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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
Fuel/injection pump assembly
Fuel/injection pump assembly
Injection sequence
Injector nozzle
Nozzle and holder assembly
Nozzle opening pressure - new/used
Leak rate (dribble)

Make Bosch
Type VE 4/9
Part No. 0 460 494 207
1-3-4-2
Make Bosch
Part No. 0 432 217 159
bar 130-138/120
bar/secs 110/10

Tuning and emissions


Plunger travel (pump)
Crankshaft position (n = ATDC)
Adjusting method
Dynamic timing

mm ABDC 0,900,02
BTDC 0
Engine/Pump Pointer / Dial gauge
v = BTDC, n = ATDC v

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

/rpm 161/875

- Time Trac Stanadyne, Snap-on

/rpm 11,5/930

- Tecnotest

/rpm 121/90050

Idle speed

rpm 87525

Rated no load speed

rpm 535050

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
Regulated voltage

A/V/rpm 65/14/3000
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.


Glow plug - part no.
Glow plug - part no.

Beru 857 MJ
Bosch 0 250 201 032
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
Oil pressure
Radiator cap
Thermostat (primary/secondary) open

bar 34,0
bar/rpm 2,0/2000
bar 1,2-1,5
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
Engine oil grade
Engine oil classification

Cold climate
SAE 5W/30
API/ACEA CF/B2

Ambient temperature range


Engine oil grade
Engine oil classification

Moderate climate
SAE 15W/40
API/ACEA CF/B2
Moderate climate
alternative

Ambient temperature range


Engine oil grade
Engine oil classification

SAE 10W/40
API/ACEA CF/B3

Ambient temperature range


Engine oil grade
Engine oil classification
36

Engine with filter(s)

Hot climate
SAE 20W/40
API/ACEA CF/B2
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 50C

Stage 5
Stage 6
Stage 7

Tighten 90
Run engine 600 miles/1000 km
Tighten 90

Other engine tightening torques


Main bearings

Stage 1 32 Nm

Main bearings

Stage 2 65 Nm

Big end bearings

15

Renew bolts/nuts No

Main 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

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

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

30 Nm

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


Parking brake travel

Rear 2,5 mm
No. of notches 2-3

Air conditioning
Air conditioning refrigerant
Air conditioning refrigerant quantity
Air conditioning oil
Air conditioning oil quantity

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

Type R12
grams 105050
Type Dens Oil 6
cm 30020

76289

Cylinder layout

Idle speed adjustment (A)

Tightening sequence