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...
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 -...
(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 -...
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.
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 -...
(*) 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 -...
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 -...
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 -...
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...
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...
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 -...
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 -...
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 -...
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 -...
- 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 -...
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...
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 -...
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...
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...
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 -...
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...
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 -...
(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 -...
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...
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 -...
(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...
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 -...
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...
÷ ° ÷ 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 -...
÷ ÷ 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...
(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 -...
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...
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 -...
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...
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 -...
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...
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...
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 -...
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...
«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 -...
(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...
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 -...
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...
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 -...
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...
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 -...
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...
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 -...
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...
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 -...
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...
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 -...
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...
(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 -...
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 -...
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 -...
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 -...
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 -...
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...
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 -...
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.
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 -...
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 -...
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...
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 -...
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...
« 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 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...
Need help?
Do you have a question about the LGW 523 mpi and is the answer not in the manual?
Questions and answers