Lombardini LDW502 Service Manual
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Lombardini LDW502 Service Manual

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code 1.5302.727
SERVICE MANUAL

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April 6, 2025

tappet gap for fuel injectors on ldw 502

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Summary of Contents for Lombardini LDW502

  • Page 1 code 1.5302.727 SERVICE MANUAL...
  • Page 2 1° Copyright 2005 - Lombardini. Reproduction, even partial, of this document is subject to the manufacturer’s written authorisation. The manufacturer is committed to a policy of continuing improvement and reserves the right to modify the document, with no obligation to notify, providing that omission to do so constitutes no safety risk. The text may be reproduced in part or in whole, providing that the author is cited. Text and graphics by: IDM Esperti in Comunicazione Tecnica - Forlì...

  • Page 3: Table Of Contents

    GENERAL INDEX GENERAL REMARKS AND SAFETY REMOVING THE COOLING FAN BELT DRIVE ..30 5.3.1 Disassembling the cooling fan belt (with external alternator) .......... 31 PURPOSE OF THE MANUAL ........5 5.3.2 Disassembling the cooling fan belt USING THIS MANUAL ..........5 (with internal alternator) ...........
  • Page 4 GENERAL INDEX ADJUSTING MINIMUM AND MAXIMUM REPLACING PARTS IDLE SPEED RPMS ..........60 ADJUSTING INJECTION DELIVERY ....... 60 RECOMMENDATIONS FOR REPLACING PARTS .. 83 6.9.1 Adjusting injection delivery (without dyno brake) ... 60 REPLACING THE ALTERNATOR – FAN BELT ..83 6.9.2 Adjusting injection delivery (with dyno brake) ..

  • Page 5: General Remarks And Safety

    (technical specifications, diagrams, - However, the actual sequence of operations that LOMBARDINI service centres must use may in some tightening torques, malfunctions, etc.). - The fifth, sixth, seventh and eighth chapters describe the cases be different from the ones described in this manual.

  • Page 6: Glossary And Terminology

    - Rotation direction: clockwise or anticlockwise “viewed from the timing belt side of the engine”.. WARRANTY CLAUSES LOMBARDINI issues a warranty certificate for each engine giving details of all relevant general terms. GENERAL SAFETY REGULATIONS In designing and building its product, the manufacturer...

  • Page 7: Safety And Environmental Impact

    GENERAL REMARKS AND SAFETY GENERAL REMARKS AND SAFETY - Discontinue use of the engine if any irregularities Use the oils and greases recommended by the manufacturer. Do not mix different brands or oils with arise, particularly in the case of unusual vibrations. different characteristics.
  • Page 8 GENERAL REMARKS AND SAFETY Notes : ..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

  • Page 9: Technical Information

    TECHNICAL INFORMATION GENERAL DESCRIPTION OF THE ENGINE Main components Cylinder head L) Alternator Engine block M) Oil filter Crankcase N) Exhaust manifold Timing belt assembly P) Starter motor Flywheel and crankshaft assembly Q) Camshaft Air intake assembly R) Coolant pump Cooling fan S) Fuel supply pump Negative-pressure vent valve...

  • Page 10: Technical Specifications

    TECHNICAL INFORMATION TECHNICAL SPECIFICATIONS DIMENSIONS (mm) (1) with suction fan (2) with blower fan GENERAL DETAILS 4-stroke diesel Operating cycle Number of cylinders n° Bore x stroke 72x62 Displacements Compression rate 22,8:1 Intake Air filter (dry) Filter capacity µ m 13÷14 Filtering surface 4470...
  • Page 11 TECHNICAL INFORMATION CONSUMPTION AT MAXIMUM POWER g/kWh Specific fuel onsumption Kg/h 0,007 Specific oil consumption SUPPLY CIRCUIT Supply type Indirect injection Fuel type Car diesel Fuel supply Electric or membrane pump Fuel filter Screw-on or in-line “fispino” Filter paper PF905 Filtering surface 2400 Filter capacity...

  • Page 12: Characteristic Curve Diagrams

    TECHNICAL INFORMATION CHARACTERISTIC CURVE DIAGRAMS Power curve diagram 80/1269/CEE - 95/1/CE (3000 tr/min) Legend NB = Power curve MB = Torque curve C= Specific consumption curve Power curve diagram 80/1269/CEE - 95/1/CE (3600 tr/min) service manual - 12 - mod. 051135...

  • Page 13: Alternator Load Curve Diagrams

    TECHNICAL INFORMATION ALTERNATOR LOAD CURVE DIAGRAMS Internal load curve diagram Reading taken after heat stabilisation at 25°C and constant voltage 13,5V. * To determine engine r.p.m.s, check the gear ratio adapted to pulleys. External load curve diagram Reading taken after heat stabilisation at 20°C and constant voltage 12,5V.

  • Page 14: Lubricants

    TECHNICAL INFORMATION LUBRIFICANTS 2.5.1 SAE Classification In the SAE classification, oils differ on the basis of their viscosity, and no other qualitative SAE 10W* characteristic is taken into account. The first number refers to the viscosity when SAE 20W* the engine is cold (symbol W = winter), while SAE 30* the second considers viscosity with the engine SAE 40*...

  • Page 15: Operating Principle For Lubrication

    TECHNICAL INFORMATION OPERATING PRINCIPLE FOR LUBRIFICATION Ref. Description Pressure switch Rocker-arm pin Connecting rod big end pin Oil filter cartridge Main jurnal Oil drain plug Oil dipstick Air vent Oil refilling pump Camshaft Oil pressure regulating valve Oil pump Crankshaft Oil suction filter OPERATING PRINCIPLE FOR COOLING Ref.

  • Page 16: Operating Principle For Fuel Injection

    TECHNICAL INFORMATION OPERATING PRINCIPLE FOR FUEL INJECTION With mechanical supply pump Ref. Description Tank Fuel filter Supply pipe Supply pump Injection pump Injector Fuel rail Exhaust pipe Plug Solenoid valve Note: the tank is supplied complete with filter on request. With electrical supply pump Ref.

  • Page 17: Wiring Diagram

    TECHNICAL INFORMATION WIRING DIAGRAM With external alternator Electric pump version Ref. Description Ref. Description 40A alternator Coolant thermostat indicator light Starter motor Engine oil preassure lamp Battery (recommended 44Ah-210A-DIN) Oil preassure gauge Preheating glow plugs Battery load indicator Coolant temperature monitoring sensor Coolant thermometer Glow plug pre-heating control box Coolant thermomenter sensor...
  • Page 18 TECHNICAL INFORMATION With internal alternator Electric pump version Ref. Ref. Description Description 40A alternator Coolant thermostat indicator light Starter motor Engine oil preassure lamp Battery (recommended 44Ah-210A-DIN) Oil preassure gauge Preheating glow plugs Battery load indicator Coolant temperature monitoring sensor Voltage regulator Glow plug pre-heating control box Coolant thermometer...

  • Page 19: Special Tools And Equipment For Maintenance

    TECHNICAL INFORMATION 2.10 SPECIAL TOOLS AND EQUIPMENT FOR MAINTANANCE Serial number Description Serial number Description Instrument for balancing injection Tool for lowering injection advance control pump delivery valve Equipment for injection advance control and Precombustion chamber extractor injector calibration Pin wrench for ring nut on pump/ Driving shaft clamping tool injector pumping element Pivot pin precombustion chamber...
  • Page 20 TECHNICAL INFORMATION Tightening torques for standard screws (fine threads) 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 M 8x1 M 10x1 M 10x1,25 M 12x1,25 M 12x1,5 M 14x1,5 M 16x1,5 M 18x1,5 M 18x2 M 20x1,5 M 20x2...

  • Page 21: Table Of Sealants

    TECHNICAL INFORMATION 2.12 TABLE OF SEALANTS Area of application Sealant Fuel rail attachment Loctite 638 Oil filter cartridge union (M 20X1,5) Loctite 601 Camshaft bearing screw (M 6) Loctite 270 Stud bolt for tightening pulley (M 10) Loctite 601 Cylinder head plug (ø 18) Loctite 510 Engine and engine block cylinder head plug (ø...
  • Page 22 TECHNICAL INFORMATION Notes : .............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

  • Page 23: Malfunctions

    MALFUNCTIONS LOOKING FOR MALFUNCTIONS The following information is provided to help identify and correct any irregularities and malfunctions that may arise during use. Problem Probable cause Clogged pipes Clogged fuel filter Air in the fuel circuit Clogged tank breather Faulty fuel pump Blocked injector Blocked injection pump valve Injector not adjusted...
  • Page 24 MALFUNCTIONS ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... .

  • Page 25: Storing The Engine

    STORING THE ENGINE 4.1 HANDLING AND LIFTING - Secure the engine using a lifting device (lifting beam) of suitable capacity. - Hook the lifting device to the points indicated in the drawing. - Before lifting, check the load’s centre of gravity. Important The dimensions of the brackets on the fastening points have been specially...

  • Page 26: Protective Treatment

    STORING THE ENGINE 4.4 PROTECTIVE TREATMENT 14 - Close all openings to prevent foreign bodies from Check that the engine oil and coolant are up to level. 2 - Start the engine and keep idle at minimum speed for entering. 15 minutes.

  • Page 27: Preparing The Engine For Operation (Installed)

    STORING THE ENGINE 4.6 PREPARING THE ENGINE FOR OPERATION (INSTALLED) After a period of inactivity and before installing and running Important the engine, it is necessary to carry out a few measures in order to ensure that it runs at maximum efficiency. Over time, a number of engine components and lubricants lose their properties, even when the engine 1 - Use a cloth soaked in degreasing product to remove...
  • Page 28 STORING THE ENGINE .............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

  • Page 29: Removing The Assemblies

    REMOVING THE ASSEMBLIES 5.1 RACCOMENDATIONS FOR REMOVING THE ASSEMBLIES - Information is given in a logical order in terms of timing Important and sequence of operations. The methods have been Importante To locate specific topics, the reader should refer to selected, tested and approved by the manufacturer’s the index.

  • Page 30: Disassembling The Exhaust Manifold

    REMOVING THE ASSEMBLIES 5.2.2 Disassembling the exhaust manifold 1 - Remove the dipstick tube (H). 2 - Remove the exhaust manifold (L). Remove the gaskets (M). 4 - Close the openings and ducts to prevent foreign bodies from entering. 5.3 REMOVING THE COOLING FAN BELT DRIVE 1 - Remove the cooling fan (A).

  • Page 31: Disassembling The Cooling Fan Belt (With External Alternator)

    REMOVING THE ASSEMBLIES 5.3.1 Disassembling the cooling fan belt (with external alternator) 1 - Loosen the nuts (B - B1). 2 - Loosen the belt (D) by adjusting the alternator (C) manually. 3 - Remove the belt (D). 4 - Remove the hub (E) and flange. pulley flange 5 - Remove the pulley (F), washers and spacer.

  • Page 32: Disassembling The Timing Belt

    REMOVING THE ASSEMBLIES 4 - Loosen the screws and remove the pulley (H). 5 - Remove the casing (L). 5.4.2 Disassembling the timing belt 1 - Twist the pulley nut (M) to fully loosen the belt (N). 2 - Remove the belt (N), working it away in sequence first from the pulley and (P) and then from the others.

  • Page 33: Removing The Cylinder Head

    REMOVING THE ASSEMBLIES 5.5 REMOVING THE CYLINDER HEAD 5.5.1 Disassebling the rocker arm cover 1 - Remove the negative-pressure vent valve (A). 2 - Remove the rocker arm cover (B). 3 - Remove the gasket (C). 5.5.2 Disassebling the rocker arms 1 - Press the rocker arm to fully push the drive rod down (E).

  • Page 34: Disassembling The Injection-Pumps

    REMOVING THE ASSEMBLIES 5.5.4 Disassembling the injection-pumps 1 - Remove the fuel rail (F). Important Make sura that the injector gaskets remain in position. 2 - Unhook the spring (L). Important If injector pumps are to be used during installation, do not loosen the screws (LI) in order to not balance injector pump deliveries during tuning.

  • Page 35: Disassembling The Speed Governor And Flow Limiter

    REMOVING THE ASSEMBLIES 4 - Screw the extractor “7107-1460-030” onto the precombustion chamber (S) and remove extractor 7107-1460-027 5.5.6 Disassembling the speed governor and flow limiter Remover the cover (T). Extract the weights assembly (U) from the camshaft. 3 - Remove the fuel flow limiter (V). 4 - Unscrew the pin and extract the governor tinkage adjustment pin (W).

  • Page 36: Disassembling The Camshaft

    REMOVING THE ASSEMBLIES 5.5.7 Disassembling the camshaft 1 - Remove the cover (X). 2 - Extract the camshaft (Y) from the cylinder head. Important Make sure the drive rod has been removed and rotate the camshaft gently to remove it easily. 5.5.8 Disassembling the cylinder head 1 - Remove the cylinder head (A).

  • Page 37: Disassembling The Oil Pump

    REMOVING THE ASSEMBLIES 4 - Remove the support (C). 5.6.2 Disassembling the oil pump 1 - Remove the flange (D). 2 - Extract the key (E) from the crankshaft. 3 - Bring piston number one (flywheel side) to the top dead centre, with the oil pump activation key in line with break in the flange, in order to be able to remove it.

  • Page 38: Disassembling The Crankcase And Crankshaft

    REMOVING THE ASSEMBLIES 5.6.3 Disassembling the crankcase and crankshaft 1 - Remove the flange (H). 2 - Tske off the gasket (L). 3 - Remove the crankcase (M). 4 - Remove the connecting rod cap (N). Caution - Warning Before removing the cap, mark the area of contact with the connecting rod, in order to recognise the right position during reassembly.

  • Page 39: Disassembling The Connecting Rod And Piston

    REMOVING THE ASSEMBLIES 5.6.4 Disassembling connecting rod and piston 1 - Extract the connecting rod/piston assembly (Q). 2 - Remove the crankshaft half bearings. Caution - Warning Before removing the crankshaft half bearings, mark the seat position, in order to recognise and match it up during reassembly.

  • Page 40: Disassembling The Piston

    REMOVING THE ASSEMBLIES 5.8 DISASSEMBLING THE PISTON 1 - Remove the stop ring (B). 2 - Extract the wrist pin (C) to separate the piston (D) from the connecting rod (E). Important Keep each connecting rod together with its piston and wrist pin. 3 - Remove the stop rings (F).

  • Page 41: Overhauls And Tuning

    OVERHAULS AND TUNING 6.1 RECOMMENDATIONS FOR OVERHAULS AND TUNING – Wash the components with special detergent and do – Information is given in a logical order in terms of timing not use steam or hot water. and sequence of operations. The methods have been selected, tested and approved by the manufacturer’s technical experts.

  • Page 42: Dimensional Check And Overhaul Of Cylinders

    OVERHAULS AND TUNING 6.2.2 Dimensional check and overhaul of cylinders 1 - Place the engine block on the workbench. 2 - Using a micrometer, measure the diameter at points 1-2-3 (see diagram). 3 - Rotate the micrometer 90° and remeasure. If ovalization or wear is greater than 0.05mm, the cylinder must be ground .

  • Page 43: Dimensional Check Of Sealing Rings

    OVERHAULS AND TUNING 6.2.4 Dimensional check of sealing rings 1 - Place a sealing ring in the cylinder and measure the distance between the two tips using a thickness gauge (H). 2 - Repeat for all the sealing rings. If the distance between the tips does not correspond to the indicated values, replace the sealing ring with an original spare (see “Dimensional table of sealing rings”).

  • Page 44: Dimensional Check And Overhaul Of Crankshaft

    OVERHAULS AND TUNING 6.2.5 Dimensional check and overhaul of crankshaft 1 - Wash the crankshaft thoroughly using suitable detergent. 2 - Introduce a pipe cleaner into the lubrication ducts to remove any residual dirt. 3 - Blow compressed air into the points indicated to free the ducts from oil.

  • Page 45: Dimensional Check And Overhaul Of Connecting Rods

    OVERHAULS AND TUNING 6.2.6 Dimensional check and overhaul of connecting rods 1 - Check that the contact surfaces are perfectly clean and intact. 2 - Assemble the cap (N) onto the connecting rod big end and tighten the screws to a connecting torque of 38 Nm.

  • Page 46: Checking And Overhauling The Fuel Pump

    OVERHAULS AND TUNING 6.2.8 Check and overhaul of the fuel pump Disassemble the oil pump before checking or overhauling. See “Disassembling the oil pump” for the correct procedure. 1 - Remove the plate (A). 2 - Remove the O-ring (B). 3 - Remove the sealing ring (C) from the flange and clean the seat.

  • Page 47: Overhauling The Decanting Device

    OVERHAULS AND TUNING 6.2.9 Overhauling the decanting device In order to overhaul the decanting device, it is necessary to disassemble the starter motor. See “Replacing the starter motor” for the correct procedure. 1 - Loosen the clamp and extract the pipe (A). 2 - Remove the cover (B).

  • Page 48: Checking And Overhauling The Rocker Arm Pin

    OVERHAULS AND TUNING 6.3.2 Checking and overhauling the rocker arm pin 1 - In order to carry out a control of the rocker arm assembly, it is necessary to disassemble the cylinder head. See “Disassembling the rocker arms” for the correct procedure. 2 - Bore a hole in the blocking pin (A), using a 4mm bit to remove it.

  • Page 49: Checking And Replacing The Camshaft

    OVERHAULS AND TUNING 8 - Insert a new pin (E) and drive it in 0÷1 mm from the flat part of the support. 9 - Reassemble the rocker arm assembly in the cylinder head (see “Assembling the rocker arms”). 6.3.3 Checking and replacing the camshaft In order to carry out a control of the camshaft, it is necessary to disassemble it from the cylinder head.

  • Page 50: Checking And Replacing The Fuel Pump Drive Rod

    OVERHAULS AND TUNING 2 - Use a micrometer to measure the maximum dimensions of the involutes of the intake, exhaust and injection cams (see “Table of cam dimensions”). Table of cam dimensions Ref. Dimensions (mm) ÷ ÷ If the dimensions of cam involutes are lower than the values shown by 0.1mm (maximum dimension), replace the camshaft with an original spare.

  • Page 51: Checking And Overhauling The Valves

    OVERHAULS AND TUNING 6.3.5 Checking and overhaulimg the valves In order to carry out a control of the valves, it is valve guide necessary to remove them from the cylinder head. See “Disassembling the valves” for the correct procedure. 1 - Use a gauge to measure the length of the springs (see “Table of dimensions for valve guide...

  • Page 52: Adjusting Valve-Rocker Arm Clearance

    OVERHAULS AND TUNING 6.3.6 Adjusting valve-rocker arm clearance In order to make the adjustment, it is necessary to remove the rocker arm cover. See “Disassembling the rocker arm cover” for the correct procedure. Important Adjustment of valve clearance must be done when the engine is cold.

  • Page 53: Calibrating The Injector

    OVERHAULS AND TUNING 6.3.8 Calibrating the injector Pump To carry out setting, the injector pump must be disassembled from the engine. Per conoscere la procedura corretta, vedi Union “Smontaggio pompe-iniettori”. 1 - Remove the non-return valve (A) and replace it with the plug supplied with the “7107-1460-074”...

  • Page 54: Checking Timing Belt Rating

    OVERHAULS AND TUNING 6.4 CHECKING TIMING BELT RATING 6.4.1 Valve adjustments Fan drive pulley 1 - Bring the piston to the compression top dead centre. 2 - Adjust the screw (A) and the lock nut in order to adjust the rocker arm valve clearance to 2 mm.

  • Page 55: Diagram Of Timing Belt Rates

    OVERHAULS AND TUNING 6.5 DIAGRAM OF TIMING BELT RATES Rotate the crankshaft clockwise to find out the timing rates of the entire cycle in each cylinder (operation and control). Timing belt operating angles (valve clearance 0.25 mm) α α α α α = 14° before S (top ded centre) β...
  • Page 56 OVERHAULS AND TUNING 4 - Assemble the dial indicator on stud bolt (C). 5 - Place the dial indicator tracer on the exhaust valve collar. 6 - Remove the O-ring (D) from the little non- dial indicator return valve and replace it with the suitable rubber cap (E) (part of tool “7107-1460- dial indicator tracer 048”).

  • Page 57: Important

    OVERHAULS AND TUNING 16 - Rotate the crankshaft anticlockwise until liquid leaks from the pipe (M), and then stop turning when the flow is constant and without air bubbles. 17 - Then turn slowly the crankshaft clockwise in order to identify the exact point at which liquid stops leaking.

  • Page 58: Balancing Injection-Pump Delivery

    OVERHAULS AND TUNING 23 - Once adjustment is finished, assemble the new O-rings (D) on the injector pumps. Important The O-rings must always be replaced with original spare parts whenever the fuel rail is disassembled. 24 - Apply some silicone sealant on the fuel rail seat.

  • Page 59: Important

    OVERHAULS AND TUNING 3 - Position the assembly “7107-1460-127" above the height of the injectors. assembly 7107-1460-127 4 - Connect the outlet and intake pipes of the assembly to the test heads. fuel filter Important Be careful not to reverse the intake and outlet pipes when connecting.

  • Page 60: Adjusting Minimum And Maximum Idle Speed Rpms

    OVERHAULS AND TUNING 6.8 ADJUSTING MINIMUM AND MAXIMUM IDLE SPEED RPMS 1 - Connect a revolution counter to the engine. 2 - Run the engine and bring it to the operating temperature. 3 - Turn the idle adjusting screw (A) and set the engine to the minimum speed required.

  • Page 61: Adjusting Injection Delivery (With Dyno Brake)

    OVERHAULS AND TUNING 6.9.2 Adjusting injection delivery (with dyno break) 1 - Start the engine and bring it to the operating temperature. 2 - Bring the engine to maximim rpm allowed. 3 - Loosen the locknut (A). 4 - Firmly tighten the screw (B) of the flow limiter.
  • Page 62 OVERHAULS AND TUNING .............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

  • Page 63: Installation Of Assemblies

    INSTALLATION OF ASSEMBLIES 7.1 RECOMMENDATIONS FOR INSTALLING THE ASSEMBLIES – For safety and convenience, you are advised to place – Information is given in a logical order in terms of timing and sequence of operations. The methods have been the engine on a special rotating stand for engine selected, tested and approved by the manufacturer’s overhauls.

  • Page 64: Pre-Assembly Of Connecting Rods - Pistons

    INSTALLATION OF ASSEMBLIES 7.3 PRE-ASSEMBLY OF CONNECTING RODS - PISTONS Important Before pre-assembly, check that the weight difference between the two connecting rod-piston-wrist pin assemblies does not exceed 10 g to prevent weight imbalances. 1 - Lubrificate the wrist pin (A) and the seat of the small end of the connecting rod (B).

  • Page 65: Installation Of Crank Gear And Crankcase

    INSTALLATION OF ASSEMBLIES 4 - Mount the collar (C), the spring (D), the cup (E) and the half collets (F). 5 - Press down hard on the cup (E), using the special tool “7107-1460-047” to insert the half collets (F) into the valve stem groove. 6 - Release the tool and check that the half collets are positioned correctly.

  • Page 66: Assembling The Crankshaft

    INSTALLATION OF ASSEMBLIES 7.5.2 Assembling the crankshaft 1 - Mount the half-bearings (C) and the standard shoulder half-rings (E) (flywheel side). Important – Follow the marks made during the removal phase. – The shoulder half-rings must be placed with the lubrication grooves facing outwards.

  • Page 67: Measuring Crankshaft Axial Clearance

    INSTALLATION OF ASSEMBLIES 4 - Tighten the screws (M) temporarily in alternating pattern. 5 - Tighten the screws (L) in a crisscross pattern to a final torque of 50Nm. engine block 6 - Tighten the screws (M) in an alternating pattern to a final torque of 10Nm.

  • Page 68: Installing The Oil Pump

    INSTALLATION OF ASSEMBLIES 4 - Slip on a new gasket (P). 5 - Replace the falnge (Q) and put in the screws (R). Important Be careful not to damage the sealing rings during this operation. 6 - Tighten the screws (R), in a crisscross pattern to a final torque of 12Nm.

  • Page 69: Assembling The Flywheel

    INSTALLATION OF ASSEMBLIES 5 - Tighten the screws in a crisscross pattern, and tighten each of them to their respective final torques (see image). 6 - Insert the key (D) into the crankshaft. 7 - Install the alternator support (E) and tighten the screws to a torque of 2.2Nm.

  • Page 70: Installation Of Cylinder Head And Components

    INSTALLATION OF ASSEMBLIES 7.6 INSTALLATION OF CYLINDER HEAD AND COMPONENTS 7.6.1 Assembling the precombustion chamber Important Check that the contact surfaces are perfectly clean and intact. 1 - Install the precombustion chamber (A), so tool 7170-1460-031 that its hole coincides with the one on the pre-heating glow plug.

  • Page 71: Assembling The Cylinder Head

    INSTALLATION OF ASSEMBLIES 7.6.2 Assembling cylinder head Important – Make sure there are no foreign bodies or residual material in the cylinder head cavity. – Check that the contact surfaces are perfectly clean and intact. 1 - Slip on a new gasket (G). 2 - Choose the gasket shim to be installed (see “Check clearance volume”) 3 - Make sure that the length of the screws...

  • Page 72: Assembling The Speed Governor And Flow Limiter

    INSTALLATION OF ASSEMBLIES 7.6.4 Assembling the speed governor and flow limiter Important – Make sure that all components are perfectly clean and dry. flow – Check that all components are intact limiter and, if necessary, replace them with original spares. 1 - Mount the levers (C) and pivot them with the screw (D) to a torque of 0.70 Nm.

  • Page 73: Assembling Injection-Pumps

    INSTALLATION OF ASSEMBLIES 7.6.5 Assembling injection-pumps Important – Check that all components are intact and, if necessary, replace them with original spares. – Before replacing the injectors it is always necessary to replace the flameproof bulkhead, the copper gasket and the oil and diesel O-ring seals.

  • Page 74: Assembling The Mechanical Fuel Pump

    INSTALLATION OF ASSEMBLIES 11 - Tighten the screws (T) to a torque of 1,1 12 - Balance the injector deliveries (see “Balancing injector pump deliveries”). 13 - Put the new O-rings on the injector pumps. fuel rail 14 - Apply sealant to the seat of the fuel rail. 15 - Assemble the fuel rail and fasten the screws without tightening them.

  • Page 75: Assembling The Rocker Arms

    INSTALLATION OF ASSEMBLIES 7.6.7 Assembling the rocker arms Important Check that the contact surfaces are perfectly clean and intact. 1 - Press down hard on the pump stroke to insert the pin, which facilitates assembly of the drive rods (B). 2 - Mount the rocker arm assembly (A).

  • Page 76: Installing The Timing Belt Drive

    INSTALLATION OF ASSEMBLIES 7.7 INSTALLING THE TIMING BELT DRIVE 7.7.1 Assembling the timing belt pulley 1 - Insert the key (B) into the crankshaft. 2 - Mount the pulley (A). 3 - Mount the pulley (C) and tighten the screw to a torque 80 Nm.

  • Page 77: Assembling The Belt Drive Cover

    INSTALLATION OF ASSEMBLIES 4 - Insert tool “7107-1460-049” in the tensioner holder lever. tool 7107-1460-049 5 - Calibrate the torque wrench to 20 Nm and insert it into the tool, with the lever perpendicular to the belt. 6 - Loosen the nut slightly (D). tensioner 7 - Turn the torque wrench clockwise to holder...

  • Page 78: Installation Of The Cooling Fan Belt Drive

    INSTALLATION OF ASSEMBLIES 7.8 INSTALLATION OF THE COOLING FAN BELT DRIVE 7.8.1 Assembling the fan belt drive pulleys 1 - Check that all components are intact and, if necessary, replace them with original spares. 2 - Mount the pulley (G1) and fasten the screws without tightening them.

  • Page 79: Assembling The Fan Belt Drive

    INSTALLATION OF ASSEMBLIES 9 - Mount the pulley (P), washers and spacer. 10 - Tighten the screw (Q) to a torque of 25 7.8.2 Assembling the fan belt drive With internal alternator With external alternator The engine may have an external or internal alternator.

  • Page 80: Assembling The Cooling Fan

    INSTALLATION OF ASSEMBLIES 7.8.3 Assembling the cooling fan 1 - Check that the fan is intact and, if necessary, replace it with an original spare. 2 - Install the cooling fan (U). 3 - Tighten the screws to a torque of 10 Nm. screw 7.9 INSTALLING INTAKE AND EXHAUST MANIFOLDS 7.9.1 Assembling exhaust manifold...
  • Page 81 INSTALLATION OF ASSEMBLIES 7 - Clean the cover (H) witha a jet of air. 8 - Check the state of the filter cartridge (G). If necessary, remove the cartridge, knock it repeatedly against a flat surface to eliminate dirt and clean with a jet of air. 9 - Return the cleaned filter cartridge or replace it with an original spare.
  • Page 82 INSTALLATION OF ASSEMBLIES Notes : ..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

  • Page 83: Replacing Parts

    REPLACING PARTS 8.1 RACCOMMENDATIONS FOR REPLACING PARTS – This chapter describes the procedures for replacing a – All operations, except where expressly stated otherwise, number of components and/or assemblies which are not must be carried out when the engine is not running and recommended for repairs.

  • Page 84: Important

    REPLACING PARTS 5 - Adjust the alternator manually while at the same time tightening the screw to regulate belt tension. Important Use the method shown in the diagram to check belt tension. The resultant (R) must be 10÷15 mm. belt 6 - Tighten the nuts (B -B1) to a final torque of 40Nm and 25Nm respectively.

  • Page 85: Replacing The Timing Belt

    REPLACING PARTS 9 - Install the cooling fan. 10 - Tighten the screws to a torque of 10 Nm. cooling fan flange fan hub pulley 8.3 REPLACING THE TIMING BELT Important 4 - Replace the timing belt with an original spare (see Replacement may be carried out with the engine “Assembling the timing belt drive”).

  • Page 86: Replacing The Air Filter

    REPLACING PARTS 8.5 REPLACING THE AIR FILTER Important – Polluting substances should be disposed of properly, in full compliance with the law. – Replacement may be carried out with the engine installed on the machine. Filtro “a pannello” 1 - Switch off the engine and leave to cool. 2 - Remove the cover (A).

  • Page 87: Replacing The Alternator

    REPLACING PARTS 8.6 REPLACING THE ALTERNATOR Caution - Warning Replacement may be carried out with the engine installed on the machine. 1 - Switch off the engine and leave to cool. 2 - Disconnect the battery. 3 - Disconnect the electrical connectors. 4 - Loosen the nut (A).

  • Page 88: Replacing The Flywheel Ring Gear

    REPLACING PARTS 8.8 REPLACING THE FLYWHEEL RING GEAR In order to replace the ring gear, it is necessary to disassemble the flywheel. See “Disassembling the flywheel” for the correct procedure. 1 - Cut the ring gear (A) in several places using a chisel and remove it.

  • Page 89: Replacing The Coolant Pump

    REPLACING PARTS 8.10 REPLACING THE COOLANT PUMP Important Replacement may be carried out with the engine installed on the machine. Coolant pump 1 - Switch off the engine and leave to cool. Disassemble the cooling fan (see “Removing the cooling fan belt drive”).

  • Page 90: Replacing The Negative-Pressure Vent Valve

    REPLACING PARTS 8.12 REPLACING THE NEGATIVE-PRESSURE VENT VALVE Important Replacement may be carried out with the engine installed on the machine. 1 - Switch off the engine and leave to cool. Caption 2 - Loosen nut (A). 1) Nut 2) Bushing 3 - Loosen the clamps and disconnect the 3) Valve body pipes.

  • Page 91: Replacing Injector Pump Parts

    REPLACING PARTS 8.14 REPLACING INJECTOR PUMP PARTS Exploded diagram of the injector pump The figure shows the injector pump parts. Caption 1) Tension washer 2) Tappet 3) Stop collar 4) Plunger 5) Spring 6) Screw 7) Support 8) Lever 9) Ring nut 10) O-ring 11) Barrel 12) Delivery valve...

  • Page 92: Important

    REPLACING PARTS 9 - Check the good seal of the delivery valve (12) as well as of the pumping element (parts 4-11). If necessary, replace them with original spare parts. 10 - Assemble all parts (15-14-13). 11 - Assemble the delivery valve (12). tool 7107-1460-029 Important The needle (B) and the valve seat (C) must...

  • Page 93: Replacing The Nozzle-Injector

    REPLACING PARTS 8.14.2 Replacing nozzle-injector Important Replacement may be carried out with the engine installed on the machine. 1 - Disassemble the injection pump (see “Disassembling injection pumps”). 2 - Loosen the ring-nut (21). 3 - Extract the nozzle (23) and the parts (24- 25-26-27).
  • Page 94 REPLACING PARTS Notes : .............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

  • Page 95: Index

    Coolinf fan belt drive, removing, 30 ACEA Standards, 14 Cooling fan belt drive, installation, 78 Adjusting injection delivery, 60 Cooling fan blet (with external alternator), disassembling, 31 Adjusting injection delivery (with dyno brake) 61 Cooling fan blet (with internal alternator), disassembling, 31 Adjusting injection delivery (without dyno brake), 60 Cooling fan support, replacing, 93 Adjusting minimum and maximum idle speed rpms, 60...
  • Page 96 Fan belt drive pulleys, assembling, 78 Oil filter, replacing, 85 Fan belt drive, assembling, 79 Oil preassure, checking, 61 Oil pump, disassembling, 37 Flow limiter and speed governor, assembling, 72 Flow limiter and speed governor, disassembling, 35 Oil pump, installing, 68 Flywheel ring gear, replacing, 88 Operating phases, general safety, 6 Operating principle for cooling, 15...
  • Page 97 Replacing the nozzle-injector, 93 Replacing the oil filter, 85 Valve - rocker arm clearance, adjusting, 52 Replacing the starter motor, 87 Valve adjustments, 54 Replacing the theromstatic valve, 89 Valve guides - springs - valve stems dimensions, table, 51 Replacing the timing belt, 85 Valve stems - springs - valve guides dimensions, table, 51 Rocker arm - pin dimensions, table, 48 Valves, assembling, 64...
  • Page 98 SERVICE MANUAL - code 1.5302.727...

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