Specifications

ManualsBrandsArrow ManualsLawn and GardenVM1012-B

2.5L VM DIESEL

INDEX

page page

GENERAL INFORMATION

ENGINE IDENTIFICATION ................. 37

GENERAL SPECIFICATION ................ 36

DESCRIPTION AND OPERATION

LUBRICATION SYSTEM .................. 37

DIAGNOSIS AND TESTING

ENGINE DIAGNOSIS—MECHANICAL ......... 0

ENGINE DIAGNOSIS—PERFORMANCE ...... 38

HYDRAULIC TAPPETS ................... 39

SERVICE PROCEDURES

CHANGING ENGINE OIL AND FILTER ....... 40

CHECKING OIL LEVEL ................... 40

CRANKSHAFT END PLAY ................. 43

FITTING PISTON RING ................... 43

TIMING PROCEDURE .................... 41

VALVE AND SEAT REFACING .............. 42

REMOVAL AND INSTALLATION

CAMSHAFT BEARINGS .................. 60

CAMSHAFT............................ 59

CRANKSHAFT MAIN BEARINGS ............ 60

CRANKSHAFT SPROCKET ................ 58

CRANKSHAFT—REMOVAL ................ 71

CYLINDER HEAD COVER ................. 47

CYLINDER HEAD ....................... 49

CYLINDER LINER ....................... 70

ENGINE ASSEMBLY ..................... 46

ENGINE MOUNT—FRONT ................ 44

ENGINE MOUNT—REAR ................. 45

ENGINE MOUNT—RIGHT ................. 44

HYDRAULIC TAPPETS ................... 53

HYDRAULIC TENSIONER ................. 59

INJECTION PUMP ....................... 54

MOUNT—LEFT SIDE .................... 45

OIL FILTER ADAPTER AND OIL COOLER ..... 64

OILPAN .............................. 63

OIL PUMP PRESSURE RELIEF VALVE ....... 64

OIL PUMP ............................. 63

PISTONS AND CONNECTING ROD ......... 68

REAR CRANKSHAFT OIL SEAL ............ 71

ROCKER ARMS AND PUSH RODS .......... 48

TIMING CHAIN COVER OIL SEAL ........... 54

TIMING CHAIN COVER ................... 55

TIMING CHAIN ......................... 55

VACUUM PUMP ........................ 64

VALVE SPRINGS—

CYLINDER HEAD NOT REMOVED ......... 48

VALVES AND VALVE SPRINGS—HEAD OFF . . . 53

VIBRATION DAMPER .................... 54

DISASSEMBLY AND ASSEMBLY

HYDRAULIC TAPPETS ................... 71

CLEANING AND INSPECTION

CRANKSHAFT MAIN BEARING ............. 76

CRANKSHAFT ......................... 76

CYLINDER HEAD COVERS ................ 72

CYLINDER HEAD ....................... 72

CYLINDER LINER ....................... 77

HYDRAULIC TAPPETS ................... 75

OILPAN .............................. 77

OIL PUMP ............................. 75

PISTON AND CONNECTING ROD ........... 75

ROCKER ARMS AND PUSH RODS .......... 72

TIMING CHAIN COVER ................... 74

VALVES AND VALVE SPRINGS ............. 74

SPECIFICATIONS

2.5L VM DIESEL ........................ 77

TORQUE .............................. 78

SPECIAL TOOLS

2.5L VM DIESEL ........................ 80

GENERAL INFORMATION

GENERAL SPECIFICATION

Type ........................425CLIEE (36B)

Displacement ...................2.5L (2499 cc)

Bore .............................92.00 mm

Stroke ............................94.00 mm

Compression Ratio ....................20.95:1

Vacuum at Idle ..........600mm/Hg (23.6 In/Hg)

Thermostat Opening ................80°C62°C

Generator Rating ............Bosch 50/120 Amp

Cooling System Capacity ..............9.5Liter

Type ........................425CLIEE (36B)

Power Steering Capacity .............0.75 Liter

Engine Oil Capacity .............6.8Liters With

Oil Filter Change

Timing System . Pushrod Operated Overhead valves,

With Chain-Driven Camshaft.

Air Intake ........................DryFilter

Fuel Feed ...........Vacuum Pump Incorporated

in Injection Pump.

Fuel System .............Indirect Fuel Injection

(Precombustion Chamber)

Combustion Cycle ....................4Stroke

Cooling System ..................Water Cooled

9 - 36 ENGINE NS/GS

Summary of content (49 pages)

PAGE 1
9 - 36 ENGINE NS/GS 2.5L VM DIESEL INDEX page GENERAL INFORMATION ENGINE IDENTIFICATION . . . . . . . . . . . . . . . . . GENERAL SPECIFICATION . . . . . . . . . . . . . . . . DESCRIPTION AND OPERATION LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . DIAGNOSIS AND TESTING ENGINE DIAGNOSIS—MECHANICAL . . . . . . . . . ENGINE DIAGNOSIS—PERFORMANCE . . . . . . HYDRAULIC TAPPETS . . . . . . . . . . . . . . . . . . . SERVICE PROCEDURES CHANGING ENGINE OIL AND FILTER . . . . . . . CHECKING OIL LEVEL . .
PAGE 2
ENGINE NS/GS 9 - 37 GENERAL INFORMATION (Continued) Type . . . . . . . . . . . . . . . . . . . . . . . . 425CLIEE (36B) Injection Pump . . . . . . . . . . . . . . . . . . Rotary Pump Electronically Controlled. Lubrication . . . . . . . . . . . . . Pressure Lubrication by Rotary Pump, Full-Flow Filtration. Engine Rotation . . . . . . . . . . . . . . Clockwise Viewed From Front Cover.
PAGE 3
9 - 38 ENGINE NS/GS DIAGNOSIS AND TESTING ENGINE DIAGNOSIS—PERFORMANCE CONDITION ENGINE WILL NOT CRANK OR CRANKS SLOWLY POSSIBLE CAUSES 1. Starting motor operating, but not cranking the engine. 2. Crankshaft rotation restricted. 3. Starting circuit connections loose or corroded. 4. Neutral safety or starter relay inoperative. 5. Battery charge low. 6. No voltage to starter solenoid. 7. Solenoid or starter motor inoperative. ENGINE CRANKS, BUT WILL NOT START, NO SMOKE 1. No fuel in supply tank. 2.
PAGE 4
ENGINE NS/GS 9 - 39 DIAGNOSIS AND TESTING (Continued) CONDITION LUBRICATING OIL PRESSURE LOW POSSIBLE CAUSES 1. Low oil level. 2. Oil viscosity thin, diluted, or wrong specification. 3. Improperly operating pressure switch/gauge 4. Relief valve stuck open. 5. Plugged oil filter. 6. Oil cooler was replaced, shipping plugs left in cooler. 7. Worn oil pump. 8. Suction tube loose or seal leaking. 9. Worn bearing or wrong bearing installed. 10. Oil jets under piston loose or bad fit.
PAGE 5
9 - 40 ENGINE NS/GS DIAGNOSIS AND TESTING (Continued) oil level, check dipstick. The oil level in the pan should never be above the FULL mark or below the ADD OIL mark on dipstick. Either of these 2 conditions could be responsible for noisy tappets. OIL LEVEL HIGH If oil level is above the FULL mark, it is possible for the connecting rods to dip into the oil. With the engine running, this condition could create foam in the oil pan.
PAGE 6
ENGINE NS/GS 9 - 41 SERVICE PROCEDURES (Continued) Run engine until achieving normal operating temperature. (1) Position the vehicle on a level surface and turn engine off. (2) Remove oil fill cap. (3) Hoist vehicle. Refer to Hoisting and Jacking Recommendations. (4) Place a suitable drain pan under crankcase drain. (5) Remove drain plug from crankcase and allow oil to drain into pan (Fig. 5). Inspect drain plug threads for stretching or other damage. Replace drain plug if damaged.
PAGE 7
9 - 42 ENGINE NS/GS SERVICE PROCEDURES (Continued) VALVE AND SEAT REFACING VALVE REFACING (1) Use a valve refacing machine to reface the intake and exhaust valves to the specified angle. (2) After refacing, a margin of at least 4.52-4.49 mm (.178-.177 inch) must remain (Fig. 9). If the margin is less than 4.49 mm (.177 inch), the valve must be replaced. VALVE SEAT REFACING (1) Install a pilot of the correct size in the valve guide bore.
PAGE 8
ENGINE NS/GS 9 - 43 SERVICE PROCEDURES (Continued) Fig. 10 Checking Valve Stand Down Fig. 11 Valve Guide Height FITTING PISTON RING (1) Wipe cylinder bore clean. Insert ring and push down with piston to ensure it is square in bore. The ring gap measurement must be made with the ring positioning at least 12 mm (0.50 in.) from bottom of cylinder bore (Fig. 12). Check gap with feeler gauge. Top compression ring gap .25 to .50mm (.0098 to .0196 in.). Second compression ring gap .25 to .35mm (.0098 to .
PAGE 9
- 44 ENGINE NS/GS SERVICE PROCEDURES (Continued) Fig. 12 Ring Gap Measurement Fig. 14 Measuring Crankshaft End Play REMOVAL AND INSTALLATION ENGINE MOUNT—FRONT (1) Disconnect battery. (2) Remove lower air dam at front fascia. (3) Remove the bolts holding tow bracket and front mount to the lower crossmember. (4) Remove thru bolt in engine mount (Fig. 15). Remove mount. (5) Reverse removal procedure for installation. (6) Torque engine mount thru bolt to 65 N·m (48 ft. lbs.
PAGE 10
ENGINE NS/GS 9 - 45 REMOVAL AND INSTALLATION (Continued) (7) Torque engine mount top bolt (Vertical) to 101 N·m (75 ft. lbs.) (8) Torque engine mount thru bolt (Horizontal) to 145 N·m (107 ft. lbs.) (9) Torque engine mount to frame bolts to 68 N·m (50 ft. lbs.) (5) Disconnect both shifter cables at transmission. Remove the retainers holding the cables to the mount (Fig. 19). (6) Remove the mount assembly. (7) Reverse removal procedure for installation. (8) Install mount assembly.
PAGE 11
9 - 46 ENGINE NS/GS REMOVAL AND INSTALLATION (Continued) (6) Disconnect oil pressure switch connector (Fig. 20). (7) Disconnect Wiring harness bracket at transaxle shift tower. (8) Disconnect transaxle wiring at speed sensor, crank sensor, and backup light switch. (9) Remove both transmission shift cables at transmission. (10) Remove negative battery cable at cylinder block (Fig. 20). (11) Remove oil separator. (12) Remove connectors at coolant temperature sensor and A/C compressor.
PAGE 12
ENGINE NS/GS 9 - 47 REMOVAL AND INSTALLATION (Continued) (43) Mount both special tool, engine support brackets VM-1026 to cylinder block (Fig. 22). (44) Using engine dolly and cradle assembly with 4 adjustable posts align posts with holes in the engine support brackets. Fig. 21 Right Side Splash Shield (24) Remove fuel line at injector pump and cap. (25) Remove power steering reservoir and reposition. (26) Remove upper radiator crossmember. (27) Disconnect cooling fan module connector.
PAGE 13
9 - 48 ENGINE NS/GS REMOVAL AND INSTALLATION (Continued) (5) Connect battery cable. ROCKER ARMS AND PUSH RODS REMOVAL (1) Disconnect the battery cables. (2) Remove generator bracket. (3) Remove breather hose. (4) Remove coolant pressure tank. (5) Remove cylinder head cover. (6) Remove rocker retaining nuts (Fig. 23). Fig. 23 Rocker Arm Retaining Nut (7) Remove rocker assembly. Place them on a bench in the same order as removed.
PAGE 14
ENGINE NS/GS 9 - 49 REMOVAL AND INSTALLATION (Continued) CYLINDER HEAD REMOVAL (1) Disconnect the battery cable. WARNING: DO NOT REMOVE THE CYLINDER BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR DRAIN COCK WITH THE SYSTEM HOT AND PRESSURIZED BECAUSE SERIOUS BURNS FROM THE COOLANT CAN OCCUR. (2) Drain the cooling system. Refer to Group 7, Cooling. (3) Remove wiper module. Refer to Group 8K, Windshield Wiper Unit Removal for procedure. (4) Remove coolant pressure bottle.
PAGE 15
9 - 50 ENGINE NS/GS REMOVAL AND INSTALLATION (Continued) Fig. 27 Rocker Arm Oil Feed Lines (20) Remove Crankcase breather hose from valve cover (21) Remove the engine cylinder head cover. (22) Remove the injector sensor wire at the connector, and glow plug Connectors. Fig. 29 Fuel Injector (25) Remove rocker retaining nuts (Fig. 30). NOTE: The attachment point for the injector sensor wire at the injector is not a connector. The connector is located in the wire 4 to 6 inches away from the injector.
PAGE 16
ENGINE NS/GS 9 - 51 REMOVAL AND INSTALLATION (Continued) (30) Remove the engine cylinder heads and gasket. NOTE: A single steel head gasket is used for 4 cylinder heads (Fig. 33). (31) Stuff clean lint free shop towels into the cylinder bores. CYLINDER HEAD GASKET NOTE: If cylinder wall liners have not been removed; the same thickness head gasket removed, may be used. Fig.
PAGE 17
9 - 52 ENGINE NS/GS REMOVAL AND INSTALLATION (Continued) (5) Tighten the engine cylinder head bolts in sequence according to the following procedure (Fig. 34): a. The threads and underside heads of the bolts should be lubricated. Use the cylinder head alignment studs tool number VM-1009. Position the heads on the block and secure with the ten large center bolts and spacers (clamps), finger tight only. b.
PAGE 18
ENGINE NS/GS 9 - 53 REMOVAL AND INSTALLATION (Continued) (21) Connect crankcase breather hose. (22) Connect the injector sensor wire connector, and the glow plug connectors. (23) Install oil feed line, tighten banjo bolts to 12.7 N·m (108 in. lbs), and oil drain line to turbo. (24) Install water manifold tighten bolts to 12 N·m (106 in. lbs.). (25) Install exhaust pipe to turbo elbow, tighten bolts to 28 N·m (250 in. lbs.). (26) Install the support strut from block to turbocharger exhaust elbow.
PAGE 19
9 - 54 ENGINE NS/GS REMOVAL AND INSTALLATION (Continued) (6) Remove engine starter. Refer to Group, 8B for procedure (7) Install flywheel locking tool VM.1014 to prevent engine rotation. NOTE: Crankshaft thread. damper nut is left handed (8) Remove vibration damper nut. (9) Remove vibration damper. No special tool is needed for removal. CAUTION: If thread sealant is used it is important to remove all the old thread sealant from the threads on the crankshaft. Fig.
PAGE 20
ENGINE NS/GS 9 - 55 REMOVAL AND INSTALLATION (Continued) Fig. 37 Front Cover Seal TIMING CHAIN COVER REMOVAL (1) Disconnect the battery cable. (2) Raise vehicle on hoist. (3) Remove right splash shield. (4) Remove accessary drive belts. Refer to Group 7, Cooling. (5) Remove vibration damper nut. NOTE: Crankshaft thread. damper nut is left handed (6) Remove vibration damper. (7) Remove power steering/air conditioning pulley nut. Remove pulley. CAUTION: Remove old loctite from threads on pump.
PAGE 21
9 - 56 ENGINE NS/GS REMOVAL AND INSTALLATION (Continued) Fig. 39 Splash Shield (5) Remove crankshaft vibration damper. Refer to removal procedure outlined in this section. (6) Remove power steering/air conditioning pulley nut. Remove pulley. Fig. 41 Oil Pump Drive Gear CAUTION: Remove old thread sealant from threads on pump. (7) Remove pump shaft support bracket assembly (Fig. 40). Fig. 40 Pump Shaft Support Bracket (8) Remove timing chain cover. Refer to removal procedure outlined in this section.
PAGE 22
ENGINE NS/GS 9 - 57 REMOVAL AND INSTALLATION (Continued) (15) Remove timing chain. Fig. 45 Tensioner Blade Fig. 43 Alignment Timing Sprockets Fig. 46 Hydraulic Tensioner and Oil Feed Line Fig. 44 Lower Chain Guide INSTALLATION (1) Install timing chain. Starting at the crankshaft align the dark link on the chain to the timing mark on the crankshaft sprocket. Next align the second dark link on the chain with the timing mark on the camshaft sprocket.
PAGE 23
9 - 58 ENGINE NS/GS REMOVAL AND INSTALLATION (Continued) (5) Remove timing chain. Refer to procedure in this section. (6) Remove vacuum pump. (7) Install crankshaft sprocket remover VM.1000A and remove sprocket (Fig. 48). Fig. 47 Timing Chain Procedure (7) Install timing chain cover. Refer to installation procedure outlined in this section. (8) Install pump shaft support bracket assembly. Tighten nuts to 24.5 N·m (216 in. lbs.). (9) Install power steering/air conditioning pulley.
PAGE 24
ENGINE NS/GS 9 - 59 REMOVAL AND INSTALLATION (Continued) (3) Align notch in sprocket with alignment pin in crankshaft. (4) Using crankshaft sprocket installer VM.1029 press on the new sprocket. (5) Remove alignment pin. (6) Install vacuum pump. CAUTION: The vacuum pump must be centered in the block and tighten with two bolts. Ensure that the pump spins freely. If vacuum pump drags or does not spin freely loosen bolts and perform procedures again. (7) Install timing chain. (8) Install oil pump.
PAGE 25
9 - 60 ENGINE NS/GS REMOVAL AND INSTALLATION (Continued) (10) Install Vibration damper. (11) Reinstall Engine. CAMSHAFT BEARINGS This procedure requires that the engine is removed from the vehicle. (16) Remove oil pump drive gear. (17) Remove timing chain. Refer to procedure in this section. (18) Install special tool VM-1004 onto crankshaft over gear (Fig. 52). REMOVAL (1) With engine completely disassembled, drive out rear cam bearing core hole plug.
PAGE 26
ENGINE NS/GS 9 - 61 REMOVAL AND INSTALLATION (Continued) Fig. 53 Crankshaft and Bearings Fig. 54 Carrier Bolts (1) Thoroughly clean crankcase and oil passages, and blow dry with compressed air. (2) Install new main bearing shells in each of the carrier halves. Assemble the carriers to the crankshaft journals, ensuring that the carriers are installed in their original locations. Secure each carrier with the two bolts tightening evenly to 42 N·m (31 ft. lbs.) (Fig. 55).
PAGE 27
9 - 62 ENGINE NS/GS REMOVAL AND INSTALLATION (Continued) CAUTION: Use NEW flywheel bolt for the following procedure. (22) Install new O-ring on flywheel. Install flywheel. The 6 flywheel bolts must be tightened as follows: a. Torque the 6 flywheel bolts to 60 N·m (44 ft. lbs.). b. Loosen 2 of the 6 bolts, 180° apart. Torque the 2 bolts to 20 N·m (180 in. lbs.). Then using a torque angle gauge rotate the 2 bolts 65° additional. c. Loosen the next 2 bolts, 180° apart and follow the same procedure. d.
PAGE 28
ENGINE NS/GS 9 - 63 REMOVAL AND INSTALLATION (Continued) CAUTION: The vacuum pump must be centered in the block and tighten with two bolts. Ensure that the pump spins freely. If vacuum pump drags or does not spin freely loosen bolts and perform procedures again. (29) Before installing oil pump check pump bore depth in block (A) and pump body height (B) (Fig. 58). Difference between A and B should be 0.020-0.082 mm (.0007 to 0032 in.). OIL PAN REMOVAL (1) Disconnect battery cable.
PAGE 29
9 - 64 ENGINE NS/GS REMOVAL AND INSTALLATION (Continued) Fig. 60 Oil Pump Drive Gear Fig. 61 Oil Pressure Relief Valve INSTALLATION (1) Install new O-ring and lubricate with clean engine oil. (2) Install oil pump and tighten retaining screws to 27.5 N·m (240 in. lbs.). (3) Install oil pump drive gear on crankshaft. (4) Install front cover. Refer to Timing Chain Cover Installation in this section. (5) Install pump shaft support bracket assembly.
PAGE 30
ENGINE NS/GS 9 - 65 REMOVAL AND INSTALLATION (Continued) Fig. 64 Pump Shaft Support Bracket Fig. 62 Oil Cooler Fig. 63 Splash Shield Fig. 65 Oil Pump Drive Gear (6) Remove vibration damper. (7) Remove power steering/air conditioning pulley nut. Remove pulley. (10) Remove oil pump drive gear on crankshaft (Fig. 65). (11) Remove lower chain guide (Fig. 68).
PAGE 31
9 - 66 ENGINE NS/GS REMOVAL AND INSTALLATION (Continued) Fig. 66 Timing Marks (13) (14) 70). (15) (16) (17) Fig. 68 Lower Chain Guide Remove hydraulic tensioner blade (Fig. 69). Remove hydraulic tensioner oil feed line (Fig. Remove hydraulic tensioner. Remove timing chain. Remove vacuum pump (Fig. 71). Fig. 69 Hydraulic Tensioner Blade CAUTION: The vacuum pump must be centered in the block and tighten with two bolts. Ensure that the pump spins freely.
PAGE 32
ENGINE NS/GS 9 - 67 REMOVAL AND INSTALLATION (Continued) Fig. 70 Hydraulic Tensioner and Oil Feed Line Fig. 72 Vacuum Pump Assembly Fig. 71 Vacuum Pump—Removal Fig. 73 Timing Chain Procedure the camshaft sprocket. Third align the final dark link on the chain to the timing mark on the injection pump sprocket. Last install the chain around the vacuum pump (Fig. 73). (3) Install hydraulic tensioner. (4) Install hydraulic tensioner oil feed line. (5) Install hydraulic tensioner blade.
PAGE 33
9 - 68 ENGINE NS/GS REMOVAL AND INSTALLATION (Continued) (10) Install power steering/air conditioning pulley. Tighten nut to 170 N·m (125 ft. lbs.). CAUTION: Correct torque on the crankshaft vibration damper nut is important or engine damage can occur. NOTE: Be careful not to nick crankshaft journals. (8) After removal, install bearing cap on the mating rod. (11) Install crankshaft vibration damper. Torque to 441 N·m (325 ft. lbs.) (12) Install both accessory drive belts. Refer to Group 7, Cooling.
PAGE 34
ENGINE NS/GS 9 - 69 REMOVAL AND INSTALLATION (Continued) Fig. 76 Piston Rings—Removing and Installing cylinder bore. Check gap with feeler gauge (Fig. 77). Top compression ring gap .25 to .50 mm (.0098 to .0196 in.). Second compression ring gap .25 to .35 mm (.0098 to .0137 in.). Oil control ring gap .25 to .58 mm (.0098 to .0228 in.). Fig. 78 Piston Ring Side Clearance Fig. 77 Ring Gap Measurement Fig.
PAGE 35
9 - 70 ENGINE NS/GS REMOVAL AND INSTALLATION (Continued) rod big end should also face in the same direction. To insert piston into cylinder, use a ring compressor as shown in (Fig. 81). PISTON PIN—INSTALLATION (1) Secure connecting rod in soft jawed vice. (2) Lubricate piston pin and piston with clean oil. (3) Position piston on connecting rod. CAUTION: Ensure combustion recess in piston crown and the bearing cap numbers on the connecting rod are on the same side. (4) Install piston pin.
PAGE 36
ENGINE NS/GS 9 - 71 REMOVAL AND INSTALLATION (Continued) CRANKSHAFT—REMOVAL Refer to CRANKSHAFT REMOVAL in this section. MAIN BEARING REAR CRANKSHAFT OIL SEAL REMOVAL (1) Remove transmission. Refer to Group 21, Transmission for removal procedure. (2) Remove flywheel. NOTE: Inspect O-ring in flywheel (Fig. 85). (3) Remove rear crankshaft oil seal from retainer (Fig. 86). CAUTION: When removing seal from retainer take care not to damage retainer. INSTALLATION (1) Install crankshaft oil seal.
PAGE 37
9 - 72 ENGINE NS/GS Fig. 83 Cylinder Liner—Installation CLEANING AND INSPECTION CYLINDER HEAD COVERS Remove any original sealer from the cover sealing surface of the engine cylinder head. Remove all residue from the sealing surface using a clean, dry cloth. ROCKER ARMS AND PUSH RODS CLEANING Clean all the components (Fig. 87) with cleaning solvent. Use compressed air to blow out the oil passages in the rocker arms and push rods. INSPECTION Inspect the pivot surface area of each rocker arm.
PAGE 38
ENGINE NS/GS CLEANING AND INSPECTION (Continued) Fig. 86 Crankshaft Seal Fig. 84 Liner Clamp Location Fig. 85 Flywheel Check to ensure that no coolant or foreign material has fallen into the tappet bore area. Remove the carbon deposits from the combustion chambers and top of the pistons. Fig.
PAGE 39
9 - 74 ENGINE NS/GS CLEANING AND INSPECTION (Continued) INSPECTION Use a straightedge and feeler gauge to check the flatness of the engine cylinder head and block mating surfaces (Fig. 88). Minimum cylinder head thickness 89.95mm (3.541 in.) stem clearance in valve guide. Clearance of inlet valve stem in valve guide is .040 to .075 mm (.0015 to .0029 in). Clearance of exhaust valve stem in valve guide is .060 to .095 mm (.0023 to .0037 in).
PAGE 40
ENGINE NS/GS 9 - 75 CLEANING AND INSPECTION (Continued) HYDRAULIC TAPPETS (1) Clean all tappet parts in a solvent that will remove all varnish and carbon. (2) Replace tappets that are unfit for further service with new assemblies. (3) If plunger shows signs of scoring or wear, install a new tappet assembly. If valve is pitted, or valve seat on end of plunger is prevented from seating, install a new tappet assembly.
PAGE 41
9 - 76 ENGINE NS/GS CLEANING AND INSPECTION (Continued) Note: When changing connecting rods, all four must have the same weight and be stamped with the same number. Replacement connecting rods will only be supplied in sets of four. (4) Connecting rods are supplied in sets of four since they all must be of the same weight category. Max allowable weight difference is 18 gr. NOTE: On one side of the big end of the con-rod there is a twodigit number which refers to the weight category.
PAGE 42
ENGINE NS/GS 9 - 77 CLEANING AND INSPECTION (Continued) (2) Check internal diameter of bearings. (3) If internal diameter of original bearing is being checked and figures are not within specifications, new bearings must be used. (4) Check crankshaft main bearing journals to bearing clearances. Clearances of main bearings is .03 to .088mm (.0011 to .0035 in.). OIL PAN Remove all gasket material from cylinder block. Be careful not gouge pan sealing surface.
PAGE 43
9 - 78 ENGINE NS/GS SPECIFICATIONS (Continued) DESCRIPTION SPECIFICATIONS Protrusion . . . . . . . . . . . . . . . . . . . . 0.01–0.06 mm Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . Shims Available Shims: . . . . . . . . . . . . . . . . . . . 0.15 mm Available Shims: . . . . . . . . . . . . . . . . . . . 0.17 mm Available Shims: . . . . . . . . . . . . . . . . . . . 0.20 mm Available Shims: . . . . . . . . . . . . . . . . . . . 0.23 mm Available Shims: . . . . . . . . . . . . . . . . . .
PAGE 44
NS/GS ENGINE 9 - 79 SPECIFICATIONS (Continued) DESCRIPTION TORQUE Camshaft Locating Plate Bolt . . . . . . . . . . . . . . . . . . . . . 11 N·m (96 in. lbs.) Camshaft Sprocket Bolt . . . . . . . . . 19.6 N·m + 60° (170 in. lbs. + 60°) Cylinder Head Bolts . . See Cylinder Head Installation Procedure Connecting Rod Bolts . . . . . . . . . . . 29.5 N·m +60° (22 ft. lbs. +60°) Crankshaft Bearing Carrier Bolts . . . . . . . . . . . . . . . . . . . . 44 N·m (32 ft. lbs.) Crankshaft damper (Pulley) Nut . . . .
PAGE 45
9 - 80 ENGINE NS/GS SPECIFICATIONS (Continued) DESCRIPTION TORQUE Turbocharger Oil Delivery Bolt . . . . . . . . . . . . . . . . . . 27.5 N·m (240 in. lbs.) Turbocharger Oil Drain Bolts . . . . . . . . . . . . . . . . . . 10.8 N·m (95 in. lbs.) Vacuum Pump Mounting Bolts . . . . . . . . . . . . . . . . . . 10.8 N·m (95 in. lbs.) Water Manifold Mounting Bolts . . . . . . . . . . . . . . . . . . 11.8 N·m (108 in. lbs.) Water Pump Pulley Bolts . . . . . . . . . . . . . . . . . 27.5 N·m (240 in. lbs.
PAGE 46
ENGINE NS/GS 9 - 81 SPECIAL TOOLS (Continued) Crankshaft Remover/Installer Sleeve VM.1004 Torque Angle Gauge VM.1005 Cylinder Head Bolt Wrench VM.1006A Cylinder Head Guide Studs VM.1009 Cylinder Liner Protrusion Tool VM.1010 Injector Socket Remover/Installer VM.
PAGE 47
9 - 82 ENGINE NS/GS SPECIAL TOOLS (Continued) Dial Indicator Gauge VM.1013 Cylinder Retainers VM.1016 Flywheel Locking Tool VM.1014 Cylinder Head Bolt Wrench M12 VM.1018 Timing Cover Oil Seal Installer VM.1015 Cylinder Head Bolt Wrench M14 VM.
PAGE 48
ENGINE NS/GS 9 - 83 SPECIAL TOOLS (Continued) Adapter Oil Filter VM.1020 Camshaft Locating Plate Alignment VM.1028 Adapter Cylinder Leakage Tester VM.1021 Crankshaft Sprocket Installer VM.1029 Support Brackets Engine Removal/Installation VM.
PAGE 49
9 - 84 ENGINE SPECIAL TOOLS (Continued) Locating Pin Crankshaft Sprocket VM.1030 Camshaft Sprocket Locking Tool VM.1031 Injection Pump Sprocket Locking Tool VM.