Benz engine manual

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BDC From the Library of Barrington Diesel Club

ENGINE REPAIR MANUAL ADE 360 SERIES

ATLANTIS DIESEL ENGINES (PTY) LTD

Part No. 805*&S4i by th e S ervice D e partm ent o f A tla n tis Diesel Enain®

FOREWORD The 360 Series are direct injection, water-cooled four-stroke diesel engines. The cylinders are arranged in line and are positioned vertically. Depending on application 360 series engines can be fitte d w ith a turbocharger. The engines have been designed to take advantage of the latest technology, w ith special em phasis on the sm allest possible dim ensions, a favourable power to w eight ratio and low fuel consum ption. ADE engines have a left hand rotation when viewed from the rear. Throughout this manual, whenever Left or Right hand side of the engine is referred to, it is the side of the engine when viewed from the flywheel end.

This publication has been w ritten to assist all personnel engaged in the maintenance and overhaul of the ADE Diesel Engine. All necessary information contained in this manual is presented in a logical step by step form at with the text supported by line illustrations, which are positioned on the right hand side of the page, together w ith precise instructions on the servicing and overhaul procedure.

In addition each section contains a schedule of m anufacturing data and dim ensions which must be closely followed when overhauling any part of the engine to the M anufacturers standards. Effec­ tive maintenance can only be carried out if the personnel concerned are fully conversant with the various com ponents of the engine. Before maintenance operations are commenced, therefore, this manual should be carefully studied, and should at all tim es be kept where it w ill be needed in the workshop. Certain operations described in this manual require the use of special tools. These tools ' are obtainable from Grundy-Techniform . Full details are given in the appropriate sections.

A Product Training Representative, highly skilled in the special ch aracte ristics of ADE Engines, is available to assist you w ith product training through your O riginal Equipment M anufacturer (O.E.M.).

ENGINE PARTS Whenever parts are required for ADE Engines, it is essential that the fullest inform ation possible is given, always quote the engine number, type of application, and where possible the part number and description. In accordance with the Preventative Maintenance Plan, your engine will require such items as fuel, oil and air filters. It is in your own interest to ensure that only genuine ADE Parts are used. Each genuine ADEPART, is backed with a six month guarantee ensuring the highest quality, and every part com plies with the original specification.

RUNNING-IN PROCEDURE It is not necessary to gradually run-in a new ADE engine, and any prolonged light load running during early life of the engine can in fact prove harm ful to the bedding in o f the piston rings and liners. Full load can be applied provided that the engine has reached operation tem perature.

This publication is produced by the Service Department of A tla n tis Diesel Engines (Pty) Ltd, and every endeavour has been made to ensure that the inform ation contained in this manual is correct at the tim e of publication, however, continuous development and advancem ent in product design may reflect changes made to your engine which are not included in this publication. ©

C O P Y R IG H T 1988 A T L A N T IS DIESEL E N G IN E S (PTY) LTD.

Reproduction or translation, in part or full is subject to the w ritten authorization of A tla n tifD ie s e l Engines (Pty) Ltd.

CONTENTS TECHNICAL DATA .......................................................................................................................................... 08 OPERATING MAINTENANCE SCHEDULE AND LUBRICATING OILS ..............................................09 FAULT FINDING ...............................................................................................................................................10 CYLINDER BLOCK AND LINERS .................................................................................................................11 CYLINDER HEAD .............................................................................................................................................12 PISTONS AND CONNECTING RODS .......................................................................................................... 13 CRANKSHAFT AND MAIN BEARINGS ....................................................................................................... 14 CAMSHAFT, TIMING CASE AND DRIVE-TIMING ................................... ...................................................15 LUBRICATING SYSTEM AND SUMP ............................................................................................................16 FUEL SYSTEM .................................................... ............................................................................................ 17 TURBOCHARGER ........................................................................................................................................... 18A POWER STEERING

....................................................................................................................................... 18B

EXHAUST BRAKE ...........

....18C

FLYWHEEL ...................................................................................................................................................... 18D ALTERNATOR AND STARTER MOTOR .................................................................................................... 18E COMPRESSOR/VACUUM PUMP ..................................................................................................................18F COOLING SYSTEM ........................................................................................................................................ 19 APPROVED SERVICE TOOLS ......................................................................REFER TO EACH SECTION

SECTION 08-1 Technical Data ADE 364N/C/T/TI ENGINE DATA ADE 364N

AD E 364C

A D E 364T

A D E 364TI

B o r e ...........................................................................

S tro k e .......................................................................

No. o f c y lin d e r s ....................................................

C u b ic c a p a c ity .....................................................

C o m p re s s io n ra tio ...............................................

C o m p re s s io n te s t p re s s u re a t o p e ra tin g te m p e ra tu re (M ax. d iffe re n c e b e tw e en a n y tw o c y lin d e rs — 400 k P a ) .......................

97,5 m m ..................97,5 m m .................. 97,5 m m .................. 97,5 m m 133 m m ...................133 m m ................... 133 m m ................... 133 mm 4 ................................4 ................................. 4 ................................. 4 3,972 t .................... 3,972 ( ..................... 3,972 ( ..................... 3,972 f 17,25:1 ..................... 17:1 ........................... 16,5:1 ........................ 16,5:1

F irin g o rd e r ............................................................

C o m b u s tio n s y s t e m ............................................

C y c le .........................................................................

1 -3 -4 -2 ..................... 1-3-4-2 ....................... 1-3-4-2 .......................1-3-4-2 D ire c t in je c tio n ...D ire c t in je c tio n ...D ire c t in je c tio n ...D ire ct in je c tio n 4 s tro k e ................. 4 s tro k e ..................4 s tro k e .................. 4 s tro k e

M in 2000 kPa a t 180-200 r/m in

M in 2000 kPa a t 180-200 r/m in

DETAIL OF RATINGS (AUTOMOTIVE) TO SABS 013-1977 M a x im u m to rq u e (N .m ) .....................................

266 @ 1400 r/m in 300 @ 1400 r/m in 380 @ 1400 r/m in 408 @ 1400 r/m in O u tp u t Kw ...................................................................

66 @ 2800 r/m in 70 @ 2800 r/m in 85 @ 2600 r/m in 100 @ 2600 r/m in

ENGINE MASS T y p ic a l d ry m a s s ..................................................

335 kg ..................... 343 kg ..................... 343 kg ..................... 370 kg

ADE 366N/C/T/TI ENGINE DATA A D E 366N

A D E 366C

A D E 366T

A D E 36831

B o r e ............................................................................

S tro k e .......................................................................

No. o f c y lin d e r s ....................................................

C u b ic c a p a c ity ......................................................

C o m p re s s io n ra tio ...............................................

C o m p re s s io n te s t p re s s u re a t o p e ra tin g te m p e ra tu re (M ax. d iffe re n c e b e tw e en a n y tw o c y lin d e rs — 400 k P a ) .......................

97,5 m m ..................97,5 m m ..................97,5 m m .........97,5 m m 133 m m ...................133 m m ........... ....... 133 m m ................... 133 m m 6 ................................ 6 ................................ 6 ................................. 6 5,958 f .....................5,958 f .....................5,958 ( ......................5,958 I 17,25:1 ..................... 17:1 ............................16,5:1 ........................16,5:1

F irin g o rd e r ............................................................

C o m b u s tio n s y s te m ............................................

C y c le .........................................................................

1-5-3-6-2-4 ............... 1-5-3-6-2-4................1-5-3-6-2-4.................1-5-3-6-2-4 D ire c t in je c tio n ...D ire ct in je c tio n ...D ire ct in je c tio n ...D ire ct in je c tio n 4 s tro k e ................. 4 s tro k e ..................4 s tro k e .................. 4 s tro k e

M in 2000 kPa at 180-200 r/m in

M in 2000 kPa a t 180-200 r/m in

DETAIL OF RATINGS (AUTOMOTIVE) TO SABS 013-1977 M a x im u m to rq u e (N .m ) .....................................

O u tp u t K w ...............................................................

402 @ 1400 r/m in 420 @ 1400 r/m in 560 @ 1400 r/m in 640 @ 1400 r/m in 100 @ 2800 r/m in 100 @ 2800 r/m in 125 @ 2600 r/m in 150 @ 2600 r/m in

ENGINE MASS T y p ic a l d ry m a s s ..................................................

445 kg ..................... 460 kg ..................... 460 kg ......................495 kg

T h ro u g h o u t th is E n g in e R e p a ir M a n u a l, S1 (In te rn a tio n a l M e tric S yste m ) u n its a s a p p ro ve d by th e S o u th A fric a n B ureau o f S ta n d a rd s (SABS) are used. A ll m e a s u re m e n ts are in m m u n le s s o th e rw is e in d ic a te d .

A D E 360 S e rie s

08-2 TORQUE SPECIFICATIONS FOR BOLTS UNDER DIFFERENT GRADE CLASSIFICATIONS

Q uality grade

8.8

10.9

M6

8.6

11.8

14.5

M8

21

29

35.5

M8x1

23

32

38

M 10

42

58

70

M 10 x 1,5 M 12

46,5

65

78

73

100

123

76

105

128

M 14

114

165

195

M 14x1,5

128

178

215

M 16

178

250

300

M 12x1,5

M 16x1,5

190

270

320

M 18

245

355

415

M 18x1,5

280

390

465

M20

350

490

590

M 20x1,5

390

550

660

M22

465

660

800

M 22x1,5

520

730

875

M24

600

850

1000

M 24x2

660

910

1100

NO TE 1 — T he B o lt g ra d in g a p p e a rs on th e b o lt head NO TE 2 — B o lt to rq u e is s u b je c t to fe m a le th re a d m a te ria l

A D E 360 S e rie s

12.9

TECHNICAL DATA -

08-3

IDENTIFICATION NUMBER POSITIONS W hen o rd e rin g spare p a rts a llw a ys q u o te th e eng in e n u m b e r in fu ll.

ENGINE IDENTIFICATION T h e e n g in e n u m b e rin g sy s te m fo r ADE e n g in e s c o n s is ts o f 16 le tte rs a nd n u m b e rs.

E xam ple

ATLANTIS DIESEL ENGINES (PTY) LTD LICENCE DAIMLER-BENZ AG

ENGINE No DB ADE

M J 01002 SA 046315 T MADE IN RSA

ENGINE FAMILY 300 Series ENGINE TYPE i.e.

G = 364N H = 364C J = 366N K = 366T

L = 366TI M = 364T N = 366C

BUILD CODE COUNTRY OF ORIGIN ENGINE SERIAL NUMBER YEAR OF MANUFACTURE S T

= 1988 = 1989

U = 1990 V = 1991

W = 1992 X = 1993 Y = 1994

N o te :

T he le tte r d e n o tin g th e ye a r o f m a n u fa c tu re c h a n g e s on th e 1st d a y o f J a n u a ry e a ch year.

T he le tte rs I, O, Q, R and Z are n o t used.

A D E 360 S eries

TECHNICAL DATA — 08-4

AD E 360 S e rie s

SECTION 09-1 Operating and Maintenance RECOMMENDED SERVICE/ MAINTENANCE INTERVALS

OPERATING AND MAINTENANCE Preparation before Starting

Normal oil and filter changes/service intervals

C h e c k th e ra d ia to r c o o la n t level.

C ategory 1

C ategory 2

C ategory 3

E n su re th a t th e re is fu e l in th e ta n k.

7 500 km /150 h rs

5 000 km /100 h rs

2 500 km /50 hrs

C h e c k th a t th e b a tte ry is fu lly ch a rg e d and th a t a ll e le c ­ tr ic a l c o n n e c tio n s are p ro p e rly m ad e a nd a ll c ir c u its are in order.

A t le a s t tw ic e a ye a r w h e n s e rv ic e in te rv a l is n o t re a ch e d

C h e c k th e e n g in e s u m p o il le ve l.

.

To Stop the Engine R em ove th e e n g in e lo a d . D e cre a se sp e e d g ra d u a lly to a vo id h e a tin g up th e c o o la n t, th e n run th e e n g in e a t id l­ in g s p e e d fo r a s h o rt tim e . S h u t d o w n e n g in e . (a) By a c tu a tin g th e s to p p in g c a b le . (b) By m o v in g th e s p e e d c o n tro l le ve r to “ s to p ” . (c) By a c tu a tin g th e s h u t-o ff s o le n o id . (d) By a c tu a tin g th e e x h a u s t b ra ke d e p e n d in g on th e e n g in e s p e c ific a tio n .

Points to note

EXTENDED oil and filter changes/service intervals T he e xte nd e d m a in te n a n ce and se rvice in te rva ls m ay o n ly c o m m e n c e a fte r th e ru n n in g in p e rio d (a p p ro x im a te ly 20 000 km).

T h e e n g in e lu b ric a tin g o ils fo r e x te n d e d o il c h a n g e in te r­ va ls, as s p e c ifie d in th e ADE S e rvice B u lle tin on C o n ­ s u m a b le s have been a p p ro ve d a n d are m a n d a to ry .

T he s u c c e s s fu l a p p lic a tio n o f th e e x te n d e d o il and filte r c h a n g e s /s e rv ic e in te rv a ls w a rra n ts c a re fu l se rv ic e and m a in te n a n c e o f e n g in e s . A s e x te n d e d in te rv a ls a ls o d e ­ pend on o p e ra tin g c o n d itio n s o f th e e n g in e s , it is e s s e n ­ tia l to a p p ly th e 3 c a te g o rie s a s o u tlin e d b e lo w .

C ateg ory 1

C ategory 2

C ategory 3

15 000 km /30 0 h rs 10 000 km /200 h rs 5 000 km /10 0 hrs

A lw a y s ensure th a t th e s ta rte r p in io n has sto p p e d ro ta tin g b e fo re re -e n g a g in g th e s ta rte r, as th e rin g g e a r o r p in io n m ay be d a m a g e d .

A t le a s t o n c e a ye a r w h e n s e rv ic e in te rv a l is n o t re a ch e d

Flame-Proofed Engines

N o te 1:

E n g in e s a rra n g e d to c o n fo rm w ith fla m e -p ro o fin g re g u la ­ tio n s are u s u a lly fitte d w ith n o n -e le c tric s ta rtin g e q u ip ­ m ent. T h is is s u p p lie d by th e m a n u fa c tu re r o f th e a p p lic a ­ tio n a nd fo r s ta rtin g in s tru c tio n s re fe re n c e s h o u ld be m a d e to th e a p p ro p ria te m a n u fa c tu re r’s h a n d b o o k.

E n g in e s th a t leave th e fa c to ry are fille d w ith ru n n in g -in o il. T h e o il m u s t be c h a n g e d d u rin g th e fir s t s e rv ic e a t 1 500 km o r 30 h o u rs o p e ra tio n .

Preventive Maintenance

For approved engine lubricants and coolant additives, refer to ADE G eneral Service B ulletin on C o n ­ sum ables.

C ategory 1 U n its o p e ra tin g u n d e r n o rm a l c o n d itio n s , m ore th a n 100 000 km o r 2 000 h o u rs a n n u a lly e.g. lo n g h a u l o p e ra tio n s .

C ategory 2 U n its o p e ra tin g u n d e r n o rm a l c o n d itio n s , up to 100 000 km o r 2 000 h o u rs a n n u a lly e.g. m e d iu m to lo n g haul o p e ra tio n s .

C ategory 3 U n its s u b je c t to severe o p e ra tin g c o n d itio n s e.g. e x tre m e ­ ly p o o r road c o n d itio n s , he a vy d u s t c o n d itio n s , e x tre m e c lim a tic c o n d itio n s (te m p e ra tu re and h u m id ity), very s h o rt d is ta n c e s in tr a ffic o r c o n s tru c tio n o p e ra tio n . U n its o p e ra tin g up to 10 000 km o r 200 h o u rs a n n u a lly e.g. u n its o p e ra tin g u n d e r lig h t lo a d s o r in te rm itte n t o p e ra tin g c o n ­ d itio n s , s u c h as s ta n d -b y g e n e ra to r s e ts a n d e m e rg e n c y v e h ic le s . H o w e ve r, w h e n o p e ra tin g le ss th a n th e re c o m ­ m e n d e d s e rv ic e in te rv a ls , th e o il a nd o il filte r s h o u ld be ch a n ge d o n ce o r tw ic e a year de p e n d in g on th e lu b ric a tin g o il used. W e re c o m m e n d th a t m a in te n a n c e a nd se rvice be c a rrie d o u t a c c o rd in g to h o u rs o f o p e ra tio n ra th e r th a n m ile a g e co ve re d .

Pre-delivery Service 1. C h e ck g e n e ra l e n g in e in s ta lla tio n i.e. A ll p ip e s and h o se s fo r tig h t s e a lin g , c o n d itio n a nd ro u tin g .

2. O p e n a ir c le a n e r a n d e n su re e le m e n t is p o s itio n e d c o rr e c tly a n d b o lte d d o w n .

3. C h e c k fo r fu e l a n d o il le a ks.

4. C h e c k o il level.

5. C h e c k c o o la n t level.

6. C h e ck c o o la n t fo r co rre ct m ixtu re , i.e. a n ti-fre e ze/a n ti­ c o rro s io n a g e n t a nd c o rro s io n in h ib ito r.

7. C h e c k V -b e lt te n s io n .

.

8. C h e c k e le c tric a l e q u ip m e n t a n d c o n n e c tio n s .

AGE 360 Series

OPERATING AND MAINTENANCE — 09-2 9. C h e c k in je c tio n p u m p lin k a g e fo r to ta l m o ve m e n t.

13. E n su re ra d ia to r fin s have an u n o b s tru c te d a ir flo w .

10. C h e c k e x h a u s t brake lin ka g e and a d ju s tm e n t if fitte d .

14. T en sio n all V -Belts, c h e ckin g sa m e fo r a g eing, re p la c­ ing d e fe c tiv e V -B e lts. T w in V -B e lts s h o u ld o n ly be

11. C h e c k th a t th e fa n has been fitte d c o rre c tly .

12. S ta rt up, th e n c h e c k te m p e ra tu re g a u ge s.

o il

p re s s u re

a nd

replaced in pairs. N ew b e lts m u st be rete n sio n e d a fte r 10-15 m in u te s o f o p e ra tio n .

c o o la n t

13. C h e c k fo r a n y u n u s u a l n o ise s.

14. W h ile e n g in e is w a rm in g up c h e c k fo r o il a nd w a te r leaks.

15. C h e c k o p e ra tio n o f v is c o fa n (if fitte d ).

16. Run to o p e ra tin g te m p e ra tu re a nd c h e c k m a x im u m r/m in.

Daily Before Starting and 8-10 Hours Operation

15. C h e ck e x h a u s t s y s te m fo r d a m a g e o r le a ks.

16. C h e ck c o n tro l lin ka g e on in je c tio n p u m p a nd e xh a u st b ra ke fo r c o rre c t fu n c tio n a nd a d ju s tm e n t, lu b ric a te a ll jo in ts .

17. C h e c k a ll lin e s a nd h o se s fo r tig h t s e a lin g , c h a fin g and leaks.

18. A d ju s t va lve c le a ra n c e s .

19.

R e tig h te n all v is ib le n u ts and b o lts on th e e n g in e and in p a rtic u la r. (a) In le t a nd e x h a u s t m a n ifo ld s and d u c ts .

1. C heck e n g in e o il level and p re ssu re upon s ta rt up (en­ s u re m a c h in e is s ta n d in g level).

(b) E x h a u s t fla n g e . (c) S ta rte r m o to r a nd a lte rn a to r fittin g .

2. C h e c k c o o la n t level in ra d ia to r.

(d) N ozzle h o ld e rs.

3. S e rvice a ir c le a n e r d u s t b o w l, p re -filte r if a p p lic a b le .

4. C h e c k a ir c le a n e r re s tric tio n in d ic a to r, s e rvice filte rs if re q u ire d .

(e) E n g in e m o u n t on c ro s s m e m b e r a nd e n g in e s u p p o rt. \

(f)

B e ll h o u s in g b o lts a n d n u ts.

5. E nsure th e re is a m p le fu e l in ta n k.

20. C h e c k fo r fu e l a n d o il le a ks.

6. E nsure fu e l ta n k c a p /b re a th e r is u n o b s tru c te d .

21. C h e c k o p e ra tio n o f o il p re s s u re and te m p e ra tu re g a u ge s.

7. C h e c k th a t th e e x te rio r o f th e s u m p is c le a n w ith an u n re s tric te d a ir flo w o ve r th e s u rfa c e .

8. E n su re ra d ia to r fin s have an u n o b s tru c te d a irflo w .

9. C h e c k o il p re s s u re in d ic a to r.

10. D ra in w a te r fro m s e d im e n to r.

11. D ra in a ir ta n k (if fitte d ).

Note: Injectors: S a tis fa c to ry lo n g te rm fu n c tio n in g o f in je c to rs d e p e n d s la rg e ly on th e q u a lity a n d p u rity o f th e fu e ls u s­ e d. A s p e c ific s e rv ic e in te rv a l ca n th e re fo re n o t be p re s c rib e d . D e a le rs a nd F le e to w n e rs s h o u ld a d o p t s e r­ v ic e in te rv a ls w h ic h w o u ld s u it th e in d iv id u a l o p e ra tin g c irc u m s ta n c e s .

22. C h e c k b a tte ry e le c tro lite level. In S u m m e r a nd h o t re g io n s o n c e a w eek.

23. C h e ck b a tte ry te rm in a ls fo r tig h tn e s s and c o n d itio n .

24. C h e c k o p e ra tio n o f V is c o Fan (if fitte d ).

A d d itio n a l ite m s re q u irin g s e rv ic in g a t 50 000 km in te r­ val lis tin g .

1. C h e ck ca rb o n b ru s h e s in th e s ta rte r.

2. In s p e c t a nd c le a n o il c o o le r filt e r e le m e n t ADE 360T/TI

Schedule A Service Schedule B Service 1. C h a n g e e n g in e o il, d ra in o il w h e n s t ill hot.

2. R enew o il filte r.

3. R enew fu e l filte rs .

4. D rain w a te r fro m s e d im e n to r o r fu e l filte r d ra in co c k s .

5. S e rvice a ir c le a n e r d u s t b o w ls /p re -filte r if a p p lic a b le .

6. C h e c k a ir c le a n e r in d ic a to r, se rvice filte rs if required.

7. S e rv ic e a ir c le a n e r a n d f ilte r (oil b a th type).

8. C h e c k a ll a ir c le a n e r in ta k e d u c ts , h o se s a nd c lip s e tc ., fo r s e rv ic e a b ility a nd tig h tn e s s .

9. C h e c k th a t in te rc o o le r is fre e fro m o b s tru c tio n .

10. C h e ck c o o la n t hoses, hose c lip s fo r s e rv ic e a b ility and tig h tn e s s .

11. P re ssu re te s t c o o lin g syste m .

12. E n su re th a t re c o m m e n d e d c o rro s io n in h ib ito r has been a d d e d to th e c o o lin g syste m .

A D E 360 S e rie s

* 1 . C h a n g e e n g in e o il and o il filte r, d ra in w h e n s t ill hot.

2. D ra in fu e l s e d im e n to r o r fu e l f ilte r d ra in ta p s.

3. S e rvice a ir c le a n e r d u s t b o w l/p re filte r if a p p lic a b le .

4. C h e ck a ir c le a n e r in d ic a to r, se rvice filte rs if required.

5. C h e c k a ll a ir c le a n e r in ta k e d u c ts , h o se s a nd c lip s fo r s e rv ic e a b ility and tig h tn e s s .

6. C h e ck th a t in te rc o o le r is free fro m o b s tru c tio n .

7. C heck c o o la n t hoses, h ose c lip s fo r s e rv ic e a b ility and tig h tn e s s .

8. P re ssu re te s t c o o lin g s y s te m .

9. E n su re ra d ia to r fin s have an u n o b s tru c te d a ir flo w .

10.

T e n s io n V -B e lts c h e c k in g sa m e fo r a g e in g , re p la c e d e fe c tiv e V -B e lts . T w in V -B e lts s h o u ld o n ly be replaced in pairs. R e tension new b e lts a fte r 10-15 m in. o p e ra tio n .

OPERATING AND MAINTENANCE 11. C h e c k e x h a u s t s y s te m fo r d a m a g e o r le a ks.

09-3

T h e a n ti-c o rro s io n o il c o n te n t in th e c o o la n t i.e. 1% by vo lu m e , m ay be d e te rm in e d by a re fra c to m e te r.

12. C h e c k fo r fu e l a nd o il le a ks.

13. C h e c k o p e ra tio n o f o il p re s s u re a nd te m p e ra tu re ga u ge s.

14. C h e c k b a tte ry e le c tro lite le ve l. In S u m m e r and h o t re g io n s o n c e a w eek.

O n ly use a p p ro ve d p ro d u c ts fo r m ix tu re w ith th e c o o la n t as s p e c ifie d in o u r G e n era l S e rvice B u lle tin on C o n ­ s u m a b le s a n d a t a ll tim e s s tr ic tly a d h e re to th e m ix tu re s p e c ific a tio n s .

15. C h e c k b a tte ry te rm in a ls fo r tig h tn e s s a n d c o n d itio n .

A d d itio n a l ite m s re q u irin g s e rv ic in g a t 50 000 km in te r­ v a ls o r to th e e q u iv a le n t s h o w n on th e m a in te n a n c e in ­ te rv a l lis tin g .

1. C h e c k th e c a rb o n b ru s h e s in th e s ta rte r.

2. C le a n tu rb o c h a rg e r im p e lle r, d iffu s e r a n d o il d ra in pipe.

ENGINE PRESERVATION W hen an e n g in e is laid-up fo r a p ro lo n g e d period, it sh o u ld be p ro p e rly p ro te c te d a g a in s t c o rro s io n . P re se rva tio n m e a su re s s h o u ld be c a rrie d o u t in a c c o rd a n c e w ith th e d iffe re n t c a ta g o rie s lis te d in th e fo llo w in g s e c tio n s .

1.0 G eneral

3. In s p e c t a nd c le a n o il c o o le r filt e r e le m e n t (360T/TI) A tte n tio n ! S a tis fa c to ry lo n g te rm o p e ra tio n o f th e a ir c o m p re s s o r, d e p e n d s on m a n y va ry in g fa c to rs . T h e re fo re a s p e c ific s e rv ic e in te rv a l c a n n o t be re c o m m e n d e d .

D e a le rs and F le e to w n e rs s h o u ld a d o p t s e rv ic e in te rv a ls w h ic h w ill s u it th e ir in d iv id u a l o p e ra tin g c o n d itio n s .

ENGINE COOLANT In v ie w o f th e s ig n ific a n c e o f m a in ta in in g th e c o o lin g s y s te m a t a s p e c ifie d level, it is e s s e n tia l to e n su re th a t th e fo llo w in g c o o la n t s p e c ific a tio n s are m a in ta in e d .

F o r th e p re p a ra tio n o f c o o la n ts , use c le a n w a te r th a t is n o t to o hard. O fte n , d rin k in g w a te r (tap w a te r) w ill m eet th e d e s ire d re q u ire m e n ts , b u t n o t a lw a ys.

Sea w a te r, s a lt w ater, in d u s tria l w a ste w a te r and b ra ckish w a te r w h ic h in c lu d e s in m o s t c a s e s w a te r fro m d a m s, p o n d s a n d rive rs, s h o u ld be c o n s id e re d to be u n s u ita b le , as th e s e m ay c o n trib u te h e a v ily to th e fo rm a tio n o f c o rro s io n .

Specification of fresh water S u m o f a lk a lin e e a rth (w a te r h a rd n e ss) p H v a lu e a t 2 0 °C C o n te n ts o f c h lo rin e io n s: T o ta l c o n te n t o f c h lo rid e s a nd s u lp h a te s

89.5 — 358 m g /litre 6.5 — 8,5 m ax 100 m g /litre

2.0 Installed Engines 2.1 L a id up fo r up to 12 m o n th s 2.2 L a id up fo r 12 to 36 m o n th s 2.3 L a id up fo r m o re th a n 36 m o n th s 3.0 N on-installed Engines 3.1 L a id up fo r up to 12 m o n th s 3.2 L a id up fo r 12 to 36 m o n th s 3.3 L a id up fo r m ore th a n 36 m o n th s 4.0 Preparing Engine for operation 1.0 General A n e n g in e is c la s s ifie d as “ la id u p ” w h e n it has n o t o p e ra te d fo r o ve r o n e m o n th . L a id up v e h ic le s o r e n g in e s s h o u ld be stored in dry, w e ll-ve n tila te d room s a n d m u s t a lw a y s be p ro te c te d a g a in s t d ire c t m o is tu re , e.g. rain o r s p la s h w a te r. If th is is n o t p o s s i­ ble, la yin g up c o n d itio n s are c la s s ifie d as extre m e and th e tre a tm e n t s p e c ifie d fo r a g ive n p e rio d s h o u ld be in c re a s e d , e.g. if an e n g in e is to be la id up fo r up to 12 m o n th s , it m u s t re ce ive tre a tm e n t o f an e n g in e to be la id up fo r 12 to 36 m o n th s .

1.1 O n a n y la id up e n g in e a ll m a c h in e d e xte rn a l u n p ro te c te d s u rfa c e s , e.g. fly w h e e ls , V -b e lt p u lle y g ro o ve s, e tc. s h o u ld be c o a te d w ith a p re se rvin g a g e n t o r g rease.

V -b e lts m u s t be s la c k e n e d o ff and be rem oved fro m th e grooves.

m ax 200 m g /litre

F u ll in fo rm a tio n o n th e q u a lity o f d rin k in g w a te r s h o u ld be o b ta in e d fro m lo c a l d e p a rtm e n ts o f W a te r A ffa irs o r lo c a l a u th o ritie s . It is e s s e n tia l to p ro te c t y o u r e n g in e at a ll tim e s a g a in s t c o rro s io n by th e a d d itio n o f A n ti­ c o rro s io n /A n ti-fre e z e a d d itiv e s (e th y le n e g ly c o l w ith c o rro s io n in h ib ito rs ) w h ic h a m o n g s t o th e rs , w ill m ee t th e fo llo w in g d e m a n d s : •

a d e q u a te a n ti-c o rro s io n a n d c a v ita tio n p ro te c tio n fo r a ll c o m p o n e n ts iû th e c o o lin g sy s te m

•

lo w e rin g th e f r e t t in g p o in t

•

ra is in g th e boiH ÉÉ üfofR t

A t no tim e s h o u ld th e c o b là h t'm ix tu re e x c e e d 5 5 % by v o lu m e a n ti-fre e z e /a n ti-c o rro s io n a g e n t as a h ig h e r p e rc e n ta g e w ill re d u c e th e a n ti-fre e z e p ro te c tio n as w e ll as lessen the heat d is s ip a tio n . A s a n ti-co rro sio n in h ib ito rs d e c o m p o s e d u rin g o p e ra tio n , as w e ll a s a n ti-c o rro s io n c o n c e n tra tio n b e in g re d u ce d by to p p in g up th e c o o lin g s y s te m w ith w a te r, th e fr o s t p ro te c tio n m u s t be c h e cke d reg u la rly. F ro st p ro te c tio n o f - 3 0 ° C c o rre s p o n d s w ith 40 to 45 p e rc e n t (by v o lu m e ) a n ti-fre e z e / a n ti-c o rro s io n c o n ­ te n t in th e c o o la n t w h ic h m ay be d e te rm in e d by an o p ­ tic a l o r m e c h a n ic a l h y d ro m e te r, ( - 3 0 ° C ) .

A ll o p e n in g s m u st be s e a le d a ir tig h t. T h is in clu d e s e xh a u st and a ir in le t d u c ts/cle a n e rs on in s ta lle d e n g in e s. ' B a tte rie s m u s t be d is c o n n e c te d in la id up v e h ic le s a nd s h o u ld be re c h a rg e d o u ts id e th e v e h ic le as req u ire d .

2.0 Installed Engines T h e se m e a su re s a p p ly to a ll e n g in e s in v e h ic le s , tra c to rs , as w e ll as in d u s tria l e n g in e s .

2.1

Laid up for up to 12 m onths

2.1.1 N EW E N G IN E S (d is ta n c e covered up to 300 km o r 6 h o u rs o f o p e ra tio n ): T he en g in es m u st be fille d to th e m a xim u m level w ith a p p ro v e d s e rv ic e p ro d u c ts . A m b ie n t te m p e ra tu re s m u st be ta ke n in to c o n s id e ra tio n w h e n s e le c tin g SAE g ra d e s. N o fu rth e r p re s e r­ v a tio n m e a su re s are re q u ire d .

2.1.2 USED E N G IN E S (d is ta n c e co ve re d m o re th a n 300 km o r 6 h o u rs o p e ra tio n ):

A D E 360 S e rie s

OPERATING AND MAINTENANCE -

09-4

Run e n g in e u n til w a rm a n d d ra in e n g in e o il.

(R u n n in g -in o il m ay re m a in in th e e n g in e).

R enew o il filte r c a rtrid g e . F ill w ith an a p p ro ve d ru n n in g -in o il (a n ti-c o rro s io n e n g in e oil). F ill o r to p up c o o lin g sy s te m w ith th e s p e c ifie d c o o la n t m ix tu re . Run e n g in e a t m e d iu m sp e e d fo r a p p ro x . 5 to 10 m in u te s u n til o p e ra tin g te m p e ra tu re is re a ch e d (c o o la n t te m p e ra tu re 75-79° C). S w itc h o ff e n g in e , f ill th e s u m p and th e o il b a th a ir filte r (if fitte d ) to m a xim u m level.

2.2

c y lin d e r via th e c o m p re s s o r a ir in ta k e w h e re ­ a fte r th e e n g in e ,m u s t be ro ta te d a t le a s t one h a lf a tu rn .

2.3

Laid up for more than 36 months If th e laying-up period is exte nd e d fo r m ore th a n 36 m o n th s , p re s e rv a tio n m e a su re s m u s t be rep e a te d every 3 ye a rs o r 18 m o n th s in a c c o r­ d a n ce w ith S e c tio n 2.2 in fu ll.

Laid up for 12 to 36 m onths A ll th e m e a su re s se t o u t in S e c tio n s 1.0 “ G e n e ra l” a nd 2.1 “ M e a su re s fo r In s ta lle d E n g in e s L a id up fo r up to 12 m o n th s ” , m u s t be c a rrie d o u t.

3.0 N O N -IN STA LLED E N G IN E S T hese m ea su re s co ve r new n o n -in s ta lle d e n g in e s, as w e ll as re m a n u fa c tu re d e n g in e s.

3.1

In a d d itio n , th e fu e l s y s te m , th e c o m b u s tio n c h a m b e rs and th e a ir c o m p re s s o r m u s t be p re se rve d In a c c o rd a n c e w ith th e fo llo w in g in ­ s tru c tio n s .

NEW ENGINES w h ich have o n ly been su b je cte d to th e ru n n in g -in p e rio d a t ADE, do n o t re q u ire any a d d itio n a l p re s e rv a tio n m ea su re s.

R u n n in g -in o il m ay be le ft in th e e n g in e s.

C o o la n t m u s t be c o m p le te ly d ra in e d . R em ove th e th e rm o s ta t/s and in s e rt o n e C h a d p a c k T a b le t (ADE Part N o 36170072) in to th e h o u sin g .

R e fit th e th e rm o s ta t/s a n d c lo s in g c o v e r/o u tle t and e n s u re th a t th e jo in ts fo rm a g o o d se a l. A ll e n g in e o p e n in g s m u s t be s e a le d a irtig h t.

N o te 1: T he p ro c e d u re in th is s e c tio n s h o u ld a ls o be fo llo w e d a fte r le s s th a n 12 m o n th s in th e ca se o f sea s h ip m e n ts and in tro p ic a l a reas.

2.2.1 Preservation of Fuel System : A d d a p p ro x im a te ly 10% ru n n in g -in o il to d ie se l fu e l a nd o p e ra te th e e n g in e w ith th is m ix tu re fo r a p p ro x im a te ly 5 to 10 m in u te s .

If a n u m b e r o f ve h ic le , tra c to r o r in d u s tria l e n g in e s are to be p reserved a t th e sa m e tim e , th e fu e l a n d th e ru n n in g -in o il m ay be m ix e d in a s e p a ra te c o n ta in e r b e fo re fe e d in g th e s o lu ­ tio n in to th e fu e l syste m via a th re e -w a y o r fo u r­ w a y c o c k valve. T h is e n a b le s th e c o n c e n tra tio n o f o il in d ie s e l fu e l to be in cre a se d to 15-20% .

N o te 5: F o llo w th e in s tru c tio n s fo r sea s h ip m e n ts or tro p ic a l areas.

USED ENG INES m u s t be tre a te d in a cco rd a n ce w ith th e m e a s u re s s e t o u t in Ite m s 2.1.2 and 2.2.1 b e fo re b e in g la id up o r d is m o u n te d .

C o o la n t m u s t be d ra in e d c o m p le te ly and a C h a d p a c k T a b le t m u s t be In se rte d in th e th e r­ m o s ta t h o u s in g .

2.2.2 Preservation of C om bustion Cham bers: O il m ay be sp ra ye d in to th e c o m b u s tio n c h a m b e rs v ia th e in je c to r p o rts a fte r rem o va l o f th e in je c to rs w h ic h m ay be im m e rs e d in o il fo r a d d ed p ro te c tio n .

F or b e st re s u lts th e m ete re d a m o u n t o f o il m ust be in je c te d in to th e c o m b u s tio n c h a m b e r u n d er p re s s u re to e n s u re c o m p le te s p ra y in g o f a ll areas. U pon c o m p le tio n o f each c y lin d e r (pisto n d o w n ), ro ta te th e e n g in e a t le a st o n e fu ll tu rn by hand.

R E M A N U FA C TU R E D E N G IN E S m u s t in all ca se s be p reserved in a c c o rd a n c e w ith S e c tio n 2.2 in fu ll.

3.2

Laid up for 12 to 36 months: T he p re s e rv a tio n m e a su re s se t o u t in S e c tio n 2.2 m u s t be c a rrie d o u t in fu ll.

3.3

Laid up for more than 36 months: If th e laying-up period is exte nd e d fo r m ore than 36 m on th s, p re se rva tio n m u st be repeated every 36 m o n th s (3 years) o r 18 m o n th s in a cco rd a n ce w ith S e c tio n 2.2 in fu ll.

N o te 2: D u rin g th e a bove o p e ra tio n th e in je c tio n p u m p /g o v e rn o r c o n tro l m u s t be in th e s h u t-o ff p o s itio n .

Oil Per Cylinder

Laid up for up to 12 months:

If th e re is o il in th e e n g in e , th is m ay be d ra in e d o ff a t roo m te m p e ra tu re (a b o u t 20°).

8-10 ml

It Is n o t n e c c e s a ry to c a rtrid g e .

N o te 3: Do n o t e x c e e d a bove a m o u n ts as th is m ay lead to h y d ra u lic lo c k and p o s s ib le e n g in e d a m a g e .

R e fit a ll p a rts re m o ve d a nd e n su re th a t s e a ls a nd g a s k e ts are in p la c e . R e -p o s itio n th e in je c tio n p u m p g o v e rn o r c o n tro ls to th e o p e ra tin g p o s itio n .

4.0 PREPARING E N G IN E FOR O PERATIO N 4.1

R em ove s e a lin g fro m a ll o p e n in g s .

4.2

R em ove p re s e rv in g a g e n t o r g re a se fro m th e grooves o f V -belt pulleys, flyw h e e l and o th e r un ­ p ro te c te d s u rfa c e s .

4.3

R e p o s itio n a nd te n s io n V -b e lts in a c c o rd a n c e w ith in s tru c tio n s .

4.4

If n o t a lre a d y in s ta lle d , f it e n g in e to m a c h in e .

4.5

F ill w ith a p p ro ve d lu b ric a tin g a n d c o o la n t s e r­ v ic e p ro d u c ts o r to p up to m a x im u m level.

N o te 4: E n g in e s m u s t n o t be s ta rte d a fte r th e c o m ­ b u s tio n c h a m b e r p re s e rv a tio n has been c a rrie d o u t.

2.2.3

Preservation o f Air Compressors: A ir c o m p re s s o r p re s e rv a tio n s h o u ld be d o n e in c o n ju n c tio n w ith th e c o m b u s tio n c h a m b e rs . A m a x im u m o f 5 c u b ic c e n tim e tre s o f ru n n in g -in o il s h o u ld be in je c te d o r p o u re d in to e a ch

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ren e w th e o il filte r

OPERATING AND MAINTENANCE — 09-5 N o te 6: E n g in e s w h ic h have n o t rece ive d th e ir firs t s e rv ic e m u s t be fille d w ith ru n n in g -in o il, a ll o th e rs s h o u ld be fille d w ith a p p ro ve d o p e ra tin g o ils .

4.6

R e ch a rg e and re c o n n e c t b a tte rie s .

4.7

Run e n g in e to o p e ra tin g te m p e ra tu re (c o o la n t te m p e r a tu r e 7 5 -7 9 ° C) w h ile m o n ito r in g p re s s u re s a n d te m p e ra tu re s .

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TECHNICAL DATA — 09-6

LUBRICATING OILS VISCOSITY GRADES A m bient A ir Temperature

SAE Grades

°C

mm. «

o o 5S

o

=£

1

in

o

CM

«

■ 35

in

DUE TO CONTINUOUS DEVELOPMENT, ATLANTIS DIESEL ENGINES ARE CONSTANTLY REVISING THEIR OIL RECOMMENDATIONS. TO OBTAIN THE LATEST OIL RECOMMENDATIONS, PLEASE REFER TO OUR SERVICE BULLETINS, OR CONSULT YOUR NEAREST OIL COMPANY FOR THEIR ADVICE.

A D E 360 S e rie s

SECTION 10-1 Fault Finding

CONTENTS OF THIS SECTION

STARTER MOTOR TURNS ENGINE TOO S L O W L Y .......................................................... 10-2 HARD STARTING WHEN C O L D .............................................................................................

10-3

ENG INE TURNS OVER BUT REFUSES TO S T A R T ..........................................................

10-4

ENG INE DIFFICULT TO S T A R T ..............................................................................................

10-5

E NG INE L O C K -U P ...................................................................................................................... 10-6 ENG INE CUTS OUT AFTER S T A R T IN G ...............................................................................

10-7

ENG INE O V E R H E A T IN G .......................................................................................................... 10-8 E N G IN f RUN NING TOO C O L D .............................................................................................. 10-9 ENG INE KNOCKING . . . : .......................................................................................................... 10-10 ENG INE V IB R A T IO N .................................................................................................................. 10-11 ENG INE M IS F IR E S .....................................................................................................................10-12 LOSS OF P O W E R ........................................................................................................................ 10-13 BLACK SMOKE FROM E X H A U S T ...........................................................................................10-14 BLUE SMOKE FROM E X H A U S T ...........................................................

10-15

W HITE SMOKE FROM E X H A U S T ...........................................................................................10-16 EXCESSIVE FUEL C O N S U M P T IO N ....................................................................................... 10-17 ABN O R M A L OIL C O N S U M P T IO N .......................................................................................... 10-18 LOW O IL P R E S S U R E ...................................................................

10-19

O IL PRESSURE TOO H I G H ......................................................................................................10-20 ENG INE O IL S L U D G E ................................................................................................................10-21

FA U LTFIN D IN G - 10-2

COMPLAINT

FAULT FINDING - 10-3

COMPLAINT

FAULT FINDING - 10-4

COMPLAINT

NOTE: Refer also to pages: 10-2) S tarter m otor turns engine too slow ly 10-5) Engine is d iffic u lt to start 10-3) Hard starting when cold

AD E 360 S e rie s

FAULT FINDING - 10-5

COMPLAINT

A D E 360 S e rie s

FAULT FINDING - 10-6

COMPLAINT

AD E 360 S e rie s

FAULT FINDING - 10-7

COMPLAINT

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FAULT FINDING - 10-8

COMPLAINT

ADE 360 S e rie s

FAULT FINDING - 10-9

COMPLAINT

FAULT FINDING - 10-10

COMPLAINT

FAULT FINDING - 10-11

COMPLAINT

ADE 360 S e rie s

FAULT FINDING - 10-12

COMPLAINT

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FAULT FINDING - 10-13

COMPLAINTS

ADE 360 S e rie s

FAU LTFIN D IN G - 10-14

COMPLAINT

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FAULT FINDING - 10-15

COMPLAINT

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FAULT FINDING - 10-16

COMPLAINT

A D E 360 S e rie s

FAULT FINDING - 10-17

COMPLAINT

A D E 360 S eries

FAULT FINDING - 10-18

COMPLAINT

A D E 360 S e rie s

FAULT FINDING - 10-19

COMPLAINT

A D E 360 S eries

FAULT FINDING - 10-20

COMPLAINT

ADE 360 S eries

FAULT FINDING -

COMPLAINT

10-21

__________SECTION 111 Cylinder Block and Liners

CONTENTS OF THIS SECTION Page INTRODUCTION ........................................................................................................................................... 11-3 SPECIFICATIONS ........................................................................................................................................ 11-3 CHECKING CYLINDER BORES FOR WEAR .................................

11-5

REBORING CYLINDER BLOCK ............................................................................................................... 11-6 REMOVING CYLINDER LINERS ...............................................................................................................11-7 REPLACING CYLINDER LINERS ............................................................................................................. 11-8 CRANKCASE VENTILATION SYSTEM ..................................................................................................11-11 REMOVING BREATHER ...........................................................................................................................11-13 REPLACING BREATHER ............................................................................

11-1411-14

A d e 360 S e rie s

SECTION 11 Cylinder Block and Liners

CYLINDER BLOCK 1 R EA R M A IN O IL S E A L S 2 SUMP 3 SUM P G ASKETS

7 GASKET 8 TIM ING COVER

13 SIDE COVER 14 CYLINDER LINER .

15 CRANKCASE BREATHER

4 M A IN B E A R IN G C A PS

9 OIL SEAL 10 COVER

5 GASKET

11 GASKET

17 GASKET

6 T IM IN G G E A R C A S E

12 O-RING

18 OIL COOLER

16 CYLINDER BLOCK

ADE 360 Series

CYLINDER BLOCK AND LINERS — 11-3 INTRODUCTION The cylinder block is designed to form an integral casting with the crankcase and is manufactured from high grade cast iron, alloyed with copper and chrome. U tilising the latest in engineering technology, the cylinder block is machined to very fine tolerances and is subject to a rigorous quality control inspection.

Interference fit, dry cylinder liners (Sleeves), are fitte d to the ADE 364T and 366T/TI. Engines fitted w ith cylinder liners can be identified by a “ Z” , stam ped on the cylinder block, to one side of the push rod cover.

SPECIFICATIONS CYLINDER LINER N om inal diam eter of cylinder

R epair stages

S ta n d a rd (N/C/T/TI)

97,50

C ylinder bore 97,510 97,490

Rep s ta g e 1(N) + 0,5 R e b o re *

98,00

358,80 358,70

Rep s ta g e 1 (N/C/T/TI)

97,50

97,510 97,490

Rep s ta g e 3 (N/C/T/TI)

359,10 ----- — (STD) 359,00

98,010 97,990

Rep s ta g e 2 (N/C/T/TI)

Total height of cylinder block

358,50 ----- ’— ( - 0,6) 358,40 358,20 -------— ( - 0,9) 358,10

*1 s t Rep s ta g e fo r n a tu ra lly a s p ira te d o p tio n a l I.e. e ith e r rebore fo r o ve rsize p is to n o r f it sleeve.

L in e r P a re n t B ore

100,435 100,400

L in e r F la n g e R ecess — d e p th

— d ia

4 8 ’ 4,6 103,626 103,572

C y lin d e r L in e r O.D.

1 0 0 49 5

_______________________________________________________________■ _____________________________________100,475 C y lin d e r L in e r F la n g e O.D.

103,428 103,375

NO TE 1: S tam p ed num bers appear on the side of the cylinder block for each cylinder. The num bers are for grading purposes during production only.

ADE 360 Series

CYLINDER BLOCK AND LINERS — 11-4 N O TE 2: It is essen tial to m achine to a piston clearance depth of at least 250 mm when reboring the 360 Series N aturally aspirated engine to next repair stage or for liner fitm en t. (See item B illustration below.)

D im e n s io n D im e n s io n D im e n s io n D im e n s io n

A B C hi

= = = =

9 8 ,0 - 9 8 ,3 mm 251 - 2 5 2 mm 2 2 4 - 2 2 5 mm B lo c k H e ig h t fro m c e n tre o f m ain b e a rin g bore to jo in t fa c e o f c y lin d e r head.

(R efer to c o lu m n s , c y lin d e r b lo c k a nd c y lin d e r lin e r fo r s ta n d a rd and re p a ir s ta g e s fo r b lo c k h e ig h t)

•

O v a lity o f c y lin d e r bore

0,01

T a p e r o f c y lin d e r bore

0,01

V e rtic a l d e v ia tio n o f c y lin d e r b o re s w ith in a d is ta n c e o f 200 m m in re la tio n to c ra n k s h a ft a x is

0,04

R o u g h n e s s o f bore a fte r h o n in g

R3Z

3-5 jim R m ax. 6-11

L e a kag e te s t p re s s u re w ith c y lin d e r b lo c k su b m e rg e d in w a te r a t 70°C

200 kPa

D is to rtio n lim it — L e n g th N o t to e xce e d 0,015 m m over a d is ta n c e of

0,03 150 mm

P is to n p ro tru s io n /re c e s s io n to u p p e r c y lin d e r b lo c k s u rfa c e

+ 0,30

W e a r lim it o f bore

0,12 0,05

- 0,088

to p p is to n rin g u p p e r re tu rn p o s itio n h a lfw a y s tro k e

60,030

C a m s h a ft b e a rin g b a s ic bore

60,000 M a in b e a rin g b a s ic bore

new

93,022 93,000

lim it fo r re p a ir

93,040 92,970

O v a lity o f m a in b e a rin g b a s ic bore

0,01

T a p e r o f m a in b e a rin g b a s ic bore

0,01

R o u g h n e s s u p p e r jo in t fa c e o f c y lin d e r b lo c k

8-16

TORQUE SPECIFICATIONS O il g a lle ry p lu g s (fro n t and r e a r ) ..................................................

C o n n e c tio n p lu g fo r t a c h o m e t e r ..............................................

P u sh ro d c o v e r to c y lin d e r b l o c k ...............................................

E n g in e m o u n tin g b ra c k e t to c r a n k c a s e ...................................

P is to n c o o lin g n o z z e ls ...................................................................

B la n k in g p lu g s (fo r p is to n c o o lin g n o z z e ls ) .........................

S id e c o v e r (w a te r ja c k e t) to c y lin d e r .........................................

AD E 360 S e rie s

M 1 6 x 1 ,5 ...............................................

M 1 8 x 1,5 ...............................................

M 20 x 1,5 ...............................................

M 2 6 x 1 ,5 ...............................................

M8 ...........................................................

M 1 4 x 1 ,5 ...............................................

M 1 0 x 1 ..................................................

M 1 0 x 1 ..................................................

M8 ...........................................................

40-45 N.m 70-90 N.m 90-110 N.m 60 N.m 15 N .m _ 150-190 N.m 25 N.m 10 N.m 25 N.m

CYLINDER BLOCK A N D ^ P E R S -

11-5

CHECKING CYLINDER BORES FOR WEAR In th e e ve n t o f E xce ssive O il C o n s u m p tio n and in a d d i­ tio n to a visual check, m easurem ents o f th e cylin d e r bores w ill be n e ce ssa ry. B e fo re a tte m p tin g to m e a su re th e c y lin d e r bores th e y sh o u ld be th o ro u g h ly cleaned and free fro m o il a nd c a rb o n d e p o s its .

1. U sin g co m p re s s e d air, cle a n th e to p o f th e c y lin d e r b lo c k , (fig . 11-1).

2. W ip e c y lin d e r b o re s u s in g c le a n rag. (fig . 11-2).

r r —m

fT " “<H It—<~I [mmtras

F ig. 11-2

3.

4.

C h e ck c y lin d e r b lo c k to p fa c e fo r lo c a lis e d d is to rtio n u s in g a s u ita b le s tra ig h t edge, (fig . 11-3).

S et in te rn a l m e a s u rin g in s tru m e n t, (fig . 11-4).

A D E 360 S e rie s

CYLINDER BLOCK AND LINERS 5. In s e rt m e a s u rin g (fig. 11-5).

11-6

in s tru m e n t in to c y lin d e r bores,

6. C h e ck c y lin d e r b o re s a t p o in ts 1, 2 and 3. The c h e c k s s h o u ld be m ade in d ire c tio n A = C e n tre lin e and B = 9 0 ° fro m c e n tre lin e , (fig. 11.6).

W h e n p is to n s are n o t rem oved, th e m e a s u rin g p o in t 3 is ju s t a b o ve th e p is to n a t BDC.

REBORING CYLINDER BLOCK FOR OVER­ SIZE PISTONS OR FITMENT OF LINERS 1. A fte r th e c y lin d e r b lo c k has been th o ro u g h ly c le a n ­ ed it s h o u ld be s e c u re ly m o u n te d u n d e r th e b o rin g bar, (fig . 11-7).

F ig. 11-7

2. A lig n a n d c e n tre th e b o rin g b a r a b o ve th e c y lin d e r to be m a c h in e d .

3. In s e rt to o l in to b o rin g b a r head and a d ju s t to th e re­ q u ire d d im e n s io n , (fig . 11-8).

A ttention!

If m ore th a n one c y liin d e r req u ire s b o rin g fo r lin e r fitm e n t th e fo llo w in g s e q u e n c e s h o u ld be fo llo w e d : B ore c y lin d e rs 1-3-5-2-4-6 — (6 c y lin d e r), 2-4-1-3 — (4 c y lin d e r).

W h e n u s in g th is s e q u e n c e o f b o rin g e x c e s s iv e th e rm a l s tre s s w ill be a vo id e d .

A D E 360 S e rie s

CYLINDER BLOCK AND LINERS — 11-7 4. Bore c y lin d e r to 0,05 m m b e lo w th e fin a l c y lin d e r bore d im e n s io n , (fig. 11-9).

A tten tio n!

M a c h in e o r s u rfa c e g rin d c y lin d e r b lo c k to p fa c e by 0,3 m m to n e x t b lo c k h e ig h t re p a ir sta g e, i.e. fo r o ve rsize d p is to n s o r lin e r fitm e n t (see s p e c ific a tio n s ) and e n su re c o rre c t re p a ir s ta g e p is to n s are used.

F ig. 11-9

5. S e cu re ly m o u n t cylin d e r b lo c k under hon in g m achine.

H o n e c y lin d e r lin e rs to fin a l d im e n s io n s , (see s p e c ific a tio n s ), (fig . 11-10).

6. B e fo re a s s e m b lin g th e e n g in e th o ro u g h ly cle a n the cy lin d e r b lo ck and cran kca se inside and out. B low o u t o il g a lle ries e n su rin g th a t no residue from th e m a c h in ­ ing p ro ce ss is le ft.

REMOVING CYLINDER LINERS 1. S ecurely m ou n t cran kca se under b o ring m ach in e , (fig.

1 1 - 1 1 ).

2. A lig n a nd c e n tre b o rin g bar a b o ve th e c y lin d e r to be m a c h in e d .

Attention!

If m ore th a n one c y lin d e r re q u ire s b o rin g , th e fo llo w in g s e q u e n c e s h o u ld be fo llo w e d : B ore c y lin d e rs 1-3-5-2-4-6 — (6 cylin d e r), 2-4-1-3 — (4 cylin d e r).

W hen u s in g th is se q u e n ce o f b o rin g e xce ssive th e rm a l s tre s s w ill be avo id e d.

3. In s e rt to o l in to b o rin g bar head a nd a d ju s t so th a t the c y lin d e r lin e r w ill be b o re d o u t to a p p ro x im a te ly h a lf its fo rm e r th ic k n e s s , (fig. 11-12).

AD E 360 S e rie s

CYLINDER BLOCK AND LINERS — 11-8 4. Re-set to o l in b o rin g b a r head and m a c h in e c y lin d e r lin e r to 0,2 m m b e lo w o u te r d ia m e te r o f c y lin d e r lin e r (Standard Size). Bore c y lin d e r lin e r and rem ove flanqe, (fig . 11-13).

A tten tio n! A t th is s e ttin g th e fla n g e o f th e lin e r w ill b e c o m e d e ta c h e d fro m th e sleeve.

Fig. 11-13

5. In s e rt b o rin g b a r head in to c y lin d e r bore, w ith c u ttin g to o l s ta tio n a ry and in c o n ta c t w ith cylin d e r liner. M ove c u ttin g to o l v e rtic a lly up and d o w n c y lin d e r bore, a llo w in g c u ttin g to o l to break th ro u g h w a ll o f c y lin d e r lin e r. Rem ove c y lin d e r lin e r fro m c y lin d e r b lo ck, (fig . 11-14).

F ig. 11-14

REPLACING CYLINDER LINERS 1. T h o ro u g h ly c le a n b o re fo r c y lin d e r lin e r a nd fla n g e s e a t, (fig . 11-15).

2. M o u n t c y lin d e r b lo c k u n d e r p re ss and a lig n c y lin d e r bore.

3. A p p ly a lig h t c o a tin g o f g re a se to bore in c y lin d e r b lo c k .

F ig. 11-15

4. L o c a te c y lin d e r lin e r over b o re in c y lin d e r b lo c k and a lig n , u s in g a s e t sq u a re , (fig . 11-16).

F ig. 11-16 AD E 360 S e rie s

CYLINDER BLOCK AND LINERS -

11-9

5. F it a s u ita b ly ste p p e d s te e l p la te b e tw e e n p re ss head and c y lin d e r lin e r. Press c y lin d e r lin e r in to c y lin d e r b lo ck u n til it p ro tru d e s a p p ro xim a te ly 20 mm, (fig. 11-17).

6. B e fo re p re s s in g lin e r fu lly hom e, c h e c k lin e r fla n g e and se a t fo r m e ta l p a rtic le s and d irt. B lo w o u t w ith c o m p re s s e d air, (fig . 11-18).

7. Press c y lin d e r lin e r fu lly h om e, re lie ve p re s s u re fo r a s h o rt p e rio d and p re ss o n ce a g a in , re ta in in g p re s s u re fo r 5 se co n d s.

8. M a c h in e o r s u rfa c e g rin d c y lin d e r b lo c k to p fa c e by 0,3 m m to n e x t b lo c k h e ig h t re p a ir s ta g e (in c lu d in g p ro tru d in g c y lin d e r lin e r) see s p e c ific a tio n s fo r re­ q u ire d s u rfa c e fin is h , (fig . 11-19).

A ttention!

B e fo re m a c h in in g o b se rve c y lin d e r b lo c k h e ig h t and re p a ir s ta g e a nd e n su re c o rre c t re p a ir sta g e p is to n s are use d . R efer p is to n c o m p re s s io n h e ig h a nd b lo c k h e ig h t s p e c ific a tio n s .

9. A fte r m a c h in in g /s u rfa c e g rin d in g , c h e c k c y lin d e r b lo c k fa c e w ith a s tra ig h t edge, (fig . 11-20).

A D E 360 S e rie s

CYLINDER BLOCK AND LINERS — 11-10 10. A fte r th e c y lin d e r b lo c k has been th o ro u g h ly c le a n ­ ed it s h o u ld be s e c u re ly m o u n te d u n d er th e b o rin g bar, (fig . 11-21).

11. A lig n and c e n tre th e b o rin g b a r a bove th e c y lin d e r to be m a c h in e d .

12. In s e rt to o l in to b o rin g bar head and a d ju s t to the re q u ire d d im e n s io n , (fig. 11-22).

13. Bore c y lin d e r lin e r in se ve ra l s ta g e s to 0,050 mm b e lo w th e re q u ire d b o re d im e n s io n , (fig. 11-23).

A ttention!

If m ore th a n one c y lin d e r re q u ire d b o rin g , th e fo llo w in g s e q u e n c e s h o u ld be fo llo w e d : B ore c y lin d e rs 1-3-5-2-4-6 (6 c y lin d e r), 2-4-1-3 (4 c y lin d e r).

W hen u s in g th is s e q u e n c e o f b o rin g , e x c e s s iv e th e rm a l s tre s s w ill be a vo id e d.

14. R em ove c y lin d e r b lo c k fro m b o rin g m a ch in e .

15. S ecurely m ou n t c y lin d e r b lo ck under hon in g m achine.

H o n e c y lin d e r lin e rs to fin a l d im e n s io n s , (see s p e c ific a tio n s ), (fig . 11-24).

16. B e fo re a s s e m b lin g th e e n g in e th o ro u g h ly cle a n the c y lin d e r b lo ck and cran kca se inside and out. Blow o u t o il g a lle ries e n su rin g th a t no residue from th e m a ch in ­ ing p ro c e s s is lef*

F ig. 11-24 A D E 360 S e rie s

CYLINDER BLOCK AND LINERS — 11-11 CRANKCASE BREATHER OPERATION AND PROBLEM DIAGNOSIS Introduction D e p e n d in g on a p p lic a tio n , th e c ra n k c a s e b re a th e r m ay be m o u n te d to th e ro c k e r cover, p u sh ro d co ve r o r tim in g

-4

g e a r h o u s in g , (fig. 25).

T h e c ra n k c a s e b re a th e r c o n tro ls th e p re s s u re in th e cran kca se w ith in a prescribed o p e ra tin g range. The d e vice is o p e n to c ra n k c a s e g a sse s a t th e lo w e r end (7) w ith a c o n n e c tio n to th e in d u c tio n m a n ifo ld (4) a nd a ve n t to a t­ m o s p h e re (3).

N o te 1: F o r p ro p e r o p e ra tio n th e a re a a ro u n d th e a ir vent (3) m u s t be k e p t c le a n to p re ve n t b lo c k a g e . In a d d itio n a ll jo in ts , c o n n e c tio n s and o il f ille r cap m u s t fo rm a tig h t se a l to p re ve n t c ra n k c a s e d e p re s s io n lo s s e s a n d /o r d irt e n try in to th e e n g in e .

N o te 2: T he fle x p o in t o f th e b re a th e r d ia p h ra g m is s u b ­ je c t to d e te rio ra tio n e.g. h a rd e n in g o r c ra c k in g . It is th e re fo re strongly recom m ended that the breather be replaced a fter every tw o years operation, as a p re c a u ­ tio n a ry m easure.

F ig. 25

1 2 3 4 5 6 7 8 9 10

1.0 Operation 1.1 A tm o s p h e ric p re ssu re a c ts on th e o u te r su rfa ce o f th e d ia p h ra g m (1) via th e vent (3). Before s ta rt­ up, a tm o s p h e ric p re ssu re w ill a ls o be p re se n t in th e c ra n k c a s e and in d u c tio n sy s te m s . The p re s s u re on b o th s id e s o f th e d ia p h ra g m w ill th u s be equal.

1.2 T he s p rin g (9) a c ts a g a in s t th e d ia p h ra g m and h o ld s th e valve (2) o ff its se a t in th e open p o s i­ tio n . To c lo s e th e valve, s u ffic ie n t d e p re s s io n m u st o c c u r in th e c ra n k c a s e to a llo w a tm o s ­ p h e ric p re ssu re a c tin g on th e o u te r s u rfa c e o f - th e d ia p h ra g m , to o ve rco m e th e s p rin g fo rc e .

T he o p e ra tio n o f th e b re a th e r is th e re fo re d e p e n d e n t on e n g in e o p e ra tio n .

— — — — — — — — — —

mm +

Q

1.3 A t e n g in e id le sp e e ds, th e s p rin g fo rc e w ill be s u ffic ie n t to hold th e valve from its se a t a g a in s t a tm o s p h e ric p re ssu re a c tin g on th e o u te r s u r­ fa ce o f th e d ia p h ra g m . C ra n k c a s e g a sse s w ill su s e q u e n tly be d ra w n d ire c tly in to th e c o m b u s ­ tio n c h a m b e rs and w ill be b u rn t d u rin g th e c o m ­ b u s tio n p ro ce ss.

1.4 A t n o rm a l o p e ra tin g sp e e d s and lo a d s th e ever ch a n g in g in d u c tio n m a n ifo ld d e p re s s io n a c tin g w ith in th e b re a th e r, is h ig h e r th a n th e req u ire d cra n kca se d e p re ssio n . The b re a th e r w ill rea ct to th e h ig h m a n ifo ld d e p re s s io n and c o n tro l c ra n k c a s e d e p re s s io n . e.g. S h o u ld th e c ra n k c a s e d e p re ssio n a p p ro a ch th e u p p e r n e g a tiv e lim it in th e o p e ra tin g range, th e valve w ill m ove to w a rd s th e c lo s e d p o s itio n to re d u ce th e e ffe c t o f m a n ifo ld d e p re s s io n w ith in th e c ra n kca se .

T he va lve in tu rn w ill re a ct w h e n c ra n k c a s e d e p re s s io n is re d u ce d to w a rd s th e lo w e r or p o s itiv e lim it and w ill open m a rg in a lly to a llo w th e h ig h m a n ifo ld d e p re s s io n a c c e s s to th e cran kca se .

In th is m a n n e r th e b re a th e r w ill c o n tin u o u s ly se n se and a c c o rd in g ly , re sp o n d to m a n ifo ld d e p re s s io n u n d e r v a rio u s o p e ra tin g c o n d itio n s and th e re b y, c o n tro l cra n kca se d e p re ssio n w ith th e d e s ire d o p e ra tin g range.

D ia p h ra g m V alve A ir V e n t T o In le t M a n ifo ld O il D rain H o le Gauze F rom C ra n k c a s e P e rfo ra te d P la te s S p rin g ‘O ’ Ring

t t X

40 _ 50 _

mm-

X

J

F ig. 26

OPERATING RANGE SERVICE S P E C IF IC A T IO N FOR A L L BREATHERS: + 10 TO - 100 m m H 20

Note: X — EX AM PLE O N LY = m a n o m e te r r e a d in g - 6 0 m m H 20

AD E 360 S e rie s

CYLINDER BLOCK AND LINERS — 11-12 1.5

C ra n k c a s e g a s s e s p a s s in g v ia th e b re a th e r are o il b e a rin g and m o s t o f th e o il w ill be tra p p e d by th e gauze m esh (6). E xce ss o il n o t tra p e d by th e gauze w ill return to th e cra n kca se via a dra in h o le (5) p ro v id e d in th e b re a th e r neck.

H ow ever, it is n o rm a l fo r a s m a ll q u a n tity o f o il, in th e fo rm o f m is t to be tra n s fe rre d to th e in ­ ta k e a ir to lu b ric a te th e valves (3 — 5 g/hr). T he d a m p n e s s c re a te d by th e o il fu m e s is n o rm a lly e vid e n t in th e in le t/m a n ifo ld o f e n g in e s u tiliz in g th is ty p e o f b re a th in g s y s te m a n d is n o t n e c e s s a rily in d ic a tiv e o f a p ro b le m .

3.3

Excessive positive reading is indicated at all engine speeds.

CAUSE

REMEDY

a) Broken collapsed spring

— Renew

b) Valve s tu ck in closed p o sition

— Renew breather

breather

c) B lockage o f breather gauze by sludge*

diesel If this fails, renew breather

d) Severe com bustion gas blow by

2.0 Operational Test

2.2 Use a w a te r m a n o m e te r (see fig . 26) and co n n e ct o ne end o f th e g a u g e to th e e n g in e d ip s tic k g u id e tube. The o th e r end o f th e tu b e is le ft open to a tm o s p h e ric p re ssu re . B e fo re s ta rtin g th e e n g in e e n s u re th a t th e in s tru m e n t re g is te rs a zero re a d in g in b o th c o lu m n s .

2.3 S ta rt and run th e e n g in e a t id le speed. A te n ­ d e n cy to w a rd s a ne g ative re a d in g ( - ) s h o u ld be n o ted . in c re a se th e e n g in e speed to a p p ro x i­ 500 r/m in . The in s tru m e n t s h o u ld negative reading in crea sin g w ith in the range.

2.5 F u rth e r in c re a s e th e e n g in e speed to a p p ro x i­ m a te ly 2 000 r/m in . The n e g a tive rea d in g s h o u ld ra is e w ith in th e o p e ra tin g range. T h is w o u ld in d ic a te th a t th e va lve is w o rk in g .

N o te 3: The o p e ra tio n a l c h a ra c te ris tic s o f a b re a th e r w ill d e p en d on th e c o n d itio n o f th e e n g in e e.g. a m o u n t o f b lo w b y .

3 .0

Evaluation of Test Results 3.1

M inim al negative reading at low r/min w ith little or no change at high r/min.

CAUSE

REMEDY

a) Gauge con nection s leaking

— Secure

b) Leak in vacuum line to

— Check and

con nection s m anifold c) Poor seal at breather

correct — C heck/replace

m ounting

O-ring or gasket

d)

Diaphragm cracked/holed

— Renew breather

3.2

Excessively high negative reading.

CAUSE a) Valve not closing

REMEDY — Check b, c, d below, or renew breather

b) Vent hole blocked

— C lear and

c) Vent hose pinched

—

retest Repair hose and retest d) Foreign p a rtic le on

—

valve seat e) Diaphragm ruptured

Remove object and retest

—

Renew breather

ADE 360 S e rie s

— Repair as necessary

'In v e s tig a te reason fo r sludge and rectify.

2.1 Park th e v e h ic le on level g ro u n d and e n su re th a t th e o il level is c o rre c t (n o t o ve r-fille d ).

2.4 G ra d u a lly m a te ly 1 in d ic a te a o p e ra tin g

— W ash in clean

N o te 4: A s a rule c ra n k c a s e p re ssu re d e p re s s io n s h o u ld rem a in w ith in th e p re scrib e d range ( + 10 to - 1 0 0 mm H 2 O). If th is is n o t th e case and all p o ssib le c o n trib u tin g fa c ­ to rs have been e lim in a te d , it m ay be a ssu m e d th a t th e b re a th e r is fa u lty .

4.0 Conclusion A fa u lty cra n k c a s e b re a th in g syste m c o u ld re s u lt in th e fo llo w in g p ro b le m s: 4.1 E xce ssive o il c o n s u m p tio n .

4.2 D u st e n try v ia — a) A ru p tu re d o r p u n c tu re d d ia p h ra g m , b) A p o o r seal a t th e “ O ” ring ( 10), c) O th e r in le t o r cra n k c a s e c o n n e c tio n s , c o u ld ca u se s e rio u s d a m a g e to th e e n g in e.

4.3 A h ig h c ra n k c a s e p re ssu re c o u ld fo rc e o il p a st th e c ra n k s h a ft and tu rb o c h a rg e r seals.

CYLINDER BLOCK AND LINERS -

11-13

REMOVAL AND REPLACEMENT OF BREATHER Removal 1. U n scre w c lip on (fig. 11-27).

pipe le a d in g to

in le t m a n ifo ld ,

2. Rem ove p ip e w ith c lip , (fig. 11-28).

3. U n scre w c la m p on c ra n k c a s e end o f b re a th e r pipe, (fig. 11-29).

4. Pull o ff b re a th e r fro m m o u n tin g p ipe, (fig . 11-30).

Fig. 11-30 A D E 360 S e rie s

CYLINDER BLOCK AND LINERS — 11-14 5.

R em ove o-ring fro m th e in s id e o f th e b re a th e r pipe, (fig . 11-31).

F ig. 11-31

Replacing 1.

F it new o -rin g in th e b re a th e r p ip e , (fig . 11-32).

2.

S lid e b re a th e r w ith o -rin g in to p la ce over m o u n tin g p ip e , (fig. 11-33).

3.

A lig n bre a th e r to in le t m a n ifo ld and secure c la m p over in le t pipe, (fig. 11-34).

A D E 360 S e rie s

CYLINDER BLOCK AND LINERS 4.

R eplace pipe le a d in g to th e in le t m a n ifo ld , (fig. 11.35).

5.

T ig h te n c lip on th e pipe, (fig. 11-36).

11-15

AD E 360 S e rie s

" QaM *ington Diesel Club

ADE 364 and ADE 366

Workshop Manual Section 12 - Cylinder Head

B o n in g to n D iesel C lu b

SECTION 12 Cylinder Head

3

1 2 3 4 5 6 7 8 9 10 11

G A S K E T (EXHAUST M A N IF O L D ) G A S K E T (IN LE T M A N IF O L D ) C Y L IN D E R H E A D G A S K E T C Y L IN D E R H E A D IN JE C T O R S E A L IN G W A S H E R IN JE C T O R C Y LIN D E R H E A D BO LT EX H AU S T V A L V E S E AT INSERT IN L E T V A L V E SEAT INSERT V A LV E G U ID E V A LV E STEM O IL S E A L

12 13 14 15 16 17 18 19 20 21

IN L E T V A LV E EXH AU S T V A LV E V A LV E SPR IN G A S S E M B LE Y V A LV E C O LLE T S PUSH ROD RO CKER CO VER G A S K E T RO CKER COVER O IL F ILLE R C A P (SCREW TYPE) O IL F ILLE R C A P (CLIP TYPE) RO CKER GEAR R E T A IN IN G BO LT

2

22 RO CKER S H A F T R E T A IN IN G G R U B SC R EW 23 ROCKER G EAR R E T A IN IN G BO LT 24 RO CKER A S S E M B LE Y 25 RO CKER S H A F T C O U P LIN G B U S H * 26 SPR IN G

* N O T FITTE D O N A D E 364

ADE 360 Series

SECTION 12-1 Cylinder Head CONTENTS OF THIS SECTION Page INTRODUCTION ............................................................................................................................... ........ 12-3 SPECIFICATIONS .....................................................................................................................................12-3 TORQUES ....................................................................................................................................................12-6 REMOVING ROCKER COVER ................................................................................................................12-7 REMOVING CYLINDER HEAD ............................................................................................................... 12-7 CHECKING VALVE RECESSION ........................................................................................................... 12-11 REMOVING VALVES .................................................................................................................................12-11 CHECKING VALVE STEM/GUIDE CLEARANCE ................................................................................ 12-12 VALVE FACING .......................................................................................................................................... 12-13 VALVE SEAT FACING ...............................................................................................................................12-14 REMOVING VALVE GUIDES ...................................................................................................................12-14 REPLACING VALVE G U ID E S .................................

12-14

CHECKING CYLINDER H E A D ............................................................................................................... 12-16 REPLACING VALVES .....................

12-16

INJECTOR PROTECTION SLEEVES .....................................................................................................12-18^ CHECKING INJECTOR PROTRUSION ................................................................................................. 12-19 REPLACING CYLINDER HEAD ...............................................................................................................12-20 VALVE CLEARANCE ADJUSTMENT 364 ............................................................................................ 12-23 VALVE CLEARANCE ADJUSTMENT 366 ............................................................................................ 12-24 REPLACING ROCKER COVER ............................................................................................................... 12-24 CHECKING COMPRESSION PRESSURE ............................................................................................ 12-25 SPECIAL SERVICE TOOLS ...................................................................................................................... 12-27

AD E 360 S e rie s

CYLINDER HEAD — 12-3

INTRODUCTION U tilising the latest in autom otive engineering technology, the ADE 360 series cylinder head is of advanced design common for all cylinders and is m anufactured from high grade grey cast iron alloyed w ith copper and chrome, and machined to a very high tolerance. The fuel injectors are mounted w ith in the cylinder head and enclosed by a light alloy rocker cover.

Separate inlet and exhaust m anifolds are fitted , providing enhanced gas flow and improved fuel efficiency.

SPECIFICATIONS 92,1

O v e ra ll h e ig h t o f c y lin d e r head (new)

91,9 M in im u m h e ig h t a fte r m a c h in in g *

90,9

P eak to v a lle y fin is h o f m a tin g s u rfa c e in (m icro n s)

8,16

D is to rtio n lim it

over L e n g th o f head o ve r d is ta n c e o f 150 m m

0,150 0,040

M a x p a ra lle l d e v ia tio n b e tw e e n u p p e r and lo w e r s u rfa c e

0,1

In je c to r nozzle p ro tru s io n

1,6-2,6

L e a k a g e te s t p re s s u re w ith c y lin d e r head su b m e rg e d in w a te r a t 70°C

200 kPa

*C h e c k n o zzle p ro tru s io n a fte r e a ch m a c h in in g sta g e o f c y lin d e r hSiad m a tin g s u rfa c e and c o rre c t w ith nozzle s h im s if re q u ire d . W h e n m in im u m h e ig h t is re a ch e d f it 1 m m s p a c e r u n d e r ro c k e r p e d e s ta ls .

i§ .

!

z

i

--------- D -------- ►

t

I/ALVE SEAT INSERTS

S ta n d a rd

In le t va lve s e a t in s e rt Rep. s ta g e 1 Rep. s ta g e 2

O D “ D” o f va lve s e a t in s e rt

43,88 43,87

44,18 44,17

44,38 44,37

B a s ic b o re “ D 1” in c y lin d e r h e a d fo r va lve se a t in s e rt

43,825 43,800

44,125 44,100

44,325 44,300

In te rfe re n c e f it o f se a t in s e rt in c y lin d e r head

E xh a u st va lve s e a t in s e rt S ta n d a rd Rep. s ta g e 1 Rep. s ta g e 2 38,080 38,070

38,380 38,370

38,580 38,570

38,025 v \ 38,000 '■

38,325 38,300

38.525 ■/.38,500

0,045-0,080

0,045-0,080

D e p th “ t ” o f bore in c y lin d e r head

11,2 11,0

11,2 11,0

H e ig h t “ H ” o f va lve s e a t in s e rt

7,4 7,3

6,1 8,0

3,6-3,9

2,9-3,2

D is ta n c e “ t1 ” b e tw e e n m a tin g s u rfa c e o f c y lin d e r h e a d and fa c e o f va lve s e a t in s e rt

CYLINDER HEAD — 12-4 VALVE SEATS

In le t V a lv e s e a t a n g le

30° =----------------------------------------

E xh a u st

D ia m e te r “ A ” o f va lve se a t w ith new va lve s e a t in s e rts a fte r m a c h in in g

45°

' n ^e t 41’3 -----------------------------------------------------------E xh a u st

35,3

In le t

1,3-2,4 :---------------- =-----

W id th ,,B ”

S ize “ C ”

E xh a u st

1,8-3,0

ln le t

3,6-3,9

In s p e c tio n size ---------------------------------------------------------------------------------------------------------------------------------------E xh a u st

:-2,9-3,2

Valve re c e s s io n *

0,7-1,1

* l f th e va lve re c e s s io n is e xce e de d a fte r m a c h in in g th e va lye se a t in s e rts , new in s e rts m u s t be fitte d .

VALVE SPRINGS

ID

’

2 5 ,0 - 2 5 ,4

Wire dia.

Unloaded length

4,25

60,5

Preloaded Length (1) Load (N) 46,7

1)( In in s ta lle d c o n d itio n . C o rre s p o n d s to le n g th w ith va lve c lo s e d .

2) -.4n in s ta lle d c o n d itio n . C o rre s p o n d s to le n g th w ith valve o p e n e d .

285 - 315

Final Load Length (2) Load (N)

35,18

570 - 630

CYLINDER HEAD In le t

12-5

Exhaust

VALVE GUIDES

V a lve g u id e ID S ta g e s

OD In le t

S ta n d a rd

15,046 15,028

Rep. s ta g e 1

15,146 15,128

Rep. s ta g e 2

Rep. s ta g e 3

V a lve g u id e le n g th

15,246

E xh a u st

In le t

E xh a u st

B.ore in c y lin d e r head

In te rfe r­ e n ce in c y lin d e r head

"

C le a ra n c e o f va lve s te m in va lve g u id e In le t

Exhaust

0,050 to 0,087

t t 'f 0,097

15,018 15,000

9,022* 9,000

10 ,022** 10,000

(“ B ” )

(“ C ” )

15,118 15,100

72

67

15,218

15,228

15,200

15,546 15,528

15,518 15,500

0,010 to 0,046

* W e a r lim it 9,050 “ W e a r lim it 10,050 0,04

M a x im u m o f f c e n tre o f valve s e a t to valve g u id e M a x im u m c y lin d ric a l d e v ia tio n o f valve se a t to valve g u id e a t

42 m m d ia fo r in le t 0,01 34 m m d ia fo r e x h a u s t

“ A ” — R e p la c e m e n t V alve g u id e in s ta lla tio n h e ig h t

V a lve s te m /g u id e c le a ra n c e In le t va lve — re a d in g n o t to e xce e d E x h a u s t va lve — re a d in g n o t to e xce e d

N O TE: R e p la c e m e n t va lve g u id e s m u s t be u se d to g e th e r w ith va lve s te m se a ls.

17,5 17,0

0,2 m m 0,3 m m

CYLINDER HEAD — 12-6 VALVES Dimen­

“A”

“ B”

“E”

,.p ,

Seat

Dia Seat

“C" Valve

“D”

sions

Height

Width

Stem

Stem

Valve

(mm)

Angle

Centre

Head Dia

New Min

Dia

Hardness

Length

In le t

30°

40

Exhaust

34

4§?

42 ,9

2,8

42 ,7

2,6

3 6 ,1 0

2,8

3 5 ,9 0

2,5

2,1

2,1

4.3

8,9 50

3.3

,8 ,9 3 5

4,2

9,9 40

3,5

9,9 25

— HRC 54

140,7 140,3 140,7

t54 >

rc

14,03

R u n o u t b e tw e e n v a lv e se a t and ste m

0,0 3

-

R u n o u t b e tw e e n va lve head a nd ste m

0,20

O v a lity o f va lve se a t

0,01

VALVE ADJUSTMENT

360 Series N

V a lve c le a ra n c e (te m p e ra tu re m ax, 50°C ) •

360 S e rie s C/T/TI

In le t

0,40

0,40

E xh a u st

0,60

0,60

VALVE TIMING

E xhaust

O pen

BTDC

15°

15°

C lo s e

AB D C

45°

25°

BBDC

67°

O CO CO

In le t

ATD C

13°

12°

Open

.

C lo s e

ROCKtRSHAFT/ROCKER ARM :---------------------------- f— B a s ic b o re ro c k e r arm R o c k e r a rm bush

22,052

22,000 2 2 ,1 3 0

O u te r dia.

22,100

In n e r dia.

20,021 20,000

R o c k e r s h a ft d ia arance s h a ft/b o re ;

19,980 1 9 ,967

0,020-0,054

^TORQUE SPECIFICATIONS T h e fo llo w in g to rq u e s p e c ific a tio n s w ill a p p ly w ith th e c o m p o n e n ts lig h tly o ile d . / C y lin d e r h e a d b o l t s .......................................................................................1 st S tage: 60 N .m .(M a x im u m s tre tc h le n g th 113m m ) 2nd S ta g e : 90 N.m 3 rd S tage: 120 - 130 N.m 4 tti S ta g e : 9 0 ° -ip o ° S c re w p lu g s to c y lin d e r h e a d .................................................................. ,.M 2 4 x 1 ,5 ..70-150 N .m >' M 3 0 x 1 ,5 ....... 100-200 N.m in ie b t o r p ro te c tio n sleeve to c y lin d e r head ...................... ..................M 1 4 x f , 5 .............. 50 N.m In je c to r s e c u rin g n u t to c y lin d e r h e a d ..........................................M 3 4 x 1,5 ..... ....... 70 N.m R o c k e r c o v e r to c y lin d e r h e a d .................................................................M 8 ..........................25 N.m v a iy e a d ju s tin g s c re w lo c k n u t ................................................................M 1 2 x 1 .................. 40 N.m R o flJ ^ r s h a ft p e d e s ta l to c y lin d e r h e a d ............................................... M 1 2 ........................100 N.m R o c k e r s h a ft lo c k s c re w to p e d e s ta l ..................................................... M 6 ................... .......5 N.m i/E x h a u s t m a n ifo ld to c y lin d e r h e a d .......................................................... M 1 0 ............... ........60 N .m + 90 ° . In le t m a n ifo ld to c y lin d e r h e a d ................................................................M 8 x 1 .................... 30 N .m ' (C h e ck a t e ve ry se rvice) IT y rb o c h a rg e r to e x h a u s t m a n ifo ld 3 6 6 C /T m .......................................M 1 0 ........................50 N.m 3 6 4 C /T .......................................... M10 .........................30 N.m E x h a u s t fla n g e to tu rb o c h a rg e r ................................................................ M 8 ......................... 30 N.m p re s s u re d u c t to tu rb o c h a rg e r (V -cla m p )« .............................................................................. 6 N.m

WÊÈ, 360?i*rìèsS

CYLINDER HEAD REMOVAL OF ROCKER COVER 1.

U n s cre w a nd rem o ve b o lts re ta in in g ro c k e r cover, (fig . 12-1).

F ig. 12-1

2.

L ift o ff ro c k e r cover, (fig . 12-2).

3.

R em ove g a s k e t fro m c y lin d e r head, (fig . 12-3).

Fig. 12-3

¡REMOVING CYLINDER HEAD Preparation C le a n th e e n tire u p p e r h a lf o f th e e n g in e , to p re ve n t d irt e n te rin g th e c y lin d e r b o r e s jjn d ta p p e t ch a m b e r.

1. D ra in c o o la n t fro m ra d ia to r a nd c y lin d e r b lo ck.

2. R em ove fu e l filte rs and if fitte d , p ow er ste e rin g pum p (fig . 12-4).

3. D is c o n n e c t ra d ia to r h o se s and d ip s tic k g u id e tu b e.

4. D is c o n n e c t and rem o ve th e rm o s ta t h o u s in g .

F ig . 1 2 ^ 7

12-7

CYLINDER HEAD — 12-8 5. R em ove ro c k e r c o ve r, see page 12-7.

6. U n screw and rem ove cla m p s re ta in in g in je c to r pipes, (fig. 12-5).

7. D is c o n n e c t o u te r in je c to r c y lin d e r head, (fig. 12-6).

8.

p ip e

c o n n e c tio n s

on

U sin g s p e c ia l to o l p a rt n u m b e r 40200705, u n s c re w and rem ove in je c to r p ip e s, (fig . 12-7).

Fig. 12-7

9. U n s c re w and rem ove fu e l le a k o ff p ip e , (fig. 12-8).

CYLINDER HEAD — 12-9 10. R em ove in je c to r p ip e s fro m c y lin d e r head.

11. U n s c re w b o lts re ta in in g ro c k e r a s s e m b ly , (fig . 12-9).

12. R em ove ro c k e r a s s e m b ly (and c o n n e c tin g n ip le 6 c y lin d e r only).

Fig. 12-9

13.

L ift o u t p u sh ro d s. The p u s h ro d s s h o u ld be n u m b e re d to e n su re re p la c e m e n t in th e o rig in a l p o s itio n s , (fig .

12 - 10 ).

14.

Rem ove in je c to r se cu rin g nuts, using sp e cia l to o l part n u m b e r 40200873, (fig. 12-11).

15.

R em ove in je c to rs fro m c y lin d e r head, u s in g im p a c t p u lle r p a rt n u m b e r 40201076, (fig . 12-12).

F ig. 12-12

LSerW*

CYLINDER HEAD — 12-10 A ttention!

16. S h o u ld th e in je c to rs n o t m ove u sin g im p a c t p u lle r, u se s p e c ia l to o l p a rt n u m b e r 40201063, (tig . 12-13).

17. D is c o n n e c t e x h a u s t d o w n pipe.

18. U n s c re w b o lts and rem ove e x h a u s t m a n ifo ld , (if f i t ­ te d w ith a tu rb o c h a rg e r, d is c o n n e c t tu rb o c h a rg e r o il fe e d and d ra in p ip e s firs t), (fig . 12-14).

19.

20.

U n scre w b o lts and rem ove in le t m a n ifo ld , (fig. 12-15).

U n s c re w s n d rem ove c y lin d e r head b o lts (in reverse tig h te n in '^ se q u en ce ), (fig. 12-16). See p age 12-20.

A D E ':S 8£Ii*S *

CYLINDER HEAD — 12-11 21. S cre w liftin g h a n d le s, p a rt n u m b e r 40200747 in to c y lin d e r head and lift o ff fro m c y lin d e r b lo ck. Rem ove liftin g h a n d le s fro m c y lin d e r head, (fig . 12-17).

Fig. 12-17

22. R em ove c y lin d e r head g a s k e t, and c le a n to p o f c y lin d e r b lo c k , (fig. 12-18).

7>r

ir—

Fig. 12-18

CHECKING VALVE RECESSION 1. P la ce s p e c ia l to o l p a rt n u m b e r 40201351 o n to th e c y lin d e r head w ith the probe o f th e d ia l gauge restin g on a valve head. N ote reading on d ia l gauge and ch e ck th e re m a in d e r o f th e va lve s in th is m an n e r, e n su re th a t re a d in g s c o rre s p o n d w ith th e s p e c ific a tio n s , (fig . 12-19).

REMOVING VALVES as follows: 2. A tta c h valve s p rin g c o m p re s s o r, Part No. 40200679, to e x h a u s t m a n ifo ld s tu d , (fig . 12-20).

Fig. 12-20

ir—

\r-

CYLINDER HEAD -

12-12

3. P ress d o w n le ve r o f valve s p rin g c o m p re s s o r and rem ove c o lle ts , (fig. 12-21).

4. R em ove valve s p rin g cap, valve, s p rin g a nd valve s p rin g s e a tin g w a sh e r, (fig . 12-22).

F ig. 12-22

5. T urn o v e r c y lin d e r head a nd rem ove valves.

A tten tio n! B e fo re re m o vin g va lve s, e n su re th a y are num bered in the c o rre c t re p la ce m e n t se quence (fig. 12-23).

Do n o t p in p u n c h o r s ta m p n u m b e r on th e va lve s as th is m ay w e a ke n th e va lve head.

C H E C K IN G VALVE STEM /G U ID E CLEARANCE 6. In s e rt va lve s so th a t th e valve h e a ds p ro tru d e by 10 m m . U sin g a m a g n e tic b a se d d ia l g a u ge , p la c e th e p ro b e a g a in s t th e o u te r d ia m e te r o f th e va lve head.

Z ero th e g a uge w h ils t th e valve Is p u sh ed a g a in s t th e pro b e . A fte r z e ro in g th e g a u ge , p u sh th e va lve aw a y fro m th e p ro b e and n o jp th e re a d in g (fig. 12-24). T h is p ro c e d u re m u s t be c a rrie d o u t on a ll valves. C h e ck re a d in g s a g a in s t s p e c ific a tio n s .

ADEI360'Series

CYLINDER HEAD — 12-13 VALVE FACING 1. R em ove c a rb o n d e p o s its fro m valves.

2. C h e ck to see if valves can be re-used. Valve ends m ust have no s u rfa c e d a m a g e . V a lve c o lle t g ro o ve s m u s t n o t be w o rn a nd c h ro m iu m p la tin g on va lve s te m s m u s t be w ith o u t fla w s . B u rn t va lve s m u s t a lw a y s be re p la c e d .

3. U sin g V -b lo cks a nd a d ia l ga u ge , c h e c k run o u t o f valve stem s. Do not a tte m p t to s tra ig h te n bent valves, (fig . 12-25).

4. If no V -b lo c k s a n d d ia l g a u g e is a v a ila b le , a q u ic k c h e c k can be m ad e u s in g a s u ita b le s tra ig h t edge, (fig . 12-26).

Fig. 12-26

5. M in o r v a ria tio n s in to le ra n c e can be c o rre c te d by re fa c in g on a va lve g rin d e r.

6. A d ju s t g rin d in g a n g le to 3 0 ° fo r in le t and 4 5 ° fo r e x ­ h a u s t, in s e rt va lve and c la m p d ire c tly b e h in d valve h ead to a vo id v ib ra tio n (fig . 12-27).

7. U sin g a lo w fe e d ra te g rin d u n til va lve fa c e is c le a n ly c u t a ll rou n d .

8. The valve ste m fa c e can bp lig h tly g round, by lo c a tin g th e valve ste m in th e s p e c ia l a tta c h e m e n t m o u n te d on th e va lve g rin d in g m a c h in e , (fig. 12-28).

AD E 360 S e rïÿs

CYLINDER HEAD — 12-14 VALVE SEAT FACING 1. P lace c y lin d e r head on w o o d e n b lo c k s .

2. In s e rt valve s e a t fa c in g to o l and re-cut s e a t to 3 0 ° fo r In le t a nd 45 ° fo r e xh a u st, (fig. 12-29).

Caution: Do not c u t va lve se a t d ia m e te r above th e ir m axi: m um lim its , see s p e c ific a tio n s .

Note: A s th e re p la c e m e n t o f va lve s e a ts re q u ire s th e use o f c e rta in s p e c ia lis e d e q u ip m e n t, w e s u g g e s t th a t th is o p e ra tio n is carried o u t by an ADE approved e n g in e recon­ d itio n e r. If valve g u id e s need to be re p la ce d new g u id e s m u s t be fitte d b e fo re valve se a t re -fa cin g .

REMOVING VALVES GUIDES 1. P la ce c y lin d e r head u n d e r a h y d ra u lic press.

2. U sin g s u ita b le m a n d re l p re ss o u t valve g u id e s fro m c y lin d e r head, (fig. 12-30).

3. If necessary, ream valve g u id e parent-bore in cylin d e r h ead to n e xt re p a ir s ta g e u s in g s p e c ia l to o l P a rt No. 40200750, (fig . 12-31).

REPLACING VALVE GUIDES 1. C o a t ne w va lve g u id e w ith g ra p h ite d o il and p o s itio n in c y lin d e r head, (fig , 12-32).

A D E 360 S e rie s

CYLINDER HEAD — 12-15 2. F it 1 7 - 1 7 ,5 m m s p a c e r fro m s p e c ia l to o l Part No. 40200556 o ve r valve g u id e , (fig. 12-33).

3. U sing m andrel o f sp e cia l to o l Part No. 40200556, press valve gu id e in to cylin d e r head to the s p e cifie d in s ta lla ­ tio n h e ig h t, (fig . 12-34) i.e. u n til flu s h w ith spacer.

4. F in is h in n e r d ia m e te r o f va lve g u id e , u s in g s p e c ia l rea m e r p a rt n u m b e r 40200828 (exh a u st), 40209591 (in le t), (fig . 12-35).

"A /**/ <&> _/ ° f ffti

s.

J L '» if

1 ®) o

Pig. 12-35

5. Using a sp ring te n sio n tester, ch e ck valve sp rin g s and e n s u re th e y c o n fo rm to s p e c ific a tio n , (fig. 12-36). ■

A 0 E 360 S e rie s

CYLINDER HEAD -

12-16

CHECKING CYLINDER HEAD 1. U sing a s tra ig h t edge, ch e ck su rfa c e o f c y lin d e r head fo r d is to rtio n a lo n g its le n g th , (fig. 12-37).

2. A nd a cro ss the c y lin d e r head (fig. 12-38). If th e cylin d e r head is fo u n d to be d is to rte d , it m u s t be re fa ce d to th e re q u ire d s u rfa c e s p e c ific a tio n and h e ig h t.

N o te : O b se rve fu e l in je c to r p ro tru s io n w h e n re fa c in g c y lin d e r head. R e fe r to p ro c e d u re on page 12-19.

REPLACING VALVES 1. Insert valve stem o il seal item 3 (fig. 12-42) in to sp e cia l to o l p a rt n u m b e r 40202253, (fig. 12-39).

2. Place o il seal o n to to p Of va lve g u id e and p re ss do w n as fa r as p o s s ib le , (fig. 12-40).

ADE 360 S e rie s

CYLINDER HEAD -

12-17

3. L ib e ra lly o il va lve s te m s ite m 1 (fig. 12-42) and in se rt v a lv e s in to c y lin d e r head. E n su re th a t th e va lve s are in s e rte d in th e ir o rig in a l p o s itio n s , (fig . 12-41).

F ig . 12-41

4. F it valve sp ring se a tin g w a sh e r (2), valve s p rin g (4) and va lve s p rin g ca p (5), (fig . 12-42).

5. A tta c h v a lv e s p rin g c o m p r e s s o r p a rt n u m b e r 40200679, to e x h a u s t m a n ifo ld s tu d , (fig . 12-43).

6. Press d o w n le ve r o f valve s p rin g c o m p re s s o r and in ­ s e rt va lve c o lle ts , ite m s 6, (fig . 12-42). R e le a se lever a n d e n su re th a t th e c o lle ts are se a te d c o rre c tly . The g a p b e tw e e n th e c o lle ts s h o u ld be id e n tic a l, (fig.

12-44).

F ig. 12-44 A D E 360 S e rie s

CYLINDER HEAD 12-18

INJECTOR PROTECTION SL EE V ES W h e n o v e r h a u lin g th e c y lin d e r h e a d it is e s s e n tia l th a t all th e in je c to r p ro te c tio n s le e v e s a r e r e m o v e d a n d e x a m in e d fo r c o rro s io n .

R e m o v in g 1.

U s in g s p e c ia l to o l p a r t n u m b e r 4 0 2 0 0 6 2 4 , u n s c r e w a n d r e m o v e a ll in je c to r p ro te c tio n s le e v e s , (F ig . 1 2 -4 5 ) .

2.

E x a m in e

o u te r s u r f a c e o f p ro te c tio n s le e v e s fo r c o rro ­

s io n . B a d ly c o rr o d e d s le e v e s m u s t b e re p la c e d .

3.

R em ove

a ll in je c to r p ro te c tio n s le e v e O -r in g s e a ls fro m

th e c y lin d e r h e a d . D O N O T R E - U S E . (F ig . 1 2 - 4 6 ) .

R e p la c in g 1.

A p p ly s ilic o n

g r e a s e to n e w O -r in g s e a ls a n d in s e rt in to

c y lin d e r h e a d , (F ig . 1 2 - 4 7 ) .

F ig . 1 2 -4 7 ____________________________________________ 2.

L ig h tly

c o a t b o tto m s u r f a c e o f p ro te c tio n s le e v e s w ith a

s ilic o n s e a lin g c o m p o u n d , (F ig . 1 2 - 4 8 ) .

April ‘96

CYLINDER HEAD 12-19 3.

In s e r t s le e v e s a n d tig h te n to th e s p e c ifie d to rq u e , u s in g s p e c ia l to o l p a rt n u m b e r 4 0 2 0 0 6 2 4 , (F ig . 1 2 -4 9 ) .

F ig . 1 2 - 4 9

C H E C K I N G F U E L I N J E C T O R P R O T R U S IO N 4.

A tta c h a d ia l g a u g e w ith a m a g n e tic b a s e , to th e c y lin ­ d e r h e a d w ith th e p r o b e o f th e d ia l g a u g e re s tin g o n th e tip o f th e in je c to r n o z z le .

A t t e n t i o n : N o t e r e a d in g o n d ia l g a u g e a n d c h e c k th e re m a in d e r o f t h e in je c tio n n o z z le s in th is m a n n e r , e n ­ s u rin g t h a t m e a s u r e m e n t s c o rr e s p o n d w ith th e s p e c i­ fic a tio n s . T h e d e p th o f th e in je c to rs c a n b e a lte r e d by fittin g a th ic k e r o r th in n e r s e a lin g w a s h e r , (F ig . 1 2 -5 0 ) .

F ig . 1 2 - 5 0 R E P L A C IN G C Y L IN D E R H E A D E n s u r e c y lin d e r h e a d a n d b lo c k fa c e s a r e c le a n .

1.

U s in g c o m p r e s s e d a ir,

b lo w o u t b o lt h o le s in to p o f c y ­

lin d e r b lo c k , (F ig . 1 2 - 5 1 ) .

F ig . 1 2 -5 1 2.

P la c e n e w c y lin d e r h e a d g a s k e t in p o s itio n , (F ig . 1 2 - 5 2 )

i* Q O O

Fig. 12-52

April ‘96

C O O

O O P

o p e

a O e

CYLINDER HEAD 12-20

3.

S c r e w liftin g h a n d le s ,

p a r t n u m b e r 4 0 2 0 0 7 4 7 , o n to c y ­

lin d e r h e a d , a n d lift in to p o s itio n , (F ig . 1 2 - 5 3 ) .

n e i r=| ■II »

F ig . 1 2 - 5 3

4.

U n s c re w

and

and

a re a

g rip

r e m o v e liftin g h a n d le s . L u b r ic a te th r e a d s o f th e c y lin d e r h e a d

b o lts ,

(F ig . 1 2 -5 4 :

1 2 - 5 5 ) in s e r t b o lts a n d s c r e w d o w n .

F ig . 1 2 - 5 4

F ig . 1 2 - 5 5 5.

T ig h te n

c y lin d e r h e a d b o lts

c a tio n s )

by

re fe r r in g

in fo u r s ta g e s

( s e e s p e c ifi­

to s e q u e n c e d ia g r a m b e lo w . (F ig .

1 2 -5 6 ).

0

®

®

®

®

®

©

©

®

@

®

®

®

®

®

®

0

^

A D E 366

ADE 364

Fig. 12-56

April '96

s

CYLINDER HEAD 12-21

6.

In s e r t p u s h ro d s ,

e n s u r in g

th e y a r e p la c e d in th e ir o rig i­

n a l p o s itio n s , (F ig . 1 2 - 5 7 ) .

F ig . 1 2 -5 7 7.

R e p la c e r o c k e r s h a fts ,

in s e r t b o lts b u t D O N O T tig h te n ,

(F ig . 1 2 - 5 8 ) .

F ig . 1 2 - 5 8 8.

U s in g s p e c ia l to o l p a r t n u m b e r 4 0 2 0 2 1 8 5 , n e c tin g n ip p le b e tw e e n r o c k e r s h a fts ,

in s e rt c o n ­

(F ig . 1 2 - 5 9 ) .

Not

r e q u ire d o n A D E 3 6 4 .

lilie s Fig . 1 2 - 5 9 9.

T ig h te n r o c k e r s h a ft

b o lts to th e s p e c ifie d to rq u e ,

(F ig .

1 2 -6 0 ).

if

frTl FT) fFH fFPi I P » »5 Fig. 12-60

April ‘96

CYLINDER HEAD 12-22

10.

R e p la c e th e fu e l th e

s p e c ifie d

in je c to rs

to rq u e ,

u s in g

a n d tig h te n s e c u rin g n u ts to s p e c ia l to o l

p a rt n u m b e r

4 0 2 0 0 8 7 3 , (F ig . 1 2 - 6 1 ) .

11.

R e -c o n n e c t

upper and

lo w e r in je c to r p ip e s a n d o u te r

c o n n e c tio n s . A tta c h fu e l le a k - o f f p ip e .

N o te :

S e a l o u te r c o n n e c tio n s w ith h y lo m a r o r s u ita b le s e a la n t.

T ig h te n a ll c o n n e c tio n s to t h e s p e c ifie d to rq u e , u s in g s p e c ia l to o l p a r t n u m b e r 4 0 2 0 0 7 1 8 , (F ig . 1 2 - 6 2 ) .

12.

T ig h te n

a ll fu e l

le a k -o ff b o lts to

th e s p e c ifie d to rq u e ,

(F ig . 1 2 - 6 3 ) .

13 .

R e p la c e in le t m a n if o ld fitte d

new

g a s k e ts ,

a n d tig h te n

b o lts to t h e s p e c ifie d to r q u e , (F ig . 1 2 - 6 4 ) .

N o t e : In le t m a n ifo ld m u s t b e fitte d b e fo r e e x h a u s t m a n i- fo ld .

April ‘96

CYLINDER HEAD 12-23

1 4 . R e p la c e c h a rg e r

e x h a u s t m a n if o ld if fitte d .

w ith n e w g a s k e t, a n d tu rb o ­

T ig h te n a ll

b o lts fr o m th e m id d le o u t­

w a r d s , to th e s p e c ifie d to rq u e , (F ig . 1 2 - 6 5 ) .

1 5 . U s in g a n e w g a s k e t,

a tta c h e x h a u s t d o w n p ip e to m a n i­

fo ld , in s e r t b o lts a n d tig h te n to th e s p e c ifie d to rq u e .

1 6 . F it r a d ia to r h o s e s

and

tig h te n

clip s,

a tta c h

d ip s tic k

g u id e tu b e .

17.

R e p la c e fu e l filte rs ,

a n d if fitte d ,

p o w e r s te e rin g

pum p.

R e -t e n s io n V -b e lt. (F ig . 1 2 - 6 6 ) .

VALVE CLEARANCE ADJUSTM ENT ADE 3 6 4 1.

In s e r t fe e le r g a u g e b e tw e e n v a lv e s te m a n d r o c k e r a rm .

V a lv e c le a r a n c e is c o rr e c t w h e n th e fe e le r g a u g e s lid e s th ro u g h w ith a s lig h t re s is ta n c e , (F ig . 1 2 - 6 7 ) .

2.

If th e v a lv e lo c k n u t,

c le a r a n c e r e q u ire s a d ju s tm e n t,

r e le a s e th e

a d ju s t v a lv e c le a r a n c e a n d tig h te n th e lo c k n u t

w h ile h o ld in g th e a d ju s tin g s c re w .

D e sc r ip tio n

E n g in e

364

April ‘96

ADE 3 6 4 ADE 366

C ra n k sh a ft Intake v a lv e s p o s itio n o f to b e a d ju ste d c y lin d e r N o.1

E xh. v a lv e s to b e a d ju ste d

N o .1 v a lv e ro c k in g

3 ,4

2 ,4

N o .1 v a lv e c lo s e d

1 ,2

1 ,3

CYLINDER HEAD 12-24

VALVE 1.

CLEARANCE A DJU STM EN T ADE 3 6 6

In s e r t fe e le r g a u g e b e tw e e n v a lv e s te m a n d r o c k e r a rm .

V a lv e

c le a r a n c e is c o rr e c t w h e n th e fe e le r g a u g e s lid e s

th ro u g h w ith a s lig h t re s is ta n c e .

2.

If th e v a lv e c le a r a n c e r e q u ire s a d ju s tm e n t, r e le a s e lo c k nut an d

a d ju s t th e v a lv e

c le a r a n c e .

T ig h te n

lo c k nu t

w h ile h o ld in g th e a d ju s tin g s c re w , (F ig . 1 2 - 6 9 ) .

D e sc r ip tio n

E n g in e

366

ADE 3 6 4 ADE 3 6 6

C ra n k sh a ft In tak e v a lv e s p o s itio n o f to b e a d ju s te d c y lin d e r N o.1

E xh. v a lv e s to b e a d ju ste d

N o . 1 v a lv e ro c k in g

3 ,5 ,6

2 ,4 ,6

N o . 1 v a lv e c lo s e d

1 ,2 ,4

1 ,3 ,5

REPLACING ROCKER COVER 1.

2.

C h e c k s u r f a c e o f r o c k e r c o v e r fo r d a m a g e , (F ig . 1 2 -7 1 ) .

F it n e w

r o c k e r c o v e r g a s k e t to

c y lin d e r h e a d ,

(F ig

1 2 -7 2 ) .

Fig. 12-72

April ‘96

CYLINDER HEAD 12-25

3.

P la c e r o c k e r c o v e r in p o s itio n , in s e rt b o lts a n d tig h te n to th e s p e c ifie d to r q u e , (F ig . 1 2 - 7 3 ) .

4.

R e p la c e t h e r m o s ta t

5.

F ill

h o u s in g a n d tig h te n

b o lts to th e

r a d ia to r w ith c o o la n t, s ta rt e n g in e a n d run to o p e r a -

F ig . 1 2 - 7 3

CHECKING C O M PRESSIO N 1.

R e m o v e r o c k e r c o v e r.

2.

C h e c k v a lv e c le a r a n c e , ( s e e p a g e 1 2 -2 3 ) .

3.

R e p la c e r o c k e r c o v e r.

4.

Run

e n g in e

u n til o p e r a tin g

te m p e r a tu r e

is

re a ch ed

(7 0 -9 5 ).

5.

E n s u r e t h a t th e b a tte r y is in a g o o d c o n d itio n .

6.

R e m o v e r o c k e r c o v e r, in je c to rs a n d s e a lin g w a s h e r s .

7.

S e t in je c tio n p u m p c o n tro l to s to p p o s itio n .

F ig . 1 2 - 7 4

T e stin g 1.

2.

In s e r t in je c to r s e a lin g w a s h e r , (F ig . 1 2 - 7 4 ) .

In s e r t a d a p t o r fo r t h e c o m p re s s io n te s te r (p a r t n u m b e r 4 0 2 0 0 7 8 9 ) in t h e c y lin d e r h e a d a n d tig h te n w ith in je c to r s e c u r in g n u t, (F ig . 1 2 - 7 5 ) .

Fig . 1 2 - 7 5 3.

A tta c h

c o m p r e s s io n te s te r e x te n s io n to

a d a p to r ,

(F ig .

1 2 -7 6 ).

4.

C h e c k c o m p r e s s io n

a t a n e n g in e s p e e d

o f a p p r o x im a ­

te ly 1 8 0 - 2 0 0 r /m in (s ta r te r s p e e d ) w ith th e th ro ttle in th e c lo s e d

p o s itio n .

T u r n th e e n g in e u n til th e te s t in d ic a to r

s to p s ris in g . R e p e a t th is p r o c e d u re fo r a ll c y lin d e rs .

5.

6.

R e m o v e c o m p r e s s io n te s te r a n d a d a p te r .

R e p la c e

s e a lin g

w a s h e rs ,

in je c to rs a n d le a k o ff p ip es ,

tig h te n to th e s p e c ifie d to rq u e .

Fig. 12-76

April '96

CYLINDER HEAD 12-26 7.

R e p la c e r o c k e r c o v e r a n d tig h te n b o lts to th e s p e c ifie d to rq u e , (F ig . 1 2 - 7 7 ) .

April ‘96

CYLINDER HEAD — 12-27

SPECIAL TOOLS FOR THIS SECTION OBTAINABLE FROM: GRUNDY-TECHNIFORM, BURMAN ROAD, DEAL PARTY ESTATE PORT ELIZABETH 6001 '

S p lit rin g sp a n n e r fo r in je c to r pipes, (see fig . 12-7) P art N u m b e r 40200705

S o c k e t fo r in je c to r se c u rin g n u ts (see fig . 12-11, 1 2 -6 1 ) P a rt N u m b e r 40200873

F ue l in je c to r Im p a c t e x tra c to r (see fig . 12-12) P a rt N u m b e r 40201076

E x tra c to r fo r in je c to rs (see fig . 12-13) P a rt N u m b e r 40201063

,c

L iftin g h a n d le s c y lin d e r head (see fig . 12-17, 12-53) P a rt N u m b e r 40200747

V A LV E DEPTH G AUG E (see fig . 12-19) P a rt N u m b e r 40201351

AD E 360 S eries

CYLINDER HEAD — 12-28

en

V alve s p rin g c o m p re s s o r (see fig . 12-43) Part N u m b e r 40200679 40200682

R e a m e r fo r valve g u id e p a re n t b o re in cyl./h e a d 13,5 x 15,5 m m (see fig . 12-31) P art N u m b e r 40200750

oT^ V a lve g u id e re p la c e m e n t m a n d re l (see fig . 12-33, 12-34) P a rt N u m b e r 40200556

R e a m e r fo r e x h a u s t valve g u id e s (see fig . 12-35) P a rt N u m b e r 40200828 R e a m e r fo r in le t valve g u id e s (see fig . 12-35) P art N u m b e r 40209591

V a lve ste m seal re p la c in g to o l (see fig . 12-40) P a rt N u m b e r 40202253

R e m o v in g /R e p la c in g to o l for in je c to r p ro te c tio n sle e ve s (see fig . 12-45, 12-49) P art N u m b e r 40200624

P lie rs ro c k e r s h a ft c o u p lin g bush (see fig . 12-59) P a rt N u m b e r 40202185 A D E 366N/C/T/TI o n ly

ADE 360 S e rie s

CYLINDER HEAD — 12-29

C r o w f o o t r in g s c a n n e r R e m o v e ' R e p la c e m e n t o f m ie c to r pipes (s e e fi g

12-62)

P a rt N u m b e r 4 0 2007 18

A d a p to r fo r c o m p re s s io n te ste r. (see fig . 12-75) P a r t N u m b e r 40 20 0 7 8 9

Attention!

A s w e re c o m m e n d th a t th e re m o va l and re p la c e m e n t o f va lve s e a ts s h o u ld o n ly be c a rrie d o u t by an ADE A p p ro v e d e n g in e re b u ild e r, th e use o f th e s e th re e s p e c ia l to o ls is n o t illu s tra te d in th e te x t. T he se s p e c ia l to o ls are h o w e ve r o b ta in a b le fro m G ru n d y -T e c h n ifo rm .

ADE 360 Series

_____________ SECTION 13 Piston and Connecting Rods

CONTENTS OF SECTION 13

Page I L L U S T R A T I O N .................................................................................................................................................................................................................................... 1 3 -2 I N T R O D U C T I O N ................................................................................................................................................................................................................................. 1 3 -3 S P E C I F I C A T I O N S .............................................................................................................................................................................................................................. 1 3 -3 R E M O V I N G P I S T O N S A N D C O N N E C T I N G R O D S ...................................................................................................................................................... 1 3 -5 R E M O V I N G P I S T O N R I N G S ....................................................................................................................................................................................................... 1 3 -6 C H E C K IN G B I G - E N D B E A R I N G S ............................................................................................................................................................................................ 1 3 -7 C H E C K I N G P I S T O N S A N D P IS T O N R I N G S .................................................................................................................................................................... 1 3 -1 1 R E P L A C I N G P I S T O N S A N D C O N N E C T I N G R O D S .................................................................................................................................................... 1 3 -1 3 S P E C IA L T O O L S ................................................................................................................................................................................

A p ril '9 6

'...................... 1 3 -1 6

Piston and Connecting Rods 13-2

1. S M A L L E N D B U S H

7. C O M P R E S S I O N R IN G

3. C O N N E C T I N G R O D B O L T S

8. O IL S C R A P E R R IN G

4 . B E A R IN G S H E L L S 5 . C IR C L IP S

April '96

6 . C O M P R E S S I O N R IN G

2. C O N N E C T IN G R O D

9. P IS T O N 10.

G U D G E O N P IN

PISTONS AND CONNECTING RODS 13-3 INTRODUCTION T h e lig h t a llo y p is to n s u s e d h a v e th e c o m b u s tio n c h a m b e r c a s t in th e p is to n c ro w n . T w o c o m p r e s s io n a n d o n e oil c o n tro l rin g a r e fitte d to th e p is to n s w ith th e to p c o m p re s s io n rin g r e ta in e d in a n A l-fin b o n d e d in s e rt. G u d g e o n p in s a r e tu b u la r to r e d u c e w e ig h t a n d a r e lo c a te d in th e p is to n s b y c irc lip s . C o o lin g n o z z le s a r e fitte d to a s s is t w ith p is to n c o o lin g o f tu r b o ­ c h a r g e d e n g in e s .

F o rg e d s te e l c o n n e c tin g ro d s a r e u s e d w ith s e rr a te d m a tin g s u rfa c e s b e tw e e n th e c o n n e c tin g ro d a n d th e c a p to p ro v id e in c re a s e d r ig id ity a n d to e x te n d b e a r in g life. T h e b ig -e n d b e a r in g s h e lls a r e s te e l b a c k e d a n d lin e d w ith a lu m in iu m /tin . T h e s m a ll- e n d b u s h is m a n u fa c tu r e d fr o m a h ig h q u a lity p h o s p h o r b r o n z e a n d s e a ts in a n in te r fe r e n c e fit in th e c o n n e c tin g rod W it h t h e c y lin d e r h e a d a n d s u m p r e m o v e d , th e p is to n s c a n e a s ily b e w ith d r a w n fr o m th e to p o f th e c y lin d e r b lo ck .

PIST O N S AND CONNECTING R ODS R ep air s t a g e s

N o m in a l P isto n d ia m e te r

S ta n d a r d N /C / T / T I R e p 1 N + 0 ,5 R e b o r e

*

C o m p r e s s io n h e ig h t **

B lo c k h e ig h t

9 7 ,5

6 2 , 8 0 to 6 2 ,8 6

3 5 8 , 8 2 to 3 5 9 , 0 7 ( S T D )

9 8 ,0 0

6 2 , 5 0 to 6 2 ,5 6

3 5 8 , 5 2 to 3 5 8 , 7 7 ( - 0 , 3 )

R e p 1 n / c /t / t i

9 7 ,5

R e p s t a g e 2 N /C /T / T I

9 7 ,5

6 2 , 2 0 to 6 2 ,2 6

3 5 8 , 2 2 to 3 5 8 , 4 7 ( - 0 , 6 )

R e p s t a g e 3 N /C / T / T I

9 7 ,5

6 1 , 9 0 to 6 1 ,9 6

3 5 7 , 9 2 to 3 5 8 , 1 7 ( - 0 ,9 )

*

1 s t r e p a ir s t a g e fo r n a tu r a lly a s p ir a te d o p tio n a l, i.e . e ith e r re b o re fo r o v e r s iz e p is to n o r fit s le e v e .

■ m e a s u r e m e n t fr o m g u d g e o n p in c e n tr e to p is to n to p .

M a x w e ig h t v a r ia tio n b e tw e e n p is to n s

20g

G u d g e o n pin d ia m e t e r

3 5 , 9 9 5 to 3 6 ,0 0 0

G u d g e o n p in b o re d ia m e t e r

3 6 , 0 0 2 to 3 6 ,0 0 7

G u d g e o n pin to p is to n b o re c le a r a n c e

0 , 0 0 2 to 0 , 0 1 2

P is to n p ro tru s io n a t T D C to b lo c k s u r fa c e

0 ,1 7 0 to 0 ,5 8 0

N ote: T h e c o d e s B A 0 9 o r B C 0 1 a p p e a r on th e p is to n c ro w n s . T h e s e a r e g r a d in g c o d e s fo r p r o d u c tio n o n ly .

PISTON RINGS 360N/C/T/TI

T yp e

S id e C le a r a n c e

G ap

1

K e y s to n e

0 ,0 4 2 to 0 ,0 9 7

0 ,2 0 to 0 ,3 5

2

T a p e r e d f a c e c o m p re s s io n

0 ,0 6 0 to 0 ,0 9 5

0 ,2 0 to 0 ,3 5

3

O il c o n tro l (s p r in g e x p a n d e r )

0 , 0 3 0 to 0 ,0 6 5

0 ,2 5 to 0 ,4 0

A tte n tio n : G a p a n d s id e c le a r a n c e a r e e q u a l to a b o v e in a ll b o re r e p a ir s ta g e s .

April '96

Piston and Connecting Rods 13-4 C O N N E C T IN G R O D

R e p a ir s iz e

C o n n e c t i n g r o d b e a r in g d i a m e t e r

C o n n e c tin g ro d w id th

. in s t a l l e d S ta n d a r d

B ig e n d

S m a ll e n d

3 7 ,7 3 0 to 3 7 ,8 3 0

3 5 ,5 to 3 5 ,6

6 0 , 0 5 6 to 6 0 , 0 9 5

S ta n d a r d 1 ( - 0 , 1 )

5 9 ,9 5 6 to 5 9 ,9 9 5

S ta n d a r d 2 ( - 0 , 2 5 )

5 9 ,8 0 6 to 5 9 ,8 4 5

R e p 1 (-0 ,5 )

5 9 ,5 5 6 to 5 9 ,5 9 5

R e p 2 (-0 ,7 5 )

5 9 , 3 0 6 to 5 9 ,3 4 5

R ep 3 (-1 ,0 )

5 9 , 0 5 6 to 5 9 ,0 9 5

C o n n e c tin g ro d big e n d b a s ic b o re

6 5 , 0 0 0 to 6 5 , 0 1 9

T a p e r o f big e n d b a s ic b o re

0 ,0 0 5

B ig e n d b e a r in g c le a r a n c e

ra d ia l

0 ,0 4 1 to 0 , 1 0 0

a x ia l

0 ,1 0 to 0 ,4 0

L e n g th o f c o n n e c tin g ro d b e tw e e n c e n tr e s o f big e n d a n d s m a ll en d

2 3 0 , 0 0 to 2 3 0 , 0 5

W e ig h t v a r ia tio n b e tw e e n c o n n e c tin g ro d s fo r r e p a ir

40g

M a x . p a r a lle l d e v ia tio n b e tw e e n c e n tr e lin e o f b ig e n d a n d s m a ll e n d

0 ,0 1 0

B ig e n d b e a r in g c ru s h

0 ,0 4 to 0 ,0 7

SM ALL END S m a ll e n d b a s ic b o re in c o n n e c tin g ro d

s ta n d a r d

3 9 ,0 0 0 to 3 9 ,0 2 5

R e p 1 (1 -0 ,2 )_____________________________ 3 9 , 2 0 0 to 3 9 ,2 2 5 R e p 2 (+ 0 ,5 )

S m a ll e n d b u s h

3 9 , 5 0 0 to 3 9 , 5 2 5

In n e r d ia m e te r in s ta lle d _________________ 3 6 , 0 3 0 to 3 6 ,0 4 0 T a p e r /o v a lit y to le r a n c e _________________ 0 ,0 0 2 _____________ In te r fe r e n c e fit___________________________0 , 0 2 0 to 0 ,0 7 5 C le a r a n c e to g u d g e o n pin

0 , 0 3 0 to 0 , 0 4 5

T O R Q U E S P E C IF IC A T IO N S C o n n e c tin g ro d b o lt s ..............................................................................................................1 s t s t a g e ..........................................4 0 - 5 0 N m ........................................................................................................................................................... F in a l.................................................... + 9 0 ° - 1 0 0 ° ........................................................................................................................................................... S tr e tc h lim it.................................... 5 6 ,8 m m ( M 1 2 ) P is to n c o o lin g n o z z le s

- u p to e n g in e no . S A 0 7 0 9 0 0 V .................................. M 1 0 x 1 .............................................2 5 N m fr o m .e n g in e no. S A 0 7 0 9 0 1 V .................................. M 1 0 x 1 .............................................1 5 - 1 8 N m

April '96

PISTONS AND CONNECTING RODS 13-5 R EM O V IN G PISTONS AND C O N NECTING RODS (C y lin d e r h e a d a n d s u m p r e m o v a l) R e m o v in g 1.

U s in g a s u ita b le s c ra p e r , r e m o v e c a rb o n d e p o s its fro m to p o f c y lin d e r b o re s , (F ig . 1 3 -1 ).

F ig . 1 3 -1 2.

U n s c re w

r e ta in in g

b o lts

and

re m o v e

p is to n

c o o lin g

n o z z le s , 3 6 0 C / T / T I , (F ig . 1 3 -2 ).

3 6 0 N e n g in e s h a v e c lo s in g p lu g s in p la c e o f n o z z le s .

3.

U n s c re w

c o n n e c tin g

ro d

b o lts

and

re m o v e

b e a rin g

c a p s , (F ig . 1 3 -3 ).

A tte n tio n !

B e a r in g c a p s a n d c o n n e c tin g ro d s a r e m a r k e d a s

m a tc h e d p a irs (n o te n u m b e r s b e fo r e a s s e m b ly ).

4.

R e m o v e p is to n s a n d c o n n e c tin g ro d s fr o m to p o f c y lin ­ d e r b lo c k , (F ig . 1 3 - 4 ) .

Fig. 13-4

Piston and Connecting Rods 13-6

5.

R em ove

b e a r in g s h e lls fr o m c a p a n d c o n n e c tin g ro d s ,

if th e o ld

b e a r in g s h e lls

s h e lls to

en s u re

a r e to

r e p la c e m e n t

b e u s e d a g a in ,

m a rk

in th e o r ig in a l p o s itio n ,

(F ig . 1 3 -5 ).

R em o v a l o f P is to n R in g s /P is to n fro m C o n n e c tin g R o d s.

1.

C la m p

c o n n e c tin g ro d

a n d p is to n a s s e m b ly in a v ic e ,

fitte d w ith p r o te c tiv e ja w s , (F ig . 1 3 -6 ).

F ig . 1 3 -6 2.

T u rn

a d ju s tin g

s c re w

o f rin g e x p a n d e r ,

p a rt n u m b e r

4 0 2 0 0 3 0 7 , to a p p r o x . 9 8 m m , (F ig . 1 3 -7 ).

3.

R e m o v e p is to n rin g s a t th is s e ttin g , (F ig . 1 3 - 8 ) .

Fig. 13-8

April '96

PISTONS AND CONNECTING RODS 13-7

4.

R em ove

c irc lip s

fr o m

p is to n ,

push

o u t g u d g e o n pin

a n d r e m o v e p is to n fr o m c o n n e c tin g ro d , (F ig . 1 3 -9 ).

F ig . 1 3 -9

C h e c k in g B ig E nd B e a r in g s 1.

C le a n

c o n n e c tin g

ro d a n d

b e a r in g c a p s u rfa c e ,

(F ig .

1 3 -1 0 ).

F ig . 1 3 - 1 0 2.

F it big

end

b e a r in g c a p

and

in s e rt b o lts ,

(c a p

and

c o n n e c tin g ro d n u m b e r s a lig n e d ), (F ig . 1 3 - 1 1 ) .

F ig . 1 3 -1 1 3.

T ig h t e n

c o n n e c tin g ro d b o lts to th e

s p e c ifie d to rq u e ,

(F ig . 1 3 - 1 2 ) .

III: A » i

Fig. 13-12

April '96

Piston and Connecting Rods 13-8

4.

U s in g a n in te r n a l m e a s u r in g in s tr u m e n t c h e c k big e n d p a re n t b o re in th r e e p la c e s , ( F i g . 1 3 - 1 3 ) .

F ig .1 3 - 1 3 5.

U s in g

an

in te r n a l m e a s u r in g in s tr u m e n t c h e c k b o re o f

th e s m a ll e n d b u s h , (F ig . 1 3 - 1 4 ) .

A tte n tio n !

If th e s m a ll e n d

m e e t th e s p e c ific a tio n , th e

bush

bush

in n e r d ia m e te r d o e s

m u s t b e p re s s e d

not

ou t and

r e p la c e d . W it h th e s m a ll e n d b u s h r e m o v e d , c h e c k th e p a re n t b o re

and,

S ta n d a r d

if n e c e s s a r y , and

o v e r s iz e

m a c h in e o u ts id e

to

th e

d ia m e te r

1st

r e p a ir

s m a ll

end

s ta g e . bushes

h a v e a n u n fin is h e d in n e r d ia m e t e r w h ic h m u s t b e r e a m e d to th e s p e c ifie d s iz e a f te r in s ta lla tio n . W h e n fittin g a n e w s m a ll e n d b u s h to th e c o n r o d , a lu b r ic a tin g h o le m u s t b e d rille d a fte r th e b u s h is fitte d . R e a m in g o f th e b u s h c a n n o w b e c a rrie d out.

■nu ra= F ig . 1 3 - 1 4 6.

M o u n t th e

c o n n e c tin g ro d

in a n a lig n m e n t g a u g e a n d

c h e c k fo r b e n d in g , (F ig . 1 3 - 1 5 ) .

7.

C h e c k fo r tw is tin g , (F ig . 1 3 - 1 6 ) .

W A R N IN G !

U n d e r n o c ir c u m s ta n c e s s h o u ld a n y a t te m p t b e

m a d e to s t ra ig h te n a b e n t c o n n e c tin g th a t

do

not

c o n fo r m

to

ro d . C o n n e c tin g

s p e c ific a tio n s

m ust

a lw a y s

ro d s be

re p la c e d .

Fig. 13-16

PISTONS AND CONNECTING RODS 13-9 8.

U n s c re w

c o n n e c tin g

ro d

b o lts

and

re m o v e

b e a rin g

c a p s , (F ig .1 3 -1 7 ).

9.

F it b e a r in g s h e lls in to c o n n e c tin g ro d a n d b e a r in g c a p .

E n s u r e t h a t th e lo c a tin g ta b s a r e

fitte d c o rre c tly ,

(F ig .

1 3 -1 8 ).

10 .

F it b e a r in g c a p to th e c o n n e c tin g ro d , (n u m b e r s o n th e b e a r in g

c a p a n d c o n n e c tin g ro d a lig n e d ).

n e c tin g

ro d in a v ic e fitte d w ith

C la m p c o n ­

p r o te c tiv e ja w s ,

(F ig .

1 3 -1 9 ).

11.

In s e r t b o lts

and

tig h te n

to

th e s p e c ifie d to rq u e ,

(F ig .

1 3 -2 0 ).

Fig. 13-20

April '96

Piston and Connecting Rods 13-10

12.

U s in g a n in te r n a l m e a s u r in g in s tr u m e n t

c h e c k big en d

b e a r in g b o re in th r e e p la c e s , (F ig , 1 3 -2 1 ) .

C h e c k in g th e B ea r in g C ru sh 13.

M o u n t th e c o n n e c tin g ro d in a v ic e fitte d w ith s o ft ja w s .

F it th e rod.

b e a r in g s h e lls in to b e a r in g c a p a n d c o n n e c tin g

In s e r t

b o lts

and

tig h te n

to th e s p e c ifie d to rq u e .

A tta c h a d ia l g a u g e w ith a m a g n e tic w ith

th e

cap,

a n d s e t th e g a u g e to “0".

b a s e to th e v ic e ,

p r o b e r e s tin g o n t h e u n d e rs id e o f th e b e a rin g L o o s e n th e big e n d b o lt

n e a r e s t to th e d ia l g a u g e , n o te th e r e a d in g o n th e g a u ­ ge.

The

s h o u ld

fig u r e w ill be

r e p r e s e n t th e

c o m p a re d

w ith

th e

b e a r in g

c ru s h a n d

s p e c ific a tio n ,

(F ig . 1 3 - 2 2 ) .

14.

U n s c re w

th e

c o n n e c tin g ro d b o lts a n d u s in g a v e r n ie r

g a u g e , c h e c k b o lts fo r s tre tc h ,

r e fe r to

s p e c ific a tio n s ,

(F ig . 1 3 - 2 3 ) .

15.

C o n n e c tin g ro d s a n d b e a r in g s h e lls s h o u ld to

e n s u re

r e p la c e m e n t

b e m a rk e d

in th e o rig in a l p o s itio n ,

(F ig ,

1 3 - 2 4 ) . c h e c k r e m a in d e r o f c o n n e c tin g ro d s a s a b o v e .

Fig. 13-24

April '96

PISTONS AND CONNECTING RODS 13-11 C HECKING PISTONS AND PISTON RINGS B e fo r e

c h e c k in g

p is to n s ,

p is to n

rin g s

and

gudgeon

p in s,

e n s u r e t h a t th e p is to n a n d p is to n rin g g r o o v e s a r e c le a n a n d fr e e o f c a rb o n d e p o s its . C a r e s h o u ld b e ta k e n to e n s u r e th a t th e p is to n rin g g r o o v e s a r e n o t d a m a g e d d u rin g c le a n in g .

A tte n tio n !

In a ll c a s e s p is to n s a n d th e ir a s s o c ia te d g u d g e o n

p in s a r e c o n s id e r e d to b e m a tc h e d p a irs . W h e n d is m a n tlin g , th e s e

ite m s

m a r k in g s

m u s t b e m a rk e d ,

c o rr e s p o n d ,

and

s o th a t d u rin g

th e

p a rts

a re

a s s e m b ly th e

r e tu rn e d

to

th e ir

o rig in a l p o s itio n .

1.

P is to n s

and

rin g s

s h o u ld

b e r e m o v e d a s d e ta ile d on

p a g e 1 3 -8 .

2.

3.

4.

W h e n c le a n , c h e c k p is to n s c a r e fu lly b e fo r e r e -u s e .

U s in g

an

U s in g

m ic r o m e te r ,

a

In s e r t a p is to n ,

p in ,

b o re

m e a s u r in g

pin

gudgeon

5.

in te r n a l

gudgeon

in s tr u m e n t,

p is to n ,

April ‘96

th e

c h e c k th e o u te r d ia m e te r o f th e

rin g in to t h e c y lin d e r b o re a n d u s in g a

th e

rin g

s q u a r e ly d o w n in to th e c y lin d e r

b o re to a d e p th o f a p p r o x im a t e ly (F ig . 1 3 - 2 7

check

(F ig . 1 3 - 2 5 ) a n d

(F ig . 1 3 - 2 6 ) .

p is to n push

in th e

3 0 m m fr o m th e to p ,

Piston and Connecting Rods 13-12

6

M e a s u r e th e e n d g a p o f t h e p is to n rin g a n d r e p e a t th is p r o c e d u r e w ith th e r e m a in in g rin g s . R in g g a p s m u s t b e w ith in th e s p e c ifie d lim its , (F ig . 1 3 - 2 8 ) .

N o te :

W it h th e p is to n s r e m o v e d a c a re fu l e x a m in a tio n s h o u ld

b e m a d e o f th e c y lin d e r b o re fo r w e a r a n d lo c a lis e d s e iz u re .

7.

R e -f it p is to n s to c o n n e c tin g ro d s , c le a n c a rb o n a n d oil d e p o s its

fr o m

p is to n

rin g

g ro o v e s .

E n s u r e th a t th e

g r o o v e s a r e n o t d a m a g e d , (F ig . 1 3 - 2 9 ) .

F ig . 1 3 - 2 9 8.

R e p la c e a ll p is to n rin g s u s in g rin g e x p a n d e r , p a rt n u m ­ b e r 4 0 2 0 0 3 0 7 , (F ig . 1 3 - 3 0 ) .

9.

C h e c k c le a r a n c e o f p is to n rin g s in th e g r o o v e s , r e p la c e p is to n

a n d /o r

rin g s t h a t d o

tio n s , (F ig . 1 3 - 3 1 ) .

April '96

n o t c o n fo rm to s p e c ific a ­

PISTONS AND CONNECTING RODS 13-13

R E P L A C I N G P I S T O N S , P I S T O N R IN G S A N D C O N N E C T IN G RODS 1.

C la m p

c o n n e c tin g

ja w s , w ith t h e pum p

s id e )

c o n n e c tin g

rod

in

e lo n g a te d

a v ic e fitte d w ith p ro te c tiv e s id e to th e

rig h t (in je c tio n P la c e p is to n on

as

in d ic a te d

b y a r ro w s .

ro d ,

w ith th e

a rro w

on th e

p is to n c ro w n

fa c in g fo r w a r d a s in d ic a te d , (F ig . 1 3 -3 2 ) .

F ig . 1 3 - 3 2 2.

In s e r t g u d g e o n

p in

and

s e c u r e w ith

c irc lip s ,

(F ig .

1 3 -3 3 ).

m u /©= F ig . 1 3 - 3 3 3.

R e p la c e

p is to n rin g s , u s in g rin g e x p a n d e r p a rt n u m b e r

40 20 0307, fr e e ly

in th e

s ta g g e r g ro o v e ,

p is to n 180°

rin g s , w h ic h

m u s t ro ta te

e a c h s id e o f th e g u d g e o n

pin, (F ig . 1 3 - 3 4 ) .

F ig . 1 3 - 3 4 4.

L u b r ic a te p is to n rin g s w ith e n g in e oil, (F ig . 1 3 -3 5 ) .

mu *e= Fig. 13-35

April ‘96

._____________________________________

Piston and Connecting Rods 13-14

5.

P o s itio n

rin g s q u e e z e r o v e r p is to n rin g s a n d c o m p re s s

so t h a t th e s le e v e w ill ju s t m o v e (F ig . 1 3 - 3 6 ) .

6.

L u b r ic a te b ig e n d b e a r in g s a n d c r a n k s h a ft jo u r n a l w ith e n g in e oil, (F ig . 1 3 - 3 7 ) .

7.

In s e r t c o n n e c tin g w ith a r r o w

on

ro d

and

p is to n

in to

c y lin d e r b o re ,

p is to n c ro w n p o in tin g to w a r d s th e fro n t

o f th e e n g in e , (F ig . 1 3 - 3 8 ) .

8.

P u s h p is to n d o w n in to c y lin d e r b o re a n d g u id e th e c o n ­ n e c tin g

ro d

u n til th e

b ig

end

b e a r in g

c o n ta c ts th e

c r a n k s h a ft jo u r n a l, (F ig . 1 3 - 3 9 ) .

Fig. 13-39

PISTONS AND CONNECTING RODS 13-15

9

L u b r ic a te

b ig

end

b e a r in g

cap

w ith

e n g in e oil, (F ig .

1 3 -4 0 ).

10.

F it m a tc h e d b ig e n d b e a r in g c a p to c o n n e c tin g rod a n d in s e r t b o lts (F ig . 1 3 - 4 1 ) .

11.

T ig h te n

big e n d

b e a r in g b o lts to th e s p e c ifie d to rq u e ,

(F ig . 1 3 - 4 2 ) .

Fig . 1 3 -4 2 12.

In s e r t on

p is to n c o o lin g n o z z le s e n s u rin g th a t lo c a tin g pin

n o z z le

body

3 6 0 C / T / T I o n ly ),

a lig n s w ith d rillin g in oil g a lle ry , (A D E (F ig . 1 3 - 4 3 ) ,

to s p e c ifie d to rq u e . q u e to s p e c ific a tio n ).

April '96

in s e r t b o lts a n d tig h te n

(In 3 6 0 N e n g in e s fit p lu g s a n d to r ­

Piston and Connecting Rods 13-16 SPECIAL TO O LS FOR SECTION 13 O B T A IN A B L E F R O M G R U N D Y T E C H N I F O R M , B U R M A N R O A D , D E A L P A R T Y E S T A T E , P O R T E L IZ A B E T H 6 0 0 1

April '96

_________SECTION 14 Crankshaft and Main Bearings

CONTENTS OF SECTION 14

Page I L L U S T R A T I O N ..................................................................................................................................................................................; ................................................ 1 4 -2 I N T R O D U C T I O N ................................................................................................................................................................................................................................. 1 4 -3 S P E C I F I C A T I O N S .............................................................................................................................................................................................................................. 1 4 -3 R E M O V I N G V IB R A T IO N D A M P E R ......................................................................................................................................................................................... 1 4 -5 R E P L A C I N G V IB R A T IO N D A M P E R ........................................................................................................................................................................................ 1 4 -5 R E M O V A L O F C R A N K S H A F T .................................................................................................................................................................................................... 1 4 -6 G R I N D I N G C R A N K S H A F T ........................................................................................................................................................................................................... 1 4 -8 C H E C K I N G B E A R IN G A N D P A R E N T B O R E S ................................................................................................................................................................1 4 - 1 0 C H E C K I N G B E A R IN G S A N D H O U S I N G ............................................................................................................................................................................. 1 4 -1 0 R E P L A C I N G R E A R M A IN B E A R IN G O IL S E A L .............................................................................................................................................................1 4 -1 3 R E P L A C I N G C R A N K S H A F T ........................................................................................................................................................................................................1 4 -1 6 S P E C IA L T O O L S F O R S E C T I O N 1 4 .................................................................................................................................................................................... 1 4 -1 9

A p ril '9 6

Crankshaft and Main Bearings 14-2

15

CRANKSHAFT A SSEM BLY 9 CRANKSHAFT GEAR 1

B E A R IN G R E T A IN E R

10 S P A C E R

2

S P I G O T B E A R IN G

11 V IB R A T IO N D A M P E R

3

BO LT

1 2 C E N T E R I N G R IN G

4

FLYW HEEL

13 P U L L E Y

5

BO LT

14 B O L T

6

B A L A N C E W E IG H T

1 5 C R A N K S H A F T M A IN B E A R IN G S

7

CRANKSHAFT

8

W O O D R U FF KEY

April ‘96

Crankshaft and Main Bearings 14-3 INTRODUCTION T h e c r a n k s h a ft is p r e c is io n fo rg e d , in d u c tio n h a rd e n e d a n d s u p p o rte d by s e v e n th r e e - la y e r b e a r in g s h e lls o n A D E 3 6 0 a n d fiv e o n A D E 3 6 4 . A th ru s t b e a r in g is fitte d to th e n u m b e r 4 m a in b e a rin g . S e p a r a t e a n d d e ta c h a b le b a la n c e w e ig h ts a r e b o lte d to th e c r a n k s h a ft.

SPECIFICATIONS CRANKSHAFT R ep air s i z e (d ia m e te r )

Main b ea rin g jo u r n a l d ia.

W idth for th r u st b ea rin g

C on rod b e a rin g jo u rn a l d ia m e te r

W idth

Dia for rear ro p e s e a l

S ta n d a r d

8 7 ,9 9 to 8 8 ,0 1

3 2 ,0 0 0 to

5 9 ,9 9 5 to 6 0 , 0 1 5

S ta n d a r d 1 ( - 0 , 1 )

8 7 ,8 9 to 8 7 ,9 1

3 2 ,0 6 2

5 9 ,8 9 5 to 5 9 ,9 1 5

3 7 ,9 3

to

S ta n d a r d 2 ( - 0 , 2 5 )

8 7 ,7 4 to 8 7 ,7 6

3 2 ,3 0 0 to 3 2 ,3 6 2

5 9 ,7 4 5 to 5 9 ,7 6 5

to

9 0 ,9 2 8

5 9 ,4 9 5 to 5 9 ,5 1 5

3 8 ,1 3

9 0 , 5 5 4 to 9 0 ,5 0 8

R e p a ir 1 ( - 0 , 5 )

8 7 , 4 9 to 8 7 ,5 1

R e p a ir 2 ( - 0 , 7 5 )

8 7 ,2 4 to 8 7 ,2 6

3 2 ,5 0 0 to 3 2 ,5 6 2

5 9 ,2 4 5 to 5 9 ,2 6 5

R e p a ir 3 ( - 1 , 0 )

8 6 ,9 9 to 8 7 ,0 1

( + 0 ,5 )

5 8 ,9 9 5 to 5 9 ,0 1 5

( + 0 ,3 )

or

9 0 ,8 7 4

9 0 , 2 3 4 to 9 0 ,2 8 8

M a in a n d big e n d jo u r n a l h a rd n e s s

HRC

56 ± 3

M in jo u r n a l h a r d n e s s o n a t le a s t 2 /3 o f c ir c u m fe r e n c e

HRC

46

(fo r r e p a ir o n ly ) M a x . m a in a n d big e n d jo u r n a l ta p e r

0 ,0 0 5

M a x . m a in a n d big e n d jo u r n a l o v a lity

0 ,0 1

M a x . c r a n k s h a ft ru n o u t w ith c r a n k s h a ft tu rn in g

4 c y lin d e r jo u r n a l 3

0 ,1 1

on o u te r jo u r n a ls

6 c y lin d e r jo u r n a l 4

0 ,1 5

P a r a lle lis m o f big e n d jo u r n a ls to m a in jo u r n a ls

0 ,0 1

L a te r a l ru n o u t a t th r u s t fa c e s

0 ,0 2

M a x ru n o u t o f fly w h e e l fla n g e w ith c r a n k s h a ft tu rn in g on

L a te r a l

0 ,0 3

o u te r jo u r n a ls

R a d ia l

0 ,0 3

R a d ii o n th ru s t b e a r in g jo u r n a l

m in im u m

3 ,7 5

E n d flo a t (th r u s t b e a r in g )

0 ,1 9 0 -0 ,2 9 0

R a d ia l (th r u s t b e a r in g )

0 ,0 5 0 - 0 , 1 0 8

R a d ia l (o th e r m a in s )

0 ,0 4 2 - 0 , 1 0 8

M a in b e a r in g c le a r a n c e

T o r q u e to tu rn c r a n k s h a ft w ith n e w s e a ls a n d b e a r in g s fitte d

12 N m

R e a r c r a n k s h a ft

0 ,5 to 0 ,8

s e a l (r p p e ty p e ) p ro tru s io n a fte r in s ta lla tio n

M a in /B ig e n d jo u r n a l s u r fa c e fin is h

(la p p e d )

R a 0 ,2 p m R. m a x 2 pm

M a x . im b a la n c e o f c r a n k s h a ft w ith c o u n te r w e ig h ts (w ith o u t fly w h e e l) r u n n in g o n o u te r m a in b e a rin g s

April ‘96

30 cm p

Crankshaft and Main Bearings 14-4

CRANKSHAFT MAIN BEA R ING S Main b ea rin g d ia . in sta lle d

R epair s i z e (d ia m e te r )

T h ru st b ea rin g w id th

S ta n d a r d

8 8 , 0 5 2 to 8 8 ,0 9 8

S td .

S ta n d a r d 1 ( - 0 , 1 )

8 7 , 9 5 2 to 8 7 ,9 9 8

S td .1 & S t d .2

S ta n d a r d 2 ( - 0 , 2 5 )

8 7 , 8 0 2 to 8 7 ,8 4 8

R e p a ir 1 ( - 0 , 5 )

8 7 , 5 5 2 to 8 7 ,5 9 8

S t d .2 & all

R e p a ir 2 ( - 0 , 7 5 )

8 7 , 3 0 2 to 8 7 ,3 4 8

r e p a ir s ta g e s

R e p a ir 3 ( - 1 , 0 )

8 7 , 0 5 2 to 8 7 ,0 9 8

3 1 ,7 4 to 3 1 ,8 1 (s td ) 3 2 ,0 4 to 3 2 ,1 1 (+ 0 ,3 )

or

3 2 ,2 4 to 3 2 ,3 1 (+ 0 ,5

TORQUE SPECIFICATIO NS B a la n c e w e ig h t to c r a n k s h a f t

M 1 2 x 1 ,5

I n i t i a l ................................................. 3 0 - 4 0 N m F i n a l ......................................... .........p lu s 9 0 ° - 1 1 0 ° M a x . s tre tc h le n g th

F ly w h e e l to c r a n k s h a f t

M 1 2 x 1 ,5

4 5 ,3 m m

I n i t i a l ................................................. 3 0 - 4 0 N m F i n a l ......................................... .........

M a x . s tre tc h le n g th

p lu s 9 0 ° - 1 1 0 ° 2 6 ,3 m m

P u lle y to c r a n k s h a ft (k e y

d r iv e n )

M 2 4 x 1 ,5

(s h a n k e d b o lt ) .................... ........ 5 0 0 - 6 0 0 N m

P u lle y to c r a n k s h a ft (k e y

d r iv e n )

M 2 4 x 1 ,5

(fu lly th r e a d e d b o l t ) ................. 8 0 0 - 9 0 0 N m

M 2 4 x 1 ,5

(1 s t s t a g e ) ..................................... 8 0 0 - 9 0 0 N m

P u lle y to c r a n k s h a ft (c o n e e le m e n t d r iv e n )

(2 n d s t a g e ) ..........................

M a in b e a r in g c a p b o lts - s ta n d a r d h e x. b o l t s ........................................M 1 5 x 2

p lu s 4 5 ° - 5 5 °

I n i t i a l ................................................. 8 0 - 9 0 N m F i n a l ......................................... .........p lu s 9 0 ° - 1 0 0 ° M a x . s tre tc h le n g th ..........

M a in b e a r in g c a p b o lts - m u lti h e x . b o lts o n ly ...................................... M 1 5 x 2

I n i t i a l ................................................. 4 5 - 5 5 N m F i n a l .........................................

2 n d p u lle y to v ib r a tio n d a m p e r .......................................................................................

V ib r a tio n d a m p e r to c r a n k s h a f t

April '96

M 2 4 x 1 ,5

123 m m

p lu s 9 0 ° - 1 0 0 ° 47 Nm ......... 5 0 0 N m

Crankshaft and Main Bearings 14-5

REM OVAL AND REPLACEM ENT OF C R A N K S H A F T V IB R A T IO N D A M P E R

R em oval 1.

S la c k e n b e lts ,

2

V - b e lt

a d ju s te r

on

a lte r n a to r a n d

rem o ve

(F ig . 1 4 -1 ).

U s in g s p e c ia l to o l p a r t n u m b e r 4 0 2 0 0 1 4 5 , r e le a s e a n d r e m o v e c e n tr e b o lt fr o m c r a n k s h a ft, (F ig . 1 4 -2 ).

3

D ra w

v ib r a tio n

d a m p e r fr o m c r a n k s h a ft u s in g s p e c ia l

to o l p a rt n u m b e r 4 0 2 0 0 0 1 9 , (F ig . 1 4 -3 ).

R e p la c e m e n t 1.

If n e c e s s a r y 80 °C

in

h e a t v ib ra tio n

a w a t e r b a th , a n d

d a m p e r to a p p r o x im a te ly s lid e

o n to c r a n k s h a ft. E n ­

s u re t h a t th e w o o d r u f f k e y e n g a g e s g r o o v e in th e v i­ b r a tio n d a m p e r (a r r o w s ), (F ig . 1 4 -4 ).

April '96

Crankshaft and Main Bearings 14-6

2.

S c re w

c e n tr e

b o lt

in to

c r a n k s h a ft

and

tig h te n to th e

s p e c ifie d to rq u e , (F ig . 1 4 - 5 ) .

A tte n tio n !

U n d e r no c ir c u m s ta n c e s h o u ld th e c e n tr e b o lt b e

tig h te n e d w ith a n im p a c t w r e n c h .

REM OVAL OF CRANKSHAFT The

fo llo w in g

ite m s

m ust

be

re m o v e d

fr o m

th e

e n g in e :

c y lin d e r h e a d , s u m p , c o n n e c tin g ro d s , p is to n s , fly w h e e l a n d h o u s in g , tim in g g e a r c a s e c o v e r a n d oil p u m p .

1.

U n s c r e w tim in g

gear

re ta in in g

b o lt fr o m c ra n k s h a ft,

(F ig . 1 4 - 6 ) .

2.

U s in g s p e c ia l to o l, p a rt n u m b e r 4 0 2 0 0 0 1 9 ,

pu ll tim in g

g e a r fr o m c r a n k s h a ft, (F ig . 1 4 - 7 ) .

3.

R e m o v e lo w e r h a lf o f tim in g g e a r c a s e , (F ig . 1 4 -8 ).

Fig. 14-8

Crankshaft and Main Bearings 14-7

4.

U n s c re w

m a in

b e a r in g

c a p b o lts

and

lift o ff b e a rin g

c a p s , (F ig . 1 4 - 9 ) .

F ig . 1 4 -9 5.

L ift o u t c r a n k s h a ft fr o m c r a n k c a s e , (F ig . 1 4 -1 0 ) .

F ig . 1 4 - 1 0 6.

R em ove

all

m a in

b e a r in g

s h e lls

fr o m

cran kcas e.

If

b e a r in g s h e lls a r e to b e r e -u s e d , th e y m u s t b e m a rk e d to

e n s u r e r e p la c e m e n t

in th e

o rig in a l

p o s itio n ,

(F ig .

1 4 -1 1 ).

F ig . 1 4 -1 1 7.

C le a n a ll p a rts , m e a s u r e c r a n k s h a ft jo u r n a ls a n d c o m ­ p a r e w ith s p e c ific a tio n s , (F ig . 1 4 -1 2 ) .

Fig. 14-12

April '96

Crankshaft and Main Bearings 14-8

8.

C heck

c r a n k s h a ft fo r

m is a lig n m e n t,

jo u r n a l

ru n o u t

(F ig . 1 4 - 1 3 ) .

F ig . 1 4 - 1 3 9.

C h e c k a ll m a in b e a r in g c a p b o lts fo r s tre tc h lim it,

re fe r

to s p e c ific a tio n s , (F ig . 1 4 - 1 4 ) .

F ig . 1 4 - 1 4

CRANKSHAFT GRINDING 1.

M a rk

c r a n k s h a ft

b a la n c e

w e ig h ts

and

re m o v e

fro m

c r a n k s h a ft, (F ig . 1 4 - 1 5 ) .

F ig . 1 4 - 1 5 2.

R em ove

tim in g

g e a r fr o m

c r a n k s h a ft,

u s in g

s p e c ia l

to o l p a rt n u m b e r 4 0 2 0 0 0 2 2 , (F ig . 1 4 - 1 6 ) .

A tten tion !

W h e n g rin d in g th e c r a n k s h a ft it is e s s e n tia l th a t

th e ra d ii o f th e b e a r in g jo u r n a ls a r e m a in ta in e d .

(S e e F ig . 1 4 - 3 4 , p a g e 1 4 - 1 3 ) .

Fig. 14-16

April '96

I

Crankshaft and Main Bearings 14-9

C h e c k in g C ra n k sh a ft a fter G rin d in g 1.

2.

c h e c k a n d c r a c k te s t c r a n k s h a ft, (F ig . 1 4 - 1 7 )

C heck

all

b a la n c e w e ig h t b o lts fo r s tre tc h lim its ,

re fe r

to th e s p e c ific a tio n s , (F ig . 1 4 - 1 8 ) .

A t t e n t i o n ! A ll c r a n k s h a ft b a la n c e w e ig h t b o lts th a t e x c e e d th e m a x im u m s tre tc h lim it m u s t b e re p la c e d .

3.

R e p la c e

b a la n c e

w e ig h ts ,

a lig n in g

m a rk s on w e ig h ts

w ith m a r k s o n c r a n k s h a ft, (F ig . 1 4 -1 9 ) .

4.

In s e r t

b a la n c e

w e ig h t

b o lts a n d

fie d 'to r q u e , (F ig . 1 4 - 2 0 ) .

April '96

tig h te n

to th e s p e c i­

Crankshaft and Main Bearings 14-10

5.

U s in g

c o m p re s s e d

c r a n k s h a ft to

a ir,

e n s u re

b lo w

o u t all g a lle r ie s

in th e

t h a t n o m e ta l p a rtic le s a r e r e ta i­

n e d w ith in th e d r illin g s , (F ig . 1 4 - 2 1 ) .

F ig . 1 4 -2 1 6.

R e p la c e c r a n k s h a ft tim in g g e a r u s in g s p e c ia l to o l, p a rt n u m b e r 4 0 2 0 0 1 9 0 , (F ig . 1 4 - 2 2 ) .

F ig . 1 4 - 2 2

C h eck in g C r a n k sh a ft B ea r in g an d P a ren t B o r e s A tten tion !

B e a r in g

s h e lls

a r e s u p p lie d

r e a d y fo r fittin g ,

in

s ta n d a r d a n d v a r io u s r e p a ir s iz e s . N o a t te m p t s h o u ld b e m a d e to a lte r th e p r e - d e t e r m in e d s iz e .

1.

T h o r o u g h ly c le a n a n d v is u a lly m a in

b e a r in g

b o re s

in

in s p e c t c o n d itio n o f all

c ra n k c a s e

a n d b e a r in g c a p s ,

(F ig . 1 4 - 2 3 ) .

mi » = F ig . 1 4 - 2 3 2.

R e p la c e

m a in

b e a r in g c a p s in s e r t b o lts a n d tig h te n to

th e s p e c ifie d to rq u e , (F ig . 1 4 - 2 4 ) .

Fig. 14-24

April '96

Crankshaft and Main Bearings 14-11

3.

A d ju s t a n in te r n a l m e a s u r in g in s tr u m e n t, (F ig . 1 4 -2 5 ) .

F ig . 1 4 - 2 5 4.

M e a s u re

m a in

co m p a re

m e a s u r e m e n ts w ith th e

b e a r in g

p a r e n t b o re s in o n e d ire c tio n s p e c ific a tio n s ,

(F ig

1 4 -2 6 ).

A

F ig . 1 4 - 2 6 5.

R em ove

m a in

b e a r in g

b o lts

and

b e a r in g c a p s , (F ig .

1 4 -2 7 ).

6.

In s e r t

b e a r in g s h e lls in to c r a n k c a s e a n d b e a r in g c a p s .

E n s u r e th a t lo c a tin g ta b s on b e a r in g s h e lls a r e c o rre c t­ ly in s e r te d in c a p a n d c r a n k c a s e , (F ig . 1 4 - 2 8 ) .

Fig. 14-28

Crankshaft and Main Bearings 14-12

A tte n tio n !

M a in b e a r in g s h e lls h a v e oil d rillin g s w h ic h m u s t

lin e u p w ith h o le s in th e c r a n k c a s e , (F ig . 1 4 -2 9 ) .

F ig . 1 4 - 2 9 7.

R e p la c e

m a in

fo r A D E 3 6 6 fitte d

b e a r in g

and

in th e

c a p s w h ic h a r e m a r k e d 1 to 7

1 to 5 fo r A D E 3 6 4 ,

c o rr e c t

p o s itio n s

w ith

w h ic h m u s t b e

th e

n u m b e r s to ­

w a r d s th e fr o n t o f t h e e n g in e , (F ig . 1 4 - 3 0 ) .

F ig . 1 4 - 3 0 8.

In s e r t

b e a r in g

cap

b o lts

and

tig h te n to th e s p e c ifie d

to rq u e , (F ig . 1 4 - 3 1 ) .

F ig . 1 4 -3 1 9.

A d ju s t/s e t a n in te r n a l m e a s u r in g in s tru m e n t, (F ig . 1 4 - 3 2 ) .

Fig. 14-32

April ‘96

Crankshaft and Main Bearings 14-13

10. M e a s u re p la c e s ,

all

m a in

c o m p a re

b e a r in g

in s id e

m e a s u r e m e n ts

d ia m e te r s w ith

th e

in th re e

s p e c ific a ­

tio n s , (F ig . 1 4 - 3 3 ) .

F ig . 1 4 - 3 3 11 S h o u ld th e c r a n k s h a ft

have

been

r e -g ro u n d

e x a m in e

th e r a d iu s ( R ) to e n s u r e t h a t th e s p e c ific a tio n h a s b e e n a d h e r e d to , (F ig . 1 4 - 3 4 ) .

F ig . 1 4 - 3 4 12.

R e m o v e all m a in b e a r in g c a p s , (F ig . 1 4 - 3 5 ) .

F ig . 1 4 - 3 5 R E P L A C I N G R E A R M A IN B E A R I N G O I L S E A L A tte n tio n !

T h e fitm e n t o f th e s e s e a ls m u s t b e c a rrie d o u t

w ith th e b e a r in g s h e lls r e m o v e d fr o m c r a n k c a s e a n d b e a rin g cap.

1.

W it h

th e

oil s e a l r e m o v e d , T h o r o u g h ly c le a n b o th h a l­

v e s o f th e b e a r in g h o u s in g , (F ig . 1 4 - 3 6 ) .

Fig. 14-36

April ‘96

Crankshaft and Main Bearings 14-14

2.

U s in g a p a ir o f lo n g n o s e p lie rs , r e m o v e th e oil s e a l re­ ta in in g

p in s fr o m

th e

seal

h o u s in g in c r a n k c a s e a n d

b e a r in g c a p , ( F i g . 1 4 - 3 7 ) .

F ig . 1 4 -3 7 3.

U s in g a n a lu m in iu m d rift, ta p n e w oil s e a l r e ta in in g pin in to

c ra n k c a s e

and

b e a r in g

cap

seal

h o u s in g , (F ig .

1 4 -3 8 ).

A tte n tio n !

D o n o t d a m a g e th e tip o f th e re ta in in g pins.

F ig . 1 4 - 3 8

4.

F it o n e

h a lf o f t h e

n e w oil s e a l in to s p e c ia l to o l,

p a rt

n u m b e r 4 0 2 0 1 6 0 7 , (F ig . 1 4 - 3 9 ) .

F ig . 1 4 - 3 9 5.

N ew

s e a l m u s t fit e x a c tly in to s p e c ia l to o l.

B o th e n d s

o f s e a l m u s t to u c h to o l h o ld e r, (F ig . 1 4 - 4 0 ) .

Fig. 14-40

Crankshaft and Main Bearings 14-15

6.

L o c a te

s p e c ia l to o l,

c ra n k c a s e

and

fitte d w ith

d r iv e th e s e a l

new

oil s e a l on to th e

in to th e h o u s in g , (F ig .

1 4 -4 1 ).

F ig . 1 4 -4 1 7.

In s e r t n e w

h a lf s e a l fo r b e a r in g c a p in to th e s p e c ia l

to o l a n d d r iv e in to b e a r in g c a p , (F ig . 1 4 - 4 2 ) .

A tten tio n !

N e w s e a l e n d s m u s t p r o tru d e 0 ,5 m m

a b o v e th e

b e a r in g c a p a n d c r a n k c a s e m a tin g s u rfa c e s o r 0 ,8 m m w h e n th e c r a n k s h a ft is r e g r o u n d to th e n e x t r e p a ir s ta g e . N o fib re s s h o u ld b e tr a p p e d b e tw e e n th e b e a r in g c a p a n d th e c r a n k c a s e m a tin g s u rfa c e s .

8.

C o a t th e s e a l in th e c r a n k c a s e a n d b e a r in g c a p w ith a h e a t r e s is ta n t g r e a s e , (F ig . 1 4 - 4 3 ) .

F ig . 1 4 -4 3 9.

A p p ly

a

s m a ll a m o u n t o f s ilic o n e s e a la n t to th e g ro o ­

v e s in th e r e a r m a in b e a r in g c a p .

The

end

s u rfa c e

of

s e a ls m u s t n o t b e c o a te d w ith s e a la n t, (F ig . 1 4 -4 4 ) .

A tten tio n ! s e a la n t

to

If th e b e a r in g c a p d o e s n o t h a v e g ro o v e s , a p p ly th e

s u r fa c e s

o f th e

cap

and

th e

cran k-

case.

S u r fa c e s to b e c o a te d w ith s e a la n t m u s t b e fr e e o f g re a s e .

Fig. 14-44

April '96

Crankshaft and Main Bearings 14-16

REPLACING THE CRANKSHAFT 1.

L ib e r a lly c o a t th e b e a r in g s w ith e n g in e oil, (F ig . 1 4 -4 5 ).

Fi<g. 1 4 - 4 5 2.

L o w e r t h e c r a n k s h a ft o n to th e b e a r in g s , (F ig . 1 4 -4 6 ) .

nB.i F ig . 1 4 - 4 6 3.

R e p la c e

a ll

m a in b e a r in g c a p s m a r k e d 1 to 7 fo r A D E

3 6 6 o r 1 to 5 fo r A D E 3 6 4 . c o rr e c t

p o s itio n

They

m ust

b e fitte d in th e

w ith th e n u m b e r s to w a r d s th e fro n t o f

th e e n g in e , (F ig . 1 4 - 4 7 ) .

F ig . 1 4 - 4 7 4.

C o a t th e th r e a d s o f th e m a in b e a r in g b o lts w ith e n g in e oil, (F ig . 1 4 - 4 8 ) .

Fig. 14-48

April '96

Crankshaft and Main Bearings 14-17

5.

In s e r t

b o lts a n d

tig h te n to

th e

s p e c ifie d to rq u e ,

(F ig .

1 4 -4 9 ).

6.

C h e c k th e to r q u e r e q u ire d

to tu rn th e c r a n k s h a ft, w ith

n e w b e a r in g s a n d oil s e a l fitte d ,

r e fe r to s p e c ific a tio n s ,

(F ig . 1 4 - 5 0 ) .

A tte n tio n !

S h o u ld th e

c r a n k s h a ft n o t tu rn

a t th e re q u ire d

to rq u e , r e m o v e r e a r m a in b e a r in g c a p a n d c h e c k c o rre c t fittin g o f th e oil s e a l.

7.

R e fit c a m s h a f t tim in g g e a r , lin in g up tim in g m a rk s . In ­ s e rt

b o lts

and

tig h te n

to

th e

s p e c ifie d

to rq u e ,

(F ig .

1 4 - 5 1 . S e e a ls o p a g e s 1 5 - 1 2 a n d 1 5 -1 3 .

8.

M ount

a

m e a s u re

d ia l th e

gauge

in d ic a to r o n th e c r a n k c a s e a n d

c r a n k s h a ft e n d

flo a t in a c c o r d a n c e w ith

s p e c ific a tio n s , (F ig . 1 4 - 5 2 ) .

Fig. 14-52

April '96

Crankshaft and Main Bearings 14-18

9.

R e p la c e th e b o tto m h a lf o f th e tim in g c o v e r a n d tig h te n th e b o lts to th e s p e c ifie d to rq u e , (F ig . 1 4 - 5 3 ) .

April ‘96

CRANKSHAFT AND MAIN BEARINGS — 14-19

SPECIAL TOOLS FOR THIS SECTION O B T A IN A B L E E L IZ A B E T H

FROM :

6001

G R U N D Y -T E C H N IF O R M .

BURM AN

ROAD.

DEAL

PARTY

ESTATE.

PORT

.

Im p a c t so cke t scan ner ¡s e e fig. 14.-21

3

P a rt N u m b e r 40 2001 45

P u lle r for c a m s h a ft g e ar (see fig. 14-71

n

P a rt n u m b e r 40 2000 19

1

C ran ksha ft h a rd n e s s tester (s e e fig. 14-13) P a rt N u m b e r 40 200501

C ra n k s h a ft gear re placer (s e e fig. 14-22) P a rt N u m b e r 40 2001 90

R e a r oil se a l r e p l a c e r (see fig. 14-39) P a rt N u m b e r 40 20 1 6 0 7

P u lle r for v ib ra tio n d a m p e r

=7 =7

0

(se e fig. 14-3) P a rt n u m b e r 40 200 019

rn

A D E 360 S e rie s

ADE 360 S eries

________________SECTION 15 Camshaft, Timing Case and Drive Timing

CONTENTS OF SECTION 15

Page

I L L U S T R A T I O N ...................................................................................................................................................................................................................................... 1 5 -2 I N T R O D U C T I O N ....................................................................................................................................................................................................................................1 5 -3 S P E C I F I C A T I O N S ................................................................................................................!............................................................................................................... 1 5 -3 R E M O V I N G C A M S H A F T ..................................................................................................................................................................................................................1 5 -5 R E P L A C I N G C A M S H A F T ................................................................................................................................................................................................................ 1 5 -9 R E M O V IN G T IM IN G C O V E R O IL S E A L

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

R E P L A C I N G T I M I N G C O V E R O I L S E A L .................................................................................................

S P E C IA L T O O L S ..................................................................................................................................................

1 5 -1 4 1 5 -1 5 1 5 -1 7

Camshaft, Timing Case and Drive Timing 15-2

C A M S H A F T A N D T IM IN G G E A R S 1. C A M S H A F T

7. R E T A IN IN G B O L T

2. T H R U S T W A S H E R

8. B O L T

3. F L Y -W E IG H T

10 . IN J E C T IO N P U M P D R IV E G E A R

5. S P R IN G

11. F E A T H E R K E Y

6. C A M S H A F T G EA R

April ‘96

9. R O L L E R

4 . P IN

Camshaft, Timing Case and Drive Timing 15-3 IN T R O D U C T I O N T h e c a m s h a f t is p r e c is io n fo rg e d a n d in d u c tio n h a rd e n e d . It is s u p p o r te d b y s te e l b a c k e d b r o n z e b e a r in g s a n d g e a r d riv e n fr o m th e c r a n k s h a ft. A c c e s s to t h e tim in g g e a r s c a n b e g a in e d b y r e m o v a l o f th e c r a n k s h a ft v ib ra tio n d a m p e r a n d tim in g c a s e , w h ic h is s it u a te d a t th e fr o n t o f th e e n g in e .

S P E C IF IC A T IO N S C a m s h a f t B e a r in g s B e a r in g p o s itio n 364 —

S ta n d a r d 366

J o u r n a l d ia.

B e a r in g ID

1

5 5 ,9 4 1 to 5 5 ,9 6 0

5 6 , 0 0 0 to 5 6 , 0 3 0 5 5 , 7 4 0 to 5 5 , 7 7 0

1

2

5 5 ,6 9 1 to 5 5 ,7 1 0

2

3

5 5 ,4 4 1 to 5 5 ,4 6 0

5 5 , 4 9 0 to 5 5 , 5 2 0

3

4

5 5 ,1 9 1 to 5 5 ,2 1 0

5 5 , 2 4 0 to 5 5 , 2 7 0

C a m s h a f t lo b e a n d jo u r n a l s u r f a c e fin is h

R z 3 pm

E c c e n tr ic - C o m p r e s s o r d r iv e

R a 0 ,2 pm ; R m a x 2 p m

B a s ic b o r e fo r c a m s h a f t b e a r in g

6 0 , 0 0 0 to 6 0 , 0 3 0

C a m s h a f t b e a r in g O D

6 0 , 1 5 0 to 6 0 , 1 8 0

C a m s h a f t b e a r in g c le a r a n c e

H a rd n e s s

R a d ia l

0 , 0 3 0 to 0 ,0 7 9

A x ia l

0 , 1 8 0 to 0 ,5 2 0

J o u rn a l

5 7 to 6 3 H rc

C a m lo b e s

5 7 to 6 3 H rc

R u n -o u t o f c a m s h a f t jo u r n a ls ( c a m s h a f t s u p p o r te d a t o u te r jo u r n a ls )

0 ,0 2 5

B a c k la s h c r a n k s h a f t /c a m s h a f t g e a r , c a m s h a ft/in je c tio n p u m p g e a r

0 , 0 7 0 to 0 , 1 8 0

In le t

Exhaust

V a lv e tr a v e l s p e c ific a tio n s fo r c h e c k in g

364N , 366N

0 ,5 6 to 0 , 9 6

0 ,6 4 to 1 ,0 4

v a lv e tim in g a t T D C a n d "O " c le a r a n c e

3 6 6 C /T /T I, 3 6 4 C /T

0 ,5 8 to 0 , 9 8

0 ,6 1 to 1 ,0 1

In le t

Exhaust

M a x im u m v a lv e lift (w ith s p e c ifie d

3 6 4 N /C /T , 3 6 6 N

1 0 ,5 6

1 0 ,5 6

v a lv e c le a r a n c e )

3 6 6 C /T /T I

1 0 ,1 6

1 0 ,5 6

April '96

Camshaft, Timing Case and Drive Timing 15-4

Outer shaft dia.

Bore in cylinder block

Standard

27,980 to 27,990

28,000 to 28,033

Repair stage 1 (+0,2)

28,180 to 28,190

28,200 to 28,233

Repair stage 2 (+0,5)

28,480 to 28,490

28,500 to 28,533

Repair stage 3 (+0,75)

28,730 to 28,740

28,750 to 28,783

Clearance shaft /bore

0,010 to 0,053

TORQUE SPECIFICATIONS Timing degree pointer.............................................................. M6............................................8 Nm Timing device to camshaft....................................................... M16 x 1,5................................. 300 Nm Timing segment to camgear.................................................... M8............................................30 to 40 Nm (+90° to 100°) Injection pump gear 364N/C/T, 366N.......................................M14 x 1,5..................................80 Nm 366C/T/TI................................................. M18 x 1,5..................................105 Nm Camshaft thrust plate to block................................................. M8 x 1.......................................35 Nm Timing case to cylinder block................................................... M10..........................................65 Nm Timing case cover to timing case.............................................M6............................................10 Nm*

April '96

Camshaft, Timing Case and Drive Timing 15-5

REMOVING AND REPLACING THE CAMSHAFT 1. Remove rocker cover, (refer to page 12-7).

2. Unscrew and remove rocker shaft, (refer to page 12-9).

3. Remove pushrods and mark to ensure replacement in the original position.

4. Unscrew and remove side cover, (Fig. 15-1).

5. Lift out camfollowers, (Fig. 15-2), and number each in order to replace in the same position.

6. Drain engine oil and remove sump, (Fig. 15-3).

7. Unscrew and remove bolts retaining oil pump, lift out pump, (Fig. 15-4).

April ‘96

Camshaft, Timing Case and Drive Timing 15-6 8. Slacken the V-belt adjuster on the alternator and re­ move the belts, (Fig. 15-5).

9. Using special tool, part number 4020 0145, unscrew and remove centre bolt retaining vibration damper, (Fig. 15-6).

10. Attach special puller, part number 4020 0019, to vibra­ tion damper and puli off, (Fig. 15-7).

11. Unscrew and remove bolts retaining the timing case cover and lift off, (Fig. 15-8).

April '96

Camshaft, Timing Case and Drive Timing 15-7 12. Using a socket, unscrew and remove the Allen cap screw retaining the timing gear to the camshaft, (Fig. 15-9).

A il

g. 1 5 -9

13. Using special tool, part number 4020 0019, pull off timing gear from camshaft, (Fig. 15-10).

14. Remove shim and feather key from the camshaft, (Fig. 15-11).

15. Unscrew bolts retaining the camshaft thrust plate and remove from the camshaft, (Fig. 15-12).

Fig. 15-12

V 1

O

I

Camshaft, Timing Case and Drive Timing 15-8 16. If the engine is fitted with a crankcase mounted com­ pressor remove the compressor cylinder head bolts together with the gasket, (Fig. 15-13).

Fig. 15-13 17. Turn the piston of the compressor to TDC and pull off the cylinder barrel, (Fig. 15-14).

Fig. 15-14 18. Remove the circlips retaining the gudgeon pin, push out and remove the piston, (Fig. 15-15).

Fig. 15-15 19. Unscrew the nuts retaining the bearing cap to the connecting rod, (Fig. 15-16).

Fig. 15-16

April '96

Camshaft, Timing Case and Drive Timing 15-9 20. Remove connecting rod and bearing cap, (Fig. 15-17).

21. Pull out the camshaft from the cylinder block. Do not damage the camshaft bearings, (Fig. 15-18).

REPLACING 1. Carefully insert the camshaft into the cylinder block without damage to the camshaft bearings, (Fig. 15-19).

Fig. 15-19 2. Fit thrust plate to camshaft, insert retaining bolts and tighten to the specified torque, (Fig. 15-20).

April '96

Camshaft, Timing Case and Drive Timing 15-10 3. Fit shim to camshaft, (Fig. 15-21)

Fig. 15-21 4. Fit timing gear to camshaft; ensure that the marks on timing gear and crankshaft gear are aligned, (fFig. 15-22).

Fig. 15-22 5. Insert feather key, locating timing gear to camshaft, (Fig. 15-23).

Fig. 15-23 6 Insert Allen cap screw into camshaft, (Fig. 15-24).

Fig. 15-24

April '96

Camshaft, Timing Case and Drive Timing 15-11

7. Tighten cap screw to the specified torque, (Fig. 15-25).

Fig. 15-25 8. Replace timing case cover and align using special tool 4020 2198, (Fig. 15-26).

Fig. 15-26 9. Insert bolts retaining the timing cover and tighten to the specified torque, (Fig. 15-27).

Fig. 15-27 10. If necessary, heat the vibration damper to approxima­ tely 80°C in a water bath before sliding onto the crank­ shaft. Ensure that the woodruff key locates in the groove, (Fig. 15-28).

Fig. 15-28

April '96

Camshaft, Timing Case and Drive Timing 15-12 11. Screw centre bolt into crankshaft and tighten to the specified torque, (Fig. 15-29).

Attention! The centre bolt must not be tightened with an impact wrench

■ni)

Fig. 15-29 12. If the engine is fitted with a crankcase mounted com­ pressor the crankshaft should be turned so that the lobe for the compressor connecting rod is at TDC. Re­ place bearing cap and connecting rod, (Fig. 15-30).

Note: When using belt driven compressors the oil supply hole in the eccentric is closed off with a jubilee clamp.

13. Tighten nuts to the specified torque, (Fig. 15-31).

14. Fit compressor piston to connecting rod, insert gud­ geon pin and circlips, (Fig. 15-32).

Fig. 15-32

April '96

ak

Camshaft, Timing Case and Drive Timing 15-13 15. Lightly apply a suitable sealing compound to the base of the cylinder barrel.

16. With the special piston ring squeezer, part number 4020 1131, compress the piston rings, insert piston into the cylinder barrel, push the barrel down over the piston rings and remove the piston ring squeezer.

Push the barrel fully home, (Fig. 15-33).

17. Replace the compressor cylinder head, fitted with a new gasket, insert bolts and tighten to the specified torque, (Fig. 15-34).

18. Replace the oil pump, insert the retaining bolts and tighten to the specified torque, (Fig. 15-35).

19. Using new gaskets, replace the sump, insert bolts and tighten to the specified torque, (Fig. 15-36).

Fig. 15-36

April '96

Camshaft, Timing Case and Drive Timing 15-14 20. Insert cam followers in the same position from which they were removed, (Fig. 15-37).

21. Replace side cover, insert bolts and tighten to the spe­ cified torque, (Fig. 15-38).

22. Insert push rods in their original position, see page 12 - 21 .

23. Replace the rocker shafts and insert the bolts but do not tighten.

24. Use special tool, part number 4020 3185 and insert the connecting nipple between the rocker shafts, see page 12-21.

25. Tighten the rocker shafts to the specified torque, see page 12-23.

26. Adjust the valve clearance, see page 12-23.

27. Replace the rocker cover with a new gasket, insert bolts and tighten to the specified torque, (Fig. 12-24).

REMOVING AND REPLACING THE TIMING COVER OIL SEAL Timing cover removed from the engine.

Removing 1. Place the support ring of special tool, part number 4020 0200, under the front of the timing cover to prevent distortion when the oil seal is removed, (Fig. 15-39).

2. Use the adapter ring and spacer of the special tool to press the oil seal from the housing, (Fig. 15-40).

Fig. 15-40

Camshaft, Timing Case and Drive Timing 15-15 Replacing 1. Locate a new oil seal in front of the housing, (Fig. 15-41).

2. Place a 12 mm distance piece inside the timing cover, behind the oil seal housing, (Fig. 15-42).

3. Place the spacer of the special tool on top of the oil seal, (Fig. 15-43).

4. Press the seal into the timing housing until it is flush with the inside edge of the timing cover and butts onto the distance piece, (Fig. 15-44).

Fig. 15-44

Camshaft, Timing Case and Drive Timing 15-16 5. Section through timing case with the oil seal in place, (Fig. 15-45).

Note: When replacing the timing case oil seal it is essential to replace the wear ring on the crankshaft.

April '96

CAMSHAFT, TIMING CASE AND DRIVE TIMING — 15-17

SPECIAL TOOLS FOR THIS SECTION O B T A IN A B L E E L IZ A B E T H

FROM :

G R U N D Y -T E C H N IF O R M .

BURM AN

ROAD.

DEAL

PARTY

ESTATE.

PORT

6001

im pa ct socket s o a nner

ise e tig

15-6 i

Part N u m D e r 40200145

P u lle r fo r c a m s h a ft gear, (see fig . 15-10) P art N u m b e r 40200019.

P u lle r fo r v ib ra tio n a a m D e r (see fig . 15-7) P art n u m b e r 40200019

T im in g co ve r c e n tra liz in g to o l. .. (see fig . 15-26) P art N u m b e r 40202198.

C o m p re s s o r p is to n rin g squeezer u se w ith p lie rs b e lo w , (see fig . 15-33) P art N u m b e r 40201131.

P lie rs fo r c o m p re s s o r p is to n rin g squeezer, (see fig. 15-33) P art N u m b e r 40201144.

AM ENDMENT 6/91

CAMSHAFT, TIMING CASE AND DRIVE TIMING — 15-18

T im ing cover oil seal remover/ replacer, (see fig. 15-40).

P art N u m b e r 40200200.

F ab ricate a 12 mm spacer x 100 mm dia., which is used as a distance piece under the tim ing case cover, when pressing in the seal, (see fig. 15-42).

AMENDMENT 6/91

_________SECTION 16 Lubricating System and Sump

CONTENTS OF SECTION 16

Page

I L L U S T R A T I O N ...................................................................................................................................................................................................................................... 1 6 -2 O IL F L O W C H A R T ............................................................................................................................................................................................................................... 1 6 -3 I N T R O D U C T I O N ....................................................................................................................................................................................................................................1 6 -4 S P E C I F I C A T I O N S .................................................................................................................................................................................................................................1 6 -4 R E M O V I N G T H E O IL C O O L E R ................................................................................................................................................................................................... 1 6 -6 R E P L A C I N G T H E O IL C O O L E R ..................................................................................................................................................................................................1 6 -8 R E M O V I N G T H E O I L C O O L E R A D E 3 6 6 T ....................................................................................................................................................................... 1 6 - 1 0 R E P L A C I N G T H E O IL C O O L E R A D E 3 6 6 T ....................................................................................................................................................................... 1 6 -1 2 R E M O V I N G T H E O IL F I L T E R E L E M E N T ............................................................................................................................................................................1 6 -1 5 R E P L A C I N G T H E O IL F I L T E R E L E M E N T .......................................................................................................................................................................... 1 6 -1 6 R E M O V I N G T H E O IL F I L T E R H E A D .................................................................................................................................................................................... 1 6 -1 7 R E P L A C I N G T H E O IL F IL T E R H E A D ...................................................................................................................................................................................1 6 -1 8 R E M O V I N G T H E O IL P U M P ........................................................................................................................................................................................................1 6 -2 1 A S S E M B L Y O F T H E O I L P U M P ................................................................................................................................................................................................1 6 - 2 3

April '96

Lubricating System and Sump 16-2

OIL PUMP AND FILTER ASSEMBLY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

April '96

OIL FILTER ELEMENT FILTER ELEMENT RETAINER SEALING WASHER WASHER SEALING WASHER FILTER BOWL RETAINING BOLT DRAINPLUG AND WASHER GEAR SHAFT OIL PUMP DRIVEN GEAR OIL PUMP DRIVE SHAFT OIL PUMP DRIVE GEAR OIL PUMP DRIVE SHAFT/TACHO DRIVE WOODRUFF KEY OIL PUMP COVER RETAINING BOLT RELIEF VALVE OIL PUMP COVER PLATE

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

STRAINER STRAINER RETAINING BOLT OIL PUMP RETAINING BOLT OIL PUMP BODY OIL PUMP GEAR BY-PASS VALVE SCREW PLUG WASHER BY-PASS VALVE SPRING BY-PASS VALVE OIL FILTER HEAD BANJO BOLT AND WASHER GASKET INJECTION PUMP OIL FEED PIPE BANJO BOLT AND WASHER BLANKING PLUG BLANKING PLUG AND WASHER

Lubricating System and Sump 16-3

TYPICAL OIL FLOW - ADE 360 SERIES

Oil is drawn from the engine sump by a gear type pump, through a gauze strainer. The oil under pressure then flows between the oil pump body and drive shaft into a gallery, passing to the oil filter. From the oil filter, cleansed oil flows via an intersecting gallery to a plate type oil cooler. On the naturally aspirated engine, oil from the cooler enters the main oil gallery to the crankshaft, camshaft, rocker gear, etc.

The turbocharged engine oil flow differs from the naturally aspirated engine, in that the oil flowing from the main oil filter passes into an additional micro type filter, mounted on the outside of the oil cooler cover, before flowing into a large capacity fin type oil cooler, providing an increase in the cooling capacity. To assist with dissipation of the additional heat generated by the turbocharged engine, piston cooling nozzles are fitted to the main oil gallery, supplying a constant jet of cooling oil to the underside of the piston crowns. The turbocharger is fed under pressure from the main oil gallery, with a drain to the engine sump.

The ADE 364C/T/TI engine has a small finned cooler mounted integrally with the engine oil filter to assist with heat dissipation.

Note: The micro type oil filter mentioned above has since been removed on turbocharged engines built from mid 1995.

April '96

Lubricating System and Sump 16-4

INTRODUCTION A g e a r ty p e p u m p s u p p lie s o il u n d e r p re s s u re th ro u g h a fu ll flo w p a p e r ty p e o il filte r to th e c r a n k s h a ft, c a m s h a ft, c o n n e c tin g ro d b ig e n d b e a rin g s , ro c k e r s h a ft b e a rin g s , fu e l in je c to r p u m p a n d g o v e rn o r. O il u n d e r p re s s u re is a ls o fe d to th e c ra n k c a s e m o u n te d a ir c o m p r e s s o r a n d tu rb o c h a rg e r ( if fitte d ). P re s s u re re lie f a n d b y -p a s s v a lv e s p ro te c t th e s y s te m a g a in s t o v e rlo a d .

SPECIFICATIONS OIL PUMP 364N/C/T 366N

366C/T/TI

Width of pump gears

39,936 to 39,975

49,936 to 49,975

Axial play between gear face and housing

0,025 to 0,089

0,025 to 0,089

Clearance between teeth and housing

0,030 to 0,105

0,030 to 0,105

Outside dia. of pump gears

42,020 to 42,070

42,020 to 42,070

Inside dia. of pump driving gear

16,944 to 16,958

16,944 to 16,958

Inside dia. of pump driven gear

15,050 to 15,073

15,050 to 15,073

Diameter in housing for shaft of driven gear

15,000 to 15,018

15,000 to 15,018

Inside diameter of oil pump drive sprocket

16,944 to 16,958

16,944 to 16,958

A - Installation height between drive sprocket and pump housing flange when moving shaft in the indicated direction

+

0,5

116,5 - 0,3

B - Diameter of oil pump driving shaft

16,976 to 16,984

16,976 to 16,984

C - Diameter of oil pump driven gear shaft

15,028 to 15,039

15,028 to 15,039

D - Installation height of driven gear shaft

39,2 to 39,5

47,5 to 48,5

E - Installation height of drive gear to drive shaft

0,5 to 0,8

7,2 to 7,8

Min. delivery rate (¿/min) with SAE 10 oil at 50°C and 400 kPa pressure

April '96

Pump speed

364N/C/T 366N

366C/T/TI

300 r/min 1 400 r/min

45

58

Lubricating System and Sump 16-5 OIL PRESSURE RELIEF VALVE____________________________________________________________ I Opening pressure (kPa) 470 - 570 SPRING FOR PRESSURE RELIEF VALVE Wire dia.

Unloaded OD spring length mm mm mm 49,4 9,3 1,7 OIL FILTER BY-PASS VALVE SPRING Wire Unloaded OD dia spring length mm mm mm 16,5 66 1,5

Spring preload Length Load mm N 45,4 43,9

Spring preload Length Load mm N 31 42 to 48

Spring final load Length Load mm N 36,2 !

145

Spring final load Length Load mm N 21,0 57

Opening pressure of by-pass valve kPa 160 - 250

OIL PRESSURE Minimum operating oil pressure (warm engine) 600 r/min 80 kPa gauge pressure 2800 r/min 280 kPa gauge pressure Warning! Stop engine immediately when the oil pressure drops below the following values 600 r/min 50 kPa gauge pressure 2800 r/min 250 kPa gauge pressure OIL CAPACITY Depending on application

364N/C/T approximately 10 litres 366N/C/T/TI approximately 17,5 litres

TORQUE SPECIFICATIONS Turbocharger oil drain to crankcase/sump (364C/T/TI)....

Turbocharger oil supply from oil cooler cover (366C/T/TI) Turbocharger oil drain to sump (366C/T/TI).....................

Oil supply to turbocharger................................................

Oil drain from turbocharger..............................................

Oil pressure gauge switch................................................

Oil filter mounting............................................................

Dipstick adapter...............................................................

Sump drain plug..............................................................

Dipstick tube to cylinder block..........................................

Sump to cylinder block - Pressed steel............................

- Aluminium casting

M 1 6 x 1 , 5 ........................................................ 4 0 N m M 1 4 x 1 , 5 ........................................................ 4 0 N m M 2 6 x 1 , 5 ........................................................ 7 0 N m M 8 ....................................................................... 3 5 N m M 8 ....................................................................... 3 5 N m M 1 4 x 1 , 5 ........................................................ 5 0 N m M 1 0 .................................................................... 5 0 N m M 1 4 x 1 , 5 ........................................................ 4 0 N m M 2 6 x 1 , 5 ........................................................ 8 0 N m M 1 6 x 1 , 5 ........................................................ 2 5 N m M 8 ( S t u d s ) ....................................................

9 Nm

M 6 ( B o lt s ) .....................................................

8 Nm

M 8 ( S t u d s ) ..................................................... 2 5 N m M 6 ( B o lt s ) ....................................................... 1 5 N m

Drain plug bush to sump.................

Relief valve cap to oil pump cover....

By-pass valve cap on oil filter'.........

Banjo bolt to oil filter head...............

Plug to oil filter head........................

Plug to oil filter head (Aluminium)....

Drain plug to filter head (Aluminium) Oil filter bowl to filter head...............

Oil supply pipe to injector pump......

Oil supply pipe to filter....................

Suction pipe to oil pump cover........

Oil pump cover to pump body.........

Oil pump to cylinder block...............

Oil cooler filter to cooler..................

Oil cooler cover to cylinder block.....

Oil cooler by-pass valve..................

Oil cooler bolts (centre) 366N..........

Cooler to cover 366C/T/TI...............

April ‘96

-

.......................................................................... 9 0 - 1 1 0 N m

M 2 4 x 1 , 5 ........................................................ 2 0 N m (w ith L o c tite ) M 2 4 x 1 , 5 ........................................................ 7 0 N m M 2 6 x 1 , 5 ........................................................ 6 0 N m M 1 0 x 1 .............................................................2 0 N m M 1 4 x 1 , 5 ........................................................ 3 5 N m M 1 0 x 1 .............................................................2 0 N m M 1 2 x 1 , 5 ........................................................ 4 5 N m M 1 0 x 1 .............................................................1 5 N m M 10 x 1

15 Nm

M 8 ....................................................................... 3 5 N m M 8 ....................................................................... 3 4 N m M 8 ....................................................................... 3 5 N m M 1 0 .................................................................... 4 0 N m M 8 .......................................................................4 0 N m M 2 2 x 1 , 5 ........................................................ 6 5 N m M 8 ....................................................................... 3 0 N m M 8 ....................................................................... 3 5 N m

, :

Lubricating System and Sump 16-6 REMOVING AND DISMANTLING PLATE TYPE OIL COOLER 366N 1.

2.

R e m o v e s ta r te r m o to r.

U n s c re w

b o lts

and

re m o v e th e

e x h a u s t m a n ifo ld ,

(F ig . 1 6 - 1 ) .

3.

U n s c re w

th e

b o lts

and

r e m o v e th e

in le t m a n ifo ld ,

(F ig . 1 6 - 2 ) .

4.

U n s c re w

and

r e m o v e th e

oil p r e s s u r e g a u g e s e n d e r

un it, (F ig . 1 6 - 3 ) .

5.

R em ove 1 6 -4 ).

April '96

by- pass

v a lv e

fr o m

o il c o o le r c a s in g ,

(F ig .

Lubricating System and Sump 16-7

6.

U n s c re w a n d r e m o v e a ll b o lts re ta in in g th e o il c o o le r to th e c y lin d e r b lo c k , (F ig . 1 6 -5 ).

7. Remove the oil cooler casing from the cylinder block, (Fig. 16-6).

8. Unscrew and remove bolts joining both halves of the oil cooler, (Fig. 16-7).

9. Dismantle the oil cooler halves, (Fig. 16-8).

M m >e=

Fig. 16-8___________________________________

April '96

Lubricating System and Sump 16-8 ASSEMBLY AND REPLACEMENT OF OIL COOLER 1. Fit new gasket between oil cooler halves, (Fig. 16-9).

¡

A

N jT '~

,

r- ,

J iff

■in g. 16-9 2. Insert bolts joining the oil cooler halves and tighten to the specified torque,(Fig. 16-10).

Fig. 16-10 3. Replace oil pressure gauge sender unit and tighten the bolts to the specified torque, (Fig. 16-11).

4. Replace the by-pass valve and tighten the bolts to the specified torque, (Fig. 16-12).

Fig. 16-12

April ‘96

Lubricating System and Sump 16-9

5.

F it a

new

g a s k e t b e tw e e n oil c o o le r c a s in g a n d c y lin ­

T

d e r b lo c k .

6.

'

^

R e p la c e th e oil c o o le r to c y lin d e r b lo c k , (F ig . 1 6 -1 3 ) .

F ig . 1 6 - 1 3 7.

In s e r t b o lts s e c u r in g th e oil c o o le r to th e c y lin d e r b lo c k and

tig h te n in c ro s s fa s h io n fr o m th e c e n tr e o u tw a rd s ,

to th e s p e c ifie d to r q u e , (F ig . 1 6 - 1 4 ) .

mu / © s F ig . 1 6 - 1 4 8.

F it n e w g a s k e ts to th e in le t m a n ifo ld ,

in s e rt b o lts a n d

tig h te n to th e s p e c ifie d to rq u e , (F ig . 1 6 -1 5 ) .

F ig . 1 6 - 1 5 9.

F it n e w

g a s k e ts to

th e e x h a u s t m a n ifo ld ,

in s e rt b o lts

a n d tig h te n to t h e s p e c ifie d to rq u e , (F ig . 1 6 - 1 6 ) .

1 0 . R e p la c e th e s t a r t e r m o to r.

1 1 . W it h

th e e n g in e s to p c o n tro l s e t to th e “O F F " p o s itio n ,

tu rn th e e n g in e w ith t h e s t a r t e r m o to r u n til oil p r e s s u r e is r e g is te r e d o n th e g a u g e .

1 2 . S ta r t th e e n g in e a n d

a llo w to id le fo r s e v e r a l m in u te s ;

c h e c k a ll jo in ts fo r oil le a k s .

till A3 =

Fig. 16-16

April '96

Lubricating System and Sump 16-10 REMOVING OIL COOLER ADE 366T 1. Remove the starter motor.

2. Disconnect the oil feed and drain pipes to the turbo­ charger, (Fig. 16-17).

3. Unscrew bolts and remove the exhaust manifold, (Fig. 16-18).

4. Unscrew bolts and remove the inlet manifold, (Fig. 16-19).

5. Do not remove the oil cooler retainer bolts until the housing has been removed from the cylinder block, (Fig. 16-20).

April '96

Lubricating System and Sump 16-11

6

U n s c re w h o u s in g

and and

re m o v e re m o v e

a ll b o lts r e ta in in g th e oil c o o le r fr o m

th e

c y lin d e r b lo ck ,

(F ig .

1 6 -2 1 ).

7.

U n s c re w a n d re m o v e

b o lts re ta in in g th e oil c o o le r e le ­

m e n t to th e h o u s in g , (F ig . 1 6 - 2 2 ) .

Fig. 16-22 8.

D e ta c h

th e

oil c o o le r e le m e n t fr o m

th e h o u s in g , (F ig .

c e n tr e b o lt r e ta in in g

th e oil c o o le r filte r

1 6 -2 3 ).

9.

U n s c re w

th e

e le m e n t to t h e h o u s in g , (F ig . 1 6 - 2 4 ) .

April '96

Lubricating System and Sump 16-12

10.

L ift o f f th e filte r c o v e r a n d (F ig . 1 6 -2 5 ).

r e m o v e th e filte r e le m e n t,

Fig. 16-25 11. Unscrew and remove the oil pressure gauge sender unit, (Fig. 16-26).

Fig. 16-26 12. Remove the by-pass valve from the oil cooler housing, (Fig. 16-27).

— I ss>

mi /©=

Fig. 16-27 R E P L A C IN G

1. Replace the oil pressure gauge sender unit and tighten to the specified torque.

2. Replace the by-pass valve and tighten to the specified torque, (Fig. 16-28).

III! M s

Fig. 16-28

April '96

Lubricating System and Sump 16-13 3. Fit a new O-ring to the oil cooler filter element cover, (Fig. 16-29).

4. Replace the oil cooler filter element.

Note: The wide sealing face on the filter element goes towards the sealing surface of the oil cooler housing, (Fig. 16-30).

5. Replace the filter element cover, fitted with new O-ring, insert the retaining bolt and tighten to the specified torque, (Fig. 16-31).

6. Fit new gaskets between oil cooler element and hou­ sing, replace the cooler element and insert bolts, (Fig. 16-32).

Fig. 16-32

April '96

Lubricating System and Sump 16-14 7. Tighten oil cooler retaining bolts to the specified torque, (Fig. 16-33)

Fig. 16-33 8. Fit a new gasket between the cylinder block and the oil cooler housing.

9. Replace all bolts retaining the oil cooler housing to the cylinder block and tighten in cross fashion from the centre outwards to the specified torque, (Fig. 16-34).

Fig. 16-34 10. Fit a new gasket to the inlet manifold, insert bolts and tighten to the specified torque, (Fig. 16-35).

Fig. 16-35 11. Insert the exhaust manifold bolts and tighten to the specified torque, (Fig. 16-36).

■ ill » =

Fig. 16-36

April ‘96

Lubricating System and Sump 16-15

1 2 . C o n n e c t oil fe e d

and

d ra in

p ip e to th e tu rb o c h a r g e r ,

a n d tig h te n to s p e c ifie d to r q u e (F ig . 1 6 -3 7 ) .

1

1 3 . R e p la c e th e s t a r t e r m o to r.

1 4 . W it h

th e e n g in e S to p c o n tro l s e t to th e “O F F " p o s itio n

tu rn t h e e n g in e w ith th e s t a r te r m o to r un til oil p re s s u re is r e g is te r e d o n th e g a u g e .

1 5 . S ta r t th e

e n g in e a n d a llo w to id le fo r s e v e r a l m in u te s .

C h e c k a ll jo in ts fo r oil le a k s .

I F ig . 1 6 - 3 7 ___________

R e m o v in g th e Oil F ilter E le m e n t 1.

U n s c re w

and

r e m o v e th e

filte r b o w l

d ra in

p lu g a n d

a llo w oil to d ra in (F ig . 1 6 - 3 8 ) .

2.

U n s c re w

th e

c e n tr e b o lt re ta in in g th e filte r b o w l to th e

filte r h e a d , (F ig . 1 6 - 3 9 ) .

3.

R e m o v e th e

o il filte r b o w l a n d th e filte r e le m e n t,

1 6 -4 0 ).

4.

C le a n filte r b o w l, e le m e n t r e ta in e r a n d c e n tr e bo lt.

April '96

(F ig .

Lubricating System and Sump 16-16 Replacing 1.

F it a n e w O - rin g to th e filte r h e a d , (F ig , 1 6 -4 1 ).

2

Insert a new filter element into the filter bowl, (Fig. 16-42).

3 Position the filter bowl to the centre of the filter head, insert bolt and tighten to the specified torque, (Fig. 16-43).

4. Replace the filter drain plug and tighten to the speci­ fied torque, (Fig. 16-44).

Attention! With the engine Stop control set to the “OFF" position, turn the engine with the starter motor until oil pressure is registered on the gauge.

5. Start the engine and allow to idle for several minutes.

Check all joints for oil leaks.

April '96

Lubricating System and Sump 16-17 REMOVING AND REPLACING THE OIL FILTER HEAD Removing 1. Drain the filter bowl.

2. Remove the filter bowl and element, (Fig. 16-45).

Fig. 16-45 3. Unscrew and remove the feed pipe to injection pump, (Fig. 16-46).

FicJ. 16-46 4. Unscrew and remove bolts retaining the filter head to the crankcase, (Fig. 16-47).

5. Remove the filter head from the crankcase.

Note: New level oil filter elements have integrated seal rings, and therefore the loose seal ring depicted in Fig. 16-47 will no longer be required.

Fi.q. 16-47 6. Unscrew and remove the oil filter by-pass valve from the filter head, (Fig. 16-48).

mi » =

Fig. 16-48

April '96

Lubricating System and Sump 16-18

7.

R em ove

th e oil filte r s e a l a n d re ta in in g sp rin g fr o m th e

filte r h e a d , (F ig . 1 6 - 4 9 ) .

N o te :

T h is s e a l is n o w in te g ra l p a rt o f th e oil filte r

a s s e m b ly .

Fig . 1 6 - 4 9 8.

T h o r o u g h ly

c le a n

a ll p a rts a n d b lo w o u t oil d rillin g s in

th e h e a d w ith c o m p r e s s e d a ir, (F ig . 1 6 - 5 0 ) .

llll A3 =

F ig . 1 6 - 5 0 R e p la c in g 1.

U s in g

a

te n s io n ,

s p rin g te s te r ,

c h e c k th e b y -p a s s v a lv e s p rin g

r e p la c e if r e q u ire d ,

see

s p e c ific a tio n s ,

(F ig .

1 6 -5 1 ).

F ig . 1 6 -5 1 2

F it a

new

oil filte r s e a l a n d

r e ta in in g rin g to th e filte r

h e a d , (F ig . 1 6 - 5 2 ) .

m

Fig. 16-52

April '96

A»s

Lubricating System and Sump 16-19

3.

U se

a

new

g a s k e t,

fit th e filte r h e a d to th e c r a n k c a s e

a n d in s e r t b o lts ,(F ig . 1 6 - 5 3 )

Fig . 1 6 - 5 3 4.

T ig h t e n to th e s p e c ifie d to rq u e , (F ig . 1 6 - 5 4 ) .

F ig . 1 6 - 5 4 F it b y -p a s s

v a lv e

in to th e filte r h e a d a n d tig h te n th e

s c r e w p lu g to th e s p e c ifie d to rq u e , (F ig . 1 6 - 5 5 ) .

Fig . 1 6 - 5 5 6.

C o n n e c t th e filte r h e a d ,

oil fe e d p ip e to tig h te n

th e

s c re w

th e in je c tio n p lu g to

pum p and

th e s p e c ifie d

to r q u e , (F ig . 1 6 - 5 6 ) .

Attention!

A b a n jo c o n n e c tio n w ith a s m a ll h o le is fitte d to

th e filte r h e a d ; th is a p p lie s a r e s tric tio n to th e oil flo w a n d s h o u ld n o t b e re v e r s e d .

Fig. 16-56

April '96

Lubricating System and Sump 16-20

7

8.

F it a n e w O -r in g to th e filte r b o w l, (F ig . 1 6 - 5 7 ) .

In s e r t a

new

o il filte r e le m e n t

in to th e filte r b o w l,

(F ig . 1 6 - 5 8 ) .

9.

F it th e filte r b o w l a n d e le m e n t to r e ta in in g

th e filte r h e a d ,

in s e rt

b o lt a n d tig h te n to t h e s p e c ifie d to rq u e ,

(F ig .

1 6 -5 9 ).

1 0 . R e p la c e t h e filte r b o w l

d r a in p lu g a n d tig h te n

to th e

s p e c ifie d to r q u e , (F ig . 1 6 - 6 0 ) .

1 1 . W it h

t h e e n g in e S to p c o n tro l s e t to th e “O F F " p o s itio n ,

tu rn th e e n g in e w ith t h e s t a r t e r m o to r u n til oil p r e s s u r e is r e g is te r e d o n t h e g a u g e .

1 2 . S ta r t th e

e n g in e a n d a llo w to id le fo r s e v e r a l m in u te s .

C h e c k a ll jo in ts fo r o il le a k s .

April '96

Lubricating System and Sump 16-21 REMOVAL, STRIPPING, ASSEMBLY AND REPLACEMENT OF OIL PUMP Removal 1.

D r a in e n g in e oil a n d r e m o v e th e s u m p , (F ig . 1 6 -6 1 ) .

F ig . 1 6 -6 1 2.

R e m o v e oil p u m p r e ta in in g b o lts , (F ig . 1 6 - 6 2 ) .

F ig . 1 6 - 6 2 3.

P u ll o u t oil p u m p fr o m c r a n k c a s e , (F ig . 1 6 - 6 3 ) .

F ig . 1 6 - 6 3

Stripping 1.

2.

C la m p th e oil p u m p in a v ic e fitte d w ith s o ft ja w s .

R em ove

b o lts r e ta in in g

th e s t r a in e r a n d

p ic k -u p p ip e ,

(F ig . 1 6 - 6 4 ) .

3.

R e m o v e th e

p ic k -u p

p ip e a n d

s tra in e r fr o m

th e

oil

pu m p body.

Fig. 16-64

April '96

Lubricating System and Sump 16-22

4

R em ove

th e

p r e s s u r e r e lie f v a lv e ,

s p rin g

and

p isto n

r e ta in in g th e

cover

fr o m th e oil p u m p c o v e r, (F ig . 1 6 - 6 5 ) .

5.

U n s c re w

and

r e m o v e th e

b o lts

p la te to th e oil p u m p b o d y , (F ig . 1 6 - 6 6 ) .

6.

Lift o u t t h e oil p u m p g e a r fr o m th e oil p u m p b o d y , (F ig .

1 6 -6 7 ).

7.

P re s s t h e 1 6 -6 8 ).

oil p u m p

s h a ft fr o m

th e d r iv e g e a r ,

(F ig .

Lubricating System and Sump 16-23

8.

R em ove

th e

oil p u m p d riv e s h a ft fr o m th e b o d y , c o m ­

p le te w ith g e a r , (F ig . 1 6 - 6 9 ) .

9.

P r e s s oil p u m p d r iv e s h a ft fr o m th e g e a r , (F ig . 1 6 - 7 0 ) .

1 0 . E x a m in e th e

oil p u m p b o d y a n d g e a r s fo r s ig n s o f e x ­

c e s s iv e w e a r , a ll fa u lty p a rts . show

s ig n s

s c o r in g S h o u ld

and th e

lo c a lis e d s e iz u r e . R e p la c e o il p u m p

body

or g e a rs

o f e x c e s s iv e w e a r th e c o m p le te oil p u m p

m u s t b e r e p la c e d .

Assembly 1.

P r e s s g e a r o n to t h e oil p u m p d r iv e s h a ft, (F ig . 1 6 -7 1 ) .

2.

C h e c k th e

in s ta lla tio n

s h a ft, (F ig . 1 6 - 7 2 ) .

April '96

h e ig h t o f th e g e a r to th e d riv e

Lubricating System and Sump 16-24

3.

In s e r t th e

oil p u m p

d r iv e s h a ft

in to th e

pum p

body,

(F ig . 1 6 - 7 3 ) .

Fig . 1 6 -7 3 4.

P re s s th e

h e lic a l

g e a r o n to th e s h a ft a n d b y u s in g

v e r n ie r c h e c k th e p u m p fla n g e ;

d is ta n c e

a

b e tw e e n th e g e a r a n d th e

r e fe r to s p e c ific a tio n s fo r th e c o rr e c t d is ­

ta n c e , (F ig . 1 6 - 7 4 ) .

c

0

d ■nil F ig . 1 6 - 7 4 5.

In s e r t th e

oil p u m p

d r iv e n g e a r in to th e p u m p b o d y ,

(F ig . 1 6 - 7 5 ) .

F ig . 1 6 - 7 5 6.

C h e c k th e

c le a r a n c e

b e tw e e n th e o il p u m p g e a r s a n d

h o u s in g , (F ig . 1 6 - 7 6 ) .

iiiiaas

fig. 16-76

April '96

Lubricating System and Sump 16-25

7.

C heck

th e

c le a r a n c e

b e tw e e n

c o v e r p la te a n d g e a rs ,

(F ig . 1 6 - 7 7 ) .

F ig . 1 6 - 7 7 8.

R e p la c e th e

oil p u m p p la te , in s e rt b o lts a n d tig h te n to

t h e s p e c ifie d to rq u e , (F ig . 1 6 - 7 8 ) .

■in /© = F ig . 1 6 - 7 8 9.

F it oil r e lie f v a lv e

in to th e

oil p u m p c o v e r p la te a n d

tig h te n to th e s p e c ifie d to rq u e , (F ig . 1 6 -7 9 ) .

F ig . 1 6 - 7 9 1 0 . P r im e t h e oil p u m p w ith e n g in e oil.

1 1 . B o lt th e

oil s u c tio n

p ip e a n d

s tr a in e r to th e oil p u m p

b o d y a n d tig h te n to t h e s p e c ifie d to rq u e , (F ig . 1 6 -8 0 ) .

^51

Fig. 16-80

April '96

Lubricating System and Sump 16-26

12 .

F it th e s t r a in e r to th e s u c tio n p ip e , {F ig

1 6 -8 1 )

F ig . 1 6 -8 1 13.

In s e r t th e

o il p u m p

in to th e

c ra n k c a s e ,

r e p la c e th e

re ta in in g b o lts a n d tig h te n to t h e s p e c ifie d to rq u e , (F ig .

1 6 -8 2 ) .

F ig . 1 6 - 8 2 14.

F it n e w s u m p g a s k e ts to th e c r a n k c a s e , (F ig . 1 6 -8 3 ) .

F ig . 1 6 - 8 3 1 5 . R e p la c e th e

sum p,

in s e r t th e b o lts a n d tig h te n to th e

s p e c ifie d to rq u e , (F ig . 1 6 - 8 4 ) .

1 6 . F ill th e s u m p w ith r e c o m m e n d e d oil.

1 7 . W it h

t h e e n g in e S to p c o n tr o l s e t to t h e “O F F " p o s itio n ,

tu rn th e e n g in e w ith t h e s t a r t e r m o to r u n til oil p r e s s u r e is r e g is te r e d o n t h e g a u g e .

1 8 . S ta r t th e e n g in e a n d a llo w to id le fo r s e v e r a l m in u te s .

C h e c k a ll jo in ts fo r o il le a k s .

Fig. 16-84

April ‘96

SECTION 17 Fuel System

CONTENTS OF SECTION 17

Page

ILLU S TR A TIO N .......................................................................................................................................................................................... 17-2 IN T R O D U C T IO N ........................................................................................................................................................................................ 17-3 S P E C IF IC A T IO N S ..................................................................................................................................................................................... 17-3 REM OVING THE INJECTION P U M P ..................................................................................................................................................

17-4

REPLACING THE INJECTION P U M P .................................................................................................................................................. 17-5 SETTING “A" TYPE INJECTION PUMP TIMING .............................................................................................................................. 17-7 SETTING “ M W ” TYPE INJECTION PUMP T IM IN G .......................................................................................................................... 17-10 REM OVAL AND REPLACEM ENT OF FUEL IN JE C T O R S .............................................................................................................. 17-13 TESTING THE INJECTOR FOR LEAKAGE.........................................................................................................................................17-15 TESTING THE NOZZLE OPENING AND INJECTION P R E S S U R E .........................................................

17-16

JET SPRAY T E S T ..................................................................................................................................................................................... 17-16 DISM ANTLING AND ASSEMBLY OF FUEL INJECTO RS............................................................................................................... 17-16 ASSEM BLY OF THE NOZZLE .

II

SPECIAL TOO LS FOR SECTION 1 7 ................................................................................................................................................... 17-19

A pril '96

’-16

Fuel System 17-2

INJECTION SYSTEM

April ‘96

1

S E A L IN G W A S H E R

14

S E A L IN G W A S H E R

2

B A N JO B O LT

15

IN J E C T O R A S S E M B L Y

3

S P L IT S E A L

16

IN J E C T O R S E C U R I N G N U T

4

IN J E C T O R P IP E S

17

NOZZLE CAP NUT

5

CLAM P

18

6

CLAM P

19

SPACER

7

S P R IN G W A S H E R

20

T H R U S T P IN

8

SCREW

21

S P R IN G

9

“A" T Y P E I N J E C T IO N P U M P

22

S H IM

10

“M W " T Y P E IN J E C T IO N P U M P

23

S C R E W PLUG

11

C L IP

24

S P L IT S E A L

12

P A C K IN G

25

CONNECTOR

13

CLAM P

26

L E A K - O F F P IP E

Fuel System 17-3 INTRODUCTION T h e A D E 3 6 0 s e rie s o f e n g in e s a r e fitte d w ith tw o ty p e s o f B o s c h fu e l in je c tio n p u m p s . T h e s u c c e s s fu l “A" ty p e in je c tio n p u m p is fitte d to th e n a tu r a lly a s p ir a te d e n g in e , a n d th e " M W " ty p e fu e l in je c tio n p u m p is u s e d on th e tu rb o c h a r g e d e n g in e . T h e “M W " fu e l in je c tio n p u m p , b e in g o f a la r g e r a n d m o r e rigid d e s ig n , e n a b le s it to p r o v id e h ig h e r p re s s u re s , a llo w in g th e tu r b o c h a r g e d e n g in e to d e v e lo p g r e a te r p o w e r a n d a h ig h e r to rq u e

SPECIFICATIONS FUEL SYSTEM In je c tio n p u m p a n d g o v e r n o r

BOSCH

In je c tio n p r e s s u r e

In je c tio n p u m p tim in g

New

2 0 ,0 to 2 0 ,8 M P a

U sed

m in . 1 8 ,0 M P a

r e fe r e n g in e n u m b e r

364N

19° B TD C

D a ta p la te - o th e r w is e u s e

3 6 4 C /T /T I

15° B TD C

tim in g a s lis te d

366N

19° B TD C

3 6 6 C /T

16° B TD C

3 6 6 T I - up to 1 5 0 k W

16° B T D C

36 6T I - above 150 kW

12° B TD C

F u e l lift p u m p d e liv e r y p r e s s u r e

Id le s p e e d

80 kPa

6 0 0 r/m in

TORQUE SPECIFICATIONS In je c to r p ro te c tio n s l e e v e .....................

....................................................... M 1 4 x 1 ............................................................... 5 0 N m

In je c to r s e c u r in g n u t.................................

....................................................... M 3 4 x 1 , 5 .......................................................... 7 0 N m

In je c to r c a p n u t to n o z z le b o d y .........

....................................................... M 2 4 x 1 . 5 .......................................................... 8 0 N m

S tu d fo r in je c tio n p u m p m o u n tin g ...

....................................................... M 1 0 ...................................................................... 1 0 - 2 0 N m

In je c tio n p u m p g e a r to p u m p .............

....................................................... M 1 4 x 1 , 5 .......................................................... 8 0 N m

In je c to r p ip e n u ts to in je c tio n p u m p

....................................................... M 1 2 x 1 , 5 .......................................................... 2 5 N m

In je c to r p ip e n u ts to in je c t o r ...............

........................................................M 1 4 x 1 , 5 .......................................................... 2 5 N m

P r e s s u r e /R e tu r n p ip e a d a p t e r to cyl

h e a d .......................................... M 2 2 x 1 , 5

10 N m

....................................................... M 1 6 x 1 , 5 ............

10 N m

L e a k o ff p ip e to in je c t o r s ......................

....................................................... M 8 x 1 ................................................................ 2 0 N m

S u p p ly a n d re tu rn p ip e c o n n e c tio n s

....................................................... M 1 4 x 1 . 5 .......................................................... 3 5 N m

In je c tio n p u m p s u p p o r t...........................

....................................................... M 8 ......................................................................... 3 5 N m

D e liv e r y v a lv e h o ld e r: “A" ty p e p u m p ..............................................

....................................................... s ta g e 1 ...............................................................4 0 N m * s ta g e 2 ............................................................ 4 0 N m * s ta g e 3 ............................................................ 4 0 N m * F in a l t o r q u e .................................................. 4 5 N m

* L o o s e n a f te r 1s t, 2 n d a n d 3 rd s ta g e s “M W " ty p e p u m p ...............................................

8 m m n u t .................................................................

April '96

50 - 60 Nm 12 - 16 Nm

Fuel System 17-4 REMOVING THE INJECTION PUMP 1

D e ta c h

th e

oil fille r

p ip e o r b r e a th e r fr o m

th e tim in g

c a s e ( if fitte d ) o r r e m o v e th e b la n k in g p lu g , (F ig . 1 7 -1 ).

F 2.

R e m o v e th e r o c k e r c o v e r, (F ig . 1 7 -2 ).

Fi g. 1 7 -2 3.

T u rn th e e n g in e in th e n o r m a l d ire c tio n o f r o ta tio n un til th e

N o . 1 p is to n

is

on

c o m p r e s s io n

s tro k e

m a r k on th e v ib ra tio n d a m p e r is in lin e w ith

a n d th e

( F B ) p o in ­

te r on th e tim in g c a s e , (F ig . 1 7 -3 ).

Attention! Never turn the engine in the reverse direction of rotation.

Fi 4.

D is c o n n e c t th e fu e l filte r, in je c tio n

pum p,

fu e l a n d oil fe e d p ip e s to th e

(F ig . 1 7 - 4 ) .

Fig. 17-4

April ‘96

Fuel System 17-5 5.

U se and

,

s p e c ia l to o l,

p a rt n u m b e r 4 0 2 0 0 7 0 5 , to u n s c r e w

d e ta c h th e in je c to r p ip e s fr o m th e in je c tio n p u m p

(F ig . 1 7 - 5 ) .

6.

U n s c re w

and

r e m o v e n u ts re ta in in g th e in te r m e d ia te

fla n g e o f th e in je c tio n p u m p to th e tim in g h o u s in g .

F it

p r o te c tiv e d u s t c a p s ,( F ig . 1 7 - 6 )

7.

L ift o ff th e in je c tio n p u m p , (F ig . 1 7 -7 ).

Fig . 1 7 -7

REPLACING THE INJECTION PUMP 1.

T u rn th e e n g in e in th e n o r m a l d ire c tio n o f r o ta tio n u n til .

No. 1

p is to n

is

on

c o m p r e s s io n s tro k e . T h e m a r k on

th e v ib ra tio n d a m p e r m u s t b e p o in te r o n t h e tim in g c a s e

in

lin e

w ith th e

(F B )

(F ig . 1 7 - 8 )

Fig. 17-8 April '96

Fuel System 17-6 2.

R e p la c e in je c tio n p u m p fla n g e g a s k e t, in s e rt th e p u m p in to th e tim in g

h o u s in g

and

e n s u r e th a t th e m a r k on

th e in je c tio n p u m p g e a r to o th lin e s u p w ith th e a r ro w in th e tim in g c a s e , (F ig . 1 7 - 9 0 ) .

(R e f e r fig. 1 7 - 1 6 o h p a g e 1 7 -7 ).

F ig . 1 7 -9 3.

R e p la c e

th e

in je c tio n p u m p re ta in in g n u ts a n d tig h te n

to th e s p e c ifie d to r q u e (F ig . 1 7 - 1 0 ) .

F ig . 1 7 - 1 0 4.

S e t s ta rt

o f d e liv e r y

( R e f e r to

in je c tio n p u m p tim in g

F ig . 1 7 - 1 4 ) 5

A tta c h in je c to r p ip e s to th e in je c tio n p u m p . U s e s p e c ia l to o l

p a rt N o .

4020 0718

to tig h te n a ll c o n n e c tio n s to

th e s p e c ifie d to rq u e , (F ig . 1 7 - 1 1 )

F ig . 1 7 -1 1 6.

A tta c h

th e fu e l a n d oil fe e d p ip e s to th e in je c tio n p u m p

a n d tig h te n to th e s p e c ifie d to rq u e . R e p la c e th e b r e a th e r p ip e o r p lu g . (F ig . 1 7 - 1 2 )

7

R e p la c e r o c k e r c o v e r.

Fig.17-12 April '96

Fuel System 17-7 SETTING “A" TYPE INJECTION PUM P TIMING 1.

R e m o v e r o c k e r c o v e r , (F ig . 1 7 - 1 3 )

2.

T u rn

F ig . 1 7 -1 3 e n g in e

p is to n

is o n

v ib ra tio n

in th e

d ire c tio n

o f r o ta tio n

c o m p r e s s io n s tro k e

u n til

No. 1

a n d th e m a r k o n th e

d a m p e r is in lin e w ith th e p o in te r o n th e

tim in g c a s e , (F ig . 1 7 - 1 4 )

/v N \ 1- - 1 m k

M ill « S F ig . 1 7 - 1 4 3.

D e ta c h case

th e

o il fille r p ip e

o r b r e a th e r fr o m

( if fitte d ) o r r e m o v e th e

b la n k in g

th e tim in g

p lu g ,

(F ig .

1 7 -1 5 ).

F i g .1 7 -1 5 4.

C h e c k to e n s u r e t h a t th e m a r k e d to o th on th e in je c tio n

p u m p g e a r is in lin e w ith

th e p o in te r in th e tim in g g e a r

c o v e r, (F ig . 1 7 - 1 6 ) .

Fig.17-16 April '96

Fuel System 17-8 5.

D is c o n n e c t a ll in je c to r p ip e s fr o m th e in je c tio n p u m p u s in g s p e c ia l to o l

p a r t n u m b e r 4 0 2 0 0 7 0 5 . ( F ig .1 7 -

1 7 ).

6.

A tta c h

P re s s u re

num ber 40 20 2376,

L im itin g

V a lv e s ,

s p e c ia l

to o ls

p a rt

to in je c tio n p u m p o u tle ts n u m b e r s

2 to 6 . ( R e f F ig . 1 7 - 1 8 )

Pump Unit

7

Item 1 Item 2 Item 3 Item 4 Item 5 Item 6 Item 7 Item 8 Item 9 tern 10

8 . D e ta c h

( R e f fig .1 7 - 1 9 )

Electric Motor Gear Pump Pressure Limiting Valve Fuel Tank.

Return Line.

Test Line with Sightglass.

12v connection cablel Connection line (supply) Base plate Relay box with switch

fu e l s u p p ly lin e

at pum p

and

c o n n e c t s u p p ly

lin e ( 8 ) o f th e p u m p u n it ( R e f F ig 1 7 - 2 0 )

9

D e ta c h fu e l re tu rn lin e ( 1 2 ) a n d o v e r flo w v a lv e a t th e in je c tio n p u m p a n d s e a l b o re w ith a d u m m y p lu g .(1 3 ).

10.

T o th e N o 1 o u tle t o f th e fu e l p u m p c o n n e c t th e te s t

lin e w ith s ig h tg la s s ( R e f ( 6 ) F ig . 1 7 - 2 0 ) .

April '96

Fuel System 17-9 1 1 . T u r n th e c r a n k s h a ft in th e d ire c tio n o f r o ta tio n u n til it is

a p p ro x .

h a lf

a

tu rn

b e fo r e

T .D .C .

of

th e

No.

1

c y !in d e r .(R e f . F i g 1 7 - 2 1 ) 12.

L o c k th e in je c tio n p u m p le v e r a t F u ll lo a d p o s itio n

N o te :-B e fo re

s w itc h in g

on

th e

Test

Pum p

U n it

th e

in je c tio n p u m p le v e r m u s t b e lo c k e d a t fu ll lo a d a n d m u s t n o t b e m o v e d w h e n th e p u m p u n it is ru n n in g .

S w itc h o n th e T e s t P u m p U n it o n ly w h ile p e rfo rm in g m e a s u re m e n t

13.

S w itc h o n th e T e s t P u m p U n it th e n s lo w ly c r a n k s h a ft in t h e d ire c tio n o f r o ta tio n

r o ta te th e

and

o b s e rv e

th e fu e l je t in th e s ig h t g la s s . - T h e e x a c t s ta rt d e liv e r y

of

is r e a c h e d w h e n t h e fu e l je t c h a n g e s fro m a

ta p e r e d je t s t r e a m

to

a c h a in o f d ro p s .

A = ‘ F u ll * fu e l je t B .= F u e l j e t t a p e r e d - s h o r tly b e fo r e s ta rt o f d e liv e ry C .= C h a in o f d r o p s = s ta r t o f d e liv e ry

1 4 .C h e c k s ta r t o f d e liv e r y m a r k in g b e tw e e n s e ttin g p o in te r on tim in g c a s e a n d m a r k in g o n v ib ra tio n d a m p e r o r b e lt p u lle y . R e f. F ig . 1 7 - 2 3 )

1 5 If it is n e c e s s a r y to c o r r e c t t h e s ta r t o f d e liv e ry o f th e in je c tio n

pum p,

d ire c tio n

of

m a r k in g o f

th e

r o ta tio n

c r a n k s h a ft

s h o u ld

e x a c x tly

th e

to

be

s ta rt

tu rn e d of

in

d e liv e ry

s e ttin g p o in te r w ith v ib ra tio n d a m p e r o r b e lt

p u lle y .

16.

S la c k e n

th e

n u ts

(1 3 )

s e c u rin g

th e

in je c tio n

p u m p . (R e f .F ig . 1 7 - 2 4 ) N o t e : - T h e in je c tio n p u m p le v e r m u s t b e lo c k e d a t fu ll lo a d a n d m u s t n o t b e m o v e d w h e n th e p u m p u n it is ru n n in g .

S w itc h

on

th e

pum p

u in it

o n ly

fo r

p e rfo rm in g

m e a s u r e m e n t o t h e r w is e fu e l m a y g e t in to th e c o m b u s tio n c h a m b e r if th e n o z z le is le a k in g

April '96

Fuel System 17-10 1 7 .M o v e

th e

in je c tio n

pum p

on

th e

s lo tte d

h o le s

fa r

e n o u g h to a c h ie v e e x a c t s ta rt o f d e liv e ry

8 .R e -tig h te n

th e

h e x .n u ts

(1 3 )

of

in je c tio n

pum p

to

s p e c ifie d to r q u e

19 .

R e p e a t te s tin g o f s ta r t o f d e liv e r y o p e r a tio n s 11 to 1 4 above

20.

R e m o v e th e P r e s s u r e lim itn g v a lv e a n d th e te s t lin e fitte d

to

n o .1

c y lin d e r

and

r e a s s e m b le

in je c tio n

p ip e s .R e f. F IG . 1 7 - 2 6

2 1 . R e p la c e th e oil fille r p ip e / b r e a th e r o r b la n k in g p lu g to th e tim in g c a s e . R e f. F ig . 1 7 -2 7 .

SETTING “ MW” TYPE INJECTION PUMP TIMING Note: W ith th e fittin g o f t h e “M W " in je c tio n p u m p to th e A D E 3 6 0 s e rie s

tu r b o c h a r g e d

e n g in e

th e

tim in g

p r o c e d u re

has

c h a n g e d . It is n o lo n g e r a d v is a b le to r e m o v e th e d e liv e ry v a lv e w h e n c a rr y in g o u t th e s p ill tim in g . O n c e th e v a lv e h a s b e e n r e m o v e d th e v a lv e s e a l c o u ld b e d a m a g e d a n d c a u s e a le a k to d e v e lo p a t h ig h p r e s s u r e .

1.

R e m o v e r o c k e r c o v e r.

2.

T u rn th e e n g in e in th e d ire c tio n o f r o ta tio n a n d p o s itio n N o . 1 c y lin d e r o n firin g s tro k e ± 4 5 d e g r e e s b e fo r e to p d e a d c e n tr e , (F ig . 1 7 - 2 8 ) .

April '96

Fuel System 17-11 3.

R em ove

th e lo w p r e s s u r e p ip in g to a n d fr o m th e in je c ­

tio n p u m p p res su re

and

fu e l

filte rs .

N o te

p o s itio n

v a lv e N o . 1 a n d fu e l s u p p ly to

of

g a lle r y

g a lle r y N o . 2,

(F ig . 1 7 - 2 9 ) .

4.

F it th e s u p p ly p ip e fr o m th e p r e s s u r e sp ill p u m p to th e fr o n t

end

o f th e in je c tio n p u m p g a lle ry .

F it a b la n k in g

p lu g to th e r e a r e n d o f th e g a lle ry .

(S p ill p u m p p a r t n u m b e r 4 0 2 0 2 3 6 3 o r a lt e r n a t iv e ly 4 0 2 0 - 2 4 6 0 )

5.

D is c o n n e c t a ll v e ry

v a lv e

in je c to r

p ip e s

and

th e r e s p e c tiv e d e li­

u n io n s o n th e in je c tio n p u m p .

F it p r e s s u re

r e lie f v a lv e u n io n s , (F ig . 1 7 - 3 1 ) .

6.

C onnect

th e

p r e s s u r e sp ill p u m p re tu rn p ip e w ith spill

p ip e to th e N o . 1 d e liv e ry v a lv e u n io n , (F ig . 1 7 -3 2 ) .

7.

M ove

th e

a c c e le r a to r

c o n tro l

p u m p to th e fu ll s p e e d p o s itio n .

April '96

le v e r on

th e

in je c tio n

Fuel System 17-12 8.

C o n n e c t th e s u p p ly ;

p re s s u re

s p ill

e n s u r e t h a t th e

p u m p to a s u ita b le p o w e r

pum p

p res su re

is

a p p ro x .

2 5 0 0 kPa. 9.

C o n tin u e

tu rn in g

th e e n g in e in th e n o rm a l d ire c tio n o f

r o ta tio n u n til th e fu e l d is c h a r g e in th e g la s s b o w l c h a n ­ g e s fr o m a ta p e r e d je t s t r e a m to a c h a in o f d ro p s , (F ig . 1 7 - 3 3 ) .

10.

C h e c k th e tim in g m a r k s ( F B )

on

th e tim in g c o v e r a n d

v ib ra tio n d a m p e r fo r a lig n m e n t, (F ig . 1 7 - 3 4 ) .

11.

If th e tim in g s e c u rin g to w a r d s

Is

n u ts th e

r e ta r d e d

lo o s e n

th e

in je c tio n

pum p

a n d m o v e th e to p o f th e in je c tio n p u m p

c y lin d e r b lo c k

or

a w a y fr o m th e c y lin d e r

b lo c k to a d v a n c e , (F ig . 1 7 - 3 5 ) .

12 . A fte r a d ju s tm e n t r e -c h e c k th e tim in g b y r e p e a tin g o p e ­ ra tio n s 2 to 9.

13. T ig h te n

th e

n u ts

re ta in in g

th e

tim in g g e a r h o u s in g , (F ig . 1 7 - 3 6 ) .

April '96

in je c tio n

p u m p to th e

Fuel System 17-13 1 4 . R e m o v e th e b la n k in g p lu g a n d h ig h p r e s s u r e p ip e fro m th e and

te s t

pum p.

R e c o n n e c t th e g a lle r y p r e s s u r e v a lv e

t h e lo w p r e s s u r e fe e d

to th e p u m p a n d tig h te n

to

th e s p e c ifie d to rq u e .

1 5 . R e c o n n e c t th e

in je c to r p ip e s a n d

tig h te n

th e

b o tto m

u n io n s to th e s p e c ifie d to rq u e , (F ig . 1 7 - 3 7 ) 1 6 . R e p la c e r o c k e r c o v e r.

REMOVAL AND REPLACEMENT OF FUEL INJECTORS Removal 1.

2.

R e m o v e r o c k e r c o v e r.

U s e s p e c ia l to o l, p a r t n u m b e r 4 0 2 0 0 7 0 5 , a n d u n s c re w th e p ip e s to th e fu e l in je c to r.

P ush

th e in je c to r p ip e to

o n e s id e . D o n o t b e n d th e p ip e , F ig . 1 7 -3 8 ) .

3.

4.

D is c o n n e c t t h e fu e l le a k o ff p ip e , (F ig . 1 7 -3 9 ) .

R em ove

th e

in je c to r

s e c u r in g

n u t w ith

s p e c ia l to o l

4 0 2 0 0 8 7 3 , (F ig . 1 7 - 4 0 ) .

Fig. 17-40 April '96

Fuel System 17-14

5.

Use

s p e c ia l to o l 4 0 2 0 1 0 7 6

to

pu ll th e in je c to r o u t o f

th e c y lin d e r h e a d , (F ig . 1 7 - 4 1 ) .

6.

If to o tig h t w it h d r a w th e in je c to r w ith s p e c ia l e x tra c to r, p a rt n u m b e r 4 0 2 0 1 0 6 3 , (F ig . 1 7 - 4 2 ) .

K e e p m a tc h e d w a s h e r w ith th e r e s p e c tiv e in je c to r.

A tte n tio n !

S e e s e c tio n 1 2 fo r r e m o v a l a n d r e p la c e m e n t

o f in je c to r p ro te c tio n s le e v e s

R e p la c e m e n t 1.

In s e r t a n e w

in je c to r s e a lin g w a s h e r

in to th e

c y lin d e r

h e a d , (F ig . 1 7 - 4 3 ) .

N o te :

T h e n e w s e a lin g w a s h e r s m u s t b e th e s a m e s iz e

a n d th ic k n e s s a s th e o n e s r e m o v e d .

2.

In s e r t

in je c to r in to

n o tc h

on

th e

th e

c y lin d e r h e a d

in je c to r w ith

and

th e g r o o v e in

lo c a te th e th e c y lin d e r

h e a d , (F ig . 1 7 - 4 4 ) .

Fig. 17-44 April '96

Fuel System 17-15 3.

R e p la c e

th e

in je c to r

s e c u rin g

nut

and

use

a

to rq u e

w r e n c h fitte d w ith s p e c ia l to o l 4 0 2 0 0 8 7 3 to tig h te n to th e s p e c ifie d to rq u e , (F ig . 1 7 - 4 5 )

4.

R e p la c e th e fu e l le a k

o ff p ip e fitte d w ith

new

s e a lin g

w a s h e r s a n d tig h te n to th e s p e c ifie d to rq u e , (F ig . 1 7 - 4 6 )

5.

R e p la c e th e p r e s s u r e p ip e to th e fu e l in je c to r a n d u s e s p e c ia l

to o l

4020

0718

to

tig h te n

to

th e

s p e c ifie d

t o r q u e ,( F ig 1 7 - 4 7 )

TESTING THE INJECTOR FOR LEAKAGE 1.

W it h

s p e c ia lis e d

re m o v e

c a rb o n

n o z z le d e p o s its

h o le s , (F ig . 1 7 - 4 8 )

April ‘96

c le a n in g fr o m

th e

e q u ip m e n t in je c to r

c a re fu lly

n o z z le

tip

Fuel System 17-16 2 . A tta c h th e in je c to r to th e te s te r , (F ig . 1 7 - 4 9 )

Attention

!

O n ly u s e c le a n te s tin g flu id o r filte re d d ie s e l fu e l fo r

te s tin g p u rp o s e s .

Note:

C a r e m u s t b e ta k e n d u rin g te s tin g a s th e s p ra y is u n d e r c o n s id e r a b le p r e s s u r e a n d w o u ld

p e n e tr a te th e sk in o f

h a n d s o r fa c e 3.

S lo w ly p re s s d o w n th e p u m p te s te r le v e r u n til th e p re s s u re gauge

show s

200 kPa

b e lo w o p e n in g p r e s s u r e o f th e

in je c to r n o z z le . T h e in je c to r is fa u lty if fu e l le a k s fr o m th e n o z z le w ith in 4

10 secon ds.

In a ll c a s e s o f s ie z u r e o r le a k a g e d is m a n tle a n d c le a n th e in je c to r. T h e n o z z le m u s t b e r e p la c e d if c a re fu l c le a n in g F ig . 1 7 -4 9

TESTING NOZZLE OPENING AND INJECTION PRESSURE 1. A tta c h in je c to r to te s te r .

2. S lo w ly a d v a n c e th e p u m p te s t l e v e r ; n o te th e p r e s s u r e w h e n th e in je c to r o p e n s , (F ig . 1 7 - 5 0 ) 3.

T h e in je c to r p r e s s u r e m a y b e a d ju s te d b y a d d in g o r re m o v in g

s h im s on to p o f t h e c o m p r e s s io n s p rin g .

JET SPRAY TEST 1.

2.

T u rn o ff th e p r e s s u r e g a u g e .

O p e r a t e th e h a n d p u m p le v e r

(s e v e r a l b ris k s tro k e s ).T h e

in je c tio n is c o rr e c t w h e n all fo u r je t s s p ra y fin e a n d e v e n , (F ig 1 7 -5 1 )

DISMANTLING AND ASSEMBLY OF FUEL INJECTORS 1 . C la m p s p e c ia l in je c to r s u p p o r t 4 0 2 0 0 9 1 2 2.

in a v ic e .

In s e r t th e in je c to r in to th e h o ld e r, (F ig . 1 7 - 5 2 )

Fuel System 17-17 3.

W it h

s p e c ia l to o l

4020

0925

u n s c re w

th e

in je c to r

n o z z le c a p n u t fr o m th e in je c to r b o d y a n d d is m a n tle th e in je c to r a s s e m b ly , (F ig . 1 7 - 5 3 ) .

Fig. 1 7 - 5 3 4.

C a r e fu lly r e m o v e c a rb o n d e p o s its fr o m

in je c to r h o le s ,

(F ig . 1 7 - 5 4 )

5.

D ip n e e d le v a lv e a n d n o z z le b o d y in to c le a n d ie s e l fu el a n d c a r y o u t d r o p te s t, s e e o p e r a tio n 6 b e lo w .

Fig. 1 7 - 5 4 6.

L ift n e e d le v a lv e

b y a p p r o x im a t e ly

o n e th ird

o f its

le n g th fr o m th e n o z z le b o d y . R e le a s th e n e e d le v a lv e s o t h a t it r e tu rn s to its s e a t u n d e r its o w n w e ig h t, (F ig .

1 7 -5 5 ) If th e n e e d le v a lv e s tic k s

b e fo r e r e a c h in g th e s e a t ,

r e p la c e th e c o m p le te n o z z le a s s e m b ly .

F ig . 1 7 -5 5

ASSEMBLY OF THE NOZZLE 1.

In s e r t th e in je c to r b o d y in to s p e c ia l h o ld in g to o l

4020

0 9 1 2 , (F ig . 1 7 - 5 6 )

Fig. 17-56

April '96

Fuel System 17-18

2. In s e r t s h im

(2 ), s p rin g (3 ), th ru s t pin ( 4 ), a d a p t o r ( 5 ) in to th e

in je c to r b o d y (1 ).

In s e r t th e n e e d le v a lv e ( 6 ) in to th e n o z z le

(7 ). P la c e th e n o z z le o n to th e a d a p t o r ( 5 ), (F ig . 1 7 - 5 7 )

F ig . 1 7 - 5 7 3.

T w o g u id e p in s a r e fitte d o n b o th s id e s o f th e a d a p te r . T h e g u id e

p in s w h ic h

lo c a te

in th e

c o rr e s p o n d in g

h o le s

in th e

n o z z le h o ld e r a r e in d iffe r e n t p o s itio n to th e tw o p in s w h ic h lo c a te th e n o z z le . In c o r re c t fit m e n t o f th e a d a p t e r is th e r e fo re im p o s s ib le . T h e a d a p t e r f a c e w h ic h m a te s w ith th e n o z z le is c h a m fe r e d a t th e e d g e , (F ig . 1 7 - 5 8 ) .

F ig 1 7 -5 8 4.

S c r e w in je c to r c a p n u t ( 8 ) o n to th e in je c to r b o d y (1 ), (F ig . 1 7 ­ 5 9 ).

F ig . 1 7 -5 9 5.

U s e s p e c ia l to o l

4020 0925

to tig h te n th e in je c to r c a p to th e

s p e c ifie d to rq u e , (F ig . 1 7 - 6 0 )

Fig. 17-60

Fuel System 17-19

SPEC IA L TOO LS FOR SECTION 17 O B T A IN A B L E F R O M : G R U N D Y T E C H N IF O R M , B U R M A N R O A D , D E A L P A R K , P O R T E L IZ A B E T H 6 0 0 1 TE L: (0 4 1 ) 4 3 -2 2 9 9 ,

FA X : (0 4 1 ) 4 3 -2 2 2 4

S p lit rin g s p a n n e r fo r in je c to r p ip e s s e e fig. 1 7 -5 , 1 7 -1 8 p a rt n u m b e r 4 0 2 0 0 7 0 5

C r o w fo o t rin g s p a n n e r fo r r e m o v in g /r e p la c in g in je c to r p ip e s s e e fig . 1 7 - 1 1 , 1 7 -2 6 , 1 7 - 4 7 p a rt n u m b e r 4 0 2 0 0 7 1 8

S p ill p ip e s e e fig . 1 7 - 2 0 p a rt n u m b e r 4 0 2 0 0 8 6 0

F u e l c o n ta in e r fo r c h e c k in g s ta rt o f d e liv e ry s e e fig . 1 7 -2 1 p a rt n u m b e r 4 0 2 0 0 8 5 7

S o c k e t fo r in je c to r s e c u rin g nu ts s e e fig. 1 7 - 3 2 p a rt n u m b e r 4 0 2 0 0 8 7 3

F u e l in je c to r im p a c t e x tra c to r s e e fig . 1 2 -1 2 p a rt n u m b e r 4 0 2 0 1 0 7 6

April ‘96

Fuel System 17-20

E x tr a c to r fo r in je c to rs s e e fig. 1 2 - 1 3 p a rt n u m b e r 4 0 2 0 1 0 6 3

S u p p o r t fo r s trip p in g a n d a s s e m b lin g in je c to rs , s e e fig . 1 7 -4 4 p a rt n u m b e r 4 0 2 0 0 9 1 2

S p a n n e r fo r s trip p in g a n d a s s e m b lin g in je c to rs , 2 2 m m s e e fig . 1 7 - 4 5 p a rt n u m b e r 4 0 2 0 0 9 2 5

P r e s s u re r e lie f v a lv e (s e t o f 5 ) fo r b la n k in g o ff th e d e liv e ry v a lv e s e e fig . 1 7 - 3 2 p a rt n u m b e r 4 0 2 0 2 3 7 6

P r e s s u re s p ill tim in g p u m p s e e fig. 1 7 - 3 3 p a rt n u m b e r 4 0 2 0 2 3 6 3 A lte r n a tiv e p a rt n u m b e r 4 0 2 0 2 4 6 0 J .S . B a r n e s tim in g u n it a v a ila b le fro m : P r o -H y d Im p o r t & E x p o rt ( P ty ) Ltd. 111 T e n th R o a d , K e w J o h a n n e s b u rg

A p ril '9 6

SECTION 18A-1 Turbocharger

CONTENTS OF SECTION 18A

Page

T U R B O C H A R G E R ........................................................................................................................................................................ 1 8 A -2

I L L U S T R A T IO N

KKK

I L L U S T R A T IO N

GARRETT

T U R B O C H A R G E R ........................................................................................................................................................... 1 8 A - 3

S P E C I F I C A T I O N S - K K K 8c G A R R E T T ................................................................................................................................................................................1 8 A -4 I N T R O D U C T I O N ................................................................................................................................................................................................................................ 1 8 A -5 R E M O V A L ............................................................................................................................................................................................................................................... 1 8 A -6 M E A S U R I N G T U R B O C H A R G E R S H A F T E N D P L A Y .................................................................................................................................................1 8 A -7 M E A S U R IN G T U R B O C H A R G E R S H A F T S ID E P L A Y ............................................................................................................................................... 1 8 A -8 D IS M A N T L IN G

......................................................................................................................................................................................................................1 8 A - 9

A S S E M B L Y ......................' ....................................................................................................................................................................................................

1 8 A -1 5

R E P L A C E M E N T ...............................................................................................................................................................................................................................1 8 A - 2 2 I N T E R C O O L E R ................................................................................................................................................................................................................................ 1 8 A - 2 5

April ‘96

Turbocharger 18A-2

KKKTURBO CHARG ER 1 T U R B IN E W H E E L A N D S H A F T A S S E M B L Y

1 2 T H R U S T B E A R IN G

2

S E A L IN G R IN G S

13

O IL D E F L E C T O R

3

H E A T S H IE L D

14

SPACER

4

C IR C U P

15

S E A L C A R R IE R /T H R U S T W A S H E R

5

B E A R IN G

16

S E A L IN G R IN G S

6

C IR C L IP

17

O - R IN G

7

B E A R IN G H O U S I N G

18

E N D PLATE

8 C IR C L IP

19

SOCKET CAP SCREW

9

B E A R IN G

20

COM PRESSOR ROTO R W HEEL

10

C IR C L IP

21

COM PRESSOR ROTO R W HEEL

11

THRUST W ASHER

April '96

R E T A IN IN G L O C K N U T

Turbocharger 18A-3

Garrett AiResearch 1 C O M P R E S S O R R O T O R W H E E L R E T A IN IN G N U T

S P R I N G L O C A T IN G P IN S

CO M PRESSO R ROTO R W HEEL

12

B E A R IN G H O U S I N G

3

EN D PLATE

13

C IR C L IP

4

O -R IN G

14

B E A R IN G

5

S E A L IN G R IN G

15

C IR C L IP

6

S E A L C A R R IE R /T H R U S T W A S H E R

16

H E A T S H IE L D

7

C IR C L IP

17

LO CK PLATE

8

B E A R IN G

18

B OLT

9

C IR C L IP

19

S E A L IN G R I N G

T H R U S T B E A R IN G

20

T U R B IN E W H E E L A S S E M B L Y

10

April '96

11

2

Turbocharger 18A-4

S P E C IF IC A T IO N S F O R K K K T U R B O C H A R G E R R o to r s h a ft -

end p la y

0 15 m m m ax

s id e p l a y

0 ,4 5 m m m a x .

ru n o u t

0 ,0 0 7 m m m ax.

T O R Q U E S P E C IF IC A T IO N S

8-10

E n d p l a t e ............................................................

Nm

C o m p r e s s o r ro to r w h e e l re ta in in g n u t.......................................... 1 s t.s t a g e .................................................................................................................... 1 0 N m 2 n d s t a g e ............................................................................. a n g le o f r o ta tio n

+60°

T u r b in e h o u s in g to c e n tr e h o u s in g .........................................................................................................................................................................................2 0 N m C o m p r e s s o r h o u s in g to c e n tr e h o u s in g ................................................................................................................................................................................. 7 N m O il r e t u r n

M8

- 25 Nm

O il s u p p ly

M8

- 25 Nm

O il s u p p ly b a n jo b o l t ........................................................................................................................................................................................................................ 40 N m T u r b o c h a r g e r to e x h a u s t m a n if o ld .......................................................................................................................................................................................... 65 N m

S P E C IF IC A T IO N S F O R G A R R E T T T U R B O C H A R G E R R o to r s h a f t -

end p la y

0 ,1 0 m m m ax.

s id e p l a y

0 ,7 5 m m m ax.

ru n o u t

0 ,0 0 7 m m m ax.

T O R Q U E S P E C IF IC A T IO N S E n d p l a t e ..........................................................................................................................................................................................................................................8 - 1 0 N m C o m p r e s s o r ro to r w h e e l r e ta in in g n u t..........................................................1 s t s t a g e ........................................................................in itia l to r q u e

2 Nm

2 n d s t a g e ............................................................. a n g le o f r o ta tio n

90°

T u r b in e h o u s in g to c e n tr e h o u s in g .......................................................................................................................................................................... 1 1 , 5 - 1 5 N m C o m p r e s s o r h o u s in g to c e n tr e h o u s in g ................................................................................................................................................................1 1 , 5 - 1 5 N m O il r e t u r n ..............................................................................................................................................;

M8

- 25 Nm

O il s u p p ly

M8

- 25 Nm

O il s u p p ly b a n jo b o lt ......................................

40 Nm

T u r b o c h a r g e r to e x h a u s t m a n if o ld .......................................................................................................................................................................................... 6 5 N m

April '96

Turbocharger 18A-5 INTRODUCTION

T u r b o ch a rg er T h e G a r r e t t /A iR e s e a r c h a n d K K K tu r b o c h a r g e r s fo r in te rn a l c o m b u s tio n e n g in e a p p lic a tio n c o m p r is e s o f a tu r b in e a n d a r a d ia l c o m p r e s s o r w h ic h u tilis e a c o m m o n s h a ft. T h e tu rb in e a n d c o m p re s s o r w h e e ls a r e m o u n te d a t o p p o s ite e n d s o f th e s h a ft. T h e s h a ft is e n c lo s e d a n d s u p p o r te d b y fu lly flo a tin g b e a r in g s in a h o u s in g . T h e tu r b in e a n d c o m p r e s s o r w h e e ls a r e e n c lo s e d in c a s t h o u s in g s .

A fte r th e e n g in e is s ta r te d th e flo w o f e x h a u s t g a s fr o m th e e n g in e p a s s e s th ro u g h a s s e m b ly to

r o ta te .

The

c o m p r e s s o r w h e e l,

m o u n te d

a t th e

o p p o s ite e n d

th e tu r b in e h o u s in g a n d c a u s e s th e s h a ft

o f th e

s h a ft,

d raw s

a m b ie n t

a ir in to th e

c o m p r e s s o r h o u s in g , c o m p r e s s e s t h e a ir a n d d e liv e rs it to th e e n g in e .

D u r in g o p e r a tio n th e tu r b o c h a r g e r re s p o n d s to t h e e n g in e lo a d d e m a n d s b y re a c tin g to th e e x h a u s t g a s e n e r g y . A s th e p o w e r o f t h e e n g in e in c re a s e s , th e s p e e d a n d o u tp u t o f th e ro ta tin g a s s e m b ly in c re a s e s p r o p o r tio n a te ly .

T h e r e m o v a l a n d r e p la c e m e n t p r o c e d u r e illu s tra te d s h o w s a ty p ic a l in s ta lla tio n , w h ic h m a y v a r y d e p e n d in g o n s p e c ific a tio n .

C h e c k in g a T u r b o c h a r g e r in a V e h ic le D is c o n n e c t th e in le t d u c t a n d tu rn th e ro to r. E n s u r e e a s y a n d u n ifo rm ru n n in g . If n e c e s s a r y tu rn b a c k a n d fo rth s e v e ra l tim e s u n til th e ro to r is fr e e o f oil a n d c a rb o n d e p o s its .

T h e t u r b o c h a r g e r h a s g y ro s c o p ic s ta b ilis a tio n a n d ru n s in flo a tin g b e a rin g s . T r y to m o v e th e ro to r in a n d o u t. T h e e n d p la y is s e t c o rr e c tly if v e r y little o r n o p la y c a n b e fe lt. M o v e a n d tu rn th e ro to r u p a n d d o w n in e ith e r d ire c tio n . T h e s id e p la y is a d ju s te d c o rr e c tly if n o s c ra p in g o c c u rs .

T u rb o c h a r g e r Oil L e a k s T h e b e a r in g h o u s in g s o n a ll ty p e s o f tu r b o c h a r g e r s u s e d o n A D E e n g in e s a r e s e a le d w ith oil c o n tro llin g rin g s to p r o v id e a s e a l b e tw e e n th e oil a n d th e a ir /e x h a u s t g a s . T h e fu n c tio n o f th e s e s e a ls c o m p r e s s o r h o u s in g . T h e r e c o u ld , h o w e v e r, b e a v a c u u m

is b a s e d

o n th e

p res su re

b u ild

u p in th e

a t h ig h e n g in e R P M w h ile c o a s tin g w h ic h w o u ld fa v o u r oil

le a k a g e a n d o il c o a tin g o f t h e in le t p o rt. T h e a m o u n t o f o il lo s t in th is w a y is e x tr e m e ly lo w a n d h a s n o m e a s u r a b le in flu e n c e o n t h e e n g in e 's oil c o n s u m p tio n .

T h e tu r b o c h a r g e r s h o u ld n o t b e r e m o v e d if oil c o v e re d p o rts a r e fo u n d d u rin g a s e rv ic e , a s lo n g a s a n in s p e c tio n o f th e tu r b o c h a r g e r d id n o t s h o w a n y d e fe c ts .

A n o th e r c a u s e fo r o il le a k s c o u ld b e a d a m a g e d (d e fo r m e d ) o r c lo g g e d oil re tu rn p ip e . T h e r e d u c e d c r o s s -s e c tio n a l s iz e o f th e p ip e w o u ld le a d t o a n in c r e a s e in r e s is ta n c e , c a u s in g t h e oil le v e l in t h e tu r b o c h a r g e r to ris e a n d oil to le a k p a s t th e s e a ls o n t h e tu r b in e a n d c o m p r e s s o r s id e s . In th is c a s e c le a n o r r e p la c e th e o il re tu rn p ip e .

F itting a R e c o n d itio n e d T u r b o c h a r g er P rio r to fittin g t h e tu r b o c h a r g e r th e in le t a n d fla n g e d m a n ifo ld a h e a d o f t h e c o m p r e s s o r , t h e e x h a u s t m a n ifo ld a n d e x h a u s t p ip e , a s w e ll a s th e o il fe e d

and

re tu rn p ip e s m u s t b e in s p e c te d th o r o u g h ly fo r d irt a n d

d a m a g e . T h e p lu g s o n th e

tu r b o c h a r g e r o p e n in g s s h o u ld o n ly b e r e m o v e d ju s t b e fo r e fittin g . T h e b e a r in g h o u s in g m u s t b e fille d w ith c le a n e n g in e oil th r o u g h t h e o il in le t p o rt p r io r to c o n n e c tin g th e oil fe e d p ip e . D u rin g fillin g tu rn t h e m o v in g p a rts b y h a n d to c o a t th e b e a r in g s w ith oil.

April '96

Turbocharger 18A-6

REM OVAL, O VERHAUL AND REPLACEM ENT 1.

D is c o n n e c t th e

oil fe e d

p ip e to

th e tu rb o c h a r g e r ,

i

(F ig . 1 8 A - 1 ).

F ig . 1 8 A -1 2.

R e m o v e t h e oil fe e d r e ta in in g b r a c k e t, if fitte d , a n d lo o s e n t h e b o tto m b a n jo u n io n , (F ig . 1 8 A - 2 ).

F ig . 1 8 A - 2 3.

D is c o n n e c t th e

o il d r a in

p ip e fr o m

tu r b o c h a r g e r to

s u m p , (F ig . 1 8 A - 3 ) .

F ig . 1 8 A - 3 4.

If a h e a ts h ie ld is fitte d , u n s c r e w t h e r e ta in in g n u ts a n d r e m o v e , (F ig . 1 8 A - 4 ) .

Fig. 18A-4

April ‘96

Turbocharger 18A-7

5.

P rio r to e lb o w

in

re m o v a l r e la tio n

m a r k th e p o s itio n to

o f th e e x h a u s t

th e tu r b o c h a r g e r b o d y ,

(F ig .

1 8 A -5 ).

6.

R e m o v e th e e x h a u s t p ip e e lb o w fr o m

th e tu r b o c h a r ­

g e r, (F ig . 1 8 A - 6 ) .

7.

U n s c r e w th e

m o u n tin g

n u ts o f t h e tu r b o c h a r g e r a n d

r e m o v e t h e tu r b o c h a r g e r fr o m t h e e x h a u s t m a n ifo ld , (F ig . 1 8 A - 7 ).

M ea su rin g t h e tu r b o c h a r g e r s h a f t e n d p lay.

1. C la m p

t h e tu r b o c h a r g e r , tu r b in e e n d u p , in a v ic e fit­

te d w ith s o ft ja w s .

2.

M ount a

d ia l g a u g e fitte d w ith a m a g n e tic b a s e o n to

t h e t u r b o c h a r g e r h o u s in g .

P la c e t h e d ia l g a u g e p ro ­

b e a t t h e e n d o f t h e tu r b in e s h a ft a n d s e t th e g a u g e to “0", (F ig . 1 8 A - 8 ) .

3.

Push

th e tu r b in e

s h a ft a g a in s t t h e d ia l g a u g e p ro b e

a n d n o te t h e r e a d in g . E n s u r e t h a t th e r e a d in g a g re e s w ith s p e c ific a tio n s .

Fig. 18A-8

April ‘96

Turbocharger 18A-8

M e a s u r in g t h e t u r b o c h a r g e r s h a f t s i d e p la y A tte n tio n !

T h e s id e p la y s h o u ld b e m e a s u r e d a t th e tu rb in e

e n d o n ly .

1.

P u s h th e tu r b in e w h e e l to o n e s id e g a p b e tw e e n

th e b la d e s a n d

and

m e a s u r e th e

t h e h o u s in g

w ith a fe e le r

g a u g e . N o t e c le a r a n c e . (F ig . 1 8 A - 9 ).

2.

P u s h t h e tu r b in e w h e e l m e a s u re

in t h e

th e g a p b e tw e e n

o p p o s ite

th e b la d e s

d ire c tio n a n d

a n d th e h o u s in g

w ith a fe e le r g a u g e . N o t e c le a r a n c e .

3.

The

s u m o f th e tw o r e a d in g s d iv id e d b y tw o r e p r e s e n ts

th e a v e r a g e s id e p la y . C o m p a r e w ith s p e c ific a tio n s .

A tte n tio n !

M e a s u r e m e n t s s h o u ld b e m a d e a t tw o d iffe re n t

p o in ts.

H O L D IN G T O O L S

120

K K K H O L D IN G T O O L A

K N U R L IN G

J__ orvf § ^ 4— 2f t

Fig. 18A-11

April '96

GARRETT HOLDING TOO L

1

B A D A P T E D T O A V A IL A B L E R O T O R

I -

F i g .1 8 A - 1 0

p

Turbocharger 18A-9

D IS M A N T L IN G 1.

P r io r to r e m o v a l m a r k p o s itio n s o f th e tu rb in e a n d c o m ­ p r e s s o r h o u s in g s in re la tio n to th e c e n tr e h o u s in g , (F ig .

1 8 A -1 2 ).

2.

B end

d o w n th e

h o ld in g

lo c k in g

th e tu r b in e

and

p la te s

a n d u n s c r e w th e b o lts

c o m p re s s o r

h o u s in g s

to th e

c e n tr e h o u s in g , (F ig . 1 8 A - 1 3 ) .

A tten tio n !

T ig h t h o u s in g s c a n b e r e m o v e d w ith a ru b b e r

o r h id e fa c e d h a m m e r .

3.

U n s c re w

a n d r e m o v e t h e b o lts a n d lo c k in g p la te s fr o m

th e c o m p r e s s o r h o u s in g , (F ig . 1 8 A - 1 4 ) .

4.

R e m o v e th e

c o m p r e s s o r h o u s in g fr o m th e c e n tr e h o u ­

s in g , (F ig . 1 8 A - 1 5 ) .

A tten tio n !

T ig h t h o u s in g s c a n b e r e m o v e d w ith a ru b b e r

fa c e d h a m m e r .

Fig. 18A-15

April ‘96

Turbocharger 18A-10

5

R e m o v e th e O -r in g fr o m t h e c o m p r e s s o r h o u s in g . ( G a r r e tt ), (F ig 1 8 A - 1 6 ) .

F ig . 1 8 A - 1 6 6.

U s in g

s p e c ia l

h o ld in g

1 8 A - 1 0 , 1 8 A - 1 1,

to o l

m ade

to

illu s tra tio n

F ig .

c la m p th e t u r b o c h a r g e r s h a ft a n d u n ­

s c r e w t h e c o m p r e s s o r r o to r w h e e l re ta in in g n u t,

(F ig .

1 8 A -1 7 ).

a F ig . 1 8 A - 1 7 7.

R e m o v e th e 1 8 A -1 8 ).

o u te r O -r in g fr o m th e b a c k in g p la te , (F ig .

(K K K -tu rb o s ).

F ig . 1 8 A - 1 8 8.

W it h

a

B osch

h o t a ir

b lo w e r o r

s im ila r h e a t s o u rc e ,

h e a t t h e c o m p r e s s o r ro to r w h e e l, (F ig . 1 8 A - 1 9 ) .

A tte n tio n !

D o n o t h e a t t h e c o m p r e s s o r ro to r w h e e l w ith a

w e ld in g to rc h .

Fig. 18A-19

April '96

Turbocharger 18A-11

9.

L ift o ff th e c o m p r e s s o r ro to r w h e e l fr o m th e tu rb o ro to r s h a ft.

R e m o v e r e ta in in g a lie n c a p s c re w s fr o m c o p r e s s o r e n d p la te , (F ig . 1 8 a - 2 0 ) .R e m o v e c o m p r e s s o r e n d p la te fro m c e n tr e h o u s in g

U n iq u e t o KKK tu r b o c h a r a e r s :

10.

L ift o u t th e

seal

c a r r ie r /th r u s t w a s h e r

fr o m th e c o m ­

p r e s s o r e n d p la te , (F ig . 1 8 A - 2 1 ) .

11.

R e m o v e th e

in n e r O -r in g

fr o m

th e

end

p la te ,

(F ig .

1 8 A -2 2 ).

F ig . 1 8 A - 2 2 12.

R em ove

t h e o il d e fle c to r fr o m t h e c e n tr e h o u s in g , (F ig .

1 8 A -2 3 ).

Fig. 18A-23

April '96

Turbocharger 18A-12

13.

R e m o v e th e th r u s t b e a r in g , (F ig . 1 8 A - 2 4 ) .

F ig . 1 8 A - 2 4 14.

R e m o v e t h e s p a c e r s le e v e , (F ig . 1 8 A - 2 5 ) .

F ig . 1 8 A - 2 5 15.

R e m o v e th e th r u s t w a s h e r , (F ig . 1 8 A - 2 6 ) .

■III ASS F ig . 1 8 A - 2 6

U n iq u e t o GARRETT tu r b o c h a r a e r s : 16.

R e m o v e t h e O -r in g fr o m t h e c e n tr e h o u s in g , ( F ig .1 8 A - 2 7 ) .

Fig. 18A-27

April '96

Turbocharger 18A-13

17.

L ift o u t t h e th r u s t b e a r in g a n d th ru s t w a s h e r fr o m th e c e n tr e h o u s in g , (F ig . 1 9 - 2 8 ) .

F ig . 1 8 A - 2 8 18.

R e m o v e t h e s e a l c a r r ie r /th r u s t w a s h e r fr o m th e th ru s t b e a r in g , (F ig . 1 8 A - 2 9 )

19.

R e m o v e t h e s e a lin g rin g fr o m th e s e a l c a rr ie r /th ru s t w a s h e r , ( F ig .1 8 A - 3 0 )

All T u r b o c h a r a e r s: 20.

L ift o f f t h e c e n tr e h o u s in g fr o m th e tu rb o ro to r s h a ft, (F ig . 1 8 A - 3 1 ).

Fig. 18A-31

April '96

Turbocharger 18A-14

21.

R e m o v e th e h e a t s h ie ld fr o m th e tu rb o ro to r s h a ft, (F ig . 1 8 A - 3 2 ) .

2 2 . R e m o v e t h e b o tto m s e a lin g rin g s fr o m th e tu rb o ro to r s h a ft, (F ig . 1 8 A - 3 3 ) .

2 3 . R e m o v e t h e tu r b o -r o t o r s h a ft a s s e m b ly a n d th e h o ld in g to o l c la m p fr o m t h e v ic e .

24.

R e m o v e t h e s e a lin g rin g s fr o m

th e

s e a l c a rr ie r ,

(F ig .

1 8 A -3 4 ).

25.

Rem ove

th e

c irc lip s

r e ta in in g th e tu rb o ro to r b e a r in g s

fr o m th e c e n tr e h o u s in g , (F ig . 1 8 A - 3 5 ) .

Fig. 18A-35

April '96

Turbocharger 18A-15

26.

L ift o u t t h e

b e a r in g s

and

re m o v e

th e

in n e r

circlip s,

(F ig . 1 8 A - 3 6 ) .

A tte n tio n ! c le a n in g

A ll'p a r t s s h o u ld n o w b e w a s h e d in a s u ita b le

flu id .

Do

not

use

a b r a s iv e

c le a n in g

m e th o d s

w h ic h m a y d a m a g e o r d e s tr o y m a c h in e d s u rfa c e s .

T h o r o u g h ly c le a n t h e tu r b in e e n d oil c a v ity in th e c e n tre h o u s in g . R e m o v e a ll c a r b o n is e d oil.

C h e c k th e tu r b in e

h o u s in g

and

ro to r b la d e s

fo r c ra c k s ,

s c o r e m a r k s a n d fo re ig n p a rtic le s . C h e c k b o th ro to rs fo r b e n t o r d a m a g e d b la d e s a n d s e a l rin g s fo r w e a r . R e p la c e a ll w o rn p a rts . E x a m in e m a tin g s u rfa c e s fo r th e s e a l rin g s in th e c e n tr e h o u s in g a n d b a c k p la te .

E x a m in e th e s e a l

g r o o v e s in t h e s h a ft a n d s e a l c a rr ie r fo r w e a r .

ASSEMBLY 1.

P la c e tu r b o ro to r s h a ft o n a s u ita b le V -b lo c k , le v e l w ith th e

b e a r in g

r u n n in g th e

p o in ts

10 m m

and

fr o m

check

th e

end

th e

s h a ft fo r

p a ra lle l

o f t h e th r e a d s . R e fe r to

s p e c ific a tio n s fo r m a x im u m

p e r m is s ib le

run

out,

(F ig . 1 8 A - 3 7 ) .

2.

F it t h e in n e r c irc lip s a n d b e a r in g s to th e c e n tr e h o u s in g , (F ig . 1 8 A - 3 8 ) .

3.

In s e r t th e

o u te r b e a r in g c ir c lip s in th e c e n tr e h o u s in g ,

(F ig . 1 8 A - 3 9 ) .

A t t e n t i o n ! A lw a y s u s e n e w c irc lip s a f te r a n o v e r h a u l.

Fig. 18A-39

April ‘96

Turbocharger 18A-16

4.

5.

C la m p th e ro to r s h a ft in a v ic e .

F it th e s e a lin g rin g s to th e b o tto m o f th e ro to r s h a ft a n d lu b r ic a te , (F ig . 1 8 A - 4 0 ) .

F ig . 1 8 A - 4 0 6.

F it th e

h e a t s h ie ld

o v e r th e tu r b o

ro to r s h a ft,

(F ig . 1 8 A - 4 1 ).

Ill: /© = F ig .1 8 A -4 1 7.

F it th e c e n tr e h o u s in g o v e r t h e tu r b o ro to r s h a ft. D o no t d a m a g e t h e s e a lin g rin g s , (F ig . 1 8 A - 4 2 ) .

F ig . 1 8 A - 4 2

U n iq u e t o KKK tu r b o c h a r a e r s : 8.

F it th e in n e r th r u s t w a s h e r , (F ig . 1 8 A - 4 3 ) .

Fig. 18A-43

April '96

Turbocharger 18A-T7

9.

10.

R e p la c e th e s p a c e r, (F ig . 1 8 A - 4 4 ) .

F it th e th r u s t

b e a r in g

o v e r th e

r e ta in in g

p in s ,

(F ig

1 8 A -4 5 ).

11.

In s e r t t h e o il d e fle c to r , (F ig . 1 8 A - 4 6 ) .

12.

F it a n e w in n e r O -r in g to th e e n d p la te , ( F ig .1 8 A - 4 7 ) .

Fig. 18A-47

April '96

Turbocharger 18A-18

13.

R e p la c e a n d lu b ric a te th e s e a lin g rin g s on th e c a rr ie r a n d fit in to th e e n d p la te , (F ig . 1 8 A -4 8 ).

se a l

F ig . 1 8 A - 4 8 14.

F it th e e n d p la te to t h e c e n tr e h o u s in g , (F ig . 1 8 A - 4 9 ) .

■wi' F ig . 1 8 A - 4 9 15.

In s e r t th e

cap

s c re w s

r e ta in in g

th e

e n d p la te to

th e

c e n tr e h o u s in g a n d tig h te n to t h e s p e c ifie d to rq u e , (F ig .

1 8 A -5 0 ).

A3=

F ig . 1 8 A - 5 0

U n iq u e t o GARRETT T u r b o c h a r a e r s: 16.

L u b r ic a te a n d r e p la c e t h e s e a lin g rin g s o n t h e s e a l c a r r ie r /th r u s t w a s h e r (F ig . 1 8 A - 5 1 ).

Fig. 18A-51

April '96

Turbocharger 18A-19

17.

F it th e th ru s t b e a r in g to th e s e a l c a r r ie r /th ru s t w a s h e r a n d s lid e o v e r th e tu r b o ro to r s h a ft. A lig n th e th ru s t b e a r in g w ith th e r e ta in in g p in s , (F ig . 1 8 A - 5 2 ) .

F ig . 1 8 A - 5 2 18.

R e p la c e th e O -r in g a t th e to p o f t h e c e n tr e h o u s in g , ( F ig . 1 8 A - 5 3 ) .

F ig . 1 8 A - 5 3 19.

L in e u p t h e s e a lin g rin g o n th e s e a l c a r r ie r /th ru s t w a s h e r a n d fit th e e n d p la te , (F ig . 1 8 A - 5 4 )

F ig . 1 8 A - 5 4 20.

In s e r t th e b o lts fitte d w ith t h e lo c k p la te s in to th e e n d p la te , (F ig . 1 8 A - 5 5 ) .

Fig. 18A-55

April '96

Turbocharger 18A-20

21.

T ig h te n th e b o lts to th e s p e c ifie d to r q u e a n d s e c u r e th e lo c k p la te s , (F ig . 1 8 A - 5 6 ) .

AH tu rb o c h a ra e rs 22.

H e a t th e c o m p r e s s o r w h e e l w ith a B o s c h h o t a ir b lo w e r o r a lt e r n a t iv e h e a t s o u r c e , (F ig . 1 8 A - 5 7 ) .

A tte n tio n ! w e ld in g

Do

not

heat

th e

c o m p re s s o r

w heel

w ith

a

to rc h .

F ig . 1 8 A - 5 7 23.

F it th e c o m p r e s s o r w h e e l to t h e tu rb o ro to r s h a ft,

(F ig .

1 8 A -5 8 ).

F ig . 1 8 A - 5 8 24.

R e p la c e th e o u te r O -r in g

o n t h e e n d p la te , a p p ly

p e tro ­

le u m je lly to a s s is t, (F ig . 1 8 A - 5 9 ) .

Fig. 18A-59

Turbocharger 18A-21

25.

R e p la c e th e tig h te n

to

c o m p r e s s o r w h e e l r e ta in in g lo c k n u t a n d

th e s p e c ifie d

to rq u e . D o n o t b e n d th e s h a ft,

(F ig . 1 8 A - 6 0 ) .

A tte n tio n !

26.

A lw a y s u s e a n e w lo c k n u t

M o u n t th e

c e n tr e h o u s in g

in a v ic e a n d tu rn th e ro to r

s h a ft b y h a n d to c h e c k fo r fr e e r u n n in g , (F ig . 1 8 A - 6 1 ) .

27.

F it th e c o m p r e s s o r h o u s in g to th e c e n tr e h o u s in g , (n o te s c rib e d a s s e m b ly m a r k s ). R e p la c e th e b o lts a n d r e ta i­ n in g c la m p s a n d tig h te n to t h e s p e c ifie d to rq u e , (F ig .

1 8 A -6 2 ).

28.

F it t h e tu r b in e

h o u s in g to t h e

c e n tr e

h o u s in g

(n o te

s c rib e d a s s e m b ly m a r k s ), (F ig . 1 8 A - 6 3 ) .

N o te :

O n G a r r e t t tu r b o c h a r g e r s e n s u r e t h a t a n e w O -r in g is

fitte d in t h e c o m p r e s s o r h o u s in g .

April ‘96

Turbocharger 18A-22

2 9 . R e p la c e

th e b o lts a n d c la m p s ,

tig h te n to

th e s p e c ifie d

to r q u e a n d b e n d o v e r th e lo c k in g p la te s , (F ig . 1 8 A - 6 4 ) .

A tte n tio n !

3 0 . T u rn

A lw a y s fit n e w lo c k in g p la te s .

th e tu rb o

ro to r s h a ft b y

h a n d a n d c h e c k fo r fr e e

ru n n in g .

F ig . 1 8 A - 6 4 31.

L u b r ic a te b e a r in g s in th e c e n tr e h o u s in g w ith e n g in e oil, (F ig . 1 8 A - 6 5 ) .

■III /B s F ig . 1 8 A - 6 5

R e p la c in g t h e tu r b o c h a r g e r 1.

M o u n t th e

tu r b o c h a r g e r

E n s u re th a t th e

o n to

th e

m a tin g s u r f a c e s

exhaust

m a n ifo ld .

o f fla n g e d a r e a s a r e

c le a n a n d f r e e o f b u rrs o r h ig h s p o ts , (F ig . 1 8 A - 6 6 ) .

III U s F ig . 1 8 A - 6 6 2.

F it th e

e x h a u s t p ip e e lb o w

to

t h e tu r b o c h a r g e r (n o te

s c rib e d a s s e m b ly m a r k s ), (F ig . 1 8 A - 6 7 ) .

(Fig. 18A-67

April '96

Turbocharger 18A-23

M o u n t th e

heat

s h ie ld , if fitte d ,

to th e tu rb o s tu d s

a n d s e c u r e w ith n e w s e lf lo c k in g n u ts , (F ig . 1 8 A - 6 8 ) .

F ig . 1 8 A - 6 8 4.

In s e r t t h e th e

b a n jo b o lt c o n n e c tin g

oil p r e s s u r e g a lle r y

on

th e tu rb o fe e d p ip e to

th e c y lin d e r b lo c k a n d tig h ­

te n t h e b o lt to th e s p e c ifie d to r q u e , (F ig . 1 8 A - 6 9 )

F ig . 1 8 A - 6 9 5.

T ig h t e n

t h e tu rb o oil fe e d p ip e re ta in in g b r a c k e t to

th e

s p e c ifie d to rq u e , (F ig . 1 8 A - 7 0 ) .

F ig . 1 8 A - 7 0 6.

U se

a

new

gasket and

r e p la c e th e to p o il fe e d p ip e ,

in s e r t t h e b o lts a n d tig h te n to th e s p e c ifie d to rq u e , (F ig .

1 8 A -7 1 ).

Fig. 18A-71

April '96

Turbocharger 18A-24

April '96

Turbocharger 18A-25

INTERCOOLER D e p e n d in g

on

a p p lic a tio n

a n d /o r

r e q u ir e m e n t th e A D E

360

s e rie s

e n g in e s

a re

b u ilt to

accept a

c h a rg e

a ir c o o le r

(In te r c o o le r ), m o u n te d b e tw e e n th e tu r b o c h a r g e r c o m p re s s o r h o u s in g a n d in le t m a n ifo ld .

T h e in te r c o o le r r e s e m b le s a c o o la n t r a d ia to r c o re (s e e fig 1 8 A - 1 1 8 ) . U n d e r lo a d , a ir is c o m p r e s s e d a n d fo rc e d v ia th e in te r c o o le r in to th e c o m b u s tio n a r e a b y th e tu r b o c h a r g e r . D u rin g c o m p re s s io n b y th e t u r b o c h a r g e r th e a ir h e a ts up an d e x p a n d s , c o n s e q u e n tly b e c o m in g le s s d e n s e . B y d ire c tin g th e h o t a ir th ro u g h a n in te r c o o le r s o m e h e a t is r e m o v e d . T h e e x p a n s io n o f th e c h a r g e d a ir is th e r e fo r e r e d u c e d , w h ic h m e a n s m o r e a ir w ill b e fo rc e d in to th e c o m b u s tio n a r e a , th e in c r e a s e d d e n s ity o f t h e c h a r g e d a ir (o x y g e n ) a llo w s fo r m o r e fu e l to b e in je c te d , a n d c o n s e q u e n tly m o r e p o w e r w ill be d e v e lo p e d .

1m

m

Exhaust

2 E S S jifl C h a rg e air

M a in te n a n c e 1.

K e e p t h e c o o le r e x te r n a lly c le a n a n d fr e e fr o m o b s tru c tio n w h ic h m a y a f fe c t th e a ir flo w .

2.

C h a r g e a ir le a k s w ill re s u lt in lo s s o f p o w e r, th e re fo re : A ll in d u c tio n tu b in g a n d h o s e jo in ts m u s t b e k e p t tig h t.

E n s u r e t h a t a ll m o u n tin g s a r e s e c u r e to p r e v e n t v ib ra tio n s w h ic h m a y c r a c k th e in te r c o o le r tu b e s .

P e r io d ic a lly in s p e c t t h e in te r c o o ie r t u b e s fo r h o le s d u e to c o rro s io n o r im p a c t b y d e b ris .

3.

In t h e e v e n t o f d u s t o r fo re ig n o b je c ts e n te r in g th e in d u c tio n s y s te m a n d /o r tu r b o c h a r g e r c o m p r e s s o r w h e e l fa ilu re ,

c le a n

t h e in d u c tio n tu b in g /h o s e s to a n d fr o m th e in te rc o o ie r. D is m a n tle a n d c le a n th e in te r c o o ie r . S e a le d u n its th a t

c a n n o t b e c le a n e d p r o p e r ly s h o u ld b e re p la c e d .

April '96

SECTION 18B Power Steering Pump

CONTENTS OF SECTION 18B

Page I L L U S T R A T I O N ........................................................................................................................................................................................................................................1 8 B I N T R O D U C T I O N ................................................................................................................................................................................................................................ 1 8 B -3 S P E C I F I C A T I O N S ............................................................................................................................................................................................................................. 1 8 B -3 F A U L T F I N D I N G ..................................................................................................................................................................................................................................1 8 B -4 R E M O V A L O F T H E P O W E R S T E E R IN G P U M P

:..........................................................................................................................................1 8 B -5

Z . F . H IG H P R E S S U R E P U M P D IS M A N T L IN G O F T H E R O T O R A N D C A M R I N G .......................................................................................................................................................1 8 B -6 R E M O V A L O F T H E D R IV E S H A F T ........................................................................................................................................................................................ 1 8 B -7 R E M O V A L O F F L O W A N D P R E S S U R E R E S T R IC T IO N V A L V E ........................................................................................................................ 1 8 B -8 D IS M A N T L IN G , I N S P E C T I O N A N D A S S E M B L Y O F F L O W A N D P R E S S U R E R E S T R I C T I O N V A L V E ..........................................................................................................................................................1 8 B -8 R E P L A C E M E N T O F F L O W A N D P R E S S U R E R E S T R IC T IO N V A L V E ...........................................................................................................1 8 B -9 P R E - A S S E M B L Y O F P U M P H O U S I N G .............................................................................................................................................................................. 1 8 B -9 A S S E M B L Y A N D R E P L A C E M E N T O F D R IV E S H A F T ........................................................................................................................................... 1 8 B - 1 0 R E P L A C E M E N T O F D R IV E E N D F A C E P L A T E ..........................................................................................................................................................1 8 B -1 1 R E P L A C E M E N T O F C A M R IN G A N D R O T O R .............................................................................................................................................................1 8 B -1 1 R E P L A C E M E N T O F E N D F A C E P L A T E A N D C O V E R ........................................................................................................................................... 1 8 B - 1 2 V I C K E R S H IG H P R E S S U R E P U M P D IS M A N T L IN G A N D R E M O V A L O F R O T O R A N D C A M R I N G ..........................................................................................................................1 8 B - 1 3 R E M O V A L A N D D IS M A N T L IN G O F V O L U M E C O N T R O L A N D P R E S S U R E R E L IE F V A L V E ........................................................................................................................................................................................ 1 8 B - 1 4 R E P L A C E M E N T O F D R IV E S H A F T A N D S E A L ..........................................................................................................................................................1 8 B - 1 6 R E P L A C E M E N T O F R O T O R A N D C A M R I N G .............................................................................................................................................................1 8 B - 1 7 R E P L A C I N G T H E P U M P ..........................................

1 8 B -1 8

SPECIAL TOOLS................................................................................................................................................................................. 18B-20

April '96

SECTION 18B Power Steering Pump

Z F -R O T A R Y P U M P T Y P E 7 6 7 3 1 NUT

1 7 O -R IN G

2

S P R IN G W A S H E R

18

F R O N T P L A T E , D R IV E - E N D

3

D R IV E S H A F T

19

ROTO R

4

W O O D R U FF KEY

20

VANE

5

C IR C L IP

21

C A M R IN G

6

B A L L B E A R IN G

22

O - R IN G

7

C IR C L IP

23

F R O N T P L A T E C O V E R -E N D

8

SHAFT SEAL

24

S P R IN G

9

N E E D L E B E A R IN G

25

O - R IN G

H O U S IN G

26

COVER

11 B L A N K IN G P L U G

27

H O O K E D C IR C L IP

12

S E A L IN G R I N G

28

T H R O T T L E IN S E R T

13

P H IL L IP S S C R E W

29

V A L V E P IS T O N C O M P L E T E

14

ID E N T I F I C A T I O N P L A T E

30

P R E S S U R E R IN G

15

F I T T E D P IN

31

S E A L IN G R IN G

16

O -R IN G

32

B L A N K IN G P L U G

10

April '96

Power Steering Pump 18B-3

IN T R O D U C T IO N D e p e n d in g o n a p p lic a tio n th e A D E 3 6 0 s e rie s e n g in e s c a n b e fitte d w ith e ith e r o f tw o ty p e s o f ro ta ry p o w e r s te e rin g p u m p s , b o th o f w h ic h o p e r a te a s fo llo w s : W h e n th e d r iv e s h a ft a n d its ro to r a r e tu rn e d , th e v a n e s a r e g u id e d in s lo ts a n d b e in g r a d ia lly m o b ile , a r e p r e s s e d a g a in s t th e g u id e p a r t o f t h e c a m rin g b y th e a c tio n o f c e n trifu g a l fo rc e a n d oil p re s s u re . T w o s u c c e s s iv e v a n e s a r e c la s s e d a s a ce ll ( a to ta l o f 1 0 ). T h e ir la te r a l m o v e m e n t is re s tric te d b y th e p r e s s u r e p la te s . E a c h c e ll d e liv e rs th e m a x im u m e ffe c tiv e v o lu m e t w ic e p e r r e v o lu tio n . T h e s u c tio n a n d p r e s s u r e c h a m b e r s a r e a r r a n g e d s o t h a t th e h y d r a u lic a n d r a d ia l fo rc e s a c tin g o n th e ro to r w ill n e u tr a lis e e a c h o th e r. T h e c o v e r e n d fro n t p la te a n d th e d r iv e e n d fr o n t p la te a r e p ro v id e d w ith fo u r g r o o v e s s o t h a t t h e p r e s s u r is e d oil r e a c h e s th e in te rn a l fa c e o f th e p u m p v a n e s , w h ic h w ill th e n b e s u p p o r te d b y th e c e n tr i­ fu g a l fo rc e . F r o m th e p r e s s u r e c h a m b e r th e oil tr a v e ls th ro u g h h o le s to th e flo w re s tric tin g v a lv e , a n d b y w a y o f a th ro ttle r e s tr ic tio n to th e p r e s s u r e lin e. T h e re d u c e d p r e s s u r e b e h in d th e th ro ttle re s tric tio n is t r a n s m itte d v ia h o le s to th e s p rin g lo a d e d e n d o f th e flo w r e s tric tin g p is to n a n d th e r e fo r e o n to th e r e lie f v a lv e .

In c r e a s in g t h e s p e e d o r p u m p d e liv e r y w ill p r o d u c e a g ro w in g p r e s s u r e d ro p b e h in d th e th ro ttle r e s tr ic to r a n d a ls o a g a in s t th e s p rin g e n d o f t h e v a lv e p is to n . W h e n th e h y d r a u lic p o w e r (p r e s s u r e d iffe r e n tia l tim e s p is to n a r e a ) e x c e e d s th e sp rin g fo rc e , t h e p is to n w ill m o v e to w a r d s th e s p rin g a n d th e oil d e liv e re d in e x c e s s w ill flo w th ro u g h th e n o w e x p o s e d e je c tio n h o le in to t h e s u c tio n d u c t o f t h e p u m p . A s a re s u lt, a n a lm o s t c o n s ta n t oil flo w fo r th e s te e r in g g e a r is p r o v id e d th ro u g h o u t th e e n tir e s p e e d r a n g e .

TORQUE SPECIFICATIONS P u lle y to p u m p s h a f t .................................................................................................... M 1 4 C o v e r to p u m p h o u s in g

x 1 , 5 ................................................. 8 0 N m 3 5 to 4 0 N m

P u m p b r a c k e t to fu e l filte r b r a c k e t ....................................................................... M 1 0 .............................................................. 4 0 N m A d ju s tin g b o lt to w a t e r p u m p .................................................................................. M 1 0 ...............................................................4 0 N m A d ju s tin g b o lt to b r a c k e t .............................................................................................M 1 2

x 1 , 5 ................................................. 5 0 N m

V -b elt t e n s io n fo r 1 2 ,5 m m w id e b e lts N e w V - b e l t ..................... »..................................................................................... ..................................................................................... 4 0 to 4 5 k.q A fte r ru n -in p e r io d ...... *.................................................................................... ..................................................................................... 3 0 to 4 0 kg U s e d V - b e l t ........................................................................................................... ..................................................................................... 3 0 to 4 0 kg

April ‘96

Power Steering Pump 18B-4

V i c k e r s H ig h P r e s s u r e O il P u m p V T 2 7

F a u lt f i n d i n g

Problem

Possible Cause

Remedy

P u m p is n o t d e l i v e r i n g

P u m p r u n n in g in w ro n g d ire c tio n

C h a n g e d ire c tio n o f r o ta tio n

P u m p d r iv e s h a ft s h e a r e d

R e m o v e th e p u m p to d e te r m in e th e e x te n t o f th e

V - b e lt s lip s o r is to rn

d a m a g e a n d R e p la c e d a m a g e d p a rts

F lo w r e s tric tio n , v a lv e b in d s

D is m a n tle t h e in s ta ll

v a lv e

pum p

and

p is to n

and

c le a n

th e

check

v a lv e .

fo r

R e­

ease

of

o p e r a tio n . S lig h t ro u g h s p o ts c a n b e r e m o v e d by la p p in g . D o n o t g rin d o r c h a m f e r c o n tro l e d g e s No

re fin is h in g

is

p e r m itte d

p a rts m u s t b e c le a n e d s y s te m

on

p r io r to

v a lv e

b o re .

a s s e m b ly .

s h o u ld b e th o r o u g h ly flu s h e d

and

A ll The

fille d

w ith c le a n oil.

V a n e s b in d in ro to r s lo ts

R e m o v e th e p u m p a n d c h e c k th e ro to r s lo ts fo r d irt, a b r a s iv e s a n d s w a rf. C le a n ro to r a n d v a n e s .

D u rin g

a s s e m b ly

c h e c k th e v a n e s

fo r e a s e

of

o p e ra tio n .

O il v is c o s ity to o high.

U s e oil o f c o rr e c t v is c o s ity .

P u m p can n o t suck In le t p ip e s p a r tia lly b lo c k e d .

D ra in th e oil fr o m th e s y s te m . F lu s h a ll p ip e s . Fill t h e s y s te m w ith fr e s h oil in a c c o r d a n c e w ith re ­ c o m m e n d a tio n s .

T a n k v e n t c lo g g e d .

R e m o v e ta n k c o v e r a n d c le a n . C h e c k t h e s y s te m

In le t filte r c o n ta m in a te d .

filte r o r in ta k e filte r fo r c lo g g in g . If t h e in ta k e filte r is c lo g g e d , d r a in th e s y s te m , flu s h a n d refill.

E x c e s s iv e p u m p n o is e

In ta k e

p ip e

p a rtia lly

or

c o m p le te ly

c lo g g e d . F ilte r c lo g g e d .

T h e p u m p s h o u ld b e a b le to s u c k w ith o u t re s ­ tric tio n to p r e v e n t c a v ita tio n . D r a in t h e s y s te m , c le a n

th e

in ta k e

p ip e

and

filte r.

F ill

up

w ith

r e c o m m e n d e d oil.

L e a k in g in le t p ip e c o n n e c tio n s .

C h e c k b y p o u rin g oil o n c o n n e c tio n s .

N o t e th e

c h a n g e in p u m p n o is e , tig h te n c o n n e c tio n s .

L e a k in g s h a ft s e a ls .

M is a lig n m e n t o f s h a ft c o u p lin g .

R e p la c e in a c c o r d a n c e w ith in s tru c tio n s In s p e c t th e s h a ft b e a r in g a n d o il s e a l fo r p o s s ib le fa u lts , r e p la c e a s n e c e s s a r y . R e a lig n s h a ft.

C o n ta in e r s e a l le a k in g .

R e p la c e th e c o n ta in e r c o v e r s e a l, tig h te n p ip e to ta n k c o n n e c tio n s

April '96

Power Steering Pump 18B-5 REMOVING AND REPLACING THE STEERING PUMP R e m o v in g th e p u m p 1.

L o o s e n th e c la m p b o lt o f th e V -b e lt a d ju s te r, (F ig

1 8 B - 1 ).

Fig

2.

18B-1

S la c k e n o ff t h e V - b e lt a d ju s te r fr o m th e p u lle y , (F ig . 1 8 B -2 ).

F ig . 1 8 B - 2 3.

U n s c r e w a n d r e m o v e t h e b o tto m p u m p m o u n tin g re ta in in g b o lt, (F ig . 1 8 B - 3 ).

F ig . 1 8 B - 3 4.

C la m p t h e p u m p d r iv e p u lle y in a v ic e , fitte d w ith s o ft ja w s , u n s c r e w t h e p u lle y r e ta in in g n u t a n d r e m o v e th e p u lle y , (F ig . 1 8 B - 4 )

Fig. 18B-4 April '96

Power Steering Pump 18B-6

5.

U n s c r e w t h e b o lts r e ta in in g th e m o u n tin g b r a c k e t to th e p u m p a n d r e m o v e th e b r a c k e t, (F ig . 1 8 B - 5 ).

F ig . 1 8 B - 5

DISMANTLING R em o v a l o f R o to r an d C am R in g ZF H igh P r e s s u r e V a n e P u m p 1.

R e m o v e t h e c irc lip fr o m th e g r o o v e in th e p u m p h o u s in g (F ig . 1 8 B - 6 ) .

2.

R e m o v e th e c o v e r, s p rin g a n d c o v e r e n d p la te fr o m th e h o u s in g , (F ig . 1 8 B - 7 ) .

F ig . 1 8 B - 7

3.

T ilt th e p u m p b o d y a n d r e m o v e c a m rin g a n d ro to r, (F ig . 1 8 B - 8 ) .

Fig. 18B-8 April '96

Power Steering Pump 18B-7 R e m o v in g t h e d riv e s h a ft 4.

R e m o v e th e c irc lip , (F ig . 1 8 B - 9 ).

F ig . 1 8 B - 9 5.

W it h a R u b b e r o r p la s tic h a m m e r k n o c k th e d riv e s h a ft fr o m th e h o u s in g , (F ig . 1 8 B - 1 0 ) .

■in

ra~

F ig . 1 8 B - 1 0

6.

K n o c k th e d r iv e e n d fa c e p la te fr o m th e h o u s in g .

7.

R e m o v e t h e v o lu m e c o n tro l v a lv e .

8 . W it h a s u ita b le p u n c h k n o c k th e n e e d le b e a r in g a n d d riv e s h a ft s e a l fr o m t h e h o u s in g , (F ig . 1 8 B - 1 1 ) .

9.

R e m o v e th e O -r in g s fr o m t h e h o u s in g , th e h o llo w p in a n d d r iv e e n d fa c e p la te .

II M B S

Fig . 1 8 B -1 1 10.

A fte r r e m o v in g th e c irc lip t h e b e a r in g c a n b e p re s s e d fr o m

th e d r iv e s h a ft, (F ig . 1 8 B - 1 2 ) .

Fig. 18B-12

April '96

Power Steering Pump 18B-8 R e m o v i n g t h e F l o w a n d P r e s s u r e R e s t r i c t i o n V a lv e o f t h e Z . F . H ig h P r e s s u r e V a n e P u m p 1.

R e m o v e th e s c r e w p lu g fr o m th e h o u s in g , (F ig . 1 8 B - 1 3 ) .

2.

R e m o v e th e s p rin g a n d v a lv e p is to n fr o m th e h o u s in g b o re

F ig . 1 8 B - 1 3

D ism a n tlin g , I n s p e c tio n a n d A s s e m b ly o f th e F lo w an d P r e s s u r e R e str ic tio n V a lv e 1.

C h e c k th e p r e s s u r e a n d flo w re s tric tio n v a lv e fo r s c o r e m a rk s a n d w e a r . T h e f lo w c o n tr o l p is to n s h o u ld n o t b in d in th e h o u s in g b o re . C h e c k th e ite m n u m b e r s o n t h e h o u s in g fa c e a n d th e p is to n to e n s u r e m a tc h in g p a rts a r e u s e d , (F ig . 1 8 B - 1 4 ) .

2.

U n s c r e w t h e v a lv e s e a t s c r e w fr o m th e p r e s s u r e re s tric tio n v a lv e (d o n o t u s e a v ic e ). E n s u r e t h a t n o n e o f th e w a s h e r s , th e b a ll, th e s p rin g g u id e a n d c o m p re s s io n s p rin g s a r e lo st.

T h e th ic k n e s s o f t h e w a s h e r is c ritic a l fo r t h e r e s p o n s e r a n g e o f t h e p r e s s u r e r e lie f v a lv e . N e w w a s h e r s m u s t b e fitte d to p r e v e n t t h e p o s s ib ility o f d a m a g e , (F ig . 1 8 B - 1 5 ) .

3.

C le a n t h e c o n tro l v a lv e a n d th e v a lv e s c r e w a n d b lo w o u t w ith c o m p r e s s e d a ir. R e in s e r t t h e c o m p re s s io n s p rin g , g u id e pin a n d b a ll. S c r e w t h e v a lv e ,s e a t s c r e w in to th e c o n tro l p is to n , to g e t h e r w ith t h e p r e v io u s ly in s ta lle d w a s h e r s .

F ig . 1 8 B - 1 5 ______________________________________________

1 2 3 4 5 6 7 8

April '96

VALVE PISTON COMPRESSION SPRING PRESSURE RELIEF VALVE SPRING GUIDE PIN VALVE BALL ADJUSTING W ASHERS VALVE SEAT S C R EW SPRING VOLUME CO NTRO L VALVE S C R EW PLUG W IT H SEALING W ASHER

Power Steering Pump 18B-9

R e p l a c e m e n t o f F l o w a n d P r e s s u r e R e s t r ic t io n V a lv e 4.

In s e r t a s s e m b le d v a lv e p is to n in to th e b o re . C h e c k fo r c o rr e c t to le r a n c e , (F ig . 1 8 B - 1 6 ) .

5.

S lid e t h e c o m p r e s s io n s p rin g o n to th e v a lv e p is to n a n d s c r e w t h e b la n k in g p lu g in to th e th r e a d h o le w ith th e s e a lin g w a s h e r p la c e d u n d e r n e a th , (F ig . 1 8 B - 1 7 ) .

P r e - a s s e m b l y o f P u m p H o u s in g N o te :

P r io r to a s s e m b ly c le a n a ll p a rts , m o is te n s lig h tly w ith

A T F o il a n d r e p la c e a ll s e a ls a n d O -r in g s .

1.

W it h

s u ita b le m a n d r e l p re s s th e n e e d le b e a r in g in to th e

h o u s in g , (F ig . 1 8 B - 1 8 ) .

T h e f a c e e n d o f th e n e e d le b e a r in g m u s t b e 3 7 ,0 to 3 7 ,2 m m fr o m t h e f a c e e n d o f t h e h o u s in g , (F ig . 1 8 B - 1 9 ) .

N o te :

T h e n e e d le b e a r in g is in s ta lle d o n ly in p u m p s w ith

V - b e lt d riv e .

Fig. 18B-19

Power Steering Pump 18B-10

2.

W ith a m a n d r e l p re s s th e s h a ft s e a l in to th e h o u s in g .

F it th e s e a l w ith b e a r in g g r e a s e b e tw e e n th e s e a lin g lip s, (F ig . 1 8 B - 2 0 ) .

3.

S c r e w th e p lu g in to t h e h o u s in g a n d tig h te n .

4.

F it a n O -r in g in to th e b o tto m g r o o v e o f t h e h o u s in g .

5.

In s e r t a h o llo w p in in to th e h o le p ro v id e d , (F ig . 1 8 B - 2 1 ) .

A s s e m b ly a n d R e p la c e m e n t o f t h e D rive S h a ft 6.

P re s s th e b a ll b e a r in g o n th e d r iv e s h a ft a n d r e p la c e th e c irc lip . F it th e w o o d r u f f k e y , (F ig . 1 8 B - 2 2 ) .

LL|

7.

ig. 1 8 B - 2 2

In s e r t t h e p r e - a s s e m b le d d r iv e s h a ft in to t h e h o u s in g u n til th e b a ll b e a r in g r e s ts a g a in s t t h e h o u s in g fla n g e , (F ig . 1 8 B - 2 3 ) .

Fig. 18B-23

April '96

Power Steering Pump 18B-11

8.

In s e r t th e c irc lip r e ta in in g th e b a ll b e a rin g , (F ig . 1 8 B - 2 4 )

R e p la c e m e n t o f th e D rive End F a c e P la te 9.

In s e r t th e O -r in g in to t h e g r o o v e in th e n e c k o f t h e f a c e p la te .

1 0 . S lid e t h e d r iv e e n d p la te o n to th e h o llo w p in a n d p re s s w ith th e n e c k in to t h e h o u s in g , (F ig . 1 8 B - 2 5 ) .

R e p la c e m e n t o f th e C am R in g a n d R otor 11.

In s e r t O -r in g ( 1 ) in to th e g r o o v e in th e h o u s in g , (F ig . 1 8 B - 2 6 ) .

12.

In s e r t t h e c a m rin g . T h e s m a lle r h o le lo c a te s th e h o llo w p in . T h e c a s t h a lf a r r o w in d ic a te s th e d riv in g d ire c tio n o f t h e p u m p , (F ig . 1 8 B - 2 7 ) .

April '96

Power Steering Pump 18B-12

13.

F it th e ro to r w ith th e s m o o th b o re o n th e d r iv e s h a ft, (F ig . 1 8 B - 2 8 )

F ig . 1 8 B - 2 8 14.

In s e r t th e te n v a n e s w ith t h e r o u n d e d -o ff o u te r s u r fa c e s fa c in g t h e c a m rin g in to th e s lo ts o f th e ro to r, (F ig . 1 8 B - 2 9 ) .

F ig . 1 8 B - 2 9

R e p la c e m e n t o f th e E nd F a c e P la te an d C o v er 15.

F it th e c o v e r e n d o n to t h e c a m rin g , a s s h o w n . T h e h o llo w p in fits in o n e o f th e s m a lle r h o le s , (F ig . 1 8 B - 3 0 ) .

ii » = F ig . 1 8 B - 3 0 16.

In s e r t t h e O -r in g , (F ig . 1 8 B - 3 1 ) .

Fig. 18B-31

April '96

Power Steering Pump 18B-13

1 7 . In s e r t t h e s p rin g in to th e b o re o f th e c o v e r e n d p la te .

P o s itio n th e c o v e r w ith th e re c e s s in w a r d s a n d p u sh in to th e h o u s in g u n til th e c irc lip c a n b e in s e rte d , (F ig . 1 8 B - 3 2 ) .

1 8 . In s e r t t h e flo w a n d p r e s s u r e re s tric tio n v a lv e .

V ic k e r s H igh P r e s s u r e Oil P u m p VT27 D ism a n tlin g -R e m o v a l o f R otor a n d C am R ing 1.

R e m o v e t h e s c r e w s o n th e p u m p h o u s in g to w h ic h th e h o u s in g c o v e r is c o n n e c te d ; r e m o v e th e p u m p h o u s in g .

2.

R e m o v e t h e s p rin g fr o m th e th r u s t p la te . M a r k th e th ru s t p la te , c a m rin g a n d h o u s in g c o v e r to e n s u r e th e p a rts a r e c o rr e c tly a lig n e d o n a s s e m b ly (r e fe r to a r ro w s ), ( F ig . 1 8 B - 3 3 )

F ig . 1 8 B - 3 3

3.

1 O -R IN G

4

C A M R IN G

2 T H R U S T PLATE

5

O -R IN G

3

6

H O U S IN G C O V E R

S P R IN G

R e m o v e t h e th r u s t p la te fr o m th e lo c a tin g p in s a n d t a k e o ff th e c a m rin g , (F ig . 1 8 B - 3 4 ) .

2 TH R U S T PLATE 4

April ‘96

C A M R IN G

6 7

H O U S IN G C O V E R M A R K IN G L IN E

Power Steering Pump 18B-14

4.

R e m o v e ro to r w ith p u m p v a n e s fr o m th e d r iv e s h a ft s p lin e s , (F ig . 1 8 B - 3 5 ) .

Fig . 1 8 B - 3 5 4

C A M R IN G

6

H O U S IN G C O V E R

7

M A R K IN G L IN E

8

L O C A T IN G P IN

9

ROTO R

A

O IL I N F L O W F R O M

B

H Y D R A U L IC O IL O U T ­

C

IN T A K E B O R E S

S U P P L Y C O N T A IN E R F L O W O N C A M R IN G

10 V A N E S 5.

R e m o v e O -r in g s ite m s 1 & 5 , (F ig . 1 8 B - 3 6 ) .

6.

R e m o v e th e v o lu m e c o n tr o l v a lv e .

7.

C le a n a ll p a rts th o r o u g h ly a n d rin s e .

F ig . 1 8 B - 3 6 1 O -R IN G

4 C A M R IN G

2

TH R U ST PLATE

5 O -R IN G

3

S P R IN G

6 H O U S IN G C O V E R

R e m o v a l a n d D is m a n tlin g o f V o lu m e C o n tr o l a n d P re s s u r e R e lie f V a lv e 1.

2.

K n o c k h o llo w p in fr o m t h e p u m p h o u s in g .

R e m o v e th e b la n k in g c o v e r o f t h e v o lu m e c o n tro l v a lv e a n d th e c o m p r e s s io n s p rin g fr o m t h e p u m p h o u s in g , (F ig . 1 8 B - 3 7 ) .

N o te :

C a u tio n ! T h e c o m p r e s s io n s p rin g m a y p u s h o f f th e

b la n k in g c o v e r a n d t h e v o lu m e c o n tro l v a lv e a f te r r e m o v in g th e h o llo w p in . L o o s e n th e b la n k in g c o v e r w ith lig h t h a m m e r b lo w s if it s h o u ld r e m a in in t h e h o u s in g . D o n o t d a m a g e th e v o lu m e c o n tro l v a lv e .

F ig . 1 8 B - 3 7

April '96

1 B L A N K IN G C O V E R

4

2

H O L L O W P IN

5

V O LU M E C O N TR . VALVE S P R IN G S

3

O -R IN G

6

P U M P H O U S IN G

Power Steering Pump 18B-15

3.

C la m p th e v o lu m e c o n tro l v a lv e a t Its u n g ro u n d en d in a v ic e a n d u n s c r e w th e v a lv e s c r e w o f th e p re s s u re r e lie f v a lv e . E n s u r e t h a t n o a d ju s tin g s c re w s a r e lost.

R e m o v e th e v a lv e a n d s p rin g fr o m th e v o lu m e c o n tro l v a lv e . (F ig . 1 8 B - 3 8 ) .

4.

P rio r to r e p la c e m e n t c h e c k th e g ro u n d s u rfa c e o f th e v o lu m e c o n tro l v a lv e a n d th e b o re in th e p u m p h o u s in g fo r w e a r a n d d a m a g e . If t h e s u r fa c e s a r e s h o w in g s c o re m a r k s r e p la c e th e c o m p le te oil p u m p . N e v e r r e p la c e th e v o lu m e c o n tro l v a lv e o n ly .

F ig . 1 8 B - 3 8 1 B L A N K IN G C O V E R W I T H O - R I N G 2

V O LU M E C O N TR O L VALVE

3 S P R IN G F O R P R E S S U R E R E L IE F V A L V E 4

VALVE C O N E

5 A D J U S T IN G W A S H E R 6

VALVE S C R E W

7

S P R IN G F O R V O L U M E C O N T R O L V A L V E

S p e c ia l T ool T o b e m a n u fa c tu r e d , (F ig . 1 8 B - 3 9 ) .

A

IN S T A L L A T IO N T O O L

B

IN S T A L L A T IO N T O O L

C

IN S T A L L A T IO N S L E E V E

Fig.18B-39

Power Steering Pump 18B-16

R e p l a c e m e n t o f D r i v e S h a f t a n d S e a l i n g R in g 1.

R e m o v e t h e p u m p h o u s in g a n d p re s s th e d r iv e s h a ft fr o m th e h o u s in g c o v e r. P a y a tte n tio n to th e s h e ll h a lv e s ( it e m 1 0 ), (F ig . 1 8 B - 4 0 ) .

2.

W it h a s c r e w d r iv e r lift th e o il s e a l fr o m th e h o u s in g c o v e r.

Fig . 1 8 B - 4 0 1 O - R IN G

8

2

9

P U M P H O U S IN G

3 TH R U S T PLATE

3.

O IL G U I D E P L A T E

11

D R IV E S H A F T

5

S P R IN G

12

BUSH

6

C A M R IN G

13

O IL S E A L

7

R O T O R W IT H P U M P V A N E S

14

H O U S IN G C O V E R

P la c e b o th s h e ll h a lv e s o n t h e d r iv e s h a ft, th e n p re s s th e

T h e s h e ll h a lv e s d e te r m in e t h e e n d p la y o f t h e d riv e

s h a ft w h ic h is 0 ,7 m m m a x . fo r n e w h ig h p r e s s u r e o il p u m p s a n d s h o u ld n o t b e m o r e th a n 1 m m fo r u s e d p u m p s .

R e p la c e t h e h ig h p r e s s u r e oil p u m p if t h e e n d p la y is h ig h e r.

10 S H E L L H A LF

4.

11

D R IV E S H A F T

14

H O U S IN G C O V E R

U s e t h e in s ta lla tio n to o l to p r e s s t h e b u s h in to th e h o u s in g , (F ig . 1 8 B - 4 2 )

F ig . 1 8 B - 4 2

.April '96

B E A R IN G B U S H S H ELL HALF

4

d r iv e s h a ft in to t h e h o u s in g c o v e r, (F ig . 1 8 B - 4 1 ) .

N o te :

10

O -R IN G

12

B E A R IN G B U S H

14

H O U S IN G C O V E R

B

IN S T A L L A T IO N T O O L

Power Steering Pump 18B-17

R e p la c e th e a s s e m b ly s le e v e o n th e d riv e s h a ft a n d w ith th e in s ta lla tio n to o l p re s s th e oil s e a l in to th e h o u s in g , (F ig . 1 8 B - 4 3 ) .

F ig . 1 8 B - 4 3 11

D R IV E S H A F T

C

ASSEM BLY SLEEVE

13

O IL S E A L

A

IN S T A L L A T IO N T O O L

14

H O U S IN G C O V E R

R e p la c e m e n t o f R o to r a n d C am R ing 1.

M o is te n a ll p a rts w ith A T F oil.

2.

In s ta ll v o lu m e c o n tro l v a lv e .

3.

P la c e t h e ro to r o n t h e d r iv e s h a ft so t h a t th e c o u n te r ­ s u n k e n d o f t h e s p lin e d b o re fa c e s th e h o u s in g c o v e r.

4.

P la c e t h e c a m rin g o n th e fitte d p in s so t h a t th e r e s p e c tiv e m a r k in g s o n th e h o u s in g c o v e r a n d o n th e c a m rin g a r e a lig n e d , (F ig . 1 8 B - 4 4 ) .

F ig . 1 8 B - 4 4 6

N o te :

C A M R IN G

15

F I T T E D P IN

11

D R IV E S H A F T

16

M A R K IN G L IN E

14

H O U S IN G C O V E R

W h e n a n e w c a m rin g is in s ta lle d , it m u s t b e

p o s itio n e d s o t h a t t h e h y d r a u lic o il b o re s a r e a c c u r a te ly lo c a te d a b o v e th e r e c e s s e s in t h e h o u s in g c o v e r, (ite m 4 & 5 F ig . 1 8 B - 4 5 ) .

5.

In s e r t p u m p v a n e s in to s lo ts o r ro to r so t h a t th e ro u n d e d e n d s a r e fa c in g o u tw a rd s to w a r d th e c a m rin g .

6.

P o s itio n t h e th r u s t p la te o v e r th e c a m rin g , e n s u rin g m a r k in g s a r e a lig n e d ,

N o te :

T h e o u tle t h o le s fo r th e h y d r a u lic oil s h o u ld b e a b o v e

t h e h y d r a u lic o il b o re s ( it e m 5 ) o f th e c a m rin g .

F ig 1 8 B - 4 5 A

O IL I N F L O W F R O M S U P P L Y C O N T A IN E R

B H Y D R A U L IC O IL O U T F L O W F R O M C A M R I N G ROTO R PUMP VANE H Y D R A U L IC O IL U N D E R P U M P V A N E R E C E S S O N H O U S I N G F O R IN L E T O F H Y D R . O IL IN T O B O R E

April ‘96

O IL B O R E

7

IN T A K E B O R E S

C A M R IN G

8

D R IV E S H A F T

Power Steering Pump 18B-18

R e p la c in g t h e P u m p 1.

F it th e m o u n tin g b r a c k e t to th e p u m p , in s e r t b o lts a n d tig h te n to th e s p e c ifie d to r q u e , (F ig . 1 8 B - 4 6 ) .

F ig . 1 8 B - 4 6 2.

F it t h e p u lle y to t h e p u m p , c la m p t h e p u lle y in a v ic e fitte d w ith s o ft ja w s , r e p la c e t h e re ta in in g n u t a n d tig h te n to t h e s p e c ifie d to r q u e , (F ig . 1 8 B - 4 7 ) .

mi F ig . 1 8 B - 4 7 3.

F it th e p u m p to th e m o u n tin g in t h e c y lin d e r b lo c k , in s e rt th e b o tto m r e ta in in g b o lt. D o n o t tig h te n , (F ig . 1 8 B - 4 8 ) .

III! F ig . 1 8 B - 4 8 4.

F it t h e V - b e lt to t h e p u lle y , (F ig . 1 8 B - 4 9 ) .

\ r ■im ras Fig. 18B-49

April '96

Power Steering Pump 18B-19

5.

In s e r t th e V - b e lt a d ju s te r c la m p b o lt. D o n o t tig h te n , (F ig . 1 8 B - 5 0 ) .

6.

U s e s p e c ia l to o l 4 0 2 0 2 3 2 1 a n d a d ju s t th e V -b e lt te n s io n to 4 0 - 5 0 kg (n e w b e lts ), ru n th e e n g in e fo r 1 0 - 1 5 m in . a n d r e -c h e c k t h e te n s io n , w h ic h s h o u ld b e 3 0 - 4 0 kg.

A d ju s t to 3 0 - 4 0 kg if t h is fig u r e is n o t re a c h e d .

P o s itio n t h e te n s io n g a u g e o n t h e b e lt w ith th e fla n g e p a r a lle l a g a in s t t h e b e lt e d g e . G r a d u a lly a p p ly p re s s u re to t h e p r e s s u r e p a d . W h e n a “c lic k ” is h e a r d o r fe lt, s to p a n d r e m o v e th e g a u g e . T u rn t h e g a u g e s id e w a y s a n d t a k e a r e a d in g a t t h e s p o t w h e r e th e in d ic a to r a r m in te r s e c ts t h e s c a le , (F ig . 1 8 B - 5 1 ) .

7.

T ig h t e n th e lo c k n u t o n th e V - b e lt a d ju s te r, (F ig . 1 8 B - 5 2 ) .

8.

T ig h t e n t h e c la m p b o lt o n th e V - b e lt a d ju s te r, (F ig . 1 8 B - 5 3 ) .

April '96

Power Steering Pump 18B-20 9.

T ig h te n th e b o tto m p u m p r e ta in in g b o lt, (F ig . 1 8 B - 5 4 ) .

SPECIAL T O O LS FO R SECTION 18B O B T A IN A B L E F R O M : G R U N D Y T E C H N I F O R M , B U R M A N R O A D , D E A L P A R K , P O R T E L IZ A B E T H 6 0 0 1 TEL: (0 4 1 ) 4 3 -2 2 9 9 ,

. April ‘96

FA X : (0 4 1 ) 4 3 -2 2 2 4

SECTION 18C-1 Exhaust Brake

CONTENTS OF SECTION 18C

Page I L L U S T R A T I O N ...................................................................................................................................................................................................................................1 8 C - 2 I N T R O D U C T I O N ................................................................................................................................................................................................................................ 1 8 C - 3 S P E C I F I C A T I O N S ............................................................................................................................................................................................................................. 1 8 C - 3 R E M O V I N G T H E E X H A U S T B R A K E ..................................................................................................................................................................................... 1 8 C - 4 R E P L A C I N G T H E E X H A U S T B R A K E .................................................................................................................................................................................. 1 8 C - 5 C H E C K I N G E X H A U S T B R A K E S E T T I N G ......................................................................................................................................................................... 1 8 C - 7

April '96

Exhaust Brake 18C-2

April '96

1 SHAFT A ND BUSH

7

2

EXH A U ST BRAKE VALVE

8

N U T AND BOLT NUT AND W ASHER

3

V A L V E R E T A IN IN G N U T A N D B O L T

9

O P E R A T IN G C Y L IN D E R

4

B R A C K E T R E T A IN IN G B O L T

10

E X H A U S T B R A K E IN P O S I T I O N

5

SHAFT BUSH

11

BRACKET

6

O P E R A T IN G A R M

12

EXHAUST BRAKE BO DY

Exhaust Brake 18C-3

IN T R O D U C T I O N D e p e n d in g o n a p p lic a tio n , s o m e A D E 3 6 0 s e rie s e n g in e s a r e fitte d w ith a n e x h a u s t b r a k e c o n s is tin g o f a b u tte rfly v a lv e p iv o tin g o n a s p in d le w ith in a s e p a r a te h o u s in g , s itu a te d in th e e x h a u s t s y s te m . T h e b u tte rfly v a lv e is a c tu a te d b y a p n e u m a t ic a lly o p e r a te d le v e r, w h ic h is s e c u r e d to th e b u tte rfly v a lv e s p in d le , w h e r e th e s p in d le p r o tru d e s th ro u g h th e h o u s in g .

W h e n a fo o t o p e r a te d e x h a u s t b r a k e v a lv e , lo c a te d on th e flo o r o f th e c a b (d riv e r s s id e ), is p r e s s e d , c o m p r e s s e d a ir flo w s p a s t a v a lv e a n d e n te r s a n a ir o p e r a te d c y lin d e r. A p is to n in s id e th e c y lin d e r a tta c h e d to th e v a lv e s p in d le p u s h e s th e le v e r fo rw a rd a n d th u s c lo s e s th e v a lv e . A t th e s a m e t im e th e fu e l s u p p ly to th e in je c to rs is c u t o ff (i.e . t h e s p e e d c o n tro l le v e r m o v e s to t h e s to p p o s itio n ).

T h e p r e s s u r e b u ilt-u p in th e e x h a u s t m a n ifo ld a n d c o m b u s tio n c h a m b e r s e x e rts a b r a k in g e ffe c t v ia th e tr a n s m is s io n to th e w h e e ls o f t h e v e h ic le .

T O R Q U E S P E C IF IC A T IO N S C o n tr o l le v e r c la m p b o l t .....................................

C o n tr o l le v e r s e c u r in g b o lt................................

C le a r a n c e b e tw e e n v a lv e a n d v a lv e b o d y

April '96

M 6 .............................................................. 8 ,5 N m M 1 0 ........................................................... 4 2 N m .......................................................................0 , 2 - 0 ,5

mm

Exhaust Brake 18C-4 R E M O V IN G A N D R E P L A C IN G T H E E X H A U S T B R A K E VALVE, BUSHES AN D SH AFT

R e m o v in g 1.

2.

D is c o n n e c t th e in n e r a n d o u te r c o n tro l lin k a g e .

D is c o n n e c t a n d r e m o v e t h e e x h a u s t b r a k e b o d y fr o m th e e x h a u s t d o w n p ip e .

3.

M o u n t th e e x h a u s t b r a k e b o d y in a v ic e fitte d w ith s o ft ja w s . M a r k th e lo c a tio n o f th e e x h a u s t b r a k e v a lv e to th e c o n tro l le v e r, (F ig . 1 8 C - 1 ) .

4.

R e m o v e t h e e x h a u s t b r a k e c y lin d e r b a ll jo in t re ta in in g c lip a n d le v e r o f f t h e o p e r a tin g a r m , (F ig . 1 8 C - 2 ) .

5.

R e m o v e th e c la m p b o lt fr o m t h e o p e r a tin g a r m , (F ig .

1 8 C -3 ).

6.

R e m o v e t h e o p e r a tin g a r m fr o m t h e s h a ft, (F ig . 1 8 C - 4 ) .

Fig. 18C-4

Exhaust Brake 18C-5

April '96

Exhaust Brake 18C-6

2.

In s e r t th e b o lt r e ta in in g th e b r a k e v a lv e to th e s h a ft a n d tig h te n to th e s p e c ifie d to r q u e , (F ig . 1 8 C - 9 ) .

3.

M e a s u r e t h e c le a r a n c e b e tw e e n th e h o u s in g a n d th e b r a k e v a lv e w ith a fe e le r g a u g e , r e fe r to s p e c ific a tio n .

T h e c le a r a n c e c a n b e a lt e r e d b y m o v in g th e b r a k e v a lv e s h a ft in o r o u t, (F ig . 1 8 C - 1 0 ) .

4.

L in e u p t h e m a r k s a n d r e p la c e th e c o n tro l le v e r to th e b r a k e v a lv e s h a ft, (F ig . 1 8 C - 1 1 ) .

5.

In s e r t th e c o n tro l le v e r r e ta in in g b o lt a n d tig h te n to th e s p e c ifie d to r q u e , (F ig . 1 8 C - 1 2 ) .

Exhaust Brake 18C-7

6.

R e p la c e th e e x h a u s t b r a k e c y lin d e r b a ll jo in t to th e o p e ra tin g a r m a n d in s e r t th e re ta in in g c lip , (F ig . 1 8 C - 1 3 ) .

F ig . 1 8 C - 1 3

C h e c k in g t h e E x h a u s t B ra k e S e ttin g 1.

D is c o n n e c t t h e e x h a u s t p ip e fr o m th e e x h a u s t b r a k e b o d y .

2.

E n s u r e t h a t t h e e x h a u s t b r a k e v a lv e is in t h e fu lly o p e n p o s itio n , (F ig . 1 8 C - 1 4 ) .

3.

O p e r a t e t h e e x h a u s t b r a k e a n d e n s u r e t h a t th e v a lv e fu lly c lo s e s .

F ig . 1 8 C - 1 4

A d ju stin g t h e E x h a u s t B ra k e C y lin d er L en gth 1.

R e m o v e t h e o p e r a tin g le v e r.

2.

A d ju s t t h e e x h a u s t b r a k e c y lin d e r le n g th to 1 7 0 m m fr o m th e

----------------- 170mm----------------r

n=

c e n tr e o f t h e m o u n tin g b o lt to th e c e n tr e o f th e b a ll jo in t h e a d , (F ig . 1 8 C - 1 5

F ig . 1 8 C - 1 5 3.

O p e n th e e x h a u s t b r a k e v a lv e fu lly a n d r e p la c e th e o p e ra tin g le v e r. P r e -te n s io n t h e c y lin d e r b y 2 to 4 m m a n d fit th e b a ll jo in t, (F ig . 1 8 C - 1 6 ) .

4.

In s e r t t h e b o lt in to t h e o p e r a tin g le v e r a n d tig h te n to th e s p e ­ c ifie d to rq u e .

5.

In s e r t t h e lo c k in g c lip to th e b a ll jo in t.

6.

C o n n e c t t h e e x h a u s t p ip e to t h e e x h a u s t b r a k e b o d y .

Fig. 18C-16 April '96

...

,

is

^

(aph itigioit Diesel Club

ADE 364 and ADE 366

Workshop Manual

Section 18D - Flywheel

B a rrin g to n D iesel C lu b

______________________ SECTION 18D Flywheel

CONTENTS OF SECTION 18D

Page I L L U S T R A T I O N ...................................................................................................................................................................................................................................1 8 D - 2 I N T R O D U C T I O N ................................................................................................................................................................................................................................1 8 D - 3 S P E C I F I C A T I O N S ............................................................................................................................................................................................................................. 1 8 D - 3 R E M O V I N G T H E F L Y W H E E L .....................................................................................................................................................................

1 8 D -4

R E P L A C I N G T H E F L Y W H E E L .................................................................................................................................................................................................1 8 D - 5 R E M O V I N G A N D R E P L A C I N G T H E R IN G G E A R ........................................................................................................................................................1 8 D - 6 R E M O V I N G A N D R E P L A C I N G T H E S P I G O T B E A R IN G ......................................................................................................................................... 1 8 D - 8 S P E C IA L T O O L S ................................................................................................................................................................................................................................1 8 D - 8

April '96

Flywheel 18D-2

April '96

1 S T A R T E R R IN G G E A R

4

B E A R IN G R E T A IN E R

2

FLYW HEEL

5

F L Y W H E E L R E T A IN IN G B O L T

3

S P I G O T B E A R IN G

Flywheel 18D-3 IN T R O D U C T I O N M a n u f a c t u r e d fr o m h ig h g r a d e g r e y c a s t iron th e fly w h e e l is p re c is io n m a c h in e d a n d b a la n c e d rin g g e a r

to fin e lim its

T h e s ta rte r

is h e a t tr e a t e d a n d s h ru n k o n to th e fly w h e e l. E ig h t s tre tc h b o lts re ta in th e fly w h e e l to th e c r a n k s h a ft

W hen

re m o v in g it is n o t n e c e s s a r y to m a r k th e r e la tiv e p o s itio n o f th e fly w h e e l a s th e e ig h t b o lt h o le s a r e d rille d e c c e n tric a lly , m a k in g in c o r re c t fittin g im p o s s ib le .

T h e fly w h e e l is t h e s to r e h o u s e o f e n e r g y a n d is re q u ire d to a.

p r o v id e e n e r g y fo r o p e r a tin g th e e n g in e b e tw e e n p o w e r s tro k e s , a n d

b. to r e d u c e t h e v a r ia tio n in th e r o ta tio n a l s p e e d o f th e c r a n k s h a ft d u rin g th e e n g in e c y c le a s it tr a n s m its p o w e r to th e d riv e n m a c h in e .

S P E C IF IC A T IO N S

FLYW HEEL D ia m e t e r fo r s t a r t e r rin g g e a r

3 3 5 , 3 9 0 to 3 3 5 ,5 3 0

D ia m e t e r fo r m o u n tin g c r a n k s h a ft fla n g e

1 3 0 , 0 0 0 to 1 3 0 ,0 4 0

A x ia l r u n -o u t c r a n k s h a ft fla n g e

0 ,1

F ly w h e e l r u n -o u t m o u n te d to c r a n k s h a ft

ra d ia l

0 ,1

la te r a l

0 ,1

Im b a la n c e o f fly w h e e l w ith rin g g e a r

2 0 gem

M a x im u m c lu tc h s u r f a c e m a te r ia l r e m o v a l

2 mm

C lu tc h s u r f a c e fin is h

R z 1 6 |jm

S T A R T E R R IN G G E A R ID o f rin g g e a r

3 3 4 , 6 9 0 to 3 3 4 , 8 3 0

R in g g e a r in te r fe r e n c e fit

0 , 5 6 to 0 ,8 4

L a te r a l r u n - o u t o f m o u n te d s ta r te r rin g g e a r

0 ,5 m m m a x .

S ta r te r rin g g e a r m o u n te d a t a te m p e r a t u r e o f

2 5 0 ° to 2 8 0 °

T O R Q U E S P E C IF IC A T IO N S F ly w h e e l to c r a n k s h a f t

M 1 2 x 1 ,5 ... In itia l..............................

90°-110°

B o lt le n g th 2 5 , 8 m m .................................................................. M a x .

s tre tc h le n g th

2 6 .3 m m

o r B o lt le n g th 4 3 , 8 m m ............................................................ M a x .

s tre tc h le n g th

4 4 .3 m m

B e ll h o u s in g t o r q u e .......................................................................................................................................................

April '96

30 - 40 Nm

................................................................................................................F i n a l ................................

110 Nm

Flywheel 18D-4

REMOVAL AND REPLACEM ENT O F F L Y W H E E L A N D H O U S IN G R em oval 1.

U n s c r e w a n d r e m o v e th e b o lts re ta in in g th e fly w h e e l, (F ig . 1 8 D - 1 ).

Fig . 1 8 D -1

2.

L ift o ff t h e fly w h e e l, (F ig . 1 8 D - 2 ) .

F ig . 1 8 D - 2 3.

U n s c r e w t h e fo u r b o lts r e ta in in g t h e fly w h e e l h o u s in g to th e c y lin d e r b lo c k , (F ig . 1 8 D - 3 ) .

F ig . 1 8 D - 3 4.

U n s c r e w t h e tw o o u te r b o lts , (F ig . 1 8 D - 4 ) .

Fig. 18D-4

. April '96

Flywheel 18D-5 5.

L ift o ff th e h o u s in g , (F ig . 1 8 D - 5 ).

F ig . 1 8 D - 5

R e p la c e m e n t 1.

F it t h e fly w h e e l h o u s in g to t h e c y lin d e r b lo c k . R e p la c e a n d tig h te n th e o u te r b o lts , F ig . 1 8 D - 6 ) .

F ig . 1 8 D - 6 2.

In s e r t t h e fo u r in n e r b o lts , (F ig . 1 8 D - 7 ) .

F ig . 1 8 D - 7 3.

In s e r t th e tw o to p b o lts a n d tig h te n a ll b o lts to th e s p e c ifie d to rq u e , (F ig . 1 8 D - 8 ) .

Fig. 18D-8

April '96

Flywheel 18D-6

4.

R e p la c e th e fly w h e e l, in s e r t th e b o lts a n d tig h te n to th e s p e c ifie d to rq u e , (F ig . 1 8 D - 9 ) .

F ig . 1 8 D - 9 REMOVAL AND REPLACEM ENT OF S T A R T E R R IN G G E A R Rem oval 1.

R e m o v e t h e fly w h e e l, (F ig . 1 8 D - 1 0 ) .

F ig . 1 8 D - 1 0 2.

P u n c h m a r k th e rin g g e a r a n d d rill tw o h o le s in to th e s id e o f th e g e a r . D o n o t d rill th r o u g h t h e rin g g e a r a s th is w ill d a m a g e th e fly w h e e l, (F ig . 1 8 D - 1 1 ) .

F'<r I 8 D - I I 3.

W it h a s h a r p c h is e l s p lit t h e rin g g e a r b e tw e e n th e d rille d h o le s a n d r e m o v e t h e g e a r fr o m th e fly w h e e l, (F ig . 1 8 D - 1 2 ) .

A t t e n t i o n ! T h o r o u g h ly c le a n t h e fly w h e e l a n d fla n g e p rio r to re p la c in g .

Fig. 18D-12

April '96

Flywheel 18D-7

R e p la c in g 1.

2.

P la c e t h e fly w h e e l o n a fla t s u rfa c e .

H e a t th e n e w rin g g e a r to a p p r o x im a te ly 2 5 0 ° C w ith a w e ld in g to rc h o r o th e r s u ita b le h e a t s o u rc e ,

(fig . 1 8 D - 1 3 ) .

F ig . 1 8 D - 1 3 3.

P la c e th e h e a te d rin g o n to t h e fly w h e e l, (F ig . 1 8 D - 1 4 ) .

F ig . 1 8 D - 1 4 4.

If n e c e s s a r y u s e a c o p p e r o r a lu m in iu m h a m m e r to fu lly lo c a te th e rin g g e a r o n th e fly w h e e l s o t h a t it s e a ts a g a in s t th e f la n g e s h o u ld e r , (F ig . 1 8 D - 1 5 ) .

F ig . 1 8 D - 1 5 5.

R e p la c e t h e fly w h e e l a n d tig h te n th e b o lts to th e s p e c ifie d to r q u e , (F ig . 1 8 D - 1 6 ) .

Fig. 18D-16

April ‘96

Flywheel 18D-8

R E M O V IN G A N D R E P L A C IN G T H E S P IG O T B E A R IN G T h e fly w h e e l s p ig o t b e a r in g c a n b e e x tra c te d w ith th e fly w h e e l in p o s itio n o r r e m o v e d fr o m t h e e n g in e .

1.

W ith s p e c ia l to o l 4 0 2 0 0 3 8 1 pu ll th e s p ig o t b e a r in g fr o m th e h o u s in g , (F ig . 1 8 D - 1 7 ) .

2.

In s e r t th e b e a r in g in to t h e h o u s in g a n d d r iv e in to p la c e w ith a s u ita b le d rift, (F ig . 1 8 D - 1 8 ) .

A tte n tio n !

T h e s p ig o t b e a r in g is s e a le d a n d d o e s n o t

r e q u ire g r e a s in g .

S P E C IA L T O O L S F O R S E C T IO N 1 8 D O B T A IN A B L E F R O M : G R U N D Y T E C H N I F O R M , B U R M A N R O A D , D E A L P A R K , P O R T E L IZ A B E T H 6 0 0 1 TEL: (0 4 1 ) 4 3 -2 2 9 9 ,

April ‘96

FA X : (0 4 1 ) 4 3 -2 2 2 4

SECTION 18E-1 Alternator and Starter Motor

CONTENTS OF SECTION 18E

Page I N T R O D U C T I O N ................................................................................................................................................................................................................................ 1 8 E - 2 T O R Q U E S P E C I F I C A T I O N S ..................................................................................................................................................................................................... 1 8 E - 2 ALTERNATO R

- S E C T I O N A L V I E W ..................................................................................................................................................................................... 1 8 -3

P R E C A U T I O N S ................................................................................................................................................................................................................................... 1 8 E - 4 M A I N T E N A N C E ................................................................................................................................................................................................................................... 1 8 E - 4 T E S T I N G T H E A L T E R N A T O R IN P O S I T I O N .................................................................................................................................................................. 1 8 E - 4 T R O U B L E S H O O T I N G ...................................................................................................................................................................................................................1 8 E - 4 STARTER M OTOR G E N E R A L ............................................................................................................................................................................................................................................... 1 8 E - 5 R O U T I N E M A I N T E N A N C E ..........................................................................................................................................................................................................1 8 E - 5 S E R V IC IN G

April '96

- T E S T I N G IN P O S I T I O N ..............................................................................................................................................................................1 8 E - 6

Alternator and Starter Motor 18E-2

INTRODUCTION

A ltern ator A lte r n a to r s u s e d o n th e 3 6 0 s e rie s e n g in e s a r e o f th e c la w p o le ty p e w h ic h ra n g e fr o m 1 4 V - 5 5 A to 1 4 V - 9 0 A a n d 2 8 V - 2 8 A to 2 8 V - 5 5 A . T h e s e a lt e r n a t o r s a r e fitte d w ith e ith e r o n e o r tw o d riv e p u lle y s , d e p e n d in g o n a p p lic a tio n .

S ta rter M otor S ta r te r m o to r s fitte d to t h e 3 6 0 s e rie s e n g in e s a r e o f th e fo u r p o le , fo u r b ru s h e a rth re tu rn ty p e w ith s e rie s p a ra lle l c o n n e c te d fie ld c o ils . T h e s e s t a r t e r m o to rs r a n g e fr o m 1 2 V - 3 k W to 1 2 V - 3 ,5 k W a n d 2 4 V ~ 4 k W to 2 4 V - 4 , 5 k W o n a p p lic a tio n .

TORQUE SPECIFICATIO NS ALTERNATOR AND STAR TER MOTOR S ta r te r to fly w h e e l h o u s in g ........

. M 1 0 ............................................................ 6 0 N m

A lte r n a to r to b r a c k e t .....................

, M 1 2 x 1 , 5 ...............................................6 0 N m

A d ju s tin g b o lt to c y lin d e r b lo c k

. M 1 0 ............................................................ 4 0 N m

A d ju s tin g b o lt c l a m p .....................

. M 1 2 ............................................................ 3 5 N m

P u lle y to a lt e r n a t o r .........................

. M 1 4 x 1 , 5 ...............................................6 0 N m

P u lle y to a lt e r n a t o r .........................

. M 1 6 x 1 , 5 ............................................... 8 0 N m

April ‘96

d e p e n d in g

Alternator and Starter Motor 18E-3

S E C T IO N A L V IE W O F T H E

April '96

K 1 C L A W -P O L E A L T E R N A T O R

Alternator and Starter Motor 18E-4 ALTERNATO R

P r e c a u tio n s T h e d io d e s in th e a lt e r n a t o r fu n c tio n a s o n e -w a y v a lv e s .

a.

In s p e c t th e V -b e lts r e g u la r ly

fo r w e a r a n d

c o rr e c t te n ­

sio n . It is im p o rta n t to e n s u r e th a t all V -b e lts o n a m u l­

T h e tr a n s is to r s in th e r e g u la to r /c o n tr o l b o x o p e r a te a s fa s t

tip le

s w itc h e s . B o th a r e a c c u r a te a n d s e n s itiv e .

d riv e

have

th e ir s h a r e

of

e q u a l te n s io n

a n d a r e e a c h c a rry in g

th e lo a d . S la c k d r iv e b e lts w ill w e a r r a ­

T h e y d o n o t w e a r o u t a n d s e ld o m r e q u ire a d ju s tm e n t, b u t

p id ly a n d

b e c a u s e th e y a r e s e n s itiv e to v o lta g e c h a n g e s a n d high

a t th e re q u ire d s p e e d .

c a u s e s lip

w h ic h w ill n o t d riv e th e a lte r n a to r

te m p e r a tu r e th e fo llo w in g p r e c a u tio n s a r e v ita l to p re v e n t

p o s e s e v e r e s id e th ru s t on

th e m fr o m b e in g d e s tro y e d :

s h o rte n th e ir life. E n s u r e p e rio d ic a lly t h a t th e a lte r n a to r

V -b e lts

w h ic h a r e to o tig h t im ­

th e a lt e r n a t o r b e a r in g s a n d

is c o rre c tly a lig n e d to th e d riv e . a.

DO

NOT

ru n n in g .

d is c o n n e c t th e

b a tte r y w h ile th e

e n g in e is

T h is w ill c a u s e a v o lta g e s u rg e in th e a lt e r n a ­

to r c h a r g in g

s y s te m

w h ic h

w ill

b.

im m e d ia t e ly ru in th e

DO NO T

d is c o n n e c t th e le a d w ith o u t firs t s to p p in g th e

e n g in e a n d

tu rn in g

a ll

e le c tr ic a l

s w itc h e s

to

c.

DO NOT

s e t o f V -b e lts m u s t a l­

K e e p th e a lt e r n a t o r c le a n flu id .

w ith a c lo th m o is te n e d w ith a E n s u re

th a t

v e n tila tio n

slo ts

a n d a ir s p a c e s a r e c le a r a n d u n o b s tr u c te d .

c a u s e a s h o r t c irc u it b y c o n n e c tin g A lw a y s

c o rr e c t t e r m in a l.

s h o r t c irc u it o r w r o n g c o n n e c tio n

re v e rs e

A

p o la r ity w ill

fir s t id e n tify

le a d s to

in c o rre c t te r m in a ls . g iv in g

m a tc h e d

A c o m p le te

s u ita b le c le a n in g

th e o ff

p o s itio n . c.

V -b e lts in d iv id u a lly in a m u lti b e lt

s y s te m .

w a y s be used.

d io d e s o r tr a n s is to r s . b.

D o n o t r e p la c e fa u lty

im m e d ia t e ly

a le a d to its and

d.

R e m o v e a n y d irt a c c u m u la te d b o x h o u s in g .

E n s u re

th a t

on

th e r e g u la to r/c o n tr o l

c o o lin g

a ir c a n p a s s fre e ly

o v e r th e c a s in g .

p e rm a ­

n e n tly ru in tr a n s is t o r s o r d io d e s .

T e stin g th e a ltern a to r in p o s itio n d.

DO NOT

c o n n e c t a b a tte r y to th e s y s te m w ith o u t p rio r F irs t c h e c k th e

c h e c k in g fo r c o r r e c t p o la r ity a n d v o lta g e .

V -b e lts

fo r c o n d itio n

and

te n s io n .

The

n o m in a l h o t o u tp u ts a t 6 0 0 0 r /m in ( a lte r n a to r s p e e d ) a r e e.

DO NOT No

“fla s h " c o n n e c tio n s to c h e c k fo r c u rr e n t flo w .

m a tte r h o w

b r ie f t h e c o n ta c t,

a s fo llo w s :

th e tr a n s is to r s m a y

14V

-

35A

28V

-

28A

b e r u in e d .

M a in ten a n ce These T h e a lt e r n a t o r c h a r g in g s y s te m w ill n o r m a lly r e q u ire v e ry little a tte n tio n ,

b u t it s h o u ld

b e k e p t fr e e fr o m

fig u re s

m ay

be

exceeded

s lig h tly

w hen

th e

a lte r n a to r is ru n n in g co ld .

d irt a n d

c h e c k s s h o u ld b e m a d e if th e a lt e r n a t o r fa ils to k e e p th e

A d u s t p r o o fe d a lt e r n a t o r c a n b e fitte d a s a n o p tio n ,

b a tte ry c h a r g e d .

d e p e n d in g o n a p p lic a tio n .

T ro u b le S h o o tin g If a m a lfu n c tio n s h o u ld d e v e lo p in t h e c u rr e n t g e n e r a tin g s y s te m it m u s t b e k e p t in m in d t h a t tr o u b le s o u r c e s m a y e x is t in th e b a tte ry , c a b le s o r o t h e r lo c a tio n s b e s id e s th e a lte r n a t o r o r re g u la to r. T h e m o s t c o m m o n fa u lt s y m p to m s a r e lis te d in th e c h a r t b e lo w w ith p r o b a b le c a u s e s a n d a p p r o p r ia te c o rr e c tiv e m e a s u re s :

P r o b lem - C a u s e B a ttery is d e a d o r in s u ffic ie n tly c h a r g e d ;

C o rrectio n R e c h a r g e b a tte ry

1. O p e n c ir c u it o r c o n ta c t r e s is ta n c e in c h a r g in g c irc u it

R e m o v e o p e n c irc u it o r c o n ta c t r e s is ta n c e

2.

D e fe c tiv e b a tte r y

R e p la c e b a tte ry

3.

D e fe c tiv e a lt e r n a t o r

H a v e a lt e r n a t o r r e p a ire d in a u th o r is e d w o rk s h o p

4.

D e fe c tiv e r e g u la to r

R e p la c e r e g u la to r

5.

V - b e lt lo o s e

T ig h te n V -b e lt

April '96

Alternator and Starter Motor 18E-5 P r o b le m - C a u s e ________________________________________

Correction

C h a rg e in d ic a to r la m p d o e s n o t burn w ith th e e n g in e s t o p p e d an d t h e ig n itio n o n .

1.

In d ic a to r b u lb is b u rn e d o u t

R e p la c e w ith a n e w b u lb

2.

D e a d b a tte ry

C h a r g e b a tte ry

3.

D e fe c tiv e b a tte ry

R e p la c e b a tte ry

4.

L o o s e o r d a m a g e d c a b le s

R e p la c e o f tig h te n c a b le s

5.

D e fe c tiv e r e g u la to r

R e p la c e re g u la to r

6.

S h o r te d p o s itiv e d io d e in th e a lte r n a to r

H a v e a lte r n a to r r e p a ire d b y a u th o ris e d w o rk s h o p

7.

W o r n c a rb o n b r u s h e s

R e p la c e b ru s h e s

O x id e la y e r o n s lip rin g s o r b ro k e n w ir e in ro to r

H a v e a lte r n a to r r e p a ire d

8.

w in d in g

C h a rg e in d ic a to r la m p c o n t in u e s t o burn b righ tly d u rin g h ig h e r e n g in e s p e e d s 1.

C a b le D + /6 1 is s h o r te d to g ro u n d

R e p a ir o r r e p la c e c a b le

2.

D e fe c tiv e r e g u la to r

R e p la c e r e g u la to r

3.

O v e r v o lta g e p r o te c tio n d e v ic e d e fe c tiv e

R e p la c e o v e r v o lta g e p ro te c tio n d e v ic e

4.

D e fe c tiv e re c tifie r, d irty s lip rin g s , s h o rt in c a b le “D F ”

H a v e a lte r n a to r r e p a ire d b y a u th o ris e d w o rk s h o p

o r in ro to r w in d in g

C h a rg e in d ic a to r la m p b u rn s b rig h tly w ith e n g in e s t o p p e d , b u t o n ly d im s o r g lim m e r s w ith e n g in e ru n n in g: 1.

R e m o v e c o n ta c t r e s is ta n c e

P o o r c o n n e c tio n s (c o n t a c t r e s is ta n c e ) in th e c h a r ­ g in g c irc u it o r in t h e c a b le to th e c h a r g e in d ic a to r la m p

2.

D e fe c tiv e r e g u la to r

R e p la c e r e g u la to r

3.

D e fe c tiv e a lte r n a t o r

H a v e a lte r n a to r r e p a ire d

C h a r g e in d ic a to r la m p flic k e r s 1.

R e p la c e r e g u la to r

C o n ta c t r e g u la to r m a y b e in c o r re c tly a d ju s te d o r r e g u la tin g r e s is to r is b u rn e d o u t

STARTER MOTOR c.

G en era l

S e lf-in d e x in g

p in io n to

b e tw e e n th e

p in io n

e n s u re

s m o o th

engagem ent

a n d t h e rin g g e a r te e th b e fo re th e

s ta rte r m o to r b e g in s to ro ta te .

T h is s t a r t e r m o to r is a fo u r p o le , fo u r b ru s h e a rth re tu rn d.

m a c h in e w ith s e rie s p a r a lle l c o n n e c te d fie ld co ils.

A r m a t u r e b ra k in g s y s te m to e n s u r e r a p id re tu rn to re s t w h e n th e s ta rte r b u tto n is re le a s e d .

A

s o le n o id

o p e r a te d

p re -e n g a g e d

d riv e

a s s e m b ly

is

c a rr ie d o n a n e x te n s io n o f th e a r m a tu r e s h a ft. T h e m a in f e a tu r e s o f t h is ty p e o f d r iv e a r e a s fo llo w s : a.

P o s itiv e

p in io n

e n g a g e m e n t p re v e n tin g th e p in io n b e ­

Routine Maintenance

in g th r o w n o u t o f m e s h w h ile s ta rtin g . a. b.

An

o v e r ru n n in g

c lu tc h

is in c o r p o ra te d in th e d riv e a s ­

s e m b ly g iv in g o v e r s p e e d a n d o v e r lo a d p ro te c tio n .

The

s ta rte r m o to r re q u ire s n o r o u tin e m a in t e n a n c e b e ­

y o n d th e

o c c a s io n a l

b e c le a n a n d tig h t.

April ‘96

in s p e c tio n

n e c tio n s , b ru s h g e a r a n d

o f th e e le c tr ic a l c o n ­

th e c o m m u t a to r , w h ic h m u s t

Alternator and Starter Motor 18E-6

b.

A fte r th e

s ta r te r m o to r h a s

been

in s e rv ic e fo r s o m e

tim e , r e m o v e th e s ta r te r m o to r fr o m th e e n g in e , s u b m it

m in a ls b e fo re p ro c e e d in g . O p e r a te th e s ta rte r c o n tro l a n d w a tc h fo r th e fo llo w in g s y m p to m s :

it to a th o r o u g h b e n c h in s p e c tio n .

1.

The

la m p s

d im

a b o u t 6 v o its ) 1.

B ru s h

w e a r (th is

w o rk d o n e ),

is a

re n e w

fa ir in d ic a tio n o f th e a m o u n t o f

b ru s h e s

w o rn

to

or

(o r th e v o ltm e te r

r e a d in g

d ro p s to

a n d th e m o to r d o e s n o t tu rn th e e n g in e .

C h e c k th e b a tte ry (m u s t b e a t le a s t h a lf-c h a r g e d ) a n d

a p p r o a c h in g

b a tte ry p o s ts (c le a n a n d g o o d e a r th c o n n e c tio n )

7 ,9 m m le n g th .

2.

2.

B ru s h s p rin g te n s io n :

C o r r e c t te n s io n is 0 ,8 5 - 1 ,1 3 N ,

Lam ps

do

n o t d im ,

th e

s te a d y a t a b o u t 1 2 v o lts ,

r e n e w s p rin g s if te n s io n h a s d r o p p e d b e lo w 0 , 7 1 N.

th e e n g in e .

Connect

v o ltm e te r and

re a d in g

v o ltm e te r

b e tw e e n s o le n o id te r ­

m in a l a n d s ta rte r y o k e , th e n o p e r a te s ta rte r.

3.

S k im c o m m u t a t o r if it is p itte d o r b a d ly w o rn .

4.

C heck

b e a r in g s

fo r e x c e s s iv e

s id e p la y

on a r m a tu r e

in d ic a te d

C a u ses:

s h a ft.

5.

C h e c k p in io n m o v e m e n t.

6.

C le a n a n d lu b r ic a t e p in io n s le e v e b e a rin g .

7.

C le a n a n d lu b r ic a te d r iv e e n d b r a c k e t b u s h .

a.

P o o r p o s t c o n n e c tio n a t b a tte ry .

b.

B a d e a rth c o n n e c tio n .

c.

B ro k e n s ta rte r le a d , b a tte ry to s ta r te r

F u ll v o lts , i.e . 1 2 /1 4 v o lts in d ic a te d :

S e r v ic in g - T e s tin g in P o s it io n - S y m p t o m s

a.

F a u lty s o le n o id s w itc h .

S w itc h o n th e lig h ts .

b.

O p e n c irc u it in s t a r te r - c h e c k b ru s h e s ,

If th e v e h ic le is n o t e q u ip p e d w ith

lig h tin g c o n n e c t a 0 / 2 0 v o ltm e te r a c r o s s th e b a tte r y te r -

C u t-a w a y v ie w o f p re e n g a g e d d riv e sta r tin g m o to r w ith o u te r -w e d g e roller ty p e o v err u n n in g c lu tc h .

April '96

r e m a in s

th e m o to r d o e s n o t tu rn No

v o lts

Diesel Club

ADE 364 and ADE 366

Workshop Manual Section 18 F - Compressor and Vacuum Pump

B a rrin g to n D iesel C h ib

SECTION 18F-1 Compressor/Vacuum Pump

CONTENTS OF SECTION 18F

Page IL L U S T R A T IO N - C A M S H A F T D R IV E N C O M P R E S S O R ..........................................................................................................................................1 8 F - 2 I N T R O D U C T I O N ................................................................................................................................................................................................................................ 1 8 F -3 S P E C I F I C A T I O N S ............................................................................................................................................................................................................................. 1 8 F - 3 T O R Q U E S P E C I F I C A T I O N S ......................................................................................................................................................................................................1 8 F - 4 M E A S U R IN G T H E B E A R IN G C L E A R A N C E ..................................................................................................................................................................... 1 8 F - 5 D IS M A N T L IN G T H E C Y L IN D E R H E A D ................................................................................................................................................................................1 8 F -7 R E - A S S E M B L Y O F T H E C Y L IN D E R H E A D ..................................................................................................................................................................... 1 8 F - 8 S P E C IA L T O O L S F O R T H I S S E C T I O N .............................................................................................................................................................................. 1 8 F - 9 B E L T - D R I V E N C O M P R E S S O R ............................................................................................................................................................................................. 1 8 F - 1 0 B E L T D R IV E N C O M P R E S S O R - D I S A S S E M B L Y .................................................................................................................................................... 1 8 F -1 1 B E L T D R I V E N C O M P R E S S O R - A S S E M B L Y ............................................................................................................................................................. 1 8 F -1 3 S P E C IA L T O O L S ............................................................................................................................................................................................................................. 1 8 F - 1 7

April '96

Compressor/Vacuum Pump 18F-2 (C a m sh a ft d riv en )

N o te :

W h e n b e lt d riv e n c o m p re s s o rs a r e u s e d th e oil h o le in th e lo b e o f th e c a m s h a ft, u s e d fo r d riv in g th e c o m p re s s o r, is c lo s e d w ith a J u b ile e c la m p . T o p re v e n t oil lo ss d u rin g e n g in e r e -c o n d itio n in g e n s u re th a t th e c la m p is in p o s itio n .

AIR COMPRESSOR 1 C Y L IN D E R B A R R E L

12

P IS T O N

2

B E A R IN G S H E L L

13

S C R A P E R R IN G P IS T O N R IN G

3

B E A R IN G S H E L L

14

4

C O N N E C T IN G R O D

15 V A LV E

5

C O N N E C T IN G R O D B O L T

16

VALVE

6

NUT

17

GASKET

7

BO LT

18

S E A L IN G W A S H E R

8

C IR C L IP

19

IN L E T P IP E

G U D G E O N P IN

20

U N IO N

10

P IS T O N R IN G

21

S E A L IN G W A S H E R

11

SM ALL EN D BUSH

22

C Y L IN D E R H E A D

.9

April ‘96

Compressor/Vacuum Pump 18F-3

IN T R O D U C T I O N A ir c o m p r e s s o r s a r e u s e d in v e h ic le s y s te m s to p ro v id e c o m p re s s e d a ir u s e d fo r b r a k in g a n d th e o p e r a tio n o f a n c illa ry air e q u ip m e n t. T h e s e c o m p r e s s o r s h a v e a s in g le r e c ip ro c a tin g p is to n a n d a r e a ir c o o le d . T h e c o m p r e s s o r s h a v e a o n e -p ie c e c y lin d e r h e a d , w ith th e in le t v a lv e p a rts s c re w e d in to th e h e a d a n d th e d e liv e ry v a lv e s r e ta in e d b y a lo c k n u t. T h e p isto n ru n s in a r e p la c e a b le c y lin d e r b a rr e l w h ic h is m o u n te d d ire c tly o n to th e e n g in e c r a n k c a s e a n d s e a le d w ith a g a s k e t a t th e c y lin d e r h e a d .

D u r in g th e d o w n s tro k e o f th e p is to n a p a rtia l v a c u u m is c r e a te d a b o v e th e p is to n , w h ic h u n s e a ts th e in le t v a lv e a llo w in g a ir to e n te r t h e c y lin d e r a b o v e th e p is to n . O n th e u p s tro k e , th e a ir p r e s s u r e u n d e r th e v a lv e , p lu s th e e ffo rt o f th e in let v a lv e s p rin g c lo s e s th e in le t v a lv e a n d th e n o p e n s th e d e liv e ry v a lv e , th e a ir u n d e r c o m p re s s io n is th e n d is c h a rg e d into a re s e rv o ir. A t t h e s ta rt o f t h e d o w n s tro k e th e d e liv e ry v a lv e c lo s e s a n d th e c y c le is r e p e a te d . T h e c o m p r e s s o r fe e d s a ir into a r e s e r v o ir fitte d w ith a n u n lo a d e r v a lv e to m a in ta in c o n s ta n t p re s s u re .

T h e a ir c o m p r e s s o r a s s e m b ly c a n b e c h a n g e d to a v a c u u m p u m p b y s im p ly tu rn in g th e c y lin d e r h e a d .

A IR C O M P R E S S O R /V A C U U M P U M P C y lin d e r ........................................................................................................................................................................................ 1 B o r e .................................................................................................................................................................................................9 4 m m S t r o k e ............................................................................................................................................................................................ 3 0 m m D is p la c e m e n t ............................................................................................................................................................................ 2 0 8 c m 3 B o r e d i a m e t e r .......................................................................................................................................................................... 9 3 , 9 8 5 - 9 4 , 0 1 5 m m P is to n d i a m e t e r ........................................................................................................................................................................9 3 , 8 5 0 - 9 3 , 8 8 0 m m P is to n c le a r a n c e .....................................................................................................................................................................0 ,0 6 8 - 0 , 0 9 2 m m P is to n p r o tr u s io n .....................................................................................................................................................................0 ,2 5 0 - 0 , 7 0 0 m m G u d g e o n p in

d ia m e t e r ................................................................................................................................. 1 6 ,0 1 2 - 1 6 , 0 1 5 m m B o r e in p is to n ....................................................................................................................1 6 ,0 1 8 - 1 6 ,0 2 2 m m C le a r a n c e in p is to n ........................................................................................................ + 0 ,0 0 3 to + 0 , 0 1 0 m m C le a r a n c e in s m a ll e n d b u s h ....................................................................................0 ,0 1 0 - 0 , 0 2 3 m m

C o n n e c tin g ro d

B ig e n d b a s ic b o r e ........................................................................................................... 3 5 , 0 0 0 - 3 5 , 0 1 6 m m S m a ll e n d b a s ic b o r e ....................................................................................................1 9 ,0 0 0 - 1 9 ,0 2 1 m m S m a ll e n d b u s h o u te r d ia ........................................................................................... 1 9 ,0 3 5 - 1 9 ,0 4 8 m m S m a ll e n d b u s h in n e r d i a ...........................................................................................1 6 ,0 2 5 - 1 6 ,0 3 5 m m S m a ll e n d b u s h in te r fe r e n c e f i t ............................................................................. 0 ,0 1 4 - 0 , 0 4 8 m m B ig e n d b e a r in g c le a r a n c e

r a d ia i.........................................................0 ,0 2 0 - 0 , 0 6 6 m m a x i a l ......................................................... 0 ,0 6 5 - 0 , 3 1 7 m m

W id t h o f s m a ll e n d ........................................................................................................ 2 7 , 8 8 3 - 2 7 , 9 3 5 m m W id t h o f b ig e n d ..............................................................................................................2 7 , 8 8 3 - 2 7 , 9 3 5 m m L e n g th o f c o n n e c tin g ro d (c e n tr e to c e n t r e ) ....................................................9 6 , 9 5 0 - 9 7 , 0 0 0 m m B ig e n d b e a r in g /s m a ll e n d b u s h , p a ra lle l w ith in .............................................0 ,0 1 m m P is to n rin g s ( a ll)

G a p ........................................................................................................................................... 0 ,2 5 - 0 ,4 0 m m S id e c l e a r a n c e ................................................................................................................ 0 , 0 2 0 - 0 , 0 5 5 m m

April '96

Compressor/Vacuum Pump 18F-4

C O N N E C T I N G R O D B E A R I N G A N D C R A N K P IN D IA M E T E R S C a m s h a f t j o u r n a l d ia .

B e a r in g i n n e r d i a .

S ta n d a r d

3 1 ,9 8 4 to 3 2 ,0 0 0

3 2 ,0 2 0 to 3 2 ,0 5 0

S ta n d a r d 1 ( - 0 , 1 )

3 1 ,8 8 4 to 3 1 ,9 0 0

3 1 , 9 2 0 to 3 1 ,9 5 0

R e p a ir s t a g e 1 ( - 0 , 2 5 )

3 1 ,7 3 4 to 3 1 ,7 5 0

3 1 , 7 7 0 to 3 1 ,8 0 0

R e p a ir s t a g e 2 ( - 0 ,5 )

3 1 ,4 8 4 to 3 1 ,5 0 0

3 1 , 5 2 0 to 3 1 ,5 5 0

R e p a ir s t a g e 3 ( - 0 ,7 5

3 1 ,2 3 4 to 3 1 ,2 5 0

3 1 , 2 7 0 to 3 1 ,3 0 0

S ta g e s

C A P A C IT Y .D e liv e r y a g a in s t.

A ir c o m p r e s s o r a t 2 8 0 0 r /m in .

100 kPa

-

1 4 0 £ /m in

810 kPa

-

1 3 0 ¿ /m in

810 kPa

M a x im u m o p e r a tin g p r e s s u r e ..

VACUUM PUMP

T a n k c a p a c ity

E n g in e s p e e d

T im e (s e c )

V a c u u m (m m H g )

61

6 0 0 r /m in

30

625

2 8 0 0 r /m in

30

700

6 0 0 r /m in

30

450

2 8 0 0 r/m in

30

675

201

T O R Q U E S P E C IF IC A T IO N S A IR C O M P R E S S O R /V A C U U M P U M P C a p to c o n n e c tin g r o d ................................................................................................. M 6 ................................................................. 1 5 N m E x h a u s t v a lv e to c y lin d e r h e a d .............................................................................. M 6 ................................................................. 1 0 N m In le t v a lv e to c y lin d e r h e a d ....................................................................................... M 4 0 x 1 , 5 ................................................. 1 8 0 N m C y lin d e r h e a d b a rr e l to c r a n k c a s e .......................................................................M 8 ................................................................. 3 5 N m

B E L T -D R IV E N C O M P R E S S O R C y lin d e r lin e r to c r a n k c a s e .............................................................................................................................................................. 2 2 N m C y lin d e r h e a d to c y lin d e r lin e r ....................................................................................................................................................... 3 0 N m P u lle y n u t ....................................................................................................................................................................................................1 0 0 N m

April ‘96

Compressor/Vacuum Pump 18F-5 M e a s u r in g b e a r in g c le a r a n c e s A tte n tio n !

S e e p a g e 1 5 - 8 fo r r e m o v a l o f th e c o m p re s s o r fro m

th e e n g in e 1.

C la m p th e c o n n e c tin g ro d in a v ic e fitte d w ith s o ft ja w s a n d r e m o v e t h e b e a r in g c a p , (F ig . 1 8 F - 1 ) .

F ig . 1 8 F -1 2.

R e m o v e t h e b e a r in g s h e lls fr o m th e c o n n e c tin g rod a n d c a p , (F ig . 1 8 F - 2 ) .

3.

F it th e b e a r in g c a p to th e c o n n e c tin g ro d , in s e rt th e b o lts a n d tig h te n to th e s p e c ifie d to rq u e , (F ig . 1 8 F - 3 ) .

4.

S e t a n in te r n a l m e a s u r in g in s tr u m e n t, (F ig . 1 8 F - 4 ) .

April ‘96

Compressor/Vacuum Pump 18F-6

5.

M e a s u r e th e b ig -e n d b a s ic b o re in th e v e rtic a l p o s itio n , (F ig . 1 8 F - 5 ) .

F ig . 1 8 F - 5

6.

M e a s u r e th e b o r e o f t h e c o n n e c tin g ro d s m a ll e n d b u sh , (F ig . 1 8 F - 6 ) .

Fi.q. 1 8 F - 6 7.

U n s c r e w t h e b e a r in g b o lts a n d r e m o v e th e b ig -e n d b e a rin g c a p , (F ig . 1 8 F - 7 ) .

F ig . 1 8 F - 7 8.

In s e r t t h e b ig -e n d b e a r in g s h e lls , fit th e c a p to th e c o n n e c tin g ro d , in s e r t th e b o lts a n d tig h te n to th e s p e c ifie d to rq u e , (F ig . 1 8 F - 8 ) .

Fig. 18F-8

April '96

Compressor/Vacuum Pump 18F-7

9.

M e a s u r e th e b ig -e n d b e a r in g in s id e d ia m e te r in th re e p la c e s , (F ig . 1 8 F - 9 ) .

1 0 . R e m o v e t h e b ig -e n d b e a r in g c a p a n d c o n n e c tin g rod fr o m th e v ic e .

M e a s u r e th e c a m s h a f t e c c e n tric lo b e to d e te r m in e th e c le a r a n c e a f te r o b ta in in g th e b e a r in g I.D .

D ism a n tlin g t h e c y lin d e r h ea d 1.

R e m o v e t h e n u t r e ta in in g th e c y lin d e r h e a d , (F ig . 1 8 F - 1 0 ) .

F ig . 1 8 F - 1 0 2.

R e m o v e a n d d is m a n tle th e d e liv e ry v a lv e , (F ig . 1 8 F - 1 1 )

F ig . 1 8 F -1 1

3.

U n s c r e w th e in le t v a lv e fr o m th e c y lin d e r h e a d , u s in g s p e c ia l to o l 4 0 2 0 1 7 3 3 , (F ig . 1 8 F - 1 2 ) .

Fig. 18F-12

Compressor/Vacuum Pump 18F-8

R e a s s e m b ly o f t h e c y lin d e r h e a d 1

M o u n t th e c y lin d e r h e a d in a v ic e , in s e rt th e d e liv e ry v a lv e in to th e c y lin d e r h e a d a n d tig h te n th e re ta in in g n u t to t h e s p e c ifie d to r q u e , (F ig . 1 8 F - 1 3 ) .

2.

T u rn o v e r t h e c y lin d e r h e a d a n d in s e r t th e s u c tio n v a lv e a s fo llo w s :

1 v a lv e s e a t, 2 v a lv e d is k , 3 s p rin g w a s h e r s ,

4 s u c tio n v a lv e n u t, (F ig . 1 8 F - 1 4 ) .

N o te :

T h e s u c tio n v a lv e n u ts 4 A a n d 4 B a r e a lt e r n a t e fittin g s

re q u irin g th e u s e o f tw o d iffe r e n t s p e c ia l to o ls fo r r e m o v a l a n d r e p la c e m e n t. R e fe r to s p e c ia l to o ls lis t p a g e 1 8 F -9 .

3.

T ig h te n t h e s u c tio n v a lv e n u t to t h e s p e c ifie d to rq u e , u s in g s p e c ia l to o ls 4 0 2 0 1 7 3 3 o r 4 0 2 0 2 3 3 4 , (F ig . 1 8 F - 1 5 ) .

A tte n tio n !

S e e p a g e 1 5 - 1 2 fo r r e p la c e m e n t o f c o m p r e s s o r to

e n g in e

4.

In s e r t a n e w g a s k e t, r e p la c e t h e c y lin d e r h e a d , in s e rt th e re ta in in g b o lts a n d tig h te n to th e s p e c ifie d to rq u e , (F ig . 1 8 F - 1 6 ) .

N o te :

0 , 6 5 a n d 0 , 9 m m g a s k e t d e p e n d in g o n p is to n p ro tru s io n .

Fig. 18F-16

April '96

Compressor/Vacuum Pump 18F-9

5.

C o n n e c t th e a ir in le t a n d d e liv e ry p ip e s , (F ig . 1 8 F -1 7 ).

SPEC IA L T O O LS O B T A IN A B L E F R O M :

G R U N D Y - T E C H N I F O R M , B U R M A N R O A D , D E A L P A R T Y E S T A T E , P O R T E L IZ A B E T H 6 0 0 1

0 €>

April '96

\v S o c k e t fo r r e m o v a l/r e p la c e m e n t

■‘Z

o f c o m p r e s s o r v a lv e . ( T y p e A ).

J

¡L

( V

( S e e F ig . 1 8 F - 1 2 , I8 F - 1 5 ) P a rt n u m b er 4 0 2 0 17 33.

S o c k e t fo r r e m o v a l/r e p la c e m e n t o f c o m p r e s s o r v a lv e , ( T y p e B ).

/ fs r*

\//

( S e e F ig . 1 8 F - 1 2 , I8 F - 1 5 ) j

L0 ^ P a rt n u m b er 4 0 2 0 2 3 3 4 .

Belt-driven Compressor 18F-10

11 BELT-DRIVEN C O M P R E SSO R 1 C O M P R E S S O R P U L L E Y R E T A IN IN G N U T A N D W A S H E R 2

C O M PR ESSO R PULLEY

16

C Y L IN D E R H E A D R E T A IN IN G B O L T S

17

C Y L IN D E R H E A D B O L T F L A T W A S H E R S

3

P IS T O N W IT H C O N N E C T IN G R O D

18

C Y L IN D E R H E A D G A S K E T

4

C O N N E C T IN G R O D C A P

19

VA LVE PLATE V A L V E P L A T E R E T A IN IN G S C R E W

5

C O N N E C T IN G R O D C A P B O L T S

20

6

C R A N K S H A F T B U S H H O U S IN G

21

IN L E T V A L V E

7

S T E E R I N G P U M P D R IV E W A S H E R

22

E X H A U S T V A L V E R E T A IN E R

8

CRANKSHAFT

23

EXHAUST VALVE

9

CRANKCASE

24

10

E X H A U S T V A L V E R E T A IN IN G S C R E W S A N D W ASHERS

C R A N K C A S E M O U N T IN G B O L T S W IT H F L A T W A S H E R S

11

O IL IN L E T B A N J O B O L T A N D H O U S I N G

25

C Y L IN D E R S L E E V E

12

C R A N K S H A F T B E A R IN G

26

C Y L IN D E R S L E E V E R E T A IN IN G S C R E W S

27

C O M P R E S S O R M O U N T C A S T IN G B R A C K E T

13

C R A N K S H A F T B E A R IN G R E T A I N I N G C L IP

14

C R A N K S H A F T S E A L H O U S IN G

15

C Y L IN D E R H E A D

April '96

AND W ASHERS W I T H O IL D R A IN A N D ID L E R P U L L E Y

Belt-driven Compressor 18F-11

D IS A S S E M B L Y 1.

L o o s e n th e p u lle y fa s te n in g n u t, (F ig . 1 8 F -1 8 ).

2.

P u ll o ff th e p u lle y , (F ig 1 8 F - 1 9 ) .

3.

U n s c r e w a n d r e m o v e th e c y lin d e r h e a d , (F ig . 1 8 F -2 0 ).

4.

R e m o v e t h e v a lv e p la te w ith s u c tio n v a lv e a n d d e liv e r y v a lv e , (F ig . 1 8 F - 2 1 ) .

Fig. 18F-21

April '96

Belt-driven Compressor 18F-12

5.

R e m o v e t h e c y lin d e r lin e r re ta in in g n u ts a n d pu ll th e lin er fr o m th e p is to n , (F ig . 1 8 F - 2 2 ) .

6.

7.

R e m o v e t h e lo c k in g rin g fo r t h e p is to n pin, (F ig . 1 8 F - 2 3 ) .

P u s h o u t t h e p is to n a n d d e ta c h fr o m th e c o n n e c tin g rod, (F ig . 1 8 F - 2 4 ) .

8.

U n s c r e w th e h o u s in g c o v e r b o lts a n d r e m o v e th e h o u s in g c o v e r, (F ig . 1 8 F - 2 5 ) .

Fig. 18F-25

April '96

Belt-driven Compressor 18F-13

9.

D e ta c h th e c o n ro d fr o m th e c r a n k s h a ft a n d r e m o v e th e c r a n k s h a ft, (F ig . 1 8 F - 2 6 ) .

F ig . 1 8 F - 2 6 10.

R e m o v e th e s h a ft s e a lin g rin g fr o m th e b e a r in g c a p , (F ig . 1 8 F - 2 7 ) .

F ig . 1 8 F - 2 7 11.

R e m o v e th e p is to n rin g s w ith s p e c ia l to o l 4 0 2 0 0 3 0 7 (p is to n rin g p lie r s ), (F ig . 1 8 - 2 8 ) .

F ig . 1 8 F - 2 8

A SSEM B L Y 1.

In s e r t s h a ft s e a lin g rin g in to th e b e a r in g c a p , (F ig . 1 8 F - 2 9 ) .

mW i

Fig. 18F-29

April ‘96

Belt-driven Compressor 18F-14

2.

M o u n t O -r in g o n b e a r in g c a p . (F ig . 1 8 F - 3 0 ) .

F ig . 1 8 F - 3 0 3.

A s s e m b le c o n n e c tin g ro d to th e c r a n k s h a ft a n d in s ta ll th e c r a n k s h a ft, (F ig . 1 8 F - 3 1 ) .

F ig . 1 8 F -3 1 4.

M o u n t t h e b e a r in g c a p , (F ig . 1 8 F - 3 2 )

N o te :

R e c e s s in m o u n tin g b o s s in u p w a r d p o s itio n .

F ig . 1 8 F - 3 2 5.

M o u n t p is to n rin g s , (F ig . 1 8 F - 3 3 ) . U s e p is to n rin g p lie rs p a rt no . 4 0 2 0 0 3 0 7 .

,—

Fig. 18F-33

April '96

ii

fas

Belt-driven Compressor 18F-15 6.

P o s itio n t h e p is to n w ith rin g s o v e r th e c o n n e c tin g rod a n d in s e r t th e p is to n p in , (F ig . 1 8 F - 3 4 ) .

F ig . 1 8 F - 3 4 7.

M o u n t t h e r e ta in in g rin g s fo r th e p is to n pin, (F ig . 1 8 F - 3 5 ) .

F ig . 1 8 F - 3 5 8.

9.

M o u n t t h e g a s k e t fo r t h e c y lin d e r lin er.

U s e t h e p is to n rin g s q u e e z e r to b rin g th e p is to n ring d ia m e t e r to p is to n d ia m e t e r a n d m o u n t th e c y lin d e r lin e r, (F ig . 1 8 F - 3 6 ) .

U s e c o m p r e s s o r p is to n rin g s q u e e z e r 4 0 2 0 1 1 3 1 to g e th e r w ith p lie rs 4 0 2 0 1 1 4 4 .

ill'A M F ig . 1 8 F - 3 6 10.

F it t h e c y lin d e r lin e r o v e r t h e m o u n tin g s tu d s a n d tig h te n t h e n u ts to 2 2 N m , (F ig . 1 8 F - 3 7 ) .

Fig. 18F-37

April '96

Belt-driven Compressor 18F-16

11.

P la c e th e g a s k e t

a n d h e a d a s s e m b ly o n th e c y lin d e r lin er,

(F ig . 1 8 F - 3 8 ) .

N o te :

G u id e pin o f t h e v a lv e p la te m u s t lo c a te in to a p p r o p ria te

h o le s a t th e to p o f th e c y lin d e r lin e r.

Fig . 1 8 F - 3 8 12.

M o u n t c y lin d e r h e a d w ith g a s k e t a n d tig h te n th e b o lts to 3 0 N m , (F ig . 1 8 F - 3 9 ) .

F ig . 1 8 F - 3 9

13.

M o u n t p u lle y to t h e c o m p r e s s o r a n d tig h te n th e n u t to 1 0 0 N m , F ig . 1 8 F - 4 0 ) .

F ig . 1 8 F - 4 0

April '96

Belt-driven Compressor 18F-17

S P E C IA L T O O L S O B T A IN A B L E F R O M : G R U N D Y T E C H N IF O R M , B U R M A N R O A D , D E A L P A R K , P O R T E L IZ A B E T H 6 0 0 1 TE L : (0 4 1 ) 4 3 -2 2 9 9 ,

FA X: (0 4 1 ) 4 3 -2 2 2 4

P is to n ring p lie rs p a rt n u m b e r 4 0 2 0 0 3 0 7

:> *

C o m p r e s s o r p is to n rin g s q u e e z e r u s e w ith p lie rs b e lo w p a rt n u m b e r 4 0 2 0 1131

A

April '96

P lie r s fo r c o m p r e s s o r p is to n ring squeezer p a rt n u m b e r 4 0 2 0 1 1 4 4

Diesel

Club

ADE 364 and ADE 366

Workshop Manual Section 19 - Cooling System

B a rrin g to n D iesel C lu b

_______________________ SECTION 19 Cooling System

CONTENTS OF SECTION 19

Page I L L U S T R A T I O N ...................................................................................................................................................................................................................................... 1 9 -2 I N T R O D U C T I O N ....................................................................................................................................................................................................................................1 9 -3 S P E C I F I C A T I O N S .................................................................................................................................................................................................................................1 9 -3 R E M O V I N G T H E W A T E R P U M P ................................................................................................................................................................................................ 1 9 -5 D I S M A N T L I N G ........................................................................................................................................................................................................................................ 1 9 -6 A S S E M B L Y ............................................................................................................................................................................................................................................... 1 9 -9 T H E R M O S T A T A N D H O U S I N G ................................................................................................................................................................................................ 1 9 - 1 5 R E M O V I N G / R E P L A C I N G T H E T H E R M O S T A T H O U S I N G ...................................................................................................................................1 9 -1 6 T H E R M O S T A T T E S T ................................................................................................................................................................................................

1 9 -1 9

V I S C O F A N ..................................................................................................... : ..................................................................................................................................... 1 9 -2 1 I N T R O D U C T I O N ............................................................................................................................................................................................

1 9 -2 2

S P E C I F I C A T I O N S ............................................................................................

1 9 -2 2

O V E R H A U L I N G V I S C O F A N ...................................................................................................................................................................................................... 1 9 - 2 3 D I S M A N T L I N G ..................................................................................................................................................................................................................................... 1 9 - 2 3 A S S E M B L Y ............................................................................................................................................................................................................................................ 1 9 - 2 5 S P E C IA L F A B R IC A T E D T O O L S ...............................................................................................................................................................................................1 9 - 2 9 S P E C IA L T O O L S .................................................................................................................................................................................................................................1 9 -3 1

April '96

Cooling System 19-2

360 SERIES WATER PUMP 1.

IM P E L L E R

2.

CARBON SEAL ASSEM BLY

3. W A T E R P U M P H O U S IN G 4. S E A L 5.

B E A R IN G

6.

SHAFT

7.

B E A R IN G

8.

O -R IN G

9.

SEAL

10.

B E A R IN G C A R R IE R

11.

C O U P L IN G F L A N G E /P U L L E Y C O U P L IN G F L A N G E

April '96

Cooling System 19-3

IN T R O D U C T I O N T h e w a t e r p u m p is o f t h e im p e lle r ty p e a n d d riv e n b y V -b e lts fr o m th e c r a n k s h a ft. It is a s e a le d u n it, fille d w ith a s p e c ia l h ig h m e ltin g p o in t g r e a s e d u rin g a s s e m b ly a n d re q u ire s n o fu r th e r a tte n tio n d u rin g its life tim e .

A t h e r m o s ta t h o u s in g is m o u n te d to t h e c y lin d e r b lo c k w h ic h is jo in e d to th e w a t e r p u m p b y a c o n n e c tin g tu b e a n d s e a le d b y O -r in g s .

S P E C IF IC A T IO N S C O O L IN G S Y S T E M S ta n d a rd

O p tio n a l

7 9 ± 2 °C

71 + 2 °C

S tr o k e m m

8 mm

8 mm

F u lly o p e n a t

9 4 °C

85 °C

B y p a s s v a lv e c lo s e d a t

9 1 °C

8 2 °C

M a x . o p e r a tin g t e m p e r a t u r e

9 5 °C

95 °C

11<

11^

T h e rm o s ta t S ta r ts o p e n in g a t

M a in v a lv e

C o o la n t c a p a c ity ( e n g in e o n ly )

W ATER PUMP Im p e lle r s h a f t d ia m e t e r

1 5 ,0 2 8 to 1 5 ,0 3 9

F o r la r g e b e a r in g

2 9 , 9 9 6 to 3 0 , 0 0 9

F o r s m a ll b e a r in g

1 6 , 9 9 7 to 1 7 ,0 0 8

Fo r hub

2 9 ,0 4 1 to 2 9 , 0 5 4

B o r e in h u b d ia

2 9 , 0 0 0 to 2 9 ,0 2 1

H u b d ia . fo r fr o n t s e a l

4 1 , 8 4 0 to 4 2 , 0 0 0

B o r e d ia . in im p e lle r

1 5 ,0 0 0 to 1 5 ,0 1 8

P re s s in g im p e lle r o n w a t e r p u m p s h a ft

Im p e lle r fla n g e flu s h w ith h o u s in g M a x . ± 0 ,1 m m

L u b r ic a tio n o f w a t e r p u m p

April ‘96

G re a s e ap p ro x . 8 0 gr

Cooling System 19-4 A t t e n t i o n : W h e n in s ta llin g a n e x c h a n g e e n g in e , e n s u r e th a t

W ATER PUMP

th e s p a c e r rin g fitte d b e tw e e n t h e w a t e r p u m p a n d th e fa n is o f th e s a m e th ic k n e s s a s in t h e r e m o v e d e n g in e . I f n e c e s s a r y

A

W a t e r p u m p s h a ft

r e p la c e th e s p a c e r rin g s o t h a t t h e d is ta n c e o f 2 5 to 3 0 m m

B

Hub

b e tw e e n th e r a d ia to r a n d t h e fa n is re ta in e d .

C

B e a r in g c a r r ie r

D

O -r in g

E

L a r g e b a ll b e a r in g

F

S m a ll b a ll b e a r in g

G

R ear seal

H

C a rb o n seal

J

Im p e lle r

K

D is t a n c e im p e lle r a n d h o u s in g : 0 , 5 + 0 / ^ 0 3

.1 1 9 ± 0 , 5

364N/C/T

T O R Q U E S P E C IF IC A T IO N W a t e r p u m p to c y lin d e r b l o c k ................................................................................. M 1 0 ............................................................ 5 0 N m C o o la n t d r a in p lu g to c y lin d e r b l o c k ...................................................................M 1 8 x 1 , 5 ................................................ 5 0 - 6 0 N m T e m p e r a t u r e g a u g e p r o b e ......................................................................................... M 1 4 x 1 , 5 ................................................2 0 N m T h e r m o s ta t h o u s in g c o v e r ........................................................................................M 6 ................................................................ 2 5 N m W a t e r ja c k e t c o v e r to c y lin d e r b lo c k ( 3 6 4 N / C / T ) ......................................... M 8 ............................................................... 3 5 N m W a t e r p u m p b e a r in g c a r r i e r .................................................................................... M 6 x 3 0 .................................................... 1 5 N m C a p s c r e w /s p a c e r t o w a t e r p u m p s h a f t ............................................................... M 1 4 x 1 , 5 ............................................... 1 4 0 N m (L u b r ic a te th r e a d s w ith e n g in e o il)

F A N R E T A IN IN G B O L T S (D IN 9 3 3 ) - T IG H T E N IN G T O R Q U E B o lt d i a .

Q u a l i t y _________________________T o r q u e 25 Nm

M8

8 .8

M8

1 0 .9

35 Nm

M 10

8 .8

50 Nm

M 10

1 0 .9

60 Nm

April ‘96

Cooling System 19-5 Removing the water pump 1.

D r a in r a d ia to r .

2.

D is c o n n e c t u p p e r r a d ia to r h o s e .

3.

D is c o n n e c t lo w e r r a d ia to r h o s e .

4.

L o o s e n b o tto m a lt e r n a t o r r e ta in in g b o lt, (F ig . 1 9 - 1 ) .

5.

S la c k e n o f f a d ju s te r a n d r e m o v e t h e V -b e lt.

6.

R e m o v e t h e th e r m o s t a t h o u s in g .

F ig . 1 9 -1 7.

If a p o w e r s te e r in g p u m p is fitte d , lo o s e n th e a d ju s te r c la m p in g b o lt, ( F ig . 1 9 - 2 ) .

F ig . 1 9 - 2 8.

S la c k e n o f f t h e a d ju s te r a n d r e m o v e th e V -b e lt, (F ig . 1 9 -3 ).

F ig . 1 9 - 3 9.

U n s c r e w a n d r e m o v e t h e b o lts re ta in in g t h e V - b e lt p u lle y o r t h e c a p b o lt r e ta in in g th e fa n to th e w a t e r p u m p s h a ft.

R e m o v e p u lle y o r fa n , (F ig . 1 9 - 4 ) .

Fig. 19-4

April '96

Cooling System 19-6

10.

S la c k e n t h e t h e r m o s t a t h o u s in g r e ta in in g b o lts .

U n s c r e w a n d r e m o v e t h e b o lts r e ta in in g t h e w a t e r p u m p to t h e c y lin d e r b lo c k . R e m o v e w a t e r p u m p a n d g a s k e t, (F ig . 1 9 - 5 ) .

F ig . 1 9 -5

Dismantling 1.

W it h a s u ita b le p u lle r r e m o v e t h e h u b fr o m t h e w a t e r p u m p s h a ft, (F ig . 1 9 - 6 ) .

F ig . 1 9 -6 2.

U n s c r e w t h e b o lts r e ta in in g t h e fr o n t b e a r in g c a rrie r, (F ig . 1 9 - 7 ) .

.

F ig . 1 9 - 7 3.

L ift o f f t h e b e a r in g c a r r ie r , ( F ig . 1 9 - 8 ) .

Fig. 19-8

April ‘96

Cooling System 19-7 4.

W it h s p e c ia l to o l 4 0 2 0 2 3 0 5 t a p th e o ld s e a l fr o m th e s e a l c a rr ie r , (F ig . 1 9 - 9 )

F ig . 1 9 - 9 5.

R e m o v e t h e O -r in g fr o m t h e to p o f t h e fr o n t b e a rin g , (F ig . 1 9 - 1 0 )

F ig . 1 9 - 1 0

6.

R e m o v e t h e b o lts fr o m t h e fro n t, (F ig . 1 9 - 1 1 ) .

F ig . 1 9 -1 1 7.

R e m o v e t h e b o lts fr o m t h e b a c k p la te a n d d e ta c h th e b a c k p la te fr o m t h e p u m p b o d y , (F ig . 1 9 - 1 2 ) .

Fig. 19-12

April ‘96

Cooling System 19-8 8.

M o u n t t h e w a t e r p u m p b o d y u n d e r a p re s s a n d w ith a s u ita b le m a n d r e l r e m o v e t h e s h a ft c o m p le te w ith b e a r in g s fr o m th e w a t e r p u m p b o d y , (F ig . 1 9 - 1 3 ) .

F ig . 1 9 - 1 3

9.

L ift o u t t h e im p e lle r fr o m t h e r e a r o f t h e w a t e r p u m p b o d y , (F ig . 1 9 - 1 4 ) .

F ig . 1 9 - 1 4

10.

G e n tly k n o c k o u t t h e r e a r s e a l fr o m th e w a t e r p u m p b o d y , (F ig . 1 9 - 1 5 ) .

F ig . 1 9 - 1 5

1 1 . P r e s s t h e la r g e b e a r in g f r o m t h e s h a ft, (F ig . 1 9 - 1 6 ) ,

Fig. 19-16

April '96

Cooling System 19-9

12.

R e m o v e t h e s m a ll b e a r in g s fr o m th e w a t e r p u m p s h a ft, (F ig . 1 9 - 1 7 ) .

F ig . 1 9 - 1 7

Assembly 1. T h o r o u g h ly c le a n t h e w a t e r p u m p . E x a m in e th e b o d y fo r c o rr o s io n , c r a c k s a n d w e a r . R e p la c e t h e w a t e r p u m p c o m p le te ly if a n y p a r t s h o w s e x c e s s iv e w e a r .

2.

U s e s p e c ia l to o l 4 0 2 0 2 3 5 0 to in s e r t t h e r e a r s e a l in to th e w a t e r p u m p b o d y , ( F ig . 1 9 - 1 8 ) .

F: ig. 1 9 - 1 8 3.

U s e s p e c ia l to o l 4 0 2 0 2 2 9 5 a n d in s e r t t h e c a rb o n s e a l

.

V

a s s e m b ly in to t h e h o u s in g , (F ig . 1 9 - 1 9 ) .

: ig. 1 9 - 1 9

4.

P a c k b o th b e a r in g s w it h m u lti-p u r p o s e g r e a s e .

5.

P r e s s t h e s m a ll b e a r in g o n to th e w a t e r p u m p s h a ft, (F ig . 1 9 - 2 0 ) .

Fig. 19-20

Aoril '96

■

V

/

m

----------------------------------

Cooling System 19-10

6.

P r e s s th e la r g e b e a r in g o n to t h e w a t e r p u m p s h a ft, (F ig . 1 9 - 2 1 ) .

F ig . 1 9 -2 1

7.

U s e s p e c ia l to o l 4 0 2 0 2 3 1 8 a n d r e p la c e t h e s e a l in th e s e a l c a rr ie r , (F ig . 1 9 - 2 2 )

F ig . 1 9 - 2 2 8.

P la c e t h e s e a l c a r r ie r o v e r t h e w a t e r p u m p s h a ft a n d p re s s th e h u b o n to t h e s h a ft a s f a r a s it w ill g o , (F ig . 1 9 - 2 3 )

F ig . 1 9 - 2 3 9.

F ill t h e s p a c e b e tw e e n t h e b e a r in g s w ith m u lti-p u rp o s e g r e a s e , (F ig . 1 9 - 2 4 ) .

Fig. 19-24

April '96

Cooling System 19-11 10.

F it O -r in g o v e r t h e la r g e b e a r in g , (F ig . 1 9 - 2 5 ) .

F ig . 1 9 - 2 5 11.

P r e s s t h e w a t e r p u m p s h a ft w ith b e a r in g s in to th e w a t e r p u m p b o d y , (F ig . 1 9 - 2 6 ) .

F ig . 1 9 - 2 6 12.

In s e r t t h e b o lts in to t h e s e a l c a r r ie r a n d tig h te n to t h e s p e c ifie d to r q u e , (F ig . 1 9 - 2 7 ) .

F ig . 1 9 - 2 7 13.

P r e s s t h e im p e lle r o n to th e w a t e r p u m p s h a ft a s f a r a s t h e s p e c ifie d c le a r a n c e b e tw e e n t h e im p e lle r a n d th e w a t e r p u m p b o d y . U s e a fe e le r g a u g e to c h e c k th e c le a r a n c e , (F ig . 1 9 - 2 8 ) .

Fig. 19-28

April '96

Cooling System 19-12

14.

R e p la c e t h e w a t e r p u m p b a c k p la te w ith a n e w g a s k e t a n d in s e r t t h e fr o n t a n d r e a r b o lts , (F ig . 1 9 - 2 9 ) .

F ig . 1 9 - 2 9 15.

T ig h t e n a ll b o lts to t h e s p e c ifie d to rq u e , F ig . 1 9 3 0 ).

F ig . 1 9 - 3 0 16.

R e p la c e t h e w a t e r p u m p a n d in s e r t th e b o lts re ta in in g t h e p u m p t o t h e c y lin d e r b lo c k a n d tig h te n to th e s p e c ifie d to rq u e . F it t h e t h e r m o s t a t h o u s in g to t h e c y lin d e r b lo c k w ith a n e w g a s k e t a n d tig h te n t h e b o lts to t h e s p e c ifie d to rq u e , ( F ig . 1 9 - 3 1 ) .

F ig . 1 9 -3 1 17.

In s e r t a lie n c a p b o lt in to t h e c e n tr e h u b a n d tig h te n to th e s p e c ifie d to r q u e . If fitte d w ith a fa n , in s e r t t h e b o lts re ta in in g th e fa n to t h e h u b a n d tig h te n to t h e s p e c ifie d to rq u e , (F ig . 1 9 - 3 2 ) .

Fig. 19-32

April '96

Cooling System 19-13

18.

W it h te n s io n g a u g e (s p e c ia l to o l) 4 0 2 0 2 3 2 1 a d ju s t th e V -b e lt te n s io n to 4 0 - 4 5 k g ( n e w b e lts ), ru n t h e e n g in e fo r 1 0 - 1 5 m in u te s a n d r e -c h e c k t h e te n s io n , w h ic h s h o u ld b e 3 0 - 4 0 kg.

If th is is n o t r e a c h e d a d ju s t t h e te n s io n to 3 0 - 4 0 kg . P o s itio n t h e te n s io n g a u g e o n t h e b e lt w ith t h e fla n g e p a ra lle l to th e b e lt e d g e . G r a d u a lly a p p ly p r e s s u r e to th e p r e s s u r e p a d .

W h e n a c lic k is h e a r d o r fe lt, s to p a n d r e m o v e th e g a u g e .

T a k e a n a c c u r a te r e a d in g a t th e s p o t w h e r e th e in d ic a to r a r m in te r s e c ts th e s c a le , (F ig . 1 9 - 3 3 ) .

19.

W h e n t h e c o r r e c t V - b e lt te n s io n s h a v e b e e n o b ta in e d , lo c k th e s te e r in g p u m p V - b e lt a d ju s te r b o lt ( if fitte d ), (F ig . 1 9 - 3 4 ) .

20.

T ig h te n t h e a lt e r n a t o r V - b e lt a d ju s te r n u ts , (F ig . 1 9 -3 5 ) .

21.

T ig h t e n t h e b o tto m a lt e r n a t o r m o u n tin g b o lt, (F ig . 1 9 - 3 6 ) .

April '96

Cooling System 19-14

2 2 . T ig h t e n t h e s te e r in g p u m p m o u n tin g b o lt, (F ig . 1 9 - 3 7 ) .

2 3 . C o n n e c t t h e u p p e r a n d lo w e r r a d ia tio n h o s e s , fill th e r a d ia to r w ith c o o la n t t o w h ic h t h e c o r r e c t a m o u n t o f a p p r o v e d c o rr o s io n in h ib ito r h a s b e e n a d d e d .

2 4 . S t a r t t h e e n g in e , a llo w to r e a c h n o r m a l r u n n in g te m p e r a tu r e a n d c h e c k fo r c o o la n t le a k s .

A tte n tio n t

N e v e r fo r c e a V - b e lt o n to t h e p u lle y b y u s in g a le v e r.

T h e V - b e lt m a y b e d a m a g e d a n d th u s c a u s in g a n e a r ly fa ilu re .

T h e a d ju s te r s h o u ld b e fu lly r e le a s e d a n d t h e V - b e lt tu rn e d o n to th e p u lle y b y h a n d . I f o n e b e lt in a s e t r e q u ire s r e p la c e m e n t a lw a y s in s ta ll a m a tc h e d p a ir. If o n ly o n e b e lt is r e p la c e d it w ill b e c a rr y in g a ll t h e lo a d , w h ic h w ill le a d to e a r ly fa ilu r e .

F ig . 1 9 - 3 7

April '96

Cooling System - Thermostat and Housing 19-15

CAMSHAFT AND TIMING GEARS 1 BOLTS

6

2

7 C O N N E C T IN G T U B E

CO O LANT OUTLET

3 O -R IN G

8 GASKET

4

9 W ASHER

THERM OSTAT

5 T H E R M O S T A T H O U S IN G

Aprii '96

O -R IN G S

1 0 T E M P E R A T U R E S E N D E R U N IT

Cooling System - Thermostat and Housing 19-16 REMOVING/REPLACING THERMOSTAT AND HOUSING Removing 1.

U n s c r e w t h e b o lts r e ta in in g t h e c o o la n t o u tle t to th e t h e r m o s ta t h o u s in g , ( F ig . 1 9 - 3 8 ) .

F ig . 1 9 - 3 8

2.

L ift o f f t h e c o o la n t o u tle t, (F ig . 1 9 - 3 9 ) .

F ig . 1 9 - 3 9 3.

W it h a s u ita b le s c r e w d r iv e r lift t h e t h e r m o s ta t fr o m th e h o u s in g .

F ig . 1 9 - 4 0 4.

R e m o v e t h e O -r in g fr o m t h e th e r m o s t a t b o d y , (F ig . 1 9 - 4 1 ) .

Fig. 19-41

April ‘96

Cooling System - Thermostat and Housing 19-17

5.

U n s c r e w a n d r e m o v e t h e b o lts r e ta in in g th e th e r m o s ta t h o u s in g to t h e c y lin d e r h e a d , (F ig . 1 9 - 4 2 ) .

F ig . 1 9 - 4 2 6.

R e m o v e t h e t h e r m o s t a t h o u s in g a n d g a s k e t fr o m th e c y lin d e r head

F ig . 1 9 - 4 3 7.

P u ll o u t t h e c o n n e c tin g tu b e fr o m t h e th e r m o s ta t h o u s in g , (F ig . 1 9 - 4 4 ) .

-ig . 1 9 - 4 4

8.

R e m o v e a n d d is c a r d t h e O -r in g s fr o m th e c o n n e c tin g tu b e , (F ig . 1 9 - 4 5 ) .

N o te :

P r io r to r e p la c in g th e t h e r m o s ta t c a rr y o u t th e th e r m o s ta t

t e s t a s d e s c r ib e d o n p a g e 1 9 - 1 9 .

Fig. 19-45

April ‘96

Cooling System - Thermostat and Housing 19-18

Replacing 1.

F it n e w O -r in g s to t h e c o n n e c tin g tu b e , (F ig . 1 9 - 4 6 ) .

F ig . 1 9 - 4 6 2.

A p p ly a lig h t c o a t o f s ilic o n g r e a s e to th e O -r in g s a n d in s e r t t h e c o n n e c tin g t u b e in to t h e to p o f t h e w a t e r p u m p h o u s in g , (F ig . 1 9 - 4 7 ) .

F ig . 1 9 - 4 7 3.

F it t h e th e r m o s t a t h o u s in g to t h e c o n n e c tin g tu b e , in s e rt a n e w g a s k e t b e tw e e n t h e h o u s in g a n d t h e c y lin d e r h e a d a n d in s e r t r e ta in in g b o lts , ( F ig . 1 9 - 4 8 ) .

F ig . 1 9 - 4 8 4.

T ig h t e n t h e r e ta in in g b o lts to t h e s p e c ifie d to rq u e , (F ig . 1 9 - 4 9 ) .

Fig. 19-49

April '96

Cooling System - Thermostat and Housing 19-19

5.

In s e r t t h e th e r m o s t a t w ith a n e w O -r in g in to th e h o u s in g , (F ig . 1 9 - 5 0 ) .

F ig . 1 9 - 5 0 6.

R e p la c e th e c o o la n t o u tle t, in s e r t b o lts a n d tig h te n to th e s p e c ifie d to r q u e , (F ig . 1 9 -5 1

F ig . 1 9 -5 1

THERMOSTAT TEST Preparation 1.

R e m o v e t h e t h e r m o s t a t fr o m t h e h o u s in g , ( S e e p a g e 1 9 -1 6 ).

2.

In s e r t a le n g th o f c o tto n th r e a d b e tw e e n t h e v a lv e a n d th e t h e r m o s t a t b o d y , s u ita b le to s u s p e n d th e th e r m o s ta t in t h e c o n ta in e r , ( F ig . 1 9 - 5 2 ) .

F ig . 1 9 - 5 2 3.

S u s p e n d t h e t h e r m o s t a t in a c o n ta in e r fille d w ith w a t e r a n d in s e r t a th e r m o m e t e r . E n s u r e t h a t th e r m o s ta t a n d th e r m o m e t e r a r e s u s p e n d e d a t t h e s a m e le v e l, (F ig .

1 9 -5 3 ).

Fig. 19-53

April '96

Cooling System - Thermostat and Housing 19-20 Check for Thermostat Opening Temperature 1.

H e a t t h e c o n ta in e r to a t e m p e r a t u r e o f 7 1 ° C . A t th is t e m p e r a t u r e t h e th e r m o s t a t s h o u ld d ro p o ff t h e c o tto n th r e a d , (F ig . 1 9 - 5 4 ) .

Full Open Check 2.

C o n tin u e t o h e a t t h e c o n ta in e r , w ith th e th e r m o s ta t re s tin g a t t h e b o tto m , to a t e m p e r a t u r e o f 8 2 ° C . T h e T h e r m o s t a t s h o u ld n o w b e fu lly o p e n , (F ig . 1 9 - 5 5 ) .

Checking for Length of Travel 3.

R e m o v e t h e t h e r m o s t a t fr o m t h e c o n ta in e r. M e a s u r e th e d is ta n c e b e tw e e n t h e b y -p a s s v a lv e a n d th e lo w e r s u p p o rt b r a c k e t o f t h e t h e r m o s t a t b o d y . A llo w t h e th e r m o s ta t to c o o l a n d r e tu rn to its c lo s e d p o s itio n . A g a in m e a s u r e th e d is ta n c e a n d s u b tr a c t fr o m t h e p r e v io u s ly o b ta in e d d im e n ­ s io n . T h e r e s u lt is t h e le n g th o f tr a v e l, (F ig . 1 9 - 5 6 ) .

A tte n tio n !

If t h e t h e r m o s t a t fa ils to r e a c h m e a s u r e m e n ts

a s p e r s p e c ific a tio n s o r a n y o f t h e o th e r c h e c k s , it m u s t b e r e p la c e d .

April '96

Cooling System - Visco Fan 19-21

B A S IC V IS C O F A N 1 COVER

8 SEAL

2

GASKET

3

D IS K D R IV E

9 B E A R IN G

4

FAN B O D Y

5

FLANG ED SHAFT

12 S P A C E R

6

SCREW

13 C A P S C R E W

7

L O C K I N G D E V IC E

1 0 C IR C L IP 11 S P A C E R

Visco Fan 19-22 IN T R O D U C T I O N D e p e n d in g o n a p p lic a tio n 3 6 0 s e r ie s e n g in e s a r e fitte d w ith a th e r m o s ta tic a lly c o n tr o lle d v is c o u s d r iv e fa n , w h ic h is m o u n te d o n t h e w a t e r p u m p h u b a n d d riv e n b y V -b e lts fr o m th e c r a n k s h a ft.

T h e v is c o u s d r iv e fa n d o e s n o t h a v e a rig id c o n n e c tio n to t h e w a t e r p u m p p u lle y . A d r iv e c o n n e c tio n , fitte d to t h e p u lle y , c a n m o v e w ith in a c h a m b e r o f t h e fa n w ith a s m a ll c le a r a n c e . O n r e a c h in g a p r e d e te r m in e d t e m p e r a t u r e t h e th e r m o s ta t o p e n s , a llo w in g o il to e n te r t h e c h a m b e r . A s a re s u lt o f t h e fric tio n c r e a te d b y th e oil w ith in t h e fa n c h a m b e r , t h e n o n ­ d riv e n b o d y o f t h e fa n w ill tu rn th u s d r iv in g th e fa n .

C h e c k i n g a n d lo c k i n g v i s c o u s d r i v e f a n

V IS C O F A N

If th e r e is a n a b n o r m a l r is e in c o o la n t te m p e r a tu r e c h e c k

A D E No.

w h e th e r t h e v is c o u s d r iv e fa n e n g a g e s p r o p e r ly w h e n th e

7620 0504

e n g in e is w a r m . W it h

t h e v e h ic le

r a d ia to r . S t a r t t h e e n g in e a n d

s ta tio n a r y ,

a llo w to

ru n

S ilic o n N o .

3 9 cm 3

3808 0720

c o v e r th e a t m e d iu m

s p e e d u n til t h e w a t e r t e m p e r a t u r e is 9 0 - 9 5 ° C . R e m o v e t h e r a d ia to r c o v e r .

C a p a c ity

V i s c o s i t y o f O il

T h e t h e r m o s t a t is n o w h e a te d b y th e

h o t a ir fr o m t h e r a d ia to r a n d o p e n , a llo w in g s ilic o n flu id to

S ilic o n

V is c o s ity

flo w in to t h e fa n c h a m b e r , th e r e b y d riv in g t h e fa n .

3808 0720

1 2 ,5 0 c S t

In th e e v e n t o f a fa ilu r e o f t h e v is c o u s f a n d r iv e th e d e v ic e c a n b e lo c k e d . T h e lo c k in g d e v ic e a t th e r e a r e n d o f th e

T o rq u e s

fa n s e rv e s to c o u p le t h e f a n r ig id ly to t h e p u lle y .

D r iv e d is c b o lt s ..........................M 6 ...................... 1 0 - 1 3 N m T o c o u p le t h e fa n u n s c r e w t h e lo c k in g n u t (F ig . 1 9 - 2 6 ) u p to th e lo c k s to p , th e n tu rn t h e f a n s lo w ly b y h a n d u n til th e

............................................................. M 8 ...................... 2 8 , 5 - 3 3 N m T h e r m o s ta t c o v e r ..................................................... 1 0 - 1 3 N m

p in o f h e lo c k in g d e v ic e is fe lt t o s n a p in to p la c e a id e d b y th e s p rin g p r e s s u r e .

T h e v is c o u s d r iv e fa n c a n b e u s e d fo r a lim ite d p e rio d o n ly in

th e

lo c k e d

c o n d itio n .

E x te n d e d

o p e r a tio n

in

th is

c o n d itio n is n o t a d v is a b le . T h e fa n s h o u ld b e o v e r h a u le d a s s o o n a s p o s s ib le .

N o te :

T h e v is c o u s fa n d r iv e s h o u ld a lw a y s b e tr a n s p o rte d

a n d s to r e d in a v e r tic a l p o s itio n ( a s fitte d to t h e e n g in e ) to p rev en t

th e

s ilic o n

flu id

fr o m

r u n n in g

o u t.

W hen

o v e r h a u lin g t h e fa n it is e s s e n tia l to e n s u r e t h a t o n ly th e r e c o m m e n d e d s ilic o n flu id

is u s e d . D o n o t u s e m in e r a l

b a s e d o il. T h e fa n w ill n o t o p e r a t e c o rr e c tly , c a u s in g o v e r ­ h e a tin g a n d s e rio u s d a m a g e to t h e e n g in e .

Fig. 19-57

Cooling System - Visco Fan 19-23

O V E R H A U L IN G T H E V IS C O F A N D is m a n tlin g P rio r t o d is m a n tlin g t h e v is c o f a n th o r o u g h ly c le a n th e o u ts id e w ith a s u ita b le c le a n in g flu id .

1.

S e c u r e t h e fa n in a v ic e fitte d w ith s o ft ja w s , (F ig . 1 9 - 5 8 ) .

F ig . 1 9 - 5 8 2.

R e m o v e t h e t h e r m o s t a t c o v e r re ta in in g s c re w s w ith a 5 m m A lle n k e y , (F ig . 1 9 - 5 9 ) .

F ig . 1 9 - 5 9

3.

in s e r t tw o M 8 b o lts in t h e th r e a d e d h o le s in t h e th e r m o ­ s t a t c o v e r , (F ig . 1 9 - 6 0 ) .

4.

S c r e w d o w n t h e b o lts t o lift o f f t h e t h e r m o s ta t c o v e r. T h e t h e r m o s t a t is p r e - s e t a n d m u s t n o t b e d is m a n tle d .

F ig . 1 9 - 6 0 5.

L o o s e n a n d r e m o v e t h e d r iv e d is k r e ta in in g s c re w s w ith a n in h e x s o c k e t, (F ig . 1 9 - 6 1 ) .

A tte n tio n !

T h e s e s c r e w s a r e s e c u r e d w ith L o c tite a n d m a y b e

d iffic u lt to lo o s e n . T h e s c r e w s c a n b e lo o s e n e d b y lig h tly ta p p in g th e e n d o f th e s o c k e t w re n c h .

Fig. 19-61

April '96

Visco Fan 19-24

6.

L ift o u t t h e d r iv e d is k fr o m t h e fa n b o d y , (F ig . 1 9 - 6 2 ) .

F ig . 1 9 - 6 2 7.

C a r e fu lly r e m o v e t h e t h e r m o s t a t c o v e r g a s k e t fr o m th e fa n b o d y , (F ig . 1 9 - 6 3 ) .

F ig . 1 9 - 6 3 8.

P la c e s u p p o r t ( i t e m i p a g e 1 9 - 3 0 ) u n d e r t h e fa n b o d y a n d u s e a m a n d r e l ( it e m 2 p a g e 1 9 - 3 0 ) to p re s s o u t th e d r iv e s h a ft, (F ig . 1 9 - 6 4 ) .

F ig . 1 9 - 6 4 9.

R e m o v e t h e s p a c e r rin g , (F ig . 1 9 - 6 5 ) .

Fig. 19-65

April ‘96

Cooling System - Visco Fan 19-25

10.

L ift o u t t h e s e a l, (F ig . 1 9 - 6 6 ) .

F ig . 1 9 - 6 6 11.

R e m o v e th e c irc lip , (F ig . 1 9 - 6 7 ) .

F ig . 1 9 - 6 7 1 2 . T u r n t h e fa n b o d y o v e r a n d u s in g a s le e v e (it e m 4 p a g e 1 9 - 3 0 ) p r e s s o u t t h e b e a r in g , (F ig . 1 9 - 6 8 ) .

1 3 . T h o r o u g h ly c le a n t h e h o u s in g w ith a s u ita b le c le a n in g flu id .

1 4 . In s p e c t t h e fa n b o d y fo r a n y d a m a g e .

F ig . 1 9 - 6 8

A s s e m b ly 1.

U s e t h e s le e v e a n d s u p p o r t (it e m s 3 a n d 1 p a g e 1 9 - 2 9 ) a n d fit t h e b e a r in g s , (F ig . 1 9 - 6 9 ) .

A tte n tio n !

N e w b e a r in g s a n d fa n m u s t b e u s e d w h e n re­

a s s e m b lin g t h e fa n .

2.

R e m o v e t h e s u p p o r t fr o m u n d e r t h e fa n a n d fit th e d riv e s h a ft in to p la c e .

3.

U s in g t h e s le e v e p r e s s th e d r iv e s h a ft in to th e h o u s in g , (F ig . 1 9 - 6 9 ) .

Fig. 19 69

April '96

Visco Fan 19-26

4.

S e c u r e t h e fa n in a v ic e fitte d w ith s o ft ja w s , (F ig . 1 9 - 7 0 ) .

F ig . 1 9 - 7 0 5.

F it t h e c irc lip , (F ig . 1 9 - 7 1 ) .

F ig . 1 9 -7 1

6.

G r e a s e t h e s e a l lip s w ith a s u ita b le g r e a s e a n d r e p la c e th e s e a l, (F ig . 1 9 - 7 2 ) .

F ig . 1 9 - 7 2

7.

W it h a p la s tic o r r u b b e r h a m m e r r e p la c e t h e s p a c e r rin g , (F ig . 1 9 - 7 3 ) .

A tte n tio n !

.

T a p e r o f s p a c e r to p o in t to w a r d s d r iv e d is k .

Fig. 19-73

April ‘96

Cooling System - Visco Fan 19-27

8.

C a r e fu lly r e p la c e t h e d r iv e d is k in to t h e fa n b o d y , (F ig . 1 9 - 7 4 ) .

F ig . 1 9 - 7 4 9.

C le a n t h e d r iv e d is k s c r e w th r e a d s a n d in s e r t t h e s c re w s w ith L o c tite , (F ig . 1 9 - 7 5 ) .

F ig . 1 9 - 7 5 10.

T o r q u e t h e s c r e w s u s in g a n In h e x s o c k e t, (F ig . 1 9 -7 6 ) .

F ig . 1 9 - 7 6 11.

U s e a s y r in g e fille d w ith s ilic o n o il ( s e e s p e c ific a tio n s fo r q u a n tity a n d b r a n d ) to fill t h e c e n tr e o f t h e h o u s in g , (F ig . 1 9 - 7 7 ) .

Fig. 19-77

April '96

Visco Fan 19-28

12.

T h o r o u g h ly c le a n t h e t h e r m o s t a t c o v e r w ith a s u ita b le c le a n in g flu id , (F ig . 1 9 - 7 8 ) .

F ig . 1 9 - 7 8

13.

F it a n e w g a s k e t in to t h e fa n h o u s in g , (F ig . 1 9 - 7 9 ) .

F ig . 1 9 - 7 9 14.

R e p la c e t h e t h e r m o s t a t c o v e r w ith tw o M 8 b o lts in th e t h r e a d e d h o le s , ( F ig . 1 9 - 8 0 ) .

F ig . 1 9 - 8 0

15.

T ig h t e n t h e A lle n c a p s c r e w s w ith a 5 m m A lle n k e y s o c k e t, (F ig . 1 9 - 8 1 ) .

A t t e n t i o n ! A lw a y s s t o r e t h e fa n in a n u p rig h t p o s itio n .

Fig. 19-81

April '96

Cooling System - Visco Fan 19-29 Special tools for Visco Fan These tools must be self fabricated

( It e m 1 ) S u p p o r t fo r r e m o v in g b e a r in g s a n d d r iv e fla n g e .

35

~L ( It e m 2 ) M a n d r e l f o r r e m o v in g fla n g e d s h a ft.

100

( It e m 3 ) S le e v e fo r in s ta llin g t h e d r iv e fla n g e .

April '96

Visco Fan 19-30

( It e m 4 ) S le e v e fo r r e m o v in g t h e b e a r in g s .

(It e m 5 ) S le e v e fo r in s ta llin g t h e d r iv e fla n g e .

(It e m 6 ) S u p p o r t fo r t h e fa n b o d y , fo r in s ta lla tio n o f b e a r in g s .

( It e m 7 ) S u p p o r t fo r t h e fa n b o d y , fo r in s ta lla tio n o f b e a r in g s .

April '96

Cooling System 19-31 SPEC IA L T O O LS FO R SECTION 19 O B T A IN A B L E F R O M : G R U N D Y T E C H N IF O R M , B U R M A N R O A D , D E A L P A R K , P O R T E L IZ A B E T H 6 0 0 1 T E L : (0 4 1 ) 4 3 -2 2 9 9 ,

FA X : (0 4 1 ) 4 3 -2 2 2 4

W a t e r p u m p fr o n t s e a l R e m o v e m a n d r e l, P a rt N o. 4 0 2 0 2 3 0 5

W a t e r p u m p fr o n t s e a l r e p la c in g m a n d r e l, P a rt N o. 4 0 2 0 2 3 1 8

C a r b o n a s s e m b ly s e a l r e p la c in g to o l, P a rt N o. 4 0 2 0 2 2 9 5

W a t e r p u m p In n e r lip ty p e s e a l r e p la c in g m a n d r e l P a rt N o. 4 0 2 0 2 3 5 0

V - b e lt te n s io n in g g a u g e , P a rt N o. 4 0 2 0 2 3 21

April ‘96

D iesel

C lu b

ADE 364 and ADE 366 End of Workshop Manual

B arrin g to n Ehesel C lub