1 General

UALMET
diesel
3o,9 Cylinderhead and
911 valvemechanism
4tl
611
612

WoftshopManual
lnlet-and exhaust
system. Turbocharger.
1. Edition

1 5 .1 .1 9 8 6

YAITIT
VALMETCorDorrllon. Llnn.vuo,i Wo.ka
372i10LINNAVUORI,Flnl.nd 11 optionat
equipment
Tol. (lntl.)+ 358 31 il03 300
Tgl€x 2212Evålll st
T.lohx (lntl.l + 358 31 403 2E3

12
rO Tf USER

Thls Iqkshop Manu6l tq- valmdt diesel €nglnes ls Intendsd io facllliaie rcr-kshop op€rallons and
re palr r or k .

l O9 , lll, 4ll, 6 l l a n d 6 1 2 e n g l n e s ä r e mal nl y i ha same In construci l on, so tha same repolr

Instructlons usually apply to dlffereni eflglne lypes. The dltf{ences betr€n the vc'lous englnE
iypes rhlch alfecl repalr rcrk have been n ilon€d ln technlcal data ånd repalr Insfructlons. All
n€tasu rgments a-e In nllllmsires and valld yh6n thg iemperaiur€ of the paris ls +20qC, unless
othefti ls9 sta+ad.

Before star+lng rsprlrs, makE sure tha+ you havo öll necessary i@ls, parts and accessorles 6i your
dlsposal. The speclal tools nsrfloned ln fhe rcrk Instruqlloos re nof all essenilal, but th€y sp€d
up and tacllltafo thg rrork and contrlbu+e io successfuI execuilon ot rork. An enqlne rhlch has under-
gone rspålrs nusf be run ln Jusi llke a nef, one.

Should the €nglng rgqulre meosur€snoi descrI bed In thl s manuol , pl ease consul f your l ocal agent or
ihe S€rvlce Departnent of Valmet Llnnavuf I lq'ks. To facl l l tatE consul fl ng, fl nd out the fol l o r lng
fac+s about +he englne beforg cgniaciing us:

- Englno typo
- EngIne nunber
- A ppl l ca+ l on or equl pmenf
- Hours og{afod or kl lon€irgs drlven

4fl DS
 EGtfE SPECTF
tClTt(r{S

Englne type JO9o/!S 5 D llt Ds ill I D

Numb€rot cy I I nCf s t l 1
Dlsp I aca[srf dn) 2,7 t,t 5,t 4,4
Bore nn lo0 108 l 0B 108
Sfroke ml llil t20 t20 t20
Coipress lon rdf lo l7 3l l 7: l l 6: I l 7:l
InJetlon ader | -2-5 | -2-5 l-2-5 | -2-1-5
Compress lon pr€ssurp borl) 24 21 21 24

Englne type 4 DS 6t I D 6lt Ds/Ds8 612 D S

Numberol cyl lndf,s 1 6 6 6
Dlsp lecsmqrt dn) 4,4 6,6 7,4
Bore fin r08 t08 t08 r08
Stroke m 120 t20 120 ltI
Cdprass lon röflo l 6: I l 7: I l 6: I l trl
InJ€cilon ad€|' l-2-4-5 l-r-fr-2-1 l -t-5-6-2-1 t-5-H-2-4
CoDr€ss I on pressure brr) 24 21 21 21

| ) l.llnl"u,n vclue cf oprallng tonpratuftt

ond sterllng ngvs. Mox pg.rDltfed
dllterencp bqtr€gn cyllnders 3,0 bar.

E 6tE Tt?E DESt€rTtOtS

6t | 0sBJA

AppI I cat lon

A . v€hl cl e srql ne
G - gen€ratlng-set €nglne
L. co[b ln€ hcrvGtor or|olne
l.l . nrlnc engln€
P = pump s€i srglne

E ngl ne oqul ppedrl th boost cl r cool l ng

(ilntercoolrt)

InJ6cilon punp iype ln 6-cyllnder er|glngs

B . Eosch iPr
tlo cod€ . Bosch r^n

Turbochcrg€d q|glne

BasI c tpc

olsp laclm€n+ of one cyllnd€r (e.g. l , | ö5)

Numb€.ol cyllnd€rs

't-2
TtGHrEiltrc TmqES
ObJect Nm
E nglne:

Cy llnd€r he a d s c r€ rs a n d n u ts f0 9 , ,l l Jö 4l l .................... l 60
Cyllnder head screws and nu+s 6ll cnd 512 . . . . . . . . . . . . . . . . . . . . . . . . See Ins+ ructl ons, pol nt f I K
Cy llndr he å d s fu d s to c y l l n d € r b l c k ............................ lO
M oln b€ar lng s c ro ts 5 0 9 ........ 160
M aln bear lng s c re rs 5 l l , 4 l l , 6 l t J o 6 12 ......................... 200
Connec ilngr o d n u i s ........ ..................... 90
Connec llng ro d s c rs rs 6 1 2 ............. .......... S @ Instructl ons, pol rt 4 2 J
F ly r heel s c r e w s ................ l 2O
F ly uh€l ho u sIn g s c re rs i
- ouf er s c r o rs tl 1 2 ............ ................. llO
- I nnr s c r e rs M l 0 ........... .................. 60
ldler ggar scrers:
- M 10. . . . . . . . . . ............... 60
_ M t 4 . . . . . . .... ............... l 4o
ldler gear ({ l + h b o l l b e a rl n g ) s c re | l 6 l l and 612 . . . . . . . . . . . . . . . . . IB O
ldlt r ged- b e a rl n g h o l d q - s c r€ rs M 8 6 l l Ja 612 ................. 22
Cr ank s hot i e n d n u i l O9 , l l l J o 4 l l .............. 600
Cr ak s haf t e n d n u l 6 l l a n d 6 1 2 ......... .........10m
S c r ev s of ad d l l l o n o l c o u n te rb a l a n c e s4 l | ......................... 45
Coolonl pum pp u l l e y n u t M 1 4 ........... ......... IOO
Fuel equlpment:

lnJ ec t lqr pu rrpg e q ' n u f B o s c h trAn ...... ............,............. 90

InJsctlon punp gscr nui Bosch nPi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l,lO
I nJ ec ic r r e+ a l n l n g n u i s (to s tu d s ) B o sch ........ 15
I nJ c ioi r ei a l n l n g n u ts (to s fu d s ) C A V .......... 20
tlozzle flxlng bush Bosch @
t loz zle t lx lng b u s h C A V........ 90
I nJ ec t c r adj u s tl n g n u + c o v € r C å V ............. io
P r es s ur e v al v e h o l d e r B o s c h n A ' ........ 15
Pressut€ valve holdf Bosch "Pr 80
Corpresscr-:
Codpresscr- pu I ley nut Knorr 80
Conpressor gear nu+ B€ndlx t40
Compressq'gef nui C lay+cn 180
E lec t r lc al e q ul p D g n f:
A lt er nät c r p uI l e y n u t .......... 45

1-3
CYLINDERBLOO(ANDFLY|IfEL I{oUSIT{G

I r{)€x

Coostrustlott .. ... 2- 3
Reoclr I nstrucilons

l. C y l l n &r b l a k a n d c y l l n d e r l l ners
A . M e a s u rl n gl -h e c y l l n d e r ll ner w ear....... ......... 2- 5
B . R e rp v l n g th e c y l l n d e r I I ner. . . . . . . . . . . . ..........2- 5
C . C h e c k l n gth s c y l i n d e r b lck............ .......... 2- ,
D . R e p fa c l n g i h e c a ms h a fi b eorl ng bush tl 1/4l l /309................... 2- 5
E . R € p l a c l n g th e c a ms h a ff b earl ng bushes 6l l /612..................... 2- 6
F. C a m s h a ftc o rre c i l o n b e 6 rl ng bushes 5l l /411........................ 2- 6
G . C a ms h ö ttc o r.e c i l q r b e a rl ng bush 509.........' .................... 2- 6
H . C o m s h a ttc o rre c i l o n b e a rl ng bushes 611/612........................ 2- 7
f. F ftfl n g fh a b l a k l n g p l u g of th€ cansh6ft l l ne 3@ /5l l /411........ 2- 1
J . F l i tl n g i h e b l o c k l n g p l u g of the canshaft l l ne 611/612.. . .. . .. . . . . 2- 7
K . F l ttl n g + h e d l p s + l c k g u l de p| pe....... ........... 2- 1
L . F l ftl n g + h e c y l l n d e r 1 1 ner............ ........... 2- I

2. Flyrh€el houslng
A . In s i o l l l n g th e fl y w h e e l housl ng.' .. . . . . . . . . . . . .. 2_l 0
B . R e p l a c l n g th e c ra n k s h a fl rear end seal .... ....... 2-10

vAlitEr
 lCåL DATA (reJect llrnl+ of pari stäted In brockets afier ra+lno)
IECHN

Cyllndar b lod( ,09

Holes f o. d o i eI s . . . . . . . . . . ..... l l ,OOO...l l ,O4l
Dlam €ier o l ma l n b € ö rl n g b o re . . . . . . . . . . . . ....... 76,000...76;019
Dlanet or o l c y l l n d e i - l l n e r b o re :
- upper en d ... l l 6,ot2,,.l l 6,o47
- lower en d ,,. l t5,0oo...l l i ;Ol 5
I ns lde d la n o + e r o f c a m s h a ft b e a rl n g b ush (rhen fl ti ed l n posl tl on).50,ö00...50,0å5 (50,o5o)
T lgh+ enln 9 l o rq u € o f fl y rh € e l h o u s l n g scrers:
- ouf er s c re H s Ml 2 ............, ................. l l O Nm
- I nnq' s c re rs M1 0 ..........,.. ......,.......... 60 Nm
T lghienlng to rq u o o f ma l n b e a rl n g c a p s ...r....................... l 60 Nn

Cy llndar b l o c k tl l , 4ll, 6ll, 612

Holos for doye I s . . . . . . . . . . I l ,000. .. I r,041
Dla n1 oie r o f m 6ln b€6r lng bor e . . . . . . . . . . . . 91,000...9t,022 ( 9l ,0 i10)
0 lan etq - of c y llnder llner bor e:
- upper end 12t,r14.. .123,r54
- toref eno 122,oco. ..122, O4O
In sld e dl€ f l€t er of c am s haf l bear lng b u s h ( w h e n f l +t e d In poslilon) 50,000.,.50,025 ( 50,0 50)
In sld e d lam et er of c öm s hof + baor lng b u s h ( r h e n f l i t e d In posltlon)
be 6r I n gs 2 . . . 7 611, 612. , . . . . . . 49,990...50,050 ( 50,0 80)
Tlgh ten lng ior que of f ly r heel hous lng s c r e r s l
- out er s cre H sM l 2 ............. ................. llO Nm
- I nnei s c re x s M l o .........,... .,............... 60 N D
T lght enlng to rq u e o f m ö l n b € a rl n g c a p retal nl ng screw g ..,.........200 Nn

Cyllnd€r I Iner 509

Profru slq l of c y llnder lln€r abov e c yl l n d s r b l @ k l o p f a c e . . . . . . . . 0,0J0...0,080

Ma x pe rnlss lble holght dlf f er onc e b€tr , e € n c y l l n d e r l l n e r s 0,020
L Inq' bore tm,0m... t@ ,022 ( 100, 080)
Ma x pe roiss lble ov alnes s ot llner . . . . . . . , . . . 0,020
Hel ght of cy I Inder I Intr f I ange 8, 0t. ..8, 05
He lgh t of c y llnder llner t lange, ' ls t o v e r s l z o , p ä r l n o 8 f 6 5 f 6 B 2 B . 8,08.. .8, l 0
l-le lgh t of c y llnder lln€r f lange, 2nd o v e r s l z e , p a - t n o 8 J 6 5 J 6 8 2 9 . I, 1t. ..8, 15
He lgh i o f c y llnder llner f lange, f r d o v e r s l z 6 , p ö r i n o 8 1 6 5 j 6 8 l o . 8,2t...a,25
Outq ' d lam eier of c y llnder llnei t ldt g e t2l , ...122,@

Cyllnd €r lln€r lll, 4ll, 6ll

Protru siq r ot c y llndq- llner abov o c y l l n d e r b l c c k t o p f a c € . , . . . . . . 0,0J0...0,080

Ma x p ermiss lble helghi dlf f er enc e bei w € n l l n e r s ( u n d e r s a m e h o a d ) . 0,020
L Iner bore 108,000...108,022 ( t 08,080)
Ma x pe rmisslble ov alnes s ot llner . . . . .. . . . . . 0,020
Helg hi o f cy l I nd€r llner t langs 9,01.,.9,05
Helg h+ of cy llnder llner f lange, ls + o v e r s l z e , p c r t n o 8 t 5 J 2 9 8 2 9 . 9,08...9,t0
Helg ht o f c y llnder llnt r f lange, 2nd o v € r s l z e , p a r t n o S J j f 2 9 g j o . 9, l l . ..9, | 5
Helg hf o f cy llnder llner f lange, f r d o v e r s l z e , p o r t n o 8 f 5 j 2 9 g l l . 9,25...9,25
Ou t€r dla m ef er ot c y llnder llner f l ge I l l , 700... I11,800

Cylln d€ r ll nor 612

Pro irusio.r of c y llndei- I I ns - abov e c y l l n d e r b l a k f o p f a c s . . . . . , . . 0,010...0,080

Ma x p ern lss lble helght dlt t er enc e bet w € n l l n e r s ( u n d e r s a f l € h e a d ) . 0,020
L Inef bore 16,0@ ...108,022 ( | 08, 080)
Mö x p eimiss lble ov ölnes s ot llner . . . . .. . . . . . 0,020
He lgh i o t c y llnd€. llnq- f lange 9,01. ..9, 05
He lgh t o f c y llnd, ei llner f lange, ls ' t o v e r s l z e , p 6 r t n o 8 l 6 J 1 8 4 j 6 . . 9,08.. .9, | 0
He lgh i o f c y llnder llns - t lange, 2nd o v e r s l z € , p a r t n o B f 6 f f 8 4 l 7 . . 9,13...9,15
He lgh t o f c y llnder llner f t ange, f r d o v 6 r s l z € , p ö . f n o 8 f 6 j 5 9 4 3 9 . . 9,25...9,25
ouier d lamete|- of cy I Ind€r I Iner f I ange Il l ,70...I]l ,80
 2
o

v
L O o L S( C yl i nder bl ock and fl yw heel housl ng)
S PE C IA T

I a3@ 91315 F l i + l n g i ool l or crankshafl rear end soal

2 4360 97314 F I y{heeI housIng contra I lz In9 bush
3 9045 348oO c h a m fg r i ng reamer for cyl l nder l l ner bore
4 9051 7J100 T o o l fo r exi rac+ l ng and ro+ afl ng cyl l nder l l ner 309
90]o 26too T o o l fo r extractl ng and ro+ afl ng cyl l nder l l ner
5 51 72 0 c o rre c tlon reamer for cyl l nder l l ner fl t+ l ng 309
9045 A1200 C o rre c +l on ream€r for cyl l nder l i ner fl i fl ng tl l , 4l l , 6l l
9051 72800 C o rre c +l on reamer for cyl l nder l l ner fi i + l n9 612
9045 87600 Exchangeblade Jor correct lon rearner
6 9025 52400 T o o l fo r ro+ atl ng cyl l nder l l ner
1 A36t 91466 C u p p l u g tappl ng drl f+ 40 mm
I A36t 9146A C u p p l u g + appl ng drl fi 16 mm
9 9025 98700 D o re l p l n + appl ng drl ft
r0 9025 78100 C y l l n d e r I Iner cl ampl ng fool
11 9025 79200 G a u g efor- measurl ngcyl l nder l l ner hel ghi
2-2
S elf - m a d eto o l s (c y l l n d e r b l c k a n d fl yvrheel housl ng) A 35t 9l 5 .emovl ng-
and fl++lng equlpmenf for ihe bushlngs ot +he cansha{+.

O)
o
o)
@
\
or
CYLIIDERBLCOK
ANDFLYB}EELTIOUSING
co{sTRtcT I oN
CYLINDER
BLOCK

E LOC K(4II)
C Y LIN D E R
l. C yI Inder bl ock
2. B oarl ng bush
J. Scrow
4. B earl ng cap
5. B earl ng cap (9ul de bear ing)
o. P tn D U sh
7. C yI l nder I l ner
8. 0-r Inq seal l no
9. P tug i camshafi l l ne)
10. Dl pstl ck p tpe
I l . N ui
12. S + ud ' -
l J. S crew
14. S eaI Inq rl no
15. P l uq
16. C up p l ug
17. D ral n cock
18. Pressure qauoe sender
19. Pl pe

T he cylind er blo c k f o. m s l- he englne body t o 6 l 1 1 6 1 2 e n g l n e s h ö v e a n o - r l n g s e a l a l s o l n +h e

whlch +he other englne conponents are flxed. top end of +he cyllnder llner. There are
c o o l l n g g r o o v e s w h l c h n a k e f h e c o o l l n g o f th e
T he cylln de r llne r s ( 7) ar e of r et t y pe t {h l c h hot top part nore efllclent.
nEans thä-t ihe coolan+ comes dlrecily ln+o
conta c+ rlth +h e llner ou+ e. s u. f ac e. Th6 The cyllnder b l o c k I n c o r p o r a t e s +h e c a msh a fi -
seal ing b e+Hee n + he c y llnder llner lo|ler e n d w h l c h h a s +h o J r o n l b e a r l n g p o l n + ( j 0 9 , l and
and cylln de r b lock c om pr ls es of + r o o- r lngs ( 8 ) 4ll englnes) equlpped rlfh a s e p a r a +e b e a r l n g
whlch have been placed ln the g.ooves on the b u s h ( 2 ) r {h l l e t h e o t h e r b e a r l n g p o l n +s h a ve
cyllnd er lln er. The t op end ls s ealed by m e a n s b e e n m a c h l n e d I n t h e c y l l n d e r b l o c k d l r e c tl y.
of a h ea d ga ske+ s l+ uaf ed bet ween + he c y lln d e r ln 611/612 englnos €ve.y camshaf+ bearlng poini
llne r fla ng e a nd c y llnder head. The ac c u r ö - t e has a separöle bearlng bush.
flf +ln9 o f th e c y llnder llner f lange and +h e
matin g face of ihe f lange ln t he c y llnder b l o c k T h e r e a r e n d o { t h e c a m s h a f t l l n e l s b l ocke d
ls also e ssen tlal f or ihe iop end s eallng. l {e wlth a dlsc plug In 309, fl I and 4ll englnes
ask yo u io n ote t hls es pec ially in c onnec+l o n r h e r e a s t h e 6 l l a n d 6 '1 2 e n g l n e s h a v e a p l u g
v. l-i'h cy l in de r llner as s enbly . equlpped r,lth an o-rlng seal.-

On both sldes of the rear maln bearlna +here are

posltlons f o r g u l d e b € a r l n g s h e l l s i c r a n ksh a fi
axlal bear ings).

2-3
 FLITfEL IOIISIIG

Flyrhcl ho{sl ng
l. Fl yyh€€l housl no
2. Hgxagon screw -
f. Hexagon s€ket screy
4. Sheft seaI
5. P l u9
6. DoreI pln
22 7. S+ud
8. llasher
9. Nui

Th€ flyrheel houslng Is flxed to ihe rear end

of ihe cyllnder block. The crankshaft rear and
shafi seal (4) ls DlacEd In ihe recess machlned
to f ha hous lng. l o o d d l tl o n , + h € h o u s l n g has a
rDuntlng polni lor ihe s+arter.

The bot+o föc€ ol ihe flyrh€el houslng Parfly

acis os the maflng tace of ihe ol I sunp seal,
so lt nay not dlffer much from lhe cyllnder
block bottom foc€. The carreci Doslflon of +he
flyrheel houslng ls secured a+ ihg manufaciurlng
s+a ge, lt h dox el p l n s (6 ).
The tlyyhe€l houslngs are dellvered occordlng
io + he r E qulr a m€ n ts s e f b y th e e n gl ne
a p p llc ailon and d l ffe re n t fl y rh g e l s c a n be
mounld on all anglne +yp€6.

2-4
 TIORKI NSTRIjCT
I ONS P l ace the turnabl e dl sc of + he l l nor ext r ac+or
(9010 26100) + hroughthe l l ner on l i s lowar end
I. CYLIIOERSLOCKANDCYLIND€RLI]GRS and draw + he l l ner ou+ fron the cvl l nder block.
I t{G I}IE CYLITDERL INERIiEAR
A. I,GASUR
CHECKI
NG IHE CYLINDER
BI-OCI(
l. Set ihe dlal gauge +o zero wlih a mlcrome+eror
wlt h a n e ' , c y l l n d e r l l n e r, l n d l catl ng Tne l . C areful l y cl ean the cyl l nder bl ock of ol I and
diam et er o f a n u n w o rn l l n e r (1 0 8 ,0 0 m m). other l mpurl tl es, preferabl y In a {ashlng
rnachl ne.A fi er H ashl ng bl ow i he cyl lnder block
dry wlth pressure alr and pay speclal afienflon
to ol I channel s. R emoveal l scra ps of old
gasKeTs.

C heck the cl eenness of the cool l ng channols.

Remove the bol ler scale sedlneni to ensure
engl ne cool l ng.

Check +he +lgh+ness of fhe cup plugs önd screw

pl ugs l n i he cyl l nder bl ock as l ,ell as lhe
condl + l on of + he cyl l nder bl ock a nd seallng
laces.

I\4easure +he wear of the camshaft bearIngs

(comparew l i h ra+ l ng).
.-\J l/.. REPLACI]'IG ItE C/tljISMFTBEÄRINGBUSHtO9, 5l I
ond I
'll
R gnove fhe bearl ng bush rl + h an I nslde
exiracfor (e.9. SYKESno. 854). You can also
remove the bush by +apping t{lth a drlfi af+or
i akl ng oui + he bl ockl ng pl ug from the r ear ond
of tho camsha{ +l l ne.

2. C l ean i he bearl ng housl ng l n fhe cyl l nder block

carefu | | y.
2. Cle an ih e I nner s ur f ac e o{ ihe c v ll n d e r llner
j-horough ly before measureneni.

Perfoim the neasuremoni crosswlse a+ tho llner

top e nd , loYer end and m lddle.

Check ihe gauge readlng for maxlmum vrear and

o va lne ss ( c onpar e r { lih r at lng) .

RETOYII€ llf CYLINDERLINER

l. It you in+ end io r elns iall t he c y llnd e r l l n e r s ,

mark +he liners so +ha+ +hey can be placed ln
ihe lr orig lnal pos l+ lons I n t he c y lln d e r b l o c k .
Make ihe marklng on the lnner sdge of the llnsr
+op flange, e.g. on +he edge towards canshaft,
s+a+lng the c y linder num ber .

3. Fl + + he bearl ng bush In pl ace by p r esslng and

a+ ihe sameilme ensure the correc+ poslilon of
ol I hol es.
4. Af+er fl+tlng |-eamihe bush io lis proper slze
(d 50.000...d 50,025).

I
linder block
i front face
I
I

309
26
Notel The bearlng bush of the 509 e n g l n e l s
In l l s ra+ ed si ze afi er fl i ti ng an d does nol
rqul re reamIng.

Measure ihe clearance of +he bush and the

camshaft and cornparewlth railngs.
2-5
E. FEPLTCI }G I}E C,AT.6FåFT
8EÄRI iG BU$f S 6t I /61 2

Dla[€+er o{ c.mshaff b€arlnq bush holes ln 27

6ll,/612 englles (nurb6rs star+ fron the englne
front endt.
Order nul5€rs for bearlng bushes (mårked oo the
outer surface of bear lng)

no.
22171
a36t 2297'
at63 22608
4,5 a36t 22609
7 2261O

6ll1612 englnes hav€ seven replaceable camshafl

b€arlng bushes. obs€rve the varylng ouiar
dlangters of th€ bush holes In the cyllnder
block rhen renovlng and tlttlng ihe bush€s. Cairshaft corr€ctlon beorlng bushes for fll
engI ne.
t. Rsnove the b€arln9 bushes by tapplng rlth a
sultable dr I ft, fa Instance.

Cl e a n t he bear ln g h o u s l n g s In th € c y l l n d er
block +horo0ghly.
Fl t t he ner bear ln g b u s h e s In i h e l r p l o c e s by
presslng, usfng a selfnnode tool 8t5t 91556,
for examo19. No+e fhg cgrrect order of fhe
b u shesand t he Dos l tl o n o f th e o l l h o l e s o f the
bushes In both 6nds.
4 . Reant fhe flrsf b€arlng bush fro.n fhe englne
front end to lts correci slze. (l 50,000...
50,025). ThE othEr bushes ere ln ihelr correct
slzes äfter llttlng and do not requlre reamlng.
Comshafi @rrectlon bearlng bushes for 4ll
Measure the clooranca of thg bushes and the 9n9lne.
caiEhaft and comparexlth råiln9s.

F. C IGHAFTmRECr tor{ EEAR 5r1l/ l

titc BUSHES G. cålrsr{ FT @RREcfl ON 8€ Rt}G BUSfl 509
l f needad, y ou ca n In s ta l l l n i h e c y l l n der l f needed, you can l nstal l In the cyllnder
block a bush rlth I rfl overslze outer dlanqter block a bush rlih 0,4 rm overslze outer
In plåce of the camshati froni bearlng bush. dl emster In Dlaca of thg camshaft froni end
The bearlng poln+s machlned In fhe cyllndor bearlng bush. The o.-dEr number lor fhe ov€r-sl ze
block can also, ll necassary, be equlpped rlfh bush ls 85f 24661 and the dlrFnslons lor
s€parate bearlng bush€s. Flgur€s 2 8 and 2 9 machlnlng ihe cyllnder block are-d 56,0+0,010.
shoy the order numb€rs tf correcilon bearlno
bushes and th€ dlmenslons for machlnlno thå Vlhenflitlng fhe beärlng bush chock tho correci
cyl l nder bloc k f or b € a rl n g b u s h fl ffl n g . - posltlon ot oll holes. The b€arlng do€s not
need reamlng after f liflng.
tlotel tlhen flfilng the tront and rear bush
Other bearlng poln+s In 309 englnes can be
fltted xlih- ihe correspondlngi correctton
b€orl ng bushesof l l l 6ngl ne. S €e fl g. 2 8.

2-6
H. C^I,ISHAFT
@RRECT|ONBEARTNG
BUSHES6 l6t2

Camshatt correctlo4 bearfng bushes for 6ll1612

engI nes

lf needed, y o u c a n l n s i a l I l n + h e cyl l nder

bloc k a bush v l th I m o v e rs l z e o u + e r dl amsi er
I n Dlac e of th e c a m s h a f+fro n f e n d bushl ng.
Oiher b'lshes can b€ replaced by overslze bushes
wlih 0, 4 m mo u te r d l a me i e r. F l g u re 2 1 0 shors
the order numbers for the correctlon beårlng
bus hes and i h e d l me n s l o n s fo r ma c h l nl ng i he
c y llnder blo c k .

t. FITTING IIf BLOCK

I NG PLUGOF lHE CAIT.ISHAFT
LI]G
n9/ t t l/ 111

Clean t he b l o c k l n g p l u g s p a c e + o g e i r l d of ol d
s eallng c on p o u n dre m a n l s.
Apply seallng compound(6909 J0008) on the slde
of lhe b lockI n g p l u g .
P ress the bl ockl ng pl ug In l ts posl +lon and f lx
Its shl el d pl ate (l n engl nes w here lhe f lyxheel
housl ng does not cov6r the bl ockl ng plug) .

K . FITTII{GTIf, DIPSTICKGUIDEPIPE

l . C l ean + he pl pe hol e l n the cyl l nder block.

A ppl y rei al nl ng fl ul d (6909 J0012) t o t he gulde

pl pe l oxer end.

211

T öp t he bl o c k l n g p l u g In i + s p l a c e yl i h the
f lttl ng iool (9025 87400).

Notel Be careful no+ io lap ihe blocklng

plug + oo de e p b e c a u s e+ h l s rl l l a ffe c l l he com-
s h€f t end p l a y l T h o re fo re a l ra y s u s e a fl ftl ng
t ool.

J. FITTIT{GTHE SLOCTI NG PLUGOF THE CÄI.IIiHAFT LINE

6t | /612
l. Clean t he b l o c k l n g p l u g p o s l + l o n a n d use emery 213
Cloth to renove ihe posslble sharp edges On ihe
hole r l m . l . Tap the gul de pl pe In l l s posl tl on a i f he level
Indl cated In fl gure 2 l J.
2. P lac e E n o -rl n g In l h e b l o c k l n g p l u g groove and
lubr lc at e l + tv l i h , fo r l n s + a n c e ,- sl l l cone
s eallng c o m p o u n d .
L . FITTI}IG IIG CIL I ]OER LIICR
t . Cl e a n th o c y llnder lln € r o n d l ts l l ttl n g p o l n i s 6. It fhe l l ner must be ral sed, Ins+ cl l one r lth
In th a c y llnder bloc k th o ro u g h l y . T h e q y l l n d o r an overth lc-k top tlang€.
llner lusf roiate easllv around ln lts bore
rhen +he g-rlng s€ollngs of the llner have been
relpveo.

Apply marklng colour fo th6 undersld6 of the

c yl l n d e r llnei f lang 6 a n d p l a o e i h e l l n e r In
Its p o s lilon nlihou+ o -rl n g s . R o i a te th e l l n s r
ln b o i h dlr ec t lons . l l | l i h d ra y + h e l l n e r a n d
check lf +he louch ls even.

309
PART H GROOVES
NO. QTY
8365 36827 8,03+o,02 -(s t d )
8365 36828 9.08 +0,o2 1
8365 36829 8,13 +0,o2
214 8365 36830 8,23 +0,02

5 . lf i h e m ailng lac e ls d o ma g o do r l i + h e l l n e r 311,411.611

proiruslon abovg the cyllnder block face needs
rnachlnlng, use o correcilon reaner. Af+er PART H GROOVES
r a a ml n g y ou c on per fo rm € l l g h + l Ep p l n g rl + h NO. QTY
th e l l ner , lf need e d . A p p l y g rl n d l n g p a s + e
be+r€n +ho cy I Inder I Iner I lange and the 4363 227A7 o +o,02 -( s t d )
cyl Inder block and rofaie ihe llner rlth tool ^1
no. 6. Lapplng ls .|oi, hoyever, ihe rlgh+
8353 29829 9,Og+o,02 1
tEihod, It th9 cyllnder llner protruslon has io 8353 29830 9.13 +o,o2 2
b€ adj usied.
8353 29831 9,23 +0,02 3
4. A t+e r r oam lng and l e p p l n g c l e a n l h e m a i l n g
taces caretully b€torg meosurlng the cyllnder
l l n e r D r o+ r us lon. 2
PART H GROOVES
NO. QTY
8363 36331 g,O3+0,02 - ( std )
8363 38436 g.o8 +0,02 1
836338437 9.13+0,02
8363 38438 q 2.1 +o,o2 .t

An overthlck iop flange ls marked rlth ihe

nurber ol machlned gr@v€s on th9 flcngB outer
surtåce: lst olrat slze O10D I cna gn@rc,
2nd oversl zo 0,10 n. -
fro groova3 and
oYf,slz€ 0120 rn thr€ gr@vca. 'rd
-

5, Fo|- the fiFasurglEn+ procedure press tho

c yl l n d e r llner s I n p l o c a w l l h c l a n p l n g i o o l s
(9 0 2 5 78100) . M eas u reth e l l n e r D ro i ru s l o n e l i h
me a su r lng gauge ( 90 2 5 7 9 2 0 0 ). F l x th e d l a l
gauge +o +he measurlng gauge and sel lf to zero
} tl i h a c ar ef ully cl e a n e d c y l l n d e r b l o c k to p
face. Move +he dlål gauge onto ihe top of +he
cy I I nder | | ner f lang€ and note ihe gauge
readlng. Corry oui ih€ measuremeni ln tour
dlffereni polnts. The proiruslon of ih€
cyllnder llners obove the cyllnder block iop 21 7
tace should be b€tyeen orOJ cnd O,O8 ||r. l{ofiol In the ll and 12 serles englnes the
The max helght dl tterenca betr€n the llners cyllnd€r llners rtih standord tlange fhlckness
under lhe sane cyllnder head may nof exceod åre dlvlded Into tyo ca'tegor les dependlng o.l
'".,KR T\T\R NTT\q \\Rl\ K\ K R \qK tR \\'ss \\\Str=. q\'f"b+"\'$iså"=
\,{\. ..
fhan fhe ones ln ellher ends. 9,04 - no narktng. F lange fhlcknåss 9,O4...9,O,
a- ö - fl hl te pal nfed mark (d 20) as shorn l n fl g . 2
 l{ ot €l I n c o n n e c l l o n rl fh cyllnder l l ner
fltflng renove nEierlal, lf ne€ded' Ylth
correctlon reanFr 9045 87200 In case of ll ond
12 €erles onglnes and wl+h reair€r 905.| 72m0 In
case of f09 englnes.
( for 311and411engi-
lf t he llne r p ro tru d e s h l g h e r o n o n e sl de than nes if needed)
on the opposl+e slde, chack the thlckness of
+he llner flange and the deplh of the flange
r ec es s ln ih e c y l l n d e r b l o c k .-l f th e r e are any
lr r egular l+ l o s , re p l a c e i h e l l n e r. C orreci i he
I lange .ecess In the cy I Inder block slth
correcllon r€amer.

red
.L'CJ

220

Insi al l atl on ordor of o-rl ngs l n 3l l, 4ll, 6ll

and 612 engIne cy I Inder | | ner.

P ress the l l nei - In l fs posl fl on In f he cyllnder

bl ock. The l l ner rl l l go l n easl l y ll ihe o-

'n rlngs are correcily placed. Ensure fhal ihe

l l ner vtl l l no+ rl se ou+ of l i s D o slt lon af +er
Insi ol l a+ l on.
.a 214

9 . Place ihe o- r lngs I n the cy I Indor llner gr@vgs

and lubricate ihem, p re fe ra b l y w l th gear ol l to
a vo ld sel zur e.

t{otel Try io åvold even sllghiest streichlng

ot ihe o-rl ngs dur lng lns f allailon because the
max sl-retch ot ihe lorer o-rlngs may only be
about 6 t. So as no't io lose the elasiiclty of
th e rin g, I ns t all l+ lr om f he loYer e n d a n d i r y
to a vo ld s + r et c hlng ( e. g. do not place f i n g e r s
be free n liner and r lng) .

10. lf ihe cyllnder block ls badly corraded ai +he

l orer o-rl ngs of i hg l l ner, you can I nst all a
thr€€-groove cyl l nder l l ner In 5l l , 4ll and 6ll
engl nes, spare pari no 8555 24480. The cyllndsr
l l ners rl + h ovsri hl ck fop fl ange (l ll, 4ll, 6ll
and 612 engl nes) are al so equl ppe d wlf h +hr e€
gr@ves for lorrer o-rlngs. The boftom groove
of thgse +hree-gr@ve llners rlll hove a red o-
rlng and lha t{o upper gr@vas a block ong.

ll n€€ded, an o-rlng (parf no 8565 29808) can

be l nsl al l ed l n the fop groove of t he f ll and
4l l engl ne l l ner. S houl d you I nsf all lt ,
chamter i ho cyl l nder l l ner top par+ guldance I n
the cyllnder block ylth reamer 9045 54800 io
l acl l l i ate the pl acl ng ol the o-rl ng .

219

I ns + allailo n o rd g r o f o -r I n g s ln the f09 s n g l n e

c y llnder lln e r.

2- 9
 2. FLYXIfEL rcUS II{G
I NS'ALLIl{G llf FLYIHEEL IloUSII{G

The correc+ posltlon ot ihe tlyrheel houslng io

cyllndar block ls secured ai ihe manufaciurlng
s+ age r lt h + r o d o w e l p l n s . D u rl n g In s i a l l o + l on
It ls not necassary io canirallze lhe rolaflve
poslflon of the flyuh€€l houslng and the
cyllnder bloc k . T h € fl y x h e e l h o u s l n g s d e l l vered
as spore parts also have ihe doxeI pln holes
ready.

t. Clean the ma lng faces of the cyllnder block

o n d t he t ly r he€l h o u s l n g c å re fu l l y .

Coaf the taces wlih seallng compound (6909

50008) .

3. Llti f ho f ly lJ h e e l h o u s l n g l n l ts p l a c e and
tl g hien + he r et a l n l n g s c re x s l l g h + l y .
4. MovE the flyxheel houslng so +hai +he doreI
p l ns holas m ee t. F l t th g d o w e l p l n s l n p l ace
r lfh tapplng drl f+ (9025 987@).
5. Check that ihe llD of lie nex shali s€al ls
Tlghten the flyrhe€l houslng retalnlng screys fl arl ess and i hat i ha l l p sprl ng l s l n lis
gvenly +o +hs ccr€ci forque, lnner hexagon poslilon. Lubrlcat6 the seal and ihe natlng
socket scrers (8 |I|n) to 60 ltr and o|iier tace of the crankshafi recr gnd xlfh oll. Push
hexagonscr€vrs (19 |l|tn)io ll0 iln. the shaft seal caretullv on lhe crankshaft and
agal nsi the fl yw heel housl ng. Top the seal
B. REPLAC
ING I}IE CRANGMFT FEAREI{D SEAL evenly dorn io ihe botiom wlih flitlng too I
8560 97515. Do noi use a pln-type tapplng drlti
DI srnou
nf the englne. because ihe meial body of the shafi sgal may
b€nd and cause leakaoe.
Open the flyrhesl retalnlng scrers and renbvo
ihe f lyr.heel.

,. Rerpve fhe old shaJf seal. Be careful noi io

damagethe crankshafi seellng surfaca.

4. Clean ih€ s€al recess ln the flyrhe€l houslng

cnd us9 enEry cloth io rerDve posslble sharp
Edges ln +h€ crankshafi rear end.

222

Notcl It the crankshafi ls so badlv rq-n ai

the seal ihat you doubt +he tlqhinels of ihe
s€al, change flie posltlon of ih; s€at t{tlh a
sh a f t s €al dls + a n c erl n g . A 2 rn mth l c k d l s t ance
rl n g r hlc h ls pl a c e d u n d € r fh 6 s € a l h a s sD arg
spore parl no 8560 20054.
CIL I NDERlffi) At|) Y LYE l,Ectl l Sr{

IIIEX

T ec inlc r l d a ta ........... ................. J- |

S p*lal t@ls ............ f- f

c ons t r qc o n ............. f- 4

ReDclr lnslruqtldrs

l. Cyl lndgr h€rd

A. R e m o v l n gi h e c y l l n d e r h eod.. . . . . . . . . . . . .......... 5- 7
B. R e m o v l n g+ h e v o l v e s ....... ...... 3- 1
C . C h { k l n g th e c y l l n d e r h eod.. . . . . . . . . . . . .......' .. l- 7
D . R e p l a c l n g th e v a l v e g uI d e. . . . . . . . . . . . ............ l- I
E. R e p l a c l n g th e In J e c i o r s| eeve........... ......... l- I
F . Ma c h l n l n gth e v a l v e s e of............. ............ J- 9
G . R e p l a c l n g th e v a l v e s e oi r1n9........ ............ l- 9
H . Gri n d l n g th e v a l v e s ....... ...... l- 9
l . F l ttl n g + h e v a l v e s ....... ....... l -10
J . F l + tl n g i h e c y l l n d e r h e ad J09,Jl l ,4l l . ........... l -l o
K. F l tfl n g th s c y l l n d € r h e ad 6l l , 6 | 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l -l I

2. Valvs rEchrnl sD
A. R e c o n d l i l o n l n g i h e v a l v e m€chanl sm....... ........ 3-12
B. R e p l a c l n g th e c a n s h a f+ /camshafi9e4r....... ...... l -12
C . C h e c k l n g a n d a d J u s fl n g t l € val vg c l earanc€s.. . . . . . .. . . . . . . . . ' . . . .. J-l l

VAIiIET 3-0
 L DATA(reJeci llnlt of par+ s+aied In brackets €fier ra+lng)
IECHNIC
volves, rocker crms and +rppets
Va lve flm Ing

}Jlfh a valve c lear an@ of 0, 30 r nm

-ln le + va lve ooens . . . . . . . . . . . l 0o b.t. d. c.
-ln le i va lve c los es , , . . . . . . . . 42o a. b. d. c.
-exha usf va lv e opens . . , . . . . . . . . 42o b. b. d. c.
-exha us+ va lv e c los es . , . . . . . . . . t0o a. t. d. c.
va lve cle ara nc €s c old and ho+ :
- ln le i va Ive 0, ,0
-exha ust va l v e 0, t0
Ang le o t valve s eai I n c y llnder head . . . . . . . . . . . . f00
l{id th o f va lv e s ea+ I n c y llnder head 1,0.,.t,5
Ang le o f va lv e t ac e. . , , , . . . . . . . 29,5o+0,17
ou tsid e dla m e+ ei of v alv e head:
- in le t valve llf , 4ll, 611, 612. . . . . . . .
-e xh au si va l v e J ll, 4ll, 6ll , 612 . . . . . . . . io
-i n le t valve 109 . . . . . . . . . . . . . l9
-exha ust va lv e f 09 , . . . . . . . . . . . .

In lsi valve s ' f em d lam eis - 9,465...9, 480

Exhausl va lve siem dlarneier 9,445...9 , 460
In lsf valve s f en c lear an@ ( gulda r eady f l i t e d ln cyllnder head) 0,040. ..0, 070
( 0,10)
Exh au st valve s + em c lear ön@ ( guld€ r ea d y f l i i e d In cyllnder head) 0,060...0 , 090
lo,t5l
Inside d lame + er of v alv e gulde ( nof f lf f e d ) 9,520...9 , 535
Ou +side d lao eier of v alv e gulde 16,02A...16,0t9
D la mefs' o t v alv e gulde bor e ln c y llnder h e a d | 6, 000... 16, 01I
Profru slo n o f v alv e gulde + op abov e c y ll n d e r h e a d s u r f a c e . . . . . . . . . l8
Dep +h o f valv e head f ac e be loer c y llnder h e a d s u r {a @ . . . . . . . . .
Valve sprln g f r ee lengt h:
-in ne r..,....... ,1
-o uTer , ... . . . . r . 6l
Sprlng p.essure Hhen sprlng comprossed io a length of:
-41 ,5 n m (ln nei s pr lng) . . . . . . , , . 70.,.90 N
-47 nrn (ouier sprlng) 19...2t0 N
Rccke. rn shafi d lamefer 19,959.. . | 9, 98O
Inslde d iame f er o{ r oc k er ar m bear lng b u s h :
- (rh en fltte d ln oos l+ lon) | 9,990.. . 20. 010
ouiside dlamefei of rockq' d-m bearlng b ush . . . . . . . . . . . . 2t,035.. . 23, 044
D lanEier of .ocker arm bore . . . . . . . . . . . . 23,O00.. . 2t , 021
Max pe rmlsslble pus h r od del lec f lon ( wh e n f r € ) ........... 0,4
Fre e len gih ol r oc k er ar n s pr lng 80
Sprlng pressure lihen sprlng @mpressed to € length of 58 fir 80...100 N
outs I de dlameter of taooef 29,919... 29, O
D la oe te. o f + appli bor e I n c y llnder bt c k ........... 10,000.. . 50, 021
Push ro d len gt h 109 , . , . . . , . . . . . . )al - |
Push ro d le ngt h t 11 , 4ll , 6ll . . . . . . . . . . . . . ,iä-l
Pu sh .od len g+ h 612 . . . . . . . . . . . . . 2791
Cyllnd€r held

Dlame ff o f I njec f c r - s leev e f lx lng hole :

-uDoer end 28,000.. . 28, 031
- toder eno 21, O@ ... 27 , 035
outslde dlameler of Injeclor sleeve:
-upoer end 21,979... 2A, 000
- towei eno 27,OT5. . . 21, O 9O
D la me+er of I nls t v alv e s 6at r lng ( s + an d a r d ) 48,054... 48, 070
Dla ne ier of ex haus + y alv e s eat r lng ( s ta n d a r d ) 45,045... 43, 01O
Dlan ete r o t r ec es s I n c y llnder head ( s + a n d a r d ) :
-fo r e xh au sf y alv e s ea+ 43,000.. . 41, 0t 6
-for In let v alv e s eaf 48,000... 48, 0r6

J- |
Overslz6 of exhcu+ valrc seat rlngs:
-ls+ oversl ze, part no. 8f6l l90o4 ........... 4t,251...15,27O
-2nd ovrslze, part no. 8f6l | 9OO5........... 4t,454...1t,17O
OYerslzes of lnlet velve s€ai rlngs:
-lsf ovsrsl ze, pari no. 8f6l 2296, ........... 48.2r 4. . , 18.21O
-2nd overslze, part no. 8161 229f5 ........... 48,454.. .48 ,l70
DI aneter of exhaust valva seöf rlng recesses In cyllnd€r hEod: '
-l st oversl za 45,2O0...45, 216
-2nd overs I za 43,40O...45, 416
Dl a m eid' of I nlgt v a l v e s e 6 t rl n g re c e s s e s In cyl l nder head:
-lsi oversl z9 48,2OO...44,216
-2nd ovgrsl ze 48,400...48,416
Cyllnder heod ih lckness | 04,90... | 05, 10
Cyl lnds head m l n th l c k n e s s (a fte t- m a c h l n l ng) | 04, 70
Ti g hienlng ioc qu e o f c y l l n d e r h e a d s c re rs .......... se€ | nsiruqt lons
nl nsi ol l l ng
cy | | nder h6ådn

CGhrtt 509, tl I
DI aneter of c am s h o f+b e a rl n g j o u rn a l n o . ' l (509) ......... 19,925...19, O
DI alFigr of c om s h a tt b e a rl n g J o u rn a l n o . | (l l l ) ......... 49,905...49,950
Dlamet€r ot c am s h a ft b e a rl n g i o u rn a l s n o s . 2...4 ........... 49, 885. . . /t9, 910
DI ameter of comshoft bearlng bores (f09) 50,04...50,06
(50,085)
Dlame+er of c am s h a ft b e a rl n g b o ra s (3 l l ) 50,000...50,025
( 50,050)
Cöm s haf lend pla y rl th a 0 ,5 n n g a s k e f b e t{ e€n cyl l ndei bl ck and l l ml ng
g € a r hous lng and b g tr€ e n tl m l n g g e a r h o u s l n g and tront cover ..... 0,450...1,550
Camhelght ( dls t a n c € b e fx e e n b a c k o l c a n a n d i l p ol com) ......... 41,44
Cam llf i ...... 1,44
co m s haf l m ax Der m l s s l b l e d a tl e c fl o n 0,05 (toi al
Indlcstor r.tdl ng

caEhafi 4l I

Dlameler of cangbcft beorlng iournal 49,905...49,95O

DI anleier ot canshalt b€arlng journals 49,875... i l 9, 900
Dlamel€r of camshatt berlng boros.. 50,000...50,025
( 50,050)
Camshafi end play rlth r 0,5 tlrt|gaskei belYe€n cyllnd€r bl€k 6nd flmlng
gear houslng and betu€n tlmlng gear houslng and front cover ..... 0,450...1,550
C helghi (dlstanco betu€€n brck ol cai and tlp of c4) ........ 41,4,1
ca n f t f i ......7.41
Camshaftmåx p€rmlsslble del lectlon 0,05 (toial
Indlcatd rcadlng

CrEhrft 6l l, 612.
D l a nef s - ol c om s h a ft b e a rl n g j o u rn a l s n o s . I . . . 7 . . . . . . . . . . . ...... 49,905...49,950
In slde dlam et er o f c a m s h a fl b e a rl n g b u s h e s l n cyl l nder bl ock
Bear lng bus h no. I .........' . .. 50,000...50,025
( 50,050)
Beår lng bus h nos .2 ...7 49,990...50,050
(50,080)
Camshöftend ploy rlih o 0,5 rn gaskei beireen cyllndf blck and tlmlng
gpar houslng ond b€tre€n tlmlng gear houslng ond froni cover 0,450...1,550
Can helgh+ (dlstenca betveen back of cam and tlp of cån) 4l . ,f4
C am| | t t . . . . . . . . 7,14
Camshaftmax p€rnlsslble def l€cilon 0,05 ( iotal
Indlcator reedl ng

3-2
 4
&
5
@ 8

6
@ I

10 11 12 13 14

18
15

SPECIALTOOLS( c y llnder I sn)

head and valve rnechan

I 8160 97r52 V al ve sprl ng fl ttl ng l ever

2 8160 Lock nut for val ve sprl ng l l ttl ng l ever
sJ60 97454 Torqug orm
8560 974t E xhaust v6l ve seat l evel -cuti er (509 al so l nl et val v e)
8J@ 914]5 E xhaust vol ve seat cufts' (f09 cl so l nl el val ve)
8560 914t7 E xhausi val ve seöf l nsl de cui i er (509 al so l nl at val ve)
1 8561 971t8 In lst valve seat level-cutter
8 8561 97459 In lei vrlve s€ei cutter
9 8561 91440 Inlst v!lvg seat lnslde cuiier
l0 8560 86085 InJectoi s leeve exfracior
ll 8560 9146t l nJecfa s l @ vo fl ttl ng drl ft
l2 8561 91410 InJocior matlng face reaner
It 85@ 97tt1 Vclve gulde r€movlng drlft
t4 8560 914r1 V al va gul de f l ti l ng drl ft
t5 E 58000 Cyl lnd€r heod tq.que rrench 309, 5ll, 4ll
t6 8r6l 51542 lndlcator tor elongation scrers 6ll, 612
t7 4565 5t 541 Scksi rrerch fc elongatlon scr€rs 6ll, 612
t8 7tt 4 05506 C up pl ug fl ttl ng drl { i f6 n

Q-a
CYLlilDER HEADAND VALVETECHNlsll

CYLINDERHEAD 10

Cyllnd,ar head 4ll

l . C yl l nd€r h ead
z. v-f tng
l. Injoc+f s leeve
4. C up p l ug
5. C up pl ug
6. V al ve gul de
7. Valve seai
8. V al ve ssat
9. Thread p l u g
10. Valve gear cover
l l . Gaske+
12, N u+
15. W asher
14. Rubber seaI
15. B reai her p lpe
to 16. C l amp
17. Ll {i l ng l ug
18. Scre{
19. S + ud
20. Seal r Ing

7ol
2l . P l ug
22. Hose connecfor
21. S eal rl ng
24. P l u9
25. S fud
26. Siud
27. CyI lnder head
gaske+
28. O-rl ng
29. O-rlng

109, ,ll cnd 4ll €nglnes have a one-part,

cross-flor cyllnder head of casf lron }rhere
each cyllnder has l+s ol'n Inlei and exhausi
channel on opposlte sldes of +he head. The
r lgld c ons + r u c tl o n a n d i h e e v e n l y s p a c ed head
bol+ s c on+ rlbu te + o g o o d s € a l l n g . T h e cool ant
c lr c ulat lon is d l re c te d In s u c h a w a v l h 8i the
c oollng of t he v a l v e s e a t a re a l s a s e ff l cl ent
as pos s lble.

6ll and 612 e n g l n e s h a v e i w o s e parate

c y llnder head s w h l c h a re + h e s a me l n basl c
consiruct lon as those of 3-cy I and 4-cy I
englnes. Än exiernal {ater-co I lec+| ng plpo
jolns +he cyllnder heads io fhe ihermos+af
houslng.

3-4
 Cr$s-s€st lon ot cyl Indor haad
l. Va lv e gul de
2. Yalve seoi
5. InJectcr s leeve
4. O- r lng s eals

The lnlet vclve guldes and exhousi volve guldes

(l) are rep loceable and lnterchang€ab16. Hlgh-
porer -turbocharged5ll and 4ll englngs and all
6ll and 612 englnes have separate, replaceablE
va l ve s €af r lngs (2 ). T h e In J e c to rs a.e
gncompassgd In o rep laceab19 copper sle€ve (5)
surrounded by coolant. Thls tloans the b€si
posslble cool Ing of tt|9 lnJectd-s.

3-5
YALYEi€CH]{^I STI

VrlYe flEchanlsn ,ll I

1. C l rcl l p
2. Spaclng rasher
5. Nut
4. Rck€r arm
5. B ushIng
6. Adjustlng screr
7. Brackei
8. S prl ng
9. Shaft
10. P l ug
ll. P ush rod
12. Tappet
S pl l t col l ei
14. S prI ng col l c r
V al ve sprl ng
V ol ve sprl ng
17. S prl ng cup
t8. Exhaus+valve
t9. l nl st val ve
20. Gear
21. Key
Camshaft
2t. Thread pl ug

T h€ c åm s h€ft (2 2 ), s l tr.ra i e d In fh e cyl l nder

bloc k , ölv es l -h e v c l v e m e c h a n l s ml h rough the
iappat s ( 12) a n d p u s h ro d s (l l ). T h e c amshatf
gear ( 20) ls fl x e d v rl th c rl m p c o n n e c tl on and
f lt ied r l+ h a k a y (2 1). Ev e ry b Eo rl n g Journal
ls pressure-lubr lcaied ihrough ihe oll bore ln
tho camshaft.

3-6
 XORKI NSTRIJCT
IONS

CIL I ND€RIfAD ATD VALVEI.ECHAN

I SM 2. Fl x i he val v€ sprl ng ftttl ng l ever (8 160 975f 2)
on l-op of +he valve sprlngs and compress fhe
t. CYLII{DERI€AD sprl ngs. R emovespl l i col l gfs, sP rl ng collar s
and sprl ngs and dei ach l he val ve.
REI,IOY T€AD
ING THE CYLINDER
c. CTCCKING I}IE CYLI NDERIfAD
Clean +he outslde of l-he gnglne and draln the
coolant. Dlsconneci fhe rater hoses flxed +o t. Removs the carbon deposl+ from ihe exhaust
ihe c y llnde r h e a d a n d th e rn o s i a t h o u sl ng. po-fs, clean the seallng taceg and liash ihe
cyl l nder hgad caretu l l y.
Removethe al. plpes bettregn alr fi lier and
turbocharger and between+urbocharger and lnlef
r nanlf old. C heckthe cyl l nder head for possl bl e cr acks ånd
other danage.
Loosen ihe screws of +he mounilng flange of ihe
+urbocharger pressure ol I plpe and the lower
plpe connec+or, then remove the plpe. Loosen
ihe scrers of ihe turbocharger reiurn ol I plpe
flange and the louer clanp, fhen renove the
p lpe.

Dlsconneci ihe olDes of fhe fusl reservolr of

+ he T hgr n|o s i a rt d e v l c e (l f a s s e mb l e d ).

open ihe c o n n e c + l n gs c r6 * s o f th e o v e r fl ov/ pl pe

of ihe I nJ e c + o rs , re m o v eth e p l p o a n d dl snoun+
+ he lnJ ec tl o n p l p e s , 0 p e n + h e Inj ec+ or
r eialnlng n u ts a n d re n p v e th e l n j e c iors. Fl i
pr ot ec ilv e p l u g s l n th e c o n n e c tl o n p ol nts ol
the {ue I eouiomenl-.
5o9oO
open fhe connec+lng screr of +he lube oi I plpe
leadlng + o + h e c y l l n d e r h e a d a n d th e p l pe j ol nf C heck+ he s+ rol gh+ n6ssof i he seal l ng t ace wlt h
at t he lor e r e n d , th e n re d p v e i h e p l pe (Jl l , a hal rl l ne gauge agal nsi l l ght. l f i he seallng
611, 612t , face i s not si ral gh+ , l + mus+be machlnedunt ll
It l s.0ff the cyl l nder head can b e m achlned
1 . O pen + he ln l e i ma n l fo l d fl x l n g s c re w s, exhaus+ 0,20 ri n, l eavl ng a thl ckness of 104, 70 dm .
m anlf old nu i s , + h e rrn o s i a t h o u s l n g s cre{s and Further 0,20 rm rnay be machlned, bu+ thls
lr onf llf f lng l u 9 s c re rs o n d rs m o v e- the parts l nvol ves l nstal l l ng 0,20 rm shorter plsions
from ihe cy I I ndor head. (s€ lnstructlons,pol nt il 2 | ). After the
second machl nl ng i he ml nl mumthl ckness of ihe
open the refalnlng nuts ol thg valve gear cover head ls 104,50 im.
and renove +he cover and thg breaiher DlDe
( 309, 51t , 41 1 ).

9 . open + he v a l v e g e a r re i a l n l n g n u + s a n d bol f and

remove ihe valve gear. Llfi ihe push rods off
of f helr Do sl f l o n s .

1 0 . Loos enihe cy l l n d e r h e a d fl x l n g g c fe x s by i urn-

I ng t hem t lr s l o n l y € b o u i 1 /4 o t a roi ai l on ai
a ilme. Renove +he screxs and dismolni th9
c y llnder he a d . l f th e c y l l n d e r h e a d i s i l ghfl y
fltted, d<rnot tap a {edge bet{eon lhe cyllnder
bloc k and h e a d , s l n c e th l s ma y d amagei he
s eallng l8c e s .

REIIOV
ll,lc IHE VALVES
lf y ou I nt e n d i o fl + + h e s a n e v a l v e s b ack, mark
+ hem s o f ha t y o u c a n l n s i a l l + h e n In i hel r
or lg I nal po sl t l o n s .

1. Ffx +he lock nut (At6O 91t561 oI t h e v a l v g

s pr lng llf t ln g l e v e r In th e v a l v e gear cover
s + ud ( f r y l a n d 6 -c y l e n g l n e s h a v e no studs a+
ihe m lddle va l v e s . l n + h l s c a s e fl x a a sTuo or
a hex agof sc l re w o f s u l + a b l e l e n g i h ).
f4easurothe wear be+weenthe valve siem and lis
gul de w l fh a dl al gauge. Ll fi i ho valv6 ln l+s
place to have lhe valve head 15 mmabove the
cyl l nder head tace and fl l i he dlal gauge
measurlng end on the valve head edge. Move -the
valve ln fhe dlrec+lon of +he dlal gauge and
read ihe clearance. The max clearönce ln +he
lnlet valve gulde may no+ exceed 0,lO m
@" and In the exhaust valve gulde 0r55 ||m.
By uslng a ne}, valve {or +he measurementvou
can determl ne i h€ val ve gul de w ear.

3- 7
 D. REFTICII{G IHE YAI-YEGUIOE E. REPLACI}GIT€ I}IJECTOR
SLEEVE

l . Fl x i he i h r e a d e d p l n of fhe lnJec+or s lgeve

l . R e n ov ef he old gu l d e el+h a drlf+ (Bt6O 91331), exfractor (8160 86085) l n i h e s leeve by turn-
e l th er I n a v lc e o r b y + € p p l n g . C l € a n th e g ul de Ing.
b o re of lm pur lf le s .

o
2. Place 'the extrac+or shroud on top ot fhe
fhreaded pl n, fl x fhe nuf l n ihe P l n and turn
un-tl l the sl €ve l s l @ s€.
(
l . C l eön fhe l nJ€c+ or sl eeve bore l n + he cyl l n der
head cai eful l y. E nsure i haf th€ upper end gulde
2. L u b rlc ai€ ihe oui s l d e o f i h e n e w g u fa . f? g 8 h+ fy has no sharp edges shlch mlght damage lh6
l 'l th oll. T ap ihe g u l d e In l ts p o s l tl o n { l th a o-rl ngs dur Ing Insi al l a+ l on.
drlfi (8f60 97457). |{han uslno fhe neniloned
fl t+lng dr lf t t h e u p p e r e n d - o { fh e g u l de
remalns ai the correct level (18 mm) above -ihe
cyl l nder head lac e a n d + h e o l I g u l d e b e vel
si a ys I nt ac f .

39

3 . Th e lnle+ v alv e g u l d e s a n d e x h a u s t v a l v e g u l des 4. Apply seallng conpound (6909 J0008) fo the

a re lden+ lc al. I n s ta | | the guldes {lih +he more sl eeve l orer end. P l ace nex o-rl ng soal s l n t ha
cham{ered ond upyards. Ensure iha+ ihe valves upper end and lubrlcaie th€n llghtly r,lth
move sn@ih ly ln ihglr guI des. vasel l ne. Tap the sl €€ve l nto posl i l on xt t h a
3 -8 drl f+ (81@ 9746ö).
 2. Turn the cyllnder heod ihe rlght ray and tap
'the valve s+em unill the seat rlnq congs loose.

f. C l aan the seat rl ng posl tl on In the cyllnder

head. B efor€ tl ttl ng a n€r, seat rl ng, coo I the
rl ng rl th l l qul d nl i rogen. Let th€ r lng cooI
doin In n lirogen uni | | f I zz Ing around ll siops.
4. Tap the ssa+ rl ng l n pl öce w l i h ö sult ab le
drl ft and nachl ne th€ ssai l nq fac€.

Nofel ll needed, a s+andard seai rlng can be

replaced n l +h a rlng tilih |rlder o u i sl d e
dlameier. Seai rlnqs for b o f h In l e + a n d
e x h a u s t v a l v o s a r 6 d e a l v e r e d I n t t o ove r sl ze s.
313 See Technlcal data, polnf cyllnder head.

I t nec es s a ry , s tra l g h + e n a n d c l e a n + he matl ng

s ur f ac e of th € In J e c + o r s e a l l n g w a s h er In l he
cy I I nder head Hlfh a r€amer ( 8161 974?0).
H. GRINDIIIGI}C YALVES

Icrtcl lJ requlred, the standard lniec'tor

slee ve cä n b e r oplac ed by one r lt h 0,4 ||m
o ve rslze top . B€f or e lns + alllng t he s l e e v e ,
ma ch lne the cy llnder head upper gulde bo r e +o ö
0,4 m blgger slze. The c.d€r nunber for ihe
o ve rslze In jec + or s leev e ls 8160 f 8721.

F. llÄo{lNl}c THE VALVESE T

315

To ensure max ilghiness betHeon +ho valve önd

th6 seat, ihe dlffgrence In lncllnatlon b g tr e € n
s e a l l n g s u r f a c e s l s 0 , 5 0 . T h l s m o ke s a ve r v
n a . r o w s e a l l n g s u r f a c e w h l c h s e 6 l s b e tte r i h a n
a wlde one, evon yhen worn.

t. ll ihe valvo head ls domagod, ireoi l t In th e

g r l n d l n q m a c h l n e . A d J u s t f h e g r l n d l n g n a ch l n a
to 29,54. Do no+ grlnd fllore than ls necessarv
io clean the contaqi surtace.

l f f h e v a l v e h e a d o u t e r e d g e t h l c k n e ss remalns
under 1,5 mn, replaco ihe valve.

It the valve stem l-op has rorn hol lor, lgvel lt

by grlndlng.

'14

t4 achIn e fh e dom agedv alv o s ea+ us lng va l v e ssöi

cutters 8160 97454...91440 or use a valve sect
g rind er. lf t he s eat s ur f ac e ls { lder l h a n 1,5
nm, närrow lf olthe. lrom the outer or ihe
in ne r ed 9e . The lnc llna+ lon of ihe v a l v e seat
surJace ls J oo.

REPLACII{G TIIE Y^LVE SEAT R I NG

Th e Jll a nd 4ll englnes of hlgher o u t p u t a n d

a ll 6 ll a nd 612 englnes ar e f ur nls h e d r l l h c) o
sep ara te v alv e s eöt r lngs . lf t he s e a l l n g
surface ls so torn that ll canno+ be lrDroved
by ma ch inln g, r epl6c e t he s eai r ln9.
66
Grlnd +he hs ad ot f he r ejec t ed v alv e so t h a + l t
flis ln+o t he s eai r lng. Fli + he v a l v 6 l n
po sl+lon an d * eld lt io f he s eai r lnq. C o o l t h e
ee ld r lih r at * .
4 . Grl n d t he v aly e a g a l n s i l i s s e a + x l i h a fl ne
grlndlng pasie. Check the con+act surfaces rlth
te s+ lng c o lour .

5 . C l e an t he c y llnd e r h e a d a n d th e v a l v e s of
g rl nd I ng r es ldue s c a re fu l l y .

I . F ITTII{G TIf, VALVES

l . C h e c k t he c ondli l o n o t th e v a l v e s p rl n g s . l f
nocessary, irfal press lhe sprlngs ln å control
devlce, for pressure see Technlcal da+a, poln+
va l v os . 309
2 . L u b r lc a+ e t he v a l v e s te ms u l th e n o l n e o l l and
place ihe valves ln the correc+ örder ln ihe
cyl lnder head.
i . Fl t t hg v alv e sp rl n g s a n d s p rl n g c o l l a rs In
p l a c e, c om pr es si h e s p rl n g s | rl i h fl ttl n g l ever
l At6O 97552t and fl t s p l l t c o l l e + s In p l a c e.

Af+ er f lt ilng lhe v a l v e s a n s u re fh a t th e spl i t

col lets a.e corroct ly posl+loned by, for
e xa m ple, c ar ef ull y ta p p l n g o n i h e v a l v e heads
rl i h a plås ilc ha n me r.
311
J. FITTINGTHECrl-tiFER IEAD rO9, lll, 4ll
En s ur e f ha' f t he c y l l n d e r h e a d fi x l n g s tu d s (no+
1 0 9 ) ar e pr oper l y i l g h i e n e d to i h e c y l bl ock
(5 0 ilo) . F lt th e v a l v s + a o o e ts In thel r
D o sl+ lons .

411
318

T l g h +e n i h e h e a d s c r e w s I n p h a s s s a n d I n l h e
sequence shown ln llg. ! 18. The tlghtenlng
s e q u e n c e l s a l s o I n d l c a +e d b y n u m b e r s l n i h e
c y l l n d e r h e a d . T l g h t e n a l l g c r e w s t l r s + +o l h €
torque of 80 Nn, then io | 40 Nn and
f I n ö l l y +o 1 6 0 N n .

I n s l - a l l D u s h r o d s l n t h e l r o o s l +l o n s a n d fl x
i h e v ö l v e g e a r i o i h e c y l l n d e r h e a d . T l gh te n
ihe valve gear flxlng brackgts evenly and lhe
411 ou+ermosf brackeis so +hat the eashers ai ihe
l. 0- ring 13,1X 1,6 rocker arm shalt ends beslde +he lock rlnq
rotate free lv.
2.0- ring 1l x 2
317 6. Adj ust ihe va lve clearancos. S€ lnsiructlo|ls
pol nt J 2 C .
Check tha t ihe s eallng f ac es of t he c y lln d e r
bloc k a nd cyllnd er head ar e c lean. J 09 engln e s :
7. Fl t al l + he oi her parts you dl smounl eddu r lng
T ap the do wel p lns of t he c y llnder cyllnder head renoval. S9g lnstructlons polnt
head I n i o
thelr l tA .
h ole s. Flt t he c y llnder head gas k e t I n
posltlon. Place o-rlngs ln ihe hsad gaske+ rear
end around the ol I bore and ihe coollng boro 8. Run +he englne for max 0,5 hrs and retlghien
(4ll 'the cyllnder hgad screys. Parform ihe ilghfen-
beslde ll englnas : noie lhe dlf f er l n g
slzes of ihe o -rlngs ) . Ing In + he order i ndl ca+ ed, sl l gh+ l y open +he
screw and +lghten li to fhe correct iorque
F li
rhl le rofatl n9.
fh e he ad In plac e. Clean and lubr lc a i e
flxlng scrsw ihreads and tlghten +he screws.
N qtet A l rays adj ust + he val ve cl earances
afts' tlghtenlng cyl indq- head screxs.
Note I }lhen ilghtengd io +he correci forque
unlub rlca ted scr ey s c aus e. y r ong pr es s lng f o r c e
on +he head gasket,

3-10
K. FITTI G Tlf CrL |l|)€R rf D 6 , 6t2

321

5, Tlghien the scrers ln ihe mentloned sequenco

60ö (angular dlstance on lhe screr head). Use
socket rrench 4361 31341 and lndlc6tor 856f
319 l l f42 rl i h magnetl c fl xl ng. The ou+ slda of +he
socke+ wrench has a hole marked ai Iniervals o{
Me asure ihe lengl- h ot ihe c y llnd€ r head 600. S eftl ng the Indl cai or af the ho les helps
flxlng scre r s . The lengih s hould b€ r l i h l n -the tlght€n fhe screr to the corrgct iorque.
llnlts lnd lc aied in f lg. J 19 . ll a n y s c r e r
d llfers in lengt h, r eplac e ii. Tlghten the scrers 600 (one öngular dls+ance
= one hole dis+ance on fhe socket rrench).
2. Flx fhe cy l lnder head s t uds io t he c y l l n d € i
b lock (J0 Nm ) . I ns t öll lhe v alv e la D D e t s I n Tlghten ihe scrsrs 600 (one angulor dls+anco
= one holg dlstance on fhe sockef rrench).
ihe lr po s ltlo ns .

f. Ch ock tha t the s eallng s ur f ac es of t he c y l l n d e r 8. Fl i fhe val ye tappe+ s In l hel r posl t lons and
b lock a nd heads ar e c lean. Plac a +h e h € a d tl x i he val ve gears i o + he cyl l nd€ r heads.
g aske ts a nd c y llnder heads ln t hglr p o s l t l o n s . Tl ghi en fhe val ve geat- fl xl ng brackst s evenly
Ensure lha+ +he cy I Inder heads are stra lght and the outernosi brackets so lhat lhe yashers
and parallel fo each qther by uslng a stg6 | o+ thg rocker arn shat+ gnds beslde the lock
ru ler ( lnle t nanlf old s €allng) . Tlg h t e n +h o rl ng rotaie lreely.
cle an ed a nd I lghily ol led s c r ews and n u t s .
9. Adjust the valve clearances. Sco lnstructloos
polnt I 2 C.

10. Fl f al l fhe o+ her p€rts you dl snoun+eddur lng

cy I Inder head removal .

ll. Run lhe englne for abouf 50 nlnuies ,lth a

l l ght l oad.

Tlghten the scrers 600 (one angular dlstance

= one hole dlsiance on ihe sockel rrench) and
adJust lhe valves,

6 1 1, 61 2

Perform the f l.st tl gh+enI ng ln lhe order g lven

I n f lg. 5 2 0 fo ihe +orque of 40 N m, usl ng 6
+cr'queyagnch.

3- 11
2 . Y LVE I,ECHI{t Stl
RECtf{D|T|O{|r'rG
ItG VALVEl€CH N|SM
Check fhe condl+lon of +he valve iappets paylng
speclal afientlon lo iha coniac+ face agalnsi
ihe camshafi. Replace any worn or otherwlse
defectl ve lappets. OLD

NE W
324

Not€ | There are +ro types of rocker arm

shat+ s l n use. In + he shaf+ used earl l er ths r e
Here 'fldo horlzonfal ol I bores for lubrlcatlno
all rocker arms. The ner{ shaft has one verilcai
oll bore at each rocker arm. To ldenilfv the
nee shaf+ there are il{o Insialla+lon rnarks
machl nedon l ts top face. I{hen l ns+ al l l ng i h e
rockor arms noie the c!.rec+ Dosl+lon of ihe
marks = upward.
Check the s+ralghiness of fhe push rod uslng a
p l ane dls c . A ls o c h e c k th a + th e b a l l e n d f aces
of ihe Dush rods are lntact.

Dlsmantlo ihe rocker at-rnassemblyand clean ihe
p a r + s c ar ef ully . C h e c k i h a t i h e s h a ft l s nol -
v,o r n and t hat + h e l u b rl c a + l o n D o rts a re c lean.
B. REPIICING T1€ CAIISMFT / CÄI.|SHT|FT
GEAR
l. Removethe boost alr Dlpe betvleen the +urbo-
charger and the l nl e+ manl fol d (l f Ins+ alled) ,
Open the fl xl ng nu+ s of + he val ve gear cover
and rerpve the cover and +he breather plpo.
Loosen the val ve gear fl xl ng nu+ s (and ihe
screH l n f-cyl and 6-cy I engl nes), t hen
renove +he valve gear.

2. L@son ihe fan flxlng scrers and remove ihe

fan. open the al i ernator fl xl ng screw s, t hen
reflpve th6 al+erna+or, beli spanner and y-bolt.

f. Oponfhe crankshafi end nu+ of i 09, Jl l an d 4ll

engl nes w l + h tool 9024 74200 and of 6l l an d 612
englnes wlth tool 9024 55800. Draw fhe beli
pul l ey - hub pl ece combl natl on off the c r ank-
s haff.

4. Loosen ihe fron+ cover scrers and nuts and

removo +he faonf covs'.

Check ihe rocker arm bearlng bush lor xear. lf

you replace +he bush, ensuro thal +he oll Pori
l s t n pos l+ lon b e fo re p re s s l n g i h e b u sh l n
p l ac e. A f t er lns + a l l l n g + h e b u s h , b ro a c h lt ' to
l +s c or r ec + s lze 1 9 ,9 9 0 ...2 0 ,0 1 0 mr. l f the
ihrusi faco of +he rockor arrn ls worn, grlnd lt
to lts correct form. Slnce +he ihrusi face has
boen case hardened, grlnd only deep enough fo
srnoo+houf the lrregu lar ll les.

Pl ac e a loc k rl n g In fh e o fh e r e n d o f the
rocker arm shafl, lubrlcaie the shaft and
Insiall the parts on ihe shafi ln correci
order. Make sure ihai the lock rlngs sl't Lck the i appei s up to el l ml nafe i he rl sk ol
properly ln ihelr grooves. and fha+ ihe cup + hel r fal l l ng doun l { hen renovl ng i he camshaf t
p l ugs I n f he s ha f+ e n d s a re l n l h e l r p o s l + lons. and thus preven+ i ng + he Instal l a+ l on of +he

3 -12
 Ncrtel BendIn9 the push rods excesslve ly
causes bends! Use only s u c h o -rl n g s whl ch nl l l
not be f lt ied l n + h e l r actua I p laces.
Roia+e +he crankshaft so as io have Tne
I ns ialla+ lon ma rk s o f i h e c a ms h a fi gear and
ldler gear mee+. Draw the camshaf+ou+ of Tne
c v I lnder b lo c k .
7. Us e a dr lf + o f s u l fa b l e s l z e to remove l he
c am s haf f ge a r.
lf y ou I nt e n d to i n s i a l l a n o l d c amshaft or
gear , c lean i h e p a r+ s b e fo re fl ttl n g i hem.
9. P lac e t hr ea d p l u g s In th e c a m s h a ft ol I bore
ends. Sef a wedge in+o the camshafi key groove.
I,Jarmfhe camshaft gear up io the fempera+ureof
2 0 0 o C an d p l a c e l i l n l i s p o s l + l o n .
1 0. Lubri cate ihe camshaf+ bearIng journa I s and
pus h + he s h a t+ i n fo i h e c y I In d e r b l o c k checkIng
ihe ins + alla + i o n m a rk s o n + h e g e a r.
ll.
Fl+ ih e fro nt c ov er and ihe pulley - h u b p l e c e
comblnaflon, see Instruqtlons, polnt 5.
12. L ei ih e ta ppeis dor n and I ns t all + he v a l v e g e a r
( ln stru ctlo ns 3 | J polnt 5) . Fl+ +h e v a l v o
gear cover and +he brea+her plpe as \{ell as the
boost alr pipe bel-lreen ihe tu.bocharger and the
ln le+ mani fo ld.
lJ. In sia ll +h e al- t er naior and l' he beli s p a n n e r a n d
a dju s+ th e v - belt t ens lon. Fll' t he f a n a n d
ii g h+en lis llx ing s c r ews .
C. CHECKINGAND ADJUSTITIGTHE YALVE CLEARANC€S
T he c lear an c e o f b o + h l n l e i a n d e x h a us+val ves
ls 0,30 Fn. The clearanca can be checked
r egar dles s o f w h e + h e r i h e e n g l n e l s col d or
ho1. Chec k a n d a d j u s t th 6 v a l v e c l o a ra nces of a
c er t aln c v l l n d e r w h e n th e D l s to n ls at l fs
comoression stroke too dead cenfre. Check ihe
v alv es ln + h e In j e c l -l o n o rd e r o f th e engl ne.
Rgmove+he boost alr Dloe beivroen +he turbo-
c har ger and th e In l e i m a n l fo l d . Op e nihe fl xl ng
nu+s of the valvg gear cover, removg+he covor
and lhe br e a + h e rp l p e . T a k e o ff th e p l ug on + he
s lde of th e fl y w h e e l h o u s l n g (crankshafi
rotatlon ).
ENCINES
'O9
Ro+a+ethe crankshai't by the flywheel gear rlm
v . lt h, f or e x 6 m p l e , a s c re w d rl v e r, u ni l l the
ex haus + v a l v e o f th e l rd c y l l n d e r ( 5th val ve
f . om ihe e n g l n e fro n + ) l s c ö mp l e t el y open.
Chec klhe va l v e c l e a ra n c a o f th e l s f cvi l nder.
327
l f the cl earance dl ffers f.dn i ho ra+lng, open
the l ock nut sl l gh+ l y and adj ust a cor r ect
cl oarance vl l th an adj us+ l ng screx. Tho clear -
ance ls correc+ *hen a 0,30 |Im feeler gauge ls
sl l ghtl y + l ght-fl tl ed bei w een the rocker ar m
and the va lve head,
J. Turn the crankshaf+ furi her l n l ts r unnlng
dl rec+ l on, un+ l l -i he exhausl val ve of +he lst
cyl l nder (2nd val vo) l s i ul l y open. Check t he
val ve cl earance of the znd cyl l nder.
4. Ro+aie the crankshaft fur+her In runnlng
dl reci l on, un+ l l + he exhausi val ve of +he 2nd
cyl l nder (4i h val ve) i s ful l y open. Check - t he
val ve cl earance of + he Jrd cvl l nder.
]I I ENGI
NES
2. Turn + he crankshaf+ by + he l l yw heol gear r lm
| {l + h, for exampl e, a screw drl vor, unt ll t he
exhaust val ve of + he frd cyl l nder (5 t h valve
leiel y open.
frorn ihe englne front) ls cornp
C heck the val ve cl earance ol + he l si cyllnder .
l f the cl earance dl ffers from + he ra+lng, open
i he l ock nu+ sl l gh+ l y and adj us+ a cor r ec+
cl earance w l + h an adj ustl ng screw . The clear -
ance ls co.rect rhen a 0,30 mm feeler gauge Is
sl l ghtl y tl ght-fl tted bet{ een the ro cker ar m
and the va lve hoad.
J. Turn + he crankshafi
furl her In r unn I n9
dl rectl on, untl l + he exhausi val ve of +he lst
cyl l nder (l sl val ve) l s fu l l y open. Check t ho
val ve cl earance of + he 2nd cyl l nder.
4. Ro+aie the crankshaf+ {uriher
ln runnlng
dl rectl on, un+ l l i he exhaus+ val ve of ihe 2nd
cyl i nder (frd val ve) l s compl etel y open. Check
the val ve cl earan@ of + he frd cvl l nder .
4II ENGI
NES
2. R o+ a+ e the crankshaft In runnl ng d lr ecllon,
-untl l l ho val ves of the 4th cvl l n dsr ar e
rockl ng (exhausi val ve cl osss, l nl ol valve
opens), Check the valve clearance of l-he ls+
cyl l nder. l l the cl earance dl tfers f r om t he
ratl ng, open l he l ock nui sl l ghfl y and adjust a
correct clearance erl+h an adjustlng screw. The
clearance ls correci when a 0,J0 nm feelor
gauge l s sl l ghi l y
i l ghi -fl i ted between t he
r€ker ö.m and the va lve head.
l. Turn lhe crankshaft furlher l/2 of a rotailon
l n l he runnl ng dl rectl on so + ha+ the valves of
the frd cyl l nder are rockl ng. C heck the valve
crearan@ of + he 2nd cV l l nder.
3-13
4. Procaed elth checklng the clearances ln ihe
InJecllqr ordei:
- InJectfon ordar l, 2, 4, t enoinefronl end
@
- v alv e r c k lng p h a s o l n c y l l n d € ,- 4 , t, l , 2

6 1 1 1612 E NG I N E S

309

ond tho volvs heåd.

Rotäte ihe cränkshaff ltr+her l/3 of a ro+ailon
In r unnlng dlr ec tl o n s o i h o t th e v a l v e s o f i he
@^o-@
o"oo
2nd cyllnder öre rocklng. Check ihe valve
cl 6 or anc 6 of t he 5 th c y l l n d f.
1 . Proce€d rlth ch€cklng the clearances In lhe 311
InJec+lql ordEr:
- lnjectlon order l, 5, 5, 6, 2, 4
- v af v e r c k lng p h a s e In c y l 6 ,2 ,4 , l ,5 ,5
Cleon thg valve gear cover ond check ih6t the r@^Q:("ftO^e3g
o o"o o-@o"@o
J^ l
411

@_o-@
o-@ o

6111612

@.exhaust@- intet

3-14
CRANKCåSE

D{IEX

T €c hnlc ll d å ta ........... . . . . . . . . . . . . . . . . . 4- |

S p€c lal t @ l s ............ 4- 5

c oos t r us o n ............. 4- 6

Repolr lnstrustlons

l. Crankshalf
A. Remov lng th6 cranksha{+... 4-9
g . C h e c kIn g + h e c ra n k s h a fl ... 4-9
C . R e p l a c l n g i h e c r k s h a ft gear rl n 411..... 4-9
0 . R e p l a c l n g l h e c ra n k s h a fi gears.. . . . . . . . . . . 4-t 0
E . In s i a l l l n g i h e c ra n k s h a ft" .............. 4-t0
F. C ra n k s h a ft h u b p l e c e .. .... .. 4-11
G . R e p l s c l n g ft| e v l b ra i l o i d ampq-....... .... 4-tl

2. Conn€ctlng rods cnd plsions

A . R e molvn g th e c o n n e c l l n g r od and pl s+ qr... ........ 4-12
B . C h e c k fn ga n d re p l a c l n g l h e connectlng rod bear1ngs....,........... 4-12
C . O v e rs l z e p l s i q r p l n b a a rl ng bush..... ............ 4-12
D . l n s p e c i fn g + h e c o n n e c tl n g rod.............. ...... 4-12
E . C o n n e c i l n gro d re l g h + c I asses.. . . . . . . . . .......... 4-15
F. In s p e c + l n ga n d re p l a c l n g i he pl sl on r1ngs......................... 4-14
O . l n s p e c tl n g th e p l s i o n ....... .... 4-1,
H . F l ttl n g i h e p l s i o n p I n . . . . . . . . . . . . . . ............. 4-15
l. Sh o ri e n e do I s i o n s .......... .....4-15
J . F l ttl n g i h e p l s i o n a n d th e conneci l ng rod. . . . . . . . . . . . . . . . . . . . . . . . . 4-16

t. counferbcl ancå Fchrnlsn

A . R e n o yl n g a n d d l s a s s e m b l l ngthe counterbal ance mechanl sm........... 4-17
B . R e c o n d l tl o n l n g + h e c o u n terbal ancemehanI sm....................... 4-17
C . F l l -tl n g + h e c o u n + e rb a l a n cam€ch€nl srn..... ........ 4-17

{. F l yrh6l
A . R e p l a c l n g i tF { l y x h € e l s t ar+ s rl n...... ......... 4-18
B . F l i -tl n g + h e fl y rh e e l ..... ....... 4-18

vAlitEr
TECHNICAL DATA ('I)
(reje ct llml t of pa. t s f af ed I n br ac k e i s a f t € r 'r o t l n g )

Plsto n, p lsl on r lngs and pls t on pln

Itlln dlstance betwoen plston and cyl head, measured wlttt lead vllre through
I nJector h olo 0,900... 1, 150
P I ston d lameie. see l nst r uct lons,
pol ni 4 2 G
,09

P In bore In D I sion . . . . . . . . . . 16,001.. . 16, 009

Plsto n p ln d I am et er . . . . . , . . f5,995.. . 16, 000
l{ld th o f rln g gr@ves:
- ls+ groove 2,58O., . 2, 600
- 2nd gr@ve i ,040... J, 060
- lrd groove 4,040.., 4, 060
Slde cle ara nc os of pls t oo r lngs ln + he l r g r @ v e s :
- lst gro ove, har d c hr om e- p laied c om pr e s s l o n r 1 n 9 . . . , . . . . . . . . o,o9.,.o , 122
- 2nd gr@ve, compresslon r I ng . . . . . . . , . . . . o, 05. ..0, 082
- Jrd gro ove, ol I r lng . . . . . . . . 0,05, . .0, 085
- re ie qt llm lt 0, l 5
P I ston r Ing helght ( I n dlr ec ilc . r of c y l l n d e r ) :
- lsi r ing . . . . 2 , 4 7 4 . - . 2 , 49 0
- 2n d r In g 2,978... 2, 9
- f . d r f ng .... 3,975... 1, 990
P ls + on r lng g a p (e l th p l s + o n re a d y fl tted In cyl l ndar):
- c am pr es s l o nr In g s ........... 0,4...0,6
- ol I r lng .,. 0,25...0, 55
- r B jec t llm l + ..............,. 1,0

5 , 4 , 6
P ln bor e I n p l s i o n I ) 40,0m... 40, 006
P ls t on pin d l a rEi -e r ........ ... 19,995.. . 40, 000
t{ | dfh of r l n9 gr@ves:
- lsl' gaoove 2,560...2, 540
- 2 nd gr@ve 3,0ro...1 , 050
- frd groove 5,040...5 , 060
Slde clea ran c es of pls t on r lngs I n t he l r g r @ v e s :
- lst groove, hard chrohe-plated compresslon r I ng . . . . , . . . . . . . 0,07...0,102
- 2 nd g rco v e, c om pr es s lon r lng . . . . . . . . . .. . 0,04...0,072
- Jrd g roo v e, oll r lng , . . . . , . . 0,05...0, 082
- re j e qt llnlf 0, 15
P lsioi rln g helght ( ln d lr ec ilon of c y I I n d e r ) :
- lst rln g 2,474...2 , 490
- 2 nd rln g 2,97a,..2, 990
- lrd rin g 4,978. . .4, 990
Plsto o rln g gap ( * lt h pls ion r eady f l+ t o d ln cyllnder):
- compresslon r I n 95 . . , . . . , . . . . 0,4...0,6
- oll rln g 0,J...0,45
- re ject lim lt . . . . . . . . . . . . 1,0
lltn Ott OS e englne ( pls f on 816l I O ?OO ) b y t h e l c k rlng grcove 40,003.. . 40, 009
612

Pln b ore in pls ion , . . . . . . , . , ,14,001.

. . 44, 009
P lsion p ln dlar Eler . . . . . . . . 41,994.. . 44, 000
I{ld th of r Ing gr@ves:
- lst groove . . . . . . . . . . . r r . r . . 2,580...2, 600
- 2 nd gr@ve ...r ..,......r l, 040.. . r, 060
- Jrd groove . . . . . . . . . . . . . . 5,040.. ,5, 060
Slde clea ran c es of pls f oo . lngs ln ihe l r g r @ v e s :
- lsf groove, hard chrone-plafed compresslon r I ng . . . . . . . . . . . . 0,09.. .0 , 122
- 2n d g rco v e, c om pr os s lon r lng . . . . . . . . . .. . 0,05...0,082
- )a o g ao ov e, ol I r lng . . . . . , . . 0,05...0,082
- re j ecf llm lt 0, 15
 Pl s t oo r lng helg h + (l n d l re c + l q l o f c y l l n d er):
- ls + r I ng 2,474...2,490
- 2nd r I ng 2,97a...2,9q
- f r d r I ng 4,974...4,99O
Pl s ion r lng gap (l ,l i h p l s + o n re a d y fl + + e d In cyl l nder):
- conpression r I ngs . . . . . . . . . . . 0,4...0,6
- o ll r I n9 0,3...0,45
- rejec t llm lt t,0
[4 a xper nls s lble w e l g h f d l ffe re n c e b s tre e n p l s+ ons In sane engl ne 259
Pl s ion + o be hea + e du p to l 0 0 o c b e fo re J l ti l ng pl s+ on pl n.
Pl s + on pos lf lon In c y l l n d e r: c D m b u s tl o nc h ambeiof pl sfcn to facs tow ards l nj ector.

connectlng rod

509
In s lde d lam et er o f p l s + c n p l n b u s h
(whenbus h pr es se d l n + o c o n n e c + l n gro d ) .' ... ....... 36,025. . .36,O40
( 56,050)
o u i s lde d lam et er o f D l s i c n o l n b u s h (s i a n d ard) ............. 40,060...40.076

Ou + s ided lam et er o f p l s to n p l n b u s h , o v e rs l ze 8J6O18605 ...' ...." . 40,580... 40, 620

C o n nec t lngr od s m a l l e n d b o re ..,..... 40,000...40,025
( 40,040)
C o n nec t lngr od s m a l l e n d b o re (o v e rs l z e b u sh) ......... 40,5@ ,..40,525
Connec+lngrod blg end bore . . . . , . . . . . . . 6' ,' t 30. . .65, 749
| 65,77O
Tlghtenlng +orque of connec+ln9rod bsarlng cap screHs 90 Nm '

5 , 4 , 6t l
l n slde d lam e+ ero f Dl s ' fo n p l n b u s h
(whenbus h pr es se d i n + o c o n n e c + l n gro d ) ............ 40,025...40,040
( 40,050)
o u i s lde d lanet ei o f p l s to n p l n b u s h (s i a n d a rd) ............. 44,0A 2...44, 12O

Ou ls lde d lam et er o { p l s i o n p l n b u s h , o v e rs l z e 8J53 24326 ........... 44,5@ . ..44,6 20

connoc+Ing rod sma| | end bore .. . . . . .. 44,0OO...44,O 25
( 44, 0il0)
C o n neclng
t r od s m a l l e n d b o re (o v e rs l z e b u sh) ' .......' 44,500,..44,5 25
C o n nec + lngr od bl g e n d b o re .. . . . . . . , . . . 7t,73O...71,149
(11,1101
Tl ght enlng ir que o f c o n n e c i i n g ro d b e a rl n g cap screi s 90 Nm

612

l n s lde d lam eier o f o l s to n p l n b u s h

(w henbus h pr es s e d l n to c o n n o c + l n gro d ) .....' ...' .. 44,O2r...44,O4O
( 44,050)
Ou is lde d lam e+ e ro f p l s + o o p l n b u s h (s ta n d a rd) ............. 48,080...48, | 20

ouistde d lamoler of plsion ptn bush, overslze 8161 18606 48, 580.. .48,620
C o n nec f ingr od s m a l l e n d b o re ........ 48, 000.. .48,025
(48,040)
C o n nec + lngr od s m a l l e n d b o re (o v e rs l z e b u sh) ......' .. 48,5UJ...44,525
Connec'tlngrod bl9 end bore . . . . . . . . . . . . 76,13O...76.149
t16,770'
Tlgh+enlng +q'que of connec+lngrod bearlng caP screls see l nsi ructl o ns,
pol ni 4 2 J

C l e ar anc e ai blg e n d b e a rl n g ......... 0,046...0,098

C o n noc f lngr od en d p l a y o n c ra n k s h a f+ (l n dl rectl on of crankshaff axl s) ........... o,2o0...0,512

}ialghi ls stampedon blg end of connectlng rod.

Max pq- m ls s lble w e l g h + d l ffe re n c a b e tw e e nconneci l ng rods In sai E engl ne 20s

C o n nec f lngr od po s l + i o n r o rd l n a l n u n b e r to wards val ve mechanl sn

(co m bus ilonc ham b e ro f p l s l o n o n o p p o s l i e sl de).

4-2
Crcnksh!ft

509

ir ank p ln d la me t* :
- standard 61,981.. . 62, 000
- fst underslze 0,25 ftn (bearlng 8360 9126, 6t .131... 61 , 7r O
- 2nd unders fz e 0 ,5 0 ri n (b e a rl n g A 5 6 0 91261r...... 6t .481.. . 61. 500
- J r d unders l z e l ,@ n n (b e a rl n g At6 o 972@ 1...... 60,98t... 61 , 000
- 4ih unders l z e 1 ,5 0 n (b e a rl n g 8 3 6 0 972111..,.,, 60,48t.. . 60, 500
Crankpln length ,O,000. . . 40, l60
Cleör anc e at b l g € n d b € a rl n g ......... 0,046.. .0, 098
JournaI d lameier:
- standard 69,988. . . 70, 018
- ls+ underslze 0,25 nn (bearlng A360 91215, 69,7tA .. . 69, 78
- 2nd underslze 0,50 r|n (bearlng At60 97274, 69,488. . . 69, 5t I
- J r d under s l z e l ,c o n n (b e a rl n g A t@ 91276\ 68,988. . . 69, 0l8
- 4i-h underslze 1,50 mrn(bearlng 8360 972741 68,488.. . 68, 5t 8
M aln be6rlng c l e ö ra n c a 0,51...o , l ol
Lengih of ih ru s t b e a rl n g j o u rn o l (j o u r nal nearest to fl yrheel ):
- s t anda. d l e i g + h (2 s ta n d a rd + h ru s + pl ates) ....." .. 47,0@ .. . 47, 08O
- ls t ov er le n g + h (o n e s + a n d a rda n d o n e 0,2 nm over+ hl ck thrusl pl al e) 41,2O0 . . . 47, 280
- 2nd ov er le n g th (' tw o 0 ,2 ftn o v e rth l c k th.ust pl a+ es) 41,4O0.. . 41 , 4AO

ot her c r ank s h a ff j o u rn a l s ma y n o ' i b e g round l onger.

Cr ank s haf t e n d o l ö v ........ 0, | 00. ..0, i20

M ax per m ls s i b l e o v a l n e s s o r o th e r d e fo .nl ty ot crankpl ns or j ournal s 0,0J
Cr ank s haf t u n b a l a n c e I ,0 Ncmmax

5 , 4 , 6 tl
Crankpln d lame+e':
- standard 67,981... 68, 000
- f s t under s l z e 0 ,2 5 n n (b e a rl n g A 3 6 1 127621..' ... 67,131. . . 61, 150
- 2nd under s l z e 0 ,5 0 n rn (b e a rl n g 8 1 6 1 12761)...... 61,441. . . 6't , 5O O
- 3r d under s fz e 1 ,0 0 rl rn(b 6 a rl n g a t6 1 127651...... 65, 9Bt. .. 67, 000
- 4t h under s l z e 1 ,5 0 mm(b e a rl n g 8 t6 1 12761)...... 66,481. . , 66, 500
Cr ank pln len g fh 40,000. . . 40,160
Clear anc ea i b l g € n d b e a rl n g ......... 0,046... 0, 098

Journal d lamef€r-:
- sfandard 84,985.. . 85, 020
- ls t under s l z e 0 ,2 5 n rn (b e a rl n g 8 t6 1 2ot26, 84,1t5.. . 44, 770
- 2nd unders l z o 0 ,5 0 n m (b e a rl n g 8 t6 1 20327) a4,4A5.. .A4,520
- lr d unds r s l z e l ,m n n (b e a rl n g 8 3 6 1 2ot29l ........ 81, 985.. .84, 020
- 4ih u nd er s lz e 1, 50 r m ( bear lng A361 2 j t t 1 ) ............... 8t,4Ar...A5,520

Maln b eo rlng c loar onc a 0, 070... 0, I 55

Le ng ih of ih r us + bear lng jour nal ( J our n a l n e a r e s i t o f l y r h e a l ) l
- stan då rd leng+ h ( 2 s t andar d f hr us t p l a i e s ) . . . . . . . . . 45,000. . . 45, 08O
- lst overlength (one standard and one 0,1 |Im overthlck fhrust plate A561 20552, .. 45,100. . . 45, | 80
- 2nd ovarlengih (on6 standard and one 0,2 nrn overihlck thrust plate 8161 20515) .. 45,20o.. . 45, 2@
- lrd overlengih (one 0,1 mm and one 0,2 rrn overlhlck thrusi pla-te) 45,100. . . 45, 180
- 4th overlenglh (fwo 0,2 rrn ov€.fhlck lhrus+ plates) 45,400. . . 45, 480

Oths' crdkshaft journals may not be ground longer.

Cran ksha fi end p lay . . . . . . . . 0, 100... 0, 150

Max p srmlssl ble ov alnes s and o+ hgr def o r m l i y o f c r a n k p l n s o r j o u r n a l s 0,05
Cran ksha ft unba lanc a 1,0 N cmm ax
D la ne ter o f gear r lm of addlt lonal c ou n f e r b a l a n c € o n c r a n k s h a f t ( 4 l l e n g l n o s ) . . . . . l ro,22o . . . l50, 260
In sld e d lam els - of gear r lm of addlf lon a l c o u n t g r b a l ö n c a ( 4 l l e a g l n e s ) | 50,o0o... | 50, 040

4-3
 612
Crd|kp ln d lanei€r:
- stondard
JournaI d lameiei:
- stondord
- lsl undsrslz€ 0,25
- 2nd underslze 0,50
- Jr d und€r s lz e l ,O
- 4 ' lh under s lz e l ,i 0
Ma l n bearI ng c lea ra n c e
Othq' crankshoft Journals nay no+ be ground longer.
550) . . . . . . . . . . . .
72,981...13,00O
12,731...72,1 50
o
t5 t ) ..........., 72,441...72,50O
t 2 , .... .... .. .. 7l , t ...72,0@
............ 71,481...7t,5 00
' 5 1) 40, 000. .. /t0, | 60
0,066.. .0, | 05
84,985.. .85,0 20
nn (bearlng Bt6l 20326, u,735...A 4,7 70
fln (beartnö 8361 2032j, 84,445...A4,520
rm (b e a rl n o A t6 l 2 o j 2 9 l 8l , 985...84, 020
n m (b € a rtn a A t6 t 2 ' 5 tt ) ............... 43,4Ar...At,520
0,070...0, | 5 5
n oarest to f l yrhe€I ):
e s ) ,.......,.... 45,000.. .45,080
I n m ove.fhl ck fhrust pl ate) 45, 100...45, | 80
2 |rmoveri hl ck thrust pl ai e) 4' ,200...45,28O
fin ovo.+hlck thrust p löte) 45,3@ . .. 45,t f f i
ru si pl ates) 45,400.. .45,4 80

Cro nk s håf t end p l a y ..,.....

Ma x pgr m ls s lb19o v a l n e s s a n d o i h e r d e fo rmi ty of crånkpl ns cr- j ournöl s 0, l 0o. ..0, 150
Cr kshaff u nbaI ance 0,05
1,0 Non rnax
F lyrhco I

l n tq - t er en€ of sfa r+ q - rl m q t fl y w h € e l o, 422...O,600

Be fo r e t lt t lng t o fl y w h e e l s i ö ri e r| -l n i o b € heai ed up + o a + exT€rai ure of ........
F lyrh€l u nbaI anc\-6. , . . . . . . , . . . . . I 50.. .20CpC
Ma x ps r m ls s lble a x l a l ro b b l e o J fl y rh e e l c l u tch fac€, neasuredat l nner 1,0 N cmrnax
edge.of clutch t ace . . . , . . . . . . . .
Tl g h+ enlng ior que o f fl y w h e e l re i a l n l n g s c re rs ....r... O,06tö2OO
120 N m
Addltloncl coonterbalances (ill I englnes)

Eacklash bsfween gef si

- crank s haf t gear rl rn - @ u n te ro a ta n c eg e a r ............ 0,1...0,J
: g d! " €n gs ar s o f c o u n te rb al a n c e s ........ o, 05. . .0,25o
End_plöy of coun+erbalances
Shaft d lametq- a+ be6rlngs 0,1...0,5
In sroe ot anet or o ? c o u n te rb a l a n c eb u s h (fl ffe d) 25.979...26,06
26,O40...26,61
Sh öf t hole d lam el e rs € + re a s u rfa c e o f b o d y .....,... 26,065...26,0 6
Sh af t hole dlam e fe rs a t fro n t s u rfa c e o f b o åy.........
25,965..,25,9A6
Th l c k nes s of s hlit, b g frd e e nb o d y a n d c y l l n d 6 r ' bl ck o,2

4 -4
 3

IAL TO-S (crankcase )

SPEC
I 436, 97335 Pl s l q r r l ng p I l ers
8160 85825 Plsion flttlng ioo I J09
836t 85826 Pl s i c rf fl ttl ng i ool 3l l , 4l l , 6l l , 612
4360 91121 Crankshaff gaar extroc+or
9024 74200 Crankshaft end nut rrench t0g. tll, 411
24 558oO Crankshafi end nut rreoch 6ll, 612

4-5
CRANKCASE

10
I

Crankcaso fl I

l. Cra rksha f+ 12. Gear The fl yrheel (5) w l i h the gear rl m (6) fl xed io
2. Key 13. P uI l e y I-i wlth pressed-on fli ls fastened io ihs
3. MaIn b ea r Ing i4. Nuf crankshaf+ rear end. The conn6c+lng rod (20)
4. Thru st be ar lng 15. Hexagonsocks+ screw transfers +he gas forces generated by th9
5. F lytrheel 16. P l s to n combustlon of luel from the Dlston to the
6. Gea r rlm 17. P l s to n r In g s crankshafl. The cross-sectlon of ihe lorqad
7. Hexagon screr 18. Pls+on pln conneci l ng rod l s an l -profl l e. The bear ing
8. Hub 19. C l rc l l p housl ng l n the connec+ l ngrod bl g end l s spll+
9. Dust cover foi 20. Connectlng rod horl zoni al l y and the bearl ng cap l s fl xed t r l+h
shaft sea I 2l . B e a rIn g b u s h fvro speclal screyis (22) and nuts (21). The
l0.0 llde flector 22. Screw smal l end has an Ini egral be€rl ng housl n g yhlch
2f. Nu+ has + he pl si on pl n bearl ng bush (21) fl xed +o
24. B l g e n d b e a rl ng l i w l th pressed-onfl i .
The crankshafl' (l) ls fq-ged out of chrome- The connectlng rod blg end of ihe 612 englne
a lloy ed s pec la l s + e e l a n d l s I n d u c tI o n-h ardened has a bearl ng housl ng oJ angl e spl l t deslgn and
a t ihe bear lng a n d s e a l l n g p o l n + s . T h l s makes the bearl ng cap l s fl xed w l th tl {o rrel ongaf lon
ll pos s lble t o g rl n d th e s h a fi to fo u r under- scretsrr.
slzes wlihout new heai ireainent. The gears (ll
a nd 12) nhlc h d rl v e + h e l d l e r g e a r a n d + he ol I
Dump have been flxed +o +he crankshaf+ fron+
end vrl+h pressed-on flt. The crankshafi froni
e nd als o has g ro o v e s fo r fl + + l n g th e h u b pl ece
( 8) and ihe o u l l e y (1 3 ) l s fl x e d to i h e hub.
Betweenthe hub plece and ihe gears there ls an
ol I deflec+or (10) and ihe dust cover tor the
s haf f s eal ( 9) i s l o c a i e d o n i o o o f th e hub.
 Th9 crankshati boarlngs are ilxed to l-he
cyl l ndsr bl ock on bol h sl des of -i he cyl l nde r ,
whlch means thai therg ls one bearlng polni
more + han l here are cyl l nders l n i he engl n e.
The cranksha{t thrust bearlngs (4) are locaied
on ihg sldes of ihe endmost bearlng Journal.
o
The mal n and bl g end bearl ngs are so-cal l ed
three-layer bearlngs rhlch have on top of lhe
s+Eel body c lead-bronze layer wlfh load
capacl i y cnd good heai conductl bl l l i y. The
actual sl l dl ng surfoce l s covE red rl th o l hln
layer ot lead-lndlum f,hlch f6cl I l'tales +he
runnIng l n.

44

PI ston
Vlbratlon darD€r 6l l/612
l. Combustlonchamber
l. Vlbratlon damDer 2. C asi l ron r Ing
2. Pu l ls y 5. C l rcl l p
f. Hub 4. P l si on ol n
4. Nui 5. B earl ng bush
6. ConnectI ng rod
l n slx - c y llnder en g l n e s i h e c ra n k s h 6 f' t fro n+ 7. Chrome-p lafed cornpresslonrlng
€nd lncorporales a forslonal vlbrailon damper 8. Compresslonr Ing
o f vl s c ous t y pe. T h E d a m p e rh a s a c a s l n g fl l l e d 9. S prl ng-l oadedol l rl ng yl th sl l dl ng sur{ aces
l {l i h v ls c ous s lllc o n o fl u l d , e n c o mp a s s l n gthe chromed
d a mplng pas t e ll{ lt h m l n l m u nc l e a ra n c e s .
The pl s+ on l s madeof eutectl c ol uml nl umal l oy.
The speclally formed cqbustlon chambar (l) oo
the plston +op end lmproves the mlxlng of alr
and fuel . In i he hl gh-pow er engl ne versl ons
the groove for the top plston rlng ls In +he
c€st l ron rl ng (2) cast onto the pl ston. Ther e
are ihr€€ plsion rlngs: +he topnpst rlng ls a
compresslonrlng (7) vlth a barrel-iype, chrone
pl ai ed surface. The oi her compressl onrl ng (8)
Is a so-col l ed ml nute rl ng w l i h a Jor or
90r angl o. The + hl rd rl ng l s a sprl ng-l oad 6d
ol I rl ng (9). The pl s+ on pl n (4) l s Insl do +he
plston t|l+h accurate fliilng and fhe connecllng
rod smal l end and i he pl ston pl n have a
so-called floåtlng fl|oun+lng bo+vreen each
other.

The plstons of the 612 englnes are cooled by

dlrecilng an ol I jet to the boftom surface.

Borrlng shel I

l. lnd lu m lea d a lloy

2. Lead bronze
l. Sieel body

4-7
 CE IGCH^NIST44II
COi'NTERBALA

45

Counterbalonca rFchanlsm 4l I

l. B ody 8. Shlm
2. B al I 9. Hexagon socket
5. S haft 10. Lcck screv
4. Thrust p lato ll. Banjo boli
5. B earl ng bush 12. Connectq-
6. Counferbalance li. Lube oll plpe
7. Pln

So.ie of ihe ,tll englnes are furnlshed tlth a

counierbö lance nEhnanlsm rhere ihe eccenirlc
reighis ro+ailng ai a speed double +he speed of
the englne compensaie rlth +helr orn Inerila
the Ine-tla fq@s caused by the pd-fs rlth +o
and fro rptlon, lhe pls+ons and l-he s|nall end
of conneqt lng rods.

The bodv (l) of ihe coun+erbalan@ rEchanlsm ls

flxed io ihe cyllnder block bottorn face. The
shafis (3) locaied in the body have b€arlngs
bushes (5) for ihe actual counferba lances (6).
The counierba lan@s are drlven by the gear rlm
on ihe ci-ankshaf+ through gears. The bearlngs
of iho counierbalance assembly are lubrlcaled
by the eflglne pressure lubrlca+lon sysiem
ihro ug h a lu be oll plpe ( lJ ) .

The clearance b€fneon lhe gear of fhe counter-

balance nechanlsm and the crankshafi gear rlm
ls ödjusied lrlth +he shlms (8) placed be+we€n
+h e b od y an d ihe c y llnd€t ' blc k .

4-A
REPAIRINSTRI'CT
I OI{S
CR^NKCASE
I. CRANKSHÅFT

A. REMOVINO
THE CMNKSMFT
l. ReDoveilp ol I sumo.
2. Losen the connec+lng scre$ ot ihe lube ol I
plpe of the countorbalance m€hanlsm troo ihe
c y llnder bl o c k o s re l l a s th e re i a l n i n q scrors
of th€ counierbal6nce mechanlsm. Rem;ve +he
c oun+ er bal a n c eme c h a n l s na n d i h e l u b e ol I ol o€
( 41| englne sl .

f. Loosen the flxlng screys of ihe ol I pump

pressuro plpo trom lhe cyllnder block and iho
ol I pumpreialnlng screus. Removsihe oll punp
and the ol I Iniako and pressur€ plpes.
4 . L@s en ih€ fl y w h e e l rs ta l n l n g s c ro w s and r€move
t he f ly Hhee l , T h o n l o o s e n i h e fl y rh e e l housl ng
llx lng s c r e w s o n d re n b v e th e h o u s l n g .

5. Renroveihe gear houslng ( Instruc ons, polnt

5) .

Loosen fhe nuts/sc.eis ol ihe connecllno rod Max pgrml ssl bl e cl eorance In i h6 ma ln beor lng
b ea rlng ca ps , qem ov e t he c aps and p u s h t h e l s 0rl 8 | ' n and l n the bl 9 end b€ar lng
co nn eciing r ods s o t ar dor n + hat t hey w l l l n o t 0,14 rn. l f ne€ded, th€ j ournal s m ust bo
pr€vent you from removing +he cr6nkshafi. ground. l l hsn grl ndl ng fol l ow the st ondar d
undersl zes and use undersl zed bearl ng shells
Lo osen the r et alnlng s c r er s ot t he naln b e a r l n g suppl l ed es spare ports, see + echnlcal doia,
caps and reirove the caps. Llft fhe crankshafi polnt crlnkshaft. lhen grlndlng not€ that the
o fl from lts pos lt lon. Journll ådgos must renåln round.
CIfCKING THE CR^iIKSHAFT

vJö sh +he c.ank s hof t c ar ef ully 6nd ens u r e i h a f C. REF.ÄCING TIf CRA KSI{AFTG€ARRIM
th e o i I ch an nels ar e c lean. (41| engl ncs)

Mark i he posl tl on of fhe gear rl n on the cr ank-

shaf t.
2. He6t the rlm evenly, for example rlth o gas
torch, a n d t a p o f f t h e r l m w l l h o su l to b l e
dr I lt.

46
M 6ös ur e f he j o u rn ö l re a r a n d o v o l n e ss yi l + h a
mlcrome+er. Pertorm the measuremen+ crosswlse
ai s gv er al p o l n ts o f th g j o u rn a l . T h e Jo' l rnal
ov6lness or o+her delormlty oay noi exceed +he
llm lf O , of r m .

4-9
D. REPI.AC
ING TTE CRANKSHAFT
Gf,ARS l. Clean the oll channels and the con+ac+sur{aces
of + he bsarl ng shel l s, cyl l nder bl ock and
bearlng caps. Ensure lhat +he crankshal+ ls
cl ean.
2. Fl i + he bearl ng shel l s l nto + he cyl l nder b lock
and +he bearlng caps. Ensure that +he bearlng
shel l cl ampl ng cl aw s fl t l n+ o + hel r noi che s and
i hai the shel l s i o be fl i i ed In i he cyl lnder
bl ock have a hol s col ncl dl ng t{ l i h the ol i por t .

Lubrl ca+ e + he bearl ng shel l s In the cyl lnder

bl ock and the c.ankshaft bearl ng j ournal s. Llf l'
i he crankshaft back l ni o l + s pl aca and sl l p t he
thrusi bearl ng shel l s ot the cyl l nder block
l n+ o thel r posl tl ons. P l aco the thrus+ bea r lngs
so + hat thel r l ubrl catl on grooves are ag alnst
fhe sl l dl nq surface of i he crankshaft.
P l ace + he bearl ng c6ps l nto + hel r posl tl on s ln
the crder lndlcatod by the numbors. Place
+ hrust bearl ngs shel l s equl pped { l th cl am plng
claws on +he slde of ihe andmost beårlng caP.
Lubrlcate +he lhreads of the retalnlng screws
l l gh+ l y w l + h otl and + l ghten + he screw s fo t he
coirecl torques (200 t{mlll, 4ll, 6ll, 612
and 160 Nn J09).

Flx the extractor (8360 973271 loio ihe ihread

holes o f +he g ea r dr lv lng + he oll pum p and p u l l
+he gears oui.

C lea n +h e llxln g polnt of + h6 gear s oo +h e

crankshaft |,lth a *ire brush, for instance.

Heai the ne* gears io a 2O0oC ienperature.

Place the gears on ihe '.rp crankshöf+ and iap +he
hot gears dorn to ihe boliom using a brass
drlfi o r a sulta ble s leev e. Chec k t höl- t he k e y
ls In po sl+lon and t ha+ + ho I ns iallaiion mark
of the fron+ gear remalns in slghl-. Lei ihe
gears coo l n atu ra lly .

E. I NSTAI.LII{G TI.IE CRANKSMFT

Ensure ihö+ tho crankshaf+ rofates easl ly.

f G a s u r e +h e c r a n k s h a f t e n d p l a y t | l t h a d l a l
Indlca+oi. Irench ihe qankshafi io one end
llml+ poslilon and -ihen back +o +he o+her and
n o t e i h e d l a l I n d l c a t o r r e a d l n g f o r e n d p l a y.
Codpare {lth the roilng 0,10-O,r5 f,I||. lf
+he readlng ls too hlgh, replace ihe thrus+
bearing sholls wlth overslzed onss.

lloigl Never rean l-he bearlng shells or make

+h e b e a r l n g c l e a r a n c a s m a l l e r b y {l l l n g th s
edges of 'the bearlng caps.
 HUBPIECE
F. CMNKSHAFT Vlbratlon damoers dellvered as spare paris do
no+ havo InJec+lon ltmlng nark. Make the
marklnq on ihe ne|, danper on the same spo+ as
on the-old damper. Use an elecirlc pen' do not
tap the markI

Fl x + he vl bral l on damperand i he pul ley on ihe

crankshaf' t. Tap the dow ol pl n l n l + s Placo and
itghfen the flxlng screws to a torque of f0 Nm.

412

Uhen f lt t lng i h e h u b p l e c e i o i h e crankshafi

fronf end note the corroc+ posltlon of the hub.
T he hub plec e h a s a n l n s + a l l a tl o n m a rk - on i w o
+ eeih and + h e c o rre s p o n d i n g In s + a l l a + l on mark .
of the crankshaf+ ls on one +ooth.
6I11612
ING THE VIBRATIONDAI..IPER
REPLAC

Loosen +he al+ernator flxlng screws and renove

the v-be lf.

Open the hexagon sockei screes of the beli

pulley and the vibratlon danper and remove+he
par is f r om + h e c ra n k s h a f+ . T h e p u l l e y and the
vlbrailon damoer hava been oosltloned to thg
c r ank s haf + h u b p l e c e w l i h a d o w e l p l n (l nj .
t lm lng nar k e d o n i h e v l b ra i l o n d a mp e r).

Notet Even a small dent makes ihg vlbra+lon

damperInoperatlve. Do no+ remove l+ by iurnlng
forclbly and be careful not to damagel+ 'dhen
l+ ls loose. lf you de+ec+ a den+ on the ouier
surface, do not lnsfall +he damperback ln the
enoIne.
2. @NiECTING ROOSANDPISTONS
REIII)VIl{G Ir€ @Nt€CTt t{G R00 AID P|STo|I
R q p v e + ho ol I sumo and ihe oll lnlet and
pressure p lpes.

Renpve +he cyllndor heöd ( s€€ Instrugtloos,

p o l nt 5 | A ) .

Scrape of f t he p o s s l b l e s o o + l n i h e c y l l n der
llner top edge. lf nec€ssory, uso a reamer 10
remove +he sharp rear edg€ ln the plsion .lng
+op dead cenir€.

Remove +he connecilng rod bearlng caps and

b € a r ln9 s hells . l f y o u l n te n d fo fl + + h e s ame
shells back, nole +helr correc+ order.

Press the connecilng rod and pls'ton off +he

cyllnder by uslng a ,ooden haftEr handlo or P r€ss + he ner bush In l ts pl ace. E nsurg ihai
equI va len+. the ol I hol e In i he bush col ncl des rl th 't he
respectlve hole in the connocilng rod. Al+er
R q rDv eihe pls ion p l n c l rc l l p s . H e a i -i h e p l ston flttlno ream ihe bush to aitaln lts corrasl
evenly to a ienperoture of t 00oc and push out dlametår (s6 techntccl datc iconnesil ng
th 6 pls + on pln m o n u a l l y u s l n g a s u l i a b l e d rll t. rodr ),
Noiel Due to I luc+uatIng to lerances the ING BUSH
p l st on pln c ön b e re mo v e dm a n u a l l y e v e n r hen OVERSI4 PI STOIIPI}I BEAR
cold. tf ihe pln does not com€off rhen pressed It requl red, you can fl x In i he connsc+ l ngr od
by hand, do no+ +ry lo iap l+ off b€for€ snal l end a bush w l i h an oversl ze oufsl de dla-
h e a f lng, bec ous e+ h 6 p l n l s fl ti e d to o fl g htl y nE for. Machl ne + he connectl ng rod smal l end
and the plsfon may be dömaged. bearl ng housl ng accoi dl ng i o the fabl es bololr :
B. CIICKI NG AIO REPLACINGTHE CONI€CTING ROD oroer number
Order oe
EEARIl|GS Bearinghousing for bearinq
Enoine bu
t. C l e an t he c onnec tl n g ro d 6 n d th e b € a rl n g s hel l s 309 40,500 . 40,525 8360 38605
ca ref ully . P lac e th o b e a rl n g s h e l l s l n thel r
corresl posltlons önd f lght en t he bear ing c a P 3 r1
io +he corr€ci torque (9O lfi JO9, 5ll, 4ll
44.500 44.525
l n d 6ll) . T lght e n i h s connectlng rod scrsrs
411 83s3 28326
of th e 61 2 e no ln6 f lr s t lo the +orque ol l0 Nm 6 r1
€nd ihon oach :crer 9Oo.
612 48,500...48,525 8363 38606

A l i er fl t+ l ng ream+ he bush + o lls correct slz6

(s€ tschnlcal data 'conncsil n9 rodt ).

INSPECT iG ROD
It{G T}€ @NTCCTI

41 4 31'1,411,611

2. Measure the bsorlng cleorances rl-th a dlal

Indlcafor zor€d to ihe crankshaft b6örlng
j o u r nal. M ax perm l s s l b l g b € a rl n g c l e a ra n ce In
+he connectlng rod blg end bearlngs ls 0rt4
mm . I f nec es so ry , g r I n d -th e c ra n k s h aft
b e a r lng jour nöls 6 n d In s ta l l th e u n d e rs l zed
bearlngs dellvgred as sparg parts.

J. It ihe plston pln bush ls too rorn, removaihg 4 16

b u sh by pr es s lng rl th a s u l l a b l e d rl ff.
The connecilng rods of dl fferenl etgl ne iypes

4 -1 2
 Use a ioo I s p e c l a l l y ma d efo r + h e l n s p ec+ l onof 4. l.,llth the +ester plns ln a verilcal posl+ion you
lhe c onnec i l n g ro d (e .9 . C a rl L a rs s o n ). can deiernine ihe connocflna rod deflec+lon.

P lac e t he c o n n e c i l n g ro d b e a rl n g c a p In l fs
pos l+ lon no i l n g + h e ma rk l n g s a n d tl ghten the
nuts evenly io +he torquo of 90 l{m ln +he
c as e of 309 , fl l , 4 l l a n d 6 l ' l e n g l n e s. Tl ghten
the connectlng rod screws of the 612 englne
flrs+ io +he lorque o{ 30 Nm and then each
sCf€ri 90o.

2. Fl+ the connectlng rod to ihe lnspecilon iool

and ihe ols i o n o l n l n + o l i s b u s h .

5. Also check the connec+lng rod for any S-shaped

defl ecl -l on. Thl s i s done by usl ng a sllde gauge
to measure the dlstance bete€€n +he pln bush
ouier edge and ihe lnspec+lon tool plane
surface. Then +urn the connectlng rod the o+her
vay round and measure+he same dlsfance agaln.
The dlfference may nol exceed 0,6 nrn.

420

l.4easure+he length of +he 612 englne connec+lng

Place +he Indlca+or on fop of fh e p I sfon p In.
l{Ifh ihe +es+er plns of the l n d l c a+ or l n a
horizontal posl+lon check l-he connec+lng rod
tor s lon .
rod scrers and comparethem wl+h the nax length
gl ven l n fl g. 4 20. l t l he l ong+ hof any scr ew
exceeds+ he max l l ml + , repl ace fhe scr e{ wlt h a
o9ll orlgr l{9 recommendthat you rgplace screws
wlth new ones each tlme you open them.

E. CON}ECTI
NG RODXEIGHTCLASSES

4 2l
The connec+lng rods are dlvided Into rtelghi
classes a+ 2o-gramne Intervals. A le+ter
Indl catl ng the w el ght cl ass l s markad on +he
connec+ l ngrod sl de face. The cyl l ndor or dlnal
number ls stamDed on +he same slde as fhe
w el ghl cl ass. A l l the conneci l ng rod s I n one
engl ne mus+ be of the sano uel ghi cl ass, l. e.
+ he max pernl ssl bl e vl el ghf dl fl erence ls 20 g.

Le+ + ers l ndl cate w el ghi cl asses as tolloxs:

5 0 9 engl ne

Welght Spcre parf no

1990 - 2010 s 4360 36562
I 2010 - 2030 8160 J6561
2030 - 2050 s 8560 56564
K 2050 - 2010 8360 36565
4 - 13
 2070 - 2090 s 8360 36566 INSPECTII{G
ANDREPLACI
NG THE PISTONRINGS
N4 2O9O- 2110 g 4360 36561
N 2l1o - 2130 9 4360 36564 Use pls+on rlng pllers lA360 91333, fo remove
0 2130 - 2150 g 4360 36569 ihe rlngs. Do no+ spread tho rlngs more than ls
P 2l5O - 2170 g 8360 36170 necessary to remove+hem. lf you ln+end lo re-
R 2l7O - 2190 g 4560 36571 fl + i hs same ri ngs, ensure + haf i h€y w l l l be
s 2l% - 2210 g 4360 36572 pl aced l n thel r orl gl nal posl + l ons.
T 2210 - 2230 g 8 1 6 0 5 8 1l 6
2230 - 2250 g 8160 J8l l7
2250 - 2270 g 8560 381l8
5 l t, 4ll and 6ll e n g l n o s
Welght Spare pcrt no
2190 - 2210 g 4361 36573
2210 - 2230 g a36l 36514
2230 - 2250 g a361 36515
K 2250 - 2270 9 a361 36516
L 2270 - 2290 9 4361 36117
M 2290 - 2310 9 8361 36518
N 23lO - 2330 g 4361 36179
o 2330 - 2t5O 9 8361 36580
P 2350 - 2310 g 8J6l 16581
R 2370 - 2t9O g 8361 36582
S 2390 - 2410 g 8361 t6r83
T 2410 - 2430 I at61 36544
2430 - 2450 g 8161 36545
2450 - 2410 I 8J6l 16586
X 2470 - 2490 9 8361 36141
z 2490 - 2510 g 8561 16588
2510 - 25tO g 8161 36549
2530 - 2550 g 8361 36590
c 2550 - 2570 9 8361 36591
0 2510 - 2590 g 4361 36592
E 2190 - 2610 g 8361 36593

6 t2 e ngln€

Helght Spare pcrt no

E 2911 - 29 8t6t ta1
2991 - 3010 8t63 3A796
Jol I - 3030 8363 3879-7
H totl - 3050 8363 3A194 2. C l ean i he rl ng grooves careful l y. Measur et he
I 30rt - 3010 8361 34799 pl ston rl ng sl de cl earance In l + s groove . The
107't - 3090 8J6l J8800 cl earance must be l ess fhan 0,15 nm .
K J 09t - J t 10 8l6J 18801 De+ermlnewhether the slde clearance ls due +o
l l - 3130 8363 18802 rlng or groove wear and replace the rlngs or
T4 lljl - 150 8J6J 1880J i he pl sfons as w el l , l f necessary.
N ll5l - ll70 8l6i 18804
o lr T l - J l90 8J6J 18805
P 3191 - 3210 8161 18806
3211 - 3230 8J6J 18807
s 3231 - 3250 8161 18808
T 3251 - 3270 856J J8809
3211 - 3290 8l6J 38810
v 3291 - 3t10 816l l88l I
x 3311 - 3330 a3$ 3ABl2
Y 33tt - 3350 8561 l88r J
z 3351 - 3370 836J J8814

J. Place the rlng In fhe cyllnd6r, adjusilng ll

p e r p e n d l c u l a r +o f h e c y l l n d e r a x l s , a n d m e a su r e
iho rlng cap. Thls may nof exceed I mr.

4 -1 4
 H . F ITTII{G THEPISTONPIN

424

4. F l+ lhe pl s to n rl n g s u s l n g th e rl n g pl l ers.
E ns ur e + ha i i h e rl n g s a re fl ffe d l n + hel r
correct places and +hai lhe marklng TOP or
+ he nanuf a c + u re rrs m a rk l n g In i h g rl ngs l s
upldards.

I NSPECT
ING THE PISTON

426
Heat ihe plston evenly to a tempera-fure of
l00ct. Flt +he connectlng rod Into the pls+on
and press i he pl s+ on pl n Info l + s poslllon.

NoieI The combus+lon chamber of +he Dlslon

and and the ordlnal nurnberon the connectlng
rod musi face In ogDoslie dlrectlons.

Fl i the pl s+ on pl n cl rcl l ps In i he pls+on.

E nsure + hat + he cl rcl l ps engage pro per ly I n
ihelr grooves.

t. SHORTET€D
P ISTot{S
425 lf l-he cyllnder block top face has b€en
machl ned, l ns+ al I respecfl vel y shortg r pls+ons
+o ensure +he correci dlstance betwsen +he
Piston diameter pl ston head and cyl l nder head. A l w ays r eplaco
gD al l i he pl s+ ons l n one engl ne to have ldenllcal
Engine A pl sj -ons. Max perml ssl bl e rel ght dlf {er ence
be+ reenpl s+ ons In one engl ne l s 25 g.
309 26 99,873...99.887
There are fl ve dl fferenl undersl zes ln +he
311 lengihs of ihe pls+ons dellvsred as spare par+s
for 3l l ,4l l and 6l l engl nes. The cor r ect
4tI 19 107,853...107,867 length can be chosen accordlng to +he ne€d Jor
machl nl ng. l n the case of f09 and 61 2 englnes
61 1 +he s+andard plston rnust be shor+ened +o
correspondto i he cyl l nder bl €k machlnlng.
612 22 107,8s3...102867

Check +he condltion of ihe plsfon and the

pls + on pln v l s u a l l y . Pa y s p e c l a l a tt eni l on to
posslble cracks ln +he area of the plsion top
and the pln bore. Measure +he plsfon dlamo+er
a+ t he poln i In d l c a i e d In fl g . 4 2 5. C oopare
ihe r es uli ' .i l i h th e ra i l n g a n d re pl ace the
pls+on ',ilth a new one, if necessary.

427

4-15
 4. Lubrlca+e +he crankshafi bearlng Journal and
Spare part Shortened Mark on beari ng shsl l s and push l he conneci l ng rod ont o
no oy mm piston + he crankshaf+ bearl ng Journal . Fl t fhe be ar lng
caD so fhal- l+s ordlnal number faces +he
311,411,611D respec+lve number on the connecilng rod.
Tlgh+en fhe nu+s of 109, 3l I , 4l I and 61I
8353 16177 std englnes ln phases +o the +orque of 90lln.
8353 31044 o,2
8353 31045 o,4 4 Tlghien ihe connec+lng rod screws of 612 englne
8353 31046 0,6 o as l ol l ow s:
8353 31047 0,8 8 L Preilohfenlno vrlih ioroue wrench J0 Nm
2. Tlghtänlng 9öo, both sirews
8353 31048 1,0 10 J. Tl ghi enl ng 90o, both screw s.
31.1,411,611
DS S',lng ihe connectlng rod sldeways and ensure
8353 16033 std i hat i he connecl l ng rod bl g end has a
8353 31049 o,2 2 suffl cl en+ sl de cl earance on fhe crankshaf f
8353 31050 bearIng j ourna | .
o,4
8353 31051 0,6 o
8353 31052 0,8 I
8353 31053 1,O 10
611DSB
8363 30700 std
8363 31054 o,2 2
8363 31055 o,4 Plstoo dlstance frs ta dged contre vs.
8363 31056 0,6 6 crcnk rng l€
8363 31057 0,8 I
8363 31058 'l ,0 10 oegrees Jl l ,4l t,6
nm

t0 r,l 0l 1,172
J. FITTING THE PISTONANDTIE @N}€CTIIG RCD ll 1,417
Fl i + he c onnec l l n g ro d b l g e n d b e a ri n g s hel l s l2 l ,rB 5 r,685
In ihelr plac es . C h e c k + h a + + h e ma i l n g faces
a re c lean and fh e b e a rl n g s h e l l s c o .re ci l y tl 1,8!b 1,976 2,207
p o sl+ loned.
l4 2 ,15O 2,28
L u b r lc a+ e t he pls + o n , p l s + o n rl n g s a n d c y l l n der
l rl + h englne ol l. P l a c e + h e rl n g g a p s ra d l al l y t) 2,465 2 ,624
a + r egular I n+ e rv a l s , fa c l n g l n d l ffe r en' t
d l rec f lons . 2,8Ol 2,982
t1 3,361
l8 3,5 3,163 4 ,205
to 4, 186 4 ,674
20 4 ,351 4 ,631

4 ,189 5,O91
22 5,247 5,583 6,240
5,724 6,091 6,808
24 6,220 6,619
6, l35 1,161 8,O12
7,270 4,64' t
a1 7,822 a,3E 9,3O5
28 a,391 8, 9JO
42 4 29 I,982 10,686
JO 9,58 10,202 | | ,408
f. U se a pls ion r lng s + r6 p o r p re fe ra b l y a fl fi lng
tool. Fli the plston and ihe connec+lng rod
In i o + he c y llnd e r In d l c a i e d b V + h e o rdl nal
numberso as lo have ihe nunber and ihe wolghf
class mark fowards +o +he camshafl.
4 -1 6
l. CoU]{IEREL NCE iCC}l,ANlSH ,ll|

RE OYITGA]O DISASSEIALIrcTHE COI'XIERBAL,ATCE

lccH Nl sf.l

De+achlhe englne.

O pent he c o n n e c l l n g s c re w s o f th e l u be ol l pl ps
of +he coun+9rbalance assenblv and rqnov€ the
Dloe.
open ihe f l x l n g s c re w s o f + h e c o u n i erbal ance
mechanlsm,remove+ho assemblyand the posslble
s hlm s b€f t r e e ni h e b o d y a n d + h e c y l l n d er bl ock.

431
4 . Ensure thal' lhe backlash b€lween +he aears ls
accordlng to ratlng (0,O5...0,25) a-nd ttrai
the @unterbalance end play ls corr€ct (O,l
...0,5 ).

FITTIT{GTTE CDUI{IERBAIINCE
iCCHANISI,t
4. Open the refalnlng scref,s of the counterbölance
shat+s. Press fhe shafis off ihe bodv to ihe Tap the dorel plns ln ihe body ot the counter-
di. ec ilon o f + h e re tö l n l n o s c re rs . R enovefhe bal önce mechan
I sm.
c ounier balo n c e s a n d -th e + h ;u s + D l a te s.
5. Clean + he o a rfs c a re fu l l y .

B. RECONDITIONI]€ IfCHANI SI,I

IHE COUNTERBALÄNCI
Check ihe shafis for wear and ihe condl+lon of
the counteib€lance gears and bearlngs.
lf the counterbalance gears are rorn, rep lace
th9 coun+erboI ances. The gears are not supplled
separo+ely as spare par+s.

lf needed, press lh6 old bearlng bushes ott the

c lun+ er bol å n c e w l + h a s u l i a b l e d rl f+ . B gfore
renovaI mark the bush oll groovo posltlon on
ihe counierb€lance. Press the ne'r bushes onio
+he counferb8| ance no+Ing +he ol I groove
pos liion. Afte r fl i tl n g ma c h l n e + h e bearl ng
bus hes io l h e l r c o rre c i d l m e n s l o n 26,040...
26, 061 m m .
2. Fl t the coun+ erbal anceassembl y In place so
lha-i' +he dot on +he counterbolanca gear allgns
wlih the dot on the crankshaft gear rlm.

5. Tlghien the flxlng screxs ot ihg counierbalance

nEchanlsm lo the toroue of ilt ltl. t4easure
the back lash betroen ihg cauntgrbalånce gear
and the gear rl n. S houl d l + dl ffar fr on r at lng
(0,1...0,5 hr), make the adj us t m eni by
placlng 0,2 |Im shlDs beireen the body of ihe
counierbalance assemblyand +he cyllnder block.
4. Fl x i he l ube ol I D l D e.

1.Line t iminqma rk s
2.Dot timing-ma1kn 30 5. l'4ou
nt fhe englne.

F lt ihe c o u n + e rb laa n c e s l n s l d e th e b ody notl ng

thelr correct posltlon. The counierbalance wlth
6- dot on t h e g e a r l s p l a c e d h l g h e r o n the body.
A llgn t he l l n e n a rk s o n i h e c o u n te rb al ances and
t l+ t he s hä fi s In p o s l tl o n fro m + h e s lde of i he
r et alnlng s c re rs . l i h l l e l h e s h a ff l s b€l n9
f lt ied ln p o s l + l o n , p l a c e th e i h ru st pl al å
befeeen thg counferbalance and the body. Tha
s haf t end l s p re s s e d fl u s h rl th fh e b ody. A ppty
relalnlng compound(6909 lo0ll) oo the sciei
threads and tasfen lhe scrers.
4-17
4. FLYHHEEL

REPLAC
I NG TI{E FLYTI€EL STARTERRI I,t
lf the sfar+er rlm ls worn, replace l+. The
s+arier rlm cannot be +urngd around because lts
+eeih have been chamfered and +empered on ihe
slde of +he s+arlor.

Remove+he old s+arior rlm by tapplng l+ a+

va r lous polnf s w l th a d rl ft. C l e a n l h e fl y w heel
confaqt face vrl+h a wlre brush.

4 33

2. Heat fhe slarter rlm evenly +o a iomperalure of

1 5 0 - 200uC. Fl + th e rl m In p o s l tl o n o n i he
flyvlheel so +hat ihe chamfer of ihe openlng ls
towards the flv*heel and +he chönfe.ed side ot
ihe teeth iovrards the s-tarter.

f. Lef ihe siarter rlm cool dorn na+urallv.

B. F ITTII{G T}€ FLYXHEEL

Clean +he maflng faces on ihe crankshafl rear

f lan ge a nd f lywh ee| .

F lx +h e flvwhe el on t he c r ank s haf + end. F o i

guldln g yo u ca n us o lV l2 s iuds ( 2 pc s ) w h l c h
sult the flywh eel r et alnlng s c r er holes . T h e
poslilo n of ih e f ly r heel ls { r ee ln eng l n e s
w he re ihe lnje c ilon ilm lng ls m ar k ed on t h e
cran ksha f+ fron + end. I n s one englne v or s l o n s
one of +he relalnlng screws have been replaced
by a gu lde p ln i' o deier m lne ihe c r ank s h a f +
posli lon .

T lgh +e n the llyvlheel r e+ alnlng s c r er is ev en l y I n

phases io ihe torque of 120 Nm.

4 -'18
T IMI1{OG€ARASSEICLY

I ioEx

T ec hnlc ll d a ta ........... .. . . . . . . . . . . . . . . . . . 5- I

S De f al t o o fs .... .......... 5- 2

Cons f r uc i l o n ..... . ...... ... 5- l

Repalr lnsfruslloos

l. G€ar houslng
A , R e m olvn g + h e g e a r h o u s l n g. ...... 5- 6
B . R e c o n d l tl o n l n g + h e l d l e r gear.. . . . . . . . . . . . ....... 5- 6
C . F l ftl n g th e g e a . h o u s l n g ........5- 6
D. Replaclng +he crankshaf+ fron+ end shati seaI . . . . . . . . . . . . . . . . . . . . . 5- I

VAIiIET 5-0
IECflNICAL D TA (reject llmli of part sfated ln brackeis of-ter raflng)

Blck I cshos
Cr änk s hat t - l d l e r g e o r o,or ...o,2,
ld ler gear - camshaft o,o5...o,25
ldler geor - I n J e c l l o n p u m p......,r.... o,6...0,25
Cans haf l - dr l v 9 u n l t o,0r...0,2,
M ax per nls s lbl e s l d g w o b b l o o f g e a rs ,.... ... 0, 05
Tlnlng Frrks
T lnlng m or k s o n g e a rs 6 re l n a l l g n me n t w henthe l s+ cyl l nder pl ston l s 6l l ts
iop deöd c€nt.e betre€n compr€sslonond poror slrokas.

0n crankshöfi gear . . . . . , . . , . . . 2 dois on te€th

O n ld 16r gear:
- c galns i c r an k s h a fi g e a r .....,,..... mEik non on tooth
- cgöl nst canshaft ger I dcrt on ioolh
- 6galns+ Injectlon pumpgear I doi on nqlch
0n camshaff ge€r:
- f 09, llt , 4 ,6 l t ........ I dot on nqlch
- 6lr , 6t 2 ) dois on fe€th
0n Injecf lon punp geör I doi on toofh
Cr ank s hat t m u s t b e fu rn d to b rl n g a l l fl ml ng mfks l n al l gnnenf agöl n ....... o TUrns

ldlcr galr
8161 2986t ( r lth p l a l n b e a ri n g )
I ns lde dlör €t o r o f l d l e r g e a r b € a rl n g b u sh (fl fi ed) ......,. 55,000...55,050
Dläm eier ol ld l o r g e a r s p l n d l e .,,....., ,4,951. ..54,910
T lgh+ enlnglor q u e o i M l 0 re ta l n l n g s c re i ........... 60 Nm
T lght enlng iorq u e o f l rl l 4 re ta l n l n g s c re y ........... 140 Nrr
8f 61 , 8J 54 ( r li h p l a l n b e a rl n g , s p l n d l e lengi h 50,7 nn)
Ins lde dl af lE fe r o f l d l e r g e a r b e a rl n g b u sh (fl tted) ........ ,, ,20O...5' ,2tO
0löm eie ot ld 1 e | ' g e a . s p i n dl e . . . . . . . . . 5r,111...55,110
T lght €nlng' t orq u e o f M l 0 re i a l n l n g s c re B ........... 60 Ntn
T lght enlng t f qu e o f M l ,l re fa l n l n g s c re r ........... 140 N m
4361 227@ ( r lt h b € v e l l e d b a l l b e a rl n o )
Dlane+ €rot ld l e r g e a r s p l n d l e ..,...;.. 14,984...15,000
T lghienlng idq u e o f l d l e r g e a r b e a rl n g h ol def scr€rs .......... 22 Nm
T lghlenlng t or q u e o f l d l e r g e a r re ta l n l n g scrgr ........... 180 N m
Crcnkshcfl troit 6nd nut
T lgh+ enlng lor q u e o t fro n + e n d n u t 1 0 9 , f l l , 4l l ............. 600 Nm
T lght enlng f or q u e o t fro n + o n d n u t 6 l l ,6 1 2 1000 Nm

5-1
o

'I 2 3 4

o
SPEC|ALIIn_S (ilrlng gear 6senbl y)

t. 90Jo I'm Flt-ilng +@l tcr crdrkshaft frort aod shati seal
2. qzt gm T+plng flfi fq- dusi covei
l. 9025 98m T+plng drlft fo.- doreI pln
a. 25 9Er7N T+pfng ölft tor dore I pln
n21 712@ G-ankshaf+ fror|i end nut rrench JO9, l l l , 4l l , see Insi ructl ons po lnt 4
21 55mo Crankshafl fron+ end nut rrench 6ll, 612, see lnstructlons polnt 4

o
c- z
T I I' I NO G€ARASSEI,BLY

cor{slRl,cT
Io{ 22
G€AR
r.tous
I NG5o9, ]|t, 4 , 6tl 23

l. Oear housl n g
2, Scret
f. Gaske+
4. S i ud
5. D oroI pl n
6. Gasket
7. Froni cover
8. Shatf seaI
9. S hl el d p l aie
10. N ui
ll, S eal l ng
12. Fl l l er pl pe
ll, O-r I ng
14. Cover
15. W asher
16. Spacer
17. B earl ng ho uslng
13 14 18. Gasket
19. B earIng
20. C l rcl l p
51 21. D rl ve unl + shaf +
22. P l ug
23. S eal l ng rl ng

GE^RHOUS'tc 6ll, 612

13 12

t. Gear housI ng
2. Screr{
Gaskef
D oY i elpl n
Front cover
S eal l ng
Cover
8. S ealIng
S hafl ' seal
10. }lasher
. S haff
C l rcl i p
ldler gear of compressor
14. BearI ng
15. B earl ng hol der

5-3
 Th e fl m lng gear a s s e mb l y c o mp rl s o s h e l l c a l The + l ml ng gear assenbl y equl ppedv,l i h an l dl e r
gears rhlch have b€en nachlned and tempered goar },l th bevel l ed bal l bearl ng l s moun+ gdon
!rlih preclslon. The gears are locatod ln +he 6l I engl nes. Thl s gear assembl y has noun+ lng
g e a r hous lng f lx ed to + h e c y l l n d e r b l o c k fro n t pol nts ready for a drl ve unl + and a l -cyl l nder
face. The camshaf+, lnjec+lon pump and ol I o' 2-cyllnder, gear-drl ven clnpressor can be
pump as yell as +he compressor ol 611/612 npunl'edon ihe englne lef+ slde.
e n g l n e s ar e dr lv en + h ro u g h th e fl m l n g g e a rs.
The gear houslng can alio encompass -a
drlve
u n l l for , s ay , hy dr a u l l c p u m p .
There are three maln +ypes of +lmlng gsar
a sse m blles :

l. 1

l. Camshaft geör
2. ld ler gear
f. Injec+lon pufip gear
4. Hydrau I lc pump gear
5. Crankshafi gears
6. 0i I pump gear
l. Camshaf+gear 7, ldler gear of compressor
2. l d l e r gear 8. Compressor- goar
5. Injec+ lon pumpgear
4. Crankshaf+ gear The 6l I and 612 englnes have a tlmlng gear
5. 0l I punp gear assembly where the gear-drlven conpressor ls
locöfed on the englne rlght slde. The ldler
Th e tl mlng gear as s e m b l ye q u l p p e d{ l+ h an ld ler gear has bevelled ball bearlng.
g e a r '. { lt h plaln be a rl n g Is u s e d ln f 09, 111
4 l l a nd s om e 611 e n g l n e s . T h l s llm lng gear
a sse m bly c an be f u rn l s h o d w l th a dr lv e unlt
drlven by ihe camshaft gear. I DLER GEAR

T he 6ll en gln es h av e a s lm llar v er s lon of gear The ldlor gear ls connecied io a shaft llxed to
assembly, e qu lpp ed t |lt h a longer ldlor g9aa fhe cyllnder block front face by means of a
shafi, ho{over. bearlng rhlch ls elther a plaln bearlng or a
bevelled ball b€arlng 1611/612r.

l. D rl v e unl+ gear (s h a ft) M o u n i l n g p a r +s o f ldler g e a r l {l i h plaln

2. Camshaftgear bear Ing.
i. l d ler goar
4. Compressor/I nJect I on pump goar l. S crer. 2, S crer J. R etal nl ng fl ange
5. C ra nk s haf t qeår s B oarl ng bush 5. cear 6. S håfi
6. ol I pumpgeär
5-4
Mou n+lng pa rts ol ldler gear r lt h bev elle d ball
b ea r In g.

l. Scre x 2 . Sc r e{ 5. Flånge 4. Re i a l n l n g
rln g 5 , Bevelled ball bear lng 6. G ear
7 . Sh af+ 8. Loc k lng pln

c- 5
 TllllNG GE^RASSEIGLY
t. GEAR}IOUSI }G
REIOYI I{G THE GEARI{OUS
I }lG
As the gear houslng bo+ion face forms pari of
ihe mgilng face tor ihe ol I sunp gasket, ihe
ol I sumpäusi- be removed fron the-engtnå, lf
fhe 9e6r houslng needs fo be taken olf |.hlle
f he 9n9lne l s In p l a c e .
Remove+ha ol I sumpfrom ihe englns.
opgn t he t a n fl x l n g s c re rs a n d rg m o vethg fun.
Loosgn the alternator flxlng scrers and refl|ove
t he alt er na to r, b e l i p u l l e y a n d b € l f.
N otcl I f l he cy I I nder head and vo I v€
flEchanlsmhave no+ been renoved, lock ihe valve
+ appets up In such y.ay thaf i hey rl l l not dr oP
down when removI ng +he carlsha{t and ihus
prgvent fhe lns+allailon o{ ihe camshöft. Se€
Ins+ rucfl ons, pol nl S 2 g.
r^ Open +he gear houslng flxlng screws and rgmove
'"' ihe houslng. lf you noed to tap a red99 betxeen
ih€ gear houslng and cyllndsr block io re[bve
ihe houslng, ensure +haf +he seallng taces
rsmaln I n+ac1.
ll' Tap the crankshaf+ shafi seal off lhe fronl-
cover usl ng a sul + abl e drl { 1. w ash al l det ached
parts and cl ean i he seal l ng surfoces car ef ully.

J. Re dto ve ihe oll pr es s ur e r egulailng valve (Jll,

B. REOOIIDITIOTIrc IHE IDLER GEAR
4 11 a nd 6ll enqlnes ) .
ldler g e a r r l +h plaln bearlng:

l f y o u r e p l a c e l - h e l d l e r g e a r b e a r l n g b u sh ,
oress +he nefl bush ln Dlace so thäl lis rEar
edge renalns 0,1 ...o,25 nm Inslde lhe gear rear
f ace.

Afier lnstallailon t h € b e a r l n g b u s h m u si b e
m a c h l n e d +o 5 5 , 0 0 0 . . . 5 5 , 0 3 0 | t r n I n c a s g o t 1 0 9 ,
511, 4ll and 611 englnes and to 55
n m l n c a s e o f 6 l l e n g l n e s y l t h 5'200, 7 0 ...5
r m5 ,2l o5n0g
l d l e r g e a r s h a f +.

l|otcl Hhen machlnlng lhe beörlng b u sh

cenirallze +h e l d l o r g e a r a c c o r d l n g i o tl g . 5
8.1 ln order to k6eD the back lashes correqt.

Rol ls,

open fhe crankshai+ lront end nuf vrl+h iool

9 02 4 1 42 00 I n c as e of J 09, 3ll and 4 1 I e n g l n e s
an d rlth +ool 9024 55800 ln c as e of 6 l l a n d 6 1 2
e ng lne s. P u | | t he belf pu lley - h u b p l e c e
comblnal lon oJf the crankshafl-

Remove the fron+ cover flxlng scrers and nuis

and lake off the cover. lf you need io tap a
wedge b€freen ihe cover and the gear houslng +o
remove ihe covor, be sure not to damagg ihe
se alln g sur f ac es . ldl6r g e a r r l +h bevelled ball bearlng:
Renovo the ol I def lecior from the crankshati,

Remove fhe Injectlon pump andlor compressor.

Notcl lf you do noi ln+end to rep lace the

g€ar houslng, li ls noi necessary to remove +h€
ln jectlon punp. O nly r ef lDv e f he f uet , l u b e o l I
end lnjecilon plpes frorn the Injec-t lon pump
(en gln es r her e lhe I njec t lon punp ls f l x e d i o
th e g ea r h ous lng) .

Opgn ihe ldler gear flxlng scrgus. Romovo tho

ihe refa lnln g f lange, gear €nd s haf t .

9. Pull ih e c am s h€f t of f { r om + he c v llnd e r block.

q- A
 Fl x ihe bear lng s a s s h o rn l n fl g u re 5 9 (o-
sysieD) presslng from -the ouier rlD. Atiach ihe
b e ar lng r ef alnln g rl n g a n d tl g h te n ti s l l g h+ l y
ol led screl{s to th€ +orque of 22 Nm. press the
sh af i I n pos ltl o n p l a c l n g s u p p o ri s o n ths
E€ arI no I nner r lm .

c. Frrfl; Tl€ 6EARHoUstNG

The posltlon of +he gear houslng towards +he
cyllnder block ls deigrmlned ',{lfh tuo dowel
plns. Thls also sgcures the posltlons of ihe
gear houslng and lhe froni cover rhlch need nof
b e s apar 8t ely c e n i ra l l z e d d u rl n g l n s i a l l a fl on,
Ensure, howevor, the correc+ back lash of ihe
gears. The gear houslng and front cover rhlch
are del I vered as sDare Darls are furnlshed rrlth
ready holes for th; dcr;tsi
Pl a c o o ngr gas k e t b e i x e € n + h e c y l l n d e r b l ock
a n d t he gear ho u s l n g a n d l l fi i h e h o u s l n g l n
l i s pos lilon. T a p th e d o re l -p l n s In h o l e s rl i h 5. lf ihe compressor ldler geör shaf+ has been
ihe tool (9025 98700) and tlghfen ih6 houslng rencved, appl y rei al nl ng tl utd 6909 tool2 on
t l x lng s c r ews an d n u i s . Its ouislde and tap lhe shaft In posl+lon so
that the rear faces of the shaf+ and +he oear
Attach the lnjecilon pump/compressorand lts housl ng cre l eval l l ng. Ftx the bearl ng and- lhe
gear ( It removed). gear In such a ray fhat the notch on the
be6rlng Inner clrcle cones on ihe outslde.
L u b r lc 6le ihe co ms h a ft b g a rl n g J o u rn a l s ond R enember+ he beörl ng rei al nl ng rl ngsl At +ach
p u s h , ihe c ans h å fi l n i o + h e c y l l n d e r b l ock. 1' he l dl er gear l ock pl åi e and ghfen lf s
Releadb ihe val.ve t€ppets lf locked. fl xl ng screes l o f0 N m (611,/612E ngl nes r l+h
conpressor on l-he the englne rlght-hand slde).

6. Check ihe gear backlash rhlch should b€ 0r0t

Tl mlng gear m ark s (s e e i e c h n l c a l d o ta I' tl ml ng ...0,25 m.
marksir)

l. Crankshaft gear
2. G ear dr lv lng o l l p u m p
3. Camshatt gear
4. ld ler gear
5. I njec t lon pun p g € a r
4 . Pl a c e t he ldler g e a r s h a tt l n p o s l i l o n and
l n s t all t he ldl € r g e a r o n fh e s h a ff. }l hen
l n s ialllng ihe l d l e r g e 6 r p l e a s e p o y a tte ntl on
to ihe correcf posl+lons of +he tlmlng marks on
g a ar s . F lt f he r e ta l n l n g fl a n g e å n d i l g h te n the
ldler g€ar flxlng scrors to fhe rlgh+ forque
(f7 rl . 60 Ir rnd Z2 n l1O t|; for ldl.r
gcar rlth pl.ln bclrlng lnd- l8O Ir for ldlor
g.!r rlth b.vcl l.d ball bcarlngl.

7. place +he oll def lec+or on the crankshaft and a

ngx gasket bsiwggn +he gear houslng and front
cover and llfi ihe front covgr In Dosltlon. use
too | 902i 98700 to taD the froni cover doUel
plns In posl+lon and lool 9025 98gOO{or the
ptn around the stud. Tl ghten the fronf co ver .
5_7
 D. RE'IACI]G ITC CMT'(SMFT FROiITEID SMFT SEA
(5O9. 5lt cnd 4ll englnasl

Flx the sh leld Plat e on fhe fron+ cover seållng 5 t6

box and top ihe shaft s e a l In Pl a c e rl + h the
to o | (9 01 0 15200) . L@san thg alternator llxlng scrers and remove
the v-b€ lt.

2. oDen fhe crankshöfi fron+ end nuf rllh ihe fool

19024 14200\. Pull the belt pulley - hub plece
contblnailon off fhe crankshoft.

R€|lpvo +ha shaft seol fron lhe tront cover 6nd

cl oan the soal l ng box careful l y. Top a ner seal
l n posl tl on rl th the t@ l (9010 15200 ) .

Lubrl cate fhe seal l l p coreful l y rnd push t he

bel + pul l ey - hub pl ece corbl natl on ont o ihe
cr6nkshatt groovgs. Tlghten ihe crankshaft
froni end nut to th6 torqua of 600 lln.

Fl x the v-bel f and tl ghten i he al te r nö+or ln

Its corrggt Dosltlon.

l otel Tho 5l l and 612 engl nes equlpped xlt h

l dl er gear trl + h bevsl l ed bol l be6rl n g can, lf
necessary, have iro shafi seals ln a ror. Also,
the ooslflon of the shalt seol can b€ altEred
by fti tl ng ä J ri n thl ck shtm unde r neaih t he
sgel. The order nunber for ihe shlm ls 8f5t
515 28899.

9. tt the shalt sacl dus+ cover has b€en re|l|oveo

t.or itr. crankshaft hub plece top' lap ll In
posltlon rlth toot 9025 98900'

t0. A oDlv r ef a l n l n g fl u l d 6 9 0 9 f0 0 l l o n the hub

oiåiå o.*""t.- Lubrlcote the shaft s€äl llp
ioiåir ljv o n d p u s h th e b e l i p u l l e y - hub pl ece
comblnofion onto ihe crankshaft grooves'

ll. A oolv r et o l n l n q fl u td 6 9 0 9 f0 0 l I o n i he front

'n"+ +nread-s. Tloh+en the crankshöft lroni
-'"i -9024 74200 fo 600 iln In
ånå ,ifit tool
ioi. oi "rt r o s , tl l o n d 4 l l e n g l n e s a n d rl i h tol
-i:äoo'io
ööäl t ooo Nttr In cose of 6ll and
612 eng I ne s .
(sa
12. Aftoch the oll Pressura regulatlng volve
lns t r uc t lon s D o l n t6 ).

lf. Flx th€ rlternoior and the v-beli and adJust

ths belt tens lon.

14. F lx t he b re o th e r p l p e (5 0 9 ' 5 l l and 4l l

englnes ) . M o u n t i h e fo n a n d tl g h i e n l + s {l xl ng
SCrelS. 5-8
LIER|C TI0 SYSIE|,|

tlGX

T €c hnlc . l d s i c ............. . . . . . . . . . . . . . . . . . 6- |

Cons t r uc t l o n ..... .......... 6- 2

R?!lr Insfrustlons

l. Lubrlcrtld syslqr
A . In s p € c tl n g th e o l l p re s s ure regul etl ng va| ve...................... 6- 5
g . R q l b v l n g o n d In s p e c i l n g the ol l punp..... ........ 6- 5
C . As s e mb l l n ga n d l n s i å l l l n g fhe ol I punP . . . . . . . . . . . . . . . . . . . . . . . . . .. 6- 5
D . R e p l a c l n g fh e o l l c @ l e r. .. ..... 6- 6
E. Pl s to o c o o l In g .p z z l o 6 1 2.............. .......... 6- 7
F . L u b € o l l q u a l l ty re q u l re r| €nfs............... ..... 6- 8

vAlilEr 6 -O
IECHNICALDATA (reject llmlf of part sfated In brackols after rötlng)

Lubrlcotlo||
OII pressure al no-nal runnlng lemperature:
- ai ld le speed ( m ln. ) I5O kP o (1,5 kplcm 2)
- dt run n ln g s p€ds . . . . . . . . . . 300...500 kP a
lt...5 kp/cn2,
Fr@ le ng th of oll pr es s ur e v aly e s pr ln g 80
Sprln g p ress ur e ehen v alv e s pr lng ls c o r D p r e s s e di o a l g n g t h o f 9 2 r m . . . . . . . . 54+ 5 N (5,4+ 0 , 5 kp)
DloD€i€r ol oll prossure valve plunger t9,602...19,6t 5
Dlan ete r o f oll pr s s s ur e v alv e c y llndgr 19,70O..19,75 2
Oll fllts' b y - pas s v alv e opens at a pr e s s u r e d l f f e r e n @ o f . . . . . . . . . . . . , . . . . . 2 !O,5 b{
Ope nln g p res s ur e of pls t on c €olln9 noz z l e ( 6 1 2 ) . . . . . . . . . . . 5 ! 0,2, bar
Oll pu tlp 5 O 9, J ll, 4ll

Backlo sh b elv €€n gear s r hen c r ank s hat t l l e s f l r m l y 6 g o l n s l t h e l o r e r s i d e o f

lis be örl n 9
- crankshåft drlve gear - ol I purrp drlve gear o,o5...0,25
- betreen oll pump gsars 0, | 6...0,26
Cle ara nco b €lr e€n dr lv e s halt and lls b e a r l n g s I n b o d y o n d c o v o r , . . . . . , . . . . r 0,016...0,052 ( 0, 070)
D la me+ers o f dr lv e s haf + holes I n bodv a n d c o v e r . . . . . . . . . . . r8,000...r8,018
Go6r hole dl omelers I 8,060.. . 18,0 78
Cle ara ncs be t w@n gear and llx ed s haf f . . . . . . . . . . . 0,021..,0,050
Protru slo n ol f lx ed s haf t end beloi pu m p b d y f a c e . . . . . . . , . . . . 0,5...1,0
T h lck ness ol covei' gask€rt 0,06...0,08
o ufs lde d I am et er of gear s . . . . . . . . 43,4A 6...43,r2 5
Cle ara nce o f geör s I n t helr hous lngs 0, | 25...0,264 ( 0, 100)
HousIng d lameter 45,650...4t,75 0
Thlckn ess o f gear s ( J 09, J ll) . . , . , . . . . . . . | 8, 000.. . | 8, 02 7
Thlckn ess o t gear s ( 4ll and f lt DS/ VB!, | V5 0 5 , 6 0 5 ) 24,0O0...24,021
End p lay of geais . . . , , . . , . . . 0, 01. ..0, 11
De pih of h ou s lng ( 109, 5ll ) . . . . . . . . . . . . . . . 18,000... t 8, o4 l
De pth of h ou s lng ( f ll and 5ll DS, / VBM V 505, 605) ............ 24,OOO...24, O 4t
Tlgh fen lng t or que of gear r e- t alnlng nu t . . . . . . . . . . . . . 60 Nn
Oll pu ||p 6 ll, 612

Backlesh befr.een gears rhen crankshaft l1€6 tlrmly agölnst the lorer slde ot
Its be ar In g
- cra nksh afi dr lv e gear - oll pum p dr lv e g e ä r 0,05.. .0,25
- betYeen oll pump gears 0, t 6..,0,26
Cle ara nce b ef r een dr lv e s haf i and lt s b e a r l n g s I n b o d y a n d c o v e r r . r . . . . . . . . . 0,0t 6...0,o52 ( 0, 070)
D la m€to r o t dr lv e s haf t bear lng hole I n b o d y a n d c o v f . . . . . . . . . . . . 18,000... t8,0t I
Cle ara nce b €t r e€n gear and f lx gd s hat i . . . . . . . . . . . 0,0t6...0,052 ( 0, 070)
Hole dlönet€r ot gear runnlng on flxed shotl r8,000...t8,0r8
Protruslon of flxod shaft end belor pump body löce . . . . . . . . . . . . 0,5...1,0
Th lck ness of cover gaskel o, 06. ..0, 08
o ufslde dlö m eler of gear s ( 6ll) 43,4A 6...41,r2 5
Qu tsld e d la m et er of gear s ( 612) 49,1 . . .49,175
Clo ära nce of gear s ln + helr hous lngs 0,125...0,264 ( 0, 100)
Ho uslng d la m e+ er ( 6ll ) . . . . . 4t,650...43,750
Ho uslng dlö Deier ( 612) . . . . . . . . . , . 49,900...50,000
Th lckne ss of gear s . . . . . . . . 32,000.. . t2,021
E nd p lay of g e a rs ........... o,05...0, | |
Depih ot houslng t2 ,oco. ..52, O45
T lght enlng t o rq u e o f g e a r re i a l n l n g n u t ............. 60 Nm

6-1
 LUERICÄTIol{ SYSTEX

6l

Ol I c Ircu lal lon

Lubr I catlon sys+em

The englne has a pressure lubrlcatlon system
c of t bI ned s lt h th e o l l p u mpw h l c h p u mps+ ho ol l

a I nf o l- he d l l fe re n t e n g l n e p o l n ts th ai need
lubr lc a+ lng. T h e p u mp s u c k s th e o l I fron + he
englne ol I su mpfh ro u g h a s u c fl o n l l l te r.
oll ls + hen l e d + o th e o l l c h a n n e l a n d furfher
The

t o t he pr e s s u re re g u l a + l n g v a l v e and ol I
f l l+ er . F r om fh e fl l te r + h e o l l fl o w s l nto fhe
m aln dls ' t r lb u tl o n g a l l e ry w h l c h h € s branch
c hannels le a d l n g + o th e c ra n k s h a ft mal n
bear lngs . T h ro u g h + h e c h a n n e l s In th e cronk-
shaf+ +he ol I ls then led from fho maln
bearlngs -io +he connecflng rod blg end
bearI ngs.

The lnjocflon pump and ihe turbocharger also

gef thelr ol | 'ihrough ihe maln dlsirlbuilon
galler y and a i b o i h e n d s o f fh e c y l l n d sr bl ock
ihere are ol I channels vhlch lead the oll to
ihe camshafi, The camshaft has an lnner bore
through rhlch other canshafi bearlngs are
lubrlcated. The fronl channel also f€eds +he
bear lng o{ i h e l d l e r g e a r l i l th p l a l n bearl ng.
From ihe canshalf rear end a channgl (ln fll,
6'll and 612 englnes an exiernal plpe) leods io
ihe valve [Echanlsm. Tho oll returns fron ihe
cyllnder head io the crankcase ihrough push rod
holes .
The b€lt or gear drlven compressor ls connec+ed
f o ihe engln e l u b rl c a + i o n s y s + e nw l + h a pl pe.
Oll pu!?

P r e s s u r e a e g ul a t l n g v a l v e 64
Ol l pum p6ll
1.0-rlng 6. Gasket
l. N ut 9. Scr6n 2 . C yI I n d e r 7. Covgr
2. W€sher 10. Sh a tt J. P lunger 8. N ut
l. Gear I l. Gear 4. Sprlng 9. W6sher
4. Body 12. Cover 5. Hashe. 10.
5. S + ud
Beär lng bus h l f. Sp a c e r
6. Key 14. Screr
7. Ge6r 15. Pre s s u re p l p e
8. Gaskat 16. In l e t p l p e
0l I fl ltlr
The oll pump ls a gear p'rnp flxed io l-he
cyl l n der bloc k lo w e r fa c 6 a n d d rl v e n b y l ha
g e a r on + he c r anks h a f+ fro n t e n d . T h e o l l p unp
body has a houslng ehere lhs gears are located.
|{hen ihe gears rolate ihe oll movesthrough the
iooth sp6ces, baiwoon the 9€6r and fhe houslng,
fro m + he I nlel s ld e i o th e p re s s u re s l d e . The 4365 36797
h o u slng I n t hg bod y h a s a c o v e r H h e re i h e l n l ef
p l p e ond + he pr es s u re p l p e a rs fl x e d . T h € e nd
play of ihe ol I pump gears ls adjusted by
changlng ihe nunbei of gaskets betreen ihe body
and ihg cover.
The clelrance ol the gears drlvlng +he puip ls
adJusied by chänglng the number of shl|ns
be+re€n the pumpbody and +he cyllnder block.

Th e oll pum ps us a d In d l l fe rs n t e n g l n e ty p es
aro slmllar ln consfrucilon ond vary from each
o i h e r m alnly v l+ h ra g a rd s to g e a r d l n F n s l o n s.

Pressuro rogulatlng valYe

In lll, 4ll and 6 l l e n g l n e s th e p re s s u re

re g 'rlöllng v alv e ls l o c a te d l n i h e g a a r h o u sl ng
a t th e loeer oll c h a n n s l . In 1 0 9 e n g l n e s f he
va l ve lles under lh e o l I l l l + e r, o n i h e e n g l ne The ol t fl l fer l s of mal n i l o* type and h 6s o
l e tf-h and s lde. I n 6 1 2 s n g l n e g l h e p rg s s u re repl aceabl e fl l i gr c6rtrl dge, mounfed on f h6
rsg u lailng v alv e l s o n th 6 6 n g l n e rl g h t-h önd threaded socket In lhe bracket. At the bo+tom
sl d e , bes lde t h€ o l I fl l te r. T h e v o l v e k e o ps of l he ol l fl l + er crrfrl dge i here l s ä by-pass
i h e o ll pr es s ur o o f th e rl g h t l e v e l , l rre s p g ct- yal ve for col d si ari or possl bl e cl oggl n g of
l ve of t he englne s p e e d . T h e c y l l n d e r a n d t he the fl l te.. The fl l ter l s al so equl pped r,lih 6
p l u n ger whlc h ar e s o a l s d w l i h a n o -rl n g c l ose baffl € w hl ch prev€nts + he fl l i er l rom emp iylng
i h e ol I c hannel. l { h e n i h g o l l p re s s u re g ro rs rhen th6 engl ne l s noi l n use.
h l g h er ihan t he r e s l s + l n g fo c c e o f i h e s p rl ng
part of ihe ol I relurns io the ol I sunp through
'the vaI ve,

Dependln g on oll qualliy 6nd t em per at ur e lh

ol I p rossu re 6 i r unnlng r qv s ls f . . . 5 k plc m
and a t ld ls spe €d 1, 5 k plc nz .

o -J
ol I cooler
s one onglne v g rs l o n s a r€ fu rn l s h e d w l th an ol l
c ooler whlc h l s e l i h o r In c o n n e c i l o n t {l i h i he
f l lt er or , f o r l n s i a n c e , l o c a + e d o n + h e engl ne
fronf end and connec+edio the fllter bracket
wlih plpes . T h e o l l c l rc u l a + l n g In the ol l
c ooler ls c o o l e d rl l + h e n o l n s c o o l a n f.

oll tl ltq - ol | cDl€r conblnatlon

0ll f I l i e | -
Oi I c@ler
F I ller brrcket
F l l+ e r b y -p a s s v a l v e
Baff le Jo. backf loY
C@ler b y -p a s s v a l v e
Threaded n lpp le

6-4
 UORKI NSIRI,'CT
IONS B. REIiOV THE OIL PUif
I NG AND INSPECTING
l . D ral n the engl ne ol l and ren| ove + h s oll sut lp
t. LIERICATI()t{SYSIE
fro + he engIne.
}{G THE OIL PRESSURE
INSPECTI IiIG YALVE
REGII-AT punp lnlet
2. Open fhe fl xl ng screw s ol i he ol l
Chgck the valvg functlon every ilme lf tho DlDe and r€irove the lnlei PIPe.
englne ol I p re s s u re d o e s n o t rl s e s u tfl cl eni l y
or lf lt v a rl e s c o n s l d e ro b l y . F l rs t, how ever,
ensure iha+ +here ls enoughol I In lhe engln€.

o n l y o p e n i h s f l x l n g s c r e w s o n t h e o l l Pu m p e n d
a n d l e a v e t h e p r e s s u r e p l p e I n l t s p o sl tl o n .

Open the oll pump flxlng screys. Reflpve ihe

p u m p a n d p o s s l b l e s h l m s b e t r e e n t h g p u m p fo o t
and the cy I Inder block.

5. Loson iho flxlng scre*s of +h€ purlp cover ond

r€npve +he cover and +he gaskels. Pull ou+ ths
gear on the tlxed shafi.

6 . F l x t h e p u m p a i l t s d r l v e g e a r l n a scr e p vl ce
67 equlpped vlfh protectlve lugs and open the
Oll p ressu re r egulat lng v oly g ( 109) d r l v e g e a r n u t . T a p t h 6 p u m p d r l v e sh a fl o fl
t h € g e a r r l +h a p l a s t l c hamrpr. Pull out th e
dr lve shafi - gaar.
open +he valve cover flxlng scr6v.s and remove
fh6 cover and ihg sprlng underneath lf. Noie 7. l{ash ihe paris ca.etully and check +hem tor
ths washer betre€n lhe cover and ihe sorlno. r e a r , c o n p a r l n g H l i h i e c h n l c a l d ö t a p o l n + 'r o l l
Pu ll fhe vo lv e c y llndei and lhe plung e r l n s l ä 6 p u m p r r . R e p l ö c s t h e p o s s l b l e i o r n p ö r ts a n d a l l
li out of the gear houslng/cyllnder block. Make paper gaskgts.
su re lh6 i t he c y llnder o- r lng s oal t o l l o w s . lf
nol', re[bve +he o-rlng from tho cyllnder block. 8. l f y o u r e p l a c s +h o o l l p u n p b e ö r l n g s b u sh e s o f
the 611/612 englnes, machlne them af'ter
Clea n ihe par is c ar gf ully . Plac e lhe p l u n g e r Insfallatlon +o 1 8 , 0 0 0 . . . 1 8 , 0 1 8 .
b ack ln the c y llnd€r and s r lng ihem + o a n d f r o .
lf fhe plunger do€s noi move smoo+hly rllhln ASSEiGI-II{G AND INSTALLIilG THE OIL PUI,P
th e cylln de r , s c r ape of f t he pos s lble d l r + o r
o the r lmpu r l+ y ly lng bet v , een t he p a r f s . ll l. P l a c a +h e g e a r s I n f h e h o u s l n g l o c Efe d In th e
n ecesso ry, gr ind t he par t s llght ly wlih flne body. lf n€oded, rep I ace ihe gaskoi bel-reen the
a bra slve cl ot h or r eplac e t he par is . C l e a n i h e body and the cover. Tlghten the flxlng scraws
sea I lng surfaces ol the cover and +he gear o t l h e c o v e r l l g h - t l y . T u r n +h e s h ö l i a n d i a p
h ou sl n g/cy I lnder bloc k . i h e c o v e r s l d o w o y s u n +l l y o u f l n d f h e p o sl i l o n
w h e r g +h e s h a f t r o t a i e s a s f r e e l y a s p o ssl b l e .
Place a ner o-rlng seal In fhe groove on fhs Tlghten the tlxlng s c r e v s o f +h 6 co ve r a n d
cyllnd er end. Flx t he plunger Inslde the c h e c k t h a i t h e s h a f + s 't l l l t u r n s s n o oth l v.
cyllnd er an d pus h t he par t s I nt o ihelr p o s l +l o n
In th e g ea r hous lng/ c y llnder bloc k . P l a c e i h e F l f t h e k e y a n d t h e d r l v e g e a r o n i h e sh a ff.
woshe r an d t he s pr lng I n + he hous ln g I n t h e A p p l y r e +a l n l n g f l u l d 6 9 0 9 f 0 0 2 5 on +h e n u f
cover and replace fhe gasket beireen fhe cover ihread and ilgh+en the nu+ +o +he lorque ot 60
an d ihe ho us ing. Flt t he s pr lng ag a l n s + t h e Nm. Donrf forget fhe lock rashor underneath the
plu ng er b ol - t om and t lght en lhe c ov er l n p l a c e .
lf needed, use extTa long scrers rhen prs-
tlghtenlng l-he cov€r, ln crdor +o overcoip ihe
sprlng pressure. l{hen you gei ihe cover near
gnough to the houslng, use standard scrers.

Flx the puip ot lts flxlng fooi ln a screr vlce

9!l.lpp"g rilfh^ proiscf I ve tugs. Chsck the gear
4. l{ho n fl++l ng f he v alv e c ov er note l +s ond pl oy (0,05...0,11 nD ) ul i h a dlal
g ccon irlcl+y . The r lder dls t anc o be +i e e n +h e Ind.lcaior. lf ne€ded, change fhe number of
cover ce ntr ellne and t he f lx lng hole l s t o b e gasKers beilleen ihe cover and the body.
on the lorer slde. lf +he covei ls mounied the
6- 5
rrong iay, li may causg oll leak q- ihe cover
mav cracK.
 A ppl y rei al nl ng tl ul d (6909 l 00l l ) on t he
thraad of the threadod nlpplo and tlghten lt to
i|o tln. Flx the rater plpes to the c@ler.

Instal l a neH l ubo ol l fl l t€r.

Close fhe coolgr dralnlng clck and flx the lub€

ol l c@ l er drål nl ng pl ug In pl ace by turn lng.
R efl l l the cool Ing sysl on.

9. Siari +ho englne ond make sure ihaf there

no lgaks.

Cools- w lih oyn brackot

6 10 @
Fl x t he punp I n p o s l i l o n o n th e c y l l n d e r bl ock
boiton f6ca €nd check ihe back lash of ihe
cra nk s hc t t and p u mp g e a rs (0 r0 5 ...0 ,25,
}rl t h a dlol lnd l c a to r. l f n e e d e d , c h a n g e i he
numberof shlns bet',{eenthe pump body and the
cy I I nder bloc k .
5. Aitach ihe pump Inlet önd pressure plpes and
re p lac e lhe f lx ln g l l a n g e g a s k e i s . F l x i h e ol l
su n p t o t he engl n e a n d fl l l i h e e n g l n e rl fh ol l
D . REPL.IC
I IG I}f OIL @OI-ER
C@ler on I I lier bracket

c@ler body ls flxed to the bracket lrlfh iro

benjo bolts. To remove these bol+s you flrsi
have to +ake olf the ol I tl ltsr and tts
brackef.
61r
l . C l E on t he c ooler a n d l ts s u rro u n d l n g s fro m the
outslde and refiove lhg oll c@ler. WlDe otl
l a ak E dol l.

2. Draln ihe englne c@lanf. Open the ol I c@l6r

cap ånd the draln cck as rel I cs lhe dralnlng
plug on lhe c@ler slde. Let ihe coolani tlo;
Into o c l6a n bo nl.

5. Dlsconneci the {aier plpes off lhe cooler. Open

fh e ihr E adod n l p p l e h o l d l n g th e c o o l e r and
remove th€ cooler.

4 . C l e an ihe t hr ead s o t .th e n l p p l e 6 n d i h e l l l ter

ca r ef u I ly .
5. Mouni a n€'i c(pler In lts plac€ on ih€ fllter
bracket In such a tay that ihe rater plpes ar6
torards ihe cyllnder block. Ensure ihat +he
gasket on lhe cooler ls ln lis posl on önd +h6
se allng s ur t oc € l s tn l 6 c + .
o -t)
 Pf sIoN c00L | 1{Gl€ztE 612
Tha plston cool lng nozzles of ihe 612 englnes
come off after fhg oll sump has been removad.
T he noz z lo h a s a b a l l v a l v e t{ l i h an oD anl nq
pressure of 5 + 0,25 bar.

lf necessary, clean ihe valve. Renpve ihe valve

from +he englne and iake off l-he nozzle plpa.
0p9n ihe plug In tho valve body and ramove +he
sp r In g a nd t he ball.

o o

3 o
6 14

6- 7
F. L UB E .O I L Q U AL IT Y R E Q U IR E M EN T S

I. O I L G RA DE A PI

Naf ur ally a s p l ra te i l e n g l n o s AP t cB or cc 1
T ur boc har ge d e n g In e s A PI C D o r S H P D
V I S CO SI T Y G R AD E

T e npgrature
S A E gr a d e

-30 -20 -10 +10 +20 +30

5W-20 5W- 2()

5W-30 5W-30
5W-40 5W-40
10 w 10w
10W-20 10w-20
10w-30 10w-30
10w-40 r 0w- 40
15W-30 15W-30
15W-40 15W- 40
20w-20 20w-20
20w-30 20w-30
20w-40 20w-40
30 30

0ll of CD gra d e c a n a l s o b e u s e d I n naturE I l y asp l ra+ ed eng I nos

a f + er r un- ln p€r I od.

6-8
cooltrG sYsrEr,l

tEX

T ec hnlc r l d a ta ............. ...,............. 7- |

S pc l. f t @ fs .... .......... 1- 2
Cons f r uqtl o n .... ........... 7- l
RsDalr I nstrustloos

l. Thenrcsfct
A . R e n o v l n ga n d In s p e c tl n g i he thq' dpsi at... ........ 7- 5
2. Cool ant pulp
A . R e m o v l n gfh e c o o l a n i p u mp.. . . . . . . . . . . . ........... 7- 5
B . R e c o n d l i l o n l n g fh e c o o l ant punp (309, l l l and 4l l
Ip a c k a g e b 6 a rl n g s n )...... ......... ....,.......... 7- 5
C . R e c o n d l fl o n l n g th a c o o l ant pui p (s€pörai e bal l bearl ngs
,l l ,' l l l ,6 l l a n d 6 1 2 )..... .... .................... 7- 6
D . fn s ta l l l n g i h e c @ l a n + pump.. . . . . . . . . . . . ......,.. 7- 7

vAlitEr
IECHiIICAL D TA (reJect llmlf of par+ s'ialed ln bracke+s atier rallng)

Coolcnt punp (t09, lll, 'lll englnes)

ouislde d lame+erof boarlng 18,087,..18, 100
Dlameter ot b€arI ng houslng 58,075...18,| 00
Sh6f+ d lame+er 15,9O7...1r,92O
I npeller hole d I a m s fe r . . . . . . . . 15,881.,.15,899
lmpeller should bs pressed on+o shaft so +haf lfs rear end ls In depfh of:
- t r oo r ear s u rfa c e o f b o d v ............
Hub pleca should bo pressed onfo shafi so thdt dtstanca o{ tlxlng level
ot lt s f an f r om re a r s u rfa c e o f { a + e r p u mpl s (509) ........ 157
Hub pleca should be pressed onio shaft so lhat dlstanca of flxlng lavel
of lt s f an t r o n re a r s u rfa c e o f b a c k p l 6 te l s (511, 4l l ) | 74,t...114,7
D lam ei€r of f a n h u b ......... 25,OO...25 ,20
B alancI ng pr ec l s l o n o f fa n .......... 0,1 Ncmmax
M ax . per m ls s lb l e g c c e n + rl c l i y o f fd r .......... ! 0,1
C@lant puip (rlth s€plrrie ball b€arlngs, 5ll drd lll angln€sl

outslde d lameter of bearIng

Dlanet er ol be a rl n g h o u s l n g ,t,979...r2,OO9
Shati d lane+er ai bearlng | 9, 980... t 9, 991
S haf i dl am e+ e ra + l n p e l l e r 1r, 1.. .15,920
lm DeI l€r hole d l a me te r ........ 15,881... r 5,899
lm Deller s hou l d b e D re s s o do n + o s h a ft s o fhai l + s rear face l s on l evel
r lt h s höli end . . . . . . . . . . . . . (dlslance betreen body
and l mp€l l er edge:
t ...1 ,1)
B alancI ng pr ecl s l o n o f fa n .,........ 0,3 N cmmax (10 pcm )
M öx . oer m ls s lb l e e c c e n trl c l i v o f fa n .......... 1 0,1
T lgh+ enlng t or q u e o f b o l l p u l l e y fl x l n g n u+ 100 N m

Coolanf punp (6ll and 612 €nglnest

Ouislde d låd€ler ol bearlng 52
lns lde dlar E le r o f b e a rl n g h o u s l n g l n p u mpbody 51,919...52,0O9
Shoti d laneter at bearlng 19,980... I 9,99'
Shaft dlarrter at InDeI ler 15,907... | 5,920
lnpeI lei hole d i a d | e te r . ,,..,.. | 5, 876... I 5,894
lm peller s hou l d b e p re s s e d o n to s h a f+ s o + hai l ts rear f6co l s on l evel
r lf h s halt end ... ....,. ... . (dlstance betre€n body
and lmpeller edg€:
0,3...0,6)
Dls i€nc e of be l + p u l l e y frq n re a - s u rfa @ of body ............ 115
B alanc lng pr eci s i o n o l fa n .......,.. 0,5 Ncmmax (50 pcm)
M ax . oer m ls s lb l e e c c e n tri c l ty o f fa n ..... ..... 1 0,l
T lghienlng t orq u e o f b e l f p u l l e y fl x i n g n u+ 100 Nm
Th€fiFstrts:

Spare pa-t no Type openlng b€gIns at Fu I ly open ai openl ng mm

8160 t 5l56 ö 54/7*. 77.. . moc 940C

8560 15489 ö 51/$q, 80. . . 850C 9oc
8561 I 5646 6 61/1*, 77...8t(t 940C I
8t 6l I 5?r 8 6 67/8t<1 8t .. .850C 970C
8t65 590 6 61/giq, 8t ...850C 950C
't
SFECIALTOOLS(CoolIng sys+em)

t . 8160 | 3 0 9 t Coolan+ pumphub exirac+or

2. At60 A5499 Coolanl pump l mpel l er extrac+ or (f09, fl l and 4l l )
3. 9025 415co Coolant pumplnp€ffer exfracfq rcll, 612,
4. 9051 40200 F l ttl n g to o I for coolant pumpaxlal seal
5. 9051 6 4 9 0 0 F l ti l n g to o l fq ' cool ant pumpshaff ( f09, fl l and 4l l )
CML I NG SYSIEi,I lh€ripstct 109, lll rnd 4ll

CONSTRT'CT
ION

CoolIng sy3tdtr 4ll

Thermosta+housI n9 tll and 4l I

l. Thernos+ai l.
2. B y - pas s p l p e Hexagon sockg+ screr 6. Hexagon socket
5. Radi a+or 2. R eturn pl pe screr
5. Gäskel- 7. Gaskei
4. C@l ant pump 4. Therrpsiat 8. By-pass p lpe
T he c ool lng s y s i e m l s l l l u s tra l ' e d l n fl g. 7 l . 5. Thermostai houslng 9. Gosket
The coolant punp (4) sucks fhe coolant trom th€ The J09. engl ne has c nornal sl ngl e - acilng
under s ld6 o f i h s rö d l a to r (J ) a n d D ressos l t lhornpstat. The theritost6i ln the lll änd 4li
I nl- o t hg c @ l l n g jackei s u rro u ndl ng the englnes ls the so-cclled double-actlng iype
c y llnder s I n th € c y l l n d e r b l o c k . T h rough the { hl ch rogul afes i he cool oni cl rcul ai l on bet r €€n
holes In ihe cyllnder block +op face th€ the by-pass and the rödlator.
c oolani r ls e s In to i h e c y l l n d e r h ead änd
fur+her onto th€ thernoslai (l ). 6l I and 612
englnes have a s € p ä ra te c @ l a n t o u i l e f ral l to The thernpstat l s pl acad l n a housl ng flxed t o
dlr ec t t he c o o l a n t fro m th e c y l l n d e r heads l nfo the cyl l ndsr head tron+ face. The by-pass plpe
the thernostEt houslng. }rlth lts gaskel lles beir€en ihe +hermostaf
houslng and ihe coolanf pump. The +herflpstaf
l{hen the englne runnlng iemperaiure ls lorar opgns ai ihe temperoture of 7fC. In rlnigr
than ihe apenlng teiperature of ihe th€rmosta+ o ihermostat vrlth of|enlng +enperature of
+he c€olani relurns fhrough the by-pass (2) 85 o C can be used.
siralghf Inio lhe coolont punp and then back
I nlo + he eng | n e . Thorrpstct 6ll cnd 612

l{hen the englne runnlng iemperature rlses up to

the ihermostot control ronge ihe thermostät
opens , let ll n g p o ri o l th e c @ l a n + cl rcul åte
+hrough fhe radlöior ond part +hrough ths
by-pass. l{hen the thermosta't ls lully apon lt
c los es + he b y -p c s s p l p e (n o + J 0 9 e n gl ne) and
+ hs c oolani fl o | .s th ro u g h i h e ra d l a i or onl y.
The by-pass arrongemgn+ ensures a steody
ieDper a+ ur e In g n g l n e u n d e r a l l c l rc u m stanc€s.

C@I cnt
T hs c oolani u s € d l s o n l x tu ra o { g l ycol -basgd
antl{reeze änd water rhgre ihe DroDortlon of
ihe antlfr€€ze ls l0 to 50 t. Due to l+s antl-
c or r os lv e q u a l l tl e s th e a n i l fre € z e s houl d b€
us ed I n t h e s u i g ri l n e a s re l l . C hönge the
coolant every fro years. Never use plaln rc+er
as c@l ant I

7-3
The 6ll and 612 englnes have tvo separa+e
thermos+a+s,one of |ihlch regulaies ihe coolant
by-pass. The thernostol houslng ls flxed on+o
+he +op of +he c@lant pumpor lis rlght slde.

The iheritoslats dllfer ln types and openlng

+emperaiures. l{hen fhe coolan+ tqnperature ls
belo{ +he thermosiat opgnlng temperature fhe
c@lan+ (A) clrculales through the by-pass hole
l n i o t he c oolan f p u mp . T h e s rn a l l e r, g l n gl e-
a c+ lng + har m os ta f (l ) o p e n s fl rs t (a + 7 9 oC ),
let+ln9 par+ of ihe coolant (B) into lhe
ra d laior . F ollol' l n g th e l o a d l n c re a s o , a l s o l he
other lhermostat (2) opens (at SloC). Thls ls
a d ouble- ac t lng + y p e l { h l c h c l o s e s th e b y - pass
h o l e when li ope n s a n d d l re c ts l h e c o o l a n + (C )
Into fhe radlalor. These englne lFdels do no+
have separat€ r Inter-+yp9 thermosia+s.

C@l ant purP

Th e c oolanl pur p l s a c a n + rl tu g a l p u mpl l x e d i o

ihe cyllnder block tronf face. The purp ls
d rl v en by lhe c r€ n k s h a l i b e l + p u l l e y + h r ough
th e v - belt . T he J 0 9 , 3 l l a n d 4 1 1 e n g l n e s have
+he pump shat+ and bearlngs ös an Iniegrated
u n l + or + he pumpl s e q u l p p e drl + h s e p a ra te bal I
b e a r lngs . I n 6ll a n d 6 1 2 e n g l n e s fh e c o o l anf
p u m p ls f ur nls he d l l i l i h s e p a ra fe b a l l b e a ri ngs.
Th e lm peller ls fl x e d fo th e s h a f+ w l + h
pressed-on fl+. The €xlal seal on the pumpbody
and the ceramlc counter rlng rolailng on ihe
shaft take care of lhe seallng. The pump body
h a s c onnec t lons to r th e fl u l d c l rc u l a i l o n of
the heatlng devlce ond ihai of ihe oll cooler.
The f09 and fll englnes also höve a connectlon
fot' ihe b lock hoaier.

Coolan+ pump, separate b a| | b e 6 rIn g s , l l I a nd

4ll a ng lne s.

l. L ockln q rlno 12. Gaskei

l! Ee artn g l f. Ba c k p l a te
f. Bush 14. Hexagonscrew
4. Sh ali 15. Hexagonnu+
5. Shafi sea I 16. Washer
6. Orease nlpp le I 7. B e l + p uI l e y
7. Body 18. Key
8. Seö llng rlng 19. Hexagonscrew
9. Plug 20. Connec+or
10. Axla l sea l 21. S e a l l n q rl n o
ll. lmpe l ler Z Z . \ja sKe i

7-4
 f,ORKINSTRI'CTIO
S IHE @0L |tT pt[f
B. RE@ND|T|ON|NG , ftl
'09, '
c00L G sYsIErl

|. IllE 0,r)ST T
A. RErcYINGArI' INSPECTI]€T}C T}€S'PSTAT

l . Dr aln + he e n g l n e c o o l a n i u n fl I th e fl ul d l evel
ls underngath the thermosia+ houslng.
2. Renpve fhe uoDer Hater hose from ihe return
plpe. O pen i h e re tu rn p l p e fl x l n g s crers and
remove tl|e rgiurn olDe and +h9 thq-nostal.
5. lmmerseihe thermos+af ln a waler conialner so
+hat lt cannot louch iho *alls or lhe boi+om.

4. t lär m up + he w o i e r s l o w l y , n o fl n g l h e rl se In
tempera+ure on å thermometer. Compare lhe
openlng ienperafure of fhe fhermostai and *he
fempera+ure rhere lt ls lully open rlth lhe
r af lng (see te c h n l c a l d o ta , pol nl
rThernpstalsn).

5. lf the therrpsfat valve stlcks or ihe thermo-

s+ai opens ai foo lori or foo hlgh a +empera+urg
replace the thernostai.

Clean iha seöllng tac€s of the therrpsfaf

houslng and the reiurn plpe. Place the thermo-
s t at I n pos l tl o n rl i h th e b y -p a s s c l o sl ng dl sc
dornr€rd. Rgplace the return plpe gasket and
Inslall the return plpe and the upper xa+er
n0se.

7. F lll t he c o o l l n g s y s + e n . S i a ri i h e e n gl ne and
c hec k f or p o s s l b l a l o a k s . R u n + h e engl ne t . Renovs iha fan t lxlng hub from fhe shafi lalth
llgh+ ly loa d l n g l t u n tl l y o u s e e i höi i he exirac+or 8560 | 1091. Remove the lod(lng rlng
thq-mosia+ ln lts posltlq| operetes nq-mally. frorn +he pump body.

2. @OLANT flTP

A. REIOY I G IHE ML^I{T PIIP

l. Dra ln +h e englne c @lant . Dls c onnec i + h e u p p € r

and ihe lorer rater hoses. Open ihe tlxlng
screis of the thermosiai houslng, renpve the
houslng and the by-pass plpa.

2. Renrove fh€ hea'i'lng deylce connecilon, +he ol I

cooler connecilon and ln the case ol f-cyllnder
e ng lno s +he bloc k heaier ( ll as s em b l e d ) {r q r
the c@len+ punp.

J. Loosen lhe aligrnaior flxlng scrers. Open lhe

lan flxlng scrers, reflpve ihg fan, the pulp
pu I ley and the v-beli.

4. Open the coolani pufip flxlng screys and roflbve

the punp. Rerpve ihe gasket bgtreen the pump
a nd lh e cyl lnder bloc k and c le€n ihe s e a l l n g
t€cas.

76

2. open the bock plafe flxlng screr and reflpva the

back plaie from the purp. RErove the ltnpeller
from lhe shaft xl+h exiractor 8560 85499.

5. Press the shaft oui of +hs bodv towards ih6 tån

w l i h e.g. a hydraul l c press. S upport t he body
so that ih9 bearlng cones oil+.
4. Tap out +he shafi seal rlih å drlfi. Clean fhe
parts and ch€ck lhelr condlilon. Replac€ rorn
or defecilve par+s rlth ne{ ongs.

7- 5
 Notel lf vou ne€d +o replace the purnpshafi,
the bes+ soiutlon ls to ossemblea pumprepalr
kl + s hlc h lnc lud e s a l l g a s k e i s n e c e s s a ry for
recondlilonlng (see spore par+s catalogue).
Press the shöft In lis posl+lon ln +he body
,fih tool 905'161900. Install the locklng rlng.
77
6. C l e an + he s haf + a n d th e a x l a l s e a l re c e ss on
+h e pum p body . P l a c € i h e p l a s i l c c o v e re d seal
and counl-er rlng on fhe shaf+. lf necessary,
u se an+ lf r eez e a s rrl u b rl c a n tr' . T a p p l n g i h e seal
ln Dosltlon wl+h drlf+ 9051 40200 rernovesl-he
p l as ilc c ov er eh l c h p o s s l b l y c o me so u + trl i h the
d rl fi. t f lt r en a l n s l n th e h o u s l n g , re trp ve l t
b e f or e f lt t lng ih € l mp e l l e r.
78
Press l'he lmDeller and fhe hub on the correct
post+lon, supporilng lhe shal+ at the qther
end. Ensure fhat the shoft rofaies freelv.
8. Flx ihe back plale on the body and rep laco the
OaSKeT.
/ -o
RECONDITIoNII€
n€ CooLANT R tlP
(Separ6+e
ball boarlngstl1,411,611' 612,
1. open the bel t pul l ey fl xl ng nut and renove t he
pulley. Uso exfracior 8560 15091, lf neoded.
R€orove ihe l|tpeller from the shaft vl+h
extracior 8160 85499 (fll and illl englnes) or
extractor 9025 4l5OO(6ll cnd 612 englnes).
Removethe locklng rlng fron ihe pump body.
Press the shaf+ and bearlngs out of +he body
i ow ards the fan w l + h e.g. a hydraul l c pr ess.
Support ihe body so tha+ th6 bearlngs comeou+.
4 . TaD the axl al seal s and sh€ft seal s ou+ of t he
body l rl + h a drl fi . C l ean the par+ s and c heck
i hel r condl i l on. R gpl ace w orn or defecilve
oeris wl+h ne|l{ones.
N oi el lf you need i o rep l ace the pum p
beärlngs, l-he besi goluilon ls to assembl6 a
pump repal r kl i yhl ch l ncl udes al l gasket s
necessary fo|- recondltlonlng (s€ spare parts
cata I oguo).
5. T6p the ner shafi seal onfo the body {l+h a
sul l abl e drl ft. P l ace fhe bearl ngs and t he
lntermedla+e bush on the shölt. Lubrlcate +he
beorl ngs w l i h a suffl cl ent amount of h sat -
resl stant bal l bearl ng grease. P l ace l he sha{+
and + he bearl ngs l n posl tl on 9o thal + he {or css
caused by the presslng are not +ransmlffed
through i he bal l bearl ngs. Fl + i he bear lng
l 6k l ng rl ng.
6. Clean +he shaft and the axlal s€al recess on
the pump body. Place the plasilc-covered seal
and counier rlng on thg shaft. lt ne@ssary,
use antl freezo as nl ubrl ccntn. Toppl ng the seal
ln Dosl+lon ylth f lft 9O5l 40200 removes +he
pl astl c cov€;rrhl ch possl bl e com€soul vl th- t he
drl l t. l l l t remal ns In i he housl ng, rerpve lt
befors f l i i Ing fhe l mpel l er.
C ool ant pump6l l ,612
 Press ihe lmpeller ln poslilon suppor+ln9 one
end of the shaf+. The shafl end and the
lm peller c e n tre a re l e v e l l l n g , w h l c h m 6anstha+
+he dlsiance b€teeen ihe body End the lmpeller
r ear edge l n 5 1 1 /4 l l e n g l n e s l s 1 ...1,3 mmand
ln 611/ 612 e n g i n e s 0 ,f...0 ,6 n m. Ensure i hat
+he shaft rolates freely.

F lx ihe be l t p u l l e y o n to l h e s h a fi a nd tl ghi en
I t s f lx lng n u t to i h e + o rq u e o f l 0 O N m.

Ir{sT LLtrG I}tE Coot.ANI Pti,P

Replac€ ihe gaskei between ihe pump and the
c y llnder b l o c k . In s + a l l + h e p u mp a n d + l ghten
f hs f lx lng s c re rs e v e n l y a n d In tu rn a round the
bodv.

F lx t he pu l l e y , v -b e l t a n d fa n . T l ghten i he
a lierna+cr- flxing screws.

J . I ns f all + h e c o n n e c tl o n s fo r th e h e a tl ng devl ce
and oll coolgr and +h9 enolne heafer of ihe
f < y I I nder e n gIn e s .
4. Flx the by-pass plpa vil+h nett gaskei In lts
pos lilon o n i o p o f fh e p u m p . In si al l the
lhermos+a+houslng ln the cyllnder head, a+ the
sanE +lme mounilng ihe by-pass plpe beiweenihe
puip and ihe houslng.

5. F lx + he uD o e r a n d l o w e r { a + E r h o s e s. Fl l l the
englne c oo l tn g s y s + 9 ma n d c h e c k fo r possl bl a
leak s .

Noi€l lf you lntend to lns+all a coolant pump

wlih a net| sprlng sgal and counler rln9, the
cool ani mav drlo from +he hole underneath +he
pur p dur ln g + h e fl rs l ru n h o u rs . Thl s l eak
should siop yrhen lhe seallng faces adjus+ io
each other.

T-T
II{.ET AIO EXHAUSTSYSIEI{, TURBOCMRGER

I to€x

Technlcol dato

construcf I oo 8-l

Reoalr lnstruqtloos

l. Inlet cnd exh.ust systerl

In s p e c tl n g th e a l r fl l i e r U -J
B . In s p e c tl n g i h e In l e + a n d exhausl pl pes ........... a -t
Turbochargsr
A . D o + e rml lnn g th s c o n d l tl o n of fhe + urbocharger,.. i ................ 8-4
B. Renpvlng the iurbocharger 8-4
C. Recondltlonlng th€ furbochargtr v5
D . In s fa l l l n g + h e tu rb o c h a rger ............ 8-6
E . In s + a l l l n g i h e In i e rc o o l er-

VA1DIET 8- 0
INLET ANDEXHAUSTSYSIEM

@NSIRI'CTI ON

In lei cnd €xhrusf systen 4lt Ds

l. Cy clon€
2. Hexagonnu+
f. F I I ter
4. llasher
5. F | | ter
6. Hous lng
7. Gaskei
8. C lam p
9. Rubber plpe
10. S er v lc e In dl c a i o r
l l. I nlet plp e
12. I n lei m a n fo
l ld
lJ. Hex6gonscrei
14. Turbocharger
15. E x h€us tm a nI fo l d
16. O ll r et u rn p l p 6
17. P r gs s ure p l p e
18. Connoctor
I 9. S eaI I ng r i n g
20. P lpe
21. O ll plpe b a n d

Technlcrl dqic

Turbochcrger
Hols€i HID

0ll pr gs s ur e a t ru n n l n g s p e o d ........... n l n. 2 bar

E nd Dlav of s h a f+ ........... o , lo . . . o , I 6
RadI ol olav o f s h a f+ ........ 0, J0...0, 46
T lght enlng i o rq u e o f + u rb l n e h o u s l n g re tal nl ng scretrs (Mgxl 2) .... I l ,J N m
T lght enlng + o rq u e o f i u rb o h o u s l n g re + al nl ng scrers (t{ 6x12} ...... 5,7 N n
T lght enlng to rq u e o f b e a rl n g h o u s l n g re + al nl ng scrers (M6xl 6) .... 5,7 N m
T lght enlng i o rq u e o f h e x ö g o nn u i o f s haft ........ 14,0 N m
Threåd ot shaft: lefi-handed

G ar r et T 04B T T

O ll pr es s ur e a i ru n n l n g s p e € d ......,.... ........ ml n. 1,4 bar

E nd play of s h a { -i ........... ... 0,025...0,10
Rodlal play o f s h a fl ........ ... 0,075...0,18
T lght enlng i o rq u e o f h e x a g o ns c re rs 5 /1 6-' 18 ...................... lil Nn
T lght enlng to rq u e o f h e x a g o ns c re rs l /4 -n ...................... l0 Nm

Lor pressures rnd back-prGsures

V ac uumlndu c € db y a l r c l e a n e r ...............r... möx. 5 kPa (500 rm r.c. )
E x haus +plpe b a c k -p re s s u re ..... mE x. o K ra (600 m e.c. )

8- 1
T he eng lne fll+e rlng s y s t em f or + hs lnle+ alr The englnes höve an exhaust charger, l.e. 6
mosfly co nslsts of t he c y c lone ac ilng as pr e- iurbocharger where par+ of ihe energy of the
Jl lt er a nd +h e oa oe r - €lem eni f llt er as f he m al n exhaust gasos ls utlllzed io gef npre alr lnto
Jllfer. In th e cvclone t he lnlet alr ls m ade t o ths cyllndsrs. The turbo ls flxed dlreclly io
whlrl, whlch se pa raies r ios f oi t he lm pur iiles ths top of the exhaust manlfold or to lis 196r
and co llects ih em Inlo + he dus t c ont alner . Th e end. The energy of the exhaust gases rotaies
paper fllter h as el iher one or ir o r eplac oable ihe furbine trheel ot ihg iurbo rhlch drlves the
car+ rldg es rhlch a r o pleat ed t o ob+ aln a n iurbo rotor at ihe o+her end of ihe shaf+. Th9
adequa ie fllfsrln g ar eo 6nd equlpped wlf h a iurnlng turbo roior boosis pressurlzed alr lnto
rEta I support. fhs cyllnders. Thls nEans ihat iherg ls o
lörger arnouni of alr In the cyllnders lhan
T he lmpu rlfles In the I nlet alr ac c um ulaie o n normally and lhus rrore tuel can be combusted
fhe ouier surfaco of the carirldge from whlch 6nd Increasod ouiput c6n bo achleved. As +he
ihey c an € aslly b e r em ov ed. The I nnor f llf er or e n g l n e e x h a u s f g a s e s d r l v e t h e +u r b l n e r h e e l ,
the so-called safe+y glenlen+ prevenis ihe i h € +u r b o a u t o r n a t l c a l l y o d J u s t s i o t h € e n g l n e
lmpurlflss fro m ge ff lng lnt o t he €nglne, ll t he load and spe€d.
prlnary llltsr b ecom es c logged or lf ihe f llt er
assem bly ls fau l+y. Ths -turbo shafl have bearlnqs tlxed to the
bsarlng houslng wlih tro so-called tloailng
A mech an lco l o |- e lec + r lc al s e. v lc e I ndlc aior bushlngs. These bushlngs are lubrlc6ted a nd
can be mounled on +ho lllier houslng or on the c o o l e d +h . o u g h t h e e n g l n e p r e s s u r e l u b r l c a i l o n
Inlef plp e io sho w r hen ihe f l lt er c ar t r ldge Is s y s +e m . T h e s e a l l n g r l n g s o f p l s f o n r l n g t y p e
clogge d . Th e ln lei s y s t em als o c om pr ls es t he p r o v e n t o i I l o a k s t r o m +h e b e a r l n g h o u s l n g .
plplng b etwe €n ih e alr f llt er and ihe iur bo,
the plplng b€+'reen the turbo and fhe lnlet
manlf old an d +h e In let nanlt olo.
EOOST AIR I iITER@OLER
The turbo tlxed on top of lhe exhausl' manlfold (DSJ cng l nos I
on at lis r€or end gets lts lubrlcal'lon from
the englns pressure lubrlcal-lon sysj'om through
the prossure plpe and the ol I return plpe.

T he marlne e ng lne s ar e f ur nls hod v r lih a wai- er -

c@led exha ust man lf old r hlc h ls c onnoc led t o
ths eng ln€ coo lan i c lr c ula+ lon ( ' r f r es h r aier
c I rcu lailo n),

The opercf lon ot th€ turbchrgcr

(DS engl ncs)

Boostair
Coolant I

The engl nes rl i h i ype d€sl gnatl on D S J o r e

equlpped rlth alr-+o-rater boosi alr lnier-
coollng. The cool Ing slements are encased cnd
I M U IL IIA Jol ned v,l th the Inl et manl fol d and connec+ e dio
€ the engI no cool ani cl rcul öl -l on.
PAKOKAASUT
\r-J In ihe c@l ln9 el€monts the compressed Inlot
öl r c@ l s doxn, havl ng a greatar densl ty and
V O IT E L ULÖJ Y npre oxygen rhlch ls negdedfor the combus on.
: a2

8 -2
 TMK INSIRI'CTIONS
I NLEI A}D EXHAUSTSYSIEM, NNBMMRGER

t. {LET A||) EpUST SYStEr,l

A +urbocharggdgnglne ls much npre susceptlble
to lnlef a n d e x h a u s f s y s + e m iroubl gs,
lm pur llles , e i c ., th a n a In a tu ra l l y a spl roi edr
englne, Thergfore speclal a++antlon musi bo
pald t o t he c o n d l tl o n o f fh e a l r l l l i e r ånd l he
lnlei and g x h a u s t D l o g s .

INSP€CTING
THEAIR F ILTER
Th€ englne performance and llfe are dependeni
on ihe c on d l tl o n o f i h e a l r fl l te r. A faul ty
f lller leis th ro u g h l m p u rl l l e s rh l c h gradual l y
damage lhe iurbo and +he englne. A clogged
f llt er r es u l ts In l o s s o f e n g l n e p o rg r and ol so
of+6n causes an ol I leak frorn tho iurbo lhrouoh
+ he s haf t se a l l n g rl n g .

t. Check ihe cleaned fllter bv p l å c l n 9 a l a m p

lnslde lt. l{ You d€tecf holes or lf ihe f I lier
l s rorn ( l l ght-col oured pol nfs r h l c h l e t l l g h +
through), repl ace i he fl l ter.
4, C l aan i he { l l + er housl ng l rom fhs lnslde io
remove dus+ and lmpurliles. Check that l-he
gasko+s are Infac+ and thai +helr ma+lng faces
are cl ean. P ush i he fl l ter Into + h€ h ouslng and
ensure that l 1 l s properl y l n posl + l o n. Tlghlen
ihe reialnlng nul to the correcl torque (about
1...1,5 i urns after + he fl ange gasket +ouches
+ hs fl l ter housl ng €dge).

tlotol The safeiv elerpnt Inslde the alr

fllier ls not to be rsnoved unnecessarlly In
connoctlon rlih fhe lnspecllon and servlca of
ihe prlmary flltar. Do not clean the safety
slement, bul replace li once a year o. then
necessary (see Operatorrs Manual, polnf
S ervl ce ).

Refircvethe fllter by op€nlng the nuf ai the end

o f ihe fllie r hous lng and pull out t h e f I l ter.
lf you dcntf In+end io reolace fhe sa{ ei y
e lerle ni Ins lde t hs lll+ er , t eave It ln
o oslilon . B. IIISPECT
IIG TI€ I II-ET AIO EXMUSTPIPES
leftcntl Leaks In the lnlet and exhaus+
plpes impalr thg performonce of the +urbo
conslderably. Due io hlgh prgssure even a mlnor
l eak i n the exhausi manl fol d or l n tha iur blng
Inl et fl ange may gror ropl dl y. Theref or e also
sDall leöks musi be aftended to lmnedlaiely
öf'ter ihey have been deiected.

Check thai the plpes bgireen ihe alr fllter and

ihe turbo and bett{e€n fhe turbo and the lnlei

E5

Clean + he fl l te r e l i h e r w l + h ö v a c u umctsener
or by dlrgcilng a compressedalr Jef ouixards
f r om t he l n s l d e o f th e fl l + e r.
The max.
pressure of thg cpmpressod alr may noi exceed
500 k P a ( 5 k p l c mz ). R e p l a c e th 6 i l l ter ofl er
y ou hav e c la a n o d l f fl v e tl m e s , a + l h e l otesf.
Replaco ihe gaskets cnd end fix the lnlet
manl fol d. Tl ghfen i he retal nl ng screws of +he
manttoto evenl y i o r0 N n. Mount t he alr
pl pes carefu l l y.
6-3
 Ch€ck the exhaust manlfold for seallng and ih€
torque of the retalnlng nufs (60 Nm) as
rell as pos s lb l e d a n a g e s (c ra c k s , d l s + o r tl on,
@rroslon, etc.). Also Inspec+ ihat ihe iurbo
l s pr oper ly f lx e d to th e e x h a u s t m a n l to l d .

6 . Fl x f he ox hou s + m a n l fo l d u s l n g a l w a y s new
g€skeis. Run lhe englne rarm and check ihe
torque of the refalnlng nuis (60 Nn).

Ensura thai fhere 6re no extra obs+ructlons ln

th e - ex haus t plpe o r In + h e s l l e n c e r w h l c h m l gh+ aa
b u lld up ex c €s sl v e b € c k -p re s s u rsfo th e e x haust
gosos coolng from ihe turbln€ vrh€el.
4. Measure the end play of the turbo shaft. Sef
the tip of the dlat gauge on the shafi end and
(DS engl nes)
2. TIJRtsOCMRGER nbve the shaff longltudlnally, b a c k a n d fo r i h .
uqflpa.e th€ resul+ rlth the ratlng.
To ens ur e + hai + h 9 tu rb o fu n c tl o n l s fa u l fl ess
lf the €bove Inspectlons reveal dahages oi.
excess lve reaa, renove .i'he turbo for -repalr
(lnstruqtloos, polnt 8 2 B).

DEIEilIINING IHE @T{DITIONOF T}C TURBOCMRGER

^.
lf you suspeci fhai +he operailon of the iurbo
l s uns a+ ls f ac t ory , c h e c k l h e fo l l o v .tn g :
l . C hec k t he c ond l i l o n o f i h e tu rb l n e rh e e l and
th e + ur bo r ot or v l s u a l l y . T h e b ta d e s s h oul d l f i he engl ne operafl on Is no+ normal and ihe
have no damag€, bend or qlhe ear coused by lufP Is noi dörnagedo|. excesslvely worn, fhe
fo rolgn par f lc le s . fol l oyi ng reasons may l l e behl nd fhe i rouble:

2. S€€ +hot fhere are no oll leaks lnio +he - al r fl l fer cl ogged
furblne houslng o|. iurbo houslng +hrough the - l eaks In l nl e+ or exhaust pl pes
sh a f + s e€ls . l eaks l n gaske+ot turbo moun+ l ngfl onge
- l nj ectl on pumpi l ml ng l ncorreci ör opei ailon
o tel Dur lng ld l l n g th 6 re n a y o c c u r s ll ght rau tty
o l l leak age ln + h e c o m p re s s l o ns l d e . T h l s l s - fhrofi l e l everage tal sel y adj usi od
however, no reason for concern, unless ll- - l nj ecfors fal sel y adJusi äd oi mal funcfl onlng
causes hlgher ol I consumptlon. - fuel fged pressura l or (9.q. fuel fl l fer
clogged)
- englne coopresslon pressure lovr, valve
cl6arances mlsadJusted

B . REI,|oV
ING I}E TURBOCHARGER
R€rnove. +he_re+alnlng scrors of +he exhåusf plpe
and take off i he pl pe. D l sconnoct + he l urbo alr
p l pes.

remove the p lpe.

,. the turbo ftxtng screrlsand removethe

ifffi:
,. ptuss rn ihe rurbo lnte+ ond
:li::.f."T:r"Jlve
t7
J. Me os ur et he r adla l p l a y o f i h e fu rb o s h o ft.
+he flp of the dlal gauge on +he slde of fhe
shatt and movethe shaf+ laterally. Comparethe
ro sult wlih ihe r a tl n g .

8 -4
 RE@NDIT (IIOLSETHID)
I otl ll{c IHE TTRBoCHARGER Remove+he turblne vihe€l and the shaft (25)
O Notel Llke r.lth ihe ropalr of fuel equlprFni
+he rocondl+lonlng of 'the turbo should be made
+ ogefher yl th the seal l ng rl ng (24) and llf i
off tho l urbl ne shl el d pl ats (25) f r om +he
shaf+. Remove the ou+ermost lock rlngs (16)
t ilt h u+ 0los i p re c i s l o n a n d c l e a n l l n e s s . l f you fron tha bearl ng housl ng. P u+ your flnger f lp
donr+ have al your dlsposal ihe necessary Into ihe baarlng (15) and pu | | out bqth
s pec lal lool s , e .g . fo r b a l a n c l n g + h e ro+ atl ng bearl ngs. R onove+ he Inner l ck rl ngs ( 16) .
par t s , dls a s s e m b l e o n l y + u rb o h o usl ng and TURBO HOLSET HID 14. Thrusi bearlng
turblne houslng for ihe checklng of ihe rofors. l . Turbo housl ng 15. B earl ng
In r|os+ cases l+ pays 1o lnstall a replacemeni 2. Hexagonnu+ 16. Lock rlng
turbo del lvered by the manufacturer. 5. R oi or 17. B earl ng h ouslng
4. Intermadlale dlsc 18. Hexagonscrev
5. rrsQrr seal l ng rl ng 19. Lock w asher
6. Mounl l ng p l a+ e 20. lttounilng plale
7. l{asher 21. Lock washer
8. Hexagon screY 22. Hexagon screw
9. S eal l ng rl ng 25. S hl el d p lat e
10. 0l l def l ector 24. S eal l ng rl ng
l l . Gul do pl ate 25. Turb lne rheel and
12. Screv, shafi
lJ. Thrust p late 26. Turbl ne h ouslng
27. S €al l ng r I ng

89

Dlsass€*llng th€ iurbo

Clean the turbo from ihe outslde and clamo li

I n a v lc e (rl i h p ro te c t Iv e l u g s ) u sl ng + he
f lange as t h e c l a n p l n g p o l n + .
2 . Mark i'he rela+lve poslilons ol 'i'he turbo
hous lng ( l ), In i e rrn e d l a + e d i s c (4 ), bearl ng
hous lng ( 17) a n d + u rb l n e h o u s l n g (2 6 ). open the
loc k r as her s (1 9 a n d 2 l ).
3 . Ren|ovethe i-urbo houslng screws (8), rashers
( 7) and m o u n tl n g p l a i e s (6 ) a n d l l ft off the
iur bo hous l n g .
Loos€n ihe turblns houslng screws (18). Renove
t he loc k wa s h e rs (1 9 ) a n d m o u n tl n g p l ates (20)
and I lli o ff fh e b e 6 rl n g h o u s l n g l rom -the
+ ur bI ne hou s l n g .
Hold + he lur b l n e (h e e l b y + h e fo o + s l +uated In
ihe nlddle of the vlh6el and remove the roior
r eialnlng nu t (2 ). Pu l l i h e ro i o r (5 ) off from
the shaft.
NoteI The thread of ihe reialnlng nut
left-handed. Do nql bend ihe shaft.
Open the screris (22) flxlng ihe lnfermedla+e
dlsc io fhs bearlng houslng and removelhe lock
tiashers (21). Take oft the Iniermedla+s dlsc
(4) and fhe ol I def leclor (10) frorn the shaft.
Press l-he oll daf lecloc off the back plate and
r em ov e t he s e a l l n g rl n g (5 ) fro n the l nter-
nedlat e dls c . L l ft o { f th e o l l g u t de pl ate
( |l ) .
7. Loosen the rotalnlng scrers 2) of the ihrus+
bearlng. Renove +he +hrus+ pla+e fif) and +he
t hr us i bearI n g fi 4 ).
Clecnlng the turbo prts
N otgI U se onl y w ashl ng agen+ s you kn ow. Don't
raEh ',rlih co-rodlng washlng agen+s, as +hey
dönagesone of the turbo pari9.
W asho{ f al l dl r+ fron + he D ar+ s w l i h ihe wash-
l ng agont. U se a pl asi l c spatul a or a br ush io
cl ean tho al uml nl umparfs.
2. C l ean al I ol l channel s vrl i h pressur lzed alr .
E nsure thai al l j ol ni s are cl ean and ln good
condI t l on.
Chscklng lhe turbo psrls
l. S hal i - i urbl ne w heel combl natl on
Check the bearlng surfaces for woar and
scratches. Minor scraiches are alloved.
C heck + he seal l ng rl ng groove l {al l for
scratches. Mlnor scraiches ar9 allougd.
C heck + he turbl ne rrheol bl ades for posslble
ls dan6ges, b€nds and cracks. Under no clrcun-
stcnc€s b€nd the blades.
Thrusf bearlng se+
ReDla@ worn or dofgctlve Darts
Thrus+ bearlng ol I grooves should be clgan
Turbo rotor
Check the turbo rofor blades for posslble
damages, bends and cracks. Und€i no clrcuF-
stoncas b€nd the b I adas.
BearI ngs
Replacp worn or scraiched bearlngs
 5 . Be ar lng housI ng
- R6pI ace bearlng houslng, ll fhe bearl ng
surtacos or- the seallng rlng groovgs are
notably rorn or scraiched.
6 . Roiatlng paris
Chock ihe balanclng of the roiatlng parts
rS Q r s 6allng r ' ln g
Rgplace damaged,vorn ol- hardened seallng rlng
8. Tur bo hous lng an d + u rb l n e h o u s l n g
Check th6 houslngs for any damageor cracks
caused bv the coniact of the roior or detects
du6 io posslble overheatlng. l4lnor damagescan
be accepted, bu+ ofher*lse replace ihe houslng.
AssembI lng the iurbo
After c leanlng a n d In s p e c tl n g i h e tu rb o p arts
ca r ef ully and re p l a c l n g i h e fa u l + y p ari s,
assembleihe +urbo. Perlorm ihe assenbly In the
reverse order comparedio dlsassenbly. Pl6ase
p a y 6+ + ent lon io fo l l o w l n g p o l n ts :
The r ot at lng pa rts s h o u l d b e b ö l a n c e d | rl t h an
accuracy of 1,44 gfln a+ both ends. Ensure
i h at y ou t lnd th e m a rk s y o u n a d e d u rl n g dl s-
e s s em bly I ndlc a tl n g th e re l a + l v o p o s l tl o ns oJ
dl fforeni parls.
Pl ac e + he loc k rl n g s In + h e l r p o s l tl o n s w l th
fhe chanfared slde lowards l-he bearlno.
f. L u br lc at e f h€ s u rfa c e s o f a l l b e a rl n g h o u s l ngs,
th rus t par t s an d s e a l s ,l th p l a l n e n g l n e o l l .
4. |{h€n you set +he shati +hrough +hs shlsld plate
and ln+o ihe bearlng houslng and +he ol I
def lector lnto +he lniernodla+e dlsc donrl
fo rc e t he s eal l n g rl n g s l n to p o s l tl o n s , for
tlEy may broak oasl ly.
5. Tlgh+en ihe ihrusi bearlng scrers to the torque
of il,5 In.
}{hen I ns f al llng i h e l n + e rme d l a i e d l s c l n to the
bearlng houslng be careful noi io damogeihe
'SQ r s eallng r ln g .
Tlgh+en the lurbo roior relalnlng nu+ to the
to rque of l4r 0 N n .
Not€l The nu+ has a lef+-handed +hread. lvake
sure you donr+ bend +he shaf+, tjse a sul+able
T-wrench or torque wrench.
Sgt the dlal gauge on lhe shaft end and meösurg
l h € end play v h l c h s h o u l d b e 0 ,1 0 ..0 ,1 6 rn.
The r eadlng c an b e s l l g h i l y s m a l l e r, l f a l o+
o f ol I has be o n u s e d d u rl n g th ru s + b e arl ng
a ss emtDy .
9. Set the dlal gauge on the shaf+ slde and
tp € s ur e ihe r adl a l p l a y , T h e ra d l a l p l a y s houl d
b€ 0,50...0,46 rn.
1 0 . Tlghi€n fhe screws (22) b€tve€n ihe bearlng
houslng and the Iniormedla+e dlsc fo +he lorque
of 5r7 n, the turbo houslng reialnlng
sc r er s ( 8) io 5 ,7 N n € n d l h e i u rb l ne
h o us lng r eiölnlng s c re { s (1 8 ) to l l ,3 l { n .
||. Ensuro thal the shafi rotates froelv.
12. Attach ihe lck rashers (19 and 2'l).
8 -6
8 l0
Notof Siarflng fron turbo se.lal rto. 841272,
a seal l ng rl n9, spare par+ no. 8f5f f9104, has
been placed bein€€n +he +urbo housing and ihe
l ntermedl afe dl sc. Tho i urbo housl ng of older
turbqs can be seal ed by pl acl ng an o-rl ng seal,
order no. 6146 12114, bei{e€n fhe houslng and
fhe dl sc.
D. IISTALL I IG Tlf TIRB&MRGER
Flnd ouf fhe reason for fhe danageof the turbo
and alvrays el lmlnate the cause of +he defeci
before l nstal l l ng a ner turbo.
To make sure ihat lhe turbo functlons properly
It l s essoni l al + hat the engl ne l ube ol I ls
ch€nged acco.dlng to Insfruc+lons glvon and
that correcl oll grade ls used. lnstruc+lons
regardl ng the servl ce of ol l and al r fl l; ier s
shoul d al so be fol l ol rsd.
The adJustmeni of ihe Injectlon pump has a
dgcl sl ve l mpac' ton i he functl on of + he tur bo.
Therefore, ihe manutac+urerr s Insirucilons
apply for +he pumpadjusiment.
C heck + ha+ i he exhausi and l nl et manl fol ds ar e
properl y fas+ ened and thel r j ol ni s tlght .
Ensure ihat there ls no loose carbon resldue or
rust or o+ her forel gn par+ l cl es l nsl de t he
månl fol ds.
Fl+ the turbo flange on ihe iop of the exhaust
manl fol d. A l w ays use a ner gaskei .
A ttoch the l nl et pl pe and + he exhaus+ plpe on
the turbo.
P our pl ol n engl ne ol I Ini o + he bearl ng h ouslng
through the ol I Inl el i o ensure + he l ubrl cat lon
of the iurbo bearlngs af+er start.
Flx the pressure and oll return plpes of ihe
turbo, uslng ner gaskets. Make sure +hai ihg
turbo l s w hol l y suppori ed by l ts fl xl ng flange
and that fhe plpes do not cause any pressuro on
the turbo.
Pull +he stop lever lnlo stop poslilon önd +urn
i he engl no w l th + he si artsr for a xhl l e. Thls
guarantges that ihe ol I Dressure rlses bg{ore
startlng. Star+ the englne and check +hai there
are no leaks from +he DlDes.
 E. INSTALLII{G THE I NTER@OLER

8 11

Cross-secflon of I nlercooler
l6 t1/6 12 \

Flt +h € lnlet m anlf old + o ihe c v llnd e r h e a d .

R6place the gaskeis boii€en fhe cyllnder head
a nd the In let m anllold! Fli ihe plugs f o | - t h e
u pp er rela lnlng s c r er holes In the Inlei
man lfold cl + he 6l' l1612 englnes .

Place a ne y s eal qr ioD of f he lnlei m a n l f o l d

and lorer tho cooler in lis Doslilon. Set a
gaskei on top of ihe cooler flxlng flange and
lns+all fhe lntercooler houslng on top of +he
coo | €r_.

412

T hen f lx i h e w a + e r p l p e a n d d ra l nl ng pl ug
guldes . P l a c e o -rl n g s e a l s l n to ihe gul de
grooves and apply seallng conpound6909 ,0024
on ihe face leve ls.
Atfach tho r.a+er Dloes on +he cooler and -ihe
boost alr plpo on ihe cooler houslng.

ö- I
FIEL SYSIEM

I I{DEX

T ec hnlc ol d a to ........... . . . . . . . . . . . . . . . . . 9- f

S p€c laf t o o fs ............ 9- 2

Cons t r uc t l o o l n d c p e rc tl o n ................ 9- l

Reclr Instrustloos

l. Fe€d purp
A . Bl e e d l n g th e fu e l s y s + e m.. ...... 9-l l
B . M e a s u rl n g+ h o fe e d p re s sur9................ ...... 9-l l
C . C h e c k i n g+ h € o v e rf l o rt v a l ve. . . . . , . . . . . . .......... 9-l l
D . D l s rD u n tl n g + h e te e d p u mpand checkl ng the va| ves..............,.. 9-12

InJeqllon purp Bosch iAi

A . C h e c k i n g th e In j e c tl c n i Im 1n9........... .........9-13
B . Ad j ' rs + l n g i h e l n j e c + l o n t I mI ng. . . . . . . . . . . ........9-14
C . R e n o vIn g th e In j e c tl o n p u mp.. . . , , . . . . . . . ......... 9-14
D . M o u n + l n gi h e In j e c i l o n p url P ............. ......... 9-15
E . C h € c k l n g a n d re p l a c l n g th e pressura v41ve......................... 9-15
F . Ad j u s tl n g i h e l d l l n g s p € €d.. . . . . . . . . . . ........... 9-16

5. I nJoctlon purp Bosch iPi

A . M o u n l ' l n g+ h e l n j e c + l q r p u mp.. . . . . . . . . . . . .........9-17
B . C h e c k l n ga n d a d j u s tl n g the Inj eci l on t1m1n9....................... 9-18
C . Ad j u s tl n g i h € l d l l n g s p e €d............ ........... 9-19
il. I nJ€qtas
A . D l s mo u n tl n gth e l n j e c to rs .... .....,.............. 920
B . C h e c k l n gi h o In j e c to r..... ...... 9-20
C . D l s a s s € rn b l l n g ,c h e c k l n g a nd assembl l ngi he Inj ecfq......,........ 9-21
D . fn s ta l ffn g l h e l n j e c to r I n the engl ne.... ........ 9-22

5. I nJ€ctlon plp€s
A . In s i a l l l n g th e l n J e c i l o n p I pes. . . . . . . . . . . . ....... 9-22

F uef s y s +e rne q u l p me n ta n d fe € d l n g + a bl es. . . . . . . . . . . .......... 9-23

vAlitEr 9-O
IEO{N ICAL DATA

InJoctlon purp BOSCfliAr ,(8, tll, 4lt, 6ll

T y po ( pum p/ g o v e rn o r)..,......... B oschP E S ...A ,/R S V

I njec f lon ord e r:
109, ll l .....,.. 1-2-3
4 . . ........,,. | -2-4-t
6ll . . ........... | -5-t-6-2-4
0 irect lon ot rotailon cl ockrl se
DIai€ter of pumpelen|ent 9,5 rm
Stroke . . , , . , . , . . 8n
I nje c+lon ad v anc e r . . . . . . . . . . . . . S e€ l nj . pui rp odJusi l ng values
Oll tllllng sl:
t@ , 311 ................ O,l
4 l I .... . . . . . . . . . .........0,4
6 ll .... . . . . . . . " ....,....0,6
Tig h+en lnq fo r que of f he pr es s ur e v alv e h o l d e r . . . . . . . , . . . , . . . . . . . 4 0 Ntn
Tlgh ten lng to r que of f he pum p gear r et al n l n g n u t . . . . . . . . . . . . . . . . . 9 0 NM
I ) I{h en In sta lllng + he I njec t lon pum p.

Fee d pu mp, iy pe:

10 9, fl t . . . . . . . . Bosch FPIKSG22 N 6/2
4lt, 6 lt . . . , . . . . Bosch FP,/KEG22 tO 22t/2
Cons+r uct Ion Plston type, seParaie
nano pump
F uel f eedlng p re s s u re (o p e n l n g p .e s s u re ot the over-fl or yal ve) ... 0,6 - t,0 bar
F eed pum ppr e s s u .e (w l th o u t å n o v e rfl o H val ve) .....,.... 2,1 bar
InJecllon punp BOSCH nP' 6ll, 612

Type ( pump/governor ) .,,,........ Bosch PE6P,/RQV

lnject lon ord€r . . . . . . . . . . . t-r-3-6-2-4
DIrectlon ot rotaf loi c lockr lse
DiarFier of puop elefien+ l l | l tn
Siroke . , , , . . . . . . l0 rm
lnjec t lon od v a n c e......... S ee Inj . pumpadj usl l ng v6lues
Tighfenlng iorque of +he pressure valvo holder 80 Nm
T lghf enlng t o rq u e o f i h e d rl v e u n l t re i al nl ng nut.,.............. 140 N m
F eed pum p,t yp e ............ Bosch FPIK2? P9
Consiruc+lon Plsion type, separöle hand
pump
Fuel fe€d Ing pressure (oponlng pressur0 of fhe overf low valvo) .,. | ,2 - 1,5 bör
Feed pumppressure (rllhoui an ov er f lot r v ä l v e ) . . . . t,5 bar
I nJector BOSCH

Consirucf I on Four-hol e nozzl o

openI n9 pressure 200 + 5 bar
Con+rol pressure 2l o ;5 b6r
S eallng r lng a9gs1t4%
T lghienlng lo rq u e o t + h e n o z z l e re ta l n l ng nu+ .................... 60 Nm
Tlghtenlng forque of the InJec+o. retalnlng nufs (tcr the s.i'uds) . l5 Nm
l) T he v alue u s e d In a d j u s tl n g th g o p e n l ng pressur€ of a ne| , and o used InJecfor.
I nJector c v

Construcl I on Four-hole nozzle

vPe,, I rig Pl 200 bar
S eallng r I ng 8999 01495
Tighienlng torque of +he cap nut of the lnJecior adjusllng scrsr . 40 tti
T lgh+ enln9 t o rq u e o f fh e n o z z l e re ta l n l n g nuf . . . . . . . . . . . . . . . . , . .. 90 Nm
T lghienlng io rq u e o f th e In J e c to r re i a l nl ng nuts (tor the studs) . 20 Nm
InJeqior BOSCH(612-engI nes,

Construc+lon FIvg-hol e nozzl e

OpenI ng pressure 230 6ar
Conirol paessure 2t5 + 5 bar
S ealI ng r lng 8999 0t 495
T lght enlng t o rq u e o f i h e n o z z l e re ta l n i ng nuf ......,......,...... 60 Nrr
T lght enlng + o rq u e o i i h e l n J e c to r re ta l nl ng nui s (for the studs) . l5 tln
l) T he v alue u s e d In a d j u s fl n q fh e o p e nl ng pressure of a nev ano a used Injector.
9-r
 -=F
t-_--]t._

4-_=}_

t-----F

-.F

E"---E
ffiFhE=--
\y|-v

--n------?=
{:F

.<--'--'fi-----:
5

8tr:@
7

SPECIALToOLS(Fuel sysiem)
| 6 5 4 1 JO600 Pressure valve +es+lng gauge
2 8360 lt09l Exiractor for lnjeqtlon punp gear
3 9025 9 9 1 0 0 In j e ctl on tl ml ng check pl n
4 At6t 10002 Pressure valve spanner (Bosch rrPn)
5 8160 975f9 Injectlon +lnle check plpe
625 99000 Con+rol rod locklng bush
7 8J60 8 f2 8 8 N o zzl e cl eanl ng tool s
I 9051 71f00 Extractor for Injec'tor (Bosch)
COT{SIRI'CTION
ATD OFERATIO OF FUEL SYSIEI,I

TilJECIt(r{ PtfP 8601 'Ai

l. Fuel iank 2. Yater seDara+or 5. Feed punP
4. F llt er 5. In J e c i l o n p u m p 6 . In J e c fo r
7. Fugl reservolr of thermosiari devlce
8. olor plug 9 . o v e rfl o w v a l v e

T he f uel f lot rs l ro m th e i a n k (l ) v l a vaTer

separator (2) to the teird punp (i) whlch forces
the hlgh-pressurlzed fuel +hrough the f I lfer
(4) io ihe InJectlon puitp (5).
The lnJectlon punp pumpsthe fuel through lhe
I nJ ec + lon plpe s l n to + h e l n J e c to rs (6 ) ,hl ch
s pr ay + he f ue l In i o th e c y l l n d e rs l n a fl ne
spray.

The excess fuel rlhlch lubrlcates ihe nozzle

needle reiurns from the InJectors to +he fuel
reservolr of lhe thermostart devlce (7) and on
t o t he luel t a n k . D u rl n g g l o y rl n gl h e fu el runs
from +he reservolr (7) +hrough +herdps+art glovr
plug ( 8) and i h e n b u rn s In fh e l n l e + manl fol d.
The excess fuel fron the lnJecilon pumpreiurns
fhrough overf lov, valve (9) In+o ihe fuel +,ank.

l .0l l fl l l er pl ug 2. S pe€dl ever l . Hand

pump 4, Lube ol I lnio the lnJec+lon pump
5. O-rl ng seal 6. Lube ol l back to tho englne
7. Gear 8. l den+ l fl catl on ol a+ e

The- InJec+ l on pump l s an In-l l ne pump and lf s

basl c cons+ ruci l on l s the same In al l enqlnes
lrrespectlve of the cvllnder number.

9- 3

The lnJec+lon pump ls flxed fo +he goar houslng
rl l h ö t longe and s € c l e d rl th a n O -rl n 9 (5 ).
The punp ls drlven by cronkshafl vla ldler gear
and pung geär (6). The InJectlon pump ls
connecied to ih€ englne lubrlcatlon sysfem by
Deansol on oui€r plpe (4).
93
l . Pres s ur g v alv e h o l d e r 2 . P ro s s u re
f. El6nen+ 4. Conlrol rod 5. Return spr I ng of
e l e me nf pls ion 6. R o l 1 6 r ta p p e + 7 . Comshafl-
The tunqllon of the InJectlon punp ls +o
d l strl but e t he r lg h t a n o u n f o f fu e l l n to the
d l ffe r ent c y llnders a t th e rl g h i i l n e . The
e l e men+ ( 5) dr lv en b y i h E c a ms h a fi (7 ) l h ro u g h
ro l l e r t appei ( 6) fo rc e s th e fu e l v l a p re s s ure
va l va ( 2) lnio ihe c v l l n d o r l l n e r a n d l u rl h er
io the I nJec+or.
A8C
T!,o-hole eleneni ( fu I l-te€d posltlo.r)
Boiim dead contre B. Sfart of f€ed
End of teed
In l e+ bor e 2. C y l l n d e r t. Starilng groove
Gulde bor e 5. P l u n g € r 6 . R e g ul 6 t In g rl m
L o nglt udlnal gr o o v e .
g_4
The el enE nt consl sts of a pl ungE r (4) and a
cyl l nder (2) vi hl ch have been tl i i ed to €ach
o+ her w l th a thouscndth-ml l l l rnei re accurac y.
D ue + o + hl s accuracy In fl i tl ng + he el enent
shoul d al vays b9 repl eced as ö xhol 9.
The cyllnder of the elgn€ni has iro borlngs:
l nl ei bore (l ) ond gul de bore (4) i hrough thl ch
fha fuel ls dlreclod lnto +he orgssure chamber.
0n the sl de of the pl ston (5) + here l s a l ong-
l l udl nal groove (7) and a regul atl ng rl m (6 )
rhlch regulate the amountof fuel lnJecied lnio
the cy l l nders.
On th6 head of the elerient Dlslon there ls also
a siarilng g.@ve (l) r,hlch delöys the
InJ€c+ l on tl ml ng by aboui 70...80 durl n g
slort. (Not€ thls Hhen checklng the lnJectlon
tl ml ng, seo l nstrucl l ons l n pol nt 9 2 A ' . Thls
func+ l on, ehl ch l s ful l y aui omotl c, l s to
lmprove +he englne cold start characlerlsilcs.
lh6n ihe englne stops ihe conirol rod turns thg
6lel€nt siartlng grooye so that li ls at ihe
cyl l nder gul de hol e. D url ng sl arl l ng, atl e r
the lnjocilon pumphas reached a certaln spe€d,
the governor drors fhe control rod back to the
runnIng posl i l on.
@
Pressure valve
9 5
l . P ressure yol vg hol der 2, V 6l ve sprl ng
J. V al ve stefl 4. V al v€ gul de 5. V al v€ h€ad
6. P ressurs reduci l on pl ston 7. Longl i udl nal
ga@ves
The pressuro valve ls placed on top of tho
glgmenl +o cui ihe conngcllon between lhe
elemen+ and the InJ€ctlon plpe when lhe
regul atl ng rl o ol the el enent pl sfon passesthe
gul de hol e of i he cyl l nder and i he pressur e
cdnss dorn. An crther tunctlon ls to reduce
pr€ssure In the InJeci l on pl pe. Thl s ls
lmDor+ani ln order lo have the nozzle needle
cl ose aui ck l v.
The pressure valvg stern (i) has a pressure
reducl l on pl ston (6) rhl ch, as the val ve
cl oses, fl rsf 9€s dorn i o the val ve gul d6 (4 )
and cuts +he conngctlon betreen ihe elemenl and
l nJE c+ l on pl pe. Ther€after the val va head (5)
presses agalnst lts sga+ and ihe space for fuel
In ihe InJectlon plpe Increoses by the
dlsplacenent of the pressure reduqflon plsfon.
lllrtlng ot ihc I nJoctlon purp
Th€ l dentl fl cofl on pl €te of + h€ Inj ecfl on pur p
sfåtes a lo+ter codg for the puDp appllcatlon,
:L,*ä";" J,R'Ji,l'?,
l nJoc+ l on pumpor Inqul re""i'lT'
#::'%.'1::
E dj us+ l ng våtues.
@vERNOR

t. Cen't.ifugal relghi 2. Coofrot rod

l. Sia rilng s pr ing 4. Hain t ev er 5. t d l l n g
control 6. Goyefnd- sorlno 7. Addl-flonal
sprin g foi id ling 8. ba t aic er s pr t ng 9.
Control levs'.

The centr i tu ga | -type governoi ls loca+ed ai ihe

rear end of ft|e Injectlon pulp. The governor
reg ulö tes ih € englne s peed y lt hln t he | r h o l e
speed range and recognlses ihe speed wlth the
he lp o f th e c en' ir if ugal Helghis (l ). Th€
po slilo ns o t t t E ihr qf + le lev er and + he c 6 n +r l -
fugal relghis are iransnltted io ihe conlrol
rod (2) vla the governor leverage. Tho
gove.nor has one governor sprlng (6). |lhen the
en gln e s+op s t t |e s + ar t lng s pr lng ( f ) f l x e d t o
l'he iop ol tl|e cootrol lever (9) draws the
co niro l ro d lnt o it |e s iar t lnq pos lilon, vlhlch
au+oma+ically sets an Increasld feed raie for
sta rilng .

9- 5
|ITJEC ON Pttf BOSCH?r

l@

l. Cold start bu+toi 2. Boost Pressure coniro I lei J. Ov6rl l ow val ve 4. S top l ever 5. Ol l fl l l er
plug 6. RQv-governor 7. SPeed lever 8. Lub€ ol I from Inj ectl on punp 9. H andpump 10. Feed pump
tl . Lube oll t o I ni e c i l o n Pu mP 1 2 . l d e n t l f I ca+ l on o l a+ e 11. P ressure equal l zei

The ouislde and ihe construc+lon of lnJec+lon

DumoBosch nPr dllfer from those of the rrAtr
+ype pump. The funcflon, hor6yor, ls ihe sam6.

In the 'P'r iype pump every pump eleiEn+ rlih

l i s p r es s ur e v alv e a n d v € l v 9 h o l d e r l s l n a
cl o se d elem ent hous l n g .
The baslc adJusiment of +he feod ra+e ls made
b y +u r nlng t he elem e n l h o u s l n g , w h l l e fh e fe ed
sfa ri ls E dJ us iedb y c h o n g l n g th o i h l c k n e s s of
i h e shlm s s lt uat ed u n d e r th e e l e m e n i h o u s l n g
tlange. The closed type pumpbody has no slde
hatchgs a other control holes.
The feed roie ls adjusted by ihe control rod
made of angle pro{lle sleel. The rod has
notchos on *hlch +hs balls of +he control iag
d € s lean.
The InJectlon pump ls bof+om-mounied.The pump
ls rcunied on a separale base on the englne
l e f+ s lde. T he lnje c tl o n p u mpl s d rl v e n b y i h e
e n g l n e llm lng gear v l a s h o fi a n d mu l i l p l E p l a +e
clu+ch. The pump ls @nnected to ihe englne
lubrlcailon sysiem.

Prossure valvg holder 2. pressure v a l v e

E lsment 4. Conlrol rod 5. Control
Valve iaooe+ 7. Camshafl

I -6
FEEDPTIf

F€ed pump 4l I

l. Hand pump
2. P lug
f. S eal l n g rl n g
4. S prI n g
5. V alv e
6. Valve fappei
7. Body
8. 0- r ln g
9, Plsion
10. S pr ln g
ll. S eal l n g rl n g
12. P lug
lf. Oaskol-
14. l{asher
15. Nut

The fuel feed pressure ls produced by a plston

p umo llxe d fo ihe s lde of t he I niec t lon pump.
The puDp ls drlven by ihe eccen+rlc loca+ed on
ihe lnjecilon pump carnshaf+. The anouni of
fuel +hai cofiEs fron l-he {e€d purp exceeds
conslderably +he fuel needed by +he Iniectlon
pump. The extra fuel ls led ihrQgh th€ over-
flo r valve b ac k + o ihe f uel t ank . Thls e r f r a
fuel cools -th€ lnjec+lon purp and ble€ds the 9lo
fuel svs+em.

The eccenirlc on ihe lnjecilon purp camshafi

(l) presses dorn the feed pump pls+on (5).
Thls ollors fuel lo enfer from feed pump lnlei
chaitber (7) In+o prossure chamber (4) vla
pressure valve (8) and ihe plsfon sprlng
stretchas ( Infermedlaie stroke).
After fhe eccen+rlc has rota+ed oast lts loD
deod c6n+re lf ls followed upvard by fhe
pl sfon, pressure pl n (f) and i he rol l er t appet
(2) prassed by i he sprl ng. D url ng thl s phase
fuel l s fed through fl l i er to the In Jecilon
punp ond ai ihe same tlmo fuel ls suckgd
through l nl ei val ve (6) to + he feed pum p lnlel
chamber (pressure stroke).
Durlng the pressure stroke ihe leed pumppumps
ngarl y al l + hs necessary fuel anount l nf o +he
lnJec+lon pump. Durlng lhe ln+ormedlöta stroke
It del l vers onl y a smal l amount w hl ch cor r es-
ponds to the prossure pl n pushl ng l tself lnio
+he pressur€ chamber.

WhEnthe prgssure ln ihe feed plpg excegds €

cerialn value fhe sprlng forces the plston up
rlih only pari of the stroke and +he fuel raie
Is correspondlngly lorer, l.e. +he hlgher ihe
back pressurg ln tha feed plpo, fhe smaller ihe
4nouni of fuel dellvered by +ho pump.

9 lt
A. Pressure sfroke B. Intermedlaie stroke
l. lnJsctlon pumpcamshaft 2. Rol ler iappet
5. Pressure pln 4. pressure chamber S. plston
6. I nlet v alv g 7 . In l e + c h a mb e r 8 . p re ssure 9- 7
v alv 9
 T JECTORBOSCH INJECIoR C Y (61I englnes)
The lnJector has a four-hole nozzle. The maln The InJeci or manutacturedby C A V l s prl ncl pal l y
parfs ot thg I njec'tor ar6 the nozzle holder and the same as fhe Bosch InJector, rlth regard io
ih€ nozzla tlp. The funcilon of ihe I nJecfor qanstructlon and tuncilon. The greaiest
ls lo taed tuel lnio ihe cvllnder ln the form dlfferences ln construcilon are to do wlfh the
of a flne vopour and fo starl cnd cui off ths lnJecior fixlng and the adjustn|en+ of the
l n Je c+ lon r apldly . T h e l n J e c to r l s c o n tro l l e d openlng pressure. The InJeclor dpun+lng lugs
by th6 fuel pi€ssuro. are casl ln the body ond the openlng pressure
l s adj us+ ed w l th an ödJustl ng nui , rl + hou f
ssparate sh lms.

912
l . Fuel Inl e+ 2. Ov€rt l ow pl D e connec+ l on
l . Fu €l I nlet 2. O v e rtl o r p l p e c o n n e c tl o n f. A dj usti ng nui 4. P ressure sprl ng
l . Sh l m 4. P r es s ure s p rl n g 5 . Pre s s u re p l n 5. P ressure D l n 6. N ozzl e bodv 7. N ozzl g
6 . N o zz le body 7. N o z z l e n e e d l e 8 . Pre s s u re ne€dl e 8. N ozzl e hol e
chamb€r 9. Nozzle hole
The fuel pressure ls dlrecled to ihe conlc
pressur€ should€r o{ the .pzzle needle (7).
Hhen thls pressure ls greater fhan the reslst-
Ing forcg of ihe pressure sprlng (4) li ralses
the n€dle froi! Its seat. Fuel ls then e iected
through the holes (9) In the nozzle bod-'I (6)
Into ihe combus+lonchamber ol +he cvllnder.
The tenslon ot ihe pressure sprlng, lrhlch
d e l e rm I nE s t he o p e nI n g p re s s u re o { fh e
In Je cf or , c än be adJ u s i e d w l th s h l m s (l ).

Th e o v gr f low f uel lu b rl c a tl n g fh e n o z z l e n e e d l e
ls led to lhe overfloy plpe ond back +o fhe
fuel iank.

I -8
FUELFILTER BOSCH The C A V fuel l l l ter has + !,o rrparallellyr r
connectgd fllfer cartrldges. There are tYo
i ypes of fl l + ers, ons l Jl th a gl ass se dlm ent
boul (fl gure 9 15) and the oi her ul thout li,

I{AIER SEPARATOR

l. Cover 2. Seallng r lng 3. Paper f il+ or

ca rtridg e 4 . lnner plpe 5. Sheei r E+ al
ho us ln g 6 , Bleedlng s c r et

Th e fue l fl l'ter ls a s o- c al led c aps ul6 f l l i e r

co nslsiin g o f t he f llt er c ov er ( l ) r lt h tuel
in let an d re tur n c penings and t he f lll- er body
whlch has a shee+ rneial housing (5) encqnpass-
In g a p ap er ll lier c ar + r ldge ( l) . I n ' t he n l d d l e
of th e b od y ihe r e ls a t hr eaded hole f or f l x l n g
It io +he ll l+er cover.

Scrne englne l-ypes are equlpped rlih a double-

f I lte r r ith se lec + I n9 v a lv e, r he. eby one I I l i e r
ca rirldg e ca n be r eplac ed r hlle t he eng l n e l s
run nln g.
FiEL FILIER C v ( 6l11612 er gln9s l
Mos+ englne verslons are equlpped t{l+h an
englne oi machlne mountedwato. sepäraior, the
func+ l on of w hl ch l s presenl ed In fl gure 9 16.

I 15

l. B leedI ng sc re w l. F I lier
c ar t r i dge 4. Ol a s s sed lmeni bo{ | 5. D r a l n l n g
p r u9
9- 9
FI'EL RESERYOIR
OF THEN'|oSTART
DEVICE

s 17

t. Res er v olr f l I lln g 2 . T o + h e b u rn € r

Rgfurn to fuel tank 4. Breather

The overflowlng fuel fron +he InJeciors ls led

to ihe fuel rgservolr of the ih€rnpstart
devlce. Thls plasilc reservolr stores ihe fuel
n€ded by the burngr and th9 exlra fuel rsturns
furlher io the fuel iank. In some equlpttnt
and work nachlnes +he breather plpe (4) of +h€
therrnosiarl devlce also lakes care of the
actual fuel tank ven+| ng.

Notol lf ihe breofher plpe of ihe thern|o-

s+a r+ dev lc e ls + h e o n l y s u b s i l i u i l n g a l r p l p€
+o fhe fuel +ank, lt nay unCer no clrcums+ances
be b laked.

I-l0
 IOiIS FORREPAIRII{Gr}€ Flf,L SYSTEII
I XSTRI'CT
genorol
ilot al T hls ma n u a l g l v e s o n l y
lns+ruc+lons for rEpalr and s€rvlce fiEosurgs
related io +he luel system. Thls applles
par t lc ular ly to th e In J e c tl o n p u mprh l ch can b€
r epalr ed on l y b y o s p € c l a l l y + ra l n e d P erson
rho has the necessary spgcläl iools and gaug€s.
All s6rvlc6 and roDelr rork rgloted to the fuel
s y s iem r equl re s s p e c l a l c a rs a n d c l e onl l nessl
B.
1. FEEDPUIiP
ELEEDII{G THE FIEL SYSIEM
t. OpEnthe hand pumpplston by turnlng.
Open 'the bleedlng screi on iop of fhe fue I
f llt er . P u r| prl th i fl € h a n d p u n p u n + l l the fuel
conlng ou't of th€ ble€dlng screr ls free { roir
bubbles . Cl o s e th € fl l i e r b l € e d l n g s crer.
C.
9 19
open the connecilon of the InJectlon pumpover-
tlor valve c the pressuro equollzgr ln the
[Pn type purnp. Conilnue purplng untll ihe fuel
conlng out of ihe overf lor valve conn€cllon ls
tre€ lrqn bubbl€s. Close +he overf lo[ valve
connec+lon and close the hand pu|l|f' plston by
turn Ing.
4 . !l l pe l eaked fuel otf .
ICASI.RI }tG TI€ FEEDPR€SSiNE
Cl6an the lnJecilon pump and the fl l+er
external l y 6s rel l as + he fuel pl pes Inbet r een.
U - brush and sul tabl e sol veni .
Attach ihe geug€ betre€n fhe fllier and fhe
plpe leadlng io the lnjecflon pump.
f. R un fhe ongl ne at l dl l ng speed for o r hlla and
coopare ihe gaug€ roadlng rl+h englne ratlng.
Nqtcl lf l-he 9au9e readlng falls b€lor railng
li moy be cöused by:
- defoctlvg ovgrf lor valve
- cl oggod fusl t I l ter
- defoctlve feed pump
- clogged or leaklng fuel plpas or connectlons
C}ECKIIG I}E OYERfLO| VALVE
lf the fe€d pressure dlt{ers from +he ratlng,
check fhe opanlng pressure of th€ overf lox
l. Attach the pressure gauge as wlth feed pressure
ipösuremen+(Dolnt B).
2. P ump {l i h hand pump untl l the overf lor valv6
opens. Comporeihe raadlng In ihe gaug€ at +he
openlng rpDenf rlih lhe ratlng.
l f the readl ng ln fhe gauge dl{ters from ihe
ratl ng, rep lace the ov€rf low valve rlth a n9r
one.
Notol lf the prgssure do€s not rlse io the
overf lor volve openlng pressure, ellher th€
hand pump or the feed punp va lves ar e
defect I ve.
9- 11
 DI9rcUXTI]{G TIIE FEEDPTIP AID C}CCKIt{G IlE
v LtEs
t. cleän fho lnJecilon pu[p and lts surroundlngs
car€fu | | Y.
2. Dlscoon€cf the fusl plpos leadlng to the feed
puop.

Op€n ttre te€d puip retalnlng nu+s and dlsnpunt

the f€d purnp.

Flx the te€d punp flonge to a screr clalp

equlpped rlih protecflng Jars. Rg|tpvel'he hcnd
purp frdr tho lnJoctlon puip as xell as the
plug or conneqtor noar lt (509, lll).

Rd|pvg the vclvg sprlngs and valves frqn th€

f6€d pump body. Check the condlilon of ihe
valve gasket surfoce cnd replace rorn parts.
6. Pl a c e t he y ålve s c n d s p rl n g s l n + hel r
p o slilons . T he I n l e t a n d e x h a u s t-v a l v e s a re ot
lhe sor|9 lype. Flx +he hond punp and ihe
p lug./conn€ctorby uslng n€s seollng ilngs.

Clean ihe gcskei surleces betreen fhg leed pump

and the lnJectlon pump. Remountlhe teed punp
by uslng a n€r gosket.

9 -12
2. I NJECII O{ PnP 8osctr i i
TII,IING
NG T}E I NJECTIOiI
CHECKI

Turn the crankshatt to 6 posltlon rhsre lhe lst

cytlnder plsion reoch6s lls cqrpresslon stroke
top dead cenfre. Thgn turn ihe cronkshaf+
backvards unttl the l l ml ng mark oo the pulley
Dassesth€ lnsoectlon hole.

tlotcI The lnJ6ctlon tlmlng ls marked qr the

c r ank s haf + p uI l 6 y l n f O 9, lll and 4ll e n g l n e s
and on t he v l b rö tl o n danpei In 6l I and 612
engI nes.
I n lr ac lor e n g l n e s th e In j e c i l o n i lml ng l s
marked on the slde of +he tlyrheel. The
t ly r hoel ho u s l n g h ö s a n l n s p e c tl o n o p enl ng end
a hole f q- i h g tl m l n g c h e k Pl n .
oue +o the autonailc excess tuel feed of tho
lnjecilon pumpth€ control rod musl be npved to
dr ly e pos lfl o n rh e n ö e c k l n g th e l nJectl on
t lolng, ot he rrl s e fh e In j e c tl o n i l m l n g rl l l be
I ncorreqt !

lst rcy ot ch€cllng3 Reriove the con+rol rod cover fron the lnJecilon
Dumo. Turn lhe control rod to drlvg posltlon
l . Clean ihe l n J e c tl o n p u n p a n d l l s s u r roundl ngs rlth tool 9025 99000.
c ar ef u I ly .
Rqrcve the lst cyllnder lnJectlon plpe.

6. Blor the clnlc part of th€ pressure valYe

holder fr€€ of tuel. Turn ihe crenkshaft
lorrards un+ll tuel surtoce In the pressure
valve holder stlrs, but d€s nof yet rlse.

l f l he l nl eci l on tl ml na märk l s l n llne r lih

ttre tlp oi the Indl caioir, fhe InJec+lon +lmlng
ls correct. OtlFrxlse cdJust the tlmlng as
lnsiructed In Dolrf 9 2 B.
8. A fter checkl ng and possl bl e adJustl ng I nst all
ihe InJec+lon plpe 6nd fhe conlrol rod cover.
Let ih-e englne run for o lel mlnutes and
recheck. Thus you con ensur€ ihat there ls no
alr lef+ In the luel sysiem rhlqh nlghi aftoct
ih€ tl mlng.

2. ln iractor Englnes rslpvo +he rubber plug fro||l

the Inspectlon hole In ihe tlytrheel houslng.

Ins€rt +he check eln (9025 99100) ln the hole 9-13

sltuoted on thg front f6ce ot the flyrheel
housI n g.
 2nd rry ot chrck I n9 B. ADJUSTI
IG Nf, INJECTIOITII,IIIG
fl o t c l lf pos s I b te , u s o t he I s l v a y of lf the tlnlng ls found I ncorrect, adJust as
checklng b€couse fhere less rl s k o f fuel fol lors:
systen gettlng d lrty.
l. Loosen th€ reialnlng nufs of ihe lnJecilon purnp
l. Do as lns+ruc+ed ln lhe lsi tray of checklng, and t.emovefhe lnJec+lon plpes.
polnfs I to 5.

2 . Op€n t he loc k a n d c l o m p o f + h e l s t c y l l ndor

pressure valve hold€r. Renove ihe Dressure
valve stem and renpunf the holdgr tlth äbsolute
cl eanl I nos s .

lvl I 27

It the InJec+ l on + l ml ng l s re+ arded, + urn t he

pump anilclockrlse (vlered lrom lhe fronl end
of i he pump). l f i he tl ml ng l s advanced,t ur n
+he punp c lockwI se.

Chack the lnJec+lon tlmlng and iurn ihe pump

f. Fl x + he lnJ ec ilo n tl ml n g c h e c k p l p e (8 1 6 0 97j t9) agaln, lf necessary.
to t hg ls i c y llnd e r p re s s u rg v a l v e h o l d e r.
4. lih6n fhe tlnlng ls correct flghten ihe
retalnlng nuts of ihe pump and flx ths
InJectl on pl pes.

c. REIOVI NG I}IE INJECTIOIPIIP

t. Carelully vesh ihe lnjectlon pump and tho

surroundl ng engl ne parts as vrel l as t he
Injoctlon Into the lst cy nder beglns. l nJectl on pump pl pl ngs and i hel r connecilons
oxtgrnal ly.
5 . l t.ihg llm lng m a rk o n th e fl y rh e e l l s l n l l ne
wlih ihe tlp of +he chack pln, fhe InJectlon
tl n l ng ls c or r eci . o i h e rw l s e a d J u s f i h e -tl m l ng
as Inslructed ln Dolnt 9 2 B.

6. Removglhe check plpg and open ihe pressure

va l v e holder . P l a c e th e D re s s u re v a l v e s + e ml n
Its pos lf lon, iep l a c e th e s e a l l n g rl n g a n d the
0-rlng and ntouni th€ valve sprlng and the
h o l d er .
7. Tlghtu tho Dr€ssur€ vclve tlol dor rs tollois:

- fl r s t t lgh+ enln g i o ,0 N m
- open ihe holder by about l/2 iurn and
retlghten 40 Nm
- open the holder by aboll+ l/2 furn and
fl nE lly t lght en i o 4 5 N m

Remove..+he lnjecilon plpes, fhe fead plpe

connectlor screls and the oll plpe connocilän
Flt ihe connectlons rlih 6 profecrtve
;ifi:.

9 -1 4
o
5. Opsn the scrers ot the oll flller plpelcover. Connect the fdel f€€d plpgs and th€ lub€ oll
Re|t|ovethe plpe. Renove +he flxlng sfuds ol plpe. Replaca old gaskels tlih rct ones.
the ol | 1l ller plpe (nof necessary lf the
latgsf oxtracior modgI usgd). 6. Bleed ihe fuel sysldn (sF lnslrustlq|s In
pol rt 9 | A).
4. open ihe flxlng nut of the lnJecilon pumpgear.
Adjust ihe lnjectlon flmlng (sc l||3lructtd|s
l npol nt92B ,
8. Attach ihe lnjef lon plpes.

Attach +he gear ertracl-o. (8560 lJO9l) and

renove the g€arrhegl fror ifie lnjgqtlon pulp
can|shafi.
Open ihe retalnlng nuis ot the Injec+lon pudp.
Rem ov e + h e In j e c ' tl o n p u n p . tl ofe I The
Injecflon puflp g€arlng rqnalns ln coniact rl+h
the ldler gear, so you donrt h6v9 to mark thelr
relatlve poslflon rhen renovIng ttF puirp.
9. lf yos change th€ lnJectlon plpe or lf the
lnj€cllon pump lube oll has b€€n dralned, add
oll lnto the Injectlon pumpbefor€ starflng tt|e
englne. Open ih6 hex socket plug ofl the pulp
conirol caslng and pour fhe oll lnfo fhe
InJecifon pump. The quantlty lor t@. tll
englnes ls O,f I tor 4ll engln€s 0,4 | and 16
6ll englnes 0,6 | (us€ fhe sarp oll quallt as
In the englne).

E. C'CCKIIIO AII' REPLACI

I€ T}C PRESSMEYÄI.YE
l. Clean ihe lnJectlon punp, lnj€ciors and thelr
l.o(n|Tlrc nc lNJEcno PnP surroundlngs carefu I ly. Rsnove fhe I nJestlon
p lpss.
l. Check ihe O-rIng of the npunilng flan96 and
re p la ce it, lf n* es s ar y .

2 . Lubr lc at e + h e O -rl n g a n d l n s l a l l + h e Inj €ci ton

pumpso +hat fh€ shoft key ls poslfloned In th€
kgy groove of the gearrhgel. Screr ln ihe
I nJ ec at onp u mpre + o l n l n g n u T s .
5. T lgh+en The gearrheel nut lo the torquo
90 Nrn. of

F as t en t he. o l I fl l l e r p l p e fl x l n g s + u ds. Seo

I
ll9--s.tud threads rlfh seallng conpouno (
50008). Flx fh€ olt f ter plöe,/corjor. - 6909 2. Attach the tes+lng gauge (6541 JO60O) In ihe
tpldor ot thg giessuro v.lYe io b€ ln3P*red-

9- 15
5 . C ra nk t he engln e w l th s to rte r u n i l l th e g auge Open+ h6 safe+ y nu+ (10 mm)of i he l dl l ng speed
Indlca+es aboui fJo bar pressure. 6dJusi l ng scre{ and + he sa{ ety nuf (17 nm) of
+ he adj ustl ng screw of i he addl tl onal sp r lng
Notel The pressure r lses qulck ly - be tor l dl l ng.
careful no+ io damageihe gaugel Be ready +o
pull the stop lever as soon as ihe gauge shors 2. E nsure that the + hroti l e l averäge l s l n l d llng
the requlred pressure. Dosl+ lon.
4 . L e + + he gauge r e a d l n g fl rs i ta l l b y a b o u t f0
bar. }lhen lhe gauge readlng ls dol{n to 300 bar
keop an eye on the readlng for one mlnuie.
D u rlng + hls t lm e th e ro a d l n g m a y n o + fal l
co n s lder ably ( f 0...5 0 b a r). l f ' th e p re ssure
fa l l s t as t er ih a n th e ra tl n g , th e p re ssure
va l v e m us t be c le a n e d o r re p l a c e d .
N o t€l A lway s r ep l a c e + h e p re s s u re v a l v e stem
a n d gulde t ogeihe r.

Start ihe eng I ne and open iha adjustlng screr

o f +h e a d d i +l o n a l s p r l n g s o i h a l li does not
a f f e c t i h e l d l i n g sPe€d.

A d j u s t +h e l d l l n g s p e e d b y i h e a d j u s f l n g scr e w
a 't a b o u + 2 0 r p m b e l o i t h o r a +l n g .

Race lhe englne lor a fer ilmes and ensure thai

the ldllng speed remalns as set.

T l g h t e n +h e a d j u s t l n g s c r e w o t t h e a d d l i l o n a l
sprlng unil I ihe ldllng s p e e d r l s e s 't o i h e
ra-ted value. Lock +he adjus+lng screr In +hls
posltlon.
Ope n ih e lock a nd c lam p ol t he pr es s ur e v a l v e
ho lde r. Re no ve ihe v alv e s pr lng, t he s + e m a n d 7. Fl x the safei y nuts of + he adj ustl ng screws.
fhe gu ld€.
Note l Other adj ustmgn+s (output and max
R ln se +he p ress ur e v alv e s + em and gulde H l +h speed) vll+h +he InJectlon pumpcon be perforned
pu re fue l o r tes + t luld at t he s am e t lm e +u r n - onl y by a specl al l y fral ned person N l hohas t he
I ng fh e slem ln t he gulde and pr es s lng f h e necessaryspecl al + ool s and gaugesaval l ab le.
gaskei surfaces agalnsi each oi-her.

7 . In s + all f he pre s s u re v a l v e In ' th e In j e c+ l on

purnp, moun+ +he valve sprlng and close +he
hoI der.

l l ot el Replac o s e a l l n g | -l n g a n d O-rl n g .
L Tlghton the holder as follors:

- f lr s t + lght en l n g + o 5 0 N m
- open ihe holder by about l/2 turn and
rei lghien 40 Nm
- open the holder by about l/2 lurn and I I n a l l y
f lgh+en to 45 Nm

Chec k ihai t he c l e a n e d p re s s u re v a l v e l s tl ghi

e n ough by c ö rry l n g o u t + h e m e a s u rement
procodure descrlbed above, lf ihe gaugo
readlng s + lll d l ffe rs fro m fh e ra i l n g , re pl ace
ihe Dressure va lve.
10. Check each pressure valve In iurn as lnsiruc+ed
above.

F. ADJUSTINGTHE IDLIIG SPE€O

lf ih e en gln o ldllng s peed dif f er s f r om +h o

ra t I ng , a dju sf as f ollo* s :

9-16
5. lNJEcTloN PttP BoGCHiPn
6t t / 612

I.OUNTII{G TTIEINJECTIONPUIiP
( E nglne { lt h c o mp re s s o ro n i h e rl g h + s l de)

935

Flt +h e ln jec t ion pum p dr lv e unl+ A ln t h e g e a r

houslng. Place ihe gaskef B befv.een fhe houslng
a nd l-he drlv e unlt and ihe loc k las her C I n s l d e
+h e g ea . ho us lng under ihe r 6t alnlng sc r e u s .

t,lotrni ihe gear and the key on the drlve unll

shafi. Tlghten ih€ gear retalnlng nui io ihe
+orque of 140 Nm, Noie +he gear lns+alla+lon
marks !

Fll +h e cou pllng plec e D on t he I njec i l o n p u r p

sha ft. Tlg hien ilp r e+ alnlng nut io 1 4 0 N m .

Attach the lnjectlon puip clu+ch E onto +he

dr lv e unli s h a f+ . T l g h i e n th e d rl v e p l ece screr
to 50 Nn.

Turn +he crankshafi io a oosl+lon where ihe lsi

c y llnder ha s l ts In j e c + l o n i l ml n g . T h e Inj etl on
tlmlng ls markedon the vlbrailon danp€r of ihe
c r ank s haf l.

936

6. Turn ths Inj€ctlon purp camshaft to it|e

dlrectlon of rotaflon unill the lst cyllnd€r
has lts Injectlon tlmtng. The 6R mark 'on ihe
coupllng plece flange ls then af ihe machlned
chamfer on tt|e upper left-hand corner of lhe
punp front f lange.

ilot€l It you ned to lnsfall a nes cyllnder

block d- InJ€cfl6n purt| Eun+lns base. +l|€
relatlve oosltlons of fh€s€ Darfs rust be
(btsrmlned rlth a speclal t@|. I - 17
 9 37

o' It the l nJectl on tl ol ng mark l s In l l ne r lf h

Pl a c e gulde bus h l n g s b e i re e n th e l n J e c tl o n punp i he tl p of i h€ l ndl cai or, i he Inj ec+ l on tl m lng
bottom and lhe mounllng bose. Loror the punp on Is corrgcl, It nof, perlorrn ihe adjustnent as
l 'h e npunilng ba s e a n d fl x th e c o u p l l n g pl ece tol l ow s:
a n d t he pum pr eia l n l n g s c re w s .

8. Attach the lnjectlon pump dellvery önd refurn

ol I plpes, ihe fu6l plpe and ths boost pressure
re gulaio|' pipe.

B. CHECKI ITC INJECTIoiITII,III{G

ilG ANDADJUSTING

C l e an ihe I njec i l o n p u n p a n d l ts s u rro u n dl ngs

ca r et ully . B leed i h e fu e l s y s i e m.

Turn ihe crankshafl to a posltlon *here thg lst

cyl lnder pls ion l s a i l ts c o mp re s s l o ns + roke
top dead cenire. Nor lurn the crankshat+
o p p os lie + o t he ru n n l n g d l re c i l o n u n tl l the
In J ec ilon ilm lng n a rk o n i h e v l b ra tl o n d a mper
Dassesthe I ndlcafor.
Ensur€ that ihe 'rexcess fual feed butfon'r on
iho slde ol ihe boosi pressuro rsgulaior ls nol 93 9
swlic hed on.

Rem ov et he I njec tl o n p l p e o f i h e l s + c y l l n der. j.

Blow the conlc part of the pressure valvs
h older f r ee of f u e l .
Tu rn ihe c r ank gh a ft s l o rl y In ru n n l n g d l re c + l on
u n + ll f uel s ur f a c o In th e p re s s u re v a l v e h o l der
stlrs, bu+ does nof yel rlse.
C heck fhe l nJectl on tl ml ng and + urn +hs
coupl l ng pl ece agal n, l f nec€ssary.

} l hen l h€ tl nl ng l s correct tl ghten the cou pllng

pl ece fl xl ng screw s and l l t i he l nj ecfton plpe
ot the l st cyl l nder.

I -18
c. AÄIUSTII{GI}€ IDLIIIG SPEED
lf ihe en g l n e l d l l n g s p e € d d l ff€ rs from the
r at I ng, adj u s i a s fo l l o rs :

o
!t
:l
\_t

Ensure ihat fhe throitle leverage funcflons

propa-ly. It so, open the safely nu+ of ihe
ldllng speed adjusflng screw and adius+ ihe
ldllng s pe e d to i h e ra tl n g . T l g h+ en the
adjustlng screr and flx ihe satety nut.

t{otE I Oiher adjustments (ouipui and max

speed) ylih ihe lnJecilon pu0rpcan be performed
only by a speclally trolned p€rson xho has the
necessary speclal iools and gauggs a+ hls
dls Dos al.

9- 19
 2. Attåch ihc I nJ€cior fo ! tast purp and ch€d(
4. INJECTGS
thr fol lor I ng3
Dlslilotl{IlNG l}E INJEcrCRS
- openlng gressure of ttP nozzle
Hash the InJectors and thelr suiroundlngs - creaklng chöracigrlsilcs ond the spray form
caref u I ly. - tlghtness of nozzle n€€dlg ogalnsi the seat

2. Renpve the InJecilons plpes and the ovsrf lor

plP e.

Corr# spray form

B. Incorrect sprey {orm

Bl. op€nlng pressure

Ope n the lnjec t or r et alnlng nut s and l l f i ihe Press the tesl pumph6nd levgr slorly untll ih6
lron out of tho nozzl e l l ghi l y q-eaks. R E ed the openlng
ln iec'ior anå lts aqJnting
Pt ac e piot ec + iv e Plu g s I n a l l pressure In ihe 9au90. It the openlng pressurg
cvlln de r he öd,
ihe connec+ions.
dlffers from 'ihe raflng, the lnJector nust b€
d lsassembledfot- odJusimenl.
Re firove sea llng r lngs lr dn t he c y llnd e r heod'
Th6 Bosch InJec+or ls adJusted by r6plöclng +he
u nle ss fhe y c qie of f r t t h t he lniec + or s '
shl m (par+ 2 In fl gure 9 59). The fh lckness
of the shl ms varl es trom 1,00 to 1,98 f t n and
CHECKI}G THE INJECTfi
the dlfferencg b€tw€en slzes ls 0,02 nrn. A
|rhen testlng the Iniector do noi hol6 + hl cker shl n rol ses + he openl ng pressure, r hlle
N,otal
vou r ha nd n eor t he ; oz z le, f o- ihe f l n e l y d l s - o thlnner one rgspectlvely lorers ll. A 0,02fl1
p€rsed fuel spr6y may peneiraie the skln cnd dllference In ihe shlm thlckness changes ihe
cöu se sevor e lnjur les !
oponlng pressure by about 5 bar. Becauseihe
nozzl e openl ng pressure drops sl l ghtl y af f er a
I niac t or c år elully r lt h cleon.lng tex run hours frcm the adJustn€nt, se+ the
clea n ihe
flu ld a nd br us h. Nev er s c r ope of { ' t h e c a r b o n openlng pressure at 210 ! 5 brr. The conirol
prossure appl l es to both ner and used
wl+h a kn lle o. å s lm lla. f ool.
I nJeciors.

9 44

The openlng prgssure of the CAV Injector ls

adJusled by th6 adJustlng nut rh lch I les under
942 the caP nut at tt€ +<+ ot - 0-20
 82. Crock I ng
Tesilng rllh a nanual iest pump d€s noi
cofrespond to ihe condltlons In the englne and
i h gr gt or e glv es a re l l a b l a rg s u l t o n l y rl ih a
ner nozzle. At a cerfaln puflplng speed ihe used
nozzles have an uncreaklng range rhlch ls
alfected by the nozzle construcflon.

Howsver, € qulck press should makgthe Injector

creak cleårly andlor producE o flne spray.
Wlf hln f he unc re a k l n g ra n g e i h e s p ra y l s rough
a n d lr r egular .

S5. Tlghtmss ot fhe nozzl€ n€€dle

Prsss the tesf pump lever slowly unlll ihe
gauge readlng ls 20 bar b€lo{ the rated openlng
pressura. Kgep +he pressure ot thls level fo|'
l0 seconds. lf a drop does not appear ln the
n o z z le llp, t ho n o z z l e tl g h tn e s s l s c o rreqt.
Dl sås s em blea le a k l n g In J e c l o r, c l e a n i h e seat
surfoces and perform a ne{ lesi. lf leaks
a p pear agaln, r e p l a c e + h e n o z z l g .

C. DISASSEIGLING,
CHES(IIG ANDASSEI,BL
It{G I}€
IIIJECTfi f. C l ean the nozzl es w l + h cl eanl ng Jl ul d froo t he
oufsl de and the l nsl de.

4. opgn cl ogged nozzl e hol es by soakl ng and byö

cl e6nl ng needl e (l ncl udad In i he cl eanl ng tool
se+ 8f60 85288),

I 45

Parts ot c Bosch I nJoqtor

Noz zle holde r

2 . S hlm
Pressure sprlng
Prsssure pln
Intermedlate plece
Nozzle
Noz zle r gt aln l n g n u i

l . Fl x t he lnJ ec + o r to a s c re x c l 6 mp e q u l p p e ds i i h
pro+ec+lve Jalds. 948

2. Opsn the nozzle retalnlng nui. Rgrpve the Tesi the rDv€iFnf ot the nozzlg n€dlc cs
n oz z le 6nd t he p å rfs o f fh e h o l d g r. tol lors:
llash +h€ Darts t{el I rlih fuel or fest fluld.
Puff the needle out of tho body un+ll l/t ot
lls slldtng p l a n e l e n g +h l s o u t . T h e ne e d l e
shoutd slld; ttself back lnfo ihs seat. Repeoi
ihls wlth varlous needle posltlons. T h o n€ e d l e
g-21 m å v n o f s +l c k I n a n v p o s l +l o n . R e c le o n a
sl-icklng ngzzlg ond räPeol fhe iesr' lr +h €
noz z l o silll f€nds +o s tl c k ' r apl 6c e l t'
 ,. INJECTION
PIP€S
6. B egln t he a s s e n b l y b y c a re tu l l y rl nsl ng öl l
parTs ln DU re tu e l o r to s t fl u l d . I NSTALL
IiG T}C INJECTIO{PIPES
7 . Place l'he shlm ln ihe holder. Check It ihe Chack +he condl+lon of ihe Dloes betore
openlng pressure n@ds adjusitng. Atlach ihe Insi al l l ng. l l i he pl pe has cracks, abr aslon
o'iher parls and check thelr correct Dosltlons oi It fhe seallng cone ls damaged,rep lace the
( pr es s ur e p In , l n te rm o d l a i e p l g c e ). olge r|th ö hori on€r
8. Clos e ihe r e ta l n l n g n u + o f th e n o z z l e fl rsf by E nsure that i he pl pes are noi l n an obllque
hand and f l n a l l y fl g h te n rl th a i o rq ue w rench posl fton w hl l e fhe retal ntng nu+ s ar e b€lng
to 60 Nn In cose ihe InJector ls Bosch and i l ghtened. Otherrl se the cone H Il l b€ dam aged
t o 90 Nn lf l t l s C AV . 6nd l eaks rl l l resul + .

D. INSTALLINGIHE I NJECTffi IN THE ENGITG f. Fl x + he l nJocfl on pl pe supports.

9 ,19

Ins ialllng a Bos c h I njec f or

liloun't Ing lron

l{asher
Protecl lve rubber
Gasksi Yasher

t . C lean the I njector counler surface on the

c y llnde. he a d . S i ra l g h + e n th e s u rfa ce w l th a
reamer (8J61 914101, ll necessfy.
2. P lac e t he l n j e c i o r In l ts p o s l l l o n on the
c y llndd' he a d . U s e a .p v r s e a l l n g rl n g .

Nof el T h e l n J e c fl o n p a tts rn ot the

I njec t or ls n o t s y n e l rl c a l . T h e re t ore l + l s
lmpor+ant +o posltlon ihe lnJec+or on the
c y llnder h e a d c o rre c tl y . T h e o v e rfl or pl p6
f lx ed t o t h € In J e c l o r s l d e s h o u l d b e on the
s lde of ihe v a l v e n e c h a n l s m(Bo s c h l n J€ctor).

P lac e + he n p u n i l n g l ro n (l n B o s c h In Jector) In
lis pos lt lon a n d tl g h te n i h s n u i s e v e nl y to i he
glven torque (15 lh In Bosch lnJector ond
20 Nn ln CAV lnjector).
4. F lx f he ov o rf l o r p l p e a n d th e In j e c + l on pl pes.
 6s8
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o ELECTRICJ\LEQIIIPICI{T

I NDEX

T€chnlc.l data

A lf er naiors ..... .......... l 0- |

S + ar t er s .. . . . . . . . ......... l 0- 5

o vAlitEr 10 - 0
ELECTR tC L EQt,,
tPfCl{T
IECH}IICAL DATA

AL*RMTMS

A lt€rnator Bosch Kl R 11 V 25/65 A

Nom lnal v o l i a g e .. 12y
Output
1400 rp m ........ . 204
2100 rp m .,....... 444
6000 rD m......... 65A
Slator reslstance 0,1 ohms+ l 0 t
Rolor res lstoncg 2,8 ohns + l 0 t
ReguI ot ln g v o l ta g e .......... 13,1...14,5 U
M ln. s llp rl n g d l a rEi e r.... 26,8 mn
B r us h lf lg i h rh e n n e r......... 14 ml
M ln. br ush 1 e n g th ........... 5l ' m
T lght anln g to rq u e o f h e x a g q rn u t o f shai t......... 45 Nn

Altornrtor Lucas A ll5 il5 A

Nomlnal vo l fa g e .. 12y
M ax . v olfa g e 6 0 0 0 rp m ... ,..,.. 45A
E ar t h I n9 ......... (-)nl nus
M ax . allo t{ e d s p e e d ...... ... ... | 5000 rpm
B r us h len g th rh e n n e r......... 20 mm
M ln. br ush l e n g i h .... ...... . l 0 mn
B r us h s pr In g fe n s l o n ,..... .... 1,3...2,7 N
Num berof s fa + o r p o l e s ..,.. 12
Numbq of slaior phases... .
Stalor res I stance. . . . . . . . . . . . . . . . 0,092 1! !e665
Rotc reslslancE t,2!5rohns
Regulot ln g v o l i o g e . . . . . . . . . . 11,6... t4,4 v
T lght enln g i o rq u e o f h e x a g o nn u l o l shafi ......... 47 Nm

Alt€rnator Lrcås A lti 65 A

Nom lnal v o l fa g e .. ............... 12 V
M ax . v ollå g e 6 0 0 0 rp m ......... ................... 65 A
E ar t h I ng......... ............... ( -)m I nus
Max. allorod speed.. . . . . . . . . . . .. 15000rpm
B r us h len g i h w h e nn € y ......... ................... 20 r| n
M ln. br us h 1 E n 9 th ........... .... l 0 rn
B r us h s prfn g te ns I o n. . . . . . . . . . .. 1,1...2,1 N
Num berof s i a + o r p o l e s ..... .................,.... l2
Num berof s i a i o r p h a s e s .... . . ... .. .... ,... ..... .. J
S t aior r e s 1 s ta n c e ................ 0,t52 15 t ohms
Rotcr reslstanca 5,2 !5 tr ohns
R€gula+ l n gv o l ta g e .......... .... t1,6...14,4 V
T lgh+ enl n gi o rq u e o f h e x a g o nn u + o f shatt...................,..... 47 N m

A lternltor Lucls A lr, 75 A

Nonlnal v o l fa g e .. l 2u
M ax . v olta g e 6 0 0 0 rp m ......... 15^
Eorih I n9. . . . . . . . . (-)m I nus
M ox . al lo rEd s D a e d ............ | 5000 rpit
B r us h l6n g + h rh g n n e H ......... 20 rm
M ln. br us h 1 e n g i h ,.......... lO n||l
B r us h s pr I n g l En s l o n .......... | ,1...2,1 N
Num berof s + a to r p o l e s ..... 12
Nunb€r of siatr phases....
Staior res lstance 0,144.+ 5 t ohms
Rotor rgs lsfanca 2,45 ! 5l ohns
Regulat I n g v o l fa g e .......... | 1,6... | 4,4 V
T lght enln g to rq u e o f h e x a g o nn u i o f shatt......... 47 Nm

10-1
A lternator Lucas 23 ACRcnd 25 ACR
Nom lnal v ol+ a g e .. 12\
M ax . v olt age 6 0 0 0 rp m ......... 2l ACR 55 A, 25 ACR65 A
E ar ihlng. . . . . . ... (-)ml nus
l'4ax. allovred speed.. . . . . . . . . . . 15000rprn
B r us h leng+ hw h e n n e ' .{ ......... l2,'l Nl
MI n. br us h le n g + h . . . . . . . . . . I nrn
Brush spr I ng fens lon. . . . . . . . . . 2,5...5,5 N
l2
Numberof stator phases.... 3
Ro+or resl stance 1... f,5 ohms
Ragula+ lng v o l i a g e . . . . . . . . . . 15,6...14,4 tl
T lgh+ enlng t o rq u e o f h e x a g o nn u f o f s h a ft,........ 4l Nm

A lfern6tor CAYAC 5 R 24 Y
Nom lnal v ol+ a g e .. 24y
OuiDu+
2000 r om . . ....... 16,5 A
25,5 A
4o o or ;m ......... 29A
Char gebeglns .... | 250 rpm
l' lax . s peed. . . .... 10000rpm
Pol{q_ rgqu I renen+s. . . . . . . . . . . . . . . 1,8 ktl,/f500 rpm
I t lln. s llp r ln g d l a m e i e r.... 28,5 r|n
MI n. br us h le n g + h . . . . . . . . . . I firn
B r us h s pr lng i e n s 1 o n .......... 2,23 N (227 pl
Max. al loyiedtelpera+ure of surroundlngs.. 7@C
Rec t l f y 1n9. . ..... by sl l l con d l odes

A lternator Bosch Nl 28 | 55 25
^
NomI nal v ol+ a g e .. 24U
Ou+ouf
l0 A
2500 r Dm . ........ 16A
6000 r Dm . ....... 554
S+ator reslsi€nc€ 0,21 ohms+ to'
Roior res lstance 9 ohms+ l 0 ,
ReguI at lng v o l i a g e .......... 21,6...2A ,4
MI n. s llp r lng d l a me te r.... 26,4
B r us h lengt h w h e n n e | ..,....... 14 mn
M ln. br us h le n g + h ........... 5mm
T lght enlng + o rq u e o f h o x a g q rn u i o f s h 4 f1......... 45 Nm

Altornator Bosch T | 28 v 95 A 16
Nom lnal v olt a g e . 24 \l
Ouipui
900 r pm .......... 20A
| 150 r pm ......... 45A
1500 r Dm ..,...... 60A
5500 r pm ......... 954
S+alor r6s I s+ance 0,0f5...0,058 ohms
Roto' resl stance 8,5...9,4 ohms
Rs gulafI ng v o l + a g e .......... 2' t,6...29,4 \
Nlln. s llp r ln g d l a me fe r.... 32''[|.|.
B r us h lengih rh e n n o tr......... tö nn
M ln. br us h 1 e n g th ........... 7|Im
T lghf enlng t o rq u e o f h e x a g o nn u f o f s h a fi ......... 140 N m

10 - 2
STARTERS

Start€r Lucrs M 50 12 V

Valu es u n lo ad ed
.un nln g speed. . . . 5500.,.7500 rpm (max)
amp era ge .. . . . . . . . ............ l0o A
Va lu es un de r loading
run nln g speed. . . . ..........., l00O rpn
amp era ge ., . . . . . . . .,.......... 590 A
torq ue ...,., . . . . . 2l,f Nm (2,2 kpm)
Valu es lo cked
run n I n g speed. . . . ............0
amp era ge . . . r . r . . t . '. . . . . . . . . . 9 8 0 A
+o rqu e. . , . , . . . , , . 46 Nm (4,7 kpm) mln

Bru sh sp rlng lens lon ( ner br us h ) . . . . , . . . . . . ...... ll,7 N (1,2 kp)

Min . bru sh I e n9+ h . . . . . . . . , . . ....8 mm
Mln . co nrn uta i- or d iane+ ei . . , . . . . . . ................ l8 tnn

Siarfer Luccs A 121/2,4 12 |

Valu es u nlo ad ed
run nln g soeed. . . , 5500...8000 rpm (max)
amp era ge ., . . . . . , . ............ ll5 A
vo lta ge .. ,..........,.....,.. ll V
Valu es u nd ei loaCing
. . i ri ri r. , i i rv v v I l
u

amp era ge r, . t ! . ! . . . ', . . . . . . , , . 670 A

+o rqu e...... . . . . . 20,8 Nm (2,1 kpm)
vo l+a 9e .... . . . ... ....,......,8,0 v
Va lu es Io cked
run n In g speed. . , . ,....,......0
amp era ge r . r . . r . . . ............ ll@ A
iorq ue ...... . . . . . 45,4 Nm (4,6 kpm) mln
vo l +a qe . . . , . . . , . . . '. . . . . . . . . . 5,0 V

Bru sh sp rlng + ens ic i ( ' Er . . - r s h) . . . . . . . . . . . ...... 11,6...15,5 N (1,2...1,6 kp )

Min . bru sh leng+ h, . . . . . . . . , . .... 8 firn
l'1 in. clmu tato . c i a- e+ €. . . . . . . . . . ................ 18 ftln

Starter Bosch JF (R) 12 v J kl

VaI ue s u n l@ded
run nln g sJ e€d. . . . >7 0 0 0 r p m
an pe rag e.,. . . . . . . ............ <I J o A
vo l+a 9e .... . . . . . . .......,.... ll,5 V
Va I ues rifh d'na'fure l€kea
run nin g g peed. . . . 0 .
amp e.a ge , , . . . . . ! , l l 5 O . ! . l l O O A *)
vo fTa ge .... . . . . . . ............ I,z y ,
+o rqu e. . .. . , . . . . . . . . . . . . . . . . . >5 7 N m
So len oid e ng aging s oeed r in. . . . . . . , .............. I V
Mln . co .mu+at or C i anet er . . . . . . . . . ................ 42,5 nm
Mln . bru sh I e ngt h . . . . . . . . , , . ....8,5 nm
End p lay o f a. naiu. e . , . . , . . , , ..,0,1...0,f mn

* ) Whe n p erlo r oing + hes e m eas ur em ent s t h e s o u r c e o l p o w e r m u s t c o n s l s + o f t | | o p 6 r a l l e l l y

co nn ected öa+ + e. ies of 12 V l4J Ah

10-3
AOC€SSmtES

|l|lEx

Cont r ol llng + h e o p e ra + l q l o t s to p s o l gnol d .................. ll- |

Coopr es s q 8 e n d 1 x ........... ............... ll- 2
A. Rerpvfng and flxlng the conpressor... ... ll- 2
B . R€c ond l tl o n l n g i tF c d t| p r€ s s q . ........... ll- 2
S s - v lc lng e n d c d J u s i l n g i h e In d u s trl c l c| utch........... .... l l -,1

vÄtitET '11-0
 @NIRON-L
ING THE OPERATION
OF STOPSOLEM)ID
l. Clean ihe lever assembly befween +he slop
s olenold a n d + h e In J e c + l o n p u m p .L u bri ca+ e the
joint s *llh e n g l n e o l I a n d e n s u re + ha+ + he
leverage funqtlons srnooihly.

2. Renove the rubber cover (A) at +he rea- end of

the stop solenoid. Check that +he disiance
betxeen -the lixed sprlng con'tacis and itle
fllovlng contac+ undea the covei is min. 1,0 rm
rh en the s - t op s olenoid plunger ( B) i s f u l l y
d raHn ln (e nglne s t op pos i+ ion) .

No+el Fo i- he oper a+ ion of ihe s +o p

solenoid i+ is of advanl-age if the lever
asse nb ly h as been adjus t ed y l+ h t he p l u n g e r ( 8 )
sllgh fly in r ar ds f r qn l- he ouier loc k p o s i i i o n .
l{lih +his adjus'||IEn+, lprevec, if should be
che cked +h at + he f oik s c . er is s u f f l c l e n l l v
In sid e th e plunger and t hat t he I njec i i o n p u m ö
funciions proper I y.

11- l
 @IfRESSOR BENDIX
(61 l16 12 en glnes )

REI.IOVING AND F I X I }G TIIE COPRESSOR

l. Drain lh e e nglne c oolan+ .

Re move the c oolan+ pipes A and ihe l u b e o l l

plpe B frdn the compressor. Remove +ho alr
in let p ipe C and f he air deliv er y pl p e D f r o f l !
+he compressor s lde.

Lo osen ih e c om pr es s or r et alnlng s c r ew s a n d p u l l
+he comp.essor off lhe gear houslng.

Clea n +h e c om pr es s or I I r c Un+ lng s ur f a c e s . lf

needed, renpve ihe drive gear from +he
compre ss or- .

Flt a ner 0-rlng seal lo the colnpiessor

mou ntln g f lange. Af t ac h t he dr iv e gea r . T l g h t e n
+h e ge ar re t alning nut + o 140 M n.

Push the compressor Into il-s posi+lon In +he

ge ar h ou si ng and + ighien I ' he r eiainlnq n u f s +o
14 0 Nm.

1 . Fix +he air inlei pipe, ihe deliv er y pipe, 11 2

l-he
lu be oil p lpe and f he c oolan+ pipes .

Fill th e e ngine c ooling s y s f em and e n s u r e +h a i

+here are no leaks,

RECOND IT ION II{G THE COfRESSM

(Usln g a re palr k it )

11 3

The numbered par is ( l. . . lf ) ar e I n c l u d e d l n +h e

rep alr k l+ .

11-2
 Dts ssEiaLY
Refipve lhe re+alnlng scrers A (ll pcs] fo fake
ofl +h e cylln de r head B and + he v alv e Dlale C .
Rem ove th e In let v alv e heads l, s pr ings 2 ,
valve g uld es 5 a nd gas k ei 4.
2 . Loo se n i-h e re talnlng s c r ews D ( 2 pc s ) a n d
dela ch the cylln der head f r on ihe v alv e pla +e .
R eno vo lh e d ellver y v alv e heads 5, s pr lng s 6
and oasket 7.
Renf,ve the re+alnlng screvrs of +he alr
( lf asse mble d) and t ak e of f t he t llier
gaske+ 9.
Fl l the l nl e' i val ve head gul des l ni o i helr
recesses rlth ihe cut-aeay sldos lowards +helr
respectl ve cyl l nder bores. A ssembl e+ he I nlei
val ve heads and i he sprl ngs. Fl t fhe cyl l nder
head usl ng a nel r gaskei . Tl ghi en i he re+ a lnlng
screi s evenfy + o 20,3...21,0 N m. E nsure ihat
ihe valve heads move freelv. DO NOTLUBR ICATE
THE VALVEHEADSOR SPRINGS.
fl l ter I A t+ ach l ' he al r fl l + er (l f necessary) and usd a
and +he new qasKer,

Rer ov e f he unlo a d e r s p rl n g a n d s a d d l e l 0 as
v{ell a6 lhe pls io n s a n d + h e o -rl n g s s o a l s l l .

lf necessary, remove lhe roar end cover E and

Its o-rlng seal 12 and +he boi+om cover F lrlth
Its gas k ef ll.
Not€ | Do no+ +ry io renove +he valve sea+s
O. They are pressed ln durlng manufac-iureand
aro Iniegral par+s of the crankcase H.

INSPECT
ION
Thoroughly clean all removedparis. Ensure l-hat
a l l alr and waie r p a s s a g e sa re c l e a r. C l e a n off
anv cårbon lrom +he olsion heads and +he
cyllnder t op par i s .

C hec k t he c ondl + l o n o f i h e i n l e t a n d d e l l very

va lv e s eat s . 0 n l y s l l g h + , e v e n w e a r l s
p e r m l+ t ed. lf th e d e l l v e ry v a l v e s e a + s show
co ns lder able we a r, re n e w + h e v a l v e p l a i e C. l {
+h e I nle+ v alv e s e a + s a re e x c e s s i v e l v w orn,
rep lace ihe crankcase H. You can also replace
+he lnle+ valve seats, bu+ +hen you need +o
re-bore +he cyllnders after the new seats have
been J li+ed.

N,oiel The are +wo overslze plsions supplled

for +he compressor. The overslzes are 0,254 rm
and 0,508 rin. Bore ihe cyllnders ihen +o l'he
dlmenslons ö 15,254 rnmor d 75,508 lltn.

En s ur e ihat + ho n e v l u n l o a d e r p l s + o n s l 1 a re a
g o od s l ldlng f l+ In + h e l r g u l d e s . l f th e g ul des
ore appreclably worn, renew them.

Check the bearings for wear and replace +hem,

l f nec es s ar y . lf n e e d e d , + h e s l l d e b e a rl ng l n
ihe end cover E can be renewed.
REASSEtaLY
Fl t a nev , O - r ln g s e a l l 2 In I1 -s g ro o v e and
p l ac e t he end c o v e r l n l ts p o s l + i o n b y p u shl ng
fron fhe back. T lghien +he cover re+aI nl ng
scr ews ev enly t o 1 7 ...2 1 N m .

Fli +he bo+tomcover wl+h a nev gaske+ ln place

( lf removed). Tlghten +he refalnlng screv.s
e venly t o 8. . . 10 N m .
In ser t now O - rl n g s l n + h e u n l o a d e r p l s i ons.
L u br lc a+ e lhe O -rl n g s a n d l h e p l s i o n g u l des
l l gh+ ly t { l+ h e. g . s l l l c o n e l u b rl c a n + . F l i + he
p l s + ons I n + he l r g u l d e s a n d re a s s e mlbe + he
u n loader s addle a n d s p rl n g . En s u re th a + i he
unloader mechan lsm movesfreely.
Fl + t he dellv ery v a l v e h e a d s a n d s p rl n g s In+ o
th e v alv e pla+ e . In s e r+ a n e v r g a s k e + a n d fl x
th e v alv e pla+ e l n i h e c y l l n d o r h e a d . T l g hten
l -he s c r ows D + o 5 ,4 ...8 ,1 N m. E n s u re i h a l + he
valve heads move freely. DO t{oT LUBR ICATE
THE V^I-YEHEADSM SFRINGS.
11-3
 THE INDUSIRIALCLUTCH
StRVICI I'IGANDADJUSTII{G
(4.P. Borg t Beck)

Notgl Never servlce or adj us+ +he c I u+ch

|llt h f he en gIn e ru n n l n g .

11 6
AdJustlng rlngs of th€ clifch
3
Renovs the Inspectlon @v€r and release the
4 adj usi er l ock on i ha red adJusl l ng rl ng.
Ncrtel SorE clu+ches are furnlshgd wllh E
sockei headodscrew to lock ihe €dJus+lng rlng.
Rencve +he screw be{ore adJusilng. At+er
adj ustfl €nf tl ghten i he screw i o 11,5. . , 18 Nm
and ensure ihai l-he lnner end of ihg screw
engagesbe+teen +he spllnes on the body.
Turn the adj us+ l ng rl ng cl ockrl l se by h and or by
fappl ng yl i h a l l ghi hanrner,uni l I i he cor r oct
adj usinen+ ls reached.

Flt ihe adj usler lock and the Inspectlon cover.

AdJustlng tlp nlln b€arI ng

The tapered roller bearlngs on ihe drlve shafi

Inspeci lon cover nusl be adjus-ted rhen +he shaft eod plöy
PuI l-oul hole exce€ds 0,25 rm.
Grease nlpple tor release bearlng
4 . G r eos e n l p p l e fo r ma l n b e a rl n g

Lubrl cai lon

Lubr lc af e + h e re l e a s e b e a rl n g d a l l y and + he
m aln bear ln g a t l n te rv a l s o { 5 0 ru n n l ng hours.
Us e lllhlum -b a s e d g re a s e fo r l u b rl c a f l on (e.9.
S hell A lv anl a n o . 2 ).

A t lnier v als o f 5 0 0 ru n n l n g h o u rs l u b r l cafe + he

wrlst plns, the yoke ends and +he cross shotl
beor lngs nl i h a fe u d ro p s o f e n g l n e o l l .

AdJustnont
T he c luic h l s c o rre c tl y a d j u s l e d rhen,' the
engageneni load at the end of fhe operatlng
lever ls 14...41 kg (operatl ng lever ,fength
65, 5 c m ) .

l. Lock p lafe
2. Tapersd rol ler bearlnos
l. Adj ust Ing rlng

Remove +he Inspectlon @ver and iakg ofl ih€

lock p late.

11 5
 Uslng a soft nefal drlft iurn tha adjus+lng
r lng t oward s l h e b € a rl n g , u n + l l th e d rl ve shaft
end glay ls 0,10...0,20 nm. One no+ch of ihe
adjusier ls oqulvalent to abou+ 0,09 r b€arlng
movemenT.

Nqtel The bearlng xlll b€ overstressed and

v r lll. r un h o i , l f a l l , e n d p l a y l s el l ml nated.
Afier adjustmont ensure +haf fhe shåff end play
ls s uf f lc le n f (0 ,' 1 0 .,.0 ,2 0 rfl n ).

Replace the lock plate and ihe lnspecilon

RerDvlng fhe poflsr take-ff froo the englno

Dlsconnect lhe drlvs from ihe clutch and remove
t he pulley , /c o u p l l n g a n d fh e s h a fl k e y.
2. Supporf +he welgh+ of the poxer fake-off trlih
e. g. a c ha l n h o l s t. R e n o v ei h e c l u i c h operai l ng

Loos en t he c l u tc h re ta l n l n g scr€ns. The c luich

hous lng f la n g e h å s p u l l -o u i h o l e s (th read 0,5tr
B S F ) . P lac e s c re w s l n th e h o l e s a nd tl ghten
ihem on6 h a l l o f a + u rn a + a + l rF a l + erna+ el y,
un+ l I ihe c l u tc h h o u s l n g l s removed from lis
spI go+.

1.t-5