Workshop Manual: Sisudiesel 320 420 620 634

WORKSHOP MANUAL
SISUDIESEL 320
420
620
8366 40634 634
Downloaded from www.Manualslib.com manuals search engine

Sisudiesel
320, 420, 620, 634
engines
Workshop Manual
09 09
Sisu Diesel Inc.

FIN–37240 Nokia, Finland
Telephone: +358 3 341 7111
E–mail: [email protected]
www.sisudiesel.com
Diesel Engines, After Sales

Telefax: +358 3 341 7333
Sisu Diesel Inc. takes no responsibility for any damages caused

because of incorrect information in this manual

Contents 0---0
CONTENTS
TO THE USER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---1
ENGINE TYPE DESIGNATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---1
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---2
ENGINE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---3
LIFTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---3
LOCATION OF THE ENGINE SERIAL NO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---4
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---6
Cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---6
Cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---6
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---6
Valves, rocker arms and tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---7
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---7
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---8
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---8
Balancing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---9
Timing gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---9
Connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---9
Piston, piston rings and pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---10
Lubricating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---10
Oil pump (320, 420) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---10
Oil pump (620, 634) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---11
Coolant pump (320, 420) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---11
Coolant pump (320, 420 separate ball bearings) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---11
Coolant pump (620, 634) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---12
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---12
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---12
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---13
CONSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---14
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---14
Cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---14
Flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---14
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---15
Valve mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---15
Crank mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---15
Timing gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---16
Lubricating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---17
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---18
Inlet and exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---19
Electronic Engine Management system (EEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0---20
WORK INSTRUCTIONS
1. CYLINDER BLOCK
A. Measuring cylinder liner wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---1
B. Removing cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---1
C. Checking cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---1
D. Changing camshaft bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---1
E. Oversize bushings for camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---2
F. Fitting plug at camshaft rear end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---3
G. Fitting pipe for oil dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---4
H. Fitting cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---4
2. FLYWHEEL HOUSING
A. Fitting flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2---1
B. Changing crankshaft rear oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2---1
3. CYLINDER HEAD
A. Removing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3---1
B. Removing valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3---1
C. Checking cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3---1
D. Changing valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3---2
E. Machining valve seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3---2
F. Changing valve seat ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3---3
G. Grinding valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3---3
H. Fitting valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3---3
I. Fitting cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3---4

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4. VALVE MECHANISM
A. Reconditioning valve mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---1
B. Changing camshaft/camshaft gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---2
C. Adjusting valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4---3
5. CRANKSHAFT
A. Removing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5---1
B. Checking crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5---1
C. Changing crankshaft gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5---1
D. Changing crankshaft gear rim (420) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5---2
E. Fitting crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5---2
F. Crankshaft hub piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5---3
G. Changing crankshaft pulley/vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5---3
H. Checking element of the rubber damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5---4
I. Viscose type vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5---4
6. CONNECTING RODS AND PISTONS
A. Removing pistons together with connecting rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6---1
B. Changing connecting rod bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6---1
C. Checking connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6---1
D. Changing piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6---3
E. Checking pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6---3
F. Fitting piston pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6---4
G. Fitting piston together with connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6---4
7. COUNTERBALANCE (420)
A. Removing and disassembling counterbalance unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7---1
B. Reconditioning counterbalance unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7---1
C. Fitting counterbalance unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7---1
8. FLYWHEEL
A. Changing starter ring gear on flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8---1
B. Fitting flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8---1
9. TIMING GEAR ASSEMBLY
A. Removing timing gear casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9---1
B. Reconditioning idler gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9---1
C. Fitting timing gear casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9---2
D. Idler gear with bevelled ball bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9---4
E. Power take ---off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9---5
10. LUBRICATION SYSTEM
A. Reconditioning of oil relief valve for lubricatin oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10---1
B. Removing and dismantling lubricating oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10---1
C. Assembling and fitting lubricating oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10---2
D. Fitting oil sump gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10---3
E. Lubricating oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10---3
F. Piston cooling nozzles (620, 634) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10---3
G. Lubrication oil quality requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10---4
11. COOLING SYSTEM
A. Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11---1
B. Reconditioning coolant pump (320, 420) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11---1
C. Reconditioning coolant pump (320, 420, 620, 634 separate ball bearings) . . . . . . . . . . . . . . . 11---2
D. Coolant pumps with heavy ---duty bearings (620, 634) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11---4
E. Quality requirements of coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11---4
12. INLET --- AND EXHAUST SYSTEM
A. Checking air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12---1
B. Checking inlet and exhaust pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12---1
C. Checking turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12---1
D. Fitting turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12---2
13. FUEL SYSTEM
IN ---LINE FUEL INJECTION PUMP
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---1
A. Bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---6
B. Bleeding Thermostart system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---6
C. Measuring fuel feed pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---7
D. Checking overflow valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---7
E. Changing fuel feed pump valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---7
F. Checking injection timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---8
G. Adjusting fuel injection timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---9

Contents 0---0
H. Removing fuel injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---10

I. Fitting fuel injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---10
J. Checking and changing pressure valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---12
K. Adjusting idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---12
L. Removing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---13
M. Inspecting injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---13
N. Reconditioning injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---14
O. Fitting injector in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---15
P. Fitting delivery pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---15
CAV DISTRIBUTOR PUMP
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---16
A. Dismounting and mounting injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---17
B. Injection pump gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---17
C. Bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---17
D. Feed pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---18
E. Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---18
STANADYNE DISTRIBUTOR PUMP
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---19
A. Removing pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---24
B. Fitting injection pump and adjusting injection timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---24
C. Bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---25
D. Fuel feed pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---25
E. Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---25
F. Adjusting low idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---26
G. Bleeding Thermostart system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---26
H. Wiring diagram of electrical advance (CCA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---26
I. Checking injection timing (dynamic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---27
Fuel quality requirement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---29
14. EQUIPMENT AND FEEDING TABLES
15. ELECTRICAL SYSTEM
A. Alternators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15---1
B. Starters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15---4
C. Electric stop device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15---7
D. Installation of magnetic pick up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15---9
E. Temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15---9
16. OPTIONAL EQUIPMENT
A. Compressor (Bendix) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16---1
B. Compressor (Knorr) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16---2
C. Industrial clutch (A.P. Borg & Beck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16---3

To the User 0---1
TO THE USER
This Workshop Manual is intended to facilitate workshop operations and repair work.
320, 420, 620 and 634---engines are mainly the same in construction, so the same repair instructions usually apply to different
engine types. The differences between the various engine types which affect repair work have been mentioned in technical data
and repair instructions. All measurements are in millimetres and valid when the temperature of the parts is +20˚C, unless other-
wise stated.
Before starting the repair work read the safety instructions in the beginning of this book. Make sure that you have all necessary
tools, parts and accessories at your disposal. The special tools mentioned in the work instructions are not all essential, but they
speed up and facilitate the work and contribute to successful execution of work. An engine which has undergone repairs must
be run in just like a new one.
Should the engine require measures not described in this manual, please consult your local agent or the Service Department of
Sisu Diesel Inc., Linnavuori, Finland. To facilitate consulting, find out the following facts about the engine before contacting us:
--- engine type

--- engine number
--- application or equipment
--- hours operated or kilometres driven.
In this Workshop Manual the regular service procedure is not handled as this is explained in the 20/34---series Operator’s Manual.
As Sisu Diesel Inc. is continuously developing the products, all rights are reserved without separate notice to change the adjust-
ments, accessories and service --- and repair procedure.
ENGINE TYPE DESIGNATIONS
420 DSRIEL
Application
A = vehicle engine
G= generating set engine
L = combine harvester engine
M= marine engine
P = pump set engine
E = emission tested engine (certified) for off---road
C = emission tested engine (certified) for on---road
Equipped with intercooler
A = air to air
I = air to water
Rotary fuel injection pump (B, if equipped with Bosch P---type
injection pump)
Turbocharged engine (W, if equipped with by---pass turbo)
Basic type (E, if equipped with electronic engine control)
Number of cylinders (3, 4 or 6)

Safety Instructions 0---2
SAFETY INSTRUCTIONS When you are operating the engine or working near it,
use hearing protectors to avoid noise injuries.
In the service --- and repair work of the engine there is al-
ways the possibility of injury. Before starting the work Stop the engine always before service --- or repair work.
read and understand the following safety instructions
and remarks!
Avoid touching the exhaust manifold, turbocharger and
the other hot parts of the engine.
Do not start a repair work that you do not fully handle.

Open the radiator cap with care when the engine is hot
as the cooling system is pressurised. The cooling liquid and
Make sure that the place of the repair and the surround- lubrication oil of a hot engine causes injuries when touching
ing gives the possibility for safe working. the skin.
Open fire, smoking and sparks should not be allowed

Always be sure of the cleanness and the good order of
near the fuel system and batteries. (Specially when loading
the repairing place.
batteries, explosive.)
Do not use faulty or otherwise useless tools.

Always disconnect the minus (---) wire of the battery
when doing service or repair of the electric system.
Remove all finger rings, chains and watch before start-
ing work.
At temperatures on excess of 300˚C, e.g. if the engine
is burnt by a fire, the viton seals of the engine (e.g. the under-
most o---ring of the oil pressure regulating valve) produce very
Use up ---todate protection equipment when you work.
highly corrosive hydrofluoric acid. Do not touch with bare
For example eye protection as working with compressed air
hands, viton seals subjected to abnormally high tempera-
for cleaning, grinding, hammering or other work.
tures. 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
Use lifting device for lifting and transporting heavy (over
alkali solution. Put all removed material in sealed plastic bags
20 kg) pieces. make sure of good condition of lifting hooks
and deliver them to the point stated by the Authorities con-
and chains. The lifting ears on the engine must not be applied
cerned. NOTE! Never destroy viton ---seals by burning!
by side forces when lifting.
When checking fuel injectors do not let the jet of high

Never work under an engine that is left handling under
pressure fuel contact your skin. The fuel penetrates the skin
a lifting device or lifted up by a jack. Always use strong sup-
causing severe injuries. Contact your doctor immediately!
ports before starting the work.
The fuel, lubricating oil and coolant cause irritation in

Use only genuine Sisudiesel spare parts.
skin contact for long time.
Start the engine only by using the starting switch in the

cabin.
Avoid unnecessary idling of the engine.
Do not start an engine if the protection covers are re-

Do not let oil and other liquids drop into the soil when
moved. NOTE! The fan is difficult to see as the engine is run-
servicing the engine.
ning! Make sure that wide clothes or long hear is not caught
in the rotating parts of the engine.
All the gaskets of the engine are of non ---asbestos ma-
terial.
If you start the engine indoors, be sure you have proper
ventilation.
Be careful when washing the engine with a high pres-
sure washing machine. Do not use high pressure to wash e.g.
the electric and fuel equipment or the radiator because they
Never use aerosol type of starting aid while operating
can easily be damaged.
the thermostart device (risk for explosion).

Engine Specifications 0---3
ENGINE SPECIFICATIONS
Engine type 320D 320DS 420D 420DS 420DW 420DWI 620D 620DS 634DS
Number of cylinders 3 3 4 4 4 4 6 6 6
Displacement (dm3) 3,3 3,3 4,4 4,4 4,4 4,4 6,6 6,6 7,4
Cylinder bore (mm) 108 108 108 108 108 108 108 108 108
Stroke (mm) 120 120 120 120 120 120 120 120 134
Compression ratio 16,5/18,5:1
Combustion direct injection
Firing order 1---2---3 1---2---4---3 1---5---3---6---2---4
Compression pressure bar1 24
Weight kg2 275 280 335 340 340 345 500 510 515
Direction of rotation
from the engine front clockwise
1) Minimum value at operating temperature and starting revs. Max permitted difference between cylinders 3,0 bar.
2) Without flywheel and electrical equipment.
LIFTING THE ENGINE

Safe lifting of the engine is done with a lifting device where
the lifting force effects the lifting ears vertically.
A = Engine lifting ears
A
A
20--- 4 20--- 5
Engine weight: see Engine Specifications
LOCATION OF THE ENGINE SERIAL NO.
20--- 1

Special Tools 0---4
SPECIAL TOOLS
Order no Description
1 9051 73100 Puller for cylinder liner

2 9101 65600 Milling cutter for cylinder liner seat
9045 87600 Spare cutting blade for milling cutter
3 9052 46400 Centring tool for flywheel housing
4 9052 46300 Drift for fitting rear crankshaft seal
5 9030 15200 Drift for fitting front crankshaft seal
6 9052 46620 Drift for 40 mm cup plug

8 9025 87400 Drift for fitting camshaft cup plug
9 9101 66300 Press tool for cylinder liner
10 9025 79200 Holder for dial gauge
11 9101 66100 T ---handle for valve seat milling cutter

12 9101 71100 Milling cutter for facing exhaust valve seat
13 9101 65502 Milling cutter for exhaust valve seat
14 9101 65503 Inner milling cutter for exhaust valve seat
15 9101 75800 Milling cutter for facing inlet valve seat
16 9101 65505 Milling cutter for inlet valve seat

17 9101 65506 Inner milling cutter for inlet valve seat
18 9101 66200 Lever for compressing valve spring
19 9052 47200 Counter nut for lever above
20 9101 66000 Milling tool for injector seat

22 9101 65800 Drift for removing valve guide
23 9101 65900 Drift for fitting valve guide
24 9024 55800 Spanner for crankshaft nut, 634 ---engines (620/MF/Steyr ---tractors)
25 9101 65700 Spanner for crankshaft nut
26 9052 48800 Puller for crankshaft gears

27 9020 01100 Conical sleeve for fitting pistons
28 9052 46900 Piston ring pliers
29 9025 98900 Drift for fitting dust cover, crankshaft front seal
30 9025 98800 Drift for fitting tension pin in timing gear casing
31 9025 98700 Drift for fitting tension pins in timing gear casing and flywheel housing
32 9101 93200 Coolant pump impeller extractor 620, 634
33 9104 27700 Coolant pump impeller extractor 320, 420
34 9051 40200 Fitting tool for coolant pump axial seal (seal 8353 31202)
35 9051 79300 Fitting tool for coolant pump axial seal (seal 8353 39425)
36 9051 64900 Fitting tool for coolant pump shaft 320, 420
37 9052 47800 Pressure valve testing gauge
38 9052 48900 Extractor for injection pump gear
39 9025 99100 Injection timing check pin (320, 420, 620, 634/Valtra Valmet---tractors)
40 8366 62022 Electronic timing kit
41 9025 99000 Control rod locking bush

42 9051 71300 Extractor for injector

Special Tools 0---5
2 6 7 8
1
4
9
11
10
12 15 5
18
13
16
19
26
14 17
24
27
22 23 29
21 25
20
28
32
30 31
39
38 41
33 42
36 37 40
34 35
20--- 6

Technical Data 0---6
TECHNICAL DATA
Cylinder block
Holes for guide pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13,250...13,320 mm

Main bearing housing diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91,000...91,025 mm
Main bearing housing diameter (with bearing 8361 40950) . . . . . . . . . . . . . . . . . . . . . . . . 92,000...92,025 mm
Cylinder liner location, diameter:
--- upper end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124,514...124,554 mm
--- lower end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123,000...123,040 mm
Inner diameter of camshaft bushing (fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50,010...50,070 mm
Height of cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428,170...428,430 mm
Cylinder liners
Protrusion of cylinder liner above cylinder block top face . . . . . . . . . . . . . . . . . . . . . . . . . . 0,030...0,080 mm

Max. permissible height difference between liners (under same head) . . . . . . . . . . . . . . 0,02 mm
Outer diameter of cylinder liner guide:
--- at upper end of liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124,475...124,500 mm
--- at lower end of liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122,961...122,986 mm
Liner bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108,010...108,032 mm
Height of cylinder liner flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9,03...9,05 mm
Height of cylinder liner flange, 1st oversize, part no 8366 47933 . . . . . . . . . . . . . . . . . . . . 9,08...9,10 mm
Height of cylinder liner flange, 2nd oversize, part no 8366 47934 . . . . . . . . . . . . . . . . . . . 9,13...9,15 mm
Height of cylinder liner flange, 3rd oversize, part no 8366 47935 . . . . . . . . . . . . . . . . . . . 9,23...9,25 mm
Outer diameter of cylinder liner flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131,700...131,800 mm
Cylinder head
Height of cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104,800...105,000 mm

Height of cylinder head after repair grinding (minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . 104,000 mm
Inside diameter of valve guide (not fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9,000...9,015 mm
Outside diameter of valve guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16,028...16,039 mm
Diameter of valve guide bore in cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16,000...16,018 mm
Position of valve guide top above cylinder head surface . . . . . . . . . . . . . . . . . . . . . . . . . . 21 mm
Depth of valve head face below cylinder head surface:
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,7±0,05 mm (max. 2,20 mm)
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,6±0,05 mm (max. 2,20 mm)
Angle of valve seat:
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35˚+20’
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45˚+20’
Width of valve seat:
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,9...3,7 mm
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,3...2,3 mm
Diameter of exhaust valve seat ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44,070...44,132 mm

Diameter of exhaust valve seat rings recess . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44,000...44,025 mm
Diameter of exhaust valve seat ring (overhaul part 8366 52269) . . . . . . . . . . . . . . . . . . . . 44,270...44,332 mm
Diameter of exhaust valve seal ring recess (overhaul part 8366 52269) . . . . . . . . . . . . . . 44,200...44,225 mm
Diameter of inlet valve seat ring (8366 47936) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48,570...48,632 mm

Diameter of inlet valve seat ring recess . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48,500...48,525 mm
Diameter of inlet valve seat ring (overhaul part 8368 55347) . . . . . . . . . . . . . . . . . . . . . . . 48,770...48,832 mm
Diameter of inlet valve seat ring recess (overhaul part 8368 55347) . . . . . . . . . . . . . . . . . 48,700...48,725 mm
(See page 3---3)

Valves, rockers and tappets
With a valve clearance of 1,0 mm:

--- inlet valve opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0˚±2˚ B.T.D.C
--- inlet valve closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16˚±2˚ A.B.D.C
--- exhaust valve opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39˚±2˚ B.B.D.C
--- exhaust valve closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1˚±2˚ A.T.D.C
Valve clearance cold and hot:
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,35 mm
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,35 mm
Angle of valve seat in cylinder head:
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35˚+20’
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45˚+20’
Width of valve seat in cylinder head:
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,9...3,7 mm
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,3...2,3 mm
Angle of valve face:
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35˚ ---20’
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45˚ ---20’
Outside diameter of valve head:
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 mm
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 mm
Max valve movement:
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10,9 mm
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12,1 mm
Inlet valve stem diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8,960...8,975 mm
Exhaust valve stem diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8,925...8,940 mm
Inlet valve stem clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,025...0,055 mm
--- Reject limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,30 mm
Exhaust valve stem clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,060...0,090 mm
--- Reject limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,35 mm
Inside diameter of valve guide before fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9,000...9,015 mm
Outside diameter of valve guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16,028...16,039 mm
Diameter of valve guide bore in cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16,000...16,018 mm
Protrusion of valve guide top above cylinder head surface . . . . . . . . . . . . . . . . . . . . . . . . 21 mm
Depth of valve face below cylinder head surface:
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,7±0,05 mm (max. 2,20 mm)
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,6±0,05 mm (max. 2,20 mm)
Valve spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69,8 mm
Spring pressure when spring compressed to a length of:
--- 48,6 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327±17 N
--- 37,4 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500±23 N
Rocker arm shaft diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19,959...19,980
Inside diameter of rocker arm bearing bush:
--- (when fitted in position) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19,990...20,010 mm
Outside diameter of rocker arm bearing bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23,035...23,075 mm
Diameter of rocker arm bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23,000...23,021 mm
Max. permissible push rod deflection (when free) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,4 mm
Free length of rocker arm spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 mm
Spring pressure when spring compressed to a length 58 mm . . . . . . . . . . . . . . . . . . . . . 80...100 N
Outside diameter of tappet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29,939...29,960 mm
Diameter of tappet bore in cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30,000...30,043 mm
Engines from 96 week 34
Rocker arm shaft diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22,970...22,990 mm
Diameter of rocker arm bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23,000...23,021 mm
Camshaft
Diameter of camshaft bearing journal no 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49,925...49,950 mm

Diameter of camshaft bearing journals (others that no 1) . . . . . . . . . . . . . . . . . . . . . . . . . . 49,885...49,910 mm
Diameter of camshaft bearing journals nos 2, 3 and 4 (620/634---engines) . . . . . . . . . . . 49,865...49,890 mm
Inside diameter of camshaft bearing bushes (when fitted in position) . . . . . . . . . . . . . . . 50,010...50,070 mm
Diameter of camshaft bearing bores (others than no 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . 50,000...50,025 mm
Camshaft clearance in bearing bush no 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,060...0,145 mm

Camshaft clearance in bearing bushes (others than no 1) . . . . . . . . . . . . . . . . . . . . . . . . . 0,090...0,140 mm

Camshaft clearance in bearing bushes nos 2, 3 and 4 (620/634---engines) . . . . . . . . . . . 0,110...0,160 mm
Bearing bush tolerance in block (press fit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,025...0,080 mm
Diameter of bearing bush bore in block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55,620...55,650 mm
Camshaft end play with 0,5 mm gasket between cylinder block and timing gear
housing and between timing gear housing and front cover . . . . . . . . . . . . . . . . . . . . . . . . 0,5...1,0 mm
Cam height (distance between back of cam and tip of cam):
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41,180...41,430 mm
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40,080...40,330 mm
Cam lift:
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7,38 mm
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8,28 mm
Camshaft max. permissible deflection (total indicator reading) . . . . . . . . . . . . . . . . . . . . . 0,03 mm
Crankshaft
Crankpin diameter:
--- standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67,981...68,000 mm
--- 1. undersize 0,25 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67,731...67,750 mm
--- 2. undersize 0,50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67,481...67,500 mm
--- 3. undersize 1,00 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66,981...67,000 mm
--- 4. undersize 1,50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66,481...66,500 mm
Crankpin length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40,000...40,160 mm
Main bearing journal diameter:

--- standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84,985...85,020 mm
--- 1st undersize 0,25 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84,735...84,770 mm
--- 2nd undersize 0,50mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84,485...84,520 mm
--- 3rd undersize 1,00 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83,985...84,020 mm
--- 4th undersize 1,50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83,485...83,520 mm
Main bearing housing diameter (in cylinder block) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91,000...91,025 mm
Main bearing shell thickness:

--- standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,955...2,965 mm
--- 2nd undersize 0,50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,205...3,215 mm
--- bearing 8361 40950 (see page 5---1 instruction B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,705...3,715 mm
Main bearing clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,050...0,127 mm

Length of thrust bearing journal (journal nearest to flywheel):
--- standard (2 standard thrust plates) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45,000...45,080 mm
--- 1st oversize (one std and one 0,1 mm overthick thrust plate) . . . . . . . . . . . . . . . . . . . . 45,100...45,180 mm
--- 2nd oversize (one std and one 0,2 mm overthick thrust plate) . . . . . . . . . . . . . . . . . . . . 45,200...45,280 mm
--- 3rd oversize (one 0,1 mm and one 0,2 mm overthick thrust plate) . . . . . . . . . . . . . . . . 45,300...45,380 mm
--- 4th oversize (two 0,2 mm overthick thrust plates) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45,400...45,480 mm
Other crankshaft journals may not be ground longer.
Crankshaft end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,100...0,380 mm

Max. permissible ovality and other deformity of crankpins or journals . . . . . . . . . . . . . . . 0,03 mm
Crankshaft unbalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,0 Ncm Max.
Balancing unit ring gear location, diameter (420---engines) . . . . . . . . . . . . . . . . . . . . . . . . 150,220...150,260 mm
Balancing unit ring gear I.D. (420---engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150,000...150,040 mm
Flywheel
Flywheel ring gear no. of teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 pcs

Interference fit between ring gear ---flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,425...0,600 mm
Before fitting the ring gear, heat up to a temperature of . . . . . . . . . . . . . . . . . . . . . . . . . . . 150...200˚C
Flywheel unbalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,0 Ncm Max
Max permissible axial wobble of flywheel clutch face, measured at inner edge
of clutch face on diameter 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,06:ø200

Balancing unit (420---engines)
Tooth backlash:
--- crankshaft ring gear ---balancer weight gear wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,1...0,3 mm
--- between the balancer weights gear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,05...0,250 mm
Balancing weights end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,1...0,5 mm
Shaft diameter at bearing surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36,000...36,016 mm
Bearing bushing inner diameter (fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36,050...36,075 mm
Diameter of holes in body for shafts, rear end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36,058...36,083 mm
Diameter of holes in body for shafts, front end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35,958...35,983 mm
Shim thickness, cylinder block ---balancer unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,2 mm
Timing gears
Tooth backlash:
Crankshaft---idler gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,05...0,25 mm
Idler gear ---camshaft gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,05...0,25 mm
Idler gear ---fuel injection pump gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,05...0,25 mm
Max. permissible side wobble of gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,05 mm
Idler gear shaft, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54,951...54,970 mm
Inner diameter of idler gear bushing (fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55,000...55,030 mm
Inner diameter of Idler gear hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60,000...60,030 mm
Camshaft gear hole diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32,000...32,025 mm
Camshaft end diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32,043...32,059 mm
Timing marks:
Timing marks on gears are in alignment when the 1st cylinder piston is at its top dead centre
between compression and power strokes.
On crankshaft gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 dots on tooth

On idler gear:
--- against crankshaft gear mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 on tooth
--- against camshaft gear mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 dot on tooth
--- against fuel injection pump gear mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 dot on notch
On camshaft gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 dot on notch
On injection pump gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 dot on tooth
Connecting rod
Inside diameter of piston pin bush (with bush pressed into connecting rod) . . . . . . . . . . 40,025...40,040 mm
Outside diameter of piston pin bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44,080...44,120 mm
Outside diameter of piston pin bush (oversize 8353 28326) . . . . . . . . . . . . . . . . . . . . . . . . 44,580...44,620 mm
Interference fit: connecting rod small end bushing ---connecting rod . . . . . . . . . . . . . . . . 0,057...0,120 mm
Connecting rod small end bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44,000...44,025 mm
Connecting rod small end bore (oversize bush) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44,500...44,525 mm
Connecting rod big end bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71,730...71,749 mm
Big end bearing shell thickness:

--- standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,835...1,842 mm
--- 2nd undersize 0,50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,085...2,092 mm
Big ---end bearing clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,046...0,098 mm
End float (side clearance) at big ---end on crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,200...0,410 mm
Piston pin bushing location perpendicular to longitudinal axis of connecting
rod to be within . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,15:100
Piston pin bushing location and big ---end bearing location to be parallel to within . . . . . 0,05:100
Weight marking (letter) at lower end.
Max. permissible weight difference between connecting rods in the same engine . . . . . 20 g
Position of connecting rod; weight marking at valve mechanism side
(away from the combustion chamber in the piston)

Piston, rings and pin
Minimum distance between piston and cylinder head (measured with a piece
of lead wire thought the injector location hole) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,900...1,150 mm
Piston diameter:
--- 17 mm from lower edge (320, 420, 620---engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107,873...107,887 mm
--- 19 mm from lower edge (634---engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107,883...107,897 mm
Pin bore in piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40,003...40,009 mm
Piston pin diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39,991...40,000 mm
Width of ring grooves:

--- 1st groove (right---angled ring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,560...2,580 mm
--- 2nd grove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,520...2,540 mm
--- 3rd groove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,040...4,060 mm
Side clearance of piston rings in their grooves:

--- 1st ring (right---angled ring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,07...0,102 mm
--- 2nd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,03...0,062 mm
--- 3rd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,05...0,082 mm
--- reject limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,15 mm
Piston ring height (in direction of cylinder):

--- 2nd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,478...2,490 mm
--- 3rd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,975...3,990 mm
Piston ring gap (with piston fitted in cylinder)

--- 1st ring (wedge shaped ring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,40...0,55 mm
--- 2nd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,60...0,80 mm
--- 3rd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,30...0,60
--- reject limit 1st and 3rd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,0 mm
--- reject limit 2nd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,5 mm
Max. permissible weight difference between pistons in same engine . . . . . . . . . . . . . . . . . 25 g

Piston to be heated up to 100˚C before fitting gudgeon pin.
Piston position in cylinder: combustion chamber of piston to face towards injector.
Lubricating system
Oil pressure at normal running temperature:

--- at idling speed (min.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 kPa (1,0 kp/cm2)
--- at running speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250---400 kPa(2,5---4,0 kp/cm2)
Free length of oil pressure valve spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 mm
Spring pressure when valve spring is compressed to a length of 52 mm . . . . . . . . . . . . . 54+5 N (5,4+0,5 kp)
Diameter of oil pressure valve plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19,602...19,635 mm
Diameter of oil pressure valve cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19,700...19,752 mm
Oil filter by ---pass valve opens at a pressure difference of . . . . . . . . . . . . . . . . . . . . . . . . . . 2±0,5 kp/cm2
Oil pump (320, 420---engines)
Backlash between gears when crankshaft lies firmly against the lower side of main bearings:
--- crankshaft gear ---lubricating oil pump gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,05...0,25 mm
--- between the pump gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,16...0,26 mm
Diameter of drive shaft at bearings for body and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17,966...17,984 mm
Diameter of shaft holes on body and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18,000...18,018 mm
Diameter of gear wheel hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18,060...18,078 mm
Fixed shaft, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18,028...18,039 mm
Protrusion of fixed shaft end below pump body face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,5...1,0 mm
Thickness of cover gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,06...0,08 mm

Outside diameter of gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43,486...43,525 mm

Housing diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43,650...43,750 mm
Thickness of gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24,000...24,027 mm
End play of gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,03...0,11 mm
Depth of housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24,000...24,043 mm
Number of teeth on drive gear (320---engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 pcs
Number of teeth on drive gear (420---engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 pcs
Oil pump (620/634---engines)
Backlash between gears when crankshaft lies firmly against the lower side of main bearings:
--- crankshaft gear ---lubricating oil pump gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,05...0,25 mm
--- between the pump gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,16...0,26 mm
Diameter of drive shaft at bearings for body and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17,966...17,984 mm
Diameter of drive shaft bearing hole on body and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . 18,000...18,018 mm
Hole diameter of gear pressed on drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18,060...18,078 mm
Diameter of fixed shaft at gear wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17,966...17,984 mm
Inner diameter of bearing for gear wheel which rotates on fixed shaft . . . . . . . . . . . . . . . . 18,000...18,018 mm
Fixed shaft in pump body, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20,035...20,048 mm
Protrusion of fixed shaft end below pump body face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,5+0,5 mm
Thickness of cover gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,06...0,08 mm
Outer diameter of gear wheels (620---engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43,486...43,525 mm
Outer diameter of gear wheels (634---engines/620---engines J 7891>) . . . . . . . . . . . . . . . 55,824...55,870 mm
Housing diameter (620---engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43,650...43,750 mm
Housing diameter (634---engines/620---engines J 7891>) . . . . . . . . . . . . . . . . . . . . . . . . . 56,000...56,120 mm
Thickness of gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32,000...32,027 mm
End play of gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,03...0,11 mm
Depth of housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32,000...32,043 mm
Number of teeth on drive gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 pcs
Coolant pump (320, 420---engines)
Outside diameter of bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38,087...38,100 mm

Inside diameter of bearing housing in pump body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38,058...38,083 mm
Shaft diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15,910...15,920 mm
Impeller hole diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15,881...15,899 mm
Diameter of the seal recess in the pump body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36,450...36,489 mm
The impeller is pressed onto the shaft until the distance between
the rear face of impeller and the rear face of the pump body is . . . . . . . . . . . . . . . . . . . . . 1,8...2,2 mm
Distance of belt pulley from rear face of body:
--- 320; <E 7535, 420; <E 7054 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178,3...178,7 mm
--- 320; E 7536>, 420; E 7055> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174,4...174,6 mm
Fan guide diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25,00...25,20 mm
Balancing precision of fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,3 Ncm max.
Max. permissible eccentricity of fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±0,3 mm
Belt deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15...20 mm
Coolant pump (with separate ball bearings 320 --- and 420 ---engines)
Outside diameter of bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 mm
Diameter of bearing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51,979...52,009 mm
Shaft diameter at bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20,002...20,015 mm
Shaft diameter at impeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15,907...15,920 mm
Impeller should be pressed onto shaft inside the housing . . . . . . . . . . . . . . . . . . . . . . . . . 1,8...2,2 mm
Diameter of fan hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,3 Ncm max. (30 pcm)
Max. permissible eccentricity of fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±0,3 mm
The fan belt tension pushing from the middle,
deflection from the line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15...20 mm

Coolant pump (620/634---engines)
Outside diameter of bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 mm

Inside diameter of bearing housing in pump body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51,979...52,009 mm
Shaft diameter at bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19,980...19,993 mm
Shaft diameter at impeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15,907...15,920 mm
Diameter of the seal recess in the pump body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36,450...36,489 mm
Distance between impeller and rear face of pump body . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,8...1,2 mm
Balancing precision of fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,3 Ncm max (30 pcm)
Belt deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15...20 mm
Pump equipped with reinforced bearing:

Outer diameter of the front bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 mm
Bearing up diameter in water pump wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95,000...95,035 mm
Outer diameter of bearings position in pump frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59,991...60,009 mm
Thermostat
Spare part number Type Opening Fully Max. stroke

begins at open at mm
8361 15646 ø67/79˚C 79˚±2˚C 94˚C 8

8361 15718 ø67/83˚C 83˚±2˚C 97˚C 8
8366 59685 ø67/86˚C 86˚±2˚C 99˚C 8
8360 15156 ø54/79˚C 79˚±2˚C 94˚C 7,5
8363 31590 ø67/83˚C 83˚±2˚C 95˚C 8
Turbocharger
Schwitzer S1A (320 DS)

Shaft end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max. 0,14 mm
Shaft radial clearance 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max. 0,61 mm
Turbine housing attaching bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm
Nut at end of shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6,8 Nm
Schwitzer S1B (420 DS) and S1BG by -- pass turbo (420DW)

Shaft radial clearance1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max. 0,51 mm
Nut at end of shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8,1 Nm
By ---pass passage opening pressure (S1BG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,035 bar
Schwitzer S2B (620/634 DS) and S2BG by -- pass turbo (620/634DW)

Shaft radial clearance1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max. 0,95 mm
Nut on end of shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15,6 Nm
1) Measured at nut on end of shaft.

Tightening Torques 0---13
TIGHTENING TORQUES
Object Nm
Cylinder head bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm+90˚+90˚ (see page 3--- 4)

Cylinder head studs to cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Main bearing bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Connecting rod bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Nm + 90˚
Crankshaft nut:
--- 320/420 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600
--- 620/634 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000
Crankshaft counterweight, 320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Crankshaft pulley bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Flywheel bolts, 10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Flywheel bolts, 12.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Flywheel housing bolts:
--- outer ring M12, 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
--- outer ring M12, 12.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
--- inner ring M10, 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
--- inner ring M10, 12.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Idler gear bolts:
--- M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
--- M14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Idler gear retaining screws (with ball bearing):
--- the bigger bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
--- the bolts for holding the bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Balancing weights, 420 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Piston cooling valve (620/634) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Oil pump gear nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Oil pump retaining screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Oil cooler connecting piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Coolant pump pulley nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Fan bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Exhaust manifold bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Intake manifold bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Injection pump pressure valve holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Injection pump gear retaining nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Injection pump gear retaining nut (Bosch ---P) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Injector attaching nuts (on studs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Injector nozzle sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Compressor pulley nut (Knorr) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Always use the torque values listed in the following tables when specific torque values are not available.
M8 M10
Cast iron 35±5 Nm 70±5 Nm
Aluminium 25±5 Nm 50±5 Nm
Use a washer with the aluminium parts.
The bolts of a self carrying oil sump
1 M8 12.9 30 Nm
2 M10 12.9 90 Nm
21 M12 12.9 150 Nm
3 M14 10.9 200 Nm
4 M20 10.9 700 Nm
5 M16 10.9 300 Nm
6 M20 10.9 700 Nm
6 M22 10.9 700 Nm
1) 320 and 420

Construction 0---14
CONSTRUCTION
General
The Sisudiesel 20/34---series engines (3---, 4---, or 6---cylin- The flywheel housing are delivered according to the require-
ders) are water ---cooled, four stroke, direct---injection in ---line ments set, by the engine application and differet flywheel
diesel engines. All engines are produced as naturally aspir- housings can be mounted on all engine types.
ated engines, turbocharged engines and the four --- and six
cylinder engines also as intercooled.
The engines 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.
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 cylinder liner lower part and the cylinder
block is achieved by three o---rings, which are fitted in grooves
in the liner. 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.
The remaining bearing locations are machined directly in the
cylinder block. The latest 620/634---engines have separate
bearing sleeves in all camshaft bearing locations. The drilling
for the camshaft rear end is covered with a plug.
There are spaces on both sides of the rear main bearing for
guide bearing shims (the crankshaft thrust bearings).
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 fly-
wheel housing.
The lower face of the flywheel housing functions as a sealing 20--- 7

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.

Construction 0---15
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 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. In addition, the front end of the crankshaft has
splines for the hub of the V ---belt pulley. An oil deflector ring
is fitted between the hub and gear wheel, and a dust shield is
fitted on the hub in order to protect the seal.
The crankshaft is supported on the cylinder block by main

bearings which are placed on both sides of each cylinder.
Thus there is one main bearing more than cylinders. The
crankshaft thrust washers are placed in both sides of the rear-
most main bearing.
At the rear end of the crankshaft there is fitted a flywheel on

which is a press---fit a starter ring gear. The forged connecting
rod has an I ---section cross---section. The bearing location at
the bottom end of the connecting rod is split, and the bearing
cup is secured by two special bolts and nuts. The upper part
has a wedge ---shaped bearing location, in which the piston
pin bearing bushing is fitted with a press fit.
20--- 8
The piston is made of an 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 piston has three rings. The upper molyb-
Cylinder head denum ---coated ring has a wedge ---shaped cross---section.
On natural aspirated engines and on slight supercharged en-
gines the upper ring is right---angled. The middle ring is tap-
320--- and 420---engines have one cylinder head. ered and it fits into its groove. The taper taking up the clear-
620/634---engines have two cylinder heads which are ex- ance. The oil control ring is spring loaded and it has a
changeable with each other and also with the cylinder head two---stage, chromed scraping edge.
on the 320---engine. Each cylinder has its own inlet and ex-
haust ports located on either side of the head. Between hot ex-
haust valves a cool inlet valve is fitted to balance the thermal On the turbocharged engines the upper ring location is
load. formed in a cast iron ring which is cast in the piston. In addi-
tion, the piston on supercharged engines is graphite coated
Cylinder head bolts are high tensile bolts which are tightened to ensure correct running ---in.
up to yield limit using angle tightening principle. Due to the
large stretch the tightening forces are kept constant during the
whole lifetime and retightening is unnecessary. Four ---cylinder engines (420) are equipped with a balancer
unit. The eccentric weights, which rotate at twice the engine
The injector locations are machined directly into the cylinder speed, even out the vibration forces exerted by the movement
head. The inlet and exhaust valve guides are identical and can of the pistons and the crank mechanism.
be interchanged. In addition, the exhaust valves are equipped
with replaceable valve seat inserts.
Valve mechanism
The valve mechanism is operated by the camshaft which is lo-
cated in the cylinder block. The drive is transferred with the
help of tappets and pushrods. The camshaft gear wheel is
fitted with a press fit and fixed with a key. Each bearing is lubri-
cated by the force feed lubrication system through drilled oil-
ways in the motor block.

Construction 0---16
20--- 9
Timing gears
The timing gear train consists of hardened, helically cut gear
wheels. The gears are encased by the timing gear casing
which is fitted to the front of the engine. The timing gear drives
the camshaft, fuel injection pump and oil pump.
If the engine is equipped with a hydraulic pump, it is driven via

a gear or a separate drive unit.
The idler gear is supported with a bearing sleeve/ball bearing

(620/634) on the shaft on the front face of the cylinder block.
Two different dimensions of gear and shaft is used.

Construction 0---17
7 3
5
6
1 Lubricating system (620/634-- engines)
1. Lubricating oil pump

20--- 10 2. Pressure ---relief valve
3. Oil filter
4. Turbocharger
5. Main oil gallery
6. Piston cooling nozzle
7. Oil pressure sensor
Lubricating system
The engine has a pressure lubricating system in which the oil
pump (gear pump) is attached to the cylinder block lower
face. The oil is sucked up by the pump through a suction The oil pressure relief valve is located under the oil filter on the
strainer. After the pump the oil is led through an oilway to the left hand side of the engine. The valve regulates the lubricat-
relief valve and to the oil filter. After the filter, the oil is led ing oil pressure so that it is kept constant, regardless of the en-
through the main oil gallery from which oilways branch out. gine speed. Oil pressure is about 2,5 ---4 bar depending on
The oil is led through the oilways in the main bearings and revs, oil quality and temperature, and at engine idling speed
through the crankshaft to the big ---end bearings. the pressure is min 1,0 bar.
The oil is further directed from the main gallery to the injection The oil filter is full---flow disposable type and is fitted on the
pump, turbocharger, balancing unit (420) and to a possible left---hand side of the engine. A by ---pass valve is located at
compressor. In addition, the idler gear bushing, the camshaft the base of the filter to ensure safe cold ---starting or to ensure
bearing points and the valve mechanism get their lubrication adequate lubrication in case the filter becomes blocked. In
oil via the main oil gallery. addition, there is a non ---return valve which stops the filter
from being emptied of oil.
In 620/634---engines, with high power rating, is the bottom of
the piston cooled with oil spray always when the oil pressure
is higher than 3 bar.

Construction 0---18
6
1
4 20--- 11
The cooling system In some 620/634---engines there are two separate thermo-
stats where one of them is steering the by ---pass of coolant
1. Coolant pump liquid. The thermostats differ in types and opening tempera-
2. Thermostat tures. When the coolant temperature is below the thermostat
3. By ---pass pipe opening temperature the coolant circulates through the by ---
4. Radiator pass hole into the coolant pump. The smaller, singleacting
5. Expansion tank thermostat opens first (at 79˚C) letting one part of the coolant
6. Oil cooler into the radiator. Following the load increase, also the other
thermostat opens (at 83˚C). This is a double ---acting type
which closes the by ---pass hole when it opens and directs the
coolant into the radiator. These engine models do not have
Cooling system any separate winter ---type thermostats.
The belt driven, centrifugal type coolant pump is attached at

the front end of the cylinder block and the thermostat housing
is fitted above the pump. The system has an internal coolant
circulation via the by ---pass passage and the circulation is
controlled by a two---way thermostat. With this is achieved an
even warming in all conditions. C
The coolant pump has separate ball bearings or the pump
1
shaft and the bearings are built together to form one unit
(320--- and 420 engines). 2
The thermostat opens at 79˚C. During a cold season, a ther-
B
mostat with the opening temperature of 83˚C can be use.
20--- 12

Construction 0---19
20--- 13
Inlet and exhaust system

The filter system for the engine inlet air comprises a cyclone
type precleaner, and a paper filter which acts as the main filter.
The incoming air is made to rotate in the cyclone precleaner.
This causes most of the impurities to settle out and collect in
the cyclone precleaner dust collector. The paper filter com-
prises one or two replaceable filter elements. The paper is
corrugated and surrounded by a metal support.
The impurities in the air collect at the larger filter element

which can be cleaned when necessary. The inner safety filter
prevents impurities form entering the engine should the main
filter element break, or be fitted incorrectly.
A mechanical or electrical service indicator can be mounted

on the filter housing or on the inlet pipe to show when the filter
20--- 13/1
cartridge is clogged. The inlet system also includes the hoses
between the air cleaner and the turbocharger and the turbo-
charger and the intake manifold.
The exhaust manifold is attached to the cylinder head with

high tensile bolts without a separate gasket. Retightening of
the manifold bolts is unnecessary.
In the marine --- and generator engines a liquid cooled exhaust

manifold is used, that is connected to the engines cooling
liquid circulation (so---called freshwater circulation). These
exhaust manifolds are sealed from the liquid circulation part The compressed air is cooled by the air to water basis. The air
with o---rings in 420---engines and with level seals in coming from the turbocharger has a temperature about
320/620/634---engines. 150˚C which is cooled by the cooling water of the engine
down to about 95˚C.
The turbocharger is turbo---compressor driven by exhaust
gas. The compact design of the turbocharger is sensitive to The cooling cell is installed on the intake manifold and con-
react even during low revolutions. The turbocharger is lubri- nected to the engine cooling system. The cooling of the com-
cated and cooled by the lubrication system of the engine. pressed air stabilised the combustion, irrespective of the tem-
DW/DWI engine is equipped with a by ---pass turbocharger perature, and minimises the thermal and mechanical load of
where the highest air pressure is adjusted by so---called by --- the engine thus lowering nitric oxides (NOx).
pass channel.

Construction 0---20
20--- 14
Electronic Engine Management sys-

tem (EEM)
The Sisudiesel EEM system is a microprocessor based diesel
engine control system to replace the traditional mechanical
speed governor on the engine. This system significantly im-
proves the properties of the engine and adds several func-
tions and operational features that could not be realised with
mechanical governors. The EEM system is applicable to all
kinds of vehicles, on --- or off ---road.
The system consists of the following components:
--- Fuel injection pump with electrical actuator system

--- Electronic control unit
--- Sensors for engine parameters and speed demand value
--- Wiring harness

Cylinder Block 1---1
WORK INSTRUCTIONS
1. CYLINDER BLOCK
A. Measuring cylinder liner wear 9051 73100
1. Using a micrometer set the dial gauge to zero using a new

cylinder liner indicating the initial dimension of the bore:
108,00 mm.
2. Clean the inner surface of the cylinder liner thoroughly be-

fore measurement.
21--- 2
C. Checking cylinder block

1. Clean the cylinder block and all oil ways.
2. Check the cooling channels and remove the scale and sedi-
ment to ensure engine cooling.
3. Check the tightness of the cup plugs and threaded plugs

in the cylinder block as well as the condition of the cylinder
block and sealing faces.
21--- 1
4. Measure the wear of the camshaft bearing points (compare
with rated).
3. Perform the measurement crosswise at the liner top end,
lower end and middle. Note! If it is necessary to machine the upper face of the cylin-
der block, the pistons must be shortened by the same dimen-
4. Check the gauge reading for maximum wear and ovalness sion. Observe the valve disc spaces on the piston upper face.
(compare with rated).
B. Removing cylinder liner

D. Changing camshaft bushing
1. If the cylinder liners are to be used again they should be
marked so that they can be fitted in the same position. 1. Extract the bushing with an internal puller, for example
Sykes 854. If the camshaft rear end plug is removed the bush-
2. Remove the cylinder liners using cylinder liner puller 9051 ing can be forced out with a long drift.
73100.
2. Clean the bushing location carefully.

30˚
0,1...0,4 mm
21--- 3/1
21--- 3
3. Press in a new bushing. Note the position of the oil hole. It Note! From engine number L 13188 the cam shaft front end
is unnecessary to ream the bushing because it has a correct bushing is equipped with the oil groove on the outside (the
inner diameter when it is fitted in place. groove was earlier on the cam shaft). As spare part the earlier
bushing always be replaced with the new one. Fit the hole of
Note! On the 620--- and 634---engines from the engine ser. the new bushing in 30˚ angle from horizontal level as picture
number C2751, all camshaft bearing points are provided with shows. The bushing is after assembly in its correct measures
a separate bearing bushing. Observe the different outer diam- (no need for machining).
eters when removing and fitting.
5 4 3 2 1
21--- 4
Order numbers of the camshaft bushings and hole diameters Order no. Hole diameter
for the bushings on the 620/634---engines.
1. 8363 22610 55,62...55,65
Note! Numbering begins from the front end of the engine. 2. 8368 52460 55,42...55,45
3. 8368 52459 55,22...55,25
4. 8368 52460 55,42...55,45
5. 8368 52461 55,64...55,67
E. Oversize bushings for camshaft 140 mm 134 mm

6...7 mm
If the location of the camshaft bushing (front bearing) is dam-
aged, a bushing with a 0,4 mm oversize outer diameter can
be fitted. Bushings are available even for other camshaft bear-
ings which do not normally have bushings. Part numbers and
machining dimensions for the bushing locations are shown in
the figure. 4 3 2 1
Observe the position of the bushing oil holes. It is unnecess- 21--- 5

ary to ream the bushings after fitting.
Oversize camshaft bushings for 320---engines. Numbering
begins from the front end of the engine.
Order no. Hole diameter
1. 8363 24661 56,02...56,05

2. 8368 52460 55,42...55,45
3. 8368 52460 55,42...55,45
4. 8368 52461 55,64...55,67

272 mm 134 mm
6...7 mm
4 3 2 1 Order no. Hole diameter
1. 8363 24661 56,02...56,05

21--- 6
2. 8368 52460 55,42...55,45
3. 8368 52460 55,42...55,45
4. 8368 52461 55,64...55,67
Camshaft oversize bearing bushings for 420---engines.
Numbering begins from the front end of the engine.
266 mm
272 mm 134 mm
6...7 mm
5 4 3 2 1
21--- 7
Camshaft oversize bearing bushings for 620/634---engines. Order no. Hole diameter
Numbering begins from the front end of the engine.
1. 8363 24661 56,02...56,05
2. 8368 52466 55,62...55,65
3. 8368 52460 55,42...55,45
4. 8368 52466 55,62...55,65
5. 8368 52467 55,84...55,87
F. Fitting plug at camshaft rear end

1. Clean the seat for the plug.
2. Apply sealing compound to the contact surface of the plug
max. 1,0 mm
21--- 8
21--- 9
The camshaft rear end plug is replaced with plug 8363 24391
and o---ring 6146 05125 after machining. Use plate 8361
24210 in those engines where the flywheel housing is not 3. Drive in the plug with fitting drift 9025 87400.
covering the blocking plug.
Note! Do not drive in the plug too far because it will affect the
camshaft end float.

G. Fitting guide pipe for oil dipstick 3. If the recess is damaged, or the cylinder liner height (see
point 5) needs to be adjusted, use milling cutter 9101 65600.
If necessary, a light lapping can be executed after milling with
1. Clean the seat for the pipe. the help of the cylinder liner. Apply lapping paste to the under-
side of the cylinder liner flange, and twist the liner with twisting
2. Apply locking fluid Loctite 601 to the lower end of the guide tool. Lapping is not suitable for adjusting the cylinder liner
pipe. height.
4. Clean the contact surfaces.
9101 65600
21--- 10
3. Tap the guide pipe in its position at the level indicated in the
picture.
9025 95900 20--- 12
0,03...0,08 mm
9025 79200
21--- 11
4. Tap the guide pipe 8361 29747 (bent pipe) in to the correct
fitting height with tool 9025 95900.
Note! The position of the guide pipe affects an oil level in the
engine. 9101 66300
20--- 13
5. Fit the cylinder liners and fix each liner with two press tools
H. Fitting cylinder liner 910166300. Measure the cylinder liner height with a dial
gauge and holder 9025 79200. Zero the dial gauge against a
flat surface, for example, the cylinder block face. Measure
1. Clean the cylinder liner and its recess in the cylinder block. each liner in four places. The height of the liner above the cyl-
Without o---rings the liner should rotate easily in its recess. inder block face should be 0,03...0,08 mm. The height differ-
ence between cylinder liners under the same cylinder head
2. Apply a thin layer of marking paint on the underside of the must not exceed 0,02 mm, nor must an intermediate cylinder
cylinder liner flange. Fit the cylinder liner without o---rings and liner lie lower than an outer one.
turn it forwards and backwards. Lift out the liner and check
that paint has been deposited on the whole contact surface.

6. If the cylinder liner height is too low, a liner with a higher

flange is fitted.
21--- 14
Order no H Markinggrooves
pcs
8366 47420 9,03+0,02 --- (std.) 21--- 16
8366 47933 9,08+0,02 1
8366 47934 9,13+0,02 2
8366 47935 9,23+0,02 3 9. Press the cylinder liners into the cylinder block. It should be
easy to press them fully home. Make sure that the liners do not
Cylinder liners with oversize flanges (higher flanges) are rise up after fitting.
marked with grooves on the outer circumference as follows:
1st oversize, 0,05 mm = 1 marking groove

2nd oversize, 0,10 mm = 2 marking grooves
3rd oversize, 0,20 mm = 3 marking grooves
Note! Recess depth is adjusted with a cylinder liner recess

cutter 9101 65600.
7. If the liner height of a cylinder liner is not the same all the way
round, the cylinder liner flange and the cylinder block recess
depth should be checked. Cylinder liners with warped flanges
should be discarded.
Musta/Black/Svart/Schwarz
Vihreä/Green/Grön/Grün
21--- 15
8. Fit the o---rings into the grooves in the cylinder lower part
and lubricate them with a liquid soap (not with engine oil).
Note! Stretch the o---rings as little as possible when fitting

them. Max allowable stretching is 6 %.

Flywheel Housing 2---1
2. FLYWHEEL HOUSING A
A. Fitting flywheel housing

E
The flywheel housing is centred on the cylinder block by two
tension pins. Even the flywheel housings which are delivered
as spare parts have ready ---made holes for the pins.
1. Clean the sealing surfaces between the cylinder block and

the flywheel housing.
E E
22--- 2
B. Changing crankshaft rear oil seal

1. Lift out the engine. Remove the clutch assembly (and poss-
ible turbine clutch).
2. Remove the flywheel.
3. Remove the oil seal. Do not damage the crankshaft.
4. Clean the seal location and grind off any burrs.

22--- 1
2. Apply silicone sealant as shown in figure above.
3. Lift the flywheel housing into place and fit all the bolts.
4. Centre the housing with centring tool 9052 46400 (Note!

This is important of the engines with a turbine clutch) and fit
the tension pins with drift 9025 98700.
5. Tighten the fixing bolts, the inner ring socket head bolts to
60 Nm (8.8) / 80 Nm (12.9) and outer ring hexagonal bolts to
110 Nm. (8.8) / 150 Nm (12.9)
NOTE! MODIFICATION OF THE FLYWHEEL HOUSING
All the below mentioned flywheel housings have been in the

inner circle added with 3pcs Æ11 mm holes (E) and in in the
outer circle with 1 pcs Æ13 mm hole (A). Under the bolts in the
added holes has to be added a spring washer Æ10 mm, order
no. 5009 51000, 3 pcs (E) and Æ12 mm, order no. 5009 51200,
1 pc (A). 22--- 3
The modified flywheel housings:

Note! If the crankshaft is worn at the sealing location, a 2 mm
8363 46658 spacer ring, part no. 8360 20054, can be fitted in front of the
8366 47441 crankshaft rear oil seal.
8366 47440
8366 47442

Flywheel Housing 2---2
5. Fit the seal as follows:
--- Do not remove the plastic sleeve in before hand.
--- NOTE! FIT THE SEAL DRY, NOT OILED!
O 22--- 4
O = Sleeve
T = Seal
--- Put the sleeve against the crankshaft rear end so that the
sleeve is on the shaft bevelling.
--- Push the seal over the sleeve on the shaft and further
against the flywheel housing.
9052 46300 22--- 5
--- Remove the sleeve and hit the seal into position with the fit-
ting tool 9052 46300.

Cylinder Head 3---1
3. CYLINDER HEAD C. Checking cylinder head

1. Remove the soot from the exhaust ports, clean the sealing
A. Removing cylinder head surfaces and wash the cylinder head.
1. Clean the engine externally and drain the coolant. Discon- 2. Check for cracks and other damage.
nect the coolant hoses from the cylinder head and the thermo-
stat housing.
2. Remove the suction hoses between the turbocharger and

the air filter and between the turbocharger and the inlet mani-
fold.
3. Disconnect the turbocharger pressure and return oil pipes.
4. Remove the pipes to the thermostart fuel reservoir.
5. Remove the injector leak ---off fuel pipes and the delivery
pipes. Remove the injectors. Fit blanking ---off caps on all
open connections.
23--- 2
6. Remove the inlet and exhaust manifolds and the thermostat
housing.
3. Check the flatness of the cylinder head by using a straight
Note! It is possible to remove the cylinder head even thought edge. An uneven or warped surface should be surface
these parts are attached to the head. ground. The height of the cylinder head, after grinding, should
not be less than 104,00 mm. The valve disc depth from the
7. Remove the valve cover and the breather hose. cylinder head surface should be 0,60 mm for the exhaust
valves and 0,70 mm for the inlet valves.
8. Remove the rocker arm mechanism and the push rods.
9. Loosen all the cylinder head bolts first by a 1/4 turn and then
remove them. Remove the cylinder head.
B. Removing valves 9101 66000
Ensure that valves which are to be re ---used are marked, so

that they are fitted in their original locations.
9052 47200
9101 66200
23--- 3
23--- 1
4. Straighten and clean the injector location seat in the cylin-
der head with cutter 9101 66000.
1. Install the counter screw 9052 47200 for the valve spring in-
stalling tool in the rocker arm cover bolt. On the 320--- and
620/634---engines there is not a screw stud at the valves for
the centre cylinder. A bolt of suitable length should be used
instead.
2. Compress the valve springs using lever 9101 66200. Re-

move the valve cotters, spring guide and spring. Remove the
valves.

Cylinder Head 3---2
9101 65900
23--- 6
23--- 4
5. Measure the clearance between the valve stem and the

valve guide with a dial gauge. Lift the valve so that the valve
head is 15 mm from the face of the cylinder head, and
measure the clearance. It must not be greater than 0,30 mm
for the inlet valves and 0,35 mm for the exhaust valves. In
order to establish the valve guide wear, a new valve should be
used when measuring.
23--- 7
D. Changing valve guides

3. The guides are the same for the inlet and exhaust valves.
Ensure that the steepest chamfer on the guide, faces the valve
head. Check that the valves do not bind in the guides.
9101 65800 E. Machining valve seat
9101 66100
23--- 5
23--- 8
1. Press or knock out the old guides using drift 9101 65800.
Clean the valve guide locations. Machine the damaged valve seat with milling cutter. If the
width of the seat exceeds 2,3 mm in exhaust and 3,7 mm in
2. Lubricate the outside of the new guides and fit them using intake, it should be reduced primarily at the outer edge.
drift 9101 65900, which ensures the correct fitting height (21
mm over the spring face). The valve seat angle is 45˚+20’ for exhaust valve and 35˚+20’
for inlet valve.

Cylinder Head 3---3
F. Changing valve seat rings G. Grinding valves

Exhaust valves are fitted with separate valve seat rings. If the In order to ensure that there is a proper seal around the valves,
sealing surface is damaged so badly that it cannot be repaired there is a difference in the sealing surface angles. Thus there
with machining, the seat ring should be changed. is a very narrow sealing surface which seals effectively even
after prolonged running.
1. Grind the valve head on a discarded valve so that it sits
down in the valve seat. Fit the valve and weld it in place in the
seat. Cool with water.
2. Turn the cylinder head over and knock out the valve and
seat.
B
3. Clean the valve seat location. Cool the new seat ring in liquid
nitrogen until it stops bubbling, or alternatively place it in dry A
ice.
4. Fit the seat with a suitable drift. Machine the seat. C

Note! Where necessary, standard size seats can be replaced
by inserts with a larger outer diameter. See technical data,
point cylinder head.
23--- 10
11±0,1 A B C
Inlet 35˚ ---20’ 35˚+20’ 0,7±0,05 mm (max. 2,20 mm)
Exhaust 45˚ ---20’ 45˚+20’ 0,6±0,05 mm (max. 2,20 mm)
1. Grind the damaged valve disc with a valve refacer. Adjust

angles to 45˚ --- 20’ for exhaust valves and 35˚ --- 20’ for inlet
valves.
2. If the edge of the valve head is less than 1,5 mm after it has
48,500...48,525 been ground, or if the valve stem is bent, the valve should be
discarded.
3. If necessary, grind the end of the valve stem.
4. Lap the valves with lapping paste and check the contact
23--- 9 surface with marking paint.
5. Clean the cylinder head and valves of any remaining lap-

The inlet valve seat machined direct on the cylinder head, can
ping paste.
be provided with a separate valve seat ring, order no 8366
47936. Machine the seat insert location on the cylinder head
(see figure above). Fit the insert like a seat of the exhaust
valve. H. Fitting valves
More powerful engine specs are equipped with separate inlet
1. Check the valve springs for straightness, length and ten-
valve seats. Use in these engines when repairing seat ring no.
sion using a spring tester. Compare with specifications.
8368 55347. See technical data, point cylinder head.
2. Lubricate the valve stems and fit the valves in the correct
order in the cylinder.
3. Fit the springs, spring guides and valve keepers with the aid
of a lever for compressing valve springs, 9101 66200.
4. Tap the end of the valve stems lightly after fitting the valve
in order to ensure that they are secure.

Cylinder Head 3---4
I. Fitting cylinder head

14 10 7 5 9 15
1. Measure the length of the cylinder head bolts. Compare 16 1
3 17
with dimensions shown in figure below. Change too long
bolts.
2 4
12 13
max. 142 8 6 11
320, 620, 634 23--- 12
max. 188,5
22 19 12 6 4 11 14 17
21 10 7
2 16
23--- 11 8 1 9
20 15
18 3 5 13
2. Screw the cylinder head stud bolts in to the cylinder block
to a torque of 30 Nm. Fit the valve tappets if removed. 420 23--- 13
3. Check that the sealing surfaces are clean and fit the cylinder
head gasket(s) and the cylinder head(s). Ensure that on the 4. Pictures above show the correct tightening order of the cyl-
six cylinder engines both cylinder heads are parallel by inder head bolts. The order has also been marked on the cyl-
fastening lightly the exhaust manifold before tightening the inder heads.
cylinder head bolts (the exhaust manifold can damage, if the
heads are not parallel). Clean and lubricate and fit the bolts. 5. Tighten the cylinder head bolts progressively as follows:
1. First tightening to 80 Nm
2. Tightening of 90˚
3. Tightening again of 90˚.
6. Adjust the valve clearances (see instruction 4 C).
7. Run the engine with a light load to the normal running tem-
perature (~ 75˚C).
8. Tighten the bolts 60˚ and adjust the valve clearances.
Note! After this the cylinder head does not need retightening.
Tighten the exhaust manifold bolts/nuts to 50 Nm. DO NOT OVERTIGHT!
50 Nm 23--- 131

Valve Mechanism 4---1
4. VALVE MECHANISM 60˚
A. Reconditioning valve mechanism

1. Check the valve tappets, especially the contact surface
against the camshaft. Worn or damaged tappets should be
discarded.
24--- 4
5. Fit the plug to the other end of the rocker arm shaft. Lubri-
cate the shaft and fit various parts in a correct order. Note the
correct position of the shaft and the bearing brackets. The split
side of the bracket and the shaft oil holes must be turned to
the valve side (see figure above). Fit the other end plug.
NOTE! ENGINES FROM 96 WEEK 34

24--- 1
From the above mentioned date a new valve mechanism,
push rods and rocker cover fastening taken in use.
2. Check the straightness of the pushrods by rolling them on
a surface table. Check also the spherical surfaces at the ends. The modification effects mainly the under mentioned parts:
3. Dismantle and clean the rocker arm mechanism. Check the
shaft for wear and that the oilways are clean.
19,990...20,010
24--- 2
24--- 5
4. Check that the rocker arm bushings are not worn. Ensure
that the oil hole is positioned correctly when pressing in new --- Valve mechanism shaft diameter grows from 20 Þ 23 mm.
bushings. After pressing in the bushings they should be re- The plugs in both ends are replaced by threaded plugs.
amed to 19,990...20,010 mm. Where necessary grind the
rocker arm valve contact surface to the correct shape. Do not --- The rocker arm is without bushing. The adjusting screw is
grind more than necessary as the hardened layer is thin. modified from M8 Þ M10x1.
--- The push rod top end ball cup is growing from R4 Þ R5.
--- The bracket structure and material is modified.
--- The rocker cover studs are shorter and the cover is tigh-
tened with hexagon screws.
As spare part the separate parts are not exhangeable. The

24--- 3 whole valve mechanism can be replaced with the new one to-
gether with the new push rods. The fastening parts do not
have to be modified.

B. Changing camshaft/camshaft gear Modification of the cam shaft
From engine no L 13188 all 620/ 634--- engines are equipped

1. Remove the inlet pipe between the turbocharger and the
with a cam shaft where the front end bearing location has no
induction manifold. Remove the valve cover and the breather
oil groove ( the bearing location is so called barrel shape).
pipe. Remove the rocker arm mechanism.
2. Remove the radiator, cooling fan, alternator and the v ---belt.
3. Remove the crankshaft nut. Remove the V ---belt pulley in-

cluding the hub (on 620---engines the belt pulley must be re- 30˚
moved first).
4. Remove the timing gear casing cover (engine front cover).
21--- 3/1
Note! The new cam shaft is not fitting together with any previ-
ous bushing. The new bushing is recognised from the posi-
tion of the oil drilling which is not at the same place as the oil
drilling of the cylinder block, 30˚ angle upwards from the hori-
zontal level.
24--- 6
5. Connect the pushrods in pairs, using o---rings or elastic

bands to prevent them from falling through.
Note! Do not connect the pushrods too tightly as this might

cause them to bend or snap.
6. Crank the engine until the aligning marks on the idler gear
and camshaft gear are facing each other. Extract the cam-
shaft.
7. Separate the camshaft from the gear wheel using a press

or suitable drift.
8. Clean the parts which are to be refitted.
9. Fit the key in its groove. Heat the camshaft gear to 200˚C
in an oven and fit it on the shaft.
10. Lubricate bearing surfaces and lobes and insert the shaft
in the cylinder block. Ensure that the aligning marks on the
gears agree.
11. Fit the timing gear casing cover and the crankshaft V ---belt
pulley and hub.
12. Free the pushrods and fit the rocker arm mechanism. Ad-
just the valves. Fit the valve cover and the breather pipe and
the inlet pipe between the turbocharger and the induction
manifold.
13. Fit the alternator. Fit the fan and the fan belt. Fit the radiator.

C. Adjusting valves 420 ---engines

--- Rotate the crankshaft in the running direction until the
valves in the 4th cylinder are rocking (exhaust closes, inlet
opens). Check the valve clearance of the 1st cylinder.
--- Rotate the crankshaft by 1/2 of a turn in the running direc-
tion so that valves in the 3rd cylinder are rocking. Check
0,35
valves in the 2nd cylinder.
--- Continue according to the order of injection:
Injection order 1 2 4 3
Valves rock in cyl. no. 4 3 1 2
620/634 ---engines
24--- 7
--- Rotate the crankshaft in the running direction until the val-
ves in the 6th cylinder are rocking (exhaust closes, inlet
The valve clearance, which can be adjusted on a hot or cold opens). Check the valve clearance of the 1st cylinder.
engine, is 0,35 mm for both inlet and exhaust valves. The --- Rotate the crankshaft by 1/3 of a turn in the running directi-
clearance is adjusted when the respective piston is at T.D.C. on so that valves in the 2nd cylinder are rocking. Check valves
in the compression stroke. The valves for the different cylin- in the 5th cylinder.
ders are adjusted in the same sequence as the order of injec- ---Continue according to the order of injection:
tion.
--- slacken the lock nut of the adjusting screw Injection order 1 5 3 6 2 4
--- measure clearance with a feeler gauge. The clearance is Valves rock in cyl. no. 6 2 4 1 5 3
correct when a 0,35 mm feeler gauge is slightly tight---fitted
between the rocker arm and the valve stem end. Adjust clear-
ance by rotating the adjusting screw.
--- tighten the locking nut and check the clearance
I P I P I P
320, 620, 634
I P I P I P I P
420 24--- 8
I = Inlet
P = Exhaust
320 ---engines
Check the valve clearances in the injection order of the en-
gine. Injection order is 1---2---3.
--- Check valves in the 1st cylinder, when the exhaust valve of
no. 3 cylinder is completely open (valve no. 6).
--- Check valves in the 2nd cylinder, when the exhaust valve
of no. 1 cylinder is completely open (valve no. 2).
--- Check valves in the 3rd cylinder, when the exhaust valve of
no. 2 cylinder is completely open (valve no. 4).

Crankshaft 5---1
5. CRANKSHAFT
A. Removing crankshaft
1. Remove the oil sump.
2. Disconnect the balancing unit lubricating oil pipe from the

cylinder block and unscrew the balancing unit fixing bolts. Re-
move the balancing unit and the lubricating oil pipe (only
420 ---engines).
3. Unscrew the lubricating oil pump pressure pipe fixing

screws from the cylinder block. Remove the oil pump and the
suction and pressure pipes.
25--- 2
4. Remove the flywheel and the flywheel housing.

4. If the bearing clearance exceeds 0,18 mm for main bear-
5. Detach the belt pulley/hub from the crankshaft front end ings or 0,14 mm for connecting rod big ---end bearings with
(see instr. timing gears). new bearing shells, the bearing journals on the crankshaft
should be ground. Refer to the specifications for the relevant
6. Remove the connecting rod bearing caps and push the correct undersize and the corresponding bearings, see
connecting rods out of the way of the crankshaft. technical data, point crankshaft. When grinding note that
the journal edges must remain round.
7. Remove the main bearing caps and lift out the crankshaft.
Note! If needed, also the main bearing can be fitted with outer
diameter 1,0 mm oversize and inner diameter 0,5 mm under-
B. Checking crankshaft size. Ordernumber is 8361 40950 (includes halfs 55593 and
55600). The main bearing housing is machined to
92,000...92,025 and crankshaft to 84,485...84,520.
1. Clean the crankshaft. Do not forget the oilways.
C. Changing crankshaft gears
9052 48800
25--- 1 25--- 3
2. Measure the journal wear in several points. Out---of ---round, 1. Apply puller for the crankshaft gears and pull off both gears.
taper or other wear must not exceed 0,03 mm.
2. Clean the seat on the crankshaft with, for example, a wire
3. Refit the bearing caps with new bearing shells and tighten brush.
them to the correct torque. Measure the I.D. with a dial gauge
which has been zeroed to the dimensions obtained in point 2. 3. Heat the new gears to 200˚ C. Tap them onto the shaft with
With this method the indicator shows the actual bearing clear- a suitable sleeve or soft drift. Note the position of the key and
ance. Measure in several points in case the worn bearing ensure that the aligning marks on the front gear are visible.
housing is not round. Leave it to cool.

Crankshaft 5---2
D. Changing crankshaft gear rim 2. Assembly the bearing with oilholes/groove (A) to the cylin-
der block and the bearing with no hole (B) to the bearing cap.
(420---engines only) Ensure that the bearing shell clamping claws fit into their
notches and that the shells to be fitted in the cylinder block
have a hole coinciding with the oil port.
20˚
3. Lubricate the bearing surfaces and fit the crankshaft. Fit the
crankshaft thrust bearings with the lubricating grooves facing
the crankshaft.
200 Nm
25--- 4
1. Mark the position of the gear rim on the shaft.

25--- 6
2. Heat the gear rim with a welding torch and drive it off using
a suitable drift.
4. Fit the main bearing caps according to their numbering
3. Heat the new gear rim to max. 250˚C. Fit the gear rim with (bearing lock in the block and in the cap are on the same side),
the chamfer facing the crankshaft flange, and with the teeth the rear with thrust bearings provided with guide lugs. Lubri-
according to markings or according to figure above. Tap the cate the bolts and tighten them to 200 Nm.
gear rim down and leave it to cool.
Note! The figure above shows a rear view of the crankshaft

and no 2 cylinder big end bearing journal. 0,10...0,35 mm
E. Fitting crankshaft
1. Clean the oilways, bearing shells and bearing locations.
Check that the crankshaft is clean.
B
A 25--- 7
5. Check that the crankshaft can rotate without binding. Check

the end float using a dial gauge. The correct end float is
0,10...0,35 mm. If the end float is too large, oversize thrust
bearings should be fitted.
Note! Bearing shells should never be reamed or machined in

any other way, nor should the sides of the bearing caps be
filed
25--- 5

Crankshaft 5---3
Note! 320---engines. Tightening torque of screws of crank- 3. Fix the new vibration damper/pulley on the crankshaft. Tap
shaft counterweight is 160 Nm. Apply locking fluid Loctite the timing indicator in its place and tighten the fixing screws
2701 on the screw threads. to a torque of 30 Nm.
Note! Vibration dampers (pulleys) delivered as spare parts do

F. Crankshaft hub piece not have injection timing mark. Make the marking on the new
damper in connection with installation.
4. Rotate the crankshaft until the piston of the 1st cylinder re-
aches its top dead centre. Drop cyl. no 1 inlet valve down
against the piston head. Set the dial gauge on top of the valve
stem end and zero it at the piston top dead centre. Then rotate
the crankshaft opposite to running direction until dial gauge
shows about 15 mm below TDC. After that rotate the crank-
shaft slowly to running direction until the dial gauge shows the
figure corresponding injection timing (see table below).
5. Mark the injection timing on the tip of indicator with an elec-

tric pen (do not tap).
Piston distance from top dead centre vs. crank angle

25--- 8
Grad 320, 420, 620 634

When fitting the hub piece to the crankshaft front end note the mm mm
correct position of the hub. (Engines with the timing mark on
the crankshaft pulley/vibration damper.) The hub piece has an 1˚ 0,012 0,013
installation mark --- on two teeth and the corresponding in- 2˚ 0,047 0,054
stallation mark · of the crankshaft is on one tooth. 3˚ 0,106 0,121
4˚ 0,188 0,216
5˚ 0,294 0,337
6˚ 0,423 0,485
G. Changing crankshaft pulley/vibra- 7˚ 0,576 0,660
tion damper 8˚
9˚
0,752
0,951
0,861
1,089
10˚ 1,173 1,344
11˚ 1,418 1,624
12˚ 1,686 1,931
13˚ 1,976 2,264
14˚ 2,289 2,623
15˚ 2,625 3,007
16˚ 2,983 3,417
17˚ 3,363 3,852
18˚ 3,765 4,312
19˚ 4,188 4,797
20˚ 4,633 5,307
21˚ 5,100 5,841
22˚ 5,587 6,399
23˚ 6,095 6,980
24˚ 6,624 7,585
25˚ 7,173 8,214
26˚ 7,742 8,865
27˚ 8,331 9,539
28˚ 8,939 10,235
29˚ 9,567 10,952
30˚ 10,213 11,692
25--- 9
1. Loosen the alternator fixing screws and remove the v ---belt.
2. Open the bolts of the pulley/vibration damper and remove

the parts. The pulley/vibration damper is positioned to the
crankshaft hub with a timing indicator (engines with timing
mark on the pulley/vibration damper).

Crankshaft 5---4
H. Checking element of the rubber I. Viscose type vibration damper

damper (620/420)
2
A 3
1
1,5
4
25--- 12
1. Housing
2. Damper mass
30 Nm 3. Liquid cavity
4. Bushing
In the 634---engines and some 620---engine versions there is

25--- 10
a vibration damper of so---called viscose type. Inside the
damper there is a housing filled with stiff silicone oil in where
the damping substance is situated with very small tolerances.
1. Check the alignment marks (A) on both sides of the rubber
element. If the difference is more than 1,5 mm, change the
Note! Even a small dent makes the vibration damper inoper-
damper for a new one.
ative. Do not remove it by turning forcibly and be careful not
to damage it when it is loose. If you detect a dent on the outer
surface, do not install the damper back in the engine.
Note! Mark the injection timing on the vibration damper with

an electric pen (do not tap).
25--- 11
2. Check also the condition of the rubber element. If rubber

pieces have been loosened from the element, rubber has
been pressed to the depth of more than 3,5 mm or the outer
circumference is slack or it moves in the direction of the shaft,
change the damper.
Note! Vibration damper should be replaced every 4000

running hours!

Connecting Rods and Pistons 6---1
6. CONNECTING RODS AND

PISTONS
A. Removing pistons together with 5

connecting rods 40,025...
40,040
1. Remove the oil sump and the oil inlet and pressure pipes.
2. Remove the cylinder head.
3. Scrape off the possible soot in the cylinder liner. If the turn-
ing edge is clearly marked, smooth it down carefully with a
scraper.
4. Remove the big ---end bearing caps and bearing shells.

Place the shells in order if they are to be re ---used.
26--- 2
5. Push up the piston and connecting rod with the shaft of a

hammer or similar wooden tool. 4. Press the new bush in its place. Ensure that the oil hole in
the bush coincides with the respective hole in the connecting
6. Remove the piston pin snap rings. Push out the pin. rod. After fitting drill Æ 5 mm oil hole and ream the bush to at-
tain its correct diameter.
Note! If the piston pin does not move under thumb pressure
the piston should be heated to 100˚C. Note! The connecting rod can, if needed, be fitted with a 0,5
mm oversize bushing (8353 28326). See technical data, point
connecting rod.
B. Changing connecting rod bear-
ings Big end bearing
1. Fit the bearing shells together and tighten the screws.

Piston pin bushing
2. Measure the I.D. using a cylinder gauge which has been
1. Clean the connecting rod and bearing shells.
zeroed to the diameter of the respective bearing journal. If the
clearance exceeds 0,14 mm with new bearing shells, the big
end journals require grinding. Refer to the specifications for
the correct undersize and the corresponding bearing. Ensure
that the radii at the end of the bearing journals is not altered
when grinding.
C. Checking connecting rod
The connecting rod is checked in a special fixture, intended

for the purpose (e.g. Carl Larsson). See technical data, point
connecting rod.
Note! If the connecting rod is damaged so that it has to be

changed, please note the following:
--- The earlier used connecting rod is replaced in production

with a new type from engine number L 11212. In the new con-
necting rod the big end is split by the breaking technique.
26--- 1/1
--- Single connecting rods are not interchangeable. As spare

part the new connecting rod replaces the earlier only by
2. Measure the I.D. of the piston pin bushing using a cylinder
changing the whole set.
gauge.
3. If the piston pin bushing is worn, it should be driven out

using a suitable drift.

Earlier used connecting rod New connecting rod from engine number L 11212
40 Nm + 90˚ Torx E18

max. 86,50
40 Nm + 90˚
Measure the length of the connecting rod screws. The length Note! Always change the screws when opened.
should be max 86,50 mm. If the screw is longer, change it with
a new one. It is recommended that the screws are always The connecting rods are divided into weight classes with inter-
changed when they are unscrewed. vals of 20 g. The weight class (a letter) is stamped on the side
face of the connecting rod. All the connecting rods in one en-
The connecting rods are divided into weight classes with inter- gine should be of the same weight class, that is to say the
vals of 20 g. The weight class (a letter) is stamped on the side greatest permissible weight difference is 20 g.
face of the connecting rod. All the connecting rods in one en-
gine should be of the same weight class, that is to say the The letters show the weight classes as follows:
greatest permissible weight difference is 20 g.
Letter Part no. Weight
The letters show the weight classes as follows:
F 8366 66430 1935---1954 g
Letter Part no. Weight V 8366 66431 1955---1974 g
X 8366 66432 1975---1994 g
X 8366 47460 2150---2169 g Y 8366 66433 1995---2014 g
A 8366 52104 2170---2189 g W 8366 66434 2015---2034 g
B 8366 52105 2190---2209 g Z 8366 66435 2035---2054 g
C 8366 52106 2210---2229 g G 8366 66436 2055---2074 g
D 8366 52107 2230---2249 g
E 8366 52108 2250---2269 g

H 8366 52109 2270---2289 g
I 8366 52110 2290---2309 g
J 8366 52111 2310---2329 g
K 8366 52112 2330---2349 g
L 8366 52113 2350---2369 g

M 8366 52114 2370---2389 g
N 8366 52115 2390---2409 g
O 8366 52116 2410---2429 g
P 8366 52117 2430---2449 g
R 8366 52118 2450---2469 g

S 8366 52119 2470---2489 g
T 8366 52120 2490---2509 g
U 8366 52121 2510---2529 g

D. Changing piston rings 4. Fit the piston rings on the piston using the piston ring pliers.
Ensure that the rings are fitted in the correct groove and that
”TOP”, or the manufacturer’s designation, faces upwards.
1. Remove the piston rings with piston ring pliers 9052 46900.
Do not open the rings more than necessary. If the rings are to
be used again ensure that they are fitted in the same groove.
26--- 9
26--- 11
2. Clean the piston ring grooves and measure the piston ring
clearance, which must not exceed 0,15 mm. Determine
whether too large a clearance is due to worn rings or a worn
groove. Change worn parts.
E. Checking pistons
Check the condition of the pistons and piston pins. Pay
special attention to possible cracks on the edge of the com-
bustion chamber and on the upper edge of the piston pin
hole. Measure the diameter of the piston at the point shown
in the figure below. Renew a piston if needed.
320, 420,
634: 620:
26--- 10 26--- 12
3. Measure the piston ring gap by pushing one piston ring at

a time into the cylinder bore. The piston ring gap must not ex-
ceed 1 mm on 1. and 3. piston rings and 1,5 mm on 2. piston
ring.

F. Fitting piston pin G. Fitting piston together with con-

necting rod.
1. Place the connecting rod inside the piston and push the pis-
ton pin into place.
1. Check that the bearing locations are clean and place the
Earlier used connecting rod bearing shells in the connecting rod and bearing cap. Note
the position of the bearing shells.
2. Lubricate piston, rings and cylinder bore. Ensure that the

piston ring gaps are spread around the piston.
9020 01100
26--- 13
The combustion chamber and the weight class letter should

be on opposite sides.
New connecting rod
26--- 14
3. Use a piston ring strap or preferably a fitting tool. Fit the pis-
ton with the marking on the connecting rod (weight class)
facing the camshaft (an arrow on the piston must point for-
ward).
4. Lubricate the big ---end bearing journal and bearing shells,

and push the piston down. Fit the bearing cap so that the
notches for the guide lugs are in the same side. Tighten the
connecting rod screws to 40 Nm+90˚.
5. Check that the connecting rod has sufficient end float on the
big ---end bearing journal.
26--- 13/1
The combustion chamber and the weight class letter should

be on same side.
2. Fit the piston pin circlips. Ensure the the circlips are pressed
correctly into the grooves. The circlip ends must point up-
wards.

Counterbalance 7---1
7. COUNTERBALANCE (420)
A. Removing and disassembling

counterbalance unit
1. Remove the oil sump
2. Disconnect the lubricating oil pipe of the counterbalance

unit.
3. Remove the counterbalance unit. Take care of any shims.
4. Loosen the locking screws and press out the shafts in the
direction of the locking screws. Remove the counterweights
and thrust washers. 0,1...0,5 mm
5. Clean all parts.
B. Reconditioning counterbalance 27--- 2
unit
4. Check that the tooth backlash is 0,05...0,25 mm and that
the end float is 0,1...0,5 mm
Check the shafts, gear wheels and bushings for wear and
damage.
1. If one of the gear wheels is damaged, change both counter

C. Fitting counterbalance unit
weights as a complete unit. The gear wheels are not available
separately as a spare part. 1. Fit the tension pins to the cylinder block.
2. Remove, if necessary, the old bearing bushings with a suit-

able drift. Before removing them, mark the position of the
bushing oil groove on the counter weigh. Press in new bush-
ings in the correct position. After fitting the bushings should
be reamed to a correct dimension, see Specifications.
27--- 3
2. Turn the crankshaft and weights so that the markings agree,

and lift the unit into place.
3. Tighten the bolts to 60 Nm. Check that the tooth backlash

between the crankshaft and counterweight is 0,1...0,3 mm.
27--- 1
The backlash can be increased by placing shims 0,2 mm thick
(order no 8361 19920) between the cylinder block and ba-
1. Synchronisation marking (notch) lancer unit body. One shim (0,2 mm) changes tooth backlash
2. Marking against crankshaft (punch mark) about 0,07 mm.
4. Fit the lubricating oil pipe, using new seals.

3. Place the weights in the body, observing the notch mark-
ings. The gear wheel with the punch mark runs against the 5. Fit the oil sump.
crankshaft and should therefore be placed highest. Insert the
shafts, remembering the thrust bearings. Apply thread lock
fluid Loctite 270 to the locking screws, and lock the shafts.

Flywheel 8---1
8. FLYWHEEL Note! E ---engine’s flywheel delivered as spare parts do not

have injection register mark. Make the marking on the new
flywheel in connection with installation.
A. Changing starter ring gear on fly- --- Rotate the crankshaft until the piston of the 1st cylinder re-
wheel aches its top dead centre. Drop cyl. no 1 inlet valve down
against the piston head. Set the dial gauge on top of the valve
If the ring gear is worn, change it with a new one. The ring stem end and zero it at the piston top dead centre. After that
gear cannot be turned around because its teeth are cham- rotate the crankshaft slowly to running direction until the dial
fered and hardened on the starter motor side. gauge shows 4,633 mm ATDC (420, 620) or 5,307 mm ATDC
(634).
1. Remove the old starter ring by tapping it at various points
with a drift. Clean the flywheel contact face with a steel---wire --- Bore the injection register mark hole by a drill (see picture
brush. below) to the flywheel.
28--- 1
2. Warm the ring gear to the temperature of 150...200˚C. Fit

the ring gear with the inner diameter chamfering turned
against the flywheel and the teeth chamfering against the
starter motor.
3. Allow the ring gear to cool freely without using any coolant.
B. Fitting flywheel
Note! In E ---engines the injection register mark is marked on
the flywheel. The flywheel has been positioned to the crank-
shaft with aid of quide sleeve.
1. Clean the contact surfaces on the crankshaft rear flange

and on the flywheel.
2. Fasten the flywheel to the crankshaft rear end. As a guide

pins can be used studs (M12, 2 pcs) which are screwed in to
the flywheel fixing bolt holes. The position of the flywheel is
free in engines where the injection timing is marked on the
crankshaft front end. In some engine versions one of the re-
taining screws have been replaced by a guide pin to deter-
mine the crankshaft position.
3. Tighten the flywheel retaining screws evenly to a torque of

140 Nm (10.9) / 150 Nm (12.9).

Timing Gear Assembly 9---1
9. TIMING GEAR ASSEMBLY 7. Unscrew the idler gear bolts (17 and 22 mm). Remove the
flange, gear wheel and bearing journal.
8. Extract the camshaft.

A. Removing timing gear casing
Note! If the cylinder head and valve mechanism have not
been removed, the tappets must be prevented from falling
As the timing gear casing bottom face forms a part of the mat-
down, see instruction point 4 B.
ing face for the oil sump gasket, the casing cannot be re-
moved without first removing the oil sump. 9. Remove the timing gear casing. Ensure that all sealing sur-
faces are not damaged.
1. Remove the oil sump.
10. Remove the crankshaft front sealing ring from the front
2. Remove the radiator, fan, alternator, belt tensioning and belt casing and clean all the parts that have been removed.
(if not removed earlier). If the engine is equipped with a air
compressor or air conditioner, it has to be removed.
B. Reconditioning idler gear

If the idler gear bushing is changed, press in a new bushing
so that its rear edge is 0,1...0,25 mm inside the gear wheel
rear edge (see picture on next page).
1
2
9101 65700 29--- 1
3. Loosen the crankshaft nut (special tool 9101 65700 for 320,
420, 620---engines and tool 9024 55800 for 634 engines) and
remove the belt pulley/hub. 29--- 2
Note! On 620---engines the belt pulley must be removed be-

fore unscrewing the nut. If the 620---engine is equipped with 1. Chuck of lathe
a viscose damper, the front end nut is opened with tool 9024 2. Roller ø=5 mm
55800.
4. Remove the drive unit and hydraulic pump (if installed).

Machine the idler gear bushing inner diameter to a correct di-
5. Remove the timing gear casing cover and the oil deflector mension after fitting. Centre the idler gear according to figure
ring at the front end of the crankshaft. above so that tooth backlash is kept the same.
6. Remove the injection pump.
Note! If the timing gear casing is not to be changed, the injec-

tion pump can remain in place. In which case disconnect all
leads and pipes from the pump.

29--- 4
4. Fit the idler gear with shaft stud and ensure that the mark-
ings are in the correct position. Fit the washer and tighten the
bolts to the correct torque.
29--- 3
C. Fitting timing gear casing

29--- 5
The position of the timing gear casing and cover is deter-
mined by two tension pins. Therefore centring should not be
undertaken in connection with fitting. However, the tooth
backlash between the different gears should be checked. 5. Check the tooth backlash which should be 0,05...0,25 mm.
Casing and covers that are delivered as spare parts also have
holes for the tension pins already machined.
1. Fit the casing with a new gasket against the cylinder block.
Drive in the tension pins with drift 9025 98700. Tighten bolts
and nuts.
2. Fit the injection pump together with gear wheel (if re-
moved).
3. Lubricate the camshaft bearings and insert the shaft in the

cylinder block. Release the pushrods and tappets if they have
been suspended.

9025 98700
9025 98800
29--- 6
9025 98900
6. Fit the oil deflector ring on the crankshaft and fit the timing
gear casing cover using a new gasket. Drive in the tension
pins with drifts 9025 98700 and 9025 98800 respectively (the
tubular pin round the screw stud). Tighten bolts and nuts.
29--- 8
8. Fit the dust shield on the crankshaft V ---belt pulley hub, if it

has been removed. Use drift 9025 98900.
9030 15200
29--- 7
7. Fit the protective plate into the seal location and fit the 600 Nm (320, 420)
crankshaft front seal with special tool 9030 15200. 1000 Nm (620, 634)
29--- 9
9. Lubricate both the seal and sealing surfaces and fit the
crankshaft V ---belt pulley with hub.
10. Lubricate the crankshaft nut threads. Tighten the nut to

600 Nm on 320--- and 420---engines and 1000 Nm on 620 and
634 engines.
11. Fit the other detached parts.

D. Idler gear with bevelled ball bear-

ings
1 2 3 4
1. Camshaft gear
2. Idler gear
3. Injection pump gear
4. Hydraulic pump gear
5. Crankshaft gears
6. Oil pump gear
7. Idler gear of compressor
8. Compressor gear
7
5
29--- 10 6
In some 620/634---engines versions bevelled ball bearings

are need in the idler gear. The two---cylinder compressor,
fitted to the gear housing, is run trough a separate rear.
30 Nm
22 Nm
29--- 12
2. If the compressor gear shaft has been removed, apply on

180 Nm its outer face Loctite 601 and hit the shaft in its position so that
the shaft and gear housing back surfaces are at the same
level. Fit the bearing and the gear so that the groove of the
bearing inside ring comes outwards. Remember the lock
rings! Fit the retaining ring and tighten the screws to 30 Nm.
29--- 11
1. Fit the idler gear bearings, as the picture shows, pressing

from the outer ring. Fit the holding ring and tight the bolts,
lightly oiled, to 22 Nm. Press the shaft to its position support-
ing the bearing from the inner ring. The idler gear screw tight-
ness is 180 Nm.
29--- 13
3. Note when assembling the camshaft, the timing mark that

differs from the other engines.

E. Power take---off
In the 20/34---series engines is used a transmission that can
be equipped with a P.T.O. run from the camshaft gear. The
P.T.O. can run e.g. a hydraulic pump.
29--- 14
Note when assembling the P.T.O. the front bearing seal posi-
tion.
Use molybdenite ---sulphide (MoS2) ball bearing grease

(NLGI 2) for the grooves of the hydraulic pump shaft and the
coupling sleeve.
Note! Some P.T.O. are equipped with on outer lubricating

possibility (pipe). In this case the front bearing is not sealed
(like in picture). This P.T.O. is known from the M6x1 thread in
the cover.

Lubrication System 10---1
10. LUBRICATION SYSTEM

Loctite 638
A. Reconditioning of oil relief valve
for lubricating oil pressure
If the engine lubricating oil pressure is insufficient or if it varies,
the relief valve should be checked after first checking the oil
level.
210--- 1/1
B. Removing and dismantling lubri-

cating oil pump
1. Drain the engine oil and remove the oil sump.
210--- 1 2. Remove the oil pump suction and pressure pipe.
1. Remove the cover over the valve and spring. Take care of 3. Remove the oil pump together with any shims between the
the washer between the cover and spring. Remove the valve pump and the cylinder block.
insert together with the valve cone and ensure that the o---ring
is also removed. 4. Remove the pump cover and the gasket. Remove the gear
on the dead axle.
2. Clean the parts and check that the valve cone slides freely
in the insert and that the sealing surface are undamaged. Mi- 5. Clamp the pump gear across the teeth in a vice fitted with
nor damage can be adjusted, but in general, damaged parts soft jaws, and loosen the drive gear nut. Knock the gear wheel
should be changed. Scrape off any remains of the gasket. off by hitting the end of the shaft with a soft hammer. Pull out
the drive shaft---gear wheel
3. Assemble the valve with a new o---ring and insert it in the
cylinder block. Place the washer and spring in the cover and 6. Clean the parts and check for wear and other damage.
fit it with a new gasket. Compare with the specifications. Change damaged parts and
all seals.
210--- 2
4. Note that the relief valve cover is not symmetrical. The

greater distance between the spring housing and bolt should
be turned downwards.
60 Nm
Note!
From engine no. J 7595 (engines without oil cooled piston)
From engine no. J 14016 (engines with oil cooled piston) 210--- 3
The engines are equipped with a new type of oil pressure

7. On 620/634---engines the bearing points are provided with
valve. In the construction of the new valve the hydraulic vibra-
separate bearing bushings. If You change the bushings, ma-
tions are damped, it is more reliable and it gives the best, opti-
chine them to dimension of 18,000...18,018 after fitting.
mised pressure level.

Note!
320---engines from engine number C 1474
The connection between the gear and shaft in the lubrication

oil pump has been modified to a conical connection without
key.
The new gear and shaft/gear combination can be used as a

pair in pumps of earlier type.
210--- 5
3. Fasten the oil pump in a vice and check the end float be-
tween gear and pump housing. The clearance which should
be 0,03...0,11 mm, is adjusted by the number of gaskets be-
tween the cover and body.
210--- 4
1. Gear
2. Shaft/gear
Note!
620/634 engines from engine number J 7891.
As a part of the standardization process all 6---cyl. engines are

now fitted with the same oil pump. The pump 8368 52607 in
620 engines and 8363 38187 in 634 engines has been re-
placed with 8368 55300.
210--- 6
The new pump can be used also in older 6---cyl. engines,
when suction and pressure pipes are replaced as well (loca-
tion of pipe connection is different in respect to crankshaft 4. Fit the pump and check the tooth backlash against the
center line). crankshaft gear. The clearance, which should be 0,05...0,25
mm, is adjusted with shims between the pump body and the
cylinder block (shim 0,2 mm, order no 8360 07871). One shim
C. Assembling and fitting lubricating increases/decreases the backlash about 0,07 mm.
oil pump Note! When measuring the tooth backlash, the engine should
be the correct way up as the crankshaft bearing clearance af-
1. Fit the gear wheels in the pump body. Fit the cover using fects the tooth backlash.
a new gasket. Partly tighten the bolts. Rotate the pump shaft
and tap the side of the cover lightly until the position is reached 5. Connect suction and pressure pipes together with new
where the shaft rotates most freely. Tighten the bolts and seals. Fit the oil sump and fill in the lubrication oil.
check that the shaft still rotates freely.
2. Fit the key and drive gear onto the shaft (tapered joint with-
out key on the later pumps). Apply Loctite 242 onto the nut
threads and tighten the nut to 60 Nm. Remember the washer
under the nut.

D. Fitting oil sump gasket F. Piston cooling nozzles (620/634)
Fit the oil sump gasket with the silicone stripes against the cyl- The cooling nozzles can be removed after removing the oil
inder block (self carrying and casted oil sumps). sump. The nozzles have a ball valve with an opening pressure
of 3±0,25 bar.
210--- 7
E. Lubricating oil cooler
Some engines are equipped with a oil cooler, positioned in 210--- 9
between the oil filter and the cylinder block.

1. Change the valve if necessary. Detach the valve from the
engine and remove the nozzle pipe. Fit a new valve.
1. The engine coolant should be drained before removing the
lubricating oil cooler.
90˚
60 Nm
210--- 10
210--- 8
2. Fit the nozzle pipe at the angle of 90˚ to the centre line of
the crankshaft according to the above picture. Tighten the val-
2. Fit new sealing rings. Fit the cooler with draining plug tur-
ve to 30 Nm. Ensure that the pipe does not touch the pistons
ned downwards. Connect coolant pipes in the correct way.
or connecting rods when the engine is running.
3. Apply locking fluid to the nipple (the thread which attaches
to the filter head) and tighten it to a torque of 60 Nm.

G. Lubricating oil quality requirements
--- Naturally aspirated and turbocharged engines API CF ---4, CG ---4, CH---4 ACEA E2/E3 ---96, E4 ---98, E5 ---99
--- Low emission (E) engines API CG ---4, CH---4 ACEA E3 ---96, E4 ---98, E5 ---99
TEMPERATURE ˚C
---40 ---30 ---20 ---10 0 +10 +20 +30 +40
5W---30
5W---40
SAE---GRADE
10W---30
10W---40
15W---40
20W---20
20W---40
30
210--- 11

Cooling System 11---1
11. COOLING SYSTEM
A. Thermostat
211--- 3
The rubber seal ring between the coolant pump and the ther-
mostat housing has been modified to two o---ring seals.
211--- 1 At the same time also the by ---pass pipe is modified. The new
parts can, during a repair, be installed instead of the earlier
The thermostat is of a two---way type. Its opening temperature used.
is 79˚C. In winter a thermostat can be used with an opening
temperature of 83˚C.
Check the function of the thermostat as follows:

B. Reconditioning coolant pump
(320, 420)
--- Lower the thermostat into a vessel of boiling water so that
the thermostat does not touch the sides or bottom.
--- Opening must begin under 20 seconds. 1. Drain the engine coolant. Disconnect the water hoses from
--- The thermostat must be fully open under 50 seconds. the thermostat housing and from the coolant pump. Remove
Stroke, see specifications point thermostat. the thermostat housing and the by ---pass pipe.
2. Slacken the alternator fixing bolts. Remove the fan and the
pump belt pulley. Remove the v ---belt.
3. Detach the coolant pump. Remove the pump rear plate and
clean the sealing surfaces.
9052 48900
211--- 2
Some 620/634---engines have two separate thermostats.

These are separated from the type of the single thermostat
and they are not interchangeable. To these engine there are
no separate winter thermostats.
211--- 4
Note! Modification of the by ---pass pipe.
320/420---engines from engine number D 3056 4. Remove the fan hub using puller 9052 48900. Remove the
620---engines from engine number D 3532 circlip from the pump body.

178,5 mm
9104 27700 174,5 mm

320 E 7536>
420 E 7055>
1,8...2,2 mm
320
420
211--- 5
5. Remove the impeller using puller 9104 27700. Press the

shaft out of the pump body in the direction of the fan. Use a
hydraulic press. Support the body so that the shaft bearing
unit has enough space for releasing.
211--- 7
6. Tap out the axial seal in the body using a suitable drift.
Clean all parts and inspect their condition. Replace damaged
parts with new ones. 9. Press the impeller and the hub to the correct depth (see fig-
ure) and support the shaft at the other end. Ensure that the
Note! If the pump shaft has to be changed, use a recondition- shaft can rotate freely. Fit the rear plate using a new gasket.
ing kit. This kit also contains all seals (see Parts Catalogue).
7. Press the shaft into its location in the body using special tool C. Reconditioning coolant pump
9051 64900 and fit the circlip.
(Separate ball bearings 320, 420, 620, 634)
1. Drain the coolant. Remove the thermostat housing, fan and

the v ---belt.
2. Remove the coolant pump. Detach the pump rear plate and
clean the sealing surfaces.
3. Unscrew the belt pulley fixing nut and remove the belt
pulley. Use puller 9052 48900 if needed.
9104 27700
9101 93200
9051 40200
9051 79300
211--- 8
8353 39425 8353 31202 211--- 6
4. Remove the impeller on the shaft with puller 9104 27700

8. Fit the axial seal. Use as a ”lubricating liquid” coolant be- (320/420---engines) or 9101 93200 (620/634---engines).
tween the shaft and the seal. Two different seal types are
used. Both these seals are fitted with their own drift (see figure 5. Remove the circlip in the pump body. Press the shaft to-
above). gether with bearings in the direction of the fan. Use e.g. a hy-
draulic press. Support the pump body so that the bearings
have enough space for releasing.

6. Tap out axial and shaft seals using a drift. Clean the parts 11. Fit the rear plate using new seals. Use in 620/634---en-
and inspect their condition. Replace faulty or worn parts with gines guide pins (ø8,5 mm) in the holes shown with arrows in
new ones. the picture 211---10.
Note! If the pump bearings have to be changed, use a re-

conditioning kit. This kit also contains all seals (see Parts Cata- Note! Some 320/420---engines are equipped with a new type
logue). of coolant pump, where the diameter of impeller has changed
87 > 97 mm. The reconditioning of this pump is done accord-
7. Drive in the new shaft seal in the housing using a suitable ing to the instruction in part C.
drift. Put the bearings and the intermediate sleeve onto the
shaft. Grease bearings with heat---resistant ball bearing
grease. Fit the shaft and the bearings in such a way that the
pressing force is not transmitted by the bearing balls. Fit the
circlip for the bearing.
8. Fit the axial seal, see instruction 11 B point 8.
9,0...9,3 mm
1,8...2,2 mm
80 Nm
120 Nm
211--- 9/1
Note specially the left hand thread of belt pulley fixing bolt and
the measuring point of position of impeller.
211--- 9
9. Press the impeller into position while, at the same time, sup-
porting the shaft at the other end. The mounting depth of the
impeller is in 320/420---engines 1,8...2,2 mm and in
620/634---engines 0,8...1,2 mm (see figure above). Make
sure that the shaft can rotate freely.
10. Fit the belt pulley and tighten its attaching nut to a torque
of 120 Nm.
Loctite 572 211--- 9/2
If the rear plate is removed, fit the rear plate to the cylinder
block. Apply sealing compound to the thread of screw, see
picture above.
211--- 10

D. Coolant pumps with heavy---duty

bearings (620, 634)
Some versions of 620/634---engines have a heavy ---duty

bearings in the coolant pump. The reconditioning of this
pump is done according to the instruction in part C. Note
specially the position of the front bearing as assembling.
0,8...1,2 mm
120 Nm
211--- 11
E. Quality requirements of coolant

The coolant used must meet the standards ASTM D 3306 or
BS 6580:1992.
--- Mixing proportion should be 40---60 % of ethylene/propy-

lene ---glycol based coolant and the rest water. The best ratio
is 50/50 %.
--- In warm climates the 30 % mixture ratio gives enough good

protection against corrosion.
--- Water used should be clean and soft water i.e. that it does
not include metals and their salts.
--- Check the coolant frost resistance every now and then.
Change the coolant every other year.
Note! Never use only water as coolant!

Inlet and Exhaust System 12---1
12. INLET AND EXHAUST SYS- C. Checking turbocharger

TEM
If a fault is suspected in the turbocharger it can be located in
the following way:
An engine that is equipped with a turbocharger is a great deal
more sensitive to disturbances and impurities in the inlet and 1. Visually inspect the turbine and compressor wheels. The
exhaust systems than a naturally aspirated engine. Therefore vanes must not show any signs of damage, deformation or
special attention should be given to the whole inlet and ex- wear caused by foreign objects.
haust system.
2. Investigate any oil leaks through the sealing rings on the
shaft in the turbine and compressor housing.
A. Checking air cleaner
Note! At low idling there is always a certain amount of oil leak-
age on the compressor side. However, this should not cause
The engine performance and length of service life depend to
too much concern unless the oil consumption is too great.
a great extent on the state of the air cleaner. A defective air
cleaner allows impurities to pass through, which in time dam-
age the turbocharger and the engine. A blocked air cleaner
lowers the engine output and also causes oil leakage through
the sealing ring on the turbocharger shaft.
Note! The safety filter inside the main filter should not be re-
moved unnecessarily, for checking or cleaning. The safety
filter must not be cleaned, but should be changed once a year
or when necessary (see Operator’s Manual)
B. Checking inlet and exhaust pipes

Important! Leaks in the inlet or exhaust system markedly
lower the effect of the turbocharger. Because of the pressure,
even small leaks in the manifold or in the turbine inlet contact
flange quickly increase in size. For this reason all leaks must
be dealt with immediately.
1. Inspect the pipes and sealing surfaces between the air 212--- 1
cleaner and the turbocharger, as well as between the turbo-
charger and the intake manifold. If the intake manifold is dusty 3. Check the turbine shaft running clearance. Place the stylus
on the inside, there is a leak in either the air cleaner or the inlet of a dial gauge against the shaft and move the shaft sideways.
pipes. Remedy the leak. refer to the clearance given in the specifications on page
0 ---12.
2. Clean the intake manifold sealing surface. Check that the
sealing surface is flat using a straight ruler. If the surface is not
flat or it has scratches, machine or renew the intake manifold.
On 620/634---engines ensure that the cylinder heads are par-
allel.
3. Fit a new gasket and fasten the intake manifold. Tighten the
manifold fixing screws to a torque of 30 Nm. Fasten the air
pipes carefully.
4. Check that the exhaust manifold is air tight. Tighten the

nuts/bolts to 50 Nm and inspect for any damage (cracks, de-
formation, corrosion etc.). Check also the connection be-
tween the turbocharger and the exhaust manifold.
5. Remove the manifold if necessary. Clean the sealing sur-

faces and remove any carbon deposits. Check that the seal-
ing surfaces are flat. If the fastening flanges are twisted or
there are scratches on the sealing surfaces, machine the 212--- 2
flanges or renew the exhaust manifold.
4. Check the shaft end float. Place the stylus of the dial gauge
6. Ensure that no loose objects or impurities have entered the against the end of the shaft and move the shaft axially. Refer
exhaust pipe or the silencer. Any such loose objects or impu- to the clearance given in the specifications on page 0 ---12.
rities can increase the back pressure for the exhaust gases
from the turbine wheel.

Inlet and Exhaust System 12---2
If any defects or wear are confirmed, the turbocharger should

be reconditioned.
If the engine does not work correctly and the turbocharger is

not defective or too worn, the fault could be traced to one of
the following items:
--- Blocked air filter

--- Leakage in the inlet or exhaust systems. Leaking flange
seal
--- Defective or wrongly adjusted injection pump.
--- Wrongly adjusted throttle linkage
--- Defective or wrongly adjusted injectors
--- Low fuel pressure (e.g. blocked fuel filter)
--- Low compression, wrong valve clearance
6
4
3
Turbocharger Schwitzer S1A
1. Compressor cover
2. Lock nut
3. Compressor wheel
4. Bearing housing
5. Journal bearings
6. Turbine housing
7 7. Shaft and turbine wheel
1 2
5
212--- 3
D. Fitting turbocharger
Locate the cause of the defects on the turbocharger. Remedy 3. Connect the inlet pipe and the exhaust pipe on the turbo.
the fault before fitting the new turbocharger.
4. Pour clean engine oil into the bearing housing through the
In order for the turbocharger to work satisfactorily, it is import- inlet oilway. This is very important in order to ensure that the
ant that the engine oil is in good condition. Likewise the oil turbocharger is lubricated at the time of starting.
should be to the correct quality specification. The air filter and
oil filter should be serviced according to the handbook specifi- 5. Connect the pressure and return oil pipes. Use a new seal.
cation. Check that there are no tensions in the pipes when tightening.
The setting of the injection pump critically affects the function 6. Before starting, pull out the stop control and crank the en-
of the turbocharger. The injection pump should be adjusted gine over with the starter motor so that the oil pressure rises.
according to the manufacturers instructions. Start the engine and check that there are no leaks.
1. Check the tightness of the intake and exhaust manifolds,

and that they are securely fastened. Ensure that there are no
loose carbon or rust particles, or other foreign objects in the
manifolds.
2. Connect the turbocharger to the exhaust manifold and

tighten down using a new gasket.

Fuel System 13---1
13. FUEL SYSTEM
IN---LINE FUEL INJECTION PUMP

Note! This manual gives only general instructions for repair
and service measures related to the fuel system. This applies
particularly to the injection pump which can be repaired only
by a specially trained person who has the necessary special
tools and gauges. All service and repair work related to the
fuel system requires special care and cleanliness!
TECHNICAL DATA
Injection pump Bosch-- A/Bosch-- P
Type (pump/governor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bosch PES_A/RSV (PES6P/RSV)

Injection order:
--- 320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---2---3
--- 420 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---2---4---3
--- 620, 634 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---5---3---6---2---4
Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . clockwise
Diameter of pump piston:
--- Bosch ---A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9,5 mm
--- Bosch ---P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 mm
Stroke:
--- Bosch ---A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 mm
--- Bosch ---P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 mm
Injection advance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see injection pump adjusting values
Oil fillings 1):

--- 320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,3 l
--- 420 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,4 l
--- 620/634 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,6 l
1) When fitting fuel injection pump.
Fuel feed pump
Type:
--- 320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bosch FP/KSG 24 AD 207
--- 420, 620, 634 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bosch FP/KEG 24 AD 504
Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . piston pump, separate hand pump
Fuel feed pressure (overflow valve opening pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,7---1,2 bar (70---120 kPa)
Pressure from fuel feed pump (without overflow valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,7 bar (270 kPa)
Injectors
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . five hole nozzle

Opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see page 14---10
Sealing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8999 01495
Tightening torques
Injection pump gear nut:

--- Bosch ---A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Nm
--- Bosch ---P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 Nm
Overflow valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm
Injector nozzle sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm
Injector attaching nuts (on studs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Nm

Fuel System 13---2
7a
7b
8
4
5 1
3 2
1. Fuel tank 213--- 1
2. Prefilter
3. Fuel feed pump
4. Fuel filter
Fuel system, description 5. Fuel injection pump
6. Injector
7a. Thermostart fuel reservoir
Fuel feed pump (3) draws fuel from tank (1) through pre-
7b. Magnetic valve
filter (2) and forces it through filter (4) to fuel injection pump
8. Glow plug
(5). The fuel injection pump pumps fuel at high pressure
9. Overflow valve
through the delivery pipes to injectors (6) which inject the
fuel in the form of a fine mist into the combustion chamber.
The fuel system is often equipped with the Thermostart de-

Symptoms of dirty or faulty injectors are:
vice to be used in cold conditions. The glow plug (8) re-
ceives fuel from a separate reservoir (7a) of the thermostart
--- Knocking is an indication that one of the injectors is
device or from the overflow valve (9) of the injection pump
faulty. When a cold engine ticks over a certain amount of
regulated by the magnetic valve (7b). Excess fuel returns
knocking is unavoidable. If the engine knocks after it has
from the fuel injection pump through overflow valve (9) to
reached normal operating temperature, it is very likely that
the fuel tank.
one of the injectors is faulty. Air in the fuel system can also
cause knocking (which should disappear after the system
has been bled of air).
--- Smoky exhaust gases may indicate impaired perform-
ance of the injectors. However, this can also be caused by
other faults such as a blocked air cleaner.
The fuel system should always be bled when the fuel sys-
tem has been emptied (e.g. the fuel tank has been emptied
during driving, in connection with maintenance or repair
work or after a long idle period).

Fuel System 13---3
Bosch ---P injection pump 1

10 2
1. Boost control
2. Cold start solenoid
3. Speed lever
4. Injection timing indicator
5. Lube oil into the injection pump 3
6. Hand pump
7. O ---ring seal
8. Return of lube oil to engine
9. Identification plate
9
10. Overflow valve
8 4
5
Bosch ---A injection pump
1
6
7
8
2 1. Oil filler plug

2. Speed lever
3. Hand pump
4. Lube oil into the injection pump
7 5. O ---ring seal
6b 6a. Return of lube oil to engine
6b. Alternative oil return to engine
(e.g. aggregate application)
6a 7. Drive gear
3
1
4
5
The injection pump is an in ---line pump and the basic con- 2

struction is the same in all engines irrespective of the cylinder
number. The fuel injection pump is flange mounted and
sealed by one o---ring in the timing gear casing. The injection
pump is driven from the crankshaft through an idler gear. The
injection pump is connected to the engine force ---feed lu- 3
brication system through an external pipe. Lubricating oil re-
turns to the engine via the hole at the front end of the injection
pump. In some versions, specially locally installed engines, 213--- 2
the return of the oil is lead through a hose from the regulator
cover to the crankcase.
The fuel feed pressure which fills the high pressure pump el-
ements with fuel is created by a piston pump which is at-
tached to the side of the fuel injection pump. The piston pump Injection pump with the boost control
is driven from an eccentric on the camshaft of the injection
pump. The fuel feed pump supplies more fuel than the injec- 1. Boost control
tion pump needs. The excess fuel flows through the overflow 2. Cold start solenoid
valve back to the fuel tank. The fuel cools the injection pump 3. Indicator plug for adjusting injection timing
and also takes any air bubbles with it back to the tank.

Fuel System 13---4
The pump element consists of one plunger and one cylinder

which are a matched pair and because of the fine tolerances
the whole element should be changed as a complete unit.
The cylinder has two passages: inlet passage and release

passage. Both passages allow fuel to enter the pressure
space. The side of the plunger has one vertical groove and
one metering edge which are used for adjusting the amount
of fuel injected into the combustion chamber of the engine.
The top of the plunger is provided with a starting groove

(delay groove) which delays the injection timing by approx.
8˚. (This should be borne in mind when checking the fuel in-
jection timing). This groove improves the cold starting prop-
erties of the engine. It works fully automatically. When the en-
gine has stopped the control rod in the injection pump turns
the plungers so that the starting groove faces towards the re-
lease passage. When the engine has started and when the in-
jection pump has reached a certain speed, the governor pulls
the control rod back into running position.
213--- 4
1
1. Pressure valve holder
2. Pressure valve 2
3. Pump element 5
4. Control rod
3
5. Return spring for pump plunger
6. Roller tappet 6
7. Camshaft 4 7
213--- 6
The purpose of the fuel injection pump is to meter out fuel to
the combustion chamber at the correct time. Plunger (3) Pressure valve
which is driven by the pump camshaft (7) via roller tappet (6)
forces the fuel through pressure valve (2) and further through 1. Holder for pressure valve
the delivery pipe to the injector. 2. Valve spring
3. Valve cone
3 4 5 4. Valve guide
6
2
5. Valve head
6. Pressure ---reducing piston
7. Vertical grooves
The pressure valve is fitted on top of the pump element and

its purpose is to close the connection between the pump el-
ement and the delivery pipe. This happens when the metering
7 edge of the plunger passes the lower edge of the release
passage, thus reducing the pressure in the space above the
plunger. Its second purpose is to reduce the pressure in the
delivery pipe. This is important as it enable the nozzle valve
(needle) to close more quickly.
213--- 5 A B C
Pressure valve cone contains a pressure ---reducing piston
which, when the valve closes, is first lowered into the guide
Two---hole pump element (maximum feed)
and then closes the connection between the delivery pipe and
the pump element. The valve head is then pressed against its
A. Bottom dead centre 1. Inlet passage
seat and the fuel in the delivery pipe is given the same space
B. Fuel injection begins 2. Cylinder
as the displacement of the pressure ---reducing piston.
C. Fuel injection ends 3. Starting groove
4. Release passage
5. Plunger
6. Metering edge
7. Vertical groove

Fuel System 13---5
Governor Fuel injection pump type plate
The injection pump type plate shows one particular letter indi-
4 cating the user application, see figure below. This letter should
always be quoted when ordering a replacement pump or
when looking for setting values.
3
2
5
7
1
213--- 8
9 213--- 7
1. Governor weight
2. Control rod
3. Starting spring
4. Main lever
5. Idler screw
6. Governor spring
7. Additional spring, idling
8. Spring for equaliser
9. Governor control arm
The governor is of the centrifugal type and is fitted at the rear

end of the injection pump. The governor controls the rota-
tional speed of the engine throughout the whole speed range,
and identifies the rotational speed by means of the governor
weights. The position of the governor control and of the gov-
ernor weights is transferred through the governor lever link-
age to the control rod. The governor has one governor spring.
Starter spring, which is attached to the upper end of the con-
trol lever, it pulls the control rod to the starting position when
the engine stops. This means that the amount of fuel injected
when the engine is started automatically becomes greater.

Fuel System 13---6
A. Bleeding fuel system B. Bleeding Thermostart system
Always remove air from the glow plug fuel pipe when the pipe
or reservoir has been emptied during repair work etc. This
prevents damages to the glow plug caused by lack of fuel dur-
ing starting.
System with the magnetic valve
213--- 9
1. Slacken the bleeder screw on the filter head. Pump with the
hand pump until the fuel flowing out at the bleeder screw is 213--- 11
free from air bubbles. Then tighten the bleeder screw.
1. Disconnect the electrical wire from the glow plug and the
fuel pipe.
2. Connect electricity to the magnetic valve and rotate the en-

gine until fuel comes out from the fuel pipe connection.
3. Tighten the pipe connection and connect the electrical wire.
System with a fuel reservoir
1. Reservoir filling
2. To the glow plug
3. Return the fuel tank
4. Breather
213--- 10
3. Slacken the injection pump overflow valve. Pump with the

hand pump until the fuel flowing out is free from air bubbles.
Tighten the overflow. 1 2 3 213--- 11/1
4. Wipe off any fuel from the engine.

1. If the tank is empty fill it first e.g. through the breather.
2. Open the fuel pipe connection to the glow plug and let the
fuel come out. Tighten the pipe.

Fuel System 13---7
C. Measuring fuel feed pressure E. Changing fuel feed pump valves
1. Clean the fuel injection pump and the filter and the pipes be- 1. Clean the feed pump. Disconnect fuel pipes to the feed
tween them. pump. Remove the feed pump.
213--- 12
213--- 13
2. Secure the pump in a vice provided with soft jaws. Loosen

the tappet body from the pump and remove the piston, seal
2. Fit the gauge at the banjo connection on the pump, as rings, suction valve and the spring.
shown above (between filter and injection pump).
3. Detach from the pump body the outlet side threaded con-
3. Run the engine at low idling for a while and compare the nector, in which is placed the pressure valve.
gauge reading with the prescribed value (0,6...1,0 bar).
4. Rinse the valves with clean fuel and check the function and
Note! If the measured pressure is below the prescribed value, possible wear.
this may be caused by:
5. Change the valve if needed and assemble the pump using
--- faulty overflow valve new o---rings and gasket.
--- blocked fuel filter
--- faulty fuel feed pump Note! The manufacturer has standardised the pressure valve
--- blocked or leaking fuel pipes or unions A in different feed pumps. The earlier used M20 and M24
tightening threads are replaced by M22 thread (see picture
below). At the same time also the seal rings of the valve are
D. Checking overflow valve modified.
29
If the fuel feed pressure deviates from the prescribed value,

check the opening pressure of the overflow valve. M22 x 1,5
1. Connect a pressure gauge to the banjo union in the same

way as in previous instruction 13 C.
2. Pump with the hand pump until the overflow valve opens.
Compare the reading on the gauge at the moment the valve
opens with the prescribed value (0,6...1,0 bar). 32 28
3. If the recorded opening pressure deviates from the pre-

scribed value, the overflow valve should be changed.
M24 x 1,5
M20 x 1,5
Note! If the recorded pressure is considerably lower than the
prescribed value, there may be a fault in the hand pump or
the fuel feed pump valves.
420, 620/634
213--- 131 320

Fuel System 13---8
F. Checking injection timing
213--- 16
4. Turn the crankshaft to a position where the 1st cylinder pis-

ton reaches its compression stroke top dead centre. Then turn
the crankshaft backwards until the timing mark on the pulley
(flywheel) passes the timing indicator.
243--- 14
The injection timing for cylinder no. 1 is marked on the crank- 9025 99000
shaft pulley. The timing indicator can be on the right or left side
of the pulley, depending on engine version. In some tractor
versions the timing mark is on the flywheel.
Note! Due to the automatic excess fuel feed of the injection

pump the control rod must be moved to drive position before
checking the injection timing, otherwise the injection timing
will be 8˚ incorrect!
1st way of checking
1. Clean the injection pump and its surroundings carefully.
2. In tractor engines remove the inspection hole rubber plug

213--- 17
from the flywheel housing.
5. Remove the protecting cap for the control rod on the injec-
tion pump front face. Fit adjusting tool (sleeve for limiting con-
trol rod travel) 9025 99000. The tool moves the control rod to
the ”running position”.
6. Disconnect the delivery pipe for the number one cylinder in-
jector at the pump.
7. Clean the delivery valve of fuel. Slowly turn the crankshaft

in the correct direction of rotation until the fuel level in the deliv-
ery valve just begins to rise.
8. Check if the mark on the pulley is at the point of the timing

indicator the injection timing is correct. Repeat the check pro-
cedure. If the injection pump needs to be adjusted, follow the
instructions under heading 13 G.
9025 99100
9. Fit the delivery pipe and the rubber plug in the flywheel
213--- 15 housing. Remove the locator and the sleeve which was used
to limit the control rod travel. Start the engine.
3. Insert the locator (9025 99100) in the hole on the flywheel
housing front face.

Fuel System 13---9
2nd way of checking
Note! In some types of injection pumps the injection starting

point in the 1st cylinder has been positioned with aid of an 0 986 612 174
indicator pin in the pump governor housing. Do the inspection
of injection timing as follows:

the crankshaft backwards until the mark on the pulley passes
the timing indicator. After that rotate the crankshaft slowly to
running direction until the mark on the pulley is at the point of
the timing indicator or the timing mark on the flywheel is at the
point of locator 9025 99100 (see instruction 13 F).
3. Connect the inspection device sensor into the governor

housing. Note the position of the sensor! Connect the ---wire
into earth.
4. Rotate the crankshaft in running direction until light A is on.
5. Continue rotating the crankshaft in running direction very

slowly until light B is on.
6. If the mark on the pulley is at the point, the injection timing

is correct. If the marks are not at the point, preform the adjust-
ment according to instruction 13 G.
213--- 23
G. Adjusting fuel injection timing

2. Unscrew the plug on the side of the injection pump. Take
out the indicator pin.
If the timing is incorrect, adjust as follows:
3. Turn the indicator pin and push it into the hole so that the
groove at the end of the pin points towards the pump. 1. Loosen the retaining nuts of the injection pump and remove
the delivery pipes.
4. If the pin groove fits on the boss on the governor weight as-
sembly, the injection timing is correct. Otherwise, turn the
pump to a position where the boss and the pin groove align. A
Note! Do not rotate the crankshaft when the groove end of the
pin is inside the pump, since the pin end damages easily and
plastic pieces remain in the governor housing.
6. When the adjustment is correct, turn the indicator pin so that

the groove points outwards (running position) and push the
pin into the hole. Refit the plug.
Usage of the electrical inspection device (Bosch KDEP

1601 0 986 612 174) R 213--- 19
Also in electrical device can be used to check the timing. 2. If the injection timing is retarded, turn the pump anti ---clock-
wise (viewed from the front end of the pump). If the timing is
1. Turn the crankshaft to a position where the 1st cylinder pis- advanced, turn the pump clockwise.
the crankshaft backwards until the timing mark passes the 3. Check once again the injection timing and set again if
dowel pin. needed.
2. Unscrew the plug on the side of the injection pump. Take 4. When the timing is correct tighten the retaining nuts of the
out the indicator pin. pump and fix the delivery pipes.

Fuel System 13---10
H. Removing fuel injection pump I. Fitting fuel injection pump
1. Clean the injection pump and surrounding engine parts Bosch ---A injection pump
and the pipes and connectors on the injection pump.
1. Check the condition of the o---ring between the pump and
2. Disconnect the delivery pipes and the banjo bolts at the the timing gear casing. Change the o---ring if necessary.
supply and return fuel connections. Disconnect the lubricat-
ing oil line. Plug all connections.
3. Detach the oil filler pipe/cover from the front cover. Unscrew
the pump drive gear nut.
9052 48900
213--- 21
2. Lubricate the o---ring and place the injection pump so that

the key on the pump shaft aligns with the key slot inside the
gear. Tighten the pump attaching nuts.
Note! The injection pump with adjusting indicator in the cov-

ernor housing don’t have any key slot in the gear.
213--- 20
3. Tighten the gear nut to 90 Nm . Fix the oil filler pipe/cover.
4. Connect the supply and return fuel lines. Connect the lubri-
4. Use puller 9052 48900 and loosen the gear from the injec- cating oil line. Use new sealing washers.
tion pump camshaft front end.
5. Bleed the fuel system (instruction 13 A).
5. Remove the injection pump attaching nuts. Remove the in-
jection pump. 6. Adjust the injection timing (instruction 13 G).
7. Fit the delivery pipes.
213--- 22
8. If the injection pump is changed or if the lubricating oil has

been drained from the pump, fill the pump with lubricating oil
before starting the engine. Open the hexagonal socket plug
213--- 20/1
on the governor housing and pour in oil.
Note! When removing the Bosch ---P injection pump, open Filling quantity: 320---engines 0,3 l
bottom mounting screws on the both side of injection pump. 420---engines 0,4 l
620/634---engines 0,6 l
Note! If the engine is not to be disturbed while the pump is re-
moved, there is no need to secure the pump gear. The gear Same oil specification as in the engine.
rests against the idler gear.

Fuel System 13---11
Bosch ---P injection pump Note! In some types of injection pumps the injection starting
point in the 1st cylinder has been positioned with aid of an
1. Check the condition of the o---rings between the pump and indicator pin in the pump governor housing. This type of injec-
the timing gear casing. Change the o---rings if necessary. tion pump is installed as follows:

the crankshaft backwards until the mark on the pulley passes
the timing indicator. After that rotate the crankshaft slowly to
running direction until the mark on the pulley is at the point of
the timing indicator or the timing mark on the flywheel is at the
point of locator 9025 99100 (see instruction 13 F).
213--- 22/1
213--- 23
2. Lubricate the o---ring and put the fit ring to the timing gear
casing. 2. Unscrew the plug on the side of the injection pump. Take
out the indicator pin.
3. Lubricate the o---ring and place the injection pump so that
the key on the pump shaft aligns with the key slot inside the 3. Turn the indicator pin and push it into the hole so that the
gear. Tighten the gear nut to 200 Nm and fit the cover. groove at the end of the pin points towards the pump.
4. Adjust the injection timing, see instruction 13 G.
4. Install the injection pump and tighten the installation nuts
and the nut on the gear. Note! The groove for the key has been
5. Connect the supply and return fuel lines. Connect the lubri- left out for the gear.
cating oil line. Use new sealing washers. Fit the delivery pipes.
Warning! Do not rotate the crankshaft when the groove end
6. Bleed the fuel system, see instruction 13 A. of the pin is inside the pump, since the pin end damages eas-
ily and plastic pieces remain in the governor housing.
5. When the adjustment is correct, turn the indicator pin so that

the groove points outwards (running position) and push the
pin into the hole. Refit the plug.

Fuel System 13---12
J. Checking and changing pressure Note! Replace the sealing ring and o---ring.
valve 8. Tighten the holder as follows:
--- Tighten first to 30 Nm.

1. Clean the injection pump, injectors and surrounding parts. --- Open the holder about ½ a turn and tighten to 40 Nm.
Disconnect the delivery pipes. --- Open the holder about ½ a turn and tighten to 45 Nm.
9052 47800
K. Adjusting idling speed
If the idling speed of the engine deviates from the value given
in the specifications or if the engine revs vary at the idling
speed, adjust the idling speed as follows:
213--- 24
2
2. Connect the pressure gauge 9052 47800 to the pressure

valve holder which is to be checked.
3. Rotate the engine with the starter motor, until the gauge re-
ading is about 330 bar.
213--- 26
Note! Pressure rises fast, do not damage the gauge. Get

ready to pull the stop control out as soon as the gauge reading 1. Unscrew the idling speed adjusting nut cap (1) and the cap
reaches an adequate pressure value. (2) on the idling speed additional spring adjusting screw.
4. Let the gauge reading lower at first about 30 bar. When the 2. Ensure that the throttle lever is in the idling position and that
gauge shows 300 bar, observe the reading during one min- the engine is at normal operating temperature.
ute. During this time the gauge reading must not lower too
much (max 30...50 bar). If the pressure lowers faster than 3. Start the engine and loosen the adjusting screw of the addi-
specified, the pressure valve must be cleaned or replaced. tional spring so that it does not affect the idling speed.
Note! The pressure valve plunger and guide should always

be replaced in pairs.
5. Open the pressure valve holder locking and holder. Re-

move the valve spring, plunger and the guide.
6. Rinse the plunger and guide in clean fuel or test liquid and
at the same time rotate the plunger in its guide and press the
sealing surfaces against each other.
213--- 27
4. Adjust the idling speed using the adjusting screw to about

20...30 rpm below rated speed and lock the adjusting screw.
213--- 25
5. Run the engine a few times and ensure that the idling speed
remains as set.
7. Fit the pressure valve into the fuel injection pump. Place the
spring in place and tighten the holder.

Fuel System 13---13
6. Tighten the adjusting screw of the additional spring until the

idling speed rises to the rated value. Lock the adjusting screw
in this position. M. Inspecting injectors
7. Fix the safety caps of the adjusting screws.
Note! When pressure testing the injectors, it is important
Note! Other adjustments (output and max. speed) of the in- to avoid the nozzle end as the fuel jetting out easily pen-
jection pump can only be performed by a specially trained etrates the skin. Also bear in mind that the fuel ”mist” is
person who has the necessary special tools and gauges avail- dangerous to inhale.
able.
1. Clean the injector with cleaning fluid and a soft brush.

The carbon deposits must not be knocked off or removed in
L. Removing injectors any other way which may damage the nozzle.
1. Clean the injectors and the area around them. Disconnect

the delivery pipes and the leak ---off pipes.
9051 71300
213--- 29
2. Secure the injector in a test bench and check the follow-

213--- 28
ing:
--- injector opening pressure
--- the properties of the chattering (creaking) sound and the
2. Remove the injector attaching nuts and remove the injector form of the spray pattern
from the cylinder head. Fit protective plugs to all connections. --- sealing of nozzle valve against its seat
If the injector does not rise by hand, use puller 9051 71300.
Opening pressure
3. Remove the sealing washers from the bottom of the injector
location in the cylinder head if they do no come out with the Pump a few times to fill the injector. Increase the pressure in
injector. the injector until the chattering (creaking) sound becomes
audible. Read off the opening pressure of the injector. If the
opening pressure deviates from the given value, the injector
should be taken apart and checked.
Adjustment is achieved by changing the shim. The thickness

of the shims varies from 1,00...1,90 mm and they are available
in increments of 0,05 mm. A thicker shim will raise the opening
pressure while a thinner one lowers it. A difference in shim
thickness of 0,05 mm changes the opening pressure by ap-
prox. 5,0 bar. As the opening pressure of the injector drops
slightly after adjustment, the opening pressure should be set
to approximately 10 bar above the value given in the specifica-
tions. This value applies both to new and used injector.

Fuel System 13---14
Chattering sound properties

1
Testing with a hand powered pump does not create the same
circumstances as when the injector is fitted in the engine. Only
with new nozzles are the test results reliable. With used
nozzles, there is no chattering (creaking) sound when the
tester is pumped at a certain rate. This has to do with the de- 2
sign of the nozzles.
However, with a rapid pumping on the tester handle, it should

be possible to hear the chattering (creaking) sound or/and
see a mist of the fuel jetting out.
Tightness of nozzle
Press down the tester pump lever until the pressure rises to 3
approx. 20 bar below the adjusting value. Maintain this pres-
sure for approximately 10 seconds and check whether drops
of fuel are formed on the point of the nozzle. If the injector 4
leaks, it should be cleaned or the nozzle should be changed.
5
N. Reconditioning injectors
6
1. Secure the injector in a suitable way.
7
2. Unscrew the nozzle cap nut. Remove the nozzle and the
parts inside the holder.
8
3. Clean the nozzle in cleaning fluid both inside and outside.
9 213--- 31
4. Clean the nozzle holes with a needle (including in cleaning
set 8360 83288).
Injector
5. Test the movement of the nozzle valve as follows:
1. Fuel inlet 6. Nozzle body
2. Leak ---off fuel 7. Pressure chamber
3. Shim 8. Nozzle valve
4. Pressure spring 9. Nozzle hole
5. Valve stop spacer
6. Before assembling, all parts should be carefully cleaned in

clean fuel or testing fluid.
7. Put the same thickness of shim back as were fitted earlier.

Note possible adjustment of the opening pressure. Assemble
the rest of the injector. Note the position of the spring guide
and the valve stop spacer.
8. Tighten the nozzle cap nut by hand and then to 60 Nm.
213--- 30
Rinse the parts thoroughly in fuel or testing fluid. Pull the valve
out of the nozzle body to 1/3 of its length. If the fit is correct,
the valve should be able to slide down in the nozzle body
under its own weight. Turn the valve slightly and repeat the
test. Should the nozzle valve bind slightly, it should be
changed.

Fuel System 13---15
O. Fitting injector in engine P. Fitting delivery pipes
1. Clean the injector sealing surface in the cylinder head. If 1. Check the state of the pipes. If there are kinks, damage by
necessary use a reamer 9101 66000. chafing, or if the tapered sealing end is damaged, the pipes
should be changed.
2. Fit the pipes without tension and check that they are at right
angles to the union.
3. Fit the clamps for the pipes.
3
213--- 32
1. Washer
2. Rubber ring
3. Sealing washer
2. Fit the injector in the cylinder head using a new sealing

washer.
Note! The spray pattern from the injector is not symmetrical

on purpose. It is therefore important that the injector is fitted
correctly in the cylinder head. The connection for the leak ---off
line should be facing the valve mechanism.
3. Fit the attaching clamp and tighten the nuts evenly to 15

Nm.
4. Connect the leak ---off line together with new sealing

washers and connect the delivery pipes .
Note! The screw studs in the cylinder head for the injectors
should only be finger tight. If tools have to be used the studs
should be tightened only lightly.
Note! Make sure, that the injector is of a correct type. Wrong

injectors cause malfunctions and can damage the engine.

Fuel System 13---16
CAV DISTRIBUTOR PUMP 3 4

2
Some 420--- and 620---engines are having a CAV made
DPA ---type distributor pump. The pump is equipped with an
electrical solenoid (ignition key starting and stopping) and 1 5
automatic bleeding system. The internal lubrication of the
injection pump is done by the fuel it is pumping. The sepa-
rate feed pump, of diaphragm type, is driven by the cams-
haft of the engine. The system is also equipped with a Ther-
mostart---device that receives the fuel through the fuel filter.
213--- 33 6
1. Installation marks of injection pump

2. Overflow flange
3. Throttle lever
4. Stop lever
5. Stop solenoid
TECHNICAL DATA
Injection pump CAV
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DPA
Injection order
420 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---2---4---3
620 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---5---3---6---2---4
Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . clockwise
Injection advance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see pump installation marks
Fuel feed pump
Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . diaphragm pump, separate hand

lever
Fuel feeding pressure (static) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,48 bar (48 kPa)
Fuel feeding pressure min. (used pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,20 bar / max. rpm
Injectors CAV
Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . five ---hole nozzle

Control pressure (new injector) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250+8 bar
Control pressure (used injector) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230+8 bar
Sealing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8999 01495
Tightening torques
Pump gear retaining nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Nm

Nozzle retaining nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm
Injector retaining nuts (for the studs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Nm

Fuel System 13---17
A. Dismounting and mounting in- B. Injection pump gear

jection pump
The engines equipped with a rotary injection pump have a
1. Clean the pump and the surrounding parts carefully. different timing mark on the gear in 420--- and 620---en-
Remove the delivery pipes, the throttle cable wire from the gines.
revolution lever and the stop solenoid wire from the pump.
Fit protective caps on the delivery pipe unions.
2. Remove the cover of the front covering so that the pump

gear wheel becomes accessible.
3. Unscrew the gear wheel attaching nut. Detach the gear

wheel by using puller 9052 48900.
Note! If the timing gear casing has not been removed, the
injection pump gear wheel remains in contact with the idler
gear and it is unnecessary to mark the positions of the
gears.
4. Detach the injection pump from the timing gear casing.

Clean the sealing surfaces.
5. Place a new sealing ring on the pump flange. Push the 213--- 35
pump into place so that the key on the shaft engages with
the key slot on the gear wheel.
To identify the gear, in 620---engines the gear has a ma-
chined groove shown in the picture. In 420---engines the
gear does not have this groove. The gears must not be
mixed with each other.
C. Bleeding fuel system

Note! This fuel system removes automatically small
amounts of air bubbles from the filter and the pump when
the engine is running. However, bleed the system always,
when the system has been opened or fuel has been
exhausted during driving or a new spare pump has been
fitted (to avoid long starting time).
Bleed the fuel filter

213--- 34
6. Tighten the pump into position, where the timing marks

align.
7. Tighten the gear wheel nut to a torque of 90 Nm. Fasten

the pump gear wheel covering.
8. Remove the protective caps from the delivery pipe uni-

ons and fit the delivery pipes. Fit the overflow pipe, throttle
cable wire and the stop solenoid wire. Bleed the fuel sys-
tem (see instruction C).
213--- 36
1. Pump by hand the fuel feed pump lever. If the pumping

seems to be ineffective, turn the engine a little so that the
camshaft cam is not at the feed pump lifter.

Fuel System 13---18
Bleed the thermostart system
Always remove air from the glow plug fuel pipe when the
pipe or reservoir has been emptied during repair work etc.
This prevents damages to the glow plug caused by lack of
fuel during starting.
1. Open the pipe adaptor of the glow plug.
2. Pump with the hand pump until the fuel is running out of
the pipe adaptor.
3. Tighten the pipe adaptor. Clean the engine of leaked fuel.
213--- 38
D. Feed pump
2. Unscrew the bleed screw on the top of the fuel filter The feed pump of diaphragm type is not supplied with
spare parts separately, replace the complete pump if the
3. Pump with the hand pump until the fuel running out of feed pressure is very low (min. 0,20 bar/max. rpm) or the
the bleed screw is free of air bubbles. pump has otherwise been damaged.
4 Close the bleed screw. Clean the engine of leaked fuel.
Bleed the injection pump

E. Injector
1. Turn the ignition key to the position ON (stop solenoid is The inspection and reconditioning of the injector is mainly
opening) done in the instruction 13 L...O on pages 13 ---13...13 ---15.
The difference is opening pressure and the adjusting
shims.
The new injector has a opening pressure of 250+8 bar. An

used injector has a opening pressure of 230+8 bar.
The adjusting shims are delivered with a 0,02 mm differ-

ence, from 0,42 to 0,70 mm thickness. Also 0,30, 1,00, 1,28
and 1,56 mm thick shims are available. A difference of 0,02
mm in the shim thickness changes the opening pressure
about 2 bar.
Note! Ensure that always the correct nozzle type is used,

because an incorrect nozzle leads to incorrect function of
the engine and damages.
213--- 37
2. Unscrew the bleed screw on the top of the injection

pump.
3. Pump with the hand pump until the fuel running out of
the bleed screw is free of air bubbles.
4. Close the bleed screw. Switch off the current. Clean the
engine of leaked fuel.

Fuel System 13---19
STANADYNE DISTRIBUTOR PUMP

Note! This manual gives only general instructions for repair
and service measures related to the fuel system. This
applies particularly to the injection pump which can be re-
paired only by a specially trained person who has the
necessary special tools and gauges. All service and repair
work related to the fuel system requires special care and
cleanliness!
TECHNICAL DATA
Injection pump Stanadyne
Type:
--- DB 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (two pressure plungers)
--- DB 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (four pressure plungers)
Injection order:
--- 320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---2---3
--- 420 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---2---4---3
--- 620/634 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1---5---3---6---2---4
Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise
Injection advance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see pump installation marks
Fuel feed pump
Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . diaphragm pump, separate hand

lever
Fuel feed pressure (static) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,48 bar (48 kPa)
Fuel feed pressure min. (used pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,20 bar / max. rpm
Injectors
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . five hole nozzle

Opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see page 14---10
Sealing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8999 01495
Tightening torques
Pump gear retaining nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Nm
Nozzle retaining nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm
Injector retaining nuts (for the studs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Nm

Fuel System 13---20
Fuel system with distributor pump
1. Fuel tank
213--- 40 2. Prefilter
3. Fuel feed pump
4. Fuel filter
5. Distributor pump
6. Injector
7a,b,c. Return fuel to tank
8. Thermostart reservoir
9. Glow plug
10a,b. Bleeding screws
11. Valve of reverse back flow
In this fuel system, there is a separate fuel feed pump (3)

on the RH side of the engine.
The system includes a separate prefilter (2) and a fuel filter

(4). The lower parts of the fuel filter housings have a space
for possible impurities and there is a draining tap under
both filter housings.
The fuel feed pump has a washable filter. There is also a

tapered metal net filter inside the distributor pump in the
inlet line before the pump transfer pump.
The fuel system is often equipped with the Thermostart de-

vice to be used in cold conditions. The glow plug (9) re-
ceives fuel from a separate reservoir (8) of the thermostart
device or from the overflow valve of the injection pump
regulated by the magnetic valve.

Fuel System 13---21
Stanadyne---distributor pump
F
6 5
E
4
C B
1 2
213--- 40/1
G
D
1. Type plate with pump order number

2. Timing marks under the cover
3. Fuel inlet
4. Return fuel/overflow valve
5. Revolution lever
6. Connector for wire to electric stop solenoid
Eventual injector pump equipment (e.g. E-- engines)
A. Interrupted screw (order no 8366 59038) G. Compact Cold Advance CCA

B. Timing sensor Electrical device for earlier injection advance at start and
low load (under 1100 RPM) to minimize the so called cold
C. Fuel Limiter FL smoke. The device includes an injector pump solenoid
The fuel limiter FL restricts the injection mostly at low and a separate control unit to follow the engine rotating
RPM as the air ratio otherwise would be too low. speed.
D. Light Load Advance LLA
Adjustment of the injection advance according to the ro-
tating speed and load steered by the fuel delivery pres-
sure after the metering valve.
E. Aneroid Control AC
The aneroid control regulates fuel delivery to match
turbocharger air flow characteristics at low speeds to
minimize smoke during acceleration on low speed.
F. Boost pressure

Fuel System 13---22
Stanadyne distributor pump 1. Drive shaft

2. Governor weights
3. Governor spring
4. Stop solenoid
5. Overflow valve
6. Metering valve
7. Cam ring rollers
8. Hydraulic head
9. Pressure regulator valve
10. Transfer pump blades
11. Distributor rotor
12. Pressure valve
13. Cam ring
14. Automatic advance
15. Centrifugal governor
16. Pumping plungers
213--- 41
Construction
The main rotating components are the drive shaft, transfer The distributor rotor incorporates two charging ports and a
pump blades, distributor rotor and governor. single axial port (pressure chamber), in which is placed the
pressure valve. After the delivery valve, there is one dis-
The drive shaft engages the distributor rotor in the hydraulic charge port to serve all head outlets to the fuel injection
head. The drive end of the DB2 rotor incorporates two pipes.
pumping plungers and DB4 four.
The hydraulic head contains the bore in which the rotor
The plungers are actuated toward each other simulta- revolves, the metering valve bore, the charging ports and
neously by an internal cam ring through rollers and shoes the connections to the fuel injection pipes.
which are carried in slots at the drive end of the rotor. The
numbers of cam lobes normally equals the number of cylin- The pump contains a mechanical governor. The centrifugal
ders (not 3---cyl. engines). force of the weights is transferred to the metering valve via
a linkage. The metering valve can be closed electrically with
The transfer pump at the rear of the rotor is of the positive aid of the solenoid in the pump housing.
displacement vane type and is enclosed in the end cap.
The end cap also houses the fuel inlet strainer and transfer The automatic advance is a hydraulic mechanism which
pump pressure regulator. The face of the regulator assem- turns the cam ring and advances or retards the beginning
bly is compressed against the liner and distributor rotor and of the fuel delivery from the pump.
forms an end seal for the transfer pump.
The injection pump is designed so that end thrust is against

the face of the transfer pump pressure regulator.

Fuel System 13---23
Stanadyne distributor pump
Housing pressure
213--- 42
Transfer pump pressure Injection pressure
1. Fuel tank 10. Regulator spring

2. Water trap 11. Centrifugal weights
3. Fuel feed pump 12. Overflow valve
4. Fuel filter 13. Hydraulic head connecting passage
5. Transfer pump 14. Metering valve
6. Pressure regulator valve 15. Hydraulic head charging pasage
7. Automatic advance 16. Distributor rotor
8. Air vent passage 17. Pressure valve
9. Stop solenoid 18. Injector
Function
The fuel feed pump draws fuel from the tank via the water While the discharge post is opened, the rollers contact the
trap and the filter into the fuel injection pump. cam lobes forcing the plungers together. Fuel trapped
between the plungers is then pressurised and delivered by
In the pump fuel flows through the inlet filter screen into the the nozzle to the combustion chamber.
vane type fuel transfer pump. Some fuel is bypassed through
the pressure regulator assembly to the suction side. The injection pump is self ---lubricating, and it has not been
connected to the engine lubrication system.
Fuel under transfer pump pressure (1---6 bar) flows through
the center of the transfer pump into the circular groove on As fuel at transfer pump pressure reaches the charging
the rotor. It then flows through a connecting passage in the ports, slots on the rotor shank allow fuel and any entrapped
head to the automatic advance and up through a radial air to flow into the pump housing cavity. In addition, an air
passage and then through a connecting passage to the vent passage in the hydraulic head connects the outlet side
metering valve. The metering valve adjusts amount of of the transfer pump with the pump housing. This allows air
injected fuel and position of the metering valve is con- and some fuel to be bled back to the fuel tank via the over-
trolled by the governor (revolution lever) and the stop sole- flow valve.
noid. From the metering valve fuel flows to the radial charg-
ing passage and further to the head charging ports. The fuel thus bypassed fills the housing, lubricates the
internal components, cools and carries off any small air
As the rotor revolves, the two rotor inlet passages register bubbles. The pump operates with the housing completely
with the charging ports in the hydraulic head, allowing fuel full of fuel; there are no dead air spaces anywhere within
to flow into the pumping chamber. With further rotation, the the pump.
inlet passages close and the port to the injectors opens.

Fuel System 13---24
A. Removing pump
1. Clean the pump and the surrounding parts carefully.
Remove the delivery pipes, the throttle cable wire from the
revolution lever and the stop solenoid wire from the pump.
Fit protective caps on the delivery pipe unions.
2. Remove the cover of the front covering so that the pump

gear wheel becomes accessible.
3. Unscrew the gear wheel attaching nut. Detach the gear

wheel by using puller 9052 48900.
Note! If the timing gear casing has not been removed, the
injection pump gear wheel remains in contact with the idler
gear and it is unnecessary to mark the positions of the
gears.
4. Detach the injection pump from the timing gear casing.

Clean the sealing surfaces.
Note! In E ---engines have one retaining screw so---called in-

terrupted screw. Unscrew it with a drift.
213--- 44
B. Fitting injection pump and
adjusting injection timing 2. Remove the small cover plate on the side of the injection
pump. Rotate the pump shaft until the timing marks align
(see arrow in picture above).
3. Place a new sealing ring on the pump flange. Push the

pump into place on the timing gear housing. Note! key
groove in gear left out from beginning of 1996.
4. Tighten the pump into position, where the timing marks

align.
5. Tighten the gear wheel nut to a torque of 90 Nm. Fit the

small cover onto the side of the pump. Fasten the pump
gear wheel covering (+oil filler tube).
6. Remove the protective caps from the delivery pipe uni-

ons and fit the delivery pipes. Fit the overflow pipe, throttle
cable wire and the stop solenoid wire. Bleed the fuel sys-
tem (see instruction C).
Note! Lubrication oil is not needed because fuel in the

213--- 43
pump lubricates the internal parts.
1. Turn the crankshaft to a position where the 1st cylinder

piston reaches its compression stroke top dead centre.
Then turn the crankshaft backwards until the mark on the
pulley passes the timing indicator. After that rotate the
crankshaft slowly to running direction until the mark on the
pulley is at the point of the timing indicator.
Note! Distance between the piston top face and the top
dead center with different crankshaft angles, see page
5 ---3.

Fuel System 13---25
C. Bleeding fuel system D. Fuel feed pump

Note! This fuel system removes automatically small For the membrane type fuel feed pump no spare parts are
amounts of air bubbles from the filter and the pump when supplied. The feed pump must be changed for a new one,
the engine is running. However, bleed the system always, if the feed pressure has dropped noticeably (min. 0,20 bar/
when the system has been opened or fuel has been max. rpm) or if the fuel feed pump has been damaged.
exhausted during driving or a new spare pump has been
fitted (to avoid long starting time). Note! From engine number H 6794 have engines provide
with new type fuel feed pump. New pump is fixed to cylin-
der block with four screws instead of the previous two. The
new pump can be used as spares also to earlier made en-
gines using repair kit 8366 62052, see Service information
no 50 98.
Measuring fuel feed pressure
--- Clean the injection pump, filter and all fuel pipes.
--- Connect a pressure gauge between the filter and the in-
jection pump, connect the pressure gauge to the inlet pipe
in the middle of the injection pump rear end (point B in the
previous instruction).
213--- 45
--- Allow the engine to run at the idling speed and read off
the fuel feed pressure in the pressure gauge.
1. Pump by hand the fuel feed pump lever. If the pumping
seems to be ineffective, turn the engine a little so that the Note! If the feed pressure value is below the rated value,
camshaft cam is not at the feed pump lifter. possible reason can be:
--- blocked fuel filter/fuel feed pump metal gauze filter
A --- faulty fuel feed pump
--- blocked or leaked fuel pipes or pipe connections
Important! Under the fuel feed pump cover there is a

washable filter. If much impurities have gathered on this
filter, fuel cannot flow to the feed pump and further to the
B injection pump and this causes malfunctions in the fuel sys-
tem. Always when malfunctions appear, the feed pump
cover should be removed and the metal gauze filter must
be checked and cleaned.
E. Injectors
213--- 46
Injectors are checked and serviced according to instruc-
tions 13 L...O on pages 13 ---13...13 ---15.
2. Loosen the bleeding screw A on the filter. Pump with the
hand pump until no air bubbles flows out of the bleeding Opening and setting pressures of the injectors are on page
screw hole. Tighten the bleeding screw. 14 ---10.
3. Pump further with the hand pump and loosen the fuel Adjustment is achieved by changing the shims. The thick-
inlet connection B on the pump, until the fuel coming out is ness of the shims varies from 1.00...1,90 mm and they are
free from air bubbles. Tighten the connection. available in increments of 0,05 mm. A thicker shim will raise
the opening pressure while a thinner one lowers it. A differ-
4. Start the engine and assure, that no leaks exist. ence in shim thickness of 0,05 mm changes the opening
pressure by approx. 5,0 bar. As the opening pressure of the
Note! When the bleeding is done in this way, fuel flows injector drops slightly after adjustment, the opening pres-
immediately into the internal transfer pump when the starter sure should be set to approximately 10 bar above the value
motor is rotating and the distributor pump housing is filled given in the specifications. This value applies both to new
quickly with fuel. In the pump housing there is a stop sole- and used injector.
noid, which must not be switched on for longer periods
when the pump housing is empty of fuel.

Fuel System 13---26
F. Adjusting low idling speed H. Wiring diagram of electrical ad-

vance (CCA)
2
Ignition switch
1 3 +
Alternator Red 1,5 mm2
Control unit
+
W Green 1,5 mm2
W
(R)
OUT
---
213--- 47
Blue 1,5 mm2
1. Low idling speed

2. Revolution lever
3. Max. revs Brown 1,5 mm2
The low idling speed can be adjusted with a limiting screw

Stop solenoid
in front of the revolution lever. The adjusting screw for max.
revs has been sealed. This adjustment has been done in
the factory, and adjustment of max. revs afterwards is pro-
hibited.
Note! The throttle cable is attached to the revolution lever

lower hole. To the upper hole is fastened a return spring. Injection pump
Other information 213--- 48
The injection pump housing upper cover has been sealed

to prevent adjustment of engine output afterwards. Also the
stop solenoid is fitted under this cover. It is recommended,
that all pump repairs are made by an authorised Stanadyne
workshop.
G. Bleeding Thermostart system
Always remove air from the glow plug fuel pipe when the The control unit of the electrical advance depends on gear
pipe or reservoir has been emptied during repair work etc. ratio of the alternator.
This prevents damages to the glow plug caused by lack of
fuel during starting.
SPARE PART GEAR ALTERNA-
1. If the reservoir is empty, fill it e.g. with a drip pot through NO RATIO TOR
the breather hole on the reservoir. 8368 54777 2.32 12 V MM
2. Open the glow plug pipe connector and drain fuel from 8368 54778 2.90 12 V Delco
the pipe. Connect the pipe. 8368 54817 3.97 12 V Valeo

Fuel System 13---27
I. Checking injection timing (dy-

namic)
B
213--- 49
1. Warm up engine and fuel injection system. display to read ”R=___ Set RPM”.
Note! All connections, including the magnetic probe insertion Note! Before starting engine, make certain that all cables are
and removal, must be done with the engine stopped. clear of any moving parts or hot manifold.
2. Remove the protective plug from access hole (Æ 8 mm) and 8. Once the proper RPM is displayed, press ENTER. The dis-
attach the magnetic probe assembly A to the engine by insert- play shows ”Calibrating...” for a short period of time.
ing the probe into the access hole (in tractor versions into the
upper hole), and the RETRACTING SLIGHTLY (0,5...1,0 Note! If for some reason the meter loses the engine speed sig-
mm). This must be done to prevent wear of the end of the nal or the engine is not running, the display will show ”Eng.
probe caused by contact with the flywheel. Connect the mag- Not running”, flash this message 3 times, and return to the tac-
netic probe cable to the meter socket MP. hometer mode. To restart the procedure, press MAG PROBE
(point 5).
3. Install the adapter clamp B by first placing the clamp as-
sembly around sensor slightly above the brass contact ring 9. If for example the engine were running at 850 RPM and tim-
and then moving down over the contact ring. Tighten the ing were 6˚ BTDC, display should now read ”R=850 MP +
thumb screw of the clamp ensuring that the end of the screw 6.0”. Now the meter is ready for use.
contacts the ring. Connect the transducer cable to the meter
socket SR. Connect the alligator clip to some clean unpainted Note! If for some reason the meter loses the magnetic probe
metallic portion of the fuel system or engine. signal the display will show ”R=850 No Probe”. Once the
magnetic probe signal is restored, the display will show the
4. Turn the meter on by pressing the ON/CLEAR key. The proper timing reading.
words ”Time Trac” and then”Model TT 1000” should appear
briefly followed by ”R= 0”. The meter can be used as a tac- 10. You can measure the pump timing at high idle speed [TT
hometer at this point without further manipulation. (HI)]. This value is valid for pump timing setting. Adjust if
necessary. The cam advance operation of the injection pump
5. Press MAG PROBE. Display shows ”Trig Level 30%”. Press you can check at low idle [TT (LI)].
ENTER leaving the trigger point at 30%.
Setting values are available through Service Department of
6. Display shows ”Offset 20.0˚”. Press ENTER leaving the Sisu Diesel Inc.
offset at 20,0˚.
Read also manufacturer service manual.
7. Display shows ”Calibrate?”. Start the engine and run it at
low idle speed. Press ENTER to continue which will cause the

Fuel System 13---28
Trouble shooting
If the timing deviates remarkably from given, check the fol-

lowing:
1. Vibrating delivery pipe, hold the pipe with hand.
2. Distance of magnetic probe from flywheel not correct, re ---

set the magnetic probe.
3. ”Offset” or “Trig Level” value wrong, re ---set.
4. Disturbing scratches on the flywheel.
5. Alignment of flywheel---crankshaft wrong, remove the fly-

wheel and reassemble correct.

Fuel System 13---29
Fuel quality requirement
Requirement Test method

Density, +15˚C 0,82...0,86 kg/dm3 ASTM D 4052, EN ISO 12185
Viskosity, +40˚C 1,2...4,5 mm2/s ASTM D 445, ISO 3104
Sulphur content max. 0,2 % m/m ASTM D 4294, ISO 8754
Cetane index min. 45 ASTM D 4737
Water content max. 200 mg/kg ASTM D 1744
The fuel should be according to norm EN 590. OUTPUT %

+5
Engine output depending on fuel quality
Different fuel qualities like temperature, density and viscosity B

affect the actual output of the engine. Our output rates use fuel
with a density of 0.84 kg/dm3 and specific heat rate of 42,7 Mj/
kg at a fuel temperature of +15˚C.
0
The correction in % caused by the change of fuel qualities is
seen in the attached figures.
OUTPUT %
+5
---5
0,84
A
0,80 0,85 0,90
DENSITY kg/dm3
0 FIG. B. Engine output dependence on fuel density. Normal

value is 0,84 kg/dm3 at +15˚C.
OUTPUT %
+5
---5
35 C
10 20 30 40 50 60
FUEL TEMPERATURE ˚C
0
FIG.A. Engine output dependence on fuel temperature.
+35˚C is the reference temp (correction 0 %).
---2
The fuel temperature is not only a function of ambient condi-
tions but also varies according to the fuel system of the ap- 2 3 4 5 6 7 8
plication (tank size and location, return flow etc.). VISCOSITY cSt
FIG. C. Engine output dependence on fuel viscosity. Normal
value is 3 cSt at +20˚C.
Note fig. B and C only if the fuel quality is changed. In fig. A

there are all the quality dependencies caused by the change
of the temperature. The fuel density and viscosity can be seen
in the produce declaration given by the manufacturer.
The output correction is made as follows: Correction percen-

tages from figures A, B and C are summed up. The given rated
power is then corrected with the resulting percentage.

FUEL SYSTEM Test equipment ISO 4008 Nozzle ISO 4010 173 bar or
EQUIPMENT AND FEEDING TABLE Fluid ISO 4113 nozzle ISO 7440 207 bar
Pipes ø 6 x 2 x 600 ISO 4093 0,60 orifise plate
320
Engine Application Pump spare part no Pump Injection advance˚ Feed rate RW mm Control rod Control rod Element
Fuel adjustment card Governor Max. output r/min mm3/stroke min. position Pressure valve
Idling r/min ISO 4010 ISO 7440 ---1 mm 4 mm Covernor spring
Output kW mm3 rpm mm3 rpm rpm

320 DS Valmet 6100 8366 40199 PES 3A 95D 19 102---104 1150 101---103 12,1...12,5 1170---1190 1240---1260 8353 31161
13.222/1 320 RS 2810 2300 1000 +0,1...0,2 8353 39126
/C 750 800 +0,3...0,4 8353 31163
RSV 375---1150 58 500 +0,3...0,4
A2C 2178---10R 12---15 375 13---16 4,1...4,7
320 D Valmet 355 8366 40198 PES 3A 95D 21 79---81 1150 73---88 10,7...11,1 1200 1280---1300 8353 31161
13.202/1 320 RS 2810 2350 950 11,1...11,5 8353 39126
/B 750 800 11,6...12,0 8353 31163
RSV 375---1175 45 500 11,6...12,0
A2C 2178---10R 12---15 325 13---16 4,1...4,7
320 DS Valmet 455 8366 40197 PES 3A 95D 19 79---81 1150 82---84 10,0...10,4 1200---1220 1270---1300 8353 31161
13.223/1 320 RS 2810 2350 1000 +0,2...0,3 8353 39126
/A 750 800 +0,5...0,6 8353 31163
RSV 375---1175 49 500 +0,5...0,6
A2C 2178---10R 10---15 325 11---16 4,1...4,7
Equipment and Feeding Table
320 DS Valmet 555 8366 40156 PES 3A 95D 19 94---96 1175 94---96 11,3...11,7 1200 1255---1285 8353 31161
13.230 320 RS 2810 2350 950 11,3...11,7 8353 39126
750 800 12,0...12,4 8353 31163
RSV 375---1175 53 500 11,9...12,5
A2C 2178---10R 10---15 375 11---16 4,1...4,7
320 DG Aggregate 8366 40382 PES 3A 95D 21 78---80 740 82---84 10,9...11,3 754---756 778---782 8353 31161
13.250/1 320 RS 2810 1500 750 10,9...11,3 8353 39126
/D 1570 760 8,6...9,0 8367 54532
RSV 375---750 33 770 6,1...6,5
14---1
A2C 2178---10R 780 3,8...4,2

420

420 D Valmet 665 8367 40392 PES 4A 95D 21 73---74 1150 77---78 9,8...10,2 1195---1205 1270---1285 8353 31161
4600 14.212 320 RS 2807 2350 1000 +0,4...0,5 8353 39126
/BE 750 900 +0,8...0,9 8353 31163
RSV 375---1175 59 600 +0,8...0,9
A2C 2178---7R 11---15 375 11---15 3,9...4,5
420 DS Valmet 6300 8367 40174 PES 4A 95D 19 82---84 1100 87---89 10,7...11,1 1130 1200---1210 8353 31161
14.226/1 320 RS 2807 2225 1040 10,9...11,3 8353 39126
/B 750 800 11,2...11,6 8353 31163
RSV 375---1125 63 500 11,2...11,6
A2C 2178---7R 11---15 375 11---15 4,2...4,5
420 DS Valmet 6400 8367 40157 PES 4A 95D 19 84---87 1100 91---93 11,2...11,6 1135---1145 1210---1230 8353 31161
14.227/1 320 RS 2807 2225 1000 +0,3...0,4 8353 39126
750 900 +0,5...0,6 8353 31163
RSV 375---1125 70 500 +0,5...0,6
A2C 2178---7R 11---15 375 11---15 4,2...4,5
420 DS Valmet 6600 8367 40173 PES 4A 95D 19 98---100 1100 101---103 12,3...12,7 1140---1150 1200---1220 8353 31161
14.228/1 320 RS 2807 2225 1000 ±0,2 8353 39126
/A 750 900 +0,4 8353 31163
RSV 375---1125 77 800 +0,5
A2C 2178---7R 500 ±0,5
11---15 375 11---15 4,2...4,5
420 D Hymax 8200 8367 40200 PES 4A 95D 21 83---84 1000 87---88 11,1...11,3 1030---1050 1090---1110 8353 31161
14.209 320 RS 2807 2000 800 ±0,1 8353 39126
/S 750 600 ±0,1 8353 31163
RSV 375---1000 60 11---15 375 11---15 3,9...4,5
14---2
A2C 2178---7R
420

420 DS Hymax 8200T 8367 40203 PES 4A 95D 19 104---106 1000 104---106 12,6...13,0 1030---1050 1190---1210 8353 31161
14.242 320 RS 2807 2000 800 ±0,1 8353 39126
/V 750 600 ±0,1 8353 31163
RSV 375---1000 80 11---15 375 11---15 4,0...4,4
A2C 2178---7R
420 D Wille 645 8367 40181 PES 4A 95D 21 76---78 1200 78---80 9,6...9,8 1230---1150 1290---1310 8353 31161
Joonas 14.202/1 320 RS 2807 2400 1100 +0,1...0,2 8353 39126
Lännen C15 /J 750 1000 +0,2...0,3 8353 31163
RSV 375---1200 62 900 +0,4...0,5
A2C 2178---7R 500 +0,4...0,5
11---15 375 11---15 4,3...4,7
420 D Wille 725 8367 40202 PES 4A 95D 21 77---78 1100 82---83 10,5...10,7 1125---1140 1185---1210 8353 31161
14.210 320 RS 2807 2200 800 ±0,1 8353 39126
/U 750 500 ±0,1 8353 31163
RSV 375---1100 60 11---15 375 11---15 4,5...5,1
A2C 2178---7R
420 DS Wille 745/ 8367 40201 PES 4A 95D 19 97---99 1100 98---100 12,1...12,5 1125---1140 1185---1210 8353 31161
845 14.241 320 RS 2807 2200 800 ±0,1 8353 39126
/T 750 500 ±0,1 8353 31163
RSV 375---1200 80 11---15 375 11---15 3,9...4,5
A2C 2178---7R
420 DSI Valmet 836 8367 40180 PES 4A 95D 19 101---103 1000 101---103 12,2...12,6 1120---1135 1185---1200 8353 31161
DW 838 14.235/1 320 RS 2807 2200 800 12,2...12,6 8353 39126
/H 750 500 12,2...12,6 8353 31163
RSV 325---1100 82 11---15 325 11---15 4,0...4,4
14---3
A2C 2178---7R
420

420 DW Valmet 828 8367 40399 PES 4A 95D 19 101---103 1200 102---104 12,4...12,8 1230---1240 1330---1350 8353 31161
DSM 836 14.237/1 320 RS 2807 2400 1100 +0,1...0,3 8353 39126
838 /BF 650 1000 +0,3...0,5 8353 31163
840 RSV 375---1200 84 900 +0,5...0,6
901 A2C 2178---R 700 +0,5...0,6
Marine 11---15 325 11---15 4,0...4,4
420 DSG Aggregate 8367 40386 PES 4A 95D 19 106---108 740 107---109 12,8...13,2 748---750 777---780 8353 31161
14.270/1 320 RS 2807 1480 750 11,6...12,0 8353 39126
/BD 1560 760 9,0...9,4 8367 54532
RSV 375---750 64 770 6,3...6,7
A2C 2178---7R 780 3,8...4,2
420 DS Lännen C20 8367 40176 PES 4A 95D 19 99---101 1200 101---103 12,3...12,5 1225---1240 1285---1310 8353 31161
C100 14.230/1 320 RS 2807 2400 800 ±0,1 8353 39126
C200 /D 750 500 ±0,1 8353 31163
James 73 RSV 375---1200 82 11---15 325 11---15 3,9...4,5
83 A2C 2178---7R
420 DS Lännen S30 8367 40178 PES 4A 95D 19 94---96 1000 97---99 12,1...12,3 1025---1035 1085---1110 8353 31161
M213 14.232/1 320 RS 2807 2000 800 ±0,0 8353 39126
T214 /F 650 600 ±0,0 8353 31163
M314 RSV 325---1000 70 500 ±0,0
T315 A2C 2178 R 14---17 325 14---17 4,2...4,6
420 DSI Lännen M215 8367 40179 PES 4A 95D 19 110---112 1000 110---112 13,1...13,5 1025---1040 1085---1110 8353 31161
M316 14.233/1 320 RS 2807 2000 800 ±0,0 8353 39126
/G 650 600 ±0,0 8353 31163
RSV 325---1000 80 11---15 325 11---15 4,0...4,4
14---4
A2C 2178 R
420

420 DWI Ponsse S 15e 8367 40194 PES 4A 95D 19 106---108 1200 106---108 12,8...13,2 1220---1235 1285---1300 8353 31161
14.240 320 RS 2807 2400 800 ±0,1 8353 39126
/R 750 600 ±0,1 8353 31163
RSV 375---1200 90 11---15 375 11---15 4,0...4,4
A2C 2178---7R
420 DSI Ponsse S 15e 8367 40162 PES 4A 95D 19 95---97 1150 1,0(* 11,6...12,0 1215---1225 1290---1310 8353 31161
14.236 320 RS 2654 2400 1000 1,0 +0,1 8353 39126
/PK 650 800 1,0 +0,3 8353 31163
RSV 325---1200 90 700 +0,4 Boost control operation
A2C 2218 R 500 1,0 +0,4 start at 0,45 bar (declining pressure)
95---98 800 0,0 11,8...12,0
12---15 325 0,0 4,8...5,0
*) boost pressure regulators pressure bar
420 DS Lännen C15 8367 54501 PES 4A 95D 19 86---88 1200 90---92 11,1...11,3 1225---1240 1285---1310 8353 31161
14.249 320 RS 2807 2400 800 ±0,1 8353 39126
/BU 750 500 ±0,1 8353 31163

RSV 375---1200 74 11---15 375 11---15 3,9...4,5
A2C 2178---7R
14---5
620

620 D Valmet 8000 8368 40210 PES 6A 95D 23 61---63 1100 64---66 7,6...8,0 1150---1160 1190---1210 8353 31161
16.205 320 RS 2806 2220 950 8,3...8,7 8353 39126
/F 750 700 8,8...9,2 8353 31780
RSV 325---1125 72 13---16 375 13---16 4,0...4,4
A0C 2178---8R
620 D Valmet 8100 8368 40158 PES 6A 95D 23 73---75 1100 77---79 8,9...9,1 1120---1130 1190---1215 8353 31161
16.203/1 320 RS 2806 2225 980 +0,3...0,4 8353 39126
750 800 +0,8...0,9 8353 31780
RSV 375---1150 88 500 +0,8...0,9
A0C 2178---8R 12---15 375 12---15 3,8...4,2
620 DS MF 3670 8368 40193 PES 6A 95D 21 101---103 1100 100---102 11,4...11,6 1130---1140 1170---1190 8353 31161
VA 66 SB 16.232/1 320 RS 2806 2200 1000 +0,3...0,4 8353 39126
1000 900 +0,4...0,6 8353 31780
RSV 500---1100 125 790 +0,5...0,6
A0C 2178---9R 500 +0,5...0,6
12---15 500 12---15 3,7...4,1
620 DSL Dr 8400 8368 39976 PES 6A 95D 21 90---93 900 92---95 10,4...10,8 1105---1110 1148---1157 8353 31161
MF 30 16.223 320 RS 2684 2200 18---22 1150 19---23 3,8...4,2 8353 39126
/CO 1000 11---14 500 11---14 4,0...4,4 8353 31780
RSV 325---1110 110
A0C 2178 2R x=1,5---2 R
620 DSL Dr 8700 8368 40195 PES 6A 95D 21 116---118 1100 113---115 12,5...12,9 1110---1115 1155---1165 8353 31161
MF 32 16.233 320 RS 2806 2200 20---24 1150 21---25 4,0...4,3 8353 39126
32 RS /DA 1000 12---15 500 12---15 4,0...4,4 8353 31780
RSV 500---1100 129
14---6
A0C 2178---9R
620

620 DSP VA 66S 8368 40230 PES 6A 95D 21 83---85 1100 86---87 9,8...10,2 1130---1140 1180---1190 8353 31161
16.238 320 RS 2806 2200 800 ±0,0 8353 39126
/DI 750 500 ±0,0 8353 31780
RSV 375---1100 106 12---15 375 12---15 3,8...4,2
A0C 2178---9R
620 DSA Sisu ---Masi 8368 40152 PES 6A 95D 21 0,8(* 1250 107---109 12,4...12,8 1270---1290 1340---1360 8353 31161
SA 130 16.230 320 RS 2832 2500 0,8 1000 ±0,0 8353 39126
/A 800 0,8 600 ±0,0 8353 31780
RSV 375---1250 132 0,0 600 102---104 12,0...12,1
A0C 2218---1R LDA
0,50 500 12,4...12,5
0,45 500 12,2...12,3
0,0 375 11---15 3,7...4,3
x=5,0 R
620 DG Aggregate 8368 40421 PES 6A 95D 23 850 9,8...10,2 897---899 936---938 8353 31161
16.250/1 320 RS 2806 1760 67---69 900 71---73 8,6...9,0 8353 39126
/DN 1570 910 7,3...7,7 8367 54532
RSV 740---900 81 920 6,0...6,4
A0C 2178---9R 930 4,6...5,0
940 3,3...3,7
620 DSG Aggregate 8368 54502 PES 6A 95D 21 700 13,9...14,3 748---750 776---778 8353 31161
16.274/2 320 RS 2806 1500 130---132 740 133---135 14,0...14,2 8353 39126
/DT 1570 750 13,1...13,5 8368 54727
RSV 500---1100 110 760 9,8...10,2
A0C 2178---9R 770 6,4...6,8
14---7
780 3,0...3,4
620

620 DS Valmet 860 8368 40398 PES 6A 95D 21 96---98 1200 97---99 11,5...11,9 1130---1140 1170---1190 8353 31161
911 16.237 320 RS 2806 2400 1000 11,6...12,0 8353 39126
/DE 780 800 12,0...12,4 8353 31163
RSV 375---1200 130 700 12,2...12,6
A0C 2178---9R 500 12,2...12,6
12---15 390 12---15 3,7...4,3
x=12 NAPS, 4,5 R
14---8
634
Idling r/min ISO 7440 ---1 mm 4 mm Covernor spring
Output kW rpm mm3 rpm rpm

634 D Valmet 8200 8368 54570 PES 6A 95D 22 1100 86---88 9,8...10,2 1130 1190---1210 8353 31161
18.201 320 RS 2806 2225 1000 9,9...10,3 8353 39126
/EG 750 900 10,1...10,5 8353 31780
RSV 500---1125 96 800 10,2...10,6
A0C 2178---8R 750 10,3...10,7
600 10,3...10,7
375 11---13 3,8...4,2
634 DS Steyr 9190A 8368 54524 PES 6A 95D 20 1,0(* 1100 120---122 13,8...14,2 1115 1180---1200 8353 31161
MF 3690 18.223 320 RS 2848 2200 1,0 1000 13,9...14,3 8353 39126
1000 1,0 900 14,1...14,5 8353 54532
RSV 500---1100 140 1,0 800 14,2...14,6
A5C 2269---R 1,0 750 14,3...14,7
1,0 600 14,3...14,7
LDA
0,65 500 14,0...14,4
0,42 500 12,4...12,8
0,0 500 12,2...12,6
500 16---19 6,5...7,5

14---9
FUEL SYSTEM
INJECTOR
Order no. Manufacturer Type Nozzle no. Opening pressure bar Setting pressure bar 1) Adjusting plate no. 1,00...2,00 mm Code (C)
8366 39956 Stanadyne S 8366 39957 230 240 8366 40104...8366 40122 736
8363 40034 Stanadyne S 8363 39985 230 240 8366 40104...8366 40122 655

8368 40397 Stanadyne S 8368 40396 230 240 8366 40104...8366 40122 105
8368 54786 Stanadyne S 8366 39957 260 270 8366 40104...8366 40122 780
8368 54755 Stanadyne M 8368 54757 270+8 278 8368 62000...8368 62020 423
8368 54791 Stanadyne M 8368 54792 270+8 278 8368 62000...8368 62020 876
8368 54831 Stanadyne M 8368 54832 270+8 278 8368 62000...8368 62020 446
8366 59808 Stanadyne M 8366 59902 270+8 278 8368 62000...8368 62020 358
8366 40167 CAV 8366 40165 230+8 250+8 8366 40337...8366 40355 (0,30...1,57 mm) ---
8367 64613 Stanadyne M 8367 64614 270+8 278 8368 62000...8368 62020 927
1) Value to be used when adjusting the opening pressure of a new or used injector.
14---10
Electrical System 15---1
15. ELECTRICAL SYSTEM
A. Alternators
Magneti Marelli A 127 45 A/65 A (Sisu Diesel no. 8366 40127 45 A)

(Lucas) (Sisu Diesel no. 8366 40128 65 A)
Nominal voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 V
Max. voltage 6000 r/min . . . . . . . . . . . . . . . . . . A 127 45 A . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 A
A 127 65 A . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 A
Earthing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (---) minus
Max. allowed speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 000 r/min
Brush length when new . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 mm
Min. brush length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm
Brush spring tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,3...2,7 N
Number of stator poles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Number of stator phases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Stator resistance . . . . . . . . . . . . . . . . . . . . . . . . . A 127 45 A . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,25 ohm
A 127 65 A . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,18 ohm
Rotor resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,9 ohm
Regulating voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13,6...14,4 V
Tightening torques:
1. Shaft nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm
2. Assembling screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,5 Nm
3. Phase connection (M5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,0 Nm
4. Regulator screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,5 Nm
5. Main connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,0 Nm
5
1
1
45 A
A 127 AC 5 RS
65 A 215--- 1
CAV AC 5 RS 24 V 55 A (Sisu Diesel no. 8353 39422)
Nominal voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 V
Output
2000 r/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 A
3000 r/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42,5 A
4000 r/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 A
Charge begins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1250 r/min
Max. allowed speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 000 r/min
Min. slip ring diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 mm
Brush spring tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,23 N
Rotor resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8,0...8,3 ohm
Stator resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,09 ohm
Tightening torques:
1. Shaft nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Nm

Bosch N1 28 V 10/80 A (Sisu Diesel no. 8353 39751)
Nominal voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 V
Output
1500 r/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ³16 A
2700 r/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ³53,5 A
6000 r/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ³79 A
Min. slip ring diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26,8 mm
Brush length when new . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 mm
Min. brush length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm
Rotor resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7,5...8,2 ohm
Stator resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,057...0,062 ohm
Regulating voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 V
Tightening torques:
1. Shaft nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Nm
2. Assembling screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,1...5,5 Nm
3. Regulator screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,6...2,3 Nm
4. Joint B--- (M6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,8...6,8 Nm
5. Joint W (M5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,7...3,8 Nm
6. Joint D+ (M4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,6...2,3 Nm
7. Joint B+ (M8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7,5...8,0 Nm
5 1 6 1 4 5
3
2 6
7 7
3
2
80 A 100 A 215--- 2
Bosch N1 28 V 0/100 A (Sisu Diesel no. 8353 40374)
Output (warm generator, testing voltage 26 V)
2000 r/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ³26 A
3500 r/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ³72 A
7000 r/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ³94 A
Brush length when new . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 mm
Stator resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,038...0,041 ohm
Regulating voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28,5 V
Tightening torques:
1. Shaft nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Nm
2. Assembling screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,1...5,5 Nm
3. Regulator screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,6...2,3 Nm
4. Joint B--- (M6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,8...6,8 Nm
5. Joint W (M5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,7...3,8 Nm
6. Joint D+ (M4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,6...2,3 Nm
7. Joint B+ (M8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7,5...8,0 Nm

Iskra AAK 5118 14 V 95 A (Sisu Diesel no. 8366 40927)

(Sisu Diesel no. 8366 66225)
Output (testing voltage 13 V)
2000 r/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ³50 A
4000 r/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ³84 A
6000 r/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ³94 A
Charge begins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1100 r/min
Max. allowed speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 000 r/min
Stator resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,33...036 ohm
Tightening torques:
1. Shaft nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50...70 Nm
2. Joint B+ (M6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,2...6,0 Nm
3. Joint D+ (M5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,7...3,8 Nm
4. Joint W (M 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,7...3,8 Nm
1 3
215--- 3
Bosch NC 14 V 70 ---120 A (Sisu Diesel no. 8368 40939)
Output (13,5 V)
2000 r/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 A
4000 r/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 A
6000 r/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 A
Charge begins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200 r/min
Max. allowed speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 000 r/min
Brush length when new . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12,5 mm
Tightening torques (see figure above):
1. Shaft nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60...70 Nm
2. Joint B+ (M8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm
3. Joint D+ (M5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Nm
Bosch NC 14 V 150 A (Sisu Diesel no. 8368 64048)
Brush length when new . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12,5 mm
Tightening torques (see figure above):
1. Shaft nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60...70 Nm
2. Joint B+ (M8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm
3. Joint D+ (M5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Nm

B. Starters
Magneti Marelli M 127/2,8 12 V (Sisu Diesel no. 8353 31592)

(Lucas)
Values, unloaded
Running speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5500...8000 r/min (max.)
Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 A
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 V
Values, under loading
Running speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000 r/min (max.)
Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 670 A
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8,0 V
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20,8 Nm
Values, locked
Running speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 r/min
Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1160 A
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,0 V
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45,4 Nm
Brush spring tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11,6...15,5 N
Min. commutator diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 mm
Tightening torques:
1. Solenoid battery jointing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Nm
2. Solenoid retaining screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Nm
3. Fork link nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm
4. Assembling screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Nm
5. Earth joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Nm
1
3
0,14 ... 1,14
5 4 Magneti Marelli 215--- 4
Bosch JF (R) 24 V 4kW (Sisu Diesel no. 8353 30965)

Bosch JF (R) 24 V 4 kW, 2 ---pole (Sisu Diesel no. 8361 30388)
Values, unloaded
Running speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . >7000 r/min
Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . <85 A
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 V
Values with armature locked
Running speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 r/min
Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 900...1050 A
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13,5 V
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . >65 Nm
Solenoid engaging voltage min. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 V
Min. brush length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8,5 mm
Min. commutator diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42,5 mm
End play of armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,1...0,3 mm

Iskra AZJ3234 12 V 3,1 kW z11 (Sisu Diesel no. 8366 40949)
Values, unloaded
Running speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . £10 000 r/min
Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . £140 A
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 V
Running speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 r/min
Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . £1660 A
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,6 V
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ³45 Nm
Brush length (new) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 mm
Brush spring tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40...48 N
Min. commutator diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43,5 mm
Tightening torques:
1. Studs (M6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,8 Nm
2. Screws on solenoid (M5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,2 Nm
4. Pole shoes (M10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Nm
Brush holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,2 Nm
Lever pin on engagement lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Nm
Contact screws on solenoid switch (M8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8,5 Nm
Contact screws on solenoid switch (M10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Nm
Iskra AZJ3247 12 V 3,6 kW z11 (Sisu Diesel no. 8366 40940)
Values, unloaded
Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . £140 A
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 V
Running speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 r/min
Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . £1756 A
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,3 V
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ³47 Nm
Min. commutator diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43,5 mm
Tightening torques:
1. Studs (M6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,8 Nm
4. Pole shoes (M10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Nm
Brush holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,2 Nm

Iskra AZJ3319 12 V 3 kW z10 (Sisu Diesel no. 8366 40949)
Values, unloaded
Running speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . £8000 r/min
Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . £90 A
Running speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 r/min (max.)
Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . £1375 A
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ³51 Nm
Tightening torques:
Studs (M6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,8 Nm
Screws on solenoid (M5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,2 Nm
Pole shoes (M10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Nm
Brush holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,2 Nm
Iskra AZJ3256 24 V 4 kW z11 2 ---pole (Sisu Diesel no. 8366 64355)
Values, unloaded
Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . £80 A
Running speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 r/min (max.)
Amperage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . £1200 A
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ³70 Nm
Tightening torques:
Studs (M6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,8 Nm
Pole shoes (M10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Nm
Brush holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,2 Nm

C. Electric stop device
FASTENING TO INJECTION PUMP
Assembly Loctite 242
1. Solenoid Loctite 242

2. Thread sleeve
3. Rubber bad
4. O ---ring 2 3
5. Screw
6. O ---ring
7. Parts to be removed
4 5 6
1
Electrical connection
30 87
*
1. Solenoid 86
2. Relay 85
3. Fuse
10 A
4. Battery 6 7 3
5. Starter 2 1
6. Ign. switch
7. Fuse
Johdin
Wire 2,5 mm 2
Kabel
4 5
215--- 5
* Relay control voltage must not break during engine crank-

ing.
--- Max. wire length with 2,5 mm2 wire:

--- 2,7 m 12 V system
--- 10,4 m 24 V system
--- It is not allowed to connect any other power consuming
devices to the solenoid feed lines.
--- Voltage drop in wiring should not exceed 7 % of rated
voltage when pull coil is activated.

FASTENING TO BRACKET A. Connect a voltmeter or a suitable lamp between the sole-

noid positive pole and AUX---pole. When the current is
Checking the solenoid operation (Synchro start) switched on and the solenoid moves to the end of its motion
range, the voltmeter reading should indicate approximately
battery voltage or the light should be on. If such is not the
case, adjust the leverage or change the position of the sole-
25,4 noid.
B. Before attaching the drawing lever or the bar, press the

plunger in until it is complete down. Measure the solenoid
length, e.g. from bottom plate edge to a suitable spot on the
plunger rod. Fix the leverage and energise the solenoid.
Measure the length again and ensure it remains unchanged.
215--- 6
Testing the external circuit of the solenoid

The solenoid plunger has 25,4 mm motion range. Fix the sole-
noid and adjust the leverage in such a way that the energised Measure the voltage between the positive and negative poles
plunger will reach its lock position. of the solenoid when the current is on and the draw coil draws.
At the same time measure the voltage between the battery
Following are the methods to establish the solenoid plunger poles. The voltage difference may not exceed 7 % of battery
being in its lock position when the current is switched on. voltage.
Note! Operating the solenoid more than six times within a

minute may result in overheating of coils.
AUX
215--- 7
Checking the solenoid operation (Elettrostart)
A B
A Running position
B Stop position
For a correct use of the dual coil solenoid (pull coil and hold
coil) the plunger should reach the end of its magnetic stroke
at each pulse. In this way, it will press the internal switch which
connects the continuous operation second hold coil working
without over ---heating and with a minimum power absorption.
1. Fit the solenoid energized and adjust the leverage in such

a way that the stop lever will reach its position or running posi-
tion (stop solenoid energized during running).
Note! Energize the solenoid through a battery with suitable

voltage and keep it energized during installation.

D. Installation of magnetic pick up
1. Rotate the flywheel to a position so that one of the flywheel

ring gears teeth are in front of the pick up installation hole.
0,75
215--- 8
2.Turn the pick up in, until it comes in contact with the tooth.
3.Turn the pick up out ½ turn and tighten the lock nut. This way
the pick up end is 0,75 mm from the tooth.
Note! Clean the pick up end from dirt in the yearly service.
E. Temperature sensor
1
215--- 9
1. Connection for warning light

2. Connection for temperature gauge
Gauge monitoring resistances:
60˚C . . . . . . . . . . . 134 ± 13,5 ohm

90˚C . . . . . . . . . . . 51,2 ± 4,3 ohm
100˚C . . . . . . . . . . . 38,5 ± 3,0 ohm
Part no. Alarming tem-

perature
6542 71208 98±3˚C
8366 40772 106±3˚C
8366 64017 110±3˚C

Optional Equipment 16---1
16. OPTIONAL EQUIPMENT
A. Compressor (Bendix)
A 5 6 D 3
7
C 2 4
G 1
10
8 H
11
12
140 Nm
13 F 216--- 1
A. Cylinder head retaining screws 1. Inlet valve heads

2. Spring
B. Cylinder head
3. Valve guide
C. Valve plate
4. Gasket
D. Ventil plate retaining screws
5. Delivery valve heads
E. Cover
6. Spring
F. Bottom cover
7. Gasket
G. Valve seat
8. Air filter
H. Crankcase
9. Gasket
10. Unloader saddle and spring
Note! The numbered parts (1...13) are included in the repair
11. Piston
kit.
12. O ---ring
13. Gasket
DISASSEMBLY
4. Remove the unloader spring and saddle as well as the pis-
1. Remove the retaining screws (A, 11 pcs.), take off the cylin-
tons and the o---rings seals.
der head and the valve plate. Remove the inlet valve heads,
springs, valve guides and gasket.
5. If necessary, remove the rear end cover and its o---ring seal
and the bottom cover with its gasket.
2. Loosen the retaining screws (D, 2 pcs.) and detach the cyl-
inder head from the valve plate. Remove the delivery valve
Note! Do not try to remove the valve seats. They are pressed
heads, springs and gasket.
in during manufacture and are integral parts of the crankcase.
3. Remove the retaining screws of the air filter (if assembled)
and take off the filter and the gasket.

INSPECTION B. Compressor (Knorr)

1. Thoroughly clean all removed parts. Ensure that all air and
water passages are clear. Clean off any carbon from the pis-
ton heads and the cylinder top parts.
2. Check the condition of the inlet and delivery valve seats. 12 Nm

Only slight, even wear is permitted. If the delivery valve seats
show considerable wear, renew the valve plate. If the inlet
valve seats are excessively worn, replace the crankcase. You 130 Nm
can also replace the inlet valve seats, but then you need to re-
bore the cylinders after the new seats have been fitted.
Note! There are two oversize pistons supplied for the com-
pressor. The oversize are 0,254 mm and 0,508 mm. Bore the
cylinders then to the dimensions ø 75,254 mm or ø 75,508
mm.
3. Ensure that the new unloader pistons are a good sliding fit 2,5...3,0
in their guides. If the guides are appreciably worn, renew
them.
4. Check the bearings for wear and replace them, if necessary.

If needed, the slide bearing in the end cover can be renewed.
0,1...0,4
REASSEMBLY
1. Fit a new o---ring seal in its groove and place the end cover
in its position by pushing from the back. Tighten the cover re-
taining screws evenly to 17...23 Nm.
2. Fit the bottom cover with a new gasket in place (if removed). 22 Nm
80 Nm
Tighten the cover retaining screws evenly to 8...10 Nm.
3. Insert new o---rings in the unloader pistons. Lubricate the

o---rings and the piston guides lightly with e.g. silicone lubric-
ant. Fit the pistons in their guides and reassemble the un-
loader saddle and spring. Ensure that the unloader mechan- 30 Nm
ism moves freely.
4. Fit the delivery valve heads and springs into the valve plate.
Insert a new gasket and fix the valve plate in the cylinder head.
Tighten the screws to 5,4...8,1 Nm. Ensure that the valve
heads move freely. DO NOT LUBRICATE THE VALVE
HEADS OR SPRINGS!
5. Fit the inlet valve head guides into their recesses with the
cut---away sides towards their respective cylinder bores. As-
semble the inlet valve heads and the springs. Fit the cylinder
head using a new gasket. Tighten the retaining screws evenly
to 20,3...23,0 Nm. Ensure that the valve heads move freely. 22 Nm
DO NOT LUBRICATE THE VALVE HEADS OR SPRINGS!
22 Nm
6. Attach the air filter (if necessary) and use a new gasket.
22 Nm
60 Nm
216--- 2

C. Industrial clutch (A.P. Borg & ADJUSTMENT
Beck) The clutch is correctly adjusted when the engagement load at

the end of the operating lever is 34...41 kg (operating lever
length 63,5 cm).
SERVICE
Note! Never service or adjust the clutch with the engine

Adjusting rings of the clutch
running.
4
3
216--- 4
1. Remove the inspection cover and release the adjuster lock

on the red adjusting ring.
2
216--- 3
1. Inspection cover
2. Pull---out hole
3. Grease nipple for release bearing
4. Grease nipple for main bearing
216--- 5
1. Lubricate the release bearing daily and the main bearing at
intervals of 50 running hours. Use lithium ---based grease for Note! Some clutches have a socket headed screw to lock the
lubrication (e.g. Shell Alvania no. 2). adjusting ring. Remove the screw before adjusting. After ad-
justment tighten the screw to 13,5...18 Nm and ensure that
2. At intervals of 500 running hours lubricate the wrist pins, the the inner end of the screw engages between the splines on
yoke ends and the cross shaft bearings with a few drops of en- the body.
gine oil.
2. Turn the adjusting ring clockwise by hand or by tapping with
a light hammer, until the correct adjustment is reached.
3. Fit the adjuster lock and the inspection cover.

Adjusting the main bearing
The tapered roller bearings on the drive shaft must be ad-

justed when the shaft end play exceeds 0,25 mm.
max.
1 A 0,25 "
1. Lock plate
2. Tapered roller bearings
3. Adjusting ring
216--- 6
1. Remove the inspection cover and take off the lock plate.
2. Using a soft metal drift turn the adjusting ring towards the
bearing, until the drive shaft end play is 0,10...0,20 mm. One
notch of the adjuster is equivalent to about 0,09 mm bearing
movement.
Note! The bearing will be overloaded and will run hot, if all end
play is eliminated. After adjustment ensure that the shaft end
play is sufficient (0,10...0,20 mm).
3. Replace the lock plate and the inspection cover.
Removing the power take ---off from the engine
1. Disconnect the drive from the clutch and remove the pulley/
coupling and the shaft key.
2. Support the weight of the power take ---off with e.g. chain
hoist. Remove the clutch operating lever.
3. Loosen the clutch retaining screws. The clutch housing

flange has pull---out holes (thread ½” BSF). Place screws in
the holes and tighten them one half of a turn at the time alter-
nately, until the clutch housing is removed from its spigot.

Workshop Manual: Sisudiesel 320 420 620 634

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Workshop Manual: Sisudiesel 320 420 620 634

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WORKSHOP MANUAL

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Sisu Diesel Inc.

Diesel Engines, After Sales

Sisu Diesel Inc. takes no responsibility for any damages caused

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H. Removing fuel injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13---10

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--- engine type

ENGINE TYPE DESIGNATIONS

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Do not start a repair work that you do not fully handle.

Open fire, smoking and sparks should not be allowed

Do not use faulty or otherwise useless tools.

When checking fuel injectors do not let the jet of high

The fuel, lubricating oil and coolant cause irritation in

Start the engine only by using the starting switch in the

Do not start an engine if the protection covers are re-

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LIFTING THE ENGINE

A = Engine lifting ears

Engine weight: see Engine Specifications

LOCATION OF THE ENGINE SERIAL NO.

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1 9051 73100 Puller for cylinder liner

6 9052 46620 Drift for 40 mm cup plug

11 9101 66100 T ---handle for valve seat milling cutter

16 9101 65505 Milling cutter for inlet valve seat

21 9052 46660 Drift for 36 mm cup plug

26 9052 48800 Puller for crankshaft gears

41 9025 99000 Control rod locking bush

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Holes for guide pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13,250...13,320 mm

Protrusion of cylinder liner above cylinder block top face . . . . . . . . . . . . . . . . . . . . . . . . . . 0,030...0,080 mm

Height of cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104,800...105,000 mm

Diameter of exhaust valve seat ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44,070...44,132 mm

Diameter of inlet valve seat ring (8366 47936) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48,570...48,632 mm

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Valves, rockers and tappets

With a valve clearance of 1,0 mm:

Diameter of camshaft bearing journal no 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49,925...49,950 mm

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Camshaft clearance in bearing bushes (others than no 1) . . . . . . . . . . . . . . . . . . . . . . . . . 0,090...0,140 mm

Main bearing journal diameter:

Main bearing shell thickness:

Main bearing clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,050...0,127 mm

Other crankshaft journals may not be ground longer.

Crankshaft end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,100...0,380 mm

Flywheel ring gear no. of teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 pcs

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Balancing unit (420---engines)

On crankshaft gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 dots on tooth

Big end bearing shell thickness:

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Piston, rings and pin

Width of ring grooves:

Side clearance of piston rings in their grooves:

Piston ring height (in direction of cylinder):

Piston ring gap (with piston fitted in cylinder)

Max. permissible weight difference between pistons in same engine . . . . . . . . . . . . . . . . . 25 g

Oil pressure at normal running temperature:

Oil pump (320, 420---engines)

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Outside diameter of gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43,486...43,525 mm

Oil pump (620/634---engines)

Coolant pump (320, 420---engines)

Outside diameter of bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38,087...38,100 mm

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Coolant pump (620/634---engines)

Outside diameter of bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 mm

Pump equipped with reinforced bearing:

Spare part number Type Opening Fully Max. stroke

8361 15646 ø67/79˚C 79˚±2˚C 94˚C 8