MAN 2842 E Industrial Gas Engine Repair Manual

 

Foreword  These instructions are intended to help perform repairs properly on the engine described here. The illustrations and associated descriptions are typical for the current state of development. Please note that all work in these repair instructions was performed with the engine removed. The expert technical knowledge required for handling gas engines has been assumed in creation of this publication. Repairs to drive units are to be performed by our customer service or the customer service of the manufacturer.

Yours sincerely MAN Nutzfahrzeuge Aktiengesellschaft Nuremberg Works

The right to make technical changes resulting from further development is reserved.  2002 MAN Nutzfahrzeuge Aktiengesellschaft Reproduction, duplication or translation, also of excerpts, is not permitted without written permission of MAN. All rights in accordance with copyright law are expressly reserved by MAN. MTDA

Technical status: 07.2002

1

51.99598-8018

 

Contents

Page Engine type classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Fault table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 General notes on engine overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Illustrations of E 2842 E 302 engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Engine lubrication diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Cooling system diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Engine timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Ignition Microprocessor-controlled ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking and setting ignition timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking and setting the ignition timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 21 22 23

Cooling Draining and filling with coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Lubrication Changing oil filter cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Removing and installing oil pump, servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Oil injection nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Flywheel / crankshaft sealing Removing and fitting vibration damper, replacing front crankshaft gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing flywheel, replacing gear ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing crankshaft seal (flywheel end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing bearing race . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 38 40 41 42

Intake and exhaust system Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Removing and installing exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Cylinder head Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dismantling and assembling rocker arm mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 50 51 52 55

Valve timing Removing and installing timing case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Removing and installing camshaft, replacing camshaft bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

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Contents

Page Crankgear, pistons Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing pistons with conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing pistons from conrod and fitting, checking – replacing conrod . . . . . . . . . . . . . . . . . . . . . . . . . Removing pistons from conrod and fitting, checking – replacing conrod . . . . . . . . . . . . . . . . . . . . . . . . . Removing and installing piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing cylinder liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

62 65 68 69 70 72

Measuring piston recess under crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Attachments Removing and installing starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 “Active” impulse sensor for IC 500 ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 “Passive” impulse sensor (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Service Data Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

80 81 81 82

F wrhoedesl .a.n.d. .s.ta. r.te Cloyn . .r .g.e.a. r. r.in . .g. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder-head bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque guide values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 85 6 87 88 90 92 94 94 95 99 96

Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

3

 

Engine type classification

The type designation, consisting of a sequence of letters and numbers, indicates some characteristics of each engine, provided you are familiar with the basic terminology. The system is explained here using the type E 2842 E 302 as an example: E

The “E” at the start of the type designation stands for natural gas (German: Erdgas)

28

The numbers “28” indicate that this is a power unit with 128 mm bore

4

The “4” means 142 mm stroke

2

The “2” indicates the number of cylinders 12

E

The “E” stands for “fitted engine” (German: Einbaumotor) and is intended to distinguish MAN vehicle engines

302

This is a factory-internal development number

4

 

Safety instructions

General This brief overview summarises important instructions and is structured into areas of main concern in order to impart the knowledge necessary to prevent accidents involving injury to persons, damage to the engine or other property and harm to the environment. Additional notes are included in the operator’s manual for the engine.

Important: Should an accident occur despite all precautionary measures, particularly one involving contact with corrosive acid, penetration of fuel under the skin, scalding by hot oil, antifreeze splashing into the eyes etc. you  must seek medical assistance immediately. 1. Regulat Regulations ions for the the prevention prevention of accidents accidents with with personal personal injury

Inspection, adjustment and repair work may only be performed by authorised and skilled personnel. D

The engine may only be started and operated by authorised personnel.

D

When the engine is running, do not get too close to revolving components. Wear tight-fitting work clothes.

D

Do not touch hot engine with bare hands: risk of burning yourself.

D

Keep engine vicinity, ladder and steps free of oil and grease. Accidents resulting from slipping may have serious consequences.

D

Work only with tools that are in good condition. Worn spanners slip: risk of injuries.

D

Persons must not stand under an engine suspended from a crane hook. Keep lifting gear in good order.

D

Open coolant circuit only after the engine has cooled down. If it is unavoidable that the circuit be opened with the engine at operating temperature, observe the instructions in the chapter “Maintenance and care” in the operating instructions.

D

Neither retighten nor open pressurised pipelines and hoses (lube oil circuit, coolant circuit and downstream hydraulic oil circuit if fitted): risk of injuries resulting from emerging fluids.

D

When working on the electrical system, first disconnect the earth cable of the battery and reconnect this last to prevent short circuits.

5

Ë

 Ë

Ë

 Ë

 

Safety instructions

D

Observe manufacturer’s instructions for handling batteries. Caution: Battery acid is toxic and caustic. Battery gases are explosive.

D

When performing welding work, observe the “Notes for welders”. 2. Regula Regulations tions for the preventi prevention on of engine damage damage and premature premature wear wear

D

The engine must be cleaned thoroughly prior to repair. Ensure that during repair work no dirt, sand or foreign bodies enter the engine.

D

If engine operation is disrupted, immediately determine the cause and have it remedied to prevent additional damage.

D

In every case, use only original MAN spare parts. The installation of parts that are “just as good” not originating from MAN can under certain circumstances cause severe damage – for which the workshop performing the repair must bear responsibility.

D

Never allow the engine to run dry, i.e. without lubricant or coolant. Appropriate notices must be attached to engines that are not ready for operation.

D

Only use lubricants, fluids and fuel approved by MAN (gas, engine oil, antifreeze and corrosion protection agents). Ensure cleanliness at all times.

D

Do not fill engine oil beyond the max. notch on the dipstick. Do not exceed the maximum per-  mitted operating inclination of the engine. Nonobservance can lead to severe engine damage.

D

Control and monitoring devices (charge control, oil pressure, coolant temperature) must be in perfect working order. 3. Safety instructions instructions for for handling handling the ignition ignition system system

D

D

When the engine is in operation, the following parts of the ignition system must not be touched or disconnected under any circumstances:  – ignition coils and caps  – cables of the high-voltage circuit  – cables of the low-voltage circuit  – connectors of the output and input wiring harness For all work related to set–up, operation, conversion, customisation, maintenance and repairs, the power must be disconnected from the ignition system and secured against inadvertent reactivation.

6

 

Safety instructions

4. Regulations Regulations for the prevention prevention of environm environmental ental damage damage

Engine oil and filter cartridges D

Old oil must be passed on for recycling.

D

Take extreme care that no oil enters the waste water system or seeps into the ground. Caution: Danger of contaminating potable water!

D

Treat used filter inserts and cartridges as hazardous waste.

Coolant D

Treat undiluted corrosion protection agents and / or antifreeze as hazardous waste.

D

When disposing of used coolant, the regulations issued by the relevant local authorities must be observed. 5. Instructions Instructions for for handling handling used used engine engine oil oil ∗

Prolonged or repeated skin contact with any type of engine oil draws grease from your skin. This can lead to dryness, irritation or skin inflammation. Used engine oil also contains hazardous substances that have caused skin cancer in tests on animals. If the basic principles of work safety and hygiene are observed, handling used engine oil does not represent a health hazard. Precautionary measures to protect your health: D

Avoid prolonged, repeated skin contact with used engine oil.

D

Protect your skin with suitable skin protection cream or protective gloves.

D

D

Clean any skin that comes into contact with engine oil.  – Wash thoroughly with soap and water. A nail brush provides effective assistance here.  – Special hand cleaning agents make it easier to clean dirty h hands. ands.  – Do not use petrol (gasoline), diesel fuel, gas g as oil or solvents as washing agents.

D

After cleaning, apply skin cream containing fat. Change clothing and shoes that are soaked in oil.

D

Do no put oily cloths in you pockets. Ensure that used engine oil is disposed of in the appropriate manner.  – Engine oil is a substance subst ance that endangers the water supply –

for this reason, do not pour engine oil on the ground, in lakes or rivers, down plugholes or in the waste water system. Violations of this regulation are punishable offences. Carefully collect and dispose of used engine oil. Information on collection points can be obtained from sales personnel, the supplier or the local authorities. ∗

Based on “Information sheet for handling used engine oil”.

7

 

Safety instructions

6. Safety instructions instructions for for handling handling gaseous fuels

Gaseous fuels consist essentially of methane, propane and butane as well as traces of higher hy-  drocarbons and inert components such as carbon dioxide and nitrogen.

D

The regulations applicable to gas installations must be observed.

D

Exhaust gases are toxic. Comply with the regulations for the installation of MAN industrial gas engines for operation in enclosed areas. Ensure adequate ventilation.

D

Smoking and naked flames are prohibited.

D

Leaks in the gas supply system mean danger of explosion and these must be remedied immediately.

D

Fire extinguishers and other firefighting equipment must be on hand.

D

Do not store combustible material in the engine room.

Conduct in the case of gas leaks D

Close the shutoff valve of the gas supply.

D

Switch off the main switch of the electric system.

D D

Cordon off the danger zone. Ask uninvolved persons to leave the danger zone. If gas is leaking, inform the relevant authorities immediately and initiate repairs.

Conduct in the event of fire D

Alert the fire brigade.

D

Immediately assist any injured persons, call paramedics if necessary.

D

In the case of a pure gas fire, do not extinguish the gas flame; if necessary, cool down the burning object (e.g. by starving the fire of oxygen: close doors and windows). Burning gas = controlled gas!

D

Prevent the flames from spreading.

D

If the flames spread to the surroundings, use a fire extinguisher.

D

Stay calm!

8

 

Fault table

Operating faults and possible causes We recommend A repair is only complete when both the damage that occurred and the possible causes have been eliminated. Finding out the cause of damage is often more difficult than repairing the damage that occurred. We therefore recommend that you obtain a precise description of the operating fault before removing and dismantling components. Then use a process elimination (questions) to pinpoint the probable causes and investigate and eliminate these successively on the basis of the table and your own experience . This helps to reduce repairs to the required scale and to counteract claims regarding “overeager” replacement of parts and complaints about expensive work and down time.

Note: The following list is conceived as an aid to memory for experts so that to causes of damage are overlooked when dealing with faults. It is expected of experts that they are very familiar with the repair instructions for the engine, but also with the engine operating instructions and “Fluids and lubricants for industrial gas engines”.

9

 

Fault table

Starter motor does not not turn e engine ngine or or only slowly (solen (solenoid oid switch switch en energise ergises s (“click” is audible) 2. Sta Starte rterr motor motor turns, turns, engine engine does not turn turn 3. Starter Starter motor motor turns engine, engine, eng engine ine does does not start start / starts starts poorly 4. Ig Igni niti tion on fa fail ilur ure e 5. . IIrr rreg egul ular ar en engi gine ne ru runn nnin ing g 6. Engine Engine stall stalls s during during o oper perati ation, on, no no longer longer star starts ts 7. En Engi gine ne “s “sha hake kes” s” 8. Engi Engine ne o onl nly y run runs sa att idle idle speed speed 9. Idle Idle spee speed d un unst stab able le 10. Engine does n not ot reach reach its nomin nominal al speed speed 11. Engine does not reach reach its nominal nominal power 12. Fuel Fuel consum consumpti ption on too too high high 13. Oil con consum sumpti ption on too too high high 14. Engine too ”loud” ”loud” / mechanica mechanicall noi noise se 15. Heavy Heavy bl blue ue sm smoke oke form formatio ation n 16. Heavy Heavy white white sm smoke oke form formati ation on 17. Exhaust Exhaust temperat temperature ure / exhaust back back pressure pressure too high (thermal (thermal overload) overload) 18. Lubric Lubricati ation on oil pr press essure ure to too o low 19. Temperature emperature differenc difference e engine exit exit / engine entry too too great 20. Coolan Coolantt tempera temperatur ture e too high high Possible causes x Batteries discharged, battery cable connections loose or corroded, power circuit interrupted 1.

x x

Starter motor defective (carbon brushes loosened / worn, coil damaged, ground fault) Crankshaft drive blocked x x x x x x x x o

x x x o

x x x

Ignition control unit defective Impulse sensor defective / gap incorrectly set Spark plug defective Ignition cable defective Ignition coil defective Ignition point incorrectly set Throttle valve does not open / actuating rod jammed / setting unit de–energized or defective

x

x x x x x

x

x x x x

Throttle valve not in full–load position / actuating rod jammed / throttle valve incorrectly adjusted

x

x x x x x x x x x x x

x

x

x x

x x

x x

x x

Shut–off solenoid valve of gas supply closed / does not open Zero pressure regulator of gas supply not correctly set or defective Gas metering valve defective Gas / air mixture too rich or too lean Lambda control defective Lack of compression, or more than 3 bar pressure difference between the individual cylinders Valve clearance not correct Valve guides heavily worn Valve seats leaking Piston rings heavily worn, broken (overpressure in the crankcase) Air filter heavily soiled Charge mixture piping leaking Cool Coolan antt e ent nter erin ing gc com ombu bust stio ion nc cha hamb mber er (c (cy ylind linder er head head gask gasket et leak leakiing) ng) Crankcase breather blocked Oil level in oil pan too high Safety Safety valve valve in tthe he oil oil circui circuitt d defec efectiv tive e ((does does not clo close, se, spr spring ing fatigue fatigued d or broken broken)) Heavy bearing wear Oil pump heavily worn Safety Safety valv valve e in the oil circui circuitt de defec fectiv tive e (does (does not ope open), n), oil lin lines es / oil duc ducts ts b bloc locked ked Uns Unsuit uitabl able e ex exha haus ust– t–ga gas s pi pipi ping ng,, heat heat e exc xcha hang nger er and and cat catal alyt ytic ic c con onve vert rter ers s with with exce excess ssiv ive e resistance

x

x x x x x x x x x x x x x

x x x x x x x

Flow Flow rres esis istan tance ce of of cool coolin ing g sy syst stem em ttoo oo g gre reat at

x x Soil Soilin ing g of cool coolin ing g sys syste tem m x Coolant llevel evel too low, low, air air in the coolant coolant circuit circuit x Wa Water ter pump too smal smalll or defe defecti ctive, ve, o orr speed speed incor incorrec rectly tly set x = o =

likely to apply might apply

10

 

Fault table

1.

Starte Starterr motor does not not turn engine or only only slowly slowly (so (solenoid lenoid switch energi energises ses (“click” is audible) 2. Sta Starte rterr motor motor turns, turns, engine engine doe does s not not turn turn 3. Starter Starter motor motor turns turns engine, engine, engine does not start start / starts poorly 4. Ig Igni niti tion on fa fail ilur ure e 5. . IIrr rreg egul ular ar en engi gine ne runn runnin ing g 6. Engine Engine stal stalls ls du durin ring g ope operat ration ion,, no longe longerr sta starts rts 7. En Engi gine ne “sha “shake kes” s” 8. Engi Engine ne on only ly runs runs at id idle le spee speed d 9. Id Idle le spee speed d un unst stab able le 10. Engine does not not reach reach its nomin nominal al speed speed 11. Engine does not reach reach its nominal nominal power 12. Fuel Fuel consu consumpt mption ion too too high high 13. Oil consum consumpti ption on ttoo oo h high igh 14. Engine Engine too ”loud” ”loud” / mechan mechanical ical noise 15. Heavy Heavy blue blue smoke smoke forma formatio tion n 16. Hea Heavy vy wh white ite s smok moke e formati formation on 17. Exhaust Exhaust temperat temperature ure / exhaust back back pressure pressure too high (thermal (thermal overload) overload) 18. Lubric Lubricati ation on oil pr press essure ure to too o low 19. Temperature emperature differenc difference e engine exit / engine entry entry too great 20. Coolan Coolantt tempera temperatur ture e too high high Possible causes x x Coolant Coolant line lines s leakin leaking, g, bl block ocked ed or twis twisted ted x Engine mounting unsuitable / worn

Note: You will find instructions for troubleshooting and rectifying faults in the IC 500 ignition system in the product information from Motortech GmbH, Hogrevestrasse 21, D–29223 Celle.

x = o =

likely to apply might apply

11

 

General notes on engine overhaul

The service life of an engine is influenced by very different factors. It is therefore not possible to specify certain fixed numbers of operating hours for general overhauls. In our view, it is not necessary to open up and engine or perform a general overhaul as long as the engine has good compression values and the following operating values have not changed significantly in relation to the values measured on commissioning the engine: D

Exhaust temperature

D

Coolant and lubricant temperature

D

Oil pressure and oil consumption

The following criteria greatly influence the length of the engine service life: D

Correct power setting in accordance with conditions of use

D

Technically correct installation

D

Inspection if installation by authorised personnel

D

Selection and quality of lubricants, fuel and coolant according to publication “Fluids and lubricants for industrial gas engines”

12

 

Illustrations of E 2842 E 302 engine

13

 

Engine lubrication diagrams

1

10

2 9 3 4

8

7

5

6

1 Rocker arm lubrication

6 Oil overpressure valve

2 Pi Pist ston on bolt bolt lubr lubric icat atio ion n

7 Oi Oill cool cooler er

3 Spray nozzles for piston cooling

8 Bypass valve

4 Camshaft bearing lubrication

9 Oil filter

5 Oil intake pipe

10 Main oil channels

14

 

Engine lubrication diagrams

1

2

2

5

4

4

3

1 Oil lines to crankshaft and camshaft

4 Bore holes for conrod bearing lubrication

2 Bore holes to main bearing lubrication

5 Oil intake pipe

3 Oil pump pump with with oil– oil–pres pressur sure e relief relief valv valve e

15

 

Cooling system diagrams

Cooling system with membrane expansion tank

4 5 6

7

3 2 8

9

1

10

1 En Engine

6 Pl Plate with 5x10 mm bore

2 Venti entila lati tion on lin line e ∅12 mm

7 Membrane expansion tank 0.35 bar

3 Ventilation tank

8 Connecting line to intake side

4 Automatic ventilation valve

of coolant pump ∅25 mm

5 Transmitter for coolant level

9 Coolant outlet 10 Cool Coolan antt inl inlet et

Overpressure safety valve: 3,5 bar Operating pressure: min. 0,6 bar / max. 3,0 bar

16

 

Cooling system diagrams

Cooling system in semi-open system

3

4

5

2 6

7

1

8

1 Engine 2 Venti entila lati tion on lin line e ∅12 mm 3 Filling Filling cap with overpre overpressure/v ssure/vacuum acuum valve 0,6 / –0,06 bar 4 Se Sens nsor or fo forr lliq iqui uid d lev level el 5 Exp xpan ansi sion on ta tank nk 6 Connec Connectin ting g line line to intake intake side side of coola coolant nt pump pump ∅25 mm 7 Cool Coolan antt out outle lett 8 Cool oolant ant in inle lett

17

 

Engine timing

1

2

3

4

5

1 Intermediate gear

4 Drive gear, oil pump

2 Drive gear, camshaft

5 Oil pump supply gears

3 Cr Cran anks ksha haft ft gea gearr

18

 

Microprocessor-controlled ignition system

Structure of the ignition system

The ignition system consists of the following parts: D

IC 500 control unit, see page 20 page 20

D

12 ignition coils

D

12 high-voltage cables

D

wiring harnesses for input and output signals and for ignition control

D

active impulse sensor, triggered by camshaft gear (trigger disc), see page  77 Note: You will find a detailed description of the ignition system in the product information from Motortech GmbH, Hogrevestrasse 21, D-29223 Celle.

19

 

Microprocessor-controlled ignition system

Ignition system control unit

The control unit of the IC 500 microprocessor–controlled ignition system records the crank angles of the engine at very short intervals and calculates from these data the times for triggering the ignition pulse for each cylinder. Caution: The parameters of the control unit may only be set by trained and skilled personnel (password required).

20

 

Replacing spark plugs

 Special spark plugs for long service life have been developed for industrial gas engines in continuous operation. We do not recommend adjusting the electrode gap on these special spark plugs (see ”Service Data”, page 94). page  94). Fig. 1 Pull off spark plug connectors. Danger: Do not pull off the spark plug connectors when the engine is running. High voltage!

1

Figs. 2 and 3 Unscrew the spark plugs.

2

3 Fig. 4 Fitting the spark plugs when the engine is cold:

Tightening torque: see “Service Data” (Do not grease or oil the spark plug threads!)  Fitting the spark plugs when the engine is warm: D D

D

Insert spark plugs and only tighten by hand Wait until the spark plugs have assumed the temperature of the engine (at least 2 minutes) Only then use a torque wrench to tighten

4

21

 

Checking and setting ignition timing

Checking the ignition timing Fig. 1 Remove cover at the front end crankshaft guard plate.

1 Fig. 2 Turn the engine using the barring gear until the piston of the cylinder to be set is at ignition “TDC”.

2 Fig. 3 Before the first cylinder reaches the top dead centre, a scale becomes visible on the flywheel beginning with 40° crank angle before “TDC” to 0°. The countermarking is a reference edge on the flywheel housing. The ignition timing is set and/or checked using a stroboscope lamp when the engine is running; this is pointed to the marking and lights up at the moment of ignition.

3 Fig. 4 The correct timing of the triggering of the flash takes place at the same time as the ignition spark of the 1st or 12th cylinder. The inductive fork transmitter is connected via the ignition cable. The fork transmitter senses the ignition impulse and passes it on to the stroboscope lamp.

4

22

 

Checking and setting the ignition timing

Setting the ignition timing To parametrise the ignition control unit see the operating instructions from the manufacturer, Motortech GmbH. Fig. 5 The ignition timing is set at the control unit (accessory). D D

Start engine Shine the stroboscope lamp against the scale on the flywheel and counter-marking

If the value at the control unit does not match the actual value on the flywheel disc, the engine must be stopped and the value for the reset signal corrected. The password is required for this setting.

5

Electronic speed control

The pulse recorder records the actual engine speed at the camshaft (trigger disc) and forwards these data to the control unit.

2

In the control unit the actual value is compared with the specified value.

1 Figs. 6 and 7 If there are speed deviations from the target value, there is a change in the current flowing to the setting unit. This causes a change in the setting unit position and thus a filling change from the throttle valve.

6

À Setting unit Á Throttle valve

7

23

 

Draining and filling with coolant 1

Draining coolant Drain coolant when the engine is cold  as  as follows: Danger: Risk of scalding if hot coolant is drained! Drain coolant into a container and dispose of it in accordance with local regulations.

Fig. 1 Remove the fastening cover at the filling neck of the expansion tank. 1 Fig. 2 Open the drain screw on the engine or at the lowest point in the cooling circuit of the engine.

2 Fig. 3 Drain screw in the coolant pipe. Drain off coolant; use a sufficiently large container to collect the coolant. Screw the screw plug back in.

3

Filling up with coolant (cooling system with expansion tank)

Fig. 4 The engine’s cooling system is to be filled up with a mixture of potable tap water and antifreeze agent on ethylene glycol basis or anticorrosion agent. See publication “Fluids and lubricants for industrial gas engines”. Coolant must be filled only at the filling neck . Do not add cold coolant while the engine is hot.

Ensure that the ratio of mixture water to antifreeze is reestablished.

4

24

1

24  

1

Draining and filling with coolant

Fig. 5 D D D D D

Unscrew fastening cover (large cap) on filling neck. Slowly add coolant. Close expansion tank. Allow engine to run for approx. 15 minutes at nominal speed. Switch off the engine, carefully turn the fastening cover with safety valve to preliminary engaging point – let off pressure – and add coolant if necessary Caution: If the cap with the working valves is opened, there is the risk that it will not close tightly again afterwards. The excess pressure required in the system will then no longer build up. Premature boiling occurs and coolant is lost. To prevent damage to the engine open this cap only in exceptional circumstances and fit a new one as soon as possible.

5

Danger: If in exceptional cases the cooling circuit has to be opened when the engine is warm, observe the safety instructions of the manufacturer of the cogeneration power unit.

Filling up with coolant (cooling system with diaphragm expansion vessel) Caution: Comply with filling instructions of the manufacturer of the cogeneration system. D

Fill up the cooling system with the filler device, keeping the breathers open until the coolant emerges bubble-free

D

Close breathers and increase pressure to a value which is approx. 0,2–0,4 bar above the pre-pressure of the expansion vessel

D

Start up system. Let it cool down after trail operation (i.e. after it reaches the operating temperature)

D

When the cooling temperature has fallen to below 50 _C, increase the system pressure to 0,5 bar above the pre–pressure of the expansion vessel via the filler device

25  

Changing oil filter cartridge

Caution: Old oil and used oil filters are hazardous waste. Observe safety instructions for the prevention of environmental damage.

Fig. 1 Open oil drain plug and use container to catch oil that may emerge. Danger: Oil filter bowl and oil filter cartridge are filled with hot oil. Risk of burns and scalds.

1

Fig. 2 Remove mounting bolt of the relevant filter bowl. Take off filter bowl and clean it internally.

2 Fig. 3 Insert a new filter cartridge and fit the filter cup with new gaskets. Observe tightening torque for securing screw.

3

26  

Removing and installing oil cooler

D D

Drain coolant, see page 24 page 24 Drain engine oil

Fig. 1 Remove oil filter. Remove filter head gasket.

1 Fig. 2 Remove oil cooler housing cover with the two oil coolers attached. The oil cooler is secured by the 10 bolts marked. Only loosen these screws after removing the housing cover.

3 Fig. 3 Check oil cooler for damage and replace if necessary. Fit oil cooler with new gaskets. Fit oil filter with new gasket. Fill up with engine oil and coolant.

3

27  

1

Removing and installing oil pump, servicing 1

Removing the oil pump Fig. 1 Drain the engine oil from the oil pan and the oil filters. Use a sufficiently large container to prevent oil from overflowing. Danger: The oil is hot – risk of scalding. Do not touch the oil drain plug with bare fingers. Oil is an environmental hazard. Handle it with care!

1 Caution: Old oil is hazardous waste. Observe safety instructions for the prevention of environmental damage.

Fig. 2 Remove oil pan.

2 Fig. 3 Unscrew the oil intake pipe.

3 Fig. 4 Remove pressure relief valve. The pressure relief valve is encapsulated. Opening pressure, see “Service Data”. Unscrew the oil pump.

4

1

28  

Removing and installing oil pump, servicing

Servicing the oil pump Fig. 5 Fit the oil pump in a vice (use protective jaws). Unscrew the oil pump cover.

5 Fig. 6 Pull the driven oil pump wheel from the casing. Check gears and pump housing for wear (see “Service Data”).

6 Fig. 7 Remove the pump drive gear. To do this, lay pump on suitable support and press off drive gear using a mandrel. To install, place the drive gear on the shaft while supporting the opposing shaft end. Press on the drive gear, observing the prescribed gap (see “Service Data”).

7 Fig. 8 Fit on the cover. Tighten the mounting bolts with the prescribed torque. Grind or replace covers with residues.

8

29  

Removing and installing oil pump, servicing

Checking the axial clearance of the pump gears Fig. 9 Apply the dial gauge; bring the shaft in one direction to the stop and set the dial gauge to “0”. Press the shaft in the opposite direction and read off the reaction of the dial gauge.

9

Installing the oil pump

2

Fig. 10 Before fitting, check that the oil pump is running smoothly. Fit the oil intake line À with seals. Fit pressure relief valve Á without seal. Before fitting the oil pan, turn over the engine to

1

check that the crankshaft drive and oil pumps are running smoothly and easily easily.. Attach a new oil pan gasket with grease and screw on the oil pan. 10

Fitting the oil pan Fig. 11 Replace the oil pan gasket. Position the oil pan at the crankcase and screw in the mounting bolts. Tighten the mounting bolts with the prescribed torque.

11

30  

Removing and installing oil pump, servicing

Filling engine oil Caution: Do not fill engine oil beyond the max. notch on the dipstick. Overfilling leads to engine damage!

Figs. 12 and 13 Fresh engine oil is filled at the oil filler neck (arrow). After filling, cut off the gas supply to the engine. Turn engine with the starter motor until the oil pres12 sure warning lamp goes out and / or the oil pressure gauge shows pressure. Then reset the electric connection to the speed sensor. Start the engine and allow to run for a few minutes at medium speed. Check oil pressure and leaks. Turn off the engine. After approx. 20 minutes, check the oil level. D D D D

Oil

?

Pull out dipstick with a lint-free, clean cloth press inoil again as far as possible pull out dipstick again

The oil level should be between the two notches on the dipstick and must never fall below the lower notch. Top up oil if necessary. Do not overfill.

MAX MIN 13

31  

Oil injection nozzle

Removing the oil injection nozzle D D

Drain oil, see page 28 page 28 Remove the oil pan, see page 28 page  28

Fig. 1 Unscrew the mounting bolts of the oil injection nozzle (arrow). Remove oil injection nozzle with valve.

1

Check the oil injection nozzle valve Fig. 2 Unscrew the oil injection nozzle valve from the body of the oil injection nozzle. The valve plunger must move up and down easily. If the valve plunger sticks or jams, replace the oil injection nozzle valve. Opening pressure, see “Service Data”.

2

Installing the oil injection nozzle Fig. 3 Position the oil injection nozzle À at the oil injection nozzle flange Á.

2 3 Fig. 4 Tighten the mounting bolts with the prescribed torque.

4

1

32  

Oil injection nozzle

Fig. 5 The oil spray from each nozzle must reach the entry bore hole of the cooling duct in the piston crown À and cams Á without hindrance. Bent oil injection nozzles must on no account be repaired. Turn the engine. The crankshaft drive or pistons must not collide with the oil injection nozzle.

2 1

1

1 2

1

5

2

33  

Removing and fitting vibration damper, replacing front crankshaft gasket Removing vibration damper D

Turn engine to ignition “TDC”. This ensures that the scale disk is in the right position on reassembly

Fig. 1 Block the crankshaft drive. The illustration shows a special tool that is to be fitted to the inspection port of the flywheel housing.

1 Fig. 2 Unscrew the barring gear.

2 Fig. 3 Loosen the securing screws of the vibration damper.

3 Fig. 4 Unscrew the two mounting bolts opposite one another and screw in the guide mandrel (M16x1.5). Remove all remaining bolts. Remove the vibration damper. Caution: The vibration damper is sensitive to impacts.

Remove oil thrower from the crankshaft. 4

34  

Removing and fitting vibration damper, replacing front crankshaft gasket Replacing the front crankshaft gasket Fig. 5 Loosen the mounting bolts of the cover.

5 Fig. 6 Remove the cover. Only replace the front crankshaft gasket as a complete unit, i.e. replace the bearing race and the radial shaft sealing ring.

6 Replacing the bearing race Note: The engines are supplied ex works without race on the front end of the crankshaft. If the radial shaft seal is replaced (as described here, see Fig. 11, page 36) a race must be fitted too.

Fig. 7 A stripping device (special tool) is required to remove the bearing race.

7

Fig. 8 Pull off the bearing race.

8

35  

Removing and fitting vibration damper, replacing front crankshaft gasket Fig. 9

1

A special tool is required to fit the bearing race.

2

Clean the inside of the bearing race and tail shaft. Coat crankshaft stub with sealing agent “Antipor 46”. D

D D

Push the bearing race À and press–in sleeve Á onto adapter Å. Tighten spindle Ä in the adapter Å with nut Æ. Screw adapter Å securely onto the crankshaft.

7

6

9

5

4

Fig. 10 The adapter must lie free of clearance on the crankshaft so that the right press–in depth of the bearing race is ensured. Pull the bearing race as far as it will go into the press-in sleeve Á on the adapter with collar nut and thrust washer ( and àin Fig. 9). Note: The bearing race can also be mounted when the cover is fitted.

1

10

2

5

Changing radial shaft seal

Fig. 11 To ensure perfect installation, the replacement cover and shaft sealing ring are only delivered as a complete unit. So that it remains possible to mount the shaft sealing ring, it must stay on the transport and installation sleeve until unt il assembly. Refer to the comments and assembly instructions on page 42. page 42. 11 Fig. 12 Fit cover À with new gasket

Á.

The cylinder pins  provide better guidance for the cover.

2

The sealing ring is thus not damaged so easily when the cover is replaced.

1

Tighten the bolts with the prescribed torque.

3 12

3

36  

Removing and fitting vibration damper, replacing front crankshaft gasket Installing vibration damper Fig. 13 Position the oil thrower on the crankshaft. Position the vibration damper on two guide mandrels (M16x1.5). Observe the position of the scale disk in relation to the crankshaft! Tighten the mounting bolts with the prescribed torque. Screw on the barring gear. Caution: Unblock the crankshaft drive!

13

37  

Removing and installing flywheel, replacing gear ring

Removing the flywheel D

Remove impulse sensor (optional), see page 78 page  78

Fig. 1 Loosen mounting bolts, securing the engine against turning if necessary.

1 Fig. 2 Remove two bolts facing each other and replace them by two guide pins (special tool, item. 13, see page 107). page  107). Remove all bolts. Pull off flywheel with suitable lifting gear. Danger: The flywheel is heavy! Use lifting gear.

2

Installing the flywheel Fig. 3 Screw in guide mandrels. Apply sealing agent “Antipor 46” to the inside of the flywheel. Place guide mandrels on the flywheel, ensuring that the centering mandrel (arrow) fits correctly into the bore in the flywheel. Push on flywheel until it stops. 3 Fig. 4 Lightly oil new mounting bolts (elasticated bolts), screw them in and tighten alternately on opposite sides of the ring gear to specified torque.

4

38  

Removing and installing flywheel, replacing gear ring

Replacing starter gear ring Fig. 5 Remove the flywheel. Drill the starter motor toothed wheel and break with a chisel. Caution:

In doing so, do not damage the flywheel.

5 Fig. 6 Note: As the maximum axial run-out of the starter motor toothed wheel must not be exceeded, the axial run-out of the flywheel should be measured on the contact surface of the starter motor toothed

wheel prior to shrinking motor toothed wheel. on the starter If the required value is exceeded, replace the flywheel. Engage the flywheel at the hub. Apply dial gauge to contact face of ring gear. Turn flywheel by hand by several revolutions and observe the deflection shown on the dial gauge.

6

Fig. 7 Heat new starter gear ring up to approx. 200°C to 230°C and press on until it stops. Danger: The parts are hot. Risk of burns. Wear protective gloves.

Check axial runout and compare with max. permissible value.

7

39  

Removing and installing crankshaft seal (flywheel end) Removing crankshaft seal D

Removing flywheel, see page 38 page 38

Fig. 1 Use special tool (Fig. 2) or a screwdriver to prise out seal.

1 Fig. 2 Special tool for prising out crankshaft seal.

2 Installing crankshaft seal Fig. 3 When fitting a new shaft seal, you should also exchange the bearing race of the flywheel. Insert a new shaft seal into the flywheel housing. Use mandrel (special tool) to drive in a sealing ring until flush . Refer to  42. the comments and assembly instructions on page 42. page

3

40  

Replacing bearing race

 Replacing the bearing race D

Removing flywheel, see page 38 page 38

Fig. 1 If the shaft sealing ring on flywheel side is replaced, it is also recommended to replace the bearing race of the flywheel. Break the bearing race to be replaced using a hammer. Danger: Wear protective glasses and gloves to protect against metal splinters!

1

Caution: In doing so, do not damage the flywheel. Do not use chisels!

Fig. 2 Insert the new bearing race in the drift (special tool) in such a way that the inner bevelled side faces the flywheel when fitted later. Carefully warm up the drift with bearing race. The installation temperature of the bearing race is approx. 150_C. 2 Fig. 3 Press in the bearing race as far as it will go.

3 Fig. 4 Seal the gap between flywheel and bearing race with “Antipor 46”.

4

41  

Crankshaft seals

General notes on the crankshaft seals As a general principle, the radial shaft sealing rings are made of polytetrafluorethylene (PTFE), otherwise known as Teflon. PTFE sealing rings differ from the elastomer sealing rings that used to be common in that they have a much wider, flat sealing lip that is not pretensioned by a coiled spring expander. The relatively large pretension of the sealing lip itself means that it curves inwards. This is why the PTFE sealing ring is delivered on a transport sleeve. So that it remains possible to mount the sealing ring, it must stay on this sleeve until assembly. This applies also because the sealing lip is very sensitive and the smallest damage causes leaks. The sealing lip and the bearing race of the flywheel must not be coated with oil or other lubricants. On fitting the new sealing ring, always replace the bearing race alongside it.

Assembly instructions for crankshaft seals D

The PTFE sealing ring must be fitted absolutely free of oil and grease. Even the slightest traces of oil or grease on the bearing race or sealing ring lead to leaks.

D

Clean oil, grease and corrosion protection agents from the bearing race before assembly. Commercially available cleaners are permitted for this purpose.

D

If the PTFE sealing ring is soiled with oil or grease, it is unusable. Cleaning is not permitted in this case.

D

The PTFE sealing ring must never be stored without the supplied transport sleeve. Even after only 1/2 hour of storage without the transport sleeve, it loses its initial tension and becomes unusable.

42  

Removing and installing intake manifold

Note: When working with the intake system, take care to ensure that everything remains very clean to prevent foreign bodies from entering the engine.

Removing the intake manifold Fig. 1 Loosen mounting bolts. 1 Fig. 2 Loosen hexagon bolts on flange.

2

Installing the intake manifold Fig. 3 Position the intake manifold with new gaskets, screw in the mounting bolts and tighten with the prescribed torque.

3

43  

Removing and installing exhaust manifold

Removing the exhaust manifold D

Drain coolant, see page 24 page 24

Fig. 1 Loosen the securing bolts of the exhaust manifold. Before unscrewing all mounting bolts, if appropriate replace 2 bolts by stud bolts as guides. The stud bolts with thread M10 are of local manufacture. Remove exhaust manifold. 1

Installing the exhaust manifold Fig. 2 Before fitting the exhaust manifold, screw in 2 stud bolts as a guide. Position the exhaust manifold with new gaskets. Ensure that the gaskets are correctly seated.

2 Fig. 3 Tighten the mounting bolts to specified torque (see “Service Data”). Fill up with coolant, see page 21

3

44  

Removing and installing cylinder head

Removing cylinder head D

Drain coolant, see page 24 page 24 Note: To remove the cylinder head, the intake inta ke and exhaust manifolds do not need to be removed.

Fig. 1 Unscrew the valve cover (T (Torx orx screws with spanner size E12”). 1 Fig. 2 Turn back the valve setting screws. Loosen the mounting bolts of the rocker arm bracket. Remove the rocker arm bracket.

2 Fig. 3 Take out the tappet push rods.

3 Fig. 4 Unscrew the cylinder-head bolts in reverse order to their tightening and remove the bolts. Note: Use a reinforced socket (screw driving machine) to loosen and tighten the cylinder-head bolts. In the case of newer engines, Torx screws are used. A spanner of size E20 - 1/2” is required.

4

45  

Removing and installing cylinder head

Figs. 5 and 6 Loosen and remove the mounting bolts of the intake and exhaust maifolds for the relevant cylinder. Loosen all bolts on the intake and exhaust pipes. This reduces the tension on the cylinder head and it is easier to remove the head.

5 Fig. 7 Remove the cylinder head and cylinder head gasket. Note: If all the cylinder heads of a bank are removed during an engine overhaul, use a straightedge to check the evenness of the sealing surfaces of the cylinder head

and cylinder block. Cylinder heads that are not flush can be milled by 1 mm. Observe the prescribed valve projection (see “Service Data”). Check the cylinder heads for cracks.

7

46  

Removing and installing cylinder head

Installing the cylinder head Fig. 8 Before fitting, clean and blow out the threaded holes in the crankcase. Clean the sealing surfaces on the cylinder head and on the crankcase. Put on the new cylinder head gasket (dry), taking account head. of the hole pattern, and attach the cylinder

8 Fig. 9 Two adjusting sleeves are used to secure each cylinder head. Fig. 10 Check cylinder-head bolts for max. permitted length (see “Service Data”). Removed bolts can be reused if the max. permitted length is not exceeded. Before inserting the cylinder head bolts, apply engine oil to the thread and coat the seating surface of the bolt head with installation paste “Optimoly White T”.

9

Fig. 11 Tighten the bolts according to the rotation angle method. Observe the tightening sequence, prescribed tightening method, instructions and notes on cylinder-head bolts in the chapter “Service Data”. Note: To avoid possible deformation between the cylinder heads and exhaust pipes, we recommend the following procedure: D Fit the cylinder head gaskets and cylinder heads. D Turn the head bolts a few thread turns. D Secure steel ruler (special tool) with ground face on the exhaust side; tightening torque for mounting bolts 20 Nm. If a steel ruler is not available, mount exhaust manifold and tighten to 20 Nm. D Tighten the cylinder head bolts as D D

prescribed. Unscrew the straightedge. Tighten the exhaust pipe and intake manifold with the prescribed torque.

10

11

47  

Removing and installing cylinder head

Fig. 12 Check the tappet push rod for deformation. When inserting the tappet push rods, ensure that they fit in the socket of the valve tappet. Fit the rocker arm mechanism. Insert the mounting bolts without washers and tighten slightly. Align the rocker arms to the valves. Tighten the mounting bolts with the prescribed torque. Note: Use only M10x70 mounting bolts with property class 10.9.

12

Fig. 13 Fit new gaskets between the cylinder head and intake / exhaust manifold. Tighten the mounting bolts of the intake and exhaust manifold with the prescribed torque.

13 Fig. 14 Set the valve clearance. Fit the cylinder head cover with a new gasket. Top up coolant.

14

48  

Removing and installing cylinder head

General notes The sealing effect of the cylinder head gasket depends mainly on whether the required initial tension of the cylinder–head bolt is actually achieved and retained. To tighten the cylinder–head bolts, use a calibrated torque wrench. The prescribed tightening torque must be kept for at least 5 seconds for final tightening using a torque wrench. With “snapping” torque wrenches, tighten the bolts slowly, as otherwise the set torque is not fully transferred to the bolts. Observeinthe on the usability of cylinder–head bolts, tightening sequence, and prescribed tightening method thenotes chapter “Service Data”.

Tightening “Tightening” is the initial tightening of the newly fitted bolts that have not yet been tightened following a repair - e.g. after replacement of the cylinder head gasket. Tighten the cylinder–head bolts with the engine cold, i.e. the crankcase is hand-warm or colder. Before inserting the cylinder-head bolts, apply engine oil to the thread (not the threaded hole) and coat the seating surface of the bolt head with installation paste “Optimoly White T”. Do not use oils or oil additives containing MoS 2. In the case of unoiled bolts, a significant portion of the tightening torque is converted into friction and is thus lost for the bold pretensioning. D

To secure the cylinder head, only tighten the cylinder head bolts slightly

D

Align the cylinder heads by screwing on the straightedge (special tool). If no straightedge is available, use the exhaust pipe or intake manifold Tighten step by step in the right order and with the prescribed tightening torque and/or angle of rotation

D

Caution: If individual bolts are tightened too much during preliminary tightening, the cylinder head is distorted. The distortion can no longer be removed with continued tightening in accordance with regulations!

49  

Setting valve clearance

Only set the valves when the engine is cold (maximum coolant temperature 50°C). Fig. 1 Remove cylinder head covers. Caution: Here, oil residues can escape.

Old oil is hazardous waste. Observe safety instructions for the prevention of environmental damage. Turn the engine using the barring gear until the piston of the cylinder to be set is at ignition TDC and the rocker arms are relieved of load.

1

The valves of the synchronised cylinder are then on overlap.

7 Fig. 2

8

Set valves on cylinder: 1

12

5

8

3

10

6

7

2

11

4

9

6

7

2

11

4

9

1

12

5

8

3

10

9 10 11

Valves on overlap at cylinder:

12 2 Fig. 3 D

D

D D D D

Slide the feeler gauge between the valve shaft and the rocker arm Loosen lock nut and turn adjusting screw with screwdriver until feeler gauge can be moved with slight resistance Tighten theclearance locknut with theagain prescribed torque Check the once Fit the cylinder head covers Tighten the bolts with the prescribed torque

3

1 2 3 4 5 6

50  

Dismantling and assembling rocker arm mechanism

D

Remove the rocker arms, see page 45 page 45

Fig. 1 Disengage securing ring.

1 Fig. 2 Remove rocker arm from rocker shaft. Note: If the rocker arm bearing bushes need to be replaced, new or exchange rocker arms ready for fitting are to be used.

2 Fig. 3

1

On fitting the rocker arms À on the rocker shafts or pedestals, the sliding surfaces Á and  are to be coated with Optimoly paste White T.

2

This applies to new parts and parts that have already run.

3

3

2

51  

Removing and installing valves

Removing the valves D

Remove rocker arms, take off cylinder head, see page 45 page 45

Fig. 1 Screw the valve fitting lever onto the cylinder head. Note: Valve springs and spring plates can also be replaced with the cylinder head still fitted. The relevant piston must be at “TDC”; the valve fitting lever is required.

1 Fig. 2 Note: If available in the workshop, the work operations described can also be performed on a valve frame.

Use the valve fitting lever to press the spring plates and springs downwards and use a magnet to take out the conical parts. Raise the fitting lever (caution: spring tension), swing away to the side. 2 Figs. 3 and 4 Remove valve plates, spring and washers. Unscrew the valve fitting lever. Note: The engines E 2842 E 302 / 312 are equipped with valve stem seals at the intake valves.

Pull off valve stem seals. Turn around the cylinder head and pull out valves. 3

4

52  

Removing and installing valves

Installing the valves Fig. 5 Oil the valves at the shaft and insert in the valve guide. Note: Slight damage to the valve seat can be repaired by lapping in using valve lapping paste. New valves must always be lapped in until an even valve seat is achieved. If necessary, rework the valve seat ring.

5 Turn around the cylinder head and insert the valve spring washers. Screw the valve fitting lever onto the cylinder head.

Figs. 6 and 7 Place insert sleeve for valve stem seals (special tool) on the respective valve and push on seal. Note: The picture shows a valve stem seal being fitted on an exhaust valve. In the E 2842 E 302 / 312 gas engines, however, only the inlet valves have valve stem seals. Only use new valve stem seals.

6

7 Fig. 8 Remove the guide sleeve. Position the press–in sleeve and press in the sealing ring.

8

53  

Removing and installing valves

Fig. 9 Insert washers and valve springs. The letters “TOP” must be at the top; tighter coils are at the bottom. Replace damaged or fatigued springs.

8 7 6

Fit the valve–spring pockets and conical parts. 1 2 3 4 5 6 7 8

5

Valve Val alve ve-s -ste tem m seali sealing ng Washer Ou Oute terr v val alve ve spri spring ng Washer In Inne nerr val valve ve spri spring ng Sprin ring pl plate ate Con oniical part

4 3 2 1

9

Measuring valve projection Figs. 10 and 11 Apply the dial gauge bracket with dial gauge to the cylinder head. Place the dial gauge tip on the cylinder head and set the dial gauge to “0”; swing towards the valve plate and read off projection. If necessary, replace the valve and valve seat ring.

10

11

54  

Checking compression

D

D

D

Check and / or set valve clearance, see page 50 page 50 Allow the engine to warm up until the coolant has reached a temperature of approx. 60–80°C Guide values for compression pressures are specified in the chapter “Service Data”

Fig. 1 Cut off the gas supply, switch off the ignition. Starting with the 1st cylinder, pull off the spark plug connectors and unscrew the spark plugs. 1 Fig. 2 Insert a test sheet in the compression recording device. Connect the compression recording device as appropriate and press onto the spark plug bore hole (∅14 mm). Throttle valve fully opened. Turn the engine using the starter motor until the pointer on the compression recording device no longer reacts. Connect the compression recording device with testing connection on the next cylinder and test all cylinders as described above.

2

Fig. 3 Depending on the configuration of the compression recording device, the engine can also be turned directly from the compression recording device. Here, the electric connections are to be made to the starter motor magnet switch (Terminals 50 and 30).

3 Fig. 4 Compare measured values with target values. Insert spark plugs and tighten by hand. Wait until the spark plug has assumed the temperature of the engine (at least 2 minutes). Tighten the spark plugs with the prescribed torque, see “Service Data”. Fit the spark plug connectors.

4

55  

Removing and installing timing case

Removing the gear case D D

Removing the starter motor, see page 76 page  76 Removing the flywheel, see page 38 page 38

Fig. 1 Oil and coolant lines, brackets for wiring harnesses etc. are attached to the gear case, and these must be removed. Remove the gear case cover.

1 Fig. 2 Loosen the securing bolts of the gear case. The bottom of the gear case is bolted to the oil pan! Loosen the securing bolts of the oil pan.

2 Fig. 3 Danger: The gear case is heavy!

To facilitate assembly, two bolts on opposite oppo site sides can be replaced by guide pins M12x1.5 À. Two long M10 Á bolts screwed into pocket holes on the flanging level make it easier to handle the gear case.

1

Remove the gear case. 3

1

2

56  

Removing and installing timing case

Installing the gear case Fig. 4 Clean residues of gaskets from the seating surface on the crankcase. Stick the new gasket on with a little grease. Guide the gear case onto the dowel pins and screw on. In doing so, examine the oil pan gasket; replace if necessary.

4 Fig. 5 Tighten the bolts with the prescribed torque. Tighten the mounting bolts of the oil pan. Clean gasket residues from the sealing surface of the gear case cover. Screw the gear case cover on with a new gasket. Secure the oil and coolant lines. Fit all removed components.

5

57  

Removing and installing camshaft, replacing camshaft bearings Removing the camshaft D D D D D

Drain coolant, see page 24 page 24 Remove oil pan, see page 30 page 30 Remove starter motor, see page 76 page 76 Remove flywheel and gear case, see page 38 page  38 Remove the rocker arms and take out the push rods, see page 45 page 45 Note: When removing the camshaft, the engine must be turned by 180 _. To do so, the engine must be placed on a dolly. dolly.

Fig. 1 Turn the engine upside down so that the valve tappets do not obstruct removal of camshaft. Pull out the camshaft; do not damage the camshaft bearings in doing so. Check the camshaft for wear and damage; replace if necessary. If the camshaft or the drive gear is damaged the entire camshaft/gear unit must be changed.

1 Fig. 2 Use a suitable mandrel to push the valve tappet out of the guide; check for wear; if required, renew. The valve tappets can be removed only after removal of the camshaft.

Replacing the camshaft bearings 2

Fig. 3 Use a suitable mandrel to drive out the camshaft bearing bushings and drive in new bushings until they are flush. In doing so, observe the correct position of the oil supply bore hole (arrow). Note: On the last camshaft bearing bushing on the gear case side, the axial camshaft stop is located behind the bushing. Due to the oblique toothing of the drive

wheel, the camshaft is continuously drawn against this stop.

3

58  

Removing and installing camshaft, replacing camshaft bearings Installing the camshaft Fig. 4 Oil and insert the valve tappets. Oil the camshaft bearing bushings. Apply oil to camshaft and insert it carefully. Caution: Do not damage the bearings.

4 Fig. 5 Ensure that the marks on the crankshaft and the camshaft gear match.

5 Fig. 6 If the camshaft cover in the crankcase has been removed, insert it as follows: D D D D

Remove grease from bore hole and cover Apply the sealing compound ”Hylomar” to the bore hole and cover, including bevel Carefully press in the cover as straight as possible Ensure there are no oil leaks

6

Measuring the axial clearance of the camshaft Fig. 7 Unscrew the screw plug and/or right–angle gear drive for the revcounter from the camshaft cover. Apply the sensor of the dial gauge to the front of the camshaft or driver for the revcounter. Set the dial gauge to ”0”.

7

59  

Removing and installing camshaft, replacing camshaft bearings Fig. 8 Use a suitable lever to press the camshaft as far as it will go on the gear case. Press the camshaft forwards against the dial gauge sensor as far as it will go. The movement of the dial gauge corresponds to the axial clearance of the camshaft. Refit all of the removed parts. Fill engine oil and coolant in accordance with regulations. Check the ignition point and valve clearance. 8

60  

Checking valve timing

Note: Unsynchronised valve timing can cause severe engine damage. For this reason, following engine faults that can cause twisting of the shrunk–on camshaft toothed wheel, the correct seating must be checked by checking the

valve timing. This check is also recommended after the camshaft is fitted. Fig. 1 Remove the cylinder head cover from the 1st cylinder. Set the valve clearance of the 1st cylinder correctly.

1

Fig. 2 Turn the engine using the barring gear until the valves of the 1st cylinder overlap Turn the engine back to approx. 50 _ before “TDC”, then turn forwards to 30_ before “TDC” again. - Note the degree marking on the flywheel 2 Fig. 3 Place the dial gauge with approx. 2 mm initial tension on the valve–spring pocket of the outlet valve on the 1st cylinder and set to “0”. Turn the engine in the running direction by 180_. - The outlet valve is then fully closed –  Read the stroke of the valve on the dial gauge. The valve stroke must lie between 4.5 and 5.4 mm. 3

61  

Removing and installing crankshaft

Removing the crankshaft D D D

Removing the oil pan and oil pump, see page 28 page 28 Removing the gear case, see page 56 page  56 Removing the front cover with crankshaft gasket, see page 34 page 34

Fig. 1 Undo the bolts of the conrod bearing cover and place the bearing covers to one side in the order or installation. Removing the pistons with conrods, see page 65. page 65. 1 Fig. 2 Undo the side bolts of the crankshaft bearing cover.

2

Fig. 3 Gradually loosen the mounting bolts of the crankshaft bearing cover from inside to out and unscrew. Remove the bearing cover and place to one side in the order of installation. Remove the bearing bush halves from the bearing covers and place to one side assigned to the bearing covers. Lift out the crankshaft. Caution: Do not damage the bearing surfaces of the crankshaft bearing pins.

3 Remove the bearing shells from the crankcase and place to one side in the order of installation. Clean the parts and check for wear; replace if necessary.

Fig. 4 The bearing covers are marked as regards order of installation. Note: Crankshaft bearing no. 1 is located on the opposite side of the flywheel.

4

62  

Removing and installing crankshaft

Check the spread of the bearing bushes

Fig. 5 Place the bearing bushes together on a level surface. Measure the spread “A”, note down, measure dimension “B”, note down.

B

Spread dimension = A – B

Installing the crankshaft Fig. 6

A

Clean the oil ducts in the crankcase and in the crankshaft with dry compressed air.

5

Thoroughly clean the bearing bushes and journals. Insert the bearing bushes in the crankcase, observing the numbering. Caution: If new bearing shells are used, pay attention to the corresponding repair level.

Oil the bearing surfaces of the bearing bushes and insert the crankshaft. In doing so, note the marking of the crankshaft and camshaft toothed wheel. Figs. 7 and 8

6

Check bearing cover bolts for max. permitted length (see “Service Data”). Removed bolts can be reused if the max. permitted length is not exceeded. Complete the bearing covers with the associated bearing bushes. Insert the vertical bearing cover bolts and tighten them in stages from inside to out to the prescribed torque value (see “Service Data”). Final tightening according to rotation angle method. Screw in the crankshaft bearing cover bolts and tighten them to the prescribed value.

7

Caution: As replacement for the lateral crankshaft bearing cap bolts now use only collar bolts 51.90020–0382 (M12x1.5x85, 12.9). Previously used bolts of other types must be replaced by these bolts.

Check that the crankshaft runs smoothly. Caution: Damaged bearing covers cannot be replaced on an individual basis.

8

63  

Removing and installing crankshaft

Checking axial clearance

Fig. 9 Note: The axial clearance of the crankshaft is determined by the crankshaft bearing (alignment bearing) on the flywheel side. D D D

D

Fit the dial gauge bracket with dial gauge to the crankcase Apply the tip of the dial gauge to the crankshaft Move the crankshaft back and forth in axial direction and read off the clearance from the dial gauge If the permitted axial clearance is exceeded, fully replace the main bearing bushes

9

Fig. 10 Measure conrod bearings, insert pistons with conrods. Coat the conrod bushes with oil and pull the conrods to the journals. Fit the conrod bearing cover with bearing bush (observe marking - numbers must be on the same side). Screw in the securing bolts and tighten them in stages to the prescribed value. 10 Final tightening according to rotation angle method. For tightening torques and reusability of bolts, see “Service Data”. Fit oil pan and other detachable components.

64  

Removing and installing pistons with conrods

Removing pistons with conrods D D

Remove oil pan, see page 28 page 28 Remove cylinder heads, see page 45 page  45

Fig. 1 Loosen and remove conrod bearing cover bolts.

1 Fig. 2 Take off connecting rod bearing bear ing caps with bearing shells, expediting the procedure by means of light strokes with a synthetic hammer if necessary. Note: Connecting rod bearing caps are match–  marked with the connecting rod big ends; arrange them in corresponding order.

2 Fig. 3 Remove combustion residues (oil carbon) from top cylinder edge using a piece of hard wood. Caution: Do not damage the cylinder liners!

Press out the conrod with piston upwards. Caution: Do not damage the oil injection nozzles!

3 Fig. 4 Lay pistons with connecting rods and associated caps aside; use deposit rack if available. Perform visual check of piston and piston rings. Note: For remachined crankcase sealing surfaces, there are repair pistons with 0.2, 0.4 and 0.6 mm lower dimension in compression height (see “Service Data”).

4

65  

Removing and installing pistons with conrods

Installing pistons with conrods Note: If the pistons have to be replaced, it must be determined whether oversize pistons were fitted by measuring the pistons or reading off the dimension on the piston crown. If this is the case, oversize pistons are to be used.

5

Fig. 5 Check bearing shells for wear and damage. Measure spread as in the case of main bearing shells. if required, fit new bearing shells. In the case of repairs to the conrod journals, use bearing bush of the corresponding repair level.

Fig. 6 Insert the bearing shells in the conrod or conrod bearing cover. Caution: Rod shell has red colour marking on side.

6

The top coat must not be damaged! Apply a thin coat of oil to the conrod bushes.

Fig. 7 Apply a thin coat of oil to the cylinder walls and pistons. Adjust the piston ring joints by approx. 120 ° each. Slide on the piston ring scuff band and tension the piston rings. 7 Fig. 8 Guide the conrod and push the piston on until it contacts the conrod foot on the conrod journal. Caution: Do not damage the oil injection nozzles!

8

66  

Removing and installing pistons with conrods

Fig. 9 The arrow on the top of the piston must always point towards the engine centre.

9 Fig. 10 Fit the conrod bearing cover. Caution: The numbers on the conrod bearing cover and the conrod foot must be on one side and must match up.

10 Fig. 11 Screw in the conrod bolts and tighten them in stages to the prescribed value. Final tightening according to rotation angle method. For tightening torques and reusability of bolts, see “Service Data”.

11 Fig. 12 Turn the engine slowly. slowly. The conrods and oil injection nozzles (arrow) must not collide or scuff. Note: If possible, only turn the engine in direction of rotation (viewed on flywheel, anticlockwise).

12

67  

Removing pistons from conrod and fitting, checking – replacing conrod Removing pistons from conrod and fitting Fig. 1 Remove pistons with conrods Fit conrod in a vice, use protective jaws. Remove guggeon pin circlip.

1 Fig. 2 Push out gudgeon pin; holding piston in place. Remove piston and place to one side.

2 Measure conrod foot bore (base hole)

Fig. 3 Insert new conrod bearing and fit cover. Tighten bolts according to regulation. Measure bearing bore hole with an internal micrometer in measuring directions 1, 2 and 3 as well as planes a and b.

1

2 3

Max. values, see “Service In thepermitted case of deviations beyond the Data”. tolerance range, replace conrod. 3 Fig. 4 Piston pin sockets are not available. In the case of worn sockets, fit exchange conrods.

4

8 mm

A

8 mm

B

68  

Removing pistons from conrod and fitting, checking – replacing conrod Fig. 5 Clean conrod. Check for externally visible damage; if necessary, scrap damaged rods.

Ø

Check parallel location of conrod and twisting of piston pin eye to bearing bush bore hole. In the case of deviations beyond the tolerance range, replace conrod.

   A    2    0  ,    0      Ø

A

5 Figs. 6 and 7 Fit piston to the conrod. Caution: The recess for the oil injection nozzle in the piston shaft (arrow) must lie on the side of the long conrod foot.

Insert piston pin. Fit circlips. Install piston, see page 65. page 65. 6

7

69  

Removing and installing piston rings

Piston ring arrangement Fig. 1 1 Com Compre pressi ssion on ring ring (key (keysto stone ne ring) ring) 2 Com Compre pressi ssion on ring ring ((tap tapered ered ring) ring) 3 Oil control control ring ring (beve (bevelle lled d ring) ring)

1 2 3

Removing piston rings Fig. 2 Remove pistons with conrods Clamp conrod in a vice, use protective jaws. Adjust piston ring pliers to piston diameter.

2 Fig. 3 Apply piston ring pliers at piston ring gap and unclip piston rings from the piston ring grooves. Note: Owing to the hose-type spring the oil scraper ring has a higher tangential tension.

Carefully clean the piston ring grooves using a piece of wood. Do not damage the piston ring grooves. 3

Checking ring gap Fig. 4 Insert piston rings singly into the cylinder and ascertain the ring gap using a feeler gauge. Replace piston rings if the ring gap is too large. For ring gap see “Service Data”.

4

70  

Removing and installing piston rings

Installing piston rings Figs. 5 and 6 TOP

Use the piston ring pliers to place the piston rings in the correct piston ring groove (TOP facing upwards).

6

Checking piston ring axial clearance Fig. 7 Use feeler gauge to ascertain the piston ring clearance at several points in each groove. For this purpose the piston ring is to be fully pressed into the piston ring groove at the point to be measured. The pistons must be replaced if the clearance ascertained is too large. Piston ring axial clearance, see “Service Data”. 7

71  

Replacing cylinder liners

Removing cylinder liners Note: Observe oversizes for cylinder liner outer diameters and collar heights (see “Service Data”). D D

Remove cylinder see 65 page 45 page 45 Remove pistons, head, see page 65 page

Fig. 1 Mark cylinder liner position relative to engine so that it can be reinstalled in the same position if reused.

1

Insert cylinder liner extractor device into cylinder liner, taking care not to damage the oil spray nozzle. Put support on extractor spindle and tighten nut.

Fig. 2 Hold extractor spindle in place and extract cylinder liner by turning nut. Take off extractor device and take out cylinder liner.

2

Fig. 3 Deposit cylinder liner upright. uprigh t. T Take ake off O-rings. O-ring s. Number cylinder liners in order of installation.

3

Installing cylinder liners Fig. 4 Checking cylinder liner protrusion

Clean basic bore and cylinder liner. Insert cylinder liner without O-rings into crankcase, observing the marking (ensure that it is identical with the position prior to removal). Measure cylinder liner protrusion at at least four different points, using gauge holder and gauge. 4

72  

Replacing cylinder liners

Fig. 5 Note: If available, use measuring plate for the measurement (special tool). Proceed as follows: Position press-on measuring plate with turned collar facing the liner using 2 fitting sleeves to centre plate. Tighten 4 bolts (improvised: collar bolt 51.90020–0270, length shortened to 90 mm) on the press-on measuring plate in stages and crosswise to 40 Nm. Set dial gauge combination above press-on plate to “0” under preload relative to the crankcase. Measure cylinder liner protrusion at least at four points.

A B

1

5

The cylinder liner protrusion is the difference between the collar height and the collar recess in the crankcase. 1 Crankcase 2 Cy Cyli lind nder er lin iner er B – A = Cylinder liner protrusion

Fig. 6

6

Install shim if the protrusion is below the minimum protrusion even at only one point. The shim is placed under the cylinder liner collar. However, it may be used only if after installation the upper tolerance limit is not exceeded.

Fig. 7 Oil new O-rings for lower seal (144x4) and insert them in crankcase. 7 Fig. 8 Oil new O-rings for upper seal (138x2) and roll them from below on to the cylinder liner and into the grooves. Do not overstretch the O-rings.

8

2

73  

Replacing cylinder liners

Fig. 9 Apply thin coat of engine oil to cylinder liner in the area of the upper and lower O-ring. Apply thin coat of engine oil to lower O-rings in the crankcase. Insert cylinder liners into crankcase and push them down by hand. Place cleanpressure metal plate liner and exert uniform downward untilon the liner is seated in the crankcase recess. If a perceptible resistance can be felt in this operation, the O-rings are no longer in their proper place. Reposition O-rings and insert cylinder liner again. Note: No grease or sealing agents of any kind must be used for installing cylinder liners and O-rings.

Note:

After fitting the cylinder liners ensure that the O-rings are in the correct position by checking the liner protrusion: Position press-on measuring plate with turned collar facing the liner using 2 fitting sleeves to centre plate. Tighten 4 bolts (improvised: collar bolt 51.90020–0270, length shortened to 90 mm) n the press–on measuring plate in stages and crosswise to 40 Nm. Set dial gauge combination above press-on plate to “0” under preload relative to the crankcase. Measure cylinder liner protrusion at least at four points.

9

74  

Measuring piston recess under crankcase

Measuring piston recess Fig. 1 Remove cylinder heads. Turn the piston to be measured to TDC. Apply the dial gauge bracket with dial gauge to the crankcase gasket surface. Set the dial gauge to -0-.

1 Fig. 2 Carefully swing the dial gauge bracket around while raising the tip of the dial gauge. Lower the tip of the dial gauge to the piston crown and read off the piston recess.

2

75  

Removing and installing starter

Fig. 1 Disconnect the negative cable from the battery or, if present, switch off the main battery switch. Disconnect cable from terminal 31 (minus terminal, thick cable), terminal 30 (plus terminal, thick cable) and terminal 50 from starter.

1 Fig. 2 Remove mounting nuts. Note: A curved wrench is advantageous for the inner bolts (see Fig.).

Take off starter. Check starter pinion for wear and that it can move freely. If necessary, clean piston using a brush dipped in fuel and regrease it. 2 Check flywheel gear ring for wear and damage. Turn over engine by hand once, paying particular attention to the positions at which the engine finally stops; i.e. when the engine is switched off it always stops in certain positions. The starter pinion engages in these positions when the engine is started. For changing starter gear ring, see page 39. page 39. The starter is installed in reverse sequence to the removal procedure. Ensure that the cables are correctly connected up and the bolts tightened to specified torque. Connect up battery or switch on battery main switch. After installation check starter to see that it works properly.

76  

“Active” impulse sensor for IC 500 ignition system Fig. 1 The speed signal for the IC 500 microprocessor–  controlled ignition system is supplied by an “active” impulse sensor. This is located on the timing case cover and is axially aligned to the camshaft drive gear.

Fig. 2 For triggering this impulse sensor the camshaft is fitted with seven M6 hex bolts. Six bolts À supply the ignition impulse, which is processed in the control unit. One bolt Á supplies the “RESET” signal.

1

1

Fig. 3 Set distance ”B” for the impulse sensor as follows: D

D D D

Turn the engine in anti–clockwise direction (looking at the flywheel) until a bolt head is opposite the impulse sensor. sen sor. (the direction of rotation guarantees that the camshaft is in axial contact with the collar bearing because of the helical teeth of the drive gear). Coat the thread of the impulse sensor with “Loctite” sealing compound. Carefully screw in the impulse sensor as far as it will go. Turn the engine back by half to one full revolution and lock (tightening torque 15 Nm).

2 2

Caution: If the impulse sensor is incorrectly set it may be sheared off by the projecting bolts. Fragments may fall into the engine!

B

3

77  

“Passive” impulse sensor (optional) Fig. 1 À

Impulse sensor “passive”

Á

Impulse sensor (optional)

1

1 Fig. 2

A

Set gap A of the impulse sensor “passive” as follows: D D

D

Set one tooth of the starter motor toothed ring centred in relation to the threaded hole Carefully screw in the impulse sensor as far as it will go Turn back one revolution and lock

2 Fig. 3

A

Set gap A of the impulse sensor “passive” (optional) as follows: D D

Carefully screw in the impulse sensor as far as it will go Turn back one revolution and lock

3

2

78  

Service Data

79  

Specifications

Engine Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V 90° Mode of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-stroke Otto engine Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Compression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 : 1or 12.5 : 1 Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 mm Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 mm Engine capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21,927 cm3 Direction of rotation viewed on flywheel . . . . . . . . . . . . . . . . . . . . anti clockwise Power based on ISO 3046 E 2842 E 302 l = 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222 kW 229 kW l = 1,43 (< TA Luft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 kW 167 kW

at 1,500 rpm at 1,800 rpm at 1,500 rpm at 1,800 rpm

Power based on ISO 3046 E 2842 E 312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 kW at 1,500 rpm 280 kW at 1,800 rpm Blocked ISO-standard power based on ISO 3046 / Part 7 Standard reference conditions: air temperature 298 K, air pressure 1000 mbar, humidity 30% for operation with natural gas (Group H) with a calorific value H u of 10 kWh/m3N Methane numberu80 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure circulation forced feed lubrication by gear oil pump Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . in main flow Filling capacities Oil capacity in the oil pan Deep oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . min. 40 ltr. max. 90 ltr. Semi–flat oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . min. max. Oil change capacity (with filter) Deep oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 ltr. Semi-flat oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 ltr.

22 ltr. 30 ltr.

Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fluid cooling Coolant temperature normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80°C

80  

Service Data

Dimensions Limiting values

Crankcase Base version: 153.90–154.00 mm for cylinder liners with 0.5 und 1.0 mm larger outside Ø: 154.40–154.44 mm Ø Ø

Base version: 145.80–145.84 mm for cylinder liners with 0,5 mm larger outside Ø: 146.30–146.34 mm for cylinder liners with 1,0 mm larger outside Ø: 146.80–146.84 mm

9.97–9.99 mm Base version: 144.50–144.54 mm for cylinder liners with 0,5 mm larger outside Ø: 145.00–145.04 mm for cylinder liners with 1,0 mm larger outside Ø: 145.50–145.54 mm Ø

Cylinder liner

Ø Ø

Base version: 153.761–153.786 mm with 0.5 and 1.0 mm larger outside Ø: 154.194–154.257 mm

Base version: 10.03–10.05 mm with 0,2 mm more flange height: 10.23–10.23 mm 0,005

Ø

Base version: 145.761–145.786 mm with 0.5 mm larger outside Ø: 146.261–146.286 mm with 1.0 mm larger outside Ø: 146.761–146.786 mm 127.990–128.010 Max. wear limit: 0.15 mm below base dimension Base version: 144.432–144.457 mm with 0.5 mm larger outside Ø: 144.932–144.957 mm with 1.0 mm larger outside Ø: 145.432–145.457 mm

Ø

Liner protrusion above upper deck of crankcase: 0.04–0.08 mm

81  

Dimensions Dimensions

Service Data Crankshaft Crankshaft, front (opposite side to flywheel)

99.985–100.020 mm Base version: 89.98–90.00 mm undersize –0.25: 89.73–89.75 mm undersize –0.50: 89.48–89.50 mm undersize –0.75: 89.23–89.25 mm undersize –1.00: 88.98–89.00 mm

1

Base version: 103.98–104.00 mm undersize –0.25: 103.73–103.75 mm undersize –0.50: 103.48–103.50 mm undersize –0.75: 103.23–103.25 mm undersize –1.00: 102.98–103.00 mm 2

1 = colour marking for installation levels crankpin 2 = colour marking for installation level main bearing undersize –0.25: red undersize –0.50: white undersize –0.75: yellow undersize –1.00: lilac max. axial clearance of crankshaft: 0,190–0,322 mm

Bearing race for crankshaft, front end Inner diameter: 99.907–99.942 mm

 Ø

82  

Service Data

Dimensions Grenzwerte

Crankshaft, rear end (adjacent to flywheel) Max. permissible runout with crankshaft taken up in end bearings: at bearing 4: 0.08 mm

1

Base version: 38.000–38.062 mm undersize 0.25 and 0.50: 38.500–38.562 mm undersize 0.75 and 1.00: 39.000–39.062 mm 1 = Colour marking for size identification of thrust bearing journal length undersize 0.25: red undersize 0.50: white undersize 0.75: yellow undersize 1.00: lilac

Main bearing Data for wall thickness and bearing inner diameter also apply to the alignment bearing

Base version: 3.455–3.467 mm undersize 0.25: 3.580–3.592 mm undersize 0.50: 3.705–3.717 mm undersize 0.75: 3.830–3.842 mm undersize 1.00: 3.955–3.967 mm Bearing bore in installed condition: Base version: 104.066–104.112 mm undersize 0.25: 103.816–103.862 mm undersize 0.50: 103.566–103.612 mm undersize 0.75: 103.316–103.362 mm undersize 1.00: 103.066–103.112 mm Spread: 0.3–1.2 mm Marking: top / bottom standard size: 0958 / 0959 undersize 0.25: 0962 / 0963 undersize 0.50: 0964 / 0965 undersize 0.75: 0966 / 0967 undersize 1.00: 0968 / 0969

83  

Service Data

Dimensions Dimensions

Thrust bearing Base version: 37.74–37.81 mm undersize 0.25: 38.24–38.31 mm undersize 0.50: 38.24–38.31 mm undersize 0.75: 38.74–38.81 mm undersize 1.00: 38.74–38.81 mm Spread: 0.1 – 0.5 mm Marking: top / bottom standard size: 0164 / 0165 undersize 0.25: 0168 / 0169 undersize 0.50: 0170 / 0171 undersize 0.75: 0172 / 0173 undersize 1.00: 0174 / 0175 31.01–31.04 mm Data for wall thickness and bearing bore also apply to thrust bearing”

Mounting bolts for crankshaft bearing caps

100

Length: With each tightening, the bolts are deliberately stressed beyond the stretch limit and each tightening thus extends their length permanently. When the max. length has been reached, the bolt may no longer be used. new: 152.5–153 mm max. 154.5 mm

84  

Dimensions Grenzwerte

Service Data Flywheel and starter gear ring

Ø Flywheel: 432.490–432.645 mm Starter gear ring, inside diameter: 432.000–432.155 mm Interference: 0.335–0.645 mm Installation temperature: 200–230_C

Ø

m = 65.1 kg (with starter gear) J = 2.412 kgm2

Number of teeth: Z=160, Module 3 Matching gear: Starter pinion number of teeth: (Z = 9)

Backlash: 0.6–0.9 mm

85  

Dimensions Grenzwerte

Service Data Conrods

46.055–46.065 mm Ø

   A    2    0  .    0      Ø

A

1

2 3

8 mm

A

Bearing bore in directions 1,2 and 3 and in planes a and b: 90.064–90.106 mm

8 mm

B

Pre-condition: new big-end bearing in place, conrod assembled

Conrod bearings Base version: 2.463–2.473 mm undersize –0.25: 2.588–2.598 mm undersize –0.50: 2.713–2.723 mm undersize –0.75: 2.838–2.848 mm undersize –1.00: 2.963–2.973 mm Spread: 0.6–1.5 mm If signs of wear are present (scores,antiwear coating damaged), change both bearing shells Important: Observe installation position (rod bush has red or yellow colour marking on side).

Conrod bolts Length: During tightening the bolts are intentionally stressed beyond the yield point and therefore subjected to some permanent elongation each time they are tightened. When the max. length has been reached, the bolt may no longer be used. 51. 90020-0139 new: 67.2–67.5 mm, max. 68.5 mm

86  

Dimensions Grenzwerte

Service Data Pistons

Compression height: 80.650–80.700 mm Piston recess under deck of crankcase: 0.59–0.22 mm Ø 46.003–46.009 mm Piston bolt diameter: 45.994–46.000 mm Ø

127.840–127.870 mm

   5    2

Piston weight difference per set in an engine: max. 100g

Piston ring grooves 2,5 3.195–3.225 mm I 3.040–3.060 mm II III 5.020–5.040 mm

Piston rings 2,5 I

1st ring – keystone ring Height: 2.796–2.830 mm

II

2 nd ring – taper faced ring: Height: 2.978–2.990 mm Axial clearance: 0.050–0.082 mm

III

3rd ring – bevelled ring Height: 4.978–4.990 mm Axial clearance: 0.030–0.062 mm Ring gap: 1st ring: 2nd ri ring: 3rd ring:

0.50–0.70 mm 0.45–0.70 m mm m 0.25–0.40 mm

87  

Dimensions Grenzwerte

Service Data Cylinder head Ø

12.000–12.018 mm

Ø

ö

b

Ø Ø

Intake valve ö = 60 _  Exhaust valve b = 60 _

Valve guide bore in cylinder head: 18.000–18.018 mm Valve guide outside diameter: 18.028–18.046 mm

stand tandar ard: d: 113 13.9 .9–1 –114 14 mm minimum: 112.9 mm (observe specified dimensions for valve recess))

Ø Ø

Valve seat insert bore in cylinder head: 53.00–53.03 mm Valve seat insert outside diameter: 53.10–53.11 53.10–53.1 1 mm Valve seat insert bore in cylinder head: 61.00–61.03 mm Valve seat insert outside diameter: 61.10–61.11 61.10–61.1 1 mm

88  

Dimensions Grenzwerte

Service Data Cylinder-head bolts

   X    X    X

90+3

Length: With each tightening, the bolts are deliberately stressed beyond the stretch limit and each tightening thus extends their length permanently. pe rmanently. When the max. length has been reached, the bolt may no longer be used. Angle of rotation symbol

51.90490–0022: new: 167.5–168 mm, max. 170 mm 51.90490–0023: new: 143.5–144 mm, max. 146 mm 51.90490–0024: new: 108.5–109 mm, max. 111 mm

Valve recess Ø Intake valve:

11.968–11.982 mm

Exh xhau aust st va valv lve: e: 11.94 1.943– 3–1 11.95 1.957 7 mm Max. wear limit: 0.1 mm below base dimension Do not reuse valves with damaged chromium layer!

Valve recess for intake and exhaust valve: 0.7– 1.3 1.3 mm

Valve springs

L

Free length (L), approx. 59 mm Spring force at L = 46.8 mm: 330–360 N Spring force at L = 32.8 mm: 670–770 N The lowest spring force is at the same time the wear limit value.

89  

Dimensions Limiting values

Service Data Valve gear Rocker arm bracket

24.967–24.980 mm

14 Ø

Rocker arms Rocker arm radial clearance: 0.025–0.054 mm Wear limit: 0.08 mm      Ø

25.005 – 25.021 mm

Camshaft Replace if there are traces of wear

 Ø

Camshaft axial clearance: 0.20–0.90 mm Wear limit: 1.5 mm

 Ø

69.91 – 69.94 mm (Ø 70 e7) Backlash: Crankshaft gear and camshaft gear: 0.118 mm–0.242 mm

Camshaft bearing

 Ø

70.00 – 70.03 mm diameter 70.070 70.070–70.090 mm for bush 7 (bush at timing case end)

90  

Dimensions Limiting values

Service Data Valve tappet

Bore in crankcase: 20.000–20.021 mm

19.944 – 19.965 mm

Ø

Valve clearance Set when engine is cold up to engine no. 491 9625 000 .... 1500 rpm: Intake valve: 0.35 mm Exhaust valve: 0.5 mm 1800 rpm: Intake valve: 0.25 mm Exhaust valve: 0.4 mm engine no. and up: 491 9625 001 .... Intake valve: 0.6 mm Exhaust valve: 0.6mm

Valve timing 1 2 3 4   5 6 7

1 2 TDC 3

7

6

= = = =

Engine di direction of of tu turn Intake valve o op pens 12 12° before TDC Exhaust va valve cl closes 11 11° after TDC Exhaust valve open ens s 61° before BDC = Intake valve closes 48° after BDC = Exh xhau aust st va valv lve e ope openi ning ng angl angle e 252 252° = Inta Intake ke va vallve open openin ing g ang angle le 240 240°

The degrees specified refer to the crankshaft angle

4 5 BDC

Compression pressures good permitted repair required Pressure difference (between the individual cylinders)

above 16 bar 13 – 16 bar below 13 bar max. 3 bar

91  

Dimensions Limiting values

Service Data Engine lubrication Valve opening pressures Bypass valve for oil filter Overpressure valve on the oil pump Pressure valve of the oil injection nozzles Opening pressure

2.2–2.8 bar 5–16 bar 1.4–1.6 bar

Pressure at max. opening Spray hole diameter of the oil injection nozzles

1,9–2,1 bar 1.75–1.85 mm

Three-gear oil pump Oil pump gear

14.5–14.7 mm 28.927–28.960 mm Housing depth: 28.000–28.033 mm Axial clearance: 0.040–0.106 mm

 Ø

Shaft: 21.930–21.940 mm Bore Ø in housing: 22.000–22.021 mm

Drive gear with oil pump gear

 Ø

Shaft: 21.930–21.940 mm Bore Ø in drive gear: 21.870–21.885 mm Press on force: 12000 N 0.5 mm

Backlash: Drive gear and crankshaft gear: 0.099–0.451 mm

Oil pump capacity at oil pump speed (with SAE 20W/20 oil, at 90°C and p = 6 bar) Oil pump speed = engine speed x 0.977 at n = 600 rpm at n = 600 rpm at n = 600 rpm

49 ltr./min 128 ltr./min 159 ltr./min

92  

Dimensions Limiting values

Service Data Two-gear oil pump Oil pump gear

11.5–11.7 mm 42.911–42.950 mm Housing depth: 43.000–43.039 mm Axial clearance: 0.050–0.128 mm  Ø

Shaft: 21.930–21.940 mm Bore Ø in housing: 22.000–22.021 mm

Drive wheel with oil pump gear

 Ø

Shaft: 21.930–21.940 mm Bore Ø in drive gear: 21.870–21.885 mm Press on force: 12000 N 0.5 mm

Oil pump capacity at oil pump speed (with SAE 20W/20 oil, at 90°C and p = 6 bar) Oil pump speed = engine speed x 0,977 at n = 600 rpm at n = 600 rpm at n = 600 rpm

Backlash: Drive gear and crankshaft gear: 0.099–0.451 mm

42 ltr./min 105 ltr./min 127 ltr./min

93  

Service Data

Dimensions Limiting values

Ignition system Ignition system Firing sequence Firing interval

High-voltage capacitor ignition system 1–12–5–8–3–10–6–7–2–11–4–9 90_ , 30_ , 90_ ...

Ignition timing Engine model E 2842 E 302 TA-Luft

t

Ignition timing ± 1° deg. before TDC 1500 rpm 1800 rpm 12° 16° 16° 16°

Spark plug Manufacturer: Type: Electrode gap when wh en new: new:  

DENSO GE 3-1 0.23 0.23–0 –0.3 .33 3 mm

94  

Service Data

Dimensions Limiting values

Starter Manufacturer: Type: Oper Op erat atiing met metho hod: d:

Bosch KB sp spli line ned d shaf shaftt

Starter motor pinion: Number of teeth: Z=9 Module: 3 Nominal power: Nominal voltage:

6.6 kW 24 V

95  

Torque guide values Note: All screw connections whose purpose is not stated in the following table are to be tightened in accordance with the guide values in our company standard M 3059 (see page  98). Fit  98). Fit the bolts slightly oiled! Screw plugs

DIN 908 M14x1.5, M16x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M18x1.5, M22x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M24x1.5, M26x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M30x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIN 7604 AM10x1, M12x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AM14x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

80 Nm 100 Nm 120 Nm 150 Nm 50 Nm 8 0 Nm

Crankcase, crankshaft drive

Engine foot to crankcase M14, 12.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear case to crankcase M10, 12.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stop disc to gear case M8, 12.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection port cover to gear case M8, 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft bearing cover to crankcase M18x2 Pretightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft main bearing caps (side), M 12 x 1,5 x 85, 12.9 (51.90020–0382) Pretightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vibration damper to crankshaft M16x1.5, 10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel to crankshaft M16x1.5 Pretightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle tightening / final tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Conrod bearing cover M14x1.5 Pretightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

225 Nm 75 Nm 40 Nm 10 Nm 300–330 Nm 90–100° 8 0 Nm 180° 260 Nm 100–110 Nm 90–100° 90–100° 100–110 Nm 90–100°

Cylinder head

Spark plug in cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm Tightening / retightening the cylinder–head bolts, see page 99. page 99. Rocker arm bearing pedestal to cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Nm Locknut on valve setting screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm

96  

Torque guide values Lubrication

Oil pump to crankcase M8, 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cover oil pump M8, 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil cooler to oil filter head M8, 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filter cup to oil filter head M12, 12.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil pan to crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil drain plug to oil pan M26x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil injection nozzle flange to crankcase M14x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 Nm 22 Nm 2 2 Nm 50 Nm 2 2 Nm 80 Nm 70 Nm

Exhaust / intake manifold

Exhaust manifold to cylinder head M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm Intake manifold to cylinder head M8, 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm Starter

Starter motor to gear case M12x1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm Impulse sensor

Impulse sensor “BERU” to timing case M 20x1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38–52 Nm Impulse sensor “active” to cover in timing case M12x1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Nm

97  

Torque guide values Installation tightening torques according to company standard M 3059 Bolts / nuts with external or internal hexagon, head without collar or flange Thread size x pitch M4

Property classes / tightening torques in Nm

for 8.8 / 8 2.5

for 10.9 / 10 4.0

for 12.9 / 12 4.5

M5

5.0

7.5

9.0

M6

9.0

13.0

15.0

M7

14.0

20.0

25.0

M8

22.0

30.0

35.0

M8x1

23.0

35.0

40.0

M10

45.0

65.0

75.0

M10x1.25

45.0

65.0

75.0

M10x1

50.0

70.0

85.0

M12

75.0

105.0

125.0

M12x1.5

75.0

110.0

130.0

M12x1.25

80.0

115.0

135.0

M14

115.0

170.0

200.0

M14x1.5

125.0

185.0

215.0

M16

180.0

260.0

310.0

M16x1.5

190.0

280.0

330.0

M18

260.0

370.0

430.0

M18x2

270.0

290.0

450.0

M18x1.5

290.0

410.0

480.0

M20

360.0

520.0

600.0

M20x2

380.0

540.0

630.0

M20x1.5

400.0

570.0

670.0

M22 M22x2

490.0 510.0

700.0 730.0

820.0 860.0

M22x1.5

540.0

770.0

900.0

M24

620.0

890.0

1040.0

M24x2

680.0

960.0

1130.0

M24x1.5

740.0

1030.0

1220.0

98  

Torque guide values Cylinder-head bolts General notes

The engine can be equipped with the following cylinder head bolts: D

Rotation angle cylinder–head bolts with hexagon head, WAF 19

D

Rotation angle cylinder head bolts with Torx head Torx WAF E18

Bolts to be fitted on repair:

Hexagon bolts can be replaced by Torx bolts if all the bolts of an engine are replaced. Mixed use of hexagon and Torx bolts is not permitted!

99  

Torque guide values Tightening the cylinder-head bolts on a new engine

(Engine cold or warm) The cylinder heads are fitted with cylinder–head bolts for rotation angle tightening. On new engines, the cylinder-head bolts are retightened at the factory after running in and marked by the sticker “First retightening of cylinder–head bolts ...” on a cylinder head cover.

After the first 400 hours of operation, tighten the cylinder–head bolts 1 to 4 in the order specified in the tightening schedule “1” by 90° (1/4 turn).

Erster Nachzug der Zylinderkopfschrauben erledigt First retightening of cylinderhead-bolts completed Spare part no. 51.97801–0211

Intake side / injection nozzle

The two outer bolts (intake and exhaust side) must not be retightened. Note: The cylinder–head bolts to be retightened must not be loosened; they are to be tightened further from their current position by 90°  (1/4 turn).

1

4

3

2

MAN Remove the sticker “First retightening of the cylinder–head bolts ...” and attach the sticker “Second retightening of the cylinder–head bolts ...” to verify the second retightening.

Exhaust side Tightening schedule “1”

Zweiter Nachzug der Zylinderkopfschrauben erledigt Second retightening of cylinderhead-bolts completed Spare part no. 51.97801–0212

100  

Torque guide values Tightening the cylinder-head bolts following a repair (engine cold)

Intake side / injection nozzle

Before inserting the cylinder-head bolts, apply engine oil to the thread (not the threaded hole) and coat the seating surface of the bolt head with installation paste “Optimoly White T”. Do not use oils or oil additives containing MoS2. The bolts are to be tightened using the rotation angle method according to tightening schedule “2” as follows. D D D D D

1st pretightening 2nd pretightening 3rd pretightening 4th pretightening Final tightening

= = = = =

6 1

4

3

2

to 10 Nm to 80 Nm to 150 N Nm m 90° 90°

Set the valve clearance.

MAN

5

Exhaust side Tightening schedule “2”

Retightening the cylinder-head bolts following a repair (Engine cold or warm)

After the first 10 to 20 hours of operation, following a repair, tighten the cylinder–head bolts in the order specified in the tightening schedule “2” by 90° (1/4 turn). The cylinder–head bolts to be retightened must not be loosened; they are to be tightened further from their current position by 90°  (1/4 turn). Attach the sticker “First retightening of cylinder–head bolts ...” (remove sticker that might already be attached). After the first 400 hours of operation, following a repair, tighten cylinder–head bolts 1 to 4 in the order specified in the tightening schedule “1” by another 90° (1/4 turn). The two outer bolts (intake and exhaust side) must not be retightened. Attach sticker “Second retightening of cylinder–head bolts ...”. Note: When the head has been removed, the cylinder head gasket must always be replaced.

101  

Torque guide values Reuse of used cylinder-head bolts Check  Before used cylinder-head bolts are reused, they must be checked as follows:

90+3 Length  With each tightening, the bolts are deliberately stressed beyond the stretch limit and each tightening thus extends their length permanently.

Surface  The bolts must have a perfect surface, i.e. closed phosphatisation and no rust stains. Rusted or damaged bolts or bolts stretched beyond the maximum length are to be made unusable immediately – e.g. by hammering the thread  – and to be scrapped.

L L = shaf shaftt len lengt gth h

Shaft lengths “L” in the case of new bolts

Largest permitted dimension

109 mm

111 mm

144 mm

146 mm

168 mm

170 mm

102  

Special tools

103  

Special tools

2 1

4

3

5 5.1 5.2 5.3

6

104  

Special tools

Fig. no.

De Designation

Item code

1

Valve gauge

80.99607–0076

2

Valve setting key

80.99603–6007

3 4

Stroboscope lamp Special spanner for spark plugs

0 684 100 500* 51.97710–0005

5

Special spanner for cylinder–head bolts

5.1

Special spanner for cylinder–head bolts

80.99603–0069

5.2

Special spanner for cylinder–head bolts

80.99603–0095

5.2

Special spanner for cylinder–head bolts (Torx)

80.99603–0255

5.3

Drive socket for cylinder–head bolts (Torx)

08.06143–0215

6

Compression tester

80.99605–0164

105  

Special tools

8

7

9

9.2

9.1

11

10

11.1

12 12.4 12.3 12.2

12.6 12.1

12.3

12.7

12.5 12.1

13

14

15.1 15

106  

Special tools

Fig. no.

De Designation

Item code

7

Stripping device for v–belt pulley of the water pump

80.99601–0037

8

Press–in mandrel for cassette sealing in conjunction with handle 11.1

80.99617–0091

9

Drift for sealing ring in the gear case consisting of:

9.1

Guide bush

80.99604–0068

9.2

Press plate in conjunction with handle 11.1

80.99604–0069

10

Extractor for front crankshaft bearing race

80.99601–0076

11

Drift for bearing race on flywheel in conjunction with handle 14.1

80.99617–0017

11.1

Detachable handle for all press–in plates

80.99617–0129

12

Special tool for front crankshaft gasket

80.99606–6011

Components: 12.1

Spindle

80.99606–0299

12.2

Extractor device

80.99606–0298

12.3

Adapter

80.99606–0264

12.4

Extractor hook

80.99606–6013

12.5

Press–in sleeve

80.99606–0300

12.6

Adapter

80.99606–0302

12.7

Application sleeve

80.99606–0301

13

Guide mandrels for flywheel

80.99617–0020

14

Straightedge

80.99605–0175

15

Engine barring gear

80.99626–0004

15.1

Standard ratchet for 18

80.99627–0001

107  

Special tools

17

16

16.1

16.2

17.1

20

19

18

17.2

21

22.1 22 23

22.2

24

24.1

24.2

108  

Special tools

Fig. no.

De Designation

Item code

16

Sleeves for valve–stem sealing

16.1

Guide sleeve for valve shaft sealing ring

80.99616–0004

16.2 17

Press–in sleeve for valve shaft sealing ring Pressing tool for valve guide

80.99604–0005

17.1

Press mandrel for valve guide

80.99617–0013

17.2

Press rings in conjunction with 20.1

80.99616–0003

18

Piston ring scuff band

80.99613–0035

19

Piston ring tensioning sleeve

80.99604–0134

20

Angle of rotation measuring device

80.99607–0134

21

Piston ring pliers

83.09144–6090

22

Cylinder liner extractor

80.99602–0019

22.1

Support for 25

80.99623–0003

22.2

Extractor plate

83.09143–0195

23

Cooling system tester

80.99607–0061

24

Thread cutter

24.1

Set of screw taps M15 x 2 for cylinder–head bolt thread

80.40001–0001

24.2

Die ring in addition

80.43001–0001

109  

Special tools

25

26

110  

Special tools

Fig. no.

De Designation

Item code

25

Valve fitting lever

80.99606–0031

26

Dial gauge bracket

90.99605–0172

111  

Special tools

1 3

4

27

5 2 6

28

29

Fig. no.

27

D De esignation

Item code

Measuring combination, consisting of: (1) Dial gauge

08.71000–1205

(2) Tracing pin for dial gauge

80.99605–0197

(3) Dial gauge bracket

80.99605–0179

(4) Seating pin

80.99605–0180

(5) Dial gauge bracket (6) Dial gauge bracket

80.99605–6006 80.99605–0172

28

Press–on measuring plate

80.99605–0195

29

Adjusting sleeves

51.91701–0247

Note: There is a complete catalogue of “MAN special tools”. This catalogue contains all of the special tools for maintenance and servicing MAN trucks, buses and engines available from MAN. Available from the central spare parts warehouse.

112  

Special tools

Press–in mandrel for fastening cover diameter 50.1 mm, diameter 62.1 mm

113  

Notes

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.............................................................................................................................................

114  

Index

B

E

Bearing race on flywheel side . . . . . . . . . . . . . . . 41

Electronic speed control . . . . . . . . . . . . . . . . . . . . 23 Engine illustrations . . . . . . . . . . . . . . . . . . . . . . . . 13

C

Engine lubrication . . . . . . . . . . . . . . . . . . . . . . 80, 92

Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Engine overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Measuring axial clearance . . . . . . . . . . . . . . . . 59

Engine ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Removing and installing . . . . . . . . . . . . . . . 58–59 Changing the oil filter . . . . . . . . . . . . . . . . . . . . . . 26

Engine specifications . . . . . . . . . . . . . . . . . . . . . . 80 Engine timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Checking conrod . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Engine type classification . . . . . . . . . . . . . . . . . . . . 4

Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Exh xhau aust st ma mani nifo fold ld,, Remo Removi ving ng and and in inst stal alli ling ng . . . . 44

Compression pressures . . . . . . . . . . . . . . . . . . . . 91 Conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

F

Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Fault table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–11

Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Coolant

Fires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Filling up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Removing and installing . . . . . . . . . . . . . . . . . . 38

Cooling system, Diagrams . . . . . . . . . . . . . . . . . . 16 G

Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Checking axial clearance . . . . . . . . . . . . . . . . . 64 Main bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Removing and installing . . . . . . . . . . . . . . . . . . 62

Gas leak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 I

Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Thrust bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Firing interval . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Crankshaft bearing race . . . . . . . . . . . . . . . . . . . . 35

Firing sequence . . . . . . . . . . . . . . . . . . . . . . . . . 94

Crankshaft bearings, Checking spread . . . . . . . 63 Crankshaft seal Assembly instructions . . . . . . . . . . . . . . . . . . . . 42

Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Ignition timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Flywheel end . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Front end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Impulse sensor for IC 500 ignition system . . . . . . . . . . . . . . . . . . . 77 optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Intake manifold Removing and installing . . . . . . . . . . . . . . . . . . 43

Removing and installing . . . . . . . . . . . . . . . . . . 45 Cylinder head bolts . . . . . . . . . . . . . . . . . . . . . . . . 89

O

Cylinder head covers . . . . . . . . . . . . . . . . . . . . . . 50

Oil cooler

Cylinder liners Checking protrusion . . . . . . . . . . . . . . . . . . . . . 72

Removing and installing . . . . . . . . . . . . . . . . . . 27 Oil injection nozzle

Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Removing and installing . . . . . . . . . . . . . . . . . . 32

Removing and installing . . . . . . . . . . . . . . . 72–74

Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Cylinder-head bolts, Thightening . . . . . . . . . . . 100

Axial clearance of the pump gears, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Removing and installing . . . . . . . . . . . . . . . . . . 28 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

115  

Index

P

T

Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87–89

Timing case Removing and installing . . . . . . . . . . . . . . . . . . 56

Piston recess, Measuring . . . . . . . . . . . . . . . . . . . 75 Piston rings

Torque guide values . . . . . . . . . . . . . . . . . . . 96–102

Checking axial clearance . . . . . . . . . . . . . . . . . 71 Checking ring gap . . . . . . . . . . . . . . . . . . . . . . . 70

V

Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87–89 Removing and installing . . . . . . . . . . . . . . . 70–71

Valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Pistons from/to conrod Removing and installing . . . . . . . . . . . . . . . . . . 68 Pistons with conrods Removing and installing . . . . . . . . . . . . . . . . . . 65

Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Valve projection, Measuring . . . . . . . . . . . . . . . . . 54 Valve recess . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Valve springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . 53

R

Valve stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Rocker arm mechanism . . . . . . . . . . . . . . . . . . . . 51

Valve tappet . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5891

Rocker arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

S

Valves

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . 5–7 Handling gaseous fuels . . . . . . . . . . . . . . . . . . . . 7

Removing and installing . . . . . . . . . . . . . . . . . . 52 Vibration damper

Handling used engine oil . . . . . . . . . . . . . . . . . . . 7

Removing and installing . . . . . . . . . . . . . . . . . . 34

Prevention of accidents with personal injury . . . . . . . . . . . . . . . . . . . . . . . 5 Prevention of engine damage and premature wear . . . . . . . . . . . . . . . . . . . . . . . 5 Prevention of environmental damage . . . . . . . . 7 Safety instructions for handling the ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . 79–103 Spark plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Spark plugs, Replacing . . . . . . . . . . . . . . . . . . . . . 21 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . 103–114 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Removing and installing . . . . . . . . . . . . . . . . . . 76 Starter gear ring . . . . . . . . . . . . . . . . . . . . . . . . . 39

116