FOREWORD
Thi s
wor kshop
manual
cont ai ns
r epai r
i nst r uct i ons
f or
t he 2001,
2002
and
2003
engi nes
.
The
i nst r uct i ons
concer ni ng over haul i ng
descr i be
t he
most
sui t abl e
wor ki ng
met hod
usi ng
t he
speci al
t ool s
l i st ed
under
t he
headi ng
" Speci al
t ool s"
.
Bot h t he
engi ne
desi gnat i on
and
i t s
ser i al
number
must
be
cl ear l y
st at ed
i n
al l
cor r espondence
concer ni ng
t he
engi ne
and
when
or der i ng
par t s
.
We
r eser ve
t he
r i ght
t o
car r y
out
desi gn
modi f i cat i ons
and,
f or
t hi s
r eason,
t he
cont ent s
of
t hi s
manual cannot
be
r egar ded
as
bi ndi ng
.
SI
UNI T
SYSTEM
Power
i s
gi ven
i n
kW
( ki l owat t )
Speed
i s
gi ven
i n
r ev/ s
( r evol ut i ons
per
second)
ear l i er uni t
hp
( hor se- power )
ear l i er
uni t
r ev/ mi n
( r evol ut i ons
per
mi nut e)
Tor que
i s
gi ven
i n
Nm
( newt on
met r e)
Vol ume
i s
gi ven
i n
dm
3
( cubi c
deci met r e)
ear l i er uni t
kpm
( ki l opond
met r e)
ear l i er
uni t
l
( l i t r e)
ear l i er uni t
l bf
f t ( poundf oot )
ear l i er uni t
I mp
. gal ( I mper i al gal l on)
ear l i er
uni t
US
gal
( Uni t ed
St at es
gal l on)
Pr essur e
i s
gi ven
i n
Pa
( Pascal )
ear l i er
uni t
kp/ cm
2
( ki l oponds
per
squar e
cent i met r e)
ear l i er
uni t
I bf / i n
2
( pounds
per
squar e
i nch)
AB
VOLVO
PENTA
Techni cal
Publ i cat i ons
Depar t ment
Uni t s
accor di ng
t o
t he
i nt er nat i onal
SI
syst em
have been
used
i n
t hi s
book
.
The
ear l i er
uni t s
ar e
gi ven
af t er
t he
SI
uni t s
.
ProCarManuals.com
Component s
gui de
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2
DI SASSEMBLY
Cyl i nder
head
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3
Tr ansmi ssi on
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4
Pi st on,
pi st on
r ods
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5
Fl ywheel
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5
Cr ankshaf t
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5
Camshaf t
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5
OVERHAUL
Di sassembl i ng
t he
cyl i nder
head
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7
Val ve
gui des
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7
Val ve
seat s
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7
Val ves
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7
Val ve
spr i ngs
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8
Rocker
ar m
mechani sm
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8
I nj ect or
sl eeve
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8
I nj ect or s
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8
Assembl i ng
t he
cyl i nder
head
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9
Feed- pump
.
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10
Pi st ons
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11
Cr ankshaf t
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11
Camshaf t
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11
Connect i ng
r ods
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. 12
Ther most at
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13
Sea- wat er
pump
.
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13
ASSEMBLY
I NDEX
Cr ankshaf t
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14
Pi st ons
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14
Fl ywheel
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:
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15
Tr ansmi ssi on
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15
Adj ust i ng t he
val ve
cl ear ance
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17
Checki ng
t he
i nj ect i on
angl e
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17
2003
Tur bo
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21
Fr esh
wat er
cool i ng
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.
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25
El ect r i cal
syst em
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26
Faul t t r aci ng
scheme
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.
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28
Speci al
t ool s
.
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29
Techni cal
Dat a
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30
ProCarManuals.com
COMPONENTS
GUI DE
8
1
.
Exhaust
el bow
2
.
I nj ect or s
3
.
Temper at ur e
sender
4
.
El ect r i cal
di st r i but i on
box
5
.
Fuel
f i l t er
6
.
Al t er nat or
7
.
St ar t er
mot or
8
.
Dr ai nage,
cool i ng
wat er
9
.
Feed- pump
10
.
Engi ne
ser i al
number
11
.
Decompr essi on
devi ce
12
.
I nl et
ai r
si l encer
13
.
Fuel
i nj ect i on
pumps
14
.
Oi l
di pst i ck
15
.
Sea- wat er
pump
ProCarManuals.com
Dr ai n
of f
t he
cool i ng
wat er
and
t he
l ubr i cat i ng
oi l
f r om
t he
on
engi ne
cr adl e
p/ n
9992520
and
f i xt ur e
p/ n
884837
.
I f
t he
engi ne
i s
f r esh
wat er
cool ed,
see
page
21
.
1
.
Remove
t he
al t er nat or ,
t he
t ensi oner
br acket
and
t he
st ar t er
mot or
.
Remove
t he
connect i ons
f r om
t he
el ect r i cal
di st r i but i on
box
f r om
t he
engi ne
and
r emove
t he
box
and
t he
wi r e
har ness
.
2
.
Remove
t he
r et ur n
f uel
l i ne,
t he
f uel
pr essur e
l i nes
and
t he
i nl et
ai r
si l encer
.
I nst al l
pr ot ect i on
caps on
t he
f uel
i nj ect i on
pumps
and
i nj ect or s
.
Remove
t he
scr ew
hol di ng
t he l ever
of
t he
decompr essi on
devi ce
( 1)
and
pul l
out
t he
l ever
.
Remove
t he
val ve cover
.
DI SASSEMBLY
3
.
Remove
t he
f uel
f i l t er ,
t he
oi l
f i l t er ,
t he
f eed- pump,
t he
t her most at
housi ng
and
t he
exhaust
el bow
.
Al so
r emove
t he
sea- wat er
pump
wi t h
i t s
at t achment
t ubes
.
4
.
Remove
t he
val ve
br i dge
and
l i f t
out
t he
push
r ods
.
Remove
t he
r ubber
r i ngs
f or t heoi l
pi pe
.
Remove
t he
cyl i nder
head
and
t he
val ve
l i f t er s
.
Put t he
l i f t er s
on
a
r ack
i n
consecut i ve
or der , NOTE!Thecyl i nder
head
bol t sar e
phosphat i sed
andmustnot becl eanedwi t ha
st eel
br ush.
ProCarManuals.com
5
.
Remove
t he
f uel
i nj ect i on
pumps
.
Mar k
t he
pumps
t o
ensur e
i nst al l at i on
i n
t he
same
cyl i nder s
f r omwhi ch
t hey
wer e
r emoved
.
Take
car e
of
t he
shi ms
.
Remove
t he
scr ews
on
t he
si de of
t he
engi ne
bl ock
and
l i f t
out t he
pump
l i f t er s
.
6.
Remove
t he
pul l ey
cent er
bol t
and
pul l
of f
t he
pul l ey
usi ng
pul l er
p/ n
9992265
.
Pl ace
a
pr ot ect i on
pad bet ween
t he
pul l er
and
t he
cr ankshaf t
t o
avoi d
t he
cr ankshaf t
bei ng
damaged
.
7
.
Remove
t he
t r ansmi ssi on
cover
:
St ar t
by
r emovi ng
t he
t hr ot t l e
cont r ol
cover
.
Use a
sui t abl e
t ype
of
pl i er s
t o
r emove
t he
spr i ng
( 1)
.
Then
r emove
t he
end- ni ppl e
( 2)
and
t he spr i ng
( 3)
.
Remove
t he
oi l
pump
cover
and
mar k
t he
gear
wheel s
wi t h
a
col our - pen
bef or e
r emovi ng
t hem
.
( When
i nst al l i ng
t he
gear
wheel s,
t he
mar ked
si de
must
be
f aci ng
out war ds)
.
Remove
t he
br aci ng
pi n
of
t he
camshaf t
usi ng
t he
speci al
t ool
p/ n
884839
.
Never
r emove
t he
br aci ng
pi n
by
punchi ng
i t
out ,
t hi s
can
ver y
wel l
bend
t he
camshaf t
.
Remove
t he
scr ews
on
t he
t r ansmi ssi on
cover
and
pul l
i t
st r ai ght
out war ds
.
8
.
The
max
. - vol ume- scr ew
( 1)
and
t he
max
. - r ev- scr ew
( 2)
ar e
set
by
Vol vo
Pent a
and
must
never
be
changed
si nce
t hi s
wi l l
af f ect
t he
engi ne out put
.
9
.
Remove
t he
cont r ol
r od
.
St ar t
by
r emovi ng
t he
pl ug
at
t he
r ear of
t he
bl ock
and
t het wo
scr ews
on
t he
pump
pl ane,
hol di ng
t he
cont r ol
r od
.
ProCarManuals.com
10
.
Pul l
out t he
camshaf t
.
11
.
Remove
t he
out er
f l ywheel housi ng,
t he
f l ywheel
and
t he i nner
f l ywheel
housi ng
.
12
.
Tur n
t he
engi ne
upsi de
down
and
r emove
t he
oi l
pan
.
Be
car ef ul
as
t he
pan
i s
gl ued
.
NOTE!
The
oi l
pan
ends
al so
f unct i on
as
mai n
bear i ngs
.
13
.
Remove
t he
connect i ng
r od
bol t s
and
r emove
t he
connect i ng
r ods
and
t he
pi st ons
.
The
connect i ng
r od
and
t he
connect i ng
r od
cap
ar e
mar ked
wi t h
f i gur es
.
ProCarManuals.com
14
.
Remove
t he
mai n
bear i ng
caps
.
The
mai n
bear i ng
caps
ar e
mar ked
wi t h
a f i gur e
.
The
cor r espondi ng
f i gur e
i s
punched
i nt o
t he
bl ock
.
Li f t
out
t he
cr ankshaf t
.
On
l at er
engi ne
ver si ons
an
ar r ow
i s
cast
i n
t he
separ at e
mai n
bear i ng
caps
( 2002,
2003)
.
The ar r ow
i s
t o
poi nt
t owar ds
t he
di pst i ck
.
ProCarManuals.com
THE CYLI NDER
HEAD
1 .
Remove
t he
" col l et s"
and
val ve
spr i ngs
usi ng
a
val ve
bow
.
Remove
t he val ves
.
Remove
t
he
val ve
st em
seal s
.
Pl ace
t he
val ves
i n
t he
pr oper
sequence
i n
a
val ve
st and
.
Val ve
gui des
2
.
Check
t he val ve
gui de
wear
by
i nser t i ng
anew
val ve
st em
i nt o
t he
gui de
.
Measur e
t he pl ay
usi ng
a
di al
i ndi cat or
.
I f
necessar y,
r epl ace t he
val ve
gui des
.
Wear
l i mi t s
:
I nl et
val ve,
max
pl ay
. .
.
.
. . . . . . .
.
. . .
0
. 15
mm
( 0
. 0059
i n)
Exhaust
val ve,
max
pl ay
. . . . . . . . . . . .
0
. 15
mm
( 0
. 0059
i n)
3
.
Use
mandr el
p/ n
5218
t o
pr ess
out t he
val ve
gui des
.
Oi l
t he
new
val ve
gui des
ext er nal l y
and
use
mandr el
p/ n
884559
t o
i nst al l
t hem
.
Pr ess
down
t he
mandr el
al l
t he
way
down
t o
t he
cyl i nder
head
.
Ream
t he
val ve
gui des
i f
necessar y
.
Val ve
seat s
and
val ves
4
.
Mi l l
or
r eam
t he
val ve
seat s
.
The
angl e
( C)
shoul d
be
45°
( f or
2003T,
30°
f or
t he
i nl et
val ve)
.
The
seal i ng
sur f ace' s
wi dt h
( B)
shoul d
be
1
±0
. 1
mm
( 0
. 039±0
. 0039
i n)
.
Gr i nd
t he
val ves
i n
a val ve
gr i ndi ng
machi ne
.
The
angl e
( D) ,
see
Tech
.
dat a
.
I f
t he
di sc
t hi ckness
af t er
gr i ndi ng
i s
l ess
t han
1
. 0
mm
( 0
. 039
i n)
f or
nat ur al l y
aspi r at ed
engi nes
or 0
. 8
mm
( 0. 031
i n)
f or
t ur bochar ged
engi nes,
t he
val ves
must
be scr apped
.
Val ves
wi t h
bent
st ems,
or
i f
t he
measur ement
( A)
exceeds
2
. 5
mm
( 0
. 098
i n)
must
al so
be
scr apped
.
Gr i nd
t he
val ve
t i p
t owar ds
t he
r ocker s
i f
necessar y
.
Lap
i n
t he
val ves
usi ng
val ve
gr i ndi ng
past e
and
check
t he
cont act
ar ea
wi t h
mar ki ng
dye
.
ProCarManuals.com
Repl aci ng
t he
val ve
seat
exhaust
por t
2003T
Gr i nd
down
t he
val ve
di sc
of
a
di scar ded
val ve
t o j ust
bel ow
27
mm
( 1
. 063
i n)
di amet er
.
Push
t he
val ve
st em
t hr ough
t he
gui de
.
NOTE! Do
not
push
i n t oo
f ar -
t he
val ve
di sc
shoul d
be
j ust
bel ow
t he
edge
of t he
seat
.
Spot
wel d
t he
di sc
i n
pl ace
at
t hr ee poi nt s usi ng
a
el ect r i c
wel der
.
Knockout
t he seat
by
hi t t i ng
t he
val ve
gui de
wi t h
a
pl ast i c- headed
hammer
.
Cool
t he
new
seat
t o
appr ox
.
- 20°C
( - 4° F)
;
t he
cyl i nder
head
shoul d
beat
r oom
t emper at ur e
( +
20°0168°F)
.
Pl ace
t he
cool ed
seat on
t ool
884961- 4
and
knock
i t
down
unt i l
i t
bot t oms.
NOTE!
Tur n
t he seat
wi t h
t he
val ve
f ace
t owar ds
t he
t ool
.
Val ve
spr i ngs
5
.
Checkt he
f r ee
l engt h
of
t he
val ve
spr i ngs
and
t he
l engt h
when
l oaded
.
L =
Lengt h,
unl oaded
42, 5
mm
( 1
. 67323
i n
. )
L
1 =
Lengt h,
l oaded
wi t h
170±10 N
( 17±1
kp)
32
mm
( 1
. 25984
i n
. )
L
2
=
Lengt h,
l oaded
wi t h
300±20
N
( 30±3
kp)
24
mm
( 0
. 94488
i n
. )
Rocker
ar m
mechani sm
6
.
Di sassembl e
t he
r ocker
ar mmechani sm
and
cl ean
t he
par t s
.
Check
t he
wear
of
t he
shaf t
and
r ocker ar m
bush
i
ngs
.
Shoul d
t he
bushi ngs
need
t o
be
r epl aced,
uset he
mandr el
p/ n
9991867
f or t he
r emoval
and
i nst al l at i on,
( make
sur e
t hat
t he
oi l
hol e
i n
t he
bushi ng
coi nci des
wi t h
t he
one
i n
t he
r ocker
ar m)
.
Af t er
t he
i nst al l at i on
t he
bushi ngs
ar e
r eamed
t o
a
cl ose
r unni ng
f i t
. When
i nst al l i ng
t he r ocker ar m shaf t ,
i t
must
be t ur ned
so
t hat
t he
l ubr i cat i on
hol es
ar e
f aci ng
t he
val ve- si de
.
Check
t o
make
sur e
t hat t he
r ocker
ar m
cont act
sur f ace
agai nst t he
val ve
i s
concave
.
Mi nor
adj ust ment s
ar e
made
i n
a
val ve
gr i ndi ng
machi ne
.
Oi l
t he
shaf t
and
i nst al l
t he
par t s
.
Pr essur e
t est i ng
t he
nozzl es
7
.
Check
t he
nozzl e' s
spr ay
pat t er n
at
t he
cor r ect
openi ng
pr essur e
( see
Techni cal
Dat a)
.
Check
al so t hat t he
f uel
spr ays
st op
si mul t aneousl y
and
no
dr i ppi ng
occur s
.
Adj ust
t he
openi ng- pr essur e
wi t h
adj ust ment - washer s
( 1)
bei ng
avai l abl e
i n
di f f er ent
t hi cknesses
f r om
1
mm
U3937
i n
. )
t o 1, 95
mm
(
. 076772
i n
. )
i n
st eps
of
0, 05
mm
(
. 001969
i n
. )
.
Di sassembl e
t he
i nj ect or
and
r epl ace
t he
adj ust ment - washer
agai nstat hi nneroneorat hi ckeronedependi ngon
whet her
t he
pr essur e
must
be
r educed
or
i ncr eased
.
Assembl e
t he
i nj ect or
and
check
t he
openi ng- pr essur e
and
t he
spr ay- pat t er n
.
ProCarManuals.com
I nj ect or - sl eeve
8
.
I nser t
t he
expandi ng
scr ew
on
t he
speci al
t ool
p/ n
884811
i nt o
t he
copper
sl eeve
and
t ur n
t he
scr ew
ant i - cl ockwi se
unt i l
t he
scr ew
has
st uck
i n
t he
sl eeve. Ti ght en
t he
scr ew
har d
t o
al l ow
t he
t hr eads
t o
wor k
t hemsel ves
i nt o
t he
copper
mat er i al
.
Then
i nst al l
t he
yoke
( 1)
on
t he
st ud
bol t of
t he
i nj ect or
.
Put
a
cyl i nder
head
scr ew
i n
t he
cyl i nder
head
as
a
suppor t f or t he
l eg
of
t he
yoke
.
I nst al l
t he
nut
( 2)
and
t i ght en
i t
unt i l
t he
sl eeve
i s
r emoved
.
9
.
Repl ace
t he
O- r i ng,
seal i ng
of f
bet ween
t he
sl eeve
and
t he
cyl i nder
head
.
Di p t he
new
O- r i ng
i n
soap- wat er
i n
or der
t o
f aci l i t at e
t he
i nst al l at i on
.
Oi l
t he
new
i nj ect or
sl eeve
and
i nst al l
i t ,
usi ng
speci al
t ool
p/ n
884557
.
Knock
down
t he
sl eeve
unt i l
i t
bot t oms
.
10
.
Oi l
t hef l ar e- t ool
p/ n
884283 and
i nser t
i t
i nt ot he
sl eeve
( make
sur e
t hat
t he
dowel
i s
pr oper l y
r et r act ed)
.
Br ace
t he
t ool
wi t h
t he
i nj ect or
yoke
.
Scr ew
down
t he
f l ar e- t ool
as
f ar
as
t he
shoul der
i n
t he
i nj ect or
sl eeve
al l ows,
t her eby
f l ar i ng
t he
sl eeve
.
Remove
t he
t ool
.
Adj ust
t he
l engt h
of t he
sl eeve
out si de
t he
pl ane
of
t he
cyl i nder
head
t o
maxi mum
1
mm
(
. 03937
i n
. )
.
Assembl i ng
t he
cyl i nder
head
11
.
Cl ean
t he
cyl i nder
head
.
I f
t he
wat er
di st r i but i on
pi pe
has
been
di sassembl ed,
i t
must
be
i nst al l ed
wi t h
t he
hol es
t ur ned
as
i ndi cat ed
i n
t he
pi ct ur e
.
I nst al l
new
val ve
st em
seal i ngs
.
Oi l
t he
val ve
st ems
and
i nst al l
t he val ves
.
Make
sur e
t o
i nst al l
t he
val ves
and
t he
val ve
spr i ngs
i n
t hei r
r espect i ve
or i gi nal
posi t i ons
.
I nst al l
t he
val ve
spr i ngs
and
t he
" col l et s"
.
Use
a
val ve- bow
.
ProCarManuals.com
Reduct i on
val ve
12
.
Remove
t he
cover
of
t he r educt i on
val ve
and
check
t o
make
sur e t hat
t he
spr i ng
and
t he
pi st on
ar e
f aul t l ess
.
I f
t her e ar e
r easons
t o
suspect
a
f aul t
i n
t he
openi ng
pr essur e
of t he
r educt i on
val ve,
t hen
check
t he
dat a
of
t he spr i ng
.
See
under
" Techni cal
Dat a"
-
r educt i on val ve
.
Feed- pump
13
.
Depr ess
t he
pump
l ever
.
i f
t he
di aphr agm
of t he
pump
sounds
squeaky,
t he
di aphr agm
i s
f aul t l ess
.
Changi ng
t he
di aphr agm
14
.
Remove
t he
si x
scr ews, hol di ng
t he
upper
and
l ower
pump
housi ngs
t oget her
.
Remove
t he
pump
l ever
spr i ng
( 1)
and
r emove
t he
scr ew
( 2)
hol di ng
t he
pump
l ever
shaf t
.
15
.
Use
a
sui t abl e
pai r
of
pl i er s
and
r emovet he
pump
l ever
shaf t
.
Pul l
out
t he
l ever
and
t he
di aphr agm
.
ProCarManuals.com
16
.
Cl ean
t he
pump
housi ng
car ef ul l y
and
r epl ace
wor n
par t s
.
I nst al l
t he
di aphr agm
and
t he
l ever
on
t he
di aphr agm
shaf t
.
Then
i nser t
t he
shaf t
and
t i ght en
i t
wi t h
t he
scr ew
.
Assembl e
t he
t wo
housi ng
hal ves
and
i nst al l
t he
at t achment
pl at e
( 1)
.
Then
i nst al l
t he
spr i ng
( 2)
and
t he
O-
r i ng
( 3)
.
Val ve
l i f t er s
17
.
Check
t he
val ve
l i f t er s
f or
wear
.
Repl ace
t hem
i f
neces
sar y
.
Camshaf t
18
.
Check
t he
camshaf t
f or
wear
on
cams
and
bear i ng
r a
ces
.
Al so
check
t he
wear
of
t he
bear i ngs
.
The
bear i ngs
ar e
pr essed
i nt o
t hei r
l ocat i ons
and must
be
l i ne
bor ed
af t er
t he
i nst al l at i on
.
19
.
Pl ace a
suppor t
under
t he
camshaf t
gear
and
use
a
hydr aul i c pr ess
t o
r emove
t he
gear
.
Cr ankshaf t
20
.
Remove
t he
gear
wheel
.
Use
a
pr ong
pul l er
.
Cl ean
t he
cr ankshaf t
.
Measur e
t he
cr ank- and
mai n
bear i ng
pi ns
.
The
eccent r i ci t y
must
not
exceed
0
. 06
mm
(
. 002362
i n
. )
and
t he
t aper
0. 05
mm
(
. 001969
i n
. )
.
Shoul d
t hese
val ues
be
exceeded,
t he
cr ankshaf t
must be gr ound
t o
a
sui t abl e
under - di mensi on,
seeunder"Techni calDat a".
ProCarManuals.com
Pi st ons,
cyl i nder s
21
.
Check
t he
wear
on
pi st ons, pi st on r i ngs
and
gudgeon
pi ns
.
Repl ace
t hese
i f
necessar y
.
Use
a
cyl i nder
i ndi cat or
gauge
t o
measur e
t he
cyl i nder
bor es
.
The
measur ement
of
t he
bi ggest
wear
i s
made
i mmedi at el y
beneat h
t he
edge
of
t he
upper
dead
cent er
and
cr osswi se
t he
engi ne
.
The
mea
sur ement
of
t he
smal l est
wear
i s
made
at
t he
l ower
dead
cent er
.
As
t o
t he
cyl i nder
di amet er , see
" Techni cal
Dat a"
.
Use
a
mi cr omet er
t o
measur e
t he
pi st ons
.
Pi st on
di amet er ,
see
under
" Techni cal
Dat a"
.
22
.
I nser t a
new
pi st on
r i ng i nt o
t he
cyl i nder and
measur e
t he
pi st on r i ng
gap
.
As
t o
t he
measur ement ,
see
under
" Techni cal
Dat a"
.
I f
necessar y
i ncr ease
t he
gap,
usi ng
a
speci al
f i l e
.
23
.
Measur e
t he
cl ear ance
of
t he
pi st on r i ngs
i n
t he
pi st on
r i ng
gr ooves
.
Regar di ng
t he
measur ement ,
see
under
" Techni cal
Dat a"
.
24
.
Use
pi st on
r i ng
pl i er s
t o
i nst al l
t he
pi st on
r i ngs
.
The
mar ki ng
of
t he
r i ngs
( TOP
or
t he
mar k
of
t he
manuf act ur er )
must
be
t ur ned
upwar ds
.
The
hei ght
of
t he
upper
com
pr essi on
r i ng
:
1, 75
mm
(
. 068898
i n
. )
The
hei ght
of
t he
l ower
compr essi on
r i ng
;
2, 00
mm
(
. 07874
i n
. )
.
Tur n
t he
pi st on
r i ngs
so
t hat
t he
gaps
ar e
t ur ned
120
°
f r om
each
ot her.
Connect i ng
r ods
25
.
Check
t he
connect i ng
r ods
f or
st r ai ght ness
and
t wi st i ng
.
ProCarManuals.com
26
.
Check
t he
connect i ng
r od
bushi ngs
by
usi ng
t he
gudgeon
pi n as
a
gauge
.
Ther e
must
be
no
pl ay
.
I f
t he
bushi ngs
must
be
r epl aced,
use
a
sui t abl e
mandr el
f or
t he
r emoval
and
i nst al l at i on
.
Make
sur e
t o
i nst al l
t he
bushi ng
wi t h
t he
oi l
hol e
coi nci di ng
wi t h
t hat of
t he
connect i ng
r od
.
Ream
t he
new
bushi ngs
.
The
f i t
i s
cor r ect
when
an
oi l ed
gudgeon
pi n
by
i t s
own
wei ght
can
sl owl y
sl i de
t hr ough
t he
bushi ng.
Sea- wat er
pump
27
.
The
pump
i s
equi pped
wi t h
t wo
bal l - bear i ngs
( 1)
.
When
di sassembl i ng,
r emove
t he
l ocki ng- r i ng
( 2)
i n
t he
housi ng
and
push
out t he
shaf t ,
wher eby
t he
bear i ngs
ar e
f ol l owi ng
.
Use
a
sui t abl e
mandr el
t o
r emove
t he
bear i ngs
f r om
t he shaf t
.
NOTE!
Do
not
f or get t he
spacer
sl eeve
( 3)
.
Repl ace
t he
seal i ngs
( 4)
.
NOTE!
Tur n
t he
seal i ngs
cor r ect l y
and
make
sur e
t hat
t hey
do
not
bl ock
t he
dr ai nage
hol e
i n
t he
pump- housi ng
.
Repl ace
t he
O- r i ng
( 5)
.
I nst al l
t he
bal l - bear i ngs
and t hespacersl eeve
ont o
t heshaf tand
l eave
a
di st ance
of
39, 5
mm
( 1
. 55512
i n
. )
f r om
t he shaf t
end
t o
t he
bal l - bear i ng
.
Coat
t he
shaf t
wi t h
gr ease
and
" scr ew"
i t
t hr ough
t he
seal i ngs
and
t he
O- r i ng
and
t ake
car e
not
t o
damage
t hem
.
Push
i n
t he
shaf t
as
f ar
as t o
al l ow
t he
bear i ngs
t o
bot t om
and
t hen
i nst al l
t he
l ocki ng- r i ng
( 2)
.
Checki ng
t he
t her most at s
28
.
I mmer se
t he
t her most at
i n
wat er
and,
usi ng
a
t her momet er ,
check
i f
i t
opens
at
t he
cor r ect
t emper at ur e
.
See
Techni cal
Dat a
f or openi ng t emper at ur es
.
I f
t he
t her most at
i s
f aul t y,
i t
must
be
r epl aced
.
ProCarManuals.com
Al ways
use
new
gasket s,
seal i ng
r i ngs,
seal i ng
washer s
and
l ock- washer s
.
Coat
t he
seal i ngs wi t h
gr ease
or
oi l
t hem
and
al so
oi l
al l
movi ng
par t s
pr i or t o
i nst al l i ng
t hem
.
I f
t he
engi ne
i s
f r esh- wat er
cool ed,
see
page
21
.
1
.
Heat
t he
cr ankshaf t
gear wheel
t o
appr ox
.
150°C
( 302
°
F)
pr i or
t o
t he
i nst al l at i on
.
Pl ace
t he
key
i n
t he
key- way
of
t he
cr ankshaf t
and
pr ess
on
t he
gear
wheel
.
Oi l
t he
new
mai n
bear i ng
hal ves
( wi t h
oi l
hol e)
and
i nst al l
t hem
i n
t he
bl ock
.
Put
i n
t he
cr ankshaf t
.
NOTE!
The
mai n
bear i ng
shel l
at
t he
f l ywheel
al so
f unct i ons
as a
t hr ust - bear i ng
.
ASSEMBLY
2
.
Oi l
t he
cap
bear i ng
hal ves
and
i nst al l
t hem
.
I nst al l
t he
caps
i n
accor dance
wi t h
t he
mar ki ng
i n
t he
bl ock
( 2001
has
no
i nt er medi at e
bear i ng)
.
I f
an
ar r ow
i s
cast ,
i t
shal l
poi nt
t owar ds
t he
oi l
di pst i ck
.
Ti ght eni ng t or que
f or
t he
mai n
bear i ngs
: 1st
t i ght eni ng
20
N
m
( 2
kpm)
( 14
. 7
f t
. l b) ,
2nd
t i ght eni ng
60
Nm
( 6
kpm)
( 44
. 2
f t
. l bs)
.
Tur n
t he
engi ne
.
3
.
Tur n
t he
pi st on
r i ngs
so t hat
t he
gaps
ar e
of f set
i n
r el at i on
t o
each
ot her
.
The
pi st on
cr own
i s
mar ked
wi t h an
ar r ow
t hat
poi nt s
t owar ds
t he
bel t
pul l ey
.
Use
i nst al l at i on
r i ng
884813- 7
.
Fi t
t he
caps
wi t h
t he
mar ki ng
al i gned
wi t h
t he cr ankshaf t ' s
mar ki ng
.
The
cr ankshaf t
can
be
t ur ned
i n
any
di r ect i on
t owar ds
t he pi st on
.
Ti ght eni ng
t or ques
:
St ep
1
:
25
Nm
( 2
. 5
kpm)
( 18
f t / l b)
St ep
2
:
70
Nm
( 7
. 0
kpm)
( 53
f t / l b)
4
.
I nst al l
t he
mai n
bear i ng
hal ves
i n
t he
oi l
pan
and
coat
t he
edge
of
t he
oi l
pan
wi t h
t hi n l ayer of
seal i ng
compound
p/ n
840879
.
I nst al l
t he
oi l
pan and
t i ght en
t he
oi l
pan
scr ews
and
t he
mai n
bear i ng
scr ews
al t er nat i ngl y
t o
20
Nm
( 2, 0
kpm)
( 14
. 7
f t
. l bs
. )
and
t hen
t he
mai n
bear i ng
scr ews
t o
60
Nm
( 6, 0
kpm)
( 44
. 2
f t
. l bs
. )
.
ProCarManuals.com
5
.
Repl ace
t he
f l ywheel
housi ng
seal i ng
( 1)
.
Smear
seal i ng
compound
( p/ n
840879)
on
t he
edge
bet ween
t he
f l ywheel
housi ng
and
t he
seal i ng
.
NOTE!
The
seal i ng
l i p
wi t h
a
spr i ng
shal l
be t ur ned
t owar ds
t he
engi ne
.
Make
sur e
t hat
t he
seal i ng
i s
i nst al l ed
i n
accor dance
wi t h
t he pi ct ur e
.
r
6
.
Repl ace
t he
O- r i ngs
and
i nst al l
t he
f l ywheel
housi ng
.
Ti ght eni ng
t or que
25
Nm
( 2, 5
kpm)
( 18
. 4
f t
. l bs)
.
I nst al l
t he
f l ywheel
.
Ti ght eni ng t or que 65
Nm
( 6, 5
kpm)
( 48
. 0
f t
. l bs) .
7A
.
Heat
t he
camshaf t
gear
wheel
t o
a
t emper at ur e
of
appr ox
.
150°C
( 302°F)
and use
a
sui t abl e
sl eeve
t o
i nst al l
i t
.
Check
t o
make
sur e
t hat
t he
gear
wheel
" bot t oms"
on
t he
camshaf t
.
I nst al l
t he
camshaf t
and
make
sur e
t hat
t he
mar ki ngs
on
t he
camshaf t
gear
wheel
and
on
t he
cr ankshaf t
gear
wheel
coi nci de
.
Put t he
washer
( 1)
on
t he
hub
of
t he
camshaf t gear
wheel
.
Check
t hat
al l
wei ght s
ar e
pr essed
i n
so
t hat
t he
t abs
( 2)
ar e
i nsi de
t he
washer
.
7B
.
I nst al l
anew
seal i ng
r i ng
f or
t he
camshaf t
i n
t he
t r ansmi ssi on
housi ng,
usi ng
mandr el
p/ n
884838
.
The
seal i ng
l i p
wi t h
t he spr i ng
i s
t o
bet ur ned t owar ds
t he
engi ne
.
Pr ess
i n
t he
seal i ng
r i ng
f r om
t he
out si de
unt i l
t he
mandr el
" bot t oms"
agai nst
t he
housi ng
.
I nst al l
a
new
O- r i ng
i n
t he
oi l
channel
i n
t he
bl ock
( 3
f i g
.
7A)
.
Use
a
new
gasket
and
i nst al l
t he t i mi ng
gear
cover
.
Pl ace
t he
pr essur e
sl eeve
( wi t h
t he
bear i ng
t owar ds
t he
pr essur e
washer )
i n
t he
cont r ol
ar m
l ever
.
Hol d
t he
sl eeve
i n
pl ace
by
pr essi ng
t he
l ever
t o
i t s
bot t om
posi t i on
wher e
t he
sl eeve
i s
pr essed
agai nst
t he
housi ng
.
I nst al l
t he
pi n of t he
camshaf t ,
usi ng
speci al
t ool
p/ n
884839
.
The
pi n
must
pr ot r ude
equal l y
much
on
bot h
si des
.
Under no
ci r cumst ances
ar e
you
t o
use
a
hammer
or
some
such
t ool
t o
punch
t he
pi n
i nt o
i t s
l ocat i on
wi t h
t he
ai d of a
mandr el
.
The
camshaf t
wi l l
t hen
be
bent
.
ProCarManuals.com
8
.
I nser t
t he
cont r ol
r od
t hr ough
t he
bl ack
and
i nt o
t he
t i mi ng
gear
casi ng
.
I nst al l
t he bear i ng
bal l
( 1)
i nt o
t he
cont r ol
r od
and
push
t he
cont r ol
r od
t hr ough
t he
hol e
i n
t he
cont r ol
l ever
( 2)
.
Fi t
t he
spr i ng
( 3)
and
scr ew
on
t he
end
ni ppl e
( 4)
unt i l
i t
bot t oms
( Not e!
Do
not use
any
t ool s)
.
Scr ew
i n
t he
upper
bol t s
( wi t h
copper
seal i ng
washer s)
t hat
gui de
t he
cont r ol r od
.
Then,
scr ew
t he
l ower
bol t s
t hat
hol d
t he
cont r ol
r od
i n
pl ace
i n
t he engi ne
bl ock
.
NOTE! The
l ower
bol t s
shoul d
not
have
seal i ng
washer s
.
Appl y
Per mat ex
t o
t he
t hr eads
.
Check
t hat
t he
cont r ol
r od
moves
f r eel y
.
9
.
I nst al l
t he
oi l
pump' s
gear wheel
accor di ng
t o
t he
mar ks
( f r om
t he
di sassembl y)
.
I nser t
a
new
O- r i ng
i n
t he t i mi ng
gear
cover
.
Oi l
t he
gear
wheel and
f i t
The
cover
usi ng
a
new
seal i ng
r i ng
.
2001
10
.
I nser t
t he key
f or
t he
pul l ey
i n
t he
cr ankshaf t
and
i nst al l
t he
pul l ey
.
Ti ght eni ng t or que 40
Nm
( 4, 0
kpm)
( 29
. 5
f t
.
I bs)
.
11
.
Cl ean
t he
val ve
l i f t er s
car ef ul l y
and
coa
t
t he
cont act
sur f
ace
agai nst
t he
camshaf t
wi t h
mol ybdenum
di sul phi de
.
Oi l
t he
val ve
gui des
i n
t he
bl ock
and
i nst al l
t he
l i f t er s
.
Cl ean
t he
r ol l er
l i f t er s
of
t he
f uel
i nj ect i on
pumps
and
i nst al l
t hen
i n
t he
bl ock
.
Lock
t he
r ol l er
l i f t er s
wi t h
scr ews
t hr ough
t he
bl ock
af t er
t he
i nst al l at i on
( appl y
Per mat ex
t o
t he
t hr eads)
.
Check
car ef ul l y
t o
make
sur e
t hat
t he
l i f t er s
ar e
cor r ect l y
i nst al l ed
and
t hat
t hey
ar e
r unni ng
easi l y
i n
t he
gr oove
.
Regar di ng
t he
i nst al l at i on
of
t he
cyl i nder
head,
seet he
f ol l owi ng
page
.
ProCarManuals.com
2002
2003
12
.
Ti ght en
t he
t wo
gui de
scr ews
p/ n
884840
i n
t he
bl ock
and
i nst al l
t he
cyl i nder
head
gasket wi t h
t he
mar ki ng
" Top"
f aci ng
upwar ds
.
I nst al l
t he
cyl i nder
head
.
Make
sur e
t hat
t he
cont act sur f ace
f or
t he
cyl i nder
head
bol t s
ar e
f r ee
f r om
pai nt
.
Shoul d
t her e
be
pai nt
on
t he
bol t s,
t her e
i s
al ways
t he
r i sk
of
havi ng an
i nsuf f i ci er t
t i ght eni ng
f or ce
i n
t he
bol t
j oi nt
wi t h
subsequent
l eakages
as a
r esul t
.
NOTE!
The
bol t s
ar e
phospat ed,
t her ef or e
do
not
cl ean
t hem
wi t h
a
st eel - br ush
.
Coat
t he
cyl i nder
head
bol t s
wi t h
mol ybdenum
di sul phi de
and
t i ght en
t hem
i n
accor dance
wi t h
t he
di agr am,
f i r st
t o
20
Nm
( 2
. 0
kpm/ 14. 7
f t
. l bs)
and
t hen
t o
70
Nm
( 7
. 0
kpm/ 51
. 6
f t . l bs) .
13
.
I nst al l
t he
push
r ods
and
t he
r ocker
ar m
br i dge,
push
on
new
r ubber
r i ngs
t o
t he
oi l
pi pe
whi ch
i s
f i t t ed at
t he
same
t i me as
t he r ocker
ar m
br i dge
.
14
.
Val ve
cl ear ance
col d/ war m
engi ne
0
. 30
mm
(
. 01181
i n
. )
.
Tur n
t he
engi ne
i n
t he
di r ect i on of r ot at i on
unt i l
t he
val ves
i n
one
cyl i nder
ar e
" r ocki ng"
.
Then
t ur n
t he
engi ne
one
t ur n
mor e
and
adj ust
t he val ves
f or
t hi s
cyl i nder
.
Repeat
t he
pr ocedur e
f or
t he
r emai ni ng
cyl i nder s
.
Adj ust i ng
t he
f uel
i nj ect i on
pump
l ocat i on
wi t h
shi ms
15
.
i f
t he
same
bl ock
camshaf t
and
f uel
I nj ect i on
pumps
ar e
used
when
assembl i ng,
t he
f uel
i nj ect i on
pump
must
be
i nst al l ed
i n
t hei r
or i gi nal
posi t i ons
and
wi t h
t he
same
shi m
t hi ckness
as
ear l i er
.
The
so
cal l ed
sof t
shi ms,
al ways
bei ng
i nst al l ed
agai nst
t he
bl ock,
must
be
r epl aced
agai nst
new
ones
.
Car ef ul l y
cl ean
t he
cont act
sur f aces
bet ween
t he
bl ock
and
t he
f uel
i nj ect i on
pumps
and
i nst al l
shi ms
wi t h
t hi ckness
equal
t o t he
sum
of
t he
mar ki ng
on
t he
bl ock
and
t hat
on
t he
f uel
i nj ect i on
pump,
( 4)
ear l i er
mar ki ng
.
Exampl e
:
The
bl ock
mar ki ng
4 ( =
4
t ent hs
of
a
mi l l i met er )
(
. 015748
i n
. )
The
pump
mar ki ng
4
( =
4
t ent hs
of a
mi l l i met er )
(
. 015748
i n
. )
Tot al
amount
of
shi ms
=
0
. 8
mm
(
. 031496
i n
. )
I n
t hi s
case
sel ect
t wo
sof t
shi ms
0
. 2
and
0
. 3
mm
(
. 011811
i n
. )
.
Pl ace
t he
har d
shi m bet ween
t he
t wo
sof t
ones
and
i nst al l
t he
pump
.
NOTE!
Never
i nst al l
a
har d
shi m
t oget her
wi t h
anot her
har d
shi m
or
agai nst
t he
bl ock
or
t he
f uel
i nj ect i on
pump
.
Har d
shi ms
ar e
avai l abl e
i n
t hi cknesses
0
. 3,
0
. 6
and
0
. 9
mm
(
. 011811, . 02362,
. 035433
i n
.
r espect i vel y)
.
Sof t
shi ms
ar e
avai l abl e
i n
t hi cknesses
0
. 2
and
0
. 3
mm
(
. 007874
and
. 011811
i n
. )
.
ProCarManuals.com
On
l at er
ver si on
engi nes
an
O- r i ng
has
been
i nt r oduced
as a
seal
bet ween
t he
i nj ect i on
pump
and
t he
bl ock
.
Onl y
so- cal l ed
har d
shi ms
may
be
used
on
t hese
engi nes
when
shi mmi ng
.
Har d
shi ms
ar e
avai l abl e
i n
t hi cknesses
of 0
. 2
mm
( 0
. 0079
i n) ,
0
. 3
mm
( 0
. 0118
i n) ,
0
. 6
mm
( 0
. 0024
i n)
and
0
. 9
mm
( 0
. 0354
i n)
.
16
.
New
bl ock
or
camshaf t
I f
t he
bl ock
or
t he
camshaf t
ar e
r epl aced
t he
bl ock
must be
measur ed and
mar ked,
usi ng
t he
set t i ng- di sc
p/ n
884787
and
a
sl i di ng
cal i per
.
A
.
The
set t i ng- di sc
consi st s
of
t wo
r i ngs,
an
i nner
and
an
out er
.
The
i nner
r i ng
det er mi nes
t he
i nj ect i on
angl e
f or
each
r espect i ve
engi ne
t ype,
see
Techni cal
Dat a
( page
25)
.
The
i nj ect i on
angl e
i s
st amped
i n
degr ees
and
i s
f i xed
wi t h
a
pi n
( 1)
.
B
.
Mount
t he set t i ng- di sc
or
t he
pul l ey
wi t h
t wo
bol t s,
do
not t i ght en t he bol t s
.
Tur n
t he
set t i ng- di sc
so
t hat t he
gui de
pi n
( 2)
comes
i n
t he l ar gest of
t he
f our
hol es
i n
t he
pul l ey
.
Pr ess
i n
t he
gui de
pi n
( 2)
so
t hat
t he
di sc
i s
cent er ed
and
t i ght en
t he
bol t s
.
The
set t i ng- di sc
i s
mar ked
f or
each
r espect i ve
cyl i nder
:
Mar ki ng
Denot es
Cyl i nder
1
Cyl i nder
1
( 1,
2,
3
cyl i nder
engi nes
;
Cyl i nder
2/ 2
Cyl i nder
2
( 2
cyl i nder
engi ne)
Cyl i nder
2/ 3
Cyl i nder
2
( 3
cyl i nder
engi ne)
Cyl i nder
3/ 3
Cyl i nder
3
( 3
cyl i nder
engi ne)
ProCarManuals.com
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