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    FPT Iveco Workshop Manual 8001 Series Section 3

    Uploaded by

    Jovie Grohl

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    © All Rights Reserved
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    gensets and genset engines. section 3 8001 SERIES WORKSHOP MANUAL 8061Si06 8061Si07 8061SRi26 8061SRI27 Publication No L32022008 Iveco aifo 98 Date 10 - 19) The data contained in this publication may not have been updated following modifications carried out by the manufacturer, at any time, foe technical or com- ‘mercial reasons and also to conform to the require- ments of the law in the various countries. This publication supplies features and data together with the suitable methods for repair operations to be carried out on each single components of the gensets and genset engines. Following the supplied instructions and using the inherent specific fixtures, a correct repair procedure will be obtained in due time, protecting the operators from all possible accidents. Before starting any repair, be sure that all accident prevention devices are available and efficient. Therefore check and wear what indicated by the safely provision protective glasses, helmet, gloves, safety shoes, Before use, cheok all work, lifting and transport equipment. GENERAL .. DATA ON ASSEMBLY CLEARANCES mi TIGHTENING TORQUES....... TOOLS.. FAULT DIAGNOSIS .. . DISMANTLING OF THE GENSET. ENGINE BENCH DISASSEMBLY... CYLINDER BLOCK....... repens . CAMSHAFT.......ee000 BUSHES... TAPPETS.. CRANKSHAFT... FLYWHEEL. CONNECTING ROD / PISTON ASSEMBLY..... TIMING GEARS........ CYLINDER HEAD... VALVES. VALVE GUIDES.......-. é PUSH RODS.......c0:s:sseseessesseeees LUBRICATION - OIL PUMP... COOLING - WATER PUMP........-. ss MOUNTING OF THE INJECTION PUMP AND TIMING. OVERHAUL OF THE ELECTRIC MACHINE... REASSEMBLING THE ENGINE. ASSEMBLING OF THE ALTERNATOR WITH THE ENGINE... 8001 SERIES 8061 | 8061 | 8061 | 8064 $i 06 | Si 07 | SRi26| SRi27 4 4 2 2 3 3 3 3 9 9 9 9 1o | to | 10 | 10 aw | a | a} 22_| 22 | 22 | 22 22_| 22 | 22 | 22 25 | 25 | 25 | 25 23 | 28 | 28 | 2 29 | 29 | 29 | 2 30_| 30 | 30 | 30 31_|_31 | 31 | 34 36_| 36 | 36 | 36 36_| 36 | 36 | 36 42_|_42 | 42 | 42 44 | 44 | 44 | 44 45_| 45 | 45 | 45 45 | 45 | 45 | 45 48_| 48 | 48 | 48 so | 50 | 50 | 50 s2_| 52 | 52 | 52 53 | 53 | 54 | 54 55 | 55 | 55 | 55 55 | 55 | 55 | 55 sv_|_s7_| s7 | 87 c 8001 GENERAL Engine p. 1 TIMING LUBRICATION Valve Timing : Minimun oil pressure: = Intake - at full throttle. 2 kglom? opens : before T.D.C. : 12° | | -whenidling, 0,7 kgfem* closes : afters B.0.C. : one Bt ~ Exhaust opens : before B.D.C. 50" closes : afters .D.C. oe A Clearance between valves and rockers for STARTING timing checks... oe 45 mM Operating clearance between valves and rockers, By starter motor cold engine’ intake and exhaust. seen, 30 MM FUEL SYSTEM * ELECTRIC SYSTEM FOR : Inline injection pump type Bosch VEO Fixed injection pump delivery start advance...8° + 0,5" Fuel injectors setting... 250 + 3 bar Firing order : conned 5+ B-6-2-4 = GENSET ENGINE 8061S! 06 A.550 = GENSET ENGINE 8061S1 06 A.580 - GENSET G.E. 8061S! 06 A.955 = GENSET ENGINE 8061S! 07 A.550 = GENSET ENGINE 8061S1 07 A.580 = GENSET G.E. 80611 07 A.955 = Voltage... = Self - regulated alternator. - Starting motor power... - Battery (optional ) ** ELECTRIC SYSTEM FOR : = GENSET 8064S! 06 A.956 = GENSET 8061S1 07 A.956 -Votage. - Sef - regulated alternator. = Sterling motor power. = Baitery (optional ). 12V 14V, 45 A, oe KW 4X180 Ah nV 28 V, 30A aKW 2420 Ah 8001 GENERAL Engine p. 2 TIMING LUBRICATION Valve Timing Minimun oil pressure: Intake al full throttle. 2 kglom* ‘opens : before T.D.C. wont? || -when idling, neeO,T kglom® closes : afters B.D.C. : ate - Exhaust opens : before B.D.C..... ane closes : alters D.C... eee iGa Clearance between valves and rockers for STARTING timing checks. 00,45 mm, Operating clearance between valves and rockers, By starter motor cold engine: intake and exhaust. 0,30 mm FUEL SYSTEM In ine injection pump type Bosch VE6 Fixed injection pump delivery start advance...3° # 0, 250 + 3 bar -5-3-6-2-4 Fuel injectors setting Firing order * ELECTRIC SYSTEM FOR: + GENSET ENGINE 8061SRI 26 A.550 = GENSET ENGINE 8061SRI 26 A.580 + GENSET G.E. 8061SRI 26 A.955 + GENSET ENGINE 8061SRI 27 A.550 - GENSET ENGINE 8061SRI 27 A.580 + GENSET G.E. 8061SRI 27 A.955, -Voltage, sod 2V - Self - regulated alternator... AAV, 45 A, - Starting motor power.. 3kw - Battery (optional). 41X180 Ah * ELECTRIC SYSTEM FOR : - GENSET 8061SRI26 A.956 + GENSET 8061SRI27 A.956 a 24V - Self - regulated alternator. 2.28 V, 30, - Starting motor power. akw - Battery (optional ). 2X120 Ah 8001 DATA ON ASSEMBLY CLEARANCES ES CYLINDER BLOCK AND CRANK” MECHANISM Engine p. 3 COMPONENTS aac ecco ia Bores for ender ners @ | 10685 + 10690 t iinder ners [} & I outside diameter @2 106,94 + 106,97 a length L 19800 + 19850 s Glinderliners-crankcase bores 004+ 0.12 i A > Outside diameter @2 02 @3 mi Gflinder liners x inside diameter Sa 3 104,000 + 104,024 protrusion x Pistons: ae measurement height X 2 xE ft 1 outside diameter OI 10370 + 103852 Le o housing for gudgeon pin @2 38,000 + 38,006 Qe Piston-cylinder liner 0,130#0,172 | Pesondameter ov-08 x 7 ra la Piston protrusion x 064 +097 Cc i Ds Gudgeon pin @3 37,984 + 37,990 Gudgeon pin — pin housing 0010-0022 xt 3.20 + 3.23 a Kg ——-Pistonring grooves 2 255 +257 1x3 x3 403 +405 * measuredon 101 mm diameter 8001 Engine p. 4 , ST 3095 + 3075 s| Piston rings 32 2490 + 20478 courrfy $2 83 $3 3990 + 3975 * measured on 101 mm diameter \ 01105 + 0,155 qe Piston ring grooves 2 0.060 + 0092 3 0,040 + 0.075 { “4 A> Piston rings 04-08 Piston ring end gap in xt cylinder liner: — {x2 x1 030+055 a x2 060+ 0.85 x3 030+ 0.60 | Si ‘Small end bush housing 21 41846 + 41,864 Big end bearing 2 housing @2 61407 + 67422 4 ‘Small end bush diameter © afer ws 24 41.979 + 42017 inside 8S 3 38,004 + 38014 s Oo} or Big end bearing shell S 1,805 + 1.815 (S-thickness) os Smal end bush — housing 0095 + 0.171 Qe Ginlgeon pn bash 0014 +0031 | A Big end bearing shells 0.254 ~ 0508 < x Measurement dimension x 125 Maximum out-of parallel error on connecting rod axes = 0.07 8001 |e Engine p. 5 ao on Main journals oI 79791 «79810 | - Crankpins 22 cas + 63744 H Main bearngshels SI 2.69 + 2.178 (Gzthickness) st 52 TT 6g end bearing shel 82 1.05 + 1.815, (G=thieknest) Main bearing - 423 fousings 3 84,200 + 84,230 Bearing sels — man OOH O10T Qe isu Bearing hels— crankpins 0033 + 0087 noo Main bearing shols - bearing x! 220+324 x! bE Main bearing housing, thrust bearing x2 25010 + 25,060 x2 x3 Thevst washer babes x3 3378-+3429 ES Crankshaft end float (0082 + 0334 { 4 a “Thrust washer halves 0254-0508 - 0762 1.016 > ' <010 Alignment (= 2 £025 ovalty © 1-2 008 ~ Taper > 1 0012 8001 CYLINDER HEAD. VALVE GEAR Engine p. mm oi Vale guide housings inthe cyinder head | 13950 + 13983 @2 - a 92 8023 +8043 Vale guide @3 13.993 + 14.016 @3 wat Vales guides and seatings nthe aooeons head eae Valve guides +02 O4 “Valves 24 7985 + 8000 ala 60° 307 @4 7.985 + 8.00 x bn oa 4593027 Qe Valve stem and its guide 2023 + 0.058 Housing in head for valve seat = aq 8 . @ po eo 39,000 + 39.025 ‘Outside diameter of valve seat; | angle of vale seat in cinder heed @2 = Ho. 60s 22 39.136 + 39.161 pl oe sos Recessng ofvahes — X 07+! a Between valve seat aecrel and head 6 8001 Engine p. Valve spring height Q Free he ros 8 height H a6 | Se fay Ui Under a oad of TH2 270414 HI u 528 26N HD 238 a Re _ ‘Camshaft bearing housing in : crankcase ol 55.280 + 55305, a2 54780-+ 54805, 23 54.280+ 54305, 04 53780 + 53805 Camshaft bearing journals 25 51.470 + 51.500 26 50970 + 51.000 07 50.470 + 50.500 @8 49.970 + 50.000 Ouaside dameter of camshaft bushes 33 55.375 + 55.430 @ 7 * Ol foninemedae 2 945 «54930 ae rear intermediate @3 54375 + 54.430 ia A 53875 + 53930 Inside dameter x ofbushes, front intermediate @2 51,080 + 51.130 rear intermediate @3 50.580 + 50.630 rear @4 50.080 + 50.130 os Bushes and housingsin crankcase 007 +015 Qe Bushes and bearing ooo e016 journals 5 8001 Engine p. 8 om : Bfeaive ca i 7 aon 597 hoon 625 a - : ine Tappet cup housing in crank Poe -\ case ol ‘Ouuside diameter of a tappet cup IE o3 22 14740 + 14780 @ 3 14950 + 14970 Between tappets and Qe — 0030 + 0068 d A> Popes 01-02-03 Bi =} Rocker shaft oI 17.982 18000 Rockers @2 18016 + 18034 @2 Qe Between rockers and shat ore +0052 ‘" MOTOMETER" VALUES : TOC pressure bar 2% Min, permissible TO.C @ neeera tar <9 Engine motoring over speed rom ea (©) Starter—driven engine with ol temperature at 40° - 50° C and injection pump at shut-of. 8001 Engine p. 9 TIGHTENING TORQUE DESCRIPTION —_ TORQUE - : Nm (kgm) Gindernead epscren sage |: pretghtening 7 7) stage 2: pretgntening a 7 0) . sage 3ange - 180° Canscrew: main bearng cas prightening a) angle - Ao CCapscrew, connecting rod cans pretigntening 80) angle 90° Fiywmnee! fang screw preightenng 40. (4) i: ange 2 4 oo for injector fixing stuc pretightening 9.9 (I) Nutfor injector fixing stud ectghtening, 2502.3) (il sump fang screw 165(17) Oilsurp drain plug 3585) Heater seat plug . 125 (12,5), Ne Cepscrew. rh and th rear bracket 0 © ‘Capscrew, engine block rear cover 22,5 (2.3) Capecrew, rear cover 2503) Capscrew, timing cover and housing 22,5 (2.3) ‘Nut for timing cover and housing stud 22.5(23) Pipe union, piston cooing of nozzle 45 (45) Capscrew intake maniold 22503) Capscrew, ake mario and hook 506) ‘Capscrew, exhaust manifold 2.52.3) Nut. cylinder upper cover (14) (Capserew. rocker mounting - 225023) Nuk. rocker adjustment screw 135004) “Nut fywheel hub 295 (29.5) Capscrew drive pulley 50_8) Capscrew, intermediate pin with fange 506) ‘Capserew: camshaft thrust place __ 32503) Capscrew gear mounting 2252.3) Capscrew. injection pump 22503) ‘Capserew, injection pump - 506) Capscrew. turbocharger 50 (5) ‘Capserew, gas exhaust pipe from turbocharger 1eS(17) Capscre. ol pump to front cover 225 (23) ‘Capscrew, retaining plate for oi pressure adjustment valve 225023) Capscrew, heat exchanger 30 @) Capscrew water pump 50) Capscrew, fan hub 115 (115) ‘Capscrew, bet tightener 506) A Lubricate with oi 8001 Engine p. 10 TOOLS TOOL NUMBER DESCRIPTION 99305049 Equipment for checking spring loading, 99305121 Hot air unit 99322230 ‘swiveling telescopic stand 99340033, Damper fywhee! extractor 99340205 Impact extractor 99341003, Single action bridge 99341016 Pair of brackets with holes 99342135 Pin for extracting injectors (to be used with 99340205) 199342145 Extractor for injector holder case 99348001 Extractor with locking device 99348004 Universal extractor internal, 5 to 70 mm 99350108 ‘Wrench for valve gear clearance adjustment screw 99360183 Tongs for fitting engine piston rings 99360288 Drift for removing valve guides 99360293 Drift for refitting vive guides (use with 9936028) 99360322 Too! for rotating engine fywhee! 99360314 Tool for removing cartridge fiters 99360352 Too! for locking engine fywheel 99360268, Too! for removing and reiting engine valves 99360365 Instaling tool for fting crankshaft rear seal (use with 99370005) 99305019 Box with set of tools for recutting valve seatings 99360467 ‘Adapter for checking cinder compression (to be used with 99395682) 99360500 Crankshaft iting tool 99360508 Ring for ling cylinder block 99360595 Hoisting beam for removing and refitting engine 99360605 Ring clamp for inserting standard and oversize pistons into the cylinders 99361033 Brackets for securing engine to swiveling stand 99322230 99365063 ‘Too! for refitting injector holder cases 99370005 Handle for interchangeable drifts99370006 Handle for interchangeable drifts 99370349 Installing tool for fiting crankshaft front seal (use with 99370006) 99390310 Reaming too! for valve guide 99390425, Tap for threading injector holder cases to be extracted 99394017 Reamer for reconditioning lower part of injector holder case (use with 99394019) 99394018 Cutter for reconcitionng injector seating housing (use with 99394019) 99394019 Pilot bush 99395216 Pair of gauges for angle tightening with 1/2" and 3/4” square attachment 99395363, Tee square assembly for checking connecting rod distortion 99395682 Diese! engine cylinder compression tester 99395687 Bore micrometer (50~ 175 mm) 993958501 ‘Torque wrench for checking belt tension 8001 Engine p. 11 FAULT DIAGNOSIS Main engine operating faults 1 = Engine will not start 2 Engine overheats 3 Engine lacks power 4 Engine emits black or dark grey smoke 5 — Engine emits grey (whitish) smoke | ENGINE WILL NOT START 6~ Engine emits ue moke 7 Abnormal knocking rom the engine B- Engine stops 9 Engine exceeds maximum rpm TO Ol pressure to high oF to love 11 — Bxcessve fuel consumption Battery terminal connections serviceable Clean, check, tighten clamp nuts or replace ~ No >| ‘Yes ves Y Starter heater serviceable Replace | NO-b} T YES Y Starter heater serviceable (if fitted) Replace | NO-p T Yes v Injection pump timing correct Check correct timing as described in the | Noy -pe| relevant chapter: T Yes v Fuel pump operating correctly Check and replace if necessary + NOP 8001 Engine p.12 = Injectors serviceable Check operation and adjust as described, > NO-| : = — Yes No air leaks nf! circuit or injection pump Check and bleed p> NOt ; : Y No water in fuel crcuit o pump Check and clean fuel Greuit,ineluding tank } No my - = Y Compression ratio as specified (Overhaul the engine o- it repairs to the parts con- Lo pe} cored valves, piston rings etc.) T Y Fuel fiters serviceable Replace NO : - — Yes ‘Automatic advance regulator and electric STOP valve CCheck and replace the pars concerned serviceable ee 8001 2| ENGINE OVERHEATS Coolant level correct —~— Engine p. 13 Check for leaks and top up NO T YES r v - Water pump and belts serviceable ‘Check, adjust tension and replace parts if necessary | NOP) T YES Water pump serviceable (Overhaul or replace the unit L NOP ' | - YES ‘Thermostat serviceable ] Replace | NOP T YES Air lter and circuit ducts serviceable ‘Clean or replace defective parts + NO r - YES Engine brake disengages (Check and replace ifnecessary + NO 8001 Engine p. 14, Injection pump timing correct Check correct timing as described in the relevant L Nop} section T YES, y Cylinder head gasket serviceable Replace F NO->| 3 | ENGINE LACKS POWER (l —- Fuel fiters serviceable Replace, proceeding as described in the L No Bel. "Use and maintenance” booklet Fuel circuit serviceable Check and if necessary repair as required } No by _ T 4 Thermostat serviceable Replace L Nom ¥ Feed pump serviceable Replace NO by 8001 Engine p. 15 Injectors serviceable Check operating and adjust a described + NO - T ves Injection pup timing correct Check correct timing as described inthe relevant No py section - | YES. Injection purp aduste as specied CChecc and ajst te injection pur on the bench |- NO — T Yes Compression ratio a speciied Check using Motometer too! 99395682 and carry | No pel out necessary repairs = = Y Turbocharger serviceable Repair o replace the unt T Yes LDA ercuit and device serviceable heck | NO > 8001 4 | ENGINE EMITS BLACK OR DARK GREY to Engine p. 16. Replace” Airfiter serviceable NO 7 = Yes Starter heater serviceable (if fitted) Replace F No > T YES —__y Automatic boost device cutting in NO Py Check and replace if necessary Injectors serviceable No > (Check operation and adjust as described, T YES - y Injection pump timing correct | NO Check correct timing as described in the relevant section Yes yv LDA device serviceable - NO Adjust the LDA. device usirg tool 97309002 T Yes y Injection pump adjusted as specified + NO (Check injection purnp and ajust on bench, 8001 Engine p.17 Compression ratio as specified T Yes y Good quality diese! fuel + No->| ‘Check using Motometer too! 99395682 and repair as | necesary | Clean the tank and replace the diese ters F NOP 5 | ENGINE EMITS GREY (WHITISH) SMOKE “Thermostat operating correctly Repace - NOP _| T ‘ Injectors serviceable ‘Check operation and agjust as described. L NO i a YES Injection pump timing correct (Check correct timing as described in the relevant L- No b+ sedion - a Coolant level correct NO Ccolant probably entering combustion chamber; replace cylinder head gasket or overhaul the engine T Yes v Good qualty diesel fuel NOP (Clean the tank and replace the diesel fiters 8001 Engine p. 18. 6 | ENGINE EMITS BLUE SMOKE Excessive oil consumption Check oil breather, yinder compressions Yes pe! Fnecessary, overhaul the cyinder head or engine 7 | ABNORMAL KNOCKING FROM THE ENGINE Knocking coming from crankshaft Check main journals for clearance and ovalty.tight- |- YES Be} ness of main bearing cap bolts and flywheel bolts, oil pressure, Replace parts or overhaul the engine ; - - NO Knocking coming from connecting rods ‘Check crankpins for clearance and ovat tightness of | yes pe! connecting rod cap boks. connecting rods for distor ‘ion. Replace parts or overhaul the engine ; _ - No Knocking coming from pistons Check clearance between pistons and eyinder ners | ves -be|_ piston rings for breaks, gudgeon pin to piston boss dearances Replace parts or overhaul the engine = - - No Knocking coming from cyinder head Check operating clearance between rocker arms and LES pel sakes injection pump timing vave timing, Adjust — - No _ on Knocking coming rom timing gears (Check gears and replace if necessary | YES > 8001 Engine p. 19 Knocking coming rom injectors Check and adjust as desrbes ves 8 | ENGINE STOPS Fuel in tank Replenish and bleed ifnecessary. NOP L ' - ves Fuel fiters serviceable Replace + NOP] ; _| ves Engine brake engaing Check and replace if necessary | Nob ; - zl a Fuel circuit serviceable ‘Check circuit and bleed T ¥ Idling speed correct Adjust “| L No 8001 Engine p. 20, (Check delivery on bench Injector pump delivery correct Ff NOP - 1 — - YES Injector pump controls serviceable Replace parts showing deterioration and adjust F NO-| 9 | ENGINE EXCEEDS MAXIMUM RPM Speed governor operating correctly fF NOP ‘Check and replace worn parts if necessary OIL PRESSURE TOO LOW OR TOO HIGH Pressure relief valve operating T YES y + NOB (Check and replace ifnecessary Oil pump and delivery pipes serviceable | NO ‘Check and replace ifnecessary T Yes __¥ Main and big end bearings serviceable | NOB} Replace bearings and if necessary recandition crank shaft 8001 Engine p. 21 Engine oil viscosity correct NOP} Replace engine oll wth one of suitable viscosity Ar filter serviceable 11) EXCESSIVE FUEL CONSUMPTION | Fuet tank and pipes serviceable Eliminate any leaks and replace parts showing No-b| deterioration \ 7 I T YES No] [ Replace T YES : —yv Injector adjustment correct Check operation and adjust as described. No» ; _ ves [ jector pup adjustment correct Check and adjust on test bench no T YES y LIDA device serviceable NOP} ‘Adjust the LDA. device using tool 99309002 T YES v Injection pump tining correct No Check static setting of injection pump 8001 Engine p. 22 DISMANTLING OF THE GENSET Remove al1 the external conponents of the genset Radiator Guards Air cleaner Electric machine Pipes for air/water Electric wiring Injection pump Flywhee! housing Heat exchangers Oi1/fuel filters Intake and exhaust. manifolds Fan Turbocharger ‘in order to fit the engine to the swivelling stand and to performe the overhaul 1 Electric wiring (1) 1 Electric machine (2) © Air cleaner (3) © Pipe for radiator (4) 0 Guard for fan and alternator (5) Radiator (6) 1 Engine (8) ENGINE BENCH DISASSEMBLY ‘Take off the fan mounting (I), rernove the crankshaft pulley (2) ‘and the damper ywheel (3), and ne water pump drive pulley (5), Remove the alternator () and its bracket, remove the pipe (2) running from the water pump tothe radiator. Detach the com- pressor lubricating cil delivery and return pipes (3,4), Remove the thermostat (6) Remove the water pump (3). Straighten the locking plate (1) ‘on the hub and unscrew the nut (2). 8001 Remove the hub (I) for the damper flywheel using tool 99340033 (3) Remove the injectors (1) and the rocker shaft assembly. Engine p. 23 Recover the pushrods (I) and the caps (2) from the valve stems. ‘Unscrew the bolts (3) securing the cylinder head (4) and re: rove the head, recovering the gasket. Remove the oi suction (I) and delivery (2) pipesand the tim- ing gear cover (3). Engine p. 24 Remove the big end caps, recover the bearing shells and then ‘withdraw the pistan-connecting rad assemblies (I) from the top of the crankcase Unscrew the botts (1) for the main beating caps (2) and re- move the caps Unscrew the flywheel attachment botts (1), remove the tool 99360352 (2) and remove the flywheel. 8001 Lift and dismount the crankshaft (2) by means of tool 99360500 (1); keep the main bearing shells and the shoulder semi-rings of the crankcase. Loosen the locking screws () ofthe colar plate and pull out the camshaft. Pllthe valve liters out oftheir seats and dismount the ‘oll spring nozzles. Remove the bracket (3) ofthe transmission gear wheel and the control housing (2) SST ‘Clean carehily ll dismounted parts and check ther in- tegity after cismounting of the engine. (Onthe following pages instructions for the main checks ‘and measurings are given wich have to be carried out to determine whether the parts can be used again for ‘mounting, A REPAIRS CYLINDER BLOCK CONTROLS AND MEASURE- | MENT ‘Because of ts ductilty the cylinder liner must never be measured inside when dismounted: the inner diameter must be measured at completely mounted liner Inorderto determine the value ofthe out-of-round, ofthe con ‘cal form and of the wear the inner diameter of the liners is, checked by means of gauge 99395687 (2) provided with centi incicating caliper (1) that has been previously calibrated ata ring gauge (3) with a diameter of 104 mm. faring gauge with a diameter of 104 mm is not aval able, use a slide gauge. Se 8001 By Ss SSNS SNE SSS SS om) PLAN FOR CHECKING CYLINDER LINER. DIAMETER, ‘The measurements must be carried out for each individual ¢yl- inder at three different levels in the liner and in two planes at right angles to each other, one parallel to the lengthwise axis (A)and the otherat right anglesto it(8). Maximum wearisgen- erally found in ths plane (B) and in line with the first measure: ‘ment. Ifovalty or taper or wear of any kind is found, it may be eliminated at overhaul by grinding the liners ifthe wear or scor- ingis ight, orby reboring and then grinding fthere is deep scor- ing or marked ovality, eee Where reconditioning is carried out, all liners rust be finished to the same oversize (0.4 08 mm). PLAN OF CHAMFER TO BE APPLIED TO CYLINDER LINERS AFTER RECONDITIONING |.Crankease 2. Cylinder liner Engine p. 26 REPLACING CYLINDER LINERS. Removal and installation of the eylinder black liners is carried ‘out using a hydraulic press and the appropriate adaptor plate, ‘oinstallthe cylinderlinersinthe cylinder blockby usingapress, the following steps have to be carried out Measure to ensure cylinder liner outer diameter is, 106970 - 106940 mm and the cylinder block bore iameter is 106.850 ~ 108 900 mm: Cl Insert cylinder liner into the cylinder block and test, after pressing-in 70-90 mm the load must be nat less than 5000 N and not more than 23.000 N; Continue pressing in and test, 30 mm before finishing, ‘the load must be between 102000 and 40.000 N; ‘When pressing in is completed, wait 5° with a load of 50.000 or mare to ensure liner is fully home; Strike blow with a hammer to ensure the liner is fush with the cylinder block, lf the fitting load is not within the specific figures, extract the liner and install a new one in its place. Aiter they have been fitted, yinderliners must be reamed and ‘ground. (NOTE: 10.000 N = | Tonne) Cylinder liners are supplied with an inner diameter slightly below nominal diameter to allow for any deformation which ‘occurs during fitting to be corrected Replacement cylinder liners are also supplied with the outside diameter 0.2 mm oversize. 8001 Engine p.27 ‘Check the condition of the machining plugs (|) in the cylinder block, ifthey are rusted or there isthe least suspicion of leak age, replace them, ‘Check that the cylinder head mating surface (3) are flat using a calibrate cule (2) and 2 feeler gauge (I). Grind any rough spats removing as litle material as possible after removing the locating dowels ‘After grinding the ¢ylinder head surface, restore the proptru: sion of the cylinder liner border support base to 0.64 0.97 Using the tool (I), remove the locating dowel (2) fromthe mat- ing surface (3) of the cylinder: Extract the locating dowel only ifthe mating surface requires skimming FUR Go ES ENOTES 8001 CAMSHAFT oa70 51.000 Engine p. 28 0.070 S000 [e—oe MAIN DATA FOR THE CAMSHAFT ‘The surfaces of the shaft bearing journals and thase of the ‘cams must be absolutely smooth; CHECKING CAM LIFT AND. JOURNAL ALIGNMENT Aall|e=t ifthey show traces of seizing and scoring, the shaft and associated bushes must be replaced. FIGURE 54 Acrange the camshaft (4) between the cenres (I) and using the hundrecths dal gauge (2) check the it ofthe eas (3) which should be: ($97 mm for the niet cam 1625 mm for the exhaust cam fam] Still withthe camshaft (4) arranged between centres (I),check the alignment ofthe support journals (3) using the huncredths dal gauge; this must not be more than 0020 mm. Ifa larger misalignment is found, replace the shaft To check the assembly clearance, measure the inside ciame- ters ofthe bushes (fg. 57) and the diameter ofthe journals (I, ‘ig. 54) of the camshaft; the difference will give you the actual clearance. fclearances of more than 0.160 mm are found, e- place the bushes and the shaft too, if necessary REPLACING THE CAMSHAFT GEAR (a) ‘Check that the teeth of the camshaft gear (1) are not exces- sively damaged or worn: if they are, replace it. When fting the new gear, it should be heated in an oven for 10' zt atemn- | perature of 180° and then shrunk onto the shaft having frst fitted the plate (3) and key (2) to the shaft 8001 Engine p.29 BUSHES “The surfaces of the bushes must nat show any signs of seizing (scoring; if they do, replace them. enter iets ein| core (JU - | Hee |e Gey |. MAIN DATA FOR CAMSHAFT BUSHES AND THEIR HOUSINGS IN THE CRANKCASE © Dimension to be obtained after the bushes have been installed REPLACING THE BUSHES FIGURE 57 | | = Before replacing the bushes (|), measure the bush diameters Using a bore micrometer (2) When fing the buses (I) rake sre that the To remove and refit the camshaft bushes, use a suitable drift. : { holes (2) are lined up with the cil feed holes in the crankcase. 8001 Engine p. 30 cm) ‘After fiting ream the camshaft bushes using the arbor (I) fitted ‘with the pilotbushes (2) and cutter (3) so thatthe specified val- ves are obtained, TAPPETS Replacement tappets are supplied in standard size and 0,10, (0.20 and 0.30 mm oversizes, REPLACING TAPPETS Replacing the tappets because of excessive playin the housings involves fiting oversize tappets and reaming out the seatings using an appropriate reamer (I). aus 15000 | W018 SSNS \ \ 010mm (total racing on the dal gauge) es <= ramyournat Alignment of the crankpins with the main journals: the ccentreline ofeach pair of crankpins and the centretine of ‘the main journals must be in the same plane : the maxi mum tolerance permitted at right angles to this plane is £025 mm Forthe distance between the axis of rotation of the shaft ‘and the outer surface of the crankpins the maximum tol- france permitted is + 0.10. mm a REPLACING CAMSHAFT AND OIL PUMP DRIVE GEARS ‘Check that the teeth of the gears (I, 2) are not damaged or ‘worn, f they are, remove them using a suitable extractor (3) ‘hea fitting new gears (1,2), they must be heated in an oven. for 10’ to a temperature of 180° and shrunk on to the crank- shaft having frst fitted the key. 8001 MOUNTING MAIN BEARING Replacement main bearings are supplied in inside diameter un. dersizes, Do not carry out fitting operations on the bearings eR ETE Position the bearing shells (1) in the main bearing housings in the crankcase am Lift the crankshaft (2) using tool 99360500 (1) and carefully place it on the bearing shells in the housings. Engine p.34 MEASURING MAIN BEARING ASSEMBLY CLEARANCES i ai st = =fole v 3 - —} - 4 ) ote : oH TS The clearance between the crankshaft journals and the rele- vvant bearings is checked by the plastigage method, proceeding as follows a ‘thoroughly clean the parts and remove all traces of ol o arrange 2 strip of plastigage (6) on the main journals (4), parallel with the lengthwise axis a fit the caps (1) together with the bearing shel to the relevant housings a fit the cap securing botts and tighten them to the prescribed torque using a torque wrench: the bolts must be lubricated with oil beforehand remove the caps from the housings and determine the clearance between the bearing shells and the crankshaft main journals by ‘comparing the with of the plastigage at the point of greatest flattening with the scale divisions given on the package (3) containing the plastigage ‘Checking crankshaft end float The normal assembly clearance is 0.082 —0.334 mm. Ifalarger tend float is found, replace the thrust washer halves with new ones of standard thickness orf necessary an oversize of 0127, 0254, 0508 mm, 8001 Engine p.35 | SA “The bolts must be lubricated. | Fit the cial gauge (1) with magnetic base and check end float Using a torque wrench (I). tighten the securing botts (2) to a torque of 80 Nm 8001 ‘CRANKSHAFT REAR COVER ‘The oil sea! (2) is fitted to the cover (I) using the appropriate instaling tool (3) Fit the rear cover (1) to the crankcase, having frst fitted the gasket. FLYWHEEL Check the surface on which the clutch plate bears: if itis scored, skimming will be required REPLACING THE FLYWHEEL RING GEAR Ifthe teeth ofthe gear fittedto the fywheel are badly damaged, replace the ring gear. Before fiting, the gear must be heated to a temperature of 80°C. Engine p. 36 Fitting the flywheel Se SRR The bolts may be re-used provided that the @ of the thread is not less than 11.5 mm. Fit the flywheel (I), fit too! 99360352 (2) and, using a torque wrench, tighten the bolts (3) previously coated with LOCTITE HVX 576 to a torque of 40 Nm, Fittool 9939521 6(1) and further tighten the screws (2) by 60°, Remove the flywheel locking tool (3) CONNECTING ROD/PISTON ASSEMBLY =a COMPONENT PARTS OF THE CONNECTING ROD/PISTON ASSEMBLY |LRetaining clips 2Gudgeon pin Piston 4.Piston rings SBolt ” 6Bearing shells 7Connecting rod BBush 8001 Engine p. 37 Remove the piston rings (1) from the piston (2) using tongs 99360183 (3) “The gudgeon pin (1) retaining clips (2) are removed using 2 seriber (3) as shown in the figure. PISTON Replacement pistons are supplied in standard size or 04, 08 mm oversizes Measuring the piston diameter The diameter ofthe piston (|) is measured using a micrometer | The diameter must be measured 12 mm from the base of the skirt. “The clearance between the piston and cylinder liner can also be measured using a feeler gauge (I) GUDGEON PIN “The pins are fitted with clearance both in the small end and in the piston. am “The diameter of the pin (I)is measured usinga micrometer (2) (2) to determine the assembly clearance. 8001 ions for a correct gudgeon pin to piston fit ‘When fitting new pins, check the correct fit with the housing in the piston by carrying out the following check: 1 _ lubricate the pin and its housing in the piston bosses with engine oll holding the pin in a vertical postion, insert it into the bosses in the piston it should be possible to insert the pin simply by pressing oO onit the pin should not drop out of the bosses by itself a PISTON Engine p. 38 PISTON RINGS Replacement piston rings are supplied in standard size and O4, 08 mm oversize, 8 &) CCheck the thickness of the piston ring 2) using a micrometer (I). = MAIN DATA FOR THE PISTON, PISTON RINGS AND GUDGEON PIN * The dimension is measured on a @ 101 mm, 8001 Engine p. 39 Check the clearance between the piston rings (3) and the grooves on the piston (2) using 2 feeler gauge (1) NY fe] ‘The compression ring 2) inthe first slot is wedge shaped. The clearance between the compression ring and the groove measured by postioning the piston (I) with the relevant ring inthe eyinderiner (3) such away that the compression ring half projects Fom the cinder ine: “The clearance between the ends of the piston rings (1) in- serted into the cylinder ner (3) is measured using a feeler gauge (2). Ifthe gap between the ends is found to be less or more than the specified value, replace the piston rings, CONNECTING RODS MAIN DATA FOR THE CONNECTING ROD, BUSH, ‘GUDGEON PIN AND BEARING SHELLS * Dimension to.be obtained ater installing the bush 8001 Engine p.40 . Checking connecting rods for distortion ‘Check that the connecting rod axes are parallel. The tolerance permitted is 0.07 mm measured at 125 mm from the length- wise axis of the rod, Each connecting rod is marked on the body and cap ‘with a number corresponding to that of the cylinder towhich itis fitted, Incase ofreplacement, itisthere- fore necessary to number the new connecting rod with the same number as the one replaced, BUSHES Ey The bush (2) removed andreftted using the aporoprite dit “0 ‘After instaling the bush in the connecting rod small tend, remove the part which protrudes atthe side and ‘then ream the bush to the specified diameter Reaming the small end bush using reaming machine 99301044, ASSEMBLING THE CONNECTING ROD/| PISTON ASSEMBLY Assembling connecting rod to piston ‘The piston (2) must be fitted so that the words TAP- PET SIDE (|) on the crown are on the opposite side to the number (4) engraved on the connecting rod. Insert the gudgeon pin (3) and fit the retainer snap rings Checking connecting rodipiston for distortion ‘Check the connecting rod-piston assembly for distortion using fixture 99395363 (|) and a feeler gauge (2), The plane of the Piston crown must be exactly at right angles to the plane ofthe fixture 99395363. 8001 Engine p.41 Fitting piston rings ial “The piston rings (1) are fitted tothe pistons (2) using tongs 99360183 (3). Therings rus be ftted with the word TOP fac Ingupwards and als the ring gape mustbe locatedsothatthey are [20° apart from each other aa] Fit the bearing sels (1) tothe connecting rod and tothe cap. Do not carry out any fitting operations on the bearing shells “The connecting rod bolts may be reused provided ‘that the @ of the thread measured between 19 and 35mm fromthe beginning of the screw isnotlessthan 10.5 mm. a PLAN FOR ASSEMBLING THE CONNECTING ROD TO THE P'S: “TON FOR FITTING THE ASSEMBLY INTO THE CYLINDER L.Pston 2.Combuston chirnber 3Area stamped with the rurber of the olinder to which the connecting rod belongs 4 Camshaft “The arrow indicates the direction of rotation of the engine Viewed from the camshaft drive end, “The connecting rod/piston assembly (I) i fitted into the cylin- der liner using ing clamp 99360605 (2) Lubricate the parts concerned before fitting ‘When fitting the connecting radipiston assemblies into the liners, check that: the connecting rod number corresponds to the ‘umber of ts cylinder the words TAPPET SIDE stamped on the crown are facing the camshaft 1 the numbers an the connecting rods are facing away from the camshaft side © the piston ring gaps are staggered 120° from each other | ganeSeTSESLSNT SELSIOSTEEESS 8001 Engine p. 42 MEASURING CRANKPIN ASSEMBLY CLEARANCE To measure the clearance, carry out the following operations Gi thoroughly clean the parts and remove all traces of oil Position a strip of plastigage (2) on the crankshaft journals OW) ft the connecting rod cap (3) and tighten the bots to the 1 prescribed torque: the bolts must be lubricated remove the cap (3) and determine the clearance by G comparing the width of the plastigage (2) at the point of greatest flattening with the scale divisions given on the package (3) containing the plastigage Lubricate the parts concerned before final assembly. Before re-using the connecting rod cap securing bolts, ‘check that the diameter ofthe thread measured at 19. ~ 35 mm from the beginning of the screw is not less than 105 mm; ifitis, replace the bolt Fitting connecting rod caps Fit the connecting rod caps (2) and, using a torque wrench (1), tighten the bolts (3) toa torque of 40. Nm: the bolts must be lubricated beforehand, Fit tcol 993952116 (1) to the dial wrench and tighten the boks (2) further by 60°. Check that the connecting rods can be moved axially on the crankpins, (am ‘Whe fiting is complete, check the position ofthe pistons (4) at TEC with respectto the cylinder blackface using a cial gauge 2) with magnetic base (3), The top lands of the pistons must project 0.64 — 0.97 mm above the face of the cylinder block (1) TIMING GEARS CHECKING AND REPLACING THE IDLER GEAR Check the idler gear for damage and excessive tooth wear re placing it if necessary. 8001 REPLACING THE IDLER GEAR BUSH Check the contact surfaces ofthe buh (1) for scoring or signs of seizing, ifthese are found, replace the bush using 2 suitable drift. 42.035" 42.060 0.20.55, 182 =a After fiting the bush (1), it must be reamed to the dameter shown in the figure (*). Engine p. 43 TIMING CONTROL ‘The timing check is carried out as follows: © provisionally set the play between the valves and rockers at 0,80 mm and check with a graduated sector that the advance and retard angles for intake and exhaust correspond to those indicated in the page 1 for engine 8061Si..; and page 2 for engine 8061SRi Install the idler gear (2), locating it so that the numbers 1,2 and 3 marked onit ine up with the samie numbers engraved onthe crankshaft gear (I), the camshaft gear (3) and the injection pump gear (4). 8001 CYLINDER HEAD Hydraulic leak test Before cismanting the cylinder head, carry out the hydraulic leak test using the appropriate equipment (|, 3). By means of| ‘the coupling (3), pump in water heated to approx. 90°, to a pressure of 4-5 bars. Under these conditions, no leaks should bbe found, and if they are, the cylinder head (2) should be re placed DISMANTLING THE VALVES Rest the cylinder head on the workbench and, using tool 99360357 (|), apply pressure to the upper spring cup Engine p.44 (6.fg, 121) so that the vale collets (4) can be extracted and the valve released: take off the upper cup (6), the spring (3) and the lower cup (5). Repeat the operation on all the valves “Turn the cylinder head upside dawn and withdraw the valves. FIGURE 121 COMPONENT PARTS OF THE VALVE ASSEMBLY L.Exhaust valve inlet valve 3Spring 4,Collets Slower cups Upper cups Checking the mating surface of the head with the cylinder block The mating surface of the head with the cylinder block is checked using a straignt edge and a feeler gauge. IFvalues of ‘more than 0.15 mm are found aver the whole length ofthe sur- face, tue up the head on a suitable surface grinder removing, as litle materia as possible. UNSERE EE After this operation, the recessing ofthe valves and protrusion of the injectors should be checked. 8001 Engine p.45 VALVES Removal of deposits and inspection of valves Remove carbon deposits from the valves using a suitable wire brush (Check the valves for signs of seizing or cracking and also, using ‘amicrometer,check that the diameter ofthe valve stems with- | in the specified mits (see fig 124). IF not replace the valves. FIGURE 124 Sau, EXHAUST ae MAIN DATA FOR VALVES AND VALVE GUIDES * Dimension to be obtained after instaling the valve guides Refacing the valves Irnecessary.reface the seatings on the valves using grinding ma- chine 99301014, setting an angle of 455 30°" 7' for exhaust valves and 605 30°" 7'forinlet valves, removingaslitie material as possible Checking the play between a valve stem and its valve guide Using a dial gauge (2) with magnetic base (1), check the play between the valve stem (3) and its guide. If excessive play is found, replace the valve and, if necessary. the valve guide. VALVE GUIDES The valve guides are removed and fitted using drifts 99360288 and 99360293. Replacement valve guides are also supplied with the outside diameter 0.2 mm oversize. 8001 MAX 2 az VALUES FOR INSTALLING VALVE GUIDES Reaming the internal surfaces of valve guides ‘After instaling the valve guides, ream the hole inthe valve guide (2) using reaming too! 99390310 (1), Engine p.46 Recutting the valve seats Using the Hunger too! 99360419 (1), recut the valve seats in the cylinder head so as to obtain perfect sealing, ‘The valve seatsin the cylinder head are recut whienev- ter the valves or valve guides are reconditioned or re- placed EEE ANNI exnaust INET a O7+1_w RECESSING ase_| REFERENCE REFERENCE @ MAIN DATA ON THE INLET AND EXHAUST ‘VALVE SEATINGS. eed When assembling after the recutting operations, check that the recessing of the inlet and exhaust valves with respect to the cylinder head face is 07 — Timm, 8001 Engine p. 47 Valve leakage test = “Theleakage teston the valvesin the cylinderhead (1) iscasied cut using the appropriate equipment (2 and 3) VALVE SPRINGS Before fitting, the characteristics of the valve springs must be checked using too! 99305049, and the data on load and elastic ‘deformation compared with those given for new springs in the following figure i N270 #14 4 N 526 #26 446. i 24 MAIN DATA FOR CHECKING THE VALVE SPRINGS Refitting the valves “To fit reverse the order of the operations carried out for re moval as described, Lubricate the valve stems with engine cil, Fitting the cylinder head Before re-using the cylinder head bolts (2), with a micrometer (1) measure that the thread diameter of the bots i not less than 11.5 mm at ary point; ifitis, replace them. 8001 To fit and tighten down the cylinder head, follow the instruc tions given below “arrange the gasket (1) on the crankcase with the word ALTO [TOP] (2) facing the operator FIGURE 137 (eas) PLAN SHOWING CYLINDER HEAD BOLT TIGHTENING SEQUENCE 1D fitthe cylinderhead (2), insertthe bot (3) after lubricating ‘them and tighten them as follows in the sequence shown in figure 137, stage |: using a torque wrench (I), tighten tothe prelimi nary torque of 70 Nm stage 2 :retighten to the torque of 70 Nm Engine p. 48 1 stage 3: ft t001 99395216 (1) to the angle gauge wrench and tighten by an angle of 180° PUSH RODS S © =a The wv pshodsmsthe Fe emdstarton the cise iebricchommmenautuaaueedte te aaj eentiay aaron ea aa aise aelenaee ae eno oe faehardargabe Fit the pushrods (I) into their seatings, 8001 Engine p.49 PUSH RODS ROCKER SHAFT COMPONENT PARTS OF THE ROCKER SHAFT I.Girelip 2Adjustment shims 3Rockers 4Pedestal for shaft SSpring 6Shaft =a MAIN DATA FOR ROCKER SHAFT PEDESTALS, ROCKER SHAFT AND ROCKERS itting the rocker shaft and adjusting the operat ig clearance between the valves and rockers Check that the contact surfaces ae free from scoring or signs of seizing, if not, replace the parts showing deterioration. ‘Check the clearance between the valve gear rockers and the rocker shaft and between the pedestals and rocker shaft which shouldbe 0016-0052and 0~0.061 mmrespectivey, replace any parts giving rise to clearances larger than those specified, Check that the plugs fitted to the ends of the shaft provide a | Fit the caps (1) onto the valve stems. 8001 Engine p. 50 Fit the rocker shaft assembly (1) ‘Adjust the operating clearance between the valves androckers as described below. Theclearancebetweenthe rockersand ves s adjusted sng wrench 99380108 (2), a bichexagon wench (1) an a fel ge (3). The operating clearance ¢025:2 008mm forboth ilet and exhaust subsequent adusments are cared Out wena valve outside the range 015-04 mis found, Mowe thecylner on which the clearance sto be ajusted to thet ing poston the vas of this cynder are closed whe those athe symmetrical cylinder are rochng, Symetiaeynders are land 6 2 and 9 and 3 and 4 ey To speed up adjustmentofthe rocker to valve operat- ing clearances, proceed as follows rotate the crankshaft until the valves of no. | cylinder are rocking and adjust the valves marked with an as- terisleas shown in the table gfinderno 123 cama inlet anand “ @haust rotate the crankshaft until the valves of no, 6 cylinder are rocking and adjust the vaives marked with an as- terisk as shown inthe table cfinderno 1234 LUBRICATION Engine lubrication is obtained by means of a gear type pump (ig, 147) fitted to the lower part ofthe crankcase inline with the front main bearing: itis driven by the crankshaft gear OIL PUMP FIGURE 147 OIL PUMP ASSEMBLY LPump body 2Reliefvalve 3.Driven gear 8001 Engine p. 51 FIGURE 148 COMPONENT PARTS OF THE OIL PUMP ASSEMBLY. I screw 2Washer 3Locating dowel 4Bush 5.0il pump gear 6Locating dowel 7.Driven gear operating the ol pump Deed 9NaWe body 1OSprng, lINave 12Screw 13Washer I4.Attchment plate 15,0 pump body 165ush 17.01 pump gear 18.Bush 19.Spindie 20.0 pump cover Chels ry Check tat he gears 517 148) andgearwhel (show ro signs of wear or seizing: if they do, replace the complete pump. Check that the vale (I fig, 148) sides freely nits housing and shows no signs of seizing or scoring, also check the setting data for the relief spring (10) compared with those given in figure 151 Valve starts to open: 6 bars, valve finishes opening : |! bars: =a) SECTIONAL VIEW OF OIL PUMP FIGURE 151 ness Era) 7 __245,70N ZA Gs =a =a MAIN DATA FOR CHECKING THE SECTIONAL VIEW OF Ol. PRESSURE RELIEF VALVE ale VALVE SPRING 8001 OIL FILTER ‘Two double fitration fiters are fitted to the engine. Opening pressure for the fiter valve :2.5 -& 02 bars, AAA eo i 1G “| LOW We LN W727 oc er] Zo5 eee | SECTIONAL VIEW OF THE OIL FILTER a RESO ‘When fitting the fiters, observe the following instruc tions ~ oilthe seals ~ screw the fiters up until the seals contact the seating bases ~ tighten further for another 3/4 of a turn | Fitting the oil pump Fit the ol pump 2), the suction (1) and delvery @) pipes Engine p. 52 COOLING | WATER PUMP | ‘The water pump is ofthe centrifugal impeller type. The pump | bearings integral with the rotor spindle Water sealing between the pump body (4, fig. 154) and the spindle (2) is obtained by means of a seal (5). The screw (3, fig. 154) retaining the bearing must be locked in its housing using LOCTITE 242 sealant. FIGURE 154 ee SECTIONAL VIEW OF WATER PUMP: Hub 2Spincle with bearing 3Screw 4.Pump body SSeal Cover 7Rotor ‘Check that the pump body has no cracks or water leaks; iit has, replace the water pump complete 8001 MOUNTING OF THE INJECTION PUMP AND TIMING (FOR ENGINES WITH ROTARY INJECTION PUMP) Fit the injection pump, proceeding 2s follows : check that the timing gears are set correctly 5 install the injection pur (1): lining up the double recess inside the drive coupling with the double dog in the sleeve D_ screw up the screws without tightening ther fully screw on tool 99395099 (2) complete with the hun- dredths dial gauge (1) with the stylus in contact with the crown of the contro! piston apply 3 mm preload to the dial gauge turn the engine backwards until the control piston on. ‘the pump reaches BDC as indicated by the dial gauge zero the dial gauge oo Engine p. 53 remove the plug (I) on the pump closure screw © turn the engine forwards and bring the.8” 30° mark (2) raved on te fywheelndcainginjecton avance'into | fine withthe reference pointer (1) 1D under these conxitions, the control piston of the pump should have traveled Irom, the value being read off from the cal gauge Ifthisisnot the case, rotate the jump body ns dotted hole until the spctied values ob- tained filly tighten the pump securing screws 12 remove tool 99395099 and screw the plug back into the closure screw. 8001 MOUNTING OF THE INJECTION PUMP AND TIMING (FOR ENGINES WITH ROTARY INJECTION PUMP) Fit the injection pump, proceeding as follows check that the timing gears are set correctly C__installthe injection pump (1), ning up the double recess inside the drive coupling with the double dog in the sleeve 3 screw-up the screws without tightening ther fully 1D screw on tool 99395099 (2) complete with the hun-

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