Sisu Diesel Forius Engine Workshop Manual

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SisuDiesel

Fortius Series

Engines

Workshop Manual

03 08

Sisu Diesel Inc.

FIN-37240 Linnavuori, Finland

Telephone: +358 3 341 7111

E-mail: [email protected]

www.sisudiesel.com

Diesel Engines, After Sales

Telefax: +358 3 341 7333

Sisu Diesel Inc. takes no responsibility for any damages caused

because of possible incorrect information in this manual

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GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

TO THE USER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

ENGINE TYPE DESIGNATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

LOCATION OF THE ENGINE SERIAL NO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

MARKING OF THE EEM 2 CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

LIFTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

CONSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Valve mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Crank mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Timing gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Lubricating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Inlet and exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Cylinder block, 84-engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Cylinder liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Valves, rockers and tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Crankshaft, 84-engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Balancing unit, 44-engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Timing gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Timing gears, 84-engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Piston, rings and pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Piston, rings and pin, 84-engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Lubricating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Oil pump, 33- and 44-engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Oil pump, 66-, 74- and 84-engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Coolant pump, 33- and 44-engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Coolant pump, 66- and 74-engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Coolant pump, 84-engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Timing gear- and flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Cylinder head and valve mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Crank mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

1. CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

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A. Measuring cylinder liner wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

B. Removing cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

C. Checking cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

D. Changing camshaft bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

E. Fitting plug at camshaft rear end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

F. Oversize bushings for camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

G. Fitting plug at camshaft rear end (oversize bushings) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

H. Fitting cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

2. FLYWHEEL HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

A. Fitting flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

B. Changing crankshaft rear oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

3. CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

A. Removing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

B. Removing valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

C. Checking cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

D. Changing valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

E. Machining valve seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

F. Changing valve seat rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

G. Grinding valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

H. Fitting valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

I. Fitting cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

4. VALVE MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

A. Reconditioning valve mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

B. Changing camshaft / camshaft gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

C. Adjusting valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

5. CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

A. Removing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

B. Checking crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

C. Changing crankshaft gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

D. Fitting crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

E. Crankshaft hub piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

F. Checking element of the rubber damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

G. Viscose type vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

H. Changing crankshaft pulley / vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

6. CONNECTING RODS AND PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

A. Removing pistons together with connecting rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

B. Changing connecting rod bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

C. Checking connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

D. Changing piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

E. Checking pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

F. Fitting piston pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

G. Fitting piston together with connecting rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

7. COUNTERBALANCE (44-engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

A. Removing and disassembling counterbalance unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

B. Reconditioning counterbalance unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

C. Fitting counterbalance unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

D. Changing crankshaft gear rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

8. FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

A. Changing starter ring gear on flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

B. Fitting flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

9. TIMING GEAR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

A. Removing timing gear casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

B. Reconditioning idler gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

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C. Fitting timing gear casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

D. Idler gear with bevelled ball bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

E. Power take-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

9. TIMING GEAR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

A. Removing timing gear casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

B. Fitting timing gear casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

C. Fan drive device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

10. LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

A. Oil pressure regulating valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

B. Removing and dismantling lubricating oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

C. Assembling and fitting lubricating oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

D. Piston cooling nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

E. Fitting oil sump gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

F. Lubricating oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

G. Lubricating oil quality requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

H. Oil capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

11. COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

A. Quality requirements of coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

B. Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

C. Reconditioning coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

D. Coolant pumps with heavy duty bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

E. Reconditioning the coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

12. INLET AND EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

A. Checking air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

B. Checking inlet and exhaust pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

C. Checking turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

D. Fitting turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

13. FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

A. Removing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

B. Inspecting injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

C. Reconditioning injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

D. Fitting injector in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

E. Fitting delivery pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Bosch VE rotary pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Fuel system, description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

A. Bleeding the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

B. Measuring the fuel feed pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

C. Removing the fuel injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

D. Fitting the fuel injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Bosch VP 30 and VP 44 rotary pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Fuel system, description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

A. Bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

B. Measuring fuel feed pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

C. Removing fuel injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

D. Fitting fuel injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

E. Fuel quality requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

14. ENGINE CONTROL SYSTEM EEM 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Construction of the EEM 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

EEM 2 Engine Control System, description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Service tool of EEM 2 system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

A. Changing of Control Unit (ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Page 6

B. Sensors of Engine Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

15. ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

A. Alternators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

B. Starters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

16. OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

A. Compressor (Bendix) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

B. Compressor (Knorr) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

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General

GENERAL

TO THE USER

This Workshop Manual is intended to facilitate workshop operations and repair work.

Fortius series engines (types 33, 44, 66, 74 and 84) are mainly the same in construction, so the same repair instructions usually apply to different engine types. The differences between the various engine types which affect repair work have been mentioned in technical data and repair instructions. All measurements are in millimetres and valid when the temperature of the parts is +20°C, unless otherwise stated.

Before starting the repair work read the safety instructions in the beginning of this book. Make sure that you have all necessary tools, parts and accessories at your disposal. The special tools mentioned in the work instructions are not all essential, but they speed up and facilitate the work and contribute to successful execution of work. An engine which has undergone repairs must be run in just like a new one.

Should the engine require measures not described in this manual, please consult your local agent or the Service Department of Sisu Diesel Inc., Linnavuori, Finland. To facilitate consulting, find out the following facts about the engine before contacting us:

- engine type

- engine number

- application or equipment

- hours operated or kilometres driven.

In this Workshop Manual the regular service procedure is not handled as this is explained in the Fortius series Instruction Manual.

As Sisu Diesel Inc. is continuously developing the products, all rights are reserved without separate notice to change the adjustments, accessories and service- and repair procedure.

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Page 8

General

SAFETY INSTRUCTIONS

In the use and service of the engine there is always the possibility of injury. Before starting the service read and understand the following safety instructions and remarks!

Do not start a repair work that you do not fully handle.

Make sure that the place of the repair and the surrounding gives the possibility for safe working.

Always be sure of the cleanness and the good order of the repairing place.

Do not use faulty or otherwise useless tools.

Remove all finger rings, chains and watch before starting work.

Use up-todate protection equipment when you work. For example eye protection as working with compressed air for cleaning, grinding, hammering or other work.

Use lifting device for lifting and transporting heavy (over 20 kg) pieces. make sure of good condition of lifting hooks and chains. The lifting ears on the engine must not be applied by side forces when lifting.

Never work under an engine that is left handling under a lifting device or lifted up by a jack. Always use strong supports before starting the work.

Use only genuine SisuDiesel spare parts.

Avoid touching the exhaust manifold, turbocharger and the other hot parts of the engine.

Open the radiator cap with care when the engine is hot as the cooling system is pressurised. The cooling liquid and lubrication oil of a hot engine causes injuries when touching the skin.

Open fire, smoking and sparks should not be allowed near the fuel system and batteries. (Specially when loading batteries, explosive.)

Always disconnect the minus (-) wire of the battery when doing service or repair of the electric system.

At temperatures on excess of 300°C, e.g. if the engine is burnt by a fire, the viton seals of the engine (e.g. the undermost o-ring of the cylinder liner) produce very highly corrosive hydrofluoric acid. Do not touch with bare hands, viton seals subjected to abnormally high temperatures. Always use neoprene rubber or heavy duty gloves and safety glasses when decontaminating. Wash the seals and the contaminated area with a 10% calcium hydroxide or other alkali solution. Put all removed material in sealed plastic bags and deliver them to the point stated by the Authorities concerned. Note! Never destroy viton-seals by burning!

When checking fuel injectors do not let the jet of high pressure fuel contact your skin. The fuel penetrates the skin causing severe injuries. Contact your doctor immediately!

The fuel, lubricating oil and coolant cause irritation in skin contact for long time.

Start the engine only by using the starting switch in the cabin.

Do not start an engine if the protection covers are removed. Note! The fan is difficult to see as the engine is running! Make sure that wide clothes or long hear is not caught in the rotating parts of the engine.

If you start the engine indoors, be sure you have proper ventilation.

Never use aerosol type of starting aid! (Risk for explosion.)

When you are operating the engine or working near it, use hearing protectors to avoid noise injuries.

Stop the engine always before service- or repair work.

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Avoid unnecessary idling of the engine.

Do not let oil and other liquids drop into the soil when servicing the engine.

All the gaskets of the engine are of non-asbestos material.

Be careful when washing the engine with a high pressure washing machine. Do not use high pressure to wash e.g. the electric and fuel equipment or the radiator because they can easily be damaged.

Page 9

ENGINE TYPE DESIGNATIONS

Equipped with intercooler

= air-to-air

= air-to-water

Turbocharged engine

= by-pass turbo

T = standard turbo

Basic type

74 = cylinder displacement, decilitres

= electronic engine management

D = mechanical injection pump

General

LOCATION OF THE ENGINE SERIAL NO.

The engine serial number is always stamped on the cylinder block as the picture shows.

The serial number is also markes on the type plate.

Type

SISUDIESEL 74.234 ETA

Power

135 kW 2200 rpm

Serial nr

M07575

Valve

0,35 mm

clearance Timing

23 degrees

TDC

Low idle

650 rpm

Cust.

N 5853420

Part nr EU

D20AEE

Family EPA

YSIDL07.4C2A

Family

Displace ment: 7.4 l

Assembled by:

M07575

Manufacturer

SISU Diesel Inc .

FIN-372 40 Linnavuor i

FINLAND

Fuel: 2-D fuel oil

e17*97/68EA*97/68EA*0016*00

This engine conforms to199 U.S EPA

regul ations l arge nonro ad compress ion

ignition engines

M07576

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Page 10

General

MARKING OF THE EEM 2 CONTROL UNIT

The specification of the application is indicated on the type plate of the EEM 2 control unit. This specification must always be stated when ordering a control unit or asking for adjusting settings.

Note! The engine meets EU97/68/EC Stage 2 and EPA 40 CFR 89 Tier 2 emission requirements.

Do not fit any components on the engine other than those originally suited for it. The use of other than original SisuDiesel spare parts invalidates the responsibility of Sisu Diesel Inc. on the fulfilment of the emission requirements.

Manufacturer

SISU Diesel Inc.

FIN-37240 Linnavuori

FINLAND

EEM 2 Engine Control Unit

Hw. ver.

Partno

836864630

Cust. Part no

Engine Serial nr

M07575

Type

74 ETA

LIFTING THE ENGINE

Safe lifting of the engine is done with a lifting device where the lifting force effects the lifting ears vertically.

Weight of engine

Engine type

33 280 44 340 66 510 74 520 84 660

*) Dry weight without flywheel and electrics

A = Engine lifting ears

Weight kg *)

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Page 11

General

CONSTRUCTION

Technical data

Engine type 33 44 66 74 84

Principal dimensions and data

Number of cylinders 34666

Displacement (ltr) 3,3 4,4 6,6 7,4 8,4

Cylinder bore (mm) 108 108 108 108 111

Stroke (mm) 120 120 120 134 145

Combustion Direct injection

Injection timing (installation mark) Marked on the crankshaft pulley/damper

Valve clearance, intake and exhaust (mm) 0,35 (cold or hot)

Direction of rotation from the engine front Clockwise

Fuel system

Injection pump

Stanadyne DB4

Bosch VP 30

Bosch VP 44

Bosch P 7100

Fuel The fuel must be according to norm EN 590,

see page 93

Injection order 1-2-3 1-2-4-3 1-5-3-6-2-4

Feed pressure at idle speed 1,0...1,2 bar

Injector Five-hole nozzle

Opening pressure of the nozzle 270 bar

Adjusting pressure of the nozzle 278 bar

Fuel filters

Pre-filter Stanadyne 30 µ

Final filter Stanadyne 5 µ

Lubrication system

Oil pressure in hot engine at running speed 2,5...5,0 bar

Oil pressure at idle speed, min 1,0 bar

Oil capacity see page 73

Oil quality requirements see page 73

Cooling system

Number of thermostats 1 1 1/2 2 2

Opening temperature ∅ 54 mm = 79°C ∅ 67 mm = 83°C

Coolant quality requirements see page 74

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Page 12

General

The Fortius engine series consists of water-cooled inline diesel engines with three, four and six cylinders. The turbocharged engines are equipped with wet, changeable cylinder liners.

The all engine types have a rigid and ribbed cylinder block. The crank mechanism is designed for supercharging. The cylinder liners are wet and supported at the middle. The cylinder head bolts are high tensile bolts.

Cylinder block

The cylinder block is the main body of the engine, to which other engine parts are attached. Wet and replaceable cylinder liners are supported at the middle which reduces vibrations and directs coolant circulation mainly to the upper part of the liners.

The seal between the cylinder liner lower part and the cylinder block is achieved by three o-rings, which are fitted in grooves in the liner. The upper part is sealed by the cylinder head gasket.

The camshaft is located in the cylinder block. The camshaft front bearing location is fitted with a separate bearing sleeve. The remaining bearing locations are machined directly in the cylinder block. The 66-, 74- and 84-engines have separate bearing sleeves in all camshaft bearing locations. The drilling for the camshaft rear end is covered with a plug.

There are spaces on both sides of the rear main bearing for guide bearing shims (the crankshaft thrust bearings).

Flywheel housing

The flywheel housing is fitted at the rear end of the cylinder block. The seal for the crankshaft rear end is placed in a bore in the housing. The starter motor fixing point is fitted in the flywheel housing.

The lower face of the flywheel housing functions as a sealing surface for the oil sump gasket. This means that the lower face of the cylinder block must be level with the flywheel housing. When fitting the flywheel housing, its position is determined by tension pins.

The flywheel housing are delivered according to the requirements set, by the engine application and different flywheel housings can be mounted on all engine types.

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Page 13

General

Cylinder head

Crank mechanism

The crankshaft is forged from chrome alloy special steel and is induction hardened at the bearing and sealing surfaces. This makes it possible to grind bearings four times without a new heat treatment. Gear wheels are located at the front end of the crankshaft. They are a press fit, and drive the idler wheel and oil pump. In addition, the front end of the crankshaft has splines for the hub of the V-belt pulley. An oil deflector ring is fitted between the hub and gear wheel, and a dust shield is fitted on the hub in order to protect the seal.

The crankshaft is supported on the cylinder block by main bearings which are placed on both sides of each cylinder. Thus there is one main bearing more than cylinders. The crankshaft thrust washers are placed in both sides of the rearmost main bearing.

At the rear end of the crankshaft there is fitted a flywheel on which is a press-fit a starter ring gear. The forged connecting rod has an I-section cross-section. The bearing location at the bottom end of the connecting rod is fracture-split, and the bearing cup is secured by two special elongated screws. The upper part has a wedgeshaped bearing location, in which the piston pin bearing bushing is fitted with a press fit.

33- and 44-engines have one cylinder head. 66-, 74and 84-engines have two cylinder heads which are exchangeable with each other and also with the cylinder head on the 33-engine. Each cylinder has its own inlet and exhaust ports located on either side of the head. Between hot exhaust valves a cool inlet valve is fitted to balance the thermal load.

Cylinder head bolts are high tensile bolts which are tightened up to yield limit using angle tightening principle. Due to the large stretch the tightening forces are kept constant during the whole lifetime and retightening is unnecessary.

The injector locations are machined directly into the cylinder head. The inlet and exhaust valve guides are identical and can be interchanged. Exhaust valves are fitted with separate valve seat rings. Also the engines with high output are equipped with separate inlet valve seats.

Valve mechanism

The piston is made of an eutectic aluminium alloy. In the upper face of the piston there is a combustion chamber. The shape of the chamber is intended to maximise the mixture of air and fuel. The upper ring location is formed in a cast iron ring which is cast in the piston. In addition, the piston is graphite coated to ensure correct runningin.

The piston has three rings. The upper molybdenum-coated ring has a wedge-shaped cross-section. On some slight supercharged engines the upper ring is right-angled. The middle ring is tapered and it fits into its groove. The taper taking up the clearance. The oil control ring is spring loaded and it has a two-stage, chromed scraping edge.

Some four-cylinder engines (44) are equipped with a balancer unit. The eccentric weights, which rotate at twice the engine speed, even out the vibration forces exerted by the movement of the pistons and the crank mechanism.

The valve mechanism is operated by the camshaft which is located in the cylinder block. The drive is transferred with the help of tappets and push rods. The camshaft gear wheel is fitted with a press fit and fixed with a key. Each bearing is lubricated by the force feed lubrication system through drilled oilways in the cylinder block.

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Page 14

General

Timing gears

33-, 44-, 66- and 74-engines

The timing gear train consists of hardened, helically cut gear wheels. The gears are encased by the timing gear casing which is fitted to the front of the engine. The timing gear drives the camshaft, fuel injection pump and oil pump.

If the engine is equipped with a hydraulic pump, it is driven via a gear or a separate drive unit.

The idler gear is supported with a bearing sleeve / ball bearing (66- and 74-engines) on the shaft on the front face of the cylinder block. Two different dimensions of gear and shaft is used.

84-engines

There are two main types of a timing gear assemblies, so-called narrow (A) and broad (B) timing gear casing.

If the engine is equipped with the broad timing gear casing, there is a separate drive unit for a hydraulic pump or a compressor. The drive unit is driven via a small idler gear.

The idler gear is supported with a bevelled ball bearing on the shaft on the front face of the cylinder block.

Timing gears

1. Camshaft gear

2. Idler gear

3. Injection pump gear

4. Coolant pump gear

5. Crankshaft gears

6. Oil pump gear

7. Small idler gear

8. P.T.O. gear

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Page 15

Lubricating system

General

The engine has a pressure lubricating system in which the oil pump (gear pump) is attached to the cylinder block lower face. The oil is sucked up by the pump through a suction strainer. After the pump the oil is led through an oilway to the oil pressure regulating valve via the oil cooler to the oil filter. After the filter, the oil is led through the main oil gallery from which oilways branch out. The oil is led through the oilways in the main bearings and through the crankshaft to the big-end bearings.

The oil is further directed from the main gallery to the turbocharger and to a possible compressor. In addition, the camshaft bearing points and the valve mechanism get their lubrication oil via the main oil gallery.

Lubricating system (66- and 74-engines)

1. Oil pump

2. Oil pressure regulating valve

3. Oil filter

4. Turbocharger

5. Main oil gallery

6. Piston cooling nozzle

7. Oil pressure sensor

The oil filter is of main flow type. It has a replaceable cartridge mounted on the left side of the engine, 84-engines on the right side. At the bottom of the oil filter cartridge there is a by-pass valve for cold start or possible clogging of the filter.

Some engine types are equipped with a oil cooler located between the cylinder block and the oil filter. All oil that circulates through the filter also goes through the cooler and is cooled by the engine coolant circulating in the oil cooler.

The 84-engines are equipped with an plate type oil cooler, that is situated on the right side of the engine above the filter. The cooler is of main flow type.

The undersides of the pistons of the engines with high output are always cooled by the oil spray when the oil pressure is more than 3 bar.

The oil pressure regulating valve is located under the oil filter on the left side of the engine, 84-engines on the right side. The regulating valve keeps the oil pressure constant, independent of the engine speed. At working speed the oil pressure is 2,5 to 5 bar depending on the temperature and the quality of lubricating oil. At idling the pressure is 1,0 bar minimum.

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Page 16

Cooling system

General

Cooling system (84-engine)

1. Radiator

2. Coolant pump

3. By-pass pipe

4. Thermostats

5. Expansion tank

6. Oil cooler

The coolant pump is attached to the front face of the cylinder block and the thermostat housing is mounted above it.

On 84-engines, the gear driven coolant pump is attached to the front face of the timing gear housing. The thermostat housing is mounted on front end of the cylinder head.

The system has the internal liquid circulation via the bypass pipe. The circulation is regulated by the 2-way thermostat. This arrangement ensures a steady warming-up of the engine under all conditions.

In some 66- and 74-engines and 84-engines there are two separate thermostats where one of them is steering the by-pass of coolant liquid. The thermostats differ in types and opening temperatures. When the coolant temperature is below the thermostat opening temperature the coolant (A) circulates through the by-pass hole into the coolant pump. The smaller, singleacting thermostat (1) opens first (at 79°C) letting one part of the coolant (B) into the radiator. Following the load increase, also the other thermostat (2) opens (at 83°C). This is a double-acting type which closes the by-pass hole when it opens and directs the coolant (C) into the radiator. These engine models do not have any separate winter-type thermostats.

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Inlet and exhaust system

General

The filter system for the engine inlet air comprises a cyclone type pre-cleaner, and a paper filter which acts as the main filter. The incoming air is made to rotate in the cyclone pre-cleaner. This causes most of the impurities to settle out and collect in the cyclone pre-cleaner dust collector. The paper filter comprises one or two replaceable filter elements. The paper is corrugated and surrounded by a metal support.

The impurities in the air collect at the larger filter element which can be cleaned when necessary. The inner safety filter prevents impurities form entering the engine should the main filter element break, or be fitted incorrectly.

A mechanical or electrical service indicator can be mounted on the filter housing or on the inlet pipe to show when the filter cartridge is clogged. The inlet system also includes the hoses between the air cleaner and the turbocharger and the turbocharger and the intake manifold.

The exhaust manifold is attached to the cylinder head with high tensile bolts without a separate gasket. Retightening of the manifold bolts is unnecessary.

The turbocharger is a turbo-compressor driven by exhaust gas. The compact design of the turbocharger is fast to react even during low revolutions. The turbocharger is lubricated and cooled by the lubrication system of the engine. EWA-engine is equipped with a by-pass turbocharger where excessive air pressure is adjusted by a so-called by-pass channel. The boost pressure is adjusted correctly by the manufacturer, and must not be changed afterwards.

The compressed air is cooled on the air-to-air basis. The air coming from the turbocharger has a temperature abt. 150°C which is cooled by the cooling air of the engine. The intercooler's cell is ideally installed in front of the radiator or side-by-side with radiator. The cooling of the compressed air stabilises the combustion, irrespective of the temperature, and minimises the thermal and mechanical load of the engine thus lowering nitric oxides (NOx) and particles (PT). Certain engine versions can also be equipped with an air-to-water intercooler. In that case, the engine specification is ETI.

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General

TECHNICAL DATA

Cylinder block

Holes for guide pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13,250...13,320 mm

Main bearing housing diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91,000...91,025 mm

Main bearing housing diameter (with bearing 8361 40950) . . . . . . . . . . . . . . . . . 92,000...92,025 mm

Cylinder liner location, diameter:

- upper end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124,514...124,554 mm

- lower end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123,000...123,040 mm

Inner diameter of camshaft bushing (fitted). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50,010...50,070 mm

Height of cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428,170...428,430 mm

Cylinder block, 84-engines

Holes for guide pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13,250...13,320 mm

Main bearing housing diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96,000...96,025 mm

Cylinder liner location, diameter:

- upper end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125,014...125,054 mm

- lower end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121,000...121,040 mm

Inner diameter of camshaft bushings (fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50,010...50,070 mm

Height of cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468,900...469,100 mm

Cylinder liners

Protrusion of cylinder liner above cylinder block top face . . . . . . . . . . . . . . . . . . . 0,030...0,080 mm

Max. permissible height difference between liners (under same head) . . . . . . . . 0,02 mm

Outer diameter of cylinder liner guide:

- at upper end of liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124,475...124,500 mm

- at lower end of liner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122,961...122,986 mm

Liner bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108,010...108,032 mm

84-engines

Outer diameter of cylinder liner guide:

- at upper end of liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124,975...125,000 mm

- at lower end of liner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120,966...120,991 mm

Liner bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111,000...111,022 mm

Height of cylinder liner flange, std . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9,03...9,05 mm

Height of cylinder liner flange, 1st oversize. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9,08...9,10 mm

Height of cylinder liner flange, 2nd oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9,13...9,15 mm

Height of cylinder liner flange, 3rd oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9,23...9,25 mm

Outer diameter of cylinder liner flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131,700...131,800 mm

Cylinder head

Height of cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104,800...105,000 mm

Height of cylinder head after repair grinding (minimum) . . . . . . . . . . . . . . . . . . . . 104,000 mm

Inside diameter of valve guide (not fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9,000...9,015 mm

Outside diameter of valve guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16,028...16,039 mm

Diameter of valve guide bore in cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . 16,000...16,018 mm

Position of valve guide top above cylinder head surface . . . . . . . . . . . . . . . . . . . 21 mm

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General

Depth of valve head face below cylinder head surface:

- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,7±0,05 mm (max. 2,20 mm)

- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,6±0,05 mm (max. 2,20 mm)

Angle of valve seat:

- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35°+20'

- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°+20'

Width of valve seat:

- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,9...3,7 mm

- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,3...2,3 mm

Diameter of exhaust valve seat ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44,070...44,132 mm

Diameter of exhaust valve seat rings recess . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44,000...44,025 mm

Diameter of exhaust valve seat ring (overhaul part 8366 52269) . . . . . . . . . . . . . 44,270...44,332 mm

Diameter of exhaust valve seal ring recess (overhaul part 8366 52269) . . . . . . . 44,200...44,225 mm

Diameter of inlet valve seat ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48,570...48,632 mm

Diameter of inlet valve seat ring recess . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48,500...48,525 mm

Diameter of inlet valve seat ring (overhaul part 8368 55347) . . . . . . . . . . . . . . . . 48,770...48,832 mm

Diameter of inlet valve seat ring recess (overhaul part 8368 55347) . . . . . . . . . . 48,700...48,725 mm

Valves, rockers and tappets

With a valve clearance of 1,0 mm:

- inlet valve opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0°±2° B.T.D.C

- inlet valve closes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16°±2° A.B.D.C

- exhaust valve opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39°±2° B.B.D.C

- exhaust valve closes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1°±2° A.T.D.C

Valve clearance cold and hot:

- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,35 mm

- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,35 mm

Angle of valve seat in cylinder head:

- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35°+20'

- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°+20'

Width of valve seat in cylinder head:

- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,9...3,7 mm

- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,3...2,3 mm

Angle of valve face:

- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35°-20'

- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°-20'

Outside diameter of valve head:

- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 mm

- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 mm

Max valve movement:

- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10,9 mm

- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12,1 mm

Inlet valve stem diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8,960...8,975 mm

Exhaust valve stem diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8,925...8,940 mm

Inlet valve stem clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,025...0,055 mm

- Reject limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,30 mm

Exhaust valve stem clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,060...0,090 mm

- Reject limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,35 mm

Inside diameter of valve guide before fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9,000...9,015 mm

Outside diameter of valve guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16,028...16,039 mm

Diameter of valve guide bore in cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . 16,000...16,018 mm

Protrusion of valve guide top above cylinder head surface. . . . . . . . . . . . . . . . . . 21 mm

Depth of valve face below cylinder head surface:

- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,7±0,05 mm (max. 2,20 mm)

- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,6±0,05 mm (max. 2,20 mm)

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General

Valve spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69,8 mm

Spring pressure when spring compressed to a length of:

- 48,6 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327±17 N

- 37,4 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500±23 N

Rocker arm shaft diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22,970...22,990

Diameter of rocker arm bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23,000...23,021

Max. permissible push rod deflection (when free). . . . . . . . . . . . . . . . . . . . . . . . . 0,4 mm

Free length of rocker arm spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 mm

Spring pressure when spring compressed to a length 58 mm . . . . . . . . . . . . . . . 80...100 N

Outside diameter of tappet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29,939...29,960 mm

Diameter of tappet bore in cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30,000...30,043 mm

Camshaft

Diameter of camshaft bearing journal no 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49,925...49,950 mm

Diameter of camshaft bearing journals (others that no. 1) . . . . . . . . . . . . . . . . . . 49,885...49,910 mm

Diameter of camshaft bearing journals nos 2, 3 and 4 (66/74/84-engines) . . . . . 49,865...49,890 mm

Inside diameter of camshaft bearing bushes (when fitted in position) . . . . . . . . . 50,010...50,070 mm

Diameter of camshaft bearing bores (others than no. 1). . . . . . . . . . . . . . . . . . . . 50,000...50,025 mm

Camshaft clearance in bearing bush no. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,060...0,145 mm

Camshaft clearance in bearing bushes (others than no. 1) . . . . . . . . . . . . . . . . . 0,090...0,140 mm

Camshaft clearance in bearing bushes nos 2, 3 and 4 (66/74/84-engines) . . . . . 0,110...0,160 mm

Bearing bush tolerance in block (press fit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,025...0,080 mm

Diameter of bearing bush bore in block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55,620...55,650 mm

Camshaft end play with 0,5 mm gasket between cylinder block and timing gear

housing and between timing gear housing and front cover. . . . . . . . . . . . . . . . . . 0,5...1,0 mm

Cam height (distance between back of cam and tip of cam):

- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41,180...41,430 mm

- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40,080...40,330 mm

Cam lift:

- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7,38 mm

- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8,28 mm

Camshaft max. permissible deflection (total indicator reading). . . . . . . . . . . . . . . 0,03 mm

Crankshaft

Crankpin diameter:

- standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67,981...68,000 mm

- 1. undersize 0,25 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67,731...67,750 mm

- 2. undersize 0,50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67,481...67,500 mm

- 3. undersize 1,00 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66,981...67,000 mm

- 4. undersize 1,50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66,481...66,500 mm

Crankpin length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40,000...40,160 mm

Main bearing journal diameter:

- standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84,985...85,020 mm

- 1st undersize 0,25 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84,735...84,770 mm

- 2nd undersize 0,50mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84,485...84,520 mm

- 3rd undersize 1,00 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83,985...84,020 mm

- 4th undersize 1,50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83,485...83,520 mm

Main bearing housing diameter (in cylinder block) . . . . . . . . . . . . . . . . . . . . . . . . 91,000...91,025 mm

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General

Main bearing shell thickness:

- standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,955...2,965 mm

- 1st undersize 0,25 mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,080...3,090 mm

- 2nd undersize 0,50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,205...3,215 mm

- 3rd undersize 1,00 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,455...3,465 mm

- 4th undersize 1,50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,705...3,715 mm

- bearing 8361 40950 (see instruction 5 B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,705...3,715 mm

Main bearing clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,050...0,127 mm

Length of thrust bearing journal (journal nearest to flywheel):

- standard (2 standard thrust plates) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45,000...45,080 mm

- 1st oversize (one std and one 0,1 mm overthick thrust plate) . . . . . . . . . . . . . . 45,100...45,180 mm

- 2nd oversize (one std and one 0,2 mm overthick thrust plate) . . . . . . . . . . . . . . 45,200...45,280 mm

- 3rd oversize (one 0,1 mm and one 0,2 mm overthick thrust plate). . . . . . . . . . . 45,300...45,380 mm

- 4th oversize (two 0,2 mm overthick thrust plates). . . . . . . . . . . . . . . . . . . . . . . . 45,400...45,480 mm

Other crankshaft journals may not be ground longer.

Crankshaft end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,100...0,380 mm

Max. permissible ovality and other deformity of crankpins or journals . . . . . . . . . 0,03 mm

Crankshaft unbalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,0 Ncm max.

Balancing unit ring gear location, diameter (44-engines) . . . . . . . . . . . . . . . . . . . 150,220...150,260 mm

Balancing unit ring gear I.D. (44-engines). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150,000...150,040 mm

Crankshaft, 84-engines

Crankpin diameter:

- standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72,981...73,000 mm

- 1. undersize 0,25 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72,731...72,750 mm

- 2. undersize 0,50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72,481...72,500 mm

- 3. undersize 1,00 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71,981...72,000 mm

- 4. undersize 1,50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71,481...71,500 mm

Crankpin length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40,000...40,160 mm

Main bearing journal diameter:

- standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89,985...90,020 mm

- 1st undersize 0,25 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89,735...89,770 mm

- 2nd undersize 0,50mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89,485...89,520 mm

- 3rd undersize 1,00 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88,985...89,020 mm

- 4th undersize 1,50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88,485...88,520 mm

Main bearing housing diameter (in cylinder block) . . . . . . . . . . . . . . . . . . . . . . . . 96,000...96,025 mm