section 4 8361 series workshop manual Publication No. 32033003 Date 10-1991 IVECO aifo‘The data contained in this publication may not have been updated following modifications carried out by the manufacturer, at any time, for technical or commer- cial reasons and also to conform to the requirements, of the law in the various countries. This publication supplies features and data together with the suitable methods for repair operations to be carried out on each single component of the engine, Following the supplied instructions and using the inherent specific fixtures, a correct repair procedure will be obtained in due time, protecting the operators from all possible accidents. Before starting any repair, be be sure that all accident prevention devices are available and efficient, Therefore check and wear what indicated by the safely provision: protective glasses, helmet, gloves, safety shoes. Before use, check all work, lifting and transport equipment.INDEX GENERAL... SEA WATER PUMP. FITTING TOLERANCES FAULT -FINDING DIAGNOSIS... ENGINE BLOCK.. PISTONS AND RINGS.. z CONNECTING RODS AND BUSHINGS. CRANKSHAFT. CYLINDER HEAD... VALVE GEAR VALVE TIMING LUBRICATION SYSTEM . WATER PUMP... WATER PUMP AND ALTERNATOR DRIVE BELT. TORQUE LOADS. SPECIAL TOOLS... FRESH WATER-SEA WATER HEAT EXCHANGER... SECTION 4 8361 M 16 PageSECTION 4 8361 SM 21 INDEX Page GENERAL .... SEA WATER PUNP.. FRESH WATER-SEA WATER HEAT EXCHANGE! FITTING TOLERANCES FAULT -FINDING DIAGNOSIS. ENGINE BLOCK... PISTONS AND RINGS CONNECTING RODS AND BUSHINGS CRANKSHAFT..... CYLINDER HEAD...... VALVE GEAR ... VALVE TIMING LUBRICATION SYSTEM .. WATER PUNP... tote | WATER PUMP AND ALTERNATOR DRIVE BELT. TORQUE LOADS. SPECIAL TOOLSGSECTION 4 8361 SRM 32 INDEX Page GENERAL SEA WATER PUMP. FRESH WATER-SEA WATER HEAT EXCHANGER ... FITTING TOLERANCES.......... FAULT -FINDING DIAGNOSIS. ENGINE BLOCK.. PISTONS AND RINGS......... CONNECTING RODS AND BUSHINGS.. CRANKSHAFT. CYLINDER HEAD VALVE GEAR VALVE TIMING LUBRICATION SYSTEM WATER PUMP. WATER PUMP AND ALTERNATOR DRIVE BELT. TORQUE LOADS: SPECIAL TOOLS. BaRoaeSECTION 4 8361 SRM 37 INDEX Page GENERAL, SEA WATER PUMP. FRESH WATER-SEA WATER HEAT EXCHANGER: FITTING TOLERANCES... FAULT -FINDING DIAGNOSIS. ENGINE BLOCK... PISTONS AND RINGS.... ares CONNECTING RODS AND BUSHINGS CRANKSHAFT. CYLINDER HEAD .. VALVE GEAR VALVE TIMING.. LUBRICATION SYSTEM WATER PUMP... WATER PUMP AND ALTERNATOR DRIVE BELT. TORQUE LOADS... SPECIAL TOOLS .. SBSSSLRSBRRBBAR Od8361 GENERAL Engine p.1 ENGINE SPECIFICATIONS LUBRICATION Engine type once 8361Mi6 | | Minimum oil pressure 4- stroke Diesel with direct injection at full throttle... son 5 kgfom® Cylinders, number and arrangement... w6,inling | | when idling... 0.8 kg/cm Bore x stroke... 118x130 mm Displacement. ail Compression rat ATA Net power at flywheel (*): Pleasure cra. 118 KW (160 CV) At : “ 2600 rpm - Light-duty commercial. 107 KW (145 CV) Le 1.2400 rpm = Continuous duty... 96 KW (130 CV) AL ee se 2300 rpm Engine rotation (see from flywheel)... cow (+) Net rating at flywheel according to ISO 9046-1 - Ambient reference conadltions : 750 mmHg ; 25°C ; 90 % relative humidity. TIMING Valve Timing = Intake ‘opens : before T.D.C. closes : after B1D.C..... Exhaust ‘opens : before B.0.C. closes : after T.D.C.... Clearance between valve and rockers for timing checks... sen 0A0 M1 Operating clearance between valves and rockers, cold engine - intake .. 0.30 mm exhaust, 0.50 mm FUEL SYSTEM Rotary injoction pump type PES 6A. Fixed injection pump delivery start advance .... 25° 1° Fuel injectors setting. 200 + 8bar Firing order.. 1-5-3-6-2-4 COOLING SYSTEM Cooling by dual water circuit - Primary circuit (closed) by fresh water; - Secondary circuit (open) by sea water. Water circulation is provided by a self priming pump featuring a neoprene Impeller. Complete sea water circuit is protected trom corrosion| by replaceable sactifical anodes. STARTING By starter motor. ELECTRIC SYSTEM Voltage 24 - Solf-ragulated alternator. 28V, 30. - Starting motor power 4K - Battery (optiona).. .2,each 110. Ah MARINE GEAR Available in diferent modets for their overhauling see the specific manual of the manufacturer.8361 GENERAL Engine p.2 ENGINE SPECIFICATIONS TURBOCHARGING Engine type. .83618M21 | _ |The engine is turbocharged by turbocharger driven by| 4- stroke Diesel with direct injection the exhaust gases Cylinders, number and arrangement, 6,inline | _ |The turbocharger is lubricated with the engine oil under Bore x stroke. 118 130mm |_| Pressure. Displacement. atl Compression ratio. 16531 Net power at flywheel (*) LUBRICATION - Pleasure cra. 1-185 KW (210 CV) At. uuu 12.2200 rpm | |Minimum oil pressure - Light-duty commercial ..140 kW (190 CV) at full throttle 8.5 kgfom? A. 2700 rpm | |- when idling .. 0.8 kglorn? Continuous duty 192 KW (175 CV) A 2000 rpm Engine rotation COOLING SYSTEM (cee from flywheel) cow (*) Net rating at flywheel according to ISO 9046-1 - Ambient reference conditions : 750 mmHg ; 25°C ; 30 % relative humidity. TIMING Valve Timing : Intake opens : before T.D.C. closes : after B.D. - Exhaust opens : before B.D.C. we 27° 85° closes : after T.D.C..... 17° Clearance between valve and rockers for timing checks .. .-0.44 rom Operating clearance between valves and rockers, cold engine + intake 0.30 mm exhaust, 10.50 mm FUEL SYSTEM Inline injection pump type PES 6P. Fixed injection pump delivery start advance .... 23° = 1° Fuel injectors setting. 200 + Bar Firing order. 1-8-3-6 -2-4 Cooling by dual water circuit - Primary circuit (closed) by fresh water; - Secondary circult (open) by sea water. Water circulation is provided by a self priming pump] featuring a neoprene impeller. Complete sea water circuit is protected from corrosion| by replaceable sacrifical anodes. STARTING By starter motor. ELECTRIC SYSTEM - Voltage AV - Sol reguated alternator. 28V, 30 + Starting motor power... 4kW - Battery (optional) .2, each 110. Ah MARINE GEAR Available in different models for their overhauling see the specific manual of the manufacturer.8361 GENERAL Engine p.3 | ENGINE SPECIFICATIONS TURBOCHARGING Engine typ0 ennnnnnn ssuouen8961SRM32 | |The engine is turbocharged by turbocharger driven by 4- stroke Diesel with direct injection the exhaust gases Cylinders, number and arrangement. _..6,inline | _ {The turbocharger fs lubricated with the engine oil under BOre x SMOKE nnn 1 115% 190mm | [Pressure Displacement. aal Compression rato 18521 Not power at flywheel (* LUBRICATION - Pleasure craft. sn 236 KW (820 CV) Nt 2400 rpm | |Minimum oil pressure : - Light-duty commercial... 184kW (250CV) | _|-at full throttle ..... 3.5 kgicm® A oe 2200 rpm = when idling ... 0.8 kgicm® Engine rotation (600 from flywined) cow COOLING SYSTEM (¢) Net rating at flywheel according to ISO 2046-1 - Ambient reference conditions : 750 mmHg ; 25°C ; Cooling by dual water circuit 30 % relative humidity - Primary circuit (closed) by fresh water; - Secondary circuit (open) by sea water Water circulation is provided by a self priming pump featuring a neoprene impeller. Complete sea water circult is protected from corrosion uo by replaceable sacral anodes, Valve Timing - Intake opens : before T.D.C. 11 | [STARTING closes : after B.D.C. are aes By starter motor. ‘opens : before B.0.C. 55° closes : ater T.D.C. AT? ‘Clearance between valve and rockers for ELECTRIC SYSTEM timing CHECKS nnn 0.44 mm Operating clearance between valves and rockers, cold engine - intake .. ~ exhaust... FUEL SYSTEM In fine injection pump type PES 6P. Fixed injection pump delivery start advance ..... 18° t 1° Fuel injectors setting. 215 + Sbar Firing order. w1-5- 3-6 -2-4 -Voltagk a - Selfregulated alternator... - Starting motor power - Battery (optional). 1 24V 1 28V, 30A MARINE GEAR Available in ifferent models for their overhauling see the specific manual of the manufacturer.8361 GENERAL Engine p.4 ENGINE SPECIFICATIONS TURBOCHARGING Engine type .. 8361SRM37 |__| The engine is turbocharged by turbocharger driven by, 4- stroke Diesel with direct injection the exhaust gases . Cylinders, number and arrangement.uncsu.-6,intine | |The turbocharger is lubricated with the engine oil under’ Bore x stroke. 115x130 mm eee Displacement... B11 Compression ratio... Net power at flywheel (*) - Pleasure craft. At os Engine rotation (see from flywheel) 188:1 ..272 KW (870 CV) 2400 rpm. cow (¢) Netrating at flywheel according to ISO 3046-1 Ambient reference conditions : 750 mmHg ; 25° 80 % relative humidity. TIMING Valve Timing + Intake opens : before T.D.C.. closes : after B.D.C... ~ Exhaust 1° 278 ‘opens : before B.0.C. 55° closes : after T.0.C. 17 Clearance between valve and rockers for timing checks 7 0.44 mm Operating clearance between valves and rockers, cold engine : = Intake... = 0.30 mm - exhaust... 0.50 mm FUEL SYSTEM Inne injection pump type PES 6P. Fixed injection pump delvery start advance ... 20° 1° Fuel injectors setting. 215 + Sbar Firing order... snl -B- 8-6 -2-4 LUBRICATION Minimum oll pressure : ~ al full throttle... 108.6 kgfom? when idling 0.8 kglem? COOLING SYSTEM Cooling by dual water circuit - Primary circuit (closed) by fresh water; - Secondary circuit (open) by sea water. Water circulation is provided by a self priming pump] featuring a neoprene impeller. [Complete sea water circuit is protected from corrosion, by replaceable sacrifical anodes. STARTING By starter motor. ELECTRIC SYSTEM - Voltage... - Selfregulated alternator... + Starting motor power. Battery (optional. sennsnn 2BV, 308, 2, each 110 Ah, MARINE GEAR ‘Avaliable in different models for their overhauling see the specific manual of the manufacturer.8361 Engine p.5 SEA WATER PUMP GENERALITIES The sea water circulation for cooling the fresh water and the marine gear oil Is ensured by a self-priming pump type neoprene impeller INSTRUCTION FOR USE [Each time the engine is started, check that the sea wa- {ter Intake valve Is open. Dry running of the pump would Idamage the impeller (1) — ina very short time. Under normal operating conditions of the engine (check every 800 hours the state of the neoprene im- peller, after removing first the cover [Make sure that it Is free from cracks or excessive we- lar of the lobs It not replace it.8361 Engine p. 6 FRESH WATER_SEA WATER HEAT EX-| CHANGER | GENERALITIES | When the fresh water circulating in the engine reaches| temperature values in excess of 66°C (8361 M16) 75° C (8361 SM 21-8361 SAM 32- 8361 SRM 37) itis convoyed under thermostatic control to the fresh wa- ter-sea water heat exchanger, where itis cooled and re-| turned to circulation This heat exchanger consists essentially of a cast iron bo- dy with the fresh water circulation therein and a copper! tube bundle containing the circulating sea water for coo-| ling the fresh water. ' 6 MAINTENANCE [sea water heat exchanger itis necessary to clean pe- lodically the tube bundle: = Remove the tube bundle from the exchanger body ‘and Immerse it into a solution of water and anti-incru- stator type "P3" or the like (*) which does not attack copper, brass, aluminium and tin. - After the end of the reaction (Indicated by efferve- /scence) after about 15 to 20 minutes, rinse the tube bundle aboundingly with running water for completely eliminating any residue of the solution and re-assem- : ensuring the perfect efficiency of the fresh water- : the bundle into the exchanger body. i | (*) When using solvents observe the prescriptions of !the makers. D08361 Engine p. 7 FITTING TOLERANCES DESCRIPTION om ENGINE BLOCK - CONNECTING Rops Cylinder sleeve bore diameter... . 118,000 + 115,022 Cylinder sleeve bore oversize _- . 06 Cylinder bore diameter in block -....... . 122,000 + 122,030 Cylinder steove pilot diamotor . «121,920 + 121,970 Cylinder sleeve fitted clearance in block .- . 0,030 + 0,110 Cylinder sleeve protrusion above block top . 0,130 + 0,170 Maximum cylinder sleeve top misalign- ment . . we 0,030 Sleeve protrusion shim thickness range 3,09-3,11-3,13- 3,18-3.17-3,19- 3.21-3,23-3,25- 3.27-3,29-3,31- 3,33-3,35-3,37- 3,39-3,41-3,43- 3,45-3,47-3,49- 3.51 Camshaft bushing housing bore diameter. - 52,000 + 52,025 Camshaft bushing 0.0. oe Le 2,098 + 52,136 Camshaft bushing interference fit in hou- sing Bee . 0,073 + 0,136 Camshaft bushing fitted 1.0. 5 49,055 + 49,090 Camshaft journal diameter... -- . 48,950 + 48,975 Camshaft journal running clearance in bushing : - . 0,080 + 0,140 Main bearing housing bore diameter . 84,206 + 84,226 ‘Tappet housing bore diameter in block . 27,000 + 27,033 Tappet housing oversize o ' 0,30-0.40-0,50 Big end bore diameter : 76,698 + 76,7°9 J ‘Small end bushing bore diameter 45,946 + 45,971 Big end bearing wall thickness _ 2,060 + 2,070 Big ond bearing undersize range 0.254-0,508- 0,762-1,016 ‘Small end bushing 0.0. ee 46,069 + 46,1208361 Engine p. 8 DESCRIPTION mm ‘Small end bushing fitted 1.0. 42,028 + 42,036 Piston pin clearance in small end bushing 0.019 0,035 ‘Small end bushing interference fit in hou- sing ‘i poner oes 0,174 Crankpin running clearance in big end bearing ‘i . cae 0,058 + 0,111 Connecting rod axle misalignment 125 mm from conn. rod... Bo54 . 0.050 PISTONS - PINS - RINGS Piston diameter at right angles to pin and 30 mm from base of skiet é ‘i 114,833 + 114,847 Piston oversize a 0.6 Piston clearance in cylinder sleeve at right angles to pin and 30 mm from base of skirt 0,153 + 0,189 Pin housing bore diameter in piston 42,013 + 42,019 Ring groove width in piston: — top c - 2,580 + 2,600 — second an 2,540 + 2,660 — bottom =. 4,030 + 4,050 Piston pin diameter 42,000 + 42,006 Piston pin oversize . . - 02 Piston ring thickness: top compression ring, chromed second compression ring... bottom oil scraper ring, slotted and spring loaded 2,478 2,478 2,490 2,490 3.978 + 3,990 Piston ring oversize - 06 Ring clearance in groove ~ top compression ring 0.000 + 0,122 ~ second compression ing . 0.050 + 0.082 — bottom oil craper ting . woe 0.040 + 0,0728361 Engine p.9 DESCRIPTION mm Ring fitted gap: — top compression ring 0.40 + 0.65 — second compression 0,40 + 0,60 — bottom oil scraper ring 030 + 045 Piston pin clearance in small end bushing 0.019 + 0,035 Pin clearance in piston 0.007 + 0,019 CRANKSHAFT - BEARINGS Main journal diameter 78,777 t0 79.800 Main bearing housing bore diameter 84,206 + 84.226 Main bearing shell thickness 2,169 + 2,178 Main bearing undersize range 0,254-0.508- 0,762-1,016 Crankpin diameter Main journal running clearance in bea- rings 72.477 10 72.500 0.050 to 0.111 Big end bearing shell thickness Crankpin running clearance in big end 2,060 + 2,070 bearing 0.088 100.0116 Big end bearing undersize range 0,254-0,508- 0,762-1,016 Centre main bearing housing width over thrust shoulders. Centre m shoulders journal width over thrust Thrust washer thickness Thrust washer oversize Crankshaft end float Maximum main journal misalignment (TIR) Crankpin misalignment relative to main journals 43,024 + 43,074 50,000 + 50.050 3,378 + 3,429 0,127-0,254.0,508 0,068 + 0,270 0,100 + 0.2508361 Engine p. 10 DESCRIPTION = Maximum main journal and crankpin ovalty after grinding .. .. 0,095 Crankshaft flange face run-out on perip- hery (TR) a . F 0.026 Flywheel face run-out over 330 mm dia~ meter (TIR) : . 0,050 CYLINDER HEAD Valve guide housing bore diameter in head Valve guide 0.0. 13,995 + 14,018 - 14,028 = 14,039 Valve guide oversize . 0.4-02.0,4 Valve guide fitted 1.0. 7,987 + 8,012 Valve guide interference fit in head. 0,010 + 0,044 Valve stem diameter fee cee 7,945 + 7,960 Valve stem working clearance in guide 0,027 + 0,067 Valve stand in: = Intake. cee é 0,10 + 0,50 = Exhaust : 0.40 + 0.80 Valve face angle... - - = 7 45° 15) Exhaust valve seat housing bore diame- ter . . - é 42,980 = 43,020 Exhaust valve seat 0.0, : pre 43,150 + 43,170 Exhaust valve seat interference fit in head . F ___0,130 + 0,190 Injector nozzle stand-out: — injector EPPZ 10 F 1 cee 2,70 + 3,50 — injectorZEPPZ 50 F 15 Veto EPPZ TOF 15 .. oe a 2,20 + 3,00 VALVE SPRINGS Free height eae Paar 49,30 Spring hi t under 23.70 kg 30 . A 42,00 Spring height under 64.30 kg . . 29,508361 Engine p.11 DESCRIPTION VALVE TIMING GEAR Camshaft bushing housing bore diameter 52,000 + 52,025 Camshaft bushing 0.0. “52,098 + 52,136 Camshaft bushi block interference fit. in 0.073 + 0,136 Camshaft bushing fitted |.D. tse ne : oa os 49,055 49,080 _| Camshaft journal diameter 48,950 + 48.975 Camshaft journal running clearance in bushings . a 6,080 + 0.140 Tappet housing bore diameter . 27,000 + 27.033 Tappet housing oversize 7 0,30-0,40-0,50 Tappet 0.0. Tappet oversize 26,939 = 26,960 aS 0,30-0,40-0,50 Tappet working clearance in block : i 0.040 + 0,094 Rocker shaft 0.0. - ee 21,015 + 21,036 Rocker bracket bore diameter 21,040 + 21,061 Rocker bore diameter z a : 21,050 + 21,080 Rocker shaft clearance in bracket 0,004 + 0,046 Rooker shaft clearance in rocker 0.014 = 0,0658361 Engine p. 12 FITTING TOLERANCES ENGINE BLOCK - CONNECTING RODS DESCRIPTION mm Cylinder sleeve bore diameter Cylinder sleeve bore oversize Cylinder bore diameter in block Cylinder sleeve pilot diameter 118,000 to 115.022 06 122,000 to 122.040 121.920 to 121.970 Cylinder sleeve fitted clearance in block 0.030 t0 0.120 Cylinder sleeve protrusion above block top 0.120 100.160 Maximum cylinder sleeve top misalignment 0.030 30910 351 Sleeve protrusion shim thickness range Main bearing housing bore diameter Tappet housing bore diameter in block, Tappet housing oversize Big end bore diameter ‘Small end bushing bore diameter Big end bearing wall thickness Big end bearing undersize range é Small end bushing 0.0. 84.206 0 84.226 27.000 10 27.088 0:20 -0.40 76.698 to 76.713 45.946 10 45.971 2,060 t0 2.070 0.2540 508.0.762.0016 46,069 10 46.120 ‘Small end bushing fitted 1.0. 45.025 to 42.035 Piston pin clearance in small end bushing 0.019 100.035 ‘Small end bushing interference fit in housing 0.098 10 0.174 Grankpin running clearance in big end bearing e 0.058 to 0.174 PISTONS - PINS - RINGS DESCRIPTION mm Piston diameter at right angles to pin and 35 mm from base of skirt 114813 to 114.827 Piston oversize 06 Piston clearance in cylinder sleeve at right angles to pin and 35 mm from base of skirt peers Pin housing bore diameter in piston 42.008 to 42.014 Piston pin diameter 42.000 to 42.006 Piston pin oversize 02 Pin clearance in piston 0.002 100.014 Ring groove width in piston: — top 3.052 to 3082 = second 2.550 to 2.570 = bottom 4.030 to 4.060 Piston ring thickness = top compression ring, chromed = second compression ring = bottom oil scraper ring, slotted and spring loaded (3) 2.478 to 2.490 3978 10 39908361 Engine p. 13 Ring clearance in groove: — top compression ring 0.052 10 0082 = second compression ring 0060 10 0092 — bottom oilscraper ring 4 0,040 t0 0072 Ring fitted gap: 7 — top compression ring 0.40 10 0.65 — second compression ring (0.40 to 0.60 — bottom oil scraper ring . 0.30 t0 0.45 CRANKSHAFT - BEARINGS DESCRIPTION mm Main journal diameter ; 79.782 to 79.800 Main bearing housing bore diameter . 84.206 to 84.226 Main bearing shell thickness . 2.169 to 2.178 ‘Main bearing undersize range. si =. - 0.254-0.508-0.762-1.014 Crankpin diameter an 72.482 to 72.600 Main journal running clearance in bearings 0,050 to 0.106 Big end bearing shell thickness . : 2,060 to 2.070 Crankpin running clearance in big end bearing 0.058 t0 0.111 Big end bearing undersize range. 0.264-0.5080.762-1 01 Centre main bearing housing width over thrust shoulders 43.024 to 43.074 Centre main journal width over thrust shoulders - 50.000 to 60.050 Thrust washer thickness . 3.378 to 3420 Thvust washer oversize - . _..9.127-0.2540.508 Crankshaft end float . 01068 to 0.270 CYLINDER HEAD DESCRIPTION mm Valve guide housing bore diameter in head 13.995 t0 14.018 Valve guide 0.0. 14.028 to 14.039, Valve guide oversize... 0.04-02-0.4 Valve guide fitted 10. _ 7.987 19 8012 Valve guide interference fit in head 7 (0.010 10 0,004 Valve stem diameter. as . 7.945 to 7.960 Valve stem working clearance in guide (01027 to 0,067 Exhaust valve seat housing bore diameter . =e ss _ 42,980 10 48,020 Exhaust valve seat 0.D. _ 43,150 to 43.170 Exhaust_valve seat interference fit_in head 0.190 t0 0.190) Valve stand in: = Intake . 0.10 t0.0.60 = Exhaust = a. (0.40 1000.80 Valve face angle coe 4° 15"8361 Engine p.144 VALVE SPRINGS DESCRIPTION ram Free height 553) Spring height under 2521 kg 43 Spring height under 6422.5 kg : 305 VALVE TIMING GEAR DESCRIPTION mm Camshaft bushing housing bore diameter 52,000 to 52025 Camshaft bushing 0.0. f 2,098 to 62.136 Camshaft bushing interference fit_in block... 0,073 10 0.136 Camshaft bushing fitted 1.0. = z 49.056 to 49.090 ‘Camshaft journal diameter a 48.960 to 48.975 Camshaft journal running clearance in bushings 0.080 t0 0.140 ‘Tappet housing bore diameter 27.000 to 27.933 Tappet housing oversize 0.20 -0.40 Tappet 0.0. . 26,939 to 26,960 Tappet oversize 0.20 -0.40 Tappet working clearance in block 0.040 100.094 Rocker shaft 0.0. Rocker bracket bore diameter. 21.016 to 21.036 21,040 to 21.061 Rocker bore diameter 21.050 to 21.080 Rocker shaft clearance in bracket 0,004 10 0,046 Rocker shaft clearance in rocker 0.014 10 0,0658361 Engine p.15 FAULT-FINDING DIAGNOSIS TROUBLE POSSIBLE CAUSE Theenginedoes Battery charged partially. REMEDY Check batteries and charge them. hot start If necessary. replace them. Battery terminal connections cor- Clean, check and tighten nuts on battery terminals. Replace roded or loose. cable terminals and nuts, if badly corroded. Incorrect timing of injection pump. Check and carry aut injection pump timing Deposits or water in fuel lines Detach pipes and clean them with air. Disasse and clean injection pup. Dry fuel tank and refvel. Insufficient fuel reserve, Refuel. Defective fuel pump. (Overhaul pump or change it ‘Air bubbles in fue! lines or in injec- Check pipes and fuel feed pump to detect the reasons of air ton pump, presence; bleed air from injection pump unscrewing the relevant plug and manually operating fuel feed pump. Defective starter. Repair or replace starter. Theengine stops Too low idling Adjust idle speed by adjusting screw. Uneven delivery of injection pump. Foreign matter or water in fuel pipings. Fuel fiters clogged. ‘Abnormal clearance between valves and valve rockers, Valves burnt, corroded or cracked. Air in fuel feed or injection systems. Fuel fiter and fuel feed pump valves clogged. Injection pump controls broken, ‘The engine warms Defective water pump. up excessively ‘Thermostat failure. Partially ineffective radiator. Scale in water passages in engine black and cylinder head. Insufficient tension of water pump belt: ‘Adjust delivery. f broken, replace pumping element spring. Replace tappets plunger and barrel, if seized or not sealing. ‘Detach pipes and clean with air. Disasse and clean injection ‘pump, Clean fuel tank and refuel Remove filter elements and replace them, if necessary. Adjust clearance Replace valves. Check pipes for possible cracks: check for loose connectors. Replace worn parts, then bleed air from pipes and proceed to deaerate injection pump and fuel fter unscrewing the relevant plugs and operating the fuel feed pump manually, Replace fuel fiter and overhaul fuel feed pump valves. Replace defective parts and check pump timing Check clearance between impeller blades and pump casing ‘Overhaul the assembly and replace gasket, Replace thermostat. ‘Wash out possible scaling in compliance with the instructions given for the type of scale remover used, Detect and repair Dossible leaks from radiator hoses. Wash thorougy. in compliance with directions given for the type of scale remover used, Check and adjust belt tensions.8361 TROUBLE POSSIBLE CAUSE ‘The engine warms up excessively Cooling water level too low. Incorrect engine timing Incorrect injection pump calibration (upwards or downwards). Incorrect timing of injection pump. power and its Engine p. 16 REMEDY Top-up radiator with water. Check timing and proceed to correct timing. (On test bed correct pump delivery so that injection has the prescribed delivery Check pump timing and correct it. operation isuneven Automatic advance of injection On test bed check injection pump operation: ifthe observed pump defective values do not comply with the prescribed ones, replace inner springs of advance unit Excessive wear in plungers and bar Ovehaul injection pump and replace worn-out parts. rels of injection pump. Incorrect calibration of speed gov- Check governor calibration and again calibrate it. if necessary. ernor. Injector nozzles clogged or incor- Clean nozzle holes with Suitable tool and totally overhaul rect injector operations. injectors. Foreign matter or water in injection Thorougly clean and refill with new fuel. feed system. Defective fuel feed pump. Disassemble pump, and, if necessary, replace pump compo: rents Incorrect clearance between valves Check clearance and proceed to a correct adjustment. and rockers. Low compression, With too! ‘check compression pressure, Defective turbocharger. (Overhaul the assembly or replace it Air cleaner clogged. Clean air cleaner and inherent system, Incorrect adjustment of injection Adjust stops correctly ump peak capscrew or of control rod stop. The engine knocks —Uncorrect injector operations. Check that nozzle pin does not cause resistance and calibration abnormally 's of prescribed value, Fuel lines clogged. Uncorrect injection pump timing. Crankshaft knocks. because of ex- cessive clearance of one or more main bearings or of high thrust clearance, CCranckshaft unbalanced. Flywheel capscrew loose, Connecting rods out-of alignment. Piston knocks due to slap. Remove pipes: clean them and replace those which are ‘damaged or clogged. Correct pump timing so that injection takes place according to the prescribed advance angles, Recondition cranckshaft journals and mount undersize bear- ings Replace thrust washer halves with oversized ones. Check shaft alignment; if necessary correct as required and check balance. Replace loose screws and tighten to the prescribed torque value, Straighten connecting rods under a hydraulic press, and check parallelism. Replace cylinder sleeves and pistons,8361 TROUBLE The engine knocks abnormally The engine smokes abnormally 1) Black or dark grey smoke: 1) Dark grey or black smoke: 2) Blue, grey/blue, POSSIBLE CAUSE Noisy piston pins due to excessive clearance in piston and in connecting rod bushing Loose bushings in connecting rod seat Tapping dive to noisy valve system, Excessive pump delivery. ‘After starting the automatic fuel excess device does release. Injection pump retarded excessively (or advance governor defective). Injection pump excessively adv anced, Nozzle holes (or some of them) partially or totaly clogged. Air cleaner clogged or worn-out Nozzle pin intermittently locked in ‘open position, Governor adjustment over max. stated Nozzle sprays are sent to the head because of incorrect injector assem- bly. Excessive lit of injector pin due to abnormal wear. Engine compression loss due to: = Piston rings stuck = Cylinder sieeve worn-out, —Valves worn-out or adjusted un- correct Incorrect type of injector, oF injec- tors of different types or uncali- brated Injection pipes of inadequate inside bore, pipe ends squashed because of repeated refitting Excessive injection delay or automa ticadvance device worn-out, Injector needles blocked or defec- tive injectors. Oil seeping through piston rings due to stuck rings or to wear of sleeve walls Engine p. 17 EMEDY Replace piston pin with an oversize one and adjust piston hubs and connecting rod bushings. Replace bushings with new ones. ‘Adjust clearance between valves an rockers and check if there are broken springs or excessive clearance between stems and guides, or tappets and seats. Detach pump and adjust delivery according to the data of libration table. Check and. in case, replace this device, Correct timing, verify governor. Correct timing Replace injectors with a set of new injectors, or clean and recondition the original ones with suitable fixtures. Clean or replace fiter element. Check injectors. check for possible locked pins, broken springs, too low calibration. Bench adjust governor, according to table data. Check nozzle protrusion as to head face. Replace affected nozzle. ‘Overhaul engine or repair concerned parts. Replace injectors or calibrate them, Check conditions of ends and connectors. Replace where necessary. Correct pump timing and check governor. Check for blocked needles or broken springs. Overhaul engine.8361 TROUBLE 2) Blue, grey/blue, or clear grey smoke Stepless change of max. speed (engine POSSIBLE CAUSE Engine oil seeping through intake valve guides, due to wear of valve stems or guides. Engine too cold (thermostat missing ‘oF not present) Governor springs too weak, causing an excessive sensitivity from gov- Engine p. ig REMEDY : Recondition cylinder head Replace trermostat. Replace governor springs. not loaded) enor. Excessive clearance between the Adjust all clearances among the various parts transmitting various parts transmiting control to control (be sure that pushrod stroke is exactly as prescribed) pump. The pump doesnot Foreign matter in pipes. Clean thorougly. deliver fuel Dirty fuel fiers Clean thorougly. The pump does deliver fuel The pump does not deliver enough fuel The pump feeds abnormally Injection start faulty timed The control rod shakes Squashed pipes. Ar in injection pump. Plunger tappets may be seized. Plunger seized Delivery valves seized. Imperfect seal unions, Imperfect seal in delivery valves of some elements. Pumping elements worn-out Air bubbles in fuel feed pump. Plunger return spring broken, ‘The plunger is about to seize ‘Tappet pin worn-out Uneven delivery start Eccentric damaged. Vibration due to high pump stress Critical engine rpm. Replace pipes or. if possible repair them (the low pressure ones) Deaerate pump. Remove part and repair it (if failure is minor): if necessary, replace it, Change defective pumping element, as barrels and piston are ‘ot interchangeable. If failure is only due to foreign matter, clean valve and sligtly regrind teper faces with an_emery'cloth; if reasons are diferent, replace pair valve holder - valve with are not interchageable from each other. Be sure that fuel feeding pipe nut washers are not broken or deformed then tighten joints very carefully Replace the pair valve - tube holder Replace pumping elements Deaerate fuel feed pump, Replace spring Thorougly clean plunger and its cylinder: Replace tppet. Adjust delvery start replacing adjusting shims. Replace camshaft, using the stroboscopic check method. Check the fen of spring sal Bocs of acting device Check the efficiency of spring small blocks of adjusting device.8361 Engine p.i19 TROUBLE POSSIBLE CAUSE REMEDY INJECTORS The injector drips Nozzle and needle valve (pin) are Thorougly clean nozzle if the trouble is due to foreing matter rot sealed. preventing normal operaton; otherwise replace the nozzle valve pair. Too high injection Incorrect injector calibration. Calibrate injector with the greatest care. pressure Valve seized inside spray nozzle, Replace nozzle-valve pair ‘Adjusting spring too strong Replace spring with a more suitable one. Fuelseepsfrom The upper air bleeder plug is not Tighten it. injector unions tightened Nozzle check nut not tightened. Tighten it. Abnormal jet Nozzle holes clogged by carbon deposits. Holes deformed due to wear. Clean nozzle holes with :he suitable tool and stee! wire of smaller diameter than holes. Then clean the whole nozzle, Replace nazzle-valve pai.Engine p. 20 ENGINE BLOCK - Block inspection Where necessary, carry out a block leakage test to en- sure that the casting is free from cracks. To test, plug all block apertures and apply water at 6 bar. Check block top surface for distortion; if necessary, dress using a grinder or by filing after checking by means of a surface plate to assess the amount of distor- tion, Engine block - Cylinder sleeve alignment Check abutment faces in contact with cylinder sleeves for misalignment relative to engine block top and dress, as necessary using cutter 394107 and handle 394102, bushing 394133 and taper 394134 (see fig. 2 . Check by measuring sleeve protrusion at two diame' cally opposed points 120 mm from centreline of cylin- dor under 700 kg load evenly distributed on top of slee- ve. The difference between the two readings should not ex- ceed .030 mm. Fig. 2 - Rogrinding sloove abutment. Cylinder sleeve inspection Exai the cylinder sleeve surfaces; there should be no sign of pick-up, scoring, ovality, taper or undue wear To check cylinder sleeve bore for ovality, taper and wear, use gauge A, 395687 (2, Fig, 3) fitted with dial gauge zeroed on ring gauge (1) A, 396147 (115 mm diameter). For each cylinder sleeve, the readings at three heights as shown in Fig. 4 are taken on two planes: namely| one parallel (a, Fig. 4 ) and the other at right angles (b) to longitudinal centieline of engine Maximum wear is generally found on (b) plane at the top, During overhaul, bore sleeves to obtain the working clearanct 8361 M sn, 0.153 10 0.189 between sleeves and oversize pistons, pin centreline, 30 mm. above base of piston skirt 8361 SM SRM. mm 0.173 t0 0.209 between sleeves and oversize pistons, pin centraline, 35 mm above base of piston skirt 1. Reference ring gauge 396147 - 2. Gauge 3946878361 \T | \) i risurazione } | 2 MisuRAZIONE I 3 MISURAZIONE | | g000 | nis022 | Engine p. 21 Fig. 2 - Checking sloeve bore diameter. 1. Reference ring gauge 396147 - 2. Gouge 394687 Fig, 4 - Slaove diameter check Misurazione = Measurement - Cylinder sleeve fit relative to engine block Main data on cylinder sleeve and engine block bore are given in fig. 6.. Sleeve outside diameter is to be measured at no more than 15 mm from shoulder. Fit ted clearance should be 0.030 to 0,110 mm, 8361 M.., 8961 SM SRM. mm 0.030 to 0.120 + Cylinder sleeve installation Before installing cylinder sleeves proceed as follows — Clean thoroughly sleeve and block surfaces with chiorothene to remove all old sealing compound. — Degrease surfaces to coated with sealing com- pound both on block and sleeves (see fig. 7.) — Trace a reference mark on block (cylinder head gasket end) and on relevant sieeve Check stand-out of sleeves above block; correct pro- trusion is .130 to . 160 mm, This amount of protrusion makes for efficient sealing through pressure as cylin- dor head is tightened. 8251 SM SRM Cylinder sleeve protrusion above block top’ 0.130 t0.0.160 mm. Fig. 5 - Cylinder slooves withdrawing. 1. Tool 360715 - 2. Cylinder sleeve. Fig. 6 - Sleeve and block bore detals8361 Engine p. 22 To check stand-out clamp the sleeve in question | through 360406/1/3 (1, fig.62) tightening the tool screw to 14 to 17 Nm, zero gauge 396017 (2, fig.62 ) on a surface plate and read amount of protrusion; to adjust, alter thickness of shim inserted between sleeve and engine block. NOTE - Cylinder sleeve shims are available in the fol- lowing thicknesses: 3.09-3.11-3.13-3.15-3.17-3.19- 3.21-3,23-3.25-3.27-3.29-3.31-3.33-3,35-8.37-3.39- 3.41-3.43-3.45-3.47-3.49 and 3.51 mm. — Withdraw sleeves and smear a thin layer of LOC- TITE HVX/PIPE type SEALANT, N° 576, avoid sag- gings due to excess of compound. — Install sleeves with relevant shims previously deter- mined when checking protrusion from block, posi- tion according to reference marks. Sealant curing take place within 24 h. NOTE - If crankshaft with pistons has to be revolved before sealant curing time has lapsed, cylinder sleeves should be secured to block by retainers 360712, Fig.8 - Checking sleeve stand-out from engine block top. 1. Tool 360406/1/3- 2. Too! 396017.8361 Engine p. 23 9 PISTONS AND RINGS seo | [4 ~ Piston | 3082) (2870) [4050 Check pistons for pickup, score marks or cracks and re- new without hesitation as necessary. Prior to fitting the pistons, check that they are of the sa- me weight, maximum allowance being + 15 grams. Check pistons for wea and ovality using @ micrometer gauge; piston wear is to be added to that of cylinder sleeves to determine existing clearance. Pistons and rings are available with .6 mm oversize out- side diameter. sagia# 1148271 Piston grade details (8961 M) ~ Piston ring clearance inspection Chack as shawn, placing the ring in its seat on piston and inserting feeler gauge 395113 (fig. 10 ). If piston ring side clearance is found to exceed the spe- cified value, renew the ring in question without hesita- tion, ‘and ring data 8361 SM SRM 8351 SM SAM Piston ring clearance should be as follows: = Top chromed compression Fig. 9 = Piston, ‘ ring (082 to 082 mm . = Second compression ring (060 t0 .092 mm ne, Oil scraper ring (040 10.072 mm | Ring clearance date (8361M engine) —Top compression ring, chromium plated 0.090 to 0.122 mm — 2nd compression ring 0.050 to 0.082 mm — Oil scraper ring 0,040 to 0.072 mm If the clearance is higher than the maximum permitted, | check ring thickness with micrometer (2, fig. 11} to | establish whether wear has affected ring or groove and renew either or both as necessary. 10 Fig. 10. - Checking ring clasrance using a fooler gauge.8361 Engine p. 24 Fig. 11 ~ Checking Hag thicknass 1. Compression ring - 2. Micrometer. - Piston ring gap inspection For this check introduce the ring in the cylinder sleeve and use feeler gauge 395113, If piston ring gap is found to be lower than prescribed, dress as shown using file 360188 (fig. 12 ); if the gap is wider than prescribed renew the rings without hesita- | tion. Piston ring gap should be as follows: = Top chromed compressionrng 40 to 65 mm. = Second compression ring 40 to 60 mm = Oil scraper ring... 30 to .45 mm Fig. 12. ~ Drossing piston ring ands on dresser 360188, - Piston Pin Clearance Check ‘The piston pin is fitted to the piston with a slight clea- rance. In case of excessive clearance, pin or piston bore ovalty or deep scoring, renew the gudgeon pin and/or the pi- ston without hesitation, Disassemble and install piston pin as indicated in fig, 13 using driver 360182 Fig. 19 -8361 | be carried out as indicated in fig. 15, using driver Engine p. 25 - Piston ring assembly Ensure that the pin retaining rings are free from damage (or weakness. If found to be inefficient, they should be renewed without hesitation. Top compression ring must be fitted with its inner chamfer and wording “TOP” uppermost. Secondo compression ring may be fitted either way. il scraper ring must be positioned with the spring par- ting line at 180° to the split. Assembly is carried out as indicated in fig. 14 using pliers 360184, Fig.14 nstaling piston rings using pliers 260184, CONNECTING RODS AND BUSHINGS - Bushing inspection and assembly ‘Small end bushing is press fitted, interference fit being 098 to .174 mm. Check for bushing looseness in small end, Check bushing bore for pick-up and score marks and re- new as necessary; slight scratches may be remedied by | reaming. Removal and installation of small end bushing should 360277, On assembly, check that bushing hole is lined up with, lubricant port drilled in connecting rod body. Fig, 15_~ installing small ond busin 1. Bushins - 2, Driver 360277 - Connecting rod inspection Check each connecting rod for distortion as shown in fig. 6 ; check for connecting rod axis misalignment, ma- ximum allowance being .050 mm. Slight distortion may be remedied by straightening at the press: if distortion is found to be considerable, re- ‘new the connecting rod in question without hesitation. 19.16 = Checking connecting rod axis misalignment.8361 Engine p. 26 iB s ZZ. Z) Tr 0T <6 17 - Connecting rod assembly Each connecting rod is marked on the body and cap by ‘a number correspo they belong. Accordingly, when a conne: newed, the replacement rod must be stamped with the Jsame number as that of the discarded rod. Connecting rod assembly must be carried out as indica- ted in the illustration, noting the following points: — Number of each connecting rod (1, fig. 18 ) must cor- respond to the number of the associated cylinder. — Numbers stamped on connecting rods must face to- wards side opposite camshaft (2). Fin. 17 - Connecting rod bia and bering, bushing end piston pin ‘detaile, * With bushings and piston pin datas, Fig. 18 - Piston - connecting rod assembly installation diagram. 1. Connecting rod reference number - 2. Camshet8361 Engine p.27 = Ring gaps should be spaced 120° apart from one, another. To facilitate installation use compressor 360603 (1. fig. 19). Check piston T.D.C. position relative to engine block top: the correct position is from .164 mm above to .298 mm below block top. Check as shown, Fig. 19 - Installing pistons 1. Piston ring compressor 360603, Fig. 20 - Checking piston T.0-C. postion 1. Dial gauge - 2. Magnatic base8361 CRANKSHAFT ~ Main journal and crankpin dressing If journals are found to be affected by pick-up or score marks, take a measurement using a micrometer gauge ‘and establish at what diameter the juornals in question must be ground, on the basis of the available undersize range and taking into account running clearances which must be as follows: 8361 SM SRM: — Main journals .050 to .106 mm. — Crankpins 058 to .111 mm. 8361 M Crankshaft journal clearances are as follows Main journals (0,050 t0 0.111 mm. — Crankpins 0,058 10 0.116 mm. In the course of grinding, pay the utmost attention and care to restore the correct size of fillet radii as shown. Moreover, it is recommended that on completion of grinding, the lubrication ports should be suitably cham- red ‘After grinding and prior to shaft installation, check the bearing running clearance as indicated in the illustra- tion, adopting the calibrated wire procedure. Engine pp. 28 = Crankshaft journal alignment check After regrinding, place crankshaft over V-blocks and check journal misalignment using a suitable dial gauge (see fig. 24 } — The centreline of each pari of crankpins should lie ont he same plane as main journal centreline to wit- hing +.25 mm (see fig. 24 ). = Main journal misalignment (A) should not exceed 10 mm TIR. — Crankshaft flange runout (8) on periphery should not exceed .025 mm. as fo 22 | if erankpin filet radi deta 21 1 Fig. 23 - Crankaheft journal misalignment detail. Posizione limite Postione normale = Normal postion Perna di biella ~ Crankpins Perni di banco = Main journal Max. position | _ PERWO 1 BANCO! ie 238361 Engine p. 29 | - Crankshaft Bearings and 24 Running Clearance Check | Check the bearings’ invernal surfaces: scratches can be removed using a suitable bumishor. Ronow if heavily scored oF excessively worn, cq |_| If the bearings are in good condition, check clearance between them and the crankshaft-journals using a length of plastigage calbrated wire. Check the journal running clearance using 2 lengths of calibrated wire (fig. 25) in the following way: Throughly clean the engine block in the neigh- bourhood of the bearings to be checked to remove | all traces of oi | |— Lower cranshaft into position = Position a length of calibrated wire ont he crankshaft journals parallel to cranshaft longitudinal centreline. = Position main bearing or can rod caps, with attached | bearing halves over the bearing housings ~ Fit capscrews wet and torque using a torque wrench I Fig.24 - Diagram for journal Romove caps from searing housings; or can rods the calibrated wire will adhere to bearings or main jour- nals. Assos the amount of existing clearance by compa- ring the width of the calibrated wire at the point of maximum deformacion to the scale printed on wire container (see fig. 2 }. The figures given ont he con- tainer indicate the amount of clearance in mm, | Fg. 26 - Checking canpine clorance using eatbated wie. 1. Connecting rod ap - 2. Main journal - 3. Calibrated wie - End float adjustment Use a magnetic base dial gauge as shown and prize en- idwise. The correct end float is .068 to .270 mm. To ad- just, alter thrust washer thickness as necessary. Endwise shaft movement arrowed, Position thrust washers with grooved white metal lined side facing towards the crankshaft shoulder Fig. 26 - Checking crankshaft and fk8361 Engine p. 30 Fig. 29 - Disessombiing vaive guides. 1. Driver 360409/1 CYLINDER HEAD |The cylinder assembly is equipped with a cast iron head on juhich are fitted by interference the exhaust valve seat, whereas] the seat of the intake valve are bored directly into the head, HThe intake and exhaust valves are actuated by a cancentric, Jrariable flexibility spring, and are centered by the cups and tached to the stem with cotter [The valve guides are driven into the head and require an inter: ference fir between them and the soats. If the fit is not tight, the guides must be replaced either with regular ones or with thers having an oversized (0,04 -0,2 -0.4 mm) outer diameter] - Cylinder head face inspection To check for cylinder head face distortion smear a surfo- ce plate with a light coat of carbon black and apply to head face. If necesséry, skim using a surface grinder re- moving as little material as possible. Fig. 27 - Cylinder hea. Fig. 28 - Diasasembling cylinder head. 1. Compressor 360357. - Valve removal and installation Place cylinder head on bench and apply pressure to top spring cap using compressor 360357, as shown in Fig, 28 so as to remove the split cones and release the val- ves; withdraw top and bottom spring cups. Repeat the above sequence on the remaining valves. Overturn cylinder head and withdraw valves. For assembly, reverse the disassembly sequence. - Leakage test In the course of overhault, check that the water jackets in cylinder head are free from cracks. ‘To do this apply tool 360438 {to be used with tool 305048) and admit water at 4 to 5 bar. Under this pressure, the cylinder head should be free from leakage. Renew as necessary. - Valve inspection ‘After removing the valves from the cylinder head, check both stem and valve face for distortion and signs of pick-up or score marks and renew as necessary.8361 Engine p. 31 - Valve guide removal and installation Valve guides are press fitted in the cylinder head Valve guides should always be tight in their housings. For intake and exhaust valve guide removal, proceed as indicated in Fig. 29, using driver 360409 /1. VALVE AND GUIDE DETAILS Valve quide Valve stem Working bore diameter diameter clearance mm mm mm. 7.987 108.012 | 7.945107.960 | .027 10.067 For intake valve guide installation proceed as indicated in Fig. 30, using driver 360409 /3, fitted to installer 360409/1 VALVE GUIDE FIT DATA Valve guide Valve guide Interference housing bore outside \eeaany diameter diameter mm, mm mm 1 3.995 to 14.018|14.028 to 14.039 | .010 0.044 For exhaust valve guide installation, proceed as indica~ ted in Fig, 31 using driver 360283, fitted to installer 360409/1 Fig. 20 = Artombling i 1. Diver 360409/3 - 2 valve guido Fig. 31 - Assembling exhaust valve guides. 4, Driver 360283 - 2. Handle 360409/1, - Valve seat dressing Valve seat and face dressing becomes necessary when valve sealing is inefficient. For valve seat dressing proceed as indicated in Fig. 92 , 19 dresser 360419. - Valve spring inspection Valve-springs should be tested for cracks or weakness; check spring rate using tester 305049 as indicated in Fig. 33 If spring rate is not as specified, renew springs without hesitation, Fig. 32 - Re-grnding valve seats using Universl grinder 360419,8361 Engine p.32 ing springs using toot 305049. injector sleeves If compression loss through fLel injector sleeves is de- tected, renew leaking sleeves without hesitation. To remove tap sleeve with se: of taps 390424 /1 and withdraw as shown in the illustration (fig. 24), using puller 342137 install a new sleeve with sealing rings and burnish using burnisher 365059, Dress injector seat as indicated in Fig. 35, using cutter 394013 /8 and handle with pilot 3904013 /12. Fig. 34 - Disassembling injector el 1, Puller 242137 Fig. 95 - Dressing injector slooves. 1. Pilot 394013. 12,8361 g Q Q © Q Q Engine p. 33 - Cylinder head assembly To assemble cylinder head proceed as follows — Position head gasket on engine block top with “AL- TO" mark facing upward. — Hoist cylinder head and lower on engine block. — Fit hold-down nuts in the order shown and tighten in three stages as follows: = Stage 1-0 88 Nm = Stage2- 90° = Stage 3- 90° Fig. 96 - Cylinder he tightening diagra8361 37 lame zeeee|s 38 48,950 48,975 Engine p.34 VALVE GEAR - Camshaft Crankcase-mounted camshaft runs on 7 bearings and is ‘gear driven from crankshaft, Camshaft gear is shrunk after heating in oven until a temperature differential of 240° C relative to shaft is, obtained - Camshaft journal and lobe inspection Camshaft journals should be perfectly smooth; if signs of pick-up or score marks are detected, the shaft should be renewed without any hesitation. Light scratches may be remedied by means of O- jgradeemery clotch, 37 - Camshaft drive goar and housing details, Fig. 38 - Comahatt dati, - Camshaft bushing inspection Bushings should be tight in their housings; if found to be loose, the bushings should be renewed without hesi- tation Check bushing bore: the surface should be perfectly ‘smooth and free from pick-up or scoring: renew as ne~ cossary. If light scratch marks are detected, dress the bushings with a suitable burnisher. For bushing removal or assembly, use driver 360380 (and grip. 370008) as shown (fig. 39 ) Following assembly, bushings should be reamed to 49.055 to 49.090 mm dia. using handle 380352 with 390365 and centralizers 390364. Fig, 39 - Camshaft bushing replacement8361 Engine p.35 - Tappet inspection Tappets are accessible upon removal of eylinder head ‘and may be withdrawn from engine block using remo- ver 360404 as shown (fig. 40). Tappet surface in contact with camshaft lobe should be smooth and free from dents. Light imperfections may be remedied by means of a ve~ ry fine abrasive stone. Fig. 40 - Tappet remove 1. Remover 360404 Normal tappet working clearance in engine block is, 040 to .094 mm. If excessive clearance is detected, replace the tapprts (1, fig. 41 ) with oversize equivalents after opening out the housings (2) in the engine block 20 - .40 - .50 mm oversize tappets are available, Fig, 41 = Dataited section through engine. 1. Tappets - 2. Housings in engine block - Pushrod inspection Pusnrods (1, fig. 42) should not be distorted and the sp- herical seat in contact with rocker (2) should be free from any pick-up or roughness whatever; if defective, renew without hesitation, Fig, 42 - Detailed section through ongine. 1, Pushiod - 2. Rocker.8361 PMS. sano e cD aor 8361 M PML. Engine p. 36 - Bracket, rocker and rocker shaft inspection Check shaft surface (2, Fig. 43) and rocker bore (1) for pick-up or score marks and renew as necessary. Light scratches may be remedied by means of an extra fine grade abrasive stone. ‘Check rocker shaft clearance in rocker; the correct clea- ance should be .014 to .065 mm. Shaft clearance in bracket (3) should be .004 to .046 mm; if excessive clearance is detected, renew the affected parts without hesitation Fig. 43 - Rocker 1. Rocker - 2, Shah - 3. Bracket - Valve timing For valve timing proceed as follows: — Adjust valve clearance to .40 mm. — Apply a graduated sector with 0 facing downward at rear of engine. — Turn camshaft until intake and exhaust valves of oy- linder No. 1 are fully closed, which is equivalent to| compression stroke. Such condition may also be ob-| tained by bringing the valves of the symmetrical cy- linder in a condition of balance. — Install all valve timing gears as indicated in Fig. 44 ensuring that the reference marks stamped on the| gears are in register. — Slowly turn the crankshaft and check on the gradua-| ted sector that valve opening and closing occurs as| specified in the timing diagram shown (see fig. 45) — Adjust valve clearance to the normal value, cold, on) all cylinders. 8361 SM SRM i8361 46 Engine p. 37 ~ Valve clearance adjustment Valve clearance adjustment should be carried out with the utmost attention in order not to alter the timing, Indeed, excessive clearance causes noise or retards val ve opening and advances valve closing, whereas insuffi- cient clearance has a reverse effect. If no clearance exists, the valves remain constantly just ‘open, which results in premature valve and seat deterio- ration. To adjust valve clearance proceed as follows: = Slowly turn crankshaft until the cylinder of the valves | to be adjusted is on firing stroke. The valves of this cylinder are closed when those of the symmetrical cylinder are in a condition of balance. Hold adjusting screw stationary with 2 suitable screwdriver (or using tool 352137) and slacken re- taining nut using a suitable wrench; insert feeler ‘gauge 395113 (1, fig. 46 ) between rocker and valve and actuate screwdriver to turn adjusting screw until feeler gauge blade binds slightly. At this point hold adjusting screw stationary and tighten nut. Cold vaive clearance should be .30 mm intake, and .50| mm exhaust. After valve clearance adjustment on one cylinder, re-| peat the same procedure ont he remaining cylinders. nce adjustment. 1. Feoler gauge 395113,8361 Engine p.38 | | | | LUBRICATION SYSTEM Lubrication system includes a gear type oll pump in bot- tom of engine block (1, fig. 47 } attached to front main bearing housing and driven through a crankshaft- mounted gear. The pump incorporates two lines for suction (2) and de- livery (3) to cartridge filter. Oil pressure relief valve is situated on cartridge filter support. If oil pressure exceeds rated setting, relief valve is activated to return part of the oil to the sump until normal pressure is restored, Fig. 47 ~ Engine without off sump. 1. Git pump - 2. Oi! pump suction piping - 3. Oi! pump delivery pi- ping = 4: Cantidge fier support Fig. 48 - Ol pump. 1. Front main bearing - 2. Oil pump - 3. Drive gear8361 Engine p.39 50 Fig, 50 - Section through water pump. 1. Bearing - 2. Retainer serew 3. Pump body -4. Cover - 5. Impel- Ter" 6: Seal - 7. Hub, - Water pump Water pump is of the centrifugal vane type, To install water pump proceed as follows: — Fit bearirg (1, fig. 50) to pump body (31, acting only fon outer race, and lock in position by means of cap- serew (2| which will subsequently have to be staked (on pump body. — Air heat hub (7) until a 130° to 150° C differential is established between hub and shaft — Shrink hub on shaft placing an adequate support on ‘opposite end in order not to damage the balls. Fit seal (6) on water pump body. — Air heat impeller assembly (5) until a 90° to 110° C temperature differential between impeller and shaft is obtained and couple the parts applying a suitable ‘support on the opposite end to avoid damaging balls, Check that impeller depth relative to cover (4) is .7 to 1mm, On completion of assembly, check impeller and hub ro- tating torque; the correct rotating torque is 1.5 kgm. Fi- nally, check Seal for leakage at 1.15 to 1.25 bar. - Water pump and alternator drive belt Check and if necessary adjust belt tension noting that belt yield is 10 to 15 mm under 12 kg approximately. To increase belt tension proceed as follows: — Back off nut (1, fig. 62) on alternator pivot pin. — Back off retaining nut (2). — Move aternator outward and fully tighten pivot nut and retaining nut Fig. $2 - Regulating fan, water pump and alternator drive belt te 1. Pivot nut = 2, Lock nut8361 Engine p.40 TORQUE LOADS mua eaeagaaaca] waanagsi@ [owraceim | acne ie, | tmeaen,] acd ome Psion | “Sah i! |'"S hatte | rots al roars eSta| neste 9 [npn = a te te te ter te te taewrsoe | ana | aes 7 oor | ae | mere | omer evar | en oss | ates rn cova | ser er neni —[avareae [aan ase | aes rm ‘one | sere er8361 Engine p.41 SERVICE TOOLS CODE FOR MANUAL CORRESPONDENT CODE FOR ORDER <340006/301 99341009 Legs, puller, ctanksha-mounted oll pump drive geat and camshaft gear (use with 99341000/001/015 and 99345052) 340046 99340046, Remover, postioning pin 340046/11 99340050 Pair of exchange connectors for 99340036 340206/801 99340205 Puller, slide hammer, water pump impeller 342197 99342145, Remover, injector sleeve 345050, 99345050 Steady 345052 99345052 Palle, erankshatt pulley hub 347093 99347093 Remover, steering pump and compressor cover bushing 950135 99350135 Remover, cartridge filter 362137 99352137 Wrench, valve clearance adjustment 357051 99357051 Wrench, engine block oil port sore plug 60182 gag6o1e2 Remover/teplacer, engine piston 360184 goseotes Pliers, engine piston ting 360185 9aa6o18s Pliers, compressor piston rings 360277 99360277 Remover/replacer, small end bushing 360283, 99360283 Installer, exhaust valve guide use with 99360288) 360304 99360004 Handle, tywheel rotator (use with 99860307) 360307 99360307 Rotator, thywheel (use with 96360304) 360357 99360357 Removerireplacer, engine vave 360380 99360380, Remover/replager,camshatt bushing (use with 99370008) 360404 99360404 Remover, engine tappet 360406/1 99360488 Preloader, cylinder sleeve (use with 99360490) 360406/3 99360490 Fitting, cylinder sleeve compression for 99360488 and 9939607 360409/1 99360288 Handle , intake and exaust valve guide (use with specific rivers) 360409/3 99360492 Installer, intake valve gui (usewith 99360288) 360419 99360419 Dresser, universal, HUNGER , valve seat 360435 99360435, Connection, engine cylindercompression tester (use with 99395682) 360437 90360437 Steady, tywheel8361 Engine p. 42 CODE FOR MANUAL, 360438 360500 360802 380503 360603 360712 361002/25 365059 370005 370006 370008 370136 370362 370421 374178/1 374178/11 374195 390352 390364 390365 390424/1 394013/8 sa4o1g/12 394102 394107 304116 CORRESPONDENT CODE FOR ORDER 99360438 ‘99360500 99360502 99360503 99360603 99360712 99361020 99365059 99370005 99370006 99370008 99370136 99370362 99370421 99374511 99374521 99374195 99390352 99390364 99390365 99390789 99394031 99394150 99394102 99394107 99394116 Plate, cylinder head leakage test (use with 99305048 Sling, crankshaft Eyes, lit, cylinder head Eyes, l,engine block Compressor, piston ring Retainer, cylinder sleeve Brackets, engine (use with revolving stand 99322220) Burnisher, injoctor sleeve Handle, interchangeable,driver Handle, interchangeable,driver Handle, interchangeable,criver Installer, valve timing gear to orankshaft and oil pump drive gear Installer, front crankshatt seal (use with 98360006) Installer, camshalt gear Handle Remover replacer jection pump support bushing, Remover replacer, steering pump and compressor cover bushing. Remover replacer, valve timing intermediate gear bushing, (Use with 99374511) Installer, rear crankshaft seal ( use with 99370005) Handle, camshatt bushing Centralizers, camshaft bushing (use with 99390352 and 99390365) Cutter, camshaft bushing (use with 99390352 and 99390634) Taps, injector sleeve Reamer, injector sleeve Handle/pilot, injector seat in sleeve (use with 99394031) Handle, cylinder sleeve housing cutter Cutter, cylinder sleeve housing (use with 99394102, 19939433 and 99394134) Reamer engine valve guide8361 Engine pp. 43 CODE FOR MANUAL 304133 394134 395113 396017 | 396147 360715 CORRESPONDENT CODE FOR ORDER, 99394133 99394134 99395113 99396017 99396147 99360715 Bushing (use with 99394134 and 99394107) Tapert (use with 99394102 and 99394107) Adjuster, valve rocker Gauge cylinder sleeve height Gauge, ring zeroing, cylinder sleeve (use with 99395687) Tool, cylinder sleeve removal.