Technical Information for repair and operation. Compress the springs in a press using tool 99 322 and fit the collets. Remove the charge air sensor, intake manifold and fuel manifold. It is possible to sense differences of less than a tenth of a millimetre. Fit the crankshaft gear so that the marks on the crankshaft gear and the intermediate gear are pointing at each other.
Tightening torques Main bearing cap bolts 90 Nm+90° Side bolts 180 Nm Smallest permitted diameter 112. Grind a groove as deep as possible in the ring gear and crack it open with a chisel. Camshaft Camshaft Pin Guide flange Flange bolt Thrust washer Camshaft gear Camshaft gear Flange bolt Intermediate gear Ball bearing Retaining ring Spacing sleeve Shaft Bolt Oil pump gear 01:05-02 17. Torque tighten all bolts to 63 Nm. Make sure the oil filter drain has emptied the oil from the filter housing. Secure the gear with two flywheel bolts and two 50 mm long spacers. Remove the wiring to the control unit.
Sealing surface for crankshaft seal 114 486 3. Bent connecting rods must not be straightened. Renew the rocker cover gasket. Fit extension 588 672 on the cylinder liner cutter 587 512. Make sure all the washers with rubber seals are intact.
Carefully remove any remains of the old gasket. Fit the coolant temperature sensor and oil pressure sensor with clamp. Fit the fuel connections on the feed pump. If the system has been emptied, pour approximately 1 dl oil on the bottom of the filter housing to fill the fluid trap. Place the piston rings inside the cylinder liner and measure the gap with a feeler gauge. Otherwise the vertical feed screw must be wound up until the cutter is released from the liner seat. Oil will then accompany the air into the charge air system.
Torque tighten the bolt to 135 Nm. Torque tighten the cap bolts to 90 Nm +90°. If it does not, the piston will become too warm resulting in engine breakdown. These cylinder blocks must be discarded. Fill with oil and coolant as directed in booklet 00:03-01.
Take a reading from the dial gauge, it should be between 4. . Fit the intermediate gear as described in Intermediate gear, fitting. Check the that the bearing surface in the belt pulley is not damaged. On the right camshaft, the recess on the bearing must be turned forwards in the direction of the water pump. Make sure the sealing surfaces are clean and free from damage. If any of the bolts has 3 marks, it must be replaced with a new one.
The main bearing seats must comply with the demands on roundness given in the table. The regularity of servicing a truck is the key to long-term operation of equipment. Loosen the centre bolt on the intermediate gear. Fit the front camshaft gear. Press in new valve seat inserts.
The cylinder liner must be slightly above the face of the cylinder block. Fit the fuel connections on the feed pump. Fit a new sealing washer on the unit injector. Press down the unit injector by hand as far as possible. Their relative position is not important.
Remove the bearing cap and bearing shells. Remove the strainer and the suction pipe. To be able to rotate the crankshaft, the crankshaft gear must be secured with two flywheel bolts and two 50 mm spacers. Lift the rapid feeder ring and move the cutter by hand until it is positioned above the liner seat surface without including the cylinder block walls. Diagnostic and repair procedures are covered in great detail to repair, maintain, rebuild, refurbish or restore your vehicle.
Important Make sure the bearings are facing the right direction so that the lubrication holes in the bearing correspond to the lubrication holes in the cylinder block. Compare the dimensions with those in the table. The cylinder head bolts can be reused up to 3 times. Fill the engine with coolant. Press in place the new gasket in the lower rocker cover. Fit the pipe between the charge air coolers, the catwalk, expansion tank and belt guard. Place the crankshaft seal on the tool and fasten the tool with the bolts.