D7D Engine Shop Manual For EC290&240
September 16, 2022 | Author: Anonymous | Category: N/A
Short Description
Download D7D Engine Shop Manual For EC290&240...
Description
EC290B/240B Engine (D7D)
Workshop manual
1
Spec Sp ecif ifii ca cati ti ons ons General Specifications, tightening torques ......................................... Screw plugs ........................................................................ Volvo standard standard tightening torques ........................................ ... ..................................... Engine .................................................................................. Cylinder liner, piston ............................................................. ........................................................ ..... Valve mechanism ............................................................ ................................................................. ..... Engine timing timing gears, camshaft ............................................. Crankshaft, connecting rod, flywheel ....................................
4 4 5 6 6 7 7 8
Fuel system ..................................................................... .......................................................................... ..... 9
Tools General Special tools ....................................................................... 10
Engine General Specifications, general ....................................................... 12 Description .......................................................................... 13 ........................................................ 13 Engine overview Engine, reconditioning ........................................................ 15 Turbocharger, removing ................................................... ................................................ ... 16 Engine, installing in mechanic's trestle ............................. ....... ...................... 17 Cable harness, removing .................................................. 17 Oil cooler and oil filter, filter, removing ...................................... 19 Fuel feed pump, removing ................................................ Coolant pump and thermostat housing, removing ............ Oil trap, removing ............................................................. Cylinder head, removing ................................................... Pump element, removing .................................................. Flywheel, removing ........................................................... Front cover with oil pump, removing ................................. Pistons and connecting rods, removing ............................ Crankshaft, removing ....................................................... Camshaft and valve tappets, removing ............................ Camshaft bushings, bushings, checking ........................................... Power take-off housing, removing .................................... Pressure control valve, removing ..................................... Cylinder liners, removing .. .................................................. ................................................ Cylinder block, checking ................................................... Pistons, checking .............................................................. Connecting rods, checking ............................................... Crankshaft, checking ........................................................ Oil cooler core, checking .................................................. Front cover with oil pump, dismantling ............................. ............. ................ Front cover with oil pump, assembling ............................. ............. ................ Timing gear casing, replacing crankshaft crankshaft oil seal ............. Pressure control control valve, installing ...................... ...................................... ................
2
20 21 22 22 26 27 28 31 32 34 34 35 35 37 38 39 41 43 45 46 47 47 48
Cylinder liners, checking ................................................... Cylinder liners, liners, installing ................................................... Camshaft and valve tappets, checking ............................. Camshaft, installing .......................................................... Crankshaft, installing ........................................................ Piston and connecting rod, assembling ............................ Pistons and connecting rods, installing ............................ Determining thickness of cylinder head gasket ................ Timing gear casing, installing ..... ........................................... ...................................... Front cover with oil pump, installing .................................
49 50 51 51 53 56 57 58 59 60
Power take-off housing, installing ..................................... Flywheel, installing ........................................ ........................................................... ................... Cylinder head, installing ................................................... Pump element, installing .................................................. Injectors and fuel lines, installing ...................................... Manifold, charge air pipe and valve valve cover, installing ........ Oil trap, installing .............................................................. Coolant pump and thermostat housing, installing installing ............. Fuel feed pump, installing ................................................. Oil cooler and oil filter, installing ....................................... Cable harness, installing .................................................. Valve adjustment .............................................................. Engine, removing from mechanic's trestle ........................ Turbocharger, installing .................................................... Cylinder head Cylinder head, reconditioning ............................................. Dismantling ....................................................................... Rocker arm retainer, checking .......................................... Cylinder block Specifications, tightening torques ....................................... Screw plugs ......................................................................
64 64 65 67 68 70 71 72 73 73 74 76 77 78 80 80 83 84 84
Cylinder liner, piston Specifications, general ....................................................... 85 Valve mechanism Specifications, general ....................................................... 86 Engine timing gears, camshaft Specifications, general ....................................................... 87 Crankshaft, connecting rod, flywheel Specifications, general ....................................................... 87 Starter ring gear, replacing ................................................. ..................................... ............ 89
Lubrr ic Lub icat at io ion n and oil oil system system s Oil cooler, engine Leakage check ................................................................... ................................... ................................ 90
Fuell system Fue Injectors Specifications, general ....................................................... 92 Injector, checking ................................................................ 92
3
General Spec pecif ifii cat catio io ns General Speci Sp ecific fic ati ations ons,, t igh ighten tening ing tor torque ques s Screw plugs plugs
Fig. 1 4 35 N m (2 (26 6 lbf lbf ft) 6 95 N m (7 (70 0 lbf lbf ft) 7 65 N m (4 (48 8 lbf lbf ft) 8 35 N m (2 (26 6 lbf lbf ft) 13 35 N m (2 (26 6 lbf lbf ft) 17 29 N m (2 (21 1 lbf lbf ft) 21 9 N m (6 (6.6 .6 lbf lbf ft) ft)
4
Volvo Vol vo stan standar dard d tig tighte htenin ning g torqu torques es The tightening torques in the following tables apply to bolts with a tensile strength as shown below. The tables are to be considered as a general instruction for the tightening torque of nuts and bolts when no other torque is stated. OBS ! Fo Forr ffla lang nged ed bo bolt lts s typ type eU U6F 6FS S the the valu values es shoul should d be be increased increas ed by 10 %. Nuts and bolts should be cleaned and lubricated with oil. Thre ads
Nm
kgf m
lbf f t
M6
10 2
1.0 0.2
7.4 1.5
M8
24 5
2.4 0.5
18 3.5
M10
48 10
4.8 1.0
35 7.4
M12
85 18
8.5 1.8
63 13.0
M14
140 25
14.0 2.5
103 18.0
M16
220 45
22.0 4.5
160 33.0
M20
430 85
43.0 8.5
320 63.0
M24
740 150
74.0 15.0
550 110.0
Nm
kgf m
lbf f t
M6
12 2
1.2 0.2
9 1.5
M8
30 5
3.0 0.5
22 3.5
M10
60 10
6.0 1.0
44 7.5
M12
105 20
10.5 2.0
78 14.5
M14
175 30
17.5 3.0
130 22
M16
275 45
27.5 4.5
204 33
M20
540 90
54.0 9.0
400 66
M24
805 160
80.5 16.0
594 118
Nm
kgf m
lbf f t
1/4"
9 2
0.9 0.2
6.6 1.5
5/16"
18 4
1.8 0.4
13 3.0
3/8"
33 8
3.3 0.8
24 5.9
7/16" 1/2"
54 14 80 20
5.4 1.4 8.0 2.0
40 10 59 15
9/16"
120 30
12.0 3.0
89 22
5/8"
170 40
17.0 4.0
130 30
3/4"
300 70
30.0 7.0
220 52
7/8"
485 115
48.5 11.5
360 85
1"
725 175
72.5 17.5
530 130
Thre ads
Thre ads
5
Engine General Designation
Volvo D7D
Number of cylinders
6
Cylinder bore Wear limit
108 +0.02 mm (4.251 +0.0008 in) 108.1 mm (4.256 in)
Stroke
130 mm (5.118 in)
Displacement
7150 cm3 (436 in3)
Compression ratio
17.6
Compression pressure
30–38 bar (435–551 psi)
Order of injection
1-5-3-6-2-4
Max. torque EC290B
940Nm(96 kgf.m)
EC240B
750Nm(76.5 kgf.m)
Direction of rotation
Facing the flywheel, counterclockwise
Working cycle
Four-stroke diesel
Combustion system
Direct injection
Cylinderliner,piston Cylinder liner,piston Cylin nder der liner Number of seal rings per cylin- 3 der liner Piston Number of ring grooves
3
Piston pin, diameter
42 +0 / –0.006 mm (1.653 +0 / –0.0002 in)
Piston rings Compression sion r ing s Number of
2
Piston ring clearance in grooves: upper compression ring lower compression ring
tapered 0.17 mm (0.007 in)
Piston ring gap: upper compression ring lower compression ring
0.8 mm (0.031 in) 2.5 mm (0.098 in)
Oil scraper scraper r ing
6
Number of
1
Piston ring clearance in grooves
0.10 mm (0.004 in)
Piston ring gap
1.5 mm
Valv e mechanism Valves Valve head diameter: inlet exhaust Stem diameter: inlet
48.0 +- 0.1 mm (1.8890 +- 0.004 in) 42.0 +- 0.1 mm (3.9386 +0.0004 in) 8.98+- 0.015 mm (0.354 +- 0.0006 in) 8.96 +- 0.015 mm (0.150 +- 0.0006 in)
exhaust Valve head edge: inlet exhaust
2.1 mm (0.083 in) 1.8 mm (0.071 in)
Seat insert angle in cylinder head: inlet exhaust
30 45
Distance valve head – underside of cylinder head Valve clearance, cold engine, value when adjusting: inlet exhaust
1.5 mm
0.3 mm (0.012 in) 0.5mm (0.020 in)
Valve seat inserts Valve seat width: Valve inlet exhaust Valv e
2.8 mm (0.110 in) 2.2 mm (0.087 in)
guides
Clearance, valve stem – guide inlet exhaust
max 0.10 mm (0.004 in) max 0.13 mm (0.005 in)
Valve springs +
Length, unloaded
6 4.7 - 1. 1+.3 mm (2.547 - 0.051 in)
Engine timing gears,camshaft Camshaft Camsh aft bear ings Camshaft bearings, inside diameter
65 +0.054 / –0 mm (2.559 +0.0021 / –0 in)
Wear limit
65.080 mm (2.562 in)
Tooth backlas h Max. tooth backlash camshaft gear – crankshaft gear
0.031 +- 0.095 mm (0.0.0012 +- 0.0037 in)
7
Crankshaft, connecting rod,flywheel Crankshaft Max. "throw"
0.07 mm (0.0028 in)
Main bearing journals Diameter, standard
85.00 +0 / –0.02 mm (3.346 +0 / –0.0008 in)
Each undersize
0.25 mm (0.010 in)
Limit for undersize
84.75 +0 / –0.02 mm (3.337 +0 / –0.0008 in)
Max. out-of-round
0.01 mm (0.0004 in)
Width, standard
38.00 +0.06 / –0 mm (1.496 +0.0024 / –0 in)
Each oversize
0.40 mm (0.016 in)
Limit for oversize
38.46 +0 / –0.2 mm (1.514 +0 / –0.008 in)
Big-end bearing journals Diameter, standard
68.00 +0 / –0.02 mm (2.677 +0 / –0.0008 in)
Each undersize
0.25 mm (0.010 in)
Limit for undersize
67.50 +0 / –0.02 mm (2.657 +0 / –0.0008 in)
Max. out-of-round
0.01 mm (0.0004 in)
Connecting rod Marking of connecting rod and cap respectively
digit code
Small-end, bushing inside diameter
42 +0.05 / –0 mm (1.654 +0.0020 / –0 in)
Small-end, bushing outside diameter
45.5 +0.12 / –0 mm (1.791 +0.0047 / –0 in)
Hole diameter in connecting rod
45.5 +0.02 / –0 mm (1.791 +0.0008 / –0 in)
Max. clearance bushing – con- 0.08 mm (0.0031 in) necting rod Big-end, inside diameter with bearing cap installed
72.5 +0.05 / –0 mm (2.854 +0.0020 / –0 in)
Big-end, inside diameter with 68.036–68.076 mm ( bearing cap and bearing shells 2.6786–2.6802 in) installed Each undersize
0.25 mm (0.010 in)
Wear limit radial clearance big- 0.12 mm (0.0047 in) end bearings
8
Parallelism (twist) Measurement "a" max. 0.05 mm (0.020 in) per 100 mm (3.937 in) length.
Fig. 2
Straightness Permissible tolerance A to B: 0.05 mm (0.020 in) per 100 mm (3.937 in) length.
Fig. 3
Fuell s Fue syste yste m Injector Opening pressure
275 +8 bar (3989 +116 psi)
9
Tools General Special tools The following special tool are used when working on the engine. The tools may be ordered from Volvo CE Customer Support.
Fig. 4 Special tools
11 666 014 11 666 030 998 6485 999 2000 999 3713 999 3717 999 3722 999 6400 999 999 6662 6662 999 6685 999 8007
10
Jack Pump Trestle Drift handle Puller bolt Quick nut Support Impact puller Pr Pres essu sure re te test stin ing g equi equipm pmen entt Clamp for oi oil cooler Adapter
Fig. 5 Special tools
999 999 999 999 999 999 999
8671 8672 8673 8674 8675 8678 8679
Fixture Installation tool Installation tool Adapter Puller plate Measuring tool Protractor
999 999 999 999
8681 8687 8692 8695
Cranking tool Installation tool Installation tool Installation tool
11
Engine Engine General Specifications, general General
12
Designation
Volvo D7D
Number of cylinders
6
Cylinder bore Wear limit
108 +0.02 mm (4.251 +0.0008 in) 108.1 mm (4.256 in)
Stroke
130 mm (5.118 in)
Displacement
7150 cm3 (436 in3)
Compression ratio
17.6
Compression pressure
30–38 bar (435–551 psi)
Order of injection Max. torque (@1400 rpm)
1-5-3-6-2-4
EC290B
940Nm(96 kgf.m)
EC240B
750Nm(76.5 kgf.m)
Direction of rotation
Facing the flywheel, counterclockwise
Working cycle
Four-stroke diesel
Combustion system
Direct injection
Engine overview
Air heater
Fuel filter Oil filter
Alternator
Oil cooler
Oil pan
Injection pump
Air inlet
Turbo-charger
Coolant inlet
Starter
Oil drain v/v
13
Air cooler to intake
Alternator
Turbo-charger to air cooler
Oil drain v/v
Oil refill
Fuel filter
Coolant outlet
Air inlet
14
Turbo charger
Nameplate
Engine, re recondi conditionin tioning g Op nr Verktyg: 11 666 014 11 666 030 999 2000 999 3713 999 3717 999 3722
Jack Pump Drift handle Puller bolt Quick nut S upport
999 6400 998 6485 999 8007 999 8671 999 8672 999 8673 999 8674 999 8675 999 8678 999 8679 999 8681 999 8687 999 8692 999 8695
Impact puller Trestle Adapter Fixture Installation tool Installation tool Adapter Puller plate Measuring tool Protractor Gear wheel (Cranking tool) Installation tool Installation tool Installation tool
Socket or spanner Torx E10 Socket Torx E12 Socket Torx E18 Socket Torx E20 Lifting eyes M10 Lifting sling Thread tap M8 with turning bar Indicator gauge with magnetic base Dial test indicator with angled "base" Dial test indicator for inside measurements (crankshaft) Depth gauge Piston ring pliers Feeler gauge Screw micrometer Connecting rod tester Drift 20 mm Steel ruler Torque wrench with open end grip OBS! The number 1 cylinder cylinder is nearest nearest to the flywheel. flywheel.
15
Turbocharger, removing 1
Remove Remove the the oil oil supply supply and and retur return n pipes pipes fr from om th the e tur turbobocharger. Install protective plugs in the connections on the turbocharger.
2
Remove Remove the the attach attaching ing nu nuts ts and and rem remove ove the the tu turboc rbocharg harger er..
3
Instal Installl protecti protective ve plugs plugs in the c conne onnecti ctions ons fo forr oil retur return n and supply pipes and the manifold.
Fig. 10 1 Return pipe 2 Oil su su p pp p ly ly pi pip e
Fig. 11
Fig. 12 1 Pr o ott ec ect i ve ve pl u ug gs
16
Engi En gi ne, ne, i nst nst alling i n m echa echanic's nic's trest trestle le
4
Instal Installl tthe he engine engine fixture fixture on the engine. engine. VIKTIGT! VIKTIG T! Use the supplied supplied bolts. They are of a higher strength than the standard bolts.
5
Lif Liftt the engin engine e into posi positio tion n and bo bolt lt the engi engine ne fixtur fixture e onto the mechanic's trestle. The weight of the engine is approx. 700 kg (1543 lb).
Fig. 13 1 999 8671
Cable Cab le harn ess, ess, removing 6
Remove Remove the the a atta ttachi ching ng p plat late e for the ECU conn connect ector or..
7
Discon Disconnec nectt the c conne onnecto ctorr from tthe he coolan coolantt tempera temperatur ture e sensor. Take Take apart the connector for the induction temperature sensor. Disconnect the connector from the camshaft cam shaft speed sensor.
Fig. 14 1 Co Conn nne ect ctor or for for EC ECU U
Fig. 15 1 Se Sens nsor or,, coo coola lant nt te temp mper erat atur ure e 2 Con Connec nector tor for ind induct uction ion ttemp empera eratur ture e se senso nsor r 3 Sens Sensor or,, ca cams msha haft ft s spe peed ed
17
8
Discon Disconnec nectt the c conn onnect ector or fr from om the the cha charge rge air air press pressure ure sensor.
9
Discon Disconnec nectt the c conn onnect ectors ors ffrom rom tthe he senso sensors rs fo forr fue fuell tem tem-perature, oil pressure and crankshaft speed.
10
Disconne Disconnect ct the the ele electr ctrica icall lea leads ds from from the p pump ump e elem lement ents. s.
Fig. 16 1 Sensor, Sensor, char charge ge air air pre pres s sur sure e
Fig. 17 1 Sens Sensor, or, ffuel uel tem tempera perature ture 2 Senso Sensor, r, crank crankshaft shaft spe speed ed 3 Se Sens nsor, or, o oil il pres press sure
Fig. 18 1 El Elec ectric trical al lea leads
18
11
Fig. 19
Rem Remove ove the the cable cable rail rail toget together her with with electr electrica icall lea leads. ds.
Oil Oil coo cooler ler and and oi l fifi lter, removing 12
Discon Disconnec nectt the ho hose se from from the ffuel uel pipe. pipe. Disc Disconne onnect ct the the hose from the connection nipple on the fuel feed pump.
13
Remove Remove the fuel fuel and lu lubri bricat cating ing oi oill filters filters.. Install Install pr protec otectin ting g plugs.
14
Remove Remove the the attach attaching ing b bolt olts s and rremov emove e the oil oil cooler cooler..
Fig. 20 1 Hose to f u e ell pi pi p pe e 2 Hose tto o fue fuell ffe eed pu pump mp 3 Fuel ffiil te ter 4 Lubri ubric cat ating ing o oil il fil filter ter
Fig. 21
19
15
Remove Remove any any gasket gasket rem remnant nants. s. Insta Install ll pro protec tectiv tive e plug plugs, s, proprotect the opening with masking tape.
Fig. 22 1 Pr o ott ec ect i ve ve pl u ug gs
Fuell feed pump Fue pump,, r emoving 16
Slacken Slacken the the bolts bolts retai retainin ning g the fuel fuel fe feed ed pump. pump. Remov Remove e the V-belt.
17
Remove Remove the bolts bolts and remove remove the fuel fuel feed feed p pump ump..
Fig. 23 1 Att a ac chin g b ol olt 2 Tensio ni ni ng ng b o lltt
Fig. 24
20
Cool Co ol ant ant pum p and and t herm herm ost ost at hous housii ng, re remo mov v ing 18
Remove Remove the the bo bolts lts and rremo emove ve the the co coola olant nt pump pump an and d the intermediate housing.
19
Remove Remove gask gasket et remna remnants nts and p prot rotect ect tthe he op openi enings ngs wit with h masking tape.
20
Remove Remove the the bo bolts lts and rremo emove ve the the the thermo rmosta statt hou housin sing. g.
Fig. 25 1 Coo la lan t p pu um mp p 2 In te term e d diiat e h o ou us i n g 3 Therm o s tta at hou s i n ng g
Fig. 26
Fig. 27
21
Oil trap, removing 21
Remove Remove the bolts bolts and remove remove the oil tra trap. p.
Fig. 28
Cylinder head, rem rem oving 22
Remo Remove ve th the e val valve ve cove coverr.
23
Remove Remove the the attach attaching ing bo bolts lts and lift lift away away the char charge ge air air pipe.
Fig. 29
Fig. 30 1 Ch a arrge a aii r pi p pe e
22
24
Remove Remove the the at attac taching hing bol bolts ts and and re remove move the mani manifol fold. d.
25
Remove Remove the the p pipe ipes s betwe between en the the pump pump elem element ents s and the injectors. Discard the pipes. Disconnect the return hoses from the injectors.
26
Discon Disconnec nectt the retu return rn ho hose se from from tthe he overf overflow low valv valve. e. Remove all hoses.
Fig. 31 1 Mani anifo foll d
Fig. 32 1 Pipe 2 Return hose
Fig. 33 1 Ov Over erfl flow ow val valve ve
23
Fig. 1 2 3
Mark the the rocke rockerr arm reta retaine iners. rs. Remov Remove e the roc rocker ker arm arm retainers together with rocker arms and the push rods. OBS ! Spring force.
28
Remove Remove the the nozzle nozzle holde holders, rs, use tools tools for T Torx orx E10. E10.
34 Rock cker er arm ret etai ainer ner Roc ke ke r ar ar m Pus h r o d
Fig. 35 1 To r x E10 2 No zz zzle hol d de er
24
27
29
Mark the inje injecto ctors rs an and d pull the them m out. out. If ne neces cessar sary y use an an impact puller with adapter.
30
Remove Remove the bolts bolts using using a Torx E18 soc socket. ket.
31
Connec Connectt a liftin lifting g sli sling ng to th the e lif liftin ting g eyes and li lift ft away away th the e cylinder head. The cylinder head weight is approx. 80 kg (17 6 lb lb). ).
Fig. 36 1 999 6400 2 999 8007
Fig. 37
Fig. 38 1 Lifti ng ng sl ing
25
Pump element element,, remo remov v ing
32
Remove Remove the fuel fuel pipe pipe ffrom rom the pump pump eleme elements nts..
33
Mark the the pump pump elemen elements. ts. Slac Slacken ken tthe he attac attachin hing g bolts bolts approx. 4 mm (0.16 in) and loosen the pump elements from the block.
34
Slacken Slacken the the attach attaching ing b bolt olts s fully fully and re remov move e them a and nd the pump elements. OBS! Spring Spring force. Make Make sure that the pump pump element elements s do not jump up.
Fig. 39 1 Fuel pipe
Fig. 40
Fig. 41
26
35
Remove Remove the rol roller ler tappet tappets s and and tthe he shims. shims. OBS ! Th The e shi shims ms and the the rrol olle lerr ttap appe pets ts mus mustt n not ot be move moved d from one pump element to another.
Fi g. 42
Flywheel, Flywhee l, r emoving 36
Remo Remove ve the the o oil il di dips psti tick ck..
37
Tu Turn rn the engi engine ne in the the mechan mechanic' ic's s tre trestl stle e so tha thatt the o oil il sump comes uppermost. Remove the bolts and remove rem ove the oil sump. OBS ! Th The e oil oil su sump mp iis s glue glued d to the cyli cylind nder er b blo lock ck.. Tak Take e ca care re when removing, so that the sump is not damaged. Use a pinch-bar at therefore intended recesses. The oil sump weight weight is approx. approx. 40 kg (88 lb) .
Fi g. 43
38
Tu Turn rn the engi engine ne in the the mechan mechanic' ic's s tre trestl stle e so tha thatt the fflylywheel comes uppermost.
Fi g. 44
27
39
Remo Remove ve th the e cov cover er wa wash sher er..
40
Install Install lif lifting ting eye eyes s M1 M10 0 an and d a lifti lifting ng s slin ling. g.
41
Li Lift ft away away the the fly flywh whee eel. l. The weight of the flywheel is approx. app rox. 40 kg (88 l b ).
Fi g. 45
Fi g. 46 1 Lifti ng eyes M10
Front Fro nt cov cov er wit wit h oil pum p, re remo mov v ing
Fi g. 47 1 Oil Oil s suc uctio tion n pip pipe e 2 Bra c ck ket 3 Oil ffiiller pipe
28
42
Turn Turn the en engin gine e in the the mechanic mechanic's 's trestl trestle e so tha thatt the ffront ront end comes uppermost.
43
Remove Remove the the oil sucti suction on pip pipe e togethe togetherr with with bracket. bracket. Remo Remove ve the oil filler pipe.
44
Mark the the posit position ion of of the bel beltt pulley pulley ttoge ogethe therr with with the toothed wheel and the two oscillation dampers with a felttip pen or similar.
45
Ins Instal talll the crank cranking ing tool. tool. U Use se it a as s a cou counte nterho rhold ld wh when en lo loososening the attaching bolts in points 46 and 48.
46
Rem Remove ove the the attach attaching ing bolt bolts s and rremo emove ve the the oute outerr osc oscill illaation damper damper..
Fig. 48 1 999 8681
Fig. 49
29
Fig. 1 2 3
48
Remove the attaching attaching bolts using a T Torx orx E E20 20 socket socket and llift ift away the V-belt pulley. pulley.
49
Remove Remove the the attach attaching ing b bolt olts s and remov remove e the cove coverr toge togethe therr with the oil pump.
50
Remove Remove the the attach attaching ing b bolt olts s and remove remove the the ti timin ming g gea gearr casing.
51 Torx E20 To Toot othe hed d wh whee eell V-belt pully
Fig. 52 1 Oil pu m mp p
Fig.53 Fig. 53 Timing Timing ge gear ar c asing removed
30
Pistons and con nec nectt ing rods, rods, removing 51
Mark Mark the the conn connec ecti ting ng ro rod d cap caps. s.
52
Remove Remove the the attach attaching ing bo bolts lts and re remove move the caps caps toget together her with bearing shells.
53
Push out out the piston pistons s togethe togetherr with conne connecti cting ng rod rods. s. Take Take care of the bearing shells.
Fig. 54
Fig. 55
31
Cr Cran anks ksha haff t, remov remov in ing g 54
Turn Turn the en engin gine e in the the mech mechanic anic's 's trestl trestle e so tha thatt the cr crankankshaft comes uppermost.
55
Check Check tha thatt the c cams amshaf haftt and crank crankshaf shaftt gea gears rs ar are e marked. marked.
56
Check Check tha thatt the b bigig-end end be beari aring ng caps caps are are mar marked. ked. Remo Remove ve the attaching bolts and remove the caps together with the bearing shells.
57
Remove Remove the the thrust thrust wash washers ers b by y mai main n bea bearin ring g number number 2 (the (the thrust bearing journal). The number 1 main bearing is nearest to the flywheel.
Fig. 56 1 Mar ki n g
Fig. 57
Fig. 58 1 Thrus t w a as s he rs
32
58
Connec Connectt a lifting lifting sl sling ing to th the e cran cranksh kshaft aft and and lif liftt it away away. The crankshaft weight we ight is approx. 75 kg (165 (16 5 lb) .
59
Remove Remove all all bearin bearing g shells shells and and the tthru hrust st washer washers s at main main bearing number 2. Mark the bearing shells, if they are to be used again.
60
Remo Remove ve the the p pis isto ton n co cool olin ing g nozz nozzle les. s.
Fig. 59
Fig. 60 1 B ear i ng ng s sh h el el l 2 Thrus t w a as s he rs
Fig. 61
33
Camshaf Camsh af t and valv e tapp tappet et s, rremo emov v ing 61
Pull Pull ou outt th the e ca cams msha haft ft.. OBS! Take care not to damage the camshaft camshaft bearings. bearings.
62
Remove Remove the the valve valve tapp tappets ets.. Mar Mark k them them if tthey hey a are re to be be used again
Fi g. 62
Fi g. 63
Camshaf t b bushi ushings ngs checking checking
Fi g. 64
Fi g. 65 1 Ang Angled led dial test test indicator indicator
34
63
Set the the dial dial tes testt in indic dicato atorr to 65 mm mm (2 (2.55 .559 9 in). in).
64
Check Check the iinsi nside de me measu asureme rement nts s of the the bush bushing ings s at point points s "a" and 2 and in planes "a" and "b" as shown in the figure. Inside diameter: 65 +0.054 / –0 mm ( 2.559 +0.0 +0.0021 021 / –0 in) . Wear limit: limit: 65.080 mm (2.562 in) .
65
Remove Remove the the camsha camshaft ft be bearin aring g bushin bushings, gs, ifif thes these e are to to be replaced.
Fig. 66 1 999 8695
Powe Pow er take-off take-off housin housing, g, remov ing 66
Discon Disconnec nectt th the e oil pipe pipe from from th the e cy cylin linder der block. block.
67
Remove Remove the the attach attaching ing b bolt olts s (so (socke ckets ts Torx Torx E10 E10 and E E12) 12) and remove power take-off housing together with the oil pipe.
Fig. 67 1 Att ac achin g b ol olt s 2 Oil pi pe
Pressur Press ure e cont rol valve, remov remov in g
68
Tap the hole hole for for the p pres ressur sure e control control valv valve e to M8 us using ing an an M8 thread tap.
Fig. 68 1 Threa d t a ap p M8
35
69
Pull up the pres pressur sure e control control valv valve e with an impac impactt puller puller..
70
Re Rem mov ove e the the va valv lve. e.
Fig. 69 1 999 8674 A Ad dapter 2 99 999 9 6400 6400 Im Impa pact ct pull puller er
Fig. 70
36
Cylinder liners, removing 71
Tu Turn rn the engi engine ne in the the me mechan chanic' ic's s tre trestl stle e so tha thatt the c cyli ylinnder liners come uppermost.
72
Insta Install ll ttoo ools ls as as sh show own n in tthe he ffig igur ure. e. Align puller plate 999 8675 with the halves of the quick nut under the lower edge on the cylinder liner.
Fig. 71 1 2 3 4 5 6
11 666 014 11 666 030 999 3722 999 3713 999 8675 999 3717
73
Pump wit with h the hyd hydraul raulic ic pump. pump. The The li liner ner shoul should d loosen loosen after approx. 15 mm (0.6 in).
74
Remove Remove the the to tools ols a and nd li lift ft out out th the e cyl cylind inder er liner liner..
Fig. 72
Fig. 73
37
Cylinder block, checking 75
Check Check tha thatt the c cyli ylinde nderr liner liner co colla llarr loc locati ations ons a and nd the cyli cylinnder liner sealing surfaces are not damaged.
76
Check Check wi with th a de depth pth g gauge auge the d dist istanc ance e bet betwee ween n the cyli cylinnder block face and the bottom of the cylinder liner collar location. Measure in approx. eight different places for each cylinder. cylinde r. The depth depth must be 8.92 + 0.03 mm (0.3512 +0.0 +0. 0012 iin n) . VIK TIGT! Is the TIG the dept depth h grea greater ter,, the cylin cylinder der bl block ock must must be discarded.
77
Remove Remove all screw screw p plug lugs s from from the end faces. faces.
Fig. 74 1 Cyli Cylind nder er line linerr c col olla larr loc locat atio ion n
Fig. 75 1 Depth g ga auge
38
Pistons, checking 78
Remove Remove the the llock ock rring. ing. Take out the piston piston pin. pin.
79
Remove Remove the the piston piston ri rings ngs u usin sing g a pai pairr of pis piston ton ri ring ng plier pliers. s.
80
Push down down one pist piston on ri ring ng at a tim time e in th the e cyl cylind inder er bore, bore, below the upper turning point, with the aid of a piston. Make sure that the piston ring is positioned horizontally. Check the piston ring gaps with a feeler gauge. Wear limits: Piston ring ring 1: 0.8 mm (0.031 (0.031 in) .
Fig. 76 1 Pis Piston ton ring ring pl plie ierrs
Piston ri (0.0 Piston ring ring ring ng 2: 3: 2.5 1.5 mm mm (0.098 (0.059 (0.098 59 in) in) .. 81
Clean Clean th the e pis piston ton ri ring ng gr groov ooves es..
Fig. 77 1 Feeler g ga auge
39
39
82
If new piston piston rring ings s are to be u used sed,, mea measur sure e the pist piston on ri ring ng grooves using the new piston rings 2 and 3 together with a feeler gauge. Wear limits: Piston ring ring 2: 0.17 mm (0.007 (0.007 in) . Piston ring ring 3: 0.10 mm (0.004 (0.004 in) .
83
Install Install the the pisto piston n ring rings s using using a pa pair ir of pist piston on ri ring ng plier pliers. s. OBS! Displace Displace the spring gap on the oil oil control control ring ring 180 to the ring gap.
84
Measure Measure the the pist piston on p pin in with with a scr screw ew m micr icrome ometer ter.. Out side Outsid e diamet dia meter: er: 42 42 – 0 0.006 .0 06 mm (1. (1.653 6535 5 –0.00 –0. 00 0 02 2 iin). n).
Fig. 78
Fig. 79 1 T aper apamfe ered ed comp co ress ssio ion nion ring rin ngri 2 Cham Ch fere red dmpre co comp mpre ress ssio ring ng 3 Slot Slotte ted do oil il cont contro roll rin ring g The piston rings are marked "TOP"
Fig. 80
Fig. 81
40
Connecting rods, checking 85
Check Check the the small-en small-end d bearin bearing g bushing bushing in in the conne connecti cting ng rods with a dial test indicator. i ndicator. Measure at points 1 and 2 and in the planes "a" and "b" according to the figure. The bushings are to be installed in the connecting rods when measuring. Inside diameter:42 +0.05 / –0 – 0 mm (1.6535 +0.002 +0.0020 0 / –0 in).
86
Check Check the the clea clearanc rance e of the bearing bearing bus bushin hings. gs. Permissible clearance is 0.08 mm (0.003 in) .
87
Replac Replace eb beari earing ng bushin bushings gs whe when n nece necessa ssary ry.. Hole diameter in connecting rod: 45.5 4 5.5 +0.02 / –0 mm in) . (1.791 +0.0008 / –0 – 0 in). Outside diameter of bushing: 45.5 +0.12 12 / –0mm (1.791 +0.0008 / –0 in) .
Fig. 82
Fig. 83
88
Press Press in the the new new bearin bearing g bushin bushing g until until flus flush h wit with h the rod rod.. OBS! The lubricating lubricating oil hole hole in the bushing must must align with the connecting rod oil duct. 89 After After the the pressi pressing ng in, in, pre precis cision ion rream eam the the bu bushi shing ng to an inside diameter of 42 +0.05 /–0 mm (1.654 + 0.0020 / –0in) .
Fig. 84 1
999 8692
41
90
Check Check tha thatt the numb numberin ering g on the the bea bearin ring g cap matc matches hes tthat hat on the connecting rod. Check that the guide studs are correctly positioned.
91
Install Install the bearing bearing cap and tig tighte hten n the bol bolts ts.. Initial tighteni tightening ng torque: 30 N m (22 lbf ft) . 1st tight tighteni ening ng angle: angle: 60 . 2nd tighte tightening ning angle: 60 .
92
Set the the dial dial test test ind indica icator tor to 72.5 72.5 m mm m (2 (2.85 .854 4 in). in).
93
Measure Measure the the insi inside de d diam iamete eterr at poin points ts 1 and 2 and in planes "a" and "b" according to the figure. Diamete Diam eter: r: 72.5 72.5 +0.05 +0.05 / –0mm (2. (2.854 854 +0. +0.0020 0020 / –0in –0in)) .
94
Remove Remove the the bear bearing ing cap cap and inst install all new new beari bearing ng shells shells..
Fig. 85
Fig. 86
Fig. 87
Re-install the bearing cap and tighten the bolts. Initial tighteni tightening ng torque: 30 N m (22 lbf ft) . 1st tight tighteni ening ng angle: angle: 60 . 2nd tighte tightening ning angle: 60 .
42
95
Set the the dial test test in indic dicator ator.. Measure Measure th the e inside inside dia diamete meterr of the bearing shells at points 1 and 2 and in planes "a" and "b" According According to Fig. 86. Inside diameter: 68.036–68.076 mm (2.6786–2.6802 in) . There are two 0.25 mm (0.010 in) undersizes. Limit for undersize: undersize: 67.536–67.576 67.536–67.576 mm (2.659–2.660 in) . Wear limit: Radial clearance for big-end bearings: 0.12 mm (0.0047 in). OBS! If the obtained obtained values do not not exceed the bearing bearing tolerances by more than 0.015 mm (0.0006 in), the connecting rod may be used again. If the limit value is exceeded, replace the connecting rod with a new one.
96
Check Check the the connect connecting ing ro rod d withou withoutt bearing bearing shell shells s in i co connnecting rod testing fixture as regards parallelism (twist). Tolerance "a" = 0.05 mm (0.0020 in) per 100 mm (3.937 in) length. Straightness test: Permissible tolerance A to B: 0.05 mm (0.0020 in) per 100 mm (3.937 in) length.
97
Check Check the the conne connecti cting ng rrod od as as regar regards ds strai straightn ghtness ess.. Permissible tolerance A to B: "a" = 0.05 mm (0.0020 in) per 100 mm (3.937 in) length.
Fig. 88
Fig. 89
Crankshaft, checking 98
Fig. 90
Place Place the crank crankshaf shaftt in a ttres restle tle with with V V-bl -block ocks. s.
43
99
Measure Measure the the diame diameter ter of of the big big-end -end bearin bearing g journal journals s at 1 and 2 and in the planes "a" and "b". Bearing journal diameter: 85.00 +0 / –0.1 mm (3.346 +0 / – 0.0039 in) One 0.25 mm (0.010 in) undersize undersize is available. available. Limit for undersize: 84.75 + 0 / – 0.02 mm (3.337 + +0 0/ –0.0008 in) Wear limit out-of-rou out-of-round: nd: 0.01 mm (0.0004 in) .
Fig. 91
100 Measure the the width width of the thrust thrust bearing journal. journal. Use a dial test indicator intended for inside measurements. Make a note of the measurement, it will be needed when installing the crankshaft. Bearing journal journal width: width: 34.00 34.00 +0. +0.04 04 mm (1.339 + +0.0016 0.0016 iin) n) Oversize: 0.40 mm 0.016 in) Limit for oversize: oversize: 34.46 mm (1.357 in)
Fig. 92
101 Measure the the diameter diameter of the bigbig-end end bearing bearing journals. journals. Bearing journal diameter: 68.00 + 0 / – 0.02 mm (2.677 (2.677 +0 / –0.0008 in) Two 0.25 mm (0.010 in) undersizes are available Limit for undersize: 67.50 + 0 / –0.02 mm (2.657 +0 / –0.0008 in) Wear limit out-of-rou out-of-round: nd: 0.01 mm (0.0004 in) .
Fig. 93
102 Rotate the crankshaf crankshaftt and me measure asure throw throw.. Max. deviation: deviation: 0.07 mm (0.0028 (0.0028 in).
Fig. 94
44
Oil cooler core, checking 103 Remove Remove the screw screw p plug. lug.
Fig. 95
104 Remove the the flange h head ead bolts bolts (17 mm) ret retaining aining the the oil cooler. 105 Check that that the oil oil coole coolerr core is not damaged. damaged. If da damage mage is suspected, pressure test the cooler core, see Leakage check, chec k, sid sid 90. 90. 106 Replac Replace e all seal rin rings. gs.
Fig. 96
107 Install Install oil cooler core in in the housing housing..
Fig. 97
108 Install Install flange head bolts bolts together together with the w washers. ashers. TightTightening torque torque 170 N m (125 lbf ft) . 109 Apply locking locking fluid fluid to the sc screw rew plug th threads. reads. Install Install the the screw plug. Tightening Tigh tening torque torque 80 N m (59 lbf lbf ft) .
Fig. 98
45
Front cover with oil pump, dismantling 110 Knock out the crankshaf crankshaftt oil se seal al with a drift. drift. 111 Secure the cover cover in a vice with soft soft jjaws. aws.
Fig. 99
112 Press down down the compressi compression on sprin spring g with a 13 13 mm (0. (0.5 5 in) wide screwdriver. Move the lock plate out sideways. VIK TIGT! Great TIG Great sprin spring g force. force. Make Make su sure re tha thatt the lock lock p plat late e location is not damaged. Remove the pressure control valve.
Fig. 100
113 Remove the the oil pump c cover over.. Check tthat hat the pum pump p components are not damaged. Replace damaged parts.
114 Tighten Tighten down down the cover to a torque torque of 8–9N m (5. (5.9– 9–6. 6.6 6lb lbff ft) ft) .
46
Front cover with oil pump, assembling 115 Install Install tthe he pressure pressure control control val valve. ve. 116 Press down down the compressio compression n spring an and d install install the lock plate. VIK TIGT! TIGT! Great Great sprin spring g forc force. e. Mak Make e sur sure e that tthe he lo lock ck pl plate ate is correctly located. 117 Lubricate Lubricate the new cranksh crankshaft aft oil seal seal with o oilil and install install it it..
Fig. 103 1 999 2000 2 999 8673
Timing gear casing, replacing crankshaft oil seal 118 Knock out the cra crankshaf nkshaftt oil s seal eal wit with h a drift. drift.
Fig. 104
119 Lubricate Lubricate the new cranksh crankshaft aft oil seal seal with o oilil and install install it it..
Fig. 105 1 999 2000 2 999 8672
47
Pressure control valve, installing 120 Clean the the seat seat for the pressure pressure control valve. 121 Check that that it is possible possible to pr press ess in the the valv valve e poppet poppet.. 122 Apply locking locking fluid fluid to the sea sealing ling sur surface face of the va valve. lve.
Fig. 106
123 Install Install the valve. valve.
Fig. 107
124 Drive in the the valve until until it bottoms bottoms u using sing a dri drift ft with a 20 20 mm (0.79 in) diameter.
Fig. 108
48
Cylinder liners, checking 125 Check that that the liner liner iis s free from from crac cracks ks or oth other er damag damage. e. 126 Measure the the cylin cylinder der line linerr inside diameter diameter.. Measure Measure at three different depths according to the figure, both longitudinally and across. Diameter: 108 +0.02 +0.02 mm (4.252 +0.0008 +0.0008 in). in) . Wear limit: limit: 108.1 mm (4.256 in) .
Fig. 109
127 Measure the the height o off the cylinder cylinder lin liner er collar. collar. M Measure easure in several places around the liner. Height:: 9 –0.02 mm (0.354 –0.0008 Height –0.0008 in) .
Fig. 110
49
Cylinder liners, installing 128 Make sure that that the cylinder cylinder liliner ner location location and the the sealing sealing surface are clean. 129 Install Install new O-rings O-rings..
Fig. 111 1 O-rings
130 Lubricate Lubricate the cylinder cylinder bloc block k and the cylinder cylinder line linerr with oil to to cover the area marked with an "x" in the figure.
Fig. 112
131 Install Install the cylinder cylinder liners in th the e cylinder cylinder block. Dri Drive ve them down as far as possible. VIK T TIG IGT! Sealin Sealing gc comp ompound ound must must no nott be used. used.
Fig. 113
50
Camshaft and valve tappets, checking Check that the contact face on the valve tappets against the camshaft is convex or level. If the surface is concave, replace the valve tappet(s). If the valve tappet is worn across the contact surface, the tappet must be discarded. "The ditch" indicates that the tappet has not rotated. A dark stripe outermost on the contact surface indicates, however, that the surface is not worn down. It is the condition of the valve tappets which determines, if it isnecessary to check the camshaft wear.
Fig. 114 1 Steel ruler
Check that the contact surfaces on the camshaft and the valve tappets do not have large pitting damage. Pitting damage may arise for different reasons. The damage consists of small metal particles loosening from the hardened surface. Tappet and camshaft with minor pitting damage may be used. Pitting type damage rarely become worse. Check that the camshaft bearing races and cam lobes are not abnormally worn. The cams may, for example, be worn obliquely ob liquely in an axial direction. If the damage is slight, it can be corrected by honing. Replace the camshaft, in case of major damage or wear. When replacing a camshaft, all valve tappets must be replaced at the same time.
Camshaft, installing 132 Replace Replace bearing bearing bushings bushings whe when n necessary necessary.. OBS! The wider wider bushing (27 (27 mm = 1.063 in) in) should should be positioned at the gear end. Replace bearing bushings, if they are worn. OBS! The lubricating lubricating oil holes must must align with the oil ducts ducts in the bearing locations.
Fig. 115 Positioning bearing bushings
Fig. 116 1 Lu Lub bric ricat atin ing go oil il hole hole
51
133 Press in in the bushing bushing to the corre correct ct position. position.
Fig. 117 1 999 8695
134 Lightly lubricat lubricate e the valve tappets tappets wi with th oil and inst install all them.
Fig. 118
135 Install Install the camshaf camshaft. t. OBS! Take care not to damage the bearing bearing bushings bushings.. Check that the camshaft can rotate freely. freely.
Fig. 119
52
Crankshaft, installing
136 Install Install the piston piston cooli cooling ng nozzles. nozzles. Press them in as far a as s possible.
Fig. 120
137 Install Install the bearing shells shells in the cylinder cylinder bloc block k and lubricate lubricate them with oil.
Fig. 121 1 Bearing shell
138 Install Install the bearing bearing shells shells in the bear bearing ing caps and lubri lubricate cate them with oil.
Fig. 122
53
139 Wipe the bearing bearing cap for the the thrust thrust bearing bearing and the the thrust thrust washers provided with a locating lug until clean. Install the thrust washers and measure the width. 140 Determine Determine the axi axial al clearance. clearance. The w width idth of tthe he cranks crankshaft haft bearing journal, see Crankshaft, checking, sid 43 43,, less the measured width of the bearing cap and the thrust washers will result in the actual clearance. Permissible end float: 0.10–0. 30 mm (0.004–0. 012 in) .
Fig. 123
141 Lift the cranksha crankshaft ft into pos position. ition. Ma Make ke sure that the the markin marking g against the camshaft gear is correctly lined up.
Fig. 124
142 Oil and install install the thrust thrust wa washer sher halves halves without without a locating locating lug. Insert them under the crankshaft. Turn the surfaces with oil grooves toward the thrust bearing surfaces on the crankshaft.
Fig. 125
143 Attach the the other thrust thrust washers washers to the be bearing aring cap cap using a little grease. Turn the surfaces with oil grooves on the washers toward the thrust bearing surfaces on the crankshaft.
Fig. 126
54
144 Lubricate Lubricate the bearing bearing caps caps with oil oil and inst install all them accordaccording to markings. No. 1 next to the flywheel end. Initiall tightening Initia tightening torque: 50 N m (37 lbf ft) . 1st tightening angle: 60 2nd tightening angle: VIK TIGT! TIGT! The bolt bolts s must b be e rep replac laced ed wi with th ne new w one ones s after after the third time the engine has been dismantled.
Fig. 127
145 Make sure that that the thrust thrust was washers hers on the ca cap p align wi with th the washers in the block.
Fig. 128
146 Install Install the indicator indicator gauge gauge together together with ma magnetic gnetic base. base. Prize with a pinch-bar and check the crankshaft end float. Permissible clearance: 0.10–0.30 mm (0.004–0.012 in).
Fig. 129 1 Pinch-bar 2 Magnetic base 3 Di Dial al tes test ind indic icat ator or
55
Piston and connecting rod, assembling
147 Install Install one of the lock lock rings in the groo groove ve in the pi piston. ston. VIK TIGT! The ring TIG ring ga gap p on the the spr spring ing ri ring ng sh shoul ould d be turned turned toward the piston crown.
Fig. 130
148 Install Install the connecting connecting rod rod in the pis piston ton with tthe he guide pi pins ns toward the side on the piston which has a flywheel symbol. Push in the piston pin. Check that the connecting rod can be moved sideways on the piston pin.
Fig. 131 1 Guide pin
56
Pistons and connecting rods, installing 149 Install Install the bearing bearing shells shells on the conn connecting ecting ro rods ds and lub lubriricate them with oil.
Fig. 132
150 Install Install the piston piston rings. Ar Arrange range the piston piston rin ring g gaps di dissplaced at 60 from each other.
Fig. 133
151 Use a piston piston ring co compress mpressor or and inst install all the pistons pistons together with connecting rods from the cylinder head side. The flywheel symbol must be turned toward the flywheel end.
Fig. 134 1 999 8687
152 Lubricate Lubricate the big-end big-end bearing bearing journals journals on the cranksh crankshaft. aft. Push the connecting rod against the bearing journal and install the caps according to markings. Install new bolts and tighten them down. d own. Initiall tightening Initia tightening torque: 30 N m (22 lbf ft) . 1st tightening angle: 60 2nd tightening angle: 60 153 Check that that the cranksh crankshaft aft can rotate freely. freely.
Fig. 135
57
Determining thickness of cylinder head gasket Cylinder head gaskets are marked with one, two or three holes in one corner. The gaskets should be used according to the table.
Piston height
Number of holes
0.28 up to 0.54 mm (0.011 up to 0.021 in)
1
0.54 up to 0.64 mm (0.021 up to 0.025 in)
2
0.64 up to 0.75 mm (0.025 up to 0.030 in)
3
Fig. 136 1 Ma Mark rkin ing g of cyli cylind nder er h hea ead d ga gask sket et
154 Install Install the protractor protractor on the crankshaf crankshaft. t. Use the short bo bolts lts (M10x1, 30 mm (1.18 in) long).
Fig. 137 1 999 86 8679 79 Pro rotr trac acto tor r
155 Position Position the measuring measuring tool together together with spacer spacer washers washers and dial test indicator on the cylinder block. Set the dial test indicator to zero. OBS! Place the spacer spacer washe washers rs on the block, block, not on the liner collar.
Fig. 138 1 999 8678 2 Dial te tes st ind indic ica ato tor r 3 Spacer washe herrs
58
156 Position Position the dial test test indi indicator cator sty stylus lus at poin points ts indi indicated cated in the figure. Crank the engine with the handles on the protractor to find the highest position. Read off the piston height on the gauge.
Fig. 139 Checking points
Timing gear casing, installing 157 Remove gasket gasket remnants remnants from the tim timing ing gear c casing asing and the cylinder block. 158 Apply sealing sealing compound compound to th the e timing g gear ear casin casing g sealing sealing surface. 159 Lightly Lightly oil the cranksh crankshaft aft oil oil seal. seal.
Fig. 140
160 Install Install the timing timing gear cas casing ing witho without ut tight tightening ening do down wn the bolts. Position the casing in line with the sealing surface on the oil sump. 161 Tighten Tighten down the the bolt bolts s (apart from from the two bolts bolts w where here the cranking tool is to be fastened). Tightening Tigh tening torque: torque: 21 N m (15 (15 lbf ft) .
Fig. 141
59
Front cover with oil pump, installing
162 Install Install the cranking cranking tool tool at th the e flywhe flywheel el end. 163 Turn the the engine in in the mechanic's mechanic's tres trestle tle so tha thatt the front end comes uppermost. 164 Remove any any gasket remnant remnants s from the casing casing and tthe he cylinder block.
Fig. 142 1 999 8681
165 Lightly Lightly oil oil the oil oil pump ro rotor tors. s.
Fig. 143
166 Attach the the gasket gasket to the casing casing wi with th a little little grea grease. se.
Fig. 144
167 Position Position the oil pump drive drive against against the cranksha crankshaft. ft. OBS! Will only only fit in in one pos position. ition.
Fig. 145
60
168 Install Install the casing casing together together with th the e oil pump w without ithout tightentightening down the bolts. Align the casing with the oil sump sealing surface. 169 Ti Tight ghten en down down th the e bolts bolts.. Tightening Tigh tening torque: torque: 21 N m (15 (15 lbf ft) .
Fig. 146
170 Install Install the toothed toothed wheel and the V-belt V-belt pu pulley lley and align align the guide sleeve and the guide pin.
Fig. 147 1 Guide sl sleeve 2 Guide pin
171 Tighten Tighten down the bolts bolts (Torx (Torx E20), holdi holding ng the shaft in posiposition with the cranking tool at the flywheel end. Initiall tightening Initia tightening torque: 30 N m (22 lbf ft) . 1s 1stt ti tigh ghte teni ning ng ang angle le:: 60 2nd ti tigh ghte teni ning ng angl angle: e: 60 60
Fig. 148 1 Torx 20 E 2 V-belt pu pulley 3 Toothed wheel
61
172 Check that that the oscillatio oscillation n damper dampers s are free from from external external damage. Install the inner oscillation damper and the spacer. Make sure that the bolt holes align with the holes in the belt pulley.
Fig. 149 1 Spacer 2 Oscillation damper
174 Install Install a new gasket gasket at the connection connection ffor or the oil s suction uction pipe in the front cover.
Fig. 151 1 Gasket
62
175 Install Install the oil suction suction pipe toget together her with the bracket. bracket. Install Install the oil filler pipe.
Fig. 152 1 Oil su suction p piipe 2 Bracket 3 Oil filler ler pipe
176 Fill the joints joints in the oil su sump mp sealin sealing g surfac surface e with sea sealing ling compound.
Fig. 153
178 Install Install the oil sump and tighten tighten down the the bolts. bolts. OBS! There are bolts bolts of two different different len lengths. gths. Tightening torque: 25 N m (18 lbf ft)
Fig. 155
63
Power take-off housing, installing 179 Install Install the power take-of take-offf housing. App Apply ly lockin locking g fluid and tighten down the bolts (socket Torx E10 and E12). 180 Install Install the oil pip pipe. e.
Fi g. 156 156 1 Atta Attach chin ing g bo bolt lts s 2 Oil pipe
Flywheel, installing 181 Turn the the engine in in the mechanic's mechanic's tres trestle tle so tha thatt the flywheel end comes uppermost. 182 Lif Liftt the flywhe flywheel el into into positio position. n.
Fi g. 157 1 Lif Lifti ting ng eyes eyes M1 M10 0
183 Install Install the bolts bolts and tighten tighten them down. down. Use the the cranki cranking ng tool a ratchettorque, handle30–45 to hold the(1.18–1.77 shaft. Initialand tightening mm in) long bolts: 20–30 N m (15–2 2 lbf ft) ft) . Initial tightening torque, 50–85 mm (1.97–3.35 in) long bolts: 30–40 N m (22–30 (22–30 lbf ft) ft) . 1st tight tighteni ening ng angle: angle: 60 . 2nd tightening tightening angle, 30 mm (1.18 (1.18 in) bolts: bolts: 30 . 2nd tightening angle, 35–85 mm (1.38–3.35 in) bolts: 60 .
Fig. 158
64
184 Instal Installl the cover cover washer washer.. 185 Remove Remove the the c cran ranking king tool. tool.
Fig. 159
186 Re-install Re-install the the cover cover togeth together er with the O-ring. O-ring.
Fig. 160 1 Cover
Cylinder head, installing 187 Lay the cylinder cylinder h head ead gasket gasket on the cylinder cylinder b block lock with with the digits upward. Place the guide sleeves in the holes.
Fig. 161 1 Guide s slleeves
188 Lift the cylinder cylinder head into po positio sition. n. Pay atte attention ntion to th the e guide sleeves.
Fig. 162
65
189 Lightly oil oil the bolts and and instal installl them. Ti Tighten ghten them d down own in three stage, noting the sequence. Initial tighteni tightening ng torque: 50 N m (37 lbf ft) . 2nd stage: stage: 134 N m (99 lbf fft) t) . Finall tighte Fina tightening ning:: 90 .
Fig. 163
190 Install Install the push push ro rods. ds.
Fig. 164
191 Place the rocker rocker arm retaine retainers rs according according to the m marking arkings. s. Align them with the push rods and the valves and tighten down the bolts. Tightening Tigh tening torque: torque: 21 N m (15 lb lbff ft) . 192 Adjust the va valve lve clearanc clearance, e, see Valv Valve e adjust adjustment, ment, s sid id 76 76..
Fig. 165
66
Pump element, installing 193 Install Install the roller tappets tappets.. Make sure that the the correct tappet tappet comes in the correct place according to markings on the pump elements. Make sure that the guide on the tappet engages the groove in the bore.
Fig. 166 1 Guide lug
194 Lower the washer washer into into the tapp tappet et with tthe he aid of a sc screwrewdriver. The washers are 2.4 mm (0.094 in) thick.
Fig. 167
195 Install Install the pump element elements s accord according ing markings. markings. Crank Crank the engine, so that the camshaft ends up in a position to suite each pump element before tightening down the bolts. Tightening Tigh tening torque torque stage 1: 5 N m (3.7 lbf ft) . Stage Stage 2: 3 30 0 N m (22 lbf lbf ft) .
Fig. 168
67
Injectors and fuel lines, installing 196 Attach a new new copper washer washer to the the injec injector tor with a little little grease.
Fig. 169 1 Washer
197 Install Install the injectors injectors with with the con connectio nection n for retur return n fuel toward the exhaust side. Install the holders and screw in the bolts loosely. Torx E10.
Fig. 170 1 Co Conn nnec ecti tion on ffor or rret etur urn n fuel fuel 2 Bolt, lt, Torx E10 3 Retainer
198 Install Install new delivery delivery pipes. pipes. Tighten Tighten the bolts loosely loosely.. VIK TIGT! The deli TIG deliver very y pipes pipes must must not be res reshap haped ed (bent) (bent).. 199 Tighten Tighten down down the spring spring anchorage anchorage a attach ttaching ing bolt. bolt. Tightening Tigh tening torque: torque: 16 N m (12 lb lbff ft) .
Fig. 171
68
200 Tighten Tighten down down tthe he delivery delivery pipe nuts. Tightening Tigh tening torque: torque: 30 N m (22 (22 lbf ft) .
Fig. 172
201 Install Install new return return fuel lines. lines. Use new new clamp clamps s and rubb rubber er grommets. Connect the lines to the injectors and the return valve.
Fig. 1 173 Return fuel line 2 Rubber grommet
202 Install Install the fuel pipe pipe on the pump pump element elements. s. The thicker thicker gasket is to be placed between the pipe and the pump element, the thinner between the pipe and the bolt head.
Fig. 174 1 2 3
Thin gasket Fuel pipe Thick g ga asket
Fig. 175 1 Fuel pipe
69
Manifold, charge air pipe and valve cover, installing 203 Install Install the manifold manifold together together wit with h new gask gaskets. ets. Th The e gasket flange should be facing the cylinder head. Install and tighten down the nuts. Tightening Tigh tening torque: torque: 25 N m (18 lb lbff ft) .
Fig. 176 1 Manifold
204 Install Install the charge charge air pipe ttogether ogether with with new gasket gaskets s and tighten down the bolts. Tightening Tigh tening torque: torque: 9 N m (6.6 lbf ft) .
Fig. 177 1 Charge air pipe
205 Place the gasket gasket for the the valve c cover over on the c cylinde ylinderr head. Make sure that return fuel lines do not get pinched. Install the valve cover and tighten down the bolts. Tightening Tigh tening torque: torque: 9 N m (6.6 lbf ft) .
Fig. 178
70
Oil trap, installing 206 Install Install a new gasket in the oil trap trap groove. groove.
Fig. 179 1 Gasket
207 Align the the oil trap trap connection connection w with ith th the e oil line. line.
Fig. 180 1 Oil line
208 Bolt down down the oil oil trap ag against ainst the valv valve e cover cover..
Fig. 181
71
Coolant pump and thermostat housing, installing 209 Check that that there is no no noticeable noticeable play in the cool coolant ant pump pump.. 210 Remove the the protective protective tape. tape. Inst Install all the co coolant olant pum pump p together with a new gasket. Pull the bolts loosely.
Fig. 182
21 211 1 Lubricate Lubricate the O-rings O-rings and install install the the inter intermediate mediate housing housing..
Fig. 183
212 Install Install the thermost thermostat at housing. housing. U Use se a new gasket. gasket. 213 Tighten Tighten down all all bolts bolts to the cool coolant ant pump pump,, the intermediintermediate housing and the thermostat housing. Tightening Tigh tening torque: torque: 21 N m (15 lbf lbf ft) .
Fig. 184
72
Fuel feed pump, installing 214 Install Install the fuel feed feed pump. Pull Pull the bol bolts ts loose loosely ly..
Fig. 185
215 Install Install the V-belt V-belt on the belt pulleys. pulleys. Tension Tension the be belt lt by moving the fuel feed pump. At correct tension it should be possible to depress the belt approx. 10 mm (0.40 in) at the centre between the belt pulleys. Tighten down the bolts.
Fig. 186 1 Attaching bolt 2 Tensi ension onin ing g bolt bolt
Oil cooler and oil filter, installing 216 Remove protect protective ive plugs and and masking masking tape tape.. Install Install the oil cooler together with a new gasket. Install the bolts and tighten down. Tightening Tigh tening torque: torque: 21 N m (15 (15 lbf ft) . 217 Connect Connect the hoses hoses to th the e fuel ffeed eed pump and and the ffuel uel pipe. pipe. 218 Instal Installl new oil oil and fuel fuel filter filters. s.
Fig. 187
73
Cable harness, installing 219 Install Install the rail together together with the electric electrical al leads. Mak Make e sure that none of the electrical leads become pinched.
Fig. 188
220 Connect Connect the electric electrical al leads to the pump pump elem elements ents.. Tightening Tigh tening torque: torque: 1 N m (0.7 lbf ft) .
Fig. 189 1 Electr ectric ical al lle eads
221 Connect Connect the connector connectors s to the s sensors ensors ffor or fuel temper temperaature, oil pressure and crankshaft speed.
Fig. 190 1 Sens Sensor or,, fu fuel el tem tempe pera ratu ture re 2 Sens Sensor or,, cr cran anks ksha haft ft spee speed d 3 Sens Sensor or,, oil oil pr pres ess sur ure e
74
222 Connect the connector to the charge air temperatur temperature e sensor.
Fig. 191 1 Sensor Sensor,, charge air temperature
223 Connect Connect the connector connector to the se sensor nsor for coolant temper temperaature. Join the connector halves for the boost pressure sensor. Connect the connector to the sensor for camshaft speed.
Fig. 192 1 Se Sens nsor or,, coo coola lant nt te temp mper erat atur ure e 2 Connector for boost pressure sensor 3 Sens Sensor or,, ca cams msha haft ft s spe peed ed
75
Valve adjustment
224 Crank the engine engine until until the va valves lves on c cylinder ylinder N No. o. 1 overlap. overlap. Overlapping means that the exhaust valve is about to close, and inlet valve is about to open. In this position it should not be possible to rotate any of the push rods for the cylinder in question.
Fig. 193
Fig. 194 1. 3, 5. 7. 9, 11: exhaust valves 2. 4. 6, 8. 10. 12: inlet valves
225 Adjust the clearan clearance ce for the valves valves ma marked rked blac black k in the figfigure. Inlet valve: valve: 0.30 mm (0.012 in) . Exhaust valve: valve: 0.50 mm (0.020 in) . OBS! The valve valve clearan clearance ce shoul should d be increa increased sed by 0.1 mm (0.004 in), when the cylinder head gasket has been replaced. The valve clearance should be adjusted to normal after 50 hours operation.
Fig. 195
226 Tighten Tighten down down the lock lock nut nut to 20 N m ((15 15 lbf ft) ft) . Check Check the adjustment again with the feeler gauge.
Fig. 196
76
227 Crank the engine engine one one revolution. revolution. Adj Adjust ust the clearanc clearance e for the valves marked black in the figure. 228 Install Install the valve valve cover tog together ether wi with th a new gas gasket ket and tighten down the bolts. Tightening Tigh tening torque: torque: 9 N m (6.6 lbf f t).
Fig. 197
Engine, removing from mechanic's trestle 229 Connect Connect a lifting lifting device to tthe he engine lilifting fting eyes. eyes. The weight of the engine is approx. 700 kg (1543 lb).
Fig. 198
230 Remove the the bolts between tthe he mechanic's mechanic's trestle trestle and th the e engine fixture and lift away the engine. 231 Remove Remove the the en engin gine e fixtur fixture. e.
Fig. 199 1 Engine fixture
77
Turboch urbocharg arger er , inst all ing
232 Remove the the protec protective tive plugs plugs from the co connecti nnections ons for the return pipe, the pressure pipe and the manifold.
Fi g. 200 200 1 Prot Protec ectiv tive e pl plug ug
233 Install Install the turbocharge turbochargerr together together with a new g gasket asket and tighten down the attaching nuts. Tightening Tigh tening torque: torque: 40 N m (30 lb lbff ft) .
Fig. 201
234 Install Install the pressure-o pressure-oilil pipe together together wi with th a new gas gasket. ket. Tighten down the bolts. Tightening Tigh tening torque: torque: 21 N m (15 lb lbff ft) .
Fi g. 202 202
78
235 Install Install a new O-ring on the return pipe.
Fig. 203
236 Install Install the return return pipe together together with a new gasket. gasket. Ti Tighten ghten down the bolts. Tightening Tigh tening torque: 21 Nm Nm (15 lbf ft) .
Fig. 204
237 Instal Installl the retain retaining ing yoke. yoke.
Fig. 205
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Cylind Cylin d er head head Cylinder head, reconditioning Op nr 21168 168 Verktyg: Valve spring compressor Dial test indicator with magnetic base Sliding calipers for depth measuring
Dismantling 1
Remove Remove the the lifti lifting ng eyes, eyes, the the tem temper peratu ature re sensor sensor,, the fuel fuel connection and the plug. Install protective plugs in the openings.
2
Stand Stand the the cylin cylinder der h head ead edge edgeway ways s and secure secure with with CCclamps.
3
Remove Remove valv valve e cot cotters ters,, valve valve washer washers, s, valve valve s spri prings ngs and and valves.
Fig. 206 1 Lift Liftin ing ge eye ye 2 Plug 3 Fu Fuel el co conn nnec ecti tion on 4 Te Temp mper erat atur ure e sen senso sor r
Fig. 207
Fig. 208
80
4
Remo Remove ve the the v val alve ve s ste tem m se seal als. s.
5
Clean Clean the the cylind cylinder er head head and and che check ck that that th there ere iis s no damdamage.
6
Measure Measure the the valve valve clea clearan rance ce in the the va valve lve guid guides es with with a di dial al test indicator. Wear limits: Inl Inlet et valve: valve: 0.1 0.10mm 0mm (0.004 (0.004in) in) . Exhaust valve: valve: 0.13mm (0.005in)
7
Check tth he va valves. – Valve stem diameter standard: Inlet valve: 8.98 +0/-0.015mm (0.354 +0/-0.0006in) Ex Exha hau ust va valv e: 8.96 +0/-0.015mm (0.353 +0/-0.0006in) – Thickness of valve head edge: Wear limits: Inlet valve: 2.1mm (0.083in) . Exhaust valve: 1.8mm (0.071in) – Valve head diameter: Inlet valve: 48.0 +0.1/-0.1 mm (1.890 +0.004/-0.004 in) Ex Exha hau ust va valv e: 48.0 +0.1/-0.1 mm (1.890 +0.004/-0.004 in)
Fig. 209 1 Valve stem seal
Fig. 210
Fig. 211
81
8
Chec Check k tthe he valv valve es sea eatt ins inser erts ts.. Wear limits: Inlet valve: 2.8 mm (0.110in) . Exhaust valve: 2.2mm (0.087in)
9
Measur Measure e the depth depth of tthe he va valve lves s in tthe he c cyli ylinder nder head head (the (the distance between the valve head centre and the cylinder head face). Wear We ar limi limit: t: 1. 1.5m 5mm m (0.05 (0.059i 9in) n) .
Fig. 212 .
Fig. 213
10
Fig. 214
Measure Measure the the lengt length h of the the va valve lve sprin springs gs (unlo (unloade aded). d). Standard lengths: 64.7 +1.3/-1.3 mm (2.547 +0.051/-0.051 in)
82
Rock Ro cker er arm ret ret ainer, ainer, ch ecki ecki ng
Fig. 215
11
Rem Remove ove the the lock lock rin rings gs and remo remove ve the the roc rocker ker ar arms. ms. Check Check that the shaft studs and the rocker arms are not damaged.
12
Check Check tha thatt the the o oil il duc ducts ts are not blocked blocked..
83
Cylin Cyl ind d er blo blo ck Specifications, tightening torques Screw plugs
Fig. 216 4 35 Nm (26 lbf ft) 6 95 Nm (70 lbf ft) 7 65 Nm (48 lbf ft) 8 35 Nm (26 lbf ft) 13 35 Nm (26 lbf ft) 17 29 Nm (21 lbf ft) 21 9 Nm (6.6 lbf ft)
84
Cylin Cyl ind d er line linerr , pis pistt on Specifications, general Cylinder liner Number of seal rings per cylin- 3 der liner Piston Number of ring grooves
3
Piston pin, diameter
42 +0 / –0.006 mm (1.653 +0 / –0.0002 in)
Piston rings Compression rings Number of
2
Piston ring clearance in grooves: upper compression ring lower compression ring
tapered 0.17 mm (0.007 in)
Piston ring gap: upper compression ring
0.8 mm (0.031 in)
lower compression ring Oil scraper ring
2.5 mm (0.098 in)
Number of
1
Piston ring clearance in grooves
0.10 mm (0.004 in)
Piston ring gap
1.5 mm
85
Val alv v e mec m echa ha ni nism sm Specifications, general Valves Valve head diameter: inlet exhaust
Stem diameter: inlet exhaust
Valve head edge: inlet exhaust Seat insert angle in cylinder head: inlet exhaust Distance valve head – underside of cylinder head Valve clearance, cold engine, value when adjusting: inlet exhaust
48.0+ - 0.1 mm (1.890 + - 0.004 in) + 42.0 - 0.1 mm (1.653 + - 0.004 in) 8.98 –0.015 mm (0.354 –0.0006 in) 8.96 – 0.015 mm (0.353 – 0.0006 in) 2.1 mm (0.083 in) 1.8 mm (0.071 in) 30 45 1.5 mm
0.3 mm (0.012 in) 0.5 mm (0.020 in)
Valve seat inserts Valve seat width: inlet exhaust
2.8 mm (0.110 in) 2.2 mm (0.087 in)
Valve guides Clearance, valve stem – guide inlet exhaust
max 0.10 mm (0.004 in) max 0.13 mm (0.005 in)
Valve springs Length, unloaded
64.7 + - 1.3 mm (2.547 + - 0.051 in)
86
Engin Engi n e tim tim ing ing gear gears, s, cam cam shaf shaf t Specifications, general Camshaft bearings Camshaft bearings, inside diameter
65 +0.054 / –0 mm (2.559 +0.0021 / –0 in)
Wear limit
65.080 mm (2.562 in)
Tooth backlash back lash Max. tooth backlash camshaft gear – crankshaft gear
0.031–0.095 mm (0.0012–0.0037 in)
Cranks Cra nksh h aft, aft, con con nect nect ing rod, f lywhe lyw heel el Specifications, general Crankshaft Max. "throw"
0.07 mm (0.003 in)
Main bearing journals Diameter, standard
85.00 +0 / –0.02 mm (3.346 +0 / –0.0008 in)
Each undersize
0.25 mm (0.010 in)
Limit for undersize
84.75 +0 / –0.02 mm (3.337 +0 / –0.0008 in)
Max. out-of-round
0.01 mm (0.0004 in)
Width, standard
38.00 +0.06 / –0 mm (1.496 +0.0024 / –0 in)
Each oversize
0.40 mm (0.016 in)
Limit for oversize
38.46 +0 / –0.2 mm (1.514 +0 / –0.008 in)
Big-end bearing journals Diameter, standard
68.00 +0 / –0.02 mm (2.677 +0 / –0.0008 in)
Each undersize
0.25 mm (0.010 in)
Limit for undersize
67.50 +0 / –0.02 mm (2.657 +0 / –0.0008 in)
Max. out-of-round
0.01 mm (0.0004 in)
87
Connecting rod Marking of connecting rod and cap respectively
digital code
Small-end, bushing inside diameter
42 +0.05 / –0 mm (1.654 +0.0020 / –0 in)
Small-end, bushing outside diameter
45.5 +0.12 / –0 mm (1.791 +0.0047 / –0 in)
Hole rod diameter in connecting
45.5 +0.02 / –0 mm (1.791 +0.0008 / –0 in)
Max. clearance bushing – con- 0.08 mm (0.003 in) necting rod Big-end, inside diameter with bearing cap installed
72.5 +0.05 / –0 mm (2.854 +0.0020 / –0 in)
Big-end, inside diameter with 68.036–68.076 mm bearing cap and bearing shells (2.6786–2.6802 in) installed Each undersize
0.25 mm (0.010 in)
Wear limit radial clearance big- 0.12 mm (0.0047 in) end bearings Parallelism (twist) Measurement "a" max. 0.05 mm (0.020 in) per 100 mm (3.937 in) length.
Fig. 217
Straightness Permissible tolerance A to B: 0.05 mm (0.020 in) per 100 mm (3.937 in) length.
Fig. 218
88
Starter Star ter ring gea gearr , re repla placing cing Op nr Verktyg: 1
Heat Heat the new starte starterr ring gear to +210 +210 C (410 F). If an oven is used, begin work by heating the ring gear. If a welding torch is used, heat the ring gear just before installing.
2
Drill Drill a 1 10 0 mm (0.40 (0.40 iin) n) ho hole le betwe between en two two gear gear teeth teeth on the the old ring gear. Drill to a depth of 9 mm (0.35 in). VIK TIGT! TIGT! Do not dril drilll into the the fly flywhe wheel. el. Risk Risk of imbal imbalanc ance. e.
3
Secure Secure the flywh flywheel eel in a vice vice wit with h sof softt jaws. jaws. Sp Split lit th the e star starter ter ring gear at the drilled hole using a cold chisel.
4
Instal Installl the star starter ter ring ring gear gear.. Make Make sure sure that itit bott bottoms oms against the flywheel flange. If necessary use a drift.
5
All Allow ow the star starte terr ri ring ng gea gearr to cool. cool.
Fi 219 g.
Fi 220 g.
Fi 221 g.
89
Lubrication and oil sys t
s
Oil cooler, engine Leakage check Op nr Verktyg: 999 6662 999 6685
Pressure testing equipment Clamp for cooler
Plug M26x1.5 Part No. 942352 Spacer 30 mm (1.18 in) (e.g. a 10 mm socket) When checking, the oil cooler core should be as dry as possible internally, as remaining water may have a sealing effect on any possible crack. Neither must water leak into the oil cooler core during the check. During the test avoid starting or stopping fan systems or letting air in or out of the room, as the air pressure in the room may then change and be misinterpreted a a leak. The oil cooler core should, during the test, have the same temperature as the surroundings. The oil cooler core must not be repaired.
Fi g. 222 222 1 Plug 2 999 6685 3 Spacer
1
Instal Installl a clamp clamp on he oil oil coole coolerr core core accord according ing to the the fi figur gure. e. Make sure a good seal is obtained.
2
In Inst stal alll a clam clamp p at the the ot othe herr co conne nnect ctio ion. n.
90
3
Connec Connectt the the pressu pressure re tes testing ting equi equipme pment. nt.
4
Immers Immerse e the oil cooler cooler core core in a bowl bowl of wate waterr.
5
Set the the air air pre pressu ssure re to 100 100 kP kPa a (14 (14.5 .5 psi) psi).. Ch Check eck whet whether her any air bubbles rise from the oil cooler core. Leave the pressure on for one minute. The pressure must not drop during this time.
6
Increas Increase e the pres pressur sure e to 500 500 kPa (73 (73 psi) psi).. Lea Leave ve th the e pre presssure on for one minute. The pressure must not drop during
this time. If the pressure drops during the check, there is a leak. Replace the oil cooler core.
Fi g. 22 223 3 1 999 6 66 685
91
Fuel uel s ys yste tem m Injectors Specifications, general Injector Opening pressure
275 +8 bar (3989 +116 psi)
Injector, checking Op nr Verktyg: Testing equipment for injectors I The utmost cleanliness must be observed when working with the testing of injectors. Only use clean testing oil according to ISO 4113 or clean diesel fuel.
VARNING! Fuel is forced out of the injector at very high pressure. If a jet of fuel should hit an unprotected part of your body, the fuel may penetrate the skin and possibly cause blood-positioning
Fig. 224
1
Connect Connect the inj inject ector or tto o th the e testi testing ng e equi quipme pment. nt.
2
Make Make sur sure e that that the pres pressur sure e gauge gauge is con connec nected. ted. Slowly Slowly push down the lever and read off the pressure gauge. When the pressure gauge pointer stops or suddenly falls, the opening pressure has been reached. The opening pressure should be 27
92
3
To adjust adjust the the op openi ening ng press pressure ure,, unscre unscrew w the cap cap nu nut. t.
4
Set the the pres pressure sure by by sel select ecting ing s suit uitabl able e shims. shims. A th thick icker er shims will result in a higher opening pressure.
5
Dry the the nozzle nozzle and and the n nozz ozzle le holde holderr with with compres compressed sed air air. Press down the lever until the pressure gauge shows approx. 20 bar (290 psi) below the earlier ear lier recorded opening pressure.
6
Check Check that that fuel fuel do does es no nott drip drip from from the inj inject ector or du durin ring g the first 10 seconds.
7
If drops drops appea appearr within within 10 seco seconds nds,, dis dismant mantle le th the e inj inject ector or and clean. Assemble the injector and again check for leaks. If drops still appear, discard the injector.
8
Disc Disconn onnec ectt the the pr pres essu sure re gauge. gauge.
9
Check Check the the spray spray pa patte ttern rn and tthe he so sound und the the inj inject ector or ma makes kes.. It should make a buzzing sound when the lever is moved rapidly and at the same time show an evenly distributed spray pattern. The buzzing sound is different from a new and a used injector. This is due to the wear at the needle seat area. If no buzzing sound is audible, even though the injector has been cleaned, discard the injector.
Fig. 225
Fig. 226 1 Cap mut 2 Inj e ec c tto or n no ozzle 3 Ad ap apt e err 4 Thrus t p iin n 5 Compre Compress ssion ion spring 6 Shim
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