Home

SERVICE MANUAL - lombardini service

1. 2 5 1 SAE Classification In the SAE classification oils differ on the basis EE of their viscosity and no other qualitative 40 35 30 25 20 15 10 5 0 5 10 15 20 25 30 35 40 45 50 characteristic is taken into account SAE 10W The first number refers to the viscosity when SAE 20W the engine is cold symbol W winter while SAE 30 the second considers viscosity with the engine SAE 40 at r gime SAE 10W 30 The criteria for choosing must consider during SAE 10W 40 winter the lowest outside temperature to which SAE 10W 60 the engine will be subject and the highest 15W 40 functioning temperature during summer SAE 15W 40 Single degree oils are normally used when the SAE 20W 60 running temperature varies scarcely SAE 5W 30 Multi degree oil is less sensitive to temperature SAE 5W 40 changes SAE 0W 30 Mineral base Semi synthetic base Sythetic base Key to abbreviations A P American Petroleum Institute MIL USA military specifications for engine oils issued for logistic reasons ACEA European Automobile Manufacturers Association 2 5 2 API MIL Sequences DIESE L BENZINA ESSENCE PETROL BENZIN GASOLINA GASOLINA eni B HE 2 5 3 ACEA Standards ACEA Sequences
2. Crankcase and crank gears Overhauling Crankcase and crankgear Crankcase and crankshaft disassembling Crankcase assembling ssssssssseeseeeeeeneenene Crankgear and crankcase installation Crankshaft and crankcase disassembling Crankshaft axial clearanca measuring Crankshaft flange flywheel side assembling K Crankshaft assembling ssssssssseseeeeeeenne Crankshaft dimensional check and overhaul Oylinder piston classes and dimensions table e Cylinder head and components installation Cylinder head and components overhaul Oylinder head assembling Cylinder head checking and overhauling Cylinder head disassembling sssssssseee Oylinder head removing Oylinders and pistons overhauling Cylinders dimensional check and overhaul D Decanting device overhauling rrrnrrnnnrvnnnnrnnnnvrnnnnrnnrnnnnnnnrnnennennnn 47 Diagram of timing belt rates X Dimensional check and overhaul of connecting rods 45 Dimensional check and overhaul of crankshaft Dimensional check and overhaul of cylinders Dimensional check and overha
3. 26 PREPARING THE ENGINE FOR OPERATION sio c ome scia GN 26 PREPARING THE ENGINE FOR OPERATION INSTALLED ee EE 27 REMOVING THE ASSEMBLIES RECOMMENDATIONS FOR REMOVING THE ASSEMBLIES asst cies eee teet 29 REMOVING THE EXHAUST AND INTAKE MANIFOLDS tata tree oet pes 29 Disassembling the intake manifold 29 Disassembling the exhaust manifold 30 6 1 1 GENERAL INDEX REMOVING THE COOLING FAN BELT DRIVE 30 Disassembling the cooling fan belt with external alternator 31 Disassembling the cooling fan belt with internal alternator 31 REMOVING THE TIMING BELT DRIVE 31 Disassembling the timing belt casing 31 Disassembling the timing belt 32 Disassembling the pulleys camshaft and crankshaft 32 REMOVING THE CYLINDER HEAD 33 Disassembling the rocker arm cover 33 Disassembling the rocker arms 33 Disassembling the fuel PUMP 33 Disassembling the injection pumps 34 Disassembling the precombustion chamber 34 Disassembling the speed governor Stee ale
4. 80 7 9 INSTALLING INTAKE AND EXHAUST MANIFOLDS 80 7 9 1 Assembling the exhaust manifold 80 7 9 2 Assembling the intake manifold 80 4 Service Manual LW 502 automotive _ cod 1 5302 727 2 ed rev 01 LOMBARDINI 1 1 PURPOSE OF THE MANUAL This manual was written by the manufacturer to provide technical and operating information to authorised LOMBARDINI after sales service centres to carry out assembly disassembly overhauling replacement and tuning operations This information is provided by the manufacturer in its own language Italian and may be translated into other languages to satisfy legislative and or commercial requirements As well as employing good operating techniques and observing the right timing for operations operators must read the information very carefully and comply with it scrupulously Time spent reading this information will help to prevent health and safety risks and financial damage Written information is accompanied by illustrations in order to facilitate your understanding of every step in the operating phases 1 2 USING THIS MANUAL This manual is divided into several chapters The first chapter gives general information and details about safety purpose of the manual safety etc The second third and fourth chapters provide general technical information technical specif
5. 66 7 5 4 Measuring crankshaft axial clearance 67 7 5 5 Assembling the crankshaft flange flywheel side 67 7 5 6 Installing the oil 68 7 5 7 Assembling the 69 7 6 INSTALLATION OF CYLINDER HEAD AND GOMPONENLTS tei Rare iet eere 70 7 6 1 Assembling the precombustion chamber 70 7 6 2 Assembling the cylinder head 71 7 6 8 Assembling the 71 7 6 4 Assembling the speed governor and flow limiter 72 7 6 5 Assembling injection pDumpe esee 73 7 6 6 Assembling the mechanical fuel pump 74 7 6 7 Assembling the rocker ams 75 7 6 8 Assembling the rocker arm 75 7 7 INSTALLING THE TIMING BELT DRIVE 76 7 7 1 Assembling the timing belt pulley 76 7 7 2 Assembling the timing belt 76 7 7 8 Assembling the belt drive 77 7 8 INSTALLATION OF THE COOLING FAN BELT DRIVE 2 208 tee Eee 78 7 8 4 Assembling the fan belt drive pulleys 78 7 8 2 Assembling the fan belt drive 79 7 8 8 Assembling the cooling
6. 21 Table of sealing rings clearance 43 Table of specific fuel consumption 61 Table of tightening torques essen 19 Table of uprated shoulder half rings 2 44 Technical specifications 10 Terminology and glossary ssssssseeeseeeeeeenennee 6 Thermostatic valve replacing 89 Tightening torques table 19 Timing belt casting disassembling 31 Timing belt drive installing 76 Timing belt drive removing ee cece eee eee eeeeeeeeeeseeeeeeeeeeeeeeenees 31 Timing belt pulley assembling eeeeeen 76 Timing belt rates diagram rrnnnvrnnnnvrnnnnrnnnnvnnnnnvnnennnnnrnrnnrnnrnnennneennn 55 Timing belt rating checking 54 Timing belt assembling rrrrrnnnrnnnnnrnnnnnnnnnvrnnnnrnnnnnrnnnnrnnrnnrnnennenennnn 76 Timing belt disassembling 32 Timing belt replacing essent 85 U Uprated shoulder half rings table 44 Using this manual 5 V Valve rocker arm clearance adjusting 52 Valve adjusitmerits
7. ADJUSTMENTS REPAIRS Service Manual LDW 502 automotive _ cod 1 5302 727 2 ed_rev 01 23 5 LOMBARDINI MALFUNCTIONS Service Manual LW 502 automotive _ cod 1 5302 727 2 ed rev 01 5 LOMBARDINI 4 1 HANDLING AND LIFTING STORING THE ENGINE 4 Secure the engine using a lifting device lifting beam of suitable capacity Hookthe lifting device to the points indicated in the drawing Before lifting check the load s centre of gravity A The dimensions of the brackets on the fastening points have been specially conceived to lift the engine and have not been tested for lifting additional weights Do not lift the engine using different methods from those described Non observance of this requirement will invalidate the insurance warranty from any Important damages caused in this way 4 2 STORING THE ENGINE UNINSTALLED If the engine is not to be used for extensive periods check the surroundings and the type of packaging and make sure that they are suitable for correct storage If necessary cover the engine with a protective sheet Avoid storing the engine directly on the ground or in an environment that is humid exposed to bad weather or close to sources of danger including less visible ones such as high voltage power lines etc 4 3 STORING THE ENGINE INSTALLED
8. LOMBARDINI Screw the extractor 7107 1460 030 onto the precombustion chamber S and remove it 4 extractor 7107 1460 027 5 5 6 Disassembling the speed governor and flow limiter 1 Remover the cover T Extract the weights assembly U from the camshaft 2 3 Remove the fuel flow limiter V 4 Unscrew the pin and extract the governor tinkage adjustment pin W 35 Service Manual LDW 502 automotive _ cod 1 5302 727 2 rev 01 QQ LOMBARDINI REMOVING THE ASSEMBLIES 5 5 5 7 Disassembling the camshaft 1 Remove the cover X 2 Extractthe camshaft Y from the cylinder head AN Important Make sure the drive rod has been removed and rotate the camshaft gently to remove it easily 5 5 8 Disassembling the cylinder head 1 Remove the cylinder head A 2 Take off the gasket B 5 6 REMOVING THE CRANK GEAR AND CRANKCASE 5 6 1 Disassembling the flywheel 1 Disassemble the starter motor A 2 Install tool 7107 1460 051 to inhibit rotation of the crankshaft 3 Remove the flywheel B 96 Service Manual LW 502 automotive _ cod 1 5302 727 2 ed rev 01 LOMBARDINI 4 Remove the support REMOVING THE ASSEMBLIES 5 6 2 Disassembling the oil pump 1 Remove the flange D 2 Extract the key E from the crankshaft 3 Bring piston number one flywheel side to the top dead cent
9. 23 Manufacturer and engine identification 5 Measuring crankshaft axial clearance 67 Mechanical fuel pump assembling 74 N Negative preassure vent valve replacing 90 Nozzle injector replacing e Oil filler CET RE 85 Oil preassure checking 61 Oil pump disassembling rrnrrrnrnnnvnnnrnnnvnrnrnnnrennrnrnnennnennnnnnennnennnn 37 Oil pump installing eeennnnn m 68 Operating phases general safety 6 Operating principle for cooling 15 Operating principle for fuel injection Operating principle for lubrification 4 15 iS Se REPE EE PP 41 Overhaul and dimensional check of connecting rods 45 Overhaul and dimensional check Cylinders 42 Overhaul and dimensional check pistons Overhaul and dimensionalcheck crankshaft Overhaul of cylinder head and components 47 Overhauling and checking the cylinder head Overhauling and checking the fuel pump Overhauling and checking the rocker arm pin Overhauling cylinders and pistons 4 Overhauling the crank gears and crankcase Overhauling the decanting device 47 Overhauls and tuning recomme
10. 50 Fuel pump checking and overhauling 46 Fuel pump disassembling A 33 Fuel pump mechanical assembling 74 G General description of the engine ssseeee 9 General safety during operating phases 6 General safety regulations sse 6 Glossary and terminology eene 6 H Half bearings and connecting rods table of diameters 44 Handling and lifting seeeeeeeeeee Head gasket and clearance volume values table I IIdle speed rpms minimum and maximum adjusting 60 Injection pumps assembling eene 73 Injection delivery with dyno brake adjusting 61 Injection delivery without dyno brake adjusting 60 Injection delivery adjusting 60 Injection pump delivery balancing 58 Injection pumps disassembling 34 Injector pump parts replacing 91 Injector pump exploded diagram 91 Injector calibrating sseeseeeeseeeeeeenneeenneennnnn 538 Injetion timing conversion table for establishing 57 Installation of crankgear and
11. 61 84 REPLACING THE OIL FILTER 85 85 REPLACING THE AIR FILTER eee 86 8 6 REPLACING THE ALTERNATOR 87 7 INSTALLATION OF ASSEMBLIES 8 7 REPLACING THE STARTER MOTOR 87 8 8 REPLACING THE FLYWHEEL RING GEAR 88 7 1 RECOMMENDATIONS FOR INSTALLING THE 8 9 REPLACING THE COOLANT THERMOSTAT 88 STEI 63 8 10 REPLACING THE COOLANT PUMP 89 7 2 PRE ASSEMBLY OF 8 11 REPLACING THE THERMOSTATIC VALVE 89 SEALING RINGS 63 8 12 REPLACING THE NEGATIVE PRESSURE VENT 7 3 PRE ASSEMBLY OF VALVE buc nes ede pedes 90 CONNECTING RODS PISTONS 64 8 13 REPLACING THE PRE HEATING GLOW PLUGS 90 7 4 INSTALLING VALVES esee 64 8 14 REPLACING INJECTOR PUMP PARTS 91 7 4 1 Assembling the valves AA 64 8 14 1 Pumping element replacement 91 7 5 INSTALLATION OF CRANK GEAR 8 14 2 Replacing the 221 93 AND CRANKCASE A 65 8 15 REPLACING THE COOLING FAN SUPPORT 93 7 5 1 Installing piston connecting rod engine block 65 7 5 2 Assembling the crankshaft 66 INDEX Ten Ee SE Ee 95 7 5 3 Assembling the crankcase
12. PETROL 1 Low viscosity 1 for friction reduction 2 Standard 2 High performance 4 2 5 4 00 08 SE 55 50 5 SM Si SL L 2104 D E L 46152 B C D E CORRENTI CURRENT 7 DB SOLET OBSOLETE LIGHT DUTY DIESELS HEAVY DUTY DIESELS Low viscosity E1 OBSOLETE for friction reduction E2 Standard Standard Heavy conditions Euro1 High performance indirect Euro2 engines injection E4 Heavy conditions Euro1 High quality direct injection Euro2 Euro3 E5 High performance in heavy conditions Euro1 Euro2 Euro3 engines Oil type Oil characteristics Engine oil Agip SINT 2000 5W40 API SJ CF ACEA A3 96 B3 96 MIL L 4615 D E 14 Service Manual LW 502 automotive _ cod 1 5302 727 2 ed rev 01 LOMBARDINI 2 6 OPERATING PRINCIPLE FOR LUBRIFICATION TECHNICAL INFORMATION I L Description Pressure switch Rocker arm pin Connecting rod big end pin Oil filter cartridge Main jurnal Oil drain plug Oil dipstick SIO JONI Air vent 9 Oilrefilling pump 10 Camshaft 11 Oil pressure regulating valve 12 Oil pump 13 Crankshaft 14 Oil suction filter N N 10 11 12 13 14 oO WM OPERATI
13. 5 1 RACCOMENDATIONS FOR REMOVING THE ASSEMBLIES Information is given in a logical order in terms of timing and sequence of operations The methods have been selected tested and approved by the manufacturer s technical experts This chapter describes procedures for removing assemblies and or individual components in order to carry out work on specific parts of the engine See the chapter entitled Overhauls and tuning for operations involving checks overhauls and tuning of assemblies and or components See the chapter entitled Installation of assemblies for operations involving the installation of assemblies and or components 5 2 REMOVING THE EXHAUST AND INTAKE MANIFLODS AN Important To locate specific topics the reader should refer to the index Before any intervention the operator should lay out all equipment and tools in Such way as to enable him to carry out operations correctly and safely Before proceeding with operations make sure that appropriate safety conditions are in place in order to safeguard the operator and any persons involved For safety and convenience you are advised to place the engine on a special rotating stand for engine overhauls 5 2 1 Disassembling the intake manifold Air filter square type 1 Remove the cover A 2 Remove the intake manifold B 3 Unhook the minimum maximum device C or the spring C1 4 Remove the gasket D 5 Close the open
14. 2 9 E 5 c uj S Q 939 2 S S O D Clogged pipes Clogged fuel filter Air in the fuel circuit Clogged tank breather Faulty fuel pump Blocked injector Blocked injection pump valve Injector not adjusted Excess leaking in the plunger Jammed injection pump delivery control Wrong injection pump delivery setting High oil level Blocked pressure relief valve Worn oil pump Air in the oil intake pipe Faulty pressure gauge or switch Clogged oil suction hose Burnt fuse on pre heating glow plugs Failure in glow plugs control unit Discharged battery Inefficient or wrong cable connection Faulty ignition switch Faulty starter motor Air filter clogged Excessive idle operation Incomplete running in Overloaded engine Clogged cooling circuit Slack or broken fan control belt Incorrect injection timing Delayed injection Incorrect governor linkage adjustment Broken or loose governor spring Low idle setting Worn or stuck piston rings Worn or scored cylinders Worn valve guides Valves stuck Worn crankshaft connecting rod bearings Non sliding speed governor leverage Driving shaft not turning freely Damaged head gasket Slack pump injector control rod Incorrect pump injector delivery balancing FUEL CIRCUIT a EE E o gt MAINTENANCE
15. 2400 Filter capacity u 2 3 Maximum operating pressure bar 4 LUBRIFICATION CIRCUIT Type of lubrication Completely forced Circuit supply Trochoid pump Maximum oil quantity including filter 1 Maximum oil quantity excluding filter 1 Oil pressure at minimum speed with oil temperature of 120 C no lower than 1 bar Oil filter cartridge Maximum operating pressure bar 7 Maximum combustion pressure bar 20 Filter capacity u 15 By pass valve setting bar 1 5 1 7 Filtering surface cm 730 COOLING CIRCUIT Coolant 50 water 50 antifreeze fluid Thermostatic valve Opening temperature C 83 87 Max stroke at 94 mm 7 Liquid return 30 80 ELECTRICAL EQUIPMENT Nominal voltage 12 Alternator nominal voltage 14 Internal external alternator nominal current see Alternator load curve diagrams Starter motor power 1 1 Preheating glow plugs Nominal voltage 12 5 Absorption after 5 seconds 12 14 Surface temperature of the sheath 850 Control unit temperature sensor Working field 30 80 Voltage 6424 Max temperature 150 Cil pressure switch Operating pressure 0 15 0 45 Coolant temperature monitoring sensor Electric circuit Unipolar system Supply voltage 6 24 Absorbed power 3 Closed circuit temperature 107 113 40 Service Manual LDW 502 automotive _ cod 1 5302 727 2 ed rev
16. 3 Carefully lubricate the crankshaft main journals and crank pins 4 Assemble the crankshaft G 5 Replace the connecting rod caps F and put in the screws 6 Tighten the connecting rod cap screws to a temporary torque of 25Nm 7 Tighten the connecting rod cap screws to a final torque of 30 Nm 50 Nm x PROGRESS 8 Assemble the crankcase see Assembling the crankcase 9 Measure the axial clearance of the crankshaft see Measuring crankshaft axial clearance 7 5 3 Assembling the crankcase AN Important Make sure that the contact surfaces and related pins are perfectly intact and clean Make sure there are no foreign bodies or residual material in the engine block and crankcase 1 Mountthe new gaskets H1 H2 for the engine block contact surface with the crankcase 2 Replace the crankcase and put in the screws L M 3 Tighten the screws L temporarily in a crisscross pattern 66 Service Manual LW 502 automotive _ cod 1 5302 727 2 rev 01 Q LOMBARDINI INSTALLATION OF ASSEMBLIES 7 4 Tighten the screws M temporarily in alternating pattern 5 Tighten the screws L in a crisscross pattern to a final torque of 50Nm 6 Tighten the screws M in an alternating pattern to a final torque of 10Nm 7 5 4 Measuring crankshaft axial clearance To measure the axial clearance of the crankshaft it is necessary to assemble th
17. 5 7 DISASSEMBLING THE VALVES 1 Place the cylinder head on the workbench 2 Press down hard on the cup A using the special tool 3 Remove the half collets B blocking the cup A the spring C the collar D and the gasket E 4 Remove the valves F AN Important Keep components together during the disassembly phase in order to be able to reassemble correctly Service Manual LDW 502 automotive _ cod 1 5302 727 2 ed rev 01 39 C LOMBARDINI REMOVING THE ASSEMBLIES 5 5 8 DISASSEMBLING THE PISTON 1 Remove the stop ring B 2 Extract the wrist pin C to separate the piston D from the connecting rod E AN Important Keep each connecting rod together with its piston and wrist pin 3 Remove the stop rings F 40 Service Manual LW 502 automotive _ cod 1 5302 727 2 ed rev 01 5 LOMBARDINI OVERHAULS AND TUNING 6 6 1 RECOMMENDATIONS FOR OVERHAULS AND TUNING Information is given in a logical order in terms of timing and sequence of operations The methods have been selected tested and approved by the manufacturer s technical experts This chapter describes procedures for controlling overhauling and tuning assemblies and or individual components AN Important To locate specific topics the reader should refer to the index Before any intervention the operator should lay out all equipment a
18. M in the injector seat with the flat part directed as in the drawing 2 Grease the copper gasket N and the oil O ring seals N1 copiously 3 Install the injector pumps Q and fasten the nuts without tightening them 4 Tighten the nuts to a temporary torque of 10 Nm 5 Tighten the nuts to a final torque of 20 Nm 6 Hook the connecting rod R to the adjustment levers and fasten the injector pumps without fully tightening the Screws 7 Tighten the screws to a final torque of 1 1 Nm 8 Hook the spring S AN Important The following procedures must be performed only if pumps have been replaced Otherwise go directly to point 13 Prepare the injector pumps for running the engine as explained below 9 Loosen the screws T of every injection pump 10 Move the plates U fully towards the flywheel side in order to maximise the injector delivery Service Manual LDW 502 automotive _ cod 1 5302 727 2 ed rev 01 73 Q LOMBARDINI INSTALLATION OF ASSEMBLIES 7 11 Tighten the screws T to a torque of 1 1 Nm 12 Balance the injector deliveries see Y Cx Balancing injector pump deliveries URS 0 de EE fuel rail 13 Put the new O rings on the injector pumps 14 Apply sealant to the seat of the fuel rail 15 Assemble the fuel rail and fasten the screws without tightening them 16 Tighten the screws to a final torque of 4Nm 17
19. and without air bubbles 17 Then turn slowly the crankshaft clockwise in order to identify the exact point at which liquid stops leaking In these conditions the point which coincides with the static injection timing can be identified 18 Act again on lever L to lower the valve and bring it again on the piston 19 Measure the piston lowering value by using the dial indicator 20 Convert the value registered from millimetres to degrees see Conversion table for establishing injection timing AN Important When converting refer to the table value that is nearest to the registered one see Conversion table for establishing injection timing For a good engine operation the injection static advance must be as follows Engine with maximum speed up to 3000 rpm 13 1 Engine with maximum speed above 3000 rpm 15 1 Conversion table for establishing injection timing injection advance angle If the static advance does not correspond to the ideal values change the adjustment by means of the screw N To increase the angular value higher static advance turn the screw clockwise qur To decrease the angular value lower static advance turn the screw anticlockwise AN Important Half turn of the screw equals approximately 5 of static angular advance 21 Disassemble all equipment when the injection static advance is reached 22 Fasten and tighten th
20. 18 Switch off the engine 26 Service Manual LW 502 automotive _ cod 1 5302 727 2 ed rev 01 LOMBARDINI 4 6 PREPARING THE ENGINE FOR OPERATION INSTALLED After a period of inactivity and before installing and running the engine it is necessary to carry out a few measures in order to ensure that it runs at maximum efficiency Use a cloth soaked in degreasing product to remove the external protective treatment Adjust the alternator fan belt tension Make sure that electrical contacts are intact and efficient Check the filters for aging air oil fuel and if necessary replace them with original spares STORING THE ENGINE 4 o Over time a number of engine components and lubricants lose their properties even when the engine is not in use and so it is important to consider whether they need replacing based not only on the number of hours of use but also on age and wear 5 6 Check that the engine oil and coolant are up to level Start the engine and keep at minimum speed for a few minutes Check for leaks and if necessary find and eliminate the cause Switch off the engine Service Manual LDW 502 automotive _ cod 1 5302 727 2 ed rev 01 27 5 LOMBARDINI STORING THE ENGINE 4 Service Manual LW 502 automotive _ cod 1 5302 727 2 ed rev 01 LOMBARDINI REMOVING THE ASSEMBLIES 5
21. 2 2 11 TABLE FOR TIGHTENING TORQUES The table shows the tightening torques for standard Tightening torques are provided again along with method screws and the main components and sequence in the instructions for assembling components and or assemblies Tightening torques for standard screws coarse thread Resistance class R R gt 400N mm R gt 500 R gt 600N mm R gt 800N mm R gt 1000N mm R gt 1200N mm Nm Nm Nm Nm Nm Nm Nm 0 5 0 7 0 6 1 1 4 1 9 2 3 1 1 1 5 1 4 2 2 2 9 4 1 49 2 3 3 2 8 4 5 6 8 5 10 3 8 5 4 7 10 14 17 9 4 13 12 19 25 35 41 18 25 23 37 49 69 83 32 43 40 65 86 51 68 63 79 98 Service Manual LDW 502 automotive _ cod 1 5302 727 2 ed rev 01 19 LOMBARDINI TECHNICAL INFORMATION 2 Tightening torques for standard screws fine threads Resistance class R R gt 400N mm R gt 500 R gt 600N mm R gt 800N mm R gt 1000N mm R gt 1200N mm Nm Nm Nm Nm Nm Nm Nm M 8x1 10 14 13 20 27 38 45 M 10x1 21 28 26 42 56 79 95 10x1 25 20 26 24 39 52 73 88 12x1 25 36 48 45 71 95 M 12x1 5 38 45 42 68 90 M 14x1 5 56 75 70 M 16x1 5 84 M 18x1 5 18 2 M 20x1 5 M20x2 22x1 5 M 24x2 M27x2 M 30x2 Diameter Tightening torques for main components Description Diameter x thread Tightening torque Nm Injector
22. 502 automotive _ cod 1 5302 727 2 rev 01 Q LOMBARDINI INSTALLATION OF ASSEMBLIES 7 4 Insert tool 7107 1460 049 in the tensioner holder lever 5 Calibrate the torque wrench to 20 Nm and insert it into the tool with the lever perpendicular to the belt 6 Loosen the nut slightly D tensioner holder 7 Turn the torque wrench clockwise to tighten the belt to 20 Nm Once the specified torque is reached 20 Nm tighten the nut D temporarily without allowing the belt tension to loose 8 Mount the pulley G1 9 Tighten the nut D to a final torque of 40Nm 10 Rotate the crankshaft a few times to settle and position the belt correctly 11 Before doing so make sure that the pulley notches crankshaft and camshaft are lined up with their respective timing notches 12 Insert the tool again into the lever on the pulley nut support and repeat all the steps to check belt tension 13 Disassemble the pulley G1 7 7 3 Assembling the belt drive cover 1 Mount the guard G without tightening the screws completely 2 Tighten the screws in an alternating pattern to a final torque of 10 Nm AN Important If replacement of the optional dust guard rings H H1 and the peripheral sleeve becomes necessary for technical or construction reasons please request the pre assembled guard G complete with rings and gaskets Service Manual LDW
23. 54 Valve guides springs valve stems dimensions table Valve stems springs valve guides dimensions table Valves assembling sssseeeeene 64 Valves checking and overhauling esee 51 Valves disassembling esee 39 Valves installing eisni 1 tiec tiet 64 W Warranty Clauses e eei reda 6 WING CIAQrAM EE 17 Service Manual LDW 502 automotive _ cod 1 5302 727 2 ed_rev 01 97 LOMBARDINI J 42100 Reggio Emilia Italy Vin dal Lavoro Adelmo Lombardini gt Tel 390522 3891 gt emali atitombardini it TE www lombarcdini t SERVICE MANUAL code 1 5302 727
24. If the engine has been installed on a machine and is not due to be used for extensive periods it is necessary to carry out a few maintenance measures in order to ensure it remains efficient and to protect its components If the engine is installed on the machine and is not to be used for short periods of time the following measures must be carried out Check the condition of the electrical contacts and protect them if necessary using an anti rust spray Disconnect the battery Empty the fuel tank to prevent the risk of fire If the engine is not to be used for more than 1 month it is necessary to apply the protective measures that are valid for 6 months see Protective treatment first 6 months of inactivity If after the first 6 months the engine is still not to be used it is necessary to carry out a further measure to extend the protection period see Protective treatment after 6 months of inactivity Remove the key from the dashboard and put it in a safe place to avoid acts of vandalism Lock the cabin and the cowls to prevent strangers getting access If the engine is not to be used for more than 1 month it is necessary to apply protective measures that are valid for 6 months see Protective treatment If after the first 6 months the engine is still not to be used it is necessary to carry out a further measure to extend the protection period see Protective treatment Service Manual
25. LDW 502 automotive _ cod 1 5302 727 2 ed rev 01 55 Q LOMBARDINI OVERHAULS AND TUNING 4 Assemble the dial indicator on stud bolt C D 5 Place the dial indicator tracer on the exhaust valve collar a 6 Remove the O ring D from the little non return valve and replace it with the suitable rubber cap E part of tool 7107 1460 048 dial indicator dial indicator tracer 7 Install the tool metal base plate F 8 Remove the rocker arm cover gasket 9 Fix the tool lever base G on cylinder head 10 Rotate the crankshaft clockwise until the injection cam acts on the rocker arm that controls the injector pump In these conditions the piston is near the compression top dead centre 11 Place the auxiliary tank at a height higher than that of the injectors 730 40 cm 12 Connect the tank to union H 13 Rotate slowly the crankshaft clockwise keeping the lever L lowered and the valve set on the piston crown until the dial indicator shows the maximum measurement 14 Set the dial indicator to zero In these conditions the compression top dead centre can be identified 56 Service Manual LW 502 automotive _ cod 1 5302 727 2 ed_rev 01 Q LOMBARDINI OVERHAULS AND TUNING 6 16 Rotate the crankshaft anticlockwise until liquid leaks from the pipe M and then stop turning when the flow is constant
26. Mount the rocker arm cover see Assembling the rocker arm cover 7 6 6 Assembling the mechanical fuel pump AN Check that the contact surfaces are perfectly clean and intact Make sure that the length of the drive rod is between 153 15 153 25 mm otherwise replace it 1 Insert the drive rod V 2 Mounta new O ring W 3 Install the fuel pump Z and fasten the nuts without tightening them 4 Tighten the nuts to a final torque of 22Nm 5 Connect the pipes to the pump 74 Service Manual LW 502 automotive _ cod 1 5302 727 2 ed rev 01 Q LOMBARDINI INSTALLATION OF ASSEMBLIES 7 7 6 7 Assembling the rocker arms AN Important Check that the contact surfaces are perfectly clean and intact 1 Press down hard on the pump stroke to insert the pin which facilitates assembly of the drive rods B 2 Mount the rocker arm assembly A 3 Insert the pump injector activation drive rods B 4 Tighten the nuts by hand 5 Tighten the nuts to a temporary torque of 20 Nm 6 Tighten the screws in an alternating pattern to a final torque of 40 Nm 7 Remove the pins and check that the rocker arms B have been inserted correctly 7 6 8 Assembling the rocker arm cover AN Important Make sure that the rocker arm cover is perfectly clean and dry Check that the contact surfaces are perfectly clean and intact m 2 1 Slip on a new gas
27. Repeat the same operation on the other valves 7 5 INSTALLATION OF CRANK GEAR AND CRANKCASE 7 5 1 Installing piston connecting rod engine block AN Important Make sure that the engine block and the crankcase are perfectly clean and dry 1 Assemble the pipe A with the oil suction filter 2 Mount the new O rings A1 3 Carefully clean and lubricate the cylinders and the connecting rod piston assembly B 4 Rotate the sealing rings so that the cuts have displacement of about 120 between them AN Important In order not to damage the sealing rings and the contact areas while inserting the piston into the cylinder use the special containment device 5 Mount the connecting rod piston assembly B onto the engine block and position the connecting rod big ends along the axis of the crankshaft AN Important The piston combustion chamber must be assembled on the precombustion chamber Service Manual LDW 502 automotive _ cod 1 5302 727 2 ed rev 01 65 Q LOMBARDINI INSTALLATION OF ASSEMBLIES 7 7 5 2 Assembling the crankshaft 1 Mount the half bearings C and the standard shoulder half rings E flywheel side AN Important Follow the marks made during the removal phase The shoulder half rings must be placed with the lubrication grooves facing outwards 2 Lubrificate the half bearings C the connecting rod big ends D and caps F
28. UE 35 Disassembling the camshaft 36 Disassembling the cylinder head 36 REMOVING THE CRANK GEAR AND CRANKCASE eene 36 Disassembling the flywheel 36 Disassembling the oil 37 Disassembling the crankcase and crankshaft 38 Disassembling the connecting rod and piston 39 DISASSEMBLING THE VALVES 39 DISASSEMBLING THE 40 OVERHAULS AND TUNING RECOMMENDATIONS FOR OVERHAULS AND TUNING tic deere sd eet 41 Shaftseals eee Ree 41 ORIS cese oM ERR CIERRE 41 SE lo ME TEENS 41 OVERHAULING THE CRANK GEARS AND CRANKCASE 5 5 52 ctas d ee 41 Overhauling cylinders and pistons 41 Dimensional check and overhaul of cylinders 42 Dimensional check and overhaul of pistons 42 Dimensional check of sealing rings 43 Dimensional check and overhaul of crankshaft 44 Dimensional check and overhaul of connecting rods 45 Checking parallelism of the connecting rod axes 45 Checking and overhauling the fuel pump 46 Overhauling the decanting device 47 OVERHAUL OF CYLINDER HEAD AND RELATED COMPONENTS e
29. WARRANTY CLAUSES 6 GENERAL SAFETY REGULATIONS 6 GENERAL SAFETY DURING OPERATING PHASES 6 SAFETY AND ENVIRONMENTAL IMPACT 7 PRECAUTIONS WHEN THE ENGINE IS INSTALLED ON THE MACHINE een 7 PRECAUTIONS WHEN THE ENGINE IS ON THE ROTATING STAND rororervvvvvevnnvvvvnrrrnrnrrrersrsssrsrrrrrrneeee 7 TECHNICAL INFORMATION GENERAL DESCRIPTION OF THE ENGINE 9 TECHNICAL SPECIFICATIONS e 10 CHARACTERISTIC CURVE DIAGRAMS 12 ALTERNATOR LOAD CURVE DIAGRAMS 13 LUBRICANT O iere geed 14 SAE Classification E 14 API MIL sequences AA 14 ACEA Standards cette ettet e 14 Recommended ol 14 OPERATING PRINCIPLE FOR LUBRICATION 15 OPERATING PRINCIPLE FOR COOLING 15 OPERATING PRINCIPLE FOR FUEL INJECTION 16 WIRING DIAGPRAM n 17 SPECIAL TOOLS AND EQUIPMENT FOR MAINTENANCE s rrrrvvvvevvvvvvvvrvrrrrrrrrsrssrsssssrsrrrvrvenvevee 19 TABLE OF TIGHTENING TORQUES 19 TABLE OF SEALANTS 21 ROUTINE ENGINE MAINTENANCE 21 MALFUNCTIONS LOOKING FOR MALFUNCTIONS 23 STORING THE ENGINE HANDLING AND LIFTING 25 STORING THE ENGINE UNINSTALLED 25 STORING THE ENGINE INSTALLED 25 PROTECTIVE TREATMENT
30. _ cod 1 5302 727 2 ed rev 01 81 LOMBARDINI INSTALLATION OF ASSEMBLIES 7 Service Manual LW 502 automotive _ cod 1 5302 727 2 rev 01 LOMBARDINI 8 1 RACCOMMENDATIONS FOR REPLACING PARTS This chapter describes the procedures for replacing a number of components and or assemblies which are not recommended for repairs Some of these operations are also contained in the user s operation and maintenance manual Before any intervention the operator should lay out all equipment and tools in such a way as to enable him to carry out operations correctly and safely Before proceeding with operations make sure that appropriate safety conditions are in place in order to safeguard the operator and any persons involved 8 2 REPLACING THE ALTERNATOR FAN BELT AN Important Replacement may be carried out with the en Th alternator With external alternator 1 2 3 2 gine installed on the machine e engine may have an external or internal Switch off the engine and leave to cool Loosen the nuts B B1 Loosen the belt by adjusting the alternator manually and tighten the nut B1 Slip off the belt D and replace it with an original spare REPLACING PARTS 8 All operations except where expressly stated otherwise must be carried out when the engine is not running and has cooled sufficiently to avoid the risk of burns AN
31. a final torque of 25 Nm 80 Service Manual LW 502 automotive _ cod 1 5302 727 2 rev 01 LOMBARDINI INSTALLATION OF ASSEMBLIES 7 7 Clean the cover H witha a jet of air 8 Checkthe state of the filter cartridge G If necessary remove the cartridge knock it repeatedly against a flat surface to eliminate dirt and clean with a jet of air 9 Return the cleaned filter cartridge or replace it with an original spare Caution Warning Do not use liquids to clean the filter cartridge 10 Replace the cover H and re hook it carefully into place Air filter cylindrical type 1 Check that the contact surfaces are perfectly clean and intact 2 Eliminate any blockages in the ducts governor spring 3 Slip on a new gasket L 4 Bring the manifold M up to the cylinder pe 5 Z SS head and hook on the minimum ms TTS NT maximum device 5 Install the manifold M without tightening the screws N completely 6 Tighten the screws in an alternating pattern to a final torque of 25Nm 7 Check the state of the filter cartridge If necessary remove the cartridge and clean with a jet of air 8 Return the cleaned filter cartridge or replace it with an original spare Caution Warning Do not use liquids to clean the filter cartridge 9 Replace the filter housing 10 Mount the cover P Service Manual LDW 502 automotive
32. crankcase 65 Installation of cylinder head and components 70 Installation of the cooling fan belt drive 78 Installing piston connecting rod engine block 65 Installing the assemblies recommendations 63 Installing the intake and exhaust manifolds 80 Installing the oil pump eese 68 Installing the timing belt drive 76 Installing valves rrrnrnvrnnnnrnnnnvrvnonvnnnnvrnnnnrnnnnnnnnnnnenrnnrnnennnerrnrnnennnnnnn 64 Intake and exhaust manifolds installing 80 Intake and exhaust manifolds removing 29 Intake manifold assembling sse 80 Intake manifold disassembling sees 29 L Looking for malfunctions sessseeeeemeeeneenn 23 14 Lubrification operating principle 15 M Maggiorazioni semianelli di spallamento tabella 42 Maintenance engine routine 21 Maintenance special tools and equipment 19 Malfunctions looking for
33. do not 9 Slide the valves into their seats 10 Measure the degree of indentation of each valve from correspond to the values shown replace the valve seat ring with an original spare Use a pointed tool to take out the valve seats the flat part of the cylinder head see Table of dimensions for springs valve stems valve guides Se le dimensioni rilevate corrispondono ai valori indicati smerigliare ogni valvola nella propria sede AN Important Protect the contact surfaces with lubricant oil to prevent them from rusting 6 Remove any debris clean the valve seat holder carefully and scrape the mouth 7 Lubricate the new valve seats and put them into the holder manually 11 Assemble the valves see Assembling the flywheel Service Manual LDW 502 automotive _ cod 1 5302 727 2 ed rev 01 51 LOMBARDINI OVERHAULS AND TUNING 6 3 6 Adjusting valve rocker arm clearance In order to make the adjustment it is necessary to remove the rocker arm cover See Disassembling the rocker arm cover for the correct procedure AN Important Adjustment of valve clearance must be done when the engine is cold 1 Place the pistons at the compression top dead centre 2 Turnthe screw and the lock nut to adjust clearance Adjustment can be made in two different points the contact area between the rocker arm and the camshaft 0 15mm and or the contact area between
34. equipment for maintenance 19 Specific fuel consumption Table 61 Speed governor and flow limiter assembling 72 Speed governor and flow limiter disassembling 95 Speed governor checking and overhauling 53 Speed governor exploded diagram 53 Springs valve stems valve guides dimensions table 51 Starter motor replacing sssseeeeeeeneen 87 Static injection timing adjusting e 55 Storing the engine installed s 25 Storing the engine uninstalled ssssssss 25 T Tabella classi e dimensioni cilindri pistoni 42 Table of cam dimensions 50 Table of camshaft dimensions sse 49 Table of connecting rod dimensions 45 Table of cylinder piston classes and dimensions 42 Table of diameters of connecting rods and half bearings 44 Table of dimensions for springs valve stems valve guides 51 Table of dimensions pin rocker 48 Table of head gasket and clearance volume values 52 Table of sealants
35. fumes at maximum load loosen the flow limiter screw If it gives off no fumes or does not achieve maximum power tighten the flow limiter screw Table of specific fuel consumption Time secs Rpm 3600 2 Service Manual LDW 502 automotive cod 1 5302 727 2 ed rev 01 61 5 LOMBARDINI OVERHAULS AND TUNING 6 Service Manual LW 502 automotive _ cod 1 5302 727 2 ed rev 01 LOMBARDINI INSTALLATION OF ASSEMBLIES 7 7 1 RECOMMENDATIONS FOR INSTALLING THE ASSEMBLIES Information is given in a logical order in terms of timing and sequence of operations The methods have been selected tested and approved by the manufacturer s technical experts This chapter describes procedures for installing assemblies and or individual components that have been checked overhauled or replaced with original spare parts AN Important To locate specific topics the reader should refer to the index The operator must wash clean and dry components and assemblies before installing them The operator must make sure that the contact surfaces are intact lubricate the coupling parts and protect those that are prone to oxidation Before any intervention the operator should lay out all equipment and tools in such a way as to enable him to carry out operations correctly and safely 7 2 PRE ASSEMBLY OF SEALING RINGS PISTONS Thoroughly cle
36. in order to prevent risks to the health and safety of all persons involved Do not use flammable liquids petrol diesel etc to degrease or wash components Use special products Keep flames away from the engine to avoid the risk of fire Replace worn or damaged parts exclusively with original LOMBARDINI spare parts This will contribute to ensuring better performance and longer product life Service Manual LW 502 automotive _ cod 1 5302 727 2 rev 01 LOMBARDINI Use the oils and greases recommended by the manufacturer Do not mix different brands or oils with different characteristics Usea torque wrench to tighten the main fixing points of engine components Stick to the tightening torques indicated by the manufacturer 1 8 SAFETY AND ENVIRONMENTAL IMPACT Every organisation has a duty to implement procedures to identify assess and monitor the influence of its own activities products services etc on the environment Procedures for identifying the extent of the impact on the environment must consider the following factors Liquid waste Waste management Soil contamination Atmospheric emissions Use of raw materials and natural resources Regulations and directives regarding environmental impact GENERAL REMARKS AND SAFETY 1 Discontinue use of the engine if any irregularities arise particularly in the case of unusual vibrations The engine has been desi
37. manual For this reason the reader should refer to the index to find his her topic of interest quickly e MADE IN ITALY LOMBARDIN Type rpm DE O O s n JO Tes mM Service Manual LDW 502 automotive _ cod 1 5302 727 2 ed rev 01 5 5 LOMBARDINI 1 4 GLOSSARY AND TERMINOLOGY For clarity here are the definitions of a number of terms used recurrently in the manual 1 5 LO WARRANTY CLAUSES MBARDINI issues a warranty certificate for each engine giving details of all relevant general terms 1 6 1 7 GENERAL SAFETY REGULATIONS In designing and building its product the manufacturer has paid particular attention to those aspects posing a risk to the health and safety of persons handling the engine In addition to legislative requirements all rules for good technical construction have been applied The purpose of this information is to invite operators to pay particular attention in order to prevent any form of risk Caution is always the best policy Safety is also the responsibility of all operators who handle the GENERAL SAFETY DURING OPERATING PHASES The procedures contained in this manual have been tested and selected by the manufacturer s technical experts and hence are to be recognised as authorised operating methods A number of procedures must be carried out with the aid of equipment and tools that simplify and improve the timing
38. pump connecting rod M 3 sp c 1 2 Aluminium connecting rod 8x1 30 Steel connecting rod 8x1 50 Preheating glow plugs 12x1 25 25 Rocker arm cover 6x1 9 Crankcase screws for fixing crankshaft M10 30 Crankcase screws for fixing engine block M6 10 Screw for speed governor bearing support cover M6 10 Preheating glow plugs cable nuts 5x0 8 5 Fuel supply pump nuts 8x1 5 24 Nut for synchronous timing belt pulley M10 40 Injector pump nut 8x1 25 20 Rocker arm support nuts 10x1 5 40 Fuel pump control eccentric 10x1 25 80 sealing ring flange screws flywheel side M6 12 Precombustion chamber ring nut 30x1 5 Governor tinkage adjustment pin 6x1 Crankshaft pulley screw timing belt side 16x1 5 gauche Camshaft pulley screw 10x1 25 Oil pressure switch 12x1 5 Oil plug 12x1 5 Cylinder head screws Injector pump head screws TCEI 4x1 5 Flywheel screws 10x1 5 Coolant thermostat Control unit sensor Control unit temperature sensor 9 For more detailed information see Assembling the cylinder head 20 Service Manual LW 502 automotive _ cod 1 5302 727 2 rev 01 Q LOMBARDINI TECHNICAL INFORMATION 2 2 12 TABLE OF SEALANTS Area of application Sealant Fuel rail attachment Loctite 638 Oil filter cartridge union M 20X1 5 Loctite 601 Camshaft bearing screw M 6 Loctite 270 Stud bolt for tightening pulley M 10
39. specified by the manufacturer Close all engine openings carefully exhaust intake etc wash the outside and dry with a jet of compressed air Anchor the engine to the rotating stand to facilitate all operations Note the engine may also be placed on the workbench depending on the type of work to be carried out Service Manual LDW 502 automotive _ cod 1 5302 727 2 ed rev 01 7 LOMBARDINI GENERAL REMARKS AND SAFETY Service Manual LW 502 automotive _ cod 1 5302 727 2 ed rev 01 LOMBARDINI 2 1 GENERAL DESCRIPTION OF THE ENGINE Main components A Oylinder head B Engine block C Crankcase D Timing belt assembly E Flywheel and crankshaft assembly F Airintake assembly G Cooling fan H Negative pressure vent valve TECHNICAL INFORMATION 2 L Alternator M Oil filter N Exhaust manifold P Starter motor Q Camshaft R Coolant pump S Fuel supply pump T Oil pump Service Manual LDW 502 automotive _ cod 1 5302 727 2 ed rev 01 9 LOMBARDINI 2 2 TECHNICAL SPECIFICATIONS 112 Q TECHNICAL INFORMATION 2 DIMENSIONS mm A 451 C 353 E 181 H 36 N 340 51 R 182 B 491 D 238 G 213 M 280 P 151 DOC 5 160 1 with suction fan 2 with blower fan GENERAL DETAILS Op
40. that it runs at maximum efficiency 1 Remove the protective treatment 2 Remove any blockages from the exhaust and intake ducts 3 Useacloth soaked in degreasing product to remove the external protective treatment 4 Remove the intake manifold 5 Inject lubrication oil no more than 2 cm into the valves and replace the intake manifold 6 Adjust the alternator fan belt tension 7 Turn the flywheel manually to check the movement of the mechanical parts 8 Startthe engine and run at 34 of the maximum speed for 5 10 minutes 9 Switch off the engine 10 Remove the protective oil to replace with engine oil 11 Introduce new oil see Table of lubricants up to the correct level marked on the dipstick 12 Check the filters for aging air oil fuel and if necessary replace them with original spares E Important Over time a number of engine components and lubricants lose their properties even when the engine is not in use and so it is important to consider whether they need replacing based not only on the number of hours of use but also on age and wear 13 Install the engine onto the machine and make the necessary connections and unions 14 Make sure that electrical contacts are intact and efficient 15 Check that the engine oil and coolant are up to level 16 Start the engine and keep at minimum speed for a few minutes 17 Check for leaks and if necessary find and eliminate the cause
41. the rocker arm and the valve 0 2mm 3 Repeat the same operation on the other valves 6 3 7 Checking clearance volume 1 Position the pistons at the top dead centre 2 Measure the distance in four diametrically opposite points on the piston crown 3 Repeat the operation on all pistons The maximum value determines the measurement A Choose the gasket corresponding to the measured value This match determines the value of the clearance volume see Table of head gasket and clearance volume values Table of head gasket and clearance volume values Clearance Number of holes volume mm gt 0 39 0 48 11721 25 fet 0 40 0 48 52 Service Manual LW 502 automotive _ cod 1 5302 727 2 ed rev 01 5 LOMBARDINI 6 3 8 Calibrating the injector To carry out setting the injector pump must be disassembled from the engine Per conoscere la procedura corretta vedi Smontaggio pompe iniettori 1 Remove the non return valve A and replace it with the plug supplied with the 7107 1460 074 tool 2 Mount the tool head B and fasten with the screws 3 Connect the pump for calibrating the diesel injectors to the head union 4 Press the pump and bring to a pressure of 130 bars for 10 sec in order to check the needle seal Replace the nozzle see Nozzle injector replacement if there is any dripping 5 Pressthe pump again and check to see whether the fuel comes out at a
42. to be installed see Check clearance volume 3 Make sure that the length of the screws H does not exceed 92mm otherwise replace 4 Lubricate the screws copiously H 5 Mount the cylinder head L and put in the screws H Important 6 Tighten the screws in sequence see If the screws H belong to 10 9 class the tightening diagram to a temporary torque of 40 torque is 60Nm and it is not necessary to tighten them Nm further AN Important Use torque wrench with an angle torque tool to tighten the screws 7 Tighten the screws further clockwise rotating 90 8 Tighten the screws to their final torque rotating 90 7 6 3 Assembling the camshaft AN Important Make sure that the camshaft and it s housing are perfectly intact and clean 1 Lubricate the camshaft and its housing 2 Insert the camshaft into its housing 3 Mount a new O ring onto the cover B 4 Mount the cover B and tighten the screws to a torque of 10 Nm Service Manual LDW 502 automotive _ cod 1 5302 727 2 ed rev 01 71 LOMBARDINI 7 6 4 Assembling the speed governor flow limiter AN Important Make sure that all components are perfectly clean and dry Check that all components are intact and if necessary replace them with original spares 1 Mountthe levers C and pivot them with the screw D to a torque of 0 70 Nm 2 Install the flow limiter 3 Mount t
43. with lubricant oil to prevent them from rusting 42 Service Manual LW 502 automotive _ cod 1 5302 727 2 ed rev 01 3 LOMBARDINI OVERHAULS AND TUNING 6 6 2 4 Dimensional check of sealing rings 1 Place a sealing ring in the cylinder and measure the distance between the two tips using a thickness gauge H 2 Repeat for all the sealing rings If the distance between the tips does not correspond to the indicated values replace the sealing ring with an original spare see Dimensional table of sealing rings Dimensional table of sealing rings tips mm mm 0 25 0 45 3 Putthe sealing rings on the piston in the order shown in the figure AN Important Place the sealing rings with the markings facing up towards the upper part of the piston crown 4 Using thickness gauge measure the clearance of each sealing ring If clearance does not correspond to the values shown replace the sealing rings with original spares Table of sealing rings clearance Sealing rings Clearance mm Sealing rings cannot be replaced separately Protect the contact surfaces with lubricant oil to prevent them from rusting Service Manual LDW 502 automotive _ cod 1 5302 727 2 ed rev 01 43 LOMBARDINI OVERHAULS AND TUNING 6 2 5 Dimensional check and overhaul of crankshaft 1 Wash the cranksha
44. 01 11 TECHNICAL INFORMATION 2 5 LOMBARDINI 2 3 CHARACTERISTIC CURVE DIAGRAMS Power curve diagram 80 1269 CEE 95 1 CE 3000 rpm Caption o S o o E 8 8 E N e E s N N o o Ei o 8 8 N Power curve NB t Torque curve Specific consumption curve MB C Power curve diagram 80 1269 CEE 95 1 CE 3600 rpm CIE TT ED Service Manual LW 502 automotive _ cod 1 5302 727 2 ed rev 01 12 LOMBARDINI TECHNICAL INFORMATION 2 2 4 ALTERNATOR LOAD CURVE DIAGRAMS Internal load curve diagram Reading taken after heat stabilisation at 25 and constant voltage 13 5V P 4 2 2 5 c x 3 o To determine engine r p m s check the gear ratio cos ED JR Meuse adapted to pulleys Alternator RPM External load curve diagram Reading taken after heat stabilisation at 20 and constant voltage 12 5V Current supplied A 1000 1500 2000 2500 3000 3500 4000 The alternator turns at the same rate as the engines Alternator RPM Service Manual LDW 502 automotive _ cod 1 5302 727 2 ed_rev 01 13 5 LOMBARDINI 2 5 LUBRIFICANTS TECHNICAL INFORMATION 2
45. 502 automotive _ cod 1 5302 727 2 ed rev 01 77 C LOMBARDINI INSTALLATION OF ASSEMBLIES 7 7 8 INSTALLATION OF THE COOLING FAN BELT DRIVE 7 8 1 Assembling the fan belt drive pulleys 1 Check that all components are intact and if necessary replace them with original spares 2 Mount the pulley G1 and fasten the screws without tightening them 3 Tighten the screws in a crisscross pattern to a final torque of 10 Nm 4 Mount tool 7107 1460 051 to inhibit rotation of the crankshaft 5 Apply some anti seize product to the screw thread L Caution Warning The screw is left handed Turn anticlockwise to screw 6 Tighten the screw L to a torque of 180 Nm 7 Remove the tool M 8 Install the starter motor N and tighten the screws to a torque of 45 Nm 78 Service Manual LW 502 automotive _ cod 1 5302 727 2 rev 01 LOMBARDINI 9 10 Mount the pulley P washers and Spacer Tighten the screw Q to a torque of 25 Nm 7 8 2 Assembling the fan belt drive The engine may have an external or internal alternator With internal alternator 1 2 3 Install the belt flange and the pulley hub R Tighten the screws S to a torque of 10 Nm Carry out belt tension see Replacing alternator fan belt With external alternator Install the flange and the pulley hub R Tighten the screws S to a tor
46. 6 2 18 mm a 50 Service Manual LW 502 automotive _ cod 1 5302 727 2 ed rev 01 5 LOMBARDINI OVERHAULS AND TUNING 6 6 3 5 Checking and overhaulimg the valves In order to carry out a control of the valves it is necessary to remove them from the cylinder head See Disassembling the valves for the correct procedure 1 Use a gauge to measure the length of the springs see Table of dimensions for springs valve stems valve guides Table of dimensions for springs valve stems valve guides S cca Wear amp tear limit 7 005 7 020 6 960 6 990 43 5 46 0 valve guide If the length does not correspond to the value shown replace the springs with original spares 2 Use a micrometer to measure the diameters of the valve stems and guides see Table of dimensions for springs valve stems valve guides If the diameters do not correspond to the values show replace the valves and guides with original spares AN Important Take measurements in several places in order to discover possible ovalization and or wear valve seat 3 Thoroughly clean the valves and their seats 8 Use the special tool to put the valve seats in the holder 4 Measure the width of the seal for each valve J and the indentation W from the flat part of the cylinder head see Table of dimensions for springs valve stems valve guides If the dimensions
47. DJUSTING MINIMUM AND MAXIMUM IDLE SPEED RPMS 1 Connect a revolution counter to the engine 2 Run the engine and bring it to the operating temperature 3 Turn the idle adjusting screw A and set the engine to the minimum speed required 4 Tighten the lock nut B when finished AN Important To decrease the rpm number loosen the screw To increase it tighten the screw 5 Turn the peak rpm adjusting screw D and set the engine to the maximum speed required 6 Tighten the lock nut C when finished AN Important To decrease the rpm number tighten the screw whereas to increase it loosen the screw 6 9 ADJUSTING INJECTION DELIVERY The adjustment may be performed with the dynamometric brake accurate adjustment or without it approximate adjustment 6 9 1 Adjusting injection delivery without dyno break 1 Loosen locknut A 2 Firmly tighten the screw B of the flow limiter 3 Start the engine and bring it to the operating temperature 4 Bring the engine to maximim rpm allowed 5 Loosen the screw B of the flow limiter until the engine speed starts to decrease 6 Retighten the screw rotating it 2 5 revolutions then fasten with the lock nut A 60 Service Manual LW 502 automotive _ cod 1 5302 727 2 rev 01 LOMBARDINI OVERHAULS AND TUNING 6 6 9 2 Adjusting injection delivery with dyno break 1 Start the engine and brin
48. Distribution timing angle diagram 10 Repeat these procedures on the other valves 54 Service Manual LW 502 automotive _ cod 1 5302 727 2 ed rev 01 LOMBARDINI 6 5 DIAGRAM OF TIMING BELT RATES Rotate the crankshaft clockwise to find out the timing rates of the entire cycle in each cylinder operation and control Timing belt operating angles valve clearance 0 25 mm a 14 before S top dead center 38 after I bottom dead center y 34 before I bottom dead center 6 18 after S top dead center Timing belt control angles valve clearance 2 mm 25 after S top dead center B closes 2 after I bottom dead center y 5 after I bottom dead center 6 18 before S top dead center 6 6 ADJUSTING STATIC INJECTION TIMING In order to adjust injection timing it is necessary to remove the rocker arm cover See Disassembling rocker arm cover for the correct procedure 1 Disassemble the injector pump fuel rail A 2 Selectthe cylinder on which the injection static advance adjustment will be carried out 3 Unscrew the rocker arm support nut B corresponding to the cylinder on which the procedure will be carried out OVERHAULS AND TUNING Legenda S piston at top dead center l piston at bottom dead center a intake valve open intake valve closed y exhaust valve open 6 exhaust valve closed Service Manual
49. Important To locate specific topics the reader should refer to the index Service Manual LDW 502 automotive _ cod 1 5302 727 2 ed rev 01 83 Q LOMBARDINI REPLACING PARTS 5 Adjust the alternator manually while at the same time tightening the screw to regulate belt tension AN Important Use the method shown in the diagram to check belt tension The resultant R must be 10 15 mm 6 Tighten the nuts B B1 to a final torque of 40 Nm and 25 Nm respectively With internal alternator 1 Switch off the engine and leave to cool V fl 2 Remove the cooling fan fan hub PU e 3 Remove the hub and flange 4 Slip off the belt and replace it with an original spare 5 Install the flange and pulley hub a 6 Manually rotate the fan to make sure the cd E belt is fitted correctly 7 Tighten the screws to a torque of 10 Nm 8 Regolare la tensione della cinghia AN Important To check the belt tension follow the procedure explained in the figure The resultant R must be 10 15 mm If the belt is too tense insert a spacer between the flange and the pulley or remove a spacer if it is too slack 84 Service Manual LW 502 automotive _ cod 1 5302 727 2 rev 01 A LOMBARDINI REPLACING PARTS 8 9 Install the cooling fan 10 Tighten the screws to a torque of 10 Nm SE fan hub pulley 8 3 REPLACING THE
50. LDW 502 automotive _ cod 1 5302 727 2 rev 01 25 LOMBARDINI 4 4 PROTECTIVE TREATMENT 1 Check that the engine oil and coolant are up to level 2 Start the engine and keep idle at minimum speed for 15 minutes 3 Switch off the engine and leave to cool 4 Take out the lubricant 5 Fill the casing with AGIP RUSTIA C protective oil 6 Empty the fuel tank completely 7 Replace fuel filter 8 Fill the fuel tank with a mixture made up of 1096 AGIP RUSTIA NT protective oil and 9096 fuel 9 Release the air from the fuel supply circuit 10 Start the engine and check for fuel leaks 11 Start the engine and bring to 34 of the maximum speed for 5 10 minutes 12 Switch off the engine 13 Spray SAE 10W oil on the exhaust and intake STORING THE ENGINE 4 manifolds 14 Close all openings to prevent foreign bodies from entering 15 Thoroughly clean all external parts of the engine using suitable products 16 Treat non painted parts with protective products AGIP RUSTIA 100 F 17 Loosen the alternator fan belt 18 If necessary cover the engine with a protective sheet AN Important After a year of engine inactivity the coolant loses its properties and must be replaced 4 5 PREPARING THE ENGINE FOR OPERATION UNINSTALLED After period of inactivity and before installing and running the engine it is necessary to carry out a few measures in order to ensure
51. LDW502 Pa wee ag bie code 1 5302 727 SERVICE MANUAL S LOMBARDINI LOMBARDINI REGISTERING DOCUMENT MODIFICATIONS This document is made up of 98 pages sides excluding the cover and title page Pages are numbered in progressive order from 051135 01 to 051135 98 Any modifications to this document must be registered by the drafting body and approved by the head of the Quality Management System with completion of the table below Document Replaced Added Eliminated Drafting bod Copyright 2005 Lombardini Reproduction even partial of this document is subject to the manufacturer s written authorisation The manufacturer is committed to a policy of continuing improvement and reserves the right to modify the document with no obligation to notify providing that omission to do so constitutes no safety risk The text may be reproduced in part or in whole providing that the author is cited Text and graphics by IDM Esperti in Comunicazione Tecnica Forli 2 Service Manual LW 502 automotive _ cod 1 5302 727 2 ed rev 01 LOMBARDINI ch sch cnn cll oh un 3 1 5 1 5 2 5 2 1 5 2 2 GENERAL REMARKS AND SAFETY PURPOSE OETHEMANUAL nnm 5 USING THIS 5 MANUFACTURER AND ENGINE IDENTIFICATION 5 GLOSSARY AND TERMINOLOGY 6
52. Loctite 601 Oylinder head plug 18 Loctite 510 Engine and engine block cylinder head plug 30 Loctite 510 2 13 ROUTINE ENGINE MAINTENANCE After the first REGULARITY KM per 1000 Km 500 Km PROCEDURE DETAL injectors CLEANING ERR Valve and rocker arm clearance Engine oil Solenoid valve operation Oil vapor CHECK recovery Fuel pipe and connections Coolant Alternator belt Timing belt Alternator Air filter element Engine oil Oil filter CHANGE Fuel filter Coolant Alternator belt Timing belt EVERY 50000 Km or at every disassembly Fuel pipes EVERY 4 years Service Manual LDW 502 automotive _ cod 1 5302 727 2 ed rev 01 21 LOMBARDINI TECHNICAL INFORMATION 2 Service Manual LW 502 automotive _ cod 1 5302 727 2 ed rev 01 LOMBARDINI MALFUNCTIONS 3 3 1 LOOKING FOR MALFUNCTIONS The following information is provided to help identify and correct any irregularities and malfunctions that may arise during use Problem S g S H o t L S c S8 E lt 2 o w 5 o D 5 2 9 g 992 a 2 55 8566 Probable cause S S 2 a S 2 8 112 2 8 S9 9 59 rt 5 518 55 5 58 8 sz
53. NG PRINCIPLE FOR COOLING I Description Coolant refilling plug Compensation tank Thermostatic valve Oylinder block Liquid temperature monitoring thermostat Circulating pump Fan INI Radiator Service Manual LDW 502 automotive _ cod 1 5302 727 2 rev 01 15 LOMBARDINI 2 8 OPERATING PRINCIPLE FOR FUEL INJECTION With mechanical supply pump TECHNICAL INFORMATION 2 D Q Description Tank Fuel filter Supply pipe Supply pump Injection pump Injector Fuel rail NI B G Po Exhaust pipe co Plug 10 Solenoid valve Note the tank is supplied complete with filter on request With electrical supply pump I f Description Tank Fuel filter Supply pipe Electrical supply pump Pump Injector Fuel rail Exhaust pipe O MINSID TO R O Pp Plug 16 Service Manual LW 502 automotive _ cod 1 5302 727 2 ed rev 01 LOMBARDINI 2 9 WIRING DIAGRAM TECHNICAL INFORMATION 2 Electric pump version With external alternator NUS Aus 15 40A 16 p 22 NN L IG M AP B ROSS ROUGE RED ROT ROJO VERMELHO A
54. TIMING BELT AN Important 4 Replace the timing belt with an original spare see Replacement may be carried out with the engine Assembling the timing belt drive installed on the machine 5 Check the timing belt rating see Checking timing 1 Switch off the engine and leave to cool belt rating 2 Disassemble the cooling fan belt drive see 6 Mountthe belt drive cover see Assembling the belt Removing the cooling fan belt drive drive cover 3 Disassemble the timing belt drive see Removing 7 Replace the cooling fan belt drive see Installation the timing belt drive of the cooling fan belt drive 8 4 REPLACING THE OIL FILTER AN Important Replacement may be carried out with the engine installed on the machine 1 Switch off the engine and leave to cool 2 Prepare a receptacle to catch leaks 3 Remove the filter A using the special tool 4 Lubricate the new filter seal with engine oil 5 Install and tighten the filter manually AN Important Polluting substances should be disposed of properly in full compliance with the law Service Manual LDW 502 automotive _ cod 1 5302 727 2 ed rev 01 85 LOMBARDINI REPLACING PARTS 8 8 5 REPLACING THE AIR FILTER AN Important Polluting substances should be disposed of properly in full compliance with the law Replacement may be carried out with the engine installed on the machine Air fil
55. ZZUARO AZUR BLUE SA AZUL Azur 30 Z re 5 gr AZZURRO RO 2 AZUA Ref Description Ref Description 1 40A alternator 13 Coolant thermostat indicator light 2 Starter motor 14 Engine oil preassure lamp 3 Batter recommended 44Ah 210A DIN 15 Oil preassure gauge 4 Preheating glow plugs 16 Battery load indicator 5 Coolanttemperature monitoring sensor 18 Coolant thermometer 6 Glow plug pre heating control box 19 Coolant thermomenter sensor 7 Ignition switch 20 Fuel level light 8 50A fuses 21 Fuel level indicator 9 5A fuses 22 Relay normally closed with a 3 second delay 40 50 A 10 Electrostop device or electrical fuel lift pump Electrical fuel lift pump 23 11 Glow plugs indicator 12 Coolant temperature indicator Service Manual LDW 502 automotive _ cod 1 5302 727 2 ed rev 01 17 LOMBARDINI TECHNICAL INFORMATION Electric pump version With internal alternator RED NESS tar e BLACK 12 qm BROWN YELLOW D Description Ref Description 40A alternator 13 Coolant thermostat indicator light Starter motor 14 Engine oil preassure lamp Battery recommended 44Ah 210A DIN 15 Oil preassure gauge Preheating glow plugs 16 Battery load indicator Coolant temperature mo
56. aces B are perfectly level with a deviation of no more than 0 05 mm If the deviation is greater than this replace the speed governor with an original spare Service Manual LDW 502 automotive _ cod 1 5302 727 2 ed rev 01 53 Q LOMBARDINI OVERHAULS AND TUNING 6 4 CHECKING TIMING BELT RATING 6 4 1 Valve adjustments Fan drive pulley 1 Bring the piston to the compression top dead centre 2 Adjust the screw A and the lock nut in order to adjust the rocker arm valve clearance to 2 mm 3 Rotate the crankshaft clockwise through 360 in order to make the piston reaching magnetic the balancing top dead centre goniometer 4 Apply a magnetic goniometer on the crankshaft pulley and set it to zero 5 Place two dial indicators on the collars of the intake and exhaust valves then set them to zero 6 Rotate the crankshaft clockwise until the dial indicator moves away from zero 7 Measure the rotation angle of the crankshaft by using the magnetic goniometer The value registered indicates when the intake valve starts opening 8 Go on rotating the crankshaft clockwise until the dial indicator stops at point 0 Exhaust 9 Measure the rotation angle of the valve crankshaft by using the magnetic goniometer The value registered indicates when the intake valve starts closing The values registered must coincide with those indicated on the timing angle diagrams see
57. an the pistons and lubricate the coupling areas Put the sealing rings on the piston in the order shown in the figure AN Important Place the sealing rings with the markings facing up towards the upper part of the piston crown Keep the pistons together with their own connecting rods and wrist pins For safety and convenience you are advised to place the engine on special rotating stand for engine overhauls Before proceeding with operations make sure that appropriate safety conditions are in place in order to safeguard the operator and any persons involved In order to fix assemblies and or components securely the operator must tighten the fastening parts in a criss cross or alternating pattern Assemblies and or components with specific tightening torque must initially be fastened at level lower than the assigned value and then subsequently tightened to the final torque Service Manual LDW 502 automotive _ cod 1 5302 727 2 ed rev 01 63 LOMBARDINI INSTALLATION OF ASSEMBLIES 7 7 3 PRE ASSEMBLY OF CONNECTING RODS PISTONS AN Important Before pre assembly check that the weight difference between the two connecting rod piston wrist pin assemblies does not exceed 10 g to prevent weight imbalances 1 Lubrificate the wrist pin A and the seat of the small end of the connecting rod B 2 Place the lock ring C on the piston comple
58. ave to cool NG 2 Disconnect the electrical connectors e N A Remove the thermostat AN Important The screw is left handed turn clockwise to unscrew 4 Install the new thermostat 5 Tighten the thermostat to a torque of 30 Nm AN Important The screw is left handed turn anti clockwise to tighten 6 Reconnect the electrical connectors 88 Service Manual LW 502 automotive _ cod 1 5302 727 2 ed rev 01 LOMBARDINI 8 10 REPLACING THE COOLANT PUMP AN Important Replacement may be carried out with the engine installed on the machine 1 Switch off the engine and leave to cool 2 Disassemble the cooling fan see Removing the cooling fan belt drive 3 Disassemble the timing belt drive see Removing the timing belt drive 4 Disassemble the coolant pump 5 Install a new pump and tighten the screws to a torque of 20 Nm AN Important Following a failure the coolant pump cannot be repaired and must be replaced with an original spare 8 11 REPLACING THE THERMOSTATIC VALVE AN Important Replacement may be carried out with the engine installed on the machine 1 Switch off the engine and leave to cool 2 Remove the cover 3 Remove the valve and make sure it is working properly AN Important The valve must be heated in order to check weather it is functioning correctly Dip the thermostatic valve in metal container of water Use a thermomete
59. d of uprated of uprated shoulder half rings EEN E C A B Protect the contact surfaces with lubricant oil to prevent them from rusting 44 Service Manual LW 502 automotive _ cod 1 5302 727 2 ed rev 01 LOMBARDINI 6 2 6 Dimensional check and overhaul of connecting rods 1 Check that the contact surfaces are perfectly clean and intact Assemble the cap D onto the connecting rod big end and tighten the screws to a torque of 38 Nm 40 Nm x PROGRESS Using a micrometer measure diameters ga b AN Important If the diameter of the conncting rod small end does not match the diameter of the wrist pin the connecting rods must be replaced to achieve the right match see Table of connecting rod dimensions The half bearings are supplied smaller than the nominal dimensions by 0 25 mm and 0 50 mm Before replacing the connecting rods check that the weight difference does not exceed 10g to prevent weight imbalances see Table of connecting rod dimensions Protect the contact surfaces with lubricant oil to prevent them from rusting J 3 6 2 7 Checking parallelism of the connecting rod axes 1 Insert the wrist pin V in the connecting rod small end 2 Useadial indicator to check that there is parallelism between the small end and big end axes Parallel deviation measured at the very tip of the wrist pin must not exceed 0 015 0 030mm I
60. dere eite dee erc d 47 Checking and overhauling the cylinder head 47 Checking and overhauling the rocker arm pin 48 Checking and replacing the camshaft 49 Checking and replacing the fuel pump drive rod 50 Checking and overhauling the valves 51 Adjusting valve rocker arm clearance 52 Checking clearance volume 52 Calibrating the 53 Checking and overhauling the speed governor 53 CHECKING TIMING BELT RATING 54 Valve adjustments AAA 54 DIAGRAM OF TIMING BELT RATES 55 ADJUSTING STATIC INJECTION TIMING 55 BALANCING INJECTION PUMP DELIVERY 58 Service Manual LDW 502 automotive _ cod 1 5302 727 2 ed rev 01 LOMBARDINI GENERAL INDEX 6 8 ADJUSTING MINIMUM AND MAXIMUM 8 REPLACING PARTS IDLE SPEED RPMS i ient 60 6 9 ADJUSTING INJECTION DELIVERY 60 8 1 RECOMMENDATIONS FOR REPLACING PARTS 83 6 9 1 Adjusting injection delivery without dyno brake 60 8 2 REPLACING THE ALTERNATOR FAN BELT 83 6 9 2 Adjusting injection delivery with dyno brake 61 8 3 REPLACING THE TIMING BELT 85 6 10 CHECKING OIL PRESSURE
61. e 1 Switch off the engine and leave to cool 2 Disassemble the cooling fan belt drive see Removing the cooling fan belt drive 3 Remove the belt drive cover see Disassembling timing belt casing 4 Remove the support A 5 Install the new support 6 Tighten the screws B to a torque of 20 Nm 7 Mountthe belt drive cover see Assembling the belt drive cover 8 Replace the cooling fan belt drive see Installation of the cooling fan belt drive Service Manual LDW 502 automotive _ cod 1 5302 727 2 ed rev 01 93 LOMBARDINI REPLACING PARTS 8 Service Manual LW 502 automotive _ cod 1 5302 727 2 ed rev 01 LOMBARDINI ACEA Standards oeh 14 Adjusting injection delivery sse 60 Adjusting injection delivery with dyno brake 61 Adjusting injection delivery without dyno brake 60 Adjusting minimum and maximum idle speed rpms 60 Adjusting static injection timing 2785 Adjusting valve rocker arm clearance 52 Air filter replacing 86 Alternator fan blet replacing 83 Alternator load curve diagrams 13 Alternator replacing reete enhn nnns 87 API MIL seque
62. e shaft complete with crankcase See Assembling the crankcase for the correct procedure 1 Using a dial indicator measure the axial shift of the crankshaft Axial shift must be between 0 130 and 0 313mm If axial shift is above these values it is necessary to insert uprated shoulder half rings and once again disassemble the crankcase see Dimensional check and overhaul of crankshaft 7 5 5 Assembling the crankshaft flange flywheel side 1 Clean the flange and the sealing ring seat N 2 Using the special pad insert a new sealing ring N into the flange Q AN Important Given the particular function played by this sealing ring it is important to use only original spares 3 Check that the contact surfaces are perfectly clean and intact Service Manual LDW 502 automotive _ cod 1 5302 727 2 ed rev 01 67 Q LOMBARDINI INSTALLATION OF ASSEMBLIES 7 4 Slip on new gasket 5 Replace the falnge Q and put in the screws R AN Important Be careful not to damage the sealing rings during this operation 6 Tighten the screws in crisscross pattern to a final torque of 12Nm 7 5 6 Installing the oil pump Before installing the oil pump make sure there are no malfunctions see Check and overhaul the oil pump T Check that the contact surfaces are perfectly clean and intact 1 Slip on a new gasket A 2 Insertthe oil pum
63. e nut B to a final torque of 40 Nm AN Important Repeat on the other cylinder Service Manual LDW 502 automotive _ cod 1 5302 727 2 ed rev 01 57 LOMBARDINI 23 Once adjustment is finished assemble the new O rings D on the injector pumps Important The O rings must always be replaced with original spare parts whenever the fuel rail is disassembled 24 Apply some silicone sealant on the fuel rail seat 25 Assemble the fuel rail and fasten the screws without tightening them 26 Tighten the screws to a final torque of 4 Nm 27 Slip on a new gasket P 28 Reassemble the rocker arm cover see Assembling the rocker arm cover OVERHAULS AND TUNING 6 6 7 BALANCING THE INJECTION PUMP DELIVERY AN Importante It is necessary to balance delivery whenever the injection pump is replaced In order to work on the injector it is necessary to remove the rocker arm cover See Disassembling the rocker arm cover for the correct procedure 1 Remove the fuel rail A 2 Mount the 7107 1460 127 tool heads B 58 Service Manual LW 502 automotive _ cod 1 5302 727 2 ed_rev 01 Q LOMBARDINI OVERHAULS AND TUNING 6 3 Position the assembly 7107 1460 127 above the height of the injectors Ve S assembly 4 Connect the outlet and intake pipes of 7107 1460 127 the assembly t
64. e to the coupling 8 13 REPLACING THE PREHEATING GLOW PLUGS AN Important Replacement may be carried out with the engine installed on the machine pre heating glow plugs 1 Switch off the engine and leave to cool 2 Remove the intake manifold see Disassembling the intake manifold 3 Disconnect the electric cable 4 Disconnect the preheating glow plugs 5 Install the new preheating glow plugs and tighten the screws to a torque of 20 Nm 6 Reconnect the electric cable 7 Mount the intake manifold see Assembling the intake manifold 90 Service Manual LW 502 automotive _ cod 1 5302 727 2 ed rev 01 LOMBARDINI REPLACING PARTS 8 8 14 REPLACING INJECTOR PUMP PARTS Exploded diagram of the injector pump The figure shows the injector pump parts Caption 1 Tension washer 2 Tappet 3 Stop collar 4 Plunger Spring Screw Support Lever Ring nut 10 O ring 11 Barrel 12 Delivery valve 13 Gland 14 Spring 16 Pin 17 O ring 18 Non return valve 19 O ring 20 Metal gland new type 21 Ring nut 23 Nozzle 24 Spacer 15 S 15 Filler SZ 32 ODO 25 Preassure rod 30 Plunger guide 26 Spring 31 O ring 27 Setting adjusting shim 32 Copper gland 28 Injector case 29 Control blade 8 14 1 Pumping element replacement 1 Press down hard on the pump collar to fit the pin A 2 Disassemble the lock ring 1 3 P
65. earance valve rocker arm adjusting 52 Connecting rod piston engine block installing 65 Connecting rod and piston disassembling 39 Connecting rod axes checking parallelism 45 Connecting rod dimensions 45 Connecting rods pistons pre assembly 64 Connecting rods and half bearings table of diameters 44 Connecting rods dimensional check and overhaul 45 Conversion table for establishing injection timing 57 Coolant pump replacing 89 Coolant thermostat replacing see 88 Coolinf fan belt drive removing Cooling fan belt drive installation Cooling fan blet with external alternator disassembling Cooling fan blet with internal alternator disassembling Cooling fan support replacing Cooling fan assembling Cooling operating principle Crank gear and crankcase removing Crank gears and crankcase overhauling Crankcase and crank gear removing
66. elt with internal alternator 1 Remove the hub E and flange 2 Remove the belt D 3 Remove the pulley F washers and spacer 5 4 REMOVING THE TIMING BELT 5 4 1 Disassembling the timing belt casing 1 Disassemble the starter motor 2 Install tool 7107 1460 051 to inhibit rotation of the crankshaft Loosen the screw G Caution Warning The screw is left handed Turn clockwise to unscrew tool 7107 1460 051 Service Manual LDW 502 automotive _ cod 1 5302 727 2 ed rev 01 31 Q LOMBARDINI REMOVING THE ASSEMBLIES 5 4 Loosen the screws and remove the pulley H 5 Remove the casing L 5 4 2 Disassembling the timing belt 1 Twist the pulley nut M to fully loosen the belt N 2 Remove the belt N working it away in sequence first from the pulley and P and then from the others AN Important The timing belt must always be replaced with an original spare part whenever it is removed 5 4 3 Disassembling the pulleys camshaft and crankshaft 1 Remove the pulley P 2 Remove the pulley Q 32 Service Manual LW 502 automotive _ cod 1 5302 727 2 ed rev 01 LOMBARDINI 5 5 REMOVING THE CYLINDER HEAD 5 5 1 Disassebling the rocker arm cover 1 Removethe negative pressure vent valve A 2 Remove the rocker arm cover B 3 Remove the gasket C 5 5 2 Disassebling the rocker arms 1 Pres
67. ength of the spring is not between 27 50 and 27 75mm replace it with an original spare 9 Replace the valve G the spring F the gasket E and the plug D 10 Fill the sealing ring C with grease and lubricate the rim with oil 11 Mount the new sealing ring C using a special tool AN Important Given the particular function played by this sealing ring it is important to use only original spares 12 Mount the rotors with the referance notches facing upwards so that they are visible 13 Using a thickness gauge measure the clearance between the rotor teeth If clearance is above the 0 25mm limit for wear replace the rotors with original spares 14 Check that the contact surfaces are perfectly clean intact and not deformed 15 Mount the new O ring OVERHAULS AND TUNING 6 AN Important The O ring must always be replaced with an original spare part whenever the pump is disassembled 16 Replace the plate A and put in the screws L 17 Tighten the screws L to torque of 10 Nm 46 Service Manual LW 502 automotive _ cod 1 5302 727 2 ed rev 01 LOMBARDINI OVERHAULS AND TUNING 6 6 2 9 Overhauling the decanting device In order to overhaul the decanting device it is necessary to disassemble the starter motor See Replacing the starter motor for the correct procedure 1 Loosen the clamp and extract the pipe A 2 Remo
68. erating cycle 4 stroke diesel Number of cylinders Bore x stroke Displacements Compression rate 22 81 Intake Air filter dry Filter capacity 13 14 Filtering surface cm 4470 Cooling Water Driving shaft rotation Clockwise from distribution side Combustion sequence 1 2 Timing system Synchronous toothed belt Dry weight of engine Kg Maximum tilt while operating no more than 1 minute Maximum tilt while operating no more than 30 minutes Volume of air flow at 3800 RPM Nimm Volume of cooling air at 3600 RPM m min 36 POWER AND TORQUE Maximum operating speed RPM 3600 Max power N 80 1269 EEC ISO 1585 DIN 7020 kW CV 9 8 13 4 Max power NB ISO 3046 1 IFN DIN 6270 kW CV 9 1 12 4 Max power NA ISO 3046 1 ICXN DIN 6270 kW CV 8 2 11 2 Maximum torque at 2400 RPM Nm 28 7 Axial load allowed on driving shaft Kg 300 10 Service Manual LW 502 automotive _ cod 1 5302 727 2 ed rev 01 LOMBARDINI TECHNICAL INFORMATION 2 CONSUMPTION AT MAXIMUM POWER Specific fuel onsumption g kWh Specific oil consumption Kg h SUPPLY CIRCUIT Indirect injection Car diesel Electric or membrane pump Screw on or in line fispino Filter paper m PF905 Filtering surface cm
69. es of the cylinders using emery cloth Protect the contact surfaces with lubricant oil to prevent them from rusting The table shows the reference values and their class only applies to new engines 6 2 3 Dimensional check and overhaul of pistons 1 Clean the piston thoroughly D 2 Using a micrometer measure the piston 9mm from the base of the skirt 3 Checkthe table to identify the class from the values detected The class letter is engraved on the piston If clearance between cylinder and piston is greater than 0 05mm the piston and sealing rings must be replaced and rematched according to the diameter of the ground cylinders see Table of cylinder piston classes and dimensions AN Important Before replacing the pistons check that the weight difference does not exceed 49 to prevent weight imbalances OVERHAULS AND TUNING 6 AN Important Pistons with nominal diameter are supplied only in class A spares Those uprated by 0 5 and 1 mm have the uprating referance 072 5 e 973 engraved on the upper part of the piston see Table of cylinder piston classes and dimensions Table of cylinder piston classes and dimensions Dimension Cylinders Q Pistons clearance mm mm mm 71 990 72 000 71 930 71 940 72 000 72 010 71 940 71 950 0 05 0 07 72 010 72 020 71 950 71 960 72 100 72 120 72 031 72 049 iota Y H 6 mm Protect the contact surfaces
70. f parallel values do not correspond to those indicated replace the connecting rod with an original spare connecting rod small end connecting 3 After carrying out all checks and rod overhauls remount the connecting rods pistons and sealing rings see Pre assembly of sealing rings pistons and Pre assembly of connecting rods pistons Important Protect the contact surfaces with lubricant oil to prevent them from rusting connecting rod big end 19 995 20 000 OVERHAULS AND TUNING connecting rod Table of connecting rod dimensions Clearance wear amp tear limit mm 109 975 110 025 20 010 20 020 b c 0 010 0 025 40 020 40 035 55 000 55 020 Wear Clearance and tear mm limit mm m Dimensions mm T r Service Manual LDW 502 automotive _ cod 1 5302 727 2 ed rev 01 45 LOMBARDINI 6 2 8 Check and overhaul of the fuel pump Disassemble the oil pump before checking or overhauling See Disassembling the oil pump for the correct procedure 1 Remove the plate A 2 Remove the O ring B 3 Remove the sealing ring C from the flange and clean the seat 4 Unscrew the oil D and extract the gasket E the spring F and the valve G 5 Disassemble the rotors H 6 Blow compressed air into the valve seat to clean it 7 Thoroughly clean all the components 8 Measure the length of the spring F If the l
71. ft thoroughly using suitable detergent 2 Introduce a pipe cleaner into the lubrication ducts to remove any residual dirt 3 Blow compressed air into the points indicated to free the ducts from oil 4 Check the surfaces of the main journals and crank pins for wear and tear to see whether grinding is necessary 5 Usingamicrometer measure the diameter of the main journals A1 and crank pins B1 6 Using a dial indicator measure the inside diameters of the crankshaft A2 and connecting rod B2 half bearings 47 9844 47 984248 000 000 47 47 900 A2 A1 0 032 0 016 ANN important 39 894 40 000 39 900 B2 B1 0 021 0 066 Crankshaft half bearings cannot be 10020 40035 replaced separately Table of diameters of Seen rods and half bearings PROGRESS If the crankshaft needs to be ground i i Dimension Max establish the diameters of the ensions clear connecting rod and crank pins in order mm EZ to choose the matching measurements Ee d 41 available of connecting rod and half A2 A1 0 025 0 087 bearing spare parts see Table of Pe ems as diameters of connecting rods and half 21 39 984 40 000 3955 bearings ES B2B1 0 021 0 066 When grinding the crankshaft it is possible to downrate the crankshaft Table of uprated shoulder half rings and connecting rod pins by 0 25 mm and 0 50 mm necessary to consider grinding the sides shoulder to be able to choose Standar
72. g it to the operating temperature 2 Bring the engine to maximim rpm allowed 3 Loosen the locknut A 4 Firmly tighten the screw B of the flow limiter 5 Activate the dyno brake to bring the engine to maximum power and speed 6 Make sure that fuel consumption corresponds to the recommended values see Table of specific fuel consumption If fuel consumption does not correspond to the values shown reduce the load of the dyno brake 7 After afew minutes of running the engine and when it has stabilised slowly unscrew the limiter screw B until the speed starts to decrease 8 Fasten the screw B with the locknut A 9 Deactivate the dyno brake and take note of the stabilized engine speed 10 Switch off the engine and leave to cool 11 Check the valve rocker arm clearance see Adjusting valve rocker arm clearance 6 10 CHECKING OIL PREASSURE 1 Remove the preassure switch A 2 Mount a union in the hole B and connect to a 10 bar pressure gauge C 3 Start the engine and bring it to the operating temperature 4 Start the engine and bring it to a speed of 900 RPM while at the same time making sure that the pressure gauge shows a pressure of 1 bar oil temperature 80 120 C 5 Switch off the engine 6 Remove the pressure gauge C and the union B 7 Replace the pressure switch A and tighten it to a torque of 25Nm AN Important If the engine gives off too many
73. gned and built to satisfy all the operating conditions described by the manufacturer Do not tamper with any devices to alter the level of performance guaranteed by the manufacturer In order to minimise the impact on the environment the manufacturer now provides a number of indications to be followed by all persons handling the engine for any reason during its expected lifetime All packaging components must be disposed of in accordance with the laws of the country in which disposal is taking place Keep exhaust pipes in efficient working order to limit the noise level of the engine and reduce environmental pollution When discontinuing use of the engine select all components according to their chemical characteristics and dispose of separately 1 9 PRECAUTIONS WHEN THE ENGINE IS INSTALLED ON THE MACHINE All operations except where expressly stated otherwise must be carried out when the engine is not running and has cooled sufficiently to avoid the risk of burns Donotkeepthe engine running in areas that are closed and inadequately ventilated Take all necessary precautions to prevent a build up of exhaust fumes 1 10 PRECAUTIONS WHEN THE ENGINE IS ON THE ROTATING STAND Before removing the engine from the machine on which it is installed disconnect the electric current the fuel supply coolant and all connections including mechanical ones Tolift the engine attach the lifting device at the points eyebolts
74. he rotation components onto the camshaft The rotation components are produced in several versions Consult the diagram when mounting 1 Mountthe weights assembly H onto the camshaft Carry out this operation with the weights open so that they close on the flat part of the spacing collar 2 Check that all the components of the cover L are intact and if necessary replace them with original spares AN Important Make sure that the contact surfaces are perfectly intact and clean 3 Mount the new O ring on the cover L 4 Mount the cover L and fasten the screws without tightening them 5 Tighten the screws in an alternating pattern to a final torque of 10 Nm AN Important Check that the camshaft has no axial clearance INSTALLATION OF ASSEMBLIES 7 Governor counterweight entire support 72 Service Manual LW 502 automotive _ cod 1 5302 727 2 ed rev 01 LOMBARDINI INSTALLATION OF ASSEMBLIES 7 7 6 5 Assembling injection pumps AN Important Check that all components are intact and if necessary replace them with original spares Before replacing the injectors it is always necessary to replace the flameproof bulkhead the copper gasket and the oil and diesel O ring seals Always make sure that the injectors are calibrated correctly see Calibrating and replacing the injector 1 Insertthe flameproof bulkhead
75. heck that the contact surfaces are perfectly clean and intact T 9 10 11 Install the precombustion chamber so that its hole H coincides with the one on the pre heating glow plug Insert tool 7107 1460 031 into the seat of the preheating glow plug in order to lock the chamber while the ring nut B is being tightened Apply some anti seize product to the ring nut thread B and to the surface that is in contact with the precombustion chamber Mount the ring nut B Tighten the ring nutto a temporary torque of 100Nm Make sure that the precombustion chamber protrusion C is between 3 56 4 04 mm If the protrusion C exceeds the recommended value insert a shim D provied ad spare part beneath the precombustion chamber A Tighten the ring nut to a final torque of 180Nm Remove the tool and install the preheating glow plug E Tighten the glow plug to a torque of 20 Nm Repeat the same operations on the other chamber Connect the glow plug power supply cable F 70 Service Manual LW 502 automotive _ cod 1 5302 727 2 ed rev 01 LOMBARDINI INSTALLATION OF ASSEMBLIES 7 7 6 2 Assembling cylinder head AN Important Make sure there are no foreign bodies or residual material in the cylinder head cavity Check that the contact surfaces are perfectly clean and intact 1 Slip on new gasket 2 Choose the gasket shim
76. ications diagrams tightening torques malfunctions etc The fifth sixth seventh and eighth chapters describe the most important operating procedures removal overhaul and tuning installation replacements etc 1 3 MANUFACTURER AND ENGINE IDENTIFICATION The identification plate shown in the figure can be found directly on the engine It contains the model engine identity and all information needed to operate safely A Manufacturer s identity B Engine type C Engine serial number D Maximum speed E Customer code E Approval data GENERAL REMARKS AND SAFETY 1 Important remarks and features of the text are highlighted using symbols which are explained below AY Danger Attention This indicates situations of grave danger which if ignored may seriously threaten the health and safety of individuals A Caution Warning This indicates that it is necessary to take proper precautions to prevent any risk to the health and safety of individuals and avoid financial damage AN Important This indicates particularly important technical information that should not be ignored This final section which is reserved specifically for LOMBARDINI after sales service centres has been prepared with technical and practical considerations in mind However the actual sequence of operations that LOMBARDINI service centres must use may in some cases be different from the ones described in this
77. ings and ducts to prevent foreign bodies from entering Air filter cylindrical type 1 Remove the cover E 2 Disconnect the intake and air vent pipes 3 Remove the intake manifold F 4 Unhook the minimum maximum device or the spring 5 Remove the gasket G 6 Close the openings and ducts to prevent foreign bodies from entering Service Manual LDW 502 automotive _ cod 1 5302 727 2 rev 01 29 LOMBARDINI REMOVING THE ASSEMBLIES 5 5 2 2 Disassembling the exhaust manifold 1 Remove the dipstick tube H 2 Remove the exhaust manifold L 3 Remove the gaskets M 4 Close the openings and ducts to prevent foreign bodies from entering 5 3 REMOVING THE COOLING FAN BELT DRIVE 1 Remove the cooling fan A AN Important with external alternator with internal alternator The cooling fan belt drive comes in more than one version with external or internal alternator 30 Service Manual LW 502 automotive _ cod 1 5302 727 2 ed rev 01 A LOMBARDINI REMOVING THE ASSEMBLIES 5 5 3 1 Disassembling the cooling fan belt with external alternator 1 Loosen the nuts B B1 2 Loosen the belt D by adjusting the alternator C manually 3 Remove the belt D 4 Remove the hub E and flange 5 Remove the pulley F washers and Pulleyflange spacer 5 3 2 Disassembling the cooling fan b
78. k that the position of both lever 8 and plunger control blade 29 is the same as that shown in the figure If the control blade is positioned in a different way the engine may not run 18 Tighten the screws 6 to join the support to the injector pump case 19 Press down hard on the pump collar to remove the pin A REPLACING PARTS 8 delivery valve 12 sealing surfaces 92 Service Manual LW 502 automotive _ cod 1 5302 727 2 ed rev 01 A LOMBARDINI REPLACING PARTS 8 8 14 2 Replacing nozzle injector AN Important Replacement may be carried out with the engine installed on the machine 1 Disassemble the injection pump see Disassembling injection pumps 2 Loosen the ring nut 21 3 Extractthe nozzle 23 and the parts 24 25 26 27 4 Check that all components are intact and if necessary replace them with original spare parts 5 Reassemble the parts 27 26 25 24 6 Assemble a new nozzle 23 7 Tighten the ring nut 21 to a final torque of 70 Nm AN Important Check the setting see Injector pump setting since 8 Repeat the same operation on the other injector it could be necessary to replace the adjusting shim 27 and the spring 26 9 Assemble the injector pump see Injector pump assembly 8 15 REPLACING THE COOLING FAN SUPPORT AN Important Replacement may be carried out with the engine installed on the machin
79. ket C 2 Apply some silicone sealant on the fuel rail seat D 3 Mount the cover E and fasten the screws without tightening them 4 Tighten the screws in a crisscross pattern to a final torque of 9 Nm 5 Assemble the negative pressure vent valve F Service Manual LDW 502 automotive _ cod 1 5302 727 2 ed rev 01 75 LOMBARDINI INSTALLATION OF ASSEMBLIES 7 7 7 INSTALLING THE TIMING BELT DRIVE 7 7 1 Assembling the timing belt pulley 1 Insert the key B into the crankshaft 2 Mount the pulley A 3 Mount the pulley C and tighten the screw to a torque 80 Nm AN Important To ensure the correct timing line up the reference notches on the pulley A C with the respective gear timing notches X Y 7 7 2 Assembling the timing belt 1 Insertthe belt into the pulley C Keeping it taut insert into pulley A AN Important Keep the reference arrows G directed as shown in the diagram The timing belt must always be replaced with an original spare part whenever it is removed 2 Keepthe belt inserted into the two pulleys and then mount it onto pulley E and the pulley nut F 3 Tighten the belt using the pulley nut F and fasten temporarily AN Important To maintain engine timing while the timing belt is being installed keep it slotted onto the two pulleys A C which must remain lined up with their notches 76 Service Manual LW
80. mshaft dimensions Table of camshaft dimensions Clearance Tear amp wear n 37 035 37 060 b 0170 36 975 37 000 0 035 0 085 If the diameters do not correspond to the values shown replace the camshaft with an original spare Service Manual LDW 502 automotive _ cod 1 5302 727 2 ed rev 01 49 LOMBARDINI 2 Use a micrometer to measure the maximum dimensions of the involutes of the intake exhaust and injection cams see Table of cam dimensions Table of cam dimensions Ref Dimensions mm If the dimensions of cam involutes are lower than the values shown by 0 1mm maximum dimension replace the camshaft with an original spare AN Important Protect the contact surfaces with lubricant oil to prevent them from rusting 3 Replace the camshaft see Assembling tha camshaft 6 3 4 Checking and replacing the fuel pump drive rod To check the drive rod it is necessary to disassemble the fuel pump See Disassembling the fuel pump for the correct procedure 1 Rotate the camshaft until the drive rod is at the most indented point 2 Check that the distance between the drive rod A and the cylinder head is between 1 66 and 2 18mm If the distance does not correspond to this value replace the drive rod with an original spare 3 Assemble the fuel pump see Assembling the fuel pump OVERHAULS AND TUNING 6 Fuel pump 1 6
81. nces A 14 Assembling injection DUMPS 73 Assembling the belt drive cover TT Assembling the camshaft 71 Assembling the Cooling fan 80 Assembling the crankcase ccccceeceeeeseeeeneeeeeeeeeeaeeseneeeseeeeeneeeees 66 Assembling the crankshaft essen 66 Assembling the crankshaft flange flywheel side 67 Assembling the cylinder head 2 71 Assembling the exhaust manifold sssssesesess 80 Assembling the fan belt drive 79 Assembling the fan belt drive pulleys 78 Assembling the flywheel 69 Assembling the intake manifold 80 Assembling the mechanical fuel pump 74 Assembling the precombustion chamber 70 Assembling the rocker arm cover 75 Assembling the rocker arms ssssssseeeeeeenen 75 Assembling the speed governor and flow limiter 72 Assembling the timing belt 76 Assembling the timing belt pulley 76 Assembling the valves AAA 64 B Balancing injection pump delivery 58 Bearings 41 Belt drive cover assembling rrrnrrnnnnvnnnnrvnnnnrnnnnvrn
82. nd tools in such a way as to enable him to carry out operations correctly and safely The operator must comply with the specific measures described in order to avoid errors that might cause damage to the engine Before carrying out any operation clean the assemblies and or components thoroughly and eliminate any deposits or residual material 6 1 1 Shaft seals Clean the shaft thoroughly and make sure that it is not damaged or scored or has become oval shaped in the areas of contact with the seals Lubricate the seal lips and pointing them in the right direction place them in their seat using a special pad 6 1 2 O Rings Lubricate the seal before introducing it to its seat Avoid rolling the gasket during the attachment phase 6 1 3 Bearings Use special extractors or plugs to remove bearings Clean the bearings thoroughly Check their condition and if they are fully intact lubricate all over otherwise replace with original spares Wash the components with special detergent and do not use steam or hot water Do not use flammable products petrol diesel etc to degrease or wash components Use special products Dry all washed surfaces and components thoroughly with a jet of air or special cloths before reassembling them Apply a layer of lubricant over all surfaces to protect them against oxidation Check all components for intactness wear and tea
83. ndations 41 P Parallelismo assi biella controllo 45 Pin rocker arm dimensions table 48 Piston cylinder classes and dimensions table 42 Piston connecting rod engine block installing 65 Piston and connecting rod disassembling 99 Piston disassembling 40 Pistons connecting rods pre assembly 64 Pistons sealing rings pre assembly 63 Pistons and cylinders overhauling 44 Pistons dimensional check and overhaul 42 Pre assembly of connecting rods pistons 64 Pre assembly of sealing rings pistons 63 Precautions when the engine is installed on the machine LEAR Precautions when the engine is on the rotating stand sed Precombustion chamber assembling 70 Precombustion chamber disassembling 94 Pre heating glow plugs replacing 90 Preparing the engine for operation istalled 27 Preparing the engine for operation unistalled 26 Protective treatment rrrnrnnnnvrrnrnnrnnvvrnrrnnnvvnnsnnnnnnnr 26 Pulleys camshaft and crankshaft disassembling 32 Pumping element replacement 91 Purpose of the manual srrnnnnrnnnnnrnnenvrnn
84. ne 1 Switch off the engine and leave to cool 2 Disconnect the electrical connectors 3 Remove the starter motor AN Important If in order to take care of the problem it is necessary to remove the motor please refer to an authorised BOSCH service centre 4 Install the starter motor and tighten the screws 5 Tighten the screws to a final torque of 40 Nm 6 Make sure that the distance B is between 17 5 19 5 mm 7 Reconnect the electrical connectors Service Manual LDW 502 automotive _ cod 1 5302 727 2 ed rev 01 87 A LOMBARDINI REPLACING PARTS 8 8 8 REPLACING THE FLYWHEEL RING GEAR In order to replace the ring gear it is necessary to disassemble the flywheel See Disassembling the flywheel for the correct procedure 1 Cut the ring gear A in several places using a chisel and remove it AN Important Remove any debris and carefully clean the ring gear 2 Heat the new ring gear uniformly and keep it at a temperature of 300 C for15 20 minuti E Caution Warning 4 Leave to the ring gear to cool gently before Risk of burning be careful of hot surfaces reassembling the flywheel 3 Insertthe ring gear into its seat and place it carefully on the rim of the flywheel B 8 9 REPLACING THE COOLANT THERMOSTAT AN Important Replacement may be carried out with the engine installed on the machine 1 Switch off the engine and le
85. ng gear 88 Replacing the negative preassure vent valve 90 96 Service Manual LW 502 automotive _ cod 1 5302 727 2 ed rev 01 LOMBARDINI Replacing the nozzle injector 93 Replacing the oil filter 85 Replacing the starter motor ssssssseseeeeeene 87 Replacing the theromstatic valve 89 Replacing the timing bet 85 Rocker arm pin dimensions 48 Rocker arm valve clearance adjusting 52 Rocker arm cover assembling eene 75 Rocker arm cover disassembling 93 Rocker arm pin checking and overhauling 48 Rocker arm disassembling 33 Rocker arms assembling wi 75 Routine engine maintenance 21 S SAE Classification sisina iR AES SEE 14 Safety and environmental Impact 7 Sealants table 21 Sealing rings pistons pre assembly 63 Sealing rings clearance table 43 Sealing rings dimensional check 48 Sealing rings dimensional table 43 Shalt Seals n tee AEE 41 Special tools and
86. nitoring sensor 17 Voltage regulator Glow plug pre heating control box 18 Coolantthermometer Ignition switch 19 Coolant thermomenter sensor 50A fuses 20 Fuellevel light CO NIDA BR OO Po 5A fuses 21 Fuel level indicator E Electrostop device or electrical fuel lift pump 22 25V 10000 uF condensator 23 Electrical fuel lift pump Glow plugs indicator A De Coolant temperature indicator 18 Service Manual LW 502 automotive _ cod 1 5302 727 2 rev 01 LOMBARDINI TECHNICAL INFORMATION 2 2 10 SPECIAL TOOLS AND EQUIPMENT FOR MAINTANANCE Serial number Description Serial number Description 7107 1460 127 7107 1460 048 Instrument for balancing injection pump Tool for lowering injection advance control valve delivery 7107 1460 030 T 460 074 Precombustion chamber extractor 9 A Equipment for injection advance control and D injector calibration e 9 7107 1460 029 7107 1460 051 Pi h for ri n Mene ring nut pump Driving shaft clamping tool injector pumping element Q 7107 1460 027 7107 1 460 031 C Precombustion chamber pin wrench Pivot pin precombustion chamber a a eae 7271 1460 049 7107 1460 047 Tool for mounting intake exhaust valve Tool for adjusting timing belt tension DD guide gasket
87. nnnrnnrnnnnnnnrenennennnn 77 C Calibrating the injector seene 53 Cam dimensions Table 50 Camshaft dimensions table A 49 Camshaft assembling rrrrnrrrnnnnvrnrnnvnrrnrvnnnnnnennrnnvervnsvernernenneersennenn 71 Camshaft checking and replacing 49 Camshaft disassembling sssssssssseseseeeeeee 36 Characteristic curve diagrams 12 Checking and overhauling the cylinder head 47 Checking and overhauling the fuel pump 46 Checking and overhauling the rocker arm pin 48 Checking and overhauling the speed governor 53 Checking and overhauling the valves 51 Checking and replacing the camshaft 49 Checking and replacing the fuel pump drive rod 50 Checking clearance volume 52 Checking oil preassure 61 Checking parallelism of the connecting rod axes 45 Checking the timing belt rating rrnrrrnrrnnrnrnrnrnrrrnrrrnrenn vnr rennnennnnnn 54 Clearance table of sealing rings 43 Clearance volume and head gasket values table 52 Clearance volume checking seeeeeeen 52 Cl
88. nnrnnnnvrnnnnvnnnnnrnnnnvnnrnnrnnennnnennn 5 R Raccomandazioni per l installazione dei gruppi 63 Recommendations for installing the assemblies 63 Recommendations for overhauls and tuning 41 Recommendations for removing the assemblies Recommendations for replacing parts 83 Recommended Removing the assemblies recommendations Removing the cooling fan belt drive 90 Removing the crank gear and crank case 36 Removing the cylinder head AA 33 Removing the exhaust and intake manifolds 29 Removing the timing belt drive 31 Replaceing the pre heating glow plugs 90 Replacing and checking the camshaft 49 Replacing injector pump parts Replacing parts recommendations 83 Replacing the air filter 86 Replacing the alternator 87 Replacing the alternator fan 83 Replacing the coolant pump esee 89 Replacing the coolant thermostat 88 Replacing the cooling fan support 93 Replacing the flywheel ri
89. o the test heads fuel filter AN Important Be careful not to reverse the intake and outlet pipes when connecting 5 Open the cocks C 6 Start the engine and keep it at minimum idle speed 1150 1250 Rpm 7 Turn the equipment switching valve by means of the lever D The engine is supplied by tubes and no more by tool tank 8 Checkthe level of the test heads after 1 minute 9 Make sure the difference in volume is no greater than 1 cm AN Important If the difference is greater increase delivery of the injector pump with the highest level or reduce the one with the lowest level 10 Loosen the screw E to adjust delivery at the injector 11 Shift the plate F gently in one of the two directions Shift the plate towards the flywheel to increase delivery Shift the plate towards the timing belt to reduce delivery 12 Tighten the screw E to a torque of 1 1Nm 13 Close the cocks and disconnect the assembly 14 Put the new O rings on the injector pumps 15 Apply sealant to the seat of the fuel rail AN Important The O rings must always be replaced with original spares whenever the fuel rail is disassembled 16 Assemble the fuel rail and fasten the screws without tightening them completely 17 Tighten the screws to a torque of 4Nm Service Manual LDW 502 automotive _ cod 1 5302 727 2 ed rev 01 59 LOMBARDINI OVERHAULS AND TUNING 6 8 A
90. of operations Some of these tools are normal workshop equipment while others are specific instruments that have been constructed by the engine manufacturer All tools must be in good working condition so that engine components are not damaged and that operations are carried out properly and safely It is important to wear the personal safety devices prescribed by work safety laws and also by the standards of this manual Holes must be lined up methodically and with the aid of suitable equipment Do not use your fingers to carry out this operation to avoid the risk of amputation GENERAL REMARKS AND SAFETY 1 Piston number one first piston viewed from the flywheel side of the engine Rotation direction clockwise or anticlockwise viewed from the timing belt side of the engine All persons carrying out work on the engine at any point in its life must possess precise technical qualifications and skills as well as experience recognised and gained in the specific sector Non compliance with these requirements may cause damage to the health and safety of individuals Do not tamper with sidestep eliminate or bypass the installed safety devices Non compliance with this requirement may be hazardous to the health and safety of individuals Some phases may require the assistance of more than one operator If so it is important to inform and exercise them regarding the type of activity they will be performing
91. om the pivot pin B 4 Thoroughly clean the components 5 Using a micrometer measure the diameters of the pivot pin and the rocker arms see Table of dimensions pin rocker arm Table of dimensions pin rocker arm Tear amp wear Clearance nhan Dimensions limit mm mm 17 989 18 000 a b gt zess If the diameters do not correspond to the values shown replace the pin and if necessary the rocker arms with original spares If the pin can be re used remove the plugs and clean the inside carefully to eliminate residual dirt 6 Place the new plugs in the pin 7 Carefully clean and lubricate the supports and rocker arms and remount on the pin OVERHAULS AND TUNING 6 48 Service Manual LW 502 automotive _ cod 1 5302 727 2 rev 01 LOMBARDINI OVERHAULS AND TUNING 6 8 Insert a new pin E and drive it in 0 1 mm from the flat part of the support 9 Reassemble the rocker arm assembly in the cylinder head see Assembling the rocker arms 6 3 3 Checking and replacing the camshaft In order to carry out a control of the camshaft it is necessary to disassemble it from the cylinder head See Disassembling the camshaft for the correct procedure 1 Using a dial indicator measure the diameters of the seats X and with a micrometer find out the diameters of the camshaft O Y see Table of ca
92. p activation key into the crankshaft 3 Bring piston number one flywheel side to the top dead centre with the oil pump activation key in line with break in the flange in order to be able to assemble the pump 4 Installthe pump B and put in the screws C AN Important Be careful not to damage the sealing rings during this operation oil pump activation ke 68 Service Manual LW 502 automotive _ cod 1 5302 727 2 rev 01 LOMBARDINI INSTALLATION OF ASSEMBLIES 7 5 Tighten the screws in a crisscross pattern and tighten each of them to their respective final torques see image 6 Insert the key D into the crankshaft 7 Install the alternator support E and tighten the screws to a torque of 2 2Nm oil pump activation ke 7 5 7 Assembling the flywheel 1 Install the support F and tighten the screws to a torque of 25 Nm 2 Install the flywheel G and put in the screws H 3 Tighten the screws temporarily in a crisscross pattern 4 Tighten the screws in a crisscross pattern to a final torque of 80Nm AN Important Turn the flywheel manually to check the movement of the mechanical parts Service Manual LDW 502 automotive _ cod 1 5302 727 2 ed rev 01 69 A LOMBARDINI INSTALLATION OF ASSEMBLIES 7 7 6 INSTALLATION OF CYLINDER HEAD AND COMPONENTS 7 6 1 Assembling the precombustion chamber VA po C
93. pressure of 140 155 bars optimal operating calibration 6 If calibration is not optimal it is possible to modify the action of spring using the adjustment shims The adjustment shims are available in 11 sizes between 1mm and 2mm uprated at 0 1mm gaps If after inserting the largest adjustment shim 2mm optimal calibration is still not achieved the spring see Nozzle injector replacement must be replaced 6 3 9 Checking and overhauling the speed governor Disassemble the speed governor before checking or overhauling See Disassembling the speed governor and flow limiter for the correct procedure Exploded diagram of the speed governor Caption Oil seal Screw Cover O ring Ball bearing Plate Screw Weighted support Spacing collar 10 Fith wheel coupling 11 Nut 12 ldle spring 13 Maximum speed ring 14 Barrel 15 Thrust washer 16 Stop ring 17 Pivot 18 Leverage assembly 19 Clearance ring 20 Hose in some versions OVERHAULS AND TUNING 6 7 Afterreplacing the spring calibrate at 10 bars higher than the optimal operating calibration of 140 155 bars When the spring settles the calibration will level at the optimal value 8 Remove the tool 7107 1460 074 9 Replace the non return valve 10 Assemble the injection pump on the engine see Assemble injection 1 Use a gauge to make sure that the distance A is between 45 and 46 mm 2 Make sure that the contact surf
94. que of 10 Nm Install the belt T Tighten the belt T see Replacing the alternator fan belt With internal alternator INSTALLATION OF ASSEMBLIES With external alternator Service Manual LDW 502 automotive _ cod 1 5302 727 2 ed rev 01 79 LOMBARDINI INSTALLATION OF ASSEMBLIES 7 7 8 3 Assembling the cooling fan 1 Check that the fan is intact and if necessary replace it with an original spare 2 Install the cooling fan U 3 Tighten the screws to a torque of 10 Nm 7 9 INSTALLING INTAKE AND EXHAUST MANIFOLDS 7 9 1 Assembling exhaust manifold 1 Make sure that the manifold ducts are clean and intact 2 Check that the contact surfaces are perfectly clean and intact 3 Eliminate any blockages in the ducts 4 Puton the new gaskets A 5 Mountthe manifold B without tightening the nuts completely 6 Tighten the screws in an alternating pattern to a final torque of 25 Nm 7 9 2 Assembling the intake manifold minimum maximum Air filter square type 1 Check that the contact surfaces are perfectly clean and intact 2 Eliminate any blockages in the ducts 3 Slip on a new gasket D 4 Bring the manifold C up to the cylinder head and hook on the minimum maximum device or the governor spring 5 Install the manifold C without tightening the screws F completely 6 Tighten the screws in an alternating pattern to
95. r seizure cracks and or faults to be sure that the engine is in good working condition Some mechanical parts must be replaced en bloc together with their coupled parts e g valve guide valve etc as specified in the spare parts catalogue Do not use a hammer directly on the gaskets during assembly to avoid damaging them Be careful not to damage the gaskets while joining them to the shaft Do not use a hammer directly on the bearings during assembly to avoid damaging them 6 2 OVERHAULING THE CRANK GEARS AND CRANK CASE 6 2 1 Overhauling cylinders and pistons Before deciding what kind of overhaul needs to be done itis important to carry out a dimensional check and verify the correspondence of cylinders pistons sealing rings crankshaft and connecting rods Service Manual LDW 502 automotive _ cod 1 5302 727 2 ed rev 01 41 LOMBARDINI 6 2 2 Dimensional check and overhaul of cylinders 1 Place the engine block on the workbench 2 Using a micrometer measure the diameter at points 1 2 3 see diagram 3 Rotate the micrometer 90 and remeasure If ovalization or wear is greater than 0 05mm the cylinder must be ground AN Important The increases recommended by the manufacturer for the cylinder head 0 5 and 1 mm When grinding make sure that the working angle is 45 55 and that the average roughness is Ra 0 5 1 Donotsand the internal surfac
96. r with a full scale of 150 C to monitor the temperature of the water in the container Heat the water and using the thermometer make sure that the temperature at which the valve begins to open is between 78 and 82 If the thermostatic valve opens at a different temperature it must be replaced Maintaining the conditions described above heat the water to 94 and check whether or not the valve is completely open at this temperature i e that it has lifted to 7mm REPLACING PARTS 8 Coolant pump thermostatic valve Check whether the valve is completely shut once it has cooled down If the length does not correspond to the value shown replace the valve spring with an original spare 4 Mount the cover and fasten the screws Service Manual LDW 502 automotive _ cod 1 5302 727 2 ed rev 01 89 LOMBARDINI REPLACING PARTS 8 8 12 REPLACING THE NEGATIVE PRESSURE VENT VALVE AN Important Replacement may be carried out with the engine installed on the machine 1 Switch off the engine and leave to cool 2 Loosen nut A Caption Nut 3 Loosen the clamps and disconnect the XX UN pipes Diaphram Bottom plate 4 Take off the negative pressure vent valve Quicklock ring B O ring Collar O ring 10 Seal collar 11 Spring 6 Tighten the nutto a final torque of 22Nm 12 Gas vent pipe 5 Install the negative pressure vent valve 7 Connectthe pip
97. re with the oil pump activation key in line with break in the flange in order to be able to remove it AN Important You should in no way try to force removal of the pump if its activation key is not lined up with the break in the flange 4 Remove the oil pump F 5 Take off the gasket G oil pump activation key crankshaft Service Manual LDW 502 automotive _ cod 1 5302 727 2 ed rev 01 37 QQ LOMBARDINI REMOVING THE ASSEMBLIES 5 5 6 3 Disassembling the crankcase and crankshaft 1 Remove the flange H 2 Tske off the gasket L 3 Remove the crankcase M 4 Remove the connecting rod cap N A Caution Warning Before removing the cap mark the area of contact with the connecting rod in order to recognise the right position during reassembly 5 Remove the crankshaft P and place it in a container for washing 38 Service Manual LW 502 automotive _ cod 1 5302 727 2 ed rev 01 Q LOMBARDINI REMOVING THE ASSEMBLIES 5 5 6 4 Disassembling connecting rod and piston 1 Extract the connecting rod piston assembly Q 2 Remove the crankshaft half bearings Caution Warning Before removing the crankshaft half bearings mark the seat position in order to recognise and match it up during reassembly bearings Important Be careful not to damage the half bearing thrust bearings during removal
98. ress down hard on the pump collar to remove the pin A 4 Remove the parts 2 3 4 5 5 Loosen the screws 6 6 Disassemble the support 7 and the lever 8 7 Insert tool 7107 1460 029 and disassemble the ring nut 9 AN Important sealing surfaces Rotate in an alternating way the ring nut during disassembling to avoid damaging 77 B G the O ring 10 delivery valve 12 8 Extract the barrel 11 the valve 12 as well as the parts 13 14 15 Service Manual LDW 502 automotive _ cod 1 5302 727 2 ed rev 01 91 LOMBARDINI 9 Check the good seal of the delivery valve 12 as well as of the pumping element parts 4 11 If necessary replace them with original spare parts 10 Assemble all parts 15 14 13 11 Assemble the delivery valve 12 AN Important The needle B and the valve seat C must be assembled as shown in the figure 12 Assemble the barrel 11 and tighten the ring nut 9 provided with new O ring 10 AN Important Rotate in an alternating way the ring nut during assembling to avoid damaging the O ring 10 13 Assemble in sequence all parts 5 4 3 2 on the support 7 14 Press down part 2 to fit the pin A 15 Reassemble the stop ring 1 16 Rotate the plunger 4 by means of the control blade 29 as shown in the figure 17 Insert the lever 8 and engage it in the plunger 4 LN Caution Warning Chec
99. rnnnnrnnnnvnnnnnrrnrrrnnnsnrnnrnrrerenrnnenn E Engine and manufacturer identification 5 Engine block piston connecting rod installing 65 Establishing injetion timing conversion table 57 Exhasut and intake manifolds installing Exhaust and intake manifolds removing Exhaust manifold assembling Exhaust manifold disassembling Exploded diagram of the Injector pump 91 Exploded diagram of the speed 53 Service Manual LDW 502 automotive _ cod 1 5302 727 2 ed rev 01 95 LOMBARDINI F Fan belt drive pulleys assembling 78 Fan belt drive assembling AAA 79 Flow limiter and speed governor assembling 72 Flow limiter and speed governor disassembling 35 Flywheel ring gear replacing 88 Flywheel assembling A 69 Flywheel disassembling rrnrnnnnvnnnnnrnnnnvvnnnnrnnnnvrnnnnrnnennnnnnnvnnennnnnen 36 Fuel injection operating principle eee 16 Fuel pump drive rod checking and replacing
100. s the rocker arm to fully push the drive rod down E 2 Introduce a pin to interrupt the injector stroke in order to be able to extract the drive rod 3 Let go of the rocker arm and remove the drive rod 4 Repeat the same operation on the other injector 5 Remove the rocker arm pin and support D 5 5 3 Disassebling the fuel pump 1 Disconnectthe supply pipe G1 from the union 2 Remove the supply pump G 3 Remove the O ring G2 4 Extract the drive rod H REMOVING THE ASSEMBLIES Service Manual LDW 502 automotive _ cod 1 5302 727 2 ed rev 01 33 LOMBARDINI REMOVING THE ASSEMBLIES 5 5 5 4 Disassembling the injection pumps 1 Remove the fuel rail F AN Important Make sura that the injector gaskets remain in position 2 Unhook the spring L AN Important If injector pumps are to be used during installation do not loosen the screws L1 in order to not balance injector pump deliveries during tuning 3 Unscrew the screws M 4 Remove the connecting rod M1 5 Dismount the injection pumps N 5 5 5 Disassembling precombustion chamber 1 Disconnect the electric cable P 2 Remove the preheating glow plugs Q 3 Unscrew the ring nut R using the special pin wrench 7107 1460 027 34 Service Manual LW 502 automotive _ cod 1 5302 727 2 ed rev 01 REMOVING THE ASSEMBLIES 5
101. te with sealing rings D AN Important Insert the lock rings with the tips pointing towards the base of the piston with tolerance of 15 3 Insert the wrist pin into the piston D and install the connecting rod B complete with cap 4 Insert the wrist pin completely and fasten with the lock ring AN Important Make sure the lock rings are positioned correctly in their seats Lubricate the coupling parts and those that are prone to oxidation 7 4 INSTALLING VALVES 7 4 1 Assembling the valves AN Important Make sure that the cylinder head is perfectly clean and dry Check that all components are intact and if necessary replace them with original spares 1 Lubrificate the valve stem sealing ring A insert it into tool 717 1460 047 and mount it right into the seat of the valve guide 2 Lubrificate the vale stem B 3 Slip the valve into the seats 64 Service Manual LW 502 automotive _ cod 1 5302 727 2 ed_rev 01 LOMBARDINI INSTALLATION OF ASSEMBLIES 7 4 Mount the collar C the spring D the cup E and the half collets F 5 Press down hard on the cup E using the special tool 7107 1460 047 to insert the half collets F into the valve stem groove 6 Release the tool and check that the half collets are positioned correctly If the half collets are not correctly positioned repeat the operation 7
102. ter square type 1 Switch off the engine and leave to cool 2 Remove the cover A 3 Extractthe cover that is to be replaced B 4 Clean the cover with a jet of air 5 Replace the cartridge with an original spare 6 Mount the cover and hook it carefully into place Air filter cylindrical type 1 Switch off the engine and leave to cool 2 Remove the cover C 3 Extractthe cover that is to be replaced D 4 Clean the cover with a jet of air 5 Replace the cartridge with an original spare 6 Mount the cover and hook it carefully into place 86 Service Manual LW 502 automotive _ cod 1 5302 727 2 rev 01 A LOMBARDINI REPLACING PARTS 8 8 6 REPLACING THE ALTERNATOR A Caution Warning Replacement may be carried out with the engine installed on the machine 1 Switch off the engine and leave to cool 2 Disconnect the battery 3 Disconnect the electrical connectors 4 Loosen the nut A 5 Loosen the belt C by adjusting the alternator B manually 6 Slip the belt C off the alternator pulley 7 Remove the alternator and replace it with a new one 9 Regulate belt C tension see Replacing alternator fan belt 8 Insert the belt into the alternator pulley 10 Reconnect the electrical connectors 8 7 REPLACING THE STARTER MOTOR Caution Warning Replacement may be carried out with the engine installed on the machi
103. ul of pistons Dimensional check of sealing rings Dimensional table of sealing rings n Disassembling the camshaft Disassembling the connecting rod and piston Disassembling the cooling fan belt with external alternator Disassembling the cooling fan belt with internal alternator Disassembling the crankcase and crankshaft Disassembling the cylinder head Disassembling the exhaust manifold Disassembling the flywheel AA Disassembling the fuel pump Disassembling the injection pumps Disassembling the intake manifold Disassembling the oil pump Disassembling the piston Disassembling the precombustion chamber Disassembling the pulleys camshaft and crankshaft A Disassembling the rocker arm Disassembling the rocker arms sssssseseeeen Disassembling the speed governor and flow limiter Disassembling the timing belt Disassembling the timing belt casing Disassembling the valves rrrrrnnnrnnnnn
104. ve the cover B 3 Thoroughly clean the inside of the cover and blow compressed air on the decanting device C to eliminate residues 4 Checkthat the decanting device is intact and if necessary replace it with an original spare 5 Slip ona new gasket D 6 Replace the cover B and fix it using the screws 7 Replace the pipe A and fasten it using the clamp 8 Mount the starter motor and tighten the screws to a torque 45 Nm 6 3 OVERHAUL OF CYLINDER HEAD AND RELATED COMPONENTS 6 3 1 Checking and overhauling the cylinder head 1 Place the cylinder head on a surface plate and position it with the corners on the stud bolts 2 Using a dial indicator make sure the cylinder head is level AN Important If the level deviation is above 0 1mm the cylinder head must be ground removing not more than 0 2mm 3 Before grinding remove the valves see Disassembling the valves and the precombustion chambers see Disassembling the precombustion chamber Service Manual LDW 502 automotive _ cod 1 5302 727 2 ed_rev 01 47 LOMBARDINI 6 3 2 Checking and overhauling the rocker arm pin 1 Inorderto carry out a control of the rocker arm assembly it is necessary to disassemble the cylinder head See Disassembling the rocker arms for the correct procedure 2 Boreahole in the blocking pin A using a 4mm bit to remove it 3 Extract the supports and the rocker arm fr

SERVICE MANUAL - lombardini service

Contents

Download Pdf Manuals

Related Search

Related Contents