FOREWORD

Thi s
workshop manual contai ns repai r
i nstructi ons f or the 2001, 2002 and2003engi nes.
The i nstructi ons
concerni ng overhaul i ngdescri be themost sui tabl e
worki ngmethodusi ngthespeci al tool s l i sted under
the headi ng
"Speci al tool s" .
Boththeengi ne
desi gnati onandi ts seri al number must be cl earl y statedi nal l correspondence
concerni ngtheengi ne and
whenorderi ng
parts.
We
reserve the ri ght
to carry out desi gnmodi f i cati ons and, f or thi s reason, the contents of thi s manual cannot be regarded as
bi ndi ng.
SI
UNI T SYSTEM
Power i s
gi ven i n kW( ki l owatt)

Speedi s gi ven
i n rev/ s ( revol uti ons per second)
earl i er uni t hp ( horse- power)

earl i er uni t rev/ mi n ( revol uti ons per mi nute)
Torque i s gi ven i n Nm( newton
metre)

Vol ume
i s gi ven i n dm3 ( cubi c deci metre)
earl i er uni t
kpm( ki l opond metre)

earl i er uni t
l
( l i tre)
earl i er uni t
l bf f t ( poundf oot) earl i er uni t I mp. gal ( I mperi al gal l on)
earl i er uni t US gal ( Uni ted States
gal l on)
Pressure i s gi ven i n Pa
( Pascal )
earl i er uni t kp/ cm
2 ( ki l oponds per square
centi metre)
earl i er uni t I bf / i n2 ( pounds per
square i nch)
ABVOLVOPENTA
Techni cal Publ i cati ons
Department
Uni ts accordi ng tothe
i nternati onal SI systemhave been used i n thi s
book. The earl i er uni ts are gi ven af ter the SI
uni ts
.
Components gui de. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 2
DI SASSEMBLY
Cyl i nder head. . . . . . . . . .
.
. . .
. . . . . . . . . . . . . . . . . . . . . . . . . 3
Transmi ssi on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Pi ston, pi ston rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fl ywheel . . . . . . . .
.
.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Crankshaf t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Camshaf t . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . .
. .
. . . . . . . . . . .
5
OVERHAUL
Di sassembl i ng thecyl i nder head. . . . . . . . . . . . . . . . . . . . .
7
Val ve
gui des
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Val veseats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Val ves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
. .
.
. .
. . .
. .
7
Val vespri ngs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Rocker armmechani sm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
I nj ector sl eeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
I nj ectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Assembl i ng thecyl i nder head. . . . . . . . . . . . . . . . . . . . . . . . 9
Feed-pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pi stons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Crankshaf t . . .
.
. .
. .
.
. .
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
Camshaf t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Connecti ng rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Sea-water pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ASSEMBLY
I NDEX
Crankshaf t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pi stons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Fl ywheel . . . . . . . . . . . . . . . . . . . . . . . . : . . . . . . . . . . . . . . . . . .
15
Transmi ssi on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Adj usti ng theval ve cl earance. . . . . . . . . . . . . . . . . . . . . . . 17
Checki ng thei nj ecti on angl e. . . . . . . . . . . . . . . . . . . . . . . . 17
2003 Turbo. . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . 21
Fresh water cool i ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
El ectri cal system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Faul t traci ng scheme. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Speci al tool s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29
Techni cal Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
COMPONENTS GUI DE
8
1 .

Exhaust el bow
2. I nj ectors
3. Temperature
sender
4.

El ectri cal di stri buti on
box
5.

Fuel f i l ter
6. Al ternator
7.

Starter
motor
8.

Drai nage,
cool i ng water
9. Feed- pump
10.

Engi ne seri al number
11 .

Decompressi ondevi ce
12.

I nl et
ai r
si l encer
13.

Fuel
i nj ecti on pumps
14. Oi l di psti ck
15.

Sea- water pump
Halpert@Optonline.net
Drai nof f thecool i ngwater
andthel ubri cati ngoi l f romthe
onengi necradl e p/ n 9992520andf i xture p/ n 884837
. I f the
engi ne i s f res h water cool ed, s ee
page 21 .
1 . Remove the al ternator, the tens i oner bracket and the
s tarter motor . Removetheconnecti ons
f romthe
el ectri cal
di s tri buti on box f romtheengi neand removethe box and
the
wi re
harnes s .
2.
Remove
the return
f uel l i ne, thef uel pres s ure l i nes and
the i nl et ai r s i l encer . I ns tal l protecti on caps on thef uel
i nj ecti on pumps andi nj ectors
. Remove the s crewhol di ng
the l ever of thedecompres s i on devi ce
( 1)
andpul l out the
l ever . Remove the
val ve cover .
DI SASSEMBLY
3. Remove the f uel f i l ter, the oi l f i l ter, thef eed-pump, the
thermos tat
hous i ng andthe exhaus t el bow. Al s o remove
the s ea-water pump wi th i ts attachment tubes .
4. Removethe val ve bri dge
andl i f t out the pus h rods .
Remove therubber ri ngs f ortheoi l pi pe. Removethe
cyl i nder
head andthe
val ve l i f ters . Put the l i f ters ona rack i n
cons ecuti veorder, N O T E! T he cyl i nder headbol ts are phos phati s edand mus t not be cl eaned wi th as teel brus h .
5. Removethef uel i nj ecti on pumps. Markthepumpsto
ensurei nstal l ati on i n thesamecyl i ndersf romwhi chthey
wereremoved. Takecareof theshi ms. Removethescrews
on thesi deof theengi nebl ock and l i f t out thepump
l i f ters .
6. Removethepul l ey center bol t and pul l of f the pul l ey
usi ng pul l er
p/ n
9992265. Pl ace
a protecti on pad between
thepul l er andthecrankshaf t toavoi dthecrankshaf t bei ng
damaged.
7. Removethetransmi ssi on cover: Start by removi ngthe
throttl e
control cover. Useasui tabl etypeof pl i ersto
remove thespri ng ( 1) . Then removetheend-ni ppl e( 2) and
thespri ng ( 3) . Removetheoi l pumpcover and markthe
gear wheel s wi th a col our-pen bef ore
removi ng them.
( When i nstal l i ngthegear wheel s, themarkedsi demust be
f aci ngoutwards) . Removethebraci ng pi n of thecamshaf t
usi ngthespeci al tool
p/ n
884839. Never removethe
braci ng pi n by punchi ng i t out, thi s can very wel l bend the
camshaf t . Removethescrewson thetransmi ssi on cover
and pul l i t strai ght outwards.
8. The max. -vol ume-screw
( 1) andthemax. -rev-screw( 2)
areset by
Vol voPentaand must never be
changed si nce
thi s
wi l l
af f ect theengi neoutput
.
9. Removethecontrol rod. Start by removi ngthepl ug at
therearof thebl ockandthetwoscrewson thepumppl ane,
hol di ng thecontrol rod.
10. Pul l out the camshaft
.
11.
Remove
the
outer fl ywheel housi ng, the fl ywheel and
the i nner fl ywheel housi ng.
12. Turntheengi ne upsi de downandremovethe
oi l pan.
Be
careful asthepani s gl ued.
NOTE! Theoi l panends al so
functi on as mai n
beari ngs.
13. Removetheconnecti ng rodbol ts andremovethe
connecti ng rodsandthe pi stons.
Theconnecti ng rodandthe
connecti ng rodcap are markedwi th fi gures.
14. Remove
themai nbeari ngcaps. Themai n
beari ngcaps
aremarkedwi thaf i gure. Thecorrespondi ng
f i gurei s
punched i ntothebl ock. Li f t out the
crankshaf t . Onl ater engi ne
versi onsan
arrowi s cast i ntheseparatemai n
beari ngcaps
(2002, 2003)
.
Thearrowi s to
poi nt towards thedi psti ck.
THECYLI NDER
HEAD
1 . Removethe
"col l ets" andval ve
spri ngs usi ng
a val ve
bow. Removetheval ves . Remove
t
heval vestemseal s.
Pl ace the
val ves
i n the
proper sequence i n a val ve
stand.
Val ve
gui des
2. Checktheval vegui dewear byi nserti ng anewval vestem
i nto the gui de. Measurethe pl ay
usi ng
a di al i ndi cator
.
I f
necessary, repl acetheval vegui des.
Wear l i mi ts:
I nl et
val ve, maxpl ay . . . . . . . . . . . . . . . 0. 1 5
mm(0. 0059
i n)
Exhaust val ve, maxpl ay . . . . . . . . . . . . 0. 1 5 mm(0. 0059 i n)
3. Use
mandrel p/ n 521 8topress out theval vegui des
.
Oi l
the newval ve gui des external l y and use mandrel p/ n
884559to
i nstal l
them
.
Press downthemandrel al l theway
down to the cyl i nder head. Reamthe val vegui des i f
necessary
.
Val ve
seats andval ves
4. Mi l l or reamtheval veseats. Theangl e
(C)
shoul d be45
(f or
2003T, 30 f or thei nl et val ve) . The
seal i ng
surf ace' s
wi dth
(B) shoul dbe1 0. 1 mm(0. 0390. 0039 i n) . Gri ndtheval ves
i n
a val ve
gri ndi ng machi ne
.
Theangl e(D) ,
see
Tech. data. I f
the
di sc thi ckness af ter gri ndi ngi s l ess
than1
. 0
mm(0. 039 i n)
f or natural l y aspi rated engi nes or 0. 8 mm
(0. 031
i n) f or
turbocharged engi nes, theval ves must bescrapped. Val ves
wi th
bent stems, or i f themeasurement (A) exceeds 2. 5 mm(0. 098
i n)
must al sobescrapped. Gri nd the
val veti p
towards the
rockers i f necessary. Lap i ntheval ves usi ng val vegri ndi ng
pasteandcheckthecontact area
wi th
marki ng dye.
Repl aci ngtheval ve seat exhaust port 2003T
Gri nddowntheval vedi sc of a di scardedval veto j ust bel ow
27 mm( 1 . 063
i n)
di ameter
. Push theval vestemthroughthe
gui de. NOTE! Donot push i ntoo f ar- the val ve di sc shoul d be
j ust bel owtheedgeof theseat . Spot
wel dthedi sc i n pl aceat
threepoi nts usi nga el ectri c wel der . Knockout theseat by
hi tti ng theval vegui de
wi tha pl asti c- headed hammer .
Cool the
new
seat
to approx. - 20C( - 4F) ; the cyl i nder
headshoul dbeat roomtemperature( +200168F)
.
Pl acethe
cool edseat on tool
884961- 4 and knocki t downunti l i t
bottoms . NOTE! Turnthe seat wi th theval vef ace
towards
the
tool
.
Val ve spri ngs
5 . Checkthef ree l engthof
theval vespri ngs andthe l ength
when l oaded.
L = Length, unl oaded
42, 5 mm( 1 . 67323i n. )
L1 = Length, l oaded wi th 17010 N( 171 kp) 32
mm
( 1 . 25984
i n. )
L2 = Length, l oaded wi th 30020 N( 303 kp) 24
mm
( 0. 94488 i n. )
Rocker armmechani sm
6.
Di sassembl e the rocker armmechani smand cl eanthe
parts . Checkthewear of theshaf t and rockerarmbushi ngs.
Shoul dthebushi ngs needto berepl aced, usethemandrel
p/ n
9991867 f or the removal and i nstal l ati on, ( make
sure
that theoi l hol ei n thebushi ngcoi nci des wi ththeonei nthe
rocker arm) .
Af ter the
i nstal l ati on the bushi ngs
are reamed
to a cl ose runni ngf i t. When i nstal l i ng the rockerarmshaf t,
i t must beturnedso that thel ubri cati on hol es are f aci ng the
val ve- si de
. Checkto makesurethat the rocker armcontact
surf aceagai nsttheval ve i s concave. Mi nor adj ustments are
madei n
a
val vegri ndi ng
machi ne. Oi l theshaf t andi nstal l
the parts.
Pressuretesti ngthenozzl es
7. Check the nozzl e' s spray pattern at the correct openi ng
pressure( see Techni cal Data) .
Checkal sothat thef uel sprays
stop
si mul taneousl y and nodri ppi ngoccurs.
Adj ust theopeni ng- pressure
wi th adj ustment- washers ( 1)
bei ngavai l abl e
i n di f f erent thi cknesses f rom1 mmU3937
i n. ) to 1, 95 mm( . 076772i n. ) i n steps
of 0, 05 mm( . 001969
i n. ) . Di sassembl e
the i nj ector and repl ace theadj ustment- washer
agai nst athi nner one or athi cker one dependi ng on
whether
the pressure must be reduced or i ncreased.
Assembl e
thei nj ector andchecktheopeni ng- pressureand
the spray- pattern.
I nj ector- sl eeve
8. I nsert the expandi ng screwon the speci al tool p/ n
884811 i nto the copper sl eeve andturn the screw
anti - cl ock wi seunti l the screwhas stuck i n thesl eeve . T i ghten
the screwhardto al l owthe threads to work themsel ves
i nto the copper materi al . T hen i nstal l the yok e
( 1)
on the
studbol t of the i nj ector . Put
a
cyl i nder
headscrew
i n
the
cyl i nder headas a supportf orthe l egof theyok e. I nstal l the
nut ( 2) andti ghten
i t
unti l the sl eeve i s removed.
9 . Repl ace the O- ri ng, seal i ngof f between the sl eeve and
the cyl i nder head. Di pthe newO- ri ngi n
soap- water i n
order
to f aci l i tate the i nstal l ati on. Oi l the newi nj ector sl eeve
andi nstal l i t, usi ngspeci al tool p/ n
884557
.
Knock downthe
sl eeve
unti l i t bottoms.
10. Oi l thef l are- tool p/ n 884283 and i nsert i t i ntothe sl eeve
( mak e sure that the dowel i s properl yretracted) . Brace the
tool
wi th
the i nj ector yok e. Screwdownthef l are- tool as f ar
as the shoul der i n the i nj ector sl eeve al l ows, thereby
f l ari ng
the sl eeve. Remove the tool . Adj ust the l ength of the
sl eeve outsi de the pl ane of the
cyl i nder headto maxi mum
1 mm(
. 03937i n . ) .
Assembl i ng
the cyl i nder head
11. Cl ean the cyl i nder head. I f
the water di stri buti on pi pe
has been di sassembl ed, i t
must be i nstal l edwi th the hol es
turnedas i ndi cated i n the pi cture. I nstal l newval ve
stem
seal i ngs. Oi l the val ve
stems and i nstal l the val ves. Mak e
sure to i nstal l the val ves andthe val ve spri ngs i n
thei r
respecti ve ori gi nal
posi ti ons. I nstal l the val ve spri ngs and
the
"col l ets" . Use a val ve- bow.
Reducti onval ve
12. Removethecover of the reducti onval veandcheck
to
make
surethat the
spri ng
andthe pi stonare f aul tl ess . I f
therearereasons tosuspect af aul t i ntheopeni ngpressure
of the reducti on val ve, thencheckthe dataof thespri ng.
Seeunder "Techni cal Data" - reducti on val ve
.
Feed-pump
13.
Depress
thepumpl ever. i f thedi aphragmof thepump
sounds squeaky, the di aphragmi s f aul tl ess.
Changi ng thedi aphragm
14. Removethesi x screws, hol di ng the upper
and l ower
pump
housi ngs together . Removethe pumpl ever spri ng
( 1) and remove the screw( 2) hol di ng the pump l ever
shaf t .
15. Useasui tabl epai r of pl i ers andremovethepumpl ever
shaf t . Pul l out the
l ever
andthe
di aphragm.
16. Cl ean the pumphousi ng
caref ul l y
and repl ace worn
parts. I nstal l the di aphragm
and the
l ever on the
di aphragm
shaf t .
Then i nsert the shaf t andti ghten i t wi th the
screw
.
Assembl e the two housi ng hal ves andi nstal l the
attachment pl ate ( 1) . Then
i nstal l
the spri ng ( 2) andtheO - ri ng ( 3 ) .
Val ve l i f ters
17. Checktheval ve l i f ters f or wear . Repl acethemi f neces
sary.
Camshaf t
18. Checkthe camshaf t f or wear on cams andbeari ng
ra
ces. Al socheckthe wear of the beari ngs. Thebeari ngs are
pressed
i nto
thei r l ocati ons and must be l i ne bored af ter
the i nstal l ati on.
19. Pl ace a support under the
camshaf t gear and use a
hydraul i c press to removethe gear .
Crankshaf t
20. Removethegear
wheel .
Usea
prong
pul l er . Cl ean
the
crankshaf t. Measurethecrank- andmai nbeari ngpi ns. The
eccentri ci ty must not exceed0. 06 mm( . 0023 62
i n. )
andthe
taper 0. 05 mm( . 001969 i n. ) . Shoul dthese val ues beexceeded,
the crankshaf t must be ground
to
a sui tabl e
under- di mensi on, see under " Techni cal D ata" .
Pi stons, cyl i nders
21. Checkthewear on pi stons, pi ston ri ngs and gudgeon
pi ns . Repl ace these i f necessary.
Use a
cyl i nder
i ndi cator
gaugeto measurethe cyl i nder bores. Themeasurement of
the
bi ggest wear i s madei mmedi atel y beneaththe edge of
the upper deadcenter andcrosswi se the engi ne
.
The
mea
surement of the smal l est wear i s madeat the l ower dead
center . As to the cyl i nder di ameter, see "Techni cal
Data".
Useami crometer to measurethe pi stons. Pi ston di ameter,
see under "Techni cal Data".
22. I nsertanewpi ston ri ng i nto the cyl i nderand
measure
the pi ston ri ng
gap. As to the measurement, see under
"Techni cal Data" . I f necessary i ncrease the
gap,
usi ng
a
speci al f i l e .
23
.
Measurethecl earance of the pi ston ri ngs i n the
pi ston
ri ng grooves. Regardi ng
the measurement,
see under
"Techni cal Data".
24.
Use pi ston
ri ng pl i ers
to i nstal l the pi ston ri ngs. The
marki ng of the ri ngs (TOP or the markof the
manuf acturer)
must
be
turned
upwards. The hei ght of the upper com
pressi on ri ng: 1, 75 mm( . 068898 i n . ) The hei ght
of the
l ower compressi on ri ng;
2, 00mm( . 07874i n. ) . Turn the
pi ston ri ngs so that the gaps are turned 120
f romeach
other .
Connecti ng
rods
25. Checkthe connecti ng rods f or
strai ghtness and
twi sti ng
.
26.
Checktheconnecti ngrod bushi ngs
byusi ng the
gudgeon pi nas a gauge. Theremust benopl ay. I f the
bushi ngs
must be
repl aced, usea sui tabl e mandrel f or the
removal
and i nstal l ati on. Makesure
to i nstal l thebushi ngwi ththe
oi l hol e
coi nci di ng wi ththat of theconnecti ng
rod. Ream
thenewbushi ngs. Thef i t
i s correct whenanoi l edgudgeon
pi n by
i ts ownwei ght cansl owl y sl i de
through the
bushi ng .
Sea-water pump
27. The pump
i s equi pped wi th two bal l -beari ngs ( 1)
.
When di sassembl i ng, remove
the l ocki ng-ri ng
( 2)
i n the
housi ngandpush
out theshaf t, wherebythe beari ngs
are
f ol l owi ng. Usea sui tabl e mandrel
to removethe beari ngs
f romthe shaf t . NOTE!
Donot f orget the spacer
sl eeve
( 3) .
Repl ace the
seal i ngs ( 4) . NOTE!
Turntheseal i ngs correctl y
and make
surethat theydonot bl ockthedrai nage
hol e i n
the pump-housi ng. Repl acethe
O-ri ng
( 5) . I nstal l the
bal l -beari ngsand the spacer sl eeve ontothe shaf t and l eavea
di stanceof
39, 5 mm( 1 . 55512i n. ) f romthe shaf t
endtothe
bal l -beari ng. Coat the shaf t
wi th grease and "screw" i t
throughthe
seal i ngs and the O-ri ng and take
care not to
damage them. Push i n the
shaf t as f ar as to al l owthe
beari ngs
to bottomand then i nstal l the l ocki ng-ri ng ( 2) .
Checki ng thethermostats
28. I mmerse
the thermostat i n water and, usi ng
a
thermometer, check i f i t opens
at thecorrect temperature. See
Techni cal
Data f oropeni ngtemperatures. I f the
thermostat i s
f aul ty, i t must berepl aced.
Al ways use newgaskets,
seal i ng r i ngs, seal i ng washer s
and
l ock-washer s. Coat the seal i ngs wi th gr ease or
oi l
themandal so oi l
al l movi ngpar ts pr i or toi nstal l i ng them.
I f
the
engi ne i s f r esh-water cool ed, see page
21.
1 . Heat thecr ankshaf t
gear wheel to appr ox.
150C(302 F)
pr i or to
thei nstal l ati on. Pl acethe
keyi nthekey-wayof the
cr ankshaf t andpr ess
onthegear wheel .
Oi l
the
newmai n
bear i nghal ves (wi thoi l hol e) and
i nstal l themi nthe bl ock.
Put i n
the cr ankshaf t. NOTE! Themai nbear i ng
shel l at the
f l ywheel
al sof uncti ons as a thr ust-bear i ng
.
ASSEMBLY
2. Oi l thecap bear i ng hal ves
andi nstal l them. I nstal l the
capsi n accor dancewi th
themar ki ngi nthebl ock (2001 has
no i nter medi ate
bear i ng) . I f anar r owi s cast, i t shal l
poi nt
towar ds the oi l di psti ck.
Ti ghteni ng tor que f or the mai n
bear i ngs: 1st ti ghteni ng 20Nm(2 kpm) (14. 7 f t . l b) ,
2nd
ti ghteni ng 60Nm(6 kpm)
(44. 2 f t . l bs) . Tur nthe engi ne.
3.
Tur n
thepi ston
r i ngs
sothat thegaps
ar eof f set i nr el ati on
toeach
other . The
pi ston
cr owni s mar kedwi thanar r owthat
poi ntstowar dsthe bel t pul l ey. Usei nstal l ati onr i ng 884813-7
.
Fi t
the caps
wi ththe mar ki ng al i gned wi ththe cr ankshaf t' s
mar ki ng. The cr ankshaf t can be tur ned i n any di r ecti on
towar dsthe pi ston
.
Ti ghteni ngtor ques:
Step
1 :
25
Nm(2
. 5 kpm)
(18
f t/ l b)
Step2: 70Nm(7 . 0 kpm) (53
f t/ l b)
4. I nstal l the mai nbear i ng hal ves
i n
the
oi l pan
andcoat
the edge of the
oi l panwi th thi n l ayer of seal i ng
compound
p/ n
840879.
I nstal l theoi l panandti ghtentheoi l pan
scr ews
andthemai nbear i ngscr ews
al ter nati ngl yto 20Nm
(2, 0kpm) (14. 7 f t . l bs. )
andthenthemai nbear i ngscr ewsto
60 Nm(6, 0
kpm) (44. 2
f t . l bs. ) .
5. Repl acethe
f l ywheel housi ngseal i ng ( 1) . Smear seal i ng
compound( p/ n840879) ontheedgebetweenthef l ywheel
housi ng andthe seal i ng. NOTE! The seal i ng l i p wi th a
spr i ng shal l betur nedtowar dstheengi ne. Makesur ethat
the seal i ng i s i nstal l edi n accor dance wi th the pi ctur e.
r
6. Repl acethe O-r i ngs andi nstal l the f l ywheel housi ng.
Ti ghteni ngtor que 25 Nm( 2, 5 kpm) ( 18. 4 f t . l bs) .
I nstal l the f l ywheel . Ti ghteni ng tor que 65 Nm( 6, 5 kpm)
( 48. 0f t. l bs) .
7A. Heat the camshaf t gear wheel to a temper atur e of
appr ox. 150C( 302F) andusea sui tabl esl eeveto i nstal l i t .
Checkto makesur e
that the
gear
wheel "bottoms" onthe
camshaf t . I nstal l the camshaf t andmake sur e that the
mar ki ngs onthe camshaf t gear
wheel
andon
the
cr ankshaf t
gear wheel coi nci de. Put thewasher ( 1) onthe hubof
the camshaf t gear
wheel .
Checkthat
al l wei ghts
ar e pr essed
i n so that the tabs ( 2) ar e i nsi de the washer .
7B. I nstal l
anewseal i ngr i ngf or thecamshaf t i n the
tr ansmi ssi on housi ng, usi ngmandr el
p/ n
884838. Theseal i ng
l i p wi th
thespr i ngi s tobetur nedtowar ds theengi ne. Pr ess
i n the seal i ng r i ng f r om
the outsi de unti l the mandr el
"bottoms" agai nst the housi ng. I nstal l anewO-r i ng i n the
oi l channel i n
the bl ock( 3 f i g. 7A) .
Usea newgasket andi nstal l theti mi ng gear
cover
.
Pl ace
thepr essur esl eeve( wi ththebear i ngtowar ds thepr essur e
washer ) i n thecontr ol ar ml ever . Hol dthe
sl eeve i n pl ace
by pr essi ng the l ever to i ts bottomposi ti on wher e the
sl eevei s pr essedagai nst thehousi ng. I nstal l
thepi nof the
camshaf t, usi ngspeci al tool
p/ n
884839. Thepi n must
pr otr ude equal l y muchonbothsi des. Under noci r cumstances
ar e youto use a hammer or somesuch
tool to punch the
pi n
i ntoi ts l ocati onwi ththeai dof amandr el . Thecamshaf t
wi l l then be bent .
8.

I nser t t he cont r ol r odt hr ought he bl ackand i nt o t he t i mi ng
gear casi ng. I nst al l t he bear i ngbal 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 ewon t he end ni ppl e ( 4) unt i l i t
bot t oms
( Not e! Do not use anyt ool s) . Scr ewi n t he upper bol t s
( wi t h copper seal i ng washer s) t hat gui de t he cont r ol r od.
Then,
scr ewt he l ower bol t s t hat hol d t he cont r ol r od i n pl ace
i n t he engi ne bl ock. NOTE! The l ower bol t s shoul d not have
seal i ng
washer s .
Appl y
Per mat ex t o t he t hr eads . Check t hat
t he cont r ol r od moves f r eel y.
9.
I nst al l t he oi l
pump' s gear wheel accor di ngt ot he
mar ks
( f r omt he
di sassembl y) . I nser t a
newO- r i ng i n t he t i mi ng
gear
cover . Oi l t he gear
wheel andf i t The cover
usi nga new
seal i ng
r i ng.
2001
10.

I nser t t he keyf or t he pul l eyi n t he cr ankshaf t andi nst al l
t he pul l ey. Ti ght eni ng t or que 40 Nm( 4, 0 kpm) ( 29. 5
f t . I bs)
.
11 . Cl ean t he val ve l i f t er s car ef ul l y and coat t he cont act
sur f ace agai nst t he camshaf t wi t h mol ybdenumdi sul phi de
.
Oi l t he val ve gui des i n t he bl ock and i nst al l t he l i f t er s .
Cl ean t he r ol l er l i f t er s of t he f uel i nj ect i on pumps and
i nst al l t hen i n t he bl ock. Lock t he r ol l er l i f t er s wi t h scr ews
t hr ough t he bl ock af t er t he i nst al l at i on ( appl y Per mat ext o
t he t hr eads) . Check car ef ul l y t o make sur e t hat t he l i f t er s
ar e cor r ect l y i nst al l ed and t hat t hey ar e r unni ng easi l y i n
t he gr oove
.
Regar di ng t he i nst al l at i on of t he cyl i nder head, seet he
f ol l owi ng page.
2 0 0 2
2 0 0 3
12 . Ti ghtenthe
two gui descrews p/ n 884840 i n the bl ock
and i nstal l the cyl i nder head gasket wi th the marki ng
"Top" f aci ng upwards
. I nstal l the cyl i nder head.
Make sure that the contact surf ace f or the cyl i nder
head
bol ts are f ree f rom
pai nt . Shoul d there be pai nt on the
bol ts, there
i s al ways
the
ri sk of havi ng ani nsuf f i ci ert
ti ghteni ng f orcei nthe bol t j oi nt wi thsubsequent
l eakages as a
resul t . NOTE! The
bol ts are phospated, theref ore do not
cl ean themwi th a steel - brush.
Coat thecyl i nder
headbol ts wi thmol ybdenumdi sul phi de
andti ghten themi n accordance wi th thedi agram, f i rst
to
2 0 Nm( 2 . 0
kpm/ 14. 7 f t . l bs) andthento70 Nm( 7. 0 kpm/ 51. 6
f t. l bs) .
13. I nstal l the push rods andthe rocker armbri dge,
push
on
new
rubber ri ngs to the oi l pi pe whi chi s f i tted at the
same ti me as the rocker armbri dge.
14. Val ve cl earance
col d/ warmengi ne 0 . 30 mm
( . 0 1181
i n. ) . Turn
the engi ne i n the di recti on of rotati on unti l the
val ves i n onecyl i nder are"rocki ng". Thenturntheengi ne
oneturn more
and
adj ust
the val ves f or thi s cyl i nder.
R epeat the procedure f or the remai ni ng cyl i nders.
Adj usti ng thef uel i nj ecti on
pump l ocati on wi th shi ms
15. i f the samebl ock camshaf t and f uel I nj ecti on
pumps
are used whenassembl i ng,
thef uel i nj ecti on pump must
be i nstal l ed i n thei r ori gi nal posi ti ons andwi th
the same
shi mthi ckness as earl i er . The
socal l ed sof t shi ms, al ways
bei ng i nstal l ed
agai nst the
bl ock, must berepl aced
agai nst
newones. Caref ul l ycl eanthecontact surf aces between
the
bl ock andthef uel i nj ecti on
pumpsandi nstal l shi ms wi th
thi ckness equal tothesumof themarki ng
onthebl ock and
that onthef uel i nj ecti on
pump, ( 4) earl i er marki ng.
Exampl e: Thebl ock marki ng 4( =4tenths of
a
mi l l i meter)
( . 0 15748 i n. )
Thepump
marki ng4( =4tenthsof ami l l i meter)
( . 0 15748 i n. )
Total amount of shi ms =0 . 8 mm( . 0 31496 i n. )
I n thi s case
sel ect twosof t shi ms 0 . 2 and0 . 3 mm( . 0 11811
i n. ) . Pl ace the hard shi mbetween the
two sof t ones and
i nstal l thepump. NOTE!
Never i nstal l ahardshi mtogether
wi thanother hardshi mor agai nst thebl ock
or thef uel
i nj ecti on pump.
Hard
shi ms
areavai l abl e i n thi cknesses 0 . 3,
0 . 6 and0 . 9 mm( . 0 11811, . 0 2 362 , . 0 35433i n.
respecti vel y) .
Sof t shi ms
are avai l abl e i n thi cknesses 0 . 2 and 0 . 3 mm
( . 0 0 7874 and. 0 11811 i n. ) .
Onl at er ver si onengi nes
an
O- r i ng
has beeni nt r oduced as a
seal bet weent he i nj ect i onpumpandt he bl ock. Onl y so- cal l ed
har d shi ms may
be usedont hese engi nes whenshi mmi ng.
Har dshi ms ar e avai l abl e i nt hi cknesses of 0. 2 mm( 0. 0079i n) ,
0. 3 mm( 0. 0118
i n) ,
0. 6 mm
( 0
. 0024i n)
and0. 9
mm
( 0. 0354i n) .
16. New
bl ock
or camshaf t
I f
t he bl ock or t he camshaf t ar e r epl acedt he bl ock must be
measur ed and mar ked, usi ng t he set t i ng- di sc p/ n
884787
and a sl i di ng cal i per .
A. The set t i ng- di sc consi st s of t wo r i ngs,
an
i nner
and an
out er . The i nner r i ng det er mi nes t he i nj ect i on angl e f or
eachr espect i ve engi ne t ype, see Techni cal
Dat a ( page 25) .
The
i nj ect i onangl e i s st amped i ndegr ees and i s f i xed wi t h
a pi n ( 1) .
B. Mount t he set t i ng- di sc or t he pul l ey wi t ht wo
bol t s, do
not t i ght ent he bol t s. Tur nt he
set t i ng- di sc
sot hat t he gui de
pi n( 2) comes i n t he l ar gest of t he f our hol es i n
t he pul l ey.
Pr ess i nt he gui de pi n ( 2) so t hat t he di sc i s
cent er ed and
t i ght ent he bol t s .
The set t i ng- di sc i s mar ked f or
each r espect i ve cyl i nder :
Mar ki ng Denot es
Cyl i nder 1

Cyl i nder 1 ( 1, 2, 3 cyl i nder
engi nes ;
Cyl i nder
2/ 2

Cyl i nder 2 ( 2 cyl i nder engi ne)
Cyl i nder 2/ 3

Cyl i nder 2 ( 3 cyl i nder engi ne)
Cyl i nder
3/ 3

Cyl i nder 3 ( 3 cyl i nder engi ne)
C.
Turn cyl i nder no. 1 t o i t ' s i nj ect i on. pos i t i on
. Pl ace t he
gui de pi n ( 2) i nt he s et t i ng- di s c' s hol e marked cyl
. 1 . Turn
t he cranks haf t a l i t t l e agai ns t
t he normal di rect i on of
rot at i on andt hereaf t er i n t he normal rot at i ondi rect i on
unt i l t he
s et t i ng- di s c' s gui de
pi n ( 2) goes i nt he t i mi ng cover' s hol e.
Meas ureus i ng a cal i per t he di s t ance bet weent he
cyl i nder
bl ockand t he rol l er
l i f t er' s edge ( do not meas ure ont he
rol l er) .
The di s t ance s houl d be:
2001
:
55. 8
mm
( 2. 1 9685
i n)
2002, 2003: 55, 6 mm( 2 . 18504i n)
2003T: 55. 9
mm( 2 . 2007i n)
Exampl e:
2001
. I f t he meas ured di s t ance
i s 55. 2 mm
( 2
. 17323i n)
t hi s
means t hat a
s hi mwi t ht hi cknes s 0. 6 mm( 0. 02362
i n)
i s t o
be pl aced bet weent he cal i per and t he
bl ock.
2002, 2003. I f t he meas ured di s t ance i s 55. 0
mm( 2 . 16535
i n) t hi s
means t hat a s hi mwi t ht hi cknes s 0. 6 mm( 0. 02362
i n) i s t o be pl aced bet weent he
cal i per and t he
bl ock.
Themeas ureds hi ms
t hi cknes s ( i n t hi s exampl e0. 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 mt hi cknes s i s
f ound
by addi ng t he bl ock' s
meas urement s and t he pump' s
marki ng.
Exampl e
The bl ock' s meas urement s

6 ( =
0
. 6
mm/0. 02362
i n)
The pump' s marki ng

2 ( =0. 2 mm/0. 007874
i n)
No.
of s hi ms

0. 8 mm
I n
t hi s cas e choos e t wo s of t s hi ms 0. 2 and 0. 3
mm
( 0. 007874 and 0
. 011811
i n) and one hard s hi mof 0. 3
mm
( 0
. 011811 i n) . Pl ace t he hard
s hi mbet weent he t wo s of t
ones
andref i t t he pump. NOTE!Ahard
s hi mmus t never be
f i t t ed t oget her wi t h
anot her hards hi mor di rect l y
agai ns t
t he
bl ock or pump.
Hard
s hi ms are avai l abl e i n t hi cknes s es 0. 3, 0. 6 and 0. 9 mm
( 0. 011811, 0. 02362 and 0. 035433
i n) .
Sof t
s hi ms are avai l abl e i n t hi cknes s es 0. 2 and 0. 3 mm
( 0, 007874and 0. 011811 i n) .
D. Repeat t he procedure
f or t he ot her pumps ( 2002, 2003)
i n t he
s ame way as f or cyl i nder 1 .
The s et t i ng- di s c' s marki ng i s
expl ai ned under poi nt B.
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 mt hi cknes s .
Turnt he engi ne s o t hat t he camf or t he
pumpi s not i n t he l i f t i ng pos i t i on. Checkt hat t he
pump' s
pi n l ocat es i nt he cont rol rod' s
groove and
t hat t he
pump( s )
and t he l ocks marki ngs coi nci de ( s ee
f i gure) . Checkaf t er
f i t t i ng each pump t hat t he cont rol rod operat es eas i l y
.
Ti ght eni ng t orque
f or
t he nut s i s
20 Nm( 2, 0 kpm)
( 14. 7
f t . l bs ) . Connect t he f uel pi pe bet weent he pumps and t he
pi pe f romt he f uel f i l t er t o t he
i nj ect i on pump. NOTE! The
hol e
bol t f or t he ret urn hos e has a s mal l er t hrough- f l ow
channel t han t he ot hers ( on l at er vers i ons
i t i s marked
' Out ") .
18. I ns t al l t hef eed
pumpandt hef uel f i l t er . Al s oi ns t al l t he
t hermos t at hous i ng wi t h t he t hermos t at
.
NOTE! Do not
f orget t he l i f t i ng eyel et bet weent he f uel
f i l t er andt he
t hermos t at hous i ng
.
19. I nst al l t he sea-wat er pumpandt he cool i ng wat er
pi pes .
20. I nst al l t hei nj ect ors andt heret urn f uel pi pe. Ti ght eni ng
t orquef or t he i nj ect ors 20
Nm( 2, 0 kpm) ( 14. 7 f t . l bs . ) . Al so
i nst al l t he exhaust el bowandt hewat er pi pe bet ween t he
t hermost at housi ng andt he
exhaust el bow.
21. Fi t t he val ve cover usi nga newgasket . Makesure t hat
t he roundhol ef or t he crankcase vent i l at i on i s i n t he ri ght
posi t i on . Fi t t he decompressi on devi ce l ever . Fi t t he
pressure pi pes bet ween t hei nj ect ors andt he i nj ect i on pumps .
Al so ref i t t he i nl et ai r si l encer .
22. I nst al l t he st art er mot or, t he al t ernat or andt he
al t ernat or
V-bel t . Al so i nst al l t he el ect ri cal di st ri but i on boxand
hook-upt he
cabl eharness .
23.
Fi l l up wi th l ubri cati ng oi l to the correct l evel . R egard i ng
quanti ty and qual i ty, see und er
"Techni cal
Data".
24. Venti ng thef uel system
A. Openthe venti ng screwon thef uel f i l ter approx. 4turns.
Watch out f or f uel - spl ashes.
B. Usethe hand - pumpto pumpf uel unti l f uel f ree
f romai r
bubbl es i s comi ng out . Cl ose theventi ng screw.
C. Easeof f thef uel pressure pi pe nuts at the i nj ectors.
P osi ti on thethrottl e control i n the posi ti on f or f ul l speed and
turn the engi newi th thestarter motor unti l f uel comesout
of the f uel pressure pi pes. Ti ghten the f uel pressure pi pe
nuts.
2003T
Turbo- Compressor
Wherethere i s an excessi ve amount of
smoke i n the
exhaustf umes or theengi ne output i s parti cul arl y l ow i t may
bethat theturbo- compressor i s not f uncti oni ng properl y
. I f
the boat' s speed through
thewater i s grad ual l y d ecreasi ng,
the boat' s bottomshoul d al so be i nspected ,
and
cl eaned wherenecessary
.
Check
that the ai r i ntake has not
become
cl ogged , and cl ean the i ntake si l end er .
I nspecti ng theSeal s
Checkthe
j oi ntsbetween
theturbi nehousi ng and the
compressor beari ng housi ng, and between the compressor
beari ng housi ng and the
compressor housi ng.
Checks
Checkthepre- i nj ecti on angl e, the i nj ector' s openi ng
pressure and thespray pattern.
Theval ve cl earanceand
compressi on shoul d al so be checked .
Checki ng axi al and rad i al cl earance
Di smount the turbo- compressor
f romthe engi ne, and
measure the rotor uni t' s axi al and rad i al cl earance.
Maxi mumpermi ssi bl e axi al cl earance

0. 09 mm
Maxi mumpermi ssi bl e
rad i al cl earance

0. 17 mm
I f wear and tear has
reached themaxi mumpermi ssi bl ethe
turbo- compressor shoul d be recond i ti oned
or
repl aced .
Make
l i ne- up marks between the turbi ne housi ng, the
beari ng housi ng andthecompressor
housi ng. Di smantl e
the compressor housi ng ( 1) . Unscrew the l ef t- hand
threaded nut whi ch hol ds the compressor wheel , usi ng
dol l i es on theturbi neshaf t. Removethecompressor
wheel
( 2) anddi smantl etheturbi ne housi ng ( 3)
.
RECONDI TI ONI NG
Di smantl etheturbi neshaf t ( 4) andthe heat shi el d. I f the
turbi neshaf t sti cks, taptheendgentl y wi th awooden
hammer . Unf asten thethree screwswhi ch hol dthecover ( 3)
andscrewtwo M5screws i nto thecover. Then l i f t i t up.
Taketheoi l def l ector ( 7) out of thecover.
Removethepacki ng ri ng ( 12) ontheturbi neshaf t andthe
twopacki ng
ri ngs
( 13) on
theoi l def l ector. Cl eantheparts
caref ul l y.
Measuri ng
andI nspecti on
Turbi neWheel
andShaf t
Unf asten thef our screws whi ch hol d thecompressi on
beari ng ( 8) . Usi ng a smal l copper
mandrel ,
tap
out the
compressi on beari ng andthebushi ng ( 9) . Then remove
theci rcl i ps ( 10) i nsi dethebeari ng
housi ngandremovethe
twobeari ngs ( 11) .
Checkthat the
turbi newheel andshaf t aref ree
f rom
mechani cal damage. Thevanes must
not bewornor out of
shape. Donot
try to real i gn thevanes. Damaged
parts
shoul d
berepl aced.
Pl acetheshaf t ontwosupports, whi chshoul dbeunder the
beari ng recesses, andcheck thethrowat the endof the
shaf t . Themaxi mumpermi ssi bl ethrowi s 0. 011
mm.
Checkthedi ameter of theshaf t beari ng recesses. The
mi ni mum permi ssi bl edi ameter
i s 7. 98
mm
.
Checkthewi dth of
theshaf t pi ston ri ng groove.
Maxi mumpermi ssi bl ewi dth
i s 1 . 29 mm.
Compressor Housi ng, Turbi neHousi ng
Checkthat thehousi ngs aref reef romcracks or other
damage caused by excessi vewear
and
tear
.
Damagedparts
shoul dberepl aced.
Heat Shi el d
Checkthat theheat shi el d i s f reef romdamagecausedby
wear and tear, heat or corrosi on, andrepl ace i t i f necessary
.
Bushi ng, Oi l Def l ector, Compressor
Beari ng
Check that the
parts aref reef romwear andtear and
di scol ourati on . Damagedparts shoul dberepl acedeven
i f the
amount of
wear andtear i s wi thi n the permi tted
tol erances .
Bushi ng
Oi l
Def l ector
Beari ngs
Check measurement ( A) , whi ch shoul d not bel ess
than
4. 07 mm.
Check measurements
( B) and( C) . ( B) shoul dnot bemore
than 1 . 31
mm, ( C) shoul dnot bemorethan 1 . 11 mm.
Compressor Beari ng
Checkthe
wi dth
of
thebeari ng, andrepl acei t i f theamount
of wear andtear i s i n excess of thepermi ttedtol erance
.
Mi ni mumpermi ssi bl ewi dth i s 3. 98 mm.
Checkthebeari ngs f or abnormal wear
andtear or
di scol ourati on, andrepl ace them wherenecessary .Check the
i nternal andexternal
di ameters of al l beari ngs. Theexternal
di ameter shoul dnot bel ess than
12. 31 mm, thei nternal
di ameter shoul d
not
be
morethan 8. 04mm.
Beari ngHousi ng
Check
the housi ng f or corrosi on or
cracks. Check
m easurem ents ( D) and
( E) , andrepl acethe housi ngwherenecessary
.
Measurem ent ( D) shoul dnot
be
m ore than
12. 42 m m ,
m easurem ent ( E)
shoul dnot be m orethan 15. 05
m m .
Cover
Check m easurem ents ( F) and( G) .
andrepl acethe cover
where necessary .
Measurem ent ( F) shoul d not be m ore
than12. 45m m , m easurem ent ( G)
shoul dnot bem orethan
10. 05 m m .
Packi ngRi ngs
Checkthe packi ng ri ngs to
see i f they areworn or out of
shape,
and repl ace them wi th newones where necessa
ry .
Reassem bl y
Greaseal l rem ovabl epartswhenreassem bl i ngthem .
Posi ti on theci rcl i ps i n the
beari nghousi ngsothat the
openi ngs i n them are f aci ng towards the oi l outl et .
Mount thepacki ngri ng
on the turbi ne
shaf t . Turntheopeni ng
i n
the
ri ng so that i t i s f aci ng towards the oi l i ntake.
Posi ti on the heat shi el donthe beari ng casi ng, andthen
pl acethe turbi ne axl e i n the beari ng
housi ng.
Mount
thebushi ngontheturbi neshaf t . Greasei nthe
com pressor beari ng wi th engi ne oi l , and m ount i t on the
beari ng casi ng, usi ngnewscrews andwashersto
f asteni t .
Thetorque
shoul dbe 1 . 3 Nm 0. 1 .
Ti ghtenthe
screwstotheabovetorque, thenl oosenthem a
quarter
turn bef ore ti ghteni ng them up to the correct
torque agai n.
Posi ti on
thetwo packi ng ri ngs ontheoi l def l ector. NOTE :
Theopeni ngi n the i nner ri ng shoul dbef aci ngthe oi l
outl et, that i n the outer ri ng shoul dbe
f aci ng theoi l i ntake.
Posi ti on theoi l def l ector i n thecover . Sm ear theedges of
the beari ng housi ng whi chcom ei n touchwi ththe cover,
usi ng Perm atex f or the
purpose.
Thethi ckness of the seal ant shoul dbeabout 0. 1- 0. 2 m m
.
Fi tthecover onthebeari nghousi ng, andf asteni twi th
new
screws and
washers. Thetorque shoul dbe 1 . 3 Nm 0. 1 .
Ti ghtenthe
screwsto
theabovetorque, thenl oosenthem a
quarter turn bef ore ti ghteni ng them
up to the correct
torque agai n
.
Posi ti on thecom pressor wheel onthe turbi ne shaf t
and
f asten i t wi ththe l ef t- handthread
nut . The torque shoul d
be
2 . 0 Nm 0. 1 .
Mount theturbi nehousi ngonthebeari nghousi ngaccordi ng
tothe
l i ne- up
m arks. Screw
the l ocki ngcover i nto
posi ti on,
m aki ngsurethat thescrews usedare not those
f or
the com pressor housi ng
. The torque shoul d be 11 . 0
Nm 0. 5
( M6) , 26. 01, 0 ( M8) .
Sm ear theedges of thebeari ng housi ngwherei t com es
i n
touch wi ththe
com pressor housi ng, usi ng Perm atex f or
the purpose. Thethi ckness of theseal ant
shoul dbe about
0. 1- 0. 2 m m . Then
m ount thecom pressor housi ngaccordi ng
tothe l i ne- up m arks, andscrewthe l ocki ng
cover i nto
posi ti on. Thetorque
shoul d be 4. 5 Nm 0. 5.
Check the axi al
andradi al cl earance. Maxi m um perm i ssi bl e
axi al cl earance i s 0. 09 m m , m axi m um
perm i ssi bl e
radi al cl earance i s 0
. 17 m m .
Fi tti ngtheTurbo- Com pressor
Bef oref i tti ng the turbo- com pressor
on theengi ne, spray
cl ean engi ne
oi l i nto the oi l i ntake, andturn
the turbi ne
shaf t so that the oi l i s evenl y
di stri buted. Cl eanthe
turbo- com pressor' sdel i very and return oi l l i nes .Change the engi ne oi l and the f i l ter f or the l ubri cant .Be sure to use the
correct qual i ty of oi l ( see under
"Techni cal Data") . Oi l
changes shoul d be
carri edout i n accordance
wi ththe
i nstructi ons i ntheManual , i n order
tokeeptheengi necl ean.
Cl ean the ai r f i l ter
.
FRESHWATERCOOLING2002, 2003
Pos 21 and23are f or hot water outl et .
1 .

Fi t theci rcul ati onpump(compl etewi thtensi oner bracket andspacer sl eeve,
posi ti on
4). Ti ghten
the bol ts (M8x75) to
20 Nm(2, 0 kpm)
(14. 7f t . l bs), posi ti on1 .
2.

Suspendthe heat exchanger l oosel y bythe rear bol t (M8x16and
spri ng washer . ), posi ti on5.
a) Fi t the pi pe (posi ti on 6) andthe hose (posi ti on 3) betweenthe heat exchanger and the sea- water pump, usi ng
doubl e hose cl amps (appl y soapywater to the rubber ri ngs, appl i es
f or al l rubber ri ngs) .
b) Fi t the pi pe betweenthe
heat- exchanger andthermostat housi ng, posi ti on7.
c)
Fi t the pi pe betweenthe heat- exchanger andthe ci rcul ati on pump, posi ti on
8.
3.

Locate the pi pes i nthe heat- exchanger
andanddrawi t f orwardti ghteni ng i t wi th the twobol ts (M8x16and
spri ng
washers), posi ti ons 5and9.
4.

Fi t the pi pe betweenthe heat- exchanger andthe exhaust el bow, posi ti on10.
NOTE! Thehol derf orthe pi pe, (posi ti on
11) andthe l ock (posi ti on
11
a) .
5.

Fi t the pi pe betweenthe ci rcul ati on pump(l ower outl et) andthe cyl i nder
head, posi ti on12.
6.

Fi t the pi pe betweenthe
ci rcul ati on pump(upper outl et) andthe cyl i nder head, posi ti on13.
7.

Fi t the al ternator, pl ace the bol t f or the tensi oner bracket wi th the head
f orwards. Put onandtensi onthe V- bel t .
8.

Fi t the expansi ontank tothe
exhaust el bow, posi ti on15.
9.

Fi t the hose betweenthetank andthe ci rcul ati onpump(doubl e pi pe ) 2002
=450 mm(17. 7i n), 2003=550mm(21. 7
i n) (onl y si ngl e hose cl amps are
usedonthe f resh- water system), posi ti on 16.
10.

Fi t the ni ppl e, posi ti on17.
11 .

Fi tthe hose betweenthetankandthe thermostat housi ng (ni ppl e 17) : 2002=350
mm(13
. 8
i n), 2003=450mm(17. 7
i n), posi ti on 18.
12. Fi t the pl ugs i nthe exhaust el bowandthe cyl i nder head, posi ti ons 19 and20.
13.

Fi l l the systemto the ri ght l evel
wi th
a
mi xture of f reshwater (50%
)
andanti - f reeze
(50%),
al temati vel y rust- protecti on
addi ti ve (VP accessory) . The f resh- water systemvol umes: 2002 =4. 0 dm2 (l i tre) (0. 88 Imp. gal s) (1. 1 USgal s),
2003 =5. 5 dm3 (l i tre) (1 . 2 Imp. gal s) (1
. 45 USgal s) .
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 mt est but t on
6. Al ar m
Maxout 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
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 msender
4.

Oi l
pr essur e al ar msender
Wi r e ar eas i n mm2
Wi r e ar ea
mm2
1 , 0

1 6
1 , 5

1 4
2, 5

1 2
1 0

6
26
AWG
Wi r i ngdi agr am, al t er nat i ve A
( St andar d)
Z
Wi ri ng di agram, al t ernat i ve B
(De Luxe)
INSTRUMENTPANEL
1 . Vol t met er
2. Oi l pressure gauge
3.

Cool ant t emperat ure gauge
4.

Pri nt ed ci rcui t card
5
.

Al armt est
6.

Swi t ch f or i nst rument l i ght i ng
7.

Rev. count er
8.

Keyswi t ch
9. Al arm
Max out put f rom
t he panel : 5A
Cabl e col our
GR

=Grey
SB

=Bl ack
BN

=Brown
LBN
=
Li ght
brown
R

=Red
P

=Purpl e
GN

=Green
Y

=Yel l ow
W

=Whi t e
BL

=Bl ue
LBL

=Li ght bl ue
ENGINE
1 .

Cool ant t emperat ure sender
2.

Oi l
pressure al armsender
3.

Cool ant t emperat ure al armsender
4.

pi t pressure sender
5. Rel ay
6. Fuse
Wi re
areas i n mm2
FAULT
TRACI NG
Engi ne
does
not
star t
Engi ne
stops
Engi ne not
r eachi ng
cor r ect temp
at f ul l r pm
Engi ner uns
r oughl y or
vi br ates
abnor mal l y
Engi ne
becomes
abnor mal l y
hot
Faul t
Stop
contr ol not f ul l y pushed
back. Mai n swi tch: not
swi tched
on. Fl at batter y. Br oken
el ectr i c
wi r es
. Mai nf use bl own.
" Empty
f uel tank, cl osedf uel cock
or cl oggedf uel f i l ter .
" " "
Water or i mpur i ti es i n the f uel .
Faul ty
i nj ector s or ai r i n the f uel
system.
" Boat abnor mal l y
l oaded, cl ogged
i ntake ai r f i l ter or mar i negr owth
onthe boat bottom.
Engi nenot pr oper l y
al i gned.
P r opel l er damaged.
" Cl oggedcool i ng water i ntake
or
water
j ackets i n theexhaust
mani f ol d . Faul ty i mpel l er i n
sea-water
pump.
Faul ty ther mostat . Cl ogged
cool i ngwater pi pe i nthe
cyl i nder
head.
9992265- 0
884813- 7
9995218- 6
884557- 0
884559- 6
884787- 3
884811- 1
884823- 6
884837- 6
884838- 4
884839- 2
884840- 0
1
Pul l ey pul l er
I nst al l at i on r i ng f or pi st on
Mandr el
f or val ve gui de r emoval
Mandr el f or i nst al l at i on of
i nj ect or sl eeve
Mandr el f or i nst al l at i on of val ve
gui de
Set t i ng- di sc f or i nj ect i on pump set t i ng
Pul l er f or
i nj ect or
sl eeve
Fl ar i ng t ool f or i nj ect or sl eeve
Fl ange f or engi ne cr adl e
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 anddi sassembl y
t ool
f or
camshaf t pi n
Gui de pi n f or cyl i nder head. NOTE! Two ar e r eq ui r ed
.
TECHNICALDATA
Cyl i nder bore. . . . . . . . .
.
.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
Stroke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . .
Compressi on rati o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressi on rati o at starter motor
speed . . . . . . . . . . . . . . . . .
79 mm( 3 . 11024 i n)
87
mm
( 3 . 4252 i n)
17. 5 : 1
2-2. 5 MPa ( 20-25 kp/cm2)
Di recti on of rotati on
( seenfromthe front end) . . . . . . . . . .
Idl i ng speed . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . .
Oi l pressure
at ful l speed and warmengi ne. . . . . . . . . . . . .
Oi l pressure at i dl i ng and warmengi ne
. . . . . . . . . . . . . . . . .
Cl ockwi se
13-14
r/' s ( 775-825 rpm)
0, 35-0, 40 MPa ( 3, 5-4, 0
kp/cm2)
0, 08-0, 15 MPa ( 0, 8-1, 5 kp/cm2
)
Cyl i nder bl ock
Materi al . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Speci al al l oy cast i ron
Pi ston ri ng gapi n the cyl i nder
Upper compressi on ri ng
. . . . . . . .
.
. . . . . . . . . . . . . . . . . .

Lower compressi on ri ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oi l ri ng . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0, 30-0, 50 ( 0, 001181--0, 00197
i n. )
0, 30-0, 50
( 0, 001181-0, 00197 i n. )
0, 25-0, 50 : 0, 009842-0, 00197
i n. )
General
Type desi gnati on. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2001
2002
2003, 2003T
Number
of cyl i nders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 2 3
Di spl acement . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . .
, . . .
0. 43
dm3 ( 26. 2 cu0. 852 dm3
( 51 . 9 cu i n) 1. 278 m3 ( 77. 99
i n)
cu i n)
Cyl i nder di ameter, standard
. . . . . . . . . . . . . . . . . . . . . . .
. . . .
79, 00-79, 03 ( 3. 11025-3. 11142 i n. )
0, 25 mmover-si ze
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
79, 25-79, 28
( 3
. 12008-3
. 12126 i n. )
0, 50 mmover-si ze. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . .
79, 50-79, 53 ( 3. 12992-3. 1311 i n. )
Pi stons
Materi al . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
.
. . . . . . . . . .
Li ght-al l oy
Total hei ght . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
78, 3 mm
( 3. 08268 i n. )
Hei ght from
gudgeon pi n center to pi ston top. . . . . . . . . .
50, 3 mm( 1
. 98031 i n. )
Pi ston cl earance i n cyl i nder . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0, 09 mm( . 00354 i n. )
Pi ston i n
standard di mensi on . . . . . . . . . . . . . . . . . . . . . . . . . .
78, 903-78, ) 17
( 3, 10642-3, 10697 i n. )
0, 25 mmover-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. )
Gudgeonpi ns
Di ameter . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25, 995-26, 000
( 1, 02343-1, 02362 i n. )
Gudgeon pi n bushi ng, di ameter. . . . . . . . . . . . . . . . . . . . . . . .
26, 005-26, 011 ( 1, 02382-1, 02406 i n. )
Cl earance gudgeon pi n
- bushi ng . . . . . . . . . . . . . . . . . .
0, 0050-0. 0160
( 0, 00020-0, 0063 i n. )
Pi ston ri ngs
Compressi on ri ng, number
. . . .
.
. . . . . . . . . . . . . . . . . . . .
. . . 2
Oi l
ri ng, number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
The upper compressi on
ri ng has an i nl ay of chrome.
Thepi ston ri ngs are avai l abl e for
standarddi mensi on and
for 0, 250
and 0, 500 mmoversi ze ( 0, 00984 and 0, 0996)
i n. )
Pi ston ri ng axi al cl earance i n the
groove
Upper compressi on
ri ng
. . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . .
0, 070-0, 102 ( 0. 00276-0, 00402
i n. )
Lower compressi on ri ng . . . . . . . . . . . . . .
. . . . . . . . . . .
. . . . . .
0, 050-0, 082
( 0, 00197-0, 00323 i n. )
Oi l ri ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0, 030-0, 062 ( 0, 00118-0, 00244
i n. )
Crankshaft
Materi al . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nodul ar i ron
Crankshaft axi al cl earance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0, 040-0, 221 ( 0, 00157-0, 00870
i n. )
Mai n beari ng radi al cl earance. . . . . . . . . . . . . . . . . . . . . . . . . . 0, 040-0, 092 ( 0, 00157-0, 00362 i n. )
Bi g-end beari ng, radi al cl earance
. . . . . . . . . . . . . .
.
. . . . . . . .
0, 024-0, 068
( 0, 00094-0. 00268 i n. )
1 Propel l er shaft output i n accordance wi th DIN6270B.
Mai nbeari ngj ournal s
Di ameter, standard
0, 250 mmunder- si ze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . .
0, 500 mmunder- si ze- . . . . . . . . . . . . .
59, 987- 60, 000 (2, 36169- 2, 36220 i n. )
59, 737- 59, 750 (2, 35185- 2, 35236 i n. )
59, 487- 59, 500(2, 34200- 2, 34252
i n. )
Bi g- end beari ng
shel l s
Thi ckness, standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0, 250 mmover- si ze . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0, 500 mmover- si ze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1, 478- 1, 488 (0, 05819- 0, 05858 i n. )
1, 603- 1, 613 (0, 06311- 0, 06350 i n. )
1, 728- 1, 738 (0, 06803- 0, 06843
i n. )
Connecti ngrods
Axi al cl earanceat the crankshaf t
. . . . . . . . . . . . . .
. . .
. . . . . .
0, 15- 0, 35 mm(0, 00590- 0, 01378 i n. )
Camshaf t
Axi al

cl earance. . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radi al cl earance i n beari ngs . . . . . . . . . . . .
Camshaf t di ameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Li f ti ng
hei ght of cams . . . . . . . . . . . . - - - . - - - - - - - - - - . . . - - . .
0, 160- 0, 300 mm(0, 0063- 0, 01181 i n. )
0, 020- 0, 075 mm(0, 000787- 0, 00295 i n. )
46, 975- 47, 000 (1, 8494- 1, 85039 i n. )
5, 48- 5, 52 mm(0, 21575- 0, 21732 i n. )
Mai n
beari ngshel l s
Thi ckness, standard . . . - - . - . . . . . . . . . . . . . . . . . . . . . . . . 2, 987- 2, 997 (0, 11760- 0, 11799 i n. )
0, 250 mmover- si ze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3, 112- 3, 122 (0, 12252- 0, 12291
i n. )
0, 500 mmover- si ze . . . . - - - . - . . . . . . . . . . . . . . . . . . . . . . . . . 3, 237- 3, 247 (0, 12744- 0, 12783 i n. )
Bi g- end j ournal s
Di ameter, standard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47, 989- 48, 000 (1, 88933- 1, 88976 i n. )
0, 250 mmaver- si ze - - - . . . . . . . . 47, 739- 47. 750 (1, 87949- 1, 87992
i n. )
0, 500
mmover- si ze
. - . - - . . - . . . . . . . . . . . . . . . . . . . . . . . . . . .
47, 489- 47, 500
(1, 86965- 1, 87008 i n. )
Bushi ngdi ameter . . . . . . . . . . . . . . . . . . . . . . - - - - - - - - - - - - . . . 47, 02- 47, 05 mm(1, 85118- 1, 85236 i n. )
Cyl i nder head
Materi al . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Speci al al l oy cast i ron
I nl et val ves
20031
Di sc di ameter
. . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34, 4- 34, 6 mm(1, 35433- 1. 36220 i n. ) 35, 8- 36, 0mm
Stemdi ameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7, 955x7, 970 mm(0, 31319- 0, 31378 i n. ) 7, 995- 7, 970 mm
Val veseat angl e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4455' - 44

85' 2945' - - 3015'

Cyl i nder head seat angl e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 30
Seat wi dth i n thecyl i nder head . . . . . . . . . . . . . . . . . . . . . . . . appr
. 1 mm
(0, 03) 37 i n. ) appr. 1 mm! 0. 03) 37 i n.
Cl earance,
col d/warm
engi ne. . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust val ves
Di sc di ameter . . . . . . . . . . - - - - . . . . . . . . . . . . . . . . . . . . . . . . . . .
0, 3 mm(0, 011811 i n. ) 0. 3 mm(0, 011811 i n. )
29, 9- 30, 1
mm(1, 14716- 1, 18504 i n. )
Stemdi ameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7, 950- 7, 465 mm
(0
. 31299- 0, 31339 i n. )
Val veseat angl e. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4455' - 4485'
Cyl i nder head seat
angl e
- . . - . . . . . . . . . . . . . . . . . . . . . .
45
Seat wi dth- i nthecyl i nder head . - - . . . . . . . . . . . . . . . . . . . . . appr
. 1 mm
(0, 03937 i n. )
Cl earance, col d/warmengi ne - - - - - . . . . . . . . . . . . . - - . . . - - -
0, 3 mm(0, 011811 i n. )
Val vegui des
Length,
i nl et val ve
. . . . . . . . . . . . . . . . . . . . .
.
. . . . . . . . . . . . . . 38mm(1, 49606 i n. )
Length, outl et val ve. . . .
.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
mm
(1, 49606i n. )
I nner di ameter - - - - - - - - - - - - . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8, 000- 8, 015 (0, 31496- 0, 31555 i n. )
Hei ght
above
spri ng- pl ane
of cyl i nder head
. . . . . . . . . . . . .
8, 70- 9, 30 mm(0, 34252- 0, 36614 i n. )
Val vespri ngs
Length, unl oaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42, 5 mm
(1, 67323 i n. )
Loaded wi th 17010 N(171
kp)
. . . . . .
.
. . . . . . . . . . . . . . .
32 mm(1 . 25984i n. )
Loaded wi th 30020 N(302 kp) . . . . . . . . . . . . . . . . . . . . . .
24 mm
(0, 94488 i n. )
Lubri cati ng system
ENGI NE
Oi l quanti ty model 2001 . . . . . . . . . . . . . .
1, 40
dm3 ( 1 . 2 quarts)
Oi l
quanti ty model 2002 . . . . . . . . .
2. 75 dm3 ( 2. 42 quarts)
Oi l quanti ty model 2003
. . . . . . . . . . . . . . . . . . . .
. . 4, 10 dm3 ( 3. 6 quarts)
Oi l qual i ty accordi ng totheAPI - system CD( DS)
Vi scosi ty . . . . . . . . . . . . .
. . . . . . . . .
. . . . . . 15 W/ 40
Oi l
pressure, warmengi ne, i dl i ng speed. . . . . . . . . . . . . . . . 0, 8- 1, 5 kp/ cm2
( 11. 37- 21
. 33 l bf t/ i n2
)
Oi l pressure, warmengi ne, f ul l rpm. . . . . . . . . . . . . . . . . . . . 3, 5- 4, 0 kp/ cm2 ( 49
. 78- 56. 89
l bf t/ i n2
)
Lubri cati ng oi l pump
Type
. . . . . . . . . . . . . . . . . . . . . . . .
. . . .
. . . . . . . . . . . . . . . . . . .
. . Gearwheel
pump
Gear wheel
axi al
cl earance . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0, 025- 0, 065 ( 0, 00098- 0, 00256 i n. )
Spri ng f or reducti on val ve, l ength unl oaded . . . . . . . . . . . . 49 mm( 1, 92913 i n. )
Loadedwi th 35 Nm( 3, 5 kp) ( 25. 8 f t . l bs. ) . . . . . . . . . . . . . . . .
40 mm( 1, 57480 i n. )
Fuel System
Openi ng
pressure.
i nj ectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . 180- 190 kp/ cm2 ( 2560- 2702 l bf t/ i n2)1)
Spray
angl e. . . . . . . . . . . . . __
. . . . . . . . . . . . . . . . . . . . . . . . . . 150
I nj ecti on angl e 2001 . . . . . . . . . . . . . . . . . . . .
221

B. T. D. C
I nj ecti on
angl e 2002, 2003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20+1 CB. T. D- C.
I nj ecti on angl e 2003T
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
231
B. T. D
. C.
I nj ecti on
quanti ty . . . . . . . . . . . . . . . . . . 25+1 . 5 mm3/ stroke
at
405 C( 104 F10
. 6 F)
andat 25 r/ s ( 1500 rpm) pump revs
Governor
overrun. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 r/ s ( 3250 rpm)
Feedpump
Feedpressure42 r/ s ( 2500 rpm)
. . . . . . . . . . . .
.
. . . . . . . . . .
. . . .
0, 65- 0, 85 kp/ cm2 ( 9 . 20- 12. 10 l bf / i n2)
El ectri cal system
Battery vol tage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V
Battery capaci ty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : . . . . . . . . . .
Max. 70 Ah
Starter- motor output 2001 . . . .
. . . . . . . . . . . . . . . . . . . . . -
0. 8 kW! 1 . 1 HP)
Starter- motor output 2002 and2003. . . . . . . . . . . . . . . . . . . . . . .
1 . 4 kW( 1 . 9 HP)
Al ternator output :
Vol tage/ max. current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14W50 Amp
Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700
Watts
El ectrol yte spec. gravi ty: Ful l yl oaded battery. . . . . . . . . . .
1, 275- - 1, 285
To be chargedat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1, 230
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wax
thermostat
Begi ns to open at
. . . . . . . . . . . . . . . .
.
. . . . . . . . . . .
. .
. . . . . . . 602`C( 1404 F)
Ful l y openat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75' C
{165 F1
Cool i ng system
Wi th f resh- water cool i ng
( 2002,
2003)
Starts openi ng at . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
741 C( 1642 F)
Ful l y open at . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 C( 189 F)
Fresh- water system, vol ume2002 . . . . . . . . . . . . . . . . . . . . . . . . .
4. 0 dm
3
l i tre) ( 0 . 88
I mp.
gal s) ( 1 . 1 US gal s)
2003_____ 5. 5 dm3 ( l i tre) 11 . 2 I mp. gal s) ( 1 . 45 US gal s)
WEARTOLERANCES
Cyl i nders
Tobeboredat
0, 25 mmwear
( 0, 00984 i n. )
Crankshaf t
Mai n-
andbi g- endj ournal s:
Permi ttedout- of - round . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0, 06 mm( 0, 00236 i n- )
Permi ttedtaper . . . . . . . . . .
. . . . . . . . . . . . . .
. . . . . . . . . . . . .
. .
0, 05 mm( 0, 00197 i n. )
Max.
axi al cl earance on crankshaf t . . . . . . . . . . . . . . . . . . . . . 0, 40 mm
( 0, 01575
i n. )
1) 2003T
=204- 212 kp/ cm2 ( 2900- - 3015
l bf / i n2
)
Camshaft
Beari ng j ournal s, permi tted out-of-round . . . . . . . . . . . . . . .
Max. cl earance between camshaft andbushi ngs. . . . . . . .
0, 03mm(0, 00118 i n. )
0, 15mm(0, 00590 i n. )
Val ves
Max. cl earance between val vestemandval ve gui de. . . .
The val ve
di sc edge
must
be
at l east
0, 15mm(0, 00590 i n. )
1, 5 mm(0, 05906 i n. )
Ti ghteni ng torques
Mai n beari ngbol ts, 1st ti ghteni ng . . . . . . . . . . . . . . . . . . . . . .
2ndti ghteni ng . . . . . . . . . . . . . . . . . . . . . .
Bi g-endbeari ngbol ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fl ywheel housi ng bol ts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fl ywheel bol ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cyl i nder headbol ts, 1st
ti ghteni ng . . . . . . . . . . . . . . . . . . . . .
2ndti ghteni ng . . . . . . . . . . . . . . . . . . . .
Rocker armbri dge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel i nj ecti on pumps. . . .
. . . . . .
.
. . . . . . . . . .
.
. . . . . . . . . . . .
Pul l ey . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . .
I nj ectors. . . . . . . . . . . . . . . . . . .

. . . . . . . .
20
20 Nm(2, 0 kpm) (14. 7
ft . l bs
. )
60 Nm(6, 0 kpm) (44. 2 ft . l bs. )
70 Nm(7, 0 kpm) {51. 6 ft . l bs. )
25 Nm(2, 5 kpm) (18. 4 ft . l bs. )
65 Nm(6, 5 kpm) (47 . ) ft . l bs. )
20 Nm(2, 0 kpm) (14. 7 ft . l bs
. )
70 Nm(7, 0 kpm) (51. 6 ft . l bs
. )
25 Nm(2, 5 kpm) (18. 4 ft. l bs
. )
25 Nm(2, 5 kpm) (18. 4 ft . l bs
. )
40 Nm{4, 0 kpm) (29
. 5 ft . l bs. )
20 Nm(2, 0 kpm) (14. 7 ft. l bs. )