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From the Library of Barrington Diesel Club
ENGINE REPAIR MANUAL

ADE
A DE 360 SER
SERIES
IES
ATL
A TLA
A NTIS DIESEL
DIESEL ENGINES
ENGIN ES (PTY
(PTY)) LTD
LTD
Part No. 805*&S4i

by the Service Department of Atlantis Diesel Enain®
FOREWORD
The 360 Series are direct injection, water-cooled four-stroke diesel engines. The cylinders are
arranged in line and are positioned vertically. Depending on application 360 series engines can
be fitted with a turbocharger. The engines have been designed to take advantage of the latest
technology, with special emphasis on the smallest possible dimensions, a favourable power
to we ight ratio and low fuel c onsum ption. ADE engines havehave a left
left hand rotation when viewed
viewed from
the rear. Throughout this manual, whenever Left or Right hand side of the engine is referred to, it
is the side of the engine when viewed from the flywheel end.
This publication has been written to assist all personnel engaged in the maintenance and overhaul
of the ADE
ADE Diesel Engine
Engine.. All necessary inform ation contained
containe d in this manual is presented
presented in a logical
step by step format with the text supported by line illustrations, which are positioned on the right
hand side of the page, together with precise instructions on the servicing and overhaul procedure.
In addition each section contains a schedule of manufacturing data and dimensions which must
be closely followed when overhauling any part of the engine to the Manufacturers standards. Effec
tive maintenance can only be carried out if the personnel concerned are fully conversant with the
various components of the engine. Before maintenance operations are commenced, therefore, this
manual should be carefully studied, and should at all times be kept where it will be needed in the
workshop. Certain operations described in this manual require the the use of special tools. These tools
' are ob taina ble from
from G rundy-Te chniform. Full details areare given in in the app ropriate section s.
A Product Training Representative, highly skilled in the special characteristics of ADE Engines,
is available to assist you with product training through your Original Equipment Manufacturer
(O.E.M.).
ENGINE PARTS
Whenever parts are required for ADE Engines, it is essential that the fullest information possible
is given, always quote the engine number, type of application, and where possible the part number
and
itemsdescription.
as fuel, oilIn and
accordance with
air filters. It the
is inPreventative Maintenance
your own interest Plan,that
to ensure youronly
engine will require
genuine such
ADE Parts
are used. Each genuine ADEPART, is backed with a six month guarantee ensuring the highest quality,
and every part complies with the original specification.
RUNNING-IN PROCEDURE
It is not necessary to gradually run-in a new ADE engine, and any prolonged light load running
during early life of the engine can in fact prove harmful to the bedding in of the piston rings and
liners. Full load can be applied provided that the engine has reached operation temperature.
This publication is produced by the Service Department of Atlantis Diesel Engines (Pty) Ltd, and
every endeavour has been made to ensure that the information contained in this manual is correct
at the time of pub lication, however
however,, continu ous development and advancement in product design
may reflect changes made to your engine which are not included in this publication.
© COPY RIGHT 198
19888 ATLA NTIS DIESEL ENGINES (P
(PTY)
TY) LTD
LTD..
Reproduction or translation, in part or full is subject to the written authorization of AtlantifDiesel

Engines (Pty) Ltd.
CONTENTS
TECHNICAL DATA .....................................................

................................................................................
......................................................
.................................................
...................... ........ . 08
OPERATING MAINTENANCE SCHEDULE AND LUBRICATING OILS .............................................. 09
FAULT FINDING ......................................................

.................................................................................
......................................................
......................................................
...................................
........ 10
CYLINDER BLOCK AND LINERS ......................................................

.................................................................................
........................................................
................................
... 11
CYLINDER HEAD ......................................................

.................................................................................
......................................................
......................................................
.................................
...... 12
PISTONS AND CONNECTING RODS ........................................................

..................................................................................
..................................................
........................ 13
CRANKSHAFT AND MAIN BEARINGS ......................................................

................................................................................
.................................................
....................... 14
CAMSHAFT, TIMING CASE AND DRIVE-TIMING ...................................

................................... ...................................................
................................................... 15
LUBRICATING SYSTEM AND SUMP ............................................................................................................16
FUEL SYSTEM ..................................................... ........................

..................................................
......................................................
.........................................
............. 17
TURBOCHARGER ....................................................
................................................................................
......................................................
....................................................
.................................
.......
18A
POWER STEERING .......................................................
...................................................................................
......................................................
....................................................
.......................... 18B
EXHAUST BRAKE ........... ....18C
FLYWHEEL .................................................
...........................................................................
......................................................
......................................................
...............................................
..................... 18D
ALTERNATOR AND STARTER MOTOR ...................................................

...............................................................................
.................................................
..................... 18E
COMPRESSOR/VACUUM PUMP ..................................................

................................................................................
.........................................................
..................................
....... 18F
COOLING SYSTEM ....................................................

..............................................................................
......................................................
......................................................
..............................
.... 19
......................................................................
APPROVED SERVICE TOOLS REFER TO EACH SECTION
SECTION 08-1
Technical Data
ADE
A DE 364N/C/T
364N /C/T/TI
/TI
ENGINE DATA
ADE 364N ADE 364C ADE 364T ADE 364TI
Bore ........................................................................... 97,5 mm 97,5 mm

.................. .................. 97,5 mm .................. 97,5 mm
S t ro ke ....................................................................... 133 mm 133 mm
................... ................... 133 mm ................... 133 mm
No. of cylinders .................................................... 4 ................................ 4 ................................. 4 ................................. 4
Cubic capacity ..................................................... 3,972 t .................... 3,972 ( ..................... 3,972 ( ..................... 3,972 f
C o m p re s s io n ra tio ....
........
........
........
........
........
........
........
........
.........
.........
........ 17,25:1 ..................... 17:1 ........................... 16,5:1 ........................ 16,5:1
Co m p re ssi o n t e st p re ssu re a t o p e ra t i n g
temperature (Max. difference between
a n y t wo cyl i n d e rs — 4 0 0 kP a ) ....................... M in 2000 kPa at 180-
180-200
200 r/min Min 2000 kPa at 180-
180-200
200 r/min
Firing order ............................................................ 1-3-4-2 1-3-4-2

..................... 1-3-4-2 1-3-4-2
....................... .......................
Combustion system ............................................ Direct injection ...

...Direct
Direct injection ..
...Direct
.Direct injection ..
...Direct
.Direct injection
Cycl e ......................................................................... 4 stroke 4 stroke
................. 4 stroke 4 stroke
.................. ..................
DETAIL OF RATINGS (AUTOMOTIVE) TO SABS 013-1977
Maximum torque (N.m) ..................................... 266 @ 1400 r/m in 300 @ 11400

400 r/m in 380 @ 1400 r/m in 408 @ 1400 r/m in
Ou t p u t K w ................................................................... 66 @ 2800 r/m in 70 @ 2800 r/m in 85 @ 2600 r/m in 100 @ 2600 r/m in
ENGINE MASS
T y p ic
ic a l d ry
ry m a s s .................................................. 335 kg ..................... 343 kg ..................... 343 kg ..................... 370 kg
ADE
A DE 366N/C/T
366N /C/T/TI
/TI
ENGINE DATA
ADE 366N A DE 366C ADE 366T ADE 36831
Bore ............................................................................ 97,

97,55 mm .................. 97,5 mm .................. 97,5 mm ......... 97,5 mm
S t ro ke ....................................................................... 133 mm ................... 133 mm ........... . ...... 133 mm ................... 133 mm
No. of cylinders .................................................... 6 ................................ 6 ................................ 6 ................................. 6
Cu b i c ca p a ci t y ...................................................... 5,958 f ..................... 5,958 f ..................... 5,958 ( ...................... 5,958 I
C o m p re s s io n ra tio ....
........
........
........
........
........
........
........
........
.........
.........
........ 17,25:1 ..................... 17:1 ............................ 16,5:1 ........................ 16,5:1
Co m p re ssi o n t e st p re ssu re a t o p e ra t i n g
temperature (Max. difference between
a n y t wo cyl i n d e rs — 4 0 0 kP a ) ....................... Min 2000 kPa at 180-200
180-200 r/min Min 2000 kPa at 180-
180-200
200 r/min
Firing order ............................................................ 1-5-3-6-2-4 1-5-3-6-2-4

............... 1-5-3-6-2-4 1-5-3-6-2-4
................ .................
Co m b u st i o n syst e m ............................................ Direct injection ...Direct injection ...

...Direct
Direct injection ...
...Direct
Direct injection
Cycl e .........................................................................
4 stroke .................
4 stroke ..................
4 stroke ..................
4 stroke
DETAIL OF RATINGS (AUTOMOTIVE) TO SABS 013-1977
M a xi m u m t o rq u e (N. m ) ..................................... 402 @ 1400 r/m in 420 @ 1400 r/m in 560 @ 1400 r/m in 640 @ 1400 r/m in
Ou t p u t K w ............................................................... 100 @ 2800 r/min 100 @ 2800 r/m in 125 @ 2600 r/min 150 @ 2600 r/m in
ENGINE MASS
T y p ic
ic a l d ry
ry m a s s .................................................. 445 kg ..................... 460 kg ..................... 460 kg ......................495 kg
Throughout this Engine Repair Manual, S1 (International Metric System) units as approved by the South African Bureau
of Standards (SABS) are used. All measurements are in mm unless otherwise indicated.
ADE 360 Series
08-2
TORQUE SPECIFICATIONS FOR BOLTS UNDER DIFFERENT GRADE CLASSIFICATIONS
Quality grade 8 .8 1 0 .9 1 2.9

M6 8 .6 1 1 .8 1 4.5
M8 21 29 3 5 .5
M8x1 23 32 38
M 10 42 58 70
M10 x 1,
1,55 4 6,5 65 78
M 12 73 11000 123
M 12x1,5 76 105 128
M 14 1 14 165 195
M14x1,5 128 178 21 5
M 16 178 2 50 300
30 0
M16x1,5 1 90 2 70 32 0
M 18 245 3 55 41 5
M18x1,5 28 0 3 90 465
46 5
M2 0 35 0 4 90 590
M 20x1,5 390 550 660
M2 2 46 5 6 60 800
M22x1,5 5 20 7 30 875
M2 4 600 8 50 10 00
M24x2 66 0 91 0 1100
NOTE 1 — The Bolt grading appears on tthe

he bolt head
NOTE 2 — Bolt torque is subject to female thread material
ADE 360 Series
TECHNICAL
TECHNICAL DAT
DATA
A - 08-3
IDENTIFICATION NUMBER POSITIONS
When o rdering spare parts allways quo te the engine

number in full.
ENGINE IDENTIFICATION
The engine numbering system for ADE engines consists

of 16 letters and numbers.
Example
ATLANTIS
ATL ANTIS DIE
DIESEL
SEL ENG
ENGINES
INES (PTY) LT
LTD
D
LICENCE DAIMLER-BENZ AG
ENGINE No DB
ADE M J 01002 SA 046315 T
MADE IN RSA
ENGINE FAMILY
300Series
ENGINE TYPE
TYPE
i.e.
G = 36
36 4N
4N  L = 3
366TI
H = 3
36 4C M =
=364T
J  = 3
36 6N  N = 3
366C
K =366
=366T T
BUILDCODE
COUNTRYOF
COUNTRYOF ORIG
ORIGIN
IN
ENGINESERIAL NUMBER
YEAR
YEAR OFMANUFACTURE
S =  1988 U =  19 90  W  =  1992
T =  1989 V =  1991 X  =  1993
Y  =  1994
Note:
T h e l e tte r d e n o ti n g th e y e a r o f ma n u fa c tu r e c h a n g e s o n
the 1st day of January each year.
The letters I, O, Q, R and Z are not used.
ADE 360 Series
TECHNICAL DATA — 08-4

ADE 360 Series
SECTION 09-1
Operating and Maintenance
OPERATING AND MAINTENANCE RECOMMENDED SERVICE/
MAINTENANCE INTERVALS
Preparation before Starting
Normal oil and filter changes/service intervals
Check the radiator coolant level.
Che ck the engine sump oil level.
level. . Category 1 Category 2 Category 3
Ensure that there is fuel in the tank. 7 500 km/15 0 hrs 5 000 km/100 hrs 2 500 km/50 hrs
Check that the battery is fully charged and that all elec At least tw
tw ice a year when s ervice interval is not reached
trical connections are properly made and all circuits are
in order. EXTENDED oil and filter changes/service
intervals
To Stop the Engine The extended maintenance and service intervals may only
Remove the engine load. Decrease speed gradually to c om m enc e af t er t he runni ng i n peri od (approx i m at el y
avoid heating up the coolant, then run the engine at idl 20 000 km).
ing speed for a short time. Shut down engine. The engine lubricating o ils for extende
extende d oil change inter
vals, as specified in the ADE Service Bulletin on Con
(a) By actuating the stopping cable. sumables have been approved and are mandatory.
(b)
(b) B y m ov ing
ing t he s peed c ont rol l ever
ever t o “ s t op ” . T he s uc c es s f ul app l ic
ic at i on o f t he ex t ended oi l and f i l ter
ter
(c) By actuating the shut-off solenoid. changes/service intervals warrants careful service and
m ai nt enanc e of engi nes . A s ex tended tended i nterv
nterv al s al s o de
(d) By actuating the exhaust brake depending on the pend on operating conditions of the engines, it is essen
engi ne s pec i f i c at i on. tial to apply the 3 categories as outlined below.
Cat eg o r y 1 C at eg o r y 2 Category 3
Points to note
15 000 km/300 hrs 10 000 km/200 hrs 5 000 km/100 hrs
Always ensure that the starter pinion has stopped rotating
before re-engaging the starter, as the ring gear or pinion At least on ce a year when se rvice interval is not reached
may be damaged.
Flame-Proofed Engines Note 1:

Engines arranged to conform with flame-proofing regula Engines that leave the factory are filled with running-in
t i ons are us ual ly
ly f i t ted
ted w i t h no n-el ec tri
tri c s t arti
arti ng equ i p oil. The oil must be changed d uring the first service at
ment. This
This is supplied
supplied by the m anufacturer of the a pplica 1 500 km
km o r 30 hou rs ope ration.
tion and for starting instructions reference should be
m ade t o t he appropri at e m anuf ac t urer’ s handbook . For approved
approved engine lubric ants and coo lant additives,
refer to ADE General Service Bulletin on Co n
Preventive Maintenance sumables.
Category 1
Units operating under normal conditions, more than

10
1000 000 km or 2 000 ho urs ann ua lly e.g. long haul
operat i ons .
Category 2
Units ope rating und er normal co nd itions

itions , up to 100 000
km or 2 000 hours an nua lly e.g.
e.g. med ium to long haul
Pre-de
Pre-delivery
livery Se
Servic
rvic e
operat i ons .
1. Check general en gine insta llation i.e.
i.e. All pipes and
Category 3
hoses for tight sealing, condition and routing.
Units subject to severe
severe operating co nd itions itions e.g.
e.g. extreme
extreme
2. Open air cleaner and ensure element is positioned
ly poor road conditions, heavy dust conditions, extreme
c orrec t l y and bol t ed dow n.
clima tic co nditions (temperature and humidit humidity),
y), very
very short
di s t anc es i n t raf f i c or c ons t ruc t i on operat i on. U ni t s 3. Check for fuel and oil leaks.
ope rating up to 10 000 km or 200 200 hours ann ually e.g. e.g. units
operating under light loads or intermittent operating con 4. Check oil level.
di t ions
ions , s uc h as s tand-by
tand-by generat or s et s and em ergenc y 5. Check coolant level.
vehicles. However, when operating less than the recom
mended service intervals, the oil and oil filter should be 6. Check co olant for correct m ixture, i.e.
i.e. anti-freeze/anti
anti-freeze/anti
changed once o r twice a year year depending on the lubricating
lubricating corrosion agent and corrosion inhibitor.
oil used. We recommend that maintenance and service
7. Chec k V-belt tension. .
be carried
carried out acco rding to hours of operation rather than than
mileage covered. 8. C hec k el ec t ri c al equi pm ent and c onnec t i ons .
AGE 360
360 Series
OPERATING AND MAINTENANCE — 09-2
9. Check injection pump linkage for total movement. 13

13.. Ensure radiator
radiator fins have an
an uno bstructed air flow.
10
10.. Che ck exha ust brake linkage and ad justm ent if fitted. 14
14.. Tension all V-Belts,
V-Belts, checking same for ageing, replac
ing defective V-Belts. Twin V-Belts should only be
11. Check that the fan has been fitted correctly.
replaced in pairs.
pairs. New b elts must be retensioned after
12.
12. Start up, then check oil pressure and coo lant 10-15 minutes of operation.
t em perat ure gauges.
gauges.
15.
15. Check exha ust system
system fo r damag e or leaks.
13. Check for any unusual noises.
16.
16. Check control linkage
linkage on injection pum p and exhaust
14
14.. W hile
hile engine is warming up check for oil and water brak e f or c orrec
orrec t f unc t i on and adj us t m ent , l ubri c at e
leaks. all joints.
15. Check operation of visco fan (if fitted). 17.

17. Check all lilines
nes and hoses for tigh
tigh t sealing, chafing
and leaks.
16. Run to operating temperature and check maximum
r/min. 18
18.. Ad just valve cleara nces .
19
19.. Retighten all visible
visible nuts and bolts on the engine and
Daily Before Starting and 8-10 Hours
Operation
in particular.
(a) Inlet and exhaust manifolds and ducts.
1. Check eng ine oil level
level and pressure upon start up (en (b) Exhaust flange.
sure machine is standing level).
(c) Starter motor and alternator fitting.
2. Check coolant level in radiator.
(d) Nozzle holders.
3. Service air cleaner dus t bowl, pre-filter
pre-filter if applicable. (e) Engine mount on cross member and engine
4. Check air cleaner restriction
restriction indicator, service
service filters
filters support.
if required. \ (f
(f)) Bell hous ing bo lts and nuts.
5. Ensure there is ample fuel in tank. 20. Che ck for fuel
fuel and oil leaks.
leaks.
6. Ensure fuel tank cap/breather is unobstructed. 21. Check operation of oil pressure and temperature
gauges.
7. Check tha t the
the exte rior of the sump is clean
clean w ith an
unrestricted air flow over the surface. 22. Check ba ttery electrolite level.
level. In Summ er and hot
regions once a week.
8. Ensure radiator fins have an unobstructed airflow.
23
23.. Check battery term inals for
for tightne
tightne ss and condition.
9. Check oil pressure indicator.
24.
24. Check op eration of Visco Fan (if
(if fitted).
fitted).
10
10.. Drain wa ter from sed imentor.
Ad ditiona l items requiring servicing a t 50
50 000 km inter
11. Drain air tank (if fitted). val listing.
Note:
1. Check carbon b rushes in the
the starter.
Injectors: S at i s f ac t ory l ong t erm
erm f unc t i oni ng of i nj ec t ors
depends largely on the quality and purity of the fuels us 2. Inspect and clean oil cooler filter element ADE
ed. A specific service interval can therefore not be 360T/TI
prescribed. Dealers and Fleetowners should adopt ser
vice intervals which would suit the individual operating
c i rc um s t anc es .
Schedule A Service
Schedule B Service
1. Change engine oil, drain oil when still hot.
*1. Change eng ine oil
oil and oil filter,
filter, drain when still hot.
2. Renew oil filter.
3. Renew fuel
fuel filters. 2. Drain
Drain fuel sed imen tor or fuel
fuel filter drain taps.
taps.
3. Service
Service air cleane r du st bow l/prefilter
l/prefilter if app licable.
4. Drain
Drain water from sed imentor or fuel
fuel filter
filter drain cocks.
4. Check air cleane r iindica
ndica tor, service filters if required.
required.
5. Servic
Servicee air cleaner dust bow ls/pre-filter
ls/pre-filter ifif applicable.
5. Check all ai
airr cleane r intake
intake duc ts, hoses and clips
clips
6. Che ck air cleane r indica
indica tor, service filters if required.
required.
for serviceability and tightness.
7. Service air cleane r and filte r (oil
(oil bath type).
type).
6. Check that intercoo ler is fre
freee from
from ob struction .
8. Check all air cleane r intake
intake duc ts, hoses and clips
7. Check coo lant hoses, hose clips for serviceab ility
ility and
etc., for serviceability and tightness.
t i ght nes s .
9. Check that intercooler is free from obstruction.
8. Pressure test coo ling system.
10. Check co olan t hoses, hose clips for serviceability and
and
9. Ensure radiator fins have an unob structed a ir flow.
t i ght nes s .
11.
11. Pressure test cooling system. 10.
10. Tension V-Belts che cking same for ageing, replace
replace
defective V-Belts. Twin V-Belts should only be
12. Ensure that recommended corrosion inhibitor has replaced in pairs. Retension new belts after 10-15 min.
been added to the cooling system. operation.
ADE 360 Series
OPERATI
OPERATING
NG AND MAINTENANCE - 09-3
09-3
11
11.. Check exha ust system for damage or leaks.
leaks. The anti-corrosion oil content in the coolant i.e. 1% by
volume, may be determined by a refractometer.
12
12.. Che ck for fuel and oil leaks.
leaks.
Onl y us e approv
approv ed produ c t s f or m i x t ure w i t h t he c ool ant
13. Check operation of oil pressure and temperature
as specified in our General Service Bulletin on Con
gauges.
s um ab l es and at al l t im
im es s t ri c t l y adhere t o t he m i x t ure
ure
14
14.. Che ck battery elec trolite level. In Sum me r and hot s pec i f i c at i ons .
regions once a week.
15
15.. C hec k bat t ery term
term i nal s f or titi ght nes s and c ond i titi on.
Ad ditiona l items req uiring servicing at 50 000 km inter ENGINE PRESERVATION
vals or to the equivalent shown on the maintenance in
terval listing. When an engine is laid-up for a prolonged period, it should
be properly protected against corrosion. Preservation
1. Check the carbon brushes in the starter. measures should be carried out in accordance with the
2. Clean turbocharger impeller, diffuser and oil drain different catagories listed in the following sections.
pipe.
3. Inspect and clean o il cooler filter elem ent (36
(360T
0T/T
/TI)
I) 1.0 General
2.0 Installed Engines
2.1 Laidup
Laid up for up to 12 m onths
S at i s f ac t ory l ong t erm operat i on of t he ai r
A t t en t i o n !
2.2 Laidup
Laid up for 12 to 36 m onth s
compresso r, depends on m any varying varying factors. Therefore
2.3 Laid up for more than 36 months
a specific service interval cannot be recommended.
Dealers and Fleetowners should adopt service intervals 3.0 Non-installed Engines
w hi c h w i l l s ui t t hei r i ndi v i dual operat i ng c ondi t i ons . 3.1 Laid up for up to 12 mo nths
Laidup
3.2 Laidup
Laid up for 12 to 36 mo nths
ENGINE COOLANT 3.3 Laid up for more than 36 months
I n v i ew of t he s i gni f i c anc e of m ai nt ai ni ng t he c ool i ng 4.0 Preparing Engine for operation
system at a spe cifi cified
ed level
level,, it is essential to ensure that
t he f ol l ow i ng c ool ant s pec i f i c at i ons are m ai nt ai ned. 1.0 General
For the preparation of coolants, use clean water that is An engine is classified as “ laid up” whe n it has not
not too hard. Often, drinking wa ter (tap
(tap water) will meet operated for over one month. Laid up vehicles or
the desired requirements, but not always. engines sh ould be stored in dry, well-ventilated
well-ventilated rooms
Sea water, salt water, industrial waste water and brackish and m us t al w ay s be prot ec t ed agai ns t di rec t
moisture, e.g. rain
rain or splash w ater. If this is not p ossi
w at er w hi c h i nc l udes i n m os t c as es w at er f rom dam s , ble, laying
laying up co nditions are class ified
ified as extreme and
ponds and ri rivers,
vers, shou ld be considered to be un suitable,
as these may contribute heavily to the formation of the treatment specified for a given period should be
corrosion. increased, e.g. if an engine is to be laid up for up to
12 mo nths, it mus t receive
receive treatm ent o f an engine to
Specification of fresh water be laid up for 12 to 36 months.
Sum of alkaline earth 89.5 — 358 mg/litre 1.1 On any laid up eng ine all ma chine d external
(water hardness) unprotected surfaces, e.g. flywheels, V-belt
pH value at 20°C 6.5 — 8,5 pulley grooves, etc. should be coated with a
C ont ent s of c hl ori ne i ons : max 100 mg/litre preserving agent or grease.
T ot al c ont ent of c hl ori des
V-belts must be slackened off and be removed
and sulphates max 200 mg/litre
from the grooves.
F ul l i nf orm at i on on t he q ual i ty
ty of d rink
rink i ng w at er s hould
hould All openings must be sealed air tight. This
be obt ained
ained f rom l oc al depart m ent s of W at er A f fai fai rs or includes exhau st and air inlet
inlet ducts/clean ers on
local auth orities.
orities. It iiss esse ntial to prote ct your engine at installed engines. '
al l t i m es agai ns t c orros i on by t he addi t i on of A nt i
corrosion/Anti-freeze additives (ethylene glycol with Batteries must be disconnected in laid up
corrosion inhibitors) wh ich am ong st others, others, will meet the the vehicles and should be recharged outside the
f ol l ow i ng dem ands : vehicle as required.
• adequate anti-corrosion and cavitation protection for
2.0 Installed Engines
al l c om ponent s i û t he c oo l ing
ing s y s tem
tem
• l o w e riri n g t h e f r e t t i n g p o in
in t These measures apply to all engines in vehicles,
tractors, as well as industrial engines.
• raising the boi
boiHÉÉüf
HÉÉüfofRt
ofRt
2.1 Laid up for up to 12 months
A t no t i m e s houl d t he c obl àht ' m i x t ure ex c eed 55% by
volume anti-freeze/anti-corrosion agent as a higher 2.
2.1.
1.11 NEW ENGINES (distance covered up to 300 km
percentage w ill reduce the the anti-freeze
anti-freeze p rotection as we ll or 6 hours of operation):
as lessen the heat dissipation. As an ti-corrosion
ti-corrosion inhibitors
decompose during operation, as well as anti-corrosion The engines mu st be filled
filled to the maxim um le level
vel
c onc e nt rat ion
ion bei ng reduc ed
ed by toppi
toppi ng up t he c ool inging w i t h approv ed s erv i c e produc t s . A m bi ent
system with water, the frost protection must be checked tempera tures must be taken into consideration
regularl
regul arly.
y. Frost protection of - 3 0 °C corresponds with 40 40 when selec ting SAE grades. No furthe r preser
to 45 percent (by volume)
volume) an ti-freeze/
ti-freeze/ anti-corrosion con vation measures are required.
t ent in t he c ool ant w hi c h m ay be det erm erm i ned by an
an o p 2.1.2 USED ENGINES (distance covered more than
t i c al or m ec hani c al hy drom et er, (-30°C ). 300 km or 6 hours operation):
ADE 360 Series
OPERATI
OPERATING
NG AND MAINTE
MAINTENANCE
NANCE - 09-4
9-4
Run engine until warm and drain engine oil. c y l inde

inde r v ia
ia t he c o m pres s or a i r int
int ak e w he re
(Running-in oil may remain in the engine). after the engine,must be rotated at least one
Renew oil filter cartridge. Fill with an approved half a turn.
running-in o il (anti-corrosion
(anti-corrosion e ngine oil).
oil). Fill or
t op up c ool i ng s y s t em w i t h t he s pec i f i ed 2.3 Laid up for more than 3
36
6 month s
coolant mixture. Run engine at medium speed If the laying-up

laying-up period is extended
extended for more than
for approx. 5 to 10 minutes until operating 36 months, preservation measures must be
temperature is reached (coolant temperature repeated every 3 years or 18 months in accor
75-79°° C)
75-79 C). Sw itch o ff engine, fill the su mp and dance with Section 2.2 in full.
the oil bath a ir filter (if fitt
fitted)
ed) to max imum levlevel.
el.
2.2
2.2 Laid up for 1
12
2 to 36
36 mon ths
3.0
3. 0 N O N - IIN
NSTALLED ENGINES
All the measures set out in Sections 1.0
“ Ge neral” and 2.
2.1 “ Measures for Installed
Installed These measures cover new non-installed engines, as
Engines Laid up for up ttoo 12 mon ths” , mu st be well as remanufactured engines.
carried out.
3.1 Laid up for up to 1
12
2 month s:
In addition, the fuel system, the combustion
chambers and the air compressor must be NEW ENGINES which have only been subjected
preserved In accordance with the following in to the running-in period at ADE, do not require
any additional preservation measures.
s t ruc t i ons .
Note 1: The procedure in this section sho uld also be Running-in oil may be left in the engines.
followed after less than 12 months in the case of sea Coolant must be completely drained. Remove
shipments and in tropical areas. t he t herm os t at / s and i ns ert one C hadpac k
Tablet (ADE Part No 36170072) into the housing.
2.2.1 Preservation of Fuel System: Refit the
the therm ostat/s and closing cove r/outlet
Add a pproxim ately 10% running-in
running-in oil to diesel
diesel and ensure that the join ts form a good seal. All
fuel and operate the engine with this mixture engine openings must be sealed airtight.
for approximately 5 to 10 minutes.
Note 5: F ol low
low t he i ns t ruc t ions
ions f or s ea
ea s hi pm e nt s or
If a number of vehicle, tractor or industrial
tropical areas.
engines are to be preserved at the same time,
the fuel and the running-in oil may be mixed in USED ENGINES must be treated in accordance
a separate container before feeding the solu with the measures set out in Items 2.1.2 and
tion into the fuel system via a three-way or four 2.
2.2.
2.11 before being laid up or dism oun ted.
way cock valve.
valve. This enables the co ncen tration
tration
Coolant must be drained completely and a
of oil in diesel fuel to be increased to 15-20%.
Chadpack Tablet must be Inserted in the ther
2.2.2 P r e s e r v a t i o n o f C o m b u s t i o n C h a m b e r s : m os t at hous i ng.
Oil may be sprayed into the combustion REMANUFACTURED ENGINES must in all
chambers via the injector ports after removal cases be preserved
preserved in accordance with Section
of the injectors which may be immersed in oil 2.2 in full.
for added protection.
3.2 Laid up for 12 to 36 months:
For best results the
the m etered
etered am ount of o il must
be injected
injected into the
the com bustion cha mber under The preservation measures set out in Section
pressure to ensure complete spraying of all 2.2 must be carried out in full.
areas. Upon completion of each cylinder (piston 3.
3.33 L a id
id u p f o r m o r e t h a n 3 6 m o n t h s :
down), rotate the engine at least one full turn
by hand. If the laying-up
laying-up period is extended for more than
36 months, preservation m ust be repeated every
every
Note 2: During the above operation the injection 36 months (3 years) or 18 months in accordance
pump/governor control must be in the shut-off with Section 2.2 in full.
position.
If there is oil in the engine, this may be drained
Oil Per Cylinder 8-10 ml off at room temperature (about 20°).
It Is not neccesary to renew the oil filter
cartridge.
Note 3: Do not exceed above amounts as this may
lead to hydraulic lock and possible engine damage. 4. 0 PREPARING ENG INE FO R O PERA TIO N
Refit all parts removed and ensure that seals and 4.
4.11 Remove sea ling from all ope nings.
gas kets are
are in place.
place. Re-position the injection pump
gov ernor c ont rol s t o t he op erat ing
ing pos i t ion.
ion. 4.
4.22 Remove preserving agent or grease from the the
grooves of V-belt pulleys,
pulleys, flywhee l and othe r un
Note 4: Engines must not be started after the com
protected surfaces.
bustion chamber preservation has been carried out.
4.3 Re position
position and tension V-belts in accorda nce
2.2.3
2.2.3 Preservation of Air Compress ors:
with instructions.
Air com presso r preservation
preservation shou ld be done in 4.4 If not already installed,
installed, fit engine to
to machine.
c onj unc t i on w i t h t he c om b us t i on c ham bers . A
m ax i m um of 5 c ubi c c ent i m et res of runni ng-in
ng-in 4.5 Fill with approved lubricating and coo lant ser
oil should be injected or poured into each vice products or top up to maximum level.
ADE 360 Series
OPERATING AND MAINTENANCE — 09-5
Note 6: Engines which have not received their first

service must be filled with running-in oil, all others
should be filled with approved operating oils.
4.
4.66 Recharge and reconnec t batteries.
4.
4.77 Run engine to operating temperature (coolant
temperature 75-79° C) while monitoring
pressures and temperatures.
ADE 360 Series
TECHNICAL DATA — 09-6
LUBRICATING OILS
VISCOSITY GRADES
Ambient Air
Temperature SAE Grades
°C
mm. o
«
o
5S
=£
o
o
1
«
in CM
■
35
in
DUE TO CONTINUOUS DEVELOPMENT, ATLANTIS DIESEL ENGINES ARE CONSTANTLY

REVISING THEIR OIL RECOMMENDATIONS.
TO OBTAIN THE LATEST OIL RECOMMENDATIONS, PLEASE REFER TO OUR SERVICE
BULLETINS, OR CONSULT YOUR NEAREST OIL COMPANY FOR THEIR ADVICE.
ADE 360 Series
SECTION 10-1
Fault Finding
CONTENTS OF THIS SECTION
START
ST ARTER
ER MOTOR
MOTOR T
TURNS
URNS ENGINE T
TOO
OO SLO W LY .......................................................... 10-2
HARD STA
STARTI
RTING
NG WHE
WHENN C O LD ............................................................................................. 10-3
ENGINE TURNS OVE
OVER
R BU
BUTT REFUSES
REFUSES T
TO
O START .......................................................... 10-4
ENGINE DIF
DIFFI
FICUL
CULTT TO S T A R T .............................................................................................. 10-5
ENGINE
ENGI NE LOC K-UP ...................................................................................................................... 10-6
ENGINE CUTS
CUTS OUT AF
AFTER
TER ST A R TIN G ............................................................................... 10-7
E N GI
G I N E O V E R H E A T IN G .......................................................................................................... 10-8
E N G IN f R U N N
NII N G T O O C O L D .............................................................................................. 10-9
ENGINE KNOCKING . . . : .......................................................................................................... 10-10
E NG
N G IIN
N E V IB R A T IO N .................................................................................................................. 10-11
E NG
N G IIN
N E MIS F IR E S ..................................................................................................................... 10-12
LOSS
LOSS OF POW ER ........................................................................................................................ 10-13
BLACK
BL ACK SMOKE FR
FROM
OM E XH AU ST ........................................................................................... 10-14
BLUE
BL UE SMOKE FR
FROM
OM EX H AU ST ........................................................... 10-15
WHITE
WHI TE SMOKE F
FRO
ROM
M EX HA US T ........................................................................................... 10-16
EXCESSIVE FUEL CONSUMPTION ....................................................................................... 10-17
ABNORMAL OIL CONSUMPTION .......................................................................................... 10-18
LOW
LOW OIL PR ES SU RE ................................................................... 10-19
OIL PRE
PRESSU
SSURERE TO
TOOO H IG H ......................................................................................................
10-20
ENGINE
ENGI NE OI
OILL SL U D G E ................................................................................................................ 10-21
F A U L T F IN
I N D IN
IN G - 10-2
COMPLAINT
FAUL
FA ULT
T FINDING
FINDING - 1 0-3
0-3
COMPLAINT
FAULT
FAULT FINDING
FINDING - 10-4
10-4
COMPLAINT
NOTE: Refer also to pages:
10-2) Starter motor turns
engine too slowly
10-5) Engine is difficult to start
10-3) Hard starting when cold
ADE 360 Series
FAULT
FAULT FINDING
FINDING - 10-5
10-5
COMPLAINT
ADE 360 Series
FAULT
FA ULT FINDI
FINDING
NG - 10-6
10-6
COMPLAINT
ADE 360 Series
FAULT
FAULT FINDING
FINDING - 10
10-7
-7
COMPLAINT
ADE 360 Series
FAULT
FA ULT FINDI
FINDING
NG - 10
10-8
-8
COMPLAINT
ADE 360 Series
FAULT
FAULT FINDING - 10
10-9
-9
COMPLAINT
FAULT
AULT FINDING
FINDING - 10-1
10-10
0
COMPLAINT
FAULT
FAULT FINDING - 10-
10-11
COMPLAINT
ADE 360 Series
FAULT FINDING
FINDING - 10-1
10-12
2
COMPLAINT
ADE 360 Series
FAULT FINDING
FINDING - 10-1
10-13
3
COMPLAINTS
ADE 360 Series
F A U L T F IN
IN D IIN
NG - 1 0-
0- 1 4
COMPLAINT
ADE 360 Series
FAULT
FAULT FINDI
FINDING
NG - 10
10-1
-15
5
COMPLAINT
ADE 360 Series
FAULT
FA ULT FIND
FINDING
ING - 10
10-1
-16
6
COMPLAINT
ADE 360 Series
FAULT
FAULT FINDI
FINDING
NG - 10
10-1
-17
7
COMPLAINT
ADE 360 Series
FAULT
FA ULT FINDI
FINDING
NG - 10-1
10-18
8
COMPLAINT
ADE 360 Series
FAULT FINDI
FINDING
NG - 10
10-1
-19
9
COMPLAINT
ADE 360 Series
FAULT
FAULT FINDI
FINDING
NG - 10-
10-20
20
COMPLAINT
ADE 360 Series
FAULT
FAU LT FINDING - 10-
0-21
21
COMPLAINT
__________
__________
SECTION 111
Cylinder Block and Liners

Page
...........................................................................................................................................
INTRODUCTION 11-3
SPECIFICATIONS ........................................................................................................................................ 11-3
CHECKING CYLINDER BORES FOR WEAR ................................. 11-5
REBORING CYLINDER BLOCK ............................................................................................................... 11-6
REMOVING CYLINDER LINERS ............................................................................................................... 11-7
REPLACING CYLINDER LINERS ............................................................................................................. 11-8
CRANKCASE VENTILATION SYSTEM .................................................................................................. 11-11
REMOVING BREATHER ........................................................................................................................... 11-13

REPLACING BREATHER ............................................................................ 11-1411-14
11-1411-14
Ade 360 Series
SECTION 11
Cylinder Block and Liners
CY L INDE R B L O CK
1 R E AR
AR M A I N O
OII L S E A L S 7 GASKET 13 SIDE COVER
2 SUMP 8 TIMING COVER 14 CYLINDER LINER .
3 SUMP GASKETS 9 OIL SEAL 15 CRANKCASE BREATHER
4 MAIN BEARING CAPS 10 COVER 16 CYLINDER BLOCK
5 GASKET 11 GASKET 17 GASKET
6 TIMING GEAR CASE 12 O-RING 18 OIL COOLER
ADE 360 Ser ies
CYLINDER BLOCK AND LINERS — 11-3
INTRODUCTION
The cylinder block is designed to form an integral casting with the crankcase and is manufactured
from high grade cast iron, alloyed with copper and chrome. Utilising the latest in engineering
technology, the cylinder block is machined to very fine
fine tolerances and is subject to a rigorous quality
control inspection.
Interference fit, dry cylinder liners (Sl
(Sleeve
eeves),
s), are fitted to the ADE 364T
364T and 366T/TI
366T/TI.. Engines fitted
with cylind er liners can be identified by a “ Z” , stamped on the cylind er block, to one side of the the
push rod cover.
SPECIFICATIONS
CYLINDER LINER
Nominal diameter T otal hei ght of

Repai r s tages Cy l i nder bore
of cylinder cylinder block
97,510 359,10
S t a n d a r d (N / C / T / T I ) 9 7 ,5 0 — (STD )
-----
97,490 359,00
98,010
R e p s t a g e 1(N ) + 0 , 5 R e b o r e * 9 8 ,0 0
9 7 ,99 0 3 5 8 ,8 0
358,70
Rep stage 1 (N/C/T/T
(N/C/T/TI)
I)
97,510 358,50
R e p s t a g e 2 (N /C /T /T I) 9 7 ,5 0 ’— ( - 0 , 6)
----- 6)
97,490 358,40
358,20
Rep stage 3 (N/C/T/TI) -— ( - 0,9)
------
358,10
*1st Rep stage for naturally aspirated optional I.e. either rebore for oversize piston or fit sleeve.
Line r Parent Bore 100,4355

100,43
100,400
48
Liner Flange Recess — depth ’
4,6
103,626
— di a
103,572
Cylinder Liner O.D. 100495

____________________________________________________________________________________________________ ■ 100,475
Cylinde r Liner Flange O.D.

O.D. 103,
103,428
428
103,375
NOTE 1:
S t a m p e d n u m b e r s a p p e a r o n t h e s i d e o f t h e c y l i n d e r b l o c k f o r e a c h c y l i n d e r . Th
Th e n u m b e r s a r e f o r g r a d i n g p u r p o s e s d u r i n g
production only.
ADE 360 Ser ies
NOTE 2:
It i s es s en ti al to m ac h i ne to a pi s ton c l earanc e depth of at l eas t 250 m m when r ebori ng the 360 S eri e
es
s Natu ral l y as pi rated
engi ne to nex t repai r s tage or for l i ner fi tm ent. (S ee i tem B i l l us trati on bel ow.)
Dimension A = 98,0 -98,3 mm

Dimension B = 25
2511 -2 52 mm
Dimension C = 22 4-2 25 mm
Dimension h i = Block Height from centre of main
bearing bore to joint
face of cylinder head.
(Refer to columns, cylinder

block and cylinder liner
for standard and repair •
stages for blockheight)
Ovality of cylinder bore 0,01

0,01
Taper of cylinder bore 0,01
Vertical deviation of cylinder bores within a
d i s t a n c e o f 2 0 0 m m in r e l a t i o n t o c r a n k s h a f t a x i s 0 ,0 4
Roughness of bore after honing R3Z 3-5 jim R max. 6-11
Leakage test pressure with cylinder block submerged in
200 kPa
water at 70°C
Distortion limit — Length 0,03
Not to exceed 0,015 mm over a distance of 150 mm
Piston protrusion/recession to upper cylinder block + 0,30
surface - 0,088
0,088
Wear limit of bore top piston ring upper return position 0,12
halfway stroke 0,05
Camshaft bearing basic bore 60,030

60,000
Main bearing basic bore ne w 93,022

93,000
limit for repair 93,040

92,970
Ovality of main bearing basic bore 0,01
Taper of main bearing basic bore 0,01
Roughness upper joint face o f cylinder block 8-16
TORQUE SPECIFICATIONS
Oil g allery plugs (front

(front and
andrr e a r ) .................................................. M16x1,5 ............................................... 40-45 N.m
M 1 8 x 1,5 .......
............
..........
..........
..........
...........
............
............
........
.. 70-90 N.m
M20 x 1,5 ............
.................
..........
..........
...........
............
............
........
.. 90-11 0 N.m
C o n n e c t io
io n p l u g f o r t a c h o m e t e r .............................................. M26x1,5 ............................................... 60 N.m
Pushrod cover to cylinder block ............................................... M8 ........................................................... 15 N.m _
Enginem
Engine mounting bracket toc r a n k c a s e ................................... M14x1,5 ............................................... 150-190 N.m
Piston cooling nozzels ................................................................... M10x1 .................................................. 25 N.m
B l a n k in
in g p l u g s ( ffoo r p i s t o n c o o l i n g n o z z e l s ) ......................... M10x1 .................................................. 10 N.m
Sidecover (water jacket) to cylinder ......................................... M8 ........................................................... 25 N.m
ADE 360 Series
CYLIN
CYLINDER
DER BLOCK
BLOCK A ND ^ PER S - 11-5
CHECKING CYLINDER BORES FOR WEAR

In the event of Excessive Oil Consumption and in addi
tion to a visual check, measurements of the cylinder bores
w ill be necessary. Before attempting to m easure the
cylinder bores they should be thorough ly cleaned and free
from oil and carbon deposits.
1. Using com pressed air, clean the top of the cylinder
cylinder
block, (fig. 11-1).
2. Wipe cylinder bores using clean rag. (fig. 11-2).
rr—m f T " “<H It —<~I [mmtras

Fig. 11-2
3. Check cylinder block top face for locali

localised
sed distortion
using a suitable straight edge, (fig. 11-3).
4. Set internal measuring ins trumen t, (fig.
(fig. 111-
1-4)
4)..
ADE 360 Series
CYLINDER BLOCK
BLOCK AND LINER
LINERS
S - 11
11-6
-6
5. Insert measuring instrument into cylinder bores,

(fig. 11-5).
6. Check cy linde r bores at poin ts 1, 2 and 3.

3. The checks
should be made in direction A = Centre line and B
= 90° from centre line, (fig. 11.6).
When pistons are not removed, the measuring point 3 is
ju s t ab ov e th e p is to n at BDC .
REBORING CYLINDER BLOCK FOR OVER

SIZE PISTONS OR FITMENT OF LINERS
1. After the cylinder block has been
been thoro
thoro ugh ly clean
ed it should be securely mounted under the boring
bar, (fig. 11-7).
Fig. 11-7
2. Align and cen tre the boring bar above the cylinder to
be machined.
3. Insert tool into boring bar head and adjust to the re

quired dimension, (fig. 11-8).
A tt en ti o n !
If more than one cyliinder requires boring for liner fitment
t h e f o l l o w i n g s e q u e n c e s h o u l d b e f o l lloo w e d :
Bore cylinders 1-3-5-2-4-6 — (6 cylinder),
2-4-1-3 — (4 cylin der ).
When using this sequence of boring excessive thermal
stress will be avoided.
ADE 360 Series

4. Bore cylind er to 0,05 mm below the ffinal

inal cylinder bore
dimension, (fig. 11-9).
A tt en ti o n !
Machine or surface grind cylinder block top face by 0,3
mm to next block height repair stage, i.e. for oversized
pistons or liner fitm
fitm ent (see specifications) and ensure
correct repair stage pistons are used.
Fig. 11-9
5. Securely mount cylinder block under honi

honing
ng m achine.
Hone cylinder liners to final dimensions, (see
specifications), (fig. 11-10).
6. Before assem bling the engine thorou ghly clean th thee

cylinder block and crankcase inside and out. Blow out
oil galleries
galleries ensuring that no residue from the m achin
ing process is left.
REMOVING CYLINDER LINERS

1. S ecurely mount crankca se under boring machine, (fig.
g.
11 - 11 ).
2. Align and centre bo ring bar above the

the cylinde r to be
machined.
A tt en ti o n!
If more than one cylinder requires boring, the following
sequence should be followed:
Bore cylinders 1-3-5-2-4-6 — (6 cylinder),
2-4-1-33
2-4-1- — (4 cylind er).
When using this sequence of boring excessive thermal
3. Insert tool
tool into boring bar head
head and adjust so that the
cylinder liner will be bored out to approximately half
its former thickness, (fig. 11-12).
ADE 360 Series
4. Re-set
Re-set tool in bori
boring
ng bar head and machine cylinder
liner to 0,2
0,2 mm below ou ter diameter of cylinder liner
(Standard Size).
Size). Bore cylinde r liner and rem ove flanqe,
(fig. 11-13).
At this setting the flange of the liner will

A tt en ti o n !
become detached from the sleeve.
Fig. 11-13
5. Insert boring bar head into cylinde

cylinde r bor
bore,
e, with cutting
tool stationary and in contact with cylinder liner. Move
cutting tool vertically up and down cylinder bore,
allowing cutting tool to break through
through w all of cylinder
cylinder
liner. Remove cylinder liner from cylinder block,
(fig. 11-14).
Fig. 11-14
REPLACING CYLINDER LINERS
1. Thoroughly clean bore for cylinder liner and flange

seat, (fig. 11-15).
2. Mou nt cylinder block under press
press and align
align cylinder
bore.
3. Apply a light coating of grease to bore in cylinder

block.
Fig. 11-15
4. Locate cylinder liner over bore in cylinde r block and

align, using a set square, (fig. 11-16).
Fig. 11-16
ADE 360 Series
CYLINDER BLOCK
BLOCK AND LINERS
LINERS - 11-9
11-9
5. Fit a suitably stepped steel plate between press

head and cylinder liner. Press cylinder liner into
cylinder block until it protrudes approximately 20 mm,
(fig. 11-17).
6. Before pressing liner fully home, check liner flange

and seat for metal particles and dirt. Blow out with
compressed air, (fig. 11-18).
7. Press cylinder liner fully hom e, relieve

relieve pressure for
a short period and press once again, retaining
pressure for 5 seconds.
8. Machine or surface grind cylinde

cylinde r block ttop
op face by
0,3 mm to next block height repair stage (including
protruding cylinder liner) see specifications for re
quired surface finish, (fig. 11-19).
A tt en ti o n !
Before machining observe cylinder block height and
repair stage and ensure correct repair stage pistons
are used. Refer piston compression heigh and block
h e i g h t s p e c i f i c a titi o n s .
9. After machining/surface grinding, check cylinder

block face with a straight edge, (fig. 11-20).
ADE 360 Series
10
10.. After the cylinder block has been thoroug hly clean
ed it should be securely mounted under the boring
bar, (fig. 11-21).
11
11.. Align and centre the boring b ar above the cylinder to
be machined.
12. Insert tool into boring bar head and adjust to the
required dimension, (fig. 11-22).
13. Bore cylind er liner in several stages to 0,050 mm

below the required bore dime nsion, (fig.
(fig. 11-23)
11-23)..
A tt en ti o n !
If more than one cylinder required boring, the following
sequence should be followed:
Bore cylinders 1-3-5-2-4-6 (6 cylinder),
2-4-1-3 (4 cylin de r).
When using this sequence of boring, excessive thermal
14
14.. Remove cylinder block from boring machine.
15. Secu rely mou nt cylinder block under honing mach ine.
Hone cylinder liners to final dimensions, (see
specifications), (fig. 11-24).
16.. Before assem bling the engine thorou

16 thorou ghly clean the
cylinder block and crankcase inside and out. Blow out
oil galleries ensuring that no residue from the machin
ing process is lef*
Fig. 11-24
ADE 360 Series
CRANKCASE BREATHER -
OPERATION AND PROBLEM DIAGNOSIS
Introduction
Depending on application, the crankcase breather may -4

be mounted to the rocker cover, pushrod cover or timing
timing
gear housing, (fig. 25).
The crankcase breather controls the pressure in the
crankcase within a prescribed operating range. The device
is open to crankcase gasses at the lower end (7) with a
conn ection to the indu ction m anifold (4)
(4) and a vent to at
mosphere (3).
Note 1: For proper operation the area around the air vent
(3) must be kept clean to prevent blockage. In addition
all joints,
joints, co nne ctions and oil filler cap must form a tigh
tigh t
seal to prevent crankcase depression losses and/or dirt
entry into the engine.
Note 2: Th e f l e x p o i n t o f t h e b r e a t h e r d i a p h ra
ra g m i s s u b
je c t to d e te ri o ra tio n e.g . ha rd en in g or cr ac ki ng . It is
therefore strongly recommended that the breather be
repl ac ed after ev ery two y ears operati on, as a precau
Fig. 25
tionary measure.
1 — D i aapp h rraa g m
1.0 Operation 2 — Valve
1.
1.11 Atmo spheric pressure acts on the outer surface 3 — Air Vent
of the diaph ragm (1)
(1) via tthe
he vent (3)
(3).. Before sta rt 4 — To Inlet Manifold
up, atmosph eric pressure will also be present in 5 — Oil Drain Hole
the crankcase and induction systems. The 6 — Gauze
pressure on both sides of the diaphragm will 7 — From Crankcase
thus be equal. 8 — Perforated Plates
9 — Spring
1.2 The spring (9) acts against the diaphragm and 10 — ‘O’ Ring
holds the valve (2) off its seat in the open posi
tion. To close the valve, sufficient depression
must occur in the crankcase to allow atmos
pheric pressure acting on the outer surface of
- t h e d ia
ia p h r ag
ag m , t o o v er
er c om
om e t h e s p r iinn g f o rrcc e .
The operation of the breather is therefore mm +
dependent on engine operation.
Q
1.3 At engine idle speeds, the spring force will be
sufficien t to hold the valv
valvee from its seat against
atmospheric pressure acting on the outer sur
face of the diaphragm. Crankcase gasses will
susequently be drawn directly into the combus
tion chambers and w ill be burnt during the com
bustion process.
t
X
1.4 At no rmal operating speeds and loads the ever
changing induction manifold depression acting
within the breather, is higher than the required
t
40 _
crankcase depression. The breather will react to 50 _
the high manifold depression and control
crankcase depression.
e.g.
e.g. Should the crankcase de pression approach
the upper negative lim it in the
the opera ting range, mm-
the valve will move towa rds the closed p osition
to reduce the effect of manifold depression
within the crankcase.
X J Fig. 26
The valve in turn will react when crankcase
depression is reduced towards the lower or OPERATING RANGE
positive limit and will open marginally to allow
the high manifold depression access to the SERVICE SPECIFICATION FOR
crankcase. ALL BREATHERS:
In this manner the breather will continuously
sense and accordingly, respond to manifold + 10 TO - 100 mm H 20
depression under various operating conditions
and thereby, control crankcase depression with
the desired operating range. Note: X — E XA
XA M P L E O N L Y = m a n o m e t e r r e a d i n g - 6 0 m m H 2200
ADE 360 Series
1.5 Crankcase gasses passing via the breather ar aree 3.3 E x c es s i v e pos i ti v e readi ng i s i ndi c ated at al l
oil bearing and most of the oil will be trapped engi ne s peeds .
by the
the gauze
gauze will mesh
return(6). Excess
to the oil notvia
crankcase traped by
a drain CAUSE REMEDY
hole (5) provided in the breather neck.
a ) B ro
ro ke
ke n
n c ol
ol l a ps
ps ed
ed  s
spp riri n g
g —  Re
Re n e w
However, it is normal for a small qu antity of oil,
breather
in the form of mist to be transferred to the in
b) Va lv e  st
s t u ck
ck  iin
n  cl
c lo s e d  —  R ene w
take air to lubricate the valves (3 — 5 g/hr). The
p o s it i o n  b re a th e r
dampness created by the oil fumes is normally
c )
) B l o c
ck
k a g e
e o f b re a th e rr g a u z
ze
e — Washincle
ea
an
evident in the inlet/manifold o f engines utilizing
b y s lu d g e *  d i e s e l If  t h i s
this type of breathing system and is not
fails,
fails, renew
renew
necessarily indicative of a problem.
breather
d) Se v e re  c om
om b us
us titi on
on  g
gaas  —  Re
Re pa
pa irir a
as
b lo w b y  n e ce ss a ry
2.0 Operational Test 'Investigate reaso
reasonfor
nfor sludgeandrectify.
2.1 Park the vehicle on level groun d and ensure that
the oil level is correct (not over-filled). Note 4: As a rule crankcase pressure depression should
remain within the prescribed
prescribed range (+ 10 to -1 0 0 mm H 2
2.2 Use a water ma nom eter (see fig. 26)
26) and conn ect O). If this is not the case and all possible contributing fac
one end of the gauge to the engine dipstick tors have been eliminated, it may be assumed that the
guide tube. The other end of the tube is left open breather is faulty.
to atmospheric pressure. Before starting the
engine ensure that the instrument registers a
zero reading in both columns. 4.0 Conclusion
A faulty crankcase breathing system could result in
2.3 Start and run the engine at idle speed. A ten
t h e f o l l o w i n g p r o b llee m s :
dency towards a negative
negative reading
reading ( - ) shou ld be
4.1
4.1 Excessive oil consum ption.
noted.
2.4 Gradua lly iincrease
ncrease the engine speed ttoo approxi 4.2 Dust entry via — a) A ruptured or punctured
diaphragm,
mately 1 5 0000 r //m
m i n . Th
Th e i n s t ru
ru m e n t s h o u l d
b) A po or seal at the “O ” ring
indicate a negative reading increasing within the
( 10 ),
operating range.
c) Other inlet or crankcase
2.5 Further increase the engine speed to approxi connections, could cause
mately 2 000 r/min.
r/min. The negative reading sh ould serious damage to the
raise within the operating range. This would engine.
indicate that the valve is working.
Note 3: The operational characteristics of a breather will
4.3 A high crankcase pressure could force oil past
depend on the condition of the engine e.g. amount of the crankshaft and turbocharger seals.
blowby.
3 .0 Evaluation of Test Results
3.1 M i ni m al negati v e readi ng at l ow r/m i n wi th
l i ttl e or no c hange at hi gh r/m i n.
C AU S E  REMEDY
a )) G a u
ug
g e  c o n n e cti
cti o n
ns
s  l e a k in
in g  —  S e c u re
re
connections
b) Lea
Leakinvacuum
kinvacuum lineto
lineto —  Che ck and
manifold correct
c) Poor
Poorsealat
sealat breather
breather —  Ch eck /re plac e
mounting O-ringor
gasket
d ) D i a
ap
p h rag
rag m  c ra c ke
ke d /h
/ho
o l ed
ed —  Renew 
breather
3.2 E x c es s i v el y hi gh negati v e readi ng.
CAUSE REMEDY
a) Valvenotclosing
Valvenotclosing —  Che ck b, c, d
below,or
renewbreather
b) Ventholeblocked —  Cle ar and
retest
c) Venthosepinched —  Rep air hose
andretest
d) Forei
Foreignp
gnp articleon —  Rem ove ob ject 
valveseat andretest
e)
e) Diaphra
Diaphragm
gm rupture
ruptured
d —  Rene w
breather
ADE 360 Series
CYLINDER BLOCK
BLOCK AND LINERS - 11-1
11-13
3
REMOVAL AND REPLACEMENT OF

BREATHER
Removal
1. Unscrew clip on pipe leading to inlet manifold,

(fig. 11-27).
2. Remove pipe with c lip, (fig.

(fig. 11-
11-28)
28)..
3. Unscrew clamp on crankcase end of breather pi

pipe,
pe,
(fig. 11-29).
4. Pull off brea ther from m oun ting pipe, (fig. 11-3
11-30).
0).
Fig. 11-30
ADE 360 Series
5. Remove o-rio-ring
ng from the inside of the breather pipe,
(fig. 11-31).
Fig. 11-31
Replacing
1. Fit new o-ring in the bre athe r pipe, (fig. 111-3

1-32).
2).
2. Slide breather with o-ring into place over mo unting

pipe, (fig. 11-33).
3. Align breather to inlet ma nifold and secure clam p over

over
inlet pipe, (fig. 11-34).
ADE 360 Series
CYLINDER BLOCK
BLOCK AND LINERS
LINERS - 11-1
11-15
5
4. Replace pipe leadin
leadin g to the inlet manifold, (fig. 11.3
11.35)
5)..
5. Tighte n clip on the pipe, (fig.

(fig. 11-3
11-36).
6).
ADE 360 Series
" Q aM
aM*ingt
*ington
on Di
Dies
esel
el Cl
Club
ub
ADE 364 and ADE 366
Workshop Manual
Section 12 - Cylinder Head
B o n i n g t o n D i e s el
el C l u b
SECTION 12
Cylinder Head
3 2
1 GASKET (EX XHH A U ST

ST M A N I FO L D ) 12 INLET VALVE 22 ROCKE ER
R S H A FT R E TA IN
IN I N G
2 G A S K E T ( IN L E T M A N IF O L D ) 13 E XHA UST V A LV E GRU B S CREW
3 CYLINDER HEAD GASKET 14 VALVE SPRING ASSEMBLEY 23 ROC CKKE ER
R G EA
EA R
4 C Y L IN
IN D E R H E A AD
D 15 V A L V E C O L LE TS R E T A IN IN G B O L T
5 IN J E C T O R S E A L I N G W A S H E R 16 PU SH ROD 2 4 ROCKER ASSEMBLEY
6 INJECTOR 17 ROCKER COVER GASKET 25 ROCKER SHAFT
7 CYLINDER HEAD BOLT 18 R OC KER COVER C O U P L IN G B U S H *
8 E XH
XH AAU
USST
T VA
VA L VE
VE S EEA A T IIN
N SE
SE RT
RT 19 O IL
IL F IL
IL LE
LE R C A
AP
P (S
(S CR
CR E
EWW TTYY PE
PE ) 2 6 S PR
PR IIN
NG
9 I NL
N L ET
ET V A
ALL VE
VE SSE
E A T IIN
NS EERRT 20 O IILL F
FII L LE
LE R C AP
AP ( C LI
LIP T Y P E )
10 V
VAA L V E G U ID E 21 R OCKER GE AR
11 V A L V E S T E M O IL S E A L R E T A I N IN G B O L T * NOT FITTED ON ADE 364
ADE 360 Ser ies
SECTION 12-1
Cylinder Head
Page
INTRODUCTION ............................................................................................................................... ........ 12-3
SPECIFICATIONS ..................................................................................................................................... 12-3
TORQUES .................................................................................................................................................... 12-6
REMOVING ROCKER COVER 12-7

................................................................................................................
REMOVING CYLINDER HEAD ............................................................................................................... 12-7
CHECKING VALVE RECESSION ........................................................................................................... 12-11
REMOVING VALVES ................................................................................................................................. 12-11
CHECKING VALVE STEM/GUIDE CLEARANCE ................................................................................ 12-12
VALVE FACING .......................................................................................................................................... 12-13
VALVE SEAT FACING ............................................................................................................................... 12-14
REMOVING VALVE GUIDES ................................................................................................................... 12-14
REPLACING VALVE GUIDES ................................. 12-14
CHECKING CYLINDER HEAD ............................................................................................................... 12-16
REPLACING VALVES ..................... 12-16
INJECTOR PROTECTION SLEEVES ..................................................................................................... 12-18^
CHECKING INJECTOR PROTRUSION ................................................................................................. 12-19
REPLACING CYLINDER HEAD ............................................................................................................... 12-20
VALVE CLEARANCE ADJUSTMENT 364 ............................................................................................ 12-23
VALVE CLEARANCE ADJUSTMENT 366 ............................................................................................ 12-24
REPLACING ROCKER COVER ............................................................................................................... 12-24
CHECKING COMPRESSION PRESSURE ............................................................................................ 12-25
SPECIAL SERVICE TOOLS ...................................................................................................................... 12-27
ADE 360 Series
CYLINDER HEAD — 12-3
INTRODUCTION
Utilising the latest in automotive engineering technology, the ADE 360 series cylinder head is of
advanced design common for all cylinders and is manufactured from high grade grey cast iron
alloyed with copper and chrome, and machined to a very high tolerance. The fuel injectors are
mounted within the cylinder head and enclosed by a light alloy rocker cover.
Separate inlet and exhaust manifolds are fitted, providing enhanced gas flow and improved fuel
efficiency.
SPECIFICATIONS
Overall height of cylinder head (new) 92,1

91,9
Minimum height after machining* 90,9
Peak to valley finish of mating surface in (microns) 8,16
Distortion limit over Length of head 0,150
over distance of 150 mm 0,040
Max parallel deviation between upper and lower 0,1
surface
Injector nozzle protrusion 1,6-2,6
Leakage test pressure with cylinder head submerged in 200 kPa
water at 70°C
*Check nozzle protrusion after each machining stage of cylinder hSiad mating surface and correct with nozzle shims if
r e q u i re
re d . W h e n m i n i m u m h e i g h t i s r e a c h e d f itit 1 m m s p a c e r u n d e r r o c k e r p e d e s ta
ta l s .
i§ . ! i z
t
- -------- D -------- ►
I/ALVE SEAT INSERTS
Inlet valve seat insert Exhaust valve seat insert

S ttaa nd
nd aarr d R e p . s t a ge
ge 1 R e p . s t a ge
ge 2 S ta n d a rd R e p . s t a g e 1 Rep. stage 2
OD “D” 4 3 ,8 8 4 4 ,1 8 4 4 ,3 8 3 8 ,0 8 0 3 8 ,3 8 0 38,580
o f v a lv e s e a t i n s e r t 43,87 4 4 ,1 7 4 4 ,3 7 38,070 3 8 ,3 7 0 3 8 ,5 7 0
Basic bore “ D 1” in in 4 3 ,8 2 5 4 4 ,1 2 5 4 4 ,3 2 5 3 8 ,0 2 5 v \ 3 8 ,3 2 5 38.525 ■ /./.--
cylinder head for 4 3 ,8 0 0 4 4 ,1 0 0 4 4 ,3 0 0 3 8 ,0 0 0 '■ 3 8 ,3 0 0 3 8 ,5 0 0
valve seat insert
Interference fit of seat
0,045-0,080 0,045-0,080
insert in cylinder head
Depth “t” of bore 11,2 11,2
in cylinder head 11,0 11,0
Height “ H” of 7,4 6,1
valve seat insert 7,3 8,0
Distance “ t1” between
mating surface of
3,6-3,9 2,9-3,2
cylinder head and face
of valve seat insert
VALVE SEATS
Inlet 30°
Valve seat angle =----------------------------------------
Exhaust 45°
Diame ter “ A” of valve seat 'n^et

'n^et 41’3
with new valve seat inserts after machining ------------------------------------------------------------
Exhaust 35,3
Inlet 1,3-2,4
Width ,,B” : =
----------------
---------------- -----
Exhaust 1,8-3,0
Size “ C” lnlet 3,6

3,6-3,
-3,99
Inspection size ---------------------------------------------------------------------------------------------------------------------------------------- :
--
--
Exhaust 2,9-3,2
Valve rec ess ion* 0,7-

0,7-1,1
1,1
*lf the valve recession is exceeded after machining the valye seat inserts, new inserts must be fitted.
VAL VE SPRI
SPRINGS
NGS
P r e l o a d ed F i n a l L o ad
ID ’ Wire U n l o ad e d Length (1
(1)) Load (N) L e n g t h (2) L o ad (N)
d i a. l en g t h
25,0-25,4 4 ,2 5 6 0 ,5 46,7 285 - 315 35,18 570 - 630
1)(( In installed
1) installed con dition. Corresponds to length with valve closed.
2) -.
-.4n
4n installed con dition. Correspo nds to length with valve opened.
CYLINDER
CYLINDER HE
HEAD
AD - 12-5
12-5
Inlet Exhaust
VALVE GUID
GUIDES
ES
Valve guide Interfer " Clearance of

Valve guide ID length B.ore in ence in valve stem in
S ta g e s OD cylinder cylinder valve guide
Inlet E x h au st I n le t E x h au st head head In le t E xhaust
15,046 15,018
Standard
15,028 15,000
15,146 15,118
Rep. stage 1
15,128 (“B”) (“C”) 15,100 0,010 0,050
9,022* 10,022**
72 67 15,218 to to tt'f
15,246 9,000 10,000
Rep. stage 2 0,046 0,087 0,097
15,228 15,200
15,546 15,518
Rep. stage 3
15,528 15,500
* Wea r limit 9,050 9,050

“ W e a r l im
im i t 1 00,, 0055 0
M a x i m u m o f f c e n t r e o f v al
al v e s e a t t o v a lv
lv e g u i d e 0,04
Maximum cylindrical deviation of valve seat to valve

guide at 42 mm dia for inlet
0,01
34 mm dia for exhaust
“ A ” — R e p l a c e m e n t V a lv
lv e g u i d e i n s t a l la
la t i o n h e i g h t
17,5
17,0
Valve stem/guide clearance

Inlet valve — reading not to exceed 0,2 mm
Exhaust valve — reading not to exceed 0,3 mm
NOTE: Replacement valve guides must be used together with valve stem seals.
VALVES
,. p ,
Dimen “ A” “ B” “ C" “ D” “ E”
sio ns S e at Dia Seat Valve Hei g h t Widt h St em St em Va l v e
(m m ) A ng le C en t r e Head Dia New Mi n Di a H ar d n e s s L en g t h
42,9 2,8 4.3 8,950 140,7

Inlet 30 ° 40 2,1 — HRC
42,7 2,6 3.3 ,8,935 54 140,3
36,10 2,8 4,2 9,940 140,7

Exhaust 4§ ? 34 2,1
35,90 2,5 3,5 9,925 >
t54 r c 14,03
Runout between valve seat and stem 0,03
Runout between valve head and stem - 0,20

Ovality of valve seat 0,01
VALVE ADJUSTMENT 3 6 0 S e rie s 360 S e r ie s

Valve clearance (temperature max, 50°C) N C / T /T I
• I n le t 0 ,4 0 0,40
Exhaust 0,60 0,60
VALVE TIMING
Inlet Open BTDC 15° 15°
Close ABDC 45 ° 25 °
CCO
OO
E xhaust Open . BBDC 67°
Close ATDC 13° 12°
ROCKtRSHAFT/ROCKER
ROCKtRSHAFT/ROCKER ARM
: f—
----------------------------
----------------------------
Basic bore rocker arm 22,052

22,000
22,130
Rocker arm bush
Outer dia. 22,100
Inner dia. 20,021
20,000
19,980
R o c k e r s h a f t d ia
ia
19,967
arance shaft/bore; 0,020-0,054
^TORQUE SPECIFICATIONS
Th e f o l l o w i n g t o r q u e s p e c i f i c a t iioo n s w i l l a p p l y w i t h t h e c o m p o n e n t s l i g h t l y o i llee d .
/.(Maxim
C y l i n d eum
r h estretch
a d b o l tlength
s .......................................................................................
113mm) 1st Stage:

2nd Stage: 60
90 N.mN.m
3rd Stage: 120 - 130 N.m
4tti Stage: 90°-ipo°
Screw plugs to cylinder head .................................................................. ,.M2 4x1 ,5 ..70-
..70-150
150 N.m
>' M30x1,5 ....... 100-200 N.m
iniebto r protection sleeve to cylinder head ........................................ M14xf,5 .

........50 N.m
.....
Injector securing nut to cylinder head .......................................... M 3 4 x 1 ,5

,5 . ..... 70 N.m
......
Rocker cover to cylinder head ................................................................. M8 25 N.m

..........................
v a i y e a d j u s t in
in g s c r e w l o c k n u t ................................................................ M12x1 40 N.m
..................
RoflJ^r shaft pedestal to cylinder head ............................................... M 12 100 N.m

........................
Rocker shaft lock screw to pedestal ..................................................... M6 5 N.m

................... .......
i/Exhaust manifold to cylinder head .......................................................... M 10 ......

........60
.................60 N .m + 90°
. I n l e t m a n i f o l d t o c y l in
in d e r h e a d ................................................................ M8x 1 30 N.m
....................
' (Check at every service)

I Ty r b o c h a r g e r t o e x h a u s t m a n i f o l d 3 6 6 C / Tm ....................................... M 10 ........................ 50 N.m
364C/T .......................................... M10 ......................... 30 N.m
Exhaust flange to turbocharger ................................................................ M8 ......................... 30 N.m
p r e s s u r e d u c t t o t u r b o c h a r g e r ( V - cl
cl a m p )«
)« . ............................................................................. 6 N.m
WÊÈ, 360?i*rìèsS
CYLINDER
CYLINDER HEAD - 12
12-7
-7
REMOVAL OF ROCKER COVER
1. Unscrew and rremove

emove bolts retaining rocker cover,
(fig. 12-1).
Fig. 12-1
2. Lift off rocke r cover, (fig.

(fig. 12
12-2)
-2)..
3. Remo ve gas ket from cylinde r head, (fig. 12-3).

12-3).
Fig. 12-3
¡REMOVING CYLINDER HEAD
Preparation
Clean the entire upper half of the engine, to prevent dirt

entering the cylinder boresjjnd tappet chamber.
1. Drain coolant from radiator and cylinder block.
2. Remove ffuel
uel filters and if fitted,
fitted, power steering pump
(fig. 12-4).
3. Disconnect radiator hoses and dipstick guide tube.
4. Disconnect and remove thermostat housing.
Fi g . 1 2 ^ 7
5. Re move rocke r cover, see page 12-7

12-7..
6. Unscrew and remove clamp s retaining injecto r pipes,
(fig. 12-5).
7. Disconnect outer injector pipe connections on

cylinder head, (fig. 12-6).
8. Using special tool part num ber 404020070

200705,
5, unscrew
and remove injector pipes, (fig. 12-7).
Fig. 12-7
9. Unscrew and remove fuel leak off pipe, (fig. 12-8).
10. Remove injector pipes from cylinder head.

11. U nscrew b olts retaining rocker assem bly, (fi
(fig.
g. 12
12-9
-9).
).
12. Remove rocker assembly (and connecting niple 6

cylinder only).
only).
Fig. 12-9
13. Lift out pushrods. The pushrods should be numbered

to ensure replacement in the original positions, (fig.
12 - 10 ).
14. Remove injector securing nuts, using special tool part

number 40200873, (fig. 12-11).
15. Remove injecto rs from cylinder head,

head, using impact
puller part number 40201076, (fig. 12-12).
Fig. 12-12
LSerW*
A tt en ti o n !
16. Should the injectors not move using impact puller,
use special tool part number 40201063, (tig. 12-13).
17. Disconnect exhaust down pipe.
18. Unscrew bolts and remove exhau st manifold, (if fit

t e d w i t h a t u r b o c h a rg
rg e r , d i s c o n n e c t t u r b o c h a r g e r o i l
feed and drain pipes first), (fig. 12-14).
19. Unscre w bolts and remove

remove inlet manifold , (fig. 12-15)
12-15)..
20. Un screw snd remove cyli
cylinde
nde r head bolts (in revers
reversee
tightenin'^ sequence), (fig. 12-16). See page 12-20.
A DE ': S8 £I i* S*
21. Screw lifting handles, part num ber 40200747

40200747 iinto
nto
cylinder head and lift off from cylinder block. Remove
lifting handles from cylinder head, (fig. 12-17).
Fig. 12-17
22. Remove cylinder head gasket, and clean top of

cylinder block, (fig. 12-18).
7>r ir— ir— \ r -
Fig. 12-18
CHECKING VALVE RECESSION
1. Place special tool part num ber 402402013

01351
51 onto the
cylinder head with the probe of the dial gauge resti
resting
ng
on a valve head. Note reading on dial gauge and check
the remainder of the valves in this manner, ensure
that readings correspond with the specifications,
(fig. 12-19).
REMOVING VALVES as follows:
2. Attach valve spring com pressor, Part No. 40

402006
200679,
79,
to exhaust manifold stud, (fig. 12-20).
Fig. 12-20
CYLINDER
CYLINDER HEAD
HEAD - 12
12-1
-12
2
3. Press down lever of valve spring com presso r aand

nd
remove collets, (fig. 12-21).
4. R emove valve spring cap, valve, spring an d valve

spring seating washer, (fig. 12-22).
Fig. 12-22
5. Turn over cyli

cylinde
nde r head and remove valves.
valves.
Before removing valves, ensure thay are
A tt en ti o n !
numbered in the correct re placem ent seque nce (fig. 12-23
12-23).
).
Do not pin punch or stamp number on the valves as this
may weaken the valve head.
CHECKING VALVE STEM/GUIDE

CLEARANCE
6. Insert valv
valves
es so that the valve heads protrude by 10
mm. Using a magnetic based dial gauge, place the
probe against the outer diameter of the valve head.
Zero the gauge w hilst the valve Is pushed against the
probe. After zeroing the gauge, push the valve away
from the probe and nojp the reading (fig. 12-24). This
procedure must be carried out on all valves. Check
readings against specifications.
ADEI360'Series
VALVE FACING
1. Remove carbon deposits from valves.

2. Check to see if valves can be re-used. Valve ends must
have no surface damage. Valve collet grooves must
not be worn and chromium plating on valve stems
must be without flaws. Burnt valves must always be
replaced.
3. Using V-blocks and a dial gauge, check run out of

valve stems.
stems. Do not attemp t to straighten bent val
valves,
ves,
(fig. 12-25).
4. If nnoo V-blocks and dial gauge is available, a quick

check can be made using a suitable straight edge,
(fig. 12-26).
Fig. 12-26
5. Minor variations in tolerance can be corrected by

refacing on a valve grinder.
6. Adjus t grinding angle to 30° for inlet and 45° for ex
haust, insert valve and clamp directly behind valve
head to avoid vibration (fig. 12-27).
7. Using a low feed rate grind until valve fface

ace is cleanly
cut all round.
8. The valve stem face can bp lightly ground, by locating

the valve stem in the special attachement mounted
on the valve grinding machine, (fig. 12-28).
ADE 360 Serïÿs
VALVE SEAT FACING
1. Place cylinder head on wooden blocks.

2. Insert valve seat facing tool and re-cut seat to 30° for
Inlet and 45° for exhaust, (fig. 12-29).
Cauti on:
Do not cut valve seat diame ter above their maxi:
mum limits, see specifications.
Note: As the replacem ent of valve seats requires the use
of certain specialised equipment, we suggest that this
operation is carried out by an ADE approved engine recon
ditioner. If valve guides need to be replaced new guides
must be fitted before valve seat re-facing.
REMOVING VALVES GUIDES
1. Place cylinder head under a hydraulic press.
2. Using su itable mandrel press out valve guides from

cylinder head, (fig. 12-30).
3. If necessary, ream valve guide parent-bore in cylinder

head to next repa ir stage using special tool Part No.
40200750, (fig. 12-31).
REPLACING VALVE GUIDES
1. Coat new valve

valve guide with graphited oil and position
in cylinder head, (fig, 12-32).
ADE 360 Series
2. Fit 17- 17 ,5 mm spacer from special tool Part No.

40200556 over valve guide, (fig. 12-33).
3. Using mandrel of spec ial tool Part No. 40200

40200556,
556, pr
press
ess
valve
valve guide into cylinder head to the specified installa
tion height, (fig. 12-34) i.e. until flush with spacer.
4. F inish inner diameter of valve guide, using special

reamer part number 40200828 (exhaust), 40209591
(inlet), (fig. 12-35).
"A s.
/**/ <&> _/ ° f J L '» 1 ®) o

ffti if
Pig. 12-35
5. Using a spring tension tester, chec k valve springs and

ensure they conform to spe cification, (fig. 112-2-36)
36).. ■
A0E 360 Series
CYLINDER HEAD - 12
12-1
-16
6
CHECKING CYLINDER HEAD
1. Using a straigh t edge, check surface of cylinde r head

head
for distortion along its length, (fig. 12-37).
2. And acro ss the cylinder head (fig. 12
12-3
-38).
8). If the cylinder
head is found to be distorted, it must be refaced to
the required surface specification and height.
Note: Observe fuel injector protrusion when refacing

cylinder head. Refer to procedure on page 12-19.
REPLACING VALVES
1. Inser t valve stem oil seal item 3 (fig. 12-4

12-42)
2) into sp ecial
tool part number 40202253, (fig. 12-39).
2. Place oil seal onto top Of valve guide and press down
as far as possible, (fig. 12-40).
ADE 360 Series
CYLINDER
CYLINDER H
HEAD
EAD - 12
12-1
-17
7
3. Liberally oil val

valve
ve stem s item 1 (fig.
(fig. 12-
12-42)
42) and insert
valves into cylinde r head. Ensure that the va lves are
inserted in their original positions, (fig. 12-41).
Fig. 12-41
4. Fit valve spring seating wash er (2),

(2), valve spring (4) and
valve spring cap (5), (fig. 12-42).
5. Attach valve spring compressor part number

40200679, to exhaust manifold stud, (fig. 12-43).
6. Press down lever of valve spring com presso r and iinn
sert valve collets, items 6, (fig. 12-42). Release lever
and ensure that the co llets are seated correctly. The
gap between the collets should be identical, (fig.
12-44).
Fig. 12-44
ADE 360 Series
CYLINDER
CYLI NDER HEAD 12-18
INJECTOR PROTECTION SLEEVES
Wh en ov erhauling the cylinder head it is essential that all

t h e i n j ec
ec t o r p r o t e c t i o n s l e e v e s a r e r e m o v e d a n d e x a m i n e d
for corrosion.
Removing
1. U s i n g s p e c i a l t o o l p a r t n u m b e r 4 0 2 0 0 6 2 4 , u n s c r e w an
an d
remo ve all injector protection sleeves, (Fig. 12-45).
2. Exam ine outer surface of pro tection sleeves for corro

s i o n . B a d l y c o r r o d e d s l e e v e s m u s t b e r ep
ep l a c e d .
3. Rem ove all injector protection sleeve O-ring seals from

t h e c y l in
in d e r h e a
add . D O N O T R E - U S E . ( F ig
ig . 1 2 - 4 6 ) .
Replacing
1. A p p l y s i lili c o n grease to new O-ring seals and insert into
cylinder head, (Fig. 12-47).
F i g . 1 2 - 4 7 ____________________________________________
2. Lightly c o a t b o t t o m s u r f a c e o f p r o t e c t iio
on sleeves with a
s i l iic
con sealing comp oun d, (Fig. 12-48).
April ‘96
CYLINDER
CYL INDER HEAD 12-19
12-19
3. I n s e r t s l e e v e s a n d t i g h t e n t o t h e s p e c i f i e d tto
orque, using
special tool part num ber 4020 0624, (Fig. 12-49).
Fig. 12-49
C H E C K I N G F U E L IN
IN J E C T O R P R O T R U S I O N
4. Attach a dial gaug e with a m agnetic base, to the cylin

der head with the probe of the dial gauge resting on the
tip of the injector nozzle.
A t t e n t i o n : N o t e r ea d in g o n d ia l g a u g e an d c h ec k th e
re main der of the injection nozzles in this man ner, en
s u r iin
ng that m easuremen ts correspond with the speci
f i c a t i o n s . T h e d e p t h o f t h e i n j e c t o r s c a n b e a l t er
er e d b y
f i t t iin
ng a thicker o r thinner sealing was her, (Fig. 12-50).
Fig. 12-50
R E P L A C I N G C Y L IN
IN D E R H E A D
Ensu re cylinder head and block faces are clean.
1. Using co mp ressed air, b l o w o u t b o l t h o l e s in

in t o p o f c y 
linder block, (Fig. 12-51).
Fig. 12-51
2. P l a c e n e w c y l i n d e r h e a d g a s k e t i n p o s it
it i o n , (F
(F i g . 1 2 - 5 2 )
i*Q O O C O O O O P o p e a O e
Fig. 12-52
April ‘96
CYLINDER
3. S c r e w l i f ttii n g h a n d l e s , part num ber 4020 0747, onto cy

linder head, and lift into pos ition, (Fig. 12-53).
n e i rr=
=|
■II » s
Fig. 12-53
4. Unsc rew and r e m o v e l i f ttii n g h a n d l e s . L u b r i c a t e t h r e a d s
and grip ar ea o f the cylinder head bolts, (Fig. 12-54:
1 2 - 5 5 ) i n s e r t b o l t s an
an d s c r e w d o w n . Fig. 12-54
Fig. 12-55
5. Tighten cylinder head bolts in four stages (see specifi

cations) by referring to sequen ce diagram below. (Fig.
12-56).
0 ® ® ® ® © ® @ ® ® ® 0
® © ® ® ® ^
ADE 366
ADE 364
Fig. 12-56
April '96
CYLINDE
CYL INDER
R HEAD 12
12-21
-21
6. Insert pushrod s, ensuring t h e y a r e p l a c e d in

in t h e i r o r i g i 
nal positio ns, (Fig. 12-57).
Fig. 12-57
7. Replac e rocker shafts, i n s e r t b o ltlt s b u t D O N O T t ig

ig h t e n ,
(Fig. 12-58).
Fig. 12-58
8. Using special tool part num ber 4 020 2185, insert con
necting nipple between rock er shafts, ( F i g . 1 2 -5
-5 9 ) . Not
r e q u i r ed
ed o n A D E 3 6 4 .
lilies
Fig. 12-59
9. Tighten rocker shaft b o l t s t o t h e s p e c if

if i e d t o r q u e , (Fig.
12-60).
if
frTl FT) fFH fFPi IP » »5
Fig. 12-60
April ‘96
CYLINDER
1 0.
0. Rep lace the fuel injectors and tighten securing nuts to
the specified torque, using special tool part num ber
4020 0873, (Fig. 12-61).
1 1.
1. Re-co nnec t upper and lower i n j ec
ec t o r p i p e s a n d o u t e r
c o n n e c t i o n s . A t t a c h f u e l l e a k - o f f p i p e.
e.
Note: S e a l o u t e r c o n n e c ti
ti o n s w i t h h y l o m a r o r s u i tta
a b l e s e a lla
ant.
Tighten all connections to the sp ecified torque, using special
tool part num ber 4020 0718, (Fig. 12-62).
12. Tighten all fuel leak-off bo lts to th e specified torque,

(Fig. 12-63).
13. Rep lace inlet man ifold fitted new gaskets, and tighten
bolts to the specified torqu e, (Fig. 12-64).
N o t e : I n l e t m a n i f o l d m u s t b e f i tt
tt e d b e f o r e e x h a u s t m a n i - f o l d .
April ‘96
CYLINDER
12-23
14. Rep lace exhaust man ifold with new gasket, and turbo
charg er i f f i t t e d . T i g h t e n al
al l bolts from the midd le out
wards, to the specified torque, (Fig. 12-65).
15. Using a new gasket, a t t a c h e x h a u s t d o w n p i p e to

to m a n i 
f o l d , i n s e r t b o l t s a n d t i g h t e n t o t h e s p e c i f i ed
ed t o r q u e .
16. Fit radiator ho ses and tighten clips, attach dipstick

guide tube.
17. R e p l a c e f u e l f i l t er
er s , and if fitte
edd, p o w e r s t e er
er i n g pump .
Re-tension V-belt. (Fig. 12-66).
V A LVE
LVE C LEA R A N C E A D J U STME N T A D E 3 6 4
1. Insert feeler gau ge between valve ste

emm and rocker arm.
Valve clearan ce is correct w h e n t h e f e e l e r g a u g e s llii d e s
throug h with a slight resistance, (Fig. 12-67).
2. If the valve clearanc e requires adjustm ent, release the

lock nut, adjust valve clearance and tighten the lock nut
wh ile holding the adjusting screw.
Description ADE 364

ADE 366
Engine Crankshaft Inta

ak
ke valve s Exh. valves
position of to be adjusted to be adjusted
cy l i nder N o .1
364 No.1 valve rocking 3,4 2,4
No.1 valve closed 1,2 1,3
April ‘96
CYLINDER HEAD 12-24
V A L V E C LEA R A N C E A D J U STMEN T A D E 3 6 6
1. Insert feeler gaug e between valve stem and rocker arm.

Valve c l e a r a n c e i s c o r r e c t w h e n t h e f e e l er
er g a u g e s l i d e s
through w ith a slight resistance.
2. If the valve clearance requires adjustment, release lock

nut and adjus t the valve clearanc e. Tighten lock nut
w h i l e h o l d i n g t h e ad
ad j u s t i n g s c r e w , ( F i g . 1 2 - 6 9 ).
).
Description ADE 364

ADE 366
Engine Crankshaft I n t ak
ak e v a l v e s Exh. valves
position of to be adjusted t o b e a d j u s ttee d
cylinder No.1
366 No. 1 valve rocking 3,5,6 2,4,6
No. 1 val ve closed 1 ,2,4 1,3,5
REPLACING ROCKER COVER
1. C h e c k s u r f a c e o f r o c k e r c o v e r f o r d a m a g e , (F
(F i g . 1 2 - 7 1 ))..
2. Fit new rocker cover gasket to cylinder head, (Fig
12-72).
Fig. 12-72
April ‘96
CYLINDER
12-25
3. P l a c e r o c k e r c o v e r i n p o s i t i o n , i n s e r t b o l t s an
an d t i g h t e n
to the specified torque, (Fig. 12-73).
4. Replac e therm ostat ho using and tighten bolts to the
5. Fill radiator with coolant, start engine and run to opera-
Fig. 12-73
C HEC KIN
KIN G C OM P R ESSI ON
1. Rem ove rocker cover.
2. C h e c k v a l v e c l e a r a n c e , ( s e e p a g e 1 2 -2
-2 3 ) .
3. Replac e rocker cover.
4. Run engine u n ti
ti l operating tem peratu re is reached
(70-95).
5. Ensu re that the battery is in a good condition.
6. Rem ove rocker cover, injectors and sea

all i n g w a s h e r s .
7. S e t i n j ec
ec t i o n p u m p c o n t r o l t o s t o p p o s i t i o n .
Fig. 12-74
Testing
1. I n s e r t in
in j e c t o r s e a l i n g w a s h e r , ( F i g . 1 2 - 7 4 ) .
2. Inse
err t a d a p t o r ffo
o r t h e c o m p r e s s i o n tte
ester (part number
4020 0 789 ) in the cylind er head and tighten with injector
securing nut, (Fig. 12-75).
Fig. 12-75
3. Attach com pressio n tester extension to adaptor, ( F iig

g.
12-76).
4. Check compression at an e
enngine speed o f approxima
t e l y 1 8 0 - 2 0 0 r / m i n ( s t a r t e r s p e e d ) w i t h t h e t h r o t t l e in
in t h e
closed position. T u r n t h e e n g i n e u n t iill t h e t e s t i n d i c a to
to r
s t o p s r i s i n g . R e p e a t t h i s p r o c e d u r e f o r a l l c y l in
in d e r s .
5. Rem ove compression tester and a

add a p t er
er .
6. Replac e sealing wash ers, injectors and leak off pipes,

tighten to the specified torque.
Fig. 12-76
April '96
CYLINDER
7. Rep lace rocker cover and tighten bolts to t h e s p e c if
if i e d
torque, (Fig. 12-77).
April ‘96
SPECIAL TOOLS FOR THIS SECTION

OB TAIN ABL E FROM: GRUND Y-TECH NIFORM , BURMAN ROAD, DEAL P
PARTY
ARTY ESTATE PORT
ELIZAB ETH 600
60011 '
Split ring spanner for

injector pipes,
(see fig. 12-7)
Part Number 40200705
Socket for injector securing

nuts
(see fig. 12-11, 12 -61 )
Fuel injector
Impact extractor
(see fig. 12-12)
Extractor for injectors

(see fig. 12-13)
,c Lifting handles cylinder head

(see fig. 12-17, 12-53)
VALVE DEPTH GAUGE

(see fig. 12-19)
ADE 360 Series
en
Valve spring compressor
(see fig. 12-43)
Part Num ber 4020067

402006799
40200682
Reamer for valve guide

parent bore in cyl./head
13,5 x 15,5 m m
(see fig. 12-31)
o T^
Valve guide replacement
mandrel
(see fig. 12-33, 12-34)
Reamer
(see for exhaust valve guides
fig. 12-35)
Reamer for inlet valve guides

(see fig. 12-35)
Valve stem seal

replacing tool
(see fig. 12-40)
Removing/Replacing tool for

injector protection sleeves
(see fig. 12-45, 12-49)
Pliers rocker shaft

coupling bush
(see fig. 12-59)
ADE 366N/C/T/TI
366N/C/T/TI only
ADE 360 Series
C r o w f o o t  r i ng
ng  s c a n n e r  R e m o v e ' 
Replacementof miectorpipes
s
( s e e
e f i g
g 12 -6
-6 2)
2)
PartN umber 4020071

18
8
A d a p t o r f o r c o m p r e s s io
io n
tester.
(see fig. 12-75)
PartN umber 4020
00
0789
A
Att
tt en ti o n!
As we recommend that the removal and replacement of valve seats should only be carried out by an ADE Approved engine
rebuilder, the use of these three spec ial tools
tools is not illustrated in the ttext.
ext. These special tools are however obtainable
f r o m G r u n d y - Te c h n iiff o r m .
ADE 360 Series
______
_________
______
____
_ SECTION 13
Piston and Connecting Rods
CONTENTS OF SECTION 13
Page
ILLUSTRATION .................................................................................................................................................................................................................................... 13-2
INTRODUCTION ................................................................................................................................................................................................................................. 13-3
SPECIFICATIONS .............................................................................................................................................................................................................................. 13-3
R E M O V I N G P I S TO
T O N S A N D C O N N E C T IN
IN G R O D S ...................................................................................................................................................... 13-5
R E M O V I N G P IS
IS T O N R I N G S ....................................................................................................................................................................................................... 13-6
CHECKING BIG-END BEARINGS ............................................................................................................................................................................................ 13-7
CHECKING PISTONS AND PISTON RINGS .................................................................................................................................................................... 13-11
R E P L A C I N G P IS
IS T O N S A N D C O N N E C T I N G R O D S .................................................................................................................................................... 13-13
S P E C IA
IA L T O O L S ................................................................................................................................................................................ ' ...................... 1 3 - 1 6
April '96
Piston and Con nec tin g R

Rods
ods 13
13-2
-2
1. SMA LL END BUSH 6. COM PRESS ION RING
2. CONN ECTING ROD 7. CO MPR ESSION RING
3. C O N N E C T I N G R O D B O L T S 8. OIL SCRAP ER RING
4. BEARING SHELLS 9. PISTON
5. CIRCLIPS 1 0.
0. GUD GEO N PIN
Apr il '96
PISTONS AND CONNECTING RODS 13

13-3
-3
INTRODUCTION
T h e l iig
g h t a llll o y p i s t o n s u s e d h a v e t h e c o m b u s t i o n c h a m b e r c a s t in
in t h e p i s t o n c r o w n . T w o c o m p r e s s i o n a n d one oil control
r i n g a r e fi
fi t t e d t o t h e p i s t o n s w i t h t h e t o p c o m p r e s s i o n r i n g r e t a in
in e d i n a n A l - ffii n b o n d e d i n s e r t . G u d g e o n p i n s a r e t u b u l a r t o
r e d u c e w e i g h t a n d a r e l o c a t e d i n t h e p i s t o n s b y c i r c l ip
ip s . C o o l i n g n o z z l e s ar
ar e f i t te
te d t o a s s i s t w i t h p i s t o n c o o l i n g o f t u r b o 
charged engines.
Forged steel connecting rods are used with serrated mating surfaces betw een the connecting rod and the cap to provide
i n c r e a s e d r i g i d i t y a n d t o e x t e n d b e a r i n g l i f e.
e. T h e b i g - e n d b e a r i n g s h e l l s a
arr e s t e e
ell b a c k e d a n d l i n e d w i t h a l u m i n i u m / t i n . T h e
s m a l l - e n d b u s h i s m a n u f a c t u r e d f r o m a h i g h q u a l i t y p h o s p h o r b r o n z e a n d s e a t s in
in a n i n t e r f e r e n c e f it
it i n t h e c o n n e c t i n g r o d
With the cylinder head and su mp removed, the pistons can ea

assily be withdrawn from the top of the cylinde
err b l o ck
ck .
P I STON S A N D C ON N EC TI N G R OD S
R e p a ir s t a g e s N o m in a l P is t o n C o m p r e s s i o n h e i g h t **
** Block height
diameter
Standard N/C/T/TI 97,5 62,80 to 62,86 358,82 to 359,07 (STD)
R e p 1 N + 0 ,5 R e b o r e * 9 8 ,0 0 62,50 to 62,56 358,52 to 358,77 (-0,3)
Rep 1 n / c /t / t i 97,5
R e p s t a g e 2 N /C /T /T I 9 7 ,5 62,20 to 62,26 358,22 to 358,47 (-0,6)
R e p s t a g e 3 N /C /T /T I 9 7 ,5 61,90 to 61,96 357,92 to 358,17 (-0,9)
*
1 s t r e p a i r s t a g e f o r n a t u r a l l y a s p i r a t e d o p t i o n a l , i . e.
e. e i t h e r r e b o r e f o r o v e r s i z e p i s t o n o r f i t s l e e
ev
ve.
■ m e a s u r e m e n t f r o m g u d g e o n p i n c e n tr
tr e t o p i st
st o n t o p
p..
M a x w e i g h t v a r i a t iio
on between pistons 20g
Gudgeon pin diameter 35,995 to 36,000
Gudgeon pin bore diameter 36,002 to 36,007
Gud geon pin to piston bore clearance 0,002 to 0,012
Piston protrusion at TDC to block surface 0,170 to 0,580
N o te: T h e c o d e s B A 0 9 o r B C 0 1 a p p e a r o n t h e p i s tto
o n c r o w n s . T h e s e a r e g r a d in
in g c o d e s f o r p r o d u c t iio
on only.
PISTON RINGS
360N/C/T/TI Type S i d e C l e a r a n ce
ce G ap
1 Keystone 0,042 to 0,097 0,20 to 0,35
2 T a p e r e d f a c e c o m p res s io n 0,060 to 0,095 0,20 to 0,35
3 O i l c o n tr o l (s p r i n g e x p a n d e r ) 0,030 to 0,065 0,25 to 0,40
Attention : Ga p a n d s id e c le a ra n c e a re e q u a l to a b o v e in a ll b o re re p a ir s ta g e s .
Apr il '96
Piston and
and Connectin g Rods 13-4
13-4
C O N N E C T IN
IN G R O D
Repair size C o n n e c t i n g r o d b e a r iin

ng d iameter Connecting rod width
. ins talled Big end S m a l l en
en d
Standard 60,056 to 60,095
S t a n d a r d 1 (-
(- 0 , 1 ) 59,956 to 59,995
Standard 2 (-0,25) 59,806 to 59,845 37,730 to 37,830 35,5 to 35,6
Rep 1 (-0,5) 59,556 to 59,595
Rep 2 (-0,75) 59,306 to 59,345
Rep 3 (-1,0) 59,056 to 59,095
Connecting rod big end basic bore 65,000 to 65,019
T a p e r o f b i g en
en d b a s i c b o r e 0,005
B ig en d b e a r in g c l e a r a n c e rad ial 0,041 to 0,100

axial 0,10 to 0,40
L e n g t h o f c o n n e c t i n g r o d b e t w e e n c e n t r e s o f bi
bi g e n d a
annd sm all e
ennd 230,00 to 230,05
W e i g h t v a r i at
at i o n b e t w e e n c o n n e c t i n g r o d s f o r r e p a i r 40g
M a x . p a r a l l e l d e v i a t i o n b e t w e e n c e n t r e l i n e o f b i g en
en d a n d s m a l l e n d 0,010
B ig en d b e a r in g c r u s h 0 ,0 4 to 0 ,0 7
SMALL END
Sm all end basic bore in conn ecting rod standard 39,000 to 39,025
R e p 1 ( 1 -0
-0 , 2
2)) _____________________________ 3 9 , 2 0 0 t o 3 9 , 2 2 5
Rep 2 (+0,5) 39,500 to 39,525
Sm all end bush I n n e r d i a m e t e r i n s t a l l ed

ed _________________ 3 6 , 0 3 0 t o 3 6 , 0 4 0
T a p e r / o v a l i t y t o l e r a n c e _________________ 0 , 0 0 2 _____________
I n t e r f e r e n c e f i t ___________________________0 , 0 2 0 t o 0 , 0 7 5
Clearanc e to gudgeon pin 0,030 to 0,045
Connecting rod bolts .............................................................................................................. 1 s t s t a g e .......................................... 4 0 - 5 0 N m

........................................................................................................................................................... F i n a l .................................................... + 9 0 ° - 1 0 0 °
........................................................................................................................................................... S t r e t c h l i m i t .................................... 5 6 ,,8
8 mm (M12)
P i s t o n c o o l in
in g n o z z l e s - u p t o e n g i n e n o.
o. S A 0 7 0 9 0 0 V .................................. M10 x 1 ............................................. 25 Nm
f r o m .e n g i n e no
no . S A 0 7 0 9 0 1 V .................................. M10 x 1 ............................................. 15-18 Nm
Apr il '96
PISTONS AND CONNECTING RODS 13-

13-5
5
RE MO V I NG P I S TO
TONS
NS A ND CO NNE CTI NG RO DS
( C y l i n d e r h ea
ea d a n d s u m p r e m o v a l )
Removing
1. Using a suitable scraper, remov e ca

arr b o n d e p o s i t s f r o m
top of cylinder bores, (Fig. 13-1).
Fig. 13-1
2. Un screw retaining bolts and remove piston c o o lili n g

n o z z l e s , 3 6 0 C / T / T I , ( F i g . 1 3 - 2 ).
).
3 6 0 N e n g i n e s h a v e c l o s i n g p l u g s i n p l a c e o f n o z z le
le s .
3. Unsc rew conn ecting rod bolts and remov e bearing
caps , (Fig. 13-3).
A tten tio n ! B ea r in g c a p s a n d c o n n ec t in g ro d s a r e m ar k ed as
m a t c h e d p a i r s (n
(n o t e n u m b e r s b e f o r e a
asssembly).
4. R e m o v e p i s t o n s a n d c o n n e c t iin
n g r o d s f r o m t o p o f c y l iin
n
der block, (Fig. 13-4).
Fig. 13-4
Piston and
and Connecti ng Rods 13-6
13-6
5. Rem ove b e a r i n g s h e l l s f r o m c a p an
an d c o n n e c t i n g r o d s ,
if the old bearing shells are to be used again, mark
shells to ensure replacem ent in the original position,
(Fig. 13-5).
R e m o v a l o f P i s t o n R i n g s / P i sstt o n f r o m C o n n e c t i n g R o d s .
1. Clam p conn ecting rod and piston assem bly in a vice,

fitte
edd with pro tective jaws , (Fig. 13-6).
Fig. 13-6
2. Turn adjusting screw of ring expander, p art num ber

4 0 2 0 0 3 0 7 , t o a p p r o x . 9 8 m m , ( F i g . 1 3 - 7 ).
).
3. Rem ove piston rings at this setting, (Fig. 13-8).

Fig. 13-8
Apr il '96

13-7
-7
4. Rem ov e c i r c l iip
ps from piston, push out gudgeon pin
and rem ove piston fro m connecting rod, (F
Fii g . 1 3 - 9 ))..
Fig. 13-9
Checking Big End Bearings
1. Clean conn ecting rod and bearing cap surface, (Fig.

13-10).
Fig. 13-10
2. Fit big end bearing cap and insert bolts, (cap and
c o n n e c t i n g r o d n u m b e r s a l i g n e d ) , (F
(F i g . 1 3 - 1 1 ) .
Fig. 13-11
3. Tighten conn ecting rod bolts to the sp ecified torque,

(Fig. 13-12).
III:
I : A» i
Fig. 13-12
Apr il '96
Piston and
and Connectin g Rods 13-8
13-8
4. Using an internal m easuring ins trum ent check big end

parent bore in three places, (F ig.13-13).
Fig.13-13
5. Using an internal m easurin g instrum ent check bore of
the small end bush , (Fig. 13-14).
A tten tio n ! If t h e s m a ll en d bush in n er d i a m e t e r d o es no t
m eet the specification, the bush m ust be pressed out a annd

r e p l ac
ac e d . W i t h t h e s m a l l e n d b u s h r e m o v e d , c h e c k t h e p a r e n t
bore and, if necessary , m achin e to the 1st repair s t a g e.
e.
Standard and ov ersize outside diameter sm all end bushes
h a v e a n u n f i n is
is h e d i n n e r d i a m e t e r w h i c h mu st be reamed to
the specified size after installation. Wh en fitting a new small
e n d b u s h t o t h e c o n r o d , a l u b r i c a t i n g h o l e m u s t b e d r i llll e d a f t e
err
t h e b u s h i s f it
it t e d . R e a m i n g o f t h e b u s h c a n now be carried
out.
■nu ra=
Fig. 13-14
6. Mou nt th e c onnecting rod in an alignm ent gaug e and

check for bending, (Fig. 13-15).
7. C h e c k f o r t w i s t i n g , ( F i g . 1 3 - 1 6 ).
).
W AR NING! Under no circumstances should any attempt be

m ade to straighten a bent connecting rod. Con necting rods
that do not conform to s p e c i f iic
cations must always be
replaced.
Fig. 13-16

13-9
-9
8. Unsc rew conn ecting rod bolts and remove b e a r iin

ng
caps, (Fig.13-17).
9. Fit b e a r i n g s h e l l s in
in t o c o n n e c t i n g r o d a n d b e a r i n g c a p .
Ensu re that the locating tabs are fitte
ed
d correctly, (Fig.
13-18).
1 0.
0. Fit bearing cap to the connecting rod, (numb ers on the
bearing c a p a n d c o n n e c t i n g r od
od a l i g n e d ) . Clam p con
necting r o d iin
n a v i c e f it
it t e d w i t h protective jaw s, (Fig.
13-19).
11. Insert bolts an d tighten to th e specified torque, (Fig.
13-20).
Fig. 13-20
Apr il '96
Piston and Conn ecti ng Rods

Rods 13-1
13-10
0
12
2.. Using an internal m easuring instru men t c h e c k b ig
ig e n d
bearing bo re in three places, (Fig, 13-21).
Checking the Bearing Crush
13. Moun t the conn ecting rod in a vice fitte

edd with soft jaws.
Fit th e b e a r i n g s h e l l s in
in t o b e a r i n g c a p a n d c o n n e c t i n g
rod. Insert bolts and tighten to the specified torque.
A t t ac h a d ia l g a u g e w it h a m a g n e t ic b as e to t h e v ic e,
with the probe resting on the undersid e of the bearing
cap, and set the gau ge to “0". Loosen the big e
ennd bolt
nearest to the dia
all g a u g e , n o t e t h e r e a d i n g o n t h e g a u 
ge. The figu re will represen t the bearing crus h and
should be com pared with the s p e c i fi
fi c a ti
ti o n ,
(Fig. 13-22).
14. U nscr ew the conn ecting rod bolts and using a vernier
g a u g e , c h e c k b o l ts
ts f o r s t r e t c h , refer to specifications,
(Fig. 13-23).
15. C onnec ting rods and bearing shells should be marked

to ens ure replacem ent in the original position, (Fig,
13-24).check remaind er of connecting rods as above.
Fig. 13-24
Apr il '96

13-1
-11
1
CHECKING PISTONS AND PISTON RINGS

Before checking p istons, piston rings a
annd gudg eon pins,
ensure that the piston and piston ring grooves are clean and
free of carbon d e p o s i t s . C a r e s h o u l d b e t a k e n t o e n s u r e tth
hat
the piston ring grooves are not dam aged during cleaning.
A tte n tio n ! In al l c a s e s p is to n s an d t h ei r as s o c ia te d g u d g eo n
p i n s a r e c o n s i d er
er e d t o b e m a t c h e d p a i r s . W h e n d i s m a n t l in
in g ,
these items m ust be marked, so that d u r in
in g assem bly the
m arkings co rrespond , and the parts are returned to their
original position.
1. Pistons and rings sh ould be remo ved as detailed on

page 13-8.
2. W hen c lean, check pistons carefully before re-use.
3. Using an internal measuring instrum ent, check the

gudg eon pin bo re in the piston, (Fig. 13-25) and
4. Using a microm eter, check the outer diameter of the

gudg eon pin, (Fig. 13-26).
5. Insert a piston ring into the cylinder bore and using a

piston, push the ring squarely down into the cylinder
bore to a depth of approxim ately 3 0 m m f r o m t h e tto
op,
(Fig. 13-27
Apr il ‘96
Piston and
and Connect
Conn ecting
ing Rods 13-1
13-12
2
6 Meas ure t h e e n d g a p o f t h e p i s t o n ri
ri n g a n d r e p e a t t h i s
p r o c e d u r e w i t h th
th e r e m a i n i n g r i n g s . R i n
ngg gaps m ust be
within the specified limits, (Fig. 13-28).
Note: With the pistons removed a care

eff u l e x a m i n a t iio
on should
be mad e of the cylind er bore for w ear and localised seizure.
7. Re-fit p i s t o n s t o c o n n e c t i n g r o d s , c l e a n c a r b o n a n d o ilil
deposits from piston ring grooves. Ens ure that the
groov es are not damag ed, (Fig. 13-29).
Fig. 13-29
8. R e p l a c e a l l p i s t o n r i n g s u s i n g ri
ri n g e x p a n d e r , p a r t n u m 
ber 4020 0307, (Fig. 13-30).
9. C h e c k c l e a r a n c e o f p i s t o n ri
ri n g s i n t h e g r o o v e s , r e p l a c e
piston an d/or rings that do not conform to specifica
tions , (Fig. 13-31).
Apr il '96
PISTONS AND CONNECTING RODS 13-13

13-13
R E P L A C I N G P I S T O N S , P IS
IS T O N R I N G S A N D C O N N E C T I N G
RODS
1. Clam p conn ecting rod in a v ice fitte

ed
d with protective
j aw s , w it h th e e lo n g at ed s id e to th e r ig h t (i n je c ti o n
pum p side) as indicated by arrows. Place piston on
conn ecting rod, w ith the arrow on the piston crown
f a c i n g f o r w a r d a s i n d i c a t e d , ( F iig
g. 13-32).
Fig. 13-32
2. Insert gudgeon pin and secure with c i r c lili p s , (Fig.

13-33).
m u /©
©==
Fig. 13-33
3. Replac e p i s t o n r i n g s , u s i n g r in
in g e x p a n d e r p a r t n u m b e r
4020 0307, s tagger piston rings, which m ust rotate
freely in the groov e, 180° each side of the gudgeon
pin, (Fig. 13 -34).
Fig. 13-34
4. L u b r i c a t e p i s t o n r i n g s w i t h e n g i n e o i l,
l, ( F iig
g. 13-35).
mu *e=
Fig. 13 35 ._____________________________________
Apr il ‘96
Piston
Piston and
and ConnectingRods 13
13-1
-14
4
5. Position ring squ eezer over piston rings and comp ress
so that the sleeve will just mo ve (Fig. 13-36).
6. Lubr icate big end bearings a

annd cranksh aft journal with
e n g i n e o i l,l, ((F
Fig. 13-3 7).
7. Insert co nnecting rod and piston into cylinder bore,

w i t h ar
ar r o w on p i s t o n c r o w n p o i n t in
in g towards the front
of the engine, (Fig. 13-38).
8. Push piston down into cylinder bore and guide the con
necting rod until the big en
en d bearing con tacts tth
he
c r a n k s h a f t j o u r n a l , (F
(F i g . 1 3 - 3 9 ) .
Fig. 13-39
PISTONS AND CONNECTING RODS 13-1

13-15
5
9 Lub ricate big end b earing cap with e n g i n e o i l,

l, ( F i g .
13-40).
10. F i t m a t c h e d b i g e n d b e a r i n g c a p tto
o connecting rod and
insert bolts (Fig. 13-41).
11. Tighten big end bearing bolts to the specified torque,

(Fig. 13-42).
Fig. 13-42
12. Insert piston cooling nozzles ensuring that locating p

pii n
on nozzle body a l i g n s w i t h d r i l lili n g i n o i l g a l l e r y , ( A D E
360C /T/TI only), (Fig. 13-43), insert bolts and tighten
to specified torque. (In 360N engines fit plugs and tor
que to specification).
Apr il '96
Piston and
and Conn ecti ng Rods
Rods 13-1
13-16
6
SP EC I A L TOOLS F OR SEC TI ON 1 3
OBTA INABLE FROM G RUN DY TECHN IFORM, BURMA N ROAD, DEAL PARTY EST
TAATE, PORT ELIZABETH 6
60001
Apr il '96
_________
_________ SECTION 14
Crankshaft and Main Bearings
Page
ILLUSTRATION ;
.................................................................................................................................................................................. ................................................ 14-2
INTRODUCTION ................................................................................................................................................................................................................................. 14-3
SPECIFICATIONS .............................................................................................................................................................................................................................. 14-3
R E M O V I N G V IB R A T I O N D A M P E R ......................................................................................................................................................................................... 14-5
R E P L A C I N G V IB
IB R A T I O N D A M P E R ........................................................................................................................................................................................ 14-5
REMOVAL OF CRANKSH AFT .................................................................................................................................................................................................... 14-6
G R I N D IN
IN G C R A N K S H A F T ........................................................................................................................................................................................................... 14-8
C H E C K I N G B E A R IN G A N D P A R E N T B O R E S ................................................................................................................................................................ 14-10
CHECK ING BEARINGS AND HOUS ING ............................................................................................................................................................................. 14-10
REPLACING REAR MAIN BEARING OIL SEAL ............................................................................................................................................................. 14-13
R E P L A C IN
IN G C R A N K S H A F T ........................................................................................................................................................................................................ 14-16
S P E C IA
IA L T O O L S F O R S E C T I O N 1 4 .................................................................................................................................................................................... 14-19
April '96
Cranks haft and

and Main
Main Bearin
Bearin gs 14-2
14-2
15
C R A N K S H A FT A S S E M B L Y
9 CRANKSHA FT GE
EAAR
1 B E A R IN
IN G R E TA
T A IN
IN E R 10 SPACER
2 SPIGOT BEARING 11 VIBRATION DAM PER
3 BOL T 12 CENTERING RING
4 FLYWHEEL 13 PULLEY
5 BOL T 14 BOLT
6 BALANCE W EIGHT 15 CRANKSH AFT MAIN BEARINGS
7 CRANKSHA FT
8 WO ODRUFF KEY
Apr il ‘96
Cranks haft and Ma

Main
in Bearings
Bearin gs 14-3
14-3
INTRODUCTION
The cranks haft is precision forged, induction hardened and sup ported by seven three-layer b earing shells on ADE 360
a n d f i v e o n A D E 3 6 4 . A t h r u s t b e a r i n g i s f i t te
te d t o t h e n u m b e r 4 m a i n b e a r i n g . S e p a r a t e a n d d e t a c h a b l e b a l a n c e w e i g h t s
are bolted to the crankshaft.
SPECIFICATIONS
C R A N KSHA F T
Repair size Ma i n bea ri ng Width for Conrod bearing Width Dia for rear
(diameter) jo u rn al di a. thrust bearing jo ur na l d ia m et er rope seal
Standard 8 7 , 9 9 t o 8 8 , 01
01 3 2 ,0 0 0 to 5 9 ,9 9 5 t o 6 0 , 0 1 5 90,874
S t a n d ar
a r d 1 ( - 0,
0, 1 ) 87,89 to 87,91 3 2 ,0 6 2 5 9 ,8 9 5 t o 5 9 , 9 1 5 37,93 to
Standard 2 (-0,25) 87,74 to 87,76 32,300 to 32,362 59,745 to 59,765 to 90,928
R e p a ir
i r 1 ( - 0,
0, 5 ) 87,49 to 87,51 (+0,3) or 59,495 to 59,515 38,13 90,554 to 90,508
R e p a i r 2 (-0 ,7 5 ) 8 7 , 2 4 t o 87
87 , 2 6 3 2 ,5 0 0 to 3 2 ,5 6 2 59,245 to 59,265 90,234 to 90,288
R e p a ir 3 (-1 ,0 ) 8 6 , 9 9 t o 8 7 ,0 1 (+ 0 ,5 ) 58,995 to 59,015
M a i n a n d b i g e n d jo
jo u r n a l h a r d n e s s HRC 56 ± 3
M i n j o u r n a l h a r d n e s s o n a t l e a s t 2 //3
3 of circumference HRC 46
(for repair only)
Max. m ain and big end journ al taper 0,005
Max. m ain and big end journal ovality 0,01
Max. cranks haft run out with cranksh aft turning 4 cylinder journ al 3 0,11
o n o u t e r jo
jo u r n a l s 6 cylinder journal 4 0,15
P a r a l l e l i s m o f b i g en
en d j o u r n a l s t o m a i n jo
jo u r n a l s 0,01
Lateral run ou t at thrust faces 0,02

M a x r u n o u t o f f ly
ly w h e e l f l a n g e w i t h c r a n k s h a f t t u r n i n g o n Lateral 0,03
outer journals Radial 0,03
R ad ii o n th ru s t b ear in g jo u r n al m in im u m 3,75
E n d f l o a t (t
(t h r u s t b e a r i n g ) 0,190-0,290
Main bearing clearance Radial (thrust bearing) 0,050-0,108
R a d i a l (o
(o t h e r m a i n s ) 0,042-0,108
T o r q u e t o t u r n c r a n k s h a f t w i t h n e w s e a l s a n d b e a r i n g s f i tt
tt e d 12 Nm
Rear crank shaft s e a l (r

(r p p e t y p e ) p r o t r u s i o n a f t e r i n s t a l l at
at i o n 0,5 to 0,8
M a i n / B i g e n d jjo
our nal surface finish (l a p
pppe
edd) R a 0 ,2
,2 p
pmm
R. max 2 pm
M a x . i m b a l a n c e o f c r a n k s h a f t w i t h c o u n t e r w e ig
ig h t s 30 cmp
( w i t h o u t f lly
yw heel) running on outer main bearings
Apr il ‘96
Crankshaft and
and Main
Main Bearings 14-4
14-4
CRANKSHAFT MAIN BEARINGS
Repair size (diameter) Ma i n bea ri ng Thrust bearing width

di a . i ns ta l l ed
Standard 88,052 to 88,098 Std. 31,74 to 31,81 (std)
Standard 1 (-0,1) 87,952 to 87,998 Std.1 & Std.2
Standard 2 (-0,25) 87,802 to 87,848 32,04 to 32,1
111
Rep air 1 (-0,5) 87,552 to 87,598 Std.2 & all (+0,3) or
Repair 2 (-0,75) 87,302 to 87,348 repair stages 32,24 to 32,31
Repair 3 (-1,0) 87,052 to 87,098 (+0,5
TOR QU E SP EC I F I C A TION
TION S
Balance weight to cran ksh aft M 1 2 x 1 ,5

,5 In i t ia l........................
l...............................
................
.................. 3 0 - 4 0 N m
F i n a l ......................................... ......... p llu
us 90°-110 °
M a x . s tret c h len g t h 4 5 ,3 m m
Flywheel to cran ksh aft M12 x 1 ,5

,5 In i t ia l........................
l...............................
................
.................. 3 0 - 4 0 N m
F i n a l ........................ ................. ......... p l u s 9 0 ° - 1 1 0°
0°
M a x . s tret c h len g t h 2 6 ,3 m m
P u l lle
ey to crankshaft (key driv en) M 2 4 x 1 ,5
,5 ( s h a n k e d b o l t ) .................... ........ 500-600 Nm
P u l l ey
ey t o c r a n k s h a f t ( k e y dr iven ) M 2 4 x 1 ,5
,5 ( f u llll y t h r e a d ed
e d b o l t ) ......... ........ 8 0 0 - 9 0 0 N m
P u l lle
ey to crankshaft (cone element driven ) M 2 4 x 1 ,5
,5 ( 1s
1 s t s t a g e ) ....................... ............. . 8 0 0 - 9 0 0 N m
( 2n
2 n d s t a g e ) .......................... plus45° - 55°
Ma in b ear in g c ap b ol ts - sta nd ar d h ex. b o lt s ..

.....
......
......
......
.....
....
.....
......
......
.....
.....
......
.....
.....
...M
M 15 x 2 In it i a l........................
l................................................. 8 0 - 9 0 N m
................
F i n a l ........................ ................. ......... p l u s 9 0 ° - 1 0 0 °
M a x . s t r e t c h l e n g t h .......... 123 mm
M a i n b e a r i n g c a p b o l t s - m u l t i h e x . b o lltt s o n l y ...................................... M15x2 In i t ia l........................

l...............................
................
.................. 4 5 - 5 5 N m
F i n a l ......................................... plus 90 °- 100°
2 n d p u l l e y t o v i b r at
at i o n d a m p e r ....................................................................................... 47 Nm
V i b r at
at i o n d a m p e r t o c r a n k s h a f t M 2 4 x 1 ,5
,5 ......... 500 Nm
Apr il '96
Crankshaft
Cranks haft and
and Main
Main Bearings 14-5
14-5
REMOVAL AND REPLACEMENT OF

C R A N K S H A F T V IB R A T IO N D A M P E R
Removal
1. Slacken V-belt adjuster on alternator an d

an remo ve
belts, (Fig . 14-1).
2 Using special tool part num ber 4020 0145, release and
r e m o v e c e n t r e b o l t f r o m c r a n k s h a f t , ( F i g . 1 4 - 2 ))..
3 Draw v i b r a t io
io n d a m p e r f r o m c r a n k s h a f t u s i n g s p e c ia
ia l
R e p l ac e m e n t
1. If necessary heat vibration dam per to approx imately

80°C in a w ater bath, and slide onto crankshaft. En
sure that the woo druff key engages groove in the vi
b r a t i o n d a m p e r ( a r r o w s ) , ( F i g . 1 4 - 4 ))..
Apr il '96
Crankshaft and Main

Main Bearings 14-6
14-6
2. Screw centre bolt into cranks haft and tighten to the

specified torque, (Fig. 14-5).
A tte n tio n ! U n d e r no c ir c u m s t a n c e s h o u ld t h e c en tr e b o lt b e
t i g h t en
en e d w i t h a n i m p a c t w r e n c h .
REMOVAL OF CRANKSHAFT
The f o l lo
lo w i n g items mu st be remov ed from the engine
e::
cylinder head, sum p, conn ecting rods, pistons, flywheel an
an d
housing, timing g ear case cover and oil pump .
1. Un screw timing gear retaining bolt fr

fr o m c r a n k s h a f t ,
(Fig. 14-6).
2. Using special tool, part num ber 4020 0019, pull timing
gear from crank shaft, (Fig. 14-7).
3. R e m o v e l o w e r h a l f o f t i m i n g g e a r c a s e , ( F i g . 1 4 -8
-8 ) .
Fig. 14-8
Cranksh
Crank shaft
aft and Main
Main Bearings
Bearing s 14-7
14-7
4. Uns crew m ain b earing cap bolts and lift off bearing
caps, (Fig. 14-9).
Fig. 14-9
5. L i f t o u t c r a n k s h a f t f r o m c r a n k c a s e , ( F ig
ig . 1 4 - 1 0 ) .
Fig. 14-10
6. Rem ove all main b earing s h e l lls

s from crankcase. If
bearing sh ells are to be re-used, they m ust be marked
to ensu re replacem ent in the original position, (Fig.
14-11).
Fig. 14-11
7. Clean all parts, m easu re cranks haft journ als and com 
pare with specifications, (Fig. 14-12).
Fig. 14-12
Apr il '96
Crankshaf
Crank shaf t and Main
Main Bearing s 14-8
14-8
8. Check crankshaft for misalignment, journal run out

(Fig. 14-13).
Fig. 14-13
9. Check all main bearing cap bolts for stretch limit, refer
to specifications, (Fig. 14-14).
Fig. 14-14
CRANKSHAFT GRINDING
1. Mark crankshaft balance weights and remove from

cranksh aft, (Fig. 14-15).
Fig. 14-15
2. Rem ove timing gear from crankshaft, using s p e c i al

al
A ttenti o n! W hen g r i n d i n g t h e c r a n k s h a f t i t i s e s s e n t i a l th
th a t
the radii of the bearing journ als are maintained .
(See Fig. 14-34, page 14-13).
Fig. 14-16
Apr il '96
Crankshaft and Main Bearings 14-9
Checking Crankshaft after Grinding
1. c h e c k a n d c r a c k t e s t c r a n k s h a f t , ((F
Fig. 14-17)
2. Chec k all b alance weigh t bolts for stretch limits, refer
to the specifications, (Fig. 14-18).
A t t e n t i o n ! A ll c r an k s h a f t b a la n c e w ei g h t b o lt s t h a t ex c ee d t h e
m a x i m u m s t r et
e t c h l i m i t m u s t b e r e p la
la c e d .
3. Replac e balanc e weights, aligning marks on weights

with m arks on crankshaft, (Fig. 14-19).
4. Insert b alance w eight bolts and tighten to the speci

f i e d 't't o r q u e , ( F i g . 1 4 - 2 0 ) .
Apr il '96
Cranksh
Crank shaft
aft and Main Bearings
Bearin gs 14-1
14-10
0
5. Using c om pressed air, blow out a llll g a l l e r i es

es in the
cranks haft to ensure that no metal particles are retai
ned within the drillings, (Fig. 14 -21).
Fig. 14-21
6. Rep lace cranks haft timing gear using special tool, part
num ber 4020 0190, (Fig. 14-22).
Fig. 14-22
Checking Crankshaft Bearing and Parent Bores
A ttenti o n! Bearing shells are supp lied ready for f i tt

tt i n g , in
standard and various repair sizes. No attemp t should be m ade
t o a l t e r t h e p r e - d e t e r m i n e d s i z e.
e.
1. Thoro ugh ly clean and visually inspect condition of all

main bearing bores in cran kcase and bearing caps,
(Fig. 14-23).
mi » =
Fig. 14-23
2. Replac e m ain bearing caps insert bolts and tighten to
the specified torque, (Fig. 14-24).
Fig. 14-24
Apri l '96
3. A d j u s t a n in
in t e r n a l m e a s u r i n g i n s t r u m e n t , ( F i g . 1
144-25).
Fig. 14-25
4. Meas ure m ain bearing parent b o r e s i n o n e d i r e c t io

io n
com pare m e a s u r e m e n t s w i th
th t h e s p e c iiff i c at
at i o n s , ( F i g
14-26).
Fig. 14-26
5. Rem ov e main bearing bolts and b e a r i n g c a p s , ( F ig

ig .
14-27).
6. Insert b e a r i n g s h e l l s i n t o c r a n k c a s e a n d b e a r in
in g c a p s .
Ensu re that locating tabs on bearing sh ells a
arr e c o r r e c t 
l y in
in s e r t e d i n c a p a n d c r a n k c a s e , ( F i g . 1 4 - 2 8 ) .
Fig. 14-28
Cranksh
Crank shaft
aft and Main
Main Bearings
Bearing s 14-1
14-12
2
A tten tio n ! M ai n b e ar in g s h el ls h a v e oi l d r il li n g s w h ic h m ust

line up with ho les in the crankcase, (Fig. 14-29).
Fig. 14-29
7. Replace main bearing caps which are marked 1 to 7

for ADE 366 and 1 to 5 for ADE364, which must be
fitte
edd in the co rrect positions w ith the nu mb ers to
wards th e front of the engine, (Fig. 14-30).
Fig. 14-30
8. Insert bearing cap bolts and t i g h t e n t o t h e s p e c i f i ed

ed
Fig. 14-31
9. Adju st/set an internal m easuring instrum ent,

(Fig. 14-32).
Fig. 14-32
Apri l ‘96
10. Meas ure all main bearing inside diam eters in three
p l a c es
es , com pare measurem ents with the s p e c if
if i c a
a
tions, (Fig. 14-33).
Fig. 14-33
11 Shou ld the crank shaft h ave been re-ground ex amine

t h e r a d i u s ( R ) t o e n s u r e t h a t t h e s p e c i f ic
ic a t i o n h a s b e e n
adhered to, (Fig. 14-34).
Fig. 14-34
12. R e m o v e al
al l m a i n b e a r i n g c a p s , ((F
Fig. 14-35).
Fig. 14-35
REPLA CING REAR MAIN BEARING OIL SEAL
A tten tio n ! The f it m e n t o f t h e s e s e al s m ust b e c ar r ie d out

w i t h t h e b e a r in
in g s h e l l s r e m o v e d f r o m c r a n k c a s e a n d b e a r iin
ng
cap.
1. W ith the oil seal remo ved, Thorough ly clean both hal
ves of the bearing housing, (Fig. 14-36).
Fig. 14-36
Apr il ‘96
Crankshaft and Main

Main Bearings 14-1
14-14
4
2. U s i n g a p a i r o f l o n g n o s e p l i er
er s , r e m o v e t h e o i l s e a l r e
e
taining pins from the seal ho using in crank case and
bearing cap, (Fig.14-37).
Fig. 14-37
3. Using an alum inium drift, tap new oil seal reta

aii n i n g p i n
into crankc ase and bearing cap seal housing, (Fig.
14-38).
A tten tio n ! D o n o t d a m a g e t h e t ip o f t h e r et ai n in g pi ns .
Fig. 14-38
4. Fit o ne half of th e n e w o ilil s e a l i n t o s p e c i a l t o o l , part

num ber 4020 1607, (Fig. 14-39).
Fig. 14-39
5. New s e a l m u s t f i t e x a c t l y iin
nto special tool. B o t h en
en d s
of seal must touch too l holder, (Fig. 14-40).
Fig. 14-40
6. Loc ate special tool, fitte

edd with new oil seal on to the
crank case and drive th e seal into th e housing, (Fig.
14-41).
Fig. 14-41
7. Insert new half seal for bearing cap into the special
tool and dr ive into bearing cap, (Fig. 14-42).
A ttenti o n! New seal ends must protrude 0,5mm a b o v e tth

he
b e a r in
in g c a p a n d c r a n k c a s e m a t i n g s u r f a c e s o r 0,
0, 8 m m when
the cranksh aft is reground to the next repair stage. No fibre
es
s
should be trapped between the bearing cap and the crankcase
m a t i n g s u r f a c es
es .
8. Coat the seal in th e crank case and bearing cap with a

heat resistant grease, (Fig. 14-43).
Fig. 14-43
9. Apply a s m a l l a m o u n t o f s i l iic
cone sealant to the groo
v e s in
in t h e r e a r m a i n b e a r i n g c a p . The end surface of
s e a l s m u s t n o t b e c o a t e d w i t h s e a l a n t , ( F ig
ig . 1 4 - 4 4 ) .
A ttenti o n! If the bearing cap does n ot have grooves, apply

sealant to the surfaces of the cap and th e crankcase.
Surfaces to be co ated with sealant m ust be free of grease.
Fig. 14-44
Apr il '96
Cranks haft
haf t and Main Bearings
Bearin gs 14-1
14-16
6
REPLACING THE CRANKSHAFT
1. L i b e r a l l y c o a t t h e b e a r i n g s w i t h e n g i n e o i l , ((F
F i g . 1 4 - 4 5 ).
).
Fi<g.
Fi<g. 14 -4 5
2. L o w e r t h e c r a n k s h a f t o n t o t h e b e a r i n g s , ( F ig
ig . 1 4 - 4 6 ) .
nB.i
Fig. 14-46
3. Replac e all main bearing caps marked 1 to 7 for AD E

3 6 6 o r 1 t o 5 fo
fo r A D E 3 6 4 . They must b e f i tttt e d i n t h e
correct p o s i t io
io n with the numbers towards the front of
the engine, (Fig. 14-47).
Fig. 14-47
4. Coat the threads of the m ain bearing bolts with engine

oil, (Fig. 14-48).
Fig. 14-48
Apr il '96
5. Insert bolts and tighten to th e sp ecified torque, ( F iig

g.
14-49).
6. Chec k the torqu e required to turn the crankshaft, with

n e w b e a r i n g s a n d o i l s e al
al f i t te
te d , r e f e r t o s p e c i f i c a t io
io n s ,
(Fig. 14-50).
A tten tio n ! S h o u ld th e c ran k s h aft n o t tu rn at th e r eq u ir ed

t o r q u e , r e m o v e r e a r m a i n b e a r i n g c a p a n d c h e c k c o r r e c t f i t ti
ti n g
of the oil seal.
7. Refit cam shaft timin g gear, lining up timing marks. In

sert bolts and tigh ten to the specified torque, (Fig.
14-51. See also pages 15-12 and 15-13.
8. Mou nt a d ial gaug e indicator on the crankcas e and
m easure the crankshaft end float in accordance with
specifications, (Fig. 14-52).
Fig. 14-52
Apr il '96
Cranksh
Crank sh aft and Main
Main Bearings
Bearing s 14-1
14-18
8
9. R e p l a c e t h e b o t t o m h a l f o f t h e t im
im i n g c o v e r a n d t i g h t e n
the bolts to the specified torque, (Fig. 14-53).
Apr il ‘96
CRANKSHAFT AND MAIN BEARINGS — 14-19

OB TAINABLE FROM: G R U N D Y - TE C H N IF O R M . BURMAN ROAD. DE A L P A R TY E ST A TE . PO R T
ELIZABE TH 6 00 1 .
Impact socketscanner
¡see fig. 14.-2
.-21
3
00
0145
P u l lle
erforcamshaft gear
(s e e  fi g . 1 4-7
4-71
1
P a r t
t n u m b e r  4 0 2 0
00
0019
n
1
Crankshaft
hardness tester
(s e e  fi g . 1 4-1
4-13
3)
P a r t  N u m b e r  4 0 20
20 0 50
50 1
C r a n k s h a f t  g e a r  r e p l a ce
ce r 
(s e e  fi g . 1 4-2
4-2 2)
2)
00
0190
R e a r  o i ll s e a ll r e p l a c e r 
(s e e  fi g . 1 4-3
4-3 9)
9)
01
1607
Pullerfor vibrationda mper
=7 =7 0 (s e e  fi g . 1 4-3
Partnum ber 4020
4-3))
00
0 0 19
19
rn
ADE 360 Series
ADE 360 Series
____________
________________
____ SECTION 15
Camshaft, Timing Case and Drive Timing
Page
ILLUSTRATION ...................................................................................................................................................................................................................................... 15-2
IN T R O D U C T IO N .........
................
................
................
................
................
................
................
................
.................
................
................
...............
................
................
................
................
................
................
................
................
................
.................
...............
................
................
................
................
...........15
....15 -3
SPECIFICATIONS !
................................................................................................................ ............................................................................................................... 15-3
R E M O V IN
IN G C A M S H A F T .................................................................................................................................................................................................................. 15-5
R E P L A C IN
IN G C A M S H A F T ................................................................................................................................................................................................................ 15-9
R E M O V I N G T IM I N G C O V E R O I L S E A L ............................................................................................................ 15-14
R E P L A C I N G T IM
IM I N G C O V E R O I L S E A L ................................................................................................. 15-15
S P E C IA
IA L T O O L S .................................................................................................................................................. 15-17
Camshaft,, Timing
Camshaft Timi ng Case and Driv
Drivee Timing
Timin g 15-2
15-2
C A M S H A F T A N D T IM I N G G E A R S
1. C A M S H A F T 7 . R E T A I N IIN
NG BO LT
2. THRUS T WASHER 8. BOLT
3. FLY -WEIG HT 9. ROLL ER
4. PIN 1 0.
0. I N J E C T I O N P U M P D R I V E G E A R
5. SPR ING 11. FEA THER KEY
6. CAMSHAFT GEAR
Apr il ‘96

Timi ng 15-3
15-3
INTRODUCTION
T h e c a m s h a f t iis
s p r e c i s i o n f o r g e d a n d i n d u c t i o n h a r d e n e d . I t iis
s s u p p o r t e d b y s t ee
ee l b a c k e d b r o n z e b e a r i n g s a n d g e a r d r i v e n
f r o m t h e c r a n k s h a f t . A c c e s s t o t h e t i m i n g g e a r s c a n b e g a i n e d b y r e m o v a l o f th
th e c r a n k s h a f t v i b r a ti
ti o n d a m p e r a n d t i m i n g
case, which is situated at the front of the engine.
SPECIFICATIONS
C a m s h a f t B e a r iin
ngs
B e a r in g p o s itio n S ta n d a r d
364 366 J o u r n a l d i a. Bearing ID
— 1 5 5 ,9 4 1 t o 5 5 ,9 6 0 56,000 to 56,030
1 2 55,691 to 55,710 55,740 to 55,770
2 3 5 5 ,4 4 1 to 5 5 ,4 6 0 55,490 to 55,520
3 4 5 5 , 1 9 1 to
t o 55
5 5 ,,2
210 55
5,, 2 4 0 t o 55
5 5 ,2
,2 7 0
C a m s h a f t lo b e a n d j o u r n a l s u r f a c e fin is h Rz 3 pm
Eccentric - Com pressor drive Ra 0,2 pm; Rmax 2 pm
Basic bore for cams haft bearing 60,000 to 60,030
Camsh aft bea

arr i n g O D 60,150 to 60,180
C a m s h a f t b e a r i n g c le
le a r a n c e R ad ia l 0 ,0 3 0 t o 0 ,0 7 9
A x ia l 0,180 to 0,520
Hardness Journal 57 to 63 Hrc

C a m lo b es 5 7 to 6 3 H rc
R u n - o u t o f c a m s h a f t jjo
ournals (cam shaft supported at outer journals) 0,025
B a c k l a s h c r a n k s h a f t / c a m s h a f t g e a r , c a m s h a f t //ii n j e c t iio
on pum p gear 0,070 to 0,180
Inlet Exhau st
V a l v e t r a v e l s p e c i f iic
cations for ch ecking 364N, 366N 0,56 to 0,96 0,64 to 1,04
v a l v e ti
ti m i n g a t T D C a n d " O " c l e a r a n c e 3 6 6 C /T /T I, 3 6 4 C /T 0 ,5 8 to 0 ,9 8 0 ,6 1 t o 1 ,0 1
Inlet Exhaust
M a x i m u m v a l v e l ifif t ( w i t h s p ec
e c i f iie
ed 364N/C/T, 366N 10,56 10,56
valve clearance) 366C/T/TI 10,16 10,56
Apr il '96
Camshaft,, Timi ng Case and Driv

Camshaft Drivee Timing
Timin g 15-4
15-4
Outer shaft dia. Bore in cylinder block
Standard 27,980 to 27,990 28,000 to 28,033
Repair stage 1 (+0,2) 28,180 to 28,190 28,200 to 28,233
Clearance shaft /bore 0,010 to 0,053
Timing degree pointer .............................................................. M6 ............................................ 8 Nm

Timing device to camshaft ....................................................... M16 x 1,5 ................................. 300 Nm
Timingg segment to camge
Timin camgear
ar .................................................... M8 ............................................ 30 to 40 Nm (+90° to 100°)
Injection pump gear 364N/C/T, 366N ....................................... M14 x 1,5 .................................. 80 Nm
366C/T/TI M18 x 1,5
................................................. ..................................105 Nm
Camshaft
Camshaft thrust plate to bloc k M8 x 1
................................................. .......................................35 Nm
Timing case to cylinder block M10
................................................... ..........................................65 Nm
Timingg case cover to timing case
Timin M6
............................................. 10 Nm*
............................................
Apr il '96
Camshaft, Timi
Timi ng Case and Drive Timing
Timi ng 15-5
15-5
REMOVING AND REPLACING THE CAMSHAFT
1. Remove rocker cover, (refer to pag

pagee 12
12-7).
-7).
2. Unscrew and remove rocker shaft, (refer to page 12-9).
3. Remove pushrods and mark to ensure replacement in
the original position.
4. Unscrew and remove side ccover,

over, (Fig. 15-1).
5. Lift out camfol

camfollowers,
lowers, (Fig. 15-2), an
andd number each in
order to replace in the same position.
6. Drain engine oil and remove sum

sump,
p, (Fig. 15-3).
7. Unscrew and remove bolts reta

retaining
ining oil pump, lift oout
ut
pump, (Fig. 15-4).
April ‘96
Camshaft , Timi ng Case and Driv
Drivee Timing
Timin g 15-6
15-6
8. Slacken the V-belt adjuster on the alternator and re

move the belts, (Fig. 15-5).
9. Using special tool, part number 4020 0145, unscrew

and remove centre bolt retaining vibration damper,
(Fig. 15-6).
10
10.. Attach special puller, part number 4020 001
0019,
9, to vibra
tion damper and puli off, (Fig. 15-7).
11
11.. Unscrew and remove bolts retaining the timing cas
casee
cover and lift off, (Fig. 15-8).
Apr il '96
Camsh
Camshaft,
aft, Timi
Timing
ng Case and Driv
Drivee Timing
Timi ng 15-7
15-7
12.
12. Using a socket, unscrew and remove the Allen cap
screw retaining the timing gear to the ca
camshaft,
mshaft, (Fig.
(Fig.
15-9).
A V 1 O I
i
l
g. 15-9
13
13.. Using special ttool,
ool, part number 4020 0019
0019,, pull off
timing gear from camshaft, (Fig. 15-10).
14
14.. Remove shim an
andd feather key from the camsh
camshaft,
aft, (Fig.
15-11).
15
15.. Unscrew bolts retaining the camshaft thrust plate and
remove from the camshaft, (Fig. 15-12).
Fig. 15-12

Timi ng 15-8
15-8
16.
16. If the
t he engine is fitted
fitte d with a crankcas
crankcasee mounted com
pressor remove the compressor cylinder head bolts
together with the gasket, (Fig. 15-13).
Fig. 15-13
17
17.. Turn the piston of the compressor to TDC aand
nd pull off the
cylinder barrel, (Fig. 15-14).
Fig. 15-14
18
18.. Remo
Remove
ve the circlips ret
retaining
aining the gudgeon pin, push out
and remove the piston, (Fig. 15-15).
Fig. 15-15
19. Unscrew the nuts retaining the bearing cap to the
connecting rod, (Fig. 15-16).
Fig. 15-16
Apr il '96
Camshaf t, Timing Case

Case and Drive
Drive Timing
Timin g 15-9
15-9
20. Remove connect

connecting
ing rod and bearing cap, (Fig. 15-17
15-17).).
21. Pull out the camshaft from the cylinder block

block.. Do not
damage the camshaft bearings, (Fig. 15-18).
REPLACING
1. Carefully insert the ca

camshaft
mshaft into the cylinder block
without damage to the camshaft bearings,
(Fig. 15-19).
Fig. 15-19
2. Fit th
thrust
rust plate to camshaft, insert retaining bolts and
tighten to the specified torque, (Fig. 15-20).
Apr il '96

Timin g 15-1
15-10
0
3. Fit shim to camshaft, (Fig. 15-21)

Fig. 15-21
4. Fit ttiming
iming gear to camshaft; ensure that the marks on
timing gear and crankshaft gear are aligned, (fFig.
15-22).
Fig. 15-22
5. Insert feather key,
key, locating ttiming
iming gear to camsh
camshaft,
aft,
(Fig. 15-23).
Fig. 15-23
6 Insert Allen cap screw into camsha
camshaft,
ft, (Fig. 15-24).
Fig. 15-24
Apr il '96
Camshaft, Timing Case

Case a
and
nd Drive Timing 15-1
15-11
1
7. Tighten cap screw to the specified torque, (Fig. 15-25).
Fig. 15-25
8. Replace timing case cover and align using sp
special
ecial tool
4020 2198, (Fig. 15-26).
Fig. 15-26
9. Insert bolts retaining th
thee timing cover and tighten to
Fig. 15-27
10
10.. If nec
necessary,
essary, heat the vibration damper to approxima
tely 80°C
shaft. in a water
Ensure that bath before sliding
the woodruff key onto the in
locates crank
the
groove, (Fig. 15-28).
Fig. 15-28
Apr il '96
Camshaft,
Camshaf t, Tim
Timin
ing
g Case and Driv
Drivee Timin g 15-12
15-12
11
11.. Screw centre bolt into crankshaft and tighten to the
Atte ntion!
nti on! The cen
centre
tre bolt must not bbee tightened w
with
ith an
impact wrench
■ni) a k
Fig. 15-29
12
12.. If the engine is fitted with a crankcase m
mounted
ounted com
pressor the crankshaft should be turned so that the
lobe for the compressor connecting rod is at TDC
TDC.. Re
place bearing cap and connecting rod, (Fig. 15-30).
Note: When using belt drive drivenn compressors the oil su

supply
pply
hole in the eccentric is closed off with a jubilee clamp.
13
13.. Tighten nuts to the specified torque, (Fig. 15-31).
14
14.. Fit compressor piston to connecting rod, insert gud
geon pin and circlips, (Fig. 15-32).
Fig. 15-32
Apr il '96
Camshaf
Camshaft,
t, Timing Case and Drive Timing
Timi ng 15-1
15-13
3
15.
15. Lightly apply a suitabl
suitablee sealing compound to the base
of the cylinder barrel.
16. With the spspecial
ecial piston ring squeezer, part number
4020 1131
1131,, compress the piston rings, insert piston
into the cylinder barrel, push the bbarrel
arrel dow
downn over the
piston rings and remove the piston ring squeezer.
Push the barrel fully home, (Fig. 15-33).
17
17.. Replace the compressor cylinder head,
head, fitted with a
new gasket, insert bolts and tighten to the specified
18.
18. Replace the oil pump, insert tthe he retaini
retaining
ng bolts and
19.
19. Using new gaskets, re replace
place the sump, insert
inser t bolts and
tighten to the specified
speci fied torque, (Fig. 15-3
15-36).
6).
Fig. 15-36
Apr il '96
Camshaft,, Tim
Camshaft Timin
ing
g Case and Drive
Drive Timi
Timi ng 15-1
15-14
4
20. Insert cam followers

follo wers in th
thee same positi
position
on from which
they were removed, (Fig. 15-37).
21. Replace side cover, insert bolts and tighten to the spe
cified torque, (Fig. 15-38).
22. Insert push rods in ttheir
heir original position, see page
12 - 21 .
23. Replace the rocker shafts and insert the bolts bbut
ut do
not tighten.
24. Use special tool, part number 4020 3185 and insert
the connecting nipple betwe
between
en the rocker shafts, see
page 12-21.
25. Tighten the rocker shafts to the specified torque, see
page 12-23.
26. Adjust the vvalve
alve clearance, see page 12-23
12-23..
27. Replace the rocker cover wi withth a new gasket, insert
bolts and tighten to the specified torque, (Fig. 12-24).
REMOVING AND REPLACING

THE TIMING COVER OIL SEAL
Timing cover removed from the engine.
Removing
1. Place the support ring of special tool, part number

4020 0200, under the front of the timing cover to
prevent distortion when tthe
he oil se
seal
al is remove
removed,
d, (Fig.
15-39).
2. Use the adapter ring and spacer of the spespecial

cial tool to
press the oil seal from the housing, (Fig. 15-40).
15-40).
Fig. 15-40

Timi ng 15-1
15-15
5
Replacing
1. Locate a new oil seal in front of the housing, (Fig.

15-41).
2. Place a 12 mm dist
distance
ance piece inside the timi
timing
ng cove
cover,r,
behind the oil seal housing, (Fig. 15-42).
3. Place the
t he spacer of the special tool oonn top of the oil
seal, (Fig. 15-43).
4. Press the seal into the timing housing until it is flush

with the inside edge of the timing cover an
andd butts onto
the distance piece, (Fig. 15-44).
Fig. 15-44
Camsh
Camsh aft, Timin g Case and Driv
Drivee Timing 15-1
15-16
6
5. Section through
thr ough titiming
ming case with the oil
seal in place, (Fig. 15-45).
Note: When replacing the timing case oil se
seal
al it is essential to
replace the wear ring on the crankshaft.
Apri l '96
CAMSHAFT, TIMING CASE AND DRIVE TIMING — 15-17

OB TAINABLE FROM : GR UND Y-TECHNIFORM. BURM AN ROAD. DEAL P A RT Y E ST A T E. PO R T
ELIZAB ETH 6 0 01
impact socket soanner
isee tig
tig 15-6i
Part N u m D e r 40200145
Puller for camshaft gear,

(see fig. 15-10)
Part Number 40200019.
Puller for vibration a a m D e r

(see fig. 15-7)
Part number 40200019
Timing cover centralizing

tool. ..
(see fig. 15-26)
Compressor piston ring squeezer

use with pliers below,
(see fig. 15-33)
Pliers for compressor

piston ring squeezer,
(see fig. 15-33)
AMENDMENT 6/91
CAMSHAFT, TIMING CASE AND DRIVE TIMING — 15-18
T i m i ng c ov er oi l s eal
eal rem ov er/
repl ac er,
(see fig. 15-40).
F abri c ate a 12 m m
s pac er x 100
100 m m di a., whi c h i s
us ed as a di s tanc e pi ec e under the
ti m i ng c as e c ov er, when pres s i ng
in the seal, (see fig. 15-42).
AMENDMENT 6/91
_________SECTION
_________SECTION 16
Lubricating System and Sump
Page
ILLUSTRATION ...................................................................................................................................................................................................................................... 16-2
O IIL
L FLOW CHA RT ............................................................................................................................................................................................................................... 16-3
IN T R O D U C T IO N ................
.........................
................
................
................
................
..................
................
................
................
................
.................
................
................
................
................
................
................
...............
................
................
................
................
................
.................
................
................
..........16
..16 -4
SPECIFICATIONS ................................................................................................................................................................................................................................. 16-4
R E M O V I N G T H E O IL
IL C O O L E R ................................................................................................................................................................................................... 16-6
R E P L A C IN G T H E O IL C O O L E R ........
...............
................
................
................
.................
................
................
................
................
................
................
...............
................
................
................
.................
................
................
................
................
................
................
...............
..........16
...16 -8
R E M O V I N G T H E O IIL
L COOLER ADE 366T ....................................................................................................................................................................... 16-10
R E P L A C I N G T H E O IL
IL C O O L E R A D E 3 6 6 T ....................................................................................................................................................................... 16-12
R E M O V I N G T H E O I L F IIL
LTER ELEMENT ............................................................................................................................................................................ 16-15
R E P L A C I N G T H E O I L F I L TE
TE R E L E M E N T .......................................................................................................................................................................... 16-16
L F IL
IL T E R H E A D .................................................................................................................................................................................... 16-17
R E P L A C I N G T H E O I L F IL
IL T E R H E A D ................................................................................................................................................................................... 16-18
L PUMP ........................................................................................................................................................................................................ 16-21
A S S E M B L Y O F T H E O IL P U M P ................................................................................................................................................................................................ 16-23
Apr il '96
Lubric
Lub ric ating System and Sump 16-2
16-2
OIL PUMP AND FILTER ASSEMBLY
1 OIL FILTER ELEMENT 17 STRAIN

STRAINER
ER
2 FILTER ELEMENT RETAINER 18 STRAINER RETAINING BOLT
3 SEA
SEALING
LING WASHE
WASHER R 19 OIL PUMP
PUMP RRETAIN
ETAINING
ING BOLT
BOLT
4 WASHER 20 OIL PU
PUMP
MP BO
BODY
DY
5 SEALING WASHER 21 OIL PUMP GEAR
6 FILTER BOWL RETAINING BOLT 22 BY-PASS VALVE SCREW PLUG
7 DRAINPLUG AND WASHER 23 WA
WASH
SHER
ER
8 GEAR SHAFT 24 BY-P
BY-PASS
ASS VALVE
VALVE SPR
SPRING
ING
9 OIL PUM
PUMPP DR
DRIVEN
IVEN GEAR
GEAR 25 BY-PA
BY-PASS
SS VA
VALV
LVE
E
10 OIL PUM
PUMPP DR
DRIVE
IVE SH
SHAFT
AFT 26 OIL F
FILTE
ILTER
R HEAD
HEAD
11 OIL PU
PUMP
MP DR
DRIVE
IVE G
GEAR
EAR 27 BAN
BANJO
JO BOLT AND W WASH
ASHER
ER
12 OIL PUMP DRIVE SHAFT/TACHO DRIVE 28 GASKET
13 WOODRU
WOODRUFF FF K
KEY
EY 29 INJECTION PUMP OIL FEED PIPE
14 OIL PUM
PUMPPCCOVER
OVER RETAINING BOLT 30 BANJO BOLT AND WASHER
15 REL
RELIEF
IEF VA
VALVE
LVE 31 BLANKING
BLANKING PLU
PLUG
G
16 OIL PU
PUMP
MP C
COVE
OVERR PLATE
PLATE 32 BLANKING PLUG AND WASHER
Apr il '96
Lubr icati ng Syst

System
em and Sump 16-3
16-3
TYPICAL OIL FLOW - ADE 360 SERIES

Oil is drawn from the engine sump by a gear type pump, through a gauze strainer. The oil under pressure then flows
between the oil pump body and drive shaft into a gallery, passing to the oil filter. From the oil filter, cleansed oil flows via
an intersecting gallery to a plate type oil cooler. On the naturally aspirated engine, oil from the cooler enters the main oil
gallery to the crankshaft, camshaft, rocker gear, etc.
The turbocharged engine oil flow differs from the naturally aspirated engine, in that the oil flowing from the main oil filter
passes into an additional micro type filter, mounted on the outside of the oil cooler cover, before flowing into a large
capacity fin type oil cooler, providing an increase in the cooling capacity. To assist with dissipation of the additional heat
generated by the turbocharged engine, piston cooling nozzles are fitted to the main oil gallery, supplying a constant jet of
cooling oil to the underside of the piston crowns. The turbocharger is fed under pressure from the main oil gallery, with a
drain to the engine sump.
The ADE 364C/T/TI engine has a small finned cooler mounted integrally with the engine oil filter to assist with heat
dissipation.
Note: The micro type oil filt
filter
er mentioned above has since been removed oonn turbocharged engi
engines
nes built from mid 1995.
Apr il '96
Lubri cating System and

and Sump
Sump 16-4
16-4
INTRODUCTION
A g e a r t y p e p u m p s u p p l i e s o i l u n d e r p r e s s u r e t h r o u g h a f u llll f lo lo w p a p e r t y p e o i l f iill t e r ttoo t h e c r a n k s h a f t , c a m s h a f t ,
connecting rod big end bearings, rocker shaft bearings, fuel injector pump and governor. Oil under pressure is also fed to
t h e c r a n k c a s e m o u n t e d a i r c o m p r e s s o r a n d t u r b o c h a r g e r ( i f f i tttt e d ) . P r e s s u r e r e l i e f a n d b y - p a s s v a l v e s p r o t e c t th
th e s y s t e m
against overload.
SPECIFICATIONS
OIL PUMP
364N/C/T 366C/T/TI
366N
Width of pump gears 39
9,, 9
93
36 to 39
9,, 9
97
75 49
9,, 9
93
36 to 49
9,, 9
97
75
Axial play bet ween gea r f ace and hou sin g 0,025 to 0,089 0,025 to 0,089
Clearance between teeth and housing 0,030 to 0,105 0,030 to 0,105
Outside dia. of pump gears 42,020 to 42,070 42,020 to 42,070
Inside dia.
dia. of pump driving gear 16,944 to 16,958 16,944 to 16,958
Inside dia.
dia. of pump driven gear 15
5,, 0
05
50 to 1
15
5 ,,0
0773
3 15
5,, 0
05
50 to 15
5,, 0
07
73
Diameter in housing for shaft o f driven gear 15,000 to 15,018 15,000 to 15,018
Ins i d e d i am et er o f oil p u m p d ri ve s p r o c k et 1 6 , 9 4 4 t o 16 , 95 8 1 6 ,9 4 4 t o 1 6 ,9 5 8
A - Inst allati on heig ht bet ween driv e sp roc ket + 0,5

116,5 0,3
and pump housing flange when moving shaft -
in the indicated direction
B - Di am e t er o f oil p u m p d ri v i ng s h af t 16 , 9 7 6 t o 1 6 , 98 4 1 6 ,97 6 t o 1 6 ,9 8 4
C - Di am et er o f oil p u m p d r i v en g ear s h af t 15 , 0 2 8 t o 15 , 03 9 1 5 , 02 8 t o 1 5 , 0 39
D - In s t al l at i on h ei g h t o f d r i v en g ear s h af t 3 9 ,2 t o 3 9 ,5 4 7 ,5 t o 4 8 , 5
E - In s t al l at i on h ei g h t o f d r i v e g ea r t o d r i v e s h af t 0 , 5 t o 0 ,8 7 ,2 to 7 ,8
364N/C/T
Pump speed 366N 366C/T/TI
Min. delivery rate (¿/min) with SAE 10 oil at 50°C and 300 r/min
400 kPa pressure 1 4 0 0 r / m in 45 58
Apr il '96
Lubric
Lub ricating
ating System and Sump 16-5
16-5
OIL PRESSURE RELIEF VALVE ____________________________________________________________
I Opening pressure (kPa) 470 - 570
SPRING FOR PRESSURE RELIEF VALVE

OD Wire dia. Unloaded Spring preload Spring final load
spring length Length Load Length Load
mm mm mm mm N mm N ,
9,3 1,7 49,4 45,4 43,9 36,2 ! 145 :
OIL FILTER BY-PASS VALVE SPRING

OD Wire Unloaded Spring preload Spring final load Opening pressure
dia spring le
length Length Load Length Load of by-pass valve
mm mm mm mm N mm
16,5 1,5 66 31 42 to 48 21,0 N
57 160kPa
- 250
OIL PRESSURE
Minimum operating oil pressure (warm engine)
600 r/min 80 kPa gauge pressure
Warning!
Warn ing! Stop engin
enginee immediately w
when
hen the oil pressure drops be
below
low the following values
OIL CAPACITY
Depending
Depending on application 364N/C/T
364N/C/T approximately 10 litres
366N/C/T/TI approximately 17,5 litres
Turbocharger oil drain to crankcase/sump (364C/T/TI) .... M16 x 1,5 ........................................................ 40 Nm
Turbocharger oil supply from oil cooler cover (366C/T/TI) M 1 4 x 1 ,5
,5 ........................................................ 40 Nm
Turbocharger oil drain to sump (366C/T/TI) ..................... M26 x 1,5 ........................................................ 70 Nm
Oil supply to turbocharger ................................................ M 8 ....................................................................... 35 Nm
Oil drain from turbocharger .............................................. M 8 ....................................................................... 35 Nm
................................................ M14 x 1,5 ........................................................ 50 Nm
Oil pressure
filter mounting
gauge switch
............................................................ M 10 .................................................................... 50 Nm
Dipstickk ada
Dipstic adapter
pter ............................................................... M14 x 1,5 ........................................................ 40 Nm
Sump drain plug .............................................................. M 2 6 x 1 ,,5
5 ........................................................ 80 Nm
Dipstickk tube to cylinder block
Dipstic .......................................... M16 x 1,5 ........................................................ 25 Nm
Sump to cylinder block - Pressed steel ............................ M 8 ( S t u d s ) .................................................... 9 Nm
M 6 ( B o l t s ) ..................................................... 8 Nm
- Aluminium casting M 8 ( S t u d s ) ..................................................... 2 5 N m
M 6 ( B o l t s ) ....................................................... 1 5 N m
Drain plug bush to sump ................. - .......................................................................... 90-110 Nm
Relief valve cap to oil pump cover.... M 2 4 x 1 , 5 ........................................................ 2 0 N m ( w i t h L o c t i t e )
By-pass valve cap on oil filter' ......... M24 x 1,5 ........................................................ 70 Nm
Banjo bolt to oil filter head ............... M26 x 1,5 ........................................................ 60 Nm
Plu
Plugg to oil filter h ead........................ M 1 0 x 1 ............................................................. 2 0 N m
Plug to oil filter head (Aluminium).... M14 x 1,5 ........................................................ 35 Nm
Drain plug to filter head (Aluminium) M 1 0 x 1 ............................................................. 2 0 N m
Oil filter bowl to filter head ............... M12 x 1,5 ........................................................ 45 Nm
Oil supply pipe to injector pump ...... M 1 0 x 1 ............................................................. 1 5 N m
Oil supply pipe to filter .................... M10 x 1 15 Nm
Suction pipe to oil pump cover ........ M 8 ....................................................................... 35 Nm
Oil pump cover to pump body ......... M 8 ....................................................................... 34 Nm
Oil pump to cylinder block ............... M 8 ....................................................................... 35 Nm
Oil cooler filter to cooler .................. M 10 .................................................................... 40 Nm
Oil cooler cover to cylinder block ..... M 8 ....................................................................... 40 Nm
Oil cooler by-pass valve .................. M 2 2 x 1 ,,5
5 ........................................................ 65 Nm
Oil cooler bolts (centre) 366N .......... M 8 ....................................................................... 30 Nm
Cooler to cover 366C/T/TI ............... M 8 ....................................................................... 35 Nm
Ap ril ‘96

and S
Sump
ump 16-6
16-6
REMOVING AND DISMANTLING

PLATE TYPE OIL COOLER 366N
1. Rem ove starter motor.
2. U nscrew bolts and rem ove the exhaust m a n i ffo

old,
(Fig. 16-1).
3. Uns crew the bolts and remo ve the iin
nlet manifold,
(Fig. 16-2).
4. Unscrew and remo ve the o ilil p r e s s u r e gauge sender

unit, (Fig. 1 6-3).
5. Rem ove by- pass v alve from oil cooler casing, (Fig.
16-4).
Apr il '96
Lubr icati ng Syst

Syst em and Sump 16-7
16-7
6 . U n s c r e w a n d r e m o v e a l l b o l ttss r e t a i n i n g th
th e o i l c o o l e r t o
t h e c y l i n d e r b l o c k , ( Fi g . 1 6 - 5 ) .
7. Remove the
t he oil cooler casing from the cylind
cylinder
er block,
(Fig. 16-6).
8. Unscrew and remove bolts jo

joini
ining
ng both halves of the
oil cooler, (Fig. 16-7).
9. Dismant
Dismantle
le the oil cooler ha
halves,
lves, (Fig. 16-8).
Mm >e=
Fig. 16-8 ___________________________________
Ap ril '96

and Sump
Sump 16-8
ASSEMBLY AND REPLACEMENT OF OIL COOLER

1. Fit new gasket between oil cooler halves, (Fig. 16-9).
¡ A
N jT '~ , r- , J if f
■ in
g. 16-9
2. Insert bolts joining the oil cooler halves and tighten ttoo
the specified torque,(Fig. 16-10).
Fig. 16-10
3. Replace
Replace oil pressure gauge sender uunitnit and tighten th
thee
bolts to the specified torque, (Fig. 16-11).
4. Replace the by-pass valve and tighten the bo

bolts
lts to the
Fig. 16-12
Apr il ‘96
Lubric
Lub ricating
16-9
5. Fit a new g a s k e t b e t w e e n o ilil c o o l e r c a s i n g a n d c y l iin
n
der block.
T ' ^
6. R e p l a c e t h e o ilil c o o l e r t o c y l i n d e r b l o c k , (F
(F i g . 1 6 - 1 3 ) .
Fig. 16-13
7. I n s e r t b o l t s s e c u r i n g t h e o i l c o o l e r t o t h e c y l i n d e r b lo
lo c k
and tighten in cross fashion from the centre outwards,
to the specified torque, (Fig. 16-14).
mu /© s
Fig. 16-14
8. F i t n e w g a s k e t s t o t h e i n l et
et m a n i f o l d , insert bolts and
Fig. 16-15
9. Fit new gaskets to th e exhaust manifold, insert bolts

and tighten to the sp ecified torque, (Fig. 16-16).
10. Rep lace the starter motor.
11. W ith the engin e stop control set to the “OFF" position,
turn the engine with the starter motor until o
oii l p r e s s u r e
is registered on the gauge.
12. Start the engine and allow to idle for several minutes;
check all joints for oil leaks.
till A3 =
Fig. 16-16
Apr il '96
Lubri cating System and Sump 16-1

16-10
0
REMOVING OIL COOLER ADE 366T

1. Remove the starter motor.
2. Disconnect the oil feed and drain pipes to the turbo
charger, (Fig. 16-17).
3. Unscrew bolts and remove the exhaust manifold, (Fig.

16-18).
4. Unscrew bolts and remove the inlet manifold, (Fig.
16-19).
5. housing
Do not remove therremoved
has been oil cooler
emoved retainer
ffrom
rom boltseruntil
the cylind
cylinder the
block,
(Fig. 16-20).
Apr il '96
Lubr icati ng Syst

System
em and Sump 16-1
-11
1
6 Uns crew and rem ove all bolts retaining the oil cooler
housing and rem ove from the cylinder block, ( F iig
g.
16-21).
7. Uns crew and rem ove b o l t s r e t a i n i n g t h e o iill c o o l e r e l e 

m e n t to
to t h e h o u s i n g , ( F i g . 1 6 - 2 2 ) .
Fig. 16-22
8. Detach the oil cooler eleme nt from the housing, (Fig.

16-23).
9. Unsc rew th e cen tre bolt retaining the oil cooler filter
elem ent to the hous ing, (Fig. 16-24).
Apr il '96

and Sump
Sump 16-1
16-12
2
1 00.. L i f t o f f t h e f i ltlt e r c o v e r a n d r e m o v e t h e f i ltlt e r e l e m e n t ,

(Fig. 16-25).
Fig. 16-25
11. Unscrew and remove th
thee oil pressure gauge sender
unit, (Fig. 16-26).
Fig. 16-26
12.
12. Remove the by-pass valve from the oil cooler housing,
(Fig. 16-27).
— I ss> mi /© =
Fig. 16-27
REPLACING
1. Replace the oil pressur

pressuree gauge sender unit and tighte
tightenn
to the specified torque.
2. Replace the
t he by-pass valve aand
nd tighten to the sspecified
pecified
III!
I! M s
Fig. 16-28
Apr il '96
Lub ric
ricating
ating Syst
16-13
3
3. Fit a new O-ring to the oil cooler fil

filter
ter element cover,
cover,
(Fig. 16-29).
4. Replace the oil cooler filter elem
element.
ent.
Note: The wide sealing face on the filter element goes
towards the sealing surface of the oil coo
cooler
ler housing,
housing,
(Fig. 16-30).
5. Replace the filter

fil ter element cover, fitted with new O-ring,
insert the
t he retaining bolt and tighten to the spec specified
ified
6. Fit new gas

gaskets
kets between oil cooler element and hou
sing, replace the cooler element and insert bbolts,
olts, (Fig.
16-32).
Fig. 16-32
Apr il '96
Lubr icating System and

and Sump 16-1
16-14
4
7. Tighten oil cooler retaining

retai ning bolts to the specified
torque, (Fig. 16-33)
Fig. 16-33
8. Fit a new gasket between the cylinde
cylinderr block and the oil
cooler housing.
9. Replac
Replacee all bolts retaining the oil cooler housing to the
cylinder block and tighten in cross fashion from the
centre outwards to the specified torque, (Fig. 16-34).
Fig. 16-34
10.
10. Fit a new gasket to the inlet manifold, insert bolts an
andd
Fig. 16-35
11
11.. Insert the exhaust manifold bolts and tighten to the
■ill »=
Fig. 16-36
Apr il ‘96
Lubricat
Lub ricating
ing Syst
16-15
5
12. Con nect oil feed and drain pipe to the turbocharger,
and tighten to sp ecified torque (Fig. 16-37). 1
13. Rep lace the starter motor.
14. With the engine Stop control set to the “OFF" position
turn the engine with the starter motor until o
oii l p r e s s u r e
15. Start the engine and allow to idle for several minutes.
Chec k all joints for oil leaks.
F i g . 1 6 - 3 7 ___________
Removing the Oil Filter Element
1. U nsc rew and rem ove the filte

err bowl drain plug and
allow oil to drain (Fig. 16-38).
2. Uns crew the c e n t r e b o l t r e t a i n i n g t h e ffii l t e r b o w l t o t h e

filter head, (Fig. 16-39).
3. Rem ove the oil filter bowl and the filter element, (Fig.
16-40).
4. Clean filter bowl, elem ent retainer a

ann d c e n t r e b o ltlt .
Apr il '96

and Sump
Sump 16-1
16-16
6
Replacing
1. Fit a new O-ring to the filter head, (Fig, 16-41).
2 Insert a new filter

fil ter element into the filter
filt er bowl, (Fig.
16-42).
3 Position the filter bowl to the centre of the filter hhead

ead,,
insert bolt and tighten ttoo the specified torque, (Fig.
16-43).
4. Replace
Replace the filter drain plug and ttighten
ighten to the spe
speci
ci
fied torque, (Fig. 16-44).
Atten
Att entio
tion!
n! With the engine Stop control set to the “OFF"
position, turn the engine with the starter motor until oil
pressure is registered on the gauge.
5. Start the engine and allow
all ow to idle for several m
minutes.
inutes.
Check all joints for oil leaks.
Apr il '96
Lubric
Lub ricating
ating System and
and Sump
Sump 16-1
16-17
7
REMOVING AND REPLACING THE OIL FILTER HEAD

Removing
1. Drain the filter bow
bowl.l.
2. Remove the filt
filter
er bow
bowll and element, (Fig. 16-45).
Fig. 16-45
3. Unscrew and remove the feed pipe to injection pum
pump,
p,
(Fig. 16-46).
FicJ. 16-46
4. Unscrew and remove bolts re retaining
taining the filter head
head to
the crankcase, (Fig. 16-47).
5. Remove the filte
filterr head from the crankcase.
Note: New le level
vel oil filter elements have integrate
integratedd seal
rings, and therefore the loose seal ring depicted in Fig.
16-47 will no longer be required.
Fi.q. 16-47
6. the
Unscrew and (Fig.
filter head, remove the oil filter
16-48). fil ter by-pass valve from
mi » =
Fig. 16-48
Apr il '96
Lubri cating System and Sump 16-1

16-18
8
7. Rem ove t h e o iill f i l t e r s e a l a

ann d r e t a i n i n g s p r i n g fr
fr o m t h e
filter head, (Fig. 16 -49).
Note: T h i s s e a l i s n o w i n t e g r a l p a r t o f t h e oi
oi l f iill t e r
assembly.
Fig. 16-49
8. Thoro ugh ly clean all parts and blow out o

oii l d r i l l i n g s i n
the head with com press ed air, (Fig. 16-50).
llll A3 =
Fig. 16-50
Replacing
1. Using a spring tester, check the by-pass valve spring

tension, replace if required, see sp ecifications, (Fig.
16-51).
Fig. 16-51
2 Fit a new oil filter seal and retaining ring to the filte
err
head, (Fig. 16-52).
m A »s
Fig. 16-52
Apr il '96
Lubric
Lub ricating
16-19
9
3. Use a new gasket, fit the filte

err h e a d t o t h e c r a n k c a s e
and insert bolts,(Fig. 16-53)
Fig. 16-53
4. T i g h t e n t o t h e s p e c i f i e d t o r q u e , ( F iig
g. 16-54).
Fig. 16-54
Fit b y-pass valve into the filter head and tighten the
screw p lug to the specified torque, (Fig. 16-55).
Fig. 16-55
6. Con nect th e oil feed pipe to t h e i n j e c t iio

on pum p and
filter head, tighten the screw plug to the s p e c i f i ed
ed
Attention! A b an jo c o n n ec ti o n w it h a s m a ll h o le is fi tt ed to
the filter head; this applies a r e s t r i c t i o n t o t h e o ilil f l o w a n d
should not b e reversed.
Fig. 16-56
Apr il '96

and S
Sump
ump 16-2
16-20
0
7 Fit a new O-ring to the filter bowl, (Fig. 16-57).

8. Insert a new oil filter element into the f i lltt e r bowl,
(Fig. 16-58).
9. F i t t h e f i l tte
e r b o w l an
an d e l e m e n t t o t h e f i lt
lt e r h e a d , insert
retaining bolt and tighten to the specified torque, ( F iig
g.
16-59).
10. Replace the filter bowl drain plug and tighten to th e

11. W ith the engin e Stop control set to the “OFF" position,
turn the engine with the starter mo tor until oil pressure
is registered on the gau ge.
12. Start the engin e and allow to idle for several minutes.
Chec k all joints for oil leaks.
Apr il '96
Lubricat
Lub ricating
ing System and
and Sump
Sump 16-2
16-21
1
REMOVAL, STRIPPING, ASSEMBLY AND

REPLACEMENT OF OIL PUMP
Removal
1. D r a i n e n g i n e o ilil an
an d r e m o v e t h e s u m p , ((F
Fig. 16-61).
Fig. 16-61
2. R e m o v e o i l p u m p r e t ai
ai n i n g b o l t s , ( F i g . 1 6 - 6 2 ) .
Fig. 16-62
3. P u l l o u t o ilil p u m p f r o m c r a n k c a s e , (F
(F i g . 1 6 - 6 3 ))..
Fig. 16-63
Stripping
1. C l a m p t h e o i l p u m p i n a v i c e f it
it t e d w i t h s o f t j a w s .
2. Rem ove bolts retaining th e strainer and pick-up pipe,

(Fig. 16-64).
3. Rem ove the pick-up pipe and strainer from the oil
pum p body
y..
Fig. 16-64
Apr il '96

and S
Sump
ump 16-2
16-22
2
4 Rem ove the p ressure relief valve, spring and piston

f r o m t h e o i l p u m p c o v e r , ((F
Fig. 16-65).
5. Unsc rew and remo ve the bolts retaining the cover

plate to the oil pump body, (Fig. 16-66).
6. L i f t o u t t h e o i l p u m p g e a r f r o m t h e o ilil p u m p b o d y , ( F i g .
16-67).
7. Press the oil pu mp shaft from the drive gear, (Fig.

16-68).
Lubr icati ng Syst

System
em and Sump 16-2
16-23
3
8. Rem ove the o ilil p u m p d r i v e s h a f t f r o m t h e b o d y , c o m 

plete with gear, (Fig. 16-69).
9. P r e s s o i l p u m p d r i v e s h a f t f r o m t h e g e a r , ( Fi
Fi g . 1 6 - 7 0 ) .
1 0.
0. E x a m i n e the oil pump body and gears for signs of ex
cessive wear, scoring and localised seizure. Replace
all faulty parts. Sh ould th e oil pum p b ody or gears
show signs of e x c e s s i v e w e a r t h e c o m p l e t e o iill pu
pu m p
mu st be replaced.
Assembly
1. P r e s s g e a r o n t o t h e o ilil p u m p d r i v e sh
sh a f t , (F
(F i g . 1 6 - 7 1 ) .
2. Chec k th e installation height o f the gear to the drive

shaft, (Fig. 16-72).
Apr il '96

and Sump 16-2
16-24
4
3. Insert the oil pum p dr ive shaft into the pu mp body,
(Fig. 16-73).
Fig. 16-73
4. Press the helical g ear onto the shaft and by using a

vernier ch eck the distance between the gear and the
pump flange
e;; r e f e r t o s p e c i f i c a t iio
o n s f o r t h e c o r r e c t d is
is 
tance, (Fig. 16-74).
c
0
d
■nil
Fig. 16-74
5. Insert the oil pum p driven gear into the pum p body,
(Fig. 16-75).
Fig. 16-75
6. Check the clearance between the oil pum p gears and

housing, (Fig. 16-76).
iiiiaas
fig. 16-76
Apr il '96
Lubric
Lub ricating
ating Syst
16-25
5
7. Check the clearanc e b etween cover plate and gears,

(Fig. 16-77).
Fig. 16-77
8. Replac e the o i l p u m p p l a t e,
e, i n s e r t b o l t s a n d t i g h t e n t o
■in /© =
Fig. 16-78
9. Fit oil relief valve into the oil pum p cover plate and
tighten to the specified torqu e, (Fig. 16-79).
Fig. 16-79
1 0 . P r i m e t h e o i l p u m p w i t h e n g i n e o i l.l.
11. Bolt the oil suction pipe and strainer to the oil pump
body and tig hten to the specified torque, (Fig. 16-80).
^51
Fig. 16-80
Apr il '96

and Sump
Sump 16-2
16-26
6
12. F i t t h e s t r a i n e r tto
o t h e s u c t io
io n p i p e , { F i g 16-81)
Fig. 16-81
13. Insert the oil pum p into the crank case, replac e the
retaining bolts and tigh ten to the specified torque, (Fig.
16-82).
Fig. 16-82
14. F i t n e w s u m p g a s k e t s t o t h e c r a n k c a s e , ( F i g . 1 6 --8
83).
Fig. 16-83
15. Rep lace the sum p, insert th e bolts a

annd tighten to the
1 6 . F i llll t h e s u m p w i t h r e c o m m e n d e d o i ll..
17. With t h e e n g i n e S t o p c o n t r o l s e t t o t h e “ O F F " p o s i ti

ti o n ,
turn t h e e n g i n e w i t h t h e s t a r t e r m o t o r u n t ilil o i l p r es
es s u r e
18. Start the engin e and allo w to idle for several minu tes.
C h e c k a l l j o i n t s f o r o i l l e ak
ak s .
Fig. 16-84
Apr il ‘96
SECTION 17
Fuel System
Page
ILLUSTRATION .......................................................................................................................................................................................... 17-2
INTRODUCTION ........................................................................................................................................................................................ 17-3
SPECIFICATIONS ..................................................................................................................................................................................... 17-3
REMOVING THE INJECTION

INJECTION PUM P .................................................................................................................................................. 17-4
REPLACING THE INJECTION PUMP .................................................................................................................................................. 17-5
SETTING “A" TYPE INJECTION PUMP TIMING .............................................................................................................................. 17-7
SETTING “MW” TYPE INJECTION PUMP TIMING .......................................................................................................................... 17-10
REMOVAL AND REPLACEMENT OF FUEL

FUEL INJECTOR S .............................................................................................................. 17-13
TESTING THE INJECTOR FOR LEAKAGE ......................................................................................................................................... 17-15
TESTING THE NOZZLE OPENING AND INJECTION PRESSURE ......................................................... 17-16 ’-16
JET SPRAY TEST ..................................................................................................................................................................................... 17-16
...............................................................................................................
DISMANTLING AND ASSEMBLY OF FUEL INJECTORS 17-16

ASSEMBLY OF THE NOZZLE . II
SPECIAL TOOLS FOR SECTION 17 ................................................................................................................................................... 17-19
April '96
Fuel Syst em 17-2

17-2
INJECTION SYSTEM
1 SEALING WA SHER 14 SEALING WA SHER
2 B A N J O B OL T 15 I N J EC
EC T O R A S S E M B L Y
3 S P L IIT
T S
SEEA L 16 I N J EC
EC T O R S E C U R I N G N U T
4 INJECTOR PIPES 17 NOZZLE
5 CLAMP 18 CA P NUT
6 CLA MP 19 SPACER
7 SPRING WA SHER 20 T HR U S T P
PII N
8 SCREW 21 S P R IIN
NG
9 “ A"
A" T Y P E I N J E C T I O N P U M P 22 SHIM
10 “MW" TYPE INJECTION PUMP 23 SCREW PLUG
11 C L IP 24 SPLIT SEAL
12 P A C K IN
IN G 25 CONNECTOR
13 CLAMP 26 L E A K -O
- O F F P IP
IP E
Apri l ‘96
Fuel System
Syst em 17
17-3
-3
INTRODUCTION
T h e A D E 3 6 0 s e r i e s o f e n g i n e s a r e f i t tte
e d w i t h t w o t y p e s o f B o s c h f u e l i n j e c t io
io n p u m p s . T h e s u c c e s s f u l “ A " t y p e i n j e c ti
ti o n
pum p is fi
fi t t e d t o the naturally aspirated engine, and the "MW" typ e f u el
el i n j e c t iio
on pu mp is used on the turbocharg ed
engine. The “M W" f u e l i n j ec
ec t i o n p u m p , b e i n g o f a lla
a r g e r a n d m o r e r i g id
id d e s i g n , e n a b l e s it to provide h igher pressures,
allowing the turboc harged engine to develop greater pow er a
annd a higher torque
SPECIFICATIONS
FUEL SYSTEM
In j e c t i o n p u m p a n d g o v e r n o r BOSCH
Injection pressure N ew 2 0 , 0 t o 2 0 ,8
,8 M P a
Used min. 18,0 MPa
I n je
je c t io
io n p u m p t i m i n g refe
err e n g i n e n u m b e r 364N 19° BTDC
D at
a t a p l a t e - o t h e r w iis
s e use 3 6 4 C //T
T /T
/T I 15° BTDC
t i m i n g a s l i s t ed
ed 366N 19° BTDC
366C/T 16° BTDC
366TI - up to 150 kW 16° BTDC
366TI - above 150 kW 12° BTDC
F u e l lift p u m p d e li v e r y p r e s s u r e 80 kPa
Idle speed 600 r/min
I n j ec
ec t o r p r o t e c ti
ti o n s l e e v e ..................... ....................................................... M 1 4 x 1 ............................................................... 5 0 N m
I n j e c t o r s e c u r i n g n u t ................................. ....................................................... M34 x 1,5 .......................................................... 70 Nm
Injector cap nut to nozzle bo dy ......... ....................................................... M24 x 1.5 .......................................................... 80 Nm
S t u d f o r i n j ec
e c t i on
o n p u m p m o u n t i n g . .... ....................................................... M 10 ...................................................................... 10 - 20 Nm
I n je
je c t iio
on pum p gear to pum p ............. ....................................................... M14 x 1 ,5 .......................................................... 80 Nm
I n j e c t o r p i p e n u t s to
to i n j e c t i o n p u m p ....................................................... M12x 1 ,,5
5 .......................................................... 25 Nm
I n j e c t o r p i p e n u t s tto
o injec tor ............... .................
.........................
................
................
................
...............M1
.......M1 4 x 1 ,5 .......................................................... 25 Nm
Pressure/Return pipe adap ter to cyl head .......................................... M22 x 1,5 10 Nm
....................................................... M16 x 1,5 ............ 10 Nm
Leak off pipe to injectors ...................... ....................................................... M8 x 1 ................................................................ 20 Nm
Supply and return pipe connections ....................................................... M 1 4 x 1 . 5 .......................................................... 3 5 N m
I n je
je c t iio
o n p u m p s u p p o r t ........................... ....................................................... M 8 ......................................................................... 35 Nm
Delivery valve holder:

“A
A"" t y p e p u m p .............................................. ....................................................... stage 1 ............................................................... 40 Nm*
stage 2 ............................................................ 40 Nm*
stage 3 ............................................................ 40 Nm*
F iin
nal torqu e .................................................. 45 Nm
* Loosen after 1st, 2nd and 3rd stages
“MW" type pum p ............................................... 50 - 60 Nm

8 m m n u t ................................................................. 12 - 16 Nm
Apr il '96
Fuell Syst em 17-4

Fue
REMOVING THE INJECTION PUMP

1 Detach the oil f i l le
le r pipe or breather from the timing
c a s e ( i f fi
fi t t e d ) o r r e m o v e t h e b l a n k i n g p l u g , ( F i g . 1 7 - 1 ) .
2. R e m o v e t h e r o c k e r c o v e r , (F
(F i g . 1 7 - 2 ).
).
Fi g . 1 7 - 2
3. T u r n t h e e n g i n e i n t h e n o r m a l d i r e c t i o n o f r o t a t i o n u n ttii l
the No. 1 p i s t on
on is on compression stroke and the
m a r k o n t h e v i b r a t i o n d a m p e r i s in
in l i n e w i t h (FB) poin
t e r o n t h e ti
ti m i n g c a s e , ( F i g . 1 7 - 3 ) .
Attention! Neve
Neverr turn the engine in the reverse direction
of rotation.
Fi
4. Discon nect the fuel filte

err , fuel and oil feed pipes to the
i n j e c ti
ti o n pum p, (Fig. 17-4).
Fig. 17-4
April ‘96
Fuel Syst em 17-5

17-5
5. Use special too l, part num ber 4020 0705, to unscrew
and d e t a c h t h e i n j e c t o r p i p e s f r o m t h e i n j e c ttii o n p u m p
, (Fig. 17-5).
6. Unscrew and remo ve nuts reta

aii n i n g t h e i n t e r m e d i at
at e
f l a n g e o f t h e i n j e c t io
io n p u m p t o t h e timing housing. Fit
protective dust caps,(Fig. 17-6)
7. L i f t o f f t h e in
in j e c t i o n p u m p , ( F i g . 1 7 - 7 ) .
Fig. 17-7
REPLACING THE INJECTION PUMP
1. Turn the engine in the norm al dire ec

c t i o n o f r o t a t i o n u n t iill .
N o . 1 p i s t o n i s o n c o m p r e s s i o n s t r o k e.
e. T h e m a r k o n
t h e v i b r a t iio
on damper must be in line w ith the (FB)
pointer on the timing case (Fig. 17-8)
Fig. 17-8
Apr il '96
Fuell Syst em 17-6

Fue 17-6
2. Replace injection pum p flange gasket, insert the pump

i n tto
o the tim ing housing and e n s u r e t h a t t h e m a r k on
on
the injection pum p gear tooth lines up with the arrow in
the timing case, (Fig. 17-90).
(Refer fig. 17-16 oh pag e 17-7).
Fig. 17-9
3. Replace the injection pum p reta
aii n i n g n u t s a n d t i g h t e n
to the specified torque (Fig. 17-10).
Fig. 17-10
4. Set start of delivery (Refer to i n j e c t io

io n p u m p t i m i n g
Fig. 17-14)
5 Attach injector pipes to the injection pump. Use special

tool part No . 4020 0718 t o t i g h t e n a l l c o n n e c t i o n s to
to
the specified torque, (Fig. 17-11)
Fig. 17-11
6. Attach t h e f u e l a n d o i l f e e d p i p e s t o t h e i n j e c t iio
on pum p
and tighten to the specified torque. R eplace the breather
pipe or plug. (Fig. 17-1 2)
7 Replace rocker cover.
Fig.17-12
Apri l '96
Fuel Syst em 17-7

17-7
SETTING “A" TYPE INJECTION PUMP TIMI
TIMING
NG
1. Rem ove rocker cover, (Fig. 17-13)
Fig. 17-13
2. Tu rn eng ine in tth
he direction of rotation u n t iill No. 1
piston is on comp ression stroke and the mark on the
vibration dam per is in line with the pointer on the
timing case, (Fig. 17-14)
/v N \
1- - 1
m k
M i llll « S
Fig. 17-14
3. Detach the oil filler pipe or breather fro m the timing
case (if fitted) or remov e the b l an
an k i n g plug, ( F iig
g.
17-15).
Fig.17-15
4. C h e c k t o e n s u r e t h a t t h e m a r k e d t o o t h o n t h e i n j e c t iio
on
pum p gear is in line with t h e p o i n t e r i n t h e ti
ti m i n g gear
cover, (Fig. 17-16).
Fig.17-16
Ap ril '96
Fuel Syst em 17-8

17-8
5. Discon nect a llll injector pipes from the in
in j e c t i o n pump
using special tool part number 4020 0705. (Fig.17-
17).
6. A ttach Pressu re Limiting Valves, special tools part

num ber 4020 2376, t o i n j ec
ec t i o n p u m p o u t l e ts
ts n u m b e r s
2 t o 6.
6. ( R e f F i g . 1 7 - 1 8 )
7 Pump Unit ( R e f f i g . 1 7 - 1 9 )
Item 1 Elec tric Moto r
Item 2 Gea r P Pump
ump
Item 3 Pressure Limiting Valve
Item 4 Fuel Tank.
Item 5 Retu
Returnrn Line.
Item 6 Test Line with Sightglass.
Item 7 12v conne ction cablel
Item 8 Conn ection line (supply)
Item 9 Base plate
tern 10
10 Relay box with switch
8.Detach fuel supply line at pump an d connect supply

line (8) of the pum p unit (Ref Fig 17-20)
9 Detach fuel r e tu
tu r n line ((1
12) and overflow valve at the
i n j e c t io
io n p u m p a n d s e a l b o r e w i t h a d u m m y p l u g . ( 1 3 ) .
1 0.
0. To the No 1 outle
ett o f t h e f u el
el p u m p connect the tes
stt
l i n e w i t h s i g h t g l a s s ( R e f ( 6 ) F i g . 1 7 - 2 0 ).
).
Apr il '96
Fuel Syst em 17
17-9
-9
1 1 . T u r n t h e c r a n k s h a f t i n t h e d i r e c t i o n o f r o t a t i o n u n t i l iitt
is approx. half a turn before T.D.C. of the No. 1
cy!inder.(Ref. Fig17-21)
12. L o c k t h e i n j e c t i o n p u m p l e v e r a t F u l l l o a d p o s i ttii o n
Note:-Befo re switching on the Test Pump Unit the

i n j e c t i o n p u m p l e v e r m u s t b e l o c k e d a t fu
fu l l l o a d an
an d
m u s t n o t b e m o v e d w h e n t h e p u m p u n i t is
is r u n n in
in g .
Switch on the Test Pum p Un it only while performing
measurement
13. Sw itch on the Test Pum p Unit then slowly rotate the
cranks haft in the direction of rotation and observe
the fuel jet in the sight glass. - The exact start of
delivery is reached wh en the fuel jet changes from a
tapered jet stream to a chain of drops.
A = ‘ Fu ll * fu el je t
B.= Fu el jet tapered - shortly before start of delivery
C . = C h a i n o f d r o p s = s t a r t o f d e lili v e ry
ry
14.Check start of delivery markin g between setting pointer

o n t im
im i n g c a s e a n d m a r k i n g o n v i b r a t io
io n d a m p e r o r b el
el t
p u l l e y . R e f . Fi
Fi g . 1 7 - 2 3 )
15 If it is necessary to correct the s tart of delivery of the

injection pump , the cranksh aft should be turned in
direction of rotation exacxtly to the start of delivery
marking o f s e t ttii n g p o i n t e r w it
it h v i b r a ttii o n d a m p e r o r b el
el t
pulley.
16. Slacken th e nuts (13) securing the i n j e c ttii o n

pum p. (Ref.Fig. 17-24)
No te:-Th e injection pum p lever must be locked at full load

a n d m u s t n o t b e m o v e d w h e n t h e p u m p u n i t iis
s r u n n in
in g .
Switch on the pu mp u init only for performing
m e a s u r e m e n t o t h e r w i s e fu
fu e l m a y g e t in
in t o tth
he combustion
c h a m b e r i f t h e n o z z l e i s le
le a k i n g
Apr il '96
Fuell System
Fue Sys tem 17-10
17-10
17.Move the i n j ec
ec t i o n pum p on th e s l o t t ed
ed holes far
e n o u g h t o a c h i e v e e x a c t s t a r t o f d e lili v e r y
8.Re-tighten the hex.nuts (13) of injection pump to

specified torque
19
9.. R e p e a t t es
es t i n g o f s t a r t o f d e l i v e r y o p e r a t i o n s 11 to 14
above
20. Rem ove the Pressur e l iim

mitng valve and the test line
fitte
ed
d to no.1 cylinder and reassem ble i n j e c t iio
on
pipes.Ref. F IG. 17-26
2 1 . R e p l a c e t h e o i l ffii l l e r p i p e / b r e a t h e r o r b l a n k i n g plug to
t h e t i m i n g c a s e . R e f . F i g . 1 7 -2
-2 7 .
SETTING “MW”
“ MW” TYPE INJECTION PUMP TIMING
Note:
W i t h t h e f i t ti
ti n g o f t h e “ M W " i n j e
ecction pump to the AD E 360
s e r iie
es turbocharged engine the timing procedure has
c h a n g e d . I t i s n o l o n g e r a d v i s a b l e t o r e m o v e t h e d e l i v e ry
ry
valve when carrying o u t t h e s p i llll t im
im i n g . O n c e t h e v a l v e
h a s b e en
en r e m o v e d t h e v a l v e s e a l c o u l d b e d a m a g e d a n d
cause a leak to develop at high pressu re.
2. Turn the engine in the direction of rotation and position
No. 1 cylinder on firing stroke ± 45 degrees before top

dead centre, (Fig. 17-28).
Apr il '96
Fuel System
Sys tem 17
17-1
-11
1
3. Rem ove t h e lo
lo w p r e s s u r e p i p i n g t o an
an d f r o m t h e i n j e c 
tion pum p and fuel f i l t er
er s . No te position of gallery
pressure v a l v e No
No . 1 a n d f u el
el s u p p l y t o g a l l er
er y N o . 2 ,
(Fig. 17-29).
4. F i t t h e s u p p l y p i p e f r o m t h e p r e s s u r e s p i llll p u m p t o th
th e
front end of the inje
ecction pump gallery. F i t a b la
la n k i n g
p l u g t o t h e r e a r e n d o f t h e g a l l er
er y .
( S p ilil l p u m p p a r t n u m b e r 4 0 2 0 2 3 6 3
o r a l t e r n a t iv
iv e l y 4 0 2 0 - 2 4 6 0 )
5. Discon nect all injector pipes and the respective deli

very valve unions on the injection pum p. Fit pressure
relief valve un ions, (Fig. 17 -31).
6. Con nect the p r e s s u r e s p i llll p u m p r e t u r n p i p e w i t h s p iill l

pipe to the No. 1 deliver y valve union, (Fig. 17 -32).
7. Mo ve the accelerator control lever on the i n j e c ti

ti o n
p u m p t o t h e f u llll s p e e d p o s i t i o n .
Apr il '96
Fuel Syst em 17-12

17-12
8. Conn ect the pressu re spill pum p to a suitable power

supply; ensur e that the pum p pressure is approx.
2500 kPa.
9. Contin ue turning t h e e n g i n e i n t h e n o r m a l d i re
re c t i o n o f
r o t a t i o n u n t i l t h e f u el
el d i s c h a r g e i n t h e g l a s s b o w l c h a n 
ges from a tapered jet stream to a chain of drops,
(Fig. 17-33).
1 0 . C h e c k t h e t i m i n g m a r k s (F
(F B ) on the tim ing cover and
v i b r a t i o n d a m p e r f o r a l i g n m e n t , ( F i g . 1 7 --3
34).
11
1.. If the timing Is retarded loosen the injection pum p
s e c u r in
in g nuts a n d m o v e t h e t o p o f t h e i n je
je c t iio
on pump
towards the cylinder block or a w a y f rro
o m t h e c y l iin
nder
b l o c k to
to a d v a n c e , ( F i g . 1 7 - 3 5 ) .
1 2.
2. A f t e r a d j u s t m e n t r e - c h e c k t h e t i m i n g by repeating ope
rations 2 to 9.
1 3.
3. T i g h t e n the nuts retaining th e i n j e c t iio
on pum p to the
timing g ear housing, (Fig. 17-36).
Apr il '96
Fuel Syst em 17
17-1
-13
3
14. Rem ove the blanking plug and high pressure pipe from
the test pum p. Recon nect th e gallery pressure valve
and the low pressu re feed t o t h e p u m p a n d t ig
ig h t e n to
the specified torque.
15. Reco nnec t the injector pipes and tighten the bottom
unions to the specified torque, (Fig. 17-37)
16. Replace rocker cover.
REMOVAL AND REPLACEMENT OF FUEL INJECTORS

Removal
2. U s e s p e c i a l t o o l , p a r t n u m b e r 4 0 2 0 0 7 0 5 , an
an d u n s c r e w
the pipes to the fuel inje
ecctor. Push t h e i n j e c t o r p ip
ip e t o
one side. Do not bend the pipe, Fig. 17-38).
3. D i s c o n n e c t t h e f u e l l ea
ea k o f f p ip
ip e , ( Fi
Fi g . 1 7 - 3 9 ) .
4. Rem ove the injector securing nut with special tto

ool
4020 0873, (Fig. 17-40).
Fig. 17-40
Apr il '96
Fuell Syst em 17-14
Fue 17-14
5. Use special tool 4020 1076 to p u l l t h e in

in j e c t o r o u t o f
the cylinder head, (Fig. 17-41).
6. If too tight withdraw the injector with special extra

ac
ctor,
part num ber 4020 1063, (Fig. 17-42).
K e e p m a t c h e d w a s h e r w i t h t h e r e s p e c t i v e i n jje
e c tto
or.
A tten tio n ! S e e s e c ti o n 12 f o r r em o v al an d r ep la c em en t
of injector protection sleeves
Replacement
1. Insert a new injector sealing was her into the cylinder

head, (Fig. 17-43).
Note: T h e n e w s e a lili n g w a s h e r s m u s t b e t h e s a m e s iiz

ze
a n d t h i c k n es
es s a s t h e o n e s r e m o v e d .
2. Insert injector into the cylinder head and locate the

notch on th e injector w ith th e groove in the cylinder
head, (Fig. 17-44).
Fig. 17-44
Apri l '96
Fuel System 17-15
3. Rep lace the injector securing nut and use a torque

wrenc h fitted with special tool 4020 08 73 to tighte
enn to the
specified torque, (Fig. 17-45)
4. Rep lace the fuel leak off pipe fitted with new s e a l iin
ng
was hers and tighten to the specified torque, (Fig. 17-46)
5. R eplace the pres sure pipe to the fuel i n j ec
ec t o r and use
special tool 4020 0718 to tighten to the specified
torque,(Fig 17-47)
TESTING THE INJECTOR FOR LEAKAGE

1. With specialised no zzle cleaning equip men t c a r e f u l ly
ly
rem ove carbo n deposits from the injector nozzle tip
h o l e s , ( F ig
ig . 1 7 - 4 8 )
Apr il ‘96
Fuell Syst em 17-16

Fue 17-16
2 . A t t a c h t h e i n j e c t o r t o t h e t es
es t e r , ( F i g . 1 7 - 4 9 )
Attention ! Only u se clean te

ess t i n g f l u i d o r f i l t e r ed
ed d i e s e l f u el
el f o r
testing purposes.
Note: C a r e m u s t b e t a k e n d u r i n g t e s t i n g a s t h e s p r a y is
cons iderable pressu re and wou ld penetrate the skin of
is u n d e r
hands or face
3. S l o w l y p r e s s d o w n t h e p u m p t e s t e r l e v e r u n titi l t h e p r e s s u r e
gauge shows 200 kPa below opening pressure of the
injector nozzle. The injector is faulty if fuel leaks from the
nozzle within 10 seconds.
4 In all cases of siezure or leakage dism antle and clean the

i n j e c t o r . T h e n o z z l e m u s t b e r e p l a c e d i f c a r e ffu
ul cleaning
Fig. 17-49
TESTING NOZZLE OPENING AND INJECTION PRESSURE

1. A t t a c h i n j e c t o r t o t e s t e r .
2 . S lo
lo w l y a d v a n c e t h e p u m p t e s t l e v e r ; n o t e t h e p r e s s
suure when
t h e i n j e c t o r o p e n s , ( F ig
ig . 1 7 - 5 0 )
3 . T h e i n j e c t o r p r e s s u r e m a y b e a d j u s t e d b y ad
ad d i n g o r r em
em o v i n g
shims on top of the com pression spring.
JET SPRAY TEST

1. Turn off the pressure gauge.
2. Op erate the hand pum p lever (several b r is

is k s t r o k e s ).
). T h e
i n j e c ti
ti o n i s c o r r e c t w h e n a l l f o u r j e t s s p r a y f i n e a n d e v e n , (Fig
17-51)
DISMANTLING AND ASSEMBLY OF FUEL INJECTORS
1. Clam p special injector support 4020 091 2 in a vice.

2. I n s e r t t h e i n j e c t o r i n t o t h e h o l d e r , ( F iig
g. 17 -52)
Fuel Syst em 17-1

17-17
7
3. With special tool 4020 0925 unscrew tth

he injector
n o z z l e c ap
ap nut from the injector body and d ismantle
the injector assembly , (Fig. 17-53).
Fig. 17-53
4. Carefu lly remov e carbon deposits from injector hole
es
s,
(Fig. 17-54)
5. Dip needle valve and n o z z l e b o d y i n t o c l e a n d i e s e l f u el

el
a n d c a r y o u t d r o p t e s t , s e e o p e r a t i o n 6 b e llo
ow.
Fig. 17-54
6. L i ft
ft needle valve by approxim ately one third of itit s
length from th e nozzle body. Releas the needle valve
s o t h a t i t r e t u r n s t o i t s s e a t u n d e r i t s o w n w e i g h t , ( F iig
g.
17-55)
If the need le valve sticks before reaching the seat ,

r e p l a c e t h e c o m p l e t e n o z z l e a s s em
em b l y .
Fig. 17-55
ASSEMBLY OF THE NOZZLE

1 . I n s e r t t h e in
in j e c t o r b o d y i n t o s p e c i a l h o l d i n g t o o l 4020
0912,(Fig. 17-56)
Fig. 17-56
Apr il '96
Fuell Syst em 17-18

Fue 17-18
2 . IIn
nsert shim ( 2 ) , s p r i n g ( 3 ) , t h r u s t p i n ((4
4 ) , a d a p t o r ( 5 ) in
in t o tth
he
injector body (1). Insert the n eedle valve (6) into the nozzle
( 7 ).
). P l a c e t h e n o z z l e o n t o t h e a d a p t o r ( 5 ) , ( F i g . 1 7 - 5 7 )
Fig. 17-57
3 . T w o g u i d e p i n s a r e f itit t e d o n b o t h s i d e s o f t h e a d a p t e r . T h e
guide pins which loc ate inthe corresponding holes in the
nozzle holder are in different position to the two pins which
locate the nozzle. Incorrect fitment of the adapt er is therefore
impossible. The adapter face wh ich m ates with the nozz
zll e i s
cham fered at the edge, (Fig. 17-58).
Fig 17-58
4. S c r e w i n j e c t o r c a p n u t ( 8 ) o n t o t h e in
in j e c t o r b o d y ( 1 ),
), ( F i g . 1 7 
59).
Fig. 17-59
5. Use special tool 4020 0925 t o t i g h t e n t h e i n j e c t o r c a p tto
o tth
he
specified torque, (Fig. 17-60)
Fig. 17-60
Fuel System 17-1

17-19
9
O B T A I N A B L E F R O M : G R U N D Y T E C H N I F O R M , B U R M A N R O A D , D E A L P A RK
RK , P O R T E L I Z A B E T H 6 0
0001
TEL: (041) 43-2299, FAX: (041) 43-2224
Split ring spanner for

injector pipes
see fig. 17-5, 17-18
part number 4020 0705
Crowfoot ring spanner for

remo ving/replacin g injector pipes
see fig. 17-11, 17-26, 17 -47
Spill pipe
see fig. 17-20
Fuel container for checking start
of delivery
see fig. 17-21
Socket for injector securing nuts

see fig. 17-32
Fuel injector impact extractor

see fig. 12-12
Apr il ‘96
Fuel System 17-20
Extractor for injectors

see fig. 12-13
Suppo rt for stripping and

assem bling injectors, see fig. 17-44
Spann er for stripping and

assem bling injectors, 22 mm
see fig. 17-45
Pressure relief valve (set of 5)

for blanking off the delivery valve
see fig. 17-32
P r e s s u r e s p ilil l t im
im i n g p u m p
see fig. 17-33
A lt e r n at iv e p ar t n u m b er 4 0 2 0 2 4 6 0
J . S . B a r n e s t i m i n g u n i t a v a i l a b l e ffrr o m :
Pro-Hyd Import & Export (Pty) Ltd.
1 11
11 T e n t h R o a d , K e w
Johannesburg
April '96
SECTION 18A-1
Turbocharger
CONTENTS OF SECTION 18A
Page
I L L U S T R A T IO
IO N KKK TURBO CHAR GER ........................................................................................................................................................................ 18A-2
I L L U S T R A T IO
IO N GARRETT TURBOCHA RGER ........................................................................................................................................................... 18A-3
S P E C I F IC
IC A T I O N S - K K K 8c G A R R E T T ................................................................................................................................................................................ 18A-4
INTRODUCTION ................................................................................................................................................................................................................................ 18A-5
REMOVAL ............................................................................................................................................................................................................................................... 18A-6
MEASURING TURBOCHARGER SHAFT END PLAY ................................................................................................................................................. 18A-7
M E A S U R I N G T U R B O C H A R G E R S H A F T S IID
DE PLAY ............................................................................................................................................... 18A-8
DISMANTLING ...................................................................................................................................................................................................................... 18A-9
A SSEMBLY ...................... ' .................................................................................................................................................................................................... 18A-15
REPLACEMENT ............................................................................................................................................................................................................................... 18A-22
INTERCOOLER ................................................................................................................................................................................................................................ 18A-25
Apr il ‘96
Turbocharger 18A-2
KKKTURBOCHARGER
1 TURBINE WHEEL AND SHAFT ASS

SEEMBLY 12 THRUS T BEARING
2 SEA LING RINGS 13 O IL DEFLECTOR
3 H EAT SHIELD 14 SPAC ER
4 CIRCUP 1 5 S E A L C A R R I E R //T
THRUST WASHER
5 BEARING 16 SEA LING RINGS
6 CIRCLIP 17 O-RING
7 BEARING HOUSING 18 END PLATE
8 CIRCLIP 19 SOCK ET CAP SCREW
9 BEARING 20 COMPRESSOR ROTOR WHEEL
10 CIRCLIP 21 COMPRESSOR ROTOR WH EEL
11 THRUST WA SHER RETAINING LOCK NUT
Apr il '96
Turbocharger 18A-3
Garrett AiResea
AiResearch
rch
1 C O M P R E S S O R R O T O R W H E E L R E TA
T A I N IIN
N G N UT 11 S P R I N G L O C A T IN
IN G P I N S
2 COMPRESSOR ROTOR WHEEL 12 BEARING HOUSING
3 END PLA TE 13 CIRCLIP
4 O -R IN G 14 BEARING
5 S E A L IN G R IN G 15
CIRCLIP
6 S E A L C A R R IE R /T H R U S T W A S H E R 16 HEAT SHIELD
7 C IR
IR C L I P 17 LOCK PLATE
8 B E A R IN G 18 BOLT
9 C IR
IR C L I P 19 SEALING RING
10 T H R U S T B E A R IN G 20 T U R B IN
IN E W H E E L A S S E M B L Y
Apr il '96
Turbocharger 18A-4
S P E C IF
I F IIC
CATIONS FOR K KK TURB OCHARGER
Rotor shaft - end pla y 0 15 mm max

side pla y 0,4
455 mm max.
ru
unn ou t 0,007 mm max.
T O R Q U E S P E C IF
IF I C A T I O N S
E n d p l a t e ............................................................ 8-10 Nm
C o m p r e s s o r r o t o r w h e e l r e t a i n in
in g n u t .......................................... 1s t .s t a g e .................................................................................................................... 10 Nm
2nd stage ............................................................................. angle of rotation
+60°
Turbine housing to centre ho usin g ......................................................................................................................................................................................... 20 Nm
Com pressor housing to ce
enntre housing ................................................................................................................................................................................. 7 Nm
Oil return M8 - 25 Nm
Oil sup ply M8 - 25 Nm
O i l s u p p l y b a n jo
jo b o l t ........................................................................................................................................................................................................................ 40 N m
Turbocharger to exhaust m anifold .......................................................................................................................................................................................... 65 N m
S P E C IF
I F IIC
CATIONS FOR GARRETT TURBOC HARGER
Rotor sh aft- end play 0,10 mm max.

side play 0,75 mm max.
run ou t 0,007 mm max.
En d p la te .................
.........................
................
................
................
................
................
................
................
...............
................
.................
................
................
................
................
................
................
................
................
...............
................
.................
................
................
................
................
................
.........8
.8 - 1 0 Nm
C o m p r e s s o r r o t o r w h e e l r e t ai
ai n i n g n u t .......................................................... 1 s t s t a g e ........................................................................ i n i t i al
al t o r q u e 2 Nm
2nd stag e ............................................................. angle of rotation 90°
Turbine housing to centre hou sing .......................................................................................................................................................................... 11,5-15 Nm

Com pressor housing to centre hou sing ................................................................................................................................................................ 11,5-15 Nm
Oil return .............................................................................................................................................. ; M8 - 25 Nm
Oil sup ply M8 - 25 Nm
O i l s u p p l y b a n jo
jo b o l t ...................................... 40 Nm
Turboch arger to exhaust manifold .......................................................................................................................................................................................... 65 Nm
Apr il '96
Turbocharger 18A-5
INTRODUCTION
Turbocharger
The Garrett/AiResearch and K K K t u r b o c h a r g e r s f o r i n t e rrn

n a l c o m b u s t i o n e n g i n e a p p l i c a ttii o n c o m p r i s e s o f a t u r b i n e a n d a
r a d i al
a l c o m p r e s s o r w h i c h u t i llii s e a c o m m o n s h a f t . T h e tu
tu r b i n e a n d c o m p r e s s o r w h e e l s a r e m o u n t e d a t o p p o s i t e e n d s o f tth
he
shaft. The shaft is enclosed and supp orted by fully floating bearings in a housing. The turbine and c om presso r wheels are
enclosed in cast housings.
A f te r t h e e n g in e is s t ar t ed t h e f lo w o f ex h a u s t g as f r o m t h e en g in e p as s es th r o u g h t h e t u r b in e h o u s in g an d c au s e s th e s h af t
assemb ly to r o t at
at e . The com pressor w h e e l,
l, m ounted at the opposite end of the shaft, d r aw
aw s ambient air in
in t o tth
he
c o m p r e s s o r h o u s i n g , c o m p r e s s e s t h e a i r a n d d e l iiv
v e r s i t t o t h e en
en g i n e .
D u r i n g o p e r a t i o n t h e t u r b o c h a r g e r r e s p o n d s t o t h e e n g i n e l o ad
ad d e m a n d s b y r e ac
ac t i n g t o t h e e x h a u s t gas energy. As the
p o w e r o f t h e e n g i n e i n c r e as
a s e s , t h e s p e e d a n d o u t p u t o f t h e r o t at
a t i n g a s s e m b l y i n c r e as
as e s p r o p o r t i o n a t e l y .
T h e r e m o v a l a n d r e p l a c e m e n t p r o c e d u r e iill l u s t r a t ed
ed s h o w s a t y p i c a l i n s t a l la
la t i o n , w h i c h m a y v a r y d e p e n d i n g o n s p e c i f i c at
at i o n .
Checking a Turbocharger in a Vehicle
D i s c o n n e c t t h e i n l e t d u c t a n d tu
tu r n t h e r o t o r . E n s u r e e a s y a n d u n i f o r m running. If necessary turn back and forth several
t i m e s u n t i l t h e r o t o r i s f r e e o f o iill a n d c a r b o n d e p o s i t s .
T h e t u r b o c h a r g e r h a s g y r o s c o p i c s t a b i l i s a t i o n a n d r u n s i n f l o a t i n g b e a r in
in g s . T r y t o m o v e t h e r o t o r i n a n d o u t . T h e e n d p l a y
i s s e t c o r r e c t l y i f v e r y l i t ttll e o r n o p l a y c a n b e f e lt
lt . M o v e a n d t u r n t h e r o t o r u p a n d d o w n in either direction. The s ide play is
adjusted co rrectly if no scraping occu rs.
Turbocharger Oil Leaks
The bearing hous ings on all types of turboch argers used on ADE eng ines are sealed with oil controlling rings to provide a
seal between the oil and the air/exhaust gas. The function of these s e a ls
ls is based on th e pressu re build up in the
c o m p r e s s o r h o u s i n g . T h e r e c o u l d , h o w e v e r , b e a v a c u u m a t h i g h e n g i n e R P M w h i l e c o a s t in
in g w h i c h would f a v o u r o ilil
l e a k a g e a n d o i l c o a t i n g o f t h e i n l e t p o r t.
t. T h e a m o u n t o f o i l l o s t in
in t h i s w a y i s e x t r e m e l y l o w a n d h a s n o m e a s u r a b l e i n f l u e n c e
on the engine's oil consumption.
The turbo charg er should not be remov ed if oil covered ports are found during a service, as long as an inspection of the
t u r b o c h a r g e r d iid
d n o t s h o w a n y d e f e c ts
ts .
A n o t h e r c a u s e fo r oi l le a k s c o u ld b e a d a m a g ed (d ef o r m ed ) o r c lo g g ed oi l r et u rn p ip e. T h e r ed u c ed c r o s s -s ec t io n al s iz e o f
the pipe wo uld lead to an i n c r e a s e i n r e s i s t a n c e , c a u s i n g t h e o i l l e v el
el i n t h e t u r b o c h a r g e r t o r i s e a n d o i l t o l e a k p a s t t h e
s e a l s o n t h e t u r b i n e a n d c o m p r e s s o r s i d e s . I n t h i s c a s e c l e a n o r r e p l a c e t h e o i l r e tu
tu r n p i p e .
Fitting a Reconditioned Turbocharger
P r i o r t o f i tttt i n g t h e tu
tu r b o c h a r g e r the inlet and flanged manifold ahead of the compressor, the exhaust manifold and exhaust
pipe, as well as the oil f ee
ee d and return pipes m ust be inspected thoroug hly for dirt a
annd d am age. Th e plugs on the
t u r b o c h a r g e r o p e n i n g s s h o u l d o n l y b e r e m o v e d j u s t b e f o r e ffii t t i n g . T h e b e a r i n g h o u s i n g m u s t b e f i l le
le d w i t h c l e a n e n g i n e o i l
t h r o u g h t h e o i l i n l e t p o r t p r i o r t o c o n n e c t i n g t h e o i l f e e d p i p e . D u r i n g f i llll i n g tu
tu r n t h e m o v i n g parts by hand to coat the
bearings with oil.
Apr il '96
Turbocharger 18A-6
REMOVAL, OVERHAUL AND REPLACEMENT
1. Discon nect the oil feed p ipe to the turboc harger, i

(Fig. 18A-1).
Fig. 18A-1
2. Rem ove the oil feed retaining bracket, if fitted, and

loosen the bottom banjo union, (Fig. 18A-2).
Fig. 18A-2
3. Disconnect the oil drain pipe from turbocharger to

s u m p , (F
(F i g . 1 8 A - 3 ) .
Fig. 18A-3
4. If a heatshield is fitted, unscrew the retaining nuts

and remov e, (Fig. 18A-4).
Fig. 18A-4
Apr il ‘96
Turbocharger 18A-7
5. Prior to rem oval m ark the position of the exhaust

elbow in r el
el a t i o n to the turbo charg er body, ( F iig
g.
18A-5).
6. Rem ove t h e e x h a u s t p iip

pe elbow from the turbochar
ger, (Fig. 18A -6).
7. Unscrew the mounting nuts of the turbocharger and

remov e t h e t u r b o c h a r g e r ffrr o m t h e e x h a u s t m a n i ffo
old,
(Fig. 18A-7).
Measuring the turbocharger shaft end pla

ay
y.
1. Clam p the turbo charger, turbin e end up, in a vice fit

ted with soft jaws.
2. Mo unt a dial gaug e fitted with a mag netic base onto

the t u r b o c h a r g e r h o u s iin
ng. P l a c e t h e d i al
al g a u g e p rro
o
be at the end of the turbine shaft and set the gauge
t o “ 0 " , (F
(F i g . 1 8 A - 8 ) .
3. Push the turbin e shaft against the dial gaug e probe

and no te the reading. Ensu re that the reading agrees
with specifications.
Fig. 18A-8
Apr il ‘96
Turbocharger 18A-8
Measuring the turboch arger shaft side play
A tt en ti o n ! T h e s id e p la y s h o u ld b e m ea s u r e d a t th e tu r b in e
end only.
1. Push the turbine wheel to one side and measure the

gap between the blades and the housing with a feeler
gauge. Not e clearance. (Fig. 18A-9).
2. Push the turb ine wh eel in the oppo site direction and
measure the gap between the blade
ess a n d th
th e h o u s in
in g
with a feeler gaug e. Note clearance.
3. The s u m o f t h e tw
tw o r e a d i n g s d i v i d e d b y t w o r e p r e s e
ennts
the average side play
y.. C o m p a r e w i t h s p e c i f i c a
att i o n s .
A tten tio n ! M e a s u r e m e n t s s h o u ld b e m a d e a t t w o d if fe r en t
points.
HOLDING TOOLS
120
K K K H O L D IN G T O O L
A K N U R L IN G
F i g . 18
18 A - 1 0 B ADAPTED TO AVAILABLE ROTOR
J__
orvf -
I 1
§
4—
^ p
2f
t
F iig
g. 1
18
8A-1
11
1 G A R R E TT
TT H
HO
O L D IIN
NG TOOL
Apr il '96
Turbocharger 18A-9
DISMANTLING
1. P r i o r t o r e m o v a l m a r k p o s i t iio
o n s o f tth
h e t u r b iin
ne and com
p r e s s o r h o u s i n g s i n r e l a t io
io n t o t h e c e n t r e h o u s i n g , ( F i g .
18A-12).
2. Bend down the lock ing p lates and unscr ew the bolts
holding the turbine and co mpressor housings to the
centre housing, (Fig. 18A-13).
Attention! Tight housings can be removed with a rubber

or hide faced hamm er.
3. Uns crew a n d r e m o v e t h e b o l t s a n d l o c k in
in g p l a t es
es f r o m
the com pressor housing, (Fig. 18A-14).
4. Rem ove the c o m p r e s s o r h o u si

s i n g f r o m tth
he centre hou
s i n g , ( F ig
ig . 1 8 A - 1 5 ) .
Attention! Tight housings can be removed with a rubber

face
edd ham mer.
Fig. 18A-15
Apr il ‘96
Turbocharger 18A-10
5 R e m o v e t h e O - r i n g fr
fr o m t h e c o m p r e s s o r h o us
us i n g .
(Garrett), (Fig 18A-16).
Fig. 18A-16
6. Using special holding tool m ade to ilil l u s t r a t i o n Fig.

18A-10, 18A-11, c l a m p t h e t u r b o c h a r g e r s h a fftt a n d u n 
screw the com pressor rotor wh eel re
ett a iin
ning nut, ( Fi
Fi g .
18A-17).
a
Fig. 18A-17
7. Rem ove the outer O - r i n g f r o m t h e b a c k i n g p l at

at e , ( F i g .
1 8 A - 1 8 ).
). (KK K-turb os).
Fig. 18A-18
8. W ith a B osch hot air blow er or sim ilar heat source,

h e a t th
th e c o m p r e s s o r r o t o r w h e e l,
l, ( F i g . 1 8 A - 1 9 ) .
A tten tio n ! D o n o t h e a t t h e c o m p r e s s o r r o to r w h e el w it h a
welding torch.
Fig. 18A-19
Apr il '96
Turbocharger 18A-11
9. L i f t o f f t h e c o m p r e s s o r r o t o r w h e e l f r o m t h e ttu
urbo rotor
shaft.
R e m o v e r e t a i n in
in g a l i e n c a p s c r e w s f r o m c o p r e s s o r e
ennd
plate, (Fig. 18a-20).Rem ov e comp ressor end plate from
centre housing
Unique to KKK turbocharaers:
1 0.
0. Lift out the seal c a r r i e rr// t h r u s t w a s h e r f r o m t h e c o m 
presso r end plate, (Fig. 18A -21).
11. Remo ve the inner O-ring from the end plate

e,, ( F ig
ig .
18A-22).
Fig. 18A-22
12. Rem ove the oil deflector from the centre housing, (Fig.
18A-23).
Fig. 18A-23
Ap ril '96
Turbocharger 18A-12
13. R e m o v e t h e t h r u s t b e a r i n g , ( F i g . 1 8 A - 2 4 ))..
Fig. 18A-24
14. Rem ove the spacer sleeve, (Fig. 18A-25).
Fig. 18A-25
15. R e m o v e t h e t h r u s t w a s h e r , (F
(F i g . 1 8 A - 2 6 ) .
■III ASS
Fig. 18A -26
Unique to GARRETT turbocharaers:
1 6.
6. R e m o v e t h e O - r iin
ng from the centre housing,
(Fig.18A-27).
Fig. 18A-27
Ap ri l '96
Turbocharger 18A-13
17. Lift out the thrust bearing and thrust wash er from the
centre housing, (Fig. 19-28).
Fig. 18A -28
18. R e m o v e t h e s e a l c a r rrii e r //tt h r u s t w a s h e r f r o m t h e t h rru

ust
bearing, (Fig. 18A -29)
19. R e m o v e t h e s e a l iin
n g r i n g f r o m t h e s e a l c a r r i e r / tth
hrust
washer, (Fig.18A-30)
All Turb ocharaers:
20. L i f t o f f t h e c e n t r e h o u s i n g f r o m t h e t u r b o r o t o r s h af
af t ,
(Fig. 18A -31).
Fig. 18A-31
Apr il '96
Turbocharger 18A-14
21. R e m o v e t h e h e a t s h i e l d f r o m t h e t u r b o r o t o r s h a fftt ,
(Fig. 18A-32).
2 2 . R e m o v e t h e b o t t o m s e a l iin
ng rings from the turbo rotor
shaft, (Fig. 18A-33).
2 3 . R e m o v e t h e t u r b o - r o t o r s h a f t a s s e m b l y a n d t h e h o l d in
in g
tool clamp from the vice
e..
24. R em ove th e sealing rings from the seal carrier, (Fig.

18A-34).
25. R em ove the circlips retaining the turbo ro

ro t o r b e a r i n g s
from the centre housing, (Fig. 18A -35).
Fig. 18A-35
Apr il '96
Turbocharger 18A-15
26. Lift out the bearings and rem ove the inn er c i r c llii p s ,
(Fig. 18A-36).
A tten tio n ! A l l' p a r t s s h o u ld n o w b e w as h e d in a s u it ab le

cleaning fluid. Do not use abrasive cleaning m ethods
w h i c h m a y d a m a g e o r d e s tr
tr o y m a c h i n e d s u r f a c es
es .
Thoro ugh ly clean the turbine end oil cavity in the centre
h o u s i n g . R e m o v e a l l c a r b o n i s e d o iill .
Check the turbine housing and rotor blade
ess for cracks,
score m arks and foreign particles. Check both rotors for
bent or damaged blades and seal rings for wear. Replace
all worn p a r t s . E x a m i n e m a t i n g s u r f a c e s f o r t h e s e a l r i ng
ng s
in the centre housing an d back plate. Exam ine the sea
all
groo ves in the shaft and seal carrier for wear.
A SSEM B L Y
1. Place t u r b o r o t o r s h a f t o n a s u i t a b l e V -b
-b l o c k , l e v e l w i t h
the bearing points and check the shaft for p a r a llll e l
running 10 m m from the end of the threads. Refer to
the s p e c i f i c a t io
io n s for m aximum permissible r un
un out,
(Fig. 18A-37).
2. Fit the inner circlips and bearings to the centre housing,

(Fig. 18A-38).
3. Insert th e outer bearing circlips in the centre housing,

(Fig. 18A-39).
A tten tio n ! A lw ay s u s e n e w c ir c li p s af t er an o v er h au l.
Fig. 18A-39
Apr il ‘96
Turbocharger 18A-16
4. C l a m p t h e r o t o r s h a f t in
in a v i c e .
5. Fit the sealing rings to the bottom of the rotor shaft and
l u b r i c a t e , ( F ig
ig . 1 8 A - 4 0 ) .
Fig. 18A -40
6. Fit the heat sh ield over the turbo rotor shaft,

( F i g . 18
18 A - 4 1 ) .
Ill: /©=
Fig.18A-41
7. Fit the centre housing ov er the turbo rotor shaft. Do not

d a m a g e t h e s e al
al i n g r i n g s , ((F
Fig. 18A-42).
Fig. 18A -42
Unique to KKK turboc haraers:
8. F i t t h e i n n e r t h r u s t w a s h e r , (F
(F i g . 1 8 A - 4 3 ) .
Fig. 18A-43
Apr il '96
Turbocharger 18A-T7
9. R e p l a c e t h e s p a c e r , ((F
Fig. 18A-44).
10. Fit the thrust bearing over the r e t a i n in

in g pins, (Fig
18A-45).
11. I n s e r t t h e o i l d e f l e c t o r , (F
(F i g . 1 8 A - 4 6 ) .
12. F i t a n e w i n n e r O - r i n g t o t h e e n d p l a t e,
e, (F
(F i g . 1 8 A - 4 7 ) .
Fig. 18A-47
Apr il '96
Turbocharger 18A-18
13. R e p l a c e a n d l u b r i c a t e th
th e s e a l i n g r i n g s o n th
th e s e a l
carrier and fit into the end plate, (Fig. 18A-48).
Fig. 18A-48
14. Fit the end plate to the centre housing, (Fig. 18A-49).
■wi'
Fig. 18A -49
15. Insert the cap s crews retaining the end plate to the
centre hous ing and tighten to the specified torque, (Fig.
18A-50).
A3 =
Fig. 18A -50
Unique to GARRETT Turb ocharaers:
16. Lubricate and replac e the sealing rings on the seal

c a r r i e r/
r/ t h r u s t w a s h e r ( F ig
ig . 1 8 A - 5 1 ) .
Fig. 18A-51
Apr il '96
Turbocharger 18A-19
17. Fit the thrust bearing to the seal carrier/thrust washer

a n d s l i d e o v e r t h e t u r b o r o t o r s h a f t . A l i g n th
th e t h r u s t
bearing with the retaining pins, (Fig. 18A-52).
Fig. 18A -52
18. Rep lace the O-ring at the top of the centre housing,
(Fig. 18A-53).
Fig. 18A-53
19. Line up the sealing ring on the seal carrier/thrust

w a s h e r a n d f i t t h e en
en d p l a t e , ( F i g . 1 8 A - 5 4 )
Fig. 18A-54
20. I n s e r t t h e b o l t s f i t te
te d w i t h t h e l o c k p l a t e s i n t o t h e e n d
p l a t e , (F
(F i g . 1 8 A - 5 5 ) .
Fig. 18A-55
Ap ri l '96
Turbocharger 18A-20
21. Tighten the bolts to the specifie

edd t o r q u e a n d s e c u r e tth
he
l o c k p l a t e s , (F
(F i g . 1 8 A - 5 6 ) .
AH tu rb o c h araers
22. Heat the comp ressor wheel with a Bosch hot air blower
or alternative heat source, (Fig. 18A -57).
A tten tio n ! Do not h e at th e c o m p res s o r w h ee l w it h a

welding torch.
Fig. 18A-57
23. Fit th e com press or wh eel to the turbo rotor shaft, ( F iig
g.
18A-58).
Fig. 18A-58
24. Replac e the outer O -ring o n t h e en

en d p l a te
te , a p p l y petro
l e u m j e l l y t o a s s i s t , (F
(F i g . 1 8 A - 5 9 ) .
Fig. 18A-59
Turbocharger 18A-21
25. Re place th e com presso r wh eel retaining lock nut and

tighten to t h e s p e c i f i ed
ed t o r q u e . D o n o t b e n d th
th e s h a
aff t ,
(Fig. 18A-60).
A tten tio n ! A lw ay s u s e a n e w lo c k nu t
26. Mou nt th e c entre housing in a vice and turn the rotor

shaft by hand to ch eck for free running, (Fig. 18A-61).
27. Fit the com press or housing to the centre housing, (note
s c r i b e d a s s e m b l y m a r k s ) . R e p l a c e t h e b o lltt s a n d r e t a i 
n i n g c l a m p s a n d t i g h t e n t o t h e s p e c i f ie
ie d t o r q u e , ( F ig
ig .
18A-62).
28. Fit the turbine hou sing to the centre housing (note
s c r i b ed
ed a s s e m b l y m a r k s ) , ( F
Fii g . 1 8 A - 6 3 ) .
Note: O n G a r r e t t t u r b o c h a r g e r s e n s u r e t h a t a n e w O -r
-r i n g i s
f i tttt e d i n t h e c o m p r e s s o r h o u s i n g .
Apr il ‘96
Turbocharger 18A-22
29. Replace the bolts and clamp s, t i g h t e n to
to t h e s p e c i fi
fi e d
t o r q u e a n d b e n d o v e r t h e l o c k i n g p l a t e s , (F
(F i g . 1 8 A - 6 4 ) .
A tten tio n ! A lw ay s fi t n ew lo c k in g p la te s .
30. Turn the turbo rotor shaft by hand and check for free
running.
Fig. 18A-64
31. L u b r i c a t e b e a r i n g s i n t h e c e n t r e h o u s i n g w i t h e n g i n e o iill ,
(Fig. 18A-65).
■ III
III /B s
Fig. 18A-65
R e p l a c in
in g t h e t u r b o c h a r g e r
1. Mount the turbocharger onto the exhaust manifold.

Ensure that th e mating surfaces of f l a n g ed
e d a r ea
ea s a
arr e
clean and free of burrs or high spots, (Fig. 18A-66).
III U s
Fig. 18A-66
2. Fit the exhaust pipe elbow to th e turbocharger (note

s c r i b ed
ed a s s e m b l y m a r k s ) , ( F
Fii g . 1 8 A - 6 7 ) .
(Fig. 18A-67
Apr il '96
Turbocharger 18A-23
Mou nt the heat shield, if fitte

edd, to the turbo studs
a n d s e c u r e w i t h n e w s e l f l o c k i n g n u t s , ((F
Fig. 18A-68).
Fig. 18A-68
4. I n s e rrtt the b a n j o b o ltlt co

co n n e c t i n g the turbo feed pipe to
the oil pressu re gallery on t h e c y l i n d e r b l o c k an
an d t ig
ig h 
t e n t h e b o l t t o t h e s p e c i f i e d to
to r q u e , ( F i g . 1 8 A - 6 9 )
Fig. 18A -69
5. Tighten t h e t u r b o oi
oi l f e e d p i p e r e t a
aii n i n g b r a
accket to the
specified torque, (Fig. 18A-70).
Fig. 18A-70
6. Use a new gasket and replace the top oil feed pipe,
insert the bolts and tigh ten to the specified torque, (Fig.
18A-71).
Fig. 18A-71
Apr il '96
Turbocharger 18A-24
Apr il '96
Turbocharger 18A-25
INTERCOOLER
Depend ing on application and /or requirem ent the AD E 360 series en
en g i n e s are built to accept a charge air cooler
( In
In t e r c o o l e r ),
), m o u n t e d b e t w e e n t h e t u r b o c h a r g e r c o m p r e s s o r h o u s i n g a n d i n l e t m a n i f o l d .
The intercoo ler resemb les a coolant radiator core (see fig 18A-118). Und er load, air is compr essed and forced via the
intercooler into the com bustion a r e a b y t h e t u r b o c h a r g e r . D u r i n g c o m p r e s s i o n b y t h e t u r b o c h a r g e r t h e a i r h e a t s u p an
an d
expands, co nsequ ently becom ing less dense. By directing the hot air through an interco oler some h eat is remo ved. The
e x p a n s i o n o f t h e c h a r g e d a i r is
is t h e r e f o r e r e d u c e d , w h i c h m e a n s m o r e a i r w i l l b e f o r c e d i n t o t h e c o m b u s t i o n a r e a , t h e
increased d ensity of the charged a i r (o
(o x y g e n ) a llll o w s f o r m o r e fu
fu e l t o b e i n j e c t e
ed
d, and con sequently m ore pow er will be
developed.
1m m Exh au s t
2 E SSjifl Charge air
Maintenance
1. K e e p t h e c o o l e r e x t e r n a l l y c l e an
an a n d f r e e f r o m o b s t r u c t i o n w h i c h m a y a f f e c t t h e a i r f l o w .
2. C h a r g e a i r l e a k s w i l l r es
es u l t i n lo
lo s s o f p o w e r , th
th e r e f o r e :
A ll in d u c ti o n tu b in g an d h o s e j o in ts m u s t b e k ep t ti g h t.
E n s u r e t h a t a l l m o u n t i n g s a r e s e c u r e t o p r e v e n t v i b r at
at i o n s w h i c h m a y c r a c k t h e i n t e r c o o l e r t u b es
es .
Period ically inspect the intercooier tubes for holes due to corrosion or impac t by debris.
3. I n t h e e v e n t o f d u s t o r f o r e iig
g n o b j e c t s e n t e r i n g t h e i n d u c t iio
o n s y s t e m a n d / o r t u r b o c h a r g e r c o m p r e s s o r w h e e l f a ilil u r e ,
clean the induc tion tubing/hos es to and from the i n t e r c o o i er
er . Dism antle and clean the intercooier. Sealed units that
canno t be cleaned pr operly should be replace
edd.
Apr il '96
SECTION 18B
Power Steering Pump
CONTENTS OF SECTION 18B

Page
ILLUSTRATION ........................................................................................................................................................................................................................................ 18 B
INTRODUCTION ................................................................................................................................................................................................................................ 18B-3
SPECIFICATIONS ............................................................................................................................................................................................................................. 18B-3
FAULTFINDING .................................................................................................................................................................................................................................. 18B-4
R E M O V A L O F T H E P O W E R S T E E R IN
IN G P U M P : .......................................................................................................................................... 1 8 B - 5
Z.F. HIGH PRESSUR E PUMP
DISMANTLING OF THE ROTOR AND CAM RING ....................................................................................................................................................... 18B-6
REMOVAL OF THE DRIVE SHAFT ........................................................................................................................................................................................ 18B-7
R E M O V A L O F F L O W A N D P R E S S U R E R E S T R IC
I C T IO
IO N V A L V E ........................................................................................................................ 18B-8
D I S M A N T L I N G , I N S P E C T IO
IO N A N D A S S E M B L Y O F
F L O W A N D P R E S S U R E R E S T R IC T IO N V A L V E ........
............
.......
.......
.......
.......
.......
.......
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.....18B
.18B -8
R E P L A C E M E N T O F F L O W A N D P R E S S U R E R E S T R I C TI
TI O N V A L V E ........................................................................................................... 18B-9
P R E -A
-A S S E M B L Y O F P U M P H O U S I N G .............................................................................................................................................................................. 18B-9
A S S E M B L Y A N D R E P L A C E M E N T O F D R IV E S H A F T ........................................................................................................................................... 18B-10
R E P L A C E M E N T O F D R IV
IV E E N D F A C E P L A T E .......................................................................................................................................................... 18B-11
R E P L A C E M E N T O F C A M R IN
IN G A N D R O T O R ............................................................................................................................................................. 18B-11
...........................................................................................................................................
R E P L A C E M E N T O F E N D F A C E PL
PL A T E A N D C O V E R 18B-12
VICKERS HIGH PRESSURE PUMP
D IS M A N TL IN G A N D R EM O V A L O F R O TO R A ND CA M R IN G ..
.....
......
......
......
.....
....
.....
......
......
......
......
......
......
.....
.....
.....
.....
......
......
.....
.....
.....
.....
......
......
......
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....
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......
......
......
......
......
......
....18B
.18B -13
REMOVAL AND DISMANTLING OF VOLUME CONTROL

A N D P R E S S U R E R E L IE F V A L V E ........................................................................................................................................................................................ 18B-14
REPLACEMENT OF DRIVE SHAFT AND SEAL .......................................................................................................................................................... 18B-16
R E P L A C E M E N T O F R O T O R A N D C A M R IN
IN G ............................................................................................................................................................. 18B-17
R E P L A C IN
IN G T H E P U M P .......................................... 18B-18
SPECIAL
SPECIAL TOO LS ................................................................................................................................................................................. 18B-20
Apr il '96
SECTION 18B
Power Steering Pump
Z F --R
ROTARY PUMP TYPE 767
733
1 NU T 17 O-RING
2 S P R IN
IN G W A S H E R 18 FRO NT PLATE, DR IVE-END
3 DR IVE SHA FT 19 ROTOR
4 WO ODRU FF KEY 20 VANE
5 CIRCLIP 21 CA M RING
6 B A L L B E A R IN G 22 O-RING
7 CIRCLIP 23 FRONT PLATE COVER-END
8 SH AFT SEAL 24 SPRING
9 NEEDLE BEARING 25 O-RING
10 HO USING 26 COVER
11 B L A N K I N G P L U G 27 H O O K E D C I R C L IIP
P
12 SEAL ING RING 28 THRO TTLE IN
IN S E R T
13 PHILLIPS SCR EW 29 V A L V E P IIS
STON COMPLETE
14 IDENTIFICATION PLATE 30 PRES SURE R IIN
NG
1 5 F I T T E D P IN
IN 31 SEA LING RING
16 O-R ING 32 B LANKING PLUG
Apr il '96
Power Steering
Steerin g Pump 18B-3
18B-3
INTRODUCTION
Depending o n a p p l i c a t i o n t h e A D E 3 6 0 s e r i e s e n g i n e s c a n b e f i t te
te d w i t h e i t h e r o f t w o t y p e s o f r o t a r y p o w e r s t e e ri
ri n g
pum ps, both of which op erate as follows:
W h e n t h e d r i v e s h a f t a n d i t s r o t o r a r e t u r n e d , t h e v a n e s a r e g u i d e d i n s lo
lo t s a n d b e i n g r a d i a l l y m o b i l e , a r e p r e s s e d a g a i n s t
the guid e part of the cam r i n g b y t h e a c t iio
o n o f c e n t r i f u g a l f o r c e a n d o iill p r e s s u r e . T w o s u c c e s s i v e v a n e s a r e c l a s s e d a s a
c e l l ( a to
to t a l o f 1 0 ) . T h e i r l a t e r a l m o v e m e n t i s r e s tr
tr i c t e d b y t h e p r e s s u r e p l a t e s . E a c h c e l l d e l i v e r s t h e m a x i m u m effective
volu m e twic e per revolution. The suction and pressure cham bers are arranged so that the hydraulic and radial forces
a c t i n g o n t h e r o t o r w i l l n e u t r a l i s e e a c h o t h e r . T h e c o v e r e n d f r o n t p l a t e an
an d t h e d r i v e e n d f r o n t p l a t e a r e p r o v i d e d w i t h f o u r
g r o o v e s s o t h a t t h e p r e s s u r i s e d o i l r e a c h e s t h e i n t e r n al
al f a c e o f t h e p u m p v a n e s , w h i c h w i l l t h e n b e s u p p o r t e d b y t h e c e n t r i 
f u g a l f o r c e . F r o m t h e p r e s s u r e c h a m b e r t h e o iill t r a v e l s t h r o u g h h o l e s t o t h e f l o w r e s t r i c t i n g v a l v e , a n d b y w a y o f a t h r o t t l e
restriction to the pressure line. The reduced pressu re behind the throttle re
esstriction is transmitted via holes to the s pring-
loaded end of the flow restricting piston and therefore on to the relief valve.
I n c r e a s i n g t h e s p e e d o r p u m p d e l i v e r y w i llll p r o d u c e a g r o w i n g p r e s s u r e d r o p b e h i n d t h e t h r o t t l e r e s t r i c t o r a n d a l s o a g a i n s t
t h e s p r i n g e n d o f t h e v a l v e p i s t o n . W h e n t h e h y d r a u l i c p o w e r ( p r e s s u r e d i f f e r e n t i al
al t i m e s piston area) exceeds th e spring
f o r c e , t h e p i s t o n w i l l m o v e t o w a r d s t h e s p r i n g a n d t h e o i l d e l i v e r ed
ed i n e x c e s s w i l l f llo
o w t h r o u g h t h e n o w e x p o s e d e j e c ti
ti o n
h o l e i n t o t h e s u c t i o n d u c t o f t h e p u m p . A s a r e s u lt
lt , a n a l m o s t c o n s t a n t o i l f l o w f o r t h e s t e e r i n g g e a r i s p r o v i d e d t h r o u g h o u t
the entire speed range.
TOR QU E SP EC I F IC
IC A TI ON S
P u l lle
e y to
to p u m p s h a f t .................................................................................................... M 1 4 x 1,5 ................................................. 80 Nm
Cover to pump housing 35 to 40 Nm
P u m p b r a c k e t to
to f u e l f ilil t e
err b r a c k e t ....................................................................... M 1 0 .............................................................. 40 Nm
A d ju s t in g b o lt t o w a t e r p u m p .................................................................................. M 10 ............................................................... 40 Nm
A d ju s t in g b o lt t o b r a c k e t ............................................................................................. M 1 2 x 1,5 ................................................. 50 Nm
V - b e lt
lt t e n s i o n f o r 1 2 , 5 m m w i d e b e l t s
N e w V - b e l t ..................... »..................... ......................... ....................... ................ ........................ ....................... ........................ .............. 4 0 t o 4 5 k.q
A f t e r ru n -i n p e r i o d ...... * .................................................................................... ..................................................................................... 3 0 t o 4 0 kg
U s e d V - b e l t ........................................................................................................... ..................................................................................... 3 0 t o 4 0 kg
Apr il ‘96
Power Steering
Steerin g Pump
Pump 18B-4
18B-4
V i c k e r s H i g h P r e s s u r e O i l P u m p V T 27
27
Fault finding
Problem Possible Cause Remedy

P u m p i s n o t d e l i v e r in
in g P u m p r u n n i n g i n w r o n g d i r e c t io
io n C h a n g e d i r e c t i o n o f r o t a t iio
on
P u m p d r i v e s h a fftt s h e a r e
edd R e m o v e t h e p u m p t o d e t e r m i n e t h e e x t e n t o f tth
he
V-belt slips o r is torn dam age a
ann d R e p l a c e d a m a g e d p a r tts
s
F l o w r e s t r i c t iio
on, valve binds Dismantle the pump and clean the v a l v e.
e. Re
install valve piston and c heck for ease of
operation. Slight rough spots can be removed by
lapping. Do not grind or cham fer control edges
No refinishing is permitted on valv e bore. All
parts must be cleaned prior to
to assemb ly. The
system sh ould be thoro ughly flushed an d f i l le
le d
w i t h c l e a n o i l.
l.
Van e
ess bi
bi n d i n r o t o r s l o t s Re
emm o ve
v e t h e p um
um p a
ann d c h e c k t h e r o to
to r s
sll o t s f o r
dirt, abrasives and sw arf. Clean rotor and vanes.
During assembly check the vanes for ease of
operation.
Oil viscosity too high. Use oil of correct viscosity.

P u m p c a n n o t su
su c k
I n lle
e t p ip
ip e
ess p a rrtt iia
a llll y b llo
o ck
c k ed
ed . D ra
r a iin
n th
th e o ilil ffrr o m t h e sy
s y s te
te m . F
Fll u
ussh a
all l p iip
pees
s . Fi
Fi l l
t h e s y s t e m w i t h f r e s h o i l in
in a c c o r d a n c e w i t h r e 
commendations.
Tank vent clogged. R e m o v e t a n k c o v e r a n d c l e an

an . C h e c k t h e s y s t e m
I n l e t fi
fi l t e r c o n t a m i n a t e d . f i l t e r o r i n t a k e f i l t er
er f o r c l o g g i n g . I f t h e i n t a k e f i l t e r
i s c l o g g e d , d r a i n t h e s y s t e m , f l u s h a n d r e fi
fi l l.
l.
Excessive pum p noise Intake pipe partially or completely The pum p should be able to suck without res
clogged. Filter clogged. triction to prevent cavitation. Drain th e system,
clean the intake pipe an d filter. Fill up with
r e c o m m e n d e d o ilil .
L ea
e a k in
in g i nl
n l et
et p i pe
p e c o nn
n n ec
e c ttii on
on s . Che
ecck by
by po
ouu ri
r i ng
ng o iill on
on con
nnnec
ctt io
io n s . N ot
ot e t h e
c h a n g e in
in p u m p n o i s e , t i g h t e n c o n n e c t i o n s .
L eak in g s h af t s eals . R e p l a c e i n a c c o r d a n c e w iitt h in

in s t r u c t i o n s
M i s al
al iig
g n m e n t o f s h af
a f t c o up
u p llii ng
ng . I n s pe
pe c
ctt t h e s h af
a f t b e ar
ar in
in g a n
ndd o iill s ea
ea l f o r p o s
sss ib
i b lle
e
faults, replace as necessary. Realign sh aft.
C on
o n tta
ain e
err s ea
ea l l e a k i n g
g.. Re
epp lla
a c e t h e c o n tta
a in e
err c o
ovve
err s e
eaal, tig ht en pip e to
tank connections
Apr il '96
Power Steering Pump 18B-5

18B-5
REMOVING AND REPLACING THE STEERING PUMP
Removing the pump
1. L o o s e n t h e c l a m p b o l t o f t h e V -b
-b e l t a d j u s t e r , ( F i g 18B-1).
Fig 18B-1
2. S l a c k e n o f f t h e V - b e l t a d j u s t e r f r o m t h e p u l l e y , ((F
Fig. 18B-2).
Fig. 18B-2
3. U n s c r e w a n d r e m o v e th
th e b o t t o m p u m p m o u n t i n g r e
ett a iin
ning
bolt, (Fig. 18B -3).
Fig. 18B-3
4. C l a m p t h e p u m p d r i v e p u l l e y in
in a v i c e , f itit t e d w i t h s o f t j a w s ,
u n s c r e w t h e p u l l e y r e t a i n in
in g n u t a n d r e m o v e t h e p u l lle
ey,
(Fig. 18B-4)
Fig. 18B-4
Apr il '96
Power Steering
Steering Pump 18B-6
18B-6
5. Uns crew the bolts retaining the mounting br acket to the

p u m p a n d r e m o v e t h e b r a c k e t , (F
(F i g . 1 8 B - 5 ) .
Fig. 18B-5
DISMANTLING
Remo val of Rotor and Cam R ing

Z F H ig
ig h P r e s s u r e V a n e P u m p
1. R e m o v e t h e c ir
ir c l i p f r o m t h e g r o o v e i n t h e p u m p h o u s i ng
ng
(Fig. 18B-6).
2. Rem ove the cover, spring and cover end plate from the
housing, (Fig. 18B-7).
Fig. 18B-7
3. T i l t t h e p u m p b o d y a n d r e m o v e c a m r i n g a n d ro
ro t o rr,,
(Fig. 18B-8).
Fig. 18B-8
Apr il '96

18B-7
R e m o v i n g t h e d r i v e sh
sh a f t
4. Rem ove the circlip, (Fig. 18B-9).
Fig. 18B-9
5. W i t h a R u b b e r o r p la
la s t iic
c h a m m e r k n o c k t h e d r iiv
v e s h af
af t f r o m
the housing, (Fig. 18B-10).
■in ra~
ra~
Fig. 18B -10
6. Kno ck the drive end face plate from the housing.
7. R e m o v e t h e v o l u m e c o n ttrr o l v a l v e .
8 . W i t h a s u i t a b l e p u n c h k n o c k t h e n e e d l e b e a r i n g an
an d d r i v e
shaft seal from the housing, (Fig. 18B-11).
9. R e m o v e t h e O - r i n g s f r o m t h e h o u s i n g , t h e h o l lo
lo w p i n a
an
nd
drive end face p late.
II M B S
Fig. 18B-11
10. After remov ing the circlip the bearing can be pressed from
the drive shaft, (Fig. 18B -12).
Fig. 18B-12
Apr il '96
Power Steering
Steerin g Pump
Pump 18B-8
18B-8
R e m o v i n g t h e F l o w a n d P r e s s u r e R e s t r iic
ction Valve
o f t h e Z.
Z . F . H ig
ig h P r e s s u r e V a n e P u m p
1 . R e m o v e t h e s c r e w p l u g f r o m t h e h o u s i n g , ((F
Fig. 18B-13).
2. R e m o v e t h e s p rrii n g a n d v a l v e p i s to
to n f r o m t h e h o u s in
in g
bore
Fig. 18B -13

D i s m a n t li
li n g , I n s p e c t io
io n a n d A s s e m b l y o f
t h e F l o w a n d P r e s s u r e R e s t r i cctt i o n V a l v
vee
1. Check the pressu re and flow re

esstriction valve for score marks
and wear. Th e flow control piston sho uld not bind in the
housing bore. Check the item n umb ers on the housing fa
acce
and the piston to ensu re match ing parts are used,
(Fig. 18B-14).
2. U n s c r e w t h e v a l v e s e a t s c r e w f r o m t h e p r e s s u r e r es
es t r iic
c t i on
on
valve (do not us e a vice). Ensure that none of the washers,
t h e b a llll , t h e s p r i n g g u i d e a n d c o m p r e s s i o n s p r i n g s a r e lo
lo s t .
T h e t h i c k n e s s o f t h e w a s h e r i s c r i t i c al
al f o r t h e r e s p o n s e r a n g e
o f tth
h e p r e s s u r e r e l i e f v a l v e . N e w w a s h e r s m u s t b e f i tt
tt ed
ed
to prevent the possibility of dam age, (Fig. 18B-15).
3 . C l e a n t h e c o n t r o l v a lv
lv e a n d t h e v a l v e s c r e w a n d b l o w o u t w i t h
c o m p r e s s e d a i r . R e i n s e r t t h e c o m p r e s s i o n s p r i n g , g u i d e p iin
n
a n d b a l l . S c r e w t h e v a l v e , s e a t s c r e w i n t o t h e c o n t r o l p i s tto
on,
t o g e t h e r w i t h t h e p r e v i o u s l y i n s t a l le
le d w a s h e r s .
F i g . 1 8 B - 1 5 ______________________________________________
1 V A LVE
LVE P IST
IST ON
2 COMPRESSION SPRING PRESSURE RELIEF VALVE
3 SPRING GUIDE PIN PIN
4 VALVE BALL
5 A DJ US T ING
ING W A S HE RS
6 VALVE SEAT SCREW
7 SPRING VOLUME CONTROL VALVE
8 S CRE W P LUG W IT H S E A LING W A S HE R
Apr il '96

18B-9
R e p l a c e m e n t o f F l o w a n d P r e s s u r e R e s t r iic
ction Valve
4. I n s e r t a s s e m b l e d v a l v e p i s t o n i n tto
o the b
boore. Check for
correct tolerance, (Fig. 18B-16).
5. Slide the comp ression spring onto t h e v a l v e p i s to

to n a n d
screw th e blanking plug into the thread hole with the sea
all i n g
w a s h e r p l a c e d u n d e r n e a t h , (F
(F i g . 1 8 B - 1 7 ) .
P r e -a
-a s s e m b l y o f P u m p H o u s iin
ng
Not e: P r i o r t o a s s e m b l y c l e a n a llll p a r t s , m o i s t e n s llii g h t l y w i t h

A T F o il an d r e p la c e al l s e al s an d O -r in g s .
1. W ith s u i t a b l e m a n d r e l p r e s s t h e n e e d l e b e a r i n g i n tto
o the
housing , (Fig. 18B-18).
T h e f a c e e n d o f t h e n e e d l e b e a r in
in g m u s t b e 3 7 , 0 to
to 3 7 , 2 m m
from th e face end of the housing, (Fig. 18B -19).
No te: The needle bearing is installed only in pum ps with

V-belt drive.
Fig. 18B-19
Power Steering
Steerin g Pump
Pump 18B-10
18B-10
2. With a m andrel press the shaft seal into the housing.

F i t t h e s e a l w i t h b e a r i n g g r e a s e b e t w e e n t h e s e a l in
in g
lips, (Fig. 18B -20).
3 . S c r e w t h e p l u g i n t o t h e h o u s i n g a n d t iig
ghten.
4. Fit an O-ring into the bottom gro ove of the housing.
5. I n s e r t a h o l l o w p i n i n t o t h e h o l e p r o v i d e d , ( F ig
ig . 1 8 B - 2 1 ) .
Assem bly and R eplacemen t of the Driv

vee S h a fftt
6. Press the ball bearing on the drive shaft and replace the
c i r c l ip
ip . F i t t h e w o o d r u f f k e y , ( F i g . 1 8 B - 2 2 ) .
L
L
| ig. 18B -22
7. Insert the pre-ass em bled drive shaft into the housing until
the ball bearing rests agains t the hou sing flange,
(Fig. 18B-23).
Fig. 18B-23
Apri l '96
Power Steering Pum p 18B-1

18B-11
1
8. I n s e r t t h e c i r c l i p r e t a iin
ning the ball bearing, (Fig. 18B-24)
Rep lacement of the Drive En

nd
d F a c e P l a te
te
9. I n s e r t tth
he O-ring into the groo ve in the neck of the
face plate.
10. Slide the drive end plate onto the hollow pin and press
with the neck into the housing , (Fig. 18B-25).
Rep lacement of the Cam Ring and Rotor
11. I n s e r t O - r i n g ( 1 ) i n t o t h e g r o o v e iin
n the housing,
(Fig. 18B-26).
12. Insert the cam ring. Th e sm aller hole locates the hollow
pin. The cast h alf arrow indicates the driving direction of
t h e p u m p , (F
(F i g . 1 8 B - 2 7 ) .
Apr il '96
Power Steerin g Pump 18B-12

18B-12
13. Fit the rotor with the smoo th bore on the drive shaft,
(Fig. 18B -28)
Fig. 18B-28
14. Insert the ten vanes with the round ed-off outer
surfaces facing th e cam ring into the slots of the
r o t o r , (F
(F i g . 1 8 B - 2 9 ) .
Fig. 18B-29
R e p l a c e m e n t o f tth
he End Face Plate and Cover
15. Fit the cover end onto the cam ring, as shown. The
hollow pin fits in one of the sm aller holes,
(Fig. 18B-30).
ii » =
Fig. 18B-30
16. I n s e r t t h e O - r i n g , (F
(F i g . 1 8 B - 3 1 ) .
Fig. 18B-31
Apr il '96
Power Steerin g Pump 18B-1

18B-13
3
17. Insert the spring into the bore of the cover end plate.
Position the cover with the recess inwards and push
into the hous ing until the circlip can be inserted,
(Fig. 18B-32).
1 8 . I n s e r t t h e f l o w a n d p r e s s u r e r e s t r i c t i o n v a l v e.
e.
Vickers High Pre ssure Oil Pump VT27

Dismantling -Removal of Rotor and Cam Ring
1. Rem ove the screws on the pump housing to which the

h o u s i n g c o v e r i s co
co n n e c t e d ; r e m o v e t h e p u m p h o u s i n
ngg.
2. R e m o v e t h e s p r i n g f r o m t h e t h r u s t p la
la t e
e.. M a r k t h e t h r u s t
plate, cam ring and hous ing cov er to ensure the parts are
correctly aligned on assem bly (refer to arrows),
(Fig. 18B -33)
Fig. 18B-33
1 O-RING 4 CAM RING

2 THR UST PLATE 5 O-RING
3 SPRING 6 HOUS ING COVER
3. R e m o v e t h e t h r u s t p l a te
te f r o m t h e l o c a ttii n g p i n s a nd
nd
take off the cam ring, (Fig. 18B -34).
2 THRUST PLATE 6 HOUSING COVER

4 CAM RING 7 MA RKING LINE
Apr il ‘96
Power Steering
18B-14
4. R e m o v e r o t o r w i t h p u m p v a n e s f r o m t h e d r i v e s h a fftt
s p l i n e s , ( F ig
ig . 1 8 B - 3 5 ) .
Fig. 18B -35

4 C A M R IN
IN G A O I L IN
IN F L O W FROM
6 H O U S IN G C O V E R S U P P L Y C O N T A IN E R
7 M A R K IN G L IN E B HYDRAULIC OIL OUT
8 L O C A TIN G P IN FLOW ON CAM RING
9 R OTOR C IN T A K E B O R E S
10 VAN ES
5. Rem ove O-rings item s 1 & 5

5,, (F
(F i g . 1 8 B - 3 6 ) .
6. R e m o v e t h e v o l u m e c o n t rro
o l v al
al v e .
7. C l e a n a l l p a r t s t h o r o u g h l y a n d r in
in s e .
Fig. 18B -36

1 O-R ING 4 CAM RING
2 THRUST PLATE 5 O-RING
3 SPRING 6 HOUS ING COVER
R e m o v a l a n d D i s m a n t l iin
ng o f Volum e Control
and Pressure Relief Valve
1. Knock hollow pin from the pum p housing.
2. R e m o v e t h e b l a n k iin
ng cover of the volume control
v a l v e a n d t h e c o m p r e s s i o n s p r i n g fr
fr o m t h e p u m p
Note: Caution! The compression spring may push off the

b l a n k in
in g c o v e r a n d t h e v o l u m e c o n t r o l v a l v e a f te
te r r e m o v i n g
t h e h o l l o w p i n.
n . L o o s e n t h e b l a n k i n g c o v e r w iitt h l i g h t h a m m e r
b l o w s i f it
it s h o u l d r e m a i n i n t h e h o u s i n g . D o n o t d a m a g e t h e
v o l u m e c o n t r o l v a lv
lv e .
Fig. 18B-37
1 BLANK ING COVER 4 VOLU ME CON TR. VALVE
2 HOLLOW P IN
IN 5 SPRINGS
3 O - R IN
IN G 6 PUMP HOUSING
Apr il '96
Power Steering
18B-15
5
3. C l a m p t h e v o l u m e c o n t r o l v a l v e a t ItIt s u n g r o u n d e n d
in a vice and uns crew the valve screw o f the pressure
relief valve. Ens ure that no adjusting screws are lost.
R e m o v e t h e v a l v e a n d s p r i n g f r o m t h e v o l u m e c o n t ro
ro l
valve. (Fig. 18B-38).
4. Prior to replacement check the ground surface of the

v o l u m e c o n t r o l v a llv
ve and the bore in the pump housing
for wear and d amag e. If the surfaces are showing score
m a r k s r e p l a c e th
th e c o m p l e t e o iill p u m p . N e v e r r e p l a ce
ce t h e
v o l u m e c o n t r o l v a l v e o n lly
y.
Fig. 18B -38

1 B L A N K I N G C O V E R W I T H O - R IIN
NG
2 VOLUME CONTROL VALV
VEE
3 SPR ING FOR PRESSU RE RELIEF VALVE
4 VA LVE CONE
5 ADJUSTING WA SHER
6 VALVE SCREW
7 S P R I N G FO
FO R V O L U M E C O N T R O L V A L V E
Special Tool
To be m anufactu red, (Fig. 18B-39).
A IN S T A L L A T IO N T O O L
B INS
STTALLATION TOOL
C INSTALL ATION SLEEVE
Fig.18B-39
Power Steering
18B-16
R e p l a c e m e n t o f D r i v e S h a f t a n d S e a l iin
ng Ring
1. R e m o v e t h e p u m p h o u s i n g a n d p r e s s t h e d r i v e s h a fftt
f r o m t h e h o u s i n g c o v e r . P a y a t t e n t i o n t o t h e s h e llll
halves (item 10), (Fig. 18B-40).
2 . W i t h a s c r e w d r i v e r l i ft
ft tth
h e o i l s e a l fr
fr o m t h e h o u s i n g
cover.
Fig. 18B -40

1 O-RING 8 O-RING
2 P U M P H O U S IN G 9 BEARING BUSH
3 T H R US T P LA TE 10 S H EL
EL L H A L F
4 O IL G U I D E P L A T E 11 DRIVE SHAFT
5 SPRING 12 BUSH
6 C A M R IN G 13 OIL SEAL
7 ROTOR WITH PUMP VANES 14 HOUS ING COVER
3. Place both shell halves on the drive shaft, then press the
d r i v e s h a f t i n t o t h e h o u s i n g c o v e r , ( F iig
g. 18B -41).
Note: The shell halves determine the end play of the drive
shaft which is 0,7 mm m a x . f o r n e w h i g h p r e s s u r e oi
oi l p u m p s
a n d s h o u l d n o t b e m o r e t h a n 1 m m f o r u s ed
ed p u m p s .
Replace the high pressu re oil pump if the end play is higher.
10 SHELL HALF
11 DRIVE SHA FT
14 HOU SING COVER
4. Use the installation tool to press the bush into the housing,
(Fig. 18B -42)
Fig. 18B-42
12 BE ARING BUSH
14 HOUS ING COVER
B INSTALLATION TOOL
.April '96

18B-17
7
Replace the ass embly sleeve on the drive sha

aff t a n d
with th e installation tool press the oil seal into the
Fig. 18B -43

11 D RIVE SHA FT C ASSEMBLY SLEEVE
13 O IL SEAL A IN S T A L L A T IO N T O O L
14 HOUS ING COVER
Replacem ent of Rotor a

ann d C a m R iin
ng
1. M o i s t e n a l l p a r t s w i t h A T F o i ll..
2. Install volu m e control valve.
3. Place the rotor on the drive shaft so that the counter

sunk end of the splined bore faces the housing cover.
4. Place the cam ring on the fitted pins so that the

r e s p e c t iv
iv e m a r k i n g s o n t h e h o u s i n g c o v e r a n d o n t h e
cam ring are aligned, (Fig. 18B-44).
Fig. 18B-44
6 C A M R IIN
NG 1 5 F I T T E D P IN
IN
11 DR IVE SHA FT 1 6 M A R K I N G L IIN
NE
14 HOU SING COVER
Note: W hen a new cam rin

ngg is insta
all l e
edd, it must be
positioned so that the hydrau lic oil bores are accurately
located abo ve the recesses in the hous ing cover,
(item 4 & 5 Fig. 18B-45).
5. Insert pum p vanes into slots or rotor so that the

rounded ends are facing outwards toward the cam
ring.
6. Position the thrust plate over the cam ring, ensuring

m a r k i n g s a r e a l iig
gned,
Note: The ou tle

ett h o l e s f o r t h e h y d r a u l i c o
oii l s h o u ld
ld b e a b o v e
the hyd raulic oil bores (item 5) of the cam ring.
Fig 18B-45
A O IL IN F L O W F R O M S U P P L Y C O N T A IN E R
B H Y D R A U L IIC
C OIL OUTFLO W FROM CAM RING
ROTOR
PUMP VANE
H Y D R A U L I C O IL
IL U N D E R P U M P V A N E
RECESS ON HO USING FOR INLET OF HYDR. OIL
INTO BORE
OIL BORE 7 INTAKE BOR ES
CAM RING 8 DRIVE SHAFT
Ap ril ‘96
Power Steerin g Pump

Pump 18B-18
18B-18
R e p l a c in
in g t h e P u m p
1. F i t t h e m o u n t i n g b r a c k e t t o t h e p u m p , i n s e r t b o lltt s a
annd
tighten to the specified torque, (Fig. 18B-46).
Fig. 18B -46
2. F i t t h e p u l l e y tto
o the pum p, clam p the pulley in a vice
fitte
ed
d with soft jaws, replace the retaining nut and
tighten to the specified torque, (Fig. 18B -47).
mi
Fig. 18B-47
3. Fit the pum p to the mo unting in the cylinder block,

insert the bottom retaining bolt. Do not tighten,
(Fig. 18B-48).
III!
Fig. 18B-48
4. F i t t h e V - b e l t t o t h e p u l l e y , ((F
Fig. 18B -49).
\r ■im ras
Fig. 18B-49
Apr il '96

18B-19
9
5. Insert the V-belt adju ster clamp bolt. Do not tighten,

(Fig. 18B-50).
6. U s e s p e c i a l t o o l 4 0 2 0 2 3 2 1 a n d a d j u s t t h e V - b e l t t en
en s i o n
to 40-5 0 kg (new belts), run the engine for 10-15 min.
and re-chec k the tension, which s hould be 30-40 kg.
A d ju s t t o 3 0 -4 0 kg if t h is f ig u r e is n o t r ea c h ed .
Position the tension gaug e on the belt with the flange
p a r a l l e l a g a i n s t t h e b e l t ed
ed g e . G r a d u a l l y a p p l y p r e s s u r e
t o t h e p r e s s u r e p a d . W h e n a “ c l i c k ” i s h e a r d o r f e lt
lt , s t o p
and rem ove the gauge. Turn the gauge sideways and
take a reading at the spot wh ere the indicator a
arr m
i n t e r s e c t s t h e s c a l e , ( F ig
ig . 1 8 B - 5 1 ) .
7. Tighten the lock nut on the V-belt adjuster,

7. Tighten the lock nut on the V belt adjuster,
(Fig. 18B-52).
8. Tighten the clam p bolt on the V-belt a

ad
djuster,
(Fig. 18B-53).
Apr il '96
Power Steerin g Pump

Pump 18B-20
18B-20
9. T i g h t e n t h e b o t t o m p u m p r e t ai
ai n i n g b o l tt,, ((F
Fig. 18B-54).
SP EC I A L TOOLS F OR SEC TI ON 1 8 B
O B T A I N A B L E F R O M : G R U N D Y T E C H N I F O R M , B U R M A N R O A D , D E A L P A RK
RK , P O R T E L I Z A B E T H 6 0
0001
TEL: (041) 43-2299, FAX: (041) 43-2224
. April ‘96
SECTION 18C-1
Exhaust Brake
CONTENTS OF SECTION 18C
Page
ILLUSTRATION ................................................................................................................................................................................................................................... 18C-2
INTRODUCTION ................................................................................................................................................................................................................................ 18C-3
SPECIFICATIONS ............................................................................................................................................................................................................................. 18C-3
REMO VING T
THH E E X H A U S T B R A K E ..................................................................................................................................................................................... 18C-4
R E P L A C IN
IN G T H E E X H A U S T B R A K E .................................................................................................................................................................................. 18C-5
CHECKING EXHAUST BRAKE SETTING ......................................................................................................................................................................... 18C-7
Apr il '96
Exhaust
Exhau st Br
Brake
ake 18C-
18C-2
2
1 SH AFT AND BUSH 7 NUT AND BOLT
2 EXHAUST BRAKE VALVE 8 NUT AND WA SHER
3 V A L V E R E T A I N IN
IN G N U T A N D B O L T 9 O P E R A T I N G C Y L IIN
NDER
4 B R A C K E T R E T A I N IN
IN G B O L T 1 0 E X H A U S T B R A K E IIN
N POSITION
5 SHA FT BUSH 11 BRA CKET
6 OPERATING ARM 12 EXHA UST BRAKE BODY
Apr il '96
Exhaus t Brake 18C-

18C-3
3
INTRODUCTION
Depend ing on application , som e ADE 360 series engines are fitte
ed
d w i t h a n e x h a u s t b r a k e c o n s i s t i n g o f a b u t t er
er f l y v a l v e
pivoting on a spindle within a separate housing, situated in the exhaust system . The bu tterfly valve is actuated by a
pneu matic ally operated lever, which is secured to the butte
err f l y v a l v e s p i n d l e , w h e r e t h e s p i n d l e p r o t r u d e s t h r o u g h t h e
housing.
W hen a foot operated exh aust brake valve, located on the floor of the cab (drivers side), is pressed, co mp ressed air flows
past a valve and en ters an air operated cylinder. A piston inside the cylinder attached to the valv e spind le pushes th e lever
f o r w a r d a n d t h u s c l o s e s t h e v a l v e . A t t h e s a m e t i m e t h e f u el
el s u p p l y t o t h e i n j ec
ec t o r s i s c u t o f f ( i .e
.e . t h e s p e e d c o n t r o l l e v e r
m o v e s t o t h e s t o p p o s i t io
io n ) .
T h e p r e s s u r e b u i l t --u
u p i n t h e e x h a u s t m a n i f o l d a n d c o m b u s t i o n c h a m b e r s e x e r tts
s a b r a k i n g e f f e c t v ia
ia t h e t r a n s m i s s i o n t o t h e
wh eels of the vehicle.
T O R Q U E S P E C IF
IF I C A T I O N S
C o n t r o l l e v er
er c l a m p b o l t ..................................... M 6 .............................................................. 8,5 Nm
C o n t r o l l e v e r s e c u r i n g b o l t ................................ M 10 ........................................................... 42 Nm
Clearance between valve and valve body ....................................................................... 0 , 2 - 0 ,5
,5 mm
Apr il '96
Exhaus t Brake
Brak e 18C-4
18C-4
REMOVING AND REPLA CING THE EXHAUST BRAKE

VALVE, BUSHES AND SHAFT
Removing
1. Discon nect the inner and outer control linkage

e..
2. D i s c o n n e c t a n d r e m o v e t h e ex
ex h a u s t b r a k e b o d y fr
fr o m t h e
exhaust down pipe.
3. M o u n t t h e e x h a u s t b r a k e b o d y i n a v i c e f i tt
tt e d w i t h s o f t
ja w s . M a r k t h e lo c at io n o f t h e ex h a u s t b r ak e v a l v e to t h e
control lever, (Fig. 18C-1).
4. R e m o v e t h e e x h a u s t b r a k e c y l i n d e r b al
al l j o i n t r e t a
aii n i n g
clip and lever off the op erating arm , (Fig. 18C-2).
5. R e m o v e t h e c l a m p b o l t f r o m t h e o p e r a t iin
ng arm, (Fig
g..
18C-3).
6. R e m o v e t h e o p e r a t i n g a r m f r o m t h e s h a f t,
t, (F
(F i g . 1 8 C - 4 ).
).
Fig. 18C-4
Exhau st Brake 18C

18C-5
Apr il '96
Exhaustt Brake
Exhaus Brak e 18C-6
18C-6
2. Insert the bolt retaining the brake valve to the shaft and
tighten to the specified torque, (Fig. 18C-9).
3. Measure the cleara

ann c e b e t w e e n t h e h o u s i n g an
an d t h e
b r a k e v a l v e w i t h a f e e l e r g a u g e , r e f e r t o s p e c i f ic
ic a t i o n .
T h e c l e a r a n c e c a n b e a l t e r e d b y m o v i n g t h e b r a k e v a llv
ve
s h a f t i n o r o u t,
t, ( F i g . 1 8 C - 1 0 ) .
4. Line up the m arks and replace the control lever to the brake
v a l v e s h a f t , ( F ig
ig . 1 8 C - 1 1 ) .
5. Insert the control lever retaining bolt and tighten to the
specified torque, (Fig. 18C -12).
Exhaust
Exhau st Brake 18C
18C-7
6. R e p l a c e t h e e x h a u s t b r a k e c y l i n d e r b a l l j o i n t tto
o t h e o p e r a ti
ti n g
a r m a n d i n s e r t t h e r e t a i n i n g c l i p , ((F
Fig. 18C-13).
Fig. 18C-13
C h e c k i n g t h e E x h a u s t B r a k e S e t t iin
ng
1 . D i s c o n n e c t t h e e x h a u s t p i p e f r o m t h e e x h a u s t b r a k e b o dy
dy .
2. E n s u r e t h a t t h e e x h a u s t b r a k e v a l v e i s in
in t h e f u l l y o p e n
p o s i t i o n , ( F ig
ig . 1 8 C - 1 4 ) .
3. O p e r a t e t h e e x h a u s t b r a k e a n d e n s u r e t h a t t h e v a l v e f u l lly
y
closes.
Fig. 18C-14
Adjusting the Exhaust Brake Cylinder Length
----------------- 170mm
-----------------
1. R em ove the operating le

ev
ver.
r
is
... ,
2 . A d j u s t t h e e x h a u s t b r a k e c y l iin
c e n t r e o f t h e m o u n t i n g b o l t to
head, (Fig. 18C-15
nder le
enngth to 170 mm from the
to t h e c e n t r e o f t h e b a llll j o i n t n=
Fig. 18C-15
3. O p e n t h e e x h a u s t b r a k e v a l v e f u l l y an
an d r e p l a c e t h e o p e r a t iin
ng
l e v e r . P r e - t e n s i o n t h e c y l i n d e r b y 2 to
to 4 m m a n d f i t t h e b a l l
jo in t , (F ig . 1 8 C -1 6 ).
4. Insert the bolt into the op erating lever and tighten to the spe
cified torque.
5. Insert the locking clip to the ball joint.
6. C o n n e c t t h e e x h a u s t p i p e t o t h e e x h a u s t b r a k e bo
bo d y .
Fig. 18C-16
Apr il '96
^ (aphitigi
io
oit
it Diesel Club
ADE 364 and ADE 366
Workshop Manual
Section 18D - Flywheel
Bar r ington Diesel Club
____________
__________________
__________
____ SECTION 18D
Flywheel
CONTENTS OF SECTION 18D

Page
ILLUSTRATION ................................................................................................................................................................................................................................... 18D-2
INTRODUCTION ................................................................................................................................................................................................................................ 18D-3
SPECIFICATIONS ............................................................................................................................................................................................................................. 18D-3
REMOVING THE FLYWHEEL ..................................................................................................................................................................... 18D-4
R E P L A C IN
IN G T H E F L Y W H E E L ................................................................................................................................................................................................. 18D-5
R E M O V I N G A N D R E P L A C I N G T H E R IIN
NG GEA R ........................................................................................................................................................ 18D-6
REMO VING AND REPLACING THE SPIGOT BEARING ......................................................................................................................................... 18D-8
S P E C IA
IA L T O O L S ................................................................................................................................................................................................................................ 18D-8
April
April ' 96
Flywheel 18D-2
1 STAR TER RING GEAR 4 BEA RING RETAINER

2 FLYW HEEL 5 F L Y W H E E L R E T A I N IN
IN G B O L T
2 FLYW HEEL 5 F L Y W H E E L R E T A I N IN
IN G B O L T
3 S P I G O T B E A R IN
IN G
Ap
April
ril ' 96
Flywheel 18D-3
INTRODUCTION
Manu factured from h i g h g r a d e g r e y c a s t i rro

o n t h e fl
fl y w h e e l is
is p r e c is
is i o n m a c h i n e d a n d b a l a n c e d t o f i n e l im
im i t s The sta
arr t e r
ring gear i s h e a t t r e a t e d a n d s h r u n k o n t o t h e f l y w h e e l . E i g h t s t r e t c h b o l t s r e t a i n t h e f lly
ywh eel to thec rank s haft When
r e m o v i n g i t iis
s n o t n e c e s s a r y t o m a r k t h e r e l a t i v e p o s i t iio
o n o f t h e f l y w h e e l a s th
th e e i g h t b o l t h o l e s a r e d r i l l e d e c c e n t r i c a l l y ,
m a k i n g i n c o r r e c t fi
fi t t i n g iim
mpo ssible.
T h e f l y w h e e l i s t h e s t o r e h o u s e o f e n e r g y a n d i s r e q u i r e d tto
o
a. provide energy for operating the engine between power strokes, a
annd
b. to reduc e the variation in the rotational speed of the cranksh aft during the engin e cycle
a s i t tr
tr a n s m i t s p o w e r t o th
th e d r i v e n m a c h i n e .
SPECIFICATIONS
FLYWHEEL
D i a m e t e r f o r s t a r t e r r in
in g g e a r 335,390 to 335,530
D i a m e t e r f o r m o u n t i n g c r a n k s h a f t f l an
an g e 130,000 to 130,040
A x ia l r u n -o u t c r a n k s h af t f la n g e 0, 1
F l y w h e e l r u n -o u t m o u n t e d to c r a n k s h a f t r ad ia l 0, 1
lateral 0, 1
I m b a l a n c e o f f ly
ly w h e e l w i t h r i n g g e a r 20 gem
Maxim um clutc
chh s u r f a c e m a t e r i a l r em
em o v a l 2 mm
C lu tc h s u rf ac e fin is h R z 1 6 |j m
STARTER RING GEAR
ID o f r i n g g e a r 3 3 4 ,6 9 0 to 3 3 4 ,8 3 0
Ring gear in terference fit 0,56 to 0,84
Lateral run-out of m ounted starte

err r i n g g e a r 0 ,,5
5 mm max.
S t a r t e r r in
in g g e a r m o u n t e d a t a t e m p e r a t u r e o f 250° to 280°
T O R Q U E S P E C I F IC
IC A T I O N S
Flywheel to cran ksh aft M 1 2 x 1 , 5 .... . I n i t iia

a l .............................. 30 - 40 Nm
........
.................
................
................
................
................
................
................
..................
.................
................
................
................
..............Fi
......Fi n a l .........
................
................
................
....... 90°-110°
B o l t le
le n g t h 2 5 , 8 m m .................................................................. Max. s tretch length 26.3 mm
o r B o l t l en
en g t h 4 3 , 8 m m ............................................................ Max. s tretch length 44.3 mm
B e llll h o u s i n g t o r q u e ....................................................................................................................................................... 110 Nm
April
April '96
Flywheel 18D-4
REMOVAL AND REPLACEMENT

O F F L Y W H E E L A N D H O U S IN G
Removal
1. U n s c r e w a n d r e m o v e t h e b o l t s r e ta
ta i n i n g t h e f l y w h e e l ,
( F i g . 1 8 D - 1 ))..
Fig. 18D-1
2. L i f t o f f t h e f l y w h e e l , (F
(F i g . 1 8 D - 2 ) .
Fig. 18D-2
3. U n s c r e w t h e f o u r b o l t s r et
e t a i n iin
n g t h e f l y w h e e l h o u s iin
n g t o th
th e
cylinder block, (Fig. 18D-3).
Fig. 18D-3
4. Uns crew the two outer bolts, (Fig. 18D-4).
Fig. 18D-4
. April '96
Flywheel 18D-5
5. Lift off the housing , (Fig. 18D-5).
Fig. 18D-5
Replacement
1. F i t t h e f l y w h e e l h o u s i n g t o t h e c y l i n d e r b lo
lo c k . R e p l a c e
a n d t i g h t e n t h e o u t e r b o l t s , Fi
Fi g . 1 8 D - 6 ) .
Fig. 18D-6
2. Insert the four inner bolts, (Fig. 18D-7).
Fig. 18D-7
3. I n s e r t t h e t w o t o p b o l t s a n d t i g h t e n a l l b o l t s t o t h e s p e c i f i ed
ed
torque, (Fig. 18D-8).
Fig. 18D-8
Ap ri l '96
Flywheel 18D-6
4. R e p l a c e t h e f l y w h e e l , i n s e r t t h e b o l t s a n d t ig
ig h t e n t o t h e
specified torque, (Fig. 18D-9).
Fig. 18D-9
REMOVAL AND REPLACEMEN T OF

STARTER RING GEAR
Removal
1. Rem ove the flywh eel, (Fig. 18D-10).
Fig. 18D-10
2. P u n c h m a r k t h e r i n g g e a r a n d d r i llll t w o h o l e s i n t o t h e s i d e o f
t h e g e a r . D o n o t d r ilil l t h r o u g h t h e r i n g g e a r a s t h i s w i l l d a m a g e
t h e f ly
ly w h e e l , (F
(F i g . 1 8 D - 1 1 ) .
F'<
F'<r I8 D- I I
3. W i t h a s h a r p c h i s e l s p l i t t h e r i n g g e a r b e t w e e n t h e d r ilil l e d
h o l e s a n d r e m o v e t h e g e a r f r o m t h e f l y w h e el
e l , ( F iig
g . 1 8 D - 1 2 ))..
A t t e n t i o n ! T h o r o u g h ly c l ea n t h e f ly w h e el an d f la n g e p r io r to
replacing.
Fig. 18D-12
Ap ri l '96
Flywheel 18D-7
Replacing
1. Place the flywheel on a flat surface.
2. Heat the new ring gear to approxim ately 250°C with a

welding torc h or other suitable heat source, ( f iig
g. 18D-13).
Fig. 18D-13
3. P l a c e t h e h e a t e d r i n g o n t o t h e f l y w h e e l , (F
(F i g . 1 8 D - 1 4 ) .
Fig. 18D-14
4. I f n e c e s s a r y u s e a c o p p e r o r a l u m i n i u m h a m m e r t o ffu
ully
locate the ring g ear on the flywh eel so that it seats against
the flange shoulder, (Fig. 18D-15).
Fig. 18D-15
5. R e p l a c e t h e f l y w h e e l a n d ttii g h t e n t h e b o l t s t o t h e s p ec
ec i f i e d
torqu e, (Fig. 18D-16).
Fig. 18D-16
Apr il ‘96
Flywheel 18D-8
REMOVING AND R EPLACING

T H E S P IG
IG O T B E A R I N G
The flywheel spigo t bearing can be extracted with the

f l y w h e e l i n p o s i t io
io n o r r e m o v e d f r o m t h e e n g i n e .
1. With special tool 4020 0381 pull the spigot bearing from
the housing, (Fig. 18D-17).
2. I n s e r t t h e b e a r i n g i n t o t h e h o u s i n g a n d d r i v e in
in t o p l a c e
w i t h a s u i t a b l e d r i f t , (F
(F i g . 1 8 D - 1 8 ) .
A tte n tio n ! T h e s p ig o t b e ar in g is s e a le d an d d o es n o t
require greasing.
SPECIAL TOOL S FOR SECTION 18D
OBTAINAB LE FROM: GR UND Y TECHNIFORM , BURMAN ROAD, DEAL P

PAA R K , P O R T E L I Z A B E T H 60
60 0 1
T E L : (0
(0 4 1 ) 4 3 - 2 2 9 9 , FAX: (041) 43-2224
Apr il ‘96
SECTION 18E-1
Al ter nat or and Star ter Motor
Moto r
CONTENTS OF SECTION 18E
Page
INTRODUCTION ................................................................................................................................................................................................................................ 18E-2
.....................................................................................................................................................................................................
IC A T I O N S 18E-2
A LTERNA TO R - S E C T IO N A L V IE W ..................................................................................................................................................................................... 18-3
PRECAUTIONS ................................................................................................................................................................................................................................... 18E-4
MAINTENANCE ................................................................................................................................................................................................................................... 18E-4
T E S T I N G T H E A L T E R N A T O R I N P O S I T IO
IO N .................................................................................................................................................................. 18E-4
T R OU B L E S H O O T I N G ................................................................................................................................................................................................................... 18E-4
STARTER MOTOR
GENERAL ............................................................................................................................................................................................................................................... 18E-5
R O U T IN E M A I N T E N A N C E .......................................................................................................................................................................................................... 18E-5
SERVICING - T E S T I N G IN
I N P O S I T IO
IO N .............................................................................................................................................................................. 18E-6
Apr il '96
Al ter nat or and St

Start
art er Mot or 18E-2
18E-2
INTRODUCTION
A l terna to r
A lt e r n at o r s u s ed o n t h e 3 6 0 s er ie s en g in es a r e o f th e c la w p o le ty p e w h ic h r an g e f r o m 1 4 V -5 5 A t o 1 4 V -9 0 A an d 2 8 V -2 8 A
t o 2 8 V - 5 5 A . T h e s e a l t e r n a t o r s a r e f i t t e d w i t h e i t h e r o n e o r t w o d r i v e p u l l ey
ey s , d e p e n d i n g o n a p p l i c a t i o n .
Sta rter Mo to r
Starter mo tors fitted to the 360 series engines are of the four pole, four brush earth return type w ith series parallel
c o n n e c t e d fi
fi e lld
d c o i lls
s . T h e s e s t a r t er
er m o t o r s r a n g e f r o m 1 2 V - 3 k W t o 1 2 V - 3 , 5 k W and 24V~ 4kW to 24V-4,5kW d e p e n d in
in g
on application.
TOR QU E SP EC I F IIC
C A TI ON S
A LTER N A TOR A N D STA R TER MOTOR
S t a r t e r t o f l y w h e e l h o u s i n g . .... .... .... . .M10 ............................................................ 60 Nm

A l te r n a to r to b r a c k e t ..................... ,M12x 1,5 ............................................... 60 Nm
A d ju s ti n g b o lt t o c y li n d er b lo c k .M10 ............................................................ 40 Nm
A d ju s ti n g b o lt c l a m p ..................... .M12 ............................................................ 35 Nm
P u l l e y to
to a l t e r n a t o r ......................... .M14 x 1 ,5 ............................................... 60 Nm
P u l l e y to
to a l t e r n a t o r ......................... .M16 x 1,5 ............................................... 80 Nm
Apr il ‘96
Al ter
ternat
nator
or and Star ter Motor
Mot or 18E-
18E-3
3
SECTIONAL VIEW OF THE K 1 CLAW -POLE ALTER NATO R
Apr il '96
Al ter nat or and Sta

Start
rt er Motor
Mot or 18E-4
18E-4
A LTER NA TO R
Precautions
The diodes in the alternato r function as one-w ay valves. a. I n s p e c t t h e V - b e l t s r e g u l a r ly

ly for we ar and correct ten
The transistors in the regulator/control box op erate as fast sion. It is important to ensure that all V-belts on a mu l
switches. Both are accu rate and sensitive. tiple drive h ave equal tension and are each carrying
their share of the loa
add. Slack drive belts will w ear ra
They do not wear out and seldom r e q u i re

re a d j u s t m e n t , b u t pidly and cause slip which will not drive the alternator
because they are sensitive to voltage chan ges and high a t t h e r eq

eq u i r e d s p e e d . V-belts w h i c h a r e t o o t ig
ig h t i m 
t e m p e r a t u r e t h e f o l l o w i n g p r e c a u t i o n s a r e v i t al
al t o p r e v e
ennt pose severe side thrust on the alternator bearings and
t h e m f r o m b e i n g d e s tr
tr o y e d : s h o r t e n t h e i r l i fe
fe . E n s u r e p e r i o d i c a l l y t h a t t h e a l t e r n a t o r
is correctly aligned to the drive.
a. DO NO T d isconnect the battery while the engine is

running. This will cause a voltag e surge in the alterna b. Do not replace faulty V - b e l t s i n d i v i d u a l l y i n a m u l t i b el
el t
tor charging system which will i m m e d i a t e l y r u in
in t h e system. A complete matched set of V-belts must al
diodes or transistors. w a y s b e u s ed
ed .
b. DO N OT disconnect the le
eaa d w i th
th o u t f ir
ir s t s t o p p i n g t h e c. K e e p t h e a lt
lt e r n a t o r c l e a n w i t h a c lo
lo t h m o i s t e n e d w i t h a
engine and tu rning all e l e c t r iic

cal sw itches to the off suitable c l e an
an i n g fluid. Ensur e that ventilation slots
position. and air spaces are clear and unob structed.
c. DO NO T caus e a short circuit by co nnecting leads to d. Rem ove any dirt accum ulated on th e regulator/control
incorrect term inals. Alw ays f i r s t i d e n t i f y a l ea

ea d t o i t s box housing. Ensure that cooling a i r c a n p a s s f r e e lly
y
correct terminal. A s h o r t c i r c u it
it o r w r o n g c o n n e c ttii o n over the casing.
g i v i ng
ng reverse p o l a r i ty
ty will i m m e d i a t e lly
y and perma
n e n t l y r u i n tr
tr a n s i s t o r s o r d i o d e s .
T e s t i n g t h e a l t e r n a t o r in
in p o s i t i o n
d. DO NO T connect a b a tt
tt e r y t o t h e s y s t em
em w i t h o u t p r iio
or
checking for correct polarity and voltage. First check the V -b
-b e l t s for cond ition and tension. Th e
nom inal hot outputs at 6000 r/min (alternator speed ) a
arr e
e. DO NO T “ f la
la s h " c o n n e c t i o n s to check for curre
en
n t ffll o w . as follows:
No matter how brief the contact, t h e t r a n s is

is t o r s m a y 14
4VV - 35A
be ruined.
28V - 28A
Maintenance
These f i g u re
re s m ay be exceeded slig
ghhtly when the
The alternator charging system w i l l n o r m a l l y r e q u i r e v e rry

y alternator is running cold.
l i t t lle
e atte
enntion, but it should be kept free from dirt and
c h e c k s s h o u l d b e m a d e i f t h e a l t e r n a t o r f a ilil s t o k e e p t h e A d u s t p r o o fe d a lt er n at o r c an b e fi t te d as an o p ti o n ,
battery charged. depending on application.
T r o u b le
le S h o o t i n g
If a malfunctio n shou ld develop in the current generating system it must be kept in mind that trouble sources m ay exist in
t h e b a t t e r y , c a b l e s o r o t h e r l o c a t i o n s b e s i d e s t h e a l t e r n a t o r o r r e g u l a t o r . T h e m o s t c o m m o n f a u l t s y m p t o m s a r e l i s t ed
ed i n
t h e c h a r t b e l o w w i t h p r o b a b l e c a u s e s a n d a p p r o p r i a t e c o r r e c t iv
iv e m e a s u r e s :
P r o b l em
em - C a u s e C o rrecti o n
Battery is dead or insufficiently charged; Recharge battery
1. Open circuit or con tact resistance in charging circuit R e m o v e o p e n c i r c u i t o r c o n t a c t r e s i s tta

ance
2. Defective battery Replace battery
3. D efective alternator Have alternator repaired in authorised wo rkshop
4. D efe c tiv e r eg u la to r R e p l a c e r e g u la t o r
5. V-b elt loose Tighten V-belt
Apr il '96
Al ter
ternat
nator
or and Star ter Mot or 18
18E-
E-5
5
em - C a u s e ________________________________________
P r o b l em Correction
C h a r g e i n d i c a t o r l a m p d o e s n o t b u rn
rn w i th
th t h e e n g i n e
s t o p p e d a n d t h e i g n it
it i on
on o n .
1. I n d i c a t o r b u l b iis
s burned out Replace with a new bulb
2. D ead batte
err y Charge battery
3. Defective battery Replace battery
4. L o o s e o r d a m a g e d c a b l es
es Replace of tighten cables
5. Defec tive regulator Replace regulator
6. S h o r t e d p o s i t i v e d i o d e in
in t h e a l t e r n a t o r H a v e a l t e r n a t o r r ep
ep a i r e d b y a u t h o r i s e d w o r k s h o p
7. W orn carbon brushes Replace brushes
8. O x i d e l a y e r o n s l i p r in
in g s o r b r o k e n w i r e i n r o t o r Have alternator repaired
winding
Charge indicator lamp continues to burn brightly

d u r in
in g h i g h e r e n g i n e s p e e d s
1. Cab le D + /61 is shorted to ground Repair or replace cable
2. D efective regulator Replace regulator
3. O v e r v o l t a g e p r o t e c t i o n d e v i c e d e f e c t iiv
ve Replace over voltage protection device
4. D e f e c t i v e r e c t i f i e r , d i r t y s llii p r i n g s , s h o r t i n c a b l e “ D F ” H a v e a l t e r n a t o r r e p a i r ed
ed b y a u t h o r i s e d w o r k s h o p
or in rotor winding
C h a r g e i n d i c a t o r l a m p b u r n s b r i g h t lly
y w iitt h e n g i n e
s t o p p e d , b u t o n l y d i m s o r g l iim
m m e r s w i tth h engine
runni ng :
1. Poo r connections (contac t resistance) in the char R e m o v e c o n t a c t r e s i s tta

ance
ging circuit or in the cable to the charge indicator lamp
2. D efective regulator Replace regulator
3. D efective alternator Have alternator repaired
Charge indicator lamp flickers
1. Con tact regulator m ay be incorrectly adjusted or Replace regulator

regulating resistor is burned out
STARTER MOTOR
c. S e l f -i
-i n d e x i n g pinion to ensur e smo oth engagem ent
General between the pinion a n d t h e r i n g g e a r t ee
ee t h b e f o r e t h e
starter motor begins to rotate.
This starter m otor is a four pole, four brush earth return
m a c h i n e w i t h s e r i e s p a r a l l e l c o n n e c t e d f i el
el d c o i l s.
s. d. A r m a t u r e b r a k i n g s y s t e m t o en
en s u r e r a
appid return to rest
w h e n t h e s t a r t e r b u t t o n i s r e le
le a s e d .
A s o le n o id o p er a te d p r e -e n g ag e d d r iv e as s em b ly is
carried on an extension of the arm ature shaft. The main

features o f this type o f drive are as follo
owws:
a. Positive pinion engag em ent preventing the pinion be Routine Maintenance
i n g t h r o w n o u t o f m e s h w h i l e s t a rrtt i n g .
a. The starter mo tor requires no routine maintenan ce be
b. An overrunn ing clutch i s i n c o r p o r a t e d iin
n the drive as yond th e occasion al ins pection o f the electrical con
s e m b l y g i v i n g o v e r s p e e d a n d o v e r l o a d p r o t e c t io
io n . n e c ttii o n s , b ru
ru s h g e a r an
an d the comm utator, which must
be clean and tight.
Ap ril ‘96
Al ter nat or and Star te
terr Motor
Mot or 18E-6
18E-6
b. After the starter mo tor has been in service for som e minals before proceeding. Op erate the starter control and
t i m e , r e m o v e t h e s t a r te
te r m o t o r f r o m t h e e n g i n e , s u b m i t w a t c h f o r t h e f o llll o w i n g s y m p t o m s :
it to a thorou gh b ench inspection.
1. The lamps dim (or the voltm eter reading drops to
about 6 voits) a n d t h e m o t o r d o e s n o t t u r n t h e en
en g i n e .
1. Brush w ear (this is a f a i r i n d i c a t i o n o f t h e am
am o u n t o f Check t h e b a t t er
er y ( m u s t b e a t le
le a s t h a l f --c
charg ed) and
work done), renew brushes worn to or approaching battery posts (clean and good earth conn ection)
7 , 9 m m l en
en g t h .
2. Lamps do no t
no dim, the voltm eter r ea
ea d i n g remains
2. B r u s h s p r i n g t en
en s i o n : C o r r e c t t e n s i o n i s 0 , 8 5 - 1 ,,1
13 N, s t e a d y at
at a b o u t 1 2 v o l t s , and the mo tor does not turn
r e n e w s p r i n g s i f t en
en s i o n h a s d r o p p e d b e l o w 0 , 7 1 N . the engine. Conn ect voltm eter b etween solenoid ter
minal and starte
err y o k e , t h e n o p e r a t e s t ar
ar t e r . No volts
3. S k i m c o m m u t a t o r iiff i t i s p i t t e d o r b a d l y w o r n . indicated
4. Check bearings for exc essive side play on arm ature Causes:
shaft.
a. Poor post connection at batte
err y .
5. Check pinion mov ement.
b. Bad earth connection.
6. Clean and lubricate pinion sleeve bearing.
c. Broken starter lead, battery to starter
7. Clean and lubricate drive end bracket bush.
Full volts, i.e. 12/14 volts indic ated:
S e r v i c in
in g - T e s t i n g i n P o s i t iio
on - Sym ptom s a. Faulty solenoid switch.
Switch on the l ig
ig h t s . If the vehicle is not equipped with b. Open circuit in starter - check brushes,
l i g h t in
in g c o n n e c t a 0 / 2 0 v o l t m e t e r a c r o s s t h e b a t t e r y t er
er -
C u t - a w a y v i e w o f p r e e n g a g e d d r i v e st
st a r t i n g m o t o r
with outer-wedge roller type overrunning clutch.
Apr il '96
Diesel Club
ADE 364 and ADE 366
Workshop Manual
Section 18 F - Compre
C ompressor
ssor and Vacuum
Vacuum Pump
Bar r ington Diesel Chib
SECTION 18F-1
Compressor/Vacuum Pump
CONTENTS OF SECTION 18F
Page
I L L U S T R A T I O N - C A M S H A F T D R I V EN
EN C O M P R E S S O R .......................................................................................................................................... 18F-2
................................................................................................................................................................................................................................
INTRODUCTION 18F-3
SPECIFICATIONS ............................................................................................................................................................................................................................. 18F-3
T O R Q U E S P E C I F IIC
CATIONS ...................................................................................................................................................................................................... 18F-4
MEASUR ING THE BEARING CLEARA NCE ..................................................................................................................................................................... 18F-5
D IS M A N T L IN G T H E C Y L IN D E R H E A D .........
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...............
.......18
18 F- 7
R E - A S S E M B L Y O F T H E C Y L IN
IN D E R H E A D ..................................................................................................................................................................... 18F-8
S P E C IA
IA L T O O L S F O R T H I S S E C T I O N .............................................................................................................................................................................. 18F-9
B E L T -D
- D R IIV
VEN COM PRESSO R ............................................................................................................................................................................................. 18F-10
BELT DRIVEN COMPRESSO R - DISASSEMB LY .................................................................................................................................................... 18F-11
BELT DRIVEN COMP RESSOR -ASSEMB LY ............................................................................................................................................................. 18F-13
S P E C IA
IA L T O O L S ............................................................................................................................................................................................................................. 18F-17
Apr il '96
Compressor/Vacuum Pump 18F-2

(Camshaft driven)
No te: W hen belt driven compresso rs are used the oil hole in the lobe of the
cams haft, used for driv
vii n g t h e c o m p r e s s o r , i s c l o s e d w i t h a J u b i l e e
c l a m p . T o p r e v e n t o ilil l o s s d u r in
in g e n g i n e r e - c o n d i t i o n i n g e n s u r e
t h a t t h e c l a m p i s i n p o s i t iio
on.
AIR COMPRESSOR
COMPRESSOR
1 CYLINDER BARREL 12 PISTON

2 BEARING SHELL 1 3 S C R A P E R R IN
IN G
3 B E A R I N G S HE
HE L L 14 PISTON RING
4 CONNECTING ROD 15 VALVE
5 C O N N E C T I N G R O D B O LT 16 VALVE
6 NUT 17 GASK ET
7 BOLT 18 SEALING WA SHER
1 9 I N L E T P IP
IP E
8 CIRCLIP
. 9 G U D G E O N P IN
IN 20 UNION
10 PISTON RING 21 SEALING WA SHER
11 SMALL END BUSH 22 CY LINDER HEAD
Apr il ‘96
INTRODUCTION
A ir c o m p r e s s o r s a r e u s ed in v e h ic le s y s t em s to p r o v id e c o m p r es s ed ai r u s ed fo r b r ak in g an d t h e o p er at io n o f an c il la r y ai r
e q u i p m e n t . T h e s e c o m p r e s s o r s h a v e a s i n g l e r ec
ec i p r o c a t i n g p i s t o n a n d a r e ai
ai r c o o l ed
ed . T h e c o m p r e s s o r s h a v e a o n e - p i e c e
c y l i n d e r h e a d , w i t h t h e i n l e t v a l v e p a r t s s c r e w e d i n t o t h e h e ad
ad a n d t h e d e l i v e r y v a l v e s r e t a i n e d b y a l o c k n u t . T h e p i s t o n
runs in a replaceable cylinder barrel which is moun ted directly onto the engine cran kcase and sealed with a g asket at the
cylinder head.
D u r i n g t h e d o w n s t r o k e o f t h e p i s t o n a p a r t iia
al vacuum i s c r ea
ea t e d a b o v e t h e p i s t o n , w h i c h u n s e a t s t h e i n l e t v a l v e a l l o w i n g
a i r tto
o e n t e r t h e c y l i n d e r a b o v e t h e p i s t o n . O n t h e u p s t r o k e , t h e a i r p r e s s u r e u n d e r t h e v a l v e , p l u s t h e e f f o r t o f t h e i n l et
et
v a l v e s p r i n g c l o s e s t h e i n l e t v a l v e a n d t h e n o p e n s t h e d e l i v e r y v a lv
lv e , t h e a i r u n d e r c o m p r e s s i o n i s th
th e n d i s c h a r g e d i n t o a
r e s e r v o i r . A t t h e s t a r t o f t h e d o w n s t r o k e t h e d e l i v e r y v a l v e c l o s e s a n d t h e c y c l e i s r e p e a t e d . T h e c o m p r e s s o r f e e d s a i r i n to
to
a reservoir fitted with an unload er valve to m aintain constant pressure.
T h e a i r c o m p r e s s o r a s s e m b l y c a n b e c h a n g e d t o a v a c u u m p u m p b y s i m p l y ttu
u r n i n g t h e c y l in
in d e r h e a d .
A IR C O M P R E S S O R /V A C U U M P U M P
C y l i n d e r ........................................................................................................................................................................................ 1
B o r e ................................................................................................................................................................................................. 94 mm
S t r o k e ............................................................................................................................................................................................ 30 mm
D i s p l a c e m e n t ............................................................................................................................................................................ 208 cm3
B o r e d i a m e t e r .......................................................................................................................................................................... 9 3 , 9 8 5 - 9 4 ,0
,0 1 5 m m
Pi s to n di am e te r .........
................
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................93
.......93 ,8 5 0 - 9 3 ,8 8 0 m m
P i s tto
o n c l e a r a n c e ..................................................................................................................................................................... 0,068 - 0,092 m m
P i s tto
o n p r o t r u s i o n ..................................................................................................................................................................... 0,250 - 0,700 m m
Gudgeon pin d i a m e t e r ................................................................................................................................. 1 6 ,,0

012 -16,01 5 m m
Bore in piston .................................................................................................................... 1 6 , 0 1 8 - 1 6 , 0 22
22 m m
C l e a r a n c e i n p i s t o n ........................................................................................................ + 0 , 0 0 3 t o + 0 , 0 1 0 m m
C l e a r a n c e i n s m a l l en
en d b u s h .................................................................................... 0,010 - 0,023 m m
Connecting rod B i g e n d b a s i c b o r e ........................................................................................................... 3 5 , 0 0 0 - 3 5 ,0

,0 1 6 m m
S m a l l e nd
n d b a s i c b o r e .................................................................................................... 1 9 , 0 0 0 - 1 9 ,0
,0 2 1 m m
S m a l l e n d b u s h o u t e r d i a ........................................................................................... 1 9 , 0 3 5 - 1 9 , 0 48
48 m m
Sm all end bush inner dia ........................................................................................... 1 6 , 0 2 5 - 1 6 , 0 35
35 m m
S m a l l e n d b u s h i n t e r fe
fe r e n c e f i t ............................................................................. 0,014 - 0,048 m m
Big end bearing clearance r a d i a i ......................................................... 0 , 0 2 0 - 0 ,0
,0 6 6 m m
a x i a l ......................................................... 0 , 0 6 5 - 0 , 3 1 7 m m
Width of small end ........................................................................................................ 2 7 , 8 8 3 - 2 7 ,9
,9 3 5 m m
W i d t h o f b iig
g end .............................................................................................................. 27,883 - 27,935 mm
L e n g t h o f c o n n e c t iin
ngrod (centre t o c e n t r e ) .................................................... 9 6 , 9 5 0 - 9 7 ,0
,0 0 0 m m
Big end bearing/sm all e
enn d b u s h , p a r a l l e l w i t h i n ............................................. 0 , 0 1 m m
Piston rings (all) Ga p ........................................................................................................................................... 0 , 2 5 - 0 ,4

,4 0 m m
S i d e c l e a r a n c e ................................................................................................................ 0 , 0 2 0 - 0 ,0
,0 5 5 m m
Apr il '96
C O N N E C T I N G R O D B E A R I N G A N D C R A N K P I N D IIA
AMETERS
Stages C a m s h a f t jjo
o u r n a l d i a.
a. B e a r i n g i n n e r d i a.
a.
Standard 31,984 to 32,000 32,020 to 32,050
Standard 1 (-0,1 ) 3 1 ,8 8 4 to 3 1 ,9 0 0 3 1 ,9 2 0 to 3 1 ,9 5 0
R e p a i r s t a g e 1 (-
(- 0 , 2 5 ) 31,734 to 31,750 31,770 to 31,800
R e p a i r s t a g e 2 ( - 0 ,,5
5) 3 1 ,4 8 4 to 3 1 ,5 0 0 3 1 ,5 2 0 to 3 1 ,5 5 0
R e p a i r s t a g e 3 ( - 0 ,,7
75 3 1 ,2 3 4 t o 3 1 ,2 5 0 3 1 ,2 7 0 to 3 1 ,3 0 0
CAPACITY
A ir c o m p r e s s o r a t 2 8 0 0 r /m in . .Delivery against. 100 kPa - 140£/m in

810 kPa - 130 ¿/min
M a x i m u m o p e r a t iin
n g p r e s s u r e ..
.. 810 kPa
VACUUM PUMP
Tank capacity Engine speed T i m e (s e c ) V a c u u m (m m Hg)
6 1 6 0 0 r /m i n 30 625
2 8 0 0 r /m i n 30 700
201 6 0 0 r /m i n 30 450
2 8 0 0 r /m i n 30 675
IC A T I O N S
A IR C O M P R E S S O R /V A C U U M P U M P
Cap to connecting rod ................................................................................................. M6 ................................................................. 15 Nm

Exhaust valve to cylinder head .............................................................................. M6 ................................................................. 10 Nm
Inle
ett v a l v e t o c y l i n d e r h e a d ....................................................................................... M40 x 1,5 ................................................. 180 Nm
....................................................................... .................................................................
C y l i n d e r h e ad
ad b a r r e l t o c r a n k c a s e M8 35 Nm
B E L T -D R IV E N C O M P R E S S O R
C y l i n d e r l i n er
er t o c r a n k c a s e .............................................................................................................................................................. 22 Nm
C y l i n d e r h e a d t o c y l i n d e r l i n e r ....................................................................................................................................................... 30 Nm
Pu ll ey n u t ...............
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............10
....10 0 Nm
Apri l ‘96
Compr essor/Vacuu
esso r/Vacuum
m Pump 18F-
18F-5
5
M e a s u r i n g b e a r iin
n g c l e a rra
ances
A tten tio n ! S e e p a g e 1 5 -8 f o r r em o v al o f th e c o m p r e s s o r fr o m
the engine
1. C l a m p t h e c o n n e c t i n g r o d i n a v i c e f i t te
te d w i t h s o f t j a w s
and rem ove the bearing cap, (Fig. 18F-1).
Fig. 18F-1
2. Rem ov e the bearing shells from the connecting rod and cap,
(Fig. 18F-2).
3. Fit the bearing c ap to the connecting rod, insert the bolts and
tighten to the specified torque, (Fig. 1 8F-3).
4. Set an internal m easuring instrum ent, (Fig. 18F-4).
Apr il ‘96
5. M e a s u r e t h e b i g - e n d b a s i c b o r e i n t h e v e r t i c a l p o s itit i o n ,
(Fig. 18F-5).
Fig. 18F-5
6. M e a s u r e t h e b o r e o f t h e c o n n e c t i n g r o d s m a l l e n d b u sh
sh ,
(Fig. 18F-6).
Fi.q. 18F-6
7. U n s c r e w t h e b e a r i n g b o l t s a n d r e m o v e t h e b i g - en
en d b e a r i n g
c a p , (F
(F i g . 1 8 F - 7 ) .
Fig. 18F-7
8. Insert the big-end bearing shells, fit the cap to the connecting
rod, insert the bolts and tighten to the specified torque,
(Fig. 18F-8).
Fig. 18F-8
Apr il '96
9. Measu re the big-end bearing inside diameter in three

places, (Fig. 18F-9).
10. Remo ve the big-end bearing cap a

annd connecting rod
f r o m t h e v i c e.
e.
M e a s u r e t h e c a m s h a f t e c c e n t r i c l o b e to
to d e t e rrm
mine the
c l e a r a n c e a f t e r o b t a i n i n g t h e b e a r i n g I .D
.D .
Dismantling the cylinder head
1. Rem ove the nut reta

aii n i n g t h e c y l i n d e r h e a d ,
(Fig. 18F-10).
Fig. 18F-10
2. Rem ove and dism antle the delivery valve, (Fig. 18F-11)
Fig. 18F-11
3. U n s c r e w t h e i n l et
et v a l v e f r o m t h e c y l i n d e r h e a d , u s i n g
special tool 4020 1733, (Fig. 18F-12).
Fig. 18F-12
Reassemb ly of the cylinder head
1 Moun t the cylinder head in a vice, insert the delivery

valve into the cylinder head and tighten the retaining
nut to the specified torqu e, (Fig. 18F-13).
2. T u r n o v e r t h e c y l i n d e r h e a d a n d i n s e r t t h e s u c t iio
on valve as
follows: 1 v a l v e s e a t , 2 v a l v e d is
is k , 3 s p r in
in g w a s h e r s ,
4 suction valve nut, (Fig. 18F-14).
Note: T h e s u c t i o n v a l v e n u t s 4 A a n d 4 B a r e a l te
te r n a t e ffii t ttii n g s
requiring the use of two different special tools for remo val and
replacem ent. Refer to special tools list page 18F-9.
3. Tighten the suction valve nut to the specified torque, using

s p e c i a l to
to o l s 4 0 2 0 1 7 3 3 o r 4 0 2 0 2 3 3 4 , ( F i g . 1 8 F - 1 5 ) .
A tte n tio n ! S e e p a g e 1 5 -1 2 fo r r e p l a c e m e n t o f c o m p r es s o r to
engine
4. Insert a new gasket, replac e the cylinder head, insert the

retaining bolts and tighten to the specified torque,
(Fig. 18F-16).
Note: 0 , 6 5 a n d 0 , 9 m m g a s k e t d e p e n d in
in g o n p i s t o n p rro
o t r u s io
io n .
Fig. 18F-16
Apr il '96
5. C o n n e c t t h e a i r i n l e t a n d d e l i v e r y p ip
ip e s , ((F
Fig. 18F-17).
SP EC I A L TOOLS
OBTA INABLE FROM: G R U N D Y - T E C H N I F O R M , B U R M A N R O A D , D E A L P A R T Y E S T A T E , P O R T E L IIZ

ZABETH 60
0001
0
\v
Socket for removal/replacement

■‘Z
of com pressor valve. (Type A).
(See Fig. 18F-12, I8F-15)
J ¡L
( V P a r t n u m b e r 4 0 2 0 1 7 3 3.
3.
€>
S o c k e t f o r r e m o v a l / r e p l ac
ac e m e n t
of comp ressor valve, (Type B).
(See Fig. 18F-12, I8F-15)
/ j L0 ^
f s r * P a r t n u m b e r 4 0 2 0 2 3 3 4.
4.
\//
Apr il '96
Belt-driven Compressor 18F-10

11
BELT-D R I V EN C OMP R ESSOR
1 C O M P R E SS O R P U L LE Y R E T
TAA I N IN
IN G N U T A N D W A S H E R 16 C Y L IIN
N D E R HE A D R E T
TAA IN
I N IN
IN G B O L T S
2 COMPRESSOR PULLE
EYY 17 C Y L I N D E R H E A D B O L T FL
FL A T W A S H E R S
3 P IS T O N W IT H C O N N E C T IN G R O D 18 C Y L IN D E R H E A D G A S K E T
4 C O N N E C T IIN
N G R O D C AP 19 VALVE PLATE
5 C O N N E C T I N G R O D C A P B O L TS
TS 20 V A L V E PL
PL A T E R E T
TAA I N IIN
NG SCREW
6 C R A N K S H A F T B U S H H O U S IN G 21 IN L E T V A L V E
7 S T E ER IN G P U M P D R IV E W A S H E R 22 EXHAUST VALVE RETAINER
8 CRANKSHAFT 23 E X HA
HA U S T V A L V E
9 CRANKCASE 24 E X H A U S T V A L V E R E T A I N IIN
NG SCREWS AND
10 CRANKCASE MO UNTING BOLTS WITH FLAT WA SHERS WASHERS
11 O I L IN
IN L E T B A N J O B O L T A N D H O U S I N G 25 C Y L IN
IN D E R S L E EV
EV E
12 CRANKSHA FT BEARING 26 C Y L IN
IN D E R S L E EV
E V E R E T A IIN
N IN
IN G S C R E W S
13 C R A N K S H A F T B E A R I N G R E T A I N IN
IN G C L IP
IP A ND W A SHERS
14 CRANKSHA FT SEAL HOUSING 27 C O M P R E S S O R M O U N T C A S T IIN
N G B R A C K ET
15 CYLINDER HEAD W ITH OIL DRAIN AND IDLER PULLEY
Apr il '96
DISASSEMBLY
1. L o o s e n t h e p u l l e y f a s t e n i n g n u t , ((F
Fig. 18F-18).
2. P u l l o f f t h e p u l l ey
ey , ((F
Fig 18F-19).
3. Uns crew and rem ove the cylinder head, (Fig. 18F-20).
4. Rem ove the valve pla
att e w i t h s u c t i o n v a l v e a
an
nd
delivery valve, (Fig. 18F-21).
Fig. 18F-21
Apr il '96
5. R e m o v e t h e c y l i n d e r l i n e r r et
et a i n i n g n u t s a n d p u l l t h e l i ne
ne r
from the piston, (Fig. 18F-22).
6. Rem ove the locking ring for the piston pin, (Fig. 18F-23).
7. Push out the piston and detach from the connecting rod,
(Fig. 18F-24).
8. U n s c r e w t h e h o u s i n g c o v e r b o lt
lt s a
annd rem ove the housing
cover, (Fig. 18F-25).
Fig. 18F-25
Apr il '96
9. Detach the conrod from the crankshaft and remove the

crankshaft, (Fig. 18F-26).
Fig. 18F-26
10. R e m o v e t h e s h a f t s e a l i n g r i n g f r o m t h e b e ar
ar i n g c a p ,
(Fig. 18F-27).
Fig. 18F-27
11. R e m o v e t h e p i s t o n r iin
ngs with special tool 4020 0307
(piston ring pliers), (Fig. 18-28).
Fig. 18F-28
ASSEMBLY
1. Insert shaft sealing ring into the bearing cap,

(Fig. 18F-29).
mW i
Fig. 18F-29
Ap ril ‘96
2. M o u n t O - r i n g o n b e a r in
in g c a p . ( F i g . 1 8 F -3
-3 0 ) .
Fig. 18F-30
3. A s s e m b l e c o n n e c t i n g r o d t o t h e c r a n k s h a f t a n d i n s t a llll t h e
c r a n k s h a f t , (F
(F i g . 1 8 F - 3 1 ) .
Fig. 18F-31
4. M o u n t t h e b e a r iin
ng cap, (Fig. 18F-32 )
Note: R e c e s s i n m o u n t i n g b o s s i n u p w a r d p o s i t io
io n .
Fig. 18F-32
5. M o u n t p i s t o n r i n g s , (F
(F i g . 1 8 F - 3 3 ) . U s e p i s t o n r i n g p l i e
err s
part no. 402 0 0307.
, — ii fa
fass
Fig. 18F-33
Ap
April
ril '96
6. Position the piston with rings over the connecting rod

a n d i n s e r t t h e p i s t o n p i n , ((F
Fig. 18F -34).
Fig. 18F-34
7. M o u n t t h e r e t a in
in i n g r i n g s f o r t h e p i s t o n p i n
n,,
(Fig. 18F-35).
Fig. 18F-35
8. M o u n t t h e g a s k e t f o r t h e c y l i n d e r l i ne
ne r .
9. U s e t h e p i s t o n r i n g s q u e e z e r t o b r i n g t h e p i s to
to n r i n g
d i a m e t e r to
to p i s t o n d i a m e t e r an
a n d m o u n t t h e c y l iin
nder
liner, (Fig. 18F -36).
Use com pressor piston ring squ eeze

err 4 0 2 0 1 1 3 1 t o g e t h e r w i th
th
pliers 402 0 1144.
ill'AM
Fig. 18F-36
10. Fit the cylinder liner over the m ounting studs and tighten
t h e n u t s t o 2 2 N m , ( F i g . 1 8 F - 3 7 ).
).
Fig. 18F-37
Apr il '96
11. Place the gasket and head assem bly on the cylinder line
err ,
(Fig. 18F-38).
Note: G u i d e p i n o f t h e v a l v e p l a t e m u s t l o c a t e iin
nto appropriate
holes at the top o f the cylinder liner.
Fig. 18F-38
12. M o u n t c y l i n d e r h e a d w i t h g a s k e t a n d t iig
ghten the bolts to
30 Nm, (Fig. 18F-39).
Fig. 18F-39
1 3.
3. Mount pulley to the compresso r and tighten the nut to
100 Nm, Fig. 18F-40).
Fig. 18F-40
Ap
April
ril ' 96
S P E C IA
IA L T O O L S
O B T A I N A B L E F R O M : G R U N D Y T E C H N I F O R M , B U R M A N R O A D , D E A L P A R K , P O R T E L IZ
IZ A B E T H 6 0 0
011
TEL: (041) 43-229 9, FAX: (041) 43-2224
Piston ring pliers
:> *
C o m p r e s s o r p i s t o n r i n g s q u e e z er
er
use with pliers below
part number 4020 11
1331
A P l i e r s f o r c o m p r e s s o r p i s t o n r in
squeezer
in g
Aprilil ' 96
Apr
Diesel Club
ADE 364 and ADE 366
Workshop Manual
Section 19 - Cooling System
Bar r ington Diesel Club
___________
_________________
____________
______ SECTION 19
Cooling System
Page
ILLUSTRATION ...................................................................................................................................................................................................................................... 19-2
IN T R O D U C T IO N ................
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...........19
....19 -3
SPECIFICATIONS ................................................................................................................................................................................................................................. 19-3
REMOVING THE WA TER PUMP ................................................................................................................................................................................................ 19-5
DISMANTLING ........................................................................................................................................................................................................................................ 19-6
ASSEMBLY ............................................................................................................................................................................................................................................... 19-9
THERMOSTAT AND HOUSING ................................................................................................................................................................................................ 19-15
REMO VING / REPLACING THE THERMOSTAT HO USING ................................................................................................................................... 19-16
T H E R M O ST A T T E S T ................................................................................................................................................................................................ 19-19
V IS C O F A N ..................................................................................................... : ..................................................................................................................................... 19-21
IN T R O D U C T IO N ........
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.... 19 -2 2
SPECIFICATIONS ............................................................................................ 19-22
O V E R H A U L I N G V IS
IS C O F A N ...................................................................................................................................................................................................... 19-23
DISMANTLING ..................................................................................................................................................................................................................................... 19-23
ASSEMB LY ............................................................................................................................................................................................................................................ 19-25
S P E C IA
IA L F A B R I C A T E D T O O L S ............................................................................................................................................................................................... 19-29
S P E C IA
IA L T O O L S ................................................................................................................................................................................................................................. 19-31
Aprilil '96
Apr
Cooling System 19-2
19-2
360 SERIES WATER PUMP
1. IMPEL LER
2. CA RBON SEAL ASSEMBL Y
3. WA TER PUMP HOU SING
4. SEAL
5. BE AR ING
6. SHAFT
7. BEARING
8. O-R ING
9. SEA L
1 0.
0. BEA RING CA RRIER
1 1.
1. C O U P L I N G F L A N G E / P U L L E Y C O U P L IN
IN G F L A N G E
Ap
April
ril '96
Cooling
Cool ing System 19-3
19-3
INTRODUCTION
T h e w a t e r p u m p i s o f t h e i m p e l l e r t y p e a n d d r i v e n b y V - b e l t s f r o m t h e c r a n k s h a f t . I t i s a s e a l e d u n i t , f iill l e d w i t h a s p e c i a l
h i g h m e l t i n g p o i n t g r e a s e d u r i n g a s s e m b l y a n d r e q u i r e s n o f u r t h e r a t t e n t io
io n d u r i n g i t s l iiff e t i m e .
A t h e r m o s t a t h o u s in g is m o u n t ed t o t h e c y li n d er b lo c k w h ic h is jo in ed to t h e w a t e r p u m p b y a c o n n ec t in g t u b e an d s ea le d
by O-rings.
SPECIFICATIONS
COOLING SYSTEM
Thermostat Standard Optional
Starts opening at 79 ± 2°C 71 + 2°C
Main valve Stroke mm 8 mm 8 mm

Fully open at 94°C 85°C
Bypass valve closed at 91°C 82°C
Max. operating temperature 95°C 95°C

Coolant capacity (engine only) 11< 11^
WATER PUMP
Impeller shaft diameter 15,028 to 15,039
For large bearing 29,996 to 30,009
For sm all bearing 16,997 to 17,008
For hub 29,041 to 29,054
Bore in hub dia 2 9 , 0 0 0 t o 2 9 , 0 21

21
Hub d ia. for front seal 41,840 to 42,000
Bore dia. in impeller 15,000 to 15,018
P res s in g im p e ller o n w a t e r p u m p s h aft Im p e l le r f l a n g e flu s h w ith h o u s in g

M a x . ± 0 ,1
,1 m m
L u b r i c a t io
io n o f w a t e r p u m p Grease approx. 80 gr
Apr il ‘96
Cooling System 19-4

19-4
A tten tio n : W h e n in s t al li n g an e x c h a n g e en g in e, en s u r e t h at W A T E R PU M P
t h e s p a c e r r i n g f it
it t e d b e t w e e n t h e w a t e r p u m p a n d t h e f a n i s
o f t h e s a m e t h i c k n e s s a s i n t h e r e m o v e d e n g i n e.
e . I f n e c e s s a ry
ry A W a t e r p u m p s h a ft
replace the spacer ring so th at the distance of 25 to 30 m m B Hub
between the radiato r and the fan is retained. C Bearing carrier
D O-ring
E Larg e ball bearing

F Sm all ba
all l b e a r i n g
G Rear seal
H C a r b o n s ea
ea l
J Impeller
K Distance impeller and housing: 0 ,5+0/^ 0 3
.119 ±0,5
364N/C/T
IC A T I O N
W a t e r p u m p t o c y l iin
nder block ................................................................................. M 10 ............................................................ 50 Nm
C o o l a n t d r a i n p l u g to
to c y l i n d e r b l o c k ...................................................................M18 x 1,5 ................................................ 50-60 Nm
T e m p e r a t u r e g a u g e p r o b e ......................................................................................... M 1 4 x 1 , 5 ................................................ 20 Nm
Th er m o s ta t ho us in g c o v e r ........
............
........
........
........
........
........
........
........
........
........
........
........
........
........
........
........
........
........
........
........
....M
M6 ................................................................ 25 Nm
W a t e r j a c k e t c o v e r to
to c y l i n d e r b l o c k ( 3 6 4 N / C / T ) ......................................... M 8 ............................................................... 35 Nm
W a t e r p u m p b e a r iin
n g c a r r i e r .................................................................................... M 6 x 3 0 .................................................... 15 Nm
C a p s c r e w /s
/s p a c e r t o w a t e r p u m p s h a f t ............................................................... M 1 4 x 1 , 5 ............................................... 140 Nm
( L u b r i c a t e th
th r e a d s w i t h e n g i n e o i l )
F A N R E T A I N IN
IN G B O L T S ( D I N 9 3 3 ) - T IG
IG H T E N I N G T O R Q U E
Bolt dia. Qu ality _________________________ Torque
M8 8 .8 25 Nm
M8 10.9 35 Nm
M10 8 .8 50 Nm
M10 10.9 60 Nm
Ap
April
ril ‘96
Cooli ng System 19-5

19-5
Removing the water pump
1 . D r a i n r ad
ad i a t o r .
2. D i s c o n n e c t u p p e r r a d i a tto
or hose.
3. D i s c o n n e c t l o w e r r a d i a tto
o r h o s e.
e.
4. L o o s e n b o t t o m a l t e r n a t o r r e ta
ta i n i n g b o l t , ( F i g . 1 9 -1
-1 ) .
5. S l a c k e n o f f a d j u s t e r a n d r e m o v e t h e V --b
belt.
6. Rem ove the thermo stat housing.
Fig. 19-1
7. I f a p o w e r s t e e r i n g p u m p i s fi
fi t t e d , l o o s e n t h e a d j u s t e r
clam ping bolt, (Fig. 19-2).
Fig. 19-2
8. S l a c k e n o f f t h e a d j u s t e r an
an d r e m o v e t h e V - b e l t , (F
(F i g . 1 9 - 3 ) .
Fig. 19-3
9. Unscrew and rem ove the bolts re

ett a iin
n i n g t h e V -b
-b e l t p u l le
le y
o r t h e c a p b o l t r e ta
ta i n i n g t h e f a n t o t h e w a t e r p u m p s h a f t .
Rem ov e pulley or fan, (Fig. 19-4).
Fig. 19-4
Apr il '96
Cooling
19-6
10. S l a c k e n t h e t h e r m o s t a t h o u s i n g r e t ai
a i n i n g b o l ts
ts .
Unscrew and remo ve the bolts reta
aii n i n g t h e w a t e r
p u m p t o t h e c y l iin
n d e r b l o c k.
k. R e m o v e w a t e r p u m p a n d
gask et, (Fig. 19-5).
Fig. 19-5
Dismantling
1. W i t h a s u i t a b l e p u l l e r r em
e m o v e t h e h u b f rro
om the water
pum p shaft, (Fig. 19-6).
Fig. 19-6
2. U n s c r e w t h e b o l t s r e t a i n i n g t h e f r o n t b e a r i n g c a r rrii e r ,
(Fig. 19-7). .
Fig. 19-7
3. L i f t o f f t h e b e a r i n g c a r r i e r , (F
(F i g . 1 9 - 8 ) .
Fig. 19-8
Apr il ‘96

19-7
4. W i t h s p e c i a l t o o l 4 0 2 0 2 3 0 5 t a p t h e o ld
ld s e a l f r o m t h e s e al
al
carrier, (Fig. 19-9)
Fig. 19-9
5. R e m o v e t h e O - r i n g f r o m t h e tto
o p o f t h e f r o n t b e a r iin
ng,
(Fig. 19-10)
Fig. 19-10
6. R e m o v e t h e b o l t s f r o m t h e f r o n t , ( F i g . 1 9 - 1 1 ))..
Fig. 19-11
7. R e m o v e t h e b o l t s f r o m t h e b a c k p l a t e a n d d e t ac
ac h t h e b a c k
plate from th e pump b ody, (Fig. 19-12).
Fig. 19-12
Apr il ‘96
Cooling
Cooli ng Syst
System
em 19-8
19-8
8. Mount the water pum p body un der a pre

ess s a n d w i t h a s u it
it a b l e
mandrel rem ove the shaft comp lete with bearings from the
w a t e r p u m p b o d y , ((F
Fig. 19-13).
Fig. 19-13
9. L i fftt o u t t h e i m p e l l e
err f r o m t h e r e a r o f th
th e w a t e r p u m p b o d y ,
(Fig. 19-14).
Fig. 19-14
10. G e n t l y k n o c k o u t t h e r e a r s e a l ffrr o m t h e w a t e r p u m p b o d y ,
(Fig. 19-15).
Fig. 19-15
11. Press the larg e bearing from the shaft, (Fig. 19-16),
Fig. 19-16
Apri l '96
Cooling
Cool ing System 19 9
12. R e m o v e t h e s m a l l b e a r iin
n g s f r o m t h e w a t e r p u m p s h a f t,
t,
(Fig. 19-17).
Fig. 19-17
Ass embly
1. Thoroug hly clean the water pump. Examine the body for
corrosion, cracks and wear. Rep lace the water pum p
com pletely if a
anny part shows excessive wear.
2. U s e s p e c i a l t o o l 4 0 2 0 2 3 5 0 t o i n s e r t t h e r e a r s e a l in
in t o th
th e
w a t e r p u m p b o d y , ( F ig
ig . 1 9 - 1 8 ) .
F: i g . 1 9 - 1 8
3. U s e s p e c i a l t o o l 4 0 2 0 2 2 9 5 a n d i n s e r t t h e c a r b o n s ea
ea l . V ■ V / m ----------------------------------
a s s e m b l y i n t o t h e h o u s i n g , (F
(F i g . 1 9 - 1 9 ) .
:ig. 19-19
4. P a c k b o t h b e a r i n g s w i t h m u l t i -p
-p u r p o s e g r e a s e
e..
5 . P r e s s t h e s m a l l b e a r i n g o n t o th
th e w a t e r p u m p s h a f t ,
(Fig. 19-20).
Fig. 19-20
Aor il '96
Cooling
Cooli ng Syst
System
em 19-10
19-10
6. P r e s s tth
h e l a r g e b e ar
a r i n g o n t o t h e w a t e r p u m p s h a f tt,,
(Fig. 19-21).
Fig. 19-21
7. U s e s p e c i a l t o o l 4 0 2 0 2 3 1 8 a n d r e p l a c e t h e s e al
al i n t h e s e a l
c a r r i e r , (F
(F i g . 1 9 - 2 2 )
Fig. 19-22
8. P l a c e tth
he seal carrier over the water pump shaft and pre
esss
the hub o nto the sh aft as far as it will go, (Fig. 19-23)
Fig. 19-23
9. F i llll t h e s p a c e b e t w e e n t h e b e a r i n g s w i th
th m u l t i -p
-p u r p o s e
grease, (Fig. 19-24).
Fig. 19-24
Apr il '96
Cooli ng Syst
Syst em 19-1
19-11
1
10. F i t O - r i n g o v e r t h e l a r g e b e ar
ar i n g , ( F i g . 1 9 - 2 5 ) .
Fig. 19-25
11. P r e s s t h e w a t e r p u m p s h a f t w i t h b e a r in
in g s i n t o t h e
w a t e r p u m p b o d y , ( F ig
ig . 1 9 - 2 6 ) .
Fig. 19-26
12. Insert the bo lts into the seal carrier and tighten to
Fig. 19-27
13. P r e s s t h e i m p e l l e r o n t o th
th e w a t e r p u m p s h a f t a s ffa
ar as
the specified clearance between the impeller and the
water pu mp body. Use a feeler gauge to check the
c l e a r a n c e , ((F
Fig. 19-28).
Fig. 19-28
Apr il '96
Cooling
19-12
1 4.
4. Replace the water pump back plate with a new gasket
and insert the front and rear bolts, (Fig. 19-29).
Fig. 19-29
15. Tighten all bolts to the specified torque, Fig. 19 30).
Fig. 19-30
16. R e p l a c e t h e w a t e r p u m p a n d i n s e r t t h e b o lt
lt s r e tta
a i n iin
ng
t h e p u m p t o t h e c y l i n d e r b l o c k a n d t i g h t e n t o t h e s p ec
e c i f ie
ie d
torque. Fit the thermo stat housing to the cylinder block
w i t h a n e w g a s k e t a n d t i g h t e n t h e b o l t s t o t h e s p e c i fi
fi e d
Fig. 19-31
17. I n s e r t a l i en
en c a p b o l t i n t o t h e c e n t r e h u b a n d t i g h t e n t o t h e
s p e c i f i e d t o r q u e . I f f i t t ed
ed w i t h a f a n , i n s e r t t h e b o l t s r e t a i n i n g
the fan to the hub and tighten to the specifie
edd torque,
(Fig. 19-32).
Fig. 19-32
Apr il '96
Cooling
19-13
3
18. W i t h t e n s i o n g a u g e ( s p e c i a l to
to o l ) 4 0 2 0 2 3 2 1 a d j u s t tth
he V-belt
tension to 40 -45 kg (new belts), run the engine for 10-15
minutes and re-check the te
ennsion, which should be 30-40 kg.
If this is not reached adjust the tension to 30-40 kg. Position
t h e t e n s i o n g a u g e o n t h e b e l t w i t h t h e f l a n g e p a r al
al l e
ell t o t h e
b e l t e d g e.
e. G r a d u a l l y a p p l y p r e s s u r e t o t h e p r e s s u r e p a d .
W h e n a c l i c k iis
s heard or fe
ell t , s t o p a
annd rem ove the gauge.
Take an accurate reading at the spot where the indicator a
arr m
intersects the scale, (Fig. 19-33).
19. W h e n t h e c o r r e c t V - b e l t t en
e n s i o n s h a v e b e e n o b t a in
in e d , l o c k
t h e s t e e r i n g p u m p V - b e l t a d j u s t e r b o l t ( i f f i t t e d )),, ( F i g . 1 9 - 3 4 ) .
20. Tighten the alternator V-belt adjuster nuts, (Fig. 19-35).
21. T i g h t e n t h e b o t t o m a l t e r n a t o r m o u n t i n g b o l t , ( F i g . 1 9 -3
-3 6 ) .
Apr il '96
Coolin g System 19-14

19-14
2 2 . T i g h t e n t h e s t e e r i n g p u m p m o u n t i n g b o l t , ( F ig
ig . 1 9 - 3 7 ) .
2 3 . C o n n e c t t h e u p p e r a n d l o w e r r a d i a t i o n h o s e s , f iill l t h e
radiator with coo lant to wh ich the correct amoun t of
approved corrosion inhibitor has been added.
2 4 . S t a r t t h e e n g in
in e , a l l o w t o r e a c h n o r m a l r u n n i n g t e m p e r a t u r e
a n d c h e c k f o r c o o l a n t l e ak
ak s .
A tt en tio n t N e v e r f o r c e a V -b e l t o n to t h e p u ll ey b y u s in g a le v er .
T h e V - b e l t m a y b e d a m a g e d a n d t h u s c a u s i n g a n e a r l y f ai
ai l u r e
e..
T h e a d j u s t e r s h o u l d b e f u l l y r e l e a s e d a n d t h e V - b e l t ttu
urned
onto the pulley by hand. If one belt in a set requires replacem ent
always install a match ed pair. If only one belt is replaced it will
b e c a r r y i n g a l l t h e l o a d , w h i c h w i l l l e a d t o e a r l y f a i llu
ure.
Fig. 19-37
Apr il '96
Cooling
Coolin g System
System - Thermos
Therm ostat
tat a
and
nd Housing
Housin g 19-1
19-15
5
CAMSHAFT AND TIMING GEARS
1 BO LTS 6 O - R IN
IN G S
2 C O O L A N T O U T L ET 7 C O N N E C T I N G TU
TU B E
3 O-RING 8 GASKET
4 THERMOSTAT 9 WA SHER
5 T H E R M O S T A T H O U S IN
IN G 1 0 T E M P E R A T U R E S E N D E R U N IT
IT
Apr ii '96
Cooling System - Thermo

Thermo stat and Housing
Housing 19-1
19-16
6
REMOVING/REPLACING THERMOSTAT
AND HOUSING
HOUSING
Removing
1. Unscrew the bolts reta

aii n i n g t h e c o o l a n t o u t l e
ett tto
o the
thermo stat housing, (Fig. 19-38).
Fig. 19-38
2. L i f t o f f t h e c o o l a n t o u t l e t , (F
(F i g . 1 9 - 3 9 ) .
Fig. 19-39
3. W i t h a s u i t ab
a b l e s c r e w d r i v e r l iiff t t h e th
th e r m o s t a t f rro
om
the housing.
Fig. 19-40
4. R e m o v e t h e O - r i n g f r o m t h e tth
h e r m o s t a t b o d y , ( F ig
ig . 1 9 - 4 1 ).
).
Fig. 19-41
Apr il ‘96
Cooling System - Thermos tat and Housi

Housi ng 19-1
19-17
7
5. U n s c r e w a n d r e m o v e t h e b o lltt s r e t a
aii n i n g tth
he thermostat
housing to the cylind er head, (Fig. 19-42).
Fig. 19-42
6. R e m o v e t h e t h e r m o s t a t h o u s i n g a n d g a s k e t f r o m t h e c y lili n d e r
head
Fig. 19-43
7. P u l l o u t tth
he connecting tube from the thermostat housing,
(Fig. 19-44).
-ig. 19-44
8. R e m o v e a n d d i s c a r d t h e O - r in
in g s f r o m t h e c o n n e c t i n g t u b e ,
(Fig. 19-45).
Note: P r i o r to
to r e p l a c i n g t h e t h e r m o s t a t c a rrrr y o u t t h e t h e r m o s t a t
test as described on page 19-19.
Fig. 19-45
Apr il ‘96
Cooling System - Thermo

Thermo stat and Housing
Housing 19-1
19-18
8
Replacing
1. F i t n e w O - r i n g s t o t h e c o n n e c t i n g t u b e , ( F ig
ig . 1 9 - 4 6 ) .
Fig. 19-46
2. A p p l y a l i g h t c o a t o f s i l iic
con grease to the O-rings and
insert the connecting tub e into the top of the water pump
housing, (Fig. 19-47).
Fig. 19-47
3. F i t t h e t h e r m o s t a t h o u s i n g t o t h e c o n n e c t i n g t u b e , i n se
se r t
a new gas ket between the housing and the cylinder hea
add
and insert retaining bolts, (Fig. 19-48).
Fig. 19-48
4. T i g h t e n t h e r e t a i n i n g b o l t s t o t h e s p e c i f i e d to
to r q u e ,
(Fig. 19-49).
Fig. 19-49
Apr il '96
Cooling System - Thermos tat and

and Housing 19-1
19-19
9
5. I n s e r t t h e t h e r m o s t a t w i t h a n e w O - r i n g i n t o t h e h o u s i ng
ng ,
(Fig. 19-50).
Fig. 19-50
6. R e p l a c e t h e c o o l a n t o u t l e t , i n s e r t b o l t s a n d t iig
ghten to the
specified torque, (Fig. 19-51
Fig. 19-51
THERMOSTAT TEST
Preparation
1. R e m o v e t h e t h e r m o s t a t f r o m t h e h o u s i ng
ng , ( S e e p a g e
19-16).
2. I n s e r t a l en
en g t h o f c o t t o n t h r e a d b e t w e e n t h e v a l v e a n d
the thermo stat body, suitable to suspend the thermostat
in the con tainer, (Fig. 19-52).
Fig. 19-52
3. S u s p e n d t h e t h e r m o s t a t i n a c o n t a i n e r f iill l e
edd with water
and insert a thermom eter. Ensure that thermostat and
t h e r m o m e t e r a r e s u s p e n d e d a t t h e s a m e l e v el
el , (F
(F i g .
19-53).
Fig. 19-53
Apr il '96
Cooling System - Thermos tat and

and Housing 19-2
19-20
0
Check for Thermostat Opening Temperature
1. H e a t t h e c o n t a i n e r t o a t e m p e r a t u r e o f 7 1 °°C
C. At this
temp erature the thermostat should drop off the cotton
thread, (Fig. 19-54).
Full Open Check
2. C o n t i n u e tto
o h e a t t h e c o n t a i n e r,
r, with the thermostat
r e s ttii n g a t t h e b o t t o m , t o a t e m p e r a t u r e o f 8
822°C. The
T h e r m o s t a t s h o u l d n o w b e f u llll y o p e n , ( F iig
g. 19-55).
Checking for Length of Travel
3. R e m o v e t h e t h e r m o s t a t f r o m t h e c o n t a in
in e r . M e a s u r e t h e
distance between the by-pass valve and the lower support
bracket of the therm ostat body. Allow the therm ostat to
cool and return to its closed po sition. Again m easure the
d i s t a n c e a n d s u b t r a c t f r o m t h e p r e v i o u s l y o b t ai
ai n e d d i m e n 
s i o n . T h e r e s u l t i s t h e l e n g t h o f t r a v e l , ( F ig
ig . 1 9 - 5 6 ) .
A tten tio n ! If t h e t h e r m o s t a t fa i ls t o r ea c h m ea s u r e m e n t s
a s p e r s p e c i f ic
ic a t i o n s o r a n y o f t h e o t h e r c h e c k s,
s, i t m u s t b e
replaced.
Apr il '96
Cooling
Coolin g System - Visco
Vis co Fan 19-2
19-21
1
B A S IIC
C VISCO FAN
1 COV ER 8 SEAL
2 GASK ET 9 BEARING
3 DISK DRIVE 1 0 C I R C L IP
IP
4 FAN BO DY 11 S P A C E R
5 FLANGED SHAFT 12 SPACER
6 SCREW 13 CAPSCREW
7 LOCK ING DEVICE
Visco
Vis co Fan 19-22
19-22
INTRODUCTION
Depend ing on app lication 360 series engines are f i t t ed

ed with a therm ostatically controlled viscous drive fan, which is
m o u n t e d o n t h e w a t e r p u m p h u b a n d d r i v en
en b y V - b e l t s f r o m t h e c r a
annkshaft.
The viscous d rive fan does not h ave a rigid connection to the water p um p pulley. A drive conn ection, fitted to the pulley,
can mo ve within a cham ber of the fa
ann with a sm all cle
eaa r a n c e.
e. O n r e ac
ac h i n g a p r e d e t e r m i n e d t e m p e r a t u r e t h e t h e r m o s t a t
o p e n s , a l l o w i n g o i l t o e n t e r t h e c h a m b e r . A s a r e s u l t o f t h e f r i c t i o n c r e a t e d b y t h e o ilil w i t h i n t h e f a n c h a m b e r , t h e n o n 
driven bod y of the fan will turn thus driving th e fan.
Checking and locking visco us drive fan VISCO FAN
If there is an abnorm al rise in coolant temperature check A DE No. C a p a c it y S ilic o n N o .

w h e t h e r t h e v i s c o u s d r i v e f an
an e n g a g e s p r o p e r l y w h e n t h e 7620 0504 39 cm 3 3808 0720
engine is warm . With the vehicle s t a ti
ti o n a r y , cover the
r a d i at
at o r . Start the engine and allow to run at m edium
s p e e d u n t ilil t h e w a t e r t em
em p e r a t u r e i s 9 0 - 9 5 ° C . R e m o v e Viscosity of Oil
t h e r a d i a to
to r c o v e r . The therm ostat is now hea
att e d b y t h e
hot air from t he radiato r and open, allowin g silicon fluid to S ilic o n V is c o s ity
flow into the fan cham ber, thereby driving the fan. 3808 0720 12,50 cSt
In the event of a failure of the viscous fan drive the device

can be locked. The locking device at the rear end of the
Torques
fan serves to co uple the fan rigidly to the pulley.
D r i v e d is
is c b o l t s .......................... M 6 ...................... 10-13 Nm
T o c o u p l e t h e f a n u n s c r e w t h e l o c k i n g n u t (F
(F i g . 1 9 - 2 6 ) u p
............................................................. M 8 ...................... 28,5-33 Nm
to the lock stop, then turn the fan s lowly by hand until the
T h e r m o s t a t c o v e r ..................................................... 1 0 - 1 3 N m
pin of he locking device is felt to sn ap into place aided by
the spring pressure.
The viscous drive fan can be used for a limite

edd period only
in the locked con dition. Ex tended op eration in this
condition is not advisable. The fan sho uld be overhauled
as soon as possible
e..
Note: T h e v i s c o u s f an
an d r i v e s h o u l d a
all w a y s b e t r a n s p o r t ed
ed
a n d s t o r e d i n a v e r t i c a l p o s i t i o n ( a s f i t t e d t o t h e e n g i n e ) tto
o
prevent the silicon f l u id
id from running out. When
o v e r h a u l i n g t h e f a n i t iis
s essential to ens ure that only the
recomm ended silic
coon fluid is used. Do not use m inera
all
based oil. The fan will not operat e correctly, causing over
h e a ttii n g a n d s e r i o u s d a m a g e t o t h e e n g i n e .
Fig. 19-57

Vis co Fan 19-2
19-23
3
O V E R H A U L I N G T H E V IS
IS C O F A N
D i s m a n t l in
in g
Prior to dismantling the visco fan thoroughly clean the outside

with a su itable cleaning fluid.
1. Secu re the fan in a vice fitted with soft jaws,

(Fig. 19-58).
Fig. 19-58
2. R e m o v e t h e t h e r m o s t a t c o v e r re
re t ai
ai n i n g s c r e
ewws with a
5 m m A l l e n k e y , ((F
Fig. 19-59).
Fig. 19-59
3. insert two M8 bolts in the threaded holes in the thermo

stat cover, (Fig. 19-60).
4. S c r e w d o w n t h e b o l t s t o l i ft
ft o f f t h e t h e r m o s t a t c o v e r . T h e
therm ostat is pre-set and m ust not be dismantle
edd.
Fig. 19-60
5. L o o s e n a n d r e m o v e t h e d r i v e d i s k r et
e t a i n in
in g s c r e w s w i t h
an inhex socket, (Fig. 19-61).
A tten tio n ! T h e s e s c r ew s a r e s ec u r ed w it h L o c t it e an d m a y b e
difficult to loosen. Th e screws can be loosened by lightly tapping
the end o f the socket wrench.
Fig. 19-61
Apr il '96
Visco
Visc o Fan
Fan 19-24
19-24
6. Lift out the drive disk from the fan body, (Fig. 19-62).
Fig. 19-62
7. Carefully remov e the thermostat cover gasket from the

fan body, (Fig. 19-63).
Fig. 19-63
8. P l a c e s u p p o r t ( i t e m i p a g e 1 9 - 3 0 ) u n d e r t h e ffa
an body
and use a m andrel (item2 p age 19-30) to pre
esss out the
drive shaft, (Fig. 19-64).
Fig. 19-64
9. Rem ove the spac er ring, (Fig. 19-65).
Fig. 19-65
Apr il ‘96
Cooling
Cooli ng System - Visco
Vis co Fan 19-2
19-25
5
10. L i f t o u t t h e s e a l , ((F
Fig. 19-66).
Fig. 19-66
11. R e m o v e t h e c i r c l i p , ( F i g . 1 9 - 6 7 ).
).
Fig. 19-67
1 2.
2 . T u r n t h e f a n b o d y o v e r a n d u s i n g a s l e e v e (i
(i t e m 4
page 1 9-30) press out the bearing, (Fig. 19-68).
13. Thoroughly clean the housing with a suitable

cleaning fluid.
14. Inspect the fan body fo r any damage.
Fig. 19-68
A s s e m b ly
1. Use the sleeve and sup port (items 3 and 1 page 19-29)
and fit the bearing s, (Fig. 19-69).
A tten tio n ! N e w b ea r in g s an d fa n m u s t b e u s ed w h en re 
a s s e m b l i n g t h e f an
an .
2. R e m o v e t h e s u p p o r t f r o m u n d e r t h e ffa
an and fit the drive
shaft into place.
3. U s i n g t h e s l e e v e p r e s s t h e d r i v e s h a f t iin
nto the housing,
(Fig. 19-69).
Fig. 19 69
Apr il '96
Visco
Vis co Fan 19-26
19-26
4. Secure the fan in a vice fitted with soft jaws,

(Fig. 19-70).
Fig. 19-70
5. Fit the circlip, (Fig. 19-71).
Fig. 19-71
6. G r e a s e t h e s e a l l i p s w i t h a s u i t a b l e g r e a s e an
a n d r e p l a c e tth
he
seal, (Fig. 19-72).
Fig. 19-72
7. W i t h a p l a s t ic
ic o r r u b b e r h a m m e r r e p l a
acce the spacer rin
ngg,
(Fig. 19-73 ). .
A tte n tio n ! T a p e r o f s p a c e r t o p o in t t o w a r d s d r iv e d is k.
Fig. 19-73
Apr il ‘96

Vis co Fa
Fan
n 19-2
19-27
7
8. Carefully rep lace the drive disk into the fan body,
(Fig. 19-74).
Fig. 19-74
9. Clean the drive disk screw threa
add s a n d i n s e rrtt t h e s
sccrews
with Loctite, (Fig. 19-75).
Fig. 19-75
10. Torq ue the screw s using an Inhex socket, (Fig. 19-76).
Fig. 19-76
11. U s e a s y r i n g e f iill l e d w i t h s i l i c o n o i l ( s e e s p e c i f i c a t io
io n s
f o r q u a n t i t y a n d b r a n d ) t o f iill l t h e c e n t r e o f t h e h o u s i n g ,
(Fig. 19-77).
Fig. 19-77
Apr il '96
Visco
Visc o Fan 19-28
19-28
1 2.
2. T h o r o u g h l y c l e a n th
th e t h e r m o s t a t c o v e r w i t h a s u i ta
ta b l e
cleaning fluid, (Fig. 19-78).
Fig. 19-78
13. Fit a new gasket into the fan housing, (Fig. 19-79).
Fig. 19-79
1 4.
4. R e p l a c e t h e t h e r m o s t a t c o v e r w i t h t w o M 8 b o l t s iin
n th
th e
t h r e a d e d h o l e s , (F
(F i g . 1 9 - 8 0 ) .
Fig. 19-80
1 5.
5. T i g h t e n t h e A l l en
en c a p s c r e w s w i t h a 5 m m A l l e n k e y
socket, (Fig. 19-81).
A tte n tio n ! A lw ay s s t o r e t h e fa n in an u p ri g h t p o s it io n .
Fig. 19-81
Apr il '96
Cooling
Cooli ng System - Vis co Fan 19-2
19-29
9
Special tools for Visco Fan
These tools must be self fabricated
( It
It e m 1 )
S u p p o r t f o r r e m o v i n g b e a r i n g s a n d d r i v e ffll a n g e.
e.
35
~L
( It
It e m 2 )
M a n d r e l f o r r e m o v i n g f l a n g e d s h a f t.
t.
100
( It
It e m 3 )
Sleeve for installing the driv e fla
annge.
Apr il '96
Visco
Visc o Fan
Fan 19-
19-30
30
( It
It e m 4 )
S l e e v e f o r r e m o v i n g t h e b e a r iin
ngs.
(Item 5)
Sleeve for installing the drive flange.
( It
It e m 6 )
S u p p o r t f o r t h e f a n b o d y , f o r i n s t a l l at
at i o n o f b e a r i n g s .
( It
It e m 7 )
S u p p o r t f o r t h e f a n b o d y , f o r i n s t a llll a t iio
o n o f b e a r in
in g s .
Apr il '96

-31
1
O B T A I N A B L E F R O M : G R U N D Y T E C H N I F O R M , B U R M A N R O A D , D E A L P A R K , P O R T E L I Z A B E T H 60
60 0
011
TEL: (041) 43-2299, FAX: (041) 43-2224
W ater pump front s

seea
all
R e m o v e m a n d r e l,
l,
Part No. 4020 2305
W ater pump front s

seea
all
r e p l ac
ac i n g m a n d r e l ,
Part No. 4020 2318
C a r b o n a s s e m b l y s e al
al
replacing tool,
Part No. 4020 2295

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■»11111/®= “

ENGINE REPAIR MANUAL

Part No. 805*&S4i

Reproduction or translation, in part or full is subject to the written authorization of AtlantifDiesel

TECHNICAL DATA .....................................................

OPERATING MAINTENANCE SCHEDULE AND LUBRICATING OILS .............................................. 09

FAULT FINDING ......................................................

CYLINDER BLOCK AND LINERS ......................................................

CYLINDER HEAD ......................................................

PISTONS AND CONNECTING RODS ........................................................

CRANKSHAFT AND MAIN BEARINGS ......................................................

CAMSHAFT, TIMING CASE AND DRIVE-TIMING ...................................

LUBRICATING SYSTEM AND SUMP ............................................................................................................16

FUEL SYSTEM ..................................................... ........................

EXHAUST BRAKE ........... ....18C

ALTERNATOR AND STARTER MOTOR ...................................................

COMPRESSOR/VACUUM PUMP ..................................................

COOLING SYSTEM ....................................................

ADE 364N ADE 364C ADE 364T ADE 364TI

Bore ........................................................................... 97,5 mm 97,5 mm

Firing order ............................................................ 1-3-4-2 1-3-4-2

Combustion system ............................................ Direct injection ...

DETAIL OF RATINGS (AUTOMOTIVE) TO SABS 013-1977

Maximum torque (N.m) ..................................... 266 @ 1400 r/m in 300 @ 11400

ADE 366N A DE 366C ADE 366T ADE 36831

Bore ............................................................................ 97,

Firing order ............................................................ 1-5-3-6-2-4 1-5-3-6-2-4

Co m b u st i o n syst e m ............................................ Direct injection ...Direct injection ...

DETAIL OF RATINGS (AUTOMOTIVE) TO SABS 013-1977

ADE 360 Series

TORQUE SPECIFICATIONS FOR BOLTS UNDER DIFFERENT GRADE CLASSIFICATIONS

Quality grade 8 .8 1 0 .9 1 2.9

NOTE 1 — The Bolt grading appears on tthe

ADE 360 Series

IDENTIFICATION NUMBER POSITIONS

When o rdering spare parts allways quo te the engine

The engine numbering system for ADE engines consists

ADE M J 01002 SA 046315 T

ADE 360 Series

TECHNICAL DATA — 08-4

Flame-Proofed Engines Note 1:

Units operating under normal conditions, more than

Units ope rating und er normal co nd itions

OPERATING AND MAINTENANCE — 09-2

9. Check injection pump linkage for total movement. 13

15. Check operation of visco fan (if fitted). 17.

ADE 360 Series

ADE 360 Series

Run engine until warm and drain engine oil. c y l inde

coolant mixture. Run engine at medium speed If the laying-up

ADE 360 Series

OPERATING AND MAINTENANCE — 09-5

Note 6: Engines which have not received their first

TECHNICAL DATA — 09-6

DUE TO CONTINUOUS DEVELOPMENT, ATLANTIS DIESEL ENGINES ARE CONSTANTLY

ADE 360 Series

CONTENTS OF THIS SECTION

ADE 360 Series

CONTENTS OF THIS SECTION

CRANKCASE VENTILATION SYSTEM .................................................................................................. 11-11

REMOVING BREATHER ........................................................................................................................... 11-13

Ade 360 Series

ADE 360 Ser ies