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Summary of Contents for Lombardini LGW 523 mpi

  • Page 1 code 1.5302.711 W W W W W or orkshop kshop kshop kshop Manual kshop...
  • Page 2 Quality Management System, by completing the following table. Document Review Replaced Eliminated Added Edition Issue date Drafting body code date pages pages pages 1-5302-711 ATLO 1° 26-04-2007 - 2 - Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00...
  • Page 3: Table Of Contents

    Disassembling the crankcase and crankshaft ..53 5.7.4 Disassembling the connecting rod and piston ... 54 FOR MAINTENANCE ..........30 DISASSEMBLING THE PISTON ......54 Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 3 -...
  • Page 4 Installing the rocker arm assembly ...... 81 7.6.5 Installing the rocker arm cover ......81 7.6.6 Installing the spark plug ........82 7.6.7 Installing the injectors ........... 82 - 4 - Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00...
  • Page 5: General Remarks And Safety Information

    A) Manufacturer’s identity B) Engine type C) Engine serial number D) Maximum operating speed E) Number of the customer version (form K) Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 5 -...
  • Page 6: Glossary And Terminology

    - 6 - Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00...
  • Page 7: Safety And Environmental Impact

    (eyebolts) specified by the manufacturer. Note: the engine may also be placed on the workbench, depending on the type of work to be carried out. Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 7 -...
  • Page 8 ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................- 8 - Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00...
  • Page 9: Technical Information

    Lambda exhaust probe. Integrated injection and ignition control. Forced lubrication by crankshaft-driven oil pump. Cooling by forced liquid circulation. Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 9 -...
  • Page 10: Technical Specifications

    Max. power (N 80/1269/EEC - ISO 1585 - DIN 7020) 15 * Maximum torque (at 2150 RPM) Axial load allowed on crankshaft * Self-limiting power for quadricycle applications. - 10 - Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00...
  • Page 11: Fuel Supply Circuit

    Oil pressure switch 0,45÷0,75 Operating pressure bars Coolant temperature monitoring sensor Unipolar system Electrical circuit 6÷24 Supply voltage Absorbed power °C 97°÷103° Closed circuit temperature Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 11 -...
  • Page 12: Performance Curve Diagram

    These power rates are reduced by approx. 1% every 100m of altitude and by 2% for every 5°C exceeding 25°C. Note: Please contact Lombardini for power, torque, and specific consumption curves at different speeds from the above. Caution – Warning Please remember that any variation in the intake or exhaust system during the application phase of LGW 523 engines involves a variation in fuel.
  • Page 13: Alternator Load Curve Diagrams

    Alternator RPM Reading taken after heat stabilisation at 20°C and constant voltage 12.5V. * The alternator turns at the same rate as the engine. Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 13 -...
  • Page 14: Lubricants

    Euro 2 - Euro 3 engines) B1 = Low-viscosity, for friction reduction B2 = Standard B3 = High performance (indirect injection) B4 = High quality (direct injection) - 14 - Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00...
  • Page 15: Coolant

    (*) Replace the timing belt whenever it is removed, even if has not completed its scheduled motion time. Maintain the same maintenance intervals above 100,000 km. Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 15 -...
  • Page 16: Operating Principle For Lubrication

    Hydraulic tappet 2.10 OPERATING PRINCIPLE FOR COOLING Réf. Description Coolant refill plug Compensation tank Thermostatic valve Cylinder block Liquid temperature monitoring thermostat Circulation pump Radiator - 16 - Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00...
  • Page 17: Operating Principle For Fuel Supply

    Filter Supply duct Injector supply pipe Injector Pressure regulator Injector check spring Return pipe from the pressure regulator Fastening screws of the supply pipe Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 17 -...
  • Page 18: Wiring Diagram

    Coolant temperature indicator light Coolant thermostat indicator light Engine oil pressure indicator light Oil pressure switch Battery load indicator light Coolant thermometer Coolant thermometer sensor - 18 - Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00...
  • Page 19 Coolant temperature indicator light Coolant thermostat indicator light Engine oil pressure indicator light Oil pressure switch Battery load indicator light Voltage regulator Coolant thermometer Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 19 -...
  • Page 20: Electronic Engine Control Wiring Diagram

    Technical information 2.13 ELECTRONIC ENGINE CONTROL WIRING DIAGRAM - 20 - Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00...
  • Page 21: Electrical Wiring For Electronic Engine Control

    Technical information 2.14 ELECTRICAL WIRING FOR ELECTRONIC ENGINE CONTROL See page 20 for descriptions and reference numbers. Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 21 -...
  • Page 22: Fuel Supply System

    Filtering capacity: 8-10 ìm Please comply with the manufacturer’s data when replacing. 2.15.3 Pressure regulator (Calibrated to 3.5 bars) 2.15.4 Prefilter Filtering capacity: 70 ìm - 22 - Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00...
  • Page 23: Injector Supply Pipe

    Resistance: 12Ù(20°C) 2.15.7 Inertial switch (not supplied by Lombardini) Cuts off fuel supply pump in the event of violent collisions. Usually located inside the cabin. Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 23 -...
  • Page 24: Electronic Engine Control System

    Regulation of the air/petrol mixture occurs continuously based on the information from the Lambda probe. The device integrates the self-diagnostic functions and ensures protection against engine runaway and stalling. Calibration of the control unit is done by Lombardini s.r.l. and tailored to all approved vehicles. Engine RPM/TDC Main relay...
  • Page 25: Ignition Coil

    Components: 1 «CINCH» Connector 2 Protective pipe 3 Formed PTFE pipe 4 Sensor Resistance: 9 Ù Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 25 -...
  • Page 26: Electronic Control Unit (E.c.u.)

    Lombardini Spare Parts Centre. 2.16.6 Speed sensor Coil resistance: 200Ù - 270Ù Important A heat-shrink sleeve should be used to secure the cable connector. - 26 - Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00...
  • Page 27: Air Temperature Sensor

    Temperature sensor for the water in the cooling circuit, attached to the thermostat case. Heat resistance CTN INJ with P1 - P2 Temp. °C Ù (resistance in ± ± Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 27 -...
  • Page 28: Throttle Control Sensor

    DC motor: Resistance 1.5 Ù Potentiometer: Resistance 1.25 kÙ ± 30% - 28 - Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00...
  • Page 29: Intake System

    The exhaust system must in no way be altered from the specifications approved by Lombardini version. modifications prevent the proper functioning of the engine. Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 29 -...
  • Page 30: Special Tools And Equipment For Maintenance

    2.20.1 Table of tightening torques for standard screws (coarse thread) Resistance class (R) 10.9 12.9 Quality/ Dimensions R>1200N/mm R>400N/mm R>500N/mm R>600N/mm R>800N/mm R>1000N/mm Diameter 1000 1200 1050 1500 1800 1088 1450 2000 2400 - 30 - Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00...
  • Page 31: Table Of Tightening Torques For Standard Screws (Fine Thread)

    Coolant thermostat 10x1,5 Lubricate the underside of the screw and pulley centring pin with «Molyslip». For more detailed information see «Assembling the cylinder head». Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 31 -...
  • Page 32: Table Of Sealants

    ............................................................................................................................................................................................................................................................................................................................................................................................................................................................... - 32 - Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00...
  • Page 33: Malfunctions

    Oil level too high Electrical system Bad fuel pump connector contact Burnt-out fuse Faulty relays Faulty engine wiring Battery element out of order Sulphurised battery clamps Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 33 -...
  • Page 34 ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................- 34 - Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00...
  • Page 35: Storing The Engine

    - Remove the key from the dashboard and put it in a safe place to avoid acts of vandalism. - Lock the cabin and the cowls to prevent strangers getting access. Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 35 -...
  • Page 36: Protective Treatment

    13 - Replace the filters (air, oil, fuel) with original spare parts. 14 - Empty the cooling circuit completely and pour in the new coolant up to the correct level. - 36 - Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00...
  • Page 37: Removing The Assemblies

    4 - Remove the entire air filter. 5 - Unscrew the two fastening screws on the filter support (S) and remove it. Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 37 -...
  • Page 38 7 - Disconnect the connector (F) from the absolute pressure sensor and connector (F1) from the temperature sensor. (F1) 8 - Unscrew the fastening nuts and remove the throttle body. - 38 - Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00...
  • Page 39 13 - Remove the gaskets between the cylinder head pipes and the intake manifold. 14 - Close the openings and ducts to prevent foreign bodies from entering. Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 39 -...
  • Page 40: Disassembling The Air Flow Sensors

    1 - Remove the case holding the dipstick. 2 - Take off the thermal protection. Caution – Warning Do not start the engine when the thermal protection is not in place. - 40 - Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00...
  • Page 41: Removing The Cooling Fan Belt Drive

    Fan (A) consequently, activation of the starter motor. 1 - Remove the cooling fan (A). Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 41 -...
  • Page 42: Disassembling The Cooling Fan Belt (With External Alternator)

    Belt (D) 1 - Remove the fan hub (E) and flange. Remove the belt (D). 3 - Remove the pulley (F), washers and spacer - 42 - Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00...
  • Page 43: Removing The Timing Belt Drive

    1 Camshaft toothed pulley 2 Timing belt 3 Crankshaft toothed pulley 4 Coolant circulation pump gear 5 Sliding pulley and belt tightener 6 Speed sensor Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 43 -...
  • Page 44: Removing The Speed Sensor

    5.4.5 Sliding pulley and belt tightener Components: 1 Nut 2 Washer 3 Belt sliding pulley 4 Ball bearing 5 Shaft axle 6 Base plane 7 Toothed belt tensioning lever - 44 - Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00...
  • Page 45: Disassembling The Synchronous Timing Belt Pulleys (Camshaft And Crankshaft)

    Remove pulley (Q). Pulley (Q) 5.4.7 Disassembling the coolant circulation pump Unscrew the water pump fastening screws and nuts. Extract the water pump and its gasket. Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 45 -...
  • Page 46: Disassembling The Pump Scroll

    5.5.1 Disassembling the spark plug Important The engine must always be cold before disassembling the spark plugs to avoid damaging the cylinder head thread. - 46 - Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00...
  • Page 47: Disassembling The Rocker Arm Cover

    3 Rocker arm cover 4 Rocker arm cover gasket 5.5.3 Disassembling rocker assembly 1 - Loosen the nuts in the rocker arm supports. Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 47 -...
  • Page 48: Disassembling The Injectors

    Disconnect the electrical connections from the injectors by squeezing the check spring (B). 2 - Loosen the anchoring bracket screws on the injector supply pipe. - 48 - Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00...
  • Page 49 With the aid of a screwdriver remove the injector check spring (A), then repeat the operation on the other injector. Disconnect the injectors from the fuel supply pipe. Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 49 -...
  • Page 50: Disassembling The Camshaft

    4 - Extract the camshaft (Y) from the cylinder head. Camshaft (Y) Cover (X) 5.5.6 Disassembling the thermostatic valve body Loosen the screws. Remove the thermostatic valve body. - 50 - Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00...
  • Page 51: Removing The Cylinder Head

    (E). Gasket(E) Remove the valves (F). Fan (F) Important Keep components together during the disassembly phase, in order to be able to reassemble correctly. Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 51 -...
  • Page 52: Removing The Crank Gear And Crankcase

    In order to remove the pump the key (A) must be passed through the case (B). To do this, position the first cylinder (on the flywheel side) at the top dead centre. - 52 - Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00...
  • Page 53: Disassembling The Crankcase And Crankshaft

    Disassembling the crankcase and crankshaft Remove the flange (H). Take off the gasket (L). Gasket (L) Flange (H) Remove the crankcase (M). Crankcase (M) Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 53 -...
  • Page 54: Disassembling The Connecting Rod And Piston

    (D) from the connecting rod (E). Lock rings (B) Important Keep each connecting rod together with its piston and wrist pin. piston (D) Wrist pin (C) - 54 - Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00...
  • Page 55 Removing assemblies Remove sealing rings (F). Sealing ring (F) Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 55 -...
  • Page 56 ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................- 56 - Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00...
  • Page 57: Overhauls And Tuning

    Before deciding what kind of overhaul needs to be done, it is important to carry out a dimensional check and verify the correspondence of cylinders, pistons, sealing rings, crankshaft and connecting rods. Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 57 -...
  • Page 58: Dimensional Check And Overhaul Of Cylinders

    6g to prevent weight imbalances. Protect the contact surfaces with lubricant oil, to prevent them from rusting. - 58 - Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00...
  • Page 59: Dimensional Check Of Sealing Rings

    ÷ ° ÷ Important – Sealing rings cannot be replaced separately. – Protect the contact surfaces with lubricant oil, to prevent them from rusting. Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 59 -...
  • Page 60: Dimensional Check And Overhaul Of Crankshaft

    ÷ ÷ half-ring replacements (see «Table of uprated shoulder half-rings»). Important Protect the contact surfaces with lubricant oil, to prevent them from rusting. - 60 - Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00...
  • Page 61: Dimensional Check And Overhaul Of Connecting Rods

    (see «Pre-assembly of sealing rings - pistons» and «Pre-assembly of Important Protect the contact surfaces with lubricant oil, to connecting rods - pistons»). prevent them from rusting. Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 61 -...
  • Page 62: Checking And Overhauling The Oil Pump

    Mount the new sealing ring (C) using a special tool. Important Given the particular function played by this sealing ring, it is important to use only original spares. - 62 - Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00...
  • Page 63: Overhauling The Decanting Device

    Important If the level deviation is greater than 0.10mm, the cylinder head must be ground, removing no more than 0.2mm. Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 63 -...
  • Page 64: Checking And Overhauling The Valves

    8 - Use the special tool to put the valve seats into the holder. 11 - Assemble the valves (see «Assembling the valves»). 9 - Slide the valves into their seats. - 64 - Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00...
  • Page 65: Checking And Overhauling The Rocker Arm Pin

    6 - Place the new plugs in the pin. 7 - Carefully clean and lubricate the supports and rocker arms and remount on the pin. Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 65 -...
  • Page 66: Hydraulic Tappets

    Reduces wear of the timing system components, thanks to there being no collisions at the opening with consequent breaking of the oil film. No maintenance. - 66 - Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00...
  • Page 67 Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 67 -...
  • Page 68: Checking And Replacing The Camshaft

    Important Protect the contact surfaces with lubricant oil, to prevent them from rusting. Mount camshaft (see «Assembling the camshaft»). - 68 - Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00...
  • Page 69: Diagram Of Timing Belt Rates

    Important Only replace with the proper spark plugs. Do not use other types of spark plugs with this engine. Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 69 -...
  • Page 70: Replacing The Flywheel Ring Gear

    Risk of burning: be careful of hot surfaces. Insert the ring gear into its seat while still hot and place it carefully on the rim of the flywheel (B). - 70 - Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00...
  • Page 71: Installation Of Assemblies

    «717-1460-047», and mount it right into the seat of the valve guide. Lubricate the valve stem (B). Valve (B) Slip the valve into its seat. Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 71 -...
  • Page 72: Preassembly Of Sealing Rings - Pistons

    (crown). – Keep the pistons together with their own connecting rods and wrist pins. portante - 72 - Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00...
  • Page 73: Pre-Assembly Of Connecting Rods - Pistons

    5 - Rotate the sealing rings so that the cuts have a Oil suction pipe (A) displacement of about 120° between them. Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 73 -...
  • Page 74: Assembling The Crankshaft

    50Nm. Assemble the crankcase (see «Assembling the crankcase»). Measure the axial clearance of the crankshaft (see «Measuring crankshaft axial clearance») Connecting rod cap (F) - 74 - Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00...
  • Page 75: Assembling The Crankcase

    If axial shift is above these values, it is necessary to insert uprated shoulder half- rings and once again disassemble the crankcase (see «Dimensional check and overhaul of crankshaft»). Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 75 -...
  • Page 76: Assembling The Crankshaft Flange (Flywheel Side)

    1 - Clean the flange and the pump scroll seat. 2 - Slip on a new gasket (A). 3 - Install the pump scroll and put in the screws. - 76 - Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00...
  • Page 77: Installing The Coolant Circulation Pump

    5 - Tighten the screws in a crisscross pattern, and Be careful not to damage the sealing rings tighten each of them to their respective final torques during this operation. (see figure). Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 77 -...
  • Page 78: Assembling The Flywheel

    4 - Tighten the screws in crisscross order to a final torque of 80Nm. Important Turn the flywheel manually to check the movement of the mechanical parts. Flywheel (F) Screw (H) - 78 - Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00...
  • Page 79: Determining Clearance Volume

    Clearance Number holes of A (mm) volume(mm) ÷ ÷ Important The two-hole head gasket is rigorously to be installed on engine LGW 523 MPI. Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 79 -...
  • Page 80: Installation Of Cylinder Head And Components

    Insert the camshaft into its housing. Mount a new O-ring onto the cover (B). Mount the cover (B) and tighten the screws to a torque of 10Nm. - 80 - Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00...
  • Page 81: Installing The Camshaft Support And Timing Belt Pulley

    Any damage or breakage of the gasket may cause a drop in pressure in the lubrication circuit. On reassembly of the cover, tighten the screws to 9Nm. Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 81 -...
  • Page 82: Installing The Spark Plug

    O-rings. Insert the check spring to block the injector on the fuel supply pipe. Repeat this operation on the other injector. - 82 - Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00...
  • Page 83: Installing The Thermostatic Valve Body

    3 - Put in the screws and tighten to 20 Nm. The thermostatic valve body holds the coolant temperature sensors (A) and the coolant thermometer sensor (B). Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 83 -...
  • Page 84: Installation Of The Timing Belt Drive

    2 - Install the phase sensor onto the support and tighten the screws temporarily. - 84 - Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00...
  • Page 85: Assembling The Timing Belt Pulleys (Camshaft And Crankshaft)

    (F) and the pulley (E). Belt Pulley (A) Pulley (A) Tauten the belt using the pulley nut (F) and fasten temporarily. Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 85 -...
  • Page 86: Assembling The Timing Belt Guard

    (H-H1) and the peripheral sleeve becomes necessary technical construction reasons, please request the pre-assembled guard (G) complete with rings and gaskets. Dust guard ring (H) - 86 - Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00...
  • Page 87: Installation Of The Cooling Fan Belt Drive

    7 - Remove the locking tool (M). 8 - Install the starter motor (N) and tighten the screws to a torque of 45 Nm. Starter motor (N) Locking device (M) Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 87 -...
  • Page 88: Assembling The Cooling Fan Belt (With Internal Alternator)

    Install the cooling fan. Tighten the screws to a torque of 10Nm - 88 - Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00...
  • Page 89: Assembling The Cooling Fan Belt (With External Alternator)

    Alternator Nut (B1) Fan (U) 6 - Install the cooling fan (U) . 7 - Tighten the screws to a torque of 10Nm. Screw Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 89 -...
  • Page 90: Installation Of The Exhaust And Intake Manifolds

    6 - Tighten the screws in an alternating pattern to a final torque of 10Nm. 7 - Connect the spark plug and coil power supply cables. - 90 - Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00...
  • Page 91 11 - Fit the air filter hose (C) to the throttle body. 12 - Connect the breather pipe (B). 13 - Tighten the clamps on the air filter manifolds and the breather. Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 91 -...
  • Page 92: Assembling The Exhaust Manifold

    25Nm. Connect the breather pipe to the manifold. 7 - Install the Lambda probe and fasten it to a torque of 50 Nm. - 92 - Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00...
  • Page 93 Caution - Warning Do not start the engine when the thermal protection is not in place. 9 - Install the case holding the dipstick. Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 93 -...
  • Page 94 ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................- 94 - Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00...
  • Page 95: Vehicle Controls

    3 Accelerator cable adjustment screw 4 Accelerator cable 5 Accelerator sensor 6 Accelerator connector 7 Electronic control unit (ECU) 8 Ignition system relays and fuses Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 95 -...
  • Page 96: Petrol Pressure Check

    Danger - Attention To avoid the risk of accident, do not smoke or use any kind of flame when checking the injectors. - 96 - Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00...
  • Page 97: Adjusting The Accelerator Cable

    This function is necessary to prevent the danger generated by sudden halting of the vehicle while running, in the event of abnormalities with the components of the electronic engine control system Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 97 -...
  • Page 98: Diagnostic

    To obtain a good diagnosis procedure it is absolutely necessary to use the scan tool Lombardini("1460.191 »). The tool « 1460.191 » is a scan tool instrument that allows to perform the diagnosis on the vehicles with Lombardini engine LGW 523 MPI.
  • Page 99: Accessories

    ECU and the ST-6000. 8.3.5 Autodiagnostic software 1 - Compact flash : it contains the data bank for the car autodiagnostics. Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 99 -...
  • Page 100: Preliminary Operations

    Components layout inside the engine case». 8.4.2 Vehicle and system selection From the main menu press « F1 DIAGNOSTIC » to display the type of car selection menu. - 100 - Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00...
  • Page 101 3 - Select the model of the car confirming each time by 4 - Select by keys the version and the type of the car confirming each time by Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 101 -...
  • Page 102: Available Functions For Diagnostic

    From this page it is possible to have access to the information contained in the programme by using the menu bar on the right of the LCD display. - 102 - Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00...
  • Page 103: Menu Bar

    To know parameters that can be enabled or errors that can be detected see the list of the screen page. Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 103 -...
  • Page 104: Errors

    ECU memory. To cancel errors memorized in the ECU select the box by the key and press displayed errors will accompanied by the icon - 104 - Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00...
  • Page 105: Construction Parameters

    « F1 INFO » key it is possible to obtain some information about the parameter itself and about the diagnostic strategy. Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 105 -...
  • Page 106 Vehicle controls At the end press to go back to the« PARAMETRES» menu. - 106 - Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00...
  • Page 107 ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................Service Manual LGW 523 MPI automotive _ cod. 1.5302.711 - 1° ed_rev. 00 - 107 -...
  • Page 108 Cod. fiscale e Partita IVA 01829970357 - CEE Code IT 01829970357 E-MAIL: atl@lombardini.it Internet: http://www.lombardini.it La Lombardini si riserva il diritto di modificare in qualunque momento i dati contenuti in questa pubblicazione. Lombardini se rèserve le droit de modifier, à n'importe quel moment, les données reportées dans cette publication.
  • Page 110 42100 Reggio Emilia – Italia - ITALY Via Cav. del Lavoro Adelmo Lombardini, 2 Tel. (+39) 0522 3891 E-MAIL: atl@lombardini.it Internet: http://www.lombardini.it SERVICE MANUAL - code 1.5302.711...

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