Service Workbook XUD9A EngineSy XUD9A DIESEL ENGINE Service Workbook ‘This Service Workbook covers the XUD9A Diesel engine fitted to LDV vehicles. It is primarily designed to assist skilled technicians in the efficient repair and maintenance of this engine, but can also be used as a feference workbook for training purposes. This Service Workbook should always be consulted prior to servicing or repair work. SPECIFICATION LDV (the Company) reserves the right to change the procedures, material, specification, dimensions or design of the vehicles shown, described or referred to herein at any time and without prior notice in accordance with the Company's policy of constant product improvement. Every reasonable effort is made to ensure that the Company's publications are accurate, but nothing ‘shown, described or referred to herein should be regarded as an infallible guide to the procedures, materials, specifications, dimensions, design or avaliablity of any particular vehicle, nor does this publication constitute an offer for the sale of any particular vehicle. No lability can be accepied by the Company or any Distibutor or Dealer for any malfunction, damage, loss, injury, or death caused by the use of incorrect or misinterpreted information, omissions or errors that may have arisen during the preparation, of this workbook. Purchasers are advised that the specification details set out inthis publication apply to a range of vehicles ‘and not to any particular vehicle. For the specification of any particular vehicle, purchasers should consult their LDV Distributor or Dealer. Please note that LDV Distributors and Dealers are not agents of the ‘Company, and have no right or authority whatsoever to bind the Company in any way, of to assume on its behalf any obligation expressed or implied. COPYRIGHT © Lov 1904 All rights reserved. No part ofthis publication may be reproduced, stored in a retrieval system or transmitted, in any form, whether electronic, or mechanical, or by photocopying, recording or other means. without prior permission in writing of LDV. Published by LDV, from whom further copies may be obtained through your normal literature ordering procedure. LDV Training & Publications ‘Common Lane Washwood Heath Birmingham Bs 2UP Publcaton Part No.DW 03904001 08/04CONTENTS Introduction and General Precautions .. Technical data .. Lubricants and Sealants. Service summary Special tools ...... Torque wrench settings ...... Engine ilustrations .......... SETTINGS = S F fry x = rm =} fe] ie fe) S Engine: — remove and refit Extemal drive belts - remove, ref, adjust ‘Atemator dive belt (models with power assisted steering) ‘Attemator drive belt (modets without power assisted steering) Vacuum pump drive belt sees Timing case: Timing belt - remove ..... fees Crankshaft pulley and front oll seal remove and refit Timing belt — refit Cylinder head: Camshaft pulley and oll seal ~ remove and refit ‘Tappet clearances check ... — adjust Cylinder head Remove ~ Dismantling = Inspection / overhaul . — Re-assembly ~ Refit Flywheet: Clutch — remove and refit : ceteteseeeeeee Crankshaft ear ol seal and spigot bearing — remove and ret 61 Crankease: Dismanting 65 Inspection and overhaul — Cylinder block .. cevteteeeteeeeseeeeees : or = Crankshaft... ceeeseee ceseesesesecsssess 67 — Pistons & connecting rods 68 Rebuild 69 CRANKCASE J FLYWHEEL | CYLINDER HEAD §| TIMING CASE9 Lubrication system: Oil circulation wees ill pump — Inspection .... Fuel system: ‘System operation Injection pump adjustments = Throttle cable Idle speed Automatic fast idle Anti-stall . - Injection pump timing — check and adjust . Injection pump — remove and refit Injectors ~ remove, test and refit Bleeding Cooling system: Coolant circulation Coolant drain and refi Cooling fans testing ....... ‘Water pump - remove and refit Sia LUBRICATION SB828% x 39 Uae ‘Thermostat ~ remove and refit 4 Heater plug system: er ‘system components ng System operation wo Heater plug testing go FeSy INTRODUCTION WARNINGS and CAUTIONS are given throughout this Service Workbook inthe following form: WARNING: Procedures which must be followed precisely to avoid the possibilty of personal injury CAUTION: This calls attention to procedures which must be followed to avoid damage to components. NOTE: This calls attention to methods which make a job easier to perform. REFERENCES References to the left or right hand side in this Service Workbook are made when viewing the vehicle from the rear, unless instructed otherwise. ‘To reduce repetition, operations covered in this Service Workbook do not always include reference to testing the vehicle after repair. Itis 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 concemed, GENERAL PRECAUTIONS 1 ooh eon When disconnecting the vehicle battery, always disconnect ihe earth retum (negative) cable first, and then the positive cable. On twin battery installations, disconnect both earth retum (negative) cables first, and then the positive cables. When reconnecting the battery(s), connect the positive cable(s) first, then the negative cable(s). ‘Absolute cleanliness is essential when working on fuel injection components. ‘Always plug fue! injection system connectors when disconnected to avoid the possiblity of dit ingress. ‘Always tum the engine in a clockwise direction unless instructed otherwise. ‘The mating faces of all pulleys contained within the timing case must be assembled clean and dry. Correct storage and handling of timing belts is most important, and the following points must be observed: ‘© Timing belts must be stored flat and circular; never hang on a peg. '® Do not crimp or bend to a diameter of less than 25 mm (1 in ‘© A timing bett is constructed with a reinforcement of fibre running circumferentially inside it. Do not ‘attempt to lever a belt on or off its pulleys as this may damage the fibres; use finger pressure only. © Before removing a belt which is to be re-used, identify its direction of rotation for refitment. © Abelt must be renewed if contaminated with oil, uel or other detrimental fluids. The pulleys must, bbe cleaned ifthe belt has been contaminated, and the cause of the contamination identified and rectified. © Timing belt pulleys have a smooth finish to prolong belt life. Prior to fiting a belt, ensure the pulleys have no burrs or rough surfaces,Sy © Correct tensioning procedures are essential to ensure full service life ofthe belt. ‘© During the time a timing belt is removed, to prevent damage to components itis important that neither crankshaft nor camshaft are turned unless instructed to do so. 7. Care must be taken when working underbonnet to avoid rotating pulleys and drive belts. 8. Use only the approved LDV anti-freeze. REPAIRS AND REPLACEMENTS ‘When replacement parts are required, it is essential that only genuine LDV parts are used.DATA Engine Type Bore Stroke Capacity Injection order (No.1 cylinder at flywheel end) Compression ratio Compression pressure (minimum) Maximum compression pressure variation Idle speed (minimum) Anti-stall speed Fast idle speed ‘Speed at maximum torque Maximum goveried speed No load speed (maximum) Cylinder Head Nominal height Max. permissible bow Max. permissible gasket face machinit Valve guide bore = for ist oversize guide — for 2nd oversize guide Inlet vaive seat bore = for oversize insert Exhaust valve seat bore = for oversize insert ‘Swirl chamber seat bore diameter depth ~ for 1st oversize diameter ‘depth = for 2nd oversize diameter depth ‘Camshaft End float Valve Seats Inlet valve seat angle ~ Seat width (maximum) ~ External diameter = Oversize Exhaust valve seat angle = Seat width (maximum) — External diameter Oversize sy 10 CUAI, 4 cylinder in line 83mm 88mm 1905 om? 116.25 in? 1-3-4-2 25 ~ 30 bar 967 ~ 441 psi Sbar 735 psi ‘800 +0 RPM 900 = 50 RPM 95075 RPM 2000 RPM 4600 RPM 5100 RPM 157,40~157,75mm 6.1968 - 6.2106 in. 0,07 mm. 0.003 in, 0,40 mm 0.016 in. 13,98-14,05mm 0.5504 --0.5531 1421-14,24mm 0.5594 -0.5606 1451-14,54mm —0.5713-0.5724 40,00 - 40,20 mm 1.8748 — 1.5827 in. 40,475 ~ 40,525 mm 1.5935 — 1.5955 in 34,00 ~ 34,20 mm 1.3389 - 1.3468 in. 34,475 - 34,525 mm 1.3573 — 1.3592 in. 32,00 - 32,20 mm 1.2598 ~ 1.2677 in. 3,90~4,00 mm 0.1835 - 0.1575 in. 32,40 mm 1.2756 in 4,10 mm 0.1614 in. 32,60 mm 1.2836 in. 4,20 mm 0.1654 in 0,025 - 0,114 mm 0.001 — 0.0048 in. “5° 2,45 mm O1in 40,19 - 40,36 mm 1.5823 — 1.589 in, 40,636 ~ 40.61 mm 1.5998 ~ 1.6008 in, pry 3,00 mm our2in. 34,14 34,34 mm 1.3441 ~ 1.352 in, 34,612 - 34,637 mm 1.3627 — 1.3697 in,Sy Valve Guides Intemal diameter Extemal diameter = Istoversize = 2nd oversize Fitted height above cylinder head face Inlet Valves Seat angle Maximum permissible refacing of seat Stem diameter Head diameter Valve recession in head ‘Tappet clearance Exhaust Valves ‘Seat angle Maximum permissible refacing of seat ‘Stem diameter Head diameter Valve recession in head Tappet clearance Valve springs Outside diameter Free length Underioad length: 304-336 N (68-75 522,5-577,5N (117 = 130 tb Swirl chamber Extemal diameter Flange thickness ~ for tst oversize diameter flange thickness — for 2nd oversize diameter flange thickness Cylinder block Cylinder bore diameters Standard size identification ‘None - AY Oversize Rt Re R3 10 8,02- 8,22 mm 14,02 - 14,18 mm 14,279 - 14,29 mm 14,579 — 14,59 mm 96-37 mm’ as. 0,2 mm 8,005 mm, 38,50 mm 0.5 ~ 1,05 mm 0,18 0,04 mm 45° None 7,985 mm 33 mm 0.9— 1,45 mm 0,30 0,04 mm 29mm 57 mm 42.4 mm 33 mm 32,05 ~ 92,25 mm 4,00~4,10 mm 32,45 mm, 4,20 mm 32,65 mm 4 83,00 ~ 83,018 mm 83,03 ~ 83,048 mm 83,20 - 63,218 mm 83,50 ~ 83,518 mm 83,80 ~ 83,818 mm 0.8157 ~ 0.3236 in. 0.852 - 0.5563 in 0.5622 ~ 0.5626 in. 0.5739 - 0.5744 in, 1.42 ~1.46 in, 0.008 in 0.3182 in, 1.5157 in, 0.02 - 0.04 in 0.006 + 0.0015 in. 0.3144 in. 13in. 0.085 — 0.06 in. 0.012 + 0.0015 in. 1.14 2.24 in 1.67 i 13in. 1.2618 - 1.2697 in, 0.1875 - 0.1614 in. 1.276'n, 0.1654 in. 1.2854 in, 0.1688 in. 8.2677 ~ 3.2684 in, 3.2689 ~ 3.2696 in. 3.2756 -3,2768 3.2874 - 3.2881 3.2992 — 3.2966 in.Pistons Piston diameters Standard size Identification None Al Oversizes RI R RB Piston ring gaps Top ring 2nd ting Oil control ring Gudgeon pin diameter Connecting Rods Big end bearing oversize ‘Small end bush intemal dia. (after reaming) Crankshaft Main journal diameter Main joumal dia. (for undersize bearings) Big end crankpin diameter BBig end crankpin dia. (for undersize bearings) Crankshaft end-float No.2 main journal wicth Ist oversize 2nd oversize ‘3rd oversize End float thrust washer thickness. ‘Ist oversize 2nd oversize ‘rd oversize Rear oil seal contact surface diameter Minimum diameter after machining Flywheel ‘Maximum permissible radial run-out ‘Maximum permissible axial run-out Fuel System Fuel injection pump ‘Type Static timing Dynamic timing Fuel injectors Type Body Nozzle Injection pressure 82,93 + 0,009 mm 182,96 + 0,009 mm 83,13 + 0,009 mm 83,43 + 0,009 mm 83,73 + 0,009 mm 0,20 ~ 0,40 mm. 0,15 - 0,35 mm 0,10-0,30 mm. 25.00 mm, +0,15 mm 25,007 — 25,02 mm ‘59,981 - 60,00 mm ‘59,681 - 59,70 mm ‘49,984 ~ 50,00 mm 49,684 ~ 49,70 mm 0,07 ~0,32 mm 26,60 + 0,05 mm. 26,80: 0,05 mm 26,90 0,05 mm. 27,00 + 0,05 mm 2,805 + 0,025 mm. 2,405 + 0,025 mm. 2,455 + 0,025 mm 2,505 + 0,025 mm 89,913 - 90,00 mm 89,713 - 89,80 mm 0,15 mm 0,10. mm, Lucas CAV rotary DPC 844389528 ‘See figure on pump 12° Lucas CAV Lcr LCR 3735201D LCRRDNOSDC8887D 125 & Sbar 3.2849 + 0.0003 in. 3.2661 + 0.0003 8.2728 + 0.0008 in. 3.2846 0.0003 in. 3.2964 0.0003 in. 0.008 ~ 0.01 0.006 ~ 0.014 in, 0.004 - 0.012 in. 0.9842 in. +0.006 in. 0.9845 — 0.9850 in 2.9614 ~ 2.3622 in. 2.9496 ~ 2.3504 in. 1.9679 ~ 1.9685 in. 1.9561 - 1.9567 in. 0.003 ~ 0.012 in. 1.0472 + 0.002 in 1.0551 + 0.002 in. 1.0591 + 0.002 in, 1.083 + 0.002 i 0.9075 + 0.001 in. 0.0947 + 0.001 in. 0.0967 + 0.001 in. 0.0986 + 0.001 in. 3.5399 ~ 3.5433 3.592 ~ 3.5354 in. 0.004 in. BTDC AT IDLE (ENGINE HOT) 1812.5 + 75 psi 1"Sy Heater plugs Make Voltage Tip starts to glow Initial current draw Current draw after 20 seconds ‘Vacuum pump Make Minimum vacuum Lubrication System Fitter Oil pressure = at 800 RPM — at 4000 RPM ‘Waring light switch pressure Oil cooler Cooling System Pressure cap setting ‘Thermostat opening temperature Clutch Type Clutch plate diameter 2 Bosch 11 volts 3 seconds 25 amps 12 amps Saginaw 560 mm Hg at idle speed for 2 minutes Full flow, disposable 1.6 bar 23 psi 3,5 bar 50 psi 05 bar 7 psi Water cooled, Modine 1 bar a3 ‘Single dry plate 215mm 8.48 inLUBRICANTS. MULTIPART Muttigrade Super 15W 40 Engine refll and filter change 5,2 litres Dipstick "MIN’ and "MAX Titre lls must conform to specification CCMC PD2 or RES.22.01. PD2. COOLANT Capacity 10.6 litres Only approved anti-freeze must be used for this ‘engine, and the correct coolant proportions are 50% anti-freez ‘50% water. tre Silitres ‘SEALANTS Crankshaft front oil seal housing Loctite 518 Contact area of rear main bearing cap. Loctite 518 Cam cover, front /rear inboard contact areas. Loctite 518 Contact area, front/rear camshaft caps Loctite 518 Crankshaft damper bolt Loctite 270 Oil cooler securing bolt Loctite 270 Cylinder head bolt threads Motycote G Rapid ‘Sump Rhodoseal 5661 (0.15 pints) (1.76 pints) (18.66 pints) Part no. BBU 9320 BBU 9319 Partno. BBU 8377 BBU 8377 BBU 8377 BBU 8377 ACU 1857 ACU 1857 100 mi ~ BBU 9422 350 mi - BBU 9423 13‘SERVICE SUMMARY 1,000 | 6,000 | 12,000 | 24,000 | 48,000 RENEW ENGINE OIL & FILTER e e e e e DRAIN WATER FROM FUEL e e FILTER RENEW FUEL FILTER e e e VISUALLY CHECK ALTERNATOR/ RENEW POWER STEERING & VACUUM rene PUMP BELTS FOR CONDITION & e e BELTS TENSION : CHECK CONDITION OF TIMING e oe | renew BELT BELT ‘CHECK COOLANT LEVEL & INSPECT HOSES/CONNECTIONS RENEW | RENEW FOR LEAKS. CHECK ANTLFREEZE i @ =| coovanr} cooLanr SOLUTION STRENGTH (50%) ape aa CHECK COOLING FAN OPERATION e ° e e e RENEW AIR FILTER : e e VISUALLY CHECK CRANKCASE. pe BREATHER SYSTEM FOR LEAKS, | HOSES FOR SECURITY & re s 7 @ e e CONDITION eos ne 16‘SPECIAL TOOLS © Crankshaft rear main oil seal replacer LDV 103 ‘ Fuel injection pump pulley remover LDV 104 ‘© Flywheel timing pin LDV 101 mo ‘¢ Fiywhee! locking too! (0480028 (18G 1508) Seal remover (0480039 (FR 1509) ‘Seal replacer ‘© NEW TOOLS INTRODUCED FOR THIS ENGINE 16(0480054 (186 1205) ee é) Flange holder 1210504 (18G 1507) Seal replacer (0480059 (MS 1501) » Injector socket 1210507 (18G 15194) Valve spring compressor “ Dial gauge bracket, fuel (0480080 (LST 122) | injection pump elise Angular torque gauge 7DIAGNOSTIC TOOLS (0484976 (OX 710) 1210515 (OX 900) Injector tester "1210518 (OX 511) 1210524 (DX 801) ‘Compression tester Optical tachometerTORQUE WRENCH SETTINGS Component . Air box to manifold bolts .. ‘Camshaft bearing cap nuts . Camshaft cover bolts Camshaft pulley nut Clutch securing bots Conn.rodbigendnuts ist stage pre-tghten 2nd stage tighten 23rd stage check Crankshaft front cil seal housing bots. Crankshaft main bearing cap bolts ....... Crankshaft damper . Cylinder head bolts st stage pre-tghten 2nd stage tighten 3rd stage tighten Exhaust manifold Flywheel botts .. Fuel injection pump pulley nut Glow plugs . Injectors Inlet manifold bolts ii cooler fixing Oil drain plug il pump bolts Starter motor securing bolts ‘Sump bolts Timing belt tensioner ..... . Water pump Nm 10 178 10 2022 Tos5° 50210 18 .70 40+ 60° 15-20 - 575 Loft 30+60° 11415 180° 18 37 37 16 7 2 18 16 15 " u 19 Sages Fa fe] FA i 4 = w 5 fe] [4 igsienoo Bunty eid uojoedsuy yea, Bujsnoy 1228 10 addsdssssgesggss dung ce) yexou1q Bununow duund uopoeluy B98 Yo 801 yeysyUEID yeysouvau eos Bujsnoy yeisounoy,, sequreyo IMS. Bnid seyeo} sdeo Buyeeq yeysured ees 40n00 yeysWeD yeyswied SLNANOdINO9 TWNYSLXS anBuy uorssesdwiog td uos6ipn Suu deus, sng puo jews pos Bunaeuuog WeYSAUEID sreu seddn-seysen ysruu, feoumAig ud jong sng yobids, Buyeoq yous pue Big deo Buyeaq puo Big Suneed 1194s UW Hey semoy-sioysen smu, dduind #0 ‘wreyo eaup duund id sho} oa, eos onjen ou} enyea yoru N “9h ‘Aaynd duind voyoefuy jen 3} ‘Aaund yeyswed 8 L 9 ees 10 °S y wOysem °C z + ‘SLNSNOdWOD TWNYSLNIFig.1 XUD9A engine compartment 1. Clutch pipe 5 2. Airbox 6 3. Throttle cable 7. 4. Bonnet closing platform ENGINE REMOVE AND REFIT Remove 1 2 Disconnect the battery(s), negative ‘terminal(s) first. WARNING: USE CAUTION IF THE COOLANT IS HOT. Drain the cooling system, by removing the bottom radiator hose at the coolant manifold Remove the alr box and intake alr duct. Remove: © Bonnet. © Radiator grille © Bonnet locking platform. Disconnect coolant hoses as necessary. Radiator grille Batter Remove the radiator and fan assembly. Disconnect: Clutch pipe trom master cylinder. Engine earth strap at the body. ‘Throttle cable. All electrical connections to the engine. Fuel lines connected to the engine; plug all connections.Sy 13, 14. 18, 16. Under the vehicle Disconnect: ‘© Propeller shaft at gearbox flange (mark flange for re-alignment). © Speedometer drive at gearbox. © Reverse lamp cables. Remove the gearchange mechanism. ‘Support the rear of the gearbox and remove the gearbox crossmember, WARNING: USE CAUTION IF THE EXHAUST PIPE IS HOT. Detach the exhaust downpipe from the ‘manifold and from the bellhousing bracket. . Remove the vacuum pump, and the power assisted steering pump (I fitted). Attach lifting equipment and take the weight of the engine. Remove the engine crossmember. Suitably support the rear of the gearbox and ‘manoeuvre the engine and gearbox assembly ut of the vehicle, WARNING: THE GEARBOX MOUNTING PLATE IS HEAVY AND IS LOCATED TO ‘THE CYLINDER BLOCK ON DOWEL PINS. WHEN THE GEARBOX IS REMOVED. DO NOT ALLOW THE PLATE TO BE DISPLACED INADVERTENTLY. Remove the gearbox and remove the ‘gearbox mounting plate, or temporarily ‘secure it with a suitable bolt. Refit Refitting is the reverse of the removal procedure, but note the following points: ‘© Align the marks made during removal and engage the propeller shaft on the gearbox flange bolts before raising the gearbox to fit the crossmember. © Apply Loctite 270 to the propeller shaft flange bot threads. © Bleed the fuel system. © Bleed the clutch hydraulics. © Adjust the throte cable as necessary (Gee section ‘Fuel injection Pump Adjustments}. © Refil with coolant (60% anti-freeze) to the correct level. © Check the oi level and top up as necessary. © When fitted, start the engine and run unti ‘normal operating temperature is reached. ‘Cheok for leaks. WARNING: PLACE A THICK CLOTH OVER THE CAP AND EXPANSION TANK BEFORE ATTEMPTING TO REMOVE THE CAP SLOWLY, TO AVOID THE POSSIBILITY OF SCALDING IF THE ENGINE IS HOT. Check the coolant level and top up as necessary.EXTERNAL DRIVE BELTS Remove, Refit, Adjust WARNING: DO NOT ATTEMPT TO CHECK BELT TENSION OR MAKE BELT ADJUSTMENTS WITH THE ENGINE RUNNING. ‘SERIOUS INJURY COULD RESULT. ALTERNATOR DRIVE BELT ‘Models with power assisted steering OVE Fig.1 Belt tension adjustment 4. Security bott 2. Tensioner bolt 1. Slacken the belt tansioner security bolt. Release belt tension by slackening the tensioner bol. 2. Remove the belt. If not due for renewal, examine for wear, damage, cracks etc. and renew if necessary. 3. Fitthe belt. 4. Tighten the tensioner bolt unti the belt deflection is 6 mm (1/4 in.) at the mid point of the longest run. Tighten the security bolt. 5. CAUTION: itis essential that drive belts are correctly fitted. Ha new belt has been fited, start the engine and run at 1,000 rpm for § minutes. Then stop the engine and check the belt tension, re-adjusting i necessary. Sy Models without power assisted steering TP Fig.2 Belt tension adjustment 1. Tensioner bracket securing nut 2. Alternator pivot bolt 3. Tensioner bolt 1, Slacken the belt tensioner bracket securing nut and the altemator pivot bol. 2. Release belt tension by slackening the tensioner bolt, and remove the belt. 3. not due for renewal, examine the belt for wear, damage, cracks etc. and renew it necessary. Fit the belt. Tighten the tensioner bolt until the belt deflection is 6 mm (1/4 in.) at the mid point of the belt run, then tighten the alternator pivot bolt and the tensioner bracket securing nut. 6. CAUTION: It is essential that drive belts are correctly fitted. anew belt has been fitted, start the engine and run at 1,000 rpm for 5 minutes. Then stop the engine and check the belt tension, re-adjusting if necessary. 27Sy VACUUM PUMP DRIVE BELT Coa Fig.3 Belt tension adjustment 1. Tensioner bracket securing nut 2. Tensioner adjustment bolt 1. Slacken the belt tensioner bracket securing rut and the adjustment bolt. ENGINE crt 2. Push the vacuum pump inwards and remove the drive belt. 3. If not due for renewal, examine the belt for wear, damage, cracks etc. and renew if necessary. 4, Fitthe bett 5. Pivot the pump outwards, and tighten the adjuster nut and securing bolt when there is a belt deflection of 6 mm (1/4 in.) at the mid Point of the belt run. 6. CAUTION: Itis essential that drive belts are correctly fitted. anew belt has been fitted, start the engine and run at 1,000 rpm for § minutes. Then stop the engine and check the belt tension, re-adjusting if necessary. 28TIMING CASE ‘TIMING BELT REMOVE & REFIT Tools required: 0480086, LDV 102, LDV 104. TIMING BELT - Remove The timing belt can be removed with the engine in situ aftr first carrying out the following operations. NOTE: Components at the front of the engine (e.g. pulleys, crankshaft front oll seal, water pump etc.) ‘can be accessed after removing the timing belt. 1. Disconnect the battery(s), negative (earth) terminal(s) fist. 2. Detach the intake air duct. 3. Drain the coolant, and alsconnect radiator ‘hoses and cables to fans. 4. Remove the radiator grille, bonnet locking platform and radiator complete with fans. 5. Remove the extemal drive belts. 6. Restrain the crankshaft from tuming (flywhee! locking tool LDV 102 can be used for this purpose), and remove the crankshaft damper. Remove the flywheel locking tool Fig.1 Timing pulleys Camshatt pulley Fuel injection pump pulley Ider roller Crankshaft pulley ‘Water pump pulley ‘Timing bet tensioner roller 7. _ Remove the timing belt inspection plate and the 3-part timing covers. eo seneBTU Mener 1 Fitting timing pin and timing bolts 1. Flywhee! timing pin LDV 104. 2. Camshatt timing bol. '3._Injection pump timing botts. 8. Tum the crankshaft clockwise unt no.4 cylinder (ront of engine) is at TDC firing Position. Fit the timing pin LDV 104 in the flywheel location. Fit suitable length MB bolts in the camshaft pulley and fuel injection pump pulley timing holes, finger tight only. Fig.3 Releasing timing belt tension 1. Tensioner securing bolt 2. Tensioner roller 3. Tensioner securing nut 9. Slacken the belt tensioner securing nut and bolt. Release the bolt tension by pulling the tensioner roller fully away from the belt ‘against spring pressure, and tighten the ‘securing bolt. NOTE: A square drive hole is provided in the tensioner bracket to facilitate this. 10. CAUTION: 1. Unless instructed, do not turn the ‘camshaft or crankshaft when the timing belt is not fitted. 2. If the belt is contaminated it must be ‘changed and all pulleys cleaned. 3. Do not contaminate the pulleys when handling them. Ifthe timing belt is to be re-used, mark its direction of rotation with chalk then remove the bett, NOTE: The camshaft pulley, fuel injection ump pulley, tensioner, plunger housing, Idler assembly and the water pump can now be removed if required.11, Examine all pulleys for wear, damage and contamination, Clean or renew as necessary. ‘To refit and tension the timing belt, check the {uel injection timing and re-build the engine, ssee section "Timing Belt Refi. CAMSHAFT PULLEY NOTE: The camshaft pulley and oil seal can be removed / refitted at this stage if desired, but for specific procedures see section "Cylinder head’. FUEL INJECTION PUMP PULLEY NOTE: The fuel injection pump pulley can be removed / refitted at this stage if desired, but {or specific procedures see section ‘Fuel Injection Pump Remove and Refft. CRANKSHAFT PULLEY AND FRONT OIL SEAL Remove and Refit Tools required: 0480066, LDV 102, LDV 104, 1210504 (18G 1507) Remove the timing bett (see section "Timing Belt Remove’). 12, Remove the crankshaft pulley, and recover the loose key. NOTE: On chassis cab vehicles, if this work is being carried out in situ, it may first be necessary to disconnect the engine mountings and lft the engine to provide sufficient clearance for the pulley to be removed, Fig.4 Removing crankshaft front oil seal 1. Ollseal 2. Self tapping screw 18, Extract the oil seal as follows: CAUTION: Do not allow the drill to penetrate too far and cause damage to the oil pump drive chain or its sprocket. © Carefully drill a3 mm hole in the position iMustrated, © Fita suitable self-tapping screw in the hole to a depth of no more than 6 mm (1/4 in.), and use itto prise out the seal as illustrated © Clean out any swarf or dit at TIMING CASETIMING CASE Figs 14. 16. Fitting crankshaft oll seal 1. 1210804 (18G 1507) Lubricate the ip of the new seal, then position with its garter spring towards the rear of the engine. Use tool 1210504 (186 1507) to tap the seal into place until itis flush with the front face of the housing. Fit the crankshatt pulley with its key. Fit and tension the timing belt, check the fuel injection pump timing and rebuild the engine (ee section ‘Timing Belt Refi). TIMING BELT — Refit 16, 17. 18, MW removed, fit: © Idler roller assembly © Water pump (use new gasket) ‘© Tensioner plunger housing; check that plunger has free movement in housing, ‘© Tensioner with its plunger and spring. If previously disturbed, tighten the tensioner ‘hut and bolt with the plunger spring fully compressed. ‘Check that the crankshaft remains at TDC (flywheel timing pin fitted), and that the ‘camshaft and fuel injection pump are in their timing position (timing bolts fitted). Fig.6 Timing pulleys 19, 1. Crankshaft pulley Idler roller Fuel injection pump pulley Camshaft pulley Tensioner assembly Water pump pulley ‘Check the direction-of-rotation mark made during removal if re-fiting the old timing belt. Hi fiting a new belt, ensure that the printing (on the belt can be read from the front.To fit the belt start at the crankshaft pulley, and then fitit round the other pulleys in the following sequence, keeping its run taut. © Crankshaft pulley Idler roier Fuel injection pump pulley ‘Camshatt pulley Tensioner roller Water pump pulley. Remove the timing bolts and the fywhee! timing pin LDV 104.Fig.7 Timing belt adjuster 1. Tensioner bolt 2. Tensioner nut 21. Slacken the tensioner securing bolt and nut by two turns, and allow the spring and plunger to self-tension the timing belt. Temporarily tighten the bolt and nut. 22. Fit the lower timing cover. Fit the crankshaft damper, and tighten its securing bolt finger tight. J (a a Vy A ad rm ra e é ro = Zz Fig.8 Fitting timing pin and timing botts 1. Flywheel timing pin LDV 104. 2. Camshaft timing bolt. 3. Injection pump timing bolts. 23. Tum the crankshaft clockwise 7 complete tums, then continue turing until the flywheel timing pin LDV 104 can be fitted, together with the camshaft and injection pump timing bolts. NOTE: If tis not possible to fit all the timing pins / bolts, the timing belt fitting procedure hhas not been carried out correctly and must be repeated. NOTE: Do not tum the crankshaft anti-clockwise. 24. Slacken the tensioner nut and bolt by two tums, and allow the spring and plunger to re-tension the timing belt. Then tighten the bolt and the nut to the correct torque. 25. Remove the camshaft and fue! injection pump timing bolts, and the flywheel timing pin LDV 104.TIMING CASE Fig.9 Tightening crankshaft damper 26. Secure the crankshaft damper as follows: ‘© Fitthe flywhee! locking tool LDV 102. © Carefully degrease and clean the bolt threads, bolt head, bearing faces of washer and the threaded hole in the crankshaft. Coat bolt threads with Loctite 270. ‘Torque tighten bolt to 40 Nm (0 Ib f). ‘Tighten bolt a further 60°, © Remove the flywheel locking tool. 27. Check the fuel injection pump timing as described in the section ‘Fuel System’ NOTE: This requirement only applies at this stage if the timing is being checked statically, Ifthe timing is to be checked dynamically, it will have been set in such a position to start the engine, and the check can then be made with the engine running, 20. 8 & Fit the upper timing covers and the belt inspection plate. Fit the extemal drive belts and adjust to the ‘correct tension. Ifthe engine is in the vehicle, carry out the Tollowing operations: Fit the radiator, reconnect all hoses and fan cables. |. Fit the bonnet lacking platform and radiator grille. Fit the intake air duct. Refil with coolant (50% anti-freeze) to the correct level. (Check the oi level and top up as necessary. ‘e-connect the batterys, positive terminals first ‘Start the engine and run until normal ‘operating temperature is reached. Check the coolant level and top up as necessary. WARNING: PLACE A THICK CLOTH OVER THE CAP AND EXPANSION TANK BEFORE ATTEMPTING TO REMOVE THE CAP SLOWLY, TO AVOID THE POSSIBILITY OF SCALDING IF THE ENGINE IS HOT. Check / adjust the fue! injection pump timing dynamically if not already checked statically).CYLINDER HEAD (CAMSHAFT PULLEY AND OIL SEAL Remove and Refit NOTE: The camshatt front oll seal is directly behind the camshaft pulley and can be renewed after removing the pulley as follows, Camshaft Pulley Remove Tools required: 0480054 (18G 1205), LDV 104. The camshaft pulley and front oll seal can be removed / renewed in situ, but the following operations must be carried out first. 1. Disconnect the battery(s), negative (earth) terminal(s) first. Detach the intake air duct. 3. _ Remove the timing bett inspection plate and the two upper timing belt covers. Fig.1 Fitting timing pin and timing bolts CYLINDER HEAD 1. Flywheel timing pin LDV 104 2. Camshaft timing bolt 3. Injection pump timing bolts 4, Tum the crankshaft clockwise until no.4 cylinder (front of engine) is at TDC fring position. Fit the timing pin LDV 104 in the flywheel location. Fit suitable length MB bots in the camshaft pulley and fue! injection pump pulley timing holes, finger-tight only.CYLINDER HEAD Fig.2 Releasing timing bett tension 7. 1. Tensioner securing bott 2. Tensioner roller 3. Tensioner securing nut Slacken the timing belt tensioner securing nut and bot. Release the belt tension by pulling the tensioner roller fully away from the belt against spring pressure, and tighten the ‘securing bolt. NOTE: A square drive hole is provided in the tensioner bracket to facilitate this. Carefully ease the timing bett off the camshaft pulley. Remove the camshaft timing bolt. Figs Removing camshaft pulley 1, 0480054 (186 1205) 2 Bolts 8. CAUTION: Do not allow the camshaft to turn, Restrain the camshaft pulley with flange holder 0480054 (18 1205) fitted with suitable length bolts/nuts, and remove the pulley securing bott. 9. Remove the camshaft pulley. ‘Camshaft Front Oil Seal Remove and Refit Tools required: 0480028 (18G 1508), 0480039 (FR 1509), 0480054 (186 1205), 0480066, LDV 104, Remove the camshaft pulley as described in the section ‘Camshaft Pulley Remove’, then Proceed as follows.ey Refit the camshaft pulley as described in the following section. Camshaft Pulley - Refit Tools required: 0480054 (18G 1205), 0480066, LDV 104, 12. Fitthe camshaft pulley, restrain it with flange holder 0480054 (18G 1205) fitted with suitable length botts/nuts, and tighten the pulley securing bolt to the correct torque. wy A Fig.4 Removing camshaft oil seal 1. 0480028 (186 1508) 10. Remove the camshaft front oil seal using tool (0480028 (186 1508). CYLINDER HEAD lA | r\(@)5, 3 Fig Fitting camshatt oil seal OND oe 1. Ollseal 2. 0480039 (FR 1808) Fig Timing bolts and pin 3. Bot , 1. Flywheel timing pin LDV 104 11. Ensure eo ofthe carehat i can and 1 Rhoet ming pin ; . a bolt the seal jour is serviceable. 2 Cameha ng Ot t ‘Sparingly lubricate the tip of a new seal with " pump 19 Pol engine oll and ft, garter spring inwards, using tool 0480039 (FR1509). NOTE: If the engine isin stu, space limtations requie thatthe seal is pulled into 18: Fit the camshaft pulley timing bot, and check place using a suitable length bolt as shown in ‘that the injection pump timing bolts and the Peano flywheel timing pin LDV 104 remain in place. 37CYLINDER HEAD ipy 14. Carefully slide the timing belt over the pulleys, keeping the drive side taut. 15. Remove the camshaft and fue! injection pump ov 1. Tensioner bolt 2. Tensioner nut 16. Slacken the tensioner securing bolt and nut by two tums, and allow the spring and plunger to self-tension the timing belt. ‘Temporarily tighten the bolt and nut. 17. Tum the crankshaft clockwise 7 complete tums, then continue turning until the flywheel timing pin LDV 104 can be fitted, together with the camshaft and injection pump timing bolts. NOTE: | itis not possible to fit all the timing pins / bolts, the timing bet fiting procedure has not been carried out correctly and must be repeated. NOTE: Do not tum the crankshaft anti-clockwise. 18. Slacken the tensioner nut and bolt by two tums, and allow the spring and plunger to rectension the timing belt. Then tighten the bolt and the nut to the correct torque. 19. Remove the camshaft and fuel injection pump timing bolts, and the flywheel timing pin LDV 104, 20. 21 23. Check the fuel injection pump timing as described in the section ‘Fuel System’. NOTE: This requirement only applies at this ‘stage if the timing is being checked statically. I the timing is to be checked dynamically, it will have been set in a position to enable the ‘engine to be started, and the check can then be made with the engine running. Fit the timing belt covers and the belt inspection plate. Connect the battery(s), positive terminals) first Check the fuel injection pump timing dynamically (if not already checked statically).TAPPET CLEARANCES ‘Tappet Clearances — Check CAUTION: Do not attempt to turn the camshaft if the head is fitted to the cylinder block but the timing belt is removed unless specifically instructed to do so. The tappet clearances can be checked in situ after carrying out the following operations 1. Disconnect the battery, negative (earth) terminal first. Disconnect the Mann valve from its vertical Pipe. 3. Remove the air box. 4, Remove the 3 bolts securing the camshaft ‘cover, noting the position of the fibre and plain washers under the bolt heads. Lift off the cover and recover the rubber seal. 'N IN IN 'N EX EX EXEX an Fig.1 Camshaft 5. Turn the engine clockwise until no.7 and 8 valves are ‘on the rock’ NOTE: No. 4 cylinder and nos. 7 & 8 valves are at the front of the engine. Fig.2 Checking tappet clearances With no.7 & 8 valves on the rock’, check and record the following clearances: ©” No.1 tappet (rear of engine) © No.2 tappet © Nos tappet '* Nos tappet ‘Turn the engine until nos. 1 & 2 valves are ‘on the rock’. Check and record the following clearances: No tappet © NoS tappet No.7 tappet © Nos tappet “Tappet adjustment is only necessary if any of the clearances just measured are outside limits of: Inlet 0,15 mm +0,04 mm (0.008 in. + 0.0015 in.) Exhaust 0,30 mm + 0,04 mm (0.012 in, + 0.0015 in.) CYLINDER HEAD Htadjustment 1S necessary, see next section "Tappet Clearances — Adjust. 39Cea et © Fitthe camshaft cover and secure with: fibre washers — plain washers = bolts. Tighten the bolts to the correct torque. Do NOT over-tighten. NOTE: Make sure the coolant hose bracket is secured to the front cover bot. 7. Fitthe air box, tightening the bolts to the correct torque. Connect the Mann valve. Connect the battery(s), positive terminal(s) frst. Fig.3 Sealing camshaft cover 6. adjustment is NOT necessary: '® Check that the camshaft cover gasket is serviceable. © Sparinaly apply Loctite $18 sealant at the 4 points on the cylinder head as ilustrated. Fig.4 Fitting camshaft cover 1. Bolt 2. Plain washer 3. Fibre washer‘Tappet Clearances - Adjust ‘Tools required: LDV 104, 0480039 (FR 1509), (0480054 (186 1208), 0480066. NOTE: The following procedure assumes that the ‘camshaft cover has been removed and the tappet clearance checking procedure (see Tappet Check, ‘operations 1 to 5) has already been carried out. adjustment is necessary, proceed as follows: Fig.6 Crankshaft in ‘safe’ position 2. Remove the flywhee! timing pin LDV 104, then tum the crankshaft anti-clockwise by ‘1/4 tum (90°) to the ‘sate’ position. CYLINDER HEAD Fig.5 Timing pin and timing bolts 1. Flywheel timing pin LDV 104 2. Camshatt timing bolt 3. Injection pump timing bolts 1. Remove the timing bett upper covers, fit the timing pin / bolts, release the tension on the timing belt and remove the camshaft pulley as. described in the section "Camshaft Pulley Remove’. aCYLINDER HEAD Fig.7 42 Camshatt, tappet and shim layout 1. Camshaft pulley 2. Oilseal ‘O'ring Rear cover Camshaft caps Camshaft Tappet Shim’ Remove the camshaft rear cover and discard the ‘0’ ring, Note the identification markings on each camshatt bearing cap, then progressively release the 3 caps and remove the camshatt. Discard the oil seal. NOTE: The camshaft caps are line bored with the cylinder head during manufacture, ‘and are not available separately. CAUTION: Do not allow the shims to fall down the oil drain passages in the cylinder head. Carefully remove the tappets and shims that require adjustment, identifying them to their bore(s) for refiting. Use a micrometer to ‘measure the thickness of each shim removed. exNeone Calculate the correct shim thickness(s) required using the following formula: A+B-¢ Measured tappet clearance ‘Thickness of shim removed Correct tappet clearance Example: No.1 (inlet) valve, measured clearance 0,25 mm, thickness of shim removed 2,42 mm Calculation: 0,25 + 2,42 — 0,15 = 2,52 ‘Therefore shim required is 2,52 mm + 0,04 mm. Select the shim(s) required from the range available, then carefully locate ivthem into its/their valve spring cap(s). Lubricate and fit each removed tappet. Check that the crankshaft is stilin the ‘safe’ 90° position. Fig.8 Camshaft bearing cap marks 9. 10. Lubricate the camshaft and place in position, Pulley end to the front. Temporarily fit the camshaft bearing caps, making sure they are in their correct locations. No.1 cap is fitted at the rear, and when the caps have been fitted the numbers should be readable from the front of the engine. Progressively tighten the cap securing nuts to the correct torque. Betore proceeding further, check all tappet clearances and re~adjust any that are outside tolerances.Fig.9 Sealing camshaft bearing caps ‘11. CAUTION: Do not allow the seal to spread ‘onto the journal areas, or into the ‘grooves on the underside of caps 1 and 3. Remove the camshaft bearing caps and ‘sparingly apply Loctite 518 sealant at the points shown in the illustration. 12, Fitthe caps in their correct locations as before and progressively tighten the securing Nuts to the correct torque. 13, Fitanew" the cover. ring to the rear cover, then fit LZ Tey Fig.10 Sealing camshaft cover 14. Check that the camshaft cover rubber seal is serviceable. ‘Sparingly apply Loctite 518 sealant at the 4 points on the cylinder head as illustrated. Fig.11_ Fitting camshaft cover 1. Bott 2. Plain washer 3. Fibre washer 16. Fit the camshaft cover and secure with: — fibre washers — plain washers = _ bolts. Tighten the bolts to the correct, torque. Do NOT over-tighten, NOTE: Make sure the coolant hose bracket is. ‘secured to the front cover bolt. CYLINDER HEAD18. Tum the camshaft clockwise until the timing bolt can be fitted through the pulley. Check that the two timing bolts are stil fitted in the injection pump pulley. Fig.12 Fitting camshaft oil seal ne Fe.14 Fyne ning pin LDV 104 2 oraonao (150) 40. Tum te carta 90° tockoes ut te sarees ten oes cna 16. Sparingly lubricate the lip of a new camshaft flywheel. fotodsealand IR per ngs, a Carn ttn b wie kesng is NOTE: If working with the engine in situ, use ‘un taut on the drive side. Seorana ee near a Siolnrame emg tesrte ite 2. anon aia tno 17. Ensure the key is located correctly, fit the ‘camshatt pulley, and tighten the securing bolt to the correct torque CYLINDER HEAD Fig.13. Pulley timing bolts fitted 1. Camshaft timing bott 2. Injection pump timing boltsoe © per fr a Fig.15 Adjusting timing belt tension 1. Tensioner bolt 2. Tensioner nut 22. ‘Slacken the tensioner securing bolt and nut by two tums, and allow the spring and plunger to selt-tension the timing belt. ‘Temporarily tighten the bolt and nut. 23. Turn the crankshaft clockwise 7 complete tums, then continue turing until the flywheet timing pin LDV 104 can be fitted, together with the camshatt and injection pump timing bolts. NOTE: Ifitis not possible to fit all the timing pins / bolts, the timing belt fitting procedure has not been carried out correctly and must be repeated. NOTE: Do not turn the crankshaft anti-clockwise. 24. Slacken the tensioner nut and bolt by two ‘tums, and allow the spring and plunger to re-tension the timing belt. Then tighten the bolt and the nut to the correct torque. 25. 26. 31. ipy Remove the camshaft and fuel injection pump timing bolts and the flywheel timing pin LDV 104. Check the fue! injection pump timing as described in the section ‘Fuel System’. NOTE: This requirement only applies at this stage if the timing is being checked statically. If the timing is to be checked dynamically, it will have been set in a position to start the engine, and the check can then be made with the engine running, Fit the timing belt covers and the belt inspection piate. Fit the air box, tightening the bolts to the correct torque. Connect the Mann vatve. 2. Connect the battery(s), positive terminal(s) first. Check the fuel injection pump timing dynamically, (itt aready checked statically.) CYLINDER HEADCYLINDER HEAD Remove Tool required: LDV 104. The cylinder head can be removed with the engine in situ by first carrying out the following operations. 1. Disconnect the batterys, negative terminals fist. 2. Disconnect the Mann valve from its vertical pipe, and remove the air box. 3. WARNING: USE CAUTION IF THE COOLANT IS HOT. Drain the coolant. 4. Disconnect the thermostat housing from the cylinder head and pull clear. Discard the gasket. 5. Disconnect: = Glow plug supply cable. = Throttle cable. = Exhaust down pipe. ~ Coolant bieed hose from cylinder head. 6. Remove the timing belt inspection plate and the two belt upper covers. Fig. CYLINDER HEAD Fitting timing pin and timing botts 1. Flywheel timing pin LDV 104 2. Camshaft timing bolt 3. Injection pump timing bolts ‘Turn the crankshaft clockwise until no.4 cylinder (front of engine) is at TDC fring position. Fit the flywheel timing pin LDV 104 in the flywheel location. Fit suitable length MB bolts in the camshaft pulley and fuel injection pump pulley timing holes, finger-tight only a7CYLINDER HEAD Fig.2 Releasing timing belt tension 1. Tensioner securing bolt 2. Tensioner roller 3. Tensioner securing nut 8. Slacken the timing belt tensioner securing nut and bolt. Release the belt tension by pulling the tensioner roller fully away from the belt ‘against spring pressure, and tighten the securing bot. NOTE: A square drive hole is provided in the tensioner bracket to facilitate this. 9. Carefully ease the timing belt off the camshaft, pulley. a (ED VY. Fig.3 Crankshaft in’safe’ position 10. Remove the flywheel timing pin LDV 104, then tum the crankshaft anti-clockwise by 11/4 turn (90°) to the ‘sate’ position. 11, Remove the bolt which secures the belt tensioner plunger housing to the cylinder head. 12. Disconnect the breather pipe from the camshaft cover. Fig.4 Loosening fuel injector pipes. 18. Remove the fuel injector pipes, making sure each union is restrained from turing while its ut is loosened. Plug the unions. 14. Disconnect the spill return pipe. 3 7 0 6 2 Fig.5 Cylinder head bolt loosening sequence 15. Remove the 10 cylinder head bolts in the sequence shown and carefully liftoff the head. CAUTION: Lay head on its side or on its face supported by wooden blocks to protect valves. 16. Remove and discard the cylinder head gasket. Clean off all traces of the gasket from the cylinder head and block faces.Fig.6 Cylinder head assembly SeNogronn ‘Camshatt cover Seal ‘Camshaft caps Camshaft Tappet Shim’ Valve collets ‘Spring cap Valve stem oil seal Valve spring Spring seat Valve guide Camshatt oil seal Cylinder head °O' ring seal Camshaft rear cover Injector Copper washer CYLINDER HEAD Heat shield washer Injector shroud ‘Swirl chamber Heater plug Heater plug cable Coolant bleed pipe adaptor Valve Cylinder head dowel pin Cylinder head gasket.CYLINDER HEAD ey Dismantling Tools required: 0480054 (1861205), 0480059 (MS 1501), 1210507 (186 15194) 17. Remove the inlet and exhaust manifolds and discard the gaskets. 18. Remove the injectors using 0480059 (MS 11501), and remove the glow plugs. 18. Remove the camshaft pulley timing bolt Restrain the camshaft pulley with lange holder 0480054 (1861206) fted with suitable length bolts / nuts, and remove the securing bolt o release the pulley. 20. Remove the camshaft rear cover and discard the ‘0' ring 21. Remove the camshaft cover, noting the Position of the fibre and plain washers under the securing botts. Fig.7 Camshaft bearing marks 22. Note the identification number on each camshaft bearing cap, then progressively release the 3 caps and remove the camshatt. Discard the oi! seal 23. Remove each tappet with its shim, and retain in their Mted order. Fig.8 Removing valves 24. Use spring compressor 1210507 (186 1519A) to remove the valves; retain the ‘components in related sets. Discard the vaive stem oil seals. Fig.2 Removing swirl chambers 25. Identity each swirl chamber with its original location before using a sultable brass drift to tap it out (and the injector shrouds if Necessary). Note that the swirl chambers are located by peened-in ball bearings.Inspection / Overhaul 26 Clean and inspect the cylinder head and ‘component parts for wear and damage. Note particularly the valve seats, injector shroud locations, tappet bores and camshaft bearings. Inspect the supply ollways to the camshatt ‘Check the camshaft cover sealing faces for damage. NOTE: The camshatt journals are line bored ‘and therefore the cylinder head and the camshatt bearing caps are only available as an assembly. CYLINDER HEAD DISTORTION , , 27. Betore proceecng wih ctor overhaul work -FH-TY_Gyinder head height fhe cytinder head must frst be checked for It excessive distortion is evident, itis permissible to reface by machining up to 0.40 First lubricate and fit the camshaft, secure mm (0.016 in) from the cylinder head, but withthe bearing caps and check that tums only ifthe cyinder head height will remain freely. If it does not, the cylinder head must within tolerance after machining. be renewed. ‘To measure the height, refit the camshaft land secure with 2 bearing caps. Measure the distance ‘h’ from the head face to the top of the oil seal journal on the camshaft. ‘ht = 157,40 to 187,75 mm (6.197 to6211 in) Fig.10 Checking for cylinder head distortion Use a straight edge and feeler gauge to check for distortion in a number of planes across the cylinder head face. Maximum bow or twist 0,07 mm (0,003 in.) Fig.12 Machining identification After retacing, stamp the letter 'R’ on the flat surface just above the coolant outlet. 51CYLINDER HEAD NOTE: After machining it will be necessary to: ‘© Recut the valve seats to restore the correct valve head recess. Check / adjust swirl chamber protrusion. Fit compensation washers 0,40 mm (0.016 in.) thick under the valve spring seats. ‘SWIRL CHAMBERS, 28. Examine for cracks or damage. x Fig.13 Swirl chamber protrusion Check the protrusion of each swirl chamber ‘above the face of the cylinder head. NOTE: This will be incorrect f the head has been re-faced, ‘Swirl chamber protrusion: 0 t0.0,03 mm (00 0.001 in} It the protrusion is too great, it can be corrected by machining the swirl chamber at andy. Hf there is no protrusion, two oversize swit chambers are available and the head must be machined to accommodate them as follows. Measure the outer diameter of the flange of the new swirl chamber, and machine the cylinder head to give an interference fit of 0,05 mm (0.002 in.) Install the swirl chamber and measure the protrusion. If excessive, machine faces x’ and "Y’ equally until the correct protrusion is obtained 82 VALVE SEATS 29. Examine the seats for damage and pitting, Fig.14 Valve recession Fit each valve in tun and check its recession by measuring the depth of the valve below the face of the cylinder head, Inlet 0,5~1,05 mm (0.002 - 0.04 in.) Exhaust 0,9~ 1,45 mm (0.035 ~ 0.06 in.) Fig.15 Valve seats IN- Inlet EX— Exhaust Seats can be re-cut to the dimensions shown. After re-cutting valve seats, the valve recession must be checked. NOTE: To ensure concentricty of each seat tits valve guide, they should not be re—cut Until the guides have been checked and renewed as necessary (see VALVE GUIDES). ‘One oversize seat is available for both inlets and exhausts, and can be fitted as follows.WARNING: WEAR EYE PROTECTION. ‘A faulty vaive seat can be renewed in the ‘normal manner by machining a crescent in the seat, and then spiitit for removal. ‘Accurately measure the diameter of the new seat, and machine the location in the cylinds hhead to give an interference fit of: Inlet 0,161 mm (0.0063 in.) Exhaust 0,037 mm (0.0054 in.) ‘The new seat must be chilled (typically using liquid Nitrogen) prior to installation VALVE GUIDES 30. Check each valve guide for wear or damage. Hf renewal is necessary, two oversize guides are available. Fit the new guide as follows: ‘© Press out the old guide towards the ‘camshaft side using a suitable mandrel ‘© Ream the cylinder head to the dimension given in ‘Data’ to suit the dimension of ‘oversize guide selected, Fig.16 Fitted position of valve guide ‘© Press in the oversize guide until itis 36 to 37 mm (1.42 to 1.46 in.) from the cylinder head face. ‘© Ream out the fitted guide to 8,02 to 8,22 mm (0.3157 to 0.236 in). NOTE: After fiting a new guide, the ‘concentricity of its valve seat must be checked and refaced as necessary (see VALVE SEATS). VALVES 31. Check the valve heads for cracks, pits and ‘signs of buming. Check the stems for wear and correct fit in their guides. Check the valves for concentricty By ‘Minor imperfections on inlet valves may be rectified by re-cutting the valve head face. Exhaust valves cannot be re-faced. NOTE: After rectification, the valve recession in the head must be checked and the valve renewed if outside tolerances. Lap each vaive into its seat using a fine paste Until a satisfactory seal is obtained, ‘Thoroughly clean each valve, place in position and check its recession. VALVE SPRINGS, CAPS, SEATS, COLLETS & TAPPETS, 87mm Fig.17 Valve spring length ‘32. Inspect the springs for damage. Check their free length which should be 57 mm (2.24 in). and the length under load. ( See "Data") Inspect the spring caps, seats and collets for ‘obvious signs of wear or damage. Inspect the tappets for piting or wear on the camshaft contact face. Examine the outside diameter for wear or scoring. If scored, check the relevant bore in the head. Replace components as necessary. CAMSHAFT & CAMSHAFT COVER, 33. Inspect all lobes, and bearing and oil seal joumals for wear and damage. Camshatt end-oat is controlled by the centre bearing cap and is not adjustable. Camshaft end-float: — 0,025 to 0,114 mm (0.001 to 0.0045 in} Inspect the camshaft cover gasket. INJECTOR SHROUDS ‘34. Inspect the injector shrouds for cracking or pitting. Renew as necessary. To refit each shroud, locate it in the head, position an old copper washer on its outer diameter and tap it into the head using a ‘suitable drift against the copper washer. Final Positioning of the shroud can be left until itis. Pushed into place when fiting the injector. CYLINDER HEADey Re-assembly Tools required: 0480039 (FR 1509), 1210507 (186 1519A) Before starting reassembly, check that all swarf, ‘grinding paste etc. has been removed from the cylinder head, valves ete. Place the head on suitable supports. 35. Working at each valve in tur, fit © Anew vaive oll seal. © The valve, the stem lubricated with engine oil © Valve spring seat (with 0,40 mm ‘compensation washer under seat if head has been re-faced). © Valve spring, either way up. © Valve spring cap. Compress the spring with 1210507 (186 1519A) and fit the collets. 96. CAUTION: Do not drop shims down the oil drain passages in the head. Lubricate and fit the original shims and their tappets, CYLINDER HEAD ‘Camshaft bearing cap marks 37. Fitthe camshaft temporarily, pulley end to the front, to enable the tappet clearances to be checked. Before fitting the camshaft bearing caps note the identification numbers on them, no.t cap is fitted at the rear, and when the caps have been fitted the numbers should be readable ‘rom the front of the engine. Fit the caps and progressively tighten the securing nuts to the correct torque. 38. Fit the camshaft pulley temporarily. Fi 19 Camshaft 39. Tum the camshaft until no.7 and 8 valves are ‘on the rock’ NOTE: No. 4 cylinder and nos. 7 & 8 valves are at the front of the engine. Fig.20 Checking tappet clearances With no.7 & 8 valves’on the rock’, check and record the following clearances: No.1 tappet No.2 tappet No.4 tappet No.6 tappeta ‘Tum the engine until nos. 1 & 2 valves are ‘on the rock’. Check and record the following clearances: © No.3 tappet © No.5 tappet © No.7 tappet © No.8 tappet ‘Tappet adjustment is only necessary if any ofthe clesrances just mensured are outside Inlet 0,15 mm 0,04 mm (0.008 in. + 0.0015 in.) Exhaust 0,30 mm + 0,04 mm (0.012 in. + 0.0015 in.) To adjust the clearances, remove the camshaft pulley and the camshatt. Working at each tappet in turn that requires adjustment: ‘© Remove the tappet and shim, and use a ‘micrometer to measure the shim thickness. © Calculate the correct shim thickness(s) required using the following formula: A+B-C ‘Measured tappet clearance. Thickness of shim removed. Correct tappet clearance. Example: ‘No.1 (inlet) valve, measured clearance 0,25 mm, thickness of shim removed 2,42 mm, Calculation: 0,25+2,42 - 0,15 = 2,52 ‘Therefore shim required is 2,52 mm + 0,04 mm. © Select the shim required from the range available, then carefully locate it into its valve spring cap. © Lubricate and fit the tappet. Lubricate the camshaft and place in position, pulley end to the front. Temporarily fit the ‘camshaft bearing caps, making sure they are in their correct locations.and the correct way round as before. Progressively tighten the cap securing nuts to the correct torque. Before proceeding further, check all tappet Clearances and re-adjust any that are outside tolerances. Fig.21 Sealing camshaft bearing caps 44, CAUTION: Do not allow the seal to spread onto the journal areas, or into the grooves on the underside of caps 1 and 3. Remove the camshaft bearing caps and sparingly apply Loctite 518 sealant at the points shown in the illustration 45. Fitthe caps in their correct positions as before, and progressively tighten the securing bolts to the correct torque Fig.22 Sealing camshaft cover CYLINDER HEADfo 7eN Dae) 46. Check that the camshatt cover seal is serviceable. ‘Sparingly apply Loctite 518 sealant at the 4 points on the cylinder head as illustrated, Fig.23 Fitting camshaft cover 1. Bolt 2. Plain washer 3. Fibre washer 47. Fit the camshaft cover and secure with: fibre washers plain washers bolts. Tighten the bolts to the correct torque. Do NOT over-tighten. NOTE: Make sure the coolant hose bracket secured to the front cover bot. 48. Fita new’ the cover. ring to the rear cover, then fit Fig.24 Fitting camshaft oil seal 1. Ollseal 2. 0480039 (FR 1509) 3. Bolt 49. Sparingly lubricate the lip of a new camshaft oil seal and fit it using too! 0480039 (FR. 11509), garter spring inwards. 50. Ensure the key is correctly located and fit the camshatt pulley. Restrain the pulley with flange holder 0480054 (18G 1205) fitted with suitable length bolts/nuts, and tighten the securing bolt to the correct torque. Tum the camshaft unti! the timing bolt can be fitted through the pulley. 51. Fitthe glow plugs, and tighten them to the correct torque. 52. Fitthe manifolds, using new exhaust ‘manifold gaskets. Refi Tools required: 0480059 (MS 1501), 0480066, 0480080 (LST 122), LDV 104. 53. Bofore the cylinder head can be fitted to the block, the correct cylinder head gasket must be selected by measuring piston protrusion as follows: © Clean all traces of carbon from a small flat area in the centre of each piston above the gudgeon pin.Fig.25 Zeroing gauge © Position a dial gauge so that the gauge stylus rests on a flat part of the cylinder block adjacent to the piston to be checked. ‘© Pre-toad and zero the gauge. ig.26 Measuring piston protrusion © Turn the crankshaft to position the piston atthe top ofits bore. Carefully move the the gauge without disturbing ts setting Until its stylus rests on the previously cleaned area of the piston. Piston protrusion "Rock’the crankshaft so that the gauge registers the rise and fall of the piston. Note the highest point reached by the piston. Record this figure, ’d’, which is the protrusion of the piston being measured, Repeat the measuring procedure on the ‘other three pistons. From the 4 measurements taken, identity the height of the piston which has the greatest protrusion. The measurement ‘taken from that piston is used to select which cylinder head gasket is fitted. CYLINDER HEAD Cylinder head gasket identification ‘Two cylinder head gasket options are available, identifiable by the number of otches cut into the end of the gasket. 2rnotches — use for 0,77 mm (0.03 in) protrusion (d) oF less. 3 notches — use for more than 0,77 mm (0.08 in.) protrusion (). 7CYLINDER HEAD 54. Tum the crankshaft anti-clockwise to position all the pistons at mid-stroke with the crankshaft pulley key at approximately 9.0' clock. ‘55. Clean the tapped holes in the cylinder block face (12 x 1,50 mm thread). 56. Check that the cylinder head centralsing dowel is fitted (it may be useful to fit a dummy stud at the opposite end), 57. Fit the head gasket just selected, dry. 58. Position the cylinder head on the cylinder block. 59. Brush clean the threads of the cylinder head bolts, and coat the threads and the underside of the bolt heads with Molycote G Rapid. Fit new washers, concave face downwards (ie. towards the cylinder head). 8 4 1 5 9 Fig.29 Cylinder head bott tightening sequence Tighten the cylinder head bolts using the following procedure: ‘© Pre-tighten all the bolts in the sequence shown to: 15—20 Nm (11-15 Ibf ft), ‘© Tighten the bolts in the same order to 55—65 Nm (40 - 48 Ib ft). ‘© Tighten the botts in the same order a further 180°, using angular torque gauge (0480080 (LST 122). 60. Fit and tighten the two bolts securing the belt tensioner plunger housing to the eyiinder head. 61. Tum the camshaft untl the timing bolt can be inserted in the pulley timing hole. 58 Fig.30 Pulley timing botts fitted 1. Camshaft timing bolt 2. Injection pump timing bolt 62. Check that the injection pump timing bolts are Fig.31 Flywheel timing pin LDV 104 63. Tum the crankshaft 90° clockwise until the flywheel timing pin LDV 104 can be fitted in the flywheel. 64. Carefully it the timing belt while keeping its run taut on the drive side. 65. Remove the timing bolts and the flywhee! timing pitFig.33 Injector 1. Injector 2. Copper washer Fig.32 Adjusting timing belt tension 3. Heat shield washer 1. Tensioner bolt 71. Fitnew injector washers, heat shield washer 2. Tensioner nut domed side upwards, and ft the injectors 166. Siacken the tensioner securing bott and nut rang woe oes (MS 1501), tightening 67. by two tums, and allow the spring and them to the correct torque. plunger to selt-tension the timing belt. ‘Temporarily tighten the bolt and nut. ‘Tur the crankshaft clockwise 7 complete tums, then continue tuming unti the flywheel timing pin LDV 104 can be fitted, together with the camshaft and injection pump timing bolts. NOTE: tf itis not possible to fit all the timing pins / bots, the timing belt fitting procedure hhas not been carried out correctly and must. be repeated. NOTE: Do not tum the crankshaft anti-clockwise. Slacken the tensioner nut and bolt by two tums, and allow the spring and plunger to re-tension the timing belt. Then tighten the bolt and the nut to the correct torque. CYLINDER HEAD Remove the camshaft and fuel injection pump fing bots and te timing pn LDV 108 Fig.34. Tightening injector pipes Check the fl injection pur ing as ' rook te fel nection gure tinge 72. Fite uelinector pipes, making sure each Union is restrained while its nuts tightened. NOTE: This requirement only applies at this i Bageiithe ting ebong stecedsiaiealy. 78, Conectihe sil eum ppes othe rectors, ike unin ls tobe choked marca, tnd tote econ pu. wal pave been stin a poston to start he nine snd check canthon be mage mh 74 Using anew gasket, fi the hermosa ‘the engine running. ing fo the cylinderCYLINDER HEAD Sy 78. Connect the breather pipe to the camshaft cover. 76. Fitthe timing belt upper covers and the belt inspection plate. I the engine is in situ, complete the installation by carrying out the following operations: 77. Connect: = Glow plug supply cable. Throttle cable. Exhaust down pipe. coolant bleed hose to the cylinder head. 78. Fit the thermostat housing using a new gasket. 79. Fill with coolant (50% anti-freeze) to the correct level. ree 60. Check the oil level and top up as necessary. 1. Fit the air box and the air intake ducting. Connect the Mann valve, 82. Connect the battery(s), positive terminals) frst 83. Start the engine and run until normal ‘operating temperature is reached. Check the coolant level and top up as necessary. WARNING: PLACE A THICK CLOTH OVER THE CAP AND EXPANSION TANK BEFORE ATTEMPTING TO REMOVE THE CAP SLOWLY, TO AVOID THE POSSIBILITY OF SCALDING IF THE ENGINE IS HOT. 64. Check /adjust the fuel injection pump timing dynamically (if not already checked statically).FLYWHEEL CLUTCH Remove and Refit Tools required: LDV 101, LDV 102. Remove 1. WARNING: THE GEARBOX MOUNTING PLATE IS HEAVY AND IS LOCATED TO ‘THE CYLINDER BLOCK ON DOWEL PINS WHEN THE GEARBOX IS REMOVED. DO NOT ALLOW THE PLATE TO BE DISPLACED INADVERTENTLY. Remove the gearbox, and temporarily secure ‘the mounting plate with a suitable bolt. 2. _Fitthe flywheel locking tool LDV 102. 3. Support the clutch and progressively remove its securing botts. Remove the pressure plate and friction plate. Inspection Inspect the flywheel friction face and ‘crankshaft spiget bush for wear or damage. NOTE: Fiywheel bolts must be renewed if removed. Rectify as necessary. 5. Check that the clutch release mechanism is serviceable. Refit 6. Fit the clutch friction plate and pressure plate, aligning the friction plate to the crankshaft spigot with the clutch centraliser LDV 101. Progressively tighten the securing bolts, finally tightening them all to the correct 7. Remove the flywhee! locking tool LDV 102. 8. Remove the mounting plate temporary ‘securing bott, and fit the gearbox. Sy CRANKSHAFT REAR OIL SEAL & ‘SPIGOT BUSH Remove and refit Tools required: 186 1628A, LDV 101, LDV 102 Remove ‘The crankshaft rear oil seal and spigot bush can be renewed with the engine in situ, after removing the gearbox. Fig.1_ Flywheel 1. Crankshaft 2. Dowel 3. Spigot bush 4. Flywheel 1. Remove the clutch as detalled in the section “Clutch Remove and Refit, noting the waming given about the gearbox mounting plate. 2. ‘Support the flywheel and remove and discard its securing botts. Remove the flywheel restraining tool and the flywheel, noting the dowel pin 3. To remove the spigot bush, fil the bush area with thick grease, and use a suitable size of dfift to "hydraulic' the bush out. Aas 61faa Fig.2 Removing crankshatt rear oil seal 1. Oilseal 2. Self tapping screw. 4. Totemove the crankshatt rear oil se Refit 5. © CAUTION: Do not allow the drill to penetrate too far and cause damage to the rear main bearing cap. Carefully dril a 3 mm hole centrally across the section of the seal at the point itustrated. © Fit suitable selt-tapping screw and washer approximately 6 mm into the drilled hole. © Use the screw to prise out the seal as ilustrated. © Clean out any swart or dirt Carefully tap a new spigot bush into position, Check that the internal diameter of the bush has not become damaged. Fig.3 Fitting crankshaft rear oil seal 1. Tool 186 1628A 6. Fitthe crankshaft rear oil seal as follows: ‘© Examine the smaller outside diameter surface of tool 18G 1628A to check that there are no imperfections that could damage the oll seal. ‘© Smear the surface of the tool with oil, then carefully fit the oil seal to it. ‘© Tap the seal into place, garter spring towards the crankshaftFig.4 Positioning seal lip ‘© Check that the seal outer lip is seated correctly (1. not folded inwards) Re-position if necessary, using a small tool (e.g a paper clip) that cannot cut the seal. 7. Cheok that the dowel pin is correctly located, then fit the flywheel using new bolts and tighten them to the correct torque, restraining the flywheel with tool LDV 102. Remove the tool 8. Fit the clutch (see section ‘Clutch Remove and Refi). aa teFig.t 1. 2. 3 4 5 6 7. 8 CRANKCASE Crankshaft, connecting rods and pistons Bolt _ Washer ‘Vacuum pump pulley Crankshaft damper / pulley Crankshaft bett pulley Oil seal Oil pump drive sprocket Keys 9. 10. "1 12. 13, 14. 15. 16, il pump drive chain il pump ‘Thrust washers — lower half Main shell bearing Big end bearing cap Big end shell bearing ‘Thrust washers — upper half Crankshaft 17. 18. 19, 20. an. 22. 23. Connecting rod ‘Small end bush Snap ring Gudgeon pin Piston il control ring ‘Compression ring |. Compression ringCRANKCASE Tools required: 18G 1627A, 18G 1628A, (0480066, 0480080 (LST 122), 1210504 (186 1507), LDV 102, LDV 104. Dismantling ‘A number of operations can be carried out on the crankcase in situ. The following operations assume that the engine has been removed from the vehicle. 1. Remove the timing belt (see section ‘Timing Belt Remove’). 2. Remove the cylinder head (see section "Cylinder Head Remove’) 3. Fit the flywheel locking tool LDV 102: remove the crankshaft pulley and recover its key. Remove the flywheel (see section 'Flywhee!’), and discard the bolts. 5. Remove the sump and clean off all sealant. Fig.2 Oil seal housing gabon it pump key Housing gasket (if fited) Oil seal housing Crankshaft front ol seal Pulley 6. Remove the crankshaft front oil seal housing, Remove and discard the oil seal, and the gasket if fitted. eT NL ol 1eer tis Fig.3 Oil pump 66 1. Centralising dowel bott 2. Oil pump assembly 3. Drive chain 4. Crankshaft sprocket. ‘To remove the oil pump: ‘© Mark direction-of-rotation on chain drive. © Remove the 3 bolts securing the pump. NOTE: Rear bolt is a centralising dowel bolt. © Slide the assembly forwards together with the crankshaft sprocket and chain. Recover the sprocket drive key. For oll pump inspection see section "Lubrication System’ Ll Lee Main bearing cap identification 8 To remove the crankshaft: ‘© CAUTION: Do not use a punch to mark caps. NOTE: No.1 piston and connecting rod assembly is at rear (flywheel end) of engine. ‘© Note the identification numbers on the main bearing caps (read from fuel injection pump side). NOTE: No.1 cap is at rear (fiywheel end) of engine. ‘© Remove the main bearing caps. Note the dowels in No.1 cap, and the thrust ‘washers in No.2 cap. © Liftout the crankshaft. '® Recover the upper halves of the thrust washers in No.2 bearing, and the main bearing shells. 9. Carefully tap out the pistons and connecting rods. 10. Remove the water pump and any ancillary ‘components. Inspection and Overhaul ‘Thoroughly clean all component parts prior to inspection / overhaulCYLINDER BLOCK n 12, 18. 14, Fig.5 Degrease the block and remove all traces of old sealant. Inspect the block for cracks and other damage. ‘Assess the condition of the cylinder bores for excessive wear. Rectify /re-bore as necessary. Machining: © The top face of the block cannot be ‘machined as this would affect the piston protrusion. ‘© Bores can be machined and 8 piston oversizes are available. Oversize R1- +0,20 mm Oversize R2— +0,50 mm Oversize R3- + 0,80 mm ‘The size of the bores is stamped at point °X’ on the cylinder block. ‘No stamping or 'At” indicates a standard bore size, Ifthe bores are machined oversize, the block must be stamped’R1’, ’R2’, or’R3! as appropriate. A similar marking will be ‘found on oversize piston crowns. ‘See ‘Data’ for re-boring dimensions. Sy CRANKSHAFT 18. Degrease the crankshaft and check that the oil ways are not restricted or blocked. 16. Examine the crank pins, main bearing journals and thrust washer bearing faces for Signs of wear, scores, grooves and overheating. Examine the spigot bush for wear or damage. oe A ; 4 Fig.6 Crankshaft 17. Crankshaft machining is permissible; © One undersize of main and big end bearing shells available. Main (dimension 'B’) and big end (dimension ’A}) undersizes — 0,30 mm. Undersize main and big end bearing shells are identified withthe size stamped on the steel side. © 3 thrust washer oversizes are available to adjust crankshaft end-float C’. © The rear oll seal contact surface 'D’ can bbe machined undersize by up to 0,20 mm 10 eliminate grooving. ‘See ‘Data’ for machining dimensions. CRANKCASE or