Page 1
WORKSHOP MANUAL
SISUDIESEL 645
8368 41000
Page 2
Sisudiesel
645
engine
Workshop Manual
02 02
Sisu Diesel Inc.
FIN–37240 Nokia, 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 incorrect information in this manual
Page 3
Contents
0 --- 0
CONTENTS
TO THE USER 0 --- 1.........................................................................
Engine type designations 0---1..........................................................
Location of the engine serial no. 0--- 2....................................................
Lifting the engine 0 --- 2.................................................................
SAFETY INSTRUCTIONS 0 --- 3................................................................
SPECIAL TOOLS 0 --- 4.......................................................................
ENGINE SPECIFICATION 0 --- 6................................................................
TECHNICAL DATA 0 --- 7......................................................................
Cylinder block 0 --- 7...................................................................
Cylinder liner 0 --- 7.....................................................................
Cylinder head 0 --- 7....................................................................
Valves, rocker arms and tappets 0--- 8....................................................
Camshaft 0 --- 8........................................................................
Crankshaft 0 --- 9.......................................................................
Flywheel 0 --- 9........................................................................
Timing gears 0 --- 10.....................................................................
Connecting rod 0 --- 10..................................................................
Piston, piston rings and pin 0---11........................................................
Lubricating system 0 --- 11................................................................
Oil pump 0 --- 11........................................................................
Coolant pump 0 --- 1 2....................................................................
Thermostat 0 --- 12......................................................................
Turbocharger 0 --- 12....................................................................
TIGHTENING TORQUES 0 --- 13................................................................
CONSTRUCTION 0 --- 14.......................................................................
General 0 --- 14.........................................................................
Cylinder block 0 --- 14...................................................................
Flywheel housing 0 --- 14.................................................................
Cylinder head 0 --- 15....................................................................
Valve mechanism 0 --- 1 5.................................................................
Crank mechanism 0 --- 15................................................................
Timing gears 0 --- 16.....................................................................
Lubricating system 0 --- 17................................................................
Cooling system 0 --- 18..................................................................
Inlet and exhaust system 0-- -19..........................................................
WORK INSTRUCTIONS
1. CYLINDER BLOCK
A. Measuring cylinder liner wear 1---1....................................................
B. Removing cylinder liner 1-- -1.........................................................
C. Checking cylinder block 1---1.........................................................
D. Changing camshaft bushing 1---1.....................................................
E. Fitting plug at camshaft rear end 1---2.................................................
F. Oversize bushings for camshaft 1---3..................................................
G. Fitting plug at camshaft rear end (oversize bushings) 1---3................................
H. Fitting cylinder liner 1-- -4.............................................................
2. FLYWHEEL HOUSING
A. Fitting flywheel housing 2---1.........................................................
B. Changing crankshaft rear oil seal 2---1.................................................
3. CYLINDER HEAD
A. Removing cylinder head 3---1........................................................
B. Removing valves 3 --- 1...............................................................
C. Checking cylinder head 3--- 1.........................................................
D. Changing valve guides 3---2..........................................................
E. Machining valve seat 3-- -2...........................................................
F. C h an gi n g v a lv e s e a t r i n g 3 --- 3........................................................
G. Grinding valves 3 --- 3................................................................
H. Fitting valves 3 --- 3..................................................................
I. Fitting cylinder head 3-- -4............................................................
4. VALVE MECHANISM
A. Reconditioning valve mechanism 4---1.................................................
B. Changing camshaft/camshaft gear 4---1................................................
C. Adjusting valves 4 --- 2...............................................................
Page 4
Contents
0 --- 0
5. CRANKSHAFT
A. Removing crankshaft 5---1...........................................................
B. Checking crankshaft 5--- 1............................................................
C. Changing crankshaft gears 5---1......................................................
D. Fitting crankshaft 5 --- 2...............................................................
E. Checking vibration damper 5---2......................................................
6. CONNECTING RODS AND PISTONS
A. Removing pistons together with connecting rods 6---1....................................
B. Changing connecting rod bearings 6---1...............................................
C. Checking connecting rod 6---1........................................................
D. Changing piston rings 6---3..........................................................
E. Checking pistons 6 --- 3..............................................................
F. Fitting piston pin 6 --- 4...............................................................
G. Fitting piston together with connecting rod 6--- 4.........................................
7. FLYWHEEL
A. Changing starter ring gear on flywheel 7---1............................................
B. Fitting flywheel 7 --- 1.................................................................
8. TIMING GEAR ASSEMBLY
A. Removing timing gear casing 8 ---1....................................................
B. Fitting timing gear casing 8--- 1........................................................
9. TENSIONING DEVICE
A. Tensioning device for ribbed belt 9 --- 1.................................................
B. Fan drive device 9 --- 1...............................................................
10. LUBRICATION SYSTEM
A. Reconditioning of oil relief valve for lubricating oil pressure 10---1...........................
B. Removing and dismantling lubricating oil pump 10---1.....................................
C. Assembling and fitting lubricating oil pump 10---2.........................................
D. Fitting oil sump gasket 10 --- 2..........................................................
E. Piston cooling nozzles 10--- 2..........................................................
E. Oil cooler 1 0 --- 3.....................................................................
G. Lubrication oil quality requirements 10--- 4...............................................
11. COOLING SYSTEM
A. Quality requirements of coolant 11---1..................................................
B. Thermostat 1 1 --- 1....................................................................
C. Reconditioning coolant pump 11--- 2....................................................
12. INLET --- AND EXHAUST SYSTEM
A. Checking air cleaner 12--- 1............................................................
B. Checking inlet and exhaust pipes 12---1.................................................
C. Checking turbocharger 12--- 1.........................................................
D. Fitting turbocharger 12--- 2............................................................
E. Fitting intercooler 1 2 --- 3..............................................................
13. FUEL SYSTEM
IN---LINE FUEL INJECTION PUMP
Technical data 1 3 --- 1...................................................................
A. Bleeding fuel system 13---6...........................................................
B. Bleeding thermostart system 13--- 6.....................................................
C. Measuring fuel feed pressure 13--- 7....................................................
D. Checking overflow valve 13- --7........................................................
E. Changing fuel feed pump valves 13 ---7.................................................
F. Checking injection timing 13---7........................................................
G. Adjusting fuel injection timing 13---9....................................................
H. Adjusting idling speed 13--- 9..........................................................
I. Removing fuel injection pump 13---9....................................................
J. Fitting fuel injection pump 13---10.......................................................
K . R e m o v i n g i n j e c t o r s 1 3 --- 1 0.............................................................
L . In s p e c t i n g i n j e c t o r s 13 --- 1 0.............................................................
M. Reconditioning injectors 13---11.........................................................
N. Fitting injector in engine 13 ---12.........................................................
O. Fitting delivery pipes 13---12............................................................
Fuel quality requirement 13---13...........................................................
14. EQUIPMENT AND FEEDING TABLES
15. ELECTRICAL SYSTEM
A. Alternators 1 5 --- 1....................................................................
B. Starters 1 5 --- 5.......................................................................
C. Fitting stop solenoid 15 - --8............................................................
D. Installation of magnetic pick up 15--- 8...................................................
E. Temperature sensor 15---8............................................................
Page 5
645 DSBAEL
Application
A = vehicle engine
G= generating set engine
L = combine harvester engine
M= marine engine
P=pump set engine
Equipped with intercooler
A=airtoair
I = air to water
Equipped with Bosch P---type injection pump
Turbocharged engine (W, if equipped with by --- pass turbo)
Basic type (E, if equipped with electronic engine control)
Number of cylinders
E = emission tested engine (certified) for off--- road
C= emission tested engine (certified) for on---road
To th e U s e r
0 --- 1
TO THE USER
This workshop Manual for Sisudiesel 645---diesel engines is intended to facilitate workshop operations and repair work.
645--- engines are mainly the same in construction, so the same repair instructions usually apply to different engine versions. The
differences between the various engine versions 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:
--- e n g i n e t y p e
--- 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 645---engines Operator’s 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.
Engine type designations
Page 6
WARNING
4 0 --- 2
A
A
To th e U s e r
0 --- 2
Location of the engine serial no.
4 0 --- 1
Lifting the engine
Safe lifting of the engine is done with a lifting device
where the lifting force effects the lifting ears vertically.
A = Engine lifting ears
Engine weight (dry, without flywheel and electrical equipment).
--- self carrying and casted oil sump 826 kg
--- normal oil sump 690 kg
Page 7
Safety Instructions
0 --- 3
SAFETY INSTRUCTIONS
In the service--- and repair work of the engine there is always the possibility of injury. Before starting the work
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 surround-
ing 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 start-
ing 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.
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 while operating
the thermostart device (risk for explosion).
When you are operating the engine or working near it,
use hearing protectors to avoid noise injuries.
Stoptheenginealwaysbeforeservice--- orrepairwork.
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 oil pressure regulating valve) 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.
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 8
Special Tools
0 --- 4
SPECIAL TOOLS
Order no Description
1 9104 51500 Puller for cylinder liner
2 9104 52000 Milling cutter for cylinder liner seat
3 9104 52700 Centring tool for flywheel housing
4 9104 52600 Drift for fitting rear crankshaft seal
5 9103 94600 Drift for fitting front crankshaft seal
6 9052 46620 Drift for 40 mm cup plug
7 9052 46650 Drift for 16 mm cup plug
8 9025 87400 Drift for fitting camshaft cup plug
9 9101 66300 Press tool for cylinder liner
10 9025 79200 Holder for dial gauge
11 9101 66100 T--- handle for valve seat milling cutter
12 9101 71100 Milling cutter for facing exhaust valve seat
13 9101 65502 Milling cutter for exhaust valve seat
14 9101 65503 Inner milling cutter for exhaust valve seat
15 9101 75800 Milling cutter for facing inlet valve seat
16 9101 65505 Milling cutter for inlet valve seat
17 9101 65506 Inner milling cutter for inlet valve seat
18 9101 66200 Lever for compressing valve spring
19 9052 47200 Counter nut for lever above
20 9101 66000 Milling tool for injector seat
21 9052 46660 Drift for 36 mm cup plug
22 9101 65800 Drift for removing valve guide
23 9101 65900 Drift for fitting valve guide
24 9024 55800 Spanner for crankshaft nut
25 9103 94700 Drift for fitting crankshaft gears
26 9103 41300 Drift for fitting coolant pump bearings
27 9105 18700 Conical sleeve for fitting pistons
28 9052 46900 Piston ring pliers
29 9103 94900 Drift for fitting oil deflector ring, crankshaft front end
30 9103 94800 Drift for 45 mm cup plug
31 9025 98700 Drift for fitting tension pins in timing gear casing and flywheel housing
32 9104 53300 Puller for crankshaft hub
33 9104 05400 Centring tool for idler gear, broad timing gear casing
34 9104 34600 Centring pin for idler gear, narrow timing gear casing
35 9103 41000 Fitting tool for coolant pump shaft seal
36 9103 41100 Fitting tool for coolant pump water seal
37 9052 48900 Extractor for injection pump gear
38 9104 52800 Injection timing check pin
39 9104 53700 Extractor for injector
Page 9
Special Tools
0 --- 5
1
2
3
4
6
7
8
9
10
5
11
12
13
14
15
16
17
18
19
21
22 23
24
26
25
29
27
30
31
20
28
39
38
37
4 0 --- 3
32
33
34
35
36
Page 10
Engine Specifications
0 --- 6
ENGINE SPECIFICATIONS
PRINCIPAL DIMENSIONS AND DATA
Motor type 645...................................................
Number of cylinders 6...........................................
Displacement (ltr) 8,4..............................................
Cylinder bore (mm) 111............................................
Stroke (mm) 145..................................................
Combustion Direct injection..................................................
Compression ratio 16/17:1.............................................
Injection timing (B.T.D.C.) Marked on the flywheel or damber.......................................
Valve clearance, intake and exhaust (mm) 0,35 (cold or hot).........................
Direction of rotation from the engine front Clockwise.........................
Compression pressure (bar)
1
24....................................
1
) Minimum value at operating temperature and starting revs. Max permitted difference
between cylinders 3,0 bar.
FUELSYSTEM
Injection pump Bosch, in --- line type................................................
Fuel Gas oil, see page 13---13.........................................................
Feed pressure
--- overflow valve opening pressure 0,6 --- 1,0 bar...............................
--- static 2,7 bar......................................................
I n j e c t i o n o r d e r 1 --- 5 --- 3 --- 6 --- 2 --- 4................................................
Injector Four/five hole nozzle......................................................
Opening pressure of the nozzle See page 14 --- 3..................................
Adjusting pressure of the nozzle See page 14 - --3.................................
Fuel filter CAV.....................................................
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 (ltr) See page 10 --- 4...............................................
COOLING SYSTEM
Numbers of thermostats 2........................................
Opening temperature ˚C Æ54 mm = 79 Æ67 mm = 83.......................................
Coolant liquid See page 11 --- 1.................................................
Page 11
Technical Data
0 --- 7
TECHNICAL DATA
Cylinder block
Holes for guide pins 13,250...13,320 mm........................................................
Main bearing housing diameter 96,000...96,025 mm...............................................
Cylinder liner location, diameter:
--- u p p e r e n d 125,014...125,054 mm...............................................................
--- l o w e r en d 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 124,975...125,000 mm......................................................
--- at lower end of liner 120,961...120,986 mm.......................................................
Liner bore 111,000...111,022 mm.................................................................
Height of cylinder liner flange 9,03...9,05 mm.................................................
Height of cylinder liner flange, 1st oversize, part no 8368 59581 9,08...9,10 mm....................
Height of cylinder liner flange, 2nd oversize, part no 8368 59582 9,13...9,15 mm...................
Height of cylinder liner flange, 3rd oversize, part no 8368 59583 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..........................
Depth of valve head face below cylinder head surface:
--- i n l e t v a l v e 0,7±0,05 mm (max 2,20 mm)...............................................................
-- - exhaust valve 0,6±0,05 mm (max 2,20 mm)............................................................
Angle of valve seat:
--- i n l e t v a l v e 35˚
+20’
...............................................................
--- exhaust valve 45˚
+20’
............................................................
Width of valve seat:
--- i n l e t v a l v e 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.................
Page 12
Technical Data
0 --- 8
Valves, rockers and tappets
With a valve clearance of 1,0 mm:
--- i n l e t v a l v e o p e n s 0 ˚±2˚ B.T.D.C.........................................................
--- i n l e t v a l v e c l o s e s 1 6 ˚±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:
--- i n l e t v a l v e 0,35 mm...............................................................
--- exhaust valve 0,35 mm............................................................
Angle of valve seat in cylinder head:
--- i n l e t v a l v e 35˚
+20’
...............................................................
--- exhaust valve 45˚
+20’
............................................................
Width of valve seat in cylinder head:
--- i n l e t v a l v e 2,9...3,7 mm...............................................................
--- exhaust valve 1,3...2,3 mm............................................................
Angle of valve face:
--- i n l e t v a l v e 35˚
--- 2 0 ’
...............................................................
--- exhaust valve 45˚
--- 2 0 ’
............................................................
Outside diameter of valve head:
--- i n l e t v a l v e 48 mm...............................................................
--- exhaust valve 41 mm............................................................
Max valve movement:
--- i n l e t v a l v e 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....................................................
--- R e j e c t l i m i t 0,30 mm..............................................................
Exhaust valve stem clearance 0,060...0,090 mm................................................
--- R e j e c t l i m i t 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:
--- i n l e t v a l v e 0,7±0,05 mm (max 2,20 mm)...............................................................
-- - exhaust valve 0,6±0,05 mm (max 2,20 mm)............................................................
Valvespringfreelength 69,8mm......................................................
Spring pressure when spring compressed to a length of:
--- 4 8 , 6 m m 327±17 N................................................................
--- 3 7 , 4 m m 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 nos 2, 3 and 4 49,865...49,890 mm............................
Diameter of camshaft bearing journals no 5 49,885...49,910 mm.....................................
Inside diameter of camshaft bearing bushes (when fitted in position) 50,010...50,070 mm...............
Camshaft clearance in bearing bush no 1 0,060...0,145 mm......................................
Camshaft clearance in bearing bushes nos 2, 3 and 4 0,110...0,160 mm............................
Camshaft clearance in bearing bushes no 5 0,090...0,140 mm....................................
Bearing bush tolerance in block (press fit) 0,025...0,080 mm......................................
Page 13
Technical Data
0 --- 9
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):
--- i n l e t v a l v e 41,180...41,430 mm...............................................................
-- - exhaust valve 40,080...40,330 mm............................................................
Cam lift:
--- i n l e t v a l v e 7,38 mm...............................................................
--- exhaust valve 8,28 mm............................................................
Camshaft max. permissible deflection (total indicator reading) 0,03 mm.....................
Crankshaft
Crankpin diameter:
--- s t a n d a r d 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:
--- s t a n d a r d 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...............................
Main bearing shell thickness:
--- s t a n d a r d 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....................................................
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.
Corner rounded of crankpins and journals R4+0,5 mm......................................
Crankshaft end float 0,100...0,380 mm.........................................................
Max. permissible ovalness and other deformity of crankpins or journals 0,03 mm.............
Crankshaft unbalance 1,0 Ncm Max........................................................
Flywheel
Interference fit between ring gear - -- flywheel 0,425...0,600 mm.....................................
Before fitting the ring gear , heat up to a temperature of 150...200˚C...........................
Flywheel unbalance 1,0 Ncm Max.........................................................
Max permissible axial wobble of flywheel clutch face, measured at inner edge
of clutch face on diameter 200 0,06:ø200................................................
Page 14
Technical Data
0 --- 1 0
Timing gears
Tooth backlash:
Crankshaft---idler gear 0,05...0,25 mm.......................................................
Idler gear --- camshaft gear 0,05...0,25 mm....................................................
Idler gear --- fuel injection pump gear 0,05...0,25 mm...........................................
Max. permissible side wobble of gears 0,05 mm.........................................
Idler gear shaft, diameter 49,995...50,011 mm....................................................
Inner diameter of idler gear bearing hole 89,955...89,990 mm.......................................
Camshaft gear hole diameter 32,000...32,025 mm.................................................
Camshaft end diameter 32,043...32,059 mm......................................................
Timing marks:
Timing marks on gears are in alignment when the 1st cylinder piston is at its top dead centre between
compression and power strokes.
On crankshaft gear 2 dots on tooth.........................................................
On idler gear:
--- against crankshaft gear mark 1 dot on tooth...............................................
--- against camshaft gear mark 1 dot on tooth................................................
--- against fuel injection pump gear mark 2 dots on notch.......................................
On camshaft gear 1 dot on notch..........................................................
On injection pump gear 1 dot on notch.....................................................
Connecting rod
Inside diameter of piston pin bush (with bush pressed into connecting rod) 44,025...44,040 mm..........
Outside diameter of piston pin bush (std) 48,080...48,120 mm.......................................
Outside diameter of piston pin bush (oversize 8363 38606) 48,580...48,620 mm........................
Interference fit: connecting rod small end bushing ---connecting rod 0,057...0,120 mm................
Connecting rod small end bore 48,000...48,025 mm...............................................
Connecting rod small end bore (oversize bush) 48,500...48,525 mm.................................
Connecting rod big end bore 76,730...76,749 mm.................................................
Big end bearing shell thickness:
--- s t a n d a r d 1,833...1,842 mm................................................................
--- 1st undersize 0,25 mm 1,958...1,967 mm....................................................
--- 2nd undersize 0,50 mm 2,083...2,092 mm...................................................
--- 3rd undersize 1,00 mm 2,333...2,342 mm....................................................
--- 4th undersize 1,50 mm 2,583...2,592 mm....................................................
Big---end bearing clearance 0,046...0,102 mm..................................................
End float (side clearance) at big ---end on crankshaft 0,200...0,312 mm.............................
Piston pin bushing location perpendicular to longitudinal axis of connecting
rod to be within 0,10:100............................................................
Piston pin bushing location and big --- end bearing location to be parallel to within 0,05:100.....
Weight marking (letter) at lower end.
Max. permissible weight difference between connecting rods in the same engine 20 g.....
Position of connecting rod; weight marking at valve mechanism side
(away from the combustion chamber in the piston)
Page 15
Technical Data
0 --- 1 1
Piston, rings and pin
Minimum distance between piston and cylinder head (measured with a piece
of lead wire thought the injector location hole) 0,900...1,150 mm....................................
Piston diameter:
-- - 15 mm from lower edge 110,863...110,877 mm....................................................
Pin bore in piston 44,003...44,009 mm............................................................
Piston pin diameter 43,994...44,000 mm..........................................................
Width of ring grooves:
--- 1 s t g r o o v e wedge shaped ring................................................................
--- 2 n d g r o v e 2,520...2,540 mm................................................................
--- 3 r d gr o o v e 4,040...4,060 mm...............................................................
Side clearance of piston rings in their grooves:
--- 1 s t r i n g wedge shaped ring..................................................................
--- 2 n d ri n g 0,03...0,062 mm.................................................................
--- 3 r d ri n g 0,05...0,082 mm..................................................................
--- r e j e c t l i m i t 0,15 mm................................................................
Piston ring height (in direction of cylinder):
--- 1 s t r i n g wedge shaped ring..................................................................
--- 2 n d ri n g 2,478...2,490 mm.................................................................
--- 3 r d ri n g 3,975...3,990 mm..................................................................
Piston ring gap (with piston fitted in cylinder)
--- 1st ring (wedge shaped ring) 0,35...0,50 mm................................................
--- 2 n d ri n g 0,60...0,80 mm.................................................................
--- 3 r d ri n g 0,30...0,60..................................................................
-- - reject limit 1. and 3. ring 1,0 mm....................................................
--- reject limit 2. ring 1,3 mm..........................................................
Max. permissible weight difference between pistons in same engine 25 g.................
Piston to be heated up to 100˚C before fitting gudgeon pin.
Piston position in cylinder: combustion chamber of piston to face towards injector.
Lubricating system
Oil pressure at normal running temperature:
--- at idling speed (min.) 1,0 bar......................................................
--- at running speed 2,5...5,0 bar..........................................................
Free length of oil pressure valve spring 71 mm.........................................
Spring pressure when valve spring is compressed to a length of 52 mm 74+5 N.............
Diameter of oil pressure valve plunger 19,602...19,635 mm..........................................
Diameter of oil pressure valve cylinder 19,700...19,752 mm..........................................
Oil filter by --- pass valve opens at a pressure difference of 2±0,5 bar..........................
Oil pump
Backlash between gears when crankshaft lies firmly against the lower side of main bearings:
--- crankshaft gear ---lubricating oil pump gear 0,05...0,25 mm....................................
--- between the pump gears 0,16...0,26 mm...................................................
Diameter of drive shaft at bearings for body and cover 17,966...17,984 mm............................
Diameter of drive shaft bearing hole on body and cover 18,000...18,018 mm...........................
Diameter of fixed shaft at gear wheel 17,966...17,984 mm...........................................
Inner diameter of bearing for gear wheel which rotates on fixed shaft 18,000...18,018 mm................
Fixed shaft in pump body, diameter 20,035...20,048 mm............................................
Protrusion of fixed shaft end below pump body face 0,5 mm..............................
Thickness of cover gasket 0,06...0,08 mm....................................................
Outer diameter of gear wheels 55,824...55,870 mm.................................................
Housing diameter 56,000...56,120 mm...........................................................
Thickness of gears 32,000...32,027 mm...........................................................
End play of gears 0,03...0,11 mm............................................................
Depth of housing 32,000...32,043 mm............................................................
Number of teeth on drive gears 46 pcs................................................
Page 16
Technical Data
0 --- 1 2
Coolant pump
Outside diameter of bearing 52 mm..................................................
Inside diameter of bearing housing in pump body 51,970...52,000 mm...............................
Shaft diameter at bearing 24,996...25,009 mm....................................................
Shaft diameter at impeller 15,907...15,920 mm....................................................
Impeller hole diameter 15,881...15,899 mm.......................................................
Diameter of the water seal recess in the pump body 39,981...40,020 mm..............................
Thermostat
Spare part number Type Opening Fully Max. stroke
begins at open at mm
8360 15156 ø54/79˚C79˚±2˚C94˚C7,5
8363 31590 ø67/83˚C83˚±2˚C95˚C8
Turbocharger
Schwitzer S2B
Max. axial end play 0,14 mm.........................................................
Max. radial play
1
)0,95mm...........................................................
Turbine housing attaching bolts 17 Nm...............................................
Nut on end of shaft 15,6 Nm.........................................................
1
) Measured at nut on end of shaft.
Schwitzer S300
Min. axial end play 0,05 mm..........................................................
Max. axial end play 0,12 mm.........................................................
Max. radial play, turbine end 0,64 mm.................................................
Max. radial play, compressor end 0,88 mm.............................................
Turbine housing attaching bolts 22 Nm...............................................
Compressor housing attaching bolts 13,5 Nm...........................................
Nut on end of shaft 20,3 Nm.........................................................
Page 17
Tightening Torques
0 --- 1 3
TIGHTENING TORQUES
Object Nm
Cylinder head bolts 80 Nm +90˚+90˚
( s e e p a g e 3 --- 4 ).......................................................
Cylinder head studs to cylinder block 30............................................
Main bearing bolts 200...........................................................
Connecting rod bolts
seepage6---2......................................................
Crankshaft nut 1000..............................................................
Oil pump gear nut 60............................................................
Crankshaft pulley bolts 80........................................................
Flywheel bolts 200...............................................................
Flywheel housing bolts:
-- - outer ring M12 110............................................................
--- i n n e r r i n g M 1 0 60..............................................................
Belt tightener shafts bolts:
--- M 1 0 80......................................................................
--- M 1 6 200.....................................................................
Idler gears retaining bolts:
-- - the bigger bolt (M14) 180.......................................................
--- the bolts for holding the bearing (M8) 22..........................................
Piston cooling valve 30...........................................................
Oil pump retaining bolts 60.......................................................
Coolant pump gear nut 180.......................................................
Exhaust manifold nuts 50.........................................................
Intake manifold bolts 30..........................................................
Injection pump gear nut 200......................................................
Injector attaching nuts (on studs) 15................................................
Injector nozzle sleeve 60..........................................................
Always use the torque values listed in the following tables when specific torque values are not available.
M8 M10
Cast iron 35±5 Nm 70±5 Nm
Aluminium 25±5 Nm 50±5 Nm
Use a washer with the aluminium parts.
The bolts of a self carrying oil sump
1 M8 12.9 30 Nm
2 M10 12.9 90 Nm
3 M12 12.9 150 Nm
4 M16 10.9 300 Nm
5 M20 10.9 700 Nm
6 M22 10.9 700 Nm
Page 18
4 0 --- 4
Construction
0 --- 1 4
CONSTRUCTION
General
6 4 5 --- e n g i n e i s l i q u i d c o o l e d , 6 --- c y l i n d e r, 4 --- s t r o k e , i n --- l i n e
diesel engine with direct injection. It is designed with wet, replaceable, mid support cylinder liners, oil --- cooled pistons
and two separate cylinderheads.
The engines 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 cylinder block. The upper part is sealed by the
cylinder head gasket.
The camshaft is located in the cylinder block. 645---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.
Page 19
Construction
0 --- 1 5
4 0 --- 5
Cylinder head
645---engines have two cylinder heads which are exchangeable with each other. 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. In addition, the inlet and exhaust valves
are equipped with replaceable valve seat inserts.
Valve 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 pushrods. 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 motor block.
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 ribbed V ---belt pulley. An
oil deflector ring is fitted between the hub and gear wheel.
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 --- s e c t i o n cr o s s --- s e c t i o n . T h e b e a r i n g l o c a t i o n a t
the bottom end of the connecting rod is angle split, and the
bearing cup is secured by two special elongated bolts. The
upper part has a wedge ---shaped bearing location, in which
the piston pin bearing bushing is fitted with a press fit.
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 piston has three rings. The upper molybd e n u m --- c o a t e d ri n g h a s a we d g e --- s h a p e d c r o s s --- s e c t i o n .
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.
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 running --- in.
Page 20
1
2
3
4
6
5
1
2
3
4
6
5
7
8
4 0 --- 6
Construction
0 --- 1 6
Timing gears
There are two main types of a timing gear assemblies, so --called narrow --- and broad timing gear casing.
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, oil pump and coolant
pump.
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.
Narrow timing gear casing
1. Camshaft gear
2. Idler gear
3. Injection pump gear
4. Coolant pump gear
5. Crankshaft gears
6. Oil pump gear
Broad timing gear casing
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
Page 21
1
2
3
4
5
6
9
7
8
4 0 --- 7
Construction
0 --- 1 7
Lubricating system
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
relief 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 injection
pump, 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.
In 645 ---engines is the bottom of the piston cooled with oil
spray always when the oil pressure is higher than 3 bar.
The oil pressure regulating valve is located on the right---hand
side of the engine. The valve regulates the lubricating oil pressure so that it is kept constant, regardless of the engine
speed. Oil pressure is about 2,5...5 bar depending on revs,
oil quality and temperature, and at engine idling speed the
pressure is min 1,0 bar.
Lubricating system
1. Oil pump
2. Oil pressure regulating valve
3. Oil cooler
4. Oil filter
5. Piston cooling nozzle
6. Main oil bore
7. Turbocharger
8. Injection pump
9. Oil pressure sensor
The oil filter is of main flow type. It has a replaceable cartridge
mounted on the right side of the engine. At the bottom of the
oil filter cartridge there is a by --- pass valve for cold start or
possible clogging of the filter.
The 645---engines are equipped with a oil cooler of plate type,
that is situated on the right side of the engine above the filter.
The cooler is of main flow type.
Page 22
4 0 --- 8
1
2
3
4
5
6
Construction
0 --- 1 8
The cooling system
1. Radiator
2. Coolant pump
3. By ---pass pipe
4. Thermostats
5. Expansion tank
6. Oil cooler
Cooling system
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 by --- pass pipe. The circulation is
regulated by the 2---way thermostat. This arrangement ensures a steady warming ---up of the engine under all conditions.
The coolant pump has separate ball bearings.
In 645---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, single --- acting 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.
C
A
B
A
1
2
4 0 --- 9
Page 23
40--- 10
Construction
0 --- 1 9
Inlet and exhaust system
The filter system for the engine inlet air comprises a cyclone
type precleaner, and a paper filter which acts as the main filter.
The incoming air is made to rotate in the cyclone precleaner.
This causes most of the impurities to settle out and collect in
the cyclone precleaner 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
elongated stud bolts without a separate gasket. Retightening
of the manifold bolts is unnecessary.
The turbocharger is turbo ---compressor driven by exhaust
gas. The compact design of the turbocharger is sensitive to
react even during low revolutions. The turbocharger is lubricated and cooled by the lubrication system of the engine.
DW/DWI engine is equipped with a by --- pass turbocharger
where the highest air pressure is adjusted by so--- called by--pass channel.
The compressed air is cooled by the air to water basis. The air
coming from the turbocharger has a temperature about
150˚C which is cooled by the cooling water of the engine
down to about 95˚C. The cooling cell is installed on the intake
manifold and connected to the engine cooling system. The
cooling of the compressed air stabilised the combustion, irrespective of the temperature, and minimises the thermal and
mechanical load of the engine thus lowering nitric oxides
(NO
x
). There can be also air to air intercooler in the certain en-
gine versions.
Page 24
Cylinder Block
1 --- 1
WORK INSTRUCTIONS
1. CYLINDER BLOCK
A. Measuring cylinder liner wear
1. Using a micrometer set the dial gauge to zero using a new
cylinder liner indicating the initial dimension of the bore:
111,00 mm.
2. Clean the inner surface of the cylinder liner thoroughly
before measurement.
4 1 --- 1
3. Perform the measurement crosswise at the liner top end,
lower end and middle.
4. Check the gauge reading for maximum wear and ovalness
(compare with rated).
B. Removing cylinder liner
1. If the cylinder liners are to be used again they should be
marked so that they can be fitted in the same position.
9104 51500
4 1 --- 2
2. Remove the cylinder liners using cylinder liner puller 9104
51500.
C. Checking cylinder block
1. Clean the cylinder block and all oil ways.
2. Check the cooling channels and remove the scale and
sediment to ensure engine cooling.
3. Check the tightness of the cup plugs and threaded plugs
in the cylinder block as well as the condition of the cylinder
block and sealing faces.
4. Measure the wear of the camshaft bearing points (compare with rated).
Note! If it is necessary to machine the upper face of the cylinder block, the pistons must be shortened by the same dimension. Observe the valve disc spaces on the piston upper face.
D. Changing camshaft bushing
On the 645 --- engines, all camshaft bearing points are provided with a separate bearing bushing.
1.Remove the camshaft rear end plug and tap the bushings
out with a long drift. Observe the different outer diameters
when removing.
2. Clean the bushings location carefully.
Page 25
12345
4 1 --- 3
4 1 --- 4
4
51
2
3
272 mm
266 mm
134 mm
7,2...8,0 mm
0,1...0,4 mm
Cylinder Block
1 --- 2
Order numbers of the camshaft bushings and hole diameters
for the bushings.
Note! Numbering begins from the front end of the engine.
3. Press in a new bushings. Observe the different outer diameters. Note the position of the oil hole. It is unnecessary to
ream the bushing because it has a correct inner diameter
when it is fitted in place.
30˚
41--- 4/1
Note! From engine number L 17961 the cam shaft front end
bushing is equipped with the oil groove on the outside (the
groove was earlier on the cam shaft). As spare part the earlier
bushing always be replaced with the new one. Fit the hole of
the new bushing in 30˚ angle from horizontal level as picture
shows. The bushing is after assembly in its correct measures
(no need for machining).
Order no. Hole diameter
1. 8363 22610 55,62...55,65
2. 8368 52460 55,42...55,45
3. 8368 52459 55,22...55,25
4. 8368 52460 55,42...55,45
5. 8368 52461 55,64...55,67
E. Fitting plug at camshaft rear end
1. Clean the seat for the plug.
2. Apply sealing compound to the contact surface of the plug
4 1 --- 5
max. 1,0 mm
3. Drive in the plug with fitting drift 9025 87400.
Note! Do not drive in the plug too far because it will affect the
camshaft end float.
Page 26
4
5 1
2
3
272 mm
266 mm
134 mm
7,2...8,0 mm
4 1 --- 6
0,1...0,4 mm
Cylinder Block
1 --- 3
F. Oversize bushings for camshaft
If the location of the camshaft bushing is damaged, a bushing
with a 0,2 / 0,4 mm oversize outer diameter can be fitted.
Camshaft oversize bearing bushings. Numbering begins
from the front end of the engine.
Press in a new bushings. Observe the different outer diameters. Note the position of the oil hole. It is unnecessary to
ream the bushing because it has a correct inner diameter
when it is fitted in place.
G. Fitting plug at camshaft rear end
(oversize bearing bushings)
4 1 --- 7
The camshaft rear end plug is replaced with plug 8363 24391
and o --- ring 6146 05125 after machining. Use plate 8361
24210 in those engines where the flywheel housing is not
covering the blocking plug.
Order no. Hole diameter
1. 8363 24661 56,02...56,05
2. 8368 52466 55,62...55,65
3. 8368 52460 55,42...55,45
4. 8368 52466 55,62...55,65
5. 8368 52467 55,84...55,87
Page 27
Cylinder Block
1 --- 4
H. Fitting cylinder liner
1. Clean the cylinder liner and its recess in the cylinder block.
Without o ---rings the liner should rotate easily in its recess.
2. Apply a thin layer of marking paint on the underside of the
cylinder liner flange. Fit the cylinder liner without o --- rings and
turn it forwards and backwards. Lift out the liner and check
that paint has been deposited on the whole contact surface.
4 1 --- 8
9104 52000
3. If the recess is damaged, or the cylinder liner height (see
point 5) needs to be adjusted, use milling cutter 9104 52000.
If necessary, a light lapping can be executed after milling with
the help of the cylinder liner. Apply lapping paste to the underside of the cylinder liner flange, and twist the liner with
twisting tool. Lapping is not suitable for adjusting the cylinder
liner height.
4. Clean the contact surfaces.
9101 66300
9025 79200
4 1 --- 9
0,03...0,08 mm
5. Fit the cylinder liners and fix each liner with two press tools
910166300. Measure the cylinder liner height with a dial
gauge and holder 9025 79200. Zero the dial gauge against a
flat surface, for example, the cylinder block face. Measure
each liner in four places. The height of the liner above the cylinder block face should be 0,03...0,08 mm. The height difference between cylinder liners under the same cylinder head
must not exceed 0,02 mm, nor must an intermediate cylinder
liner lie lower than an outer one.
6. If the cylinder liner height is too low, a liner with a higher
flange is fitted.
41--- 10
H
Order no. H Marking grooves
pcs
8368 55445
8368 59581
8368 59582
8368 59583
9,03
+0,02
9,08
+0,02
9,13
+0,02
9,23
+0,02
--- ( s t d . )
1
2
3
Cylinder liners with oversize flanges (higher flanges) are
marked with grooves on the outer circumference as follows:
1st oversize, 0,05 mm = 1 marking groove
2nd oversize, 0,10 mm = 2 marking grooves
3rd oversize, 0,20 mm = 3 marking grooves
Note! Recess depth is adjusted with a cylinder liner recess
cutter 9104 52000.
7. If the liner height of a cylinder liner is not the same all the
way round, the cylinder liner flange and the cylinder block recess depth should be checked. Cylinder liners with warped
flanges should be discarded.
Page 28
41--- 11
Cylinder Block
1 --- 5
Black
Green
8. Fit the o --- rings into the grooves in the cylinder block and
lubricate them with a liquid soap (not with engine oil).
41--- 12
9. Press the cylinder liners into the cylinder block. It should be
easy to press them fully home. Make sure that the liners do
not rise up after fitting.
Page 29
Flywheel Housing
2 --- 1
2. FLYWHEEL HOUSING
A. Fitting flywheel housing
The flywheel housing is centred on the cylinder block by two
tension pins. Even the flywheel housings which are delivered
as spare parts have ready --- made holes for the pins.
1. Clean the sealing surfaces between the cylinder block and
the flywheel housing.
4 2 --- 1
2. Apply silicone sealing as shown in figure above.
E
E
E
A
4 2 --- 2
3. Lift the flywheel housing into place and fit all the bolts.
Note! Use a spring washers under the bolts in the holes A
and E !
9104 52700
4 2 --- 3
4. Centre the housing with centring tool 9104 52700 (Note!
This is important of the engines with a turbine clutch). Fit the
tension pins with drift 9025 98700.
5. Tighten the fixing bolts, the inner ring socket head bolts to
60 Nm and outer ring hexagonal bolts to 110 Nm.
B. Changing crankshaft rear oil seal
1. Lift out the engine. Remove the clutch assembly (and possible turbine clutch).
2. Remove the flywheel.
3. Remove the oil seal. Do not damage the crankshaft.
4. Clean the seal location and grind off any burrs.
4 2 --- 4
Note! If the crankshaft is worn at the sealing location, a 2 mm
spacer ring, part no 8360 20054, can be fitted in front of the
crankshaft rear oil seal.
Page 30
Flywheel Housing
2 --- 2
5. Fit the seal as follows:
--- Do not remove the plastic sleeve in before hand.
--- NOTE! FIT THE SEAL DRY, NOT OILED
T
O
4 2 --- 5
O = Sleeve
T=Seal
-- - Put the sleeve against the crankshaft rear end so that the
sleeve is on the shaft bevelling.
--- Push the seal over the sleeve on the shaft and further
against the flywheel housing.
9104 52600
4 2 --- 6
-- - Remove the sleeve and hit the seal into position with the fit-
ting tool 9104 52600.
Page 31
Cylinder Head
3 --- 1
3. CYLINDER HEAD
A. Removing cylinder head
1. Clean the engine externally and drain the coolant. Disconnect the coolant hoses from the cylinder head and the thermostat housing.
2. Remove the suction hoses between the turbocharger and
the air filter and between the turbocharger and the intake
manifold.
3. Disconnect the turbocharger pressure and return oil pipes.
4. Remove the pipes to the thermostart fuel reservoir.
5. Remove the injector leak---off fuel pipes and the delivery
pipes. Remove the injectors. Fit blanking--- off caps on all
open connections.
6. Remove the intake and exhaust manifolds and the thermostat housing.
Note! It is possible to remove the cylinder head even thought
these parts are attached to the head.
7. Remove the valve cover and the breather hose.
8. Remove the rocker arm mechanism and the push rods.
9. Loosen all the cylinder head bolts first by a 1/4 turn and
then remove them. Remove the cylinder head.
B. Removing valves
Ensure that valves which are to be re---used are marked, so
that they are fitted in their original locations.
9052 47200
4 3 --- 1
9101 66200
1. Install the counter screw 9052 47200 for the valve spring
installing tool in the rocker arm cover bolt. For the valves in the
middle, use a bolt of suitable length.
2. Compress the valve springs using lever 9101 66200. Remove the valve cotters, spring guide and spring. Remove the
valves.
C. Checking cylinder head
1. Remove the soot from the exhaust ports, clean the sealing
surfaces and wash the cylinder head.
2. Check for cracks and other damage.
4 3 --- 2
3. Check the flatness of the cylinder head by using a straight
edge. An uneven or warped surface should be surface
ground. The height of the cylinder head, after grinding,
should not be less than 104,00 mm.Thevalvediscdepth
from the cylinder head surface should be 0,60 mm for the
exhaust valves and 0,70 mm for the inlet valves.
9101 66000
4 3 --- 3
4. Straighten and clean the injector location seat in the cylinder head with cutter 9101 66000.
Page 32
Cylinder Head
3 --- 2
4 3 --- 4
5. Measure the clearance between the valve stem and the
valve guide with a dial gauge. Lift the valve so that the valve
head is 15 mm from the face of the cylinder head, and
measure the clearance. It must not be greater than 0,30 mm
for the inlet valves and 0,35 mm for the exhaust valves. In
ordertoestablishthevalveguidewear,anewvalveshouldbe
used when measuring.
D. Changing valve guides
9101 65800
4 3 --- 5
1. Press or knock out the old guides using drift 9101 65800.
Clean the valve guide locations.
2. Lubricate the outside of the new guides and fit them using
drift 9101 65900, which ensures the correct fitting height (21
mm over the spring face).
21 mm
9101 65900
4 3 --- 6
3.Theguidesarethesamefortheinletandexhaustvalves.
Ensure that the steepest chamfer on the guide, faces the
valve head. Check that the valves do not bind in the guides.
E. Machining valve seat
4 3 --- 7
9101 66100
Machine the damaged valve seat with milling cutter. If the
width of the seat exceeds 2,3 mm in exhaust and 3,7 mm in
intake, it should be reduced primarily at the outer edge.
The valve seat angle is 45˚
+20’
for exhaust valve and 35˚
+20’
for inlet valve.
Page 33
44,000...44,025
10,1
4 3 --- 8
48,500...48,525
11
±0,1
Cylinder Head
3 --- 3
F. Changing valve seat rings
Exhaust and inlet valves are fitted with separate valve seat
rings. If the sealing surface is damaged so badly that it cannot
be repaired with machining, the seat ring should be changed.
1.Grindthevalveheadonadiscardedvalvesothatitsits
down in the valve seat. Fit the valve and weld it in place in the
seat. Cool with water.
2.Turnthecylinderheadoverandknockoutthevalveand
seat.
EXHAUST
INLET
3. Clean the valve seat location and check dimensions. Cool
the new seat ring in liquid nitrogen until it stops bubbling, or
alternatively place it in dry ice.
4. Fit the seat with a suitable drift. Machine the seat.
Note! Where necessary, standard size seats can be replaced
by inserts with a larger outer diameter . See technical data,
point cylinder head.
G. Grinding valves
In order to ensure that there is a proper seal around the
valves, there is a difference in the sealing surface angles.
Thus there is a very narrow sealing surface which seals effectively even after prolonged running.
A
B
4 3 --- 9
C
AB C
Inlet 35˚
--- 2 0 ’
35˚
+20’
0,7±0,05 mm (max. 2,20 mm)
Exhaust 45˚
--- 2 0 ’
45˚
+20’
0,6±0,05 mm (max. 2,20 mm)
1.Grindthedamagedvalvediscwithavalverefacer.Adjust
angles to 45˚
--- 2 0 ’
for exhaust valves and 35˚
-- -20’
for inlet
valves.
2.Iftheedgeofthevalveheadislessthan1,5 mm after it has
been ground, or if the valve stem is bent, the valve should be
discarded.
3. If necessary , grind the end of the valve stem.
4. Lap the valves with lapping paste and check the contact
surface with marking paint.
5. Clean the cylinder head and valves of any remaining lapping paste.
H. Fitting valves
1. Check the valve springs for straightness, length and tension using a spring tester. Compare with specifications.
2.Lubricatethevalvestemsandfitthevalvesinthecorrect
order in the cylinder.
3. Fit the springs, spring guides and valve keepers with the
aid of a lever for compressing valve springs, 9101 66200.
4. Tap the end of the valve stems lightly after fitting the valve
in order to ensure that they are secure.
Page 34
max. 142
max. 188,5
43--- 10
50 Nm
43--- 12
Cylinder Head
3 --- 4
I. Fitting cylinder head
1. Measure the length of the cylinder head bolts. Compare
with dimensions shown in figure below. Change too long
bolts.
2. Screw the cylinder head stud bolts in to the cylinder block
to a torque of 30 Nm. Fit the valve tappets if removed.
3. Check that the sealing surfaces are clean and fit the cylinder head gaskets and the cylinder heads. Ensure that both
cylinder heads are parallel by fastening lightly the exhaust
manifold before tightening the cylinder head bolts (the
exhaust manifold can damage, if the heads are not parallel).
Clean and lubricate and fit the bolts.
43--- 11
1
2
3
4
5
6
7
8
910
11
12
13
14 15
16
17
4. Picture above show the correct tightening order of the cylinder head bolts. The order has also been marked on the cylinder heads.
5. Tighten the cylinder head bolts progressively as follows:
1. First tightening to 80 Nm.
2. Tightening of 90˚.
3. Tightening again of 90˚.
6. Adjust the valve clearances (see instruction 4C).
7. Run the engine with a light load to the normal running temperature (~ 75˚C).
8. Tighten the bolts 60˚ and adjust the valve clearances.
Note! After this the cylinder head does not need retightening.
Tighten the exhaust manifold nuts to 50 Nm. DO NOT OVER TIGHTEN THE NUTS!
Page 35
Valve Mechanism
4 --- 1
4. VALVE MECHANISM
A. Reconditioning valve mechanism
1. Check the valve tappets, especially the contact surface
against the camshaft. Worn or damaged tappets should be
discarded.
4 4 --- 1
2. Check the straightness of the pushrods by rolling them on
a surface table. Check also the spherical surfaces at the ends.
3. Dismantle and clean the rocker arm mechanism. Check the
shaft for wear and that the oilways are clean.
23,000...23,021
4 4 --- 2
4. Check diameter of the rocker arm bore. Change the worn
or damaged rocker arm. Where necessary grind the rocker
arm valve contact surface to the correct shape. Do not grind
more than necessary as the hardened layer is thin.
2 4 --- 3
60˚
4 4 --- 4
5. Fit the plug to the other end of the rocker arm shaft. Lubricate the shaft and fit various parts in a correct order. Note the
correct position of the shaft and the bearing brackets. The
split side of the bracket and the shaft oil holes must be turned
to the valve side (see figures above). Fit the other end plug.
B. Changing camshaft/
camshaft gear
1. Remove the inlet pipe between the turbocharger and the
intake manifold. Remove the valve cover and the breather
pipe. Remove the rocker arm mechanism.
2. Remove the radiator, cooling fan, alternator and the ribbed
V---belt.
3. Remove the belt pulley and damper. Slacken the crankshaft nut. Do not remove it! Remove the hub using puller
9104 53300. Take off the puller, open the nut and remove the
hub.
4. Remove the timing gear casing cover (engine front cover).
4 4 --- 5
5. Connect the pushrods in pairs, using o --- rings or elastic
bands to prevent them from falling through.
Note! Do not connect the pushrods too tightly as this might
cause them to bend or snap.
6. Crank the engine until the aligning marks on the idler gear
and camshaft gear are facing each other. Extract the camshaft.
Page 36
IP IP
IP
4 4 --- 7
I
P
Valve Mechanism
4 --- 2
7. Separate the camshaft from the gear wheel using a press
or suitable drift.
8. Clean the parts which are to be refitted.
9. Fit the key in its groove. Heat the camshaft gear to 200˚C
in an oven and fit it on the shaft.
10. Lubricate bearing surfaces and lobes and insert the shaft
in the cylinder block. Ensure that the aligning marks on the
gears agree.
11. Fit the timing gear casing cover ,the hub, damper and
crankshaft V -- -belt pulley.
12. Free the pushrods and fit the rocker arm mechanism.
Adjust the valves. Fit the valve cover and the breather pipe
and the inlet pipe between the turbocharger and the intake
manifold.
13. Fit the other removed parts.
Modification of the cam shaft
From engine no L 17961 all 645 engines are equipped with a
cam shaft where the front end bearing location has no oil
groove (the bearing location is so called barrel shape)
30˚
41--- 4/1
Note! The new cam shaft is not fitting together with any previous bushing. The new bushing is recognised from the position of the oil drilling which is not at the same place as the oil
drilling of the cylinder block, 30˚ angle upwards from the horizontal level.
C. Adjusting valves
0,35
4 4 --- 6
The valve clearance, which can be adjusted on a hot or cold
engine, is 0,35 mm for both inlet and exhaust valves. The
clearance is adjusted when the respective piston is at T.D.C.
in the compression stroke. The valves for the different cylinders are adjusted in the same sequence as the order of injection.
--- Slacken the lock nut of the adjusting screw.
--- Measure clearance with a feeler gauge. The clearance is
correct when a 0,35 mm feeler gauge is slightly tight --- fitted
between the rocker arm and the valve stem end. Adjust clearance by rotating the adjusting screw.
--- Tighten the locking nut and check the clearance.
Engine front end
INLET
EXHAUST
Adjusting
--- Rotate the crankshaft in the running direction until the
valves in the 6th cylinder are rocking (exhaust closes, inlet
opens). Check the valve clearance of the 1st cylinder.
--- Rotate the crankshaft by 1/3 of a turn in the running direction so that valves in the 2nd cylinder are rocking. Check
valves in the 5th cylinder .
---Continue according to the order of injection:
Injection order
153624
Valves rock in cyl. no. 624153
Page 37
Crankshaft
5 --- 1
5. CRANKSHAFT
A. Removing crankshaft
1. Remove the oil sump.
2. Unscrew the lubricating oil pump pressure pipe fixing
screws from the cylinder block. Remove the oil pump and the
suction and pressure pipes.
3. Remove the flywheel and the flywheel housing.
4. Detach the belt pulley and vibration damper from the
crankshaft front end. Pull of crankshaft hub and remove timing gear housing (see instruction 8A).
5. Remove the connecting rod bearing caps and push the
connecting rods out of the way of the crankshaft.
6. Remove the main bearing caps and lift out the crankshaft.
B. Checking crankshaft
1. Clean the crankshaft. Do not forget the oilways.
4 5 --- 1
2. Measure the journal wear in several points. Out---of--round, taper or other wear must not exceed 0,03 mm.
3. Refit the bearing caps with new bearing shells and tighten
them to the correct torque. Measure the I.D. with a dial gauge
which has been zeroed to the dimensions obtained in point 2.
With this method the indicator shows the actual bearing clearance. Measure in several points in case the worn bearing
housing is not round.
4 5 --- 2
4. If the bearing clearance exceeds 0,18 mm for main bearings or 0,14 mm for connecting rod big---end bearings with
new bearing shells, the bearing journals on the crankshaft
should be ground. Refer to the specifications for the relevant
correct undersize and the corresponding bearings, see
technical data, point crankshaft. When grinding note that
the journal edges must remain round.
C. Changing crankshaft gears
1. Break the crankshaft gears using e.g. a grinder. Grind the
gears enough. Hit the gears apart with a chisel. Do not damage the crankshaft!
2. Clean the seat on the crankshaft with, for example, a wire
brush.
4 5 --- 3
9103 94700
3. Heat the new gears to 220...250˚ C. Tap them onto the
shaft with drift 9103 94700. Note the position of the key and
ensure that the aligning marks on the front gear are visible.
Leave it to cool.
Page 38
4 5 --- 7
80 Nm
1
2
3
4
Crankshaft
5 --- 2
D. Fitting crankshaft
1. Clean the oilways, bearing shells and bearing locations.
Check that the crankshaft is clean.
A
B
4 5 --- 4
2. Assembly the bearing with oilholes/groove (A)tothecylinder block and the bearing with no hole (B) to the bearing cap.
Ensure that the bearing shell clamping claws fit into their
notches and that the shells to be fitted in the cylinder block
have a hole coinciding with the oil port.
3. Lubricate the bearing surfaces and fit the crankshaft. Fit the
crankshaft thrust bearings with the lubricating grooves facing
the crankshaft.
200 Nm
4 5 --- 5
7
6
4. Fit the main bearing caps according to their numbering
(bearing lock in the block and in the cap are on the same
side), the rear with thrust bearings provided with guide lugs.
Lubricate the bolts and tighten them to 200 Nm.
0,10...0,38 mm
4 5 --- 6
5. Check that the crankshaft can rotate without binding.
Check the end float using a dial gauge. The correct end float
is 0,10... 0,38 mm. If the end float is too large, oversize thrust
bearings should be fitted.
Note! Bearing shells should never be reamed or machined in
any other way, nor should the sides of the bearing caps be
filed
E. Checking vibration damper
1. Housing
2. Damper mass
3. Liquid cavity
4. Bushing
In the 645---engines the crankshaft front end incorporates a
torsional vibration damper. The vibration damper consists of
a sealed housing in which there is a mass of steel. This mass
(the damper ring) is carried in the centre on a bushing and is
surrounded on all sides by a viscous silicone fluid.
Do not remove the damper by turning forcibly and be careful
not to damage it when it is loose. Even a small dent makes the
damper inoperative. If you detect a dent on the outer surface,
do not install the damper back in the engine.
Note! (645 - -- engines with timing mark on the damper) Vibration dampers delivered as spare parts do not have injection
timing mark. Make the marking on the new damper with an
electrical pen, do not tap!
Piston distance from top dead centre vs. crank angle, see instruction 7B.
Page 39
Connecting Rods and Pistons
6 --- 1
6. CONNECTING RODS AND
PISTONS
A. Removing pistons together with
connecting rods
1. Remove the oil sump and the oil inlet and pressure pipes.
2. Remove the cylinder head.
3. Scrape off the possible soot in the cylinder liner. If the turning edge is clearly marked, smooth it down carefully with a
scraper.
4. Remove the big end bearing caps and bearing shells.
Place the shells in order if they are to be re ---used.
5. Push up the piston and connecting rod with the shaft of a
hammer or similar wooden tool.
6. Remove the piston pin snap rings. Push out the pin.
Note! If the piston pin does not move under thumb pressure
the piston should be heated to 100˚C .
B. Changing connecting rod bearings
Piston pin bushing
1. Clean the connecting rod and bearing shells.
4 6 --- 1
2. Measure the I.D. of the piston pin bushing using a cylinder
gauge.
3. If the piston pin bushing is worn, it should be driven out
using a suitable drift.
44,025...
44,040
4
4 6 --- 2
4. Press the new bush in its place. Ensure that the oil hole in
the bush coincides with the respective hole in the connecting
rod. After fitting drill Æ 4mmoil hole and ream the bush to at-
tain its correct diameter .
Note! The connecting rods from engine number L 1110. The
bushing (8368 64288) has a Æ 4 mm oil hole, therefore no drilling after assembly is needed. Scrape the bushing to correct
dimension.
Note! The connecting rod can, if needed, be fitted with a 0,5
mm oversize bushing (8363 38606). See technical data, point
connecting rod.
Big end bearing
1. Fit the bearing shells together and tighten the screws.
2. Measure the I.D. using a cylinder gauge which has been
zeroed to the diameter of the respective bearing journal. If the
clearance exceeds 0,14 mm with new bearing shells, the big
end journals require grinding. Refer to the specifications for
the correct undersize and the corresponding bearing. Ensure
that the radii at the end of the bearing journals is not altered
when grinding.
C. Checking connecting rod
The connecting rod is checked in a special fixture, intended
for the purpose (e.g. Carl Larsson). See technical data, point
connecting rod.
Note! If the connecting rod is damaged so that it has to be
changed, please note the following:
--- The earlier used connecting rod is replaced in production
with a new type from engine number L 1110. In the new connecting rod the big end is split by the breaking technique.
--- Single connecting rods are not interchangeable. As spare
part the new connecting rod replaces the earlier only by
changing the whole set.
--- The cap screw and torque is different for each connecting
rod types.
Page 40
Connecting Rods and Pistons
6 --- 2
Earlier used connecting rod
40 Nm + 90˚+90˚
max. 66,50
E
Measure the length of the connecting rod screws. The length
should be max 66,50 mm. If the screw is longer, change it
with a new one. It is recommended that the screws are always
changed when they are unscrewed.
The connecting rods are divided into weight classes with intervals of 20 g. The weight class (a letter) is stamped on the
side face of the connecting rod. All the connecting rods in one
engine should be of the same weight class, that is to say the
greatest permissible weight difference is 20 g.
The letters show the weight classes as follows:
Letter Part no. Weight
C 8363 55175 2931---2950 g
D 8363 55176 2951---2970 g
E 8363 52751 2971-- -2990 g
F 8363 52752 2991---3010 g
G 8363 52753 3011---3030 g
H 8363 52754 3031---3050 g
I 8363 52755 3051--- 3070 g
J 8363 52756 3071--- 3090 g
K 8363 52757 3091--- 3110 g
L 8363 52758 3111-- -3130 g
M 8363 52759 3131---3150 g
N 8363 52760 3151--- 3170 g
0 8363 52761 3171---3190 g
P 8363 52762 3191---3210 g
R 8363 52763 3211--- 3230 g
S 8363 52764 3231---3250 g
T 8363 52765 3251---3270 g
U 8363 52766 3271--- 3290 g
V 8363 52767 3291--- 3310 g
X 8363 52768 3311--- 3330 g
Y 8363 52769 3331--- 3350 g
Z 8363 52770 3351- --3370 g
New connecting rod from engine number L 1110
To r x E1 8
40 Nm + 90˚
G
Note! Always change the screws when opened.
The connecting rods are divided into weight classes with intervals of 20 g. The weight class (a letter) is stamped on the
side face of the connecting rod. All the connecting rods in one
engine should be of the same weight class, that is to say the
greatest permissible weight difference is 20 g.
The letters show the weight classes as follows:
Letter Part no. Weight
E 8368 64101 2230-- -2249 g
F 8368 64102 2250--- 2269 g
G 8368 64103 2270---2289 g
H 8368 64104 2290---2309 g
I 8368 64105 2310--- 2329 g
J 8368 64106 2330---2349 g
K 8368 64107 2350--- 2369 g
Page 41
Connecting Rods and Pistons
6 --- 3
D. Changing piston rings
1. Remove the piston rings with piston ring pliers 9052 46900.
Do not open the rings more than necessary. If the rings are to
be used again ensure that they are fitted in the same groove.
4 6 --- 9
2. Clean the piston ring grooves and measure the piston ring
clearance, which must not exceed 0,15 mm. Determine
whether too large a clearance is due to worn rings or a worn
groove. Change worn parts.
46--- 10
3. Measure the piston ring gap by pushing one piston ring at
a time into the cylinder bore. The piston ring gap must not
exceed 1mmon 1. and 3. piston rings and 1,3 mm on 2. pis-
ton ring.
4. Fit the piston rings on the piston using the piston ring pliers.
Ensure that the rings are fitted in the correct groove and that
”TOP”, or the manufacturer’s designation, faces upwards.
46--- 11
E. Checking pistons
Check the condition of the pistons and piston pins. Pay
special attention to possible cracks on the edge of the combustion chamber and on the upper edge of the piston pin
hole. Measure the diameter of the piston at the point shown
in the figure below. Renew a piston if needed.
46--- 12
110,863...
110,887
15
Page 42
Connecting Rods and Pistons
6 --- 4
F. Fitting piston pin
1. Place the connecting rod inside the piston and push the
piston pin into place.
46--- 13
Note! The combustion chamber and the weight class letter
should be on opposite sides!
2. Fit the piston pin circlips. Ensure that the circlips are
pressed correctly into the grooves. The circlip ends must
point upwards.
G. Fitting piston together with connecting rod.
1. Check that the bearing locations are clean and place the
bearing shells in the connecting rod and bearing cap. Note
the position of the bearing shells.
2. Lubricate piston, rings and cylinder bore. Ensure that the
piston ring gaps are spread around the piston.
46--- 14
9105 18700
3. Use a piston ring strap or preferably a fitting tool (9105
18700). Fit the piston with the marking on the connecting rod
(weight class) facing the camshaft (an arrow on the piston
must point forward).
4. Lubricate the big end bearing journal and bearing shells,
and push the piston down. Fit the bearing cap so that the
notches for the guide lugs are in the same side. Tighten the
connecting rod screws, see instruction 6C(page 6 - --2).
5. Check that the connecting rod has sufficient end float on
the big end bearing journal.
Page 43
Flywheel
7 --- 1
7. FLYWHEEL
A. Changing starter ring gear on flywheel
If the ring gear is worn, change it with a new one. The ring
gear cannot be turned around because its teeth are chamfered and hardened on the starter motor side.
1. Remove the old starter ring by tapping it at various points
with a drift. Clean the flywheel contact face with a steel---wire
brush.
4 7 --- 1
2. Warm the ring gear to the temperature of 150...200˚C.Fit
the ring gear with the inner diameter chamfering turned
against the flywheel and the teeth chamfering against the
starter motor.
3. Allow the ring gear to cool freely without using any coolant.
B. Fitting flywheel
1. Clean the contact surfaces on the crankshaft rear flange
and on the flywheel.
2. Fasten the flywheel to the crankshaft rear end. As a guide
pins can be used studs (M14, 2 pcs) which are screwed in to
the flywheel fixing bolt holes.
4 7 --- 2
50˚
40˚
Note! The flywheel fixing bolt holes are unsymmetrical.
3. Tighten the flywheel retaining screws evenly to a torque of
200 Nm.
Note! Flywheel delivered as spare parts do not have injection
timing mark. Make the marking on the new flywheel in connection with installation.
4. Rotate the crankshaft until the piston of the 1st cylinder reaches its top dead centre. Drop cyl. no 1 inlet valve down
against the piston head. Set the dial gauge on top of the valve
stem end and zero it at the piston top dead centre. Then rotate
the crankshaft opposite to running direction until dial gauge
shows about ten (10) mm below TDC. After that rotate the
crankshaft slowly to running direction until the dial gauge
shows the figure corresponding injection timing (see table
below).
5. Bore the injection timing mark hole by a drill (see picture
below) to the flywheel.
7
Piston distance from top dead centre vs. crank angle
Grad
mm Grad mm
1˚
2˚
3˚
4˚
5˚
6˚
7˚
8˚
9˚
10˚
11˚
12˚
13˚
14˚
15˚
0,014
0,058
0,130
0,232
0,362
0,521
0,709
0,925
1,170
1,443
1,745
2,075
2,432
2,818
3,230
16˚
17˚
18˚
19˚
20˚
21˚
22˚
23˚
24˚
25˚
26˚
27˚
28˚
29˚
30˚
3,671
4,138
4,633
5,154
5,701
6,275
6,874
7,499
8,150
8,825
9,525
10,249
10,997
11,768
12,563
Page 44
WARNING
Timing Gear Assembly
8 --- 1
8. TIMING GEAR ASSEMBLY
A. Removing timing gear casing
As the timing gear casing bottom face forms a part of the mating face for the oil sump gasket, the casing cannot be removed without first removing the oil sump.
1. Remove the oil sump.
2. Remove the radiator, fan, belt,alternator and belt tensioner
assy. If the engine is equipped with a air compressor or air
conditioner, it has to be removed.
3. Remove the crankshaft belt pulley and the vibration
damper.
Note! When removing the hub piece from the crankshaft front
end mark the correct position of the hub. (Engines with the
timing mark on the vibration damper.)
9104 53300
4 8 --- 1
4. Loosen the crankshaft nut about two turns (special tool
9024 55800). Fit extractor 9104 53300 and extract the crankshaft hub. Take off the extractor, open the nut and remove the
hub.
Do not remove the nut completely
first. The hub will be dashed
dangerously when it is loosen.
5. Remove the cooling pump, observe the retaining screws
on the injection pump side. Remove the timing gear casing
cover.
6. Remove the injection pump.
Note! If the timing gear casing is not to be changed, the injection pump can remain in place. In which case disconnect all
leads and pipes from the pump and loosen bottom mounting
from the pump.
7. Unscrew the idler gear bolts and remove the idler gear
(broad timing gear casing).
8. Extract the camshaft.
Note! If the cylinder head and valve mechanism have not
been removed, the tappets must be prevented from falling
down, see instruction point 4B.
9. Remove the timing gear casing. Ensure that no sealing surfaces are damaged.
10. Remove the crankshaft front seal ring from the front casing cover and clean all parts removed.
B. Fitting timing gear casing
The position of the timing gear casing and cover is determined by two tension pins. Therefore centring should not be
undertaken in connection with fitting. However, the backlash
between the different gears should be checked. Casing and
covers that are delivered as spare parts also have holes for
the tension pins already machined.
4 8 --- 2
1. Screw in the thread piece M14/M8 to the cylinder block
(narrow timing gear casing). Fit the casing with a new gasket
against the cylinder block. Hit in the tension pins with drift
9025 98700. Tighten bolts and nuts.
2. Fit the injection pump and its gear wheel (if removed).
3. Lubricate the camshaft bearings and insert the shaft in the
cylinder block. Release the pushrods and tappets if they have
been suspended.
4 8 --- 3
Timing gear position
Page 45
Timing Gear Assembly
8 --- 2
Narrow timing gear casing
22 Nm
180 Nm
4 8 --- 4
4. Assemble the idler gear as in picture. Place the o --- ring between the shaft and the cylinder block and fit the idler gear in
its place. Note the correct position of the timing marks. Place
an o--- ring also in the shaft front end.
9104 34600
4 8 --- 5
5. Fit the guide pin 9104 34600 instead of the idler gear bolt.
Fit the camshaft axial controller in the cover (apply sealing
compound to the thread) and fit the cover. Hit in the tension
pins.
Note! If the crankshaft oil throwing ring is removed, fit it (drift
9103 94900) before fitting the cover.
6. Tighten the cover bolts. Remove the guide pin, fit the idler
gear shim and tighten the bolt 180 Nm.
9103 94600
4 8 --- 6
7. Fit the protective plate into the bottom of the seal position
and fit the crankshaft front seal with special tool 9103 94600.
80 Nm
4 8 --- 7
1000 Nm
8. Lubricate both the seal and sealing surfaces and fit the
crankshaft hub. Lubricate the crankshaft nut threads and
tighten the nut to 1000 Nm.
9. Fit the other removed parts.
Page 46
4 8 --- 9
9104 05400
Timing Gear Assembly
8 --- 3
Broad timing gear casing
4 8 --- 8
4. Assemble the idler gears as in picture. Fit the big idler gear
in its position. Note the position of the timing marks. Fit also
the small idler gear.
5. Tighten the guide bolts in the guide unit frame and position
the unit on the idler gears as in picture (guide bolts in the idler
gear shaft holes and housing holes). Tighten the idler gear
bolts through the guide unit holes, tighten 180 Nm.Remove
the guide unit.
48--- 10
6. Check the tooth backlash, which should be 0,05...0,25
mm.
7. Fit the drive unit shaft and camshaft axial controller in the
front cover (apply sealing compound to the thread). Fit the
cover and hit in the tension pins. Observe the idler gear shaft
bolt seals. Fit the drive unit rear bearing and cover.
Note! If the crankshaft oil throwing ring is removed, fit it (drift
9103 94900) before fitting the cover.
8. See instruction 7...9 / Narrow timing gear casing.
Page 47
Tensioning Device
9 --- 1
9. TENSIONING DEVICE
A. Tesioning device for ribbed belt
4 9 --- 1
80 Nm
200 Nm
1. Assemble the tensioning device, as the picture shows. The
bearing bushes of the upper shaft do not have to be broached
after fitting.
2. Fasten the tensioner to the mounting plate. Lubricate the
grease nipple of the upper shaft of the tensioner. Use heat resistant grease, e.g. ISOFLEX TOP AS NB52 (NLGI 2).
4 9 --- 2
15
29
3. Note, when tightening a new ribbed belt, that the starting
position of the tensioner is determined by the mounting hole
place.
B. Fan drive device
4 9 --- 3
350 Nm
1. Assemble the drive device as the picture shows. Fit inner
bearing and circlip. Fill the bearing housing partially with heat
resistant ball bearing grease (NLGI 2). Fit the intermediate
sleeve, outer bearing and circlip. Note the position of the
outer bearing as assembling.
2. Press the shaft into its position so that the pressing force is
not transmitted by the bearing balls.
3. Tap the blocking plug (if mounted) in its place with fitting
drift 9025 87400.
4. Fit the belt pulley, washer and nut. Tighten the nut to 350 Nm.
Page 48
Lubrication System
10---1
10. LUBRICATION SYSTEM
A. Reconditioning of oil relief valve
for lubricating oil pressure
If the engine lubricating oil pressure is insufficient or if it varies, the relief valve should be checked after first checking the
oil level.
410--- 1
1. Remove the cover over the valve and spring. Take care of
the washer between the cover and spring. Remove the valve
insert together with the valve cone and ensure that the o --- ring
is also removed.
2. Clean the parts and check that the valve cone slides freely
in the insert and that the sealing surface are undamaged. Minor damage can be adjusted, but in general, damaged parts
should be changed. Scrape off any remains of the gasket.
3. Assemble the valve with a new o ---ring and insert it in the
cylinder block. Place the washer and spring in the cover and
fititwithanewgasket.
4. Note that the relief valve cover is not symmetrical. The
greater distance between the spring housing and bolt should
be turned downwards.
Note!
From engine number J 14016
The engines are equipped a new type of oil pressure valve.
In the construction of the new valve the hydraulic vibrations
are damped, it is more reliable and it gives the best, optimised
pressure level.
410--- 2
Loctite 638
B. Removing and dismantling lubricating oil pump
1. Drain the engine oil and remove the oil sump.
2. Remove the oil pump suction and pressure pipe.
3. Remove the oil pump together with any shims between the
pump and the cylinder block.
4. Remove the pump cover and the gasket. Remove the gear
on the dead axle.
5. Clamp the pump gear across the teeth in a vice fitted with
soft jaws, and loosen the drive gear nut. Knock the gear wheel
off by hitting the end of the shaft with a soft hammer. Pull out
the drive shaft ---gear wheel
6. Clean the parts and check for wear and other damage.
Compare with the specifications. Change damaged parts
and all seals.
60 Nm
410--- 3
7. On 645---engines the bearing points are provided with separate bearing bushings. If you change the bushings, machine
them to dimension of 18,000...18,018 after fitting.
Page 49
410--- 6
Lubrication System
10---2
C. Assembling and fitting lubricating oil pump
1. Fit the gear wheels in the pump body. Fit the cover using
a new gasket. Partly tighten the bolts. Rotate the pump shaft
and tap the side of the cover lightly until the position is reached where the shaft rotates most freely. Tighten the bolts
and check that the shaft still rotates freely.
2. Fit the drive gear onto the shaft. Apply Loctite 242 onto the
nut threads and tighten the nut to 60 Nm. Remember the
washer under the nut.
410--- 4
3. Fasten the oil pump in a vice and check the end float between gear and pump housing. The clearance which should
be 0,03...0,11 mm, is adjusted by the number of gaskets between the cover and body.
410--- 5
4. Fit the pump and check the tooth backlash against the
crankshaft gear. The clearance, which should be 0,05...0,25
mm, is adjusted with shims between the pump body and the
cylinder block (shim 0,2 mm, order no 8360 07871). One shim
increases/decreases the backlash about 0,07 mm.
Note! When measuring the tooth backlash, the engine
should be the correct way up as the crankshaft bearing clearance affects the tooth backlash.
5. Connect suction and pressure pipes together with new
seals. Fit the oil sump and fill in the lubrication oil.
D. Fitting oil sump gasket
Fit the oil sump gasket with the silicone stripes against the cylinder block (self carrying and casted oil sumps).
E. Piston cooling nozzles
The cooling nozzles can be removed after removing the oil
sump. The nozzles have a ball valve with an opening pressure of 3±0,25 bar.
410--- 7
1. Change the valve if necessary. Detach the valve from the
engine and remove the nozzle pipe. Fit a new valve.
410--- 8
90˚
2. Fit the nozzle pipe at the angle of 90˚to the centre line of the
crankshaft according to the above picture. Tighten the valve
to 30 Nm. Ensure that the pipe does not touch the pistons or
connecting rods when the engine is running.
Page 50
8363 36459
410--- 9
8368 59108
60 Nm
410--- 10
Lubrication System
10---3
F. Oil cooler
Practically there are two different oil coolers, the difference
being position of the oil filter, see picture.
To r e m o v e
1. Open the coolant drain plug under the oil cooler and drain
the coolant into a suitable container. Remove the pipe going
into the thermostat housing.
2. Remove the turbo oil pipes and the oil pressure pipe from
the cylinder block. Remove the oil filter. Drain the oil into a
container.
3. Remove the oil cooler from the engine. Open the cooler
housing and remove the guide plate. Unscrew the cell bolts
and remove cell from the body. Clean the all parts.
Fitting oil cooler
1. Assemble the oil cooler using new gaskets. Fit the cell to
the body. The oil side can be pressure tested before fitting the
housing. T est pressure is 5
+1
bar.
2. Push the guide plate between the cell and the body and fit
the housing. If needed now can the water side be pressure
tested, test pressure 5bar.
3. Assemble the oil cooler to the engine and assemble oil - -and coolant pipes. Replace the oil filter .
4. Fill the coolant system. Start the engine and check for leakages.
Page 51
410--- 11
TEMPERATURE ˚C
S A E --- G R A DE
--- 30 ---20 ---10 0 +10 +20 +30
5W---30
5W---40
10W---30
10W---40
15W---40
20W---20
20W---40
30
+40--- 4 0
A
B
C
410--- 12
D
Lubrication System
10---4
G. Lubricating oil quality requirements
-- - T urbocharged engines API C F --- 4 , C G --- 4 , C H --- 4 ACEA E 2 / E 3 --- 9 6 , E 4 --- 9 8 , E 5 --- 9 9
--- L o w e m i s s i o n ( E ) e n g i n e s A P I C G --- 4 , C H --- 4 ACEA E 3 --- 9 6 , E 4 --- 9 8 , E 5 --- 9 9
H. Oil capacities
A = min. 20,5 max. 24,5 ltr
B = min. 25,0 max. 29,5 ltr
C = min. 42,0 max. 46,5 ltr
D = min. 17,0 max. 21,0 ltr
Page 52
Cooling System
11---1
11. COOLING SYSTEM
A. Quality requirements of coolant
The coolant used must meet the standards ASTM D 3306 or
BS 6580:1992.
--- Mixing proportion should be 40 - --60 % of ethylene/propylene---glycol based coolant and the rest water. The best ratio
is 50/50 %.
--- In warm climates the 30 % mixture ratio gives enough good
protection against corrosion.
--- Water used should be clean and soft water i.e. that it does
not include metals and their salts.
--- Check the coolant frost resistance every now and then.
Change the coolant every other year.
Note! Never use only water as coolant!
B. Thermostat
645---engines have two separate thermostats. The smaller,
single---acting thermostat opens at 79˚C and the other,
double---acting type, at 83˚C. In 645 - -- engines there are no
separate winter thermostats.
To r e m o v e
1. Drain the cooling system so that the coolant level is below
the thermostats position and disconnect the top hose from
the water outlet cover.
2. Remove the outlet cover and the thermostats. Clean the
sealing surfaces.
Check the function of the thermostat as follows:
-- - Lower the thermostat into a vessel of boiling water so that
the thermostat does not touch the sides or bottom.
--- Opening must begin under 20 seconds.
--- The thermostat must be fully open under 50 seconds.
Stroke, see specifications.
To r e p l a c e
411--- 1
67,5
62,0
1 Put the thermostats in position in the housing. Fit a new
gasket and the outlet cover. For guiding you can use M8 studs
(2 pcs). Observe the plate (if mounted) that comes on top of
the smaller thermostat. Fit the gasket so that the bigger hole
isonthesamesideastheplate.
2. Connect the top hose and fill the cooling system.
Page 53
411--- 2
5294 01440
180 Nm
411--- 3
40
Cooling System
11---2
C. Reconditioning the coolant pump
1. Drain the coolant. Disconnect the hose at the inlet connection of the coolant pump. Loosen the coolant pipes from the
coolant pump.
2. Release the three screws which retain the coolant pump to
the cover of the timing case ---from the rear. Remove the coolant pump.
3. Unscrew the gear fixing nut and remove the gear . Remove
the pump housing from the pump body. In the double coolant
pump first remove the smaller coolant pump (for intercooler)
with impeller.
4. Remove the circlip in the pump body. Press the shaft together with bearings in the direction of the gear.
5. Tap out the water seal and shaft seal using a drift. Remove
o---ring seals and clean the parts and inspect their condition.
Replace faulty or worn parts with new ones.
Note! If the pump bearings have to be changed, use a pump
repair kit. This kit also contains all seals (see Parts Catalogue).
6. Tap the new shaft seal in the body using a drift 9103 41000.
Grease bearings with heat resistant ball bearing grease (NLGI
2). Press in the bearings and fit the circlip.
7. Fit the shaft in such a way that the pressing force is not
transmitted by the bearing balls.
8. Hit the water seal into its position with tool 9103 41100.
Press the impeller to its position (towards the shaft shoulder)
supporting the shaft from the other end. Make sure that the
shaft can rotate freely.
9. Fit the gear on the shaft and tighten the nut to 180 Nm.
10. Fit the pump housing using new gasket.
11. Fit the pump using new o --- ring
Note! If both coolant pump and injection pump are removed,
fit the coolant pump first (one fitting screw can not be fitted as
injection pump is in position).
Double coolant pump
Coolant pump for
intercooler
Telltale hole
Note when assembling the smaller water pump the following:
--- If you change the pump housing, drill a Æ 3mmhole in the
back side as picture shows.
--- Use in tightening the small impeller always a rust proof
screw (order no 5294 01440).
Page 54
Inlet and Exhaust System
12---1
12.INLETANDEXHAUSTSYSTEM
An engine that is equipped with a turbocharger is a great deal
more sensitive to disturbances and impurities in the inlet and
exhaust systems than a naturally aspirated engine. There fore
special attention should be given to the whole inlet and exhaust system.
A. Checking air cleaner
The engine performance and length of service life depend to
a great extent on the state of the air cleaner. A defective air
cleaner allows impurities to pass through, which in time damage the turbocharger and the engine. A blocked air cleaner
lowers the engine output and also causes oil leakage through
the sealing ring on the turbocharger shaft.
Note! The safety filter inside the main filter should not be removed unnecessarily, for checking or cleaning. The safety
filter must not be cleaned, but should be changed once a year
or when necessary (see Operator’s Manual).
B. Checking inlet and exhaust pipes
Important! Leaks in the inlet or exhaust system markedly
lower the effect of the turbocharger. Because of the pressure,
even small leaks in the manifold or in the turbine inlet contact
flange quickly increase in size. For this reason all leaks must
be dealt with immediately.
1. Inspect the pipes and sealing surfaces between the air
cleaner and the turbocharger, as well as between the turbocharger and the intake manifold. If the intake manifold is
dusty on the inside, there is a leak in either the air cleaner or
the inlet pipes. Remedy the leak.
2. Clean the intake manifold sealing surface. Check that the
sealing surface is flat using a straight ruler. If the surface is not
flat or it has scratches, machine or renew the intake manifold.
Ensure that the cylinder heads are parallel.
3. Fit a new gasket and fasten the intake manifold. Tighten the
manifold fixing screws to a torque of 30 Nm. Fasten the air
pipes carefully.
4. Check that the exhaust manifold is air tight. Tighten the
nuts to 50 Nm and inspect for any damage (cracks, deformation, corrosion etc.). Check also the connection between the
turbocharger and the exhaust manifold.
5. Remove the manifold if necessary . Clean the sealing surfaces and remove any carbon deposits. Check that the sealing surfaces are flat. If the fastening flanges are twisted or
there are scratches on the sealing surfaces, machine the
flanges or renew the exhaust manifold.
6. Ensure that no loose objects or impurities have entered the
exhaust pipe or the silencer. Any such loose objects or impurities can increase the back pressure for the exhaust gases
from the turbine wheel.
C. Checking turbocharger
If a fault is suspected in the turbocharger it can be located in
the following way:
1. Visually inspect the turbine and compressor wheels. The
vanes must not show any signs of damage, deformation or
wear caused by foreign objects.
2. Investigate any oil leaks through the sealing rings on the
shaft in the turbine and compressor housing.
Note! At low idling there is always a certain amount of oil leakage on the compressor side. However, this should not cause
too much concern unless the oil consumption is too great.
412--- 1
3. Check the turbine shaft running clearance. Place the stylus
of a dial gauge against the shaft and move the shaft sideways. refer to the clearance given in the specifications on
page 0 --- 1 2 .
412--- 2
4. Check the shaft end float. Place the stylus of the dial gauge
against the end of the shaft and move the shaft axially. Refer
to the clearance given in the specifications on page 0 --- 1 2 .
Page 55
412--- 3
1
2
3
4
5
6
7
8
Inlet and Exhaust System
12---2
If any defects or wear are confirmed, the turbocharger should
be reconditioned.
If the engine does not work correctly and the turbocharger is
not defective or too worn, the fault could be traced to one of
the following items:
--- Blocked air filter.
-- - Leakage in the inlet or exhaust systems. Leaking flange
seal.
--- Defective or wrongly adjusted injection pump.
--- Wrongly adjusted throttle linkage.
--- Defective or wrongly adjusted injectors.
-- - Low fuel pressure (e.g. blocked fuel filter).
--- Low compression, wrong valve clearance.
D. Fitting turbocharger
Locate the cause of the defects on the turbocharger. Remedy
the fault before fitting the new turbocharger.
In order for the turbocharger to work satisfactorily, it is important that the engine oil is in good condition. Likewise the oil
should be to the correct quality specification. The air filter and
oil filter should be serviced according to the handbook specification.
The setting of the injection pump critically affects the function
of the turbocharger. The injection pump should be adjusted
according to the manufacturers instructions.
1. Check the tightness of the intake and exhaust manifolds,
and that they are securely fastened. Ensure that there are no
loose carbon or rust particles, or other foreign objects in the
manifolds.
2. Connect the turbocharger to the exhaust manifold and
tighten down using a new gasket.
Turbocharger Schwitzer
1. Compressor cover
2. Lock nut
3. Compressor wheel
4. Bearing housing
5. Journal bearing
6. Turbine housing
7. Shaft and turbine wheel
8 . B y --- p a s s c h a n n e l
INLET AIR
EXHAUST GASES
LUBE OIL
3. Connect the inlet pipe and the exhaust pipe on the turbo.
4. Pour clean engine oil into the bearing housing through the
inlet oilway. This is very important in order to ensure that the
turbocharger is lubricated at the time of starting.
5. Connect the pressure and return oil pipes. Use a new seal.
Check that there are no tensions in the pipes when tightening.
6. Before starting, pull out the stop control and crank the engine over with the starter motor so that the oil pressure rises.
Start the engine and check that there are no leaks.
Page 56
Inlet and Exhaust System
12---3
E. Fitting intercooler
412--- 4
1. Using a new gaskets, fit the intake manifold to the cylinder
head.
2. Fit the cooler with thrust plates to the intake manifold.
Note! A conventional gasket is not used but apply a continuous bead of silicone sealing to the sealing surface.
Leak test pressure for the cooler:
--- W a t e r s i d e 2,9 bar
--- A i r s i d e 3,5 bar
3. Attach the boost air pipe to the cooler housing and coolant
pipes to the cooler. Fill the cooling system.
Page 57
Fuel System
13---1
13. FUEL SYSTEM
Note! This manual gives only general instructions for repair
and service measures related to the fuel system. This applies
particularly to the injection pump which can be repaired only
by a specially trained person who has the necessary special
tools and gauges. All service and repair work related to the
fuel system requires special care and cleanliness!
TECHNICAL DATA
Injection pump Bosch ’’P’’
Type (pump/governor) Bosch PES6P/RSV......................................................
I n j e c t i o n o r d e r 1 --- 5 --- 3 --- 6 --- 2 --- 4.............................................................
Direction of rotation clockwise........................................................
Diameter of pump piston
-- - 3000 --- series 12 mm............................................................
-- - 7100 --- series 12 mm............................................................
Stroke
-- - 3000 --- series 11 mm............................................................
-- - 7100 --- series 12 mm............................................................
Injection advance see injection pump adjusting values..........................................................
Fuel feed pump
Typ e Bo sch FP/KG24P307.....................................................................
Construction piston pump, separate hand pump..............................................................
Fuel feed pressure (overflow valve opening pressure) 0,6-- -1,0 bar...........................
Pressure from fuel feed pump (without overflow valve) 2,7 bar...........................
Injectors
Typ e four/fiveholenozzle.....................................................................
Opening pressure see page 14---3.........................................................
Setting pressure see page 14---3...........................................................
Sealing ring 8999 01495...............................................................
Tightening torques
Injection pump gear nut 200 Nm....................................................
Overflow valve 30 Nm............................................................
Injector nozzle sleeve 60 Nm.......................................................
Injector attaching nuts (on studs) 15 Nm.............................................
Page 58
413--- 1
1
2
3
4
5
6
7
8
9
Fuel System
13---2
Fuel system
1. Fuel tank
2. Prefilter
3. Feed pump
4. Fuel filters
5. Injection pump
Fuel system, description
Fuel feed pump (3) draws fuel from tank (1) through prefilter
(2) and forces it through filters (4) to fuel injection pump (5).
The fuel injection pump pumps fuel at high pressure through
the delivery pipes to injectors (6) which inject the fuel in the
form of a fine mist into the combustion chamber.
Excess fuel lubricates the nozzle valve (needle) and flows on
to the fuel tank
Excess fuel returns from the fuel injection pump through overflow valve (9) to the fuel tank.
The fuel system is often equipped with the thermostart device
to be used in cold conditions. The glow plug (8) receives fuel
from a separate reservoir of the thermostart device or from the
overflow valve of the injection pump regulated by the magnetic valve (7).
6. Injector
7. Solenoid valve
8. Glow plug
9. Overflow valve
Symptoms of dirty or faulty injectors are:
--- Knocking is an indication that one of the injectors is faulty.
When a cold engine ticks over a certain amount of knocking
is unavoidable. If the engine knocks after it has reached normal operating temperature, it is very likely that one of the
injectors is faulty. Air in the fuel system can also cause knocking (which should disappear after the system has been bled
of air).
--- Smoky exhaust gases may indicate impaired performance
of the injectors. However, this can also be caused by other
faults such as a blocked air cleaner.
The fuel system should always be bled when the fuel system
has been emptied (e.g. the fuel tank has been emptied during
driving, in connection with maintenance or repair work or after
a long idle period).
Page 59
1
2
3
4
5
6
7
8
9
10
11
413--- 2
Fuel System
13---3
Bosch --P injection pump
Injection pump
1. Boost control
2. Cold start solenoid
3. Speed lever
4. Injection timing indicator
5. Lube oil into the injection pump
6. Hand pump
7. O - -- ring seal
8. Return of lube oil to engine
9. Identification plate
10. Pressure equalizer
11. Overflow valve
The fuel injection pump is flange/bottom mounted and sealed
by one o--- ring in the timing gear housing. The injection pump
is driven from the crankshaft through an idler gear. The injection pump is connected to the engine force ---feed lubrication
system through an external pipe. Lubricating oil returns to the
engine via the hole at the front end of the injection pump.
The fuel feed pressure which fills the high pressure pump elements with fuel is created by a piston pump which is attached to the side of the fuel injection pump. The piston pump
is driven from an eccentric on the camshaft of the injection
pump. The fuel feed pump supplies more fuel than the injection pump needs. The excess fuel flows through the overflow
valve back to the fuel tank. The fuel cools the injection pump
and also takes any air bubbles with it back to the tank.
The injection pump is equipped with a boost control and an
electrical excessfuel feed device. The begining of the injection is positioned with a lock pin in the regulator housing.
Fuel injection pump type plate
The injection pump type plate shows one particular letter indicating the user application, see figure below . This letter
should always be quoted when ordering a replacement
pump or when looking for setting values.
413--- 3
PES6P120A320RV
Page 60
7
1
2
345
6
ABC
413--- 5
Fuel System
13---4
413--- 4
7
6
5
4
3
2
1
1. Pressure valve holder
2. Pressure valve
3. Pump element
4. Control rod
5. Control tag
6. Roller tappet
7. Camshaft
The purpose of the fuel injection pump is to meter out fuel to
the combustion chamber at the correct time. Pump element
(3) which is driven by the pump camshaft (7) via roller tappet
(6) forces the fuel through pressure valve (2) and further
through the delivery pipe to the injector.
1. Inlet passage
2. Cylinder
3. Starting groove
4. Release passage
5. Plunger
6. Metering edge
7. Vertical groove
Two---hole pump element (maximum feed)
A. Bottom dead centre
B. Fuel injection begins
C. Fuel injection ends
The pump element consists of one plunger and one cylinder
which are a matched pair and because of the fine tolerances
the whole element should be changed as a complete unit.
The cylinder has two passages: inlet passage and release
passage. Both passages allow fuel to enter the pressure
space. The side of the plunger has one vertical groove and
one metering edge which are used for adjusting the amount
of fuel injected into the combustion chamber of the engine.
The top of the plunger is provided with a starting groove
(delay groove) which delays the injection timing by approx.
8˚. (This should be borne in mind when checking the fuel injection timing). This groove improves the cold starting properties of the engine. It works fully automatically. When the engine has stopped the control rod in the injection pump turns
the plungers so that the starting groove faces towards the release passage. When the engine has started and when the injection pump has reached a certain speed, the governor pulls
the control rod back into running position.
1
2
3
4
5
6
7
413--- 6
Pressure valve
1. Holder for pressure valve
2. Valve spring
3. Valve cone
4. Valve guide
5. Valve head
6. Pressure --- reducing piston
7. Vertical grooves
Thepressurevalveisfittedontopofthepumpelementand
its purpose is to close the connection between the pump element and the delivery pipe. This happens when the metering edge of the plunger passes the lower edge of the release
passage, thus reducing the pressure in the space above the
plunger. Its second purpose is to reduce the pressure in the
delivery pipe. This is important as it enable the nozzle valve
(needle) to close more quickly.
Pressure valve cone contains a pressure---reducing piston
which, when the valve closes, is first lowered into the guide
and then closes the connection between the delivery pipe
and the pump element. The valve head is then pressed
against its seat and the fuel in the delivery pipe is given the
same space as the displacement of the pressure---reducing
piston.
Page 61
3
4
5
6
7
1
2
8
9
413--- 7
Fuel System
13---5
Governor
1. Governor weight
2. Control rod
3. Starting spring
4. Main lever
5. Idler screw
6. Governor spring
7. Additional spring, idling
8. Spring for equaliser
9. Governor control arm
The governor is of the centrifugal type and is fitted at the rear
end of the injection pump. The governor controls the rotational speed of the engine throughout the whole speed
range, and identifies the rotational speed by means of the
governor weights. The position of the governor control and of
the governor weights is transferred through the governor
lever linkage to the control rod. The governor has one governor spring. Starter spring, which is attached to the upper
end of the control lever, it pulls the control rod to the starting
position when the engine stops. This means that the amount
of fuel injected when the engine is started automatically becomes greater.
Manifold pressure compensator
The boost control unit on the governor housing has been
connected via a hose to the engine intake manifold. At low
revs the boost pressure is low and engine tends to smoke.
The boost control limits amount of injected fuel at low revs,
lowering exhaust gas emissions. This adjustment starts at a
certain, adjusted, boost pressure.
The boost control unit membrane is pre ---tightened and air
tight. A spring in the unit affects the lower surface of the membrane; the other end of the spring rests against the threaded
guide sleeve (2). The spring tension can thus be changed in
certain limits (adjusted in factory).
With thread equipped pin (1) is attached to the membrane.
The lower end of the pin transmits movement of the mem brane via an angle piece to the injection pump control rod (3).
When increased boost pressure presses the membrane
downwards, also the pin moves downwards against the
spring force and allows the control rod to move towards the
greater fuel amount, which is injected into the combustion
chambers. When the boost pressure decreases, the control
rod moves towards the smaller amount of injected fuel.
Important! The boost control unit has been adjusted in the
factory, and adjustments afterwards are not necessary.
1
2
3
A
B
Boost control
A. Adjustment screw with which is adjusted fuel amount,
which the injection pump injects at low boost pressure.
B. The operating pressure wheel.
Cold start solenoid
1. Forced---feed solenoid
for starting
Running position Starting position
When the engine is started, the control rod must move to the
starting position. This can be done by moving the boost control lever in the direction of the axle, so that the lever cannot
affect any more the injection pump control rod. The mechanism functions with aid of solenoid and a cross shaft.
The solenoid is energised, when the ignition switch is turned
in a starting position. The solenoid is energised as long as the
starter motor is on. In the starting position, the solenoid is
magnetic. When the solenoid moves to the starting position,
a click sound can be heard from the injection pump.
Page 62
4
231
Fuel System
13---6
A. Bleeding fuel system
413--- 8
1. Slacken the bleeder screw on the filter head. Pump with the
hand pump until the fuel flowing out at the bleeder screw is
free from air bubbles. Then tighten the bleeder screw.
413--- 9
3. Slacken the injection pump overflow valve. Pump with the
hand pump until the fuel flowing out is free from air bubbles.
Tighten the overflow.
4. Wipe off any fuel from the engine.
B. Bleeding thermostart system
Always remove air from the glow plug fuel pipe when the pipe
or reservoir has been emptied during repair work etc. This
prevents damages to the glow plug caused by lack of fuel
during starting.
System with the magnetic valve
413--- 10
1. Disconnect the electrical wire from the glow plug and the
fuel pipe.
2. Connect electricity to the magnetic valve and rotate the engine until fuel comes out from the fuel pipe connection.
3. Tighten the pipe connection and connect the electrical
wire.
System with the fuel reservoir
1. Reservoir filling
2. To the glow plug
3. Return the fuel tank
4. Breather
1. If the tank is empty fill it first e.g. through the breather.
2. Open the fuel pipe connection to the glow plug and let the
fuel come out. Tighten the pipe.
Page 63
Fuel System
13---7
C. Measuring fuel feed pressure
1. Clean the fuel injection pump and the filter and the pipes
between them.
413--- 11
2. Fit the gauge at the banjo connection on the pump, as
shown above (between filter and injection pump).
3. Run the engine at low idling for a while and compare the
gauge reading with the prescribed value (0,6...1,0 bar).
Note! If the measured pressure is below the prescribed
value, this may be caused by:
--- faulty overflow valve
--- b l o c k e d f u e l f i l t e r
--- faulty fuel feed pump
--- blocked or leaking fuel pipes or unions
D. Checking overflow valve
If the fuel feed pressure deviates from the prescribed value,
check the opening pressure of the overflow valve.
1. Connect a pressure gauge to the banjo union in the same
way as in previous instruction 13 C.
2. Pump with the hand pump until the overflow valve opens.
Compare the reading on the gauge at the moment the valve
opens with the prescribed value (0,6...1,0 bar).
3. If the recorded opening pressure deviates from the prescribed value, the overflow valve should be changed.
Note! If the recorded pressure is considerably lower than the
prescribed value, there may be a fault in the hand pump or
the fuel feed pump valves.
E. Changing fuel feed p ump va lves
1. Clean the feed pump. Disconnect fuel pipes to the feed
pump. Remove the feed pump.
413--- 12
2. Secure the pump in a vice provided with soft jaws. Loosen
the tappet body from the pump and remove the piston, seal
rings, suction valve and the spring.
3. Detach from the pump body the outlet side threaded connector, in which is placed the pressure valve.
4. Rinse the valves with clean fuel and check the function and
possible wear.
5. Change the valve if needed and assemble the pump using
new o---rings and gasket.
F. Checking injection timing
The injection starting point in the 1 st cylinder has been positioned with aid of an indicator pin in the pump governor housing and with a locator/mark hole on the flywheel. In some engines the injection timing for cylinder no. 1 is marked on the
vibration damper. The timing indicator is on the left side of the
vibration damper.
1. Clean the injection pump and its surroundings carefully.
2. Turn the crankshaft to a position where the 1 st cylinder piston reaches its compression stroke top dead centre. Then
turn the crankshaft backwards until the mark hole on the flywheel (mark on the vibration damper) passes the locator hole
on the front face of the flywheel housing (timing indicator).
After that rotate the crankshaft slowly to running direction until
the mark hole on the flywheel (mark on the vibration damper)
is at the point of the locator hole (timing indicator).
Page 64
Fuel System
13---8
9104 52800
413--- 13
3. Push the locator 9104 52800 into the holes on the flywheel
housing and on the flywheel.
413--- 13/1
Or check, that the mark on the vibration damper is at the point
of the timing indicator .
413--- 14
4. Unscrew the plug on the side of the injection pump. Take
out the indicator pin.
5. Turn the indicator pin and push it into the hole so that the
groove at the end of the pin points towards the pump.
6. If the pin groove fits on the boss on the governor weight assembly, the injection timing is correct. Repeat the check
procedure. If the injection pump needs to be adjusted, follow
the instructions under heading 13 G.
Note! Do not rotate the crankshaft when the groove end of the
pin is inside the pump, since the pin end damages easily and
plastic pieces remain in the governor housing.
7. When the adjustment is correct, turn the indicator pin so
that the groove points outwards (running position) and push
the pin into the hole. Refit the plug.
8. Take out the locator from the flywheel hole.
Usage of the electrical inspection device
(Bosch KDEP 1601 0 986 612 174)
Also in electrical device can be used to check the timing.
1. Turn the crankshaft to a position where the 1 st cylinder piston reaches its compression stroke top dead centre. Then
turn the crankshaft backwards until the mark hole on the flywheel passes the locator hole on the front face of the flywheel
housing.
2. Unscrew the plug on the side of the injection pump. Take
out the indicator pin.
0 986 612 174
413--- 15
3. Connect the inspection device sensor into the governor
housing. Note the position of the sensor! Connect the --- wire
into earth.
4. Rotate the crankshaft in running direction until light A is on.
5. Continue rotating the crankshaft in running direction very
slowly until light B is on.
6. Push the locator 9025 99100 into the hole on the flywheel
housing. If the mark hole on the flywheel is at the point of the
locator hole, the injection timing is correct. If the holes are not
at the point, preform the adjustment according to instruction
13 G.
Page 65
Fuel System
13---9
G. Adjusting fuel injection timing
If the timing is incorrect, adjust as follows:
1. Loosen the retaining nuts and screw of the injection pump
and the connection nuts of the injection pipes.
A
R
413--- 16
2. If the injection timing is retarded, turn the injection pump
anti---clockwise (viewed from the front end of the pump). If the
timing is advanced, turn the pump clockwise.
3. Check the injection timing and turn the pump again, if
necessary.
4. When the injection timing is correct tighten the retaining
nuts and screw of the pump and the connecting nuts of the
injection pipes.
H. Adjusting idling speed
If the idling speed of the engine deviates from the value given
in the specifications or if the engine revs vary at the idling
speed, adjust the idling speed as follows:
1
2
413--- 17
1. Unscrew the idling speed adjusting nut cap (1) and the cap
(2) on the idling speed additional spring adjusting screw.
2. Ensure that the throttle lever is in the idling position and that
the engine is at normal operating temperature.
3. Start the engine and loosen the adjusting screw of the additional spring so that it does not affect the idling speed.
413--- 18
4.Adjusttheidlingspeedusingtheadjustingscrewtoabout
20...30 rpm below rated speed and lock the adjusting screw.
5. Run the engine a few times and ensure that the idling
speed remains as set.
6. Tighten the adjusting screw of the additional spring until
the idling speed rises to the rated value. Lock the adjusting
screw in this position.
7. Fix the safety caps of the adjusting screws.
Note! Other adjustments (output and max. speed) of the injection pump can only be performed by a specially trained
person who has the necessary special tools and gauges
available.
I. Removing fuel injection pump
1. Clean the injection pump and surrounding engine parts
and the pipes and connectors on the injection pump.
2. Disconnect the delivery pipes and the banjo bolts at the
supply and return fuel connections. Disconnect the lubricating oil line. Plug all connections.
3. Drain the cooling system and remove the cooling pump.
4. Detach the cover from the front cover. Unscrew the pump
drive gear nut.
Page 66
Fuel System
13---10
413--- 19
9052 48900
5. Use puller 9052 48900 and loosen the gear from the injection pump camshaft front end.
6. Open the retaining nuts and bottom mounting screws and
remove the injection pump.
7. Take off the fit ring and clean the sealing surfaces.
Note! The injection pump gearing remains in contact with the
idler gear, so you don’t have to mark their position when removing the pump.
J. Fitting fuel injection pump
1. Check the condition of the o --- rings between the pump and
the timing gear casing. Change the o--- rings if necessary.
413--- 20
2. Lubricate the o --- ring and put the fit ring to the timing gear
casing.
3. Lubricate the o --- ring and place the injection pump so that
the key on the pump shaft aligns with the key slot inside the
gear. Tighten the gear nut to 200 Nm and fit the cover.
4. Adjust the injection timing, see instruction 13 G.
5. Connect the supply and return fuel lines. Connect the lubricating oil line. Use new sealing washers. Fit the delivery
pipes.
6. Bleed the fuel system, see instruction 13 A.
7. Fit the coolant pump and fill the cooling system.
K. Removing injectors
1. Clean the injectors and the area around them. Disconnect
the delivery pipes and the leak --- off pipes.
9104 53700
413--- 21
2. Remove the injector attaching nuts and remove the injector
from the cylinder head. Fit protective plugs to all connections.
If the injector does not rise by hand, use puller 9104 53700.
3. Remove the sealing washers from the bottom of the injector
location in the cylinder head if they do not come out with the
injector.
L. Inspecting injectors
Note! When pressure testing the injectors, it is important
to avoid the nozzle end as the fuel jetting out easily penetrates the skin. Also bear in mind that the fuel ”mist” is
dangerous to inhale.
1. Clean the injector with cleaning fluid and a soft brush.
The carbon deposits must not be knocked off or removed in
any other way which may damage the nozzle.
Page 67
413--- 24
1
2
3
4
5
6
7
8
9
Fuel System
13---11
413--- 22
2. Secure the injector in a test bench and check the following:
--- injector opening pressure
--- the properties of the chattering (creaking) sound and the
form of the spray pattern
--- sealing of nozzle valve against its seat
Opening pressure
Pump a few times to fill the injector. Increase the pressure in
the injector until the chattering (creaking) sound becomes
audible. Read off the opening pressure of the injector. If the
opening pressure deviates from the given value (230±5 bar),
the injector should be taken apart and checked.
Adjustment is achieved by changing the shim. The thickness
of the shims varies from 1,00...1,90 mm and they are available
in increments of 0,05 mm. A thicker shim will raise the opening pressure while a thinner one lowers it. A difference in shim
thickness of 0,05 mm changes the opening pressure by approx. 5,0 bar. As the opening pressure of the injector drops
slightly after adjustment, the opening pressure should be set
to approximately 10 bar above the value given in the specifications. This value applies both to new and used injector.
Chattering sound properties
Testing with a hand powered pump does not create the same
circumstances as when the injector is fitted in the engine.
Only with new nozzles are the test results reliable. With used
nozzles, there is no chattering (creaking) sound when the
tester is pumped at a certain rate. This has to do with the design of the nozzles.
However, with a rapid pumping on the tester handle, it should
be possible to hear the chattering (creaking) sound or/and
see a mist of the fuel jetting out.
Tightness of nozzle
Press down the tester pump lever until the pressure rises to
approx. 20 bar below the adjusting value. Maintain this pressure for approximately 10 seconds and check whether drops
of fuel are formed on the point of the nozzle. If the injector
leaks, it should be cleaned or the nozzle should be changed.
M. Reconditioning injectors
1. Secure the injector in a suitable way.
2. Unscrew the nozzle cap nut. Remove the nozzle and the
parts inside the holder.
3. Clean the nozzle in cleaning fluid both inside and outside.
4. Clean the nozzle holes with a needle (including in cleaning
set 8360 83288).
5. Test the movement of the nozzle valve as follows:
413--- 23
Rinse the parts thoroughly in fuel or testing fluid. Pull the valve
out of the nozzle body to 1/3rd of its length. If the fit is correct,
the valve should be able to slide down in the nozzle body
under its own weight. Turn the valve slightly and repeat the
test. Should the nozzle valve bind slightly, it should be
changed.
Injector
1. Fuel inlet
2 . L e a k --- o f f f u e l
3. Shim
4. Pressure spring
5. Valve stop spacer
6. Nozzle body
7. Pressure chamber
8. Nozzle valve
9. Nozzle hole
Page 68
1
2
3
413--- 25
Fuel System
13---12
6. Before assembling, all parts should be carefully cleaned in
clean fuel or testing fluid.
7. Put the same thickness of shim back as were fitted earlier.
Note possible adjustment of the opening pressure. Assemble
the rest of the injector. Note the position of the spring guide
andthevalvestopspacer.
8. Tighten the nozzle cap nut by hand and then to 60 Nm.
N. Fitting injector in engine
1. Clean the injector sealing surface in the cylinder head. If
necessary use a reamer 9101 66000.
1. Washer
2. Rubber ring
3. Sealing washer
2. Fit the injector in the cylinder head using a new sealing
washer.
Note! The spray pattern from the injector is not symmetrical
on purpose. It is therefore important that the injector is fitted
correctly in the cylinder head. The connection for the leak ---off
line should be facing the valve mechanism.
3. Fit the attaching clamp and tighten the nuts evenly to 15
Nm.
4. Connect the leak --- off line together with new sealing
washers and connect the delivery pipes .
Note! The screw studs in the cylinder head for the injectors
should only be finger tight. If tools have to be used the studs
should be tightened only lightly.
Note! Make sure, that the injector is of a correct type. Wrong
injectors cause malfunctions and can damage the engine.
O. Fitting delivery pipes
1. Check the state of the pipes. If there are kinks, damage by
chafing, or if the tapered sealing end is damaged, the pipes
should be changed.
2. Fit the pipes without tension and check that they are at right
angles to the union.
3. Fit the clamps for the pipes.
Page 69
OUTPUT %
0,80
0,85
0,90
0,84
+5
0
--- 5
B
35
+5
0
--- 5
A
OUTPUT %
10
20 30 40 50 60
FUEL TEMPERATURE ˚C
C
+5
0
--- 2
234
56
78
OUTPUT %
VISCOSITY cSt
Density, +15˚C 0,82...0,86 kg/dm3ASTM D 4052, EN ISO 12185
Viskosity, +40˚C 1,2...4,5 mm
2
/s ASTM D 445, ISO 3104
Sulphur content max. 0,2 % m/m ASTM D 4294, ISO 8754
Cetane index min. 45 ASTM D 4737
Water content max. 200 mg/kg ASTM D 1744
Requirement Test method
DENSITY kg/dm
3
Fuel System
13---13
Fuel quality requirement
The fuel should be according to norm EN 590.
Engine output depending on fuel quality
Different fuel qualities like temperature, density and viscosity
affect the actual output of the engine. Our output rates use fuel
with a density of 0.84 kg/dm
3
and specific heat rate of 42,7 Mj/
kg at a fuel temperature of +15˚C.
The correction in % caused by the change of fuel qualities is
seen in the attached figures.
FIG.A. Engine output dependence on fuel temperature.
+35˚C is the reference temp (correction 0 %).
The fuel temperature is not only a function of ambient conditions but also varies according to the fuel system of the application (tank size and location, return flow etc.).
FIG. B. Engine output dependence on fuel density. Normal
value is 0,84 kg/dm
3
at +15˚C.
FIG. C. Engine output dependence on fuel viscosity. Normal
valueis3cStat+20˚C.
Note fig. B and C only if the fuel quality is changed. In fig. A
there are all the quality dependencies caused by the change
of the temperature. The fuel density and viscosity can be seen
in the produce declaration given by the manufacturer.
The output correction is made as follows: Correction percentages from figures A, B and C are summed up. The given rated
power is then corrected with the resulting percentage.
Page 70
Equipment and Feeding Table 1 4 --- 1
FUEL SYSTEM Test equipment ISO 4008 Nozzle ISO 7440 207 bar
EQUIPMENT AND FEEDING TABLE Fluid ISO 4113 0,60 orifise plate
Pipes ø 6 x 1,5 x 600 ISO 4093
645
Engine Application Pump spare part no Pump Injection advance˚ Boost rpm Feed rate RW mm Control rod Control rod Element
Fuel adjustment card Governor Max. output r/min control mm
3
/stroke min. position Pressure valve
Idling r/min press. ---1 mm 4 mm Covernor spring
Output kW bar rpm rpm
645 DSBAEL MF 7276 8368 54748 PES 6P 120A 12 2,0 1000 242---244 14,1...14,5 1020 1065--- 1085 ---
8.000 320RS 7437 2000 2,0 500 14,1...14,5 -- -
/--- 1100 LDA -- -
RSV 550 --- 1000 263 1,5 500 14,2
P1A 678 0,0 500 150---152 10,7
0,0 550 12---14 3,8...4,2
645 DSBIE MF 8280 8363 54708 PES 6P 120A 14 1,2 1100 172 -- -174 11,8...12,2 1120 1180--- 1200 8363 54638
MF 8180 8.002 320RS 3382 2200 1,2 950 180--- 182 12,2...12,6 8363 30239
/--- 950 1,2 750 181---183 12,2...12,6 -- -
RSV 200 LDA
0,75---0,80 500 11,9
0,0 500 110 ---113 8,7...9,1
0,0 475 7 -- -10 5,5
645 DSBIE MF 8170 8363 54740 PES 6P 120B 14 1,2 1100 157 --- 159 10,5...10,9 1120 1180 - -- 1200 8363 54638
MF 8270 8.003 320RS 3382 2200 1,2 950 166 --- 168 8363 30239
Allis 9775 /A 950 1,2 750 167 ---169 ---
RSV 181 LDA
0,60---0,65 500 10,6
0,0 500 110 ---113 8,7...9,1
0,0 475 7 -- -10 5,5
645 DSBIEL MF 7272 8363 54800 PES 6P 120A 14 1,5 1000 176---178 11,5...11,9 1025 1065--- 1075 8363 54638
LAN 8.007 320RS 3382 2000 1,5 500 184 --- 185 12,0...12,4 8363 30239
/F 1100 LDA ---
RSV 425 --- 1100 205 1,1 500 11,6
P0A 669 0,0 500 100 ---102 8,7...9,1
0,0 550 7 -- -10 5,5
Page 71
Equipment and Feeding Table 1 4 --- 2
FUEL SYSTEM Test equipment ISO 4008 Nozzle ISO 7440 207 bar
EQUIPMENT AND FEEDING TABLE Fluid ISO 4113 0,60 orifise plate
Pipes ø 6 x 1,5 x 600 ISO 4093
645
Engine Application Pump spare part no Pump Injection advance˚ Boost rpm Feed rate RW mm Control rod Control rod Element
Fuel adjustment card Governor Max. output r/min control mm
3
/stroke min. position Pressure valve
Idling r/min press. ---1 mm 4 mm Covernor spring
Output kW bar rpm rpm
645 DSBIEL MF 7274 8368 54811 PES 6P 120A 12 2,0 1000 230---232 13,2...13,6 1020 1065---1085 ---
8.009 320RS 7437 2000 2,0 500 222 - --224 13,2...13,6 ---
/A 1100 LDA ---
RSV 550 ---1000 234 1,2 500 212 -- -214 13,3
P1A 678 0,0 500 150 ---152 10,7
0,0 550 12 ---14 3,8...4,2
645 DSIM BONI 8368 54775 PES 6P 120A 12 1,8 1000 242 - -- 244 14,1...14,5 1010 1080 ---1100 ---
8.005 320RS 7437 2000 1,8 800 14,0...14,4 -- -
/C 850 LDA - --
RSV 295 1,2 500 212 --- 214 13,0
0,0 500 150 -- -152 10,7
0,0 425 12 -- -14
645 DSBIE Vammas 8363 54839 PES 6P 120A 14 1,2 1000 170-- -172 11,8...12,2 1020 1090---1110 8363 54638
RG 281 8.010 320RS 3382 2000 1,2 500 12,1...12,5 8363 30239
/M 850 LDA ---
RSV 200 0,76 500 10,8...11,2
0,0 800 100 ---102 8,9...9,3
0,0 425 10 -- -13 5,5
Page 72
Equipment and Feeding Table 1 4 --- 3
FUEL SYSTEM
INJECTOR
Order no. Manufacturer Type Nozzle no. Holes Opening pressure bar Setting pressure bar
1
) Adjusting plate no. 1,00...2,00 mm Code (C)
8363 54615 Bosch P 8363 54611 4 250
+8
258 8363 40907...8363 40925 ---
8368 54929 Stanadyne M 8368 54930 5 270
+8
278 8368 62000...8368 62020 234
1
) Value to be used when adjusting the opening pressure of a new or used injector.
Page 73
Electrical System
15---1
15. ELECTRICAL SYSTEM
A. Alternators
Magneti Marelli A 127 45 A/65 A (Sisu Diesel no. 8366 40127 45 A)
(Lucas) (Sisu Diesel no. 8366 40128 65 A)
Nominal voltage 12 V...............................................................
Max. voltage 6000 r/min A 127 45 A 45 A.................. ...........................
A 127 65 A 65 A...........................
Earthing ( --- ) m i n u s......................................................................
Max. allowed speed 15 000 r/min............................................................
Brushlengthwhennew 17mm.........................................................
Min. brush length 5mm..............................................................
Brush spring tension 1,3...2,7 N...........................................................
Number of stator poles 12.........................................................
Number of stator phases 3........................................................
Stator resistance A 127 45 A 0,25 ohm......................... ...........................
A 127 65 A 0,18 ohm...........................
Rotor resistance 2,9 ohm...............................................................
Regulating voltage 13,6...14,4 V.............................................................
Tightening torques:
1. Shaft nut 60 Nm................................................................
2. Assembling screws 5,5 Nm.......................................................
3. Phase connection (M5) 4,0 Nm....................................................
4. Regulator screws 2,5 Nm.........................................................
5. Main connection 4,0 Nm..........................................................
1
2
3
4
5
2
1
A 127
45 A
65 A
AC 5 RS
415--- 1
CAV AC 5 RS 24 V 55 A (Sisu Diesel no. 8353 39422)
Nominal voltage 24 V...............................................................
Output
2000 r/min 27 A.................................................................
3000 r/min 42,5 A.................................................................
4000 r/min 49 A.................................................................
Charge begins 1250 r/min................................................................
Max. allowed speed 10 000 r/min............................................................
Min. slip ring diameter 32 mm..........................................................
Min. brush length 8mm..............................................................
Brush spring tension 2,23 N...........................................................
Rotor resistance 8,0...8,3 ohm...............................................................
Stator resistance 0,09 ohm...............................................................
Tightening torques:
1. Shaft nut 55 Nm................................................................
Page 74
Electrical System
15---2
Bosch N1 28 V 10/80 A (Sisu Diesel no. 8353 39751)
Nominal voltage 24 V..............................................................
Output
1500 r/min ³16 A................................................................
2700 r/min ³53,5 A................................................................
6000 r/min ³79 A................................................................
Min. slip ring diameter 26,8 mm.........................................................
Brushlengthwhennew 19mm........................................................
Min. brush length 5mm.............................................................
Rotor resistance 7,5...8,2 ohm..............................................................
Stator resistance 0,057...0,062 ohm..............................................................
Regulating voltage 28 V............................................................
Tightening torques:
1. Shaft nut 55 Nm................................................................
2. Assembling screws 4,1...5,5 Nm.......................................................
3. Regulator screws 1,6...2,3 Nm.........................................................
4. Joint B--- (M6) 4,8...6,8 Nm...........................................................
5. Joint W (M5) 2,7...3,8 Nm.............................................................
6. Joint D+ (M4) 1,6...2,3 Nm...........................................................
7. Joint B+ (M8) 7,5...8,0 Nm...........................................................
1
2
3
4
6
5
7
14 5
6
2
7
3
415--- 2
100 A80 A
Bosch N1 28 V 0/100 A (Sisu Diesel no. 8353 40374)
Nominal voltage 24 V..............................................................
Output (warm generator, testing voltage 26 V)
2000 r/min ³26 A................................................................
3500 r/min ³72 A................................................................
7000 r/min ³94 A................................................................
Min. slip ring diameter 26,8 mm.........................................................
Brushlengthwhennew 19mm........................................................
Min. brush length 5mm.............................................................
Rotor resistance 7,5...8,2 ohm..............................................................
Stator resistance 0,038...0,041 ohm..............................................................
Regulating voltage 28,5 V............................................................
Tightening torques:
1. Shaft nut 70 Nm................................................................
2. Assembling screws 4,1...5,5 Nm.......................................................
3. Regulator screws 1,6...2,3 Nm.........................................................
4. Joint B--- (M6) 4,8...6,8 Nm...........................................................
5. Joint W (M5) 2,7...3,8 Nm.............................................................
6. Joint D+ (M4) 1,6...2,3 Nm...........................................................
7. Joint B+ (M8) 7,5...8,0 Nm...........................................................
Page 75
Electrical System
15---3
Iskra AAK 5118 14 V 95 A (Sisu Diesel no. 8366 40927)
(Sisu Diesel no. 8366 66225)
Nominal voltage 12 V..............................................................
Output (testing voltage 13 V)
2000 r/min ³50 A................................................................
4000 r/min ³84 A................................................................
6000 r/min ³94 A................................................................
Charge begins 1100 r/min...............................................................
Max. allowed speed 15 000 r/min...........................................................
Min. slip ring diameter 15,3 mm.........................................................
Min. brush length 5mm.............................................................
Rotor resistance 2,7...2,97 ohm..............................................................
Stator resistance 0,33...036 ohm..............................................................
Tightening torques (see figure below):
1. Shaft nut 50...70 Nm...............................................................
2. Joint B+ (M6) 4,2...6,0 Nm...........................................................
3. Joint D+ (M5) 2,7...3,8 Nm...........................................................
4. Joint W (M 5) 2,7...3,8 Nm............................................................
1
2
3
4
415--- 3
Bosch NC 14 V 70 ---120 A (Sisu Diesel no. 8368 40939)
Nominal voltage 12 V..............................................................
Output (13,5 V)
2000 r/min 79 A................................................................
4000 r/min 111 A................................................................
6000 r/min 120 A................................................................
Charge begins 1200 r/min...............................................................
Max. allowed speed 12 000 r/min...........................................................
Min. slip ring diameter 14,9 mm.........................................................
Brushlengthwhennew 12,5mm........................................................
Min. brush length 5mm.............................................................
Tightening torques (see figure above):
1. Shaft nut 60...70 Nm................................................................
2. Joint B+ (M8) 10 Nm...........................................................
3. Joint D+ (M5) 5 Nm...........................................................
Bosch NC 14 V 150 A (Sisu Diesel no. 8368 64048)
Nominal voltage 12 V..............................................................
Min. slip ring diameter 14,9 mm.........................................................
Brushlengthwhennew 12,5mm........................................................
Min. brush length 5mm.............................................................
Tightening torques (see figure above):
1. Shaft nut 60...70 Nm................................................................
2. Joint B+ (M8) 10 Nm...........................................................
3. Joint D+ (M5) 5 Nm...........................................................
Page 76
Electrical System
15---4
Bosch N1 28 V 10/80 A 2 ---pole (Sisu Diesel no. 8366 64152)
Nominal voltage 24 V..............................................................
Min. slip ring diameter 31,5 mm.........................................................
Brushlengthwhennew 12mm........................................................
Min. brush length 5mm.............................................................
Tightening torques:
1. Shaft nut 70 Nm................................................................
2. Assembling screws 4,1...5,5 Nm.......................................................
3. Regulator screws 1,6...2,3 Nm.........................................................
4. Joint B--- (M6) 4,8...6,8 Nm...........................................................
5. Joint W (M5) 2,7...3,8 Nm.............................................................
6. Joint D+ (M4) 1,4...2,0 Nm...........................................................
7. Joint B+ (M8) 7,5...8,0 Nm...........................................................
1
4
5
6
2
7
3
415--- 3/1
Page 77
Electrical System
15---5
B. Starters
Magneti Marelli M 127/2,8 12 V (Sisu Diesel no. 8353 31592)
(Lucas)
Values, unloaded
Running speed 5500...8000 r/min (max.).............................................................
Amperage 115 A..................................................................
Voltage 11 V....................................................................
Values, under loading
Running speed 1000 r/min (max.).............................................................
Amperage 670 A..................................................................
Voltage 8,0 V....................................................................
Torq u e 20,8 Nm.....................................................................
Values, locked
Running speed 0r/min(max.).............................................................
Amperage 1160 A..................................................................
Voltage 5,0 V....................................................................
Torq u e 45,4 Nm.....................................................................
Brush spring tension 11,6...15,5 N...........................................................
Min. brush length 8mm..............................................................
Min. commutator diameter 38 mm......................................................
Tightening torques:
1. Solenoid battery jointing 12 Nm....................................................
2. Solenoid retaining screws 6 Nm..................................................
3. Fork link nut 20 Nm..............................................................
4. Assembling screws 11 Nm........................................................
5. Earth joint 8Nm................................................................
0,14 ... 1,14
1
2
3
45
415--- 4
Magneti Marelli
Bosch JF (R) 24 V 4 kW (Sisu Diesel no. 8353 30965)
B o s c h J F ( R ) 2 4 V 4 k W 2 --- p o l e (Sisu Diesel no. 8361 30388)
Values, unloaded
Running speed >7000 r/min.............................................................
Amperage <85 A..................................................................
Voltage 23 V....................................................................
Values with armature locked
Running speed 0r/min(max.).............................................................
Amperage 900...1050 A..................................................................
Voltage 13,5 V....................................................................
Torq u e >65 Nm.....................................................................
Solenoid engaging voltage min. 18 V..................................................
Min. brush length 8,5 mm..............................................................
Min. commutator diameter 42,5 mm......................................................
End play of armature 0,1...0,3 mm...........................................................
Page 78
Electrical System
15---6
Iskra AZJ3234 12 V 3,1 kW z11 (Sisu Diesel no. 8366 40949)
Values, unloaded
Running speed £10 000 r/min............................................................
Amperage £140 A.................................................................
Voltage 11 V...................................................................
Values with armature locked
Running speed 0 r/min (max.)............................................................
Amperage £1660 A.................................................................
Voltage 5,6 V...................................................................
Torq u e ³45 Nm....................................................................
Brushlength(new) 23mm............................................................
Min. brush length 13 mm.............................................................
Brush spring tension 40...48 N..........................................................
Min. commutator diameter 43,5 mm.....................................................
Tightening torques:
Studs (M6) 5,8 Nm................................................................
Screws on solenoid (M5) 3,2 Nm....................................................
Screws on solenoid (M6) 6,0 Nm....................................................
Pole shoes (M10) 37 Nm...........................................................
Brush holder 3,2 Nm...............................................................
Lever pin on engagement lever 12 Nm...............................................
Contact screws on solenoid switch (M8) 8,5 Nm.......................................
Contact screws on solenoid switch (M10) 13 Nm......................................
Iskra AZJ3247 12 V 3,6 kW z11 (Sisu Diesel no. 8366 40940)
Values, unloaded
Running speed £10 000 r/min............................................................
Amperage £140 A.................................................................
Voltage 11 V...................................................................
Values with armature locked
Running speed 0 r/min (max.)............................................................
Amperage £1756 A.................................................................
Voltage 5,3 V...................................................................
Torq u e ³47 Nm....................................................................
Brushlength(new) 23mm............................................................
Min. brush length 13 mm.............................................................
Brush spring tension 40...48 N..........................................................
Min. commutator diameter 43,5 mm.....................................................
Tightening torques:
Studs (M6) 5,8 Nm................................................................
Screws on solenoid (M5) 3,2 Nm....................................................
Screws on solenoid (M6) 6,0 Nm....................................................
Pole shoes (M10) 37 Nm...........................................................
Brush holder 3,2 Nm...............................................................
Lever pin on engagement lever 12 Nm...............................................
Contact screws on solenoid switch (M8) 8,5 Nm.......................................
Contact screws on solenoid switch (M10) 13 Nm......................................
Page 79
Electrical System
15---7
Iskra AZJ3319 12 V 3 kW z10 (Sisu Diesel no. 8366 40949)
Values, unloaded
Running speed £8000 r/min............................................................
Amperage £90 A.................................................................
Values with armature locked
Running speed 0 r/min (max.)............................................................
Amperage £1375 A.................................................................
Torq u e ³51 Nm....................................................................
Brushlength(new) 23mm............................................................
Min. brush length 13 mm.............................................................
Brush spring tension 30...35 N..........................................................
Tightening torques:
Studs (M6) 5,8 Nm................................................................
Screws on solenoid (M5) 3,2 Nm....................................................
Screws on solenoid (M6) 6,0 Nm....................................................
Pole shoes (M10) 37 Nm...........................................................
Brush holder 3,2 Nm...............................................................
Lever pin on engagement lever 12 Nm...............................................
Contact screws on solenoid switch (M8) 8,5 Nm.......................................
Contact screws on solenoid switch (M10) 13 Nm......................................
Iskra AZJ3256 24 V 4 kW z11 2--- pole (Sisu Diesel no. 8366 64355)
Values, unloaded
Running speed £10 000 r/min............................................................
Amperage £80 A.................................................................
Values with armature locked
Running speed 0 r/min (max.)............................................................
Amperage £1200 A.................................................................
Torq u e ³70 Nm....................................................................
Brushlength(new) 23mm............................................................
Min. brush length 13 mm.............................................................
Brush spring tension 30...35 N..........................................................
Tightening torques:
Studs (M6) 5,8 Nm................................................................
Screws on solenoid (M5) 3,2 Nm....................................................
Screws on solenoid (M6) 6,0 Nm....................................................
Pole shoes (M10) 37 Nm...........................................................
Brush holder 3,2 Nm...............................................................
Lever pin on engagement lever 12 Nm...............................................
Contact screws on solenoid switch (M8) 8,5 Nm.......................................
Contact screws on solenoid switch (M10) 13 Nm......................................
Page 80
AB
415--- 5
Electrical System
15---8
C. Fitting stop solenoid
A Running position
B Stop position
For a correct use of the dual coil solenoid (pull coil and hold
coil) the plunger should reach the end of its magnetic stroke
at each pulse. In this way, it will press the internal switch which
connects the continuous operation second hold coil working
without over ---heating and with a minimum power absorption.
1. Fit the solenoid energized and adjust the leverage in such
a way that the stop lever will reach its position or running position (stop solenoid energized during running).
Note! Energize the solenoid through a battery with suitable
voltage and keep it energized during installation.
D. Installation of magnetic pick up
1. Rotate the flywheel to a position so that one of the flywheel
ring gears teeth are in front of the pick up installation hole.
0,75
415--- 6
2.Turn the pick up in, until it comes in contact with the tooth.
3.Turn the pick up out ½ turn and tighten the lock nut. This
way the pick up end is 0,75 mm from the tooth.
Note! Clean the pick up end from dirt in the yearly service.
E. Temperature sensor
2
1
415--- 7
1. Connection for warning light
2. Connection for temperature gauge
Alarming temperature 98 ± 3˚C.
Gauge monitoring resistances:
60˚C 134 ± 13,5 ohm..........
90˚C 51,2 ± 4,3 ohm..........
100˚C 38,5 ± 3,0 ohm..........
Part no.
Alarm
temperature
6542 71208 98±3˚C
8366 40772 106±3˚C
8366 64017 110±3˚C
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