`L` Series Diesel Engine Overhaul Manual - 2nd Edition

`L` Series Diesel Engine Overhaul Manual - 2nd Edition
FREELANDER
L Series Diesel Engine
Overhaul Manual
L–Serie Dieselmotor
revisiehandboek
Moteur Diesel de série L
Manuel de révision
L Diesel motor
Überholungsanleitung
Motore Diesel serie L
Manuale di revisione
Motor Diesel serie L
Manual de revisión
Motor Diesel da série L
Manual de revisão
’L’ SERIES
DIESEL ENGINE
OVERHAUL
MANUAL
This engine is fitted to the following model:
Land Rover Freelander - Up to 2001 Model Year
Publication Part No. LRL 0157 ENG (2nd. Edition)
Published by Land Rover Technical
Communication
 2000 Land Rover Group Limited
INTRODUCTION
CONTENTS
Page
INTRODUCTION
INTRODUCTION ......................................................................................................
REPAIRS AND REPLACEMENTS ...........................................................................
SPECIFICATION ......................................................................................................
ENGINE NUMBER LOCATION ................................................................................
Engine identification ..................................................................................................
1
1
2
2
2
INTRODUCTION
INTRODUCTION
Dimensions
How to use this manual
The dimensions quoted are to design engineering
specification with Service limits where applicable.
To assist in the use of this manual the section title is
given at the top and the relevant sub-section is given
at the bottom each page.
To help readers find the information they need, the
first page of each section is marked with a black tab
which lines up with the corresponding tab on the title
page. In addition the symbol at the top of each RH
page identifies each section or group of sections.
Each section starts with a contents page, listing the
information contained within. Some sections are
divided into sub- sections such as Description and
Operation, Adjustments, Repairs and Data, Torque
and Tools. To assist filing of revised information
each of the sub-sections is numbered from page 1.
Each Adjustment and Repair procedure is fully
illustrated showing a number against each text item.
Service tools are shown in use where usage is not
obvious. The illustration appear before the text
which refers to it. Adjustment and Repair operations
also include relevant data, torque figures and useful
assembly details.
WARNINGS, CAUTIONS and Notes have the
following meanings:
WARNING: Procedures which must be
followed precisely to avoid the possibility
of injury.
CAUTION: Calls attention to procedures
which must be followed to avoid damage
to components.
NOTE: Gives helpful information.
References
References to the LH or RH side given in this
manual are made when viewing the vehicle from the
rear. With the engine and gearbox assembly
removed, the crankshaft pulley end of the engine is
referred to as the front.
During the period of running-in from new, certain
adjustments may vary from the specification figures
given in this manual. These will be reset by the
Dealer at the First Service, and thereafter should be
maintained at the figures specified in this manual.
REPAIRS AND REPLACEMENTS
When replacement parts are required it is essential
that only Land Rover recommended parts are used.
Attention is particularly drawn to the following points
concerning repairs and the fitting of replacement
parts and accessories.
Safety features and corrosion prevention treatments
embodied in the car may be impaired if other than
Land Rover recommended parts are fitted. In certain
territories, legislation prohibits the fitting of parts not
to the manufacturer’s specification. Torque wrench
setting figures given in this Manual must be used.
Locking devices, where specified, must be fitted. If
the efficiency of a locking device is impaired during
removal it must be renewed.
Owners purchasing accessories while travelling
abroad should ensure that the accessory and its
fitted location on the car conform to legal
requirements.
The Terms of the vehicle Warranty may be
invalidated by the fitting of other than Land Rover
recommended parts.
All Land Rover recommended parts have the full
backing of the vehicle Warranty.
Land Rover Dealers are obliged to supply only Land
Rover recommended parts.
Operations covered in this manual do not include
reference to testing the vehicle after repair. It is
essential that work is inspected and tested after
completion and if necessary a road test of the
vehicle is carried out particularly where safety
related items are concerned.
INTRODUCTION
1
INTRODUCTION
SPECIFICATION
ENGINE NUMBER LOCATION
Land Rover are constantly seeking to improve the
specification, design and production of their vehicles
and alterations take place accordingly. While every
effort has been made to ensure the accuracy of this
Manual, it should not be regarded as an infallible
guide to current specifications of any particular
vehicle.
This Manual does not constitute an offer for sale of
any particular vehicle. Land Rover Dealers are not
agents of Land Rover and have no authority to bind
the manufacturer by any expressed or implied
undertaking or representation.
The engine number is located on the side of the
cylinder block adjacent to Number 2 cylinder.
Engine identification
Engines fitted to Freelander have the following
prefixes to the engine serial numbers:20T2N 17N
20T2N 18N
20T2N 20N
20T2N 21N
2
INTRODUCTION
ENGINE
CONTENTS
Page
DESCRIPTION AND OPERATION
CAMSHAFT TIMING BELT COMPONENTS ............................................................
CYLINDER BLOCK COMPONENTS ........................................................................
CYLINDER HEAD COMPONENTS ..........................................................................
OPERATION .............................................................................................................
1
3
5
6
OVERHAUL
CAMSHAFT TIMING BELT AND TENSIONER ........................................................ 1
Tensioner - remove ................................................................................................... 3
Camshaft timing belt tensioner and idler pulley - inspection ..................................... 4
Tensioner - refit ......................................................................................................... 4
Camshaft timing belt - refit and adjust ....................................................................... 5
CYLINDER HEAD ASSEMBLY ................................................................................ 8
Camshaft - check end-float ..................................................................................... 10
Camshaft - remove ................................................................................................. 10
Valves and springs - remove .................................................................................. 11
Cylinder head - inspection ...................................................................................... 12
Tappets - inspection ................................................................................................ 13
Camshaft and bearings - inspection ....................................................................... 13
Camshaft bearings - check clearance ..................................................................... 14
Valve springs - inspection ....................................................................................... 15
Valves and valve guides - inspection ...................................................................... 15
Valve guides - renew .............................................................................................. 16
Valve seat inserts and valves - refacing and lapping-in .......................................... 17
Valve head stand down ........................................................................................... 19
Cylinder head bolts - inspection .............................................................................. 19
Cylinder head and camshaft carrier - cleaning ........................................................ 20
Valves - assembling ................................................................................................ 20
Tappets and camshafts - assembling ..................................................................... 21
Cylinder head gasket selection ............................................................................... 22
Cylinder head - refit ................................................................................................. 24
FLYWHEEL AND STARTER RING GEAR ............................................................. 26
GEARBOX ADAPTOR PLATE ............................................................................... 29
SUMP AND OIL STRAINER ................................................................................... 29
Oil strainer and pick-up pipe - remove .................................................................... 30
Oil strainer and pick-up pipe - refit .......................................................................... 30
Sump - refit ............................................................................................................. 31
OIL PUMP ............................................................................................................... 32
Oil pump - inspection .............................................................................................. 33
Oil pump - assembling ............................................................................................ 37
Oil pump - refit ........................................................................................................ 37
CRANKSHAFT, MAIN AND BIG-END BEARINGS ................................................. 39
Big-end bearings - remove ...................................................................................... 40
Crankshaft end-float - check ................................................................................... 40
Crankshaft - remove ............................................................................................... 41
Crankshaft - inspection ........................................................................................... 42
Crankshaft - refit ..................................................................................................... 42
Crankshaft rear oil seal - refit .................................................................................. 43
Big-end bearings - refit ............................................................................................ 44
PISTONS, CONNECTING RODS AND CYLINDER BORES ................................. 45
Piston rings - remove .............................................................................................. 45
Piston ring gaps - checking ..................................................................................... 46
ENGINE
CONTENTS
Page
Pistons - remove .....................................................................................................
Pistons and connecting rods - inspection ...............................................................
Pistons - refit ...........................................................................................................
Piston rings - refit ....................................................................................................
Cylinder bores - inspection .....................................................................................
Cylinder block .........................................................................................................
Pistons and connecting rods - refit ..........................................................................
46
47
48
49
49
50
50
DATA,TORQUE & TOOLS
ENGINE DATA .......................................................................................................... 1
TORQUE FIGURES .................................................................................................. 3
TOOL NUMBERS ..................................................................................................... 4
ENGINE
CAMSHAFT TIMING BELT COMPONENTS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Bolt - timing belt gear
Washer
Timing belt gear
Timing belt gear damper
Torx screws - damper to timing gear
Camshaft timing belt
Tensioner housing
Bolt - tensioner pulley
Tensioner pulley
Allen screw - tensioner pulley*
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Timing belt upper rear cover
Timing belt upper front cover
Timing belt lower front cover
Engine front mounting cover plate
Nut - idler pulley
Idler pulley
Stud and adaptor - idler pulley
Timing belt lower rear cover
Tensioner plunger
Tensioner spring
* Later engines - Allen screw is replaced by a bolt.
DESCRIPTION AND OPERATION
1
ENGINE
2
DESCRIPTION AND OPERATION
ENGINE
CYLINDER BLOCK COMPONENTS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Cylinder block
Foam pad
Gearbox adaptor plate
Circlip - gudgeon pin
Gudgeon pin
Piston
Connecting rod
Bolt - connecting rod
Big-end bearing shells
Big-end bearing cap
Crankshaft rear oil seal and housing
Top compression ring
2nd compression ring
Oil control ring
Crankshaft
Woodruff key
Dipstick
Dipstick tube
Main bearing cap
Thrust washer
Upper main bearing shell - grooved
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
Lower main bearing shell - plain
Bolt - main bearing cap
Gasket - sump
Sump
’O’ ring
Oil strainer and pick-up pipe
Bolt - sump
Drain plug
Sealing washer
Oil squirt jet
Banjo bolt
Gasket - oil pump
Oil pump
Bolt - M6
Bolt - M10
Crankshaft front oil seal
Sealing ring
Oil filter element
Timing gear
Crankshaft pulley
Bolt - crankshaft pulley
DESCRIPTION AND OPERATION
3
ENGINE
4
DESCRIPTION AND OPERATION
ENGINE
CYLINDER HEAD COMPONENTS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Oil filler cap
Camshaft cover
Gasket - camshaft cover
Camshaft carrier
Drive pin
Camshaft
Camshaft rear oil seal
Camshaft front oil seal
Fuel injection pump drive belt rear cover
Bolt - fuel injection pump drive gear
Fuel injection pump drive gear
Allen screw
Fuel injection pump drive belt tensioner
Gasket - cylinder head
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
Cylinder head
Bolt - cylinder head
Tappet
Collets
Spring cap
Valve spring
Spring seat and valve stem oil seal
Valve guide - exhaust
Valve seat insert - exhaust
Valve guide - inlet
Valve seat insert - inlet
Exhaust valve
Inlet valve
Coolant outlet elbow
DESCRIPTION AND OPERATION
5
ENGINE
OPERATION
The ’ L’ Series 2.0 litre engine is a 4 cylinder, in-line,
direct injection diesel engine having 2 valves per
cylinder operated by a single overhead camshaft.
A cast iron cylinder block incorporates direct bored
cylinders, each pair of cylinders being strategically
positioned to reduce engine length and give good
structural rigidity.
An alloy camshaft carrier is bolted directly to the
alloy cylinder head, the camshaft bearing journals
are line bored between the two components. The
camshaft operates the valves via hydraulic tappets,
the camshaft gear, which incorporates a tortional
damper, is driven by an internally toothed drive belt
by a gear on the front of the crankshaft. Belt tension
is achieved by means of a semi-automatic tensioner
and an idler pulley is also fitted. A gear on the rear
end of the camshaft drives the fuel injection pump
belt.
A single spring is fitted to each valve, the valve stem
oil seals are moulded onto a metal base which also
forms the valve spring seat on the cylinder head.
The valve stems run in guides pressed into the
cylinder head.
Exhaust valves fitted to later engines are of the
carbon break type, a machined profile on the valve
stem removes any build up of carbon in the
combustion chamber end of the valve guide thereby
preventing valves from sticking. These valves may
be fitted as replacements to all early engines.
The aluminium alloy, graphite coated pistons are
fitted with two compression and an oil control ring,
the top ring is located in a steel insert which helps to
provide a minimal reaction to compression forces.
The piston crowns are domed in the centre, the
combustion chamber being formed in a bowl around
the dome. Fully floating gudgeon pins retain the
pistons to the connecting rods, the pins are offset
towards the thrust side of the pistons which are
retained in the pistons by circlips. Oil squirt jets,
located in the cylinder block provide additional piston
cooling and gudgeon pin lubrication. Plain big-end
bearing shells without location tags are fitted, with
the connecting rod bearing caps retained by flange
headed bolts to the connecting rods. The big-end
has a ’Fracture Split’ type joint between the
connecting rod and the bearing cap. To prevent
incorrect fitment of the the bearing cap to connecting
rod, the bolts are off-set by 1mm.
6
DESCRIPTION AND OPERATION
The crankshaft runs in 5 main bearings, grooved
shells are fitted in the cylinder block with plain
bearing shells in each main bearing cap. Positive
location of each main bearing cap is by means of
hollow dowels. Crankshaft end-float is controlled by
single size thrust washers,located each side of the
centre - Number 3 main bearing in the cylinder
block. The crankshaft front oil seal is located in the
oil pump body whilst the rear oil seal is integral with
a housing bolted to the rear of the cylinder block.
Additional oil sealing is provided by RTV sealant
injected into grooves and along the joint lines of the
front main - Number 1 bearing cap and the
crankshaft rear oil seal.
A rotor type oil pump is driven from the front of the
crankshaft, the pump is sealed to the cylinder block
with a gasket.
The cast alloy sump is bolted to the cylinder block
and rear main bearing cap and is sealed to the block
with a rubber gasket which incorporates location
lugs for the block and sump. Compression limiters in
the bolt holes prevent distortion of the gasket.
ENGINE
Lubrication
Oil is drawn through a gauze strainer (1) and
through a passage in the cylinder block to the oil
pump (2). Pressurised oil flows via the full flow filter
(3) to the main oil gallery in the cylinder block.
Drillings from the main oil gallery direct oil to the
crankshaft main bearings (4) and cross drillings in
the crankshaft direct oil to the big-end bearings (5).
Additional drillings in the cylinder block supply oil at
reduced pressure to the oil squirt jets (7) for piston
cooling and gudgeon pin lubrication and via a
restrictor (8) in the top of the cylinder block to the
rear of the cylinder head. A full length drilling in the
cylinder head directs oil to the camshaft journals (9)
and tappets (10).
An oil pressure relief valve (11) is located in the oil
pump body which also carries the oil filter adapter
and the return union for the externally mounted oil
cooler.
A thermostatic valve (12), comprising a valve, spring
and diverter plug is located in the oil pump body.
The oil flow union to the oil cooler is screwed into the
end of the diverter plug. The valve is closed during
engine warm-up thereby preventing oil flow to the oil
cooler. As the oil reaches a pre-determined
temperature, the valve opens and allows oil to flow
to the cooler.
Crankcase ventilation
A positive crankcase ventilation system is used to
vent crankcase gases to the air induction system.
The gases are drawn from the camshaft cover,
through a depression limiting valve and into the
turbocharger intake.
As engine speed increases, the depression limiting
valve progressively closes thereby limiting the
depression in the crankcase.
DESCRIPTION AND OPERATION
7
ENGINE
CAMSHAFT TIMING BELT AND TENSIONER
Camshaft timing belt - remove
1. Remove 4 screws securing camshaft timing
belt upper front cover. Remove cover.
2. Insert timing pin LRT-12-058 through hole in
gearbox adaptor plate, hold pin in contact with
flywheel and using assistance, rotate
crankshaft clockwise by means of crankshaft
pulley bolt until timing pin can be felt to enter
hole in flywheel.
3. Check that timing mark on camshaft gear
damper is aligned with mark on timing belt
upper rear cover.
CAUTION: Do not use camshaft timing belt
gear, fuel injection pump drive belt gear,
gear retaining bolts or timing belt to rotate
crankshaft.
4. Remove and discard 3 Torx screws securing
damper to camshaft gear. Remove damper.
OVERHAUL
1
ENGINE
7. Remove 4 nuts and 2 bolts securing engine
front mounting cover plate, remove plate.
5. Remove crankshaft pulley bolt, withdraw
pulley.
6. Noting fitted position of 3 longest screws,
remove 6 screws securing camshaft timing belt
lower front cover. Remove cover.
8. Remove timing belt tensioner access plug from
camshaft timing belt lower rear cover.
9. Loosen but do not remove Allen screw
securing timing belt tensioner pulley.
NOTE: Later engines - Allen screw is
replaced by a bolt.
10. Screw timing belt tensioner retractor tool
LRT-12-143 into timing belt tensioner plunger.
11. Tighten nut on tool LRT-12-143 until timing
belt tension is released.
2
OVERHAUL
ENGINE
Tensioner - remove
1. Remove Allen screw and bolt securing timing
belt tensioner. Remove tensioner.
NOTE: Later engines - Allen screw is
replaced by a bolt.
12. Remove and discard camshaft timing belt.
2. Remove tensioner spring and plunger.
CAUTION: Ease timing belt from gears
using fingers only, metal levers may
damage the belt and gears. Do not rotate
camshaft or crankshaft with timing belt removed
and cylinder head fitted.
13. Remove tensioner retractor tool LRT-12-143.
OVERHAUL
3
ENGINE
Camshaft timing belt tensioner and idler pulley inspection
Tensioner - refit
1. Ensure that bore of plunger housing is clean.
1. Check tensioner spring for distortion, check
spring free length:
Free length = 65 mm.
2. Check tensioner plunger and bore of housing
for wear and corrosion.
CAUTION: Do not attempt to remove
corrosion by means of emery cloth,
components must be replaced.
3. Check that tensioner and idler pulleys rotate
smoothly and belt surfaces are smooth and
clean.
4
OVERHAUL
2. Smear tensioner plunger with molybdenum
disulphide based grease, locate spring and
plunger in housing.
3. Position tensioner on cylinder block, fit and
tighten bolt to 45 Nm, fit but do not fully tighten
Allen screw or bolt.
ENGINE
Camshaft timing belt - refit and adjust
1. Clean tensioner and idler pulleys and timing
belt gears.
CAUTION: If the sintered gears have been
subjected to prolonged oil contamination,
they must be soaked in a solvent bath and
then thoroughly washed in clean solvent before
refitting.
2. Check that camshaft timing belt upper and
lower cover sealing strips are correctly located
in covers.
4. Screw timing belt tensioner retractor tool
LRT-12-143 into tensioner plunger. Tighten nut
on tool to fully retract tensioner.
5. Using the fingers only, ease a new timing belt
over crankshaft and camshaft gears keeping it
as taut as possible on the idler pulley side.
6. Loosen Allen screw until tensioner pulley
moves easily without tipping.
NOTE: Later engines - Allen screw is
replaced by a bolt.
7. Loosen nut on tool LRT-12-143 until tensioner
is released; tighten Allen screw or bolt to 55
Nm and remove tool.
CAUTION: Do not exceed specified torque
figure.
8. Insert timing belt tensioner access plug into
lower rear cover.
3. Ensure that timing pin LRT-12-058 is inserted
in flywheel, and camshaft gear timing mark is
aligned exactly with pointer on timing belt
upper rear cover.
OVERHAUL
5
ENGINE
12. Using crankshaft pulley bolt, rotate crankshaft
2 turns clockwise and refit timing pin
LRT-12-058.
CAUTION: Do not use camshaft timing belt
gear, gear retaining bolt or timing belt to
rotate crankshaft.
13. Check that camshaft gear timing mark is
aligned exactly with pointer on timing belt
upper rear cover.
CAUTION: If engine front mounting plate
was removed, clean all traces of Loctite
from plate and cylinder block. Reseal plate
to block using Loctite 638.
9. Fit engine front mounting plate, fit 4 nuts and 2
bolts and tighten bolts to 45 Nm and nuts to 30
Nm then further 120°.
14. Loosen Allen screw or bolt until tensioner
pulley moves to tension belt then tighten screw
or bolt to 55 Nm.
CAUTION: Do not exceed specified torque
figure.
15. Remove crankshaft pulley bolt and pulley.
10. Locate crankshaft pulley on crankshaft, fit and
lightly tighten bolt.
11. Remove timing pin LRT-12-058.
6
OVERHAUL
ENGINE
19. Fit camshaft gear damper, ensuring that the
timing mark on the damper is aligned to the
timing mark on the camshaft gear.
20. Fit new Torx screws and tighten to 10 Nm.
16. Position camshaft timing belt lower front cover
to timing belt lower rear cover.
17. Fit lower front cover securing screws ensuring
that 3 longest screws are in correct fitted
position, tighten all screws to 5 Nm.
18. Fit crankshaft pulley and bolt, tighten bolt to 63
Nm then a further 90°. Remove timing pin
LRT-12-058.
NOTE: Do not fit camshaft timing belt
upper front cover until engine has been
installed in vehicle and FIP timing belt has
been fitted and adjusted.
OVERHAUL
7
ENGINE
CYLINDER HEAD ASSEMBLY
Remove
1. Remove and discard camshaft timing belt.
3. Restrain camshaft timing belt gear using tool
12-182 and remove bolt securing camshaft
timing belt gear. Remove gear and discard
bolt.
CAUTION: Ensure camshaft does not
rotate when removing bolt and do not
rotate crankshaft or camshaft with timing
belt removed and cylinder head fitted.
2. Restrain camshaft timing belt gear using tool
12-182 and remove bolt securing fuel injection
pump drive belt gear to camshaft, remove
gear, discard bolt.
CAUTION: Ensure camshaft does not
rotate when removing bolt and do not
rotate crankshaft or camshaft with timing
belt removed and cylinder head fitted.
4. Remove 5 screws securing camshaft timing
belt upper rear cover, remove cover, recover
sealing strip.
NOTE: Shortest screws are fitted in
camshaft carrier.
8
OVERHAUL
ENGINE
9. Using sequence shown, progressively loosen
then remove 10 Torx bolts and washers.
CAUTION: Keep bolts in their fitted order,
do not attempt to remove washers from
bolts.
5. Remove Allen screw securing fuel injection
pump drive belt tensioner, remove tensioner.
6. Remove 3 screws securing fuel injection pump
drive belt rear cover, remove cover and collect
bracket.
7. Progressively loosen then remove 12 bolts
securing camshaft cover.
8. Remove camshaft cover and discard gasket.
10. Using assistance, remove cylinder head
assembly and support each end of cylinder
head on blocks of wood to protect valves
which, when open, protrude below face of
cylinder head.
CAUTION: Cylinder head is dowel located,
do not tap it sideways to free it from
cylinder block.
11. Remove and discard cylinder head gasket.
OVERHAUL
9
ENGINE
Camshaft - check end-float
Camshaft - remove
NOTE: Prior to removing the camshaft,
check end-float.
1. Using sequence shown, loosen the 10
camshaft carrier retaining bolts 2 to 3 turns.
CAUTION: Do not fully remove bolts at this
stage.
1. Position a suitable DTI to front of camshaft.
Move camshaft rearwards and zero DTI. Move
camshaft forwards and measure end-float:
End-float - maximum = 0.51 mm.
CAUTION: Camshaft end-float is
controlled by the width of Number 1
bearing in the camshaft carrier. If end-float
exceeds the above dimension, remove the
camshaft and repeat the end-float check using a
new camshaft. If end-float still exceeds the
maximum, a new cylinder head and camshaft
carrier asssembly must be fitted.
2. Gently tap the camshaft carrier upwards to
break the sealant bond.
CAUTION: Camshaft carrier is dowel
located, do not tap it sideways.
3. Using the same sequence, continue to
progressively loosen the carrier retaining bolts
until all loading is removed from the carrier.
CAUTION: If bolts are removed completely
before loading is removed from the
camshaft carrier, the carrier may be
suddenly released and damage caused as a
result.
4. Remove retaining bolts, remove camshaft
carrier.
10
OVERHAUL
ENGINE
Valves and springs - remove
1. Support cylinder head clear of valves, use a
hollow drift and tap each spring cap to free
collets.
5. Remove camshaft, remove and discard front
and rear oil seals.
2. Using tool LRT-12-034, compress valve
spring.
3. Remove 2 collets from valve stem using a stick
magnet.
4. Remove tool LRT-12-034.
5. Remove spring cap and valve spring, remove
valve.
6. Using a stick magnet, remove 8 tappets from
the cylinder head.
CAUTION: Keep tappets in their fitted
order and store inverted to prevent oil
loss. Do not squeeze tappet chambers
together.
OVERHAUL
11
ENGINE
Cylinder head - inspection
1. Check cylinder head for warping across centre
and from corner to corner:
Maximum warp = 0.10 mm
CAUTION: Cylinder head may not be
refaced. Replace head assembly if
warping exceeds figure given.
6. Using tool LRT-12-071, remove valve stem oil
seal; discard seal.
7. Repeat above operations to remove remaining
valves.
CAUTION: Keep component parts of each
valve assembly in their fitted order.
12
OVERHAUL
2. Check tappet bores for scoring and signs of
wear or damage. Slight scoring or burring may
be removed using fine emery cloth.
ENGINE
Tappets - inspection
1. Check tappets for signs of wear, scoring and
overheating, replace as necessary.
2. Ensure oil hole in each tappet is clear.
3. Check outside diameter of each tappet:
Diameter = 34.959 to 34.975 mm.
Camshaft and bearings - inspection
1. Check camshaft cams and bearing journals for
signs of scoring and excessive wear.
CAUTION: Keep tappets in their fitted
order and store inverted to prevent oil
loss. Do not squeeze tappet chambers
together.
2. Check camshaft timing belt gear and fuel
injection pump drive belt gear drive pins for
damage and wear, replace if necessary
ensuring that split in pin faces towards centre
of camshaft.
3. Check bearing journals in cylinder head and
camshaft carrier for signs of scoring and
excessive wear.
CAUTION: Cylinder head and camshaft
carrier are machined together as an
assembly. If bearing journals in either
component are found to be damaged, complete
assembly must be replaced.
OVERHAUL
13
ENGINE
Camshaft bearings - check clearance
1. Clean all traces of oil from camshaft, cylinder
head and camshaft carrier.
2. Use suitable cleaning solvent and remove all
traces of sealant from cylinder head and
camshaft carrier.
CAUTION: Do not use a metal scraper.
7. Using sequence shown, progressively loosen,
then remove 10 retaining bolts.
8. Carefully remove camshaft carrier.
3. Position camshaft in cylinder head.
4. Place a piece of Plastigage along the centre
line of each camshaft journal.
5. Support each end of cylinder head on blocks of
wood.
9. Measure and record widest portion of
Plastigage on each camshaft journal.
10. Compare figures obtained with camshaft
bearing clearance:
Bearing clearance = 0.043 to 0.094 mm
11. If any bearing clearance is found to be
excessive, repeat the above procedure using a
new camshaft.
6. Carefully fit the camshaft carrier, fit 10 retaining
bolts and tighten in sequence shown to 11 Nm.
CAUTION: Do not rotate camshaft.
CAUTION: If, after repeating the bearing
clearance check with a new camshaft the
clearances are still excessive, a new
cylinder head and camshaft carrier assembly
must be fitted.
12. Remove Plastigage using an oily cloth, do not
use a scraper.
14
OVERHAUL
ENGINE
Valve springs - inspection
Valves and valve guides - inspection
1. Check valve springs free length:
Free length = 37mm
CAUTION: Valve springs must be replaced
as a set.
NOTE: Two types of exhaust valve may be
fitted, standard valves - A in illustration or
carbon break valves - B in illustration.
Carbon break valves may be identified by the
machined profile - C on the valve stem. To
prevent valves from sticking, standard valves
should be replaced with carbon break valves
during engine overhaul.
1. Clean carbon from valves, check valves for
burning, pitting or cracking; replace as
necessary.
2. Remove carbon deposits from valve guides
using tool 12-186.
CAUTION: Tool must be inserted from
combustion chamber face side of cylinder
head.
3. Remove carbon from valve seat inserts;
remove all loose particles of carbon on
completion.
OVERHAUL
15
ENGINE
Valve guides - renew
1. Check area on camshaft side of cylinder head
around valve guide to be replaced for marks
denoting previous valve guide replacement:
+ denotes 1st replacement
- denotes 2nd replacement
CAUTION: Valve guides may only be
replaced twice.
2. Heat cylinder head uniformly to a temperature
of 120°C.
WARNING: Take care when handling hot
cylinder head.
4. Check and record diameter of each valve stem,
replace any valve if diameter is less than
specified.
Inlet = 6.907 to 6.923 mm.
Exhaust = 6.897 to 6.913 mm.
5. Check inlet and exhaust valve to guide
clearances using the following procedures:
6. Insert a valve into its respective guide.
7. Extend valve out of seat by 10 mm.
8. Position a DTI gauge on to rear side of valve
head. Move valve towards front of cylinder
head, pre-load gauge to valve head and zero
gauge. Move valve towards rear of cylinder
head, record gauge reading obtained to give
valve stem to guide clearance.
9. Repeat above procedures for remaining
valves.
Maximum valve to guide clearance:
Inlet valve = 0.056 mm.
Exhaust valve = 0.066 mm
10. Renew any guide and its associated valve if
movement/clearance is excessive.
3. Using a suitable pilotted mandrel, press valve
guide out of cylinder head from combustion
face side; discard guide.
NOTE: Only one size of replacement guide
is available.
4. Reheat cylinder head to 120°C.
16
OVERHAUL
ENGINE
Valve seat inserts and valves - refacing and
lapping-in
Refacing valve seat inserts
1. Check valve seat inserts for pitting and
burning, if necessary, valve seats may be
refaced providing valve head stand down is
within limits after refacing.
5. Using the pilotted mandrel, press replacement
valve guide into cylinder head from camshaft
side of head until fitted height of guide from
combustion face side of cylinder head to top of
guide is 61.1 to 61.7 mm
6. Allow cylinder head to air cool.
7. Ream bores of replacement valve guide
ensuring that reamer is kept perpendicular to
and concentric with valve seat.
Valve guide bore diameter = 6.950 to 6.963
mm
CAUTION: If valve seat insert has also
been replaced, guide and insert must be
machined together.
8. Suitably mark cylinder head on camshaft side
of head to denote that guide has been
replaced.
1st replacement guide +
2nd replacement valve guide -
2. Using valve seat cutter pilot MS 76, and a
60°cutter, tool MS 76-111, cut valve seat insert
to correct angle and width:
Inlet valve seat insert:
Seat width A = 35.697 mm
Seat angle B = 60°
Exhaust valve insert:
Seat width A = 31.05 to 31.55 mm
Seat angle B = 58°to 62°
CAUTION: A new valve must always be
fitted whenever a guide is replaced.
OVERHAUL
17
ENGINE
Lapping-in valves
1. Lap each valve to its seat using grinding paste.
2. Apply Prussian Blue to valve seat, insert valve
into guide and press it firmly, without rotating,
on to seat.
3. Check face angle A of each valve, renew any
valve with incorrect face angles, do not attempt
to recut.
Valve face angle - Inlet and exhaust = 45°to
45°30’.
3. Remove valve and check that a continuous,
even line of Prussian Blue has been
transferred on to valve face; continue
lapping-in valve as necessary.
NOTE: Line does not have to be across
whole width of valve face.
4. On completion of lapping-in, check valve head
stand down. See this section
18
OVERHAUL
ENGINE
Valve head stand down
Cylinder head bolts - inspection
1. Keeping bolts in their fitted order, clean bolts
and washers, lightly oil threads.
1. Insert each valve into its respective guide.
2. Using a straight-edge and feeler gauges, check
and record stand down of each valve head.
3. Compare figures obtained with figures given
below. If any valve has a stand down greater
than specified, valve seat insert and valve must
be replaced:
Valve head stand down:
Inlet valve A= 1.45 mm.
Exhaust valve B= 1.35 mm.
2. Check bolt heads and threads for damage,
replace individual bolts as necessary.
3. Check length of bolt from top of bolt head to
end of bolt. If any bolt exceeds 243.41 mm in
length, all 10 bolts and washers must be
replaced.
CAUTION: Do not attempt to remove
washers from bolts. Keep bolts in their
original fitted order.
OVERHAUL
19
ENGINE
Cylinder head and camshaft carrier - cleaning
CAUTION: Use a suitable solvent to
remove old sealant from cylinder head and
camshaft carrier faces.
1. Clean mating surfaces of cylinder head and
camshaft carrier, remove any deposits from
camshaft oil seal recesses using a plastic
scraper.
2. Clean gasket material from cylinder head and
block using gasket removal spray and plastic
scraper.
CAUTION: Do not use a metal scraper.
3. Clean all traces of carbon from combustion
face areas.
4. Blow out all oilways and waterways.
5. Ensure threaded holes in cylinder block and
camshaft carrier are clean and dry.
6. Check core plugs for corrosion and signs of
leakage and replace if necessary; use Loctite
577 to seal replacement plugs.
20
OVERHAUL
Valves - assembling
1. Lubricate valve stem oil seals, valve guides,
valve stems, spring caps and springs with
engine oil.
2. Using tool LRT-12-071, fit new valve stem oil
seals.
3. Assemble valves, springs and spring caps
ensuring that they are in their correct fitted
order.
4. Compress valve springs using tool
LRT-12-034, fit collets, remove tool.
5. Using a wooden dowel and mallet, tap each
spring cap lightly to seat collets.
ENGINE
Tappets and camshafts - assembling
1. Lubricate tappets and tappet bores with engine
oil. Fit tappets ensuring they are in their correct
fitted order.
2. Apply a continuous bead of sealant, Part No.
GUG 705963GM to paths on cylinder head as
shown then spread to an even film using a
roller.
CAUTION: Ensure sealant does not block
oilways or is spread on to bearing
journals. Assembly must be completed
within 20 minutes of applying sealant.
4. Position camshaft in cylinder head with
camshaft timing belt gear drive pin at
approximately 2 o’clock position.
5. Fit camshaft carrier, fit and lightly tighten bolts.
3. Lubricate cams and bearing journals on
camshaft, cylinder head and camshaft carrier
with engine oil.
CAUTION: Do not lubricate oil seal
running surfaces on camshaft.
CAUTION: With camshaft carrier bolted
down, some valves will protrude below
face of cylinder head; support each end of
cylinder head on blocks of wood.
6. Using sequence shown, progressively tighten
camshaft carrier bolts to 11 Nm.
CAUTION: Bolts must be tightened to
correct torque within 20 minutes of
applying sealant.
7. Check that all bolts are tightened to the correct
torque.
OVERHAUL
21
ENGINE
Cylinder head gasket selection
NOTE: There are three thicknesses of
cylinder head gasket available and in
order that the correct gasket is fitted, it is
necessary to determine the stand proud
(protrusion) of each piston above the top face of
the cylinder block.
8. Ensure tool LRT-12-140 is clean.
9. Fit oil seals using using tool LRT-12-140.
CAUTION: Oil seals must be fitted dry.
NOTE: Gaskets have either 1, 2 or 3
identification holes and the following
procedure must be followed in order that
the correct gasket is selected.
1. Temporarily assemble pulley to crankshaft, fit
pulley bolt and washer and lightly tighten bolt.
2. Remove timing pin LRT-12-058 - if fitted.
22
OVERHAUL
ENGINE
3. Assemble a magnetic base DTI to cylinder
block top face, zero DTI with stylus touching
block top face.
4. Rotate crankshaft in a clockwise direction until
Number 1 piston is at TDC.
5. Position stylus near edge of piston crown,
measure and record Number 1 piston
protrusion.
NOTE: Measurement must be taken at
front and rear of piston.
6. Repeat above procedure for remaining pistons.
7. From readings obtained, determine highest
piston protrusion figure and select the
appropriate cylinder head gasket:
Protrusion 0.10 to 0.25 mm - Select gasket
with one identification hole.
Protrusion 0.25 to 0.40 mm - Select gasket
with two identification holes.
Protrusion 0.40 to 0.55 mm - Select gasket
with three identification holes.
OVERHAUL
23
ENGINE
Cylinder head - refit
1. Fit crankshaft pulley bolt and washer and
lightly tighten bolt.
2. Remove timing pin LRT-12-058.
3. Ensure that cylinder block and head faces are
clean and dry and that all traces of gasket
material have been removed. Check that
cylinder head location dowels are fitted in
cylinder block.
12. Using sequence shown, tighten cylinder head
bolts to:
Stage 1 - 30 Nm
Stage 2 - 65 Nm
Stage 3 - Further 90°
Stage 4 - Further 90°
CAUTION: Ensure that correct tightening
sequence is followed for all four
tightening stages.
4. Check that oil feed restrictor in cylinder block is
clear and that restrictor is below block face.
5. Ensure that cylinder head bolt holes in cylinder
block are clean and dry.
6. Using crankshaft pulley bolt, rotate crankshaft
anti-clockwise until Numbers 1 and 4 pistons
are approximately 25 mm below cylinder block
top face.
7. Position camshaft timing gear drive pin at 2
o’clock.
8. Position selected cylinder head gasket on
cylinder block ensuring that it is correctly
orientated.
CAUTION: Gasket must be fitted dry.
9. Using assistance, fit cylinder head ensuring
that it is correctly located on dowels.
10. Lubricate cylinder head bolt threads and
undersides of bolt heads with engine oil.
CAUTION: Do not oil undersides of
washers.
11. Carefully enter cylinder head bolts in their fitted
order. DO NOT DROP BOLTS INTO
CYLINDER BLOCK.
24
OVERHAUL
13. Fit fuel injection pump drive belt rear cover and
mounting bracket, fit 3 screws and tighten to 8
Nm.
14. Fit fuel injection pump drive belt tensioner, fit
but do not fully tighten Allen screw.
15. Ensure sealing strip is correctly located on
camshaft timing belt upper rear cover.
16. Fit upper rear cover ensuring that 2 shortest
screws are fitted in camshaft carrier.
17. Tighten screws to 8 Nm.
ENGINE
18. Fit camshaft timing belt gear, ensuring that
drive pin is located in slot in gear. Lubricate
threads of a new gear retaining bolt with
engine oil, fit and lightly tighten bolt.
19. Restrain camshaft timing belt gear using tool
12-182 and tighten bolt to 20 Nm then a
further 90°.
20. Fit fuel pump drive belt gear to camshaft
ensuring that drive pin is located in slot in gear.
Lubricate threads of a new gear retaining bolt
with engine oil, fit and lightly tighten bolt.
21. Restrain camshaft timing belt gear using tool
12-182 and tighten fuel pump drive belt gear
bolt to 20 Nm then a further 90°.
CAUTION: Ensure camshaft does not
rotate as bolts are tightened.
23. Hold timing pin LRT-12-058 in contact with
flywheel and using assistance, rotate
crankshaft clockwise by means of crankshaft
pulley bolt until timing pin can be felt to enter
hole in flywheel.
CAUTION: Do not rotate crankshaft too far,
pistons may contact the valves.
24. Remove crankshaft pulley bolt and washer.
25. Fit new camshaft timing belt and adjust
tension.
26. Fit crankshaft pulley.
27. Fit pulley bolt and washer, tighten bolt to 63
Nm then further 90°.
28. Remove timing pin LRT-12-058.
22. Ensure that camshaft gear timing mark is
aligned with pointer on timing belt upper rear
cover.
OVERHAUL
25
ENGINE
29. Fit a new gasket to camshaft cover ensuring
that raised holes in gasket are towards the
cover and are located on the two spigots.
FLYWHEEL AND STARTER RING GEAR
Flywheel - remove
CAUTION: Gasket must be fitted dry.
30. Fit camshaft cover bolts and tighten in
sequence shown to 12 Nm.
1. Remove bolt securing crankshaft sensor to
gearbox adaptor plate. Remove sensor.
26
OVERHAUL
ENGINE
Starter ring gear - remove
1. Remove flywheel.
2. Drill a 3 mm diameter hole at the root of 2
teeth.
3. Apply a cold chisel to root of teeth, break ring
gear and remove from flywheel.
2. Hold timing pin LRT-12-058 in contact with
flywheel and using assistance, rotate
crankshaft clockwise by means of crankshaft
pulley bolt until timing pin can be felt to enter
hole in flywheel.
WARNING: Suitable eye protection must
be worn.
CAUTION: Do not rotate crankshaft with
timing belt removed and cylinder head
fitted.
3. Remove and discard 6 bolts securing flywheel
to crankshaft.
4. Remove timing pin LRT-12-058.
5. Using assistance, remove flywheel.
NOTE: Dowel located.
OVERHAUL
27
ENGINE
Starter ring gear - refit
1. Heat ring gear evenly to 350°C indicated by
light blue colour. Locate ring gear on flywheel
and press on to flange.
WARNING: Handle hot ring gear with care.
2. Allow ring gear to air cool.
3. Fit flywheel.
28
OVERHAUL
Flywheel - refit
1. Clean threads in crankshaft using an old
flywheel bolt having 2 saw cuts at 45°along
thread of bolt.
CAUTION: Do not use a tap to clean
threads.
2. Clean flywheel faces.
3. Using assistance, position flywheel on
crankshaft, fit and lightly tighten new Patchlok
bolts.
4. Insert timing pin LRT-12-058 into flywheel.
5. Tighten bolts to 15 Nm then a further 90°.
6. Position crankshaft sensor to gearbox adaptor
plate, fit and tighten bolt to 8 Nm.
ENGINE
GEARBOX ADAPTOR PLATE
SUMP AND OIL STRAINER
Remove
Sump - remove
1. Remove dipstick.
2. Remove oil pump.
3. Remove and discard crankshaft rear oil seal
and housing.
4. Using sequence shown, remove 17 bolts
securing sump to cylinder block.
5. Remove sump.
1. Remove 4 Torx screws securing adaptor plate
to cylinder block. Remove plate.
Refit
1. Check condition of foam rubber pad, replace if
necessary.
2. Remove all traces of Loctite from Torx screws.
3. Ensure tapped holes in cylinder block are clean
and dry.
4. Apply Loctite 275 to threads of Torx screws.
5. Position adaptor plate to cylinder block, fit and
tighten Torx screws to 45 Nm.
Later engines
NOTE: Later engines are fitted with a
modified sump gasket which has an
additional locating/sealing area retained
by the oil strainer flange. This gasket should be
used as a replacement for all engines. In order to
fit the modified gasket, it will be necessary to
remove the oil strainer and pick-up pipe.
6. Remove oil strainer and pick-up pipe.
All engines
7. Remove and discard sump gasket.
OVERHAUL
29
ENGINE
Oil strainer and pick-up pipe - remove
Oil strainer and pick-up pipe - refit
1. Clean strainer and pick-up pipe.
2. Ensure bolt holes in cylinder block and main
bearing cap are clean and dry.
1. Remove 3 bolts securing oil strainer and
pick-up pipe to cylinder block and main bearing
cap noting that shortest bolt is fitted in main
bearing cap.
2. Remove oil strainer and pick-up pipe, remove
and discard ’O’ ring.
3. Later engines fitted with modified sump gasket:
Remove and discard sump gasket.
3. Lubricate a new ’O’ ring with engine oil and fit
to pick-up pipe flange.
4. Position new sump gasket to cylinder block
ensuring that locating lugs are inserted in holes
in block.
CAUTION: Gasket must be fitted dry.
5. Position strainer and oil pick-up pipe to cylinder
block and main bearing cap.
6. Fit 3 bolts noting that shortest bolt is fitted into
main bearing cap. Tighten bolts to 8 Nm.
NOTE: Patchlok bolts may be re-used
provided threads are undamaged.
30
OVERHAUL
ENGINE
Sump - refit
1. Clean sump flange and mating surfaces of
cylinder block, ensure bolt holes in cylinder
block and main bearing cap are clean and dry.
2. Using sealant, Part Number GUG 705963GM,
fill grooves on each side of front - Number 1
main bearing cap and along joint lines of main
bearing cap and cylinder block.
CAUTION: Do not apply sealant until
immediately prior to fitting sump. Do not
spread sealant bead.
3. Fit a new crankshaft rear oil seal and housing.
5. Position new gasket to sump ensuring that
locating lugs are inserted in holes in sump; fit
oil strainer and pick-up pipe.
NOTE: Gasket must be fitted dry.
6. Position sump to cylinder block ensuring that
locating lugs are inserted in holes in block.
4. Apply a 1 mm bead of sealant, Part No. GUG
705963GM to joint line of crankshaft rear oil
seal housing, rear main bearing cap and
cylinder block and around edges of sump bolt
holes in rear main bearing cap.
CAUTION: Do not apply sealant until
immediately prior to fitting sump. Do not
spread sealant bead.
OVERHAUL
31
ENGINE
OIL PUMP
Remove
1. Remove camshaft timing belt.
7. Fit and lightly tighten 17 bolts.
8. Using sequence shown, tighten bolts to 25 Nm.
9. Using the same sequence, re-check that all
bolts are torqued to 25 Nm.
10. Fit dipstick.
11. Fit oil pump.
2. Slide timing gear off crankshaft.
NOTE: The key is an integral part of the
gear.
3. Remove nut securing camshaft timing belt idler
pulley, remove pulley.
NOTE: Idler pulley mounting stud may be
unscrewed as nut is removed.
4. Remove 2 bolts securing camshaft timing belt
lower rear cover, remove cover and sealing
strips.
32
OVERHAUL
ENGINE
Oil pump - inspection
Oil pump
CAUTION: Overhaul procedures for the oil
pump are limited to carrying out
dimensional checks. In the event of wear
or damage being found, a replacement pump
must be fitted.
1. Make suitable alignment mark between pump
backplate and body.
2. Remove 4 Torx screws securing backplate to
body, remove backplate.
5. Using sequence shown, remove 1 M10 and 8
M6 bolts securing oil pump to cylinder block.
NOTE: Longest M6 bolt is fitted at position
9 (see inset).
6.
7.
8.
9.
Remove oil pump.
Remove and discard gasket.
Recover Woodruff key from crankshaft.
Remove and discard crankshaft front oil seal
from oil pump body.
3. Using a felt tipped pen, make suitable
alignment marks between inner and outer
rotors and pump body.
4. Remove inner and outer rotors.
5. Check rotors and pump body for signs of
scoring and wear.
6. Fit rotors ensuring that reference marks are
aligned and chamfered side of outer rotor
carrying a square identification mark is facing
away from backplate side of pump body.
OVERHAUL
33
ENGINE
7. Using feeler gauges, check pump body to rotor
clearance.
Clearance = 0.05 to 0.10 mm.
9. Using feeler gauges, check clearance between
inner and outer rotor lobes.
Clearance = 0.025 to 0.12 mm.
10. Renew oil pump assembly if excessive scoring
exists or clearances exceed specified limits.
8. Place a straight edge across pump body and
using feeler gauges, measure end-float of
outer rotor.
End-float = 0.03 to 0.08 mm.
34
OVERHAUL
ENGINE
Oil pressure relief valve - remove
Early engines
Oil pressure relief valve - refit
1. Remove all traces of sealant from plug threads
in oil pump body.
2. Lubricate spring, relief valve plunger and bore
with engine oil.
3. Fit plunger and spring.
Early engines
1. Apply Loctite 577 to threads of replacement
plug.
2. Fit plug and tighten to 25 Nm.
CAUTION: Do not attempt to re-seal and fit
the original plug.
Later engines
1. Remove and discard plug.
2. Remove spring and relief valve plunger.
Later engines
1. Fit a new Dowty washer to replacement plug.
2. Apply Loctite 577 to threads of plug.
3. Fit plug and tighten to 25 Nm.
CAUTION: Do not attempt to re-seal and fit
the original plug.
All engines
4. Check oil pressure switch - if fitted for damage,
replace as necessary. Apply Loctite 577 to
threads of replacement switch; fit switch and
tighten to 16 Nm.
1. Remove and discard plug.
2. Remove and discard Dowty washer.
3. Remove spring and relief valve plunger.
All engines
4. Check plunger and bore for wear, corrosion
and scoring.
NOTE: Light scoring may be removed
using grade 600 emery cloth soaked in oil.
5. Check spring free length.
Free length = 38.9 mm.
6. Renew relief valve as an assembly.
OVERHAUL
35
ENGINE
Thermostatic valve
1. Remove diverter plug, remove and discard
Dowty washer.
2. Withdraw spring and valve from oil pump body.
CAUTION: Do not separate spring from
valve.
7. Lubricate valve, spring and bore with engine
oil.
8. Secure oil pump body in a soft-jawed vice with
thermostatic valve bore facing upwards.
CAUTION: Valve bore must be as near
vertical as possible.
9. Insert valve and spring in bore ensuring that it
is positioned centrally in bore.
3. Check spring for distortion and corrosion.
4. Check valve for corrosion, seating faces of
valve and diverter plug for damage and pitting;
replace valve as an assembly.
5. Check valve bore for corrosion.
NOTE: Light corrosion may be removed
from valve bore using grade 600 emery
cloth soaked in oil.
6. Remove all traces of Loctite from threads of
diverter valve plug and oil pump body.
CAUTION: Do not remove blanking plug
from oil gallery below thermostatic valve
bore.
36
OVERHAUL
CAUTION: Valve will not seat correctly in
diverter plug if it is not positioned
centrally.
10. Fit a new Dowty washer to diverter plug.
11. Apply Loctite 577 to threads of diverter plug.
12. Fit diverter plug, carefully tighten plug by hand
ensuring that valve is not displaced as plug is
tightened.
13. When diverter plug is screwed fully down,
tighten to 35 Nm.
ENGINE
Oil pump - assembling
1. Using gasket removal spray and plastic
scraper, remove all traces of gasket material
from oil pump body.
2. Using suitable solvent, remove all traces of
sealant from oil pump body and backplate.
3. Remove all traces of Loctite from Torx screws
and holes in oil pump body, ensure holes are
clean and dry.
Oil pump - refit
1. Using gasket removal spray and plastic
scraper, remove all traces of gasket from
cylinder block.
2. Using a suitable cleaning solvent, remove all
traces of sealant from joint faces of front Number 1 main bearing cap.
3. Clean oil seal running surface on crankshaft.
4. Check that crankshaft front oil seal recess in
pump body is clean and dry.
CAUTION: Do not use a tap.
4. Ensure all components are clean, lubricate
rotors and housing with engine oil.
5. Fit rotors ensuring that reference marks are
aligned and chamfered side of outer rotor
carrying a square identification mark is facing
away from backplate side of pump body.
5. Fit new crankshaft front oil seal to pump using
tool LRT-12-069.
CAUTION: Oil seal must be fitted dry.
NOTE: Replacement oil pumps are
supplied with oil seal fitted.
6. Fit Woodruff key to crankshaft.
6. Apply a 1 mm bead of Loctite 573 to pump
backplate as shown.
7. Fit pump backplate ensuring reference marks
on backplate and pump body are aligned.
8. Apply Loctite 222 to threads of Torx screws, fit
and tighten screws.
9. Check that pump rotates freely.
OVERHAUL
37
ENGINE
10. Align Woodruff key slots in oil pump inner rotor
with Woodruff key
11. Ensure bolt holes in cylinder block are clean
and dry.
7. Using sealant, Part No. GUG 705963GM,
apply a 1 mm thick bead of sealant to joint line
of front - Number 1 main bearing cap and
cylinder block.
CAUTION: Do not fill grooves on either
side of main bearing cap or apply sealant
to sump mating flange of main bearing
cap until immediately before sump is fitted.
8. Position a new gasket to cylinder block.
CAUTION: Gasket must be fitted dry.
9. Insert oil seal protector LRT-12-070 and
adaptor sleeve LRT-12-130 into oil pump inner
rotor.
NOTE: This will assist in locating oil pump
inner rotor on Woodruff key.
38
OVERHAUL
12. Slide oil pump over crankshaft ensuring
Woodruff key is located in keyway in inner
rotor, locate oil pump on dowels.
NOTE: Tools LRT-12-070 and LRT-12-130
will be displaced as pump is fitted.
ENGINE
CRANKSHAFT, MAIN AND BIG-END BEARINGS
Crankshaft rear oil seal - remove
13. Fit and lightly tighten bolts ensuring that
longest M6 bolt is fitted at position 1 and M10
bolt at position 9.
NOTE: Patchlok bolts may be re-used
provided threads are undamaged.
1. Remove 5 bolts securing rear oil seal housing
to cylinder block, remove and discard housing
and oil seal.
14. Gradually tighten bolts in sequence shown until
oil pump is pulled against cylinder block.
CAUTION: Bolt tightening must be done
gradually due to tight fit of pump rotor on
crankshaft. Damage to oil pump will result
if the above procedure is not followed.
15. Finally, tighten bolts in sequence shown to:
M6 bolts - 8 Nm
M10 bolt - 45 Nm
16. Ensure sealing strips are fitted to camshaft
timing belt lower rear cover.
17. Fit lower rear cover, fit and tighten screws to 8
Nm.
18. Fit camshaft timing belt idler pulley ensuring
that recessed side of centre boss faces away
from engine.
19. If idler pulley stud was unscrewed during nut
removal, clean old Loctite from threads of stud
and ensure hole in cylinder block is clean and
dry. Apply Loctite 275 to threads of stud and
screw it into block, tighten stud to 12 Nm.
20. Apply Loctite 275 to threads of idler pulley nut,
fit and tighten nut to 45 Nm.
21. Slide timing gear on to crankshaft.
22. Fit new camshaft timing belt and adjust
tension.
OVERHAUL
39
ENGINE
Big-end bearings - remove
Crankshaft end-float - check
1. Attach a magnetic base Dial Test Indicator to
front of cylinder block, move crankshaft
rearwards, position stylus on end of crankshaft
and zero DTI.
2. Move crankshaft forwards, measure and record
end-float figure obtained:
End-float = 0.03 to 0.26 mm
3. If end-float exceeds above dimension, new
thrust washers must be fitted:
Thrust washer thickness = 2.31 to 2.36 mm
1. Suitably mark cylinder reference number on
each big-end bearing cap and connecting rod.
2. Remove 2 bolts securing each big-end bearing
cap, remove caps and recover big-end bearing
shells.
NOTE: The big-end bearing shells do not
have location tags for locating the
bearings in the connecting rod and
bearing cap. The big-end to connecting rod bolts
are off-set 1 mm to prevent incorrect fitment of
the bearing cap to the connecting rod.
CAUTION: Keep bolts and bearing caps in
their fitted order. Big-end bearing shells
should always be replaced whenever
crankshaft is removed.
3. Push each connecting rod up cylinder bore
until connecting rod is clear of the crankshaft
journals.
CAUTION: Ensure connecting rods do not
contact oil squirt jets or cylinder bores.
40
OVERHAUL
ENGINE
Crankshaft - remove
NOTE: Crankshaft end-float must be
checked prior to removing crankshaft.
3. Using fingers only, rock each main bearing cap
until it is released from locating dowels.
CAUTION: Do not tap caps sideways.
4. Remove main bearing caps and plain bearing
shells.
5. Using assistance, remove crankshaft.
6. Recover upper, grooved main bearing shells
and 2 thrust washers.
7. Using a suitable cleaning solvent, remove
sealant from front - Number 1 main bearing
cap and cylinder block.
1. Check that identification marks 1 to 5, and the
direction arrows which face towards the front of
the engine are marked on each main bearing
cap.
NOTE: The identification marks on number
2 main bearing cap are concealed by the
oil strainer mounting bracket which is
secured to the bearing cap.
2. Starting at centre main - Number 3 main
bearing cap and working outwards,
progressively loosen, then remove 2 bolts
securing each cap.
CAUTION: Keep bolts in their fitted order.
OVERHAUL
41
ENGINE
Crankshaft - inspection
Crankshaft - refit
1. Clean crankshaft, ensure all oilways are clear.
CAUTION: If crankshaft end-float
exceeded 0.26 mm, new thrust washers
must be fitted.
1. Clean main bearing shell locations in cylinder
block, clean main bearing caps.
2. Check that ring dowels are fitted in main
bearing cap locations and that bolt holes are
clean and dry.
3. Check threads of main bearing cap bolts for
damage, renew bolts in pairs.
4. Lubricate new upper main bearing shells with
engine oil and ensuring that they are centrally
positioned, fit to their locations in cylinder
block.
NOTE: These bearing shells are grooved.
5. Lubricate thrust washers with engine oil and fit,
oil groove side outwards to each side of centre
- (Number 3) main bearing in cylinder block.
6. Lubricate crankshaft journals with engine oil
and using assistance, position crankshaft in
cylinder block.
CAUTION: Ensure thrust washers are not
displaced as crankshaft is fitted.
2. Check crankshaft journals for wear and ovality,
make three checks at 120°intervals in centre of
journals.
Crankshaft bearing journal diameters:
Main bearings = 60.703 to 60.719 mm
Big-end bearings = 57.683 to 57.696 mm
Clearance in bearings = 0.005 mm
CAUTION: Crankshaft journals may not be
reground undersize, if journals are worn,
crankshaft must be replaced. Main and
big-end bearings are only available in one size
and should always be replaced whenever
crankshaft has been removed.
3. Check thrust washers for wear and scoring,
replace as necessary:
Thrust washer thickness = 2.31 to 2.36 mm
42
OVERHAUL
7. Lubricate new main bearing shells with engine
oil and fit to main bearing caps.
NOTE: These bearing shells are plain.
8. Fit main bearing caps ensuring that they are
correctly orientated and in their fitted order.
CAUTION: Do not apply sealant to grooves
in front - (Number 1) main bearing cap
until immediately before sump is fitted.
ENGINE
9. Lubricate threads of main bearing cap bolts
with engine oil, fit and lightly tighten bolts.
10. Starting from the centre - Number 3 main
bearing cap and working outwards, tighten
bolts to 112 Nm.
11. Check that crankshaft rotates smoothly.
12. Re-check crankshaft end-float. See this
section
CAUTION: If original thrust washers have
been refitted and end-float exceeds 0.26
mm, crankshaft must be removed and new
thrust washers fitted. If, with new thrust washers
fitted, end-float is still excessive, crankshaft
must be replaced.
Crankshaft rear oil seal - refit
CAUTION: Rear oil seal and housing must
be fitted prior to fitting sump.
1. Ensure oil seal running surfaces on crankshaft
and oil seal housing mating surface on cylinder
block are clean and oil free and that bolt and
dowel holes are clean and dry.
CAUTION: Do not lubricate oil seal or
running surface on crankshaft. The oil
seal is pre-lubricated at manufacture. Do
not separate protector sleeve from oil seal and
do not touch lip of seal. If seal is inadvertently
handled it must not be fitted as the coating
applied to the seal during manufacture will be
destroyed and oil leakage can result.
2. Slide oil seal protector sleeve, oil seal and
housing over end of crankshaft.
3. Position oil seal and housing on cylinder block.
NOTE: Oil seal protector will be displaced
as seal and housing are fitted.
4. Fit bolts and working in sequence shown,
tighten to 8 Nm.
OVERHAUL
43
ENGINE
Big-end bearings - refit
5. Apply a 1 mm thick bead of sealant, Part
Number GUG 705963GM along joint line of
seal housing, rear main bearing cap and
cylinder block and around sump bolt holes in
rear main bearing cap.
CAUTION: Do not apply sealant until
immediately prior to fitting sump, do not
spread sealant bead.
44
OVERHAUL
1. Rotate crankshaft until big-end bearing journals
are correctly positioned.
2. Lubricate crankshaft big-end journals with
engine oil.
3. Fit new big-end bearing shells to connecting
rods, lubricate shells with engine oil.
4. Taking care not to damage oil squirt jets or to
displace bearing shells, pull connecting rods on
to crankshaft journals.
5. Check that new big-end bearing shells are
correctly located on big-end bearing caps,
lubricate shells with engine oil.
6. Fit big-end bearing caps ensuring that they are
in their correct fitted order.
7. Lubricate threads of connecting rod bolts with
engine oil. Fit bolts to their respective
connecting rods and tighten to 20 Nm then a
further 90°.
ENGINE
PISTONS, CONNECTING RODS AND CYLINDER
BORES
Pistons and connecting rods - remove
1. Remove crankshaft.
Piston rings - remove
1. Using a suitable expander, remove and discard
piston rings.
2. Use a squared off end of a broken piston ring
to clean groove in piston.
CAUTION: Do not use a wire brush or
emery cloth.
2. Remove and discard banjo bolts securing oil
squirt jets to cylinder block, remove jets.
NOTE: Each jet is located by means of a
roll pin.
3. Suitably identify each piston and connecting
rod assembly to its respective cylinder bore.
4. Using assistance, lay cylinder block on its side.
5. Push each piston and connecting rod up
cylinder bore taking care to keep connecting
rod clear of bore walls; remove pistons and
connecting rods.
6. Recover big-end bearing shells from
connecting rods.
CAUTION: Big-end bearing shells should
always be replaced whenever pistons and
connecting rods are removed.
OVERHAUL
45
ENGINE
Piston ring gaps - checking
1. Check new ring to groove clearance:
Top compression ring = 0.115 to 0.135 mm.
2nd compression ring = 0.050 to 0.082 mm.
Oil control rails = 0.050 to 0.082 mm.
Pistons - remove
1. Suitably identify each piston to its connecting
rod, note position of cast boss on connecting
rod relative to arrow on piston crown.
2. Remove and discard circlips securing gudgeon
pin.
3. Push gudgeon pin out of piston and connecting
rod.
CAUTION: Keep gudgeon pins with their
respective pistons and lightly tighten bolts
to retain bearing caps to connecting rods.
2. Check new ring fitted gap 30 mm from top of
cylinder bore, ensure rings are kept square to
bore when checking gaps.
Fitted gap:
Top compression ring = 0.25 to 0.27 mm.
2nd compression ring = 0.40 to 0.42 mm.
Oil control rails = 0.30 to 0.32 mm.
46
OVERHAUL
ENGINE
Pistons and connecting rods - inspection
1. Check pistons for cracks, distortion and
damage.
2. Measure and record piston diameter at right
angles to gudgeon pin hole and 44 mm from
bottom of skirt:
Diameter = 84.262 mm.
3. Starting with Number 1 piston, invert piston
and with arrow on piston crown pointing
towards REAR of cylinder block, insert piston
into top of Number 1 cylinder bore.
4. Position piston with bottom of skirt 25 mm from
top of cylinder bore.
5. Using feeler gauges, measure and record
clearance between piston skirt and left hand
side of cylinder bore 70 mm from top of bore
(viewed from front of cylinder block).
Piston to cylinder bore clearance = 0.18 to 0.2
mm.
6. Repeat procedures for remaining pistons.
CAUTION: Measurement point must be on
the ungraphited area of the piston.
CAUTION: Oversize pistons are not
available, if clearances are excessive,
measure diameter of cylinder bore before
proceeding further - See Cylinder bores inspection. If, after inspection, cylinder bores are
found to be the correct size, pistons must be
replaced.
OVERHAUL
47
ENGINE
7. Check fit of each gudgeon pin in its respective
piston, pin must be a tight, sliding fit with no
perceptible side play.
Pistons - refit
1. Lubricate gudgeon pin and small-end bush with
engine oil.
2. Position piston to its respective connecting rod
with the direction of the arrow on the piston
crown on the same side as the cast boss on
the piston.
3. Fit gudgeon pin, fit new circlips ensuring they
are fully seated in their grooves.
4. Repeat above procedures for remaining
pistons.
8. Measure gudgeon pin diameter at each end
and centre of pin:
Diameter = 29.995 to 30.000 mm.
9. Renew gudgeon pins and pistons as an
assembly if diameters are less than specified
or if excessive pin to piston side play is
evident.
10. Check connecting rods for alignment, reject
any connecting rod which is bent.
11. Check small-end bushes for wear, check that
gudgeon pin is a close/sliding fit in the bush,
with no perceptible side play.
CAUTION: Small-end bushes may not be
replaced, a new connecting rod must be
fitted.
12. Using fingers only, check that each big-end
bearing cap bolt runs freely in the threads of its
respective thread in the connecting rod. If any
bolt is tight, then the bolt must be replaced.
48
OVERHAUL
ENGINE
Piston rings - refit
Cylinder bores - inspection
1. Check cylinder bores for scoring.
2. Check cylinder bores for wear, measure and
record diameter of each bore, 70 mm from top
of bore.
1. Fit oil control rails and spring.
2. Fit 2nd compression ring with ’TOP’ marking
upwards.
3. Fit top compression ring with ’TOP’ marking
upwards.
4. Check that rings are free to rotate, position ring
gaps at 120°to each other and away from
thrust side - left hand side of piston - viewed
from front of piston.
CAUTION: Measurements must be taken
from side to side and front to rear of bore.
Bore diameter = 84.442 to 84.460 mm.
CAUTION: No reboring, honing or glaze
busting of cylinder bores is permissible;
cylinder block must be replaced if cylinder
bores are worn beyond limits.
OVERHAUL
49
ENGINE
Cylinder block
1. Check that all oilways are clear and that oil
restrictor located in oilway to cylinder head is
fitted below face of cylinder block.
2. Check that main bearing cap, crankshaft rear
oil seal housing and cylinder head locating
dowels are fitted.
3. Check core plugs for leakage and corrosion,
replace as necessary.
Pistons and connecting rods - refit
1. Lubricate cylinder bores, pistons, rings and
crankshaft big-end journals with engine oil.
2. Lubricate new big-end bearing shells with
engine oil and fit to connecting rods and
bearing caps.
3. Check that piston ring gaps are positioned at
120°to each other and away from thrust - left
hand side of piston - viewed from front of
piston.
NOTE: Seal replacement core plugs and
main oil gallery plug on rear of cylinder
block with Loctite 577, tighten main oil
gallery plug to 45 Nm. Seal dipstick tube in
cylinder block with Loctite 638.
4. Fit suitable piston ring clamp to each piston in
turn and ensuring that pistons are in their
correct fitted order and that the arrow on piston
crown and the cast boss above the big-end is
facing towards front of cylinder block, push
pistons into their respective cylinder bores.
CAUTION: Ensure that connecting rods do
not contact cylinder bores.
5. Do not pull connecting rods fully down cylinder
bores at this stage.
6. Check that cut-out in each piston skirt is
positioned above oil squirt jet location.
7. Ensure oil squirt jets are clear and that roll pins
are inserted in jet housings.
50
OVERHAUL
ENGINE
8. Position oil squirt jets in cylinder block ensuring
that roll pins are inserted in locating holes.
9. Apply Loctite 275 to threads of new banjo
bolts.
CAUTION: Do not allow Loctite to enter oil
hole in banjo bolts.
10. Fit and tighten banjo bolts to 12 Nm.
11. Fit crankshaft and big-end bearings.
OVERHAUL
51
ENGINE
ENGINE DATA
Oil pump
Outer rotor to body clearance . . . . . . . . . . . . . . . . . .
Rotor lobe clearance . . . . . . . . . . . . . . . . . . . . . . . . .
Outer rotor end float . . . . . . . . . . . . . . . . . . . . . . . . .
Relief valve spring free length . . . . . . . . . . . . . . . . . .
0.05 to 0.10 mm
0.025 to 0.12 mm
0.03 to 0.08 mm
38.9 mm
Camshaft
Camshaft end-float . . . . . . . . . . . . . . . . . . . . . . . . . . 0.51 mm - max.
Camshaft bearing clearance . . . . . . . . . . . . . . . . . . . 0.043 to 0.094 mm
Camshaft timing belt tensioner spring free length . . . 65 mm
Tappets
Tappet outside diameter . . . . . . . . . . . . . . . . . . . . . . 34.959 to 34.975 mm.
Cylinder head
Cylinder head maximum warp . . . . . . . . . . . . . . . . . . 0.10 mm
Cylinder head bolt length . . . . . . . . . . . . . . . . . . . . . . 243.41 mm
Valve springs
Free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.0 mm
Valves
Valve stem diameter:
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve stem to guide clearance - maximum:
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve face angle . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve head stand down:
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.907 to 6.923 mm
6.897 to 6.913 mm
0.056 mm
0.066 mm
45°to 45°30’
1.45 mm
1.35 mm
Valve guides:
Inside diameter after reaming . . . . . . . . . . . . . . . . . 6.950 to 6.963 mm
Fitted length above cylinder head . . . . . . . . . . . . . . 61.1 to 61.7 mm
Valve seat inserts:
Seat angle
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Insert diameter
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60°
58°to 62°
35.697 mm
31.05 to 31.55 mm
DATA, TORQUE & TOOLS
1
ENGINE
Crankshaft
End-float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thrust washer halves thickness . . . . . . . . . . . . . . . .
Main journal diameter . . . . . . . . . . . . . . . . . . . . . . . .
Clearance in bearings . . . . . . . . . . . . . . . . . . . . . . . .
Big-end journal diameter . . . . . . . . . . . . . . . . . . . . . .
Clearance in bearings . . . . . . . . . . . . . . . . . . . . . . . .
0.03 to 0.26 mm
2.31 to 2.36 mm
60.703 to 60.719 mm
± 0.005 mm
57.683 to 57.696 mm
± 0.005 mm
Piston rings
New ring to groove clearance:
Top compression ring . . . . . . . . . . . . . . . . . . . . . . . 0.115 to 0.135 mm
2nd compression ring . . . . . . . . . . . . . . . . . . . . . . . 0.050 to 0.082 m m
Oil control rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.050 to 0.082 mm
Ring fitted gap 30 mm from top of cylinder bore:
Top compression ring . . . . . . . . . . . . . . . . . . . . . . . 0.25 to 0.27 mm
2nd compression ring . . . . . . . . . . . . . . . . . . . . . . . 0.40 to 0.42 mm
Oil control rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 to 0.32 mm
Pistons
Piston diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.262 mm
Clearance in bore . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.18 to 0.2 mm
Cylinder block
Cylinder bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.442 to 84.460 mm
2
DATA, TORQUE & TOOLS
ENGINE
TORQUE FIGURES
Camshaft timing belt upper front cover screws . . . . .
Camshaft timing belt lower front cover screws . . . . .
Camshaft timing belt upper rear cover screws . . . . .
Camshaft timing belt lower rear cover screws . . . . . .
Camshaft timing belt tensioner bolt . . . . . . . . . . . . . .
Camshaft timing belt Allen screw or bolt . . . . . . . . . .
Camshaft timing belt idler pulley nut . . . . . . . . . . . . .
Idler pulley stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine front mounting cover plate nuts . . . . . . . . . . .
Engine front mounting cover plate bolts . . . . . . . . . .
Crankshaft pulley bolt . . . . . . . . . . . . . . . . . . . . . . . .
Oil pump bolts - Patchlok: *
M6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostatic valve diverter plug . . . . . . . . . . . . . . . .
Oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil pressure relief valve plug . . . . . . . . . . . . . . . . . . .
Oil pick-up pipe bolts - Patchlok . . . . . . . . . . . . . . . .
Fuel injection pump drive belt backplate screws . . . .
Camshaft timing belt gear bolt + . . . . . . . . . . . . . . . .
Camshaft gear damper Torx screws + . . . . . . . . . . .
Fuel injection pump drive belt gear bolt + . . . . . . . . .
Camshaft cover bolts . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft carrier to cylinder head bolts * . . . . . . . . . .
Cylinder head Torx bolts *
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stage 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flywheel bolts - Patchlok + . . . . . . . . . . . . . . . . . . . .
Gearbox adaptor plate Torx screws . . . . . . . . . . . . . .
Crankshaft sensor to adaptor plate bolt . . . . . . . . . . .
Oil sump bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil sump drain plug . . . . . . . . . . . . . . . . . . . . . . . . . .
Main bearing cap bolts . . . . . . . . . . . . . . . . . . . . . . .
Connecting rod cap bolts . . . . . . . . . . . . . . . . . . . . . .
Crankshaft rear oil seal housing bolts * . . . . . . . . . . .
Oil squirt jet banjo bolts . . . . . . . . . . . . . . . . . . . . . . .
Main oil gallery plug . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Nm
5 Nm
8 Nm
8 Nm
45 Nm
55 Nm
45 Nm
12 Nm
30 Nm then further 120°
45 Nm
63 Nm then further 90°
8 Nm
45 Nm
35 Nm
16 Nm
25 Nm
8 Nm
8 Nm
20 Nm then further 90°
10 Nm
20 Nm then further 90°
12 Nm
11 Nm
30 Nm
65 Nm
Further 90°
Then further 90°
15 Nm then further 90°
45 Nm
8 Nm
25 Nm
25 Nm
112 Nm
20 Nm then further 90°
8 Nm
12 Nm
45 Nm
+ New bolts /Torx screws must be used.
* Tighten in sequence
DATA, TORQUE & TOOLS
3
ENGINE
TOOL NUMBERS
LRT-12-069
LRT-12-070
LRT-12-130
LRT-12-034
LRT-12-058
LRT-12-071
LRT-12-140
LRT-12-143
MS 76
MS 76-111
12-182
12-186
4
DATA, TORQUE & TOOLS
Replacer - Crankshaft Oil Seal
Oil Seal Protection Sleeve
Adaptor Sleeve
Valve Spring Compressor
Timing Pin
Valve Stem Oil Seal
Remover/replacer
Replacer - Camshaft Oil Seals
Camshaft Timing Belt Tensioner
Retractor
Valve seat cutter pilot
60°cutter
Camshaft timing gear holding tool
Valve guide reamer
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