Bukh DV36/48 Workshop Manual

Aabenraavej 13-17, DK - 6340 Krusaa, Denmark
Tel: [phone]
Fax [phone]
E-mail: [email protected]

– Internet: www.bukh.dk

Publ. No.

009W2329

Work shop Manual

for

BUKH diesel engine

TYPE DV36/48

009W2329-R01

Contents

Section A … Introduction and technical data

Section B … List of tools

Section C … Cylinder head

Section D … Flywheel

Section E … Front end cover

Section G … Rear end cover and hand start

Section H … Fuel system

Section IJ … Piston, connecting rod and cylinder liner

Section L … Crankcase, crankshaft, main bearings and oil sump

Section M … Camshaft

Section N … Lubricating oil system

Section O … Cooling water system

Section P … Electrical system

Section R … Gearbox ZF, BW7

Section S … Sail drive

Section T … Irregularities in operation - causes and remedies

Section V … Maintenance

009W2329-R01

A1

SECTION A

INTRODUCTION AND TECHNICAL DATA

009W2329

A2

CONTENTS

Introduction ................................................................................ page A 3

Technical Data ........................................................................... page A 4

Torques ..................................................................................... page A 5

Spare Part Nos. for Service Parts .............................................. page A 6

Torque and Rating Curves ......................................................... page A 7

Results of Measurement ............................................................ page A 8

Longitudinal Section of DV36 .................................................... page A 9

Cross Section of DV36 .............................................................. page A 10

Diagram of the Relation between the Total Weight,

Speed and Horse Power of the Boat ......................................... page A 11

009W2329

A3

Introduction

BUKH DV36 is a 3-cylinder, water cooled, 4-stroke diesel engine with direct injection, giving
an easy start at low temperatures, a low consumption of fuel and a low thermic load of the
cylinder head.

The engines are specially designed to comply with the heavy demands made on stability,
safety and environment now.

The technical structure of the engine with components and systems appears from the
individual sections of this workshop manual and therefore this introduction contains no
descriptions of this.

DV36 is designed with small installation dimensions compared to corresponding engine
outputs on the market. This applies to both height, length and width. At the same time the
weight of the engine is comparatively low and the proportion weight/horse power is in fact only

7.36 compared to corresponding engine outputs on the market with a corresponding factor of

8.28 and 8.48.
Being a 3-cylinder engine, DV36 is a naturally low level of vibration compared to 1- and 2-

cylinder engines, but in order to obtain a further improvement of the vibration level, the rotating
weight system has been continued on DV36 as it is known with great success from DV10 and
DV20. DV36 with the anti-vibration system is thus free from unpleasant vibrations and may
correctly be described as the less vibrating engine on the market.

DV36 is supplied either with sail-drive (type DV36SME) or with BW7 gear (type DV36ME). The
type description S = saildrive, M = marine gear and E = with electric start.

The temperature of the exhaust gas is for DV36 max. 550°C, which is about 100°C below
corresponding engine outputs on the market.

DV36 is delivered as standard with direct seawater cooling but may be alternatively be
delivered with heat exchanger built integral with water cooled exhaust, keel cooler or radiator
cooler.

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A4

TECHNICAL MAIN DATA

WORKING PRINCIPLE……………………………………………………… ... 4-STROKE

BORE/STROKE ...................... ................................ ................................... 85 mm / 85 mm

CYLINDER VOLUME ............. ................................ ................................... 1.447 Litres

COMPRESSION RATIO ......... ................................ ................................... 18,5:1

COMPRESSION PRESSURE …. ................. at 1800-3600 rpm………… .. 46 Bar

OUTPUT, CONTINOUS RATING.…. ............ at 2400 rpm………..……… .. 29.8 BHP - 21.9 kW

ACCORDING TO ISO 3046……. .................. at 3000 rpm…………………..34.5 BHP – 25.4 kW

.............. at 3600 rpm…………………. 36.0 BHP - 26.5 kW

OUTPUT, INTERMITENT RATING BHP ....... at 4000 rpm ......................... 39.3 BHP – 28.9 kW

MAX. TORQUE Kp*m ............. ...................... at 1800 rpm .......................... 9.2 Kpm – 90 Nm

MAX. AIR CONSUMPTION .... ................................ ................................... 2214 Litres/min.

ENGINE ROTATING, LOOKING AT FLYWHEEL .. ................................... CLOCWISE

IDLING SPEED ....................... ................................ ................................... 800 – 1000 RPM

MAX INCLINATION, FORE AND AFT ..................... ................................... 15

HEEL, MAX. CONTINOUS ..... ................................ ................................... 30

NET WEIGHT INCL. ZF MARINEGEAR ................. ................................... 265 Kg

NET WEIGHT INCL. SAILDRIVE ............................ ................................... 290 Kg

LOCATION OF ENGINE SERIAL NUMBER ........... ................................... ON CRANKCASE NEAR FUEL THE PUMP

EXHAUST TEMP. MAX / NORMAL ......................... ................................... 600

VALVE TIMING AND INJECTION POINT

FLYWHEEL DIAMETER ......... ................................ ................................... 370 mm

INLET VALVE OPENS .................. BEFORE TDC . ................................... 32

INLET VALVE CLOSES ............... AFTER BDC .... ................................... 64

EXHAUST VALVE OPENS ............ BEFORE BDC . ................................... 64

EXHAUST VALVE CLOSES ......... AFTER TDC .... ................................... 32

INJECTION STARTS……… .......... BEFORE TDC……………………… ..... 6.2

VALVE CLEARANCES (COLD ENGINE) INLET/EXHAUST ...................... 0.30 mm

FUEL SYSTEM ...................... ................................ ................................... DIRECT INJECTION

INJECTOR OPENING PRESSURE ........................ ................................... 210 Bar

INJECTION TIMING .............. ................................ ................................... AUTOMATI C VARIABLE

FUEL LIFT PUMP ................... ................................ ................................... CAM SHAFT DRIVEN DIAPHRAGM PUMP

STATIC PRESSURE OF FUEL LIFT PUMP ........... ................................... 153 - 285 mBar

FUEL FILTER ......................... ................................ ................................... THROW AWAY FILTER INSERT

FUEL QUALITY GAS OIL ....... ................................ ................................... BS 2869 CLASS A

LUBRICATING SYSTEM

TYPE OF LUBRICATING OIL PUMP ...................... ................................... ROTARY VANE PUMP

LUBRICATING OIL PRESSURE: WARM ENGINE / MINIMUM ................. 2-4.5 Bar / 1 Bar

LUBRICATING OIL QUALITY ................................ ................................... SERVICE CC or CD

LUBRICATING OIL VISCOSITY .... BELOW +5

BETWEEN +5
ABOVE +25

o

C ...................................... SAE 10 or SAE 10W-30

o

c and +25oC ................ SAE 20 or SAE 15W-40

o

C . ................................... SAE 30 or SAE 15W-40

LUBRICATING OIL CONTENT INCL. FILTER ........ ................................... 4.9 Litres

LUBRICATING OIL FILTER .. ................................ ................................... THROW AWAY FILTER INSERT

ZF BW7 MARINEGEAR

LUBRICATING OIL QUALITY ................................ ................................... API CC or CD, MILL-L-46152

LUBRICATING OIL VISCOSITY .............................. ................................... SAE 30 or SAE 15W-40

LUBRICATING OIL TEMPERATURE...................... ................................... MAX. 120

LUBRICATING OIL CONTENT ............................... ................................... 1.1 Litres

NEWAGE PRM120 MARINEGEAR

LUBRICATING OIL QUALITY ................................ ...................................

LUBRICATING OIL TEMPERATURE...................... ................................... MAX. 120

LUBRICATING OIL CONTENT ............................... ................................... 0.8 Litres

o
o

o

C – 580oC

o

(arc measure: 103 mm)

o

(arc measure: 207 mm)

o

(arc measure: 207 mm)

o

(arc measure: 103 mm)

o

(arc measure: 20 mm)

o

C

Automatic Transmission Fluid (ATF)

o

C

009W2329

A5

BAYSAN M60 MARINEGEAR

LUBRICATING OIL QUALITY ................................ ...................................

LUBRICATING OIL TEMPERATURE...................... ................................... MAX. 120

LUBRICATING OIL CONTENT ............................... ................................... 0.5 Litres

STERN TUBE (FLEXIBLE) LUBRICANT ................ ................................... OUTBOARD GEAR OIL

COOLING WATER SYSTEM – DIRECT SEAWATER COOLING

COOLING WATER TEMPERATURE ...................... ................................... 50 – 65

TYPE OF CIRCULATING PUMP / CAPACITY AT 3600 rpm ..................... CENTRIFUGAL / 24-30 Litres/min

CAM HEIGHT ......................... ................................ ................................... 2.0 mm

MAX. PUMP COUNTER PRESSURE ..................... ................................... 0.6 Bar

MAX. PUMP SUCTION PRESSURE....................... ................................... 0.3 Bar

COOLING WATER SYSTEM – INDIRECT COOLING WITH FRESHWATER

COOLING WATER TEMPERATURE ...................... ................................... 70 – 95

TYPE OF FRESHWATER PUMP / CAPACITY AT 3600 rpm ..................... CENTRIFUGAL / 135 Litres/min

PUMP PRESSURE ................. ................................ ................................... 1.1 Bar

TYPE OF SEAWTAER PUMP / CAPACITY AT 3600 rpm .......................... CENTRIFUGAL / 36-42 Litres/min

CAM HEIGHT ......................... ................................ ................................... 3.1 mm

MAX. PUMP COUNTER PRESSURE ..................... ................................... 0.6 Bar

MAX. PUMP SUCTION PRESSURE....................... ................................... 0.3 Bar

ELECTRICAL SYSTEM

BATTERY VOLTAGE / CAPACITY ............................................................ 12 VOLT / 88 Ah

STARTER TYPE / OUTPUT ....................................................................... GEAR DRIVEN / 1.0 KW

ALTERNATOR TYPE/ OUTPUT ................................................................ BELT DRIVEN / 700 W

ENGINE STOP ........................................................................................... SOLONOID / MANUAL

RELAY ........................................................................................................ EL ECTRONIC, BUILT ON

TORQUES

CYLINDER HEAD BOLTS/BEARING TOP SECTION ................................ 118 +/- 5 Nm (12 +/- 0.5 Kpm)

CONNECTING ROD BOLTS . .................................................................... 69 +/- 3 Nm (7 +/- 0.3 Kpm)

FLYWHEEL/COUNTERWEIGHTS ... .......................................................... 147 +/- 7 Nm (15 +/- 0.7 Kpm)

FLEX. COUPLING .................. .................................................................... 61 +/- 3 Nm (6.3 +/- 0.3 Kpm)

ASSEMBLY OF FUEL VALVE .................................................................... 59 +/- 3 Nm (6.0 +/- 0.3 Kpm)

BRACKET FOR ENGINE SUPPORTS ....................................................... 69 +/- 3 Nm (7 +/- 0.3 Kpm)

GEARBOX .............................. .................................................................... 25 +/- 5 Nm (2.5 +/- 0.5 Kpm)

Automatic Transmission Fluid (ATF)

o

C

o

C

o

C

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A6

Spare Part Numbers for Service Parts

In this manual we have maintained on the drawings some numbers which are also spare part
numbers. However, this manual is not to be regarded as a spare parts catalogue but only as
helping guidance for correct identification of parts.

In the daily service work, some of the parts must be replaced after the number of hours stated
in the owner´s manual and in this book, and therefore we have made the following table:

610J0200 Lubricating oil filter
610D0201 Fuel filter
020D4326 Air filter
000E0450 Sacrificial zinc anode

610G0506 Impeller
542A0602 V-belt 10*1035 (seawater cooling)

542A0609 V-belt 10*1100 (freshwater cooling)

009W2329

A7

009W2329

A8

Results of Measurement

The below curves indicate results of measurements at 762 mm Hg and a room temperature of 26 °C.

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A9

Longitudinal Section of DV36

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A10

Cross Section of DV36

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A11

Diagram of the Relation between the Total Weight,
Speed and Horse Power of the boat

The below diagram is normative and not binding in any way as many different circumstances
influence the result, especially the type and shape of the boat, the propeller and its placing as
well as the horse power of the engine.

Seek the scheme to the right of the intersection between the actual length in the waterline of the
ship and the total weight.

Draw a straight line between this point (the intersection) and the fixed point in the bottom left corner.

Where the line of the desired speed crosses the straight line, you can read the required horse
power vertically below.

If you know three of the specifications, you can by means of these schemes find the fourth one.

009W2329

B1

SECTION B

LIST OF TOOLS

009W2329-R01

B2

CONTENTS

Tools for repairs on DV36 .......................................................... page B 3

Dimensions of mounting punches ............................................. page B 6

009W2329-R01

B3

Tools for repairs on DV36

The below mentioned tools are necessary to make the engine repairs described in this
manual.

Part of the tools are special tools which can be ordered from the spare parts department at
BUKH.

We have indicated the fields of application for the special tools in this manual.

Designation of tools Fields of application Spare part No.

Slip-on ring for mounting of
pistons

Puller for cylinder liner

Punch for rear seal ring

Punch for front seal ring

Punch for mounting of
camshaft bearing in block

Punch for journal for
intermediate wheel

Punch for journal for front and
rear rotating weight

Section IJ

Section IJ

Section G

Section E

Section M and L

Section G

Section E and G

009P2235

009P3177

009P3178

009P3179

009P3180

009P3181

Punch for mounting of valve

Section C

009P3175

guide

Punch for mounting of inlet

Section C

009P3173

valve seat

Punch for mounting of exhaust

Section C

009P3174

valve seat

Punch for mounting of expan-

Section C

009P3176

sion discs in the cylinder head

009W2329-R01

B4

Designation of tools Fields of application Spare part No.

36 mm socket spanner

19 mm socket spanner for
fastening of cylinder head

19 mm crowfoot wrench for
tightening up of cyl. head

10 mm Allen top for faste-ning of
bearing top section

5 mm Allen key

6 mm Allen key

7 mm Allen key

Section C

Section C

Section L

-

-

-

009P3225

Open-end spanner/ring spanner,
8/10/12/13/14/15/17/19/22/24/27
30 and 32 mm

Dismantling tool for valve
springs

Tachometer

Testing set for fuel nozzles

Cleaning for fuel nozzles

Bosch dial indicator for
adjustment of fuel pump

-

Section C

Generally

Section H

Section H

Section H

009P3115

009P3106

009P3100

009P3101

Bosch dial indicator “holder with
extension” for adjustment of the
fuel pump (KDEP1085)

009W2329-R01

Section H

529W0002

B5

Designation of tools Fields of application Spare part No.

Flanging tools for nozzle holder
insert

Torque wrench
(Stahlwille 73/6 1.5-6.5)

Torque wrench
(Stahlwille 73/25 8-26)

Circlip tongs (external)
A1, 10-28 mm

Circlip tongs (internal)
J2, 19-75 mm

Puller for gear wheel
(Kukko 20/10)

Puller for flexible coupling

Section C

Generally

Generally Section C, D,

IJ and L

-

-

Generally

Section R

009P2565

009P3108

009P3109

T 41069

Compression gauge

Adapter for compression gauge

Section C

Section C

529W0000

009P3123

Part of the mentioned special tools can be manufactured without too much trouble at the
dealer´s workshopin periods outside the boat season. Therefore we have made sketches at
page B6 of each individual mounting punch with dimensions.

Slip-on ring for mounting of pistons is not illustrated but is manufactured of a worn out
cylinder liner or another piece of work pipe. Cut the cylinder liner so that you get a piece
being about 100 mm high, the turn it conical inside the liner or pipe.

009W2329-R01

B6

009W2329-R01

C1

SECTION C

CYLINDER HEAD

009W2329-R01

C2

CONTENTS

Exploded view of cylinder head complete ................................. page C 3

Valve adjustment ...................................................................... page C 4

Removal and refitment of cylinder head ................................... page C 5

Replacement of rocker arm or rocker shaft .............................. page C 6

Adjustment of valve lifter arrangement ..................................... page C 6

Replacement of rocker arm bushing ......................................... page C 7

Removal of fuel valves ............................................................. page C 8

Nozzle holder insert .................................................................. page C 9

Fitting measures for fuel nozzle insert ...................................... page C 10

Valve springs ............................................................................. page C 11

Replacement of valve guides .................................................... page C 12

Pressing-in dimensions for valve guide ..................................... page C 13

Valve guide stuffing box ............................................................ page C 14

Repair or replacement of inlet and exhaust valves .................... page C 15

Exhaust valve ............................................................................ page C 16

Inlet valve .................................................................................. page C 17

Grinding of valves ...................................................................... page C 18

Measures for new valves ........................................................... page C 18

Replacement of valve seats ..................................................... page C 19

Cylinder head gasket ................................................................ page C 20

Air inlet manifold arrangement ................................................... page C 21

Exhaust manifold arrangement .................................................. page C 22

009W2329-R01

C3

Exploded view of cylinder head

009W2329-R01

C4

Valve adjustment

The clearance of the inlet and exha ust valves should be adjusted at 0.3 mm w hen the
engine is cold and the clearance of the valves should always be checked after tightening-

up of the c ylinder head. The valv es are adjusted when the pisto ns are alternately at their
highest point in the working stroke.

Adjust the valves by loosening the counter nut A which makes it possible to adjust the
clearance by means of the adjusting screw B.

Measure the clearance with a feeler gauge at C.

009W2329-R01

C5

Removal and refitment of cylinder head

1. Drain off the cooling water.

2. Remove the top cover.

3. Remove valve rocker arms.

4. Remove the inlet and return pipes of the fuel valves.

5. Remove the charging alternator.

6. Remove the exhaust and inlet manifold.

7. Loosen the top bolts, after which the cylinder head can be lifted out of the engine block.

8. Refitment of the cylinder head is made in reverse order and the bolts are tightened

evenly at a torque of 118±5 Nm (12±0.5 kpm). Tighten in the order shown on the

skeleton diagram below.

009W2329-R01

C6

Replacement of rocker arm or rocker shaft

For each cylinder, a rocker arm column wit h two rocker arms for inlet valve and exhaust
valve, respectively, is fitted on a common shaft with corresponding rocker arm columns and
rocker arms for the two other cylinders.

1. Remove the top cover.

2. Unscrew the three central nuts on the rocker arm columns.

3. Lift off the shaft arrangement.

4. Knock out the tube pin and washer in one of the shaft ends.

5. Then the rocker arms and the intermediate springs can be taken out.

Reassembly is a reversal of the dismantling procedure.

Adjustment of valve lifter arrangement

Furthermore, a common shaft for decompression is fitted on the three rocker arm
columns.
For a possible removal of the shaft, remove first the pins going down on the rocker arms
at decompression, after which the shaft can be pulled out.

When adjusting, adjust the pins so that you faintly see a single groove of the pin thread
(about 1.5 mm free pin) just on the side facing the rocker arms.

When fitting the top cover, ensure that the slot in the decompression handle in the top
cover mesh with the corresponding pin on the decompression shaft.

009W2329-R01

C7

Replacement of rocker arm bushing

1. Remove the rocker arm as indicated on page C5 and check it as to wear and tear
as well as fracture.

2. Press out the defective bushing with an adequate tool.

3. Fit the new bushing as shown below paying special attention to the position of the
bearing joint and the oil grooves.

4. When fitted, calibrate the bearing bush so that the tolerance ø19-R7 is observed.
Do this either with a calibration ball or with a reamer having the mentioned tolerance.

5. After refitting the rocker arm, check the axial play with a feeler gauge. The axial
play may be 0.1 – 0.2 mm.

6. Finish refitting the rocker arm arrangement.

drwg. No. 008E4893

009W2329-R01

C8

Removal of fuel valves

The fuel valves are removed by loosening the clamping nuts for the flanges A as indicated on

the sketch below after removal of the inlet and return pipes of the fuel valves.

The drawing at the bottom right-hand side indicates the placing of the fuel valve in proportion
to the piston.

For repair of the fuel valves, we refer to section H.

009W2329-R01

C9

Nozzle holder insert

The nozzle holder inserts are placed in the cylinder head and form – a the name indicates –
an insert for the placing of the fuel valves in the cylinder head.

The nozzle holder ins erts can be replace d, which demands that the sp ecial tools below for
flanging (piston and backstop) are used and that t he surfaces are treated as indicated on the
drawing.

Remove the old nozz le holder inserts by bor ing-up the flanged end of the nozzle holder
inserts with a ø8 – ø9 mm drill, and then k nock out the nozzle h older inserts with a 10 mm
punch.

After having fitted the new nozz le holder insert s, test the cylinder head for pressure with
water in order to check the flanged seals.

drwg. No. 008E4881

009W2329-R01

C10

Fitting measurements for the fuel nozzle into insert.

009W2329-R01

C11

Valve springs

Six identical springs for inlet and exhaust valves, respectively, are fitted in the cylinder head.
The springs are identical in both ends, and therefore fitting up or down is of no importance.

The springs are locked in their position in proportion to the valve stems by means of two
conical halves for each valve spring and guided by a guide for valve spring and a
corresponding disc, respectively.

The valve springs are removed by compressi ng the valve springs and removing the c onical
locking halves with s pecial tools or the like so the valves are cut off fro m following the
movement of the springs.

When refitting the valve springs, make sure t hat the conical loc king halves are correctly
placed in their trace on the va lve stems. This can be done by knocking gently with a plastic
hammer on top of the valve stem while the cylinde r head is lifted from the file bench so that
the valve heads can move so as to be clear of the valve seats.

009W2329-R01

C12

Replacement of valve guides

Replace the valve guides whic h are pressed into the cylinder head if the tolerance is
exceeded because of wear and tear by 0.05 mm. Check the measure with a ø9 – H7 internal
gauge according to the drawing below of the valve guide.

Fit new valve guides according to the drawing on page C13. Before fitment, heat the cylinder
head in an oven or heat it in boiling water and cool down t he valve guides in a deep freezer
or otherwise.

After fitment of new valve guides, broach the bore of the valve guides with a broach in order to
remove possible ups ettings from the fitti ng. Use a broach ø 9 – H7 for the broaching.

009W2329-R01

C13

Pressing-in dimensions for valve guide.

009W2329-R01

C14

Valve guide stuffing box

In order to avoid lubricating oil consumption because of lubricating oil passing between valve
guide and valve stem causing the valves to be burnt or to be carbonized, a stuffing box has
been mounted on the upper end of the valve guides.

The stuffing box is as shown schematically on the drawing below and consists of:

A: Metal spring coat
B: Plastic bushing
C: Spring wire

The stuffing box compensates for wear and tear of the valve guides so that the lubricating oil
consumption because of leaky valve guides is reduced to a minimum.

The stuffing box cannot be repaired but has to be replaced if necessary.

009W2329-R01

C15

Repair or replacement of inlet and exhaust valves

1. Remove the cylinder head from the engine (page C5).

2. Then place the cylinder head on a file bench or the

like with the valve seats at the bottom.

3. Compress the valve springs with a special tool or the

like and remove the conical valve locking halves.

4. Then place the cylinder head upright and remove the

valves from the cylinder head.

Refitment is a reversal of removal procedure.

Note! Refit the valves in the same valve guides again.

Replace the valves if they are so damaged that a refacing with special tools and subsequent
grinding are impossible without exceeding the tolerances indicated on page C18 and C19.

A refacing of the valve seats with fixed guide should always be made if the valve does not
function satisfactorily.

After replacement of valve or valve seat, grind together with abrasive compound seat and valve
so that total tightness is obtained. It is an indispensable condition for the compression of the
engine that this work is performed carefully.

Grinding of valves is made as described on page C18.

009W2329-R01

C16

Exhaust valve

Tolerances and repair measures.

009W2329-R01

C17

Inlet valve

Tolerances and repair measures.

009W2329-R01

C18

Grinding of valves

1. Place the cylinder head with the valve seats upwards. Block the cylinder head so that
the valves fit tightly against the seats and can be turned freely by means of a rubber
suction disc or the like.

2. Apply abrasive compound to valve and seat, after w hich grinding can tak e place.

3. When grinding, turn the valve by means of the rubber suction disc in various directions
while fitting it at the same time with an equal pressure against the seat. When
grinding, lift frequently the valve and spread all over the seat the abrasive c ompound
applied.

4. You can c heck whether the valve is ti ght by cleaning off the abrasive compound
carefully by for exam ple cleaning liquid. Then make 4 pencil m arks staggered 90
degrees from each ot her on the c ontact face of the valve. Insert the valv e and turn it
about 20 degrees. If the valve is tigh t, the marks will have disappeared.

5. Before refitment in the cylinder head, cl ean the valve carefully for abrasive compound
and apply a thin coat of oil to it. Do the same with regard to the valve seat.

Measures for new valves

Valve stem diameter ................................................... ø9

-0.050 / -0.062

Valve guide bore ......................................................... ø9 – H7

Clearance between valve stem and valve guide ......... 0.050 – 0.077 mm

The valve stems have been specially treated and therefore they must not be ground.

009W2329-R01

C19

Replacement of valve seats

The valve seat rings should be replaced when, after repeated millings and grindings, they
have been milled so far down that the valv e heads are more than 0.3 mm belo w the face of
joint of the cylinder head (see the sketch below).

1. Remove the valve springs an d valves as indicated previously in this section.

2. Place a lead plate or an annealed copper plate between the cylinder head and a bent
chisel and knock out the valve s eat ring with this (crowbar princ iple) by stic king one
end of the chisel under the rear edge of the valve seat ring.

IT IS IMPORTANT THAT THE FILLING PIECE IS USED BETWEEN CYLINDER HEAD

AND CHISEL IN ORDER TO AVOID DAMAGING THE CYLINDER HEAD.

Before fitting new valve seat rings, clean the bores in the cylinder head for same and check
that the holes are not oval.

Then warm up the cylinder head in hot water to about 100° C (212° F), after which fit, by
means of a punch, the valve seat rings having been cooled down beforehand in nitrogen or
carbon dioxide.

When fitting the valve seat rings, the difference of temperature between cylinder head and
valve seat ring is to be 220 – 250° C (430 – 480° F).

DO NOT KNOCK IN THE VALVE SEAT RING VIOLENTLY. ONLY ACTIVATE THE

PUNCH WITH A RATHER GENTLE BLOW IN ORDER TO FIT THE VALVE SEAT RING.

009W2329-R01

C20

Cylinder head gasket

The cylinder head gasket is made from “Grafos eal” (Asbestos free) which is an expanded
graphite which is strengthened with a special 0.2 mm carbon steel inlay.

When replacing the cylinder head gasket, the grooves in the cylinder head must be
completely clean to obtain tightness.

If the cylinder head has been removed several time s, the metal around the studs may have
risen which can be checked by m eans of a straight-edge. If the me tal has risen, it must be
planned.

Drwg. 000E4789

009W2329-R01

C21

Air inlet manifold arrangement.

Pos. Part No. Qty. Beskrivelse Description Benennung

3 000E4923 1 Indsugningsmanifold Inlet manifold Einlasssammelrohr

4 008E7310 1 Luftfilter Air filter Luftfilter

5 501A2363 12 Cylinderskrue Unbraco screw Unbracoschraube

6 522E0521 12 Låseskive Locking washer Arretierungsscheibe

009W2329-R01

C22

Exhaust manifold arrangement.

Pos. Part No. Qty. Beskrivelse Description Benennung

1 000E7434 1 Vandkølet udstødningsmanifold Water-cooled exhaust manifold Wassergekühltes Auspuffsammelrohr

2 000E5028 3 Pakning for udstødningsmanifold Gasket for exhaust manifold Dichtung für Auspuffsammelrohr

3 008E9239 1 Flange Flange Flansch

4 560F1031 1 O-ring O-ring Abdichtung

5 500C2363 2 Sætskrue M8x20 Set screw M8x20 Setzschraube M8x20

6 503N2367 2 Tapskrue M8x35 Stud M8x35 Stiftschraube M8x35

7 000E5360 1 Udstødningspakning Exhaust gasket Auspuffdichtung

8 000E7788 1 Udstødningsflange Exhaust flange Auspuffflansch

9 522F1020 4 Fjederskive Spring washer Federscheibe

10 510A3208 4 Møtrik M8 Nut M8 Mutter M8

009W2329-R01

D1

SECTION D

FLYWHEEL

009W2329-R01

D2

CONTENTS

Removal and refitment of flywheel ............................................ page D 3

V-belt pulley fitted on flywheel ................................................... page D 3

Replacement of gear rim ........................................................... page D 4

009W2329-R01

D3

Removal and refitment of flywheel

1. Mark the flywheel in propor tion to the crankshaft out of consideration for the other
marking of the outer diameter of the flywheel.

2. Slacken the V-belt for the charging alternat or and tak e it clear of the V-belt pulley of
the flywheel.

3. Remove the six bolts securing the flywheel to the crankshaft.

4. Lift off the flywheel.

Refitment is to be carried out in reverse or der. Smear the bolts with some Loctite or
something similar and tighten them with a torque of 147±7 Nm (15.0±0.7 kpm).

When dismounting the flywheel please note to fit the flywheel in the same position as before.
This only due to the timing marks on the flywheel and not due to the balance of the flywheel.

V-belt pulley fitted on flywheel.

A V-belt pulley, as indicated on the drawing below, is fitted on the front end of the flywheel.
This V-belt pulley can be replaced by thr ee “A” grooves and diam eter 125 mm for operation
of e.g. bilge pump, winch or t he like. However, only max. 10 HP must be loaded from the
front of the engine.

The V-belt pulley may be ordered against number 023D2801.

Drwg. 000E4931

009W2329-R01

D4

Replacement of gear rim

1. Remove the flywheel.

2. Saw with a hacksaw as far int o the gear rim as possible without damaging the
flywheel.

3. Split the gear rim in the sawed slot with a chisel.

4. Clean the recess on the flywheel.

5. Heat the new gear rim gradually to about 225°C (dark blue) and fit it. Make sure at the
fitting that the gear rim lies true against th e recess and that the chamfered edge turns
towards the starter engine.

Drwg. 008E7312

009W2329-R01

E1

SECTION E

FRONT END COVER

009W2329-R01

E2

CONTENTS

Dismounting of front end cover .................................................. page E 3

Mounting of front end cover ....................................................... page E 3

Front rotating weight .................................................................. page E 3

Replacement of front oil seal ring .............................................. page E 4

Replacement of bushes in the front rotating weight ................... page E 4

009W2329-R01

E3

Dismounting of front end cover

1. Dismount the flywheel (see page D3).

2. Slacken the attachment of the end cover in engine block as well as in oil sump.

3. Dismount the tightening arrangement for shaft for rotating weight.

The tightening consists of two washers of different thickness and a fibre washer
assembled by a 8 mm screw.

4. Remove the end cover considering the guide spindles of the cover.

.

Mounting of front end cover

The mounting is carried out in reverse order of the dismounting, i.e. the tightening arrangement for
shaft for rotating weight is to be mounted last.

Front rotating weight

The front rotating weight is mounted below the front end cover, as shown on the drawing below
and overleaf.

As will appear from the drawing overleaf the weight is marked in relation to a corresponding mark
on the gear wheel of the crank.

009W2329-R01

E4

Replacement of front seal ring

A seal ring is mounted in the front end cover in order to avoid lubricating oil waste at the end of the
crank through the front end cover.

The seal ring can be replaced without dismounting the front end cover. It is, however, necessary to
dismount the flywheel.

Replacement of bushes in the front rotating weight

When replacing the bushes in the front rotating weight the new bushes must be calibrated with a
ball or reamed, with clearance and measures as indicated on the drawing.

009W2329-R01

G1

SECTION G

REAR END COVER AND HAND START

009W2329-R01

G2

CONTENTS

Rear end cover .......................................................................... page G 3

Dismounting of rear end cover .................................................. page G 3

Mounting of intermediate wheel and chain wheel ...................... page G 4

Tightening for shaft for intermediate wheel ................................ page G 4

Intermediate wheel .................................................................... page G 5

Rear of rotating weight (drawing) .............................................. page G 6

Mounting of rear of rotating weight ............................................ page G 7

Replacement of bush in the rear rotating weight

and intermediate wheel ............................................................. page G 8

Replacement of seal ring in rear end cover ............................... page G 8

Mounting of the rear end cover .................................................. page G 8

Chain adjuster ........................................................................... page G 9

Hand start .................................................................................. page G 10

009W2329-R01

G3

Rear end cover

The rear end cover contains gear-wheel for crank, cam shaft, fuel pump,hand start,
lubricating oil pump, cooling water pump and rear rotating weight.

The gear-wheels are in the gear with each other through an intermediate wheel. The sketch
below indicates the marking of the gear-wheels which have been marked in relation to each
other so that their position to each other may easily be observed when being repared.

Dismounting of rear end cover

1. Dismount the gear from the engine.

2. Dismount the flexible coupling half on the crank.

3. Slacken the attachment of the end cover on engine block and oil sump.

4. Dismount the hand start and lower the chain into the end cover (see page G10).

5. Slacken the shaft seals for intermediate wheel and rear rotating weight and remove

the end cover.

6.

7.

8.

009W2329-R01

G4

Mounting of intermediate wheel and chain wheel

After the intermediate wheel has been placed on the shaft, and after the timing marks – as
indicated overleaf – have been adapted for the corresponding marks, the chain wheel for
hand start should be mounted on the same shaft.

The two thrust collars shown form part of the arrangement.

It is necessary – when mounting – to lubricate the
washer between block and thrust washers with
grease in order to secure that it keeps its position
during the mounting and that it does not slide down.

Tightening for shaft for intermediate wheel

The tightening consists of two washers and
a fibre ring as indicated below.

009W2329-R01

G5

009W2329-R01

G6

009W2329-R01

G7

Mounting of the rear rotating weight

Mount the rotating weight on the shaft pressed into the engine block and the tooth marking in
relation to the intermediate wheel should be observed.

After the end cover has been mounted, the tightening for shaft should be mounted in
accordance with the drawing below.

The tightening consists of two washers of different thickness and a fibre ring.

009W2329-R01

G8

Replacement of bush in the rear rotating weight and intermediate wheel

Bushes have been mounted in both rear rotating weights as well as in the intermediate wheel.
These bushes can be replaced in case of wear and tear.

After the new bushes have been pressed in these should be calibrated with a ball or be reamed
with the correct measures and clearances as indicated on the drawings on page G5 and G6 for
rear rotating weight and intermediate wheel respectively.

Replacement of seal ring in rear end cover

A seal ring is mounted in the rear end cover in order to avoid leak of lubricating oil at the outlet
of the crank through the rear end cover.

It is possible to replace the seal ring without dismounting the end cover after the gearbox with
intermediate guard has been dismounted.

Mounting of the rear end cover

The mounting is carried out in reverse order of the dismounting, as the chain for hand start is to
be mounted on the chain wheel and then to be pulled up through the hole in the end cover with
a piece of string or the like, and here the hand start is to be ready-mounted later.

009W2329-R01

G9

Chain adjuster

The chain adjuster is mounted on two pins in the engine block.

The chain adjuster is self-adjusting and thus it does not require any adjustments in connection
with repairs in the end cover during which the chain is to be dismounted.

009W2329-R01

G10

Hand start

The chain case is bolted on to the rear end cover, as indicated on the drawing below.

When dismounting remove the covers “A”, and this results in the chain being slackened and

then the chain wheel and shaft can be taken out.

Mounting is carried out in reverse order and it should be taken care that the O-rings for oil­tightness are correctly placed in the grooves on the chain wheel shaft.

Dismount the chain case from the end cover by removing the bolts “B”.

009W2329-R01

H1

SECTION H

FUEL SYSTEM

009W2329.XLS

H2

CONTENTS:

Dismounting of the fuel pump ......................................................... page H 3

Mounting and Adjustment for fuel pump ......................................... page H 4

Specification of Numbers to Fig. 1 and 2 ........................................ page H 6

Fuel System ................................................................................... page H 7

Centrifugal Governor ...................................................................... page H 8

Function of the Centrifugal Governor .............................................. page H 9

Fuel Lift Pump ................................................................................ page H10

Fuel Filter ....................................................................................... page H11

Fuel Valve ...................................................................................... page H12

Causes and Remedies of the Fuel Pump ....................................... page H13

009W2329.XLS

H3

Dismounting of the fuel pump

1. Dismount the bilge pump for lubricating oil from engine and gear.

2. Dismount the flange opposite of the fuel pump.

3. Take off the gear-wheel of the pump by slackening the clamping nut on the shaft of the
pump and pull off the gear-wheel.

4. Slacken the nuts in the flange of the pump and take out the pump.

REPAIRS OF THE PUMP SHOULD ONLY BE CARRIED OUT BY AUTHORIZED BOSCH
WORKSHOPS

009W2329.XLS

H4

1. Turn piston No. 3 (rear) to TOP in the working stroke.

2. Mark the flywheel in this position in relation to the arrow mounted on the front edge of
the engine.

3. Measure 86 mm. arc measure from the TOP mark (to the right, when the flywheel faces
you).

009W2329.XLS

H5

4. The pump should be adjusted for correct injection timing:

a. Adjust the key on the conical shaft of the pump so that it flushes with the outlet hole

B to the fuel valve for cylinder No. 3.

b. Remove the screw X and mount a dial indicator with a special sensing element

instead by means of a special holder for dial indicator.

c. Push in the dial indicator 2.0 mm.

d. Mount the flywheel for the pump loosely and turn it to the left, seen from the gear-

wheel side until the dial just indicates within the range of 0.01 mm.

5. Mount the pump on the engine by means of two nuts with washers and spring washers
so that the nuts are placed about the middle of the oblong holes in the flange of the
pump.

6. Mount the gear-wheel for the pump through the hole on the opposite side of the pump.
Fasten the gear-wheel on the conical pump shaft by means of a nut.

7. Mount the flange above the hole for mounting of the gear-wheel of the pump.

8. Mount the dial indicator again at the same place and in the same way and push it 2.0
mm in.

9. Turn the flywheel back from the 86 mm arc measure to 6 mm*) arc measure before the
TOP mark. The indicator is then to show 1.0 mm variation (1 turn).

If this is not so, fine-adjust either by moving the gear-wheel one tooth in relation to the
intermediate wheel (when indicating more than 0.7 mm) or by adjusting the placing of
the clamping nuts in the oblong holes in the flange of the pump (when indicating less
than 0.7 mm).

*)

According to the Service information SI0601, the arc measure has been changed

from 6 mm. to 20 mm. from engine no. 8395.

009W2329.XLS

H6

Specification of Numbers to Fig. 1 and 2

1. Feed pump

2. Drive shaft

3. Gear-wheel

4. Thrust washer

5. Governor shaft

6. Governor bush

7. Holder

8. Governor weight

9. Governor spring

10. Timing lever

11. Adjusting screw (idling)

12. Adjusting screw (max. r.p.m.)

13. Stop lever

14. Overflow throttle

15. Correcting lever

16. Bolt

17. Adjusting screw (full load)

18. Idle spring

19. Clamping arm

20. Starter spring

21. Starting lever

22. Delivery valve holder

23. Distributor piston

24. Governor slide

25. Fuel chamber

26. Cam disc

27. Injection timing piston

28. Roller cage

29. Lift pump

30. Fine filter

31. Pressure control valve

009W2329.XLS

H7

Fuel System

The fuel is pumped by a lift pump (29 from the tank via a fine filter (30) to the internal wing
feed pump. This feed pump gives a constant quantity/revolution.

Through the pressure control valve (31), after the feed pump, a pressure is produced. Most
of the fuel flows through the pressure control valve back to the suction side. The remaining
part of the fuel flows through the inner chamber of the pump (fuel chamber) (25) to the high
pressure chamber of the distributor head and then it is led to cooling and bleeding and then
back to the tank through the overflow throttle (14).

The distributor piston (23) is activated by the drive shaft (2). By means of the cam disc (26)
and the rollers in the roller cage (28) the piston obtains an axial motion besides the rotary
motion.

The delivery (high pressure) takes place by means of the axial motion of the piston. The
distribution to the individual outlets (22) is through a slit in the distributor piston.

The injection stops when the governor slide (24) disengages the transversing hole in the
distributor piston. The fuel flows back into the fuel chamber of the pump (25).

The governor slide (24) is controlled by the centrifugal governor.

009W2329.XLS

H8

The centrifugal governor is placed in the upper part of the fuel pump.

The holder (7) with gear-wheel is placed on the governor shaft (5) and is driven by the drive
shaft (2) via the gear-wheel (3) and a rubber shock absorber (vibration damper).

Four weights (8) are mounted in the centrifugal weight holder. They press on the axially
displaceable governor bush (6) via a thrust washer (4) with their pressure arms.

The governor arm group consists of starting lever (21), clamping arm (19) and correcting lever
(15). Starting lever and clamping arm are placed in the pump housing. In this way it is possible
to adjust the full load quantity by the adjusting screw (17) without influencing th adjustment of
the revolutions.

A leaf spring is placed on the starting lever (21) and it works as a starter spring. An axially
displaceable bolt (16) with idle spring (18) is placed in the upper part of the clamping arm (19).
The governor spring (9) is fixed in this bolt. The tension of the governor spring can be changed
by the timing lever (10). The starting lever (21) has a ball in the lower part connected with the
governor slide (24).

Injection Timing

On the under side of the fuel pump, at right angles in proportion to the longitudinal axis, the
spring-loaded injection timing piston (27) is. The roller cage (28) is turned influenced by the
feed pump pressure and via a mechanism. The injection timing is thus adjusted depending on
the revolutions.

009W2329.XLS

H9

Function of the Centrifugal Governor

The revolutions of the engine are transmitted by the drive shaft (2) through gear-wheel to the
governor weights (8) and are transformed into centrifugal force there.

With stopped fuel pump, the starting lever (21) and the governor slide (24) are pressed into start
position by the starter spring (20). Through this automatic ful volume, when starting, is obtained.

When the r.p.m. of the engine goes up after start the function of the weak starter spring (20) is
taken over by the pressure from the governor bush (6). By this the starting lever (21) is pressed
against the clamping arm (19) and the starting volume is automatically declutched as the governor
slide (24) is displaced.

At low idling the governor spring (9) is not working.
The regulation is controlled by the idle spring (18).

By setting the governor spring (9) more or less with the timing lever (10) a lower or higher r.p.m.
is adjusted. The idle spring is pressed together.

The idling volume is adjusted by the adjusting screw (11) and the full load volume by the adjusting
screw (17).

Max. r.p.m. is adjusted by the adjusting screw (12).

The pump is stopped by means of a stop magnet built on to the fuel pump (not shown on the
sketch). This magnet closes the inlet port to the high pressure chamber in the distributor head at
electrical activation resulting in a dead stop magnet.

009W2329.XLS

H10

Fuel Lift Pump

The fuel lift pump is a diaphragm type and is placed at the upper side of the rear end cover.
The pump is sealed and cannot be dismantled for repair or cleaning. It is driven by the
camshaft.

Workpressure is 35 – 55 kPa.

A hand pump is fitted, which can be used for priming and bleeding by standing engine.

After priming the lever must be put in neutral position, where it is locked. If priming

not is effective, it may be caused by the driving cam being in top position. The engine must
be turned to bring the cam in bottom position.

009W2329.XLS

H11

Fuel Filter

The fuel filter used is a Bosch disposable one mounted to the port side on the front of the
engine.

The filter cannot be cleaned, but has to be changed every 300 operating hours, or if water
contamination is suspected.

Unscrew the filter casing by hand after the filter casing has been emtied for fuel via the
drain screw in the bottom of the filter casing.

Before fitting of a new filter the sealing surface of the filter casing should be cleaned. The
filter casing should now be filled with clea fuel before it is screwed on and tightened about
half a turn after the sealing surface fits tightly.

After changing the filter bleed the fuel system by actuating the manual handle on the fuel lift
pump and pump until the fuel, free from bubbles, runs out at the vent screw on the top of
the fuel filter. Tighten the screw and loosen the fuel pressure pipes at their connection on
the fuel valves and pump again with the fuel lift pump until fuel, free from bubbles, runs out
from the fuel pressure pipes.

009W2329.XLS

H12

The fuel valves are mounted in the cylinder head and are
secured here with tightening bars which are loosened when
dismounting the fuel valves.

Disassemble the fuel valves after the sketch beside and so
the nozzle can be exchanged and the pressure can be
adjusted at the washers (541).

Adjust the fuel valves by means of a pressure test apparatus
at 184 Kp/cm² *) opening pressure.

When using Bosch pressure testapparatus for nozzles you
are referred to Bosch infor-mation WPP 320/2 DK (500.8.76)
and this states test procedure and measures in detail.

The nozzle (548) is a Bosch nozzle DLLA 150P 34 combined
with a nozzle holder KBEL 78P 10/13 and this combination
makes the fuel valve (Item no. 610B9120) *).

The adjusting filling pieces for injection pressure are
obtainable from 1 mm to 1.975 mm thickness with 0.05 mm
from washer to washer.

When exchanging the nozzle the new nozzle has to be
cleaned in petrol as it has been prepared with a protective
oil. Both nozzle needle and nozzle housing should be
carefully cleaned.

When assembling the fuel valve tighten with 6 – 8 Kpm.

*)

According to Service information SI0601 the fuel valve has
been changed from 610B9120 (opening pressure 184 Bar)
to 610B9250 (opening pressure 230 Bar) from engine no.
8395 and again changed according to SI1102 from
610B9250 (opening pressure 230 Bar) to 610B9220
(opening pressure 210 Bar) from engine no. 8845.

009W2329.XLS

H13

Causes and Remedies of the Fuel Pump

009W2329.XLS

IJ1

SECTION IJ

PISTON, CONNECTING ROD AND CYLINDER LINER

009W2329-R01

IJ2

CONTENTS

Disassembling of pistons and connecting rods .......................... page IJ 3

Assembling of pistons and connecting rods .............................. page IJ 3

Exchange of pistons .................................................................. page IJ 4

Measurement of piston .............................................................. page IJ 5-6

Piston rings ................................................................................ page IJ 7-8

Exchange of piston rings ........................................................... page IJ 9

Exchange of piston pin bearing in connecting rod ..................... page IJ 9

Arrangement of connecting rod (drawing) ................................. page IJ 10

Connecting rod bearings ........................................................... page IJ 11

Cylinder liner ............................................................................. page IJ 12

Measuring of cylinder wear ........................................................ page IJ 12

Dismounting of cylinder liner ..................................................... page IJ 12

Mounting of cylinder liner........................................................... page IJ 12

Test measurement of cylinder liner (drawing) ............................ page IJ 13

009W2329-R01

IJ3

Disassembling of Pistons and Connecting Rods

1. Drain off the cooling water and the lubricating oil from the engine.

2. Dismount the cylinder head (see section C).

3. Remove any wear or soot edge which may be at the top of the cylinder liner with a scraper.

4. Turn the engine “upside down”.

5. Remove the oil pan.

6. Unscrew the connecting rod nuts and remove the bearing cap from the connecting rod.

7. Fit the connecting rod bolts with protective caps (soft plastic hose or the like) in order

to avoid the crank being damaged.

8. Turn the piston in top position and press out the piston and the connecting rod of the

cylinder liner. The crank must be in the exact top position.

Note! On later engines the connecting rod nuts have been replaced by unbraco

screws and therefore item 7 can be omitted.

Assembling of Pistons and Connecting Rods

1. Put a slip ring over the cylinder liner.
(The slip ring may be made from a worn out cylinder liner , of which 2/3 should be re­moved and the remaining 1/3 should be turned weakly conical in the top end wanted.)

2. Place the crank in the top position.

3. Fit the connecting rod bolts with protective caps.

4. Lower the piston and the connecting rod down into the cylinder liner by means of the slip
ring and do observe that the piston ring gaps are staggered. It should further be checked
that the recess in the piston head is turned towards the fuel valve. Before fitting the
pistons and connecting rods lubricate the crank journals abundantly with lubricating oil.

5. Place the engine on the side or turn it “upside down”.

6. Remove the protective caps.

7. Fit the bearing cap with the bottom bearing shells.

8. Tighten the connecting rod nuts with a torque of 69 +/- 3 Nm (7 +/- 0.3 kpm). Use self­locking nylon nuts for the connecting rod bolts and replace the nuts after each
disassembling of the connecting rod.

Note! The numbers on the connecting rod must be placed as before the disassembling
of the engine and the numbers on the connecting rod and bearing cap must fit.
The bearing cap and the connecting rod are guided by two balls which you must have
in mind when assembling.

009W2329-R01

IJ4

Exchange of Pistons

If the pistons are scored or very worn, exchange them for new ones.

This is carried out as follows:

1. Remove the pistons with connecting rods as stated on page IJ 3.

2. Take off one of the locking rings at the gudgeon pin.

3. Knock out the gudgeon pin with a punch.

4. Place the new pistons upside down. Pour a little spirit into them and light it.
The heating can also take place on a boiling plate.

5. When the piston has reached a temperature of about 100°C, smother the fire. Place the
connecting rod in the piston before the oiled gudgeon pin is pushed in.

It is recommended to cool down the gudgeon pin first, e.g. in a deep freezer or by means
of nitrogen or carbonic acid, if it is possible.

6. Relock the gudgeon pin with the locking ring.

Carefully observe that the piston is placed correctly in proportion to the numbering on the
connecting rod.

Weight of piston complete: 1,088 grams ± 7 grams.

009W2329-R01

IJ5

Measurements for Piston

009W2329-R01

IJ6

009W2329-R01

IJ7

Piston Ring 1 (Please note page IJ4)

009W2329-R01

IJ8

Piston Ring 3 (Please note page IJ4)

009W2329-R01

IJ9

Exchange of Piston Rings

The piston ring gap is 0.3 – 0.45 mm (0.0118 - 0.0177 inch) in a new engine.

The wear of the piston rings ca n be seen by measuring the piston ring gap, and the piston rings
must be changed when this is max. 2.0 mm (0.0787 inch).

This is done as follows:

1. Take out the piston with connecting rod as stated on page IJ 3.

2. Remove the piston rings either by a spec ial pair of tongs or by m eans of two piec es of
string which have been folded. With the clos ed ends around the ends of the piston rin g,
the piston ring is extended and can be lifted clear of the piston.

The mounting is carried out in the reverse order after the piston ring grooves have been
cleaned. Rotary steel brushes or a steel scrapers should not be used as cleaning tools.

Each piston has three piston rings: two compre ssion rings and one oil scraper ring as shown
on the drawing page IJ4. The upper compre ssion ring are shown on page IJ 7 the lower
compression ring is a so called M-ring and the oil scraper ring is shown on page IJ8.

Exchange of Piston Pin Bearing in connecting rod

If heavy wear of the piston pin bearing in the connecting rod is found, it may be necessary to
exchange it. Particular attention should be paid when exchanging, as the bearing must be calibrated
to correct roundness and clearance after the fitting. This is either done with a calibration ball, as
indicated on page IJ10, or with a reamer with the tolerance mentioned.

009W2329-R01

IJ10

Arrangement of Connecting Rod

009W2329-R01

IJ11

Connecting Rod Bearings

The connecting rod bearings are in two parts and consists of two steel shells in which a thin layer of
bearing metal is cast.

The connecting rod bearings must be exchanged if they are scratched or if the “red” layer between
the bearing metal and the steel shell can be seen faintly.

When grinding the crank journal, connecting rod bearings can be supplied in following undersize:

0.6 mm (0.02362inch) (see section L).

009W2329-R01

IJ12

Cylinder liner

The bore of the cylinder liner is 85.000 – 85.020 mm (3.3464 – 3.3472 inch). The cylinder liner must
be exchanged when it is worn max. 0.3 mm (0.012 inch).

Measuring of Cylinder Wear

Place a new piston ring in the upper end of the liner where this is not worn. Measure the piston ring
gap with a feeler gauge. This will be e.g. 0.3 mm (0.012 inch). Place the piston ring lower in the liner
where it is worn and measure the piston ring gap again which is now e.g. 0.9 mm (0.0354 inch).

The wear of the liner is then (0.9 – 0.3) / 3 = 0.2 mm. That is: Largest measure less smallest measure
divided by 3 (approximate value for ¶).

The cylinder liner can also be measured with a cylinder template gauge.

Dismounting of Cylinder Liner

1. Remove the cylinder head (see section C page 7).

2. Take out the pistons (see page IJ 3).

3. Cover the connecting rod journals with a piece of oil paper or plastic.

4. Pull out the cylinder liners with a special tool or place the engine block on the side and knock out
the cylinder liners carefully with a wooden block as filling piece. Knock the liners from the bottom
and upwards.

Mounting of Cylinder Liner

There is no gasket between cylinder liner and the engine block at the top. The joint faces must
therefore be completely clean and without burrs. Grind with abrasive compound, if required.

The rubber rings of the lower edge of the cylinder liner must be renewed at each disassembly and
they must not be twisted

The rubber rings and the collar may be supplied with a thin coat of jointing paste at the mounting.

When the above things are in order put back the cylinder liner in the engine block – by means of a
wooden block.

After the mounting you must check the clearance of the liner above the engine block. This clearance
must be 0.10 – 0.20 mm (0.0039 – 0.0079 inch).

when mounting.

009W2329-R01

IJ13

Test Measurements of Cylinder Liner

009W2329-R01

SECTION L

CRANKCASE, CRANKSHAFT,

MAIN BEARINGS AND OIL SUMP

L1

009W2329-R01

L2

CONTENTS

Dismounting of crankshaft ......................................................... page L 3

Change of main bearings .......................................................... page L 3

Rear part of crank ...................................................................... page L 4

Rear gear-wheel and rear part of crank ..................................... page L 5

Marking of front gear-wheel on crank ........................................ page L 6

Front part of crank ..................................................................... page L 7

Repair dimensions of crakshaft ................................................. page L 8

Connecting rod journals ............................................................ page L 8

Main bearing journals ................................................................ page L 8

Main bearings ............................................................................ page L 8

Oil sump .................................................................................... page L 9

009W2329-R01

Dismounting of crankshaft

1. Remove the cylinder head with manifold (see section C page 4).

2. Dismount the flywheel (see section D page 3).

3. Dismount the gear (see section R page 3).

4. Dismount the rear end cover (see section G page 3).

5. Turn the engine upside down.

6. Remove the oil sump.

7. Dismount the pistons and the connecting rods (see section IJ page 3).

8. Dismount the front end cover (see section E page 3).

9. Remove the bearing caps and lift out the crank.

The mounting of the crankshaft takes place in reverse order, the bearing caps being fastened

L3

at a torque of 12 kpm (86.8 ft.lbf). Further make sure that the two thrust collars are correctly

fitted in accordance with the drawing below.

Change of main bearings

Proceed in the same way as when dismounting the crankshaft.

As will appear from the drawing below, the caps are stamped in proportion to corresponding
part of the engine block. Observe this marking when disassembling.

009W2329-R01

L4

Rear part of crank

The drawing below shows the rear part of the crank with screwing-on of the counter weights of
the crankshaft.

Drwg. No. 008E4757

009W2329-R01

Rear gear-wheel and rear part of crank

L5

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L6

Marking of front gear-wheel on crank

The front gear-wheel on the crank drives the front rotating weight and is marked in proportion to
this and in accordance with the drawing below.

The gear-wheel has been shrinked on the shaft. When shrinking on a new gear-wheel there
should be a difference of temperature between the crankshaft and the gear-wheel of 231 C.

Further see the drawing overleaf.

009W2329-R01

Front part of crank

L7

009W2329-R01

L8

Repair dimensions of crankshaft

The crankshaft is made of drop-forged, heat-treated steel. Thus it is possible to gring the
crankshaft without subsequent surface treatment.

The crankshaft must never be repaired with hard chromium-plate or metal feeding, but only by
grinding in accordance with the below mentioned measures and tolerances to which we supply
undersize bearings.

The crankshaft should be ground, if it is oval and the smallest diameter is 0.05 mm (0.002 inch)
below the diameter it had when leaving the factory.

Connecting rod journals

Standard .................................................................. 53.987 – 54.000 mm (2.1255 – 2.1260”)

0.6 mm undersize .................................................... 53.387 – 53.400 mm (2.1019 – 2.1024”)

Clearance between bearing and journal…………..…..0.028 – 0.068 mm (0.0011 – 0.0027”)

Main bearing journals

Standard .................................................................. 61.981 – 62.000 mm (2.4402 – 2.4409”)

0.6 mm undersize .................................................... 61.381 – 61.400 mm (2.4166 – 2.4173”)

Clearance between bearing and journal .................. ..0.048 – 0.112 mm (0.0019 – 0.0044”)

Main bearings

The engine is fitted with four two-piece main bearings as shown on the drawing below.
The bearings must be changed when the “red” layer under the bearing metal can be seen
faintly, or if the bearings are much scratched.

Bearing shell: C10 2.1 mm thick
Bearing material: tin aluminium with net structure
External surface: tinned 0.001 mm thick

009W2329-R01

Oil Sump

The engine is fitted with an oil sump of cast iron. The oil sump is fixed to the crankcase and is
ensured correct position to this by means of guide pins.

Under the oil sump the suction strainer for the lubricating oil system is placed and pipe
connections for it.

The oil sump with pipe arrangement for lubricating oil system is shown on the drawing below.

L9

009W2329-R01

M1

SECTION M

CAMSHAFT, COMPLETE

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M2

CONTENTS

Camshaft ................................................................................... page M 3

Valve timings ............................................................................. page M 4

Guide for push rod ..................................................................... page M 4

Gear-wheel of camshaft ............................................................ page M 5

Drawing of push rod .................................................................. page M 6

Drawing of push rod guide ......................................................... page M 7

009W2329-R01