JCB Engines Scania 9 Engine Withs Cylinders (1715049) Work Description Manual - PDF DOWNLOAD

01:07-02 Edition 1

Work description9 litre engine with 5 cylinders Industrial Engine

Part No. 1 715 049

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en

Use a container to avoid spills when draining the coolant and oil.

Dispose of used coolant and oil through an authorised waste disposal contractor.

Immobilise the starting device when working on the engine.

If the engine starts out of control, there is a SERIOUS RISK OF INJURY.

It is highly dangerous to consume corrosion inhibitor.

Avoid skin contact with glycol.

Avoid naked flames or sparks near the batteries.

When the batteries are charged, oxyhydrogen gas is formed which is inflammable and explosive.

Only start the engine in a well ventilated area.

If it is run in a enclosed space, there should be an effective device to draw off exhaust gases and crankcase gases.

Corrosion inhibitor is highly dangerous if ingested and can prove fatal.

Avoid contact with the skin.

Wear gloves and protective goggles when charging and handling batteries The batteries contain a highly corrosive acid.

Never start the engine without the air filter.

There is a risk of injury or serious engine damage.

Handling cleaning agents for the cooling system: Carefully read the warning label on the container.

Do not connect the terminals up incorrectly.

This can cause serious damage to the electrical system.

If the terminals are shorted, sparking will occur.

WARNING The oil may be hot.

Wear protective gloves and goggles

2

Hot engine with pressurised cooling system: Open the cap carefully.

Water and steam may spray out.

Risk of burn injuries.

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Contents General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . 4 General tightening torques. . . . . . . . . . . . . . . . . 5 Engine assembly . . . . . . . . . . . . . . . . . . . . . . . . . 6 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Removing the engine . . . . . . . . . . . . . . . . . . . . . 6 Fitting the engine . . . . . . . . . . . . . . . . . . . . . . . . 7 Mounting the engine in a universal stand . . . . . 8 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Cylinder head. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Checking and adjusting the valve clearance and unit injectors . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Removing the cylinder head . . . . . . . . . . . . . . 15 Fitting the cylinder head . . . . . . . . . . . . . . . . . 17 Removal of valves . . . . . . . . . . . . . . . . . . . . . . 20 Fitting the valves . . . . . . . . . . . . . . . . . . . . . . . 20 Checking and machining of valves . . . . . . . . . 21 Renewal of valve stem seal . . . . . . . . . . . . . . . 22 Renewal of valve seats. . . . . . . . . . . . . . . . . . . 23 Machining the cylinder head . . . . . . . . . . . . . . 25 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . 25 Renewal of valve guides . . . . . . . . . . . . . . . . . 29 Renewal of sleeves for unit injectors . . . . . . . . 30 Cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Reconditioning. . . . . . . . . . . . . . . . . . . . . . . . . 32 Removal of cylinder liner . . . . . . . . . . . . . . . . 33 Fitting of cylinder liner . . . . . . . . . . . . . . . . . . 34 Measuring the cylinder liner height . . . . . . . . . 35 Renewal of rear crankshaft seal . . . . . . . . . . . . 40 Removal of flywheel housing . . . . . . . . . . . . . 41 Fitting the flywheel housing . . . . . . . . . . . . . . 41 Renewal of the front crankshaft seal . . . . . . . . 44 Crank mechanism . . . . . . . . . . . . . . . . . . . . . . . 47 Removal of connecting rod with piston . . . . . . 48 Fitting of connecting rod with piston. . . . . . . . 49 Renewing a piston . . . . . . . . . . . . . . . . . . . . . . 51 Checking connecting rods . . . . . . . . . . . . . . . . 54 Renewal of bearing bushing in connecting rod 56 Removal of flywheel . . . . . . . . . . . . . . . . . . . . 58 Fitting the flywheel . . . . . . . . . . . . . . . . . . . . . 59 Support bearing . . . . . . . . . . . . . . . . . . . . . . . . 61 Renewal of ring gear . . . . . . . . . . . . . . . . . . . . 62

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Removal of crankshaft . . . . . . . . . . . . . . . . . . 63 Fitting the crankshaft. . . . . . . . . . . . . . . . . . . . 64 Checking and grinding of crankshaft . . . . . . . 65 Engine transmission . . . . . . . . . . . . . . . . . . . . . 67 Removal of intermediate gear . . . . . . . . . . . . . 69 Fitting the intermediate gear . . . . . . . . . . . . . . 71 Renewal of bearing in the intermediate gear for the fuel pump (or compressor and hydraulic pump if any) . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Renewal of bearing in the intermediate gear for the camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Removal of camshaft gear. . . . . . . . . . . . . . . . 75 Fitting the camshaft gear. . . . . . . . . . . . . . . . . 76 Removal of crankshaft gear . . . . . . . . . . . . . . 77 Fitting the camshaft gear. . . . . . . . . . . . . . . . . 76 Removal of camshaft. . . . . . . . . . . . . . . . . . . . 79 Fitting the camshaft. . . . . . . . . . . . . . . . . . . . . 80 Renewing the camshaft bearings. . . . . . . . . . . 84 Balance shaft unit . . . . . . . . . . . . . . . . . . . . . . . 90 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Renewing the ring gear on the crankshaft. . . . 96 Checking the ring gear on the crankshaft . . . . 98 Lubrication system . . . . . . . . . . . . . . . . . . . . . . 99 Measuring oil pressure . . . . . . . . . . . . . . . . . 100 Oil filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Oil cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Oil cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . 110 Measuring radial and axial play . . . . . . . . . . 112 Open crankcase ventilation . . . . . . . . . . . . . . . 115 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Checking the open crankcase ventilation . . . 119 Form for measuring the crankcase pressure . 121 Closed crankcase ventilation. . . . . . . . . . . . . . 122

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General 1

2 3

4

1.

2.

3.

4.

Instruction plate: Valve play Warning label, fuel EPA label Engine type designation and engine serial number, stamped

Specifications

4

Cylinder diameter

127,0 mm

Stroke

140,0 mm

Cylinder capacity

8,87 dm3

No. of main bearings

6

Firing sequence

1-2-4-5-3

Compression ratio

18:1

Direction of rotation (engine viewed from behind)

Anticlockwise

Engine speed, low idling (all speed)

500-800 rpm

Engine speed, high idle (all speed)

2200 rpm

Oil volume

23 - 29 litre

Oil quality

see booklet 00:03-01

Weight (without oil, coolant, radiator; with fan)

887 kg

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General tightening torques The following tightening torques apply in general unless otherwise specified:*) Thread M5

6,7 Nm

Thread M6

10,2 Nm

Flange screw M6

8,6 Nm

Flange screw M8

26 Nm

Flange screw M10

50 Nm

Flange screw M12

92 Nm

Stud screw in casting M8

13 Nm

Stud screw in casting M10

25 Nm

Thread M14

149 Nm

*) A tolerance of +/- 15% applies to the specified tightening torques unless stated otherwise.

Lubrication Engine oil must be applied to all moving parts before fitting unless otherwise stated.

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Engine assembly Special tools Number 99 318 98 094

Designation Engine support Lifting chain

587 308

Lever block

1 360 442

Lifting eye

Illustration

Removing the engine

Tool board

5. Fit the rear lifting eyes (1360442) and fasten the lifting chain 98 094.

Mind the environment Use a container to avoid spills when draining the coolant and oil. Dispose of used coolant and oilthrough an authorised waste disposal contractor.

1. Drain the oil and coolant.

2. Remove the air filter and the inlet pipe between the turbocharger and the air filter.

Cover the turbo inlet.

6. Fasten the lever block 587 308 to the front lifting eye.

Note The lifting eyes are dimensioned for a maximum inclination angle of 20° when lifting the engine.

7. Undo all the engine brackets and lift away/out the engine.

3. Undo the connections for coolant, charge air pipes between engine and charge air cooler, and ventilation line to the expansion tank.

4. Remove the cables with cable clamps.

Note The engine lifting eyes are sized for lifting the engine only, not the engine together with connected equipment (high-current generator, gearbox, reverse gear, etc.) or frame. All three lifting eyes must be used.

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Fitting the engine Note The engine lifting eyes are sized for lifting the engine only, not the engine together with connected equipment (high-current generator, gearbox, reverse gear, etc.) or frame. All three lifting eyes must be used.

Note The lifting eyes are dimensioned for a maximum inclination angle of 20° when lifting the engine.

1. Fasten the lifting chain 98 094 to the rear lifting eyes (1360442).

2. Fasten the lever block 587 308 to the front lifting eye.

3. Lift the engine in position and bolt it to the front engine suspension.

4. Connect the wiring with clamps.

5. Fit the connections for coolant, charge air pipes between engine and charge air cooler, and ventilation line to the expansion tank.

6. Fit the air filter and the inlet pipe between the turbocharger and the air filter.

7. Fill with oil and coolant as directed in booklet 00:03-01.

8. Test run the engine to check that no leakage occurs. Top up with coolant if necessary.

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Mounting the engine in a universal stand Special tools Number Designation 99 331 Fixture

587 692

Illustration

Tool board

Universal stand

1. Remove the fuel filter, the control unit and the starter motor.

2. Fit tool 99 331 to the universal stand and attach the engine.

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Cylinder head

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

Cylinder head Socket Core plug Rivet plug Valve guide Valve seat insert Valve seat insert Pin Pin Cylinder head gasket Seal Intake valve

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13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

Valve spring Valve spring collar Exhaust valve Valve spring Valve spring Valve spring collar Collet Valve bridge Screw Bearing bracket Shaft Rivet plug

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26.

27.

28.

29.

30.

31.

32.

33.

34.

35.

Tight-fit screw Rocker arm Adjusting screw Hexagon nut Rocker arm Adjusting screw Hexagon nut Rocker arm Adjusting screw Hexagon nut Rivet plug

9

Checking and adjusting the valve clearance and unit injectors Specifications Valve clearance, intake valve(cold engine)

0,45 mm

Valve clearance, exhaust valve (cold engine)

0,70 mm

Measure for unit injector (cold engine)

66,9+/-0,1 mm

Tightening torques (See page 3 for general tightening torques) Lock nut for adjusting screw on the rocker arm for the unit injector

39 Nm

Lock nut for adjusting screw on the rocker arm for the valves

35 Nm

Screw for upper rocker cover

18 Nm

Screw for lower rocker cover

26 Nm

Bearing bracket and rocker arm shaft

105 Nm

Cable connection, unit injector

2 +/- 0,2 Nm

Special tools Number 99 309

Designation Tool to rotate flywheel

99 414

Setting tool

588 179

Torque screwdriver

10

Illustration

Tool board D5 Measuring tool cabinet

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Order of adjustment In order for the adjusting to be carried out on the correct revolution, proceed as follows: 1. Rotate the flywheel so that the 72° mark on the flywheel can be seen in the lower window of the flywheel housing whilst valve overlap occurs on cylinder 5.

2. Then turn the flywheel clockwise so that it passes TDC Down (0°) by about 20° and then turn it anticlockwise until TDC Down (0°) is visible in the lower window on the flywheel housing. The reason for turning past TDC down (0°) and then back is to counteract any backlash.

You are now on the first revolution and can adjust the valves and unit injectors according to the following table.

3. Rotate the flywheel anti-clockwise using tool 99 309 so that the mark on the flywheel is visible in the lower window of the flywheel housing.

Revolution

Mark on flywheel (degrees)

1 1 1 1 1 2 2 2 2 2

TDC Down 0 72 144 216 288 TDC Down 0 72 (432) 144 (504) 216 (576) 288 (648)

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Flywheel seen from the rear of the engine. * Direction of rotation when adjusting.

The solid line shows the order to take the angles on the first round and the broken line the order for round 2.

Adjust unit injector Adjust intake and rocker arm exhaust valves on on cylinder cylinder 2 1

Valve change on cylinder 5

4

2 3

5

4 1

3

5 2

1

3 4

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If reading cannot be taken from underneath: Turn the flywheel with tool 99 309 to valve overlap on cylinder 1 (which corresponds to TDC down (0°) in the lower opening). Then turn the flywheel anti-clockwise 144° at a time and observe the valve overlap. Adjust the valves according to the table below.

Valve overlap on cyl- Adjust the valves inder on cylinder

Adjust unit injector rocker arm on cylinder

TDCdown (0°)

1

5

5

(144°)

2

3

3

(288°)

4

1

1

(432°)

5

2

2

(576°)

3

4

4

The flywheel is also marked at 240°/600° and 120°/480°; these marks apply to 6 cylinder engines.

1. Start by rotating the flywheel so that the mark on the flywheel is visible in the lower window as illustrated. Never read off the flywheel mark in the top window - this reading will be completely wrong..

2. Fit adjusting tool 99 414 with the metal plate around the unit injector.

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!

WARNING!

When the unit injector is checked and the measurement is outside 66.9+/-0.1 mm, it is necessary to be very careful when handling the unit injector.

The spring is pre-tensioned and can come loose, causing personal injury.

Setting tool 99 414 acts as a gauge with the measurement 66.9 mm.

3. When adjusting, loosen the lock nut and adjust the unit injector with adjusting screw 1. The unit injector is correctly set when the small piston 2 is level with the flat upper surface of the tool. Check using a finger. It is possible to feel differences of less than a hundreth of a millimetre. The setting dimension is 66.9 +/-0.1 mm.

Refer to tables in Order of adjustment for unit injectors

The setting tool piston is above or below the flat upper surface of the tool. Adjust the unit injector.

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The setting tool piston is level with the flat upper surface of the tool. The unit injector is correctly adjusted.

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4. Torque tighten the lock nut to 39 Nm after adjusting.

5. Remove tool 99 414.

6. Fit the upper rocker cover and tighten the screws to 18 Nm. 7. Close the bleeder nipple and tighten the banjo screw.

8. Fill and bleed the fuel system, refer to Bleeding the fuel system in booklet 03:04-02.

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Removing the cylinder head 1. Open the bleeder nipple and drain the fuel system by undoing the banjo screw on the back of the fuel manifold.

!

WARNING!

The fuel system must be empty or fuel may run down into the cylinders, which will result in a great risk of liquid hammering. If fuel runs into the combustion chamber, it must be removed immediately using a pump.

2. Clean the rocker cover and the surrounding area and remove the top part of the rocker cover.

3. Detach the cable to the unit injector and remove it from the lower part of the rocker cover.

4. Relieve the pressure on the valves by undoing the bolts on the rocker arm shaft alternately.

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!

WARNING!

Do not lean over the engine when removing the rocker arm shaft. The unit injector spring is pre-tensioned and can come loose, causing personal injury.

Important If the spring comes loose from the unit injector, the unit injector must be renewed.

5. Remove the rocker arm shaft.

6. Remove the bearing bracket.

7. Remove the pushrods.

Note The pushrod for the unit injector is secured with a retaining ring. Jiggle and pull carefully on the pushrod to loosen it.

8. Remove the valve bridges.

9. Remove the lower rocker cover.

10. Remove the unit injector according to section Unit injector- Removal, items 6-11 in booklet 03:04-02.

11. Detach the intake manifold, fuel manifold, ventilation pipe for the cooling system and the exhaust manifold as necessary to remove one or more cylinder heads.

12. Remove the cylinder head. Mark the cylinder heads if more than one is being removed at the same time.

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Fitting the cylinder head Specifications

Tightening torques Cylinder head bolts: - First stage

60 Nm

- Second stage

150 Nm

- Third stage

250 Nm

- Fourth stage

90°

Screw for lower rocker cover

26 Nm

Screw for shaft with rocker arms

105 Nm

Screw for bearing bracket

105 Nm

Exhaust manifold

63 Nm

Inlet manifold

26 Nm

Lubricant Lubricant for the exhaust manifold screws and connections

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561 205

17

1. Check liner height, refer to Measuring the cylinder liner height.

2. Fit a new cylinder head gasket.

3. Fit the cylinder head.

4. The cylinder head bolts can be reused up to 3 times. Therefore, make sure the bolts have no more than 2 punch marks on top of the bolt head. If any of the bolts has 3 marks, it must be replaced with a new one.

5. Lubricate the cylinder head bolts on the thread and under the head. Tighten the bolts in the order given in the figure and in four stages as follows: 1. Tighten all bolts to 60 Nm 2. Tighten all bolts to 150 Nm 3. Tighten all bolts to 250 Nm 4. Finallt, tighten all bolts to 90° 5. Make a mark with a centre punch on the head of the bolt.

6. Fit the lower part of the rocker cover and tighten the bolts to 26 Nm.

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7. Fit the unit injector according to the section Unit injector - Fitting, steps 1-5 in booklet 03:04-02.

8. Fit the pushrods 2.

9. Fit the bearing bracket and torque tighten the bolts to 105 Nm. 10. Fit the valve bridges 4.

Important Lubricate the valve bridges with engine oil.

11. Continue according to the section Unit injector - Fitting, steps 6-8 in booklet 03:04-02.

12. Fasten the fuel manifold and the fuel lines.

Tighten the screws to 26 Nm and the banjo screws to 11 Nm. 13. Tighten the exhaust manifold using a torque of 63 Nm. 14. Attach the venting line for the cooling system.

15. Attach the intake manifold with the wiring bundles.

16. Finish according to the section Unit injector Fitting, steps 9-11 in booklet 03:04-02

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Removal of valves Special tools Number 99 322

Designation Drift

Illustration

Tool board D5

1. Press down the spring using tool 99 322 in a press so that the collets can be removed.

Remove the collets, valve spring collars, springs and valves.

2. Place the valves in a stand or mark them so that they can be refitted in the same position in the cylinder head.

Fitting the valves Special tools Number 99 322

Designation Drift

Illustration

Tool board D5

1. Lubricate all parts well with engine oil before assembly.

2. Fit the valve in the guide.

3. Fit a new valve stem seal as shown in page 22.

4. Fit the valve springs and the valve spring collar.

5. Compress the springs in a press using tool 99 322 and fit the collets. Take care to fit the collets in the correct position.

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Checking and machining of valves Specifications Intake valve Head angle

19,5 °

Minimum dimension A for ground valve

2,6 mm

Exhaust valve Head angle

44,5 °

Minimum dimension A for ground valve

1,8 mm

- Check dimension A on all valves.

- Grind the valves in a valve grinding machine

Minimum dimension A for ground valve, see table

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Renewal of valve stem seal Special tools Number 99 323

Designation Drift

Illustration

Tool board D5

1. Remove the valve.

2. Remove the valve stem seal with a pair of pliers.

3. Fit the valve.

4. Tap in a new valve stem seal carefully using tool 99 323 and a hammer.

5. Fit springs and collets according to page 20.

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Renewal of valve seats Special tools Number 99 384

Designation Drift

99 385

Shank

Illustration

Tool board D1-A3

D1-B1

1. Remove the valve seat inserts. Use a discarded valve that has been ground so that the diameter of the disc is slightly smaller than the inside diameter of the seat.

2. Fit the valve and weld around it with an electric welder. Cool with water.

The valves welded to valve seats

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3. Turn over the cylinder head and knock the valve stem so that the valve and seat insert fall out.

!

WARNING!

Wear protective goggles. Always turn the cylinder head with the underside face down while knocking out the valve seat insert. Otherwise, there is a risk that loose shivers of metal can cause personal injury.

4. Press in new valve seat inserts. Use drift 99 384 and shank 99 385. Cool the drift and valve seat to about -80°C with dry ice or liquid oxygen. Pressing must be carried out rapidly.

!

WARNING!

Be careful when handling the cold parts and the cooling agents named above.

Risk of frost injuries.

Oversize valve seat inserts can be fitted if the valve seat insert position has been damaged. The position must then be machined using tool 587 277.

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Machining the cylinder head Valve seat dimensions, machining values

Intake valve A = 1,9 - 2,6 mm B = 0,75 - 1,8 mm C = diameter 39,8 +/- 0,5 mm (setting value for machining tool)

Exhaust valve A = 1,8 - 2,6 mm B = 0,66 - 1,8 mm C = diameter 37,9 +/- 0,5 mm (setting value for machining tool)

Specifications Intake valve seat Seat angle

20,0°-20,5°

Width of contact surface A

1,9 - 2,6 mm

Valve seat insert, outer diameter

46,054 - 46,065 mm

Valve seat insert position, diameter

46,000 - 46,016 mm

Valve seat insert position, depth

11,25 - 11,35 mm

Distance B between the cylinder head plane and the valve head

0,75 - 1,80 mm

Oversize valve seat insert External diameter

46,254 - 46,265

Valve seat insert position, diameter

46,200 - 46,216

Cooling temperature when fitting valve seat insert

approx -80 °C

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Exhaust valve seat Seat angle

45,0°-45,5°

Width of contact surface A

1,8 - 2,6 mm

Valve seat insert, outer diameter

44,081 - 44,092 mm

Valve seat insert position, diameter

44,000 - 44,016 mm

Valve seat insert position, depth

11,25 - 11,35 mm

Distance B between the cylinder head plane and valve head

0,66 - 1,80 mm

Oversize valve seat insert External diameter

44,281 - 44,292

Valve seat insert position, diameter

44,200 - 44,216

Cooling temperature when cooling valve seat insert

approx -80 °C

Tool Number 587 277

Description Valve seat cutter

588 487 588 488 588 489 587 145

Cutter (exhaust valve) Cutter (intake valve) Guide spindle Valve seat cutter

587 146

Cutter attachment

26

Illustration -

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For machining measurement and oversize valve seat inserts, refer to Specifications on pages 25 and 26.

The following description applies to valve seat cutter 587 277.

1. Make sure the contact surface and magnetic stand are level and clean. Clean the valve guides.

2. Select the largest spindle that moves easily in the valve guide. Insert the guide spindle and turn the feed screw to its uppermost position.

3. Select the cutter and fit it.

4. Release the quick-action lock and move the pivot plate to the upper position with the adjusting screw.

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5. Set up the dial on the cutter adjuster using a valve.

6. Adjust the cutter. Diameter 37.9 mm and 39.8 mm respectively, refer to Valve seat dimension, machining values.

7. Turn off the magnet (position 2). Insert the guide spindle into the valve bushing. Adjust the pivot plate so that the distance between the cutter and the valve seat is approximately 1 mm. Centre the tool precisely.

8. Turn on the magnet (position 1).

9. Apply the quick-action lock. Make sure the crank can be turned easily. If not, redo the centering.

10. Machine the valve seat by cranking clockwise while turning the feed screw. Never crank counterclockwise, as this could damage the cutter.

Lubricate with cutting oil while machining.

11. When the surface of the valve seat has been machined, reduce the cutting pressure by turning 2-3 revolutions without any feed.

Continue turning while backing off the feed screw. The valve seat cutter is now ready for the next valve seat.

Cutter tool 588 145 with supplementary kit 588 146 can also be used for the machining.

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Renewal of valve guides Special tools Number 99 382

Description Drift

99 383

Drift

Illustration

Tool board D1-C6

D1-B1

1. Press out the valve guides using drift 99 383.

2. Press in the new valve guides using drift 99 382. Press the guide down as far as the drift allows, i.e. until it makes contact with the spring seat in the cylinder head.

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Renewal of sleeves for unit injectors Special tools Number 99 394

Description Guide

Illustration

Tool board D2-A1

99 395

Drift

D2-A1

99 397

Extension piece with threaded shaft

D2-C5, C6

588 221

Pilot tap

The cylinder head must be removed when renewing the sleeve for the unit injector. The valves do not need removing. The illustrations show the cylinder head with the valves removed so that the working method can be seen more clearly.

1. Thread the bottom part of the sleeve with pilot tap 588 221 and guide 99 394. Use extension piece 99 397.

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2. Knock out the pilot tap and sleeve from underneath. Use a 100 mm long metal rod with diameter 9 mm.

3. Degrease and check the contact surfaces of the sleeve and cylinder head. Smooth off any burrs and irregularities that may score the sleeve.

4. Degrease the new injector sleeve and apply a thin film of sealing agent 561 200 on the sleeve and cylinder head contact surfaces.

5. Press in the sleeve with drift 99 395 and guide 99 394.

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Cylinder block Reconditioning Heat arising from the main bearings seizing and rotating in the cylinder block will change the properties of the material in the cylinder block.

These cylinder blocks must be discarded.

If the main bearing seizes but does not rotate in the cylinder block, the cylinder block can be overhauled. The main bearing seats must comply with the demands on roundness given in the table.

Machining out-of-round main bearing seats is something we do not recommend.

Tightening torques Main bearing cap bolts: Up to engine No. 6 285 724 From engine No. 6 285 724

50 Nm + 90 ° 200 Nm + 90 °

1. Measure the diameter at four different positions as illustrated. The diameter must be measured with the main bearing caps tightened and without main bearings.

2. Compare the dimensions with those in the table.

Smallest permitted diameter

Largest permitted diameter

Maximum permitted difference between maximum and minimum diameter on same main bearing seat

112,200 mm

112,222 mm

0,016 mm

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Removal of cylinder liner Special tools Number 99 066

Description Cylinder liner puller

Illustration

Tool board D2

Note The mark must be made only on the surface indicated in the illustration.

Other surfaces are for sealing. If a marker pen is used, the marking can be done anywhere.

1. Mark the cylinder liners with numbers 1-5 if more than on cylinder is removed. The mark should face forward. The mark is necessary so that the liners can be refitted in the same place and position as previously.

2. Remove the cylinder liner using puller 99 066.

3. Remove the sealing rings in the cylinder block.

Puller for cylinder liner with hydraulic hole cylinder

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Fitting of cylinder liner 1. Carefully check the cylinder liners before fitting them, both new and old, for cracks that can arise during transport or careless handling. Tap the liner carefully with a metal object. It should give a clear metallic ring if it is intact. If it is cracked, it will sound "cracked" and should be replaced.

2. Make sure the interior of the cylinder block is clean. Clean the O-ring surfaces.

3. Check the cylinder liner height as described in Measuring the cylinder liner height.

4. Remove the cylinder liner.

5. Check that the holes for coolant to the cylinder head and cylinder liner are not blocked.

6. Lubricate the O-rings that seal between the cylinder liner and the engine block with glycerine or unscented soap and fit them.

7. Lubricate the lower guide surface on the cylinder liner.

8. Carefully tap the liner down with a rubber mallet.

Note Turn already used liners with the stamped cylinder number facing forward.

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Measuring the cylinder liner height Specifications Cylinder liner height above cylinder block

0,20 - 0,30 mm

Maximum permitted difference in height between two diametrically opposite points of a cylinder liner

0,02 mm

Special tools Number 87 198

Description Straight edge

98 075

Dial gauge

Illustration

Tool board D2

D2

1. Thoroughly clean the cylinder block liner shelf, the face around the cylinder, the cylinder liner shelf and the upper face of the cylinder liner.

2. Fit the cylinder liner without sealing rings and push down using two tension lugs 98 515. Tighten the bolts to 20 Nm. Important The tension lug bolts must not be tightened more than 20 Nm. Otherwise the cylinder liner may be damaged.

3. Place straight edge 87 198 with dial gauge 98 075 on the liner and zero the dial gauge to the liner (A). Slide the tip of the dial gauge over to the cylinder block (B) and measure the height of the liner (A-B) as illustrated.

Measure each liner at two diametrically opposite points.

4. The cylinder liner must be slightly above the face of the cylinder block.

5. The height of the cylinder liner D (=A-B) above the block should be 0.20 – 0.30 mm.

6. The difference between two diametrically opposite points on the same cylinder liner may be max. 0.02 mm.

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A = Measuring surface on cylinder liner B = Measuring surface on cylinder block C =Tip of dial gauge D =Height of cylinder liner D = A-B

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Machining cylinder liner height If, during control measuring, the cylinder liner does not reach the specified value the liner seat must be machined.

Adjust the liner to the correct height using a shim.

Shims are available in thicknesses of 0.20 mm, 0.30 mm and 0.40 mm.

If the cylinder liner height should be increased less than e.g. 0.20 mm, machine the bearing seat until the liner height including shim is correct.

Important If a shim is used to adjust the liner height and the adjustment measurement does not correspond to existing shims, the cylinder liner height must always be machined.

Tolerances for liner height Lowest permissible cylinder liner height before machining

0,15 mm

Permissible cylinder liner height on engines with machined liner seats

0,20-0,30 mm

Desired measurement when machining

0,25 mm

Example of calculation of cutter depth Height required

0,25 mm

Current cylinder liner height

0,14 mm

Increasing cylinder height (0.25-0.14)

0,11 mm

Shim thickness

0,20 mm

Material to be removed. (0,20-0,11)

0,09 mm

Special tools Number 587 512

Description Cylinder liner cutter

588 672

Extension

36

Illustration

Tool board D2

D2

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1. Clean the contact surface between the centering ring (which is included in the extension kit) and the top plane of the cylinder block.

Note It is important for the surface to be cleaned thoroughly otherwise the cylinder liner seat may be cut to the wrong depth or may be slanted.

2. Fit extension 588 672 on the cylinder liner cutter 587 512.

3. Set the depth of the extension to 206 mm.

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4. Position the centering ring over the relevant cylinder and then position the cylinder liner cutter. Energize the magnet on the cylinder liner cutter by setting the switch to position 1.

5. Check that the tool (cutter) does not touch the edge of the liner seat when the cylinder liner cutter is fitted in the centering ring. Otherwise the vertical feed screw must be wound up until the cutter is released from the liner seat.

6. Lift the rapid feeder ring and move the cutter by hand until it is positioned above the liner seat surface without including the cylinder block walls.

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7. Wind round and at the same time turn the vertical feed screw clockwise until the cutter just touches the liner seat.

8. Lift the rapid feed ring and move the cutter back so that it is within the liner seat surface.

9. Adjust the vertical feed screw in order to start machining. The maximum feed per cut is 0.05 mm. If 0.05 mm is not enough, several cuts may be required until the required position is reached.

10. Wind clockwise with an even movement.

Hold in the horizontal feed screw with the other hand at the same time. The cutter will be fed horizontally at 0.13 mm per turn. Wind carefully when the cutter starts to approach the outer edge of the liner seat. Release the horizontal feed screw when the cutter has gone over the edge so that feeding stops.

Important Never wind the cylinder liner cutter counter-clockwise, otherwise the cutter will break.

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Renewal of rear crankshaft seal Special tools Number 99 410

Description Assembly tool

Illustration

Tool board D5

1. Remove the flywheel as described in Flywheel, removing.

2. Remove the crankshaft seal using a screwdriver. Take care not to scratch the sealing surfaces on the crankshaft and the flywheel housing.

Note The crankshaft seal must be fitted dry and must not be lubricated. The sleeve in the seal must not be removed until just before the crankshaft seal is to be fitted on the engine.

3. Fit the new crankshaft seal using tool 99 410.

Place the crankshaft seal on the tool and fasten the tool with the bolts..

4. Turn the tool clockwise until is stops in order to attain the correct crankshaft seal position.

5. Fit the flywheel as described in Flywheel, fitting.

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Removal of flywheel housing 1. Remove the flywheel as described in Removal of flywheel.

2. Remove the starter motor.

3. Detach and remove any pumps in the power take-off location.

4. Remove the flywheel housing.

Fitting the flywheel housing Specifications Tightening torque Screws for flywheel housing

M10 : 50 Nm M12 : 90 Nm

Sealing agent Sealing agent for flywheel housing

816 064

Special tools Number

Description

Illustration

Tool board

588 189

Air-operated gun

-

-

584 117

Adapter for cartridge

-

-

584 118

Nozzle

-

-

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1. Remove all old sealing compound on the sealing surfaces of the timing gear casing and timing gear plate. Clean off any oil and grease using an alcohol based cleaning agent.

Important Clean carefully, the sealing surfaces must be completely clean and free from grease.

2. Apply the sealing agent (816 064) on the timing gear housing with the air powered sprayer (588 189), cartridge adapter (584 117) and nozzle (584 118). The width of the bead should be between 0.8 and 1.2 mm. Follow the pattern as illustrated.

Important Ensure that you apply sealing agent inside the screwholes, but without allowing sealing agent into the crankcase. The sealing agent may block channels and nozzles.This is particularly important to bear in mind around oil ways, where the flow of oil to the air compressor or injection pump can be blocked.

Apply sealing agent to the timing gear casing on the side against the timing gear plate.

Apply sealing agent around the screwholes marked with arrows.

Important Assembly must be completed within 25 minutes of starting to apply the sealing agent.

3. Fit the flywheel housing against the transmission plate.

Note The bolts are of various sizes and lengths. Ensure that they are fitted in the correct places.

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4. Torque tighten the M12 bolts to 90 Nm and the M10 bolts to 50 Nm.

5. Fit the power steering pump.

6. Fit the starter motor.

7. Fit the flywheel, see Fitting of flywheel.

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Renewal of the front crankshaft seal Front crankshaft seal

1.

2.

3.

4.

5.

44

Front cover Shaft seal Pin Gasket Flange bolt

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Tightening torques Screws for crankcase ventilation pipes against the rocker cover

12 Nm

Bolts for the vibration damper

135 Nm+/-20%

Special tools Number

Description

Illustration

99 374

Press tool for crankshaft seal

Tool board D5

1. Remove the poly-V-belt and the pulley.

Note The crankshaft seal seals against the belt pulley. Handle the pulley with care.

Sealing surface for crank shaft seal

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2. Remove the crankshaft seal using a screwdriver. Take care not to damage the sealing surface in the housing.

3. Wipe clean the sealing ring seat in the housing.

Note The crankshaft seal must be fitted dry and must not be lubricated. The sleeve in the seal must not be removed until just before the crankshaft seal is to be fitted on the engine.

4. Place the new seal in tool 99 374 and press it in place by tightening the bolts alternately.

The seal is correctly fitted when the tool bottoms.

5. Remove the tool. To make removal easier, fit the bolts into the threaded holes and use as a handle.

The seal is correctly fitted when the tool bottoms

6. Wipe clean the sealing surface on the belt pulley and fit it immediately.

7. Fit the poly-V-belt.

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Crank mechanism See page 90 for description of Balance shaft unit

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Connecting rod Bolt Bearing bushing Bearing cap Pin Bearing shell Crankshaft Gear wheel Vibration damper Driver

01:07-02

11.

12.

13.

14.

15.

16.

17.

18.

19.

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Bolt Crankshaft gear Pin Flywheel Ring gear Ball bearing Snap ring Bolt Piston

47

Removal of connecting rod with piston 1. Remove the cylinder head as described in Removal of cylinder head.

2. Remove the oil sump.

3. Remove the balance shaft unit in accordance with description on page 91.

4. Remove the piston cooling nozzle in the cylinder block.

Important The piston cooling nozzle must not be damaged. The oil jet must hit the piston precisely. If it does not, the piston will become too warm resulting in engine breakdown.

Damaged nozzles must not be re-aligned, renew them instead.

5. Remove the bearing cap and bearing shells.

Protect the oilway in the crankshaft e.g. by winding tape around it with the adhesive side out.

6. Mark the piston before removing it. Parts which should be reused must be refitted in the same place and position. Lift out the piston and connecting rod.

7. For dismantling see Renewing a piston.

Note Always check the connecting rod as described in Connecting rod, checking, if the cylinder has seized, been filled with water or has a broken valve. Bent connecting rods must not be straightened.

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Fitting of connecting rod with piston Tightening torques Bolts for oil sump

32 Nm

Connecting rod bolts

20 Nm + 90°

Piston cooling nozzle

23 Nm

Special tools Number 98 212

Description Piston ring compressor

Illustration

Tool board D3

1. Lubricate the piston, piston rings, cylinder liner and piston ring compressor with engine oil.

2. Remove the protection on the connecting rod journal and also lubricate the journal.

3. Turn the piston rings so that the gaps are distributed around the piston.

4. Fit the upper connecting rod bearing shell and lubricate the bearing surface.

5. Fit the connecting rod and piston. Clamp the piston ring compressor 98 212 and push the piston into the cylinder.

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6. Fit the connecting rod bearing shell into the cap and lubricate the bearing surface. Fit the cap.

7. Lubricate the bolts, fit them and torque tighten to 50 Nm + 90°.

8. Fit the piston cooling nozzle. Tightening torque 23 Nm. Important The piston cooling nozzle must not be damaged. The oil jet must hit the piston precisely. If it does not, the piston will become too warm resulting in engine breakdown.

Damaged nozzles must not be re-aligned, renew them instead.

9. Fit the balance shaft unit in accordance with description on page 94.

10. Fit the oil sump. Torque tighten the bolts to 32 Nm. 11. Fit the cylinder head. Tighten the cylinder head bolts as described in Fitting of cylinder head.

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Renewing a piston Specifications Piston rings Number of compression rings

2

Gap: 1st ring

0,35 - 0,60 mm

2nd ring

0,45 - 0,65 mm

Maximum play in groove, 2nd ring

0,25 mm

Number of oil scraper rings

1

Gap

0,40 - 0,65 mm

Maximum play in groove

0,25 mm

Important Turn the rings marked "TOP" with the mark face up.

Special tools Number 87 362

Description Drift

Illustration

Tool board D3

Description Piston ring expander

Illustration

Tool board D3

Other tools Number 587 309

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1. Place the connecting rod in a vice with soft jaws. Remove the retaining rings for the gudgeon pin.

2. Push out the gudgeon pin using drift 87 362.

3. Remove the piston rings using tool 587 309.

Take care not to scratch the surface of the piston crown with the piston rings.

4. When cleaning graphited pistons in a machine, the graphiting may disappear. This does not matter after they have been in use for a while. However, new pistons should be washed carefully using white spirit or the like.

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5. Make sure the piston ring gaps do not exceed the permitted limit. Place the piston rings in the cylinder liner and measure the gap using a feeler gauge. For permitted gap, see Specifications.

6. Fit the piston rings using tool 587 309. The oil ring is fitted with an expander. Compression rings marked with TOP must be turned with TOP face up.

7. Oil all the bushings, the gudgeon pin hole and the gudgeon pin before assembling.

8. Fit the piston to the connecting rod. Press in the gudgeon pin with drift 87 362 and fit the second retaining ring for the gudgeon pin.

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Checking connecting rods Tools Number 587 110

Description Checking device

Illustration

Tool board -

Check the connecting rods using tool 587 110.

Make sure the gudgeon pin bushing is not damaged and then proceed as below: 1. Fit the bearing cap as marked and torque tighten the bolts to 20 Nm +90°.

2. Fit the connecting rod in the tool using the expander and put the corresponding gudgeon pin in the gudgeon pin bushing.

3. Then apply the indicator to the gudgeon pin.

4. Check whether the connecting rod is twisted with the indicator studs horizontal.

Checking if connecting rod is twisted.

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5. Check whether the connecting rod is twisted with the indicator studs vertical.

Checking if connecting rod is twisted.

6. The distance between the indicator studs on the tool illustrated here is 75 mm. The distance between one of the indicator studs and the measuring surface must be maximum 0.05 mm when measured using this tool.

Check with a feeler gauge.

7. Check also whether the connecting rod is bent in an S-shape. This is done by measuring the distance between the outside of the connecting rod bushing and the level surface of the tool. Turn the connecting rod around and measure the corresponding distance. The difference must not exceed 0,6 mm.

Obs! Bent connecting rods must not be straightened. They should be scrapped.

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Checking if connecting rod is bent in an S-form

55

Renewal of bearing bushing in connecting rod Special tools Number 99 403

Description Tool for renewing bearing bushing

Illustration

Tool board

Use tool 99 403 when renewing the bearing bushing.

The tool comprises three parts: 1. Pressplate with guide pin 2. Press drift 3. Supports There are different supports, depending on the engine type. The support marked D is for 9 litre engines.

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1. Place the connecting rod on the pressplate so that the wide end of the connecting rod is resting against support D. Turn the pressplate so that the smaller diameter faces the bearing bushing and press out the bearing bushing.

2. Turn over the press drift and mount a new bearing bushing onto it. Press in the bearing bushing.

3. After pressing in a new bearing bushing, it must be finish-turned. This requires special equipment. Measurements as illustrated.

Diametre, d= 54,030 - 54,043 mm Surface finish = 0,6 Ra

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Removal of flywheel Special tools Number 87 368

Description Puller bolt

Illustration

Tool board AM1, D3, B1, AD1

1. Remove the speed sensors from the flywheel housing in order to avoid damaging them.

2. Use tool 99 411 to lock the flywheel.

3. Remove the bolts for the flywheel.

4. Pull off the flywheel from the crankshaft using puller bolts 87 368.

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Fitting the flywheel Specifications Tightening torque Flywheel bolts

130 Nm + 90°

Special tools Number

Description

Illustration

Tool board

99 324

Guide pins

D5

99 411

Tool for locking flywheel

D5

1. Fit two guide pins 99 324 in the crankshaft flange.

2. Fit the flywheel on the crankshaft.

Important Always use new bolts.

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3. Use tool 99 411 to lock the flywheel.

Locking the flywheel with tool 99 411.

4. Torque tighten the bolts alternately to 130 Nm and then a further 90°.

5. Fit the engine speed sensors.

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Support bearing Renewal Special tools Number 99 250

Description Drift

Illustration

Tool board D3, C4

The following job operations on the flywheel are done with the flywheel removed.

1. Remove the retaining rings on both sides of the support bearing.

2. Knock out the support bearing from the flywheel using drift 99 250.

3. Fit the inner retaining ring and a new support bearing using drift 99 250.

4. Fit the outer retaining ring.

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Renewal of ring gear Renew the flywheel ring gear if the gear teeth have become so worn that the starter motor pinion will not engage.

1. Grind a groove as deep as possible in the ring gear and crack it open with a chisel. Remove the ring gear from the flywheel.

!

WARNING!

Use protective goggles due to the risk of metal shivers.

2. Clean the contact surfaces on the flywheel with a wire brush.

3. Heat the new ring gear evenly around its circumference to 100 - 150 °C. 4. Place the heated ring gear on the flywheel so that the marking with the part number is facing the engine when fitting the flywheel.

Make sure the ring gear is securely against the flywheel. If necessary, knock down the ring gear with a plastic hammer.

5. The ring gear must not be cooled rapidly but be left to cool in the open air.

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Removal of crankshaft 1. Remove the crankshaft gear as described in Engine transmission - Removal of crankshaft gear.

2. Remove the oil sump, oil suction pipe with strainer and the oil pump.

3. Remove the balance shafts as described in Balance shaft unit - Removal.

4. Remove the pistons and connecting rods as described in Crank mechanism - Removing connecting rods and pistons.

5. Remove the crankshaft bearing caps, main bearings and also the axial washers at the rearmost main bearing cap.

Note The main bearings and bearing caps are marked and must be refitted in the same place.

6. Lift out the crankshaft.

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Fitting the crankshaft Tightening torques Main bearing cap bolts, engine number up to 6 285 724

50 Nm + 90°

Main bearing cap bolts, engine number from 6 285 724

200 Nm + 90°

Important All parts must be cleaned before fitting.

1. Place the bearing shells in the main bearing seats in the engine block and then lubricate the bearing surface with engine oil.

Note The outside of the bearing shells must not be lubricated.

2. Lift in the crankshaft.

3. Fit the thrust bearing washers at the rear main bearing cap.

4. Place the main bearings in the main bearing caps and fit them.

Note Fit the main bearing caps at the same location as before removal. If the main bearings are reused they should be placed in the same locations.

5. Torque tighten the cap bolts to 50 Nm +90°

for engine numbers up to 6 285 724 and 200 Nm + 90° for engine numbers from 6 285 724.

Motornummer:

50 Nm + 90

< 6 285 724

6. Fit the pistons with connecting rods according to Fitting of piston and connecting rod.

8. Fit the oil pump, oil suction pipe with strainer and the oil sump.

9. Fit the crankshaft gear as described in Fitting the crankshaft gear,.

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90

o 100150

7. Fit the balance shafts as described in Balance shaft unit - Fitting

Motornummer:

≥ 6 285 724

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Checking and grinding of crankshaft Measure the crankshaft journals. Use a micrometer to measure two diameters at right angles to each other If either of these diameters is lower than the minimum indicated limit, regrinding of the crankshaft should be considered.

Consideration must also be given to oil pressure, which is in turn affected by such things as main bearing and connecting rod bearing wear.

For dimensions see Dimensions on next page.

Measuring the crankshaft.

When regrinding, stated undersizes must be complied with. Suitable bearings are available for these sizes.

It is important that the fillet radius of the journals is correct.

See next page for correct values.

Measure the fillet radius with a template.

After grinding the journals, the oil hole connections to the bearing surfaces should be rounded off and polished.

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Dimensions Main bearing journals Standard, diameter

107,978-108,000 mm

Undersize 1, diameter

107,728-107,750 mm

Undersize 2, diameter

107,428-107,500 mm

Undersize 3, diameter

107,228-107,250 mm

Undersize 4, diameter

106,978-107,000 mm

Hole recess radius

4,75-4,85 mm

Surface quality

0,25 Ra

Connecting rod journals Standard, diameter

86,978-87,000 mm

Undersize 1, diameter

86,728-86,750 mm

Undersize 2, diameter

86,478-86,500 mm

Undersize 3, diameter

86,228-86,250 mm

Undersize 4, diameter

85,978-86,000 mm

Hole recess radius

4,8-5,2 mm

Surface quality

0,25 Ra

Width, max.

56,05

Radial clearance

0,051-0,114 mm

Thrust washers Standard, thickness

3,370-3,430 mm

Oversize 1, thickness

3,450-3,510 mm

Oversize 2, thickness

3,500-3,560 mm

Oversize 3, thickness

3,630-3,690 mm

Oversize 4, thickness

3,880-3,940 mm

Axial clearance

0,138-0,380 mm

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Engine transmission

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1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

35.

68

Camshaft Pin Shaft Roller tappet Roller tappet Snap ring Snap ring Guide sleeve Shaft Roller tappet Roller tappet Snap ring Snap ring Guide sleeve Flange bolt Banjo screw Pushrod Pushrod Camshaft bearing Camshaft gear Hexagon bolt Guide flange Thrust washer Flange bolt Crankshaft gear Intermediate gear Intermediate gear Ball bearing Shaft Snap ring Spacing sleeve Bolt Hydraulic pump gear Oil pump gear Compressor gear

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Removal of intermediate gear Special tools Number

Description

Illustration

Tool board

99 074

Impact drift

D1

99 309

Flywheel turning tool

D5

Other tools Number

Description

587 526

Puller

Illustration

Tool board -

The timing gear has one or two intermediate gears depending on specification. These gears should be removed in the same manner.

1. Turn the crankshaft so that cylinder number 1 is close to TDC. Use tool 99 309 and ratchet handle on the flywheel starter ring gear.

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2. Remove the flywheel as described in the section Removal of flywheel.

3. Remove the flywheel housing as described in Removal of flywheel housing.

4. Manufacture a thread block according to the sketch.

5. The shaft on which the gear is located has a groove. Fit puller 587 526, slide hammer 99 074 and the thread block. Pull off the gear and shaft .

Important After removing the intermediate gear, neither the camshaft nor the crankshaft must be rotated. This may cause pistons and valves to collide and be damaged.

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Fitting the intermediate gear Tightening torque Bolts for intermediate gear

50 Nm + 60°

1. Check that cylinder number 1 is close to TDC. The markings on the camshaft gear and crankshaft gear must point towards the centre of the intermediate gear.

2. Lubricate the bearing surfaces

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3. Fit the intermediate gear against the camshaft gear and the crankshaft gear so that the markings point towards each other.

4. Fit the second intermediate gear if there is any.

Note The crankshaft gear has different markings for the different engine types. See picture

5. Tighten the bolts on the intermediate gears to 50 Nm + 60°.

6. Fit the flywheel housing as described in the section Fitting the flywheel housing.

7. Fit the flywheel as described in the section Fitting the flywheel.

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Renewal of bearing in the intermediate gear for the fuel pump (or compressor and hydraulic pump if any) Special tools Number

Description

Illustration

Tool board

87 348

Drift

AM1

87 592

Drift

-

1. Remove the intermediate gear according to Removal of intermediate gear.

2. Remove the snap ring.

3. Press out the bearing assembly from the gear.

4. Press out the shaft of the bearing.

5. Press in the shaft in a new bearing using tool 87 348. Do not press on the outer ring.

6. Press the ring on the shaft journal.

7. Press in the bearing assembly in the intermediate gear. Use tool 87 592.

8. Fit the snap ring.

9. Fit the intermediate gear according to Fitting the intermediate gear.

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Renewal of bearing in the intermediate gear for the camshaft Special tools Number

Description

Illustration

Tool board

87 348

Drift

AM1

87 592

Drift

-

1. Remove the intermediate gear according to Removal of intermediate gear.

2. Press out the shaft of the bearing.

3. Press off the bearing inner ring from the shaft and remove the snap ring.

4. Place the removed bearing inner ring in the bearing and press out the bearing with drift 87 348.

5. Press on a new bearing on the shaft end with drift 87 348.

Note Do not press on the outer ring.

6. Press in the bearing with shaft into the intermediate gear with drift 87 592.

7. Fit the snap ring.

8. Press the spacing sleeve on the shaft end.

Make sure that the shaft end stands on the press table.

9. Fit the intermediate gear according to Fitting the intermediate gear.

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Removal of camshaft gear Special tools Number

Description

99 309

Flywheel turning tool

Illustration

Tool board -

1. Turn the crankshaft so that cylinder number 1 is close to TDC. Use tool 99 309 and ratchet handle on the flywheel starter ring gear.

2. Remove the flywheel as described in the section Removal of flywheel.

3. Remove the flywheel housing as described in Removal of flywheel housing.

4. Remove the intermediate gear.

Important After removing the intermediate gear, neither the camshaft nor the crankshaft must be rotated. This may cause pistons and valves to collide and be damaged.

5. Remove the camshaft gear.

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Fitting the camshaft gear Tightening torque Bolts for the camshaft gear

63 Nm

1. Fit the camshaft gear and tighten the bolts to 63 Nm. 2. Fit the intermediate gear according to Fitting the intermediate gear , points 1-2.

3. Fit the flywheel housing as described in the section Fitting the flywheel housing.

4. Fit the flywheel as described in the section Fitting the flywheel.

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Removal of crankshaft gear Special tools Number

Description

99 309

Flywheel turning tool

Illustration

Tool board -

1. Turn the crankshaft so that cylinder number 1 is close to TDC. Use tool 99 309 and ratchet handle on the flywheel starter ring gear.

2. Remove the flywheel as described in the section Removal of flywheel.

3. Remove the flywheel housing as described in Removal of flywheel housing.

4. Remove the intermediate gear.

Important After removing the intermediate gear, neither the camshaft nor the crankshaft must be rotated. This may cause pistons and valves to collide and be damaged.

5. Remove the crankshaft gear.

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Fitting the crankshaft gear 1. Fit the crankshaft gear.

2. Fit the intermediate gear according to Fitting the intermediate gear , points 1-2.

3. Fit the flywheel housing as described in the section Fitting the flywheel housing.

4. Fit the flywheel as described in the section Fitting the flywheel..

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Removal of camshaft 5. Remove the flywheel as described in the section Removal of flywheel.

6. Remove the flywheel housing as described in Removal of flywheel housing.

7. Remove the rocker covers.

8. Remove rocker arms, pushrods and valve bridges.

9. Remove the intermediate gear according to Removal of intermediate gear, and the guide flange bolts.

10. Remove the camshaft gear.

11. Remove the timing gear plate.

12. Remove the camshaft covers.

13. Remove the valve tappets.

Note Mark the valve tappets because they must be refitted in the same places.

14. Pull the camshaft backwards. Take care not to damage the cams and bearings.

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Fitting the camshaft Specifications Tightening torques Flange bolts and banjo screws for valve tappets

32 Nm

Bolts for the camshaft gear

63 Nm

Bolts for the timing gear plate

63 Nm

Camshaft covers

32 Nm

Sealing agent Sealing agent for the flywheel housing

816 064

Axial play Allowed axial play

0,05-0,35 mm

Tools Number

Description

Illustration

Tool board

588 189

Air-operated gun

-

-

584 117

Adapter for cartridge

-

-

584 118

Nozzle

-

-

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1. Lubricate camshaft bearings with engine oil and fit the camshaft. Take care not to damage the cams and bearings.

2. Lubricate with engine oil and fit the valve tappets in the same places as they were before removal. Tighten the banjo bolts to 32 Nm. 3. Fit the camshaft covers. Tighten the bolts to 32 Nm. 4. Fit the guide flange bolts.

Now the camshaft axial clearance can be checked: • Fit the camshaft gear temporarily.

• Measure the camshaft axial clearance using a dial gauge. The axial clearance should be between 0.05 - 0.35 mm.

• If the clearance is outside the permitted range, renew the thrust washer.

• Remove the camshaft gear.

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5. Remove all old sealing compound on the cylinder block and the sealing surface on the timing gear plate. Clean off any oil and grease from the sealing surfaces using an alcohol based cleaning agent.

Important Clean thoroughly, as the sealing surfaces must be completely free of grease.

6. Apply sealant using the special nozzle onto the cylinder block. The width of the bead should be between 0.8 and 1.2 mm. Follow the pattern as illustrated..

Applying sealing agent onto the cylinder block..

Important Ensure that you apply sealant inside the screwholes, but without allowing sealant into the crankcase. The sealant may block channels and nozzles. This is particularly important to bear in mind around oil ways, where the flow of oil to the air compressor can be blocked..

Important Assembly must be completed within 25 minutes of starting to apply the sealant..

7. Fit the timing gear plate onto the cylinder block. Tighten the bolts to 63 Nm.

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8. Fit the camshaft gear and torque tighten the bolts to 63 Nm. 9. Fit the intermediate gear according to the section Fitting the intermediate gear.

10. Ensure that the markings on the camshaft gear point towards the centre of the intermediate gear.

11. Fit the flywheel housing according to the section Fitting the flywheel housing.

12. Fit the flywheel as described in Fitting the flywheel.

13. Fit the push rods, rocker arms etc.

Checking camshaft setting 1. Set the crankshaft to TDC after the compression stroke on cylinder number one.

2. Put two dial gauges against the valve spring thrust washers.

3. Adjust the rocker arms to eliminate clearance plus a further 0.1 mm (so that both valves are open by 0.1 mm).

4. Zero both the dial gauges.

5. Turn the crankshaft one revolution in the direction of rotation until the crankshaft returns to TDC. 6. Read off both dial gauges and compare with the values given below: Intake valve lifting height 0,37-1,47 Exhaust valve lifting height 0,16-1,16

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Renewing the camshaft bearings Special tools Number

Description

Illustration

Tool board

99 003

Hydraulic cylinder

H1

99 004

Air-operated hydraulic pump

H1

99 373

Tool for renewing camshaft bearings

D5

1. Remove the camshaft according to the section Removal of camshaft.

2. Remove the cover for the camshaft at the front of the engine.

3. Wipe the bearing seat surfaces clean around the old bearings.

Note Wipe around the edges and the bearing seat surfaces around the old bearings to avoid damaging the contact surfaces when fitting the new bearings

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4. Place the new bearings in the space between the bearing seats for the camshaft.

109 690

Note The recess in the bearing joint must be turned towards the front of the engine.

5. Place the flange nuts on the threaded stem, part of tool 99 373, as illustrated.

Tool 99 373 1. Threaded rod with 8 flange nuts 2. Press drift 3. Flange

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6. Take the threaded stem and insert the end with flange nut number 1 from the rear of the engine past the rearmost bearing seat. Insert it further through the bearing seats and the new bearings until flange nut 1 protrudes from the front of the engine.

7. Screw the flange part of tool 99 373 securely onto hydraulic cylinder 99 003 with two M6x12 bolts. Press together cylinder 99 003 if not already in neutral position.

8. Screw the flange securely to the hydraulic cylinder at the rear of the engine with two of M10x25.

9. Screw on flange nut 7, from tool 99 373, onto the threaded stem.

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10. Hang a new bearing on the stem at the front of the engine.

11. Place the press drift on the threaded stem and place the bearing on the drift.

109 689

Note The recess in the bearing joint must be turned towards the flange on the press drifts. Secure the bearing on the drift by placing the springloaded ball in an oil way. The bearing is correctly located on the drift when the ball and a marking hole are centred on the bearing oil hole.

The bearing is correctly located on the drift when the ball and a marking hole are centred on the bearing oil hole.

12. Clean around the bearing contact surface.

Note The marking on the drift must be uppermost and vertical so that the oil hole in the bearing will be central to the oil ways.

13. Hold the press drift with the new bearing against the old. Secure the threaded stem between the press drift and hydraulic cylinder 99 003 by tightening flange nut 7 on the stem.

Secure the threaded stem by tightening the flange nut 7

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Note The new bearing is in the correct position before the old bearing is completely released. The new bearing has the correct position when the distance from the front edge of the cylinder block to the front edge of the press drift has a permitted value according to the table. -12 mm means that the drift protrudes 12 mm from the cylinder block 14. Press in the new bearing at the same time as pressing out the old bearing with hydraulic cylinder 99 003 and hydraulic pump 99 004.

Check that the bearing is correctly located by measuring it.

Check measurement of bearing number 1

Table for correctly located camshaft bearings

88

Camshaft No.

Distance (mm)

1

-12 to -14

2

150 to 152

3

314 to 316

4

478 to 480

5

642 to 644

6

806 to 808

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15. Remove the press drift by detaching flange nut 7 and pushing in the threaded stem.

16. Check that the bearing oil hole is central to the cylinder block oil ways.

17. Repeat the procedure for the remaining bearings.

Note The seats for camshaft bearings 2, 4 and 6 have two oil ducts. The others only have the lower one.

Carefully knock with a plastic hammer to release the old bearings which are still stuck.

Extraction and pressing of bearing number 2

Check measurement of bearing number 2

18. Carefully knock with a plastic hammer to release the old bearings which are still stuck.

19. Clean the sealing surface, take a new gasket and fit the cover for the camshaft at the front of the engine.

20. Refit the camshaft according to the section Fitting the camshaft. Then perform a check on the camshaft setting.

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Balance shaft unit

1.

2.

3.

4.

5.

6.

90

Balance shaft frame Pin Plug Bearing cap Bearing cap Guide sleeve

7.

8.

9.

10.

11.

12.

Screw Balance shaft Plug Radial bearing Radial bearing Thrust bearing

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13.

14.

15.

16.

Balance shaft gear Balance shaft gear Screw Screw

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Dismantling of the balance shaft unit can be facilitated by loosening the bearing cap screws before removing the balance shaft unit from the engine.

The bearing cap screws must not be totally undone.

Removal Action

Remarks

1

Remove the oil sump.

2

Remove the oil strainer.

3

Remove the oil pump

3

Remove the balance shaft unit.

There is no need to loosen the bearing cap screws if no work is to be carried out on the balance shaft unit.

The balance shaft unit may get jammed on the guide pins. Tap lightly with a rubber mallet to release the balance shaft unit.

!

WARNING!

Remember that the balance shaft unit is heavy.

Dismantling Action

Remarks

1

Remove the bearing caps and bearings.

If the bearings will be reused, they must be refitted in the same place.

2

Remove the balance shafts.

Mark the balance shafts so that they can be refitted in their original positions.

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Assembly Important Make sure that the bearing surfaces are clean before the balance shafts are refitted. When renewing bearings, all bearings should be renewed at the same time.

Important When the balance shaft unit is refitted, the bolts should be bolted back in a specific order. It is important to observe this to minimise the risk of stresses in the balance shaft unit.

Note Check that the balance shafts rotate easily after tightening each bolt.

Finish torque tightening all the bolts before tightening the angle.

Action

Remarks

1

Check that the balance shaft frame is level.

If the balance shaft frame is not level, the caps should only be loosely fitted on the balance shaft frame. When the balance shaft frame is fitted to the engine, it will be levelled and the caps can be tightened.

2

Fit the thrust bearings

3

Fit the bearing halves

4

Fit the balance shafts.

Make sure that the bearing surfaces are clean before the balance shafts are refitted.

5

Fit the bearing cap and bearing halves.

Important! The bolts must be tightened in the correct order, see illustration.

The bolts should be tightened to 25 Nm + 45°.

6

Check the balance shafts

There should be a slight axial clearance and the shafts must rotate easily.

Permissible limits for bearing play: Axial: 0.18-0.30 mm Radial, both sides: 0.026-0.081 mm

Note When renewing bearings, all bearings in the balance shaft unit should be renewed at the same time.

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Fitting Important When the balance shaft unit is refitted, the bolts should be bolted back in a specific order. It is important to observe this to minimise the risk of stresses in the balance shaft unit.

Action

Remarks

1

Position the engine so that TDC down is visible in the lower window.

2

Fit the balance shaft unit.

The balance shaft unit has a number of guide pins and a lubrication duct which must be aligned.

Important! The bolts must be tightened in the correct order, see illustration A. The bolts should be tightened to 90 Nm + 60°.

3

Remove the balance shaft gears.

Tap carefully with a rubber mallet if they are jammed on.

8

Reset the balance shafts, see illustration D.

Reset the balance shafts by inserting a drift in the resetting holes. Both balance shafts must be reset at the same time, see illustration B. A suitable drift should be 150 mm long and have a diameter of 6 mm.

9

Clean the tapered joints of the balance shafts.

10

Fit the balance shaft gears.

The balance shaft gears are marked L and R to aid fitting. The bearing caps are marked in the same way.

The bolts should be tightened to 50 Nm + 60°, see illustration C.

11

Remove the drift.

12

Fit the oil pump and oil strainer.

13

Fit the oil sump.

94

Important! Do not forget to remove the drift from the resetting holes.

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Important Do not forget to remove the drifts from the resetting holes.

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Renewing the ring gear on the crankshaft Removal 1. Lift out the crankshaft according to Removal of crankshaft.

2. Place the crankshaft in an upright position and tap with a hammer and a soft drift as illustrated. Tap all round the ring gear so that it is not jammed.

If it is difficult to remove the ring gear, it can be heated up with a gas burner. Since the ring gear is fitted using a shrink fit, it will come loose when it becomes hotter.

Important The ring gear must not be used again but should be scrapped.

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Fitting 1. Clean the surface where the new ring gear will be fitted.

Important The ring gear must never become hotter than 180°C. 2. Heat the ring gear on a heater plate of some kind. Use an instrument to measure the temperature.

!

WARNING!

Remember that the ring gear will be very hot when it is refitted. Use suitable protective equipment.

3. When the ring gear is hot enough, it can be fitted onto the crankshaft and placed in position.

4. Put back the crankshaft according to Fitting the crankshaft.

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Checking the ring gear on the crankshaft When a new ring gear is fitted onto the crankshaft, its mounting must be checked.

1. The main bearings should be screwed on so that the crankshaft cannot move in an axial direction.

2. Fit a dial gauge as illustrated.

Position of dial gauge when checking the ring gear

3. Rotate the crankshaft and check at the same time how much the ring gear runs out. The run-out must not exceed 0.05 mm.

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Lubrication system General Specifications Lubrication oil volume Lubrication oil volume

28 - 35 liter

Tightening torques Magnetic plug in oil sump

80 Nm

Oil sump bolts

30 Nm

Oil nozzle for piston cooling, banjo bolt

23 Nm

Plug for reduction valve in oil cleaner

40 Nm

The magnetic plug in the oil sump must be lubricated with oil before fitting.

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Measuring oil pressure Oil pressure Idle speed

1,6 bar

With warm engine running at 1 000 rpm

2,5 bar

With warm engine running at 2 000 rpms

4,5 - 6,0 bar

Special tools Number

Description

99 362

Measuring set

Illustration

1. Remove the oil pressure sensor from the oil filter.

2. Fit the measuring equipment with union and adapters according to the illustrations.

3. Fit the oil pressure sensor.

100

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Oil filter Only use original Scania filters.

Tools Number

Description

587 025

Filter wrench

Illustration

Tool board M1

Only use original Scania filters and renew the oil filter according to our maintenance instructions.

Use filter wrench 587 025 when removing the oil filter.

Oil the gasket and tighten the new filter by hand.

Important When renewing the oil filter the oil cleaner should be cleaned in accordance with instructions in page

Removing the oil filter

If the oil cleaner is not cleaned, the oil filter will quickly block up, increasing flow resistance in the filter. If this happens, an overflow valve in the filter retainer will open to let the oil bypass the filter without being cleaned.

The oil lubricates and cools such components as the turbocharger. The turbocharger's rotation speed is high, in some instances over 100,000 rpm. It is vital that the lubrication functions properly.

There is no separate turbo filter; the oil is cleaned by the engine oil filter. If the turbocharger receives contaminated oil, the bearings become severely worn.

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Oil cooler Tightening torques Bolts for oil cooler insert

1.

2.

3.

4.

5.

6.

102

Oil cooler O-ring O-ring Flange bolt Oil cooler cover Core plug

26 Nm

7.

8.

9.

10.

11.

12.

Cover Gasket Self-tapping screw Piston Spring Plug

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13.

14.

15.

16.

17.

Packning Nipple Protective sleeve Gasket Flange bolt

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Renewing the O-rings 1. Remove the side cover and oil cooler from the cylinder block.

2. Remove the 4 bolts securing the oil cooler to the side cover.

3. Remove the oil cooler.

4. Renew the 4 O-rings.

5. Fit the oil cooler insert and bolt securely to the side cover using 26 Nm torque.

6. Securely bolt the side cover to the cylinder block using 26 Nm torque.

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Oil cleaner Specifications Permitted thickness of dirt deposits on walls of bowl

26 mm

Tightening torques Lock nut for oil cleaner housing cover

15 Nm

Nut for rotor bowl

Tighten by hand

Rotor shaft

34 Nm

Locking compound Locking compound

104

561 200

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1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

Filter head Overflow valve Union Straight union Sealing ring Gasket Flange bolt Oil filter Housing Plug Piston

01:07-02

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

Spring Plug Gasket Shaft Washer Rotor Bearing Bearing Nozzle Rotor Cover O-ring

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23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

Nut Strainer Cover O-ring Lock nut Washer O-ring Retaining ring Gasket Flange bolt

105

Cleaning - There should be a certain amount of deposited dirt apparent in the rotor bowl during routine cleaning of the oil cleaner.

- If this is not the case, the rotor may not be turning. The cause must be established immediately.

- If the dirt deposit exceeds 20 mm after the recommended interval, the rotor bowl must be cleaned more often.

1. Undo the nut holding the outer cover and remove cover.

2. Lift out the rotor. Wipe off the outside. Undo the rotor nut and unscrew it about one and a half turns to protect the bearing.

Note The rotor must not be placed in a vice. Never strike the rotor bowl.

This may cause damage resulting in imbalance.

3. If the rotor nut is jammed: Turn the rotor upside down and fasten the nut, absolutely not the rotor, in a vice, and turn the rotor one and a half turn anti-clockwise by hand, or use M20 bolt and nuts as illustrated. The grip distance should be 30 mm.

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4. Grasp the rotor bowl and tap lightly with your hand or a plastic mallet on the rotor nut so that the rotor bowl comes loose from the rotor.

Note Never strike on the rotor directly as this may damage its bearings.

5. Remove the rotor nut and bowl from the rotor.

6. Remove the strainer located on the rotor. If the strainer has seized, pry carefully with a screwdriver at the lower edge between the rotor and the strainer.

7. Scrape away the deposits inside the bowl with a knife.

8. Wash the parts.

9. Inspect the two nozzles on the rotor. Ensure that they are not blocked or damaged. Renew any damaged nozzles.

10. Ensure that the bearings are not damaged.

11. Position a new O-ring in the lid.

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12. Assemble the parts and tighten the rotor nut hard by hand.

13. Ensure that the shaft is not loose. If it is loose, secure with locking compound 561 200. Clean thoroughly first with a suitable solvent.

14. Tighten the rotor shaft using socket 98 421.

Tightening torque 34 Nm. 15. In order to tighten the rotor shaft, it is necessary to modify socket wrench 98 421: - Drill out the threads from a M20 nut so that it fits on the square drive of the socket wrench.

- Weld on the nut.

Note The socket wrench can still be used for old oil cleaners after the modification.

16. Refit the rotor and rotate it by hand to check that it turns easily.

17. Inspect the O-ring on the cleaner housing cover and refit it. Torque tighten the lock nut to 15 Nm.

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Oil pump Tightening torques Bolts for oil pump cover

26 Nm

Bolts for oil pump against cylinder block

26 Nm

1.

2.

3.

4.

5.

Oil pump Flange bolt Gasket Flange bolt Suction pipe

6.

7.

8.

9.

10.

Strainer Ring Flange bolt Pipe Sealing ring

A faulty oil pump must not be overhauled but renewed completely.

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Turbocharger Important information Observe strict cleanliness at all times when working on the turbocharger. Never leave connections for oil inlets or outlets unprotected. Foreign bodies in the bearing housing can quickly lead to serious malfunction.

Oil leaks A blocked air filter will cause excessive underpressure in the intake pipe. There is then a risk of oil mist being drawn out from the bearing housing.

If the sealing ring on the turbine side is worn, the exhaust gases will be blue when idling.

If the oil drain tube from the turbo charger is damaged, the lubrication oil pressure may cause oil to leak out through the seals.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

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Lubrication oil pipe Ferrule Union nut Straight union Sealing ring Straight union Gasket Return oil pipe Gasket Flange bolt

01:07-02

Foreign bodies

Air and exhaust leaks

Foreign bodies in the turbine or compressor, such as a grain of sand or metal shavings, will destroy the vanes. This will lead to imbalance and bearing wear.

The power output of the engine will decrease, and if the engine continues running the reduced air supply may cause the engine to overheat, resulting in damage. This type of overheating is not visible on the coolant temperature gauge.

Even small leaks in the line between the air filter and the turbocharger will cause dirt to be deposited on the compressor wheel. The charge pressure will be reduced, resulting in increased exhaust temperature and smoke, which will reduce the service life of the engine.

Leaks in the exhaust line between the cylinder head and the turbocharger will also result in loss of charging pressure.

Important Never attempt to straighten a damaged vane. It will break off when running and the turbocharger will break down completely, causing damage to the engine.

Measuring the charging pressure The charge air pressure can be measured using ECOM.

Cleaning Low charging pressure could be caused by a dirty compressor wheel. This applies especially on engines with closed crankcase ventilation.

- Remove the air filter and the connection hose - Remove the compressor cover.

- Clean the compressor wheel with white spirit and a brush.

- Fit the compressor cover and measure the charge air pressure again.

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Measuring radial and axial play Turbine shaft wear limits Make Holset Radial play

max. 0,635 mm

Axial play

max. 0,093 mm

Special tools Number

Designation

98 075

Dial gauge

587 107

Rocker indicator

587 250

Magnetic stand

Illustration

Tool board D2

M1

Measuring radial and axial play often does not give a good indication of the remaining service life of the turbocharger.

When the turbocharger seems to be functioning poorly or noisily, measuring the charging pressure or radial and axial play may indicate whether the turbocharger is at fault.

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Radial play Measurement should be done on a removed turbocharger.

1. Measure the play both at the turbine wheel and at the compressor wheel.

2. Place the tip of the dial gauge against the turbine or compressor wheel.

3. Pull up both ends of the shaft. Take a reading.

4. Press down both ends of the shaft. Take a reading. The difference between the two readings is the radial play.

5. Repeat the measurement three times on each side.

6. If any of the wheels makes contact with the housing, even if the radial play is within the tolerances, the turbocharger must be renewed.

Axial play 1. Place the tip of the dial gauge against the end of the shaft.

2. Push the shaft longitudinally to and fro and take a reading at the end positions. The difference between the readings is the axial play.

3. Repeat the measurement three times.

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Checks after breakdown Tightening torques Bolt, turbocharger - exhaust manifold

50 Nm

Nut, turbocharger - exhaust pipe

50 Nm

Stud, exhaust manifold

20 Nm

Important Observe strict cleanliness at all times when working on the turbocharger. Never leave the connections for the oil inlet or outlet unprotected. Foreign bodies in the bearing housing can quickly lead to serious malfunction.

1. Ensure that no leaks or loose particles are present in the line between the air filter and the turbocharger.

2. Check that there are no loose particles in the exhaust or intake manifolds. Renew the charge air cooler.

3. Ensure that all valves are intact.

4. Check that the oil return pipe from the turbocharger is not blocked or deformed.

5. Check that the oil delivery pipe to the turbocharger is not blocked, deformed or leaking under pressure.

6. Renew the oil filter and clean the lubrication system.

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Open crankcase ventilation Specifications Tightening torques Screws for filter box cover

7,5 Nm +/- 0,5 Nm

Measurements Maximum oil mist and condensed water

4 g/h or 5 cc/h

Crankcase pressure

15 mbar +/- 5 mbar at 1900 rpm and full load.

Crankcase pressure with exhaust brake

25 mbar +/- 5 mbar.

Removal Pos

Action

1

Detach the intake hose.

2

Remove the bleed pipe.

Quick coupling at the crankcase ventilation filter housing.

3

Remove the draining pipe.

Quick coupling at the fluid trap.

4

Remove the crankcase ventilation filter housing.

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Remarks

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1

4

2

3

116

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Assembly â&#x20AC;˘ Insert the filter as illustrated.

Important Make sure that the filter is fitted back correctly in the filter retainer. The crankcase gases should be led via the longest route through the filter so that the oil mist can be separated properly. The text on the filter should be upside down.

1. Intake to filter 2. Draining

Fitting Pos

Action

1

Fit the draining pipe.

2

Fit the crankcase ventilation filter housing

3

Fit the bleed pipe

4

Fit the intake hose

5

Check that all the hoses are intact and no hoses are kinked.

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Remarks

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2

3

1

118

4

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Checking the open crankcase ventilation If a fault is suspected in the open crankcase ventilation, a number of checks can be carried out.

• External check of filter, hoses and pipes.

• Internal check of filter, hoses and pipes.

• Oil mist measurement.

• Crankcase pressure measurement.

External check of filter, hoses and pipes 1. Make sure the intake hose between the rocker cover and the filter box is intact and that it is fastened properly.

2. Check that all screws and hose clips are fastened properly.

3. Check that the filter box is not damaged.

Internal check of filter, hoses and pipes 1. Check that the drainage is not clogged by removing the draining pipe and blowing through it.

2. Make sure the filter is intact and not clogged with soot and oxidised oil.

3. Check that the filter box seal is not damaged.

4. Make sure there is no frost or ice in the crankcase ventilation hoses and pipes.

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Oil mist measurement 1. Unscrew the bleed hose from the bleed pipe.

2. Connect a container to the bleed hose and fasten it with a cable tie or similar. Make sure that the container is not contacting any hot engine parts.

3. Leave the container in place for a long period of time, approx. 24 running hours.

4. Check the oil mist at regular intervals.

The maximum permitted oil mist plus condensed water is 4 grammes/hour or 5cc/hour.

Crankcase pressure measurement 1. Connect a manometer to the oil filling.

2. Start the engine.

3. Note the crankcase pressure while the engine is idling. Use the form on the next page.

4. Drive the vehicle under load at an engine speed of 1900 rpm and note the crankcase pressure. Gensets are run at operating speed.

5. Repeat steps 3 and 4 three times.

6. Check the readings and compare them with the permitted pressures.

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Form for measuring the crankcase pressure Date

Engine number

Operating hours

Customer

Area of usage for engine:

Noting the problem High levels of oil mist When did the problem occur for the first time:

Pos

Operating range

Test No.1

Test No. 2

Test No. 3

1

Idle speed

mbar

mbar

mbar

2

Load 1900 r/min

mbar

mbar

mbar

Test carried out by: __________________________

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Closed crankcase ventilation

Too much oil in the oil sump If the engine is filled with too much oil, the excess will splash around in the crankcase and be atomized. This means that the crankcase gases will contain a large amount of atomized oil that the crankcase ventilation will not be able to separate oil properly. This will result in a large amount of oil from the crankcase ventilation.

Trouble shooting Increased blow-by in engine Blow-by is the flow of gases through the engine crankcase and out via the crankcase ventilation.

The closed crankcase ventilation system is very sensitive for changes to the blow-by in the engine.

If the blow-by increases, the amount of gas passing through the crankcase ventilation will also increase.

The crankcase gases can then take with it small drops of oil from the crankcase. When the amount of oil increases, the oil separator will not be able to fulfil its task of separating the oil. Oil will then accompany the air into the charge air system.

Causes of an increase in blow-by are leaking piston rings, valve guides, turbocharger or compressor. Gas leakage from the charge air system down to the crankcase also give rise to increased blowby and therefore increased excess oil from the crankcase ventilation.

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Air leak in the crankcase In a well-functioning closed crankcase ventilation system, there should be a certain amount of vacuum in the crankcase. If air enters the crankcase from outside, the flow of gas from the crankcase through the crankcase ventilation will increase. This is the equivalent of increased blowby and will lead to an increase in oil consumption.

An air leak in the crankcase can be caused by: • Poorly fitted oil filler cap.

• Defective rubber plug on the oil dipstick handle.

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2 3 2

4

5

Closed crankcase ventilation: Low turbo position

1

1.

2.

3.

4.

5.

Intake hose Ventilation unit Bleeder hose Drain hose Fluid trap

Closed crankcase ventilation: High turbo position