Lombardini LGW 523 mpi Manuals

Manuals and User Guides for Lombardini LGW 523 mpi. We have 1 Lombardini LGW 523 mpi manual available for free PDF download: Workshop Manual

Lombardini LGW 523 mpi Workshop Manual (110 pages)

Brand: Lombardini | Category: Engine | Size: 20 MB

Table of Contents
3
General Remarks and Safety Information
5
Purpose of the Manual
5
Using this Manual
5
Manufacturer and Engine Identification
5
Glossary and Terminology
6
Warranty Clauses
6
General Safety Regulations
6
General Safety During Operation
6
General Safety During Operating Phases
6
Safety and Environmental Impact
7
Precautions When the Engine Is Installed on the Vehicle
7
Precautions When the Engine Is on the Rotating Stand
7
Technical Information
9
General Description of the Engine
9
Technical Specifications
10
Dimensions (MM)
10
General Details
10
Fuel Supply Circuit
11
Lubrication Circuit
11
Cooling Circuit
11
Electrical System
11
Performance Curve Diagram
12
Alternator Load Curve Diagrams
13
Lubricants
14
Coolant
15
Fuel Specifications
15
Routine Maintenance of Lgw 523 Mpi Engine
15
Operating Principle for Lubrication
16
Operating Principle for Cooling
16
Operating Principle for Fuel Supply
17
Wiring Diagram
18
Electronic Engine Control Wiring Diagram
20
Electrical Wiring for Electronic Engine Control
21
Fuel Supply System
22
Electric Fuel Supply Pump
22
Fuel Filter
22
Pressure Regulator
22
Prefilter
22
Injector Supply Pipe
23
Injectors
23
Inertial Switch
23
Electronic Engine Control System
24
Ignition Coil
25
Spark Plug
25
Lambda Probe Sensor
25
Electronic Control Unit (E.C.U.)
26
Control Unit Identification Plate
26
Speed Sensor
26
Air Temperature Sensor
27
Absolute Pressure Sensor
27
Water Temperature Sensor
27
Throttle Control Sensor
28
Throttle Body
28
Intake System
29
Exhaust System
29
Special Tools and Equipment for Maintenance
30
Tightening Torque Tables
30
Table of Tightening Torques for Standard Screws (Coarse Thread)
30
Table of Tightening Torques for Standard Screws (Fine Thread)
31
Table of Tightening Torques for the Main Components
31
Table of Sealants
32
Malfunctions
33
Table of Likely Anomalies and Their Symptoms
33
Storing the Engine
35
Handling and Lifting
35
Engine Storage (Uninstalled)
35
Engine Storage (Installed)
35
Protective Treatment
36
Preparing the Engine for Operation after Protective Treatment
36
Removing the Assemblies
37
Recommendations for Removing the Assemblies
37
Removing the Exhaust and Intake Manifolds
37
Disassembling the Intake Manifold
37
Disassembling the Air Flow Sensors
40
Disassembling the Exhaust Manifold
40
Removing the Cooling Fan Belt Drive
41
Disassembling the Cooling Fan Belt (with External Alternator)
42
Disassembling the Cooling Fan Belt (with Internal Alternator)
42
Removing the Timing Belt Drive
43
Disassembling the Timing Belt Guard
43
Timing Belt and Gears
43
Removing the Speed Sensor
44
Disassembling the Synchronous Timing Belt
44
Sliding Pulley and Belt Tightener
44
Disassembling the Synchronous Timing Belt Pulleys (Camshaft and Crankshaft)
45
Disassembling the Coolant Circulation Pump
45
Disassembling the Pump Scroll
46
Removing the Cylinder Head and Components
46
Disassembling the Spark Plug
46
Disassembling the Rocker Arm Cover
47
Disassembling the Rocker Arm Assembly
47
Disassembling the Injectors
48
Disassembling the Camshaft
50
Disassembling the Thermostatic Valve Body
50
Removing the Cylinder Head
51
Disassembling the Valves
51
Removing the Crank Gear and Crankcase
52
Disassembling the Flywheel
52
Disassembling the Oil Pump
52
Disassembling the Crankcase and Crankshaft
53
Disassembling the Connecting Rod and Piston
54
Disassembling the Piston
54
Overhauls and Tuning
57
Recommendations for Overhauls and Tuning
57
Shaft Seals
57
O-Rings
57
Bearings
57
Overhauling the Crank Gears and Crankcase
57
Overhauling Cylinders and Pistons
57
Dimensional Check and Overhaul of Cylinders
58
Dimensional Check and Overhaul of Pistons
58
Dimensional Check of Sealing Rings
59
Dimensional Check and Overhaul of Crankshaft
60
Dimensional Check and Overhaul of Connecting Rods
61
Checking Parallelism of the Connecting
61
Rod Axes
61
Checking and Overhauling the Oil Pump
62
Overhauling the Decanting Device
63
And Components
63
Checking and Overhauling the Cylinder Head
63
Checking and Overhauling the Valves
64
Checking and Overhauling the Rocker Arm Pin
65
Hydraulic Tappets
66
Checking and Replacing the Camshaft
68
Diagram of Timing Belt Rates
69
Checking the Spark Plug
69
Replacing the Flywheel Ring Gear
70
Installation of Assemblies
71
Recommendations for Installing Assemblies
71
Installing Valves
71
Assembling the Valves
71
Preassembly of Sealing Rings - Pistons
72
Pre-Assembly of Connecting Rods - Pistons
73
Installation of Crank Gear and Crankcase
73
Installing Piston/Connecting Rod - Engine Block
73
Assembling the Crankshaft
74
Assembling the Crankcase
75
Checking Crankshaft Axial Clearance
75
Assembling the Crankshaft Flange (Flywheel Side)
76
Installing the Pump Scroll
76
Installing the Coolant Circulation Pump
77
Assembling the Oil Pump
77
Assembling the Flywheel
78
Determining Clearance Volume
79
Installation of Cylinder Head and Components
80
Assembling the Cylinder Head
80
Assembling the Camshaft
80
Installing the Camshaft Support and Timing Belt Pulley
81
Installing the Rocker Arm Assembly
81
Installing the Rocker Arm Cover
81
Installing the Spark Plug
82
Installing the Injectors
82
Installing the Thermostatic Valve Body
83
Installation of the Timing Belt Drive
84
Assembling the Phase Sensor
84
Assembling the Timing Belt Pulleys (Camshaft and Crankshaft)
85
Adjusting the Phase Sensor
85
Assembling the Synchronous Timing Belt
85
Assembling the Timing Belt Guard
86
Installation of the Cooling Fan Belt Drive
87
Assembling the Cooling Fan Belt Drive Pulleys
87
Assembling the Cooling Fan Belt (with Internal Alternator)
88
Assembling the Cooling Fan Belt (with External Alternator)
89
Installation of the Exhaust and Intake Manifolds
90
Assembling the Throttle and Sensors
90
Assembling the Intake Manifold
90
Assembling the Exhaust Manifold
92
Vehicle Controls
95
Preliminary Checks
95
Components Layout Inside the Engine Case
95
Petrol Pressure Check
96
Injector Check
96
Adjusting the Accelerator Cable
97
Diagnostic
98
Using the Diagnostic Procedures
98
Technical Features
98
Total View of the Tool
98
Accessories
99
Autodiagnostic Software
99
Preliminary Operations
100
Connecting to the Vehicle
100
Vehicle and System Selection
100
Available Functions for Diagnostic
102
Autodiagnostic
102
Detecting Faults
102
Menu Bar
103
Important to be Pointed out before Starting
103
Errors
104
Construction Parameters
105

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