1. AfterSalesTraining Welcome to AfterSalesTraining

2. Hydraulic Tappets

3. AfterSalesTraining Hydraulic Tappets K Series standard K Series VVC lightweight Bleeding tappets Run engine between 2000 & 2500 rpm until noise ceases upto 20 mins do not exceed 3000 rpm

4. AfterSalesTraining Valve Guides 18G 1576 - 1 18G 1576 - 3

5. AfterSalesTraining Valve Guides 18G 1576 – 1 18G 1576 – 2 (16v) 18G 1576 – 3 18G 1576 – 4 (8v)

6. AfterSalesTraining Valve and Valve Seats A.15 B.45 C.60 D.Inlet seat seal 1 – 1.4 mm 1 – 1.4 mm E. Exhaust seat seal 1.4 – 1.8mm 1.4 – 1.8mm

7. AfterSalesTraining Cylinder Liners Early liners & pistons graded October 2000 onwards no liner or piston grades

8. AfterSalesTraining Pistons & Con Rods Semi floating offset gudgeon pinSemi floating offset gudgeon pin Pistons offset to thrust sidePistons offset to thrust side Gudgeon pin interference fit in con rodGudgeon pin interference fit in con rod Early 1.4 aluminium alloy constructionEarly 1.4 aluminium alloy construction Latest 1.4 molybdenum coatedLatest 1.4 molybdenum coated 1.6 & 1.8 lightweight with shorter skirt1.6 & 1.8 lightweight with shorter skirt

9. AfterSalesTraining Cylinder Head Gasket & Dowels Dowel fitted height 10 to 11 mm

10. AfterSalesTraining Cylinder Head Bolts A.Bolt head flange to cylinder block face 97 mm or less B.Bolt head flange to top face of oil rail 378 mm or less A B

11. AfterSalesTraining Practical

12. Cooling System Pressure Test

13. AfterSalesTraining Cooling – System Pressure Test Check 1. 1.Visually check engine and cooling system for signs of coolant leaks. 2. 2.Examine hoses for signs of cracking, distortion and security of connections. 3. 3.Position heater temperature control to maximum heat position.

14. AfterSalesTraining Cooling – System Pressure Test Procedure 4. 4.Remove expansion tank filler cap (Figure 10). Figure 10

15. AfterSalesTraining Cooling – System Pressure Test Procedure WARNING: Since injury such as scalding could be caused by escaping steam or coolant, do not remove the filler cap from the coolant expansion tank while the system is hot.

16. AfterSalesTraining Cooling – System Pressure Test Procedure 5. 5.Select correct adaptors and fit to expansion tank (Figure 11). Figure 11

17. AfterSalesTraining Cooling – System Pressure Test Procedure 6. 6.Connect pressure hose to adaptor (Figure 12). Figure 12

18. AfterSalesTraining Cooling – System Pressure Test Procedure 7. 7.Position pressure pump, connect pressure hose to pump. 8. 8.Slowly pump up system to required pressure and check for leaks. 9. 9.Release pressure by pressing pressure release valve on pump (Figure 13). Figure 13

19. AfterSalesTraining Cooling – System Pressure Test Procedure 10. 10.Remove pump from pressure hose. 11. 11.Remove hose from adaptor. 12. 12.Remove adaptor from expansion tank and refit expansion tank filler cap

20. AfterSalesTraining Pressure Cap Test Procedure Figure 14 1. 1.Select correct cap adaptor 2. 2.Fit cap to adaptor

21. AfterSalesTraining Pressure Cap Test Procedure 3. Connect pressure hose to adaptor and pump 4. Pressurize cap to required pressure 5. Check for leaks Figure 15

22. AfterSalesTraining Pressure Cap Test 6. Release pressure by pressing pressure release valve on pump

23. AfterSalesTraining Cooling System Vacuum Refill

24. AfterSalesTraining 1. Visually check engine and cooling system for signs of coolant leaks. 2. Examine hoses for signs of cracking, distortion and security of connections. 3. Position heater temperature control to maximum heat position. 4. Remove expansion tank filler cap. Drain Cooling - Vacuum Refill System

25. AfterSalesTraining WARNING: Since injury such as scalding could be caused by escaping steam or coolant, do not remove the filler cap from the coolant expansion tank while the system is hot. Drain Cooling - Vacuum Refill System

26. AfterSalesTraining Drain 5. Position vehicle on 4 post ramp. 6. Remove underbelly panel. 7. Position container to collect coolant. 8. Loosen clip and disconnect bottom hose from radiator and engine block drain plug (where applicable). 9. Allow cooling system to drain 10. Flush system with water under low pressure. Cooling - Vacuum Refill System

27. AfterSalesTraining WARNING: Do not use water under high pressure as it could damage the radiator. 11. Connect bottom hose to radiator and secure with clip. 12. Prepare coolant to required concentration. 13. Ensure heater temperature control is set to maximum. Drain Cooling - Vacuum Refill System

28. AfterSalesTraining Refill 1. 1.Position vacuum adaptor to expansion tank and tighten hand wheels. Ensure seal is positioned midway in expansion tank neck (Figure 1). Figure 1 Cooling - Vacuum Refill System

29. AfterSalesTraining 2. Assemble both parts of vacuum adaptor, ensure both valves on vacuum adaptor are closed (Figure 2). Refill Figure 2 Cooling - Vacuum Refill System

30. AfterSalesTraining Refill 3. 3.Position fresh coolant container so that the lower level is above the expansion tank neck. 4. Connect fresh coolant hose to container, ensuring no air can enter hose (Figure 3). Figure 3 Cooling - Vacuum Refill System

31. AfterSalesTraining Refill 5. 5.Position evacuated air hose in a container (Figure 4). Figure 4 Cooling - Vacuum Refill System

32. AfterSalesTraining Refill 6. 6.Connect a regulated compressed air supply to vacuum adaptor (Figure 5). Figure 5 Cooling - Vacuum Refill System

33. AfterSalesTraining Refill 7. 7.Open air supply valve A (Figure 6). Figure 6 Cooling - Vacuum Refill System

34. AfterSalesTraining Refill 8. 8.Apply air pressure progressively from 0 to 10 bar max. Maintain air pressure until gauge reads between -0.85 and - 0.95 bar and is stable. Cooling - Vacuum Refill System

35. AfterSalesTraining Refill 9. 9.Briefly open coolant supply valve B, to prime coolant supply hose. close valve B. Coolant will exhaust from evacuated air hose (Figure 7). Figure 7 Cooling - Vacuum Refill System

36. AfterSalesTraining Refill 10. 10.Check that vacuum is holding and gauge is steady. 11. 11.Close air supply valve and disconnect air supply (Figure 8). Figure 8 Cooling - Vacuum Refill System

37. AfterSalesTraining Refill 12. 12.Open vacuum valve and allow coolant to be drawn into system. Wait until 0 bar is indicated on gauge (Figure 9). Figure 9 Cooling - Vacuum Refill System

38. AfterSalesTraining Refill 13. 13.When expansion tank is full and coolant movement has ceased close vacuum valve. 14. 14.Disconnect vacuum hose from container and remove container. 15. 15.Remove vacuum adaptor from expansion tank. 16. 16.Syphon excess coolant from expansion tank to correct level. 17. 17.Fit expansion tank filler cap. Cooling - Vacuum Refill System

39. AfterSalesTraining Refill 18. 18.Fit underbelly panel. 19. 19.Start and run engine until radiator cooling fan operates. 20. 20.Monitor temperature gauge during warm up to prevent over heating. 21. 21.Switch off engine and allow to cool. 22. 22.Check for leaks and top-up coolant to 'MAX‘ mark on expansion tank Cooling - Vacuum Refill System