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com
 FOREWORD

Thi s wor kshop manual cont ai ns r epai r i nst r uct i ons f or t he 2001, 2002 and 2003 engi nes .
The i nst r uct i ons concer ni ng over haul i ng descr i be t he most sui t abl e wor ki ng met hod usi ng t he speci al t ool s l i st ed under
t he headi ng " Speci al t ool s" .
Bot h t he engi ne desi gnat i on and i t s ser i al number must be cl ear l y st at ed i n al l cor r espondence concer ni ng t he engi ne and
when or der i ng par t s .
W e r eser ve t he r i ght t o car r y out desi gn modi f i cat i ons and, f or t hi s r eason, t he cont ent s of t hi s manual cannot be r egar ded as
bi ndi ng .
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AB VOLVO PENTA
Techni cal Publ i cat i ons Depar t ment

SI UNI T SYSTEM
Uni t s accor di ng t o t he i nt er nat i onal SI syst em have been used i n t hi s book . The ear l i er uni t s ar e gi ven af t er t he SI uni t s .

Power i s gi ven i n k W( ki l owat t ) Speed i s gi ven i n r ev/ s ( r evol ut i ons per second)
ear l i er uni t hp ( hor se- power ) ear l i er uni t r ev/ mi n ( r evol ut i ons per mi nut e)

Tor que i s gi ven i n Nm ( newt on met r e) Vol ume i s gi ven i n dm3 ( cubi c deci met r e)
ear l i er uni t k pm ( ki l opond met r e) ear l i er uni t l ( l i t r e)
ear l i er uni t l bf f t ( poundf oot ) ear l i er uni t I mp. gal ( I mper i al gal l on)
ear l i er uni t US gal ( Uni t ed St at es gal l on)
Pr essur e i s gi ven i n Pa ( Pascal )
ear l i er uni t k p/ c m2 ( ki l oponds per squar e cent i met r e)
ear l i er uni t I bf / i n 2 ( pounds per squar e i nch)
 I NDEX

Component s gui de . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

DI SASSEMBLY
Cyl i nder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Tr ansmi ssi on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Pi st on, pi st on r ods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fl ywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cr ankshaf t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Camshaf t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

OVERHAUL
Di sassembl i ng t he cyl i nder head . . . . . . . . . . . 7 . . . . . . . . . .
Val ve gui des . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 . . . . . . . . . .
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Val ve seat s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 . . . . . . . . . .
Val ves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 . . . . . . . . . .
Val ve spr i ngs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 . . . . . . . . . .
Rocker ar m mec hani s m . . . . . . . . . .
. . . . . . . . . 8 . . . . . . . . . .
I nj ect or sl eeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 . . . . . . . . . .
I nj ect or s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 8 . . . . . . . . .
Assembl i ng t he cyl i nder head . . . . . . . . .
. . . . .
. 9 . . . . . . . . .
Feed- pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 . . . . . . . .
Pi st ons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 . . . . . . . .
Cr ankshaf t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 . . . . . . . .
Camshaf t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 . . . . . . . .
Connect i ng r ods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Ther most at . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Sea- wat er pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

ASSEMBLY
Cr ankshaf t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pi st ons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Fl ywheel . . . . . . . . . . . . . . . . . . . . . . . . : . . . . . . . . . . . . . . . . . . 15
Tr ansmi ssi on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Adj ust i ng t he val ve cl ear ance . . . . . . . . . . . . . . . . . . . . . . . 17
Checki ng t he i nj ect i on angl e . . . . . . . . . . . . . . . . . . . . . . . . 17
2003 Tur bo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Fr esh wat er cool i ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
El ect r i cal syst em . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Faul t t r aci ng scheme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Speci al t ool s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Techni cal Dat a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
ProCarManuals.com COMPONENTS GUI DE

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

Halpert@Optonline.net
 DI SASSEMBLY

Dr ai n of f t he cool i ng wat er and t he l ubr i cat i ng oi l f r om t he

on engi ne cr adl e p/ n 9992520 and f i xt ur e p/ n 884837 . I f t he
engi ne i s f r esh wat er cool ed, see page 21 .
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3. Remov e t he f uel f i l t er , t he oi l f i l t er , t he f eed- pump, t he

t her most at housi ng and t he exhaust el bow. Al so r emov e
t he sea- wat er pump wi t h i t s at t achment t ubes .

1 . Remov e t he al t er nat or , t he t ensi oner br acket and t he

st ar t er mot or . Remov e t he connect i ons f r om t he el ect r i cal
di st r i but i on box f r om t he engi ne and r emov e t he box and
t he wi r e har ness .

2 . Remov e t he r et ur n f uel l i ne, t he f uel pr essur e l i nes and
t he i nl et ai r si l encer . I nst al l pr ot ect i on caps on t he f uel
pumps and i nj ect or s . Remov e t he s c r ew hol di injectong
t he l ever of t he dec ompr es s i on devi ce ( 1) and pul l out t he
l ever . Remov e t he val ve cover .
4 . Remov e t he val ve br i dge and l i f t out t he push r ods .
t he r ubber r i ngs f or t heoi l pi pe . Remov e t he cyl i nder Remov
head and t he val ve l i f t er s . Put t he l i f t er s on a r ack i n
consecut i veorde, NchTOyleEi!ndradpbroelhts aiednmouts cbaswleithnd el.brush

5 . Remov e t he f uel i nj ect i on pumps . Mar k t he pumps t o
ensur e i nst al l at i on i n t he s ame cyl i nder s f r om whi c h t hey
wer e r emov ed . Take car e of t he s hi ms . Remov e t he s c r ews
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on t he si de of t he engi ne bl ock and l i f t out t he pump
. l i f t er s
6. Remov e t he pul l ey cent er bol t and pul l of f t he pul l ey
usi ng pul l er p/ n 9992265 . Pl ace a pr ot ect i on pad bet ween
t he pul l er and t he cr ankshaf t t o avoi d t he cr ankshaf t bei ng
damaged .
7 . Remov e t he t r ansmi ssi on cover : St ar t by r emov i ng t he
t hr ot t l e cont r ol cover . Us e a sui t abl e t ype of pl i er s t o
t he spr i ng ( 1) . Then r emov e t he end- ni ppl e ( 2) and
remov
t he spr i ng ( 3) . Remov e t he oi l pump cover and mar k t he
gear wheel s wi t h a col our - pen bef or e r emov i ng t hem.
( When i nst al l i ng t he gear wheel s, t he mar k ed si de mus t be
f aci ng out war ds) . Remov e t he br aci ng pi n of t he camshaf t
usi ng t he speci al t ool 884839 . Nev er r emov e t he
pi n by punc hi ng p/i t nout , t hi s can ver y wel l bend bracing t he
camshaf t . Remov e t he s c r ews on t he t r ansmi ssi on cover
and pul l i t st r ai ght out war ds .
8 . The max . - vol ume- scr ew ( 1) and t he max . - r ev- scr ew ( 2)
ar e set by Vol v o Pent a and mus t never be c hanged si nce
t hi s wi l l af f ect t he engi ne out put .
9. Remov e t he cont r ol r od . St ar t by r emov i ng t he pl ug at
t he r ear of t he bl ock and t het wo scr ews on t he pump pl ane,
hol di ng t he cont r ol r od .
10 . Pul l out t he camshaf t . 12 . Tur n t he engi ne upsi de down and r emov e t he oi l pan .
Be car ef ul as t he pan i s gl ued . NOTE! The oi l pan ends al so
f unct i on as mai n bear i ngs .
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11 . Remov e t he out er f l ywheel housi ng, t he f l ywheel and 13 . Remov e t he connect i ng r od bol t s and r emov e t he
t he i nner f l ywheel housi ng . r ods and t he pi st ons . The connect i ng r od andconetig t he
connect i ng r od cap ar e mar k ed wi t h f i gur es .
14 . Remov e t he mai n bear i ng caps . The mai n bear i ng caps
ar e mar k ed wi t h a f i gur e . The cor r espondi ng f i gur e i s
i nt o t he bl ock . Li f t out t he cr ankshaf t . On l at er engi
punched ne
ver si ons an ar r ow i s cast i n t he separ at e mai n bear i ng caps
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( 2002, 2003) . The ar r ow i s t o poi nt t owar ds t he di pst i ck.


THE CYLI NDER HEAD
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1. Remov e t he " col l et s" and val ve spr i ngs usi ng a val ve
bow. Remov e t he val ves . Remov e t he val ve st em seal s .
Pl ace t he val ves i n t he pr oper s equenc e i n a val ve
st and .
Val ve gui des
2 . Check t he val ve gui de wear by i nser t i ng anew val ve st em
i nt o t he gui de. Meas ur e t he pl ay usi ng a di al i ndi cat or . I f
necessar y, r epl ace t he val ve gui des .
Wear l i mi t s :
I nl et val ve, max pl ay . . . . . . . . . . . . . . . 0 . 15 mm ( 0. 0059 i n)
Exhaust val ve, max pl ay . . . . . . . . . . . . 0 . 15 mm ( 0 . 0059 i n)
3 . Use mandr el p/ n 5218 t o pr ess out t he val ve gui des . Oi l
t he new val ve gui des ext er nal l y and use mandr el p/ n
884559 t o i nst al l t hem. Pr ess down t he mandr el al l t he way
down t o t he cyl i nder head . Ream t he val ve gui des i f
. nec s ar y
Val v e seat s and val ves
4 . Mi l l or r eam t he val ve seat s . The angl e ( C) shoul d be 45°
( f or 2003T, 30° f or t he i nl et val ve) . The seal i ng sur f ace' s wi dt h
( B) shoul d be 1 ±0 . 1 mm ( 0 . 039±0 . 0039 i n) . Gr i nd t he val ves
i n a val ve gr i ndi ng mac hi ne . The angl e ( D) , see Tech . dat a . I f
t he di sc t hi ckness af t er gr i ndi ng i s l ess t han 1 . 0 mm( 0 . 039 i n)
f or nat ur al l y aspi r at ed engi nes or 0 . 8 mm i n) f or
engi nes, t he val ves must be scr apped ( 0. 031
. Val ves witurbochaged t h
bent st ems, or i f t he meas ur ement ( A) exceeds 2 . 5 mm( 0 . 098
i n) must al so be scr apped . Gr i nd t he val ve t i p t owar ds t he
r ocker s i f necessar y . Lap i n t he val ves usi ng val ve gr i ndi ng
past e and check t he cont act ar ea wi t h mar ki ng dye .

Repl aci ng t he val ve seat exhaust por t 2003T
Gr i nd down t he val ve di sc of a di scar ded val ve t o j ust bel ow
27 mm( 1 . 063 i n) di amet er . Push t he val ve st em t hr ough t he
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gui de . NOTE! Do not push i n t oo f ar - t he val ve di sc shoul d be
j ust bel ow t he edge of t he seat . Spot wel d t he di sc i n pl ace at
t hr ee poi nt s usi ng a el ect r i c wel der . Knoc k out t he seat by
t he val ve gui de wi t h a pl ast i c- headed hammer .
Cool t he new seat t o appr ox . - 20° C ( - 4° F) ; t he cyl i nder
head shoul d beat r oomt emper at ur e ( + 20° 0168° F) . Pl ace t he
cool ed seat on t ool 884961- 4 and knock i t down t unt i l ds
owar it
. NOTE! Tur n t he seat wi t h t he val ve f ace
t ool .
Val ve spr i ngs
5 . Chec k t he f r ee l engt h of t he val ve spr i ngs and t he l engt h
when l oaded .
L = Lengt h, unl oaded 42, 5 mm ( 1 . 67323 i n . )
L1 = Lengt h, l oaded wi t h 170±10 N ( 17±1 kp) 32 mm
( 1 . 25984 i n . )
L 2 = Lengt h, l oaded wi t h 300±20 N ( 30±3 kp) 24 mm
( 0 . 94488 i n . )
Rocker ar m mec hani s m
6 . Di sassembl e t he r ocker ar m mec hani s m and cl ean t he
par t s . Chec k t he wear of t he shaf t and r ocker ar m bushi ngs .
Shoul d t he bushi ngs need t o be r epl aced, us et he mandr el
p/ n 9991867 f or t he r emov al and i nst al l at i on, ( mak e sur e
t hat t he oi l hol e i n t he bushi ng coi nci des wi t h t he one i n t he
r ocker ar m) . Af t er t he i nst al l at i on t he bushi ngs ar e r eamed
t o a cl ose r unni ng f i t . When i nst al l i ng t he r ocker ar m shaf t ,
i t mus t be t ur ned so t hat t he l ubr i cat i on hol es ar e f aci ng t he
val ve- si de . Chec k t o mak e sur e t hat t he r ocker ar m cont act
sur f ace agai nst t he val ve i s concave. Mi nor adj ust ment s ar e
hi t ng made i n a val ve gr i ndi ng mac hi ne . Oi l t he shaf t and i nst al l
t he par t s .
botms t he
Pr essur e t est i ng t he nozzl es
7 . Check t he nozzl e' s spr ay pat t er n at t he cor r ect openi ng
pr essur e ( see Techni cal Dat a) . Chec k al so t hat t he f uel spr ays
st op si mul t aneousl y and no dr i ppi ng occur s .
Adj ust t he openi ng- pr essur e wi t h adj ust ment - washer s ( 1)
bei ng avai l abl e i n di f f er ent t hi cknesses f r om 1 mm U3937
i n . ) t o 1, 95 mm ( . 076772 i n . ) i n st eps of 0, 05 mm ( . 001969
i n . ) . Di s as s embl e t he i nj ect or and r epl ace t he adj ust ment - washer tadoherngipcks
whet her t he pr essur e mus t be r educed or i ncr eased .
As s embl e t he i nj ect or and check t he openi ng- pr essur e and
t he spr ay- pat t er n .
I nj ect or - sl eeve
8 . I nser t t he ex pandi ng s c r ew on t he speci al t ool p/ n
884811 i nt o t he c opper sl eeve and t ur n t he s c r ew
anti -cl ockwi seuntilshecr wshatucktin he.slv Tighten
t he s c r ew har d t o al l ow t he t hr eads t o wor k t hems el v es
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i nt o t he c opper mat er i al . Then i nst al l t he y ok e ( 1) on t he
st ud bol t of t he i nj ect or . Put a cyl i nder head s c r ew i n t he
cyl i nder head as a suppor t f or t he l eg of t he y ok e . I nst al l t he
nut ( 2) and t i ght en i t unt i l t he sl eeve i s r emov ed .
9 . Repl ace t he O- r i ng, seal i ng of f bet ween t he sl eeve and
t he cyl i nder head . Di p t he new O- r i ng i n soap- wat er i n
or de
t o f aci l i t at e t he i nst al l at i on . Oi l t he new i nj ect or sl eeve
and i nst al l i t , usi ng speci al t ool p/ n 884557 . Knoc k down t he
sl eeve unt i l i t bot t oms .
10 . Oi l t hef l ar e- t ool p/ n 884283 and i nser t i t i nt ot he sl eeve
( mak e sur e t hat t he dowel i s pr oper l y r et r act ed) . Br ace t he
t ool wi t h t he i nj ect or yoke . Sc r ew down t he f l ar e- t ool as f ar
as t he shoul der i n t he i nj ect or sl eeve al l ows, t her eby
t he sl eeve . Remov e t he t ool . Adj ust t he l engt h of ftlaring he
sl eeve out si de t he pl ane of t he cyl i nder head t o max i mum
1 mm( . 03937 i n . ) .
As s embl i ng t he cyl i nder head
11 . Cl ean t he cyl i nder head . I f t he wat er di st r i but i on pi pe
has been di sassembl ed, i t mus t be i nst al l ed wi t h t he hol es
t ur ned as i ndi cat ed i n t he pi ct ur e . I nst al l new val ve s t em
seal i ngs . Oi l t he val ve s t ems and i nst al l t he val ves . Mak e
sur e t o i nst al l t he val ves and t he val ve spr i ngs i n t hei r
r espect i ve or i gi nal posi t i ons . I nst al l t he val ve spr i ngs and
t he " col l et s" . Us e a v al v e- bow.
 Changi ng t he di aphr agm
14 . Remov e t he si x scr ews, hol di ng t he upper and l ower
Reduct i on val ve pump housi ngs t oget her . Remov e t he pump l ever spr i ng
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12 . Remov e t he cover of t he r educt i on val ve and check t o ( 1) and r emov e t he s c r ew ( 2) hol di ng t he pump l ever
mak e sur e t hat t he spr i ng and t he pi st on ar e f aul t l ess . I f shaf t .
t her e ar e r easons t o suspect a f aul t i n t he openi ng pr essur e
of t he r educt i on val ve, t hen check t he dat a of t he spr i ng .
See under " Techni cal Dat a" - r educt i on val ve .

Feed- pump
13 . Depr ess t he pump l ever . i f t he di aphr agmof t he pump 15 . Us e a sui t abl e pai r of pl i er s and r emov et he pump l ever
sounds squeaky, t he di aphr agm i s f aul t l ess . shaf t . Pul l out t he l ever and t he di aphr agm.
 19 . Pl ace a suppor t under t he camshaf t gear and use a
hydr aul i c pr ess t o r emov e t he gear .
16 . Cl ean t he pump housi ng car ef ul l y and r epl ace wor n
par t s . I nst al l t he di aphr agm and t he l ever on t he
shaf t . Then i nser t t he shaf t and t i ght en i t wi t h diaphrgm t he
scr ew. Assembl e t he t wo housi ng hal ves and i nst al l t he
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at t achment pl at e ( 1) . Then i nst al l t he spr i ng ( 2) and t he O-ri ng (3).

Val ve l i f t er s
17. Chec k t he val ve l i f t er s f or wear . Repl ace t hem i f neces
sar y .

Cr ankshaf t
20 . Remov e t he gear wheel . Us e a pr ong pul l er . Cl ean t he
cr ankshaf t . Meas ur e t he cr ank- and mai n bear i ng pi ns . The
eccent r i ci t y mus t not ex c eed 0. 06 mm( . 002362 i n . ) and t he
t aper 0 . 05 mm( . 001969 i n . ) . Shoul d t hese val ues be excd,
Cams haf t t he cr ankshaf t mus t be gr ound t o a sui t abl e under-di mensi on, u.D"snaeTdtcrhil
18 . Chec k t he camshaf t f or wear on c ams and bear i ng r a
ces . Al so check t he wear of t he bear i ngs . The bear i ngs ar e
pr essed i nt o t hei r l ocat i ons and mus t be l i ne bor ed af t er
t he i nst al l at i on .
Pi st ons, cyl i nder s
21 . Chec k t he wear on pi st ons, pi st on r i ngs and gudgeon
pi ns . Repl ace t hese i f necessar y . Use a cyl i nder i ndi cat or
gauge t o meas ur e t he cyl i nder bor es . The meas ur ement of
t he bi ggest wear i s made i mmedi at el y beneat h t he edge of
t he upper dead cent er and cr osswi se t he engi ne . The mea
s ur ement of t he smal l est wear i s made at t he l ower dead 24 . Use pi st on r i ng pl i er s t o i nst al l t he pi st on r i ngs . The
cent er . As t o t he cyl i nder di amet er , see " Techni cal Dat a" . mar ki ng of t he r i ngs ( TOP or t he mar k of t he manuf act ur er )
Us e a mi c r omet er t o meas ur e t he pi st ons . Pi st on di amet er , mus t be t ur ned upwar ds . The hei ght of t he upper c om
see under " Techni cal Dat a" . pr essi on r i ng : 1, 75 mm ( . 068898 i n . ) The hei ght of t he
c ompr es s i on r i ng ; 2, 00 mm( . 07874 i n . ) . Tur n t he lower
r i ngs so t hat t he gaps ar e t ur ned 120 ° f r om each piston
. ot her
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22 . I nser t a new pi st on r i ng i nt o t he cyl i nder and meas ur e

t he pi st on r i ng gap . As t o t he meas ur ement , see under
" Techni cal Dat a" . I f necessar y i ncr ease t he gap, usi ng a
speci al f i l e .

Connect i ng r ods
23 . Meas ur e t he cl ear ance of t he pi st on r i ngs i n t he pi st on 25 . Chec k t he connect i ng r ods f or st r ai ght ness and
r i ng gr ooves . Regar di ng t he meas ur ement , see under . twisng
" Techni cal Dat a" .
 26 . Chec k t he connect i ng r od bushi ngs by usi ng t he
pi n as a gauge . Ther e mus t be no pl ay. I f t he bushigudeon ngs
mus t be r epl aced, use a sui t abl e mandr el f or t he r emoval
and i nst al l at i on . Mak e sur e t o i nst al l t he bushi ng wi t h t he
oi l hol e coi nci di ng wi t h t hat of t he connect i ng r od . Ream
t he new bushi ngs . The f i t i s cor r ect when an oi l ed gudgeon
pi n by i t s own wei ght can sl owl y sl i de t hr ough t he
. bus hi ng
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Sea- wat er pump

27 . The pump i s equi pped wi t h t wo bal l - bear i ngs ( 1) .
W hen di sassembl i ng, r emov e t he l ocki ng- r i ng ( 2) i n t he
housi ng and push out t he shaf t , wher eby t he bear i ngs ar e
f ol l owi ng . Us e a sui t abl e mandr el t o r emov e t he bear i ngs
f r om t he shaf t . NOTE! Do not f or get t he spacer sl eeve ( 3) .
Repl ace t he seal i ngs ( 4) . NOTE! Tur n t he seal i ngs cor r ect l y
and mak e sur e t hat t hey do not bl ock t he dr ai nage hol e i n
t he pump- hous i ng . Repl ace t he ( 5) . I nst al l t he
O- r i ng
ball-bearingsand ostlhpeacvrn olatshnedf vea
di st ance of 39, 5 mm( 1 . 55512 i n . ) f r om t he shaf t end t o t he
bal l - bear i ng . Coat t he shaf t wi t h gr ease and " s c r ew" i t
t hr ough t he seal i ngs and t he O- r i ng and t ake car e not t o
damage t hem. Pus h i n t he shaf t as f ar as t o al l ow t he
bear i ngs t o bot t om and t hen i nst al l t he l ocki ng- r i ng ( 2) .

Checki ng t he t her most at s

28 . I mmer s e t he t her most at i n wat er and, usi ng a
check i f i t opens at t he cor r ect t emper at ur e . thermo, See
Techni cal Dat a f or openi ng t emper at ur es . I f t he t her most at i s
f aul t y, i t mus t be r epl aced .
 ASSEMBLY

Al way s use new gasket s, seal i ng r i ngs, seal i ng was her s

and l ock- washer s . Coat t he seal i ngs wi t h gr ease or oi l
t hem and al so oi l al l mov i ng par t s pr i or t o i nst al l i ng t hem.
I f t he engi ne i s f r esh- wat er cool ed, see page 21 .
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3 . Tur n t he pi st on r i ngs so t hat t he gaps ar e of f set i n r el at i on

1 . Heat t he cr ankshaf t gear wheel t o appr ox . 150° C ( 302 ° F)
pr i or t o t he i nst al l at i on . Pl ace t he key i n t he k ey - way of t he
cr ankshaf t and pr ess on t he gear wheel . Oi l t he new mai n
bear i ng hal ves ( wi t h oi l hol e) and i nst al l t hem i n t he bl ock .
Put i n t he cr ankshaf t . NOTE! The mai n bear i ng shel l at t he
f l ywheel al so f unct i ons as a t hr ust - bear i ng .
t o each ot her . The pi st on c r own i s mar k ed wi t h an ar r ow t hat
poi nt s t owar ds t he bel t pul l ey . Us e i nst al l at i on r i ng 884813- 7 .
Fi t t he caps wi t h t he mar ki ng al i gned wi t h t he cr ankshaf t ' s
mar ki ng . The cr ankshaf t can be t ur ned i n any di r ect i on
t owar ds t he pi st on .
Ti ght eni ng t or ques :
St ep 1 : 25 Nm ( 2 . 5 kpm) (ft/lb) 18
St ep 2 : 70 Nm( 7 . 0 kpm) ( 53 f t / l b)

2 . Oi l t he cap bear i ng hal ves and i nst al l t hem. I nst al l t he 4 . I nst al l t he mai n bear i ng hal ves i n t he oi l pan and coat

caps i n accor dance wi t h t he mar k i ng i n t he bl ock ( 2001 has
no i nt er medi at e bear i ng) . I f an ar r ow i s cast , i t shal l poi nt
t owar ds t he oi l di pst i ck . Ti ght eni ng t or que f or t he mai n
bear i ngs : 1st t i ght eni ng 20 N m ( 2 k pm) ( 14 . 7 f t . l b) , 2nd
t i ght eni ng 60 Nm ( 6 k pm) ( 44 . 2 f t . l bs) . Tur n t he engi ne .
t he edge of t he oi l pan wi t h t hi n l ayer of seal i ng
p/ n 840879 . I nst al l t he oi l pan and t i ght en t he oi l compund pan
scr ews and t he mai n bear i ng s c r ews al t er nat i ngl y t o 20 Nm
( 2, 0 kpm) ( 14. 7 f t . l bs . ) and t hen t he mai n bear i ng s c r ews t o
60 Nm ( 6, 0 k pm) ( 44 . 2 f t . l bs . ) .
5 . Repl ace t he f l ywheel housi ng seal i ng ( 1) . Smear seal i ng
c ompound ( p/ n 840879) on t he edge bet ween t he f l ywheel
housi ng and t he seal i ng . NOTE! The seal i ng l i p wi t h a
spr i ng shal l be t ur ned t owar ds t he engi ne . Mak e sur e t hat
t he seal i ng i s i nst al l ed i n accor dance wi t h t he pi ct ur e .
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6 . Repl ace t he O- r i ngs and i nst al l t he f l ywheel housi ng .
Ti ght eni ng t or que 25 Nm ( 2, 5 kpm) ( 18 . 4 f t . l bs) .
I nst al l t he f l ywheel . Ti ght eni ng t or que 65 Nm ( 6, 5 k pm)
( 48 . 0 f t . l bs) .
7A. Heat t he c ams haf t gear wheel t o a t emper at ur e of
appr ox . 150° C ( 302° F) and us e a sui t abl e sl eeve t o i nst al l i t .
Chec k t o mak e sur e t hat t he gear wheel " bot t oms" on t he
camshaf t . I nst al l t he c ams haf t and mak e sur e t hat t he
mar ki ngs on t he c ams haf t gear wheel and on t he crankshft
gear wheel coi nci de . Put t he was her ( 1) on t he hub of
t he camshaf t gear wheel . Chec k t hat al l wei ght s ar e presd
i n so t hat t he t abs ( 2) ar e i nsi de t he was her .
7B. I nst al l anew seal i ng r i ng f or t p/ henc ams haf t i n t he
housi ng, usi ng mandr el 884838 . The seal transmio i ng
l i p wi t h t he spr i ng i s t o bet ur ned t owar ds t he engi ne . Pr ess
i n t he seal i ng r i ng f r om t he out si de unt i l t he mandr el
" bot t oms " agai nst t he housi ng . I nst al l a new O- r i ng i n t he
oi l channel i n t he bl ock ( 3 f i g . 7A) .
Us e a new gasket and i nst al l t he t i mi ng gear cover . Pl ace
t he pr essur e sl eeve ( wi t h t he bear i ng t owar ds t he pr essur e
washer ) i n t he cont r ol ar m l ever . Hol d t he sl eeve i n pl ace
by pr essi ng t he l ever t o i t s bot t om posi t i on wher e t he
sl eeve i s pr essed agai nst t he housi ng . I nst al l t he pi n of t he
camshaf t , usi ng speci al t ool 884839 . The pi n must
equal l y muc h on bot h sip/des.
n Under no ci r cumst ances pr ot ude
ar e you t o use a hammer or s ome such t ool t o punc h t he
pi n i nt o i t s l ocat i on wi t h t he ai d of a mandr el . The camshaf t
wi l l t hen be bent .
8 . I nser t t he cont r ol r od t hr ough t he bl ack and i nt o t he t i mi ng
gear casi ng . I nst al l t he bear i ng bal l ( 1) i nt o t he cont r ol r od and
push t he cont r ol r od t hr ough t he hol e i n t he cont r ol l ever ( 2) .
Fi t t he spr i ng ( 3) and scr ew on t he end ni ppl e ( 4) unt i l i t
( Not e! Do not use any t ool s) . Sc r ew i n t he upper bol botms t s
( wi t h copper seal i ng washer s) t hat gui de t he cont r ol r od .
Then, s c r ew t he l ower bol t s t hat hol d t he cont r ol r od i n pl ace
i n t he engi ne bl ock . NOTE! The l ower bol t s shoul d not have
seal i ng washer s . Appl y Per mat ex t o t he t hr eads . Chec k t hat
t he cont r ol r od mov es f r eel y . 10 . I nser t t he key f or t he pul l ey i n t he cr ankshaf t and i nst al l
t he pul l ey . Ti ght eni ng t or que 40 Nm ( 4, 0 k pm) ( 29 . 5
f t . I bs) .
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11 . Cl ean t he val ve l i f t er s car ef ul l y and coa t t he cont act

sur f ace agai nst t he c ams haf t wi t h mol y bdenum disulphe
. Oi l t he val ve gui des i n t he bl ock and i nst al l t he l i f t er s .
Cl ean t he r ol l er l i f t er s of t he f uel i nj ect i on pumps and
t hen i n t he bl ock . Lock t he r ol l er l i f t er s wi t h scr ews
i ns t al
t hr ough t he bl ock af t er t he i nst al l at i on ( appl y Per mat ex t o
t he t hr eads) . Chec k car ef ul l y t o mak e sur e t hat t he l i f t er s
ar e cor r ect l y i nst al l ed and t hat t hey ar e r unni ng easi l y i n
t he gr oov e .

2001
9 . I nst al l t he oi l pump' s gear wheel accor di ng t o t he mar k s
( f r om t he di sassembl y) . I nser t a new O- r i ng i n t he t i mi ng
gear cover . Oi l t he gear wheel and f i t The cover usi ng a new Regar di ng t he i nst al l at i on of t he cyl i nder head, s eet he
seal i ng r i ng . page . folwing

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2003
12 . Ti ght en t he t wo gui de s c r ews p/ n 884840 i n t he bl ock
and i nst al l t he cyl i nder head gasket wi t h t he mar ki ng
" Top" f aci ng upwar ds . I nst al l t he cyl i nder head .
Mak e sur e t hat t he cont act sur f ace f or t he cyl i nder head
bol t s ar e f r ee f r om pai nt . Shoul d t her e be pai nt on t he
bol t s, t her e i s al ways t he r i sk of havi ng an i nsuf f i ci er t
f or ce i n t he bol t j oi nt wi t h s ubs equent l eakagestighen as a
r esul t . NOTE! The bol t s ar e phospat ed, t her ef or e do not
cl ean t hem wi t h a st eel - br ush .
Coat t he cyl i nder head bol t s wi t h mol y bdenumdi sul phi de
and t i ght en t hem i n accor dance wi t h t he di agr am, f i r st t o
20 Nm( 2 . 0 kpm/ 14. 7 f t . l bs) and t hen t o 70 Nm( 7 . 0 kpm/ 51. 6
f t . l bs) .
13 . I nst al l t he push r ods and t he r ocker ar m br i dge, pus h
on new r ubber r i ngs t o t he oi l pi pe whi c h i s f i t t ed at t he
s ame t i me as t he r ocker ar m br i dge .
14 . Val ve cl ear ance c ol d/ war m engi ne 0 . 30 mm ( . 01181
i n . ) . Tur n t he engi ne i n t he di r ect i on of r ot at i on unt i l t he
val ves i n one cyl i nder ar e " r ocki ng" . Then t ur n t he engi ne
one t ur n mor e and t he val ves f or t hi s cyl i nder .
t he pr ocedur e adj
f or ust
t he r emai ni ng cyl i nder s . Repat
Adj ust i ng t he f uel i nj ect i on pump l ocat i on wi t h s hi ms
15 . i f t he s ame bl ock camshaf t and f uel I nj ect i on pumps
ar e used when assembl i ng, t he f uel i nj ect i on pump mus t
be i nst al l ed i n t hei r or i gi nal posi t i ons and wi t h t he s ame
shi m t hi ckness as ear l i er . The s o cal l ed sof t shi ms, al way s
bei ng i nst al l ed agai nst t he bl ock, mus t be r epl aced agai nst
new ones . Car ef ul l y cl ean t he cont act sur f aces bet ween t he
bl ock and t he f uel i nj ect i on pumps and i nst al l s hi ms wi t h
t hi ckness equal t o t he s um of t he mar ki ng on t he bl ock and
t hat on t he f uel i nj ect i on pump, ( 4) ear l i er mar ki ng .
Ex ampl e : The bl ock mar ki ng 4 ( = 4 t ent hs of a mi l l i met er )
( . 015748 i n . )
The pump mar k i ng 4 ( = 4 t ent hs of a mi l l i met er )
( . 015748 i n . )
Tot al amount of s hi ms = 0 . 8 mm ( . 031496 i n . )
I n t hi s case sel ect t wo sof t s hi ms 0 . 2 and 0 . 3 mm( . 011811
i n . ) . Pl ace t he har d s hi m bet ween t he t wo sof t ones and
i nst al l t he pump . NOTE! Nev er i nst al l a har d shi m t oget her
wi t h anot her har d s hi m or agai nst t he bl ock or t he f uel
pump . Har d s hi ms ar e avai l abl e i n t hi cknesses 0.injecto 3,
0 . 6 and 0 . 9 mm( . 011811, . 02362, . 035433 i n . r espect i vel y) .
Sof t s hi ms ar e avai l abl e i n t hi cknesses 0 . 2 and 0 . 3 mm
( . 007874 and . 011811 i n . ) .
 On l at er ver si on engi nes an O- r i ng has been i nt r oduced as a
seal bet ween t he i nj ect i on pump and t he bl ock . Onl y so- cal l ed
har d shi ms may be used on t hese engi nes when s hi mmi ng .
Har d shi ms ar e avai l abl e i n t hi cknesses of 0 . 2 mm( 0 . 0079 i n) ,
0 . 3 mm( 0 . 0118 i n) , 0 . 6 mm ( 0 . 0024 i n) and 0. 9 mm ( 0 . 0354 i n) .
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16. New bl ock or c ams haf t set t i ng- di sc pi n ( 2) c omes i n t he l ar gest of t he f our hol es i n t he pul l ey .
I f t he bl ock or t he camshaf t ar e r epl aced t he bl ock mus t be Pr ess i n t he gui de pi n ( 2) so t hat t he di sc i s cent er ed and
meas ur ed and mar ked, usi ng t he set t i ng- di sc p/ n 884787 t i ght en t he bol t s .
and a sl i di ng cal i per . The set t i ng- di sc i s mar k ed f or each r espect i ve cyl i nder :
A. The set t i ng- di sc consi st s of t wo r i ngs, an i nner and an
Mar ki ng Denot es
out er . The i nner r i ng det er mi nes t he i nj ect i on angl e f or
each r espect i ve engi ne t ype, see Techni cal Dat a ( page 25) .
Cyl i nder 1 Cyl i nder 1 ( 1, 2, 3 cyl i nder engi nes ;
The i nj ect i on angl e i s s t amped i n degr ees and i s f i xed wi t h
Cyl i nder 2/ 2 Cyl i nder 2 ( 2 cyl i nder engi ne)
a pi n ( 1) .
Cyl i nder 2/ 3 Cyl i nder 2 ( 3 cyl i nder engi ne)
B . Mount t he set t i ng- di sc or t he pul l ey wi t h t wo bol t s, do
Cyl i nder 3/ 3 Cyl i nder 3 ( 3 cyl i nder engi ne)
not t i ght en t he bol t s . Tur n t he so t hat t he gui de

C . Tur n cyl i nder no . 1 t o i t ' s i nj ect i on. posi t i on . Pl ace t he
gui de pi n ( 2) i n t he set t i ng- di sc' s hol e mar k ed cyl . 1 . Tur n
t he cr ankshaf t a l i t t l e agai nst t he nor mal di r ect i on of
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17 . Fi t t he i nj ect i on pump( s ) t oget her wi t h t he cal cul at ed
s hi m t hi ckness . Tur n t he engi ne so t hat t he c am f or t he
pump i s not i n t he l i f t i ng posi t i on . Chec k t hat t he pump' s
pi n l ocat es i n t he cont r ol r od' s gr oov e and t hat t he pump( s )
and t he l ocks mar ki ngs coi nci de ( see f i gur e) . Chec k af t er

and t her eaf t er i n t he nor mal r ot at i on di r ect i on unt i lrotain t he f i t t i ng each pump t hat t he cont r ol r od oper at es easi l y .
set t i ng- di sc' s gui de pi n ( 2) goes i n t he t i mi ng cover ' s hol e . Ti ght eni ng t or que f or t he nut s i s 20 Nm ( 2, 0 k pm) ( 14. 7
Meas ur e usi ng a cal i per t he di st ance bet ween t he cyl i nder f t . l bs) . Connec t t he f uel pi pe bet ween t he pumps and t he
bl ock and t he r ol l er l i f t er ' s edge ( do not meas ur e on t he pi pe f r om t he f uel f i l t er t o t he i nj ect i on pump . NOTE! The
r ol l er ) . hol e bol t f or t he r et ur n hos e has a smal l er t hr ough- f l ow
channel t han t he ot her s ( on l at er ver si ons i t i s mar k ed
The di st ance shoul d be :
' Out " ) .
2001 : 55 . 8 mm ( 2. 1 9685 i n)
2002, 2003 : 55, 6 mm ( 2 . 18504 i n)
2003T : 55 . 9 mm ( 2 . 2007 i n)

Ex ampl e :
2001 . I f t he meas ur ed di st ance i s 55 . 2 mm( 2 . 17323 i n) t hi s
means t hat a shi m wi t h t hi ckness 0 . 6 mm ( 0 . 02362 i n) i s t o
be pl aced bet ween t he cal i per and t he bl ock .

2002, 2003 . I f t he meas ur ed di st ance i s 55 . 0 mm ( 2 . 16535

i n) t hi s means t hat a shi m wi t h t hi ckness 0. 6 mm ( 0 . 02362
i n) i s t o be pl aced bet ween t he cal i per and t he bl ock.

The meas ur ed s hi ms t hi ckness ( i n t hi s ex ampl e 0 . 6 mm) i s

t o be s t amped i nt o t he bl ock as i n f i g . 15.

The t ot al s hi m t hi ckness i s f ound by addi ng t he bl ock' s

meas ur ement s and t he pump' s mar k i ng .

Ex ampl e
The bl ock' s meas ur ement s 6 ( = 0 . 6 mm/ 0. 02362 i n)
The pump' s mar ki ng 2 ( = 0 . 2 mm/ 0. 007874 i n)

No . of s hi ms 0 . 8 mm

I n t hi s case c hoos e t wo sof t s hi ms 0 . 2 and 0 . 3 mm

( 0 . 007874 and 0 . 011811 i n ) and one har d shi m of 0 . 3 mm
( 0 . 011811 i n) . Pl ace t he har d s hi m bet ween t he t wo sof t
ones and r ef i t t he pump . NOTE! A har d shi m mus t never be
f i t t ed t oget her wi t h anot her har d s hi m or di r ect l y agai nst
t he bl ock or pump .

Har d s hi ms ar e avai l abl e i n t hi cknesses 0 . 3, 0 . 6 and 0 . 9 mm

( 0 . 011811, 0 . 02362 and 0 . 035433 i n) .
Sof t s hi ms ar e avai l abl e i n t hi cknesses 0 . 2 and 0 . 3 mm
( 0, 007874 and 0 . 011811 i n) . 18 . I nst al l t hef eed pump and t hef uel f i l t er . Al so i nst al l t he
t her most at housi ng wi t h t he t her most at . NOTE! Do not
D. Repeat t he pr ocedur e f or t he ot her pumps ( 2002, 2003) f or get t he l i f t i ng eyel et bet ween t he f uel f i l t er and t he
i n t he s ame way as f or cyl i nder 1 . housi ng . thermosa
The set t i ng- di sc' s mar ki ng i s expl ai ned under poi nt B .
 21 . Fi t t he val ve cover usi ng a new gasket . Mak e sur e t hat
t he r ound hol e f or t he cr ankcase vent i l at i on i s i n t he r i ght
posi t i on . Fi t t he dec ompr es s i on devi ce l ever . Fi t t he
pi pes bet ween t he i nj ect or s and t he i nj ect i on pum
presu ps .
Al so r ef i t t he i nl et ai r si l encer .

19 . I nst al l t he sea- wat er pump and t he cool i ng wat er

. pi es
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20 . I nst al l t he i nj ect or s and t he r et ur n f uel pi pe . Ti ght eni ng 22 . I nst al l t he st ar t er mot or , t he al t er nat or and t he
t or que f or t he i nj ect or s 20 Nm ( 2, 0 k pm) ( 14. 7 f t . l bs . ) . Al so V- bel t . Al so i nst al l t he el ect r i cal di st r i but i on boxalterno and
i nst al l t he exhaust el bow and t he wat er pi pe bet ween t he hook- up t he cabl e har ness .
t her most at housi ng and t he exhaust el bow.
 2003T
Tur bo- Compr es s or

Wher e t her e i s an excessi ve amount of s mok e i n t he exhaust tofrumesheiounstgp ipltaorwcuy ma

be t hat t he t ur bo- c ompr es s or i s not f unct i oni ng pr oper l y . I f

t he boat ' s s peed t hr ough t he wat er i s gr adual l y decrasing,
t he boat ' s bot t om s houl d al so be i nspect ed, and
cl eaned wher e necessar y . Chec k t hat t he ai r i nt ake has not
bec ome cl ogged, and cl ean t he i nt ake si l ender .

I nspect i ng t he Seal s
j oi nt s bet ween t he t ur bi ne housi ng and t he
Check t hebear i ng housi ng, and bet ween t he c ompr es compres s or
bear i ng housi ng and t he c ompr es s or housi ng .

Chec k s
Chec k t he pr e- i nj ect i on angl e, t he i nj ect or ' s openi ng
and t he spr ay pat t er n . The val ve cl ear ance and presu
shoul d al so be c hec k ed . compresin

23 . Fi l l up wi t h l ubr i cat i ng oi l t o t he cor r ect l evel . Regardin

quant i t y and qual i t y, see under " Techni cal Dat a" .
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Checki ng axi al and r adi al cl ear ance

Di s mount t he t ur bo- c ompr es s or f r om t he engi ne, and
meas ur e t he r ot or uni t ' s axi al and r adi al cl ear ance .

Max i mum per mi ssi bl e axi al cl ear ance 0 . 09 mm

24 . Vent i ng t he f uel s y s t em
A. Open t he vent i ng s c r ew on t he f uel f i l t er appr ox . 4 t ur ns .
Wat c h out f or f uel - spl ashes .
B . Us e t he hand- pump t o pump f uel unt i l f uel f r ee f r om ai r
bubbl es i s c omi ng out . Cl ose t he vent i ng s c r ew.
C . Ease of f t he f uel pr essur e pi pe nut s at t he i nj ect or s .
t he t hr ot t l e cont r ol i n t he posi t i on f or f ul l s peed and
Positn
t ur n t he engi ne wi t h t he st ar t er mot or unt i l f uel c omes out
of t he f uel pr essur e pi pes . Ti ght en t he f uel pr essur e pi pe
nut s .
Max i mum per mi ssi bl e r adi al cl ear ance 0 . 17 mm

I f wear and t ear has r eached t he max i mum per mi ssi bl e t he

t ur bo- compr essor shoul d be r econdi t i oned or r epl aced .
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RECONDI TI ONI NG
Mak e l i ne- up mar k s bet ween t he t ur bi ne housi ng, t he
bear i ng housi ng and t he c ompr es s or housi ng . Di smant l e
t he c ompr es s or housi ng ( 1) . Uns c r ew t he l ef t - hand
t hr eaded nut whi c h hol ds t he c ompr es s or wheel , usi ng
dol l i es on t he t ur bi ne shaf t . Remov e t he c ompr es s or wheel
( 2) and di smant l e t he t ur bi ne housi ng ( 3) .
Di smant l e t he t ur bi ne shaf t ( 4) and t he heat shi el d . I f t he
t ur bi ne shaf t st i cks, t ap t he end gent l y wi t h a wooden
. Unf ast en t he t hr ee s c r ews whi c h hol d t he coverham er ( 3)
and s c r ew t wo M5 s c r ews i nt o t he cover . Then l i f t i t up .
Tak e t he oi l def l ect or ( 7) out of t he cover .
 Compr essor Housi ng, Tur bi ne Housi ng
Chec k t hat t he housi ngs ar e f r ee f r om cr acks or ot her
caused by excessi ve wear and t ear . Damaged damge par t s
shoul d be r epl aced .

Heat Shi el d
Chec k t hat t he heat shi el d i s f r ee f r om damage c aus ed by
wear and t ear , heat or cor r osi on, and r epl ace i t i f necsary
.

Bushi ng, Oi l Def l ect or , Compr essor

Unf ast en t he f our scr ews whi c h hol d t he c ompr es s i on
Bear i ng
bear i ng ( 8) . Usi ng a smal l c opper mandr el , t ap out t he
c ompr es s i on bear i ng and t he bushi ng ( 9) . Then r emove Chec k t hat t he par t s ar e f r ee f r om wear and t ear and
t he ci r cl i ps ( 10) i nsi de t he bear i ng housi ng and r emov e t he . Damaged par t s shoul d be r epl aced even i f discoluratn t he
t wo bear i ngs ( 11) . amount of wear and t ear i s wi t hi n t he per mi t t ed
. t ol er anc s
Remov e t he packi ng r i ng ( 12) on t he t ur bi ne shaf t and t he
t wo packi ng r i ngs ( 13) on t he oi l def l ect or . Cl ean t he par t s
car ef ul l y .
ProCarManuals.com

Measur i ng and I nspect i on

Tur bi ne Wheel and Shaf t

Chec k t hat t he t ur bi ne wheel and shaf t ar e f r ee f r om

damage . The v anes mus t not be wor n or outmechanil of
s hape. Do not t r y t o r eal i gn t he v anes . Damaged par t s
shoul d be r epl aced .
Bushi ng
Chec k meas ur ement ( A) , whi c h shoul d not be l ess t han
4. 07 mm.

Oi l Def l ect or
Chec k meas ur ement s ( B) and ( C) . ( B) shoul d not be mor e
t han 1 . 31 mm, ( C) shoul d not be mor e t han 1 . 11 mm.

Compr essor Bear i ng

Chec k t he wi dt h of t he bear i ng, and r epl ace i t i f t he amount
of wear and t ear i s i n excess of t he per mi t t ed t ol er ance .
Mi ni mum per mi ssi bl e wi dt h i s 3. 98 mm.

Pl ace t he shaf t on t wo suppor t s, whi c h shoul d be under t he

bear i ng r ecesses,and check t he t hr ow at t he end of t he Bear i ngs
shaf t . The max i mum per mi ssi bl e t hr ow i s 0 . 011 mm. Chec k t he bear i ngs f or abnor mal wear and t ear or
Chec k t he di amet er of t he shafi st 7.bear
98 i ng r ecesses . The di scol ourat i on, andwtrehplmac ret.nChcskay e
per mi ssi bl e di amet er mm. Chec k t he wi dtminu h of i nt er nal and ext er nal di amet er s of al l bear i ngs . The extrnal
t he shaf t pi st on r i ng gr oov e . Max i mum per mi ssi bl e wi dt h di amet er shoul d not be l ess t han 12 . 31 mm, t he i nt er nal
i s 1 . 29 mm. di amet er shoul d not be mor e t han 8 . 04 mm.
 Reas s embl y
Gr eas e al l r emov abl e par t s when r eassembl i ng t hem.
t he ci r cl i ps i n t he bear i ng hous i ng so t hat t he Positn
i n t hem ar e f aci ng t owar ds t he oi l out l et . openi gs

Mount t he packi ng r i ng shaf t . Tur n t he openig

i n t he r i ng so t hat i on
t i st he
f aci
t urng
bi ne
t owar ds t he oi l i nt ake .
Posi t i on t he heat shi el d on t he bear i ng casi ng, and t hen
pl ace t he t ur bi ne axl e i n t he bear i ng housi ng .

Mount t he bus hi ng on t he t ur bi ne shaf t . Gr eas e i n t he

bear i ng wi t h engi ne oi l , and mount i t oncompres t he
bear i ng casi ng, usi ng new scr ews and was her s t o f ast en i t .
The t or que shoul d be 1 . 3 Nm±0. 1 .

Ti ght en t he s c r ews t o t he abov e t or que, t hen l oosen t hem a

quar t er t ur n bef or e t i ght eni ng t hem up t o t he cor r ect
t or que agai n.

Posi t i on t he t wo packi ng r i ngs on t he oi l def l ect or . NOTE :

The openi ng i n t he i nner r i ng shoul d be f aci ng t he oi l
t hat i n t he out er r i ng s houl d be f aci ng t he oi l i nt ake
out l e , .

Posi t i on t he oi l def l ect or i n t he cover . Smear t he edges of

t he bear i ng housi ng whi c h c ome i n t ouch wi t h t he cover ,
usi ng Per mat ex f or t he pur pose .
Bear i ng Housi ng
The t hi ckness of t he seal ant shoul d be about 0 . 1- 0 . 2 mm.
ProCarManuals.com

Chec k t he housi ng f or cor r osi on or cr acks . Chec k

Fi t t he cover on t he bear i ng housi ng, and f ast en i t wi t h new
( D) and ( E) , and r epl ace t he housi
mor e ng wher e
t han measurnt necsary
scr ews and was her s . The t or que shoul d be 1 . 3 Nm±0 . 1 .
. Meas ur ement ( D) shoul d not be 12 . 42 mm,
meas ur ement ( E) shoul d not be mor e t han 15 . 05 mm. Ti ght en t he scr ews t o t he abov e t or que, t hen l oosen t hem a
quar t er t ur n bef or e t i ght eni ng t hem up t o t he cor r ect
t or que agai n .

Posi t i on t he c ompr es s or wheel on t he t ur bi ne shaf t and

f ast en i t wi t h t he l ef t - hand t hr ead nut . The t or que shoul d
be 2 . 0 Nm±0 . 1 .

Mount t he t ur bi ne housi ng on t he bear i ng housi ng acording

t o t he l i ne- up mar k s . Sc r ew t he l ocki ng cover i nt o
mak i ng sur e t hat t he s c r ews used ar e not t hose positn, f or
c ompr es s or housi ng . The t or que shoul d be 11 . 0
t he
Nm±0 . 5 ( M6) , 26 . 0±1, 0 ( M8) .

Smear t he edges of t he bear i ng housi ng wher e i t c omes i n

t ouch wi t h t he c ompr es s or housi ng, usi ng Per mat ex f or
t he pur pos e . The t hi ckness of t he seal ant shoul d be about
0 . 1- 0 . 2 mm. Then mount t he c ompr es s or housi ng acording
t o t he l i ne- up mar ks, and s c r ew t he l ocki ng cover i nt o
posi t i on . The t or que shoul d be 4 . 5 Nm±0 . 5 .

Chec k t he axi al and r adi al cl ear ance . Max i mum permisbl

axi al cl ear ance i s 0 . 09 mm, max i mum per mi ssi bl e
cl ear ance i s 0 . 17 mm. r adi l

Cover
Chec k meas ur ement s ( F) and ( G) . and r epl ace t he cover
wher e necessar y . Meas ur ement ( F) shoul d not be mor e
t han 12 . 45 mm, meas ur ement ( G) shoul d not be mor e t han
10 . 05 mm.
Fi t t i ng t he Tur bo- Compr es s or
Bef or e f i t t i ng t he t ur bo- compr essor on t he engi ne, spr ay
cl ean engi ne oi l i nt o t he oi l i nt ake, and t ur n t he t ur bi ne
shaf t so t hat t he oi l i s evenl y di st r i but ed . Cl ean t he
turbo-compressor' s fturalse.odBCihnbgvcy

Packi ng Ri ngs cor r ect qual i t y of oi l ( see under " Techni cal Dat a" ) . Oi l

Chec k t he packi ng r i ngs t o see i f t hey ar e wor n or out of c hanges shoul d be car r i ed out i n ac c or danc e wi t h t he
and r epl ace t hem wi t h new ones wher e necsa i n t he Manual , i n or der t o keep t he engi ne cl ean
i ns t r uc o .
shape,
Cl ean t he ai r f i l t er .
ry.
ProCarManuals.com

FRESHWATER COOLI NG 2002, 2003

1 . Fi t t he ci r cul at i on pump ( compl et e wi t h t ensi oner br acket and spacer sl eeve, posi t i on 4) . Ti ght en t he bol t s ( M8x75) t o
20 Nm ( 2, 0 k pm) ( 14. 7 f t . l bs) , posi t i on 1 .
2. Sus pend t he heat exchanger l oosel y by t he r ear bol t ( M8x 16 and spr i ng was her . ), posi t i on 5 .
a) Fi t t he pi pe ( posi t i on 6) and t he hose ( posi t i on 3) bet ween t he heat exchanger and t he sea- wat er pump, usi ng
doubl e hos e c l amps ( appl y s oapy wat er t o t he r ubber r i ngs, appl i es f or al l r ubber r i ngs) .
b) Fi t t he pi pe bet ween t he heat - exchanger and t her most at housi ng, posi t i on 7 .
c) Fi t t he pi pe bet ween t he heat - exchanger and t he ci r cul at i on pump, posi t i on 8 .
3. Locat e t he pi pes i n t he heat - exchanger and and dr aw i t f or war d t i ght eni ng i t wi t h t he t wo bol t s ( M8x 16 and spr i ng
washer s) , posi t i ons 5 and 9 .
4. Fi t t he pi pe bet ween t he heat - exchanger and t he exhaust el bow, posi t i on 10 . NOTE! The hol der f or t he pi pe, ( posi t i on
11) and t he l ock ( posi t i on 11 a) .
5. Fi t t he pi pe bet ween t he ci r cul at i on pump ( l ower out l et ) and t he cyl i nder head, posi t i on 12 .
6. Fi t t he pi pe bet ween t he ci r cul at i on pump ( upper out l et ) and t he cyl i nder head, posi t i on 13 .
7. Fi t t he al t er nat or , pl ace t he bol t f or t he t ensi oner br acket wi t h t he head f or war ds . Put on and t ensi on t he V- bel t .
8. Fi t t he expansi on t ank t o t he exhaust el bow, posi t i on 15 .
9. Fi t t he hose bet ween t he t ank and t he ci r cul at i on pump ( doubl e pi pe ) 2002 = 450 mm( 17 . 7 i n) , 2003 = 550 mm( 21 . 7
i n) ( onl y si ngl e hos e c l amps ar e used on t he f r esh- wat er syst em) , posi t i on 16 .
10 . Fi t t he ni ppl e, posi t i on 17 .
11 . Fi t t he hose bet ween t he t ank and t he t her most at housi ng ( ni ppl e 17) : 2002 = 350 mm( 13 . 8 i n) , 2003 = 450 mm( 17 . 7
i n) , posi t i on 18 .
12 . Fi t t he pl ugs i n t he exhaust el bow and t he cyl i nder head, posi t i ons 19 and 20 .
13 . Fi l l t he addi
s y s t tem
i vet o( VP
t heaccessor
r i ght l evel wi t hf raesh-
y) . The mi xt
waturere syst
of f rem
esh
volwat er (2002
umes: 50% =) and ant2 i (- lf ir teeze
4. 0 dm r e) ( 0.
50%88) ,I mal
p. t gal
emats)i vel
( 1. y1 rust-poecin US gal s) ,

2003 = 5 . 5 dm3 ( l i t r e) ( 1 . 2 I mp . gal s) ( 1 . 45 US gal s) .

Pos 21 and 23 ar e f or hot wat er out l et .

 Wi r i ng di agr am, al t er nat i ve A
( St andar d)

I NSTRUMENTPANEL
1. Pr i nt ed ci r cui t car d
2. Rev count er ( accessor y)
3. St ar t but t on
4. Swi t ch f or i nst r ument panel
5. Al ar m t est but t on
6. Al ar m

Max out put f r om

t he panel = 5 A

Cabl e col our

R = Red
PU - - Pur pl e
BN = Br own
OR = Or ange
GR = Gr ey
ProCarManuals.com

SB = Bl ack
W = Whi t e
Y = Yel l ow
GN = Gr een
BL = Bl ue

ENGI NE

1 . Rel ay
2 . Fuse
3 . Temp . al ar m sender
4 . Oi l pr essur e al ar m sender

Wi r e ar eas i n mm2

Wi r e ar ea

mm2 AWG

1, 0 16
1, 5 14
2, 5 12
10 6

26
 Wi r i ng di agr am, al t er nat i ve B
( De Luxe)

I NSTRUMENT PANEL

1. Vol t met er
2. Oi l pr essur e gauge
3. Cool ant t emper at ur e gauge
4. Pr i nt ed ci r cui t car d
5. Al ar m t est
6. Swi t ch f or i nst r ument l i ght i ng
7. Rev . count er
8. Key swi t ch
9. Al ar m

Max out put f r om

t he panel : 5 A
ProCarManuals.com

Cabl e col our

GR = Gr ey
SB = Bl ack
BN = Br own
LBN = Li ght br own

R = Red
P = Pur pl e
GN = Gr een
Y = Yel l ow
W = Whi t e
BL = Bl ue
LBL = Li ght bl ue

ENGI NE

1. Cool ant t emper at ur e sender

2. Oi l pr essur e al ar m sender
3. Cool ant t emper at ur e al ar m sender
4. pi t pr essur e sender
5. Rel ay
6. Fuse

Wi r e ar eas i n mm2
 FAULT TRACI NG

Engi ne Engi ne Engi ne not Engi ne r uns Engi ne Faul t

does st ops r eachi ng r oughl y or bec omes
not cor r ect t emp vi br at es abnor mal y
st ar t at f ul l r pm abnor m l y hot

St op cont r ol not f ul l y pus hed

back . Mai n swi t ch: not swi t ched
ProCarManuals.com

on . Fl at bat t er y . Br oken el ect r i c

wi r es . Mai n f use bl own . zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA

" Empt y f uel t ank, cl osed f uel cock

or cl ogged f uel f i l t er .

" " " Wat er or i mpur i t i es i n t he f uel .

Faul t y i nj ect or s or ai r i n t he f uel
s y s t em.

" Boat abnor mal l y l oaded, cl ogged

i nt ake ai r f i l t er or mar i ne gr owt h
on t he boat bot t om.

Engi ne not pr oper l y al i gned .

damaged . Propel

" Cl ogged cool i ng wat er i nt ake or

wat er j acket s i n t he exhaust
. Faul t y i mpel l er i n sea- mawat
ni f ol d er
pump . Faul t y t her most at . Cloged
cool i ng wat er pi pe i n t he
head . c y l i nder
 1

9992265- 0 Pul l ey pul l er

884813- 7 I nst al l at i on r i ng f or pi st on

9995218- 6 Mandr el f or val ve gui de r emoval

884557- 0 Mandr el f or i nst al l at i on of i nj ect or sl eeve

884559- 6 Mandr el f or i nst al l at i on of val ve gui de

884787- 3 Set t i ng- di sc f or i nj ect i on pump set t i ng

ProCarManuals.com

884811- 1 Pul l er f or i nj ect or sl eeve

884823- 6 Fl ar i ng t ool f or i nj ect or sl eeve

884837- 6 Fl ange f or engi ne cr adl e

884838- 4 Mandr el f or i nst al l at i on of seal i ng r i ng i n t r ansmi ssi on

cover

Assembl y and di sassembl y t ool f or camshaf t pi n

884839- 2

884840- 0 Gui de pi n f or cyl i nder head . NOTE! Two ar e requid

.
 TECHNI CAL DATA
Gener al

Type desi gnat i on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2001 2002 2003, 2003T

Number of cyl i nder s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 3

Di spl acement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . . 0 . 43 dm3 ( 26 . 2 cu 0 . 852 dm3 ( 51 . 9 cu i n) 1 . 278 m3 ( 77 . 99
i n) cu i n)
Cyl i nder bor e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 mm( 3 . 11024 i n)
St r oke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 mm ( 3 . 4252 i n)
Compr es s i on r at i o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 . 5 : 1
Compr es s i on r at i o at st ar t er mot or s peed . . . . . . . . . . . . . . . . . 2- 2 . 5 MPa ( 20- 25 k p/ c m2 )

Di r ect i on of r ot at i on ( seen f r om t he f r ont end) . . . . . . . . . . Cl ockwi se

I dl i ng speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 14 r / ' s ( 775- 825 r pm)
Oi l pr essur e at f ul l s peed and war m engi ne . . . . . . . . . . . . . 0, 35- 0, 40 MPa ( 3, 5- 4, 0 kp/ cm2)
Oi l pr essur e at i dl i ng and war m engi ne . . . . . . . . . . . . . . . . . 0, 08- 0, 15 MPa ( 0, 8- 1, 5 k p/ c m2 )

Cyl i nder bl oc k

Mat er i al
. . . . . . . . . . . . . . . . . . .
Cyl i nder di amet er , st andar d
0, 25 mmover - si ze . . . . . . . . . .
0, 50 mmover - si ze . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . Speci al al l oy cast i r on
. . . . . . . . . . . . . . . . . . . . . . . . . . . 79, 00- 79, 03 ( 3 . 11025- 3 . 11142 i n . )
. . . . . . . . . . . . . . . . . . . . . . . . . . . 79, 25- 79, 28 ( 3 . 12008- 3 . 12126 i n . )
. . . . . . . . . . . . . . . . . . . . . . . . . . . 79, 50- 79, 53 ( 3 . 12992- 3 . 1311 i n . )

Pi s t ons

Mat er i al . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Li ght - al l oy
Tot al hei ght . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78, 3 mm ( 3. 08268 i n . )
ProCarManuals.com

Hei ght f r om gudgeon pi n cent er t o pi st on t op . . . . . . . . . . 50, 3 mm ( 1 . 98031 i n . )

Pi st on cl ear ance i n cyl i nder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0, 09 mm ( . 00354 i n . )
Pi st on i n st andar d di mensi on . . . . . . . . . . . . . . . . . . . . . . . . . . 78, 903- 78, ) 17 ( 3, 10642- 3, 10697 i n . )
0, 25 mm over - si ze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79, 153- 79, 167 ( 3, 11626- 3, 11681 i n . )
0, 50 mm over - si ze. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79, 403- 79, 417 ( 3, 12610- 3, 12665 i n . )

Gudgeon pi ns

Di amet er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25, 995- 26, 000 ( 1, 02343- 1, 02362 i n . )

Gudgeon pi n bushi ng, di amet er . . . . . . . . . . . . . . . . . . . . . . . . 26, 005- 26, 011 ( 1, 02382- 1, 02406 i n . )
Cl ear ance gudgeon pi n - bushi ng . . . . . . . . . . . . . . . . . . 0, 0050- 0 . 0160 ( 0, 00020- 0, 0063 i n . )

Pi st on r i ngs

Compr es s i on r i ng, number . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Oi l r i ng, number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
The upper c ompr es s i on r i ng has an i nl ay of c hr ome .
The pi st on r i ngs ar e avai l abl e f or st andar d di mensi on and
f or 0, 250 and 0, 500 mm over si ze ( 0, 00984 and 0, 0996)
i n.)

Pi st on r i ng axi al c l ear anc e i n t he gr oov e

Upper c ompr es s i on r i ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0, 070- 0, 102 ( 0 . 00276- 0, 00402 i n . )

Lower c ompr es s i on r i ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0, 050- 0, 082 ( 0, 00197- 0, 00323 i n . )
Oi l r i ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0, 030- 0, 062 ( 0, 00118- 0, 00244 i n . )

Pi st on r i ng gap i n t he cyl i nder

Upper c ompr es s i on r i ng . . . . . . . . . . . . . . . . . . . . . . . . . . .zyxwvutsrqponmlkjihgfedcbaZYXWVUTSRQPONMLKJIHGFEDCBA 0, 30- 0, 50 ( 0, 001181- - 0, 00197 i n . )

Lower c ompr es s i on r i ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0, 30- 0, 50 ( 0, 001181- 0, 00197 i n . )
Oi l r i ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0, 25- 0, 50 : 0, 009842- 0, 00197 i n . )

Cr ank s haf t

Mat er i al . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nodul ar i r on
Cr ankshaf t axi al cl ear ance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0, 040- 0, 221 ( 0, 00157- 0, 00870 i n . )
Mai n bear i ng r adi al cl ear ance . . . . . . . . . . . . . . . . . . . . . . . . . . 0, 040- 0, 092 ( 0, 00157- 0, 00362 i n . )
Bi g- end bear i ng, r adi al cl ear ance . . . . . . . . . . . . . . . . . . . . . . . 0, 024- 0, 068 ( 0, 00094- 0 . 00268 i n . )

1 Pr opel l er shaf t out put i n accor dance wi t h DI N 6270B .

Mai n bear i ng j our nal s

Di amet er , st andar d 59, 987- 60, 000 ( 2, 36169- 2, 36220 i n . )

0, 250 mm under - si ze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59, 737- 59, 750 ( 2, 35185- 2, 35236 i n . )
0, 500 mm under - si ze- . . . . . . . . . . . . . 59, 487- 59, 500 ( 2, 34200- 2, 34252 i n . )

Mai n bear i ng shel l s

Thi ckness, st andar d - - . - . . . . . . . . . . . . . . . . . . . . . . . . . . . 2, 987- 2, 997 ( 0, 11760- 0, 11799 i n . )

0, 250 mm over - si ze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3, 112- 3, 122 ( 0, 12252- 0, 12291 i n . )
0, 500 mm over - si ze - - . - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 3, 237- 3, 247 ( 0, 12744- 0, 12783 i n . )

Bi g- end j our nal s

Di amet er , st andar d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47, 989- 48, 000 ( 1, 88933- 1, 88976 i n . )

0, 250 mm aver - si ze - - - . . . . . . . . 47, 739- 47 . 750 ( 1, 87949- 1, 87992 i n . )
0, 500 mm over - si ze . - . - - . . - . . . . . . . . . . . . . . . . . . . . . . . . . . . 47, 489- 47, 500 ( 1, 86965- 1, 87008 i n . )

Bi g- end bear i ng shel l s

Thi ckness, st andar d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1, 478- 1, 488 ( 0, 05819- 0, 05858 i n . )

0, 250 mm over - si ze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1, 603- 1, 613 ( 0, 06311- 0, 06350 i n . )
0, 500 mm over - si ze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1, 728- 1, 738 ( 0, 06803- 0, 06843 i n . )

Connec t i ng r ods

Axi al cl ear ance at t he cr ankshaf t . . . . . . . . . . . . . . . . . . . . . . . 0, 15- 0, 35 mm ( 0, 00590- 0, 01378 i n . )

Cams haf t
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Axi al cl ear ance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0, 160- 0, 300 mm( 0, 0063- 0, 01181 i n . )

Radi al cl ear ance i n bear i ngs . . . . . . . . . . . . 0, 020- 0, 075 mm( 0, 000787- 0, 00295 i n . )
Cams haf t di amet er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46, 975- 47, 000 ( 1, 8494- 1, 85039 i n . )
Li f t i ng hei ght of c ams . . . . . . . . . . . . --- . ---------- . . .-- . . 5, 48- 5, 52 mm( 0, 21575- 0, 21732 i n . )
Bushi ng di amet er . . . . . . . . . . . . . . . . . . . . . .------------ . . . 47, 02- 47, 05 mm( 1, 85118- 1, 85236 i n . )

Cyl i nder head

Mat er i al . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Speci al al l oy cast i r on

I nl et v al v es
20031
Di sc di amet er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34, 4- 34, 6 mm ( 1, 35433- 1 . 36220 i n . ) 35, 8- 36, 0 mm
St em di amet er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7, 955x7, 970 mm( 0, 31319- 0, 31378 i n . ) 7, 995- 7, 970 mm
Val ve seat angl e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44° 55' - 44 ° 85' 29° 45' - - 30 15'
Cyl i nder head seat angl e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° 30°
Seat wi dt h i n t he cyl i nder head . . . . . . . . . . . . . . . . . . . . . . . . appr . 1 mm ( 0, 03) 37 i n . ) appr . 1 mm! 0 . 03) 37 i n .
Cl ear ance, col d/ war m engi ne . . . . . . . . . . . . . . . . . . . . . . . . . . 0, 3 mm ( 0, 011811 i n . ) 0 . 3 mm( 0, 011811 i n . )

Ex haus t v al v es

Di sc di amet er . . . . . . . . . . - - - - . . . . . . . . . . . . . . . . . . . . . . . . . . . 29, 9- 30, 1 mm ( 1, 14716- 1, 18504 i n . )

St em di amet er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7, 950- 7, 465 mm ( 0 . 31299- 0, 31339 i n . )
Val ve seat angl e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 °5 ' - 8

Cyl i nder head seat angl e - . . - . . . . . . . . . . . . . . . . . . . . . . 45 °

Seat wi dt h- i n t he cyl i nder head . - - . . . . . . . . . . . . . . . . . . . . . appr . 1 mm ( 0, 03937 i n . )
Cl ear ance, c ol d/ war m engi ne - - - - - . . . . . . . . . . . . . - - . . . - - - 0, 3 mm ( 0, 011811 i n . )

Val v e gui des

Lengt h, i nl et val ve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 mm ( 1, 49606 i n . )

Lengt h, out l et val ve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 mm ( 1, 49606 i n. )
I nner di amet er - - - - - - - - - - - - . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8, 000- 8, 015 ( 0, 31496- 0, 31555 i n . )
Hei ght abov e spr i ng- pl ane of cyl i nder head . . . . . . . . . . . . . 8, 70- 9, 30 mm ( 0, 34252- 0, 36614 i n . )

Val v e s pr i ngs

Lengt h, unl oaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42, 5 mm ( 1, 67323 i n . )

Loaded wi t h 170±10 N ( 17±1 kp) . . . . . . . . . . . . . . . . . . . . . . 32 mm ( 1 . 25984 i n . )
Loaded wi t h 300±20 N ( 30±2 kp) . . . . . . . . . . . . . . . . . . . . . . 24 mm ( 0, 94488 i n . )
Lubr i cat i ng s y s t em
ENGI NE
Oi l quant i t y model 2001 .
Oi l quant i t y model 2002 . . .
Oi l quant i t y model 2003 . . .
Oi l qual i t y accor di ng t o t he
Vi scosi t y . . . . . . . . . . . . .
. . . .
Oi l pr essur e, war m engi ne,
Oi l pr essur e, war m engi ne,
. . . . . . . . . . . . . 1, 40 dm3 ( 1 . 2 quar t s)
. . . . . . 2 . 75 dm3 ( 2 . 42 quar t s)
. . . . . . . . . . . . . . . . . . . 4, 10 dm3 ( 3. 6 quar t s)
API - syst em CD ( DS)
. . . . . . 15 W/ 40
. . . . .
i dl i ng speed . . . . . . . . . . . . . . . . 0, 8- 1, 5 kp/ cm2 ( 11 . 37- 21 . 33 l bf t / i n2 )
f ul l r pm . . . . . . . . . . . . . . . . . . . . 3, 5- 4, 0 kp/ cm2 ( 49 . 78- 56 . 89 l bf t / i n 2 )

Lubr i cat i ng oi l pump

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear wheel pump
Gear wheel axi al cl ear ance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0, 025- 0, 065 ( 0, 00098- 0, 00256 i n . )
Spr i ng f or r educt i on val ve, l engt h unl oaded . . . . . . . . . . . . 49 mm ( 1, 92913 i n . )
Loaded wi t h 35 Nm ( 3, 5 kp) ( 25 . 8 f t . l bs . ) . . . . . . . . . . . . . . . . 40 mm( 1, 57480 i n . )

Fuel Sy s t em

Openi ng pr essur e . i nj ect or s . . . . .

. . . . . . . . . . . . . . . . . . . . . . . 180- 190 kp/ cm2 ( 2560- 2702 l bf t / i n2) 1)
Spr ay angl e . . . . . . . . . . . . . __ . . .. . . . . . . . . . . . . . . . . . . . . . . 150 °
I nj ect i on angl e 2001 . . . . . . . . . . .. . . . . . . . . 22±1 B. T . D. C
I nj ect i on angl e 2002, 2003 . . . . . .. . . . . . . . . . . . . . . . . . . . . . . 20+1°° C B. T . D- C .
23±1° B. T . D
I nj ect i on angl e 2003T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C.
I nj ect i on quant i t y . . . . . . . . . . . . . . . . . . 25+1 . 5 mm3/ st r oke at 40±5° C ( 104° F±10 . 6° F)
and at 25 r / s ( 1500 r pm) pump r evs
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Gover nor over r un . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 r / s ( 3250 r pm)

Feed pump
Feed pr essur e 42 r / s ( 2500 r pm) . . . . . . . . . . . . . . . . . . . . . . . . . . . 0, 65- 0, 85 kp/ cm2 ( 9 . 20- 12 . 10 l bf / i n 2 )

El ect r i cal syst em

Bat t er y vol t age . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V
Bat t er y capaci t y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : . . . . . . . . . . Max . 70 Ah
St ar t er - mot or out put 2001 . . . . . . . . . . . . . . . . . . . . . . . . . - 0. 8 k W! 1 . 1 HP)
St ar t er - mot or out put 2002 and 2003 . . . . . . . . . . . . . . . . . . . . . . . 1 . 4 k W( 1 . 9 HP)
Al t er nat or out put :
Vol t age/ max . cur r ent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 14W50 Amp
Out put . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 700 Wat t s
El ect r ol yt e spec . gr avi t y : Ful l y l oaded bat t er y . . . . . . . . . .. 1, 275- - 1, 285
To be char ged at . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1, 230
Ther most at . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Wax t her most at
Begi ns t o open at . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60±2` C ( 140±4° F)
Ful l y open at . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75' C { 165 ° F1

Cool i ng s y s t em
Wi t h f r esh- wat er cool i ng ( 2002, 2003)
St ar t s openi ng at . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74±1° C ( 164±2° F)
Ful l y open at . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87° C ( 189 ° F)
Fr esh- wat er syst em, vol ume 2002 . . . . . . . . . . . . . . . . . . . . . . . . . 4. 0 dm3 l i t r e) ( 0 . 88 I mp . gal s) ( 1 . 1 US gal s)
2003_____ 5 . 5 dm3 ( l i t r e) 11 . 2 I mp . gal s) ( 1 . 45 US gal s)

WEAR TOLERANCES

Cyl i nder s
To be bor ed at 0, 25 mm wear ( 0, 00984 i n . )

Cr ankshaf t
Mai n- and bi g- end j our nal s :
Per mi t t ed out - of - r ound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0, 06 mm ( 0, 00236 i n- )
Per mi t t ed t aper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0, 05 mm ( 0, 00197 i n . )
Max . axi al cl ear ance on cr ankshaf t . . . . . . . . . . . . . . . . . . . . . 0, 40 mm ( 0, 01575 i n . )

1) 2003T = 204- 212 kp/ cm2 ( 2900- - 3015 l bf / i n 2 )

 Cams haf t

Bear i ng j our nal s, per mi t t ed out - of - r ound . . . . . . . . . . . . . . . 0, 03 mm( 0, 00118 i n . )

Max . cl ear ance bet ween camshaf t and bushi ngs . . . . . . . . 0, 15 mm( 0, 00590 i n . )

Val v es

Max . cl ear ance bet ween val ve s t em and val ve gui de . . . . 0, 15 mm( 0, 00590 i n . )
The val ve di sc edge mus t be at l east 1, 5 mm ( 0, 05906 i n . )

Ti ght eni ng t or ques

Mai n bear i ng bol t s, 1st t i ght eni ng . . . . . . . . . . . . . . . . . . . . . . 20 Nm ( 2, 0 k pm) ( 14 . 7 f t . l bs . )

2nd t i ght eni ng . . . . . . . . . . . . . . . . . . . . . . 60 Nm ( 6, 0 k pm) ( 44 . 2 f t . l bs . )
Bi g- end bear i ng bol t s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Nm ( 7, 0 k pm) { 51 . 6 f t . l bs . )
Fl ywheel housi ng bol t s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm ( 2, 5 k pm) ( 18 . 4 f t . l bs . )
Fl ywheel bol t s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Nm ( 6, 5 k pm) ( 47 . ) f t . l bs . )
Cyl i nder head bol t s, 1st t i ght eni ng . . . . . . . . . . . . . . . . . . . . . 20 Nm ( 2, 0 k pm) ( 14 . 7 f t . l bs . )
2nd t i ght eni ng . . . . . . . . . . . . . . . . . . . . 70 Nm ( 7, 0 k pm) ( 51 . 6 f t . l bs . )
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Rocker ar m br i dge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm ( 2, 5 k pm) ( 18 . 4 f t . l bs . )

Fuel i nj ect i on pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm ( 2, 5 k pm) ( 18 . 4 f t . l bs . )
Pul l ey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Nm { 4 , 0 k pm) ( 29 . 5 f t . l bs . )
I nj ect or s . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm ( 2, 0 k pm) ( 14 . 7 f t . l bs. )