Engine body - Service procedures

Valve springs, checking

Check the length of the valve springs, unloaded and loaded, by using a spring gauge. The springs shall maintain the values given in the Workshop Manual, Technical Data for each engine concerned.

Rocker mechanism, overhauling

Special tools: 2267, 2677

1

Remove the circlips, rocker arms and shaft.

2

Clean the parts, observing special care with the oil channel in the bearing housing, and the oil holes in the rocker arm shaft and rocker arm.

3

Check the wear on rocker arm shaft and ball pin. The threads shall be undamaged on the ball pin and lock nut. The contact surface on the rocker arm to the valve cap must not be worn or pitted. Adjustment in a grinding machine can be made in the event of less serious wear. Check the tightness of the cap plugs at the shaft ends.

4

Ovally worn rocker bushings are replaced. Press out the bushing with drift 2677; use drift 2267 as counterforce.

Press in the new bushing with drift 2677. Make sure that the oil hole comes in the middle of the oil channel in the rocker arm.

The new bushing must be reamed after being pressed in.

5

Oil in the shaft and assemble the parts.

Cylinder head, assembly

If the injector’s copper sleeve requires replacing, see Fuel system.

1

12 ltr engine: place the lower valve spring washers on the cylinder head. There are no such washers in the 10 ltr engines.

2

Oil in the valve spindles and fit the valves in their guides. Fit the springs and upper washers.

3

Press the springs together with a valve spring tensioner and fit the valve lock. Put on the valve caps.

4

If the cylinder head’s cleaning plugs have been removed make sure that the sealing surfaces are well cleaned.

Put on new gaskets: tighten the plugs with a torque of 60 Nm (44 lbf.ft)

NOTE! The plugs must not be machine tightened.

Cylinder head, fitting

Special tools:2479,9989876

10 ltr engines: 2666 (2 pcs)

12 ltr engines: 8043 (2 pcs)

1

Clean the cylinder block surface with a brass brush. Make sure that the surfaces are not scratched.

2

Check the height of the cylinder liner over the block plane, see Cylinder liner and piston, fitting

Correct height above cylinder block surface: see WorkshopManual,TechnicalData for each engine concerned.

A: 10 ltr engines: 2666

12 ltr engines: 8043

3

Place new sealing rings and a new cylinder head gasket on the cylinder block.

10 ltr engine: clean the mating surfaces for the insert seals between the heads, use fine emery cloth.

6

10 ltr engine : fit the insert seals between the cylinder heads.

NOTE! Grease or oil must not be used on the seals. Use soap water.

Fit the lower parts of the valve covers. Tighten the screws with a torque of 10 Nm (7 lbf.ft)

NOTE! Higher torque will risk damaging the seal.

4

Place the cylinder head on the block.

5

Check the cylinder head screws. NOTE! The screws are phosphated and must not be cleaned with wire brush. If there are cut marks under the screw heads or in the threads they shall be replaced with new.

7

Fit the push rods and rocker mechanism. Adjust the valves (see below). Put on the valve covers.

8

Fit the injectors. Tightening torque 50 Nm (36.9 lbf.ft) Fit the remaining equipment.

NOTE! The gasket between cylinder head and exhaust manifold is turned so that the plate covered side faces the exhaust manifold.

Dip the cylinder head screws fully (heads also) in rustproof agent, part No. 1161346-0 (or a mixture of 75% Tectyl 511 and 25% varnolen). The screws shall be drip-free before fitting (oil may otherwise be forced up and seen as leakage).

See Workshop Manual, Technical Data for each engine concerned, for correct tightening order and torque.