AGCO Power 33 User manual

Workshop Service Manual
4th Generation Engines
AGCO POWER
Linnavuori
AGCO Power - Linnavuorentie 8-10 - FIN-37240
Linnavuori, Nokia, Finland
© AGCO 2014
November 2014
8370 79492
EAME
English

4th Generation Engines
1 Introduction ..............................................................1-1
1.1 Safety instructions .................................................1-3
1.2 To the user ........................................................1-5
1.2.1 Engine type designations ...........................................1-6
1.2.2 Location of the engine serial number ..................................1-7
1.2.3 Marking of the engine control unit ....................................1-8
1.2.4 Lifting the engine ................................................1-8
1.2.5 Starting the engine after major maintenance . . . . . . . . . . . ..................1-9
1.3 Engine construction ...............................................1-11
1.3.1 Engine construction overview ......................................1-11
1.3.2 Technical data ..................................................1-11
1.3.2.1 Principal dimensions and data ................................1-11
1.3.2.2 Fuel system .............................................1-11
1.3.2.3 Lubrication system ........................................1-12
1.3.2.4 Cooling system ..........................................1-12
1.3.2.5 SCR system technical data ..................................1-13
1.3.3 Cylinder block ..................................................1-13
1.3.4 Flywheel housing ...............................................1-13
1.3.5 Valve mechanism ...............................................1-13
1.3.6 Cylinder head ..................................................1-14
1.3.7 Crank mechanism ...............................................1-14
1.3.8 Timing gears ...................................................1-15
1.3.9 Lubrication system ..............................................1-16
1.3.9.1 Oil pressure regulating valve .................................1-17
1.3.9.2 Oil filter and oil cooler in 33-74 engines .........................1-17
1.3.9.3 Oil filter and oil cooler in 84-98 engines .........................1-17
1.3.10 Cooling system ................................................1-18
1.3.10.1 Thermostat .............................................1-18
1.3.11 Air intake system ...............................................1-19
1.3.11.1 Cooled EGR system ......................................1-20
1.3.11.2 EGR cooler .............................................1-21
1.3.12 Fuel system ..................................................1-21
1.3.13 SCR-system ..................................................1-22
1.3.13.1 SCR system overview .....................................1-22
1.3.13.2 SCR system components and their functions ....................1-23
1.3.14 Engine control system ...........................................1-24
1.3.15 Service tool of the engine control system .............................1-27
2 Specifications ............................................................2-1
2.1 Technical data .....................................................2-3
2.1.1 Cylinder block ...................................................2-3
2.1.2 Cylinder liners ...................................................2-3
2.1.3 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...........2-4
2.1.4 Valves and rockers ...............................................2-5
2.1.5 Tappets and push rods ............................................2-6
2.1.6 Camshaft ......................................................2-7
2.1.7 Crankshaft .....................................................2-8
2.1.8 Flywheel ......................................................2-12
2.1.9 Balancing unit ..................................................2-12
2.1.10 Timing gears ..................................................2-12
2.1.11 Connecting rod ................................................2-13
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2.1.12 Piston, rings and pin ............................................2-14
2.1.13 Lubrication system . . . . .........................................2-16
2.1.14 Oil pump . . . . . . . ..............................................2-17
2.1.15 Thermostat ...................................................2-18
2.1.16 Turbocharger ..................................................2-19
2.2 Tightening torques ................................................2-20
2.3 Special tools ......................................................2-22
2.3.1 Cylinder block tools ..............................................2-22
2.3.2 Timing gear and flywheel housing tools ...............................2-23
2.3.3 Cylinder head and valve mechanism tools ..............................2-24
2.3.4 Crank mechanism tools ...........................................2-25
2.3.5 Coolant pump tools ..............................................2-26
2.3.6 Engine control system tools ........................................2-27
2.3.7 Maintenance and troubleshooting tools ...............................2-27
2.4 Liquid quality requirements ........................................2-29
2.4.1 Lubricating oil quality requirements ..................................2-29
2.4.2 Coolant quality requirements .......................................2-29
2.4.3 Fuel quality requirements ..........................................2-30
2.5 Terminal diagram (3-6 cylinder engines) ............................2-33
2.6 Terminal diagram (7 cylinder engines) ..............................2-34
3 Maintenance .............................................................3-1
3.1 Cylinder block ..................................................... 3-5
3.1.1 Measuring cylinder liner wear ....................................... 3-5
3.1.2 Removing cylinder liner ............................................3-5
3.1.3 Checking cylinder block ............................................3-5
3.1.4 Changing camshaft bushing (33-49 engines) .............................3-6
3.1.5 Changing camshaft bushing (66-98 engines) .............................3-6
3.1.6 Fitting plug at camshaft rear end .....................................3-8
3.1.7 Oversize bushings for camshaft ......................................3-8
3.1.8 Fitting plug at camshaft rear end (oversize bushings) .......................3-9
3.1.9 Fitting cylinder liner ...............................................3-9
3.2 Flywheel housing .................................................3-13
3.2.1 Fitting flywheel housing ...........................................3-13
3.2.2 Changing crankshaft rear oil seal ....................................3-13
3.3 Cylinder head .....................................................3-15
3.3.1 Removing cylinder head ...........................................3-15
3.3.2 Removing valves ................................................3-15
3.3.3 Checking cylinder head ...........................................3-15
3.3.4 Changing valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..........3-17
3.3.5 Machining valve seat .............................................3-17
3.3.6 Changing valve seat rings .........................................3-17
3.3.7 Grinding valves .................................................3-18
3.3.8 Fitting valves ...................................................3-19
3.3.9 Fitting cylinder head .............................................3-19
3.4 Valve mechanism .................................................3-21
3.4.1 Reconditioning valve mechanism ....................................3-21
3.4.2 Changing camshaft or camshaft gear .................................3-22
3.4.3 Adjusting valves ................................................3-23
3.5 Crankshaft ........................................................3-26
3.5.1 Removing crankshaft .............................................3-26
3.5.2 Checking crankshaft .............................................3-26
3.5.3 Changing crankshaft gears .........................................3-27
3.5.4 Fitting crankshaft ................................................3-28
3.5.5 Crankshaft hub piece .............................................3-29
3.5.6 Checking element of the rubber damper (44-49 engines) ...................3-29
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3.5.7 Viscose type vibration damper ......................................3-30
3.6 Connecting rods and pistons .......................................3-31
3.6.1 Removing pistons together with connecting rods . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3.6.2 Changing connecting rod bearings ...................................3-31
3.6.2.1 Piston pin bushing ........................................3-31
3.6.2.2 Big-end bearing ..........................................3-32
3.6.3 Checking connecting rod . . . . . . . ...................................3-32
3.6.4 Changing piston rings ............................................3-33
3.6.5 Checking pistons ................................................3-34
3.6.6 Fitting piston pin ................................................3-35
3.6.7 Fitting piston together with connecting rod .............................3-35
3.7 Counterbalance in 4 cylinder engines ...............................3-36
3.7.1 Removing and disassembling counterbalance unit ........................3-36
3.7.2 Reconditioning counterbalance unit ..................................3-36
3.7.3 Fitting counterbalance unit .........................................3-37
3.7.4 Changing crankshaft gear rim .......................................3-37
3.8 Flywheel .........................................................3-38
3.8.1 Changing starter ring gear on flywheel ................................3-38
3.8.2 Fitting flywheel .................................................3-38
3.9 Timing gear assembly .............................................3-39
3.9.1 Removing timing gear casing .......................................3-39
3.9.2 Fitting timing gear casing . .........................................3-40
3.9.3 Fitting the crankshaft hub .........................................3-42
3.9.4 Power take-off .................................................3-44
3.9.5 Fan drive device ................................................3-44
3.10 Lubrication system ...............................................3-45
3.10.1 Oil pressure regulating valve ......................................3-45
3.10.2 Removing and dismantling lubricating oil pump .........................3-45
3.10.3 Assembling and fitting lubricating oil pump ............................3-46
3.10.4 Piston cooling nozzles ...........................................3-46
3.10.5 Fitting oil sump gasket ...........................................3-48
3.10.6 Lubricating oil cooler ............................................3-48
3.10.7 Removing the oil cooler ..........................................3-48
3.10.8 Fitting the oil cooler .............................................3-49
3.10.9 Oil sump capacity ..............................................3-49
3.10.10 Closed crankcase ventilation . . . . . . . . . . . . . . . . . . . . . ................3-50
3.10.10.1 Installing the closed crankcase ventilation system components in 33 -
74 engines ....................................................3-50
3.10.10.2 Installing the closed crankcase ventilation system components in 84
and 98 engines .................................................3-50
3.11 Cooling system ..................................................3-52
3.11.1 Removing the thermostat ........................................3-52
3.11.2 Testing the thermostat ..........................................3-52
3.11.3 Replacing the thermostat .........................................3-52
3.11.4 Reconditioning coolant pump ......................................3-52
3.11.4.1 Coolant pumps with standard bearings . . . . . . ...................3-52
3.11.4.2 Coolant pumps with heavy duty bearings .......................3-55
3.11.4.3 Coolant pumps with Flexonic belt ............................3-55
3.11.5 Installing the cylinder head connection part . . . . . . ......................3-56
3.12 Air intake system ................................................3-57
3.12.1 Checking the air cleaner ..........................................3-57
3.12.2 Checking the inlet and exhaust pipes ................................3-57
3.12.3 Checking the turbocharger ........................................3-58
3.12.4 Fitting the turbocharger ..........................................3-58
3.12.5 Checking the EGR actuator voltages ................................3-59
3.12.5.1 Link rod ...............................................3-60
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3.13 Fuel system .....................................................3-61
3.13.1 Bleeding the fuel system .........................................3-61
3.13.2 Measuring fuel feed pressure ......................................3-61
3.13.3 Inspecting injectors .............................................3-62
3.13.3.1 Removing the injectors (CRIN3) ..............................3-62
3.13.3.2 Fitting the injectors (CRIN3) .................................3-63
3.13.3.3 Removing the injectors (CRI2_16) ............................3-64
3.13.3.4 Fitting the injectors (CRI2_16) ...............................3-64
3.13.4 High-pressure pump ............................................3-65
3.13.4.1 Removing the high-pressure pump ...........................3-65
3.13.4.2 Fitting the high-pressure pump ..............................3-66
3.13.5 Rail .........................................................3-66
3.14 SCR system .....................................................3-69
3.14.1 SCR system maintenance ........................................3-69
3.14.2 Mounting of SCR system components ...............................3-69
3.14.3 Removing the supply module ......................................3-70
3.14.4 Installing the supply module .......................................3-70
3.14.5 Removing the hydraulic connectors .................................3-71
3.14.6 Installing the hydraulic connectors ..................................3-71
3.15 Engine control system ............................................3-72
3.15.1 Changing the electronic control unit .................................3-72
3.15.2 Wiring sets ...................................................3-73
3.15.2.1 Wiring set for appliance connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74
3.15.2.2 Wiring set for intake air heater ...............................3-74
3.15.3 Sensors of the engine control system ................................3-75
4 Index .................................................................Index-1
Table of contents
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1. Introduction
1.1 Safety instructions ......................................................1-3
1.2 To the user .............................................................1-5
1.2.1 Engine type designations ................................................1-6
1.2.2 Location of the engine serial number .......................................1-7
1.2.3 Marking of the engine control unit .........................................1-8
1.2.4 Lifting the engine .....................................................1-8
1.2.5 Starting the engine after major maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .......1-9
1.3 Engine construction ....................................................1-11
1.3.1 Engine construction overview ...........................................1-11
1.3.2 Technical data .......................................................1-11
1.3.2.1 Principal dimensions and data .....................................1-11
1.3.2.2 Fuel system ..................................................1-11
1.3.2.3 Lubrication system .............................................1-12
1.3.2.4 Cooling system ............................................... 1-12
1.3.2.5 SCR system technical data . . . . . . . . . . . . . . . . . ......................1-13
1.3.3 Cylinder block .......................................................1-13
1.3.4 Flywheel housing ....................................................1-13
1.3.5 Valve mechanism ....................................................1-13
1.3.6 Cylinder head . ......................................................1-14
1.3.7 Crank mechanism ....................................................1-14
1.3.8 Timing gears ........................................................1-15
1.3.9 Lubrication system ...................................................1-16
1.3.9.1 Oil pressure regulating valve ......................................1-17
1.3.9.2 Oil filter and oil cooler in 33-74 engines ..............................1-17
1.3.9.3 Oil filter and oil cooler in 84-98 engines ..............................1-17
1.3.10 Cooling system .....................................................1-18
1.3.10.1 Thermostat . . ................................................1-18
1.3.11 Air intake system ....................................................1-19
1.3.11.1 Cooled EGR system ...........................................1-20
1.3.11.2 EGR cooler ..................................................1-21
1.3.12 Fuel system .......................................................1-21
1.3.13 SCR-system .......................................................1-22
1.3.13.1 SCR system overview ..........................................1-22
1.3.13.2 SCR system components and their functions .........................1-23
1.3.14 Engine control system ................................................1-24
1.3.15 Service tool of the engine control system . . . . . . . . . .........................1-27
Table of contents
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Table of contents
1-2 4th Generation Engines
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1.1 Safety instructions
WARNING:
In the use and service of the engine there is always the possibility of injury. Before
starting the service read and understand the safety instructions and remarks!
• Do not start any repair work that you do not fully understand.
• Make sure that the location and surroundings in which you are carrying out the repair provide a safe
environment in which to work.
• Always ensure the location is clean and free of clutter.
• Do not use faulty or otherwise unsuitable tools.
• Remove all rings, chains and watches before starting work.
• Use up-to-date protection equipment while you work. For example, eye protection, as you will be
working with compressed air for cleaning, grinding, hammering or similar.
• Use a lifting device for lifting and transporting heavy (over 20 kg) pieces. Ensure all lifting hooks and
chains are in good condition. The lifting eyes on the engine must not be subjected to side forces during
lifting.
• Never work under an engine that is hanging from a lifting device or raised up on a jack. Always use
strong supports before starting the work.
• Start the engine only by using the starting switch in the cabin.
• Do not start an engine if the protection covers are removed.
NOTE: The fan is difficult to see when the engine is running! Ensure that loose clothing or long hair
does not get caught in the rotating parts of the engine.
• If you start the engine indoors, ensure that there is proper ventilation.
• Never use an aerosol starting aid! (Risk of explosion, personal injuries and engine damage.)
• When you are operating the engine or working near it, use ear protection to avoid noise injuries.
• Always stop the engine before starting any servicing or repair work.
• Avoid touching the exhaust manifold, turbocharger and any other hot parts of the engine.
• Do not remove the thermal protection of the exhaust manifold.
• Open the radiator cap with care when the engine is hot, as the cooling system is pressurised. The
cooling liquid and lubrication oil of a hot engine will cause injury if they come into contact with skin.
• Do not open high pressure pipe connectors of the fuel system when the engine is running. Wait at least
30 sec. after the stopping of the engine. If the jet of high pressure fuel contacts your skin, fuel
penetrates the skin causing severe injuries. Get medical help immediately!
• Never allow a naked flame, smoking or sparks near the fuel system or batteries, especially when
loading batteries, as these are explosive.
• Always disconnect the negative (-) battery cable when servicing or repairing the electric system.
• At temperatures in excess of 300°C, e.g. if the engine is burnt by a fire, the viton seals of the engine
(i.e. the undermost cylinder liner O-ring) produce very highly corrosive hydrofluoric acid. Do not touch
with bare hands when viton seals are subjected to abnormally high temperatures. Always use neoprene
rubber or heavy-duty gloves and safety glasses when decontaminating. Wash the seals and the
contaminated area with a 10% calcium hydroxide or other alkali solution. Put all removed material in
sealed plastic bags and deliver them to the relevant disposal point provided by the authorities
concerned.
NOTE: Never destroy viton seals by burning!
• When checking fuel injectors do not allow the jet of high-pressure fuel to come into contact with your
skin. The fuel penetrates the skin causing severe injuries. Get medical help immediately!
• The fuel, lubricating oil and coolant cause long-lasting irritation on contact with skin.
• If you are carrying out welding or similar high current operations for the appliance, we recommend that
you disconnect the electronic control unit (ECU) main connector before starting work.
Important instructions
• Avoid unnecessary idling of the engine.
1. Introduction
4th Generation Engines 1-3
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• Do not let oil and other liquids to the environment when servicing the engine. Take them to a proper
disposal point.
• Use only genuine AGCO Parts spare parts.
NOTE: Engine gaskets, seals and washers are disposable. Always change gaskets, seals and washers
when opening joints.
• All the engine gaskets are made of non-asbestos material.
• Be careful when washing the engine with high-pressure washing machine equipment. Do not use high
pressure to wash e.g. the electric and fuel equipment or the radiator because they can easily be
damaged. To get humidity removed, it is recommended to run the engine after washing.
1. Introduction
1-4 4th Generation Engines
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1.2 To the user
4th Generation engines with SCR system (AWI/ATI) meet EU97/68/EC Stage IIIB and EPA 40 CFR 89 Tier
4i emission requirements set by authorities. The manufacturer guarantees that all engines of this type are
equivalent to the engine that is officially approved.
4th Generation engines without SCR system (WI/TI) meet EU97/68/EC Stage 2 and EPA 40 CFR 89 Tier 2
emission requirements set by authorities. The manufacturer guarantees that all engines of this type are
equivalent to the engine that is officially approved.
Please note that the service schedule should be followed carefully, especially when performing periodical
maintenance. Any adjustment and repair work to the injection system or the electronic control unit should
only be carried out by a representative authorised by AGCO Power Inc. When performing any service or
repair work, only use original AGCO Parts spare parts. Inadequate or delayed service and the use of parts
other than original AGCO Parts spare parts will invalidate the responsibility of AGCO Power Inc. with
respect to the fulfilment of the emission requirements.
This Workshop Manual is intended to assist with workshop operations and repair work.
4th Generation engines (types 33, 44, 49, 66, 74, 84 and 98) are generally of the same construction, so the
same repair instructions will usually apply to various engine types. The differences between the various
engine types, which affect repair work, are mentioned in the technical data and repair instructions.
All measurements are in millimetres and valid when the temperature of the parts is +20°C, unless
otherwise stated.
NOTE: Engine gaskets, seals and washers are disposable. Always change gaskets, seals and washers
when opening joints.
Before starting any repair work, please read the safety instructions at the beginning of this book. Make
sure that you have all the necessary tools, parts and accessories to hand. The special tools mentioned in
the work instructions speed up and facilitate the work and contribute to successful execution of the work.
An engine which has undergone repairs must be run in just like a new one.
Should the engine require work not described in this manual, please consult your local agent or the Service
Department of AGCO Power Inc., Linnavuori, Finland. To facilitate consulting, find out the following facts
about the engine before contacting us:
• engine type
• engine number
• model or equipment
• operating hours
This Workshop Manual does not cover the regular service procedure as this is explained in the 4th
Generation series Operator's Manual.
As AGCO Power Inc. is continuously developing its products, all rights are reserved to alter the
specifications, accessories and the service and repair procedure without separate notice.
NOTE: AGCO Power Inc. takes no responsibility for any damages caused because of possible incorrect
information in this manual. Distribution of this manual in printed or electronic form is not allowed without
our prior agreement.
1. Introduction
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1.2.1 Engine type designations
(1) Basic type
74 = cylinder displacement, decilitres
A = aftertreatment system
(2) Turbocharged engine
W = wastegate turbo
T = standard turbo
(3) Equipped with intercooler
I = air to air
(4) C = medium duty engine
G = generating set engine
M = marine engine
Fig. 1
1. Introduction
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1.2.2 Location of the engine serial number
The engine serial number is always stamped on
the cylinder block as the picture shows.
The serial number is also marked on the type
plate.
Engines have an electronic serial number data
which is readable with engine control unit (ECU)
service tool. The data includes also detailed
specification, operation history and service
information.
Fig. 2
1. Introduction
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1.2.3 Marking of the engine control unit
The specification of the application is indicated on
the type plate of the engine control unit (ECU).
This specification must always be stated when
ordering a control unit or asking for adjusting
settings.
NOTE: Engine with SCR system meets EU97/68/
EC Stage lllB and EPA 40 CFR 1039 Tier 4i
emission requirements. Engine without SCR
system meets EU97/68/EC Stage 2 and EPA 40
CFR 89 Tier 2 emission requirements.
Do not fit any components on the engine other
than those originally intended for it. The use of
other than original AGCO Parts spare parts
invalidates the responsibility of AGCO Power Inc.
on the meeting of the emission requirements.
Fig. 3
1.2.4 Lifting the engine
DANGER:
Safe lifting of the engine is done with a lifting device where the lifting force affects the
lifting eyes vertically.
1. Introduction
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A = Engine lifting eyes
Fig. 4
Weight of engine Engine type Weight kg[1]
33 300
44 345
49 345
66 515
74 525
84 665
98 790
[1] Approximate dry weight without flywheel,
electrics, CCV , EGR and SCR system components
1.2.5 Starting the engine after major maintenance
Some parts in the exhaust system can be damaged easily by increased amount of oil and impurities.
Excessive oil can occur after a major engine overhaul, for example when the pistons are lubricated during
the assembly.
1. Introduction
4th Generation Engines 1-9
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Procedure
1. Do not connect the exhaust system to the engine, if there can be extra oil or impurities in the engine
after any maintenance work or engine overhaul.
2. Run the engine 1-2 minutes on high idle.
Running the engine burns possible extra oil and impurities from the engine.
NOTE: Excessive amount of oil can damage the catalysts.
3. Connect the exhaust system to the engine according to the instructions of the machine
manufacturer.
1. Introduction
1-10 4th Generation Engines
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1.3 Engine construction
1.3.1 Engine construction overview
AGCO POWER engines consists of water-cooled in-line diesel engines with three, four, six and seven
cylinders. The turbocharged engines are equipped with wet, changeable cylinder liners.
All the engine types have a rigid and ribbed cylinder block. The crank mechanism is designed for
supercharging. The cylinder liners are wet and supported at the middle. The cylinder head bolts are high
tensile bolts.
1.3.2 Technical data
1.3.2.1 Principal dimensions and data
Engine
type
33 44 49 66 74 84 98
Number of
cylinders
3446667
Displaceme
nt (ltr)
3,30 4,40 4,90 6,60 7,40 8,40 9,80
Cylinder
bore (mm)
108 108 108 108 108 111 111
Stroke
(mm)
120 120 134 120 134 145 145
Fuel feed Direct
injection
Direct
injection
Direct
injection
Direct
injection
Direct
injection
Direct
injection
Direct
injection
Injection
advance
Automatic
adjusted
Automatic
adjusted
Automatic
adjusted
Automatic
adjusted
Automatic
adjusted
Automatic
adjusted
Automatic
adjusted
Valve
clearance,
intake and
exhaust
(mm)
0,35 (cold
or hot)
0,35 (cold
or hot)
0,35 (cold
or hot)
0,35 (cold
or hot)
0,35 (cold
or hot)
0,35 (cold
or hot)
0,35 (cold
or hot)
Direction of
rotation
from the
engine
front
Clockwise Clockwise Clockwise Clockwise Clockwise Clockwise Clockwise
1.3.2.2 Fuel system
Engine
type
33 44 49 66 74 84 98
Fuel
injection
system
Bosch
Common
Rail
Bosch
Common
Rail
Bosch
Common
Rail
Bosch
Common
Rail
Bosch
Common
Rail
Bosch
Common
Rail
Bosch
Common
Rail
Fuel The fuel
must be
according
to norm EN
590:2009 or
ASTM
The fuel
must be
according
to norm EN
590:2009 or
ASTM
The fuel
must be
according
to norm EN
590:2009 or
ASTM
The fuel
must be
according
to norm EN
590:2009 or
ASTM
The fuel
must be
according
to norm EN
590:2009 or
ASTM
The fuel
must be
according
to norm EN
590:2009 or
ASTM
The fuel
must be
according
to norm EN
590:2009 or
ASTM
1. Introduction
4th Generation Engines 1-11
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Engine
type
33 44 49 66 74 84 98
D975 1-D/2-
D, see the
information
for fuel
quality
requiremen
ts
D975 1-D/2-
D, see the
information
for fuel
quality
requiremen
ts
D975 1-D/2-
D, see the
information
for fuel
quality
requiremen
ts
D975 1-D/2-
D, see the
information
for fuel
quality
requiremen
ts
D975 1-D/2-
D, see the
information
for fuel
quality
requiremen
ts
D975 1-D/2-
D, see the
information
for fuel
quality
requiremen
ts
D975 1-D/2-
D, see the
information
for fuel
quality
requiremen
ts
Injection
order
1-2-3 1-2-4-3 1-2-4-3 1-5-3-6-2-4 1-5-3-6-2-4 1-5-3-6-2-4 1-2-4-6-7-5-
3
Maximum
injection
pressure
Max. 1800
bar
Max. 1800
bar
Max. 2000
bar
Max. 2000
bar
Max. 2000
bar
Max. 2000
bar
Max. 2000
bar
Fuel filter:
Pre-filter
10 μ 10 μ 10 μ 10 μ 10 μ 10 μ 10 μ
Fuel filter:
Main filter
5μ5μ5μ5μ5μ5μ5μ
Maximum
continuous
fuel inlet
temperatur
e
70°C 70°C 70°C 70°C 70°C 70°C 70°C
1.3.2.3 Lubrication system
Lubrication system
Oil pressure in hot engine at running speed 2,5 - 5 bar
Oil pressure at idle speed, min 1,5 bar
Oil capacity See Oil sump capacity
Oil quality requirements See Lubricating oil quality requirements
1.3.2.4 Cooling system
Engine
type
33 44 49 66 74 84 98
Number of
thermostat
s
1112222
Opening
temperatur
e
ø 67 mm =
83 ° C
ø 67 mm =
83 ° C
ø 67 mm =
83 ° C
ø 54 mm =
79 ° C, ø 67
mm = 83 °
C
ø 54 mm =
79 ° C, ø 67
mm = 83 °
C
ø 54 mm =
79 ° C, ø 67
mm = 83 °
C
ø 54 mm =
79 ° C, ø 67
mm = 83 °
C
Coolant
quality
requiremen
ts
See
information
for coolant
quality
requiremen
ts
See
information
for coolant
quality
requiremen
ts
See
information
for coolant
quality
requiremen
ts
See
information
for coolant
quality
requiremen
ts
See
information
for coolant
quality
requiremen
ts
See
information
for coolant
quality
requiremen
ts
See
information
for coolant
quality
requiremen
ts
1. Introduction
1-12 4th Generation Engines
8370 79492

1.3.2.5 SCR system technical data
Principal data
SCR system Bosch DENOXTRONIC 2.2
Minimum operating temperature -40 °C
Maximum DEF temperature 70 °C
Maximum SCR system temperature 80 °C
Dosing system
Reagent fluid type DIN70070/ISO22241 certified DEF (Diesel Exhaust
Fluid), e.g. AdBlue
DEF consumption Approximately 6-8% of fuel consumption[1]
Pre-filters 100 μ
Main filter 10 μ
[1] DEF consumption may be higher, depending on the application and load profile of the engine.
1.3.3 Cylinder block
The cylinder block is the main body of the engine, to which other engine parts are attached. Wet and
replaceable cylinder liners are supported at the middle, which reduces vibrations and directs coolant
circulation mainly to the upper part of the liners.
The seal between the lower part of the cylinder liner and the cylinder block is achieved by three O-rings.
The O-rings are fitted in grooves in the liner in 33-, 44-, 49-, 66- and 74-engines . The O-rings are fitted in
grooves in the cylinder block in 84- and 98-engines . The upper part is sealed by the cylinder head gasket.
The camshaft is located in the cylinder block.The camshaft front bearing location is fitted with a separate
bearing sleeve and the remaining bearing locations are machined directly in the cylinder block in 33-, 44-
and 49-engines. There are separate bearing sleeves in all camshaft bearing locations and the drilling for the
camshaft rear end is covered with a plug in the 66-, 74-, 84- and 98-engines.
There are spaces on both sides of the rear main bearing for guide bearing shims (the crankshaft thrust
bearings).
1.3.4 Flywheel housing
The flywheel housing is fitted at the rear end of the cylinder block. The seal for the crankshaft rear end is
placed in a bore in the housing. The starter motor fixing point is fitted in the flywheel housing.
The lower face of the flywheel housing functions as a sealing surface for the oil sump gasket. This means
that the lower face of the cylinder block must be level with the flywheel housing. When fitting the flywheel
housing, its position is determined by tension pins.
The flywheel housing is delivered according to the requirements set by the engine model and different
flywheel housings can be mounted on all engine types.
1.3.5 Valve mechanism
The valve mechanism is operated by the camshaft which is located in the cylinder block. The drive is
transferred with the help of tappets and push rods. The camshaft gear wheel is fitted with a nut and
guided with a key. Each bearing is lubricated by the force feed lubrication system through drilled oilways in
the cylinder block.
1. Introduction
4th Generation Engines 1-13
8370 79492

1.3.6 Cylinder head
A three cylinder engine has one cylinder head.There is one cylinder head in four cylinder engine. A six
cylinder engine has two cylinder heads. The 98 engine has two cylinder heads: one for three cylinders
(front) and one for four cylinders (rear). Every cylinder has four valves and in the middle of the valves there
is a place for the injector. The injector is located vertically in the centre of the cylinder and in the middle of
the combustion chamber. This ensures accurate and homogenous mixing of fuel and air and leads to clean
and low emission combustion with good efficiency.
Each cylinder has its own inlet and exhaust ports located on either side of the head. Every inlet valve has
its own inlet port but there is only one exhaust port for every two of the cylinder’s exhaust valves. There
are no water holes on the inlet side of the cylinder head. This eliminates the possibility of water entering
the inlet air.
Cylinder head bolts are high tensile bolts, which are tightened up to yield limit using the angle tightening
method. Due to the large stretch, the tightening forces are kept constant during the whole lifetime and
retightening is unnecessary.
The injector and its side feeding pipe locations are machined directly into the cylinder head. The port for
the side feeding pipe is located between the inlet ports. The inlet and exhaust valve guides are identical
and can be interchanged. Inlet and exhaust valves are fitted with separate valve seat rings.
1.3.7 Crank mechanism
The crankshaft is forged from chrome alloy special steel and is induction hardened at the bearing and
sealing surfaces. This makes it possible to grind bearings four times and 98 engine two times without a
new heat treatment. Gear wheels are located at the front end of the crankshaft. They are a press fit, and
drive the idler wheel and oil pump. The belt pulley/vibration damper is fastened to the crankshaft with a
cone joint. An oil deflector ring is fitted between the hub and gear wheel. The 98-engine has larger cone
and an additional seal ring.
The crankshaft is supported on the cylinder block by main bearings, which are placed on both sides of each
cylinder. There is therefore one main bearing more than there are cylinders. The crankshaft thrust washers
are placed in both sides of the rearmost main bearing.
A flywheel, on which there is a press-fit starter ring gear, is fitted at the rear end of the crankshaft. The
forged connecting rod has an I-cross-section. The bearing location at the bottom end of the connecting rod
is fracture-split, and the bearing cup is secured by two special elongated screws. The upper part has a
wedge-shaped bearing location, in which the piston pin bearing bushing is fitted with a press fit.
The piston is made of a eutectic aluminium alloy. In the upper face of the piston there is a combustion
chamber. The shape of the chamber is intended to maximise the mixture of air and fuel. The upper ring
location is formed in a cast iron ring, which is cast in the piston. In addition, the piston is graphite-coated to
ensure correct running-in.
The piston has three rings. The upper molybdenum-coated ring has a wedge-shaped cross-section. The
middle ring is tapered and it fits into its groove. The taper takes up the clearance. The oil control ring is
spring-loaded and it has a two-stage, chromed scraping edge.
Four-cylinder engines are equipped with a balancer unit. The eccentric weights, which rotate at twice the
engine speed, even out the vibration forces exerted by the movement of the pistons and the crank
mechanism.
1. Introduction
1-14 4th Generation Engines
8370 79492