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Notes

     

Specified value

Vehicle identification

 
 

No. of cylinders

Type

4/OHC

 

Capacity

cc

1588

 

Compression ratio

:1

 

23

Injection system

 
 

Fuel/injection pump assembly

Make

Bosch

 

Fuel/injection pump assembly

Type

VE 4/9

 

Fuel/injection pump assembly

Part No.

0

460 494 207

 

Injection sequence

 

1-3-4-2

 

Injector nozzle

Make

Bosch

 

Nozzle and holder assembly

Part No.

0

432 217 159

 

Nozzle opening pressure - new/used

bar

130-138/120

 

Leak rate (dribble)

bar/secs

110/10

Tuning and emissions

 
 

Plunger travel (pump)

mm ABDC

0,90±0,02

 

Crankshaft position (n = ATDC)

°BTDC

0

 

Adjusting method

Engine/Pump

Pointer / Dial gauge

 

Dynamic timing

v = BTDC, n = ATDC

v

 

- AVL, Bosch, Souriau, Sun, VLT4139, Hermann

°/rpm

16±1/875

 

- Time Trac Stanadyne, Snap-on

°/rpm

11,5/930

 

- Tecnotest

°/rpm

12±1/900±50

 

Idle speed

rpm

875±25

 

Rated no load speed

rpm

5350±50

 

Oil temperature

°C

 

80

 

Idle speed - for smoke test

rpm

920-980 ISB=850-900

 

Governed speed range - for smoke test

rpm

5300-5400

 

Maximum time at governed speed

secs

 

0,5

 

Test mode

A/B

B

 

Probe type

1/2

1

 

Smoke opacity - EU limit

m-1 (%)

2,50 (66)

 

Smoke opacity - homologation value

m-1 (%)

2,00 (58)

Starting and charging

 
 

Battery

V/RC(Ah)

12/110 (65)

 

Starter motor

Make

Bosch

 

Starter motor

Type

0

001 110 022

 

Maximum cranking amps

A

176-215

 

Alternator

Make

Bosch

 

Alternator

Type

0

120 489 369

 

Alternator output

A/V/rpm

65/14/3000

 

Regulated voltage

V

13,7-14,5

Glow plugs

 
 

Glow plug nominal rating

V/A

11/13

 

Glow plug activation time

secs

10 Max

 

Glow plug - part no.

Beru

857 MJ

 

Glow plug - part no.

Bosch

0

250 201 032

 

Glow plug - part no.

Champion

CH69

 

Glow plug - part no.

Lucas/CAV

HDS217

Service checks and adjustments

 
 

Valve clearance - INLET

mm

Hydraulic

 

Valve clearance - EXHAUST

mm

Hydraulic

 

Compression pressure

bar

34,0

 

Oil pressure

bar/rpm

2,0/2000

 

Radiator cap

bar

1,2-1,5

 

Thermostat (primary/secondary) open

°C

85

 

Drive belt size - alternator

mm

9,5x732

 

Drive belt tension - alternator/PAS/AC

mm

2-5/5-10

Lubricants and capacities

 

Engine oil options

 
 

Ambient temperature range

 

Cold climate

 

Engine oil grade

SAE

5W/30

 

Engine oil classification

API/ACEA

CF/B2

 

Ambient temperature range

 

Moderate climate

 

Engine oil grade

SAE

15W/40

 

Engine oil classification

API/ACEA

CF/B2

     

Moderate climate

Ambient temperature range

alternative

 

Engine oil grade

SAE

10W/40

 

Engine oil classification

API/ACEA

CF/B3

 

Ambient temperature range

 

Hot climate

 

Engine oil grade

SAE

20W/40

 

Engine oil classification

API/ACEA

CF/B2

36

Engine with filter(s)

litres

 

Other lubricants and capacities

 
 

Manual transmission oil grade

SAE

75W/90 Synthetic

 

Manual transmission

litres

1,7

 

Automatic transmission fluid

Type

Dexron II

 

Automatic transmission (drain & refill)

litres

3,5

 

Differential front/AT

litres

0,7 (AT)

 

Differential oil grade - rear

SAE

90W

 

Cooling system - total capacity

litres

7,0

Tightening torques

 
 

Cylinder head instructions

   

Cylinder head

 
   

Renew bolts

Yes

 

Stage 1

Tighten

40

Nm

 

Stage 2

Tighten

60

Nm

 

Stage 3

Tighten

180°

 

Stage 4

Run engine

50°C

 

Stage 5

Tighten

90°

 

Stage 6

Run engine

600 miles/1000 km

 

Stage 7

Tighten

90°

Other engine tightening torques

 
 

Main bearings

Renew bolts/nuts

No

 

Main bearings

Stage 1

32

Nm

 

Main bearings

Stage 2

65

Nm

 

Big end bearings

Renew bolts/nuts

No

 

Big end bearings

Stage 1

30

Nm

 

Big end bearings

Stage 2

180°

 

Oil pump to cylinder block

 

20

Nm

 

Sump bolts

 

20

Nm

 

Sump drain bolt

 

30

Nm

15

Flywheel/driveplate

   
 

Clutch pressure plate

 

25

Nm

 

Camshaft sprocket/gear

 

45

Nm

 

Camshaft carrier/cap

 

20

Nm

 

Camshaft/rocker cover

 

10

Nm

 

Inlet manifold to cylinder head

 

25

Nm

 

Exhaust manifold to cylinder head

 

25

Nm

 

Injector/clamp

 

70

Nm

 

Injector pipe unions

 

25

Nm

 

Injector nozzle to holder

 

70

Nm

 

Fuel/injection pump sprocket/gear

 

45

Nm

 

Fuel/injection pump flange

 

25

Nm

 

Fuel/injection pump mounting

 

25

Nm

 

Glow plugs

 

30

Nm

Chassis tightening torques

 

27

Front hub

   

21

Steering track rod end

 

30

Nm

22

Brake caliper to carrier

Front

 
 

Brake caliper carrier to hub

Front

125

Nm

 

ABS sensor

Front

10

Nm

 

ABS sensor

Rear

10

Nm

 

Road wheels

 

110

Nm

Brake disc and drum dimensions

 
 

Minimum disc thickness - solid

Front

11

mm

 

Minimum pad thickness

Front

2 mm

 

Maximum drum diameter

Rear

201

mm

 

Minimum shoe thickness

Rear

2,5 mm

 

Parking brake travel

No. of notches

2-3

Air conditioning

 
 

Air conditioning refrigerant

Type

R12

 

Air conditioning refrigerant quantity

grams

1050±50

 

Air conditioning oil

Type

Dens Oil 6

 

Air conditioning oil quantity

cmі

300±20

Note 36

Eng. No. J320 479 = 3,5 litres Eng. No. J320 480= 4,0 litres

Note 15

A = 30 Nm + 90°

B = 75 Nm

Fig. 76289

Note 27

Use new nuts. 265 Nm Use new bolts. M14 = 120 Nm + 90° M16 = 200 Nm + 90°

Note 21

Use new nuts.

Note 22

Use new bolts. Teves = 25 Nm Girling = 35 Nm

76289
76289

Cylinder layout

 
Cylinder layout     Idle speed adjustment (A)
Cylinder layout     Idle speed adjustment (A)
 

Idle speed adjustment (A)

Cylinder layout     Idle speed adjustment (A)
Cylinder layout     Idle speed adjustment (A)
Tightening sequence
Tightening sequence