Nanni 4.380 TDI Manuals

Manuals and User Guides for Nanni 4.380 TDI. We have 2 Nanni 4.380 TDI manuals available for free PDF download: Workshop Manual, Instruction Manual

Nanni 4.380 TDI Workshop Manual (192 pages)

Toyota engine base

Brand: Nanni | Category: Engine | Size: 22.23 MB

Engine Base
1
Contents
2
Safety Information
6
Safety Symbols
6
Wear Protective Clothing
6
Fuels and Lubricants
7
Exhaust Gas Prevention
7
Pressure
7
Battery
7
General Information
8
Engine Identification
8
Preparation before Putting into Service
9
Identification of Main Components
9
General Check
9
Engine and Gear Box Lubrification
10
Fuel Circuit
10
Fuel Circuit Bleeding
10
Cooling System
11
Closed Coolant Circuit
11
Seawater Circuit
11
Hot Water Connection
11
Engine Operation
12
Starting
12
Engine Stopping
12
Running in
13
Servicing
13
Valve Clearance Adjustment
13
Replacing the Water Pump Rotor
13
Recommendations
14
Replacing the Fuel Filter
15
Replacement of an Injector
15
Draining of Engine Crank Case Oil
15
Oil Filter Replacement
16
Reverser Control System
16
Reverser
16
Fiche Technique
17
Recommendations Lubrication and Cooling
18
Engine Oil
18
Alternator Belts
19
Glow Plugs
19
Checking the Alternator Drive Belt
19
Check the Alternator Drive Belt
19
Checking Glow Plugs
20
Check Glow Plugs
20
Checking and Adjusting Valve Clearance (Engine Cold)
21
Remove the Rocker Cover
21
Measure the Valve Operating Clearance
21
Valve Clearance (Cold)
21
Selection Table for Thickness Shims
23
Thickness of New Thickness Shim
23
Exhaust
24
Installation of the Rocker Cover
25
Setting the Injection Advance
26
Checking and Setting the Injection Timing
26
If the Recorded Value Is Not Within the Tolerances
27
Remove the Steel Plate
28
Replacing the Timing Belt
29
EVERY 1000 HOURS or 2 YEARS
29
Remove the Timing Belt Tensioner
29
Remove the Timing Belt Intermediate Pulley
29
Check of the Timing Belt Equipments
30
Check the Intermediate Pulley
30
Check the Timing Belt Tensioner
30
Reinstallation of Timing Belt
32
Reinstall the Timing Belt
32
Reinstall the Timing Belt Intermediate Pulley
32
Position the Timing Belt Tensioner
32
Reinstall the Timing Belt Protection Cover
33
Compression Measurement
34
Checking the Compression
34
Compression Pressure
35
Minimum Pressure
35
Pressure Difference between Cylinders
35
Reinstall the Injectors
35
Piston Protrusion
36
Reinstallation and Tightening of the Cylinder Head
36
Reinstall the Cylinder Head
37
Reinstall Cylinder Head Bolts
38
Reinstall the Cam Shaft
38
Reinstall the Cam Shaft Oil Gasket Retainer
39
Checking the Cooling System Components
40
Sea Water Pump
40
Thermostat
40
Coolers
40
Exchanger
41
Intercooler
41
Anode on Exhaust Elbow
42
Coolant
42
Indicators
43
PANEL C3: Round Connector
43
PANEL C3: Rectangular Connector
43
4 Cylinders Toyota Square Connector
45
Engine Hardness Connector Round Model
47
Electrical Drawing
48
Rectangular Connector
48
List of Essential Special Tools
50
Timing Belt
52
Timing Gears
53
Cylinder Head
55
Cylinder Block
56
Injectors
58
Injection Pump
59
Water Pump
61
Oil Pump
62
Oil Cooler
63
Oil Jet
64
Turbocharger
65
Standard Tightening Torques
68
Specific Standard Bolt Torque
69
Specific Tightening Torques
70
Engine Characteristics
71
Maintenance Characteristics
71
Maintenance Data
71
Basic Special Tools
75
Removing the Timing Belt
78
Remove the Timing Belt Protection Cover
78
Removing the Timing Pinions
80
Remove the Crankshaft Pulley
80
Remove the Timing Toothed Wheels
82
Removing the Cam Shaft Timing Toothed Wheel
82
Remove the Intermediate Toothed Wheel
82
Remove the Injection Pump Drive Pinion
82
Checking the Toothed Wheel Timing
85
Gear Bearing
85
Replacing the Crankshaft Oil Gasket
87
Replace the Crankshaft Oil Gasket
87
Replacing the Injection Pump Oil Seal
88
Reinstalling the Timing Pinions
89
Reinstall the Timing Gear
90
Reinstall the Crankshaft Timing Toothed Wheel
91
Reinstall the Injection Pump Drive Pinion
91
Reinstall the Intermediate Toothed Wheel
91
Reinstall the Timing Casing Cover
93
Check the Axial Clearance of the Injection Pump Drive Gear
94
Reinstall the Crankshaft Pulley
94
Reinstall the Sea Water Pump
95
Remove the Intake Manifold
97
Remove the Water Discharge Pipe
97
Remove the Injector Return Pipe
97
Remove the Oil Level Gauge and Its Guide
98
Remove the Injectors
98
Remove the Cam Shaft Oil Seal Retainer
99
Remove the Camshaft
99
Remove the Cylinder Head
100
Removing the Cylinder Head
100
Remove Valves
101
Remove the Combustion Chambers
101
Remove the Semi-Circular Cap
102
Clean the Cylinder Head
102
Clean Valve Guide Bushes
103
Checking the Cylinder Head
103
Check for Cracks
103
Clean the Valves
104
Check Rods and Valve Guides
104
Examine and Grind Valves
106
Examine and Clean the Valve Seats
107
Checking Valve Springs
108
Verify Bearings and Camshaft
108
Checking the Cam Tops
108
Check Cam Shaft Pivot
109
Check Cam Shaft Bearings
109
Check the Valve Lifters and Their Bores
110
Check Intake and Exhaust Manifolds
111
Check Cylinder Head Bolts
111
Replacing the Cam Shaft Oil Gasket
112
Replace the Cam Shaft Oil Gasket
112
Difference in Thicknesses of Combustion Chambers
113
Reinstall the Combustion Chambers
114
Reinstall Valves
114
Reinstall the Valve Lifters with Their Thickness Shims
115
Reinstalling the Cylinder Head
116
Reinstall the Rocker Cover
120
Injectors and Injection Pump Injectors
122
Remove the Injection Pipes
123
Remove the Fuel Return Pipe
123
Injector Test
124
Injection Pressure Test
124
Drop Test
125
Fuel Atomization Condition Test
125
Thickness Shim Thickness
125
Component Part Disassembly and Reassembly
126
Disassembling the Injectors
126
Disassemble the Injectors
126
Cleaning and Checking Injectors
126
Check the Injectors
127
Reassembling the Injectors
128
Reinstalling the Injectors
128
Reinstall the Injector Fuel Return Pipe
128
Reinstall the Injector Pipes
129
Fresh Water Pump and Water Sensor
132
Checking the Water Temperature Sensor
132
Fresh Water Pump
133
Removing the Water Pump
134
Removing the Thermostat
137
Checking the Thermostat
138
Reinstalling the Thermostat
138
Pre-Heating
139
Remove the Glow Plugs
140
Reinstalling the Glow Plugs
140
Checking on Board
141
Checking the Oil Pressure
142
Check the Engine Oil Quality
142
Check the Engine Oil Level
142
Warm up the Engine
142
Oil Jet Component Part
143
Remove Oil Jets
143
Checking Oil Jets
143
Reinstalling Oil Jets
144
Reinstall Oil Jets and the Check Valves
144
Removing the Oil Pump
146
Remove the Oil Strainer
147
Remove the Oil Pump Timing Casing
147
Disassembling the Oil Pump
148
Checking the Oil Pump
148
Check the Discharge Valve
148
Check the Driving and Driven Rotors
148
Reassembling the Oil Pump
149
Reinstall the Discharge Valve
149
Reinstalling the Oil Pump
150
Reinstalling the Oil Pump (Timing Casing)
150
Put some Oil in the Oil Pump
151
Reinstall the Oil Strainer
152
Reinstall the Engine Lower Casing
152
Reinstall the Water Pump
153
Reinstall the Timing Gears
153
Removing the Oil Radiator and the Discharge Valve
155
Checking the Oil Cooler and the Discharge Valve
156
Check the Oil Radiator
156
Reinstalling the Oil Radiator and the Discharge Valve
157
Turbo-Charger
159
Checking the Turbo Charger
160
Check Rotation of the Impeller
160
Check the Radial Clearance of the Impeller
160
Check Operation of the Control Device
160
Engine Block
161
Removal Preparation
162
Disassembling the Cylinder Block
163
Connecting Rod Small End Inner Diameter
166
Crankshaft Crank Pin Diameter
166
Thickness of the Standard Size Shell Bearing Centre
166
Remove the Connecting Rod Piston Assembly
166
Measure the Crankshaft Axial Clearance
167
Remove Crankshaft Bearing Caps and Verify the Lubrication Clearance
167
Cylinder Block Bearing Pivot Bore Diameter
169
Crankshaft Bearing Pivot Diameter
169
Remove the Crankshaft
170
Thickness of the Nominal Shell Bearing Centre Wall
170
Remove Check Valves and Injectors
170
Checking the Cylinder Block
171
Clean the Cylinder Block
171
Measure the Cylinder Bore
171
Cutting Cylinder Collars
172
Check the Cylinder Block Port
172
Disassembling Connecting-Rod Piston Assemblies
173
Remove the Piston Rings
173
Uncouple the Connecting Rod and the Piston
173
Checking the Connecting Rod-Piston Assemblies
174
Clean the Pistons
174
Compression Ring and Oil Scraper Ring
176
Verify Piston Ring Fitting
176
Checking the Connecting Rods
177
Checking Connecting Rod Straightness
177
Check for Twisting
177
Check the Connecting Rod Assembly Bolts
177
Checking Balancing Shafts
180
Check Right and Left Balancing Shafts
180
Nominal Lubrication Clearance
180
Limit Lubrication Clearance
180
Cylinder Bore
181
Select Pistons at Top Dimension
181
Checking and Reconditioning of the Crankshaft
182
Check the Crankshaft Crank Pins and Pivots
182
Replacing the Crankshaft Rear Oil Gasket
183
Reassemblying the Piston-Connecting Rod Assemblies
184
Reinstall the Rings on the Piston
184
Reassembling the Cylinder Block
186
Reinstall the Cylinder Block Oil Jet
186
Reinstall the Injectors and Check Valves
186
Reinstall Crankshaft Bearing Shell Bearings
186
Reinstall the Thrust Bearing Bushes
187
Reinstall Crankshaft Bearing Caps
189
Reinstall the Rear Gasket Retaining Cage
190
Reinstall the Right and Left Balancing Shafts
190
Post-Assembly
191
Reinstall the Rear Closing Plate
191
Reinstall the Engine Fly Wheel
191

Nanni 4.380 TDI Instruction Manual (13 pages)

Brand: Nanni | Category: Engine | Size: 0.83 MB

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