Volvo Penta D65A MS Workshop Manual
  1. Manuals
  2. Brands
  3. Volvo Penta Manuals
  4. Engine
  5. D65A MS
  6. Workshop manual
Volvo Penta D65A MS Workshop Manual

Volvo Penta D65A MS Workshop Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Workshop Manual
H
2(0)
D65A MS, D65A MT
Plus d'informations sur : www.dbmoteurs.fr

Advertisement

Table of Contents
loading

Related Manuals for Volvo Penta D65A MS

Summary of Contents for Volvo Penta D65A MS

  • Page 1 Workshop Manual 2(0) D65A MS, D65A MT Plus d'informations sur : www.dbmoteurs.fr...
  • Page 2 Plus d'informations sur : www.dbmoteurs.fr...

  • Page 3: Table Of Contents

    Marine Engines D65A MS/MT Content Safety Information ..........5 Group 22:Lubrication system Warning labels ............8 Oil Pump and Safety Valve General Information ..........10 Disassembly ............139 Presentation ............16 Inspection ............140 Identification numbers ......... 18 Reassembly ............142 Specifications ............
  • Page 4 Inspection and Repair ........203 Reassembly ............207 Alternator Disassembly ............210 Inspection and repair ......... 211 Reassembly ............211 © 2003 AB VOLVO PENTA All rights reserved. Content subject to change without notice. Printed on environmentally friendly paper. Plus d'informations sur : www.dbmoteurs.fr...

  • Page 5: Safety Information

    Safety Information Introduction The Manual contains technical data, descriptions, and repair instructions for the designated Volvo Penta engines or engine versions. Make sure that the correct workshop literature is used. Read the following safety information and the General Information and Repair Instructions in the Workshop Man- ual carefully before starting service work.
  • Page 6 Safety information All fuels, as well as many chemicals, are inflam- Hot oil can cause burn injuries. Avoid skin con- mable. Make sure no naked flames or sparks tact with hot oil. Make sure that the oil system is can cause ignition. Petrol, certain thinners, and not pressurised before working on it.
  • Page 7 Use the lifting hooks mounted on the engine/re- versing gear when lifting the drive unit. Always system and fuel system on Volvo Penta prod- ucts are designed and manufactured to mini- check that the lifting equipment is in good con- dition and has the correct capacity for the lift mise the risks of explosion and fire.

  • Page 8: Warning Labels

    Safety information Warning labels D65A MS The engine carries ‘Warning Labels’ at places where you are required to pay special attention. Please read them carefully and make sure you understand the content of each label and the meaning of their position.
  • Page 9 Safety information Warning labels D65A MT The engine carries ‘Warning Labels’ at places where you are required to pay special attention. Please read them carefully and make sure you understand the content of each label and the meaning of their position. Make sure the labels are legible.

  • Page 10: General Information

    Coast Guard Safety Regulations. Volvo Penta Genuine Spare Parts comply with these requirements. All types of damage resulting from the use of non genuine Volvo Penta spare parts for the product in question will not be reg- ulated by the warranty undertakings of Volvo Penta.

  • Page 11: Repair Instructions

    Bear in mind that most chemicals used on boats are harmful to the environment if used incorrectly. Volvo Penta recommends the use of biodegradable degreasing agents for cleaning engine components, unless otherwise stated in a workshop manual.

  • Page 12: How To Use This Manual

    General information How to Use This Manual Terms used in this manual Before you read this manual, note that the following 1. Parts in illustrations are numbered to correspond special terms are used in dimensional and other with references to these numbers in text. specifications.

  • Page 13: Disassembly And Reassembly

    General information Disassembly and Reassembly This service manual covers recommended procedures to be followed when servicing diesel engines. It also con- tains information on special tools required and basic safety precautions. It is the responsibility of service personnel to be familiar with these requirements, precautions, and potential haz- ards and to discuss these points with their foreman or supervisor.
  • Page 14 General information Oil Seals When installing oil seals, carefully observe the follow- ing points. Driving oil seals into housings 1. Check the seal lip for damage, and be sure to po- sition correctly in the housing. 2. Apply a smear of grease to the surface of the oil seal (to be fitted into the housing bore).
  • Page 15 General information Bearings 1. When installing a rolling bearing, be sure to push the inner or outer race by which the bearing is fit- ted. Be sure to use a bearing driver like the one shown. 2. Whenever possible, use a press to minimize shock to the bearing and to assure proper instal- lation.

  • Page 16: Presentation

    General information Presentation D65A MS D65A MS 1. Fuel filters 2. Oil cooler 3. Fuel injection pump 4. Governor oil filter 5. Manual stop lever 6. Governor 7. Stop solenoid 8. Oil dipstick 9. Fuel feed pump 10. Oil filler cap 11.
  • Page 17 General information Presentation D65A MT D65A MT 1. Fuel filters 2. Oil cooler 3. Fuel injection pump 4. Governor oil filter 5. Manual stop lever 6. Governor 7. Stop solenoid 8. Oil dipstick 9. Fuel feed pump 10. Oil filler cap 11.

  • Page 18: Identification Numbers

    General information Identification numbers D65A Type plates with identification numbers can be found on the engine and the transmission or generator. This infor- mation must always be used as a reference when ordering service and spare parts. Engine ............................Product designation ........................Serial and basic engine number ....................

  • Page 19: Specifications

    Specifications Specification D65A MS & MT General specification Model ................Water-cooled,4-stroke, turbocharged diesel with air-cooled intercooler No. of cylinders ............. Arrangement ..............vertical V type Combustion type ............Direct injection Valve mechanism ............Overhead Cylinder bore,mm [in.] ........... 170[6.70] Cylinder stroke,mm [in.] ..........

  • Page 20: Oil System

    Specifications Fuel system cont. Fuel injector Type ................Hole type Manufacturer ..............Zexel No. of spray holes ............Spray hole diameter, mm [in.] ........0.325 [0.013] Spray angle, deg............160° Injection press., Mpa(kgf/cm²)[psi] ........ 34.32 to 34.81 (350 to 355) [4979 to 5050] Fuel filter Type ................

  • Page 21: Electrical System

    Specifications Inlet and exhaust system Turbocharger Type ................MS: TD10 or TD13 MT: TD10 or TD13 No. of units ..............Electrical system Voltage-polarity ............. 24V earth float Starter Manufacturer ..............Nikko Electric Industry Pinion mesh type ............Pinion shift (Reduction type) Output ................

  • Page 22: Maintenance Standards Table

    Maintenance Standards Maintenance Standards Table General Maximum rpm Nominal Value ..5 – 10 % higher than rated rpm Repair limit .... Lower or 20 % higher than rated rpm NOTE! Rated rpm stamped on the nameplate. Check governor setting. Minimum rpm Nominal value ..

  • Page 23: Valve Springs

    Maintenance Standards Valve guide inside diameter, mm [in.] Nominal Value ... Ø10 [0.39] Assembly Standard ... 10.000 to 10.015 [0.39370 to 0.39429] Service Limit ..... 10.060 [0.39606] NOTE! The same for both inlet and exhaust valves. Valve seat angle(A) Nominal Value ... 30° Valve depth(B), mm [in.] Nominal value ...
  • Page 24 Maintenance Standards Rockers Rocker bushing inside diameter, mm [in.] Nominal Value ... Ø36 [1.42] Assembly Standard ... 36.000 to 36.040 [1.41732 to 1.41889] Service Limit ..... 36.090 [1.42086] Rocker shaft diameter, mm [in.] Nominal Value ... Ø36 [1.42] Assembly Standard ... 35.966 to 35.991 [1.41598 to 1.41697 Service Limit .....

  • Page 25: Piston Rings

    Maintenance Standards Weight difference between pistons in one engine Assembly Standard ... ±10 g [±0.35 oz] Pin bore diameter, mm [in.] Nominal Value ... Ø70 [2.76] Assembly Standard ... 70.002 to 70.015 [2.75598 to 2.75649] Service Limit ..... 70.040 [2.75747] Protrusion, mm [in.] Assembly Standard ...

  • Page 26: Connecting Rod Bearings

    Maintenance Standards Big end bore diameter, mm [in.] Nominal Value ... Ø131 [5.16] Assembly Standard ... 131.000 to 131.025 [5.15747 to 5.15845] Service Limit ..... 131.050 [5.15944] NOTE! To be measured in combination with caps. Roundness less than (0.1 mm [0.004 in.] - service limit) Connecting rod bearings Thickness of center, STD, mm [in.] Nominal Value ...
  • Page 27 Maintenance Standards Flywheel Face runout, mm [in.] Assembly Standard ... 0.336 [0.0132] to less Radial runout, mm [in.] Assembly Standard ... 0.13 [0.0051] or less Injection pump accessory drive Bearing bore inside diameter, mm [in.] Nominal Value ... Ø90 [3.54] Assembly Standard ...

  • Page 28: Timing Gears

    Maintenance Standards Front gears Backlash, mm [in.] Assembly Standard ... (0.12 to 0.18) ([0.0047 to 0.0071]) Repair Limit ....(0.30) ([0.0118]) Service Limit ..... (0.50) ([0.0197]) NOTE! Replace gears, if necessary Idle gear shaft bushing inside diameter, mm [in.] Nominal Value ... Ø50 [1.97] Assembly Standard ...
  • Page 29 Maintenance Standards Camshaft Cam lift (A-B), mm [in.] Nominal Value ... 9.247 [0.36405] Assembly Standard ... 9.197 to 9.297 [0.36209 to 0.36602] Service Limit ..... 8.45 [0.3327] Deflection, mm [in.] Assembly Standard ... 0.05 [0.0020] or less Repair Limit ....0.08 [0.0031] NOTE! Deflection at center bushing measured with both ends supported.

  • Page 30: Main Bearing

    Maintenance Standards Fillet radius of crankpins, mm [in.] Nominal Value ... 7 [0.28] Assembly Standard ... 7.0 – 7.2 [0.268 – 0.276] Fillet radius of journals, mm [in.]S Nominal Value ... 8.5 [0.33] Assembly Standard ... 8.3 – 8.5 [0.327 – 0.335] Hardness of journals and crankpins Assembly Standard ..

  • Page 31: Inlet And Exhaust System

    Maintenance Standards Crankcase Flatness of gasket surface, mm [in.] Assembly Standard ... 0.1 [0.004] or less Repair Limit ....0.2 [0.008] NOTE! Reface if necessary Main bearing bore diameter, mm [in.] Nominal Value ... Ø179 [7.05] Assembly Standard ... 179.000 to 179.025 [7.04723 to 7.04821] Service Limit .....
  • Page 32 Maintenance Standards Bearing outside diameter, mm [in.] Service Limit ....29.876 [1.17622] Bearing inside diameter, mm [in.] Service Limit ....Ø18.050 [0.71063] Bearing length, mm [in.] Service Limit ....17.440 [0.68661] Shaft journal diameter, mm [in.] Nominal Value .... 18 [0.709] Service Limit ....

  • Page 33: Lubrication System

    Maintenance Standards Shaft & turbine wheel and turbine housing clearance, mm [in.] Standard Clearance .. 0.63 to 1.18 [0.02480 to 0.04646] Shaft end play, mm [in.] Assembly Standard ... 0.075 to 0.135 [0.00295 to 0.00531] Turbine backplate and turbine wheel clearance, mm [in.] Standard Clearance ...
  • Page 34 Maintenance Standards Oil thermostat Temperature at which valve starts opening Assembly Standard ... 80 to 84°C [176 to 183°F] Temperature at which valve lift more than 11 mm [0.43 in.] Assembly Standard ... 95°C [203°F] Piston cooling nozzle Valve opening pressure, MPa (Bar) [psi] Assembly Standard ...
  • Page 35 Maintenance Standards Vane front face clearance, mm [in.] Nominal value ... 1.04 [0.041] Standard Clearance .. (0.58 to 1.5) ([0.023 to 0.059]) Thermostat Temperature at which valve starts opening Assembly Standard ... 71±2°C [159.8±3.6°F] NOTE! Check in atmospheric pressure Temperature at which valve lift is more than 11 mm [0.43 in.] Assembly Standard ...

  • Page 36: Fuel Injector

    Maintenance Standards Fuel system Fuel injector Valve opening pressure, MPa (kgf/cm ) [psi] Nominal value ... 34.32 (350) [4977] Assembly Standard ... 34.32 to 34.81 350 to 355 [4977 to 5048] Spray cone angle Nominal value ... 160° NOTE! Check nozzle with a hand tester (at fuel oil temperature 20°C [68°F]. Replace the nozzle if the spray pattern is still bad after washing in clean fuel oil.
  • Page 37 Maintenance Standards Test force, N (kgf) [lbf] Assembly standard ... 51.6-61.4 (5.26–6.26) [11.60–13.80] Camshaft thrust clearance, mm [in.] Standard Clearance .. 0.02 to 0.06 [0.00079 to 0.00236] Resistance in rack movement Assembly Standard ... 500 g [1.102 lb] NOTE! Make sure rack moves smoothly. Total rack stroke should be 36 mm [1.42 in.]. Injection start interval Assembly Standard ...

  • Page 38: Electric System

    Maintenance Standards Inside diameter, mm [in.] Nominal Value .... 20 [0.79] Assembly Standard ..19.990–20.000 [0.78701–0.78740] Idler shaft diam., bearing section, mm [in.] Nominal Value .... 20 [0.79] Assembly Standard ..20.002–20.011 [0.78749–0.78783] Electric system Starter Diameter of commutator, mm [in.] Nominal Value ....
  • Page 39 Maintenance Standards Pinion shaft diameter (front), mm [in.] Nominal Value .... Ø19 [0.75] Assembly Standard ..(18.90 to 18.94) ([0.7441 to 0.7457]) Reapir Limit ....Ø19 +0.06 [0.75 +0.00236 +0.10 +0.00394 Metal, Pinion Nominal Value .... Ø19 [0.75] Assembly Standard ..19.000 to 19.033 [0.7480 to 0.7493] +0.033 +0.00130 Reapir Limit ....

  • Page 40: Tightening Torques

    Tightening torques Tightening torques D65A MS Thread Torque Description Diam.xPitch lbf.ft Notes (M-Thread) Cylinder Head 22 x 2,5 (a) (b) (c) Cylinder head nozzle gland (studs) 14 x 2,0 69-78 51-58 Rocker case 12 x 1,25 Rocker shaft 14 x 2,0...
  • Page 41 Tightening torques Thread Torque Description Diam.xPitch lbf.ft Notes (M-Thread) Oil pump cover 10 x 1,25 26,3-39,7 2,7-4,1 18-32 Oil & Water pump mounting plates 12 x 1,25 Bearing cover (oil & water pump) 12 x 1,25 Fresh water pump 12 x 1,25 Fresh water pump shaft pulley (nuts) 30 x 1,5 For alternator drive.
  • Page 42 Tightening torques Tightening torques D65A MT Thread Torque Description Diam.xPitch lbf.ft Notes (M-Thread) Cylinder Head 22 x 2,5 (a) (b) (c) Cylinder head nozzle gland (studs) 14 x 2,0 69-78 51-58 Rocker case 12 x 1,25 Rocker shaft 14 x 2,0 Rocker arm lock nuts 12 x 1,25 Bridge lock nuts...
  • Page 43 Tightening torques Thread Torque Description Diam.xPitch lbf.ft Notes (M-Thread) Oil pump 12 x 1,25 Oil pump cover 10 x 1,25 26,3-39,7 2,7-4,1 18-32 Oil & Water pump mounting plates 12 x 1,25 Bearing cover (oil & water pump) 12 x 1,25 Water pump 12 x 1,25 Water pump shaft pulley (nuts)

  • Page 44: Standard Bolts And Nuts

    Tightening torques Standard Bolts and Nuts Fine threads Thread Strength classification diameter x pitch 10.9 mm [in.] lbf.ft lbf.ft M10 x 1,25 [0.39 x 0.049] M12 x 1,25 [0.47 x 0.049] 11,0 M14 x 1,5 [0.55 x 0.059] 17,9 M16 x 1,5 [0.63 x 0.059] 14,8 26,7 M18 x 1,5 [0.71 x 0.059]...

  • Page 45: Standard Union Nuts

    Tightening torques Standard union nuts Cap nut size Strength classification Nominal diameter x pitch diameter mm [in.] lbf.ft M14 x 1,5 [0.55 x 0.059] M16 x 1,5 [0.63 x 0.059] M20 x 1,5 [0.79 x 0.059] M22 x 1,5 [0.87 x 0.059] M27 x 1,5 [1.06 x 0.059] M30 x 1,5 [1.18 x 0.059] M30 x 1,5 [1.18 x 0.059]...

  • Page 46: Sealants And Lubricants Table

    Selants and Lubricants Sealants and Lubricants Table Engine main parts Lubrication system Cylinder head sealing caps Oil pump, Cover and case Sealant ...... refer to parts catalogue Sealant ...... refer to parts catalogue How to use ....Coat holes in crankcase How to use ....

  • Page 47: Special Tools

    Special tools Special Tools 885423 Rocker bushing tool 885452 Ring pliers 885422 Cylinder head lifting 885425 Cylinder liner remover 885391 Valve spring pusher 885414 Piston ring tool 885410 Valve guide remover 885396 Idler bushing puller 885413 Valve guide and seal installer 885443 Piston installer 885386...
  • Page 48 Special tools 885421 Compression gauge adaptor 885455 To remove oil and water pump plate and flywheel 885409 Compression gauge 885451 Nozzle tester 885445 To remove/install injection pump gear and waterpump shaft pulley nut. 885439 To remove and install snap ring 885447 Tool for lifting piston 885441...
  • Page 49 Special tools 885426 To install front oil seal 885429 Bolt for liner pusher 885435 To installa rear oil seal 885432 Spacer for liner pusher head bolt 885430 Valve seat cutter shaft 885450 To measure crankcase counter bore depth 885431 Valve seat cutter 885449 To tighten cylinder head bolts 885448...

  • Page 50: Determination Of Overhaul Timing

    Overhaul timing Determination of overhaul timing In most cases the engine should be overhauled when the engine’s compression pressure is low. Other factors that indicate the necessity of engine overhaul are: A. Decreased power B. Increased fuel consumption C. Increased engine oil consumption D.

  • Page 51: Adjustments And Benchtesting

    Adjustments and Benchtesting Adjustment and Benchtesting Valve Clearance Check and adjust the valve clearance on a cold en- gine. The valve height is adjusted first, and then the clearance of the rocker arm. IMPORTANT! The engine must under no circum- stances be running when checking and adjust- ing the valve clearance since the valves can knock against the pistons and cause serious...
  • Page 52 Adjustments and Benchtesting Valve clearance inspection 1. Check the valve clearance with feeler gauges in- serted between the rocker arm and yoke cap. Valve Clearance: Inlet valve ....0.6 mm [ 0.024 in.] Exhaust valve ... 0.8 mm [ 0.031 in.] 2.
  • Page 53 Adjustments and Benchtesting How to use the Turning Gear 1. Loosen the two bolts securing the shaft lock plate and remove the plate from the shaft (groove). 2. Push in the shaft all the way to the TURN posi- tion. 3.

  • Page 54: Fuel System Bleeding

    Adjustments and Benchtesting Fuel system bleeding Prime the fuel filters and fuel injection pump in the fol- lowing sequence: Bleeding the Fuel filter 1. Put the fuel filter switching cock in the left filter bleed position and loosen the left air vent plug. 2.
  • Page 55 Adjustments and Benchtesting Bleeding the fuel injection pump 1. Loosen the air vent cock on the fuel injection pump about 1.5 turns. 2. Pump the priming pump to start the flow of fuel through the system. 3. When fuel without visible bubbles comes out of the air vent cock, lock the priming pump cap while holding it down.

  • Page 56: Fuel Injection Timing

    Adjustments and Benchtesting Fuel injection timing The injection timing is indicated on the caution plate attached to the No. 1 rocker cover. Check it before inspection. Bring the piston for No. 1 cylinder to top dead center on compression stroke as follows: 1.
  • Page 57 Adjustments and Benchtesting Adjust fuel injection timing 1. Make sure the timing mark (indicated on the caution plate) is aligned with the pointer, with the piston for the cylinder at top dead center on compression stroke. 2. Loosen the bolts (C) for the fuel injection pump coupling.
  • Page 58 These settings are to be inspected and adjusted at Volvo Penta Workshops only. NOTE! After adjusting the governor be sure to seal the stopper. Whether the seals are intact or not has bearing on the validity of claims under the warranty.
  • Page 59 Adjustments and Benchtesting Measure V-belt deflection Measure the deflection of the belt. Apply approxi- mately 98 to 147 N (10 to 15 kgf) [22 to 33 lbf] force midway between the pulleys. The deflection should be approximately 10 to 15 mm [0.4 to 0.6 in.]. Adjust the belt if the deflection is not correct.
  • Page 60 Adjustments and Benchtesting Bench test (dynamometer) conditions Bench testing Summary table of bench testing conditions. An overhauled engine should be performance tested on a dynamometer. This test is also for breaking in Step 1 the major running parts of the engine. To test the en- Speed (rpm) ....

  • Page 61: Engine Auxiliaries Removal

    Auxiliaries removal Engine auxiliaries removal and installation This section explains the procedures and tips for removal and installation of the accessories – the preliminary process to go through for overhauling the engine. Preparation 1. Shut off the fuel supply, and disconnect the starting system from the engine. 2.
  • Page 62 Auxiliaries removal Removing the thermostats 1. Remove the coupling (1). 2. Remove the bypass pipes (2) and (3). 3. Remove the right- and left-hand thermostat hous- ings (4). 4. Remove the thermo-brackets (5) and (6). Removing the raw water pump 1.
  • Page 63 Auxiliaries removal Remove air duct 1. Remove the clamps (1). 2. Remove the rubber hose (2) and air duct (3). 3. Remove the air duct (4). 4. Remove the stay (5). Removing the exhaust manifolds 1. Remove the couplings (1) and flexible joints (2). 2.
  • Page 64 Auxiliaries removal Removing the turbochargers and the exhaust pipe 1. Remove the turbocharger oil pipes (1) Oil pipe (2) Oil pipe (3) Oil pipe (4) Drain connector 2. Unscrew each mountin gbolt of the turbocharger (5), then remove the turbochargers (6). 3.
  • Page 65 Auxiliaries removal Removing the air cooler 1. Remove the drain pipe (1) an dvalve stay (2). 2. Remove the raw water pipe (3). 3. Remove the connectors (4) and (5). 4. Unscrew two bolts (7) (M12 x 1.75 mm [0.47 x 0.0069 in.]) on the upper side of the air cooler cover (6), then using eye-bolts, slide the air cooler cover towards the front to remove.
  • Page 66 Auxiliaries removal Removing the oil pump 1. Remove the connection stay (1) from the oil pipe located under the oil pump. 2. Unscrew the oil pump mounting bolts, then re- move the oil pump(2). Weight: approx. 25 kg [55 lb] Removing the speed control 1.
  • Page 67 Auxiliaries removal Removing the fuel control linkage 5. Remove the spring (8) and the L. H. lever (9). 1. Remove each control link (1) from the right- and left-hand injection pumps. 6. Remove each bearing cover (10) on both right- and left side.
  • Page 68 Auxiliaries removal Removing the injection pipes (right- and left hand) 1. Remove pipe clamps and dismount injection pipes. 1. Pipe seat 7. Clamp 13. No. 6 injection pipe 19. No. 12 injection pipe 2. Pipe clamp 8. No. 1 injection pipe 14.
  • Page 69 Auxiliaries removal Removing the fuel leak-off pipes (right- and left hand) 1. Remove clips and dismount fuel leak-off pipes. 1 Flexible pipe 2 Clamp 3 Seat 4 Clamp 5, 8 Fuel pipe 6, 7 Fuel leak-off pipe 9 Leak pipe Plus d'informations sur : www.dbmoteurs.fr...
  • Page 70 Auxiliaries removal Removing the fuel filter and fuel pipes (right- and left hand) 1. Remove clamps and clips and dismount fuel pipes. 1 Clamp 2 Seat 3 to 9 Fuel pipe 10 Flexible pipe 2. Remove the fuel filter brackets (11) and dismount the fuel filters (12).
  • Page 71 Auxiliaries removal Removing the fuel injection pumps (right- and left hand) 1. Remove the oil pipes (1) and (2) and the drain pipe (3) of the right side. 2. Remove the coupling cover (4). 3. Remove two coupling connecting bolts (5). 4.
  • Page 72 Auxiliaries removal Removing the right oil cooler 1. Remove oil pipes (1) and (2). 2. Remove the clip, and dismount the oil pipe (3). 3. Unscrew the oil cooler mounting bolts, then re- move the oil cooler (4). Weight: approx. 20 kg [44 lb] Removing the left oil filter and oil cooler 1.

  • Page 73: Engine Auxiliaries Installation

    Auxiliaries installation Engine Auxiliaries Installation To install the engine auxiliaries, follow the removal procedures in reverse. After installation, service them as fol- lows: 1. Refill the engine with the recommended oil up to the specified level. 2. Refill the cooling system with coolant. 3.
  • Page 74 Auxiliaries installation 5. Connect the pump drive coupling (3) to the drive shaft. Loosen the coupling mounting bolts. 6. Put the pump case on the pump bracket, then tighten the mounting bolts (4) temporarily. 7. Connect the fuel pipe and the oil pipe to the injec- tion pump.
  • Page 75 Auxiliaries installation Fuel Injection Pump Installation: Left Injection Pump 1. Align the timing marks “9 16” on the viscous ● damper with the pointer. Make sure that bolt inlet and exhaust valves of the No. 9 cylinder piston is at top dead center of the compression stroke. 2.
  • Page 76 Auxiliaries installation 5. Install the link (4) on the left-hand bank, length should be 239 mm [9.4 in.] (same as for the right- hand bank). 6. Install the rod (5) and adjust the length of the rod to a distance of 68±0.5 mm [2.68±0.020 in.] be- tween the rack end surface and the pump case end surface.

  • Page 77: Group 21:Engine Body

    Group 21 Engine Body Group 21 Engine Body Cylinder heads and valve mechanism Disassembly: Look for: 1. Rocker cover A. Cracks, oil leaks, deterioration 15. Push rod 2. Fuel inlet connector 16. Rocker case B. Cracks, damage, carbon and scale deposits 3.
  • Page 78 Group 21 Engine Body Removing fuel injector assemblies 1. Remove the fuel inlet connector and the nozzle gland 2. Use the Nozzle remover to remove the injector assembly. Take out the gasket if it is left behind in the cylinder head. 3.
  • Page 79 Group 21 Engine Body Removing the rocker cases 1. Remove the snap ring of the water outlet connec- tor. Slide the connector towards the snap ring. 2. Unscrew the rocker case mounting bolts, then re- move the rocker case from the cylinder head. Removing cylinder head assemblies 1.

  • Page 80: Inspection And Repair

    Group 21 Engine Body Inspection and Repair Rocker Bushings and Rockershaft 1. Measuring rocker bushing inside diameter and rockershaft diameter. If the measurement ex- ceeds the service limit, replace the bushing or shaft. Rocker bushing inside diameter, mm [in] Normal Value .... Ø36 [1.42] Assembly Standard ...
  • Page 81 Group 21 Engine Body Valve Guide and Valve Stems Measure valve stem and valve guide. The valve guide wears more rapidly at its ends than at any other location. Measure the inside diameter of the guide at its ends in two directions. If the service limit is exceeded, replace the guide.
  • Page 82 Group 21 Engine Body Valves and Valve Seats Inspecting the valve Coat the valve face lightly with red lead. Use the Valve lapper to inspect the valve contact with its seat. If the contact is not uniform, or if the valve is defec- tive, or if the repair limit is exceeded, repair or replace the valve and valve seat.
  • Page 83 Group 21 Engine Body Refacing the valve face If the valve face is badly worn, reface it with a valve refacer NOTE! Set a valve refacer at an angle of 30°. NOTE! Grind the valve as little as possible. If the margin seems to exceed the repair limit as a result of grinding, replace the valve.
  • Page 84 Group 21 Engine Body 2. Before inserting a new valve seat, measure the inside diameter of the cylinder head bore and the outside diameter of the valve seat to make sure that clearance (fit) is within clearance standards. Valve seat dimensions, mm [in.] Cylinder head bore diameter (A) Nominal value ...
  • Page 85 Group 21 Engine Body Lapping valves in valve seats Be sure to lap the valves in the valve seats after the seats has been replaced. 1. Coat the valve face lightly with a lapping com- pound. Lap the valve in the seat using the valve lapper. Raise the valve off the seat, then rotate the valve only a partial turn and strike it against the seat.
  • Page 86 Group 21 Engine Body Bridge-to-rotator clearance 1. When clearance is less than 1.5 mm [0.059 in.], check the valve stem top for cupping. If the stem top is badly cupped, replace the valve to obtain more than 1.5 mm [0.059 in.] clearance. 2.

  • Page 87: Reassembly

    Group 21 Engine Body Reassembly Reassembly sequence: Reverse the order of disassembly. Installing tappets Insert tappets coated with engine oil into the tappet holes and make them seat softly on the camshaft. Installing cylinder head gaskets 1. Clean the gasketed surfaces of the cylinder head and crankcase thoroughly with a solvent or de- greasing solution.
  • Page 88 Group 21 Engine Body Reassembly of the cylinder heads 1. Coat the valve Stems with engine oil, then insert them into the valve guides. 2. Install the valve springs and rotators to the valve guides. Compress each valve spring with the Valve spring pusher, then install the valve cotters on the valve Stem.
  • Page 89 Group 21 Engine Body Tightening cylinder head bolts 1. Place the Head bolt plate on the cylinder head. 2. Tighten each head bolt to 294 N m (30 kgf [217 lbf ft] torque (initial torque). 3. The head bolt plate has graduations at 30° inter- vals.
  • Page 90 Group 21 Engine Body Install fuel injector 1. Disconnect the fuel inlet connector from the injector assembly. 2. Put three O-rings on the injector and coat them with grease. 3. Coat the gasket with grease and attach it to the injector.

  • Page 91: Cylinder Liners, Pistons And Connecting Rods

    Group 21 Engine Body Cylinder liners, Pistons and Connecting rods Disassembly: Look for: 1. Bolt A. Wear, scratches, damage 2. Connecting rod cap B. Fatigue 3. Connecting rod bearing (lower shell) C. Scratches, cracks, damage, wear, carbon deposits on outside surface 4.
  • Page 92 Group 21 Engine Body Removing connecting rod caps Open the inspection hatches, remove the connecting rod caps. For identification, mark the removed con- necting rod bearing with cylinder number and upper or lower shell. IMPORTANT! Handle bearings with care. Removing pistons Preparations Use a cloth or oil paper to remove all carbon deposits from the upper areas of the cylinder liner.Carbon de-...
  • Page 93 Group 21 Engine Body 4. Turn the crankshaft a little at a time to raise the crank pin (fulcrum), while pushing the outer end of the bar, to further raise the piston assembly. IMPORTANT! Raise the piston assembly care- fully so that the connecting rod don’t interfere with the oil jet nozzle for piston cooling.
  • Page 94 Group 21 Engine Body Using the Piston remover 1. Turn the crankshaft to bring the piston assembly to 50° after top dead center for the left bank. 2. Attach the Piston remover to the top of the piston. Grip the handle of the remover, then lift the piston and the connecting rod off the liner.

  • Page 95: Inspection And Repair

    Group 21 Engine Body Inspection and Repair Cylinder Liners Inside diameter Measure the inside diameter of each liner in two di- rections, parallel and transverse to the piston pin, at three positions, top (weared position), middle and low. If measurements exceed the service limit, re- place the liner.
  • Page 96 Group 21 Engine Body When replacing cylinder liner Remove the cylinder liner (Refer to section Re- place cylinder liners) and observe the cylinder liner contacting surface to the crankcase. If the cylinder liner contacts the crankcase only on one side, use a rotary grinder to grind the surface to keep the differences of depth in four positions within 0.05 mm [0.0020 in.].
  • Page 97 Group 21 Engine Body Cylinder liner shim Insert a shim between the cylinder liner and the crankcase. NOTE! Select the shim that achieves the largest pro- trusion within the assembly standard range. Replace cylinder liners 1. Use the Cylinder liner remover to remove the cyl- inder liner from the crankcase.
  • Page 98 Group 21 Engine Body Pistons Inspecting the piston outside surfaces Check the combustion surfaces and inside surfaces of the pin bosses. Replace the piston if any defects are found. Measuring piston diameter Measure the diameter of each piston perpendicular (A) to the piston pin and 30 mm [1.18 in.] below the center of the piston pin (B).
  • Page 99 Group 21 Engine Body Measuring piston pin bore diameter Using calipers or a cylinder gauge, measure the pis- ton pin bore diameter. If the service limit is exceeded replace the piston. Piston pin bore diameter, mm [in.] Normal value ..... Ø70 [Ø2.76] Assembly standard ...
  • Page 100 Group 21 Engine Body Piston Rings Measuring piston ring gaps Place the rings in the new or master cylinder liner. Measure the gap of each ring. If the service limit is exceeded, replace all the rings on that piston. NOTE! Use a piston to place the piston ring in the lin- er by pushing it squarely.
  • Page 101 Group 21 Engine Body Connecting Rods, Bearings, and Bushings Measuring connecting rod bushing inside diameter Measure the inside diameter of each bushing in two directions and on two locations(see picture). If the service limit is exceeded, replace the bushing. Connection rod bushing inside diameter, mm [in.] Normal value .....
  • Page 102 Group 21 Engine Body Inspecting connecting rod large-end bearings Inspect each bearing shell for flaking, scratching, sei- zure, pitting, and other defects. If any defects are found, replace the shell. Measuring connecting rod end play Install the connecting rod to its crank pin, then tighten its cap bolts to the specified torque.
  • Page 103 Group 21 Engine Body Serration on connecting rod big-end. Inspect the serration on connecting rod. big-end by conducting a Magnaflux (magnetic particle) test. If cracking or damage is found, replace the connecting rod. Connecting rod bearing thickness Use a ball-point micrometer to measure the center of each bearing shell.

  • Page 104: Reassembly

    Group 21 Engine Body Reassembly Reassembly is done in the reverse order of disas- sembly. Pistons and connecting rods 1. The piston pin is clearance-fitted to the piston. To facilitate pin insertion, heat the piston with a piston heater or in hot water. 2.
  • Page 105 Group 21 Engine Body Preparation before installing pistons Clean the cylinder liner bore surface and crank pin by wiping with a cloth, then coat it with engine oil. Pistons for right bank cylinders Turn the crankshaft in the normal direction until the number (stamped on the damper) (A) of the cylinder to which the piston is to be installed is at the position of approximately SO* before top dead center.
  • Page 106 Group 21 Engine Body 2. Coat the piston rings with engine oil, then position the ring gaps as shown: A – Joint of coil spring B – Gap of top compression ring C – Gap of second compression ring D – Gap of oil ring 3.
  • Page 107 Group 21 Engine Body 3. Touch the joint between the cap and rod. Make sure that the cap is fit in place, and tighten the bolts to the specified torque. IMPORTANT! Make sure that the matching marks on the cap and rod are on the same side and show the same number.

  • Page 108: Viscous Damper And Front Gears

    Group 21 Engine Body Viscous damper and front gears Disassembly: Look for: 1. Viscous damper, damper spacer A. Worn seal lip 2. Plate B. Roughness in rotation 3. Oil pump gear C. Wear, nicking, chipping, defective splines 4. Front gear case D.
  • Page 109 Group 21 Engine Body Viscous damper 1. Attach a sling to the viscous damper. Unscrew the mounting bolts. 2. Screw the jack-bolts (M14x1.5-40 mm [0.55 x 0.059 - 1.57 in.]) into the threads evenly, then re- move the viscous damper. Weight: Approx.
  • Page 110 Group 21 Engine Body Oil pump and water pump bearing cover Unscrew the bearing cover mounting bolts, and re- move the bearing cover. Measure backlash and end play of the idler gear Measure the backlash and end play of the idler gear to obtain the data for replacement.

  • Page 111: Inspection And Repair

    Group 21 Engine Body Inspection and Repair Viscous damper inspection Check the viscous damper for cracks, deformations or cracks in the mirror plate, leakage of silicone oil, discolored or peeling paint due to excessive heat. Re- place it with a new one after 8000 to 12000 hours of service, even when no defect is observed.
  • Page 112 Group 21 Engine Body Idler gears, bushings, and shafts Measuring idler gear bushing inside diameter and idler gear shaft diameter. If the service limit is ex- ceeded, replace the bushing or shaft (whichever is worn). Idler gear bushing inside diameter, mm [in] Nominal value ...

  • Page 113: Reassembly

    Group 21 Engine Body Reassembly Reassembly is done in the reverse order of disas- sembly. Installing the front plate 1. Apply sealant to the front plate mounting surface of the crankcase, then place the packing in posi- tion. Apply the same sealant to the packing, then install the front plate.
  • Page 114 Group 21 Engine Body Installing the front gear case and pointer 1. Apply a sealant to the front gear case packing mounting surface, then mount the packing. Apply sealant to the packing, then install the front gear case. 2. Mount the water coupling of the front plate and the gear case to the crankcase.

  • Page 115: Oil Pan And Oil Strainer

    Group 21 Engine Body Oil pan and Oil strainer Disassembly: Look for: 1. Oil pipe A. Clogs 2. Oil pan B. Replace 3. Oil pan packing C. Cracks 4. Oil strainer Plus d'informations sur : www.dbmoteurs.fr...
  • Page 116 Group 21 Engine Body Reassembly Reassembly is done in the reverse order of disas- sembly. 1. Fit the O-ring to the oil passage of the oil pan mounting surface. 2. Fit the packing to the oil pan by applying sealant to the 4 separated sections.

  • Page 117: Flywheel, Timing Gears, And Camshaft

    Group 21 Engine Body Flywheel, Timing gears, and Camshaft Disassembly: Look for: 1. Flywheel A. Clogged oil hole 2. Idler shaft thrust collar B. Damage, wear 3. Timing gear case, oil seal C. Rough bearing rotation, damaged seal 4. Injection pump drive D.
  • Page 118 Group 21 Engine Body Remove the flywheel 1. Attach a sling to the flywheel. 2. Unscrew the mounting bolts. 3. Screw the two jack-bolts into the holes in the fly- wheel evenly, then remove the flywheel. Weight: Approx. 138 kg [304 lb] IMPORTANT! When you remove the flywheel, do not drop it or bump it against a hard object.
  • Page 119 Group 21 Engine Body Fuel pump drive gears (left and right) Unscrew the injection pump drive case mounting bolts, then remove the pump drive. Do not damage the gear teeth. NOTE! Remove the No. 12 cylinder cam cover before removing the pump drive case of the left side. Remove idler gears 1.

  • Page 120: Inspection And Repair

    Group 21 Engine Body Inspection and Repair Flywheel face and radial runouts Measure the runouts of the flywheel installed on the crankshaft. If the runouts exceed the assembly stan- dard, check for loose bolts or obstacles lodged be- tween the mounting faces of the flywheel and crank- shaft.
  • Page 121 Group 21 Engine Body Timing gear backlash To measure the backlash between the gears, set up a dial gauge so that it contacts the pitch circle of the gear to measure. If a dial gauge is not available, mea- sure the backlash by inserting feeler gauges between the gear teeth.
  • Page 122 Group 21 Engine Body Camshafts and Camshaft Bushings Measure cam lift Use a micrometer to measure the diameters of “A” and “B” on each cam to determine the reduction in cam lift. If the cam lift is less than the service limit, re- place the camshaft.
  • Page 123 Group 21 Engine Body Measuring camshaft end play Use a dial gauge to measure the end play of the cam- shaft to which the camshaft gear is installed. If the end play exceeds the service limit, replace the thrust plate. Camshaft end play, mm [in] Standard clearance ...

  • Page 124: Reassembly

    Group 21 Engine Body Reassembly Install the rear plate 1. Apply sealant (HERDITE) to the rear plate mounting surface of the crankcase, then place the packing in position. Apply the same sealant to the packing, then install the rear plate. 2.
  • Page 125 Group 21 Engine Body Installing camshaft gears 1. Install the camshaft gears to meet the dowel pin. 2. Tighten the camshaft gear mounting bolts to the specified torque. 3. After installing the camshaft gear, check that the gear rotates smoothly. Installing idler gears 1.
  • Page 126 Group 21 Engine Body Inspect and adjust timing gears After installing the timing gears, be sure to inspect and adjust them as follows. Inspect timing gear backlash and end play After installing the timing gears, inspect the backlash between the gears in mesh, and the end play of each gear.
  • Page 127 Group 21 Engine Body Install the idler shaft thrust collars 1. Apply grease to the thrust collars, and insert the collars in the timing gear case. In this step, make sure the “TOP” mark is located at the top and that the right and left collars are in- stalled in their original positions.

  • Page 128: Crankcase, Crankshaft And Main Bearings

    Group 21 Engine Body Crankcase, Crankshaft and Main bearings Disassembly: Look for: 1. Main bearing cap bolt A. Scale damage, cracks, clogged oil holes 2. Side bolt B. Wear scratching pitting, scoring 3. Main bearing cap C. Stripped threads 4. Main bearing (lower) D.
  • Page 129 Group 21 Engine Body Turning the crankcase upside down Use such lifting tool as a chain block and shackles to play the crankcase on its side. Then add slings to the crankcase, and turn it upside down. Weight: Approx. 1800 kg [3968 lb] Removing the main bearing caps 1.

  • Page 130: Inspection And Repair

    Group 21 Engine Body Inspection and Repair Crankshaft Crank pin and crank journal diameters 1. Using a micrometer, measure the crank pin(A.) and crank journal (B.) diameters. If the repair limit is exceeded, grind them to the next lower size: -0.25 mm [-0.0098 in.],-0.50 mm [-0.0197 in.], -0.75 mm [-0.0295 in.], or -1.00 mm [-0.0394 in.].
  • Page 131 Group 21 Engine Body Grinding dim. for undersize crankshaft Crankpin diam. undersize 0.25 [0.0098], mm [in] Finishing dimension .. 124.68–124.70 [4.9087–4.9094] Roundness ....Dia. Diff. 0.01 [0.0004] max Cylindricity ....Dia. Diff.e 0.02 [0.0008] max Crankpin diam. undersize 0.50 [0.0197], mm [in] Finishing dimension ..
  • Page 132 Group 21 Engine Body Measuring crankshaft end play 1. Install the thrust bearings in position, then secure the bearing cap. Under this condition, measure the end play. If the end play exceeds the stan- dard clearance, replace the thrust bearings. 2.
  • Page 133 Group 21 Engine Body Measuring crankshaft deflection Support the crankshaft on its journals in V-blocks, then measure the deflection at the center journal with a dial gauge. Depending on the amount of deflection, repair the crankshaft by grinding or straightening with a press.
  • Page 134 Group 21 Engine Body Replace the crankshaft gear Remove the Gear Use a gear puller to remove the gear from the crank- shaft. NOTE! Do not remove the gear by hitting it with a hammer. Install the Gear 1. Before installing the crankshaft gear, measure the inside diameter of the crankshaft gear.
  • Page 135 Group 21 Engine Body Main Bearing Bearing surfaces Inspect each bearing shell for abnormal contact such as scratching, corrosion, flaking, etc. Also check for signs of poor seating in the bore of the crankcase or bearing cap. Bearing thickness Use a ball point micrometer to measure the center of each hearing shell.
  • Page 136 Group 21 Engine Body Crankcase Flatness of gasket surface Measure flatness with a straight edge and feeler gauges. If the warpage exceeds the assembly stan- dard, reface the gasketed surfaces with a surface grinder. Crankcase gasket surface flatness, mm [in] Assembly standard ...

  • Page 137: Reassembly

    Group 21 Engine Body Reassembly Reassembly is done in the reverse order of disassem- bly. Main bearing 1. Install each upper shell of the main bearing in the crankcase by fitting its locating lug in the lug groove. The oil holes in the bearings and crank- case Will be aligned when the bearings are in- stalled in this way.
  • Page 138 Group 21 Engine Body Main bearings Main bearing caps 1. Fit the lower shell of the bearing to each bearing cap. 2. Install the thrust bearings to the No. 9 bearing cap, with the oil groove side of the bearing facing out.

  • Page 139: Group 22:Lubrication System

    Group 22 Lubrication System Group 22 Lubrication system Oil Pump and Safety Valve Disassembly Look for: 1.Oil pump cover A. Fatigue, break, wear 2.Safety valve assy B. Cracks, other damage 3.Bushing C. Worn, broken spline 4.Drive gear D. Damage, wear 5.Driven gear E.

  • Page 140: Inspection

    Group 22 Lubrication System Inspection Measuring gear backlash If the backlash exceeds the service limit, replace the gears. Drive gear and driven gear backlash, mm [in.] Standard Clearance .. 0.10–0.20 [0.039–0.0079] Service Limit ..... 0.4 [0.0157] Measuring gear clearance Use feeler gauges to measure the clearance. If the clearance exceeds the service limit, replace the gears or case, whichever is badly worn.
  • Page 141 Group 22 Lubrication System Measuring shaft and bushing diameters 1. Check the gear teeth. Replace gears if they are defective. 2. Measure the gear shafts and bushings using a dial gauge. If the diameter exceeds the service limit, replace the parts. Drive shaft diameter, mm [in.] Nominal Value ...

  • Page 142: Reassembly

    Group 22 Lubrication System Inspecting the safety valve 1. Check the valve spring of the oil pump safety valve for fatigue. If excessive fatigue, wear or break is found, replace the valve spring. 2. Measure the valve opening pressure. If the pres- sure is higher or lower than the assembly stan- dard, increase or decrease the thickness of shim inserted between the spring and spring cap nut.

  • Page 143: Disassembly

    Group 22 Lubrication System Oil Filter, Filter Alarm, Relief Valve, Left Side Cooler and Thermostat Disassembly Look for: 1. Full flow oil filter element Holes clogging, cracks 2. Filter bracket assy Replace packing 3. Adaptor A assy C. Replace O-rings 4.

  • Page 144: Inspection

    Group 22 Lubrication System Inspection Inspecting the oil filter When you replace the paper element, sample about 500 cm [30.5 in .] of oil and check for metal particles. If any metal particles are found, unfold the pleats of element and check the color and shape of the parti- cles trapped in the pleats to identify the cause.

  • Page 145: Reassembly

    Group 22 Lubrication System Inspecting the left side oil cooler Test the oil path with compressed air of 1.47 MPa (15 kgf/cm ) [213 psi] for damage or cracks in the ele- ment. If there is any leakage, replace the element. Inspection the left side thermostat 1.

  • Page 146: Right Side Oil Cooler And Oil Thermostat

    Group 22 Lubrication System Right Side Oil Cooler and Oil Thermostat Disassembly Look for: 1. Connector A. Holes clogged, cracking 2. Oil thermostat B. Deterioration, wear, cracks 3. Oil cooler C. Wear, cracks 4. Oil cooler element D. Replace packing 5.

  • Page 147: Group 23:Fuel System

    Group 23 Fuel System Group 23 Fuel System Fuel Filters Disassembly Look for 1. Filter element A. Cracks, damaged threads 2. Bolt 3. Cover 4. O-ring 5. Pin 6. Cock 7. Fuel filter bracket 8. Packing 9. Air vent plug Plus d'informations sur : www.dbmoteurs.fr...

  • Page 148: Reassembly

    Group 23 Fuel System Reassembly Reassembly sequence: To install the filter, clean the mounting surface and apply fuel oil to the gasket. After bringing the gasket into con- tact with the sealing surface of the bracket, tighten the filter with your hand about one-half to three quarters of a full tum.

  • Page 149: Fuel Injectors

    Group 23 Fuel System Fuel Injectors Disassembly Look for 1. Cap nut, gasket A. Fatigue, damage, length 2. Adjusting screw B. Wear, damage 3. O-ring C. Carbon deposits, clogged spray hole, sticking needle valve 4. Retaining nut 5. Nozzle 6. Spacer 7.

  • Page 150: Inspection And Adjustment

    Group 23 Fuel System Inspection and Adjustment Injection pressure 1. Install the nozzle on the nozzle tester. Operate the handle of the tester at a rate of about 1 stroke per setond to observe the pressure at which fuel is being injected. If the pressure is out of stan- dard, adjust it.
  • Page 151 Group 23 Fuel System Washing or replacing the nozzle 1. The nozzle is spring loaded. Remove the set screw and loosen the adjusting screw until it can be loosened by hand. 2. Loosen the retaining nut, remove the nozzle and wash the needle valve and body.

  • Page 152: Reassembly

    Group 23 Fuel System Reassembly Reassembly Sequence: IMPORTANT! Tighten the retaining nut to the specified torque. Excessive torque on the retaining nut will cause sticky movement of the needle and will result in exhaust smoke or the needle stick. NOTE! Always replace all o-rings at reassembly. Plus d'informations sur : www.dbmoteurs.fr...

  • Page 153: Fuel Injection Pump

    Group 23 Fuel System Fuel Injection Pump Disassembly Look for: 1. Drain plug 17. Bolt 2. Coupling 18. Front cover, O-ring, bearing outer race A. Fatigue 19. Camshaft 3. Flywheel B. Wear and cracks on teeth, wear of sliding 4. Feed pump 20.
  • Page 154 Group 23 Fuel System Preparing for disassembly 1. Clean the outer surface of the injection pump and mount the pump on the pump assembly stand. 2. Remove the drain plug from the bottom of the pump and drain oil from the case. 4.
  • Page 155 Group 23 Fuel System Removing the control rack 1. Dislodge the bellows from the grooves of the control rack and rack bushing installed in the pump case, and remove the bellows. 2. Remove the set screw from the back side of the pump case, and pull out the control rack.
  • Page 156 Group 23 Fuel System Disassembling plunger assemblies 1. Press the knob on the jig to compress the plung- er spring, then remove the plunger holder jig. 2. Loosen the compression of the plunger spring gradually, and remove the lower spring seat, plunger and plunger spring from the barrel.

  • Page 157: Inspection

    Group 23 Fuel System Inspection NOTE! After disassembly, wash parts in clean diesel oil. Replace defective or damaged parts. Plungers and barrels 1. Inspect the lead section and tip of each plunger for wear, scratches, discoloration, and erosion. 2. After washing with clean diesel fuel, check each plunger by tilting approximately 15’...
  • Page 158 Group 23 Fuel System Camshaft 1. Check the key and key groove for excessive play. Also check the tapered section for scratch- es, and the tam surfaces for flaking, local wear and scratches. If damage is found, replace the camshaft. 2.
  • Page 159 Group 23 Fuel System Plunger and delivery valve springs 1. Check the surface of each spring for scratches and rust. 2. Using a square, measure the perpendicularity (gap, B) at the upper end of the spring. If the measurement exceeds the service limit, re- place the spring.

  • Page 160: Reassembly

    Group 23 Fuel System Reassembly Reassembly sequence: Plus d'informations sur : www.dbmoteurs.fr...
  • Page 161 Group 23 Fuel System Assembling the bearing and front cover 1. Install the O-ring and bearing outer race on the front cover. 2. Install the front cover on the pump case by striking with a hammer. 3. Tighten the front cover mounting bolts. Assembling the camshaft center bearing 1.
  • Page 162 Group 23 Fuel System Assembling the rear cover 1. Install the bearing outer race on the rear cover. 2. Install the O-ring and shim on the rear cover, and install the rear cover on the pump case. Camshaft thrust clearance 1.
  • Page 163 Group 23 Fuel System Assembling plunger assemblies NOTE! Wash each part with clean diesel fuel before assembly. Use new O-rings and apply grease to the O-rings to prevent damage during assembly. Install the O-rings in the sequence of A, B and C. 1.
  • Page 164 Group 23 Fuel System 4. Align the flange section of the plunger properly with the plunger seating section of the pinion using a screwdriver. 5. Press down the handle of the spring compression jib to insert the plunger into the plunger seating section of the pinion, then screw the plunger spring retaining jig into the upper end of the plung- Installing the control rack...
  • Page 165 Group 23 Fuel System Installing plunger assemblies 1. Position the cam at the bottom dead center in the cylinder to which the plunger assembly is in- stalled. 2. Place the stopper plate (1) on top of the pump case to prevent damage to the pinion and control rack during the installation of the plunger assem- bly.
  • Page 166 Group 23 Fuel System 7. Remove the plunger spring retaining jig and the rack setting jig. Make sure the control rack slides and strokes smoothly. IMPORTANT! Move the rack after installing each plunger assembly to make sure it moves smoothly (sliding resistance: 4.9 N (0.5 kgf) [ 1.10 lbf] or less).

  • Page 167: Adjustment Of Injection Timing

    Group 23 Fuel System Adjustment of Injection Timing Adjustment of the prestroke After the pump assembly is completed, place it on an injection pump tester, and make the following adjust- ments. 1. Remove the deflector bolt from the back side of the pump case.
  • Page 168 Group 23 Fuel System Adjustment of injection intervals 1. For cylinder No. 2 and subsequent cylinders, use the injection start timing of cylinder No. 1 as the reference point and check the injection start inter- vals on the angle scale on the pump tester ac- cording to the injection sequence.

  • Page 169: Feed Pump

    Group 23 Fuel System Feed Pump Disassembly Look for 1. Priming pump A. Scuffing, rust on piston and cylinder 2. Spring B. Fatigue 3. Valve C. Dust particles Gauze filter: Wash with diesel fuel 4. Plug D. Cracks, damage of threads 5.

  • Page 170: Reassembly

    Group 23 Fuel System Reassembly Reassembly Sequence: Testing Airtightness test Plug the discharge port. Apply air pressure of 0.2 MPa (2 kgf/cm ) [28.4 psi] to the suction port, immerse the pump in diesel fuel, and check for air leakage (bub- bles).

  • Page 171: Psg Woodward Governor And Drive

    Group 23 Fuel System PSG Woodward Governor and Drive Disassembly Look for 1. PSG governor A. Rotation 2. Packing B. Wear 3. Drive case C. Wear of teeth 4. O-ring D. Wear of spline 5. Idler gear 6. Snap ring 7.

  • Page 172: Inspection

    Group 23 Fuel System Inspection Inspection of bearings Rotate each bearing to check for rotation. Replace a bearing which fails to rotate smoothly. Check the fit of the bearings on the drive shaft and idler shaft. Re- place the shaft or bearings whichever are badly worn. Check the fit of bearings in the drive case and replace a worn part.

  • Page 173: Reassembly

    Group 23 Fuel System Reassembly Reassembly Sequence: Plus d'informations sur : www.dbmoteurs.fr...

  • Page 174: Group 25:Inlet And Exhaust System

    Group 25 Inlet and Exhaust System Group 25 Inlet and Exhaust System Air Cooler Disassembly Look for: 1. Air cooler cover A. Replace packing 2. Packing 3. Air cooler element 4. Plate 5. Packing 6. Air cooler case 7. Packing 8.

  • Page 175: Inspection

    Group 25 Inlet and Exhaust System Inspection Cleaning air cooler 1. Remove dirt built up from the air cooler by direct- ing high pressure air of {max press. 0.29 to 0.49 MPa (3 to 5kgf/cm ) [43 to 71 psi]} in the opposite direction of the air flow.
  • Page 176 Group 25 Inlet and Exhaust System Turbocharger [TD10, TD13] Disassembly Look for: 14. Thrust ring (compressor) 1. V-clamp A. Wear 2. Turbine housing 15. Thrust bearing B. Thrust face wear 16. Thrust ring (turbo) 3. Lock plate C. Vane distortion, damage, rubbing contact on back face and gas erosion 4.

  • Page 177: Disassembly

    Group 25 Inlet and Exhaust System Disassembly Remove the turbine housing Remove the V-clamp and the turbine housing (in that order) from the turbocharger. IMPORTANT! The compressor cover, bearing housing and turbine housing must be reassem- bled in correct orientation. Therefore, put align- ment marks with a punch or marker.
  • Page 178 Group 25 Inlet and Exhaust System Removing the snap ring NOTE! Use only snap ring pliers to remove snap rings. NOTE! Put your thumb on the snap ring to prevent it from flying out in case the pliers lose grip. Removing the insert and oil deflector 1.
  • Page 179 Group 25 Inlet and Exhaust System Removing the shaft & turbine wheel 1. Remove the bolts and lock plates. 2. While gripping the shaft of the shaft & turbine wheel with one hand, hold the bearing housing with the other hand and slowly remove the shaft &...

  • Page 180: Inspection

    Group 25 Inlet and Exhaust System Inspection Bearing housing Measure inside diameter of bearing-fitted section If the measured diameter exceeds the service limit, replace the bearing housing. Inside diam. bearing-fitted section, mm [in.] Service Limit ..... 30.006 [1.18134] Bearing Measure bearing outside diameter If the measured diameter is less than the service limit, replace the bearing.
  • Page 181 Group 25 Inlet and Exhaust System Shaft & turbine wheel Measure journal diam. of shaft & turbine wheel If the measured diameter is less than the service limit, replace the shaft & turbine wheel. Shaft journal diameter, mm [in.] Service Limit ..... 17.996 [0.70850] Measure shaft deflection 1.

  • Page 182: Reassembly

    Group 25 Inlet and Exhaust System Reassembly Reassembly sequence: NOTE! Always replace the following parts at disassembly: 4. O-ring 9. Piston ring 11. O-ring 19. Piston ring IMPORTANT! If vanes are damaged or cracked, do not reuse the part. IMPORTANT! After reinstalling the overhauled turbocharger, crank the engine to lubricate moving parts of the turbo.
  • Page 183 Group 25 Inlet and Exhaust System Install shaft & turbine wheel and bearing 1. Install the bearing housing, the snap rings and the bearing on the turbine side, and the snap ring on the compressor side. NOTE! Use only snap ring pliers to install snap rings. After installing the snap ring, rotate it with a finger to make sure it rotates smoothly.
  • Page 184 Group 25 Inlet and Exhaust System Install the thrust bearing Apply engine oil to both sides of the thrust ring and thrust bearing. To install the thrust bearing, align the notch with the groove pin. Install the O-ring Apply grease to the O-ring and install. Install the oil deflector Apply engine oil to both sides of the thrust ring and in- stall.
  • Page 185 Group 25 Inlet and Exhaust System Assembly of the insert sub-assembly 1. Install the finger sleeve and the piston ring in the insert. IMPORTANT! Do not expand the piston ring ex- cessively or twist the ends when installing on the finger sleeve. IMPORTANT! Apply Moly Disulfide to the piston ring installed on the finger sleeve, then install on the insert carefully so as to avoid piston ring...
  • Page 186 Group 25 Inlet and Exhaust System Turbine wheel and housing clearance Set a dial gauge on the end face of the shaft & turbine wheel. Read the dial gauge indication while moving the shaft & turbine wheel in the axial direction. If the dial gauge indication deviates from the assem- bly standard, disassemble and locate the cause of the problem.
  • Page 187 Group 25 Inlet and Exhaust System Turbine wheel and backplate clearance Remove the bearing housing from the turbine housing and install it in the compressor cover. Measure the clearance between the turbine backplate and the back side of the turbine wheel using feeler gauges. NOTE! Use two feeler gauges, and measure at vane tips.

  • Page 188: Group 26:Cooling System

    Group 26 Cooling System Group 26 Cooling System Fresh Water Pump Disassembly Look for: 1. Snap ring A. Rotation 2. Cover B. Wear, deterioration of lip 3. Water pump impeller C. Corrosion, chafing 4. Ring D. Crack, damage 5. Unit seal E.
  • Page 189 Group 26 Cooling System Fresh water pump Touch the drain port located at the bottom of the pump with your finger. If the port is leaking water, check the condition of the unit seal. If it is leaking oil, the oil seal is defective. Remove the impeller 1.

  • Page 190: Inspection

    Group 26 Cooling System Inspection Water pump Measure the inside diameter of the pump case bore to which the bearing outer race is fitted. Measure the diameter of the pump shaft on which the bearing in- ner race is fitted. If the bearing, case, or shaft is worn, replace it Inside diameter of pump case bearing, mm [in.] Norminal value ..

  • Page 191: Reassembly

    Group 26 Cooling System Reassembly Reassembly sequence: NOTE! Replace all O-rings, unit seals and oil seals at reassembly. 1. Use the oil seal installer to drive in the oil seal. Apply engine oil to seal lip. 2. Use the unit seal installer to drive in the unit seal. Replace the unit seal once disturbed.
  • Page 192 Group 26 Cooling System 5. Insert the gear into the shaft by aligning the key. Press in the ball bearing on the nut side. 6. Press in the impeller to the depth where impel- ler’s boss end face is flush with the shaft end. 7.

  • Page 193: Thermostats

    Group 26 Cooling System Thermostats Disassembly Look for: 1. Thermostat cover A. Deteriorated, worn, cracked 2. Packing B. Replace packing 3. Snap ring C. Worn, cracked 4. Thermostat 5. Thermostat seal 6. Thermostat case Inspection Heat the thermostat in the water. Measure the temper- ature when the valve opens.

  • Page 194: Heat Exchanger

    Group 26 Cooling System Heat Exchanger Disassembly Look for: 1. Cover A. Pipes clogged, leaks 2. Packing B. Change if less than 50% remains 3. Cover 4. O-ring 5. Zinc rod 6. Element 7. Body Inspection Cleaning of element 1. While pouring running water onto the outer sur- face of the element, clean with a wire brush.

  • Page 195: Raw Water Pump

    Group 26 Cooling System Raw Water Pump (standard rubber impeller) Disassembly 1. Cover, O-ring 2. Impeller 3. Casing, gasket, plate, gasket 4. Bushing, unit seal 5. Slinger 6. Nut, spring washer 7. Pulley 8. Snap ring 9. Shaft, key 10. Bearing 11.

  • Page 196: Inspection

    Group 26 Cooling System Inspection Bearing dimensions Measure the dimensions of the bearing installation sections of the sea water pump holder and shaft. If excessive wear or damage is observed, replace the bearing, holder and shaft. Inside diameter at bearing position, mm [in.] Nominal value ...

  • Page 197: Reassembly

    Group 26 Cooling System Reassembly Reassembly sequence: Plus d'informations sur : www.dbmoteurs.fr...
  • Page 198 Group 26 Cooling System 1. Install the cam to the casing, and tighten the screw to the specified torque. The contact surfac- es must be coated with ThreeBond 1102. 2. Install the unit seal to the bushing by striking with a hammer, making sure the unit seal remains square to the bushing during installation.
  • Page 199 Group 26 Cooling System 5. Install the casing to the holder via the plate. The contact surface must be coated with ThreeBond 1102. Tighten the bolts to 7.4 to 9.8 N*m (0.75 to 1.0 kgf*m) [5.42 to 7.23 lbf*ft]. 6. Install the impeller to the shaft by striking with a hammer.

  • Page 200: Group 30:Electrical System

    Group 30 Electrical System Group 30 Electrical System Starter Disassembly Look for 1. Safety switch A. Wear of gear, damage 2. Magnetic switch assembly B. Play and unsmooth rotation 3. Rear bracket C. Adhesion of brush particles, irregular wear, brush movement in holder 4.
  • Page 201 Group 30 Electrical System 1. Remove the safety switch, wires and cables and the magnetic switch assembly. 2. Unscrew the through bolts and the brush holder mounting screws. Remove the rear bracket. 3. Remove the brushes from the brush holder as- sembly and then remove the yoke.
  • Page 202 Group 30 Electrical System 5. Remove the center bracket. 6. Remove the lever pin, inner housing, and shift le- ver from the pinion case. 7. Using a jig, remove the pinion stopper, then re- move the overrunning clutch from the pinion shaft.

  • Page 203: Inspection And Repair

    Group 30 Electrical System Inspection and Repair Magnetic Switch Testing the magnetic switch coil 1. Test the pressure coil and holding coil for an open ciruit. The coils are open-circuited if there is no continuity between the M terminal of the mag- netic switch and the case.
  • Page 204 Group 30 Electrical System Armature Measuring the armature runout Measure the runout with a dial gauge. If the deflection exceeds the assembly standard, repair or replace the armature. Armature deflection, mm [in.] Assembly Standard ... 0.05 [0.00197] Inspecting the commutator 1.
  • Page 205 Group 30 Electrical System Field coil Testing for open circuits 1. If there is no continuity between the M terminal of the field coil and the lead wire on the brush side, replace the field coil. Overrunning Clutch The clutch is in good condition if it rotates freely in one direction when tumed by hand.
  • Page 206 Group 30 Electrical System Safety Switch Connect the safety switch as shown, and check the starter and safety switch operations. 1. Connect the R terminal to the battery minus (-) side. 2. Turn the switch on, and check that the starter tums.

  • Page 207: Reassembly

    Group 30 Electrical System Reassembly Reassembly sequence: 1. Install the center bracket, overrunning clutch, and pinion stopper to the pinion shaft. Insert the shaft in position by tapping it with a soft-head mallet. 2. Install the shift lever and pinion shaft to the front bracket by aligning the matching mark on the shifi lever.
  • Page 208 Group 30 Electrical System NOTE! Install the positive (+) side brush and negative (-) side brush as shown. 5. Install the rear bracket to the yoke by aligning the matching marks. Secure the brush holders with bolts, then tighten the through bolts. 6.
  • Page 209 Group 30 Electrical System 8. Measure the end play of the pinion shaft. If the end play exceeds the assembly standard, adjust it on the internal gear side. Pinion shaft end play, mm [in.] Assembly Standard ... 0.2–0.8 [0.008–0.031] 9. Install the magnetic switch. Apply a voltage of 24 volts between the C and E terminals.

  • Page 210: Alternator

    Group 30 Electrical System Alternator Disassembly 1. Nut, washer 2. Pulley assembly 3. Set screw 4. Front bracket assembly 5. Rotor assembly 6. Field coil 7. Stator 8. Rear bracket 9. Regulator assembly 10. Rectifier assembly 11. Terminal assembly Plus d'informations sur : www.dbmoteurs.fr...

  • Page 211: Inspection And Repair

    Group 30 Electrical System Inspection and repair Stator 1. Testing the stator coil for open circuits If there is no continuity among the three lead wires, replace the stator. 2. Testing the stator coil for grounding If there is continuity between the coil and core, replace the stator.
  • Page 212 Notes ........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................Plus d'informations sur : www.dbmoteurs.fr...
  • Page 213 Notes ........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................Plus d'informations sur : www.dbmoteurs.fr...
  • Page 214 Notes ........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................Plus d'informations sur : www.dbmoteurs.fr...
  • Page 215 Plus d'informations sur : www.dbmoteurs.fr...
  • Page 216 Plus d'informations sur : www.dbmoteurs.fr...

This manual is also suitable for:

D65a mt

Table of Contents