Valmet 411 Workshop Manual

UALMET

diesel

3o,9

911

4tl

611

612

Woftshop

Manual

1 General

Cylinder head and

valve mechanism

11 optionat equipment

lnlet- and exhaust

system.

Turbocharger.

1. Edition

15. 1.1986

YAITIT

VALMET CorDorrllon.

Llnn.vuo,i Wo.ka

372i10 LINNAVUORI,

Flnl.nd

Tol.

(lntl.)+ 358 31

il03 300

Tgl€x 2212E

vålll st

T.lohx (lntl.l

+ 358 31

403 2E3 12

rO Tf USER

Should the €nglng rgqulre meosur€s noi descr I bed In

ihe S€rvlce Departnent of Valmet Llnnavuf I lq'ks.

fac+s about +he englne beforg cgniaciing us:

Thls Iqkshop Manu6l tq- valmdt diesel €nglnes ls Intendsd io facllliaie rcr-kshop op€rallons and

repalr rork.

lO9, lll, 4ll, 6ll and 612 englnes äre malnly iha same In construcilon, so tha same

repolr

Instructlons usually apply to dlffereni eflglne lypes. The dltf{ences betr€n the vc'lous englnE

iypes rhlch alfecl repalr rcrk have been n ilon€d ln technlcal data ånd repalr Insfructlons. All

n€tasu rgments a-e In nllllmsires and valld yh6n thg iemperaiu

r€ 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 successfu

I execuilon ot rork. An enqlne rhlch has under-

gone rspålrs nusf be run ln Jusi llke a nef, one.

thls manuol, please consulf your local agent or

To facllltatE consulflng, flnd out the fol lorlng

- Eng

lno typo

- Eng

Ine nunber

- Appllca+lon

or equ lpmenf

- Hours og{afod or kl lon€irgs drlven

4fl DS

EGtfE SPECTF tClTt(r{S

Englne type

Numb€r

ot cy I I nCf s

D lsp I aca[srf dn)

Bore nn

Sfroke ml

Coipress lon rdf lo

InJetlon ader

Compress lon pr€ssurp borl)

Eng lne type

Number

ol cyl lndf,s

Dlsp lecsmqrt dn)

Bore fin

Stroke m

Cdprass lon röflo

InJ€cilon ad€|'

CoDr€ss I on pressure brr)

| ) l.llnl"u,n

vclue cf oprallng tonpratuftt

dllterencp bqtr€gn cyllnders 3,0 bar.

JO9

o/!S

t

2,7

lo0

llil

l7 3l

| -2-5

24

4 DS

1

4,4

r08

120

l6: I

l-2-4-5

24

5 D

t,t

108

t20

l7: l

| -2-5

21

6t

I D

6

t08

t20

l7: I

l-r-fr-2-1

21

llt Ds

6lt Ds/Ds8

6

6,6

t08

120

l6: I

l -t-5-6-2-1

21

ill I D

1

4,4

108

t20

l7:l

| -2-1-5

24

612 DS

6

7,4

r08

ltI

ltrl

t-5-H-2-4

21

l5,t

l0B

t20

l6: I

l-2-5

21

ond sterllng ngvs. Mox pg.rDltfed

E 6tE Tt?E DESt€r TtOtS

6t | 0sBJA

App I I cat lon

A . v€hlcle srqlne

G - gen€ratlng-set €ng

lne

L. co[b

ln€ hcrvGtor or|olne

l.l . nrlnc eng ln€

P = pump

s€i srglne

Englne

oqulpped

rlth boost clr coollng

(ilntercoolrt)

InJ6cilon punp

iype ln

B . Eosch iPr

tlo cod€ . Bosch r^n

Turbochcrg€d q|glne

Bas I c tpc

6-cyllnder er|glngs

olsp laclm€n+

of one cyllnd€r (e.g.

Numb€.

ol cyllnd€rs

't-2

l, | ö5)

TtGHrEiltrc TmqES

ObJ ect

Englne:

Pressut€ valve holdf Bosch "Pr

Nm

Cyllnd€r head scr€rs and nuts f09, ,ll Jö 4ll .................... l60

Cyllnder head screws

and nu+s

6ll cnd 51 2 . . . . . . . . . . . . . . . . . . . . . . . . See

Cyllndr heåd sfuds to cyllnd€r blck ............................ lO

Moln

b€arlng scrots 509 ........ 160

Maln bearlng scrers 5ll, 4ll, 6lt Jo 612 ......................... 200

Connecilng

rod nuis ........ ..................... 90

Connecllng rod scrsrs 612............. .......... S@

F lyrheel screws ................ l2O

F lyuh€l hous Ing scrersi

- oufer scrors tl 12 ............ ................. llO

- Innr scrers M l0 ........... .................. 60

ldler ggar scrers:

-M10.......... ............... 60

_ M t4 .......... ............... l4o

ldler gear ({l+h boll bearlng) scre|l 6ll and 61 2 . .

. .

.

. . . . . . . . . . . . IBO

ldltr ged- bearlng holdq- scr€rs M 8 6ll Ja 612 ................. 22

Crankshoti

end nui lO9, lll Jo 4ll .............. 600

Crakshaft end nul 6ll and 612 ......... .........10m

Screvs

of addlllonol counterbalances 4l | ......................... 45

Coolonl pump

pulley nut M 14 ........... ......... IOO

Fuel equ lpment:

lnJectlqr purrp geq' nuf Bosch

trAn

..................,............. 90

InJsctlon punp gscr nui Bosch

nPi .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l,lO

InJecicr re+alnlng nuis (to studs) Bosch ........ 15

InJcioi reialnlng nuts (to sfuds) CAV .......... 20

tlozz

le flxlng bush Bosch

tlozz

le tlxlng bush

CAV

........

InJectcr adjustlng nu+

cov€r CåV .............

Pressure

valve holder Bosch

nA'........

Corpresscr-:

Codpresscr-

pu

I ley nut Knorr

Conpressor gear nu+ B€ndl x

Compressq'

gef nui C

lay+cn

E

lectrlcal equ lpDgnf:

Ins+ructlons, polnt f I K

Instructlons, polrt 4 2 J

@

90

io

15

80

t40

180

A lternätcr pu

I ley nut .......... 45

1-3

CYLINDER

BLOO(

AND FLY|IfEL I{oUSIT{G

I

r{)€x

... 2- 3

Coostrustlott ..

Reoclr I nstrucilons

l. Cylln&r blak and

cyllnder llners

A. Measurlng l-he

cyllnder llner wear....... ......... 2- 5

B. Rerpvlng the cyllnder I I

ner.

. . . . . . . . . . . ..........2- 5

C. Checklng

ths cylinder blck............ .......... 2- ,

D. Repfaclng ihe camshafi

beorlng bush

tl1/4ll/309................... 2- 5

E. R€placlng the camshaff bearlng bushes

6ll/612..................... 2- 6

F. Camshaft correcilon be6rlng bushes

5ll/411........................ 2- 6

G. Camshött cor.ecilqr bearlng bush 509.........'.................... 2- 6

H. Comshatt

correcilon bearlng bushes

611/612........................ 2- 7

f. Fftflng fha blaklng plug of th€ cansh6ft llne 3@/5ll/411........ 2- 1

J. Flitlng ihe blocklng plug of the canshaft llne 611

/612..

. .. . .. . . . . 2- 7

K. Flttlng +he dlps+lck gulde p|pe....... ........... 2- 1

L. Flftlng +he cyllnder 11ner............ ........... 2- I

2. Flyrh€el houslng

A. Insiolllng the flywheel houslng.'.. . . . . . . . . .

. .

.. 2_

l0

B. Replaclng

the crankshafl rear end seal.... ....... 2-10

vAlitEr

Cyllndar b lod( ,09

Holes fo. doie I s . . . . .

. . . . . ..... ll,OOO...ll,O4l

Dlam€ier

ol maln

b€örlng bore . . . . . . . . . . . . ....... 76,000...76;019

Dlanetor ol cyllndei- llner bore:

- upper

end ... ll6,ot2,,.ll6,o47

- lower

end ,,. lt5,0oo...lli;Ol5

Inslde d lano+er

of camshaft bearlng bush (rhen fltied ln posltlon).50,ö00...50,0å5 (50,o5o)

Tlgh+enln9 lorqu€ of flyrh€el houslng scrers:

IECHN

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

- oufer screHs

Ml2 ............, ................. llO

- Innq' scrers M10..........,.. ......,.......... 60

Tlghienlng torquo of maln

bearlng caps ...r....................... l60

Cyllndar block tll, 4ll, 6ll, 612

Holos for doye I

s . . . . . . . . . .

Dlan1oier of m6ln b€6rlng bore .. ..........

0lanetq- of cyllnder llner bore:

- upper end

- toref eno

Inslde dl€fl€ter of camshafl bearlng bush (when fl+ted In poslilon)

Inslde d lameter of cömshof+ baorlng bush (rhen flited In posltlon)

be6r I ngs 2...7 611,612.,......

Tlghtenlng iorque of flyrheel houslng scrersl

Nm

Nn

I l,000. .. I r,041

91,000.. .9t,022

12t,r14.. .123,r54

122

,oco.

..122,

O4O

50,000., .50,025

49,990.. .50,050

(

9l

,0i10)

(

50,050 )

(

50,080 )

- outer screHs

Ml2 ............. ................. llO Nm

- Innei screxs Mlo .........,... .,............... 60 ND

Tlghtenlng torque of möln b€arlng cap retalnlng screwg

..,.........200 Nn

Cyllnd€r I Iner 509

Profruslql of cyllnder lln€r above cyllndsr bl@k lop face ........

Max pernlsslble holght dlfferonce b€tr,e€n cyllnder llners

L Inq' bore

Max peroisslble ovalness ot llner .......,...

Hel

ght of cy I Inder I Intr f I

ange

Helght of cyllnder llner tlange, 'lst overslzo, pärl no 8f65 f6B2B .

l-lelght of cyllnder lln€r flange, 2nd overslze, pa-t no 8J65 J6829.

Helghi of cyllnder llner flange, frd overslz6, pöri no 8165 j68lo .

Outq' d lameier of cyllnder llnei tldtge

Cyllnd€r lln€r lll, 4ll, 6ll

Protrusiqr ot cyllndq- llner abovo cyllnder blcck top fac€ .,......

Max permisslble helghi dlfference beiw€n llners (under same hoad).

L Iner bore

Max permisslble ovalness ot llner ...........

Helghi of cyl Ind€r llner t langs

Helgh+ of cyllnder llner flange, ls+ overslze, pcrt no 8t5J 29829.

Helght of cyllnder llntr flange, 2nd ov€rslze, part no SJjf 29gjo.

Helghf of cyllnder llner flange, frd overslze, port no 8f5j 29gll .

Out€r dlamefer ot cyllnder llner fl ge

Cyllnd€r llnor 612

Proirusio.r of cyllndei- I Ins- above cyllnder blak fop facs .....,..

Max pernlsslble helght dltterence betw€n llners (under safl€ head).

L Inef bore

Möx peimisslble ovölness ot llner ...........

Helghi ot cyllnd€. llnq- flange

Helght of cyllnd,ei llner flange, ls't overslze, p6rt no 8l6J 184j6..

Helghi of cyllnder llns- tlange, 2nd overslz€, part no Bf6f f84l7..

Helght of cyllnder llner ftange, frd ov6rslz€, pö.f no 8f6j 59439..

ouier d lamete|- of cy I Ind€r I Iner f I

ange

0,0J0...0,080

0,020

tm,0m... t@,022

0,020

8, 0t. ..8, 05

8,08..

.8, l0

I, 1t. ..8, 1 5

8,2t...a,25

t2l , ...122,@

0,0J0...0,080

0,020

108,000...108,022

0,020

9,01.,.9,05

9,08...9,t0

9,

ll. ..9, | 5

9,25...9,25

I

ll , 700. .. I11,800

0,010...0,080

0,020

16,[email protected],022

0,020

9,01. ..9, 05

9,08.. .9, | 0

9,13...9,15

9,25...9,25

Ill,70...I]l,80

(

100,080

)

( t 08,080

)

(

| 08,080)

2

o

e

v

I a3@ 91315

2 4360 97314

3 9045 348oO

4 9051 7J100

90]o 26too

5 51 72 0

9045 A1200

9051 72800

9045 87600

6 9025 52400

1 A36t 91466

I A36t 9146A

9 9025 98700

r0 9025

78100

11 9025 79200

SPECIAL

TOoLS

(Cylinder block and flywheel houslng)

Fli+lng iool lor crankshafl rear end soal

F I

y{hee

I hous

Ing contra

I lz In9 bush

chamfgring

reamer

for cyllnder llner bore

Tool for exirac+lng and ro+aflng cyllnder llner 309

Tool for extractlng and

ro+aflng cyllnder llner

correctlon reamer for cyllnder llner flt+lng 309

Correc+lon

ream€r

for cyllnder liner fliflng tll , 4ll, 6ll

Correc+lon

reamer for cyllnder llner fii+ln9 612

Exchange blade Jor correct lon rearner

Tool for ro+atlng cyllnder llner

Cup

plug tapplng drlf+ 40 mm

Cup

plug +applng

drlfi 16 mm

Dorel pln +applng

drlft

Cyllnder I Iner clamplng fool

Gauge for- measurlng

cyllnder llner helghi

I

2-2

Self-made

tools (cyllnder blck and flyvrheel houslng) A35t 9l5 .emov lng-

and fl++lng equlpmenf for ihe bushlngs ot +he cansha{+.

O)

o

o)

@

\

or

CYLIIDER

BLCOK AND FLYB}EEL TIOUSING

co{sTRt cT I oN

CYL

INDER

BLOCK

CYL

INDER

ELOCK

(4II)

l. Cy I Inder block

2. Boarlng bush

J. Scrow

4. Bearlng cap

5. Bearlng cap (9ulde bearing)

o. Ptn DUsh

7. Cy

I lnder I lner

8. 0-r Inq seal

lno

9. Ptug icamshafi llne)

10. D

lpstlck p

tpe

I

l. Nui

12. S+ud

'-

lJ. Screw

14. Sea I Inq rlno

15. P

luq

16. Cup

p

lug

17. Draln cock

18. Pressure qauoe

sender

19. P

lpe

The cylinder block fo.ms l-he englne body to

whlch +he other englne conponents are flxed.

The cyllnder llners (7) are of ret type t{hlch

nEans thä-t ihe coolan+ comes dlrecily ln+o

contac+ rlth +he llner ou+e. su.face. Th6

seal ing be+Heen +he cyllnder llner lo|ler end

and cyllnder block comprlses of +ro o-rlngs (8)

whlch have been placed ln the g.ooves on the

cyllnder llner. The top end ls sealed by means

of a head gaske+ sl+uafed between +he cyllnder

llner flange and cyllnder head. The accurö-te

flf+ln9 of the cyllnder llner flange and +he

mating face of ihe flange ln the cyllnder block

ls also essentlal for ihe iop end seallng. l{e

ask you io note thls especially in connec+lon

v.l-i'h

cy l inder llner assenbly.

6l11612 englnes höve an o-rlng seal also ln +he

top end of +he cyllnder llner. There are

coollng grooves whlch nake fhe coollng of the

hot top part nore efllclent.

The cyllnder block Incorporates +he camshafi-

whlch has +ho Jronl bearlng poln+ (j09, l and

4ll englnes) equlpped rlfh a separa+e bearlng

bush (2) r{hlle the other bearlng poln+s have

been machlned In the cyllnder block dlrectly.

ln 611/612 englnos €ve.y camshaf+ bearlng poini

has a separöle bearlng bush.

The rear end o{ the camshaft llne ls blocked

wlth a dlsc plug In 309, fl I and 4ll englnes

rhereas the 6ll and 6'12 englnes have a plug

equlpped r,lth an o-rlng seal.-

On both sldes of the rear maln bearlna +here are

posltlons for gulde b€arlng shells icrankshafi

axlal bear

ings).

2-3

FLITfEL IOIISIIG

ö

22

Flyrhcl ho{sl ng

l. Flyyh€€l hous

lno

2. Hgxagon

screw -

f. Hexagon

s€ket screy

4. Sheft sea I

5. P lu9

6. Dore

I pln

7. S+ud

8. llasher

9. Nui

Th€ flyrheel houslng Is flxed to ihe rear end

of ihe cyllnder block. The crankshaft rear and

shafi seal (4) ls DlacEd In ihe recess machlned

to fha houslng. lo oddltlon, +h€ houslng has a

rDuntlng polni lor ihe s+arter.

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

acis os the maflng tace of ihe ol I sunp seal,

so lt nay not dlffer much from lhe cyllnder

block bottom foc€. The carreci Doslflon of +he

flyrheel houslng ls secured a+ ihg manufaciurlng

s+age

,lth doxel plns (6).

The tlyyhe€l houslngs are dellvered occordlng

io +he rEqulram€nts sef by the englne

appllcailon and dlfferent flyrhgels can be

mounld on all anglne +yp€6.

2-4

TIORK I NSTRIjCT I ONS

I. CYLIIOER SLOCK AND CYLI

ND€R LI]GRS

A. I,GASUR I t{G I}IE CYL ITDER

L INER IiEAR

l. Set ihe dlal gauge

+o zero wlih a mlcrome+er

wlth a ne', cyllnder llner, lndlcatlng

diameter of an unworn llner (108,00

mm).

2. Clean ihe Inner surface o{ ihe cvllnder llner

j-horough

ly before measureneni.

Perfoim the neasuremoni crosswlse a+ tho llner

top end, loYer end and mlddle.

Check ihe gauge readlng for maxlmum vrear and

ovalness (conpare r{lih ratlng).

RETOY

II€ llf CYLINDER LINER

It you in+end io relnsiall the cyllnder llners,

mark +he liners so +ha+ +hey can be placed ln

ihelr origlnal posl+lons In the cyllnder block.

Make ihe marklng on the lnner sdge of the llnsr

+op flange, e.g. on +he edge towards canshaft,

s+a+lng the cylinder number.

3. Fl+ +he bearlng bush In place by presslng and

a+ ihe same

ilme ensure the correc+ poslilon of

ol I holes.

4. Af+er fl+tlng |-eam ihe bush io lis proper slze

(d 50.000...d 50,025).

I

Place the turnable dlsc of +he llnor extrac+or

(9010

26100) +hrough

the llner on lis lowar end

and

draw +he llner ou+ fron the cvllnder block.

CHECKI NG

IHE CYLINDER BI-OCI(

Carefully clean the cyllnder block of ol I and

other lmpurltles, preferably In a {ashlng

rnachlne.

Afier Hashlng

blow ihe cyllnder block

dry wlth pressure alr and pay speclal afienflon

to ol I channels. Remove all scraps of old

gasKeTs.

Check the cleenness of the coollng channols.

Remove the bol ler scale sedlneni to ensure

englne

coollng.

Check

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

plugs ln ihe cyllnder block as l,ell as lhe

condl+lon of +he cyllnder block and seallng

laces.

I\4easure

+he wear of the camshaft bear

Ings

(compare

wlih ra+lng).

REPLACI]'IG

ItE C/tljISMFT BEÄRING BUSH tO9, 5l I

ond 'll I

Rgnove fhe bearlng bush rl+h an Inslde

exiracfor (e.9. SYKES

no. 854). You can also

remove

the bush by +apping t{lth a drlfi af+or

iaklng oui +he blocklng plug from the rear ond

of tho camsha{+ llne.

Clean ihe bearlng houslng ln fhe cyllnder block

carefu

| |

y.

linder block

i front face

I

or

Tne l.

2.

l.

309 2

Notel The bearlng bush of the 509

In lls ra+ed size afier fliting and

rqulre ream Ing.

Measure ihe clearance of +he bush

camshaft

and cornpare

wlth railngs.

6

englne ls

does nol

and the

2-5

.-\J l/..

E . FEPLTC

I }G I}E C,AT.6FåFT 8EÄR

I iG BU$f S 6t I /61 2

4,5

7

22171

2297'

22608

22609

2261O

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

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.

27

Cairshaft corr€ctlon beorlng bushes for fll

eng

I ne.

Comshafi @rrectlon bearlng bushes for 4ll

9n9lne.

cålrsr{ FT @RREcfl ON 8€ Rt}G BUSfl 509

lf needed, you can lnstall In the cyllnder

block a bush rlih 0,4 rm overslze outer

dl emster In Dlaca of thg camshaft froni end

bearlng bush. The o.-dEr number lor fhe ov€r-sl ze

bush ls 85f 24661 and the dlrFnslons lor

machlnlng ihe cyllnder block are-d 56,0+0,010.

Vlhen

flitlng fhe beärlng bush chock tho correci

posltlon ot oll holes. The b€arlng do€s not

need

reamlng after f liflng.

Other bearlng poln+s In 309 englnes can be

fltted xlih- ihe correspondlngi correctton

b€orlng bushes

of lll 6nglne. S€e

flg. 2 8.

a36t

at63

a36t

t.

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.

Rsnove the b€arln9 bushes by tapplng rlth a

sultable dr I ft, fa Instance.

Clean the bearlng houslngs In th€ cyllnder

block +horo0

gh

ly.

Flt the ner bearlng bushes In ihelr ploces by

presslng, usfng a selfnnode tool 8t5t 91556,

for examo

19. No+e fhg cgrrect order of fhe

bushes and the Dosltlon of the oll holes of the

bushes In both 6nds.

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.

Measure the clooranca of thg bushes and the

caiEhaft and compare

xlth råiln9s.

F. C IGHAFT mRECr

tor{ EEAR titc BUSHES 5r1l/ l

lf needad, you can Install ln ihe cyllnder

block a bush rlth I rfl overslze outer dlanqter

In plåce of the camshati froni bearlng bush.

The bearlng poln+s machlned In fhe cyllndor

block can also, ll necassary, be equlpped rlfh

s€parate bearlng bush€s. Flgur€s 2 8 and 2 9

shoy the order numb€rs tf correcilon bearlno

bushes and th€ dlmenslons for machlnlno thå

cyllnder block for b€arlng bush flfflng. -

tlotel tlhen flfilng the tront and rear bush

2-6

4.

G.

t.

H. C^I,ISHAFT

@RRECT|ON

BEARTNG

BUSHES

6 l6t2

Camshatt correctlo4 bearfng bushes for 6ll1612

eng I

nes

lf needed, you can lnsial I ln +he cyllnder

block a bush vlth I m overslze ou+er dlamsier

In Dlace of the camshaf+

fronf end bushlng.

Oiher b'lshes can b€ replaced by overslze bushes

wlih 0,4 mm outer dlameier. Flgure 210 shors

the order numbers

for the correctlon beårlng

bushes and ihe dlmenslons

for machlnlng ihe

cyllnder block.

FITTING IIf BLOCK

I

NG PLUG

OF lHE CAIT.ISHAFT LI]G

n9/ttl/111

Clean the blocklng plug space +o gei rld of old

seallng conpound remal ns.

Apply seallng compound

(6909 J0008) on the slde

of lhe b lock I ng plug.

211

Töp the blocklng plug In i+s place ylih the

f lttl ng iool (9025

87400).

Notel Be careful no+ io lap ihe blocklng

plug +oo

deep because +hls rlll affecl lhe com-

sh€ft end playl Thorefore alrays use a flftlng

tool.

J. FITTIT{G

THE

SLOCTI NG

PLUG

OF THE

CÄI.IIiHAFT

LINE

6t |

/612

l. Clean the blocklng plug posl+lon and use emery

Cloth to renove ihe posslble sharp edges

On

ihe

hole rl m.

2. Place En o-rlng In lhe blocklng plug groove

and

lubrlcate l+ tvlih, for lns+ance,

- slllcone

seallng compound.

Press the blocklng plug In lts posl+lon and flx

Its shleld plate (ln englnes

where lhe flyxheel

houslng does not cov6r the blocklng plug).

FITTII{G

TIf, DIPSTICK GUIDE

PIPE

Clean +he

plpe hole ln the cyllnder block.

Apply reialnlng fluld (6909

J0012)

to the gulde

plpe loxer end.

K.

l.

213

lls posltlon ai fhe level

lJ.

l. Tap the gulde plpe In

Indlcated In flgure 2

L.

t.

FITTI}IG IIG CIL I ]OER

LIICR

Clean tho cyllnder lln€r ond lts llttlng polnis

In tha cyllnder block thoroughly. The qyllndor

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

cyllnder llnei flang6 and plaoe ihe llner In

Its poslilon nlihou+ o-rlngs. Roiate the llnsr

ln boih dlrectlons. ll|lihdray +he llner and

check lf +he louch ls even.

214

5. lf ihe mailng lace ls domagod or li +he llner

proiruslon abovg

the cyllnder block face needs

rnachlnlng, use o correcilon reaner. Af+er

raamlng you con perform € llgh+ lEpplng rl+h

the llner, lf needed. Apply grlndlng pas+e

be+r€n +ho cy

I Inder I Iner I lange and the

cyl Inder block and rofaie ihe llner rlth tool

no. 6. Lapplng ls .|oi, hoyever, ihe rlgh+

tEihod, It th9 cyllnder llner protruslon has io

b€ adj usied.

4. At+er roamlng and lepplng clean lhe mailng

taces caretully b€torg meosurlng the cyllnder

llner Dro+ruslon.

5, Fo|- the fiFasurglEn+ procedure press tho

cyllnder llners In ploca wllh clanplng iools

(9025

78100). Measure the llner Droiruslon elih

measurlng gauge (9025 79200). Flx the dlal

gauge

+o +he measurlng

gauge

and sel lf to zero

}tlih a carefully cleaned cyllnder block top

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

tace should be b€tyeen orOJ cnd O,O8 ||r.

The max helght dl tterenca betr€n the llners

under lhe sane cyllnder head may nof exceod

'".,K

R T\T

\R NTT\q \\Rl\ K\ K R \qK

fhan fhe ones ln ellher ends.

a- ö

It fhe llner must be ralsed, Ins+cll one

an overth lc-k top tlang€.

6. r lth

311,411.611

PART

NO. HGROOVES

QTY

4363 227A7 o ^1 +o,02 -( std )

8353 29829 9,Og

+o,02 1

8353 29830 9.13

+o,o2 2

8353

29831 9,23

+0,02 3

2

PART

NO. HGROOVES

QTY

8363 36331 g,O3

+0,02 - ( std )

8363 38436 g.o8

+0,02 1

8363

38437 9.13

+0,02

8363

38438 q 2.1

+o,o2 .t

217

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 'rd

oYf,slz€ 0120 rn - thr€ gr@vca.

l{ofiol In the ll and 12 serles englnes the

cyllnd€r llners rtih standord tlange fhlckness

åre dlvlded Into tyo ca'tegor les dependlng o.l

tR \\'ss \\\Str=. q\'f"b+"\'$iså"=

\,{\. . .

9,04 - no narktng. F lange fhlcknåss 9,O4...9,O,

- flhlte palnfed mark (d 20) as shorn ln flg.2

309

PART

NO. HGROOVES

QTY

8365

36827 8,03

+o,02 -(std )

8365

36828 9.08

+0,o2 1

8365

36829 8,13

+0,o2

8365

36830 8,23

+0,02

l{ot€l In connecllon rlfh cyllnder llner

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 eng lnes.

lf the llner protrudes hlgher on one slde than

on the opposl+e slde, chack the thlckness of

+he llner flange and the deplh of the flange

recess ln ihe cyllnder block.-lf there are any

lrregularl+los, replace ihe llner. Correci ihe

I lange .ecess In the cy I Inder block slth

correcllon r€amer.

(

for 311and 411

engi-

nes if needed )

red

214

the cy I Indor llner gr@vgs

preferably wlth gear oll to

.L'CJ

220

Insiallatlon ordor of o-rlngs ln 3ll,4ll,6ll

and

61

2 eng Ine cy I Inder |

|

ner.

Press

the llnei- In lfs poslflon In fhe cyllnder

block. The llner rlll go ln easlly ll ihe o-

rlngs are correcily placed. Ensure fhal ihe

llner vtlll no+ rlse ou+ of lis Dosltlon af+er

Insiolla+lon.

lf ihe cyllnder block ls badly corraded ai +he

lorer o-rlngs of ihg llner, you can Install a

thr€€-groove

cyllnder llner In 5ll, 4ll and

6ll

englnes, spare

pari no 8555 24480. The cyllndsr

llners rl+h ovsrihlck fop flange (lll,4ll,6ll

and 612 englnes) are also equlpped

wlfh +hre€

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 lnslalled ln the fop groove

of the fll and

4ll englne llner. Should you Insfall lt,

chamter iho cyllnder llner top par+ guldance

In

the cyllnder block ylth reamer 9045 54800 io

lacllliate the placlng ol the o-rlng.

'n

.a

9. Place ihe o-rlngs In

and lubricate ihem,

avold sel zure.

t{otel Try io åvold even sllghiest streichlng

ot ihe o-rlngs durlng lnsfallailon because the

max sl-retch ot ihe lorer o-rlngs may only be

about 6 t. So as no't io lose the elasiiclty of

the ring, Install l+ lrom fhe loYer end and iry

to avold s+retchlng (e.g. do not place fingers

befreen liner and rlng).

10.

219

ln the f09

Ins+allailon ordgr of o-r I ngs

cyllnder llner. snglne

2- 9

2.

t.

FLYXIfEL rcUS II{G

I NS'ALL

Il{G llf FLYIHEEL IloUSI I{G

The correc+ posltlon ot ihe tlyrheel houslng io

cyllndar block ls secured ai ihe manufaciurlng

s+age

rlth +ro dowel

plns. Durlng Insiallo+lon

It ls not necassary

io canirallze lhe rolaflve

poslflon of the flyuh€€l houslng and the

cyllnder block. Th€ flyxheel houslngs

dellvered

as spore parts also have ihe doxe

I pln holes

ready.

Clean the ma lng faces of the cyllnder block

ond the tlyrhe€l houslng

cårefully.

Coaf the taces wlih seallng compound

(6909

50008 ) .

3. Llti fho flylJheel houslng ln lts place and

tlghien +he

retalnlng screxs llgh+ly.

4. MovE

plns

r lfh

the flyxheel houslng so +hai +he dore

I

holas meet. Flt thg dowel plns ln place

tapplng drl f+ (9025 987@).

Tlghten the flyrhe€l houslng retalnlng screys

gvenly +o +hs ccr€ci forque, lnner hexagon

socket scrers (8 |I|n) to 60 ltr and o|iier

hexagon scr€vrs

(19 |l|tn) io ll0 iln.

REPLAC ING I}IE CRANGMFT FEAR EI{D SEAL

D I

srnou nf the englne.

Open the flyrhesl retalnlng scrers and renbvo

ihe f lyr.heel

.

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

damage

the crankshafi seellng surfaca.

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

cnd us9 enEry cloth io rerDve posslble sharp

Edges ln +h€ crankshafi rear end.

222

5. Check that ihe llD of lie nex shali s€al ls

flarless and ihat iha llp sprlng ls ln lis

poslilon. Lubrlcat6 the seal and ihe natlng

tace of the crankshafi recr gnd xlfh oll. Push

the shaft seal caretullv on lhe crankshaft and

agalnsi the flywheel houslng. Top the seal

evenly dorn io ihe botiom wlih flitlng too I

8560 97515. Do noi use a pln-type tapplng drlti

because ihe meial body of the shafi sgal may

b€nd and cause leakaoe.

B.

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

shaft s€al dls+ance

rlng. A 2 rnm thlck dlstance

rlng rhlch ls placed und€r fh6 s€al has sDarg

spore parl no 8560 20054.

CIL I NDER

lffi) At|) Y LYE l,Ectl l Sr{

IIIEX

Tecinlcrl data ........... ................. J- |

Sp*lal t@ls ............ f- f

constrqc on ............. f- 4

ReDclr lnslruqtldrs

l. Cyl

lndgr h€rd

A. Removlng

ihe cyllnder heod.

. . . . . . . . . . . . .......... 5- 7

B. Removlng +he volves....... ...... 3- 1

C. Ch{klng the cyllnder heod.

.

. . . . . . . . . . . .......'.. l- 7

D. Replaclng the valve gu

I

de.

.

. . . . . . .

. . . ............ l- I

E. Replaclng the InJecior s|eeve........... ......... l- I

F. Machlnlng the valve seof............. ............ J- 9

G. Replaclng the valve seoi r1n9........ ............ l- 9

H. Grindlng the valves....... ...... l- 9

l. Flttlng +he

valves....... ....... l-10

J. Fl+tlng ihe cyllnder head

J09,Jll,4ll. ........... l-lo

K. Fltflng ths cyllnd€r head

6ll, 6 | 2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l-l I

2. Valvs rEchrnl sD

A. Recondlilonlng

ihe valve m€chanlsm....... ........ 3-12

B. Replaclng the canshaf+/camshafi

9e4r....... ...... l-12

C. Checklng

and adJusflng tl€ valvg c

learanc€s. . . . . . . .. . . . . . . . .

' . . . .. J-ll

VAIiIET 3-0

IECHNIC

L DATA

(reJeci llnlt of par+

s+aied In brackets €fier ra+lng)

volves, rocker crms and

+rppets

Va lve flm Ing

}Jlfh a valve clearan@ of 0,30 rnm

-ln le+ valve ooens ...........

-ln lei valve c loses , , . . . . . . . .

-exhausf va

lve opens ..,........

-exhaus+ va lve c loses . , . . . . . . . .

valve clearanc€s cold and ho+:

- ln lei va Ive

-exhaust va lve

Angle ot valve seai In cyllnder head ............

l{idth of valve sea+ In cyllnder head

Angle of valve tace..,,,.......

outside dlame+ei of valve head:

- in let valve llf,4ll, 611,612........

-exhausi va lve Jll, 4ll, 6ll , 612 ........

-i n let valve 109 .

. . . . . . . . . . . .

-exhaust va lve f09 ,............

Inlsi valve s'fem

d lameis-

Exhausl va lve siem dlarneier

Inlsf valve sfen clearan@ (gulda ready flited ln cyllnder head)

Exhaust valve s+em

clearön@ (guld€ ready fliied In cyllnder head)

Inside dlame+er of valve gulde (nof flffed)

Ou+side dlaoeier of valve gulde

D lamefs' ot valve gulde bore ln cyllnder head

Profruslon of valve gulde +op above cyllnder head surface .........

Dep+h of valve head face be loer cyllnder head sur{a@ .........

Va lve sprlng free length:

-inner..,.......

-ouTer , ... . ... r.

Sprlng p.essure Hhen sprlng comprossed io a length of:

-41,5 nm (lnnei sprlng) ......,,.

-47 nrn (ouier sprlng)

Rccke. rn shafi d lamefer

Inslde diamefer o{ rocker arm bearlng bush:

- (rhen fltted ln oosl+lon)

ouiside dlamefei of rockq' d-m bearlng b

ush . . . . . . . . . . . .

D lanEier of .ocker arm bore . . . . . . . . . . . .

Max permlsslble push rod del lecflon (when fr€) ...........

Free lengih ol rocker arn sprlng

Sprlng pressure lihen sprlng @mpressed to € length of 58 fir

outs I de dlameter of taooef

D laoete. of +appli bore In cyllnder btck ...........

Push rod length 109 ,. , . . . , . . . . . .

Push rod length t11

, 4ll , 6ll .............

Push.od leng+h 612 .. . . . . . .. . ...

Cyllnd€r held

Dlameff of Injecfcr- sleeve flxlng hole:

-uDoer end

- toder eno

outslde dlameler of Injeclor sleeve:

-upoer end

- towei eno

D lame+er of Inlst valve s6at rlng (s+andard)

Dlaneier of exhaus+ yalve seat rlng (standard)

Dlaneter ot recess In cyllnder head (s+andard):

-for exhausf yalve sea+

-for In let valve seaf

io

l9

l0o b.t. d.c.

42o a.

b. d. c.

42o b. b. d.

c.

t0o a.

t. d. c.

0, ,0

0, t0

f00

1,0.,.t,5

29,5o+0,17

28,000...28,031

21

,

O@.

..27

,035

21

,979...2A,000

27,OT5...21,O9O

48,054...48,070

45,045...43,01O

43,000..

.41,0t

6

48,000. ..48, 0r 6

9,465...9,480

9,445...9,460

0,040.

..0, 070

(

0,10 )

0,060...0,090

lo,t5l

9,520...9,535

16,02A...16,0t9

| 6,

000.

.. 16,01

I

l8

,1

6l

70.,.90 N

19...2t0 N

19,959...

| 9,98O

| 9,990.

. .20.010

2t,035...23,044

23,O00...2t,021

0,4

80

80...100 N

29,919...29, O

10,000...50,021

)al- |

,iä-l

2791

J- |

Overslz6 of exhcu+ valrc seat rlngs:

-ls+ oversl ze, part no. 8f6l l90o4 ...........

-2nd ovrslze, part no. 8f6l | 9OO5

...........

OYersl zes of lnlet velve s€ai rlngs:

-lsf ovsrsl ze, pari no. 8f6l 2296, ...........

-2nd overslze, part no. 8161 229f5 ...........

D

I aneter of exhaust valva seöf rlng recesses In cyllnd€r hEod:

-l st oversl za

-2nd overs I za

Dlameid'of Inlgt valve se6t rlng recesses In cyllnder head:

-lsi oversl z9

-2nd ovgrsl ze

Cyllnder heod

ih lckness

Cyllnds head

mln thlckness (aftet- machlnlng)

Tighienlng iocque of cyllnder head

scrers ..........

CGhrtt 509, tl I

D I aneter of

D I alFigr of

D lamet€r ot

DI ameter of

D lame+er of

4t,251...15,27O

4t,454...1t,17O

48

.2r 4. . , 18.21O

48,454. . .48

' ,l70

45,2O0...45,216

43,40O...45,416

48,2OO...44,216

48,400...48,416

| 04,90... | 05,10

| 04, 70

se€ | nsiruqt lons

nlnsiolllng

cy | | nder h6ådn

19,925...19, O

49,905...49,950

49, 885

. . . /t9,

91 0

50,04...50,06

(50,085

)

50,000...50,025

(

50,050)

Cömshafl end

play rlth a 0,5 nn gaskef bet{e€n cyllndei blck and llmlng

g€ar houslng

and bgtr€en tlmlng gear houslng

and tront cover ..... 0,450...1,550

Cam helght (dlstanc€ befxeen back

ol can and

ilp ol com) ......... 41,44

Cam llfi ...... 1,44

comshafl max

Dermlsslble

datlecflon 0,05 (toial

Indlcstor r.tdl ng

caEhafi 4l I

camshof+

bearlng

journal no. 'l (509) .........

comshatt bearlng Journal no. | (lll) .........

camshaft

bearlng

iournals nos. 2...4 ...........

comshoft bearlng bores (f09)

camshaft

bearlng boras (3ll)

D

lameler of cangbcft beorlng iournal

D I anleier ot canshalt b€arlng journals

D lamel€r of camshatt

berlng boros..

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 tfi ......7.41

Camshaft

måx

p€rmlsslble del lectlon 0,05 (toial

Indlcatd rcadlng

CrEhrft 6l l, 612.

Dlanefs- ol comshaft

bearlng

journals nos. I . . . 7 . .

. . . . . . . . . ...... 49,905...49,950

Inslde dlameter of camshafl

bearlng bushes

ln cyllnder block

Bearlng bush no. I .........'. .. 50,000...50,025

(

50,050)

49,905...49,95O

49,875...

il9,900

50,000...50,025

(

50,050)

49,990...50,050

(50,080)

0,450...1,550

4l . ,f4

7,14

0,05 (

iotal

Indlcator reedl ng

Beårlng bush nos.2...7

Camshöft end ploy rlih o 0,5 rn gaskei beireen cyllndf blck and tlmlng

gpar houslng ond b€tre€n tlmlng gear houslng ond froni cover

Can

helgh+ (dlstenca betveen

back of cam and tlp of cån)

Cam

| | tt .... ... .

Camshaft

max

p€rnlsslble def l€cilon

3-2

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