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Malaguti 500 cc 4T Service Manual

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  • Page 2 FOREWORD • The present manual specifically addresses to specialised technical personnel (MALAGUTI authorised service centres and single motor mechanics) and contains all the service interventions indicated by the Manufacturer until the publishing of this document. • Some basic technical information has been intentionally omitted as it is considered to be common knowledge.
  • Page 3 GENERAL WORK PROCEDURES • The recommendations given hereafter are aimed at ensuring maximum work safety as well as at considerably reducing the risk of accidents, personal injury, equipment damage and idle times, and should therefore be strictly adhered to. • Always listen with attention to the customer’s opinion and complaints about the engine operation, asking specific questions in order to have a complete understanding of all the symptoms and identify with good approximation the real causes of the trouble.

  • Page 4: Table Of Contents

    CONTENTS 1 2 3 4 1 2 3 4 1 2 3 4 DESCRIPTION DESCRIPTION 1 2 3 4 1 2 3 4 SPECIFICATIONS FLYWHEEL AND STARTING 1 2 3 4 1 2 3 4 1 2 3 4 TIGHTENING TORQUES Removing the starter motor - Removing the flywheel magneto 1 2 3 4 1 2 3 4...

  • Page 5: Specifications

    Specifications ENGINE TRANSMISSION Specification Desc./Quantity Specification Desc./Quantity Transmission Automatic expandable pulley variator with Type Single-cylinder, 4-stroke with double spark torque server, V belt, automatic clutch. plug Bore x Stroke 94 x 71 mm Cubic capacity 493 cm³ Compression ratio 10.5: 1 CAPACITY Timing system Four valves, single overhead camshaft, chain...

  • Page 6: Tightening Torques

    Tightening Torques ENGINE ASSEMBLY CRANKCASE AND CRANKSHAFT Name Torque in Nm Name Torque in Nm Starter motor retainers 11 ÷ 13 Countershaft fixing nut 25 ÷ 29 Engine oil filter 12 ÷ 16 THERMAL UNIT AND TIMING SYSTEM Engine oil drainage plug 24 ÷...
  • Page 7 FLYWHEEL COVER HEIGHT TO MEASURE PISTON AND CYLINDER Specification Desc./Quantity Name Torque in Nm 10 mm Flywheel fixing nut 115 ÷ 125 43 mm Stator retainers 8 ÷ 10 Blow-by recovery duct fixing screws 3 ÷ 4 CYLINDER - PISTON Screw fixing freewheel to flywheel 13 ÷...
  • Page 8 Piston rings Crankcase - crankshaft - connecting rod Diameter of crankshaft bearings. Measure the capacity on both axes x-y. *Fit rings "2" and "3" with the word "TOP" facing upwards. ** Position the openings in the rings as shown here. CRANKSHAFT ***Value "A"...
  • Page 9 AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD The value of the “M” fixture axial clearance is acceptable within the range of 0.20 ÷ 0.60 mm Crankshaft-crankcase axial clearance (H) Description Dimensions 0.1 ÷ 0.405 mm (when cold) Transmission-side shoulder E = 1 ± 0,025 Compression ratio 10.5: 1 Half-shaft, transmission side...
  • Page 10 BASE GASKET THICKNESS Slot packing system Name Measure A Thickness «A» MEASURE TAKEN - 0.185 - - 0.10 0.4 ± 0.05 «A» MEASURE TAKEN - 0.10 - + 0.10 0.6 ± 0.05 «A» MEASURE TAKEN + 0.10 - + 0.185 0.8 ±...

  • Page 11: Automatic Transmission

    - Remove the six M6 screws. Automatic transmission Transmission cover - Loosen the 4 fastening screws - Extract the outside plastic transmission cover. - Using a screwdriver, remove the driven - Remove the four M8 screws. pulley axle cover near the bottom of the - Remove the transmission cover.

  • Page 12: Removing The Driven Pulley Shaft Bearing 11 1 2 3

    Air duct Removing the driven pulley shaft bearing - Remove the transmission cover. - Remove the transmission cover. - Unscrew the two screws shown in the figure to remove the air conveyor. - Remove the seeger ring. Locking torques (N*m) Air conveyor screws 11 ÷...

  • Page 13: Refitting The Driven Pulley Shaft Bearing 12 1 2 3

    Refitting the driven pulley Baffle roller shaft bearing Plastic roller - Heat the transmission cover interior - Check that the roller does not show using the heat gun. signs of wear and that it turns freely. N.B. - Loosen the retaining bolt using a 13 BE CAREFUL NOT TO OVERHEAT THE mm spanner.

  • Page 14: Removing The Clutch 13 1 2 3

    Removing the driven Removing the clutch pulley - To remove the clutch with the driven pulley it is necessary to use the special - Remove the clutch bell. tool; - Arrange the tool with the mean pins screwed in position "E" on the inside; - Fit the adapter ring (020444Y010) to the clutch assembly as shown in the photograph.

  • Page 15: Removing The Driven Half-Pulley Bearing 14 1 2 3

    - Remove the 4 guide pins. Inspecting the clutch - Extract the moving driven half-pulley. - Check the thickness of the clutch mass friction material. Characteristic Minimum thickness permitted: 1 mm - The masses must not show traces of lubricants. Otherwise, check the driven pulley unit seals.

  • Page 16: Inspecting The Driven Fixed Half-Pulley 15 1 2 3

    N.B. Inspecting the driven IF YOU NEED TO OVERHAUL THE BEARINGS ON AN ASSEMBLED DRIVEN PULLEY UNIT, IT sliding half-pulley IS NECESSARY TO SUPPORT THE UNIT BY THE BELL - Check that the belt contact surface is Specific tooling free from wear. 001467Y002 - Remove the 2 inside sealing rings and Driver for OD 73 mm bearing...

  • Page 17: Refitting The Clutch 16 1 2 3

    - Install a new ball bearing using the Inspecting the clutch special tool. spring Specific tooling - Measure the length of the spring, while 020376Y it is relaxed. Adaptor handle Characteristic 020477Y Standard length: 37 mm adaptor 125.5 mm 020363Y Admissible limit after use: 20 mm guide 120 mm...

  • Page 18: Removing The Driving Pulley 17 1 2 3

    - First fit the 2 retainer clamps of the Refitting the driven pulley special tool onto the pulley so that the - Install the driven pulley assembly with splines are completely engaged. belt. - Then, insert the tool so as to insert the stud bolts on the ring into the holes obtained onto the tool itself.
  • Page 19 Inspecting the rollers case Refitting the driving pulley - Check that the inside bushings shown in the figure are not worn and measure the Installing the roller container inside diameter. - Install the spacer with the internal chamfer facing towards the inside. DO NOT LUBRICATE OR CLEAN THE BUSHINGS Characteristic Maximum admissible diameter:...
  • Page 20 - Insert the half-pulley on the - Remove the flat washer and the spring crankshaft. washer as shown in the figure. - Insert the spacer bushing. Installing the fixed driving half- - Insert the nut in the original position pulley (nut side in contact with the belleville washer).

  • Page 21: Refitting The Transmission Cover 20 1 2 3

    - Install the lock ring from the rear so that - Lock the 7 M6 retainers. the splines are completely engaged. Locking torques (N*m) - Finally install the tool by siding the M6 retainer nuts by hand and ensuring the tool is 11 ÷...

  • Page 22: End Gear

    - Install the driving pulley shaft cover, Removing the wheel axle positioning the tooth gap on the lower - Remove the countershaft. part with the reference mark on the transmission crankcase. - Remove the wheel axis complete with gear. N.B. ENSURE THAT THE AIR INTAKE AND EXHAUST OPENINGS ARE COMPLETELY FREE.
  • Page 23 - Use the special extractor to - Support the hub cover using the disassemble the bearing on the engine column kit. chassis of the countershaft. - Pull out the bearing using the special tool. Specific tooling Specific tooling 001467Y006 Extraction pliers for 20 mm bearings 020476Y 001467Y035 Stud bolt set...

  • Page 24: Removing The Driven Pulley Shaft Bearing 23 1 2 3

    Removing the driven Inspecting the hub shaft pulley shaft bearing - Check that the 3 shafts exhibit no wear or deformation on the grooved surfaces, - If you have to remove the driven pulley at the bearings and at the oil guards. shaft, the relevant bearing and the oil guard, remove the transmission cover - In case of faults, replace the damaged...

  • Page 25: Refitting The Driven Pulley Shaft Bearing 24 1 2 3

    - Heat the intermediate gear bearing Refitting the driven pulley seat. shaft bearing - Insert the intermediate shaft bearing - Heat the crankcase using the heat using the special tool. gun. N.B. Specific tooling PLACE IT WITH THE BALLS FACING THE 020151Y HUB (THIS APPLIES TO BEARINGS WITH PLASTIC CAGE).
  • Page 26 - Place the safety lock seeger ring of - Insert the intermediate shaft bearing on the cover using the special tool. the driven pulley shaft bearing. N.B. N.B. PLACE IT WITH THE BALLS FACING THE PLACE IT IN THE POSITION SHOWN IN HUB (THIS APPLIES TO BEARINGS WITH THE FIGURE.

  • Page 27: Flywheel Cover

    - Support the hub cover using the column - Position the 7 set screws, tighten them to the prescribed torque, being careful of kit. the position of the bands holding the vent tube, and the position of the 3 shortest - Insert the wheel shaft oil guard with the screws as indicated in the figure.

  • Page 28: Removing The Hub Cover 27 1 2 3

    - Loosen the 14 fastening screws. Removing the hub cover - Remove the flywheel cover with the - Drain the engine oil by removing the relevant gasket and the cooling system drainage cap. sleeve support. - Prepare a suitable container to collect N.B.
  • Page 29 - Remove the blow-by reed valve with the Removing the stator relevant sealing gasket. - Remove the two retaining screws and the cable guide bracket. - Unscrew the 3 fastening screws and - Unscrew the fastening screw and remove stator and its wiring. remove the gas outlet union with the relevant O-ring.

  • Page 30: Refitting The Stator 29 1 2 3

    - Check that the oil filter union and - Check the earth insulation of each matching surface exhibit no deformations phase. or wear. - If a fault is discovered, carry out a close check of the cable harness that contains two types of cable: Rigid cables close to the stator and flexible cables close to the connector.

  • Page 31: Refitting The Flywheel Cover Components 30 1 2 3

    - Install the wiring guide bracket - Oil vapour decantation chamber tightening the 2 screws to the prescribed torque. Locking torques (N*m) Stator cable harness guide bracket screws 3 - 4 - Temporarily install the distribution Refitting the flywheel timing check hole cover and the engine cover components oil filling cap/bar.

  • Page 32: Refitting The Flywheel Cover 31 1 2 3

    - Reinstall the blow-by reed valve using - Install the supply hose to the cylinder and connect the return hose to the pump a new sealing gasket. cover using 3 new clamps. - Reinstall the support with head and tighten the screws to the prescribed N.B.
  • Page 33 - Install a new gasket on the engine - Tho lock the 14 retaining bolts of the crankcase. cover to the prescribed torque. - Check the presence of the three N.B. centring dowels. THE BOLTS HAVE FOUR LENGTHS: - THE 3 SHORTEST ARE INSERTED AS SHOWN IN THE FIGURE.

  • Page 34: Flywheel And Starting

    N.B. Flywheel and starting IF THE TRAILING SPEED OF THE CRANKSHAFT IS LOW AND COMBINED - Remove the three bands shown in the figure WITH STRANGE NOISE, CHECK THE for an easier removal of the flywheel cover. FREEWHEEL OF THE TORQUE LIMITER Remove the feed hoses and disconnect the (SEE THE "FLYWHEEL AND STARTER return hose from the pump cover.
  • Page 35 - Tighten the bushing of the flywheel Removing the starter lock tool on the removing tool threading. motor N.B. THIS OPERATION MAY ALSO BE CARRIED OUT WITH FLYWHEEL COVER ASSEMBLED. - Loosen the two fastening screws. - Extract the complete starter motor. - Insert the special tool as shown in the Removing the flywheel figure, making sure that the pins are...
  • Page 36 - Remove the washer. - Remove the extractor. - Remove the nut and extract the flywheel with the start-up rim. - Remove the crankshaft key. - Insert the nut again so as to slightly - To remove the start-up rim from the uncover the shaft and free the space freewheel it is necessary to turn it that was occupied by the washer.
  • Page 37 - The freewheel is coupled to the Starter gear rim flywheel with high precision; if removal - Check that there is no wear or is difficult, use 2 screws as gripping abnormal impressions on the "rollers" of points and as removing tools, if the freewheel and on the surface of the required.
  • Page 38 Intermediate gear Refitting the free wheel - Check that the toothing is not worn. - Make sure the free wheel contact surfaces are in good condition. - Check the diameter of the two - Thoroughly clean the free wheel to remove LOCTITE residue. bearings.
  • Page 39 - Install the start-up rim on the flywheel Refitting the intermediate turning it clockwise and inserting at the gear same time. - Lubricate the gear housing on the engine crankcase. - Insert the intermediate gear with Refitting the flywheel torque limiter magneto - Insert the key on the crankshaft.

  • Page 40: Refitting The Starter Motor

    - Tighten thoroughly the guide bushing - Tighten the flywheel lock nut to the prescribed torque. of the flywheel lock tool and loosen by 1/4 turn. Locking torques (N*m) N.B. Flywheel fixing nut FAILURE TO OBSERVE THIS RULE 115 - 125 CAUSES THE LOCKING OF THE GUIDE ON THE FLYWHEEL.

  • Page 41: Cylinder Assy. And Timing System

    Cylinder assy. and Removing the rocker- arms cover timing system - Loosen the 6 special screws with stop - Remove the external and internal and the relevant rubber gaskets. transmission cover. - Remove the tappet cover with relevant gasket. - Remove the flywheel cover, the Removing the timing flywheel and the torque limiter.

  • Page 42: Removing The Cam Shaft

    - Remove the return spring and the valve Remove the inside hexagon screw and lifting mass with relevant travel end the counterweight as shown in the washer. figure. N.B. BE CAREFUL SO AS NOT TO ALLOW THE WASHER AND SPRING TO FALL INTO THE ENGINE THROUGH THE CHAIN COMPARTMENT.

  • Page 43: Removing The Cylinder Head

    - Remove the cam shaft. - Remove the coolant temperature sensor. N.B. THE SENSOR CONTROLS BOTH INJECTION AND THE ANALOGUE INSTRUMENT ON THE PANEL. TO CHECK THIS COMPONENT, SEE “THE INJECTION” CHAPTER. - Remove pins and rocking levers by the - Remove the 2 fastening nuts on the transmission side holes.

  • Page 44: Removing The Valves

    - Loosen the 4 head-cylinder fastening - Remove the oil guards using the nuts in 2 or 3 times and in a crossed special tool. sequence. - Remove the head, the 2 centring Specific tooling dowels, the gasket and the lower chain 020431Y guide sliding block.
  • Page 45 - Remove the piston sealing rings and Removing the cylinder - the oil scraper. piston assy CAUTION - Remove the timing chain. NOTE THE ASSEMBLY POSITIONS - Loosen the fastening screw and OF THE LININGS TO PREVENT INVERTING remove the spacer and the tightening THE POSITION IN CASE OF REUSE.

  • Page 46: Inspecting The Piston

    - Calculate the coupling clearance Characteristic between pin and connecting rod end. 10 mm Characteristic Piston diameter: Standard clearance: 94 mm nominal value 0.015 ÷ 0.029 mm - Using a bore meter, measure the Inspecting the piston cylinder inner diameter at a given height - Measure the capacity diameter on the according to the directions shown in the piston.

  • Page 47: Inspecting The Piston Rings

    Rings/housing coupling clearances: Inspecting the piston rings Carefully clean the sealing ring housings. - Alternately insert the three sealing Place a thickness gauge between the rings into the cylinder, in the area where ring and the housing as shown in the it retains its original diameter.

  • Page 48: Removing The Piston

    - Place the wrist pin stop ring into Removing the piston position using a punch - Install piston and wrist pin onto the connecting rod, aligning the piston arrow the arrow facing towards the exhaust. - Insert the locking ring into the special - Install the pin lock using the key tool, with the opening in the position shown in the figure.

  • Page 49: Choosing The Gasket

    - Identify the thickness of the cylinder base gasket to be used for reassembly by the Choosing the gasket table below. Correctly identify the cylinder base gasket thickness to keep the correct - Provisionally fit the piston into the cylinder, without any base gasket. compression ratio.
  • Page 50 Refitting the piston rings Refitting the cylinder - Place the scraper ring spring on the - Insert the cylinder base gasket with piston. the thickness determined above. - Install the scraper ring keeping the - Using the fork and the band clamp, opening opposed to the spring junction install the cylinder as shown in the and with the writing "top"...

  • Page 51: Inspecting The Valve Housings

    Inspecting the timing Inspecting the valve system components sealings - Check that the guide shoe and the - Visually inspect the valve sealing tensioner shoe are not worn out. surface. - Check that the crankshaft pinion and DO NOT REVERSE THE FITTING the camshaft timing gear and POSITIONS OF THE VALVES crankshaft pinion exhibit no wear.
  • Page 52 Inspecting the valves Inspecting the valve stem guide clearance - Measure the diameter of the valve stems in the three positions indicated in the - After measuring the valve guide diameter and the valve stem diameter, check the diagram. clearance between guide and stem. STANDARD DIAMETER INLET Specification...

  • Page 53: Inspecting The Springs And Half-Cones

    - If the checks above give no failures, Inspecting the springs and you can use the same valves. To obtain half-cones better sealing performance, grind the valve seats. Grind the valves gently with - Check that the upper and lower a fine-grained lapping compound.
  • Page 54 Refitting the valves Inspecting the cam shaft - Place the valve spring support - Check that the camshaft ends exhibit no scratches or irregular wear. washers on the head. - Using a micrometer, measure the camshaft capacity. - Alternately insert the 4 oil guards STANDARD DIAMETER using the special tool.

  • Page 55: Refitting The Head And Timing System Components

    - If any of the above dimensions are Refitting the head and outside the specified limits, or there are timing system signs of excessive wear, replace the components defective components with new ones. - Check that the retaining plate seat - Insert the chain guide sliding block.
  • Page 56 - Tighten again by 90° in a crossed - Install the coolant temperature sensor sequence. with the washer and tighten to the prescribed torque. FAILURE TO OBSERVE THE TIGHTENING TORQUE CAN DAMAGE THE SENSOR. Locking torques (N*m) coolant temperature sensor: 10 - 12 Locking torques (N*m) - Fit the spark plugs and tighten them...
  • Page 57 - Clean the camshaft by blowing with - Using the TORX wrench, remove the timing check cap little compressed air jets, especially the retaining plate housing. - Lubricate the 2 shafts. - Insert the camshaft into the head with the cams opposite the rocking levers. - Remove any LOCTITE residues from - Insert the belt on the camshaft control the screws fixing the camshaft retaining...
  • Page 58 - Install the counterweight mass. - Turn the crankshaft to move the references to the top as shown in the - Centre using the bell fastening screw. figure (intake end). - Insert the valve lifting device mass stop - Lock the mass fixing screws to the bell.

  • Page 59: Refitting The Timing Chain

    - Install a new tightener on the cylinder Refitting the timing chain using a new gasket. The ignition advance is determined electronically on the basis of parameters known - Tighten the two fastening screws to by the control unit. For this reason it is not possible to declare the reference values the prescribed torque.

  • Page 60: Refitting The Rocker-Arms Cover

    - By the driving pulley, turn the engine Specific tooling to find the alignment of the references 020460Y to identify the TDC. Scooter diagnosis and tester If the values do not match, check: - distribution timing - revolution-timing sensor - Injection control unit - Repeat for the reference between Refitting the rocker-arms driving pulley and transmission housing.

  • Page 61: Refitting The Intake Manifold

    - Install the transmission cover and the Crankcase - crankshaft relevant net filter and the outside - Remove the outside and inside transmission cover and the complete driving pulley as transmission cover as described in the described in "Automatic transmission". "Automatic transmission"...
  • Page 62 Splitting the crankcase Removing the crankshaft halves - Before removing the crankshaft, check the timing with the countershaft. To - Remove the engine support retain carry out this check, turn the crankshaft screw on the flywheel side half- to align the two holes obtained on the crankcase.
  • Page 63 Replacing the Removing the countershaft bearings countershaft - Check that the bearings are free from - Place the special tool as shown in the irregular noise or clearance. If it is, figure. replace it. Specific tooling Flywheel-side half-crankcase 020479Y - Remove the inside seeger ring. Countershaft lock wrench - Remove the fastening nut with relevant - Upturn the half-crankcase.
  • Page 64 - Before installing a new bearing, heat - Fit the seeger ring. the flywheel side half-crankcase using the special tool. - Before installing the new bearing on the transmission side crankcase, heat - Place the half-crankcase on a wooden the seat using the special tool. base.
  • Page 65 THE CRANKSHAFT CAN BE REUSED WHEN THE WIDTH FALLS WITHIN THE Inspecting the crankshaft STANDARD VALUES AND THE SURFACES ARE FREE FROM SCRATCHES. components Shimming - Check the overall height of the crankshaft - shoulders - gear assembly. - Check the axial clearance on the Characteristic connecting rod.

  • Page 66: Inspecting The Crankcase Halves

    - Check that the driving shaft cone, the Inspecting the crankcase tab seat, the oil seal capacity, the halves toothed gear and the threaded tangs are in good working order. - Before proceeding to check the crankcase halves, thoroughly clean the - In case of failures, replace the all surfaces and oil ducts.

  • Page 67: Inspecting The Crankshaft Plain Bearings

    N.B. Inspecting the crankshaft AS ALREADY DESCRIBED IN THE "LUBRICATION" CHAPTER, IT IS ESPECIALLY plain bearings IMPORTANT THAT THE BY-PASS HOUSING ON THE FLYWHEEL COVER IS FREE FROM WEAR THAT MAY IMPAIR THE PROPER SEALING OF THE LUBRICATION PRESSURE - To obtain a good bushing lubrication it ADJUSTMENT PISTON.
  • Page 68 Before assembling, check that the clearance between the engine crankcase bushing and the crankshaft is within the predetermined limits. X = Crankshaft category Y = Crankcase half-shell category Characteristic A = Red Crankshaft-bushing maximum clearance admitted: B = Blue 0.08 mm C = Yellow D = Green - The standard bushing diameter after driving is variable on the basis of a coupling...
  • Page 69 Recommended products Countershaft Loctite 243 - Using a micrometer, measure the 2 Medium strength threadlock bearings of the countershaft as shown Medium Loctite 243 threadlock in the figure. - Repeat the same procedure for the 4 fastening screws. - Insert the control gear on the crankshaft with the hole countersink visible. Characteristic - Tighten the 4 fastening screws to the prescribed torque.

  • Page 70: Refitting The Crankcase Halves

    - Install the oil pump closing plate. - Insert the gasket on the flywheel side half-crankcase. - Tighten the 2 flanged fastening screws to the prescribed torque. Locking torques (N*m) Bulkhead screws for oil pump housing cover 8 - 10 - Lubricate the main bearing on the Refitting the crankcase transmission side half-crankcase.

  • Page 71: Lubrication

    Lubrication TECHNICAL SPECIFICATIONS OIL FILTER SUMP CAPACITY Specification Desc./Quantity Specification Desc./Quantity Overhaul 1.7 l Type Paper with pressure relief and anti-cavitation by-pass Oil and filter replacement 1.5 l OIL MINIMUM PRESSURE INDICATOR LIGHT SWITCH RECOMMENDED ENGINE OIL Specification Desc./Quantity Product Description Specifications Calibration...
  • Page 72 Conceptual diagrams General characteristics Lubrication circuit is split into two sections: - High pressure - Low pressure The high pressure section includes all components located on the engine crankcase, while the low pressure section only refers to the thermal unit. The trochoidal pump is installed into the sump and is controlled through a couple of gears.

  • Page 73: Diagnosis Guide

    The camshaft bearings are marked directly on the aluminium of the head; the axial Diagnosis guide clearance of the camshaft is partly compensated by the oil supplied to the small end 1 - Minimum oil pressure warning light on with hot engine. bearings.
  • Page 74 11 - Check and restore the electrical system. STANDARD VALUES Specification Desc./Quantity 12 - If pressure lower than 4 bar is measured. 20°C Temperature approx. 4.5 bar AHEAD - go to 9 1400 rpm 13 - Remove the flywheel cover and check the by-pass and the cover sealing gasket efficiency towards the case internal side, as described in the "Flywheel cover"...
  • Page 75 Oil pressure check Oil pump 1 - In case of oil leaks from the oil filter or from the flywheel cover coupling gasket, Removal check the lubrication pressure. - Remove the closing plate of the oil AHEAD - go to 2 pump housing by loosening the 2 2 - Install the special tool.
  • Page 76 - Remove the two screws and the oil - Reassemble the rotors in the pump pump cover. body, keeping the two reference marks visible - Insert the shaft with the gear and install the lock ring; then, turn it with the opening opposed to the shaft face.
  • Page 77 - Check the rotor axial clearance using - Lubricate the internal rotors. a rectified bar as reference plane, as - Check there are no signs of scoring or shown in the figure. wear on the oil pump cover. Characteristic - If non-conforming values or signs of wear are found, replace the pump.
  • Page 78 Failure to observe the tightening torque - Keep the countershaft in position and may alter the coupling clearance of the insert the washer with the nut. rotors with the pump body. - Tighten the nut to the prescribed torque, using the recommended Locking torques (N*m) product.

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