MWM Acteon Workshop Manual
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MWM Acteon Workshop Manual

Mwm acteon engines workshop manual
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  • Page 1 Workshop Manual...
  • Page 2 Workshop Manual MWM- International Motores Assistência ao Cliente / Asistencia al Cliente / Customer Assistance Av. das Nações Unidas, 22.002 CEP- 04795-915 - São Paulo - SP - Brasil Internet: www.mwm-international.com.br e-mail mwm@mwm.com.br Fone: +55(11) 3882-3200 Fax: +55(11) 3882-3574 (DDG): 0800 0110229 9.612.0.006.7160 - 11/06...

  • Page 3: Table Of Contents

    Presentation Presentation Introduction ............................1-2 How to Use this Workshop Manual ....................1-2 Important Safety Remarks ........................ 1-3 General Instructions ......................... 1-4 Cleaning General Instructions ......................1-5 Engine Serial Number Identification and Location ................. 1-6 Cylinder Numeration ......................... 1-7 9.612.0.006.7160 - 05/04...

  • Page 4: Introduction

    The assembly and disassembly specifications and information presented in this manual are the ones which is effective in the moment of its print. MWM Motores Diesel Ltda. reserves the right of making any change, at any moment. MWM Motores Diesel Ltda. reserves the right of doing changes in the product at any moment without this to incur in any further obligation.

  • Page 5: Important Safety Remarks

    • The MWM coolant has alkaline substances. Avoid the contact with the eyes. Avoid the prolonged or repetitive contact with the skin. Do not ingest. In case of contact with the skin, wash immediately with water and soap. In case of contact with the eyes, abundantly wash with water for, at least 15 minutes.

  • Page 6: General Instructions

    • In case of any irregularity seek for a dealer or authorized service of the vehicle / equipment manufacturer or MWM. Avoid that outsiders make any service in the engine, because this cancels the warranty. • To use a parallel battery to start de engine, the amperages of both batteries must be the same to avoid tension peaks.

  • Page 7: Cleaning General Instructions

    Cleaning with Acids and Solvents Several solvents and acid substances can be used to clean the parts of the engine. MWM Motores Diesel Ltda. does not recommend any specific substance. Always follow the instructions of the manufacturer of the product.
  • Page 8 Presentation Identification and Location of the Serial Number The engine identification and serial number can be found in the following places: 1. Identification plate on the water pipe. 2. Engraving on the right side of the engine block, close to the cylinder head of the cylinder #3. 6.12 TCE Electronic Aftercooler...

  • Page 9: Cylinder Numeration

    Presentation Cylinders Numeration The numeration of the cylinders starts from the flywheel, according to the illustration below. Cylinder #1 Flywheel During the assembly, check the numbers on the block (A) and on the bearings (B), which indicates the right assembly position.
  • Page 10 NOTES 9.612.0.006.7160 - 05/04...
  • Page 11 Technical Data Technical Data Technical Data ........................... 2-2 Fuel System ........................2-2 Lubrication System ......................2-3 Cooling System ........................2-3 Thermostat .......................... 2-3 9.612.0.006.7160 - 05/04...
  • Page 12 Technical Data Technical Data Engine Data 4.12TCE 6.12TCE Engine type Vertical cylinders in line, 4 strokes Injection type Direct with electronic management Cylinder bore 105 mm Cylinder stroke 137 mm 1,2 l Unit displacement 4,745 litres 7,118 litres Total displacement Quantity of cylinders 16,8:1 Compression rate...
  • Page 13 Technical Data Lubrication System Description 4.12TCE 6.12TCE Oil pressure 4.5 bar (hot engine) • Nominal speed 1.0 bar (hot engine) • Idling speed Oil temperature 90 - 110 °C • Nominal 120 °C • Maximum Oil capacity • Minimum 13 l 17 l 13 l 23 l...
  • Page 14 NOTES 9.612.0.006.7160 - 05/04...
  • Page 15 Engine Operation ..........................3-2 Cooling fluid and Coolant ........................ 3-5 Level Check ..........................3-5 Cooling Fluid Filling Procedure ...................... 3-6 Maintenance Table ..........................3-7 MWM Acteon Engines - Vehicular ..................3-7 Conservation for Inactive Engines for Long Periods ..............3-8 9.612.0.006.7160 - 05/04...

  • Page 16: Engine Operation

    Operation and Maintenance Operation and Maintenance Engine operation Start Before operating the MWM Acteon engine check: • Water level. • Fuel level. • Lubricant level. • Soon after to start the engine, heat it up at medium speed, without load. Watch lubricant oil pressure and water temperature.
  • Page 17 Following these recommendations the useful life of the engine will be prolonged. Fuel Specifications MWM Acteon engine must operate with regular Diesel fuel. It is recommended to use fuel of specification according to the Brazilian Resolution CNP nr. 07/80 of Petroleum National Council.
  • Page 18 Stop the engine and, after 30 minutes, check oil level again, filling up if necessary. Attention • Always use genuine MWM filter. Lubricant Oil The lubricant oil is very important for a good conservation of the inner components of the engine. Lubricant oil contaminated with sand, soil, dust, water or fuel cause problems to the engine.

  • Page 19: Cooling Fluid And Coolant

    • Check the level of the cooling system daily. If the level is not correct, add clean water + MWM coolant according to the proportion recommended on the bottle. • Carefully open the first stage of the cap relieving the vapour pressure.

  • Page 20: Cooling Fluid Filling Procedure

    7. Open the drain, remove the radiator cap and leave the water to flow out all again; 8. Close the drain outlet and fill the system with clean water and MWM coolant according to the recommended proportion; 9. Operate the engine up to the normal operation temperature and leave it running for 15 minutes;...

  • Page 21: Maintenance Table

    Operation and Maintenance MAINTENANCE TABLE MWM ACTEON VEHICULAR ENGINES Initial MAINTENANCE PLAN A) Up to 50,000 km/year conditions B) Over than 50,000 km/year conditions • DRAIN FUEL FILTER • CHECK LUBRICANT OIL LEVEL • • • COLLECT SAMPLE OF LUBRICANT OIL TO ANALYSIS •...

  • Page 22: Conservation For Inactive Engines For Long Periods

    Conservation for Inactive Engines for Long Period MWM engines are produced protected for, at the most, 3 inactivity months under shut shelter. When the engine is to stay inactive for a long period, it is necessary to follow these cares: 1.
  • Page 23 Ultramo Turbo SAE 20 Graxas Manufacturer Recommended Products (*) Castrol LM 2 Texaco Marlfac MP2 Ipiranga Ipiflex 2 Petrobrás Lubrax GMA-2 (*) Other products with similar technical features could be used with a previous approval of MWM. 9.612.0.006.7160 - 05/04...
  • Page 24 NOTES 9.612.0.006.7160 - 05/04...
  • Page 25 Engine Block Engine Block Disassembly Notes ........................... 4-2 Pre-Assembly Inspections and Measurements ................4-3 Liner Protrusion Specification ..................4-3 Liners Specification ...................... 4-4 Liners and Pistons Assembly Specifications ............. 4-5 Engine Block Specifications ..................4-6 Inspections and Measurements ....................... 4-8 Assembly ............................

  • Page 26: Disassembly Notes

    Disassembly Notes The cylinder liners removal must be made with the special tool MWM nr. 9.610.0.690.017.6 in order to do not damage the engine block or the liners. The lower part of the tool must be fitted on the lower edge of the liner.

  • Page 27: Pre-Assembly Inspections And Measurements

    Engine Block Pre-Assembly Inspections and Measurements Liner Protrusion Specification Liner over Engine Block Surface Measure Protrusion *0.04 - 0.09 *Affect emissions level TOMBAK Ring Thickness 9.612.0.340.002.4 0.15 Protrusion Adjustment Shims (when necessary) Thickness 9.612.8.340.004.4 0.05 9.612.8.340.005.4 0.10 9.612.8.340.006.4 0.20 9.612.8.340.007.4 0.50 9.612.0.006.7160 - 05/04...

  • Page 28: Liners Specification

    Engine Block Pre-Assembly Inspections and Measurements Liners Specification Liners Measure Maximum waste 0.06 Out-of-roundness 0.02 Ø Inner 105.000 - 105.022 9.612.0.006.7160 - 05/04...

  • Page 29: Liners And Pistons Assembly Specifications

    Engine Block Liners and Pistons Assembly Specifications Piston Liner Engine Block Gasket Cylinder head Liners Assembly Gasket nr. / Application 8.04 to 8.06 0.23 to 0.59 0.95 to 1.10 1.35 to 1.69 9.612.0.854.003.4 / Spare part 9.612.0.006.7160 - 05/04...

  • Page 30: Engine Block Specifications

    Engine Block Engine Block Specifications Main Bearings (A) Diameter Inner 92.000 - 92.022 Tappets Housing (B) Ø Inner standard, nominal 18.000 - 18.018 standard, maximum 18.020 1st repair 18.500 - 18.518 Measure main bearings bolt lengths. Discard bolts longer than 133.5 mm. 9.612.0.006.7160 - 05/04...
  • Page 31 Engine Block Camshaft Bearing (C) and (E) Ø inner without bushing standard nominal 50.000 - 50.025 maximum 50.045 1st repair without bushing 54.000 - 54.030 with bushing 49.990 - 50.050 Camshaft Bearing (D) Ø inner without bushing 54.000 - 54.030 with bushing 49.990 - 50.050 *Remark.:...

  • Page 32: Inspections And Measurements

    As a bracket to the dial indicator gauge, it can be used the special tool MWM nr. 9.407.0.690.031.6. If necessary, use a stainless steel ring underneath Tombak ring to obtain the specified height.
  • Page 33 Temporarily install the liner in the engine block, with the Tombak ring but without the rubber sealing rings. To measure liner protrusion with the sealing rings installed, compress the liners using the special tool MWM nr. 9.610.0.690.025.4. Torque at 40 Nm. 9.612.0.006.7160 - 05/04...
  • Page 34 Engine Block Measure the liner protrusion in relation to the upper surface of the engine block with a dial indicator gauge. Remove the liner again using the procedure described previously. Attention • The rings must be completely clean to avoid torsion or cut during the assembly, causing lubricant oil contamination with water.

  • Page 35: Assembly

    Engine Block Assembly Install the sealing rings. Install the Tombak ring. Install the liners according to the procedure described previously. 9.612.0.006.7160 - 05/04...
  • Page 36 Engine Block Rings correct position with the assembled liner. 9.612.0.006.7160 - 05/04...
  • Page 37 Crankshaft Crankshaft Disassembly Notes ........................... 5-2 Crankshaft Specification ....................5-3 Main Journals Specification ..................5-4 Crankpins Specification ....................5-5 Out-of-roundness and Taper Specification ..............5-6 Radial Clearance ......................5-7 Fillets ..........................5-8 Pre-Assembly Inspections and Measurements ................5-9 Crankshaft ........................5-9 Engine Block Bearings ....................

  • Page 38: Disassembly Notes

    Crankshaft Disassembly Notes After removing the carter, pistons and connecting rods, flywheel and pulley, position the engine on the stand in upright position and loosen the main bearing caps. To remove the bearing caps use the fixation bolts. Remove the axial thrust ring from bearing #1 (flywheel side).

  • Page 39: Crankshaft Specification

    Crankshaft Crankshaft Specification Gear Diameter Seat 60.020 - 60.059 9.612.0.006.7160 - 05/04...

  • Page 40: Main Journals Specification

    Crankshaft Main Journals Specification Main Journal Diameter Standard 85.942 - 85.964 1st repair 85.692 - 85.714 2nd repair 85.442 - 85.464 3rd repair 85.192 - 85.214 4th repair 84.942 - 84.964 9.612.0.006.7160 - 05/04...

  • Page 41: Crankpins Specification

    Crankshaft Crankpins Specification Crankpins Diameter Standard 62.951 - 62.970 1st repair 62.701 - 62.720 2nd repair 62.451 - 62.470 3rd repair 62.201 - 62.220 4th repair 61.951 - 61.970 9.612.0.006.7160 - 05/04...

  • Page 42: Out-Of-Roundness And Taper Specification

    Crankshaft Out-of-roundness and Taper Specification Maximum Out-of-roundness A x C and B x D 0.01 Maximum Taper A x B and C x D 0.01 9.612.0.006.7160 - 05/04...

  • Page 43: Radial Clearance

    Crankshaft Radial Clearance Radial Clearance nominal 0.036 - 0.096 maximum 0.245 9.612.0.006.7160 - 05/04...

  • Page 44: Fillets

    Crankshaft Fillets Fillet Nominal 3.8 - 4.0 9.612.0.006.7160 - 05/04...

  • Page 45: Pre-Assembly Inspections And Measurements

    Crankshaft Pre-Assembly Inspections and Measurements Crankshaft Crankshaft, as well as the bearings, can be visually checked. It is necessary to check for overheating signs, deep scratches, cracks or other types of damage. Presenting anyone of these damages it is necessary to check the possibility of machining and to use oversized bearing shells.

  • Page 46: Engine Block Bearings

    Crankshaft Engine Block Bearings Before doing any check on the caps and main bearings, make sure that the numeration engraved on the engine block corresponds to the bearing cap. Install bearing caps and tighten according to the specification. Measure bearings diameter, out-of-roundness and taper without bearing shells.

  • Page 47: Bearing Shells

    Crankshaft Bearing shells Main Bearings Specifications Engine Block Diameter Without bearing shell 92.000 - 92.022 Bearing shell Diameter Standard 86.000 - 86.038 1st repair 85.750 - 85.788 2nd repair 85.500 - 85.538 3rd repair 85.250 - 85.288 4th repair 85.000 - 85.038 9.612.0.006.7160 - 05/04...
  • Page 48 Crankshaft Depending on the presented defect on the bearing shells it is possible to identify what is the problem of the engine: excessive clearance, out-of-roundness or taper. A failure or excessive clearance also can be detected by the reduction of the lubricant oil pressure. The prolonged operation with low oil pressure can cause beats and vibrations in crankshaft and consequently early deterioration of the bearing shells.
  • Page 49 Crankshaft Position the bearing shells with the aid of the expansion pin. Measure the crankshaft. The measurements must be taken twice at 90° and in the two edges of the bearing, checking crankpins and main journals out-of- roundness and taper. Compare the clearances obtained on the crankshaft through the bore gauge.
  • Page 50 Crankshaft Assembly bearing caps and tighten according specification. Perform the measurements in the same way that they were performed for the bearings without bearing shells to obtain the radial force. The 1st measurement is made in the centre of the bearing.

  • Page 51: Crankshaft

    Crankshaft Crankshaft With the bearing shells of the first and last bearings only installed and oiled, place crankshaft. With a dial indicator gauge on the central main journal, turn crankshaft and measure warping. 4 cyl. 6 cyl. Maximum Warping (mm) 0.11 0.15 Check crankshaft thrust rings.
  • Page 52 Crankshaft Bolts Tighten Torque Specification Main Bearing Caps Torque - Angle Step 1st: ........45 Nm ± 5 2nd: ......... 90° ± 5° Lmax = 133.50 mm Piston Oil Injector 10 ± 1.5 Nm 9.612.0.006.7160 - 05/04...

  • Page 53: Assembly

    Crankshaft Assembly Install piston cooling oil injectors. Apply torque of 10 ± 1.5 Nm. Install and oil all bearing shells. Install crankshaft. 9.612.0.006.7160 - 05/04...
  • Page 54 Crankshaft Install first bearing lower thrust ring. Attention • Thrust rings grooves must stay towards the crankshaft (mobile side). Assembly bearing caps with the upper thrust ring. 9.612.0.006.7160 - 05/04...
  • Page 55 Crankshaft Tighten bolts in two steps and tighten according the specification. The torque must be applied from the center to the extremities. 9.612.0.006.7160 - 05/04...

  • Page 56: Measurements After Assembly

    Crankshaft Measurements After Assembly Axial Clearance Specification Axial clearance (A) Nominal 0.08 - 0.25 Maximum Measure the crankshaft axial clearance. 9.612.0.006.7160 - 05/04...
  • Page 57 Camshaft Camshaft Disassembly Notes ........................... 6-2 Camshaft Specifications ....................6-3 Tappets and Lock Plate Specification ................. 6-4 Pre-Assembly Inspections and Measurements ................6-5 Bolts Tightening Specifications ..................6-9 Assembly ............................6-10 9.612.0.006.7160 - 05/04...

  • Page 58: Disassembly Notes

    Camshaft Disassembly Notes Remove camshaft gear. Remove camshaft lock. Turn the engine, keeping the carter side upwards. Remove camshaft with the hands and through the front of the engine, making a movement of rotation. Take care to do not damage the bearings of the shaft and engine block.

  • Page 59: Camshaft Specifications

    Camshaft Camshaft Specifications Axial Clearance Limitation Groove Gear seat Width Diameter Nominal 7.100 - 7.190 Nominal 51.971 - 51.990 Maximum 7.275 Main journals Bearing Clearance Diameter Axial 0.05 - 0.19 Standard 49.920 - 49.940 Radial 0.05 - 0.13 9.612.0.006.7160 - 05/04...

  • Page 60: Tappets And Lock Plate Specification

    Camshaft Tappets and Lock Plate Specification Ø Lock Plate Tappets Thickness Diameter Nominal 7.00 - 7.05 Standard Nominal 17.983 - 17.994 Minimum 17.975 1st repair 18.483 - 18.494 Nominal 9.612.0.006.7160 - 05/04...

  • Page 61: Pre-Assembly Inspections And Measurements

    Camshaft Pre-Assembly Inspections and Measurements Visually check the tappets. Check if there are marks of excessive waste on the contact area with the cams of the camshaft. Attention • During its operation the tappets perform a rotating movement, responsible for a uniform distribution of the force, uniforming the waste.
  • Page 62 Camshaft Measure the diameter and out-of-roundness of the tappets housing. Measure the tappets diameter. Measure the camshaft bearing diameters. 9.612.0.006.7160 - 05/04...
  • Page 63 Camshaft Comparing the performed measurements, obtain the clearance between the bearing and the housing. Measure the camshaft bearing housing bores. Measure the camshaft warping. 4 cyl. 6 cyl. Maximum warping (mm) 0.04 0.04 9.612.0.006.7160 - 05/04...

  • Page 64: Bolts Tightening Specification

    Camshaft Bolts Tightening Specification 8.5 ± 1.0 Nm 20 ± 3 Nm 35 ± 5 Nm 9.612.0.006.7160 - 05/04...

  • Page 65: Assembly

    Camshaft Assembly Clean and lubricate the tappets and the tappets housing. Install them with the hands. If it is not necessary to change the tappets check the original position in that they were installed and reinstall them in the same positions.
  • Page 66 Camshaft Install it with the hands making rotating movements. Take care to do not damage the bushings in the engine block. After camshaft installation, install the axial lock and tighten fixation bolts according to the specification. 9.612.0.006.7160 - 05/04...
  • Page 67 Camshaft View of the assembled camshaft and lock. Measure the camshaft axial clearance. Repeat the operation sometimes to make sure of the measurement. Assembly the pulse-wheel. Attention to the expansion bushing, which guides the correct positioning. 9.612.0.006.7160 - 05/04...
  • Page 68 Camshaft Assembly pulse wheel fixation bolts and tighten according the specification. Install camshaft gear. 4.12 6.12 Pay attention to the difference between the pulse wheels of the 4 and 6 cylinders engines. 9.612.0.006.7160 - 05/04...
  • Page 69 Pistons and Connecting Rods Pistons and Connecting Rods Disassembly Notes ........................... 7-2 Pre-Assembly Inspections and Measurements ................7-4 Piston Grooves Specifications ..................7-6 Ring Ends Gaps Specification ..................7-7 Connecting Rod Bearings Specification ..............7-7 Connecting Rods Specification ................... 7-9 Piston and Pin ......................

  • Page 70: Disassembly Notes

    Pistons and Connecting Rods Disassembly Notes After the removal of the carter and cylinder heads, position the engine in upright position to remove the connecting rods. Remove connecting rod caps. The bolts must be loosened alternately and in steps. Do not complete loosen the screw of one side and later loosen other.
  • Page 71 Pistons and Connecting Rods Remove piston rings with an appropriate device. Atenção • No ato da retirada do conjunto pistão / biela, observar a posição do ejetor de óleo para evitar batidas e amassamentos. 9.612.0.006.7160 - 05/04...

  • Page 72: Pre-Assembly Inspections And Measurements

    Pistons and Connecting Rods Pre-Assembly Inspections and Measurements The weight of the connecting rod is identified by a sequence of letters and numbers between the stem and the cap. According to the letter (X, Y and Z) it is possible to identify the weight strip. Connecting Rod Mark Letter Weight Strip...
  • Page 73 Pistons and Connecting Rods CIdentification code: (*) As spare part it is only available connecting rods of the “Y” strip mass that is used to replace connecting rods of any other strips. Important: Do not assembly connecting rods of “X” and “Z” mass strip in the same engine, because these connecting rods exceed the maximum limit of mass difference.

  • Page 74: Piston Grooves Specifications

    Pistons and Connecting Rods Piston Grooves Specifications Remark: The rings of the 10 Series engines are identified by a red strip on the outer diameter. Rings Dimensions and Clearances in the Grooves Groove Dimensions (mm) Clearance (mm) 103.0 x 3.0 x 4.40 0.25 107.0 x 2.5 x 4.40 0.20...
  • Page 75 Pistons and Connecting Rods Ring Ends Gaps Specification Ends Gap (mm) 1st and 2nd groove Nominal 0.40 - 0.65 Maximum 3rd groove Nominal 0.25 - 0.55 Maximum Connecting Rod Bearings Specification Connecting Rod Bearing, Ø (bore) Diameter (mm) standard 62.992 to 63.037 repair 1 62.746 to 62.791 repair 2...
  • Page 76 Pistons and Connecting Rods Connecting Rod Warping Maximum Torsion Maximum Warping 0.10 0.03 9.612.0.006.7160 - 05/04...

  • Page 77: Connecting Rods Specification

    Pistons and Connecting Rods Connecting Rods Specifications Radial Clearance (mm) Nominal 0.022 - 0.087 Maximum 0.178 Side Clearance (mm) Nominal 0.30 - 0.50 Maximum 0.90 9.612.0.006.7160 - 05/04...

  • Page 78: Piston And Pin

    Pistons and Connecting Rods Piston and Pin ØA Piston Pin Diameter (mm) Nominal 37.994 to 38.000 Maximum 37.900 ØB Connecting Rod Bushing (assembled) Diameter (mm) Nominal 38.030 to 38.080 Maximum 38.140 ØC Connecting Rod Bushing (housing) Diameter (mm) Nominal 41.000 to 41.016 ØD Piston Pin Clearance...

  • Page 79: Pre-Assembly Inspections And Measurements

    Pistons and Connecting Rods Pre-Assembly Inspections and Measurements Visually check pistons, pins and connecting rods. Check piston pin for marks, scratches or excessive waste. Measure the diameter of the pin. Check pins taper and out-of-roundness. Check connecting rod, possible damages, marks or waste.
  • Page 80 Pistons and Connecting Rods With the bushing assembled, measure the diameter of the housing of the piston pin. Before performing the measurement of the bearings, check the mark codes on the cap and on the connecting rod. These codes indicate the parity between connecting rod and cap, guaranteeing the perfect seating of the bearing shells in the assembly.
  • Page 81 Pistons and Connecting Rods Turn the bore gauge 90° and perform the second measurement of the diameter. Check connecting rod torsion. Maximum Torsion = 0.10 mm Check connecting rod warping. Maximum Warping = 0.03 mm 9.612.0.006.7160 - 05/04...
  • Page 82 Pistons and Connecting Rods Loosen connecting rod cap, assembly the bearing shells with the aid of the expansion pin, assembly again the connecting rod cap and tighten according to Compare the clearances obtained from the crankpins with the bore gauge. Measure the clearance with the bore gauge turned 90°...
  • Page 83 Pistons and Connecting Rods With the bore gauge at 90° from the partition of the connecting rod, reset the dial indicator gauge, remove one of the connecting rod bolts and measure its pre-tension. Pre-tension = 0.06 - 0.12 mm 9.612.0.006.7160 - 05/04...

  • Page 84: Connecting Rod Bolts Tightening Specification

    Pistons and Connecting Rods Connecting Rod Bolts Tightening Specification Torque-Angle Etep 1st ....30 ± 5 Nm 2nd ..... 60° ± 3° Lmax = 59.20 mm 9.612.0.006.7160 - 05/04...

  • Page 85: Assembly

    Pistons and Connecting Rods Assembly The "CTOPW", “CTOPK" and "CTOP" marks must be upward. Assembly the piston rings. Lubricate piston pin, assembly the piston in the connecting rod, observing the correct positioning between them. The arrow on the top of the piston must be toward the side of the 3 holes of the connecting rod.
  • Page 86 Pistons and Connecting Rods Check the ring grooves, pin housing and the skirt of the piston. Check the clearance of the rings in the piston grooves. Lubricate the liners and piston rings. When installing the piston / connecting rod set in the cylinder, mind the correct assembly position.
  • Page 87 Pistons and Connecting Rods Install the device for piston assembly to close the rings. Note: Position the engine flywheel upward. This avoids the contact of the connecting rod with the oil injectors. Carefully push the piston inside the cylinder. Never hit directly on the top of the piston.
  • Page 88 Pistons and Connecting Rods Position the connecting rod stem in the crankshaft crankpin and install the connecting rod cap. Tighten the bolts according to specification. Check if the connecting rod has free side movement. Measure the side clearance. With the piston on TDC, measure the surface height in relation with the engine block surface.
  • Page 89 Cylinder heads Cylinder Heads Disassembly Notes ........................... 8-2 Valve Seats Specification ..................... 8-3 Valves Specification ..................... 8-4 Valve Guides Specification ..................8-5 Specification of Guide Height and Distance to Cylinder Head Surface ..... 8-6 Valves Course ....................... 8-7 Rocker Arm, Cold Clearance ..................8-8 Valves Diagram ..........................

  • Page 90: Disassembly Notes

    With the aid of the fixation bolts, remove cylinder heads. Remove cylinder head gaskets. Using the special tool MWM nr. 9.407.0.690.044.6, compress the springs and remove valve locks, removing springs, seal and valves. To remove valve guides and seats send them to a specialized authorized workshop.

  • Page 91: Valve Seats Specification

    Cylinder heads Valve Seats Specification Ø (A) Housing (mm) Standard Intake 46.046 - 46.086 Exhaust 42.976 - 43.016 Ø (B) Outer (mm) Standard Intake 46.152 - 46.168 Exhaust 43.097 - 43.113 Ø (C) Seat Width (mm) Standard Intake 1.90 - 2.00 Exhaust 2.17 - 2.28 Maximum...

  • Page 92: Valves Specification

    Cylinder heads Valves Specification Ø (A) Stem (mm) Nominal 8.952 - 8.970 Minimum 8.949 Ø (B) Head height (mm) Intake Exhaust Ø (C) Surface width (mm) Intake 3.60 Exhaust 3.11 Ø (D) Head (mm) Intake 44.9 - 45.1 Exhaust 40.9 - 41.1 9.612.0.006.7160 - 05/04...

  • Page 93: Valve Guides Specification

    Cylinder heads Valve Guides Specification Ø (A) After assembly (mm) Nominal 9.000 - 9.022 Repair 9.013 - 9.028 Maximum 9.060 Ø (B) Outer (mm) Nominal 15.028 - 15.039 Ø (C) Housing (mm) Nominal 14.991 - 15.021 Ø (D) Clearance at the Stem (mm) Nominal 0.030 - 0.070...

  • Page 94: Specification Of Guide Height And Distance To Cylinder Head Surface

    Cylinder heads Specification of Guide Height and Distance to Cylinder Head Surface Guide Height (A) (mm) Intake and Exhaust 11.3 - 12.6 Distance to cylinder (mm) head surface (B) Nominal Intake 0.8 - 1.1 Exhaust 1.30 - 1.60 Maximum Intake 1.35 Exhaust 1.85...

  • Page 95: Valves Course

    Cylinder heads Valves Course and Clearance Ø (A) Course (mm) Intake 11.10 - 11.34 Exhaust 11.22 - 11.46 Ø (B) Clearance (mm) Intake 0.40 Exhaust 9.612.0.006.7160 - 05/04...

  • Page 96: Rocker Arm, Cold Clearance

    Cylinder heads Rocker arm, Cold Clearance Diameters Clearance Rocker arm (A) 16.000 - 16.018 Radial (C) 0.016 - 0.052 Shaft (B) 15.966 - 15.984 Axial (D) 0.050 - 0.260 9.612.0.006.7160 - 05/04...
  • Page 97 Cylinder heads The test is performed placing the springs on a special device and reading the closing force for two different deflections according to the following table. The intake valves springs are single (only one spring) and exhaust valves springs are double.

  • Page 98: Valves Diagram

    Cylinder heads Valves Diagram Valves clearance: 1 mm (After the check, readjust the clearance to 0.40 mm) Intake: Open 3° after TDC Close 23° after PMI Exhaust: Open 33° before PMI Close 1° after TDC Tolerance: ± 3° 9.612.0.006.7160 - 05/04...

  • Page 99: Pre-Assembly Inspections And Measurements

    Cylinder heads Pre-Assembly Inspections and Measurements Visually check cylinder heads for leaks. Check push rods. The push rods ends must not be loosen or cracked. Check for excessive waste and if the lubrication hole is not obstructed. Check if the push rods are not warped.
  • Page 100 Cylinder heads Measure the outer diameter of the valve stem in 3 different points: • Upper part • Central part • Lower part Measure the outer diameter of the valve guide. Attention • Do not measure the diameter on the lowered part of the guide. 9.612.0.006.7160 - 05/04...
  • Page 101 Cylinder heads Measure valve guide housing bore. After the measurements, install valve guides with the special tool MWM nr. 9.610.0.690.014.6. Measure the bore of the assembled valve guide. 9.612.0.006.7160 - 05/04...
  • Page 102 Cylinder heads Measure the width of the valve contact surface. Measure the valve guide height in relation to the cylinder head. Measure the width of the valves seat. 9.612.0.006.7160 - 05/04...
  • Page 103 Cylinder heads Check if the rocker arm ends do not present excessive waste or cracks in the shaft housing or on the contact area with the valve stem. After removing the rocker arms, check for grip signs. Measure the rocker arm shaft, ovalização e conicidade.
  • Page 104 Cylinder heads Measure the shaft housing bore. Check rocker arms ends axial clearance in the shafts e deformações como conicidade e ovalização. 9.612.0.006.7160 - 05/04...

  • Page 105: Bolts Tighten Torques Specifications

    Cylinder heads Bolts Tighten Torques Specifications 56 ± 8 Nm 20 + 6 Nm 15 + 5 Nm 110 ± 15 Nm Torque - Angle Step 1st ...... 60 + 10 Nm 2nd ..... 60° ± 3° 3rd ...... 60° ± 3° Lmax = 148.50 mm 15 + 5 Nm 9.612.0.006.7160 - 05/04...

  • Page 106: Assembly

    Cylinder heads Remark • Before beginning the assembly of the cylinder head set, all parts must be well clean. Assembly Make the seat of the valves on the respective seats (new seats are provided semi finished). Make sure if the seat obtained between the valve and seat is uniform.
  • Page 107 Install valves seals on the guides with the special tool MWM nr. 9.610.0.690.015.4. Oil and install valves and springs in cylinder head. With the special device MWM nr. 9.407.0.690.044.6, compress the springs and assembly the valves locks. Install a dial indicator gauge in the special measurement device MWM nr.
  • Page 108 Cylinder heads Install the guide-pins for cylinder heads assembly MWM nr. 9.407.0.690.030.4 in the place of two diametrically opposite bolts. Install cylinder head gasket with the “TOP” mark upward. The cylinder head gasket must be perfectly clean and must never be assembled with grease, oil or glue.

  • Page 109: Cylinder Head Gasket

    Gasket Identification Supplier Identification MWM Nr. Thickness Assembly side Supplier Production Date Attention • Use only MWM genuine gaskets. • The thickness of the cylinder head gasket for replacement is only of 1.4 mm. 9.612.0.006.7160 - 05/04...
  • Page 110 Cylinder heads Measure cylinder heads fixation bolts length. Discard bolts longer than 148.50 mm. Install cylinder head fixation bolts without tighten. Perform the alignment of the cylinder heads with the help of the intake manifold. Assembly intake manifold with gaskets and tighten manifold fixation bolts according to the specification.
  • Page 111 Cylinder heads Install rocker arms set assembled, tightening according to the specification. Install pushrods checking their correct seat on the tappets. Attention • Totally unscrew the valve clearance adjustment screw before installing the rocker arms. 9.612.0.006.7160 - 05/04...
  • Page 112 Cylinder heads Adjust valves clearances. Position the last cylinder in swinging and adjust the valves of the first cylinder. A cylinder is swinging when, turning the crankshaft, the intake and exhaust push rods move simultaneously. To adjust valves clearance, use a shim with the specified measure between the rocker arm and the valve.
  • Page 113 Gearing Carcass Gearing Carcass Disassembly Notes ........................... 9-2 Inspections and Measurements ....................... 9-3 Specifications ....................... 9-3 Gears Backlashes and Clearances Specification ............9-6 Bolts Tighten Torques Specification ................9-7 Assembly ............................9-11 9.612.0.006.7160 - 05/04...
  • Page 114 Gearing Carcass Disassembly Notes Before disassembling the pulley, lock the flywheel with the special tool MWM nr. 9.610.0.690.026.4. The engine can be also locked with a lever positioned on the nut of the water pump gear, until that the lever touches the pulley.
  • Page 115 Gearing Carcass Inspections and Measurements Visually check damper and pulley(s). Visually check gears. Check for waste signs or cracks on the base of the teeth. Presenting such as those defects, the gears must be replaced. Measure the components of the gearing carcass according to the following illustration: Specifications Ø...
  • Page 116 Gearing Carcass Specifications Thrust ring E (mm) MWM nr. 3.46 - 3.48 9.610.0.433.004.4 3.51 - 3.53 9.610.0.433.005.4 3.57 - 3.59 9.610.0.433.006.4 Idle gear Ø furo Without bushing 50.000 - 50.015 With bushing 45.024 - 45.070 s de dentes Crankshaft front gear Ø...
  • Page 117 Gearing Carcass Specifications High pressure pump gear Ø hole mm 20.000 - 20.033 quantity of teeth Camshaft gear Ø hole mm 52.00 - 52.03 quantity of teeth Air compressor gear Ø hole mm 30.00 - 30.033 quantity of teeth 9.612.0.006.7160 - 05/04...
  • Page 118 Gearing Carcass Gears clearances specification DENOMINATION Crankshaft gear Idle gear High pressure fuel pump gear Camshaft gear Water pump gear Air compressor gear Oil pump gear Balancer unit driving gear (*) Balancer unit gears (*) * For 4.12 engines Z = 18 Z = 27 Z = 32 Z = 72...
  • Page 119 Gearing Carcass Bolts Tightening Torques Specification 20 ± 3 Nm 8.5 ± 1 Nm 5 + 5 Nm 60 ± 5 Nm 5 + 5 Nm Tightening sequence 20 ± 3 Nm 20 ± 3 Nm 9.612.0.006.7160 - 05/04...
  • Page 120 Gearing Carcass Bolts Tightening Torques Specification 40 ± 6 Nm 105 ± 5 Nm 45 ± 5 Nm 200 + 50 Nm ( * ) ( * ) Coincide hole for cotter pin 9.612.0.006.7160 - 05/04...
  • Page 121 Gearing Carcass Bolts Tightening Torques Specification 8.5 ± 1 Nm 60 ± 5 Nm 1st) 100 ± 10 Nm 2nd) 275 ± 15 Nm Lmax= 66.00 mm 60 ± 5 Nm 9.612.0.006.7160 - 05/04...
  • Page 122 Gearing Carcass Bolts Tightening Torques Specification 30 ± 5 Nm 30 ± 5 Nm 40 ± 6 Nm 30 ± 5 Nm 20 ± 3 Nm 9.612.0.006.7160 - 05/04...
  • Page 123 Gearing Carcass Assembly Install the idle bearing without the disk and the thrust ring for a perfect centralization of the intermediary piece. Montar a junta de papel. Install the intermediary piece tightening the fixation bolts crosswise according to the specification. 9.612.0.006.7160 - 05/04...
  • Page 124 Gearing Carcass Attention • The centralization of the intermediary piece is important to guarantee the specified clearances of the distribution gears. Install water pump, tightening according to the specification. Take care to do not damage the sealing ring. Install lubricant oil pump tightening according to the specification.
  • Page 125 Gearing Carcass Install lubrication pipes tightening according to the specification. Assembly camshaft gear and tighten the bolts according to the specification. Detail of the gears timing demarcations. 9.612.0.006.7160 - 05/04...
  • Page 126 Gearing Carcass Assembly the idle gear. Remove the bolts of the idle bearing and install the thrust ring of the idle gear. The two grooves must stay towards the side of the shaft. There are 3 different thickness of thrust ring in order to guarantee the axial clearance of the idle gear.
  • Page 127 Gearing Carcass Tighten all fixation bolts of the gears with the specified torques. Install high pressure pump. View of the assembled gears set. 9.612.0.006.7160 - 05/04...
  • Page 128 • A noisy operation indicates too much clearance between gears or teeth excessive waste. Assembly the front cover of the carcass with a new sealing gasket. Centre the front cover with the special tool MWM nr. 9.610.0.690.019.6. Place the bolts without tightening to allow the movement of the cover.
  • Page 129 Gearing Carcass Install the crankshaft seal with the special tool MWM nr. 9.610.0.690.019.6. Tighten the fixation bolts of the front cover. Assembly the temperature and oil pressure sensor. Apply the specified torque. 9.612.0.006.7160 - 05/04...
  • Page 130 Gearing Carcass Lock the engine with the special tool on the flywheel. Assembly the front pulley with the damper. Tighten the bolts crosswise with the specified torque. Check the housing of the camshaft phase sensor. Clean it if necessary. 9.612.0.006.7160 - 05/04...
  • Page 131 Gearing Carcass Assembly the adapter, then the sensor of phase and apply the specified torque. Before assembling the air compressor, put on a layer of Vaseline on the o-ring area in order to facilitate the assembly. Assembly the compressor and apply the specified torque.
  • Page 132 NOTES 9.612.0.006.7160 - 05/04...
  • Page 133 Flywheel and Flywheel Housing Flywheel and Flywheel Housing Disassembly Notes ......................... 10-2 Pre-Assembly Inspections ......................10-3 Bolts Tightening Torques Specification ..............10-4 Assembly ............................10-5 Inspections After Assembly ......................10-6 9.612.0.006.7160 - 05/04...

  • Page 134: Disassembly Notes

    Flywheel and Flywheel Housing Disassembly Notes Before removing flywheel, lock the engine crankshaft with the special tool MWM nr. 9.610.0.690.026.4. The engine could also be locked with a lever positioned on the nut of the water pump gear, until that it touches the pulley.

  • Page 135: Pre-Assembly Inspections

    Flywheel and Flywheel Housing Pre-Assembly Inspections Visually check flywheel housing for cracks or any damage. Visually check flywheel and gear ring. Failures in the starter motor gearing can be caused by broken gear ring or damaged teeth. Check if the sensor holes are clean and in good conditions.

  • Page 136: Bolts Tightening Torques Specification

    Flywheel and Flywheel Housing Bolts Tightening Torques Specification 8 ± 2 Nm 100 ± 15 Nm 250 + 20 Nm * * For the application 17.260E OT, apply chemical lock. 100 ± 15 Nm 100 ± 15 Nm Pre-torque 100 ± 10 Nm Lmax= 36,00 mm 100 ±...

  • Page 137: Assembly

    Flywheel and Flywheel Housing Assembly To install the gear ring on the flywheel, first heat it up to a temperature of about 250°C and assembly paying attention to the assembly position of the chamfer indicated by an arrow. Well clean the carcass and the engine block. Apply a layer of Loctite 515 on the contact surface between the engine block and the carcass, surrounding the holes of the bolts.

  • Page 138: Inspections After Assembly

    Maximum concentricity = 0.2 mm Install the rear seal with the special tool MWM nr. 9.610.0.690.020.6. With the engine locked assembly the flywheel. Tighten the crankshaft fixation bolts according to the specification.
  • Page 139 Flywheel and Flywheel Housing Check the side oscillation of the flywheel. Maximum side oscillation = 0.30 mm Check the parallelism of the flywheel in relation to the housing. Maximum parallelism = 0.20 mm Dynamic Balancing = Holes ø10 x 12 mm maximum, in a ray of 197 mm.
  • Page 140 NOTES 9.612.0.006.7160 - 05/04...
  • Page 141 Balancer Unit Balancer Unit Remark ............................11-2 Disassembly Notes ......................... 11-2 Assembly ............................11-3 Bolts Tightening Torques Specification ..................11-4 Measurements After Assembly ....................... 11-5 9.612.0.006.7160 - 05/04...

  • Page 142: Remark

    Balancer Unit Remark The balancer unit is an exclusive item of the 4 cylinders engines, especially in vehicular applications. It is not recommended its removal because that, despite does not affect the useful life of the engine, can cause excessive vibration on the systems connected to the engine (vehicle cabin, connections, etc). Disassembly Notes After removing the carter, carefully remove the oil suction pipe in order to do not let the sealing ring to...

  • Page 143: Assembly

    Balancer Unit Assembly Loosen the bolts of the bearing caps correspondent to the balancer unit and, with a rubber hammer, move them away to the maximum. Tighten only one of the bearings with the specified torque leaving the other bearing free for the balancer adjustment.

  • Page 144: Bolts Tightening Torques Specification

    Balancer Unit Observe the marks “00” and “0” on the balancer gear and on the crankshaft gear ring to guarantee the timing of the system. Bolts Tightening Torques Specification 60 ± 5 Nm 9.612.0.006.7160 - 05/04...

  • Page 145: Measurements After Assembly

    Balancer Unit Measurements After Assembly Perform a pre-adjustment with a shim of 0.20 mm. Lean the bearing to eliminate the clearance and slightly move the bearing that is free. Remove balancer unit to apply the specified torque in the bearing which the adjustment was done. There are three thicknesses of thrust ring: 9.226.0.433.001.4 3.45 to 3.50 mm (3.5) 6.208.0.433.003.4 3.55 to 3.60 mm (3.6)
  • Page 146 Balancer Unit After installed, measure the axial clearance in the balancer unit shafts, observing that the clearance must be between 0.10 and 0.30 mm. Measure the backlash between the balancer gear and crankshaft gear ring. Determine the necessary amount of shims between the balancer and the bearing caps so that that clearance is between 0.05 and 0.18 mm.
  • Page 147 Balancer Unit Reinstall balancer deflector, oil suction pipe and carter, tightening the bolts according to the specification. 9.612.0.006.7160 - 05/04...
  • Page 148 NOTES 9.612.0.006.7160 - 05/04...
  • Page 149 Lubrication System Lubrication System Lubrication System ......................... 12-2 Lubrication Circuit ...................... 12-2 Disassembly Notes ......................... 12-3 Inspections and Measurements ..................... 12-3 Tightening Torques Specification for Components of the Lubrication System ..12-5 Tightening Torques Specification for Oil Cooler Connections ........ 12-5 Tightening Torques Specification for Lubrication Connections of the Compressor ........................

  • Page 150: Lubrication System

    Lubrication System Lubrication System Lubrication Circuit 9.612.0.006.7160 - 05/04...

  • Page 151: Disassembly Notes

    Lubrication System Disassembly Notes Remove lubricant oil cooler removing only the hexagonal bolts. During the removal of the oil cooler, do not remove the "Torx" bolts, avoiding the mixture of lubricant oil in the cooling system. The bolts "Torx" types require a special driver for their removal and, if necessary, only can be removed when the oil cooler is removed from the engine block.
  • Page 152 Lubrication System Visually check the drive gear of the oil pump, the inner part of the carcass and the rotor, for damages or excessive waste. Check the clearance between oil pump rotors. Clearance between rotors: 0.05 - 0.10 mm Check the radial clearance between the outer rotor and the pump carcass.

  • Page 153: Tightening Torques Specification For Components Of The Lubrication System

    Lubrication System Tightening Torques Specification for Components of the Lubrication System 25 ± 4 Nm 25 ± 4 Nm 65 ± 10 Nm 25 + 5 Nm 20 ± 3 Nm Tighten sequence 15 13 7 5 1 3 11 17 16 14 8 6 2 4 12 18 Tightening Torques Specification for Oil Cooler Connections...

  • Page 154: Tightening Torques Specification For Lubrication Connections Of The Compressor

    Lubrication System Tightening Torques Specification for Lubrication Connections of the Compressor 20 ± 6 Nm 20 ± 6 Nm 20 ± 6 Nm 20 ± 6 Nm 10 ± 2 Nm 9.612.0.006.7160 - 05/04...

  • Page 155: Assembly

    Lubrication System Assembly Carefully install the oil suction pipe in order to do not let the sealing ring to fall inside the suction gallery. Install a new carter gasket. The gasket must be assembled without glues or adhesives. Assembly the carter tightening the bolts from the edges, crosswise and apply the specified torque.
  • Page 156 Lubrication System Clean the sealing surfaces and carefully assembly, reinstalling the oil cooler. Tighten the sextavado bolts crosswise applying the specified torque. 9.612.0.006.7160 - 05/04...
  • Page 157 Cooling System Cooling System Cooling Circuit ..........................13-2 Disassembly Notes ......................... 13-3 Inspections ............................13-3 Thermostat Test Procedure ......................13-4 Bolts Tightening Torques Specification ..............13-5 Assembly ............................13-6 9.612.0.006.7160 - 05/04...

  • Page 158: Cooling Circuit

    Cooling System Cooling Circuit 9.612.0.006.7160 - 05/04...

  • Page 159: Disassembly Notes

    Cooling System Disassembly Notes Attention • Never perform a service in any component of the cooling system while the engine is running. • Avoid touching the components of the cooling system soon after the operation of the engine, this can cause burns. •...

  • Page 160: Thermostat Test Procedure

    Cooling System Check the inspection hole located on the left side of the engine block (seen by the flywheel side). If there are signs of water or oil leakage, probably there is leakage through the water pump or through the sealing rings.

  • Page 161: Bolts Tightening Torques Specification

    Cooling System Bolts Tightening Torques Specification 25 ± 4 Nm 8,5 ± 1 Nm 20 + 6 Nm 20 ± 3 Nm 20 ± 3 Nm 40 ± 6 Nm 20 ± 3 Nm 8.5 ± 1 Nm 20 ± 3 Nm 20 + 5 Nm 9.612.0.006.7160 - 05/04...

  • Page 162: Assembly

    Cooling System Assembly Assembly the thermostat in the carcass with a new sealing ring. Cautions • Never operate the engine without the thermostat, because the engine will not reach the correct operation temperature. • The sealing rings of the component disassembled must be always changed. Assembly the water pipe and by-pass pipe with new sealing rings.
  • Page 163 Cooling System Assembly the thermostat set and tighten the bolts according to the specification. Assembly the sensor of temperature. Apply the specified torque. Assembly all hoses and components of the system such as radiator and coolers. 9.612.0.006.7160 - 05/04...
  • Page 164 Cooling System Attention • For the best performance of the cooling system, it is necessary that all the water passages inside the engine are properly filled up. The aeration of the cooling system can cause high temperature spots on the cylinder heads and engine block surfaces, causing cracks in those components and burns on cylinder head gaskets.
  • Page 165 Fuel Injection System Fuel Injection System Cautions ............................14-2 Common Rail Modulated Pressure Fuel Injection System ............14-3 Common Rail Harness “4.12” ......................14-4 CP 3.3 Pump – Rear Part View ....................... 14-5 High Pressure Pump Removal ....................... 14-7 Bolts Tightening Torques Specification ..............14-8 Electronic Control Module (ECM) Disassembly/Assembly ............

  • Page 166: Cautions

    Fuel Injection System Cautions • Never perform service on any component of the system while the engine is running. • Do not smoke while is servicing on the fuel system or any other system of the engine. • Avoid contact with electric components that may produce sparks. •...

  • Page 167: Common Rail Modulated Pressure Fuel Injection System

    Fuel Injection System Common Rail Modulated Pressure Fuel Injection System 9.612.0.006.7160 - 05/04...

  • Page 168: Common Rail Harness "4.12

    Fuel Injection System Common Rail Harness “4.12” 9.612.0.006.7160 - 05/04...

  • Page 169: Cp 3.3 Pump - Rear Part View

    Fuel Injection System CP 3.3 Pump – Rear Part View Filter fuel inlet Rail pressure control valve (m-prop) Fuel return to the tank Fuel outlet to filter ECM cooler fuel inlet Fuel outlet to the Rail Fuel lift pump BCP 3.3 – Identification Plate The identification plate of the high-pressure fuel pump is important to help in the tracking of the component and to indicate its origin.
  • Page 170 Fuel Injection System Remoção da Tubulação de Alta Pressão e Bicos Injetores Remover o chicote elétrico dos bicos injetores. Antes da soltura da tubulação de alta pressão, recomenda-se fixar a conexão de alta pressão do injetor com uma chave de boca e só então aplicar o torque de desaperto.
  • Page 171 Fuel Injection System Remove the locks of the fuel injectors. After removing the locks, remove fuel injectors using the tool MWM nr. 9.612.0.690.001.4 and put them away. The solenoid must be protected against impacts. Atenção • A retirada da conexão de alta pressão do injetor durante montagem ou desmontagem NÃO é...

  • Page 172: High Pressure Pump Removal

    Fuel Injection System Fuel High-Pressure Pump Removal After loosening and removing the pipes, loosen high pressure pump fixation bolts on the intermediary piece. Loosen and remove the fixation nut of the high pressure pump gear by the side of the gearing cover. Remove the gear.
  • Page 173 Fuel Injection System Tightening Torques Specification - 6.12 Fuel Piping 30 + 3 Nm 30 + 3 Nm 30 + 3 Nm 10 ± 1.5 Nm 25 ± 2 Nm 25 ± 2 Nm 25 ± 2 Nm 30 + 3 Nm 25 ±...

  • Page 174: Bolts Tightening Torques Specification

    Fuel Injection System Bolts Tightening Torques Specification 1.5 ± 0.25 Nm 1 - Fuel return 1st) 14 ± 1 Nm 2 - Fuel filter/CP 3.3 Pump 2nd) 55° ± 2° Nm 3 - Cooler/CP 3.3 Pump 4 - CP 3.3 Pump/Fuel Filter 25 - 3 Nm 5 - CP 3.3 Pump/Rail 25 ±...
  • Page 175 Fuel Injection System Tightening Torques Specification - ECM Tightening Sequence 9.612.0.006.7160 - 05/04...
  • Page 176 Fuel Injection System Tightening Torques Specification - 4.12 Fuel Piping 30 + 3 Nm 30 + 3 Nm 30 + 3 Nm 25 ± 2 Nm 25 ± 2 Nm 10 ± 1.5 Nm 30 + 3 Nm 25 ± 2 Nm 30 + 3 Nm 40 ±...
  • Page 177 Fuel Injection System Tightening Torques Specification - Harness Brackets 10 ± 1.5 Nm 10 ± 1.5 Nm 10 ± 1.5 Nm 10 ± 1.5 Nm 10 ± 1.5 Nm 10 ± 1.5 Nm 10 ± 1.5 Nm 10 ± 1.5 Nm 10 ±...
  • Page 178 Fuel Injection System The removal must be done with caution. The friction between the o-ring and the housing of the pump can difficult its removal. As it is a component that requires extreme care, keep it in a reserved place and far from accidents.

  • Page 179: Electronic Control Module (Ecm) Disassembly/Assembly

    Fuel Injection System Electronic Control Module Disassembly/ Assembly (ECM) If it is necessary to change the ECM, first loosen the bolts that fix the module to the cooler. At the module removal, remove the sealing o-ring. Clean the residues from the cooler. Attention •...

  • Page 180: Inspection

    Fuel Injection System Inspection Perform a visual analysis on the cooler to check for any irregularity. Change it if necessary. Check cooler drain plug for leakages. Change it if necessary. Tighten with 10 ± 1.5 Nm. Visually check the condition of the nipples. If necessary, change them.
  • Page 181 Fuel Injection System Visually check the ECM pins set. Check for dirt and clean if necessary. 9.612.0.006.7160 - 05/04...

  • Page 182: Assembly

    Fuel Injection System Assembly Assembly the cooler bracket. Apply the specified torque. After assembling the bracket, assembly cushions on the bracket and apply the specified torque. Assembly the cooler with ECM. Install o anle o’ring novo. 9.612.0.006.7160 - 05/04...
  • Page 183 Fuel Injection System Assembly the ECM. Attention to the centralization of the fixation bolts in the cooler. After positioning the ECM, tighten the bolts and apply the specified torque. Assembly the bracket of the nipples for fast-connector. Apply the specified torque. Tighten the nuts.

  • Page 184: High Pressure Pump Assembly

    Fuel Injection System High Pressure Pump Assembly Clean the housing of the high pressure pump. Assembly a new o-ring on the high pressure pump. Clean the area and put on a Vaseline layer on the contact area of the o-ring with the housing on the intermediary piece.
  • Page 185 Fuel Injection System After assembling the pump, position the gear on the shaft and assembly. Once there is not timing on this gear the pump shaft does not have cotter for positioning. Position gear washer and fixation nut and apply the specified torque.

  • Page 186: Fuel Injection System Assembly

    Fuel Injection System Fuel Injection System Assembly First, position new o-ring on the injector and put on a Vaseline layer on the ring area. Install sealing washers. Install injector in cylinder head. Assembly the fixation locks of the fuel injectors. Tighten bolts according the specification.
  • Page 187 Fuel Injection System After positioning the injectors, assembly the return pipe. The assembly must be performed carefully in the connector tightening sense, to avoid loosening. If the connector loosen, apply the torque of 3 ± 0.5 Begin to assembly the Rail. First, assembly the bracket of the rail and apply the specified torque.
  • Page 188 Fuel Injection System The central fixation screw of the rail needs an extension for the tightening. Apply the torque according to the previous procedure. If the fuel filter is assembled, use also an articulated tool to tighten and remove the screw. Assembly the fuel filter head.
  • Page 189 Fuel Injection System Assembly the high pressure pipe on the Rail. Apply the specified torque. The high-pressure piping must be assembled free of tension, avoiding damages and deformations in the piping and nut-caps. After the installation of the high pressure pipes, assembly low pressure piping.
  • Page 190 Fuel Injection System Assembly return pipe of the high pressure pump to the fuel tank. Apply the specified tightening torque on the nut-cap, assembly the nipple of fast connection on the bracket. Assembly the cooler fuel outlet pipe to the high pressure pump.
  • Page 191 Fuel Injection System Assembly the fuel outlet pipe. Keep the same procedure used in the fuel inlet pipe assembly. Assembly fuel inlet and outlet pipes of the filter head. First, visually check the condition of the nipples. If necessary, change them. Apply the specified torque. Assembly the fuel inlet pipe.
  • Page 192 Fuel Injection System Assembly the fast connector of the return pipe on the pressure limiter valve. Fit the return pipe on the injector. Apply the specified tightening torques on the nut-caps of the fuel lift pump and of the high pressure pump. 9.612.0.006.7160 - 05/04...
  • Page 193 Fuel Injection System Assembly the high pressure pipe of the pump to the Rail. Apply the specified torque. General view of the fuel injection system assembled. General view of the high-pressure piping assembled. 9.612.0.006.7160 - 05/04...

  • Page 194: Desaeração Do Sistema De Baixa Pressão

    Fuel Injection System Montar o chicote elétrico na ECM. Atentar a trava do conector para a posição de montagem. Desaeração do Sistema de Baixa Pressão Após término da manutenção do sistema de injeção ou constatado pane-seca, escorvar o sistema com auxílio de uma bomba manual (bombear até...
  • Page 195 Intake, Exhaust and Turbocharger System Intake, Exhaust and Turbocharger System Disassembly Notes ......................... 15-2 Inspections ............................15-2 Intake Manifold and Elbow Tightening Torques Specification ......... 15-3 Exhaust Manifold Tightening Torques Specification ..........15-4 Turbocharger Tightening Torques Specification ............15-4 Assembly ............................15-5 9.612.0.006.7160 - 05/04...

  • Page 196: Disassembly Notes

    During the disassembly of the exhaust tripartite manifold, the crusts of coal must be removed from the rings and sealing seats between manifolds. To loosen the manifolds bolts use the tool MWM nr. 9.612.0.690.002.4. Inspections Check the general condition of the turbo blades. The contamination of the intake air can cause premature waste of the rotor.

  • Page 197: Intake Manifold And Elbow Tightening Torques Specification

    Intake, Exhaust and Turbocharger System Intake Manifold and Elbow Tightening Torques Specification 3 ± 0.5 Nm 25 ± 4 Nm 25 ± 4 Nm 25 ± 4 Nm 56 ± 8 Nm 3 ± 0.5 Nm 25 ± 4 Nm 56 ±...

  • Page 198: Exhaust Manifold Tightening Torques Specification

    Intake, Exhaust and Turbocharger System Exhaust Manifold Tightening Torques Specification 56 ± 8 Nm * * Retighten after the 1st operation of the engine Turbocharger Tightening Torques Specification 20 ± 6 Nm 20 + 6 Nm 10 ± 2 Nm 70 ±...

  • Page 199: Assembly

    Intake, Exhaust and Turbocharger System Assembly During the assembly of the exhaust tripartite manifold, use sealant on the sealing rings. Do not use an excessive amount in order to do not remain residues that could cause damages to the turbocharger. After applying the product, join the manifold parts and assembly on the cylinder heads, so that the drying occurs with the manifold already assembled.
  • Page 200 Intake, Exhaust and Turbocharger System Assembly exhaust elbow. Tighten nuts according to the specification. Retighten the nuts after the 1st operation of the engine. Assembly turbocharger lubrication piping. 9.612.0.006.7160 - 05/04...
  • Page 201 Intake, Exhaust and Turbocharger System Tighten the bolts according to the specification. Assembly return pipe spacer. Apply the specified torque. Assembly intake elbow on intake manifold. Apply the specified torque. 9.612.0.006.7160 - 05/04...
  • Page 202 Intake, Exhaust and Turbocharger System Assembly air temperature sensor. Apply the specified torque. 9.612.0.006.7160 - 05/04...
  • Page 203 Failure Diagnosis Failures Diagnosis Introduction ............................. 16-2 Symptom Table ..........................16-3 Symptoms ........................16-3 Probable Causes Table ........................16-5 Probable Causes ......................16-5 9.612.0.006.7160 - 05/04...
  • Page 204 Failure Diagnosis Introduction Next they are presented some typical problems which the engine may present, their probable causes and possible corrections for these problems. Attention • Study in full detail the problem before trying any action. • First check the simplest and obvious. •...
  • Page 205 Failure Diagnosis Symptoms Table SYMPTOM PROBABLE CAUSES Low crank speed 01-02-03 Engine does not start 05-06-07-08-09-10-14-15-16-17-22- 23-25-26-27-29-40-53 Difficult start (engine delays to start up) 01-02-03-05-07-08-09-10-14-15-16- 17-18-22-25-26-27-29-40-53 Power lack / Performance 07-08-09-10-14-15-16-17-18-19-20- 21-22-23-25-26-27-29-44-53-54-56- Engine misfiring 07-08-09-10-14-15-16-17-19-20-21- 22-23-24-26-29-44-53 Excessive fuel consumption 09-14-15-17-18-21-22-23-25-26-27- 29-57-60 Black smoke 09-14-15-17-18-21-22-23-25-26-27-...
  • Page 206 Failure Diagnosis Symptoms Table (Continuation) SYMPTOM PROBABLE CAUSES Engine and go off 29-49-55 High lubricant oil consumption 04-12-13-15-25-27-28-39-49-54-55- 58-59-60-66 Water mixed to lubricating oil 10-19-50 Water mixed to lubricating oil Irregular idle speed 07-08-09-10-16-17-29-59 Engine stops during vehicle stop 06-07-08-10-17-29 Engine misfiring 10-17-29 9.612.0.006.7160 - 05/04...
  • Page 207 Failure Diagnosis Symptoms Table (Continuation) Probable Cause What to do Low battery charge Charge or change battery Bad contact on the electrical connections Clean and retighten the connections Defective starter motor Correct the starter motor Inadequate lubricant oil viscosity Use oil of correct viscosity Low start tension Check connections, battery and starter motor...
  • Page 208 Failure Diagnosis Symptoms Table (Continuation) Probable Cause What to do Overheating Check cooling system, and operation and installation conditions Engine excessively cold Check thermostat Incorrect valves clearance Adjust valves clearance Griped valves Correct the operation of the valves Incorrect high pressure pipes Change Cylinders wear Correct...
  • Page 209 Failure Diagnosis Symptoms Table (Continuation) Probable Cause What to do Incorrect piston height in relation to the Use correct pistons engine block surface Damaged fan Change Defective engine bracket cushions Change / Correct assembly Flywheel or flywheel housing misaligned Align Defective thermostat Change Water galleries restriction / liners with crusts...
  • Page 210 Failure Diagnosis Symptoms Table (Continuation) Probable Cause What to do Engine operates overloaded Operate the engine inside the load limit Balancer unit out of position Correct (4 cylinders engines) Defective damper Change Liner protrusion below specification Correct (leakage through liner collar) Thermostat bad seating Change Lack or incorrect coolant proportion in...
  • Page 211 Special Tools GUIDE-PIN FOR EXHAUST AND INTAKE MANIFOLD 9.407.0.690.027.4 GUIDE-PIN FOR CYLINDER HEAD AND BEARINGS 9.407.0.690.030.4 DEVICE TO MEASURE PISTON POSITION AND HEIGHT TO LINER 9.610.0.690.025.4 DEVICE TO REMOVE INJECTORS 9.612.0.690.001.4 9.612.0.006.7160 - 05/04...
  • Page 212 Special Tools DEVICE TO DISASSEMBLY AND ASSEMBLY VALVE SPRINGS 9.407.0.690.044.6 CONNECTOR FOR CYLINDER COMPRESSION TEST 9.612.0.690.003.4 ADAPTORS FOR ENGINE STAND 9.610.0.690.011.6 DEVICE TO ASSEMBLY VALVE GUIDES 9.610.0.690.014.6 9.612.0.006.7160 - 05/04...
  • Page 213 Special Tools DEVICE TO ASSEMBLY FRONT SEAL 9.610.0.690.015.4 DEVICE TO DISASSEMBLY CYLINDER LINER 9.610.0.690.017.6 DEVICE TO ASSEMBLY VALVE SEAL 9.610.0.690.019.6 DEVICE TO ASSEMBLY REAR SEAL 9.610.0.690.020.6 9.612.0.006.7160 - 05/04...
  • Page 214 Special Tools HEXAGONAL ARTICULATED DEVICE FOR EXHAUST MANIFOLD 9.612.0.690.002.4 DEVICE TO LOCK ENGINE FLYWHEEL 9.610.0.690.026.4 DEVICE TO ASSEMBLY CYLINDER LINERS 9.610.0.690.024.6 DISPOSITIVO PARA APERTAR TAMPA DE INSPEÇÃO 9.610.0.690.032.4 9.612.0.006.7160 - 05/04...

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