21 minute read
01Perkins diesel engine
01.1Specifications
Engine 520 (303 58)
Product:Perkins diesel engine
Model:1004-4 LR
Cylinder arrangement:In line
Number of cylinders:4, water cooled
Capacity:3990 cm³
Nominal bore and stroke: 100 x 127 mm
Compression ratio:16,5
Output:50 kW / 68 HP, 2,200 rpm (DIN ISO 3046)
Rated engine torque:208 Nm
Max. torque:250 Nm, 1,200 rpm
Fuel consumption230 g/KWh minimum
Fuel injection system:Direct fuel injection with in-line pumps
Injection pressure:250 bar
Firing order:1 – 3 – 4 – 2
Start of delivery:17.5° before top dead centre
Starting aid: Flame heater system (preheating time 10 –15 seconds)
Oil lubrication of engine is ensured up to the following inclined position: max. lateral inclination left/right: 67/67 % up/downhill gradient max.: 67/67 %
Observe tilting limit of the machine!
Oil pressure:2.1 bar minimum at 2.200 rpm
Valve tip clearance: Intake valve: 0.20 mm outlet valve 0.45 mm Cold or warm engine respectively
Engine 620 (304 59)
Product:Perkins diesel engine
Model:1004-4 HR
Cylinder arrangement:In line
Number of cylinders:4, water cooled
Capacity:3990 cm³
Nominal bore and stroke: 100 x 127 mm
Compression ratio:16,5
Output:56.5 kW / 77 HP, 2,200 rpm (DIN ISO 3046)
Rated engine torque:247 Nm
Max. torque:279 Nm, 1,400 rpm
Fuel consumption230 g/KWh minimum
Fuel injection system:Direct fuel injection with in-line pumps
Injection pressure:250 bar
Firing order:1 – 3 – 4 – 2
Start of delivery:17.5° before top dead centre
Starting aid: Flame heater system (preheating time 10 –15 seconds)
Oil lubrication of engine is ensured up to the following inclined position: max. lateral inclination left/right: 67/67 % up/downhill gradient max.: 67/67 %
Observe tilting limit of the machine!
Oil pressure:2.1 bar minimum at 2.200 rpm
Valve tip clearance: Intake valve: 0.20 mm outlet valve 0.45 mm Cold or warm engine respectively
01.1.1Valve tip clearance
Checking and adjusting12A-05
The valve tip clearance is measured between the top of the valve stem and the tilt lever as per figure (A). With the engine cold or warm, the correct clearances are 0.20 mm (0.008 in) for the intake valves and 0.45 mm (0.018 in) for the exhaust valves. See B in figure for the position of the intake and exhaust valves.
Caution!
Cylinder no. 1 is located opposite the power take-off side of the engine.
Four cylinder engines
• Turn the crankshaft in the normal direction of rotation until the intake valve of the 4th ram has just opened and the exhaust valve of the same cylinder has not fully closed (“overlapping”). Check the valve tip clearances of the 1st cylinder and adjust if necessary.
• Turn the crankshaft until the position of the valves of the 2nd cylinder corresponds to the position as described in item 1, and check or adjust the valve tip clearances of the valves on the 3rd cylinder.
• Let the valves of the first cylinder overlap, and check or adjust the valve tip clearances of the valves on the 4th cylinder.
• Then let the valves of the 3rd cylinder overlap, and check or adjust the valve tip clearances of the valves on the 2nd cylinder.
Engine
01.1.2Removing and fitting the rocker assembly
Removing
• Remove the cylinder-head cover as per section 12A-01.
• Evenly and gradually release the fasteners of the rocker shaft brackets. Begin with the end brackets and move toward the centre. Remove the fasteners and washers and lift off the rocker assembly.
Important!
The latest engines do not have washers between nuts/bolts and the tilt lever bearing blocks. The retaining bolts have been changed.
• Remove the rubber oil seal (B) from the oil supply connection or the oil supply hole in the cylinder head.
Fitting
• Fit a new rubber oil seal in the oil supply hole in the oil supply hole in the cylinder head.
• Check that the push rods fit correctly in the cams of the camshaft. Fit the rocker assembly. Make sure the oil supply connection is fitted correctly into the oil seal of the cylinder head. Check that the ends of the adjustment screws of the rocker levers fit correctly in the sockets of the push rods.
• Fit the washers (if existing) and the fasteners onto the stud bolts of the rocker shaft brackets. Tighten the fasteners evenly and gradually. Begin with the inner fasteners and work towards the end fasteners. Make sure all fasteners are tightened evenly to the correct torque, see section 11 B.
Cylinder head assembly
Removing
• Drain the coolant.
• Disconnect the battery terminals.
• Remove the pipe fitted between the cold start device in the intake manifold and the fuel filter. Disconnect the electrical connection.
• Engine types AB, AD, YB and YD: Remove the boost control pipe fitted between the front of the intake manifold and the fuel pump.
• Remove the intake manifold.
• Engine types AB, AC, YB, YC and YD: Disconnect all connections to the turbocharger and remove the turbocharger, operation 18A-01.
• Remove the injection nozzles, operation 20A-02. Fit suitable covers to the nozzles and the open connections.
• Disconnect the coolant temperature sensor.
• Engine types AB, AD and certain AA: Remove the oil cooler, operation 21A-07A.
• Remove the cylinder-head cover, operation 12A-01.
• Remove the rocker assembly, operation 12A-02.
• Remove the push rods.
• Release the cylinder-head bolts evenly and gradually in the reverse order to that shown in figures 12A.08/A or B. Check the cylinder-head bolt for deformations with a straight edge (A1) as per figure (A2). If there is a visual reduction in the diameter of the thread outside the cylinder block (A3), the cylinder-head bolt must be discarded.
• Remove the cylinder head and put it on a surface that will not damage the sealing surface of the cylinder head. Do not use a lever to separate the cylinder head from the cylinder block.
Fitting
Special tools required:
Angle gauge MS.1531 for tightening the cylinder-head bolts
• Clean the sealing surface of the cylinder head and the upper surface of the cylinder block. Make sure there is no debris in the cylinder bores.
• Put the cylinder-head gasket in position. The cylinder-head gasket must be fitted without sealing compound. It is stamped “FRONT TOP” for correct assembly (12A.07/B).
• To hold the gasket in the correct position when the cylinder head is fitted, fit two suitable 1/2 UNF studs, figure (C), in positions 15 and 20 as per figure (B) or in positions 25 and 30 as per figure (A). Put the cylinder head on the cylinder block.
• Lightly lubricate the threads of the cylinder-head bolts and the thrust faces of the screw heads. Engage some of the cylinderhead bolts as per figures (A) or (B) and remove the guide studs. Engage the remainder of the cylinder-head bolts.
• Gradually and evenly tighten the cylinder-head bolt to 110 Nm (80 lbf ft) 11.1 kgf in the order shown in figures (A) or (B).
• Repeat the work steps as per section 5 to make sure all cylinderhead bolt are tightened to the correct torque.
• Tighten the cylinder-head bolts in the order shown in figures (A) or (B), taking into account the length. Short screws (S) must be turned a further 150° (2.5 flats). Medium screws (M) must be turned a further 180° (3 flats). Long screws (L) must be turned a further 210° (3.5 flats). A special tool can be used for this operation as per figure (D). Fit the tool between the socket and the handle. Position the stop mark against a suitable protrusion on the cylinder head to prevent movement of the degree dial in a clockwise direction, figure (D1). Turn the pointer to align it with the angle of the degree dial corresponding to the length of the cylinder-head bolt. Tighten the cylinder-head bolt until the pointer is at the zero position of the degree dial.
If no special tool is available, make a suitable mark on the cylinder head in line with a corner of each screw , see figure 12A.09/A. Then make another mark, at the correct angle (anticlockwise), on the edge of the flange of each screw according to the length of the screw. Tighten these screws in the correct order until the marks on the flange are next to, and in line with, the marks on the cylinder head.
• Fit the push rods. Make sure the end of each push rod fits correctly in the tappet socket.
• Fit the rocker assembly, operation 12A-01.
• Set the valve tip clearances, operation 12A-05.
• Fit the injection nozzles, operation 20A-02.
• Fit the injection lines. Tighten the union nut to 18 Nm (14 lbf ft) 1.9 kgf m. Engines with Bosch fuel pumps: Use a separate spanner to prevent movement of the pump connections.
• Fit the fuel filter and the bracket. Fit the fuel line between the fuel pump and the fuel filter.
• Fill the cooling system.
• Connect the air filter/cleaner.
• Connect the battery terminals.
• Bleed the fuel system, operation 20A-08A or 20A-08B.
• Start the engine and run it at low speed. Check that oil flows from the holes in the rocker levers. If the oil flow is correct, fit the cylinder-head cover, operation 12A-01.
It is not necessary to tighten the cylinder-head bolts again with the engine hot or after a limited period in service.
Valves and valve springs
Removing and fitting12A-08
Special tools required:
Valve spring compressor PD.6118B
Stud adapter PD.6118-7
Screw adapter PD.6118-8
Removing
• Remove the cylinder head, operation 12A-07.
• Clean the sealing surface of the cylinder head and check the distance between the valve heads and the cylinder head, see operation 12A-09.
• Make suitable marks on the valves to make sure the valves can be fitted in their original positions if they are to be used again.
• Use the valve spring compressor to compress the valve springs and remove the collets. Make sure the valve springs are compressed squarely to avoid damage to the valve stem.
• Release the valve spring compressor and remove the valve spring cap, the valve springs, the valve stem seal and the valve seat washer.
• Repeat items 4 and 5 for the other valves.
Fitting
The components of the valve assembly are shown in figure (A). Certain engines are fitted with single valve springs.
• Lubricate the valve stems (A7 and A8) with clean engine oil and fit the valves in their respective guides.
• Fit the spring seat washers (A6). Fit new valve stem seals (A5) on the valve guides. If double valve springs are used, fit the inner and outer valve springs (A3 and A4) on the spring seat washers with their damper coils toward the cylinder head. If single valve springs are used, the spring does not have a damper coil and it can be fitted with either end to the cylinder head. Fit the valve spring caps (A2).
• Use the valve spring compressor and the relevant adapter to compress the valve spring(s) and fit the collets (A1). Make sure the valve springs are compressed squarely to avoid damage to the valve stem.
Front oil seal
Removing and fitting15A-02
Removing
• Remove the fan operation 21A-04 and the drive belts operation 23A-03.
• Remove the crankshaft pulley, operation 14A-01.
• Remove the oil seal with a suitable lever behind the main lip of the oil seal. Do not damage the edge of the oil seal housing.
Fitting
Special tools required:
Replacer tool for front oil seal (main tool), PD170
Pressure plate PD170-1
Fastener plate PD170-2
Sleeve PD170-3
Seal adapter PD170-4
The oil seal is fitted to a depth of 6.75/7.25 mm (0.266/0.285 in) from the front face of the oil seal housing to the flat front face of the oil seal. If, in service, there is wear in the seal location area of the crankshaft pulley, the oil seal can be fitted to a depth of 9.3 mm (0.366 in).
• Clean the oil seal housing. Inspect the new seal for damage. If a scratch can be seen across the lip of the seal, do not fit the seal.
• Lubricate the outer circumference of the oil seal with clean engine lubricating oil and enter the seal into the housing. Make sure the spring loaded lip of the oil seal is towards the inside of the timing case cover and that the oil seal is square to the bore of the seal housing.
• Assemble the oil seal replacing tool (A). Fasten PD.170-2 (A3) to the front of the crankshaft. Hold PD.170-4 (A5) against the seal with the side stamped 9.3 mm towards the seal, put PD.170-3 (A4) and PD 170-1 (A2) in position and fasten PD.170 (A1) to the stud of PD.170-2. Fit a rod through the hole in the end of the tool so that the tool will not turn. Turn the nut with a suitable spanner and the oil seal will be pushed into the housing. Push the seal in to the correct depth. If the seal is to be pushed in to the service position, turn the nut until the face of PD.170-4 is against the face of the oil seal housing.
• Remove the replacing tool and lightly lubricate the seal location area of the crankshaft pulley with clean engine lubricating oil. Fit the crankshaft pulley, operation 14A-01.
Engine
• Fit the drive belts, operation 23A-03 and adjust the belt tension, operation 23A-02.
• Fit the fan, operation 21A-04.
Rear oil seal assembly – engines with normal oil seal
Removing and fitting14A-02A
Special tools required:
Replacer tool for rear oil seal, PD.145D
• Remove the drive components from the rear end of the engine.
• Remove the flywheel and the flywheel housing, see section 22.
• Remove the set screws and the cap screws from the housing and remove the housing and seal assembly.
• Inspect the seal for wear or for damage to the main lip and renew the seal, if necessary. If there is only a small scratch across the lip, renew the seal.
• Clean the faces of the cylinder block, the oil seal housing and the crankshaft flange.
• Check that the seal and the outer circumference of the crankshaft flange are not damaged. Where a new seal has been fitted, check that it is in the correct position in the housing.
• Make sure the two dowels are fitted in the cylinder block. Put a new seal in position on the dowels. No sealing compound is necessary.
• Put the seal guide on the crankshaft flange. Lubricate the crankshaft flange, the main lip of the seal and the seal guide with clean engine lubricating oil. The lubrication of the seal is necessary to prevent damage to the seal when the engine is first started.
• Put the seal and housing (A2) on the seal guide (A1) on the crankshaft flange. Position the housing by means of the dowels (A3). Remove the seal guide, fit the set screws and the cap screws. Tighten the set screws to 22 Nm (16 lbf ft) 2.2 kgf m and tighten the cap screws to 18 Nm (13 lbf ft) 1.9 kgf m.
Removing and fitting the fuel pump 620
Removing:
• Drain the coolant into a clean container through the fitted drain tap.
• Disconnect the suction hose from the radiator to the pump and the filler hose to the expansion tank (screwdriver, clamp).
• Unclip the accelerator linkage and return spring (ES pin).
• Remove the injection lines from the pump to the nozzles (WAF17)
• Pull off the cable connector from the cut-off solenoid.
• Remove the supply and return line from the pump to the filter (WAF13).
• Remove the leakage oil line from the pump to the first cylinder (WAF10).
• Remove the valve cover (3 bolts WAF19).
• Bring cylinder 1 into overlap (by turning the fan blades): this means the key on the injector pump is at the top.
• Screw on the valve cover (3 bolts WAF19).
• Unscrew the sealing cover from the control cover (4 bolts WAF8, small socket with ratchet).
• Unscrew the fixing nut from the injection pump on the pump wheel (WAF22).
• Remove the fixing nuts and lock washer.
• Unscrew 3 fixing nuts from the injection pump (2 upper bolts: ring spanner WAF13, lower bolt: small ratchet/extension/joint/WAF13 socket).
• Fit the pump wheel extractor (flat steel section with 2 M8 bolts).
• Tighten the M8 bolts (this pushes off the pump).
• Pull the pump off the engine.
Fuel pump gear
Removing and fitting15A-04
Removing
Special tools required: Gear puller PD.155B Adapter PD.155B-5
• Remove the fan, operation 21A-04.
• Remove the V-belts, operation 23A-03.
• Remove the crankshaft pulley, operation 14A-01.
• If necessary, remove the fan drive pulley, operation 21A-05.
• Drain the coolant and remove the water pump, operation 21A02.
• Remove the timing case cover, operation 15A-01.
• Turn the crankshaft until the marked teeth of the crankshaft gear, the camshaft gear and the fuel pump gear are all in mesh with the idler gear. The marked teeth of the idler gear will not necessarily be in mesh with the marked teeth of the other gears because of the different speed of rotation of the idler gear.
• Remove the nut and the spring washer from the fuel pump gear.
• Remove the idler gear, operation 15A-03.
• Remove the fuel pump gear with the puller and the adapters (A). Make sure the key in the fuel pump shaft is not lost.
• Inspect the gear for wear and other damage and renew it, if necessary.
Fitting
• Make sure the key in the fuel pump shaft is fitted correctly. Fit the gear and the spring washer. Loosely fit the nut.
• Turn the fuel pump gear to make sure the relevant marked tooth of the fuel pump gear (“4” for four cylinder engines or “6” for six cylinder engines) will align with the marked teeth of the idler gear (15A.05/A). Fit the idler gear, operation 15A-03.
• Tighten the nut of the fuel pump gear to 80 Nm (59 lbf ft) 8.2 kgf m.
• If a new gear has been fitted, check the backlash.
• Fit the water pump, operation 21A-02.
• Fit the crankshaft pulley, operation 14A-01.
• If necessary, fit the fan drive pulley, operation 21A-05.
• Fit the drive belts, operation 23A-03 and adjust the belt tension, operation 23A-02.
• Fit the fan, operation 21A-04.
• Fill the cooling system.
Checking the timing mark of the fuel pump17B-04
Special tools required:
Universal timing tool MS.67B
Gear adapter PD.67-3
• Remove the fuel pump, operation 20A-06B.
• Fit the adapter PD.67-3 (A) to the drive shaft of the fuel pump and fasten it with the nut of the fuel pump gear.
• Remove the banjo bolt from number 1 high pressure outlet –outlet “W” for four cylinder engines, outlet “Y” for six cylinder engines – and fit a banjo bolt which does not contain a pressure valve.
• Connect number 1 outlet to an atomiser tester. Operate the hand pump until a pressure of 30 atm (440 lbf.in2) 31 kgf/cm2 is indicated on the gauge.
• Loosen the screw (B1) on the timing tool MS.67B and set the timing tool to the correct angle, see section 11C. Tighten the screw.
• Fit the timing tool to the adapter on the fuel pump drive shaft. Turn the drive shaft of the fuel pump by hand in the normal direction of rotation – see arrow on pump data plate – until the fuel pressure prevents movement. In this position, the fuel pump is set at the start of injection from number 1 outlet.
• Loosen the screw (B2). Slide the pointer (B3) forward until it is over the centre of the pump flange and check that the mark on the flange is in the centre of the slot in the pointer.
• If the mark is not correct, remove the timing tool and eliminate the mark. Fit the timing tool and make sure the fuel pump is at the start of injection for number 1 cylinder. Loosen the screw (B2). Slide the pointer forward to the complete width of the flange and tighten the screw. Make a new mark on the flange of the pump through the slot in the pointer.
• Remove the timing tool and the adapter.
• Disconnect the atomiser tester and fit the original banjo bolt to number 1 high pressure outlet.
• Fit the fuel pump, operation 20A-06B.
• Bleed the fuel system, operation 20A-08B.
Checking the engine timing mark17B-05
Special tools required:
Universal timing tool MS.67B
Adapter PD.67-2
Pointer PD.67-4
• Set the piston of number 1 cylinder to TDC on the compression stroke, operation 17B-01.
• Remove the fuel pump and its seal, operation 20A-06B.
• Align the key in the adapter with the keyway in the gear of the fuel pump and fit the adapter to the gear. Make sure the adapter is against the rear face of the timing case. Secure the adapter to the gear with the nut supplied with the adapter.
• Loosen the screw (B1) on the timing tool MS67B. Set the timing tool to the correct engine check angle, see section 11C, and firmly tighten the screw. Loosen the screw (B2) and fit the splined shaft (B5) into the timing tool (B). Loosen the screw (B4). Fit the 90° pointer PD67-4 (B3) and tighten the screw.
• Fit the splined shaft of the timing tool to the adapter. Slide the timing tool along the splined shaft until it is against the adapter and tighten the screw (B2).
• Loosen the screw (B4). Slide the pointer forward until the flat face is against the rear face of the timing case and tighten the screw. If the mark on the timing case is correct, the mark will align with the top edge of the pointer (B3). If the mark is not correct, remove the timing tool and eliminate the mark on the timing case. Make sure the pointer is against the timing case and make a new mark on the timing case along the top straight edge of the pointer.
• Remove the timing tool and the adapter.
• Fit the fuel pump and a new seal, operation 20A-06B.
• Remove the dial gauge from number 1 cylinder inlet valve and fit the valve springs and the rocker lever. Set the valve tip clearance of number 1 cylinder inlet valve to 0.20 mm (0.008 in). Fit the cylinder-head cover, operation 12A-01.
• Bleed the fuel system, operation 20A-08B.
Removing and fitting a CAV pump20A-06B
Removing
Special tools required:
Extractor for gears PD.155C
Adapter PD.155B-5
Spanner for flange nuts on fuel pump PD.199
• Remove all lines, disconnect the shutdown device and control rod from the injection pump.
• Remove the cover for the pump gear from the control housing cover. Unscrew the gear nut and circlip.
• Turn the crankshaft until the keyway in the pump gear is in or near to the top position.
• Unscrew the fixing bolts and the retaining mechanism beneath the injection pump. Unscrew the flange nuts from the injection pump. If free access to the flange nuts is blocked, for example by a compressor, use special tool PD.199.
• Release the input gear to the injection pump using extractor PD.155 and adapter PD.155B-5 (20A.07/B).
• Remove the injection pump. Make sure the key does not fall off the drive shaft.
Engine
Fitting
• Rotate the injection pump shaft until the key lines up with the keyway in the gear. Make sure the key is correctly seated and join the injection pump onto the gear.
• Line up the mark on the injection pump flange with the mark on the rear side of the control housing (A1). Fit the flange nuts to the injection pump as well as the fixing bolt with the retaining mechanism nut. Make sure the pump is not subject to any stresses when the retaining mechanism is fitted.
• Fit the lock washer and nut onto the input shaft of the injection pump and tighten the nut to 18 Nm (59 lbf ft) 8.2 kgf m. Fit the gear cover onto the control housing cover and use a new gasket.
• Fit all lines. Connect the shutdown device and the control rod to the injection pump.
• Bleed the fuel system, operation 20A-08B.
• Start the engine and check the lines for leaks. When the engine has reached normal operating temperature, check that idling speed is set correctly in accordance with section 20A-07B.
• Check the maximum no-load speed if a new injection pump has been fitted. See section 20A-07B.
Bleeding the fuel system with CAV pump20A-08B
There are two methods of bleeding the fuel system depending on which injection pumps are fitted:
The normal method is used if the injection pump has bleed screws (C1, C2 and D1).
The self-bleeding method is used if the injection pump is fitted with a suitable device. These injection pumps have a bleed line (20A.14/ A1) running from the top of the injection pump to the return line of the injection nozzles. There are no bleed screws on these injection pumps. No connections or plugs need to be opened in order to bleed the fuel system.
Air in the fuel system must be removed before the engine can be started. Air may have entered the system as follows:
• Tank emptied during operation
• Return lines disconnected
• Part of the return lines was leaking when the engine was running Remove air from the fuel system as follows:
Normal method
• Unscrew the top vent screw on the double fuel filter (20A.12/A1) by one or two turns. Unscrew the banjo bolts fitted on top of the filter (20A.12/B1) if a single filter is fitted.
• Operate the hand lever on the fuel pump (20A.12/C) until the fuel emerging from the bleed screw or banjo bolt is free from bubbles. Tighten the bleed screw or banjo bolt. The hand lever cannot be operated if the drive cam for the fuel pump is set to maximum delivery position. In this case, turn the crankshaft through one more rotation.
• Make sure the manual stop device is in operating position. Set the ignition key to drive position if an electrical stop device is used.
• CAV DPA fuel pumps: Unscrew the bleed screws (C1) on the locknut of the hydraulic head as well as the bleed screw (C2) on top of the governor housing.
Operate the hand lever on the fuel pump until the fuel emerging from the bleed screw of the locknut on the hydraulic head is free from bubbles. Tighten the bleed screw. Continue to operate the fuel pump hand lever until the fuel emerging from the bleed points on the governor housing is free from bubbles. Tighten the bleed screw.
CAV DPA fuel pumps: Unscrew the bleed screw (D1) on top of the governor housing.
Operate the fuel pump hand lever until the fuel emerging from the bleed points is free from bubbles. Tighten the bleed screw.
• Unscrew the union nut (A1) on the auxiliary starter device, if one is fitted, and operate the hand lever on the pump until the fuel emerging from the connection is free from bubbles. Tighten the union nut for the auxiliary starter device.
• Unscrew the injection lines to two injection nozzles.
• Move the manual stop device, if one is installed, to the run position. Operate the starter until the fuel emerging from the connection lines is free from bubbles.
• Tighten the injection lines again.
• The engine is now ready to start.
• Check for air in the fuel system if the engine runs normally for a short period before stopping or running irregularly. Air in the fuel system is probably due to a leak in the intake line or the oil return line.
Self-bleeding method
If the engine stops due to air in the fuel system: Make sure there is fuel in the tank and that all leaks have been repaired.
• Move the manual stop device to the “run” position, if a manual stop device is fitted.
• Run the starter until the engine starts.
If the fuel system or a part of it was emptied:
• Turn the ignition key to the R position. If a manual stop device is fitted, make sure it is in the run position.
• Operate the bleed lever on the fuel pump (20A.12C) slowly for about 2 minutes. The bleed lever cannot be operated when the drive cam for the fuel pump is at its highest point. In this case, turn the crankshaft through a further rotation. In this case, turn the crankshaft through one more rotation.
• Run the starter until the engine starts.
Check for air in the fuel system if the engine runs normally for a short period before stopping or running irregularly. Air in the fuel system is probably due to a leak in the low pressure system.
Concerning the coolant quality
We are aware that engines are operated without antifreeze or anticorrosion agents. Such operation has a detrimental effect on the cooling system due to corrosion and even erosion.
We strongly recommend operating the engine with a 50/50 mixture of antifreeze and water in order to avoid the problems. This mixture allows small amounts of clear water to be filled without impairing the effect of the antifreeze. Brand-name antifreeze agents should also possess anti-corrosion characteristics to ASTMD1384-70, EMPA Test or the FVV guidelines.
Avoid increasing the concentration of antifreeze to cooling water above 50% because such a mixture would impair the cooling effect. Replace the antifreeze mixture every two years in order to maintain anti-corrosion protection in the cooling system.
Concerning the thermostats
Numerous thermostats are currently being returned under guarantee as supposedly damaged.
Before fitting a new thermostat in case of cooling problems, first check whether the thermostat is really defective before sending it back. An intact thermostat can be fitted again and must not be returned.
If the cooling problem is rectified after changing the thermostat, it may be that other defects were rectified during the thermostat change, e.g. air in the cooling system.
Note the following points when testing a thermostat: The cold thermostat must be closed.
It should start opening at the value stamped on the thermostat and should be fully open at 88°C (72°C thermostat), 95°C (82°C thermostat) or 100°C (88°C thermostat).
The minimum opening distance for a fully opened thermostat is 9 mm.
Test the opening value of the thermostat by suspending it in a waterfilled container together with a thermometer and heating up the water.
Engine
01.1.3Recommended tightening torques
Tightening torques valid for lightly lubricated threads.
