Volvo Penta 2001 Instruction manual

ProCarManuals.com

FOREWORD
Thi s
wor kshop manual cont ai ns r epai r
i nst r uct i ons f or t he 2001, 2002 and 2003 engi nes .
The i nst r uct i ons
concer ni ng over haul i ng descr i be t he most sui t abl e
wor ki ng met hod usi ng t he speci al t ool s l i st ed under
t he headi ng
" Speci al t ool s" .
Bot h t he engi ne
desi gnat i on and i t s ser i al number must be cl ear l y st at ed i n al l cor r espondence
concer ni ng t he engi ne and
when or der i ng
par t s .
We
r eser ve t he r i ght
t o car r y out desi gn modi f i cat i ons and, f or t hi s r eason, t he cont ent s of t hi s manual cannot be r egar ded as
bi ndi ng .
SI
UNI T SYSTEM
Power i s
gi ven i n kW ( ki l owat t )

Speed i s gi ven
i n r ev/ s ( r evol ut i ons per second)
ear l i er uni t hp ( hor se- power )

ear l i er uni t r ev/ mi n ( r evol ut i ons per mi nut e)
Tor que i s gi ven i n Nm ( newt on
met r e)

Vol ume
i s gi ven i n dm 3 ( cubi c deci met r e)
ear l i er uni t
kpm ( ki l opond met r e)

ear l i er uni t
l
( l i t r e)
ear l i er uni t
l bf f t ( poundf oot )  ear l i er uni t I mp . gal ( I mper i al gal l on)
ear l i er uni t US gal ( Uni t ed St at es
gal l on)
Pr essur e i s gi ven i n Pa
( Pascal )
ear l i er uni t kp/ cm
2 ( ki l oponds per squar e
cent i met r e)
ear l i er uni t I bf / i n 2 ( pounds per
squar e i nch)
AB VOLVO PENTA
Techni cal Publ i cat i ons
Depar t ment
Uni t s accor di ng t o t he
i nt er nat i onal SI syst em have been used i n t hi s
book . The ear l i er uni t s ar e gi ven af t er t he SI
uni t s
.
ProCarManuals.com

Component s gui de . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
DI SASSEMBLY
Cyl i nder head . . . . . . . . . .
.
. . .
. . . . . . . . . . . . . . . . . . . . . . . . . 3
Tr ansmi ssi on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Pi st on, pi st on r ods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fl ywheel . . . . . . . .
... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cr ankshaf t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Camshaf t . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . .
. .
. . . . . . . . . . .
5
OVERHAUL
Di sassembl i ng t he cyl i nder head . . . . . . . . . . . . . . . . . . . . .
7
Val ve gui des . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Val ve seat s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Val ves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... .
.. . . . . . . 7
Val ve spr i ngs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Rocker ar m mechani sm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
I nj ect or sl eeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
I nj ect or s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Assembl i ng t he cyl i nder head . . . . . . . . . . . . . . . . . . . . . . . . 9
Feed- pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pi st ons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Cr ankshaf t . . ... .
. .
.
. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
Camshaf t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Connect i ng r ods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Ther most at . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Sea- wat er pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ASSEMBLY
I NDEX
Cr ankshaf t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pi st ons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Fl ywheel . . . . . . . . . . . . . . . . . . . . . . . . : . . . . . . . . . . . . . . . . . .
15
Tr ansmi ssi on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Adj ust i ng t he val ve cl ear ance . . . . . . . . . . . . . . . . . . . . . . . 17
Checki ng t he i nj ect i on angl e . . . . . . . . . . . . . . . . . . . . . . . . 17
2003 Tur bo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . 21
Fr esh wat er cool i ng . . . . . . . . . . . . . . . . . . . ............. 25
El ect r i cal syst em ................................... 26
Faul t t r aci ng scheme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Speci al t ool s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29
Techni cal Dat a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
ProCarManuals.com

COMPONENTS GUI DE
8
1 .

Exhaust el bow
2 . I nj ect or s
3 . Temper at ur e
sender
4 .

El ect r i cal di st r i but i on
box
5 .

Fuel f i l t er
6 . Al t er nat or
7 .

St ar t er
mot or
8 .

Dr ai nage,
cool i ng wat er
9 . Feed- pump
10 .

Engi ne ser i al number
11 .

Decompr essi on devi ce
12 .

I nl et
ai r
si l encer
13 .

Fuel
i nj ect i on pumps
14 . Oi l di pst i ck
15 .

Sea- wat er pump
[email protected]
ProCarManuals.com

Dr ai n of f t he cool i ng wat er
and t he l ubr i cat i ng oi l f r om t he
on engi ne cr adl e p/ n 9992520 and f i xt ur e p/ n 884837
. I f t he
engi ne i s f r esh wat er cool ed, see
page 21 .
1 . Remove t he al t er nat or , t he t ensi oner br acket and t he
st ar t er mot or . Remove t he connect i ons
f r om t he
el ect r i cal
di st r i but i on box f r om t he engi ne and r emove t he box and
t he
wi r e
har ness .
2 .
Remove
t he r et ur n
f uel l i ne, t he f uel pr essur e l i nes and
t he i nl et ai r si l encer . I nst al l pr ot ect i on caps on t he f uel
i nj ect i on pumps and i nj ect or s
. Remove t he scr ew hol di ng
t he l ever of t he decompr essi on devi ce
( 1)
and pul l out t he
l ever . Remove t he
val ve cover .
DI SASSEMBLY
3 . Remove t he f uel f i l t er , t he oi l f i l t er , t he f eed- pump, t he
t her most at
housi ng and t he exhaust el bow . Al so r emove
t he sea- wat er pump wi t h i t s at t achment t ubes .
4 . Remove t he val ve br i dge
and l i f t out t he push r ods .
Remove t he r ubber r i ngs f or t heoi l pi pe . Remove t he
cyl i nder
head and t he
val ve l i f t er s . Put t he l i f t er s on a r ack i n
consecut i ve or der , NOTE!Thecyl i nder head bol t sar e phosphat i sed andmustnot becl eanedwi t ha st eel br ush.
ProCarManuals.com

5 . Remove t he f uel i nj ect i on pumps . Mar k t he pumps t o
ensur e i nst al l at i on i n t he same cyl i nder s f r omwhi ch t hey
wer e r emoved . Take car e of t he shi ms . Remove t he scr ews
on t he si de of t he engi ne bl ock and l i f t out t he pump
l i f t er s .
6. Remove t he pul l ey cent er bol t and pul l of f t he pul l ey
usi ng pul l er
p/ n
9992265 . Pl ace
a pr ot ect i on pad bet ween
t he pul l er and t he cr ankshaf t t o avoi d t he cr ankshaf t bei ng
damaged .
7 . Remove t he t r ansmi ssi on cover : St ar t by r emovi ng t he
t hr ot t l e
cont r ol cover . Use a sui t abl e t ype of pl i er s t o
r emove t he spr i ng ( 1) . Then r emove t he end- ni ppl e ( 2) and
t he spr i ng ( 3) . Remove t he oi l pump cover and mar k t he
gear wheel s wi t h a col our - pen bef or e
r emovi ng t hem .
( When i nst al l i ng t he gear wheel s, t he mar ked si de must be
f aci ng out war ds) . Remove t he br aci ng pi n of t he camshaf t
usi ng t he speci al t ool
p/ n
884839 . Never r emove t he
br aci ng pi n by punchi ng i t out , t hi s can ver y wel l bend t he
camshaf t . Remove t he scr ews on t he t r ansmi ssi on cover
and pul l i t st r ai ght out war ds .
8 . The max . - vol ume- scr ew
( 1) and t he max . - r ev- scr ew ( 2)
ar e set by
Vol vo Pent a and must never be
changed si nce
t hi s
wi l l
af f ect t he engi ne out put
.
9 . Remove t he cont r ol r od . St ar t by r emovi ng t he pl ug at
t he r ear of t he bl ock and t het wo scr ews on t he pump pl ane,
hol di ng t he cont r ol r od .
ProCarManuals.com

10 . Pul l out t he camshaf t
.
11 .
Remove
t he
out er f l ywheel housi ng, t he f l ywheel and
t he i nner f l ywheel housi ng .
12 . Tur n t he engi ne upsi de down and r emove t he
oi l pan .
Be
car ef ul as t he pan i s gl ued .
NOTE! The oi l pan ends al so
f unct i on as mai n
bear i ngs .
13 . Remove t he connect i ng r od bol t s and r emove t he
connect i ng r ods and t he pi st ons .
The connect i ng r od and t he
connect i ng r od cap ar e mar ked wi t h f i gur es .
ProCarManuals.com

14 . Remove
t he mai n bear i ng caps . The mai n
bear i ng caps
ar e mar ked wi t h a f i gur e . The cor r espondi ng
f i gur e i s
punched i nt o t he bl ock . Li f t out t he
cr ankshaf t . On l at er engi ne
ver si ons an
ar r ow i s cast i n t he separ at e mai n
bear i ng caps
( 2002, 2003)
.
The ar r ow i s t o
poi nt t owar ds t he di pst i ck .
ProCarManuals.com

THE CYLI NDER
HEAD
1 . Remove t he
" col l et s" and val ve spr i ngs
usi ng
a val ve
bow . Remove t he val ves . Remove
t
he val ve st em seal s .
Pl ace t he val ves i n t he
pr oper sequence i n a val ve
st and .
Val ve
gui des
2 . Check t he val ve gui de wear by i nser t i ng anew val ve st em
i nt o t he gui de . Measur e t he pl ay
usi ng
a di al i ndi cat or
.
I f
necessar y, r epl ace t he val ve gui des .
Wear l i mi t s :
I nl et
val ve, max pl ay . . . . ....... . ... 0 . 15
mm ( 0 . 0059
i n)
Exhaust val ve, max pl ay ............ 0 . 15 mm ( 0 . 0059 i n)
3 . Use
mandr el p/ n 5218 t o pr ess out t he val ve gui des
.
Oi l
t he new val ve gui des ext er nal l y and use mandr el p/ n
884559 t o
i nst al l
t hem
.
Pr ess down t he mandr el al l t he way
down t o t he cyl i nder head . Ream t he val ve gui des i f
necessar y
.
Val ve
seat s and val ves
4 . Mi l l or r eam t he val ve seat s . The angl e
( C)
shoul d be 45°
( f or
2003T, 30° f or t he i nl et val ve) . The
seal i ng sur f ace' s wi dt h
( B) shoul d be 1 ±0 . 1 mm ( 0 . 039±0 . 0039 i n) . Gr i nd t he val ves
i n
a val ve gr i ndi ng
machi ne
.
The angl e ( D) ,
see
Tech . dat a . I f
t he
di sc t hi ckness af t er gr i ndi ng i s l ess
t han 1. 0 mm ( 0 . 039 i n)
f or nat ur al l y aspi r at ed engi nes or 0 . 8 mm
( 0. 031
i n) f or
t ur bochar ged engi nes, t he val ves must be scr apped . Val ves
wi t h
bent st ems, or i f t he measur ement ( A) exceeds 2 . 5 mm ( 0 . 098
i n)
must al so be scr apped . Gr i nd t he
val ve t i p
t owar ds t he
r ocker s i f necessar y . Lap i n t he val ves usi ng val ve gr i ndi ng
past e and check t he cont act ar ea wi t h mar ki ng dye .
ProCarManuals.com

Repl aci ng t he val ve seat exhaust por t 2003T
Gr i nd down t he val ve di sc of a di scar ded val ve t o j ust bel ow
27 mm ( 1 . 063
i n)
di amet er
. Push t he val ve st em t hr ough t he
gui de . NOTE! Do not push i n t oo f ar - t he val ve di sc shoul d be
j ust bel ow t he edge of t he seat . Spot
wel d t he di sc i n pl ace at
t hr ee poi nt s usi ng a el ect r i c wel der . Knockout t he seat by
hi t t i ng t he val ve gui de
wi t h a pl ast i c- headed hammer .
Cool t he
new
seat t o
appr ox . - 20°C ( - 4°F) ; t he cyl i nder
head shoul d beat r oom t emper at ur e ( + 20°0168°F)
.
Pl ace t he
cool ed seat on t ool
884961- 4 and knock i t down unt i l i t
bot t oms. NOTE! Tur n t he seat wi t h t he val ve f ace
t owar ds
t he
t ool
.
Val ve spr i ngs
5 . Checkt he f r ee l engt h of
t he val ve spr i ngs and t he l engt h
when l oaded .
L = Lengt h, unl oaded
42, 5 mm ( 1 . 67323 i n . )
L 1 = Lengt h, l oaded wi t h 170±10 N ( 17±1 kp) 32
mm
( 1 . 25984
i n . )
L 2 = Lengt h, l oaded wi t h 300±20 N ( 30±3 kp) 24
mm
( 0 . 94488 i n . )
Rocker ar m mechani sm
6 .
Di sassembl e t he r ocker ar m mechani sm and cl ean t he
par t s . Check t he wear of t he shaf t and r ocker ar m bush i ngs .
Shoul d t he bushi ngs need t o be r epl aced, uset he mandr el
p/ n
9991867 f or t he r emoval and i nst al l at i on, ( make
sur e
t hat t he oi l hol e i n t he bushi ng coi nci des wi t h t he one i n t he
r ocker ar m) .
Af t er t he
i nst al l at i on t he bushi ngs
ar e r eamed
t o a cl ose r unni ng f i t . When i nst al l i ng t he r ocker ar m shaf t ,
i t must be t ur ned so t hat t he l ubr i cat i on hol es ar e f aci ng t he
val ve- si de
. Check t o make sur e t hat t he r ocker ar m cont act
sur f ace agai nst t he val ve i s concave . Mi nor adj ust ment s ar e
made i n
a
val ve gr i ndi ng
machi ne . Oi l t he shaf t and i nst al l
t he par t s .
Pr essur e t est i ng t he nozzl es
7 . Check t he nozzl e' s spr ay pat t er n at t he cor r ect openi ng
pr essur e ( see Techni cal Dat a) .
Check al so t hat t he f uel spr ays
st op
si mul t aneousl y and no dr i ppi ng occur s .
Adj ust t he openi ng- pr essur e
wi t h adj ust ment - washer s ( 1)
bei ng avai l abl e
i n di f f er ent t hi cknesses f r om 1 mm U3937
i n . ) t o 1, 95 mm ( . 076772 i n . ) i n st eps
of 0, 05 mm ( . 001969
i n . ) . Di sassembl e
t he i nj ect or and r epl ace t he adj ust ment - washer
agai nstat hi nneroneorat hi ckeronedependi ngon
whet her
t he pr essur e must be r educed or i ncr eased .
Assembl e
t he i nj ect or and check t he openi ng- pr essur e and
t he spr ay- pat t er n .
ProCarManuals.com

I nj ect or - sl eeve
8 . I nser t t he expandi ng scr ew on t he speci al t ool p/ n
884811 i nt o t he copper sl eeve and t ur n t he scr ew
ant i - cl ockwi se unt i l t he scr ew has st uck i n t he sl eeve. Ti ght en
t he scr ew har d t o al l ow t he t hr eads t o wor k t hemsel ves
i nt o t he copper mat er i al . Then i nst al l t he yoke
( 1)
on t he
st ud bol t of t he i nj ect or . Put
a
cyl i nder
head scr ew
i n
t he
cyl i nder head as a suppor t f or t he l eg of t he yoke . I nst al l t he
nut ( 2) and t i ght en
i t
unt i l t he sl eeve i s r emoved .
9 . Repl ace t he O- r i ng, seal i ng of f bet ween t he sl eeve and
t he cyl i nder head . Di p t he new O- r i ng i n
soap- wat er i n
or der
t o f aci l i t at e t he i nst al l at i on . Oi l t he new i nj ect or sl eeve
and i nst al l i t , usi ng speci al t ool p/ n
884557
.
Knock down t he
sl eeve
unt i l i t bot t oms .
10 . Oi l t hef l ar e- t ool p/ n 884283 and i nser t i t i nt ot he sl eeve
( make sur e t hat t he dowel i s pr oper l y r et r act ed) . Br ace t he
t ool
wi t h
t he i nj ect or yoke . Scr ew down t he f l ar e- t ool as f ar
as t he shoul der i n t he i nj ect or sl eeve al l ows, t her eby
f l ar i ng
t he sl eeve . Remove t he t ool . Adj ust t he l engt h of t he
sl eeve out si de t he pl ane of t he
cyl i nder head t o maxi mum
1 mm (
. 03937 i n . ) .
Assembl i ng
t he cyl i nder head
11 . Cl ean t he cyl i nder head . I f
t he wat er di st r i but i on pi pe
has been di sassembl ed, i t
must be i nst al l ed wi t h t he hol es
t ur ned as i ndi cat ed i n t he pi ct ur e . I nst al l new val ve
st em
seal i ngs . Oi l t he val ve
st ems and i nst al l t he val ves . Make
sur e t o i nst al l t he val ves and t he val ve spr i ngs i n
t hei r
r espect i ve or i gi nal
posi t i ons . I nst al l t he val ve spr i ngs and
t he " col l et s"
. Use a val ve- bow .
ProCarManuals.com

Reduct i on val ve
12 . Remove t he cover of t he r educt i on val ve and check
t o
make
sur e t hat t he spr i ng and t he pi st on ar e f aul t l ess . I f
t her e ar e r easons t o suspect a f aul t i n t he openi ng pr essur e
of t he r educt i on val ve, t hen check t he dat a of t he spr i ng .
See under " Techni cal Dat a" - r educt i on val ve
.
Feed- pump
13 .
Depr ess
t he pump l ever . i f t he di aphr agm of t he pump
sounds squeaky, t he di aphr agm i s f aul t l ess .
Changi ng t he di aphr agm
14 . Remove t he si x scr ews, hol di ng t he upper
and l ower
pump
housi ngs t oget her . Remove t he pump l ever spr i ng
( 1) and r emove t he scr ew ( 2) hol di ng t he pump l ever
shaf t .
15 . Use a sui t abl e pai r of pl i er s and r emovet he pump l ever
shaf t . Pul l out t he
l ever
and t he
di aphr agm .
ProCarManuals.com

16 . Cl ean t he pump housi ng
car ef ul l y
and r epl ace wor n
par t s . I nst al l t he di aphr agm
and t he
l ever on t he
di aphr agm
shaf t .
Then i nser t t he shaf t and t i ght en i t wi t h t he
scr ew
.
Assembl e t he t wo housi ng hal ves and i nst al l t he
at t achment pl at e ( 1) . Then
i nst al l
t he spr i ng ( 2) and t he O- r i ng ( 3) .
Val ve l i f t er s
17 . Check t he val ve l i f t er s f or wear . Repl ace t hem i f neces
sar y .
Camshaf t
18 . Check t he camshaf t f or wear on cams and bear i ng
r a
ces . Al so check t he wear of t he bear i ngs . The bear i ngs ar e
pr essed
i nt o
t hei r l ocat i ons and must be l i ne bor ed af t er
t he i nst al l at i on .
19 . Pl ace a suppor t under t he
camshaf t gear and use a
hydr aul i c pr ess t o r emove t he gear .
Cr ankshaf t
20 . Remove t he gear
wheel .
Use a
pr ong
pul l er . Cl ean
t he
cr ankshaf t . Measur e t he cr ank- and mai n bear i ng pi ns . The
eccent r i ci t y must not exceed 0 . 06 mm ( . 002362
i n . )
and t he
t aper 0. 05 mm ( . 001969 i n . ) . Shoul d t hese val ues be exceeded,
t he cr ankshaf t must be gr ound
t o a
sui t abl e
under - di mensi on, seeunder" Techni calDat a".
ProCarManuals.com

Pi st ons, cyl i nder s
21 . Check t he wear on pi st ons, pi st on r i ngs and gudgeon
pi ns . Repl ace t hese i f necessar y .
Use a
cyl i nder
i ndi cat or
gauge t o measur e t he cyl i nder bor es . The measur ement of
t he
bi ggest wear i s made i mmedi at el y beneat h t he edge of
t he upper dead cent er and cr osswi se t he engi ne
.
The
mea
sur ement of t he smal l est wear i s made at t he l ower dead
cent er . As t o t he cyl i nder di amet er , see " Techni cal
Dat a" .
Use a mi cr omet er t o measur e t he pi st ons . Pi st on di amet er ,
see under " Techni cal Dat a" .
22 . I nser t a new pi st on r i ng i nt o t he cyl i nder and
measur e
t he pi st on r i ng
gap . As t o t he measur ement , see under
" Techni cal Dat a" . I f necessar y i ncr ease t he
gap,
usi ng
a
speci al f i l e .
23
.
Measur e t he cl ear ance of t he pi st on r i ngs i n t he
pi st on
r i ng gr ooves . Regar di ng
t he measur ement ,
see under
" Techni cal Dat a" .
24 .
Use pi st on
r i ng pl i er s
t o i nst al l t he pi st on r i ngs . The
mar ki ng of t he r i ngs ( TOP or t he mar k of t he
manuf act ur er )
must
be
t ur ned
upwar ds . The hei ght of t he upper com
pr essi on r i ng : 1, 75 mm ( . 068898 i n . ) The hei ght
of t he
l ower compr essi on r i ng ;
2, 00 mm ( . 07874 i n . ) . Tur n t he
pi st on r i ngs so t hat t he gaps ar e t ur ned 120
° f r om each
ot her.
Connect i ng
r ods
25 . Check t he connect i ng r ods f or
st r ai ght ness and
t wi st i ng
.
ProCarManuals.com

26 .
Check t he connect i ng r od bushi ngs
by usi ng t he
gudgeon pi n as a gauge . Ther e must be no pl ay . I f t he
bushi ngs
must be
r epl aced, use a sui t abl e mandr el f or t he
r emoval
and i nst al l at i on . Make sur e
t o i nst al l t he bushi ng wi t h t he
oi l hol e
coi nci di ng wi t h t hat of t he connect i ng
r od . Ream
t he new bushi ngs . The f i t
i s cor r ect when an oi l ed gudgeon
pi n by
i t s own wei ght can sl owl y sl i de
t hr ough t he
bushi ng.
Sea- wat er pump
27 . The pump
i s equi pped wi t h t wo bal l - bear i ngs ( 1)
.
When di sassembl i ng, r emove
t he l ocki ng- r i ng
( 2)
i n t he
housi ng and push
out t he shaf t , wher eby t he bear i ngs
ar e
f ol l owi ng . Use a sui t abl e mandr el
t o r emove t he bear i ngs
f r om t he shaf t . NOTE!
Do not f or get t he spacer
sl eeve
( 3) .
Repl ace t he
seal i ngs ( 4) . NOTE!
Tur n t he seal i ngs cor r ect l y
and make
sur e t hat t hey do not bl ock t he dr ai nage
hol e i n
t he pump- housi ng . Repl ace t he O- r i ng
( 5) . I nst al l t he
bal l - bear i ngs and t hespacersl eeve ont o t heshaf tand l eave a
di st ance of
39, 5 mm ( 1 . 55512 i n . ) f r om t he shaf t
end t o t he
bal l - bear i ng . Coat t he shaf t
wi t h gr ease and " scr ew" i t
t hr ough t he
seal i ngs and t he O- r i ng and t ake car e
not t o
damage t hem . Push i n t he
shaf t as f ar as t o al l ow t he
bear i ngs
t o bot t om and t hen i nst al l t he l ocki ng- r i ng ( 2) .
Checki ng t he t her most at s
28 . I mmer se
t he t her most at i n wat er and, usi ng
a
t her momet er , check i f i t opens
at t he cor r ect t emper at ur e . See
Techni cal
Dat a f or openi ng t emper at ur es . I f t he
t her most at i s
f aul t y, i t must be r epl aced .
ProCarManuals.com

Al ways use new gasket s,
seal i ng r i ngs, seal i ng washer s
and
l ock- washer s . Coat t he seal i ngs wi t h gr ease or
oi l
t hem and al so oi l al l
movi ng par t s pr i or t o i nst al l i ng t hem .
I f
t he
engi ne i s f r esh- wat er cool ed, see page
21 .
1 . Heat t he cr ankshaf t
gear wheel t o appr ox .
150°C ( 302 ° F)
pr i or t o t he
i nst al l at i on . Pl ace t he key
i n t he key- way of t he
cr ankshaf t and pr ess
on t he gear wheel .
Oi l
t he
new mai n
bear i ng hal ves ( wi t h oi l hol e) and
i nst al l t hem i n t he bl ock .
Put i n
t he cr ankshaf t . NOTE! The mai n bear i ng
shel l at t he
f l ywheel
al so f unct i ons as a t hr ust - bear i ng
.
ASSEMBLY
2 . Oi l t he cap bear i ng hal ves
and i nst al l t hem . I nst al l t he
caps i n accor dance wi t h
t he mar ki ng i n t he bl ock ( 2001 has
no i nt er medi at e
bear i ng) . I f an ar r ow i s cast , i t shal l
poi nt
t owar ds t he oi l di pst i ck .
Ti ght eni ng t or que f or t he mai n
bear i ngs : 1st t i ght eni ng 20 N m ( 2 kpm) ( 14 . 7 f t . l b) ,
2nd
t i ght eni ng 60 Nm ( 6 kpm)
( 44 . 2 f t . l bs) . Tur n t he engi ne .
3 .
Tur n
t he pi st on
r i ngs
so t hat t he gaps
ar e of f set i n r el at i on
t o each
ot her . The
pi st on
cr own i s mar ked wi t h an ar r ow t hat
poi nt s t owar ds t he bel t pul l ey . Use i nst al l at i on r i ng 884813- 7
.
Fi t
t he caps
wi t h t he mar ki ng al i gned wi t h t he cr ankshaf t ' s
mar ki ng . The cr ankshaf t can be t ur ned i n any di r ect i on
t owar ds t he pi st on
.
Ti ght eni ng t or ques :
St ep
1 :
25
Nm ( 2 . 5
kpm)
( 18
f t / l b)
St ep 2 : 70 Nm ( 7 . 0 kpm) ( 53
f t / l b)
4 . I nst al l t he mai n bear i ng hal ves
i n
t he
oi l pan and
coat
t he edge of t he
oi l pan wi t h t hi n l ayer of seal i ng
compound
p/ n
840879 .
I nst al l t he oi l pan and t i ght en t he oi l pan
scr ews and
t he mai n bear i ng scr ews
al t er nat i ngl y t o 20 Nm
( 2, 0 kpm) ( 14 . 7 f t . l bs . )
and t hen t he mai n bear i ng scr ews t o
60 Nm ( 6, 0
kpm) ( 44 . 2
f t . l bs . ) .
ProCarManuals.com

5 . Repl ace t he
f l ywheel housi ng seal i ng ( 1) . Smear seal i ng
compound ( p/ n 840879) on t he edge bet ween t he f l ywheel
housi ng and t he seal i ng . NOTE! The seal i ng lip wi t h a
spr i ng shal l be t ur ned t owar ds t he engi ne . Make sur e t hat
t he seal i ng i s i nst al l ed i n accor dance wi t h t he pi ct ur e .
r
6 . Repl ace t he O- r i ngs and i nst al l t he f l ywheel housi ng .
Ti ght eni ng t or que 25 Nm ( 2, 5 kpm) ( 18 . 4 f t . l bs) .
I nst al l t he f l ywheel . Ti ght eni ng t or que 65 Nm ( 6, 5 kpm)
( 48 . 0 f t . l bs) .
7A . Heat t he camshaf t gear wheel t o a t emper at ur e of
appr ox . 150°C ( 302°F) and use a sui t abl e sl eeve t o i nst al l i t .
Check t o make sur e
t hat t he
gear
wheel " bot t oms" on t he
camshaf t . I nst al l t he camshaf t and make sur e t hat t he
mar ki ngs on t he camshaf t gear
wheel
and on
t he
cr ankshaf t
gear wheel coi nci de . Put t he washer ( 1) on t he hub of
t he camshaf t gear
wheel .
Check t hat
al l wei ght s
ar e pr essed
i n so t hat t he t abs ( 2) ar e i nsi de t he washer .
7B . I nst al l
anew seal i ng r i ng f or t he camshaf t i n t he
t r ansmi ssi on housi ng, usi ng mandr el
p/ n
884838 . The seal i ng
lip wi t h
t he spr i ng i s t o bet ur ned t owar ds t he engi ne . Pr ess
i n t he seal i ng r i ng f r om
t he out si de unt i l t he mandr el
" bot t oms" agai nst t he housi ng . I nst al l a new O- r i ng i n t he
oi l channel i n
t he bl ock ( 3 f i g . 7A) .
Use a new gasket and i nst al l t he t i mi ng gear
cover
.
Pl ace
t he pr essur e sl eeve ( wi t h t he bear i ng t owar ds t he pr essur e
washer ) i n t he cont r ol ar m l ever . Hol d t he sl eeve
i n pl ace
by pr essi ng t he l ever t o i t s bot t om posi t i on wher e t he
sl eeve i s pr essed agai nst t he housi ng . I nst al l
t he pi n of t he
camshaf t , usi ng speci al t ool
p/ n
884839 . The pi n must
pr ot r ude equal l y much on bot h si des . Under no ci r cumst ances
ar e you t o use a hammer or some such
t ool t o punch t he
pi n
i nt o i t s l ocat i on wi t h t he ai d of a mandr el . The camshaf t
wi l l t hen be bent .
ProCarManuals.com

8 .

I nser t t he cont r ol r od t hr ough t he bl ack and i nt o t he t i mi ng
gear casi ng . I nst al l t he bear i ng bal l
( 1)
i nt o t he cont r ol r od and
push t he cont r ol r od t hr ough t he hol e i n t he cont r ol l ever ( 2) .
Fi t t he spr i ng ( 3) and scr ew on t he end ni ppl e ( 4) unt i l i t
bot t oms
( Not e! Do not use any t ool s) . Scr ew i n t he upper bol t s
( wi t h copper seal i ng washer s) t hat gui de t he cont r ol r od .
Then,
scr ew t he l ower bol t s t hat hol d t he cont r ol r od i n pl ace
i n t he engi ne bl ock . NOTE! The l ower bol t s shoul d not have
seal i ng
washer s .
Appl y Per mat ex
t o t he t hr eads . Check t hat
t he cont r ol r od moves f r eel y .
9 .
I nst al l t he oi l
pump' s gear wheel accor di ng t o t he
mar ks
( f r om t he
di sassembl y) . I nser t a
new O- r i ng i n t he t i mi ng
gear
cover . Oi l t he gear
wheel and f i t The cover usi ng
a new
seal i ng
r i ng .
2001
10 .

I nser t t he key f or t he pul l ey i n t he cr ankshaf t and i nst al l
t he pul l ey . Ti ght eni ng t or que 40 Nm ( 4, 0 kpm) ( 29 . 5
f t . I bs)
.
11 . Cl ean t he val ve l i f t er s car ef ul l y and coa t t he cont act
sur f ace agai nst t he camshaf t wi t h mol ybdenum di sul phi de
.
Oi l t he val ve gui des i n t he bl ock and i nst al l t he l i f t er s .
Cl ean t he r ol l er l i f t er s of t he f uel i nj ect i on pumps and
i nst al l t hen i n t he bl ock . Lock t he r ol l er l i f t er s wi t h scr ews
t hr ough t he bl ock af t er t he i nst al l at i on ( appl y Per mat ex t o
t he t hr eads) . Check car ef ul l y t o make sur e t hat t he l i f t er s
ar e cor r ect l y i nst al l ed and t hat t hey ar e r unni ng easi l y i n
t he gr oove
.
Regar di ng t he i nst al l at i on of t he cyl i nder head, seet he
f ol l owi ng page .
ProCarManuals.com

2002
2003
12 . Ti ght en t he
t wo gui de scr ews p/ n 884840 i n t he bl ock
and i nst al l t he cyl i nder head gasket wi t h t he mar ki ng
" Top" f aci ng upwar ds
. I nst al l t he cyl i nder head .
Make sur e t hat t he cont act sur f ace f or t he cyl i nder
head
bol t s ar e f r ee f r om
pai nt . Shoul d t her e be pai nt on t he
bol t s, t her e
i s al ways
t he
r i sk of havi ng an i nsuf f i ci er t
t i ght eni ng f or ce i n t he bol t j oi nt wi t h subsequent
l eakages as a
r esul t . NOTE! The
bol t s ar e phospat ed, t her ef or e do not
cl ean t hem wi t h a st eel - br ush .
Coat t he cyl i nder
head bol t s wi t h mol ybdenum di sul phi de
and t i ght en t hem i n accor dance wi t h t he di agr am, f i r st
t o
20 Nm ( 2 . 0
kpm/ 14. 7 f t . l bs) and t hen t o 70 Nm ( 7 . 0 kpm/ 51 . 6
f t . l bs) .
13 . I nst al l t he push r ods and t he r ocker ar m br i dge,
push
on
new
r ubber r i ngs t o t he oi l pi pe whi ch i s f i t t ed at t he
same t i me as t he r ocker ar m br i dge .
14 . Val ve cl ear ance
col d/ war m engi ne 0 . 30 mm
( . 01181
i n . ) . Tur n
t he engi ne i n t he di r ect i on of r ot at i on unt i l t he
val ves i n one cyl i nder ar e " r ocki ng" . Then t ur n t he engi ne
one t ur n mor e
and
adj ust
t he val ves f or t hi s cyl i nder .
Repeat t he pr ocedur e f or t he r emai ni ng cyl i nder s .
Adj ust i ng t he f uel i nj ect i on
pump l ocat i on wi t h shi ms
15 . i f t he same bl ock camshaf t and f uel I nj ect i on
pumps
ar e used when assembl i ng,
t he f uel i nj ect i on pump must
be i nst al l ed i n t hei r or i gi nal posi t i ons and wi t h
t he same
shi m t hi ckness as ear l i er . The
so cal l ed sof t shi ms, al ways
bei ng i nst al l ed
agai nst t he bl ock,
must be r epl aced
agai nst
new ones . Car ef ul l y cl ean t he cont act sur f aces bet ween
t he
bl ock and t he f uel i nj ect i on
pumps and i nst al l shi ms wi t h
t hi ckness equal t o t he sum of t he mar ki ng
on t he bl ock and
t hat on t he f uel i nj ect i on
pump, ( 4) ear l i er mar ki ng .
Exampl e : The bl ock mar ki ng 4 ( = 4 t ent hs of a mi l l i met er )
( . 015748 i n . )
The pump
mar ki ng 4 ( = 4 t ent hs of a mi l l i met er )
( . 015748 i n . )
Tot al amount of shi ms = 0 . 8 mm ( . 031496 i n . )
I n t hi s case
sel ect t wo sof t shi ms 0 . 2 and 0 . 3 mm ( . 011811
i n . ) . Pl ace t he har d shi m bet ween t he
t wo sof t ones and
i nst al l t he pump . NOTE!
Never i nst al l a har d shi m t oget her
wi t h anot her har d shi m or agai nst t he bl ock
or t he f uel
i nj ect i on pump .
Har d
shi ms
ar e avai l abl e i n t hi cknesses 0 . 3,
0 . 6 and 0 . 9 mm ( . 011811, . 02362, . 035433 i n .
r espect i vel y) .
Sof t shi ms
ar e avai l abl e i n t hi cknesses 0 . 2 and 0 . 3 mm
( . 007874 and . 011811 i n . ) .
ProCarManuals.com

On l at er ver si on engi nes
an
O- r i ng
has been i nt r oduced as a
seal bet ween t he i nj ect i on pump and t he bl ock . Onl y so- cal l ed
har d shi ms may
be used on t hese engi nes when shi mmi ng .
Har d shi ms ar e avai l abl e i n t hi cknesses of 0 . 2 mm ( 0 . 0079 i n) ,
0 . 3 mm ( 0 . 0118
i n) ,
0 . 6 mm
( 0
. 0024 i n)
and 0 . 9
mm
( 0 . 0354 i n) .
16 . New
bl ock
or camshaf t
I f
t he bl ock or t he camshaf t ar e r epl aced t he bl ock must be
measur ed and mar ked, usi ng t he set t i ng- di sc p/ n
884787
and a sl i di ng cal i per .
A . The set t i ng- di sc consi st s of t wo r i ngs,
an
i nner
and an
out er . The i nner r i ng det er mi nes t he i nj ect i on angl e f or
each r espect i ve engi ne t ype, see Techni cal
Dat a ( page 25) .
The
i nj ect i on angl e i s st amped i n degr ees and i s f i xed wi t h
a pi n ( 1) .
B . Mount t he set t i ng- di sc or t he pul l ey wi t h t wo
bol t s, do
not t i ght en t he bol t s . Tur n t he
set t i ng- di sc
so t hat t he gui de
pi n ( 2) comes i n t he l ar gest of t he f our hol es i n
t he pul l ey .
Pr ess i n t he gui de pi n ( 2) so t hat t he di sc i s
cent er ed and
t i ght en t he bol t s .
The set t i ng- di sc i s mar ked f or
each r espect i ve cyl i nder :
Mar ki ng Denot es
Cyl i nder 1

Cyl i nder 1 ( 1, 2, 3 cyl i nder
engi nes ;
Cyl i nder
2/ 2

Cyl i nder 2 ( 2 cyl i nder engi ne)
Cyl i nder 2/ 3

Cyl i nder 2 ( 3 cyl i nder engi ne)
Cyl i nder
3/ 3

Cyl i nder 3 ( 3 cyl i nder engi ne)
ProCarManuals.com