WORKSHOP MANUAL

ENGINE BASE

5.250 TDI

NANNI INDUSTRIES S.A.S – Zone Industrielle

11 avenue MARIOTTE
B.P.107 – 33260 LA TESTE - FRANCE
60 300 077
 DIESEL ENGINE V2003-T-B/F2503-T-B

C O N T E N T S

TO THE READER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . 2

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-0

SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-0
1 CONTENTS
2 CONTENTS
3
CONTENTS
4
CONTENTS
45
CONTENTS
65
CONTENTS
 DIESEL ENGINE V2003-T-B/F2503-T-B

M E C H A N I S M
I N D E X

1. ENGINE BODY ...................................................................................................................M-1

[1] CYLINDER BLOCK..........................................................................................................M-1
[2] CYLINDER HEAD............................................................................................................M-1
[3] CRANKSHAFT.................................................................................................................M-2
[4] PISTON AND PISTON RINGS ........................................................................................M-2
[5] CONNECTING ROD........................................................................................................M-3
[6] ROCKER ARM.................................................................................................................M-3
[7] CAMSHAFT .....................................................................................................................M-3
[8] FUEL CAMSHAFT ...........................................................................................................M-4
[9] FLYWHEEL......................................................................................................................M-4
2. LUBRICATING SYSTEM....................................................................................................M-5
[1] GENERAL........................................................................................................................M-5
[2] OIL PUMP........................................................................................................................M-6
[3] RELIEF VALVE................................................................................................................M-6
[4] OIL FILTER CARTRIDGE................................................................................................M-7
[5] OIL PRESSURE SWITCH ...............................................................................................M-7
3. COOLING SYSTEM............................................................................................................M-8
[1] GENERAL........................................................................................................................M-8
[2] WATER PUMP.................................................................................................................M-8
[3] THERMOSTAT ................................................................................................................M-9
[4] RADIATOR (not included in the basic engine).................................................................M-9
[5] RADIATOR CAP ............................................................................................................M-10
4. INTAKE / EXHAUST SYSTEM........................................................................................ M-11
[1] AIR CLEANER (not included in the basic engine) .........................................................M-11
[2] MUFFLER (not included in the basic engine) ................................................................M-11
5. FUEL SYSTEM .................................................................................................................M-12
[1] GENERAL......................................................................................................................M-12
[2] INJECTION PUMP.........................................................................................................M-12
(1) Pump Element ..........................................................................................................M-13
(2) Delivery Valve...........................................................................................................M-13
(3) Dumping Valve .........................................................................................................M-14
(4) Injection Control........................................................................................................M-14
[3] INJECTION NOZZLE.....................................................................................................M-15
[4] FUEL FILTER (not included in the basic engine)...........................................................M-15
[5] GOVERNOR ..................................................................................................................M-16
6. ELECTRICAL SYSTEM....................................................................................................M-18
[1] CHARGING SYSTEM....................................................................................................M-18
(1) Alternator ..................................................................................................................M-18
(2) IC Regulator..............................................................................................................M-18
7. TURBO CHARGER SYSTEM...........................................................................................M-19
(1) Mechanism ...............................................................................................................M-20
(2) Turbine......................................................................................................................M-21
(3) Compressor ..............................................................................................................M-21
(4) Bearing .....................................................................................................................M-22
(5) Seals (Piston Rings) .................................................................................................M-23

M-0
CONTENTS
M-1
INDEX
M-2
INDEX
M-3
INDEX
M-4
INDEX
M-5
INDEX
M-6
INDEX
M-7
INDEX
M-8
INDEX
M-9
INDEX
M-10
INDEX
M-11
INDEX
M-12
INDEX
M-13
INDEX
M-14
INDEX
M-15
INDEX
M-16
INDEX
M-17
INDEX
M-18
INDEX
M-19
INDEX
M-20
INDEX
M-21
INDEX
M-22
INDEX
M-23
INDEX
 DIESEL ENGINE V2003-T-B/F2503-T-B

S E R V I C I N G
I N D E X
G. GENERAL.....................................................S-1 [3] PISTON AND CONNECTING ROD............S-52
[1] ENGINE IDENTIFICATION...........................S-1 [4] CRANKSHAFT............................................S-56
(1) Model Name and Engine Serial Number .......S-1 [5] CYLINDER..................................................S-61
(2) Cylinder Number......................................S-1 2. LUBRICATING SYSTEM.............................S-62
[2] GENERAL PRECAUTION............................S-2 CHECKING.......................................................S-62
[3] TIGHTENING TORQUES.............................S-3 SERVICING ......................................................S-63
(1) Tightening torques for special use [1] OIL PUMP...................................................S-63
screws,bolts and nuts .......S-3 3. COOLING SYSTEM.....................................S-64
(2) Tightening torques for general use CHECKING.......................................................S-64
screws,bolts and nuts .......S-3 [1] FAN BELT...................................................S-64
[4] TROUBLESHOOTING..................................S-4 [2] RADIATOR .................................................S-64
[5] SERVICING SPECIFICATIONS ...................S-7 DISASSEMBLING AND ASSEMBLING............S-65
(1) Engine Body............................................S-7 4. FUEL SYSTEM............................................S-67
(2) Lubricating System................................S-12 CHECKING AND ADJUSTING.........................S-67
(3) Cooling System .....................................S-12 [1] INJECTION PUMP......................................S-67
(4) Fuel System...........................................S-13 [2] INJECTION NOZZLE..................................S-69
(5) Electrical System...................................S-14 DISASSEMBLING AND ASSEMBLING............S-70
[6] MAINTENANCE CHECK LIST....................S-15 [1] INJECTION PUMP......................................S-70
[7] CHECK AND MAINTENANCE....................S-16 [2] INJECTION NOZZLE..................................S-70
(1) Daily Check Points ................................S-16 5. ELECTRICAL SYSTEM...............................S-71
(2) Check Point of Every 50 hours..............S-17 CHECKING.......................................................S-71
(3) Check Point of Every 100 hours............S-18 [1] STARTER...................................................S-71
(4) Check Point of Every 150 / 200 hours...S-19 [2] GLOW PLUG..............................................S-72
(5) Check Point of Every 400 hours............S-19 DISASSEMBLING AND ASSEMBLING............S-72
(6) Check Point of Every 800 hours............S-20 [1] STARTER...................................................S-72
(7) Check Point of Every 2 years................S-21 [2] ALTERNATOR............................................S-73
[8] SPECIAL TOOLS........................................S-22 SERVICING ......................................................S-76
1. ENGINE BODY............................................S-28 [1] STARTER...................................................S-76
CHECKING AND ADJUSTING.........................S-28 [2] ALTERNATOR............................................S-78
DISASSEMBLING AND ASSEMBLING............S-31
[1] DRAINING WATER AND OIL.....................S-32
[2] EXTERNAL COMPONENTS......................S-33
[3] CYLINDER HEAD AND VALVES ...............S-34
[4] GEAR CASE...............................................S-36
[5] PISTON AND CONNECTING ROD............S-39
[6] FLYWHEEL AND CRANKSHAFT...............S-42
SERVICING ......................................................S-44
[1] CYLINDER HEAD.......................................S-44
[2] TIMING AND CAMSHAFT..........................S-50

S-0
CONTENTS
S-1
INDEX
S-2
INDEX
S-3
INDEX
 S-17

S-17

S-67

S-69

S-28

S-38

S-54, 61
S-20

S-71

S-18

S-69
S-69
S-30
S-30
S-30

S-4
INDEX
 S-16
S-54, 61

S-67

S-29

S-21
S-18
S-69

S-67

S-69

S-28

S-29
S-29
S-18
S-30

S-54
S-54

S-54
S-46
S-56, 57
58, 59

S-69

S-5
INDEX
 S-45

S-58, 59

S-57
S-49

S-62, 63

S-19
S-18

S-16

S-65

S-67

S-64

S-80

S-6
INDEX
S-7
INDEX
S-8
INDEX
S-9
INDEX
S-10
INDEX
S-11
INDEX
S-12
INDEX
S-13
INDEX
S-14
INDEX
S-15
INDEX
S-16
INDEX
S-17
INDEX
S-18
INDEX
S-19
INDEX
S-20
INDEX
S-21
INDEX
S-22
INDEX
S-23
INDEX
S-24
INDEX
S-25
INDEX
S-26
INDEX
S-27
INDEX
S-28
INDEX
S-29
INDEX
S-30
INDEX
S-31 INDEX
S-32
INDEX
S-33
INDEX
S-34
INDEX
S-35
INDEX
S-36
INDEX
S-37
INDEX
S-38
INDEX
S-39
INDEX
S-40
INDEX
S-41
INDEX
S-42
INDEX
S-43
INDEX
S-44
INDEX
S-45
INDEX
S-46
INDEX
S-47
INDEX
 S-23

S-48
INDEX
S-49
INDEX
S-50
INDEX
S-51
INDEX
S-52
INDEX
S-53
INDEX
S-54
INDEX
S-55
INDEX
S-56
INDEX
S-57
INDEX
S-58
INDEX
S-59
INDEX
S-60
INDEX
S-61
INDEX
S-62
INDEX
S-63
INDEX
S-64
INDEX
S-65
INDEX
S-66
INDEX
S-67
INDEX
S-68
INDEX
S-69
INDEX
S-70
INDEX
S-71
INDEX
S-72
INDEX
S-73
INDEX
S-74
INDEX
S-75
INDEX
S-76
INDEX
S-77
INDEX
S-78
INDEX
S-79
INDEX
S-80
INDEX