P400, P400S Overhaul Manual

CHARACTERISTICS AND GENERAL DATA
1. WEIGHTS AND MEASURES
2. CAPACITIES
3. ENGINE
4. IGNITION SYSTEM
5. TRANSMISSION
6. CHASSIS
7. PERFORMANCE
8. MAINTENANCE DATA
8.1 Engine Oil Change
8.2 Brakes
8.3 Lubrication
8.4 Cooling System
8.5 Antifreeze
8.6 Tire Pressure
8.7 Break-in Procedure
8.8 Identification Tags

TECHNICAL OVERHAUL INSTRUCTIONS AND ASSEMBLY PROCEDURES
1 ENGINE
1.1 Insertion of Cylinder Liner into Cylinder Block
1.2 Extraction of Cylinder Liner from Cylinder Block
1.3 Tolerance Between Cylinder Liners and Pistons
1.4 Assembly of  Main Bearing Studs.
1.5 Assembly of Cylinder Head Fastening Studs
1.6 Insertion of Valve Guides Into Heads
1.7 Extraction of Valve Guides From Heads
1.8 Insertion of Valve Seats Into Heads
1.9 Extraction of Valve Seats From Heads
1.10 Assembly of the Main Bearings 

1.11 Tolerance Between Main Bearings and Journals
1.12 Assembly of Timing System Gears and Sprockets On Block
1.13 Crankshaft Installation
1.14 Piston Ring Installation
1.15 Assembly of Connecting Rods and Pistons
1.16 Tolerance Between Wrist Pin and Rod Small-Eng Bearing
1.17 Assembly of Large End Bearing
1.18 Tolerance Between the Rod Bearings and Journals
1.19 Installation of Rods On Crankshaft
1.20 Oil Pickup Installation
1.21 Assembly of the Transmission Shaft System
1.22 Insertion of the Transmission System Into Block
1.23 Assembly of the Differential System
1.24 Insertion of the Differential System
1.25 Assembly of the Gearbox Lever System
1.26 Assembly of the Gear Selector and Starter Connection
1.27 Assembly of Clutch System
1.28 Installation of Valves In Cylinder Heads
1.29 Assembly of the Heads
1.30 Camshafts Installation and Valve Adjustment
1.31 Assembly and Tensioning of Timing Chains
1.32 Timing System Setup
1.33 Assembly of the Distributors and Ignition Timing
1.34 Installation of Assembled Engine On Chassis
1.35 Carburation
1.36 Summary of Engine Bolt Torque Values
2.00 Chassis Layout
3.00 Electrical system
this is a work in progress! any help would be appreciated.

1.1 Fitting cylinder liners into block
- heat cylinder block to 130oC(140oC max),
266oF (288oF max)
- apply grease to the liners and insert them into block, down to the abutment (this must be a running fit).
- let block  cool down to 90oC.
- using special tool (see tav III) , press liners into block by applying a torque of 12 Kg/mm on screw "A".
- let block cool to room temp
- face grind liner tops to 0.09 - 0.10 mm projection above cylinder block
- bore liners to 82 mm (-.015)/ (-.025)mm diameter.
- hone finish bores to 82mm (-.000)/(-.010) mm dia

1.2 Removing cylinder liners from block
- removal is normally carried out in cold condition by means of a special tool (see tav IV).
- when withdrawal is difficult, heat cylinder block to 130oC (140oC max) then carry out operation.
- when withdrawal is difficult, heat cylinder block to 266oF (288oF max) then carry out operation.


1.3  Clearance between cylinder liners and pistons
The maximum original piston diameter is within the following limits (see tav II)
max d = 81.915 mm
min d = 81.895 mm
liner bore:
max D = 82.000 mm
min D = 81.990 mm
liner/piston clearance to be:
max clearance = 0.105 mm
min clearance = 0.075 mm
these clearance values must be maintained during subsequent rebores. It should be noted that oversize pistons are offered in steps of 0.20 mm diameter.

1.4 Fitting main bearing studs
- main bearing studs (12mm dia) next to crankshaft are tightened to torque of  3.5 mKg.
- outer studs (8mm dia) are tightened to 1.8 mKg

1.5 Fitting cylinder head studs in block
- head studs (10mm dia) must be tightened on cylinder block to a torque of 3 mKg.

1.6
Insertion of valve guides
- heat cylinder head to 130oC(140oC max),
266oF (288oF max)
- insert valve guides in their housings.
- for new cylinder heads, guides housing diameters are:
housing max D = 13.018 mm
housing min D = 13.000 mm
and valve guide external diameters (see fig.1 tav V)
max d = 13.049 mm
min d = 13.038 mm
therefore: the resulting interference is -
max interference = .049 mm
min interference = .020 mm
when replacing valve guides the following oversizes must be fitted -
max d = 13.089 mm
min d = 13.078 mm
see table V.

1.7 Removing valve guides from cylinder heads
this operation is to be carried out after heating cylinder head to 140oC (150oC max),
288oF (302oF max)

1.8
Insertion of valve seats
-heat the head to
130oC(140oC max)
- then install the valve seats in the correct locations.
a) Intake
for the location bore:
D max = 45.946 mm
D min = 45.916 mm
for the OD of the seats:
d max = 46.080 mm
d min = 46.050 mm
therefore:
max interference = 0.164 mm
min interference  = 0.104 mm
b) Exhaust
for the location bore:
D max = 43.950 mm
D min = 43.920 mm
for the OD of the seats:
d max = 44.090 mm
d min = 44.060 mm
therefore:
max interference = 0.170 mm
min interference  = 0.110 mm
when replacing the valve seats it will be necessary to use larger  valve seats of the dimensions as follows:
d max = 46.130 mm
d min = 46.100 mm
b) Exhaust
d max = 44.130 mm
d min = 44.100 mm
for  additional info see Fig. V

1.9 Removing valve seats from heads
- this operation is carried out after heating head to 140oC (150oC max),
288oF (302oF max)

1.10 Fitting main bearings ("Trione" TR 20-499)
- fix the engine block on a suitable stand and mount  the bearing half shells MM-00234-00249-00244 (Fig. 3 SPC) on main bearing seats.
- mount half shell bearings MM00239-00236-00248 (Fig. 3 SPC) on the main bearing caps.
- assemble the bearing caps (without crankshaft) tightening by means of a torque wrench, only the nuts on the stud (12mm) bolts closest to the crankshaft using a torque of 9 kgm. (Make sure the caps are assembled correctly by referencing the punched numbers on each cap, #1 goes on the timing end of the engine)
- for each bearing, loosen completely the nut of one of the two 12m stud bolts and then measure with a feeler gage the gap between the contact surfaces. This gap should be .10+ .02 mm. this assures correct compression of the bearing inserts.
- loosen all 12 mm  stud nuts

1.11 Main bearing clearance

- on each bearing cap (without the crankshaft) retighten the 12mm nuts to 9 kgm , just as you did in the last step 1.10
- check the clearance between the crankshaft main journals and the mounted main bearings. (see Fig. VI)
main journal dimensions
d amx = 62.979 mm
d min = 62.966 mm
ID of bearings
D int max = 63.030 mm
D int min = 63.005 mm
If the measured clearance is less than 0.04 mm, scrape the corners of the grooved half shells and smooth over with abrasive paper (400) the caps and the outside of the half shell until you achieve the required clearance. These clearances must be met with any under sized crank journals/bearing as well.
first undersize is typically (see Fig. VI)
d max = 62.729 mm
d min =  62.716 mm

1.12 Fitting timing gears into block
- mount the external race of the internal roller bearing CSN00429 (Fig. 4) in the block.
- insert idle sprocket MD 02691 into the internal race of the correct bearing.
- insert the external race of the bearing GRN 00433 in its seat and assemble the cover plate MD 00336.
- mount the internal bearing of the self-centering idle sprocket MD 04380 in its seat in the block.
- insert  the sprocket MD 04380 with its lowest ledge turned toward the inside.
- insert the serrated shaft MD 04381 making sure to match the reference marks on the shaft and sprocket.
- mount the internal race of the second bearing on the shaft and then insert its external race into its seat.
- insert the washer  MD 00776 in its seat making sure the bevel is turned toward the inside.
- insert the sprocket  MD 04878  and then the eccentric shaft MD 02471.
- insert the dowel pin  MD 00340 which joins the washers MD 00776 and MD 00339 and then mount the washer MD 00339 making sure the bevel  faces the outside.
- mount the bushing MD 00342
- mount the gear MD 04077 that rotates on the shaft MD 00333.
- this operation must be carried out on both  sides of the cam system.

1.13 Installing the crankshaft
 - before installing crankshaft in the block, mount the timing pinion MM01117 as follows:
    1)heat the pinion MM-01117 and the spacer MM04486 to 160 C (170 C max). lubricate crank location with oil.
    2) slip on the hot spacer
    3) tap in the key LN04489
    4) install pinion by beating it on the crankshaft end with a socket or piece of tubing .
- prelube all the crank journals and block shell inserts with  suitable lubricant.
- lay the crankshaft into place, but be sure to install the end gear MM03578 at the same time. This must be done prior to tightening caps as the gear will not go on later.
- install main bearing caps w/inserts.
- tighten all caps (except #7) to 9 kgm on the 12 mm inner studs and 2.8 kgm on the 8mm outer studs.
- at bearing cap #7 , insert the thrust washers MM01245 and check with a feeler gage the clearance or end play . 0.15 - 0.17 mm  is required play. If too tight, the face bearing material may be removed to achieve this clearance.
- tighten #7 cap to same torque as others 9 kgm, 2.8 kgm.
- recheck end play :  0.15 - 0.17 mm.

1.14 Installing piston rings
- the piston rings have to be assembled while being careful that the word "top" is facing up on all rings.

1.15 Fitting rods to pistons
Over the big end face of each connecting rod , on the side with the retaining notch for the halfshell, the weight in grams of connecting rod (without halfshells) is stamped. The same is stamped  also at the intake side of engine, below the water inlet pipe, MW-03306 (tav12), on crankcase. It is essential that each connecting rod of an engine has the same weight. On the other side of the connecting rod, both at stem and the big end cap, a sequence number (from 1-12) is stamped.
- Connecting rods and pistons must be assembled so that the recess for the inlet valve on the crown is on the side of the connecting rod where weight is stamped. To insert wrist pin it is advisable to use an aluminum drift punch.

1.16 Wrist pin clearance
Caro type bronze
- The small end bearing of connecting rod has the following internal diameter:
Max D = 19mm
MinD = 18.995mm
and the diameter of the wrist pin is :
Max d = 19mm
Min d = 18.995mm
The resulting radial play is therefore:
Max or Min play = .005mm (slight interference)
- To check correct fit between connecting rod and wrist pin, the most practical method is that of making sure that the insertion can be carried out by pressing the pin into position with the middle finger of the active hand.

1.17 Assembling rod big end bearings
Trione TR 20-416 half shells
- Assemble the half shells, MM-00242 (tav3), in each connecting rod big end bearing.
- Tighten nuts on cap with a torque of 6 Kgm.
- Fully loosen on of the bolts on cap.
- Check with a feeler gage the resulting gap between mating faces of cap and stem. 
This gap is correct when within: 0.08mm - 0.10mm
thus ensuring compression of the half shells in the housings.

1.18 Rod clearance at big end
After the big-end bearings are assembled, their internal diameter is:
Max D = 43.680mm
Min D = 43.658
Crankpin diameter are (see Table VI):
Max d = 43.604mm
Min d = 43.594
The resulting radial play is therefore:
Max Play = .086mm
Min Play = .054mm
The clearance specified above (maximum and minimum) must be maintained also when machining crankpins to undersize.
At the first undersize machining of crankpins their diameters should be (see Table VI):
Max d = 43.354mm
Min d = 43.344mm
Never do any machine work without the replacement bearings in your hands to use as the ultimate reference for sizing.

1.19 Installation of Rods On Crankshaft
- Fitting of connecting rods must be carried out in the order of numbers stamped on each of them, starting with bearing No.1 . During installation, make sure that  the recess on the crown of each piston for the inlet valve faces toward the centerline of the crankcase.
- Each connecting rod must be installed after rotating crankshaft so that the corresponding crankpin is alignment with the cylinder axis concerned. Assemble the cap on the big end bearing after applying engine oil to the halfshells, and partially tighten nuts on the bearing caps.
-After having completed the installation of all the connecting rods, make sure all the bearings turn freely on the crankpins. To check this, it is sufficient to shake each connecting rod by holding one of the nuts on the bearing cap with a spanner.
- Finally, complete the tightening of nuts on bearing caps with a torque of   6 Kgm.
- Then insert split pins into nuts.

1.20 Oil pickup installation

-Mount on the two stud bolts (12 mm) of main bearing cap #1 the baffle MB 04358 (tav 1) and tighten the nuts to 9 kgm again.
-Screw into the block the two stud bolts for attaching the oil pickup MB 04924 (tav 1) , be aware that to take out the crankshaft it is necessary to loosen these stud bolts.
-Loosen the stud nuts (12 mm) of bearing cap #4.
-Mount oil pickup unit MB 04924 and first tighten the nuts of the two stud bolts joining it to the block in such a way as to seal the block with the oil pickup tube.
-Tighten to 9 kgm the stud nuts (12 mm) of bearing cap #4 again.

1.21 Assembly of the transmission shaft svstem
-The assembly of the elements of the transmission shaft system must be carried out according to the sequence defined by the numbers shown in Fig. VII.
-In mounting it is necessary to check, by means of a dial indicator that the axial play of the gears is within the limits shown in Fig. VIII.
As far as the measuring processes are concerned see Fig. VIII.

1.22 Insertion of transmission system into block.
-Mount bearing CSN O1739 (tav 6) on the countershaft and check that it does not go in too loosely.
-Join the cluster gears of the transmission (main) shaft by means of the appropriate tool (see Fig. IX)
-Put the forks on the transmission shafts. The respective speeds are shown on each fork. Fork TC 02930 (tav 7) is relative to the 5th and reverse gear, fork TC 02931 to the 3rd and 4th fork  TC 02932 to the 1st and 2nd.
- Engage two speeds simultaneously so that it is possible to tighten the two ring nuts GHN 01760 (tav 6) on the transmission shaft and on the countershaft..
-Mount the reverse gear shaft TC 04537 (tav 6) on respective gears TC 02716 and TC 01770 with bearings CSN 02027.
-Insert all of the transmission countershaft system and the reverse shaft in the gearbox which is part of the block. Then slip off the tool that held the transmission shaft and countershaft.
-Mount lock screw EN 04349 (tav 6) of the reverse gear shaft after having rotated it until the hole opposite it is face to face with the threaded hole on the gearbox.
-Mount gasket TC 02469 (tav 5) of .5 mm. thickness after having wet the contact surfaces with sealing compound.
-Mount spacer TC 02275 (tav 5) and fix it by means of the appropriate stud bolts.
-Mount bearing GRN 03710 (tav 6) on the main shaft and bearing CSN 05483 (tav 6) on the countershaft in their housings on the spacer TC 02275 (tav 5).
-Mount flange TC 02744 (tav 5) on the housing hole of bearing CSN 05483 (tav 6) on the countershaft and tighten the nuts of the respective stud bolts.
-Mount  on countershaft TC 02734 (tav 6) lock washer RFN 01736 (tav 6) and tighten completely the ring nut GHN 01760.
(see dimensional drawing, Table XVI).

1.23 Assembly of the Differential System
- mount the internal race of the tapered roller bearing CCN02147 on differential housing TD03730 (tav14)
- mount gear TD02025 (tav14) in the housing TD03730 and mount flange TD02024, paying attention to the reference marks. tighten nut DN02191.
- check by means of a thickness gage that the clearances between housing TD03730 and flange RD02024 is within limits: 0.05-0.10 mm
-mount on housing TD03730 shaft TD03727 with planetary gears TD02026. bushings TD02132 and shim adjustment washers TD02134.
- put between planet gears TD02036 a special bolt tool of the right dimensions in such a way that as to lock them at a distance from each other (see fig.X)
- mount the internal race of tapered roller bearing CCN02147 (tav14) on the differential cover TD02022.
- mount gear TD02025 (tav14) on the cover TD02022 and then flange TD02024 paying close attention to the reference marks. Tighten nut DN02191.
- check by means of a thickness gage that the clearances between flange TD02024 and the cover TD02022 is within limits: 0.05-0.10 mm
- mount
the large spur gear TD02751 on the housing TD03730 (tav14) and then mount the cover TD02022 tightening the bolts BN02503 to 7 kgm using a torque wrench.
- with planet gears TD02026 fixed in a spaced apart position by means of a special tool previously put between them, check the backlash at each flange TD02024. The check will be carried out by means of a dial indicator and a reference marker positioned in one of the holes for the bolts of flanges TD02024 (see fig.XI). The backlash must be in the range: .14-.24mm.   In carrying out the measurement push flanges TD02024 toward the outside of the differential.


1.24 Inserting the differential system
-Mount the external race of tapered roller bearing CCN 02147 (tav14) in its housing made on the half of the differential cover integral to the block.
-Insert the differential unit together with the internal races of bearings CCN 02147 (tav14) previously mounted on elements TD 03730 and TD 02022.
-Mount pinion TC 05482 (tav14) on the transmission shaft paying attention to the reference marks.
-Mount gasket TD 02470 (tav5) having a thickness of 0.5 mm after having wet the surfaces with gasket sealant.
-Mount cover half  TD 05484 (tav5) tightening the respective bolts.
-Mount the main shaft bearing CSN05483 (tav6) and mount the external race on the rearing CCN02147 (tav14) in its seat made in cover ha1f TD 05484 (tav5).
-Mount thrust ring TD 05489 (tav5) and tighten the nuts of the respective stud bolts.
-Mount on the main shaft lock washer RPN01736 (tav6) and tighten completely the ring nut GHN01760.
-Insert oil seal GN 02192 (tav14) marked with the letter L in its seat made in the differential cover half integral to the block.
-Insert oil seal GN 02233 (tav14 ) marked with the letter R in its seat made on flange TD 02749 (tav5) and mount this flange,with any other pieces, on the cover half TD 05484 (tav5) without tightening its stud bolt nuts.
-Put flange ID 02024 (tav14) on the serrated hubs paying attention to the reference marks.
-Put all the gear box forks in the neutral position and then rotate by hand, simultaneously 3nd in the same direction, the two axle shaft flanges TD 02024 tightening the stud bolt nuts of flange TD 02749 gradually until clearance in bearings CCN 02147 (tav14) is eliminated. In case these bearings are broken in they must be free and without clearance; in case they are new ones, tighten to give some preload.
-Measure by means of a thickness gauge the light between the surfaces of flange TD 02749 and of the cover half TD 05484 (tav5) and insert between flange and cover half shims (see particular TD 02754 tav5) for a total value equal to the measured value plus 0.05 mm.
-Tighten completely the stud bolt nuts of flange ID 02749 (tav5) rotating as has already been described the two axle flanges ID 02024 ; recheck that the resistance to rotation has not varied.
-Then lock the flanges on the serrated hubs tightening completely the nuts DN 02191 (tav14).

1.25 Assembly of the gearbox  lever system
- Put gasket IC 02865 (tav5) checking a thickness of .5 mm in position after having wet its surfaces with gasket sealant.
- Mount cover TC02861 and tighten the nuts of the respective stud  bolts.
- Mount tube TC 03293 (tav7) through to1hich gear selector rod TC 02838 goes through the block. The mounting of tube TC 03293 is carried out by inserting it through the appropriate hole located on the block (tav1) until it meets bushing TC 03292 (tav5) previously mounted on cover TC 02861 (tav5). The tube must enter lightly forced in such a way as to guarantee at seal at the housings.
- Mount bushing BCN 04204 (tav7) on the block and insert oil seal ring GN 04203.
- Mount shaft TC 02845 with the widest knurl toward the high side of the engine.
- Insert gear selector rod TC 02838.
- Insert through the appropriate holes which will be found clutch side of the block links TC 02850, TC 02851, and TC 02852 in their own housings, pushing them forward until they meet the holes of the respective forks and then until they fit into the holes located on cover TC 02861.
- Insert springs TC 02242 (tav7) then balls SFN 01764 pushing the spheres downward in such a way that the links can go over them. .
- Insert on the respective links forks TC 02944 for the 5th and reverse gear, TC 02943 for the 3rd and 4th, and TC 02942 for the Ist and 2nd gear.
- Insert the dowels TC 03143, TC 03142 and TC 03142 and TC 03143 and fix the forks on the links by means of the appropriate bolts  BN 03138.
- Lock forks TC 02930, TC 02931 and TC 02932 on links TC 02851, TC 02852, and TC 02850 respectively by means of the proper nuts BN 03138 working through the three holes made for
this purpose on the gearbox. Before locking the forks on the l.-inks put all the forks in the idle position and check also that forks TC 02930 (for the 5th and reverse gear) and TC 02932 (for the Ist and 2nd) have a certain degree of freeplay (at least .2 mm.) around their locking position defined by the center of the threaded holes on their respective links (see Fig. 1 Drg XII).
- Still in idle position, mount on pin TC 02845 levers } TC 02848 and TC 02846. The assembly must be carried out in such a way that the edge of the lug TC 02836 projects about 3 mm.
beyond the contact surface of cover TC 02863 (see Fig. 2 Drawing XII).
- Then insert ball SFN 01764 (Fig. 7 SPC) and spring TC 03246 in bushing TC 03245 motmted On cover TC 02861 (Fig. 5 SPC). Push on the spring and move pin vertically TC 02845 until the sphere enters in the proper groove.
- Then check that lever TC 02848 is perfectly centered on fork TC 02945 of the 3rd and 4th speed.  If this does not happen, move the clamp of the lever TC .02848 until it centers perfectly on the fork TC 02943.
-Mount gasket TC 02864 (Fig. 5 src) after having wet it with gasket sealant and then cover TC02863.

1.26 Assembly of the gear selector starter connection
- Engage  5th gear.
- Then release fork TC 02931 (tav7) and move it toward the differential assembly and then engage the 4th gear to lock gearbox mainshaft and layshaft.
- push down the pinion carrier spindle TC-03569 (tav 6) by tapping the end with a lead hammer. Measure, with an appropriate depth gage, the distance between the machined shoulder in the block (that will receive the snap ring of the type 307 bearing CSN-01748 ) and the face of the gear  TC-03569. See Table XIII.
- Insert shim rings TC-04355 between the shoulder and the bearing snap ring as required to achieve clearance "D"=18.9mm. Total thickness "s" of shims to be inserted is given in the formula:  s = 18.9 - d + 0.1
- Install bearing CSN-01748 and flange TC-03617. If you have split sump, you will need o-ring seal on flange TC-03617and appropriate lip seal to engage gear TC-03563.
- Install gear TC-03563, then bearing CSN-03709, then lock washer RFN-02184, then ring nut GHN-02183 which must be fully tightened. To enable this ring nut tightening, main gear shaft and layshaft are locked by engaging two gears at the same time.
- screw on the remaining retainer TC-04191 (left hand thread). Split sump engine will require appropriate sealing on this retainer to keep gearbox lube oil from leaking. This retainer is also used as a "punch or peen  lock" against ring nut GHN-02183.
- move fork TC 02931 (tav 7) for 3rd and 4th gears to neutral, and lock it on rod TC 02852 with the bolt provided, after having checked that the fork end play (at least 0.2 mm) is
maintained in the locked position (see Figure I, Table XII).If fork TC 0?931 is not aligned with the tapped hole of the rod, it is necessary to adjust the total thickness of shims between bearing CSN-01748 (tav 6) and shoulder, still maintaining the above 0.2 mm axial play of the fork.
- install bearing CAN-03624 (tav 10) in its housing.
- tighten retaining screw BN-04125.
- insert bearing CSN-02826 (tav 10) in its housing in cylinder block.
- place crown gear ME-03573 in position.
- install flanged spindle ME-04101.
- place crown gear ME-04433 in position, with its machined surface towards flange of spindle ME- 04101.
- fasten assembly with bolts BN-02616.
- install spring MD-02083 and then item ME-04085, which should be inserted with a slight force.
- insert dowel GRN-03577 on crown gear MM-03578 (previously assembled- when crankshaft was installed) and assemble tapered drive hub MM-03583; tighten bolts BN-03575 with a torque of 2.8 mKg; then rivet retainers RFN-03698.
- install pinion MM-03565, with its bushes, MM-04051 and MM-04052, on hub MM-03583.
- install spacer piece MM-04054 with oil seal GN-03626 assembled.
- lock with circlip SGN-03692.
- check that pinion MM-03565 rotates freely but without end play (max. end play permissible = 0.05mm).
- using a guide bushing (tool) (see dimensional drawing. Table XIV) , assemble ring MM-03686 and oil seals GN-03626 on pinion MM-03565 after having applied sealing compound on the external surface of the ring.
- fit bearing GRN-03753 and pinion TC-03564 in cover MB-03581 (tav 10); lock with circlip SGN-04176.
- install bearing CSN-02826 in cover MB-03581
- fit seal MB-02488 after having applied sealing compounds onto the surfaces .
- fit cover MB-03581 and tighten nuts on its studs .
-Using a guide bush ,(tool, see dimensional drawing, (Table XV), fit oil seal GN-03832.
-Fit cover TF 03751 with retainer TF-04251.

1.27 Assembly of the clutch system
- fit flywheel TF-03580 (tav 9) .
- fit plate TF 03622.
- assemble cap TF 04003 on plate 03589, taking care that '0' marks stamped on their periphery are lined up.
- mount cap-plate assembly on flywheel ~F 03580, taking care that the '0' mark stamped on the flywheel periphery is lined up with the '0' marks of cap-plate assembly (these '0' marks were
stamped when balancing the three components).
- tighten bolts BN-03576 with a torque of 3 mKg.
- fully tighten ring nuts GHN-03600 (tav 10) using a special spanner.
-Install, on hub MM-03583 (tav 10) , items TF-04261, CSN-01864 and TF-03754 (tav 9), and then bearing CSN 03633.

1.28 Installation of valves in cylinder heads
- this installation should be carried out by means of a special tool (see dimensional drawing, Table XVII).
- radial play between valve stem and valve guide with valve guide already inserted in head shall be (Table V and Fig.l, Table XVIII)-
a) Inlet
Max. radial play = .035 mm
Min. radial play = .010 mm
b) Exhaust
Max. radial play = .055 mm
Min. radial play = .030 mm

1.29 Assembly of the Heads
-
mount gasket MT01815 (tav1)
- torque value for early 10mm studs = 7Kgm, torque value for 11mm studs=8.6Kgm
- mount heads, tightening in "criss-crossed order" the nuts of the stud bolts ( for tightening sequence see Fig 2, Table XVIII ).

1.30 Camshaft installation and valve adjustment
- turn the crankshaft until piston No.1 is at T.D.C. (see Table XIX).
- in this position, reference notch marked "PM. I.P.S." is aligned with notch on window of cover MB 3581 (see Table XIX).
- lubricate bearings and install inlet camshaft on r.h. head (viewed from clutch side), taking care that the location numbers stamped on the bearing caps end on the head are at the same side.
- note that inlet camshafts are marked "005/ A while exhaust c~shafts are marked 006/A". The R.H. cylinder head camshaft bearing caps (viewed from clutch side) are stamped with a 'D'
before the location number. The L.H. cylinder head camshaft bearing caps are stamped with a 'S' before the location number.
- fully tighten nuts on studs of r.h. head inlet camshaft bearing caps.
- set, by adjusting thickness of pads. r.h. inlet valve clearance to 0.25 mm ( cold condition clearance).
- unscrew nuts on studs of r.h. head inlet camshaft bearing caps.
- lubricate bearings and install r.h. head exhaust camshaft; fully tighten nuts on studs of r.h. head exhaust camshaft bearing caps.
- set r.h. head exhaust valve clearance to 0.25 mm (cold condition clearance).
- unscrew nuts on studs of r.h. head exhaust bearing caps.
- looking at the dial assembled on the end of hub MM-03583, which is set to zero with piston No.1 at T.D.C. (see Figure 1, Table XX), turn camshaft through 60 deg. in a clockwise direction (viewed from clutch side) to bring piston N.12 to T.D.C. (see Table XIX).
- lubricate bearings and install inlet camshaft on l.h. head; fully tighten nuts on studs of l.h. head inlet camshaft bearing caps.
- set l.h." head inlet valve clearance to 0.25 mm (cold condition).
- unscrew nuts on studs of l.h. head inlet bearing caps.
- lubricate bearings and install exhaust camshaft on 1.h. head; fully tighten nuts on studs of l.h. head exhaust camshaft bearing caps.
- set l.h. head exhaust valve clearance to 0.25 mm (cold condition).
- unscrew nuts on studs of l.h. head exhaust bearing caps.


1.31 Assembly and tensioning of timing chains
- with nuts screwed on studs of all camshaft bearing caps, set piston No.1 to T.D.C. (see Table IX) (reference mark 0 "P.M.I.P.S." on flywheel) to coincide with notch on window of cover MB-03581.
- rotate all camshafts to line up their setting notches with notches on caps of the last bearings, timing case side, (see Figure 1, Table XXI).
- whenever the above notches (on camshafts and caps) cannot be found because of replacement of some components, setting of camshafts can be carried out with the aid of Figure 3, Table XXI, where, with reference to each camshaft, the valve opening lifts are shown in relation to the T.D.C. position of piston No.1.
- fu11y tighten the nuts on the studs of all camshafts bearing caps, making sure that the camshafts setting does not alter.
- fit timing chains (this operation is easier with the oil pump assembly removed).
-Assemble sprockets MD 02694 (Tab~e 4) on camshafts and do not insert the retaining dowels MD 01964 at this stage.
- with the chains adjusters MD-02692 (Table 4) in slackened position, loosen also the nuts on the studs of bushings MD-00342 (Table 4) , and link together the ends of each timing chain, taking care to fit each chain retaining clip with its head pointing in the direction of movement of the chain (see Figure 2, Table XXI).
- adjust the tension of the timing chains by means of a special spanner (see dimensional drawing, Fig. I, Table XXII), with the prongs inserted through holes of plates MD 02447 (Table 4) Correct tension of the chains is obtained by applying  on t~e special spanner, a load p = 700 grams at at distance b = 22 cm. from the axis of the chain adjuster spindle. The resulting maximum deflection of each chain will be equal to 6.5 mm (see Fig. .Table XXII). When installing new chains a higher tension should be used.
- insert retaining dowel MD 00343 (Table 4) in each chain adjuster.
- tighten nuts on studs of bushings MD-00342.
- fit plate MD-00345 and tighten nut DN-00476.

1.32 Timing the overhead cam system
The valve timing will be described apart from that obtainable with the aid of the setting notches on the camshafts and the flywheel. The method outlined below, in addition to its higher
precision, allows valve timing in cases where some components have been replaced with new ones without setting notches.
- with the aid of a dial gauge, the plunger of which is inserted through the spark plug hole of cylinder No.1 (Fig. 1, Table XXIII), position piston No.1. at the precise T.D.C. This position
wil1 be obtained by gradual1y turning the crankshaft in a clockwise direction (viewed from clutch side) i.e. in the same running direction of the engine .
- set the graduated dial assembled to hub MM-03583 to zero, as shown in Fig. 1, Table XX (this setting will be used afterwards for the ignition timing).
- turn crankshaft through 50 deg. in an anticlockwise direction ( viewed from clutch side) .
- place plunger end of a dial gauge against cup of the cylinder No.3 exhaust valve (Fig. 2. Table XXIII).


1.33 Assembly of the distributors and ignition timing
-fit gaskets MT-00265 and MT-00266 (Table2) on cylinder heads after having applied sealing compound to the mating surfaces.
-install covers MT-02070, MT-00904, MT-02071, and MT-00903 taking care that gaskets slightly project (approximately 0.25mm) from the mating faces of components MT-00267, MT-03002, MT-04202, MT-03736 (Table2) and ME-04243 (Table 15).This is done in order that no oil can transdude.
-insert dowels GRN-00467 (Table 15) in their seatings of cylinder heads.
-fit oil seals GN-00466 on components ME-04243.
-with the aid of guide bushing (tool - see drawing Table XXIV) fit components ME-04243 and gaskets on the cylinder heads.
-looking at the graduated dial assembled to hub MM-03583 and set to zero with piston No. 1 at T.D.C. (see Fig1, Table XX), turn the crankshaft thru 30 deg in an anti-clockwise direction (viewed from clutch side) and then gradually through 8deg in a clockwise direction  with piston No.1 at 22deg B.T.D.C. (setting notch  A.I.P.S. stamped on flywheel , lined up with notch stamped on window of cover MB-03581) see Table XIX.
-install the distributor on left hand cylinder bank (viewed from clutch side) in the position shown on Fig.1 TableXXV, after having adjusted the contact breakers to 0.35-0.40mm opening gap.
-rotate distributor fully in an anti-clockwise direction (position of maximum retard) and slightly tighten the nuts on the distributor body locking studs.
-connect the free ends A and B of the test circuit shown in Fig.2 Table XXV with the distributor body and the coil low voltage cable connecting screw 3 (Fig.1, TableXXV). The test cicuit indicator lamp should light up in this condition.
-rotate distributor slowly in a clockwise direction up to the point in which the lamp extinquishes.
-fully tighten the nuts on the distributor body locking studs.
-looking the dial assembled to hub MM-03583, rotate the crankshaft in an anti-clockwise direction form the piston No.1 22deg BTDC position until the lamp lights up again. Then rotate the crankshaft slowly and gradually in a clockwise direction until the indicator lamp extinquishes, and check that this happens when piston No.1 is in the 22deg BTDC position. If not, adjust the position of the distributor.
-looking at the graduated dial assembled to hub MM-03583  turn the crankshaft thru 60 deg in a clockwise direction (viewed from clutch side) from the previous piston No.1 22 deg BTDC position . When near the final point of 60deg, turn the crankshaft slowly and gradually. Piston No.7 will now be in the 22 deg BTDC (the A.I.P.D. flwheel notch will align with cover notch).
-install the distributor on the right hand cylinder bank in the position shown on Fig.3 TableXXV
after having adjusted the contact breakers to 0.35-0.40mm opening gap. Proceed with timing seting as was done for left hand cylinder bank.
- after having set the ignition timing for both distributors, it is necessary to check the synchronization of the second set of contact breakers on both distributors (contact breaker 2, Table XXV). Proceed as follows:
- Connect, as previously described,
the free ends A and B of the test circuit  to the left bank distributor. Turn the crankshaft thru 60deg in a clockwise direction startng from piston No.7 22 deg BTDC. When nearing the final postion turn slowly and gradually, the position obtained is piston No.4 at 22 deg  BTDC (see Table XIX). Check that the indictor lamp extinquishes in this position. If the lamp is still on , it is necessary to adjust the second breaker until synchronization is obtained.
-check, using similar method,
synchronization of contact breaker 2 on the right hand bank distributor. The lamp must extinquish when turning the crankshaft thru 60 deg in a clockwise direction from piston No.4 22deg BTDC (see Table XIX)
- With reference to Table XIX the complete firing order  is: 1-7-4-10-2-8-6-12-3-9-5-11

1.34 Installation of assembled engine into the chassis
-Raise the engine (without oil pump, alternator, clutch cover, oil level rod guide, air filters) and place it over its mounting on the
chassis (the right and left struts CT 03741 and tie rods CT 03740 (Fig. 18 SPC) must be taken out). The engine must be put in place
with the differential box turned downward (see Part 1 Fig. XXVI).
- Lower slowly the whole unit, giving at the same time a light rotation from left to right, until bringing the differential box above the
lowest frame cross member of the chassis. Be careful to keep up the free ends of the axle shaft connected to the flanges of the rear
spindles in such a way as to fit them into those of the differential at the right moment.
-With the help of a lever with the free end placed under the differential box and the fulcrum on the lowest cross member of the
chassis, lower the engine in such a way that, controlling the end of the lever it can rotate forward until coming to rest on the chassis
(Part 2 Fig. XXVI). (Be careful that the cables of the hand brake FM 03840 (Fig.24 SPC) are on the inside of the two front bearings
of the engine.
-Place the bolts of the two front supports BN 03809 (Fig. 18 SPC) in position.
-Mount differential support MB 03810 (Fig. 18 SPC).
-Tighten completely bolts BN 03809 (tightening torque 6 kgm)
-Mount tie rod MB 03744 (Fig. 18 SPC).
-Tighten the bolts for the connection of the axle shafts to the differential unit.
-Connect loosely the exhaust manifold in the following order: left ,front, right front, left rear, right rear.
-Connect electric wire ME 03304 (Fig. 15 SPC) to the starter.
-Mount bulkhead ME 04345 (Fig.32 SPC) for the protection of the starter.
-Connect gear selector rod TC 02829 (Fig.8 SPC) (In the adjustment of the gear selector rod, be aware of the fact that screw DN
03345 (Fig.8 SPC) is left threaded.)
-Connect loosely the mufflers to the exhaust manifolds.
-Fasten manifolds and mufflers.
-Mount oil pump unit, alternator, clutch cover, oil level rod guide.
-Mount right and left struts CT 03741 and right and left tie rods CT 03740 (Fig. 18 SPC).

1.35 Carburation
- the engine is fed with four Weber carburators type 40 IDL 3C downdraft (see weber tav).
A) adjustment data  (see tav)
B) float level adjustment (see tav)
C) synchro

1.36 Summary of the tightening torques for the bolts on the engine
Description
thread
size
torque
Kgm
torque
Lbft

Main bearing studs into block
12mm
3.5
25.3

Main bearing studs into block
8mm
1.8
13.0

Head studs into block
11mm
3.0
21.7

Head studs early into block
10mm
3.0
21.7

Main bearing nuts
12mm
9.0
65.3

Main bearing nuts
8mm
2.8
20.3

Head nuts
11mm
8.6
62.4

Head nuts early
10mm
7.0
50.6
Camshaft nuts

2.8
20.3

Rod nuts

6.0
43.5

Clutch hub bolts

2.8
20.3

Flywheel bolts

2.8
20.3

Differential crownwheel bolts

7.0
50.8

















2.00 Chassis layout - see tav

3.00  Electrical system - see tav

Tavola or factory drawing listing from shop manual
Tavola No
title Italian
title English
Description
 I
curva di potenza, coppia e consumo
horsepower, torque, fuel consumption
informative performance graph
 II
dimensioni canne e pistoni
cylinder liner and piston dimensions

III
attrezzatura montaggio canne cilindri
cylinder liner installation tool

IV
attrezzo estrattore canne cilindri
cylinder liner extraction tool

V
guida valvola e sedi valvola
valve guide and valve set dimensions

VI
diametri di banco e di biella
crankshaft diameter rods and mains

VII
gruppo albero primario con giochi
transmission mainshaft layout

VIII
schema controllo gioco assiale ingranaggi cambio
end play checking scheme for trans gears

IX
attrezzo montaggio cambio
transmission assembly tool

X
attrezzo per bloccaggio satelliti
planet gear blocking tool

XI
misure scuotimento periferico flange differenziale
differential locking tool and wear measure

XII
regolazione comando cambio
trans shift linkage adjustment

XIII
gioco assiale ingranaggio entrata cambio
transmission input shaft end play

XIV
bussola per montaggio anello MM 03686
tool for clutch double lip seal installation

XV
bussola per montaggio paraoilo GN 03832
tool for clutch single lip seal install

XVI
chiave per ghiera cambio
wrench for gearbox ring nut

XVII
attrezzo per montaggio valvole
tool for valve removal and install

XVIII
dimensioni valvola molle e schema serraggio bulloni teste
valve, spring dimension & head bolt tightening

XIX
messa in fase accensione e distribuzione
distributor phasing timing

XX
disco graduato per messa in fase
dial tool for timing

XXI
messa in fase distributzione
timing system setup

XXII
schema registro tensione catena
chain tensioning diagram

XXIII
schema di determinazione punti morti superiori
TDC setup

XXIV
attrezzo per montaggio paraolio spinterogeno
distributor oil seal install tool

XXV
messa in fase accensione
ignition timing scheme w/continuity light

XXVI

engine installation

XXVII
schema quotatura autotelaio P-400 Miura
chassis dimensions

XXVIII
angoli caratteristici sospensione anteriore
front suspension alignment settings

XXIX



XXX
schema impianto elettrico P-400 Miura wiring diagram for P400
XXX
schema impianto elettrico P-400S Miura
wiring diagram for P400S


diagramma curve ammortizzatori anteriori e posteriori
Koni damping curves front and rear


diagramma curve spinterogeni S85CA
distributor advance curve


diagramma curve alternatore "R. Bosch" 55A.
Bosch alternator output graph



















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