VolvoTD70 Service Manual Engine

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Contents Group 20 General

Group 25 Intake and Exhaust Systems

Specifications . . . . . . . . . . . . . . . . . . . Wear tolerances . . . . . . . . . . . . . . Tightening torques . . . . . . . . . . . . Special tools . . . . . . . . . . . . . . . . . . . . General. . . . . . . . . . . . . . . . . . . . . . . . . Engine. removal and installation . .

Construction and Function . . . . . . . . . . . . . . . . . . . . 77 Service Procedures Starting heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Exhaust pressure governor . . . . . . . . . , . . . . . . . . 82

Group 2 1 Engine Assembly Construction 'and Function . . . . . . . Service Procedures Cylinder heads . . . . . . . . . . . . . . . . Cylinder block . . . . . . . . . . . . . . . . Cylinder liners. . . . . . . . . . . . . . . . . Valve mechanism . . . . . . . . . . . . . Timing gears . . . . . . . . . . . . . . . . . Crank mechanism . . . . . . . . . . . . .

Group 22 Lubricating System Construction and Function . . . . . . . . . . . . . . . . . . 52 Service Procedures Oil$pump. pipes . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Group 24 Fuel System Construction and Function . . . . . . . . . . . . . . . . . . . . 59 Service Procedures Injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Feed pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 . fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Air cleaner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Group 26 Cooling System

..

Construction and Function . . . . . . . . . . . . . . . . . . . . .85 Service Procedures Coolant. etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .:'89 Thermostats, coolant pump . . . . . . . . . . . . . . . .90 'Thermostat fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Group 29 Turbo-Compressor Construction and Function . . . . . . . . . . . . . . . . . . . .95 Service Procedures Checking the charging pressure. etc . . . . . . . 96 Overhauling the turbo-compressor ........ 97 Replacing turbo-compressor on engine . . . . . 102

Illustrations

1 FuelFsystem. 8 6 2 Fuel system. N7 3 Cooling system. F86 4 Cooling system. N7 5 Turbo-compressor. AiResearch 6 'TD70E engine

Reproduction permitted if source quoted

Main bearing shells

.

Diameter. bearing shell location in block Thickness. standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . undersize 0.0 1 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.030" . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.040 . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.050" . . . . . . . . . . . . . . . . . . . . . . . . . . .

Big-end bearings Connecting rod pins Big-end bearing. radial clearance . . . . . . . . . . . . . . . . . . . . . . . Bearing pin length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diameter. standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . undersize 0.0 10" . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . :. . . . . . . . . . . . . . . . . . .. 0.030" . . . : 0.040" . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.050" . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting rod shells Thickness. standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . undersize 0.0 10" . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020" . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.030 . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.040 . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.050 . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting rods Marked 1 to 6 "FR0hIT"-marking on stem faces forwards Provided with replaceable bearing shells Diameter. connecting rod bushing bearing seat . . . . . . . . bearing shell bearing seat . . . . . . . . . . . . . . . . . . gudgeon pin bushing. . . . . . . . . . . . . . . . . . . . . . . Axial clearance. connecting rod - crankshaft . . . . . . . . . . . .

a

49.89 1-49.930 m m (1.9642-1.9657") 73.740-73.753 mm (2.903 1-2.9037") See heading "Gudgeon pins" 0.15-0.35 m m (0.006-0.0 14")

Flywheel. fitted Max. permissible axial throw (measuring radius 150 m m = 6") . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ring gear on flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.15 mm (0.006") 140 teeth

Flywheel casing. fitted Max. permissible axial throw for contact surface against clutch casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Max. permjssible radial throw for steering diameter against clutch casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.15 m m (0.006") Max. 0.25 mm (0.010")

Camshaft Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Number of bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front bearing pin. diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2nd bearing pin. diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3rd bearing oin. diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4th bearing pin. diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

68.996-69.015 66.62 1-66.640 64.223-64.252 63.44G63.465

Gear 7 m m (2.7 164-2.7 17 1") m m (2.6229-2.6236") m m (2.5385-2.5296") mm (2.4979-2.4986")

6 1.058-6 1.077 mm (2.4039-2.4046") 5th bearing pin. diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60.27 1-60.290 mm (2.3729-2.3736") 6th bearing pin. diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56.29C56.3 15 m m (2.2164-2.2 17 1") 7th bearing pin. diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05-0.0 13 mm (0.002C-O.005 1") Axial clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.035-0.79 mm (0.00 14-0.003 1") Radial clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the camshaft setting (cold engine and valve clearance = 0) TD7OD TD7OE At flywheel position lo0 A.T.D.C., the inlet valve for No. 3.6 mm (0.14") 1 cyl. should have opened. . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 m m

Camshaft bearings Front bearing. diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2nd bearing. diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3rd bearing. diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4th bearing. diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5th bearing, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 t h bearing. diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7th bearing. diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

69.050-69.075 66.675-66.700 64.287-64.3 12 63.50C63.525 6 1.1 12-6 1.137 60.325-60.350 56.350-56.375

Timing gears Crankshaft gear. number of teeth . . . . . . . . . . . . . . . . . . . . . . lntermediate gear for oil pump. . . . . . . . . . . . . . . . . . . . . . . . . Drive gear for oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intermediate gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive gear for injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . Drive gear for compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive gear for servo pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . Backlash. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Journal for intermediate gear. diameter . . . . . . . . . . . . . . . . . Bushing for intermediate gear. diameter . . . . . . . . . . . . . . . . Radial clearance for intermediate gear . . . . . . . . . . . . . . . . . . Axial clearance for intermediate gear . . . . . . . . . . . . . . . . . . .

Valve system Valves Intake: DISC diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stem diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve seat angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat angle in cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . Clearance, cold engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust: Disc diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stem diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve seat angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat angle in cylinder head . . . . . . . . . . . . . . . . . . . . . . . . .I ... .. Clearance. cold engine. . . . . . . . . . . . . . . . . . . . . . . . . .

Valve seat

Valve seat location

mm mm mm mm mm mm mm

(2.7 185-2.7 195") (2.625C2.6260") (2.53 1C2.5320") (2.500C2.5010") (2.406&2.4070") (2.375C2.3760") (2.2185-2.2 195")

Valve seats Valve seat for intake valve: Diarnter (rneas. A). standard. . . . . . . . . . . . . . . . . . . . . . . . . . oversize . . . . . . . . . . : . . . . . . . . . . . . . . Height (rneas. B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve seat location. intake valve: Diameter (rneas. C). standard. . . . . . . . . . . . . . : . . . . . . . . . . overslze . . . . . . . . . . . . . . . . . . . . . . . . . Depth (meas. D). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat bottom radius (meas. I?) . . . . . . . . . . . . . . . . . . . . . . . . Valve seat for exhaust valve: Diameter (rneas. A). standard. . . . . . . . . . . . . . . . . . . . . . . . . oversize . . . . . . . . . . . . . . . . . . . . . . . . . Height (meas. 6 ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve set location. exhaust valve: Diameter. (rneas. C). standard . . . . . . . . . . . . . . . . . . . . . . . . oversize . . . . . . . . . . . . . . . . . . . . . . . . . Depth (rneas. D). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat bottom radius (meas. R) . . . . . . . . . . . . . . . . . . . . . . . . The measurement between the valve disc and the cylinder head face must be . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46.074-46.090 rnrn ( 1.8 140- 1.8 146") 46.274-46.290 rnrn (1.8218-1.8227") 6.1-6.2 rnrn (0.240-0.244") 46.000-46.025 rnrn ( 1.81 10-1.8 120") 46.200-46.225 rnrn ( 1.8 189- 1.8 199") 8.95-9.05 rnrn (0.352-0.356") 0.5-0.8 rnrn (0.020-0.031") 0.05-0.8 rnrn (0.002-0.030") 44.05G44.082 rnrn (1.7345-1.7355") 9.4-9.5 rnrn (0.370-0.374") 44.000-44.025 rnrn ( 1.732S1.7333") 44.20C-44.225 rnrn (1.7401-1.741 1") 9.8-9.9 rnrn (0.38G0.390) 0.5-0.8 rnrn (0.020-0.030") 10.55 rnrn (0.022") TD70D 0.45 rnrn (0.018")

Valve guides Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Height above cover spring face . . . . . . . . . . . . . . . . . . . . . . . . Clearance valve stem - guide: Intake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

66 rnrn (2.5984") 1 1.032-1 1.050 rnrn (0.4343-0.4350") 22 rnrn (0.866") 0.032-0.068 rnrn (0.00 13-0.0027") 0.064-0.100 rnrn (0.0025-0.0039")

Valve springs Outer valve spring Length. off.load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . With 270-330 hl (27-33 kp = 59-72 Ibf) load . . . . . . 480-600 N (48-60 kp = 105- 132 Ibf) load . . . . Coil by coil. rnax. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

64.1 rnrn (2.52") 48.6 rnrn (1.91") 36 rnrn (1.42") 31 rnrn (1.22")

Inner valve spring Length. off.load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . With 120-1 3 0 N (12-1 3 kp = 2 G 2 8 ibf) load . . . . . . 195-225 N (19.5-22.5 kp = 43-56 Ibf) load . . . Coil by coil. rnax. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60.1 rnrn (2.37") 44.6 rnrn (1.76") 32 rnrn (1.26") 27 rnrn (1.06")

Lubricating system Oil capacity. incl. lubricating oil filter (and oil cooler). . . . . Oil capacity. excl. lubricating oil filter . . . . . . . . . . . . . . . . . . . Oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil pressure. idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . viscosity. when starting difficulties can be anticipated or temperatures below -1 O°C (14OF) . . . . . . . . . . . . . . . . . . . . between -lO°C and +20°C (14 and 68OF) . . . . . . . . . . . above +20°C (68OF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricating oil pump. type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . number of teeth. . . . . . . . . . . . . . . . . .

15 litres (3.3 Irnp.gals. = 3 . 4 US gals.) 12 litres (2.6 Irnp.gals. = 3 . 1 US gals.) 300-500 kPa (3-5 kp/crn2 = 42-71 lbf/in2) Min. 50 kPa (0.5 kp/crn2 = 7 lbf/in2) Engine oil for service CD (DS) SAE 10 W or SAE 10 W / 2 0 SAE 20/20 W or SAE 20 W / 3 0 SAE 3 0 or SAE 20 W / 3 0 Gear 11

axial clearance. pump gear . . . . . . . . backlash . . . . . . . . . . . . . . . . . . . . . . . . . diam., interm. gear bearing sleeve diam.. bushing for interm. gear . . . radial clearance . . . . . . . . . . . . . . . . . . . Relief valve springs: Length. off-load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . loaded with 5.5-5.9 kp (12-13 Ibf) . . . . . . . . . loaded with 4.1-4.5 kp (9-10 Ibf) . . . . . . . . . . .

Fuel system Clockwise 1-5-3-6-2-4 Electrical

lnjection pump's direction of rotation seen from the front lnjection sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel injection pump TD70D Make. designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : . . . . . . . . Pump element. daim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injection quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Feed pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Feed pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bosch PE 6 P 100 A 3 2 0 RS 269 18-1 9' B.T.D.C. 10 mm (0.39") Bosch RQV 250-1200 PA 231 /2R See "Diesel Test Standards" Bosch FP/K 2 2 P 9 60-98 kPa (0.6-1.0 kp/cm2 = 8.5-14 lbf/in2)

TD70E

:

Make. designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump element. diam. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injection quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Feed pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Feed pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bosch PE 6 P 110 A 3 2 0 RS 272 20-2 1 B.T.D.C. 11 m m (0.43") Bosch RQV 250-12000 PA 235/2R See "Diesel Test Standards" Bosch FP/K22 P9 98-147 kPa (1.0-1.5 kp/cm2 = 14-21 lbf/in2)

. By-pass valve

TD70D

TD70E

Type designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bosch PVE 5 3 s

Bosch PVE 53S52

Fuel filter Type designation

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

Bosch FJ/ DB/ W 6x2/ 102

Injectors TD70D Nozzle holder. make and type . . . . . . . . . . . . . . . . . . . . . . . . . . Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injector. opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . adjusting pressure (new spring). . . . . . . . . . . . . . . . . . Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Nozzle holder. make and type

Bosch KBAL 100s 2 4 / 4 Bosch DLLA 150 S 633 17.5 MPa (175 kp/cm2 = 2488 lbf/in2) 18.0-18.8 MPa (180-1 8 8 kp/cm2 = 2560-2673 lbf/in2 0.325 mm (0.013") 818

. . . . . . . . . . . . . . . . . . . . . . . . . . Bosch KBAL 100s 2 4 / 4

Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bosch DLLA 150 S 138 Injector opening pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 MPa (200 kp/cm2 = 2844 lbf/in2) MPa (205-21 3 kp/cm2 adjusting pressure (new spring). . . . . . . . . . . . . . . . . . 20.5-21.3 29 15-3029 lbf/in2) Bore.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.355 mm (0.014") Marking.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 814

.

Cooling system Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator cap valve opens at.. . . . . . . . . . . . . . . . . . . . . . . . . . . Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermostats: Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Marked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starts opening at.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fully open at.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overpressure with expansion tank 0.23-0.32 kp/cm2 (3-4.5 lbf /in2) 30 litres (6.6 Imp.gals. = 8.0 US gals.) 2 Wax 76 74-78OC (165-1 72OF) 84-88OC (182-1 90°F)

Drive belts . Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HC 38 x 1050 Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coolant pump (F86) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan (N7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 HC 50 x 1100 2 HC 50 x 1200 2

Wear tolerances Cylinder head Height

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

a

Min. 108.65 mm (4.2776")

Cylinders Cylinder liners and pistons with piston rings should be changed with wear of 0.35-0.40 mm (0.014-0.01 6")

Crankshaft Max. permissible out-of-roundness on main and connectingrod journals.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.075 mm (0.0030") Max. permissible taper on main and connecting-rod journals 0.05 mm (0.0020") Max. axial clearance on crankshaft.. . . . . . . . . . . . . . . . . . . . . 0.40 mm (0.160")

Valves Valve stem, max. permissible wear. . . . . . . . . . . . . . . . . . . . . . Max. permissible clearance between valve stem and valve guide: Intake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve disc edge should be min. . . . . . . . . . . . . . . . . . . . . . . . . Valve seat may be ground down so far that the distance from the valve disc (new valve) to cylinder head face is max. .

0.02 mm (0.0008")

0.15 mm (0.0059") 0.17 mm (0.0067") 2.0 mm (0.079") 2.0 mm (0.079")

Camshaft Max. permissible out-of-roundness (with new bearings). .. Bearings, max. permissible wear.. . . . . . . . . . . . . . . . . . . . . . .

0.05 mm (0.0020") 0.05 mm (0.0020")

=

Tightening torques Cylinder head. long bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . short bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting-rod bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injection pump: Pressure valve holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive shaft. pump cam flange . . . . . . . . . . . . . . . . . . . . . . . Injectors: Retaining nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vibration damper. retaining screws . . . . . . . . . . . . . . . . . . . . . Centre bolt for hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shaft journal for intermediate gear . . . . . . . . . . . . . . . . . . . . .

Lbfft

Special tools

110286

Fig. 2.Special tools

999 (SVO) No. 1084 1531 1801 1819 2002 2013 207 1 2124 2139 2178 2182

2265 2266 Drift for removing valve guides Extractor excl. puller plate, for extracting cylinder liners Standard handle 18x200 mm Extractor for flywheel ball bearings Puller for pulley Drift for installing flywheel ball bearings Drift for removing/installing ,gudgeon pins Expander plugs (4)for cylinder head pressure teg~ng . - .. Ring for installing pistons .._ .,. _, .Puller plate used with 1531 -.-. . Extractor for injector copper sleeve

~-

2267

2268 2269 2270 2429

Puller for camshaft gear Counterhold for disassembling/assen~blingcoolant Pump Socket for removing/installing ball bearings on pulley, coolant pump and bearings in injection pump drive Drift for removing/installing ball bearings, shaft and sealing in coolant pump Fixture for installing pulley with bearings Drift.for.installing coolant pump seal Press washer for removing coolant pump ball bear.. . ,Ings. id indicator holder used when checking liner collar . . . , ..".: . .' >height above cylinder block face '

- '

2479':

,

Drift for removing/installing connecting rod bushings Extractor for oil pump gear and flange on injection Pump Extractor for crankshaft polygon hub Tool for installing crankshaft polygon hub Puller for crankshaft gear Press tool installing crankshaft gear Drift for installing valve guide Washer for pressure testing cylinder head Connection washer for pressure testing cylinder head 'ress. tool for pressing down cylinder liner when measuring liner height above cylinder block face Drift for removing/installing rocker arm bushings

Puller for camshaft gear and injection pump gear Device for testing leakage in cooling system Expander plugs (5)for cylinder head pressure testing Extractor for injectors Spanner for removing fuel filter Tool for 2682 when removing injectors Remaining tool for injector copper sleeve Device for pressure testing oil cooler Face milling tool for cleaning copper sleeve seat Pressure gauge with hose for connection to banjo nipple 6066 Banjo nipple with rapid coupling for checking fuel feed pressure Drift for removing/installing bushings on exhaust pressure governor

Fig. 3. Milling and grooving tools

9505 9508 9514

6049

Tool for marking grooves in cylinder head (cutter 9517) Milling tool, complete, for milling cylinder liner seats (miller 95 18) Expander for turning cylinder liner when lapping cylinder liners seats

Rapid coupling with hose for draining coolant (N7)

Concerning hoist equipment for engine, see page 17.

General

engine (F86)

engine (F86)

Fig. 6. TD7OE engine (F86)

Fig. 7. TD70E engine (N7)

The TD70D and the TD70E engines are a further development of the earlier TD70B engine. The TD70D is fitted only on F86 trucks and is primarily intended for trucks used in densely populated areas where there are great demands on low noise level and clean exhaust gases. Characteristic of the TD70D engine is the low, specific fuel consumption and high low-speed torque.

A number of constructional improvements have been introduced with the TD70D and TD70E. The following pages shows those components which differentiate the TD70D and TD70E from the TD70B.

The thickness of the material in the upper part of the liner has been reduced by approx. 1 m m (0.04")in order t o achieve better cooling and lower piston-ring temperature.

New material in the valve seats for the exhaust valves increase their lifespan. Double valve springs and new valve guides. The outer diameter of the guides have been adapted to suit the new, double valve springs. New valve spring retaining locks, valves and valve spring washers. The change here consists of altered lock lugs inside the valve spring retaining locks as well as corresponding modification to the valve stem. The cone angle between the valve spring retaining locks and the valve spring washers has been reduced.

This engine is fitted with the D70B-engine camshaft, which gives it improved low-speed performance.

TD7OE This engine has been given an entirely new camshaft with large valve overlap, which makes for better function. Performance has thereby also been improved throughout the entire speed range.

TD7OD

A new belt pulley where the position for the belts has been moved forwards 18 mm (0.72").

TD7OE

A new vibration damper with greater moment of inertia. The number of retaining bolts has been increased from four to eight so that a new hub has had to be fitted. The vibration damper is approx. 20 mm (0.8") wider and for this reason a new pulley has also been introduced.

New piston with compression ratio 16:1 and four piston rings. The second compression ring is filled with ferrox.

TD7OE New piston with lower compression ratio (14.5:l) and four piston rings. The second and third compression rings are ferrox-filled.

TD70E Because a wing-type servo pump is fitted, its position has been moved from the timing gear casing to the timing gear cover.

Since the vibration damper requires more space, the position for the drive belts has been moved forwards. A new pulley on the coolant pump as well as a new tensioning pulley have had to be installed as a result.

TD7OE (F86) Oil cooler, the function of which is to lower the oil temperature, particularly when the engine is under heavy load. Introduced after start of production.

15

TD7OE An electrically operated starting heater with an output of approx. 2.7 kW has been introduced as a separate unit in the engine intake pipe to assist in starting at temperatures down to -20°C (-4OF).

An exhaust pressure governor connected to the exhaust system immediately after the exhaust turbine. It has two functions: 1. To increase the exhaust back-pressure at idling and to assist in warming up the engine so that the combustion rises. The higher combustion temperature gives a more effective combustion and reduces the volume of white smoke and smelly exhaust gases. 2. To replace the earlier exhaust brake.

TD7OD A new Bosch in-line pump without smoke eliminator. Dwell angle 18-1 9O B.T.D.C. New injector with smaller bag to reduce unburnt hydrocarbons.

TD7OE New injection equipment. The injection pump has through-flow, which means that it is cooled by fuel flowing back to the tank. The relief valve has therefore been moved from the fuel filter to the injection pump. The pump element diameter is 11 mm (0.04"). 'The opening pressure for the injectors has been raised to 200 kp/cm2 (2844 lbf/in2).

TD70D hlew Holset-turbo with smaller turbine housing supplies more air at low speeds.

TD70E New turbine compressor of make AiResearch. 120 28:l

TD70E - engine versions The TD70E engine for the F86 differs from the TD7OE for the N7 among other things by a different location for the turbo-compressor, different pipe routing for the fuel system and location for the cooling fan. As far as the N7FFA (front axle moved forwards) is concerned, the oil sump and oil piping to the oil pump differs from that on the N7NFA (normal front-axle location).

Because of the special legislation in Switzerland concerning output - overall weight ratio (minimum 8 h.p. engine output/tons total weight), another version of the TD70E engine has been constructed and has been given the designation TD7OES. The injection pump for the TD70ES-engine has a "2" after the ordinary pump designation, which means that the injection volume has been altered. Otherwise the TD7OES does not differ from the TD7OE.

Service Procedures Removing and installing the engine Hoist tools:

Fig. 10. Hoist tools

Hoist tool 2760, complete, includes the following: 999

(SVO) No. 2516" 2754"2755"2756"2757

+

-

Extension piece for cab support Hoist beam for lifting engine Block and tackle with hook Lifting wire Lifting wire with holed beam

Used for F86 Used for N7

2758* 2759 2762 2770 2771 2772

Lifting Lifting Lifting Lifting Lifting Lifting

wire lug (N84, N88) eyelet (N84) lug (N86) lug (N88) lug (N88)

108 3'5

505s Dollies (two) for removing and installing engine (N7)

108 376

6052

2994

Crossbeam with lifting slings for engine (N7)

Wrench for torquing propeller shaft flanges (see illustrations for F86, N7 part 4)

Removing the engine (F86) 1. Take off the battery case cover and disconnect the (+) battery cable from the battery. Remove the bracket round the steering column.

2. Tilt up the cab and place extension sleeve 25 16 on the cab stop (Fig. 11).

3. Drain the coolant and the engine oil. 4. Disconnect the propeller shaft at the gearbox and the attachment for the intermediate bearing fixed to the frame crossmember. Disconnect the speedometer cable at the angle gear and remove the gear-control rod from the gearbox and the wire for the high-gear and low-gear control. Disconnect the hose for the exhaust pressure governor solenoid and the hose from the exhaust pressure governor. Disconnect the inhibitor valve hose from the T-branch in the arm. Separate the compressed-air line at the right-hand side of the clutch casing. 5. Remove the nuts for the silencer suspension from k disconnect the control cylinthe rubber b l o ~ and der for the clutch from the gearbox arid the thrust rod from the clutch lever.

6. Unscrew the six lower nuts round the clutch casing. Slacken and turn down the clamp for the exhaust pipe.

7. Place a jack under the gearbox.

8. Unscrew the six upper nuts round the clutch casing and pull the gearbox backwards. Remove the heat-guard plate at the left-hand side of the engine.

9. Disconnect the discharge hose for the exhaust pressure governor at the connection to the, solenoid. Unscrew the retaining bolts for the cab crossmember on the left-hand side. 10. Remove the clamp for the speedometer wire and the high-low gear control at the cab crossmember. Separate the return fuel line at the flywheel casing. 1 1. Disconnect the throttle control at the throttle arm, the stop control and the bracket for the cold-start chain. 12. Remove the side plate at the lever carrier and the cover plate at the gear lever. Remove the controls from the gear control housing. 13. Remove the split-pin bolts for the lever carrier and move to the side the gear lever and cover plate. 14. Remove the leading silencer and the exhaust pipe from the exhaust pressure governor shutter housing. Remove the exhaust pipe mounting from the engine.

15. Disconnect the fuel line at the feed pump. Disconnect the electric cables from the temperature gauge and speedormeter gauge senders, also from the alternator.

16. Disconnect the hose for the power steering at the frame. Disconnect the upper and lower radator hoses and the hose to the expansion tank. Disconnect the water hose for the heating system at the thermostat housing and the hose at the air compressor.

Fig. 11. Removing the engine, F 86

17. Disconnect the intake hose from the turbo and the hose between the air intake and air cleaner. Disconnect the hose to the compressor and the hose to the pressure-drop indicator. Remove the air cleaner.

18. Disconnect the compressed-air line to the exhaust pressure governor solenoid and undo the retaining bolts for the cab crossmember at the right-hand side.

115009

starter motor and the oil pressure sender, also the electric cable t o the solenoid for the starting heater.

20. Remove the fan hub from the vibration damper. Place the lifting tools according to the Fig. Hoist slightly and remove the bolts from the engine mounts. Lift out the engine. Concerning adjusting clutch clearance, see F 86 and N7 respectively, Part 4.

19. Remove the clamp for the battery at the flywheel casing. Disconnect the electric cables from the

Installing the engine (F86) 1. Lift the engine into the engine compartment and lower it down onto the front engine mounts. Tighter: up the bolts. Fit the rear brackets and the rubber mounting pads. Remove the hoist unit.

2. Push in the gearbox against the flywheel casing. Fit the bolts round the clutch casing and connect up the propeller shaft and the speedometer cable.

3. Fit the control cylinder for the clutch and the thrust rod to the clutch lever. Check and if necessary adjust clutch clearance.

4. Fit the hose for the T-branch inhibitor valve to the frame. Assemble the compressed-air line. 5. Connect the hoses to the exhaust pressure governor and its solenoid.

6. Fit the leading exhaust pipe and silencer. 7. Connect the electric cables to the alternator, speedometer and temperature gauge senders, also the fuel line to the injection pump.

8. Fit the lever carrier and the nuts on the brackets for the silencer and exhaust pipe. Tighten up the member under the gearbox. Connect the wire for the high-gear and low-gear controls to the gearbox.

9. Connect up the fuel line over the flywheel casing.

Fig. 13. Air-compressor connections

Fit the gear-control rod. 10. Connect the stop control and throttle control to the injection pump. Fit the cover plate at the lever carrier. 11. Position the cab member and fit the retaining bolts on the left-hand side. Fit the cold-start chain. 12. Fit the coolant hoses. Tension the drive belts. Fit the splash plate. Fit the hoses for the power steering.

Fig. 14. Hose routing over gearbox

16. Connect the compressed-air pipe to the solenoid and fix the battery cable to the flywheel casing. 17. Connect the electric cables to the starter motor and oil pressure sender. Connect the oil-pressure hose. 18. Fit the air cleaner. Connect up the hoses.

19. Fill the engine and power steering with oil. Fig. 12. Positioning the coolant hoses and hoses for the servo pump

13. Cmnect the compressed-air hoses t o the com-

20. Fill the cooling system with coolant according to the recommendations. 21. Start the engine and check the controls and instruments.

pressor. 14. Remove extension 25 16 from the cab stop. 15. Fit the retaining bolts for the cab member (r-h side).

Removing the bonnet and casing The bonnet is locket in position by means of two levers, one on each side of the cab. Lever position: forwards - bonnet locked; rearwards - bonnet open. 1. Tilt up the bonnet.

Fig. 15. Engine bonnet lever

2. Remove the calbe harness connections from the electrical distribution centre and the three adjacent couplings and the electric cable to the pressure-drop indicator. Release the cable harnessfrom the cowl wall. Remove the earth leads at the radiator attachments.

Fig. 17. Bonnet retaining bolts

Note: The bonnet can suitably be supported at the front according to Fig. 18 when working on the engine which concerns the bracket for the attachment for the stop wires and which does not require bonnet removal.

3. Off-load the stop wires and disassemble the damper springs.

Fig. 18. Bonnet support

Removing the engine, N7 1. Remove the bonnet according to the instructions Fig. 16. Disassemblingthe damper spring

and lift off the engine casing.

2. Drain the coolant (use drain hose 6049) and the engine oil. 4. Close the bonnet and then remove the retaining .bolts at the front end of the bonnet, two on each side.

3. Remove the cover over the battery case and the

5. Lift off the bonnet and place it where it can be

4. Disconnect the positive cable from the battery or from the battery separator. Disconnect the cable from the battery case.

protected. 6. Release the four locks on the engine casing and lift off the casing.

clamp for the starter motor cable at the battery case.

5. Remove the bumper and radiator.

jection pump and the pipe from the frame member. 15. Remove the throttle controls from the injection Pump-

16. Remove the stop control lever from the pump.

17. Remove the I-h bumper retaining bracket. 18. Fetch and place a vessel for collecting the powersteering oil. Drain the oil from the power steering by disconnecting the power-steering hoses from the pipes on the engine. 19. Remove the rear gearbox suspension. 20. Remove the speedometer wire (spanner 27 mm). Fig. 19. Draining the coolant

2 1. Disconnect the propeller shaft from the gearbox. Place a support under the propeller shaft. 22. Disconnect the hose from the inhibitor valve and the power take-off control cylinder. 23. Remove the control wire from the high-gear and low-gear control cylinder and the wire clamp on the gearbox cover.

24. Remove the retaining bolts for the exhaust pipe joint at the silencer. 25. Remove the retaining bolts for the gear control on the gearbox cover.

26. Remove the clutch hydraulic hose from the pipe on the power cylinder. 27. Remove the retaining bolts for the rubber seal round the gear lever. Remove the metal ring, lift up the gear control and place the control so that it remains in position. Fig. 20. Removing the radiator

6. Remove the air cleaner 7. Remove the coolant hoses between the engine and expansion tank. 8. Release the engine cable harness from the connections on the cowl. Attach the cable harness to the engine.

9. Remove the hose from the pressure governor. Separate the two fuel hoses and the compressor feed hose at the right-hand engine mounting. 10. Remove the retaining bolts for the two front retaining brackets on the suspension rail for the brake hoses. 11. Remove the r-h bumper retaining bracket from the frame. 12. Disconnect the electric cables from the horn and the hoses from the rapid - release valve. 13. Disconnect the hose from the exhaust pressure governor. 14. Remove the cold-start cord bracket from the in-

Fig. 21. Removing the gear control

28. Remove the starter motor earth cable from the starter motor.

29. Remove the bracket for the stop cable and hand throttle. Move the wires to the one side. 30. Clean the top of the frame members in front of the engine mounts.

31. Remove the retaining bolts for the attachment of the engine mounts to the frame. 32. Place a jack under the gearbox with a wooden block on the lifting head. Lift the rear end of the engine and fit creepers 6050, one under each rear engine mount. Lower the jack and chek that the creepers centre on the frame. 33. Remove the centre nut for the front engine mounting block (Spanner 2 4 mm.)

Fig. 23. Removing and installing front member

35. Remove the front crossmember.

Fig. 22 Placing dolly 6050 under I-h engine mount

34. Fit lifting sling 2756 to the engine front lifting eyelet. Lift the front end of the engine with hoist unit.

36. Pull forwards the engine so far that the rear lifting eyelets are free from the cab. Check that the dollies run in the centre of the frame. Place two trestles under the front engine mount. Lower the front end of the engine. 37. Place lifting beam 2754 in the hoist unit together with lifting sling 2756 at the front end and 2755 and 6052 at the rear end. Hoist the engine together with the gearbox.

Fig. 24. Removing and installning the engine (N 7 )

Installing the engine (N 7)

18. Assemble the rear exhaust pipe and silencer.

Before installing the engine, fit the clutch and the gearbox onto the engine. Then hoist engine, clutch and gearbox into position as follows:

19. Fit the propeller shaft. Use wrench 2994. Tightening torques 55 Nm (5.5 kpm = 4 0 Ibfft). 20. Connect the speedometer wire. Lead-seal it according to instructions.

1. Fit dollies 6050, one at each rear engine mount. Fit the hoist unit.

2 1. Fit the crossmember under the gearbox.

2. Coat the shift control contact surface with adhesion (see Fig. 2 1).

22. Connect the hose to the exhaust pressure governor. Fit the stop control lever on the pump.

3. Lift the engine off the trestles. Push the engine as far as possible into the vehicle. Lower it and check that the dollies centre on the frame members. Place two trestles under the front engine mount. Lower the engine.

23. Connect the throttle control push rod to the control on the cab.

4. Remove the lifting beam and lifting slings.

5. Lift the front end of the engine from the front life eyelet. Remove the trestles and push the engine into position. 6. Fit the front crossmember. Lower the engine and position it on the front engine mount rubber block on the crossmember. Note: check-tighten the bolts for the front engine mount. Tightening torque 118-147 Nm (12-15 kpm) = 88-1 10 Ibfft).

24. Fit the retaining bracket for the I-h shock absorber. 25. Fit the cold-start cord together with pipe and clamp. 26. Connect the power steering hydraulic hoses to the pipes on the engine. 27. Connect the hoses to the rapid-release valve and the electric cables to the horn.

7. Raise the rear end of the engine with a jack placed under the gearbox. Remove the dollies from the rear engine mounts. 8. Slightly lower the jack. Fit the retaining bolts and the nuts for the rear mounts. Lower the engine rear end fully. Do not forget to attach the bracket for the air-compressor feed hose on the front retaining bolt for the r-h engine mount. 9. Tighten the retaining bolts for the rear engine mounts and the retaining nut for the front engine mount. Note: The late prod. type bolt for the rear engine mount hassize M 10, previouslyit was M8. Where the bolting is exposed to excessive load when driving, the M 8 bolts (where fitted) should be replaced with MlOs. The bolt holes must then be widened from 9 mm to 10 mm 0.

Fig. 25. Routing pipes and hoses, I-h side

10. Fit the stop wire and the hand throttle wire to the bracket on the engine. 11. Connect up the starter motor earth cable. 12. Place the gear control in position and fit the two front retaining bolts. 13. Fit the gear lever rubber seal and metal ring. 14. Fit the rear retaining bolts for the gear control. 15. Connect the clutch hydraulic hose to the pipe on the servo cylinder. 16. Fit the control wire for the gearbox control cylinder. Fit the clamp on the gearbox cover. 17. Connect the hose to the inhibitor valve and the power take-off control cylinder.

Fig. 26. Routing pipes and hoses, r-h side

28. Fit the compressor feed line and the hose to the governor. 29. Fit the suction and return fuel lines. 30. Fit the r-h shock absorber retaining bracket. Do not forget the retaining bracket for the electric cables on the front, upper retaining bolt.

Installing the bonnet (N 7 ) 1. Place the bonnet in position folded down. Fit the retaining bolts to the front end. 2. Tilt the bonnet up halfway and fit the stop wires. Tilt up the bonnet fully. 3. Connect the earth cables to the rear retaining bolt on the radiator mounting.

31. Fit the t w o front retaining brackets for the suspension rail for the brake hoses. Check that the plastic clamps are positioned correctly.

4. Connect the rapid coupling for the headlights, etc.

32. Connect all cables between engine and cowl and electric cables. Fit the clamps, plastic clamps and connect up the rapid couplings.

6. Check the function of the lighting, direction indicators and position lights.

33. Fit the coolant hoses between the engine and expansion tank. 34. Install the radiator and bumper. 35. Install the bonnet and air cleaner according to instructions. 36. Fit the battery cable and the cover on the battery case. 37. Bleed the fuel system and fill the engine with oil. 38. Fill the cooling system with coolant and the power steering with oil. Bleed the power steering and clutch system. 39. Check function and for leakage. Install the engine casing.

Install the engine casing (N 7 ) Check the sealing strip for the engine casing. Replace if damaged. An engine casing with poor sealing means that there will be greater engine noise inside the cab and the risk of dust getting into the cab. Secure well the clasps so that the sealing strip is pressed down against the floor.

5. Close the bonnet.

Group 2 1 Engine Assembly Construction and Function

Cylinder heads 'The engine has two cylinder heads, each of which Cover three cylinders. The cylinder heads are bolted to the cylinder block by means of thirteen 9 / 16" bolts per head. The cylinder head face has special sealing grooves, which determine the size of the sealing surface so that the necessary sealing pressures are obtained without having to have excessive tightening torque which could deform the liner shelf on the cylinder block.

The cylinder heads are made of special-alloy, cast iron. The cylinder head gasket is of solid steel plating.

Cylinder block The cylinder block is cast in one piece of special-alloy, cast iron. The pulling stresses in the cylinder head bolts from the combustion pressure is transmitted via reinforced sections of the cylinder block walls directly to the main bearings.

The camshaft bearings are first fitted before being drilled t o the correct dimension.

Pistons The pistons are made of light-alloy. The upper compression ring, which transfer most of the heat being transmitted through the piston rings, lies in a ring carrier of high-alloy, special-cast iron, which is cast in the piston. This gives the piston ring groove a long lifespan, in spite of the heat stresses. The piston ring groove for the second and third compression rings and the one for the oil scraper ring are machined directly in the piston. The engine combustion chambers are situated entirely in the piston crown.

Piston rings Each piston has four piston rings. The top compression ring is chromed. The glide surface against the cylinder wall has an extra, thick layer of chrome and is slightly rounded. The second and third compression rings are slightly tapered and the slide surfaces (applies to TD70E, only second compression ring on TD70D) have ferrox-filled grooves. Because the rings are tapered, the text TOP is marked on the top to ensure that this side faces upwards.

'9 $

3 N

-TD 70 D

, Fig. 27. Pistons

D classification letter Meas. in mm

The oil scraper ring is provided with two, chromed scraper pegs, which are pressed against the cylinder wall, partly through the ring's own spring force and partly through the expander spring which is placed on the inside of the ring. Thanksto the expander spring the ring aligns itself to the cylinder wall in a more effective way and thus limits oil consumption.

Cyli~iderliners The cylinder liners are of the wet, replaceable type, centrifugally cast and made of cast iron. Three rubber O-rings are sued for the cylinder liner outer sealing. The lower rings are placed in milled grooves in the cylinder block. 120 294

The ring which is placed furthest down is of silicon rubber and can be recognized by its red colour. Sealing against the upper end of the cylinder liners is by means of an O-ring placed under the liner flange and by the cylinder head gasket pressing down the flange on the liner against the shoulder on the cylinder block.

Fig. 28. Piston rings (TD7OE)

Fig. 29. Cylinder liner w i t h seals

Valve System Valves and valve seats The valves are made of chrome nickel steel. The valve stems are chromed. The exhaust valves have stellitelined sealing surfaces in order t o cope with the heat.

The valve seats are made of special steel and are replaceable. Standard size seats and oversize seats are available as spares. The oversize seat has a 0.2 m m (0.08")greater outer diameter and is used when new valve seat position have t o be milled because of the cylinder head.

Fig. 30. Cylinder head and valve arrangement 1 Lock nut Adjusting screw Wear hat Valve spring retaining lock Rubber seal Spring dish Valve spring, outer Valve spring, inner Valve

2 3 4 5 6 7 8 9

Camshaft The camshaft is journalled in seven bearings. Axial clearance is determined by the camshaft gear, the sho-

ulder on the camshaft front journal and on the thrust washer bolted to the front of the cylinder block.

Fig. 31. Camshaft and valve mechanism

Timing Gears The timing gear assembly consists of helical spur gears. The fuel injection pump and camshaft are driven from the crankshaft via an intermediate gear. In addition to the camshaft, the camshaft gear also drives the drive gear for the air compressor and for the power-

assisted pump. The engine lubricating oil pump is also driven from the crankshaft gear. The advantage of having a gear drive for components connected to the engine is, of course, that it gives us greater reliability.

Air compressor drive

Camshaft gear assembly (includes also intermediate gear for

Steering servo pump operating gear

1mm7

Fig. 32. Timing gears

Crank Mechanism Crankshaft The crankshaft is journalled in seven main bearings. Axial journalling consists of thrust washers placed at the fourth main bearing. The crankshaft is statically and dynamically balanced. The working impulses of the engine are balanced by eight counterweights so

that torque is divided equally. crankshaft front end has a polygon profile and the rear end a flange to which the flywheel is bolted. -rhe crankshaft can be ground to all the undersizes without re-hardening.

Flywheel adapted to automatic transmission

C

Fig. 33. Crank mechanism

Main bearings and connectingrod bearings The main bearings and connecting-rod bearings consist of indium-plated, lead-bronze lined steel shells. The bearings are precision-made and are entirely ready for fitting. Five undersizes can be obtained as spare parts. Thrust washers for the axial journalling of the crankshaft are available in three oversizes.

Connecting rods The connecting rods have an I-section. Each connecting rod is drilled throughout for pressure-lubrication of the gudgeon pin. Because the connecting rods have dividing bearing seats which are oblique, the connecting rods can be drawn up through the cylinder liners when removing. The gudgeon pin bushings are of steel and overlapped with a light layer of tin.

Flywheel The flywheel is bolted to a flange on the rear end of the crankshaft. It is statically balanced and fully machined. The ring gear is shrunk onto the flywheel.

Vibration damper The vibration damper consists of a hermetically sealed housing in which a freely moving damping ring with a rectangular section is fitted. The centre of the damping ring rests on a bushing and all the other sides are surrounded by a viscous fluid (silicon).

Fig. 34. Vibration damper

1 2 3 4 5 6

Crankshaft Flat washer Hub Crankshaft oullev . . Alternator pulley Vibration mass

7 Cover 8 Bushing 9 Fluid chamber 10 Felt seal 1 I Oil deflector

Service Procedures Cylinder Heads Removing the cylinder heads 1.

Drain the coolant.

2.

Removethe rocker arm covers. Removethe water connection pipe between the heads.

3.

Disconnect the delivery pipes and the leak-off fuel pipe from the injectors. Fit protective caps over the injectors. Remove the injectors. If they are difficult to remove, use tool 2683 with 299 1 (Fig. 35).

4.

Remove the intake and exhaust manifolds.

5. Release the retaining bolts for the rocker arm bearing brackeg. Remove the rocker arm mechanism and thkib?g?sh rods. 6.

Unscrew the cylinder head bolts and remove the .-. cylinder heads.

7.

Removethe cylinder head gasket, the rubber seals and their guides from the .block.

n

Fig. 35. Removing an injector

Disassembling - the cylinder heads

The cylinder head is provided with sealing grooves immediately above the cylinder liner collar. If more than 0.1 mm (0.04) material is removed from the head yben grinding, new sealing grooves must also be mil12d. :t

Remove the valves and valve springs. Use a valve spring tensioner for compressing the springs to remove the valve spring retaining lock. Place the valves in order on a valve rack.

1.

2.

-: '"4,

Make sure that the stud bolts are securely fitted.

Clean all the parts. Pay particular attention to oil and coolant channels. Check for leakage by pressure-testing.

.*

Always change the cylinder head gaskets and rubber seals.

3

t

,,,Face-grindingthe cylinder heads

~geksure-testingthe cylinder heads

- When face-grinding thecyli;l&i heads, check the sur-

Connect a water hose to the cylinder head according to Fig. 36. Use connection 2664, sealing washer 2663, expander bolts 2 124 (3) and 2682 (5).The rubber gasket will be damaged if the wing nut is tightened too hard.

1.

+ :+,

N/,

X

face evenness according t w h e instructions given under the heading ':Inspecting the cylinder heads". The surface finish may be max. 6 p.

d

The distance from the face of the valve disc to the cylinder head fac~~bfter the face-grinding may not be less than 1.0 mmJ@CM;I'?,.;lf;;f,"rther machining of the cylinder tiead.-isiGqufed, the'Qzilveseat locations must also be milled .dow$sThe distancefrom the face of the valve discso that of the cylinder head must be max. 1.4 h m (0.~6"). After machining, the height of$'. the cylinder.hea&:must not be less t~ap:~108.65 m6. (4.278'7. Clean thi"&linder head after the machinind,;:: ,...

'.

.

,,$ii,:,i:, :.

,. , . . '.. %*:-. , , ,, ....., . .., ,. : . .;"..

Cutting new sbali'ng grooves -- in the cylinder heads '

*

-

'

.

i

Before cutting new grooves in the cylinder heads, completely obliterate the old grooves. The sealing grooves are cut with tool 9505.

Fig. 36. Pressure testing a cylinder head

1.

Fill the cylinder head with water.

2.

3. Test the cylinder head for leakage with a water pressure of- 3 kp/cm2 (43: l ~/in2). f

*

-- 'e .L

-

Set the steel cutter vertically by placing the to61 , in accordance with Fig. 37. Slacken the steel cutter retainer screws and allow the cutter to drop down towards the recess in the template and then tightening up the retaining screws. Repeat this procedure with both the other cutters. Checkthat the template is the right one for the edgise ih ,dfOest~on---

After the test, remove the expandeF seals, the sealing and connection , . shers.

4. .i

,

Check that the cutter steel is marked D70. Proceed as follows:

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..

@?

-,-

.

.

h

+

\ \I

y.:..

*

In the event of lea~agag@:f@p-tfj&copper sleeves of . -instructions on the injectbri, proc6&~&rdi"88icj&e - .. .ljag;&72-73 .:. ,.-..> =. --.., . =:. -:< ~

--

-1

~T

..

.

.

:

'

.

.

?LC-

.

. ..:s,

,

,- . '

L!.-,

The maximum unevenness for the'~~i/!iiide;':heda,:face is 0.03 mm (0.0012"). This check .should be'made with a feeler gauge and straight edge, the $ides yl wh&h are shaved to an accuracy degree in a c t g f @ % $ f ? with DIN 874/Normal. If the unevenness is ab$ifej{t') permitted value or ifsthereare blister ridges, the'cyz linder head should be machined smoothed or replaced.

'

.

. .;'..., . . .

-

A. Cutter

.

.

.. ... .

102 80(

B. Template

I>,'

2.

':

'

'

.

..-2)'

.

,

~i~the@o~~~ldi?$$ii& , - . 9 .. placing both the dowels z .s :p$ in the vdve'guides(fi& 38).'~hedo&fh0le, which .@ ,; -;+,.: ~ ' ~ :,? ! ; %~ . : % is marked "IN 70.,,mb& . . always be placed in ;;:,i%?:,.$s$,$

%$>\

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3'i \..

Fig. 37. Adjusting the cutter

.s.Lg$$;

, . .

$f$,($:

.*,:$,,>>,.: 5.;.. ,??

\ \ h $

12. Fit the i n j W T @ h t e n up the nuts alternatively and e v g a t o avoid uneven stress on the nozzle contact&su?face.The tightening torque is 2 0 Nm (2 kpm = 15 lbfft). Tighten up the delivery pipes, and the leak-off fuel line. 13. Fit the rocker arm covers. Tighten the bolts to a torque of 10 Nm (1.0 kpm = 7 Ibm. It is important that this torque is not exceeded.%xcessive tightening can cause leakage.

1

Cylinder block

;

' -3

;: 3

i

Pressure testing the cylinder block

Fig, 41. Tightening sequence

,

.

"

\

.--.

'

Cylinder heads used for the pr

. ;.

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when the engine . : be allowed to coo$$r approx. ;

,e

A Water pipe

..

, T& tightening should bkCdonein stages as fol*" lows: .2;:.,