LDV Convoy Duratorq Engine Workbook

SERVICE WORKBOOK
2.4 DURATORQ Diesel Engine

2.4 DURATORQ DIESEL ENGINE
Service Workbook
This Service Workbook covers the 2.4 DuraTorq Diesel engine fitted to LDV vehicles. It
is primarily designed to assist skilled technicians in the efficient repair and maintenance
of this engine, but can also be used as a reference workbook for training purposes.
SPECIFICATION
LDV (the Company) reserves the right to change the procedures, material, specification,
dimensions or design of the vehicles shown, described or referred to herein at any time
and without prior notice in accordance with the Company’s policy of constant product
improvement.
Every reasonable effort is made to ensure that the Company’s publications are accurate,
but nothing shown, described or referred to herein should be regarded as an infallible
guide to the procedures, materials, specifications, dimensions, design or availability of
any particular vehicle, nor does this publication constitute an offer for the sale of any
particular vehicle. No liability can be accepted by the Company or any Distributor or
Dealer for any malfunction, damage, loss, injury, or death caused by the use of incorrect
or misinterpreted information, omissions or errors that may have arisen during the
preparation of this workbook.
Purchasers are advised that the specification details set out in this publication apply to a
range of vehicles and not to any particular vehicle. For the specification of any particular
vehicle, purchasers should consult their LDV Distributor or Dealer. Please note that LDV
Distributors and Dealers are not agents of the Company, and have no right or authority
whatsoever to bind the Company in any way, or to assume on its behalf any obligation
expressed or implied.
COPYRIGHT
 LDV 2002
All rights reserved. No part of this publication may be reproduced, stored in a retrieval
system or transmitted, in any form, whether electronic, or mechanical, or by
photocopying, recording or other means without prior permission in writing of LDV.
Published by LDV, from whom further copies may be obtained through your normal
literature ordering procedure.
LDV
Training & Publications
Bromford House
Drews Lane
Birmingham
B8 2QG
MVP104601GB 01/02
CONTENTS
Page
Introduction and General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TORQUE WRENCH
Abbreviations and acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SETTINGS
Lubricants, Coolant and Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Service summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Torque wrench settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Engine illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Front end:
FRONT END
External drive belt – remove / refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Crankshaft front oil seal – renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Timing chain – remove / refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
CYLINDER HEAD
Cylinder head:
Camshaft cover – remove / refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Cylinder head – remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
– inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
– refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Flywheel
FLYWHEEL
Clutch – remove / refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Flywheel and spigot bearing – remove / refit . . . . . . . . . . . . . . . . . . . . . . . . . 70
Crankshaft rear oil seal – renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Crankcase
Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
CRANKCASE
Inspection/Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Re–build . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Crankcase position sensor mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . 89
CONTENTS
Page
Lubrication system
LUBRICATION
Oil circulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
SYSTEM
Oil filter element – renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Oil pump – remove / refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Fuel system
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Bleeding procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
FUEL SYSTEM
Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Water draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Service indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Renew element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Injectors – remove / refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Fuel injection pump – remove / refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Exhaust system
EXHAUST
SYSTEM
Turbocharger – remove / refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Exhaust gas recirculation (EGR) system
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
EGR valve – remove / refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Cooling system
COOLING
SYSTEM
Coolant circulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Coolant drain / refill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Water pump – remove / refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
ENGINE BREATHING
Engine breathing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

SYSTEM
INTRODUCTION
WARNINGS and CAUTIONS are given throughout this Service Workbook in the following
form:
WARNING: Procedures which must be followed precisely to avoid the possibility
of personal injury.
CAUTION: This calls attention to procedures which must be followed to avoid damage to
components.
NOTE: This calls attention to methods which make a job easier to perform.
REFERENCES
References to the left or right hand side in this Service Workbook are made when
viewing the vehicle from the rear, unless instructed otherwise.
To reduce repetition, operations covered in this Service Workbook do not always include
reference to testing the vehicle after repair. It is essential that work is inspected and
tested after completion and, if necessary, a road test of the vehicle is carried out
particularly where safety related items are concerned.
GENERAL PRECAUTIONS
1. When disconnecting the vehicle battery, always disconnect the earth return
(negative) cable first, and then the positive cable. On twin battery installations,
disconnect both earth return (negative) cables first, and then the positive cables.
When re–connecting the battery(s), connect the positive cable(s) first, then the
negative cable(s).
2. Absolute cleanliness is essential when working on fuel injection components.
3. Always plug fuel injection system and oil system connectors when disconnected to
avoid the possibility of dirt ingress.
4. Always turn the engine in a clockwise direction unless instructed otherwise.
5. Care must be taken when working underbonnet to avoid rotating pulleys and drive
belts.
6. Use only the approved LDV anti–freeze.
7. Before using special tools to check alignment / concentricity of oil seal housings,
ensure there are no burrs on the tool diameters which could affect the checks.
8. Many securing bolts on this engine use micro–encapsulation (patch–lock) for locking
purposes. The threads of these bolts should be cleaned and Loctite 270 applied
before re–use.
7
9. Many of the hoses and pipes used on this engine have alignment marks at each end.
To avoid stress, these marks must be aligned with the marks on the connections they
are fitted to.
10. A number of security–critical bolts are used on this engine; some must be renewed if
removed e.g. flywheel, and others can only be re–used a specified number of times
e.g. crankshaft pulley, connecting rods, main bearing caps, etc.
The workbook identifies the bolts affected, which must be punch marked on each
occasion they are removed to indicate the usage. The bolts are not marked on initial
build, therefore e.g. one punch mark indicates twice used, three punch marks
indicates four times used etc.
REPAIRS AND REPLACEMENTS

When replacement parts are required, it is essential that only genuine LDV parts are
used.
ABBREVIATIONS & ACRONYMS

The following abbreviations and acronyms may be used in this workbook.
BTDC Before top dead centre
CHT Cylinder head temperature (sensor)
CKP Crankshaft position (sensor)
EGR Exhaust gas recirculation (valve with position sensor)
EVR EGR vacuum regulator
IAT Intake air temperature (sensor)
MAP Manifold absolute pressure (sensor)
PCM Powertrain control module
PCU Pump control unit
TDC Top dead centre
DIA Diameter
MM Millimeter
T Torx
8
DATA
General
Type ZSD 424.
Diesel, 4 cylinder in line DOHC, direct
injection.
Bore 89.9 mm
Stroke 94.6 mm
Capacity 2402 cm3
Injection sequence 1 – 3 – 4 – 2 (cylinders numbered
front to rear)
Compression ratio 19 : 1
75 PS (Turbocharged):
Power output 75 PS at 3500 rpm
Torque 185 Nm at 2000 rpm
Idle speed 800 ± 50 rpm
Maximum continuous engine speed 4900 rpm
Maximum intermittent engine speed Engine speed limiter
90 PS (Turbocharged and intercooled):
Power output 90 PS at 4000 rpm
Torque 200 Nm at 1800 rpm
Idle speed 800 ± 50 rpm
Maximum continuous engine speed 4900 rpm
Maximum intermittent engine speed Engine speed limiter
Cylinder Head
Max. permissible distortion 0.1 mm
Cylinder head gasket identification:
Number of holes / teeth Piston stand–proud
1 0.310 – 0.40 mm
2 0.401 – 0.45 mm
3 0.451 – 0.50 mm
Camshafts
End float 0.125 mm
Bearing journal diameter 26.450 mm
Bearing radial clearance 0.065 mm
Cylinder block
Cylinder bore diameters:
Identification Stamped ‘A’, ‘B’ or ‘C’ on block
Grade A 89.90 – 89.91 mm
Grade B 89.91 – 89.92 mm
Grade C 89.92 – 89.93 mm
9
Main bearing shells (fitted) inner diameter:
Bearing nos. 1 – 4 65.003 – 65.030 mm
Bearing no. 5 70.004 – 70.018 mm
Main bearing radial clearance:

Bearing nos. 1 – 4 0.005 – 0.051 mm
Bearing no. 5 0.004 – 0.054 mm
Pistons
Standard piston grades marked ‘A’, ‘B’ or ‘C’ on piston crown
Standard piston diameter:
Grade A 89.84 – 89.85 mm
Grade B 89.85 – 89.86 mm
Grade C 89.86 – 89.87 mm
Piston clearance in bore 0.05 – 0.07 mm

Piston ring gaps:
Upper compression ring 0.25 – 0.50 mm
Lower compression ring 0.50 – 0.75 mm
Oil control ring (3–piece) 0.25 – 0.50 mm
Piston stand–proud 0.310 – 0.50 mm

(See ‘Cylinder head’ for gasket selection)
Gudgeon pin diameter 32.00 – 31.996 mm
Connecting Rods
Connecting rod lengths between bore
centres H 149.74 mm
I 149.80 mm
J 149.86 mm
Big ends:
Connecting rod clearance:
Radial 0.034 – 0.100 mm
Axial 0.100 – 0.320 mm
Crankshaft
Crankshaft end float 0.090 – 0.305 mm
Number of main bearing journals 5
Main bearing journal diameters:
Journals 1 to 4 64.950 – 64.970 mm
Rear journal 69.950 – 69.970 mm
Regrind undersize 0.25 mm
Big end bearing journal diameters 52.980 – 53.000 mm
Regrind undersize 0.25 mm
10
Lubrication System
Oil pump type Gear pump
Oil pressure: At idle speed 1 bar minimum
At 2000 rpm 2.0 – 2.5 bar
Fuel System
Fuel injection pump type Bosch VP30
Injectors
Make Delphi
Type / number 6–hole nozzle
75 PS engine – BO2202D
90 PS engine – BO2201D
Glow plug type (pre / post heat) EZD 38
Cooling System
Water pump type Centrifugal impeller
Thermostat Type Wax element, full flow by–pass
Opening temperature 88°C
Fully open temperature 102°C
Pressure cap setting 1.2 bar
LUBRICANTS
Engine oil: M2C913–A or M2C913–B
NOTE: The above oil must be adhered
to to ensure specified engine
performance and emission levels are
maintained.
Engine oil capacity
Initial fill (including filter) 7.22 litres
Oil change (including filter change) 7.0 litres
COOLANT
Capacity 9 litres
6.5 litres drain and refill
Only approved anti–freeze must be used for this engine, and the correct coolant
proportions are 50% anti–freeze, 50% water.
SEALANTS
Timing cover, sump, camshaft carrier Loctite 5910
Thread locking Loctite 270
Sealer, non–hardening Hylomar PL32M
11
SERVICE SUMMARY
MILEAGE
15,000 30,000 45,000
RENEW ENGINE OIL & FILTER

• • •
CHECK CONDITION OF EXTERNAL DRIVE BELT.
RENEW IF NECESSARY AND INDICATE IN SERVICE
RECORD BOOK
• • •
VISUALLY CHECK CRANKCASE BREATHER SYSTEM
AND BRAKE SERVO HOSE FOR LEAKS, SECURITY &
CONDITION
• • •
CHECK COOLING SYSTEM, HOSES & CONNECTIONS
FOR LEAKS • • •
Renew Renew
CHECK COOLANT SOLUTION STRENGTH. RECORD
•
every every
READING BY REFRACTOMETER. TOP UP WITH 2 years or 2 years or
SPECIFIED ANTIFREEZE (50/50 SOLUTION) 75,000 m 75,000 m
CHECK COOLING SYSTEM PRESSURE CAP.

RENEW IF EVIDENCE OF SEAL DETERIORATION •
Renew Renew Renew
CHECK FUEL FILTER INDICATOR filter as filter as filter as
necessary necessary necessary
Renew Renew Renew

CHECK AIR FILTER INDICATOR filter as filter as filter as
necessary necessary necessary
12
SPECIAL TOOLS
LDV118 LDV119
Flange holder Clutch aligner

LDV132 LDV167
Seal Breaker • Timing pins

LDV168 LDV169
• Injector seal installer • Injection pump sprocket retainer

LDV170 0480080(LST122)
IN 1
CR 0o
EM
E NT
S
• Crankshaft front seal remover/replacer Angular torque gauge
• denotes new tool
13
MS 1517 MS 1519A (18G 1519A)
Viscous coupling spanner Valve spring compressor

LDV 171 LDV 172
• Valve collett installer • Ladder frame aligner

LDV 173 LDV 174
• Crankshaft timing pin • Injector remove/ refit socket

LDV 175 LDV 176
• Injector aligning plate • CHT sensor socket
14
LDV177 LDV178
• Timing cover centraliser • Alternator decoupler

LDV179 LDV180
• Oil filter wrench • Oil pump aligner

LDV183
• Hose clip pliers
15
DIAGNOSTIC TOOLS
0484976 (DX 710)
Lucas
Laser 2000 Injector tester
Approved Tools
09580500 Twin beam puller )
09581100 13 mm split collet ) Spigot bearing remover
09582000 Adaptor ) Supplier – Sykes Pickavant
16
TORQUE WRENCH SETTINGS
Component Nm
TORQUE WRENCH
Alternator mounting bolts 48
Alternator and power steering pump mounting bracket 22
SETTINGS
Camshaft carrier to cylinder head bolts See ‘Cylinder Head Refit’
Camshaft cover 10
Camshaft sprocket bolts 33
Clutch pressure plate to flywheel 23
Connecting rod cap bolts Stage 1 – 30
Stage 2 – 100°
Coolant drain plug 18
Coolant manifold to cylinder block 10
Coolant outlet to cylinder head 22
Cooling fan pulley bolts 53
Cooling fan to pulley 110–115
Crankshaft main bearing cap bolts Stage 1 – 45
Stage 2 – 80
Stage 3 – 105°
Crankshaft pulley bolts Stage 1 – 30
Stage 2 – 90°
Crankshaft rear oil seal carrier 10
Cylinder head temperature sensor 10
Cylinder head to cylinder block (5 stages) See ‘Cylinder Head Refit’
Dipstick tube bolt 22
EGR valve to manifold 10
EGR pipe bolts 22
Exhaust downpipe to exhaust manifold 40
Exhaust manifold to cylinder head 40
External drive belt tensioner bolt 50
Flywheel to crankshaft (3 stages) See ’Flywheel/Spigot bearing’
Fuel injection pump to block 22
Fuel injection pump rear support bracket 22
Fuel injection pump sprocket bolts 32
Fuel injection pump banjo union connections 22
Fuel return pipe to injectors 8
Glow plugs 12
Idler pulley bolt 53
Injectors 52
Injector pipe unions 35
Inlet manifold to cylinder head 15
Ladder frame bolts (See ’Crankcase’ for tightening sequence) 23
Oil cooler attachment bolts 23
Oil pressure switch 23
Oil pick–up pipe to cylinder block bolts 10
Oil jet bolts 10
Oil pump bolts 10
Oil pump chain tensioner bolts 16
17
Component Nm
TORQUE WRENCH
Power steering pump mounting bolts 22

Rocker shaft bolts Stage 1 – 13
SETTINGS
Stage 2 – 45°
Starter motor 25
Sump to cylinder block bolts / nuts See ‘Crankcase Assembling’
Sump drain plug 24
Thermostat housing bolts 10
Timing chain tensioner bolts 15
Timing chain guides bolts 15
Timing cover bolts – 14
nuts – 10
Vacuum pump to water pump 23
Water pump to cylinder block 23
18
1
2
39
7 9
8
7 10 11
12
15
16 13
17
22 14
23 28
27
18 26
24
25
29
21 30
21
20
19
41
40
37 34
35
36 31
33
38 32
A106-213
20
Engine Components 1 of 3
1. Oil filler cap
2. Injector dust seal
3. Camshaft cover
4. Gasket
5. Exhaust rocker shaft
6. Inlet rocker shaft
7. Inlet valve rocker
8. Spring
9. Camshaft carrier
10. Glow plug
11. Fuel return pipe
12. Injector pipes
13. Injector
14. Inlet camshaft
15. Exhaust camshaft
16. Turbocharger oil feed pipe
17. Exhaust manifold
18. Turbocharger
19. Air inlet duct elbow
20. Exhaust manifold gasket
21. Lifting bracket
22. Collets
23. Spring cap
24. Valve spring
25. Valve stem seal
26. Cylinder head temperature sensor
27. Clamp
28. EGR pipe
29. Gasket
30. EGR pipe
31. O ring
32. EGR valve
33. Inlet manifold
34. Inlet manifold gasket
35. Inlet valve
36. Exhaust valve
37. Cylinder head
38. Cylinder head gasket
39. Breather pipe
40. Turbocharger oil return pipe
41. Gasket
21
7
1 3 6
5
4 8
17 14
16
15
13
11 12
18 9
20
19 33
11 10
19
21
22
23
11
32
31
24
30
28
25 29
27
26 34
35
36
42 37
39 38
41
40
A106-238
22
1. Power steering pump
2. Alternator
3. Exhaust camshaft drive sprocket
4. Inlet camshaft drive sprocket
5. Mounting bracket
6. Crankshaft position sensor
7. Cylinder block
8. Coolant manifold
9. Coolant inlet hose
10. Oil jet
11. Timing chain guide
12. Timing chain
13. Timing chain tensioner guide
14. Thermostat housing bracket
15. Coolant outlet hose
16. O ring
17. Coolant outlet elbow
18. Coolant air bleed hose
19. Thermostat housing
20. Thermostat
21. O ring
22. Timing chain tensioner
23. External drive belt tensioner
24. Fan pulley
25. Idler pulley
26. Crankshaft front oil seal
27. Timing cover
28. Gasket
29. Injection pump drive sprocket
30. Gasket
31. Injection pump
32. Fuel supply & return pipes
33. Injection pump mounting bracket
34. Main bearing cap
35. Coolant by–pass hose
36. Vacuum pump
37. Gasket
38. Hose connector
39. O ring
40. Water pump
41. Gasket
42. External drive belt
23
1
2 3
4 14
13
3
11 12
5
10 15
9
13
8
7
11
10
9 16
17
5
18
6 31
18
30
19
20
23
22
29
24
21
28
27
26
25
A106-239
24
1. Piston rings
2. Piston
3. Snap ring
4. Gudgeon pin
5. Connecting rod & cap
6. Crankshaft pulley
7. Crankshaft sprocket
8. Seal
9. Main bearing shell (front)
10. Big end bearing shell
11. Main bearing shell (centre)
12. Crankshaft
13. Main bearing shell (rear)
14. Crankshaft rear seal housing
15. Clutch pressure plate
16. Clutch driven plate
17. Flywheel
18. Gasket
19. Ladder frame
20. Oil pump drive chain
21. Tensioner
22. Oil pump sprocket
23. Oil pump
24. Oil pick–up pipe
25. Sump
26. Oil filter cover
27. O ring
28. Oil filter
29. Oil cooler
30. Coolant hose
31. Oil cooler coolant thermostat
25
FRONT END
EXTERNAL DRIVE BELT

2
1
FRONT END
4
5
8 7
6
A106-001
Fig.1 External drive belt

1. Power steering pump pulley 5. Fan pulley
2. Idler pulley 6. Crankshaft pulley
3. Vacuum pump pulley 7. Tensioner
4. Water pump pulley 8. Alternator
Remove / Refit
NOTE: If a fan cowl is fitted, it is first

necessary to uncouple the viscous fan
from the idler pulley.
To remove the drive belt, insert a 3/8”
square drive into the tensioner as
illustrated. Turn anti–clockwise to release
the tension and remove the belt.
Refitting is the reverse of the removal

procedure; ensure the belt locates
centrally on all the pulleys. A106-002
Fig.2 Releasing drive belt tension.

The belt is tensioned automatically.
27
CRANKSHAFT FRONT OIL SEAL
1
Renew
Tools required: LDV 118, LDV 170,
MS1517.
WARNING: If the engine has been
running recently, the cooling
system and engine components may
be sufficiently hot to cause burning to
skin on contact.
1. Remove the viscous fan using tool
MS1517 (right hand thread). A106-004
2. Remove the external drive belt (see Fig.2 Removing crankshaft front seal
section ‘External Drive Belt’). 1. Tool LDV 170
FRONT END
4. Use tool LDV 170 to remove the

crankshaft front oil seal by turning it
anti–clockwise, then prise it out.
(Ensure the seal housing–to–timing
cover part of the seal is removed
also.)
1 Discard the seal.

5. Thoroughly clean and dry the area of
the crankshaft on which the new seal
will run.
A106-003
Fig.1 Removing crankshaft pulley bolts

1. Tool LDV 118
3. CAUTION: Do not use flywheel
timing tool to restrain the
crankshaft.
NOTE: The crankshaft pulley bolts
can only be re–used twice and, if
re–used previously will have centre
punch mark(s) to indicate the number
of times used.
If re–usable (see note above), mark
each bolt head with a centre punch
before removal.
Restrain the crankshaft using tool
LDV 118 fitted with bolts, while
removing the 3 crankshaft pulley
securing bolts (3 x 15 mm).
Remove the pulley.
28
9. Fit the viscous fan using tool MS1517
(right hand thread).
10. Run the engine and check for leaks.
1
TIMING CHAIN
Remove / Refit
Tools required: MS1517, LDV 118,
LDV 132, LDV 167, LDV 170, LDV 173,
LDV 177.
Remove
FRONT END
The timing chain can be removed in situ
after first carrying out the following
A106-027
operations:
Fig.3 Fitting crankshaft oil seal WARNING: If the engine has
1. Protection sleeve been running recently, the
6. NOTE: cooling system and engine
• A new crankshaft oil seal is components may be sufficiently hot to
supplied compete with a lip cause burning to skin on contact.
protection sleeve which will be – Switch off the ignition.
pushed out automatically during – Disconnect the battery(s), negative
fitment. Do NOT remove the (earth) terminal(s) first.
sleeve prior to fitment. – WARNING: Use caution if the
• The crankshaft oil seal is a PTFE coolant is hot.
type and the lip must NOT be Drain coolant by removing the lower
lubricated. radiator hose.
– Remove the radiator grille.
Fit a new crankshaft front oil seal – Detach the power steering reservoir
using tool LDV 170 to turn it clockwise and secure to one side.
into position. – Unclip the top hose from the bonnet
Remove the protection sleeve. locking platform.
Carefully press inwards the outer lip – Remove the bonnet locking platform.
of the seal.
7. Fit the crankshaft pulley.
Using flange holder LDV 118 to
restrain the pulley, tighten the 3
securing bolts in 2 stages:
Stage 1: tighten to 30 Nm
Stage 2: tighten a further 90°
8. Fit the external drive belt (see section
‘External Drive Belt’).
29
2
3 1
A106-006 A106-008
Fig.1 EVR valve Fig.3 Coolant outlet

– Disconnect the pipes and multiplug
FRONT END
1. Coolant outlet pipe

from the EVR valve (EGR vacuum 2. Air bleed hose
regulator). 3. ‘O’ ring
– Detach the heater air intake duct from
the deflector plate. 4. Release the air bleed hose clips at
– Remove the deflector plates (ease the cylinder head and release the
hose.
headlights forward to access the
fixings). Remove bolts (2 x 10 mm) and nut
– Unbolt the cowl (if fitted) from the (13 mm) to release the coolant outlet
radiator. pipe from the cylinder head.
– Remove the radiator.
Remove and discard the ‘O’ ring (and
the air bleed hose if damaged).
1. Remove the viscous fan using tool
MS1517 (right hand thread).
2. Remove the external drive belt (see
section ‘External Drive Belt’).
1 A106-009
Fig.4 Detaching thermostat housing

1. Thermostat housing
5. Remove the 10 mm bolt securing the
thermostat housing to its mounting
A106-007
bracket. Slide off the housing.
Fig.2 Releasing hose clip
3. Release the clip which secures the
coolant outlet hose to the thermostat
housing.
30
1
3 2
1
A106-011
Fig.6
1. Fan pulley 2. Idler pulley
FRONT END
7. Remove the fan pulley (3 x 15 mm
bolts) and the idler pulley (1 x 15 mm
bolt).
2 A106-010
Fig.5 Removing water pump / vacuum

pump
1. Vacuum pump
1
2. Water pump
3. Water pump gasket
6. Detach the water pump / vacuum
pump assembly from the cylinder
block (4 x 10 mm bolts).
A106-230
Discard the gasket.
Fig.7 Removing crankshaft pulley bolts
1. Tool LDV 118
8. CAUTION: Do not use flywheel
timing tool to restrain the
crankshaft.
NOTE: The crankshaft pulley bolts
can only be re–used twice and, if
re–used previously, will have centre
of times used.
If re–usable (see note above), mark
each bolt head with a centre punch
before removal.
Restrain the crankshaft using tool
LDV 118 fitted with bolts, while
removing the 3 crankshaft pulley
Remove the pulley.
31
1
LA
A106-014
A106-004
Fig.8 Removing crankshaft front seal

Fig.9 Removing timing cover
1. Tool LDV 170
FRONT END
1. Tool LDV 132

9. Use tool LDV 170 to remove the
crankshaft front oil seal by turning it – Lubricate blade of tool LDV 132
anti–clockwise, then prise it out. with engine oil.
(Ensure the seal housing–to–timing
cover part of the seal is removed – CAUTION: Do not insert the
also.) blade to its full depth or
Discard the seal. damage may occur to
components within the timing
10. Remove the nuts / bolts securing the cover.
timing cover (2 x 10 mm nuts, Locate tool LDV 132 at an
20 x 8 mm bolts). accessible position on the
11. The timing cover has been fitted using circumference and carefully tap
a sealant, and therefore must be the blade into the sealant by
carefully prised off as follows: sufficient depth to cut it.
CAUTION: Considerable care must
– Holding the tool in this position,
be taken not to distort the cover.
carefully tap it sideways to break
NOTE: This operation may be easier the sealant all round the cover,
if the external drive belt tensioner is lubricating the blade frequently.
removed first (17 mm).
– Remove the cover.
– Discard the coolant outlet gasket.
32
2 3 4
10 A
9
FRONT END
1
8
7
B A106-016
A106-015
Fig.11 Locating 50° BTDC timing
Fig.10 Timing gears position
1. Exhaust camshaft sprocket 1. Timing pin LDV 173
2. Chain guide
3. Inlet camshaft sprocket 13. Turn the crankshaft clockwise until the
4. Timing chain timing hole in the injection pump
5. Chain guide sprocket almost aligns (see illustration
6. Fuel injection pump sprocket ‘A’).
7. Chain guide Slowly continue to turn the crankshaft
8. Crankshaft sprocket until timing pin LDV 173 engages in
9. Timing chain tensioner its slot in the flywheel (see illustration
10. Tensioner guide ‘B’).
12. Remove the crankshaft position The crankshaft is now positioned at
sensor. 50° BTDC (timing position).
CAUTION: Do not attempt to turn
the engine while the timing pin is
fitted; damage to the sensor
location may result.
33
1
24
1 2
3
A106-018
2 Fig.13 De–tensioning timing chain

tensioner
FRONT END
16. De–tension the timing chain tensioner

as follows:
A106-017
Use a slim screwdriver blade to push
down the pawl (Fig.13, 1), while using
Fig.12 LDV 167 timing pins fitted a large screwdriver blade to push in
1. Camshaft timing pins the lock plate (2). Hold the lock plate
2. Fuel injection pump timing pin in this position while inserting a 2 mm
pin into the hole (3).
14. Fit timing pins LDV 167 in both
camshaft sprockets and in the fuel 17. Remove the tensioner (2 x 8 mm
injection pump sprocket. bolts).
15. Slacken the camshaft (8 x 13 mm) 18. Remove the tensioner guide and then
and fuel injection pump (4 x 10 mm) the three chain guides (8 mm bolts).
sprocket bolts.
19. Temporarily mark the inlet and
exhaust camshaft sprockets, to
ensure they will be refitted on the
same camshafts.
20. Remove the injection pump sprocket,
then the camshaft sprockets and the
chain.
Do NOT remove the timing pins.
Inspection
CAUTION: Before cleaning the cylinder
block face, adequately cover the oil
pump drive chain area. Do not allow
old sealant to fall into the sump.
Clean off all sealant on the cover and its
mating face with the cylinder block etc.
Carefully check the mating face of the
cover for damage, distortion etc. Rectify /
renew as necessary.
34
Clean all components and inspect for Fit the injection pump sprocket,
wear / damage: ensuring that the chain is taut
– Chain between the sprocket and the
– All sprockets crankshaft sprocket.
– Guides Check that all slackness in the chain
– Tensioner is on the tensioner side.
Renew as necessary.
2
Refit 2
Thoroughly lubricate sprockets, chain,

tensioner, chain guides etc. before
refitting.
21. Check that the sprocket timing pins
(LDV 167) and the crankshaft timing
pin (LDV 173) remain in position.
FRONT END
1 2
2 A106-020
Fig.15 Fitting the chain guides

1. Tensioner guide
2. Chain guides
23. Fit the tensioner guide followed by the

other three guides, ensuring the chain
A106-019
lies between the guide flanges.
Fig.14 Fitting timing chain Tighten the securing bolts to 15 Nm.
1. Exhaust camshaft sprocket
2. Inlet camshaft sprocket
3. Injection pump sprocket
22. NOTE: Ensure that the three copper

links on the timing chain align with the
timing marks on the three sprockets
(see inset).
Fit the camshaft sprockets and the
timing chain. Fit the securing bolts
loosely.
35
24
A106-021 A106-231
Fig.16 Fitting the chain tensioner Fig.17 Locating 50° BTDC timing
position
FRONT END
24. Fit the chain tensioner and tighten the 1. Crankshaft timing pin LDV 173
securing bolts to 15 Nm.
WARNING: When releasing
the tensioner, do not allow
the fingers to be trapped.
Remove the pin (arrowed) to unlock
the tensioner. Check that the
tensioner is fully released.
25. Tighten the securing bolts of the
camshaft and injection pump
sprockets to 33 Nm.
1
26. Remove the 3 sprocket timing pins
and the crankshaft timing pin.
27. Check the timing as follows: 2
– NOTE: If the engine is turned too
far, continue to turn clockwise a
further 2 turns. Do NOT turn
anti–clockwise.
A106-017
Turn the engine clockwise two
complete revolutions and refit the Fig.18 LDV 167 timing pins fitted
crankshaft timing pin LDV 173. 1. Camshaft timing pins
2. Injection pump timing pin
– Check that the 3 sprocket timing
pins (LDV 167) can now be fitted
If so, the timing is correct.
– Remove all 4 timing pins.
If no pins will enter, remove the chain and
start again.
NOTE: Do not slacken the camshaft
sprocket bolts unless the timing pins are
fitted.
36
If the injection pump pin will not enter, – NOTE: The timing cover must be
slacken its 4 sprocket bolts. Turn the fitted within 5 minutes of applying
pump shaft nut slightly until the pin enters the sealant.
easily and re–tighten the bolts. Apply a 3 mm diameter bead of
28. Fit the crankshaft position sensor, sealant (Loctite 5910) to the
applying Loctite to the bolt threads. engine as illustrated.
29. To fit the timing cover: Ensure sealant is applied across

the joint faces of the camshaft
carrier and ladder frame where
indicated (arrowed).
FRONT END
1
A106-024 A106-026
Fig.19 Fitting coolant outlet gasket Fig.21 Fitting timing cover

– Fit a new coolant outlet gasket to 1. Tool LDV 177
the timing cover. – Fit the timing cover centralising
tool LDV 177 over the crankshaft
nose, and then fit the timing
cover.
– Fit the securing bolts / nuts.
Tighten the 20 bolts to 14 Nm
and the 2 nuts to 10 Nm.
– Remove the centralising tool.
A106-237
Fig.20 Applying sealant
37
31. Fit the crankshaft pulley.
Using flange holder LDV 118 to
restrain the pulley, tighten the 3
securing bolts (15 mm) in 2 stages:
Stage 1: tighten to 30 Nm
Stage 2: tighten a further 90°
1
FRONT END
A106-027
Fig.22 Fitting crankshaft oil seal

1. Protection sleeve
30. NOTE:
• A new crankshaft oil seal is
supplied complete with a lip
protection sleeve which will be
pushed out automatically during
fitment. Do NOT remove the
sleeve prior to fitment.
• The crankshaft seal is a PTFE
type and the lip must NOT be
lubricated. A106-028
Fig.23 Fitting idler pulley

Thoroughly clean and dry the area of
the crankshaft on which the new seal 32. To fit the idler pulley, first tighten the
will run. spacer (arrowed) finger–tight, then fit
Fit a new crankshaft front oil seal the pulley and tighten the centre bolt
using tool LDV 170 to turn it clockwise to 53 Nm.
into position. 33. Fit the cooling fan pulley and tighten
Remove the protection sleeve. the 3 bolts to 53 Nm.
Carefully press inwards the outer lip 34. Fit the thermostat housing.
of the seal.
35. Using a new gasket, fit the water
pump and vacuum pump assembly.
Tighten the securing bolts to 23 Nm.
38
1
FRONT END
2
A106-029
Fig.24 Fitting coolant outlet elbow

1. Air bleed hose
36. Using a new ‘O’ ring (and a new air

bleed hose if required), fit the coolant
outlet hose and elbow.
37. Refit the tensioner (if removed).
Fit the external drive belt (see section
‘External Drive Belt’).
38. Fit the viscous fan using tool MS1517
(right hand thread).
If the work is being carried out in situ:

– Refit the front end components in the
reverse of the removal procedure.
– Refill with coolant.
– Connect the battery(s), positive
terminal(s) first.
– Run the engine and check for leaks.
– Check coolant level.
39
CYLINDER HEAD
3
CAMSHAFT COVER
Remove / Refit
REMOVE
2
Tools Required: LDV 168
The camshaft cover can be removed with 1
the engine in situ by first carrying out the
following operations: A106-031
WARNING: If the engine has Fig.2 EGR pipe

been running recently, the 1. Harness bracket
cooling system and engine 2. EGR pipe bolts
components may be sufficiently hot to 3. EGR valve bolts
cause burning to skin on contact.
– Switch off the ignition. 2. To remove the EGR valve:
Disconnect the battery(s), negative – unbolt harness bracket (8 mm),
terminal(s) first. – detach EGR pipe (2 x 10 mm
– Remove the heater air intake duct. bolts) at the rear,
– Detach the fuel filter and secure to – detach EGR valve from inlet
one side. manifold (2 x 8 mm bolts).
– Disconnect the air intake duct at the Discard the ‘O’ ring.
CYLINDER HEAD
EGR valve.
2
4
1
2 3
1
2
A106-032
Fig.3 Inlet manifold

1. Inlet manifold
2. Manifold gaskets
3. EGR valve ‘O’ ring
3
4 4. EGR valve
A106-030
Fig.1 EGR valve 3. Remove the inlet manifold (9 x 10 mm

1. EGR valve bolts).
Cover the inlet ports to prevent
2. Vacuum / pressure pipes
ingress of foreign matter.
3. EGR position sensor
4. Air temperature sensor
1. Disconnect the EGR vacuum /
pressure pipes and position sensor.
Disconnect the air temperature
sensor.
41
A106-035
Fig.6 Injector pipes
6. Remove the injector pipes as follows:

– Detach the bracket (3 x 10 mm)
securing the pipes to the
A106-033 camshaft carrier.
Fig.4 Disconnecting CHT lead
CYLINDER HEAD
4. Disconnect the cylinder head

temperature sensor (CHT) as
illustrated. (slide red security cover
back and press down on lock to
release connector)
A106-036
Fig.7 Releasing injector pipe at

injection pump.
– CAUTION: Use 2 spanners
2
when disconnecting injector
A106-034
pipes at the injection pump.
Fig.5 Releasing fuel return pipe Disconnect injector pipes 3 and 4
connector at the fuel injector pump (14 & 17
mm), then disconnect the same
5. Disconnect the fuel return pipe pipes at their injectors (19 mm).
connector.
– Disconnect pipes 1 and 2 in the
same way.
– Remove pipes 1 and 2, followed
by pipes 3 and 4.
42
– NOTE: Four injector seal REFIT
installers are supplied as tool 9. Using a new gasket, fit the camshaft
LDV 168, which can be used to cover and tighten the 11 securing
cover the exposed injector bolts to 10 Nm.
connections.
Cap the injector pump and
injector connections to prevent 2
ingress of dirt.
7. Disconnect the fuel return pipe from
the injectors (10 mm) and discard.
2
1
1
A106-038
3 Fig.9 Fitting injector dust seal

1. Tool LDV 168
2. Dust seal
CYLINDER HEAD
A106-037
Fig.8 Removing camshaft cover 10. Fit new injector dust seals, protecting
1. Injector dust seal them from damage with tool LDV 168
as illustrated.
2. Camshaft cover
3. Gasket 11. Fit a new fuel return pipe to the
injectors, tightening the connectors to
8. Remove the camshaft cover as 10 Nm. Do not over–tighten.
follows:
– Disconnect the breather pipe.
– Prise out and discard the injector

dust seals.
– Remove the securing bolts

(12 x 10 mm), and lift off the
cover.
Remove and discard the cover
gasket.
43
– CAUTION: Use 2 spanners (14
mm & 17 mm) when connecting
injector pipes at the injection
pump.
Connect and tighten pipes 1 and
2. Do not over–tighten.
– Connect and tighten pipes 3 and

4. Do not over–tighten.
– Fit the stay bracket, carefully

tightening the nuts progressively
to avoid placing any of the pipes
under tension.
A106-035
13. Connect the glow plug lead, and clip
Fig.10 Injector pipes the CHT cable to the camshaft carrier.
Connect the CHT lead.
12. IMPORTANT: The mating coned
faces of the injector pipe connectors
are designed to provide a leak–free 2
seal when connected for the first time, 4
and if used more than once, a leak
point may be created. Ideally new
pipes should be used, but it may be
CYLINDER HEAD
possible to re–use the pipes if the 3

following is observed:
• Observe absolute cleanliness at
the mating faces. 1
A106-032
• Do NOT over–tighten. The
correct torque of the unions is Fig.11 Fitting inlet manifold
35 Nm. 1. Inlet manifold
NOTE: If unions leak when tightened 2. Manifold gaskets
to the correct torque, the pipes must 3. EGR valve ‘O’ ring
be renewed. 4. EGR valve
14. Renew any inlet manifold gaskets as
Fit the injector pipes in the following
necessary. Fit the manifold and
sequence:
tighten the bolts (10 mm) to 15 Nm.
– Locate pipes 3 and 4 through the
slot in the cylinder head between
5 / 6 inlet ports.

slot in the cylinder head between
3 / 4 inlet ports.
44
17. Connect:
3 – Air temperature sensor
– EGR position sensor
– EGR vacuum / pressure pipes
18. Connect the fuel return pipe.
2 If the camshaft cover has been removed
with the engine in situ:
1 – Connect the air intake duct to the
EGR valve.
A106-031
– Fit the fuel filter.
– Fit the heater air duct.
Fig.12 EGR pipe
1. Harness bracket
terminal(s) first.
2. EGR pipe bolts
– Bleed the fuel system
3. EGR valve bolts
– Start the engine and check for leaks.
15. Fit the EGR valve (8 mm) using a new
‘O’ ring.
16. Fit:
– EGR pipe (10 mm bolts)
– Harness bracket (8 mm)
CYLINDER HEAD
1
3
4
A106-030
Fig.13 EGR valve

1. EGR valve
2. Vacuum / pressure pipes
45
1
3
CYLINDER HEAD
4
A106-043
Fig.1 Cylinder head assembly

1. Camshaft cover
2. Rocker shaft assembly (exhaust)
3. Rocker shaft assembly (inlet)
4. Camshaft carrier
5. Camshaft (exhaust)
6. Camshaft (inlet)
7. Cylinder head
8. Cylinder head gasket
46
CYLINDER HEAD
Remove. Inspect. Refit

REMOVE
Tools Required: MS 1517, LDV 118,
LDV 132, LDV 167, LDV 168, LDV 170,
LDV 171, LDV 173, LDV 174, LDV 175,
LDV 176, LDV 177 LDV 183, LST 122.
The cylinder head can be removed with
the engine in situ by first carrying out the
following operations
A106-006
WARNING: If the engine has
been running recently, the Fig.2 EVR valve
cooling system and engine – Disconnect the pipes and multiplug
components may be sufficiently hot to from the EVR valve (EGR vacuum
cause burning to skin on contact. regulator).
CAUTION: The engine should be cold
before releasing the tension on the – Remove the heater air intake duct.
cylinder head bolts, or before
removing the injectors. – Remove the deflector plates (ease
headlights forward to access the
CYLINDER HEAD
– Switch off the ignition. fixings).
– Disconnect the battery(s), negative – Unbolt the cowl (if fitted) from the
(earth) terminal(s) first. radiator.
– Drain coolant by removing the lower – Remove the radiator.

radiator hose and removing the
cylinder block drain plug. Replace the – Detach the fuel filter and secure to
plug after draining. one side.
– Remove the radiator grille. – Detach the air intake duct from the
EGR valve.
– Detach the power steering reservoir 1. Remove the timing cover and timing
and secure to one side. chain (see section ‘Timing Chain
Remove / Refit’).
– Unclip the top hose from the bonnet
locking platform.
– Remove the bonnet locking platform.
47
3. To remove the EGR valve:
unbolt harness bracket (8 mm),
1 – detach EGR pipe (2 x 10 mm
bolts) at the rear.
– detach EGR valve from inlet
manifold (2 x 8 mm bolts).
2
Discard the ‘O’ ring.
2 2
4
3 3
4
A106-030
Fig.3 EGR valve 1

A106-032
1. EGR valve
2. Vacuum/pressure pipes Fig.5 Inlet manifold
3. EGR position sensor 1. Inlet manifold
4. Air temperature sensor 2. Manifold gaskets
2. Disconnect the EGR vacuum / 4. EGR valve
CYLINDER HEAD

Disconnect the air temperature 4. Remove the inlet manifold (9 x 10 mm
sensor. bolts).
A106-031
Fig.4 EGR pipe

1. Harness bracket
2. EGR pipe bolts
3. EGR valve bolts
48
A106-035

A106-033 camshaft carrier.
CYLINDER HEAD
5. Disconnect the cylinder head
temperature sensor (CHT) as
illustrated. (slide red security cover
back and press down on lock to
release connector)
A106-036

injection pump.
2
A106-034
when disconnecting injector
Fig.7 Releasing fuel return pipe pipes at the injection pump.
connector Disconnect injector pipes 3 and 4
6. Release the main fuel return at the fuel injector pump (14 &
connector. 17 mm), then disconnect the
same pipes at their injectors
(19 mm).
same way.
by pipes 3 and 4.
49
– NOTE: The 4 injector dust seal 4
installers supplied as tool
LDV 168 can be used to cover
5
the exposed injector connections.
injector connections to prevent
ingress of dirt.
8. Disconnect the fuel return pipe from
the injectors (10 mm) and discard. 2
2
3
1
1
A106-052
Fig.10 Removing EGR pipe 3
A106-053
9. Remove bolt (1) and the clamp (2)
securing the EGR pipe to the cylinder Fig.11 Turbo oil pipe connections
1. Oil return pipe
CYLINDER HEAD
head.
Discard the gasket (3). 2. Gasket
3. ‘O’ ring
10. Remove the crankcase vent pipe, the 4. Oil feed pipe
dipstick and the dipstick tube 5. Copper washers
(10 mm). Do not bend the tube.
11. Disconnect the turbocharger oil return
pipe (10 mm) to the ladder frame;
discard the gasket and ‘O’ ring.
Disconnect the oil feed pipe (13 mm)
at the turbo, discarding the 2 copper
sealing washers.
Cap the pipes and turbo connections
to prevent ingress of dirt.
50
1
2 3
1 4
A106-055
Fig.13 Power steering pump
13. Detach the power steering pump (4 x

A106-054
10 mm) (if still fitted). Secure the
Fig.12 Exhaust manifold pump to avoid damage to pipes etc.
1. Studs Remove the 10 mm bolt (arrowed)
2. Gasket behind the pump location which
3. Plastic sleeve secures the mounting bracket to the
4. Exhaust manifold cylinder head.
12. To detach the exhaust manifold: 14. Unclip the alternator harness.
– Remove the securing bolts / nuts
(6 x 13 mm bolts, 2 x 16 mm
2
nuts).
1
CYLINDER HEAD
– Remove and discard the 2 studs
(E8 torx), noting the position of
the studs for re–assembly. Pull
the manifold clear of the cylinder
head.
– Extract and discard any remains

of the plastic sleeve at the front 3
mounting.
– Discard the nuts and bolts. A106-037
Fig.14 Removing camshaft cover.

– Discard the manifold gasket. 1. Injector dust seal
2. Camshaft cover
3. Gasket
15. Prise out and discard the injector dust

seals.
Remove the camshaft cover securing
bolts (12 x 10 mm), and lift off the
cover.
Remove and discard the cover
gasket.
51
A 17. Remove the two timing pins locating
the camshaft sprockets.
Unclip the CHT cable from the
camshaft carrier.
18. Disconnect the glow plug lead (T 27).
19. Remove the thermostat housing
support bracket (2 x 10 mm stud /
nuts).
6 10 11 7
B
18 19
A106-057
14 15
Fig.15 Removing rocker shafts 24 25
16. CAUTION: If shaft securing bolts 22 23

are fully removed, rockers may
20 21
spring apart.
Working on one rocker assembly at a 16 17
time, progressively unscrew all the
securing bolts (5 x 10 mm per side). 8 9
CYLINDER HEAD
CAUTION: Rockers contain

hydraulic tappets, therefore
cleanliness is essential to avoid
blockage of oil passages.
Carefully lift off the assembly and lay 2 4 12 13 5 3 1
to one side. Repeat with the other A106-058
assembly. Fig.16 Removing camshaft carrier bolts

Renew the rocker shaft securing 20. Remove the camshaft carrier bolts in
bolts. the sequence illustrated (20 x 10 mm
NOTE: bolts, 1 x 10 mm stud, 1 x 8 mm bolt).
• If the rockers have to be removed
for inspection purposes, ensure
the position of all components
can be identified.
• Note the oil drilling into the
underside of the shafts ahead of
the front securing bolts (see
illustration inset A). Shafts must
be fitted the correct way up.
• Shafts are marked at the front:–
IN (inlet) and EX (exhaust) (see
illustration inset B).
52
A106-059
Fig.17 Separating camshaft carrier

from cylinder head 1
21. CAUTION: The camshaft carrier 2

and cylinder head are a matched
pair. Ensure damage is not caused
to either component because both A106-060
will then have to be changed.

The camshaft carrier is sealed to the Fig.18 Removing injector
cylinder head; carefully ease off the 1. Tool LDV174
carrier as illustrated. 2. Injector compression seal
CYLINDER HEAD
22. Lift out the camshafts. 23. Fully slacken the injector locking
NOTE: The inlet and exhaust sleeves using tool LDV174, then
camshafts differ in the gaps between remove the injectors by carefully
the cam lobes; the gaps on inlet working them loose.
lobes are larger due to the larger inlet Check that the injector compression
valves. seals are serviceable, and retain them
with their respective injectors.
53
1 2 • Examine the camshaft sprockets for
wear or damage. Check also the
injection pump and crankshaft
12 sprockets, and the timing chain.
11
6 Camshaft Carrier
5
16 • Thoroughly clean off old sealant on
15
10
the cylinder head mating faces.
9 Examine for damage.
18 NOTE: The camshaft carrier and
17
8 cylinder head are matched and can
7 only be renewed as a pair.
14
• Ensure all oilways are clear.
13
• Examine the camshaft bearings for
wear, scoring or damage.
If excessive wear is suspected, use
plastigage to measure wear and
3 4 A106-061
compare results with the information
given in ‘Data’.
Fig.19 Cylinder head bolt removal
sequence Rocker Shafts / Rockers
24. Remove the cylinder head bolts in the NOTE: The rockers contain hydraulic
sequence illustrated (outer bolts 8 x tappets. Ensure complete cleanliness to
CYLINDER HEAD
13 mm, inner bolts 10 x 17 mm, bolt make sure dirt cannot enter.
no.19 is an 8 mm bolt). 1
Discard the bolts.
Lift off the cylinder head and stand on
wooden blocks.
INSPECTION
Camshafts
IN
• Examine the camshaft lobes for wear,
pitting etc. A106-063
If lobe wear is suspected, accurately Fig.20 Inlet rocker shaft assembly

compare measurements with a new 1. Helical springs
camshaft.
• If dismantling, the following may be
• Examine the camshaft journals for useful for re–assembly:
signs of wear, scoring or damage.
– The rocker shafts are different;
• Camshaft end–float is controlled by they are marked ‘IN’ and ‘EX’ at
the location of the flange on the front the front (see illustration inset).
of each camshaft in the cylinder head. – Helical springs are fitted between
See ‘Data’ for camshaft end float each pair of rockers on the inlet
information. rocker shaft only.
54
– The longer bosses on the rockers Cylinder Head
are fitted to the rear on the inlet
Dismantle
shaft, and to the front on the
exhaust shaft. Tools Required: LDV 171, LDV 176.
– NOTE: Two types of rocker are
available. They are
interchangeable.
• Examine rocker, roller and shaft
bearing surfaces for wear.
CAUTION: Do not attempt to
dismantle individual rockers:
1
– The hydraulic tappets contain
precision components, supplied
with oil through the rocker shafts
and rockers.
– The rollers run on loose needle
A106-065
roller bearings.
Fig.1 Removing CHT sensor
1. Tool LDV 176
NOTE: If the Cylinder Head Temperature
(CHT) sensor is removed, a new sensor
must be fitted.
CYLINDER HEAD
If necessary, remove the cylinder head
temperature (CHT) sensor using tool
LDV 176.
A106-064 Disconnect the glow plug connectors
Fig.21 Oil supply to rocker shafts (7 mm).
Remove the glow plugs (10 mm).
• Oil to the rockers and hydraulic
tappets is supplied from the front of
the camshaft carrier to drillings
through the centre of the rocker
shafts.
Check all oilways for cleanliness.
55
Before proceeding with overhaul work,
check the cylinder head for distortion as
follows: 1
7
6
CYLINDER HEAD
A106-067
A106-066
Fig.2 Checking for cylinder head Fig.3 Cylinder head

distortion 1. Collets
2. Spring cap
Clean the cylinder head face of all 3. Valve spring
deposits etc., then use a straight edge 4. Valve stem seal
and feeler gauge to check for distortion in 5. Valve guide
a number of planes as illustrated. See 6. Exhaust valve
‘Data’ for maximum permitted distortion. 7. Inlet valve
NOTE: Cylinder head machining is not
permitted.
If any distortion is within tolerance,
dismantle and inspect the cylinder head
as follows:
56
CYLINDER HEAD
Examine the cylinder head particularly
carefully for damage (e.g. discolouration
or cracks) which may indicate that the
engine is overheating. If such damage is
found, check that the cooling system is
operating satisfactorily. Only parts that are
in good condition may be used again.
VALVE GUIDES
Check each valve guide for wear or
damage.
A106-068
Fig.4 Removing valve VALVES

Check the valves for cracks, pits and
NOTE: During dismantling, keep all signs of burning. Check the stems for
components from each valve assembly in wear and for correct fit in their guides.
identifiable sets to ensure they will be
refitted in the same location. Check the valves for concentricity.
Working on each valve in turn:
CAUTION: Take care not to damage the VALVE SEATS
valve stems. valve oil seals will only be Examine the seats for damage and pitting.
effective if the stems are free from
CYLINDER HEAD
score marks or other damage.
– Compress the valve spring using Cylinder Head Rebuild
1210507 (MS 1519A) or other Before starting to assemble the cylinder
suitable valve spring compressor, and head, ensure all swarf, grinding paste etc.
remove the valve collets. has been removed.
Release the compressor.
Working on each valve in turn:
– Remove the spring cap and spring. – Check that there are no burrs / sharp
edges on the collet grooves on the
– Remove the valve.
valve stem which could damage the
– Remove and discard the combined oil seal during installation.
valve stem oil seal and spring seat.
– Lightly oil the valve stem and insert it
Inspection in the corresponding valve guide.
Clean the cylinder head and block mating
faces (the surfaces must not be a – Slide a new combined stem seal and
spring seat over the valve stem and
polished finish).
press it fully onto the valve guide.
Remove all carbon deposits and
combustion residues from the valves and – Fit the valve spring and spring cap on
cylinder head. the valve stem.
Check the valve guides for carbon
deposits and clean as necessary.
Examine all components for wear and
damage.
57
RE–FITTING
Lubricate all journals, bearings etc. with
clean oil during assembly.
1 1. Three thicknesses of cylinder head
gasket are available, to allow for
variations in piston protrusion.
To select the correct gasket:
Measure the stand–proud of each
piston in turn as follows:
a. Remove the crankshaft timing pin
LDV 173 if fitted.
A106-069
b. Wipe clean the top of each

Fig.5 Fitting collets
piston.
1. Tool LDV 171
– Carefully compress the valve spring c. Rotate the crankshaft clockwise

using 1210507 (MS 1519A) or other until the first piston to be checked
suitable valve spring compressor. is approximately at TDC.
Insert the valve collets using magnetic

tool LDV 171. Make sure that the
collets are correctly seated in the
CYLINDER HEAD
grooves.
Release the valve spring compressor.
– Fit the remaining valves in the same
way.
Fit the glow plugs (4 x 10 mm) and their

connecting cable (4 x 7 mm).
NOTE: (If removed.) Before fitting the
CHT sensor check that the threads in the
cylinder head are clean and dry to ensure
A106-071
good contact. Do NOT use sealant,
otherwise an inaccurate temperature Fig.1 Zeroing gauge
signal will be sent to the ECM. d. Position a dial gauge so that its
Fit a new CHT sensor using tool LDV 176, stylus rests vertically on the
tightening it to 10 Nm. Do not overtighten. piston over the gudgeon pin
centreline.
e. ‘Rock’ the crankshaft so that the

gauge registers the rise and fall
of the piston, finally positioning it
at the highest point reached.
This piston is now at TDC.
f. Zero the gauge, making sure it is

pre–loaded by a minimum of
1 mm.
58
A106-073
Fig.3 Cylinder head gasket

identification
A106-072
Gasket thicknesses are identified by
Fig.2 Measuring piston stand–proud the number of holes and teeth on the
g. Carefully move the gauge without front left hand side.
disturbing its setting until the
Piston Gasket
stylus rests on an adjacent part of stand–proud
t d d
the cylinder block. Thickness Holes/Teeth
0.310–0.40mm 1.1mm 1
h. Record the gauge reading, which 0.401–0.45mm 1.15mm 2
is the piston stand–proud of that 0.451–0.50mm 1.2mm 3
CYLINDER HEAD
piston.
j. Re–position the gauge onto the

other piston already at TDC and
repeat operations ‘f’ to ‘h’ .
k. Repeat operations ‘c’ to ‘j’ for the

other two pistons.
l. Calculate the average piston

stand–proud for all four pistons.
From the average piston stand–proud 1
figure just calculated, select the
correct gasket to be fitted using the
A106-231
following table.
Fig.4 Fitting crankshaft timing pin
1. Tool LDV173
2. Turn the crankshaft clockwise until

the timing pin LDV 173 can be fitted.
59
3. Ensure that the cylinder block and
head mating faces are clean and dry,
and check that the two locating
dowels are in position in the block. 1
4. Fit the new cylinder head gasket just 2
selected.
10 9
17
18
5
6
A106-076
13
14 Fig.6 Tightening injector
1 1. Aligning plate LDV 175
2
11 2. Socket LDV 174
12
3 6. Fit the injectors with their original
4
15 compression seals.
16 Tighten the injectors to 52 Nm, using
socket LDV 174 and aligning plate
LDV 175 as illustrated to maintain the
CYLINDER HEAD
return pipe connections in the correct

plane.
8 7 A106-075
NOTE: Illustration shows No.4 injector
being tightened; tighten No.2 in the
Fig.5 Cylinder head bolt tightening same way. When tightening Nos. 3
sequence and 1 injectors, turn the aligning plate
the other way round to reduce the
5. NOTE: new bolts are pre–lubricated.
tendency for the injector to be twisted.
Do not clean; fit as is.
Fit the cylinder head using new bolts.
Tighten the bolts in 5 stages as below.
Stage 1: Tighten bolts 1–10 to
20 Nm.
10 Nm.
40 Nm.
20 Nm.
Stage 5: Tighten bolts 1–18 to 180°
60
20 16 15 19
8 7
12 11
2 1
4 3
6 5
10 9
18 17
A106-077
Fig.7 Applying sealant to cylinder head
7. CAUTION: Ensure that when

compressed, the sealant cannot 24 22 14 13 21 23 25
A106-078
enter the camshaft journals.
Apply a 2.5 mm dia. bead of Loctite Fig.8 Tightening camshaft carrier
5910 to the mating face of the
cylinder head as illustrated. Note that 9. Check that the camshaft carrier
locating dowels are fitted in the
CYLINDER HEAD
the sealant is directed around the
OUTSIDE of the bolt holes alongside cylinder head.
the camshaft journals. Carefully lower the camshaft carrier
8. NOTE: For camshaft identification, into position and check that the
the gaps on inlet lobes are larger due camshafts are free to turn.
to the larger inlet valves. Fit and tighten the bolts in the
Carefully lower the camshafts sequence shown in two stages as
squarely into position, ensuring the follows:
cylinder head casting is not damaged. Stage 1: Tighten bolts 1–22 to
23 Nm.
10 Nm.
Check that the camshafts can still turn
freely.
61
1
1
A106-080
Fig.10 Fitting rocker shafts

A106-079
Fig.9 Fitting timing pins 12. CAUTION: Ensure the oil drillings
1. Camshaft timing pins in the rocker shafts are face down
2. Injection pump timing pin (see illustration inset).
Fit the rocker shaft assemblies using
10. Fit timing pins in the camshafts and new bolts.
CYLINDER HEAD
injection pump. NOTE: This operation may be found

easier if elastic bands (arrowed) are
11. Fit the camshaft and injection pump
used to secure pairs of rockers while
sprockets, timing chain, tensioner,
fitting.
guides, timing cover etc., as
described in the section ‘Timing Chain Progressively pull the assemblies
Refit’, operations 22 to 34. down into position. Then tighten the
bolts in two stages:
Stage 1: 13 Nm.
Stage 2: 45°
13. Using a new gasket, fit the camshaft
cover and tighten the 11 securing
bolts to 10 Nm.
62
2
A106-038
A106-035
Fig.11 Fitting injector dust seal

1. Tool LDV 168
2. Dust seal Fit the injector pipes in the following
sequence:
14. Fit new injector dust seals, using one
of the installers from tool LDV 168 as – Locate pipes 3 and 4 through the
illustrated to protect them from slot in the cylinder head between
damage. 5 / 6 inlet ports.
CYLINDER HEAD
15. Fit a new fuel return pipe to the – Locate pipes 1 and 2 through the
injectors and tighten the connectors to slot in the cylinder head between
10 Nm. Do not over–tighten. 3 / 4 inlet ports.
16. IMPORTANT: The mating coned – CAUTION: Use 2 spanners
faces of the injector pipe connectors when connecting injector pipes
are designed to provide a leak–free at the injection pump.
seal when connected for the first time, Connect and tighten pipes 1 and
and if used more than once a leak 2. Do not over–tighten.
pipes should be used, but it may be – Connect and tighten pipes 3 and
possible to re–use the pipes if the 4. Do not over–tighten.
• Observe absolute cleanliness at – Fit the stay bracket. Carefully
the mating faces. tighten the nuts progressively to
• Do NOT over–tighten. The avoid placing any of the pipes
correct torque of the unions is under tension.
35 Nm.
NOTE: If unions leak when tightened
to the correct torque, the pipes must
be renewed.
63
17. Clip the CHT cable to the camshaft
carrier.
Connect the CHT lead.
2
4
3
3
1
1
A106-032

1. Inlet manifold
2. Manifold gaskets
4. EGR valve
18. Renew any inlet manifold gaskets as
necessary. Fit the manifold and
tighten the bolts (10 mm) to 15 Nm. 2 A106-010
CYLINDER HEAD
Fig.14 Fitting water pump / vacuum

pump
1. Vacuum pump
2. Water pump
19. Using a new gasket, fit the water

pump / vacuum pump assembly to the
cylinder block (4 x 10 mm bolts).
64
1 4
2 3
1 4
5
A106-054
Fig.15 Exhaust manifold

1. Studs
2. Gasket 1
3. Plastic sleeve
4. Exhaust manifold
20. Fit a new exhaust manifold gasket. 3
Fit a new plastic sleeve to the exhaust A106-053
manifold front mounting, and secure Fig.16 Turbocharger oil pipe

the manifold using new studs, nuts connections
CYLINDER HEAD
(16 mm) and bolts 13 mm). 1. Oil return pipe
Tighten the securing nuts / bolts to 2. Gasket
40 Nm. 3. ‘O’ ring
4. Oil feed pipe
5. Copper washers
21. Connect the turbocharger oil return

pipe (10 mm) to the ladder frame
using a new gasket and ‘O’ ring.
Prime the turbo by filling with clean
engine oil.
Connect the turbo feed pipe (13 mm)
using new copper washers.
65
2
3
A106-052
Fig.17 EGR pipe 1 A106-089
1. Bolt Fig.19 Fitting thermostat housing

2. Clamp 1. Thermostat housing
3. Gasket
26. Slide the thermostat housing onto its
22. Fit the EGR pipe using a new gasket. mounting bracket, and secure with a
10 mm bolt.
27. Fit the dipstick tube (10 mm), dipstick
3 and crankcase vent pipe.
28. Reclip the alternator harness.
CYLINDER HEAD
A106-031
Fig.18 EGR pipe

1. Harness bracket
2. EGR pipe bolts A106-055
3. EGR valve bolts Fig.20 Power steering pump

23. Fit the EGR valve (8 mm) using a new 29. Fit the 10 mm bolt (arrowed) which
‘O’ ring. Connect EGR pipe (2 x secures the top of the power steering
10 mm bolts), and secure the harness pump mounting and the lifting eye to
bracket (8 mm). the cylinder head.
24. Fit the thermostat housing support 30. Fit the power steering pump (4 x
bracket (10 mm). 10 mm).
Fit the glow plug connector (T27) to

the thermostat housing bracket.
Connect the harness to the glow plug
connector (8 mm).
66
1
1
3
4
2 A106-030
A106-029
Fig.22 EGR valve
1. EGR valve
Fig.21 Fitting coolant outlet elbow
2. Vacuum/pressure pipes
1. Air bleed hose
31. Using a new ‘O’ ring (and a new air If the cylinder head has been removed
CYLINDER HEAD
bleed hose if required), fit the coolant with the engine in situ:
outlet hose and elbow. – Refit the radiator and front end
32. Connect the air temperature sensor. components in the reverse of the
Connect the EGR vacuum / pressure removal procedure.
pipes and position sensor. – Connect the pipes and multiplug to
the EVR valve.
33. Fit the external drive belt (see section – Fit the air intake duct to the EGR
‘External Drive Belt’). valve.
34. Fit the viscous fan using tool MS1517 – Fit the fuel filter.
(right hand thread). – Fit the heater air intake duct .
– Fill with the specified coolant solution.
– Check the engine oil level and top up
as required.
terminal(s) first.
– Bleed the fuel system.
Check coolant level and top up if
necessary.
67
FLYWHEEL Refit
5. Fit the clutch driven plate and
CLUTCH pressure plate, aligning the driven
plate with tool LDV 119.
Remove / Refit
Tools Required: LDV 119. CAUTION: It is important to tighten
the bolts as described below.
The clutch can be removed with the
engine in situ, after removing the gearbox. Fit the pressure plate securing bolts
(10 mm) finger tight, then
1
3
progressively tighten by 2 turns at a
time in the sequence illustrated in
6
fig.1 to a torque of 23 Nm.
6. Check that tool LDV 119 can rotate
freely. If not, slacken the pressure
plate securing bolts, re–align,
re–secure and re–check.
When satisfactory, remove tool
LDV 119.
5
4
2 1 A106-094
Fig.1 Removing clutch pressure plate

1. Tool LDV 119
1. Fit tool LDV 119 and remove the

clutch pressure plate by loosening the
securing bolts
(6 x 10 mm) 2 turns at a time and in
the sequence illustrated.
Remove the clutch driven plate.
FLYWHEEL
Inspection
2. Inspect the flywheel friction face and
the starter ring gear teeth for wear /
damage / scoring etc.
Renew if necessary (see ‘Flywheel’).
3. Examine the clutch release
mechanism for serviceability; rectify
as necessary.
4. Check the crankshaft spigot bearing
for wear or damage.
If renewal is necessary, see section
‘Flywheel / Spigot Bearing’.
69
FLYWHEEL / SPIGOT BEARING 3. WARNING: The flywheel is
heavy; support it during
Remove / Refit removal.
Tools required: LDV 118, LDV 119, Bolt tool LDV 118 to the flywheel to
LST 122, puller and 13 mm split collet (to restrain it from turning while removing
remove spigot bearing). the flywheel bolts (8 x E14 torx bolts).
Discard the bolts.
1. Remove the clutch as detailed in
‘Clutch Remove / Refit’. Remove the flywheel, noting the
dowel pin.
1
A106-095
Fig.1 Removing spigot bearing

1. Puller
2. Adaptor
A106-097
3. 13 mm split collet
Fig.3 Fitting spigot bearing
2. If the spigot bearing is to be renewed, 1. Tool LDV 119
it can be removed using a suitable
puller and a 13 mm split collet as 4. Carefully drift in the replacement
illustrated (see section ‘Special Tools’ spigot bearing using LDV 119.
for approved tools).
1
FLYWHEEL
A106-096
Fig.2 Restraining the flywheel

1. Tool LDV 118
70
Fit
NOTE: The crankshaft rear oil seal /
housing must not be re–used.
3
5 3. Clean and examine the surface of the
crankshaft on which the seal will run;
it must be free of damage, burrs,
1
clean and dry.
7
Clean the crankcase mating face with
the seal housing.
6
2 1
8
2
4
A106-098
Fig.4 Fitting flywheel

3
5. Ensuring the mating faces are clean
and undamaged, fit the flywheel using
new bolts.
Tighten the bolts (E14 torx) in
3 stages and in the sequence A106-099
illustrated as follows:
Fig.1 Crankshaft rear seal kit
Stage 1: Tighten to 25 Nm. 1. Seal / housing.
Stage 2: Tighten to 40 Nm. 2. Seal protection sleeve
Stage 3: Tighten 48° 3. Centraliser
6. Refit the clutch (see section ‘Clutch 4. A new crankshaft oil seal must be
Remove / Refit’). fitted. It is supplied as a kit
comprising the items illustrated.
CRANKSHAFT REAR OIL SEAL NOTE:
• The protection sleeve maintains
FLYWHEEL
Renew the correct ‘shape’ of the seal.

Tools required: LDV 118, LDV 119, Do NOT remove it until the seal
LST 122. has been fitted.
• The seal must be fitted dry.
Remove Do NOT lubricate the seal lip.
The crankshaft rear oil seal can be
removed with the engine in situ, after
removing the gearbox.
1. Remove the flywheel as detailed in
’Flywheel / Spigot Bearing.
2. Remove the crankshaft rear oil seal /
carrier (8 x 8 mm bolts) and discard it.
71
7. Refit the flywheel (using new bolts)
and clutch (see section ‘Flywheel /
Spigot Bearing’).
A106-100
Fig.2 Fitting crankshaft rear seal

1. Protection sleeve
5. Fit the seal / housing (complete with
protection sleeve) onto the crankshaft
and carefully press it squarely into
position against the crankcase.
Remove the protection sleeve.
1
3
6
FLYWHEEL
8
2
4 A106-101
Fig.3 Centralising seal / carrier
6. Fit the centraliser supplied with the

seal kit (arrowed) over the crankshaft
and onto the seal housing.
Fit the securing bolts and tighten in
the sequence illustrated to 10 Nm.
Remove the centraliser.
72
4
10
3
5
9
2
1
11
12
10
9
6
A106-102
Fig.1 Crankshaft, connecting rods and pistons

1. Snap ring
2. Gudgeon pin
3. Piston
4. Piston rings
CRANKCASE
5. Connecting rod & cap

6. Big end bearing
7. Crankshaft main bearing (front)
8. Crankshaft
9. Crankshaft main bearing (centre)
10. Crankshaft main bearing (rear)
11. Seal
74
CRANKCASE OVERHAUL 5. Remove if necessary:
Tools Required: MS 1517, LDV 118, – Fuel injection pump (see section
LDV 119, LDV 132, LDV 167, LDV 168, ‘Fuel Injection Pump Remove’).
LDV 170, LDV 172, LDV 173, LDV 177, – Coolant distribution manifold.
LDV 179, LDV 180, LDV 183, LST 122. – Alternator and power steering
pump mounting bracket.
CAUTION: Ensure that if a suitable – Oil cooler (6 x 10 mm).
engine stand is not being used, the
machined surfaces of the cylinder 6. Remove the sump nuts / bolts
head and sump / ladder frame mating (5 x 10 mm nuts, 11 x 8 mm bolts).
faces are not damaged. Place on
wooden blocks
DISMANTLING
1
The following operations assume that the
engine has been removed from the
vehicle.
A106-104
Fig.3 Removing sump.

1. Tool LDV 132
2
7. The sump has been fitted using a
sealant and must be carefully
removed as follows:
A106-103
CAUTION: Do not distort the sump
or damage the mating face of the
Fig.2 Draining the oil ladder frame.
1. Sump drain plug
– Lubricate the blade of tool
2. Oil filter drain plug
LDV 132 with engine oil.
1. Drain the engine oil (13 mm). Refit – Carefully tap the blade into the
the drain plug with a new ‘O’ ring. sealant by sufficient depth to cut
Drain the oil filter. it.
2. Remove the timing chain (see section carefully tap it sideways to break
‘Timing Chain Remove’). the seal round the sump,
lubricating the blade frequently.
CRANKCASE
3. Remove the cylinder head (see

section ‘Cylinder Head Remove’). – Remove the sump.
8. Remove the oil pick–up pipe
4. Remove the flywheel and crankshaft
(2 x 8 mm).
rear oil seal (see section ‘Crankshaft
Check its ‘O’ ring for damage,
Rear Oil Seal Remove’).
renewing if necessary.
75
– De–tension the tensioner by
pressing the guide in and insert a
3 mm pin as illustrated.
– Remove the tensioner securing
bolts (2 x 8 mm).
A106-145
Fig.4 Oil pump alignment

1. Tool LDV 180
9. CAUTION: Correct oil pump

alignment is essential to avoid
premature component wear.
To ensure correct oil pump alignment A106-144
on refitting:
– Clean all sealant from an area of Fig.6 Removing oil pump
the ladder frame adjacent to the
11. Remove the oil pump (4 x 8 mm bolts)
oil pump sprocket,: and the drive chain.
– Attach tool LDV 180 securely into
position as illustrated so that the 12. Disconnect the oil pressure switch, if
two faces of the tool (arrowed) not already disconnected.
butt up against the sprocket.
1
CRANKCASE
A106-143
Fig.5 Removing oil pump drive chain

1. 3 mm pin
2. Tensioner securing bolts
10. To remove the oil pump drive chain:

76
3 8 4
9
7
11
14
15
F 2 3 4 R
19 16
20
22
21
18
A106-118
13 17
Fig.8 Main bearing cap marks
10 12
16. Note the identification markings cast
on the main bearing caps (position
6 2 1 5 A106-108 number, and arrow to indicate front).
Fig.7 Removing ladder frame bolts The main bearing cap bolts can be
re–used 3 times. Examine each bolt
13. To remove the ladder frame, remove
head for marking(s) in the same way
the securing bolts (22 x 10 mm) in the
as for the connecting rods, and lightly
sequence illustrated.
centre punch mark if re–usable.
Remove the ladder frame and discard
Remove the cap bolts (15 mm) and
the gaskets.
the caps. Maintain each lower shell
14. NOTE: The connecting rod bolts can bearing with its cap.
only be re–used 3 times, and if
17. CAUTION: The crankshaft is heavy.
re–used previously will have centre
Take care not to damage the
journals when handling the
of times used.
crankshaft.
If re–usable (see note above), lightly Lift out the crankshaft.
mark each bolt head with a centre
punch. Remove the upper main bearing
shells, maintaining their position with
Before removing the piston and the lower shells.
connecting rod assemblies, if no NOTE: The centre upper bearing
identification marks exist, temporarily shell has thrust faces to control
mark each connecting rod cap to its crankshaft end–float.
connecting rod, and the position of
each assembly, 1, 2, 3, or 4 in the
CRANKCASE
cylinder block.
15. Working on one assembly at a time,
remove the big end cap securing bolts
(E12 Torx), pull off the caps and
remove the piston and connecting
rod.
Retain each shell bearing and cap in
its original position.
77
Crankshaft
6. CAUTION: Take care not to damage
the journals.
Degrease the crankshaft and check
that the oilways are not restricted or
blocked.
7. Examine the spigot bearing for wear;
renew if necessary (see ‘Flywheel
and Spigot Bearing’).
8. Examine the following for wear,
scores, grooves, signs of overheating:
• Main bearing journals
• Thrust washer bearing faces
A106-110
Fig.9 Oil jet • Big end bearing journals

• Front and rear oil seal running
18. Oil jets are fitted for piston cooling;
faces
remove if necessary to allow thorough
• Main bearing shells.
cleaning of the oilways.
Assess for serviceability and renew
INSPECTION & OVERHAUL as necessary.
NOTE: Do not remove the oil pump

alignment tool from the ladder frame. 2
Thoroughly clean all components prior to

inspection / overhaul. 3
Ensure all old sealant is removed from the
ladder frame and sump mating faces. 1
Cylinder block
1. Check all cup plugs for signs of
leakage. Rectify as necessary.
2. Degrease the block and remove all A106-120
traces of old sealant. Fig.10 Crankshaft sprocket

3. Inspect for cracks and other damage, 1. Crankshaft
particularly on mating surfaces. 2. Seal
4. Flush out the oil and coolant
passages, paying particular attention NOTE: A seal (see illustration) is
to the piston oil cooling jets and holes. located between the crankshaft
sprocket and the crankshaft.
CRANKCASE
5. Assess the cylinder bores for signs of

excessive scoring. Check for wear as
necessary.
78
Pistons and Connecting Rods to be renewed, fit a replacement of the
9. De–grease the piston and connecting same length (‘H’, ‘I’ or ‘J’).
rod assemblies. 12. Examine the connecting rods for
damage.
10. Before dismantling, check for wear in Renew the big end bearing shells if
the gudgeon pin area. worn.
If the pistons are to be re–fitted, 13. Check the small end bushes for wear.
make temporary marks to indicate the
cylinder number. PISTONS
11. The pistons are fully floating on their Piston diameters are measured during
gudgeon pins, and can be detached production and graded into 3 grades A, B,
after removal of one of the snap rings and C. The grades are marked on the
to allow the gudgeon pin to be piston crowns.
removed.
BBBB
5
3 2
1
A106-113
4 Fig.12 Bore size markings
A106-121 Bore sizes are measured and also graded

Fig.11 Connecting rod A, B and C. The grades are stamped on
1. Snap ring the lower right hand side of the block.
2. Gudgeon pin The pistons are then selectively fitted to
3. Connecting rod suit the bore sizes.
4. Projection (front of connecting rod)
5. Length identification marks
6. Dimple (front of piston)
CONNECTING RODS
The connecting rods are available in three
different lengths.
CRANKCASE
For identification, the big end and big end

cap are marked with a length code as
follows:
H = 149.74 mm
I = 149.80 mm
J = 149.86 mm
NOTE: Connecting rod length affects
piston protrusion. If a connecting rod has
79
PISTON RINGS EARLY LATER
14. Ensure that the piston ring grooves
are clean.
A106-115
Fig.14 Piston rings
16. Fit the piston rings using a suitable

ring expander;
– The bottom (oil control) scraper
A106-114
and spring rings can be fitted
Fig.13 Checking piston ring gap either way round.
– The middle (compression) ring
15. Before fitting new pistons, check the has a groove on the lower side.
ring gaps as follows: – On early pistons the upper face of
– Fit each ring in turn into the bore the top ring is tapered, and the
in the cylinder to which it will be ring must be fitted the correct way
fitted. round.
On later pistons the top ring is
– Push it squarely into the bore square sectioned.
using the crown of an inverted
piston until it is approximately
15 mm (0.5 in.) down (i.e. below
the ‘lip’ made by the top ring).
– Measure the ring gap with feeler

gauges and compare with the
figures given in ‘Data’.
CRANKCASE
80
2. NOTE: The main bearing shells are
not all identical.
Fit the crankshaft upper bearing
shells (the oil grooved shells), and
lower the crankshaft into position.
1
A106-116 F 2 3 4 R
Fig.15 Fitting piston to connecting rod

1. Projection (to front of engine)
2. Dimple (to front of engine)
17. Re–assemble the pistons and A106-118
connecting rods if separated, Fig.17 Fitting main bearing caps

ensuring the dimple in the piston (see 3. NOTE: The position of all the main
illustration) and the projection on the bearing caps are identified by arrow
connecting rod cap are on the same heads to point to the front and by
side. letters / numbers to denote their
NOTE: These marks must go to the position; i.e. F (front), 2, 3, 4, R
front when refitting the assemblies. (rear).
Fit the lower shells and bearing caps
ASSEMBLING
in their correct locations.
Lubricate all bearing surfaces before
fitting.
1. Fit the oil jets (if removed).
B
CRANKCASE
A106-117
Fig.16 Main bearing shells

A. Bearings in cylinder block
B. Bearings in main bearing caps
81
10 6. Lubricate the cylinder bores with
9
clean engine oil. Lubricate and fit
each piston and connecting rod
4
assembly in turn as follows:
3
NOTE: If the original pistons are
being refitted, ensure they return to
2 their original bores.
1
– Position the ring gaps at 120° to
each other.
6
5
8
7
A106-119
Fig.18 Main bearing cap bolt

tightening sequence. 2
4. Tighten the bolts in three stages and

in the sequence illustrated.
Stage 1: 45 Nm.
1
Stage 2: 80 Nm.
A106-116
Stage 3: 105°
Fig.20 Fitting piston and connecting
Check that the crankshaft is free to rod
rotate. 1. Projection (to front of engine)
2. Dimple (to front of engine)
2 – To ensure the piston and

connecting rod is fitted the correct
way round, check your temporary
3
identification marks made on
connecting rod and cap during
1
dismantling.
The assembly must be fitted with
the dimple on the piston and the
projection on the connecting rod
cap to the front (see illustration).
A106-120
– Lubricate and fit the upper shell
Fig.19 Crankshaft sprocket bearing to the connecting rod.
1. Crankshaft
CRANKCASE
2. Seal – Use a suitable ring compressor,

3. Crankshaft sprocket and carefully fit the piston and
connecting rod.
5. If fitting a new crankshaft sprocket, fit
the sprocket together with a new seal,
ensuring the seal is fitted the correct
way round.
82
– Lubricate and fit the lower shell
bearing to the connecting rod
cap.
Fit the cap and tighten the bolts
(E12 torx) in 2 stages:
Stage 1: 30 Nm
Stage 2: 100°
7. Before assembling further, measure
the stand–proud of each piston as
follows:
a. Clean the top of each piston.
b. Rotate the crankshaft clockwise

A106-072
until the first piston to be checked
is approximately at TDC. Fig.22 Measuring piston stand–proud
f. Carefully move the gauge without
disturbing its setting until the
stylus rests on an adjacent part of
the cylinder block.
g. Record the gauge reading, which

is the piston stand–proud of that
piston.
h. Re–position the gauge onto the

other piston already at TDC and
repeat operations ‘e’ to ‘g’ .
k. Repeat operations ‘b’ to ‘g’ for

A106-071 the other two pistons.
Fig.21 Zeroing gauge
Make a note of all 4 stand–proud
c. Position a dial gauge so that its
measurements, as the average of
stylus rests vertically on the
these will be required to select the
piston and over the gudgeon pin
correct thickness of cylinder head
centre line.
gasket.
d. ‘Rock’ the crankshaft so that the
gauge registers the rise and fall
of the piston, finally positioning it
at the highest point reached.
CRANKCASE
This piston is now at TDC.
e. Zero the gauge, making sure it is

pre–loaded by a minimum of
1 mm.
83
8. Gasket thicknesses are identified by
the number of holes and teeth on the
front left hand side.
A106-073
Fig.23 Cylinder head gasket

identification A106-126
From the average piston stand–proud Fig.25 Aligning front of ladder frame
figure just calculated, select the 1. Tool LDV 172
correct gasket to be fitted using the
following table: 10. Fit the ladder frame but do not tighten
the securing bolts.
Piston Gasket
Align and secure the ladder frame as
stand–proud Thickness Holes/Teeth
follows:
0.310–0.40mm 1.1mm 1
– Attach aligner tool LDV 172 to the
0.401–0.45mm 1.15mm 2 front of the ladder frame as
0.451–0.50mm 1.2mm 3 illustrated.
– Carefully move the ladder frame

until the lower end of the tool just
contacts the boss (arrowed) on
the cylinder block.
CRANKCASE
A106-125
Fig.24 Fitting ladder frame gaskets

9. Fit new ladder frame gaskets,
ensuring the foam pads at the rear
(see illustration inset) have not been
disturbed.
84
20 15 19
14
16
12
9
8
4 7
3
1
2
5
10 6
13 11
21 17 18 22 A106-128
Fig.27 Ladder frame tightening

A106-127 sequence
Fig.26 Aligning rear of ladder frame – Tighten the ladder frame bolts
– Use a straight–edge and feeler (10 mm) in the sequence
gauge to check the alignment of illustrated to 23 Nm.
the rear of the ladder frame to the – Check that the alignment remains
cylinder block as illustrated. correct.
Check the alignment on both Remove aligner tool LDV 172.
sides of the crankshaft.
the clearance should not exceed
0.02 mm overlap to 0.2 mm gap.
– Re–check the front alignment.
– Continue to make adjustment

until ladder frame is aligned at
1
front and rear.
A106-145

1. Tool LDV 180
CRANKCASE

Fit the oil pump and chain, positioning
the pump so that the sprocket butts
squarely against tool LDV 180.
Tighten the 4 securing bolts (8 mm) to
10 Nm.
Re–check the alignment and
re–adjust if necessary.
Remove the tool.
85
1
A106-146
Fig.29 Fitting oil pump chain tensioner

1. 3mm pin
A106-131
12. Fit the oil pump chain tensioner and
tighten the securing bolts (8 mm) to Fig.30 Applying sealant to sump.
16 Nm.
14 CAUTION: Sump must be fitted
Remove the 3 mm locking pin and within 5 minutes of applying
check that the tensioner is free to sealant.
move. NOTE: Sump and cylinder block
mating faces must be clean and dry.
13. Fit the oil pick–up pipe (using a new
Apply a 3 mm diameter bead of
‘O’ ring if necessary). Tighten the 2
sealant (Loctite 5910) to the sump
securing bolts (8 mm) to 10 Nm.
mating face as illustrated.
12 15 13 16
14
5 6
1 7
4 3
11
10
9 8
CRANKCASE
A106-132
Fig.31 Sump bolt tightening sequence
15. Fit and tighten the sump securing

bolts / nuts (8 mm / 10 mm) in the
following two stages and in the
Stage 1: Tighten to 7 Nm
Stage 2: Tighten to 14 Nm.
86
16. Before fitting the crankshaft rear seal,
ensure the surface of the crankshaft
on which the seal will run is clean and
dry.
Clean the crankcase mating face with
the seal housing.
1
1
2
A106-100
A106-099 Fig.33 Fitting crankshaft rear seal

Fig.32 Crankshaft rear seal kit 1. Protection sleeve
1. Seal / housing.
2. Seal protection sleeve 18. Fit the seal / housing (complete with
3. Centraliser protection sleeve) onto the crankshaft
and carefully press it squarely into
17. A new crankshaft oil seal must be position against the crankcase.
fitted. It is supplied as a kit Remove the protection sleeve.
comprising the items illustrated. 1
3
NOTE:
• The protection sleeve maintains 5
the correct ‘shape’ of the seal.
Do NOT remove it until the seal
6
has been fitted.
• The seal must be fitted dry. Do 7
NOT lubricate the seal lip.
8
2
4 A106-101
Fig.34 Centralising seal / carrier

CRANKCASE
19. Fit the centraliser supplied with the

seal kit (arrowed) over the crankshaft
and onto the seal housing.
Fit the securing bolts and tighten in
the sequence illustrated to 10 Nm.
Remove the centraliser.
87
20. Refit the flywheel (using new bolts)
and clutch (see section ‘Flywheel /
Spigot Bearing’).
21. Refit if removed:
– Oil cooler (using new gasket).
– Alternator and mounting bracket.
– Coolant distribution manifold
(using new gasket).
– Fuel injection pump (see ‘Fuel
Injection Pump Refit’).
NOTE: Pump will have to be
retimed to the crankshaft when
the timing chain is fitted.
22. Complete the rebuild by fitting the
cylinder head, camshafts, camshaft
carrier, drive sprockets and timing
chain, timing cover, camshaft cover
etc. See sections ‘Cylinder Head
Refit’ and ‘Timing Chain Refit’ for
details.
CRANKCASE
88
CRANKSHAFT POSITION (CKP)
SENSOR MOUNTING BRACKET
Tools required: MS 1517, LDV 167, LDV
170, LDV 173.
If the CKP sensor mounting bracket has
been removed or loosened by mistake,
and if the timing chain and sprockets have
not been disturbed, the bracket can be
accurately re–positioned as follows.
1. Remove the viscous fan using tool 1
MS 1517 (right hand thread).
A106-231
Fig.2 Crankshaft timing pin
section ‘External Drive Belt’).
1. Tool LDV 173
1
5. Loosely fit the CKP sensor mounting
bracket and fit crankshaft timing pin
tool LDV 173. Ensure the tool locates
into the cutaway in the flywheel.
Tighten the mounting bracket bolts.
6. Remove the timing pins.
Refit the pump sprocket access cover
using tool LDV 170 and connect the
CKP sensor.
A106-176 7. Refit the external drive belt and
Fig.1 Removing injection pump viscous fan.
sprocket access cover
1. Tool LDV 170 NOTE: The above procedure is not
correct if the camshaft or pump timing
3. Use tool LDV 170 as illustrated to was disturbed while the CKP sensor
remove the injection pump sprocket mounting bracket was slackened /
access cover. removed.
4. Turn the crankshaft clockwise until the
timing holes in the pump sprocket and In this case the crankshaft timing
in the pump align. Fit timing pin position (50° BTDC) must first be
LDV 167. established by taking depth
measurements through an injector
hole onto the piston to position it
CRANKCASE
accurately at TDC, then use a degree

wheel on the crankshaft pulley to turn
it to 50° BTDC.
89
LUBRICATION SYSTEM
2
LUBRICATION
SYSTEM
1
4
5
8 7 6
7 9 10
11
3 13 12
14
15
16
18
17
19
A106-136
Fig.1 Lubrication system
90
OIL CIRCULATION OIL FILTER ELEMENT
The gear type oil pump (14) is located at Renew
the front of the engine and is driven off the
nose of the crankshaft by a chain. it Tool required: LDV 179
draws oil from the sump via a pick–up
LUBRICATION
pipe (17) containing a mesh strainer. A
SYSTEM
pressure relief valve (15) is integral with
the pump.
2
The pressurised oil is pumped through the
ladder frame to the combined full–flow oil
filter (19) and oil cooler (18).
From the filter oil is directed up to the
main oil gallery (10) which runs the length
of the cylinder block. Individual drillings in 1 A106-137
the cylinder block direct oil from the main Fig.1 Removing oil filter
oil gallery to each of the five crankshaft 1. Filter drain valve
main bearings (11) in the crankshaft (12), 2. Tool LDV 179
and to the 4 jets (9) which spray oil to the
underside of the pistons for cooling. 1. Position a drain tray underneath the
oil filter, and unscrew its drain plug
Internal drillings in the crankshaft webs until oil drains out.
provide lubrication from the main bearings
to the big end journals (13). 2. Use tool LDV 179 to unscrew the filter
cover.
Other drillings from the oil gallery supply:
Discard the filter element and the
– the oil pump drive chain tensioner (4), cover ‘O’ ring.
– the vacuum pump (2) via the water 3. Clean out the cover and its location in
pump mounting; the return from the the cooler housing.
vacuum pump lubricates the timing
chain, sprockets etc.,
– the timing chain tensioner (3),
– the turbocharger (16); the turbo oil
drains back to the sump via an
external pipe.
A further drilling from the gallery supplies

pressurised oil up to the inlet camshaft
front bearing (7), and from there a
passage at the front of the camshaft
carrier transfers some of this oil to the
exhaust camshaft front bearing (8).
From the two camshaft front bearings,
pressurised oil passes along the hollow
rocker shafts (6) to each of the other
camshaft bearings and to the rockers.
Internal drillings in the rockers (5) allow oil
to the hydraulic tappets and to the
camshaft rollers.
91
OIL PUMP
Remove / Refit
Tools required: MS 1517, LDV 118,
LDV 132, LDV 167, LDV 173, LDV 170,
LUBRICATION
LDV 177, LDV 180.

SYSTEM
1 Remove
The oil pump can be removed in situ after
first carrying out the following operations:
2
WARNING: If the engine has
been running recently, the
cooling system and engine
components may be sufficiently hot to
A106-138
Fig.2 Oil filter – Switch off the ignition.
1. Filter element – Disconnect the battery(s), negative
2. ‘O’ ring (earth) terminal(s) first.
– WARNING: Use caution if the
4. Fit a new ‘O’ ring to the cover. coolant is hot.
5. Fit the new element in the cover with Drain coolant by removing the lower
its tangs (arrowed) downwards (i.e. radiator hose.
into the cover). – Remove the radiator grille.
– Detach the power steering reservoir
6. Tighten the cover into the housing. and secure to one side.
locking platform.
92
2. Remove the timing chain (see section
‘Timing Chain Remove’).
3. Remove the sump nuts / bolts (5 x
10 mm nuts, 11 x 8 mm bolts).
LUBRICATION
SYSTEM
1
A106-006
Fig.1 EVR valve

– Disconnect the pipes and multiplug
from the EVR valve (EGR vacuum
regulator). A106-104
– Detach the heater air intake duct from
Fig.3 Removing sump.
the deflector plate.
1. Tool LDV 132
– Remove the deflector plates (ease
headlights forward to access the 4. The sump has been fitted using a
fixings). sealant and must be carefully prised
– Unbolt the cowl (if fitted) from the off as follows:
radiator. CAUTION: Do not distort the sump
– Remove the radiator. or damage the mating face of the
ladder frame.
– Lubricate the blade of tool
1 LDV 132 with engine oil.
– Carefully tap the blade into the
sealant by sufficient depth to cut
it.
carefully tap it sideways to break
the seal round the sump,
lubricating the blade frequently.
A106-103 – Remove the sump.
Fig.2 Draining the oil 5. Remove the oil pick–up pipe
1. Sump drain plug (2 x 8 mm).
Check its ‘O’ ring for damage,
1. Drain the engine oil (13 mm). Refit renewing if necessary.
the drain plug with a new ‘O’ ring.
93
LUBRICATION
SYSTEM
2
1
1
A106-145

1. Tool LDV 180

To ensure correct oil pump alignment
A106-143
on refitting:
Fig.5 Removing oil pump drive chain
– Clean all sealant from an area of
1. 3 mm pin
the ladder frame adjacent to the
2. Tensioner securing bolts
oil pump sprocket,:
– Attach tool LDV 180 securely into 7. To remove the oil pump drive chain:
position as illustrated so that the
– De–tension tensioner by pressing
two faces of the tool (arrowed)
guide in and insert 3 mm pin as
butt up against the sprocket.
illustrated.
– Remove tensioner securing bolts
(2 x 8 mm).
A106-144
Fig.6 Removing oil pump
8. Remove the oil pump (4 x 8 mm bolts)

and the drive chain.
94
Refit 11. Fit the oil pick–up pipe (using a new
‘O’ ring if necessary). Tighten the 2
securing bolts (8 mm) to 10 Nm.
LUBRICATION
SYSTEM
1
A106-145

1. Tool LDV 180

Fit the oil pump and chain, positioning
the pump so that the sprocket butts A106-131
squarely against tool LDV 180. Fig.9 Applying sealant to sump.

Tighten the 4 securing bolts (8 mm) to
10 Nm. 12 CAUTION: Sump must be fitted
Re–check the alignment and within 5 minutes of applying
re–adjust if necessary. sealant.
Remove the tool. NOTE: Sump and cylinder block
mating faces must be clean and dry.
Apply a 3 mm diameter bead of
sealant (Loctite 5910) to the sump
mating face as illustrated.
A106-146
Fig.8 Fitting oil pump chain tensioner

1. 3 mm pin
10. Fit the oil pump chain tensioner and
tighten the securing bolts (8 mm) to
16 Nm.
Remove the 3 mm locking pin and
check that the tensioner is free to
move.
95
12 15 13 16
14
5 6
LUBRICATION
SYSTEM
1 7
4 3
11
10
9 8
A106-132
Fig.10 Sump bolt tightening sequence
13. Fit and tighten the sump securing

bolts / nuts (8 mm / 10 mm) in the
following two stages and in the
Stage 1: Tighten to 7 Nm
Stage 2: Tighten to 14 Nm.
If the oil pump has been removed with the
engine in situ:
– Refit the radiator and front end

components in the reverse of the
removal procedure.
– Connect the pipes and multiplug to

the EVR valve.
– Fill with the specified engine oil.

terminal(s) first.

necessary.
96
FUEL SYSTEM
FUEL SYSTEM
1
A106-149
Fig.1 Fuel system

1. Fuel tank 4. Injection pump
2. Filter 5. Injector
3. Service indicator
DESCRIPTION
The basic fuel injection system consists of the fuel tank (1), a filter (2) with a service
indicator (3), an injection pump (4) and injectors (5). Fuel is drawn by the pump through
the filter, and delivered to each injector. Pump operation is controlled electronically by
EEC V Powertrain Control Module (PCM).
Excess fuel is returned via pipes from the injectors and from the injection pump to the
fuel filter, for re–supply to the pump or return to the fuel tank.
97
Fuel Filter Fuel Injection Pump
The Bosch VP30 distributor type pump is
In addition to its filtering facility, the fuel controlled electronically by the Pump
filter also contains a bi–metal control Control Unit (PCU), mounted on top of the
valve, water trap, service indicator, and injection pump, and the PCM. The PCU
hand pump in the filter housing for controls delivery of the correct amount of
bleeding purposes. fuel to the injectors and at the optimum
The control valve is located in the fuel time, dependent on driving information
return area of the filter housing; the valve received via the PCM (e.g. engine speed,
opens if the temperature of the fuel falls road speed, throttle position, air
below approximately 15°C. When that temperature etc.).
happens the returned fuel is re–directed The pump can generate fuel pressure of
to pass through the injection pump again, up to 1100 bar to ensure high atomisation
where its temperature will rise due to the of the fuel at the injectors.
high pressures created in the pump. This
FUEL SYSTEM
circulation will continue until the fuel The fuel system cannot be run dry while
temperature rises to approximately 45°C the vehicle is operating. When a
when the control valve will close and allow pre–determined low fuel level is reached,
all the returned fuel to continue back to a signal from the sender unit in the fuel
the tank. tank to the PCM initiates a shut–down
sequence, starting with power loss and
The water trap is in the filter base. Water finally switching off the fuel supply.
in the fuel passing through the filter sinks
to the bottom from where it can be Injectors
drained off by opening a ‘tap’ in the filter
base. A sensor in the filter illuminates a The 6–hole Delphi injectors are positioned
warning light on the instrument panel if to inject directly into the combustion
the water level gets too high; the water chambers (DI).
must be drained off immediately to avoid They are 2–stage injectors for smoother
water damage to the injection pump and combustion, and cannot be overhauled or
injectors. adjusted. The six holes ensure optimum
A service indicator is fitted into the top of fuel distribution in the combustion
the filter housing; It gives a visual signal chambers and cleaner emissions.
as to whether the filter needs to be
renewed. The indicator operates on
vacuum changes created in the fuel
supply system if the filter becomes
blocked.
98
BLEEDING PROCEDURE 4. Close the bleed valve and operate the
hand primer again to check that there
WARNING: Do not smoke or is now resistance to the pumping
allow open flame of any type action.
when working on or near any fuel Remove the plastic pipe.
related components. Fuel vapour can
ignite and cause damage and / or 5. Start the engine and check for leaks.
personal injury.
NOTE: If the pump and / or the injector
CAUTION: Fuel injection equipment is pipes have been removed, in addition to
manufactured to fine clearances. It is the above bleeding procedure it may be
essential to observe absolute necessary also to progressively ‘crack’ the
cleanliness when working on any part high pressure pipes at the injectors while
of the system. cranking the engine until the engine
Filter, Fuel Pipes starts.
FUEL SYSTEM
Do not crank for more than 10 seconds at
a time, and the ignition MUST be returned
3
to the ‘O’ position between crankings,
otherwise starting will be inhibited.
Wait for 30 seconds before re–cranking.
1
FUEL FILTER
WARNING: Do not smoke or
allow open flame of any type
2
when working on or near any fuel
related components. Fuel vapour can
ignite and cause damage and / or
personal injury.
A102-057
CAUTION: Fuel injection equipment is
Fig.1 Bleeding the filter manufactured to fine clearances. It is
1. Bleed valve essential to observe absolute
2. Plastic pipe cleanliness when working on any part
3. Hand primer of the system.
1. Connect a suitable length of clear
plastic pipe to the filter bleed valve,
and place the other end in a suitable
drain container.
2. Open the bleed valve by unscrewing it
approximately 1 turn.
3. Operate the hand primer slowly until a
continuous flow of air–free fuel can be
seen passing through the plastic pipe.
NOTE: if the filter has been renewed
this will take approximately 80 to 100
strokes.
99
Water Draining 2. Position a suitable drain container
under the filter.
Slacken the water drain plug 3 to 4
turns and allow liquid to drain off until
clear diesel fuel is seen.
3. Tighten the drain plug and re–connect
the sensor connection.
081297
Fig.1 Water trap warning light

Fuel Filter Service Indicator
A sensor in the base of the filter measures
the quantity of water in it. If a
pre–determined quantity is reached the
sensor will cause a warning light to
FUEL SYSTEM
illuminate on the instrument cluster.
A102-066
Fig.1 Service indicator
Check that the fuel filter element is not

obstructed as follows.
1. Switch off the ignition.
2. Press the yellow button on the
Service Indicator and hold for
3 seconds.
3
1 3. Start the engine and let it run for 5
2 seconds at 4,000 rpm. On vehicles
without a tachometer, fully depress
the accelerator for 3 seconds.
A102-069
Fig.2 Draining the water trap 4. Check the position of the yellow
1. Water sensor connector Service Indicator.
2. Drain pipe If it is in the green area, a filter
3. Water sensor change is not required.
Drain the water as follows: If it is in the clear area, the filter
should be changed at the next service
1. Disconnect the electrical connection interval.
from the water sensor. If it is in the red area, it must be
replaced immediately.
100
Renew Element
1. Detach the heater air duct.
2. Detach the fuel pipe connections to
and from the injection pump.
3. Remove the fuel filter element by
turning its locking ring anti–clockwise.
4. Disconnect the water–in–fuel sensor
electrical connection.
A106-153
Fig.2 Aligning fuel filter element
FUEL SYSTEM
7. Locate the element to the housing,
ensuring the arrow on the element
points to the cutaway in the housing
rim.
Push the element fully up into the
housing.
8. Fit the locking ring and turn it
clockwise until an audible click is
heard.
9. Connect the water–in–fuel sensor
connector.
10. Connect the fuel pipes.
2 11. Bleed air from the system as
1
described in ‘Bleeding Procedure’.
12. Start the engine and check for fuel
A106-232
leaks.
Fig.1 Water–in–fuel sensor 13. Refit the heater air intake duct.
1. Sensor electrical connector
2. Sensor
5. Remove the water–in–fuel sensor by

unscrewing it.
Discard the element.
6. Fit the water–in–fuel sensor to the
new element.
101
INJECTORS
Remove / Refit
1
when working on or near any fuel
related components. Fuel vapour can 2
personal injury.
2
CAUTION
w Only remove or fit injectors when
the engine is cold.
w Fuel injection equipment is

FUEL SYSTEM
3
manufactured to fine clearances. It 4
is essential to observe absolute A106-030
cleanliness when working on any Fig.1 EGR valve

part of the system. Always cap 1. EGR valve
any open pipe or connector. 2. Vacuum pipes
Remove 4. Air temperature sensor
Tools Required: LDV 168, LDV 174,
LDV 175.
The injectors can be removed with the Disconnect the air temperature
engine in situ by first carrying out the sensor.
following operations:
– Switch off the ignition.

Disconnect the battery(s), negative
terminal(s) first.
– Remove the heater air intake duct.
– Detach the fuel filter and secure to
one side.
– Detach the air intake duct from the
EGR valve.
102
3
A106-031
Fig.2
1. Harness bracket
2. EGR pipe bolts
FUEL SYSTEM
3. EGR valve bolts A106-035

– detach EGR pipe (2 x 10 mm
bolts) at the rear,
camshaft carrier.
– detach EGR from inlet manifold
(2 x 8 mm bolts).
2
4
A106-036
1
A106-032
Fig.3 Inlet manifold injection pump.
1. Inlet manifold
2. Manifold gaskets – CAUTION: Use 2 spanners
3. EGR valve ‘O’ ring when disconnecting injector
4. EGR valve pipes at the injection pump.
Disconnect injector pipes 3 and 4
3. Remove the inlet manifold (9 x 10 mm at the fuel injector pump (14 &
bolts). 17 mm), then disconnect the
Cover the inlet ports to prevent same pipes at their injectors
ingress of foreign matter. (19 mm).
same way.
by pipes 3 and 4.
103
– NOTE: Four injector seal Refit
installers are supplied as tool
LDV 168, which can be used to
cover the exposed injector
connections.
injector connections to prevent
ingress of dirt.
5. Remove and discard the fuel return
pipe (10 mm).
6. Prise out and discard the injector dust
seals.
2
FUEL SYSTEM
A106-161
Fig.7 Tightening injector

1. Aligning plate LDV 175
2. Socket LDV 174
8. Fit the injectors with their original

compression seals.
Tighten the injectors to 52 Nm, using
1 socket LDV 174 and aligning plate
2 LDV 175 as illustrated to maintain the
return pipe connections in the correct
plane.
NOTE: Illustration shows No.4 injector
A106-160
being tightened; tighten No.2 in the
Fig.6 Removing injector same way. When tightening Nos.3
1. Socket LDV 174 and 1 injectors, turn the aligning plate
2. Injector seal the other way round to reduce the
tendency for the injector to be twisted.
7. Use special socket LDV 174 to fully
slacken the injector locking sleeves,
then remove the injectors by carefully
working them loose.
Check that the injector compression
seals are serviceable; retain them
with their respective injectors.
104
2
A106-038
FUEL SYSTEM
A106-035
Fig.8 Fitting injector dust seal

1. Tool LDV 168
2. Dust seal Fit the injector pipes in the following
sequence:
9. Fit new injector dust seals, protecting
them from damage with tool LDV 168 – Locate pipes 3 and 4 through the
as illustrated. slot in the cylinder head between
5 / 6 inlet ports.
10. Fit a new fuel return pipe to the
injectors, tightening the connections – Locate pipes 1 and 2 through the
to 8 Nm. Do not over–tighten. slot in the cylinder head between
11. IMPORTANT: The mating coned 3 / 4 inlet ports.
are designed to provide a leak–free – Connect and tighten pipes 1 and
seal when connected for the first time, 2. Do not overtighten.
and if used more than once a leak
point may be created. Ideally new – Connect and tighten pipes 3 and
pipes should be used, but it may be 4. Do not overtighten.
possible to re–use the pipes if the
following is observed: – Fit the stay bracket. Carefully
• Observe absolute cleanliness at tighten the nuts progressively to
the mating faces. avoid placing any of the pipes
• Do NOT over–tighten. The under tension.
correct torque of the unions is
35 Nm.
be renewed.
105
2
4
1
3 2
1
A106-032 2
Fig.10 Fitting inlet manifold
1. Inlet manifold
2. Manifold gaskets
FUEL SYSTEM
4. EGR valve 3
4
12. Renew any inlet manifold gaskets as A106-030
necessary. Fit the manifold and Fig.12 EGR valve

tighten the bolts (10 mm) to 15 Nm. 1. EGR valve
2. Vacuum/pressure pipes
3
14. Connect the air temperature sensor.
Connect the EGR vacuum / pressure
pipes and position sensor.
15. Connect the fuel return pipe to the
2
return line.
1
If the injectors have been fitted with the
engine in situ:
A106-031 – Fit the air intake duct to the EGR
Fig.11 EGR pipe valve.
1. Harness bracket – Fit the fuel filter.
2. EGR pipe bolts – Bleed the fuel system (see ’Bleeding
3. EGR valve bolts Procedure’).
– Fit the heater air intake duct.
13. Fit the EGR valve (8 mm) using a new
‘O’ ring. Connect EGR pipe (2 x
terminal(s) first.
10 mm bolts), and secure the harness
– Bleed the fuel system.
bracket (8 mm).
106
FUEL INJECTION PUMP
Remove / Refit
IMPORTANT NOTE: if a new fuel injection
pump is to be fitted, it has to be
configured to the powertrain control
module (PCM) using Laser 2000 before
the engine can be started. Ensure you
have access to the necessary equipment
before starting this work.
when working on or near any fuel A106-006
related components. Fuel vapour can Fig.1 EVR valve
FUEL SYSTEM
personal injury. – Disconnect the pipes and multiplug
from the EVR valve.
CAUTION: Fuel injection equipment is – Remove the heater air intake duct .
manufactured to fine clearances. it is – Remove the deflector plates (ease
essential to observe absolute headlights forward to access the
cleanliness when working on any part fixings).
of the system. Always cap any open – Unbolt the cowl (if fitted) from the
pipe or connector. radiator.
– Remove the radiator.
Remove
– Detach the fuel filter and secure to
Tools Required: LDV 167, LDV 168, one side.
LDV 169. LDV 170, LDV 173. – Detach the air intake duct from the
EGR valve.
The fuel injection pump can be removed – Disconnect the fuel supply and return
with the engine in situ by first carrying out pipes to the injection pump. Cap the
the following operations connections.
WARNING: If the engine has 1. Remove the viscous fan using tool
been running recently, the MS 1517 (right hand thread).
components may be sufficiently hot to 2. Remove the external drive belt (see
cause burning to skin on contact. section ‘External Drive Belt’).
– Switch off the ignition. 3. Remove the idler pulley (15 mm).
– Disconnect the battery(s), negative
(earth) terminal(s) first.
– Drain coolant by removing the lower
radiator hose.
– Remove the radiator grille.
– Detach the power steering reservoir
and secure to one side.
locking platform.
107
2
1 4
2
3
2 1
A106-032

1. Inlet manifold
2. Manifold gaskets
FUEL SYSTEM
3 3. EGR valve ’O’ ring

4 4. EGR valve
A106-030
Fig.2 EGR valve 6. Remove the inlet manifold (9 x 10 mm

1. EGR valve bolts).
2. Vacuum / pressure pipes Cover the inlet ports to prevent the
3. EGR position sensor ingress of foreign objects.
sensor.
A106-031
Fig.3
1. Harness bracket
2. EGR pipe bolts A106-033
3. EGR valve bolts

5. To remove the EGR valve: 7. Disconnect the cylinder head
unbolt harness bracket (8 mm), temperature sensor (CHT) as
– detach EGR pipe (2 x 10 mm illustrated. (slide red security cover
bolts) at the rear. back and press down on lock to
– detach EGR valve from inlet release connector)
108
1
2
A106-034
Fig.6 Releasing fuel return pipe A106-036
connector
8. Disconnect the fuel return pipe Fig.8 Releasing injector pipe at

connector. injection pump.
FUEL SYSTEM
9. Remove the inlet coolant hose (water when disconnecting injector
pump to coolant manifold).
pipes at the injection pump.
Disconnect injector pipes 3 and 4
at the fuel injector pump (14 &
17 mm), then disconnect the
same pipes at their injectors
(19 mm).

same way.

by pipes 3 and 4.
– NOTE: The 4 injector dust seal

A106-035
installers supplied as tool
LDV 168 can be used to cover
Fig.7 Injector pipes the exposed injector connections.
10. Remove the injector pipes as follows: injector connections to prevent
– Detach the bracket (3 x 10 mm) ingress of dirt.
camshaft carrier.
109
A
A106-175
FUEL SYSTEM
Fig.9 Disconnecting injection pump

electrical connector
11. Slide out the locking tag and

disconnect the electrical connector at
the injection pump.
1
1
B A106-016
Fig.11 Locating 505 BTDC timing

position
1. Timing pin LDV 173
14. Turn the crankshaft clockwise until the
timing hole in the injection pump
sprocket almost aligns (see illustration
‘A’).
A106-176
Slowly continue to turn the crankshaft
Fig.10 Removing injection pump until timing pin LDV 173 engages in
sprocket access cover its slot in the flywheel (see illustration
‘B’).
1. Tool LDV 170
The crankshaft is now positioned at
12. Use tool LDV 170 as illustrated to 50° BTDC (timing position).
remove the injection pump sprocket
access cover. CAUTION: Do not attempt to turn
the engine while the timing pin is
13. Remove the crankshaft position fitted; damage to the sensor
sensor. location may result.
110
1
A106-178
2
Fig.12 Removing injection pump
FUEL SYSTEM
securing bolts
15. Access to the three injection pump

securing bolts is through the holes
indicated in the sprocket.
NOTE: The bolts cannot be
completely removed.
Unscrew the injection pump securing
bolts (3 x T45), and disengage them
from the pump body.
A106-233
Fig.13A Fitting injection pump

sprocket retainer
1. Tool LDV 169
2. Tool LDV 170
16. NOTE: If the pump sprocket is not

secured correctly, it may be
necessary to remove the timing cover
and reset the chain tensioner.
Secure the pump sprocket as follows:
– Locate tool LDV 169 in the pump
sprocket aperture, and use tool
LDV 170 to turn it clockwise.
111
2
X
1
A106-236
2
Y Fig.14 Injection pump sprocket
FUEL SYSTEM
1 securing bolts
17. Remove the injection pump sprocket
A106-179
Fig.13B
1. Tool LDV 169
2. Tool LDV 170
– Continue to turn LDV 169 until

one of the holes in the tool aligns
with a pump securing bolt access
hole in the sprocket (see
illustration ‘X’).
– Fit one of the 3 pins supplied with

tool LDV 167 through that hole
and engage in the sprocket.
– Turn tool LDV 169 slightly in

either direction until the other two
pins can be engaged in the other
two sprocket holes (see
illustration ‘Y’).
Remove tool LDV 170.
112
1
A106-181
Fig.16 Fuel supply and return pipes
3 20. If necessary, remove the supply and

return fuel pipes from the injection
FUEL SYSTEM
A106-180
pump. Discard the sealing washers.
Fig.15 Detaching pump rear mounting
bracket Refit
1. Bolts – bracket to injection pump 21. If removed, fit the supply and return
2. Bolts – bracket to cylinder block fuel pipes to the injection pump,
18. Slacken the 2 bolts (13 mm) securing using new sealing washers.
the rear of the injection pump to its
mounting bracket.
2
Remove the 2 bolts securing the
mounting bracket to the cylinder
block. 3
19. Remove the injection pump. Check
that the spacer shim on the front of
the pump flange is not displaced.
Discard the gasket.
NOTE: If a new pump is to be fitted, it
will be supplied with a spacer shim
which MUST be used.
1 A106-182
Fig.17 Timing injection pump

1. Spacer shim
2. Gasket
3. Timing pin LDV 167
22. Fit a timing pin LDV 167 through the
slot in the injection pump flange and
into the timing hole in the pump.
113
23. Check that the spacer shim is
correctly fitted on the pump drive
flange.
Fit a new gasket and bend the 2 tabs
around the pump flange to prevent
rotation.
Clean the threads of the 3 pump
securing bolts, then apply Loctite 270.
Locate the injection pump and loosely
secure its rear mounting bracket to
the cylinder block.
24. Fit the 4 sprocket retaining bolts; nip
tighten them then back off by a A106-178
quarter turn. Fig.19 Securing injection pump front

FUEL SYSTEM
mounting bolts
1 26. Locate and tighten the injection pump

front securing bolts (3 x T45) to
22 Nm.
27. Tighten the 4 injection pump sprocket
securing bolts to 32 Nm.
28. Remove the injection pump timing pin
LDV 167.
29. Use tool LDV 170 to refit the injection
pump sprocket access cover.
2 30. Progressively tighten the 4 pump rear
A106-183 mounting bracket bolts to 22 Nm, to
Fig.18 Unlocking injection pump pull the bracket to the pump and to
sprocket the cylinder block.
1. Tool LDV 169
2. Tool LDV 170
25. Remove the 3 pins and remove tool
LDV 169 by turning it anti–clockwise
with tool LDV 170.
114
• Do NOT over–tighten. The
correct torque of the unions is
35 Nm.
be renewed.
Fit the injector pipes in the following
sequence:
1 slot in the cylinder head between
5 / 6 inlet ports.
A106-231 – Locate pipes 1 and 2 through the
Fig.20 Crankshaft timing pin slot in the cylinder head between
FUEL SYSTEM
1. LDV 173 3 / 4 inlet ports.
– Connect and tighten pipes 1 and
31. Remove the crankshaft timing pin 2. Do not over–tighten.
LDV 173 and refit the crankshaft – Connect and tighten pipes 3 and
position sensor. 4. Do not over–tighten.
– Fit the stay bracket. Carefully
tighten the nuts progressively to
avoid placing any of the pipes
under tension.
33. Connect the injection pump electrical
connector and slide its locking tag into
position.
34. Connect the CHT lead to its
connector.
A106-035
32. IMPORTANT: The mating coned

are designed to provide a leak–free
seal when connected for the first time,
and if used more than once a leak
pipes should be used, but it may be
possible to re–use the pipes if the
• Observe absolute cleanliness at
the mating faces.
115
2
4
1
3 2
1
A106-032 2
Fig.22 Fitting inlet manifold
1. Inlet manifold
2. Manifold gaskets
FUEL SYSTEM
4. EGR valve 3
4
36. Renew any inlet manifold gaskets as A106-030
necessary. Fit the manifold and Fig.24 EGR valve

tighten the bolts (10 mm) to 15 Nm. 1. EGR valve
37. Refit the water pump to coolant 2. Vacuum/pressure pipes
manifold hose. 3. EGR position sensor
3 pipes and position sensor.
40. Fit the external drive belt (see section
‘External Drive belt Remove / Refit’.
2
If the injection pump has been removed
with the engine in situ:
1 – Refit the radiator and front end
components in the reverse of the
removal procedure.
A106-031
– Connect the pipes and multiplug to
Fig.23 the EVR valve.
1. Harness bracket – Fit the air intake duct to the EGR
2. EGR pipe bolts valve.
3. EGR valve bolts – Fit the fuel filter.
– Connect the fuel supply and return
38. Fit the EGR valve (8 mm) using a new pipes to the injection pump.
‘O’ ring. Connect the EGR pipe (2 x – Bleed the fuel system (see ‘Bleeding
10 mm bolts), and secure the harness Procedures’).
bracket (8 mm). – Fit the heater air intake duct .
– Check the engine oil level and top up
as required.
terminal(s) first.
necessary.
116
EXHAUST SYSTEM 4
TURBOCHARGER 5
Remove / Refit
Remove
The turbocharger can be removed in situ.
WARNING: If the engine has 2
been running recently, the
components may be sufficiently hot to
NOTE: the turbocharger is only available
complete with the exhaust manifold. The
wastegate linkage and turbocharger 1
alignment to the manifold is pre–set and
must not be disturbed.
1. Remove the crankcase vent pipe, the
3
dipstick and the dipstick tube
(10 mm). Do not bend the tube. A106-053
Fig.1 Turbo oil pipe connections

2. Disconnect at the turbo:
1. Oil return pipe
– The intake air duct. 2. Gasket
– The air outlet duct to the EGR
EXHAUST
3. ‘O’ ring
SYSTEM
valve. 4. Oil feed pipe
5. Copper washers
3. Disconnect the turbocharger oil return

pipe (10 mm) to the ladder frame;
discard the gasket and ‘O’ ring.
Disconnect the oil feed pipe (13 mm)
at the turbo, discarding the 2 copper
sealing washers.
Cap the pipes and turbo connections
to prevent ingress of dirt.
4. Remove the 4 nuts (15 mm) securing
the exhaust down pipe.
Discard the flange gasket.
117
7. Support the manifold and turbo
2 assembly while removing the 2 studs
3
(E8 torx). Note the position of the
studs for re–assembly.
1 Remove the manifold.

Discard the manifold gasket.
Extract and discard any remains of
the plastic sleeve at the front
A106-052
mounting.
Fig.2 Detaching EGR pipe
8. If necessary remove the air intake
5. Slacken the bolt (1) securing the EGR elbow (2 x 10 mm) to renew the
pipe to the rear of the cylinder head. sealing ring.
Remove the clamp (2) securing the Refit
pipe to the exhaust manifold. Discard
9. Fit a new exhaust manifold gasket.
the gasket (3).
Fit a new plastic sleeve to the exhaust
1 manifold front mounting, and locate
and secure the manifold using new
2 3
4 studs, nuts (16 mm) and bolts
1
13 mm).
Tighten the securing nuts / bolts to
40 Nm.
10. Connect the EGR pipe to the exhaust
EXHAUST
SYSTEM
manifold using a new gasket.

Tighten the pipe–to–cylinder head
bracket.
11. Fit the exhaust down pipe using a
A106-054 new gasket. Tighten the nuts to
Fig.3 Exhaust manifold 40 Nm.
1. Studs
12. Connect the turbocharger oil return
2. Gasket
pipe (10 mm) to the ladder frame
3. Plastic sleeve
using a new gasket and ‘O’ ring.
4. Exhaust manifold
Prime the turbo by filling with clean
6. Remove and discard the bolts / nuts engine oil.
(6 x 13 mm bolts, 2 x 16 mm nuts) Connect the turbo feed pipe (13 mm)
securing the manifold to the cylinder using new copper washers.
head. 13. Connect the air duct and EGR duct.
Discard the nuts and bolts.
14. Refit the dipstick tube and dipstick.
Connect the crankcase vent pipe.
118
EXHAUST GAS RECIRCULATION (EGR) SYSTEM
1
4
3
6 8
5 7
EXHAUST
SYSTEM
A106-192
Fig.1 EGR system

1. Turbocharger 3. Exhaust manifold 6. EGR valve
2. Wastegate 4. Inlet manifold 7. Exhaust vacuum regulator (EVR)
5. EGR position sensor 8. Air temperature sensor
OPERATION
This has the effect of ‘diluting’ the
The EGR system is fitted to reduce incoming air to reduce surplus Oxygen,
noxious Nitrogen Oxide (NOx) exhaust leaving just sufficient for complete
emissions. combustion.
Under certain driving conditions (e.g. idle Opening and closing of the EGR valve is
and light throttle), more Oxygen can enter operated by vacuum. This vacuum is
the combustion chambers than is required supplied from the vacuum pump via the
for burning. It then combines with solenoid operated exhaust vacuum
Nitrogen to form NOx. regulator (7), mounted on the air deflector
The EGR valve (6) is fitted to the air on the left hand side of the radiator.
intake tract of the inlet manifold (4), and is Operation of this regulator (EVR) is
piped to the exhaust system (3) around controlled by the powertrain control
the back of the engine. When the valve is module (PCM).
open, it allows exhaust gases (which A position sensor (5) is mounted on the
contains very little oxygen) to mix with the EGR valve to signal its position to the
incoming air. PCM.
119
EXHAUST GAS RECIRCULATION (EGR)
VALVE 3
Remove / Refit
The EGR valve can be removed with the
engine in situ by first carrying out the
following operations 2
Disconnect the battery(s), negative 1
terminal(s) first.
– Remove the heater air intake duct. A106-031
– Detach the fuel filter and secure to Fig.2

one side. 1. Harness bracket
– Disconnect the air intake duct at the 2. EGR pipe bolts
EGR valve. 3. EGR valve bolts

1 – detach EGR pipe (2 x 10 mm
bolts) at the rear,
– detach EGR valve from inlet
2
3. Fit the EGR valve using a new ’O’
ring. Connect EGR pipe, and secure
EXHAUST
2
SYSTEM
the harness bracket.

pipes and position sensor.
3
4 If the EGR valve has been removed with
A106-030
the engine in situ:
Fig.1 EGR valve – Connect the air intake duct to the
1. EGR valve EGR valve.
2. Vacuum / pressure pipes – Fit the fuel filter.
3. EGR position sensor – Fit the heater air duct.
4. Air temperature sensor – Connect the battery(s), positive
terminal(s) first.
sensor.
120
COOLING SYSTEM
4 5
1 A B C 2 D 3 E
7
G
8
H
L 9 K J A106-195
Fig.1 Cooling system circulation

1. Radiator 6. Expansion tank
2. Thermostat housing 7. Oil cooler coolant thermostat
3. Coolant inlet manifold 8. Oil cooler
4. Heater by–pass valve 9. Water pump
5. Heater
COOLING
SYSTEM
COOLANT CIRCULATION
The water pump (9) is driven by the If the thermostat is closed, coolant is
external drive belt, and therefore coolant directed back to the water pump via the
is circulating whenever the engine is by–pass hose (K). When the thermostat
running. is open, coolant can pass to the radiator
(1) via the top hose (A), and return from
From the water pump, coolant is directed there to the water pump via the bottom
through the inlet hose (J) to the coolant hose (L).
inlet manifold (3) and into the engine.
After passing up through the engine,
coolant exits via the outlet elbow and hose
(B) to the thermostat housing (2).
121
An oil cooler (8) is fitted, and coolant COOLANT DRAIN AND REFILL
passes through it via supply and return
hoses (G). The supply hose is connected Drain
to the coolant inlet manifold via the oil WARNING: If the engine has
cooler coolant thermostat (7); this been running recently, the
thermostat will only open to allow coolant cooling system and engine
to flow to the oil cooler when the coolant components may be sufficiently hot to
in the inlet manifold has reached a cause burning to skin on contact.
pre–determined temperature. The return
1. Set the cab heater control to the ‘hot’
hose from the oil cooler directs the
position.
coolant to a ‘T’ piece in the heater supply
hose (E) which carries coolant from the 2. WARNING: If the engine is
thermostat housing to the heater (5). hot, place a large, thick cloth
On its way to the heater, the coolant over the filler cap and expansion
tank before attempting to remove
passes through the heater by–pass valve
the cap slowly, to prevent the
(4), which will open if coolant pressure is
possibility of scalding.
excessive to allow this pressure to be
dissipated directly into the heater return Remove the expansion tank pressure
hose (F). cap.
The cooling system is filled via the 3. Position a suitable drain container
expansion tank (6) and hose ‘H’. under the vehicle.
Hoses ‘C’ and ‘D’ are air bleeds.
GENERAL PRECAUTION
Many of the hoses used on this
engine have alignment marks at
each end. To avoid stress, these
marks must be aligned with the
marks on the connections they are
fitted to.
COOLING
SYSTEM
A106-196
Fig.1 Cylinder block drain plug

4. Remove the cylinder block drain plug.
5. Disconnect the radiator bottom hose.
122
Refill WATER PUMP
6. Apply Hylomar to the drain plug, fit Remove / Refit
and tighten to 18 Nm.
Remove
7. Connect the radiator bottom hose.
The water pump can be removed with the
engine in situ by first carrying out the
following operations.
– Disconnect the battery(s), negative
termoinal(s) first.
– Drain the coolant (see ‘Coolant Drain
& Refill’).
– Remove the heater air intake duct.
– Disconnect the air intake duct at the
EGR valve.
‘External Drive Belt Remove / Refit’).
A106-234
Fig.2 Expansion tank 2. Detach the wiring harness at the

vacuum pump.
8. Fill the system slowly through the
expansion tank with the specified 3. Disconnect the following hoses at the
coolant (50% anti–freeze) to the MAX water pump:
mark on the tank. Fit the cap.
– to coolant manifold on cylinder
Start the engine and warm to normal block,
operating temperature.
9. WARNING: If the engine is – to radiator,
hot, place a large, thick cloth
over the filler cap and expansion – to heater,
tank before attempting to remove
the cap slowly, to prevent the – to expansion tank,
possibility of scalding.
COOLING
SYSTEM
Remove the cap and top up as – to thermostat housing,

necessary.
– to by pass.
Check the system for leaks.
4. Disconnect the vacuum pipe from the
vacuum pump to the brake servo.
123
1
3 2 5
1
3 A106-199
Fig.2 Water pump / vacuum pump

assembly
2 A106-010
1. Vacuum pump
Fig.1 Removing water pump / 2. Gasket
vacuum pump 3. Water pump
1. Vacuum pump 4. ‘O’ ring
2. Water pump 5. Hose connector
6. CAUTION: If either component is to
5. CAUTION: Do not allow dirt to be refitted do not allow dirt to enter
enter the oilway in the cylinder the oilways.
block when the water pump is Remove 3 bolts (10 mm) to separate
removed. the vacuum pump from the water
COOLING
SYSTEM
Detach the water pump / vacuum pump.

pump assembly from the cylinder
block (4 x 10 mm bolts). Discard the gasket.
Discard the gasket. Refit

Reasembly is the reverse of the above
removal procedure, noting the following:
– Do not allow dirt to enter the oilways.
– Fit new vacuum pump and water
pump gaskets.
– Ensure hoses are fitted to align with
the original alignment marks.
– The coolant must be a 50 / 50
anti–freeze / water mix.
124
ENGINE BREATHING SYSTEM
1
2
4 5
A106-200
Fig.1 Engine breathing system

1. Air bleed hole 4. To turbo air intake
2. Diaphragm 5. From crankcase/camshaft chambers
3. Spring
DESCRIPTION
The Duratorq engine utilises a closed breathing system.
A valve is built in to the right hand rear of the camshaft cover. It is linked by an external
pipe to the intake air duct near the turbocharger. The valve comprises a diagphragm and
a spring. In its rest position the diaphragm is held up in the open position by the coil
spring underneath it. A small hole in the valve cover allows air to enter if the conditions
require the valve to close.
The system works as follows:
The depression created at the lower end of the breather pipe by air being drawn into the
engine causes air to be drawn through the pipe and fumes to be drawn out of the engine
through the valve. Any pressure build up in the crankcase can pass freely upwards
through oil drain passages in the cylinder head and camshaft carrier to the rocker area
under the camshaft cover, and will be dissipated though the breather pipe in the same
way.
Under conditions of high depression too much suction could be sufficient to pull oil
ENGINE BREATHING
through the system, into the combustion chambers, and create smoke. To ensure this
cannot happen the high suction will cause the valve to be pulled down against spring
pressure and shut off the air flow.
SYSTEM
NOTE:
1. If the breather hole in the valve cover becomes blocked the diaphragm will be
unable to be pulled down sufficient to close the valve, and black smoke will result.
Do not stick labels on the valve cover. Use the end of a paper clip or similar to
unblock the hole but do not push in too far – the diaphragm may be pierced.
2. If the diaphragm becomes split, this will allow air to be drawn in through the valve
cover hole at all times. The valve will not then close and blue smoke will result.
125
Part Number MVP104601GB

LDV Convoy Duratorq Engine Workbook

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LDV Convoy Duratorq Engine Workbook

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SERVICE WORKBOOK

2.4 DURATORQ Diesel Engine

Clutch – remove / refit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Coolant circulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Engine breathing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

REPAIRS AND REPLACEMENTS

ABBREVIATIONS & ACRONYMS

Main bearing radial clearance:

Piston clearance in bore 0.05 – 0.07 mm

Piston stand–proud 0.310 – 0.50 mm

Gudgeon pin diameter 32.00 – 31.996 mm

Pressure cap setting 1.2 bar

RENEW ENGINE OIL & FILTER

CHECK COOLING SYSTEM PRESSURE CAP.

Renew Renew Renew

Flange holder Clutch aligner

Seal Breaker • Timing pins

• Injector seal installer • Injection pump sprocket retainer

• Crankshaft front seal remover/replacer Angular torque gauge

• denotes new tool

Viscous coupling spanner Valve spring compressor

• Valve collett installer • Ladder frame aligner

• Crankshaft timing pin • Injector remove/ refit socket

• Injector aligning plate • CHT sensor socket

• denotes new tool

• Timing cover centraliser • Alternator decoupler

• Oil filter wrench • Oil pump aligner

• Hose clip pliers

• denotes new tool

0484976 (DX 710)

Laser 2000 Injector tester

Power steering pump mounting bolts 22

EXTERNAL DRIVE BELT

Fig.1 External drive belt

NOTE: If a fan cowl is fitted, it is first

Refitting is the reverse of the removal

Fig.2 Releasing drive belt tension.

4. Use tool LDV 170 to remove the

1 Discard the seal.

Fig.1 Removing crankshaft pulley bolts

Fig.1 EVR valve Fig.3 Coolant outlet

1. Coolant outlet pipe

Fig.4 Detaching thermostat housing

Fig.5 Removing water pump / vacuum

Fig.8 Removing crankshaft front seal

1. Tool LDV 132

– Discard the coolant outlet gasket.

2 Fig.13 De–tensioning timing chain

16. De–tension the timing chain tensioner

Thoroughly lubricate sprockets, chain,

Fig.15 Fitting the chain guides

23. Fit the tensioner guide followed by the

22. NOTE: Ensure that the three copper

29. To fit the timing cover: Ensure sealant is applied across

Fig.19 Fitting coolant outlet gasket Fig.21 Fitting timing cover

Fig.20 Applying sealant

Fig.22 Fitting crankshaft oil seal

Fig.23 Fitting idler pulley

Fig.24 Fitting coolant outlet elbow

36. Using a new ‘O’ ring (and a new air

If the work is being carried out in situ:

WARNING: If the engine has Fig.2 EGR pipe

Fig.3 Inlet manifold

Fig.1 EGR valve 3. Remove the inlet manifold (9 x 10 mm