ENGINE REPAIR 6A-1
SECTION 6A
ENGINE REPAIR
CONTENT
ENGINE DIAGNOSTICS
(ONL(ONL
(ONL(ONL
(ONL
Y Y
Y Y
Y
MECHANICAL INJECTION ENGINEMECHANICAL INJECTION ENGINE
MECHANICAL INJECTION ENGINEMECHANICAL INJECTION ENGINE
MECHANICAL INJECTION ENGINE
))
))
) ............................................... 6A- 3
GENERAL CHARACTERISTICS ........................................................................................................................... 6A-13
GENERAL INSTLLATION DATA AND TOLERANCES .......................................................................................... 6A-17
SYMBOL CHART .................................................................................................................................................. 6A-23
CHARACTERISTICS AND SERVICING OF BELT TENSIONS
CHECKER (FREQUENCY METER Ref. 00000A01484) .......................................................................................... 6A-24
ON VEHICLE SERVICE ........................................................................................................................................ 6A-26
- Belts substitution .................................................................................................................................... 6A-26
• Water pump and generator belt....................................................................................................... 6A-26
• Air conditioning compressor belt (if fitted) ....................................................................................... 6A-27
• Timing belt substitution................................................................................................................... 6A-28
- Water pump substitution ........................................................................................................................ 6A-30
- Removal and installation of injectors
(mechanical injection engine)(mechanical injection engine)
(mechanical injection engine)(mechanical injection engine)
(mechanical injection engine) ................................. 6A-32
- Removal and installation of injecting pump
((
((
(
mechanical injection enginemechanical injection engine
mechanical injection enginemechanical injection engine
mechanical injection engine
))
))
) ..................... 6A-33
- Removal and installation electro-injectors, hydraulic accumulator
and high pressure pump removal
(Common Rail engine)(Common Rail engine)
(Common Rail engine)(Common Rail engine)
(Common Rail engine) ......................................................... 6A-36
- Removal and installation of flywheel
((
((
(
mechanical injection enginemechanical injection engine
mechanical injection enginemechanical injection engine
mechanical injection engine
))
))
) ................................. 6A-39
- Removal and installation of flywheel
(Common rail engine)(Common rail engine)
(Common rail engine)(Common rail engine)
(Common rail engine) .................................................... 6A-42
- Flywheel revision and ring gear substitution ...................................................................................... 6A-45
- Bearing of gearbox primary axle removal .......................................................................................... 6A-46
- Crankshaft oil-seals substitution ............................................................................................................ 6A-47
• Crankshaft rear oil-seal substitution ................................................................................................ 6A-47
• Crankshaft front oil-seal substitution ............................................................................................... 6A-47
- Camshaft front oil-seal substitution ...................................................................................................... 6A-48
- Valves play .............................................................................................................................................. 6A-49
• Checking valves play ...................................................................................................................... 6A-49
• Adjusting valves play ...................................................................................................................... 6A-50
- Removal and installation of cylinder head or cylinder head gasket substitution............................. 6A-53
- Removal and installation of generator and front support ................................................................... 6A-59
- Removal of the AA compressor (if fitted) .............................................................................................. 6A-60
- Removal and installation of starting motor .......................................................................................... 6A-61
- Removal and installation of turbocharger ........................................................................................... 6A-62
- Removal and installation of servo steering hydraulic pump .............................................................. 6A-64
- Removal and installation of vacuum pump (depressor) ..................................................................... 6A-65
- Removal and installation of auxiliary organs group ........................................................................... 6A-66
- Removal and installation or substitution of the heat exchanger ....................................................... 6A-68
- Oil filter substitution ............................................................................................................................... 6A-69
GEAR BOX, AUXILIARY ORGANS GROUP AND OIL PUMP REPAIR ................................................................ 6A-70
• Removal and repair of gearbox and oil pump ................................................................................... 6A-70
• Installation and repair of gearbox and oil pump ............................................................................... 6A-73
REMOVAL AND INSTALLATION OF ENGINE ON VEHICLE ................................................................................ 6A-77
• Removal and installation of engine .................................................................................................. 6A-77
• Checks and controls ....................................................................................................................... 6A-83
6A
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