. The threads of the six bolts on the rotor have a micro encapsulated coating.
  • Page 376 090.02 Generator 090.02.02 Installing generator ► Insert the distance washer ► Hold the stator in position. ► Screw in the bolts Tightening torque: 8 Nm +2 Nm [5.9 lbf ft +1.5 lbf ft] ► Hold the stub shaft in position. ►...
  • Page 377 090.02 Generator 090.02.02 Installing generator The bolts can be found in the spare parts catalog in chapter 020.02 Stub shaft. ► Replace the bolts ► Screw in the bolts by hand. Do not tighten. ► Hold the locking tool crankshaft on rotor.

  • Page 378: Voltage Regulator

    090.03 Voltage regulator 090.03 Voltage regulator See the portable fire pump manufacturer‘s documentation. RLF MPE850 Rev 1.2 | 406555 |...

  • Page 379: Fuel Unit

    100.01 Fuel rail Fuel unit 100.01 Fuel rail RLF MPE850 Rev 1.2 | 406555 |...

  • Page 380: Removing Fuel Rail

    100.01 Fuel rail 100.01.01 Removing fuel rail 100.01.01 Removing fuel rail – Torx® screwdriver T30 Burn injuries due to ignited fuel. Fuel is highly flammable. Leaks in the fuel system can lead to burns and vapors may ignite and cause an explosion. ►...
  • Page 381 100.01 Fuel rail 100.01.01 Removing fuel rail ► Remove the fuel rail RLF MPE850 Rev 1.2 | 406555 |...

  • Page 382: Installing Fuel Rail

    100.01 Fuel rail 100.01.02 Installing fuel rail 100.01.02 Installing fuel rail – Lubricant for o-ring injectors – Torx® screwdriver socket T30 – Torque wrench ► Coat the o-rings lightly with lubricant. ► Insert the fuel rail ► Screw in the bolts Tightening torque: 8 Nm +2 Nm [5.9 lbf ft +1.5 lbf ft] RLF MPE850 Rev 1.2 | 406555 |...

  • Page 383: Replacing Injector

    100.01 Fuel rail 100.01.03 Replacing injector 100.01.03 Replacing injector – 100.01.01 Removing fuel rail – 100.01.02 Installing fuel rail – Lubricant for o-ring injectors Burn injuries due to ignited fuel. Fuel is highly flammable. Leaks in the fuel system can lead to burns and vapors may ignite and cause an explosion.
  • Page 384 100.01 Fuel rail 100.01.03 Replacing injector ► Pull the injector out. ► Replace the injector ► Coat the o-ring lightly with lubricant. ► Insert the injector until it engages in the bracket. ► Check that the injector is engaged in the bracket Completion ►...

  • Page 385: Lubrication System

    110.01 Dry sump Lubrication system 110.01 Dry sump RLF MPE850 Rev 1.2 | 406555 |...

  • Page 386: Removing Suction Pump Cover

    110.01 Dry sump 110.01.01 Removing suction pump cover 110.01.01 Removing suction pump cover – Hexagon screwdriver 5 ► Turn the engine 180°. ► Unscrew 14 bolts The suction pump cover is caulked with a silicone liquid seal. ► Prize off the suction pump cover using the grooves ►...

  • Page 387: Installing Suction Pump Cover

    110.01 Dry sump 110.01.02 Installing suction pump cover 110.01.02 Installing suction pump cover – Torque wrench – Sealing surface cleaner – Hexagon screwdriver socket 5 – Silicone liquid seal ► Clean the sealing surface with sealing surface cleaner. ► Clean the sealing surface with sealing surface cleaner.
  • Page 388 ► Apply the silicone liquid seal without gaps as illustrated. ► Put the suction pump cover ► Screw in 14 bolts . Observe the arrangement of the bolts. Tightening torque: 8 Nm +2 Nm [5.9 lbf ft +1.5 lbf ft] RLF MPE850 Rev 1.2 | 406555 |...
  • Page 389 110.01 Dry sump 110.01.02 Installing suction pump cover Arrangement of the bolts 7 Bolts M6x20 7 Bolts M6x30 ► Turn the engine 180°. RLF MPE850 Rev 1.2 | 406555 |...

  • Page 390: Replacing Suction Pump Cover

    110.01 Dry sump 110.01.03 Replacing suction pump cover 110.01.03 Replacing suction pump cover – 110.01.01 Removing suction pump cover – 110.01.05 Installing oil suction pump – 110.01.04 Removing oil suction pump – 110.01.02 Installing suction pump cover – Open-end wrench 24 –...

  • Page 391: Removing Oil Suction Pump

    110.01 Dry sump 110.01.04 Removing oil suction pump 110.01.04 Removing oil suction pump – 110.01.01 Removing suction pump cover – Torx® screwdriver T30 Preparation ► Remove the suction pump cover. (See chapter 110.01.01 Removing suction pump cover.) Removing oil suction pump ►...

  • Page 392: Installing Oil Suction Pump

    110.01 Dry sump 110.01.05 Installing oil suction pump 110.01.05 Installing oil suction pump – 110.01.02 Installing suction pump cover – Torque wrench – Torx® screwdriver socket T30 Installing oil suction pump ► Insert the oil suction pump ► Screw in the bolts Tightening torque: 8 Nm +2 Nm [5.9 lbf ft +1.5 lbf ft] ►...

  • Page 393: Replacing Fitting

    110.01 Dry sump 110.01.06 Replacing fitting 110.01.06 Replacing fitting – Open-end wrench 24 – Insert open-end wrench 24 – Torque wrench ► Turn the engine 180°. ► Unscrew the fitting ► Replace the fitting. ► Screw in the fitting. Tightening torque: 36 Nm +8 Nm [26.6 lbf ft +5.9 lbf ft] ►...

  • Page 394: Removing Intermediate Gear Suction Pump

    110.01 Dry sump 110.01.07 Removing intermediate gear suction pump 110.01.07 Removing intermediate gear suction pump – 110.01.01 Removing suction pump cover – Pin punch axle intermediate gear – Hexagon screwdriver 8 – Plastic hammer Mount the engine on the engine stand ►...
  • Page 395 110.01 Dry sump 110.01.07 Removing intermediate gear suction pump ► Punch the axle out using the pin punch axle intermediate gear and plastic hammer. ► Remove the intermediate gear suction pump RLF MPE850 Rev 1.2 | 406555 |...

  • Page 396: Installing Intermediate Gear Suction Pump

    110.01 Dry sump 110.01.08 Installing intermediate gear suction pump 110.01.08 Installing intermediate gear suction pump – 110.01.02 Installing suction pump cover – Torque wrench – Hexagon screwdriver socket 8 Installing intermediate gear suction pump ► Hold the intermediate gear suction pump in position.

  • Page 397: Oil Pressure Pump

    110.02 Oil pressure pump 110.02 Oil pressure pump RLF MPE850 Rev 1.2 | 406555 |...

  • Page 398: Removing Oil Pressure Pump

    110.02 Oil pressure pump 110.02.01 Removing oil pressure pump 110.02.01 Removing oil pressure pump – 090.02.01 Removing generator – Lockring pliers (bore holes) – Universal pliers Mount the engine on the engine stand ► Mount the engine across from the drive side of the engine stand.
  • Page 399 110.02 Oil pressure pump 110.02.01 Removing oil pressure pump ► Remove the outer rotor of the oil pressure pump. ► Remove the inner rotor of the oil pressure pump. ► Remove the key ► Remove the timing insert RLF MPE850 Rev 1.2 | 406555 |...

  • Page 400: Installing Oil Pressure Pump

    110.02 Oil pressure pump 110.02.02 Installing oil pressure pump 110.02.02 Installing oil pressure pump – 090.02.02 Installing generator – Lockring pliers (bore holes) – Petroleum jelly Installing oil pressure pump NOTICE! Engine damage due to the lack of lubrication. If the timing insert is installed in reverse, the engine cannot build up any oil pressure.
  • Page 401 110.02 Oil pressure pump 110.02.02 Installing oil pressure pump Completion ► Install the generator. (See chapter 090.02.02 Installing generator.) RLF MPE850 Rev 1.2 | 406555 |...

  • Page 402: Oil Pressure Valve

    110.03 Oil pressure valve 110.03 Oil pressure valve RLF MPE850 Rev 1.2 | 406555 |...

  • Page 403: Removing Oil Pressure Valve

    110.03 Oil pressure valve 110.03.01 Removing oil pressure valve 110.03.01 Removing oil pressure valve – 110.01.01 Removing suction pump cover – Hexagon screwdriver 6 – Bar magnet Preparation ► Remove the suction pump cover. (See chapter 110.01.01 Removing suction pump cover.) Removing oil pressure valve ►...

  • Page 404: Installing Oil Pressure Valve

    110.03 Oil pressure valve 110.03.02 Installing oil pressure valve 110.03.02 Installing oil pressure valve – 110.01.02 Installing suction pump cover – Torque wrench – Hexagon screwdriver socket 6 Installing oil pressure valve ► Assemble the oil pressure valve in the sequence as illustrated ►...
  • Page 405 110.03 Oil pressure valve 110.03.02 Installing oil pressure valve Completion ► Install the suction pump cover. (See chapter 110.01.02 Installing suction pump cover.) RLF MPE850 Rev 1.2 | 406555 |...

  • Page 406: Oil Filter

    110.04 Oil filter 110.04 Oil filter RLF MPE850 Rev 1.2 | 406555 |...

  • Page 407: Removing Oil Filter

    110.04 Oil filter 110.04.01 Removing oil filter 110.04.01 Removing oil filter – Universal strap wrench ► Unscrew the oil filter using a universal strap wrench. RLF MPE850 Rev 1.2 | 406555 |...

  • Page 408: Installing Oil Filter

    110.04 Oil filter 110.04.02 Installing oil filter 110.04.02 Installing oil filter – Sealing surface cleaner ► Replace the oil filter ► Clean the sealing surface with sealing surface cleaner. ► Coat the oil filter seal lightly with engine oil. ► Screw in the oil filter by hand.

  • Page 409: Removing Threaded Sleeve

    110.04 Oil filter 110.04.03 Removing threaded sleeve 110.04.03 Removing threaded sleeve – 110.04.01 Removing oil filter – Reversible ratchet – Crown wrench Preparation ► Remove the oil filter. (See chapter 110.04.01 Removing oil filter.) Removing threaded sleeve ► Unscrew the threaded sleeve using a crown wrench.

  • Page 410: Installing Threaded Sleeve

    110.04 Oil filter 110.04.04 Installing threaded sleeve 110.04.04 Installing threaded sleeve – 110.04.02 Installing oil filter – Torque wrench – Crown wrench Installing threaded sleeve ► Screw in the threaded sleeve using a crown wrench. Tightening torque: 17 Nm +3 Nm [12.5 lbf ft +2.2 lbf ft] Completion ►...

  • Page 411: Engine Mount

    120.01 Lifting eye Engine mount 120.01 Lifting eye RLF MPE850 Rev 1.2 | 406555 |...

  • Page 412: Removing Bracket On The Drive Side

    120.01 Lifting eye 120.01.01 Removing bracket on the drive side 120.01.01 Removing bracket on the drive side – Hexagon screwdriver 5 ► Unscrew the bolts ► Remove the bracket RLF MPE850 Rev 1.2 | 406555 |...

  • Page 413: Installing Bracket On The Drive Side

    120.01 Lifting eye 120.01.02 Installing bracket on the drive side 120.01.02 Installing bracket on the drive side – Torque wrench – Hexagon screwdriver socket 5 ► Hold the bracket in position. ► Screw in the bolts Tightening torque: 8 Nm +2 Nm [5.9 lbf ft +1.5 lbf ft] RLF MPE850 Rev 1.2 | 406555 |...

  • Page 414: Removing Pipe Clamp

    120.01 Lifting eye 120.01.03 Removing pipe clamp 120.01.03 Removing pipe clamp – Torx® screwdriver socket T30 ► Unscrew the bolt ► Remove the pipe clamp RLF MPE850 Rev 1.2 | 406555 |...

  • Page 415: Installing Pipe Clamp

    120.01 Lifting eye 120.01.04 Installing pipe clamp 120.01.04 Installing pipe clamp – Torque wrench – Torx® screwdriver socket T30 ► Hold the pipe clamp in position. ► Screw in the bolt Tightening torque: 8 Nm +2 Nm [5.9 lbf ft +1.5 lbf ft] RLF MPE850 Rev 1.2 | 406555 |...

  • Page 416: Removing Bracket Across From The Drive Side

    120.01 Lifting eye 120.01.05 Removing bracket across from the drive side 120.01.05 Removing bracket across from the drive side – Hexagon screwdriver 5 ► Unscrew the bolt ► Remove the bracket RLF MPE850 Rev 1.2 | 406555 |...

  • Page 417: Installing Bracket Across From The Drive Side

    120.01 Lifting eye 120.01.06 Installing bracket across from the drive side 120.01.06 Installing bracket across from the drive side – Torque wrench – Hexagon screwdriver socket 5 ► Hold the bracket in position. ► Screw in the bolt Tightening torque: 8 Nm +2 Nm [5.9 lbf ft +1.5 lbf ft] RLF MPE850 Rev 1.2 | 406555 |...

  • Page 418: Repair Kits

    910.01 Long block Repair kits 910.01 Long block RLF MPE850 Rev 1.2 | 406555 |...

  • Page 419: Installing Long Block

    910.01 Long block 910.01.01 Installing long block 910.01.01 Installing long block – 070.01.01 Removing intake manifold – 090.02.02 Installing generator – 070.01.03 Removing intake manifold bracket – 090.01.02 Installing starter – 090.01.01 Removing starter – 070.01.04 Installing intake manifold bracket –...
  • Page 420 910.01 Long block 910.01.01 Installing long block ► Remove the generator. (See chapter 090.02.01 Removing generator.) ► Remove the sleeves Mount the long block on the engine stand ► Mount the engine across from the drive side of the engine stand. (See chapter 3.3.2 Mount the engine across from the drive side of the engine stand.) RLF MPE850 Rev 1.2 | 406555 |...
  • Page 421 910.01 Long block 910.01.01 Installing long block ► Insert the sleeves ► Install the generator. (See chapter 090.02.02 Installing generator.) ► Install the starter. (See chapter 090.01.02 Installing starter.) ► Install the intake manifold bracket. (See chapter 070.01.04 Installing intake manifold bracket.) ►...

  • Page 422: Appendix

    Appendix Overview of revisions Appendix Overview of revisions Revision Date Chapter Description Note Rev 1.0 25.05.2012 – 1st edition repair manual – Rev 1.1 09.07.2012 – Page numbers corrected – 050.01.03 Removing Rev 1.2 11.10.2012 fitting 050.01.04 Installing Two washers are omitted. Bolts Rev 1.2 11.10.2012 fitting...

  • Page 423: Index

    Appendix Index Index Balance shaft, replace 102 Generator, install 293 Blanking cover, replace 67 Generator, remove 290 Bracket 120.01, install 331, 335 Bracket 120.01, remove 330, 334 Ignition coils, install 157 Ignition coils, remove 156 Camshaft, replace 187 Impeller, install 249 Chain guide, replace 211 Impeller, remove 247 Chain rail, replace 210...
  • Page 424 Appendix Index Plug 010.01-1, replace 43 Timing chain, install 203 Plug 010.01-2, replace 51 Timing chain, open 198 Plug 010.01-3, install 54 Timing chain, remove 202 Plug 010.01-3, remove 53 Timing chain, replace 205 Plug 010.01-3, replace 55 Tool case, overview 22 Plug 010.02-2, replace 69 Tools, overview 23 Plug 030.02, replace 183...

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