TEXTRON MOTORS 4-STROKE ENGINE MPE 1000 OFF- ROAD SERVICE MANUAL

REPAIR MANUAL 4-Stroke Engine MPE 1000 OFF-ROAD This repair manual is valid for the following engine models: –– 410746 I2 957 UTV –– 411439 I2 957 UTV TD410035 Rev C 09.03.2018 en_English

Read the introductory chapter before performing the task on the engine.

Pay particular attention to the safety messages.

A qualified repair shop or person of the owner‘s choosing may maintain, replace, or repair emission control devices and systems with original or equivalent replacement parts. However, warranty, recall and all other services paid for by Textron Specialized Vehicles must be performed at an authorized Textron Specialized Vehicles or Textron Motors service center.

CALIFORNIA Proposition 65 Warning This engine and engine exhaust contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

TEXTRON MOTORS GmbH strives to make continual improvements as part of the ongoing technical development of its products. All documentation is therefore subject to technical modifications.

Reprints and translations, in whole or in part, require written permission from TEXTRON MOTORS GmbH. All rights reserved according to the copyright law.

TEXTRON MOTORS GmbH Daimlerstraße 5 88677 Markdorf Germany WWW.TEXTRONMOTORS.COM

TABLE OF CONTENTS ABOUT THIS DOCUMENT

5

Meaning of the symbols and signal words . . . . . . 5 Change management . . . . . . . . . . . . . . . . . . . . . . 5 SAFETY 6 Meaning of the safety alert symbol and signal words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Important safety messages . . . . . . . . . . . . . . . . . . 6 BEFORE YOU BEGIN WORKING

9

Engine identification . . . . . . . . . . . . . . . . . . . . . . . 9 Engine components . . . . . . . . . . . . . . . . . . . . . . . . 9 Workshop equipment . . . . . . . . . . . . . . . . . . . . . . 11 TEXTRON MOTORS Special tools . . . . . . . . 11 Workshop equipment and tools . . . . . . . . . . . 12 Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 SECTION A – ENGINE DISASSEMBLY

16

Removing engine from the vehicle . . . . . . . . . . .

Securing the engine . . . . . . . . . . . . . . . . . . . . . .

Mount the engine across from the drive side . . .

Removing generator cover . . . . . . . . . . . . . . . . .

Removing generator cover with support bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing generator cover without support bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing starter . . . . . . . . . . . . . . . . . . . . . . . . .

Removing intake manifold . . . . . . . . . . . . . . . . . .

Removing ignition coils . . . . . . . . . . . . . . . . . . . .

Removing spark plugs . . . . . . . . . . . . . . . . . . . . .

Removing valve cover . . . . . . . . . . . . . . . . . . . . .

Removing rocker arms . . . . . . . . . . . . . . . . . . . .

Mount the engine on the drive side . . . . . . . . . . .

Removing oil cooler . . . . . . . . . . . . . . . . . . . . . . .

Removing oil cooler bracket . . . . . . . . . . . . . . . .

Removing impeller . . . . . . . . . . . . . . . . . . . . . . . .

Removing slide ring seal . . . . . . . . . . . . . . . . . . .

Removing crankshaft cover . . . . . . . . . . . . . . . . .

Removing crankshaft sensor . . . . . . . . . . . . . . . .

Mount the engine across from the drive side . . .

Removing generator and stub shaft . . . . . . . . . .

Removing oil pressure pump . . . . . . . . . . . . . . . .

18 18 18 19

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19 20 21 22 22 23 23 23 24 25 25 26 26 26 27 27 27 28

Mount the engine on the drive side . . . . . . . . . . .

Removing suction pump cover . . . . . . . . . . . . . .

Removing suction pump intermediate gear . . . . .

Removing timing chain . . . . . . . . . . . . . . . . . . . .

Removing cylinder head . . . . . . . . . . . . . . . . . . .

Removing crank drive . . . . . . . . . . . . . . . . . . . . .

Removing thermostat housing . . . . . . . . . . . . . . .

Removing chain guide . . . . . . . . . . . . . . . . . . . . .

Removing chain rail . . . . . . . . . . . . . . . . . . . . . . .

Removing and reinstalling cylinder liners . . . . . .

29 29 30 30 31 32 34 34 34 35

SECTION B – ENGINE RESASSEMBLY

38

Mount the engine on the drive side . . . . . . . . . . .

Replacing oil filter . . . . . . . . . . . . . . . . . . . . . . . .

Installing chain rail . . . . . . . . . . . . . . . . . . . . . . . .

Installing chain guide . . . . . . . . . . . . . . . . . . . . . .

Installing thermostat housing . . . . . . . . . . . . . . . .

Installing crank drive . . . . . . . . . . . . . . . . . . . . . .

Installing cylinder head . . . . . . . . . . . . . . . . . . . .

Installing timing chain . . . . . . . . . . . . . . . . . . . . .

Installing suction pump intermediate gear . . . . . .

Installing suction pump cover . . . . . . . . . . . . . . .

Mount the engine across from the drive side . . .

Installing crankshaft oil seal . . . . . . . . . . . . . . . .

Installing oil pressure pump . . . . . . . . . . . . . . . . .

Installing generator and stub shaft . . . . . . . . . . .

Mount the engine on the drive side . . . . . . . . . . .

Installing crankshaft sensor . . . . . . . . . . . . . . . . .

Installing crankshaft cover . . . . . . . . . . . . . . . . . .

Installing slide ring seal . . . . . . . . . . . . . . . . . . . .

Installing impeller . . . . . . . . . . . . . . . . . . . . . . . . .

Installing oil cooler bracket . . . . . . . . . . . . . . . . .

Installing oil cooler . . . . . . . . . . . . . . . . . . . . . . . .

Mount the engine across from the drive side . . .

Installing rocker arms . . . . . . . . . . . . . . . . . . . . .

Installing valve cover . . . . . . . . . . . . . . . . . . . . . .

Installing spark plugs . . . . . . . . . . . . . . . . . . . . . .

Installing ignition coils . . . . . . . . . . . . . . . . . . . . .

Installing intake manifold . . . . . . . . . . . . . . . . . . .

Installing starter . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing generator cover . . . . . . . . . . . . . . . . . .

Installing generator cover with support bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 40 40 40 40 41 45 46 48 48 49 49 51 52 53 53 53 54 56 56 57 57 58 58 59 59 60 61 62 62

3

TABLE OF CONTENTS Installing generator cover without support bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Securing the engine . . . . . . . . . . . . . . . . . . . . . .

Installing engine into the vehicle . . . . . . . . . . . . .

Completing and checking of the work . . . . . . . . .

64 65 66 66

SECTION C – ADDITIONAL WORKING INSTRUCTIONS 68 Intake manifold disassembly . . . . . . . . . . . . . . . .

Removing throttle body . . . . . . . . . . . . . . . . .

Removing intake manifold sensor . . . . . . . . .

Intake manifold reassembly . . . . . . . . . . . . . . . . .

Installing intake manifold sensor . . . . . . . . . .

Installing throttle body . . . . . . . . . . . . . . . . . .

Valve cover disassembly . . . . . . . . . . . . . . . . . . .

Removing camshaft sensor . . . . . . . . . . . . . .

Valve cover reassembly . . . . . . . . . . . . . . . . . . . .

Installing camshaft sensor . . . . . . . . . . . . . . .

Suction pump cover disassembly . . . . . . . . . . . .

Removing oil suction pump . . . . . . . . . . . . . .

Suction pump cover reassembly . . . . . . . . . . . . .

Installing oil suction pump . . . . . . . . . . . . . . .

Cylinder head disassembly . . . . . . . . . . . . . . . . .

Removing brackets and oil pressure switch .

Removing camshaft . . . . . . . . . . . . . . . . . . . .

Removing valves . . . . . . . . . . . . . . . . . . . . . .

Removing fuel rail . . . . . . . . . . . . . . . . . . . . .

Cylinder head reassembly . . . . . . . . . . . . . . . . . .

Installing fuel rail . . . . . . . . . . . . . . . . . . . . . .

Installing valves . . . . . . . . . . . . . . . . . . . . . . .

Installing camshaft . . . . . . . . . . . . . . . . . . . . .

Installing brackets and oil pressure switch . .

Thermostat housing disassembly . . . . . . . . . . . .

Removing thermostat . . . . . . . . . . . . . . . . . .

Removing coolant sensor . . . . . . . . . . . . . . .

Thermostat housing reassembly . . . . . . . . . . . . .

Installing coolant sensor . . . . . . . . . . . . . . . .

Installing thermostat . . . . . . . . . . . . . . . . . . .

Tightening torques und assembly instructions . .

Other bolts . . . . . . . . . . . . . . . . . . . . . . . . . . .

Screw-in nipples . . . . . . . . . . . . . . . . . . . . . .

Screw-in plugs . . . . . . . . . . . . . . . . . . . . . . . .

Liquid sealing contours . . . . . . . . . . . . . . . . . . . .

4

69 69 69 70 70 70 71 71 71 71 71 71 72 72 72 72 73 73 74 75 75 76 77 78 78 78 79 79 79 80 83 85 86 86 87

Liquid sealing contour crankcase . . . . . . . . .

Liquid sealing contour suction pump cover . .

Liquid sealing contour thermostat housing . .

Liquid sealing contour generator cover . . . . .

Test procedures and adjustments . . . . . . . . . . . .

Valve lash . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spark plug gap . . . . . . . . . . . . . . . . . . . . . . .

Con rod bearing play . . . . . . . . . . . . . . . . . . .

Main bearing play . . . . . . . . . . . . . . . . . . . . .

Valve timing . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . .

Tie rod thread protusion . . . . . . . . . . . . . . . .

Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankshaft sensing wheel . . . . . . . . . . . . . . .

Rocker arm cam spike . . . . . . . . . . . . . . . . . .

87 88 89 90 91 91 91 92 92 92 93 94 95 95 96 96

OVERVIEW OF REVISIONS

98

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About THIS ABOUT this DOCUMENT document This repair manual describes how to step by step safely and professionally disassemble the engine and reassemble.

After the introductory chapters the repair manual is divided into four major sections: Section A

This section describes how the engine can be disassembled right down to the spare part level.

Section B

This section describes how the engine can be reassembled.

Section C

This section describes how the assemblies can be disassemble and reassemble that have not been fully disassembled in section A.

Section D

This section contains specifications, such as test procedures, adjustments, tightening torques, and assembly instructions.

Observe the following references: –– Owner’s Manual provided with your vehicle for general operation and maintenance instructions and other important information.

–– Always you also need the manufacturer‘s documentation of the vehicle.

–– Keep the spare parts catalog for the engine ready. The spare parts catalog contains for example information on components that have to be replaced after removal.

–– Information on troubleshooting can be found in the engine diagnostic manual.

–– Some figures in this repair manual are general illustrations and may differ from the actual engine.

MEANING OF THE SYMBOLS AND SIGNAL WORDS Item NOTICE Information

Meaning The signal word NOTICE indicates potential property damage.

The signal word Information indicates specific features and recommendations.

CHANGE MANAGEMENT TEXTRON MOTORS GmbH strives to make continual improvements as part of the ongoing technical development of its products. Therefore descriptions in the repair manual can be changed or added. All changes are described in the OVERVIEW OF REVISIONS chapter.

Observe the following references: –– Always use the most current repair manual on WWW.TEXTRONOFFROAD.COM.

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5

SAFETY Safety This engine is state-of-the-art and built according to recognized safety-technical regulations. Ignoring the information in this repair manual may result in personal injury or property damage.

This repair manual is solely intended for use in a workshop authorized by TEXTRON OFF ROAD. All tasks on the engine must be performed by appropriately trained personnel.

Before beginning any work, trained personnel authorized to work on the engine must have access to the complete documentation of the engine. Ensure that all the introductory chapters, in particular the chapter on safety, have been read and understood.

Observe all generally applicable laws and regulations in addition to the information in this repair manual: –– Accident prevention –– Environmental protection –– Handling of hazardous materials –– Personal safety equipment –– Traffic laws

MEANING OF THE SAFETY ALERT SYMBOL AND SIGNAL WORDS Item

Meaning The safety alert symbol draws your attention to possible dangers.

WARNING

The signal word WARNING indicates a potentially dangerous situation that may lead to a serious or fatal injury.

CAUTION

The signal word CAUTION indicates a potentially dangerous situation that may lead to a minor or moderately severe injury.

IMPORTANT SAFETY MESSAGES Defective components

Defective components may pose a safety risk. ►► Check all parts before installation and replace defective components.

Checking the work carried out

Work performed incorrectly poses a safety risk to persons. ►► Check the vehicle each time after working on the engine.

6

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Safety Spare parts

All the components in your engine have been carefully tested and fulfill strict quality and safety requirements. ►► TEXTRON OFF ROAD offers spare parts to the highest quality.

Ensure that equivalent spare parts corresponds with this quality requirements.

Add-on parts and modifications

Engine modifications may pose a safety risk. ►► Do not install add-on parts or modify the engine.

Lift and transport the engine

Spinal column injury due to incorrect lifting of heavy loads. ►► Always use a workshop crane to lift and transport the engine on the brackets provided.

Securing the engine

Crush injuries due to the engine overturning. ►► Secure the engine before starting any work. ►► Mount the engine as soon as possible to the engine stand. ►► Hold the engine as long as with the workshop crane until the engine is mounted on the engine stand.

Tools and accessories

Unsuitable tools and accessories pose a safety risk. ►► Always use the tools and accessories listed in the WORKSHOP EQUIPMENT chapter.

Protective equipment

Missing protective equipment poses a safety risk. ►► Attach all protective equipment after completing the tasks.

Engine power supply

We assume for all work that the engine is disconnected from the power supply. Leaving the engine connected to the power supply poses a risk to personnel. ►► Only reconnect the power supply when prompted to do so by the vehicle manufacturer. ►► Pay attention to the safety messages in the manufacturer‘s documentation of the vehicle.

Engine exhaust gases

Engine exhaust gases contain carbon monoxide (CO). Inhalation of carbon monoxide can deprive the body of oxygen and result in organ damage or even death by asphyxiation. ►► Never operate the engine in enclosed spaces.

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7

Safety Fuel, engine oil and coolant handling

Operating materials pose a health risk. ►► Always read the manufacturer's instructions. ►► Always wash your hands immediately after working on or around an engine.

Operating materials are hazardous to the environment. ►► Never allow operating materials to escape into the groundwater, water courses or sewage system. Always dispose of engine fluids according to applicable regulations.

Danger of slipping on spilled fluids. ►► Place a drain tray. ►► Always clean up any spilled engine fluids immediately. ►► Always use a filler neck or funnel when filling the engine with fluids.

Fuel

Fuel is highly flammable. Vapors may ignite and cause an explosion. ►► Do not smoke in the vicinity of the engine and do not allow naked flames or sparks near the engine or the fuel system. ►► Always turn off the engine before fueling. ►► Never fill with fuel while the engine is running. ►► Do not start the engine if there is a smell of fuel or you suspect that fuel is leaking. ►► Fuel on hot surfaces can cause fires. ►► In the event of a fire, use foam, dry chemical or carbon dioxide extinguishers. Do not extinguish with water.

Engine oil

Engine oil is flammable and can emit toxic gases. ►► Do not smoke in the vicinity of the engine and do not allow open flames or sparks near the engine. ►► Engine oil on hot surfaces can cause fires. ►► Do not extinguish with water. In the event of a fire, use foam, dry chemical or carbon dioxide extinguishers.

8

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Before YOU BEFORE you BEGIN begin WORKING working ENGINE IDENTIFICATION Each engine will be clearly identified by two numbers. Both numbers are located on a label on the engine.

The part number "Part No." the engine model.

2

1

is the number of

1

2

The serial number "Serial No." 3 is an unique number for each individual engine.

3

The label with the part number and the serial number is located on the valve cover 4 .

4

The serial number is also engraved on the crankcase 5 .

5

ENGINE COMPONENTS –– First cylinder

1

–– Camshaft sensor –– Fuel supply

2

/ Second cylinder

3

–– Throttle body

4

–– Intake manifold

2 3

/ Air intake 5

1

/ Intake side

–– Engine oil, oil tank to engine

6

–– Engine oil, engine to oil tank

7

4

5

6 7

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9

Before you begin working The intake manifold is not shown in the figure.

–– Oil filter

8

–– Coolant circuit to the heat exchanger

9

–– Coolant circuit from the heat exchanger

10

8 9 10

–– Permanent vent coolant circuit –– Exhaust ports

12

/ Exhaust side

–– Direction of engine rotation –– Power take off

11

13

11

14

–– Crankcase vent / Engine oil return

15

12 13

14 15

10

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Before you begin working WORKSHOP EQUIPMENT The tools and supplies described in this chapter you will require when working on the engine. Before you begin working, check that all the tools required for the repair are available.

TEXTRON MOTORS SPECIAL TOOLS Visit WWW.TEXTRONOFFROAD.COM for more information.

Figure

Description

Figure

Description

Crankshaft locking tool

Oil seal crankshaft assembling kit

Chain tool

Intermediate gear axle punch

Valve stem seal installation spike

Slide ring seal assembling kit

Bearing cap remover

Cylinder liner removal tool

TDC-adjusting tool

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11

Before you begin working WORKSHOP EQUIPMENT AND TOOLS In addition to the TEXTRON MOTORS special tools, you will require the following workshop equipment and tools when working on the engine. The figures are examples of suitable workshop equipment and tools.

Figure

12

Description

Figure

Description

Workshop crane with carrying strap Minimum lifting capacy 300 kg [650 lb]

Torque wrench 3 – 70 Nm [2 – 52 lbf ft] with extension and insert adapter

Engine stand Minimum lifting capacy 300 kg [650 lb] Mounting bolts M6 and M10

Reversible ratchet with extension and insert adapter

Drain tray

Torx® screwdriver and inserts T30

Funnel

Hexagon screwdriver and inserts 4, 5, 6, 7, 8 mm

Syringe applicator Minimum 40 ml

Hexagon nut driver and inserts 7, 10, 14 mm

Bar magnet

Combination wrench and inserts 7, 10, 12, 15, 19, 24, 27 mm

Universal strap wrench

12-point socket wrench 12 mm

Rubber mallet

Spark plug wrench Wrench size 16 mm [5/8“] Diameter: maximum 22 mm [0.87 in]

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Before you begin working Figure

Description

Figure

Description

Spark plug brush

Valve spring compressor

Stud extractor 8 mm

Feeler gauge 0,05 – 2 mm

Universal pliers

Caliper Measuring accuracy 0,05 mm

Lockring pliers (bore holes)

Angle indicator

Clamping pliers

Valve stem seal remover

Digital-multimeter

Piston ring compressor

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Oil seal slide hammer

Oil pressure tester with M10x1 adapter

Valve refacer

Optional, for checking the bearing clearances: Precision clearance gauges 0,025 mm – 0,04 mm

13

Before you begin working SUPPLIES The following supplies you will require when working on the engine. Unless otherwise specified, use the products as directed by the manufacturer.

Supplies

Examples of suitable tools

Sealing surface cleaner

–– Liqui Moly brake and parts cleaner AIII

Rust remover

–– WD-40® Multi-Use Product, WD-40 Company

Petroleum jelly for fitting o-rings and gaskets

–– Commercial petroleum jelly for industrial applications

Lubricant for injector o-rings

–– Mobil DTE-24, DTE-25, DTE-26 –– Exxon/Mobil Norpar 15

Silicone liquid seal

–– ThreeBond 1227E –– Dirko-S Profi Press HT

Anti-Seize assembly paste for lubricating threaded connections

–– WEICON® Anti-Seize "High-Tech" ASW 040 P –– LOCTITE® LB 8150

Thread locker, high strength

–– LOCTITE® 272

Thread locker, medium strength

–– LOCTITE® 243

Thread sealant

–– LOCTITE® 542 –– LOCTITE® 577

Valve grinding compound

–– TEROSON® valve grinding compound

Abrasive fleece

–– Scotch-Brite™ Superpads HP96 fine –– Scotch-Brite™ Handpads CF-HP very fine –– Scotch-Brite™ Handpads WR-HP very fine

Oil for generator interior

–– LIQUI MOLY Central hydraulic system oil 1127

14

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Before you begin working

NOTES:

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15

Engine disassembly SECTION A – ENGINE DISASSEMBLY

NOTES:

16

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Engine disassembly NOTICE

Bearing damage, increased wear and leaks due to installing components swapped over.

All components in and on the engine has been run-in together. If the components are installed swapped over, they no longer fit together well. ►► Keep your workspace clean and tidy. ►► When you have removed parts, mark the cylinder assignment and installation position. ►► Ensure there is sufficient space available. ►► Place the components in a way, that no confusion is possible. ►► Install all components back into the same place where they were removed.

NOTICE

Engine damage caused by small components in the engine or cylinder head.

Operating the engine when there are small components in the crankcase and cylinder head can result in serious damage and cause the crank drive to seize. ►► When removing small components, always cover the chain channel. ►► Make sure that no small components remain in the engine.

Before you begin working, observe the following references: –– Observe that some engine components must be replaced after removal. These parts are marked accordingly in the spare parts catalog and the work specifications will refer on it. Ensure that all required spare parts are available.

–– Before assembling components, clean all joint surfaces and sealing surfaces.

–– If there is contamination in the lubrication system, cooling system or fuel unit, clean all components concerned.

–– When disposing of engine fluids, replaced parts or the whole engine, always comply with the relevant applicable national laws and guidelines.

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17

A

A

Engine disassembly REMOVING ENGINE FROM THE VEHICLE 1. Remove the engine from the vehicle. (See the manufacturer‘s documentation of the vehicle.)

SECURING THE ENGINE WARNING! Spinal column injury caused by incorrect lifting of heavy loads. Always lift the engine using a workshop crane.

NOTICE! Breakage. Lift the engine only using the brackets.

1 2

1. Lift the engine using the brackets 1 and 2 until the engine is mounted on the engine stand. Observe the references in the chapters.

MOUNT THE ENGINE ACROSS FROM THE DRIVE SIDE 1. Mount the engine across from the drive side on the engine stand.

Suitable mounting points M10: –– Screw-in depth

1

and

2

30 mm

1

2

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Engine disassembly REMOVING GENERATOR COVER 1. Remove the generator cover with support bearing 1 . See chapter REMOVING GENERATOR COVER WITH SUPPORT BEARING. or Remove the generator cover without support bearing 2 . See chapter REMOVING GENERATOR COVER WITHOUT SUPPORT BEARING.

1

2

REMOVING GENERATOR COVER WITH SUPPORT BEARING 1.

6 mm: Remove ten bolts

1

.

1

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19

A

A

Engine disassembly 2.

5 mm: Remove ten bolts M6 B .

3.

8 mm: Remove three bolts M10 A .

A B

B

B

B

B

B A

A B

B B

The generator cover is sealed with a silicone liquid seal.

4. Remove the generator cover 5. Remove the bearing carrier 6. Remove two sleeves

3

.

2 4

B

2

.

.

3 4

REMOVING GENERATOR COVER WITHOUT SUPPORT BEARING 1.

5 mm: Remove ten bolts M6 B .

2.

8 mm: Remove three bolts M10 A .

A B

B

B

B B B A

A B

B B

20

B

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Engine disassembly CAUTION! Danger of slipping caused by leaking engine oil. Place a drain tray.

The generator cover is sealed with a silicone liquid seal.

3. Remove the generator cover 4. Remove two sleeves

2

.

.

1

1 2

REMOVING STARTER 1.

8 mm: Remove two bolts

1

.

1

2.

T30: Remove the bolt

3. Remove the starter

2

.

.

3

2

3

4.

5 mm: Remove the bolt

5. Remove the bracket

4

5

.

.

4 5

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21

A

A

Engine disassembly REMOVING INTAKE MANIFOLD 1.

5 mm: Remove four bolts

1

.

1

2.

6 mm: Remove two bolts

3

.

3. Remove the intake manifold

2

.

Observe in section C Additional working instructions the INTAKE MANIFOLD DISASSEMBLY and INTAKE MANIFOLD REASSEMBLY chapters.

2

3

REMOVING IGNITION COILS 1.

5 mm: Remove four bolts

2. Remove two ignition coils

2

1

.

.

1

2

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Engine disassembly REMOVING SPARK PLUGS WARNING! Irritations and eye injuries can be caused by blown out dirt and particles. All persons in the surrounding area must wear protective glasses.

1. Blow out two spark plug bores compressed air.

2.

with

2

16 mm: Screw in two spark plugs a spark plug wrench.

1

using

1

2

REMOVING VALVE COVER 1.

5 mm: Remove eight bolts

2. Remove the valve cover

2

1

.

1

.

Observe in section C Additional working instructions the VALVE COVER DISASSEMBLY and VALVE COVER REASSEMBLY chapters.

2

REMOVING ROCKER ARMS Start with the cylinder where the rocker arms have a certain amount of play.

1

1

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23

A

A

Engine disassembly 1. Remove the rocker axle pliers.

using a universal

2

2

2. Remove the rocker arm

3

.

3. Remove two valve adjustment shims a bar magnet.

4

using

4. Repeat the procedure with the other rocker arm.

3

4

5. Turn the crankshaft in the rotation direction until the rocker arms on the other cylinder have a certain amount of play.

6. Remove two rocker arms on the other cylinder.

MOUNT THE ENGINE ON THE DRIVE SIDE 1. Mount the engine on the drive side on the engine stand.

1

Suitable mounting points M10:

2

–– Screw-in depth

1

and

2

30 mm

3

Support: –– Minimum one mounting point M6

24

3

or

4

.

4

TD410035-C RLF

Engine disassembly REMOVING OIL COOLER 1.

T30: Remove four bolts

2. Remove the oil cooler

2

1

.

1

.

2

REMOVING OIL COOLER BRACKET 1.

5 mm: Remove the bolt M6x30 A .

2.

5 mm: Remove 14 bolts M6x20 B .

B

CAUTION! Danger of slipping caused by leaking coolant. Place a drain tray.

3. Remove the oil cooler bracket

1

B

B B

A

B

.

B 1

B

B

B

B B

B

B B 4. Remove the sleeve

2

.

2

TD410035-C RLF

25

A

A

Engine disassembly REMOVING IMPELLER 1. Hold the crankshaft locking tool position.

2.

8 mm: Install the bolt

2

1

on rotor in 1

and washer.

2

3.

10 mm: Remove the nut

4. Remove the impeller

3

4

.

3

.

4

REMOVING SLIDE RING SEAL 1.

7 mm: Remove the water pump axle

1

.

1

REMOVING CRANKSHAFT COVER 1.

T30: Remove the bolt

2. Remove the cover

1

2

.

.

1 2

26

TD410035-C RLF

Engine disassembly REMOVING CRANKSHAFT SENSOR 4 mm: Remove the bolt

1.

2. Remove the sensor

2

1

.

.

1 2

MOUNT THE ENGINE ACROSS FROM THE DRIVE SIDE 1. Mount the engine across from the drive side on the engine stand.

Suitable mounting points M10: –– Screw-in depth

1

and

30 mm

2

1 2

REMOVING GENERATOR AND STUB SHAFT 1.

2.

7 mm: Remove six bolts 2

1

.

8 mm: Remove the crankshaft locking tool .

1

2

3. Remove the rotor

3

.

4. Remove the stub shaft

4

.

3

4

TD410035-C RLF

27

A

A

Engine disassembly 5.

5 mm: Remove four bolts

6. Remove the stator

8

6

.

7. Remove the distance washer 8. Remove two sleeves

.

5

7

.

.

5 6 7 8

REMOVING OIL PRESSURE PUMP 1. Remove the circlip

1

using a lockring pliers.

2. Remove the oil pump cover universal pliers.

2

using a 1

2

3. Remove the outer rotor pump.

3

of the oil pressure

4. Remove the inner rotor pump.

4

of the oil pressure

5. Remove the key

5

3 4

.

5

6. Remove the timing insert

6

.

6

28

TD410035-C RLF

Engine disassembly MOUNT THE ENGINE ON THE DRIVE SIDE 1. Mount the engine on the drive side on the engine stand.

1 2

Suitable mounting points M10: –– Screw-in depth

1

and

2

3

30 mm

Support: –– Minimum one mounting point M6

or

3

4

.

4

REMOVING SUCTION PUMP COVER 1. Turn the engine 180°.

2.

5 mm: Remove seven bolts M6x20 B and seven bolts M6x30 A .

A

A

A

B

A A

A A

B

B B

B

B

B

The suction pump cover is sealed with a silicone liquid seal.

3. Lift off the suction pump cover at the joints and 2 .

1

1 2 4. Remove the suction pump cover 5. Remove two sleeves

4

3

.

.

Observe in section C Additional working instructions the SUCTION PUMP COVER DISASSEMBLY and SUCTION PUMP COVER REASSEMBLY chapters.

TD410035-C RLF

3

4

29

A

A

Engine disassembly REMOVING SUCTION PUMP INTERMEDIATE GEAR 1.

8 mm: Remove the plug

1

and seal.

1

2. Knock out the axle 4 using the intermediate gear axle punch 2 and plastic hammer.

3. Remove the suction pump intermediate gear 3 .

2 3

4. Turn the engine 180°.

4

REMOVING TIMING CHAIN 1.

27 mm: Remove the chain tensioner

1

.

1

2. Open the timing chain 2 using the chain tool.

(See the instruction manual of the chain tool.)

2

30

TD410035-C RLF

Engine disassembly 3. Turn the engine 180°.

4. Remove the timing chain

.

3

3

REMOVING CYLINDER HEAD 1. Check the tie rod thread protrusion according to the specification TIE ROD THREAD PROTRUSION. (See section D Test procedures and adjustments.)

Remove all nuts in the sequence as illustrated 2.

14 mm: Remove eight nuts washers.

3. Remove four cross bars

3

2

1

1

1

7

5

3

4

6

8

2

2 .

3

and

.

4. Remove the cylinder head.

5. Remove eight sleeves

4

.

6. When replacing a stud 5 , install the new stud according to the specification M8 STUD CYLINDER HEAD. (See section D Tightening torques und assembly instructions.)

Observe in section C Additional working instructions the CYLINDER HEAD DISASSEMBLY and CYLINDER HEAD REASSEMBLY chapters.

7. Remove the cylinder head gasket 8. Remove two centering pins

6

.

7

.

4

5

6 7

TD410035-C RLF

31

A

A

Engine disassembly REMOVING CRANK DRIVE 1. Turn the engine 180°.

Remove all bolts in the sequence as illustrated 1 .

2.

5 mm: Remove four bolts M6 1 – 4 .

3.

6 mm: Remove five bolts M8 5 – 9 .

1

1 7

9

8

6

4

2

5 3

4. Remove the oil pressure valve magnet.

2

using a bar 2

The crankcase is sealed with a silicone liquid seal.

5. Remove the lower case

3

.

6. When replacing a tie rod 4 , install the new tie rod according to the specification TIE RODS M10X1.25. (See section D Tightening torques und assembly instructions.)

Mark the cylinder assignment and installation position on the piston, con rod, con rod cover and bearing shells.

7.

12 mm: Remove four con rod bolts

8. Remove two con rod covers

32

6

5

.

3 4

5 6

.

TD410035-C RLF

Engine disassembly 9. Remove the balance shaft

10. Remove the crankshaft 11. Remove the oil seal

7

.

7

.

8

.

9

8

9

12.

6 mm: Remove the banjo bolt

13. Remove the oil nozzle

11

10

.

.

14. Repeat the procedure with the other oil nozzle.

10 11

15. Turn the upper case 180°.

Use an abrasive fleece and rust remover for cleaning the cylinder liners.

16. If combustion residues at the upper area of the cylinder liners 12 are present, remove the combustion residues.

12

17. Turn the upper case 180°.

18. Remove two pistons

13

.

13

TD410035-C RLF

33

A

A

Engine disassembly REMOVING THERMOSTAT HOUSING Only remove the thermostat housing if the thermostat housing or the crankcase must be replaced.

1.

5 mm: Remove ten bolts

2

1 2

.

The thermostat housing is sealed with a silicone liquid seal.

2. Remove the thermostat housing

1

.

Observe in section C Additional working instructions the THERMOSTAT HOUSING DISASSEMBLY and THERMOSTAT HOUSING REASSEMBLY chapters.

REMOVING CHAIN GUIDE 1.

5 mm: Remove two bolts

2. Remove the chain guide

2

1

.

.

1 2

REMOVING CHAIN RAIL 1.

T30: Remove the bolt

2. Remove the chain rail

2

1

.

.

1 2

34

TD410035-C RLF

Engine disassembly REMOVING AND REINSTALLING CYLINDER LINERS Only remove the cylinder liners if the cylinder liners or the crankcase must be replaced.

1. Position the cylinder liner removal tool to the cylinder liner.

1

CAUTION! Foot injuries can be caused by suddenly falling cylinder liner. Do not hit too hard onto the cylinder liner removal tool.

Ensure that the cylinder liner can not fall down.

2. Hit lightly on the cylinder liner removal tool several times using a rubber mallet and slide out the cylinder liner.

3. Repeat the procedure with the other oil nozzle.

2

Pay particular attention to the steps 3 for the cylinder liners. The areas must be clean and free of grease.

4. Clean the upper case in the area of the cylinder liners thoroughly.

3

5. Coat the areas of the cylinder liner o-rings below dimension A lightly with petroleum jelly.

A

Pay particular attention to the steps 4 of the cylinder liners. The areas must be clean and free of grease.

6. Clean the cylinder liners thoroughly.

7. Replace the o-rings on the cylinder liners.

4

8. Apply the silicone liquid seal on the step of the cylinder liner without gaps as illustrated 5 .

5

TD410035-C RLF

35

A

A

Engine disassembly The cylinder liner removal tool inserting the cylinder liner.

6

9. Insert two cylinder liners

.

7

is suitable for

10. Place the lower case onto the upper case.

11. Screw the housing together according to the specification CRANKCASE BOLTS FIRST STAGE. (See section D Tightening torques und assembly instructions.)

6 7

The cylinder head gasket must be replaced after removal. When press-in the cylinder liner, you can use the used cylinder head gasket.

12. Apply the cylinder head gasket.

Observe the installation position: –– Centering pins –– Exhaust side –– Inscription

9

8

8

12

13. Place the cylinder head on the crankcase.

Observe the installation position: –– Exhaust side

10

–– Chain tensioner

11

9 10 11 12

14. Insert four cross bars 14 . (See the following assembly instruction for cross bars.)

15. Install eight nuts 13 according to the specification CYLINDER HEAD NUTS FIRST STAGE. (See section D Tightening torques und assembly instructions.)

13 14

16. Wait 15 minutes.

17. Remove the cylinder head nuts in reverse order and remove the cylinder head.

18. Remove the crankcase bolts in reverse order and remove the lower case.

ASSEMBLY INSTRUCTION FOR CROSS BARS –– Counterbore –– Sleeve

1

1

2

2

36

TD410035-C RLF

Engine disassembly

NOTES:

TD410035-C RLF

37

A

Engine resassembly SECTION B – ENGINE RESASSEMBLY

NOTES:

38

TD410035-C RLF

Engine resassembly 1. Check if the fitting 2. Check if the plug

1

is installed. is installed.

2

1

2 3. Check if the plug

is installed.

3

3

4. Check if the plugs installed.

4

,

5

and

6

are

4 5 6 5. Check if the plugs

7

and

8

are installed.

7 8

MOUNT THE ENGINE ON THE DRIVE SIDE 1. Mount the engine on the drive side on the engine stand.

1

Suitable mounting points M10: –– Screw-in depth

1

and

2

2

30 mm

3

Support: –– Minimum one mounting point M6

TD410035-C RLF

3

or

4

.

4

39

B

B

Engine resassembly REPLACING OIL FILTER 1. Replace the oil filter

.

1

2. Install the oil filter according to the specification OIL FILTER. (See section D Tightening torques und assembly instructions.)

3. When replacing the threaded sleeve, install the new threaded sleeve according to the specification THREADED SLEEVE FOR OIL FILTER. (See section D Tightening torques und assembly instructions.)

1

INSTALLING CHAIN RAIL 1. Insert the chain rail 2.

2

.

T30: Install the bolt 1 according to the specification OTHER BOLTS M6 STANDARD. (See section D Tightening torques und assembly instructions.)

1 2

INSTALLING CHAIN GUIDE 1. Turn the upper case 180°.

2. Insert the chain guide 3.

2

1

.

5 mm: Install two bolts 1 according to the specification OTHER BOLTS M6 STANDARD. (See section D Tightening torques und assembly instructions.)

2

4. Turn the upper case 180°.

INSTALLING THERMOSTAT HOUSING 1. Apply the silicone liquid seal according to the specification LIQUID SEALING CONTOUR THERMOSTAT HOUSING. (See section D Liquid sealing contours.)

2. Hold the thermostat housing 3.

40

1

1 2

in position.

5 mm: Install ten bolts 2 according to the specification OTHER BOLTS M6 STANDARD. (See section D Tightening torques und assembly instructions.)

TD410035-C RLF

Engine resassembly INSTALLING CRANK DRIVE 1. Clean the sealing surfaces crankcase.

1

and

on the

4

2. When replacing the crankcase, check the main bearing play according to the specification MAIN BEARING PLAY. (See section D Test procedures and adjustments.)

1 2 3 4

3. When replacing the crankshaft, check the main bearing play and con rod bearing play according to the specifications MAIN BEARING PLAY and CON ROD BEARING PLAY. (See section D Test procedures and adjustments.)

4. Coat eight main bearing shells 2 lightly with engine oil and insert in the crankcase.

When replacing the balance shaft, replace the balance shaft bearing shells.

5. Coat eight balance shaft bearing shells lightly with engine oil and insert in the crankcase.

3

6. When replacing a piston with con rod, check the con rod bearing play according to the specification CON ROD BEARING PLAY. (See section D Test procedures and adjustments.)

5

7. Coat four con rod bearing shells 5 lightly with engine oil and insert in the con rods and con rod covers. (See the following assembly instructions for con rod bearings.)

ASSEMBLY INSTRUCTIONS FOR CON ROD BEARINGS NOTICE! Serious bearing damage caused by incorrect installed con rod bearing shells. ►► Insert two con rod bearing shells centered on the con rod.

1

►► Measure wether the dimensions "=" equal.

TD410035-C RLF

2

1 2

are

41

B

B

Engine resassembly 8. Coat the piston

6

lightly with engine oil.

9. Arrange the piston ring gaps. (See the following assembly instructions for piston ring gaps.)

The arrows on the pistons mark the installation position of the pistons in the engine. When the pistons are installed in the engine, the arrows point towards the chain tensioner 7 and the starter 8 . (See the following assembly instructions for pistons.)

10. Insert the piston using a piston ring compressor.

6

7 8

11. Repeat the procedure with the other piston.

ASSEMBLY INSTRUCTIONS FOR PISTON RING GAPS Arrangement of the piston rings

1

:

–– Upper compression ring a –– Lower compression ring b Three-part oil control ring, consisting of: –– Upper cover ring c –– Sinuous spring d

Position G piston ring gap lower cover ring e 1 a b c d e

–– Lower cover ring e NOTICE! Engine damage caused by damaged piston rings. Do not remove the piston rings and carefully slide into the correct position.

Position G has an arrow mark on the piston.

Arrangement of the piston ring gaps:

F G

Position F piston ring gap lower compression ring b Position F piston ring gap upper cover ring c Position G piston ring gap upper compression ring a

42

TD410035-C RLF

Engine resassembly ASSEMBLY INSTRUCTIONS FOR PISTONS Installation position pistons:

1

–– Engraved arrow on the top

2

–– Embossed arrow on the inside

1

The arrows on the pistons mark the installation position of the pistons in the engine. When the pistons are installed in the engine, the arrows point towards the chain tensioner and the starter.

2

12. Turn the upper case 180°.

13. Hold the oil nozzle 14.

10

in position.

6 mm: Install the banjo bolt 9 according to the specification OIL NOZZLE. (See section D Tightening torques und assembly instructions.)

9 10

15. Repeat the procedure with the other oil nozzle.

16. Insert the crankshaft

11

.

11

Con rods and con rod covers are cracked components. Install the con rod cover back into the same place where the con rod cover was removed.

17. Insert the con rod cover 18.

13

.

12 mm: Install two con rod bolts 12 according to the specification CON ROD BOLTS M10X1. (See section D Tightening torques und assembly instructions.)

12 13

19. Repeat the procedure with the other con rod.

TD410035-C RLF

43

B

B

Engine resassembly 20. Insert the balance shaft

14

.

14

21. Observe the markings

15

.

Both markings ends flush with the crankcase.

15

22. Turn the crankshaft

16

180°.

16

23. Check if the centering pins installed.

17

and

18

are

17

24. Apply the silicone liquid seal according to the specification LIQUID SEALING CONTOUR CRANKCASE. (See section D Liquid sealing contours.)

18

25. Check the markings

19

.

Both markings appear as shown.

44

19

TD410035-C RLF

Engine resassembly 26. Place the lower case

20

onto the upper case.

20

27. Assemble the oil pressure valve in the sequence as illustrated 22 .

28. Coat the oil pressure valve engine oil.

21

21

lightly with

29. Insert the oil pressure valve.

The crankcase is tightened in two stages. The crankcase will be tightend only after the cylinder head installation.

22

30. Screw the housing together according to the specification CRANKCASE BOLTS FIRST STAGE. (See section D Tightening torques und assembly instructions.)

31. Turn the engine 180°.

INSTALLING CYLINDER HEAD 1. Insert two centering pins

3

.

2. Replace the cylinder head gasket.

1

3. Apply the cylinder head gasket.

Observe the installation position: –– Exhaust side –– Inscription

4

2

5

4. Place the cylinder head on the crankcase.

Observe the installation position: –– Exhaust side –– Starter

2

3 4

6

5. Insert eight sleeves

1

.

5 6

TD410035-C RLF

45

B

B

Engine resassembly 6. Insert four cross bars 8 . (See the following assembly instruction for cross bars.)

7. Install eight nuts 7 and washers according to the specification CYLINDER HEAD NUTS. (See section D Tightening torques und assembly instructions.)

7 8

8. Check the tie rod thread protrusion according to the specification TIE ROD THREAD PROTRUSION. (See section D Test procedures and adjustments.)

9. Screw the housing together according to the specification CRANKCASE BOLTS SECOND STAGE. (See section D Tightening torques und assembly instructions.)

ASSEMBLY INSTRUCTION FOR CROSS BARS –– Counterbore –– Sleeve

1

1

2

2

INSTALLING TIMING CHAIN 1. Check wether the camshaft is at the crossing point.

The position of the camshaft is as illustrated 2 .

The marking

1

ends flush with the cross bar.

1 2

2. If the camshaft does not appear as illustrated, turn the camshaft.

3. Hold the TDC-adjusting tool 4 in position.

Observe the positioning pin and positioning bore 3 .

Use the bolts M10x1x35 that you removed from the rotor.

4.

7 mm: Install two bolts

5

.

3

4 5

46

TD410035-C RLF

Engine resassembly 5. Turn the crankshaft on the TDC-adjusting tool 7 in the rotation direction 6 until the marking 9 ends flush with the crankcase joint 8 .

6 7

8 9

6. Turn the engine 180°.

7. Replace the timing chain.

8. Insert the timing chain as illustrated

10

.

10

9. Insert the chain link the timing chain.

11

to the open ends of

10. Turn the engine 180°.

11. Close the timing chain. (See the instruction manual of the chain tool.)

11 12.

27 mm: Install the chain tensioner 12 according to the specification CHAIN TENSIONER. (See section D Tightening torques und assembly instructions.)

12

TD410035-C RLF

47

B

B

Engine resassembly 13. Turn the crankshaft on the TDC-adjusting tool several times in the rotation direction until the marking ends flush with the crankcase joint.

14. Check if the camshaft marking ends flush with the cross bar.

15.

7 mm: Remove two bolts

13

.

14

16. Remove the TDC-adjusting tool

13

14

.

INSTALLING SUCTION PUMP INTERMEDIATE GEAR 1. Hold the suction pump intermediate gear in position.

Observe the position of the bevel 2. Insert the axle

2

3

1

.

.

1 2 3

3.

8 mm: Install the plug 4 and seal according to the specification SCREW-IN PLUGS WITH COLLAR M18X1.5. (See section D Tightening torques und assembly instructions.)

4

INSTALLING SUCTION PUMP COVER 1. Insert two sleeves

2

.

2. Apply the silicone liquid seal according to the specification LIQUID SEALING CONTOUR SUCTION PUMP COVER. (See section D Liquid sealing contours.)

Observe when applying the suction pump cover, that the gears of the oil suction pump and the intermediate gear 3 are engaged.

3. Apply the suction pump cover

48

1

1

2 3

.

TD410035-C RLF

Engine resassembly 4.

5 mm: Install seven bolts M6x30 A and seven bolts M6x20 B according to the specification OTHER BOLTS M6 STANDARD. (See section D Tightening torques und assembly instructions.)

A

A

A

B

A A

5. Turn the engine 180°.

A A

B

B B

B

B

B

MOUNT THE ENGINE ACROSS FROM THE DRIVE SIDE 1. Mount the engine across from the drive side on the engine stand.

Suitable mounting points M10: –– Screw-in depth

1

and

2

30 mm 1 2

INSTALLING CRANKSHAFT OIL SEAL 1. Replace the oil seal

1

.

2. Coat the inside of the oil seal petroleum jelly.

1 3

lightly with

3. Slide the oil seal onto guiding sleeve

2

2

.

3

TD410035-C RLF

49

B

B

Engine resassembly 4. Slide the guiding sleeve 5 .

onto crankshaft

4

Use the bolts M10x1x35 that you removed from the rotor.

5.

7 mm: Install two bolts

.

6

4 5 6

6. Position the sliding sleeve 8 .

7

on the oil seal

Use a bolt M10x1x35 that you removed from the rotor.

7.

7 mm: Screw in the bolt

9

.

7 8 9

8.

7 mm: Screw in the bolt 10 until the oil seal ends flush with the crankcase.

10

9.

7 mm: Remove the bolt

12

.

10. Remove the sliding sleeve

11

.

11 12

50

TD410035-C RLF

Engine resassembly 11.

7 mm: Remove two bolts

12. Remove the guiding sleeve 13. Check if the oil seal

14

.

15 13

.

is tilted.

14. If the oil seal is tilted, it must be replaced.

13 14 15

INSTALLING OIL PRESSURE PUMP NOTICE! Engine damage caused by lack of lubrication. If the timing insert is installed in reverse direction, the engine cannot build up any oil pressure. Insert the side with centering pin 1 first.

1. Insert the timing insert installation position.

2

. Observe the x 1 2

NOTICE! Engine damage caused by lack of lubrication. If the key 3 is not installed, the engine cannot build up any oil pressure. Always install the key.

2. Replace the key.

3. Insert the key.

4. Insert the inner rotor pump.

4

of the oil pressure

5. Insert the outer rotor pump.

5

of the oil pressure

6. Replace two o-rings petroleum jelly.

7

and lightly coat with

7. Insert the oil pump cover

8

8. Install the circlip

9

4 5

6

.

WARNING! Serious eye injuries caused by a fast hurled circlip. Wear protective glasses.

Observe the position of the bevel

3

6

.

7 8

using a lockring pliers.

9

TD410035-C RLF

51

B

B

Engine resassembly INSTALLING GENERATOR AND STUB SHAFT 1. Insert two sleeves

.

1

2. Insert the distance washer 3. Hold the stator 4.

4

3

.

1

in position.

5 mm: Install four bolts 2 according to the specification OTHER BOLTS M6 MEDIUM STRENGTH THREAD LOCKER. (See section D Tightening torques und assembly instructions.)

2 3 4

5. Hold the stub shaft 6. Slide on the rotor

6 5

in position.

.

5

6

7. Replace six bolts 8.

7

.

7 mm: Screw in six bolts slightly. Do not tighten.

7

9. Hold the crankshaft locking tool position.

10.

11.

52

8 mm: Install the bolt

10

9

on rotor in

and washer.

7 mm: Install six bolts according to the specification OTHER BOLTS M10X1 ROTOR/ CRANKSHAFT. (See section D Tightening torques und assembly instructions.)

8

8 9 10

TD410035-C RLF

Engine resassembly MOUNT THE ENGINE ON THE DRIVE SIDE 1. Mount the engine on the drive side on the engine stand.

1 2

Suitable mounting points M10: –– Screw-in depth

and

1

2

3

30 mm

Support: –– Minimum one mounting point M6

3

or

4

.

4

INSTALLING CRANKSHAFT SENSOR 1. Replace the o-ring 2 on the sensor and lightly coat with petroleum jelly.

1

2. If a sleeve is installed on the sensor, slide the o-ring up to sleeve 1 . or If no sleeve is installed on the sensor, slide the o-ring to the illustrated distance.

3. Insert the sensor 4.

4

2

.

4 mm: Install the bolt 3 according to the specification OTHER BOLTS M6 STANDARD. (See section D Tightening torques und assembly instructions.)

3 4

INSTALLING CRANKSHAFT COVER 1. Replace the gasket petroleum jelly.

TD410035-C RLF

1

and lightly coat with

1

53

B

B

Engine resassembly 2. Insert the cover 3.

2

.

T30: Install the bolt 3 according to the specification OTHER BOLTS M6 STANDARD. (See section D Tightening torques und assembly instructions.)

2

3

INSTALLING SLIDE RING SEAL The crankshaft locking tool is still installed.

1. Replace the water pump axle

1

.

NOTICE! Leaks caused by damaged sealing surfaces of the water pump axle. Do not damage the water pump axle during installation.

2.

7 mm: Install the water pump axle.

3. Replace the sealing bracket.

4. Coat the gasket petroleum jelly.

2

The slide ring seal area and free of grease.

2

and o-ring 5

1

3

lightly with

3

must remain clean

5. Coat the inside of the oil seal petroleum jelly.

4

lightly with

4 5

6. Insert the sealing bracket

6

.

6

54

TD410035-C RLF

Engine resassembly Do not install the guide completely. A gap must remain between the guide and the water pump axle.

7.

7 mm: Install the guide

.

7

7

8. Replace the slide ring seal

.

8

NOTICE! Leaks can be caused by defective slide ring seal. Do not slide the slide ring seal by hand onto water pump axle.

8

9. Slide the slide ring seal onto guide.

10. Slide the sliding sleeve 11.

15 mm: Install the nut

onto guide.

9

10

.

9 10

12.

15 mm: Screw in the nut 11 until the slide ring seal is inserted completely.

Tightening torque: 10 Nm +1 Nm [7.4 lbf ft +0.7 lbf ft] 11

13.

15 mm: Remove the nut

14. Remove the sliding sleeve

13 12

.

.

12 13

TD410035-C RLF

55

B

B

Engine resassembly NOTICE! Leaks caused by loosened bolt connection If the connection of the water pump axle has loosened during removing the tool, repeat the procedure with a new slide ring seal.

15.

7 mm: Remove the guide

14

.

14

INSTALLING IMPELLER The crankshaft locking tool is still installed.

1. Insert the impeller

.

1

2.

10 mm: Install the nut 2 according to the specification M6 NUT IMPELLER. (See section D Tightening torques und assembly instructions.)

3.

8 mm: Remove the crankshaft locking tool from rotor.

1

2

INSTALLING OIL COOLER BRACKET 1. Replace the gasket

1

.

2. Insert the gasket into the groove and lightly coat with petroleum jelly.

3. Insert the sleeve

2

1

.

2

56

TD410035-C RLF

Engine resassembly 4. Position the oil cooler bracket crankcase.

5.

3

to the B

B

5 mm: Install the bolt M6x30 A and twelve bolts M6x20 B according to the specification OTHER BOLTS M6 STANDARD. (See section D Tightening torques und assembly instructions.)

A

B

B

B 3

B

B B

B

B B

INSTALLING OIL COOLER 1. Replace four gaskets

2

.

2. Insert four gaskets into the grooves and lightly coat with petroleum jelly.

3. Hold the oil cooler 4.

3

1

in position.

T30: Install four bolts 1 according to the specification OTHER BOLTS M6 STANDARD. (See section D Tightening torques und assembly instructions.)

2 3

MOUNT THE ENGINE ACROSS FROM THE DRIVE SIDE 1. Mount the engine across from the drive side on the engine stand.

Suitable mounting points M10: –– Screw-in depth

1

and

2

30 mm

1 2

TD410035-C RLF

57

B

B

Engine resassembly INSTALLING ROCKER ARMS On this cylinder both cams

2

point downwards.

1. Insert both valve adjustment shims

1

.

1

2 2. Coat the rocker arm 3 and rocker axle lightly with engine oil.

4

3. Hold the rocker arm in position.

4. Check if the circlip the rocker axle.

5

is installed and insert

3

5. Repeat the procedure with the other rocker arm.

6. Check the valve lash according to the specification VALVE LASH. (See section D Test procedures and adjustments.)

4 5

7. Turn the crankshaft in rotation direction, until both cams on the other cylinder point downwards. (See chapter Engine components.)

8. Install two rocker arms on the other cylinder.

INSTALLING VALVE COVER 1. Clean the grooves for gaskets 2 and the sealing surfaces on the valve cover.

1

2. Clean the sealing surfaces on the cylinder head.

3. Replace three valve cover seals

1

.

4. Insert three valve cover seals dry and without supplies into the grooves.

58

2

TD410035-C RLF

Engine resassembly 5. Apply the valve cover 6.

.

4

5 mm: Install eight bolts 3 according to the specification VALVE COVER BOLTS. (See section D Tightening torques und assembly instructions.)

3

4

INSTALLING SPARK PLUGS 1. Check two spark plugs according to the specification SPARK PLUG GAP. (See section D Test procedures and adjustments.)

2.

16 mm: Install two spark plugs 1 using a spark plug wrench according to the specification SPARK PLUGS. (See section D Tightening torques und assembly instructions.)

1

INSTALLING IGNITION COILS 1. Insert two ignition coils

3

.

2. Replace the serrated lock washers 4 .

1

and

Observe the arrangement of the serrated lock washers and washers.

3.

5 mm: Install four bolts 2 according to the specification OTHER BOLTS M6 ANTI-SEIZE ASSEMBLY PASTE. (See section D Tightening torques und assembly instructions.)

TD410035-C RLF

1 2

3

4

59

B

B

Engine resassembly INSTALLING INTAKE MANIFOLD 1. Replace two gaskets

2

.

2. Insert two gaskets into the grooves lightly coat with petroleum jelly.

1

and 1 2

3. Check if two sleeves

4

4. Hold the intake manifold 5.

are installed.

3

6 mm: Screw in two bolts tighten.

in position.

5

lightly. Do not

3

4 5 6.

5 mm: Install four bolts 6 according to the specification OTHER BOLTS M6 STANDARD. (See section D Tightening torques und assembly instructions.)

6

7.

6 mm: Install two bolts 7 according to the specification OTHER BOLTS M8 STANDARD. (See section D Tightening torques und assembly instructions.)

7

60

TD410035-C RLF

Engine resassembly INSTALLING STARTER 1. Hold the bracket 2.

in position.

1

5 mm: Install the bolt 2 according to the specification OTHER BOLTS M6 STANDARD. (See section D Tightening torques und assembly instructions.)

3. Replace the o-ring petroleum jelly.

3

1 2

and lightly coat with

3

4. Hold the starter 5.

5

in position.

T30: Screw in the bolt tighten.

4

lightly. Do not 4 5

6.

8 mm: Install two bolts 6 according to the specification OTHER BOLTS M10 STANDARD. (See section D Tightening torques und assembly instructions.)

7.

T30: Install the bolt 7 according to the specification OTHER BOLTS M6 STANDARD. (See section D Tightening torques und assembly instructions.)

TD410035-C RLF

6

7

61

B

B

Engine resassembly INSTALLING GENERATOR COVER If you replace the generator cover by a generator cover with support bearing, observe that the rotor and the stub shaft must also be replaced.

1. Install the generator cover with support bearing 1 . See chapter INSTALLING GENERATOR COVER WITH SUPPORT BEARING. or Install the generator cover without support bearing 2 . See chapter INSTALLING GENERATOR COVER WITHOUT SUPPORT BEARING.

1

2

INSTALLING GENERATOR COVER WITH SUPPORT BEARING 1. Replace the o-ring petroleum jelly.

1

and lightly coat with

2. Position the bearing carrier generator cover.

2

to the

Use thread sealant according to the specification M8 BEARING CARRIER. 3.

1 2

6 mm: Screw in ten bolts slightly. Do not tighten.

3

62

TD410035-C RLF

Engine resassembly 4. Insert two sleeves

4

.

5. Apply the silicone liquid seal according to the specification LIQUID SEALING CONTOUR GENERATOR COVER. (See section D Liquid sealing contours.)

6. Position the generator cover crankcase.

5

to the

4 5 The stator cable is not fully shown in the figures.

7. Check if the gasket of the stator cable properly seated.

6

is

6

8.

9.

10.

8 mm: Install three bolts M10x50 A according to the specification OTHER BOLTS M10 STANDARD. (See section D Tightening torques und assembly instructions.)

5 mm: Install ten bolts M6x50 B according to the specification OTHER BOLTS M6 STANDARD. (See section D Tightening torques und assembly instructions.)

6 mm: Install ten bolts M8x10 according to the specification M8 BEARING CARRIER. (See section D Tightening torques und assembly instructions.)

A B

B

B

B

7

7

B A

A B

B B

TD410035-C RLF

B

B

63

B

B

Engine resassembly INSTALLING GENERATOR COVER WITHOUT SUPPORT BEARING 1. Remove all residues of engine oil inside the generator cover 2 .

2. Remove the oil seal

1

1

.

3. Replace the oil seal.

4. Press the oil seal into the generator cover until stop.

2

5. Coat the inside of the oil seal lightly with petroleum jelly.

6. Insert two sleeves

3

.

7. Apply the silicone liquid seal according to the specification LIQUID SEALING CONTOUR GENERATOR COVER. (See section D Liquid sealing contours.)

8. Position the generator cover crankcase.

4

to the

3 4 The stator cable is not fully shown in the figures.

9. Check if the gasket of the stator cable properly seated.

5

is

5

64

TD410035-C RLF

Engine resassembly 10.

11.

8 mm: Install three bolts M10x50 A according to the specification OTHER BOLTS M10 STANDARD. (See section D Tightening torques und assembly instructions.)

A B

5 mm: Install ten bolts M6x50 B according to the specification OTHER BOLTS M6 STANDARD. (See section D Tightening torques und assembly instructions.)

B

B

B

B

B A

A B

B B

12.

14 mm: Remove the vent plug

6

B

.

If too much oil has been filled, oil may leak at the plug.

Observe the specification about oil for generator interior in the SUPPLIES chapter. (See chapter Before you begin working.)

6

13. Fill oil for generator interior using a syringe applicator.

Required quantity: 35 ml +5 ml [1.18 oz +0.17 oz] 14.

14 mm: Install the vent plug according to the specification GENERATOR COVER VENT PLUG. (See section D Tightening torques und assembly instructions.)

SECURING THE ENGINE WARNING! Spinal column injury caused by incorrect lifting of heavy loads. Always lift the engine using a workshop crane.

1

NOTICE! Breakage. Lift the engine only using the brackets.

1. Lift the engine using the brackets

1

and

2

.

2

2. Remove the engine from engine stand.

TD410035-C RLF

65

B

B

Engine resassembly INSTALLING ENGINE INTO THE VEHICLE 1. Install the engine into the vehicle. (See the manufacturer‘s documentation of the vehicle.)

COMPLETING AND CHECKING OF THE WORK Turn the ignition on for about a minute, until the throttle body opens and closes again.

When warming up the engine you must not hear any unusual noises.

1. Warm up the engine.

2. Perform a visual inspection. No leakings of fluids should be visible.

3. Run the engine through all operating modes.

66

TD410035-C RLF

Engine resassembly

NOTES:

TD410035-C RLF

67

B

Additional– working SECTION C ADDITIONAL instructions WORKING INSTRUCTIONS

NOTES:

68

TD410035-C RLF

Additional working instructions INTAKE MANIFOLD DISASSEMBLY REMOVING THROTTLE BODY 1.

7 mm: Open the screw clamp

2. Remove the throttle body

2

.

1

.

1

2

3.

5 mm: Remove four bolts

4. Remove the rubber mount

3

4

.

.

3

4

REMOVING INTAKE MANIFOLD SENSOR 1.

T30: Remove the bolt

2. Remove the sensor

2

.

1

.

1

2

TD410035-C RLF

69

C

C

Additional working instructions INTAKE MANIFOLD REASSEMBLY INSTALLING INTAKE MANIFOLD SENSOR 1. Insert the sensor 2.

2

.

T30: Install the bolt 1 according to the specification OTHER BOLTS (SELFTAPPING) 6X20. (See section D Tightening torques und assembly instructions.)

1

2

INSTALLING THROTTLE BODY 1. Hold the rubber mount

2

in position.

Screw in the bolts evenly crosswise.

2.

1

5 mm: Install four bolts 1 according to the specification OTHER BOLTS M6 STANDARD. (See section D Tightening torques und assembly instructions.)

2

3. Perform a visual inspection on the rubber mount 3 .

An even edge

4

is visible.

3 4

4. Hold the throttle body

5

in position.

5. Close the screw clamp 6 according to the specification SCREW CLAMPS. (See section D Tightening torques und assembly instructions.)

5

6

70

TD410035-C RLF

Additional working instructions VALVE COVER DISASSEMBLY REMOVING CAMSHAFT SENSOR 1.

5 mm: Remove the bolt

2. Remove the sensor

2

1

.

1

.

2

VALVE COVER REASSEMBLY INSTALLING CAMSHAFT SENSOR 1. Coat the o-ring on the sensor petroleum jelly.

lightly with

2

1

2. Insert the sensor.

3.

5 mm: Install the bolt 1 according to the specification OTHER BOLTS M6 STANDARD. (See section D Tightening torques und assembly instructions.)

2

SUCTION PUMP COVER DISASSEMBLY REMOVING OIL SUCTION PUMP 1.

T30: Remove four bolts

1

2. Remove the oil suction pump

.

2

.

1 2

TD410035-C RLF

71

C

C

Additional working instructions SUCTION PUMP COVER REASSEMBLY INSTALLING OIL SUCTION PUMP 1. Insert the oil suction pump 2.

2

.

T30: Install four bolts 1 according to the specification OTHER BOLTS M6 STANDARD. (See section D Tightening torques und assembly instructions.)

1 2

CYLINDER HEAD DISASSEMBLY REMOVING BRACKETS AND OIL PRESSURE SWITCH 1.

5 mm: Remove the bolt

2. Remove the bracket

2

3

4. Remove the bracket

1

1

.

5 mm: Remove two bolts

3.

.

4

.

.

2 3

4 5.

5 mm: Remove the bolt

6. Remove the bracket 7.

7

5

6

.

.

24 mm: Remove the oil pressure switch .

5 6

7

72

TD410035-C RLF

Additional working instructions REMOVING CAMSHAFT Only remove the camshaft if the camshaft or the cylinder head must be replaced.

1.

5 mm: Remove four bolts

2. Remove two bearing caps cap remover 2 .

3. Remove the camshaft

3

1

.

1

using a bearing 2

.

4

3 4

REMOVING VALVES 1. Install the valve spring compressor according to the manufacturer's instructions.

2. Press the valve spring 2 together using the valve spring compressor according to the manufacturer's instructions.

3. Remove two collet valves magnet.

1

using a bar

1 2

4. Remove the valve spring compressor.

5. Remove the spring cup and spring pad 5 .

3

, valve spring

4

3

4

5

TD410035-C RLF

73

C

C

Additional working instructions 6. Remove the valve

6

.

6

7. Remove the valve stem seal valve stem seal remover.

7

using the

8. Repeat the procedure with the other valves.

7

REMOVING FUEL RAIL Only remove the fuel rail if the cylinder head, the injectors or the fuel rail must be replaced.

WARNING! Burn injuries caused by ignited fuel. Fuel is highly flammable. Leaks in the fuel system can lead to burns and vapors may ignite and cause an explosion.

1.

T30: Remove two bolts

2. Remove the fuel rail

74

2

.

1

1

.

2

TD410035-C RLF

Additional working instructions Only remove the injectors if the injectors or the fuel rail must be replaced.

WARNING! Serious eye injuries caused by a fast hurled bracket. Wear protective glasses.

3. Press the bracket

carefully apart.

3

4. Remove the injector

4

.

5. Repeat the procedure with the other injector.

3 4

CYLINDER HEAD REASSEMBLY 1. Check if the fitting a is installed.

2. Check if the plugs b , c , d and e are installed.

a

b

c

d

e

INSTALLING FUEL RAIL WARNING! Serious eye injuries caused by a fast hurled bracket. Wear protective glasses.

1. Coat the o-ring o-ring injectors.

lightly with lubricant for

1

1

2. Insert the injector 2 until the injector engages in the bracket.

3. Check if the injector is engaged into the bracket.

2

4. Repeat the procedure with the other injector.

WARNING! Burn injuries caused by ignited fuel. Fuel is highly flammable. Leaks in the fuel system can lead to burns and vapors may ignite and cause an explosion.

5. Coat two o-rings o-ring injectors.

6. Insert the fuel rail

TD410035-C RLF

4 3

lightly with lubricant for

3

4

.

75

C

C

Additional working instructions 7.

T30: Install two bolts 5 according to the specification OTHER BOLTS M6 STANDARD. (See section D Tightening torques und assembly instructions.)

5

INSTALLING VALVES 1. Replace the valve stem seal

2

.

2. Install the valve stem seal using the valve stem seal installation spike 1 .

1

2

3. Coat the valve stem

3

lightly with engine oil.

4. Insert the valve.

When valves and cylinder heads are replaced by new parts, the following step can be omitted.

5. Grind in the valve using the valve refacer.

3

The valve springs are marked on the side in color.

If you replace valve springs, all installed valve springs must have the same color-code.

6. Insert the spring pad spring cup 4 .

6

, valve spring

5

4

and 5

6

76

TD410035-C RLF

Additional working instructions 7. Install the valve spring compressor according to the manufacturer's instructions.

8. Press the valve spring 8 together using the valve spring compressor according to the manufacturer's instructions.

9. Insert two collet valves

7

.

10. Remove the valve spring compressor.

7 8

11. Repeat the procedure with the other valves.

INSTALLING CAMSHAFT 1. Coat the camshaft 2 on the bearing surfaces lightly with engine oil.

2. Insert the camshaft.

Observe the installation position: –– Inscription

1 2

1

–– Exhaust side

3

3 3. Insert two bearing caps

4

.

Observe the installation position: –– Single markings a .

b

4

–– Double markings b . a b a 4.

5 mm: Install four bolts 5 according to the specification OTHER BOLTS M6 STANDARD. (See section D Tightening torques und assembly instructions.)

5

TD410035-C RLF

77

C

C

Additional working instructions INSTALLING BRACKETS AND OIL PRESSURE SWITCH 1. Hold the bracket 2.

3.

5 mm: Install the bolt 2 according to the specification OTHER BOLTS M6 HIGH STRENGTH THREAD LOCKER. (See section D Tightening torques und assembly instructions.)

24 mm: Install the oil pressure switch according to the specification OIL PRESSURE SWITCH. (See section D Tightening torques und assembly instructions.) in position.

5

5 mm: Install the bolt 6 according to the specification OTHER BOLTS M6 HIGH STRENGTH THREAD LOCKER. (See section D Tightening torques und assembly instructions.)

6. Hold the bracket 7.

1 2

3

4. Hold the bracket 5.

in position.

1

in position.

4

5 mm: Install two bolts 7 according to the specification OTHER BOLTS M6 STANDARD. (See section D Tightening torques und assembly instructions.)

3

4 5 6

7

THERMOSTAT HOUSING DISASSEMBLY REMOVING THERMOSTAT 1.

T30: Remove two bolts

2. Remove the fitting

2

.

1

.

1

2

78

TD410035-C RLF

Additional working instructions 3. Remove the thermostat washer 4 .

3

and distance

3

4

REMOVING COOLANT SENSOR 1.

19 mm: Remove the sensor

1

.

1

THERMOSTAT HOUSING REASSEMBLY INSTALLING COOLANT SENSOR 1.

19 mm: Install the sensor 1 according to the specification COOLANT SENSOR. (See section D Tightening torques und assembly instructions.)

1

TD410035-C RLF

79

C

C

Additional working instructions INSTALLING THERMOSTAT 1. Coat the contact area of the thermostat lightly with petroleum jelly.

2. Replace the distance washer

2

1

.

3. Apply the distance washer on the thermostat.

1

2

4. Insert the thermostat

4

.

Observe the installation position: –– Marker

3

3

on the thermostat

4

5. Replace the o-ring petroleum jelly.

6. Insert the fitting 7.

80

6

7

and lightly coat with

.

T30: Install two bolts 5 according to the specification OTHER BOLTS M6 STANDARD. (See section D Tightening torques und assembly instructions.)

5 6

7

TD410035-C RLF

Additional working instructions

NOTES:

TD410035-C RLF

81

C

SpeCifications SECTION D – SPECIFICATIONS

NOTES:

82

TD410035-C RLF

SpeCifications TIGHTENING TORQUES UND ASSEMBLY INSTRUCTIONS NOTICE

Engine damage caused by improper repairs.

All specifications for tightening torques and assembly instructions refer only to parts that are offered in the spare parts catalog. ►► Only remove components that are offered separately in the spare parts catalog. ►► If a component is not offered individually, replace the component by a next higher level assembly.

Observe the following references: –– Unless otherwise specified, threads are clean, dry and free from engine oil.

–– For components with coated threads, the tightening torques always refer to new components.

–– Information on the supplies for example thread sealant can be found in the SUPPLIES chapter. (See chapter Before you begin working.)

Component

Tightening torques

Spark plugs

22 Nm +10 Nm [16.2 lbf ft +7.4 lbf ft]

Coolant sensor

18 Nm +7 Nm [13.3 lbf ft +5.2 lbf ft] –– Use thread sealant.

Oil pressure switch

9 Nm +2 Nm [6.7 lbf ft +1.5 lbf ft]

–– Use thread sealant.

M10x1 Con rod bolts

First stage: 10 Nm [7.4 lbf ft]

–– Replace the con rod bolts.

–– Coat the nuts and screw head seat lightly with engine oil.

Second stage: 20 Nm [14.8 lbf ft] Third stage: +115°

Assembly instructions

–– Use thread sealant LOCTITE® 577.

M8 Bearing carrier

11 Nm +6 Nm [8.1 lbf ft +4.4 lbf ft]

Generator cover vent plug

9 Nm +2 Nm [6.7 lbf ft +1.5 lbf ft]

Chain tensioner

40 Nm +5 Nm [29.5 lbf ft +3.7 lbf ft] –– If the chain tensioner seal is missing or defective, replace the chain tensioner.

Oil nozzle

20 Nm +2 Nm [14.8 lbf ft +1.5 lbf ft]

M10x1.25 Tie rods

18 Nm +2 Nm [13.3 lbf ft +1.5 lbf ft] –– Use Anti-Seize assembly paste.

–– Remove excessive assembly paste after installation.

M8 Stud cylinder head

16 Nm +4 Nm [11.8 lbf ft +3 lbf ft]

–– Use Anti-Seize assembly paste.

M6 Nut impeller

6 Nm +2 Nm [4.4 lbf ft +1.5 lbf ft]

–– Use medium strength thread locker.

Oil filter

10 Nm [7.4 lbf ft]

–– –– –– ––

TD410035-C RLF

Replace the oil filter.

Clean the sealing surface on the crankcase.

Coat the oil filter seal lightly with engine oil.

Screw in the oil filter by hand.

83

D

D

SpeCifications Component

Tightening torques

Threaded sleeve for oil filter

17 Nm +3 Nm [12.5 lbf ft +2.2 lbf ft]

Screw clamps 9 mm width

3 Nm +0,5 Nm [2.2 lbf ft +0.4 lbf ft]

Valve cover bolts

5 mm: 1 – 8 8 Nm +2 Nm [5.9 lbf ft +1.5 lbf ft]

Assembly instructions

–– Use Anti-Seize assembly paste.

Observe the following sequence during assembly.

(Disassembly takes place in reverse order.)

8 2

4

5

6

3 1 7

Crankcase bolts

First stage: 6 mm: M8x50 1 – 2

Observe the following sequence during assembly.

(Disassembly takes place in reverse order.)

9

6 mm: M8x90 3 – 4 6 mm: M8x50 5

3

9 Nm +1 Nm [6.6 lbf ft +0.7 lbf ft] 5 mm: M6x60 6 – 8

1

2

4

6

5 mm: M6x90 9 Maximum 5 Nm [3.7 lbf ft] Second stage after installing the cylinder head: 6 mm: M8x50 1 – 2 6 mm: M8x90 3 – 4

8

5 7

6 mm: M8x50 5 23 Nm +2 Nm [17 lbf ft +1.5 lbf ft] 5 mm: M6x60 6 – 8 5 mm: M6x90 9 8 Nm +2 Nm [5.9 lbf ft +1.5 lbf ft]

84

TD410035-C RLF

SpeCifications Component Cylinder head nuts

Tightening torques 14 mm: First stage: 20 Nm ±3 Nm [14.8 lbf ft ±2.2 lbf ft] Second stage:

Assembly instructions –– Coat the nuts lightly with engine oil.

Observe the following sequence during assembly.

(Disassembly takes place in reverse order.)

8

2

4

6

5

3

1

7

40 Nm ±3 Nm [29.5 lbf ft ±2.2 lbf ft] Third stage: 180° ±4°

OTHER BOLTS Bolts M6

Tightening torques

M6 Standard

8 Nm +2 Nm [5.9 lbf ft +1.5 lbf ft]

M6 Medium strength thread locker

8 Nm +2 Nm [5.9 lbf ft +1.5 lbf ft]

Assembly instructions –– Use medium strength thread locker.

Valid for bolts M6: –– Stator/crankcase

M6 High strength thread locker

8 Nm +2 Nm [5.9 lbf ft +1.5 lbf ft]

M6 Anti-Seize assembly paste

8 Nm +2 Nm [5.9 lbf ft +1.5 lbf ft]

–– Use high strength thread locker.

Valid for bolts M6x20: –– Bracket/Cylinder head –– Use Anti-Seize assembly paste.

Valid for bolts M6: –– Ignition coils/cylinder head

M6 Pipe clamp for fuel hose

See the manufacturer‘s documentation of the vehicle.

Bolts M8

Tightening torques

M8 Standard

20 Nm +4 Nm [14.8 lbf ft +3 lbf ft]

Bolts M10

Tightening torques

M10 Standard

40 Nm +8 Nm [29.5 lbf ft +5.9 lbf ft]

M10x1 Rotor / Crankshaft

60 Nm +10 Nm [44.3 lbf ft +7.4 lbf ft] –– Replace the bolts.

Bolts (selftapping)

Tightening torques

6x20

4,5 Nm +1 Nm [3.3 lbf ft +0.7 lbf ft]

TD410035-C RLF

Assembly instructions Assembly instructions

Assembly instructions

85

D

D

SpeCifications SCREW-IN NIPPLES Screw-in nipples

Tightening torques

Assembly instructions

M8x1

8 Nm +2 Nm [5.9 lbf ft +1.5 lbf ft]

–– Replace the seal.

M18x1.5 Suction pump cover

25 Nm +3 Nm [18.4 lbf ft +2.2 lbf ft] –– When a seal is installed, replace the seal.

–– Use thread sealant.

SCREW-IN PLUGS With collar

Tightening torques

Assembly instructions

M14x1.5 M18x1.5

14 Nm +2 Nm [10.3 lbf ft +1.5 lbf ft] –– Replace the seal.

–– Plugs without seal, use thread sealant.

20 Nm +4 Nm [14.8 lbf ft +3 lbf ft]

Without collar

Tightening torques

Assembly instructions

M8x1

6 Nm +2 Nm [4.4 lbf ft +1.5 lbf ft]

M10x1

9 Nm +2 Nm [6.6 lbf ft +1.5 lbf ft]

M18x1.5

20 Nm +4 Nm [14.8 lbf ft +3 lbf ft]

–– Plugs without TufLok coating 1 , use thread sealant.

–– Replace plugs with TufLok coating.

–– When TufLok coated 2 plugs are reused, use thread sealant.

1

86

2

TD410035-C RLF

SpeCifications LIQUID SEALING CONTOURS LIQUID SEALING CONTOUR CRANKCASE 1. Clean the sealing surfaces on the lower case and upper case.

2. Apply the silicone liquid seal

1

,

2

,

3

and

4

on the upper case without gaps as illustrated.

1

2

3

4

TD410035-C RLF

87

D

D

SpeCifications LIQUID SEALING CONTOUR SUCTION PUMP COVER 1. Clean the sealing surfaces on the crankcase and suction pump cover.

2. Apply the silicone liquid seal 1 and overhang of 1 mm without gaps.

2

into the sealing groove on the suction pump cover including an

1

2

88

TD410035-C RLF

SpeCifications LIQUID SEALING CONTOUR THERMOSTAT HOUSING 1. Clean the sealing surfaces on the crankcase and thermostat housing.

2. When the thermostat housing has a sealing groove 1 apply the silicone liquid seal into the sealing groove on the thermostat housing including an overhang of 1 mm without gaps.

1

or

3. When the thermostat housing has no sealing groove apply the silicone liquid seal 2 on the thermostat housing without gaps as illustrated.

2

TD410035-C RLF

89

D

D

SpeCifications LIQUID SEALING CONTOUR GENERATOR COVER 1. Clean the sealing surfaces on the crankcase and generator cover.

2. Apply the silicone liquid seal 1 mm without gaps.

1

into the sealing groove on the generator cover including an overhang of

1

90

TD410035-C RLF

SpeCifications TEST PROCEDURES AND ADJUSTMENTS VALVE LASH Check the valve lash with a cold engine.

1. Remove the ignition coils and valve cover.

2. Check the valve lash 1 first on the cylinder where the rocker arms 2 have a certain amount of play.

Required valve lash: A

Intake side 0,08 – 0,15 mm

B

Exhaust side 0,15 – 0,22 mm

1

3. If the valve lash is incorrect, remove the rocker arm and replace the valve adjustment shim.

4. Rotate the crankshaft in the rotation direction until the rocker arms on the other cylinder have a certain amount of play.

2

B

5. Repeat the procedure on the other cylinder.

A

SPARK PLUG GAP Check spark plug gap with a cold engine.

1. Remove the ignition coils and spark plugs.

2. Check the spark plug gap

1

.

Required spark plug gap: 0,69 – 0,84 mm [0.028 – 0.032 in]

1

3. If the spark plug gap is incorrect, replace the spark plug.

Always replace spark plugs in pairs.

TD410035-C RLF

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D

D

SpeCifications CON ROD BEARING PLAY 1. When replacing the crankshaft or con rod, check the con rod bearing play.

Required con rod bearing play "A": 0,025 – 0,040 mm 2. If the con rod bearing play is incorrect, repeat the procedure with another con rod bearing shell thickness.

The thicknesses of the upper and lower con rod bearing shell may differ.

The con rod bearing shells are marked on the side in color. Each color represent a specific thickness of the con rod bearing shell. Available sizes con rod bearing shells, see spare parts catalog.

MAIN BEARING PLAY 1. When replacing the crankshaft or crankcase, check the main bearing play.

Required main bearing play "B": 0,04 – 0,06 mm 2. If the main bearing play is incorrect, repeat the procedure with another main bearing shell thickness.

The thicknesses of the upper and lower main bearing shell may differ.

The main bearing shells are marked on the side in color. Each color represent a specific thickness of the main bearing shell. Available sizes main bearing shells, see spare parts catalog.

VALVE TIMING 1. Remove the valve cover and generator.

Observe the positioning pin and positioning bore 1 .

2. Hold the TDC-adjusting tool

2

in position.

Use the bolts M10x1x35 that you removed from the rotor.

3.

92

7 mm: Install two bolts

3

.

1

2

3

TD410035-C RLF

SpeCifications 4.

8 mm: Turn the crankshaft on the TDCadjusting tool 5 in the rotation direction until the marking 7 ends flush with the crankcase joint 6 .

4

4

5

6 7

5. Check wether the camshaft is at the crossing point.

The position of the camshaft is as illustrated 9 .

The marking

8

8 9

ends flush with the cross bar.

6. If the camshaft does not appear as illustrated, adjust the valve timing.

GENERATOR 1

3-pole stator connector (yellow cables)

2

Stator

3

Rotor

1

2

3 1. Check all electrical contacts for corrosion and proper mechanical connection.

2. Check the continuity of all relevant cables.

3. If the cables are defective, replace the stator.

4. Perform a visual inspection on the rotor.

5. If mechanical damages are present, for example on the internal magnets, replace the rotor.

Continuity test with multimeter: 3-pole stator connector

A

1

A

B

C

Engine ground

d

d

–

d

–

B C

–

Engine ground d Continuity is required (Resistance 0,3 Ohm ±0,1 Ohm at 20 °C) – No continuity permitted

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D

D

SpeCifications OIL PRESSURE 1. Warm up the engine.

2.

7 mm: Remove the wire harness on the oil pressure switch 1 .

3.

24 mm: Remove the oil pressure switch.

CAUTION! Scalding caused by hot engine oil.

Wear protective gloves.

4. Install the adapter M10x1 for oil pressure tester according to the manufacturer's instructions.

1

Tightening torque: 9 Nm +2 Nm [6.6 lbf ft +1.5 lbf ft] 5. Start the engine and allow to run at idle.

6. Measure the oil pressure using the oil pressure tester according to the manufacturer's instructions.

Oil pressure troubleshooting guide: The oil pressure is too low.

Required oil pressure at idle: At least 1,5 bar

Leaks in the lubrication system/ cylinder head gasket.

Maximum 5,5 bar +0,5 bar 7. Increase the engine speed.

Repair the leaks.

yes

Replace the oil pressure valve.

yes

Replace the oil pressure pump.

yes

Clean the lubrication system.

no

The oil pressure increases immediately.

Required oil pressure at 3000 min [RPM]: -1

At least 2,5 bar Maximum 5,5 bar +0,5 bar 8. Remove the adapter M10x1.

9.

yes

24 mm: Install the oil pressure switch according to the specification OIL PRESSURE SWITCH. (See section D Tightening torques und assembly instructions.)

The oil pressure valve is always opened. no The oil pressure pump is defective. no Oil sludge and soiling in the lubrication system.

Oil pressure > 5,5 bar +0,5 bar

Replace the oil pressure valve.

94

TD410035-C RLF

SpeCifications TIE ROD THREAD PROTUSION 1. When removing the cylinder head nuts, check the tie rod thread protusion 1 to the cross bar 2 "A" before romoval and after installation.

1

2

Permissible tie rod thread protrusion: B

Maximum 15,4 mm

C

Maximum 16 mm

C

B

B

4C

C

C

C

C

2. If the maximum permissible thread protrusion is exceeded, replace the tie rod.

THERMOSTAT INFORMATION! The thermostat is fitted with a wax element. Opening temperature from 82 °C [179 °F].

The thermostat is fully open at 88 °C [190 °F].

1

Thermostat closed

2

Thermostat opened

1. Perform a visual inspection on the thermostat.

2. If the thermostat is opened at temperatures below 82 °C [179 °F], replace the thermostat.

1

3. Place the closed thermostat into hot water with at least 88 °C [190 °F].

The thermostat starts to open immediately.

4. If the thermostat is not fully open or remains closed at temperatures above 88 °C [190 °F], replace the thermostat.

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95

D

D

SpeCifications CRANKSHAFT SENSING WHEEL 1

Crankshaft sensing wheel

2

Gap (two missing teeth)

1. Perform a visual inspection on the crankshaft sensing wheel.

1 2

2. If mechanical damages are present, replace the crankshaft.

ROCKER ARM CAM SPIKE 1

Cam spike at the rocker arm

1. Perform a visual inspection on the rocker arm cam spike.

2. If mechanical damages are present, replace the rocker arm.

96

1

TD410035-C RLF

SpeCifications

NOTES:

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D

OVERVIEW OF REVISIONS

Revision Rev A

Date

Chapter

10.03.2017 – Section B - Engine reassembly

Rev B

13.12.2017 Installing timing chain

Description First edition repair manual Replace the timing chain before installation. See the spare parts catalog of the engine.

Section B - Engine reassembly Rev B

13.12.2017 Installing oil pressure pump Section D - Specifications

Installation position of the circlip described.

Rev B

Tightening torques und assembly 13.12.2017 instructions

The installation of the chain tensioner is modified. Do not use thread sealant.

Rev C

09.03.2018 –

The engine model 411439 I2 957 UTV was added. The repair manual is valid for both engine models.

Section A - Engine disassembly Rev C

09.03.2018 Removing generator cover

The disassembly of the second generator cover model was added.

Section B - Engine reassembly Rev C

Rev C

98

09.03.2018 Installing generator cover Section D - Specifications Tightening torques und assembly 09.03.2018 instructions

The reassembly of the second generator cover model was added.

The tightening torque of the bearing carrier bolts was added.

TD410035-C RLF

TEXTRON MOTORS GmbH Daimlerstraße 5 88677 Markdorf Germany WWW.TEXTRONMOTORS.COM