Vectra Fitness 175 User manual
ENGINE TECHNICAL
MANUAL
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CONTENTS
Section Description Page No.
A GENERAL INFORMATION ... 5
B ENGINE VIEW … 6
ENGINE SERIAL NUMBER LOCATION … 8
THREADS AND TORQUE SPECIFICATION … 9
C TECHNICAL DATA … 10
MANUFACTURING DATA AND DIMENSIONS … 11
D OPERATION AND MAINTENANCE … 18
E PREVENTIVE MAINTENANCE … 21
F FUEL SYSTEM … 27
G COOLING SYSTEM – WATER PUMP … 33
H FRONT OIL SEAL … 35
I FLY WHEEL AND REAR END OIL SEAL … 37
J LUB OIL SUMP, BALANCER UNIT AND OIL PUMP … 40
K CYLINDER HEAD … 45
ASPIRATION SYSTEM … 58
L TIMING CASE AND DRIVE … 62
M PISTONS AND CONNECTING RODS … 67
N CRANKSHAFT ASSEMBLY … 71
O CYLINDER BLOCK AND LINERS … 75
P LUBRICATION SYSTEM … 78
APPROVED LUBRICATING OILS … 79
Q ELECTRICAL EQUIPMENT … 80
R TROUBLE SHOOTING … 81
S SERVICE TOOLS … 92
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SAFETY PRECAUTIONS:
The safety measures that always should be
performed in order to avoid risks that is always
present.
All servicing normally be carried out with the
engine stationary.
Do not approach the running engine with loose
cloth or long hair. Keep away from the moving
parts during engine operation.
Warning: Some moving parts can not be seen
clearly while engine runs.
Be careful of hot surfaces.
Do not open the radiator ller cap when the
engine is hot.
Do not put fuel in the tank while the engine runs.
(unless it is absolutely necessary)
Avoid skin contact with oil, fuel or chemicals that
can cause burn. Long term contact with oil can
lead to the skin problem.
Run the engine only in a well-ventilated area.
When lifting the engine use the lifting eyes that
are tted to the engine.
Never work alone when removing heavy parts.
When cleaning the engine with high-pressure
washer, never direct the jet at seals, rubber
hoses or electrical components.
Always prevent diesel or oil from contacting
rubber parts or tubing
Caution: Warns of a risk of injury, serious
damage to the product or serious malfunctions
could occur if the instruction is not followed.
Important: Is used to draw attention to things
that could cause damage to or malfunction of
the product.
Note: It is used to draw attention to important
information to facilitate procedure or handling.
Section A
GENERAL INFORMATION
TOOLS AND MEASURING EQUIPMENT
Be sure that all necessary tools and
equipments are available before starting work.
Use special tools where they are
specied.
Never drop the tools.
Use specied tools only.
REMOVAL OF PARTS:
First nd the cause of the problem and then
determine whether removal or disassembly is
required before starting the job.
INSPECTION OF PARTS:
Each part when removed should be carefully
inspected for malfunction, deformation, damage
and other problems.
All disassembled parts required for reassembling
should be carefully stored.
Ensure to separate and correctly identify the
parts to be replaced from those that will be used
again.
CLEANING OF PARTS FOR REUSE:
All parts to be used again should be carefully and
thoroughly cleaned by an appropriate method.
PARTS
When replacing parts, use genuine parts.
Oil seals, Gaskets, O-rings, Lock washers, split
pins and plastic nuts should always be replaced
with new ones.
Standard values such as torque and adjustments
must be strictly observed in the reassembly of all
parts.
FITMENT
Use correct tools, gauges and testers for correct
tment of the parts to standard value.
ELECTRICAL SYSTEM
Be sure to disconnect the battery cables from
the negative terminal of the battery
Never pull on the wires when disconnecting
connectors.
Page No. : 6
Section B
ENGINE VIEW
Page No. : 7
ENGINE VIEW
Page No. : 8
ENGINE SERIAL NUMBER LOCATION
The Engine Number is stamped on the Camshaft Tunnel of the Block
When requesting information regarding the engine, please quote complete engine number.
T SJ436 E 00027
T SJ 4 3 6 E 000 27
Turbocharged Serial Number
Simpsons Export
'J' Series
4 Cylinder 3.6 Litres
Engine Cubic Capacity
Page No. : 9
SIMPSONS ‘SJ’ SERIES DIESEL ENGINES
ALL THREADS USED IN T SJ436 E ENGINES ARE
METRIC SERIES
Except for the components indicated below :
1. Bolt and Nut, connecting rod ... ... 7/16" – 20 UNF
2. De-aerator plug on water outlet body … … 1/4" – 18 NPSI
3. Water temperature sender on water outlet body (RHS) ... 3/8" – 18 NPSI
4. Lub oil pressure gauge tapping on cylinder block (LHS) ... 1/8" – 27NPSI
RECOMMENDED TIGHTENING TORQUES
Nm Kg.m. Thread Size
Cylinder head setscrew (Camshaft tunnel side) 65 6.6 (M10 x 1.0)
Cylinder head setscrew (Refer Section K) X X (M12 x 1.5)
Connecting rod nuts 80 8.3 (7/16" - 20 UNF)
Main bearing setscrews 155 15.9 (M14 x 2)
Idler gear hub nut (lower and upper) 28 2.9 (M10 x 1.25)
Camshaft gear retaining setscrews 75 7.6 (M12 x 1.75)
F.I. pump adaptor to F.I. pump camshaft nut 92.5 9.3 (M12)
F.I. pump gear to adaptor setscrew 21 2.2 (M8 x 1.25)
Flywheel setscrews 110 11.1 (M12 x 1.25)
Crankshaft pulley retaining setscrews 150 15.2 (M22 x 2.5)
High pressure fuel pipe cap nuts 20 2.1 –
Atomiser xing nut 60 6.1
Sump drain plug 45 4.5
Oil lter / fuel lter 16 1.6
Glow Plugs (leakless tightening) (M6 x 1)
Balancer Mounting Setscrews 55 5.6
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