309

1 General
UALMET
diesel
3o,9 Cylinderhead and
911 valvemechanism
4tl
611
612
WoftshopManual
lnlet-and exhaust
system. Turbocharger.
1. Edition
1 5 .1 . 1 9 8 6
YAITIT
VALMETCorDorrllon. Llnn.vuo,i Wo.ka
372i10LINNAVUORI,Flnl.nd 11 optionat
equipment
Tol. (lntl.)+ 358 31 il03 300
Tgl€x 2212Evålll st
T.lohx (lntl.l + 358 31 403 2E3
Downloaded from www.Manualslib.com manuals search engine

12
rO Tf USER
Thls Iqkshop Manu6l tq- valmdt diesel €nglnes ls Intendsd io facllliaie rcr-kshop op€rallons and
repal r r ork .
l O9, lll , 4ll, 6ll and 61 2 en glne s är e mal nly iha same In construcil on, so th a sa me r epol r
Instructlons usually apply to dlffereni eflglne lypes. The dltf{ences betr€n the vc'lous englnE
iypes rhlch alfecl repalr rcrk have been n ilon€d ln technlcal data ånd repalr Insfructlons. All
n€tasurgments a-e In nllllmsires and valld yh6n thg iemperaiur€ of the paris ls +20qC, unless
othefti ls9 sta+ad.
Before star+lng rsprlrs, makE sure tha+ you havo öll necessary i@ls, parts and accessorles 6i your
dlsposal. The speclal tools nsrfloned ln fhe rcrk Instruqlloos re nof all essenilal, but th€y sp€d
up and tacllltafo thg rrork and contrlbu+e io successfuI execuilon ot rork. An enqlne rhlch has under-
gone rspålrs nusf be run ln Jusi llke a nef, one.
Should the €nglng rgqulre meosur€snoi descrI bed In thls manu ol, pl ease co nsul f your l oca l age n t or
ihe S€rvlce Departnent of Valmet Llnnavuf I lq'ks. To fa cll ltatE consul fl ng, flnd out the fol lo r l ng
fac+s about +he englne beforg cgniaciing us:
- Englno typo
- EngIne nunber
- Appl lca+lo n or equl pmenf
- Hours og{afod or kl lon€irgs drlven
4fl DS

EGtfE SPECTF
tClTt(r{S
Englne type JO9o/!S 5 D llt Ds ill I D

Numb€rot cy I I nCf s t l 1
Dlsp I aca[srf dn) 2 ,7 t ,t 5,t 4, 4
Bore nn lo0 108 l0B 108
Sfroke ml llil t20 t20 t20
Coipress lon rdf lo l7 3l l 7: l l6: I l 7:l
InJetlon ader | -2-5 | -2-5 l-2-5 | -2-1-5
Compress lon pr€ssurp borl) 24 21 21 24
Englne type 4 DS 6t I D 6lt Ds/Ds8 612 DS

Numberol cyl lndf,s 1 6 6 6
Dlsp lecsmqrt dn) 4,4 6,6 7, 4
Bore fin r08 t08 t08 r08
Stroke m 120 t20 120 ltI
Cdprass lon röflo l 6: I l7: I l6: I ltr l
InJ€cilon ad€|' l-2-4-5 l-r-fr-2-1 l -t-5-6-2-1 t-5-H-2-4
CoDr€ss I on pressure brr) 24 21 21 21
| ) l.llnl"u,n vclue cf oprallng tonpratuftt

ond sterllng ngvs. Mox pg.rDltfed
dllterencp bqtr€gn cyllnders 3,0 bar.
E 6tE Tt?E DESt€rTtOtS
6t | 0sB JA
AppI I cat lon
A . v€hlcle sr ql ne
G - gen€ratlng-set €nglne
L. co[b ln€ hcrvGtor or|olne
l.l . nrlnc engln€
P = pump s€i srglne
E ngl ne oqulppedrlth boost clr cooll ng

(ilntercoolrt)
InJ6cilon punp iype ln 6-cyllnder er|glngs
B . Eosch iPr
tlo cod€ . Bosch r^n
Turbochcrg€d q|glne
BasI c tpc
olsp laclm€n+ of one cyllnd€r (e.g. l, | ö5)

Numb€.ol cyllnd€rs
't-2

TtGHrEiltrc TmqES
ObJect Nm
Eng l ne :
Cyl ln d€ r he a d sc r€rs a nd n ut s f 0 9, ,l l J ö 4 ll . ... .. ... ... .. ... ... l6 0

Cyllnder head screws and nu+s 6ll cnd 512 . . . . . . . . . . . . . . . . . . . . . . . . See I n s +r u c t lo n s , p o l n t f I K
Cyl l nd r he å d sf u ds t o c y l ln d€ r b lc k . ... .. ... .. ... ... .. ... ... .. . lO
Mo l n b €a rl ng scro t s 50 9 . ... ... . 160
Ma l n be ar ln g scre rs 5l l , 4 ll , 6 l t J o 6 1 2 . .. .. ... ... .. ... ... .. ... . 200
Con ne ci ln gr od nu is . .. . .. . . ... ... .. ... ... .. ... .. 90
Con ne cl ln g rod scrs rs 61 2. . . .. . . .. . . .. ... .. ... .. S @ I n s tr u c tl o n s, p o l r t 4 2 J
F l yr he el scr ew s . ... .. ... ... .. .. l2 O
F l yu h€ l ho u sI n g s cre rs i
- o u fer s c r o rs tl 1 2 . .. . . .. . .. . . ... ... .. ... ... .. . ll O
- Inn r s c r e rs M l 0 . .. . . .. . .. . .. ... ... .. ... ... .. 60
ldler ggar scrers:
-M 10 ... . . . . . . . .. .. ... ... ... .. 60
_ M t4 . . . . . . . . .. .. ... .. ... ... .. l4 o
ld l er ge ar ({ l+ h bo ll be arl n g) s c re| l 6 l l a n d 6 12 . . . . . . . . . . . . . . . . . IB O
ld l tr ge d- b earl ng h ol d q- scr€ rs M 8 6 ll Ja 6 1 2 ... ... .. ... ... .. . 22
Cra nk sho t i e nd nu i l O9 , ll l J o 4 ll .. ... ... .. ... . 600
Cra ksh af t e nd nu l 6 l l a nd 6 12 . .. . . .. . . . .. ... ... 1 0 m
Sc re vs of ad dl ll on ol c ou nt e rba la nc e s4 l | .. ... ... ... .. ... ... .. ... . 45
Coo lo nl pu mppu ll ey nu t M 14 . .. . . .. . . .. . .. ... ... IO O
Fuel equlpment:
l n Jec tl qr pu rrpge q' nu f B os ch trA n . . . .. . ... .. ... .. .., ... .. ... ... .. 90
InJsctlon punp gscr nui Bosch nPi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l,lO
I nJ eci cr r e+ al nl ng n u is (to s t ud s ) B o s ch . ... ... . 15
I nJ ci oi r ei a ln ln g nu ts (to s f ud s ) C A V .. ... ... .. 20
tlozzle flxlng bush Bosch @
tl oz zle t l x l ng b us h C A V. . . .. . . . 90
I nJ ect cr a dj us tl ng nu + c ov €r C å V . .. . . ... ... .. io
Pre ss ur e va l ve ho ld er B os c h nA ' . . . .. . . . 15
Pressut€ valve holdf Bosch "Pr 80
Corpresscr-:
Codpresscr- pu I ley nut Knorr 80
Conpressor gear nu+ B€ndlx t4 0
Compressq'gef nui C lay+cn 18 0
E l ect rl ca l e qul pD g nf :
A l ter nä t c r p uI l ey n ut .. ... ... .. 45
1 -3

CYLINDERBLOO(ANDFLY|IfEL I{oUSIT{G
I r{)€x
Coostrustlott .. . .. 2- 3
Reoclr I nstrucilons
l . C y l l n & r b l ak an d c y l l n der l ln e r s
A . Mea su rl ngl - he c yl l nd er ll n e r w ea r ....... ......... 2- 5
B . R er pv l n g t he c y l l nd er I I n e r . . . . . . . . . . . . ..........2 - 5
C . Ch ec k l ngt hs cy l i n der b lck ............ .......... 2- ,
D . R ep f ac l ng i h e ca ms hafi b e or ln g b us h tl 1/4 ll /3 09 ................... 2- 5
E . R €p l ac l n g t h e ca ms haff b e ar ln g b u sh es 6l l/6 1 2 ..................... 2- 6
F. C am sh af tc or re c i l on be6 rl n g b us h es 5 l l/4 1 1........................ 2- 6
G . Ca ms hö ttc or .e c i l qr be a rl n g b u sh 5 0 9.........' .................... 2- 6
H . C om sh at tc or re c i l on bea rl n g b us h es 6 1 1 /61 2 ........................ 2- 7
f . F ft f l n g f ha b l ak l n g p lu g o f th€ c an sh 6 ft l ln e 3 @ /5 ll /4 1 1 ........ 2- 1
J . F l i t l ng i h e bl o c kl n g p lu g o f the c a ns ha ft ll ne 6 1 1/6 1 2 .. . .. . .. . . . . 2- 7
K . F l tt l n g + he dl p s +l c k g u ld e p |p e ....... ........... 2- 1
L . F l ft l n g + he c yl l n de r 1 1 n er ............ ........... 2- I
2. Flyrh€el houslng
A . I ns i ol l l ng t he f l y wh ee l h o us ln g .' .. . . . . . . . . . . . .. 2_l0
B . R ep l ac l n g th e cr an k sh afl r e ar e n d se a l.... ....... 2- 1 0
vAlitEr
lCåL DATA (reJect llrnl+ of pari stäted In brockets afier ra+lno)
IECHN
Cyllndar b lod( ,09

Hole s fo. doieI s . . . . . . . . . . .. ... ll ,OOO... ll ,O4l
Dlam €ie r ol mal n b€ö rlng b ore . . . . . . . . . . . . ...... . 76,000... 76;019
Dlan etor ol cylln dei - llne r bore :
- upp er en d ... l l 6,ot2,,.l l 6,o47
- lo wer en d ,, . lt5,0oo.. .ll i ;Ol 5
I nsld e d lano +er of ca msha ft be arln g bus h (rhen flt ied ln posl tlon).50,ö00... 50,0å5 (50, o5o )
Tlgh + enln 9 lorq u€ of fl yrh€e l h ousl ng scrers:
- o uf er scre Hs Ml2 ............, .... ...... ..... .. l l O Nm
- I nnq ' scre rs M1 0..........,.. ... ...,. ..... .... 60 Nm
Tlgh ien lng to rqu o of maln be arln g caps ...r.... ..... ..... ...... ... l 60 Nn
Cylln dar block tll , 4ll , 6ll, 6 12

Holos for doye I s . . . . . . . . . . I l ,000. .. I r, 041
Dlan1 oie r of m6ln b€6rlng bore . . . . . . .. .. .. 91,000...9t,022 ( 9l , 0i 10 )
0la netq - of cy llnder llner bore:
- upper end 12t, r14. . .123, r54
- toref eno 122,oco. ..122, O4O
Ins lde dl€ f l€t er of c ams haf l bear lng bu s h (w he n f l +t ed In p os l i l on ) 50,000.,.50,025 ( 50,0 50)
Ins lde d lamet er of c öms hof + baorlng bu s h ( r he n fl i t ed I n po s l tl o n)
be 6r I ng s 2. . . 7 611, 612. , . . . . . . 49,990...50,050 ( 50,0 80)
T lghte nln g iorque of f ly rheel hous l ng s c r er s l
- o ut er s cre HsMl2 ............. .. ..... ...... .... ll O N m
- In nei s crexs Mlo .........,... .,.... ..... ...... 60 N D
Tlgh te nln g to rque of möln b€ arlng cap retalnl ng s crew g .., ..... ....200 Nn
Cyllnd€r I Iner 509
Pr ofru slq l of c y llnder lln€r above c yl l n d s r bl @ k l o p f ac e .. .. .. .. 0,0J0...0,080

Max pe rn lss lble holght dlf f eronc e b€t r, e€ n c y l l nd er l l ne rs 0,020
L Inq' bore t m,0m. .. t@ ,022 ( 100 , 0 8 0)
Max pe ro iss lble ov alnes s ot llner .. .. ... ,. . . 0,020
Hel ght of cy I Inder I Intr f I ange 8, 0t. .. 8, 05
He lgh t of c y llnder llner t lange, ' ls t o v e rs l z o , p är l no 8 f6 5 f6 B2B . 8,08.. .8, l 0
l-lelg ht of c y llnder lln€r f lange, 2nd o v e rs l z e , p a- t no 8 J 65 J 68 29 . I, 1t. .. 8, 15
He lgh i of c y llnder llner f lange, f r d o v e rs l z 6 , p ör i no 8 16 5 j 6 8l o . 8,2t... a,25
Ou tq' d lam eier of c y llnder llnei t ld tg e t2l , ...122, @
Cy llnd €r lln€r lll, 4ll, 6ll
Pro tru siq r ot c y llndq- llner abov o c y l l nd e r b l c c k to p fa c € . ,. .. .. . 0,0J0. ..0,080

Max pe rm iss lble helghi dlf f er enc e b ei w €n l l ne r s ( un de r s ame ho ad ) . 0,020
L Iner bore 108,000... 108,022 ( t 08,080)
Max pe rm isslble ov alnes s ot llner ... ... .. .. . 0,020
He lgh i of cy l I nd€r llner t langs 9,01., .9, 05
He lgh + of cy llnder llner f lange, ls + o v er s l z e, pc r t n o 8t 5J 2 98 29 . 9,08.. .9, t0
He lgh t of c y llnder llnt r f lange, 2nd o v €r s l z e, pa r t n o S J j f 2 9g j o. 9, l l. ..9, | 5
He lgh f of cy llnder llner f lange, f rd o v er s l z e, po r t n o 8 f5 j 2 9g l l . 9,25.. .9, 25
Ou t€r dla mef er ot c y llnder llner f l ge I l l , 700... I11,800
Cy llnd €r llnor 612
Pro iru sio. r of cy llndei- I I ns - abov e c y l l nd er bl a k fo p fa c s . .. .. ,. . 0, 010...0,080

Max pe rn lsslble helght dlt t er enc e b et w€ n l l ne rs (u nd er sa fl € he ad ). 0, 020
L Inef bore 16,0@.. .108,022 ( | 08, 0 8 0 )
Möx pe imiss lble ov ölnes s ot llner ... ... .. .. . 0,020
He lgh i o t c y llnd€. llnq- f lange 9,01. ..9, 05
He lgh t o f c y llnd, ei llner f lange, ls 't ov e r s l z e, p6 rt n o 8l 6 J 1 84 j 6. . 9, 08.. .9, | 0
He lgh i o f cy llnder llns- t lange, 2nd ov e r s l z €, pa rt n o B f 6f f 84 l 7. . 9,13.. .9, 15
He lgh t o f c y llnder llner f t ange, f rd ov 6 r s l z €, pö .f no 8f 6j 59 43 9. . 9,25.. .9, 25
ouier d lamete|- of cy I Ind€r I Iner f I ange Ill ,70. ..I]l ,80

2
o
v
TO o LS( Cyli nder bl ock and flywheel housl ng)
SP ECIAL
I a3@ 91315 Fli+l ng i ool lor cr ankshafl rear en d soal
2 4360 97314 F I y{heeI housIng contra I lz In9 bush
3 9045 348oO ch amfgr in g r eame r for cyl ln der l ln er bor e
4 90 51 7 J10 0 Too l for e xir ac+l ng and r o+aflng cyll nder ll ner 30 9
90]o 26too Too l for e xtra ctl ng and r o+aflng cyll nder ll ner
5 51 72 0 co rrectlon r eamer for cyl ln der l lne r fl t+l ng 309
9045 A1200 Correc+l on r eam€ r for cyl ln der l in er fl iflng tl l , 4ll , 6l l
9051 72800 Correc+l on r eamer for cyl ln der l lne r fi i+l n9 612
9045 87600 Exchangeblade Jor correct lon rearner
6 9025 52400 To ol for r o+atlng cyll nde r ll ner
1 A36t 91466 Cup plug tappl ng d rl f+ 40 m m
I A36t 9146A Cup plug +ap pln g dr lfi 16 mm
9 9025 98700 Dore l pl n +a ppl ng d rl ft
r0 90 25 7 81 00 Cy llnd er I Ine r cl ampl ng fo ol
11 9025 79200 G au gefor- mea sur lngcyl lnde r l lner helg hi
2- 2

Se lf-m a detools (cyll nde r b lck and f lyvrheel houslng) A35t 9l5 . emovl ng-
and fl++lng equlpmenf for ihe bushlngs ot +he cansha{+.
O)
o
o)
@
\
or

CYLIIDERBLCOK
ANDFLYB}EELTIOUSING
co{sTRtcT I oN
CYLINDER
BLOCK
ELOCK(4II)
CY LINDER
l. CyI Inde r bl ock
2. Boar lng bush
J. Scrow
4. Bear lng cap
5. Bearl ng cap ( 9ul de be ari ng)
o. Pt n D Ush
7 . CyI l nder I l ner
8. 0-r Inq seal l no
9. P tug i camshafi ll ne)
1 0. Dlp stl ck p tpe
I l . Nu i
12 . S +ud '-
l J. Screw
14 . Se aI Inq rln o
15. P luq
16 . Cup p l ug
17. Dr aln cock
18. Pressure qauoe sender
19. Plpe
T he c ylin d er b loc k fo.m s l-h e en glne bo dy t o 6l 11 612 engl nes höv e a n o-rl ng s eal al s o l n + h e
whlch +he other englne conponents are flxed. top end of +he cyllnder llner. There are
c ool l ng gr oov es w hl c h n ak e f he c o ol l ng o f t h e
T he cy llnd er llne r s (7 ) ar e of re t ty pe t{ hl c h hot top part nore efllclent.
nEans thä-t ihe coolan+ comes dlrecily ln+o
co nt ac + rlt h +h e lln er o u+ e. s u.fac e. T h6 T he c y l l nde r bl o c k I nc or porat es +he c amsh a f i -
se al in g b e+ He e n +h e cy llnde r lln er lo|l er end wh l c h h as + ho J ronl be arl n g pol n+ (j 09, l and
and c ylln de r b lo ck c omp rlse s of +r o o- rln gs ( 8) 4l l engl n es ) equ l ppe d rl f h a s e para+ e bea r l n g
whlch have been placed ln the g.ooves on the bus h (2 ) r{ hl l e t he ot her be arl ng pol n+s h a ve
cy ll nd er llne r. Th e top end ls s eale d b y me ans been mac hl ne d In th e c y l l nde r b l oc k dl re c t l y .
of a h ea d g a ske + s l+ua fed be twe en + he cyl l n der l n 61 1/61 2 engl nos €v e. y c am s haf + bear l ng p o i n i
llne r f la n ge a nd c yllnd er he ad. Th e ac c urö -t e has a s eparö l e bearl ng bus h.
f l f +ln9 of th e cylln der llner flang e and + he
mat ing f ac e of ih e flan ge ln the cylln der bl oc k T he rear end o { t he c am s haf t l l ne l s bl o cke d
ls a lso e ss en tla l fo r ihe iop end s ealln g. l {e wl th a d l s c p l ug In 30 9, f l I and 4l l eng l n e s
as k y ou io n o te t hls e spe cially in co nne c+ l o n rher eas t he 6l l an d 6' 12 e ngl n es hav e a p l u g
v . l-i'h cy l in de r llner as sen bly. equl pped r, l t h a n o-rl ng s eal .-
On both sldes of the rear maln bearlna +here are

pos l tl ons for gul d e b€ar l ng s he l l s i c ran k sh a f i
ax l a l b ear i ngs ).
2-3

FLITfEL IOIISIIG
Flyrhcl ho{sl ng
l. Fl yyh€€l hou sl no
2. Hgxagon screw -
f. Hexagon s€ket screy
4. Sheft seaI
5. P l u9
6. DoreI pln
22 7. S+ud
8. llasher
9. Nui
Th€ flyrheel houslng Is flxed to ihe rear end

of ihe cyllnder block. The crankshaft rear and
shafi seal (4) ls DlacEd In ihe recess machlned
t o f ha hou slng . lo odd ltlo n, + h€ ho usln g ha s a
rDuntlng polni lor ihe s+arter.
The bot+o föc€ ol ihe flyrh€el houslng Parfly

acis os the maflng tace of ihe ol I sunp seal,
so lt nay not dlffer much from lhe cyllnder
block bottom foc€. The carreci Doslflon of +he
flyrheel houslng ls secured a+ ihg manufaciurlng
s+a ge,lth d oxe l p lns (6).
The tlyyhe€l houslngs are dellvered occordlng
io +h e rE qu lra m€nts s ef by the en gl ne
ap pllca ilo n and d lffe ren t flyrh ge ls can be
mounld on all anglne +yp€6.
2 -4

TIORKI NSTRIjCT
I ONS P l a c e t h e tu r n a b le d l sc o f + h e l l n o r ex t r a c+o r
( 9 0 1 0 2 6 1 0 0 ) + h r o u g ht h e l l n e r o n li s l o w a r e nd
I. CYLIIOERSLOCKANDCYLIND€RLI]GRS a n d d r a w + h e l l n e r o u + fr o n t h e c v ll n d e r bl o ck .
I t{G I}IE CYLITDERL INERIiEAR
A. I,GASUR
CHECKI
NG IHE CYLINDER
BI-OCI(
l. Set ihe dlal gauge +o zero wlih a mlcrome+eror
wlth a ne ' , c y l ln de r ll ne r, l nd lc a tl n g T n e l. C a r e f u l l y c l e a n t h e c y ll n d e r b l o c k o f ol I a n d
diam e t er of a n un w orn ll ne r (1 0 8, 00 m m) . o t h e r l mp u r l t le s, p r e fe ra b l y In a { as h ln g
r n a c h l n e .A fi e r H a s h l n g b l o w i h e c yl ln d er b l oc k
dry wlth pressure alr and pay speclal afienflon
to o l I ch a n n e ls . R e m o v ea ll s c r a p s of ol d
gasKeTs.
C h e ck t h e c le e n n e s s o f t h e c o o l l n g ch a n no l s.
Remove the bol ler scale sedlneni to ensure
englne coollng.
Check +he +lgh+ness of fhe cup plugs önd screw
p l u g s l n i h e c yl l n d e r b lo ck a s l, e l l a s l h e
c o n d l+ l o n o f + h e c yl l n d e r b l o c k a nd se a l ln g
laces.
I\4easure +he wear of the camshaft bearIngs

( c o m p a r ew li h r a + l n g ) .
.-\J l/.. REPLACI]'IG ItE C/tljISMFTBEÄRINGBUSHtO9, 5l I
ond I
'll
R g n o v e fh e b e a r l n g b u s h r l +h a n I n s ld e
exiracfor (e.9. SYKESno. 854). You can also
remove the bush by +apping t{lth a drlfi af+or
i a k l n g o u i +h e b l o c k ln g p lu g fr o m th e r e ar on d
o f t h o c a m s h a {+ll n e .
2 . C l e a n i h e b e a r l n g h o u s ln g l n f h e c y ll nd e r bl o ck
carefu | | y.
2. Cle a n ih e Inner s ur fac e o{ ihe cv l l nder l l ner
j-horough ly before measureneni.
Perfoim the neasuremoni crosswlse a+ tho llner

t o p e nd , loYer end and mlddle.
Check ihe gauge readlng for maxlmum vrear and

o va ln es s ( c onpar e r{ lih ratlng) .
RETOYII€ llf CYLINDERLINER
l. I t y o u in+ end io r elns iall the c y ll nd er l l ners ,

mark +he liners so +ha+ +hey can be placed ln
ih e lr or igln al pos l+ lons In the c y l l nder bl oc k .
Make ihe marklng on the lnner sdge of the llnsr
+op flange, e.g. on +he edge towards canshaft,
s +a +ln g the c y linder number .
3 . F l+ +h e b e a r l n g b u sh In p l a c e b y p re ss l n g a nd
a+ ihe sameilme ensure the correc+ poslilon of
ol I holes.
4. Af+er fl+tlng |-eamihe bush io lis proper slze
(d 50.000...d 50,025).
I
li nd er blo ck
i front face
I
I
309
26
Notel The bearlng bush of the 509 e n g l n e l s
In l ls r a + e d s iz e a fi e r fl i ti n g a n d does nol
r q u l r e r e a mIn g .
Measure ihe clearance of +he bush and the

camshaft and cornparewlth railngs.
2- 5

E. FEPLTCI }G I}E C,AT.6FåFT
8EÄRI iG BU$f S 6t I /61 2
Dla[€+er o{ c.mshaff b€arlnq bush holes ln 27

6ll,/612 englles (nurb6rs star+ fron the englne
front endt.
Order nul5€rs for bearlng bushes (mårked oo the
outer surface of bear lng)
no.
22171
a36t 2297'
at63 22608
4, 5 a36t 22609
7 2261O
6ll1612 englnes hav€ seven replaceable camshafl

b€arlng bushes. obs€rve the varylng ouiar
dlangters of th€ bush holes In the cyllnder
block rhen renovlng and tlttlng ihe bush€s. Cairshaft corr€ctlon beorlng bushes for fll
engI ne.
t . Rsnove the b€arln9 bushes by tapplng rlth a
sultable dr I ft, fa Instance.
C le an the bear ln g h ou sln gs In th € cy llnd er

block +horo0ghly.
F lt t he ner be ar lng bus he s In ihe lr pl oce s by
presslng, usfng a selfnnode tool 8t5t 91556,
for examo19. No+e fhg cgrrect order of fhe
bu shesand the Do sltlon of the oll ho les of the
bushes In both 6nds.
4 . Reant fhe flrsf b€arlng bush fro.n fhe englne
front end to lts correci slze. (l 50,000...
50,025). ThE othEr bushes ere ln ihelr correct
slzes äfter llttlng and do not requlre reamlng.
Comshafi @rrectlon bearlng bushes for 4ll
Measure the clooranca of thg bushes and the 9n9l ne.
caiEhaft and comparexlth råiln9s.
F. C IGHAFTmRECr tor{ EEAR 5r1l/ l

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

H. CÎ,ISHAFT
@RRECT|ONBEARTNG
BUSHES6 l6t2
Camshatt correctlo4 bearfng bushes for 6ll1612

engI nes
l f need ed , y ou c an l nsi al I ln +he cyl l nder

bl oc k a b ush v lth I m o ve rslz e o u+er dl amsi er
I n Dlac e of the c ams haf+fro nf en d bu shl ng.
Oiher b'lshes can b€ replaced by overslze bushes
wlih 0, 4 mmou ter d lame ier. F lgure 210 shor s
the order numbers for the correctlon beårlng
bus hes an d ihe d lmens lon s fo r machl nl ng ih e
c y llnder bl oc k .
t . FITTING IIf BLOCK

I NG PLUGOF lHE CAIT.ISHAFT
LI]G
n9/ t tl/ 1 11
Cl ean th e b lo ck lng p lug spa ce +o gei r ld of ol d
s eallng c on p ou ndremalns .
Pr ess the blo ckl ng pl ug In l ts p osl + l on and f l x
Apply seallng compound(6909 J0008) on the slde Its sh lel d pl ate (l n en glne s whe re lhe f l y xheel
of lhe b lockI n g pl ug. h ousl ng does no t cov6 r the bl ockl ng pl ug) .
K. FITTII{GTIf, DIPSTICKGUIDEPIPE
l . Cl ean +h e plp e hole l n the cyll nder bl ock.
Ap ply r eia lnl ng fl uld ( 6909 J0 012) to t he gul de

p lpe loxer end .
2 11
T öp t he b loc k lng plu g In i+s place yli h th e

f lttl ng iool (9025 87400).
Notel Be careful no+ io lap ihe blocklng

plug + oo d ee p be ca use+hl s rlll affecl lh e com-
s h€f t end p la yl T ho refore a lray s use a flftl ng
t ool.
J. FITTIT{GTHE SLOCTI NG PLUGOF THE CÄI.IIiHAFT LINE

6t | /612
l. Clean t he b loc k lng pl ug pos l+lo n an d use emer y 213
Cloth to renove ihe posslble sharp edges On ihe
hole r l m . l. Tap the gu lde pl pe In l ls p osl tl on ai f he l evel
Indl cated In fl gur e 2 l J.
2. P lac e E n o-rln g In lhe blo ck lng plug gr oove an d
lubr lca te l+ tvlih , fo r ln s+ ance ,- sll lcone
s ealln g co mpo und .

L . FITTI}IG IIG CIL I ]OER LIICR
t. C l ean t ho c y llnder lln €r o nd lts l lttl ng polnis 6. It fhe ll ner must b e r alsed, Ins+cl l one r lth
I n t ha c y llnder b lock th orou ghly . The qy llndor an overth lc-k top tlang€.
llner lusf roiate easllv around ln lts bore
rhen +he g-rlng s€ollngs of the llner have been
relpveo.
Apply marklng colour fo th6 undersld6 of the

c yl ln der llnei fla ng 6 an d pla oe ih e llne r In
I ts p osl ilon nl iho u+ o -rln gs . Roia te the lln sr
l n boi h dlr ec t lons. ll|li hdra y +h e llne r and
check lf +he louch ls even.
309
P A RT H GROOVES
N O. QTY
8365 36827 8,03+o ,02 -(s td )
8365 36828 9.08 +0,o2 1
8365 36829 8,13 +0,o2
214 8365 36830 8,23 +0,02
5 . l f ih e m ailng l ac e l s d omag odor li +h e llne r 311 ,411 .611

proiruslon abovg the cyllnder block face needs
rnachlnlng, use o correcilon reaner. Af+er PART H GROOVES
r a am lng y ou c on per form € llgh + lE ppl ng rl+ h NO. QTY
t h e ll ner, lf ne ed ed . Ap ply g rlndl ng p as+e
be+r€n +ho cy I Inder I Iner I lange and the 4363 227A7 o +o,02 -( s td )
cyl Inder block and rofaie ihe llner rlth tool ^1
no. 6. Lapplng ls .|oi, hoyever, ihe rlgh+
8353 29829 9,Og+o,02 1
tEihod, It th9 cyllnder llner protruslon has io 8353 29830 9.13 +o,o2 2
b€ adj usied.
8353 29831 9,23 +0,02 3
4 . A t +er r oam lng and lepp lng cle an lhe mailn g
taces caretully b€torg meosurlng the cyllnder
l l ner D r o+ r us l on. 2
PART H GROOVES
NO. QTY
8363 36331 g,O3+0,02 - ( st d )
8363 38436 g.o8 +0,02 1
836338437 9.13+0,02
8363 38438 q 2.1 +o,o2 .t
An overthlck iop flange ls marked rlth ihe

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

c y ll nder llner s I n plo ca wllh cla npln g ioo ls
(9 025 78100) . M eas u rethe llne r D roirus lon e l ih
m eas ur lng gauge (90 25 792 00). Flx the dl al
gauge +o +he measurlng gauge and sel lf to zero
} t l ih a c ar efully cl eane d cy lln der blo ck to p
face. Move +he dlål gauge onto ihe top of +he
cy I I nder | | ner f lang€ and note ihe gauge
readlng. Corry oui ih€ measuremeni ln tour
dlffereni polnts. The proiruslon of ih€
cyllnder llners obove the cyllnder block iop 21 7
tace should be b€tyeen orOJ cnd O,O8 ||r. l{ofiol In the ll and 12 serles englnes the
The max helght dl tterenca betr€n the llners cyllnd€r llners rtih standord tlange fhlckness
under lhe sane cyllnder head may nof exceod åre dlvlded Into tyo ca'tegor les dependlng o.l
'".,KR T\T\R NTT\q \\Rl\ K\ K R \qK tR \\'ss \\\Str=. q\'f"b+"\'$iså"=
\,{\. ..
fhan fhe ones ln ellher ends. 9,04 - no narktng. F lange fhlcknåss 9,O4...9,O,
a- ö - flhl te pa lnfed ma rk ( d 20) a s sho rn l n flg . 2

l {o t€l In c o nne cllo n rlfh cy llnde r ll ner
fltflng renove nEierlal, lf ne€ded' Ylth
correctlon reanFr 9045 87200 In case of ll ond
12 €erles onglnes and wl+h reair€r 905.| 72m0 In
case of f09 englnes.
( f or 3 11an d411engi -
lf t he ll ne r p rotrud es h lghe r on one sl de than nes if needed)
on the opposl+e slde, chack the thlckness of
+he llner flange and the deplh of the flange
r ec es s ln ihe cy llnde r blo ck .-lf the r e ar e any
lrr eg ular l+lo s, repla ce ih e llner. Corr eci ihe
I lange .ecess In the cy I Inder block slth
correcllon r€amer.
red
.L'CJ
220
In sia ll atl on ordo r o f o- rl ngs l n 3l l, 4l l , 6l l

and 612 engIne cy I Inder | | ner .
Press the l lne i- In l fs posl fl on In fh e cyl l nder

blo ck. The l lne r r ll l go l n easl ly l l i h e o-
'n rlngs are correcily placed. Ensure fhal ihe

ll ner vtl ll no+ r lse ou + of l is Do sl t l on af +er
In sio ll a+lo n.
.a 2 14
9 . Pla ce ih e o -r lng s In the cy I Indor llner gr@vgs

and lubricate ihem, p referab ly wlth g ear ol l to
a v o ld se l zur e.
t{otel Try io åvold even sllghiest streichlng

o t ihe o -r ln gs du rln g ln sfalla ilo n b ec aus e t he
max sl-retch ot ihe lorer o-rlngs may only be
about 6 t. So as no't io lose the elasiiclty of
t h e r in g , Insta ll l+ lr om fh e loYer e nd and i ry
t o a v o ld s+r etc hlng ( e.g . do no t pl a ce f i nge rs
b e f r e en line r a nd r lng ).
1 0. lf ihe cyllnder block ls badly corraded ai +he

l orer o-r ln gs of ihg ll ner , you ca n I ns t al l a
thr €€- gro ove cyl lnde r ll ner In 5ll , 4 l l and 6l l
engl nes, spa re pari n o 8555 2 4480. Th e cyl l nds r
l lne rs rl +h ovsri hl ck fop flan ge ( lll , 4l l , 6l l
and 612 engl nes) ar e al so equl ppe d w l f h +hr e€
gr@ves for lorrer o-rlngs. The boftom groove
of thgse +hree-gr@ve llners rlll hove a red o-
rlng and lha t{o upper gr@vas a block ong.
ll n€€ded, an o-rlng (parf no 8565 29808) can

be ln slal l ed l n the fop g roove o f t he f l l and
4l l engl ne l ln er. Sho uld you I nsf al l lt,
chamter ih o cyll nde r ll ner top par + gul da nce I n
the cyllnder block ylth reamer 9045 54800 io
la cll li ate the pla cln g ol the o -r lng .
219
In s+a llailo n ordg r of o-r I ng s ln the f09 s n gl ne

c ylln der lln er.
2- 9

2. FLYXIfEL rcUS II{G
I NS'ALLIl{G llf FLYIHEEL IloUSII{G
The correc+ posltlon ot ihe tlyrheel houslng io
cyllndar block ls secured ai ihe manufaciurlng
s+age rlt h +r o d owe l p lns . Du rl ng Ins iallo +l on
It ls not necassary io canirallze lhe rolaflve
poslflon of the flyuh€€l houslng and the
c yl lnder bl oc k. Th € fl yx hee l hou sln gs dellver ed
as spore parts also have ihe doxeI pln holes
ready.
t. Clean the ma lng faces of the cyllnder block
ond t he t ly r he €l h ou sln g cåre fully .
Coaf the taces wlih seallng compound (6909
50008) .
3. Ll t i f ho f lylJ hee l ho us lng ln l ts p lace an d
t l ghi en + he re ta lnln g sc rex s llg h+ly .
4. MovE the flyxheel houslng so +hai +he doreI
pl ns holas me et. Flt thg dow el pln s ln p lace
r lfh tapplng drl f+ (9025 987@).
5. Check that ihe llD of lie nex shali s€al ls
Tlghten the flyrhe€l houslng retalnlng screys fla rl ess a nd i hat iha l lp sprl ng l s l n l i s
gvenly +o +hs ccr€ci forque, lnner hexagon poslilon. Lubrlcat6 the seal and ihe natlng
socket scrers (8 |I|n) to 60 ltr and o|iier tace of the crankshafi recr gnd xlfh oll. Push
hexagonscr€vrs (19 |l|tn)io ll0 iln. the shaft seal caretullv on lhe crankshaft and
a galn si the fl ywh eel hou sln g. Top the sea l
B. REPLAC
ING I}IE CRANGMFT FEAREI{D SEAL evenly dorn io ihe botiom wlih flitlng too I
8560 97515. Do noi use a pln-type tapplng drlti
DI srnou
nf the englne. because ihe meial body of the shafi sgal may
b€nd and cause leakaoe.
Open the flyrhesl retalnlng scrers and renbvo
ihe f lyr.heel.
,. Rerpve fhe old shaJf seal. Be careful noi io

damagethe crankshafi seellng surfaca.
4. Clean ih€ s€al recess ln the flyrhe€l houslng

cnd us9 enEry cloth io rerDve posslble sharp
Edges ln +h€ crankshafi rear end.
2 22
Notcl It the crankshafi ls so badlv rq-n ai

the seal ihat you doubt +he tlqhinels of ihe
s€al, change flie posltlon of ih; s€at t{tlh a
s haf t s €al dls +an c erln g. A 2 rnmth lck dlsta nce
r lng r hlc h ls pl ac ed un d€r fh6 s€ al h as sDar g
spore parl no 8560 20054.

CIL I NDERlffi) At|) Y LYE l,Ectl l Sr{
IIIEX
Teci nlcr l d ata ........... ................. J- |
S p* la l t@ls ............ f- f
c ons tr qc o n ............. f- 4
ReDclr lnslruqtldrs
l. Cyl lndgr h€rd

A. Remov ln gihe c yllnde r heod .. . . . . . . . . . . . .......... 5- 7
B. Remov ln g+ he volv es....... ...... 3- 1
C. Ch{klng the cy lln der heod . . . . . . . . . . . . .......' .. l- 7
D. Repla clng the valve guI de . . . . . . . . . . . . ............ l- I
E. Repla clng the In Jec ior s|ee ve........... ......... l- I
F . Mac hlnlngthe valve seo f.... ......... ............ J- 9
G . Repla clng the valv e seo i r1 n9........ ............ l- 9
H. Grindln g the va lves....... ...... l- 9
l. Flttlng + he v alve s....... ....... l -10
J. Fl+ tln g ih e cy lln der he ad J 09,Jl l ,4l l . ........... l -l o
K. Fltflng th s c yllnd€ r he ad 6 ll , 6 | 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l -l I
2. Valvs rEchrnl sD
A. Reco ndlilon ln g ihe valv e m€ chanl sm....... ........ 3-12
B. Re plac ln g the can shaf+ /camsh afi9e4r....... ...... l -12
C. Chec klng and ad Jus flng tl € val vg c l earanc€s . . . . . . .. . . . . . . . . ' . . . .. J-l l
VAIiIET 3 -0

L DATA(reJeci llnlt of par+ s+aied In brackets €fier ra+lng)
IECHNIC
volves, rocker crms and +rppets
Va lv e f lm In g
}J lf h a v alve c lear an@ o f 0,30 rnm

-ln le + va lve oo ens ........... l0 o b.t. d. c .
-ln le i va lve c los es , , . . . . . . . . 42o a. b . d. c.
-ex h au sf va lve ope ns ..,........ 42o b. b . d. c.
-ex h au s+ va lve c loses . , . . . . . . . . t0o a. t. d. c.
va lve c le a ra nc €s co ld and h o+:
- ln le i va Ive 0, ,0
-ex h au st va lve 0, t0
An gle o t va lve sea i In c yllnd er he ad .. .. .. .. .. .. f00
l{id t h o f va lv e sea + In c yllnde r he ad 1,0 .,.t,5
An gle o f va lv e tace ..,,,....... 29,5o+0,17
o ut s ide dla me +e i of valv e h ead :
- in le t v alve llf,4 ll, 61 1,61 2........
-e x ha u si va lve Jll, 4ll, 6ll , 6 12 ... .. .. . io
-i n le t v alve 1 09 . . . . . . . . . . . . . l9
-ex h au st va lve f09 ,............
I nls i v a lve s'fe m d lame is- 9,46 5...9, 480

Exhausl va lve siem dlarneier 9,44 5...9, 460
I nls f v a lve sfe n cle ar an@ (g ulda r eady fl i t ed l n c y l l nd er head) 0,04 0. ..0 , 070
( 0,1 0)
Exh a us t valve s +em c lear ön @ ( guld € re ady f l i i ed I n c y l l nder head) 0,06 0...0, 090
lo,t5l
I n s id e d lam e+ er of v alve gu lde (n of fl f fe d) 9,52 0...9, 535
O u+ s ide d lao e ier of valv e g ulde 16,02A...16,0t9
D la me f s' o t valv e g ulde bo re ln cyllnder hea d | 6, 000 ... 16, 01I
Pro f ru slo n of v alve guld e +o p a bov e c y l l nd er head s u rfa c e . .. .. .. .. l8
De p+h o f va lve hea d fac e be lo er c yllnde r hea d s ur{ a@ .. .. .. .. .
Valv e s p r lng fr ee leng th:
-in n er. . , . ...... ,1
-o u T er , ... . ... r . 6l
Sprlng p.essure Hhen sprlng comprossed io a length of:
-41 , 5 n m (ln ne i spr lng ) ......,,. 70.,.9 0 N
-47 nrn (ouier sprlng) 19...2 t0 N
Rccke. rn shafi d lamefer 19,9 59.. . | 9, 98O
I n s ld e d iam efe r o{ r oc ker a rm b ear lng b us h:
- (rh e n f ltte d ln oo sl+lon ) | 9,99 0.. .20. 010
ouiside dlamefei of rockq' d-m bearlng b ush . . . . . . . . . . . . 2t,035... 23, 044
D lanEier of .ocker arm bore . . . . . . . . . . . . 23,O0 0.. . 2t , 021
Ma x p e rm lsslb le pu sh r od de l le cflon (wh en f r€) . .. .. .. .. .. 0 ,4
F re e le n g ih o l roc ker a rn sp rln g 80
Sprlng pressure lihen sprlng @mpressed to € length of 58 fir 80...1 00 N
outs I de dlameter of taooef 29,9 19...29 , O
D la o et e . o f +a ppli bo re I n c yllnde r bt c k . .. .. .. .. . . 10,0 00.. . 50, 021
Pu sh ro d le n gt h 109 ,. , . . . , . . . . . . )al- |
Pu sh r od le ng th t1 1 , 4ll , 6 ll ......... .. .. ,iä-l
Pu sh . o d le n g+ h 61 2 .. . . . . . .. . ... 2791
Cyllnd€r held
Dla mef f o f In jec fcr- sle eve flxln g hol e :

-uDoer end 28,0 00.. . 28, 031
- toder eno 21, O@ ...2 7 , 0 35
outslde dlameler of Injeclor sleeve:
-upoer end 21,9 79...2A , 000
- towei eno 27,OT 5.. . 21, O 9O
D lam e+ e r o f In lst v alve s6 at r lng (s + an dard ) 48,0 54...48 , 070
Dla n eie r o f exh aus + ya lve s eat rlng (s ta ndar d) 45,045... 4 3, 01O
Dla ne t e r o t re ces s In cy llnde r hea d (s + a ndar d):
-f or e xh a u sf ya lv e sea + 4 3,00 0.. . 41, 0t 6
-f o r I n l e t va lve se af 48,0 00...4 8, 0r6
J- |

Overslz6 of exhcu+ valrc seat rlngs:
-ls+ oversl ze, part no. 8f6l l90o4 ........... 4t,251...15,27O
-2nd ovrslze, part no. 8f6l | 9OO5........... 4t,454...1t,17 O
OYerslzes of lnlet velve s€ai rlngs:
-lsf ovsrsl ze, pari no. 8f6l 2296, ........... 48.2r 4. . , 18.21O
-2nd overslze, part no. 8161 229f5 ........... 48,454.. .48 ,l70
DI aneter of exhaust valva seöf rlng recesses In cyllnd€r hEod: '
-l st oversl za 45,2O0...4 5,21 6
-2nd overs I za 43,40O...4 5,4 16
Dl am eid'of Inl gt va lve s e6 t rln g rec es ses In cyl ln der hea d:
-lsi oversl z9 48,2OO...44,216
-2nd ovgrsl ze 48,400...48,4 16
Cyllnder heod ih lckness | 04,90... | 05, 10
C yl lnds head m ln thlc kn ess (aftet- mac hlnl ng) | 04, 70
T i ghienlng ioc qu e of c yl lnde r hea d s crer s .......... se€ | nsiruqt lons
nln sio ll lng
cy | | nder h6ådn
CGhrtt 509, tl I
DI aneter of c ams hof+bea rlng jo urna l no. 'l (5 09) ......... 19,925...19, O
DI alFigr of c oms hatt bea rlng Jou rnal no. | ( ll l) ......... 49,905...49,9 50
Dlamet€r ot c ams haft be arlng iourn als no s. 2...4 ........... 49, 885. . . /t9, 910
DI ameter of comshoft bearlng bores (f09) 50,04...5 0,06
(5 0,08 5)
Dlame+er of c am sha ft be arlng bora s (3 ll) 50,000...50,0 25
( 50,050)
Cöm s haf lend p la y rlth a 0,5 nn g as ke f b et{ e€n cyll ndei b lck and ll mlng
g€a r hous l ng a nd bgtr€ en tl mlng g ea r housln g and tro nt co ver ..... 0,4 50...1 ,550
Camhelght ( dls ta nc€ be fx ee n bac k ol ca n an d i lp o l com) ......... 41,44
Cam llf i ...... 1,44
co m s haf l m ax D ermls slb le datle cflo n 0,0 5 (toial
Indlcstor r.tdl ng
caEhafi 4l I
Dlameler of cangbcft beorlng iournal 49,905...49,9 5O
DI anleier ot canshalt b€arlng journals 49,875... il 9, 900
Dlamel€r of camshatt berlng boros.. 50,000...50,025
( 50,050)
Camshafi end play rlth r 0,5 tlrt|gaskei belYe€n cyllnd€r bl€k 6nd flmlng
gear houslng and betu€n tlmlng gear houslng and front cover ..... 0,450...1,550
C helghi (dlstanco betu€€n brck ol cai and tlp of c4) ........ 41,4,1
can f t f i ......7.4 1
Camshaftmåx p€rmlsslble del lectlon 0,05 (toial
Indlcatd rcadlng
CrEhrft 6l l, 612.
D la nef s - ol c om sha ft be arlng journ als n os. I . . . 7 . . . . . . . . . . . ...... 49,905...49,9 50
I nsl de dlame te r of c ams hafl b ea rlng bus he s l n cyll nder bl ock
Bearl ng bus h n o. I .........' . .. 50,000...50,025
( 50,050)
Beår lng bush n os .2 ...7 49,990...50,0 50
( 50,0 80)
Camshöftend ploy rlih o 0,5 rn gaskei beireen cyllndf blck and tlmlng
gpar houslng ond b€tre€n tlmlng gear houslng ond froni cover 0,4 50...1 ,550
Can helgh+ (dlstenca betveen back of cam and tlp of cån) 4l . ,f4
C am| | t t . . . . .. . . 7,14
Camshaftmax p€rnlsslble def l€cilon 0,05 ( iotal
Indlcator reedl ng
3-2

4
&
5
@ 8
6
@ I
10 11 12 13 14
18
15
SPECIALTOOLS(c yllnd er I sn)

he ad and valve rnechan
I 8160 97r52 Val ve sprl ng fl ttl ng lever

2 8160 Lock n ut fo r valve sp rl ng l lttl ng l eve r
sJ60 97454 Torqug orm
8560 974t Exhau st v6l ve seat l eve l- cutier ( 509 also l nl et val ve)
8J@ 914]5 Exhaust vol ve seat cufts' ( f09 cl so lnl el va lve )
8560 914t7 Exhau si val ve seöf l nsl de cu ii er ( 509 also l nl at va lve)
1 8561 971t8 In lst valve seat level-cutter
8 8561 97459 In lei vrlve s€ei cutter
9 8561 91440 Inlst v!lvg seat lnslde cuiier
l0 8560 86085 InJectoi s leeve exfracior
ll 8560 9146t l nJecfa s l @vo fl ttlng drl ft
l2 8561 91410 InJocior matlng face reaner
It 85@ 97tt1 Vclve gulde r€movlng drlft
t4 8560 914r1 Valva g ulde f l ti ln g dr lft
t5 E 58000 Cyl lnd€r heod tq.que rrench 309, 5ll, 4ll
t6 8r6l 51542 lndlcator tor elongation scrers 6ll, 612
t7 4565 5t 541 Scksi rrerch fc elongatlon scr€rs 6ll, 612
t8 7tt 4 05506 Cup pl ug fl ttln g drl {i f6 n
Q-a

CYLlilDER HEADAND VALVETECHNlsll
CYLINDERHEAD 10
Cyllnd,ar head 4ll

l. Cyll nd€r h ead
z. v-f tng
l. Injoc+f s leeve
4. Cup p l ug
5. Cup plu g
6. Valve gul de
7. Valve seai
8. Val ve ssat
9. Thr ead p l u g
10. Valve gear cover
ll . Gaske+
12, Nu+
15. Washe r
14. Rubber seaI
15. Bre aihe r p l pe
to 16. C l amp
17. Ll {i lng l ug
18. Scre{
19. S+ud
20. Seal r Ing
7ol
2 l . Plu g
22. Hose connecfor
2 1. Seal rl ng
24. P l u9
2 5. Sfu d
26. Siud
27. CyI lnder head
gaske+
2 8. O-r l n g
29. O-rlng
109, ,ll cnd 4ll €nglnes have a one-part,

cross-flor cyllnder head of casf lron }rhere
each cyllnder has l+s ol'n Inlei and exhausi
channel on opposlte sldes of +he head. The
r lgld c ons +ru ctlo n an d ih e e ve nly spaced hea d
bol+ s c on+ rlbu te +o g oo d s €alln g. The cool ant
c lr c ulat lon is d lrec ted In s uc h a w av lh8i the
c oollng of th e va lve se at a re a ls as effl cle nt
as pos s l ble.
6l l and 61 2 en glne s h ave iwo se par ate

c y ll nder hea d s w hlch are +h e sa me ln baslc
consiruct lon as those of 3-cy I and 4-cy I
englnes. Än exiernal {ater-co I lec+| ng plpo
jolns +he cyllnder heads io fhe ihermos+af
housl ng.
3-4

Cr$s-s€st lon ot cyl Indor haad
l. V al v e gu l d e
2. Yalve seoi
5. InJectcr s leeve
4. O - r l ng s eal s
The lnlet vclve guldes and exhousi volve guldes
(l) are rep loceable and lnterchang€ab16. Hlgh-
porer -turbocharged5ll and 4ll englngs and all
6ll and 612 englnes have separate, replaceablE
va l ve s€ af r ln gs (2 ). T he InJ e c to rs a.e
gncompassgd In o rep laceab19 copper sle€ve (5)
surrounded by coolant. Thls tloans the b€si
posslble cool Ing of tt|9 lnJectd-s.
3- 5

YALYEi€CH]{Î STI
VrlYe flEchanlsn ,ll I

1. Cl rcl l p
2. Spaclng rasher
5. Nut
4. Rck€r arm
5. B ushIng
6. Adjustlng screr
7. Brackei
8. Sp rl ng
9. Shaft
10. P l ug
ll. P ush rod
12. Tappet
Sp ll t col l ei
14. Sp rI ng co l l c r
Va lv e sprln g
Vo lv e sprl n g
17. Sp rl ng cu p
t8. Exhaus+valve
t9. l nl s t val ve
20. Gear
21. Key
Camshaft
2t. Thre ad pl ug
Th€ c åm sh €ft (22), s ltr.ra ied In fhe cy ll nder

bloc k, ölve s l-he vc lve mech anlsmlhrou gh the
iappats ( 12) an d pu sh rod s (ll). T he ca mshatf
gear ( 20 ) ls flxed vrlth crlmp co nnec tl on a nd
flt ied r l+h a ka y (2 1). Eve ry bEorlng Journal
ls pressure-lubr lcaied ihrough ihe oll bore ln
tho camshaft.
3 -6

XORKI NSTRIJCT
IONS
CIL I ND€RIfAD ATD VALVEI.ECHAN

I SM 2 . F lx ih e val v€ sprln g f tttl ng le ver (8 1 60 9 7 5f 2 )
on l-op of +he valve sprlngs and compress fhe
t . CYLII{DERI€AD sprln gs. R em ovespl li col lg fs, sP rln g c ol l ar s
an d sprln gs an d de ia ch l he val ve.
REI,IOY T€AD
ING THE CYLINDER
c. CTCCKING I}IE CYLI NDERIfAD
Clean +he outslde of l-he gnglne and draln the
coolant. Dlsconneci fhe rater hoses flxed +o t. Removs the carbon deposl+ from ihe exhaust
ihe c y l ln d e r h e a d a n d th e r n o si a t h ou sl ng . po-fs, clean the seallng taceg and liash ihe
cyll nd er h ga d care tu ll y.
Removethe al. plpes bettregn alr fi lier and
turbocharger and between+urbocharger and lnlef
r nanl f o ld . Ch eckth e cyll nd er he ad fo r po sslb le c r a ck s å nd
other danage.
Loosen ihe screws of +he mounilng flange of ihe
+urbocharger pressure ol I plpe and the lower
plpe connec+or, then remove the plpe. Loosen
ihe scrers of ihe turbocharger reiurn ol I plpe
flange and the louer clanp, fhen renove the
p lpe.
Dlsconneci ihe olDes of fhe fusl reservolr of

+ he T hg r n | o sia r t d e vl ce ( lf a ss e mb l ed ).
open ih e c o n n e c +ln gsc r 6 * s o f t h e o ve rfl ov/ pl pe

of ihe I n J e c+ o r s, r e mo v et h e p lp o an d dl sno un+
+ he ln J e ct lo n p lp e s , 0 p e n + he Inj ec+o r
r eialnln g n ut s a n d r e n p ve t h e ln j ec iors. Fl i
pr otec i lve p lu g s ln th e c o n n e ct lon p ol nts ol
the {ue I eouiomenl-.
5o9oO
open fhe connec+lng screr of +he lube oi I plpe
leadlng + o +h e cy lln d e r h ea d a n d t h e p l pe j ol nf Ch eck+h e s+ rol gh+ n6 ssof i he se al ln g ta c e w l th
at t he lo r e r e n d , t h en re d p v e i h e pl pe (Jl l, a h al rl ln e ga ug e a gal nsi l lg ht. lf ih e s e a ll n g
611, 61 2 t , face is n ot si ral gh +, l+ mu s+b e ma ch l ne du n tl l
It l s.0f f the cyl ln de r h ead ca n b e m a ch l n ed
1 . Open + h e ln le i m a n lfo ld f lx ln g s cr e ws, exh au s+ 0 ,20 rin , l ea vln g a t hl ckn ess o f 1 0 4 ,7 0 dm .
manlf old n u is, +h e r r no s ia t h o u sln g scre{ s a nd Further 0,20 rm rnay be machlned, bu+ thls
l ronf l lf f ln g lu 9 s c re r s o n d r sm ove-t he p arts l nvol ves ln stal ll ng 0,2 0 rm sh orte r p l s io n s
from ihe cy I I ndor head. (s€ lnstructlons,pol nt il 2 | ). After the
se cond ma chl nl ng ih e m l nl mu mt hl ckn es s o f ih e
open the refalnlng nuts ol thg valve gear cover head ls 104,50 im.
and renove +he cover and thg breaiher DlDe
( 309, 51t , 41 1 ).
9 . open + h e v a lv e g e a r r e ia ln ln g n u + s an d bo lf an d
remove ihe valve gear. Llfi ihe push rods off
of f helr Do slf lo n s.
10. Loos eni he cyll nd e r h e a d f lxln g g cf ex s by iu rn-
I ng t hem t lr sl o n ly € b o u i 1 /4 o t a roi ai lo n a i
a ilme. Renove +he screxs and dismolni th9
c y l lnde r h e ad . lf t h e cy lln d e r h e ad i s i lgh fl y
fltted, d<rnot tap a {edge bet{eon lhe cyllnder
bloc k an d h e a d , s ln c e t h ls ma y da m ageih e
s eallng l8 c e s .
REIIOV
ll,lc IHE VALVES
lf y ou I n t e n d io f l+ + h e sa n e va lv es b a ck, m ark
+ hem s o f h a t y o u c a n ln sia l l +he n In ih el r
orlg I na l p o slt lo n s.
1. Ffx +he lock nut (At6O 91t561 oI t h e v a l vg

s prl ng llf t ln g le v e r I n th e v al ve gear cover
s + ud (f r yl an d 6 -c yl e n g ln e s h a ve no studs a+
ihe ml d d le va lve s . ln + h ls c a s e fl x a a sTuo or
a hex ag o f scr
l e w o f s u l+ a b le le n g ih ).
f4easurothe wear be+weenthe valve siem and lis
gu ld e wl fh a dl al ga ug e. L lf i i ho val v 6 l n l +s
place to have lhe valve head 15 mmabove the
cyl ln de r h ea d ta ce an d fl l ih e d l a l ga u g e
measurlng end on the valve head edge. Move -the
valve ln fhe dlrec+lon of +he dlal gauge and
read ihe clearance. The max clearönce ln +he
lnlet valve gulde may no+ exceed 0,lO m
@" and In the exhaust valve gulde 0r55 ||m.
By uslng a ne}, valve {or +he measurementvou
ca n det erm ln e i h€ va lve g ul de w ea r.
3- 7

D. REFTICII{G IHE YAI-YEGUIOE E. REPLACI}GIT€ I}IJECTOR
SLEEVE
l. Fl x i he i hre aded p l n of fhe lnJec+or s lgeve

l . R enov ef he ol d g u lde el+h a drlf+ (Bt6O 91331), exfractor (8160 86085) l n i he s leeve by turn-
el t her I n a vlc e o r by +€ pp lng. Cl€ an the gu lde Ing.
b ore of lm pu rlfle s.
o
2. Place 'the extrac+or shroud on top ot fhe
fh read ed p ln, flx fhe nuf ln ihe Pl n and turn
un- tl l the sl €ve l s l@ s€ .
(
l. Cle ön fh e ln J€c+ or sl eeve bor e ln +h e cyll nder
hea d cai eful ly. Ensu re iha f th€ upp er end gul de
2 . Lubr lc ai€ ihe oui s lde of ihe n ew gufa . f?g8 h+fy has no sharp edges shlch mlght damage lh6
l'l t h oll. T ap ihe gu lde In lts po sltlo n {lth a o-r ln gs dur Ing Insi all a+l on.
drlfi (8f60 97457). |{han uslno fhe neniloned
f lt +lng dr lf t the upp er en d- o { fh e gu l de
remalns ai the correct level (18 mm) above -ihe
cy ll nder head la ce a nd +he o l I gu lde be ve l
si ay s Int ac f .
39
3. T he lnle+ v alv e g u lde s an d ex hau st va lv e g ul des 4. Apply seallng conpound (6909 J0008) fo the
a re lden+lc al. Ins ta | | the guldes {lih +he more slee ve lor er end . Place n ex o-r ln g soa ls ln t ha
cham{ered ond upyards. Ensure iha+ ihe valves upper end and lubrlcaie th€n llghtly r,lth
move sn@ih ly ln ihglr guI des. vasel ln e. Tap the sl €€ve l nto posli lon xtth a
3- 8 drl f+ ( 81@ 974 6ö).

2. Turn the cyllnder heod ihe rlght ray and tap
'the valve s+em unill the seat rlnq congs loose.
f. C l a a n th e se a t r l n g po sl tl o n In th e cy llnder
h e a d . B e fo r € tl ttl n g a n € r, s e at rl n g , coo I the
r l n g r l th l l q u l d n l i ro g e n. L e t th € rlng c ooI
doin In n lirogen uni | | f I zz Ing around ll s iops .
4 . Ta p th e ssa + r l n g l n p l öc e w l i h ö s ult ab le
dr l ft a n d n a ch l n e th € ssa i l n q fa c€ .
Nofel ll needed, a s+andard seai rlng can be

rep lac e d nl+ h a r lng tili h |r lde r o u i sl d e
d lam eie r. S e ai r lnq s fo r bo fh In l e + a nd
ex ha us t v al vo s a r6 d ea lv ere d In tto over sl zes.
31 3 S ee T ec hn lc al d ata , pol nf c y lln de r h e a d .
It nec essary, stralgh+ en and c lean + h e ma tl n g

s u rfa c e of th€ InJec+ or seallng wa sh e r In l h e
cy I I nder head Hlfh a r€amer ( 8161 974?0).
H. GRINDIIIGI}C YALVES
Icrtcl lJ requlred, the standard lniec'tor

s le e ve c ä n b e r o pl a c e d b y o n e r lt h 0 ,4 | | m
o v er s lz e t o p . B € f o re l n s + al l ln g t h e s le e ve ,
m a c hl ne t h e c y l ln d e r h e ad u p p e r g ul d e bo re +o ö
0,4 m blgger slze. The c.d€r nunber for ihe
o v er s lz e I n je c+ o r s l ee v e l s 8 1 6 0 f 8 7 2 1 .
F. llÄo{lNl}c THE VALVESE T
315
To ensure max ilghiness betHeon +ho valve önd

th 6 s ea t, ih e d lffgr en ce In ln cl lna tlon bg t r e € n
se al lng su rfa ce s ls 0, 50. T hl s mok es a v er v
na .row s ea lln g s urfa ce wh lc h s e6 ls be t t e r i ha n
a w lde o ne , e v on y h en wor n.
t. ll ih e v al vo h ea d ls d om ago d, ire oi lt In the

g rln dln q mac hl ne . A d Ju s t fh e grl ndl ng na ch l n a
to 29,54. Do no+ grlnd fllore than ls necessarv
io clean the contaqi surtace.
lf fh e v al ve h ea d o ute r e dg e th lc k ness r e m a l ns
un der 1,5 m n, re pl ac o ihe va lv e.
It the valve stem l-op has rorn hol lor, lgvel lt

by grl nd lng .
'14
t 4 a c hI n e f h e do m ag e dv a l v o s e a + u s l n g v alv e s sö i
cutters 8160 97454...91440 or use a valve sect
g ri nd e r. lf t h e s e a t s u r f a c e l s { l de r lh an 1,5
nm, närrow lf olthe. lrom the outer or ihe
in ne r e d 9 e . Th e l n c l l n a+ l on o f i he valv e s ea t
s u rJ a c e l s J oo .
REPLACII{G TIIE Y^LVE SEAT R I NG
T h e J ll a n d 4 ll e n g l ne s o f h lg h e r o utp u t an d
a ll 6ll a n d 6 1 2 e n g l n es ar e f u rn lshe d rllh c) o
s e pa r ate v a lv e s e ö t r ln g s . lf the s e all ng
surface ls so torn that ll canno+ be lrDroved
b y m a ch i n l n g , r ep l 6 c e t h e s e a i rl n 9.
66
G rl nd + h e h s a d o t f h e re j e c t e d v a l v e s o tha + l t
f li s l n + o t h e s ea i rl n g . Fli + he va lv 6 l n
p os l +lo n a n d * el d l t i o f h e s e a i rl nq. C o ol th e
e el d r li h r a t *.

4. Grln d t he v a ly e ag aln s i li s s ea + x lih a fl n e
grlndlng pasie. Check the con+act surfaces rlth
te s+lng c o lou r .
5 . C le an the c y llnd er h ea d a nd th e v al ves o f
grlnd Ing resl due s ca r efu lly .
I . F ITTII{G TIf, VALVES

l. C hec k the c on dlilon o t th e v a lve s p rl ngs. lf
nocessary, irfal press lhe sprlngs ln å control
devlce, for pressure see Technlcal da+a, poln+
va lv os. 309
2. L ubrlc a+ e the v alv e s t em s ulth en oln e oll and
place ihe valves ln the correc+ örder ln ihe
cy l lnder head .
i . Fl t thg v alv e spr ln gs an d s pr ln g c ol lars In
pl ace, c ompr e s sih e s pr lng s |r lih f lttlng lever
l At6O 97552t a nd flt s p llt co lle+ s In pla ce.
Af+ er flti lng lhe v alv es an s ur e f ha t th e sp li t

col lets a.e corroct ly posl+loned by, for
e xample, car efu lly t ap pln g o n ihe v alv e he ads
rli h a plås il c h a nm er .
311
J. FITTINGTHECrl-tiFER IEAD rO9, lll, 4ll
En sure fha'f th e c ylln de r h ea d f ixln g s t uds (no +
1 09) ar e pro pe r ly ilgh ien ed to ih e c y l block
(5 0 ilo). F lt the va lv s + ao oe ts I n thel r
D osl+ lons.
411
318
Tl g h + en i he h ea d s c r ew s I n ph a s s s a n d I n l h e
s eq u en c e s h ow n l n l l g . ! 18 . T he t l g h t en l n g
s eq u en c e l s al s o I nd l c a + e d by n um be r s l n i h e
c y l l n de r h ea d . Tl gh t e n a l l g c r ew s t l rs + + o l h €
t o rq u e of 8 0 N n, t he n io | 40 Nn and
f I n öl l y + o 16 0 N n .
I n s l -a l l D u s h r od s l n th e l r o o s l + l o n s an d f lx
i h e v öl v e ge a r i o i he c y l l n d er he a d. Tl g h t e n
i h e v a l v e ge a r f l x l n g br a c k g ts e v en l y a n d l h e
411 ou+ermosf brackeis so +hat the eashers ai ihe
l. 0- r in g 13, 1X 1, 6 rocker arm shalt ends beslde +he lock rlnq
rotate free lv.
2.0- rin g 1 l x 2
317 6. Adj ust ihe va lve clearancos. S€ lnsiructlo|ls
pol nt J 2 C .
C heck th at i he s e al ln g f ac e s of t he c y l ln de r
blo ck a n d cyl ln d er he ad a r e c l ea n. J 0 9 e n gl n e s :
7 . Fl t al l +he oi h er pa rts yo u dlsmo unl e ddu r l ng
T ap th e d owe l p l ns o f t he c y ll nd er cyllnder head renoval. S9g lnstructlons polnt
h ea d I ni o
t helr ltA .
ho le s. F l t t he c y l l nd er he ad g as k e t I n
posltlon. Place o-rlngs ln ihe hsad gaske+ rear
end around the ol I bore and ihe coollng boro 8. Run +he englne for max 0,5 hrs and retlghien
( 4 ll 'the cyllnder hgad screys. Parform ihe ilghfen-
beslde ll en gl nas : noi e lh e dl f f e r l ng
slzes o f ihe o - r l ngs ) . Ing In + he o rd er i ndl ca+e d, sll gh+ ly op en +h e
screw and +lghten li to fhe correct iorque
Fli
rhl le rofatl n9.
fh e h e a d In pl ac e. Cl ea n an d l u b rl c a i e
flxlng scrsw ihreads and tlghten +he screws.
N qtet A l ra ys a djust +h e val ve cl ea ra nc es
afts' tlghtenlng cyl indq- head screxs.
Note I }lhen ilghtengd io +he correci forque
unlub rlca te d s c r ey s c au s e. y r o ng p r es s ln g f or c e
on +he head gasket,
3-10

K. FITTI G Tlf CrL |l|)€R rf D 6 , 6t2
321
5, Tlghien the scrers ln ihe mentloned sequenco

60ö (angular dlstance on lhe screr head). Use
socket rrench 4361 31341 and lndlc6tor 856f
31 9 l l f 42 r l i h m a gn e tl c fl xl n g . Th e o u + sl da of +he
socke+ wrench has a hole marked ai Iniervals o{
M e as u r e i he l e ngl -h ot i he c yl lnd €r he ad 6 0 0 . S e ftl ng the In d l c ai o r a f th e h o les helps
f lx ln g sc r e rs . T he l en gi h s ho ul d b€ rlihl n - the tlght€n fhe screr to the corrgct iorque.
l ln lt s l n d lc ai e d i n f l g. J 19 . l l a n y s cr er
dl lf e rs in l e ngt h , rep l ac e i i . Tlghten the scrers 600 (one öngular dls+ance
= one hole dis+ance on fhe socket rrench).
2. F lx f he c y l l nd er h ea d st u ds i o t he cy l lnd €i
bl oc k ( J 0 N m) . I ns t öl l l he v al v e la DDe ts In Tlghten ihe scrsrs 600 (one angulor dls+anco
= one holg dlstance on fhe sockef rrench).
ih e lr p o s lt lo ns .
f. C ho c k t h a t t he s ea l ln g su rf ac es of t he cy l lnd er 8. F l i fh e va l ye ta p p e + s In l he l r po sl t lons and

bl oc k a n d he ads are c le an . P la c a +h e h €a d tl x i h e va l ve g e a rs i o + he cy l l n d € r heads.
ga s k e t s a n d c yl l nd er he ad s l n t h gl r po sl tlo ns . Tl g h i en fhe v al ve g e a t- fl xl n g b ra ck s t s ev enly
Ensure lha+ +he cy I Inder heads are stra lght and the outernosi brackets so lhat lhe yashers
and parallel fo each qther by uslng a stg6 | o+ thg rocker arn shat+ gnds beslde the lock
ru l er ( l n le t n an lf o l d s€ al l ng ). Tlg hte n + ho rl ng rotaie lreely.
c le an e d a nd I l gh il y ol l ed s c rew s an d n uts .
9. Adjust the valve clearances. Sco lnstructloos
polnt I 2 C.
1 0 . Fl f a l l fh e o + h e r p € rts yo u d l sn o u n +eddur lng

cy I In d e r h e ad r e mo va l .
ll. Run lhe englne for abouf 50 nlnuies ,lth a

llght load.
Tlghten the scrers 600 (one angular dlstance

= one hole dlsiance on ihe sockel rrench) and
adJust lhe valves,
6 11, 61 2
Perform the f l.st tl gh+enI ng l n l he order g lven

In flg .5 20 fo ihe +orque of 40 N m, u s l n g 6
+cr'queyagnch.
3 -11

2. Y LVE I,ECHI{t Stl
RECtf{D|T|O{|r'rG
ItG VALVEl€CH N|SM
Check fhe condl+lon of +he valve iappets paylng
speclal afientlon lo iha coniac+ face agalnsi
ihe camshafi. Replace any worn or otherwlse
defectl ve lappets. OLD
NE W
32 4
Not€ | There are +ro types of rocker arm

sha t+s l n u se. In +he shaf+ used ear ll er thsre
Here 'fldo horlzonfal ol I bores for lubrlcatlno
all rocker arms. The ner{ shaft has one verilcai
oll bore at each rocker arm. To ldenilfv the
nee shaf+ there are il{o Insialla+lon rnarks
machl nedo n l ts top face. I{ hen ln s+al ll ng i h e
rockor arms noie the c!.rec+ Dosl+lon of ihe
marks = upward.
Check the s+ralghiness of fhe push rod uslng a
p lane dls c . A lso ch ec k tha+ the b all end faces
of ihe Dush rods are lntact.
Dlsmantlo ihe rocker at-rnassemblyand clean ihe B. REPIICING T1€ CAIISMFT / CÄI.|SHT|FT
GEAR
p ar +s c ar ef ully . Ch ec k iha t ihe s haft ls nol -
v , orn and t hat + h e lu brlc a+lo n Dorts are clean . l. Removethe boost alr Dlpe betvleen the +urbo-
charg er and the l nle + manl fol d ( lf Ins+all e d),
Open the flxlng nu+s of +h e valve gear cove r
and rerpve the cover and +he breather plpo.
Lo osen the valve gea r fl xlng nu +s (an d i he
scre H ln f-cyl and 6-cy I eng lnes), t hen
renove +he valve gear.
2. L@son ihe fan flxlng scrers and remove ihe
fan. o pen the al ier nator fl xl ng screws, t hen
reflpve th6 al+erna+or, beli spanner and y-bolt.
f. Opo nfh e cran ksha fi end n u+ of i 09, Jl l a nd 4l l

en gln es wl +h to ol 9024 74 200 an d o f 6l l a nd 612
englnes wlth tool 9024 55800. Draw fhe beli
pu ll ey - h ub pl ece co mbln atl on off the c r ank-
s haff.
4. Loosen ihe fron+ cover scrers and nuts and
removo +he faonf covs'.
Check ihe rocker arm bearlng bush lor xear. lf

you replace +he bush, ensuro thal +he oll Pori
l s t n pos l +lo n b efo re pre ss lng ih e bush l n
p lac e. Af ter ln s+ allln g +he b ush , bro ach lt 'to
l +s c orr ec + s lze 19 ,990 ...2 0,0 10 mr. lf the
ihrusi faco of +he rockor arrn ls worn, grlnd lt
to lts correct form. Slnce +he ihrusi face has
boen case hardened, grlnd only deep enough fo
srnoo+houf the lrregu lar ll les.
Plac e a l oc k rln g In fh e ofhe r en d of the

rocker arm shafl, lubrlcaie the shaft and
Insiall the parts on ihe shafi ln correci
order. Make sure ihai the lock rlngs sl't Lck the iap peis up to ell mlna fe i he r lsk ol
properly ln ihelr grooves. and fha+ ihe cup +hel r fa ll lng d oun l {he n r enovlng ihe camsh af t
pl ugs I n f he s haf+ end s a re ln lhe lr p osl+lo ns. and th us p reven+i ng +he Install a+l on of +h e
3 -12

Ncrtel BendIn9 the push rods excesslve ly
causes bends! Use only s uc h o-rlng s whlch nl ll
n ot be fltie d ln +h elr actua I p laces.
Roia+e +he crankshaft so as io have Tne
I nsia lla+ lon mark s of ih e cams hafi g ear and
ldler gear mee+. Draw the camshaf+ou+ of Tne
cv I ln de r b loc k.
327
lf the cl ear ance dl ffer s f.d n i ho ra+l ng, open

the l ock nut sl lgh+ ly and ad just a cor r ect
clo aran ce vll th a n ad jus+lng scr ex. Th o cl ear -
ance ls correc+ *hen a 0,30 |Im feeler gauge ls
sl lghtly + lght-fltled bei ween the ro cker ar m
and the va lve head,
7. Us e a d rlf+ o f su lfable s lze to r emove l he
ca ms haf f ge a r. J. Turn the cr ankshaf+ furi her l n lts runn l ng
dlr ec+l on, un+l l -i he e xhausl val ve of + he l s t
lf yo u I nt en d to in sia ll an old ca mshaft or cyl lnd er ( 2nd valvo) ls i ull y op en. C heck t he
g ear , cle an ihe pa r+s b efo re flttln g ih em. val ve clea rance of the znd cyll nder .
4. Ro+aie the crankshaft fur+her In runnlng
9. Pla ce t hre a d p lugs In th e c ams haft ol I b ore dlr eci lo n, un+l l +he e xhausi val ve of +he 2nd
ends. Sef a wedge in+o the camshafi key groove. cyl ln der ( 4i h valve) is full y op en. C heck - t he
I,Jarmfhe camshaft gear up io the fempera+ureof
2 0 0 o C an d p lac e li ln lis p osl +lon. val ve clea rance of +he Jrd cvll nder .
10 . Lubri cate ihe camshaf+ bearIng journa I s and ]I I ENGI

NES
pus h + he s ha t+ in fo ihe cy I In der b lock checkIng
ih e in s+ alla+ ion ma rks on +he gea r. 2 . Tur n +he cr ankshaf+ by +he ll ywhe ol gear r l m
| {l+ h, for examp le, a scr ewdr lvo r, u nt l l t he
ll.
exha ust valve of +he fr d cyl lnde r ( 5 t h va l ve
F l+ ih e fr on t c ove r a nd ih e pulle y - hub p l ec e leiel y open.
comblnaflon, see Instruqtlons, polnt 5. frorn ihe englne front) ls cornp
Check th e val ve clea rance ol +h e l si cyl l nder .
1 2. L e i ihe ta p pe is d or n and Ins tall + he val v e gear
( ln s t ru ctlo ns 3 | J poln t 5 ). Fl + + he v al v o l f the cl ear ance dlffer s fr om + he r a+ l ng, open
gear cover and +he brea+her plpe as \{ell as the ih e lock nu+ sl lg h+ly and a dju s+ a cor r ec+
boost alr pipe bel-lreen ihe tu.bocharger and the cl eara nce wl+h an a dju stl ng screw. Th e cl ear -
ln le + m ani fo ld. ance ls co.rect rhen a 0,30 mm feeler gauge Is
sl lgh tl y tl ght-fl tted be t{e en the r o cker ar m
lJ. I n s ia ll +he a l-te rna ior a nd l'h e be li s pan ne r and and the va lve hoad.
a d ju s + th e v -b elt tens lon. Fll' t he fan and J. Tur n + he cran ksha fi
ii g h +en lis llxin g scr ew s.
fur lher In r unn I n9
dl rectl on, untll +he exha usi va lve of +he l st
cyll nder (l sl val ve) l s fu l ly o pen. C heck th o
C. CHECKINGAND ADJUSTITIGTHE YALVE CLEARANC€S va lve cl eara nce of +h e 2nd cyll nde r.
The cl ear anc e o f bo+ h lnle i an d e xha us+valves 4. Ro+aie the crankshaf+ {uriher
ls 0,30 Fn. The clearanca can be checked ln runnlng
dl rectl on, un+l l ih e exha us+ va lve of i he 2nd
r eg ard les s o f whe +he r ihe e ngln e ls col d or cyli nder (frd valve) ls comp letely o p en. C heck
h o1. C hec k an d ad jus t th6 va lve c loara nces o f a the valve clea ran@ o f +he frd cvl ln der .
c er taln cv lln der whe n the Dlsto n l s at lfs
comoression stroke too dead cenfre. Check ihe 4II ENGI
NES
v alv es ln + he Inj ecl -lo n ord er of the engl ne.
2. Ro+a+ e the crankshaft In run nln g d l r ecl l on,
Rgmove+he boost alr Dloe beivroen +he turbo- - untll lho valves o f th e 4th cvll n dsr ar e
c ha rge r an d the Inle i manlfo ld. Ope ni he flxlng ro ckl ng ( exha usi valve cl osss, lnl o l v al ve
nu+s of the valvg gear cover, removg+he covor opens), Check the valve clearance of l-he ls+
a nd lh e br e a+ herp lpe . Tak e off the plu g on +he cyl ln der. l l the clea rance d ltfer s f r om t he
s lde of th e fly whe el ho us lng ( crankshafi ra tl ng, open lhe l ock nui sl lg hfl y a nd adj ust a
rotatlon ). correct clearance erl+h an adjustlng screw. The
clearance ls correci when a 0,J0 nm feelor
ENCINES gaug e l s sll ghi ly
'O9 i lg hi- fl ited b et w een t he
r€ker ö.m and the va lve head.
Ro+a+ethe crankshai't by the flywheel gear rlm
v .lt h, fo r ex 6mp le, a sc re wdrlve r, u nil l the
ex hau s+ v alv e of the lrd c ylln de r ( 5th valve l. Turn lhe crankshaft furlher l/2 of a rotailon
f .o m ihe en gln e fron +) ls c ömpletel y op en. l n l he ru nnl ng dl rectl on so +ha+ the v al v es of
Che cklhe va lve c lea ranc a o f th e lsf cvi lnd er. the fr d cyl lnd er ar e rockl ng. Che ck t he val ve
cr eara n@ of +he 2nd cVll nder .
3-13

4. Procaed elth checklng the clearances ln ihe
InJecllqr ordei:
- InJectfon ordar l, 2, 4, t enoinefronl end
@
- va lv e rc kl ng ph as o l n cy ll nd € ,- 4 , t , l, 2
6 1 11 6 12 EN G I N E S
309
ond tho volvs heåd.

Rotäte ihe cränkshaff ltr+her l/3 of a ro+ailon
In ru nn ln g dl re c t lo n s o i ho t t he v a lv es o f i h e
@ô-@
o"oo
2nd cyllnder öre rocklng. Check ihe valve
cl 6 or an c6 of t h e 5t h cy ll nd f .
1. Proce€d rlth ch€cklng the clearances In lhe 311
InJec+lql ordEr:
- lnjectlon order l, 5, 5, 6, 2, 4
- v afv e rc kl ng p ha s e In c y l 6 ,2 , 4, l ,5 ,5
Cleon thg valve gear cover ond check ih6t the r@^Q:("ftOê3g
o o"o o-@o"@o
J^l
411
@_o-@
o-@ o
6111612
@.exhaust@- intet
3 -14

CRANKCåSE
D{IEX
T€c hnl cl l då ta ........... . . . . . . . . . . . . . . . . . 4- |
S p€c lal t@ls ............ 4- 5
coost ru s on ............. 4- 6
Repolr lnstrustlons
l. Crankshalf
A. Remov lng th6 cranksha{+... 4-9
g . Chec kIng +h e cra nks hafl... 4-9
C . Re plac ln g ih e cr ks haft ge ar rl n 411..... 4-9
0 . Re plac ln g lhe cran kshafi ge ars.. . . . . . . . . . . 4 -t 0
E . Insia ll ln g ihe cra nksh aft" .............. 4 -t0
F. Crank sha ft h ub p lec e.. ...... 4-11
G. Re plsc ln g ft| e vlbrailoi d a mpq-....... .... 4-tl
2. Conn€ctlng rods cnd plsions

A. Re mov lng the c onn ecllng r od a nd pl s+ qr... ........ 4-12
B. Chec kfngan d rep la clng lhe co nnectlng rod bear1ngs....,........... 4-12
C . Ov erslz e plsiqr pln baa rl ng bush..... ............ 4-12
D . ln spe cifng + he c onn ectl ng rod.............. ...... 4-12
E. Co nne cilngro d re lgh+ c I a sses.. . . . . . . . . .......... 4 -15
F. In spe c+ln ga nd re plac ln g i he pl sl on r1ng s......................... 4 -14
O. ln spe ctlng the plsio n....... .... 4 -1,
H . Flttlng ihe p ls io n p I n. . . . . . . . . . . . . . ............. 4 -15
l . Sho riene do I sion s.......... .....4-1 5
J . Flttlng ihe p ls io n an d the c onneci l ng rod. . . . . . . . . . . . . . . . . . . . . . . . . 4 -16
t. counferbcl ancå Fchrnlsn

A. Re noylng and d lsas semb ll ngthe counterbal an ce mec hanl sm........... 4 -17
B. Re con dltlonln g +h e co unterbal anc emehanI sm....................... 4 -17
C . Fll-tlng + he cou n+e rba la n ca
m€ ch€nl srn..... ........ 4-17
{ . F l yrh6l
A. Repla clng itF {ly xh€ el s tar+s rl n...... ......... 4 -18
B. Fli-tlng +he flyrhe el..... ....... 4 -18
vAlitEr
TECHNICAL DATA ('I)
(re jec t llml t of pa .t s fafed In br ac k e i s af t€r 'rot l ng )
Pls t on , p lsl on r lngs and plsto n p ln
Itlln dlstance betwoen plston and cyl head, measured wlttt lead vllre through
I n J ec t or h olo 0 ,900 ... 1, 150
P I ston d lameie. see l nst r uct l o ns ,
p olni 4 2 G
,09
P In bore In D I sion . . . . . . . . . . 16,001 .. . 16, 009

Pls t on pln d I ame ter . . . . . , . . f5,995.. . 16, 000
l{ ld t h of r lng gr@ves:
- ls+ groove 2 ,58O .,. 2, 6 00
- 2nd gr@ve i ,0 40...J , 060
- lrd groove 4 ,040 ..,4, 060
Sld e cle a r an co s of p lstoo r lngs ln + he l r gr @v es :
- ls t g ro o ve, h ard ch ro me- p laie d com pres s l on r 1n9. .. ,. .. .. .. . o ,o9.,.o , 122
- 2nd gr@ve, compresslon r I ng . . . . . . . , . . . . o , 05. ..0, 082
- J rd g ro o ve, ol I r lng ........ 0 ,05, . .0, 085
- re ieqt llmlt 0 , l5
P I ston r Ing helg ht ( In d lre cilc.r of c y l l nd er):
- ls i r in g .. .. 2, 474. -.2 ,49 0
- 2n d r In g 2 ,978 ...2, 9
- f . d rf ng .... 3 ,975 ...1, 990
Pl s +on rlng ga p (e lth p ls+ on rea dy fltted In cyl lnda r) :
- c ampr es slonr In gs ........... 0 ,4...0,6
- ol I rln g .,. 0 ,25...0, 55
- r Bject l lml+ ..............,. 1,0
5 , 4 , 6
Pl n bore In pls ion I ) 40,0 m...40, 006
Pl s ton pin d la rEi-er ........ ... 1 9,99 5.. . 40, 000
t{ | dfh o f r l n9 gr@ves:
- ls l' gaoove 2 ,560 ...2, 540
- 2n d gr@ve 3 ,0r o...1, 050
- frd groove 5,04 0...5, 060
Slde c le a ra n ce s of plsto n r lng s In the l r gr @v es :
- lst groove, hard chrohe-plated compresslon r I ng . . . . , . . . . . . . 0,07 ...0, 102
- 2n d g rco ve, c ompr es slon r lng ....... .. .. . 0,04 ...0, 072
- Jrd g ro o ve, o ll r lng ,....,.. 0 ,05...0, 082
- re j e qt lln lf 0 , 15
P ls ioi rln g he lght ( ln d lrec ilon of c y I I nder ):
- lst rln g 2,47 4...2, 490
- 2n d rln g 2 ,97a ,..2, 990
- lr d rin g 4 ,978 . . .4, 990
Plst o o rln g gap ( *lth p lsion r ead y f l + to d l n c y l l nder) :
- compresslon r I n 95 . . , . . . , . . . . 0,4...0,6
- o ll rln g 0,J...0,45
- reje ct limlt ............ 1,0
llt n Ott O Se e ngln e ( plsfo n 81 6l IO ?OO ) by t he l c k rl n g gr c ov e 40,003... 40, 0 09
612
Pln b ore in plsio n ,......,., ,14 ,001... 44, 0 09

P ls ion pln d lar Eler ........ 41,9 94.. . 44, 000
I {ld t h of r Ing gr@ves:
- lst groove . . . . . . . . . . . r r . r . . 2,58 0...2, 600
- 2n d gr @ve ...r. .,.... ..r l, 040.. . r, 060
- Jrd groove . . . . . . . . . . . . . . 5,04 0.. ,5, 060
Sld e c le a ra n ce s of plsfo o .lngs ln i he l r gr @v es :
- lsf groove, hard chrone-plafed compresslon r I ng . . . . . . . . . . . . 0,09 .. .0 , 122
- 2 n d g rco ve, c ompr os slon r lng ....... .. .. . 0,05 ...0, 082
- )ao ga o o ve, o l I r lng .....,.. 0,05 ...0, 082
- rej ecf llm lt 0, 15

Pl st oo r lng h el gh + (l n d lre c+ l q l o f c y l ln d e r ) :
- ls+ r Ing 2 ,4 7 4 .. .2 , 4 9 0
- 2nd r Ing 2 ,9 7 a ... 2 ,9 q
- fr d r Ing 4 ,9 7 4 .. .4 , 9 9 O
Pl s ion r lng g ap (l ,l i h pl s+ on re ad y f l+ + e d In cy l l n d e r) :
- conpression r I ngs . . . . . . . . . . . 0 ,4 . .. 0 ,6
- o ll r In9 0 ,3 . .. 0 ,4 5
- r ejec t llm l t t ,0
[ 4axpern lss l bl e w e lg h f d l ff e re n c e b s t re e n p l s +o n s I n sa n e e n g l n e 259
Pl s ion + o b e he a+ edu p t o l0 0 oc be fo re Jl til n g p ls + o n p ln .
Pl s + on po slf lo n I n c y l l nd er: c D mb us tl onc h a m b e io f p l s fc n t o f a c s t o w a r d s l n j e c to r .
connectlng rod
509
I ns lde d lam e t e r o f p ls + cn p ln b us h
( whenb ush p re sse d l n+ o c on ne c + l n gro d ) .' .. . ... ... . 36,025. . .36,O40
( 5 6 ,0 5 0 )
ou i slde d lam e t er o f D ls ic n ol n bu sh (s i an d a r d ) . .. ... ... .. .. 4 0 ,0 6 0 . ..4 0 .0 7 6
Ou + si ded lam e t er o f pl s t on pl n bu sh , o ve r s lz e 8 J 6 O1 8 6 0 5 .. .' . .. ." . 40,580... 40, 620

Co n nec t lngr o d sm a ll e nd bo re . . ,. . . .. 4 0 ,0 0 0 . ..4 0 ,0 2 5
( 40,040)
Co nnec t lngr o d sm a ll e nd bo re (o v e rs lz e b u s h ) ... .. ... . 4 0 ,5 @ , ..4 0 ,5 2 5
Connec+lngrod blg end bore . . . . , . . . . . . . 6 ' ,' t 3 0 . . . 6 5, 74 9
| 6 5,7 7 O
Tlghtenlng +orque of connec+ln9rod bsarlng cap screHs 90 Nm '
5 , 4 , 6t l
l n slde d lam e + e rof Dl s ' f o n p ln b us h
( whenbu sh p re sse d i n+ o c on ne c + l n gro d) ... ... .. .... 4 0 ,0 2 5 . ..4 0 ,0 4 0
( 40,050)
ou is lde d lan et ei o f pl s t on pl n bu s h (si an d a r d ) . .. ... ... .. .. 4 4 ,0 A 2 . ..4 4 , 1 2 O
Ou lsld e d lam e t er o { pl s i on pl n bu s h , o v er s l z e 8 J 5 3 2 4 3 2 6 ... .. ... ... 4 4,5 @ . ..4 4 ,6 2 0

connoc+Ing rod sma| | end bore .. . . . . .. 4 4,0 OO .. .4 4,O 2 5
( 44, 0il0)
Co nneclng
t r o d sm a ll e nd bo re (o ve rs lz e b u s h ) ' . ... ... ' 4 4 ,5 0 0 , ..4 4 ,5 2 5
Co nnec + lngr o d bl g e nd bo re . . . . . . . . , . . . 7 t,7 3 O ... 7 1,1 49
( 1 1 ,1 1 0 1
Tl ghtenlng ir q ue of co nn e c ii n g ro d be arl n g ca p s c r e i s 90 Nm
612
ln s lde d lam e ie r o f o ls to n p ln b us h
(w henbus h p re s s ed l nt o c on no c + l ngro d) ... ..' .. .' . . 4 4 ,O 2 r . ..4 4 ,O 4O
( 4 4 ,0 5 0 )
Ou islde d lam e+ e ro f pl s+ o o pl n bu s h (s t an d a r d ) . .. ... ... ... . 4 8 ,0 8 0 . ..4 8 , | 2 0
ouistde d lamoler of plsion ptn bush, overslze 8161 18606 4 8 , 5 8 0 .. . 4 8 , 6 20

Co nnec fi ngr o d s m a ll e nd bo re . . .. . . .. 4 8 , 0 0 0 .. . 4 8 , 0 25
( 4 8 ,0 4 0 )
C o nnec + lngr o d s m a ll e nd bo re (o v ers lz e b u s h ) ... .. .' . . 48,5UJ...44,525
Connec'tlngrod bl9 end bore . . . . . . . . . . . . 7 6 ,1 3 O ... 7 6 . 1 4 9
t16,770'
Tlgh+enlng +q'que of connec+lngrod bearlng caP screls s e e l n s i r u c tl o ns ,
polni 4 2 J
C l ear anc e ai bl g e nd b ea rln g .. . .. . . .. 0 ,0 4 6 .. .0 , 0 9 8

C o nnoc fln gr o d e n d p la y o n cra nk sha f + (ln d l r e c tl o n o f c r a n ks h a ff a xl s ) ... .. ... ... o ,2 o 0 .. .0 , 5 1 2
}ialghi ls stampedon blg end of connectlng rod.
M ax pq- m ls s lb le w e l gh + dl f fe ren ca be t w ee nc o n n e ci l n g r o d s I n sa iE e n g l n e 20s
C o nnec flngr od po s l+ i on r ord ln al n un b er to wa rd s v a l v e m e c h a n ls n

(c om bus ilonc h am b e ro f pl s l on o n o p po s l ie s l d e ) .
4-2

Crcnksh!ft
509
i r an k p ln d la me t* :
- standard 61,981.. .6 2, 00 0
- fst underslze 0,25 ftn (bearlng 8360 9126, 6t .131... 61 , 7r O
- 2 n d un d er sfz e 0 ,50 rin ( be a rln g A5 60 91261r ... ... 6t .481.. .6 1. 50 0
- Jr d un d er slz e l,@ nn ( b ea rln g At 6o 972@ 1. ... .. 60, 98t... 61 , 00 0
- 4i h un d er slz e 1,5 0 n ( be a rln g 8 3 60 972111.. ,., , 60,48t.. .6 0, 50 0
Crankpln length ,O ,000.. .4 0, l 60
C l e ör a nc e at b lg € n d b€ ar lng ......... 0,046.. .0, 09 8
JournaI d lameier:
- standard 69,988.. .7 0, 01 8
- ls+ underslze 0,25 nn (bearlng A360 91215, 69, 7t A... 69 ,7 8
- 2nd underslze 0,50 r|n (bearlng At60 97274, 69,488.. .6 9, 5t I
- J r d u nd e rs lz e l,c o n n ( be a rlng A t@ 91276\ 68,988.. .6 9, 0l 8
- 4i-h underslze 1,50 mrn(bearlng 8360 972741 68,488.. .6 8, 5t 8
M al n be 6 rlng cle ö ra nc a 0,51.. .o, l ol
L en g ih o f ih r us t b ea rln g jo u rn ol (j our nal nearest to flyr heel) :
- s t a nd a .d le ig +h (2 s tan d ar d +h ru s+ plates) . ... ." .. 47,0@ ... 47 ,0 8 O
- l s t o ve r le ng +h (o ne s + an d ar da nd one 0, 2 nm over+ hlck thrusl plal e) 41, 2O0. .. 47 ,2 8 0
- 2 nd ov e r le ng th ('two 0 ,2 ftn o ve rth lck th. ust pl a+es) 41,4O0.. .4 1 , 4AO
ot he r c r an k sh a ff jou r na ls ma y no 'i be g round l onger.

C r an k s ha ft e n d o lö v ........ 0, | 00. ..0, i20
M a x p e rm ls s ible o va ln es s or o th e r defo .nlt y ot crankpl ns or journals 0,0J
C r a nk s h aft un ba lan c e I ,0 Ncmmax
5 , 4 , 6 tl
Crankpln d lame+e':
- standard 67,981... 68 ,0 00
- f s t u nd er s lz e 0,2 5 n n ( be ar lng A 361 127621.. '.. . 67, 131. . .6 1, 15 0
- 2 nd u nd er s lz e 0,5 0 n rn ( be ar lng 8 161 127 61). ... .. 61,441.. .6 't ,5 OO
- 3 r d u nd e rs fz e 1,0 0 r lrn( b6 ar lng a t61 127651.. ... . 65, 9Bt. .. 67, 000
- 4 t h u nd er s lz e 1,5 0 m m( be ar lng 8 t61 127 61). ... .. 66, 481. . ,6 6, 50 0
C r a nk pln len g fh 40, 000. . .4 0,16 0
C l e ar a nc ea i blg € nd b e ar ln g ......... 0,046. .. 0, 09 8
Journal d lamef€r-:
- sfandard 84, 985.. .8 5, 02 0
- l s t u nd er s lz e 0,2 5 n rn ( be ar lng 8t 61 2ot 26, 84, 1t5.. . 44, 77 0
- 2 nd u nd e rs lzo 0,5 0 n m (b e ar lng 8t 61 20327) a4,4A5.. .A4,520
- l r d u nd s r slz e l,m n n ( be ar lng 8361 2ot 29l . ... ... . 81, 985.. .84, 020
- 4ih un der s lz e 1,50 r m ( bear lng A 3 6 1 2 j t t1 ) . ... .. ... .. ... . 8t,4Ar...A5,520
Maln be or ln g c loar onc a 0, 070...0, I 5 5

Le ngih of ih rus + bearlng jour nal (J o u rn a l n e a re s i to fl y rh e a l )l
- s t and år d leng+h ( 2 s t andar d fhr us t p l a i e s ) . ... .. ... 45, 000. . .4 5, 08 O
- lst overlength (one standard and one 0,1 |Im overthlck fhrust plate A561 20552, .. 45, 100.. .4 5, | 8 0
- 2nd ovarlengih (on6 standard and one 0,2 nrn overihlck thrust plate 8161 20515) .. 45, 20o.. .4 5, 2@
- lrd overlengih (one 0,1 mm and one 0,2 rrn overlhlck thrusi pla-te) 45, 100.. .4 5, 18 0
- 4th overlenglh (fwo 0,2 rrn ov€.fhlck lhrus+ plates) 45, 400. . .4 5, 48 0
Oths' crdkshaft journals may not be ground longer.
Cr an ks ha fi end p lay . .. . . .. . 0, 100... 0, 15 0

Ma x ps rmls sl ble ov alnes s and o+ hgr d e fo rm l i y o f c r a n k p l n s o r j o u r n a l s 0,05
Cr an ks ha ft unba lanc a 1, 0 Ncmma x
D lan et er of gear rlm of addlt lonal c o u n fe r b al a n c € o n c ra n k s h a ft (4 l l e n g l n o s ) . .. .. lro,22o .. . l5 0, 26 0
I ns lde d lam els - of gear r lm of addl fl o n a l c o u n t gr b a l ö n c a (4 l l e a g l n e s ) | 50,o0o... | 50, 040
4- 3

612
Crd|kp ln d lanei€r:
- stondard
550) . . . . . . . . . . . .
7 2 ,9 8 1. ..13 ,00O
12 ,7 3 1.. .72 ,1 50
o
t5t ) ..........., 7 2,4 4 1 ...7 2 ,50O
t 2 , .. .. .... .. .. 7 l , t ...7 2 ,0@
............ 7 1,4 8 1 ...7 t,5 00
'5 1 ) 40, 000. .. /t0, | 60
0 ,06 6 .. .0 , | 0 5
JournaI d lameiei:
- stondord 8 4 ,9 8 5 .. .85 ,020
- lsl undsrslz€ 0,25 nn (bearlng Bt6l 20326, u ,7 3 5 ...A 4 ,7 70
- 2nd underslze 0,50 fln (beartnö 8361 2032j, 84,445...A4,520
- Jr d un d€ rs lz e l,O rm (bearlno At6l 2oj 2 9 l 8 l , 9 8 5 ...8 4 , 020
- 4 'lh un de rs lze l,i0 nm (b€artna At6t 2'5tt ) ........... .... 43,4Ar...At,520
M al n be arIn g clearance
0 ,0 7 0 ...0 , | 5 5
n o a re s t to f l y rh e €I ) :
e s ) ,. ......,.... 4 5 ,0 0 0 .. .4 5 ,080
I n m o ve .fh l ck fh ru st pl a te ) 4 5, 1 0 0 ...4 5 , | 80
2 |rmo ve ri hl ck th ru s t pl a i e ) 4 ' ,2 0 0. ..45 ,2 8O
fin ovo.+hlck thrust p löte) 4 5,3 @ . .. 4 5,t ff i
ru s i p l a te s) 4 5 ,4 0 0 .. .45 ,480
Othq' crankshoft Journals nay no+ be ground longer.
C ro nk sh åft end p lay ..,.. ...

Ma x pgr m ls s lb19ov alnes s and oiher deform i ty o f c rå n kp l n s cr- j o u rn ö l s 0 , l 0o . ..0 , 15 0
Cr kshaff u nbaI ance 0 ,0 5
1,0 Non rnax
F lyrhco I
l n tq - ter en € of sfar+q- rlm qt flywh€el o , 4 2 2 ...O,6 0 0

Be fo re tl ttln g to f ly wheel s iörier| -ln io b € h e a i e d u p + o a + e xT €r a i u re o f ........
F lyrh€l u nbaI anc\-6. , . . . . . . , . . . . . I 50.. .20CpC
M a x ps rm l ss l ble ax lal robble oJ flyrheel cl u tch fa c€ , n e a su re da t l n n e r 1 ,0 N cmr n ax
edge.of clutch t ace . . . , . . . . . . . .
Tl g h +e nl ng iorque of flywheel reialnlng s c re rs ....r... O,06tö2OO
120 Nm
Addltloncl coonterbalances (ill I englnes)
Eacklash bsfween gef si

- c rank s ha ft gear rlrn - @ unteroatancegea r .... ........ 0 ,1 ...0 ,J
: g d!" €n g sars of counterbalances ...... .. o, 05. . .0,25o
End_plöy of coun+erbalances
Shaft d lametq- a+ be6rlngs 0,1 ...0 ,5
In sro e ota net or o? counterbalancebus h (fl ffe d ) 2 5 .9 7 9 ...2 6 ,06
26 ,O4 0 ...2 6 ,61
Sh öft ho le d lam elers €+ rea surf ac e of b o d y .....,... 26 ,0 6 5 ...2 6 ,0 6
Sh aft ho le d l am efers at front surface of b oå y. ........
2 5 ,9 65 ..,2 5 ,9 A6
Th l ck ne ss o f s hlit, bgf rdeenbody and cyllnd6 r ' b l ck o ,2
4 -4

3
IAL TO-S (crankcase )

SPEC
I 436, 97335 Pls lqr r lng p I ler s
8160 85825 Plsion flttlng ioo I J09
836t 85826 Pls icrf f ltt lng i ool 3l l, 4l l, 6ll , 612
4360 91121 Crankshaff gaar extroc+or
9024 74200 Crankshaft end nut rrench t0g. tll, 411
24 558oO Crankshafi end nut rreoch 6ll, 612
4-5

CRANKCASE
I
10
Crankcaso fl I
l. C ra r k sh a f + 12. Gear Th e fl y rh e e l ( 5 ) w l i h th e g e a r rl m ( 6 ) fl x ed io
2. Key 13. PuI ley I-i wlth pressed-on fli ls fastened io ihs
3. M aI n b e a r I n g i4. Nuf crankshaf+ rear end. The conn6c+lng rod (20)
4. T h r us t b e a r l n g 15. Hexagonsocks+ screw transfers +he gas forces generated by th9
5. F lytrheel 16. Plston combustlon of luel from the Dlston to the
6. Ge a r r lm 17. Plston r I ng s crankshafl. The cross-sectlon of ihe lorqad
7. Hexagon screr 18. Pls+on pln co n n e ci l ng ro d l s a n l -p r ofl l e . Th e b earing
8. H ub 19. Clrc llp ho u sl n g l n th e co n n ec + l n gro d b l g e n d l s s pl l+
9. Dust cover foi 20. Connectlng rod ho r l zo n i a l l y a n d th e b e a rl n g ca p l s fl xe d tr l+h
shaft sea I 2l . BearIng bush fvro speclal screyis (22) and nuts (21). The
l0 .0 lld e f le c t o r 22. Screw sm a l l e n d h a s a n In i e g r a l b e €r l n g h o u sl n g y hlc h
2f. Nu+ h a s + h e p l s i o n p l n b e a rl n g b u sh ( 21) fl xed +o
24. Blg end bea rl n g l i w l th p re sse d - onfl i .
The crankshafl' (l) ls fq-ged out of chrome- The connectlng rod blg end of ihe 612 englne
a llo ye d s pec lal s+ eel and ls I nduc tI on-ha r d e n ed ha s a b e a rl n g h o u sl n g o J a n g l e s pl l t d es lgn and
a t i he b earlng and seallng poln+s . Th l s ma ke s th e b e a rl n g ca p l s fl xe d w l th tl { o rr e l ongafl on
ll p os s lble to grlnd the s hafi to four u n d e r- scretsrr.
slzes wlihout new heai ireainent. The gears (ll
a nd 1 2) nhlc h drlv e +he ldler gear and + h e o l I
Dump have been flxed +o +he crankshaf+ fron+
end vrl+h pressed-on flt. The crankshafi froni
e n d a ls o has grooves for fl+ +lng the h ub p l e c e
( 8) an d i he o ulley (13) ls flx ed to i h e h u b .
Betweenthe hub plece and ihe gears there ls an
ol I deflec+or (10) and ihe dust cover tor the
s haf f s eal ( 9) is loc aied on ioo of th e h u b .

Th9 crankshati boarlngs are ilxed to l-he
cyll nd sr bl ock o n bo lh sld es o f -i he cyl l nde r ,
whlch means thai therg ls one bearlng polni
m ore +h an lh ere a re cyl ln de rs l n i he en gl n e .
The cranksha{t thrust bearlngs (4) are locaied
on ihg sldes of ihe endmost bearlng Journal.
o
Th e ma ln a nd bl g en d be arl ng s are so-ca ll e d
three-layer bearlngs rhlch have on top of lhe
s+Eel body c lead-bronze layer wlfh load
ca pa cl iy cn d go od he ai con du ct lb ll li y. T he
a ctua l sll dl ng surfo ce ls co vE red rl th o l hl n
layer ot lead-lndlum f,hlch f6cl I l'tales +he
ru nnIn g l n.
44
PI ston
Vlbratlon darD€r 6l l/612
l. Combustlonchamber
l. Vlbratlon damDer 2. Ca si l ron r I ng
2. Pu l ls y 5. Cl rcl l p
f. Hub 4. P lsi on ol n
4. Nui 5. B ea rln g b ush
6. ConnectI ng rod
l n sl x -c y l lnde r e n g ln e s ih e cr a n k sh 6 f 't fro n+ 7. Chrome-p lafed cornpresslonrlng
€nd lncorporales a forslonal vlbrailon damper 8. Compresslonr Ing
o f v l s c ous ty pe . T h E d a mp e rh a s a c a s ln g f llle d 9. S prl ng -lo ad edo ll rln g yl th sll dl ng sur{ a c e s
l {li h v ls c ous s lll co no flu ld , e n co mp a s s ln gthe chromed
da mplng pas t e ll {lt h mln lm u nc le a r a n ce s .
Th e pl s+on ls ma deof e ute ctl c o lu ml nl uma ll oy .
The speclally formed cqbustlon chambar (l) oo
the plston +op end lmproves the mlxlng of alr
an d fu el . In i he h lg h-po we r e ng ln e versl on s
the groove for the top plston rlng ls In +he
c€ st l ro n rl ng (2 ) ca st on to the p lsto n. Th er e
are ihr€€ plsion rlngs: +he topnpst rlng ls a
compresslonrlng (7) vlth a barrel-iype, chrone
pl ai ed surfa ce. The oi he r co mp resslo nrl ng (8 )
Is a so -col le d ml nu te rl ng wl ih a Jor o r
90 r a ng lo . T he +h lrd rl ng l s a sp rln g-l oa d 6 d
ol I rln g (9 ). Th e pl s+ on p ln (4 ) ls I nsl do +h e
plston t|l+h accurate fliilng and fhe connecllng
rod sm al l end a nd i he pl sto n p ln h ave a
so-called floåtlng fl|oun+lng bo+vreen each
other.
The plstons of the 612 englnes are cooled by

dlrecilng an ol I jet to the boftom surface.
Borrlng shel I
l. ln d lu m lea d a ll oy
2. Lead bronze
l. Sieel body
4-7

CE IGCH^NIST44II
COi'NTERBALA
45
Counterbalonca rFchanlsm 4l I
l. B o dy 8. Sh l m
2. B al I 9. Hexagon socket
5. S ha f t 10. Lcck screv
4. Thrust p lato ll. B an j o b ol i
5. B ea rl n g b us h 12. Connectq-
6. Counferbalance li. Lu be ol l pl p e
7. Pln
So.ie of ihe ,tll englnes are furnlshed tlth a

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

flxed io ihe cyllnder block bottorn face. The
shafis (3) locaied in the body have b€arlngs
bushes (5) for ihe actual counferba lances (6).
The counierba lan@s are drlven by the gear rlm
on ihe ci-ankshaf+ through gears. The bearlngs
of iho counierbalance assembly are lubrlcaled
by the eflglne pressure lubrlca+lon sysiem
ih r o u g h a lu be oll pl pe ( l J ) .
The clearance b€fneon lhe gear of fhe counter-

balance nechanlsm and the crankshafi gear rlm
ls ödjusied lrlth +he shlms (8) placed be+we€n
+h e b o d y a n d i he c y ll nd €t ' b lc k .
4- A

REPAIRINSTRI'CT
I OI{S
CR^NKCASE
I. CRANKSHÅFT
A. REMOVINO
THE CMNKSMFT
l. ReDoveilp ol I sumo.
2. Losen the connec+lng scre$ ot ihe lube ol I
plpe of the countorbalance m€hanlsm troo ihe
c y llnde r b lo c k o s r e ll a s t h e re ia l nin q scro rs
of th€ counierbal6nce mechanlsm. Rem;ve +he
c oun+ e r b a l an c eme c h a n lsna n d ih e l ube o l I ol o€
(41| e n gln e sl.
f. Loosen the flxlng screys of ihe ol I pump

pressuro plpo trom lhe cyllnder block and iho
ol I pumpreialnlng screus. Removsihe oll punp
and the ol I Iniako and pressur€ plpes.
4 . L@s en ih € fly wh e e l rs ta l nl n g sc r o ws an d r€ mo ve
t he f ly H h e e l, T h o n lo o s e n ih e f ly rhe el ho usl ng
llx l ng s c r e w s o n d r e n b v e t h e h ou s lng .
5. Renroveihe gear houslng ( Instruc ons, polnt

5).
Loosen fhe nuts/sc.eis ol ihe connecllno rod M a x pg rm l ssl bl e cl eo ran ce In ih 6 m a l n b e or l ng
be arln g ca ps, qem ov e t he c aps an d p u sh t h e l s 0 rl8 |' n an d l n th e b l9 e nd b € ar l ng
c o nne c ii ng r ods s o t ar dorn + hat t h e y w ll l n o t 0,1 4 rn . lf n e€ de d, th€ jo urn al s m us t b o
pr€vent you from removing +he cr6nkshafi. gro un d. ll hsn grln dl ng fo l lo w th e s to n da r d
un de rsl zes an d u se un de rsl zed be arln g s he l ls
Lo ose n t he r et al nl ng s cr ers ot the n a ln be a r l n g sup pl le d e s spa re p ort s, see +e chn l c a l d oi a ,
caps and reirove the caps. Llft fhe crankshafi polnt crlnkshaft. lhen grlndlng not€ that the
o fl from l t s pos lt l on. Journll ådgos must renåln round.
CIfCKING THE CRîIKSHAFT
vJös h +h e c.ank shof t c aref ul ly 6nd e n su r e ih a f C. REF.ÄCING TIf CRA KSI{AFTG€ARRIM

the oi I cha nnel s are c l ean. (4 1| en gl ncs)
M ark ih e po sl tl on of fhe ge ar rln on t he c r an k -

sha f t.
2 . H e 6 t t h e r l m e v e n l y , f o r e xa m p l e r l t h o gas
torch, a n d t a p o f f t h e r l m wl l h o su l to bl e
dr I lt.
46
M 6ös ure f h e jo u r n ö l r e a r a n d o vo l nes s yil +h a
mlcrome+er. Pertorm the measuremen+ crosswlse
ai s gv e r a l p o ln ts o f th g jo u r n a l. T he Jo 'l rnal
ov6lness or o+her delormlty oay noi exceed +he
l lm lf O , o f r m .
4-9

D. REPI.AC
ING TTE CRANKSHAFT
Gf,ARS l. Clean the oll channels and the con+ac+sur{aces
of + he bsarlng shell s, cyllnder block a nd
bearlng caps. Ensure lhat +he crankshal+ ls
cl ean.
2. F li + he bearl ng shel ls lnto + he cyll nder b lo ck
and +he bearlng caps. Ensure that +he bearlng
shel l clampl ng cl aw s f lt l n+o + hel r noiche s a nd
ihai the shell s i o be fli ied I n i he cylln der
block have a hols col ncl dl ng t{l ih the oli p ort .
Lubrl ca+e +he bearlng shells In t he cylln der

block and the c. ankshaft bearl ng journals. Ll f l'
ihe crankshaft back l ni o l + s placa and sll p t he
thrusi bearlng shel ls ot the cyl lnder b lo ck
l n+o thelr posltl ons. Pl aco the thrus+ bea rl ng s
so + hat t hel r lubrl cat lon grooves are ag a ln st
fhe sll dl nq surface of ihe crankshaft .
Pl ace +he bearl ng c6ps lnto + hel r posltl on s ln
the crder lndlcatod by the numbors. Place
+hrust bearlngs shell s equlpped {l th clam pl ng
claws on +he slde of ihe andmost beårlng caP.
Lubrlcate +he lhreads of the retalnlng screws
l lgh+l y wl +h otl and + lghten + he screws fo t he
coirecl torques (200 t{mlll, 4ll, 6ll, 612
and 160 Nn J09).
Flx the extractor (8360 973271 loio ihe ihread

h ole s of +h e g ea r drlv lng + he oll pump a n d pu l l
+he gears oui.
C le an + he llx lng polnt of + h6 gears o o +he

crankshaft |,lth a *ire brush, for instance.
Heai the ne* gears io a 2O0oC ienperature.

Place the gears on ihe '.rp crankshöf+ and iap +he
hot gears dorn to ihe boliom using a brass
d rlfi o r a sult a ble s leev e. C hec k t höl- th e k ey
ls In po sl+ lon and t ha+ + ho I ns iallaiion ma rk
of the fron+ gear remalns in slghl-. Lei ihe
g ears co o l na t ur a l ly .
E. I NSTAI.LII{G TI.IE CRANKSMFT
Ensure ihö+ tho crankshaf+ rofates easl ly.

fG a s u re +h e c ra n k s h a f t e n d p l a y t| l t h a dl a l
Indlca+oi. Irench ihe qankshafi io one end
llml+ poslilon and -ihen back +o +he o+her and
n o te i h e d l a l In d l c a to r r e a d l n g f o r e n d p l ay.
Codpare {lth the roilng 0,10-O,r5 f,I||. lf
+he readlng ls too hlgh, replace ihe thrus+
b e a ri n g s h o l l s w l t h o v er s l z e d o n s s .
lloigl Never rean l-he bearlng shells or make

+h e b e a rl n g c l e a ra n c a s ma l l e r b y {l l l n g ths
edges of 'the bearlng caps.

HUBPIECE
F. CMNKSHAFT Vlbratlon damoers dellvered as spare paris do
no+ havo InJec+lon ltmlng nark. Make the
marklnq on ihe ne|, danper on the same spo+ as
on the-old damper. Use an elecirlc pen' do not
tap the markI
Fl x + he vlb ral lo n d am p era nd i he pu ll e y o n ih e

cran ksha f't . T ap the d ow ol pl n l n l +s Pl a c o a n d
itghfen the flxlng screws to a torque of f0 Nm.
41 2
U hen f lt t ln g ih e h u b p le ce io ih e cra nksha fi

fronf end note the corroc+ posltlon of the hub.
T he hub p le c e h a s a n ln s+ a lla tl o n m a rk - o n iw o
+ eeih a n d +h e co r r e sp o n d in g In s +a l la +lo n m ark .
of the crankshaf+ ls on one +ooth.
6I11612
ING THE VIBRATIONDAI..IPER
REPLAC
Loosen +he al+ernator flxlng screws and renove

the v-be lf.
Open the hexagon sockei screes of the beli
pulley and the vibratlon danper and remove+he
pari s f r o m +h e c r a nk s h a f+ . T h e p ulle y an d th e
vlbrailon damoer hava been oosltloned to thg
c r ank s h a f + hu b p le c e w lih a d o we l p ln (ln j.
t lm lng n a r ke d o n ih e v lb ra il o n d a m pe r).
Notet Even a small dent makes ihg vlbra+lon

damperInoperatlve. Do no+ remove l+ by iurnlng
forclbly and be careful not to damagel+ 'dhen
l+ ls loose. lf you de+ec+ a den+ on the ouier
surface, do not lnsfall +he damperback ln the
enoIne.

2 . @NiECTING ROOSANDPISTONS
REIII)VIl{G Ir€ @Nt€CTt t{G R00 AID P|STo|I
R qpv e + ho ol I su mo and ihe ol l lnlet and
pressure p lpes.
Renpve +he cyllndor heöd ( s€€ Instrugtloos,

pol nt 5 | A).
Scrape of f the po sslble so o+ ln ihe cylln der

llner top edge. lf nec€ssory, uso a reamer 10
remove +he sharp rear edg€ ln the plsion .lng
+op dead cenir€.
Remove +he connecilng rod bearlng caps and

b€ar ln9 s hells. lf you ln tend fo fl+ +he sam e
shells back, nole +helr correc+ order.
Press the connecilng rod and pls'ton off +he
cyllnder by uslng a ,ooden haftEr handlo or P r€ss + he ner bush I n lt s place. E nsur g i h a i
equI va len+. t he ol I hole I n i he bush colncl des r lt h 't h e
respectlve hole in the connocilng rod. Al+er
Rqr Dv eihe plsi on pln clrcllps. Heai-ihe plst on flttlno ream ihe bush to aitaln lts corrasl
evenly to a ienperoture of t 00oc and push out dlametår (s6 techntccl datc iconnesil ng
t h6 pl s+ on pln mo nua lly uslng a suli able dr ll t. rodr ),
Noiel Due to I luc+uatIng to lerances the ING BUSH
pls t on pln cön be removedmanua lly even r hen OVERSI4 PI STOIIPI}I BEAR
cold. tf ihe pln does not com€off rhen pressed I t req ulr ed, you can fl x In ihe connsc+ ln gr o d
by hand, do no+ +ry lo iap l+ off b€for€ sna ll en d a bu sh w l ih an over slze oufsl de d l a -
heaflng, becouse+ h6 pln ls fltied too flgh tl y nE for . M achl ne + he con nectl ng rod sm all e n d
and the plsfon may be dömaged. bear l ng hou slng accoi dlng io the fabl es bol o l r :
B . CIICKI NG AIO REPLACINGTHE CONI€CTING ROD oroer number
Order oe
EEARIl|GS B e a r i n gh o u s i n g for bearinq
Enoine bu
t . C l ean the c onnectlng ro d 6n d the b€ arln g shel ls 309 40,500 . 40,525 8360 38605
car ef ully . Place tho be arln g she lls ln t helr
corresl posltlons önd fl ght en t he be aring c aP 3r1
io +he corr€ci torque (9O lfi JO9, 5ll, 4ll
44.500 44.525
lnd 6ll) . Tlghte n ihs connectlng rod scrsrs
411 83s3 28326
of t he 6 12 en ol n6 f lrs t lo the +orque ol l0 Nm 6r1
€nd ihon oach :crer 9Oo.
612 4 8 , 5 0 0 . .. 4 8 , 5 2 5 8363 38606
A li er f lt +l ng r eam+ he bush + o lls correct slz6

(s€ tschnlcal data 'conncsil n9 rodt ).
INSPECT iG ROD
It{G T}€ @NTCCTI
41 4 31'1,411,611
2. Measure the bsorlng cleorances rl-th a dlal

Indlcafor zor€d to ihe crankshaft b6örlng
j our nal. M ax pe rmlsslb lg b€arlng clearance I n
+he connectlng rod blg end bearlngs ls 0rt4
mm . I f necesso ry, gr I n d -the crank sh af t
bear lng journö ls 6 nd Insta ll the un der sl zed
bearlngs dellvgred as sparg parts.
J. It ihe plston pln bush ls too rorn, removaihg 4 16

bus h by pr es slng rl th a sullable drlff.
The connecilng rods of dl f f eren l et gl n e i yp e s
4- 12

Use a ioo I speclally madefor + he lnsp ec+lonof 4. l.,llth the +ester plns ln a verilcal posl+ion you
lhe c onnec ilng rod (e.9. Carl Larsson ). can deiernine ihe connocflna rod deflec+lon.
P lac e the connecil ng rod bearlng c ap In lfs

p os l+lon noi lng +he m arklngs and tlghten the
nuts evenly io +he torquo of 90 l{m ln +he
ca se of 309, fll, 4ll and 6l' l englnes. Tlghten
the connectlng rod screws of the 612 englne
flrs+ io +he lorque o{ 30 Nm and then each
sCf€ri 90o.
2. Fl+ the connectlng rod to ihe lnspecilon iool

an d ih e ols ion oln ln+o lis bush.
5. Also check the connec+lng rod for any S-shaped

deflecl-lon. Thls is done by uslng a sllde gauge
to measure the dlstance bete€€n +he pln bush
ouier edge and ihe lnspec+lon tool plane
surface. Then +urn the connectlng rod the o+her
vay round and measure+he same dlsfance agaln.
The dlfference may nol exceed 0,6 nrn.
420
l.4easure+he length of +he 612 englne connec+lng

rod scrers and comparethem wl+h the nax length
Place +he Indlca+or on fop of fhe p I sfon p In. glven ln flg. 4 20. lt lhe long+hof any screw
l{Ifh ihe +es+er plns of the lndlc a+or ln a exc eeds+he max llml+, replace fhe scre{ wlt h a
horizontal posl+lon check l-he connec+lng rod o9ll orlgr l{9 recommendthat you rgplace screws
tor s lon . wlth new ones each tlme you open them.
E. CON}ECTI
NG RODXEIGHTCLASSES
4 2l
The connec+lng rods are dlvided Into rtelghi
classes a+ 2o-gramne Intervals. A le+ter
Indlcatlng the welght class ls markad on +he
connec+lngrod slde face. The cyllndor ordlnal
number ls stamDed on +he same slde as fhe
w elghl class. All the connecilng r od s I n one
englne mus+ be of the sano uelghi class , l. e.
+he max pernlsslble vlelghf dlflerence ls 20 g.
Le++ers lndlcate w elghi classes as tollox s:
5 0 9 englne
Welght Spcre parf no

1990 - 2010 s 4360 36562
I 2010 - 2030 8160 J6561
2030 - 2050 s 8560 56564
K 2050 - 2010 8360 36565
4 -13
2070 - 2090 s 8360 36566 INSPECTII{G
ANDREPLACI
NG THE PISTONRINGS
N4 2O9O- 2110 g 4360 36561
N 2l1o - 2 13 0 9 4360 36564 Use pls+on rlng pllers lA360 91333, fo remove
0 2130 - 2150 g 4360 36569 ihe rlngs. Do no+ spread tho rlngs more than ls
P 2l5O - 2 17 0 g 8360 36170 necessary to remove+hem. lf you ln+end lo re-
R 2l7O - 2190 g 4560 36571 fl+ i hs sa me ri n g s, en su re + h a f i h €y w ll l be
s 2l% - 2210 g 4360 36572 p l a ced l n t he l r o rl g ln a l p o sl+ l on s.
T 2210 - 2230 g 8 1 6 0 5 8 1l6
2230 - 2250 g 8160 J8l l7
2250 - 2270 g 8560 381l8
5 l t, 4ll and 6 ll e n g ln o s
Welght Spare pcrt no
2190 - 2210 g 4361 36573
2210 - 2230 g a36l 36514
2230 - 2250 g a361 36515
K 2250 - 2270 9 a361 36516
L 2270 - 2290 9 4361 36117
M 2290 - 2310 9 8361 36518
N 23lO - 2330 g 4361 36179
o 2330 - 2t5O 9 8361 36580
P 2350 - 2310 g 8J6l 16581
R 2370 - 2t9O g 8361 36582
S 2390 - 2410 g 8361 t6r83
T 2410 - 2430 I at61 36544
2430 - 2450 g 8161 36545
2450 - 2410 I 8J6l 16586
X 2470 - 2490 9 8361 36141
z 2490 - 2510 g 8561 16588
2510 - 25tO g 8161 36549
2530 - 2550 g 8361 36590
c 2550 - 2570 9 8361 36591
0 2510 - 2590 g 4361 36592
E 2190 - 2610 g 8361 36593
6t 2 e ngl n€
Helght Spare pcrt no

E 2911 - 29 8t6t ta1
2991 - 3010 8t63 3A796
Jol I - 3030 8363 3879-7
H totl - 3050 8363 3A194 2 . Cl ea n i h e rln g g roo ve s ca re fu l l y. M ea su reth e
I 30rt - 3010 8361 34799 pl sto n rl n g sld e cle a ra nce In l + s g roo ve . T he
107't - 3090 8J6l J8800 cle a ra nce m ust b e le ss fh an 0,1 5 n m .
K J 09t - Jt 10 8l6J 18801 De+ermlnewhether the slde clearance ls due +o
l l - 3 13 0 8363 18802 rlng or groove wear and replace the rlngs or
T4 lljl - 1 50 8J6J 1880J i he p l sfo ns a s w el l , l f n ece ssa ry.
N ll5l - l l7 0 8l6i 18804
o lr Tl - J l90 8J6J 18805
P 3191 - 3210 8161 18806
3211 - 3230 8J6J 18807
s 3231 - 3250 8161 18808
T 3251 - 3270 856J J8809
3211 - 3290 8l6J 38810
v 3291 - 3t10 816l l88l I
x 3311 - 3330 a3$ 3ABl2
Y 33tt - 3350 8561 l88r J
z 3351 - 3370 836J J8814
J. P l a ce t h e r l ng I n f h e cy ll n d6 r , ad j usi l n g ll
p er p en dl c ul ar +o f h e cyl l n de r a xl s , a nd m ea su re
iho rlng cap. Thls may nof exceed I mr.
4 -14

H . F ITTII{G THEPISTONPIN
42 4
4. Fl + l he p l st on rln g s u sln g t h e rln g p ll ers.

E ns ure + h a i ih e r ln g s a re f lff e d ln +h el r
correct places and +hai lhe marklng TOP or
+ he na n u f a c+ u re r r s ma r kl ng I n i hg rln gs ls
upldards.
I NSPECT
ING THE PISTON
426
Heat ihe plston evenly to a tempera-fure of
l00ct. Flt +he connectlng rod Into the pls+on
an d pre ss ih e pl s+on p ln In fo l +s po sl l l o n.
NoieI The combus+lon chamber of +he Dlslon
and and the ordlnal nurnberon the connectlng
rod musi face In ogDoslie dlrectlons.
Fli the p ls+ on pl n clrcll ps In i he pl s +o n.

E nsure +h at + he clrcl lp s en ga ge p ro pe r ly I n
ihelr grooves.
t. SHORTET€D
P ISTot{S
425 lf l-he cyllnder block top face has b€en
ma chl ne d, l ns+a l I resp ecfl vel y sho rtg r p l s+o n s
+o ensure +he correci dlstance betwsen +he
Pi s t on d i a m e t e r pl ston hea d an d cyl ln de r h ead . A l wa ys r e p la c o
gD al l ih e pl s+on s l n o ne e ng ln e to h ave l d e nl l c al
E n g in e A pl sj-o ns. M ax perm l ssl bl e re lg ht d lf {e r en c e
be +re enpl s+on s I n o ne e ng ln e l s 2 5 g.
309 26 9 9 , 8 7 3 . . . 9 9 .8 8 7
The re a re f lve dl ffe ren l u nd erslze s l n +h e
31 1 lengihs of ihe pls+ons dellvsred as spare par+s
fo r 3 ll ,4l l an d 6 ll en gl ne s. Th e c o r r e c t
4 tI 19 1 0 7 , 8 5 3 . . . 10 7 ,8 6 7 length can be chosen accordlng to +he ne€d Jor
m achl nl ng . ln th e ca se of f0 9 a nd 6 1 2 e n gl n es
61 1 +he s+andard plston rnust be shor+ened +o
corre sp on dto ih e cyl ln de r bl €k m ach l n ln g .
612 22 1 0 7 , 8 s3 . . . 1 0 2 8 6 7
Check +he condltion of ihe plsfon and the

pls + on p ln vls u a lly. Pa y sp e c la l att e nil on t o
posslble cracks ln +he area of the plsion top
and the pln bore. Measure +he plsfon dlamo+er
a+ t he p o ln i I n d lca ie d I n fl g. 4 2 5. Co op are
ihe r e s u li '. ilih th e ra iln g a n d re pl ace the
pls+on ',ilth a new one, if necessary.
427
4 - 15

4 . Lubrlca+e +he crankshafi bearlng Journal and
Spare part Shortened Mark on bea ri ng shsll s an d p ush l h e co nn ecil n g rod on t o
no oy mm piston +he cran ksh af+ be arl n g Journal . F lt fhe b e ar l ng
caD so fhal- l+s ordlnal number faces +he
311,41 1,6 1 1 D respec+lve number on the connecilng rod.
Tlgh+en fhe nu+s of 109, 3l I , 4l I and 61I
8353 16177 std englnes ln phases +o the +orque of 90lln.
8353 31044 o ,2
8353 31045 o,4 4 Tlghien ihe connec+lng rod screws of 612 englne
8353 31046 0,6 o as l ol low s:
8353 31047 0,8 8 L Preilohfenlno vrlih ioroue wrench J0 Nm
2. Tlghtänlng 9öo, both sirews
8353 31048 1, 0 10 J. Tl ghi en l ng 9 0o, b oth scre w s.
31.1,4 11,6 1DS
1
S',lng ihe connectlng rod sldeways and ensure
8353 16033 st d i hat ihe con necll ng ro d bl g end ha s a
8353 31049 o,2 2 sufflcle n+ sl de cl ea ra nce on fh e cran k s haf f
8353 31050 be arIn g jo urna | .
o ,4
8353 31051 0,6 o
8353 31052 0,8 I
8353 31053 1,O 10
611DSB
8363 30700 st d
8363 31054 o,2 2
8363 31055 o,4 Plstoo dlstance frs ta dged contre vs.
8363 31056 0,6 6 crcnk rng l€
8363 31057 0, 8 I
8363 31058 'l ,0 10 oegrees Jll ,4 lt,6
nm
t0 r,l0l 1,1 72
J. FITTING THE PISTONANDTIE @N}€CTIIG RCD ll 1,4 17
Fli + he conn ec llng r od b lg en d be ar in g sh el l s l2 l,rB 5 r,68 5
In ihelr pla c es . Che c k + h a+ + h e m ailn g faces
a re c lean a n d fhe b ea rln g s he lls co .re cil y tl 1,8!b 1,97 6 2 ,2 07
p osl+ loned.
l4 2 ,1 5O 2,28
L ubr lc a+ e t he pls +o n, p ls + on rln gs a nd c y lln de r
l rl +h englne ol l. Pla c e + h e r ln g g ap s ra dlal ly t) 2,46 5 2 ,624
a + regular In + er va ls , fa cln g ln d lf fe re n' t
d l rec flons . 2,8O l 2,9 82
t1 3,36 1
l8 3,5 3,1 63 4 ,205
to 4, 18 6 4 ,67 4
20 4 ,3 51 4 ,631
4 ,1 89 5,O91
22 5,2 47 5,5 83 6 ,240
5,72 4 6,0 91 6,808
24 6,22 0 6,6 19
6, l35 1,16 1 8 ,O12
7,27 0 4 ,64' t
a1 7 ,822 a,3 E 9,3O 5
28 a ,391 8, 9JO
42 4 29 I,982 1 0,68 6
JO 9 ,58 10,202 | | ,40 8
f. Use a pls ion r ln g s + r 6p or pr ef er ab ly a f lfilng
tool. Fli the plston and ihe connec+lng rod
I ni o +he c y llnd er Ind lc aie d bV + h e ordlna l
numberso as lo have ihe nunber and ihe wolghf
class mark fowards +o +he camshafl.
4-16

l. CoU]{IEREL NCE iCC}l,ANlSH ,ll|
RE OYITGA]O DISASSEIALIrcTHE COI'XIERBAL,ATCE
lccH Nl sf.l
De+achlhe englne.
Openthe con nec lln g s cre ws of th e lube ol l pl ps

of +he coun+9rbalance assenblv and rqnov€ the
Dloe.
open ihe flx lng s crews o f +h e c oun i e rbal an ce
mechanlsm,remove+ho assemblyand the posslble
shlm s b€ ftre enihe bod y and +he c y llnde r bl ock.
43 1
4. Ensure thal' lhe backlash b€lween +he aears ls
accordlng to ratlng (0,O5...0,25) a-nd ttrai
the @unterbalance end play ls corr€ct (O,l
. . .0, 5 ).
FITTIT{GTTE CDUI{IERBAIINCE
iCCHANISI,t
4. Open the refalnlng scref,s of the counterbölance
shat+s. Press fhe shafis off ihe bodv to ihe Tap the dorel plns ln ihe body ot the counter-
di.eci lon o f + he re tölnlno s crers. R enovef he bal önce mechan
I sm.
c ouni er balo nc es and -the + h;u s+ Dlates.
5. Clean + he o arfs care fully .
B. RECONDITIONI]€ IfCHANI SI,I

IHE COUNTERBALÄNCI
Check ihe shafis for wear and ihe condl+lon of
the counteib€lance gears and bearlngs.
lf the counterbalance gears are rorn, rep lace
th9 coun+erboI ances. The gears are not supplled
separo+ely as spare par+s.
lf needed, press lh6 old bearlng bushes ott the

clun+ erbo lån ce wl+ h a suliable dr lf +. B gfor e
renovaI mark the bush oll groovo posltlon on
ihe counierb€lance. Press the ne'r bushes onio
+he counferb8| ance no+Ing +he ol I groove
posli io n. After flitln g m ac hln e + he bearl ng
bushes io lh elr c orrec i dlmen sl on 26, 040. ..
26,061 m m.
2. F l t th e coun+ erbal anceassembl y In pl ac e s o
lha-i' +he dot on +he counterbolanca gear allgns
wlih the dot on the crankshaft gear rlm.
5. Tlghien the flxlng screxs ot ihg counierbalance
nEchanlsm lo the toroue of ilt ltl. t4easure
the back lash betroen ihg cauntgrbalånce gear
an d t he gear r l n. S h oul d l + dl ff ar f ro n ra tln g
( 0,1 .. . 0,5 h r), m ake the a dj us t m en i b y
placlng 0,2 |Im shlDs beireen the body of ihe
counierbalance assemblyand +he cyllnder block.
4. F l x i he l ube ol I D l D e.
1.Li ne t im inqm a rk s
2.Dot timing-ma1kn 30 5. l'4ou
nt fhe englne.
F lt i he c o un+ erba
lanc es lnslde the bod y no tl ng
thelr correct posltlon. The counierbalance wlth
6-dot on th e g ear ls plac ed hlghe r on th e body.
A llgn the lln e nark s on ihe c ounterbal ances and
tl+ the shä fis In pos ltlon from + he sl de of i he
r etalnlng sc rers . lihl le lhe s haf f l s b€l n 9
f lti ed ln po sl+ lo n, plac e the ihru st pl al å
befeeen thg counferbalance and the body. Tha
shaf t e nd ls pre ss ed flus h rlth fh e bod y. A ppt y
relalnlng compound(6909 lo0ll) oo the sciei
threads and tasfen lhe scrers.
4- 17

4. FLYHHEEL
REPLAC
I NG TI{E FLYTI€EL STARTERRI I,t
lf the sfar+er rlm ls worn, replace l+. The
s+arier rlm cannot be +urngd around because lts
+eeih have been chamfered and +empered on ihe
slde of +he s+arlor.
Remove+he old s+arior rlm by tapplng l+ a+
v ar lous pol nf s w lt h a d r lft . C le a n lh e flyw he el
confaqt face vrl+h a wlre brush.
4 33
2. Heat fhe slarter rlm evenly +o a iomperalure of

15 0 - 200u C. F l+ th e rlm In p o s ltlo n on ih e
flyvlheel so +hat ihe chamfer of ihe openlng ls
towards the flv*heel and +he chönfe.ed side ot
ihe teeth iovrards the s-tarter.
f. Lef ihe siarter rlm cool dorn na+urallv.
B. F ITTII{G T}€ FLYXHEEL
Clean +he maflng faces on ihe crankshafl rear

f la ng e an d f ly whe e| .
Flx +he flvwh eel on t he c rank s haf + en d . F o i

guld ln g you ca n uso lV l2 si uds ( 2 pc s ) wh l c h
s ult th e fly wheel r et alnl ng sc r er hol e s . T h e
pos lilon of i h e f ly r heel l s { r ee l n e n g l n e s
where ih e l nj ec il on i l ml ng ls mark ed o n t h e
c ran ksha f+ f ro n+ end. I n s one engl ne vo r sl o n s
one of +he relalnlng screws have been replaced
by a guld e p l n i 'o deier ml ne ihe c ra n k sh a f +
pos li lo n.
Tlgh +e n the l lyv lheel r e+ alnl ng s c rer is ev e n l y I n

phases io ihe torque of 120 Nm.
4 - '1 8

T IMI1{OG€ARASSEICLY
I ioEx
T ec hn lcll d a ta . ... .. .. .. . .. . . . . . . . . . . . . . . . . . 5- I
S D e f a l to o fs .. .. .. .... .... 5- 2
C ons f r u c i lon . .. .. . ... ... ... 5- l
Repalr lnsfruslloos
l. G€ar houslng
A , Re m oln v g +h e g e a r h o us ln g. . ..... 5- 6
B . R e co n d lt lo n ln g + h e ld l er g ear.. . . . . . . . . . . . .... ... 5- 6
C . F lft ln g th e g e a . ho u s lng . .... ...5 - 6
D. Replaclng +he crankshaf+ fron+ end shati seaI . . . . . . . . . . . . . . . . . . . . . 5- I
VAIiIET 5- 0

IECflNICAL D TA (reject llmli of part sfated ln brackeis of-ter raflng)
Blck I cshos
C r änk s hatt - l d le r ge or o,or...o,2,
ld ler gear - camshaft o,o5...o,25
ld le r g eo r - I nJ ec llo n p um p......,r .... o, 6... 0,2 5
C a ns haf l - d r lv 9 u n lt o,0r...0,2,
M ax p er nls s lble s ld g wo bb lo of ge ar s ,. ... .. . 0, 05
Tlnlng Frrks
T l nln g mo r k s o n g e ar s 6 re ln a llgn m ent whenthe ls+ cyll nder pl st on l s 6l lts
iop deöd c€nt.e betre€n compr€sslonond poror slrokas.
0n crankshöfi gear . . . . . , . . , . . . 2 dois on te€th

O n ld 16r g e ar :
- c gal ns i c r a n k sh a fi g ea r .....,,..... mEik non on tooth
- cgöl nst canshaft ger I dcrt on ioolh
- 6galns+ Injectlon pumpgear I doi on nqlch
0n camshaff ge€r:
- f 09, l lt,4 ,6 lt ........ I dot on nqlch
- 6 lr , 6t2 ) dois on fe€th
0n Injecf lon punp geör I doi on toofh
C r ank s hatt m us t be fur nd to br ln g a ll fl mlng mf ks ln all gnnenf agöln ... ... . o TUrns
ldlcr galr
81 61 298 6t ( r lth p laln b ea r in g )
I n s ld e d lö r € to r o f ld le r g e ar b €a rln g bu sh (fl fied) .. ... .,. 55,000... 55, 050
D l äm ei er o l ld lor g ea r s p ln d le .,,..... , ,4,951. . .54,910
T lg h+ enln glo r qu e o i M l0 re ta lnln g s c rei .. .... ... .. 60 Nm
T lg ht en ln g ior qu e o f lr ll4 r eta lnln g s crey .. .... ... .. 140 Nrr
8 f 61 , 8J 54 ( r lih p laln b e ar lng , s pln dle lengi h 50,7 nn)
I ns l de d l aflE fer o f ldle r ge ar b ea rln g bush (fl tted) . .... ... ,, ,20O. ..5' ,2tO
0l öm ei e o t ld 1e | 'ge a. s p i ndle . . . . . . . . . 5r,111.. .55,110
T lg ht €n ln g'to rq ue o f Ml0 re ialn lng s creB .. .... ... .. 60 Ntn
T l ght e nl ng tfq ue o f Ml,l re fa lnln g s cr er .. .... ... .. 140 N m
4 361 227 @ ( r lth b €v e lle d ba ll b ea rln o)
D l ane + €ro t ld ler g ea r sp ln dle ..,...;.. 14,984... 15, 00 0
T l gh ien ln g id q ue o f ldle r ge a r b ea rlng holdef scr€rs . ... .... .. 22 Nm
T l ghl enl ng to r qu e o f ldle r ge a r r eta ln lng scrgr .. ... ... ... 180 N m
Crcnkshcfl troit 6nd nut
T l gh + enl ng lo rq ue o t fro n + e nd n ut 1 09, fl l, 4ll .. ... ... ... .. 600 Nm
T l ght e nl ng fo r qu e o t fro n + o nd n ut 6ll ,612 1000 Nm
5-1

o
'I 2 3 4
o
SPEC|ALIIn_S (ilrlng gear 6senbl y)
t. 90Jo I'm Flt-ilng +@l tcr crdrkshaft frort aod shati seal
2. qzt gm T+plng flfi fq- dusi covei
l. 9025 98m T+plng drlft fo.- doreI pln
a. 25 9Er7N T+pfng ölft tor dore I pln
n21 712@ G-ankshaf+ fror|i end nut rrench JO9, ll l , 4 l l , se e In si ru ct lo n s p o l n t 4
21 55mo Crankshafl fron+ end nut rrench 6ll, 612, see lnstructlons polnt 4
o
c-z

T I I' I NO G€ARASSEI,BLY
cor{slRl,cT
Io{ 22
G€AR
r.tous
I NG5o9, ]|t, 4 , 6tl 23
l. Oe ar housl ng
2, Scret
f. Gaske+
4. S iu d
5. DoroI pl n
6. Gasket
7. Froni cover
8. Shatf seaI
9. S hl el d p l ai e
10. Nu i
ll, S eal l ng
12 . Fl l l er pl p e
ll, O-r I n g
14. Cover
15 . W asher
16. Spacer
17 . B earl ng ho usl n g
13 14 18. Gasket
19 . B earIng
20. Cl rcl l p
51 2 1. Drl ve unl + sh af +
2 2. P l ug
2 3. S eal l ng rl ng
GE^RHOUS'tc 6ll, 612
13 12
t. Gear housI ng
2. Screr{
Gaskef
DoY i elpl n
Front cover
Se al l ng
Cover
8 . Se alIn g
Sh afl ' seal
10. }lasher
. Sh aff
Cl rcl ip
ldler gear of compressor
14. BearI ng
15. B earl n g h ol der
5- 3

T he fl mlng g ear assembly com prlsos hel lc al The +lmlng gear assenbly equlppedv,lih an ldle r
gears rhlch have b€en nachlned and tempered goar } ,lth bevel led ball bear lng ls moun+gdon
!rlih preclslon. The gears are locatod ln +he 6l I englnes. Thls gear assembly has noun+lng
g e a r ho us lng flx ed to +he cy llnder block front polnts ready for a dr lve unl+ and a l-cy llnder
face. The camshaf+, lnjec+lon pump and ol I o' 2-cyllnder, gear-drl ven clnpressor can be
pump as yell as +he compressor ol 611/612 npunl'edon ihe englne lef+ slde.
e n g l ne s ar e dr lven + hrough the flmlng gears.
The gear houslng can alio encompass -a
drlve
u n ll for , say , hydraullc pump.
There are three maln +ypes of +lmlng gsar
a sse mbll es:
l. 1
l. C am s h a f t g e ö r
2. ld ler gear
f. Injec+lon pufip gear
4. Hydrau I lc pump gear
5. Crankshafi gears
6. 0i I pump gear
l. Camshaf+gear 7, ldler gear of compressor
2. ld l er g ear 8. Compressor- goar
5. Injec+ lon pumpgear
4. Crankshaf+ gear T h e 6 l I an d 6 12 e ng l ne s h av e a t l m l n g g ea r
5. 0l I punp gear assembly where the gear-drlven conpressor ls
l oc ö f e d on t h e e n g l n e rl g h t s l d e. T h e l d l er
Th e tl ml ng ge ar assemblyequlpped{ l+ h a n l d l e r g ea r h a s b e ve l l ed b al l b e ar l n g .
g e a r '.{ lth p laln bearlng Is used ln f 09 , 1 1 1
4 l l an d s ome 611 englnes. T hls l lm ln g gear
a sse mbly ca n be furnlshod wlth a d r lv e u n l t
drlven by ihe camshaft gear. I DLER GEAR
T h e 6l l e n g ln e s h a ve a s lm lla r v e r s lo n o f gear The ldlor gear ls connecied io a shaft llxed to

a s s em b l y, e q u l p p e d t | lt h a lon ge r ldl or g9aa f he c y l l n de r b l oc k f r o n t f ac e by me a n s of a
shafi, ho{over. b ea r l n g r hl c h l s e l t h e r a p l a l n b e ar l n g o r a
b e v el l e d b a l l b € ar l n g 1 6 1 1 / 6 12 r .
l. Drl ve un l+ gear (shaft) Mo u n i l n g p a r+ s o f l d l er ge a r l {l i h p l al n

2. Camshaftgear b ea r I n g .
i. l d ler go ar
4. Compressor/I nJect I on pump goar l. Screr. 2, Scr er J. R etalnlng flange
5. Cra nk sh aft qeårs Boarlng bush 5. cear 6. Shåfi
6. ol I pumpgeär
5- 4
Mou n+ln g pa rt s ol ldle r gear rlt h beve ll ed bal l
be ar In g.
l. Scr ex 2. Sc re{ 5. Fl ånge 4. Re ial nl ng

rlng 5, B ev elle d bal l bea rlng 6. Gea r
7 . Sh af+ 8. Loc k lng pl n
c- 5

TllllNG GE^RASSEIGLY N ot cl I f l he cy I I n der he ad and vo I v€
flEchanlsmhave no+ been renoved, lock ihe valve
t . GEAR}IOUSI }G + appet s u p In such y. ay t haf i hey r l l l n ot dr o P
down when removI ng +he carlsha{t and ihus
REIOYI I{G THE GEARI{OUS
I }lG prgvent fhe lns+allailon o{ ihe camshöft. Se€
Ins+ rucf l ons, p ol nl S 2 g.
As the gear houslng bo+ion face forms pari of
ihe mgilng face tor ihe ol I sunp gasket, ihe r^ Open +he gear houslng flxlng screws and rgmove
ol I sumpäusi- be removed fron the-engtnå, lf '"' ihe houslng. lf you noed to tap a red99 betxeen
fhe 9e6r houslng needs fo be taken olf |.hlle ih€ gear houslng and cyllndsr block io re[bve
fhe 9n9lne ls In place . ihe houslng, ensure +haf +he seallng taces
rsmaln I n+ac1.
Remove+ha ol I sumpfrom ihe englns.
ll' Tap the crankshaf+ shafi seal off lhe fronl-
opgn the tan flxlng sc rer s and r gmovet h g f un. cover usl ng a sul +abl e dr l { 1. w ash al l d et ach ed
Loosgn the alternator flxlng scrers and refl|ove p art s and cl ean i h e sea l l ng sur foces ca re fu lly.
t he alt ern ator, be li pulle y and b€ lf .
J. R e d t o v e ih e o ll pr es s ur e r egu lail ng v al v e ( J l l,
B. REOOIIDITIOTIrc IHE IDLER GEAR
4 1 1 a n d 6l l e nqlne s ).
l dl er g ear r l+h p la ln bear l ng:
l f y ou r epl ac e l - he l dl er gear bear l n g b u sh ,

oress +he nefl bush ln Dlace so thäl lis rEar
e dge re nal ns 0, 1 . . . o, 25 nm I ns l de lhe g e a r re a r
f ac e .
A f i er l ns t al l ai l on t h€ bear l ng bus h m u si b e
ma c hl ned +o 55, 000 .. . 55 ,0 30 |t r n I n c as g o t 1 0 9 ,
511, 4l l and 61 1 engl nes and t o 55
nm l n c as e o f 6l l e ngl nes y l t h 50, '200
7 ...5
r m5 ,25
l o n0g
l dl er gear s haf +.
l |ot c l H hen m ac hl nl ng lh e beör l ng b u sh

c eni r al lz e +he l dl or gea r ac c or dl ng io tl g . 5
8.1 ln order to k6eD the back lashes correqt.
R ol l s ,
open fhe crankshai+ lront end nuf vrl+h iool

9 0 2 4 1 42 0 0 I n c as e of J 09, 3ll an d 41 I engl ne s
a n d rl th + ool 9024 55 800 l n c as e of 6ll and 612
e n g ln e s . P u | | t he bel f pu ll ey - hu b pl ec e
comblnal lon oJf the crankshafl-
Remove the fron+ cover flxlng scrers and nuis

and lake off the cover. lf you need io tap a
wedge b€freen ihe cover and the gear houslng +o
remove ihe covor, be sure not to damagg ihe
se a ll n g s ur f ac es . l dl 6r gear rl +h be v el le d bal l bear l ng:
Renovo the ol I def lecior from the crankshati,
Remove fhe Injectlon pump andlor compressor.
Notcl lf you do noi ln+end to rep lace the

g€ar houslng, li ls noi necessary to remove +h€
ln j e c tl on pun p. Only r ef lD v e f he fu et , l ube ol I
end lnjecilon plpes frorn the Injec-t lon pump
( e n g ln e s r her e lhe I njec t l on punp ls f l x e d i o
t h e g e ar h ous lng ) .
Opgn ihe ldler gear flxlng scrgus. Romovo tho

ih e r e f al n ln g f lang e, ge ar € nd s haf t .
9 . Pu ll i he c am s h€f t o ff {r om + he c v ll nder bl oc k .
q- A

Fl x ihe bea r ln g s a s s h o rn ln f lg u re 5 9 (o-
sysieD) presslng from -the ouier rlD. Atiach ihe
be arlng r ef al n ln g rln g a n d tlg h t e n t is ll gh +l y
ol led screl{s to th€ +orque of 22 Nm. press the
sh af i In p o sl tlo n p la c ln g s u p p o ri s o n th s
E€ arI no Inner r lm .
c. Frrfl; Tl€ 6EARHoUstNG

The posltlon of +he gear houslng towards +he
cyllnder block ls deigrmlned ',{lfh tuo dowel
plns. Thls also sgcures the posltlons of ihe
gear houslng and lhe froni cover rhlch need nof
b e s apar 8tel y c e n i ra l lz e d d u r ln g ln sia ll afl on ,
Ensure, howevor, the correc+ back lash of ihe
gears. The gear houslng and front cover rhlch
are del I vered as sDare Darls are furnlshed rrlth
ready holes for th; dcr;tsi
P la c o o ngr g a s k e t b e ix e€ n +h e c yll nd er bl oc k
a nd t he gea r h o u s ln g a n d llf i i h e h ous ln g l n
li s pos lil on. T a p t h e d o re l- p ln s I n h o les rl ih 5. lf ihe compressor ldler geör shaf+ has been
ihe tool (9025 98700) and tlghfen ih6 houslng ren cved , a pp ly re ia ln ln g t lu td 6 90 9 to ol2 o n
t l x lng s c rews an d n u is. Its ouislde and tap lhe shaft In posl+lon so
that the rear faces of the shaf+ and +he oear
Attach the lnjecilon pump/compressorand lts h ou sln g cre le val ll ng . Ftx th e b ea rln g an d- l h e
gear ( It removed). gear In such a ray fhat the notch on the
be6rlng Inner clrcle cones on ihe outslde.
L ub rlc 6le ih e co ms h a ft b g a rln g J o u rn als on d Re ne mb er+h e be örl ng rei al nl ng rl ng sl At+a c h
p us h , ihe c a n sh å fi l n io +h e c yl ln d e r b lo ck. 1' he ld le r gea r lo ck pl åi e an d gh fe n l f s
Releadb ihe val.ve t€ppets lf locked. fl xln g scre es l o f0 Nm (6 11 ,/6 12E ng ln es r l+ h
conpressor on l-he the englne rlght-hand slde).
6. Check ihe gear backlash rhlch should b€ 0r0t

T lm lng gear ma r k s ( s e e ie c h n lca l d o t a I't lm ln g .. .0 , 2 5 m .
marksir)
l. Crankshaft gear
2. G ear dr lvln g o ll p u m p
3. Camshatt gear
4. l d ler gea r
5. I nj ec t lon p u n p g € a r
4 . P la c e t he ld le r g e ar s h a tt ln p o sli lon a n d
l ns t all t he ld l € r g e a r o n fh e s h a ff. } l he n
l ns i al llng ih e ld le r g e 6 r p le a se p o y a t te ntl on
to ihe correcf posl+lons of +he tlmlng marks on
g aar s . Flt f he r e t a ln ln g f la n g e å n d ilg h te n th e
ldler g€ar flxlng scrors to fhe rlgh+ forque
(f7 rl . 60 Ir rnd Z2 n l1O t|; for ldl.r
gcar rlth pl.ln bclrlng lnd- l8O Ir for ldlor
g.!r rlth b.vcl l.d ball bcarlngl.
7. place +he oll def lec+or on the crankshaft and a

ngx gasket bsiwggn +he gear houslng and front
cover and llfi ihe front covgr In Dosltlon. use
too | 902i 98700 to taD the froni cover doUel
plns In posl+lon and lool 9025 98gOO{or the
ptn a ro un d the stu d. Tlg hte n th e fron f cov e r .
5 _7

D. RE'IACI]G ITC CMT'(SMFT FROiITEID SMFT SEA
(5O9. 5lt cnd 4ll englnasl
Flx th e s hl el d Pl a te o n fhe fron+ cover seållng 5 t6

box and top ihe shaft s e al In Place rl +h the
to o | (9 01 0 15 200 ) . L@san thg alternator llxlng scrers and remove
the v-b€ lt.
2. oDen fhe crankshöfi fron+ end nuf rllh ihe fool

19024 14200\. Pull the belt pulley - hub plece
contblnailon off fhe crankshoft.
R€|lpvo +ha shaft seol fron lhe tront cover 6nd
cloa n the soa l ln g bo x carefull y. Top a ner s ea l
ln posltl on rlth the t@l (9 010 1 520 0 ) .
L ubrlca te fhe seal ll p co refu l ly rnd p us h t he
b el + pu l le y - hub p le ce co rbl na tl on on t o ih e
cr6nkshatt groovgs. Tlghten ihe crankshaft
froni end nut to th6 torqua of 600 lln.
F lx the v-b elf a nd tlgh te n i he al te r nö +or ln

Its corrggt Dosltlon.
l ote l T ho 5 ll a nd 61 2 eng ln es e qu l ppe d x l t h
ld le r g ea r trl+ h be vsll ed b oll be6 rln g c an, l f
necessary, have iro shafi seals ln a ror. Also,
the ooslflon of the shalt seol can b€ altEred
b y ftitln g ä J ri n thl ck shtm und e r ne ai h t h e
sgel. The order nunber for ihe shlm ls 8f5t
515 28899.
9. tt the shalt sacl dus+ cover has b€en re|l|oveo

t.or itr. crankshaft hub plece top' lap ll In
posltlon rlth toot 9025 98900'
t0. AoD lv r efa ln lng f lul d 6 90 9 f 00 ll o n the hub

oiåiå o.*""t.- Lubrlcote the shaft s€äl llp
ioiåir ljv o nd p us h the be li pu lley - hub plece
comblnofion onto ihe crankshaft grooves'
ll. Aoolv r et ol nlnq flu td 69 09 f00 l I o n ih e front

'n"+ +nread-s. Tloh+en the crankshöft lroni
-'"i -9024 74200 fo 600 iln In
ånå ,ifit tool
ioi. "rt
oi r o s , tll on d 4ll en glne s an d rli h tol
-i:äoo'io
ööäl t ooo Nttr In cose of 6ll and
612 engIn es .
(sa
12. Aftoch the oll Pressura regulatlng volve
lnst ruc tlo n sDo lnt 6 ).
lf. Flx th€ rlternoior and the v-beli and adJust
ths belt tens lon.
14. Flx th e br eo th er plpe ( 50 9' 5 ll and 4l l

englne s) . Mou nt ih e fon a nd t lgh ien l +s {l xl ng
S Cr el S . 5-8

LIER|C TI0 SYSIE|,|
tlGX
T €c hnlc .l d sic ............. . . . . . . . . . . . . . . . . . 6- |
C ons tr uc tlo n..... . .. ... .. .. 6- 2
R?!lr Insfrustlons
l. Lubrlcrtld syslqr
A. Insp€ctlng the oll pres s u r e re g ul e tl ng v a| v e. .. .. ... .. ... .. .. ... .. 6- 5
g. R qlb vln g ond Insp ec iln g th e ol l p u np ... .. ... .. .. . 6- 5
C. A s s embllngand lnsiå llln g fh e ol I pu nP . . . . . . . . . . . . . . . . . . . . . . . . . .. 6- 5
D. Replac lng fhe o ll c @le r . .. ... .. 6- 6
E . Pls to o cool Ing .pz z lo 6 12 .. .. .. .. ... .. . . ... .. .. .. 6- 7
F. L ub€ oll quallty req ulr er | € n fs .. ... .. .. ... .. . .. ... 6- 8
vAlilEr 6 -O

IECHNICALDATA (reject llmlf of part sfated In brackols after rötlng)
Lubrlcotlo||
OII pressure al no-nal runnlng lemperature:
- ai ldle s peed (m ln. ) I5O kPo (1,5 k p lcm2 )
- d t r un n lng s p€ds . . . . . .. . . . 300. ..500 kP a
lt...5 kp/cn2,
F r@ le ngt h of oll pres s ur e v aly e s pr ln g 80
Sp rln g p res s ure ehen v alv e s prlng ls c or Dp re s s edi o a l gn gth of 9 2 rm ... .. .. . 54+ 5 N (5,4+ 0, 5 kp )
DloD€i€r ol oll prossure valve plunger t 9,602...19, 6t 5
Dlan ete r of oll prs s s ure v alv e c y llndg r 19,70O..19,75 2
Oll fllts ' by -pas s v alv e opens at a p r e s s ure dl f fe re n@ of .. .. .. .. .. .. ,. .. .. 2 !O, 5 b{
Ope nln g p res s ure of pls t on c €olln9 no z z l e ( 61 2) .. .. .. .. .. . 5 ! 0,2, bar
Oll p ut lp 5O 9, J ll, 4ll
Ba ck losh belv €€n gear s rhen c rank s ha tt l l es f l r ml y 6g ol n s l t he l or er s i d e o f

lis b eö rl n9
- crankshåft drlve gear - ol I purrp drlve gear o,o5... 0,25
- betreen oll pump gsars 0, | 6.. .0, 26
Clea ran co b€lr e€n drlv e s halt and lls b ear l ng s I n b od y on d c ov o r , .. .. .,. .. .r 0,016...0,052 ( 0 , 0 7 0)
D la me+e rs o f dr lv e s haf + holes I n bod v a nd c ov e r . .. .. .. .. .. r8, 000...r8, 01 8
Go6r hole dl omelers I 8,060.. . 18,0 7 8
Clea ran cs be t w @n gear and llxed s haf f. .. .. ... .. . 0,021..,0,050
Pr otr uslo n ol f lx ed s haf t end beloi p u mp bd y f ac e . .. . .. . ,. .. . 0,5... 1,0
T h lck ness ol covei' gask€rt 0,06...0,08
ou fs ld e d I am et er of gears . . . .. . . . 43, 4A 6...43, r2 5
Cle ara nc e o f geörs I n t helr hous lngs 0, | 25. ..0,264 ( 0, 1 0 0 )
HousIng d lameter 45,650. ..4t,75 0
T hlc kne ss o f gear s (J 09, J ll) . . , . , . . .. .. . | 8, 000.. . | 8, 02 7
T hlc kne ss o t gear s (4ll and f lt DS /VB!, |V5 05 , 6 05 ) 24,0O0...24,021
End p lay of geais . . . , , . . , . . . 0, 01. . .0, 11
Dep ih of ho us lng (109, 5ll ) . . . . . . . .. . .. .. . 18, 000... t 8, o4 l
De pth of ho us lng (f ll and 5ll DS, / VB MV 5 05 , 6 05 ) .. .. ... .. .. . 24,OOO.. .24, O 4 t
T lg hfen lng t or que of gear re- t alnlng n u t ... .. .. .. .. .. 60 Nn
Oll p u|| p 6ll, 612
Backlesh befr.een gears rhen crankshaft l1€6 tlrmly agölnst the lorer slde ot
Its b ea r I n g
- cra nk sh af i drlv e gear - oll pum p dr l ve geä r 0,05.. . 0,25
- betYeen oll pump gears 0, t 6..,0,26
Clea ran ce b ef reen dr lv e s haf i and lts b e ar l ng s In b od y a nd c ov e r r .r .. .. .. .. . 0,0t 6. ..0,o52 ( 0, 0 7 0)
D lam €to r ot dr lv e s haf t bearlng hole In b ody a nd co v f. .. .. .. .. .. . 18,000. .. t8, 0t I
Cle ara nc e b €t re€n gear and f lx gd sha ti .. .. .. ... .. 0,0t6...0,052 ( 0, 0 7 0 )
Hole dlönet€r ot gear runnlng on flxed shotl r8,000.. .t8,0r8
Protruslon of flxod shaft end belor pump body löce . . . . . . . . . . . . 0,5...1,0
Th lck ness of cover gaskel o, 06. ..0, 08
ou fslde dlöm eler of gear s (6ll) 43,4A 6. ..41,r2 5
Quts ld e d la met er of gears (612) 49,1 . . .49,17 5
Cloä ran ce o f gears ln +helr houslngs 0,125.. .0, 264 ( 0, 1 0 0 )
Ho usln g d la me+ er (6ll ) . . . . . 4t, 650...43,75 0
Ho usln g dlö D eier (612) . . . . . . . . . , . 49,900...50,00 0
T h lck nes s o f gears . . . . . . . . 32,000.. . t2,021
E nd p l ay of g ea rs ........... o,05...0, | |
Depih ot houslng t2 ,oco. ..52, O45
Tlgh t enln g to rqu e of gea r r eial nlng nut . .. ..... ..... 60 Nm
6-1

LUERICÄTIol{ SYSTEX
6l
Ol I c I rcu lal lon
Lubr I catlon sys+em

The englne has a pressure lubrlcatlon system
co ftbIne d s lth the oll pumpwhlch pum p s+ h o o l l
a In fo l- he dllferent englne polnts th a i n e e d

l ubr l ca +lng. T he pump sucks the ol I fr o n + h e
eng ln e o l I sumpfhrough a s ucflon l ll te r. Th e
oll ls + hen led +o the oll c hannel a n d f ur fhe r
t o the pres sure regula+ lng valv e a n d o l I
f l l+ e r. Fr om fhe fllter + he oll flows l nt o fh e
m a ln dl s' tr lbutlon gallery whlch h € s b r a nc h
c h an nels leadlng +o the crank sh a ft ma l n
b ea r lngs . T hrough + he channels In the c ro n k-
shaf+ +he ol I ls then led from fho maln
bearlngs -io +he connecflng rod blg end
bearI ngs.
The lnjocflon pump and ihe turbocharger also

gef thelr ol | 'ihrough ihe maln dlsirlbuilon
g al le ry and ai boih ends of fhe cyll nd sr b l o ck
ihere are ol I channels vhlch lead the oll to
ihe camshafi, The camshaft has an lnner bore
through rhlch other canshafi bearlngs are
lubrlcated. The fronl channel also f€eds +he
b ea rl ng o{ ihe ldler gear lilth pla ln b e a r l n g .
From ihe canshalf rear end a channgl (ln fll,
6'll and 612 englnes an exiernal plpe) leods io
ihe valve [Echanlsm. Tho oll returns fron ihe
cyllnder head io the crankcase ihrough push rod
h ol es .
The b€lt or gear drlven compressor ls connec+ed
f o ih e englne lubrlca+ion s ys+ enwl+ h a p l p e .

Oll pu!?
P re s s u re a e g ul a t l n g v a l v e 64
Ol l p um p6 l l
1 .0 -r l n g 6. Gasket
l. Nut 9. Scr6n 2 . C y I In d e r 7. Covgr
2. W€sher 10 . Sh a tt J. P lunger 8. Nut
l. Gear I l. Gear 4 . S p rl n g 9. W6sher
4. Body 12. Cover 5 . H a s h e. 10.
5. S+ ud
B eä r ln g b us h lf. S pa c er
6. Key 14. Screr
7. Ge6r 15 . P re s su re p l p e
8. Gaskat 16 . In let p lp e
0l I fl ltlr
The oll pump ls a gear p'rnp flxed io l-he
cy l l n d er b l oc k lowe r fa c6 an d d rlv en b y l ha
g e a r o n +h e c r an ks h af+ fro n t en d . Th e oll punp
body has a houslng ehere lhs gears are located.
|{hen ihe gears rolate ihe oll movesthrough the
iooth sp6ces, baiwoon the 9€6r and fhe houslng,
f ro m +h e I nl e l s ld e io th e pr es s u re sld e. The 4365 36797
ho us l ng I n t h g bo d y ha s a c o v er Hhe re ih e lnlef
pl pe o nd +h e pr e s su re p lpe a rs flx e d. Th € end
play of ihe ol I pump gears ls adjusted by
changlng ihe nunbei of gaskets betreen ihe body
and ihg cover.
The clelrance ol the gears drlvlng +he puip ls
adJusied by chänglng the number of shl|ns
be+re€n the pumpbody and +he cyllnder block.
T h e ol l pu m p s u sa d In dllfer s nt en g lne ty pes

aro slmllar ln consfrucilon ond vary from each
o i h e r m a l nl y v l+h r ag ar ds to ge ar d ln Fn s lons.
Pressuro rogulatlng valYe
I n ll l , 4 l l an d 6 ll e ng lne s th e pr e ssu re
re g' r l öl l n g va lv e ls lo ca ted ln ih e ga ar h ouslng
a t t h e l o ee r oll ch a nn s l. In 10 9 en gln es f he
v a l v e l l es u nd er lhe ol I lll+ er , o n ihe e ng lne T he olt fl lfer ls of maln ilo* type and h 6s o
l et f -h a nd s l d e. In 6 1 2 sn g ln e g lhe pr g ssu re replaceable fl ligr c6r trl dge, m ounf ed on f h6
r s g ul a i ln g v alv e ls on th 6 6 n gln e rlg ht-hönd threaded socket In lhe bracket. At the bo+tom
s l d e , b e sl d e th € ol I fllter . T he v o lve k eops of l he oll fl l+ er cr rfrl dge ihere l s ä by- pa ss
i h e o ll p r es s ur o o f th e rlg ht lev e l, lr re s pgct- yalve for col d si ar i or possl ble cloggln g of
l v e o f t he e n gln e sp e ed . Th e c y llnd er a nd t he t he fl lt e. . T he f llt er l s al so equlpped r,l i h 6
p l u n g er w hl c h a r e so a ls d wlih a n o -r lng c lose baffl € w hlch prev€nts + he f l l ier l rom em p i yl ng
i h e o l I c ha n ne l. l{he n ih g o ll p re s s ur e grors rhen t h6 englne ls noi ln use.
h l g h e r i h an t h e r e sls +ln g fo c ce of ih e s pr lng
part of ihe ol I relurns io the ol I sunp through
'the vaI ve,
D epe n dlng o n oll qualliy 6nd temper atur e l h

o l I p ro ss ur e 6i r unnlng r qv s ls f . . .5 kplcm
a nd a t ldls sp e€d 1, 5 k plc nz .
o -J

ol I cooler
s on e on g ln e v g rs l on s a r€ fur nl s he d wlth a n ol l
c o o le r wh lc h ls e li ho r In c o nn ec i lon t {l i h i he
f l lt e r o r , f or l ns i an c e , lo c a+ e d o n +he en gl ne
fronf end and connec+edio the fllter bracket
w l ih p lp e s . T h e o ll c l rc u la + ln g In th e o ll
c o o le r ls c o ol e d r ll + h e n ol ns c o ol a nf.
oll tl ltq - ol | cDl€r conblnatlon

0l l f I l ie |-
Oi I c @ l e r
F I ller brrcket
Fl l+ e r by - pa s s v a lv e
Baff le Jo. backf loY
C@ le r by - pa s s v a l v e
Threaded n lpp le
6-4

UORKI NSIRI,'CT
IONS B. REIiOV THE OIL PUif
I NG AND INSPECTING
l. D ral n th e eng l ne ol l and re n|ove + h s o l l s ut lp
t. LIERICATI()t{SYSIE
fro + he engIne .
}{G THE OIL PRESSURE
INSPECTI IiIG YALVE
REGII-AT pu np l nl e t
2. Op en fhe fl xln g screw s o l i he o ll
Chgck the valvg functlon every ilme lf tho DlDe and r€irove the lnlei PIPe.
englne o l I p r es s ur e do es no t r ls e su tflclen il y
or lf lt v arle s c ons ld er ob ly . F lrst, h ow e ve r,
ensure iha+ +here ls enoughol I In lhe engln€.
on l y o p en i h s fl x l n g s c r e w s o n t he o ll P u m p e n d
an d l ea v e t he p re s s u re pl pe I n l t s p o slt l o n .
Open the oll pump flxlng screys. Reflpve ihe

p u mp a nd p os s l bl e s h l m s b e t re en t h g p u m p f o o t
an d t he c y I I nd e r bl oc k .
5. Loson iho flxlng scre*s of +h€ purlp cover ond

r€npve +he cover and +he gaskels. Pull ou+ ths
ge a r o n t h e t l x e d s h a f i .
6 . F l x t he p u mp a i l t s d rl v e ge a r l n a scr e p vl ce
67 equlpped vlfh protectlve lugs and open the
Oll pre ss u r e r eg ul at l ng v ol y g ( 10 9) dr l v e ge a r n u t. Ta p t h 6 p u mp dr l v e sh a f l ofl
t h € ge a r rl + h a p l a s t l c h a mr pr . P u l l o u t the
dr lve shafi - gaar.
open +he valve cover flxlng scr6v.s and remove
fh6 cover and ihg sprlng underneath lf. Noie 7. l{ash ihe paris ca.etully and check +hem tor
ths washer betre€n lhe cover and ihe sorlno. r e ar , c on p ar l n g H l i h i e c hn l c al d öt a p o l n + 'r o l l
Pu ll f h e v o lv e c y l l nde i an d l he pl u n g er l n s l ä 6 p u mp r r. R ep l ö c s t h e p os s l b l e i or n p ö r t s a n d a ll
li out of the gear houslng/cyllnder block. Make paper gaskgts.
su re lh 6 i t he c y l l nde r o - r ln g s oa l to l l ow s . lf
nol', re[bve +he o-rlng from tho cyllnder block. 8. l f y ou re pl ac s + h o o l l p u np b e ör l n g s b u s h e s o f
the 611/612 englnes, machlne them af'ter
Cle a n i h e par i s c ar g fu ll y . Pl ac e l he p l u n ge r In s f a l l a t l o n + o 1 8 ,0 0 0. . . 1 8, 0 1 8.
ba ck ln th e c y l l nd€ r and s r l ng i hem + o a n d f r o.
lf fhe plunger do€s noi move smoo+hly rllhln ASSEiGI-II{G AND INSTALLIilG THE OIL PUI,P
t he cyl l n de r , s c r ap e o ff th e pos s l bl e d l r + o r
o th e r l mp u r l+ y l y l ng b et v , een th e p a rf s . ll l. P l a c a +h e g ea r s In f he ho u s l n g l o c Efe d I n t h e
n e ce sso r y, gr i nd t he p ar t s l l gh tl y wlih flne body. lf n€oded, rep I ace ihe gaskoi bel-reen the
a b raslv e c l o th or r ep la c e t he p ar i s . C l e an i h e body and the cover. Tlghten the flxlng scraws
sea I lng surfaces ol the cover and +he gear o t l h e c o v er l l gh -t l y . T ur n + h e s h öl i a n d i a p
h o usl ng / c y I l nder bl oc k . i h e c o v er s l d ow o y s un + l l y o u f l n d f h e p o sl il o n
w h er g +h e s h af t r ot a i e s a s f re el y as p o sslb le .
Place a ner o-rlng seal In fhe groove on fhs T l g ht e n t he t l x l ng s c r e v s o f + h 6 co ve r a n d
cylln de r en d. Fl x t he pl un ger Inslde t he c he c k t h a i th e s h af + s ' tl l l t ur ns s no ot h l v.
cylln de r a n d pus h t he par t s In to i he lr po s l + l o n
I n th e g e a r ho us l ng/ c y ll n der bl oc k . P l a c e i h e Fl f t he k e y a nd t he d rl v e g ea r on i h e s h a f f .
wosh er a n d t he s pr l ng I n + h e hou s l ng I n t he A p pl y re + al nl ng f l ul d 69 0 9 f 00 2 5 on + h e n u f
cover and replace fhe gasket beireen fhe cover ihread and ilgh+en the nu+ +o +he lorque ot 60
a nd ihe h o us i ng . F l t t he s p r l ng a g a l n s + t he Nm. Donrf forget fhe lock rashor underneath the
p lu n ge r b ol - tom an d t lg ht en l he c o v er l n p l a c e .
lf needed, use extTa long scrers rhen prs-
tlghtenlng l-he cov€r, ln crdor +o overcoip ihe
sprlng pressure. l{hen you gei ihe cover near
gnough to the houslng, use standard scrers.
Flx the puip ot lts flxlng fooi ln a screr vlce

9!l.lpp"g rilfh^ proiscf I ve tugs. Chsck the gear
4. l{h on fl ++ l ng fh e v al v e c o v er note l+s o nd ploy (0,05 ...0 ,11 nD ) uli h a d l al
g cco n ir lc l +y . T he r l der d ls ta nc o be + i e e n +h e Ind.lcaior. lf ne€ded, change fhe number of
co ver c e nt r ell ne an d t he fl x l ng h o l e l s t o be gasKers beilleen ihe cover and the body.
on the lorer slde. lf +he covei ls mounied the
6- 5
rrong iay, li may causg oll leak q- ihe cover
mav cracK.
A p p l y re i a l n l ng tl u l d (6 9 0 9 l 0 0 l l ) o n t he
thraad of the threadod nlpplo and tlghten lt to
i|o tln. Flx the rater plpes to the c@ler.
I ns tal l a n e H l u b o o l l fl l t€ r.
Close fhe coolgr dralnlng clck and flx the lub€

ol l c@ l e r d rå l n l n g p l u g In p l a ce b y tu rnlng.
R e fl l l the c o ol In g sysl o n.
9. Siari +ho englne ond make sure ihaf there

n o lg ak s .
Cools- w lih oyn brackot
6 10 @
Fl x t h e p u np In pos lilon on the cyllnde r b l o c k
boiton f6ca €nd check ihe back lash of ihe
cra n ks hc tt and pump gears (0r05... 0 ,2 5,
}rl t h a dl o l lndlc ator. lf needed, cha n g e i h e
numberof shlns bet',{eenthe pump body and the
cy I I n d e r b l oc k.
5 . Aitach ihe pump Inlet önd pressure plpes and
re p l ac e l h e f lxlng llange gaskeis. F lx i he ol l
su n p t o th e englne and flll ihe englne r l fh ol l
D. REPL.IC
I IG I}f OIL @OI-ER
C@ler on I I lier bracket
c@ler body ls flxed to the bracket lrlfh iro

benjo bolts. To remove these bol+s you flrsi
have to +ake olf the ol I tl ltsr and tts
brackef.
61r
l . C l E on t h e c ooler and lt s surroundlngs f ro m t h e
outslde and refiove lhg oll c@ler. WlDe otl
l a ak Edo l l.
2. Draln ihe englne c@lanf. Open the ol I c@l6r

cap ånd the draln cck as rel I cs lhe dralnlng
plug on lhe c@ler slde. Let ihe coolani tlo;
I n to o c l6 an b o n l.
5. Dlsconneci the {aier plpes off lhe cooler. Open

fh e i h rE adod n lpple holdlng the coo le r and
remove th€ cooler.
4. C l e an i h e t hr eads ot .the nlpple 6nd ihe l l l te r

ca re fu I ly .
5. Mouni a n€'i c(pler In lts plac€ on ih€ fllter
bracket In such a tay that ihe rater plpes ar6
torards ihe cyllnder block. Ensure ihat +he
gasket on lhe cooler ls ln lis posl on önd +h6
se a ll n g su rt oc € ls tnl6c +.
o-t )

Pf sIoN c00L | 1{Gl€ztE 612
Tha plston cool lng nozzles of ihe 612 englnes
come off after fhg oll sump has been removad.
T he n o zz lo h as a ba ll v alv e t{ lih an oD anlnq
pressure of 5 + 0,25 bar.
lf necessary, clean ihe valve. Renpve ihe valve

from +he englne and iake off l-he nozzle plpa.
0p9n ihe plug In tho valve body and ramove +he
s pr I ng an d the ball.
o o
3 o
6 14
6-7

F. L UB E .OI L Q U ALI TY R EQ UI RE MEN TS
I. O I L G RAD E A PI
Na fu ra lly a sp lrat eil englnos APt cB or cc 1

T ur boc h ar ge d eng Ine s API C D or S HP D
V IS C OSI TY G RAD E
T e np gr atu re
S A E gr ade
-30 -20 -10 +10 +20 +30
5W-20 5W- 2()

5W-30 5W-30
5W-40 5W-40
10 w 10w
10W-20 10w-20
10w-30 10w-30
10w-40 r 0 w- 4 0
15W-30 1 5W-30
15W-40 1 5W - 40
20w-20 20w-20
20w-30 20w-30
20w-40 20w-40
30 30
0ll of CD gr ade c an a ls o b e us ed I n na tu rE I l y a sp l ra +e d en g I n o s
a f+ er ru n- ln p€ r I od.
6 -8

cooltrG sYsrEr,l
tEX
T ec hn lc r l d a ta ............. .. .,. .... ... ... .. 7- |

Spcl.f t@fs .... . ... ... ... 1- 2
C ons fr u qtlo n.... .. ... ... ... 7- l
RsDalr I nstrustloos
l. Thenrcsfct
A . Re no v lnga n d Ins p ec tlng ihe t hq' dpsi at.. . . ... .... 7- 5
2. Cool ant pulp
A . Re mo v lngfh e c oo lan i pum p.. . . . . . . . . . . . .. ... ... ... 7- 5
B . Re co n dlilon ln g fhe c oolant punp ( 309, lll and 4ll
Ip a c ka g e b 6 ar lng s n) ... ... .. ... .. .. .. .., ... ... ... . 7- 5
C. Re c on dlflon lng tha c oolant puip ( s€pöraie ball bearlngs
,ll,'lll,6ll an d 6 12 ).. ... .. .. ... ... ... ... ... ... .. 7- 6
D. fn s ta llln g ihe c @lan+ pump.. . . . . . . . . . . . . ... .., .. 7- 7
vAlitEr
IECHiIICAL D TA (reJect llmlf of par+ s'ialed ln bracke+s atier rallng)
Coolcnt punp (t09, lll, 'lll englnes)

ouislde d lame+erof boarlng 1 8 ,08 7 ,..1 8 , 1 0 0
Dlameter ot b€arI ng houslng 5 8 ,0 7 5.. .18 ,| 00
Sh6f+ d lame+er 1 5 ,9 O7 ...1 r,9 2O
I npel ler ho le d I a ms fe r . . . . . . . . 1 5 ,8 81 .,.1 5 ,8 99
lmpeller should bs pressed on+o shaft so +haf lfs rear end ls In depfh of:
- t roo r ea r su rf ac e o f b o d v .. .. .. .. .. ..
Hub pleca should bo pressed onfo shafi so thdt dtstanca o{ tlxlng level
ot lt s f an fr o m re a r su r fa c e o f { a +e r pum pl s (5 0 9 ) ..... ... 157
Hub pleca should be pressed onio shaft so lhat dlstanca of flxlng lavel
of lt s f an tr o n r e a r su r fa c e o f b a c k pl6t e l s (5 11 , 4 ll ) | 7 4 ,t...1 1 4 ,7
D l amei€r o f f a n h u b . .. .. .. .. 2 5 ,O O..2
. 5 ,20
B alancI ng p r e c lslo n o f f a n .. .. .. .. .. 0,1 Ncmmax
M ax . perm lss lb le gc c e n +r lc liy o f f dr . .... .. ... ! 0 ,1
C@lant puip (rlth s€plrrie ball b€arlngs, 5ll drd lll angln€sl
outslde d lameter of bearIng
D lanet er o l b e a r ln g ho u s ln g ,t,9 7 9 ...r2 ,OO 9
Shati d lane+er ai bearlng | 9, 980... t 9, 991
S haf i dl am e +e ra + l n p el le r 1 r, 1.. .1 5 ,9 20
lm D eI l€r ho le d la me t e r . .. .. ... 1 5,8 8 1... r 5,8 9 9
l mD eller s h o u ld b e D r e ss o do n +o s h a ft so fh a i l+ s re a r fa ce l s o n le ve l
rl th s höli en d . . . . . . . . . . . . . (dlslance betreen body
a n d l mp € l le r e d ge :
t ...1 , 1)
B alancIng p r e cls lo n of f a n ., ... .. .. . 0 ,3 N cmma x (10 p c m)
M öx . oerm lss lb le e c ce n t rl cliv o f fa n .. .. ...... 1 0 ,1
T lgh+ enln g to r qu e o f b o ll p u lle y f lxln g nu+ 1 00 Nm
Coolanf punp (6ll and 612 €nglnest

Ouislde d låd€ler ol bearlng 52
l ns lde dla r Ele r o f b ea r ln g h o u sln g ln pum pbo d y 5 1,9 1 9 ...5 2,0 O 9
Shoti d laneter at bearlng 1 9 ,9 8 0 ... I 9,9 9 '
Shaft dlarrter at InDeI ler 1 5,9 0 7 ... | 5,9 2 0
lnpeI lei h o le d ia d | e te r . ,, .. ,. . | 5 , 8 7 6 ... I 5, 89 4
lm peller s h o u ld b e p re s se d o n t o s h a f+ so + ha i l ts rea r f6 co ls on le ve l
r l fh s halt en d .. . .. .. ,. .. . . (dlstance betre€n body
and lmpeller edg€:
0 ,3 ...0 ,6 )
D ls i€nc e of b e l+ p u lle y f rq n r e a- s ur fa @ of b o dy ... ........ . 115
B alanc lng p r e cis io n ol fa n . .. .. .. ,. . 0,5 Ncmmax (50 pcm)
M ax . oerm lss l ble e cc e n tr ic lty o f f an .. .. ...... 1 0,l
Tl ghi enl ng to rq u e o f b e lf p u ll e y f lxin g n u + 100 Nm
Th€fiFstrts:
Spare pa-t no Type openlng b€gIns at Fu I ly open ai o p en l n g m m
8160 t 5l5 6 ö 54/7*. 77.. . moc 940C
8560 154 89 ö 51/$q, 80. . . 850C 9oc
8561 I56 46 6 61/1*, 77 ...8 t(t 940C I
8t 6l I5? r 8 6 67/8t<1 8 t .. .8 50 C 970C
8t65 590 6 61/giq, 8 t ...8 5 0C 950C
't

SFECIALTOOLS(CoolIng sys+em)
t. 816 0 | 30 9t Coolan+ pumphub exirac+or
2. At60 A5499 Coolanl pump l m p e l l e r e xtr a c+ o r (f 0 9 , f l l a n d 4 l l )
3. 9025 415co Coolant pumplnp€ffer exfracfq rcll, 612,
4. 9051 40200 F l tt ln g t oo I for coolant pumpaxlal seal
5 .9 0 51 649 00 F l t il ng t oo l f q ' co o l a n t p u m psh a ff ( f 0 9 , fl l a n d 4 l l )

CML I NG SYSIEi,I lh€ripstct 109, lll rnd 4ll
CONSTRT'CT
ION
CoolIng sy3tdtr 4ll
Thermosta+housI n9 tll and 4 l I

l. Thernos+ai l.
2. By -pa s s plp e Hexagon sockg+ screr 6. Hexagon socket
5. Radi a+or 2. R eturn p l pe screr
5. Gäskel- 7. Gaskei
4. C@l ant pump 4. Therrpsiat 8. By-pass p lpe
The cool ln g s y s iem ls lll us tr a l' ed l n fl g . 7 l . 5. Thermostai houslng 9. Gosket
The coolant punp (4) sucks fhe coolant trom th€ The J09 . eng ln e has c n ornal sl n gl e- ac i ln g
unders ld6 o f ihs r öd lator ( J ) an d D resso s l t lhornpstat. The theritost6i ln the lll änd 4li
Inl-o thg c @lln g jac k ei s ur r oun dlng the englnes ls the so-cclled double-actlng iype
c yllnder s In th € c y llnd er b loc k . Th ro ugh the {hl ch rog ulafe s i he coo lo ni clrcul ail on b e t r €€n
holes In ihe cyllnder block +op face th€ the by-pass and the rödlator.
c oolani r lse s In to ih e c y llnd er h ead än d
fur+her onto th€ thernoslai (l ). 6l I and 612
englnes ha ve a s €p är at e c @lan t o uilef ral l to The th ernpstat l s placad ln a ho usln g flx ed t o
dlr ec t t he co o lan t f ro m th e c y lln de r h ead s ln fo the cyl ln dsr he ad tron+ fa ce . The by-p as s p lpe
the thernostEt houslng. }rlth lts gaskel lles beir€en ihe +hermostaf
houslng and ihe coolanf pump. The +herflpstaf
l{hen the englne runnlng iemperaiure ls lorar opgns ai ihe temperoture of 7fC. In rlnigr
than ihe apenlng teiperature of ihe th€rmosta+ o ihermostat vrlth of|enlng +enperature of
+he c€olani relurns fhrough the by-pass (2) 85 o C can be used.
siralghf Inio lhe coolont punp and then back
Inlo + he en g| n e. Thorrpstct 6ll cnd 612
l{hen the englne runnlng iemperature rlses up to

the ihermostot control ronge ihe thermostät
opens, le tll ng p or i o l the c@ lan+ cl rculåte
+hrough fhe radlöior ond part +hrough ths
by-pass. l{hen the thermosta't ls lully apon lt
c los es + h e b y - pc s s plp e ( no + J 0 9 engl ne ) an d
+hs c oo lan i fl o|. s thr o ug h ih e ra dla i or o nl y.
The by-pass arrongemgn+ ensures a steody
ieDper a+ ur e In g ng lne u nd er all c lrcum stanc€ s.
C@I cnt
Ths c oola ni us € d ls o nlx t ur a o{ glyco l-basgd
antl{reeze änd water rhgre ihe DroDortlon of
ihe antlfr€€ze ls l0 to 50 t. Due to l+s antl-
c orros lve q u allt les the an ilfr e€ z e sho uld b€
used In th e s u igr iln e a s re ll. C hö nge the
coolant every fro years. Never use plaln rc+er
as c@l ant I
7- 3

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

+emperaiures. l{hen fhe coolan+ tqnperature ls
belo{ +he thermosiat opgnlng temperature fhe
c@lan+ (A) clrculales through the by-pass hole
ln i o th e c oolanf pump. T he s rnaller, g l n g l e -
a c+l ng + ha r mostaf (l) opens flrs t (a+ 7 9 o C ) ,
let+ln9 par+ of ihe coolant (B) into lhe
ra d l aio r . Follol' lng the load lnc reas o, al s o l he
other lhermostat (2) opens (at SloC). Thls ls
a d o ub le -a ct lng +y pe l{hlch c los es the b y - p as s
h o le wh en li opens and dlrect s lhe c oola n + ( C )
Into fhe radlalor. These englne lFdels do no+
have separat€ r Inter-+yp9 thermosia+s.
C@l ant purP
Th e c ool an l pur p ls a can+rltugal pumpll xe d i o

ihe cyllnder block tronf face. The purp ls
dr l v en by l he cr€nk shali bel+ pulley + h r o ug h
th e v- b elt . T he J09, 3ll and 411 engln e s h a v e
+he pump shat+ and bearlngs ös an Iniegrated
u nl + or +h e pumpls equlppedrl+h s eparate b a l I
be a rl ng s. I n 6ll and 612 englnes fhe co o l a n f
p um p l s fur nls hed llilih separafe ball be a ri ng s .
Th e l mp eller ls flxed fo the s haf+ w l + h
pressed-on fl+. The €xlal seal on the pumpbody
and the ceramlc counter rlng rolailng on ihe
shaft take care of lhe seallng. The pump body
h as c o nne c tlons tor the fluld clrculail o n o f
the heatlng devlce ond ihai of ihe oll cooler.
The f09 and fll englnes also höve a connectlon
fot' ihe b lock hoaier.
Coolan+ pump, separate ba| | be6rIngs, ll I a n d

4l l a n gl ne s .
l. L o c k ln q rl n o 12. Gaskei
l! Ee a r t ng lf. Back plat e
f. Bush 14. Hexagonscrew
4. Sh a li 15. Hexagonnu+
5. Shafi sea I 16. Washer
6. Orease nlpp le I 7. Bel+ puI le y
7. Body 18. Key
8. S eö ll ng rl n g 19. Hexagonscrew
9. P lu g 20. Connec+or
10. A x la l s ea l 21. Seallnq rln o
l l. lm p e l l er Z Z . \j a sK e i
7- 4
f,ORKINSTRI'CTIO
S IHE @0L |tT pt[f
B. RE@ND|T|ON|NG , ftl
'09, '
c00L G sYsIErl
|. IllE 0,r)ST T
A. RErcYINGArI' INSPECTI]€T}C T}€S'PSTAT
l . Dra ln +h e en gln e c oo lani unfl I th e flul d l evel

ls underngath the thermosia+ houslng.
2. Renpve fhe uoDer Hater hose from ihe return
plpe . Op en ihe retu rn plp e flx lng scrers an d
remove tl|e rgiurn olDe and +h9 thq-nostal.
5. lmmerseihe thermos+af ln a waler conialner so
+hat lt cannot louch iho *alls or lhe boi+om.
4 . tlä rm u p +he w oie r slo wly , no fl ng lh e r lse In
tempera+ure on å thermometer. Compare lhe
openlng ienperafure of fhe fhermostai and *he
fempera+ure rhere lt ls lully open rlth lhe
ra fln g (s ee te ch nlc al do ta, pol nl
rThernpstalsn).
5. lf the therrpsfat valve stlcks or ihe thermo-

s+ai opens ai foo lori or foo hlgh a +empera+urg
replace the thernostai.
Clean iha seöllng tac€s of the therrpsfaf

houslng and the reiurn plpe. Place the thermo-
st at I n pos ltlon rlih th e by -pas s closl ng dl sc
dornr€rd. Rgplace the return plpe gasket and
Inslall the return plpe and the upper xa+er
n0se.
7 . Flll th e c oo lln g s ys +e n. Sia ri ihe e ng lne and

ch ec k for po ss lbla lo ak s. Run + he engl ne t. Renovs iha fan t lxlng hub from fhe shafi lalth
llgh +ly lo ad lng lt u ntll yo u s ee ihöi ih e exirac+or 8560 | 1091. Remove the lod(lng rlng
thq-mosia+ ln lts posltlq| operetes nq-mally. frorn +he pump body.
2. @OLANT flTP
A. REIOY I G IHE MLÎ{T PIIP
l. Dr a ln +h e en gln e c @la nt. Dlsc onn eci + he upp€r

and ihe lorer rater hoses. Open ihe tlxlng
screis of the thermosiai houslng, renpve the
houslng and the by-pass plpa.
2. Renrove fh€ hea'i'lng deylce connecilon, +he ol I

cooler connecilon and ln the case ol f-cyllnder
en g ln o s +h e blo ck hea ier (ll ass embl ed) {r qr
the c@len+ punp.
J. Loosen lhe aligrnaior flxlng scrers. Open lhe

lan flxlng scrers, reflpve ihg fan, the pulp
pu I ley and the v-beli.
4. Open the coolani pufip flxlng screys and roflbve

the punp. Rerpve ihe gasket bgtreen the pump
a n d lh e cylln der b lock and cle€n i he s eal l ng
t€cas.
76
2. open the bock plafe flxlng screr and reflpva the

back plaie from the purp. RErove the ltnpeller
from lhe shaft xl+h exiractor 8560 85499.
5. Press the shaft oui of +hs bodv towards ih6 tån

wli h e.g. a hydr aul lc pr ess. Su ppor t t he b od y
so that ih9 bearlng cones oil+.
4. Tap out +he shafi seal rlih å drlfi. Clean fhe
parts and ch€ck lhelr condlilon. Replac€ rorn
or defecilve par+s rlth ne{ ongs.
7- 5

Notel lf vou ne€d +o replace the purnpshafi, RECONDITIoNII€ n€ CooLANT R tlP
the bes+ soiutlon ls to ossemblea pumprepalr
( S e pa r6 +e
b a l l b o a rl n g stl 1 , 4 11 ,6 1 1' 6 1 2,
kl + shlc h ln c lud e s all ga sk e is n ec es s ary fo r
recondlilonlng (see spore par+s catalogue). 1. op en the be lt pu ll ey fl xl ng nut an d ren ove t he
pulley. Uso exfracior 8560 15091, lf neoded.
Press the shöft In lis posl+lon ln +he body
,fih tool 905'161900. Install the locklng rlng.
R€orove ihe l|tpeller from the shaft vl+h
extracior 8160 85499 (fll and illl englnes) or
extractor 9025 4l5OO(6ll cnd 612 englnes).
Removethe locklng rlng fron ihe pump body.
Press the shaf+ and bearlngs out of +he body
i ow a rd s the fan w l +h e.g . a h yd rau l lc pr es s .
Support ihe body so tha+ th6 bearlngs comeou+.
4 . T a D the axl al se als an d sh€ ft se al s o u+ of t h e

b od y l rl +h a d rlfi . C le an th e pa r+ s an d c he ck
i h el r co ndl il on. R gpl ace w orn or d efeci lv e
oeris wl+h ne|l{ones.
N oiel lf you n eed i o re p l ace the p um p
beärlngs, l-he besi goluilon ls to assembl6 a
p ump rep al r kli yh l ch l n cl ud es al l ga sk e t s
necessary fo|- recondltlonlng (s€ spare parts
cata I oguo).
5. T6p the ner shafi seal onfo the body {l+h a

su l la ble drl ft. P lace fh e bea rlng s and t he
lntermedla+e bush on the shölt. Lubrlcate +he
beo rlng s w l ih a su fflcl ent a mo unt of h s at -
reslsta nt ba ll b earln g gre ase. P l ace l h e s ha{+
77 and +he be arl n gs ln po sl tl on 9o thal +he {or c ss
caused by the presslng are not +ransmlffed
th ro ugh ih e ba ll b ea rl ngs. F l + ihe b ear l ng
6 . C l ean +he sha f+ a nd the ax la l s e al re cess o n l6k lng rln g.
+ he pum p bo dy . Pl ac € ih e pla s ilc c o ve r ed seal
and counl-er rlng on fhe shaf+. lf necessary, 6. Clean +he shaft and the axlal s€al recess on
use an+ lfreez e a s r rlu br lc an tr' . T ap pln g i he seal the pump body. Place the plasilc-covered seal
ln Dosltlon wl+h drlf+ 9051 40200 rernovesl-he and counier rlng on thg shaft. lt ne@ssary,
p las ilc c ove r e hlc h p os s lbl y co m eso u+ trlih th e use an tlfreezo as n lu brlccntn. To pp ln g the s ea l
drl fi. t f lt r en a lns ln th e h ous ln g, re trpve l t ln Dosl+lon ylth f lft 9O5l 40200 removes +he
be fore fl ttlng ih € lm pe ller . plastl c cov€;rrh l ch po sslbl e com€so ul vl th- t h e
drll t. ll lt rem al n s In ih e ho usl ng, rerpve l t
befo rs f l ii Ing fhe lm pel ler.
78
Press l'he lmDeller and fhe hub on the correct

post+lon, supporilng lhe shal+ at the qther
end. Ensure fhat the shoft rofaies freelv.
8. Flx ihe back plale on the body and rep laco the
OaSKeT.
C o olan t pu mp6ll ,6 12
/ -o

Press ihe lmpeller ln poslilon suppor+ln9 one
end of the shaf+. The shafl end and the
lm pe ll er c entre are levelllng, whlc h m 6 a n sth a +
+he dlsiance b€teeen ihe body End the lmpeller
r ea r edge ln 511/4ll englnes ls 1.. .1,3 mma nd
ln 61 1/612 engines 0,f. ..0,6 nm. E n su re i h a t
+he shaft rolates freely.
Fl x i he belt pulley onto lhe s hafi a nd tl g h i e n

Its fl x lng nut to ihe +orque of l0O N m .
Ir{sT LLtrG I}tE Coot.ANI Pti,P

Replac€ ihe gaskei between ihe pump and the
c yl ln der b lock . Ins +all +he pump a n d + l g h te n
fh s f lxlng sc rers evenly and In tur n a ro u n d th e
bodv.
Fl x the pulley , v-belt and fan. T l g h te n i he

a lierna+cr- flxing screws.
J . Ins fal l +he connec tlons for the he a tl n g de v l ce

and oll coolgr and +h9 enolne heafer of ihe
f< y I Inder engInes.
4. Flx the by-pass plpa vil+h nett gaskei In lts
po s li lon on iop of fhe pump. In s i a l l th e
lhermos+a+houslng ln the cyllnder head, a+ the
sanE +lme mounilng ihe by-pass plpe beiweenihe
puip and ihe houslng.
5 . Fl x + he uDoer and lower {a+Er hos e s. Fl l l th e

e ngl ne cooltng sy s+ 9mand c hec k fo r p o ssl bl a
le ak s.
Noi€l lf you lntend to lns+all a coolant pump

wlih a net| sprlng sgal and counler rln9, the
cool ani mav drlo from +he hole underneath +he
pu r p durlng +he flrsl run hours . Th l s l e a k
should siop yrhen lhe seallng faces adjus+ io
each other.
T-T

II{.ET AIO EXHAUSTSYSIEI{, TURBOCMRGER
I to€x
Technlcol dato
construcf I oo 8- l
Reoalr lnstruqtloos
l. Inlet cnd exh.ust systerl

Insp ec tlng the alr fllier U- J
B. Insp ec tlng ihe Inle+ and exha usl pl p es .. . .. . .. .. . a-t
Turbochargsr
A. Do+ ermln lng ths c ond ltl on of f he +ur bochar ger, . . i .. . .. .. . .. . .. . .. 8-4
B. Renpvlng the iurbocharger 8- 4
C. Recondltlonlng th€ furbochargtr v5
D. Insfalllng + he turboc ha rger . . .. . .. . .. . . 8- 6
E. Ins+ alllng ihe In ierc ool er -
VA1DIET 8- 0

INLET ANDEXHAUSTSYSIEM
@NSIRI'CTI ON
In lei cnd €xhrusf systen 4lt Ds

l. Cyclon€
2. Hexagonnu+
f. F I I ter
4. llasher
5. F | | ter
6. Hous lng
7. Gaskei
8. C lamp
9. Rubber plpe
10. S ervlce Indlc aior
l l. I nl et plpe
12. I n l ei m anlfold
lJ. Hex6gonscrei
14. Turbocharger
15. E xh€us tmanI fold
16. Ol l return p lp6
17. P rgss ure p lpe
18. Connoctor
I 9. S eaI Ing r ing
20. P lpe
21. Ol l plpe ban d
Technlcrl dqic
Turbochcrger
Hols€i HID
0ll prgs su re a t ru nnlng sp eod ........ .. . n l n. 2 b ar

E nd Dlav of sh af+ ........... o , lo . . . o , I 6
RadI ol olav of s ha f+ ........ 0, J0. . .0, 46
Tl ghtenlng iorq ue of +urblne ho us ln g re tal n l ng scr etr s (Mgxl 2 ) . .. . I l ,J N m
Tl ghtenlng + orq ue o f iu rbo hou slng re +al nl n g scr ers (t { 6x12} . . .. . . 5,7 N n
Tl ghtenlng torqu e o f bea rlng hou slng re +al nl n g scr ers (M6xl 6 ) . .. . 5,7 N m
T lght enlng iorq ue o f he xö gonnui of shaf t .. . .. . .. 14, 0 N m
Threåd ot shaft: lefi-handed
G ar ret T0 4BTT
Ol l pres su re ai runn ln g s pe €d ......,. .. . . . .. . .. . ml n. 1 ,4 b ar
E nd play of sh a{-i ........... .. . 0, 025. .. 0, 10
Rodlal play of sh afl ........ . . . 0, 075. .. 0, 18
T lght enlng iorq ue of hex ag onsc rers 5/ 16 -'18 . .. . .. . .. .. . .. . .. . .. . . lil Nn
T lght enlng torqu e of hex ag onsc rers l /4 - n . .. . .. . .. .. . .. . .. . .. . . l0 Nm
Lor pressures rnd back-prGsures

V ac uumlnd uc €dby alr clea ner . .. . .. . .. . .. . .. r. . . möx. 5 kPa (500 rm r.c. )
E xhaus+p lpe bac k -p re ss ure . . .. . mE x. o K r a (600 m e. c. )
8-1

T he e n gl ne f l l + e r ln g s y s t e m f or + h s ln l e + a lr Th e e ng lne s h öv e an e x hau s t ch arg er, l.e . 6
m os f l y c on s ls t s o f t h e c y c lo n e a c i ln g a s pre - iurbocharger where par+ of ihe energy of the
J l lt er and +he o a o e r-€ l e me n i f ll t e r a s f h e maln ex ha us t ga so s ls u tlll ze d io g ef n pre a lr ln to
J ll f er . I n t h e c v c l o ne t h e ln l e t a l r l s ma d e to th s c yl lnd s rs. T he turb o ls flx ed d lre cl ly io
wh lr l, w hl c h s e p a r a ie s r io s f o i t he l mp u ri ile s ths top of the exhaust manlfold or to lis 196r
an d co l le c t s i h e m I n lo + h e d u s t c o n t a ln e r. T h e end. The energy of the exhaust gases rotaies
pa pe r f ll t er ha s e l ih e r o n e o r i ro re p l ac o a ble ihe furbine trheel ot ihg iurbo rhlch drlves the
car +rl d g es r hl c h a ro p l e a t e d t o o b + al n an iurbo rotor at ihe o+her end of ihe shaf+. Th9
ad eq uai e f ll f s rl n g ar eo 6 n d e q ul p p e d w l f h a iurnlng turbo roior boosis pressurlzed alr lnto
rEta I support. fh s c y lln de rs. T h ls n E an s i ha t ihe rg ls o
lörger arnouni of alr In the cyllnders lhan
T he l m pur lf l es I n t he I n le t a l r a c c u mu l a i e on normally and lhus rrore tuel can be combusted
fhe ouier surfaco of the carirldge from whlch 6nd Increasod ouiput c6n bo achleved. As +he
i he y c an €as l l y b e r em o v e d . Th e I n n o r f ll f e r or eng ln e e xh au sf g as es d rlv e the +urb ln e rh ee l,
the so-called safe+y glenlen+ prevenis ihe ih € +u rbo a utor nat lc all y od Ju sts io th € e ng lne
lm purl f l s s f r om g e f f l ng l n t o t h e €n g l n e , l l th e load and spe€d.
p rl nar y ll lt sr b e c o me s c l o g g e d or lf i h e f l lte r
as s em bly l s f a u l + y . Th s -t urb o s h afl ha v e b ea rln qs tlx ed to the
bs arl ng hou s lng wli h tro so -c al led tl oai lng
A m ec ha nl c ol o | - e l ec + r lc al se.vlce I nd l c aio r b us hln gs . T he se b us hln gs ar e lu brl c6 ted a nd
can be mounled on +ho lllier houslng or on the c oo led +h.o ug h th e e ngl ne pre ss u re lub rlc ai lon
I nl ef pl pe i o s h o w r he n i h e f l l t e r c a rt rl d g e Is sy s +em . T he s ea lln g rl ng s of p ls fon rl ng typ e
c lo gg ed. Th e ln le i s y s t e m a l s o c om p rl s e s the p rov en t o i I lo ak s tro m +h e bea rln g ho us ln g.
p lp ln g b et w e€ n ih e al r f l lt e r a n d i h e i u r bo ,
the plplng b€+'reen the turbo and fhe lnlet
m anl f ol d an d +h e I n l e t n a n lt o l o .
EOOST AIR I iITER@OLER
The turbo tlxed on top of lhe exhausl' manlfold (DSJ cng l nos I
on at lis r€or end gets lts lubrlcal'lon from
the englns pressure lubrlcal-lon sysj'om through
the prossure plpe and the ol I return plpe.
T he m arl ne e ngl n e s a re f u rn ls h o d v r li h a w a i- er-

c @ l ed ex h aus t m a n lf o l d rh l c h l s c o n n oc le d to
t hs e n gl n€ c oo l a n i c lr c u l a + l o n (' rf r e s h ra ie r
c I r c u l ai lo n),
The opercf lon ot th€ turbchrgcr

(DS engl ncs)
Boostair
Coolant I
Th e e n g l n e s rl i h i y p e d € sl g na tl o n D S J or e
equlpped rlth alr-+o-rater boosi alr lnier-
coollng. The cool Ing slements are encased cnd
I MUILIIA Jo l ne d v,l th th e In l e t ma n l fo l d a n d c o nn e c+ edi o
€ th e e n gI n o co o l a n i c l rc ul ö l -l o n.
PAKOKAASUT
\r-J In ihe c@l ln9 el€monts the compressed Inlot
ö l r c@ l s do x n, h a vl n g a g re a ta r d en s l ty and
VO ITELUÖ
LJY npre oxygen rhlch ls negdedfor the combus on.
: a2
8-2

TMK INSIRI'CTIONS
I NLEI A}D EXHAUSTSYSIEM, NNBMMRGER
t. {LET A||) EpUST SYStEr,l

A +urbocharggdgnglne ls much npre susceptlble
to ln le f a n d e x h a u sf s ys + e m iroub lg s,
lm pur lll es , e ic. , t h a n a In a t ur a ll y a splro ie dr
englne, Thergfore speclal a++antlon musi bo
pald to t h e c o n d ltlo n o f f h e a lr lllie r ån d l he
lnlei a n d g x h a u st Dlo g s .
INSP€CTING
THEAIR F ILTER
Th€ englne performance and llfe are dependeni
on ihe co n d ltlo n o f ih e a lr f llt e r. A fau lty
f ll ler le is t h ro u g h lm p u rll le s rh l ch g ra du al ly
damage lhe iurbo and +he englne. A clogged
f llt er r e su lt s In lo ss o f e n g ln e p o rg r and o lso
of+6n causes an ol I leak frorn tho iurbo lhrouoh
+ he s h a f t se a lln g r ln g .
t . Check ihe cleaned fllter bv p l å c l n 9 a l a m p

lnslde lt. l{ You d€tecf holes or lf ihe f I lier
l s rorn ( l lg ht-co lo ured p ol nfs r h lc h l e t l l g h +
thro ug h), rep la ce ih e fl lt er.
4 , C la an i he { ll +e r ho usl ng lro m fh s l ns l d e i o
remove dus+ and lmpurliles. Check that l-he
gasko+s are Infac+ and thai +helr ma+lng faces
are cle an . P ush ih e fl lt er In to +h€ h o us l n g a nd
en su re t ha t l 1 ls pro pe rl y ln po sl+l o n . T lg h le n
ihe reialnlng nul to the correcl torque (about
1 ...1 ,5 iu rns aft er + he fla ng e ga sk e t +ou c h es
+hs fl l te r h ou sln g € dg e).
tlotol The safeiv elerpnt Inslde the alr
fllier ls not to be rsnoved unnecessarlly In
connoctlon rlih fhe lnspecllon and servlca of
ihe prlmary flltar. Do not clean the safety
slement, bul replace li once a year o. then
ne cessary (see Op era torrs M an ua l , po l nf
S ervlce ).
Refircvethe fllter by op€nlng the nuf ai the end

of ih e fl l i er housl ng and pull out t h e f I l te r.
lf you dcntf In+end io reolace fhe sa { ei y
elerle n i I nsl de t hs l ll + er , t e a ve It ln
oos lilon . B. IIISPECT
IIG TI€ I II-ET AIO EXMUSTPIPES
leftcntl Leaks In the lnlet and exhaus+
plpes impalr thg performonce of the +urbo
conslderably. Due io hlgh prgssure even a mlnor
le ak i n the exha usi m an lfo ld or l n t ha i u r b ln g
I nl et fl an ge m ay g ror ro pl dl y. Th er e fo r e al s o
sDall leöks musi be aftended to lmnedlaiely
öf'ter ihey have been deiected.
Check thai the plpes bgireen ihe alr fllter and

ihe turbo and bett{e€n fhe turbo and the lnlei
E5
C lean +h e f ll te r e lih e r w l+ h ö v a cu umctse ner Replaco ihe gaskets cnd end fix the lnlet
or by dlrgcilng a compressedalr Jef ouixards m an lfo ld . Tl ghf en ih e reta l nl ng scre w s o f +h e
f rom t h e ln sld e o f th e f ll+ e r. m an tto to eve nl y io r0 N n. M ou nt th e al r
The ma x. p lp es care fu ll y.
pressure of thg cpmpressod alr may noi exceed
500 k P a ( 5 kp lc mz ) . R e p la c e th 6 illter o fle r
y ou ha v e cl aa n o d lf fl ve tl me s, a+ lh e lot esf. 6-3

Ch€ck the exhaust manlfold for seallng and ih€
torque of the retalnlng nufs (60 Nm) as
rell as po s s lble d anages (c racks, d ls+ o r tl o n,
@rroslon, etc.). Also Inspec+ ihat ihe iurbo
l s pr ope rl y f lxed to the exha ust manltol d .
6 . Fl x f he oxho us+ m anlfo ld uslng alway s n e w

g€skeis. Run lhe englne rarm and check ihe
torque of the refalnlng nuis (60 Nn).
Ensura thai fhere 6re no extra obs+ructlons ln

t h e- ex ha us t plpe or In +he sllencer whlc h ml gh + aa
b u lld up ex c €sslv e b€c k -pres s ursfo the e x ha u st
gosos coolng from ihe turbln€ vrh€el.
4. Measure the end play of the turbo shaft. Sef
the t ip of the dlat gauge on t he shafi en d a n d
(DS engl nes)
2. TIJRtsOCMRGER nbve the shaf f longl tudlnall y, back and fo r i h .
uqfl pa.e t h€ resul+ rl th the ratl ng.
T o ens u re + hai +h 9 turbo func tlo n ls fa ul f l e ss
lf the €bove Inspectlons reveal dahages oi.
excess lve reaa, renove .i'he turbo for -repalr
(lnstruqtloos, polnt 8 2 B).
DEIEilIINING IHE @T{DITIONOF T}C TURBOCMRGER

^.
lf you suspeci fhai +he operailon of the iurbo
ls uns a + ls f act ory , check lh e follov.tng:
l . C h ec k th e cond lilo n of ihe tu rb lne rhee l a nd
th e + ur bo ro tor vlsually . The b ta des s h ou l d l f i h e e n gl n e op er a fl on Is no + n or ma l an d i h e
have no damag€, bend or qlhe ear coused by lufP Is noi dörnagedo|. excesslvely worn, fhe
fo rol gn pa rf lc les. fo l l oy i n g r e as on s may l l e be h l nd fh e i r ou bl e :
2. S€€ +hot fhere are no oll leaks lnio +he - a l r fl l f er cl og ge d

furblne houslng o|. iurbo houslng +hrough the - l e a ks I n l n l e + or ex ha u st p l pe s
s h af + s e€l s . l e ak s l n g a sk e+o t t ur b o m ou n+ l n gf l o ng e
- l n j e ct l o n p um pi l ml ng l n co r r ec i ö r o pe ia i l on
ot el Du rl n g ldllng th6 re nay oc c ur s l l g h t r a u t ty
o l l l eak a ge ln +he c om pre s s lonslde. Th l s l s - fh ro fi l e l ev er a ge ta l se l y a dj us i o d
however, no reason for concern, unless ll- - l nj ec fo r s f al s e l y ad Ju si äd oi ma l fu nc fl on l n g
causes hlgher ol I consumptlon. - f ue l fg ed p r es su r a l o r ( 9. q. f ue l f l l fe r
clogged)
- englne coopresslon pressure lovr, valve
cl6arances mlsadJusted
B . REI,|oV
ING I}E TURBOCHARGER
R€rnove. +he_re+alnlng scrors of +he exhåusf plpe
an d t ak e of f i he p l p e. D l s co n no ct +h e l ur b o a l r
p l pe s.
remove the p lpe.
,. the turbo ftxtng screrlsand removethe

ifffi:
,. ptuss rn ihe rurbo lnte+ ond
:li::.f."T:r"Jlve
t7
J. Meo su ret he ra dla l p lay of ihe fu rb o sh oft.
+he flp of the dlal gauge on +he slde of fhe
shatt and movethe shaf+ laterally. Comparethe
ro s ul t wl ih ih e ratlng.
8 -4
RE@NDIT (IIOLSETHID)
I otl ll{c IHE TTRBoCHARGER Remove+he turblne vihe€l and the shaft (25)
O Notel Llke r.lth ihe ropalr of fuel equlprFni
+he rocondl+lonlng of 'the turbo should be made
+ og efh er ylt h th e se al ln g rln g (24 ) a nd l lf i
o ff th o lu rbl ne shl el d p la ts (25 ) f r o m +h e
shaf+. Remove the ou+ermost lock rlngs (16)
t ilt h u+ 0 lo s i p r ec islo n a nd c lea nlln ess . lf yo u fron th a be arl ng hou sln g. P u + you r f l n g e r fl p
donr+ have al your dlsposal ihe necessary Into ihe baarlng (15) and pu | | out bqth
s pec lal loo ls, e.g . fo r ba lan cln g +h e ro+a tln g be arl ng s. R on ove+h e Inn er lck rl ng s ( 16 ) .
par t s , dls a s sem b le o nly +u rb o ho usl ng a nd TURBO HOLSET HID 14. Thrusi bearlng
turblne houslng for ihe checklng of ihe rofors. l . Turbo h ou sl ng 15 . B e arln g
In r|os+ cases l+ pays 1o lnstall a replacemeni 2. Hexagonnu+ 16. Lock rlng
turbo del lvered by the manufacturer. 5 . Ro io r 17 . B e arln g h o u s ln g
4. Intermadlale dlsc 18. Hexagonscrev
5. rrsQrr se al ln g rl ng 19 . L ock wa s he r
6. Mo un ll ng p la +e 20. lttounilng plale
7. l{asher 21. Lock washer
8. Hexagon screY 22. Hexagon screw
9 . S ea ll ng rl ng 25 . S h le ld p l a t e
10. 0l l d ef l ect or 24 . Se al ln g r l ng
ll . Gul do p la te 25. Turb lne rheel and
12. Screv, sha fi
lJ. Thrust p late 26 . T urbl n e h o us l n g
27 . S€ al ln g r In g
89
Dlsass€*llng th€ iurbo

Clean the turbo from ihe outslde and clamo li
I n a v lc e ( rl ih pr ot ect Iv e lu gs) u sl ng +h e Clecnlng the turbo prts
f lange a s t he clan pln g p oln +.
N ot gI Use o nl y wash ln g age n+ s yo u kn o w . D on ' t
2 . Mark i'he rela+lve poslilons ol 'i'he turbo raEh ',rlih co-rodlng washlng agen+s, as +hey
hous lng ( l ), In ier r n ed la+e d isc (4), bea rln g dönagesone of the turbo pari9.
hous lng ( 17 ) an d +u rb lne h ous lng ( 26 ). op en th e
loc k ras he r s ( 19 an d 2l) . W asho { f a ll d lr+ fro n + he D ar+s wl ih ih e w a s h-
l ng a go nt. Use a p la sil c spa tul a o r a b r u s h io
3 . Ren|ovethe i-urbo houslng screws (8), rashers cle an th o al um l nl umpa rfs.
( 7) and m o un tln g pl aie s ( 6) an d llf t off th e
iurbo h ou sln g . 2. Cl ean a l I o ll ch an ne ls vrl ih pre ssu r l z e d al r .
E nsure t ha i al l jo ln is a re cle an a nd l n go o d
Loos€n ihe turblns houslng screws (18). Renove con dI t lo n.
t he lock w a s he r s ( 19 ) an d m oun tln g pla te s (2 0)
and I l li o ff fhe be 6r ln g h ou slng lrom -th e Chscklng lhe turbo psrls
+ urbIne ho usl ng.
l. S ha li - i urbl ne wh ee l com b ln atl on
Hol d + h e lu r b ln e (h ee l b y + he foo + sl+u ate d I n Check the bearlng surfaces for woar and
ihe nlddle of the vlh6el and remove the roior scratches. Minor scraiches are alloved.
reialnln g n u t (2 ) . P ull ih e ro ior (5) off fro m Ch eck +h e se al ln g rl ng groo ve l{ a ll fo r
the shaft. scratches. Mlnor scraiches ar9 allougd.
Ch eck +h e tu rbl ne rrh eo l b la des f or po s s lb l e
NoteI The thread of ihe reialnlng nut ls dan6ges, b€nds and cracks. Under no clrcun-
left-handed. Do nql bend ihe shaft. stcnc€s b€nd the blades.
Open the screris (22) flxlng ihe lnfermedla+e Thrusf bearlng se+
dlsc io fhs bearlng houslng and removelhe lock ReDla@ worn or dofgctlve Darts
tiashers (21). Take oft the Iniermedla+s dlsc Thrus+ bearlng ol I grooves should be clgan
(4) and fhe ol I def leclor (10) frorn the shaft.
Press l-he oll daf lecloc off the back plate and Turbo rotor
rem ov e t h e se alln g r ln g ( 5) fr on th e l nt er- Check the turbo rofor blades for posslble
nedlat e d lsc. Llf t o{ f th e oll gu td e p la te damages, bends and cracks. Und€i no clrcuF-
( |l ).
stoncas b€nd the b I adas.
7. Loosen the rotalnlng scrers 2) of the ihrus+ BearI ngs
bearlng. Renove +he +hrus+ pla+e fif) and +he Replacp worn or scraiched bearlngs
t hrus i b e a rIn g fi4 ) .

5. B e ar ln g hou sI ng
- R6pI ace bearlng houslng, ll fhe bearl ng
surtacos or- the seallng rlng groovgs are
notably rorn or scraiched.
6. Roiatlng paris
Chock ihe balanclng of the roiatlng parts
rS Qr s 6a ll ng r 'ln g
Rgplace damaged,vorn ol- hardened seallng rlng
8. T urb o hous l ng a nd +u rb lne h ou s lng

Check th6 houslngs for any damageor cracks
caused bv the coniact of the roior or detects
du6 io posslble overheatlng. l4lnor damagescan
be accepted, bu+ ofher*lse replace ihe houslng.
AssembI lng the iurbo

A f ter c le anln g a n d Ins p ec tlng ih e tur bo p art s
c ar ef u ll y a n d r e pla cln g ihe fa u l+ y par is,
assembleihe +urbo. Perlorm ihe assenbly In the 8 l0
reverse order comparedio dlsassenbly. Pl6ase
p a y 6+ + en t lon io fo llo wlng p o ln ts :
Notof Siarflng fron turbo se.lal rto. 841272,
T he r ot at ln g pa rts sh o uld be b ö la n ce d |r lth an a seal lng rl n9, spare par+ no. 8f5f f 9104 , ha s
accuracy of 1,44 gfln a+ both ends. Ensure been placed bein€€n +he +urbo housing and ihe
i h at y ou t ln d the ma rk s y o u n ad e d u rlng dls- lnterm edl afe dlsc. T ho iurbo houslng of ol d er
e s s em bl y I nd lc atln g the re la+ lv o p o sltlons oJ turbqs can be sealed by placlng an o-r lng se al ,
dl fforeni parls. order no. 6146 12114, bei{e€n fhe houslng and
fhe dlsc.
P l ac e + he lo c k r lng s In +h e lr p o s ltlons wl th
fhe chanfared slde lowards l-he bearlno.
f . L u br lc at e f h€ s u rfa ce s o f a ll be ar lng houslngs,

t h rus t par t s a n d s e als ,lth p laln en g lne oll. D. IISTALL I IG Tlf TIRB&MRGER
4. |{h€n you set +he shati +hrough +hs shlsld plate Flnd ouf fhe reason for fhe danageof the turbo
and ln+o ihe bearlng houslng and +he ol I and alvrays el lmlnate the cause of +he defeci
def lector lnto +he lniernodla+e dlsc donrl before lnstal llng a ner turbo.
f o rc e t he s e al ln g r lng s ln to po s ltlo ns, for
tlEy may broak oasl ly. To make sure ihat lhe turbo functlons properly
It l s essonilal + hat the englne lube ol I l s
5. Tlgh+en ihe ihrusi bearlng scrers to the torque ch€nged acco.dlng to Insfruc+lons glvon and
of il,5 In. that correcl oll grade ls used. lnstruc+lons
regardlng the servl ce of oll and al r f ll ; ie rs
} {hen I ns f al lln g ih e ln+ e rm ed laie d ls c lnt o the should also be f ol lolr sd.
bearlng houslng be careful noi io damogeihe
The adJustmeni of ihe Injectlon pump has a
' S Qr s e al ln g r ln g. dgcl slve lmpac'ton ihe f unct lon of + he tur bo.
Tlgh+en the lurbo roior relalnlng nu+ to the Therefore, ihe manutac+urerr s Insirucilons
t o rque of l 4 r 0 Nn . apply for +he pumpadjusiment.
Not€l The nu+ has a lef+-handed +hread. lvake Check + ha+ ihe exhausi and lnlet m anl folds are
sure you donr+ bend +he shaf+, tjse a sul+able proper ly fas+ ened and thelr jol nis tl gh t.
T-wrench or torque wrench. Ensure ihat there ls no loose carbon resldue or
rust or o+ her forelgn par+ lcl es lnslde t he
Sgt the dlal gauge on lhe shaft end and meösurg månlfol ds.
l h € end pla y v h lc h sh o uld b e 0,10 ..0,16 rn.
T he r ead ln g c a n be s llgh ily sm a lle r , lf a lo+ Fl+ the turbo flange on ihe iop of the exhaust
o f o l I ha s be o n u s e d d u rln g th ru s + bearl ng manlf ol d. A lw ays use a ner gaskei .
as s emtDy .
A ttoch the lnlet plpe and +he exhaus+ plp e on
9. Set the dlal gauge on the shaf+ slde and the turbo.
t p €s ur e ih e r ad la l p la y, T he r ad lal pla y s hould
b€ 0,50...0,46 rn. Pour ploln engl ne ol I Inio + he bearlng h o usl n g
through the ol I Inl el io ensure + he lubrlca tl o n
10 . Tlghi€n fhe screws (22) b€tve€n ihe bearlng of the iurbo bearlngs af+er start.
houslng and the Iniormedla+e dlsc fo +he lorque
of 5r7 n, the turbo houslng reialnlng Flx the pressure and oll return plpes of ihe
s c re r s ( 8 ) io 5 ,7 N n € nd lhe iurb lne turbo, uslng ner gaskets. Make sure +hai ihg
ho us ln g re iö ln ln g s c re { s (1 8) to ll,3 l{n. turbo l s wholl y suppori ed by lt s fl xlng fl ang e
and that fhe plpes do not cause any pressuro on
| |. Ensuro thal the shafi rotates froelv. the turbo.
12. Attach ihe lck rashers (19 and 2'l). Pull +he stop lever lnlo stop poslilon önd +urn
ihe engl no wl th +he si artsr for a xhll e. Th ls
guarantges that ihe ol I Dressure rlses bg{ore
startlng. Star+ the englne and check +hai there
are no leaks from +he DlDes.
8 -6

E. INSTALLII{G THE I NTER@OLER
8 11
Cross-secflon of I nlercooler
l6 t 1 / 6 12 \
Flt +h€ lnlet manlfold + o ihe c v l l nder head.

R6place the gaskeis boii€en fhe cyllnder head
a n d t h e Inlet man llo ld ! Fli ihe pl ugs f o| - the
u p p e r r ela lnlng s c rer h oles In the I nl ei
ma n lf o ld c l + he 6l'l1612 englne s .
Pla ce a n e y s e al qr ioD of fhe lnl ei m anl f ol d

and lorer tho cooler in lis Doslilon. Set a
gaskei on top of ihe cooler flxlng flange and
lns+all fhe lntercooler houslng on top of +he
coo | €r_.
412
Then f l x i h e w a+ er p lp e an d d r a ln l n g p l u g
g uldes . P l ac e o-rl ng s ea ls l n to i h e g u l d e
grooves and apply seallng conpound6909 ,0024
on ihe face leve ls.
Atfach tho r.a+er Dloes on +he cooler and -ihe
boost alr plpo on ihe cooler houslng.
ö- I

FIEL SYSIEM
I I{DEX
Te ch nlcol dato ........... . . . . . . . . . . . . . . . . . 9- f
S p €claf to ofs ............ 9- 2
Co n struc tloo lnd cperctlon ................ 9- l
Reclr Instrustloos
l. Fe€d purp
A . Bleedlng the fuel s ys+em.. ...... 9-ll
B. Measurl ng+ho feed pres sur 9................ ...... 9-ll
C. Checking+h€ overf l ort v a lve. . . . . , . . . . . . .......... 9- ll
D. DlsrDuntlng +he teed pumpand checklng the va|ves..............,.. 9-12
InJeqllon purp Bosch iAi

A . Checking the Injectlcn iIm1n9........... .........9-13
B. Adj' rs+ lng ihe lnjec+l on t I mI ng. . . . . . . . . . . ........9-14
C. RenovIng the Injectlon pu mp.. . . , , . . . . . . . ......... 9- 14
D. Moun+lngihe Injecilon purlP............. ......... 9-15
E. Ch€cklng and replaclng the pressura v41v e......................... 9- 15
F. Adjustl ng ihe ldllng sp€€d.. . . . . . . . . . . ........... 9-16
5. I nJoctlon purp Bosch iPi

A. M ounl'lng+he lnjec+lqr pu mp.. . . . . . . . . . . . .........9-17
B. Checklngand adjustlng the Injecilon t1m1n9....................... 9-18
C. Adjustlng ih€ ldllng spe€d............ ........... 9- 19
il. I nJ€qtas
A. Dlsmountlngthe lnjectors .... .....,.............. 920
B. Checklngiho Injector..... ...... 9-20
C. Dlsas s€rnbllng,chec klng and assembllngihe Injecfq......,........ 9- 21
D. fnstalffng lhe lnjec tor In the englne.... ........ 9-22
5. I nJ€ctlon plp€s
A. Insialllng the lnJ ecilon p I pes. . . . . . . . . . . . ....... 9- 22
Fu e f s ys+ernequlpm entand fe€dlng +ables. . . . . . . . . . . .......... 9-23
vAlitEr 9- O

IEO{N ICAL DATA
InJoctlon purp BOSCfliAr ,(8, tll, 4lt, 6ll
Ty po (pum p/gov erno r)..,......... B oschP E S . . .A , / R S V

I nj ecf l on orde r:
109, ll l .....,.. 1- 2-3
4 ..........,,. | -2-4-t
6ll ............. | -5-t-6-2-4
0 irect lon ot rotailon cl ockr l se
DIai€ter of pumpelen|ent 9,5 rm
Stroke . . , , . , . , . . 8n
I n j e c+ lo n a dv anc e r. . . . .. . . . .. . . S e€ l nj . pui r p odJusi l n g valu es
O ll t ll ll ng s l:
t@ , 3 11 . . . . . . .. . . . . . . . . O, l
4 l I . . .. . . . . .. . . . . . . . . . . . .0 ,4
6 ll . . .. . . . . .. . " . . . . ,. . . . 0, 6
Ti g h +e n l nq f or q ue of f he p r es s ur e v alv e hol der . . . . . . . ,. . . , . . . . .. . 40 Ntn
T lg h t e n lng t or q ue o f f he p um p ge ar re ta lnl ng nu t . . . . .. . . . . . . . .. . . 90 NM
I ) I{ h e n I n s ta l l ln g + he I nj ec t l on pu mp .
F e e d p u m p, i yp e:
1 0 9 , fl t . . . .. . . . Bosch FPIKSG22 N 6/2
4 lt , 6l t .. . , . .. . Bosch FP,/KEG22 tO 22t/2
Cons+r uct Ion Plston type, seParaie
nano pump
Fuel feedlng p re ss ure (open ln g p .es sur e ot the over- fl o r yal ve) . . . 0, 6 - t , 0 b ar
Feed pumppre s s u.e (wlthout ån ov erf loH va l ve) . .. . ., . .. . 2 ,1 bar
InJecllon punp BOSCH nP' 6ll, 612
Type ( pump/governor ) .,,,........ Bosch PE6P,/RQV

lnject lon ord€r . . . . . . . . . . . t-r-3-6-2-4
DIrectlon ot rotaf loi c lockr lse
DiarFier of puop elefien+ ll|ltn
Siroke . , , , . . . . . . l0 rm
lnj ect lon od va nc e......... S ee Inj . pumpa dj usl l ng v6 lu es
Tighfenlng iorque of +he pressure valvo holder 80 Nm
T lghf enln g torq ue of ihe drlv e u nlt r ei al n l ng nut . ,. . .. . .. .. . .. . . 140 N m
F eed pum p,type ............ Bosch FPIK2? P9
Consiruc+lon Plsion type, separöle hand
pump
Fuel fe€d Ing pressure (oponlng pressur0 of fhe overf low valvo) .,. | ,2 - 1, 5 bör
Feed pumppressure (rllhoui an ov er flot r v äl v e) . . . . t ,5 bar
I nJector BOSCH
Consirucf I on F our -hol e nozzl o

openI n9 pressure 200 + 5 bar
Con+rol pressure 2l o ; 5 b6r
S eal lng r lng a9gs1t4%
T lghi enlng lorq ue ot + he n oz zle retal nl ng nu+ . .. . .. . .. . .. .. . .. . .. 60 Nm
Tlghtenlng forque of the InJec+o. retalnlng nufs (tcr the s.i'uds) . l5 Nm
l) T he value u s ed In adjus tlng thg open l n g pressur € of a ne| , and o used InJecfor.
I nJector c v
Construcl I on Four-hole nozzle

vPe,, I ri g Pl 200 bar
S eal lng r Ing 8999 01495
Tighienlng torque of +he cap nut of the lnJecior adjusllng scrsr . 40 tti
Tl gh+enln 9 torqu e o f fh e noz zle re tal nl n g nuf . . . . . . . . . . . . . . . . , . .. 90 Nm
Tl ghienlng iorq ue o f the InJ ector rei al nl ng nut s ( tor th e st uds) . 20 Nm
InJeqior BOSCH(612-engI nes,
Construc+lon F Ivg- hol e nozzl e

OpenI ng pressure 230 6ar
Conirol paessure 2t5 + 5 bar
S ealI ng rlng 8999 0t 495
T lght enln g to rque o f ihe no zz le retal ni ng n uf . . .. . ., . .. . .. ,. . .. . . 60 Nrr
T lght enln g +o rque oi ihe ln Jec to r retal nl n g nui s (f or t he stud s) . l5 tln
l ) The value us ed In a djusfln q fhe o penl ng pre ssur e o f a ne v ano a used Injector.
9 -r

-=F
t-_--]t._
4-_=}_
t-----F
-.F
E"---E
ffiFhE=--
\y|-v
--n------?=
{:F
.<--'--'fi-----:
5
8tr:@
7
SPECIALToOLS(Fuel sysiem)
| 6541 JO600 Pressure valve +es+lng gauge
2 8360 lt09l Exiractor for lnjeqtlon punp gear
3 9025 99100 In j e c tl o n tl m l n g ch e ck pl n
4 At6t 10002 Pressure valve spanner (Bosch rrPn)
5 8160 975f9 Injectlon +lnle check plpe
625 99000 Con+rol rod locklng bush
7 8J60 8f288 N o z zl e cl e an l ng to ol s
I 9051 71f00 Extractor for Injec'tor (Bosch)

COT{SIRI'CTION
ATD OFERATIO OF FUEL SYSIEI,I
TilJECIt(r{ PtfP 8601 'Ai

l. Fuel iank 2. Yater seDara+or 5. Feed punP
4. Fl l t e r 5 . InJ ec ilo n p um p 6 . InJ e cf or
7. Fugl reservolr of thermosiari devlce
8. ol o r p lu g 9 . o v e rflo w v alv e
T h e f u e l flo tr s lr om th e ian k ( l) v la vaTer
separator (2) to the teird punp (i) whlch forces
the hlgh-pressurlzed fuel +hrough the f I lfer
(4) io ihe InJectlon puitp (5).
The lnJectlon punp pumpsthe fuel through lhe
I nJ ec + l on p lpe s lnto +h e ln J ec to rs (6) ,hl ch
s p r ay +h e f ue l In io th e c y lln d er s ln a fl ne
spray.
The excess fuel rlhlch lubrlcates ihe nozzle
needle reiurns from the InJectors to +he fuel
reservolr of lhe thermostart devlce (7) and on
t o t h e l u el ta n k. Du rln g glo y rln glh e f uel runs
from +he reservolr (7) +hrough +herdps+art glovr
p l ug ( 8 ) an d ih en b ur n s In fh e ln le + manlfol d.
The excess fuel fron the lnJecilon pumpreiurns
fhrough overf lov, valve (9) In+o ihe fuel +,ank.
l.0l l fl ll er pl ug 2. Spe€dlever l . H and

pump 4, Lube ol I lnio the lnJec+lon pump
5. O -rlng seal 6. Lube oll back to t ho en gl ne
7. G ear 8. lden+ lfl catlon ola+ e
T he- InJec+ l on pump ls an I n-ll ne pum p an d l fs

basl c cons+ rucil on ls the sam e I n al l en ql ne s
lrrespectlve of the cvllnder number.
9- 3

T he el enE nt consl st s of a pl ungE r (4 ) an d a
cyl l nder (2) vi hl ch have bee n tl i i ed t o €ac h
o +her w l t h a t houscndt h-ml l l l r nei r e accur acy.
The lnJec+lon pump ls flxed fo +he goar houslng D u e +o + hl s accur acy I n fl i t l ng +he el enen t
rl l h ö t longe and s €c le d rlth an O -rln9 (5 ).
The punp ls drlven by cronkshafl vla ldler gear shoul d al vays b9 re pl eced as ö xhol 9.
and pung geär (6). The InJectlon pump ls The cyllnder of the elgn€ni has iro borlngs:
connecied to ih€ englne lubrlcatlon sysfem by l nl ei b ore (l ) ond gul de bo re ( 4) i hr ough t hl ch
Deansol on oui€r plpe (4). fha fuel ls dlreclod lnto +he orgssure chamber.
0 n the sl de o f t he pl st on (5 ) + here l s a l ong-
l l udl nal gro ove (7) and a r egul at l ng rl m (6 )
rhlch regulate the amountof fuel lnJecied lnio
t he cy l l nder s.
On th6 head of the elerient Dlslon there ls also
a siarilng g.@ve (l) r,hlch delöys the
I nJ€c+l on tl ml ng by a boui 70 .. .8 0 d url n g
slort. (Not€ thls Hhen checklng the lnJectlon
t l ml n g, seo l nst rucl l ons l n pol nt 9 2 A '. T hl s
fun c+ l on, ehl ch l s f ul l y aui omo tl c, l s t o
lmprove +he englne cold start characlerlsilcs.
lh6n ihe englne stops ihe conirol rod turns thg
6lel€nt siartlng grooye so that li ls at ihe
cyl l nder gul de h ol e. D ur l ng sl ar l l ng, at l e r
the lnjocilon pumphas reached a certaln spe€d,
the governor drors fhe control rod back to the
ru nnIng posl i l on.
@
93
l . Press ur g valve h old er 2. Pro ss ure Pressure valve

f. El6nen+ 4. Conlrol rod 5. Return spr I ng of 9 5
eleme nf pls ion 6. Rol1 6r tapp e+ 7. Coms hafl- l . P ressur e yol vg hol der 2 , V 6l ve sp rl ng
J. V al ve st efl 4. V al v€ g ul de 5. V al v€ h€ad
The tunqllon of the InJectlon punp ls +o 6. P ressur s redu ci l on pl st on 7. Lo ngl i u dl nal
dl strl bute the rlg ht anou nf of fu el ln to t he ga@ves
dl f fer ent c yll nd ers a t the rlghi ilne. Th e
e lemen+ ( 5) dr lv en by ihE ca msh afi (7) lhr oug h The pressuro valve ls placed on top of tho
rol ler tappei (6) force s the fuel v la p re s sur e glgmenl +o cui ihe conngcllon between lhe
val va ( 2) lnio ihe cv lln dor llner an d lu rl he r elemen+ and the InJ€ctlon plpe when lhe
io the I nJec+or.
r egul atl ng rl o ol t he el enent pl sf on passest h e
gul de ho l e of i he cyl l nder and i he pressur e
cdnss dorn. An crther tunctlon ls to reduce
pr €ssur e In the I nJeci l o n pl pe. T hl s ls
lmDor+ani ln order lo have the nozzle needle
cl ose aui ck l v.
The pressure valvg stern (i) has a pressure

r educl l on pl st on ( 6) rh l ch, as t he val v e
cl ose s, f l r sf 9€ s dor n i o t he val ve g ul d6 (4 )
and cuts +he conngctlon betreen ihe elemenl and
l nJE c+ l on pl p e. T her €aft er t he val va head ( 5)
presses agalnst lts sga+ and ihe space for fuel
In ihe InJectlon plpe Increoses by the
dlsplacenent of the pressure reduqflon plsfon.
lllrtlng ot ihc I nJoctlon purp

A 8C
T!,o-hole eleneni ( fu I l-te€d posltlo.r)
Boiim dead contre B. Sfart of f€ed

End of teed
I n le+ bor e 2. C ylln der t. Starilng groove
Gul de bor e 5 . Plun g€r 6. Reg ul6t Ing rlm
Longlt udlnal g ro ove .
T h€ l dent l f l cof l on p l €t e o f + h€ I nj ecf l on pu rp

sfåtes a lo+ter codg for the puDp appllcatlon,
:L,*ä";" J,R'Ji,l'?,
l nJoc+l o n pumpor Inq ul re""i'lT'
#::'%.'1::
E dj us+l ng våt ues.
g_4

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

l . S i a ri l n g s pr in g 4. H a in t e v er 5 . t d l l n g
control 6. Goyefnd- sorlno 7. Addl-flonal
s p r i n g f o i id l ing 8. ba t ai c er s pr t ng 9.
Control levs'.
The centr i tu ga | -type governoi ls loca+ed ai ihe

rear end of ft|e Injectlon pulp. The governor
regulötes ih € e ng lne s p ee d y l t hl n t h e | rh o l e
speed range and recognlses ihe speed wlth the
h e l p o f th e c en ' ir if u ga l H e lg his ( l ). Th€
p o s li l o n s o t tt E ih rq f + le le v er a nd + h e c 6 n +r l -
fugal relghis are iransnltted io ihe conlrol
rod (2) vla the governor leverage. Tho
gove.nor has one governor sprlng (6). |lhen the
e n g l n e s +o p s tt | e s + ar t ln g s pr ln g ( f ) f l x e d t o
l'he iop ol tl|e cootrol lever (9) draws the
c o n i r ol ro d lnt o it | e s iar t l nq p os l il o n , vlhlch
au+oma+ically sets an Increasld feed raie for
s t ar i l n g .
9-5

|ITJEC ON Pttf BOSCH?r
l@
l. Cold start bu+toi 2. Boost Pressure coniro I lei J. O v6 rl l ow val ve 4 . S to p l ever 5. Ol l f l l l er

plug 6. RQv-governor 7. SPeed lever 8. Lub€ ol I fr om In j ectl on punp 9. H and pump 10. F eed pump
t l. Lube oll to Iniec ilon PumP 12. lden t lf I ca+l on o l a+e 11. P re ssur e equa l l zei
The ouislde and ihe construc+lon of lnJec+lon

DumoBosch nPr dllfer from those of the rrAtr
+ype pump. The funcflon, hor6yor, ls ihe sam6.
In the 'P'r iype pump every pump eleiEn+ rlih
li s pr essure valve an d v€ lv 9 ho ld er ls l n a
cl osed element h ouslng.
The baslc adJusiment of +he feod ra+e ls made
by +ur nl ng the e le menl ho us lng , whlle fhe fee d
sf ari ls E dJ usiedby ch ong lng tho ihlck nes s of
i he shlms s lt uated un der the eleme ni h ous l ng
tlange. The closed type pumpbody has no slde
hatchgs a other control holes.
The feed roie ls adjusted by ihe control rod
made of angle pro{lle sleel. The rod has
notchos on *hlch +hs balls of +he control iag
d€s l ean.
The InJectlon pump ls bof+om-mounied.The pump
ls rcunied on a separale base on the englne
l ef + sl de. The ln je ctlon pumpls drlve n by ih e
engl ne ll mlng gear vla sh ofi a nd m ulilplE pl a+e
clu+ch. The pump ls @nnected to ihe englne
lubrlcailon sysiem.
Prossure valvg holder 2. pressure v a l v e

E lsment 4. Conlrol rod 5. Control
Valve iaooe+ 7. Camshafl
I -6

FEEDPTIf
F€ed pump 4l I
l. Hand pump
2. P lug
f. S ea llng rln g
4. S prI n g
5. V alv e
6. Valve fappei
7. Body
8. 0 - r ln g
9, Plsion
10. S pr ln g
ll. S ea llng r lng
12. P lug
lf. Oaskol-
14. l{asher
15. Nut
The fuel feed pressure ls produced by a plston

p um o llxed fo ihe s l de of t he I ni ec t l on pu m p .
The puDp ls drlven by ihe eccen+rlc loca+ed on
ihe lnjecilon pump carnshaf+. The anouni of
fuel +hai cofiEs fron l-he {e€d purp exceeds
conslderably +he fuel needed by +he Iniectlon
pump. The extra fuel ls led ihrQgh th€ over-
f lor va lve b ac k + o i he fu el t an k . T h l s e rf r a
fuel cools -th€ lnjec+lon purp and ble€ds the 9l o
fuel svs+em.
The eccenirlc on ihe lnjecilon purp camshafi

(l) presses dorn the feed pump pls+on (5).
Thls ollors fuel lo enfer from feed pump lnlei
chaitber (7) In+o prossure chamber (4) vla
pressure valve (8) and ihe plsfon sprlng
stretchas ( Infermedlaie stroke).
After fhe eccen+rlc has rota+ed oast lts loD
deod c6n+re lf ls followed upvard by fhe
pl sfo n, pre ssure pl n (f) and i he ro l l er t app et
(2) prassed by i he sp rlng . D u rlng th l s pha se
fu el l s fe d thro ug h fll ier to th e InJ ec i l on
punp ond ai ihe same tlmo fuel ls suckgd
thro ugh l n le i val ve (6) to +he fe ed p ump l nl el
chamber (pressure stroke).
Durlng the pressure stroke ihe leed pumppumps
n garl y all +h s necessary fue l a nou nt l n f o + he
lnJec+lon pump. Durlng lhe ln+ormedlöta stroke
It d ell ve rs on ly a sma ll amou nt w hlch co r r es-
pon ds to th e pro ssu re p l n pu shl ng ltsel f ln io
+he pressur€ chamber.
WhEnthe prgssure ln ihe feed plpg excegds €
cerialn value fhe sprlng forces the plston up
rlih only pari of the stroke and +he fuel raie
Is correspondlngly lorer, l.e. +he hlgher ihe
back pressurg ln tha feed plpo, fhe smaller ihe
4nouni of fuel dellvered by +ho pump.
9 lt
A. Pressure sfroke B. Intermedlaie stroke
l. lnJsctlon pumpcamshaft 2. Rol ler iappet
5. Pressure pln 4. pressure chamber S. plston
6. Inlet v a lvg 7 . In le+ ch am be r 8 . p re ssu re 9 -7
v alv 9

T JECTORBOSCH INJECIoR C Y (61I englnes)
The lnJector has a four-hole nozzle. The maln T he In Je ci or man utacturedby C A V l s p rlncl pal ly
parfs ot thg I njec'tor ar6 the nozzle holder and the same as fhe Bosch InJector, rlth regard io
ih€ nozzla tlp. The funcilon of ihe I nJecfor qanstructlon and tuncilon. The greaiest
ls lo taed tuel lnio ihe cvllnder ln the form dlfferences ln construcilon are to do wlfh the
of a flne vopour and fo starl cnd cui off ths lnJecior fixlng and the adjustn|en+ of the
l n Jec +lon rapld ly . T h e ln J e c to r ls c o ntr o lled openlng pressure. The InJeclor dpun+lng lugs
by th6 fuel pi€ssuro. are casl ln the body ond the openlng pressure
ls a dj us+ed w l th a n öd Ju stl n g nu i, rl +ho u f
ssparate sh lms.
912
l . Fue l Inl e+ 2. O v€ rt l ow plD e conn ec+ lon
l . Fu €l Inlet 2. O v e r tlor p lp e c o nn e c tlon f. A djusti ng n ui 4. P re ssu re sprln g
l . Sh lm 4. Pres s ur e sp r ln g 5 . P re s s u r e p ln 5. P ressure D ln 6 . N ozzle bod v 7. N ozzl g
6. No zz le body 7 . N o zz le n e e dle 8. P r es s ure ne€ dle 8 . N ozzle ho l e
chamb€r 9. Nozzle hole
The fuel pressure ls dlrecled to ihe conlc
pressur€ should€r o{ the .pzzle needle (7).
Hhen thls pressure ls greater fhan the reslst-
Ing forcg of ihe pressure sprlng (4) li ralses
the n€dle froi! Its seat. Fuel ls then e iected
through the holes (9) In the nozzle bod-'I (6)
Into ihe combus+lonchamber ol +he cvllnder.
The tenslon ot ihe pressure sprlng, lrhlch
de le rm I nEs the op e nI ng p r e s s ur e o { fh e
I n Jec for, c än be adJ u s ie d w lth s hlm s ( l).
T he o vgrflow fuel lu b rlc a tln g fh e no z z le ne ed le

ls led to lhe overfloy plpe ond back +o fhe
fuel iank.
I -8

FUELFILTER BOSCH T he C AV fuel ll lter has +!,o rrparallellyrr
connectgd fllfer cartrldges. There are tYo
iypes of fll+ers, ons lJ lth a glass se dlment
boul (flgure 9 15) and the oiher ulthout li,
I{AIER SEPARATOR
l . Co v e r 2 . S ea ll ng r ln g 3 . P a pe r f il+ or
c a rt r i d g e 4 . l n ne r p lpe 5. S he ei r E + a l
h o u s ln g 6 , B l ee d lng s c r et
T he f u e l f l l' t e r l s a s o- c a l led c a ps ul 6 f l l i e r
c o n s ls i i n g o f t h e f llt e r c ov e r ( l ) rl t h tuel
i n le t a n d r e t ur n c pe nin gs an d t h e f ll l- e r b o dy
whlch has a shee+ rneial housing (5) encqnpass-
I n g a p a p e r ll l ie r c a r + r ld ge ( l) . I n ' t h e nl d d l e
o f th e b o d y ih e r e ls a t hr e ad ed ho le f o r f l x l n g
It io +he ll l+er cover.
Scrne englne l-ypes are equlpped rlih a double-

f I lt e r r i t h s e l e c+ I n9 v a lv e , rh e. e by o ne I I l i e r
c a ri r l d g e c a n b e r ep la c ed rh ll e t he e ng l ne l s Mos+ englne verslons are equlpped t{l+h an
r u n nl n g . englne oi machlne mountedwato. sepäraior, the
func +lon of w hlch ls presenled In flgur e 9 16.
F i E L F I L IE R C v ( 6l1 16 1 2 er g ln 9s l
I 15
l. B lee dIng sc rew l. F I lie r

ca rtr i dg e 4. Olass sed lmeni b o{ | 5 . D r al n l ng
p r u9
9- 9

FI'EL RESERYOIR
OF THEN'|oSTART
DEVICE
s 17
t . Re se r v o lr f l I ll n g 2 . T o + h e bur n€ r
Rgfurn to fuel tank 4. Breather
The overflowlng fuel fron +he InJeciors ls led

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

s+ a r + d ev l ce l s + h e onl y s ubs il i ui l ng a lr p lp €
+o fhe fuel +ank, lt nay unCer no clrcums+ances
be b laked.
I- l 0

IOiIS FORREPAIRII{Gr}€ Flf,L SYSTEII
I XSTRI'CT open the connecilon of the InJectlon pumpover-
tlor valve c the pressuro equollzgr ln the
ge no rol [Pn type purnp. Conilnue purplng untll ihe fuel
il otal T h ls ma n u a l g lv e s on ly
lns+ruc+lons for rEpalr and s€rvlce fiEosurgs conlng out of ihe overf lor valve conn€cllon ls
related io +he luel system. Thls applles tre€ lrqn bubbl€s. Close +he overf lo[ valve
part lc ul ar ly to t h e In J e ct lo n p u mpr hlch can b € connec+lon and close the hand pu|l|f' plston by
repalr ed o n ly b y o s p € c la lly + ra ln ed P erso n turn Ing .
rho has the necessary spgcläl iools and gaug€s.
All s6rvlc6 and roDelr rork rgloted to the fuel 4 . !ll pe le ake d fu el o tf .
s y s i em r e q u lr e s s p e c la l c a r s a n d cle on ll n essl
B. ICASI.RI }tG TI€ FEEDPR€SSiNE
1 . FEEDPUIiP
Cl6an the lnJecilon pump and the fl l+er
ELEEDII{G THE FIEL SYSIEM exte rn al ly 6 s re ll a s +he fue l p lp es In b et r e e n .
U- b ru sh a nd sul tab le so lven i.
t . OpEnthe hand pumpplston by turnlng.
Attach ihe geug€ betre€n fhe fllier and fhe

plpe leadlng io the lnjecflon pump.
f. R un fhe on gl ne at l dl ln g sp ee d for o r h ll a an d
coopare ihe gaug€ roadlng rl+h englne ratlng.
Nqtcl lf l-he 9au9e readlng falls b€lor railng

Open 'the bleedlng screi on iop of fhe fu e I li moy be cöused by:
f ll ter . P u r| prlt h ifl€ h a n d pu n p u n+ll t he fue l - defoctlvg ovgrf lor valve
conlng ou't of th€ ble€dlng screr ls free { roir - cl og go d fu sl t I lte r
bubbles . C lo s e th € fll ie r b l€ e d ln g screr. - defoctlve feed pump
- clogged or leaklng fuel plpas or connectlons
C. C}ECKIIG I}E OYERfLO| VALVE
lf the fe€d pressure dlt{ers from +he ratlng,
check fhe opanlng pressure of th€ overf lox
l. Attach the pressure gauge as wlth feed pressure

ipösuremen+(Dolnt B).
2 . Pu mp { l ih h an d pu m p u nt ll th e ove rf l o r va l v 6
opens. Comporeihe raadlng In ihe gaug€ at +he
openlng rpDenf rlih lhe ratlng.
l f t he re adl n g ln fhe gauge dl{ters from ihe
ratl ng, rep lace the ov€rf low valve rlth a n9r
one.
Notol lf the prgssure do€s not rlse io the

overf lor volve openlng pressure, ellher th€
h and p um p o r the fe ed pu np va l v e s a r e
defect I ve.
9 19
9- 11

DI9rcUXTI]{G TIIE FEEDPTIP AID C}CCKIt{G IlE
v LtEs
t . cleän fho lnJecilon pu[p and lts surroundlngs
car€fu | | Y.
2. Dlscoon€cf the fusl plpos leadlng to the feed
puop.
Op€n ttre te€d puip retalnlng nu+s and dlsnpunt

the f€d purnp.
Flx the te€d punp flonge to a screr clalp

equlpped rlih protecflng Jars. Rg|tpvel'he hcnd
purp frdr tho lnJoctlon puip as xell as the
plug or conneqtor noar lt (509, lll).
Rd|pvg the vclvg sprlngs and valves frqn th€

f6€d pump body. Check the condlilon of ihe
valve gasket surfoce cnd replace rorn parts.
6. Pl ac e t he y ål ve s c n d s p rl ng s ln +he l r
p osl ilons . T h e I n le t a n d e xh a u s t- va lv e s a re ot
lhe sor|9 lype. Flx +he hond punp and ihe
p lug./conn€ctorby uslng n€s seollng ilngs.
Clean ihe gcskei surleces betreen fhg leed pump

and the lnJectlon pump. Remountlhe teed punp
by uslng a n€r gosket.
9-1 2

2. I NJECII O{ PnP 8osctr i i
TII,IING
NG T}E I NJECTIOiI
CHECKI
Turn the crankshatt to 6 posltlon rhsre lhe lst

cytlnder plsion reoch6s lls cqrpresslon stroke
top dead cenfre. Thgn turn ihe cronkshaf+
b a ck va r d s u n t tl t h e l l ml n g m a rk o o t he pu ll ey
Dassesth€ lnsoectlon hole.
tlotcI The lnJ6ctlon tlmlng ls marked qr the

c rank s ha f + p uI l 6y l n fO 9, ll l an d 4l l e n gl n e s
and on t he v l brö tlo n danpei In 6l I and 612
engI nes.
I n lr ac lo r e ng lne s th e In je c ilo n il m l n g l s
marked on the slde of +he tlyrheel. The
t ly r hoel h o u s lng h ös a n ln s pe c tl on o p e n l n g e n d
a hole f q - i h g t lmln g c h ek Pl n.
oue +o the autonailc excess tuel feed of tho
lnjecilon pumpth€ control rod musl be npved to
dr ly e po s lf lo n rhe n öe c k lng th e l n J e c t l o n
tlol ng, o t he rrls e f he I nj ec t lo n ilm l n g rl l l b e
I ncorreqt !
lst rcy ot ch€cllng3 Reriove the con+rol rod cover fron the lnJecilon
Dumo. Turn lhe control rod to drlvg posltlon
l . Cl ean ihe l n J ec t lo n pu np a nd lls su r r o u n d l n g s rlth tool 9025 99000.
c ar efu I ly .
Rqrcve the lst cyllnder lnJectlon plpe.
6 . Blor the clnlc part of th€ pressure valYe
holder fr€€ of tuel. Turn ihe crenkshaft
lorrards un+ll tuel surtoce In the pressure
valve holder stlrs, but d€s nof yet rlse.
l f l h e l n l e c i l o n t l m l n a m ä rk l s l n ll ne r l ih
ttre tlp oi the Indl caioir, fhe InJec+lon +lmlng
ls correct. OtlFrxlse cdJust the tlmlng as
lnsiructed In Dolrf 9 2 B.
8 . A f t e r ch e ck l n g a n d p o ss l b l e a d Ju st l ng I n st al l
ihe InJec+lon plpe 6nd fhe conlrol rod cover.
Let ih-e englne run for o lel mlnutes and
recheck. Thus you con ensur€ ihat there ls no
alr lef+ In the luel sysiem rhlqh nlghi aftoct
ih€ tl mlng.
2. ln iractor Englnes rslpvo +he rubber plug fro||l

the Inspectlon hole In ihe tlytrheel houslng.
Ins€rt +he check eln (9025 99100) ln the hole 9- 13

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

pressure valve hold€r. Renove ihe Dressure
valve stem and renpunf the holdgr tlth äbsolute
c leanl I nos s .
lvl I 27
I t t he In Je c+lo n +lm l ng l s re+ arde d, + urn t he

pump anilclockrlse (vlered lrom lhe fronl end
of ih e pu m p). l f i he tlm l ng ls a dvan ced ,tu r n
+he punp c lockwI se.
Chack the lnJec+lon tlmlng and iurn ihe pump

f . F lx + he lnJ e cil o n t lml n g c h e ck p lp e (8 1 60 97 jt 9) agaln, lf necessary.
t o t hg l s i c y lln d e r p re s su r g va lv e h o ld er.
4. lih6n fhe tlnlng ls correct flghten ihe
retalnlng nuts of ihe pump and flx ths
I nJe ct lo n pl pe s.
c. REIOVI NG I}IE INJECTIOIPIIP
t. Carelully vesh ihe lnjectlon pump and tho

surro un dl ng e ng ln e p arts as vre ll a s th e
Injoctlon Into the lst cy nder beglns. ln Jectl on pu mp pl pl ng s a nd ih el r con ne ci l o ns
oxtgrnal ly.
5. l t . ihg llm ln g ma r k o n th e f lyr h e e l ls ln l ln e
wlih ihe tlp of +he chack pln, fhe InJectlon
t l nl ng ls c o r r e ci. o ih e r w lse a d J u sf ih e -tlm l ng
as Inslructed ln Dolnt 9 2 B.
6. Removglhe check plpg and open ihe pressure

va l v e holder . P la c e t h e D re s s u re v a lv e s+e mln
I t s pos lf lon, ie p la c e t h e s e a lln g rl ng and the
0-rlng and ntouni th€ valve sprlng and the
h ol d er .
7. Tlghtu tho Dr€ssur€ vclve tlol dor rs tollois:
- f l rs t t lgh+e n ln g io ,0 N m
- open ihe holder by about l/2 iurn and
retlghten 40 Nm
- open the holder by aboll+ l/2 furn and
f l nE ll y t lght e n io 4 5 Nm
Remove..+he lnjecilon plpes, fhe fead plpe

connectlor screls and the oll plpe connocilän
Flt ihe connectlons rlih 6 profecrtve
;ifi:.
9 -1 4

o
5. Opsn the scrers ot the oll flller plpelcover. Connect the fdel f€€d plpgs and th€ lub€ oll
Re|t|ovethe plpe. Renove +he flxlng sfuds ol plpe. Replaca old gaskels tlih rct ones.
the ol | 1l ller plpe (nof necessary lf the
latgsf oxtracior modgI usgd). 6. Bleed ihe fuel sysldn (sF lnslrustlq|s In
pol rt 9 | A).
4. open ihe flxlng nut of the lnJecilon pumpgear.
Adjust ihe lnjectlon flmlng (sc l||3lructtd|s
l npolnt92B ,
8. Attach ihe lnjef lon plpes.
Attach +he gear ertracl-o. (8560 lJO9l) and

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

I€ T}C PRESSMEYÄI.YE
l. Clean ihe lnJectlon punp, lnj€ciors and thelr
l.o(n|Tlrc nc lNJEcno PnP surroundlngs carefu I ly. Rsnove fhe I nJestlon
p lpss.
l. Check ihe O-rIng of the npunilng flan96 and
re p la c e it , lf n* es s ary .
2. Lubr lca t e + h e O -r l n g an d l ns l a l l +he Inj €cit on

pumpso +hat fh€ shoft key ls poslfloned In th€
kgy groove of the gearrhgel. Screr ln ihe
InJ ec a to np u m pr e + o ln l n g n u T s .
5. T lgh+en The gearrheel nut lo the torquo
90 Nrn. of
F as ten th e . o l I fl l l e r p l p e fl x l n g s +u ds. Seo

I
ll9--s.tud threads rlfh seallng conpouno (
50008). Flx fh€ olt f ter plöe,/corjor. - 6909 2. Attach the tes+lng gauge (6541 JO60O) In ihe
tpldor ot thg giessuro v.lYe io b€ ln3P*red-
9 - 15

5. C rank t he en g ln e wlth s t or te r un ill the ga ug e Ope n+h 6 sa fe+ y nu+ (1 0 mm)o f ih e ldl lng sp ee d
Indlca+es aboui fJo bar pressure. 6dJusil ng scre{ and +h e sa {e ty nuf (17 nm) of
+he a dj ustln g screw of ih e a dd ltlon al spr l ng
Notel The pressure r lses qulck ly - be to r ldl lng.
careful no+ io damageihe gaugel Be ready +o
pull the stop lever as soon as ihe gauge shors 2. E n su re th at th e + h rotil e l ave räg e ls ln ld l ln g
the requlred pressure. Dosl+ lon.
4. L e+ +he gaug e r e a dln g f lrs i ta ll by abou t f0
bar. }lhen lhe gauge readlng ls dol{n to 300 bar
keop an eye on the readlng for one mlnuie.
Du rlng + hls tlm e t he r oa dln g m ay no+ fa l l
con slderably ( f0 ... 5 0 b ar ). lf ' t he p re ssu re
fa ll s tas ter ih a n t he r atlng , t he p re ssu re
va lv e m ust be c le an ed or r ep lac ed .
N ot€l Alway s r e p lac e + he pr es s ur e v a lve ste m
an d gulde t og ei he r .
Start ihe eng I ne and open iha adjustlng screr

of + h e ad d i + l o na l s pr l n g s o i h a l l i do e s n o t
a ff e c t i h e l dl i n g sPe€d.
Ad j u s t + h e l d l l ng s p ee d b y i h e a dj us fl ng scr e w
a' t ab o u+ 2 0 r pm be l o i t h o ra + l n g .
Race lhe englne lor a fer ilmes and ensure thai

t h e l d l l ng s p ee d r em a l n s a s s et .
Tl gh t en + he a dj us tl ng s c re w ot t h e a dd l i l o n a l
s pr l n g u n i l I i he l dl l n g s p ee d rl s es ' t o i h e
ra-ted value. Lock +he adjus+lng screr In +hls
po s l t l on .
Ope n ihe lo c k a nd c l am p o l t he pr es s ure v a l v e
hold e r. Re n o v e ih e v al v e s pr l ng, t he s + e m a nd 7 . F lx the safei y nu ts of + he adj u stlng screws .
fhe gu ld€.
Note l Other adj ustmgn+s (output and max
R lnse +h e pr e s s u r e v al v e s + e m a nd gu ld e H l + h speed) vll+h +he InJectlon pumpcon be perforned
pure fu el o r te s + tl ul d a t t he s ame t lm e +u r n - onl y b y a spe cla ll y fral ne d p erso n N lhohas t he
Ing fh e sle m l n t he gu ld e a nd p r es s ln g f h e ne ce ssa ryspeclal + ool s a nd gau gesa val la b le .
gaskei surfaces agalnsi each oi-her.
7. In s+ all f he pr e s s ur e v alv e In ' t he Inje c+l on

purnp, moun+ +he valve sprlng and close +he
hoI der.
l lotel Repla c o s e a llng |- lng an d O-r lng .

L Tlghton the holder as follors:
- flr st +lg ht en ln g + o 50 Nm
- open ihe holder by about l/2 turn a nd
rei lghien 40 Nm
- open the holder by about l/2 lurn a nd I I na l l y
f lgh+en to 45 Nm
Chec k ihai t he c lea ne d p re s s ur e v a lve ls tl g hi

enough by c ö r r y lng ou t + he m ea su rem e nt
procodure descrlbed above, lf ihe gaugo
readlng s+ lll d lf fe rs f r om fh e ra ilng , re pl a ce
ihe Dressure va lve.
10. Check each pressure valve In iurn as lnsiruc+ed
above.
F. ADJUSTINGTHE IDLIIG SPE€O
lf ihe en g l no l d ll ng s pee d d i ff er s fr om + h o
rat I ng , ad ju s f a s f ol l o* s :
9-1 6

5. lNJEcTloN PttP BoGCHiPn
6 tt/61 2
I.OUNTII{G TTIEINJECTIONPUIiP
( E ng lne {lth compressoron ihe rlgh+ slde)
935
F l t + h e l nj ec ti on pu mp d r lv e un l+ A l n t h e g ea r
houslng. Place ihe gaskef B befv.een fhe houslng
a n d l- h e d rl ve un lt an d i he lo c k l ash e r C I n s l d e
+ h e g e a . h o u s ln g u nd er ih e r 6 t al nln g sc r e us .
t,lotrni ihe gear and the key on the drlve unll

shafi. Tlghten ih€ gear retalnlng nui io ihe
+orque of 140 Nm, Noie +he gear lns+alla+lon
marks !
F l l +h e c o u pl ln g p le c e D on t he I n j e c i l o n p u r p
s h a f t . T l g hi en i lp r e+ a ln ln g nu t i o 1 4 0 N m.
Attach the lnjectlon puip clu+ch E onto +he

d r lve unli s haf+. Tlghi en the drlve plece sc rer
to 50 Nn.
Turn +he crankshafi io a oosl+lon where ihe lsi

cylln d er has lts Injec+lon il mlng. The Injetlon
tlmlng ls markedon the vlbrailon danp€r of ihe
c ra n kshaf l.
936
6. Turn ths Inj€ctlon purp camshaft to it|e

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

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

9 37
o' It the lnJ ec tlon tlolng mark ls In llne rlf h

P la ce gu ld e bushlngs beireen the lnJectlon punp ihe tlp of ih€ lndlcaior, ihe Injec+lon tlmlng
bottom and lhe mounllng bose. Loror the punp on Is corrgcl, It nof, perlorrn ihe adjustnent as
l 'h e n pu n ilng base and flx the c oupllng plece tollows:
an d th e p u mpreialnlng screws.
8 . Attach the lnjectlon pump dellvery önd refurn

ol I plpes, ihe fu6l plpe and ths boost pressure
r e g ula io |' pipe.
B. CHECKI ITC INJECTIoiITII,III{G

ilG ANDADJUSTING
C le a n ih e Injecilon punp and lts surroun dlngs

ca r e tull y. B leed ihe fuel s ysiem.
Turn ihe crankshafl to a posltlon *here thg lst

cyl lnd e r pls ion l s ai lts compresslons +r oke
top dead cenire. Nor lurn the crankshat+
o pp o slie + o the runnlng dlrecil on untll the
In Je cilo n ilm lng nark on ihe v lbratlon damper
Dassesthe I ndlcafor.
Ensur€ that ihe 'rexcess fual feed butfon'r on
iho slde ol ihe boosi pressuro rsgulaior ls nol 93 9
swlich e d o n .
Remo veth e Injectlon plpe of ihe ls + cyllnder. j.

Blow the conlc part of the pressure valvs
h olde r fr ee of fuel.
Tur n i he c rankghaft slorly In runnlng dlrec +lon
u n+ ll fu el surfaco In the pressure valve holder
stlrs, bu+ does nof yel rlse.
Check fhe lnJec tlon tlmlng and +urn +hs
coupllng plece agaln, lf nec€ssary.
}lhen lh€ tlnlng ls correct tlghten the cou pllng

plece flxlng screw s and llt ihe lnjecfton plpe
ot the ls t cyllnder.
I - 18

c. AÄIUSTII{GI}€ IDLIIIG SPEED
lf ihe englne ldllng spe€d dlff€rs from the
r a t I n g, adj usi as follors:
o
!: l t
\_t
Ensure ihat fhe throitle leverage funcflons

propa-ly. It so, open the safely nu+ of ihe
ldllng speed adjusflng screw and adius+ ihe
ld llng speed to i he ratlng. Tlgh+en the
adjustlng screr and flx ihe satety nut.
t{otE I Oiher adjustments (ouipui and max
speed) ylih ihe lnJecilon pu0rpcan be performed
only by a speclally trolned p€rson xho has the
necessary speclal iools and gauggs a+ hls
d lsDo sal.
9- 19

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

pl P e .
Corr# spray form

B. Incorrect sprey {orm
Bl. op€nlng pressure
Open th e lnjec tor re talnlng nuts and l lfi i he Press the tesl pumph6nd levgr slorly untll ih6
lron out of tho n oz zl e l l g hi l y q - ea ks . RE e d th e o p en l ng
ln iec'ior anå lts aqJnting
Ptac e piotec + iv e Plugs I n all pressure In ihe 9au90. It the openlng pressurg
cv llnder he öd,
ihe connec+ions.
dlffers from 'ihe raflng, the lnJector nust b€
d lsassembledfot- odJusimenl.
Ref irov e se allng rlng s lrdn the c yl lnder heod'
Th6 Bosch InJec+or ls adJusted by r6plöclng +he
unless fhe y c qie off rtth the lniec +ors'
s hl m ( pa r + 2 In fl g u re 9 59 ) . T he fh l c k n es s
o f th e sh l m s v a rl es tr o m 1, 00 to 1 ,9 8 f t n a n d
CHECKI}G THE INJECTfi
the dlfferencg b€tw€en slzes ls 0,02 nrn. A
|rhen testlng the Iniector do noi hol6 + hl ck er sh l n r ol se s +h e op en l n g pr e ss ur e , r hl l e
N,otal
v our han d n eor the ;ozz le, fo- ihe fl nely dls- o thlnner one rgspectlvely lorers ll. A 0,02fl1
p€rsed fuel spr6y may peneiraie the skln cnd dllference In ihe shlm thlckness changes ihe
c öuse se vo r e lnjur les !
oponlng pressure by about 5 bar. Becauseihe
n oz zl e op en l n g pr e ss ur e dr o ps s l l gh tl y a f f er a
Iniac tor c årelully rlth cleon.lng tex run hours frcm the adJustn€nt, se+ the
clean ihe
f luld a nd brus h. Never sc rope o f{ 'the carbon openlng pressure at 210 ! 5 brr. The conirol
p r os su r e a pp l l es t o b o th ne r an d u s e d
wl+h a kn lle o. å s lmlla. fool.
I nJeciors.
9 44
The openlng prgssure of the CAV Injector ls

adJusled by th6 adJustlng nut rh lch I les under
942 the caP nut at tt€ +<+ ot - 0-20

82. Crock I ng
Tesilng rllh a nanual iest pump d€s noi
cofrespond to ihe condltlons In the englne and
i h gr g tor e g lves a rellabla rgsult only r lih a
ner nozzle. At a cerfaln puflplng speed ihe used
nozzles have an uncreaklng range rhlch ls
alfected by the nozzle construcflon.
Howsver, € qulck press should makgthe Injector

creak cleårly andlor producE o flne spray.
Wlf hln fh e uncreak lng range i he s pray ls rough
a n d lrr e g ular.
S5. Tlghtmss ot fhe nozzl€ n€€dle

Prsss the tesf pump lever slowly unlll ihe
gauge readlng ls 20 bar b€lo{ the rated openlng
pressura. Kgep +he pressure ot thls level fo|'
l0 seconds. lf a drop does not appear ln the
n o zz le llp , tho nozzle tlghtnes s ls correqt.
Dl s åss em b lea leaklng InJ eclor, c lean ihe seat
surfoces and perform a ne{ lesi. lf leaks
a p p e ar a ga ln, replace +he nozzlg.
C. DISASSEIGLING,
CHES(IIG ANDASSEI,BL
It{G I}€
IIIJECTfi f. C lean the noz zles w l+h cleanlng Jluld froo t he
oufslde and the lnslde.
4. opgn clogged nozzle holes by s oaklng and byö

cle6nlng needle (lncludad In ihe cleanlng tool
se+ 8f60 85288),
I 45
Parts ot c Bosch I nJoqtor
No zzle h older
2 . Sh lm
Pressure sprlng
Prsssure pln
Intermedlate plece
Nozzle
No zzle r gtalnlng nui
l . Fl x th e l nJec+ or to a screx cl6mp equlppeds i i h

pro+ec+lve Jalds. 948
2. Opsn the nozzle retalnlng nui. Rgrpve the Tesi the rDv€iFnf ot the nozzlg n€dlc cs
n ozz le 6 nd the pårfs of fhe holdgr. tol lors:
llash +h€ Darts t{el I rlih fuel or fest fluld.
Puff the needle out of tho body un+ll l/t ot
l l s s l l dt n g p l an e l e n g +h l s o u t . T h e n e e d le
shoutd slld; ttself back lnfo ihs seat. Repeoi
i h l s w l t h v a r l ou s n e ed l e p o s l t l o n s . T ho n € e d le
g- 21 må v n of s + l c k I n an v p o s l + l on . R ec l e o n a
s l - i c k l n g n g z z l g on d r ä P e ol f h e i e s r ' lr +h€
n o zz l o silll f€ nd s +o s tl c k' r ap l 6c e l t'

,. INJECTION
PIP€S
6. B eg ln the assenbly by caretully r lnslng öll
parTs ln DUre tuel or tos t fluld. I NSTALL
IiG T}C INJECTIO{PIPES
7. Place l'he shlm ln ihe holder. Check It ihe Chack +he condl+lon of ihe Dloes betore
openlng pressure n@ds adjusitng. Atlach ihe Insial llng. ll ihe plpe has cracks, abraslon
o'iher parls and check thelr correct Dosltlons oi It fhe seallng cone ls damaged,rep lace the
( pr es sure p In, lnterm odlaie plgce). olge r|th ö hori on€r
8. Cl ose ihe retalnlng nu+ of the nozz le flrsf by Ensur e that ihe plpes are noi ln an obllque
ha nd and flnally flghten rlth a iorque wrench poslfton whlle fhe retalntng nu+s are b€lng
to 60 Nn In cose ihe InJector ls Bosch and ilghtened. O therrlse the cone HIll b€ dam aged
to 90 Nn lf l t ls CAV. 6nd leak s rlll resul+.
D. INSTALLINGIHE I NJECTffi IN THE ENGITG f. Flx +he lnJocflon plpe supports.
9 ,19
I n s ia ll ln g a B o s c h I nje c f or
liloun't Ing lron

l{asher
Protecl lve rubber
Gasksi Yasher
t. C lean the I njector counler surface on the

c yllnd e. head. Siralgh+ en the surface wlth a
reamer (8J61 914101, ll necessfy.
2. P lace the l njecior In lts pos lllon on the
cylln dd ' head. Use a .pvr seallng rlng .
Nofe l T he lnJecflon pattsrn ot the
In jec tor ls not sy nelrlcal. Theretore l+ ls
lmpor+ant +o posltlon ihe lnJec+or on the
cylln de r head c orrectly. T he overflor plp6
flx ed t o th€ InJeclor slde should b e on the
slde o f ihe valve nechanls m(Bosch lnJ€ctor).
P lac e +he npunilng lron (ln Bosch InJ ector) In

lis p os ltlon and tlghten ihs nuis evenly to ihe
glven torque (15 lh In Bosch lnJector ond
20 Nn ln CAV lnjector).
4. Flx f he ovorf lor plpe and the Injec+lon plpes.

6 s8
+9 b
-LO
639 o@ (o
trJ O- (D
F
N
L-
t (a E
oo
oo \ o
-- . o o-
_o -
-
NO oF* o\o\o\
-r !20-o- o\onoo\o\o
-
n \€ r tF F fl stn\oo@ r.!
\o r o \a r\ 9| o - FFF@F-
ltltll
r7,r N (\,t \t
o E
N - s t @ r n-
@ @ o \o \o - -t -
.F O
r n o o o o| r r | r1oooo| f\
F o o oo c { F OOO ON
OE - o o \F\o n -oo \F-\or\
o
tt
OE
.F
o
E
O PL -o o
o
.F
o - =-
o o
l@
o
o
o
;8
t<
ao
o\ \o
o
I
14 dn (L r1
Å
t
F o
(9 +
2
: =
t!
ä =
co
o
- r-1
FF
u
ä# o
6
EA
rr t!
I
o -20

!9
3 Eg3
o
hb E
39E
ooLo
.
S S E E-
ou
0 oo oo o
LO 8883
PX oo oo N
Et
E z.o
:38 RS
-E
.F
o
o
XE
. Fö
-E t! al!
lI \ (L\ ( L\ o-\ (L \
t
t!
J o
dl o
s o o
!p o
o
z, o ö d3 8E L
+z
-=
lrJ ,., i
UJ
l,!
9- 24

I tt\ o r.r o
2
o
OL
(!{-
ö ö 'ä
b
o- åe
o
L
s9
+
I
g
s9 n9
trJ
öa
fi f; fi
F
2
H
-E .t< HE HC te trJ tL
[\
o o
I -
lrJ o\
+ o
6 qo o
oo
(, o,
oo
F L
--
r\= =B fiå FO
t\G
z
9- 25

@ \Or O
*Eb
op >
u J O -( 9
- oL
o-
8
L.F :
.F-
b3 oo
E
Fc)
-E
+L
o o\ o
-- €
o
-N o
t ! Zl ] . G,
-
@ - m o- F | J \ r r tr <! tn
@ o \ o\ - o - O\O!O\O!O-
ttttl rtrrl rrrrtl
l o o \ n @ o' r \ r \N FC !N -
( DC OO\ O \@ - \O O\ OA\ O-
t -o
L.F
r r\ o r \ o o r . \ ooooon\
R8 38n NO-O ON oooooN
o - o o \F | / rn - o ( D F\ o r a
o o
2
OE
l-
q
o +L - oo -oo
;
I
o - 2-
F
od,
t@
o
o
(9 E< ,
@ (, SR
;
tL rr (Lrr
g o
2 o QO
{-c
gl L L o- o
E- N
H =
d) ;
>=F
-?
IJJ
FF
ur z
o
3
E3
E ö o 6
rr- trJ
s -26

OL
hf
dt L E-o
o
LLO
3 93.
ooLo
o o@
-t-
o
.F o
LO ooo o 8 88
o o c{ o oo oN o oo o N
4q
o
oooo
3838R 8 R8 8 R8 8 3 8 3 R
o
8
-E
o ö 8 8
o
N
EL
o
o
-o
o
t-
oq!
+< st< $
ur
( L \d) lrJ O kr (9
IL\ 0-\ TL\ IL\ tt\
UJ (D =
J
dt 3 a
.F o o \o
L
oo
o oo oQ
= eE
-= F6 FL
lrJ
E
g-?7

OL
LO
oooo
(o L E . Ö
o
L L( D
o -o L
O>oL
o
\o\ o\o ooo o
ou
o o
1- ooooo
OOOOcrl OOO Oc rl
88 88 8
ooo oN
E zt^
F.
o o_
\o
-E
-L
.F
.F o
o
XE
EL
o
o
-o
oo
!
l-
-E IJJ Z uro rrr o-

(L\ o- \ tt \
t!
=
ao
o
.F \o
=< )
F
C;F
(-9 o9l- oo
= E-
E
-
sJ=t
lrJ
9-2E

o n9
o
z
L
.F
o aO-
OL
LO
OctL
oo o -
ö
o- ns
Oo-
o
s9 s9 s9 s9
9>
I
o
o
o
.F
F
z U(D bJ (9 u z trJ O
trJ
z
-E IL\ Hq d\ o-\ (t\ d\ o- \ t!\
lrl d
[\ 0- \
=- o -
a oo @ o\
o = r.\ @ o
z
o oo
o
JE ;R
o
9 ö
L
o9 ö o= 3E ö-
E
<) F=
-E FL FO -E
\ f= sl ö sfr
z,

-L
{- Pb
639
-L O @@@
U J(L < D
o
a o\
o
h3 t (,E
oo
FO
o o
-c)
{- L
oo\o
o-
(J E
--E
o
- - - 'a
-nO L
fNa
LLZ(L
=
E
rr ttl $F $T ttl rrrtl

o
{-o
Ll-
o o ool n ooo m
@ e o o ooN 88 8S oooc { R8 8 8 R 88 8S
LE - ( LO
o o
OE
.F
o .FE
o 4L F83 - oo F8 3 88 8 * RS
o qor
o
F
o o
t
8 o
c{d
-d -& Fc
L t@ t@ t@ t@ t@ l@
o
(D d< e< G< E< a
ö\t o!t ör \
o
SR o\ SR
\t t! \
< tt' P
IL
l! N
0_ r'l Hf i
J
3 o N
(D .F o
= z @
!J
!!
?e= .F
I
g< !ll)lo .FO
'r- E
EN
E-F
;(n !r \
; -F
J= ro
z.
|lI
I
ut z
äg o )
o- ;, o ö
lr, =
=o
9 -3 0
Oc
OL
+LO
E oo
- LO @@ @
rrJ o- (9
o-
t. rE
o- oo
o
E
.l- L
ooro
o-
--E
o
E
- NO
-t! zO-o -
-
o-9
.F O
Ll-
@
o
o
L
q .F E
O PL R83
o
+
o -= -
F
o
t@
o
o
(9 c<
<<J
&
t!
*
3 o
o
z
.F
o- o
.oro
llJ
ur o od
5$ 6 E
2
lrl
-<
t^ 2
ä o
-:r ! E
lrJ :t
lr lrl
-ct
9- 31

OL
LO
oooo
6L E.O
o
LL O)
ooLo
.o(9 0-o
ooo F oo F o oF ooF
1-
<) oOrr O o o6 l o on \
F@Q
o oo n
cro
'E
o
o oo o
o LO 88 88
o o o o 'l oo oN O O O ( \J
-oo
EL
E
388R
o o
o
o
oä
.F
o
o
xe
=L
o
a
o o
a o
{-ö
; oo
s
t
c
I
5
;
o oq
\o \o< \o<
o
trJ d)
o-\ o- \ HC t!\ o\
ro
lrl
J o
o
F
.F
I JO
o t5
o JO
8
o 9o o dr l d-s :F e 3- +
-6
lrl
=E @O- - LN
-
LF
I - 32

o rai o
@F tÄ
o
z
b
+ |,\ c)
E n9
OL
LO
+ - -C
o or|-
ooo-
b
o-
n8 SR
o o,
t
t o-
n9 n9 @F
s9
A LO
tL>
o
+
t
c .F
I g
o
n9 s9 n9
f
E
(,
o
6
.E
ro
gF
6 6 6 6
F
2
o _\
trJ dl
IL\
q
auJ
| IJ o
IL\ H{
-o
E
=
<, o
lrJ
8 o o
a
b
\o
oo
ö
I d
o
3 8
d-
ö
d8
lrl cd
t!o 5F -o
\o cl roö ro o \C'ö
9-33

ol
9i
;h -Gro
+eb
ctc
Pnb
.9 P ä(9 @@@
rrj O-
9-
ô o
ttO -6
o- e
EE o or
5gE
FO
t
no
-a
6E= (t
g€
}L
OOto
99 s
o3 , E
:L Z( Ls _o
-NO
d.
-
r t tt l
o E
ei
o{ ooooaT
o ooooN
o
o
E? o L
I o
c
oe
!L
g 6
.FE
O FL F 8R
C' .Fl o ,
u oc
I |o
.F
o-
c o tt
o -- -
F
8E
o
To
o
o
(9 p2
a
s
-6l
I
e
=
ro o-
6&
lrl (l
lrl
c
tr I
+
2 o
(,
oN t o
H C!
5S å å
o- o t
I - 34

LO
o\ \o
o I
3 g P .3
o
LLO
o
-oo
oo Lo
oo6
6b
o o
oo o oo o o oo
LO oo o 88 8 oo o
L
. 3å OO -
38R 38S 38R

-e
o o
\o
-E
.F
o t5
o
o o
N
XE
=L
o
o
o .Fö \o \o ro \o
+
o
c
I
o
(! d (! tL
@ s o-
\o $ $ o-
rrJo
ro
d\
l!
o-\
co
o_ \ ITJ J
Q.\ H< IJJ Z
t L\ HS LI IL
tt \
lrJ
z-
J
o
o ;x
ia =o
-F
dt 8t 9t
(D
z
o 3tE o d)YJ d)
88t o o= E3=
öb oo
33i
äb
o-
t!
Fc '<
@= -
=B R
lrJ
9-35

OL
LO
vt
t o 0
3 Pe3
o
LLO
FQ O Foo
oo L o
ooo |' r
99t r9 \ o o r. 1 0 0
fE
o o
.F ooo
LO
ooo N
IJääö
ooo(\
8 88
oo-
L
Eö OO-
E za
l- L 88R 88R
8 I @
!ä
+
o.
.F o 8 N
N N
XE
EL
e
I
6. o
E o
o @ \o
.F
t
c
I
F o
E
(,
o
@
s s $ () o-
@
-E lrl al
a!\ Hq t!<
IL\ H<
ro
UT
3 o o I
il
.F qh =5
tr qo
A 8
atso dt<
o
2,
6 8 ET
cl
lrl \o tL od
:l oI=-R
lrl
9 -3 6

o
o
z
L
o \ oa
+' H9 HS
I @o
OL
LO
no
I
8 3h
o-
HH HH S
o
3S
c
a
(D@
C!
t!>
c
o
o
c t-
I o
C o
F
(,
dl
\o
F
s s d
\o
(L
s II (L
s
z. r,rl (o trJ (,
H< o-\ o_\ d\ H< t!=
t u\
IJJ Z
(!\
Lrl O
o-\
rrJ O-
t !\
E z-
Q o
lrJ
=J =o (D .F ( 9 {-
z, CD coF dl
E g ;lo
o qo
F
o 6E OJ ö o=
L
(J ölc.r
lrJ
69 S \o 6ö
-E
\o
- - -öo
=-
z
9- 37

o
€9
o @<t
OL
8 3b
o
b :F
o-
o E! HPHH
o
\oc
$
a o-
@o
A
=
o
u
o
c
T e
HS HS
F
c
(,
o
o
o
!o
+
.L
oo @
F
trJ (E
lrl
-
d\ c\ o -\ (L\
o-
=
o o o
lrJ .F (D Ot
dL
co <
=5
d)
, oo 3 8=
o
F
ts -E
\o o- @o
=Es
\o =-
z
9- 3 8

o ELECTRICJ\LEQIIIPICI{T
I NDEX
T€chnlc.l data
A lfer na io rs..... .......... l 0- |
S+ arte r s .. . . . . . . . ......... l 0- 5
o vAlitEr 10 -0

ELECTR tC L EQt,,
tPfCl{T
IECH}IICAL DATA
AL*RMTMS
A lt€rnator Bosch Kl R 11 V 25/65 A
Nom lna l v oliag e. . 1 2y
Output
1400 r pm .. . ..... . 2 04
2100 r pm ., . ..... . 44 4
60 00 r Dm. . ..... . . 6 5A
Slator reslstance 0,1 o hms+ l0 t
Rolor res lstoncg 2 ,8 o hn s + l 0 t
ReguI o tlng v o lta ge ... . ..... . 13 ,1...14 ,5 U
Mln. s llp rln g d lar Eier . ... 26 ,8 mn
Brus h lf lg ih r hen n er ..... . ... 14 ml
Mln. b r us h 1e ng th. ..... . .... 5l ' m
Tlghta nln g t or qu e of h ex ag qrnu t of shai t......... 45 Nn
Altornrtor Lucas A ll5 il5 A
Nomlna l volfa ge .. 1 2y
M ax. v olf age 60 00 rp m... ,.. , .. 4 5A
Earth I n 9 . .... . ... (-)n l nus
M ax. a llot { e d s pe ed .. . ... ... ... | 5000 rpm
Brus h le n gt h r hen n er ... . ..... 20 mm
M ln. b r us h le ng ih.... ... . .. . l0 m n
Brus h sp r In g fe ns lo n,.. . .. . . .. 1,3 ...2 ,7 N
Numb ero f s fa + or p ole s ..,.. 12
Numbq of slaior phases... .
Stalor res I stance. . . . . . . . . . . . . . . . 0,0 92 1! !e6 65
Rotc reslslancE t,2!5 roh ns
R egul otln g v o lio ge . . . . . . . . . . 11 ,6... t4,4 v
Tlght en lng io rq ue of h ex a go nn ul ol sha fi......... 47 Nm
Alt€rnator Lrcås A lti 65 A

N om lna l vo lfa ge .. ............... 12 V
Max . v ollå ge 6 00 0 r pm .. . ..... . ................... 65 A
E arth In g. . ..... . . ............... ( -)m I nu s
Max. allorod speed.. . . . . . . . . . . .. 15000rpm
Brush len gih wh enn€ y. . ..... . . ................... 2 0 r|n
Mln. br ush 1 En 9th. ..... . .... .... l0 rn
Brush s pr fn g tens I on. . . . . . . . . . .. 1,1 ...2 ,1 N
r s ia +o r po les . ....
N um be of .................,.... l2
r s iaio r p ha s es ... .
N um be of . . ... .. .... ,... ..... .. J
S taior r e s1 st a nc e. . ..... . ..... . .. 0 ,t5 2 15 t o hms
Rotcr reslstanca 5,2 !5 tr ohns
R€gu la+ l ngvo ltag e... . ..... . .... t1,6...1 4,4 V
Tlgh+e nl ngior q ue o f he xa go nn u+ o f sh att...................,..... 47 Nm
A lternltor Lucls A lr, 75 A

Nonln al v ol fa ge .. l2u
M ax. v olt ag e 6 00 0 r pm . ..... . .. 1 5^
Eorih I n9. . . . . . . . . (-)m I nu s
Mox . al lo r Ed s Da ed ..... . ..... . | 5000 rpit
Brush l6n g+ hr h gn ne H..... . ... 20 rm
M ln. br ush 1e ng ih, . ..... . ... lO n||l
B rush s pr I n g lEn s lon ..... . .... |,1...2,1 N
Num be ofr s + a to r po les . .... 12
Nunb€r of siatr phases....
Staior res lstance 0,14 4.+ 5 t ohms
Rotor rgs lsfanca 2,45 ! 5l ohns
Regula t I ng vo lfag e... . ..... . | 1 ,6... | 4 ,4 V
Tlghten lng t or qu e o f he x ag onnu i o f sh att......... 47 Nm
1 0- 1

A lternator Lucas 23 ACRcnd 25 ACR
Nomlnal v ol+ ag e. . 12\
M ax . v ol ta ge 60 00 rpm. . .. . . .. . 2l ACR 55 A, 25 ACR65 A
E ar ihlng. . . . . . . . . (- )m l n u s
l'4ax. allovred speed.. . . . . . . . . . . 15000rprn
B r us h len g+ hwh en ne ' .{ . . .. . .. . . l2,'l Nl
MIn. br us h l en g+ h . . . . . . . . . . I nrn
Brush spr I ng fens lon. . . . . . . . . . 2,5...5,5 N
l2
Numberof stator phases.... 3
Ro+or resl stance 1 . . . f, 5 o h ms
Ragul a+lng v ol iag e. . . . . . . . . . 1 5 , 6 . . . 1 4 , 4 tl
T lgh+ enln g t o rqu e o f h ex a go nn uf o f s h a f t , . .. . . . . . 4l Nm
A lfern6tor CAYAC 5 R 24 Y
Nomlnal v ol+ ag e. . 24y
OuiDu+
2000 r om . . . .. . .. . 16,5 A
25,5 A
4oo or;m ......... 29A
Char gebegln s .. . . | 250 rpm
l'l ax . s pee d. . . .. .. 10000rpm
Pol{q_ rgqu I renen+s. . . . . . . . . . . . . . . 1,8 ktl,/f500 rpm
It ll n. s l lp r ln g d lam eie r.. . . 28,5 r|n
MIn. br us h le ng + h.. . . . . . . . . . I firn
Br us h s pr ln g ien s 1o n. .. . .. . .. . 2 ,2 3 N ( 2 2 7 p l
Max. al loyiedtelpera+ure of surroundlngs.. 7@C
Rec t l fy 1n9 . . . . .. . b y s l l l co n d l o d e s
A lternator Bosch Nl 28 | 55 25
^
NomInal v ol + age . . 24U
Ou+ouf
l0 A
2500 rDm . . .. . .. . . 16A
6000 rD m.. . .. .. . . 554
S+ator reslsi€nc€ 0 ,2 1 o h m s+ to '
Roior res lstance 9 o h m s+ l 0 ,
ReguI atl ng v o liag e. . .. . .. . .. 2 1 , 6 . . .2 A , 4
MI n. s llp rln g d lame te r. .. . 26,4
Br us h l eng t h w hen n e| .. , .. . .. . . 14 mn
Ml n. br us h le ng + h. . .. . . .. . .. 5mm
Tl ghtenlng + orqu e of ho x agq rnui of s h 4 f1 .. . . . .. . . 45 Nm
Altornator Bosch T | 28 v 95 A 16
Noml nal vo lt ag e. 24 \l
Ouipui
900 rp m. . .. .. . .. . 20A
| 150 rp m. . .. .. . .. 45A
1500 rD m. . ,. .. . .. 60A
5500 rp m. . .. .. . .. 954
S+alor r6s I s+ance 0 , 0 f 5 .. . 0 , 0 5 8 o h ms
Roto' resl stance 8,5...9,4 ohms
Rs gul afIng v o l+ ag e. .. . .. . .. . 2 ' t , 6 . .. 2 9 , 4 \
Nll n. s ll p rl ng dla mef e r.. . . 32''[|.|.
Br us h l eng ih rhe n n ot r.. . .. . .. . tö nn
M ln. br us h 1 e ng th .. . .. . .. . .. 7|I m
Tlghf enl n g t o rq ue o f he x ago nn uf of s h a fi . . . . .. . . . 140 Nm
10 -2

STARTERS
Start€r Lucrs M 50 12 V
Values un lo ad ed
.unnlng s peed.... 5500., .7500 rpm (max)
amperag e.. . . . . . . . .. .. ... ... .. l0o A
Va lues un de r loading
runnlng s peed.... . ... ... ... ., l00O rpn
amperag e., . . . . . . . ., ... .. ... .. 590 A
t orque...,.,..... 2l,f Nm (2, 2 kpm)
Values locke d
runn I n g s peed.... .. .. ... ... ..0
amperag e... r. r .. t .'. .. ... ... .980 A
+orque. . , . , . . . , , . 46 Nm (4, 7 kpm) mln
Brush sprlng lens lon (ner br us h ) . . . . , . . . . . . .. .. .. ll, 7 N (1,2 k p)

Min. brush I e n9+ h . . . . . . . . , . . . .. .8 mm
Mln. conrn utai-o r d iane+ei . . , . . . . . . . ... .. ... ... ... . l8 t nn
Siarfer Luccs A 121/2,4 12 |
Values un lo ad ed
runnlng s oeed..., 5500.. .8000 rpm (max)
amperag e., . . . . . , . .. ... .. ... .. ll5 A
vo ltage.. ,.. ... .. ... ,.. ... ,. . ll V
Values un de i loaCing
. . i ri r i r . , i i rv v v I l
u
amperag er,. t !. ! .. .', .. ... .,, . 670 A

+orque........... 20,8 N m (2, 1 kpm)
vol+a9 e....... ... .. .., .. ... .,8,0 v
Va lues Io cked
runn In g s peed.. ,. ,. .. .,. ... ..0
amperag er . r .. r... .. ... .. ... .. ll@ A
iorque........... 45,4 Nm (4, 6 kpm) mln
vo l +aq e. . . , . . . , . . .'. .. ... ... . 5,0 V
Brush sprlng +ens ic i ('Er ..-r sh) ........ ... .. .. .. 11,6... 15,5 N (1, 2. ..1,6 kp )
Min. brush leng+h,........,. . .. . 8 firn
l' 1in. c lmu ta to . c i a-e+€. . . . . . . . . . . ... ... .. ... ... . 18 ft ln
Starter Bosch JF (R) 12 v J kl
VaI ues un l@ded

runnlng s Je €d.. . . >7000 rpm
anperag e.,....... .. ... ... .. .. <IJ o A
vol+a9e.......... .. .. ... ,.. .. ll, 5 V
Va I ues rifh d'na'fure l€kea
running g peed.... 0 .
ampe.ag e,,.....!, ll5O. !.l lOO A*)
vof Tag e.......... .. .. ... ... .. I,z y ,
+orque. . .. . , . .. . . .. .. ... .. .. . >57 Nm
Solenoid e ng aging s oeed rin......., .. ... ... ... .. . I V
Mln. c o.mu+ator C i aneter . . . . . . . . . . ... ... .. ... ... . 42,5 nm
Mln. brush I e ngth . . . . . . . . , , . . .. .8, 5 nm
End play of a.naiu.e . , . . , . . , , .. ,0,1... 0,f mn
* ) When p er lo roing +hes e meas urement s the sourc e ol power mus t c onsls + of t|| o p6rallelly
connec te d öa++e.ies of 12 V l4J Ah
10 - 3

AOC€SSmtES
|l|lEx
Cont r ol lln g +he op era+l ql ot stop s ol gnol d .. ..... ..... ...... ll- |
Coopre ssq 8e nd1 x........... .... ..... ...... l l- 2
A. Rerpvfng and flxlng the conpressor... ... ll- 2
B. R€ con dl tlon lng itF cdt| p r€ssq . . ...... .... l l- 2
Ss -vl c lng end cdJu siln g ihe Ind ust rlc l c|utch... ...... .. .... l l-,1
vÄtitET '1 1 -0

@NIRON-L
ING THE OPERATION
OF STOPSOLEM)ID
l. Clean ihe lever assembly befween +he slop
s o le n ol d a n d + he I nJ ec + l on p um p.Lu br i ca + e th e
jo in ts * l l h e ngl ne ol I a nd en s ur e + h a + + he
leverage funqtlons srnooihly.
2. Renove the rubber cover (A) at +he rea- end of

the stop solenoid. Check that +he disiance
betxeen -the lixed sprlng con'tacis and itle
fllovlng contac+ undea the covei is min. 1,0 rm
rh en t h e s- top s olen oid plun ger (B) i s ful l y
dr aHn ln (e ng lne s top p osi+ ion) .
No +e l Fo i -he op era+ ion of i he s+op

solenoid i+ is of advanl-age if the lever
as s e nb ly h as bee n adju sted y l+h the pl unger (8)
s llgh f ly inr ard s frqn l-he ouier lock posii ion.
l{lih +his adjus'||IEn+, lprevec, if should be
c he c k ed +h at + he foik sc .er is suffl cl enl lv
I n si d e th e plu nger a nd tha t the Inj eci ion pumö
funciions proper I y.
1 1- l

@IfRESSOR BENDIX
( 6 1l 16 1 2 e n gl n e s )
REI.IOVING AND F I X I }G TIIE COPRESSOR
l. Dr a in l h e e n g ln e c o ol a n + .
Re m o v e t h e c oo l a n + p i p e s A a n d i he l ub e o ll
plpe B frdn the compressor. Remove +ho alr
i nl et p i p e C a n d f h e a i r d e li v er y plp e D fr ofl!
+he compressor s lde.
Lo o s en ih e c o mp r e s s o r re t a ln l n g s c re ws an d pu ll
+he comp.essor off lhe gear houslng.
Cl ea n + h e c o m p re s s o r I I rc U n + ln g su rfac e s . lf
needed, renpve ihe drive gear from +he
compre ss or- .
Flt a ner 0-rlng seal lo the colnpiessor

m ou n t ln g f l a ng e . A f t a c h t he d ri v e ge ar. T lg hte n
+he g ea r re t a l ni n g n u t + o 1 4 0 M n .
Push the compressor Into il-s posi+lon In +he

ge a r h o u s i n g a n d + ig h i e n I 'h e r ei a i n ln q nu fs +o
140 Nm.
1 . F ix +h e a ir in l e i pi p e , i h e d e li v e ry p ip e, 11 2
l- he
l ub e o il p l pe a n d f h e c o o la n + p i p es .
F ill t h e e n gi n e c o o li n g s y s f e m a n d e ns ur e +h ai
+here are no leaks,
RECOND IT ION II{G THE COfRESSM

( U s ln g a re p a lr k i t )
11 3
The numbered p a ri s ( l. . . lf ) ar e In c lud ed ln + he

r e p a l r k l+ .
11- 2

Dts ssEiaLY
Refipve lhe re+alnlng scrers A (ll pcs] fo fake
o fl +h e c yllnde r head B and + he v alv e Dl a l e C. F l l th e ln le 'i v al ve h ead gu ld es l ni o ih el r
Rem o ve t h e I nlet v alv e heads l, s prin g s 2 , recesses rlth ihe cut-aeay sldos lowards +helr
valve g u lde s 5 and gas k ei 4. re sp ectlv e c yl ln de r bor es . A ss emb l e+h e I nl e i
va lv e hea ds an d ih e s pr l ngs . Fl t fh e cy l ln de r
2 . Lo ose n i-h e r et alnlng s c rew s D (2 pc s ) a n d he ad us ln g a ne lr g ask ei . T lg hi en i h e r e+ a ln ln g
de lach t h e cy llnder head f ron ihe v alv e p l a +e . sc re is e ven fy + o 2 0,3 ...2 1,0 N m. E ns ur e i ha t
R eno vo lh e dellv ery v alv e heads 5, s prl n g s 6 ihe valve heads move freelv. DO NOTLUBR ICATE
and oasket 7. THE VALVEHEADSOR SPRINGS.
Renf,ve the re+alnlng screvrs of +he alr fllt er I A t+ ac h l' he a lr fl l+ e r (l f n ec es sar y) a nd usd a
( lf as semb le d ) and t ak e of f t he t llier and +he new qasKer,
gaske+ 9.
R e ro v e f he u nloa d er s p rln g an d s ad d le l0 as
v {el l a6 l he p lsio n s an d + he o- rln gs s oa l s ll.
lf necessary, remove lhe roar end cover E and

Its o-rlng seal 12 and +he boi+om cover F lrlth
I t s g as k e f ll.
Not€ | Do no+ +ry io renove +he valve sea+s
O. They are pressed ln durlng manufac-iureand
aro Iniegral par+s of the crankcase H.
INSPECT
ION
Thoroughly clean all removedparis. Ensure l-hat
a l l a lr an d waie r p a ss a ge sar e c le ar . Cl ean off
anv cårbon lrom +he olsion heads and +he
c y ll nder t o p p a ris .
C h ec k t he c on dl +lo n of ih e inle t a nd de ll very

v al v e s e ats . 0 n ly sllg h+ , e v e n wear ls
pe r m l+ t e d. lf the d ellv er y va lv e s ea+ s s ho w
c o ns ld er able we a r, re ne w +h e v alv e p laie C. l{
+ h e I nl e+ va lve s ea +s a re e x c es s iv el v worn,
rep lace ihe crankcase H. You can also replace
+he lnle+ valve seats, bu+ +hen you need +o
re-bore +he cyllnders after the new seats have
been J li+ed.
N,oiel The are +wo overslze plsions supplled

for +he compressor. The overslzes are 0,254 rm
and 0,508 rin. Bore ihe cyllnders ihen +o l'he
dlmenslons ö 15,254 rnmor d 75,508 lltn.
E n s u re ih at +h o ne v l u n lo a de r pls +o n s l1 a re a
g o od s l ld lng f l+ In + he lr gu lde s . lf th e guldes
ore appreclably worn, renew them.
Check the bearings for wear and replace +hem,

l f ne c es s a ry . lf n ee d ed , + he s lld e be a rl ng ln
ihe end cover E can be renewed.
REASSEtaLY
Fl t a ne v , O- r ln g s ea l l2 In I1 -s g ro ove and
p l a c e t he e n d co v e r ln lts p o sl+ ion by pushl ng
fron fhe back. T lghien +he cover re+aI nl ng
s c re w s e v e nly to 1 7 ...2 1 Nm.
Fli +he bo+tomcover wl+h a nev gaske+ ln place
( lf removed). Tlghten +he refalnlng screv.s
e v enl y t o 8...1 0 Nm .
I ns er t no w O- rln g s ln + he u nlo ad e r plsi on s.
L u br l c a + e lh e O -r lng s a nd lh e p ls io n g uldes
l l gh+ l y t { l +h e . g. s lllc o ne lu br lca n +. F li + h e
p l s + ons I n +h e lr gu ld es an d r e as s emb le + he
u nl o ader s a d dle an d s pr lng . E ns u re th a+ i he
unloader mechan lsm movesfreely.
F l + t he de llv er y v alv e h ea ds an d s p rlngs In+ o
t h e v al v e pla+ e . In se r+ a ne v r g a s ke + a nd fl x
t he v al v e p la +e ln ih e c y llnd o r h e ad . Tlghte n
l - he s c r ow s D + o 5,4 ...8,1 Nm . En s ur e ihal + he
valve heads move freely. DO t{oT LUBR ICATE
THE VÎ-YEHEADSM SFRINGS.
1 1- 3

THE INDUSIRIALCLUTCH
StRVICI I'IGANDADJUSTII{G
(4.P. Borg t Beck)
Notgl Never servlce or adj us+ +he c I u+ch

|llt h f h e en gIn e ru nn lng .
11 6
AdJustlng rlngs of th€ clifch
3
Renovs the Inspectlon @v€r and release the
4 a dj usi er lo ck on iha re d adJusll ng rlng.
Ncrtel SorE clu+ches are furnlshgd wllh E
sockei headodscrew to lock ihe €dJus+lng rlng.
Rencve +he screw be{ore adJusilng. At+er
a dj ustfl€ nf tl gh ten i h e screw i o 11,5 . . , 18 N m
and ensure ihai l-he lnner end of ihg screw
engagesbe+teen +he spllnes on the body.
Tu rn the a djus+lng rl ng cl o ckrl lse by ha nd or by
fa pp ln g yli h a l lgh i ha nrner,uni l I i he c or r oc t
adj usinen+ ls reached.
Flt ihe adj usler lock and the Inspectlon cover.
AdJustlng tlp nlln b€arI ng
The tapered roller bearlngs on ihe drlve shafi
Inspeci lon cover nusl be adjus-ted rhen +he shaft eod plöy
PuI l-oul hole exce€ds 0,25 rm.
Grease nlpple tor release bearlng
4 . G reo s e n lpp le for m aln b ea rl ng
Lubrl cai lon

Lubr lca f e + he r ele as e be ar lng dal ly a nd + he
m aln be ar ln g at ln te r va ls o { 50 r u nnl n g ho urs.
U se lllh lum - ba s ed gr e as e f or lub r lcafl on (e.9 .
Shell A lv a nla no . 2) .
A t lnie r v als o f 5 00 r u nn lng ho ur s lu brl ca fe + he

wrlst plns, the yoke ends and +he cross shotl
beorlng s nl ih a fe u d ro ps o f en gln e ol l.
AdJustnont
The c l uic h ls c o rr ec tly ad jus led rh en ,' th e
engageneni load at the end of fhe operatlng
lever ls 14...41 kg (operatl ng lever ,fength
65,5 c m ) .
l. Lock p lafe
2. T ap e rs d r o l l er b ea r l n os
l . A d j us t I n g rl ng
Remove +he Inspectlon @ver and iakg ofl ih€

lock p late.
11 5

Uslng a soft nefal drlft iurn tha adjus+lng
r lng towa rds lhe b€ arlng , un +ll the d rl ve sh aft
end glay ls 0,10...0,20 nm. One no+ch of ihe
adjusier ls oqulvalent to abou+ 0,09 r b€arlng
movemenT.
Nqtel The bearlng xlll b€ overstressed and

v r ll l. r un hoi, lf all , en d pla y ls e l l ml nated.
Afier adjustmont ensure +haf fhe shåff end play
ls s uff lc le nf (0 ,'1 0.,.0,20 rfln).
Replace the lock plate and ihe lnspecilon
RerDvlng fhe poflsr take-ff froo the englno

Dlsconnect lhe drlvs from ihe clutch and remove
t he pulley ,/c oup llng a nd fh e s ha fl ke y.
2. Supporf +he welgh+ of the poxer fake-off trlih
e. g. a ch al n hol st. Re nov eihe cl uich opera il ng
Loos en t he c lutc h reta lnln g scr€ns. The c luich

hous lng f la nge h ås p ull-o ui ho les (thr ead 0,5tr
BS F ). Pla ce s crew s ln th e hole s and tl ghte n
ihem on 6 h all o f a +u rn a+ a +lrF a l+e rna+el y,
un+l I ihe cl utch ho us lng ls removed from lis
spI go+.
1 . t-5

309

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

309

Uploaded by

Copyright:

Available Formats

1 General

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

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

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

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

E 6tE Tt?E DESt€rTtOtS

AppI I cat lon

E ngl ne oqulppedrlth boost clr cooll ng

InJ6cilon punp iype ln 6-cyllnder er|glngs

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

Downloaded from www.Manualslib.com manuals search engine

Cyl ln d€ r he a d sc r€rs a nd n ut s f 0 9, ,l l J ö 4 ll . ... .. ... ... .. ... ... l6 0

Downloaded from www.Manualslib.com manuals search engine

Cyllndar b lod( ,09

Cylln dar block tll , 4ll , 6ll, 6 12

Cyllnd€r I Iner 509

Pr ofru slq l of c y llnder lln€r above c yl l n d s r bl @ k l o p f ac e .. .. .. .. 0,0J0...0,080

Cy llnd €r lln€r lll, 4ll, 6ll

Pro tru siq r ot c y llndq- llner abov o c y l l nd e r b l c c k to p fa c € . ,. .. .. . 0,0J0. ..0,080

Cy llnd €r llnor 612

Pro iru sio. r of cy llndei- I I ns - abov e c y l l nd er bl a k fo p fa c s . .. .. ,. . 0, 010...0,080

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

On both sldes of the rear maln bearlna +here are

Downloaded from www.Manualslib.com manuals search engine

Th€ flyrheel houslng Is flxed to ihe rear end

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

Downloaded from www.Manualslib.com manuals search engine

I\4easure +he wear of the camshaft bearIngs

Perfoim the neasuremoni crosswlse a+ tho llner

Check ihe gauge readlng for maxlmum vrear and

RETOYII€ llf CYLINDERLINER

l. I t y o u in+ end io r elns iall the c y ll nd er l l ners ,

Measure ihe clearance of +he bush and the

Downloaded from www.Manualslib.com manuals search engine

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

6ll1612 englnes hav€ seven replaceable camshafl

C le an the bear ln g h ou sln gs In th € cy llnd er

F. C IGHAFTmRECr tor{ EEAR 5r1l/ l

Downloaded from www.Manualslib.com manuals search engine

Camshatt correctlo4 bearfng bushes for 6ll1612

l f need ed , y ou c an l nsi al I ln +he cyl l nder

t . FITTING IIf BLOCK

l . Cl ean +h e plp e hole l n the cyll nder bl ock.

Ap ply r eia lnl ng fl uld ( 6909 J0 012) to t he gul de

T öp t he b loc k lng plu g In i+s place yli h th e

Notel Be careful no+ io lap ihe blocklng

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

Downloaded from www.Manualslib.com manuals search engine

Apply marklng colour fo th6 undersld6 of the

5 . l f ih e m ailng l ac e l s d omag odor li +h e llne r 311 ,411 .611

An overthlck iop flange ls marked rlth ihe

5, Fo|- the fiFasurglEn+ procedure press tho

Downloaded from www.Manualslib.com manuals search engine

In sia ll atl on ordo r o f o- rl ngs l n 3l l, 4l l , 6l l

Press the l lne i- In l fs posl fl on In fh e cyl l nder

'n rlngs are correcily placed. Ensure fhal ihe

9 . Pla ce ih e o -r lng s In the cy I Indor llner gr@vgs

t{otel Try io åvold even sllghiest streichlng

1 0. lf ihe cyllnder block ls badly corraded ai +he

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

In s+a llailo n ordg r of o-r I ng s ln the f09 s n gl ne