ENGINE E7J-26210
ENGINE ASSEMBLY
10 - 18
RINGS
CONNECTING RODS
Connecting rod end side clearance: 0.310 to 0.572 mm.
AT T E N T I O N !
It is forbidden the use of punches for marking due to the risk of primer cracks A
permanent marker is to be used.
CRANKSHAFT
In case of rectifying, rolling must remain at
least on 140° of the crankpins and bearings
circumference. These areas are defined in sections A and
B as per joint drawing
Chara cteristics
Thickness (mm):
- compression ring 1.5
- sealing ring 1.75
- oiling ring 3
Number of bearings 5
Bearings diameter (mm) - nominal: 54.795 ± 0.01
- reparation: 54.550 ± 0.005
Crankpin diameter (mm) - nominal: 43.98
-0,0 2
- reparation: 43.73 -0,0 2
Axial clearance (mm) - 0.045 - 0.852 with wear
- 0.045 - 0.252 without wear
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Diagnostic – Failures interpretation
DF 109
DF 110
CONTINU AT I O N
ET093 : combustion misfire on cylinder 1
ET094 : combustion misfire on cylinder 2
RE COMMENDATIONSET0 95 : combustion misfire on cylinder 3
ET096 : combustion misfire on cylinder 4
These w ill provide information regarding failure cause and location.
C heck the ignition system ( refer to chapter “Help” ).
Fix it if necessary.
C heck the engine compression.
Fix it if necessary.
C heck the flywheel condition , in order to get a correct information of the engine RPM.
Fix it if necessary.
If no failure has been found, there is a problem on the fuel supply cir cuit.
In this situation the following must be checked:
- Fuel filter
-F uel pressure and flow
-F uel pump condition
-F uel tank cleaning condition]
-I njector s conditions
Mend the fuel supply circuit.
Ensure that all failures are solved. Erase the memorized failures.
There is no need to erase the “adaptive values” memorized by the injection
computer. In order to check the correct reparation of the system, the following
conditions must be accomplished:
AF TER - No more electrical failures.
REPARATION - All “adaptive values” to be memor ized by the injection computer.
- Warm engine (minimum 75°C)
- Run at idling, all consumers being in use for 20 minutes (1 minute
DF110).
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ET039IDLING ADJUSTMENT
RECOMMEND AT IONS No failure must be prese nt or memorized.
Attention to the recommended value of idling RPM: PR041
C heck the connection and condition of the idling regulator connector.
R eplace the connector if necessary.
C heck the resistance of the idling regulator.
R eplace the idling regulator if necessary
C heck the in su la t ion and continuity of the connections between:
Pin 12 inj ection computer >pin B idling regulator
Pin 41 inj ection computer >pin A idling regulator
Pin 42 inj ection computer >pin C idling regulator
Pin 72 inj ection computer >pin D idling regulator
M end if necessary.
Idling regime
< minimal limit RECOMMENDAT IONS The idling RPM is too low
- Check the enriching adjustment operation.
- Clean the air supply circuit (valve body, idling regulator), which may be clogged.
- Check the engine oil level ( too high ? bubbling).
- Check the engine compressions.
- Check the valves clearances and the distribution setting.
- Check the ignition.
- Check the injectors.
If all checked eleme nts are correct, replace the idling regula tor
Idling regime
> maximal limit RECOMMEND AT IONS The idling RPM is too high
- Check the oil level
- Check the good operations of the atmospheric pressure sensor.
- Check possible leaks at piping connected to the inlet manifold.
- Check the electric valve s with pneumatic control.
- Check the manifold gaskets.
- Check the gaskets of the valve body.
- Check tightening at servo-brake.
- Check the presence of nozzles in the connection hose s of the oil vapors re-aspiration circuit.
- Check the valves clearance and the distribution setting.
If all checked eleme nts are correct, replace the idling regula tor AFTER Restart the conformity checking from the beginning.
REPARATION
Diagnostic – States interpretation
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PR001 MANIFOLD PRESSURE
RECOMMEND AT IONS No failure must be prese nt or memorized.
Incoherent manifold Check the insu lation, continuity and the absence of the parasite
pressure, contact on resistance of the connections between:
Pin 15 injection computer > p in A pressure transducer
Manifold pressure < Pin 16 injection computer > pin B pressure transducer
mini mal pressure at Pin 78 injection computer > p in C pressure transducer
idling Mend if necessary.
Incohe rent
atmospheric If all checked elements are correct, replace the transduc er. pre ssure
(PR0 16 )
M anifold pressure > Check :
m aximal pressure - Sealing between manifold and transduc er.
at idling - Valves clearance. -Canister purging valve operation
-Cyli nders compression
-La ck of leaking at inlet manifold (“false air”)
- Exhaust is not clogged.
If all these elements are correct, replace the tr ansducer.
Diagnostic – Parameters interpretation
AF TER Restart the conformity checking from the beginning.
REPARATION
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PR030 ENRICHING ADAPTATION IN OPERATION
PR031 ENRICHING ADAPTATION AT IDLING
RECOMMEND AT IONS No failure must be present or memorized.
Perform the steps for memorizing the adaptation values by the injection
computer.
Erase the computer memory. A t warm, when idling adjustment, observe the se paramete rs :
- If one of t hese parameters is moving towards the minimal limit, there is not sufficient petrol or there
is t oo much air.
- If one of the se paramete rs is moving towards the minimal limit, there is too much petrol or there is
not sufficient air.
(See chapter “ Enriching adaptive correction) for the exact limit values)
Ensure the cleaning condition and the good operation of :
- fuel filter
- fuel pump
- fuel circuit
- fuel tank
- air supply piping
- air filter
- spark plugs
C heck :
- Engine compressions
- Valves cle arance
- Ignition
Diagnostic – Parameters interpretation
AF TER Restart the conformity checking from the beginning.
REPARATION
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ALP 2 STARTING PROBLEMS engine is not starting or is difficulty starting)
RECOMMEND AT IONS Do not consult this diagnostic but before performing a complete
checking by means of the CLI P tester.
Ch eck that starter is well operating
Ch eck there is petrol in the fuel tank (fuel indicator failure).
Ensure that vehic le is supplied with adequate fuel.
Ch eck tha t supply cir cuit hoses are not broken (espe cially further to a dismounting)
Ch eck the condition of the fuel filter
Ch eck the condition of the fuel tank
Ch eck that fuel tank aeration is taking place.
Ch eck the electric supply of the fuel pump.
Ch eck the good operation of the choke sensor.
Ch eck the motor of the idling regula tor.
In order to unblock it, you may slightly hit it.
Disconnect the connection hose between the canister purging valve and the intake manifold.
Cl amp the connection hose in order to stop the air passing.
If there are no more disturbances, the cause is the canister purging valve.
Ch eck the spark plugs and ignition coil condition
Ch eck tha t these eleme nts are specific to that vehicle.
Ch eck that the exhaust route is not clogged and the catalyst is not clogged.
Ch eck the engine compressions
Ch eck the flywheel condition
Ch eck the distribution setting on.
AFTER Perform a checking by means of the CLI P tester.
REPARATION
Fa ilure locating algorithm
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ALP 3 IDLING PROBLEMS (unstable idling)
RECOMMEND AT IONS Do not consult this diagnostic but before performing a complete
checking by means of the CLI P tester.
C heck if there is petrol in the fuel tank (fuel indicator failure)
C heck if the vehic le is supplied with adequate fuel
C heck tha t supply cir cuit hoses are not broken (espe cially further to a dismounting)
C heck the condition of the fuel filter
C heck the condition of the fuel tank
C heck that fuel tank aeration is taking place.
C heck the connection and the condition of the idling regulator connector.
Re place the connector if necessary.
C heck the motor of the idling regulator
In order to unblock it, you may slightly hit it.
Disconnect the connection hose between the canister purging valve and the intake manifold.
Cl amp the connection hose in order to stop the air passing.
If there are no more disturbances, the cause is the canister purging valve.
C heck the spark plugs and ignition coil condition
C heck tha t these eleme nts are specific to that vehicle.
C heck that the exhaust route is not clogged and the catalyst is not clogged.
Check, by means of the oil dipstick, that oil level is not too high.
C heck for lack of sealing at servo-brake (noise).
C heck the intake manifold condition
C heck if the valve body is not clogged
C heck the engine compressions.
C heck the engine flywheel condition
C heck the distribution setting on.
AFTER Perform a checking by means of the CLI P tester.
REPARATION
Fa ilure locating algorithm
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ALP 4 INTEMP ERATE ACCELERATION OR DECELERATION
(engine unstable running)
RECOMMEND AT IONS Do not consult this diagnostic but before a complete checking by
means of the CLIP tester
Ch eck if air filter is not deformed.
Ch eck if there is petrol in the fuel tank (fuel indicator failure)
Ch eck if the vehic le is supplied with adequate fuel
Ch eck tha t supply cir cuit hoses are not broken (espe cially further to a dismounting)
Ch eck the condition of the fuel filter
Ch eck the condition of the fuel tank
Ch eck that fuel tank aeration is taking place.
Disconnect the connection hose between the canister purging valve and the intake manifold.
Cl amp the connection hose in order to stop the air passing.
If there are no more disturbances, the cause is the canister purging valve.
Ch eck the spark plugs and ignition coil condition
Ch eck tha t these eleme nts are specific to that vehicle.
Ch eck that the exhaust route is not clogged and the catalyst is not clogged.
Ch eck the se aling of the exhaust manifold.
Ch eck, by means of the oil dipstick, that oil level is not too high.
Ch eck for lack of sealing at servo-brake (noise).
Ch eck the intake manifold condition
Ch eck if the valve body is not clogged
Ch eck the engine compressions.
Ch eck tha t brake calipers, drums and bearings are not gripped.
Ch eck that tires are inflated
Ch eck the engine flywheel condition
Ch eck tha t cooling system is properly operating
AFTER Perform a checking by means of the CLI P tester.
REPARATION
Fa ilure locating algorithm
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