Engine body - Service procedures

13

Fit the cylinder liner in the cylinder block as per the markings made. Tap down the liner with the aid of the plate 6599 and the handle 2000

Check that the arrow on the piston top and ”FRONT” marking on the connecting rod are facing the same direction. Fit the piston and connecting rod in the respective cylinder liner so that the arrow on the piston top points forward. Use piston ring compressor 885126.

14

Screw tight the big end cap as per the marking. Tightening torque: see Workshop Manual, Technical Data for each engine concerned.

15

Turn the flywheel until the piston comes to the top position. Check the piston height over the cylinder block plane.

Place a dial test indicator in a magnetic frame and set the indicator to zero to cleaned cylinder block plane. Release the magnetic frame and place the indicator tip to the piston.

11

Fit the clamp tool on the liner.

12

Place the bearing shells in their positions in the connecting rod and cap. Check that the hole in the bearing shell comes opposite the hole in the connecting rod. Lubricate the piston and big end with engine oil, and turn the rings so that the piston ring gap is uniform round the piston.

Max. piston height over the block plane: Workshop Manual, Technical Data for each engine concerned.

16

Fit the piston cooling nozzle if this has been removed.

NOTE! Use new screws.

Front crankshaft seal, replacement

Special tools: 2655, 6795, 2656

1

Oil

Fit

Timing gear cover, removing

Special tool: 2655

1

Remove the drive belts for the alternator. Remove the alternator and the bracket.

2

Remove the fan and the drive belts.

3

12 engines: Drain

4

Remove the vibration damper and pulley.

NOTE! The vibration damper must not be exposed to knocks or blows, since its characteristics can be completely changed if the carefully balanced fluid chamber changes form and volume.

5

Timing gear cover, fitting

Special tools: 2656, 115 8959

For replacement of the front crankshaft seals see page 43.

1

Remove the polygon hub’s center screw, remove the washer, and pull off the hub with extractor 2655.

Clean the mating surfaces. Scrape off all remains of the sealant.

2

Apply an even, approx. 2mm 1/16") wide bead of sealant (1161231-4) on the timing gear cover, see figure. Apply Permatex on the pan gasket.

6

Remove the screws which hold the timing gear cover. Do not forget the screws for the oil pan. Carefully tap off the timing gear cover.

1030ME: The timing gear cover and the silencer shield should not be separated.

NOTE! Observe care so that the pan gasket is not damaged. Otherwise, the oil pan must be removed and the gasket replaced.

3

Oil in the sealing rings for the crankshaft.

4

Fit the cover within 20 minutes. Tightening torque: see Workshop Manual, Technical Data for each engine concerned.

5

Check the polygon hub and its mating sur-face on the crankshaft. Cutting marks are removed with fine emery paper. Grease in the crankshaft journal with molybdenum disulphide. Fit the centering part for the tool 2656 on the crankshaft journal.

7

Fit the washer and center screw and tighten the hub while hot.

Tightening torque: 400 Nm (295 lbf.ft). When the hub has cooled tighten the screw to 550 Nm (406 lbf.ft)

8

Fit the vibration damper and pulley. Tightening torque: see Workshop Manual, Technical Data for each engine concerned.

Fit remaining equipment.

Timing gears, removing

(With the timing gear cover removed)

Special tool: 2658

WARNING! If the crankshaft and camshaft are turned without being synchronized with each other the valves can be damaged.

6

Heat the polygon hub to approx. 100°C (212°F). Tap the hub onto the shaft with the aid of the drift 2656.

1

Remove the rear valve cover. Turn the crankshaft until the valves for cylinder No. 6 ”rock” and the flywheel is at 0°.

2

Remove the screws which hold the camshaft gear and injection pump gear. Remove the gears.

Remove the intermediate gear and its bearing journal when the three screws have been released.

4

Remove the crankshaft gear with the puller 2658. If the oil pump gear is damaged the oil pump must be removed and the gear replaced.

Timing gears, fitting

Special tool: 2659

Note! Certain timing gears are nitro-carburated (marked “N” or “NITRO”). They can also be recognized by their flat grey to grey-yellow colour. These gears must not be installed together with earlier, induction hardened gears (marked HT).

Case hardened gears (marked CH) are permitted in all gear combinations.

See also Nitrokarburerade transmissionsdrev på sidorna 17–19.

WARNING! If the crankshaft and camshaft are turned without being synchronized to each other the valves can be damaged.

All gears in the timing gears which are of importance for the setting are marked with punch marks opposite the tooth and tooth gap.

See Workshop Manual, Technical Data for each engine concerned for correct tightening torques!

Timing gears, inspection

Clean the gears and other parts in the timing gears and inspect. Replace gears which are severely worn or damaged. See Workshop Manual, Technical Data for each engine concerned for dimensions.

1

Check that the crankshaft key is fitted. Fit the crankshaft gear with tool 2659

NOTE! The larger thread on the tool’s spindle fits in the crankshaft. Hold the tool’s spindle so that the crankshaft does not turn (with possible valve damage as the result).

NOTE! Make sure that the crankshaft gears meshes in the oil pump’s middle gear if this is fitted.

5

Check that the camshaft gear’s guide pin is fitted. Fit the camshaft gear. Do not tighten the screws.

Check the axial and the radial clearance of the camshaft. Correct clearance: see Workshop Manual, Technical Data for each engine concerned.

6

Check the axial and the radial clearance of the intermediate gear. Correct clearance: see Workshop Manual, Technical Data for each engine concerned.

7

Check the tooth flank clearance on all gears. Correct clearance: see Workshop Manual, Technical Data for each engine concerned.

3

Fit the intermediate gear as per the markings. The bearing shell and pressure washer are positioned as per figure.

Intermediate gear

4

Check that the guide pin is fitted in the shaft for the injection pump's drive, and fit the pump gear. Make sure that the markings correspond. Tighten the camshaft gear and the pump gear.

1

Remove the screws and lift off the timing gear casing.

2

Carefully clean the mating surfaces of the engine block and timing gear casing.