D7E Engine Manual [PDF]

Zitiervorschau

Foreword This booklet is part of a complete service manual. Read the fore‐ word in the service manual.

WARNING! Always read the booklet Safety before proceeding.

VOE21A1002167

1

Content 00 DESCRIPTION, COMPLETE MACHINE 000 General Foreword ..................................................................................................... 7

03 SPECIFICATIONS 030 General VOLVO standard tightening torques ........................................................... 8 Tensile strength class 8.8 Metric coarse and fine threads ........................ 8 Tensile strength class 10.9 Metric coarse and fine threads ...................... 8 UNC threads, coarse pitch ........................................................................ 8 Engine, specifications ................................................................................. 9 Cylinder head, specifications ...................................................................... 9 Cylinder head bolts ................................................................................... 9 Cylinder head gasket .............................................................................. 10 Cylinder block, specifications .................................................................... 10 Pistons, specifications .............................................................................. 10 Piston ...................................................................................................... 10 Piston rings ............................................................................................. 10 Cylinder liner, specifications ..................................................................... 10 Camshaft, specifications ........................................................................... 11 Crankshaft, specifications ......................................................................... 11 ................................................................................................................. 12 Connecting rods, specifications ................................................................ 12 Big-end bearings ..................................................................................... 12 Speed sensor, specifications .................................................................... 12 Valve mechanism, tightening torques ....................................................... 12 Rocker arm holder, tightening torque ..................................................... 12 Lock nut, tightening torque ..................................................................... 12 Cylinder head, tightening torques ............................................................. 13 Valve mechanism, specifications .............................................................. 13 Oil trap, tightening torque ......................................................................... 13 Timing gear casing, tightening torques ..................................................... 14 Cylinder block, tightening torques ............................................................. 14 Screw plugs ............................................................................................ 14 Flywheel, tightening torques ..................................................................... 15 Belt pulley/vibration damper, tightening torques ....................................... 15 ................................................................................................................. 15 Oil sump, tightening torque ....................................................................... 16 Fuel system, tightening torques ................................................................ 16 Oil pump, tightening torques ..................................................................... 16 Oil cooler, tightening torques .................................................................... 16 Injectors, tightening torques ...................................................................... 17 Exhaust manifold, tightening torques ........................................................ 17 Turbocharger, tightening torques .............................................................. 17 Charge-air pipe, tightening torque ............................................................ 17 Coolant thermostat housing, tightening torques ....................................... 17 Crankshaft, tightening torques .................................................................. 17 Speed sensor, tightening torque ............................................................... 18

21 ENGINE 210 General, common info about 211 - 218 Engine, mounting in work stand ................................................................ 19 Turbocharger, removing ......................................................................... 19 Mounting in work stand ........................................................................... 20 Engine, dismantling .................................................................................. 21 Cable harness, removing ........................................................................ 22 Loosen V-belts alt. flat belt ..................................................................... 23 Coolant pump and thermostat housing, removing .................................. 28 3

Oil sump, removing ................................................................................. 29 Flywheel, removing ................................................................................. 30 Pistons and connecting rods ................................................................... 33 Crankshaft, removing .............................................................................. 34 Camshaft and valve tappets, removing .................................................. 35 Power take-off housing, removing .......................................................... 36 Pressure control valve, removing ........................................................... 36 Camshaft bushings, removing ................................................................ 37 ................................................................................................................. 37 Cylinder liner, removing .......................................................................... 37 Engine, assembling .................................................................................. 39 Assembling ............................................................................................. 39 Timing gear casing, changing crankshaft seal ........................................ 39 Pressure control valve, installing ............................................................ 40 Cylinder liner, installing ........................................................................... 40 Camshaft, installing ................................................................................ 41 Crankshaft, installing .............................................................................. 44 Pistons and connecting rods, installing ................................................... 46 Timing gear casing, installing ................................................................. 47 Front cover with oil pump, installing ........................................................ 48 Power take-off housing, installing ........................................................... 52 Flywheel, installing .................................................................................. 52 Oil cooler and oil filter, installing ............................................................. 54 Determining thickness of cylinder head gasket ...................................... 54 Pistons' height above engine block ......................................................... 54 Cylinder head, installing .......................................................................... 55 Valve adjustment .................................................................................... 56 Pumps, installing ..................................................................................... 57 Exhaust pipe, inlet manifold, and valve cover, installing ......................... 57 Oil trap, installing .................................................................................... 58 Coolant pump and thermostat housing, installing ................................... 58 Crankshaft sensor, installing ................................................................... 59 Fuel pump, installing ............................................................................... 60 Belts, installing ........................................................................................ 60 Injectors and fuel lines, installing ............................................................ 61 Starter motor ........................................................................................... 63 Cable rail with cable harness, installing .................................................. 64 Engine, removing from work stand ........................................................... 65 Removing from work stand ..................................................................... 65 Turbocharger, installing .......................................................................... 66 211 Cylinder head Cylinder head, reconditioning ................................................................... 67 Valve seat, changing .............................................................................. 69 Valve seat, grinding ................................................................................ 70 Valves, grinding ...................................................................................... 71 Rocker arm bridge, dismantling .............................................................. 71 Valves, installing ..................................................................................... 71 212 Cylinder block with crankcase ventilation Cylinder block, checking and measuring wear ......................................... 74 Cylinder block, checking ......................................................................... 74 213 Cylinder liner; piston Piston with connecting rod, checking ........................................................ 75 Dismantling connecting rod and piston ................................................... 75 Connecting rods, checking ..................................................................... 77 Assembling connecting rod and piston ................................................... 78 Cylinder liner, checking and measuring wear ........................................... 78 214 Valve mechanism Valves, adjusting ....................................................................................... 80 Installing and adjusting IEGR-unit ......................................................... 82

4

215 Engine transmission; camshaft Camshaft, checking wear ......................................................................... 84 Camshaft outside diameter and bearing hole diameter measure‐ ment ....................................................................................................... 84 216 Crank shaft; connecting rod; vibration damper; fly wheel Crankshaft, checking ................................................................................ 85 Main bearings ......................................................................................... 85 Main bearing cups .................................................................................. 85 Thrust bearing ......................................................................................... 85 Big-end bearing ...................................................................................... 86 Starter ring gear, replacing ....................................................................... 87

22 LUBRICATING SYSTEM 221 Oil pump; line Oil pump removed, reconditioning ............................................................ 88 223 Oil cooler Oil cooler (removed), reconditioning ......................................................... 90 Changing ................................................................................................ 90 Leakage check ........................................................................................ 91

5

GENERAL 00 DESCRIPTION, COMPLETE MACHINE 000 General Foreword This service manuals contains specifications, descriptions, repair instructions, drawing, and diagrams for engine D7E, equipped to fulfill governing legislation according to stage 3/stage IIIA for exhaust emissions. Instructions are based on method studies conducted on D7E‐ LAE3. There may be some deviations, depending on the machine type for which the engines are adapted. Since illustrations in the service literature are re-used for different engine versions, some details may differ from the version in question. However, the essential information is always correct. The instructions are valid on the condition that the engine has been removed from the machine or that it is exposed in the machine. The instructions for necessary work to expose the engine is available in the service manual for each machine type. The instructions are based on the use of special tools and gen‐ erally available standard tools. Information about engine power, engine speeds, optional equip‐ ment, etc., see service manual for each machine type.

WARNING! This warning symbol means risk of fatalities or personal injury if the instructions are not followed. Also read through and follow the instructions in Section "Safety" in the service manual for each machine type. For reference number of each manual, see the current publica‐ tions catalogue and SSI (Service Support Information). All lifting devices such as slings, straps, ratchet blocks, etc. must comply with the governing national regulations for lifting devices. The operation numbers refer to "Time Guide". Volvo Construction Equipment will not accept any responsibility if other tools or work methods other than those described in this publication are used. The information and data given in this manual are valid at the time of publication. Volvo Construction Equipment reserves the right to modify spec‐ ifications and equipment without prior notice. 7

03 SPECIFICATIONS 030 General VOLVO standard tightening torques The tightening torques in the following tables refer to bolted joints with tensile strength as indicated. The tables should be regarded as a general guideline for tightening of bolted joints where nothing else is specified. NOTE! For flange bolt of type U6FS, values should be increased by 10%. Bolts and nuts should be clean and lubricated with oil.

Tensile strength class 8.8 Metric coarse and fine threads Thread

Nm

kpm

lbf ft

M6

10 ±2

1.0 ±0.2

7.4 ±3.5

M8

24 ±5

2.4 ±0.5

18 ±3.5

M 10

48 ±10

4.8 ±1.0

35 ±7.4

M 12

85 ±18

8.5 ±1.8

63 ±13.0

M 14

140 ±25

14.0 ±2.5

103 ±18.0

M 16

220 ±45

22.0 ±4.5

160 ±33.0

M 20

430 ±85

43.0 ±8.5

320 ±63.0

M 24

740 ±150

74.0 ±15.0

550 ±110.0

Tensile strength class 10.9 Metric coarse and fine threads Thread

Nm

kpm

lbf ft

M6

12 ±2

1.2 ±0.2

9 ±1.5

M8

30 ±5

3.0 ±0.5

22 ±3.5

M 10

60 ±10

6.0 ±1.0

44 ±7.5

M 12

105 ±20

10.5 ±2.0

78 ±14.5

M 14

175 ±30

17.5 ±3.0

130 ±22

M 16

275 ±45

27.5 ±4.5

204 ±33

M 20

540 ±90

54.0 ±9.0

400 ±66

M 24

805 ±160

80.5 ±16.0

594 ±118

UNC threads, coarse pitch Thread

8

Nm

kpm

lbf ft

1/4"

9 ±2

0.9 ±0.2

6.6 ±1.5

5/16"

18 ±4

1.8 ±0.4

13 ±3.0

3/8"

33 ±8

3.3 ±0.8

24 ±5.9

7/16"

54 ±14

5.4 ±1.4

40 ±10

1/2"

80 ±20

8.0 ±2.0

59 ±15

9/16"

120 ±30

12.0 ±3.0

89 ±22

5/8"

170 ±40

17.0 ±4.0

130 ±30

Thread

Nm

kpm

lbf ft

3/4"

300 ±70

30.0 ±7.0

220 ±52

7/8"

485 ±115

48.5 ±11.5

360 ±85

1"

725 ±175

72.5 ±17.5

530 ±130

Engine, specifications Model

Used in

Output

Torque

D7E EBE3

Excavator EC240B

125 kW (168 hp) at 1800 rpm

870 Nm (642 lb ft) at 1350 rpm

D7E EAE3

Excavator EC290B

145 kW (195 hp) at 1800 rpm

961 Nm (709 lb ft) at 1350 rpm

D7E GCE3

Motor grader G930

150 kW (201 hp) at 2100 rpm

954 Nm (704 lbf ft) at 1550 rpm

D7E GBE3

Motor grader G940

165 kW (221 hp) at 2100 rpm

1049 Nm (774 lbf ft) at 1550 rpm

D7E GAE3

Motor grader G946, G960

180 kW (241 hp) at 2100 rpm

1100 Nm (811 lbf ft) at 1550 rpm

D7E LBE3

Loader L110F

169 kW (227 hp) at 1700 rpm

1059 Nm (781 lbf ft) at 1400 rpm

D7E LAE3

Loader L120F

179 kW (240 hp) at 1700 rpm

1059 Nm (781 lbf ft) at 1500 rpm

Type

Four-stroke diesel

Combustion system

Direct injection

Number of cylinders

6

Cylinder bore

108 +0.02 mm (4.251+0.0008 in)

Stroke

130 mm (5.118 in)

Displacement

7.150 dm3 (litres) (436 in3)

No. of valves

12

Direction of rotation

Facing flywheel, counter-clockwise

Compression ratio

18:1

Ignition sequence

1-5-3-6-2-4

Cylinder head, specifications Type

6 cyl.

Length

849.5 mm (33.4 in)

Width

256 ±0.2 mm (10 in)

Height

110 mm (4.33 in)

Cylinder head bolts Quantity/cylinder head

26

Thread dimension

M15

Length

134 resp. 170 mm (5.27 resp. 6.69 in)

9

Cylinder head gasket Marking

Intended for piston height

1 hole

0.28–0.53 mm (0.011–0.0208 in)

2 holes

0.54–0.63 mm (0.0209–0.0251 in)

3 holes

0.64–0.75 mm (0.0252–0.029 in)

Cylinder block, specifications Cylinder diameter (liner)

108 +0.02 mm (4.251+0.0008 in)

Stroke

130 mm (5.118 in)

Cylinder liner's seat, depth

8.92 +0.03 mm (0.3512 +0.0011 in)

Liner position, height above engine block

0.03 – 0.08 mm (0.0012 – 0.0031 in)

Oil cooling nozzle

2-hole

Pistons, specifications Piston Height above cylinder block face

0.28–0.75 mm (0.0110-0.0295 in)

Diameter between upper and lower compression ring

107.660 mm (4.2386 in)

Number of ring grooves

3

Marking

Symbol facing the flywheel

Piston pin, diameter

42.0 –0.006 mm (1.65 –0.00024 in)

Piston rings Compression rings Quantity Piston ring clearance in grooves: upper compression ring lower compression ring Piston ring gap: upper compression ring lower compression ring

2 Trapezius-shaped profile 0.09–0.13 mm (0.0035-0.0051 in) 0.3–0.55 mm (0.012–0.022 in) 1.5–2.0 mm (0.059–0.079 in)

Oil scraper ring Quantity

1

Piston ring clearance in grooves

0.03–0.075 mm (0.0011-0.0029 in)

Piston ring gap

0.3–0.6 mm (0.012–0.024 in)

Cylinder liner, specifications Type

Wet, replaceable

Cylinder bore

108 +0.02 mm (4.25 +0.0008 in)

Cylinder liner's collar height

9.0 –0.02 mm (0.354 –0.0008 in)

Cylinder liner's contact depth

8.92 +0.03 mm (0.351 +0.0012 in)

10

Sealing surface, height above block face

0.03–0.08 mm (0.0011–0.0031 in)

Number of seal rings per cylinder liner

2

Camshaft, specifications Camshaft Drive

Gear

Bearing position, standard

64.2 ±0,2 (2.53 ±0.008)

Radial clearance

0.050–0.124 mm (0.0020– 0.0048 in)

End float

0.1–0.5 mm (0.0039– 0.0197 in)

Max. gear flank clearance camshaft gear –crankshaft gear

0.031–0.095 mm (0.0012– 0.0037 in)

Bearing bushings Quantity

7

Bearing bushings, inside diameter

65 +0.054 mm (2.559 ±0.0021 in)

Wear limit

65.08 mm (2.562 in)

Position of the bearing bushing nearest to the flywheel

2 +0.5 mm (0.08 ±0.0020 in) from the engine block's outer edge

Crankshaft, specifications General Length

973.2 mm (38.31 in)

End float

0.1–0.3 mm (0.004–0.012 in)

Radial clearance

0.03–0.092 mm (0.0012–0.0036 in)

Max. "throw"

0.1 mm (0.004 in)

Main bearing journals Diameter, standard

85.00 –0.02 mm (3.346 –0.0008 in)

1st undersize 0.25 mm

0.25 mm (0.010 in)

2nd undersize 0.50 mm (limit for undersize)

84.50 –0.02 mm (3.327 –0.0008 in)

Max. out-of-round

0.01 mm (0.0004 in)

Max. taper

0.01 mm (0.0004 in)

Width, standard

38.00 +0.06 mm (1.496 +0.0024 in)

Each oversize

0.40 mm (0.016 in)

Limit for oversize

38.46 mm (1.514 in)

Hardness, bearing position

53 ±3 HCR

Main bearings Type

Replaceable

Inside diameter

85.030–85.066 mm (3.3476–3.3490 in)

Thickness, standard

2.727–2.735 mm (0.1074–0.1077 in)

1st oversize 0.25 mm

2.852–2.860 mm (0.1123–0.1126 in)

2nd oversize 0.50 mm

2.977–2.985 mm (0.1172–0.1175 in)

11

Thrust washer (thrust bearing) Thickness, standard

2.9 +0.05 mm (0.11 +0.0019 in)

Oversize

0.2 mm (0.008 in)

Connecting rod bearing pins Diameter, standard

68.00 –0.02 mm (2.677 –0.0008 in)

1st undersize 0.25 mm

0.25 mm (0.010 in)

2nd undersize 0.50 mm

67.50 –0.02 mm (2.657 –0.0008 in)

Max. out-of-round

0.01 mm (0.0004 in)

Max. taper

0.01 mm (0.0004 in)

Connecting rods, specifications Marking of connecting rod and bearing cap respectively

Digit code

Small-end bushing, inside diameter Wear limit

42.04–42.05 mm (1.6551–1.6555 in) 0.034–0.056 mm (0.0013–0.0022 in)

Piston pin, diameter

42.0 –0.006 mm (1.65 –0.00024 in)

Big-end bearing in rod, inside diameter with installed bearing shells

72.5 +0.02 mm (2.85 +0.0008 in)

Max. clearance crankshaft – connecting rod

0.036–0.095 mm (0.0014–0.0037 in)

Piston pin parallelity

Measurement "a" max. 0.05 mm (0.0002 in) over a distance of x = 100 mm (3.94 in)

Piston pin straightness

Permissible tolerance "A" to "B": 0.05 mm (0.0002 in) over a distance of x = 100 mm (3.94 in)

Big-end bearings Inside diameter

68.03–68.07 mm (2.6783–2.6799 in)

1st oversize 0.25 mm (0.010 in)

67.78–67.82 mm (2.6685–2.6701 in)

2nd oversize 0.50 mm (0.020 in)

67.53–67.57 mm (2.6587–2.6602 in)

Speed sensor, specifications Speed sensor Crankshaft, clearance sensor — sensor ring gear

0.6 ±0.1 mm (0.024 ±0.004 in)

Valve mechanism, tightening torques Rocker arm holder, tightening torque Rocker arm holder, tightening torque

30 Nm (22 lbf ft)

Lock nut, tightening torque Lock nut, tightening torque

12

20 ±2 Nm (15 lbf ft)

Cylinder head, tightening torques Valve cover, bolts

13 Nm (9.6 lbf ft)

Attaching bolts Step 1 Step 2 Step 3

50 Nm (37 lbf ft) 130 Nm (96 lbf ft) 90°

Valve mechanism, specifications Valves Valve head diameter: inlet exhaust

48 ±0.1 mm (1.89 ±0.004 in) 42 ±0.1 mm (1.65 ±0.004 in)

Valve stem, diameter: inlet exhaust

8.98 – 0.05 mm (0.353 –0.002 in) 8.96 – 0.05 mm (0.352 –0.002 in)

Valve clearance, cold engine, value when adjusting: inlet exhaust

90° 150°

Clearance between control valve piston and rocker arm

144°

Measurement between valve disc and cylinder head's face: inlet exhaust

0.99 ±0.1 mm (0.039 ±0.0039 in) 1.0 +0.15 –0.1 mm (0.039 +0.0059 –0.0039 in )

Valve head edge, thickness: inlet exhaust

2.62 mm (0.103 in) 2.30 mm (0.091 in)

Valve guides Max. clearance valve stem - guide, wear tolerance: Inlet Outlet

0.045 — 0.075 mm (0.002 — 0.003 in) 0.065 — 0.105 mm (0.0025 — 0.004 in)

Valve springs Inlet/exhaust Length, unloaded Diameter, thread

64.7 mm (2.55 in) 4.5 mm (0.18 in)

Rocker arm Hole diameter inlet, exhaust

21.02 +0.033 (0.828 +0.0013 in)

Tapp

21.02 –0.021 (0.828 –0.0008 in)

Oil trap, tightening torque Attaching bolts

20 ±2 Nm (14.7 ±1.5 lbf ft)

13

Timing gear casing, tightening torques IMPORTANT! Regarding bolted joints which are not listed here, see “Volvo standard tightening torques” Retaining bolts: M8*55 M8*35 M16*6

20 ±2 Nm (15 lbf ft) 30 ±3 Nm (22 lbf ft) 70 ±5 Nm (52 lbf ft)

Cylinder block, tightening torques IMPORTANT! Regarding bolted joints which are not listed here, see “Volvo standard tightening torques” Starter motor

60 Nm (45 lbf ft)

Screw plugs

Fig.1 Plug 4 Plug 6 Plug 7 Plug 8 Plug 13 Plug 17 Plug 21 Plug 24

14

35 Nm (25 lbf ft) 95 Nm (70 lbf ft) 75 Nm (55 lbf ft) 35 Nm (25 lbf ft) 35 Nm (25 lbf ft) 9 Nm (6 lbf ft) 9 Nm (6 lbf ft) 10 Nm (7 lbf ft)

Flywheel, tightening torques IMPORTANT! Regarding bolted joints which are not listed here, see “Volvo standard tightening torques” Step 1, bolts 30–45 mm Step 1, bolts 50–85 mm

30 –10 Nm (22 –7 lbf ft) 30 +10 Nm (22 +7 lbf ft)

Step 2, bolts 30–85 mm

60°

Step 3, bolts 30 mm Step 3, bolts 35–85 mm

30° 60°

Flywheel housing, M12 bolts, Torx Preliminary tightening Final tightening

By hand 99 Nm (73 lbf ft)

Flywheel housing, M16 bolts, Torx Preliminary tightening Final tightening Cover plate

99 Nm (73 lbf ft) 243 Nm (180 lbf ft) 9 Nm (7 lbf ft)

Belt pulley/vibration damper, tightening torques IMPORTANT! Regarding bolted joints which are not listed here, see “Volvo standard tightening torques” Belt pulley and inner oscillation damper Step 1

30 Nm (22 lbf ft)

Step 2

60°

Step 3

60°

Belt tensioner, lock bolt

30 ±3 Nm (22 ±2 lbf ft)

Outer oscillation damper Attaching bolts

70 Nm (52 lbf ft)

15

Oil sump, tightening torque IMPORTANT! Regarding bolted joints which are not listed here, see “Volvo standard tightening torques” Oil sump

30 Nm (22 lbf ft)

Oil suction pipe

22 ±2 Nm (16 lbf ft)

Ladder frame 2

1 2 3

1

3

1

1

3

1

1

1

2

1

2

30 Nm (22 lbf ft) 30 Nm (22 lbf ft) 22 Nm (16 lbf ft)

3

3 2

1

V1027486

Fuel system, tightening torques IMPORTANT! Regarding bolted joints which are not listed here, see “Volvo standard tightening torques” Fuel rail Fuel rail, attaching bolts

30 Nm (22 lbf ft)

Electrical cables, attaching bolts

1.4 ±0.1 Nm (1.03 lbf ft)

Fuel delivery line (between fuel rail and injector)

25 Nm (18.4 lbf ft)

Injector, yoke

16 ±5 Nm (12 ±4 lbf ft)

Fuel control valve (FCV)

30 Nm (22 lbf ft)

Return line to control valve

39 Nm (28.8 lbf ft)

Fuel feed filter, attaching bolts

30 Nm (22 lbf ft)

Feed line to control valve (from fuel filter)

49 Nm (39.1 lbf ft)

Feed pipe (on control valve)

34 Nm (25.1 lbf ft)

High-pressure pump, attaching bolts Step 1: Step 2:

10 Nm (7.4 lbf ft) 50 Nm (36.9 lbf ft)

Safety valve (PRV), fuel rail

100 Nm (73.8 lbf ft)

High-pressure sensor, fuel rail

70 Nm (51.6 lbf ft)

Oil pump, tightening torques Oil pump's cover, attaching bolts

9 Nm (6.6 lbf ft)

Cover, attaching bolts

21 Nm (15.5 lbf ft)

Oil suction pipe, attaching bolts

21 ±2 Nm (15.5 ±1.5 lbf ft)

Oil cooler, tightening torques Oil cooler housing, attaching bolts Step 1 16

3 Nm (2.2 lbf ft)

Step 2

30 Nm (22 lbf ft)

Oil filter bracket

30 Nm (22 lbf ft)

Flange screws Step 1 Step 2

80 Nm (59 lbf ft) 160 Nm (118 lbf ft)

Screw plugs

80 Nm (59 lbf ft)

Oil pressure switch

30 ±5 Nm (22 ±3.7 lbf ft)

Injectors, tightening torques Bolt injector retainer: Step 1 Step 2

Tighten by hand 16 +5 Nm (12 +4 lbf ft)

Nuts, delivery pipes

25 Nm (18 lbf ft)

Electrical connection, injector

1.5 Nm (1.1 lbf ft)

Exhaust manifold, tightening torques Attaching nuts

25 Nm (18.4 lbf ft)

Turbocharger, tightening torques Stud bolt

40 ±4 Nm (30 ±3 lbf ft)

Nut

10 ±1 Nm (7.4 ±0.7 lbf ft)

Oil pressure pipe, attaching bolts

39 Nm (29 lbf ft)

Return pipe, attaching bolts

20 Nm (15 lbf ft)

Charge-air pipe, tightening torque Charge air pipe Preheating coil

11 Nm (8 lbf ft) 30 Nm (22 lbf ft)

Coolant thermostat housing, tightening torques Thermostat casing

30 Nm (22 lbf ft)

Thermostat housing

30 Nm (22 lbf ft)

Coolant pump

30 Nm (22 lbf ft)

Crankshaft, tightening torques Main bearing caps Initial tightening torque 1st tightening angle 2nd tightening angle

50 Nm (37 lbf ft) 60° 60°

17

Big-end bearing caps Initial tightening torque 1st tightening angle 2nd tightening angle

30 Nm (22 lbf ft) 60° 60°

Speed sensor, tightening torque IMPORTANT! Regarding bolted joints which are not listed here, see “Volvo standard tightening torques” Speed sensor Crankshaft sensor, holder

18

20 Nm (15 lbf ft)

ENGINE WITH MOUNTING AND EQUIPMENT 21 ENGINE 210 General, common info about 211 218 Engine, mounting in work stand Op. no.210-081 Tools: 88800050 Fixture 9986485 Support 9998547 Lifting tool

Turbocharger, removing 1

Disconnect the delivery and return pipes from the tur‐ bocharger. Install protective plugs in the turbocharger's con‐ nections.

2

Remove the attaching nuts and remove the turbocharger.

Fig.2 1 Return pipe 2 Delivery pipe

Fig.3

19

3

Fig.4 1 Protective plugs

Install protective plugs in the connections for the return pipe, delivery pipe, and the manifold.

Mounting in work stand 4

Install the engine fixture the engine. IMPORTANT! Use the supplied bolts. They have higher strength than standard bolts.

Fig.5 1 88800050 Fixture

5

V1010650

Fig.6 1 9998547 Lifting tool

20

Lift the engine into place and bolt down the engine fixture in the support. Engine weight: approx. 700 kg (1545 lbs).

Engine, dismantling Op. no.210-077 Tools: 11668409 Pliers 9998681 Rotation tool 9998674 Adapter 9996400 Impact puller 9998695 Installation tool 9993717 Quick nut 9993713 Puller bolt 9993722 Support 9998675 Puller plate Socket or spanner Torx E10 Socket Torx E12 Socket Torx E18 Socket Torx E20 Lifting eyes M12 Lifting sling Thread tap M8 with handle Drift 20 mm Check that the engine is drained of oil. 1

Remove the oil trap for the crankcase ventilation.

Fig.7 1 Oil trap

21

Cable harness, removing 2

Loosen the cable harness' clamping. Unplug the connector for the E-ECU. Unplug the connectors for the fuel control valve, oil pressure sensor, fuel feed pressure sensor, and the fuel pressure sensor in the fuel rail. Unplug the electrical connections for the injectors.

3

Unplug the connectors for coolant temperature sensor, boost pressure sensor, solenoid valve for I-EGR, and the engine rpm sensor.

Fig.8 Cable harness connections 1 Connector E-ECU 2 Fuel control valve 3 Injectors 4 Fuel feed pressure sensor 5 Oil pressure sensor 6 Fuel pressure sensor

Fig.9 Cable harness connections 1 Boost pressure sensor 2 Coolant temperature sensor 3 Solenoid valve 4 Speed sensor for camshaft

22

Loosen V-belts alt. flat belt 4

Loosen the belt tensioner for the fuel feed pump. Remove the belt.

5

Loosen the V-belt for the AC-compressor. Remove the belt. Loosen the belt tensioner for the flat belt with a wrench. Remove the belt.

Fig.10 Loader and motor grader version 1 Belt adjustment 2 Fuel feed pump's bracket 3 Water pump

6

5

4

1

2

3 V1054006

Fig.11 Excavator version 1 Water pump 2 Flat belt 3 Belt tensioner 4 V-rib belt 5 AC Compressor 6 Alternator

23

6

Loosen the clamps from the feed pump to the fuel control valve. Loosen the fuel feed pump and complete filter hous‐ ing. Loosen the banjo connection to the fuel control valve. Lift away the fuel feed pump and complete filter housing as a unit. Plug all open connections.

7

Remove the lubrication oil filter. Install protective plugs.

8

Remove the drain plug and drain the coolant. Remove the attaching bolts and remove the oil cooler. Remove gasket remains from the sealing surfaces. Install protective plugs.

9

Remove the attaching nuts and remove the exhaust pipe.

10

Remove the preheating coil.

Fig.12 1 Fuel filter 2 Fuel feed pump

Fig.13 1 Oil cooler 2 Drain plug

V1010503

Fig.14 1 Exhaust pipe

24

11

Remove the valve cover and the seal against the inlet man‐ ifold.

12

Remove the attaching bolts and lift away the charge air pipe.

13

Remove all high-pressure pipes from the injectors.

Fig.15 Valve cover

Fig.16 1 Charge air pipe

NOTE! The delivery (pressure) lines may not be reused. Cover the injector's and the rail's openings.

Fig.17 1 Fuel delivery line

25

14

Remove the return pipe and the pipes from the high-pres‐ sure pumps. NOTE! The pressure lines may not be reused. Cover the high-pressure pumps' openings.

15

Remove the fuel control valve. Store the valve in a dust-free location, e.g., in a plastic bag.

Fig.18 1 Fuel return pipe 2 High-pressure pumps 3 Control pressure valve

WARNING! Work carefully when removing due to the spring force.

Fig.19 1 Common rail

26

16

Rotate the crankshaft so that the high-pressure pumps' spring force is unloaded. Carefully loosen the high-pressure pumps' crosswise. Remove the high-pressure fuel pumps. Store the pumps in a dust-free location, e.g., in a plastic bag.

17

Remove the common rail (pressure distribution pipe).

18

Remove the holders for the injectors, and remove the injec‐ tors. NOTE! Make sure that the copper washer on the injectors' lower part also comes out. Mark up the position of the injectors. Store the injectors in a dust-free location, e.g., in a plastic bag.

Fig.20 1 Injectors 2 Retainer

19

Loosen the bolts and lift away the IEGR-unit. Pull apart the IEGR-unit and retain the small oil pipe.

Fig.21 1 IEGR-unit 2 Attaching bolts

Fig.22 IEGR-unit 1 Oil pipe

27

20

Fig.23 1 Attaching bolt

Mark up the rocker arm bridges and remove them together with the rocker arms. Mark up and remove the push rods.

Coolant pump and thermostat housing, removing 21

Remove the bolts and remove the thermostat housing. Remove the bolts and remove the intermediate housing. Remove the bolts and remove the coolant pump.

22

Loosen the bolts for the cylinder head. Use socket Torx E18.

Fig.24 1 Coolant pump 2 Intermediate housing 3 Thermostat housing

Fig.25

28

23

Connect lifting slings to lifting eyes, and lift away the cylinder head. Remove the guide sleeves. Cylinder head weight: approx. 65 kg (143 lbs)

24

Overhaul the cylinder head according to Cylinder head,

25

Remove the roller lifters with 11668409 Pliers.

reconditioning page 67

Fig.26

Fig.27 1 11668409 Pliers 2 Roller tappet

Oil sump, removing 26

Remove the oil dipstick. Turn the engine in the work stand so that the oil sump faces up. Loosen the clamps for the oil level/-temp. sensor. Remove the bolts and remove the oil sump. NOTE! The oil sump is glued to the engine block. Be careful when removing to avoid damaging the sump. Remove the suction oil pipe.

Fig.28 1 Oil level/-temp. sensor 2 Oil sump

29

Flywheel, removing 27

Turn the engine in the adjustable stand so that the flywheel comes upward. Install tool 9998681 Rotation tool.

28

Install lifting eyes M12 and lifting sling. Loosen the bolts and remove the flywheel housing. Weight: approx. 35 kg (77 lbs).

29

Remove the cover washer. NOTE! Some versions do not have this washer.

Fig.29

Fig.30 1 Lifting eyes M12

Fig.31

30

30

Remove the bolts for the flywheel. Use 9998681 Rotation tool as counterhold.

31

Install lifting eyes M12 and lifting sling. Lift away the flywheel. Flywheel weight: approx. 55 kg (120 lbs).

32

Rotate the engine to horizontal position. Make sure that 9998681 Rotation tool does not rotate. Remove the attach‐ ing bolts and remove the outer vibration damper together with the spacer and the inner vibration damper. Weight: approx. 20 kg (44 lbs).

33

Remove the attaching bolts and lift away the V-belt pulley and the ring gear.

Fig.32 1 9998681 Rotation tool

Fig.33 1 Lifting eyes M12

Fig.34

Fig.35 1 Torx E20 2 Toothed wheel 3 V-belt pulley

31

34

Remove the attaching bolts and remove the cover with com‐ plete oil pump.

35

Remove the attaching bolts and remove the timing gear cas‐ ing.

36

Tap out the crankshaft seal on the timing gear casing with a suitable drift.

Fig.36 1 Oil pump

Fig.37 Timing gear casing

Fig.38

32

Pistons and connecting rods 37

Remove the ladder frame.

38

Mark the connecting rods' caps. Remove the cap with bear‐ ing half.

Fig.39 1 Ladder frame

NOTE! Be careful so that the surface between connecting rod and cap is not damaged.

Fig.40

39

Press out the piston with connecting rod. Continue with the next piston. etc. Retain the bearing halves.

V1022057

Fig.41

33

Crankshaft, removing 40

Check that the camshaft and the crankshaft gears are marked.

41

Check that the main bearings' caps are marked. Remove the attaching bolts and remove the caps together with bearing halves.

42

Remove the thrust washers by main bearing number 2 (the thrust bearing journal). Main bearing number 1 is nearest to the flywheel.

43

Connect a lifting sling to the crankshaft and lift it away. Crankshaft weight: approx. 75 kg (165 lbs).

Fig.42 1 Marking

Fig.43

Fig.44 1 Thrust washers

Fig.45

34

44

Remove all bearing shells and thrust washers at main bear‐ ing 2. Mark the washers if they are to be used again.

45

Press out the piston cooling nozzles from underneath with a drift 4 mm (0.16 in).

Fig.46 1 Bearing shell 2 Thrust washers

NOTE! Work carefully so that the nozzle is not damaged.

Fig.47

Camshaft and valve tappets, removing 46

Make sure that the cylinders are turned to face down. Pull out the camshaft.Weight approx. 25 kg (55 lbs). NOTE! Work carefully so that the bushings are not dam‐ aged.

Fig.48 Camshaft

47

Remove the valve tappets. Mark them if they are to be used again.

Fig.49

35

Power take-off housing, removing 48

Fig.50 1 Attaching bolts 2 Oil pipe

Remove the oil pipe's connection from the engine block. Remove the attaching bolts (socket Torx E10 and E12) and remove the power take-off housing with the oil pipe.

Pressure control valve, removing 49

Thread the hole in the pressure control valve with an M8 thread tap.

50

Pull out the pressure control valve with impact hammer 9996400 Impact puller and 9998674 Adapter.

Fig.51

Fig.52

36

Camshaft bushings, removing 51

Remove the camshaft's bearing bushings with 9998695 Installation tool if these are to be replaced. Bush‐ ings can be pulled out both ways.

Fig.53 1 9998695 Installation tool

V1002028

Fig.54 1 Press sleeve 2 Guide sleeve

Cylinder liner, removing 52

Turn the engine in the adjustable stand so that the cylinder liners come upward.

37

53

V1010546

Fig.55 1 9993722 2 9993713 3 9998675 4 9993717

38

Support Puller bolt Puller plate Quick nut

Install the tools according to the figure. Fit puller plate below the lower edge of the cylinder liner. Press out the liner by turning the nut until the liner comes loose. Remove the tools and lift out the cylinder liner. Mark up the cylinder liners if they are to be used again. Repeat the procedure for all liners.

Engine, assembling Op. no.210-078 Tools: 885812 Timing tool 9992000 Handle 9992682 Sealing plug 9998672 Installation tool 9998678 Measuring tool 9998681 Rotation tool 9998687 Installation tool 9998695 Installation tool 11668406 Installation tool Socket or spanner Torx E10 Socket Torx E12 Socket Torx E18 Socket Torx E20 Lifting eyes M10 Lifting sling Thread tap M8 with handle Dial test indicator with magnetic base Dial test indicator with angled base Dial indicator for inside measurement (crankshaft) Depth gauge Piston ring pliers Feeler gauge Screw micrometer Connecting rod testing device Drift 20 mm Steel ruler Torque wrench, open end Valve spring compressor 11713514 Sealing compound

Assembling Timing gear casing, changing crankshaft seal 1

Lube the new crankshaft seal with oil and install it.

Fig.56 1 9992000 Handle 2 9998672 Installation tool

39

Pressure control valve, installing 2

Clean the seat for the pressure control valve. Check that the valve peg can be pushed in. Apply locking fluid on the valve's sealing surface.

3

Install the valve.

4

Drive in the valve until it bottoms out, use a drift 20 mm (0.8 in).

Fig.57

Fig.58

Fig.59

Fig.60 1 O-rings

40

Cylinder liner, installing 5

Make sure that the cylinder liner position and sealing surface are clean.

6

Install new O-rings.

7

Lube the engine block and cylinder liner in the indicated area, marked with an x in the figure.

8

Install the cylinder liners in the engine block. Drive them down as far as possible.

Fig.61

IMPORTANT! Do not use sealing compound.

Fig.62

9

Measure the cylinder liner's protrusion over the sealing face. First, clean the measuring surface thoroughly. Place the measuring tool with adjustments and dial indicator on the engine block. Reset the dial indicator. NOTE! Place the adjustments on the block, not on the liner's edge. Reset the dial indicator against the engine block's gasket face. Place the dial indicator against the cylinder liner's top edge. Measure in three places on the cylinder liner. Replace the cylinder liner if it's outside the tolerance. See

V1005553

Fig.63 1 9998678 Measuring tool 2 Dial gauge 3 Adjustments

Cylinder block, specifications page 10

Camshaft, installing Replace camshaft if there is major damage or wear. See

Camshaft, specifications page 11 All valve tappets should also be replaced when replacing the camshaft.

41

10

Check that the contact surface against the camshaft on the valve tappets is convex or flat. If the surface is concave, replace the valve tappets. If the valve tappet is worn across the contact surface, the tappet must be discarded. The "ditch" shows that the tappet has not been rotating. A dark line outermost on the contact surface however, indicates that the surface is not worn down. It is the condition of the valve tappets that determines whether a check of the camshaft wear is necessary. Check that the contact surfaces on the camshaft and the valve tappets do not have severe pitting damage. Pitting damage may arise for varying reasons. The damage is caused by small bits of metal loosening from the hardened surface. Tappets and camshaft with minor pitting damage may be used. Damage such as pitting usually does not get any worse. Check that the camshaft bearing races and cam profiles are not abnormally worn. The cams may, for example, be worn obliquely in an axial direction. This can, if the damage is light, be adjusted by honing.

11

Lightly lubricate the valve tappets with oil and install them

12

Change the bearing bushings if they are worn.

Fig.64 1 Steel ruler

Fig.65

NOTE! The wider bushing, 27 mm (1.0 in), shall be installed on the flywheel side. The lubrication hole slightly displaced from centre. NOTE! The lubrication holes must line up with the oil chan‐ nels in the bearing positions.

Fig.66 Position of bearing bushings

42

Fig.67 1 Lubricating oil holes

13

Press in the bushings to correct position.

14

Make sure that the cylinders face down so that the valve tappets do not move from their positions. Install the camshaft.Weight approx. 25 kg (55 lbs).

Fig.68 1 9998695 Installation tool

Fig.69 1 Guide sleeve 2 Bearing bushing 3 Press sleeve

NOTE! Take care not to damage the bearing bushings. Check that the camshaft can rotate freely.

Fig.70

43

Crankshaft, installing 15

Blow clean the holes for the piston cooling nozzles Install the nozzles. Press them in as far as possible.

16

Install the bearing shells in the cylinder block and lubricate them with oil.

Fig.71

NOTE! Make sure that the anti-rotation lug is installed cor‐ rectly in the slot.

Fig.72 1 Bearing shell

17

Install the bearing shells in the bearing caps and lubricate them with oil. NOTE! Make sure that the anti-rotation lug is installed cor‐ rectly in the slot.

Fig.73

Fig.74

44

18

Wipe clean the bearing cap together with thrust bearing and thrust washers with pin. Install the thrust washers and mea‐ sure the width.

19

Determine axial run-out. Crankshaft pin's width, see Crankshaft, checking page 85, minus the measured width of the bearing cap and thrust washers give clearance in question. Permitted axial run-out, see Crankshaft, specifications page 11.

20

Lift the crankshaft into position. Make sure that the marking in relation to the camshaft gear will be correctly positioned. Crankshaft weight: approx. 75 kg (165 lbs).

21

Lubricate the thrust washer halves without pin with oil and install them. Insert them into position under the crankshaft. Turn the surfaces with the oil grooves toward the crankshaft's axial bearing surfaces.

22

Attach the other thrust washers onto the bearing cap with a little grease. Turn the washers so that the surfaces with oil grooves are facing toward the thrust bearing surfaces on the crankshaft

23

Lubricate the bearing caps with oil and install them accord‐ ing to the marking. No. 1 nearest to the flywheel end. Make sure that the thrust washers on the cap fit correctly against the washers in the block.

Fig.75 1 Marking (Camshaft marking may be hidden)

Fig.76

Fig.77

Fig.78

45

24

Torque-tighten the bearing caps Tightening torques, see Crankshaft, tightening

torques page 17

IMPORTANT! The bolts should be changed after the engine is dismantled for the third time.

Fig.79

25

Fig.80 1 Pinch-bar 2 Magnetic base 3 Dial gauge

Install the dial indicator with magnetic base. Pry with a pry bar and check the crankshaft run-out. Permitted axial run-out, see Crankshaft, specifications page 11.

Pistons and connecting rods, installing 26

Install the bearing shells in the connecting rods and lubricate them with oil.

27

Use piston ring compressor and install the pistons with con‐ necting rods from the cylinder head side. The flywheel sym‐ bol shall face the flywheel side.

Fig.81

Fig.82 1 9998687 Installation tool

46

Fig.83 Flywheel symbol

28

Lubricate the big-end bearing journals on the crankshaft with oil. Push the connecting rod against the bearing journal and install the caps according to markings. Install new bolts and tighten them down. Tightening torques, see Crankshaft, tightening

torques page 17

Fig.84

Timing gear casing, installing 29

Remove any gasket remnants from the timing gear casing and the cylinder block.

30

Apply sealant Volvo 11713514 on the timing gear casing's sealing face.

31

Lightly oil the crankshaft oil seal.

32

Install the timing gear casing without tightening down the bolts. Position the casing aligned with the sealing surface on the oil sump.

33

Tighten the bolts (except the two bolts where the rotation tool is to be secured). Tightening torque: see Timing gear casing, tightening torques page 13 .

34

Check that the crankshaft can rotate freely.

Fig.85 Applying sealant

Fig.86

47

Front cover with oil pump, installing 35

Install the rotation tool.

36

Turn the engine in the adjustable stand so that the front end comes upward.

37

Clean the cover and the cylinder block from any gasket rem‐ nants.

38

Overhaul the oil pump according to Oil pump removed, reconditioning page 88.

39

Lightly oil the oil pump rotors.

40

Secure the gasket on the housing with a little grease.

41

Place the oil pump's drive against the crankshaft.

Fig.87 1 9998681 Rotation tool

Fig.88

Fig.89

NOTE! The drive only fits in one position.

Fig.90

48

42

Install the housing with the oil pump without tightening down the bolts. Fit the housing against the oil sump's sealing face.

43

Tighten the bolts. Tightening torque: see Oil pump, tightening torques page 16 .

44

Check the position of the wear groove on the crankshaft.

45

Install the guide (inner part of 11668406 Installation tool). Lubricate the crankshaft seal with oil and install it with the felt side facing out.

Fig.91

V1010602

Fig.92 1 Wear groove

V1010603

Fig.93 1 Crankshaft oil seal 2 Guide

49

46

Install any spacer washers, press sleeve, the bearing and the nut. Use the number of washers required to prevent the new crankshaft oil seal from ending up in the same position as the old one.

47

Screw the nut until stop. Check that the seal ends up in the correct position.

48

Install the ring gear and the V-belt pulley and align the guide sleeve and the guide pin.

49

Tighten the bolts (Torx E20), counterhold with the rotation tool on the flywheel side. Tightening torque: see Belt pulley/vibration damper, tight‐ ening torques page 15.

V1010597

Fig.94 1 Washers 2 Press sleeve 3 Bearing 4 Nut

Fig.95 1 Guide sleeve 2 Guide pin

Fig.96 1 Torx E20 2 V-belt pulley 3 Toothed wheel

50

50

Check that the vibration dampers are free from external damage. Replace with new in case of damage or leaks. Install inner vibration damper and the spacer. Make sure that the bolt holes align with the holes in the belt pulley.

51

Install outer vibration damper and the washer. Tighten down the bolts. Tightening torque: see Belt pulley/vibration damper, tight‐ ening torques page 15 .

52

Install the ladder frame.

Fig.97 1 Spacer 2 Vibration damper

Fig.98

NOTE! Allen head bolts are placed in the corners. Tighten the bolts. Tightening torque: see Oil sump, tightening torque page 16.

Fig.99 Ladder frame

53

Install a new gasket on the oil suction pipe's connection to the front cover. Install the oil suction pipe with bracket. Tightening torque: see Oil sump, tightening torque page 16.

54

Install the oil filler pipe.

Fig.100 1 Gasket

51

55

Fill the joints between the covers and the oil sump with sealant.

56

Apply a thin layer of sealant Volvo 11713514 on the engine block.

57

Install new gasket. Install the oil sump and tighten the bolts. Tighten the bolts from the centre and out, alternating from side to side. Tightening torque: see Oil sump, tightening torque page 16.

58

Install the level sensor's clamps.

Fig.101

Fig.102

Fig.103 1 Attaching bolts 2 Oil pipe

Fig.104 1 Lifting eyes M10

52

Power take-off housing, installing 59

Install the power take-off housing. Apply locking fluid and tighten down the bolts (sockets Torx E10 and E12).

60

Install the oil pipe.

Flywheel, installing 61

Rotate the engine in the work stand so that the flywheel side faces up.

62

Lift the flywheel housing into place.Weight: approx 35 kg (77 lbs).

63

Install the bolts and tighten them. Use the rotation tool as counterhold. NOTE! Use new bolts. Tightening torque: see Flywheel, tightening

torques page 14

Fig.105 1 9998681 Rotation tool

64

Install the cover washer. NOTE! NOTE! Some versions do not have this washer.

Fig.106

65

Check that the guide sleeves are in place.

Fig.107 1 Guide sleeve

53

66

Fig.108

Fig.109

Lift the flywheel housing Weight: approx 35 kg (77 lbs).. Install and tighten the bolts by hand. Pre-tighten the bolts 2, 3, 4, 5 as shown. Tighten final torque on bolts 1, 6. Tighten final torque on bolts 2, 3, 4, 5. Tightening torque, see se Flywheel, tightening torques page 14.

Oil cooler and oil filter, installing 67

Remove protective plugs and masking tape. Install the oil cooler with a new gasket. Install the bolts and tighten them. Tightening torque: see Oil cooler, tightening torques page 16.

68

Install a new oil filter.

Determining thickness of cylinder head gasket Cylinder head gaskets are marked with one, two, or three holes in one of the corners. The gaskets shall be used for different pis‐ ton heights above the cylinder block's face.

Fig.110 1 Marking of cylinder head gasket

Pistons' height above engine block 69

54

Install the rotation tool on the engine, 9998681 Rotation tool.

70

First, clean the measuring surface thoroughly. Install the measuring tool with spacer washers and dial indi‐ cator on the engine block. Reset the dial indicator to zero. NOTE! Place the spacer washers on the block, not on the liner edge.

V1005553

Fig.111 1 9998678 Measuring tool 2 Dial gauge 3 Spacer washers

71

Rotate the crankshaft with the rotation tool to find the piston's highest position. Measure at two points diagonally on the piston's upper edge straight above the piston pin. Read off the height on the indicator.

72

Repeat the same measurement on all pistons. Note the highest value and use cylinder head gasket according to Cylinder head, specifications page 9.

Fig.112 Measuring points

V1005554

Fig.113

Cylinder head, installing 73

Place the cylinder head gasket on the cylinder block with the digits upward. Place the guide sleeves in the holes.

Fig.114 1 Guide sleeves

55

74

Lift the cylinder head into position. Pay attention to the guide sleeves. Cylinder head weight: approx. 65 kg (143 lbs)

75

Oil the bolts lightly and install them. Tighten them in three steps, note the sequence.

Fig.115

NOTE! The same bolts may be used max. 3 times. Tightening torque: Cylinder head, tightening torques page 13. Use protractor 885812 Timing tool Fig.116 Torque-tightening, sequence

76

Install the push rods.

77

Install the rocker arm holders according to marking. Line them up with the push rods and valves, and tighten the bolts. Tightening torque: see Valve mechanism, tightening torques page 12.

Fig.117 Push rods

Fig.118

Valve adjustment 78

56

Adjust the valve clearance, see Valves, adjusting page 80.

Pumps, installing 79

Install the roller lifters Make sure that the guide on the lifter ends up in the groove in the engine block.

80

Install new O-rings on the pumps. Install the pumps. Install the bolts but do not tighten at this time.

81

Install the fuel control valve. Install the bolts but do not tighten at this time.

82

Install the high-pressure fuel pipes.

Fig.119 1 Guide

NOTE! Use new fuel pipes and copper washers. Tighten the nuts for the fuel pipes and the bolts for the pumps. Tightening torque: see Fuel system, tightening torques page 16.

Fig.120 1 Fuel return pipe 2 High-pressure pumps 3 Fuel control valve

Exhaust pipe, inlet manifold, and valve cover, installing 83

Install the exhaust pipe with new gaskets. Use paste for bolted flanges on the studs' threads. Install and tighten the nuts, starting from the middle of the engine and working outward. Tightening torque: see Exhaust manifold, tightening torques page 17 .

Fig.121 1 Exhaust pipe

57

84

Install the charge-air pipe with new gaskets and tighten the bolts. Tightening torque: see Charge-air pipe, tightening torque page 17.

85

Install the protective moulding on the valve cover.

Fig.122 1 Charge air pipe

NOTE! The protective moulding's profile is not symmetrical. The protective moulding shall be installed with its redcoloured end forward, in the engine's direction. Place the gasket for the valve cover on the cylinder head. Install the valve cover and tighten down the bolts. Tightening torque: see Cylinder head, tightening torques page 13. 86

Fig.123 1 Protective moulding

Oil trap, installing 87

Fig.124 1 Oil trap

58

Install a new gasket in the groove on the oil trap. Align the oil trap connection with the oil line. Tighten down the oil trap against the valve cover. Tightening torque: see Oil trap, tightening torque page 13.

Coolant pump and thermostat housing, installing 88

Fig.125

Install the preheating coil. Tightening torque: see Charge-air pipe, tightening torque page 17.

Check that the coolant pump has no noticeable play. Remove the protective tape. Install the coolant pump with new gasket. Tighten the bolts loosely.

89

Lubricate the O-rings and install the intermediate housing.

90

Install the thermostat housing, use new gasket.

91

Tighten all bolts for the coolant pump and the thermostat housing. Tightening torque: see Coolant thermostat housing, tighten‐ ing torques page 17 .

Fig.126

Fig.127 1 1 Coolant pump 2 Intermediate housing 3 Thermostat housing

Crankshaft sensor, installing 92

Install the crankshaft's speed sensor. Hand-tighten the bolts. Insert a feeler gauge between the ring gear and the speed sensor. See Speed sensor, specifications page 12. Lightly press the sensor against the feeler gauge. Tighten the bolts. Tightening torque: see Speed sensor, tightening

torque page 18 Check the clearance.

Fig.128 Checking clearance

59

Fuel pump, installing 93

Fig.129 1 Fuel filter 2 Fuel feed pump

Install the fuel pump with lines and filter bracket. Tighten the bolts loosely. Install a new filter.

Belts, installing 94

Install the V-belt on the belt pulleys. Tension the belt by moving the fuel pump. At correct tension it should be possi‐ ble to press down the belt approx. 10 mm (0.4 in) in the middle between the belt pulleys. Tighten the bolts for the belt tensioner. Tightening torque: see Belt pulley/vibration damper, tight‐ ening torques page 15. Tighten the bolts for the filter housing. Tightening torque: see Fuel system, tightening

torques page 16

Fig.130 Loader and motor grader version 1 Belt adjustment 2 Fuel feed pump's bracket 3 Water pump

60

95

6

Tighten up the belt tensioner for the flat belt with a wrench. Install the belt and release the tensioner. Install the V-belt for the AC-compressor. Tighten the belt with the belt tensioner on the AC-compressor. At correct tension it should be possible to press down the belt approx. 10 mm (0.4 in) in the middle between the belt pulleys.

5

4

1

2

Fig.131 Excavator version 1 Water pump 2 Flat belt 3 Belt tensioner 4 V-rib belt 5 AC Compressor 6 Alternator

3 V1054006

Injectors and fuel lines, installing 96

Install new O-rings and seal rings on the injectors. Install the injectors together with the holder. Torque-tighten the bolts. Tightening torque Injectors, tightening torques page 17.

Fig.132 1 Injectors 2 Retainer

61

97

Install the fuel rail and tighten the bolts loosely.

98

Install new fuel pipes between injectors and the fuel rail.

99

Torque-tighten the bolts for the fuel rail. Tightening torque: see Fuel system, tightening torques page 16.

Fig.133 1 Fuel rail

100 Torque-tighten the fuel pressure pipes Tightening torque: see Fuel system, tightening torques page 16.

Fig.134 1 Fuel delivery line

62

101 Install the return fuel line. Tightening torque: see Fuel system, tightening torques page 16.

Fig.135 1 Fuel return pipe 2 High-pressure pumps 3 Fuel control valve

102 Remove the rotation tool and reinstall the cover. Use a new O-ring. Tightening torque: see Timing gear casing, tightening torques page 13.

Fig.136 1 Cover

Starter motor 103 Install the starter motor. Tightening torque, see Cylinder block, tightening torques page 14.

63

Cable rail with cable harness, installing 104 Install the cable harness. Install the electrical connections for the injectors. Tightening torque, see Fuel system, tightening torques page 16 Plug in the connectors for the fuel control valve, oil pressure sensor, fuel feed pressure sensor, and the fuel pressure sensor in the fuel rail. Clamp the cable harness.

Fig.137 1 Connector E-ECU 2 Fuel control valve 3 Injectors 4 Fuel feed pressure sensor 5 Oil pressure sensor 6 Fuel pressure sensor

105 Plug in the connectors for coolant temperature sensor, boost pressure sensor, solenoid valve for I-EGR, and the rpm sen‐ sor. Clamp the cable harness.

Fig.138 1 Boost pressure sensor 2 Coolant temperature sensor 3 Solenoid valve I-EGR 4 Revolution sensor camshaft

64

Engine, removing from work stand Op. no.210-082 Tools: 9998547 Lifting tool

Removing from work stand 1

Secure the lifting tool on the engine. Lift away the engine from the support Set down the engine in the transport stand. Engine weight: approx. 700 kg (1545 lbs).

2

Install the engine mounts for the transport stand.

3

Remove the engine fixture from the engine.

V1010650

Fig.139 1 9998547 Lifting tool

Fig.140 1 88800050 Fixture

65

Turbocharger, installing 4

Remove protective plugs in the connections for the return pipe, delivery pipe, and the manifold.

5

Fit a new gasket. Install the turbocharger and tighten down the attaching nuts. Tightening torque: see Turbocharger, tightening torques page 17.

6

Install the turbocharger's delivery pipes. Install a new O-ring on the return pipe and install the pipe. Tightening torque: see Turbocharger, tightening torques page 17.

Fig.141 1 Protective plugs

Fig.142

Fig.143 1 Return pipe 2 Delivery pipe

66

211 Cylinder head Cylinder head, reconditioning Op. no.211-069 Tools: 2904634 Installation tool Valve spring compressor Dial indicator with magnetic stand Sliding calipers for measuring depths 88830047 installation tool for valve seal 1

Place the cylinder head in a vice. NOTE! Note! Use soft jaws so that the cylinder head is not damaged.

2

Use a valve compressor and compress the valve spring.

3

Remove the lock ring and the thrust washers with a screw‐ driver. Remove valve collets, holders, valve springs, and valves.

Fig.144

Fig.145 1 Thrust washer 2 Lock ring

67

4

Remove the valve spindle seals.

5

Clean the cylinder head and check that it is not damaged.

6

Measure the valve spindle clearance with a dial indicator and a valve free from defects in the valve guide.

V1010657

Fig.146 1 Valve spindle seal

NOTE! The valve head shall not have contact with the valve seat when measuring. “Open” the valve a few millimetres. Wear tolerances: see Valve mechanism, specifications page 13.

Fig.147 .

7

Check the valves. A Valve spindle diameter standard: see Valve mecha‐ nism, specifications page 13. B Valve head edge, thickness: Wear tolerances: see Valve mechanism,

specifications page 13

C Valve head's diameter: see Valve mechanism,

specifications page 13

Fig.148

8

Fig.149

68

Check the valve seat rings. Wear limit for valve seat width, see Valve mechanism, specifications page 13.

9

Measure the depth of the valves in the cylinder head (the distance between the valve head centre and the cylinder head sealing surface). Wear tolerances: see Valve mechanism,

specifications page 13

Fig.150

10

Fig.151

Measure the valve spring lengths (unloaded). Standard lengths: see Valve mechanism, specifications page 13.

Valve seat, changing 11

The valve seats must be replaced when the measurement between valve head and cylinder block face exceeds the value given in the specifications or when good seal is not obtained.

12

Grind down two edges on the head of a discarded valve.

13

Weld the valve in the valve seat.

V1033041

Fig.152 Principle illustration

NOTE! Work carefully so that the cylinder head is not dam‐ aged.

V1033042

Fig.153 Principle illustration

69

14

Place a suitable sleeve as protection over the valve/valve guide. Carefully tap out the valve and the valve seat with a hammer. NOTE! Work carefully so that the cylinder head is not dam‐ aged.

15

Thoroughly clean the seat's position and check the cylinder head for scratches. Scratches are not permitted on the cylin‐ der head.

16

Measure the diameter of the valve seat's position. Check if seat of standard dimension shall be used. Perform any required reworking of the valve seat's position.

V1033043

Fig.154

WARNING! Risk of frostbite! Use protective gloves. 17

Cool the seat in dry ice to a temperature between -60 °C (-76 °F) and -70 °C (-94 °F) . If needed, warm the cylinder head with a hot-air gun or similar. Press in the valve seat with a suitable drift.

18

Rework the seat to correct angle and width according to

Valve mechanism, specifications page 13

Valve seat, grinding NOTE! As spare parts the valve seats are pre-finished and shall not need any additional grinding. 19

Before grinding the valve seats, check the valve seats, valve guides and replace them if wear tolerances are exceeded.

20

When grinding valve seats, do not remove too much mate‐ rial, only enough so that the valve seat gets the right shape and the valve disc good contact surface.

21

The valve seat is ground down so that the measurement between the cylinder head's plane and the valve plate's head is according to Valve mechanism, specifications page 13.

Fig.156 Exhaust valve 1 Valve's edge thickness (A) 2 Valve's seat angle (B) 3 Valve seat's angle (C)

Fig.155 Inlet valve 1 Valve disc, thickness of edge (A) 2 Valve's seat angle (B) 3 Valve seat's angle (C)

22

70

The valve seat's angle is checked with a valve seat gauge after the seat's contact face has been coated with a thin layer of marking paint.

Valves, grinding NOTE! As spare parts the valves are pre-finished and shall not need any additional grinding. 23

The sealing surface shall be ground as little as possible, only grind enough to remove all damage.

24

Check the measurement (A) on the valve plate's edge. If the measurement is less than the wear tolerance according to Valve mechanism, specifications page 13 the valve shall be changed.

NOTE! Always change a valve with crooked valve spindle. 25

Check the seal of the valves using marking paint. In case they do not seal tight, repeat grinding of the valve seat, but not on the valve. Check once again. When the grinding result is acceptable, then the valve and seat can be lapped together using a fine lapping paste.

Rocker arm bridge, dismantling

Fig.157 Rocker arm bridge 1 Rocker arm pin 2 Rocker arm 3 Oil duct 4 Threaded hole

26

Remove the lock washer on the rocker arm bridge. Remove the rocker arm.

27

Remove the adjusting screws and check the oil channels.

28

Measure the rocker arm's hole, see Valve mechanism,

29

Measure the rocker arm's pin, see Valve mechanism,

30

Lubricate the pins lightly. Install the rocker arms.

specifications page 13

specifications page 13

NOTE! Thrust surface for the valve against the threaded hole. 31

Carefully tap the lock washer on the rocker arm bridge.

Valves, installing 32

Install the valves in the valve guides.

71

33

Install protective sleeves, included in 88830047 on the valve spindle.

34

Fit the new valve seals over the protective sleeves to the valve guides.

35

Remove the protective sleeves.

36

Press the valve seals on the valve guides with 2904634 Installation tool .

37

Install the valve. Use a valve compressor and compress the valve spring. Install holders and valve collets.

Fig.158 1 Protective sleeve

Fig.159 1 2904634 Installation tool

Fig.160

72

38

Install the thrust washers and the lock rings.

Fig.161 1 Thrust washer 2 Lock ring

73

212 Cylinder block with crankcase ventilation Cylinder block, checking and measuring wear Op. no.212-012 Tools: Depth gauge

Cylinder block, checking 1

Check that the seats for the liner collars and the cylinder liners' sealing surfaces are free from damage.

2

Use a depth micrometer to check the distance between the top of the engine block and the liner collars' seat. Measure in approx. 8 places at each cylinder. Depth shall be according to Cylinder block, specifications page 10. NOTE! If depth is greater, the engine block shall be scrapped.

V1010549

Fig.162 1 Depth gauge

74

213 Cylinder liner; piston Piston with connecting rod, checking Op. no.213-009 Tools: Piston ring pliers Feeler gauge Screw micrometer

Dismantling connecting rod and piston 1

Remove one of the lock rings that hold the piston pin in place. Press out the piston pin. Remove the connecting rod.

2

Remove the piston rings using a pair of piston ring pliers.

3

Clean and check the piston and piston ring grooves.

4

Push down one piston ring at a time into the cylinder bore, below the upper turn-around position, using a piston. Make sure that the piston ring is positioned horizontally. Check the piston ring gaps with a feeler gauge. Wear tolerances: see Pistons, specifications page 10

V1010550

Fig.163 1 Piston ring pliers

V1010551

Fig.164 1 Feeler gauge

75

5

Install the oil scraper ring. Install the tapered compression ring (2) with the text "top" facing up. Install the tapered compression ring (1) with the text "top" facing up. Displace the piston rings' gap 120° in relation to each other. NOTE! The gap of oil scraper ring's inside spring shall be displaced 180° in relation to the ring gap.

V1010553

Fig.165 1 Compression ring 2 Compression ring 3 Oil scraper ring

6

Measure the piston ring clearance axially with a feeler gauge. Wear limits, see Pistons, specifications page 10.

7

Check if the piston pin is worn. Piston pin diameter, see Pistons, specifications page 10.

8

Check the piston pin's parallelity, see Connecting rods, specifications page 12.

V1010552

Fig.166

V1010555

Fig.167

Fig.168

76

9

Fig.169

Check the piston pin's straightness, see Connecting rods, specifications page 12.

Connecting rods, checking 10

Check the bearing bushing at the connecting rods' piston end with a dial indicator. Measure at points 1 and 2 and in planes a and b according to figure. The bushings shall be in place in the connecting rods. Inner diameter: see Connecting rods, specifications page 12.

11

Calculate the clearance between bushing and pin. Permitted clearance, see Connecting rods, specifications page 12. Replace bearing bushings when required.

12

Press out the old bushing.

13

Press in the new bearing bushing until flush with the rod.

V1010559

Fig.170

NOTE! The lubrication hole in the bushing must line up with the oil channel in the connecting rod.

Fig.171 V1005509

14

After pressing in, precision-ream the bushing to correct inner diameter, see Connecting rods, specifications page 12.

15

Check that the bearing cap fits the connecting rod and that the digit marking agrees. Check that the guide studs are in their locations.

16

Install the bearing caps with new bearing shells. Torquetighten the bolts. Tightening torque: see Crankshaft, tightening torques page 17.

17

Measure the inside diameter at points 1 and 2 and in planes "a" and "b" according to the figure. Inner diameter: see Connecting rods, specifications page 12.

V1010559

Fig.172

77

18

Calculate radial run-out between bearing shells and crankshaft. Bearing clearance, see Connecting rods,

specifications page 12

Fig.173

Assembling connecting rod and piston 19

NOTE! The ring gaps for the circlips must face the piston crown. Place a circlip in correct position and install it.

V1010584

Fig.174

20

Install the piston together with the connecting rod. The fly‐ wheel symbol on the piston and the guide pins on the con‐ necting rod must be located on the same side.

21

Install the other circlip.

V1054010

Fig.175 1 Guide pin

Cylinder liner, checking and measuring wear Op. no.213-011

V1010532

Fig.176

78

1

Check that the liner is free from cracks or other damage.

2

Measure the cylinder liner's inner diameter. Measure at three different depths as shown, both longitudinally and across. Measurement, see Cylinder liner, specifications page 10.

3

Measure the height of the cylinder liner collar. Measure at eight places around the liner. Height, see Cylinder liner, specifications page 10.

V1010547

Fig.177

79

214 Valve mechanism Valves, adjusting Op. no.214-012 Tools: 885812 Timing tool 9998681 Rotation tool 1

Install M8x75 mm —10.9 bolts in the holes for the IEGR-unit on the rocker arm holders.

2

Rotate the engine to where the valves on cylinder 1 overlap each other Use 9998681 Rotation tool.

Overlapping means that the exhaust valve is about to open and the inlet valve is about to close. It should not be possible to rotate any push rods by hand for the cylinder in question in this position.

Fig.178 Overlapping

Fig.179 1, 3, 5, 7, 9 and 11 are exhaust valves 2, 4, 6, 8, 10 are 12 inlet valves

3

80

Mark the position on the vibration damper.

4

Fig.180

Adjust the valve clearance for each cylinder according to the black markings in the figure. Procedure for adjusting: 1 Loosen the adjusting screw's lock bolt on the rocker arm. 2 Install the protractor on the adjusting screw. 3 Turn the adjusting screw until zero clearance is obtained between rocker arm and valve. Reset the protractor to zero. 4 Turn the adjusting screw counter-clockwise according to Valve mechanism, specifications page 13. 5 Hold the adjusting screw and tighten the lock nut at the same time. Tightening torque: see 210, Engine, tight‐

ening torques

Fig.181 1 885812 Timing tool 2 Adjusting screw

5

6

Rotate the crankshaft another full turn until the valves for cylinder 6 overlap. Adjust the valve clearance for each cylin‐ der according to the black markings in the figure. NOTE! When all valves are adjusted, do not rotate the engine. Continue directly with installing and adjusting the IEGR-unit.

Fig.182

81

Installing and adjusting IEGR-unit 6

Change the O-rings on the pipe between the two IEGR-sec‐ tions. Lubricate the O-rings.

7

Remove the replacement bolts from the IEGR-unit's instal‐ lation holes.

8

Install the IEGR-unit.

9

With overlapping valves for cylinder 6, adjust IEGR—open‐ ing piston for cylinder 1, 3 and 5. Procedure for adjusting IEGR-opening piston: 1 Loosen the adjusting screw's lock bolt on the IEGRunit. 2 Install the protractor on the adjusting screw. 3 Turn the adjusting screw until zero clearance is obtained between the IEGR-opening piston and exhaust rocker arm. Reset the protractor to zero. 4 Turn the adjusting screw counter-clockwise according to Valve mechanism, specifications page 13. 5 Hold the adjusting screw and tighten the lock nut at the same time. Tightening torque: see 210, Engine, tight‐

Fig.183 IEGR-unit 1 Oil pipe

ening torques

10

Fig.184 1 885812 Timing tool 2 Adjusting screw

82

Rotate the crankshaft another full turn until the valves for cylinder 1 overlap. Adjust IEGR–opening piston for cylinder 2, 4 and 6.

83

215 Engine transmission; camshaft Camshaft, checking wear Op. no. Tools: Micrometer 1

Fig.185

Visually inspect cams and journals for wear, renew camshaft if necessary.

Camshaft outside diameter and bearing hole diameter measurement 2

Measure the camshaft outside diameter with a micrometer. The oil clearance shall be calculated by subtracting the mea‐ sured camshaft outside diameter from the camshaft bushing inside diameter after insertion to the cylinder measured with a cylinder gauge. Camshaft outside diameter measurement, see Camshaft, specifications page 11.

3

Diagram for measuring the journals at the points (1 and 2) in the levels (a and b).

Fig.186

V1010562

Fig.187

84

216 Crank shaft; connecting rod; vibration damper; fly wheel Crankshaft, checking Op. no. Tools: Sliding calipers Dial test indicator with magnetic base Dial test indicator for inside measurements Screw micrometer

Main bearings 1

Place the crankshaft in v-block or similar.

2

Diagram for measuring main bearing pins at points 1 and 2 in the planes a and b. Bearing pin diameter, undersizes and wear limit, see Crankshaft, specifications page 11.

V1010561

Fig.188

V1010562

Fig.189

Main bearing cups 3

Install the bearing shells in the main bearing caps, and install the main bearing caps in the engine block.

4

Measure the main bearing diameter at points 1 and 2 in the planes a and b. Inside diameter and oversizes, see Crankshaft, specifications page 11.

V1010559

Fig.190

Thrust bearing 5

Set the dial indicator to 38 mm. 85

6

NOTE! Before reworking the crankshaft, measure the width of the new thrust bearings. Measure the thrust bearing pin's width. Use dial indicator for inside measurement. Measure the width of the crankshaft's thrust bearing pins. Bearing pin width and oversize, see Crankshaft, specifications page 11.

V1010563

Fig.191

7

Wipe clean the bearing cap, the thrust bearing and thrust washers. Install the thrust washers and measure the width of the cap.

8

Determine the axial clearance. The big-end bearing pin's width, minus the measured width of the bearing cap and thrust washers gives the current clearance. Permitted axial clearance, Crankshaft, specifications page 11.

V1010578

Fig.192

Big-end bearing 9

Measure the big-end bearing pins. Big-end bearing diame‐ ter, undersize and wear limit, see Crankshaft, specifications page 11.

10

Check straightness of the crankshaft. Use dial indicator. Max. out-of-round on the middle bearing, see Crankshaft, specifications page 11.

V1010564

Fig.193

V1010565

Fig.194

86

Starter ring gear, replacing Op. no. Tools: 1

Heat the new starter ring gear to +210 °C. If oven is used, start work with heating the starter ring gear. If acetylene torch is used, heat the ring gear just prior to installing.

2

Drill a 10 mm hole between two gear teeth on the old ring gear. Drill to a depth of 9 mm. IMPORTANT! Do not drill in the flywheel. Risk of imbalance.

Fig.195

3

Secure the flywheel in a vice with soft jaws. Crack the starter ring gear by the drilled hole using a cold chisel.

4

Install the starter ring gear. Make sure that it bottoms against the flywheel flange. If necessary use a drift.

5

Allow the starter ring gear to cool.

Fig.196

Fig.197

87

22 LUBRICATING SYSTEM 221 Oil pump; line Oil pump removed, reconditioning Op. no.463-020 1

Drive out the crankshaft seal using a drift.

2

Clean the front cover.

3

Press down the compression spring and remove the stop washer. Remove the spring and valve peg for checking. Also check the valve seat in the cover.

V1036741

Fig.198

NOTE! Be careful, use protective glasses. The valve's spring force is powerful. A high-quality spring compressor is required.

V1036743

Fig.199

4

Remove the gear set and check that there is no abnormal wear. Replace the oil pump if needed.

5

Install the gear set. NOTE! The outer gear ring shall be turned with the beveled edge facing down.

6

Install the cover for the gear set. Tightening torque, see 030, Lubrication and oil system, tightening torques.

7

Install the valve peg and compression spring. NOTE! Use safety glasses.

V1036742

Fig.200

88

Press down the compression spring and install the spring's stop washer. NOTE! Make sure that the spring's stop washer is ade‐ quately secured. Apply a thin layer of oil before installing. Wait with installation of the crankshaft seal until the cover is located on the cylinder block.

89

223 Oil cooler Oil cooler (removed), reconditioning Op. no.421-013 Tools: 9996662 Pressure gauge 9996685 Clamp Plug M26x1.5 Part no. 942352 Spacer 30 mm (e.g., socket 10 mm) 1

Remove the Allen head plugs (17 mm).

2

Remove the two hollow flange bolts (17 mm) that hold the oil cooler.

3

Check all parts. If you suspect a crack, pressure-test the cooler according to the following and replace, if needed.

V1038434

Fig.201

V1038435

Fig.202

Changing 4

V1038436

Fig.203

90

Place the oil cooler core in the oil cooler housing.

5

Install a new aluminum washer on the hollow flange bolts. Use thread locking compound on the threads.

6

Tighten the flange bolts according to 030, Lubrication and

7

Install new O-rings on the Allen head plugs and oil them lightly. Tighten the Allen head plug according to 030, Lubri‐

oil system, tightening torques

cation and oil system, tightening torques

8

Secure the oil cooler with a new gasket.

V1038438

Fig.204

Leakage check When checking, the oil cooler core shall be as dry as possible on the inside, since any remaining water may have a sealing effect on possible cracks. As well, water may not leak into the cooler core during the check. During the test, avoid starting or stopping fan systems or letting air in or out of the room, since this may cause the air pressure in the room to change and this may be misinterpreted as a leak. During the test, the oil cooler core must be at the same temper‐ ature as the surroundings. The oil cooler core may not be repaired.

1

2

3

9

Install 9996685 on the oil cooler core according to fig. Make sure that it seals tight.

10

Install 942352 on the other connection.

V1038430

Fig.205 1 Plug 2 9996685 3 Spacer

91

11

Connect the pressure-test equipment.

12

Immerse the oil cooler core in a bowl of water.

13

Set the air pressure to 100 kPa (14.5 PSI) . Check if air bub‐ bles escape from the core.

14

Increase the pressure to 500 kPa (72.5 PSI). Leave the pressure on for 1 minute. The pressure may not drop. NOTE! There is a leak if the pressure drops when checking. If so, replace the oil cooler core.

1 Fig.206 V1038431 1 9996685

92

V1038431

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