Installation instructions

Oil connections (download)

Completely disassemble the oil and discharge pipes from the turbo and ensure that they are thoroughly cleaned. Mount the pipes to the turbo, make sure that liquid gaskets are never used. Do not forget to renew the engine oil !!!

Air pipes

Always install a new air filter and clean the air intake pipe. If an intercooler is fitted, any oil residue should be removed. The turbo pressure line must also be carefully checked for any metal residue and then cleaned.

Mounting on the manifold

The manifolds can still contain metal residues from the previous turbo damage. These must be removed. A manifold with cracks can damage the new turbo. Check this carefully.

Crankcase breather and engine condition

In many cases, the crankcase venting of the engine is connected to the air supply line of the turbo. A clogged crankcase venting causes oil drain problems for the turbo. An engine that is in poor condition causes cart fumes that are blown into the engine by the turbo. This causes incomplete combustion and smoke nuisance. Also check the oil pressure of the engine.

Testing

Start the engine and let it idle for a few minutes. Convince yourself of the fact that sufficient engine oil is supplied to the turbo. Slowly increase the engine speed and check all connections for any leaks. All bolted connections must be retightened when the engine is warm. Adjust the wastegate carefully if necessary. If you have any questions, please contact our sales department.

The above information is exclusively for advice to our customers. No rights can be derived from the information. Manufacturer's instructions always take precedence.

1. Check before installing: (download)

. Make sure all the (sealing) plugs that are placed against the leaks are removed before you start to build in the engine (also from the engine intake parts) . All oil seals for leaks. Refresh in case of doubt.

2. Additional points for attention / installation tips:

. Refresh the grommet under the oil drain plug.

. Oil and oil filter replaced according to factory data.

. Pay attention to viscosity and quantity.

. Replace the complete distribution (possibly including the water pump)

. When you have to convert the intake manifold, make sure it is clean (often there are metal particles of the broken engine inside that could break the new engine). Be careful not to leave both gaskets.

. Check the radiator for proper flow / leakage (check whether the heat sink motor starts after installation)

. Only allow the engine to run if there is sufficient coolant and oil in the engine. An indicator has been applied by Maresia Parts to check the temperatures in the engine.

. Avoid electronic interference. Use as many electronic components as possible, such as cable harness, sensors, temperature sensors etc. that belong to the vehicle.

Turbo engines:

. Make sure that there is sufficient oil at the turbo and that the oil can also flow away without resistance (think of a kinked return pipe).

. Make sure all suction pipes / hoses and the intercooler are clean. If the turbo has failed, you must replace the intercooler! (due to iron shavings)

. For diesel engines with a starter block on the fuel pump, it has to be converted. (the entire pump or only the immobilizer)

. Pay attention to the installation and installation instructions according to factory data, tightening moments etc.

. Check the oil level after the test drive.
. Check the engine for any leaks after the test drive.

. If necessary, ensure that the injectors of the common rail engine are re-introduced to the engine management. (Inquire at the brand dealer for which types this is of concern)

3. Outside warranty are:

. The complete distribution.
. Head gasket (in consultation).

. Leakage of water pump, hoses, gaskets and oil seals.

The information mentioned above is exclusively for advice to our customers. No rights can be derived from the information. Manufacturer's instructions take precedence.

1.Check-up before installation. (download)

.Thoroughly flush the oil cooler with pipes so that no dirt residue are left inside. .Check the faceplate for crazing, loose rivets and sway marks.

.Check the transmission externally for damage to oil cooler nipples, km counter connection, switching mechanism, dowel pins, mating surfaces etc.

.Check that the slide of the drive shaft (s) is clean and smooth and grease it lightly with Vaseline or oil.

2.Construction

.Lightly lubricate the neck of the converter with Vaseline or oil and slide it into the transmission.

Make sure that the drive cams are properly seated in the transmission pump. Now mount the transmission complete with converter against the engine.

Caution!

The transmission must be flush with the engine, in the dowel pins. If this is not the case, then the converter is not properly fitted in the pump or the centering cam does not fit into the crankshaft.

Important!

Never pull the transmission against the motor by means of the fastening bolts. This irrevocably damages the converter and oil pump, so the warranty expires!

.Make sure that the keyways of the drive shaft (s) are clean and lightly greased. The internal and external keyways must not have radial play with respect to each other.

.The switching mechanism must not be damage or have excessive play. Set the selection lever and the transmission to the "P" position, mount the linkage and adjust it.

.If the transmission is completely assembled, it can be filled with oil. First 2-3 liters with the engine stopped. Now start the engine, apply the parking brake and press the foot brake. Switch on all positions for a moment so that the servos and cylinders can fill up. Set the selection lever to "P" or "N" again, depending on the factory data, and fill the oil to the correct level at idling speed.

.Adjust the kickdown cable according to factory data, check the inner cable for fraying and the play on the carburetor gearbox (if applicable)

.In the case of machines with a vacuum modulator, the vacuum line and the engine vacuum must be checked. With diesel engines it is very important that the vacuum pump is checked.

.During the test drive, check the shift times, kick-down and after the test drive the oil level and seals.

The above information is only intended as advice to our customers. No rights can be derived from the information. Manufacturer's instructions always take precedence.

1. Mounting cylinder head: (download)

. Never place the cylinder head on the coupling face, this may cause damage to the face or valves. .Try to find the cause of the cylinder head damage and fix it first.
. Check the cylinder walls and pistons for damage and remove carbon residues.
. Thoroughly clean all parts to be transferred and check them for wear or damage.

. Check the head gasket surface of the engine for damage and deformation.

. Clean the fitting surface and bolt holes, paying attention to the roughness of the block (as smooth as possible).

. Always use new bolts (if specified) of the correct dimensions.

. Mount head gasket of the correct thickness and type with the right side up.

. Follow the prescribed tightening torques and sequence.

. Note that the timing marks of the distribution are correct and install new timing belts and tension / rollers.

. Allow hydraulic tappers to rest for at least one hour after installation to be able to adjust. Preferably rest overnight.

. Adjust the valve clearance for fixed tappets / damper plates with a margin of 0.05mm extra.

. After adjusting the distribution, first turn the engine by hand two turns to check that the valves do not touch the piston.

. Always replace the oil, oil filter, thermostat and coolant according to the type and type designation prescribed by the manufacturer.

. Check the radiator and water pump for leaks and operation.

. In an LPG installation, allow the engine to run on petrol for the first 1000 kilometers and then adjust the installation.

.Check ignition / injection system / fuel pump adjustment.
. take a test drive and check everything again.
If you have any questions, please contact our sales department.

The above information is only intended as advice to our customers. No rights can be derived from the information. Manufacturer's instructions always take precedence.

To avoid problems, we ask your attention for the following points: (download)

1. Check before installing

. All oil seals for leaks. Refresh in case of doubt.

2. Additional points for attention:

. Oil plugs: Provide filler, level and drain plugs with new sealing rings.
. Oil filling: Always follow the dealer specification for viscosity, filling quantities and filling procedure. . Check: Check the oil level again after the test drive and check for any leaks.
. Follow (de) assembly instructions according to factory data (tightening torques etc)
3.Other:
. Oil seals and any supplied thrust bearings are not covered by the warranty.
. Old gearbox returned to Maresia Parts. (unless otherwise agreed)
. Annouce your return request for the old gearbox by e-mail (mention invoice number and address)
. If you have any questions, please contact our sales department.

The above information is only intended as advice to our customers. No rights can be derived from the information. Manufacturer's instructions always take precedence.