Valmet 309 Instruction manual

UALMET
diesel
3o,9
911
4tl
611
612
Woftshop
Manual
1 General
Cylinderheadand
valvemechanism
11 optionatequipment
lnlet-andexhaust
system.
Turbocharger.
1. Edition
15.1.1986
YAITIT
VALMETCorDorrllon.
Llnn.vuo,i Wo.ka
372i10LINNAVUORI,
Flnl.nd
Tol.
(lntl.)+35831
il03300
Tgl€x2212E
vålll st
T.lohx (lntl.l
+ 35831
4032E3 12

rO Tf USER
Should the €nglng rgqulre meosur€snoi descrIbed In
ihe S€rvlce Departnent of ValmetLlnnavuf I lq'ks.
fac+s about +heenglne beforg cgniaciing us:
Thls Iqkshop Manu6l tq- valmdt diesel €nglnes ls Intendsd io facllliaie rcr-kshopop€rallons and
repalr rork.
lO9, lll, 4ll, 6ll and 612 englnes äre malnly iha same In construcilon, so tha same
repolr
Instructlons usually apply to dlffereni eflglne lypes. The dltf{ences betr€n the vc'lous englnE
iypes rhlch alfecl repalr rcrk have beenn ilon€d ln technlcal data ånd repalr Insfructlons. All
n€tasurgments a-e In nllllmsires and valld yh6n thg iemperaiu
r€ of the paris ls +20qC, unless
othefti
ls9 sta+ad.
Before star+lng rsprlrs, makE
sure tha+ you havo öll necessary i@ls, parts and accessorles 6i your
dlsposal. The speclal tools nsrfloned ln fhe rcrk Instruqlloos re nof all essenilal, but th€y sp€d
up and tacllltafo thg rrork and contrlbu+e io successfu
I execuilon ot rork. An enqlne rhlch has under-
gonerspålrs nusf be run ln Jusi llke a nef,one.
thls manuol,please consulf your local agentor
To facllltatE consulflng, flnd out the fol lorlng
- Eng
lno typo
- Eng
Ine nunber
- Appllca+lon
or equlpmenf
- Hoursog{afod or kl lon€irgs drlven
4fl DS

EGtfE SPECTFtClTt(r{S
Englnetype
Numb€r
ot cyI InCf s
Dlsp Iaca[srf dn)
Bore nn
Sfroke ml
Coipress lon rdf lo
InJetlon ader
Compresslon pr€ssurp borl)
Englne type
Number
ol cyl lndf,s
Dlsp lecsmqrt dn)
Bore fin
Stroke m
Cdprass lon röflo
InJ€cilon ad€|'
CoDr€ss Ion pressure brr)
| ) l.llnl"u,n
vclue cf oprallng tonpratuftt
dllterencp bqtr€gn cyllnders 3,0 bar.
JO9
o/!S
t
2,7
lo0
llil
l7 3l
|-2-5
24
4 DS
1
4,4
r08
120
l6: I
l-2-4-5
24
5 D
t,t
108
t20
l7: l
|-2-5
21
6t
I D
6
t08
t20
l7: I
l-r-fr-2-1
21
llt Ds
6lt Ds/Ds8
6
6,6
t08
120
l6: I
l -t-5-6-2-1
21
ill I D
1
4,4
108
t20
l7:l
| -2-1-5
24
612DS
6
7,4
r08
ltI
ltrl
t-5-H-2-4
21
l5,t
l0B
t20
l6: I
l-2-5
21
ond sterllng ngvs. Mox pg.rDltfed
E6tE Tt?EDESt€rTtOtS
6t | 0sBJA
AppIIcat lon
A . v€hlcle srqlne
G - gen€ratlng-set €ng
lne
L. co[b
ln€ hcrvGtor or|olne
l.l. nrlnc engln€
P = pump
s€i srglne
Englne
oqulpped
rlth boost clr coollng
(ilntercoolrt)
InJ6cilon punp
iype ln
B . Eosch iPr
tlo cod€ . Bosch r^n
Turbochcrg€d q|glne
BasIc tpc
6-cyllnder er|glngs
olsplaclm€n+
of one cyllnd€r (e.g.
Numb€.
ol cyllnd€rs
't-2
l, | ö5)

TtGHrEiltrc TmqES
ObJect
Englne:
Pressut€ valve holdf Bosch "Pr
Nm
Cyllnd€r headscr€rs andnuts f09, ,ll Jö 4ll .................... l60
Cyllnder headscrews
and nu+s
6ll cnd 512 ............. ...... .. ... See
Cyllndr heådsfuds to cyllnd€r blck ............................ lO
Moln
b€arlng scrots 509 ........ 160
Malnbearlngscrers 5ll, 4ll, 6lt Jo 612 ......................... 200
Connecilng
rod nuis ........ ..................... 90
Connecllngrod scrsrs 612............. .......... S@
Flyrheel screws ................ l2O
Flyuh€l housIng scrersi
- oufer scrors tl 12 ............ ................. llO
- Innr scrers M l0 ........... .................. 60
ldler ggar scrers:
-M10.......... ............... 60
_ M t4 .......... ............... l4o
ldler gear ({l+h boll bearlng) scre|l6ll and612 ..
..
.
............ IBO
ldltr ged- bearlngholdq- scr€rs M 8 6ll Ja 612 ................. 22
Crankshoti
end nui lO9, lll Jo 4ll .............. 600
Crakshaft endnul 6ll and612 ......... .........10m
Screvs
of addlllonol counterbalances4l| ......................... 45
Coolonl pump pulley nut M 14 ........... ......... IOO
Fuel equlpment:
lnJectlqr purrpgeq' nuf Bosch
trAn
..................,............. 90
InJsctlon punpgscr nui Bosch
nPi .
.. .. ..... .................. .. .. l,lO
InJecicr re+alnlng nuis (to studs) Bosch ........ 15
InJcioi reialnlng nuts (to sfuds) CAV .......... 20
tlozz
le flxlng bushBosch
tlozz
le tlxlng bush
CAV
........
InJectcr adjustlng nu+
cov€r CåV.............
Pressure
valve holder Bosch
nA'........
Corpresscr-:
Codpresscr-
pu
Iley nut Knorr
Conpressor gear nu+ B€ndlx
Compressq'
gef nui C
lay+cn
E
lectrlcal equlpDgnf:
Ins+ructlons, polnt f I K
Instructlons, polrt 4 2 J
@
90
io
15
80
80
t40
180
Alternätcr pu
Iley nut .......... 45
1-3

CYLINDER
BLOO(
ANDFLY|IfEL I{oUSIT{G
I
r{)€x
... 2- 3
Coostrustlott ..
Reoclr Instrucilons
l. Cylln&r blak and cyllnder llners
A. Measurlngl-he
cyllnder llner wear....... ......... 2- 5
B. Rerpvlngthe cyllnder II
ner.
........... ..........2- 5
C. Checklng ths cylinder blck............ .......... 2- ,
D. Repfaclngihe camshafi beorlngbush
tl1/4ll/309................... 2- 5
E. R€placlngthe camshaffbearlngbushes
6ll/612..................... 2- 6
F. Camshaftcorrecilon be6rlng bushes 5ll/411........................ 2- 6
G. Camshöttcor.ecilqr bearlngbush509.........'.................... 2- 6
H. Comshatt correcilon bearlng bushes
611/612........................ 2- 7
f. Fftflng fha blaklng plug of th€ cansh6ft llne 3@/5ll/411........ 2- 1
J. Flitlng ihe blocklng plug of the canshaft llne 611 /612..
... ... .... 2- 7
K. Flttlng +hedlps+lck gulde p|pe....... ........... 2- 1
L. Flftlng +hecyllnder 11ner............ ........... 2- I
2. Flyrh€el houslng
A. Insiolllng the flywheel houslng.'.. ......... ..
.. 2_
l0
B. Replaclng the crankshafl rear endseal.... ....... 2-10
vAlitEr

Cyllndar blod( ,09
Holes fo. doieIs ..... ..... ..... ll,OOO...ll,O4l
Dlam€ier
ol maln b€örlngbore ............ ....... 76,000...76;019
Dlanetor ol cyllndei- llner bore:
- upper end ... ll6,ot2,,.ll6,o47
- lower
end ,,. lt5,0oo...lli;Ol5
Inslde dlano+er
of camshaftbearlngbush(rhen fltied ln posltlon).50,ö00...50,0å5 (50,o5o)
Tlgh+enln9lorqu€ of flyrh€el houslngscrers:
IECHN
lCåLDATA (reJect llrnl+ of pari stäted In brockets afier ra+lno)
- oufer screHs
Ml2 ............, ................. llO
- Innq' scrers M10..........,.. ......,.......... 60
Tlghienlng torquo of maln
bearlngcaps ...r....................... l60
Cyllndar block tll, 4ll, 6ll, 612
Holos for doyeI
s . . . . . . . . . .
Dlan1oier of m6ln b€6rlng bore .. ..........
0lanetq- of cyllnder llner bore:
- upper end
- toref eno
Inslde dl€fl€ter of camshafl bearlng bush (when fl+ted In poslilon)
Inslde dlameter of cömshof+ baorlng bush (rhen flited In posltlon)
be6rIngs 2...7 611,612.,......
Tlghtenlng iorque of flyrheel houslng scrersl
Nm
Nm
Nn
Il,000. .. Ir,041
91,000...9t,022
12t,r14...123,r54
122
,oco.
..122,
O4O
50,000.,.50,025
49,990...50,050
(
9l
,0i10)
(
50,050)
(
50,080)
- outer screHs
Ml2 ............. ................. llO Nm
- Innei screxsMlo .........,... .,............... 60 ND
Tlghtenlng torque of mölnb€arlng capretalnlng screwg
..,.........200 Nn
Cyllnd€r I Iner 509
Profruslql of cyllnder lln€r above cyllndsr bl@k lop face ........
Max pernlsslble holght dlfferonce b€tr,e€n cyllnder llners
LInq' bore
Max peroisslble ovalness ot llner .......,...
Hel
ght of cy I Inder I Intr f I
ange
Helght of cyllnder llner tlange, 'lst overslzo, pärl no 8f65 f6B2B .
l-lelght of cyllnder lln€r flange, 2nd overslze, pa-t no 8J65 J6829.
Helghi of cyllnder llner flange, frd overslz6, pöri no 8165 j68lo .
Outq' dlameier of cyllnder llnei tldtge
Cyllnd€r lln€r lll, 4ll, 6ll
Protrusiqr ot cyllndq- llner abovo cyllnder blcck top fac€ .,......
Max permisslble helghi dlfference beiw€n llners (under samehoad).
L Iner bore
Max permisslble ovalness ot llner ...........
Helghi of cyl Ind€r llner t langs
Helgh+ of cyllnder llner flange, ls+ overslze, pcrt no 8t5J 29829.
Helght of cyllnder llntr flange, 2nd ov€rslze, part no SJjf 29gjo.
Helghf of cyllnder llner flange, frd overslze, port no 8f5j 29gll .
Out€r dlamefer ot cyllnder llner fl ge
Cyllnd€r llnor 612
Proirusio.r of cyllndei- I Ins- above cyllnder blak fop facs .....,..
Max pernlsslble helght dltterence betw€n llners (under safl€ head).
L Inef bore
Möx peimisslble ovölness ot llner ...........
Helghi ot cyllnd€. llnq- flange
Helght of cyllnd,ei llner flange, ls't overslze, p6rt no 8l6J 184j6..
Helghi of cyllnder llns- tlange, 2nd overslz€, part no Bf6f f84l7..
Helght of cyllnder llner ftange, frd ov6rslz€, pö.f no 8f6j 59439..
ouier dlamete|- of cy I Ind€r I Iner f I
ange
0,0J0...0,080
0,020
tm,0m... t@,022
0,020
8,0t. ..8, 05
8,08..
.8,l0
I, 1t...8, 15
8,2t...a,25
t2l, ...122,@
0,0J0...0,080
0,020
108,000...108,022
0,020
9,01.,.9,05
9,08...9,t0
9,
ll. ..9, |5
9,25...9,25
I
ll ,700... I11,800
0,010...0,080
0,020
16,[email protected],022
0,020
9,01...9, 05
9,08...9,|0
9,13...9,15
9,25...9,25
Ill,70...I]l,80
(
100,080
)
(t08,080
)
(
|08,080)

2
o
e
v
I a3@ 91315
2 4360 97314
3 9045 348oO
4 90517J100
90]o 26too
5 51 72 0
9045 A1200
905172800
904587600
6 9025 52400
1 A36t 91466
I A36t 9146A
9 9025 98700
r0 9025
78100
11 9025 79200
SPECIAL
TOoLS
(Cylinder block andflywheel houslng)
Fli+lng iool lor crankshafl rear end soal
FI
y{hee
I hous Ing contra
Ilz In9 bush
chamfgring
reamer
for cyllnder llner bore
Tool for exirac+lng andro+aflng cyllnder llner 309
Tool for extractlng and
ro+aflng cyllnder llner
correctlon reamerfor cyllnder llner flt+lng 309
Correc+lon
ream€r
for cyllnder liner fliflng tll , 4ll, 6ll
Correc+lon
reamerfor cyllnder llner fii+ln9 612
Exchangeblade Jor correct lon rearner
Tool for ro+atlng cyllnder llner
Cup
plug tapplng drlf+ 40 mm
Cup
plug +applng
drlfi 16mm
Dorel pln +applng drlft
Cyllnder IIner clamplngfool
Gaugefor-measurlng
cyllnder llner helghi
I
2-2

Self-made
tools (cyllnder blck andflyvrheelhouslng) A35t 9l5 .emovlng-
and fl++lng equlpmenffor ihe bushlngsot +he cansha{+.
O)
o
o)
@
\
or

CYLIIDER
BLCOKANDFLYB}EELTIOUSING
co{sTRtcTIoN
CYL
INDER
BLOCK
CYL
INDER
ELOCK
(4II)
l. CyIInder block
2. Boarlngbush
J. Scrow
4. Bearlngcap
5. Bearlng cap (9ulde bearing)
o. Ptn DUsh
7. Cy
Ilnder Ilner
8. 0-r Inq seal
lno
9. Ptug icamshafi llne)
10. D
lpstlck p
tpe
I
l. Nui
12. S+ud
'-
lJ. Screw
14. SeaIInq rlno
15. P
luq
16. Cup p
lug
17. Draln cock
18. Pressureqauoe
sender
19. P
lpe
The cylinder block fo.ms l-he englne body to
whlch +he other englne conponents are flxed.
The cyllnder llners (7) are of ret type t{hlch
nEans thä-t ihe coolan+ comes dlrecily ln+o
contac+ rlth +he llner ou+e. su.face. Th6
seal ing be+Heen +he cyllnder llner lo|ler end
and cyllnder block comprlses of +ro o-rlngs (8)
whlch have been placed ln the g.ooves on the
cyllnder llner. The top end ls sealed by means
of a head gaske+ sl+uafed between +he cyllnder
llner flange and cyllnder head. The accurö-te
flf+ln9 of the cyllnder llner flange and +he
mating face of ihe flange ln the cyllnder block
ls also essentlal for ihe iop end seallng. l{e
ask you io note thls especially in connec+lon
v.l-i'h
cy l inder llner assenbly.
6l11612 englnes höve an o-rlng seal also ln +he
top end of +he cyllnder llner. There are
coollng grooves whlch nake fhe coollng of the
hot top part nore efllclent.
The cyllnder block Incorporates +he camshafi-
whlch has +ho Jronl bearlng poln+ (j09, l and
4ll englnes) equlpped rlfh a separa+e bearlng
bush (2) r{hlle the other bearlng poln+s have
been machlned In the cyllnder block dlrectly.
ln 611/612 englnos €ve.y camshaf+bearlng poini
has a separöle bearlng bush.
The rear end o{ the camshaft llne ls blocked
wlth a dlsc plug In 309, fl I and 4ll englnes
rhereas the 6ll and 6'12 englnes have a plug
equlpped r,lth an o-rlng seal.-
On both sldes of the rear maln bearlna +here are
posltlons for gulde b€arlng shells icrankshafi
axlal bear
ings).
2-3

FLITfEL IOIISIIG
ö
22
Flyrhcl ho{slng
l. Flyyh€€l hous
lno
2. Hgxagon
screw -
f. Hexagon
s€ket screy
4. Sheft seaI
5. Plu9
6. Dore
I pln
7. S+ud
8. llasher
9. Nui
Th€ flyrheel houslng Is flxed to ihe rear end
of ihe cyllnder block. The crankshaft rear and
shafi seal (4) ls DlacEdIn ihe recess machlned
to fha houslng. lo oddltlon, +h€ houslnghas a
rDuntlng polni lor ihe s+arter.
The bot+o föc€ ol ihe flyrh€el houslng Parfly
acis os the maflng tace of ihe ol I sunp seal,
so lt nay not dlffer much from lhe cyllnder
block bottom foc€. The carreci Doslflon of +he
flyrheel houslng ls secureda+ ihg manufaciurlng
s+age
,lth doxel plns (6).
The tlyyhe€l houslngs are dellvered occordlng
io +he rEqulram€nts sef by the englne
appllcailon and dlfferent flyrhgels can be
mounld on all anglne +yp€6.
2-4

TIORKINSTRIjCTIONS
I. CYLIIOERSLOCKANDCYLI
ND€RLI]GRS
A. I,GASURIt{GI}IE CYLITDER
LINERIiEAR
l. Set ihe dlal gauge +o zero wlih a mlcrome+er
wlth a ne', cyllnder llner, lndlcatlng
diameterof an unwornllner (108,00
mm).
2. Clean ihe Inner surface o{ ihe cvllnder llner
j-horough
ly before measureneni.
Perfoim the neasuremoni crosswlse a+ tho llner
top end, loYer end and mlddle.
Check ihe gauge readlng for maxlmumvrear and
ovalness (conpare r{lih ratlng).
RETOY
II€ llf CYLINDERLINER
It you in+end io relnsiall the cyllnder llners,
mark +he liners so +ha+ +hey can be placed ln
ihelr origlnal posl+lons In the cyllnder block.
Makeihe marklng on the lnner sdge of the llnsr
+op flange, e.g. on +he edge towards canshaft,
s+a+lng the cylinder number.
3. Fl+ +he bearlng bush In place by presslng and
a+ ihe same ilme ensure the correc+ poslilon of
ol I holes.
4. Af+er fl+tlng |-eamihe bush io lis proper slze
(d 50.000...d 50,025).
I
Place the turnable dlsc of +he llnor extrac+or
(9010
26100)+hrough
the llner on lis lowarend
and
draw+he llner ou+ fron the cvllnder block.
CHECKING
IHE CYLINDERBI-OCI(
Carefully clean the cyllnder block of ol I and
other lmpurltles, preferably In a {ashlng
rnachlne.
Afier Hashlng
blow ihe cyllnder block
dry wlth pressure alr and pay speclal afienflon
to ol I channels. Removeall scraps of old
gasKeTs.
Check the cleennessof the coollng channols.
Removethe boller scale sedlneni to ensure
englne
coollng.
Check
+he +lgh+nessof fhe cup plugs önd screw
plugs ln ihe cyllnder block as l,ell as lhe
condl+lon of +he cyllnder block and seallng
laces.
I\4easure
+he wear of the camshaft bear
Ings
(compare
wlih ra+lng).
REPLACI]'IG
ItE C/tljISMFTBEÄRINGBUSHtO9, 5l I
ond 'll I
Rgnove fhe bearlng bush rl+h an Inslde
exiracfor (e.9. SYKES
no. 854). You can also
remove
the bush by +apping t{lth a drlfi af+or
iaklng oui +he blocklng plug from the rear ond
of tho camsha{+llne.
Cleanihe bearlng houslngln fhe cyllnder block
carefu
||
y.
linder block
i frontface
I
I
or
Tne l.
2.
l.
309 2
Notel The bearlng bush of the 509
In lls ra+ed size afier fliting and
rqulre reamIng.
Measure ihe clearance of +he bush
camshaft
and cornpare
wlth railngs.
6
englne ls
does nol
and the
2-5
.-\J l/..

E. FEPLTC
I}G I}E C,AT.6FåFT8EÄR
IiG BU$f S 6t I /61 2
4,5
7
22171
2297'
22608
22609
2261O
Dla[€+er o{ c.mshaff b€arlnq bush holes ln
6ll,/612 englles (nurb6rs star+ fron the englne
front endt.
Order nul5€rs for bearlng bushes (mårked oo the
outer surface of bearlng)
no.
27
Cairshaft corr€ctlon beorlng bushes for fll
eng
Ine.
Comshafi @rrectlon bearlng bushes for 4ll
9n9lne.
cålrsr{ FT @RREcflON8€ Rt}G BUSfl509
lf needed, you can lnstall In the cyllnder
block a bush rlih 0,4 rm overslze outer
dlemster In Dlaca of thg camshaft froni end
bearlng bush. The o.-dEr numberlor fhe ov€r-slze
bush ls 85f 24661 and the dlrFnslons lor
machlnlngihe cyllnder block are-d 56,0+0,010.
Vlhen
flitlng fhe beärlng bushchock tho correci
posltlon ot oll holes. The b€arlng do€s not
need
reamlngafter f liflng.
Other bearlng poln+s In 309 englnes can be
fltted xlih- ihe correspondlngi correctton
b€orlng bushes
of lll 6nglne. S€e flg. 2 8.
a36t
at63
a36t
t.
6ll1612 englnes hav€ seven
replaceable camshafl
b€arlng bushes. obs€rve the varylng ouiar
dlangters of th€ bush holes In the cyllnder
block rhen renovlng and tlttlng ihe bush€s.
Rsnovethe b€arln9 bushes by tapplng rlth a
sultable drIft, fa Instance.
Clean the bearlng houslngs In th€ cyllnder
block +horo0
gh
ly.
Flt the ner bearlng bushesIn ihelr ploces by
presslng, usfng a selfnnode tool 8t5t 91556,
for examo 19. No+e fhg cgrrect order of fhe
bushesandthe Dosltlon of the oll holes of the
bushesIn both 6nds.
Reant
fhe flrsf b€arlng bush fro.n fhe englne
front end to lts correci slze. (l 50,000...
50,025). ThEothEr bushesere ln ihelr correct
slzes äfter llttlng and do not requlre reamlng.
Measure the clooranca of thg bushes and the
caiEhaft and compare
xlth råiln9s.
F. CIGHAFTmRECr
tor{ EEARtitc BUSHES5r1l/ l
lf needad, you can Install ln ihe cyllnder
block a bush rlth I rfl overslze outer dlanqter
In plåce of the camshati froni bearlng bush.
The bearlng poln+s machlned In fhe cyllndor
block can also, ll necassary, be equlppedrlfh
s€parate bearlng bush€s. Flgur€s 2 8 and 2 9
shoy the order numb€rs tf correcilon bearlno
bushes and th€ dlmenslons for machlnlno thå
cyllnder block for b€arlngbushflfflng. -
tlotel tlhen flfilng the tront and rear bush
2-6
4.
G.

t.
H. C^I,ISHAFT
@RRECT|ON
BEARTNG
BUSHES
6 l6t2
Camshattcorrectlo4 bearfng bushesfor 6ll1612
engI
nes
lf needed, you can lnsial I ln +he cyllnder
block a bushvlth I m overslze ou+er dlamsier
In Dlace of the camshaf+
fronf end bushlng.
Oiher b'lshescan b€ replaced by overslze bushes
wlih 0,4 mmouter dlameier. Flgure 210 shors
the order numbers
for the correctlon beårlng
bushes and ihe dlmenslons
for machlnlngihe
cyllnder block.
FITTING IIf BLOCK
I
NGPLUG
OFlHE CAIT.ISHAFTLI]G
n9/ttl/111
Cleanthe blocklng plug space+o gei rld of old
seallng conpoundremalns.
Apply seallng compound
(6909J0008)on the slde
of lhe blockIng plug.
211
Töp the blocklng plug In i+s place ylih the
flttl ng iool (9025
87400).
Notel Be careful no+ io lap ihe blocklng
plug +oo
deepbecause+hls rlll affecl lhe com-
sh€ft end playl Thoreforealrays use a flftlng
tool.
J. FITTIT{G
THE
SLOCTING
PLUG
OFTHE
CÄI.IIiHAFT
LINE
6t|
/612
l. Clean the blocklng plug posl+lon and useemery
Cloth to renove ihe posslble sharp edges
On
ihe
hole rl m.
2. Place Eno-rlng In lhe blocklng plug groove
and
lubrlcate l+ tvlih, for lns+ance,
- slllcone
seallng compound.
Press the blocklng plug In lts posl+lon andflx
Its shleld plate (ln englnes
wherelhe flyxheel
houslngdoesnot cov6r the blocklng plug).
FITTII{G
TIf, DIPSTICKGUIDE
PIPE
Clean+he
plpe hole ln the cyllnder block.
Apply reialnlng fluld (6909
J0012)
to the gulde
plpe loxer end.
K.
l.
213
lls posltlon ai fhe level
lJ.
l. Tapthe gulde plpe In
Indlcated In flgure 2

L.
t.
FITTI}IGIIG CILI]OER
LIICR
Cleantho cyllnder lln€r ond lts llttlng polnis
In tha cyllnder block thoroughly. The qyllndor
llner lusf roiate easllv around ln lts bore
rhen +heg-rlng s€ollngs of the llner havebeen
relpveo.
Apply marklng colour fo th6 undersld6 of the
cyllnder llnei flang6 and plaoe ihe llner In
Its poslilon nlihou+ o-rlngs. Roiate the llnsr
ln boih dlrectlons. ll|lihdray +he llner and
check lf +helouch ls even.
214
5. lf ihe mailng lace ls domagodor li +he llner
proiruslon abovg
the cyllnder block face needs
rnachlnlng, use o correcilon reaner. Af+er
raamlng you con perform € llgh+ lEpplng rl+h
the llner, lf needed. Apply grlndlng pas+e
be+r€n +ho cy
IInder IIner I lange and the
cyl Inder block and rofaie ihe llner rlth tool
no. 6. Lapplng ls .|oi, hoyever, ihe rlgh+
tEihod, It th9 cyllnder llner protruslon has io
b€ adjusied.
4. At+er roamlng and lepplng clean lhe mailng
taces caretully b€torg meosurlngthe cyllnder
llner Dro+ruslon.
5, Fo|- the fiFasurglEn+ procedure press tho
cyllnder llners In ploca wllh clanplng iools
(9025
78100).Measurethe llner Droiruslon elih
measurlnggauge (9025 79200). Flx the dlal
gauge
+o +hemeasurlng
gauge
and sel lf to zero
}tlih a carefully cleaned cyllnder block top
face. Move+he dlål gauge
onto ihe top of +he
cyIInder ||ner f lang€ and note ihe gauge
readlng. Corry oui ih€ measuremeni
ln tour
dlffereni polnts. The proiruslon of ih€
cyllnder llners obove the cyllnder block iop
tace should be b€tyeen orOJ cnd O,O8 ||r.
The max helght dltterenca betr€n the llners
under lhe sane cyllnder head may nof exceod
'".,K
RT\T
\RNTT\q\\Rl\K\ K R\qK
fhan fhe ones ln ellher ends.
a- ö
It fhe llner must be ralsed, Ins+cll one
an overth lc-k top tlang€.
6. r lth
311,411.611
PART
NO. HGROOVES
QTY
4363 227A7 o^1 +o,02 -( std )
8353 29829 9,Og
+o,02 1
835329830 9.13
+o,o2 2
8353
29831 9,23
+0,02 3
2
PART
NO. HGROOVES QTY
836336331 g,O3
+0,02 - ( std )
836338436 g.o8
+0,02 1
8363
38437 9.13
+0,02
8363
38438 q 2.1
+o,o2 .t
217
An overthlck iop flange ls marked rlth ihe
nurber ol machlned gr@v€s on th9 flcngB outer
surtåce: lst olratslze O10DI - cna gn@rc,
2nd overslzo 0,10 n. fro groova3 and 'rd
oYf,slz€ 0120 rn - thr€ gr@vca.
l{ofiol In the ll and 12 serles englnes the
cyllnd€r llners rtih standord tlange fhlckness
åre dlvlded Into tyo ca'tegorles dependlng o.l
tR\\'ss\\\Str=. q\'f"b+"\'$iså"=
\,{\. ..
9,04 - no narktng. Flangefhlcknåss 9,O4...9,O,
- flhlte palnfed mark (d 20) as shorn ln flg.2
309
PART
NO. HGROOVES
QTY
8365
36827 8,03
+o,02 -(std )
8365
36828 9.08
+0,o2 1
8365
36829 8,13
+0,o2
8365
36830 8,23
+0,02

l{ot€l In connecllon rlfh cyllnder llner
fltflng renove nEierlal, lf ne€ded' Ylth
correctlon reanFr 904587200In case of ll ond
12€erles onglnes and wl+h reair€r 905.|72m0 In
caseof f09 englnes.
lf the llner protrudes hlgher on one slde than
on the opposl+e slde, chack the thlckness of
+he llner flange and the deplh of the flange
recess ln ihe cyllnder block.-lf there are any
lrregularl+los, replace ihe llner. Correci ihe
I lange .ecess In the cyIInder block slth
correcllon r€amer.
(
for 311and411
engi-
nes if needed)
red
214
the cyIIndor llner gr@vgs
preferably wlth gear oll to
.L'CJ
220
Insiallatlon ordor of o-rlngs ln 3ll,4ll,6ll
and
61
2 engIne cyIInder |
|
ner.
Press
the llnei- In lfs poslflon In fhe cyllnder
block. The llner rlll go ln easlly ll ihe o-
rlngs are correcily placed. Ensure fhal ihe
llner vtlll no+ rlse ou+ of lis Dosltlon af+er
Insiolla+lon.
lf ihe cyllnder block ls badly corraded ai +he
lorer o-rlngs of ihg llner, you can Install a
thr€€-groove
cyllnder llner In 5ll, 4ll and
6ll
englnes, spare
pari no 855524480.Thecyllndsr
llners rl+h ovsrihlck fop flange (lll,4ll,6ll
and 612 englnes) are also equlpped
wlfh +hre€
gr@ves for lorrer o-rlngs. The boftom groove
of thgse +hree-gr@ve llners rlll hovea red o-
rlng andlha t{o upper gr@vas a block ong.
ll n€€ded, an o-rlng (parf no 8565 29808) can
be lnslalled ln the fop groove
of the fll and
4ll englne llner. Should you Insfall lt,
chamteriho cyllnder llner top par+ guldance
In
the cyllnder block ylth reamer 9045 54800io
lacllliate the placlng ol the o-rlng.
'n
.a
9. Place ihe o-rlngs In
and lubricate ihem,
avold sel zure.
t{otel Try io åvold even sllghiest streichlng
ot ihe o-rlngs durlng lnsfallailon because the
max sl-retch ot ihe lorer o-rlngs may only be
about 6 t. So as no't io lose the elasiiclty of
the ring, Install l+ lrom fhe loYer end and iry
to avold s+retchlng (e.g. do not place fingers
befreen liner and rlng).
10.
219
ln the f09
Ins+allailon ordgr of o-rIngs
cyllnder llner. snglne
2- 9

2.
t.
FLYXIfEL rcUSII{G
INS'ALL Il{G llf FLYIHEELIloUSII{G
Thecorrec+ posltlon ot ihe tlyrheel houslngio
cyllndar block ls securedai ihe manufaciurlng
s+age
rlth +ro dowel
plns. Durlng Insiallo+lon
It ls not necassary
io canirallze lhe rolaflve
poslflon of the flyuh€€l houslng and the
cyllnder block. Th€ flyxheel houslngs
dellvered
as spore parts also have ihe doxe
I pln holes
ready.
Clean the malng faces of the cyllnder block
ondthe tlyrhe€l houslng
cårefully.
Coaf the taces wlih seallng compound
(6909
50008).
3. Llti fho flylJheel houslng ln lts place and
tlghien +he
retalnlng screxs llgh+ly.
4. MovE
plns
r lfh
the flyxheel houslng so +hai +he dore I
holas meet. Flt thg dowel plns ln place
tapplng drl f+ (9025987@).
Tlghten the flyrhe€l houslng retalnlng screys
gvenly +o +hs ccr€ci forque, lnner hexagon
socket scrers (8 |I|n) to 60 ltr and o|iier
hexagonscr€vrs
(19 |l|tn)io ll0 iln.
REPLACINGI}IE CRANGMFT FEAREI{DSEAL
DI
srnounf the englne.
Openthe flyrhesl retalnlng scrers and renbvo
ihe f lyr.heel
.
,. Rerpve fhe old shaJf seal. Be careful noi io
damage
the crankshafi seellng surfaca.
4. Clean ih€ s€al recess ln the flyrhe€l houslng
cnd us9 enEry cloth io rerDve posslble sharp
Edgesln +h€ crankshafi rear end.
222
5. Check that ihe llD of lie nex shali s€al ls
flarless and ihat iha llp sprlng ls ln lis
poslilon. Lubrlcat6 the seal and ihe natlng
tace of the crankshafi recr gnd xlfh oll. Push
the shaft seal caretullv on lhe crankshaft and
agalnsi the flywheel houslng. Top the seal
evenly dorn io ihe botiom wlih flitlng tooI
856097515.Donoi use a pln-type tapplng drlti
becauseihe meial body of the shafi sgal may
b€ndand cause leakaoe.
B.
Notcl It the crankshafi ls so badlv rq-n ai
the seal ihat you doubt +he tlqhinels of ihe
s€al, changeflie posltlon of ih; s€at t{tlh a
shaft s€al dls+ance
rlng. A 2 rnmthlck dlstance
rlng rhlch ls placed und€r fh6 s€al has sDarg
spore parl no 8560 20054.

CILINDER lffi) At|) Y LYE l,Ectl l Sr{
IIIEX
Tecinlcrl data ........... ................. J- |
Sp*lal t@ls ............ f- f
constrqc on ............. f- 4
ReDclr lnslruqtldrs
l. Cyl
lndgr h€rd
A. Removlng
ihe cyllnder heod.
............ .......... 5- 7
B. Removlng+he volves....... ...... 3- 1
C. Ch{klng the cyllnder heod.
.
........... .......'.. l- 7
D. Replaclngthe valve gu
I
de.
.
.......
... ............ l- I
E. Replaclngthe InJecior s|eeve........... ......... l- I
F. Machlnlngthe valve seof............. ............ J- 9
G. Replaclngthe valve seoi r1n9........ ............ l- 9
H. Grindlng the valves....... ...... l- 9
l. Flttlng +he
valves....... ....... l-10
J. Fl+tlng ihe cyllnder head J09,Jll,4ll. ........... l-lo
K. Fltflng ths cyllnd€r head
6ll, 6|2
................................ l-l I
2. Valvs rEchrnlsD
A. Recondlilonlng
ihe valve m€chanlsm....... ........ 3-12
B. Replaclngthe canshaf+/camshafi
9e4r....... ...... l-12
C. Checklng andadJusflngtl€ valvg c
learanc€s......... ........
' ..... J-ll
VAIiIET 3-0

IECHNIC
L DATA
(reJeci llnlt of par+
s+aiedIn brackets€fier ra+lng)
volves, rocker crmsand +rppets
Valve flm Ing
}Jlfh a valve clearan@ of 0,30 rnm
-ln le+ valve ooens ...........
-ln lei valve c loses , , . . . .. .. .
-exhausf va
lve opens ..,........
-exhaus+ valve closes ., . . .. . . ..
valve clearanc€s cold and ho+:
- lnlei vaIve
-exhaust valve
Angle ot valve seai In cyllnder head ............
l{idth of valve sea+ In cyllnder head
Angle of valve tace..,,,.......
outside dlame+ei of valve head:
- inlet valve llf,4ll, 611,612........
-exhausi va lve Jll, 4ll, 6ll , 612 ........
-i nlet valve 109 .
. .... ... ... .
-exhaust valve f09 ,............
Inlsi valve s'fem dlameis-
Exhausl valve siem dlarneier
Inlsf valve sfen clearan@ (gulda ready flited ln cyllnder head)
Exhaust valve s+em
clearön@ (guld€ ready fliied In cyllnder head)
Inside dlame+er of valve gulde (nof flffed)
Ou+side dlaoeier of valve gulde
Dlamefs' ot valve gulde bore ln cyllnder head
Profruslon of valve gulde +op above cyllnder head surface .........
Dep+hof valve head face beloercyllnder head sur{a@ .........
Valve sprlng free length:
-inner..,.......
-ouTer ,... .... r.
Sprlng p.essure Hhen sprlng comprossed io a length of:
-41,5 nm (lnnei sprlng) ......,,.
-47 nrn (ouier sprlng)
Rccke. rn shafi dlamefer
Inslde diamefer o{ rocker arm bearlng bush:
- (rhen fltted ln oosl+lon)
ouiside dlamefei of rockq' d-m bearlng b ush . . . . . . . . . . . .
DlanEier of .ocker arm bore . . . . . . . . . . . .
Max permlsslble push rod del lecflon (when fr€) ...........
Free lengih ol rocker arn sprlng
Sprlng pressure lihen sprlng @mpressed to € length of 58 fir
outs Ide dlameter of taooef
Dlaoete. of +appli bore In cyllnder btck ...........
Push rod length 109 ,. , ... ,.. .. ..
Push rod length t11
, 4ll , 6ll .............
Push.od leng+h 612 .. . . . . . .. ....
Cyllnd€r held
Dlameff of Injecfcr- sleeve flxlng hole:
-uDoer end
- toder eno
outslde dlameler of Injeclor sleeve:
-upoer end
- towei eno
Dlame+er of Inlst valve s6at rlng (s+andard)
Dlaneier of exhaus+ yalve seat rlng (standard)
Dlaneter ot recess In cyllnder head (s+andard):
-for exhausf yalve sea+
-for Inlet valve seaf
io
l9
l0o b.t. d.c.
42oa. b.d.c.
42ob.b.d.
c.
t0o a. t. d.c.
0,,0
0, t0
f00
1,0.,.t,5
29,5o+0,17
28,000...28,031
21
,
O@.
..27
,035
21
,979...2A,000
27,OT5...21,O9O
48,054...48,070
45,045...43,01O
43,000..
.41,0t
6
48,000...48, 0r6
9,465...9,480
9,445...9,460
0,040.
..0, 070
(
0,10)
0,060...0,090
lo,t5l
9,520...9,535
16,02A...16,0t9
|6,
000.
.. 16,01
I
l8
,1
6l
70.,.90 N
19...2t0 N
19,959...
|9,98O
|9,990.
..20.010
2t,035...23,044
23,O00...2t,021
0,4
80
80...100 N
29,919...29, O
10,000...50,021
)al- |
,iä-l
2791
J- |

Overslz6 of exhcu+ valrc seat rlngs:
-ls+ overslze, part no. 8f6l l90o4 ...........
-2nd ovrslze, part no. 8f6l |9OO5
...........
OYerslzes of lnlet velve s€ai rlngs:
-lsf ovsrslze, pari no. 8f6l 2296, ...........
-2nd overslze, part no. 8161229f5 ...........
D
Ianeter of exhaust valva seöf rlng recesses In cyllnd€r hEod:
-l st overslza
-2nd oversIza
Dlameid'of Inlgt valve se6t rlng recessesIn cyllnder head:
-lsi overslz9
-2nd ovgrslze
Cyllnder heod
ih lckness
Cyllnds head mln thlckness (aftet- machlnlng)
Tighienlng iocqueof cyllnder head
scrers ..........
CGhrtt 509, tl I
DIaneter of
DIalFigr of
Dlamet€r ot
DIameter of
Dlame+erof
4t,251...15,27O
4t,454...1t,17O
48
.2r4..,18.21O
48,454...48
',l70
45,2O0...45,216
43,40O...45,416
48,2OO...44,216
48,400...48,416
|04,90... |05,10
|04,70
se€ |nsiruqt lons
nlnsiolllng
cy||nder h6ådn
19,925...19, O
49,905...49,950
49,885 .. ./t9,
910
50,04...50,06
(50,085
)
50,000...50,025
(
50,050)
Cömshaflend
play rlth a 0,5 nn gaskefbet{e€ncyllndei blck andllmlng
g€ar houslng
andbgtr€entlmlng gear houslng
andtront cover ..... 0,450...1,550
Camhelght (dlstanc€ befxeenback
ol can and
ilp ol com) ......... 41,44
Camllfi ...... 1,44
comshaflmax
Dermlsslble
datlecflon 0,05 (toial
Indlcstor r.tdl ng
caEhafi 4l I
camshof+
bearlng
journal no. 'l (509) .........
comshattbearlng Journal no. | (lll) .........
camshaft
bearlng
iournals nos. 2...4 ...........
comshoftbearlng bores (f09)
camshaft
bearlngboras (3ll)
D
lameler of cangbcft beorlng iournal
DIanleierot canshalt b€arlng journals
Dlamel€r of camshatt
berlng boros..
Camshafiendplay rlth r 0,5 tlrt|
gaskei belYe€ncyllnd€r bl€k 6ndflmlng
gear houslngand betu€n tlmlng gear houslng and front cover ..... 0,450...1,550
C helghi (dlstanco betu€€nbrck ol cai and tlp of c4) ........ 41,4,1
can ftfi ......7.41
Camshaft
måx
p€rmlsslble del lectlon 0,05 (toial
Indlcatd rcadlng
CrEhrft 6l l, 612.
Dlanefs- ol comshaft
bearlng
journals nos. I...7 ..
......... ...... 49,905...49,950
Inslde dlameterof camshafl
bearlng bushes
ln cyllnder block
Bearlngbushno. I .........'. .. 50,000...50,025
(
50,050)
49,905...49,95O
49,875...
il9,900
50,000...50,025
(
50,050)
49,990...50,050
(50,080)
0,450...1,550
4l . ,f4
7,14
0,05 (
iotal
Indlcator reedlng
Beårlng bushnos.2...7
Camshöftend ploy rlih o 0,5 rn gaskei beireen cyllndf blck and tlmlng
gpar houslngond b€tre€n tlmlng gear houslngond froni cover
Can
helgh+ (dlstenca betveen
backof camandtlp of cån)
Cam
||tt .... ... .
Camshaft
max
p€rnlsslble defl€cilon
3-2