ml Engine Blo« cree 10. Engine Block with Bearings, Cylinder and 10.1 10.2 Oil Sump Description ‘The cast iron engine block is cast in one piece. The jacket water distributing pipes and the charge air receiver are integrated in the fengine block The main bearing eapo, which support the tndorslung, crankshaft, are clamped by hydraulically tensioned screws, two from below and two horizontally. The bearing shells are axially guided by lugs to provide correct assembly. ‘A.combined flywheelthrust bearing is located at the driving end. The flywheel bearing shells are ofthe same type as the main bearings. The four thrust wathers guide the crankshaft axially ‘Thecamshafl bearing bushes are fitted in housings directly machined in the engine Hock. ‘The cylinder liners, made of special cast iron, have cooling bores in the upper flange. At'the upper part the liners are sealed against the block metallicaly, and atthe lower part by two O-rings. ‘To eliminate the risk of bore polishing, the liner is provided with an anti polishing ring at the upper part. ‘The crankease covers, as well as other covers, tighten against the ‘engine block by rubber sealings and four serews each. On one side of the engine thecrankcase covers are equipped with safety valves which relieve the overpressure in ease of a crankease explosion. One cover incorporates the ol fing hole. The crankcase is furthermore provided with a vent pipe including a non-return valve, This pipe should be conducted away from the engine room. ‘The light, welded oil sump is attached to the engine block from below ‘and is sealed by an O-ring. Suction pipes to the lube oll pump and ‘separator as well asthe main distributing pipe for lube oil are incorpo- rated in the al sump. ‘From the main distributing pipe the lube ol is led up to the main bearing through a hydraulic jack, by means of which the bearing cap can be loweres and lifted, e.g. when inspecting the bearings. Main bearings 10.2.1 Dismantling of the main bearing IH Remove two crankcase covers on each side of the bearing, on both sides of the engine. w-1iors: SOE! BZ Loosen the nus of he side sorews on the bearing in ques- tion and on both adjacent bearings, Fig 10-1 (A). Lit the distance sloeve sV86B46 screw. One or two nuts can be loosened into position «n the side simultaneously. Ei Screw on the hydraulic tool $V86878 and proceed with open- Ing of the side serew nuts (A) 1 Loosen the nuts of the main bearing screws on the bearing ‘m question as shown in Fig 10-1 (B). Use of hydraulic cylinders pea side oe Ae ‘oer Ie re Tes | Re RE RTT or ae ae vor = eae ar ore ei eam noose even toowring A [Raanie a nts Reeecamee stim, | 916-60 oe Sencar are Ss [arena ean oh a TST Se oteng 1 |SRnrO ES” oes Wis Jager reenter esigeeapemre | — Wr iincigen seo oeaeneoas ns [ERTS aman OOTY di ie Som 10-2EYES ae TE Ut the distance sleeves 386839 into position and inser the pins 4Ve6B02 Lit ne hydrauc tool 386879 nto postion by using the inl EVB6DIE and proceed with opening offre main bearing nuts). Bl Remove the nuts of the main bearing serows. [connect the notes of he hydraulic pump IVB5AIB to the Rrraulcjch the rappiying hove st tothe side marked DOWN, see Fig 10-2 Unserow the side screws of he main beating cop tbe low red. Use the stud too 4V80D12. HI Lower the main bearing cap by pumping ol pressure to the hydraulic jack by the hydraulic pump. TB. romove tne iower bearing sll. Insert he turning tool 4V85B12 (in-line engine) or 4V85B16 {Weengine) into the main bearing jouraal radial ol hole. Tum the crankshatt carefully until the bearing shell has turned 180° and can be removed. Coverthe fo main boating journal radial ol holes with tape. At least every third main bearing should be in place at the same ‘me to support the crankshaft Hydraulic jack Shralghl side of main bearing cop fig 10-2 ‘ian 10-310-4 ETERS 10.2.2 Inspection of main bearings and journals Clean the bearing shella and check for wear, scaring and other dass ages. ©) Irimetal bearings can be used until the overlay is partially worn of ‘When the under laying nickel-barrier or the lining material is exposed in any area, the bearing must be replaced Never re-install a bearing with the nickel-bartier exposed in any’ part ofthe beating shell b) Bi-metal bearings. Wear is settled by measuring the thickness of the lower bearing shells. Fr this purpose a ball anvil micrometer can beused. The wear limit in section 06.2 mus: be applied. Ithe thickness of lower bearing shells have not reached the wear limit and the difference in thickness ofall lower bearing hells is max, 0.03 mm, the shells ean be used again. ‘Mark the new bearings with the bearingnumbers. ‘The main bearing journals should be inspected for surface finish. Damaged journals, ie. rough surface, seratches, marks of shocks etc., should be polished. If after a longer running period, considerably ‘uneven wear appears, section 06.2, the crankshaft may be roground and used together with thicker bearing shells, see Spare Parts Cata- logue. ‘No scraping or other damage of bearing shells, caps and saddles is allowed. Burrs should be locally removed, only. 10.2.3 Assembling of main bearing Clean the main bearing shells, the cap and the journal very carefully, Take off the protecting tape from the journal oil holes and Tubricate the journal with elean engine oil lubricate the bearing surface, back side and end faces of the ‘upper bearing shell with clean lubricating oi. The bearing shell can be completely destroyed (deformed) during the assembly, ifitis not lubricated carefulCaution! Pace te end of he beating shell in the slot between the Journal andthe Dering bore, with thetug guiding inthe ol grove, and push it by hand as far as possible (recommended 2/3 of its length Insert the fuming fool 4V85B12 (in-line engine) or 4V85B16 (Weengine)nta th mai beating journal radia if hole and turn the Crankshaft carefully anti te bering hel as tured int postin ‘oli care thatthe bearing shell lgelids into thecll groove without tng damaged ‘Abocring shell forced info its place can be completely destroyed duet cetormation. ° "yGoston Gl Remove the turing tool. Lubricate the bearing surface ofthe lower bearing shell with ‘lean lubricating ol and place fin the bearing csp 1 Connect the hoses of the hydraulic pump 1V86A18 to the Ihyéraulic jack, the supplying hose set to the side marked UP, see Figi0-2 1 iit tne main bearing cap by pumping ail pressure tothe hy- Grouie jack with the hydeaulte pump. TB Lwbiicate the treads ofthe side sexows (the threads towards the bearing eap) and tighten the screws to the bottom or use the stud tool 4V80D12 HD tighten the nuts by hand. TE. ut tne distance sleeves 386846 into position on the side ferews on the rear side on an inline engine, oF B-bank on an ‘Vaegine, One ortonuts canbe tightened simultaneously, Fig 10-1 (an) Serew on the hydraulic too! 386878. Tighton the nut by the pin 4V86B11 when the hydraulic pres- sure ir 200 bar. Lit he distance sleeves 3V86839 info postion on the bearing capserows and inser the pins 4VB6B02, see Fig 101 TB un ne nydroutc tool 3¥86879 into postion by using the toot S5Vs6B52 and proceed with tightening of the main bearing screws ® Lit he distance sleeves 386846 into position on the side screws on the rear side on an in-line engine, or B-bank on an ‘Veengine, straight side of the hearing eap! One or two nuts can be tightened simultaneously, Fig 10-1 (Aa) Serew on the hydraulic tool 3V86878 and proceed with tight ‘ening of sige screw nut (Aa). Tighten to fll stated pressure, 10-510.3 10-6 Engine Me en it the distance sleeves 3V86846 into postion on the eppo- site manoeuvering side screws. One or two nuts can be tightened simultaneously, Fig 10-1 (At). El] screw on he hycaulc foo! 386878 an proced with sight ting of ede crew mats (A) Pghten to il seated presse, Flywheel/thrust bearing 10.3.1 ismantling af flywhaal/thrust bearing Hl Remove the two crankcase covers next tothe Aywheel end, ‘on both aides ofthe engine. On 4R#2, remove the divided end cover inside the flywheel. 1 Loosen the nuls ofthe side screws onthe fywheeVthrusthear- ing and the adjacent main bearing, Fig 10-1 (A). Li the distance sleeve 3V86B46 info postion on the side aerew. Two nuts can be loosened simultancously. ‘Screw on the hydrauilc fool 3V86B78 and proceed with spen- Ing of the side serew nuts (A) Loosen the nuts ofthe lywheet/hrust Bearing serows x shown in Fig 10-1 (8) ft the distance sleeves 3V86B46 into position and inser: the pins 4V86B11 HZ screw on the hydraulic tools SV86B78. If necessary, ure the lifting tool SVBSB52, Proceed with opening of bearing screws (B) Remove the nuts of te fywheet/thrust bearing screws. EL Connect the hoses of the hydraulic pump 1V86A18 to the [hydraulic jack, the supplying hove set to the side marked DOWN, see Fig 102. HD) Unscrew tne side screws of ihe flywheel/thrust bearing cap. “Use the sud tool 4V@0D12. Hil Lower the bearing cap by pumping oil pressure to the hy- Araulie jack with the hydraulic pur. Remove the lower bearing shell and the thrust washers. To remove the thrust washer next tothe driving end, an M6 screw can be ited t each end ofthe washer, see Fig 103, Inset the turing toot 2VASB1S into the besring journal r ial olf hole, Tum the eronkshatt carefully until the bearing shell and the ‘washers have turned 180° and can be removed. BBS cover he two bearing journal racial ol hotes with tape.Ti check the bearing in the same way as the main bearings, section 10.2.2. The thrust washers on the same side have to be changed in pairs. Thust bearing Fig 10-9 ae 10.3.2 Assembling of flywheel/thrust bearing Hl Clean the bearing shells, washe's, cop ond joumal very carefully. Take off the protecting tape from the bearing journal radial oil holes and lubricate the journal with clean engine oil. Eh tubiicate the bearing surtace, back side and both ends of the upper bearing shell with clean lubricating oil and place the end of the bearing shell in the slot between the journal and the bearing bore. The exial location af the shell sto be secured by keeping the bearing shel end recesses at level withthe axial faces in the engine block, see Fig 10:5 El insert the shell by hand as far as possible (recommended 2/3 of | ite length. Gi insert tho turing tool SV85B15 into the bearing journal radial silhole and turn the erankshaftcarefully until the bearing shell has ‘turned into position. 10-7Caution! ‘A bearing shell forced into its place can be completely destroyed ‘due to deformation. [El Remove the tuming tool. Lubricate the bearing surlaces and back sides ofthe upper thrust washers and push the washer into postion by hand. To facilitate the mounting ofthe washer, th crankshat ean te axially Cisplaced in each direction, El tuniicate the beating surfaces of the lower thrust washers snd push them into postion on the guiding pins inthe bearing cep. Formounting the thrust washer nest tothe driving and an M6 sere an be ited to each end ofthe washer, soe Fig 10.3. EL uniicate the bearing surtace ofthe lower bearing shell with dlean lubricating oil and place the shell in bearing cap. Th axial Ibcation ofthe shell isto be secured hy keeping the bearingehell end recesses at level withthe axel faces in the cap, see Fig 1-3 TE connect the hoses of the hydraulic pump IVBGA18 to the Iyydrauli jack, the supplying hose set to the side marked UP, see Fig 10-2 TD) uinthe bearing cap by pumping oil pressure tothe hydraulie jack with the hydraulic punnp Screw the side screws into the threads of the bearing cap by hand, KE tighten tne side screws to the bottom or by using the stud tool 4ve0D12, Tighten the nuts of the side screws on the rear side of the en- gine as shown in Fig 10-1 (A). KB Litt the distance sleeves 3V86B46 into position on the fly- ‘vheel/Athrust bearing screws and insert the pins 4V86B11, see Fig 10-18), ‘Screw on the hydraulic tools 3V86B78. If necessary, use the lifting tool SVB6BS2. Proceed with tightening ofthe bearing serew ats (B). {Burt the distance sleeve 386846 into position on the side screw. ‘Two nuts can be tightened simultaneously. IB screw on the hydraulic tool 3VB6B78 and proceed with tight- ‘ning of side screw nuts (A)SEMI) 10.4 Camshaft bearings 10.4.1 Inspection of the camshaft bearing bush When the camshaf bearing journal has been removed, the inner diameter of the bearing bush can be measured at site, by using a ball fv micrometer sre The wear lini is stata in chapter 08, c:ton 0621 to wear lit fer aneeamahaf bearing bush sreeched, all caratat bering bushes shold be replaced. Fer visual inspection of the camshaft bearing bush, proced as follows THI remove both camshaft covers adjacent tothe bearing con- cornet. Remove he cover (6) from the starting air distributor, see chapter 14 Fig 142 loosen he rocker arm bracket fastening nus, see. Fig 14-1, pos 1y om the eylindre where the camesat ie to bo replaced Recording tostop, below IE open th ange connection camshaf ploce/beating ounal towards te sriing end of the engine seen fom the Neurng cerned ‘Move the part of the camshatt located towards the free end of the engine max. 25 mm in the direction of the free end by using a suitable lever, Tl Check the uncovered part of the bearing bush by means of ‘a mirror. All camshaft bearing bushes towards the free end of the ‘engine, seer from the bearing concerned, can be checked when the ‘camshaft is in this position. 10.4.2 Removing of camshaft bearing bush Remove the camshaft cover, injection pump, guide block and cemshaft piece from the two cylinders adjacent to the bearing concerned. if itis the question of an end bearing, the respective camshaft end piece has to be removed, i Remove the camshaft bearing journal. El Assombie the removing device 32.8305 according to Fig ‘10-4. Notice the difference in tool assembly for the bearing next to the free end of the engine. When itis a question of an end bearing, insert the guide sleeve 2V83H149, the thicker part being directed towards the middle of the engine. Zl Tighten the hydraulic toot sV83E61 by tensioning the pull serew 4VB3G46. Connect the hoses of the hydraulic pump 2V86A36 to the hydraulic too 10-9Pump pressure fo the hydraulic tool to withdraw the bearing bush Tae pressure must not exceed the value stated in chapter 07 Fig 07-14. Ifthe bearing bush does not move when thi pressure is achieved, alight mock on the end flange 3VS3EI150 can be neces sary. —_—-_2 EZ open the pump valve, disconnect the hoses of the hydraulic = tool and dismantle the moving device i Szeisese "0% — Removing of camshaft bearing bush {EES Memovhgotcansatbeaing bs 2vestt148 | sveaee1 veseet Fig 10-4 ae 10.4.3 Mounting of camshaft bearing bush 1 Lightly ubricate the new boating bush with clean engine oit on the outer surface and pation the guide sleeve 2V83H1189. The notch onthe Searing bush side should be portioned downwards, Le. the oll groove upwards mb the mounting device 32.83E05 according to Fig 1055, Notice the difference in tool assembly forthe bearing next to ( the free end f the engine, When itis a question of an end bearing, inser the guide sleeve 2V85H149, the thinner part being directed towards the midale of the engine. Tighten the hydraullc tool 3V83E61 by tensioning the pull ‘screw 4V83C45 lightly. Connect the hoses of the hydraulic pump 2V86A36 to the ‘hydraulic tool E Pump pressure to the hydraulic tool to mount the bearing bush, The pressure must not exceed the value stated in chapter 07, Fig 07-14. EX open the pump valve, disconnect the hoses of the hydraulic tool and dismantle the mounting device. 10-1010.5 FL Lubricate the bearing sutace of he beating bush and in sert the camshaft bearing journal. I Mount the camshaft pieces, guide blocks, injection pumps and ccarnshaft covers Mounting of camshaft bearing bush (aveRHAB 2vssH48, | svascag\ 2vesH 7 E61 3V83661 Fig 10-5 st Cylinder liner Honing of cylinder liner bore Always hone the eylinder liner when new piston rings are mounted. ‘Normally a light honing is sufficient. Ifthe honing is done when the cylinder liner is on its place in the engine block, the crankshaft ander the eylinder liner concerned must be cavered by plasti film, Honing rests must be prevented from falling into the oil sump of the ‘engine, For the honing process the following instructions are pre- senibed: ‘= The honing is to be carried out by means of “Plateau honing’ * Only coramie hones with a coarseness of 80 and 400 should be used, The hones with a coarseness of 80 should be used for about 20 strokes or until the polished areas in the cylinder liner are over seraping. The hones with a coarseness of 400 should be used for ‘about 30 strokes to give the correct surface finish, + The pitch angle of the honing lines in the cross hatch pattern should be about 80°, which is achieved by combining for example 40 strokes/min with a rotational speed of 100 RPM. 1-11SMart a + As coolant a honing cil could also be used. * After honing, the liner bore must be carefully cleaned by using a suitable brush, water (preferably hot) and soap or cleaning fluid, alternatively, light fuel oil. Then dry with a cloth and lubricate ‘with engine oil for corrosion protectien ‘The honing equipment is delivered with the engine, Check the inner diameter of the cylindsrliner, use form No. 3210V001. preferred, but a light fuel oil 2-16 cSt BI Cleaning of he cytinder liner water side 10-12 ‘The water side ofthe eylinder liner can be cleaned of deposits with a ‘wire brush. The cooling bores in the colar can be cleaned by boring with a suitable drill (@ 8.5 - 10 mm) 10.8.2 Removing cylinder liner HI Drain he engine cooling water and remove the cylinder head snd piston with connecting rod Loosen the screw (2) and remove the holder (1). Assomble the removing device 2.89602 and the hydraulic ») tool 8VEBE61 according to Fig 10-6. 1 Tohton tho hydraulic tool by tensioning the mut of the pull screw 1VB3045 lightly. Connect he hoses of the hydraulic pump 2VB4A36 to the hydraulic tol. Pump pressure tothe hydraulc tool to withdraw the eyinder Tiner. The pressure must not exceed the value stated in chapter 07, Fig 07-4. Open the pump valve, disconnect the hoses of the hydraulic fool and remove it [Ey Use the part ot he removing device intended for this pur- pose to HR the exlinder liner, se Fig 1056 10.5.3 Mounting of cylinder finer Hl Check that oil guide and contact faces of the engine block. and cylinder liner are clean and intact. 1 Check that ihe O-ring grooves ofthecylinder liner areclean, and insert new O-rings EE] unbiicate tne lower O-rings and the sealing faces with grease and assemble the liNing device, see Fig 10-5.=— Lower the liner careful info the bore of the engine block When the lowest O-ring touches the engine block, alig the liner s0 {hat the mark (3, in Pig 10-6) on the liner is directed towards the driving ond of tho engins, onthe V-engine B-bank towards the fee end of the engine. Lower further and press liner into position by fhand ‘Check the inner diameter of the cylinder liner, especially at fhe love ofthe guiding surfaces Mount the holder (1) and tighten the serew (2) to the stated torque, Ed Mount the piston withthe connecting rod, ant-plishing Ting and cylinder head, and vel the cooling water [Gl Check the O-ring seals from the crankcase side while cireu- Tating cooling wator.1rthore isan engine driven cooling water pump, spply bar state pressure Removing and iin of cyinder liner sveseet sve Fig 10-6 = 10-1310-14 °