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Lombardini LGW 523 mpi Automotive Engine Workshop Service Repair Manual

This Lombardini LGW 523 mpi Automotive manual was written by the manufacturer to provide technical and operating information to authorised LOMBARDINI after-sales service centres to carry out assembly, disassembly,overhauling, replacement and tuning operations.

This manual is divided into several chapters. – The first chapter gives general information and details about safety (purpose of the manual, safety, etc.).

– The second, third and fourth chapters provide general technical information (technical specifications, diagrams, tightening torques, malfunctions, etc.).

– The fifth, sixth, seventh and eighth chapters describe the most important operating procedures (removal, overhaul and tuning, installation, replacements, etc.). This final section, which is reserved specifically for LOMBARDINI after-sales service centres, has been prepared with technical and practical considerations in mind.

– However, the actual sequence of operations that LOMBARDINI service centres use may in some cases be different from the ones described in this manual. For this reason, readers should refer to the index to find their topic of interest quickly.

Lombardini LGW 523 mpi Automotive Engine Workshop Service Repair Manual

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File size: 16.7 MB (17,558,661  )

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The  Repair Manual Covers:
General Remarks And Safety
Technical Information

  • 2 1 GENERAL DESCRIPTION OF THE ENGINE 9
  • 2 2 TECHNICAL SPECIFICATIONS 10
  • 2 3 PERFORMANCE CURVE DIAGRAM 12
  • 2 4 ALTERNATOR LOAD CURVE DIAGRAMS 13
  • 2 5 LUBRICANTS 14
  • 2 6 COOLANT 15
  • 2 7 FUEL SPECIFICATIONS 15
  • 2 8 ROUTINE MAINTENANCE OF
  • LGW 523 MPI ENGINE 15
  • 2 9 OPERATING PRINCIPLE FOR LUBRICATION 16
  • 2 10 OPERATING PRINCIPLE FOR COOLING 16
  • 2 11 OPERATING PRINCIPLE FOR FUEL SUPPLY 17
  • 2 12 WIRING DIAGRAM 18
  • 2 13 ELECTRONIC ENGINE CONTROL
  • WIRING DIAGRAM 20
  • 2 14 ELECTRICAL WIRING FOR ELECTRONIC
  • ENGINE CONTROL 21
  • 2 15 FUEL SUPPLY SYSTEM 22
  • 2 15 1 Electric fuel supply pump 22
  • 2 15 2 Fuel filter 22
  • 2 15 3 Pressure regulator 22
  • 2 15 4 Prefilter 22
  • 2 15 5 Injector supply pipe 23
  • 2 15 6 Injectors 23
  • 2 15 7 Inertial switch 23
  • 2 16 ELECTRONIC ENGINE CONTROL SYSTEM 24
  • 2 16 1 Ignition coil 25
  • 2 16 2 Spark plug 25
  • 2 16 3 Lambda probe sensor 25
  • 2 16 4 Electronic control unit (E C U ) 26
  • 2 16 5 Control unit identification plate
  • and more

Malfunctions
Storing The Engine
Removing The Assemblies

  • 5 1 RECOMMENDATIONS FOR REMOVING
  • THE ASSEMBLIES 37
  • 5 2 REMOVING THE EXHAUST AND
  • INTAKE MANIFOLDS 37
  • 5 2 1 Disassembling the intake manifold 37
  • 5 2 2 Disassembling the air flow sensors 40
  • 5 2 3 Disassembling the exhaust manifold 40
  • 5 3 REMOVING THE COOLING FAN BELT DRIVE 41
  • 5 3 1 Disassembling the cooling fan belt
  • (with external alternator) 42
  • 5 3 2 Disassembling the cooling fan belt
  • (with internal alternator) 42
  • 5 4 REMOVING THE TIMING BELT DRIVE 43
  • 5 4 1 Disassembling the timing belt guard 43
  • 5 4 2 Timing belt and gears 43
  • 5 4 3 Removing the speed sensor 44
  • 5 4 4 Disassembling the synchronous timing belt 44
  • 5 4 5 Sliding pulley and belt tightener 44
  • 5 4 6 Disassembling the synchronous timing
  • belt pulleys (camshaft and crankshaft) 45
  • 5 4 7 Disassembling the coolant circulation pump 45
  • 5 4 8 Disassembling the pump scroll 46
  • 5 5 REMOVING THE CYLINDER HEAD
  • AND COMPONENTS 46
  • 5 5 1 Disassembling the spark plug 46
  • 5 5 2 Disassembling the rocker arm cover 47
  • 5 5 3 Disassembling the rocker arm assembly 47
  • 5 5 4 Disassembling the injectors 48
  • 5 5 5 Disassembling the camshaft 50
  • 5 5 6 Disassembling the thermostatic valve body 50
  • 5 5 7 Removing the cylinder head 51
  • 5 6 DISASSEMBLING THE VALVES 51
  • 5 7 REMOVING THE CRANK GEAR AND
  • CRANKCASE 52
  • 5 7 1 Disassembling the flywheel 52
  • 5 7 2 Disassembling the oil pump 52
  • 5 7 3 Disassembling the crankcase and crankshaft 53
  • 5 7 4 Disassembling the connecting rod and piston 54
  • 5 8 DISASSEMBLING THE PISTON 54

Overhauls And Tuning

  • 6 1 RECOMMENDATIONS FOR OVERHAULS
  • AND TUNING 57
  • 6 1 1 Shaft seals 57
  • 6 1 2 O-rings 57
  • 6 1 3 Bearings 57
  • 6 2 OVERHAULING THE CRANK GEARS
  • AND CRANKCASE 57
  • 6 2 1 Overhauling cylinders and pistons 57
  • 6 2 2 Dimensional check and overhaul of cylinders 58
  • 6 2 3 Dimensional check and overhaul of pistons 58
  • 6 2 4 Dimensional check of sealing rings 59
  • 6 2 5 Dimensional check and overhaul of crankshaft 60
  • 6 2 6 Dimensional check and overhaul
  • of connecting rods 61
  • 6 2 7 Checking parallelism of the connecting
  • rod axes 61
  • 6 2 8 Checking and overhauling the oil pump 62
  • 6 2 9 Overhauling the decanting device 63
  • 6 3 OVERHAULING THE CYLINDER HEAD
  • AND COMPONENTS 63
  • 6 3 1 Checking and overhauling the cylinder head 63
  • 6 3 2 Checking and overhauling the valves 64
  • 6 3 3 Checking and overhauling the rocker arm pin 65
  • 6 3 4 Hydraulic tappets 66
  • 6 3 5 Checking and replacing the camshaft 68
  • 6 4 DIAGRAM OF TIMING BELT RATES 69
  • 6 5 CHECKING THE SPARK PLUG 69
  • 6 6 REPLACING THE FLYWHEEL RING GEAR 70

Installation Of Assemblies
Replacing Parts
Index and more

 

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