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ASSEMBLING THE ENGINE ON THE BENCH
60559
47581
47579
Fit the underblock and, using a dynamometric wrench (2), close the splined outer screws (1) to 30 Nm torque, according to the diagram shown on page 83.
Close the inner screws (1) to 120 Nm torque by means of a dynamometric wrench (3, Figure 158), then with two further angular phases 90° + 45°, using tool 99395216 (4).
Tighten again the outer screws (1, Figure 157) with 60° angular closing, using tool 99395216 (3, Figure 157).
Fit the underblock by means of a suitable hoist and hooks (1).
60632
Sealant application diagram
Fit the underblock within 10’ of the application of the sealant.
α
α Figure 155
Figure 156
Figure 157
Figure 158
ENGINE - F3B
106 SECTION 3 ASTRA HD8Ec
60593
FRONT SIDE stage 4:
angle
stage 2: pre-tightenig
FRONT SIDE stage 3:
angle
DIAGRAM SHOWING TIGHTENING ORDER OF UNDER-CRANKCASE SECURING SCREWS Figure 159
49030
Rotate the cylinder assembly placing it vertically.
Fit the half-bearings (1) on both the connecting rod and the cap.
60615
Connecting rod-piston assembly
Piston ceiling area where the assembly position and the selection class ideogram is printed.
Connecting rod marking area
60616
Fit the connecting rod-piston assemblies (2) into the piston liners, using the band 99360605 (1). Check the following:
- the openings of the split rings are offset by 120º;
- all pistons belong to the same class, A or B;
- ideogram (2), stamped on the piston crown, is placed toward the engine flywheel, or the cavity, on the piston skirt, corresponds to the position of the oil spray nozzles
Fitting the connecting rod-piston assembly into the cylinder liners
1 2
3 Figure 160
Figure 161
Figure 162
47594
Connect the connecting rods to the relative journals, fit the connection rod caps (1) with half bearings; tighten the fixing screws (2) of the connecting rod caps to 60 Nm torque (6 kgm). Using tool 99395216 (3), further tighten screws with 60° angle.
By means of centering ring 99396035 (2), check the exact cover position (1), otherwise act as necessary and tighten the screws (3).
Fit the sealing gasket (1), install the fitting tool 99346250 (2) and drive the sealing gasket (1) by screwing nut (3).
Make sure that pistons 1-6 are exactly at the TDC Place the sealing gasket (2) on the block.
Fit the cylinder head (1) and tighten screws as shown in figs.
91, 92 and 93.
Diagram showing the cylinder head fixing screws tightening order
- Preliminary tightening by means of a dynamometric wrench (1):
ENGINE - F3B
108 SECTION 3 ASTRA HD8Ec
Fitting the cylinder head
Tighten the screws shown in the figure by means of a dynamometric wrench, in compliance with the following order and tightening torque:
no. 4 M12 x 1.75 x 35 56 to 70 Nm no. 10 M12 x 1.75 x 100 56 to 70 Nm
no. 1 M12 x 1.75 x 120 56 to 70 Nm no. 2 M12 x 1.75 x 70 56 to 70 Nm
60566
- Angular tightening using tool 99395216 (1);
3rd phase: 90° angle
4th phase: 45° angle for screws 4, 5, 12, 13, 20, 21 5th phase: 65° angle for screws 1, 2, 3, 6, 7, 8, 9, 10, 11.
Fit the oil pump (5), intermediate cogs (2) complete with P.T.O tie-rod (1) and drive cog (3)
Tighten the screws (4) to the specified torque.
Replacing flywheel casing
Apply (as shown in the figure) sealant LOCTITE 5699 to the gear box using the proper equipment (1).
47592 71773
α
α
60633
Fit the sealing gasket (1), install the fitting tool 99346251 (2) and drive the sealing gasket by screwing the nut (3).
Install the gear box within 10’ of the application of the sealant.
Second and third phase: tighten at a 60º + 30º angle using the tool 99395216 (1).
49036
α
60668
DETAIL OF PISTON POSITION MARKS ON ENGINE FLYWHEEL
C = Hole on the flywheel with 1 notch, corresponding to TDC of pistons 2-5
D = Hole on the flywheel with 2 notches, corresponding to 54°.
A = Hole on the flywheel with 1 notch, corresponding to TDC of pistons 3-4.
B = Hole on the flywheel with 1 notch, corresponding to TDC of pistons 1-6.
HOLES VIEW:
A - B - C HOLE VIEW:
D
49037
Stop rotation using the tool 99360351 (3); tighten the screws (2) in three phases.
First phase: pre-torque at a 120 Nm (12 kgm) torque using a torque wrench (4).
α Figure 174
Figure 175 Figure 176
ENGINE - F3B
110 SECTION 3 ASTRA HD8Ec
Replacing engine flywheel
Replacing camshaft, valves and injectors
- Refit the motion transmission gear (1) and secure the screws (2) to tightening torque 30 ± 3 Nm and then close at an angle of 90° with tool 99395216.
60571
- Fit the gauge 99395219 (1) and check and adjust the transmission gear connecting rod (3), tighten the screw (2) at the prescribed torque.
60570
- Replace:
- the camshaft (1) positioning it according to the ref-erences ( ) as shown in Figure 178.
This operation simplifies subsequent camshaft tim-ing
- The shoulder plate (2) with metal gasket.
60569 71774
Position the crankshaft with pistons 1 and 6 at top dead centre (TDC).
At this position check when it is possible to see a notch and hole through the inspection hole located on the lower part of the flywheel casing, and fit pin 99360612 (1) into it (Figure 177).
If this situation does not occur, turn the engine slightly until it does.
ENGINE - F3B
112 SECTION 3 ASTRA HD8Ec
60572
Fit back the gear (2), without fully tightening screws (5) on the camshaft and place it so that the 4 oval holes are centered with respect to the camshaft fixing holes. Using a magnetic gauge (1), make sure that the gear (2 and 3) clearance is 0.073 to 0.195 mm, otherwise adjust the clearance as follows:
untighten screws (4) fixing transmission gear (3);
untighten screws (2, Figure 183) fixing the rod, move the rod (3, Figure 183) to obtain the required clearance;
Tighten the rod fixing screw (2, Figure 183) as well as the screws (4, NO TAG) fixing the gear to the prescribed torque.
71775
Fit:
- the injectors (2) and tighten the bracket screws to 26 Nm using a torque wrench.
- The engine brake cylinders (1) and (4), tightening to toque of 19 Nm using a torque wrench.
- The valve bridge bars (4) with the larger hole on the same side
44908
Fit the sealing rings (1) (2) (3) on injectors.
Before fitting back the rocker shaft assembly, make sure that all the adjusting screws have been completely unscrewed.
Apply tool 99360553 (1) and remove the rocker shaft assem-bly.
60512
5
Replacing rocker shaft assembly Figure 181
Figure 182
Figure 183
Figure 184
Apply tool 99360321 (7) and shim 99360325 (6) to the gearbox.
- Assemble exhaust brake lever check springs (3) - Connect piping (2) to the exhaust brake pins (4) and to
the slave cylinder (1)
45261
Tighten the screws (2) fixing the rocker shaft as follows:
- 1st phase: tightening with a dynamometric wrench (1) to 100 Nm torque (10 kgm)
- 2nd phase: closing by means of tool 99395216 (3), with 60° angle.
60574
71776
α
71777
Fit the wires fastening them to the injectors using a torque screwdriver (1) to a torque of 1.36 - 1.92 Nm.
The arrow indicates engine rotation direction.
With the above tool, turn the flywheel (1) in the en-gine direction such that it brings piston 1 approxi-mately to TDC on the firing stroke.
This condition is realised when the hole with a notch (4) following the hole with two notches (5) present on the flywheel (1), appears in the inspection hole (2).
Figure 185
Figure 186
Figure 187
Figure 188
71774
60573 60575
The exact position of piston 1 at TDC is achieved in the previously described position, when tool 99360612 (1) fits into the hole (3) on the flywheel (4) through the engine revs sensor seat (2).
Position the magnetic dial gauge (1) with the stem on the roller (2) of the rocker controlling the injector of cylinder 1, and pre-load it 6 mm.
Using tool 99350321 (7) Figure 188, turn the crankshaft clockwise until the pointer on the gauge reaches the minimum value beyond which it cannot go.
Reset the dial gauge.
Turn the flywheel anti-clockwise until the gauge reads a lift value of 5.31 ±0.05 mm for the camshaft cam .
The camshaft is timed if the following conditions are present when the cam lift values are 5.31 ± 0.05 mm:
1) the hole marked with double notch (5) can be seen through the inspection window;
2) tool 99360612 (1) can be inserted into hole (3) on the engine flywheel (4) through the seat (2) of the engine rpm sensor.
If the conditions illustrated in Figure 191 and specified in points 1 and 2 above do not exist, proceed as follows:
Loosen the screws (2) securing gear (1) to the camshaft and use the slots (1) on the gear.
Move the engine flywheel to obtain the conditions described in points 1 and 2, Figure 191, while keeping the cam lift value the same.
Lock the screws (2) and repeat the check already described.
Tighten the screws (2) to the specified torque.
72436
Figure 189
Figure 190
Figure 191
Figure 192
ENGINE - F3B
114 SECTION 3 ASTRA HD8Ec
71778
72436
When adjustment in the slots (1) is not sufficient to recover timing offset and the camshaft rotates tight with the gear (2), to consequently vary the cam lift reference value, proceed as follows:
- Check that the screws (2, Figure 192) are tight.
- Rotate the flywheel by ca. ½ a turn clockwise.
- Rotate the flywheel anticlockwise until a cam lift value of 5.31 ± 0.05 mm can be read on the comparator.
- Remove the screws (2, Figure 192) and remove the gear (2) from the camshaft.
Rotate the flywheel again to bring it into the following condi-tions:
- Double notch (5) visible through lower inspection hole.
- Tool 99360612 (1) fitted flush into the engine revs sen-sor seat (2) and (3).
71779
Timing the phonic wheel
With the engine in timed conditions, check that pin 99360613 (2) positions itself on the marked tooth on the phonic wheel (1). If not, loosen the screws (3) and suitably orient the phonic wheel (1).
Tighten the screws (3) to the specified torque.
Fit the gear (2) Figure 193, with the 4 slotted holes centred with respect to the threaded holes in the camshaft tightening the screws to the specified torque.
Check the timing of the camshaft by first rotating the flywheel clockwise to fully drop the cam and then turning it anticlock-wise until the comparator read 5.31 ± 0.05.
Check the timing conditions described in Figure 191.
Figure 193
Figure 194
Figure 195
ENGINE - F3B
116 SECTION 3 ASTRA HD8Ec
Adjusting the unload/intake rockers play and pump injector control rockers preload
Clockwise
- Using an appropriate wrench (4), loosen the adjustment screw until the pumping element is at the end-of-stroke;
- Tighten the adjustment screw, with a dynamometric wrench, to 5 Nm tightening torque (0.5 kgm);
- Untighten the adjustment screw by 1/2 to 3/4 rotation;
- Tighten the locking nut.
The adjustment of clearance between the rockers and rods controlling the intake and exhaust valves, as well as the adjustment of pre-loading of the rockers controlling pump injectors, must be carried out carefully.
Take the cylinder where clearance must be adjusted to the bursting phase; its valves are closed while balancing the symmetric cylinder valves.
Symmetric cylinders are 1-6, 2-5 and 3-4.
In order to properly operate, follow these instructions and data specified on the table.
Adjustment of clearance between the rockers and rods controlling intake and exhaust valves:
- Using a polygonal wrench, loosen nut (1) locking the adjustment screw;
- Insert the thickness gauge blade (3);
- Tighten or untighten the adjustment screw with the appropriate wrench;
- Make sure that the gauge blade (3) can slide with a slight friction;
- Lock the nut (1), by blocking the adjustment screw.
Pre-loading of rockers controlling pump injectors:
- Using a polygonal wrench, loosen the nut locking the rocker adjustment screw (5) controlling the pump injector (6);
ADJUSTMENT OF INTAKE, EXHAUST AND INJECTION ROCKERS
60577
FIRING ORDER 1-4-2-6-3-5
In order to properly carry out the above-mentioned adjustments, follow the sequence specified in the table, checking the exact position in each rotation phase by means of pin 99360612, to be inserted in the 11thhole in each of the three sectors with 18 holes each.
Figure 196
60495
60665
- Assemble the rocker cover (1) and the timing gear cover (2)
- Fit the gasket (4) on the oil sump, position the spacer (3) and assemble the oil sump on the engine block tightening the screws (2) at the prescribed torque.
FAN - WATER PUMP - ALTERNATOR CONTROL BELT ASSEMBLY DIAGRAM
1. Alternator - 2. Fan - 3. Water pump - 4. Crankshaft Complete the engine assembly by assembling or connecting the following components:
- thermostat unit
- automatic belt tightener, water pump, alternator;
- control belt.
60578
- damping flywheel;
- fan;
- starter;
- fuel pump;
- power steering system tank;
- fuel filter and line;
- pre-heating resistance;
- suction manifold;
- heat exchanger
- oil filter, lubricating gaskets;
- exhaust manifold;
- turbocharger and relevant water and oil lines;
- Power take off (P.T.O) and respective piping.
Figure 197
Figure 198
Figure 199
COMPRESSOR CONTROL BELT ASSEMBLY DIAGRAM
1. Crankshaft - 2. Air conditioner compressor - Oil dipstick
- Electrical connections and dipstick - Fill engine with specified quantity of oil
- Remove engine from rotary bench and remove engine mounting brackets (99361036)
Fit:
- Air conditioner automatic belt tensioner - Drive belt
When assembling the belts (1-3) operate on the belt tighteners using fit tools (2-4), acting in the direction shown by the arrows.
60579
Belt tighteners are automatic and do not need further adjustment after assembly.
60667
Turbocharger cooling water and lube oil piping unions must be tighten at a torque of:
- 35± 5 Nm, water pipe unions;
- 55± 5 Nm, oil pipe female union;
- 20-25 Nm, oil pipe male union.
Figure 200
Figure 201
ENGINE - F3B
118 SECTION 3 ASTRA HD8Ec
The forced-circulation lubrication is obtained by means of gear pump (1).
The pump is driven via the cog (1) by the crankshaft (2).
A heat exchanger and the oil filter are installed on the lubrication system.
71578 60651
60628
Figure 202
The heat exchanger houses the by-pass valve with opening pressure at 3 bar and the thermostatic valve that cuts-in when temperature exceeds 82.5°C.
OIL PUMP SECTION SECTION B-B
A
A
Figure 203
Figure 204
1780320
Figure 205
1. Oil sump. 2. Crankshaft. 3. Engine oilwater heat exchanger. 4. Engine oil filter. 5. Turbocompressor. 6. Camshaft. -7. Valve timing gears.
gravity fed oil oil under pressure
ENGINE - F3B
120 SECTION 3 ASTRA HD8Ec
Lubrication system outline
1780321
Figure 206
8. Engine brake solenoid valve with 4th cylinder command piston.
DETAIL A
B - to cylinders 1 -2 - 3 C - to cylinder 4 D - to cylinders 5 - 6
Gravity fed oil Oil under pressure
60629
HEAT EXCHANGER SECTION
60630
SECTION A-A SECTION B-B
Figure 207
Figure 208
By-pass valve
Cut-in pressure 2 bar Thermostatic valve
Cut-in temperature 82 ± 2°C
ENGINE - F3B
122 SECTION 3 ASTRA HD8Ec
Heat exchanger
This is a new-generation filter, ensuring much more accurate filtering, since it can block a higher quantity of particles of smaller dimensions compared to traditional filters, with paper filtering septum.
47447
These highly filtering elements, adopted only in industrial process up to now, make it possible to:
- reduce engine components wear;
- preserve oil performance/characteristics, thus extending the period of time between replacements.
Outside spiral wrapping
The filtering elements are strictly wrapped by a spiral, so that each fold is strongly fixed to the spiral. This means a uniform use of the septum, also under the toughest conditions, such as cold start-ups with high viscosity fluids and flow peaks.
Moreover, a uniform distribution of flow is ensured through the whole length of the filtering elements; thus the loading loss is optimized, as well as its operating time.
Upstream support
In order to optimize flow distribution and filtering element stiffness, the filtering element is equipped with an exclusive support consisting of a strong nylon mesh and high-strength synthetic material.
Filtering septum
It consists of inert inorganic fibers, connected by exclusively manufactured resin to a shifting pore structure; it is exclusively manufactured following precise procedures and strict quality controls.
Downstream support
Thanks to the filtering septum and the strong nylon mesh, the septum strength is improved, especially useful during cold start-ups and long use periods. Filter performance is constant and reliable for the entire service life, on each element, regardless of operating conditions changes.
Structural parts
The O-rings equipping the filtering element ensure perfect sealing between the filtering element and the container, thus eliminating any bypass risk and keeping filter performance constant. Corrosion-proof bottom sides, as well as a solid metal core, complete the filtering element structure.
Figure 209
71731
45159
Figure 210
Figure 211
WATER PUMP SECTION
The water pump consists of: rotor, seal bearing and control pulley.
ENGINE WATER PUMP
60631
60747
Water circulating inside the engine
Water from the thermostat
60748
Forced-circulation cooling is obtained by means of a centrifugal pump, controlled by the crankshaft through a Poli-V type belt.
Water circulation is regulated by a thermostat.
The radiator is vertical.
Water pump
Thermostat operation view Check that the pump body has no cracks or water
leaks. Otherwise replace the complete water pump Check thermostat function. In case of doubt, replace the thermostat.
THE MOTOR TO THE
BY PASS Figure 212
Figure 213
Figure 214
ENGINE - F3B
124 SECTION 3 ASTRA HD8Ec
COOLING
1780322
Figure 215
1. Radiator. 2. Fan. 3. Water pump. 4. Engine oilwater heat exchanger. 5. Turbocompressor. 6. Thermostat. -7. Air compressor. - 8. Cab heater. - 9. Expansion chamber.
ENGINE - F3B
126 SECTION 3 ASTRA HD8Ec
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178315
Figure 216
Filling up the system
After having followed all these instructions, proceed as follows:
- Remove cap (2) from the water cup (3);
- Fill in the cooling liquid into the water cup (3), till it is full.
Purging the air of the system Filling up the cooling system
Preliminary operation
For vehicles with driver seat heating or hand air-condition-ing system:
- Turn on the tap of the warming liquid placed on the instrument board.
For vehicles with automatic air-conditioning system:
- Place the temperature control device in the driver’s area on position HI.
For vehicles with a supplementary heating system:
- This must be off.
Operations
Insert a sheet of cardboard between the radiator of the cooling liquid and the intercooler radiator, in order to shorten the time needed to reach the working temperature of the engine (~ 90°C).
GENERAL NOTICE
Filling up must be done when engine is cool.
The cap (1) cannot be removed.
In order to avoid air-bubbles in the system is recommended to pour out the liquid slowly (average quantity 8 Litre/Minute).
For vehicles with supplementary heating system, the percentage of glycol in the liquid cannot be higher than 50%.
For vehicles with supplementary heating system - Turn the heating device on.
Should it happen, that the water cup during these minutes gets completely empty, stop the engine and fill in the cup more slowly than before.
Start the engine once again.
- Start the engine and let the speed be a little higher than the minimum value for 5 minutes.
- After 5 Minutes, if necessary fill in the water cup;
- Close the fillers of the water cup with the corresponding cap (2).
Bring the speed to the maximum value, so that the cooling liquid can reach more quickly the temperature for the maximum opening of the thermo-stat (~ 90°C) and this can be maintained, till all air has been purged by the system.
In order to check if air is still present, check if in the water cup foam or air bubbles are visible.
The maximum time needed to purge all air out is about 15 minutes after the thermo-stat has opened (it starts opening with 79°C ± 2°C).
Do not remove the caps from the fillers of the water cup, till the liquid in the system is completely cool. If necessary, fill in only when the engine is cool.
This is to avoid:
. Burning the operators;
. Damages to the engine, because the air is pressurised in the cooling system only if the engine is warmed up from a cold condition.
Figure 217
TURBOCHARGER AND EXHAUST SYSTEM OUTLINE
1. Air duct to intake manifold. 2. Intake manifold 3. Exhaust. 4. Exhaust pipe 5. Intake piping 6. Air filter -7. Turbocompressor - 8. Air duct to intercooler - 9. Exhaust manifold - 10. Intercooler.
ENGINE - F3B
128 SECTION 3 ASTRA HD8Ec
TURBOCHARGING
Intake air
Engine exhaust gas
1780325
71767
71766
71768
Figure 218