Valmet 309, 612, 311, 411, 611 Workshop Manual

UALMET

diesel

3o,9

911

4tl

611
612

Woftshop

Manual

1

General

Cylinder head and
valve mechanism

11

optionat equipment

lnlet- and exhaust
system.

Turbocharger.

1. Edition

15. 1.1986

YAITIT

VALMET CorDorrllon.

Llnn.vuo,i Wo.ka

372i10 LINNAVUORI,

Flnl.nd

Tol.

(lntl.)+

358 31

il03

300

Tgl€x 2212E

vålll st

T.lohx

(lntl.l

+

358 31

403 2E3

12

rO Tf

USER

Should the €nglng rgqulre meosur€s noi

descr I bed In

ihe

S€rvlce Departnent

of Valmet Llnnavuf I lq'ks.

fac+s

about +he

englne beforg cgniaciing us:

Thls

Iqkshop Manu6l

tq-

valmdt diesel

€nglnes

ls Intendsd io

facllliaie

rcr-kshop op€rallons and

repalr

rork.

lO9, lll,

4ll,

6ll

and

612

englnes

äre malnly iha

same

In construcilon, so tha

same

repolr

Instructlons

usually apply to dlffereni eflglne

lypes.

The dltf{ences

betr€n the

vc'lous englnE

iypes

rhlch alfecl repalr rcrk

have

been n ilon€d ln technlcal

data ånd

repalr Insfructlons.

All

n€tasu rgments

a-e

In

nllllmsires and valld

yh6n

thg iemperaiu

r€

of the

paris

ls

+20qC,

unless

othefti

ls9 sta+ad.

Before

star+lng rsprlrs,

makE

sure

tha+

you

havo

öll necessary

i@ls,

parts

and

accessorles

6i

your

dlsposal.

The speclal tools nsrfloned ln fhe rcrk Instruqlloos

re nof

all essenilal, but th€y

sp€d

up and

tacllltafo thg rrork and contrlbu+e io

successfu

I execuilon

ot

rork. An enqlne rhlch

has

under-

gone

rspålrs nusf be run ln

Jusi

llke a nef, one.

thls

manuol, please

consulf

your

local agent or

To facllltatE

consulflng,

flnd out the fol lorlng

-

Eng

lno typo

-

Eng

Ine nunber

-

Appllca+lon

or equ lpmenf

-

Hours og{afod

or kl lon€irgs drlven

4fl

DS

EGtfE

SPECTF tClTt(r{S

Englne type
Numb€r

ot cy I I nCf

s

D lsp

I aca[srf dn)
Bore nn
Sfroke ml
Coipress

lon rdf

lo

InJetlon

ader

Compress lon

pr€ssurp

borl)

Eng lne

type

Number

ol

cyl

lndf,s

Dlsp

lecsmqrt

dn)
Bore fin
Stroke m
Cdprass

lon röflo

InJ€cilon

ad€|'

CoDr€ss

I on

pressure

brr)

|

) l.llnl"u,n

vclue

cf oprallng

tonpratuftt

dllterencp

bqtr€gn

cyllnders

3,0

bar.

JO9

o/!S

t
2,7

lo0

llil
l7

3l

|

-2-5

24

4

DS

1
4,4

r08

120
l6: I
l-2-4-5
24

5

D

t,t
108
t20
l7: l
|

-2-5

21

6t

I D
6
t08

t20
l7: I
l-r-fr-2-1

21

llt Ds

6lt

Ds/Ds8

6
6,6
t08
120
l6: I
l

-t-5-6-2-1

21

ill

I D

1
4,4
108

t20
l7:l
|

-2-1-5

24

612 DS
6

7,4

r08

ltI
ltrl
t-5-H-2-4
21

l

5,t
l0B
t20
l6:

I

l-2-5

21

ond sterllng

ngvs.

Mox

pg.rDltfed

E

6tE Tt?E

DESt€r TtOtS

6t |

0sBJA

App I

I cat

lon

A

.

v€hlcle

srqlne

G

-

gen€ratlng-set

€ng

lne

L.

co[b

ln€

hcrvGtor

or|olne

l.l

.

nrlnc

eng ln€

P

=

pump

s€i srglne

Englne

oqulpped

rlth

boost

clr

coollng

(ilntercoolrt)

InJ6cilon

punp

iype

ln

B

.

Eosch

iPr

tlo

cod€

.

Bosch

r^n

Turbochcrg€d

q|glne

Bas I

c

tpc

6-cyllnder

er|glngs

olsp laclm€n+

of

one

cyllnd€r

(e.g.

Numb€.

ol

cyllnd€rs

't-2

l,

| ö5)

TtGHrEiltrc

TmqES

ObJ ect
Englne:

Pressut€

valve

holdf

Bosch

"Pr

Nm

Cyllnd€r

head scr€rs and nuts

f09, ,ll

Jö

4ll ....................

l60

Cyllnder

head screws

and nu+s

6ll cnd 51 2

. .

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

. . . . . .

. .

. .

See

Cyllndr

heåd sfuds to cyllnd€r

blck

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

lO

Moln

b€arlng

scrots

509

........

160

Maln

bearlng scrers

5ll, 4ll, 6lt

Jo

612

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

200

Connecilng

rod

nuis ........

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

90

Connecllng rod

scrsrs 612.............

..........

S@

F lyrheel

screws

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

l2O

F lyuh€l

hous Ing

scrersi

-

oufer

scrors

tl 12 ............

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

llO

-

Innr scrers

M l0 ...........

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

60

ldler

ggar

scrers:

-M10..........

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

60

_

M

t4

..........

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

l4o

ldler

gear

({l+h

boll bearlng)

scre|l 6ll and 61 2 . .

. . . .

. . .

. . . . . . . .

IBO

ldltr

ged-

bearlng

holdq-

scr€rs M 8 6ll

Ja

612 .................

22

Crankshoti

end nui

lO9,

lll

Jo

4ll ..............

600

Crakshaft end nul

6ll and 612 .........

.........10m

Screvs

of addlllonol

counterbalances 4l

| .........................

45

Coolonl

pump

pulley

nut

M 14 ...........

.........

IOO

Fuel

equ lpment:

lnJectlqr

purrp geq'

nuf

Bosch

trAn

..................,.............

90

InJsctlon punp gscr

nui

Bosch

nPi

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

. . . . . . . .

. . . . . . . . .

l,lO

InJecicr

re+alnlng nuis

(to

studs) Bosch

........

15

InJcioi

reialnlng

nuts

(to

sfuds)

CAV

..........

20

tlozz

le flxlng

bush Bosch

tlozz

le tlxlng

bush

CAV

........

InJectcr

adjustlng nu+

cov€r CåV .............

Pressure

valve

holder Bosch

nA'........

Corpresscr-:

Codpresscr-

pu

I

ley

nut Knorr

Conpressor

gear

nu+

B€ndl x

Compressq'

gef

nui C lay+cn

E

lectrlcal

equ lpDgnf:

Ins+ructlons, polnt

f

I K

Instructlons,

polrt

4

2 J

@

90

io
15

80

80
t40
180

A lternätcr pu

I ley nut

..........

45

1-3

CYLINDER

BLOO(

AND FLY|IfEL I{oUSIT{G

I

r{)€x

...

2-

3

Coostrustlott

..

Reoclr

I nstrucilons

l. Cylln&r blak

and

cyllnder

llners

A. Measurlng l-he

cyllnder

llner wear.......

......... 2- 5

B.

Rerpvlng the cyllnder I I

ner.

. . . . . . . . . . . ..........2-

5

C.

Checklng

ths

cylinder

blck............

..........

2- ,

D. Repfaclng ihe

camshafi

beorlng bush

tl1/4ll/309................... 2- 5

E.

R€placlng the camshaff bearlng bushes

6ll/612..................... 2- 6

F.

Camshaft correcilon be6rlng bushes

5ll/411........................ 2-

6

G. Camshött cor.ecilqr bearlng bush

509.........'....................

2-

6

H.

Comshatt

correcilon bearlng bushes

611/612........................ 2-

7

f. Fftflng fha blaklng

plug

of th€ cansh6ft llne 3@/5ll/411........ 2- 1

J.

Flitlng

ihe blocklng

plug

of

the canshaft llne 611

/612..

. .. . .. . . . .

2- 7

K. Flttlng

+he dlps+lck

gulde

p|pe.......

........... 2- 1

L.

Flftlng +he cyllnder 11ner............

...........

2- I

2. Flyrh€el

houslng

A.

Insiolllng

the flywheel houslng.'..

. . . . . . . . .

. .

.. 2_

l0

B.

Replaclng

the crankshafl

rear end seal....

.......

2-10

vAlitEr

Cyllndar

b lod( ,09

Holes fo.

doie I s

. . .

. .

. . . . .

.....

ll,OOO...ll,O4l

Dlam€ier

ol

maln

b€örlng

bore

. . . . . . . .

. . . .

.......

76,000...76;019

Dlanetor ol

cyllndei- llner bore:

-

upper

end

...

ll6,ot2,,.ll6,o47

-

lower

end

,,.

lt5,0oo...lli;Ol5

Inslde d lano+er

of

camshaft bearlng bush

(rhen

fltied

ln

posltlon).50,ö00...50,0å5

(50,o5o)

Tlgh+enln9 lorqu€

of flyrh€el

houslng scrers:

IECHN

lCåL DATA

(reJect

llrnl+ of

pari

stäted In brockets

afier ra+lno)

-

oufer

screHs

Ml2 ............,

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

llO

-

Innq'

scrers M10..........,..

......,..........

60

Tlghienlng

torquo

of maln

bearlng caps ...r.......................

l60

Cyllndar

block

tll,

4ll,

6ll, 612

Holos

for doye I s . . .

. . . . . . .

Dlan1oier

of m6ln

b€6rlng

bore

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

0lanetq- of

cyllnder llner

bore:

-

upper

end

-

toref

eno

Inslde

dl€fl€ter

of camshafl

bearlng bush

(when

fl+ted

In

poslilon)

Inslde d lameter

of cömshof+

baorlng bush

(rhen

flited

In

posltlon)

be6r I ngs

2...7

611,612.,......

Tlghtenlng iorque

of flyrheel

houslng scrersl

Nm
Nm
Nn

I l,000. ..

I r,041

91,000.. .9t,022

12t,r14.. .123,r54
122

,oco.

..122,

O4O

50,000., .50,025
49,990.. .50,050

(

9l

,0i10)

(

50,050 )

(

50,080 )

-

outer screHs

Ml2

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

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

llO Nm

-

Innei

screxs

Mlo

.........,...

.,...............

60 ND

Tlghtenlng

torque

of möln b€arlng cap

retalnlng screwg

..,.........200

Nn

Cyllnd€r

I Iner 509

Profruslql

of

cyllnder lln€r above

cyllndsr bl@k lop face

........

Max pernlsslble

holght dlfferonce b€tr,e€n

cyllnder llners

L

Inq'

bore

Max

peroisslble

ovalness

ot llner .......,...

Hel

ght

of

cy I Inder I Intr f I

ange

Helght

of cyllnder

llner tlange,

'lst

overslzo,

pärl

no

8f65

f6B2B .

l-lelght

of

cyllnder lln€r

flange, 2nd overslze,

pa-t

no

8J65

J6829.

Helghi

of

cyllnder

llner flange,

frd overslz6,

pöri

no 8165

j68lo

.

Outq'

d lameier of

cyllnder llnei tldtge

Cyllnd€r

lln€r lll, 4ll,

6ll

Protrusiqr ot

cyllndq- llner abovo

cyllnder

blcck

top

fac€ .,......

Max permisslble

helghi dlfference

beiw€n llners

(under

same

hoad).

L

Iner

bore

Max permisslble

ovalness

ot llner

...........

Helghi

of

cyl

Ind€r llner

t langs

Helgh+

of

cyllnder llner

flange, ls+ overslze,

pcrt

no

8t5J 29829.

Helght

of

cyllnder llntr flange,

2nd ov€rslze,

part

no SJjf 29gjo.

Helghf

of cyllnder

llner flange,

frd overslze,

port

no

8f5j

29gll .

Out€r dlamefer

ot

cyllnder llner

fl

ge

Cyllnd€r

llnor 612

Proirusio.r

of

cyllndei- I Ins- above

cyllnder

blak

fop

facs

.....,..

Max pernlsslble

helght dltterence betw€n

llners

(under

safl€

head).

L

Inef

bore

Möx peimisslble

ovölness

ot llner ...........

Helghi

ot

cyllnd€. llnq- flange

Helght

of cyllnd,ei

llner flange,

ls't overslze, p6rt

no

8l6J 184j6..

Helghi of

cyllnder llns- tlange,

2nd overslz€,

part

no Bf6f

f84l7..

Helght

of cyllnder

llner ftange,

frd ov6rslz€,

pö.f

no 8f6j

59439..

ouier d lamete|-

of

cy I Ind€r I Iner f I

ange

0,0J0...0,080
0,020

tm,0m...

t@,022
0,020
8, 0t. ..8, 05
8,08..

.8,

l0
I, 1t. ..8, 1 5
8,2t...a,25

t2l , ...122,@

0,0J0...0,080
0,020

108,000...108,022
0,020
9,01.,.9,05
9,08...9,t0
9,

ll.

..9,

| 5

9,25...9,25

I

ll

,

700. ..

I11,800

0,010...0,080
0,020
16,0@...108,022
0,020
9,01. ..9,

05

9,08.. .9,

| 0
9,13...9,15
9,25...9,25
Ill,70...I]l,80

(

100,080

)

(

t 08,080

)

(

| 08,080)

2

o

e

v

I

a3@ 91315
2 4360 97314
3 9045 348oO
4 9051 7J100

90]o 26too
5 51 72

0

9045 A1200

9051 72800

9045 87600
6

9025

52400
1 A36t 91466
I A36t

9146A
9

9025

98700

r0

9025

78100

11

9025

79200

SPECIAL

TOoLS

(Cylinder

block

and flywheel houslng)

Fli+lng

iool lor crankshafl rear end soal

F I

y{hee

I

hous

Ing contra

I lz In9 bush

chamfgring

reamer

for

cyllnder

llner bore

Tool

for exirac+lng and ro+aflng cyllnder

llner 309

Tool for

extractlng and

ro+aflng

cyllnder

llner

correctlon

reamer for cyllnder llner flt+lng 309

Correc+lon

ream€r

for

cyllnder liner

fliflng

tll

,

4ll,

6ll

Correc+lon

reamer for cyllnder llner fii+ln9

612

Exchange blade

Jor correct

lon rearner

Tool for ro+atlng cyllnder llner

Cup

plug

tapplng

drlf+ 40 mm

Cup

plug

+applng

drlfi

16 mm

Dorel

pln

+applng

drlft

Cyllnder

I Iner clamplng fool

Gauge for- measurlng

cyllnder llner

helghi

I

2-2

Self-made

tools

(cyllnder

blck and flyvrheel houslng)

A35t

9l5

.emov lng-

and

fl++lng equlpmenf for ihe bushlngs ot +he cansha{+.

O)

o
o)

@

\
or

CYLIIDER

BLCOK AND FLYB}EEL TIOUSING
co{sTRt cT I oN
CYL

INDER

BLOCK

CYL

INDER

ELOCK

(4II)

l.

Cy I Inder

block

2.

Boarlng

bush

J.

Scrow

4.

Bearlng

cap

5.

Bearlng

cap

(9ulde

bearing)

o. Ptn

DUsh

7.

Cy

I lnder

I lner

8.

0-r Inq

seal

lno

9.

Ptug

icamshafi

llne)

10.

D

lpstlck

p

tpe

I

l.

Nui

12.

S+ud

'-

lJ.

Screw

14.

Sea I Inq

rlno

15.

P

luq

16.

Cup p lug

17.

Draln

cock

18. Pressure

qauoe

sender

19.

P

lpe

The

cylinder block

fo.ms

l-he

englne body to

whlch +he

other englne

conponents are flxed.

The

cyllnder llners

(7)

are of ret type t{hlch

nEans thä-t ihe

coolan+

comes

dlrecily

ln+o

contac+ rlth +he llner

ou+e. su.face. Th6

seal ing be+Heen +he

cyllnder llner lo|ler end

and

cyllnder block

comprlses of +ro o-rlngs

(8)

whlch

have been

placed

ln the

g.ooves

on the

cyllnder llner.

The top end ls sealed by means

of

a

head

gaske+

sl+uafed between +he

cyllnder

llner flange

and

cyllnder

head.

The accurö-te

flf+ln9

of the

cyllnder llner flange and

+he

mating

face of ihe flange

ln the cyllnder block

ls also

essentlal for ihe iop

end seallng.

l{e

ask

you

io note

thls

especially in connec+lon

v.l-i'h

cy l inder

llner

assenbly.

6l11612 englnes

höve an o-rlng

seal also

ln +he

top end of +he

cyllnder

llner. There

are

coollng grooves

whlch

nake fhe

coollng

of the

hot top

part

nore

efllclent.

The cyllnder

block

Incorporates

+he

camshafi-

whlch

has +ho Jronl

bearlng

poln+

(j09,

l and

4ll

englnes)

equlpped

rlfh a

separa+e bearlng

bush

(2)

r{hlle the

other

bearlng

poln+s

have

been machlned

In the

cyllnder

block dlrectly.

ln

611/612

englnos

€ve.y

camshaf+ bearlng

poini

has a

separöle bearlng

bush.

The

rear

end o{ the

camshaft

llne ls

blocked

wlth

a dlsc

plug

In 309,

fl I and 4ll

englnes

rhereas the

6ll

and 6'12

englnes

have a

plug

equlpped

r,lth

an o-rlng

seal.-

On

both

sldes of the rear

maln

bearlna

+here are

posltlons

for gulde

b€arlng

shells

icrankshafi

axlal

bear

ings).

2-3

FLITfEL

IOIISIIG

ö

22

Flyrhcl

ho{sl ng

l.

Flyyh€€l

hous

lno

2.

Hgxagon

screw

-

f. Hexagon

s€ket

screy

4.

Sheft

sea I

5.

P lu9

6. Dore I pln

7.

S+ud

8.

llasher

9.

Nui

Th€ flyrheel houslng

Is flxed

to ihe rear

end

of ihe

cyllnder

block. The crankshaft

rear

and

shafi

seal

(4)

ls

DlacEd

In

ihe

recess

machlned

to fha

houslng. lo

oddltlon,

+h€ houslng has

a

rDuntlng

polni

lor ihe s+arter.

The

bot+o

föc€ ol ihe

flyrh€el houslng

Parfly

acis os the

maflng tace of ihe ol I sunp seal,

so lt nay not dlffer

much

from

lhe cyllnder

block bottom foc€. The carreci

Doslflon

of +he

flyrheel

houslng

ls secured a+ ihg

manufaciurlng

s+age

,lth doxel

plns

(6).

The

tlyyhe€l houslngs

are

dellvered occordlng

io +he rEqulram€nts sef by

the englne

appllcailon and dlfferent flyrhgels

can be

mounld on all anglne

+yp€6.

2-4

TIORK I

NSTRIjCT I ONS

I. CYLIIOER SLOCK AND CYLI

ND€R LI]GRS

A. I,GASUR I t{G I}IE CYL ITDER

L INER IiEAR

l.

Set ihe dlal

gauge

+o zero wlih a

mlcrome+er

wlth a ne', cyllnder llner,

lndlcatlng

diameter of an unworn llner

(108,00

mm).

2.

Clean

ihe Inner

surface

o{ ihe cvllnder llner

j-horough

ly

before

measureneni.

Perfoim

the neasuremoni crosswlse

a+ tho llner

top end, loYer

end

and mlddle.

Check

ihe

gauge readlng

for

maxlmum vrear

and

ovalness

(conpare

r{lih

ratlng).

RETOY

II€

llf

CYLINDER LINER

It

you

in+end io relnsiall the cyllnder

llners,

mark +he

liners so +ha+

+hey

can

be

placed

ln

ihelr

origlnal

posl+lons

In the cyllnder block.

Make ihe marklng on the lnner sdge of the llnsr

+op

flange,

e.g. on

+he edge towards canshaft,

s+a+lng the cylinder number.

3. Fl+ +he

bearlng bush In

place by

presslng

and

a+ ihe

same

ilme ensure the correc+

poslilon

of

ol I

holes.

4.

Af+er

fl+tlng

|-eam ihe bush io lis

proper

slze

(d

50.000...d 50,025).

I

Place the turnable dlsc

of

+he

llnor

extrac+or

(9010

26100) +hrough

the llner on lis lowar end

and

draw +he llner ou+ fron

the cvllnder block.

CHECKI NG

IHE CYLINDER BI-OCI(

Carefully

clean

the

cyllnder block of ol I and

other lmpurltles,

preferably

In a {ashlng

rnachlne.

Afier Hashlng

blow ihe cyllnder block

dry

wlth

pressure

alr and

pay

speclal

afienflon

to

ol I channels.

Remove all scraps of old

gasKeTs.

Check the cleenness of the coollng channols.
Remove the

bol ler scale

sedlneni to

ensure

englne

coollng.

Check

+he +lgh+ness of fhe

cup

plugs

önd screw

plugs

ln ihe

cyllnder block as l,ell as lhe

condl+lon

of +he

cyllnder block and seallng

laces.

I\4easure

+he wear of the

camshaft

bear

Ings

(compare

wlih

ra+lng).

REPLACI]'IG

ItE C/tljISMFT BEÄRING BUSH tO9, 5l I

ond

'll

I

Rgnove

fhe

bearlng bush rl+h an Inslde

exiracfor

(e.9.

SYKES

no.

854).

You can

also

remove

the

bush by +apping

t{lth a drlfi af+or

iaklng

oui

+he blocklng

plug

from

the rear ond

of

tho camsha{+ llne.

Clean ihe

bearlng houslng ln fhe cyllnder block

carefu

| |

y.

linder

block

i

front

face

I
I

or

Tne

l.

2.

l.

309

2

Notel

The bearlng bush

of the 509

In lls ra+ed

size

afier fliting

and

rqulre

ream Ing.

Measure ihe

clearance

of

+he bush

camshaft

and

cornpare

wlth railngs.

6

englne

ls

does nol

and the

2-5

.-\J

l/..

E . FEPLTC

I

}G

I}E

C,AT.6FåFT 8EÄR I iG BU$f S 6t

I /61

2

4,5
7

22171

2297'

22608

22609

2261O

Dla[€+er

o{ c.mshaff

b€arlnq

bush

holes ln

6ll,/612

englles

(nurb6rs

star+

fron the englne

front

endt.

Order nul5€rs for bearlng bushes

(mårked

oo the

outer surface of bear lng)
no.

27

Cairshaft

corr€ctlon

beorlng

bushes

for

fll

eng

I ne.

Comshafi @rrectlon

bearlng bushes

for 4ll

9n9lne.

cålrsr{ FT

@RREcfl ON 8€

Rt}G BUSfl 509

lf needed, you

can lnstall In the

cyllnder

block a

bush rlih

0,4 rm overslze

outer

dl emster

In

Dlaca

of thg

camshaft

froni

end

bearlng

bush.

The o.-dEr number lor

fhe ov€r-sl ze

bush ls 85f

24661

and

the

dlrFnslons lor

machlnlng

ihe

cyllnder

block are-d 56,0+0,010.

Vlhen

flitlng

fhe beärlng

bush chock

tho

correci

posltlon

ot oll

holes. The b€arlng

do€s not

need

reamlng

after f liflng.

Other bearlng

poln+s

In 309 englnes can be

fltted

xlih-

ihe

correspondlngi correctton

b€orlng

bushes

of lll 6nglne.

S€e

flg. 2 8.

a36t
at63
a36t

t.

6ll1612 englnes hav€ seven

replaceable

camshafl

b€arlng bushes.

obs€rve

the varylng ouiar

dlangters of th€ bush

holes

In the cyllnder

block

rhen renovlng and tlttlng

ihe bush€s.

Rsnove the b€arln9 bushes by

tapplng rlth a

sultable

dr I ft, fa Instance.

Clean

the bearlng

houslngs

In

th€ cyllnder

block

+horo0

gh

ly.

Flt the ner

bearlng

bushes In

ihelr

ploces by

presslng,

usfng a selfnnode

tool

8t5t 91556,

for

examo

19.

No+e fhg cgrrect

order of

fhe

bushes and the

Dosltlon

of the

oll

holes

of the

bushes

In both 6nds.

Reant

fhe flrsf b€arlng bush

fro.n fhe englne

front

end to lts

correci

slze.

(l

50,000...

50,025). ThE

othEr bushes ere

ln ihelr correct

slzes

äfter

llttlng

and

do

not requlre

reamlng.

Measure the clooranca of thg

bushes and

the

caiEhaft

and

compare

xlth råiln9s.

F.

C IGHAFT mRECr

tor{ EEAR titc BUSHES 5r1l/

l

lf

needad, you

can Install ln

ihe

cyllnder

block

a bush rlth

I rfl overslze outer dlanqter

In

plåce

of the

camshati

froni bearlng

bush.

The

bearlng poln+s

machlned

In

fhe

cyllndor

block

can also,

ll necassary, be equlpped rlfh

s€parate bearlng

bush€s.

Flgur€s

2 8 and 2 9

shoy the

order numb€rs

tf correcilon bearlno

bushes

and

th€ dlmenslons

for

machlnlno

thå

cyllnder

block for

b€arlng bush flfflng.

-

tlotel

tlhen

flfilng the

tront and rear bush

2-6

4.

G.

t.

H.

C^I,ISHAFT

@RRECT|ON

BEARTNG

BUSHES

6

l6t2

Camshatt correctlo4 bearfng

bushes for

6ll1612

eng I

nes

lf needed,

you

can

lnsial I

ln +he

cyllnder

block a bush vlth

I m overslze

ou+er

dlamsier

In

Dlace

of

the camshaf+

fronf

end

bushlng.

Oiher b'lshes can

b€ replaced

by overslze

bushes

wlih 0,4 mm outer

dlameier.

Flgure

210 shors

the

order

numbers

for the

correctlon

beårlng

bushes

and ihe

dlmenslons

for

machlnlng

ihe

cyllnder

block.

FITTING

IIf BLOCK I NG PLUG

OF lHE CAIT.ISHAFT LI]G

n9/ttl/111
Clean the blocklng

plug

space +o

gei rld

of old

seallng

conpound remal ns.

Apply seallng compound

(6909

J0008) on the

slde

of lhe b lock I ng

plug.

211

Töp the blocklng plug

In i+s

place

ylih

the

f lttl ng

iool

(9025

87400).

Notel Be careful no+ io lap

ihe blocklng

plug

+oo

deep because +hls

rlll affecl lhe

com-

sh€ft end

playl

Thorefore alrays

use a flftlng

tool.

J. FITTIT{G

THE

SLOCTI NG

PLUG

OF THE

CÄI.IIiHAFT

LINE

6t |

/612

l.

Clean the

blocklng plug posl+lon

and

use emery

Cloth to renove

ihe

posslble

sharp edges

On

ihe

hole rl m.

2.

Place

En o-rlng

In lhe

blocklng plug groove

and

lubrlcate

l+

tvlih, for

lns+ance,

­slllcone

seallng

compound.

Press

the blocklng

plug

In lts

posl+lon

and flx

Its

shleld

plate

(ln

englnes

where lhe flyxheel

houslng does not

cov6r the blocklng plug).

FITTII{G

TIf, DIPSTICK GUIDE

PIPE

Clean +he

plpe

hole

ln the

cyllnder block.

Apply reialnlng fluld

(6909

J0012)

to

the

gulde

plpe

loxer end.

K.

l.

213

lls

posltlon

ai fhe level

lJ.

l.

Tap the

gulde plpe

In

Indlcated

In flgure

2

L.

t.

FITTI}IG

IIG

CIL I ]OER

LIICR

Clean tho cyllnder

lln€r ond

lts llttlng

polnis

In

tha cyllnder

block thoroughly. The

qyllndor

llner lusf roiate

easllv

around

ln lts

bore

rhen +he

g-rlng

s€ollngs of the llner

have

been

relpveo.
Apply

marklng colour

fo

th6

undersld6

of the

cyllnder

llnei flang6

and

plaoe

ihe llner In

Its

poslilon

nlihou+

o-rlngs.

Roiate the llnsr

ln boih dlrectlons.

ll|lihdray +he llner and

check lf +he

louch ls even.

214

5.

lf

ihe mailng

lace

ls

domagod or li +he llner

proiruslon

abovg

the cyllnder block face needs

rnachlnlng,

use o correcilon reaner. Af+er

raamlng

you

con

perform

€ llgh+ lEpplng rl+h

the

llner,

lf needed. Apply

grlndlng pas+e

be+r€n

+ho

cy I Inder

I Iner

I lange and the

cyl

Inder block

and rofaie

ihe

llner

rlth tool

no.

6.

Lapplng ls

.|oi,

hoyever, ihe rlgh+

tEihod,

It

th9 cyllnder llner

protruslon

has io

b€

adj usied.

4.

At+er

roamlng and lepplng clean lhe

mailng

taces

caretully b€torg meosurlng the cyllnder

llner

Dro+ruslon.

5, Fo|- the fiFasurglEn+

procedure

press

tho

cyllnder llners In

ploca

wllh clanplng

iools

(9025

78100). Measure the llner Droiruslon

elih

measurlng gauge

(9025

79200).

Flx the dlal

gauge

+o +he measurlng

gauge

and sel

lf to zero

}tlih

a carefully cleaned

cyllnder

block top

face.

Move +he dlål

gauge

onto

ihe top of +he

cy I I nder | | ner f

lang€

and note

ihe

gauge

readlng.

Corry

oui ih€ measuremeni

ln tour

dlffereni

polnts.

The

proiruslon

of

ih€

cyllnder

llners obove the cyllnder

block iop

tace

should

be b€tyeen

orOJ cnd O,O8 ||r.

The

max

helght dl tterenca

betr€n

the

llners

under lhe

sane

cyllnder head

may

nof exceod

'".,K

R T\T

\R NTT\q \\Rl\

K\

K R \qK

fhan fhe

ones ln ellher

ends.

a- ö

It fhe

llner must

be

ralsed,

Ins+cll one

an overth lc-k

top

tlang€.

6.

r lth

311,411.611

PART
NO.

H

GROOVES
QTY

4363

227A7

o

^1

+o,02

-(

std

)

8353

29829 9,Og

+o,02

1

8353 29830

9.13

+o,o2

2

8353

29831

9,23

+0,02

3

2

PART
NO.

H

GROOVES
QTY

8363

36331

g,O3

+0,02

-

(

std

)

8363

38436

g.o8

+0,02

1

8363

38437

9.13

+0,02

8363

38438

q

2.1

+o,o2

.t

217

An

overthlck iop

flange ls marked rlth ihe

nurber

ol

machlned gr@v€s

on

th9 flcngB

outer

surtåce:

lst olrat slze O10D I

-

cna

gn@rc,

2nd

oversl zo

0,10 n. fro

groova3

and

'rd

oYf,slz€

0120 rn

-

thr€

gr@vca.

l{ofiol In the

ll and 12

serles englnes the

cyllnd€r llners

rtih

standord tlange

fhlckness

åre

dlvlded

Into

tyo

ca'tegor les dependlng

o.l

tR

\\'ss

\\\Str=.

q\'f"b+"\'$iså"=

\,{\.

. .

9,04

-

no

narktng.

F lange fhlcknåss 9,O4...9,O,

-

flhlte

palnfed

mark

(d

20) as

shorn ln

flg.2

309

PART
NO.

H

GROOVES
QTY

8365

36827 8,03

+o,02

-(std

)

8365

36828 9.08

+0,o2

1

8365

36829

8,13

+0,o2

8365

36830

8,23

+0,02

l{ot€l

In connecllon

rlfh cyllnder

llner

fltflng renove

nEierlal, lf ne€ded'

Ylth

correctlon reanFr 9045 87200 In case

of ll ond

12

€erles

onglnes

and

wl+h reair€r 905.|

72m0 In

case

of

f09

eng lnes.

lf

the llner

protrudes

hlgher

on one

slde than

on

the

opposl+e slde, chack

the thlckness

of

+he

llner

flange and the deplh of

the

flange

recess

ln

ihe

cyllnder

block.-lf there

are any

lrregularl+los, replace

ihe llner.

Correci

ihe

I

lange .ecess

In

the cy I Inder

block slth

correcllon

r€amer.

(

for

311and 411

engi-

nes if needed )

red

214

the cy I Indor llner

gr@vgs

preferably

wlth

gear

oll to

.L'CJ

220

Insiallatlon ordor of o-rlngs ln 3ll,4ll,6ll

and

61 2 eng Ine cy I Inder | |

ner.

Press

the llnei- In lfs

poslflon

In fhe

cyllnder

block.

The llner rlll

go

ln easlly ll ihe o-

rlngs

are correcily

placed.

Ensure fhal ihe

llner vtlll no+ rlse ou+ of lis

Dosltlon

af+er

Insiolla+lon.

lf ihe

cyllnder

block

ls badly corraded

ai +he

lorer o-rlngs of ihg llner,

you

can Install a

thr€€-groove

cyllnder llner In 5ll,

4ll

and

6ll

englnes,

spare

pari

no 8555 24480. The cyllndsr

llners

rl+h ovsrihlck

fop

flange

(lll,4ll,6ll

and

612 englnes)

are

also equlpped

wlfh

+hre€

gr@ves

for lorrer o-rlngs. The boftom

groove

of

thgse +hree-gr@ve llners rlll

hove

a red o-

rlng

and lha t{o

upper

gr@vas

a

block ong.

ll n€€ded, an o-rlng

(parf

no

8565

29808)

can

be lnslalled ln the

fop

groove

of the fll and

4ll

englne llner.

Should

you

Insfall

lt,

chamter iho

cyllnder llner top

par+ guldance

In

the

cyllnder block

ylth

reamer

9045

54800 io

lacllliate

the

placlng

ol

the o-rlng.

'n

.a

9.

Place

ihe o-rlngs

In

and

lubricate

ihem,

avold

sel zure.

t{otel Try

io åvold even sllghiest streichlng

ot

ihe o-rlngs durlng lnsfallailon

because the

max

sl-retch

ot ihe lorer o-rlngs

may only

be

about 6

t.

So as

no't io lose the elasiiclty

of

the

ring, Install

l+ lrom

fhe loYer

end

and iry

to avold s+retchlng

(e.g.

do not

place fingers

befreen

liner

and

rlng).

10.

219

ln the f09

Ins+allailon

ordgr

of o-r I ngs

cyllnder

llner.

snglne

2-

9

2.

t.

FLYXIfEL

rcUS II{G

I

NS'ALL

Il{G llf FLYIHEEL IloUSI I{G

The correc+

posltlon

ot ihe

tlyrheel houslng

io

cyllndar block

ls secured

ai

ihe manufaciurlng

s+age

rlth +ro dowel

plns.

Durlng Insiallo+lon

It ls not

necassary

io canirallze lhe rolaflve

poslflon

of the flyuh€€l

houslng

and the

cyllnder

block.

Th€

flyxheel

houslngs

dellvered

as

spore

parts

also

have ihe

doxe

I

pln

holes

ready.

Clean the

ma

lng faces of the cyllnder block

ond the tlyrhe€l houslng

cårefully.

Coaf the taces wlih seallng compound

(6909

50008 )

.

3.

Llti

fho

flylJheel houslng ln

lts

place

and

tlghien +he

retalnlng

screxs

llgh+ly.

4. MovE
plns

r

lfh

the flyxheel

houslng

so +hai +he

dore

I

holas meet. Flt thg dowel

plns

ln

place

tapplng drl f+

(9025

987@).

Tlghten the flyrhe€l

houslng

retalnlng screys

gvenly

+o +hs

ccr€ci

forque, lnner hexagon

socket scrers

(8

|I|n)

to 60 ltr

and o|iier

hexagon scr€vrs

(19

|l|tn) io

ll0 iln.

REPLAC ING I}IE CRANGMFT FEAR EI{D SEAL

D I

srnou nf

the

englne.

Open the flyrhesl

retalnlng

scrers

and

renbvo

ihe f lyr.heel

.

,. Rerpve fhe old shaJf seal.

Be careful

noi io

damage

the crankshafi

seellng surfaca.

4. Clean

ih€ s€al recess ln the flyrhe€l houslng

cnd us9 enEry cloth io

rerDve

posslble sharp

Edges

ln +h€ crankshafi

rear end.

222

5. Check that ihe

llD of lie

nex shali s€al ls

flarless

and

ihat

iha

llp sprlng

ls

ln lis

poslilon.

Lubrlcat6 the

seal and ihe natlng

tace of

the crankshafi recr

gnd

xlfh

oll. Push

the

shaft seal

caretullv on lhe crankshaft and

agalnsi

the flywheel

houslng. Top the seal

evenly

dorn

io

ihe botiom

wlih

flitlng too I

8560 97515.

Do noi use a

pln-type

tapplng drlti

because ihe meial

body

of the shafi sgal

may

b€nd and

cause leakaoe.

B.

Notcl

It

the

crankshafi

ls so badlv rq-n ai

the

seal ihat

you

doubt +he

tlqhinels of ihe

s€al,

change flie

posltlon

of ih; s€at t{tlh

a

shaft

s€al dls+ance

rlng.

A 2 rnm thlck

dlstance

rlng

rhlch ls

placed

und€r fh6

s€al

has

sDarg

spore

parl

no

8560 20054.

CIL

I NDER

lffi) At|) Y

LYE

l,Ectl l Sr{

IIIEX

Tecinlcrl

data

...........

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

J- |

Sp*lal

t@ls

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

f- f

constrqc on

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

f- 4

ReDclr lnslruqtldrs

l. Cyl

lndgr

h€rd

A. Removlng

ihe

cyllnder heod.

. . . . . . . . . . . . .......... 5- 7

B. Removlng +he

volves.......

......

3- 1

C. Ch{klng the cyllnder heod.

.

. .

. . . . . . . . . .......'.. l- 7

D.

Replaclng the

valve

gu

I

de. . . . . . . . .

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

l- I

E. Replaclng the InJecior

s|eeve...........

......... l- I

F. Machlnlng the valve

seof.............

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

J- 9

G. Replaclng the

valve seoi r1n9........

............ l- 9

H. Grindlng the valves.......

......

l- 9

l. Flttlng +he

valves.......

....... l-10

J. Fl+tlng ihe cyllnder

head

J09,Jll,4ll.

...........

l-lo

K.

Fltflng ths cyllnd€r head

6ll, 6 | 2

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

l-l

I

2. Valvs rEchrnl sD
A. Recondlilonlng

ihe valve m€chanlsm.......

........ 3-12

B.

Replaclng the canshaf+/camshafi

9e4r.......

......

l-12

C.

Checklng

and adJusflng

tl€ valvg c

learanc€s. . . . . . . .. . . . . . . . . ' . . . .. J-ll

VAIiIET

3-0

IECHNIC

L

DATA

(reJeci

llnlt

of

par+

s+aied In brackets €fier ra+lng)

volves,

rocker crms and

+rppets

Va lve

flm

Ing

}Jlfh

a

valve

clearan@

of 0,30 rnm

-ln

le+ valve ooens ...........

-ln

lei valve c loses , , . . . . . . . .

-exhausf

va

lve opens

..,........

-exhaus+

va lve c loses

. , . . . . . . . .

valve

clearanc€s cold

and

ho+:

-

ln lei va Ive

-exhaust

va lve

Angle ot valve

seai

In

cyllnder

head

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

l{idth

of valve sea+ In

cyllnder head

Angle of valve tace..,,,.......

outside dlame+ei of valve

head:

-

in

let

valve

llf,4ll, 611,612........

-exhausi

va lve

Jll,

4ll,

6ll

,

612 ........

-i

n let valve

109 . . .

. .

. . . . . . . .

-exhaust

va lve

f09

,............

Inlsi

valve

s'fem

d lameis-

Exhausl va lve

siem dlarneier

Inlsf

valve

sfen clearan@

(gulda

ready flited ln cyllnder

head)

Exhaust valve

s+em

clearön@

(guld€

ready fliied

In

cyllnder

head)

Inside dlame+er

of

valve

gulde

(nof

flffed)

Ou+side

dlaoeier

of

valve gulde

D lamefs' ot valve

gulde

bore

ln cyllnder head

Profruslon

of valve

gulde

+op above cyllnder

head

surface

.........

Dep+h of valve

head face be loer cyllnder head sur{a@

.........

Va lve

sprlng free

length:

-inner..,.......

-ouTer

, ...

. ... r.

Sprlng

p.essure

Hhen

sprlng comprossed

io a length of:

-41,5

nm

(lnnei

sprlng)

......,,.

-47

nrn

(ouier

sprlng)

Rccke.

rn shafi d lamefer

Inslde

diamefer

o{

rocker arm bearlng bush:

-

(rhen

fltted

ln

oosl+lon)

ouiside

dlamefei

of rockq' d-m

bearlng b

ush

. . . . .

. . . . . . .

D lanEier

of

.ocker

arm bore

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

Max

permlsslble

push

rod del lecflon

(when

fr€) ...........

Free

lengih

ol rocker arn sprlng

Sprlng

pressure

lihen

sprlng @mpressed

to € length of 58

fir

outs I de

dlameter of taooef

D laoete. of

+appli

bore In cyllnder btck

...........

Push rod length

109

,. , . . . , . . .

. .

.

Push

rod

length

t11

,

4ll , 6ll

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

Push.od

leng+h

612

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

Cyllnd€r

held

Dlameff of Injecfcr- sleeve flxlng hole:

-uDoer

end

-

toder

eno

outslde

dlameler of Injeclor sleeve:

-upoer

end

-

towei

eno

D lame+er of

Inlst

valve

s6at rlng

(s+andard)

Dlaneier

of exhaus+

yalve

seat

rlng

(standard)

Dlaneter

ot recess

In

cyllnder head

(s+andard):

-for exhausf

yalve

sea+

-for In let

valve

seaf

io

l9

l0o

b.t.

d.c.

42o

a.

b. d. c.

42o b. b. d.

c.

t0o

a.

t. d. c.

0,

,0

0, t0

f00
1,0.,.t,5
29,5o+0,17

28,000...28,031
21

,

O@.

..27

,035

21

,979...2A,000

27,OT5...21,O9O
48,054...48,070

45,045...43,01O

43,000..

.41,0t

6

48,000. ..48, 0r 6

9,465...9,480
9,445...9,460
0,040.

..0,

070

(

0,10 )

0,060...0,090

lo,t5l

9,520...9,535

16,02A...16,0t9
| 6,

000.

.. 16,01

I

l8

,1
6l

70.,.90 N

19...2t0

N

19,959...

| 9,98O

| 9,990.

. .20.010

2t,035...23,044
23,O00...2t,021
0,4
80

80...100 N
29,919...29, O
10,000...50,021

)al-

|

,iä-l

2791

J- |

Overslz6

of exhcu+

valrc seat

rlngs:

-ls+

oversl ze,

part

no. 8f6l

l90o4 ...........

-2nd

ovrslze,

part

no.

8f6l | 9OO5

...........

OYersl zes of lnlet velve s€ai

rlngs:

-lsf

ovsrsl ze,

pari

no. 8f6l

2296,

...........

-2nd

overslze,

part

no.

8161 229f5

...........

D

I aneter of exhaust valva

seöf rlng

recesses In cyllnd€r hEod:

-l

st

oversl za

-2nd

overs I za

Dlameid'of

Inlgt

valve

se6t rlng

recesses In cyllnder

head:

-lsi

oversl z9

-2nd

ovgrsl ze

Cyllnder

heod

ih lckness

Cyllnds

head

mln

thlckness

(aftet-

machlnlng)

Tighienlng iocque of cyllnder head

scrers

..........

CGhrtt 509, tl I

D I aneter of
D I alFigr

of
D lamet€r ot
DI ameter

of
D lame+er of

4t,251...15,27O

4t,454...1t,17O
48

.2r

4. . , 18.21O

48,454. .

.48

'

,l70

45,2O0...45,216
43,40O...45,416

48,2OO...44,216
48,400...48,416
| 04,90...

| 05,10

| 04,

70

se€ |

nsiruqt

lons

nlnsiolllng
cy | |

nder

h6ådn

19,925...19,

O
49,905...49,950
49,

885

. . .

/t9,

91 0

50,04...50,06
(50,085

)

50,000...50,025
(

50,050)

Cömshafl end

play

rlth a

0,5

nn

gaskef

bet{e€n cyllndei

blck and llmlng

g€ar

houslng

and bgtr€en tlmlng

gear

houslng

and tront

cover .....

0,450...1,550

Cam helght

(dlstanc€

befxeen back

ol can and

ilp ol com) ......... 41,44

Cam llfi

...... 1,44

comshafl max

Dermlsslble

datlecflon

0,05

(toial

Indlcstor

r.tdl ng

caEhafi

4l

I

camshof+

bearlng

journal

no.

'l

(509)

.........

comshatt bearlng

Journal

no. |

(lll)

.........

camshaft

bearlng

iournals

nos. 2...4

...........

comshoft bearlng

bores

(f09)

camshaft

bearlng boras

(3ll)

D

lameler

of cangbcft beorlng

iournal

D I anleier ot

canshalt

b€arlng

journals

D lamel€r of camshatt

berlng

boros..

Camshafi end

play

rlth r

0,5

tlrt|

gaskei

belYe€n cyllnd€r

bl€k 6nd flmlng

gear

houslng

and betu€n

tlmlng

gear

houslng

and front cover

.....

0,450...1,550

C helghi

(dlstanco

betu€€n brck

ol cai and tlp

of c4)

........ 41,4,1

can f tfi

......7.41

Camshaft

måx

p€rmlsslble

del lectlon

0,05

(toial

Indlcatd

rcadlng

CrEhrft 6l l,

612.

Dlanefs- ol comshaft

bearlng

journals

nos.

I . . . 7 . .

. . . . . . . . .

...... 49,905...49,950

Inslde dlameter of camshafl

bearlng bushes

ln cyllnder

block

Bearlng bush no. I

.........'.

.. 50,000...50,025

(

50,050)

49,905...49,95O

49,875...

il9,900

50,000...50,025
(

50,050)

49,990...50,050

(50,080)

0,450...1,550
4l

.

,f4

7,14
0,05

(

iotal

Indlcator reedl ng

Beårlng bush nos.2...7

Camshöft end

ploy

rlih o

0,5 rn

gaskei

beireen cyllndf

blck and tlmlng

gpar

houslng ond b€tre€n

tlmlng

gear

houslng ond

froni cover

Can

helgh+

(dlstenca

betveen

back of cam and

tlp of cån)

Cam

| | tt

.... ... .

Camshaft

max

p€rnlsslble

def l€cilon

3-2

14

18

6

&

@
@

4

5

13

12

11

10

8

I

15

SPECIAL

TOOLS

I

2

1

8
9

l0

ll
l2
It

t4

t5
t6
t7
t8

8160
8160
sJ60
8560
8J@
8560
8561
8561
8561
8560
8560
8561
85@
8560

E

8r6l
4565
7tt

4

(cyllnder

head

97r52
97 454

974t

914]5

914t7

971t8
97459
91440
86085
9146t
91410
97tt1
914r1
58000
51542
5t 541
05506

and valve rnechan I sn)

Va lve sprlng flttlng lever
Lock

nut for valve

sprlng llttlng

lever
Torqug orm
Exhaust v6lve seat

level-cutier

(509

also

lnlet valve)

Exhaust volve seat

cufts'

(f09

clso

lnlel

valve)

Exhausi valve

seöf lnslde

cuiier

(509

also lnlat valve)
In lst valve seat level-cutter
In lei vrlve s€ei

cutter

Inlst

v!lvg seat

lnslde

cuiier

InJectoi s leeve

exfracior

lnJecfa s

l@vo

flttlng drlft

InJocior matlng

face

reaner

Vclve

gulde

r€mov

lng drlft

Valva

gulde

f ltilng

drlft

Cyl lnd€r

heod

tq.que

rrench

309,

5ll, 4ll

lndlcator

tor elongation

scrers

6ll,

612

Scksi

rrerch fc

elongatlon

scr€rs 6ll, 612

Cup

plug

flttlng

drl{i

f6 n

Q-a

CYL lilDER

HEAD AND VALVE

TECH Nlsll

CYLINDER HEAD

10

to

Cyllnd,ar

head

4ll

l. Cy llnd€r

head

z.

v-f

tng

l. Injoc+f s leeve

4.

Cup

p

lug

5. Cup

plug

6. Va

lve

gu

lde

7.

Va lve seai

8.

Valve ssat

9. Thread p lug

10.

Valve

gear

cover

ll. Gaske+

12,

Nu+

15. Washer

14. Rubber

sea I

15. Breaiher

p

lpe

16. C lamp

17.

Ll{ilng lug

18. Scre{

19.

S+ud

20.

Seal r Ing

2l . Plug

22. Hose

connecfor

21.

Seal

rlng

24. P lu9

25.

Sfud

26.

Siud

27.

Cy I lnder

head

gaske+

28.

O-rl ng

29.

O-rlng

109,

,ll cnd 4ll €nglnes

have

a one-part,

cross-flor

cyllnder

head of casf lron }rhere

each

cyllnder

has

l+s ol'n

Inlei and exhausi

channel

on opposlte sldes

of

+he

head. The

rlgld cons+ructlon

and ihe

evenly spaced head

bol+s

con+r lbute +o

good

s€allng. The coolant

clrculatlon

is dlrected

In such a wav lh8i the

coollng

of the valve

seat area ls as efflclent

as

posslble.

6ll and 612

englnes have

iwo

separate

cyllnder

heads whlch are

+he same ln

baslc

consiruct

lon

as those of 3-cy I and 4-cy

I

englnes.

Än exiernal {ater-co I

lec+

| ng

plpo

jolns

+he

cyllnder

heads

io fhe ihermos+af

hous lng.

7ol

3-4

Cr$s-s€st lon ot

cyl

Indor

haad

l. Valve

gul

de

2.

Yalve

seoi

5. InJectcr s

leeve

4.

O-rlng

sea

ls

The

lnlet vclve

guldes

and exhousi volve

guldes

(l)

are rep

loceable and lnterchang€ab 16. Hlgh-

porer

-turbocharged

5ll and

4ll

englngs

and all

6ll and

612 englnes

have separate,

replaceablE

valve s€af

rlngs

(2).

The InJectors a.e

gncompassgd

In o rep

laceab 19 copper sle€ve

(5)

surrounded

by coolant. Thls tloans the b€si

posslble

cool Ing of tt|9 lnJectd-s.

3-5

YALYE i€CH]{^I STI

14.

17.
t8.
t9.

20.

21.
2t.

VrlYe

flEchanl sn

,ll

I

1. Clrcl

lp

2. Spaclng

rasher

5. Nut

4.

Rck€r

arm

5. Bush

Ing

6.

Adjustlng screr

7. Brackei

8. Sprl

ng

9. Shaft

10.

Plug

ll.

Push rod

12. Tappet
Spllt collei

Spr

I ng col lcr
Valve sprlng
Volve sprlng
Sprlng

cup

Exhaus+ valve

lnlst

valve

Gear

Key

Camshaft
Thread

plug

Th€ cåmsh€ft

(22),

sltr.raied In fhe cyllnder

block, ölves l-he

vclve mechanlsm lhrough

the

iappats

(12)

and

push

rods

(ll).

The

camshatf

gear

(20)

ls

flxed

vrlth crlmp connectlon and

fltied

rl+h a kay

(21

).

Every bEorlng

Journal

ls

pressure-lubr

lcaied ihrough

ihe oll bore ln

tho

camshaft.

3-6

XORK I NSTRIJCT

IONS

CIL I ND€R IfAD ATD VALVE

I.ECHAN I SM
CYL II{DER I€AD
REI,IOY

ING THE CYLINDER

T€AD

Clean +he outslde of l-he

gnglne

and

draln the

coolant.

Dlsconneci

fhe

rater hoses

flxed +o

ihe

cyllnder head and thernosiat

houslng.

Remove

the

al.

plpes

bettregn

alr fi

lier

and

turbocharger

and between +urbocharger

and lnlef

rnanlfold.
Loosen

ihe

screws of +he mounilng flange of ihe

+urbocharger

pressure

ol

I

plpe

and the lower

plpe

connec+or, then remove the

plpe.

Loosen

ihe

scrers of ihe turbocharger reiurn ol I

plpe

flange

and the louer

clanp,

fhen renove the

p

lpe.

Dlsconneci

ihe olDes of fhe fusl reservolr of

+he

Thgrn|osiart

devlce

(lf

assembled).

open

ihe connec+lng scr6*s of the overflov/

plpe

of ihe

InJec+ors, remove the

plpo

and dlsnoun+

+he lnJectlon

plpes,

0pen +he Injec+or

reialnlng nuts

and

renpve

the lnjeciors. Fli

protecilve plugs

ln the connectlon

polnts

ol

the {ue

I eou iomenl-.

open

fhe

connec+lng screr of +he lube oi I

plpe

leadlng

+o +he cyllnder

head and

the

plpe

jolnf

at the

lorer end, then redpve ihe

plpe

(Jll,

611

,

612t,

Open +he lnlei manlfold

flxlng screws, exhaus+

manlfold nuis,

+herrnosiat

houslng

scre{s

and

lronf

llfflng lu9 scrers

ond

rsmove

-the

parts

from ihe

cy I I

ndor

head.

open the

refalnlng nuts

ol thg

valve gear

cover

and renove +he

cover and

thg

breaiher

DlDe

(

309,51

t,411).

open +he valve

gear

reialnlng nu+s and bolf and

remove ihe

valve

gear.

Llfi

ihe

push

rods

off

of fhelr

Dos lf lons.

Loosen ihe cyllnder

head

flxlng

gcfexs

by iurn-

Ing them

tlrsl only

€boui 1/4 ot a

roiailon

ai

a ilme.

Renove +he screxs and dismolni th9

cyllnder

head. lf the

cyllnder head

is ilghfly

fltted,

d<r not tap a {edge bet{eon lhe

cyllnder

block

and head, slnce

thls

may damage

ihe

seallng l8ces.

REIIOV

ll,lc IHE VALVES

lf

you

Intend

io fl+ +he

sane valves back, mark

+hem

so fhat

you

can lnsiall +hen

In ihelr

orlg

Inal

pos

lt lons.

1. Ffx +he lock nut

(At6O

91t561 oI

sprlng

llftlng lever

In the valve

s+ud

(fryl

and

6-cyl

englnes

have

ihe

mlddle

valves.

ln +hls case flx

a hexagofl screw of

sul+able lengih).

Flx ihe valv€ sprlng

ftttlng lever

(8160

975f2)

on l-op of +he

valve sprlngs

and compress

fhe

sprlngs. Remove splli

col

lgfs, sPrlng

collars

and sprlngs

and

deiach lhe

valve.

CTCCKI

NG I}IE CYL I

NDER

IfAD

Removs

the carbon

deposl+

from

ihe exhaust

po-fs,

clean

the seallng

taceg and

liash

ihe

cyllnder hgad

caretu

lly.

Check the cyllnder head

for

posslble

cracks

ånd

other

danage.

2.

c.

t.

t.

1.

9.

Check +he s+rolgh+n6ss

of ihe

seallng

tace wlth

a halrllne

gauge

agalnsi llght.

lf

ihe seallng

face is not

siralgh+,

l+ mus+ be machlned untll

It ls.0ff the cyllnder head can

be machlned

0,20 rin, leavlng a thlckness of 104,70

dm.

Further

0,20

rm rnay be machlned, bu+ thls

lnvolves lnstalllng 0,20 rm shorter

plsions

(s€

lnstructlons,pol nt

il

2 | ).

After the

second

machlnlng ihe mlnlmum

thlckness

of ihe

head

ls 104,50 im.

10.

the valvg

gear

cover

no studs

a+

a a

sTuo or

f4easuro the

wear be+ween the valve

siem and lis

gulde

wlfh

a dlal

gauge.

Llfi

iho

valv6 ln l+s

place

to

have lhe valve

head 15 mm above the

cyllnder

head tace and fll

ihe dlal

gauge

measurlng

end

on the valve

head edge. Move

-the

valve

ln fhe dlrec+lon

of +he

dlal

gauge

and

read

ihe

clearance.

The max clearönce

ln +he

lnlet

valve

gulde

may

no+

exceed

0,lO

m

and

In the

exhaust

valve gulde

0r55 ||m.

By

uslng

a ne},

valve

{or

+he

measurement

vou

can determlne

ih€ valve gulde

wear.

5o9oO

@"

3-7

D.

REFTIC II{G

IHE YAI-YE GUIOE

l. Renove

fhe

old

gulde

elther In a vlce or

bore of lmpurlfles.

el+h a

drlf+

(Bt6O

91331),

by +€pplng.

Cl€an

the

gulde

E.

REPLACI}G

IT€

I}IJECTOR

SLEEVE

l.

Flx ihe
exfractor

Ing.

ihreaded

pln

(8160

86085

)

of fhe

ln ihe

2.

Place

'the

extrac+or shroud

fhreaded

pln,

flx fhe nuf

ln

un-tll

the

sl€ve ls l@s€.

lnJec+or s lgeve
s leeve by turn-

top

Pln

ot fhe

and turn

on

ihe

2.

Lubrlcai€ ihe ouislde

of ihe new

gufa.

f?g8h+fy

l'lth oll.

Tap ihe

gulde

In lts

posltlon

{lth a

drlfi

(8f60

97457).

|{han

uslno fhe neniloned

flt+lng

drlft the

upper end- o{ fhe

gulde

remalns

ai the correct

level

(18

mm)

above

-ihe

cyllnder

head

lace

and +he ol

I

gulde

bevel

siays Intacf.

l. Cleön

fhe

lnJ€c+or sleeve bore ln +he

cyllnder

head

caiefully.

Ensure ihaf th€ upper end

gulde

has

no

sharp

edges shlch mlght damage lh6

o-rlngs dur

Ing Insialla+lon.

4. Apply seallng conpound

(6909

J0008)

fo

the

sleeve

lorer end. Place

nex o-rlng soals ln tha

upper end

and

lubrlcaie

th€n llghtly r,lth

vasellne.

Tap

the

sl€€ve lnto

poslilon

xtth

a

drlf+

(81@

9746ö ).

3.

The

lnle+ valve guldes

are lden+lcal.

Insta | |

cham{ered

ond

upyards.

move

sn@ih

ly ln ihglr

3-8

39

and exhaust

va lve

guldes

the

guldes

{lih

+he more

Ensure

iha+ ihe valves

gu

I des.

o

(

2.

Turn

the

cyllnder heod

ihe rlght ray and tap

'the

valve

s+em unill

the

seat

rlnq congs loose.

f. Claan the seat

rlng

posltlon

In the
head. Befor€ tlttlng a n€r, seat rlng,
rlng

rlth llquld nlirogen. Let

th€

doin In n lirogen

uni | | f

I zz Ing around

4. Tap

the ssa+ rlng ln

plöce

wlih

ö

drlft

and nachlne th€ ssailnq fac€.

cyllnder
coo I

the

rlng

coo

I

ll siops.

su ltab le

Icrtcl

lJ

requlred,

the

standard

lniec'tor

sleeve cän

be roplaced

by one rlth

0,4

||m

overslze top. B€fore

lns+alllng the sleeve,

machlne

the cyllnder head upper

gulde

bore

+o

ö

0,4

m blgger

slze.

The c.d€r

nunber for ihe

overslze Injec+or sleeve ls 8160

f8721.

F.

llÄo{lNl}c

THE VALVE

SE T

t4achIne fhe

domaged valvo sea+

uslng

valve

ssöi

cutters 8160 97454...91440

or use a valve sect

grinder.

lf the seat surface ls {lder lhan 1,5

nm, närrow lf

olthe. lrom the

outer

or ihe

inner ed9e.

The lncllna+lon of ihe valve

seat

surJace ls

Joo.

REPLAC

II{G TIIE Y^LVE

SEAT R I NG

The

Jll and 4ll

englnes of

hlgher

output and

all 6ll and 612

englnes are furnlshed rllh

separate valve

seöt rlngs.

lf

the

seallng

surface ls so

torn that ll

canno+ be lrDroved

by machinlng,

repl6ce the

seai rln9.

Grlnd

+he

hsad ot fhe rejected valve

so tha+

lt

flis ln+o

the seai

rlng. Fli

+he valv6 ln

posl+lon

and *eld

lt io fhe

seai rlnq.

Cool the

eeld

r lih r at*.

Nofel

ll

needed, a s+andard seai rlng can

be

replaced

nl+h a rlng tilih |rlder ouislde

dlameier.

Seai

rlnqs

for bofh Inle+

and

exhaust

valvos

ar6 dealvered

In tto overslzes.

313

See

Technlcal data,

polnf

cyllnder

head.

H.

GRINDIIIG

I}C YALVES

315

It

necessary, stralgh+en

and

clean

+he

matlng

surface of

th€ InJec+or seallng

washer

In lhe

cy I I nder head H lfh

a

r€amer ( 8161 974?0

).

t.

To

ensure max

ilghiness

betHeon +ho

valve

önd

th6

seat,

ihe

dlffgrence

In

lncllnatlon

bgtre€n

seallng

surfaces

ls 0,50. Thls

mokes

a verv

na.row

seallng

surface

whlch

se6ls

better

ihan

a wlde

one, evon

yhen

worn.

ll ihe

valvo

head

ls

domagod,

ireoi

lt

In the

grlndlnq

machlne.

AdJust

fhe grlndlng

nachlna

to

29,54.

Do

no+

grlnd

fllore

than

ls

necessarv

io

clean

the

contaqi surtace.

lf fhe

valve

head outer edge

thlckness

remalns

under 1,5

mn,

replaco ihe

valve.

It the

valve

stem l-op

has rorn

hol

lor,

lgvel

lt

by grlndlng.

'14

c)

o

66

4.

Grlnd the valye

agalnsi

lis sea+ xlih a flne

grlndlng pasie.

Check the con+act surfaces

rlth

tes+lng

co

lour.

5. Clean the cyllnder

head

and the valves of

grlnd

Ing resldues carefu

lly.
I . F ITTII{G TIf, VALVES
l. Check the

condlilon ot

the valve sprlngs. lf

nocessary, irfal

press

lhe sprlngs

ln å control

devlce,

for

pressure

see Technlcal

da+a,

poln+

valvos.

2.

Lubrlca+e

the

valve stems ulth enolne oll

and

place

ihe

valves

ln the correc+ örder ln ihe

cyl lnder head.

i. Flt

thg valve sprlngs and sprlng collars

In

place,

compress

ihe

sprlngs |rlih

flttlng lever

lAt6O 97552t and flt

spllt colle+s

In

place.

Af+er fltilng

lhe

valves ansure fhat the

split

col lets a.e corroct ly

posl+loned

by, for

example,

carefully tapplng

on ihe valve heads

rlih a

plåsilc

hanmer.

FITTING

THE Crl- tiFER

IEAD rO9, lll,

4ll

Ensure

fha'f the cyllnder head fixlng

studs

(no+

109) are

properly

ilghiened

to ihe cyl block

(50

ilo). Flt the

valvs +aooets

In thelr

Dosl

+

lons.

318

Tlgh+en ihe

head screws In

phasss

and In

lhe

sequence

shown

ln llg.

! 18. The

tlghtenlng

sequence ls also Indlca+ed by numbers ln

ihe

cyllnder

head. Tlghten all

gcrews

tlrs+ +o lh€

torque

of 80 Nn, then io | 40 Nn and

f

Inölly

+o 160

Nn.

Insl-all

Dush

rods

ln

thelr

oosl+lons

and flx

ihe völve gear

io ihe

cyllnder head. Tlghten

ihe valve gear

flxlng

brackgts evenly and

lhe

ou+ermosf

brackeis so +hat the eashers ai

ihe

rocker

arm shalt ends

beslde

+he lock

rlnq

rotate

free lv.

J.

317

Check that

ihe

seallng faces of the cyllnder

block and

cyllnder

head

are clean. J09 englnes:

Tap the dowel

plns

of the cyllnder

head

Inio

thelr

holes. Flt the

cyllnder head

gasket

In

posltlon.

Place o-rlngs ln ihe

hsad

gaske+

rear

end around the ol

I bore

and ihe coollng boro

beslde ll

(4ll

englnas:

noie lhe dlfferlng

slzes of ihe o-rlngs).

Fli

fhe

head In place.

Clean and

lubrlcaie

flxlng

scrsw ihreads

and tlghten

+he screws.

Note

I }lhen ilghtengd

io +he

correci forque

unlubrlcated

screys

cause.yrong

presslng

force

on +he

head

gasket,

6. Adj ust ihe
polnt

J 2 C.

va lve

clearancos.

S€ lnsiructlo|ls

7. Flt all

+he oiher

parts you

dlsmounled

durlng

cyllnder head

renoval.

S9g lnstructlons

polnt

ltA.

8. Run

+he englne for max

0,5 hrs

and retlghien

'the

cyllnder

hgad screys. Parform

ihe ilghfen-

Ing

In

+he order indlca+ed,

sllgh+ly

open +he

screw and

+lghten li to fhe correct

iorque

rhl le rofatl

n9.

Nqtet Alrays

adjust +he valve clearances

afts' tlghtenlng cyl indq- head screxs.

309

311

411

411
l.

0- ring

13,1 X 1,6

2.

0-

ring

1l x 2

3-10

K. FITTI

G Tlf CrL

|l|)€R

rf D 6 , 6t2

319

Measure ihe lengl-h

ot

ihe

cyllnd€r

head

flxlng

scrers. The lengih

should b€

rlihln

-the

llnlts lndlcaied

in

flg.

J

19

.

ll any screr

dllfers in

length,

replace

ii.

321

5, Tlghien

the

scrers ln ihe mentloned

sequenco

60ö

(angular

dlstance

on

lhe screr

head). Use

socket rrench

4361 31341

and lndlc6tor 856f

llf42 rlih magnetlc flxlng.

The ou+slda of +he

socke+ wrench

has a

hole

marked ai Iniervals

o{

600. Seftlng the Indlcaior

af the

holes helps

tlght€n

fhe

screr to the

corrgct

iorque.

Tlghten

the

scrers 600

(one

öngular dls+ance

=

one hole dis+ance on fhe

socket rrench).

Tlghten ihe

scrsrs

600

(one

angulor dls+anco

=

one

holg

dlstance on fhe

sockef rrench).

Fli fhe valye

tappe+s In lhelr

posltlons

and

tlx

ihe valve

gears

io

+he cyllnd€r

heads.

Tlghien fhe

valve

geat-

flxlng bracksts evenly

and the outernosi brackets

so lhat lhe

yashers

o+ thg rocker arn

shat+

gnds

beslde the lock

rl ng

rotaie

lreely.

ll.

Run

lhe englne for abouf

50

nlnuies ,lth a

llght load.

Tlghten the

scrers 600

(one

angular dlstance

=

one

hole

dlsiance on ihe

sockel rrench) and

adJ

ust

lhe va

lves,

2. Flx fhe

cyl lnder head studs

io the

cyllnd€i

block

(J0

Nm).

Instöll

lhe valve laDDets In

ihelr

pos

ltlons.

f. Chock that the

seallng

surfaces of the cyllnder

block and heads are

clean.

Placa +he

h€ad

gaskets

and cyllnder heads ln thglr

posltlons.

Ensure lha+ +he

cy I Inder heads are

stra lght

and

parallel

fo

each

qther

by uslng a stg6 |

ru ler

(

lnlet nanlfold s€allng). Tlghten

+ho

cleaned

and I lghily ol

led screws and

nuts.

8.

9. Adjust the valve

clearances.

Sco lnstructloos

polnt

I 2

C.

10.

Flf

all

fhe

o+her

p€rts you

dlsnoun+ed durlng

cy I Inder

head removal.

Perform

the f

l.st

In flg.5

20

fo

+cr'que

yagnch.

tl

gh+en

I ng

ihe

+orque

order g lven

Nm, uslng 6

ln lhe
of 40

611

,612

3-11

2. Y

LVE

I,ECH I{t

Stl

RECtf{D|T|O{|r'rG

ItG VALVE l€CH

N|SM

Check

fhe condl+lon of +he valve iappets

paylng

speclal afientlon lo iha coniac+ face agalnsi
ihe camshafi.

Replace

any

worn

or otherwlse

defectl

ve lappets.

Check the s+ralghiness of fhe

push rod

uslng

a

plane

dlsc.

Also

check tha+ the ball

end faces

of

ihe

Dush

rods are lntact.

Dlsmantlo ihe rocker at-rn assembly

and clean

ihe

par+s

carefully. Check ihat ihe

shaft ls nol-

v,orn

and

that +he lubrlca+lon Dorts

are clean.

Check

ihe rocker arm bearlng

bush

lor xear. lf

you

replace

+he bush, ensuro

thal

+he oll

Pori

ls tn

posl+lon

before

presslng

ihe

bush ln

place.

After

lns+alllng

+he bush,

broach lt

'to

l+s correc+

slze

19,990...20,010

mr. lf

the

ihrusi faco of

+he rockor arrn ls worn,

grlnd lt

to lts correct form. Slnce

+he

ihrusi face has

boen case hardened,

grlnd

only

deep enough

fo

srnoo+h

ouf the lrregu lar

ll les.

Place a lock rlng In fhe ofher end of the

rocker arm shafl,

lubrlcaie the shaft

and

Insiall

the

parts

on ihe

shafi

ln

correci

order.

Make sure ihai the lock rlngs sl't

properly

ln

ihelr

grooves.

and fha+

ihe

cup

plugs

In fhe

shaf+

ends

are ln lhelr

posl+lons.

324

Not€

| There

are +ro types of rocker

arm

shat+s ln

use. In +he shaf+

used earller thsre

Here

'fldo

horlzonfal ol

I bores for lubrlcatlno

all rocker

arms.

The ner{ shaft

has

one

verilcai

oll bore

at

each rocker

arm.

To

ldenilfv

the

nee shaf+

there

are il{o

Insialla+lon

rnarks

machlned

on lts top

face. I{hen lns+alllng ihe

rockor arms

noie the

c!.rec+

Dosl+lon

of ihe

marks

=

upward.

B. REPIIC

ING T1€ CAIISMFT /

CÄI.|SHT|FT GEAR

l. Remove

the

boost alr

Dlpe

betvleen

the

+urbo-

charger

and the lnle+ manlfold

(lf

Ins+alled),

Open the flxlng

nu+s

of +he valve

gear

cover

and rerpve

the cover and +he

breather

plpo.

Loosen the valve

gear

flxlng nu+s

(and

ihe

screH

ln f-cyl and 6-cy I englnes),

then

renove +he valve

gear.

2.

L@son

ihe fan flxlng scrers and

remove ihe

fan. open the aliernator flxlng screws, then

reflpve

th6 al+erna+or, beli spanner

and

y-bolt.

f. Opon fhe crankshafi end nu+ of i09, Jll

and 4ll

englnes

wl+h tool 9024

74200

and

of 6ll and 612

englnes

wlth

tool

9024 55800.

Draw fhe beli

pulley

-

hub

plece

comblnatlon off

the crank-

s ha ff.

4. Loosen ihe

fron+

cover

scrers and

nuts and

removo

+he faonf covs'.

Lck the

iappeis up to ellmlnafe ihe rlsk

ol

+helr falllng

doun

l{hen

renovlng

ihe camshaft

and thus

preven+ing

+he

Installa+lon

of +he

OLD

NEW

3

-12

Ncrtel Bend In9 the
causes

bends !

Use

only

not

be fltied ln +helr

push

rods excess lve ly

such o-rlngs whlch nl ll

actua I p laces.

Tne
and
Tne

Roia+e

+he crankshaft

so

as io

have

Insialla+lon

marks of ihe

camshafi

gear

ldler gear

mee+.

Draw the camshaf+ ou+

of

cv I lnder b lock.

7.

Use a

drlf+

of sulfable slze to remove lhe

camshaff

gear.

lf

you

Intend to insiall an old camshaft

or

gear,

clean ihe

par+s

before

flttlng ihem.

Place thread

plugs

In the camshaft ol I bore

ends.

Sef a wedge in+o the

camshafi

key

groove.

I,Jarm fhe

camshaft

gear

up

io the fempera+ure of

2 0 0 o C and

place

li ln lis

posl+lon.

Lubr i cate ihe camshaf+ bear Ing

journa

I s and

push

+he

shat+

info

ihe

cy I Inder b lock check Ing

ihe

ins+alla+ion marks on +he

gear.

ll.

Fl+ ihe front cover

and

ihe

pulley

-

hub

plece

comblnaflon,

see Instruqtlons,

polnt

5.

12.

Lei

ihe

tappeis

dorn

and Install +he valve

gear

(

lnstructlons

3 | J

polnt

5).

Fl+ +he valvo

gear

cover and +he brea+her

plpe

as \{ell

as

the

boost alr

pipe

bel-lreen ihe tu.bocharger and the

lnle+

man i

fo

ld.

lJ.

Insiall

+he

al-ternaior and l'he beli spanner and

adjus+ the v-belt tenslon. Fll' the fan and

ii

gh+en

lis llxing screws.

C. CHECKING AND ADJUSTITIG THE YALVE CLEARANC€S

The clearance of bo+h

lnlei

and exhaus+ valves

ls

0,30 Fn. The clearanca can

be

checked
regardless of whe+her ihe englne ls cold or
ho1.

Check and adjust th6 valve cloarances of a

certaln cvllnder when the

Dlston

ls

at lfs

comoression stroke too dead

cenfre. Check ihe

valves

ln +he Injecl-lon order of the

englne.

Rgmove +he boost alr

Dloe

beivroen +he turbo-

charger and the

Inlei

manlfold.

Open

ihe flxlng

nu+s of the valvg

gear

cover, removg

+he

covor

and lhe brea+her

plpe.

Take off

the

plug

on +he

slde of the

flywheel houslng

(crankshafi

rotatlon ).

'O9

ENCINES

Ro+a+e the

crankshai't by the flywheel

gear

rlm

v.lth,

for ex6mple,

a

screwdr lver, unill the

exhaus+ valve

of the

lrd cyllnder

(5th

valve

f.om ihe

englne

fron+)

ls cömpletely

open.

Check

lhe valve

clearanca

of the

lsf cvilnder.

327

lf

the clearance dlffers f.dn

iho ra+lng, open

the lock nut sllgh+ly and

adjust a correct

cloarance

vllth an adjus+lng screx.

Tho clear-

ance

ls correc+

*hen a 0,30 |Im feeler

gauge

ls

sllghtly +lght-fltled

beiween the

rocker

arm

and the va lve

head,

J. Turn the crankshaf+

furiher ln

lts runnlng

dlrec+lon, un+ll

-ihe

exhausl valve of +he lst

cyllnder

(2nd

valvo) ls iully open.

Check

the

valve

clearance

of the znd cyllnder.

4.

Ro+aie

the

crankshaft

fur+her

In

runnlng

dlrecilon, un+ll

+he

exhausi

valve of +he 2nd

cyllnder

(4ih

valve) is fully open. Check

-the

valve clearance of +he Jrd cvllnder.
]I I ENGI NES

2. Turn +he crankshaf+ by

+he llywheol

gear

rlm

|{l+h, for example, a screwdrlvor,

untll

the

exhaust valve of +he frd cyllnder

(5th

valve

frorn ihe

englne front) ls cornp

leiel y open.

Check the

valve

clearance

ol +he lsi cyllnder.

lf

the clearance dlffers from +he

ra+lng, open

ihe lock nu+

sllgh+ly and

adjus+ a correc+

clearance

wl+h

an adjustlng

screw. The clear-

ance ls co.rect rhen

a 0,30 mm feeler

gauge

Is

sllghtly

tlght-fltted bet{een the

rocker arm

and the va lve

hoad.

J. Turn

+he

crankshafi

furlher In runn

I n9

dlrectlon,

untll

+he exhausi

valve

of

+he

lst

cyllnder

(lsl

valve) ls

fu lly

open. Check tho

valve

clearance

of

+he 2nd

cyllnder.

4.

Ro+aie

the

crankshaf+ {uriher

ln runnlng

dlrectlon,

un+ll ihe

exhaus+

valve of

ihe 2nd

cylinder

(frd

valve)

ls

completely

open.

Check

the valve

clearan@

of +he

frd cvllnder.

4II ENGI NES

2. Ro+a+e

the

crankshaft

In runnlng dlrecllon,

-untll

lho valves

of

the

4th cvllndsr are

rocklng

(exhausi

valve

closss, lnlol

valve

opens),

Check

the valve

clearance of l-he

ls+

cyllnder.

ll the

clearance dltfers

from

the

ratlng,

open lhe

lock

nui sllghfly

and adjust

a

correct

clearance

erl+h an

adjustlng screw.

The

clearance

ls

correci

when a

0,J0 nm

feelor

gauge

ls sllghily

ilghi-flited

between

the

r€ker

ö.m and

the va lve

head.

l. Turn

lhe

crankshaft

furlher

l/2 of

a rotailon

ln

lhe

runnlng

dlrectlon

so

+ha+

the valves

of

the

frd cyllnder

are

rocklng.

Check

the

valve

crearan@

of +he

2nd

cVllnder.

9.

10.

3-13

4. Procaed

elth checklng

the

clearances

ln ihe

InJecllqr

ordei:

-

InJectfon

ordar

l, 2, 4, t

-

valve

rcklng

phaso

ln cyllnd€,-

4,

t,

l, 2

6111612

ENGINES

ond tho volvs

heåd.

Rotäte

ihe

cränkshaff

ltr+her l/3 of a ro+ailon

In runnlng

dlrectlon

so

ihot

the valves

of ihe

2nd

cyllnder

öre

rocklng.

Check ihe valve

cl6oranc6 of

the 5th

cyllndf.

Proce€d

rlth ch€ck

lng the

clearances In lhe

InJec+lql

ordEr:

-

lnjectlon

order l,

5, 5, 6, 2, 4

-

vafve

rcklng

phase

In cyl 6,2,4, l,5,5

Cleon thg

valve

gear

cover

ond check ih6t the

@

enoine

fronl end

1.

@.exhaust

@-

intet

309

@^o-@

o"oo

311

r@^Q:("ftO^e3g

o

o"o

o-@

o"@

o

J^l

411

@_o-@ o-@

o

6111612

3-14

CRANKCåSE

D{IEX

T€chnlcll

dåta

...........

. . . . . . . . . . . . . . . . . 4-

|

Sp€clal

t@ls

............ 4-

5

coostrus

on

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

4- 6

Repolr

lnstrustlons

l. Crankshalf

A. Remov lng th6 cranksha{+...
g.

Check Ing +he crankshafl...

C. Replaclng

ihe

cr

kshaft

gear

rln

411.....

0. Replaclng lhe

crankshafi

gears. . . . . . . . . . . .

E. Insia ll lng

ihe

crankshaft"..............

F.

Crankshaft hub p lece..

......

G. Replsclng ft|e vlbrailoi

dampq-.......

....

2.

Conn€ctlng

rods cnd

plsions

A. Remov

lng

the

connecllng

rod

and

pls+qr...

........

4-12

B.

Checkfng

and replaclng lhe connectl ng

rod

bear1ngs....,...........

4-12

C. Overslze

plsiqr pln

baarlng bush.....

............ 4-12

D.

lnspecifng

+he

connectlng

rod..............

......

4-12

E. Connecilng

rod

relgh+

c I asses.

. . . . .

. . . .

..........

4-15

F. Inspec+lng and replaclng ihe

plslon

r1ngs.........................

4-14

O. lnspectlng the

plsion....... .... 4-1,

H.

Flttlng

ihe plsion

p

I

n.

. . . . . . . . . . . . . ............. 4-15

l. Shoriened o I sions..........

.....4-15

J. Flttlng

ihe

plsion

and the connecilng

rod. . . . . . . . . . . . . . . . . . . . . . . . . 4-16

counferbcl ancå

Fchrnlsn

A. Renoy lng and dlsassembllng

the counterba

lance

mechanlsm...........

4-17

B. Recondltlonlng +he

counterbalance

mehan I sm....................... 4-17

C. Fll-tlng

+he

coun+erbalanca

m€ch€nlsrn.....

........ 4-17

F l

yrh6l

A. Replaclng

itF {lyxh€el star+s rln......

.........

4-18

B. Fli-tlng +he flyrheel..... ....... 4-18

4-9
4-9

4-9

4-t

0

4-t0

4-11
4-tl

t.

{.

vAlitEr

TECHN ICAL DATA

('I)

(reject

llmlt

of

pa.t

sfafed In

brackeis aft€r'rotlng)

Plston,

plslon

rlngs and

plston pln

Itlln dlstance betwoen

plston

and

cyl head,

measured wlttt lead

vllre through

I nJector

holo

P I

ston d lameie.
,09
P In bore In D I sion

. . . . . . . . . .

Plston pln

d I ameter . . . . . , . .

l{ldth of

rlng

-

ls+

groove

-

2nd

gr@ve

-

lrd

groove

P

I ston r Ing

-

lsi

r ing

gr@ves:

0,900...1,150
see

lnstructlons,

polni

4 2

G

16, 001...16,009
f5,995..

.16,000

2,58O.,.2,600
i,040...J,060
4,040..,4,060

o,o9.,.o,122
o, 05. ..0,082
0,05,

. .0,085

0, l5

Slde clearancos

of

plstoo

rlngs ln +helr

gr@ves:

-

lst

groove,

hard chrome-p laied compresslon r1n9...,........

-

2nd

gr@ve,

compresslon r I

n g . . . . . . . , . . . .

-

Jrd

groove,

ol I rlng ........

-

re

ieqt llmlt

helght

(

In dlrecilc.r of cyllnder):

....2,474.-.2,490

-

2nd r

Ing

2,978...2,9

-

f.d rfng

....

3,975...1,990

Pls+on rlng gap

(elth

pls+on

ready fltted In cyllndar):

-

campresslon r Ings

...........

0,4...0,6

-

ol I rlng .,.

0,25...0,55

-

rBject llml+ ..............,.

1,0

5 , 4 , 6

Pln

bore

In

plsion

I

)

40,0m...40,006

Plston pin

d larEi-er

........

...

19,995...40,000

t{

| dfh

-

lsl'

-

2nd

-

frd

I{ldth

-

lst

-

2nd

-

Jrd

of r ln9

gaoove
gr@ve
groove

gr@ves:

2,560...2,540
3,0ro...1,050

5,040...5,060

0,07...0,102

0,04...0,072
0,05...0,082
0, 15

2,474...2,490
2,97a,..2,990
4,978. . .4,990

0,4...0,6

0,J...0,45

1,0
40,003. ..40,009

,14,001.

..44,009

41,994...44,000

2,580...2,600

l, 040. . . r,

060

5,040. . ,5,060

0,09.. .0,122

0,05...0,082

0,05...0,082

0, 15

Slde

clearances of

plston

rlngs In thelr

gr@ves:

-

lst

groove,

hard chrohe-plated compresslon r I

n g . . . . , . . . . . . .

-

2nd

grcove,

compresslon rlng

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

-

Jrd

groove,

oll rlng ,....,..

-

rej

eqt

llnlf

P lsioi rlng

helght ( ln d lrecilon

of

cy

I Inder):

-

lst rlng

-

2nd rlng

-

lrd

ring

Plstoo

rlng gap

(*lth

plsion

ready fl+tod ln

cyllnder):

-

compress

lon

r I n

95

. . , . . . , . . . .

-

oll

rlng

-

reject limlt ............

lltn

Ott OSe englne

(plsfon

816l IO?OO) by

the lck

rlng

grcove

612

Pln

bore in

plsion

,......,.,

P

lsion

pln

dlarEler ........

of

r Ing

gr@ves:

groove

. . . . . .

. . . . . r r . r . .

gr@ve

...r..,......r

groove . .

. . . . . . . .

. . . .

Slde

clearances

of plsfoo .lngs

ln

ihelr

gr@ves:

-

lsf groove,

hard chrone-plafed

compresslon

r I ng

. . . .

. . . . .

. . .

-

2nd

grcove,

comprosslon rlng ............

-

)ao

gaoove,

ol I rlng .....,..

-

rej ecf llm

lt

Plstoo

rlng

helgh+

(ln

dlrec+lql of

cyllnder):

-

ls+ r

Ing

-

2nd r

Ing

-

frd

r Ing

Plsion rlng

gap

(l,lih

pls+on

ready fl++ed

In cyllnder):

-

conpress

ion

r I ngs . . . . . . . . . . .

-

oll r

In9

-

reject

llmlt

[4ax

pernlsslble

welghf dlfference bstreen

pls+ons

In sane englne

Plsion +o be

hea+ed up to l00oc before

Jltilng

pls+on pln.

Pls+on poslflon

In cyllnder: cDmbustlon chambei of

plsfcn

to

facs

towards

lnjector.

connectlng rod
509

Inslde

d lameter of

pls+cn pln

bush

(when

bush

pressed

ln+o connec+lng

rod)

.'..........

ouislde d lameter

of

Dlsicn oln

bush

(siandard)

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

Ou+side d lameter

of

plston

pln

bush,

overslze 8J6O

18605

...'....".

Connectlng rod small end bore

..,.....

Connectlng rod small

end bore

(overslze

bush)

.........

Connec+lng rod blg end bore

. . . . , . . .

. . . .

Tlghtenlng

+orque of

connec+ln9

rod bsarlng

cap screHs

5 , 4 , 6tl

lnslde

d lame+er of D ls'fon

pln

bush

(when

bush

pressed

in+o

connec+lng

rod)

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

ouislde

d lanetei of

plston

pln

bush

(siandard)

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

Oulslde d lameter

o{

plsion

pln

bush,

overslze 8J53

24326

...........

connoc+

Ing rod sma | | end

bore

.. . . . . ..

Connect

lng rod small end

bore

(overslze

bush)

'.......'

Connec+lng

rod blg end

bore .. .

. . . . . , . . .

Tlghtenlng

irque of conneciing

rod

bearlng cap screis

612

lnslde

d lameier

of

olston

pln

bush

(when

bush

pressed

lnto connoc+lng

rod)

.....'...'..

Ouislde

d lame+er of

pls+oo

pln

bush

(standard)

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

ouistde d lamoler

of

plsion ptn

bush, overslze

8161

18606

Connecfing rod small end bore

........

Connec+lng rod small

end bore

(overslze

bush)

......'..

Connec'tlng rod bl9 end

bore

. . . . . . . . . . .

.

Tlgh+enlng

+q'que of connec+lng

rod

bearlng caP screls

Clearance

ai

blg

end

bearlng

.........

Connocflng rod end

play

on crankshaf+

(ln

dlrectlon

of crankshaff axls)

...........

}ialghi ls stamped on

blg end of connectlng

rod.

Max

pq-mlsslble

welgh+

dlfferenca

between

connecilng

rods In saiE englne

Connecflng

rod

posl+ionr ordlnal

nunber towards

valve mechanlsn

(combusilon

chamber of

plslon

on opposlie

slde).

2,474...2,490
2,97a. ..2,9q
4,974...4,99O

0,4...0,6
0,3...0,45

t,0
259

36

,025

. . .36

,O40

(

56,050)

40,060...40.076
40, 580. .. 40,

620

40,000...40,025

(

40,040)

40,5@,..40,525

6'

,'t

30.

. .65 , 7 49

| 65

,77O

'90 Nm

40,025...40,040
(

40,050 )

44,0A2...44,12O

44

,5@.

..44,620

44

,0OO...44

,O25

(

44, 0il0

)

44,500,..44,525

7t,73O...71

,149

(11,1101

90 Nm

44,O2r...44,O4O
(

44,050)

48,080...48, |

20

48, 580. . .48,620
48, 000..

.48,025

(48,040)
48,5UJ...44,525

76,13O...76.149
t16,770'
see lnsiructlons,

polni

4 2 J

0,046...0,098
o,2o0...0,512

20s

4-2

Crcnksh!ft

509

irankp ln d lamet*:

-

standard

-

fst underslze 0,25

ftn

(bearlng

8360

9126,

-

2nd

undersfze

0,50 rin

(bearlng

A560 91261r......

-

Jrd underslze l,@ nn

(bearlng

At6o 972@1......

-

4ih

underslze

1,50 n

(bearlng

8360 972111..,.,,
Crankp ln length
Cleörance

at blg

€nd b€arlng

.........

Journa

I d lameier:

-

standard

-

ls+ underslze

0,25

nn

(bearlng

A360 91215,

-

2nd underslze 0,50

r|n

(bearlng

At60

97274,

-

Jrd underslze

l,co nn

(bearlng

At@ 91276\

-

4i-h underslze 1,50 mrn

(bearlng

8360

972741

Ma ln be6r lng cleöranca

Lengih of ihrust

bearlng

journol

(journal

nearest to flyrheel):

-

standa.d

leig+h

(2

standard

+hrus+

plates)

....."..

-

lst overleng+h

(one

s+andard and one 0,2

nm over+hlck thrusl

plale)

-

2nd

overlength

('two

0,2 ftn overthlck

th.ust

pla+es)

other crankshaff

journals

may

no'i be

ground longer.

Crankshaft

end o löv

........

Max permlssible

ovalness or other

defo.nlty ot crankplns or

journals

Crankshaft unbalance
5

, 4 ,

6tl

Crankp

ln d lame+e':

-

standard

-

fst underslze

0,25 nn

(bearlng

A361

127621..'...

-

2nd

underslze 0,50

nrn

(bearlng

8161 12761)......

-

3rd undersfze

1,00

rlrn

(b6arlng

at61 127651......

-

4th

underslze 1,50

mm

(bearlng

8t61

12761)......

Crankp

ln lengfh

Clearance ai blg €nd bearlng.........

Journal

d lamef€r-:

-

sfandard

61,981...62,000
6t

.131

...61

,7rO

6t .481 ..

.61

.500

60,98t

...61 , 000

60,48t

.. .60,500

,O,000...40,

l60

0,046..

.0,098

69,988...70,018

69,7tA...69,78

69,488..

.69,

5t I
68, 988...69,0l8
68,488.

. .68,

5t 8
0,51

...o,l ol

47,

0@...47,08O
41,2O0...47,280
41

,4O0.

..41

,4AO

0, | 00. ..0,

i20

0,0J

I

,0

Ncm max

67,981

...68,000

67,131...61,150
61,441...6't,5OO
65,

9Bt . .. 67, 000

66,481

. . ,66,500

40,000...40,

160

0,046...0,098

84,985.

. .85,020
84,1t5...44,770
a4,4A5..

.A4

,520

81, 985.

. .84,

020

8t,4Ar...A5,520
0,

070.

..0, I

55

45,000...45,08O

45,100...45,

| 80

45,20o. ..45,2@

45,100...45,180

45,400...45,480

0,

100...0,150

0,05

1,0

Ncm max
lro,22o...l50,260
| 50, o0o.

..

| 50, 040

-

lst underslze

0,25

nrn

(bearlng

8t61

2ot26,

-

2nd underslzo 0,50 nm

(bearlng

8t61

20327 )

-

lrd undsrslze

l,m nn

(bearlng

8361 2ot29l

........

-

4ih

underslze

1,50 rm

(bearlng

A361 2jtt1)

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

Ma ln beorlng cloaronca
Lengih

of ihrus+ bearlng

journal

(Journal

nearesi to flyrheal )l

-

standård leng+h

(2

standard

fhrust

plaies)

.........

-

lst overlength

(one

standard and

one 0,1 |Im overthlck

fhrust

plate

A561 20552,

..

-

2nd ovarlengih

(on6

standard and

one 0,2

nrn overihlck thrust

plate

8161 20515) ..

-

lrd overlengih

(one

0,1 mm and one

0,2 rrn overlhlck thrusi

pla-te)

-

4th

overlenglh

(fwo

0,2

rrn

ov€.fhlck lhrus+

plates)

Oths' crdkshaft

journals

may not be

ground

longer.

Crankshafi end

p

lay . ...... .

Max

psrmlsslble

ovalness

and

o+hgr deformliy

of crankplns or

journals

Crankshaft unba lanca
D laneter of

gear

rlm

of

addltlonal

counferbalanc€

on crankshaft

(4ll

englnos)

.....

Inslde d lamels- of

gear

rlm

of addlflonal countgrba

lönca

(4ll

eaglnes)

4-3

612

Crd|kp

ln d

lanei€r:

-

stondard

550 ) . . . . . .

. . . . . .

t5t ) ...........,

t 2,

....

.... .. ..

'51)

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

Journa I

d lameiei:

-

stondord

-

lsl

undsrslz€

0,25

nn

(bearlng

Bt6l

20326,

-

2nd

underslze

0,50

fln

(beartnö

8361

2032j,

-

Jrd

und€rslze

l,O rm

(bearlno

At6l

2oj29l

-

4'lh

underslze

l,i0

nm

(b€artna

At6t 2'5tt

) ...............

Maln

bear

Ing

clearance

noarest

to f

lyrhe€ I ):

es) ,.......,....

I

nm

ove.fhlck fhrust

plate)

2 |rm overihlck

thrust plaie)

fin ovo.+hlck

thrust

p

löte)

rusi plates)

Othq'

crankshoft

Journals

nay no+

be

ground

longer.

Cronkshåft

end

p

lay ..,.....

Max pgrmlsslb19

ovalness

and

oiher deformity

of crånkplns

cr-

journöls

Cr kshaff

u nba I ance

F

lyrhco

I

lntq-teren€

of

sfar+q-

rlm

qt

flywh€el

Before

tlttlng

to flywheel

siörier|-ln

io

b€ heaied

up +o a +exT€raiure

of ........

F

lyrh€l

u nba I

anc\-6 . , . . . . .

. , . . . . .

Max psrmlsslble

axlal

robble

oJ flyrheel

clutch fac€,

neasured

at

lnner

edge.of

clutch t ace . . .

, . . . . . . . .

Tlgh+enlng

iorque

of flywheel

reialnlng

scrers

....r...

Addltloncl

coonterbalances

(ill

I englnes)

Eack lash

bsfween gef

si

-

crankshaft

gear

rlrn

-

@unteroatance gear

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

:

gd!"€n

gsars

of

counterba lances

........

End

_p

löy

of

coun+erba

lances

S haft d

lametq-

a+

be6rlngs

Insroe

otanetor

o? counterbalance

bush

(flffed)

Shöft hole

d lamelers

€+ rea

surface of body .....,...

Shaft

hole dlamefers

at front

surface of

boåy.........

Thlckness

of

shlit, bgfrdeen

body

and cyllnd6r'blck

o

72,981...13,00O

12,731

...72,150
72,441...72,50O
7l

,

t ...72,0@
71,481...7t,500
40,

000. ..

/t0,

|

60

0,066.. .0,

| 05

84,985.. .85,020
u,735...A4,770
84,445...A4,520

8l,

985. ..84,

020

43,4Ar...At,520
0,070...0,

|

55

45,000.

. .45,080

45,

100...45, |

80
4',200...45,28O
45

,3@.

.. 45, tffi

45,400. . .45,480

0,

l0o. ..0,

150
0,05
1

,0

Non rnax

o, 422.

..O,600

I 50.. .20CpC

1,0 Ncm rnax
O,06tö2OO

120 Nm

0,1...0,J
o, 05. . .0,25o

0,1...0,5

25.979...26,06
26,O40...26,61
26,065...26,06
25,965..,25,9A6
o,2

4-4

3

SPEC

IAL TO-S

(crankcase

)

I 436, 97335

8160

85825

836t

85826

4360

91121

9024 74200

24

558oO

Plslqr

rlng

p

I lers

Plsion

flttlng

ioo I J09

Plsicrf

flttlng iool

3ll,

4ll, 6ll, 612

Crankshaff gaar

extroc+or

Crankshaft end nut

rrench t0g.

tll, 411

Crankshafi

end nut rreoch

6ll,

612

4-5

CRANKCASE

I

10

Crankcaso

fl I

l.

Crarksha

f+

2.

Key

3.

Ma In bear Ing

4. Thrust bear lng

5. F lytrheel

6. Gear rlm

7. Hexagon screr

8. Hub

9. Dust cover foi
shaft sea I

l0.0lldeflector

12.

Gear

13. Pu I ley
i4. Nuf

15. Hexagon socks+

screw

16. Plston

17. Plston

r Ings

18. Pls+on

pln

19.

Clrcllp

20. Connectlng

rod

2l . Bear Ing bush

22.

Screw

2f. Nu+

24. Blg end bearlng

The crankshafl'

(l)

ls fq-ged

out of chrome-

alloyed

speclal s+eel

and

ls

I nduct I on

-hardened

at ihe bearlng and

seallng

poln+s.

Thls

makes

ll

posslble

to

grlnd

the shafi

to four under-

slzes wlihout new heai

ireainent. The

gears

(ll

and 12) nhlch drlve +he ldler

gear

and +he ol I

Dump

have been

flxed

+o +he crankshaf+

fron+

end

vrl+h

pressed-on

flt.

The

crankshafi

froni

end also

has

grooves

for fl++lng

the

hub

plece

(8)

and ihe

oulley

(13)

ls flxed to

ihe

hub.

Between the

hub

plece

and ihe

gears

there ls an

ol

I deflec+or

(10)

and

ihe dust cover tor the

shaff

seal

(9)

is

locaied

on

ioo

of the hub.

The flyrheel

(5)

wlih the

gear

rlm

(6)

flxed io

I-i wlth pressed-on

fli ls fastened io ihs

crankshaf+ rear end. The

conn6c+lng rod

(20)

transfers

+he

gas

forces

generated

by th9

combustlon

of luel from the

Dlston

to

the

crankshafl.

The

cross-sectlon of

ihe

lorqad

connecilng

rod ls an

l-proflle. The

bearing

houslng ln the

connec+lng rod blg end

ls spll+

horlzonially and the bearlng

cap ls flxed trl+h

fvro

speclal

screyis

(22)

and nuts

(21).

The

small

end

has

an

Iniegral be€rlng

houslng

yhlch

has +he

plsion

pln

bearlng

bush

(21

) flxed +o

li

wlth

pressed-on

fli.

The

connectlng rod blg

end of ihe 612 englne

has a bearlng houslng oJ angle

spllt deslgn and

the

bearlng cap

ls flxed wlth tl{o

rrelongaflon

scretsrr.

Vlbratlon

darD€r 6l

l/612

l. V lbratlon

damDer

2. Pul lsy

f.

Hub

4.

Nui

ln

slx-cyllnder englnes

ihe cranksh6f't

fron+

€nd lncorporales a forslonal vlbrailon

damper

of vlscous type. ThE damper

has

a caslng

fllled

l{lih vlscous slllcono

fluld,

encompasslng

the

damplng

paste

ll{lth mlnlmun clearances.

Borrlng shel I

l. lnd lum lead alloy

2. Lead bronze
l. Sieel body

4-7

Th9

crankshati boarlngs are ilxed

to l-he

cyllndsr

block on bolh sldes of

-ihe

cyllnder,

whlch

means thai therg ls one bearlng

polni

more

+han lhere are

cyllnders

ln

ihe

englne.

The cranksha{t

thrust bearlngs

(4)

are

locaied

on

ihg sldes of ihe

endmost

bearlng

Journal.

The

maln

and blg end bearlngs

are so-called

three-layer bearlngs rhlch have

on

top

of

lhe

s+Eel

body

c lead-bronze

layer wlfh

load

capacliy cnd

good

heai conductlbllliy.

The

actual slldlng surfoce ls covEred rlth o

lhln

layer

ot lead-lndlum f,hlch f6cl I l'tales

+he

runn Ing

ln.

44

P I ston

l. Combustlon

chamber

2. Casi lron r Ing

5.

Clrcllp

4.

Plsion

oln

5. Bearlng bush

6. Connect I ng rod

7. Chrome-p lafed

cornpresslon

rlng

8. Compresslon r Ing

9. Sprlng-loaded

oll rlng

ylth

slldlng sur{aces

chromed

The

pls+on

ls made of eutectlc olumlnlum

alloy.

The speclally

formed

cqbustlon chambar

(l)

oo

the

plston

+op end

lmproves the mlxlng

of alr

and

fuel.

In

ihe

hlgh-power englne verslons

the

groove

for the top

plston

rlng

ls

In +he

c€st lron rlng

(2)

cast onto the

plston.

There

are ihr€€

plsion

rlngs:

+he

topnpst rlng ls a

compresslon rlng

(7)

vlth a barrel-iype,

chrone

plaied

surface.

The oiher compresslon

rlng

(8)

Is a so-colled

mlnute

rlng wlih a Jor or

90r anglo.

The +hlrd

rlng ls

a sprlng-load6d

ol I

rlng

(9).

The

pls+on pln

(4)

ls Insldo +he

plston

t|l+h

accurate fliilng

and fhe

connecllng

rod small

end and

ihe

plston pln

have

a

so-called

floåtlng

fl|oun+lng bo+vreen each

other.
The

plstons

of the

612 englnes are

cooled by

dlrecilng

an

ol

I

jet

to the

boftom surface.

o

COi'NTERBALA

CE

IGCH^NI

ST4

4II

45

Counterbalonca

rFchanlsm 4l

I

l. Body

2.

Bal I

5.

Shaft

4.

Thrust

p

lato

5. Bearlng

bush

6.

Counferba lance

7. Pln

8.

Shlm

9. Hexagon

socket

10. Lcck

screv

ll.

Banjo boli

12. Connectq-

li.

Lube

oll

plpe

So.ie

of ihe

,tll

englnes

are furnlshed tlth

a

counierbö lance

nEhnanlsm rhere

ihe

eccenirlc

reighis

ro+ailng ai a speed

double +he speed

of

the englne

compensaie

rlth

+helr

orn

Inerila

the Ine-tla fq@s

caused

by the

pd-fs rlth +o

and fro rptlon,

lhe

pls+ons

and l-he s|nall

end

of conneqt lng rods.
The bodv

(l)

of

ihe coun+erbalan@

rEchanlsm ls

flxed io ihe cyllnder block

bottorn face.

The

shafis

(3)

locaied

in the body have

b€arlngs

bushes

(5)

for ihe actual counferba

lances

(6).

The counierba lan@s

are drlven by the

gear

rlm

on

ihe

ci-ankshaf+

through

gears.

The

bearlngs

of iho counierbalance

assembly are

lubrlcaled

by the eflglne

pressure

lubrlca+lon

sysiem

ihrough

a lube oll

plpe

(lJ).

The clearance

b€fneon lhe

gear

of fhe counter-

balance

nechanlsm

and

the crankshafi

gear

rlm

ls ödjusied lrlth +he shlms

(8)

placed

be+we€n

+he body and

ihe

cyllnd€t'

blck.

4-A

REPAIR

INSTRI'CT

I OI{S

CR^NKCASE

I.

CRANKSHÅFT

A. REMOVINO

THE

CMNKSMFT

l. ReDove

ilp ol

I sumo.

2.

Losen the

connec+lng

scre$

ot

ihe lube

ol

I

plpe

of

the

countorba lance

m€hanlsm

troo ihe

cyllnder

block

os rell

as the reialninq

scrors

of

th€

counierbal6nce

mechanlsm.

Rem;ve

+he

coun+erbalance

mechanlsn

and ihe lube

ol I

olo€

(41|

engl nes

l.

f.

Loosen

the

flxlng

screys

of ihe ol

I

pump

pressuro

plpo

trom

lhe

cyllnder block

and iho

ol I

pump

reialnlng

screus.

Removs ihe

oll

punp

and the ol

I Iniako

and

pressur€ plpes.

4.

L@sen

ih€ flywheel

rstalnlng

scrows and r€move

the flyHheel,

Thon

loosen

ihe flyrheel

houslng

llxlng

screws

ond renbve

the

houslng.

5. Renrove

ihe gear

houslng

(

Instruc ons,

polnt

5).

Loosen fhe

nuts/sc.eis

ol

ihe

connecllno

rod

bearlng

caps,

qemove

the

caps and

push

the

conneciing

rods

so tar dorn +hat

they wlll

not

pr€vent

you

from

removing +he

cr6nkshafi.

Loosen the

retalnlng

scrers

ot the naln bearlng

caps and reirove

the caps.

Llft

fhe crankshafi

ofl from

lts

posltlon.

CIfCKING

THE

CR^iIKSHAFT

vJösh

+he

c.ankshoft carefully

6nd ensure ihaf

C.

the oi

I channels

are

clean.

Max pgrmlsslble

cleorance In ih6 maln beorlng

ls

0rl8 |'n

and

ln the bl9 end b€arlng

0,14

rn. lf

ne€ded,

th€

journals

must bo

ground.

llhsn

grlndlng

fol low the stondard

underslzes

and

use underslzed bearlng shells

supplled

es spare

ports,

see

+echnlcal doia,

polnt

crlnkshaft.

lhen

grlndlng

not€ that the

Journll

ådgos must

renåln round.

REF.ÄCI

NG

TIf CRA KSI{AFT

G€AR RIM

(41|

englncs)

Mark

ihe

posltlon

of

fhe

gear

rln

on the

crank-

sh

af t.

2. He6t

the rlm

evenly, for

example

rlth

o

gas

torch,

and tap off

the rlm

wllh

o sultoble

dr

I

lt.

46

M6ösure

fhe

journöl

rear and

ovolness

yil+h

a

mlcrome+er.

Pertorm

the

measuremen+ crosswlse

ai

sgveral

polnts

of thg

journal.

The

Jo'lrnal

ov6lness

or

o+her delormlty

oay noi exceed

+he

llmlf

O,of

rm.

4-9

D.

REPI.AC

ING TTE CRANKSHAFT

Gf,ARS

Flx the extractor

(8360

973271 loio ihe ihread

holes

of +he

gear

drlvlng

+he

oll

pump

and

pull

+he

gears

oui.

Clean

+he llxlng

polnt

of +h6

gears

oo +he

crankshaft |,lth a *ire brush, for instance.
Heai the ne* gears

'.rp

io a 2O0oC

ienperature.

Place the

gears

on

ihe

crankshöf+

and

iap +he

hot

gears

dorn to ihe boliom using a brass

drlfi or a sultable sleeve. Check

thöl- the key

ls In

posl+lon

and tha+ +ho Insiallaiion

mark

of

the

fron+

gear

remalns

in

slghl-. Lei

ihe

gears

cool

natura

lly.

I

NSTAI.L

II{G

TI.IE CRANKSMFT

l. Clean the oll channels and the con+ac+ sur{aces

of +he bsarlng shells, cyllnder block and
bearlng

caps. Ensure lhat +he crankshal+ ls

cl

ean.

Fli +he bearlng shells lnto +he cyllnder block
and +he bearlng

caps. Ensure that

+he

bearlng
shell clamplng claws flt ln+o +helr noiches and
ihai the

shells io be fliied In

ihe

cyllnder

block

have a hols colncldlng t{lih the oli

port.

Lubrlca+e +he bearlng shells In the cyllnder
block

and the c.ankshaft

bearlng

journals.

Llfl'

ihe

crankshaft back

lnio

l+s

placa

and sllp the

thrusi bearlng shells

ot

the

cyllnder

block

ln+o thelr

posltlons.

Placo the thrus+ bearlngs

so

+hat

thelr lubrlcatlon

grooves

are

agalnst
fhe slldlnq

surface of ihe crankshaft.

Place

+he bearlng

c6ps

lnto +helr

posltlons

ln

the

crder lndlcatod

by the

numbors.

Place

+hrust

bearlngs shells

equlpped

{lth clamplng

claws

on +he slde

of

ihe andmost

beårlng

caP.

Lubrlcate

+he

lhreads of

the retalnlng

screws

llgh+ly wl+h

otl and

+lghten

+he screws

fo the

coirecl

torques

(200

t{m lll,

4ll, 6ll,

612

and 160 Nn J09).

Ensure ihö+ tho crankshaf+ rofates

easl

ly.

fGasure +he crankshaft end

play

t|lth

a dlal

Indlca+oi. Irench ihe

qankshafi

io one end

llml+

poslilon

and

-ihen

back +o

+he o+her and

note ihe dlal

Indlcator readlng for end

play.

Codpare

{lth the

roilng 0,10-O,r5

f,I||. lf

+he readlng

ls too

hlgh,

replace ihe thrus+

bearing

sholls wlth overslzed

onss.

lloigl

Never rean l-he bearlng shells or make

+he

bearlng

clearanca smaller by {lllng ths

edges of

'the

bearlng caps.

2.

E.

F. CMNKSHAFT

HUB

PIECE

Loosen

+he al+ernator

flxlng screws and

renove

the v-be

lf.

Open the hexagon

sockei screes

of the beli

pulley

and

the

vibratlon

danper and remove

+he

paris

from +he crankshaf+. The

pulley

and the

vlbrailon damoer

hava

been

oosltloned

to

thg

crankshaf+ hub

plece

wlih a dowel

pln

(lnj.

tlmlng

narked on

ihe vlbrailon damper).

Notet

Even a small dent makes ihg vlbra+lon

damper

Inoperatlve.

Do no+ remove

l+

by

iurnlng

forclbly

and be careful

not to damage l+

'dhen

l+ ls

loose.

lf

you

de+ec+ a den+ on the ouier

surface,

do not lnsfall +he

damper back ln the

eno Ine.

Vlbratlon

damoers dellvered

as spare

paris do

no+

havo

InJec+lon

ltmlng

nark.

Make

the

marklnq

on

ihe ne|, danper

on

the

same spo+

as

on

the-old damper.

Use an

elecirlc

pen'

do

not

tap the

mark I

Flx +he

vlbrallon

damper

and ihe

pulley on

ihe

crankshaf't. Tap

the

dowol

pln

ln l+s

Placo

and

itghfen the flxlng

screws

to a

torque

of f0 Nm.

412

Uhen

flttlng

ihe

hub

plece io ihe

crankshafi

fronf end note

the corroc+

posltlon

of the hub.

The

hub

plece

has

an lns+allatlon

mark

-

on iwo

+eeih and +he corresponding

Ins+alla+lon

mark

.

of the crankshaf+

ls on

one +ooth.

REPLAC

ING

THE VIBRATION

DAI..IPER

6I11612

2.

@NiECTI

NG ROOS AND PISTONS

REIII)VI

l{G Ir€

@Nt€CTt

t{G R00 AID P|STo|I

Rqpve

+ho ol I sumo

and

ihe oll lnlet and

pressure p

lpes.

Renpve +he

cyllndor

heöd ( s€€

Instrugtloos,

polnt

5 | A).

Scrape off the

posslble

soo+ ln

ihe

cyllnder

llner

top edge.

lf nec€ssory, uso a

reamer 10

remove

+he

sharp rear edg€ ln the

plsion .lng

+op

dead

cenir€.

Remove

+he connecilng

rod

bearlng caps

and

b€arln9

shells. lf

you

lntend

fo fl+ +he

same

shells

back, nole +helr

correc+

order.

Press

the

connecilng

rod

and

pls'ton off

+he

cyllnder by uslng

a ,ooden haftEr

handlo

or

equ I

va

len+.

RqrDve

ihe

plsion

pln

clrcllps.

Heai-

ihe

plston

evenly to

a ienperoture

of t 00oc

and

push

out

th6

pls+on pln

monually uslng

a

suliable

drllt.

Noiel Due

to

I luc+uat Ing

to lerances

the

plston pln

cön be removed

manually

even rhen

cold. tf

ihe

pln

does not com€

off

rhen

pressed

by

hand,

do no+ +ry lo

iap

l+ off

b€for€

heaflng, becouse

+h6

pln

ls fltied

too flghtly

and

the plsfon may be dömaged.

CIICKI

NG AIO REPLACING

THE

CONI€CTI

NG

ROD

EEAR

Il|GS

Clean

the connectlng

rod 6nd

the b€arlng

shells

carefully.

Place

tho bearlng

shells

ln

thelr

flghten the

bearing caP

(9O

lfi JO9, 5ll,

4ll

of the 612 enoln6

flrst

€nd ihon oach :crer

9Oo.

connectlng

rod scrsrs

lo

the +orque

ol l0

Nm

Pr€ss

+he ner

bush

In lts

place.

Ensurg

ihai

the ol I hole In

ihe bush colncldes

rlth

'the

respectlve

hole

in the

connocilng

rod. Al+er

flttlno

ream ihe bush to aitaln

lts corrasl

dlametår

(s6

techntccl

datc

iconnesil

ng

rodr ),

OVERSI4

PI STOII

PI}I BEAR ING

BUSH

It

requlred,

you

can flx In

ihe connsc+lng

rod

snall

end a bush

wlih an overslze oufslde

dla-

nEfor. Machlne

+he connectlng

rod small

end

bearlng houslng

accoidlng io

the fables

bololr:

Order

oe

Enoine

Bearing housing

oroer

number

for bearinq

bu

309 40,500

.

40,525

8360 38605

3r1

411

6r1

44.500 44.525

83s3

28326

612 48,500...48,525

8363 38606

B.

t.

corresl

posltlons

önd

io +he corr€ci

torque

lnd 6ll).

Tlghten

ihs

Alier flt+lng

ream

+he

bush +o

(s€

tschnlcal data

'conncsil

n9

INSPECT It{G T}€ @NTCCTI

iG ROD

lls correct

slz6

rodt

).

414

2. Measure the bsorlng cleorances

rl-th a dlal

Indlcafor zor€d

to ihe crankshaft

b6örlng

journal.

Max

permlsslblg

b€arlng clearance

In

+he

connectlng

rod

blg end bearlngs

ls

0rt4

mm. I f necessory,

gr

I

nd

-the

crankshaft

bearlng

journöls

6nd Install the underslzed

bearlngs

dellvgred

as sparg

parts.

J.

It

ihe plston pln

bush ls too rorn,

remova

ihg

bush

by

presslng

rlth

a sullable drlff.

4-12

4 16

dl fferenl

etglne iypes

31'1,411,611

The

connecilng

rods

of

Use
lhe

a ioo I speclally

made for +he lnspec+lon

of

connecilng rod

(e.9.

Carl Larsson).

Place the

connecilng

rod bearlng

cap In lfs

posl+lon

noilng +he marklngs and tlghten

the

nuts evenly io +he torquo of 90 l{m

ln +he
case of 309, fll, 4ll and 6l'l englnes. Tlghten
the

connectlng rod screws

of the 612 englne

flrs+ io +he lorque o{ 30 Nm and then

each

sCf€ri 90o.

4.

l.,llth

the +ester

plns

ln a

verilcal

posl+ion you

can

deiernine

ihe

connocflna

rod

deflec+lon.

2. Fl+ the connectlng rod to ihe lnspecilon

iool

and ihe

olsion oln ln+o lis

bush.

Place

+he Indlca+or on fop of

l{Ifh ihe

+es+er

plns

of the

horizontal

posl+lon

check

l-he

tor

s lon

.

fhe p I sfon p In.

lndlca+or ln

a

connec+lng rod

5. Also

check the

connec+lng rod for any S-shaped

deflecl-lon.

Thls

is

done

by uslng a sllde

gauge

to measure

the dlstance bete€€n +he

pln

bush

ouier

edge and ihe

lnspec+lon tool

plane

surface.

Then +urn the connectlng rod the o+her

vay round

and measure +he

same

dlsfance agaln.

The

dlfference may

nol exceed 0,6 nrn.

420

l.4easure +he length of +he

612 englne connec+lng

rod

scrers and

compare them wl+h the nax length

glven

ln flg. 4 20.

lt lhe long+h of any

screw

exceeds +he max

llml+, replace fhe

scre{ wlth a

o9ll orlg r

l{9

recommend

that

you

rgplace screws

wlth new ones each

tlme

you

open them.

CON}ECTI NG ROD XEIGHT

CLASSES

E.

The

connec+lng

rods

are dlvided Into

rtelghi

classes a+ 2o-gramne Intervals. A le+ter

Indlcatlng

the welght class ls

markad

on

+he

connec+lng rod

slde

face.

The cyllndor ordlnal

number

ls stamDed on +he same slde as fhe

welghl class.

All

the

connecilng

rods In one

englne

mus+ be of the sano uelghi class, l.e.

+he max

pernlsslble

vlelghf dlflerence ls 20

g.

Le++ers lndlcate welghi

classes as tolloxs:

5 0 9 englne

s
s

I

K

Welght

1990 - 2010
2010

-

2030

2030

-

2050

2050

-

2010

Spcre

parf

no

4360

36562

8160

J6561

8560

56564

8360 36565

4-13

4

2l

6t2 engln€

N4
N

0
P
R

s

T

5lt,

K

L

M

N

o

P

R

S

T

X

z
c

0
E

E

H

I
K
T4

N

o

P

s

T

v
x

Y

z

2070 - 2090

s

2O9O

-

2110

g

2l1o

-

2130

9

2130 - 2150 g
2l5O - 2170 g

2l7O - 2190 g

2l% - 2210 g

2210

-

2230

g
2230 - 2250 g
2250

-

2270

g

4ll and

6ll englnos

Wel

ght

2190

-

2210

g
2210

-

2230

g
2230

-

2250

g
2250 - 2270

9
2270 - 2290

9
2290 - 2310

9
23lO

-

2330

g
2330

-

2t5O

9
2350

-

2310

g
2370

-

2t9O

g
2390 - 2410

g
2410 - 2430

I
2430

-

2450

g
2450

-

2410

I
2470

-

2490

9
2490

-

2510

g
2510 - 25tO

g
2530 - 2550 g
2550 - 2570

9
2510 - 2590

g
2190 - 2610

g

Hel

ght

2911 - 29

2991

-

3010

Jol I - 3030

totl - 3050

30rt - 3010
107't - 3090
J09t - Jt 10

l l - 3130

lljl - 150

ll5l

-

ll70

lr

Tl

-

Jl90

3191

-

3210

3211 - 3230

3231

-

3250
3251 - 3270
3211

-

3290
3291 - 3t10
3311

-

3330
33tt

-

3350

3351 - 3370

8360 36566
4360 36561
4360 36564
4360 36569
8360 36170
4560 36571
4360 36572
8160 581 l6
8160 J8l l7
8560 381 l8

Spare

pcrt

no
4361 36573
a36l 36514
a361 36515
a361 36516
4361 36117
8361 36518
4361 36179
8361 36580
8J6l 16581
8361

36582
8361 t6r83
at61 36544
8161

36545
8J6l 16586
8361 36141
8561 16588
8161

36549
8361

36590
8361 36591
4361 36592
8361 36593

Spare

pcrt

no
8t6t ta1
8t63 3A796
8363 3879-7
8363 3A194
8361 34799
8J6l J8800
8l6J 18801
8363 18802
8J6J 1880J
8l6i 18804
8J6J

18805

8161 18806
8J6J 18807
8161 18808
856J J8809
8l6J 38810
816l l88l I
a3$ 3ABl2
8561 l88r

J

836J J8814

INSPECTII{G AND REPLACI

NG THE PISTON

RINGS

Use

pls+on

rlng

pllers

lA360 91333, fo

remove

ihe rlngs.

Do no+

spread tho rlngs more than

ls

necessary to

remove +hem.

lf

you

ln+end lo re-

fl+

ihs

same

rings,

ensure +haf ih€y

wlll

be

placed

ln thelr orlglnal posl+lons.

2.

Clean

ihe

rlng

grooves

carefully. Measure

the

plston

rlng

slde

clearance In l+s

groove.

The

clearance

must

be less fhan

0,15 nm.

De+ermlne

whether

the slde

clearance ls due +o

rlng or

groove

wear

and

replace

the rlngs

or

ihe

plsfons

as

well, lf

necessary.

a

4-14

J. Place the rlng In fhe cyllnd6r, adjusilng ll

perpendlcular

+o fhe

cyllnder axls, and

measure

iho rlng

cap. Thls may nof exceed I mr.

4.

424

Fl+ lhe

plston

rlngs

uslng

the rlng

pllers.

Ensure

+hai ihe

rlngs are flffed

ln

+helr

correct

places

and +hai lhe marklng TOP or

+he nanufac+urerrs marklng

In

ihg rlngs ls

upld

ards.

I NSPECT

ING

THE

PISTON

425

H.

F ITT

II{G

THE PISTON PIN

426

Heat ihe

plston

evenly to a tempera-fure of

l00ct.

Flt

+he connectlng

rod Into the

pls+on

and

press

ihe

pls+on pln

Info l+s

poslllon.

Noie

I The combus+lon chamber of +he

Dlslon

and and the ordlnal

nurnber on the connectlng

rod

musi

face In ogDoslie dlrectlons.

Fli

the

pls+on pln

clrcllps In ihe

pls+on.

Ensure +hat

+he clrcllps engage

properly

In

ihelr grooves.
SHORTET€D

P

ISTot{S

lf l-he

cyllnder block top face has b€en

machlned,

lns+al I respecflvely

shortgr

pls+ons

+o ensure +he

correci dlstance betwsen +he

plston

head

and

cyllnder

head.

Always replaco

all ihe

pls+ons

ln one englne to

have

ldenllcal

plsj-ons.

Max

permlsslble

relght

dlf{erence

be+reen pls+ons

In

one englne ls 25

g.

There are flve

dlfferenl

underslzes

ln +he

lengihs

of

ihe pls+ons

dellvsred as

spare

par+s

for

3ll,4ll

and 6ll englnes. The

correct

length

can be chosen accordlng

to

+he ne€d Jor

machlnlng.

ln the

case of f09 and 612 englnes

+he

s+andard

plston

rnust be shor+ened +o

correspond to ihe

cyllnder bl€k machlnlng.

t.

Piston diameter

Engine

A

gD

309

26

99,873...99.887

311
4tI
61

1

19

107,853...107,867

612

22 107,8s3...102867

Check

+he

condltion

of ihe

plsfon

and the

pls+on pln

vlsually. Pay speclal attenilon to

posslble

cracks ln +he area of the

plsion

top

and the

pln

bore.

Measure +he

plsfon

dlamo+er

a+ the

polni

Indlcaied

In flg. 4

25.

Coopare

ihe resuli

'.ilih

the railng and replace the

pls+on

',ilth

a

new one,

if

necessary.

427

4-15

Spare

part

no

Shortened
oy mm

Mark

on

piston

311,411,611D

8353

16177

8353

31044

8353

31045

8353

31046

8353

31047

8353 31048

std
o,2
o,4
0,6
0,8

1,0

4

o

8

10

31.1,411,611

DS

8353

16033

8353

31049

8353 31050
8353

31051

8353

31052

8353

31053

std

o,2

o,4
0,6
0,8

1,O

2

o

I

10

611 DSB

8363

30700

8363

31054

8363

31055

8363

31056

8363

31057

8363

31058

std

o,2

o,4
0,6

0,8
'l

,0

2

6

I

10

FITTING

THE PISTON AND TIE

@N}€CTIIG

RCD

Fli +he connecllng

rod blg end bearing

shells

In

ihelr places.

Check

+ha+ +he

mailng faces

are clean and fhe bearlng

shells co.recily

pos

l+ loned.

Lubrlca+e the

pls+on, pls+on

rlngs

and

cyllnder

lrl+h englne

ol l. Place

+he rlng

gaps

radlally

a+ regular In+ervals,

faclng ln

dlfferen't

d lrecflons.

Lubrlca+e

+he

crankshafi bearlng

Journal

and

bearing shslls and

push

lhe connecilng

rod onto

+he crankshaf+ bearlng

Journal.

Flt

fhe bearlng

caD so fhal- l+s ordlnal number

faces +he

respec+l ve number on the connecilng

rod.

Tlgh+en

fhe nu+s

of 109, 3l

I , 4l I and 61

I

englnes ln

phases

+o the +orque

of

90lln.

Tlghien ihe connec+lng

rod screws of 612

englne

as lollows:

L

Preilohfenlno

vrlih

ioroue

wrench

J0 Nm

2. Tlghtänlng 9öo, both sirews

J. Tlghienlng 90o,

both screws.

S',lng

ihe connectlng rod sldeways and

ensure

ihat ihe connecllng rod blg

end

has

a

sufflclen+ slde clearance on fhe

crankshaff

bear Ing

journa

|

.

Plstoo

dlstance

crcnk

rng l€

frs ta

dged contre vs.

oegrees

Jll,4lt,6

nm

4.

J.

424

t0

ll

l2
tl
l4

t)

t1
l8

to
20

22

24

a1

28

29

JO

r,l0l

l,rB5
1,8!b
2

,15O

2,465
2,8Ol

3,5

4

,351

4

,189

5

,247

5,724
6,220
6,

l35
7,270
7,822
a,391
I,982

9,58

1

,172

1

,417

r,685

1,976
2,28
2

,624

2,982
3,361
3,163
4, 186
4

,631

5,O91
5,583
6,091
6,619
1

,161

a,3E
8,

9JO

10,202

2,207

4

,205

4

,674

6,240
6,808

8,O12
4,64't
9,3O5

10,686
| |

,408

f.

Use a

plsion

rlng

s+r6p or

preferably

a

flfilng

tool.

Fli the

plston

and

ihe

connec+

lng rod

Inio +he

cyllnder

Indlcaied

bV

+he ordlnal

number

so as

lo have ihe

nunber and ihe

wolghf

class mark

fowards

+o +he

camshafl.

4-16

l.

CoU]{IERE L NCE iCC}l,ANl

SH

,ll|

RE

OYITG A]O

DISASSEIALIrc THE COI'XIERBAL,ATCE

lccH

Nl sf.l

De+ach lhe englne.

Open the connecllng screws of

the lube oll

plps

of +he

coun+9rba lance assenblv and

rqnov€ the

Dloe.

open ihe flxlng screws of +he counierbalance

mechanlsm,

remove +ho assembly and

the

posslble

shlms b€ftreen ihe body and +he cyllnder

block.

4.

431

Ensure

thal'

lhe backlash

b€lween

+he

aears ls

accordlng

to

ratlng

(0,O5...0,25)

a-nd ttrai

the

@unterbalance

end

play

ls

corr€ct

(O,l

...0,5

).

FITTIT{G

TTE

CDUI{IERBAIINCE

iCCHANI

SI,t

Tap the

dorel

plns

ln ihe

body

ot the

counter-

balönce

mechan I sm.

4.

Open

the refalnlng

scref,s of the counterbölance

shat+s. Press fhe

shafis off ihe

bodv

to

ihe

di.ecilon

of

+he

retölnlno scrers. Renove

fhe

counierba

lonces

and-the +h;us+

Dlates.

5.

Clean +he

oarfs

carefully.

B. RECONDITIONI]€

IHE COUNTERBALÄNCI

IfCHAN

I SI,I

Check

ihe

shafis for wear and

ihe condl+lon

of

the counteib€lance

gears

and

bearlngs.

lf the counterba lance

gears

are rorn, rep lace

th9

cou

n+erbo

I ances. The

gears

are not supplled

separo+ely as spare

par+s.

lf needed,

press

lh6 old bearlng bushes ott the

clun+erbolånce wl+h a

suliable

drlf+. Bgfore

renova I mark

the

bush

oll

groovo posltlon

on

ihe counierb€lance.

Press the

ne'r bushes

onio

+he counferb8 | ance no+ Ing +he ol I

groove

posliion.

After flitlng machlne +he bearlng
bushes io lhelr correci dlmenslon 26,040...
26,061 mm.

Flt

ihe coun+erba lances

lnslde the body notlng

thelr

correct

posltlon.

The

counierba lance wlth

6-dot

on the

gear

ls

placed

hlgher on the

body.

Allgn

the

llne narks

on ihe

counterba lances

and

tl+

the

shäfis

In

posltlon

from

+he

slde of ihe

retalnlng

scrers. lihl

le lhe shaff ls

b€ln9

fltied

ln

posl+lon,

place

the ihrust

plalå

befeeen

thg

counferbalance

and

the body.

Tha

shaft

end ls

pressed

flush rlth fhe

body.

Appty

relalnlng

compound

(6909

lo0ll) oo the

sciei

threads

and tasfen

lhe

scrers.

2. Flt the coun+erbalance

assembly

In

place

so

lha-i'

+he dot on +he

counterbolanca

gear

allgns

wlih the dot

on

the

crankshaft

gear

rlm.

5. Tlghien the flxlng

screxs ot ihg counierba lance

nEchanlsm

lo

the toroue

of

ilt

ltl.

t4easure

the back

lash betroen ihg

cauntgrbalånce

gear

and the gear

rln.

Should l+ dlffar fron ratlng

(0,1...0,5

hr), make

the adjustmeni by

placlng

0,2

|Im

shlDs

beireen the body of

ihe

counierbalance

assembly and +he cyllnder block.

4.

Flx ihe lube ol

I

DlDe.

5. l'4ou

nt

fhe

englne.

1. Line

2.

Dot

t iminq marks

timing-ma1k

n

30

4-17

4.

FLYHHEEL

REPLAC

I

NG TI{E

FLYTI€EL STARTER R I I,t

lf

the sfar+er rlm

ls worn, replace l+.

The

s+arier

rlm

cannot be +urngd around because

lts

+eeih

have been chamfered

and +empered on ihe

slde

of

+he s+arlor.

Remove +he

old s+arior rlm by tapplng l+ a+

varlous

polnfs

wlth a drlft.

Clean

lhe flywheel

confaqt face

vrl+h a wlre brush.

B.

433

2. Heat fhe slarter

rlm evenly +o a

iomperalure

of

150 - 200uC.

Fl+ the rlm In

posltlon

on

ihe

flyvlheel so

+hat ihe

chamfer

of

ihe openlng ls

towards the flv*heel and

+he chönfe.ed side

ot

ihe

teeth

iovrards the s-tarter.

f.

Lef

ihe

siarter

rlm cool

dorn na+urallv.

F ITTII{G T}€ FLYXHEEL
Clean

+he maflng faces on

ihe crankshafl

rear

f lange

and f lywhee

|

.

Flx +he

flvwheel on the crankshaf+

end. Foi

guldlng you

can uso lV l2 siuds

(2

pcs) whlch

sult

the flywheel retalnlng

screr

holes.

The

poslilon

of ihe flyrheel ls

{ree ln englnes

where ihe

lnjecilon ilmlng

ls marked on

the

crankshaf+ fron+ end. In

sone englne

vorslons

one of +he relalnlng

screws have

been replaced

by a

gulde pln

i'o deiermlne

ihe crankshaf+

posli

lon.

Tlgh+en the

llyvlheel re+alnlng screris

evenly

In

phases

io ihe torque of 120 Nm.

4

-'18

T IM I1{O G€AR ASSEICLY

I ioEx

Technlcll

data...........

..

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

5- I

SDe

f al toofs....

..........

5-

2

Consfrucilon.....

. ...... ...

5- l

Repalr lnsfruslloos

l. G€ar

hous

lng

A,

Remov

lng +he

gear

houslng.

...... 5- 6

B. Recondltlonlng +he ldler

gear. . . . . . . . . . . . .

.......

5-

6

C. Flftlng the

gea.

houslng

........5- 6

D. Replaclng +he crankshaf+ fron+ end shati sea I .

. . . . . . . . .

. . . . . . . . . . .

5-

I

VAIiIET

5-0

IECflN

ICAL

D TA

(reject

llmli of

part

sfated ln brackeis of-ter raflng)

Blck

I cshos

Cränkshatt - ld ler

geor

ld ler

gear

-

camshaft

ldler

geor

-

InJecllon

pump

......,r....

Canshafl

-

dr

lv9

unlt

Max

pernlsslble

sldg wobblo of

gears

,.......

Tlnlng Frrks

Tlnlng morks

on

gears

6re ln allgnment when

the ls+ cyllnder

plston

ls 6l lts

iop

deöd

c€nt.e betre€n compr€sslon

ond

poror

slrokas.

0n crankshöfi

gear

. . . . . , . . , . . .

On ld 16r

gear:

-

cgalnsi

crankshafi

gear

.....,,.....

-

cgöl nst canshaft

ger

-

6galns+

Injectlon

pump gear

0n

camshaff

ge€r:

-

f09, llt,4

,6lt

........

-

6lr, 6t2

0n Injecf

lon

punp

geör

Crankshatt must

be

furnd

to brlng all flmlng mfks ln allgnnenf

agöln

.......

ldlcr

galr

8161

2986t

(rlth

plaln

bearing)

Inslde

dlör€tor

of ldler

gear

b€arlng

bush

(flfied)

......,.

Dlämeier ol ldlor

gear

splndle

.,,.....,

Tlgh+enlng lorque

oi Ml0 retalnlng

screi

...........

Tlghtenlng iorque

of

lrll4

retalnlng screy

...........

8f61 ,8J54

(rlih

plaln

bearlng, splndle lengih 50,7

nn)

Inslde

dl aflEfer of ldler

gear

bearlng bush

(fltted)

........

0lömeie ot ld1e|'gea.

sp i

nd

le

. . . . . .

. . .

Tlght€nlng'torque

of Ml0 reialnlng

screB

...........

Tlghtenlng tfque

of Ml,l refalnlng screr ...........

4361

227@

(rlth

b€velled ball bearlno)

Dlane+€r

ot ldler gear

splndle ..,...;..

Tlghienlng idque

of ldler

gear

bearlng

holdef scr€rs

..........

Tlghlenlng

torque

of ldler

gear

retalnlng

scrgr

...........

Crcnkshcfl troit 6nd nut

Tlgh+enlng lorque ot fron+

end

nut

109, fll, 4ll

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

Tlghtenlng

forque

ot

fron+

ond nut 6ll,612

2 dois

on

te€th

mEik

non

on

tooth

I

dcrt on

ioolh

I doi

on

nqlch

dot on

nqlch

dois on

fe€th

doi

on

toofh

TUrns

I
)

I

o

o,or...o,2,
o,o5...o,25

o,6...0,25
o,0r.. .0,2,

0, 05

55,000...55,050

,4,951 .

..54,910

60 Nm

140 Nrr

,,

,20O...5',2tO

5r,111...55,110

60 Ntn

140 Nm

14,984...15,000
22 Nm
180 Nm

600 Nm
1000 Nm

5-1

o

4

3

o

2

(ilrlng

gear

6senbl

y)

Flt-ilng

+@l tcr crdrkshaft

frort

aod shati seal

T+plng flfi

fq- dusi covei

T+plng

drlft

fo.- dore I

pln

T+pfng ölft tor dore I

pln

G-ankshaf+ fror|i end

nut rrench

JO9,

Crankshafl

fron+ end nut rrench 6ll,

SPEC|AL

IIn_S

t.

90Jo I'm

2.

qzt gm

l. 9025 98m

a.

25 9Er7N

n21 712@

21

55mo

lll, 4ll, see Insiructlons

polnt

4

612, see

lnstructlons

polnt

4

o

o

o
o

'I

c-z

T I I'

I NO G€AR

ASSEI,BLY

cor{slRl,cT

I o{

G€AR

r.tous

I NG

5o9, ]|t,

4 , 6tl

GE^R

HOUS

'tc

6ll, 612

13

12

l. Oear hous lng
2,

Scret

f.

Gaske+

4.

Siud

5.

Doro I

pln

6. Gasket

7. Froni

cover

8.

S hatf

sea I

9. Shle ld

p

laie

10. Nui
ll,

Seallng

12. Flller

plpe

ll,

O-r I ng

14. Cover

15. Washer

16.

Spacer

17.

Bearlng

houslng

18.

Gasket

19. Bear

Ing

20. Clrcllp

21. Drl ve

unl+ shaf+

22.

P lug

23.

Seallng rlng

22
23

13

14

51

t.

2.

8.

10.
.

14.

15.

Gear

hous

I ng
Screr{
Gaskef
DoYiel

pln
Front cover
Sea

llng
Cover
Seal Ing
Shafl'seal
}lasher
Shaff
Clrclip

ldler

gear

of

compressor
Bear I ng
Bearlng

holder

5-3

The flmlng gear

assembly

comprlsos

hel

lcal

gears

rhlch

have b€en nachlned

and tempered

!rlih

preclslon.

The

gears

are

locatod ln +he

gear

houslng flxed

to +he

cyllnder block

front

face.

The camshaf+,

lnjec+lon

pump

and ol

I

pump

as

yell

as

+he

compressor ol

611/612

englnes

are drlven +hrough

the flmlng

gears.

The gear

houslng

can

alio encompass

-a
drlve

unll for,

say,

hydraullc

pump.

There

are

three maln

+ypes

of +lmlng

gsar

assembl

les:

l. 1

The +lmlng

gear

assenbly

equlpped

v,lih an ldler

goar

},lth

bevel

led ball bearlng

ls moun+gd

on

6l I englnes.

Thls gear

assembly

has noun+lng

polnts

ready

for a

drlve unl+ and

a l-cyllnder

o' 2-cyllnder,

gear-drl

ven clnpressor

can be

npunl'ed

on ihe

englne

lef+ slde.

l. Camshaf+

gear

2.

ldler

gear

5. Injec+

lon

pump

gear

4.

Crankshaf+

gear

5. 0l

I

punp gear

The tlmlng

gear

assembly

equlpped

gear

'.{lth

plaln

bearlng

Is used

4ll

and

some 611 englnes. Thls

assembly can

be furnlshod wlth

drlven

by ihe

camshaft

gear.

The 6ll englnes have

a slmllar

verslon of

assembly,

equlpped t|lth a longer

ldlor

shafi,

ho{over.

l. Camshaft geör

2. ld

ler

gear

f. Injec+lon

pufip

gear

4. Hydrau

I lc

pump gear

5.

Crankshafi gears

6. 0i I

pump

gear

7,

ldler

gear

of compressor

8. Compressor-

goar

The 6l I

and 612

englnes

have a tlmlng

gear

assembly where

the gear-drlven

conpressor

ls

locöfed

on the

englne

rlght

slde.

The ldler

gear

has bevelled

ball

bearlng.

I DLER GEAR

The

ldlor gear

ls

connecied io

a shaft llxed

to

fhe

cyllnder

block

front

face by means of

a

bearlng rhlch

ls elther a plaln

bearlng or

a

bevelled

ball

b€arlng

1611/612r.

Mounilng

par+s

of ldler gear

l{lih plaln

bear

Ing.

Screr.

2,

Screr J.

Retalnlng flange

Boarlng

bush

5.

cear

6. Shåfi

{ l+h

an

ln

f09,

llmlng

a dr lve

ld ler

111

gear
unlt

gear
g9aa

l.

Drlve

unl+

gear

(shaft)

2.

Camshaft

gear

i.

ld ler goar

4.

Compressor/

I

nJ

ect I

on

pump goar

5.

Crankshaft

qeårs

6.

ol I pump geär

5-4

l.

Moun+lng

parts

ol ldler

gear

rlth

bevelled

ball

bear

Ing.

l.

Screx

2. Scre{

5. Flånge

4.

Reialnlng

rlng 5, Bevelled

ball bearlng

6. Gear

7. Shaf+ 8. Locklng

pln

c-5

t.

TllllNG GE^R ASSEIGLY
GEAR }IOUS I }G
REIOY I I{G THE GEAR I{OUS I }lG
As

the

gear

houslng bo+ion face forms

pari

of

ihe

mgilng

face tor ihe ol I sunp

gasket,

ihe

r^

ol I sump

äusi-

be removed fron the-engtnå, lf

'"'

fhe

9e6r

houslng

needs fo be taken olf

|.hlle

fhe

9n9lne ls

In

place.

Remove

+ha

ol I

sump

from ihe englns.

opgn

the tan flxlng

scrers

and rgmove thg fun.

ll'

Loosgn

the alternator flxlng scrers and

refl|ove

the alternator, beli

pulley

and b€lf.

J. Redtove

ihe oll

pressure

regulailng valve

(Jll,

411

and 6ll enqlnes).

open

fhe

crankshai+ lront end nuf

vrl+h

iool

9024

14200 In case of

J09, 3ll and 41 I englnes

and rlth

+ool

9024 55800 ln

case

of 6ll and 612

englnes.

Pu

| | the belf

pu

lley

-

hub

plece

comb lnal lon oJf the crankshafl­Remove

the

fron+ cover flxlng

scrers

and nuis

and lake off the cover.

lf

you

need

io

tap

a

wedge b€freen ihe cover and the

gear

houslng

+o

remove

ihe

covor, be sure not to damagg ihe

seallng

surfaces.

Renovo

the

ol

I def lecior

from the crankshati,

Remove

fhe

Injectlon

pump

andlor compressor.

Notcl lf

you

do noi ln+end

to

rep

lace the

g€ar

houslng, li ls noi

necessary to remove

+h€

lnjectlon

punp.

Only

reflDve fhe

fuet, lube ol I

end lnjecilon

plpes

frorn the Injec-t

lon

pump

(englnes

rhere

lhe

Injectlon

punp

ls flxed io

the

gear

houslng).

Opgn

ihe

ldler

gear

flxlng

scrgus.

Romovo tho

ihe refalnlng

flange,

gear

€nd

shaft.

Notcl I

f lhe

cy I I nder

head

and

vo I v€

flEchanlsm

have

no+ been

renoved,

lock ihe

valve

+appets up

In such

y.ay

thaf

ihey rlll not

droP

down

when

remov I

ng

+he

carlsha{ t

and ihus

prgvent fhe lns+allailon

o{ ihe

camshöft.

Se€

Ins+rucflons,

polnl

S

2

g.

Open

+he

gear

houslng

flxlng screws

and

rgmove

ihe

houslng.

lf

you noed to tap a red99

betxeen

ih€

gear

houslng

and cyllndsr

block io

re[bve

ihe

houslng,

ensure

+haf +he seallng

taces

rsmaln I n+ac1.
Tap

the crankshaf+

shafi seal

off lhe

fronl-

cover uslng

a sul+able

drl{1. wash

all detached

parts

and

clean ihe seallng surfoces

carefully.

B. REOOIIDITIOTIrc

IHE IDLER GEAR

ldler

gear

rl+h

plaln

bearlng:

lf

you

replace l-he ldler

gear bearlng bush,

oress

+he nefl bush ln

Dlace

so thäl lis

rEar

edge

renalns

0,1

...o,25

nm

Inslde

lhe

gear

rear

f ace.

Afier

lnstallailon th€

bearlng

bush musi be

machlned +o

55,000...55,030

|trn In casg ot 109,

511,

4ll and 611 englnes

and to 55

'200...55,250

nm

ln

case of

6ll

englnes

ylth

50,7

rm long

ldler

gear

shaf+.

l|otcl

Hhen

machlnlng

lhe

beörlng bush

cenirallze

+he ldlor

gear

accordlng

io tlg. 5

8.1

ln order

to k6eD the

back lashes

correqt.

ldl6r

gear

rl+h bevelled ball

bearlng:

q-

A

Rol ls,

9.

Pull ihe camsh€ft

off

{rom

+he cvllnder

block.

Flx ihe bearlngs

as

shorn ln flgure

5 9

(o-

sysieD) presslng

from

-the

ouier rlD.

Atiach

ihe

bearlng

refalnlng

rlng and tlghten

tis llgh+ly

ol led

screl{s to th€

+orque of

22

Nm.

press

the

shafi In

posltlon

placlng

supporis

on

ths

E€ar

I no Inner rlm.

c.

Frrfl;

Tl€ 6EAR HoUstNG

The

posltlon

of +he

gear

houslng

towards +he

cyllnder block

ls deigrmlned

',{lfh

tuo dowel

plns.

Thls

also

sgcures the

posltlons

of ihe

gear

houslng and

lhe froni cover

rhlch

need

nof

be sapar8tely

ceniral

lzed durlng lnsiallaflon,

Ensure, howevor, the correc+ back lash of ihe

gears.

The

gear

houslng

and front cover rhlch

are del I vered

as

sDare Darls

are furnlshed

rrlth

ready

holes for th; dcr;tsi

Placo o

ngr

gasket

beixe€n

+he cyllnder block

and the

gear

houslng and llfi ihe

houslng ln

lis

poslilon.

Tap

the

dorel-plns

In

holes rlih

ihe tool

(9025

98700) and tlghfen ih6

houslng

t lxlng

screws

and

nuis.

Attach the lnjecilon

pump/compressor

and

lts

gear

(

It removed).

Lubrlc6le

ihe comshaft bgarlng

Journals

ond

push

,ihe

canshåfi lnio +he cyllnder block.

Releadb ihe val.ve t€ppets

lf locked.

Tlmlng

gear

marks

(see

iechnlcal

dota

I'tlmlng

marksir)

l. Crankshaft

gear

2. Gear

drlvlng

oll

pump

3. Camshatt

gear

4.

ld

ler

gear

5.

Injectlon

punp g€ar

4.

Place the ldler

gear

shatt ln

poslilon

and

lnstall

the ldl€r

gear

on fhe shaff. }lhen

lnsialllng ihe

ldler

ge6r please

poy

attentlon

to

ihe

correcf

posl+lons

of +he

tlmlng

marks

on

gaars.

Flt

fhe retalnlng

flange

ånd ilghten

the

ldler

g€ar

flxlng

scrors to fhe rlgh+

forque

(f7

rl

.

60 Ir rnd

Z2

n

-

l1O t|;

for

ldl.r

gcar

rlth

pl.ln

bclrlng

lnd

l8O Ir

for

ldlor

g.!r

rlth

b.vcl l.d ball

bcarlngl.

5.

lf

ihe

compressor

ldler

geör

shaf+

has

been

rencved,

apply reialnlng

tlutd 6909

tool2 on

Its ouislde

and

tap lhe

shaft In

posl+lon

so

that the

rear faces

of the

shaf+ and +he

oear

houslng cre levalllng.

Ftx the bearlng

and-lhe

gear

In

such a

ray fhat

the notch

on the

be6rlng

Inner clrcle

cones

on ihe outslde.

Renember +he beörlng

reialnlng

rlngsl

At+ach

1'he

ldler

gear

lock plåie

and

ghfen

lfs

flxlng screes

lo

f0 Nm

(611,/612

Englnes

rl+h

conpressor

on l-he

the englne

rlght-hand

slde).

6. backlash

rhlch should b€

0r0t

Check

ihe

gear

...0,25

m.

7.

place

+he oll def

lec+or

on the crankshaft

and a

ngx

gasket

bsiwggn

+he

gear

houslng and

front

cover and

llfi ihe

front covgr

In

Dosltlon. use

too | 902i

98700

to

taD

the

froni cover doUel

plns

In

posl+lon

and

lool

9025 98gOO

{or the

5_7

ptn

around

the

stud.

Tlghten the

fronf cover.

D. RE'IACI]G

ITC

CMT'(SMFT

FROiIT

EID SMFT

SEA

(5O9.

5lt

cnd

4ll englnasl

Flx

the shleld

Plate

on

box

and

top

ihe shaft

too |

(9010

15200).

fhe

fron+

cover

seållng

seal

In

Place

rl+h

the

L@san

thg alternator

llxlng

scrers

and remove

the v-b€ lt.
oDen fhe crankshöfi

fron+

end

nuf rllh ihe fool

19024

14200\. Pull the belt

pulley

-

hub

plece

contblnailon

off fhe crankshoft.

R€|lpvo

+ha shaft

seol

fron lhe tront

cover 6nd

cloan

the

soallng box carefully.

Top a ner seal

ln

posltlon

rlth the

t@l

(9010

15200).

Lubrlcate

fhe

seal llp corefully

rnd

push

the

bel+

pulley

-

hub

plece

corblnatlon

onto ihe

cr6nkshatt

groovgs.

Tlghten

ihe crankshaft

froni end nut

to th6

torqua of

600 lln.

Flx the

v-belf

and

tlghten ihe alternö+or

ln

Its corrggt Dosltlon.

lotel

Tho

5ll and 612 englnes equlpped xlth

ldler

gear

trl+h bevslled

boll

be6rlng

can, lf

necessary, have

iro

shafi seals

ln a ror. Also,

the ooslflon

of

the shalt seol can

b€ altEred

by ftitlng

ä J rin thlck

shtm underneaih

the

sgel. The order nunber for ihe shlm ls 8f5t

28899.

2.

515

9.

t0.

12.

tt

the

shalt

sacl

dus+ cover

has

b€en

re|l|oveo

t.or

itr.

crankshaft

hub

plece

top'

lap

ll In

posltlon

rlth

toot

9025

98900'

AoDlv

refalnlng

fluld

6909

f00ll

on

the hub

oiåiå o.*""t.-

Lubrlcote

the

shaft

sۊl

llp

ioiåirljv

ond

push

the beli

pulley - hub

plece

comblnofion

onto

ihe crankshaft

grooves

'

Aoolv

retolnlnq

flutd

6909

f00l

I on

ihe

front

-'"i

'n"+

+nread-s. Tloh+en

the

crankshöft

lroni

ånå

"rt

,ifit

tool

-9024

74200

fo

600

iln

In

ioi.

oi

ros,

tll

ond

4ll englnes

and rlih

tol

ööäl

-i:äoo'io
t ooo

Nttr

In

cose

of

6ll

and

612

eng

Ines.

Aftoch

the oll

Pressura

regulatlng

volve

(sa

lnstructlonsDolnt6).

lf.

Flx

th€

rlternoior

and

the

v-beli

and adJust

ths be

lt tens

lon.

14.

Flx

the

breother

plpe

(509'

5ll and

4ll

englnes).

Mount

ihe fon

and

tlghien

l+s

{lxlng

SCrelS.

ll.

5

t6

5-8

LIER|C TI0 SYSIE|,|

tlGX

T€chnlc.l dsic.............

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

6- |

Constructlon.....

..........

6- 2

R?!lr Insfrustlons

l. Lubrlcrtld syslqr

A. Insp€ctlng the oll

pressure

reguletlng

va|ve...................... 6- 5

g.

Rqlbvlng

ond

Inspecilng the oll

punp.....

........

6- 5

C.

Assembllng

and

lnsiålllng fhe

ol

I

punP. . . . .

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

..

6- 5

D.

Replaclng fhe oll

c@ler...

..... 6- 6

E.

Plstoo

cool

Ing .pzzlo

612..............

.......... 6-

7

F.

Lub€ oll

quallty

requlrer|€nfs...............

..... 6- 8

vAlilEr

6

-O

(reject

llmlf of

part

sfated

In brackols

after rötlng)

OII

pressure

al no-nal

runnlng lemperature:

-

ai ldle

speed

(mln.)

-

dt

runn

lng

sp€ds..........

Fr@ length of

oll

pressure

valye

sprlng

Sprlng

pressure

ehen valve

sprlng ls corDpressed

io

a lgngth of 92 rm........

DloD€i€r ol oll

prossure

valve

plunger

Dlaneter

of oll

prsssure

valve cyllndgr

Oll fllts' by-pass valve opens at a

pressure

dlfferen@ of ............,.....

Openlng

pressure

of

plston

c€olln9 nozzle

(612)

...........

Oll

putlp

5O9,

Jll,

4ll

Backlosh

belv€€n

gears

rhen crankshatt lles flrmly 6golnsl the

lorer side of

lis

beörl n9

-

crankshåft

drlve

gear

-

ol I

purrp

drlve

gear

-

betreen

oll

pump gsars

Clearanco

b€lre€n drlve

shalt

and lls bearlngs In body

ond covor ,.....,....r

D

lame+ers of drlve shaf+ holes In bodv and

cover

...........

Go6r

hole dl omelers

Clearancs betw@n

gear

and llxed shaff...........

Protruslon

ol flxed shaft end beloi

pump

bdy face

.... ...

,... .

T h lck ness ol

covei'

gask€rt

oufs lde d I

ameter of

gears ........

Clearance of

geörs

In

thelr

houslngs
Hous Ing d lameter
Thlckness of

gears

(J09,

Jll)

..,.,.......

Thlckness

ot

gears

(4ll

and flt

DS/VB!,|V 505,

605)

End p lay of

geais

. . . , , . . , . . .

Depih

of houslng

(109,

5ll )

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

Depth of houslng

(fll

and 5ll

DS,/VBMV

505, 605)

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

Tlghfenlng

torque

of

gear

re-talnlng

nut .............

Oll

pu||p

6ll, 612

Backlesh befr.een

gears

rhen crankshaft l1€6 tlrmly agölnst

the lorer slde ot

Its

bear

Ing

-

crankshafi drlve gear

-

oll

pump

drlve

geär

-

betYeen oll

pump gears

Clearance

befreen drlve

shafi

and lts bearlngs

In

body

and cover r.r.........

D lam€tor ot drlve shaft bearlng hole In body and covf............

Clearance

b€tre€n

gear

and

flxgd

shati

...........

Hole dlönet€r

ot

gear

runnlng

on flxed shotl

Protruslon

of

flxod

shaft end belor

pump

body löce

. . .

. . . . . . . . .

Th lck ness

of

cover

gaskel

oufslde

dlömeler of

gears

(6ll)

Qutslde

d lameter of

gears

(612)

Cloärance

of

gears

ln +helr houslngs

Houslng d

lame+er

(6ll

)

.....

Houslng dlöDeier

(612)

.........,.

Th

lckness

of

gears........

IECHNICAL

DATA

Lubrlcotlo||

End p lay

of

gears

...........

o,o5...0,25
0, | 6...0,26
0,016...0,052

(

0,070

)
r8,000...r8,018
I 8,060.. . 18,078
0,021

..,0,050
0,5...1,0
0,06...0,08
43,4A6...43,r25
0, | 25...0,264

(0,100)

45,650...4t,750
| 8,

000..

. | 8, 027
24,0O0...24,021
0, 01. ..0, 1 1
18,000...

t 8,

o4l

24,OOO...24,O4t

60 Nn

0,05..

.0,25
0, t 6..,0,26
0,0t

6...0,o52

(0,070

)

18,000... t8,0t I

0,0t6...0,052

(0,070)

r8,000...t8,0r8

0,5...1,0
o, 06.

..0,

08
43,4A6...41,r25
49,1 . . .49,175

0,125...0,264

(0,100)

4t,650...43,750

49,900...50,000

32,000. . . t2,021

o,05...0, | |

t2

,oco.

..52, O45

60 Nm

I5O

kPo

(1,5

kplcm2)

300...500 kPa
lt...5

kp/cn2,

80

54+5

N

(5,4+0,5

kp)

t9,602...19,6t5
19,70O..19,752

2

!O,5

b{

5 ! 0,2, bar

Depih ot

houslng

Tlghtenlng

torque

of

gear

reialnlng

nut .............

6-1

LUERI CÄTIol{

SYSTEX

6l

Ol I c I

rcu lal lon

Lubr

I catlon sys+em

a

The englne

has

a

pressure

lubrlcatlon system

coftb Ined slth the oll

pump

whlch

pumps

+ho oll

Info l-he

dllferent

englne

polnts

thai need

lubrlca+lng. The

pump

sucks the ol I

fron +he
englne ol I sump fhrough a sucflon lllter. The
oll ls +hen

led

+o the oll channel and furfher

to the

pressure

regula+lng

valve and ol I

fl l+er.

From

fhe

fllter

+he oll flows lnto fhe

maln

dls'trlbutlon

gallery

whlch

h€s

branch
channels leadlng +o the crankshaft maln
bearlngs. Through +he

channels

In the cronk-

shaf+ +he ol I ls

then

led

from fho maln

bearlngs

-io

+he

connecflng

rod blg end

bear I ngs.

The lnjocflon

pump

and

ihe turbocharger also

gef

thelr ol |

'ihrough

ihe maln dlsirlbuilon

gallery

and ai

boih ends of fhe cyllndsr block

ihere are

ol I channels

vhlch lead the oll to

ihe

camshafi, The camshaft has

an lnner bore

through rhlch

other canshafi bearlngs are

lubrlcated.

The

fronl

channel also

f€eds +he

bearlng o{ ihe ldler

gear

lilth

plaln

bearlng.

From ihe

canshalf rear end

a channgl

(ln

fll,

6'll and 612

englnes an

exiernal

plpe)

leods io

ihe valve

[Echanlsm.

Tho oll returns

fron ihe

cyllnder

head io

the crankcase

ihrough

push

rod

holes.
The

b€lt

or

gear

drlven

compressor ls

connec+ed

fo

ihe englne

lubrlca+ion

sys+en

wl+h a

plpe.

Oll

pu!?

Pressure aegu lat l ng valve

64

Oll

pump

6ll

l. Nut

2. W€sher
l. Gear

4.

Body

5.

Beärlng bush

6. Key

7.

Ge6r

8.

Gaskat

9.

Scr6n

10.

Shatt

I l.

Gear

12.

Cover

lf.

Spacer

14.

Screr

15. Pressure

pl

pe

16.

In

let p lpe

1.0-rlng

2. Cy I Inder
J.

P lunger

4.

Sprlng

5.

Hashe.

0l

I fl

ltlr

6. Gasket

7.

Covgr

8.

Nut

9. W6sher

10.

S+ud

The

oll

pump

ls a

gear

p'rnp

flxed

io l-he

cyllnder block

lower fac6 and drlven by lha

gear

on

+he crankshaf+ front end. The oll

punp

body

has a houslng

ehere

lhs

gears

are located.

|{hen

ihe gears

rolate ihe oll moves

through

the

iooth

sp6ces, baiwoon the

9€6r

and fhe houslng,

from +he

Inlel slde

io the

pressure

slde. The

houslng In thg body

has

a cover

Hhere

ihe

lnlef

plpe

ond +he

pressure

plpe

ars flxed. Th€ end

play

of ihe ol I

pump

gears

ls adjusted

by

changlng

ihe

nunbei of

gaskets

betreen

ihe

body

and ihg

cover.

The

clelrance ol

the

gears

drlvlng

+he

puip

ls

adJusied

by

chänglng the

number of shl|ns

be+re€n the

pump

body

and +he cyllnder

block.

The oll

pumps

usad In dllfersnt

englne types

aro

slmllar

ln

consfrucilon

ond

vary

from each

oiher

malnly vl+h ragards to

gear

dlnFnslons.

Pressuro

rogulatlng

valYe

In lll,

4ll and 6ll englnes

the

pressure

reg'rlöllng

valve

ls located

ln ihe

gaar

houslng

at the loeer oll channsl. In 109

englnes

fhe

valve lles under lhe ol I lll+er, on

ihe englne

letf-hand slde. In

612 snglneg lhe

prgssure

rsgulailng valve

ls on

th6 6nglne

rlght-hönd

slde, beslde th€ ol I fllter. The

volve keops

ihe oll

pressuro

of the rlght level,

lrrespgct-

lve of the englne speed. The cyllnder

and the

plunger

whlch are soalsd wlih an o-rlng close

ihe

ol I channel. l{hen ihg oll

pressure grors

hlgher

ihan the

resls+lng focce of

ihe

sprlng

part

of

ihe

ol I relurns io the ol I sunp

through

'the

va I ve,

The

olt

fllfer

ls of maln ilo* type and h6s o

replaceable flligr

c6rtrldge, mounfed

on fh6

threaded

socket In lhe bracket. At the bo+tom

of lhe oll fll+er

crrfrldge

ihere ls ä by-pass

yalve

for cold siari or

posslble

clogglng of

the

fllte..

The fllter ls also equlpped r,lih 6

baffl€ whlch

prev€nts

+he fl

lier lrom

empiylng

rhen th6 englne

ls noi ln use.

Dependlng

on oll

qualliy

6nd temperature

lh

ol I

prossure

6i runnlng

rqvs

ls f...5 kplcm

and at

ldls spe€d

1,5 kplcnz.

o

-J

4365 36797

ol I cooler
sone onglne vgrslons

ar€ furnlshed wlth

an oll

cooler

whlch ls elihor In connecilon

t{lih

ihe

fl lter or, for lnsiance, loca+ed

on

+he englne

fronf end and connec+ed

io the fllter

bracket

wlih

plpes.

The

oll

clrcula+lng

In the

oll

cooler ls cooled rll+h enolns

coolanf.

oll tl ltq

-

ol | cDl€r conb lnatlon

0ll f I lie|­Oi I c@ler
F I ller brrcket
Fl l+er by-pass valve
Baff le Jo. backf loY
C@ler by-pass va

lve

Threaded n lpp le

6-4

t.

UORK I NSIRI,'CT IONS
LIERICATI()t{

SYSIE

INSPECTI

}{G THE OIL

PRESSURE

REGII-AT IiIG

YALVE

Chgck

the valvg

functlon

every

ilme lf

tho

englne

ol I

pressure

does

not

rlse sutflclenily

or

lf lt varles

conslderobly.

Flrst, however,

ensure

iha+ +here ls

enough

ol I In

lhe engln€.

67

Oll

pressure

regulatlng volyg

(109)

open +he

valve

cover flxlng scr6v.s and

remove

fh6

cover and ihg

sprlng

underneath lf. Noie

ths

washer betre€n

lhe

cover and

ihe

sorlno.

Pull fhe

volve

cyllndei

and lhe

plunger

lnslä6

li out of

the

gear

houslng/cyllnder block. Make

sure lh6i

the cyllnder

o-rlng soal tollows.

lf

nol',

re[bve

+he o-rlng

from tho cyllnder block.

Clean

ihe paris

cargfully. Place lhe

plunger

back

ln the cyllnd€r

and

srlng

ihem

+o and fro.

lf

fhe plunger

do€s noi move

smoo+h ly rllhln

the

cyllnder, scrape

off the

posslble

dlr+

or

other

lmpurl+y lylng

betv,een the

parfs.

ll

necessory,

grind the parts

llghtly wlih

flne

abraslve

cloth or replace the

paris.

Clean ihe

sea I

lng

surfaces ol the

cover

and

+he gear

housl

ng/cy

I lnder

block.

Place

a ner o-rlng

seal

In fhe

groove

on

fhs

cyllnder

end. Flx the

plunger

Inslde the

cyllnder

and

push

the parts

Into ihelr

posl+lon

In the

gear

houslng/cyllnder block.

Place

ihe

wosher

and the

sprlng In +he

houslng

In the

cover

and replace fhe gasket

beireen

fhe

cover

and

ihe

housing.

Flt

the

sprlng

agalns+ the

plunger

bol-tom

and tlghten

lhe cover ln

place.

lf needed,

use extTa long

scrers rhen

prs-

tlghtenlng

l-he

cov€r, ln crdor

+o

overcoip ihe

sprlng

pressure.

l{hen

you gei

ihe cover near

gnough

to the

houslng, use

standard scrers.

B. REIiOV I NG AND INSPECTING

THE

OIL

PUif

l. Draln

the englne

oll

and ren|ove

+hs

oll

sutlp

fro +he

eng Ine.

2. Open fhe

flxlng

screws

ol

ihe oll

punp

lnlet

DlDe

and

r€irove

the

lnlei

PIPe.

only open

ihs

flxlng screws

on

the

oll

Pump

end

and leave the

pressure plpe

In

lts

posltlon.

Open the oll

pump

flxlng

screys. Reflpve

ihe

pump

and

posslble

shlms

betreen

thg

pump

foot

and the

cy I Inder

block.

5.

Loson iho flxlng scre*s of

+h€

purlp

cover ond

r€npve

+he cover and +he

gaskels.

Pull ou+ ths

gear

on

the tlxed

shafi.

6. Flx

the

pump

ai

lts drlve

gear

ln a screp vlce

equlpped vlfh

protectlve

lugs and

open

the

drlve gear nut.

Tap

th6 pump

drlve shafl ofl

th€

gear

rl+h a

plastlc

hamrpr.

Pull out the

dr

lve shafi

-

gaar.

7. l{ash

ihe

paris

ca.etully and check +hem tor

rear,

conparlng Hlih

iechnlcal döta

poln+

'roll

pumprr.

Replöcs the

posslble

iorn

pörts

and

all

paper gaskgts.

lf

you

replacs +ho oll

punp

beörlngs bushes of

the

611/612

englnes,

machlne them af'ter

Insfallatlon +o 18,000... 18,018.

ASSEiGI-

II{G AND INSTALLIilG THE OIL PUI,P

Placa

+he

gears

In

fhe

houslng

locEfed

In the

body.

lf

n€oded, rep I ace ihe

gaskoi

bel-reen the

body

and

the

cover.

Tlghten the flxlng scraws

ot lhe

cover

llgh-tly.

Turn +he shöli

and iap

ihe

cover sldowoys un+ll

you

flnd fhe

poslilon

wherg

+he

shaft

rotaies

as freely as

posslble.

Tlghten

the

tlxlng screvs of +h6 cover and

check

thai

the shaf+ s'tlll turns snoothlv.

Flf the key and the drlve

gear

on

ihe

shaff.

Apply re+alnlng fluld

6909 f0025

on +he nuf

ihread

and

ilgh+en the

nu+ +o +he lorque ot 60

Nm.

Donrf

forget

fhe lock rashor underneath

the

8.

l.

l{hon fl++lng

fhe

valve

cover note

l+s

gcconirlcl+y.

The rlder

dlstanco

be+ieen

+he

cover

centrellne

and

the flxlng

hole ls to be

on

the lorer

slde.

lf +he

covei ls

mounied

the

rrong

iay, li may

causg oll

leak

q-

ihe

cover

mav

cracK.

Flx

the puip

ot lts flxlng

fooi

ln a

screr vlce

9!l.lpp"g

rilfh^

proiscf

I ve

tugs.

Chsck

the

gear

ond ploy

(0,05...0,11

nD)

ulih

a

dlal

Ind.lcaior.

lf ne€ded,

change

fhe

number

of

gasKers

beilleen

ihe cover

and the

body.

6-5

4.

Apply reialnlng tluld

(6909

l00ll) on the

thraad

of the

threadod

nlpplo and tlghten lt to

i|o

tln. Flx the rater

plpes

to the c@ler.

Install a neH lubo oll fllt€r.

Close fhe

coolgr

dralnlng

clck

and flx the lub€

oll

c@ler drålnlng

plug

In

place

by

turnlng.

Reflll the cool Ing syslon.

9. Siari +ho englne ond make sure ihaf

there

no

lgaks.

Cools- w lih oyn

brackot

5.

D.

c@ler body

ls flxed

to

the bracket

lrlfh iro

benjo

bolts.

To

remove

these bol+s

you

flrsi

have to +ake

olf

the ol

I tl ltsr

and tts

brackef.

Open

and

6

10

Flx

the

punp

In

poslilon

on the

cyllnder block

boiton f6ca

€nd check ihe

back lash

of

ihe

crankshctt

and

pump gears

(0r05...0,25,

}rlth

a dlol

lndlcator.

lf needed,

change

ihe

number

of shlns bet',{een

the

pump

body and the

cy

I

I nder block.

Aitach ihe pump

Inlet önd

pressure plpes

and

replace

lhe

flxlng llange

gaskeis.

Flx ihe

oll

sunp

to the

englne and flll ihe

englne

rlfh

oll

REPL.IC

I

IG

I}f OIL

@OI-ER

C@ler

on I I

lier

bracket

l.

ClEon the

cooler

and

lts surroundlngs from the

outslde and refiove

lhg oll c@ler. WlDe otl

laakEd ol l.

2. Draln

ihe

englne c@lanf.

Open the

ol I c@l6r

cap

ånd the

draln cck

as rel I cs lhe dralnlng

plug

on lhe

c@ler slde.

Let

ihe

coolani

tlo;

Into

o c l6an

bonl.

5. Dlsconneci

the

{aier

plpes

off lhe

cooler.

fhe

ihrEadod

nlpple

holdlng the

cooler

remove

th€ cooler.

4.

Clean ihe

threads

ot

.the

nlpple

6nd ihe lllter

carefu

I ly.

5.

Mouni

a

n€'i

c(pler

In lts plac€

on

ih€ fllter

bracket

In

such

a tay that

ihe

rater plpes

ar6

torards

ihe

cyllnder

block.

Ensure ihat

+he

gasket

on

lhe

cooler

ls ln

lis

posl

on önd

+h6

seallng

surtoc€

ls tnl6c+.

o-t)

@

61r

Pf

sIoN c00L | 1{G

l€ztE

612

Tha

plston

cool

lng nozzles of ihe 612 englnes

come off after fhg

oll sump

has

been removad.

The nozzlo

has

a ball

valve t{lih an oDanlnq

pressure

of

5 + 0,25 bar.

lf

necessary,

clean

ihe

valve. Renpve

ihe valve

from +he englne

and

iake

off

l-he

nozzle

plpa.

0p9n

ihe plug

In tho valve body

and

ramove

+he

spr Ing and the ball.

o

o

o

3

6

14

6-7

F. LUBE. OI

L

QUALITY

REQUIREMENTS

I.

OIL GRADE

API

Nafurally

asplrateil

englnos APt cB or cc

1

Turbocharged

eng Ines API CD

or

SHPD

V

ISCOS ITY

GRA

DE

SAE

grade

Tenpgrature

-30

-20

-10

5W-20
5W-30
5W-40
10w
10W-20
10w-30

10w-40

15W-30
15W-40
20w-20
20w-30
20w-40
30

0ll of

CD

grade

can

a lso

af+er

run-ln

p€r

I od.

+10

+20 +30

be used I n naturE I

ly asp

lra+ed eng I nos

5W- 2()

5W-30

5W-40

10w

10w-

20

10w-30

r0w-40

15W-30
15

W- 40

20w-20

20w-30

20w-40

30

6-8

cooltrG

sYsrEr,l

tEX

Technlcrl

data............. ...,.............

7-

|

Spcl.f t@fs.... ..........

1- 2

Consfruqtlon....

...........

7- l

RsDalr I nstrustloos

l. Thenrcsfct

A.

Renovlng and

Inspectlng ihe thq'dpsiat...

........ 7- 5

2. Cool ant

pulp

A. Removlng fhe coolani

pump. . . . . .

. . . . .

. .

...........

7- 5

B.

Recondlilonlng fhe

coolant

punp

(309,

lll

and

4ll

Ipackage

b6arlngsn)...............

....,..........

7-

5

C. Recondlflonlng tha

coolant

puip

(s€pöraie

ball

bearlngs

,ll,'lll,6ll

and

612).........

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

7- 6

D. fnstalllng ihe

c@lan+

pump.

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

......,..

7- 7

vAlitEr

IECHiI

ICAL

D TA

(reJect

llmlf of

par+

s'ialed ln bracke+s atier rallng)

Coolcnt

punp

(t09,

lll,

'lll

englnes)

ouislde d lame+er

of

boarlng

Dlameter

ot b€ar I ng

houslng

Sh6f+ d lame+er

Inpeller

hole

d I amsfer .

. . . . . . .

lmpeller

should

bs

pressed

on+o shaft

so +haf

lfs

rear end ls In depfh of:

-

troo rear

surface of bodv

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

Hub

pleca

should bo

pressed

onfo

shafi so thdt dtstanca o{ tlxlng level

ot

lts fan from rear

surface

of {a+er

pump

ls

(509)

........

Hub

pleca

should

be

pressed

onio shaft

so lhat dlstanca of

flxlng

lavel

of lts

fan tron rear

surface

of back

pl6te

ls

(511,

4ll)

D

lamei€r of fan hub

.........

Balanc

I ng

preclslon

of fan..........

Max.

permlsslble

gccen+rlcliy

of

fdr ..........

C@lant

puip

(rlth

s€plrrie

ball b€arlngs, 5ll drd lll angln€sl

outslde d lameter of bear Ing
Dlaneter

ol bearlng

houslng

Shati

d lane+er

ai

bearlng

Shafi

dl ame+er

a+ lnpeller

lmDe I l€r hole dlameter ........

lmDeller

should be Dressod on+o shaft so fhai l+s rear

face

ls on level

rlth

shöli end

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

Balanc Ing

preclslon

of fan.,........

Möx.

oermlsslble eccentrlcliv of

fan ..........

Tlgh+enlng

torque

of boll

pulley flxlng nu+

Coolanf

punp

(6ll

and 612 €nglnest

Ouislde d låd€ler ol bearlng

lnslde

dlarEler

of

bearlng

houslng

ln

pump

body

Shoti

d laneter

at

bearlng

Shaft dlarrter

at

InDe I ler

lnpe I

lei

hole

d iad|eter . ,,..,..

lmpeller

should

be

pressed

onto shaf+ so

+hai

lts

rear f6co

ls on level

r lfh

shalt end

... ....,.

... .

Dlsi€nce of bel+

pulley

frqn rea- surfa@ of body

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

Balanclng

precision

ol

fan .......,..

Max.

oermlsslble

eccentriclty

of

fan

..........

Tlghienlng

torque of belf

pulley

flxing

nu+

Th€fiFstrts:

Spare

pa-t

no

8160

t 5l56
8560 15489
8561 I5646
8t6l I5?r

8

8t65

't

590

open

lng b€g Ins

at

77.. .

moc

80. . .

850C

77...8t(t
8t

.. .850C

8t

...850C

18,087,..18,

100

58,075...18,|00

15,9O7...1r,92O
15,881.,.15,899

157
| 74,t...114,7

25, OO.

..25

,20

0,1 Ncm

max

!

0,1

,t,979...r2,OO9
| 9, 980. .. t 9, 991
1r, 1

.. .15,920

15,881 ... r 5,899
(dlslance

betreen

body

and lmp€ller

edge:

t ...1

,1)

0,3

Ncm

max

(10

pcm)

1

0,1

100 Nm

52
51

,919...52,0O9

19,

980.

.. I 9,99'
15,907... | 5,920
| 5,

876.

..

I 5,894

(dlstance

betre€n

body

and lmpel ler

edg€:

0,3...0,6)

115

0,5

Ncm

max

(50

pcm)

1

0,l

100 Nm

Type

ö 54/7*.
ö

51/$q,

6

61/1*,

6

67

/8t<1

6

61/giq,

Fu I ly open

ai

940C

9oc

940C
970C
950C

openlng mm

I

SFECIAL TOOLS

t.

8160

| 309t

2.

At60 A5499

3. 9025 415co

4.

9051 40200

5.9051 64900

(Cool

Ing sys+em)

Coolan+

pump

Coolanl

pump

Coolant

pump
Flttlng too I
F ltilng tool

hub exirac+or

lmpeller extrac+or

(f09,

fll

and

4ll)

lnp€ffer

exfracfq rcll,

612,

for

coolant

pump

axlal

seal

fq'

coolant

pump

shaff

(

f09, fll

and 4ll)

CML I NG SYSIEi,I
CONSTRT'CT

ION

lh€ripstct

109, lll rnd

4ll

Thermosta+ hous I n9

tll and

l.

Hexagon

sockg+ screr

2. Return

plpe

5. Gäskel-

4.

Therrpsiat

5. Thermostai

houslng

Cool Ing

sy3tdtr

4ll

l. Thernos+ai

2. By-pass

plpe

5. Rad i a+or

4.

C@l ant

pump

The

cool

lng

sysiem ls lllustral'ed

ln flg. 7 l.

The coolant

punp

(4)

sucks

fhe

coolant

trom th€

undersld6 of ihs rödlator

(J)

and

Dressos

lt

Inl-o thg

c@llng

jackei

surroundlng

the

cyllnders In th€ cyllnder block.

Through

the

holes In

ihe

cyllnder block

+op face th€

coolani rlses Into ihe cyllnder head

änd

fur+her onto

th€ thernoslai

(l

). 6l I and 612

englnes have a s€pärate c@lant

ouilef rall to

dlrect

the coolant from the cyllnder heads lnfo

the

thernostEt houslng.

l{hen the

englne runnlng

iemperaiure ls lorar

than ihe

apenlng

teiperature

of

ihe th€rmosta+

+he

c€olani relurns

fhrough

the

by-pass

(2)

siralghf Inio lhe

coolont

punp

and

then

back

Inlo +he eng|ne.

l{hen the

englne

runnlng iemperature rlses

up

to

the ihermostot

control ronge

ihe thermostät

opens, letllng

pori

ol the

c@lan+

clrculåte

+hrough fhe radlöior

ond

part

+hrough ths

by-pass. l{hen

the thermosta't ls

lully

apon

lt

closes +he

by-pcss

plpe

(no+

J09 englne) and

+hs

coolani

flo|.s

through

ihe radlaior only.
The by-pass arrongemgn+ ensures a steody
ieDpera+ure

In

gnglne

under all clrcumstanc€s.

C@ I cnt

Ths coolani us€d

ls o

nlxtura o{

glycol-basgd

antl{reeze änd water rhgre ihe

DroDortlon of

ihe

antlfr€€ze ls

l0 to 50 t. Due to l+s antl-

corros lve

qualltles

the

anilfre€ze should

b€

used In

the

su igrilne

as rell. Chönge the

coolant

every

fro

years.

Never use

plaln

rc+er

as

c@l ant I

4l I

6. Hexagon socket
screr

7.

Gaskei

8. By-pass

p

lpe

9.

Gosket

The J09. englne

has c

nornal

slngle-acilng

lhornpstat.

The

theritost6i ln the

lll änd 4li

englnes

ls the

so-cclled double-actlng iype

{hlch

rogulafes ihe

cooloni

clrculailon

betr€€n

the

by-pass and the

rödlator.

The thernpstat

ls

placad

ln

a

houslng

flxed to

the cyllndsr

head tron+ face.

The by-pass

plpe

}rlth

lts

gaskel

lles beir€en ihe +hermostaf

houslng and

ihe

coolanf

pump.

The

+herflpstaf

opgns

ai

ihe

temperoture

of 7fC. In rlnigr

o

ihermostat

vrlth

of|enlng +enperature

of

85 o C can be used.

Thorrpstct

6ll cnd

612

7-3

The 6ll and 612 englnes have

tvo separa+e

thermos+a+s, one

of

|ihlch

regulaies

ihe coolant

by-pass.

The

thernostol

houslng

ls

flxed on+o

+he +op of +he c@lant

pump

or lis rlght

slde.

The iheritoslats

dllfer ln types

and openlng

+emperaiures.

l{hen

fhe

coolan+

tqnperature ls

belo{ +he thermosiat

opgnlng

temperature

fhe

c@lan+

(A)

clrculales

through the

by-pass

hole

lnio the coolanf

pump.

The srnaller,

glngle-

ac+lng +harmostaf

(l)

opens

flrst

(a+

79oC),

let+ln9

par+

of ihe coolant

(B)

into

lhe

radlaior. Follol'lng the load

lncreaso, also

lhe

other lhermostat

(2)

opens

(at

SloC).

Thls ls

a double-actlng +ype

l{hlch

closes

the by-pass

hole

when li opens and dlrects

lhe coolan+

(C)

Into fhe

radlalor.

These

englne

lFdels do no+

have

separat€ r Inter-+yp9 thermosia+s.

C@l ant

purP

The coolanl

purp

ls a

can+rltugal

pump

llxed

io

ihe

cyllnder block

tronf

face.

The

purp

ls

drlven by lhe cr€nkshali bel+

pulley

+hrough

the

v-belt.

The J09, 3ll and

411

englnes

have

+he

pump

shat+ and bearlngs ös

an Iniegrated

unl+ or +he

pump

ls equlpped rl+h separate

bal I

bearlngs.

In 6ll and 612 englnes

fhe

coolanf

pump

ls furnlshed llilih

separafe

ball bearings.

The lmpel ler ls flxed

fo

the shaf+ wl+h

pressed-on

fl+. The €xlal seal on

the

pump

body

and the

ceramlc counter rlng

rolailng on ihe

shaft take care of lhe seallng. The

pump

body

has

connectlons

tor the fluld clrculailon

of

the

heatlng

devlce

ond

ihai of ihe oll cooler.

The f09 and

fll englnes

also

höve

a connectlon

fot'

ihe b

lock

hoaier.

Coolan+ pump,

separate

4ll

anglnes.

l.

Locklnq rlno

l!

Eeartng

f. Bush

4.

Shali

5.

Shafi

sea

I

6.

Orease

nlpp

le

7. Body

8.

Seöllng

rlng

9. Plug

10.

Axlal

seal

ll.

lmpel ler

7-4

ba | |

be6r Ings, ll I

and

12. Gaskei
lf. Back plate

14.

Hexagon

screw

15.

Hexagon

nu+

16. Washer
I 7.

Bel+

pu

I ley

18.

Key

19. Hexagon

screw

20.

Connec+or

21.

Seallnq

rlno

ZZ. \jasKei

f,ORK

INSTRI'CTIO S

c00L G

sYsIErl

|. IllE 0,r)ST T

A.

RErcYING

ArI' INSPECTI]€ T}C

T}€S'PSTAT

l.

Draln +he

englne coolani unfl I the fluld

level

ls underngath the thermosia+ houslng.

2.

Renpve fhe

uoDer

Hater

hose

from ihe return

plpe.

Open ihe return

plpe

flxlng

scrers

and

remove tl|e

rgiurn olDe and

+h9 thq-nostal.

5.

lmmerse

ihe

thermos+af ln a

waler conialner so

+hat lt

cannot louch

iho *alls

or lhe

boi+om.

4. tlärm

up

+he woier

slowly, noflng lhe

rlse

In

tempera+ure

on

å thermometer.

Compare

lhe
openlng ienperafure of fhe fhermostai and *he
fempera+ure

rhere lt ls lully

open

rlth lhe

raflng

(see

technlcal dota,

polnl

rThernpstalsn

).

5.

lf

the therrpsfat

valve

stlcks or

ihe thermo-

s+ai

opens ai foo lori or foo

hlgh

a +empera+urg

replace

the thernostai.

Clean iha

seöllng tac€s of the

therrpsfaf

houslng and the reiurn

plpe.

Place the thermo-

stat In

posltlon

rlih the by-pass

closlng dlsc

dornr€rd.

Rgplace the

return

plpe gasket

and

Inslall the return

plpe

and the upper xa+er

n0se.

Flll the coollng

sys+en. Siari ihe englne and

check for

posslbla

loaks.

Run

+he englne

llgh+ly loadlng

lt untll

you

see

ihöi ihe

thq-mosia+

ln lts

posltlq|

operetes nq-mally.

2.

@OLANT flTP

A. REIOY

I

G IHE

ML^I{T

PIIP

l. Draln +he

englne c@lant. Dlsconneci +he upp€r

and ihe lorer rater

hoses. Open

ihe tlxlng

screis of the thermosiai

houslng,

renpve the

houslng and the by-pass

plpa.

2. Renrove fh€

hea'i'lng

deylce

connecilon,

+he ol

I

cooler connecilon

and

ln the

case

ol f-cyllnder

englnos

+he

block

heaier

(ll

assembled)

{rqr

the

c@len+

punp.

J. Loosen

lhe aligrnaior flxlng

scrers.

Open lhe

lan flxlng

scrers,

reflpve ihg fan, the

pulp

pu

I ley and the v-beli.

4.

Open the

coolani

pufip

flxlng screys

and roflbve

the

punp.

Rerpve ihe

gasket

bgtreen the

pump

and lhe

cyllnder block and cle€n ihe seallng

t€cas.

B. RE@ND|T|ON|NG

IHE @0L

|tT

pt[f

'09, '

,

ftl

7.

t.

Renovs

iha fan t lxlng

exirac+or 8560

| 1091.

frorn

+he

pump

body.

hub

from fhe

shafi

lalth

Remove

the lod(lng

rlng

76

2. open the bock

plafe

flxlng screr

and

reflpva

the

back

plaie

from the

purp.

RE rove the

ltnpeller

from lhe shaft xl+h

exiractor

8560

85499.

5. Press the

shaft oui of +hs

bodv towards

ih6

tån

wlih e.g.

a hydraullc

press.

Support

the

body

so that ih9 bearlng

cones oil+.

4.

Tap out +he

shafi seal rlih å drlfi.

Clean fhe

parts

and

ch€ck lhelr condlilon.

Replac€ rorn

or defecilve

par+s

rlth ne{

ongs.

7- 5

Notel lf vou

ne€d

+o replace

the

purnp

shafi,

the bes+ soiutlon

ls to ossemble

a

pump repalr

kl+ shlch lncludes

all

gaskeis necessary

for

recondlilonlng

(see

spore

par+s

catalogue).

Press

the shöft

In lis

posl+lon

ln +he

body

,fih tool

905'1 61900. Install

the locklng

rlng.

77

Clean

+he shaf+ and

the axlal

seal

recess on

+he

pump

body. Plac€

ihe

plasilc

covered

seal

and counl-er

rlng on

fhe

shaf+.

lf

necessary,

use an+lfreeze asrrlubrlcantr'.

Tapplng

ihe seal

ln Dosltlon

wl+h drlf+

9051

40200 rernoves

l-he

plasilc

cover

ehlch

posslbly

comes

ou+ trlih

the

drlfi. tf

lt renalns

ln the houslng,

retrpve

lt

before flttlng

ih€ lmpeller.

78

Press

l'he

lmDeller

and

fhe

hub

on

the

correct

post+lon,

supporilng

lhe shal+

at the

qther

end.

Ensure

fhat

the shoft

rofaies freelv.

8. Flx ihe back

plale

on the body and rep laco the

OaSKeT.

RECONDITIoNII€ n€ CooLANT

R tlP

(Separ6+e

ball boarlngs tl1,411,611'

612,

1. open

the belt

pulley

flxlng

nut and

renove the

pulley.

Uso

exfracior

8560

15091, lf

neoded.

R€orove

ihe

l|tpeller

from the

shaft vl+h

extracior

8160 85499

(fll

and

illl

englnes) or

extractor

9025 4l5OO

(6ll

cnd 612

englnes).

Remove

the locklng rlng fron

ihe

pump

body.

Press the shaf+ and bearlngs out

of +he body

iowards the

fan

wl+h e.g. a

hydraullc

press.

Support

ihe body

so

tha+ th6 bearlngs come

ou+.

TaD the axlal seals and

sh€ft seals

ou+ of the

body lrl+h

a drlfi.

Clean

the

par+s

and

check

ihelr

condlilon. Rgplace

worn or defecilve

oeris w l+h ne|l{

ones.

Noiel

lf

you need io rep lace

the

pump

beärlngs,

l-he besi

goluilon

ls

to assembl6 a

pump

repalr kli

yhlch

lncludes all

gaskets

necessary fo|-

recondltlonlng

(s€

spare

parts

cata I oguo).

5.

T6p

the ner

shafi

seal onfo the

body {l+h a

sullable drlft.

Place fhe bearlngs

and the

lntermedl a+e

bush

on

the

shölt. Lubrlcate

+he

beorlngs wlih a sufflclent

amount of hsat-

reslstant ball bearlng

grease.

Place

lhe sha{+

and

+he

bearlngs

ln

posltlon

9o

thal +he

{orcss

caused

by the

presslng

are

not

+ransmlffed

through ihe ball bearlngs. Fl+

ihe bearlng

l6k

lng rlng.

6. Clean

+he shaft and the axlal

s€al recess

on

the

pump

body. Place the

plasilc-covered

seal

and

counier

rlng on thg shaft.

lt ne@ssary,

use

antlfreezo

as

nlubrlccntn.

Topplng

the seal

ln Dosl+lon

ylth

f lft 9O5l

40200 removes

+he

plastlc

cov€;r rhlch

posslble

com€s

oul vlth-the

drllt. ll lt remalns In

ihe

houslng,

rerpve lt

befors f lii

Ing fhe lmpeller.

4.

6.

/

-o

Coolant pump

6ll,612

Press ihe lmpeller ln

poslilon

suppor+ln9 one

end of

the shaf+. The shafl end and the

lmpeller centre are levelllng,

whlch

m6ans tha+

+he dlsiance

b€teeen ihe

body End the lmpeller

rear

edge ln 511/4ll englnes ls

1...1,3

mm

and

ln 611/612 engines

0,f...0,6 nm. Ensure ihat

+he shaft rolates freely.

Flx ihe belt

pulley

onto lhe shafi and tlghien

Its flxlng nut to ihe +orque of

l0O

Nm.

Ir{sT LLtrG I}tE Coot.ANI Pti,P

Rep lac€

ihe

gaskei

between ihe

pump

and the

cyllnder block.

Ins+all

+he

pump

and

+lghten

fhs flxlng

scrers

evenly and In turn around the

bodv.

Flx

the

pulley,

v-belt and fan. Tlghten ihe

a lierna+cr- flxing screws.

J.

Insfall

+he

connectlons for the

heatlng

devlce

and

oll coolgr and +h9

enolne heafer

of

ihe

f<y I

Inder eng Ines.

4.

Flx the by-pass

plpa

vil+h

nett

gaskei

In lts

poslilon

on

iop

of fhe

pump.

Insiall

the

lhermos+a+

houslng ln the cyllnder

head,

a+ the

sanE +lme mounilng

ihe by-pass

plpe

beiween ihe

puip

and ihe

houslng.

5.

Flx +he uDoer and lower {a+Er

hoses.

Flll the

englne

cooltng sys+9m

and check for

posslbla

leaks.

Noi€l

lf

you

lntend to

lns+all a coolant

pump

wlih

a net| sprlng

sgal and counler rln9, the

cool

ani

mav

drlo from

+he hole underneath +he

purp

durlng +he flrsl

run hours. Thls leak

should

siop

yrhen

lhe seallng faces adjus+ io

each

other.

T-T

II{.ET AIO EXHAUST SYSIEI{, TURBOCMRGER

I to€x

Technlcol

dato

construcf I oo

8-l

Reoalr lnstruqtloos

B.

U-J

a-t

8-4
8-4

v5

8-6

l.

Inlet

cnd exh.ust systerl
Inspectlng the alr fllier
Inspectlng ihe Inle+ and

exhausl

plpes ...........

Turbochargsr
A. Do+ermln lng ths condltlon

of fhe +urbocharger,.. i................

B.

Renpvlng the iurbocharger

C. Recondltlonlng th€ furbochargtr

D.

Insfalllng +he turbocharger

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

E. Ins+alllng

ihe

Iniercooler-

VA1DIET

8-0

INLET AND EXHAUST

SYSIEM

@NSIRI'CT I ON

In

lei cnd €xhrusf systen

l. Cyc lon€

2. Hexagon nu+
f. F I I ter

4.

llasher

5. F | | ter

6. Houslng

7. Gaskei

8.

C lamp

9. Rubber

plpe

10.

Servlce

Ind lcaior

l l. Inlet

plpe

12.

In lei manl fold

lJ. Hex6gon screi

14.

Turbocharger

15.

Exh€ust

man I

fold

16.

Oll return

plp6

17.

Prgssure

p

lpe

18.

Connoctor

I 9.

Sea

I Ing r ing

20.

Plpe

21.

Oll

plpe

band

4lt Ds

Technlcrl

dqic

Turbochcrger
Hol

s€i HID

0ll

prgssure

at

runnlng

speod

...........

End D lav of shaf+...........

Rad I ol olav of shaf+

........

Tlghtenlng

iorque

of +urblne

houslng

retalnlng scretrs

(Mgxl2)

....

Tlghtenlng +orque of

iurbo

houslng re+alnlng scrers

(t{6x12}

......

Tlghtenlng

torque

of bearlng houslng re+alnlng scrers

(M6xl6)

....

Tlghtenlng iorque of

hexögon

nui of shaft

........

Threåd

ot shaft: lefi-handed

GarretT04BTT

n

ln. 2

bar

o,lo...o,I6

0, J0...0, 46

I l,J

Nm

5,7 Nn
5,7 Nm

14,0 Nm

Oll

pressure

ai

runnlng

spe€d

......,....

........ mln.

1,4

bar

End

play

of sha{-i

...........

...

0,025...0,10

Rodlal

play

of shafl ........

... 0,075...0,18

Tlghtenlng iorque

of hexagon scrers 5/16-'18 ......................

lil Nn

Tlghtenlng torque

of

hexagon scrers l/4

-n

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

l0 Nm

Lor

pressures

rnd back-prGsures

Vacuum

lnduc€d by

alr cleaner

...............r...

möx.

Exhaus+

plpe

back-pressure

.....

mEx.

5

kPa

o Kra

(500

rm

r.c.

)

(600

m e.c.

)

8-1

The englne

fll+erlng system for +hs lnle+ alr

mosfly

conslsts of the

cyclone acilng as

pre-

Jl lter

and

+he

oaoer-€lemeni

fllter

as

fhe maln

Jllfer.

In the cvclone the

lnlet alr

ls made to

whlrl,

whlch separaies riosf

oi the lmpuriiles

and

collects ihem

Inlo +he dust contalner. The

paper

fllter

has

eliher

one or iro replacoable

car+rldges

rhlch aro

pleated

to ob+aln an

adequaie

fllfsrlng areo

6nd equlpped wlfh a

rEta

I support.

The

lmpurlfles

In the Inlet

alr

accumulaie on

fhe

ouier

surfaco of the

carirldge from

whlch

ihey

can €aslly

be

removed.

The Innor fllfer or

the

so-called safe+y

glenlen+

prevenis

ihe

lmpurlflss

from

gefflng

lnto the €nglne, ll the

prlnary

llltsr

becomes

clogged

or

lf

ihe fllter

assemb ly

ls

fau

l+y.

A

mechanlcol o|-

elec+rlcal se.vlce

Indlcaior

can be mounled

on +ho lllier

houslng

or on the

Inlef plpe

io

show rhen ihe fl lter

cartrldge

Is

clogged.

The

lnlei

system also comprlses the

plplng

betwe€n ihe

alr fllter and

ihe

iurbo,

the plplng

b€+'reen

the

turbo

and fhe

lnlet

manlfold

and +he Inlet nanltolo.

The turbo

tlxed on top

of lhe exhausl'

manlfold

on at lis

r€or end

gets

lts lubrlcal'lon from

the

englns

pressure

lubrlcal-lon

sysj'om through

the

prossure

plpe

and the ol I

return

plpe.

The marlne

englnes are furnlshod vrlih a wai-er-

c@led exhaust manlfold

rhlch

ls

connocled to

ths

engln€

coolani clrcula+lon

('rfresh

raier

c I

rcu

lailon),

opercf lon ot th€ turbchrgcr
engl ncs )

The

englnes

höve an exhaust charger,

l.e. 6

iurbocharger where

par+

of ihe energy of the

exhaust

gasos

ls utlllzed io

gef

npre

alr lnto

ths cyllndsrs.

The turbo ls flxed dlreclly

io

ths

top of the

exhaust manlfold or to

lis 196r

end.

The

energy

of the exhaust

gases

rotaies

ihe furbine

trheel ot ihg iurbo rhlch

drlves the

iurbo rotor

at ihe o+her end of ihe

shaf+. Th9

iurnlng turbo roior

boosis

pressurlzed

alr

lnto

fhs cyllnders.

Thls

nEans ihat iherg

ls o

lörger arnouni

of alr In the cyllnders lhan

normally and lhus rrore tuel can be

combusted

6nd

Increasod

ouiput

c6n bo achleved. As +he

englne

exhausf gases

drlve the +urblne rheel,

ih€ +urbo

autornatlcally

odJusts

io

th€ englne

load and spe€d.

Ths

-turbo

shafl

have bearlnqs tlxed to the

bsarlng houslng wlih

tro so-called

tloailng

bushlngs. These bushlngs

are lubrlc6ted and

cooled

+h.ough

the

englne

pressure

lubrlcailon

sys+em.

The

seallng rlngs

of

plsfon

rlng

type

provent

oi I loaks

trom

+he

bearlng

houslng.

EOOST AIR

I

iITER@OLER

(DSJ

cng l nos

I

Boost

air

Coolant

I

The

(DS

€
\r-J

:

IMUILIIA

PAKO

KAASUT

VOITELUÖ

LJY

The englnes

rlih iype

d€slgnatlon DSJ

ore

equlpped rlth

alr-+o-rater

boosi

alr lnier-

coollng.

The cool

Ing

slements

are

encased cnd

Jolned

v,lth

the Inlet manlfold

and

connec+ed

io

the eng I

no

coolani

clrculöl-lon.

In

ihe

c@l

ln9 el€monts the

compressed

Inlot

ölr c@ls

doxn,

havlng a

greatar

denslty

and

npre

oxygen

rhlch ls

negded for the

combus on.

8-2

a2

t.

TMK INSIRI'CTIONS

I NLEI A}D EXHAUST

SYSIEM,

NNBMMRGER

{LET

A||) EpUST SYStEr,l

A

+urbocharggd

gnglne

ls

much npre susceptlble

to

lnlef and exhausf

sys+em

iroublgs,

lmpurllles,

eic.,

than a

Inaturally

asplroiedr

englne,

Thergfore speclal

a++antlon

musi bo

pald

to the condltlon of fhe alr

lllier ånd lhe

lnlei

and

gxhaust

Dlogs.

INSP€CTING

THE AIR F ILTER

Th€ englne

performance

and llfe

are dependeni

on ihe

condltlon of

ihe alr fllter. A faulty

flller

leis through lmpurllles

rhlch

gradually

damage lhe iurbo

and +he englne. A clogged

fllter

results In loss of englne

porgr

and olso

of+6n

causes an ol I leak frorn tho

iurbo

lhrouoh

+he

shaft seallng rlng.

t. Check ihe cleaned fllter

bv

lnslde lt. l{ You

d€tecf holes

ls rorn

(

llght-coloured

polnfs

through ), replace ihe

fllter.

B.

IIISPECT

IIG TI€

I II-ET AIO

EXMUST PIPES

plåcl n9

a lamp

or lf

ihe f

I lier

rh lch let llgh+

4, Claan

ihe {ll+er

houslng

lrom fhs lnslde

io

remove dus+ and lmpurliles.

Check

that l-he

gasko+s

are Infac+ and

thai

+helr ma+lng faces

are clean. Push

ihe fllter Into

+h€

houslng

and

ensure that l1 ls

properly

ln

posl+lon.

Tlghlen

ihe reialnlng nul to the correcl

torque

(about

1...1,5 iurns after +he flange

gasket

+ouches

+hs fl lter

houslng

€dge).

tlotol The safeiv elerpnt

Inslde

the

alr

fllier ls

not

to

be rsnoved unnecessarl

ly In

connoctlon

rlih fhe lnspecllon

and

servlca

of

ihe

prlmary

flltar.

Do not clean

the

safety

slement, bul replace

li

once

a

year

o. then

necessary

(see

Operatorrs

Manual,

polnf

Serv

lce ).

Refircve

the fllter

by

op€nlng the

nuf ai

of ihe

fllier

houslng

and

pull

out the

lf

you

dcntf In+end

io

reolace fhe

elerleni

Inslde ths

lll+er,

teave

ooslilon.

the end

f I

lter.

sa{eiy

It

ln

E5

Clean

+he

fllter

eliher

wl+h ö

vacuum

ctsener

or by

dlrgcilng

a compressed

alr

Jef

ouixards

from

the

lnslde

of

the fll+er.

The

max.

pressure

of thg

cpmpressod

alr may

noi

exceed

500

kPa

(5

kplcmz). Replace

th6

illter

ofler

you

have claanod lf flve tlmes,

a+

lhe

lotesf.

leftcntl

Leaks In the lnlet

and

exhaus+

plpes

impalr thg performonce

of the

+urbo

conslderably.

Due io

hlgh

prgssure

even a mlnor

leak

in the

exhausi

manlfold

or ln

tha iurblng

Inlet

flange

may gror

ropldly.

Therefore

also

sDall

leöks

musi

be aftended to

lmnedlaiely

öf'ter ihey

have been

deiected.

Check

thai the plpes

bgireen ihe

alr fllter

and

ihe

turbo

and bett{e€n

fhe

turbo and

the lnlei

Rep laco

ihe gaskets

cnd

end fix

the

lnlet

manlfold.

Tlghfen

ihe

retalnlng

screws

of +he

manttoto

evenly

io

r0

Nn. Mount

the

alr

plpes

carefu

lly.

6-3

Ch€ck

the exhaust

manlfold

for

seallng and ih€

torque

of

the retalnlng

nufs

(60

Nm) as

rell

as

posslble

danages

(cracks,

dls+ortlon,

@rroslon,

etc.).

Also

Inspec+ ihat

ihe iurbo

ls

properly

flxed

to the

exhaust manltold.

Flx

fhe

oxhous+

manlfold

uslng always new

g€skeis.

Run

lhe

englne

rarm and

check ihe

torque

of the

refalnlng nuis

(60

Nn).

Ensura thai

fhere

6re no

extra obs+ructlons

ln

the-exhaust

plpe

or

In +he

sllencer whlch mlgh+

bulld

up exc€sslve

b€ck-pressurs

fo the

exhaust

gosos

coolng from

ihe turbln€

vrh€el.

TIJRtsOCMRGER

(DS

engl

nes)

To

ensure

+hai

+h9 turbo

functlon ls

faulfless

4. Measure

the

end play

of the

turbo

shaft.

Sef

the tip

of the

dlat

gauge

on the

shafi

end

and

nbve

the

shaff

longltudlnally,

back and

forih.

uqflpa.e

th€

resul+

rlth

the ratlng.

lf

the

€bove

Inspectlons

reveal

dahages

oi.

excess

lve reaa,

renove

.i'he

turbo

for

-repalr

(lnstruqtloos,

polnt

8 2 B).

lf ihe

englne

operaflon

Is

no+ normal

and ihe

lufP

Is noi

dörnaged

o|.

excesslvely

worn,

fhe

folloying

reasons

may

lle behlnd

fhe

irouble:

-

alr

fllfer

clogged

-

leaks

In lnle+

or

exhaust plpes

leaks

ln

gaske+

ot turbo

moun+lng

flonge

-

lnjectlon

pump

ilmlng

lncorreci

ör opeiailon

rau

tty

-

fhrofile

leverage

talsely

adjusiod

-

lnjecfors

falsely

adJusiäd

oi

malfuncflonlng

-

fuel

fged

pressura

lor

(9.q.

fuel

fllfer

clogged

)

- englne

coopresslon

pressure

lovr,

valve

cl6arances

ml

sadJ

usted

REI,|oV

ING I}E

TURBOCHARGER

R€rnove.

+he_re+alnlng

scrors

of +he

exhåusf plpe

and take

off

ihe

plpe.

Dlsconnoct

+he lurbo

alr

p

lpes.

remove

the

p

lpe.

,.

ifffi:

the

turbo

ftxtng

screrls

and remove

the

,.

:li::.f."T:r"Jlve

ptuss

rn

ihe

rurbo

lnte+

ond

6.

^.

DEIEilIINING

IHE

@T{DITION

OF T}C TURBOCMRGER

lf

you

suspeci

fhai +he operailon of the

iurbo

ls

unsa+lsfactory,

check lhe follov.tng:

l.

Check

the

condlilon

of ihe turblne

rheel and

the

+urbo

rotor vlsually.

The

btades

should

have no

damag€,

bend or

qlhe

ear coused by

forolgn parf

lc les.

2.

S€€

+hot fhere

are no

oll leaks lnio +he

furblne

houslng

o|.

iurbo

houslng

+hrough

the

shaf+

se€

ls.

otel

Durlng ldllng th6re nay

occur

sllght

oll

leakage

ln +he

compresslon slde.

Thls ls

however,

no reason

for

concern, unless ll-

causes

hlgher ol I consumptlon.

J. Meosure

the radlal

play

of ihe furbo

shoft.

+he flp

of the

dlal gauge

on +he

slde

of

shatt

and

move

the

shaf+

laterally.

Compare

rosu

lt

wlih ihe

ratlng.

8-4

aa

2.

B.

t7

fhe
the

RE@NDIT I otl ll{c IHE TTRBoCHARGER

(IIOLSET

HID )

Notel

Llke

r.lth ihe ropalr of fuel

equlprFni

+he

rocondl+lonlng of

'the

turbo should be made

tilth u+0losi

precislon

and cleanllness.

lf

you

donr+

have

al

your

dlsposal ihe

necessary

speclal lools, e.g. for balanclng +he ro+atlng
parts,

dlsassemble only +urbo

houslng

and

turblne

houslng

for ihe checklng of ihe

rofors.

In r|os+ cases l+

pays

1o lnstall a replacemeni

turbo del

lvered by the manufacturer.

Dlsass€*llng th€ iurbo

Clean the turbo from ihe outslde and clamo

li

In a vlce

(rlih

protect

Ive lugs)

uslng

+he

flange

as the clanplng

poln+.

Mark i'he rela+lve

poslilons

ol

'i'he

turbo

houslng

(l

),

Inierrnedla+e

disc

(4),

bearlng

houslng

(17)

and +urblne

houslng

(26).

open the

lock rashers

(19

and 2l).

Ren|ove the i-urbo

houslng screws

(8),

rashers

(7)

and mountlng

plaies

(6)

and llft

off the

iurbo

houslng.

Loos€n

ihe

turblns

houslng screws

(18).

Renove

the lock

washers

(19)

and mountlng

plates

(20)

and

I lli off

fhe

be6rlng houslng

lrom

-the

+urb

Ine

houslng.

Hold +he

lurblne

(heel

by +he foo+ sl+uated In

ihe nlddle of the vlh6el

and

remove the roior

reialnlng nut

(2).

Pull

ihe roior

(5)

off from

the

shaft.

Note I The thread of ihe

reialnlng nut

ls

left-handed. Do

nql

bend ihe

shaft.

Open the

screris

(22)

flxlng ihe lnfermedla+e

dlsc io fhs bearlng

houslng and remove lhe lock

tiashers

(21).

Take oft the Iniermedla+s dlsc

(4)

and

fhe ol I def

leclor

(10)

frorn

the shaft.

Press

l-he

oll daf lecloc

off the back

plate

and

remove

the

seallng

rlng

(5)

fron the lnter-

nedlate

dlsc.

Llft o{f

the oll

gutde

plate

(|l

).

Remove +he turblne

vihe€l

and the shaft

(25)

+ogefher

ylth

the

seallng

rlng

(24)

and llfi

off tho lurblne

shleld

plats

(25)

from +he

shaf+. Remove

the ou+ermost lock rlngs

(16)

fron tha bearlng

houslng. Pu+

your

flnger

flp

Into ihe baarlng

(15)

and

pu

| | out bqth

bearlngs. Ronove +he Inner lck

rlngs

(16).

TURBO

HOLSET HID

14. Thrusi bearlng

l.

Turbo houslng 15.

Bearlng

2. Hexagon nu+

16. Lock

rlng

5. Roior

17.

Bearlng

houslng

4.

Intermadl

ale dlsc

18. Hexagon

screv

5.

rrsQrr

seallng

rlng 19.

Lock

washer

O

6.

Mounllng p la+e

7. l{asher

8.

Hexagon

screY

9.

Seallng rlng

10.

0ll

def lector

ll.

Guldo

plate

12.

Screv,

20.

lttounil

ng

plale

21. Lock

washer

22. Hexagon

screw

25. Shleld

p

late

24. Seallng

rl ng

25. Turb lne

rheel and

shaf i

26.

Turbl

ne

houslng

27.

S€allng

r Ing

89

Clecnlng the turbo

prts

Notg I Use only washlng agen+s

you

know. Don't

raEh

',rlih

co-rodlng washlng agen+s, as +hey

dönage

sone

of

the

turbo

pari9.

Wash o{f

all dlr+ fron +he

Dar+s

wlih

ihe

wash-

lng agont.

Use

a

plasilc

spatula or a brush io

clean tho alumlnlum

parfs.

Clean al I oll

channels vrlih

pressurlzed

alr.

Ensure

thai

all

jolnis

are clean and ln

good

cond I t lon.
Chscklng

lhe turbo

psrls

Shali - iurblne

wheel comblnatlon

Check the bearlng

surfaces

for woar and

scratches.

Minor scraiches are alloved.

Check +he seallng rlng

groove

l{all

for

scratches.

Mlnor scraiches ar9

allougd.

Check +he turblne

rrheol

blades for

posslble

dan6ges, b€nds and

cracks. Under no clrcun-

stcnc€s b€nd

the blades.

Thrusf

bearlng se+

ReDla@

worn or

dofgctlve

Darts

Thrus+

bearlng ol I

grooves

should be clgan

Turbo

rotor

Check the turbo

rofor

blades for

posslble

damages,

bends

and cracks.

Und€i no

clrcuF-

stoncas

b€nd the

b I adas.

Bear

I ngs

Replacp

worn

or scraiched

bearlngs

2.

3.

7.

Loosen the

rotalnlng

scrers

2)

of the

ihrus+

bearlng.

Renove

+he +hrus+

pla+e

fif)

and +he

thrusi

bear

Ing

fi4).

2.

l.

lJ.

Thrust

p late

6.

8.

5.

Bearlng

hous

I ng

-

R6p I

ace bearlng

houslng,

ll

surtacos or- the

seallng rlng

notably

rorn or scraiched.

fhe bearl ng

groovgs

are

Roiatlng

paris

Chock ihe balanclng of the roiatlng

parts

rSQr

s6allng

r'lng

Rgplace

damaged, vorn ol-

hardened

seallng rlng

Turbo

houslng

and +urblne

houslng

Check th6

houslngs

for

any damage or cracks

caused bv

the coniact of the roior or detects

du6 io posslble

overheatlng.

l4lnor damages can

be accepted,

bu+ ofher*lse

replace

ihe

houslng.
Assemb I lng the iurbo
After cleanlng and Inspectlng ihe turbo

parts

carefully

and replaclng ihe faul+y

paris,

assemble ihe

+urbo. Perlorm ihe assenbly In the

reverse

order compared io dlsassenbly.

Pl6ase

pay

6++entlon io followlng

polnts:

The rotatlng

parts

should be bölanced |rlth an

accuracy of

1,44

gfln

a+ both ends. Ensure

ihat

you

tlnd

the marks

you

nade durlng dls-

essembly

Indlcatlng the rela+lvo

posltlons

oJ

dl fforeni parls.

Place +he

lock rlngs In +helr

posltlons

wlth

fhe

chanfared

slde lowards l-he bearlno.

8

l0

Notof Siarflng fron turbo

se.lal rto. 841272,

a seallng rln9, spare

par+

no. 8f5f f9104,

has

been

placed

bein€€n

+he +urbo

housing

and ihe

lntermedlafe

dlsc. Tho iurbo

houslng of older

turbqs can be

sealed

by

placlng

an o-rlng seal,

order no. 6146 12114,

bei{e€n fhe

houslng

and

fhe dlsc.

IISTALL I IG Tlf TIRB&MRGER

Flnd ouf fhe reason for fhe danage of the turbo

and alvrays el

lmlnate

the

cause of

+he

defeci

before lnstalllng

a ner

turbo.

To make

sure

ihat

lhe turbo functlons

properly

It

ls

essonilal +hat the englne lube ol I ls

ch€nged acco.dlng to Insfruc+lons

glvon

and

that

correcl oll

grade

ls used. lnstruc+lons

regardlng the servlce of oll and alr fll;iers

shou ld also be follolrsd.

The

adJustmeni of

ihe

Injectlon

pump

has

a

dgclslve lmpac't on ihe functlon

of

+he

turbo.

Therefore,

ihe manutac+urerr

s Insirucilons

apply for

+he

pump

adjusiment.

Check +ha+ ihe exhausi and lnlet manlfolds are

properly

fas+ened and thelr

jolnis

tlght.

Ensure ihat there

ls

no loose carbon resldue or

rust

or o+her forelgn

par+lcles

lnslde the

mån lfolds.
Fl+ the turbo flange

on

ihe iop

of

the exhaust

manlfold.

Always use a ner

gaskei.

Attoch

the

lnlet

plpe

and +he exhaus+

plpe

on

the

turbo.

Pour

ploln

englne ol

I Inio

+he

bearlng houslng
through the ol I Inlel io ensure +he lubrlcatlon
of

the iurbo

bearlngs af+er start.

Flx

the

pressure

and oll return

plpes

of ihe

turbo,

uslng

ner gaskets.

Make sure +hai ihg

turbo

ls wholly supporied by

lts flxlng flange

and that

fhe

plpes

do not

cause any

pressuro

on

the turbo.
Pull +he

stop

lever lnlo

stop

poslilon

önd +urn

ihe

englno

wlth +he

siartsr

for a xhlle.

Thls

guarantges

that ihe

ol

I

Dressure

rlses bg{ore

startlng.

Star+ the

englne

and check +hai

there

are no leaks

from

+he

DlDes.

f.

Lubrlcate fh€ surfaces of all bearlng

houslngs,

thrust

parts

and

seals ,lth

plaln

englne oll.

4. |{h€n

you

set

+he

shati

+hrough +hs shlsld

plate

and ln+o

ihe bearlng

houslng

and +he ol I

def lector

lnto +he lniernodla+e dlsc donrl

force

the seallng rlngs

lnto

posltlons, for

tlEy may

broak oasl ly.

5.

Tlgh+en

ihe ihrusi

bearlng scrers

to the torque

of

il,5

In.

}{hen

Insfal llng

ihe

ln+ermedlaie

dlsc

lnto

the

bearlng

houslng

be

careful noi

io damoge

ihe

'SQr

seallng

rlng.

Tlgh+en the lurbo roior relalnlng nu+ to

the

torque of

l4r0 Nn.

Not€l The nu+ has a lef+-handed

+hread. lvake

sure

you

donr+

bend +he shaf+,

tjse a

sul+able

T-wrench

or torque

wrench.

Sgt the dlal

gauge

on lhe shaft end and

meösurg

lh€ end

play

vhlch should be 0,10..0,16 rn.

The readlng can

be

sllghily smaller,

lf a lo+

of ol

I has

beon used durlng thrus+ bearlng

assemD ty.

9. Set the dlal

gauge

on the shaf+ slde and

tp€sure ihe

radlal

play,

The radlal

play

should

b€

0,50...0,46

rn.

Tlghi€n

fhe screws

(22)

b€tve€n ihe

bearlng

houslng and the

Iniormedla+e

dlsc fo +he lorque

of 5r7

n, the turbo

houslng

reialnlng

scrers

(8)

io

5,7 Nn €nd lhe

iurblne

houslng reiölnlng scre{s

(18)

to

ll,3 l{n.

Ensuro thal

the

shafi rotates

froelv.

Attach

ihe

lck rashers

(19

and 2'l ).

D.

||.

12.

10.

8-6

E. INSTALL II{G

THE I NTER@OLER

o

8

11

Cross-secflon of I nlercooler

l6t1/612\

Flt +h€ lnlet manlfold +o

ihe

cvllnder head.

R6place the

gaskeis

boii€en

fhe

cyllnder head

and the Inlet manllold!

Fli

ihe

plugs

fo|- the

upper relalnlng

screr holes

In the Inlei

manlfold

cl +he 6l'l1612 englnes.

Place a ney seal

qr

ioD of fhe lnlei

manlfold

and lorer tho cooler in lis Doslilon. Set a

gaskei

on top of ihe cooler flxlng flange and

lns+all fhe lntercooler

houslng

on top of +he

coo | €r_.

412

Then flx ihe wa+er

plpe

and

dralnlng

plug

guldes.

Place o-rlng seals

lnto ihe

gulde

grooves

and apply seallng conpound

6909 ,0024

on

ihe face leve

ls.

Atfach tho r.a+er

Dloes

on +he cooler

and

-ihe

boost alr

plpo

on

ihe

cooler

houslng.

ö- I

FIEL SYSIEM

I I{DEX

Technlcol dato ...........

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

. . . . .

9- f

Sp€claf toofs

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

9-

2

Constructloo lnd cperctlon

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

9-

l

Reclr Instrustloos

l. Fe€d

purp

A. Bleedlng the fuel sys+em..

...... 9-ll

B. Measurlng

+ho feed

pressur9................

......

9-ll

C. Checking +h€ overf lort

va lve. . . . . ,

. . . . . .

.......... 9-ll

D. DlsrDuntlng +he teed

pump

and

checklng

the va|ves..............,..

9-12

InJeqllon

purp

Bosch

iAi

A.

Checking

the

Injectlcn

iIm1n9........... .........9-13

B. Adj'rs+lng ihe lnjec+lon t I m I

ng. . . . . . . . . . .

........9-14

C. Renov Ing

the

Injectlon

pump. . . . , , . . . . . . . .........

9-14

D. Moun+lng ihe

Injecilon

purlP.............

.........

9-15

E. Ch€cklng and replaclng

the

pressura v41ve.........................

9-15

F. Adjustlng ihe ldllng

sp€€d.

. . . . . . . .

. . .

...........

9-16

I nJoctlon

purp

Bosch

iPi

A. Mounl'lng +he lnjec+lqr

pump. . . . . . . . . . . . . .........9-17

B. Checklng

and adjustlng

the Injecilon

t1m1n9.......................

9-18

C. Adjustlng ih€ ldllng spe€d............

........... 9-19

I

nJ€qtas

A.

Dlsmountlng the lnjectors....

.....,.............. 920

B.

Checklng

iho Injector.....

......

9-20

C.

Dlsass€rnbllng, checklng and assembllng

ihe

Injecfq......,........

9-21

D. fnstalffng lhe lnjector In

the

englne....

........

9-22

5. I nJ€ctlon

plp€s

A. Insialllng the lnJecilon p I

pes

. . . . . .

. . . . .

. ....... 9-22

Fuef sys+ern equlpment and

fe€dlng +ab les. . . . .

. . . . . .

.......... 9-23

5.

il.

vAlitEr

9-O

IEO{N

ICAL DATA

InJoctlon

purp

BOSCfl

iAr

,(8, tll, 4lt, 6ll

Typo

(pump/governor)

..,.........

Injecf lon order:

109, lll .....,..

4 ..........,,.

6ll .............

0 irect lon

ot

rotailon

DIai€ter

of

pump

elen|ent

Stroke . . , , . , . , . .

I njec+lon

advance r.............

Oll tllllngsl:

t@ , 311

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

O,l

4l I .............

.........0,4

6ll ..........."

....,....0,6

Tigh+enlnq

forque

of

fhe

pressure

valve

holder .......,...,.......

40

Tlghtenlng torque

of fhe

pump gear

retalnlng

nut .................

90

I ) I{hen Installlng

+he Injectlon

pump.

Feed

pump,

iype:

109,

flt

........

4lt, 6lt ...,....

Cons+r uct Ion

Bosch

PES...A,/RSV

1-2-3

|

-2-4-t

|

-5-t-6-2-4

clockrlse
9,5

rm

8n

Se€ lnj.

puirp

odJusilng values

Ntn
NM

Bosch FPIKSG

Bosch

FP,/KEG

Plston

type,

nano

pump

0,6

-

t,0 bar

2,1

bar

22 N

6/2

22

tO

22t/2

seParaie

Fuel

feedlng

pressure

(openlng

p.essure

ot the

over-f lor

yalve)

...

Feed

pump pressu.e

(wlthout

ån overfloH valve) .....,....

InJecllon

punp

BOSCH

nP'

6ll, 612

Type ( pump/governor

) . , , , . . . . . . . .

lnject lon ord€r . . . . . . . . . . .

D Irectlon

ot rotaf loi

DiarFier

of

puop

elefien+

Siroke . , , , . . . . . .

lnjectlon odvance

.........

Tighfenlng iorque

of +he

pressure

valvo

holder

Tlghfenlng torque

of ihe drlve

unlt reialnlng

nut.,..............

Feed

pump,

type ............

Consiruc+

lon

Fuel fe€d

Ing

pressure

(oponlng

Feed

pump pressure

(rllhoui

an

I

nJector

BOSCH

pressur0

of fhe

overf low

valvo)

.,.

overflotr

välve) ....

Consirucf I

on

open I n9

pressure

Con+rol

pressure

Seallng r

lng

Tlghienlng lorque

ot +he nozzle

retalnlng

nu+ ....................

Tlghtenlng

forque

of the InJec+o.

retalnlng nufs

(tcr

the

s.i'uds) .

l) The

value

used In adjustlng

thg openlng pressur€

of

a ne|,

and o

I nJector c v

Construcl I on

vPe,, I rig

Pl

Seallng r Ing

Tighienlng torque of +he

cap

nut of the lnJecior adjusllng

scrsr

.

Tlgh+enln9 torque of fhe

nozzle

retalnlng

nuf

. . . . . . . . .

. . . . .

. . , . ..

Tlghienlng

iorque

of the

InJector reialnlng nuts

(tor

the

studs) .

InJeqior BOSCH

(612-eng

I

nes,

Construc+

lon

Open I ng

pressure

Conirol

paessure

Seal Ing rlng
Tlghtenlng torque

of ihe

nozzle retalning

nuf ......,......,......

Tlghtenlng

+orque

oi ihe lnJector

retalnlng

nuis

(for

the

studs) .

l) The value

used In adjusflnq

fhe openlng

pressure

of

a nev ano

a

Bosch

PE6P,/RQV

t-r-3-6-2-4

c

lockr

lse

ll|ltn
l0

rm

See

Inj.

pump

adjusllng v6lues

80 Nm
140

Nm

Bosch

FPIK2?

P9

Plsion

type,

separöle

hand

pump
|,2

-

1,5 bör

t,5

bar

Four-hole

nozz

lo

200

+

5

bar

2lo

;5

b6r

a9gs1t4%

60 Nm

l5

Nm

used InJecfor.

Four-hole nozz

le

200

bar

8999 01495
40 tti
90

Nm

20 Nm

FIvg-hole

nozz

le

230

6ar

2t5 + 5

bar

8999

0t 495
60 Nrr
l5

tln

used

Injector.

9-r

-=F

t-_--]t._

4-_=}_

t-----F

-.F

E"---E

ffiFhE=-­\y|-v

{:F

--n------?=

.<--'--'fi-----:

8tr:@

7

5

| 6541

2

8360

3

9025

4 At6t

5 8160

625

7 8J60

I 9051

SPECIAL

ToOLS

(Fuel

sysiem)

JO600

Pressure

valve +es+lng

gauge

lt09l Exiractor

for lnjeqtlon

punp gear

99100 Injectlon

tlmlng

check pln

10002

Pressure valve spanner

(Bosch

rrPn)

975f9 Injectlon

+lnle check

plpe

99000 Con+rol

rod locklng bush

8f288

Nozz

le cleanlng

tools

71f00 Extractor

for Injec'tor

(Bosch)

COT{SIRI'CTION

ATD

OFERATIO

OF FUEL

SYSIEI,I

l. Fuel

iank 2. Y

ater

seDara+or 5. Feed

4.

Fllter 5. InJecilon

pump

6. InJecfor

7. Fugl reservolr

of thermosiari

devlce

8. olor

plug

9. overflow

valve

The fuel flotrs lrom

the iank

(l)

vla

separator

(2)

to the teird

punp

(i)

whlch

the

hlgh-pressurlzed

fuel +hrough

the

(4)

io ihe InJectlon

puitp

(5).

TilJECIt(r{

PtfP 8601

'Ai

l.0ll flller

plug

2. Spe€d lever l. Hand

pump

4,

Lube ol I lnio the lnJec+lon

pump

5.

O-rlng seal 6.

Lube

oll back

to tho englne

7.

Gear 8.

lden+lflcatlon ola+e

The-

InJec+lon pump

ls

an

In-llne

pump

and lfs

baslc

cons+rucilon

ls

the same

In all

enqlnes

lrrespectlve

of the

cvllnder

number.

punP

vaTer
forces
f

I lfer

The lnJectlon

punp pumps

the fuel

through lhe

InJec+lon

plpes

lnto +he lnJectors

(6)

,hlch

spray +he

fuel

Inio

the

cyllnders

ln

a flne

spray.

The excess

fuel rlhlch lubrlcates

ihe

nozzle

needle reiurns

from the InJectors to

+he

fuel

reservolr of lhe thermostart

devlce

(7)

and

on

to the luel tank. Durlng

gloyrlng

lhe fuel

runs

from +he reservolr

(7)

+hrough +herdps+art

glovr

plug

(8)

and

ihen burns In fhe lnle+

manlfold.

The excess

fuel

fron the lnJecilon

pump

reiurns

fhrough overf lov, valve

(9)

In+o

ihe fuel +,ank.

9- 3

The lnJec+lon

pump

ls flxed

fo +he

goar

houslng

rllh ö

tlonge and s€cled rlth an O-rln9

(5).

The

punp

ls drlven by cronkshafl vla ldler

gear

and

pung geär

(6).

The InJectlon

pump

ls

connecied to ih€ englne lubrlcatlon sysfem

by

Deans ol

on oui€r

plpe

(4).

l. Pressurg

valve holder

2. Prossure

f. El6nen+

4. Conlrol

rod

5. Return

elemenf

plsion

6. Rol16r tappe+

7.

The

elenEnt

conslsts of a

plungEr

(4)

and a

cyllnder

(2)

vihlch have been tliied

to

€ach
o+her wlth a thouscndth-mllllrneire accuracy.
Due +o +hls

accuracy In flitlng +he elenent

should

alvays

b9 repleced as ö xhol9.

The cyllnder

of the elgn€ni

has

iro

borlngs:

lnlei

bore

(l)

ond

gulde

bore

(4)

ihrough

thlch

fha fuel ls dlreclod lnto +he

orgssure chamber.

0n the slde of the

plston

(5)

+here ls a long-

lludlnal

groove

(7)

and

a regulatlng rlm

(6)

rhlch

regulate

the amount of

fuel

lnJecied lnio

the cy llnders.

On

th6

head

of

the elerient

Dlslon

there ls also

a siarilng

g.@ve

(l)

r,hlch delöys the

InJ€c+lon tlmlng

by aboui 70...80

durlng

slort.

(Not€

thls Hhen

checklng the lnJectlon

tlmlng, seo lnstrucllons

ln

polnt

9

2 A'.

Thls

func+lon, ehlch

ls fully

auiomotlc, ls to

lmprove +he

englne

cold start characlerlsilcs.

lh6n

ihe

englne

stops

ihe

conirol rod turns thg

6lel€nt siartlng

grooye

so that li ls at ihe

cyllnder

gulde

hole.

Durlng

slarllng, atler

the lnjocilon pump

has

reached

a

certaln

spe€d,

the

governor

drors

fhe

control rod back

to

the

runn Ing

poslilon.

Pressure

va

lve

9 5

l. Pressure

yolvg

holder 2, V6lve sprlng

J.

Valve

stefl

4.

Valv€

gulde

5. Valv€

h€ad

6.

Pressurs

reducilon

plston

7.

Longliudlnal

ga@ves
The

pressuro

valve

ls

placed

on top of tho

glgmenl

+o

cui

ihe

conngcllon between lhe

elemen+

and

the InJ€ctlon

plpe

when lhe

regulatlng rlo

ol

the elenent

plsfon passes

the

gulde

hole of ihe

cyllnder and ihe

pressure

cdnss

dorn.

An

crther

tunctlon

ls to reduce

pr€ssure

In

the InJecilon

plpe.

Thls

ls

lmDor+ani

ln

order lo

have

the nozzle needle

close au i ck lv.

The

pressure

valvg

stern

(i)

has

a

pressure

reducllon

plston

(6)

rhlch, as the valve

closes,

flrsf

9€s

dorn

io

the valve

guld6

(4)

and cuts +he

conngctlon betreen ihe elemenl and

lnJEc+lon

plpe.

Ther€after the valva

head

(5)

presses

agalnst

lts

sga+ and

ihe

space

for fuel

In

ihe

InJectlon plpe

Increoses by

the

dlsplacenent

of the

pressure

reduqflon

plsfon.

lllrtlng ot ihc

I nJoctlon

purp

@

Th€

ldentlflcoflon pl€te

of +h€ Injecflon

purp

sfåtes a lo+ter

codg

for

the

puDp

appllcatlon,

:L,*ä";" J,R'Ji,l'?,

""i'lT'

#::'%.'1::

g_4

lnJoc+lon pump

or Inqulre Edjus+lng våtues.

93

spr I ng of

Coms haf

l-

The

tunqllon of the InJectlon

punp

ls +o

dlstrlbute the rlght anounf of fuel

lnto the

dlfferent

cyllnders at the rlghi

ilne. The

elemen+

(5)

drlven by ihE camshafi

(7)

lhrough

roller

tappei

(6)

forces the

fuel vla

pressure

valva

(2)

lnio

ihe

cvllndor

llner and lurlher

io

the I nJec+or.

A8C

T!,o-hole eleneni ( fu I l-te€d

posltlo.r)

Boiim

dead

contre

B.

End of teed

In le+ bore

2. Cyllnder

Gulde

bore

5.

Plung€r

Longltudlnal groove.

Sfart

of

f€ed

t.

Starilng

groove

6. Regu

l6t

Ing rlm

@vERNOR

t.

Cen't.ifugal

relghi

2. Coofrot rod

l.

Siarilng

spring 4. Hain

tever

5. tdllng

control 6.

Goyefnd-

sorlno

7.

Addl-flonal

spring foi

idling

8. ba taicer

sprtng

9.

Control levs'.
The

centr

i tu ga

|

-type

governoi

ls

loca+ed ai ihe

rear

end of ft|e

Injectlon

pulp.

The

governor

regulötes

ih€

englne

speed

ylthln

the

|rhole

speed range

and recognlses

ihe

speed wlth the

help of the

cen'irifugal

Helghis

(l

).

Th€

poslilons

ot ttE ihrqf+le

lever

and +he c6n+rl-

fugal

relghis

are iransnltted

io ihe

conlrol

rod

(2)

vla

the

governor

leverage.

Tho

gove.nor

has one

governor

sprlng

(6).

|lhen the

englne

s+ops tt|e

s+artlng

sprlng

(f)

flxed to

l'he

iop

ol tl|e

cootrol

lever

(9)

draws the

conirol

rod

lnto it|e

siartlnq

poslilon,

vlhlch

au+oma+ically

sets an

Increasld

feed raie

for

starilng.

9-5

|ITJEC ON

Pttf

BOSCH

?r

l@

l. Cold

start

bu+toi 2. Boost

plug

6. RQv-governor

7.

SPeed

tl. Lube

oll to Iniecilon

PumP

Pressure

coniro

I lei

lever

8. Lub€

ol

I

12.

ldent

lf

I ca+lon

J. Ov6rllow

valve

4. Stop

lever 5.

Oll

flller

from Injectlon

punp

9. Hand

pump

10. Feed

pump

o

la+e 11.

Pressure

equallzei

The ouislde and ihe construc+lon of

lnJec+lon

Dumo

Bosch

nPr

dllfer from those of

the

rrAtr

+ype

pump.

The funcflon, hor6yor,

ls ihe sam6.

In the

'P'r

iype

pump

every

pump

eleiEn+

rlih

lis

pressure

valve and v€lv9 holder

ls ln a

closed element houslng.

The

baslc adJusiment of +he

feod ra+e ls

made

by +urnlng the elemenl

houslng,

whlle fhe feed

sfari ls EdJusied by chonglng

tho

ihlckness of

ihe shlms sltuated under

the elemeni houslng

tlange. The

closed

type

pump

body has

no slde

hatchgs a

other control holes.

The

feed roie ls adjusted

by ihe control

rod

made of

angle

pro{lle

sleel.

The rod has

notchos on *hlch +hs balls of

+he control

iag

d€s

lean.

The InJectlon

pump

ls

bof+om-mounied.

The

pump

ls rcunied

on a

separale

base on

the englne

lef+ slde. The lnjectlon

pump

ls drlven by

ihe

englne llmlng

gear

vla shofi

and mulilplE

pla+e

clu+ch. The

pump

ls @nnected

to ihe

englne

lubrlcailon sysiem.

Prossure

valvg

holder

2.

pressure

E lsment

4.

Conlrol rod

5.

Control

Va lve

iaooe+

7.

Camshafl

va

lve

I

-6

FEED PTIf

F€ed

pump

4l I

l. Hand

pump

2. Plug

f. Seallng

rlng

4. Spr I ng

5.

Va lve

6. Valve fappei

7.

Body

8. 0-rlng
9,

Plsion

10. Sprlng
ll.

Seallng rlng

12. Plug

lf. Oaskol-

14. l{asher

15. Nut

The fuel feed

pressure

ls

produced

by a

plston

pumo

llxed

fo ihe

slde

of the

Iniectlon

pump.

The

puDp

ls drlven by

ihe eccen+rlc

loca+ed on

ihe lnjecilon

pump

carnshaf+.

The anouni

of

fuel

+hai cofiEs fron l-he

{e€d

purp

exceeds

conslderably

+he

fuel needed by

+he Iniectlon

pump.

The

extra fuel ls led

ihrQgh

th€ over-

flor

valve

back +o

ihe fuel tank.

Thls erfra

fuel

cools

-th€

lnjec+lon

purp

and ble€ds

the

fuel svs+em.

9lo

The

eccenirlc on ihe lnjecilon

purp

camshafi

(l)

presses

dorn the feed

pump

pls+on

(5).

Thls

ollors

fuel

lo enfer from feed

pump

lnlei

chaitber

(7)

In+o

prossure

chamber

(4)

vla

pressure

valve

(8)

and ihe

plsfon

sprlng

stretchas

(

Infermedlaie

stroke).

After

fhe eccen+rlc has rota+ed

oast

lts loD

deod

c6n+re lf ls

followed

upvard

by fhe

plsfon,

pressure pln

(f)

and ihe rol ler tappet

(2)

prassed

by ihe

sprlng. Durlng thls

phase

fuel

ls

fed through

fllier to

the InJecilon

punp

ond ai

ihe

same tlmo fuel ls suckgd

through

lnlei valve

(6)

to +he feed

pump

lnlel

chamber

(pressure

stroke).

Durlng

the

pressure

stroke

ihe leed

pump pumps

ngarly

all +hs necessary fuel anount lnfo +he

lnJec+lon

pump.

Durlng lhe ln+ormedlöta

stroke

It dellvers

only a small amount whlch corres-

ponds

to

the

prossure pln pushlng

ltself lnio

+he

pressur€

chamber.

WhEn the

prgssure

ln ihe feed

plpg

excegds €

cerialn value fhe

sprlng forces the

plston

up

rlih

only

pari

of the stroke and +he fuel

raie

Is correspondlngly

lorer, l.e. +he

hlgher

ihe

back

pressurg

ln tha feed

plpo,

fhe

smaller

ihe

4nouni of fuel dellvered

by

+ho

pump.

9

lt

A.

Pressure

sfroke

B.

Intermedlaie

stroke

l.

lnJsctlon

pump

camshaft

2. Rol ler

iappet

5. Pressure pln

4.

pressure

chamber

S.

plston

6.

Inlet valvg

7.

Inle+

chamber

8.

pressure

va lv9

9-7

T

JECTOR

BOSCH

The

lnJector has a four-hole nozzle. The maln

parfs

ot thg I njec'tor

ar6 the nozzle

holder

and

ih€ nozzla

tlp.

The funcilon

of

ihe I nJecfor

ls lo taed

tuel lnio ihe

cvllnder ln the form

of

a flne

vopour and

fo starl cnd

cui

off ths

lnJec+lon

rapldly.

The

lnJector ls controlled

by th6

fuel

pi€ssuro.

912

l. Fu€l

Inlet 2. Overtlor

plpe

connectlon

l.

Shlm 4.

Pressure sprlng 5. Pressure

pln

6.

Nozzle

body 7. Nozzle needle 8. Pressure

chamb€r 9. Nozz le hole

The

fuel

pressure

ls dlrecled to

ihe

conlc

pressur€

should€r o{ the .pzzle need le

(7).

Hhen

thls

pressure

ls

greater

fhan the

reslst-

Ing forcg

of ihe

pressure

sprlng

(4)

li

ralses

the

n€dle froi!

Its seat. Fuel ls then e

iected

through

the

holes

(9)

In

the

nozzle bod-'I

(6)

Into ihe

combus+lon chamber

ol +he cvllnder.

The

tenslon

ot

ihe

pressure

sprlng,

lrhlch

delerm

I nEs

the open I ng

pressure

o{

fhe

InJecfor,

cän

be

adJusied wlth shlms

(l).

The ovgrflow

fuel lubrlcatlng fhe nozzle needle

ls led

to

lhe

overfloy

plpe

ond back +o

fhe

fuel

iank.

INJECIoR C

Y

(61I

englnes)

The

InJecior manutactured by CAV ls

prlnclpally

the same as fhe Bosch

InJector,

rlth regard

io

qanstructlon

and tuncilon. The

greaiest

dlfferences

ln

construcilon

are to do wlfh

the

lnJecior

fixlng and

the

adjustn|en+ of the

openlng

pressure.

The InJeclor

dpun+lng lugs

are

casl ln the body

ond

the openlng

pressure

ls

adjus+ed wlth an ödJustlng

nui, rl+houf

ssparate

sh

lms.

l. Fuel

Inle+

2. Ov€rt

low

plDe

connec+lon

f. Adjusting

nui 4.

Pressure

sprlng

5. Pressure

Dln

6.

Nozzle bodv 7.

Nozzlg

ne€d le 8.

Nozzle

hole

2

I

-8

FUEL FILTER

BOSCH

l. Cover

2.

Seallng

rlng

3.

Paper fil+or

cartridge

4. lnner

plpe

5.

Sheei

rE+al

hous

lng

6, Bleedlng scret

The fuel fl l'ter ls

a so-cal

led capsul6

fllier

conslsiing

of the fllter cover

(l

) rlth tuel

inlet and return cpenings and

the flll-er

body

whlch has a shee+

rneial housing

(5)

encqnpass-

Ing a

paper

ll

lier car+rldge

(l).

In

'the

nlddle

of the body ihere ls a threaded hole for

flxlng

It io

+he

ll l+er cover.

Scrne

englne

l-ypes

are equlpped rlih a double-

f I lter r ith

se

lec+ I n9

va

lve, rhe.eby one

I I lier

carirldge can

be replaced rhlle

the

englne ls

runnlng.

FiEL

FILIER C

v

(6l11612

ergln9sl

The

CAV fuel ll lter has

+!,o

rrparal

lellyrr

connectgd fllfer

cartrldges.

There are tYo

iypes of fll+ers,

ons

lJlth a

glass

sedlment

boul

(flgure

9 15) and

the

oiher

ulthout li,

I{AIER

SEPARATOR

Mos+ englne verslons

are

equlpped

t{l+h an

englne oi machlne

mounted wato. sepäraior,

the

func+lon

of whlch ls

presenled In flgure 9 16.

l. B

leed Ing screw

cartri dge 4.

Olass

p

ru9

I

15

l. F I lier

bo{ | 5. Dralnlngsed

lmeni

9- 9

FI'EL RESERYOIR

OF THEN'|oSTART DEVICE

Reservolr

fl I llng 2.

To

+he burn€r

Rgfurn to fuel tank 4. Breather

s 17

t.

The overflowlng

fuel fron

+he InJeciors

ls

led

to ihe fuel rgservolr

of the

ih€rnpstart

devlce.

Thls

plasilc

reservolr

stores

ihe

fuel

n€ded

by the

burngr and th9

exlra fuel

rsturns

furlher io the

fuel iank. In

some

equlpttnt

and work nachlnes

+he breather

plpe

(4)

of

+h€

therrnosiarl devlce also

lakes care

of

the

actual fuel tank ven+ |

ng.

Notol

lf

ihe breofher

plpe

of ihe

thern|o-

s+ar+

devlce ls +he only subsiliuilng

alr

plp€

+o fhe fuel +ank,

lt nay unCer

no clrcums+ances

be b laked.

I-l0

I XSTRI'CT IOiIS FOR

REPAIRII{G r}€

Flf,L

SYSTEII

ilotal Thls

manual

glves

on ly

genorol

lns+ruc+lons

for rEpalr and s€rvlce

fiEosurgs

related io +he

luel

system.

Thls

applles

partlcularly

to

the

InJectlon

pump

rhlch can

b€

repalred only by o sp€clally

+ralned

Person

rho has the necessary spgcläl

iools and

gaug€s.

All

s6rvlc6

and roDelr rork rgloted

to the

fuel

sysiem requlres speclal cars

and cleonllnessl

FEED PUIiP
ELEEDI I{G THE

FIEL SYSIEM

OpEn the

hand

pump

plston

by

turnlng.

Open

'the

bleedlng

screi on

iop of fhe

fllter. Pur|p rlth

ifl€

hand

punp

un+ll

the

conlng

ou't of th€ ble€dlng

screr ls

free

bubbles. Close th€

fllier bl€edlng screr.

open the connecilon of the InJectlon

pump

over-

tlor

valve c the

pressuro

equollzgr ln

the

[Pn

type

purnp.

Conilnue

purplng

untll ihe fuel

conlng out of ihe

overf lor valve conn€cllon

ls

tre€ lrqn

bubbl€s. Close +he overf lo[ valve

connec+lon and close the

hand

pu|l|f' plston

by

turn Ing.

!llpe leaked

fuel otf

.

ICASI.R

I

}tG

TI€ FEED

PR€SSiNE

Cl6an the lnJecilon pump

and the

fl

l+er

externally

6s rell as +he fuel

plpes

Inbetreen.

U-

brush

and sultable

solveni.

4.

B.

1.

t.

Attach ihe

geug€

betre€n fhe fllier and fhe

plpe

leadlng

io the lnjecflon

pump.

f. Run fhe onglne at ldllng speed

for o rhlla and

coopare ihe

gaug€

roadlng

rl+h

englne ratlng.

Nqtcl

lf

l-he

9au9e

readlng

falls b€lor railng

li

moy

be cöused

by:

-

defoctlvg

ovgrf lor

valve

-

cloggod fusl t I lter

-

defoctlve feed

pump

-

clogged or

leaklng fuel

plpas

or

connectlons

C. C}ECKI IG I}E OYERfLO| VALVE

lf

the

fe€d

pressure

dlt{ers from +he ratlng,

check fhe opanlng

pressure

of th€ overf lox

l. Attach

the

pressure gauge

as wlth

feed

pressure

ipösuremen+

(Dolnt

B).

2.

Pump

{lih

hand

pump

untll the

overflor

valv6

opens.

Compore

ihe

raadlng In

ihe

gaug€

at +he

openlng rpDenf rlih lhe

ratlng.

fue I

fuel

{

roir

lf

the readlng

ratl

ng, rep lace

one.
Notol lf

the
overf lor vo lve
hand

pump

or

defect I ve.

ln

fhe

gauge

dl{ters

from ihe

the

ov€rf low valve rlth a n9r

prgssure

do€s not

rlse io the

openlng

pressure,

ellher

th€

the

feed

punp

va lves are

9

19

9-11

t.

DI9rcUXTI]{G

TIIE

FEED PTIP

AID C}CCK It{G

IlE

v

LtEs

cleän fho lnJecilon

pu[p

and

lts surroundlngs

car€fu | |

Y.

2. D

lscoon€cf

the

fusl

plpos

leadlng

to the feed

puop.

Op€n ttre

te€d

puip

retalnlng nu+s and dlsnpunt

the f€d

purnp.

Flx the te€d

punp

flonge to a screr

clalp

equlpped

rlih

protecflng

Jars.

Rg|tpve

l'he

hcnd

purp

frdr

tho

lnJoctlon

puip

as xell as the

plug

or conneqtor noar lt

(509,

lll).

6.

Rd|pvg

the vclvg

sprlngs and valves frqn

th€

f6€d

pump

body.

Check the

condlilon of ihe

valve

gasket

surfoce cnd replace rorn

parts.

Place

the

yålves

cnd

sprlngs ln +helr

poslilons.

The Inlet and exhaust-valves

are ot

lhe

sor|9 lype.

Flx

+he

hond

punp

and

ihe

p

lug./conn€ctor

by

uslng

n€s

seollng ilngs.

Clean ihe

gcskei

surleces betreen fhg

leed

pump

and

the lnJectlon

pump.

Remount lhe teed

punp

by

uslng a n€r gosket.

9-12

2.

I

NJECI I O{

CHECKI

NG

PnP 8osctr

i i

T}E I

NJECTIOiI

TII,IING

tlmlng ls

marked

qr

the

fO9,

lll and

4ll

englnes

danpei In 6l I and 612

Turn the crankshatt

to 6

posltlon rhsre

lhe lst

cytlnder

plsion

reoch6s lls cqrpresslon

stroke

top dead cenfre. Thgn

turn

ihe

cronkshaf+

backvards

unttl

the llmlng

mark oo

the

pulley

Dasses

th€ lnsoectlon hole.

Reriove

the con+rol rod

cover

fron

the lnJecilon

Dumo.

Turn lhe control

rod to

drlvg

posltlon

rlth tool

9025 99000.

Rqrcve

the lst cyllnder

lnJectlon

plpe.

Blor

the clnlc

part

of

th€

pressure

valYe

holder

fr€€ of tuel.

Turn

ihe crenkshaft

lorrards un+ll

tuel surtoce

In

the

pressure

valve

holder

stlrs,

but d€s

nof

yet

rlse.

lf lhe lnlecilon

tlmlna

märk ls

ln llne

rlih

ttre tlp oi

the Indl caioir,

fhe

InJec+lon

+lmlng

ls correct. OtlFrxlse

cdJust

the tlmlng

as

lnsiructed

In

Dolrf

9

2

B.

After checklng

and

posslble

adJustlng

Install

ihe InJec+lon

plpe

6nd

fhe conlrol

rod

cover.

Let

ih-e englne

run

for o

lel mlnutes

and

recheck. Thus

you

con

ensur€

ihat there

ls

no

alr lef+ In

the luel sysiem

rhlqh

nlghi

aftoct

ih€ tl ml

ng.

tlotcI The

lnJ6ctlon

crankshaf+

pu

I l6y ln

and

on the

vlbrötlon

eng

I nes.

In

lraclor englnes

the Injecilon

ilmlng

ls

marked on the

slde

of

+he tlyrheel. The

tlyrhoel houslng hös

an lnspectlon openlng end

a hole

fq- ihg tlmlng chek

Pln.

oue +o the autonailc

excess tuel

feed of tho

lnjecilon

pump

th€ control

rod musl be npved to

drlye

poslflon rhen

öecklng

the

lnJectlon

tlolng,

otherrlse

fhe Injectlon ilmlng rlll be

I ncorreqt !

lst rcy ot ch€cllng3

l.

Clean

ihe lnJectlon

punp

and lls surroundlngs

carefu

I ly.

2.

ln

iractor

Englnes rslpvo +he rubber

plug

fro||l

the Inspectlon

hole In

ihe

tlytrheel

houslng.

Ins€rt

+he

check

eln

(9025

99100) ln

the

hole

sltuoted on thg front

f6ce

ot the flyrheel

hous

I n

g.

6.

8.

9-13

2nd

rry

ot

chrck

I n9

flotcl

lf

poss

I b te,

checklng

b€couse

fhere

systen gettlng

d lrty.

l. Do

as

lns+ruc+ed

ln

lhe

polnfs

I to 5.

B. ADJUSTI IG

Nf,

INJECTIOI TII,IIIG

lf the tlnlng

ls found I ncorrect,

adJust as

fol lors:

l. Loosen th€ reialnlng

nufs

of ihe lnJecilon

purnp

and

t.emove

fhe

lnJec+lon

plpes.

uso the

less

I

sl vay of

rlsk

of fuel

lsi tray of

checklng,

2.

Op€n

the

lock and

clomp

of +he

lst cyllndor

pressure

valve

hold€r.

Renove ihe

Dressure

valve

stem

and renpunf

the

holdgr tlth äbsolute

cleanl

I noss.

f. Flx

+he

lnJecilon

tlmlng

check

plpe

(8160

97jt9)

to

thg

lsi

cyllnder

pressurg

valve

holder.

Injoctlon

Into

the

lst cy nder

beglns.

5.

lt.ihg llmlng

mark

on the

flyrheel

ls ln

llne

wlih

ihe

tlp

of +he

chack

pln,

fhe

InJectlon

tlnlng

ls

correci.

oiherwlse

adJusf ihe-tlmlng

as

Inslructed

ln Dolnt 9 2 B.

6.

Removg lhe

check

plpg

and open ihe

pressure

valve

holder. Place the

Dressure

valve s+em

ln

Its

poslflon,

ieplace

the seallng

rlng and

the

0-rlng

and ntouni

th€ valve

sprlng and

the

holder.

7.

Tlghtu

tho

Dr€ssur€

vclve

tlol dor rs tollois:

-

flrst

tlgh+enlng io

,0 Nm

-

open ihe

holder by

about l/2 iurn

and

retlghten

40 Nm

-

open

the

holder by aboll+ l/2

furn and

flnElly

tlghten io

45

Nm

lvl

I

27

It

the

InJec+lon

+lmlng

ls

re+arded,

+urn

the

pump

anilclockrlse

(vlered

lrom lhe fronl end

of

ihe pump).

lf ihe

tlmlng

ls

advanced, turn

+he

punp

c lockw

I se.

Chack the lnJec+lon

tlmlng

and

iurn

ihe

pump

agaln, lf necessary.

lih6n fhe tlnlng

ls

correct flghten

ihe

retalnlng nuts of ihe

pump

and

flx ths

InJectlon

plpes.

REIOV

I NG I}IE INJECTIOI

PIIP

Carelully vesh

ihe

lnjectlon

pump

and tho

surroundlng englne

parts

as

vrell

as the

lnJectlon

pump plplngs

and

ihelr

connecilons

oxtgrnal

ly.

4.

c.

t.

Remove..+he

lnjecilon

plpes,

fhe

fead

plpe

connectlor

screls

and

the

oll plpe

connocilän

;ifi:.

Flt

ihe

connectlons

rlih 6 profecrtve

9-14