Ade 364 Ade366 Workshop Manual Abby PDF

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BDC From the Library of Barrington Diesel Club
ENGINE REPAIR MANUAL

ADE 360 SERIES
ATLANTIS DIESEL ENGINES (PTY) LTD
Part No. 805*&S4i

by th e S ervice D e partm ent o f A tla n tis Diesel Enain®
FOREWORD
The 360 Series are direct injection, water-cooled four-stroke diesel engines. The cylinders are
arranged in line and are positioned vertically. Depending on application 360 series engines can
be fitte d w ith a turbocharger. The engines have been designed to take advantage of the latest
technology, w ith special em phasis on the sm allest possible dim ensions, a favourable power
to w eight ratio and low fuel consum ption. ADE engines have a left hand rotation when viewed from
the rear. Throughout this manual, whenever Left or Right hand side of the engine is referred to, it
is the side of the engine when viewed from the flywheel end.
This publication has been w ritten to assist all personnel engaged in the maintenance and overhaul
of the ADE Diesel Engine. All necessary information contained in this manual is presented in a logical
step by step form at with the text supported by line illustrations, which are positioned on the right
hand side of the page, together w ith precise instructions on the servicing and overhaul procedure.
In addition each section contains a schedule of m anufacturing data and dim ensions which must
be closely followed when overhauling any part of the engine to the M anufacturers standards. Effec
tive maintenance can only be carried out if the personnel concerned are fully conversant with the
various com ponents of the engine. Before maintenance operations are commenced, therefore, this
manual should be carefully studied, and should at all tim es be kept where it w ill be needed in the
workshop. Certain operations described in this manual require the use of special tools. These tools
' are obtainable from Grundy-Techniform . Full details are given in the appropriate sections.
A Product Training Representative, highly skilled in the special ch aracte ristics of ADE Engines,
is available to assist you w ith product training through your O riginal Equipment M anufacturer
(O.E.M.).
ENGINE PARTS
Whenever parts are required for ADE Engines, it is essential that the fullest inform ation possible
is given, always quote the engine number, type of application, and where possible the part number
and description. In accordance with the Preventative Maintenance Plan, your engine will require such
items as fuel, oil and air filters. It is in your own interest to ensure that only genuine ADE Parts
are used. Each genuine ADEPART, is backed with a six month guarantee ensuring the highest quality,
and every part com plies with the original specification.
RUNNING-IN PROCEDURE
It is not necessary to gradually run-in a new ADE engine, and any prolonged light load running
during early life of the engine can in fact prove harm ful to the bedding in o f the piston rings and
liners. Full load can be applied provided that the engine has reached operation tem perature.
This publication is produced by the Service Department of A tla n tis Diesel Engines (Pty) Ltd, and
every endeavour has been made to ensure that the inform ation contained in this manual is correct
at the tim e of publication, however, continuous development and advancem ent in product design
may reflect changes made to your engine which are not included in this publication.
© C O P Y R IG H T 1988 A T L A N T IS DIESEL E N G IN E S (PTY) LTD.
Reproduction or translation, in part or full is subject to the w ritten authorization of A tla n tifD ie s e l
Engines (Pty) Ltd.
CONTENTS
TECHNICAL DATA .......................................................................................................................................... 08
OPERATING MAINTENANCE SCHEDULE AND LUBRICATING OILS ..............................................09
FAULT FINDING ...............................................................................................................................................10
CYLINDER BLOCK AND LINERS .................................................................................................................11
CYLINDER HEAD .............................................................................................................................................12
PISTONS AND CONNECTING RODS .......................................................................................................... 13
CRANKSHAFT AND MAIN BEARINGS ....................................................................................................... 14
CAMSHAFT, TIMING CASE AND DRIVE-TIMING ................................... ...................................................15
LUBRICATING SYSTEM AND SUMP ............................................................................................................16
FUEL SYSTEM .................................................... ............................................................................................ 17
TURBOCHARGER ........................................................................................................................................... 18A
POWER STEERING ....................................................................................................................................... 18B
EXHAUST BRAKE ........... ....18C
FLYWHEEL ...................................................................................................................................................... 18D
ALTERNATOR AND STARTER MOTOR .................................................................................................... 18E
COMPRESSOR/VACUUM PUMP ..................................................................................................................18F
COOLING SYSTEM ........................................................................................................................................ 19
APPROVED SERVICE TOOLS ......................................................................REFER TO EACH SECTION

SECTION 08-1
Technical Data
ADE 364N/C/T/TI
ENGINE DATA
ADE 364N AD E 364C A D E 364T A D E 364TI
B o r e ........................................................................... 97,5 m m ..................97,5 m m .................. 97,5 m m .................. 97,5 m m

S tro k e ....................................................................... 133 m m ...................133 m m ................... 133 m m ................... 133 mm
No. o f c y lin d e r s .................................................... 4 ................................4 ................................. 4 ................................. 4
C u b ic c a p a c ity ..................................................... 3,972 t .................... 3,972 ( ..................... 3,972 ( ..................... 3,972 f
C o m p re s s io n ra tio ............................................... 17,25:1 ..................... 17:1 ........................... 16,5:1 ........................ 16,5:1
C o m p re s s io n te s t p re s s u re a t o p e ra tin g
te m p e ra tu re (M ax. d iffe re n c e b e tw e en
a n y tw o c y lin d e rs — 400 k P a ) ....................... M in 2000 kPa a t 180-200 r/m in M in 2000 kPa a t 180-200 r/m in
F irin g o rd e r ............................................................ 1 -3 -4 -2 ..................... 1-3-4-2 ....................... 1-3-4-2 .......................1-3-4-2

C o m b u s tio n s y s t e m ............................................ D ire c t in je c tio n ...D ire c t in je c tio n ...D ire c t in je c tio n ...D ire ct in je c tio n
C y c le ......................................................................... 4 s tro k e ................. 4 s tro k e ..................4 s tro k e .................. 4 s tro k e
DETAIL OF RATINGS (AUTOMOTIVE) TO SABS 013-1977
M a x im u m to rq u e (N .m ) ..................................... 266 @ 1400 r/m in 300 @ 1400 r/m in 380 @ 1400 r/m in 408 @ 1400 r/m in
O u tp u t Kw ................................................................... 66 @ 2800 r/m in 70 @ 2800 r/m in 85 @ 2600 r/m in 100 @ 2600 r/m in
ENGINE MASS
T y p ic a l d ry m a s s .................................................. 335 kg ..................... 343 kg ..................... 343 kg ..................... 370 kg
ADE 366N/C/T/TI
ENGINE DATA
A D E 366N A D E 366C A D E 366T A D E 36831
B o r e ............................................................................ 97,5 m m ..................97,5 m m ..................97,5 m m .........97,5 m m

S tro k e ....................................................................... 133 m m ...................133 m m ........... ....... 133 m m ................... 133 m m
No. o f c y lin d e r s .................................................... 6 ................................ 6 ................................ 6 ................................. 6
C u b ic c a p a c ity ...................................................... 5,958 f .....................5,958 f .....................5,958 ( ......................5,958 I
C o m p re s s io n ra tio ............................................... 17,25:1 ..................... 17:1 ............................16,5:1 ........................16,5:1
C o m p re s s io n te s t p re s s u re a t o p e ra tin g
te m p e ra tu re (M ax. d iffe re n c e b e tw e en
a n y tw o c y lin d e rs — 400 k P a ) ....................... M in 2000 kPa at 180-200 r/m in M in 2000 kPa a t 180-200 r/m in
F irin g o rd e r ............................................................ 1-5-3-6-2-4 ............... 1-5-3-6-2-4................1-5-3-6-2-4.................1-5-3-6-2-4

C o m b u s tio n s y s te m ............................................ D ire c t in je c tio n ...D ire ct in je c tio n ...D ire ct in je c tio n ...D ire ct in je c tio n
C y c le ......................................................................... 4 s tro k e ................. 4 s tro k e ..................4 s tro k e .................. 4 s tro k e
DETAIL OF RATINGS (AUTOMOTIVE) TO SABS 013-1977
M a x im u m to rq u e (N .m ) ..................................... 402 @ 1400 r/m in 420 @ 1400 r/m in 560 @ 1400 r/m in 640 @ 1400 r/m in
O u tp u t K w ............................................................... 100 @ 2800 r/m in 100 @ 2800 r/m in 125 @ 2600 r/m in 150 @ 2600 r/m in
ENGINE MASS
T y p ic a l d ry m a s s .................................................. 445 kg ..................... 460 kg ..................... 460 kg ......................495 kg
T h ro u g h o u t th is E n g in e R e p a ir M a n u a l, S1 (In te rn a tio n a l M e tric S yste m ) u n its a s a p p ro ve d by th e S o u th A fric a n B ureau

o f S ta n d a rd s (SABS) are used. A ll m e a s u re m e n ts are in m m u n le s s o th e rw is e in d ic a te d .
A D E 360 S e rie s
08-2
TORQUE SPECIFICATIONS FOR BOLTS UNDER DIFFERENT GRADE CLASSIFICATIONS
Q uality grade 8.8 10.9 12.9
M6 8.6 11.8 14.5
M8 21 29 35.5
M8x1 23 32 38
M 10 42 58 70
M 10 x 1,5 46,5 65 78
M 12 73 100 123
M 12x1,5 76 105 128
M 14 114 165 195
M 14x1,5 128 178 215
M 16 178 250 300
M 16x1,5 190 270 320
M 18 245 355 415
M 18x1,5 280 390 465
M20 350 490 590
M 20x1,5 390 550 660
M22 465 660 800
M 22x1,5 520 730 875
M24 600 850 1000
M 24x2 660 910 1100
NO TE 1 — T he B o lt g ra d in g a p p e a rs on th e b o lt head
NO TE 2 — B o lt to rq u e is s u b je c t to fe m a le th re a d m a te ria l
A D E 360 S e rie s
TECHNICAL DATA - 08-3
IDENTIFICATION NUMBER POSITIONS
W hen o rd e rin g spare p a rts a llw a ys q u o te th e eng in e

n u m b e r in fu ll.
ENGINE IDENTIFICATION
T h e e n g in e n u m b e rin g sy s te m fo r ADE e n g in e s c o n s is ts
o f 16 le tte rs a nd n u m b e rs.
E xam ple
ATLANTIS DIESEL ENGINES (PTY) LTD

LICENCE DAIMLER-BENZ AG
ENGINE No DB
ADE M J 01002 SA 046315 T
MADE IN RSA
ENGINE FAMILY
300 Series
ENGINE TYPE
i.e.
G = 364N L = 366TI
H = 364C M = 364T
J = 366N N = 366C
K = 366T
BUILD CODE
COUNTRY OF ORIGIN
ENGINE SERIAL NUMBER
YEAR OF MANUFACTURE
S = 1988 U = 1990 W = 1992
T = 1989 V = 1991 X = 1993
Y = 1994
N o te :
T he le tte r d e n o tin g th e ye a r o f m a n u fa c tu re c h a n g e s on
th e 1st d a y o f J a n u a ry e a ch year.
T he le tte rs I, O, Q, R and Z are n o t used.
A D E 360 S eries
TECHNICAL DATA — 08-4
AD E 360 S e rie s
SECTION 09-1
Operating and Maintenance
OPERATING AND MAINTENANCE RECOMMENDED SERVICE/
MAINTENANCE INTERVALS
Preparation before Starting
Normal oil and filter changes/service intervals
C h e c k th e ra d ia to r c o o la n t level.
C h e c k th e e n g in e s u m p o il le ve l. . C ategory 1 C ategory 2 C ategory 3
E n su re th a t th e re is fu e l in th e ta n k. 7 500 km /150 h rs 5 000 km /100 h rs 2 500 km /50 hrs
C h e c k th a t th e b a tte ry is fu lly ch a rg e d and th a t a ll e le c A t le a s t tw ic e a ye a r w h e n s e rv ic e in te rv a l is n o t re a ch e d

tr ic a l c o n n e c tio n s are p ro p e rly m ad e a nd a ll c ir c u its are
in order. EXTENDED oil and filter changes/service
intervals
To Stop the Engine T he e xte nd e d m a in te n a n ce and se rvice in te rva ls m ay o n ly
R em ove th e e n g in e lo a d . D e cre a se sp e e d g ra d u a lly to c o m m e n c e a fte r th e ru n n in g in p e rio d (a p p ro x im a te ly
a vo id h e a tin g up th e c o o la n t, th e n run th e e n g in e a t id l 20 000 km).
in g s p e e d fo r a s h o rt tim e . S h u t d o w n e n g in e . T h e e n g in e lu b ric a tin g o ils fo r e x te n d e d o il c h a n g e in te r
va ls, as s p e c ifie d in th e ADE S e rvice B u lle tin on C o n
(a) By a c tu a tin g th e s to p p in g c a b le . s u m a b le s have been a p p ro ve d a n d are m a n d a to ry .
(b) By m o v in g th e s p e e d c o n tro l le ve r to “ s to p ” . T he s u c c e s s fu l a p p lic a tio n o f th e e x te n d e d o il and filte r
c h a n g e s /s e rv ic e in te rv a ls w a rra n ts c a re fu l se rv ic e and
(c) By a c tu a tin g th e s h u t-o ff s o le n o id .
m a in te n a n c e o f e n g in e s . A s e x te n d e d in te rv a ls a ls o d e
(d) By a c tu a tin g th e e x h a u s t b ra ke d e p e n d in g on th e pend on o p e ra tin g c o n d itio n s o f th e e n g in e s , it is e s s e n
e n g in e s p e c ific a tio n . tia l to a p p ly th e 3 c a te g o rie s a s o u tlin e d b e lo w .
C ateg ory 1 C ategory 2 C ategory 3

Points to note
15 000 km /30 0 h rs 10 000 km /200 h rs 5 000 km /10 0 hrs
A lw a y s ensure th a t th e s ta rte r p in io n has sto p p e d ro ta tin g
b e fo re re -e n g a g in g th e s ta rte r, as th e rin g g e a r o r p in io n A t le a s t o n c e a ye a r w h e n s e rv ic e in te rv a l is n o t re a ch e d
m ay be d a m a g e d .
Flame-Proofed Engines N o te 1:
E n g in e s a rra n g e d to c o n fo rm w ith fla m e -p ro o fin g re g u la E n g in e s th a t leave th e fa c to ry are fille d w ith ru n n in g -in
tio n s are u s u a lly fitte d w ith n o n -e le c tric s ta rtin g e q u ip o il. T h e o il m u s t be c h a n g e d d u rin g th e fir s t s e rv ic e a t
m ent. T h is is s u p p lie d by th e m a n u fa c tu re r o f th e a p p lic a 1 500 km o r 30 h o u rs o p e ra tio n .
tio n a nd fo r s ta rtin g in s tru c tio n s re fe re n c e s h o u ld be
m a d e to th e a p p ro p ria te m a n u fa c tu re r’s h a n d b o o k.
For approved engine lubricants and coolant additives,
refer to ADE G eneral Service B ulletin on C o n
Preventive Maintenance sum ables.
C ategory 1
U n its o p e ra tin g u n d e r n o rm a l c o n d itio n s , m ore th a n

100 000 km o r 2 000 h o u rs a n n u a lly e.g. lo n g h a u l
o p e ra tio n s .
C ategory 2
U n its o p e ra tin g u n d e r n o rm a l c o n d itio n s , up to 100 000

km o r 2 000 h o u rs a n n u a lly e.g. m e d iu m to lo n g haul
Pre-delivery Service
o p e ra tio n s .
1. C h e ck g e n e ra l e n g in e in s ta lla tio n i.e. A ll p ip e s and

C ategory 3
h o se s fo r tig h t s e a lin g , c o n d itio n a nd ro u tin g .
U n its s u b je c t to severe o p e ra tin g c o n d itio n s e.g. e x tre m e
2. O p e n a ir c le a n e r a n d e n su re e le m e n t is p o s itio n e d
ly p o o r road c o n d itio n s , he a vy d u s t c o n d itio n s , e x tre m e
c o rr e c tly a n d b o lte d d o w n .
c lim a tic c o n d itio n s (te m p e ra tu re and h u m id ity), very s h o rt
d is ta n c e s in tr a ffic o r c o n s tru c tio n o p e ra tio n . U n its 3. C h e c k fo r fu e l a n d o il le a ks.
o p e ra tin g up to 10 000 km o r 200 h o u rs a n n u a lly e.g. u n its
o p e ra tin g u n d e r lig h t lo a d s o r in te rm itte n t o p e ra tin g c o n 4. C h e c k o il level.
d itio n s , s u c h as s ta n d -b y g e n e ra to r s e ts a n d e m e rg e n c y 5. C h e c k c o o la n t level.
v e h ic le s . H o w e ve r, w h e n o p e ra tin g le ss th a n th e re c o m
m e n d e d s e rv ic e in te rv a ls , th e o il a nd o il filte r s h o u ld be 6. C h e ck c o o la n t fo r co rre ct m ixtu re , i.e. a n ti-fre e ze/a n ti
ch a n ge d o n ce o r tw ic e a year de p e n d in g on th e lu b ric a tin g c o rro s io n a g e n t a nd c o rro s io n in h ib ito r.
o il used. W e re c o m m e n d th a t m a in te n a n c e a nd se rvice
7. C h e c k V -b e lt te n s io n . .
be c a rrie d o u t a c c o rd in g to h o u rs o f o p e ra tio n ra th e r th a n
m ile a g e co ve re d . 8. C h e c k e le c tric a l e q u ip m e n t a n d c o n n e c tio n s .
AGE 360 Series

OPERATING AND MAINTENANCE — 09-2
9. C h e c k in je c tio n p u m p lin k a g e fo r to ta l m o ve m e n t. 13. E n su re ra d ia to r fin s have an u n o b s tru c te d a ir flo w .
10. C h e c k e x h a u s t brake lin ka g e and a d ju s tm e n t if fitte d . 14. T en sio n all V -Belts, c h e ckin g sa m e fo r a g eing, re p la c
ing d e fe c tiv e V -B e lts. T w in V -B e lts s h o u ld o n ly be
11. C h e c k th a t th e fa n has been fitte d c o rre c tly .
replaced in pairs. N ew b e lts m u st be rete n sio n e d a fte r
12. S ta rt up, th e n c h e c k o il p re s s u re a nd c o o la n t 10-15 m in u te s o f o p e ra tio n .
te m p e ra tu re g a u ge s.
15. C h e ck e x h a u s t s y s te m fo r d a m a g e o r le a ks.
13. C h e c k fo r a n y u n u s u a l n o ise s.
16. C h e ck c o n tro l lin ka g e on in je c tio n p u m p a nd e xh a u st
14. W h ile e n g in e is w a rm in g up c h e c k fo r o il a nd w a te r b ra ke fo r c o rre c t fu n c tio n a nd a d ju s tm e n t, lu b ric a te
leaks. a ll jo in ts .
15. C h e c k o p e ra tio n o f v is c o fa n (if fitte d ). 17. C h e c k a ll lin e s a nd h o se s fo r tig h t s e a lin g , c h a fin g

and leaks.
16. Run to o p e ra tin g te m p e ra tu re a nd c h e c k m a x im u m
r/m in. 18. A d ju s t va lve c le a ra n c e s .
19. R e tig h te n all v is ib le n u ts and b o lts on th e e n g in e and

Daily Before Starting and 8-10 Hours
in p a rtic u la r.
Operation
(a) In le t a nd e x h a u s t m a n ifo ld s and d u c ts .
1. C heck e n g in e o il level and p re ssu re upon s ta rt up (en (b) E x h a u s t fla n g e .
s u re m a c h in e is s ta n d in g level).
(c) S ta rte r m o to r a nd a lte rn a to r fittin g .
2. C h e c k c o o la n t level in ra d ia to r.
(d) N ozzle h o ld e rs.
3. S e rvice a ir c le a n e r d u s t b o w l, p re -filte r if a p p lic a b le . (e) E n g in e m o u n t on c ro s s m e m b e r a nd e n g in e
s u p p o rt.
4. C h e c k a ir c le a n e r re s tric tio n in d ic a to r, s e rvice filte rs
if re q u ire d . \ (f) B e ll h o u s in g b o lts a n d n u ts.
5. E nsure th e re is a m p le fu e l in ta n k. 20. C h e c k fo r fu e l a n d o il le a ks.
6. E nsure fu e l ta n k c a p /b re a th e r is u n o b s tru c te d . 21. C h e c k o p e ra tio n o f o il p re s s u re and te m p e ra tu re

g a u ge s.
7. C h e c k th a t th e e x te rio r o f th e s u m p is c le a n w ith an
u n re s tric te d a ir flo w o ve r th e s u rfa c e . 22. C h e c k b a tte ry e le c tro lite level. In S u m m e r a nd h o t
re g io n s o n c e a w eek.
8. E n su re ra d ia to r fin s have an u n o b s tru c te d a irflo w .
23. C h e ck b a tte ry te rm in a ls fo r tig h tn e s s and c o n d itio n .
9. C h e c k o il p re s s u re in d ic a to r.
24. C h e c k o p e ra tio n o f V is c o Fan (if fitte d ).
10. D ra in w a te r fro m s e d im e n to r.
A d d itio n a l ite m s re q u irin g s e rv ic in g a t 50 000 km in te r
11. D ra in a ir ta n k (if fitte d ).
val lis tin g .
Note:
1. C h e ck ca rb o n b ru s h e s in th e s ta rte r.
Injectors: S a tis fa c to ry lo n g te rm fu n c tio n in g o f in je c to rs
d e p e n d s la rg e ly on th e q u a lity a n d p u rity o f th e fu e ls u s 2. In s p e c t a nd c le a n o il c o o le r filt e r e le m e n t ADE
e d. A s p e c ific s e rv ic e in te rv a l ca n th e re fo re n o t be 360T/TI
p re s c rib e d . D e a le rs a nd F le e to w n e rs s h o u ld a d o p t s e r
v ic e in te rv a ls w h ic h w o u ld s u it th e in d iv id u a l o p e ra tin g
c irc u m s ta n c e s .
Schedule A Service
Schedule B Service
1. C h a n g e e n g in e o il, d ra in o il w h e n s t ill hot.
* 1 . C h a n g e e n g in e o il and o il filte r, d ra in w h e n s t ill hot.
2. R enew o il filte r.
2. D ra in fu e l s e d im e n to r o r fu e l f ilte r d ra in ta p s.
3. R enew fu e l filte rs .
3. S e rvice a ir c le a n e r d u s t b o w l/p re filte r if a p p lic a b le .
4. D rain w a te r fro m s e d im e n to r o r fu e l filte r d ra in co c k s .
4. C h e ck a ir c le a n e r in d ic a to r, se rvice filte rs if required.
5. S e rvice a ir c le a n e r d u s t b o w ls /p re -filte r if a p p lic a b le .
5. C h e c k a ll a ir c le a n e r in ta k e d u c ts , h o se s a nd c lip s
6. C h e c k a ir c le a n e r in d ic a to r, se rvice filte rs if required.
fo r s e rv ic e a b ility and tig h tn e s s .
7. S e rv ic e a ir c le a n e r a n d f ilte r (oil b a th type).
6. C h e ck th a t in te rc o o le r is free fro m o b s tru c tio n .
8. C h e c k a ll a ir c le a n e r in ta k e d u c ts , h o se s a nd c lip s
7. C heck c o o la n t hoses, h ose c lip s fo r s e rv ic e a b ility and
e tc ., fo r s e rv ic e a b ility a nd tig h tn e s s .
tig h tn e s s .
9. C h e c k th a t in te rc o o le r is fre e fro m o b s tru c tio n .
8. P re ssu re te s t c o o lin g s y s te m .
10. C h e ck c o o la n t hoses, hose c lip s fo r s e rv ic e a b ility and
9. E n su re ra d ia to r fin s have an u n o b s tru c te d a ir flo w .
tig h tn e s s .
10. T e n s io n V -B e lts c h e c k in g sa m e fo r a g e in g , re p la c e
11. P re ssu re te s t c o o lin g syste m .
d e fe c tiv e V -B e lts . T w in V -B e lts s h o u ld o n ly be
12. E n su re th a t re c o m m e n d e d c o rro s io n in h ib ito r has replaced in pairs. R e tension new b e lts a fte r 10-15 m in.
been a d d e d to th e c o o lin g syste m . o p e ra tio n .
A D E 360 S e rie s
OPERATING AND MAINTENANCE - 09-3
11. C h e c k e x h a u s t s y s te m fo r d a m a g e o r le a ks. T h e a n ti-c o rro s io n o il c o n te n t in th e c o o la n t i.e. 1% by

vo lu m e , m ay be d e te rm in e d by a re fra c to m e te r.
12. C h e c k fo r fu e l a nd o il le a ks.
O n ly use a p p ro ve d p ro d u c ts fo r m ix tu re w ith th e c o o la n t
13. C h e c k o p e ra tio n o f o il p re s s u re a nd te m p e ra tu re
as s p e c ifie d in o u r G e n era l S e rvice B u lle tin on C o n
ga u ge s.
s u m a b le s a n d a t a ll tim e s s tr ic tly a d h e re to th e m ix tu re
14. C h e c k b a tte ry e le c tro lite le ve l. In S u m m e r and h o t s p e c ific a tio n s .
re g io n s o n c e a w eek.
15. C h e c k b a tte ry te rm in a ls fo r tig h tn e s s a n d c o n d itio n .
A d d itio n a l ite m s re q u irin g s e rv ic in g a t 50 000 km in te r ENGINE PRESERVATION

v a ls o r to th e e q u iv a le n t s h o w n on th e m a in te n a n c e in
te rv a l lis tin g . W hen an e n g in e is laid-up fo r a p ro lo n g e d period, it sh o u ld
be p ro p e rly p ro te c te d a g a in s t c o rro s io n . P re se rva tio n
1. C h e c k th e c a rb o n b ru s h e s in th e s ta rte r.
m e a su re s s h o u ld be c a rrie d o u t in a c c o rd a n c e w ith th e
2. C le a n tu rb o c h a rg e r im p e lle r, d iffu s e r a n d o il d ra in d iffe re n t c a ta g o rie s lis te d in th e fo llo w in g s e c tio n s .
pipe.
1.0 G eneral
3. In s p e c t a nd c le a n o il c o o le r filt e r e le m e n t (360T/TI)
2.0 Installed Engines
2.1 L a id up fo r up to 12 m o n th s
A tte n tio n ! S a tis fa c to ry lo n g te rm o p e ra tio n o f th e a ir
2.2 L a id up fo r 12 to 36 m o n th s
c o m p re s s o r, d e p e n d s on m a n y va ry in g fa c to rs . T h e re fo re
2.3 L a id up fo r m o re th a n 36 m o n th s
a s p e c ific s e rv ic e in te rv a l c a n n o t be re c o m m e n d e d .
D e a le rs and F le e to w n e rs s h o u ld a d o p t s e rv ic e in te rv a ls 3.0 N on-installed Engines
w h ic h w ill s u it th e ir in d iv id u a l o p e ra tin g c o n d itio n s . 3.1 L a id up fo r up to 12 m o n th s
3.2 L a id up fo r 12 to 36 m o n th s
ENGINE COOLANT 3.3 L a id up fo r m ore th a n 36 m o n th s
In v ie w o f th e s ig n ific a n c e o f m a in ta in in g th e c o o lin g
4.0 Preparing Engine for operation
s y s te m a t a s p e c ifie d level, it is e s s e n tia l to e n su re th a t
th e fo llo w in g c o o la n t s p e c ific a tio n s are m a in ta in e d .
1.0 General
F o r th e p re p a ra tio n o f c o o la n ts , use c le a n w a te r th a t is
A n e n g in e is c la s s ifie d as “ la id u p ” w h e n it has n o t
n o t to o hard. O fte n , d rin k in g w a te r (tap w a te r) w ill m eet
o p e ra te d fo r o ve r o n e m o n th . L a id up v e h ic le s o r
th e d e s ire d re q u ire m e n ts , b u t n o t a lw a ys.
e n g in e s s h o u ld be stored in dry, w e ll-ve n tila te d room s
Sea w a te r, s a lt w ater, in d u s tria l w a ste w a te r and b ra ckish a n d m u s t a lw a y s be p ro te c te d a g a in s t d ire c t
w a te r w h ic h in c lu d e s in m o s t c a s e s w a te r fro m d a m s, m o is tu re , e.g. rain o r s p la s h w a te r. If th is is n o t p o s s i
p o n d s a n d rive rs, s h o u ld be c o n s id e re d to be u n s u ita b le , ble, la yin g up c o n d itio n s are c la s s ifie d as extre m e and
as th e s e m ay c o n trib u te h e a v ily to th e fo rm a tio n o f th e tre a tm e n t s p e c ifie d fo r a g ive n p e rio d s h o u ld be
c o rro s io n . in c re a s e d , e.g. if an e n g in e is to be la id up fo r up to
12 m o n th s , it m u s t re ce ive tre a tm e n t o f an e n g in e to
Specification of fresh water be la id up fo r 12 to 36 m o n th s .
S u m o f a lk a lin e e a rth 89.5 — 358 m g /litre 1.1 O n a n y la id up e n g in e a ll m a c h in e d e xte rn a l
(w a te r h a rd n e ss) u n p ro te c te d s u rfa c e s , e.g. fly w h e e ls , V -b e lt
p H v a lu e a t 2 0 °C 6.5 — 8,5 p u lle y g ro o ve s, e tc. s h o u ld be c o a te d w ith a
C o n te n ts o f c h lo rin e io n s: m ax 100 m g /litre p re se rvin g a g e n t o r g rease.
T o ta l c o n te n t o f c h lo rid e s
V -b e lts m u s t be s la c k e n e d o ff and be rem oved
a nd s u lp h a te s m ax 200 m g /litre
fro m th e grooves.
F u ll in fo rm a tio n o n th e q u a lity o f d rin k in g w a te r s h o u ld
A ll o p e n in g s m u st be s e a le d a ir tig h t. T h is
be o b ta in e d fro m lo c a l d e p a rtm e n ts o f W a te r A ffa irs o r
in clu d e s e xh a u st and a ir in le t d u c ts/cle a n e rs on
lo c a l a u th o ritie s . It is e s s e n tia l to p ro te c t y o u r e n g in e at
in s ta lle d e n g in e s. '
a ll tim e s a g a in s t c o rro s io n by th e a d d itio n o f A n ti
c o rro s io n /A n ti-fre e z e a d d itiv e s (e th y le n e g ly c o l w ith B a tte rie s m u s t be d is c o n n e c te d in la id up
c o rro s io n in h ib ito rs ) w h ic h a m o n g s t o th e rs , w ill m ee t th e v e h ic le s a nd s h o u ld be re c h a rg e d o u ts id e th e
fo llo w in g d e m a n d s : v e h ic le as req u ire d .
• a d e q u a te a n ti-c o rro s io n a n d c a v ita tio n p ro te c tio n fo r

2.0 Installed Engines
a ll c o m p o n e n ts iû th e c o o lin g sy s te m
• lo w e rin g th e f r e t t in g p o in t T h e se m e a su re s a p p ly to a ll e n g in e s in v e h ic le s ,
tra c to rs , as w e ll as in d u s tria l e n g in e s .
• ra is in g th e boiH ÉÉ üfofR t
2.1 Laid up for up to 12 m onths
A t no tim e s h o u ld th e c o b là h t'm ix tu re e x c e e d 5 5 % by
v o lu m e a n ti-fre e z e /a n ti-c o rro s io n a g e n t as a h ig h e r 2.1.1 N EW E N G IN E S (d is ta n c e covered up to 300 km
p e rc e n ta g e w ill re d u c e th e a n ti-fre e z e p ro te c tio n as w e ll o r 6 h o u rs o f o p e ra tio n ):
as lessen the heat d is s ip a tio n . A s a n ti-co rro sio n in h ib ito rs
T he en g in es m u st be fille d to th e m a xim u m level
d e c o m p o s e d u rin g o p e ra tio n , as w e ll a s a n ti-c o rro s io n
c o n c e n tra tio n b e in g re d u ce d by to p p in g up th e c o o lin g w ith a p p ro v e d s e rv ic e p ro d u c ts . A m b ie n t
s y s te m w ith w a te r, th e fr o s t p ro te c tio n m u s t be c h e cke d te m p e ra tu re s m u st be ta ke n in to c o n s id e ra tio n
w h e n s e le c tin g SAE g ra d e s. N o fu rth e r p re s e r
reg u la rly. F ro st p ro te c tio n o f - 3 0 ° C c o rre s p o n d s w ith 40
v a tio n m e a su re s are re q u ire d .
to 45 p e rc e n t (by v o lu m e ) a n ti-fre e z e / a n ti-c o rro s io n c o n
te n t in th e c o o la n t w h ic h m ay be d e te rm in e d by an o p 2.1.2 USED E N G IN E S (d is ta n c e co ve re d m o re th a n
tic a l o r m e c h a n ic a l h y d ro m e te r, ( - 3 0 ° C ) . 300 km o r 6 h o u rs o p e ra tio n ):
A D E 360 S e rie s
OPERATING AND MAINTENANCE - 09-4
Run e n g in e u n til w a rm a n d d ra in e n g in e o il. c y lin d e r via th e c o m p re s s o r a ir in ta k e w h e re

(R u n n in g -in o il m ay re m a in in th e e n g in e). a fte r th e e n g in e ,m u s t be ro ta te d a t le a s t one
R enew o il filte r c a rtrid g e . F ill w ith an a p p ro ve d h a lf a tu rn .
ru n n in g -in o il (a n ti-c o rro s io n e n g in e oil). F ill o r
to p up c o o lin g sy s te m w ith th e s p e c ifie d 2.3 Laid up for more than 36 months
c o o la n t m ix tu re . Run e n g in e a t m e d iu m sp e e d If th e laying-up period is exte nd e d fo r m ore th a n
fo r a p p ro x . 5 to 10 m in u te s u n til o p e ra tin g 36 m o n th s , p re s e rv a tio n m e a su re s m u s t be
te m p e ra tu re is re a ch e d (c o o la n t te m p e ra tu re rep e a te d every 3 ye a rs o r 18 m o n th s in a c c o r
75-79° C). S w itc h o ff e n g in e , f ill th e s u m p and d a n ce w ith S e c tio n 2.2 in fu ll.
th e o il b a th a ir filte r (if fitte d ) to m a xim u m level.
2.2 Laid up for 12 to 36 m onths

3.0 N O N -IN STA LLED E N G IN E S
A ll th e m e a su re s se t o u t in S e c tio n s 1.0
“ G e n e ra l” a nd 2.1 “ M e a su re s fo r In s ta lle d T hese m ea su re s co ve r new n o n -in s ta lle d e n g in e s, as
E n g in e s L a id up fo r up to 12 m o n th s ” , m u s t be w e ll as re m a n u fa c tu re d e n g in e s.
c a rrie d o u t.
3.1 Laid up for up to 12 months:
In a d d itio n , th e fu e l s y s te m , th e c o m b u s tio n
NEW ENGINES w h ich have o n ly been su b je cte d
c h a m b e rs and th e a ir c o m p re s s o r m u s t be
to th e ru n n in g -in p e rio d a t ADE, do n o t re q u ire
p re se rve d In a c c o rd a n c e w ith th e fo llo w in g in
any a d d itio n a l p re s e rv a tio n m ea su re s.
s tru c tio n s .
N o te 1: T he p ro c e d u re in th is s e c tio n s h o u ld a ls o be R u n n in g -in o il m ay be le ft in th e e n g in e s.
fo llo w e d a fte r le s s th a n 12 m o n th s in th e ca se o f sea C o o la n t m u s t be c o m p le te ly d ra in e d . R em ove
s h ip m e n ts and in tro p ic a l a reas. th e th e rm o s ta t/s and in s e rt o n e C h a d p a c k
T a b le t (ADE Part N o 36170072) in to th e h o u sin g .
2.2.1 Preservation of Fuel System :
R e fit th e th e rm o s ta t/s a n d c lo s in g c o v e r/o u tle t
A d d a p p ro x im a te ly 10% ru n n in g -in o il to d ie se l and e n s u re th a t th e jo in ts fo rm a g o o d se a l. A ll
fu e l a nd o p e ra te th e e n g in e w ith th is m ix tu re e n g in e o p e n in g s m u s t be s e a le d a irtig h t.
fo r a p p ro x im a te ly 5 to 10 m in u te s .
N o te 5: F o llo w th e in s tru c tio n s fo r sea s h ip m e n ts or
If a n u m b e r o f ve h ic le , tra c to r o r in d u s tria l
tro p ic a l areas.
e n g in e s are to be p reserved a t th e sa m e tim e ,
th e fu e l a n d th e ru n n in g -in o il m ay be m ix e d in USED ENG INES m u s t be tre a te d in a cco rd a n ce
a s e p a ra te c o n ta in e r b e fo re fe e d in g th e s o lu w ith th e m e a s u re s s e t o u t in Ite m s 2.1.2 and
tio n in to th e fu e l syste m via a th re e -w a y o r fo u r 2.2.1 b e fo re b e in g la id up o r d is m o u n te d .
w a y c o c k valve. T h is e n a b le s th e c o n c e n tra tio n
C o o la n t m u s t be d ra in e d c o m p le te ly and a
o f o il in d ie s e l fu e l to be in cre a se d to 15-20% .
C h a d p a c k T a b le t m u s t be In se rte d in th e th e r
2.2.2 Preservation of C om bustion Cham bers: m o s ta t h o u s in g .
O il m ay be sp ra ye d in to th e c o m b u s tio n R E M A N U FA C TU R E D E N G IN E S m u s t in all
c h a m b e rs v ia th e in je c to r p o rts a fte r rem o va l ca se s be p reserved in a c c o rd a n c e w ith S e c tio n
o f th e in je c to rs w h ic h m ay be im m e rs e d in o il 2.2 in fu ll.
fo r a d d ed p ro te c tio n .
3.2 Laid up for 12 to 36 months:
F or b e st re s u lts th e m ete re d a m o u n t o f o il m ust
T he p re s e rv a tio n m e a su re s se t o u t in S e c tio n
be in je c te d in to th e c o m b u s tio n c h a m b e r u n d er
2.2 m u s t be c a rrie d o u t in fu ll.
p re s s u re to e n s u re c o m p le te s p ra y in g o f a ll
areas. U pon c o m p le tio n o f each c y lin d e r (pisto n 3.3 Laid up for more than 36 months:
d o w n ), ro ta te th e e n g in e a t le a st o n e fu ll tu rn
by hand. If th e laying-up period is exte nd e d fo r m ore than
36 m on th s, p re se rva tio n m u st be repeated every
N o te 2: D u rin g th e a bove o p e ra tio n th e in je c tio n 36 m o n th s (3 years) o r 18 m o n th s in a cco rd a n ce
p u m p /g o v e rn o r c o n tro l m u s t be in th e s h u t-o ff w ith S e c tio n 2.2 in fu ll.
p o s itio n .
If th e re is o il in th e e n g in e , th is m ay be d ra in e d
Oil Per Cylinder 8-10 ml o ff a t roo m te m p e ra tu re (a b o u t 20°).
It Is n o t n e c c e s a ry to ren e w th e o il filte r
c a rtrid g e .
N o te 3: Do n o t e x c e e d a bove a m o u n ts as th is m ay
lead to h y d ra u lic lo c k and p o s s ib le e n g in e d a m a g e .
4.0 PREPARING E N G IN E FOR O PERATIO N
R e fit a ll p a rts re m o ve d a nd e n su re th a t s e a ls a nd
4.1 R em ove s e a lin g fro m a ll o p e n in g s .
g a s k e ts are in p la c e . R e -p o s itio n th e in je c tio n p u m p
g o v e rn o r c o n tro ls to th e o p e ra tin g p o s itio n . 4.2 R em ove p re s e rv in g a g e n t o r g re a se fro m th e
grooves o f V -belt pulleys, flyw h e e l and o th e r un
N o te 4: E n g in e s m u s t n o t be s ta rte d a fte r th e c o m
p ro te c te d s u rfa c e s .
b u s tio n c h a m b e r p re s e rv a tio n has been c a rrie d o u t.
4.3 R e p o s itio n a nd te n s io n V -b e lts in a c c o rd a n c e
2.2.3 Preservation o f Air Compressors:
w ith in s tru c tio n s .
A ir c o m p re s s o r p re s e rv a tio n s h o u ld be d o n e in
4.4 If n o t a lre a d y in s ta lle d , f it e n g in e to m a c h in e .
c o n ju n c tio n w ith th e c o m b u s tio n c h a m b e rs . A
m a x im u m o f 5 c u b ic c e n tim e tre s o f ru n n in g -in 4.5 F ill w ith a p p ro ve d lu b ric a tin g a n d c o o la n t s e r
o il s h o u ld be in je c te d o r p o u re d in to e a ch v ic e p ro d u c ts o r to p up to m a x im u m level.
AD E 360 S e rie s
OPERATING AND MAINTENANCE — 09-5
N o te 6: E n g in e s w h ic h have n o t rece ive d th e ir firs t

s e rv ic e m u s t be fille d w ith ru n n in g -in o il, a ll o th e rs
s h o u ld be fille d w ith a p p ro ve d o p e ra tin g o ils .
4.6 R e ch a rg e and re c o n n e c t b a tte rie s .
4.7 Run e n g in e to o p e ra tin g te m p e ra tu re (c o o la n t

te m p e r a tu r e 7 5 -7 9 ° C) w h ile m o n ito r in g
p re s s u re s a n d te m p e ra tu re s .
AD E 360 S e rie s
TECHNICAL DATA — 09-6
LUBRICATING OILS
VISCOSITY GRADES
A m bient A ir
SAE Grades
Temperature
°C
mm.
«
o
o
5S
=£
o
o
1
«
in CM
■
35
in
DUE TO CONTINUOUS DEVELOPMENT, ATLANTIS DIESEL ENGINES ARE CONSTANTLY

REVISING THEIR OIL RECOMMENDATIONS.
TO OBTAIN THE LATEST OIL RECOMMENDATIONS, PLEASE REFER TO OUR SERVICE

BULLETINS, OR CONSULT YOUR NEAREST OIL COMPANY FOR THEIR ADVICE.
A D E 360 S e rie s
SECTION 10-1
Fault Finding
CONTENTS OF THIS SECTION
STARTER MOTOR TURNS ENGINE TOO S L O W L Y .......................................................... 10-2

HARD STARTING WHEN C O L D ............................................................................................. 10-3
ENG INE TURNS OVER BUT REFUSES TO S T A R T .......................................................... 10-4
ENG INE DIFFICULT TO S T A R T .............................................................................................. 10-5
E NG INE L O C K -U P ...................................................................................................................... 10-6
ENG INE CUTS OUT AFTER S T A R T IN G ............................................................................... 10-7
ENG INE O V E R H E A T IN G .......................................................................................................... 10-8
E N G IN f RUN NING TOO C O L D .............................................................................................. 10-9
ENG INE KNOCKING . . . : .......................................................................................................... 10-10
ENG INE V IB R A T IO N .................................................................................................................. 10-11
ENG INE M IS F IR E S .....................................................................................................................10-12
LOSS OF P O W E R ........................................................................................................................ 10-13
BLACK SMOKE FROM E X H A U S T ...........................................................................................10-14
BLUE SMOKE FROM E X H A U S T ........................................................... 10-15
W HITE SMOKE FROM E X H A U S T ...........................................................................................10-16
EXCESSIVE FUEL C O N S U M P T IO N ....................................................................................... 10-17
ABN O R M A L OIL C O N S U M P T IO N .......................................................................................... 10-18
LOW O IL P R E S S U R E ................................................................... 10-19
O IL PRESSURE TOO H I G H ......................................................................................................10-20
ENG INE O IL S L U D G E ................................................................................................................10-21
FA U LTFIN D IN G - 10-2
COMPLAINT
FAULT FINDING - 10-3
COMPLAINT
COMPLAINT
NOTE: Refer also to pages:

10-2) S tarter m otor turns
engine too slow ly
10-5) Engine is d iffic u lt to start
10-3) Hard starting when cold
AD E 360 S e rie s
COMPLAINT
A D E 360 S e rie s
COMPLAINT
AD E 360 S e rie s
COMPLAINT
AD E 360 S e rie s
COMPLAINT
ADE 360 S e rie s

COMPLAINT
COMPLAINT
COMPLAINT
ADE 360 S e rie s

COMPLAINT
AD E 360 S e rie s
COMPLAINTS
ADE 360 S e rie s

FAU LTFIN D IN G - 10-14
COMPLAINT
AD E 360 S e rie s
COMPLAINT
AD E 360 S e rie s
COMPLAINT
A D E 360 S e rie s
COMPLAINT
A D E 360 S eries
COMPLAINT
A D E 360 S e rie s
COMPLAINT
A D E 360 S eries
COMPLAINT
ADE 360 S eries

COMPLAINT
__________SECTION 111
Cylinder Block and Liners

Page
INTRODUCTION ........................................................................................................................................... 11-3
SPECIFICATIONS ........................................................................................................................................ 11-3
CHECKING CYLINDER BORES FOR WEAR ................................. 11-5
REBORING CYLINDER BLOCK ............................................................................................................... 11-6
REMOVING CYLINDER LINERS ...............................................................................................................11-7
REPLACING CYLINDER LINERS ............................................................................................................. 11-8
CRANKCASE VENTILATION SYSTEM ..................................................................................................11-11
REMOVING BREATHER ...........................................................................................................................11-13
REPLACING BREATHER ............................................................................ 11-1411-14
A d e 360 S e rie s
SECTION 11
Cylinder Block and Liners
CYLINDER BLOCK
1 R EA R M A IN O IL S E A L S 7 GASKET 13 SIDE COVER

2 SUMP 8 TIM ING COVER 14 CYLINDER LINER .
3 SUM P G ASKETS 9 OIL SEAL 15 CRANKCASE BREATHER
4 M A IN B E A R IN G C A PS 10 COVER 16 CYLINDER BLOCK
5 GASKET 11 GASKET 17 GASKET
6 T IM IN G G E A R C A S E 12 O-RING 18 OIL COOLER
ADE 360 Series

CYLINDER BLOCK AND LINERS — 11-3
INTRODUCTION
The cylinder block is designed to form an integral casting with the crankcase and is manufactured
from high grade cast iron, alloyed with copper and chrome. U tilising the latest in engineering
technology, the cylinder block is machined to very fine tolerances and is subject to a rigorous quality
control inspection.
Interference fit, dry cylinder liners (Sleeves), are fitte d to the ADE 364T and 366T/TI. Engines fitted
w ith cylinder liners can be identified by a “ Z” , stam ped on the cylinder block, to one side of the
push rod cover.
SPECIFICATIONS
CYLINDER LINER
N om inal diam eter Total height of

R epair stages C ylinder bore
of cylinder cylinder block
97,510 359,10
S ta n d a rd (N/C/T/TI) 97,50 ----- — (STD)
97,490 359,00
98,010
Rep s ta g e 1(N) + 0,5 R e b o re * 98,00
97,990 358,80
358,70
Rep s ta g e 1 (N/C/T/TI)
97,510 358,50
Rep s ta g e 2 (N/C/T/TI) 97,50 ----- ’— ( - 0,6)
97,490 358,40
358,20
Rep s ta g e 3 (N/C/T/TI) -------— ( - 0,9)
358,10
*1 s t Rep s ta g e fo r n a tu ra lly a s p ira te d o p tio n a l I.e. e ith e r rebore fo r o ve rsize p is to n o r f it sleeve.
L in e r P a re n t B ore 100,435
100,400
4 8
L in e r F la n g e R ecess — d e p th ’
4,6
103,626
— d ia
103,572
C y lin d e r L in e r O.D. 1 0 0 49 5
_______________________________________________________________■
_____________________________________100,475
C y lin d e r L in e r F la n g e O.D. 103,428

103,375
NO TE 1:
S tam p ed num bers appear on the side of the cylinder block for each cylinder. The num bers are for grading purposes during
production only.
ADE 360 Series

N O TE 2:
It is essen tial to m achine to a piston clearance depth of at least 250 mm when reboring the 360 Series N aturally aspirated
engine to next repair stage or for liner fitm en t. (See item B illustration below.)
D im e n s io n A = 9 8 ,0 - 9 8 ,3 mm
D im e n s io n B = 251 - 2 5 2 mm
D im e n s io n C = 2 2 4 - 2 2 5 mm
D im e n s io n hi = B lo c k H e ig h t fro m c e n tre o f m ain
b e a rin g bore to jo in t
fa c e o f c y lin d e r head.
(R efer to c o lu m n s , c y lin d e r
b lo c k a nd c y lin d e r lin e r
fo r s ta n d a rd and re p a ir •
s ta g e s fo r b lo c k h e ig h t)
O v a lity o f c y lin d e r bore 0,01

T a p e r o f c y lin d e r bore 0,01
V e rtic a l d e v ia tio n o f c y lin d e r b o re s w ith in a
d is ta n c e o f 200 m m in re la tio n to c ra n k s h a ft a x is 0,04
R o u g h n e s s o f bore a fte r h o n in g R3Z 3-5 jim R m ax. 6-11
L e a kag e te s t p re s s u re w ith c y lin d e r b lo c k su b m e rg e d in
200 kPa
w a te r a t 70°C
D is to rtio n lim it — L e n g th 0,03
N o t to e xce e d 0,015 m m over a d is ta n c e of 150 mm
P is to n p ro tru s io n /re c e s s io n to u p p e r c y lin d e r b lo c k + 0,30
s u rfa c e - 0,088
W e a r lim it o f bore to p p is to n rin g u p p e r re tu rn p o s itio n 0,12
h a lfw a y s tro k e 0,05
60,030
C a m s h a ft b e a rin g b a s ic bore
60,000
M a in b e a rin g b a s ic bore 93,022

new
93,000
93,040
lim it fo r re p a ir
92,970
O v a lity o f m a in b e a rin g b a s ic bore 0,01
T a p e r o f m a in b e a rin g b a s ic bore 0,01
R o u g h n e s s u p p e r jo in t fa c e o f c y lin d e r b lo c k 8-16
TORQUE SPECIFICATIONS
O il g a lle ry p lu g s (fro n t and r e a r ) .................................................. M 1 6 x 1 ,5 ............................................... 40-45 N.m

M 1 8 x 1,5 ............................................... 70-90 N.m
M 20 x 1,5 ............................................... 90-110 N.m
C o n n e c tio n p lu g fo r t a c h o m e t e r .............................................. M 2 6 x 1 ,5 ............................................... 60 N.m
P u sh ro d c o v e r to c y lin d e r b l o c k ............................................... M8 ........................................................... 15 N .m _
E n g in e m o u n tin g b ra c k e t to c r a n k c a s e ................................... M 1 4 x 1 ,5 ............................................... 150-190 N.m
P is to n c o o lin g n o z z e ls ................................................................... M 1 0 x 1 .................................................. 25 N.m
B la n k in g p lu g s (fo r p is to n c o o lin g n o z z e ls ) ......................... M 1 0 x 1 .................................................. 10 N.m
S id e c o v e r (w a te r ja c k e t) to c y lin d e r ......................................... M8 ........................................................... 25 N.m
AD E 360 S e rie s
CYLINDER BLOCK A N D ^ P E R S - 11-5
CHECKING CYLINDER BORES FOR WEAR

In th e e ve n t o f E xce ssive O il C o n s u m p tio n and in a d d i
tio n to a visual check, m easurem ents o f th e cylin d e r bores
w ill be n e ce ssa ry. B e fo re a tte m p tin g to m e a su re th e
c y lin d e r bores th e y sh o u ld be th o ro u g h ly cleaned and free
fro m o il a nd c a rb o n d e p o s its .
1. U sin g co m p re s s e d air, cle a n th e to p o f th e c y lin d e r

b lo c k , (fig . 11-1).
2. W ip e c y lin d e r b o re s u s in g c le a n rag. (fig . 11-2).
r r —m fT " “<H It—<~I [mmtras

F ig. 11-2
3. C h e ck c y lin d e r b lo c k to p fa c e fo r lo c a lis e d d is to rtio n

u s in g a s u ita b le s tra ig h t edge, (fig . 11-3).
4. S et in te rn a l m e a s u rin g in s tru m e n t, (fig . 11-4).
A D E 360 S e rie s
CYLINDER BLOCK AND LINERS - 11-6
5. In s e rt m e a s u rin g in s tru m e n t in to c y lin d e r bores,

(fig. 11-5).
6. C h e ck c y lin d e r b o re s a t p o in ts 1, 2 and 3. The c h e c k s

s h o u ld be m ade in d ire c tio n A = C e n tre lin e and B
= 9 0 ° fro m c e n tre lin e , (fig. 11.6).
W h e n p is to n s are n o t rem oved, th e m e a s u rin g p o in t 3 is

ju s t a b o ve th e p is to n a t BDC.
REBORING CYLINDER BLOCK FOR OVER

SIZE PISTONS OR FITMENT OF LINERS
1. A fte r th e c y lin d e r b lo c k has been th o ro u g h ly c le a n
ed it s h o u ld be s e c u re ly m o u n te d u n d e r th e b o rin g
bar, (fig . 11-7).
F ig. 11-7
2. A lig n a n d c e n tre th e b o rin g b a r a b o ve th e c y lin d e r to

be m a c h in e d .
3. In s e rt to o l in to b o rin g b a r head and a d ju s t to th e re

q u ire d d im e n s io n , (fig . 11-8).
A ttention!
If m ore th a n one c y liin d e r req u ire s b o rin g fo r lin e r fitm e n t
th e fo llo w in g s e q u e n c e s h o u ld be fo llo w e d :
B ore c y lin d e rs 1-3-5-2-4-6 — (6 c y lin d e r),
2-4-1-3 — (4 c y lin d e r).
W h e n u s in g th is s e q u e n c e o f b o rin g e x c e s s iv e th e rm a l
s tre s s w ill be a vo id e d .
A D E 360 S e rie s
4. Bore c y lin d e r to 0,05 m m b e lo w th e fin a l c y lin d e r bore

d im e n s io n , (fig. 11-9).
A tten tio n!
M a c h in e o r s u rfa c e g rin d c y lin d e r b lo c k to p fa c e by 0,3
m m to n e x t b lo c k h e ig h t re p a ir sta g e, i.e. fo r o ve rsize d
p is to n s o r lin e r fitm e n t (see s p e c ific a tio n s ) and e n su re
c o rre c t re p a ir s ta g e p is to n s are used.
F ig. 11-9
5. S e cu re ly m o u n t cylin d e r b lo c k under hon in g m achine.

H o n e c y lin d e r lin e rs to fin a l d im e n s io n s , (see
s p e c ific a tio n s ), (fig . 11-10).
6. B e fo re a s s e m b lin g th e e n g in e th o ro u g h ly cle a n the

cy lin d e r b lo ck and cran kca se inside and out. B low o u t
o il g a lle ries e n su rin g th a t no residue from th e m a c h in
ing p ro ce ss is le ft.
REMOVING CYLINDER LINERS

1. S ecurely m ou n t cran kca se under b o ring m ach in e , (fig.
1 1 - 1 1 ).
2. A lig n a nd c e n tre b o rin g bar a b o ve th e c y lin d e r to be

m a c h in e d .
Attention!
If m ore th a n one c y lin d e r re q u ire s b o rin g , th e fo llo w in g
s e q u e n c e s h o u ld be fo llo w e d :
B ore c y lin d e rs 1-3-5-2-4-6 — (6 cylin d e r),
2-4-1-3 — (4 cylin d e r).
W hen u s in g th is se q u e n ce o f b o rin g e xce ssive th e rm a l
s tre s s w ill be avo id e d.
3. In s e rt to o l in to b o rin g bar head a nd a d ju s t so th a t the

c y lin d e r lin e r w ill be b o re d o u t to a p p ro x im a te ly h a lf
its fo rm e r th ic k n e s s , (fig. 11-12).
AD E 360 S e rie s
4. Re-set to o l in b o rin g b a r head and m a c h in e c y lin d e r

lin e r to 0,2 m m b e lo w o u te r d ia m e te r o f c y lin d e r lin e r
(Standard Size). Bore c y lin d e r lin e r and rem ove flanqe,
(fig . 11-13).
A tten tio n! A t th is s e ttin g th e fla n g e o f th e lin e r w ill

b e c o m e d e ta c h e d fro m th e sleeve.
Fig. 11-13
5. In s e rt b o rin g b a r head in to c y lin d e r bore, w ith c u ttin g

to o l s ta tio n a ry and in c o n ta c t w ith cylin d e r liner. M ove
c u ttin g to o l v e rtic a lly up and d o w n c y lin d e r bore,
a llo w in g c u ttin g to o l to break th ro u g h w a ll o f c y lin d e r
lin e r. Rem ove c y lin d e r lin e r fro m c y lin d e r b lo ck,
(fig . 11-14).
F ig. 11-14
REPLACING CYLINDER LINERS
1. T h o ro u g h ly c le a n b o re fo r c y lin d e r lin e r a nd fla n g e

s e a t, (fig . 11-15).
2. M o u n t c y lin d e r b lo c k u n d e r p re ss and a lig n c y lin d e r

bore.
3. A p p ly a lig h t c o a tin g o f g re a se to bore in c y lin d e r

b lo c k .
F ig. 11-15
4. L o c a te c y lin d e r lin e r over b o re in c y lin d e r b lo c k and

a lig n , u s in g a s e t sq u a re , (fig . 11-16).
F ig. 11-16
AD E 360 S e rie s
5. F it a s u ita b ly ste p p e d s te e l p la te b e tw e e n p re ss
head and c y lin d e r lin e r. Press c y lin d e r lin e r in to
c y lin d e r b lo ck u n til it p ro tru d e s a p p ro xim a te ly 20 mm,
(fig. 11-17).
6. B e fo re p re s s in g lin e r fu lly hom e, c h e c k lin e r fla n g e

and se a t fo r m e ta l p a rtic le s and d irt. B lo w o u t w ith
c o m p re s s e d air, (fig . 11-18).
7. Press c y lin d e r lin e r fu lly h om e, re lie ve p re s s u re fo r

a s h o rt p e rio d and p re ss o n ce a g a in , re ta in in g
p re s s u re fo r 5 se co n d s.
8. M a c h in e o r s u rfa c e g rin d c y lin d e r b lo c k to p fa c e by

0,3 m m to n e x t b lo c k h e ig h t re p a ir s ta g e (in c lu d in g
p ro tru d in g c y lin d e r lin e r) see s p e c ific a tio n s fo r re
q u ire d s u rfa c e fin is h , (fig . 11-19).
A ttention!
B e fo re m a c h in in g o b se rve c y lin d e r b lo c k h e ig h t and
re p a ir s ta g e a nd e n su re c o rre c t re p a ir sta g e p is to n s
are use d . R efer p is to n c o m p re s s io n h e ig h a nd b lo c k
h e ig h t s p e c ific a tio n s .
9. A fte r m a c h in in g /s u rfa c e g rin d in g , c h e c k c y lin d e r

b lo c k fa c e w ith a s tra ig h t edge, (fig . 11-20).
A D E 360 S e rie s
10. A fte r th e c y lin d e r b lo c k has been th o ro u g h ly c le a n

ed it s h o u ld be s e c u re ly m o u n te d u n d er th e b o rin g
bar, (fig . 11-21).
11. A lig n and c e n tre th e b o rin g b a r a bove th e c y lin d e r to

be m a c h in e d .
12. In s e rt to o l in to b o rin g bar head and a d ju s t to the

re q u ire d d im e n s io n , (fig. 11-22).
13. Bore c y lin d e r lin e r in se ve ra l s ta g e s to 0,050 mm

b e lo w th e re q u ire d b o re d im e n s io n , (fig. 11-23).
A ttention!
If m ore th a n one c y lin d e r re q u ire d b o rin g , th e fo llo w in g
s e q u e n c e s h o u ld be fo llo w e d :
B ore c y lin d e rs 1-3-5-2-4-6 (6 c y lin d e r),
2-4-1-3 (4 c y lin d e r).
W hen u s in g th is s e q u e n c e o f b o rin g , e x c e s s iv e th e rm a l
s tre s s w ill be a vo id e d.
14. R em ove c y lin d e r b lo c k fro m b o rin g m a ch in e .

15. S ecurely m ou n t c y lin d e r b lo ck under hon in g m achine.
H o n e c y lin d e r lin e rs to fin a l d im e n s io n s , (see
s p e c ific a tio n s ), (fig . 11-24).
16. B e fo re a s s e m b lin g th e e n g in e th o ro u g h ly cle a n the

c y lin d e r b lo ck and cran kca se inside and out. Blow o u t
o il g a lle ries e n su rin g th a t no residue from th e m a ch in
ing p ro c e s s is lef*
F ig. 11-24
A D E 360 S e rie s
CRANKCASE BREATHER -
OPERATION AND PROBLEM DIAGNOSIS
Introduction
D e p e n d in g on a p p lic a tio n , th e c ra n k c a s e b re a th e r m ay -4
be m o u n te d to th e ro c k e r cover, p u sh ro d co ve r o r tim in g
g e a r h o u s in g , (fig. 25).
T h e c ra n k c a s e b re a th e r c o n tro ls th e p re s s u re in th e
cran kca se w ith in a prescribed o p e ra tin g range. The d e vice
is o p e n to c ra n k c a s e g a sse s a t th e lo w e r end (7) w ith a
c o n n e c tio n to th e in d u c tio n m a n ifo ld (4) a nd a ve n t to a t
m o s p h e re (3).
N o te 1: F o r p ro p e r o p e ra tio n th e a re a a ro u n d th e a ir vent
(3) m u s t be k e p t c le a n to p re ve n t b lo c k a g e . In a d d itio n
a ll jo in ts , c o n n e c tio n s and o il f ille r cap m u s t fo rm a tig h t
se a l to p re ve n t c ra n k c a s e d e p re s s io n lo s s e s a n d /o r d irt
e n try in to th e e n g in e .
N o te 2: T he fle x p o in t o f th e b re a th e r d ia p h ra g m is s u b
je c t to d e te rio ra tio n e.g. h a rd e n in g o r c ra c k in g . It is
th e re fo re strongly recom m ended that the breather be
replaced a fter every tw o years operation, as a p re c a u
F ig. 25
tio n a ry m easure.
1 — D ia p h ra g m
1.0 Operation
2 — V alve
1.1 A tm o s p h e ric p re ssu re a c ts on th e o u te r su rfa ce 3 — A ir V e n t
o f th e d ia p h ra g m (1) via th e vent (3). Before s ta rt 4 — T o In le t M a n ifo ld
up, a tm o s p h e ric p re ssu re w ill a ls o be p re se n t in 5 — O il D rain H o le
th e c ra n k c a s e and in d u c tio n sy s te m s . The 6 — Gauze
p re s s u re on b o th s id e s o f th e d ia p h ra g m w ill 7 — F rom C ra n k c a s e
th u s be equal. 8 — P e rfo ra te d P la te s
9 — S p rin g
1.2 T he s p rin g (9) a c ts a g a in s t th e d ia p h ra g m and 10 — ‘O ’ Ring
h o ld s th e valve (2) o ff its se a t in th e open p o s i
tio n . To c lo s e th e valve, s u ffic ie n t d e p re s s io n
m u st o c c u r in th e c ra n k c a s e to a llo w a tm o s
p h e ric p re ssu re a c tin g on th e o u te r s u rfa c e o f
- th e d ia p h ra g m , to o ve rco m e th e s p rin g fo rc e .
T he o p e ra tio n o f th e b re a th e r is th e re fo re mm +
d e p e n d e n t on e n g in e o p e ra tio n .
Q
1.3 A t e n g in e id le sp e e ds, th e s p rin g fo rc e w ill be
s u ffic ie n t to hold th e valve from its se a t a g a in s t
a tm o s p h e ric p re ssu re a c tin g on th e o u te r s u r
fa ce o f th e d ia p h ra g m . C ra n k c a s e g a sse s w ill
su s e q u e n tly be d ra w n d ire c tly in to th e c o m b u s
tio n c h a m b e rs and w ill be b u rn t d u rin g th e c o m
b u s tio n p ro ce ss.
t
X
1.4 A t n o rm a l o p e ra tin g sp e e d s and lo a d s th e ever
ch a n g in g in d u c tio n m a n ifo ld d e p re s s io n a c tin g
w ith in th e b re a th e r, is h ig h e r th a n th e req u ire d 40 _
t
cra n kca se d e p re ssio n . The b re a th e r w ill rea ct to 50 _
th e h ig h m a n ifo ld d e p re s s io n and c o n tro l
c ra n k c a s e d e p re s s io n .
e.g. S h o u ld th e c ra n k c a s e d e p re ssio n a p p ro a ch
th e u p p e r n e g a tiv e lim it in th e o p e ra tin g range, mm-
th e valve w ill m ove to w a rd s th e c lo s e d p o s itio n
to re d u ce th e e ffe c t o f m a n ifo ld d e p re s s io n
w ith in th e c ra n kca se .
X J F ig. 26
T he va lve in tu rn w ill re a ct w h e n c ra n k c a s e
d e p re s s io n is re d u ce d to w a rd s th e lo w e r or OPERATING RANGE
p o s itiv e lim it and w ill open m a rg in a lly to a llo w
th e h ig h m a n ifo ld d e p re s s io n a c c e s s to th e SERVICE S P E C IF IC A T IO N FOR
cran kca se . A L L BREATHERS:
In th is m a n n e r th e b re a th e r w ill c o n tin u o u s ly
se n se and a c c o rd in g ly , re sp o n d to m a n ifo ld + 10 TO - 100 m m H 20
d e p re s s io n u n d e r v a rio u s o p e ra tin g c o n d itio n s
and th e re b y, c o n tro l cra n kca se d e p re ssio n w ith
th e d e s ire d o p e ra tin g range. Note: X — EX AM PLE O N LY = m a n o m e te r r e a d in g - 6 0 m m H 20
AD E 360 S e rie s
1.5 C ra n k c a s e g a s s e s p a s s in g v ia th e b re a th e r are 3.3 Excessive positive reading is indicated at all

o il b e a rin g and m o s t o f th e o il w ill be tra p p e d engine speeds.
by th e gauze m esh (6). E xce ss o il n o t tra p e d by
th e gauze w ill return to th e cra n kca se via a dra in CAUSE REMEDY
h o le (5) p ro v id e d in th e b re a th e r neck.
a) Broken collapsed spring — Renew
H ow ever, it is n o rm a l fo r a s m a ll q u a n tity o f o il,
breather
in th e fo rm o f m is t to be tra n s fe rre d to th e in
b) Valve s tu ck in closed — Renew
ta k e a ir to lu b ric a te th e valves (3 — 5 g/hr). T he
p o sition breather
d a m p n e s s c re a te d by th e o il fu m e s is n o rm a lly
c) B lockage o f breather gauze — W ash in clean
e vid e n t in th e in le t/m a n ifo ld o f e n g in e s u tiliz in g
by sludge* diesel If this
th is ty p e o f b re a th in g s y s te m a n d is n o t
fails, renew
n e c e s s a rily in d ic a tiv e o f a p ro b le m .
breather
d) Severe com bustion gas — Repair as
blow by necessary
2.0 Operational Test 'In v e s tig a te reason fo r sludge and rectify.
2.1 Park th e v e h ic le on level g ro u n d and e n su re th a t
th e o il level is c o rre c t (n o t o ve r-fille d ). N o te 4: A s a rule c ra n k c a s e p re ssu re d e p re s s io n s h o u ld
rem a in w ith in th e p re scrib e d range ( + 10 to - 1 0 0 mm H 2
2.2 Use a w a te r m a n o m e te r (see fig . 26) and co n n e ct
O). If th is is n o t th e case and all p o ssib le c o n trib u tin g fa c
o ne end o f th e g a u g e to th e e n g in e d ip s tic k
to rs have been e lim in a te d , it m ay be a ssu m e d th a t th e
g u id e tube. The o th e r end o f th e tu b e is le ft open
b re a th e r is fa u lty .
to a tm o s p h e ric p re ssu re . B e fo re s ta rtin g th e
e n g in e e n s u re th a t th e in s tru m e n t re g is te rs a
zero re a d in g in b o th c o lu m n s . 4.0 Conclusion
A fa u lty cra n k c a s e b re a th in g syste m c o u ld re s u lt in
2.3 S ta rt and run th e e n g in e a t id le speed. A te n
th e fo llo w in g p ro b le m s:
d e n cy to w a rd s a ne g ative re a d in g ( - ) s h o u ld be
4.1 E xce ssive o il c o n s u m p tio n .
n o ted .
4.2 D u st e n try v ia — a) A ru p tu re d o r p u n c tu re d
2.4 G ra d u a lly in c re a se th e e n g in e speed to a p p ro x i
d ia p h ra g m ,
m a te ly 1 500 r/m in . The in s tru m e n t s h o u ld
b) A p o o r seal a t th e “ O ” ring
in d ic a te a negative reading in crea sin g w ith in the
( 10),
o p e ra tin g range.
c) O th e r in le t o r cra n k c a s e
2.5 F u rth e r in c re a s e th e e n g in e speed to a p p ro x i c o n n e c tio n s , c o u ld ca u se
m a te ly 2 000 r/m in . The n e g a tive rea d in g s h o u ld s e rio u s d a m a g e to th e
ra is e w ith in th e o p e ra tin g range. T h is w o u ld e n g in e.
in d ic a te th a t th e va lve is w o rk in g .
4.3 A h ig h c ra n k c a s e p re ssu re c o u ld fo rc e o il p a st
N o te 3: The o p e ra tio n a l c h a ra c te ris tic s o f a b re a th e r w ill
th e c ra n k s h a ft and tu rb o c h a rg e r seals.
d e p en d on th e c o n d itio n o f th e e n g in e e.g. a m o u n t o f
b lo w b y .
3 .0 Evaluation of Test Results

3.1 M inim al negative reading at low r/min w ith
little or no change at high r/min.
CAUSE REMEDY
a) Gauge con nection s leaking — Secure
con nection s
b) Leak in vacuum line to — Check and
m anifold correct
c) Poor seal at breather — C heck/replace
m ounting O-ring or
gasket
d) Diaphragm cracked/holed — Renew
breather
3.2 Excessively high negative reading.
CAUSE REMEDY
a) Valve not closing — Check b, c, d

below, or
renew breather
b) Vent hole blocked — C lear and
retest
c) Vent hose pinched — Repair hose
and retest
d) Foreign p a rtic le on — Remove object
valve seat and retest
e) Diaphragm ruptured — Renew
breather
ADE 360 S e rie s

REMOVAL AND REPLACEMENT OF

BREATHER
Removal
1. U n scre w c lip on pipe le a d in g to in le t m a n ifo ld ,

(fig. 11-27).
2. Rem ove p ip e w ith c lip , (fig. 11-28).
3. U n scre w c la m p on c ra n k c a s e end o f b re a th e r pipe,

(fig. 11-29).
4. Pull o ff b re a th e r fro m m o u n tin g p ipe, (fig . 11-30).
Fig. 11-30
A D E 360 S e rie s
5. R em ove o-ring fro m th e in s id e o f th e b re a th e r pipe,

(fig . 11-31).
F ig. 11-31
Replacing
1. F it new o -rin g in th e b re a th e r p ip e , (fig . 11-32).
2. S lid e b re a th e r w ith o -rin g in to p la ce over m o u n tin g

p ip e , (fig. 11-33).
3. A lig n bre a th e r to in le t m a n ifo ld and secure c la m p over

in le t pipe, (fig. 11-34).
A D E 360 S e rie s
4. R eplace pipe le a d in g to th e in le t m a n ifo ld , (fig. 11.35).
5. T ig h te n c lip on th e pipe, (fig. 11-36).
AD E 360 S e rie s
" QaM *ington Diesel Club
ADE 364 and ADE 366
Workshop Manual
Section 12 - Cylinder Head
B o n in g to n D iesel C lu b
SECTION 12
Cylinder Head
3 2
1 G A S K E T (EXHAUST M A N IF O L D ) 12 IN L E T V A LV E 22 RO CKER S H A F T R E T A IN IN G
2 G A S K E T (IN LE T M A N IF O L D ) 13 EXH AU S T V A LV E G R U B SC R EW
3 C Y L IN D E R H E A D G A S K E T 14 V A LV E SPR IN G A S S E M B LE Y 23 ROCKER G EAR
4 C Y L IN D E R H E A D 15 V A LV E C O LLE T S R E T A IN IN G BO LT
5 IN JE C T O R S E A L IN G W A S H E R 16 PUSH ROD 24 RO CKER A S S E M B LE Y
6 IN JE C T O R 17 RO CKER CO VER G A S K E T 25 RO CKER S H A F T
7 C Y LIN D E R H E A D BO LT 18 RO CKER COVER C O U P LIN G B U S H *
8 EX H AU S T V A L V E S E AT INSERT 19 O IL F ILLE R C A P (SCREW TYPE) 26 SPR IN G
9 IN L E T V A L V E SEAT INSERT 20 O IL F ILLE R C A P (CLIP TYPE)
10 V A LV E G U ID E 21 RO CKER GEAR
11 V A LV E STEM O IL S E A L R E T A IN IN G BO LT * N O T FITTE D O N A D E 364
ADE 360 Series

SECTION 12-1
Cylinder Head

Page
INTRODUCTION ............................................................................................................................... ........ 12-3
SPECIFICATIONS .....................................................................................................................................12-3
TORQUES ....................................................................................................................................................12-6
REMOVING ROCKER COVER ................................................................................................................12-7
REMOVING CYLINDER HEAD ............................................................................................................... 12-7
CHECKING VALVE RECESSION ........................................................................................................... 12-11
REMOVING VALVES .................................................................................................................................12-11
CHECKING VALVE STEM/GUIDE CLEARANCE ................................................................................ 12-12
VALVE FACING .......................................................................................................................................... 12-13
VALVE SEAT FACING ...............................................................................................................................12-14
REMOVING VALVE GUIDES ...................................................................................................................12-14
REPLACING VALVE G U ID E S ................................. 12-14
CHECKING CYLINDER H E A D ............................................................................................................... 12-16
REPLACING VALVES ..................... 12-16
INJECTOR PROTECTION SLEEVES .....................................................................................................12-18^
CHECKING INJECTOR PROTRUSION ................................................................................................. 12-19
REPLACING CYLINDER HEAD ...............................................................................................................12-20
VALVE CLEARANCE ADJUSTMENT 364 ............................................................................................ 12-23
VALVE CLEARANCE ADJUSTMENT 366 ............................................................................................ 12-24
REPLACING ROCKER COVER ............................................................................................................... 12-24
CHECKING COMPRESSION PRESSURE ............................................................................................ 12-25
SPECIAL SERVICE TOOLS ...................................................................................................................... 12-27
AD E 360 S e rie s
CYLINDER HEAD — 12-3
INTRODUCTION
U tilising the latest in autom otive engineering technology, the ADE 360 series cylinder head is of
advanced design common for all cylinders and is m anufactured from high grade grey cast iron
alloyed w ith copper and chrome, and machined to a very high tolerance. The fuel injectors are
mounted w ith in the cylinder head and enclosed by a light alloy rocker cover.
Separate inlet and exhaust m anifolds are fitted , providing enhanced gas flow and improved fuel
efficiency.
SPECIFICATIONS
O v e ra ll h e ig h t o f c y lin d e r head (new) 92,1
91,9
M in im u m h e ig h t a fte r m a c h in in g * 90,9
P eak to v a lle y fin is h o f m a tin g s u rfa c e in (m icro n s) 8,16
D is to rtio n lim it over L e n g th o f head 0,150
o ve r d is ta n c e o f 150 m m 0,040
M a x p a ra lle l d e v ia tio n b e tw e e n u p p e r and lo w e r 0,1
s u rfa c e
In je c to r nozzle p ro tru s io n 1,6-2,6

L e a k a g e te s t p re s s u re w ith c y lin d e r head su b m e rg e d in 200 kPa
w a te r a t 70°C
*C h e c k n o zzle p ro tru s io n a fte r e a ch m a c h in in g sta g e o f c y lin d e r hSiad m a tin g s u rfa c e and c o rre c t w ith nozzle s h im s if
re q u ire d . W h e n m in im u m h e ig h t is re a ch e d f it 1 m m s p a c e r u n d e r ro c k e r p e d e s ta ls .
z
i§ . ! i
t
--------- D -------- ►
I/ALVE SEAT INSERTS
In le t va lve s e a t in s e rt E xh a u st va lve s e a t in s e rt
S ta n d a rd Rep. s ta g e 1 Rep. s ta g e 2 S ta n d a rd Rep. s ta g e 1 Rep. s ta g e 2
O D “ D” 43,88 44,18 44,38 38,080 38,380 38,580
o f va lve s e a t in s e rt 43,87 44,17 44,37 38,070 38,370 38,570
B a s ic b o re “ D 1” in 43,825 44,125 44,325 38,025 v \ 38,325 38.525 ■/.-
c y lin d e r h e a d fo r 43,800 44,100 44,300 38,000 '■ 38,300 38,500
va lve se a t in s e rt
In te rfe re n c e f it o f se a t
0,045-0,080 0,045-0,080
in s e rt in c y lin d e r head
D e p th “ t ” o f bore 11,2 11,2
in c y lin d e r head 11,0 11,0
H e ig h t “ H ” o f 7,4 6,1
va lve s e a t in s e rt 7,3 8,0
D is ta n c e “ t1 ” b e tw e e n
m a tin g s u rfa c e o f
3,6-3,9 2,9-3,2
c y lin d e r h e a d and fa c e
o f va lve s e a t in s e rt
VALVE SEATS
In le t 30°
V a lv e s e a t a n g le =----------------------------------------
E xh a u st 45°
D ia m e te r “ A ” o f va lve se a t ' n ^e t 41’3

w ith new va lve s e a t in s e rts a fte r m a c h in in g ------------------------------------------------------------
E xh a u st 35,3
In le t 1,3-2,4
W id th ,,B ” :---------------- =-----
E xh a u st 1,8-3,0
S ize “ C ” ln le t 3,6-3,9
In s p e c tio n size ---------------------------------------------------------------------------------------------------------------------------------------- :--
E xh a u st 2,9-3,2
Valve re c e s s io n * 0,7-1,1
* l f th e va lve re c e s s io n is e xce e de d a fte r m a c h in in g th e va lye se a t in s e rts , new in s e rts m u s t be fitte d .
VALVE SPRINGS
Preloaded Final Load

ID ’ Wire Unloaded Length (1) Load (N) Length (2) Load (N)
dia. length
2 5 ,0 - 2 5 ,4 4,25 60,5 46,7 285 - 315 35,18 570 - 630
1)( In in s ta lle d c o n d itio n . C o rre s p o n d s to le n g th w ith va lve c lo s e d .

2) -.4n in s ta lle d c o n d itio n . C o rre s p o n d s to le n g th w ith valve o p e n e d .
CYLINDER HEAD - 12-5
In le t Exhaust
VALVE GUIDES
V a lve g u id e In te rfe r " C le a ra n c e o f

V a lve g u id e ID le n g th B.ore in e n ce in va lve s te m in
S ta g e s OD c y lin d e r c y lin d e r va lve g u id e
In le t E xh a u st In le t E xh a u st head head In le t Exhaust
15,046 15,018
S ta n d a rd
15,028 15,000
15,146 15,118
Rep. s ta g e 1
15,128 (“ B ” ) (“ C ” ) 15,100 0,010 0,050
9,022* 10 ,022**
15,218 to to t t 'f
15,246 9,000 10,000 72 67
Rep. s ta g e 2 0,046 0,087 0,097
15,228 15,200
15,546 15,518
Rep. s ta g e 3
15,528 15,500
* W e a r lim it 9,050
“ W e a r lim it 10,050
M a x im u m o f f c e n tre o f valve s e a t to valve g u id e 0,04
M a x im u m c y lin d ric a l d e v ia tio n o f valve se a t to valve

g u id e a t 42 m m d ia fo r in le t
0,01
34 m m d ia fo r e x h a u s t
“ A ” — R e p la c e m e n t V alve g u id e in s ta lla tio n h e ig h t

17,5
17,0
V a lve s te m /g u id e c le a ra n c e
In le t va lve — re a d in g n o t to e xce e d 0,2 m m
E x h a u s t va lve — re a d in g n o t to e xce e d 0,3 m m
N O TE: R e p la c e m e n t va lve g u id e s m u s t be u se d to g e th e r w ith va lve s te m se a ls.

VALVES
,.p ,
Dimen “A” “ B” “C" “D” “E”
sions Seat Dia Seat Valve Height Width Stem Stem Valve
(mm) Angle Centre Head Dia New Min Dia Hardness Length
42 ,9 2,8 4.3 8,9 50 140,7

In le t 30° 40 2,1 — HRC
42 ,7 2,6 3.3 ,8 ,9 3 5 54 140,3
3 6 ,1 0 2,8 4,2 9,9 40 140,7

Exhaust 4§? 34 2,1
3 5 ,9 0 2,5 3,5 9,9 25 >
t54 rc 14,03
R u n o u t b e tw e e n v a lv e se a t and ste m 0,0 3
R u n o u t b e tw e e n va lve head a nd ste m - 0,20

O v a lity o f va lve se a t 0,01
VALVE ADJUSTMENT 360 Series 360 S e rie s

V a lve c le a ra n c e (te m p e ra tu re m ax, 50°C ) N C/T/TI
• In le t 0,40 0,40
E xh a u st 0,60 0,60
VALVE TIMING
In le t O pen BTDC 15° 15°
C lo s e AB D C 45° 25°
CO
CO
O
E xhaust Open . BBDC 67°
C lo s e ATD C 13° 12°
ROCKtRSHAFT/ROCKER ARM
:---------------------------- f—
22,052
B a s ic b o re ro c k e r arm
22,000
2 2 ,1 3 0
R o c k e r a rm bush
O u te r dia. 22,100
In n e r dia. 20,021
20,000
19,980
R o c k e r s h a ft d ia
1 9 ,967
arance s h a ft/b o re ; 0,020-0,054
^TORQUE SPECIFICATIONS
T h e fo llo w in g to rq u e s p e c ific a tio n s w ill a p p ly w ith th e c o m p o n e n ts lig h tly o ile d .
/ C y lin d e r h e a d b o l t s .......................................................................................1 st S tage: 60 N .m

.(M a x im u m s tre tc h le n g th 113m m ) 2nd S ta g e : 90 N.m
3 rd S tage: 120 - 130 N.m
4 tti S ta g e : 9 0 ° -ip o °
S c re w p lu g s to c y lin d e r h e a d .................................................................. ,.M 2 4 x 1 ,5 ..70-150 N .m
>' M 3 0 x 1 ,5 ....... 100-200 N.m
in ie b t o r p ro te c tio n sleeve to c y lin d e r head ...................... ..................M 1 4 x f , 5 .............. 50 N.m
In je c to r s e c u rin g n u t to c y lin d e r h e a d ..........................................M 3 4 x 1,5 ..... ....... 70 N.m
R o c k e r c o v e r to c y lin d e r h e a d .................................................................M 8 ..........................25 N.m
v a iy e a d ju s tin g s c re w lo c k n u t ................................................................M 1 2 x 1 .................. 40 N.m
R o flJ ^ r s h a ft p e d e s ta l to c y lin d e r h e a d ............................................... M 1 2 ........................100 N.m
R o c k e r s h a ft lo c k s c re w to p e d e s ta l ..................................................... M 6 ................... .......5 N.m
i/E x h a u s t m a n ifo ld to c y lin d e r h e a d .......................................................... M 1 0 ............... ........60 N .m + 90 °
. In le t m a n ifo ld to c y lin d e r h e a d ................................................................M 8 x 1 .................... 30 N .m
' (C h e ck a t e ve ry se rvice)
IT y rb o c h a rg e r to e x h a u s t m a n ifo ld 3 6 6 C /T m .......................................M 1 0 ........................50 N.m
3 6 4 C /T .......................................... M10 .........................30 N.m
E x h a u s t fla n g e to tu rb o c h a rg e r ................................................................ M 8 ......................... 30 N.m
p re s s u re d u c t to tu rb o c h a rg e r (V -cla m p )« .............................................................................. 6 N.m
WÊÈ, 360?i*rìèsS
REMOVAL OF ROCKER COVER
1. U n s cre w a nd rem o ve b o lts re ta in in g ro c k e r cover,

(fig . 12-1).
F ig. 12-1
2. L ift o ff ro c k e r cover, (fig . 12-2).
3. R em ove g a s k e t fro m c y lin d e r head, (fig . 12-3).
Fig. 12-3
¡REMOVING CYLINDER HEAD
Preparation
C le a n th e e n tire u p p e r h a lf o f th e e n g in e , to p re ve n t d irt
e n te rin g th e c y lin d e r b o r e s jjn d ta p p e t ch a m b e r.
1. D ra in c o o la n t fro m ra d ia to r a nd c y lin d e r b lo ck.
2. R em ove fu e l filte rs and if fitte d , p ow er ste e rin g pum p

(fig . 12-4).
3. D is c o n n e c t ra d ia to r h o se s and d ip s tic k g u id e tu b e.
4. D is c o n n e c t and rem o ve th e rm o s ta t h o u s in g .
F ig . 1 2 ^ 7
5. R em ove ro c k e r c o ve r, see page 12-7.
6. U n screw and rem ove cla m p s re ta in in g in je c to r pipes,

(fig. 12-5).
7. D is c o n n e c t o u te r in je c to r p ip e c o n n e c tio n s on
c y lin d e r head, (fig. 12-6).
8. U sin g s p e c ia l to o l p a rt n u m b e r 40200705, u n s c re w
and rem ove in je c to r p ip e s, (fig . 12-7).
Fig. 12-7
9. U n s c re w and rem ove fu e l le a k o ff p ip e , (fig. 12-8).

10. R em ove in je c to r p ip e s fro m c y lin d e r head.
11. U n s c re w b o lts re ta in in g ro c k e r a s s e m b ly , (fig . 12-9).
12. R em ove ro c k e r a s s e m b ly (and c o n n e c tin g n ip le 6

c y lin d e r only).
Fig. 12-9
13. L ift o u t p u sh ro d s. The p u s h ro d s s h o u ld be n u m b e re d

to e n su re re p la c e m e n t in th e o rig in a l p o s itio n s , (fig .
12 - 10 ).
14. Rem ove in je c to r se cu rin g nuts, using sp e cia l to o l part

n u m b e r 40200873, (fig. 12-11).
15. R em ove in je c to rs fro m c y lin d e r head, u s in g im p a c t

p u lle r p a rt n u m b e r 40201076, (fig . 12-12).
F ig. 12-12
LSerW*
A ttention!
16. S h o u ld th e in je c to rs n o t m ove u sin g im p a c t p u lle r,
u se s p e c ia l to o l p a rt n u m b e r 40201063, (tig . 12-13).
17. D is c o n n e c t e x h a u s t d o w n pipe.
18. U n s c re w b o lts and rem ove e x h a u s t m a n ifo ld , (if f i t

te d w ith a tu rb o c h a rg e r, d is c o n n e c t tu rb o c h a rg e r o il
fe e d and d ra in p ip e s firs t), (fig . 12-14).
19. U n scre w b o lts and rem ove in le t m a n ifo ld , (fig. 12-15).
20. U n s c re w s n d rem ove c y lin d e r head b o lts (in reverse

tig h te n in '^ se q u en ce ), (fig. 12-16). See p age 12-20.
A D E ':S 8£Ii*S *
21. S cre w liftin g h a n d le s, p a rt n u m b e r 40200747 in to

c y lin d e r head and lift o ff fro m c y lin d e r b lo ck. Rem ove
liftin g h a n d le s fro m c y lin d e r head, (fig . 12-17).
Fig. 12-17
22. R em ove c y lin d e r head g a s k e t, and c le a n to p o f

c y lin d e r b lo c k , (fig. 12-18).
7>r ir— ir— \r-
Fig. 12-18
CHECKING VALVE RECESSION
1. P la ce s p e c ia l to o l p a rt n u m b e r 40201351 o n to th e
c y lin d e r head w ith the probe o f th e d ia l gauge restin g
on a valve head. N ote reading on d ia l gauge and ch e ck
th e re m a in d e r o f th e va lve s in th is m an n e r, e n su re
th a t re a d in g s c o rre s p o n d w ith th e s p e c ific a tio n s ,
(fig . 12-19).
REMOVING VALVES as follows:
2. A tta c h valve s p rin g c o m p re s s o r, Part No. 40200679,

to e x h a u s t m a n ifo ld s tu d , (fig . 12-20).
Fig. 12-20
3. P ress d o w n le ve r o f valve s p rin g c o m p re s s o r and

rem ove c o lle ts , (fig. 12-21).
4. R em ove valve s p rin g cap, valve, s p rin g a nd valve

s p rin g s e a tin g w a sh e r, (fig . 12-22).
F ig. 12-22
5. T urn o v e r c y lin d e r head a nd rem ove valves.
A tten tio n! B e fo re re m o vin g va lve s, e n su re th a y are

num bered in the c o rre c t re p la ce m e n t se quence (fig. 12-23).
Do n o t p in p u n c h o r s ta m p n u m b e r on th e va lve s as th is
m ay w e a ke n th e va lve head.
C H E C K IN G VALVE STEM /G U ID E
CLEARANCE
6. In s e rt va lve s so th a t th e valve h e a ds p ro tru d e by 10
m m . U sin g a m a g n e tic b a se d d ia l g a u ge , p la c e th e
p ro b e a g a in s t th e o u te r d ia m e te r o f th e va lve head.
Z ero th e g a uge w h ils t th e valve Is p u sh ed a g a in s t th e
pro b e . A fte r z e ro in g th e g a u ge , p u sh th e va lve aw a y
fro m th e p ro b e and n o jp th e re a d in g (fig. 12-24). T h is
p ro c e d u re m u s t be c a rrie d o u t on a ll valves. C h e ck
re a d in g s a g a in s t s p e c ific a tio n s .
ADEI360'Series
VALVE FACING
1. R em ove c a rb o n d e p o s its fro m valves.
2. C h e ck to see if valves can be re-used. Valve ends m ust

have no s u rfa c e d a m a g e . V a lve c o lle t g ro o ve s m u s t
n o t be w o rn a nd c h ro m iu m p la tin g on va lve s te m s
m u s t be w ith o u t fla w s . B u rn t va lve s m u s t a lw a y s be
re p la c e d .
3. U sin g V -b lo cks a nd a d ia l ga u ge , c h e c k run o u t o f

valve stem s. Do not a tte m p t to s tra ig h te n bent valves,
(fig . 12-25).
4. If no V -b lo c k s a n d d ia l g a u g e is a v a ila b le , a q u ic k
c h e c k can be m ad e u s in g a s u ita b le s tra ig h t edge,
(fig . 12-26).
Fig. 12-26
5. M in o r v a ria tio n s in to le ra n c e can be c o rre c te d by

re fa c in g on a va lve g rin d e r.
6. A d ju s t g rin d in g a n g le to 3 0 ° fo r in le t and 4 5 ° fo r e x
h a u s t, in s e rt va lve and c la m p d ire c tly b e h in d valve
h ead to a vo id v ib ra tio n (fig . 12-27).
7. U sin g a lo w fe e d ra te g rin d u n til va lve fa c e is c le a n ly

c u t a ll rou n d .
8. The valve ste m fa c e can bp lig h tly g round, by lo c a tin g

th e valve ste m in th e s p e c ia l a tta c h e m e n t m o u n te d
on th e va lve g rin d in g m a c h in e , (fig. 12-28).
AD E 360 S e rïÿs
VALVE SEAT FACING
1. P lace c y lin d e r head on w o o d e n b lo c k s .
2. In s e rt valve s e a t fa c in g to o l and re-cut s e a t to 3 0 ° fo r

In le t a nd 45 ° fo r e xh a u st, (fig. 12-29).
Caution: Do not c u t va lve se a t d ia m e te r above th e ir m axi:

m um lim its , see s p e c ific a tio n s .
Note: A s th e re p la c e m e n t o f va lve s e a ts re q u ire s th e use
o f c e rta in s p e c ia lis e d e q u ip m e n t, w e s u g g e s t th a t th is
o p e ra tio n is carried o u t by an ADE approved e n g in e recon
d itio n e r. If valve g u id e s need to be re p la ce d new g u id e s
m u s t be fitte d b e fo re valve se a t re -fa cin g .
REMOVING VALVES GUIDES
1. P la ce c y lin d e r head u n d e r a h y d ra u lic press.
2. U sin g s u ita b le m a n d re l p re ss o u t valve g u id e s fro m

c y lin d e r head, (fig. 12-30).
3. If necessary, ream valve g u id e parent-bore in cylin d e r

h ead to n e xt re p a ir s ta g e u s in g s p e c ia l to o l P a rt No.
40200750, (fig . 12-31).
REPLACING VALVE GUIDES
1. C o a t ne w va lve g u id e w ith g ra p h ite d o il and p o s itio n

in c y lin d e r head, (fig , 12-32).
A D E 360 S e rie s
2. F it 1 7 - 1 7 ,5 m m s p a c e r fro m s p e c ia l to o l Part No.

40200556 o ve r valve g u id e , (fig. 12-33).
3. U sing m andrel o f sp e cia l to o l Part No. 40200556, press

valve gu id e in to cylin d e r head to the s p e cifie d in s ta lla
tio n h e ig h t, (fig . 12-34) i.e. u n til flu s h w ith spacer.
4. F in is h in n e r d ia m e te r o f va lve g u id e , u s in g s p e c ia l
rea m e r p a rt n u m b e r 40200828 (exh a u st), 40209591
(in le t), (fig . 12-35).
"A s.
/**/ <&> _/ ° f J L '» 1 ®) o

ffti if
Pig. 12-35
5. Using a sp ring te n sio n tester, ch e ck valve sp rin g s and

e n s u re th e y c o n fo rm to s p e c ific a tio n , (fig. 12-36). ■
A 0 E 360 S e rie s
CHECKING CYLINDER HEAD
1. U sing a s tra ig h t edge, ch e ck su rfa c e o f c y lin d e r head

fo r d is to rtio n a lo n g its le n g th , (fig. 12-37).
2. A nd a cro ss the c y lin d e r head (fig. 12-38). If th e cylin d e r

head is fo u n d to be d is to rte d , it m u s t be re fa ce d to
th e re q u ire d s u rfa c e s p e c ific a tio n and h e ig h t.
N o te : O b se rve fu e l in je c to r p ro tru s io n w h e n re fa c in g
c y lin d e r head. R e fe r to p ro c e d u re on page 12-19.
REPLACING VALVES
1. Insert valve stem o il seal item 3 (fig. 12-42) in to sp e cia l

to o l p a rt n u m b e r 40202253, (fig. 12-39).
2. Place o il seal o n to to p Of va lve g u id e and p re ss do w n

as fa r as p o s s ib le , (fig. 12-40).
ADE 360 S e rie s

3. L ib e ra lly o il va lve s te m s ite m 1 (fig. 12-42) and in se rt

v a lv e s in to c y lin d e r head. E n su re th a t th e va lve s are
in s e rte d in th e ir o rig in a l p o s itio n s , (fig . 12-41).
F ig . 12-41
4. F it valve sp ring se a tin g w a sh e r (2), valve s p rin g (4) and

va lve s p rin g ca p (5), (fig . 12-42).
5. A tta c h v a lv e s p rin g c o m p r e s s o r p a rt n u m b e r
40200679, to e x h a u s t m a n ifo ld s tu d , (fig . 12-43).
6. Press d o w n le ve r o f valve s p rin g c o m p re s s o r and in

s e rt va lve c o lle ts , ite m s 6, (fig . 12-42). R e le a se lever
a n d e n su re th a t th e c o lle ts are se a te d c o rre c tly . The
g a p b e tw e e n th e c o lle ts s h o u ld be id e n tic a l, (fig.
12-44).
F ig. 12-44
A D E 360 S e rie s
CYLINDER HEAD 12-18
INJECTOR PROTECTION SL EE V ES
W h e n o v e r h a u lin g th e c y lin d e r h e a d it is e s s e n tia l th a t all

th e in je c to r p ro te c tio n s le e v e s a r e r e m o v e d a n d e x a m in e d
fo r c o rro s io n .
R e m o v in g
1. U s in g s p e c ia l to o l p a r t n u m b e r 4 0 2 0 0 6 2 4 , u n s c r e w a n d
r e m o v e a ll in je c to r p ro te c tio n s le e v e s , (F ig . 1 2 -4 5 ) .
2. E x a m in e o u te r s u r f a c e o f p ro te c tio n s le e v e s fo r c o rro
s io n . B a d ly c o rr o d e d s le e v e s m u s t b e re p la c e d .
3. R em ove a ll in je c to r p ro te c tio n s le e v e O -r in g s e a ls fro m

th e c y lin d e r h e a d . D O N O T R E - U S E . (F ig . 1 2 - 4 6 ) .
R e p la c in g
1. A p p ly s ilic o n g r e a s e to n e w O -r in g s e a ls a n d in s e rt in to
c y lin d e r h e a d , (F ig . 1 2 - 4 7 ) .
F ig . 1 2 -4 7 ____________________________________________
2. L ig h tly c o a t b o tto m s u r f a c e o f p ro te c tio n s le e v e s w ith a
s ilic o n s e a lin g c o m p o u n d , (F ig . 1 2 - 4 8 ) .
April ‘96
CYLINDER HEAD 12-19
3. In s e r t s le e v e s a n d tig h te n to th e s p e c ifie d to rq u e , u s in g
s p e c ia l to o l p a rt n u m b e r 4 0 2 0 0 6 2 4 , (F ig . 1 2 -4 9 ) .
F ig . 1 2 - 4 9
C H E C K I N G F U E L I N J E C T O R P R O T R U S IO N
4. A tta c h a d ia l g a u g e w ith a m a g n e tic b a s e , to th e c y lin

d e r h e a d w ith th e p r o b e o f th e d ia l g a u g e re s tin g o n th e
tip o f th e in je c to r n o z z le .
A t t e n t i o n : N o t e r e a d in g o n d ia l g a u g e a n d c h e c k th e
re m a in d e r o f t h e in je c tio n n o z z le s in th is m a n n e r , e n
s u rin g t h a t m e a s u r e m e n t s c o rr e s p o n d w ith th e s p e c i
fic a tio n s . T h e d e p th o f th e in je c to rs c a n b e a lte r e d by
fittin g a th ic k e r o r th in n e r s e a lin g w a s h e r , (F ig . 1 2 -5 0 ) .
F ig . 1 2 - 5 0
R E P L A C IN G C Y L IN D E R H E A D
E n s u r e c y lin d e r h e a d a n d b lo c k fa c e s a r e c le a n .
1. U s in g c o m p r e s s e d a ir, b lo w o u t b o lt h o le s in to p o f c y
lin d e r b lo c k , (F ig . 1 2 - 5 1 ) .
F ig . 1 2 -5 1
2. P la c e n e w c y lin d e r h e a d g a s k e t in p o s itio n , (F ig . 1 2 - 5 2 )
i* Q O O C O O O O P o p e a O e
Fig. 12-52
April ‘96
CYLINDER HEAD 12-20
3. S c r e w liftin g h a n d le s , p a r t n u m b e r 4 0 2 0 0 7 4 7 , o n to c y
lin d e r h e a d , a n d lift in to p o s itio n , (F ig . 1 2 - 5 3 ) .
n e i r=|
■II » s
F ig . 1 2 - 5 3
4. U n s c re w and r e m o v e liftin g h a n d le s . L u b r ic a te th r e a d s
and g rip a re a o f th e c y lin d e r h e a d b o lts , (F ig . 1 2 -5 4 :
1 2 - 5 5 ) in s e r t b o lts a n d s c r e w d o w n . F ig . 1 2 - 5 4
F ig . 1 2 - 5 5
5. T ig h te n c y lin d e r h e a d b o lts in fo u r s ta g e s ( s e e s p e c ifi

c a tio n s ) by re fe r r in g to s e q u e n c e d ia g r a m b e lo w . (F ig .
1 2 -5 6 ).
0 ® ® ® ® © ® @ ® ® ® 0
® © ® ® ® ^
A D E 366
ADE 364
Fig. 12-56
April '96
CYLINDER HEAD 12-21
6. In s e r t p u s h ro d s , e n s u r in g th e y a r e p la c e d in th e ir o rig i
n a l p o s itio n s , (F ig . 1 2 - 5 7 ) .
F ig . 1 2 -5 7
7. R e p la c e r o c k e r s h a fts , in s e r t b o lts b u t D O N O T tig h te n ,

(F ig . 1 2 - 5 8 ) .
F ig . 1 2 - 5 8
8. U s in g s p e c ia l to o l p a r t n u m b e r 4 0 2 0 2 1 8 5 , in s e rt c o n
n e c tin g n ip p le b e tw e e n r o c k e r s h a fts , (F ig . 1 2 - 5 9 ) . Not
r e q u ire d o n A D E 3 6 4 .
lilie s
Fig . 1 2 - 5 9
9. T ig h te n r o c k e r s h a ft b o lts to th e s p e c ifie d to rq u e , (F ig .
1 2 -6 0 ).
if
frTl FT) fFH fFPi I P » »5

Fig. 12-60
April ‘96
CYLINDER HEAD 12-22
10. R e p la c e th e fu e l in je c to rs a n d tig h te n s e c u rin g n u ts to

th e s p e c ifie d to rq u e , u s in g s p e c ia l to o l p a rt n u m b e r
4 0 2 0 0 8 7 3 , (F ig . 1 2 - 6 1 ) .
11. R e -c o n n e c t upper and lo w e r in je c to r p ip e s a n d o u te r

c o n n e c tio n s . A tta c h fu e l le a k - o f f p ip e .
N o te : S e a l o u te r c o n n e c tio n s w ith h y lo m a r o r s u ita b le s e a la n t.

T ig h te n a ll c o n n e c tio n s to t h e s p e c ifie d to rq u e , u s in g s p e c ia l
to o l p a r t n u m b e r 4 0 2 0 0 7 1 8 , (F ig . 1 2 - 6 2 ) .
12. T ig h te n a ll fu e l le a k -o ff b o lts to th e s p e c ifie d to rq u e ,

(F ig . 1 2 - 6 3 ) .
13 . R e p la c e in le t m a n if o ld fitte d new g a s k e ts , a n d tig h te n

b o lts to t h e s p e c ifie d to r q u e , (F ig . 1 2 - 6 4 ) .
N o t e : In le t m a n ifo ld m u s t b e fitte d b e fo r e e x h a u s t m a n i- fo ld .
April ‘96
CYLINDER HEAD 12-23
1 4 . R e p la c e e x h a u s t m a n if o ld w ith n e w g a s k e t, a n d tu rb o
c h a rg e r if fitte d . T ig h te n a ll b o lts fr o m th e m id d le o u t
w a r d s , to th e s p e c ifie d to rq u e , (F ig . 1 2 - 6 5 ) .
1 5 . U s in g a n e w g a s k e t, a tta c h e x h a u s t d o w n p ip e to m a n i
fo ld , in s e r t b o lts a n d tig h te n to th e s p e c ifie d to rq u e .
1 6 . F it r a d ia to r h o s e s and tig h te n clip s, a tta c h d ip s tic k

g u id e tu b e .
17. R e p la c e fu e l filte rs , a n d if fitte d , p o w e r s te e rin g pum p.

R e -t e n s io n V -b e lt. (F ig . 1 2 - 6 6 ) .
VALVE CLEARANCE ADJUSTM ENT ADE 3 6 4
1. In s e r t fe e le r g a u g e b e tw e e n v a lv e s te m a n d r o c k e r a rm .
V a lv e c le a r a n c e is c o rr e c t w h e n th e fe e le r g a u g e s lid e s
th ro u g h w ith a s lig h t re s is ta n c e , (F ig . 1 2 - 6 7 ) .
2. If th e v a lv e c le a r a n c e r e q u ire s a d ju s tm e n t, r e le a s e th e
lo c k n u t, a d ju s t v a lv e c le a r a n c e a n d tig h te n th e lo c k n u t
w h ile h o ld in g th e a d ju s tin g s c re w .
D e sc r ip tio n ADE 3 6 4
ADE 366
E n g in e C ra n k sh a ft Intake v a lv e s E xh. v a lv e s
p o s itio n o f to b e a d ju ste d to b e a d ju ste d
c y lin d e r N o.1
364 N o .1 v a lv e ro c k in g 3 ,4 2 ,4
N o .1 v a lv e c lo s e d 1 ,2 1 ,3
April ‘96
CYLINDER HEAD 12-24
VALVE CLEARANCE A DJU STM EN T ADE 3 6 6
1. In s e r t fe e le r g a u g e b e tw e e n v a lv e s te m a n d r o c k e r a rm .
V a lv e c le a r a n c e is c o rr e c t w h e n th e fe e le r g a u g e s lid e s
th ro u g h w ith a s lig h t re s is ta n c e .
2. If th e v a lv e c le a r a n c e r e q u ire s a d ju s tm e n t, r e le a s e lo c k
nut an d a d ju s t th e v a lv e c le a r a n c e . T ig h te n lo c k nu t
w h ile h o ld in g th e a d ju s tin g s c re w , (F ig . 1 2 - 6 9 ) .
D e sc r ip tio n ADE 3 6 4
ADE 3 6 6
E n g in e C ra n k sh a ft In tak e v a lv e s E xh. v a lv e s
p o s itio n o f to b e a d ju s te d to b e a d ju ste d
c y lin d e r N o.1
366 N o . 1 v a lv e ro c k in g 3 ,5 ,6 2 ,4 ,6
N o . 1 v a lv e c lo s e d 1 ,2 ,4 1 ,3 ,5
REPLACING ROCKER COVER
1. C h e c k s u r f a c e o f r o c k e r c o v e r fo r d a m a g e , (F ig . 1 2 -7 1 ) .
2. F it n e w r o c k e r c o v e r g a s k e t to c y lin d e r h e a d , (F ig
1 2 -7 2 ) .
Fig. 12-72
April ‘96
CYLINDER HEAD 12-25
3. P la c e r o c k e r c o v e r in p o s itio n , in s e rt b o lts a n d tig h te n

to th e s p e c ifie d to r q u e , (F ig . 1 2 - 7 3 ) .
4. R e p la c e t h e r m o s ta t h o u s in g a n d tig h te n b o lts to th e
5. F ill r a d ia to r w ith c o o la n t, s ta rt e n g in e a n d run to o p e r a -
F ig . 1 2 - 7 3
CHECKING C O M PRESSIO N
1. R e m o v e r o c k e r c o v e r.
2. C h e c k v a lv e c le a r a n c e , ( s e e p a g e 1 2 -2 3 ) .
3. R e p la c e r o c k e r c o v e r.
4. Run e n g in e u n til o p e r a tin g te m p e r a tu r e is re a ch ed

(7 0 -9 5 ).
5. E n s u r e t h a t th e b a tte r y is in a g o o d c o n d itio n .
6. R e m o v e r o c k e r c o v e r, in je c to rs a n d s e a lin g w a s h e r s .
7. S e t in je c tio n p u m p c o n tro l to s to p p o s itio n .

F ig . 1 2 - 7 4
T e stin g
1. In s e r t in je c to r s e a lin g w a s h e r , (F ig . 1 2 - 7 4 ) .
2. In s e r t a d a p t o r fo r t h e c o m p re s s io n te s te r (p a r t n u m b e r
4 0 2 0 0 7 8 9 ) in t h e c y lin d e r h e a d a n d tig h te n w ith in je c to r
s e c u r in g n u t, (F ig . 1 2 - 7 5 ) .
Fig . 1 2 - 7 5
3. A tta c h c o m p r e s s io n te s te r e x te n s io n to a d a p to r , (F ig .
1 2 -7 6 ).
4. C h e c k c o m p r e s s io n a t a n e n g in e s p e e d o f a p p r o x im a
te ly 1 8 0 - 2 0 0 r /m in (s ta r te r s p e e d ) w ith th e th ro ttle in th e
c lo s e d p o s itio n . T u r n th e e n g in e u n til th e te s t in d ic a to r
s to p s ris in g . R e p e a t th is p r o c e d u re fo r a ll c y lin d e rs .
5. R e m o v e c o m p r e s s io n te s te r a n d a d a p te r .
6. R e p la c e s e a lin g w a s h e rs , in je c to rs a n d le a k o ff p ip es ,
tig h te n to th e s p e c ifie d to rq u e .
Fig. 12-76
April '96
CYLINDER HEAD 12-26
7. R e p la c e r o c k e r c o v e r a n d tig h te n b o lts to th e s p e c ifie d

to rq u e , (F ig . 1 2 - 7 7 ) .
April ‘96
SPECIAL TOOLS FOR THIS SECTION

OBTAINABLE FROM: GRUNDY-TECHNIFORM, BURMAN ROAD, DEAL PARTY ESTATE PORT
ELIZABETH 6001 '
S p lit rin g sp a n n e r fo r
in je c to r pipes,
(see fig . 12-7)
P art N u m b e r 40200705
S o c k e t fo r in je c to r se c u rin g
n u ts
(see fig . 12-11, 1 2 -6 1 )
P a rt N u m b e r 40200873
F ue l in je c to r
Im p a c t e x tra c to r
(see fig . 12-12)
P a rt N u m b e r 40201076
E x tra c to r fo r in je c to rs
(see fig . 12-13)
P a rt N u m b e r 40201063
,c L iftin g h a n d le s c y lin d e r head

(see fig . 12-17, 12-53)
P a rt N u m b e r 40200747
V A LV E DEPTH G AUG E
(see fig . 12-19)
P a rt N u m b e r 40201351
AD E 360 S eries
en
V alve s p rin g c o m p re s s o r
(see fig . 12-43)
Part N u m b e r 40200679
40200682
R e a m e r fo r valve g u id e
p a re n t b o re in cyl./h e a d
13,5 x 15,5 m m
(see fig . 12-31)
P art N u m b e r 40200750
oT^
V a lve g u id e re p la c e m e n t
m a n d re l
(see fig . 12-33, 12-34)
P a rt N u m b e r 40200556
R e a m e r fo r e x h a u s t valve g u id e s
(see fig . 12-35)
P a rt N u m b e r 40200828
R e a m e r fo r in le t valve g u id e s
(see fig . 12-35)
P art N u m b e r 40209591
V a lve ste m seal

re p la c in g to o l
(see fig . 12-40)
P a rt N u m b e r 40202253
R e m o v in g /R e p la c in g to o l for
in je c to r p ro te c tio n sle e ve s
(see fig . 12-45, 12-49)
P art N u m b e r 40200624
P lie rs ro c k e r s h a ft
c o u p lin g bush
(see fig . 12-59)
P a rt N u m b e r 40202185
A D E 366N/C/T/TI o n ly
ADE 360 S e rie s

C r o w f o o t r in g s c a n n e r R e m o v e '
R e p la c e m e n t o f m ie c to r pipes
(s e e fi g 12-62)
P a rt N u m b e r 4 0 2007 18
A d a p to r fo r c o m p re s s io n
te ste r.
(see fig . 12-75)
P a r t N u m b e r 40 20 0 7 8 9
Attention!
A s w e re c o m m e n d th a t th e re m o va l and re p la c e m e n t o f va lve s e a ts s h o u ld o n ly be c a rrie d o u t by an ADE A p p ro v e d e n g in e
re b u ild e r, th e use o f th e s e th re e s p e c ia l to o ls is n o t illu s tra te d in th e te x t. T he se s p e c ia l to o ls are h o w e ve r o b ta in a b le
fro m G ru n d y -T e c h n ifo rm .
ADE 360 Series

_____________ SECTION 13
Piston and Connecting Rods
CONTENTS OF SECTION 13
Page
I L L U S T R A T I O N .................................................................................................................................................................................................................................... 1 3 -2
I N T R O D U C T I O N ................................................................................................................................................................................................................................. 1 3 -3
S P E C I F I C A T I O N S .............................................................................................................................................................................................................................. 1 3 -3
R E M O V I N G P I S T O N S A N D C O N N E C T I N G R O D S ...................................................................................................................................................... 1 3 -5
R E M O V I N G P I S T O N R I N G S ....................................................................................................................................................................................................... 1 3 -6
C H E C K IN G B I G - E N D B E A R I N G S ............................................................................................................................................................................................ 1 3 -7
C H E C K I N G P I S T O N S A N D P IS T O N R I N G S .................................................................................................................................................................... 1 3 -1 1
R E P L A C I N G P I S T O N S A N D C O N N E C T I N G R O D S .................................................................................................................................................... 1 3 -1 3
S P E C IA L T O O L S ................................................................................................................................................................................ '...................... 1 3 -1 6
A p ril '9 6
Piston and Connecting Rods 13-2
1. S M A L L E N D B U S H 6 . C O M P R E S S I O N R IN G
2. C O N N E C T IN G R O D 7. C O M P R E S S I O N R IN G
3. C O N N E C T I N G R O D B O L T S 8. O IL S C R A P E R R IN G
4 . B E A R IN G S H E L L S 9. P IS T O N
5 . C IR C L IP S 10. G U D G E O N P IN
April '96
PISTONS AND CONNECTING RODS 13-3
INTRODUCTION
T h e lig h t a llo y p is to n s u s e d h a v e th e c o m b u s tio n c h a m b e r c a s t in th e p is to n c ro w n . T w o c o m p r e s s io n a n d o n e oil c o n tro l

rin g a r e fitte d to th e p is to n s w ith th e to p c o m p re s s io n rin g r e ta in e d in a n A l-fin b o n d e d in s e rt. G u d g e o n p in s a r e tu b u la r to
r e d u c e w e ig h t a n d a r e lo c a te d in th e p is to n s b y c irc lip s . C o o lin g n o z z le s a r e fitte d to a s s is t w ith p is to n c o o lin g o f tu r b o
c h a r g e d e n g in e s .
F o rg e d s te e l c o n n e c tin g ro d s a r e u s e d w ith s e rr a te d m a tin g s u rfa c e s b e tw e e n th e c o n n e c tin g ro d a n d th e c a p to p ro v id e

in c re a s e d r ig id ity a n d to e x te n d b e a r in g life. T h e b ig -e n d b e a r in g s h e lls a r e s te e l b a c k e d a n d lin e d w ith a lu m in iu m /tin . T h e
s m a ll- e n d b u s h is m a n u fa c tu r e d fr o m a h ig h q u a lity p h o s p h o r b r o n z e a n d s e a ts in a n in te r fe r e n c e fit in th e c o n n e c tin g rod
W it h t h e c y lin d e r h e a d a n d s u m p r e m o v e d , th e p is to n s c a n e a s ily b e w ith d r a w n fr o m th e to p o f th e c y lin d e r b lo ck .
PIST O N S AND CONNECTING R ODS
R ep air s t a g e s N o m in a l P isto n C o m p r e s s io n h e ig h t ** B lo c k h e ig h t
d ia m e te r
S ta n d a r d N /C / T / T I 9 7 ,5 6 2 , 8 0 to 6 2 ,8 6 3 5 8 , 8 2 to 3 5 9 , 0 7 ( S T D )
R e p 1 N + 0 ,5 R e b o r e * 9 8 ,0 0 6 2 , 5 0 to 6 2 ,5 6 3 5 8 , 5 2 to 3 5 8 , 7 7 ( - 0 , 3 )
R e p 1 n / c /t / t i 9 7 ,5
R e p s t a g e 2 N /C /T / T I 9 7 ,5 6 2 , 2 0 to 6 2 ,2 6 3 5 8 , 2 2 to 3 5 8 , 4 7 ( - 0 , 6 )
R e p s t a g e 3 N /C / T / T I 9 7 ,5 6 1 , 9 0 to 6 1 ,9 6 3 5 7 , 9 2 to 3 5 8 , 1 7 ( - 0 ,9 )
*
1 s t r e p a ir s t a g e fo r n a tu r a lly a s p ir a te d o p tio n a l, i.e . e ith e r re b o re fo r o v e r s iz e p is to n o r fit s le e v e .
■ m e a s u r e m e n t fr o m g u d g e o n p in c e n tr e to p is to n to p .
M a x w e ig h t v a r ia tio n b e tw e e n p is to n s 20g
G u d g e o n pin d ia m e t e r 3 5 , 9 9 5 to 3 6 ,0 0 0
G u d g e o n p in b o re d ia m e t e r 3 6 , 0 0 2 to 3 6 ,0 0 7
G u d g e o n pin to p is to n b o re c le a r a n c e 0 , 0 0 2 to 0 , 0 1 2
P is to n p ro tru s io n a t T D C to b lo c k s u r fa c e 0 ,1 7 0 to 0 ,5 8 0
N ote: T h e c o d e s B A 0 9 o r B C 0 1 a p p e a r on th e p is to n c ro w n s . T h e s e a r e g r a d in g c o d e s fo r p r o d u c tio n o n ly .
PISTON RINGS
360N/C/T/TI T yp e S id e C le a r a n c e G ap
1 K e y s to n e 0 ,0 4 2 to 0 ,0 9 7 0 ,2 0 to 0 ,3 5
2 T a p e r e d f a c e c o m p re s s io n 0 ,0 6 0 to 0 ,0 9 5 0 ,2 0 to 0 ,3 5
3 O il c o n tro l (s p r in g e x p a n d e r ) 0 , 0 3 0 to 0 ,0 6 5 0 ,2 5 to 0 ,4 0
A tte n tio n : G a p a n d s id e c le a r a n c e a r e e q u a l to a b o v e in a ll b o re r e p a ir s ta g e s .
April '96
C O N N E C T IN G R O D
R e p a ir s iz e C o n n e c t i n g r o d b e a r in g d i a m e t e r C o n n e c tin g ro d w id th
. in s t a l l e d B ig e n d S m a ll e n d
S ta n d a r d 6 0 , 0 5 6 to 6 0 , 0 9 5
S ta n d a r d 1 ( - 0 , 1 ) 5 9 ,9 5 6 to 5 9 ,9 9 5
S ta n d a r d 2 ( - 0 , 2 5 ) 5 9 ,8 0 6 to 5 9 ,8 4 5 3 7 ,7 3 0 to 3 7 ,8 3 0 3 5 ,5 to 3 5 ,6
R e p 1 (-0 ,5 ) 5 9 ,5 5 6 to 5 9 ,5 9 5
R e p 2 (-0 ,7 5 ) 5 9 , 3 0 6 to 5 9 ,3 4 5
R ep 3 (-1 ,0 ) 5 9 , 0 5 6 to 5 9 ,0 9 5
C o n n e c tin g ro d big e n d b a s ic b o re 6 5 , 0 0 0 to 6 5 , 0 1 9
T a p e r o f big e n d b a s ic b o re 0 ,0 0 5
B ig e n d b e a r in g c le a r a n c e ra d ia l 0 ,0 4 1 to 0 , 1 0 0
a x ia l 0 ,1 0 to 0 ,4 0
L e n g th o f c o n n e c tin g ro d b e tw e e n c e n tr e s o f big e n d a n d s m a ll en d 2 3 0 , 0 0 to 2 3 0 , 0 5
W e ig h t v a r ia tio n b e tw e e n c o n n e c tin g ro d s fo r r e p a ir 40g
M a x . p a r a lle l d e v ia tio n b e tw e e n c e n tr e lin e o f b ig e n d a n d s m a ll e n d 0 ,0 1 0
B ig e n d b e a r in g c ru s h 0 ,0 4 to 0 ,0 7
SM ALL END
S m a ll e n d b a s ic b o re in c o n n e c tin g ro d s ta n d a r d 3 9 ,0 0 0 to 3 9 ,0 2 5
R e p 1 (1 -0 ,2 )_____________________________ 3 9 , 2 0 0 to 3 9 ,2 2 5
R e p 2 (+ 0 ,5 ) 3 9 , 5 0 0 to 3 9 , 5 2 5
S m a ll e n d b u s h In n e r d ia m e te r in s ta lle d _________________ 3 6 , 0 3 0 to 3 6 ,0 4 0
T a p e r /o v a lit y to le r a n c e _________________ 0 ,0 0 2 _____________
In te r fe r e n c e fit___________________________0 , 0 2 0 to 0 ,0 7 5
C le a r a n c e to g u d g e o n pin 0 , 0 3 0 to 0 , 0 4 5
T O R Q U E S P E C IF IC A T IO N S
C o n n e c tin g ro d b o lt s ..............................................................................................................1 s t s t a g e ..........................................4 0 - 5 0 N m

........................................................................................................................................................... F in a l.................................................... + 9 0 ° - 1 0 0 °
........................................................................................................................................................... S tr e tc h lim it.................................... 5 6 ,8 m m ( M 1 2 )
P is to n c o o lin g n o z z le s - u p to e n g in e no . S A 0 7 0 9 0 0 V .................................. M 1 0 x 1 .............................................2 5 N m
fr o m .e n g in e no. S A 0 7 0 9 0 1 V .................................. M 1 0 x 1 .............................................1 5 - 1 8 N m
April '96
R EM O V IN G PISTONS AND C O N NECTING RODS
(C y lin d e r h e a d a n d s u m p r e m o v a l)
R e m o v in g
1. U s in g a s u ita b le s c ra p e r , r e m o v e c a rb o n d e p o s its fro m

to p o f c y lin d e r b o re s , (F ig . 1 3 -1 ).
F ig . 1 3 -1
2. U n s c re w r e ta in in g b o lts and re m o v e p is to n c o o lin g

n o z z le s , 3 6 0 C / T / T I , (F ig . 1 3 -2 ).
3 6 0 N e n g in e s h a v e c lo s in g p lu g s in p la c e o f n o z z le s .
3. U n s c re w c o n n e c tin g ro d b o lts and re m o v e b e a rin g

c a p s , (F ig . 1 3 -3 ).
A tte n tio n ! B e a r in g c a p s a n d c o n n e c tin g ro d s a r e m a r k e d a s

m a tc h e d p a irs (n o te n u m b e r s b e fo r e a s s e m b ly ).
4. R e m o v e p is to n s a n d c o n n e c tin g ro d s fr o m to p o f c y lin
d e r b lo c k , (F ig . 1 3 - 4 ) .
Fig. 13-4
5. R em ove b e a r in g s h e lls fr o m c a p a n d c o n n e c tin g ro d s ,

if th e o ld b e a r in g s h e lls a r e to b e u s e d a g a in , m a rk
s h e lls to en s u re r e p la c e m e n t in th e o r ig in a l p o s itio n ,
(F ig . 1 3 -5 ).
R em o v a l o f P is to n R in g s /P is to n fro m C o n n e c tin g R o d s.
1. C la m p c o n n e c tin g ro d a n d p is to n a s s e m b ly in a v ic e ,
fitte d w ith p r o te c tiv e ja w s , (F ig . 1 3 -6 ).
F ig . 1 3 -6
2. T u rn a d ju s tin g s c re w o f rin g e x p a n d e r , p a rt n u m b e r
4 0 2 0 0 3 0 7 , to a p p r o x . 9 8 m m , (F ig . 1 3 -7 ).
3. R e m o v e p is to n rin g s a t th is s e ttin g , (F ig . 1 3 - 8 ) .
Fig. 13-8
April '96
4. R em ove c irc lip s fr o m p is to n , push o u t g u d g e o n pin

a n d r e m o v e p is to n fr o m c o n n e c tin g ro d , (F ig . 1 3 -9 ).
F ig . 1 3 -9
C h e c k in g B ig E nd B e a r in g s
1. C le a n c o n n e c tin g ro d a n d b e a r in g c a p s u rfa c e , (F ig .
1 3 -1 0 ).
F ig . 1 3 - 1 0
2. F it big end b e a r in g c a p and in s e rt b o lts , (c a p and

c o n n e c tin g ro d n u m b e r s a lig n e d ), (F ig . 1 3 - 1 1 ) .
F ig . 1 3 -1 1
3. T ig h t e n c o n n e c tin g ro d b o lts to th e s p e c ifie d to rq u e ,

(F ig . 1 3 - 1 2 ) .
III: A » i
Fig. 13-12
April '96
4. U s in g a n in te r n a l m e a s u r in g in s tr u m e n t c h e c k big e n d
p a re n t b o re in th r e e p la c e s , ( F i g . 1 3 - 1 3 ) .
F ig .1 3 - 1 3
5. U s in g an in te r n a l m e a s u r in g in s tr u m e n t c h e c k b o re o f
th e s m a ll e n d b u s h , (F ig . 1 3 - 1 4 ) .
A tte n tio n ! If th e s m a ll e n d bush in n e r d ia m e te r d o e s not

m e e t th e s p e c ific a tio n , th e bush m u s t b e p re s s e d ou t and
r e p la c e d . W it h th e s m a ll e n d b u s h r e m o v e d , c h e c k th e p a re n t
b o re and, if n e c e s s a r y , m a c h in e to th e 1st r e p a ir s ta g e .
S ta n d a r d and o v e r s iz e o u ts id e d ia m e te r s m a ll end bushes
h a v e a n u n fin is h e d in n e r d ia m e t e r w h ic h m u s t b e r e a m e d to
th e s p e c ifie d s iz e a f te r in s ta lla tio n . W h e n fittin g a n e w s m a ll
e n d b u s h to th e c o n r o d , a lu b r ic a tin g h o le m u s t b e d rille d a fte r
th e b u s h is fitte d . R e a m in g o f th e b u s h c a n n o w b e c a rrie d
out.
■nu ra=
F ig . 1 3 - 1 4
6. M o u n t th e c o n n e c tin g ro d in a n a lig n m e n t g a u g e a n d
c h e c k fo r b e n d in g , (F ig . 1 3 - 1 5 ) .
7. C h e c k fo r tw is tin g , (F ig . 1 3 - 1 6 ) .
W A R N IN G ! U n d e r n o c ir c u m s ta n c e s s h o u ld a n y a t te m p t b e
m a d e to s t ra ig h te n a b e n t c o n n e c tin g ro d . C o n n e c tin g ro d s
th a t do not c o n fo r m to s p e c ific a tio n s m ust a lw a y s be
re p la c e d .
Fig. 13-16
8. U n s c re w c o n n e c tin g ro d b o lts and re m o v e b e a rin g

c a p s , (F ig .1 3 -1 7 ).
9. F it b e a r in g s h e lls in to c o n n e c tin g ro d a n d b e a r in g c a p .
E n s u r e t h a t th e lo c a tin g ta b s a r e fitte d c o rre c tly , (F ig .
1 3 -1 8 ).
10 . F it b e a r in g c a p to th e c o n n e c tin g ro d , (n u m b e r s o n th e
b e a r in g c a p a n d c o n n e c tin g ro d a lig n e d ). C la m p c o n
n e c tin g ro d in a v ic e fitte d w ith p r o te c tiv e ja w s , (F ig .
1 3 -1 9 ).
11. In s e r t b o lts and tig h te n to th e s p e c ifie d to rq u e , (F ig .

1 3 -2 0 ).
Fig. 13-20
April '96
12. U s in g a n in te r n a l m e a s u r in g in s tr u m e n t c h e c k big en d
b e a r in g b o re in th r e e p la c e s , (F ig , 1 3 -2 1 ) .
C h e c k in g th e B ea r in g C ru sh
13. M o u n t th e c o n n e c tin g ro d in a v ic e fitte d w ith s o ft ja w s .

F it th e b e a r in g s h e lls in to b e a r in g c a p a n d c o n n e c tin g
rod. In s e r t b o lts and tig h te n to th e s p e c ifie d to rq u e .
A tta c h a d ia l g a u g e w ith a m a g n e tic b a s e to th e v ic e ,
w ith th e p r o b e r e s tin g o n t h e u n d e rs id e o f th e b e a rin g
cap, a n d s e t th e g a u g e to “0". L o o s e n th e big e n d b o lt
n e a r e s t to th e d ia l g a u g e , n o te th e r e a d in g o n th e g a u
ge. The fig u r e w ill r e p r e s e n t th e b e a r in g c ru s h a n d
s h o u ld be c o m p a re d w ith th e s p e c ific a tio n ,
(F ig . 1 3 - 2 2 ) .
14. U n s c re w th e c o n n e c tin g ro d b o lts a n d u s in g a v e r n ie r

g a u g e , c h e c k b o lts fo r s tre tc h , r e fe r to s p e c ific a tio n s ,
(F ig . 1 3 - 2 3 ) .
15. C o n n e c tin g ro d s a n d b e a r in g s h e lls s h o u ld b e m a rk e d

to e n s u re r e p la c e m e n t in th e o rig in a l p o s itio n , (F ig ,
1 3 - 2 4 ) . c h e c k r e m a in d e r o f c o n n e c tin g ro d s a s a b o v e .
Fig. 13-24
April '96
C HECKING PISTONS AND PISTON RINGS
B e fo r e c h e c k in g p is to n s , p is to n rin g s and gudgeon p in s,

e n s u r e t h a t th e p is to n a n d p is to n rin g g r o o v e s a r e c le a n a n d
fr e e o f c a rb o n d e p o s its . C a r e s h o u ld b e ta k e n to e n s u r e th a t
th e p is to n rin g g r o o v e s a r e n o t d a m a g e d d u rin g c le a n in g .
A tte n tio n ! In a ll c a s e s p is to n s a n d th e ir a s s o c ia te d g u d g e o n
p in s a r e c o n s id e r e d to b e m a tc h e d p a irs . W h e n d is m a n tlin g ,
th e s e ite m s m u s t b e m a rk e d , s o th a t d u rin g a s s e m b ly th e
m a r k in g s c o rr e s p o n d , and th e p a rts a re r e tu rn e d to th e ir
o rig in a l p o s itio n .
1. P is to n s and rin g s s h o u ld b e r e m o v e d a s d e ta ile d on

p a g e 1 3 -8 .
2. W h e n c le a n , c h e c k p is to n s c a r e fu lly b e fo r e r e -u s e .
3. U s in g an in te r n a l m e a s u r in g in s tr u m e n t, check th e
gudgeon pin b o re in th e p is to n , (F ig . 1 3 - 2 5 ) a n d
4. U s in g a m ic r o m e te r , c h e c k th e o u te r d ia m e te r o f th e
gudgeon p in , (F ig . 1 3 - 2 6 ) .
5. In s e r t a p is to n rin g in to t h e c y lin d e r b o re a n d u s in g a
p is to n , push th e rin g s q u a r e ly d o w n in to th e c y lin d e r
b o re to a d e p th o f a p p r o x im a t e ly 3 0 m m fr o m th e to p ,
(F ig . 1 3 - 2 7
April ‘96
6 M e a s u r e th e e n d g a p o f t h e p is to n rin g a n d r e p e a t th is
p r o c e d u r e w ith th e r e m a in in g rin g s . R in g g a p s m u s t b e
w ith in th e s p e c ifie d lim its , (F ig . 1 3 - 2 8 ) .
N o te : W it h th e p is to n s r e m o v e d a c a re fu l e x a m in a tio n s h o u ld
b e m a d e o f th e c y lin d e r b o re fo r w e a r a n d lo c a lis e d s e iz u re .
7. R e -f it p is to n s to c o n n e c tin g ro d s , c le a n c a rb o n a n d oil
d e p o s its fr o m p is to n rin g g ro o v e s . E n s u r e th a t th e
g r o o v e s a r e n o t d a m a g e d , (F ig . 1 3 - 2 9 ) .
F ig . 1 3 - 2 9
8. R e p la c e a ll p is to n rin g s u s in g rin g e x p a n d e r , p a rt n u m
b e r 4 0 2 0 0 3 0 7 , (F ig . 1 3 - 3 0 ) .
9. C h e c k c le a r a n c e o f p is to n rin g s in th e g r o o v e s , r e p la c e
p is to n a n d /o r rin g s t h a t d o n o t c o n fo rm to s p e c ific a
tio n s , (F ig . 1 3 - 3 1 ) .
April '96
R E P L A C I N G P I S T O N S , P I S T O N R IN G S A N D C O N N E C T IN G
RODS
1. C la m p c o n n e c tin g rod in a v ic e fitte d w ith p ro te c tiv e

ja w s , w ith t h e e lo n g a te d s id e to th e rig h t (in je c tio n
pum p s id e ) as in d ic a te d b y a r ro w s . P la c e p is to n on
c o n n e c tin g ro d , w ith th e a rro w on th e p is to n c ro w n
fa c in g fo r w a r d a s in d ic a te d , (F ig . 1 3 -3 2 ) .
F ig . 1 3 - 3 2
2. In s e r t g u d g e o n p in and s e c u r e w ith c irc lip s , (F ig .

1 3 -3 3 ).
m u /©=
F ig . 1 3 - 3 3
3. R e p la c e p is to n rin g s , u s in g rin g e x p a n d e r p a rt n u m b e r
40 20 0307, s ta g g e r p is to n rin g s , w h ic h m u s t ro ta te
fr e e ly in th e g ro o v e , 180° e a c h s id e o f th e g u d g e o n
pin, (F ig . 1 3 - 3 4 ) .
F ig . 1 3 - 3 4
4. L u b r ic a te p is to n rin g s w ith e n g in e oil, (F ig . 1 3 -3 5 ) .
mu *e=
Fig. 13-35 ._____________________________________
April ‘96
5. P o s itio n rin g s q u e e z e r o v e r p is to n rin g s a n d c o m p re s s

so t h a t th e s le e v e w ill ju s t m o v e (F ig . 1 3 - 3 6 ) .
6. L u b r ic a te b ig e n d b e a r in g s a n d c r a n k s h a ft jo u r n a l w ith
e n g in e oil, (F ig . 1 3 - 3 7 ) .
7. In s e r t c o n n e c tin g ro d and p is to n in to c y lin d e r b o re ,

w ith a r r o w on p is to n c ro w n p o in tin g to w a r d s th e fro n t
o f th e e n g in e , (F ig . 1 3 - 3 8 ) .
8. P u s h p is to n d o w n in to c y lin d e r b o re a n d g u id e th e c o n
n e c tin g ro d u n til th e b ig end b e a r in g c o n ta c ts th e
c r a n k s h a ft jo u r n a l, (F ig . 1 3 - 3 9 ) .
Fig. 13-39
9 L u b r ic a te b ig end b e a r in g cap w ith e n g in e oil, (F ig .

1 3 -4 0 ).
10. F it m a tc h e d b ig e n d b e a r in g c a p to c o n n e c tin g rod a n d

in s e r t b o lts (F ig . 1 3 - 4 1 ) .
11. T ig h te n big e n d b e a r in g b o lts to th e s p e c ifie d to rq u e ,

(F ig . 1 3 - 4 2 ) .
Fig . 1 3 -4 2
12. In s e r t p is to n c o o lin g n o z z le s e n s u rin g th a t lo c a tin g pin

on n o z z le body a lig n s w ith d rillin g in oil g a lle ry , (A D E
3 6 0 C / T / T I o n ly ), (F ig . 1 3 - 4 3 ) , in s e r t b o lts a n d tig h te n
to s p e c ifie d to rq u e . (In 3 6 0 N e n g in e s fit p lu g s a n d to r
q u e to s p e c ific a tio n ).
April '96
SPECIAL TO O LS FOR SECTION 13
O B T A IN A B L E F R O M G R U N D Y T E C H N I F O R M , B U R M A N R O A D , D E A L P A R T Y E S T A T E , P O R T E L IZ A B E T H 6 0 0 1
April '96
_________SECTION 14
Crankshaft and Main Bearings
Page
I L L U S T R A T I O N ..................................................................................................................................................................................; ................................................ 1 4 -2
I N T R O D U C T I O N ................................................................................................................................................................................................................................. 1 4 -3
S P E C I F I C A T I O N S .............................................................................................................................................................................................................................. 1 4 -3
R E M O V I N G V IB R A T IO N D A M P E R ......................................................................................................................................................................................... 1 4 -5
R E P L A C I N G V IB R A T IO N D A M P E R ........................................................................................................................................................................................ 1 4 -5
R E M O V A L O F C R A N K S H A F T .................................................................................................................................................................................................... 1 4 -6
G R I N D I N G C R A N K S H A F T ........................................................................................................................................................................................................... 1 4 -8
C H E C K I N G B E A R IN G A N D P A R E N T B O R E S ................................................................................................................................................................1 4 - 1 0
C H E C K I N G B E A R IN G S A N D H O U S I N G ............................................................................................................................................................................. 1 4 -1 0
R E P L A C I N G R E A R M A IN B E A R IN G O IL S E A L .............................................................................................................................................................1 4 -1 3
R E P L A C I N G C R A N K S H A F T ........................................................................................................................................................................................................1 4 -1 6
S P E C IA L T O O L S F O R S E C T I O N 1 4 .................................................................................................................................................................................... 1 4 -1 9
A p ril '9 6
Crankshaft and Main Bearings 14-2
15
CRANKSHAFT A SSEM BLY

9 CRANKSHAFT GEAR
1 B E A R IN G R E T A IN E R 10 S P A C E R
2 S P I G O T B E A R IN G 11 V IB R A T IO N D A M P E R
3 BO LT 1 2 C E N T E R I N G R IN G
4 FLYW HEEL 13 P U L L E Y
5 BO LT 14 B O L T
6 B A L A N C E W E IG H T 1 5 C R A N K S H A F T M A IN B E A R IN G S
7 CRANKSHAFT
8 W O O D R U FF KEY
April ‘96
INTRODUCTION
T h e c r a n k s h a ft is p r e c is io n fo rg e d , in d u c tio n h a rd e n e d a n d s u p p o rte d by s e v e n th r e e - la y e r b e a r in g s h e lls o n A D E 3 6 0

a n d fiv e o n A D E 3 6 4 . A th ru s t b e a r in g is fitte d to th e n u m b e r 4 m a in b e a rin g . S e p a r a t e a n d d e ta c h a b le b a la n c e w e ig h ts
a r e b o lte d to th e c r a n k s h a ft.
SPECIFICATIONS
CRANKSHAFT
R ep air s i z e Main b ea rin g W idth for C on rod b e a rin g W idth Dia for rear
(d ia m e te r ) jo u r n a l d ia. th r u st b ea rin g jo u rn a l d ia m e te r ro p e s e a l
S ta n d a r d 8 7 ,9 9 to 8 8 ,0 1 3 2 ,0 0 0 to 5 9 ,9 9 5 to 6 0 , 0 1 5 9 0 ,8 7 4
S ta n d a r d 1 ( - 0 , 1 ) 8 7 ,8 9 to 8 7 ,9 1 3 2 ,0 6 2 5 9 ,8 9 5 to 5 9 ,9 1 5 3 7 ,9 3 to
S ta n d a r d 2 ( - 0 , 2 5 ) 8 7 ,7 4 to 8 7 ,7 6 3 2 ,3 0 0 to 3 2 ,3 6 2 5 9 ,7 4 5 to 5 9 ,7 6 5 to 9 0 ,9 2 8
R e p a ir 1 ( - 0 , 5 ) 8 7 , 4 9 to 8 7 ,5 1 ( + 0 ,3 ) or 5 9 ,4 9 5 to 5 9 ,5 1 5 3 8 ,1 3 9 0 , 5 5 4 to 9 0 ,5 0 8
R e p a ir 2 ( - 0 , 7 5 ) 8 7 ,2 4 to 8 7 ,2 6 3 2 ,5 0 0 to 3 2 ,5 6 2 5 9 ,2 4 5 to 5 9 ,2 6 5 9 0 , 2 3 4 to 9 0 ,2 8 8
R e p a ir 3 ( - 1 , 0 ) 8 6 ,9 9 to 8 7 ,0 1 ( + 0 ,5 ) 5 8 ,9 9 5 to 5 9 ,0 1 5
M a in a n d big e n d jo u r n a l h a rd n e s s HRC 56 ± 3
M in jo u r n a l h a r d n e s s o n a t le a s t 2 /3 o f c ir c u m fe r e n c e HRC 46
(fo r r e p a ir o n ly )
M a x . m a in a n d big e n d jo u r n a l ta p e r 0 ,0 0 5
M a x . m a in a n d big e n d jo u r n a l o v a lity 0 ,0 1
M a x . c r a n k s h a ft ru n o u t w ith c r a n k s h a ft tu rn in g 4 c y lin d e r jo u r n a l 3 0 ,1 1
on o u te r jo u r n a ls 6 c y lin d e r jo u r n a l 4 0 ,1 5
P a r a lle lis m o f big e n d jo u r n a ls to m a in jo u r n a ls 0 ,0 1
L a te r a l ru n o u t a t th r u s t fa c e s 0 ,0 2
M a x ru n o u t o f fly w h e e l fla n g e w ith c r a n k s h a ft tu rn in g on L a te r a l 0 ,0 3

o u te r jo u r n a ls R a d ia l 0 ,0 3
R a d ii o n th ru s t b e a r in g jo u r n a l m in im u m 3 ,7 5
E n d flo a t (th r u s t b e a r in g ) 0 ,1 9 0 -0 ,2 9 0
M a in b e a r in g c le a r a n c e R a d ia l (th r u s t b e a r in g ) 0 ,0 5 0 - 0 , 1 0 8
R a d ia l (o th e r m a in s ) 0 ,0 4 2 - 0 , 1 0 8
T o r q u e to tu rn c r a n k s h a ft w ith n e w s e a ls a n d b e a r in g s fitte d 12 N m
R e a r c r a n k s h a ft s e a l (r p p e ty p e ) p ro tru s io n a fte r in s ta lla tio n 0 ,5 to 0 ,8
M a in /B ig e n d jo u r n a l s u r fa c e fin is h (la p p e d ) R a 0 ,2 p m
R. m a x 2 pm
M a x . im b a la n c e o f c r a n k s h a ft w ith c o u n te r w e ig h ts 30 cm p
(w ith o u t fly w h e e l) r u n n in g o n o u te r m a in b e a rin g s
April ‘96
CRANKSHAFT MAIN BEA R ING S
R epair s i z e (d ia m e te r ) Main b ea rin g T h ru st b ea rin g w id th

d ia . in sta lle d
S ta n d a r d 8 8 , 0 5 2 to 8 8 ,0 9 8 S td . 3 1 ,7 4 to 3 1 ,8 1 (s td )
S ta n d a r d 1 ( - 0 , 1 ) 8 7 , 9 5 2 to 8 7 ,9 9 8 S td .1 & S t d .2
S ta n d a r d 2 ( - 0 , 2 5 ) 8 7 , 8 0 2 to 8 7 ,8 4 8 3 2 ,0 4 to 3 2 ,1 1
R e p a ir 1 ( - 0 , 5 ) 8 7 , 5 5 2 to 8 7 ,5 9 8 S t d .2 & all (+ 0 ,3 ) or
R e p a ir 2 ( - 0 , 7 5 ) 8 7 , 3 0 2 to 8 7 ,3 4 8 r e p a ir s ta g e s 3 2 ,2 4 to 3 2 ,3 1
R e p a ir 3 ( - 1 , 0 ) 8 7 , 0 5 2 to 8 7 ,0 9 8 (+ 0 ,5
TORQUE SPECIFICATIO NS
B a la n c e w e ig h t to c r a n k s h a f t M 1 2 x 1 ,5 I n i t i a l ................................................. 3 0 - 4 0 N m
F i n a l ......................................... .........p lu s 9 0 ° - 1 1 0 °
M a x . s tre tc h le n g th 4 5 ,3 m m
F ly w h e e l to c r a n k s h a f t M 1 2 x 1 ,5 I n i t i a l ................................................. 3 0 - 4 0 N m
F i n a l ......................................... ......... p lu s 9 0 ° - 1 1 0 °
M a x . s tre tc h le n g th 2 6 ,3 m m
P u lle y to c r a n k s h a ft (k e y d r iv e n ) M 2 4 x 1 ,5 (s h a n k e d b o lt ) .................... ........ 5 0 0 - 6 0 0 N m

P u lle y to c r a n k s h a ft (k e y d r iv e n ) M 2 4 x 1 ,5 (fu lly th r e a d e d b o l t ) ................. 8 0 0 - 9 0 0 N m
P u lle y to c r a n k s h a ft (c o n e e le m e n t d r iv e n ) M 2 4 x 1 ,5 (1 s t s t a g e ) ..................................... 8 0 0 - 9 0 0 N m
(2 n d s t a g e ) .......................... p lu s 4 5 ° - 5 5 °
M a in b e a r in g c a p b o lts - s ta n d a r d h e x. b o l t s ........................................M 1 5 x 2 I n i t i a l ................................................. 8 0 - 9 0 N m

F i n a l ......................................... .........p lu s 9 0 ° - 1 0 0 °
M a x . s tre tc h le n g th .......... 123 m m
M a in b e a r in g c a p b o lts - m u lti h e x . b o lts o n ly ...................................... M 1 5 x 2 I n i t i a l ................................................. 4 5 - 5 5 N m

F i n a l ......................................... p lu s 9 0 ° - 1 0 0 °
2 n d p u lle y to v ib r a tio n d a m p e r ....................................................................................... 47 Nm
V ib r a tio n d a m p e r to c r a n k s h a f t M 2 4 x 1 ,5 ......... 5 0 0 N m
April '96
REM OVAL AND REPLACEM ENT OF

C R A N K S H A F T V IB R A T IO N D A M P E R
R em oval
1. S la c k e n V - b e lt a d ju s te r on a lte r n a to r a n d rem o ve
b e lts , (F ig . 1 4 -1 ).
2 U s in g s p e c ia l to o l p a r t n u m b e r 4 0 2 0 0 1 4 5 , r e le a s e a n d
r e m o v e c e n tr e b o lt fr o m c r a n k s h a ft, (F ig . 1 4 -2 ).
3 D ra w v ib r a tio n d a m p e r fr o m c r a n k s h a ft u s in g s p e c ia l
to o l p a rt n u m b e r 4 0 2 0 0 0 1 9 , (F ig . 1 4 -3 ).
R e p la c e m e n t
1. If n e c e s s a r y h e a t v ib ra tio n d a m p e r to a p p r o x im a te ly
80 °C in a w a t e r b a th , a n d s lid e o n to c r a n k s h a ft. E n
s u re t h a t th e w o o d r u f f k e y e n g a g e s g r o o v e in th e v i
b r a tio n d a m p e r (a r r o w s ), (F ig . 1 4 -4 ).
April '96
2. S c re w c e n tr e b o lt in to c r a n k s h a ft and tig h te n to th e
s p e c ifie d to rq u e , (F ig . 1 4 - 5 ) .
A tte n tio n ! U n d e r no c ir c u m s ta n c e s h o u ld th e c e n tr e b o lt b e
tig h te n e d w ith a n im p a c t w r e n c h .
REM OVAL OF CRANKSHAFT
The fo llo w in g ite m s m ust be re m o v e d fr o m th e e n g in e :

c y lin d e r h e a d , s u m p , c o n n e c tin g ro d s , p is to n s , fly w h e e l a n d
h o u s in g , tim in g g e a r c a s e c o v e r a n d oil p u m p .
1. U n s c r e w tim in g gear re ta in in g b o lt fr o m c ra n k s h a ft,

(F ig . 1 4 - 6 ) .
2. U s in g s p e c ia l to o l, p a rt n u m b e r 4 0 2 0 0 0 1 9 , pu ll tim in g
g e a r fr o m c r a n k s h a ft, (F ig . 1 4 - 7 ) .
3. R e m o v e lo w e r h a lf o f tim in g g e a r c a s e , (F ig . 1 4 -8 ).
Fig. 14-8
4. U n s c re w m a in b e a r in g c a p b o lts and lift o ff b e a rin g

c a p s , (F ig . 1 4 - 9 ) .
F ig . 1 4 -9
5. L ift o u t c r a n k s h a ft fr o m c r a n k c a s e , (F ig . 1 4 -1 0 ) .
F ig . 1 4 - 1 0
6. R em ove all m a in b e a r in g s h e lls fr o m cran kcas e. If

b e a r in g s h e lls a r e to b e r e -u s e d , th e y m u s t b e m a rk e d
to e n s u r e r e p la c e m e n t in th e o rig in a l p o s itio n , (F ig .
1 4 -1 1 ).
F ig . 1 4 -1 1
7. C le a n a ll p a rts , m e a s u r e c r a n k s h a ft jo u r n a ls a n d c o m
p a r e w ith s p e c ific a tio n s , (F ig . 1 4 -1 2 ) .
Fig. 14-12
April '96
8. C heck c r a n k s h a ft fo r m is a lig n m e n t, jo u r n a l ru n o u t
(F ig . 1 4 - 1 3 ) .
F ig . 1 4 - 1 3
9. C h e c k a ll m a in b e a r in g c a p b o lts fo r s tre tc h lim it, re fe r

to s p e c ific a tio n s , (F ig . 1 4 - 1 4 ) .
F ig . 1 4 - 1 4
CRANKSHAFT GRINDING
1. M a rk c r a n k s h a ft b a la n c e w e ig h ts and re m o v e fro m
c r a n k s h a ft, (F ig . 1 4 - 1 5 ) .
F ig . 1 4 - 1 5
2. R em ove tim in g g e a r fr o m c r a n k s h a ft, u s in g s p e c ia l

to o l p a rt n u m b e r 4 0 2 0 0 0 2 2 , (F ig . 1 4 - 1 6 ) .
A tten tion ! W h e n g rin d in g th e c r a n k s h a ft it is e s s e n tia l th a t

th e ra d ii o f th e b e a r in g jo u r n a ls a r e m a in ta in e d .
(S e e F ig . 1 4 - 3 4 , p a g e 1 4 - 1 3 ) .
Fig. 14-16
April '96
I
C h e c k in g C ra n k sh a ft a fter G rin d in g
1. c h e c k a n d c r a c k te s t c r a n k s h a ft, (F ig . 1 4 - 1 7 )
2. C heck all b a la n c e w e ig h t b o lts fo r s tre tc h lim its , re fe r

to th e s p e c ific a tio n s , (F ig . 1 4 - 1 8 ) .
A t t e n t i o n ! A ll c r a n k s h a ft b a la n c e w e ig h t b o lts th a t e x c e e d th e
m a x im u m s tre tc h lim it m u s t b e re p la c e d .
3. R e p la c e b a la n c e w e ig h ts , a lig n in g m a rk s on w e ig h ts
w ith m a r k s o n c r a n k s h a ft, (F ig . 1 4 -1 9 ) .
4. In s e r t b a la n c e w e ig h t b o lts a n d tig h te n to th e s p e c i
fie d 'to r q u e , (F ig . 1 4 - 2 0 ) .
April '96
5. U s in g c o m p re s s e d a ir, b lo w o u t all g a lle r ie s in th e

c r a n k s h a ft to e n s u re t h a t n o m e ta l p a rtic le s a r e r e ta i
n e d w ith in th e d r illin g s , (F ig . 1 4 - 2 1 ) .
F ig . 1 4 -2 1
6. R e p la c e c r a n k s h a ft tim in g g e a r u s in g s p e c ia l to o l, p a rt
n u m b e r 4 0 2 0 0 1 9 0 , (F ig . 1 4 - 2 2 ) .
F ig . 1 4 - 2 2
C h eck in g C r a n k sh a ft B ea r in g an d P a ren t B o r e s
A tten tion ! B e a r in g s h e lls a r e s u p p lie d r e a d y fo r fittin g , in

s ta n d a r d a n d v a r io u s r e p a ir s iz e s . N o a t te m p t s h o u ld b e m a d e
to a lte r th e p r e - d e t e r m in e d s iz e .
1. T h o r o u g h ly c le a n a n d v is u a lly in s p e c t c o n d itio n o f all

m a in b e a r in g b o re s in c ra n k c a s e a n d b e a r in g c a p s ,
(F ig . 1 4 - 2 3 ) .
mi » =
F ig . 1 4 - 2 3
2. R e p la c e m a in b e a r in g c a p s in s e r t b o lts a n d tig h te n to
th e s p e c ifie d to rq u e , (F ig . 1 4 - 2 4 ) .
Fig. 14-24
April '96
3. A d ju s t a n in te r n a l m e a s u r in g in s tr u m e n t, (F ig . 1 4 -2 5 ) .
F ig . 1 4 - 2 5
4. M e a s u re m a in b e a r in g p a r e n t b o re s in o n e d ire c tio n
co m p a re m e a s u r e m e n ts w ith th e s p e c ific a tio n s , (F ig
1 4 -2 6 ).
F ig . 1 4 - 2 6
5. R em ove m a in b e a r in g b o lts and b e a r in g c a p s , (F ig .

1 4 -2 7 ).
6. In s e r t b e a r in g s h e lls in to c r a n k c a s e a n d b e a r in g c a p s .
E n s u r e th a t lo c a tin g ta b s on b e a r in g s h e lls a r e c o rre c t
ly in s e r te d in c a p a n d c r a n k c a s e , (F ig . 1 4 - 2 8 ) .
Fig. 14-28
A tte n tio n ! M a in b e a r in g s h e lls h a v e oil d rillin g s w h ic h m u s t

lin e u p w ith h o le s in th e c r a n k c a s e , (F ig . 1 4 -2 9 ) .
F ig . 1 4 - 2 9
7. R e p la c e m a in b e a r in g c a p s w h ic h a r e m a r k e d 1 to 7
fo r A D E 3 6 6 and 1 to 5 fo r A D E 3 6 4 , w h ic h m u s t b e
fitte d in th e c o rr e c t p o s itio n s w ith th e n u m b e r s to
w a r d s th e fr o n t o f t h e e n g in e , (F ig . 1 4 - 3 0 ) .
F ig . 1 4 - 3 0
8. In s e r t b e a r in g cap b o lts and tig h te n to th e s p e c ifie d

to rq u e , (F ig . 1 4 - 3 1 ) .
F ig . 1 4 -3 1
9. A d ju s t/s e t a n in te r n a l m e a s u r in g in s tru m e n t,
(F ig . 1 4 - 3 2 ) .
Fig. 14-32
April ‘96
10. M e a s u re all m a in b e a r in g in s id e d ia m e te r s in th re e
p la c e s , c o m p a re m e a s u r e m e n ts w ith th e s p e c ific a
tio n s , (F ig . 1 4 - 3 3 ) .
F ig . 1 4 - 3 3
11 S h o u ld th e c r a n k s h a ft have been r e -g ro u n d e x a m in e
th e r a d iu s ( R ) to e n s u r e t h a t th e s p e c ific a tio n h a s b e e n
a d h e r e d to , (F ig . 1 4 - 3 4 ) .
F ig . 1 4 - 3 4
12. R e m o v e all m a in b e a r in g c a p s , (F ig . 1 4 - 3 5 ) .
F ig . 1 4 - 3 5
R E P L A C I N G R E A R M A IN B E A R I N G O I L S E A L
A tte n tio n ! T h e fitm e n t o f th e s e s e a ls m u s t b e c a rrie d o u t

w ith th e b e a r in g s h e lls r e m o v e d fr o m c r a n k c a s e a n d b e a rin g
cap.
1. W it h th e oil s e a l r e m o v e d , T h o r o u g h ly c le a n b o th h a l
v e s o f th e b e a r in g h o u s in g , (F ig . 1 4 - 3 6 ) .
Fig. 14-36
April ‘96
2. U s in g a p a ir o f lo n g n o s e p lie rs , r e m o v e th e oil s e a l re

ta in in g p in s fr o m th e seal h o u s in g in c r a n k c a s e a n d
b e a r in g c a p , ( F i g . 1 4 - 3 7 ) .
F ig . 1 4 -3 7
3. U s in g a n a lu m in iu m d rift, ta p n e w oil s e a l r e ta in in g pin

in to c ra n k c a s e and b e a r in g cap seal h o u s in g , (F ig .
1 4 -3 8 ).
A tte n tio n ! D o n o t d a m a g e th e tip o f th e re ta in in g pins.
F ig . 1 4 - 3 8
4. F it o n e h a lf o f t h e n e w oil s e a l in to s p e c ia l to o l, p a rt
n u m b e r 4 0 2 0 1 6 0 7 , (F ig . 1 4 - 3 9 ) .
F ig . 1 4 - 3 9
5. N ew s e a l m u s t fit e x a c tly in to s p e c ia l to o l. B o th e n d s
o f s e a l m u s t to u c h to o l h o ld e r, (F ig . 1 4 - 4 0 ) .
Fig. 14-40
6. L o c a te s p e c ia l to o l, fitte d w ith new oil s e a l on to th e

c ra n k c a s e and d r iv e th e s e a l in to th e h o u s in g , (F ig .
1 4 -4 1 ).
F ig . 1 4 -4 1
7. In s e r t n e w h a lf s e a l fo r b e a r in g c a p in to th e s p e c ia l
to o l a n d d r iv e in to b e a r in g c a p , (F ig . 1 4 - 4 2 ) .
A tten tio n ! N e w s e a l e n d s m u s t p r o tru d e 0 ,5 m m a b o v e th e

b e a r in g c a p a n d c r a n k c a s e m a tin g s u rfa c e s o r 0 ,8 m m w h e n
th e c r a n k s h a ft is r e g r o u n d to th e n e x t r e p a ir s ta g e . N o fib re s
s h o u ld b e tr a p p e d b e tw e e n th e b e a r in g c a p a n d th e c r a n k c a s e
m a tin g s u rfa c e s .
8. C o a t th e s e a l in th e c r a n k c a s e a n d b e a r in g c a p w ith a
h e a t r e s is ta n t g r e a s e , (F ig . 1 4 - 4 3 ) .
F ig . 1 4 -4 3
9. A p p ly a s m a ll a m o u n t o f s ilic o n e s e a la n t to th e g ro o
v e s in th e r e a r m a in b e a r in g c a p . The end s u rfa c e of
s e a ls m u s t n o t b e c o a te d w ith s e a la n t, (F ig . 1 4 -4 4 ) .
A tten tio n ! If th e b e a r in g c a p d o e s n o t h a v e g ro o v e s , a p p ly
s e a la n t to th e s u r fa c e s o f th e cap and th e cran k- case.
S u r fa c e s to b e c o a te d w ith s e a la n t m u s t b e fr e e o f g re a s e .
Fig. 14-44
April '96
REPLACING THE CRANKSHAFT
1. L ib e r a lly c o a t th e b e a r in g s w ith e n g in e oil, (F ig . 1 4 -4 5 ).
Fi<g. 1 4 - 4 5
2. L o w e r t h e c r a n k s h a ft o n to th e b e a r in g s , (F ig . 1 4 -4 6 ) .
nB.i
F ig . 1 4 - 4 6
3. R e p la c e a ll m a in b e a r in g c a p s m a r k e d 1 to 7 fo r A D E
3 6 6 o r 1 to 5 fo r A D E 3 6 4 . They m ust b e fitte d in th e
c o rr e c t p o s itio n w ith th e n u m b e r s to w a r d s th e fro n t o f
th e e n g in e , (F ig . 1 4 - 4 7 ) .
F ig . 1 4 - 4 7
4. C o a t th e th r e a d s o f th e m a in b e a r in g b o lts w ith e n g in e
oil, (F ig . 1 4 - 4 8 ) .
Fig. 14-48
April '96
5. In s e r t b o lts a n d tig h te n to th e s p e c ifie d to rq u e , (F ig .

1 4 -4 9 ).
6. C h e c k th e to r q u e r e q u ire d to tu rn th e c r a n k s h a ft, w ith

n e w b e a r in g s a n d oil s e a l fitte d , r e fe r to s p e c ific a tio n s ,
(F ig . 1 4 - 5 0 ) .
A tte n tio n ! S h o u ld th e c r a n k s h a ft n o t tu rn a t th e re q u ire d

to rq u e , r e m o v e r e a r m a in b e a r in g c a p a n d c h e c k c o rre c t fittin g
o f th e oil s e a l.
7. R e fit c a m s h a f t tim in g g e a r , lin in g up tim in g m a rk s . In

s e rt b o lts and tig h te n to th e s p e c ifie d to rq u e , (F ig .
1 4 - 5 1 . S e e a ls o p a g e s 1 5 - 1 2 a n d 1 5 -1 3 .
8. M ount a d ia l gauge in d ic a to r o n th e c r a n k c a s e a n d
m e a s u re th e c r a n k s h a ft e n d flo a t in a c c o r d a n c e w ith
s p e c ific a tio n s , (F ig . 1 4 - 5 2 ) .
Fig. 14-52
April '96
9. R e p la c e th e b o tto m h a lf o f th e tim in g c o v e r a n d tig h te n

th e b o lts to th e s p e c ifie d to rq u e , (F ig . 1 4 - 5 3 ) .
April ‘96
CRANKSHAFT AND MAIN BEARINGS — 14-19

O B T A IN A B L E FROM : G R U N D Y -T E C H N IF O R M . BURM AN ROAD. DEAL PARTY ESTATE. PORT
E L IZ A B E T H 6001 .
Im p a c t so cke t scan ner

¡s e e fig. 14.-21
3
P a rt N u m b e r 40 2001 45
P u lle r for c a m s h a ft g e ar
(see fig. 14-71
n
P a rt n u m b e r 40 2000 19
C ran ksha ft
h a rd n e s s tester
(s e e fig. 14-13)
P a rt N u m b e r 40 200501
C ra n k s h a ft gear re placer
(s e e fig. 14-22)
P a rt N u m b e r 40 2001 90
R e a r oil se a l r e p l a c e r
(see fig. 14-39)
P a rt N u m b e r 40 20 1 6 0 7
P u lle r for v ib ra tio n d a m p e r
=7 =7 0 (se e fig. 14-3)

P a rt n u m b e r 40 200 019
rn
A D E 360 S e rie s
ADE 360 S eries
________________SECTION 15
Camshaft, Timing Case and Drive Timing
Page
I L L U S T R A T I O N ...................................................................................................................................................................................................................................... 1 5 -2
I N T R O D U C T I O N ....................................................................................................................................................................................................................................1 5 -3
S P E C I F I C A T I O N S ................................................................................................................!............................................................................................................... 1 5 -3
R E M O V I N G C A M S H A F T ..................................................................................................................................................................................................................1 5 -5
R E P L A C I N G C A M S H A F T ................................................................................................................................................................................................................ 1 5 -9
R E M O V IN G T IM IN G C O V E R O IL S E A L ............................................................................................................ 1 5 -1 4
R E P L A C I N G T I M I N G C O V E R O I L S E A L ................................................................................................. 1 5 -1 5
S P E C IA L T O O L S .................................................................................................................................................. 1 5 -1 7
Camshaft, Timing Case and Drive Timing 15-2
C A M S H A F T A N D T IM IN G G E A R S
1. C A M S H A F T 7. R E T A IN IN G B O L T
2. T H R U S T W A S H E R 8. B O L T
3. F L Y -W E IG H T 9. R O L L E R
4 . P IN 10 . IN J E C T IO N P U M P D R IV E G E A R
5. S P R IN G 11. F E A T H E R K E Y
6. C A M S H A F T G EA R
April ‘96
IN T R O D U C T I O N
T h e c a m s h a f t is p r e c is io n fo rg e d a n d in d u c tio n h a rd e n e d . It is s u p p o r te d b y s te e l b a c k e d b r o n z e b e a r in g s a n d g e a r d riv e n
fr o m th e c r a n k s h a ft. A c c e s s to t h e tim in g g e a r s c a n b e g a in e d b y r e m o v a l o f th e c r a n k s h a ft v ib ra tio n d a m p e r a n d tim in g
c a s e , w h ic h is s it u a te d a t th e fr o n t o f th e e n g in e .
S P E C IF IC A T IO N S
C a m s h a f t B e a r in g s
B e a r in g p o s itio n S ta n d a r d
364 366 J o u r n a l d ia. B e a r in g ID
— 1 5 5 ,9 4 1 to 5 5 ,9 6 0 5 6 , 0 0 0 to 5 6 , 0 3 0
1 2 5 5 ,6 9 1 to 5 5 ,7 1 0 5 5 , 7 4 0 to 5 5 , 7 7 0
2 3 5 5 ,4 4 1 to 5 5 ,4 6 0 5 5 , 4 9 0 to 5 5 , 5 2 0
3 4 5 5 ,1 9 1 to 5 5 ,2 1 0 5 5 , 2 4 0 to 5 5 , 2 7 0
C a m s h a f t lo b e a n d jo u r n a l s u r f a c e fin is h R z 3 pm
E c c e n tr ic - C o m p r e s s o r d r iv e R a 0 ,2 pm ; R m a x 2 p m
B a s ic b o r e fo r c a m s h a f t b e a r in g 6 0 , 0 0 0 to 6 0 , 0 3 0
C a m s h a f t b e a r in g O D 6 0 , 1 5 0 to 6 0 , 1 8 0
C a m s h a f t b e a r in g c le a r a n c e R a d ia l 0 , 0 3 0 to 0 ,0 7 9
A x ia l 0 , 1 8 0 to 0 ,5 2 0
H a rd n e s s J o u rn a l 5 7 to 6 3 H rc
C a m lo b e s 5 7 to 6 3 H rc
R u n -o u t o f c a m s h a f t jo u r n a ls ( c a m s h a f t s u p p o r te d a t o u te r jo u r n a ls ) 0 ,0 2 5
B a c k la s h c r a n k s h a f t /c a m s h a f t g e a r , c a m s h a ft/in je c tio n p u m p g e a r 0 , 0 7 0 to 0 , 1 8 0
In le t Exhaust
V a lv e tr a v e l s p e c ific a tio n s fo r c h e c k in g 364N , 366N 0 ,5 6 to 0 , 9 6 0 ,6 4 to 1 ,0 4
v a lv e tim in g a t T D C a n d "O " c le a r a n c e 3 6 6 C /T /T I, 3 6 4 C /T 0 ,5 8 to 0 , 9 8 0 ,6 1 to 1 ,0 1
In le t Exhaust
M a x im u m v a lv e lift (w ith s p e c ifie d 3 6 4 N /C /T , 3 6 6 N 1 0 ,5 6 1 0 ,5 6
v a lv e c le a r a n c e ) 3 6 6 C /T /T I 1 0 ,1 6 1 0 ,5 6
April '96
Outer shaft dia. Bore in cylinder block
Standard 27,980 to 27,990 28,000 to 28,033
Repair stage 1 (+0,2) 28,180 to 28,190 28,200 to 28,233
Clearance shaft /bore 0,010 to 0,053
Timing degree pointer.............................................................. M6............................................8 Nm
Timing device to camshaft....................................................... M16 x 1,5................................. 300 Nm
Timing segment to camgear.................................................... M8............................................30 to 40 Nm (+90° to 100°)
Injection pump gear 364N/C/T, 366N.......................................M14 x 1,5..................................80 Nm

366C/T/TI................................................. M18 x 1,5..................................105 Nm
Camshaft thrust plate to block................................................. M8 x 1.......................................35 Nm
Timing case to cylinder block................................................... M10..........................................65 Nm
Timing case cover to timing case.............................................M6............................................10 Nm*
April '96
REMOVING AND REPLACING THE CAMSHAFT
1. Remove rocker cover, (refer to page 12-7).
2. Unscrew and remove rocker shaft, (refer to page 12-9).
3. Remove pushrods and mark to ensure replacement in

the original position.
4. Unscrew and remove side cover, (Fig. 15-1).
5. Lift out camfollowers, (Fig. 15-2), and number each in

order to replace in the same position.
6. Drain engine oil and remove sump, (Fig. 15-3).
7. Unscrew and remove bolts retaining oil pump, lift out

pump, (Fig. 15-4).
April ‘96
8. Slacken the V-belt adjuster on the alternator and re

move the belts, (Fig. 15-5).
9. Using special tool, part number 4020 0145, unscrew

and remove centre bolt retaining vibration damper,
(Fig. 15-6).
10. Attach special puller, part number 4020 0019, to vibra

tion damper and puli off, (Fig. 15-7).
11. Unscrew and remove bolts retaining the timing case

cover and lift off, (Fig. 15-8).
April '96
12. Using a socket, unscrew and remove the Allen cap

screw retaining the timing gear to the camshaft, (Fig.
15-9).
A V 1 O I
il
g. 1 5 -9
13. Using special tool, part number 4020 0019, pull off
timing gear from camshaft, (Fig. 15-10).
14. Remove shim and feather key from the camshaft, (Fig.
15-11).
15. Unscrew bolts retaining the camshaft thrust plate and

remove from the camshaft, (Fig. 15-12).
Fig. 15-12
16. If the engine is fitted with a crankcase mounted com

pressor remove the compressor cylinder head bolts
together with the gasket, (Fig. 15-13).
Fig. 15-13
17. Turn the piston of the compressor to TDC and pull off the
cylinder barrel, (Fig. 15-14).
Fig. 15-14
18. Remove the circlips retaining the gudgeon pin, push out
and remove the piston, (Fig. 15-15).
Fig. 15-15
19. Unscrew the nuts retaining the bearing cap to the

connecting rod, (Fig. 15-16).
Fig. 15-16
April '96
20. Remove connecting rod and bearing cap, (Fig. 15-17).
21. Pull out the camshaft from the cylinder block. Do not
damage the camshaft bearings, (Fig. 15-18).
REPLACING
1. Carefully insert the camshaft into the cylinder block

without damage to the camshaft bearings,
(Fig. 15-19).
Fig. 15-19
2. Fit thrust plate to camshaft, insert retaining bolts and

tighten to the specified torque, (Fig. 15-20).
April '96
3. Fit shim to camshaft, (Fig. 15-21)
Fig. 15-21
4. Fit timing gear to camshaft; ensure that the marks on

timing gear and crankshaft gear are aligned, (fFig.
15-22).
Fig. 15-22
5. Insert feather key, locating timing gear to camshaft,

(Fig. 15-23).
Fig. 15-23
6 Insert Allen cap screw into camshaft, (Fig. 15-24).
Fig. 15-24
April '96
7. Tighten cap screw to the specified torque, (Fig. 15-25).
Fig. 15-25
8. Replace timing case cover and align using special tool

4020 2198, (Fig. 15-26).
Fig. 15-26
9. Insert bolts retaining the timing cover and tighten to

the specified torque, (Fig. 15-27).
Fig. 15-27
10. If necessary, heat the vibration damper to approxima

tely 80°C in a water bath before sliding onto the crank
shaft. Ensure that the woodruff key locates in the
groove, (Fig. 15-28).
Fig. 15-28
April '96
11. Screw centre bolt into crankshaft and tighten to the

specified torque, (Fig. 15-29).
Attention! The centre bolt must not be tightened with an

impact wrench
■ni) ak
Fig. 15-29
12. If the engine is fitted with a crankcase mounted com

pressor the crankshaft should be turned so that the
lobe for the compressor connecting rod is at TDC. Re
place bearing cap and connecting rod, (Fig. 15-30).
Note: When using belt driven compressors the oil supply

hole in the eccentric is closed off with a jubilee clamp.
13. Tighten nuts to the specified torque, (Fig. 15-31).
14. Fit compressor piston to connecting rod, insert gud

geon pin and circlips, (Fig. 15-32).
Fig. 15-32
April '96
15. Lightly apply a suitable sealing compound to the base

of the cylinder barrel.
16. With the special piston ring squeezer, part number

4020 1131, compress the piston rings, insert piston
into the cylinder barrel, push the barrel down over the
piston rings and remove the piston ring squeezer.
Push the barrel fully home, (Fig. 15-33).
17. Replace the compressor cylinder head, fitted with a

new gasket, insert bolts and tighten to the specified
torque, (Fig. 15-34).
18. Replace the oil pump, insert the retaining bolts and
19. Using new gaskets, replace the sump, insert bolts and
Fig. 15-36
April '96
20. Insert cam followers in the same position from which

they were removed, (Fig. 15-37).
21. Replace side cover, insert bolts and tighten to the spe
cified torque, (Fig. 15-38).
22. Insert push rods in their original position, see page

12 - 21 .
23. Replace the rocker shafts and insert the bolts but do
not tighten.
24. Use special tool, part number 4020 3185 and insert
the connecting nipple between the rocker shafts, see
page 12-21.
25. Tighten the rocker shafts to the specified torque, see

page 12-23.
26. Adjust the valve clearance, see page 12-23.
27. Replace the rocker cover with a new gasket, insert

bolts and tighten to the specified torque, (Fig. 12-24).
REMOVING AND REPLACING

THE TIMING COVER OIL SEAL
Timing cover removed from the engine.
Removing
1. Place the support ring of special tool, part number

4020 0200, under the front of the timing cover to
prevent distortion when the oil seal is removed, (Fig.
15-39).
2. Use the adapter ring and spacer of the special tool to

press the oil seal from the housing, (Fig. 15-40).
Fig. 15-40
Replacing
1. Locate a new oil seal in front of the housing, (Fig.

15-41).
2. Place a 12 mm distance piece inside the timing cover,

behind the oil seal housing, (Fig. 15-42).
3. Place the spacer of the special tool on top of the oil

seal, (Fig. 15-43).
4. Press the seal into the timing housing until it is flush

with the inside edge of the timing cover and butts onto
the distance piece, (Fig. 15-44).
Fig. 15-44
5. Section through timing case with the oil

seal in place, (Fig. 15-45).
Note: When replacing the timing case oil seal it is essential to

replace the wear ring on the crankshaft.
April '96
CAMSHAFT, TIMING CASE AND DRIVE TIMING — 15-17

O B T A IN A B L E FROM : G R U N D Y -T E C H N IF O R M . BURM AN ROAD. DEAL PARTY ESTATE. PORT
E L IZ A B E T H 6001
im pa ct socket s o a nner
ise e tig 15-6 i
Part N u m D e r 40200145
P u lle r fo r c a m s h a ft gear,
(see fig . 15-10)
P art N u m b e r 40200019.
P u lle r fo r v ib ra tio n a a m D e r
(see fig . 15-7)
P art n u m b e r 40200019
T im in g co ve r c e n tra liz in g
to o l. ..
(see fig . 15-26)
P art N u m b e r 40202198.
C o m p re s s o r p is to n rin g squeezer
u se w ith p lie rs b e lo w ,
(see fig . 15-33)
P art N u m b e r 40201131.
P lie rs fo r c o m p re s s o r
p is to n rin g squeezer,
(see fig. 15-33)
P art N u m b e r 40201144.
AM ENDMENT 6/91
CAMSHAFT, TIMING CASE AND DRIVE TIMING — 15-18
T im ing cover oil seal remover/

replacer,
(see fig. 15-40).
P art N u m b e r 40200200.
F ab ricate a 12 mm
spacer x 100 mm dia., which is
used as a distance piece under the
tim ing case cover, when pressing
in the seal, (see fig. 15-42).
AMENDMENT 6/91
_________SECTION 16
Lubricating System and Sump
Page
I L L U S T R A T I O N ...................................................................................................................................................................................................................................... 1 6 -2
O IL F L O W C H A R T ............................................................................................................................................................................................................................... 1 6 -3
I N T R O D U C T I O N ....................................................................................................................................................................................................................................1 6 -4
S P E C I F I C A T I O N S .................................................................................................................................................................................................................................1 6 -4
R E M O V I N G T H E O IL C O O L E R ................................................................................................................................................................................................... 1 6 -6
R E P L A C I N G T H E O IL C O O L E R ..................................................................................................................................................................................................1 6 -8
R E M O V I N G T H E O I L C O O L E R A D E 3 6 6 T ....................................................................................................................................................................... 1 6 - 1 0
R E P L A C I N G T H E O IL C O O L E R A D E 3 6 6 T ....................................................................................................................................................................... 1 6 -1 2
R E M O V I N G T H E O IL F I L T E R E L E M E N T ............................................................................................................................................................................1 6 -1 5
R E P L A C I N G T H E O IL F I L T E R E L E M E N T .......................................................................................................................................................................... 1 6 -1 6
R E M O V I N G T H E O IL F I L T E R H E A D .................................................................................................................................................................................... 1 6 -1 7
R E P L A C I N G T H E O IL F IL T E R H E A D ...................................................................................................................................................................................1 6 -1 8
R E M O V I N G T H E O IL P U M P ........................................................................................................................................................................................................1 6 -2 1
A S S E M B L Y O F T H E O I L P U M P ................................................................................................................................................................................................1 6 - 2 3
April '96
Lubricating System and Sump 16-2
OIL PUMP AND FILTER ASSEMBLY
1 OIL FILTER ELEMENT 17 STRAINER

2 FILTER ELEMENT RETAINER 18 STRAINER RETAINING BOLT
3 SEALING WASHER 19 OIL PUMP RETAINING BOLT
4 WASHER 20 OIL PUMP BODY
5 SEALING WASHER 21 OIL PUMP GEAR
6 FILTER BOWL RETAINING BOLT 22 BY-PASS VALVE SCREW PLUG
7 DRAINPLUG AND WASHER 23 WASHER
8 GEAR SHAFT 24 BY-PASS VALVE SPRING
9 OIL PUMP DRIVEN GEAR 25 BY-PASS VALVE
10 OIL PUMP DRIVE SHAFT 26 OIL FILTER HEAD
11 OIL PUMP DRIVE GEAR 27 BANJO BOLT AND WASHER
12 OIL PUMP DRIVE SHAFT/TACHO DRIVE 28 GASKET
13 WOODRUFF KEY 29 INJECTION PUMP OIL FEED PIPE
14 OIL PUMP COVER RETAINING BOLT 30 BANJO BOLT AND WASHER
15 RELIEF VALVE 31 BLANKING PLUG
16 OIL PUMP COVER PLATE 32 BLANKING PLUG AND WASHER
April '96
TYPICAL OIL FLOW - ADE 360 SERIES
Oil is drawn from the engine sump by a gear type pump, through a gauze strainer. The oil under pressure then flows
between the oil pump body and drive shaft into a gallery, passing to the oil filter. From the oil filter, cleansed oil flows via
an intersecting gallery to a plate type oil cooler. On the naturally aspirated engine, oil from the cooler enters the main oil
gallery to the crankshaft, camshaft, rocker gear, etc.
The turbocharged engine oil flow differs from the naturally aspirated engine, in that the oil flowing from the main oil filter
passes into an additional micro type filter, mounted on the outside of the oil cooler cover, before flowing into a large
capacity fin type oil cooler, providing an increase in the cooling capacity. To assist with dissipation of the additional heat
generated by the turbocharged engine, piston cooling nozzles are fitted to the main oil gallery, supplying a constant jet of
cooling oil to the underside of the piston crowns. The turbocharger is fed under pressure from the main oil gallery, with a
drain to the engine sump.
The ADE 364C/T/TI engine has a small finned cooler mounted integrally with the engine oil filter to assist with heat
dissipation.
Note: The micro type oil filter mentioned above has since been removed on turbocharged engines built from mid 1995.
April '96
INTRODUCTION
A g e a r ty p e p u m p s u p p lie s o il u n d e r p re s s u re th ro u g h a fu ll flo w p a p e r ty p e o il filte r to th e c r a n k s h a ft, c a m s h a ft,

c o n n e c tin g ro d b ig e n d b e a rin g s , ro c k e r s h a ft b e a rin g s , fu e l in je c to r p u m p a n d g o v e rn o r. O il u n d e r p re s s u re is a ls o fe d to
th e c ra n k c a s e m o u n te d a ir c o m p r e s s o r a n d tu rb o c h a rg e r ( if fitte d ). P re s s u re re lie f a n d b y -p a s s v a lv e s p ro te c t th e s y s te m
a g a in s t o v e rlo a d .
SPECIFICATIONS
OIL PUMP
364N/C/T 366C/T/TI
366N
Width of pump gears 39,936 to 39,975 49,936 to 49,975
Axial play between gear face and housing 0,025 to 0,089 0,025 to 0,089
Clearance between teeth and housing 0,030 to 0,105 0,030 to 0,105
Outside dia. of pump gears 42,020 to 42,070 42,020 to 42,070
Inside dia. of pump driving gear 16,944 to 16,958 16,944 to 16,958
Inside dia. of pump driven gear 15,050 to 15,073 15,050 to 15,073
Diameter in housing for shaft of driven gear 15,000 to 15,018 15,000 to 15,018
Inside diameter of oil pump drive sprocket 16,944 to 16,958 16,944 to 16,958
A - Installation height between drive sprocket + 0,5

116,5 - 0,3
and pump housing flange when moving shaft
in the indicated direction
B - Diameter of oil pump driving shaft 16,976 to 16,984 16,976 to 16,984
C - Diameter of oil pump driven gear shaft 15,028 to 15,039 15,028 to 15,039
D - Installation height of driven gear shaft 39,2 to 39,5 47,5 to 48,5
E - Installation height of drive gear to drive shaft 0,5 to 0,8 7,2 to 7,8
364N/C/T
Pump speed 366N 366C/T/TI
Min. delivery rate (¿/min) with SAE 10 oil at 50°C and 300 r/min
400 kPa pressure 1 400 r/min 45 58
April '96
OIL PRESSURE RELIEF VALVE____________________________________________________________

I Opening pressure (kPa) 470 - 570
SPRING FOR PRESSURE RELIEF VALVE

OD Wire dia. Unloaded Spring preload Spring final load
spring length Length Load Length Load
mm mm mm mm N mm N ,
9,3 1,7 49,4 45,4 43,9 36,2 ! 145 :
OIL FILTER BY-PASS VALVE SPRING

OD Wire Unloaded Spring preload Spring final load Opening pressure
dia spring length Length Load Length Load of by-pass valve
mm mm mm mm N mm N kPa
16,5 1,5 66 31 42 to 48 21,0 57 160 - 250
OIL PRESSURE
Minimum operating oil pressure (warm engine)
600 r/min 80 kPa gauge pressure
Warning! Stop engine immediately when the oil pressure drops below the following values
OIL CAPACITY
Depending on application 364N/C/T approximately 10 litres
366N/C/T/TI approximately 17,5 litres
Turbocharger oil drain to crankcase/sump (364C/T/TI).... M 1 6 x 1 , 5 ........................................................ 4 0 N m

Turbocharger oil supply from oil cooler cover (366C/T/TI) M 1 4 x 1 , 5 ........................................................ 4 0 N m
Turbocharger oil drain to sump (366C/T/TI)..................... M 2 6 x 1 , 5 ........................................................ 7 0 N m
Oil supply to turbocharger................................................ M 8 ....................................................................... 3 5 N m
Oil drain from turbocharger.............................................. M 8 ....................................................................... 3 5 N m
Oil pressure gauge switch................................................ M 1 4 x 1 , 5 ........................................................ 5 0 N m
Oil filter mounting............................................................ M 1 0 .................................................................... 5 0 N m
Dipstick adapter............................................................... M 1 4 x 1 , 5 ........................................................ 4 0 N m
Sump drain plug.............................................................. M 2 6 x 1 , 5 ........................................................ 8 0 N m
Dipstick tube to cylinder block.......................................... M 1 6 x 1 , 5 ........................................................ 2 5 N m
Sump to cylinder block - Pressed steel............................ M 8 ( S t u d s ) .................................................... 9 Nm
M 6 ( B o lt s ) ..................................................... 8 Nm
- Aluminium casting M 8 ( S t u d s ) ..................................................... 2 5 N m
M 6 ( B o lt s ) ....................................................... 1 5 N m
Drain plug bush to sump................. - .......................................................................... 9 0 - 1 1 0 N m
Relief valve cap to oil pump cover.... M 2 4 x 1 , 5 ........................................................ 2 0 N m (w ith L o c tite )
By-pass valve cap on oil filter'......... M 2 4 x 1 , 5 ........................................................ 7 0 N m
Banjo bolt to oil filter head............... M 2 6 x 1 , 5 ........................................................ 6 0 N m
Plug to oil filter head........................ M 1 0 x 1 .............................................................2 0 N m
Plug to oil filter head (Aluminium).... M 1 4 x 1 , 5 ........................................................ 3 5 N m
Drain plug to filter head (Aluminium) M 1 0 x 1 .............................................................2 0 N m
Oil filter bowl to filter head............... M 1 2 x 1 , 5 ........................................................ 4 5 N m
Oil supply pipe to injector pump...... M 1 0 x 1 .............................................................1 5 N m
Oil supply pipe to filter.................... M 10 x 1 15 Nm
Suction pipe to oil pump cover........ M 8 ....................................................................... 3 5 N m
Oil pump cover to pump body......... M 8 ....................................................................... 3 4 N m
Oil pump to cylinder block............... M 8 ....................................................................... 3 5 N m
Oil cooler filter to cooler.................. M 1 0 .................................................................... 4 0 N m
Oil cooler cover to cylinder block..... M 8 .......................................................................4 0 N m
Oil cooler by-pass valve.................. M 2 2 x 1 , 5 ........................................................ 6 5 N m
Oil cooler bolts (centre) 366N.......... M 8 ....................................................................... 3 0 N m
Cooler to cover 366C/T/TI............... M 8 ....................................................................... 3 5 N m
April ‘96
REMOVING AND DISMANTLING

PLATE TYPE OIL COOLER 366N
1. R e m o v e s ta r te r m o to r.
2. U n s c re w b o lts and re m o v e th e e x h a u s t m a n ifo ld ,

(F ig . 1 6 - 1 ) .
3. U n s c re w th e b o lts and r e m o v e th e in le t m a n ifo ld ,

(F ig . 1 6 - 2 ) .
4. U n s c re w and r e m o v e th e oil p r e s s u r e g a u g e s e n d e r
un it, (F ig . 1 6 - 3 ) .
5. R em ove by- pass v a lv e fr o m o il c o o le r c a s in g , (F ig .

1 6 -4 ).
April '96
6. U n s c re w a n d r e m o v e a ll b o lts re ta in in g th e o il c o o le r to
th e c y lin d e r b lo c k , (F ig . 1 6 -5 ).
7. Remove the oil cooler casing from the cylinder block,

(Fig. 16-6).
8. Unscrew and remove bolts joining both halves of the

oil cooler, (Fig. 16-7).
9. Dismantle the oil cooler halves, (Fig. 16-8).
M m >e=
Fig. 16-8___________________________________
April '96
ASSEMBLY AND REPLACEMENT OF OIL COOLER
1. Fit new gasket between oil cooler halves, (Fig. 16-9).
¡ A
N jT '~ , r- , J iff
■in
g. 16-9
2. Insert bolts joining the oil cooler halves and tighten to

the specified torque,(Fig. 16-10).
Fig. 16-10
3. Replace oil pressure gauge sender unit and tighten the

bolts to the specified torque, (Fig. 16-11).
4. Replace the by-pass valve and tighten the bolts to the

Fig. 16-12
April ‘96
5. F it a new g a s k e t b e tw e e n oil c o o le r c a s in g a n d c y lin

d e r b lo c k .
T ' ^
6. R e p la c e th e oil c o o le r to c y lin d e r b lo c k , (F ig . 1 6 -1 3 ) .
F ig . 1 6 - 1 3
7. In s e r t b o lts s e c u r in g th e oil c o o le r to th e c y lin d e r b lo c k

and tig h te n in c ro s s fa s h io n fr o m th e c e n tr e o u tw a rd s ,
to th e s p e c ifie d to r q u e , (F ig . 1 6 - 1 4 ) .
mu / © s
F ig . 1 6 - 1 4
8. F it n e w g a s k e ts to th e in le t m a n ifo ld , in s e rt b o lts a n d
tig h te n to th e s p e c ifie d to rq u e , (F ig . 1 6 -1 5 ) .
F ig . 1 6 - 1 5
9. F it n e w g a s k e ts to th e e x h a u s t m a n ifo ld , in s e rt b o lts
a n d tig h te n to t h e s p e c ifie d to rq u e , (F ig . 1 6 - 1 6 ) .
1 0 . R e p la c e th e s t a r t e r m o to r.
1 1 . W it h th e e n g in e s to p c o n tro l s e t to th e “O F F " p o s itio n ,

tu rn th e e n g in e w ith t h e s t a r t e r m o to r u n til oil p r e s s u r e
is r e g is te r e d o n th e g a u g e .
1 2 . S ta r t th e e n g in e a n d a llo w to id le fo r s e v e r a l m in u te s ;
c h e c k a ll jo in ts fo r oil le a k s .
till A3 =
Fig. 16-16
April '96
REMOVING OIL COOLER ADE 366T
1. Remove the starter motor.
2. Disconnect the oil feed and drain pipes to the turbo

charger, (Fig. 16-17).
3. Unscrew bolts and remove the exhaust manifold, (Fig.

16-18).
4. Unscrew bolts and remove the inlet manifold, (Fig.

16-19).
5. Do not remove the oil cooler retainer bolts until the

housing has been removed from the cylinder block,
(Fig. 16-20).
April '96
6 U n s c re w and re m o v e a ll b o lts r e ta in in g th e oil c o o le r

h o u s in g and re m o v e fr o m th e c y lin d e r b lo ck , (F ig .
1 6 -2 1 ).
7. U n s c re w a n d re m o v e b o lts re ta in in g th e oil c o o le r e le
m e n t to th e h o u s in g , (F ig . 1 6 - 2 2 ) .
Fig. 16-22
8. D e ta c h th e oil c o o le r e le m e n t fr o m th e h o u s in g , (F ig .
1 6 -2 3 ).
9. U n s c re w th e c e n tr e b o lt r e ta in in g th e oil c o o le r filte r
e le m e n t to t h e h o u s in g , (F ig . 1 6 - 2 4 ) .
April '96
10. L ift o f f th e filte r c o v e r a n d r e m o v e th e filte r e le m e n t,

(F ig . 1 6 -2 5 ).
Fig. 16-25
11. Unscrew and remove the oil pressure gauge sender

unit, (Fig. 16-26).
Fig. 16-26
12. Remove the by-pass valve from the oil cooler housing,
(Fig. 16-27).
— I ss> mi /©=
Fig. 16-27
R E P L A C IN G
1. Replace the oil pressure gauge sender unit and tighten

to the specified torque.
2. Replace the by-pass valve and tighten to the specified

III! M s
Fig. 16-28
April '96
3. Fit a new O-ring to the oil cooler filter element cover,

(Fig. 16-29).
4. Replace the oil cooler filter element.

Note: The wide sealing face on the filter element goes
towards the sealing surface of the oil cooler housing,
(Fig. 16-30).
5. Replace the filter element cover, fitted with new O-ring,

insert the retaining bolt and tighten to the specified
6. Fit new gaskets between oil cooler element and hou

sing, replace the cooler element and insert bolts, (Fig.
16-32).
Fig. 16-32
April '96
7. Tighten oil cooler retaining bolts to the specified

torque, (Fig. 16-33)
Fig. 16-33
8. Fit a new gasket between the cylinder block and the oil
cooler housing.
9. Replace all bolts retaining the oil cooler housing to the

cylinder block and tighten in cross fashion from the
centre outwards to the specified torque, (Fig. 16-34).
Fig. 16-34
10. Fit a new gasket to the inlet manifold, insert bolts and
Fig. 16-35
11. Insert the exhaust manifold bolts and tighten to the

■ ill » =
Fig. 16-36
April ‘96
1 2 . C o n n e c t oil fe e d and d ra in p ip e to th e tu rb o c h a r g e r ,
a n d tig h te n to s p e c ifie d to r q u e (F ig . 1 6 -3 7 ) . 1
1 3 . R e p la c e th e s t a r t e r m o to r.
1 4 . W it h th e e n g in e S to p c o n tro l s e t to th e “O F F " p o s itio n

tu rn t h e e n g in e w ith th e s t a r te r m o to r un til oil p re s s u re
is r e g is te r e d o n th e g a u g e .
1 5 . S ta r t th e e n g in e a n d a llo w to id le fo r s e v e r a l m in u te s .
C h e c k a ll jo in ts fo r oil le a k s .
F ig . 1 6 - 3 7 ___________
R e m o v in g th e Oil F ilter E le m e n t
1. U n s c re w and r e m o v e th e filte r b o w l d ra in p lu g a n d
a llo w oil to d ra in (F ig . 1 6 - 3 8 ) .
2. U n s c re w th e c e n tr e b o lt re ta in in g th e filte r b o w l to th e
filte r h e a d , (F ig . 1 6 - 3 9 ) .
3. R e m o v e th e o il filte r b o w l a n d th e filte r e le m e n t, (F ig .
1 6 -4 0 ).
4. C le a n filte r b o w l, e le m e n t r e ta in e r a n d c e n tr e bo lt.
April '96
Replacing
1. F it a n e w O - rin g to th e filte r h e a d , (F ig , 1 6 -4 1 ).
2 Insert a new filter element into the filter bowl, (Fig.

16-42).
3 Position the filter bowl to the centre of the filter head,

insert bolt and tighten to the specified torque, (Fig.
16-43).
4. Replace the filter drain plug and tighten to the speci

fied torque, (Fig. 16-44).
Attention! With the engine Stop control set to the “OFF"

position, turn the engine with the starter motor until oil
pressure is registered on the gauge.
5. Start the engine and allow to idle for several minutes.

Check all joints for oil leaks.
April '96
REMOVING AND REPLACING THE OIL FILTER HEAD
Removing
1. Drain the filter bowl.
2. Remove the filter bowl and element, (Fig. 16-45).
Fig. 16-45
3. Unscrew and remove the feed pipe to injection pump,

(Fig. 16-46).
FicJ. 16-46
4. Unscrew and remove bolts retaining the filter head to

the crankcase, (Fig. 16-47).
5. Remove the filter head from the crankcase.
Note: New level oil filter elements have integrated seal

rings, and therefore the loose seal ring depicted in Fig.
16-47 will no longer be required.
Fi.q. 16-47
6. Unscrew and remove the oil filter by-pass valve from

the filter head, (Fig. 16-48).
mi » =
Fig. 16-48
April '96
7. R em ove th e oil filte r s e a l a n d re ta in in g sp rin g fr o m th e

filte r h e a d , (F ig . 1 6 - 4 9 ) .
N o te : T h is s e a l is n o w in te g ra l p a rt o f th e oil filte r
a s s e m b ly .
Fig . 1 6 - 4 9
8. T h o r o u g h ly c le a n a ll p a rts a n d b lo w o u t oil d rillin g s in

th e h e a d w ith c o m p r e s s e d a ir, (F ig . 1 6 - 5 0 ) .
llll A3 =
F ig . 1 6 - 5 0
R e p la c in g
1. U s in g a s p rin g te s te r , c h e c k th e b y -p a s s v a lv e s p rin g
te n s io n , r e p la c e if r e q u ire d , see s p e c ific a tio n s , (F ig .
1 6 -5 1 ).
F ig . 1 6 -5 1
2 F it a new oil filte r s e a l a n d r e ta in in g rin g to th e filte r

h e a d , (F ig . 1 6 - 5 2 ) .
m A»s
Fig. 16-52
April '96
3. U se a new g a s k e t, fit th e filte r h e a d to th e c r a n k c a s e

a n d in s e r t b o lts ,(F ig . 1 6 - 5 3 )
Fig . 1 6 - 5 3
4. T ig h t e n to th e s p e c ifie d to rq u e , (F ig . 1 6 - 5 4 ) .
F ig . 1 6 - 5 4
F it b y -p a s s v a lv e in to th e filte r h e a d a n d tig h te n th e
s c r e w p lu g to th e s p e c ifie d to rq u e , (F ig . 1 6 - 5 5 ) .
Fig . 1 6 - 5 5
6. C o n n e c t th e oil fe e d p ip e to th e in je c tio n pum p and

filte r h e a d , tig h te n th e s c re w p lu g to th e s p e c ifie d
to r q u e , (F ig . 1 6 - 5 6 ) .
Attention! A b a n jo c o n n e c tio n w ith a s m a ll h o le is fitte d to

th e filte r h e a d ; th is a p p lie s a r e s tric tio n to th e oil flo w a n d
s h o u ld n o t b e re v e r s e d .
Fig. 16-56
April '96
7 F it a n e w O -r in g to th e filte r b o w l, (F ig . 1 6 - 5 7 ) .
8. In s e r t a new o il filte r e le m e n t in to th e filte r b o w l,

(F ig . 1 6 - 5 8 ) .
9. F it th e filte r b o w l a n d e le m e n t to th e filte r h e a d , in s e rt
r e ta in in g b o lt a n d tig h te n to t h e s p e c ifie d to rq u e , (F ig .
1 6 -5 9 ).
1 0 . R e p la c e t h e filte r b o w l d r a in p lu g a n d tig h te n to th e
s p e c ifie d to r q u e , (F ig . 1 6 - 6 0 ) .
1 1 . W it h t h e e n g in e S to p c o n tro l s e t to th e “O F F " p o s itio n ,

is r e g is te r e d o n t h e g a u g e .
C h e c k a ll jo in ts fo r o il le a k s .
April '96
REMOVAL, STRIPPING, ASSEMBLY AND

REPLACEMENT OF OIL PUMP
Removal
1. D r a in e n g in e oil a n d r e m o v e th e s u m p , (F ig . 1 6 -6 1 ) .
F ig . 1 6 -6 1
2. R e m o v e oil p u m p r e ta in in g b o lts , (F ig . 1 6 - 6 2 ) .
F ig . 1 6 - 6 2
3. P u ll o u t oil p u m p fr o m c r a n k c a s e , (F ig . 1 6 - 6 3 ) .
F ig . 1 6 - 6 3
Stripping
1. C la m p th e oil p u m p in a v ic e fitte d w ith s o ft ja w s .
2. R em ove b o lts r e ta in in g th e s t r a in e r a n d p ic k -u p p ip e ,
(F ig . 1 6 - 6 4 ) .
3. R e m o v e th e p ic k -u p p ip e a n d s tra in e r fr o m th e oil
pu m p body.
Fig. 16-64
April '96
4 R em ove th e p r e s s u r e r e lie f v a lv e , s p rin g and p isto n

fr o m th e oil p u m p c o v e r, (F ig . 1 6 - 6 5 ) .
5. U n s c re w and r e m o v e th e b o lts r e ta in in g th e cover

p la te to th e oil p u m p b o d y , (F ig . 1 6 - 6 6 ) .
6. Lift o u t t h e oil p u m p g e a r fr o m th e oil p u m p b o d y , (F ig .

1 6 -6 7 ).
7. P re s s t h e oil p u m p s h a ft fr o m th e d r iv e g e a r , (F ig .
1 6 -6 8 ).
8. R em ove th e oil p u m p d riv e s h a ft fr o m th e b o d y , c o m

p le te w ith g e a r , (F ig . 1 6 - 6 9 ) .
9. P r e s s oil p u m p d r iv e s h a ft fr o m th e g e a r , (F ig . 1 6 - 7 0 ) .
1 0 . E x a m in e th e oil p u m p b o d y a n d g e a r s fo r s ig n s o f e x
c e s s iv e w e a r , s c o r in g and lo c a lis e d s e iz u r e . R e p la c e
a ll fa u lty p a rts . S h o u ld th e o il p u m p body or g e a rs
show s ig n s o f e x c e s s iv e w e a r th e c o m p le te oil p u m p
m u s t b e r e p la c e d .
Assembly
1. P r e s s g e a r o n to t h e oil p u m p d r iv e s h a ft, (F ig . 1 6 -7 1 ) .
2. C h e c k th e in s ta lla tio n h e ig h t o f th e g e a r to th e d riv e

s h a ft, (F ig . 1 6 - 7 2 ) .
April '96
3. In s e r t th e oil p u m p d r iv e s h a ft in to th e pum p body,

(F ig . 1 6 - 7 3 ) .
Fig . 1 6 -7 3
4. P re s s th e h e lic a l g e a r o n to th e s h a ft a n d b y u s in g a
v e r n ie r c h e c k th e d is ta n c e b e tw e e n th e g e a r a n d th e
p u m p fla n g e ; r e fe r to s p e c ific a tio n s fo r th e c o rr e c t d is
ta n c e , (F ig . 1 6 - 7 4 ) .
c
0
d
■nil
F ig . 1 6 - 7 4
5. In s e r t th e oil p u m p d r iv e n g e a r in to th e p u m p b o d y ,
(F ig . 1 6 - 7 5 ) .
F ig . 1 6 - 7 5
6. C h e c k th e c le a r a n c e b e tw e e n th e o il p u m p g e a r s a n d
h o u s in g , (F ig . 1 6 - 7 6 ) .
iiiiaas
fig. 16-76
April '96
7. C heck th e c le a r a n c e b e tw e e n c o v e r p la te a n d g e a rs ,
(F ig . 1 6 - 7 7 ) .
F ig . 1 6 - 7 7
8. R e p la c e th e oil p u m p p la te , in s e rt b o lts a n d tig h te n to

t h e s p e c ifie d to rq u e , (F ig . 1 6 - 7 8 ) .
■in /© =
F ig . 1 6 - 7 8
9. F it oil r e lie f v a lv e in to th e oil p u m p c o v e r p la te a n d

tig h te n to th e s p e c ifie d to rq u e , (F ig . 1 6 -7 9 ) .
F ig . 1 6 - 7 9
1 0 . P r im e t h e oil p u m p w ith e n g in e oil.
1 1 . B o lt th e oil s u c tio n p ip e a n d s tr a in e r to th e oil p u m p

b o d y a n d tig h te n to t h e s p e c ifie d to rq u e , (F ig . 1 6 -8 0 ) .
^51
Fig. 16-80
April '96
12 . F it th e s t r a in e r to th e s u c tio n p ip e , {F ig 1 6 -8 1 )
F ig . 1 6 -8 1
13. In s e r t th e o il p u m p in to th e c ra n k c a s e , r e p la c e th e
re ta in in g b o lts a n d tig h te n to t h e s p e c ifie d to rq u e , (F ig .
1 6 -8 2 ) .
F ig . 1 6 - 8 2
14. F it n e w s u m p g a s k e ts to th e c r a n k c a s e , (F ig . 1 6 -8 3 ) .
F ig . 1 6 - 8 3
1 5 . R e p la c e th e sum p, in s e r t th e b o lts a n d tig h te n to th e

s p e c ifie d to rq u e , (F ig . 1 6 - 8 4 ) .
1 6 . F ill th e s u m p w ith r e c o m m e n d e d oil.
1 7 . W it h t h e e n g in e S to p c o n tr o l s e t to t h e “O F F " p o s itio n ,
is r e g is te r e d o n t h e g a u g e .
C h e c k a ll jo in ts fo r o il le a k s .
Fig. 16-84
April ‘96
SECTION 17
Fuel System
Page
ILLU S TR A TIO N .......................................................................................................................................................................................... 17-2
IN T R O D U C T IO N ........................................................................................................................................................................................ 17-3
S P E C IF IC A T IO N S ..................................................................................................................................................................................... 17-3
REM OVING THE INJECTION P U M P .................................................................................................................................................. 17-4
REPLACING THE INJECTION P U M P .................................................................................................................................................. 17-5
SETTING “A" TYPE INJECTION PUMP TIMING .............................................................................................................................. 17-7
SETTING “ M W ” TYPE INJECTION PUMP T IM IN G .......................................................................................................................... 17-10
REM OVAL AND REPLACEM ENT OF FUEL IN JE C T O R S .............................................................................................................. 17-13
TESTING THE INJECTOR FOR LEAKAGE.........................................................................................................................................17-15
TESTING THE NOZZLE OPENING AND INJECTION P R E S S U R E ......................................................... 17-16 ’-16
JET SPRAY T E S T ..................................................................................................................................................................................... 17-16
DISM ANTLING AND ASSEMBLY OF FUEL INJECTO RS............................................................................................................... 17-16
ASSEM BLY OF THE NOZZLE . II
SPECIAL TOO LS FOR SECTION 1 7 ................................................................................................................................................... 17-19
A pril '96
Fuel System 17-2
INJECTION SYSTEM
1 S E A L IN G W A S H E R 14 S E A L IN G W A S H E R
2 B A N JO B O LT 15 IN J E C T O R A S S E M B L Y
3 S P L IT S E A L 16 IN J E C T O R S E C U R I N G N U T
4 IN J E C T O R P IP E S 17 NOZZLE
5 CLAM P 18 CAP NUT
6 CLAM P 19 SPACER
7 S P R IN G W A S H E R 20 T H R U S T P IN
8 SCREW 21 S P R IN G
9 “A" T Y P E I N J E C T IO N P U M P 22 S H IM
10 “M W " T Y P E IN J E C T IO N P U M P 23 S C R E W PLUG
11 C L IP 24 S P L IT S E A L
12 P A C K IN G 25 CONNECTOR
13 CLAM P 26 L E A K - O F F P IP E
April ‘96
Fuel System 17-3
INTRODUCTION
T h e A D E 3 6 0 s e rie s o f e n g in e s a r e fitte d w ith tw o ty p e s o f B o s c h fu e l in je c tio n p u m p s . T h e s u c c e s s fu l “A" ty p e in je c tio n

p u m p is fitte d to th e n a tu r a lly a s p ir a te d e n g in e , a n d th e " M W " ty p e fu e l in je c tio n p u m p is u s e d on th e tu rb o c h a r g e d
e n g in e . T h e “M W " fu e l in je c tio n p u m p , b e in g o f a la r g e r a n d m o r e rigid d e s ig n , e n a b le s it to p r o v id e h ig h e r p re s s u re s ,
a llo w in g th e tu r b o c h a r g e d e n g in e to d e v e lo p g r e a te r p o w e r a n d a h ig h e r to rq u e
SPECIFICATIONS
FUEL SYSTEM
In je c tio n p u m p a n d g o v e r n o r BOSCH
In je c tio n p r e s s u r e New 2 0 ,0 to 2 0 ,8 M P a
U sed m in . 1 8 ,0 M P a
In je c tio n p u m p tim in g r e fe r e n g in e n u m b e r 364N 19° B TD C

D a ta p la te - o th e r w is e u s e 3 6 4 C /T /T I 15° B TD C
tim in g a s lis te d 366N 19° B TD C
3 6 6 C /T 16° B TD C
3 6 6 T I - up to 1 5 0 k W 16° B T D C
36 6T I - above 150 kW 12° B TD C
F u e l lift p u m p d e liv e r y p r e s s u r e 80 kPa
Id le s p e e d 6 0 0 r/m in
In je c to r p ro te c tio n s l e e v e ..................... ....................................................... M 1 4 x 1 ............................................................... 5 0 N m

In je c to r s e c u r in g n u t................................. ....................................................... M 3 4 x 1 , 5 .......................................................... 7 0 N m
In je c to r c a p n u t to n o z z le b o d y ......... ....................................................... M 2 4 x 1 . 5 .......................................................... 8 0 N m
S tu d fo r in je c tio n p u m p m o u n tin g ... ....................................................... M 1 0 ...................................................................... 1 0 - 2 0 N m
In je c tio n p u m p g e a r to p u m p ............. ....................................................... M 1 4 x 1 , 5 .......................................................... 8 0 N m
In je c to r p ip e n u ts to in je c tio n p u m p ....................................................... M 1 2 x 1 , 5 .......................................................... 2 5 N m
In je c to r p ip e n u ts to in je c t o r ............... ........................................................M 1 4 x 1 , 5 .......................................................... 2 5 N m
P r e s s u r e /R e tu r n p ip e a d a p t e r to cyl h e a d .......................................... M 2 2 x 1 , 5 10 N m
....................................................... M 1 6 x 1 , 5 ............ 10 N m
L e a k o ff p ip e to in je c t o r s ...................... ....................................................... M 8 x 1 ................................................................ 2 0 N m
S u p p ly a n d re tu rn p ip e c o n n e c tio n s ....................................................... M 1 4 x 1 . 5 .......................................................... 3 5 N m
In je c tio n p u m p s u p p o r t........................... ....................................................... M 8 ......................................................................... 3 5 N m
D e liv e r y v a lv e h o ld e r:
“A" ty p e p u m p .............................................. ....................................................... s ta g e 1 ...............................................................4 0 N m *
s ta g e 2 ............................................................ 4 0 N m *
s ta g e 3 ............................................................ 4 0 N m *
F in a l t o r q u e .................................................. 4 5 N m
* L o o s e n a f te r 1s t, 2 n d a n d 3 rd s ta g e s
“M W " ty p e p u m p ............................................... 50 - 60 Nm
8 m m n u t ................................................................. 12 - 16 Nm
April '96
Fuel System 17-4
REMOVING THE INJECTION PUMP
1 D e ta c h th e oil fille r p ip e o r b r e a th e r fr o m th e tim in g

c a s e ( if fitte d ) o r r e m o v e th e b la n k in g p lu g , (F ig . 1 7 -1 ).
2. R e m o v e th e r o c k e r c o v e r, (F ig . 1 7 -2 ).
Fi g. 1 7 -2
3. T u rn th e e n g in e in th e n o r m a l d ire c tio n o f r o ta tio n un til
th e N o . 1 p is to n is on c o m p r e s s io n s tro k e a n d th e
m a r k on th e v ib ra tio n d a m p e r is in lin e w ith ( F B ) p o in
te r on th e tim in g c a s e , (F ig . 1 7 -3 ).
Attention! Never turn the engine in the reverse direction

of rotation.
Fi
4. D is c o n n e c t th e fu e l filte r, fu e l a n d oil fe e d p ip e s to th e
in je c tio n pum p, (F ig . 1 7 - 4 ) .
Fig. 17-4
April ‘96
Fuel System 17-5
5. U se s p e c ia l to o l, p a rt n u m b e r 4 0 2 0 0 7 0 5 , to u n s c r e w
and d e ta c h th e in je c to r p ip e s fr o m th e in je c tio n p u m p
, (F ig . 1 7 - 5 ) .
6. U n s c re w and r e m o v e n u ts re ta in in g th e in te r m e d ia te
fla n g e o f th e in je c tio n p u m p to th e tim in g h o u s in g . F it
p r o te c tiv e d u s t c a p s ,( F ig . 1 7 - 6 )
7. L ift o ff th e in je c tio n p u m p , (F ig . 1 7 -7 ).
Fig . 1 7 -7
REPLACING THE INJECTION PUMP
1. T u rn th e e n g in e in th e n o r m a l d ire c tio n o f r o ta tio n u n til .

No. 1 p is to n is on c o m p r e s s io n s tro k e . T h e m a r k on
th e v ib ra tio n d a m p e r m u s t b e in lin e w ith th e (F B )
p o in te r o n t h e tim in g c a s e (F ig . 1 7 - 8 )
Fig. 17-8
April '96
Fuel System 17-6
2. R e p la c e in je c tio n p u m p fla n g e g a s k e t, in s e rt th e p u m p
in to th e tim in g h o u s in g and e n s u r e th a t th e m a r k on
th e in je c tio n p u m p g e a r to o th lin e s u p w ith th e a r ro w in
th e tim in g c a s e , (F ig . 1 7 - 9 0 ) .
(R e f e r fig. 1 7 - 1 6 o h p a g e 1 7 -7 ).
F ig . 1 7 -9
3. R e p la c e th e in je c tio n p u m p re ta in in g n u ts a n d tig h te n
to th e s p e c ifie d to r q u e (F ig . 1 7 - 1 0 ) .
F ig . 1 7 - 1 0
4. S e t s ta rt o f d e liv e r y ( R e f e r to in je c tio n p u m p tim in g
F ig . 1 7 - 1 4 )
5 A tta c h in je c to r p ip e s to th e in je c tio n p u m p . U s e s p e c ia l
to o l p a rt N o . 4020 0718 to tig h te n a ll c o n n e c tio n s to
th e s p e c ifie d to rq u e , (F ig . 1 7 - 1 1 )
F ig . 1 7 -1 1
6. A tta c h th e fu e l a n d oil fe e d p ip e s to th e in je c tio n p u m p
a n d tig h te n to th e s p e c ifie d to rq u e . R e p la c e th e b r e a th e r
p ip e o r p lu g . (F ig . 1 7 - 1 2 )
7 R e p la c e r o c k e r c o v e r.
Fig.17-12
April '96
Fuel System 17-7
SETTING “A" TYPE INJECTION PUM P TIMING
1. R e m o v e r o c k e r c o v e r , (F ig . 1 7 - 1 3 )
F ig . 1 7 -1 3
2. T u rn e n g in e in th e d ire c tio n o f r o ta tio n u n til No. 1
p is to n is o n c o m p r e s s io n s tro k e a n d th e m a r k o n th e
v ib ra tio n d a m p e r is in lin e w ith th e p o in te r o n th e
tim in g c a s e , (F ig . 1 7 - 1 4 )
/v N \
1- - 1
m k
M ill « S
F ig . 1 7 - 1 4
3. D e ta c h th e o il fille r p ip e o r b r e a th e r fr o m th e tim in g
case ( if fitte d ) o r r e m o v e th e b la n k in g p lu g , (F ig .
1 7 -1 5 ).
F i g .1 7 -1 5
4. C h e c k to e n s u r e t h a t th e m a r k e d to o th on th e in je c tio n
p u m p g e a r is in lin e w ith th e p o in te r in th e tim in g g e a r
c o v e r, (F ig . 1 7 - 1 6 ) .
Fig.17-16
April '96
Fuel System 17-8
5. D is c o n n e c t a ll in je c to r p ip e s fr o m th e in je c tio n p u m p
u s in g s p e c ia l to o l p a r t n u m b e r 4 0 2 0 0 7 0 5 . ( F ig .1 7 -
1 7 ).
6. A tta c h P re s s u re L im itin g V a lv e s , s p e c ia l to o ls p a rt
num ber 40 20 2376, to in je c tio n p u m p o u tle ts n u m b e r s
2 to 6 . ( R e f F ig . 1 7 - 1 8 )
7 Pump Unit ( R e f fig .1 7 - 1 9 )
Item 1 Electric Motor

Item 2 Gear Pump
Item 3 Pressure Limiting Valve
Item 4 Fuel Tank.
Item 5 Return Line.
Item 6 Test Line with Sightglass.
Item 7 12v connection cablel
Item 8 Connection line (supply)
Item 9 Base plate
tern 10 Relay box with switch
8 . D e ta c h fu e l s u p p ly lin e at pum p and c o n n e c t s u p p ly

lin e ( 8 ) o f th e p u m p u n it ( R e f F ig 1 7 - 2 0 )
9 D e ta c h fu e l re tu rn lin e ( 1 2 ) a n d o v e r flo w v a lv e a t th e
in je c tio n p u m p a n d s e a l b o re w ith a d u m m y p lu g .(1 3 ).
10. T o th e N o 1 o u tle t o f th e fu e l p u m p c o n n e c t th e te s t
lin e w ith s ig h tg la s s ( R e f ( 6 ) F ig . 1 7 - 2 0 ) .
April '96
Fuel System 17-9
1 1 . T u r n th e c r a n k s h a ft in th e d ire c tio n o f r o ta tio n u n til it
is a p p ro x . h a lf a tu rn b e fo r e T .D .C . of th e No. 1
c y !in d e r .(R e f . F i g 1 7 - 2 1 )
12. L o c k th e in je c tio n p u m p le v e r a t F u ll lo a d p o s itio n
N o te :-B e fo re s w itc h in g on th e Test Pum p U n it th e

in je c tio n p u m p le v e r m u s t b e lo c k e d a t fu ll lo a d a n d
m u s t n o t b e m o v e d w h e n th e p u m p u n it is ru n n in g .
S w itc h o n th e T e s t P u m p U n it o n ly w h ile p e rfo rm in g
m e a s u re m e n t
13. S w itc h o n th e T e s t P u m p U n it th e n s lo w ly r o ta te th e
c r a n k s h a ft in t h e d ire c tio n o f r o ta tio n and o b s e rv e
th e fu e l je t in th e s ig h t g la s s . - T h e e x a c t s ta rt of
d e liv e r y is r e a c h e d w h e n t h e fu e l je t c h a n g e s fro m a
ta p e r e d je t s t r e a m to a c h a in o f d ro p s .
A = ‘ F u ll * fu e l je t
B .= F u e l j e t t a p e r e d - s h o r tly b e fo r e s ta rt o f d e liv e ry
C .= C h a in o f d r o p s = s ta r t o f d e liv e ry
1 4 .C h e c k s ta r t o f d e liv e r y m a r k in g b e tw e e n s e ttin g p o in te r
on tim in g c a s e a n d m a r k in g o n v ib ra tio n d a m p e r o r b e lt
p u lle y . R e f. F ig . 1 7 - 2 3 )
1 5 If it is n e c e s s a r y to c o r r e c t t h e s ta r t o f d e liv e ry o f th e
in je c tio n pum p, th e c r a n k s h a ft s h o u ld be tu rn e d in
d ire c tio n of r o ta tio n e x a c x tly to th e s ta rt of d e liv e ry
m a r k in g o f s e ttin g p o in te r w ith v ib ra tio n d a m p e r o r b e lt
p u lle y .
16. S la c k e n th e n u ts (1 3 ) s e c u rin g th e in je c tio n

p u m p . (R e f .F ig . 1 7 - 2 4 )
N o t e : - T h e in je c tio n p u m p le v e r m u s t b e lo c k e d a t fu ll lo a d
a n d m u s t n o t b e m o v e d w h e n th e p u m p u n it is ru n n in g .
S w itc h on th e pum p u in it o n ly fo r p e rfo rm in g
m e a s u r e m e n t o t h e r w is e fu e l m a y g e t in to th e c o m b u s tio n
c h a m b e r if th e n o z z le is le a k in g
April '96
Fuel System 17-10
1 7 .M o v e th e in je c tio n pum p on th e s lo tte d h o le s fa r
e n o u g h to a c h ie v e e x a c t s ta rt o f d e liv e ry
8 .R e -tig h te n th e h e x .n u ts (1 3 ) of in je c tio n pum p to

s p e c ifie d to r q u e
19 . R e p e a t te s tin g o f s ta r t o f d e liv e r y o p e r a tio n s 11 to 1 4

above
20. R e m o v e th e P r e s s u r e lim itn g v a lv e a n d th e te s t lin e

fitte d to n o .1 c y lin d e r and r e a s s e m b le in je c tio n
p ip e s .R e f. F IG . 1 7 - 2 6
2 1 . R e p la c e th e oil fille r p ip e / b r e a th e r o r b la n k in g p lu g to
th e tim in g c a s e . R e f. F ig . 1 7 -2 7 .
SETTING “ MW” TYPE INJECTION PUMP TIMING
Note:
W ith th e fittin g o f t h e “M W " in je c tio n p u m p to th e A D E 3 6 0
s e rie s tu r b o c h a r g e d e n g in e th e tim in g p r o c e d u re has
c h a n g e d . It is n o lo n g e r a d v is a b le to r e m o v e th e d e liv e ry
v a lv e w h e n c a rr y in g o u t th e s p ill tim in g . O n c e th e v a lv e
h a s b e e n r e m o v e d th e v a lv e s e a l c o u ld b e d a m a g e d a n d
c a u s e a le a k to d e v e lo p a t h ig h p r e s s u r e .
2. T u rn th e e n g in e in th e d ire c tio n o f r o ta tio n a n d p o s itio n

N o . 1 c y lin d e r o n firin g s tro k e ± 4 5 d e g r e e s b e fo r e to p
d e a d c e n tr e , (F ig . 1 7 - 2 8 ) .
April '96
Fuel System 17-11
3. R em ove th e lo w p r e s s u r e p ip in g to a n d fr o m th e in je c
tio n p u m p and fu e l filte rs . N o te p o s itio n of g a lle r y
p res su re v a lv e N o . 1 a n d fu e l s u p p ly to g a lle r y N o . 2,
(F ig . 1 7 - 2 9 ) .
4. F it th e s u p p ly p ip e fr o m th e p r e s s u r e sp ill p u m p to th e
fr o n t end o f th e in je c tio n p u m p g a lle ry . F it a b la n k in g
p lu g to th e r e a r e n d o f th e g a lle ry .
(S p ill p u m p p a r t n u m b e r 4 0 2 0 2 3 6 3
o r a lt e r n a t iv e ly 4 0 2 0 - 2 4 6 0 )
5. D is c o n n e c t a ll in je c to r p ip e s and th e r e s p e c tiv e d e li

v e ry v a lv e u n io n s o n th e in je c tio n p u m p . F it p r e s s u re
r e lie f v a lv e u n io n s , (F ig . 1 7 - 3 1 ) .
6. C onnect th e p r e s s u r e sp ill p u m p re tu rn p ip e w ith spill

p ip e to th e N o . 1 d e liv e ry v a lv e u n io n , (F ig . 1 7 -3 2 ) .
7. M ove th e a c c e le r a to r c o n tro l le v e r on th e in je c tio n

p u m p to th e fu ll s p e e d p o s itio n .
April '96
Fuel System 17-12
8. C o n n e c t th e p re s s u re s p ill p u m p to a s u ita b le p o w e r
s u p p ly ; e n s u r e t h a t th e pum p p res su re is a p p ro x .
2 5 0 0 kPa.
9. C o n tin u e tu rn in g th e e n g in e in th e n o rm a l d ire c tio n o f

r o ta tio n u n til th e fu e l d is c h a r g e in th e g la s s b o w l c h a n
g e s fr o m a ta p e r e d je t s t r e a m to a c h a in o f d ro p s ,
(F ig . 1 7 - 3 3 ) .
10. C h e c k th e tim in g m a r k s ( F B ) on th e tim in g c o v e r a n d

v ib ra tio n d a m p e r fo r a lig n m e n t, (F ig . 1 7 - 3 4 ) .
11. If th e tim in g Is r e ta r d e d lo o s e n th e in je c tio n pum p

s e c u rin g n u ts a n d m o v e th e to p o f th e in je c tio n p u m p
to w a r d s th e c y lin d e r b lo c k or a w a y fr o m th e c y lin d e r
b lo c k to a d v a n c e , (F ig . 1 7 - 3 5 ) .
12 . A fte r a d ju s tm e n t r e -c h e c k th e tim in g b y r e p e a tin g o p e

ra tio n s 2 to 9.
13. T ig h te n th e n u ts re ta in in g th e in je c tio n p u m p to th e
tim in g g e a r h o u s in g , (F ig . 1 7 - 3 6 ) .
April '96
Fuel System 17-13
1 4 . R e m o v e th e b la n k in g p lu g a n d h ig h p r e s s u r e p ip e fro m
th e te s t pum p. R e c o n n e c t th e g a lle r y p r e s s u r e v a lv e
and t h e lo w p r e s s u r e fe e d to th e p u m p a n d tig h te n to
th e s p e c ifie d to rq u e .
1 5 . R e c o n n e c t th e in je c to r p ip e s a n d tig h te n th e b o tto m
u n io n s to th e s p e c ifie d to rq u e , (F ig . 1 7 - 3 7 )
1 6 . R e p la c e r o c k e r c o v e r.
REMOVAL AND REPLACEMENT OF FUEL INJECTORS
Removal
2. U s e s p e c ia l to o l, p a r t n u m b e r 4 0 2 0 0 7 0 5 , a n d u n s c re w
th e p ip e s to th e fu e l in je c to r. P ush th e in je c to r p ip e to
o n e s id e . D o n o t b e n d th e p ip e , F ig . 1 7 -3 8 ) .
3. D is c o n n e c t t h e fu e l le a k o ff p ip e , (F ig . 1 7 -3 9 ) .
4. R em ove th e in je c to r s e c u r in g n u t w ith s p e c ia l to o l
4 0 2 0 0 8 7 3 , (F ig . 1 7 - 4 0 ) .
Fig. 17-40
April '96
Fuel System 17-14
5. Use s p e c ia l to o l 4 0 2 0 1 0 7 6 to pu ll th e in je c to r o u t o f
th e c y lin d e r h e a d , (F ig . 1 7 - 4 1 ) .
6. If to o tig h t w it h d r a w th e in je c to r w ith s p e c ia l e x tra c to r,

p a rt n u m b e r 4 0 2 0 1 0 6 3 , (F ig . 1 7 - 4 2 ) .
K e e p m a tc h e d w a s h e r w ith th e r e s p e c tiv e in je c to r.
A tte n tio n ! S e e s e c tio n 1 2 fo r r e m o v a l a n d r e p la c e m e n t

o f in je c to r p ro te c tio n s le e v e s
1. In s e r t a n e w in je c to r s e a lin g w a s h e r in to th e c y lin d e r
h e a d , (F ig . 1 7 - 4 3 ) .
N o te : T h e n e w s e a lin g w a s h e r s m u s t b e th e s a m e s iz e
a n d th ic k n e s s a s th e o n e s r e m o v e d .
2. In s e r t in je c to r in to th e c y lin d e r h e a d and lo c a te th e
n o tc h on th e in je c to r w ith th e g r o o v e in th e c y lin d e r
h e a d , (F ig . 1 7 - 4 4 ) .
Fig. 17-44
April '96
Fuel System 17-15
3. R e p la c e th e in je c to r s e c u rin g nut and use a to rq u e

w r e n c h fitte d w ith s p e c ia l to o l 4 0 2 0 0 8 7 3 to tig h te n to th e
s p e c ifie d to rq u e , (F ig . 1 7 - 4 5 )
4. R e p la c e th e fu e l le a k o ff p ip e fitte d w ith new s e a lin g

w a s h e r s a n d tig h te n to th e s p e c ifie d to rq u e , (F ig . 1 7 - 4 6 )
5. R e p la c e th e p r e s s u r e p ip e to th e fu e l in je c to r a n d u s e
s p e c ia l to o l 4020 0718 to tig h te n to th e s p e c ifie d
t o r q u e ,( F ig 1 7 - 4 7 )
TESTING THE INJECTOR FOR LEAKAGE
1. W it h s p e c ia lis e d n o z z le c le a n in g e q u ip m e n t c a re fu lly
re m o v e c a rb o n d e p o s its fr o m th e in je c to r n o z z le tip
h o le s , (F ig . 1 7 - 4 8 )
April ‘96
Fuel System 17-16
2 . A tta c h th e in je c to r to th e te s te r , (F ig . 1 7 - 4 9 )
Attention ! O n ly u s e c le a n te s tin g flu id o r filte re d d ie s e l fu e l fo r

te s tin g p u rp o s e s .
Note: C a r e m u s t b e ta k e n d u rin g te s tin g a s th e s p ra y is u n d e r

c o n s id e r a b le p r e s s u r e a n d w o u ld p e n e tr a te th e sk in o f
h a n d s o r fa c e
3. S lo w ly p re s s d o w n th e p u m p te s te r le v e r u n til th e p re s s u re
gauge show s 200 kPa b e lo w o p e n in g p r e s s u r e o f th e
in je c to r n o z z le . T h e in je c to r is fa u lty if fu e l le a k s fr o m th e
n o z z le w ith in 10 secon ds.
4 In a ll c a s e s o f s ie z u r e o r le a k a g e d is m a n tle a n d c le a n th e
in je c to r. T h e n o z z le m u s t b e r e p la c e d if c a re fu l c le a n in g
F ig . 1 7 -4 9
TESTING NOZZLE OPENING AND INJECTION PRESSURE
1. A tta c h in je c to r to te s te r .
2. S lo w ly a d v a n c e th e p u m p te s t l e v e r ; n o te th e p r e s s u r e w h e n
th e in je c to r o p e n s , (F ig . 1 7 - 5 0 )
3. T h e in je c to r p r e s s u r e m a y b e a d ju s te d b y a d d in g o r re m o v in g
s h im s on to p o f t h e c o m p r e s s io n s p rin g .
JET SPRAY TEST
1. T u rn o ff th e p r e s s u r e g a u g e .
2. O p e r a t e th e h a n d p u m p le v e r (s e v e r a l b ris k s tro k e s ).T h e

in je c tio n is c o rr e c t w h e n all fo u r je t s s p ra y fin e a n d e v e n , (F ig
1 7 -5 1 )
DISMANTLING AND ASSEMBLY OF FUEL INJECTORS
1 . C la m p s p e c ia l in je c to r s u p p o r t 4 0 2 0 0 9 1 2 in a v ic e .
2. In s e r t th e in je c to r in to th e h o ld e r, (F ig . 1 7 - 5 2 )
Fuel System 17-17
3. W it h s p e c ia l to o l 4020 0925 u n s c re w th e in je c to r
n o z z le c a p n u t fr o m th e in je c to r b o d y a n d d is m a n tle
th e in je c to r a s s e m b ly , (F ig . 1 7 - 5 3 ) .
Fig. 1 7 - 5 3
4. C a r e fu lly r e m o v e c a rb o n d e p o s its fr o m in je c to r h o le s ,
(F ig . 1 7 - 5 4 )
5. D ip n e e d le v a lv e a n d n o z z le b o d y in to c le a n d ie s e l fu el
a n d c a r y o u t d r o p te s t, s e e o p e r a tio n 6 b e lo w .
Fig. 1 7 - 5 4
6. L ift n e e d le v a lv e b y a p p r o x im a t e ly o n e th ird o f its
le n g th fr o m th e n o z z le b o d y . R e le a s th e n e e d le v a lv e
s o t h a t it r e tu rn s to its s e a t u n d e r its o w n w e ig h t, (F ig .
1 7 -5 5 )
If th e n e e d le v a lv e s tic k s b e fo r e r e a c h in g th e s e a t ,
r e p la c e th e c o m p le te n o z z le a s s e m b ly .
F ig . 1 7 -5 5
ASSEMBLY OF THE NOZZLE
1. In s e r t th e in je c to r b o d y in to s p e c ia l h o ld in g to o l 4020
0 9 1 2 , (F ig . 1 7 - 5 6 )
Fig. 17-56
April '96
Fuel System 17-18
2. In s e r t s h im (2 ), s p rin g (3 ), th ru s t pin ( 4 ), a d a p t o r ( 5 ) in to th e
in je c to r b o d y (1 ). In s e r t th e n e e d le v a lv e ( 6 ) in to th e n o z z le
(7 ). P la c e th e n o z z le o n to th e a d a p t o r ( 5 ), (F ig . 1 7 - 5 7 )
F ig . 1 7 - 5 7
3. T w o g u id e p in s a r e fitte d o n b o th s id e s o f th e a d a p te r . T h e
g u id e p in s w h ic h lo c a te in th e c o rr e s p o n d in g h o le s in th e
n o z z le h o ld e r a r e in d iffe r e n t p o s itio n to th e tw o p in s w h ic h
lo c a te th e n o z z le . In c o r re c t fit m e n t o f th e a d a p t e r is th e r e fo re
im p o s s ib le . T h e a d a p t e r f a c e w h ic h m a te s w ith th e n o z z le is
c h a m fe r e d a t th e e d g e , (F ig . 1 7 - 5 8 ) .
F ig 1 7 -5 8
4. S c r e w in je c to r c a p n u t ( 8 ) o n to th e in je c to r b o d y (1 ), (F ig . 1 7
5 9 ).
F ig . 1 7 -5 9
5. U s e s p e c ia l to o l 4020 0925 to tig h te n th e in je c to r c a p to th e
s p e c ifie d to rq u e , (F ig . 1 7 - 6 0 )
Fig. 17-60
Fuel System 17-19
SPEC IA L TOO LS FOR SECTION 17
O B T A IN A B L E F R O M : G R U N D Y T E C H N IF O R M , B U R M A N R O A D , D E A L P A R K , P O R T E L IZ A B E T H 6 0 0 1
TE L: (0 4 1 ) 4 3 -2 2 9 9 , FA X : (0 4 1 ) 4 3 -2 2 2 4
S p lit rin g s p a n n e r fo r
in je c to r p ip e s
s e e fig. 1 7 -5 , 1 7 -1 8
p a rt n u m b e r 4 0 2 0 0 7 0 5
C r o w fo o t rin g s p a n n e r fo r
r e m o v in g /r e p la c in g in je c to r p ip e s
s e e fig . 1 7 - 1 1 , 1 7 -2 6 , 1 7 - 4 7
p a rt n u m b e r 4 0 2 0 0 7 1 8
S p ill p ip e
s e e fig . 1 7 - 2 0
p a rt n u m b e r 4 0 2 0 0 8 6 0
F u e l c o n ta in e r fo r c h e c k in g s ta rt
o f d e liv e ry
s e e fig . 1 7 -2 1
p a rt n u m b e r 4 0 2 0 0 8 5 7
S o c k e t fo r in je c to r s e c u rin g nu ts
s e e fig. 1 7 - 3 2
p a rt n u m b e r 4 0 2 0 0 8 7 3
F u e l in je c to r im p a c t e x tra c to r
s e e fig . 1 2 -1 2
p a rt n u m b e r 4 0 2 0 1 0 7 6
April ‘96
Fuel System 17-20
E x tr a c to r fo r in je c to rs
s e e fig. 1 2 - 1 3
p a rt n u m b e r 4 0 2 0 1 0 6 3
S u p p o r t fo r s trip p in g a n d
a s s e m b lin g in je c to rs , s e e fig . 1 7 -4 4
p a rt n u m b e r 4 0 2 0 0 9 1 2
S p a n n e r fo r s trip p in g a n d
a s s e m b lin g in je c to rs , 2 2 m m
s e e fig . 1 7 - 4 5
p a rt n u m b e r 4 0 2 0 0 9 2 5
P r e s s u re r e lie f v a lv e (s e t o f 5 )
fo r b la n k in g o ff th e d e liv e ry v a lv e
s e e fig . 1 7 - 3 2
p a rt n u m b e r 4 0 2 0 2 3 7 6
P r e s s u re s p ill tim in g p u m p
s e e fig. 1 7 - 3 3
p a rt n u m b e r 4 0 2 0 2 3 6 3
A lte r n a tiv e p a rt n u m b e r 4 0 2 0 2 4 6 0
J .S . B a r n e s tim in g u n it a v a ila b le fro m :
P r o -H y d Im p o r t & E x p o rt ( P ty ) Ltd.
111 T e n th R o a d , K e w
J o h a n n e s b u rg
A p ril '9 6
SECTION 18A-1
Turbocharger
CONTENTS OF SECTION 18A
Page
I L L U S T R A T IO N KKK T U R B O C H A R G E R ........................................................................................................................................................................ 1 8 A -2
I L L U S T R A T IO N GARRETT T U R B O C H A R G E R ........................................................................................................................................................... 1 8 A - 3
S P E C I F I C A T I O N S - K K K 8c G A R R E T T ................................................................................................................................................................................1 8 A -4
I N T R O D U C T I O N ................................................................................................................................................................................................................................ 1 8 A -5
R E M O V A L ............................................................................................................................................................................................................................................... 1 8 A -6
M E A S U R I N G T U R B O C H A R G E R S H A F T E N D P L A Y .................................................................................................................................................1 8 A -7
M E A S U R IN G T U R B O C H A R G E R S H A F T S ID E P L A Y ............................................................................................................................................... 1 8 A -8
D IS M A N T L IN G ......................................................................................................................................................................................................................1 8 A - 9
A S S E M B L Y ......................' .................................................................................................................................................................................................... 1 8 A -1 5
R E P L A C E M E N T ...............................................................................................................................................................................................................................1 8 A - 2 2
I N T E R C O O L E R ................................................................................................................................................................................................................................ 1 8 A - 2 5
April ‘96
Turbocharger 18A-2
KKKTURBO CHARG ER
1 T U R B IN E W H E E L A N D S H A F T A S S E M B L Y 1 2 T H R U S T B E A R IN G
2 S E A L IN G R IN G S 13 O IL D E F L E C T O R
3 H E A T S H IE L D 14 SPACER
4 C IR C U P 15 S E A L C A R R IE R /T H R U S T W A S H E R
5 B E A R IN G 16 S E A L IN G R IN G S
6 C IR C L IP 17 O - R IN G
7 B E A R IN G H O U S I N G 18 E N D PLATE
8 C IR C L IP 19 SOCKET CAP SCREW
9 B E A R IN G 20 COM PRESSOR ROTO R W HEEL
10 C IR C L IP 21 COM PRESSOR ROTO R W HEEL
11 THRUST W ASHER R E T A IN IN G L O C K N U T
April '96
Turbocharger 18A-3
Garrett AiResearch
1 C O M P R E S S O R R O T O R W H E E L R E T A IN IN G N U T 11 S P R I N G L O C A T IN G P IN S
2 CO M PRESSO R ROTO R W HEEL 12 B E A R IN G H O U S I N G
3 EN D PLATE 13 C IR C L IP
4 O -R IN G 14 B E A R IN G
5 S E A L IN G R IN G 15 C IR C L IP
6 S E A L C A R R IE R /T H R U S T W A S H E R 16 H E A T S H IE L D
7 C IR C L IP 17 LO CK PLATE
8 B E A R IN G 18 B OLT
9 C IR C L IP 19 S E A L IN G R I N G
10 T H R U S T B E A R IN G 20 T U R B IN E W H E E L A S S E M B L Y
April '96
Turbocharger 18A-4
S P E C IF IC A T IO N S F O R K K K T U R B O C H A R G E R
R o to r s h a ft - end p la y 0 15 m m m ax
s id e p l a y 0 ,4 5 m m m a x .
ru n o u t 0 ,0 0 7 m m m ax.
E n d p l a t e ............................................................ 8-10 Nm
C o m p r e s s o r ro to r w h e e l re ta in in g n u t.......................................... 1 s t.s t a g e .................................................................................................................... 1 0 N m
2 n d s t a g e ............................................................................. a n g le o f r o ta tio n +60°
T u r b in e h o u s in g to c e n tr e h o u s in g .........................................................................................................................................................................................2 0 N m
C o m p r e s s o r h o u s in g to c e n tr e h o u s in g ................................................................................................................................................................................. 7 N m
O il r e t u r n M8 - 25 Nm
O il s u p p ly M8 - 25 Nm
O il s u p p ly b a n jo b o l t ........................................................................................................................................................................................................................ 40 N m
T u r b o c h a r g e r to e x h a u s t m a n if o ld .......................................................................................................................................................................................... 65 N m
S P E C IF IC A T IO N S F O R G A R R E T T T U R B O C H A R G E R
R o to r s h a f t - end p la y 0 ,1 0 m m m ax.
s id e p l a y 0 ,7 5 m m m ax.
ru n o u t 0 ,0 0 7 m m m ax.
E n d p l a t e ..........................................................................................................................................................................................................................................8 - 1 0 N m
C o m p r e s s o r ro to r w h e e l r e ta in in g n u t..........................................................1 s t s t a g e ........................................................................in itia l to r q u e 2 Nm
2 n d s t a g e ............................................................. a n g le o f r o ta tio n 90°
T u r b in e h o u s in g to c e n tr e h o u s in g .......................................................................................................................................................................... 1 1 , 5 - 1 5 N m
C o m p r e s s o r h o u s in g to c e n tr e h o u s in g ................................................................................................................................................................1 1 , 5 - 1 5 N m
O il r e t u r n ..............................................................................................................................................; M8 - 25 Nm
O il s u p p ly M8 - 25 Nm
O il s u p p ly b a n jo b o lt ...................................... 40 Nm
T u r b o c h a r g e r to e x h a u s t m a n if o ld .......................................................................................................................................................................................... 6 5 N m
April '96
Turbocharger 18A-5
INTRODUCTION
T u r b o ch a rg er
T h e G a r r e t t /A iR e s e a r c h a n d K K K tu r b o c h a r g e r s fo r in te rn a l c o m b u s tio n e n g in e a p p lic a tio n c o m p r is e s o f a tu r b in e a n d a

r a d ia l c o m p r e s s o r w h ic h u tilis e a c o m m o n s h a ft. T h e tu rb in e a n d c o m p re s s o r w h e e ls a r e m o u n te d a t o p p o s ite e n d s o f th e
s h a ft. T h e s h a ft is e n c lo s e d a n d s u p p o r te d b y fu lly flo a tin g b e a r in g s in a h o u s in g . T h e tu r b in e a n d c o m p r e s s o r w h e e ls a r e
e n c lo s e d in c a s t h o u s in g s .
A fte r th e e n g in e is s ta r te d th e flo w o f e x h a u s t g a s fr o m th e e n g in e p a s s e s th ro u g h th e tu r b in e h o u s in g a n d c a u s e s th e s h a ft
a s s e m b ly to r o ta te . The c o m p r e s s o r w h e e l, m o u n te d a t th e o p p o s ite e n d o f th e s h a ft, d raw s a m b ie n t a ir in to th e
c o m p r e s s o r h o u s in g , c o m p r e s s e s t h e a ir a n d d e liv e rs it to th e e n g in e .
D u r in g o p e r a tio n th e tu r b o c h a r g e r re s p o n d s to t h e e n g in e lo a d d e m a n d s b y re a c tin g to th e e x h a u s t g a s e n e r g y . A s th e
p o w e r o f t h e e n g in e in c re a s e s , th e s p e e d a n d o u tp u t o f th e ro ta tin g a s s e m b ly in c re a s e s p r o p o r tio n a te ly .
T h e r e m o v a l a n d r e p la c e m e n t p r o c e d u r e illu s tra te d s h o w s a ty p ic a l in s ta lla tio n , w h ic h m a y v a r y d e p e n d in g o n s p e c ific a tio n .
C h e c k in g a T u r b o c h a r g e r in a V e h ic le
D is c o n n e c t th e in le t d u c t a n d tu rn th e ro to r. E n s u r e e a s y a n d u n ifo rm ru n n in g . If n e c e s s a r y tu rn b a c k a n d fo rth s e v e ra l
tim e s u n til th e ro to r is fr e e o f oil a n d c a rb o n d e p o s its .
T h e t u r b o c h a r g e r h a s g y ro s c o p ic s ta b ilis a tio n a n d ru n s in flo a tin g b e a rin g s . T r y to m o v e th e ro to r in a n d o u t. T h e e n d p la y

is s e t c o rr e c tly if v e r y little o r n o p la y c a n b e fe lt. M o v e a n d tu rn th e ro to r u p a n d d o w n in e ith e r d ire c tio n . T h e s id e p la y is
a d ju s te d c o rr e c tly if n o s c ra p in g o c c u rs .
T u rb o c h a r g e r Oil L e a k s
T h e b e a r in g h o u s in g s o n a ll ty p e s o f tu r b o c h a r g e r s u s e d o n A D E e n g in e s a r e s e a le d w ith oil c o n tro llin g rin g s to p r o v id e a

s e a l b e tw e e n th e oil a n d th e a ir /e x h a u s t g a s . T h e fu n c tio n o f th e s e s e a ls is b a s e d o n th e p res su re b u ild u p in th e
c o m p r e s s o r h o u s in g . T h e r e c o u ld , h o w e v e r, b e a v a c u u m a t h ig h e n g in e R P M w h ile c o a s tin g w h ic h w o u ld fa v o u r oil
le a k a g e a n d o il c o a tin g o f t h e in le t p o rt. T h e a m o u n t o f o il lo s t in th is w a y is e x tr e m e ly lo w a n d h a s n o m e a s u r a b le in flu e n c e
o n t h e e n g in e 's oil c o n s u m p tio n .
T h e tu r b o c h a r g e r s h o u ld n o t b e r e m o v e d if oil c o v e re d p o rts a r e fo u n d d u rin g a s e rv ic e , a s lo n g a s a n in s p e c tio n o f th e

tu r b o c h a r g e r d id n o t s h o w a n y d e fe c ts .
A n o th e r c a u s e fo r o il le a k s c o u ld b e a d a m a g e d (d e fo r m e d ) o r c lo g g e d oil re tu rn p ip e . T h e r e d u c e d c r o s s -s e c tio n a l s iz e o f
th e p ip e w o u ld le a d t o a n in c r e a s e in r e s is ta n c e , c a u s in g t h e oil le v e l in t h e tu r b o c h a r g e r to ris e a n d oil to le a k p a s t th e
s e a ls o n t h e tu r b in e a n d c o m p r e s s o r s id e s . In th is c a s e c le a n o r r e p la c e th e o il re tu rn p ip e .
F itting a R e c o n d itio n e d T u r b o c h a r g er
P rio r to fittin g t h e tu r b o c h a r g e r th e in le t a n d fla n g e d m a n ifo ld a h e a d o f t h e c o m p r e s s o r , t h e e x h a u s t m a n ifo ld a n d e x h a u s t

p ip e , a s w e ll a s th e o il fe e d and re tu rn p ip e s m u s t b e in s p e c te d th o r o u g h ly fo r d irt a n d d a m a g e . T h e p lu g s o n th e
tu r b o c h a r g e r o p e n in g s s h o u ld o n ly b e r e m o v e d ju s t b e fo r e fittin g . T h e b e a r in g h o u s in g m u s t b e fille d w ith c le a n e n g in e oil
th r o u g h t h e o il in le t p o rt p r io r to c o n n e c tin g th e oil fe e d p ip e . D u rin g fillin g tu rn t h e m o v in g p a rts b y h a n d to c o a t th e
b e a r in g s w ith oil.
April '96
Turbocharger 18A-6
REM OVAL, O VERHAUL AND REPLACEM ENT
1. D is c o n n e c t th e oil fe e d p ip e to th e tu rb o c h a r g e r , i
(F ig . 1 8 A - 1 ).
F ig . 1 8 A -1
2. R e m o v e t h e oil fe e d r e ta in in g b r a c k e t, if fitte d , a n d
lo o s e n t h e b o tto m b a n jo u n io n , (F ig . 1 8 A - 2 ).
F ig . 1 8 A - 2
3. D is c o n n e c t th e o il d r a in p ip e fr o m tu r b o c h a r g e r to
s u m p , (F ig . 1 8 A - 3 ) .
F ig . 1 8 A - 3
4. If a h e a ts h ie ld is fitte d , u n s c r e w t h e r e ta in in g n u ts
a n d r e m o v e , (F ig . 1 8 A - 4 ) .
Fig. 18A-4
April ‘96
Turbocharger 18A-7
5. P rio r to re m o v a l m a r k th e p o s itio n o f th e e x h a u s t
e lb o w in r e la tio n to th e tu r b o c h a r g e r b o d y , (F ig .
1 8 A -5 ).
6. R e m o v e th e e x h a u s t p ip e e lb o w fr o m th e tu r b o c h a r
g e r, (F ig . 1 8 A - 6 ) .
7. U n s c r e w th e m o u n tin g n u ts o f t h e tu r b o c h a r g e r a n d
r e m o v e t h e tu r b o c h a r g e r fr o m t h e e x h a u s t m a n ifo ld ,
(F ig . 1 8 A - 7 ).
M ea su rin g t h e tu r b o c h a r g e r s h a f t e n d p lay.
1. C la m p t h e tu r b o c h a r g e r , tu r b in e e n d u p , in a v ic e fit
te d w ith s o ft ja w s .
2. M ount a d ia l g a u g e fitte d w ith a m a g n e tic b a s e o n to

t h e t u r b o c h a r g e r h o u s in g . P la c e t h e d ia l g a u g e p ro
b e a t t h e e n d o f t h e tu r b in e s h a ft a n d s e t th e g a u g e
to “0", (F ig . 1 8 A - 8 ) .
3. Push th e tu r b in e s h a ft a g a in s t t h e d ia l g a u g e p ro b e
a n d n o te t h e r e a d in g . E n s u r e t h a t th e r e a d in g a g re e s
w ith s p e c ific a tio n s .
Fig. 18A-8
April ‘96
Turbocharger 18A-8
M e a s u r in g t h e t u r b o c h a r g e r s h a f t s i d e p la y
A tte n tio n ! T h e s id e p la y s h o u ld b e m e a s u r e d a t th e tu rb in e
e n d o n ly .
1. P u s h th e tu r b in e w h e e l to o n e s id e and m e a s u r e th e
g a p b e tw e e n th e b la d e s a n d t h e h o u s in g w ith a fe e le r
g a u g e . N o t e c le a r a n c e . (F ig . 1 8 A - 9 ).
2. P u s h t h e tu r b in e w h e e l in t h e o p p o s ite d ire c tio n a n d

m e a s u re th e g a p b e tw e e n th e b la d e s a n d th e h o u s in g
w ith a fe e le r g a u g e . N o t e c le a r a n c e .
3. The s u m o f th e tw o r e a d in g s d iv id e d b y tw o r e p r e s e n ts
th e a v e r a g e s id e p la y . C o m p a r e w ith s p e c ific a tio n s .
A tte n tio n ! M e a s u r e m e n t s s h o u ld b e m a d e a t tw o d iffe re n t

p o in ts.
H O L D IN G T O O L S
120
K K K H O L D IN G T O O L
A K N U R L IN G
F i g .1 8 A - 1 0 B A D A P T E D T O A V A IL A B L E R O T O R
J__
orvf
I -
§ ^ p
4—
2f
t
Fig. 18A-11 GARRETT HOLDING TOO L
April '96
Turbocharger 18A-9
D IS M A N T L IN G
1. P r io r to r e m o v a l m a r k p o s itio n s o f th e tu rb in e a n d c o m
p r e s s o r h o u s in g s in re la tio n to th e c e n tr e h o u s in g , (F ig .
1 8 A -1 2 ).
2. B end d o w n th e lo c k in g p la te s a n d u n s c r e w th e b o lts
h o ld in g th e tu r b in e and c o m p re s s o r h o u s in g s to th e
c e n tr e h o u s in g , (F ig . 1 8 A - 1 3 ) .
A tten tio n ! T ig h t h o u s in g s c a n b e r e m o v e d w ith a ru b b e r

o r h id e fa c e d h a m m e r .
3. U n s c re w a n d r e m o v e t h e b o lts a n d lo c k in g p la te s fr o m
th e c o m p r e s s o r h o u s in g , (F ig . 1 8 A - 1 4 ) .
4. R e m o v e th e c o m p r e s s o r h o u s in g fr o m th e c e n tr e h o u
s in g , (F ig . 1 8 A - 1 5 ) .
A tten tio n ! T ig h t h o u s in g s c a n b e r e m o v e d w ith a ru b b e r

fa c e d h a m m e r .
Fig. 18A-15
April ‘96
Turbocharger 18A-10
5 R e m o v e th e O -r in g fr o m t h e c o m p r e s s o r h o u s in g .
( G a r r e tt ), (F ig 1 8 A - 1 6 ) .
F ig . 1 8 A - 1 6
6. U s in g s p e c ia l h o ld in g to o l m ade to illu s tra tio n F ig .

1 8 A - 1 0 , 1 8 A - 1 1, c la m p th e t u r b o c h a r g e r s h a ft a n d u n
s c r e w t h e c o m p r e s s o r r o to r w h e e l re ta in in g n u t, (F ig .
1 8 A -1 7 ).
a
F ig . 1 8 A - 1 7
7. R e m o v e th e o u te r O -r in g fr o m th e b a c k in g p la te , (F ig .
1 8 A -1 8 ). (K K K -tu rb o s ).
F ig . 1 8 A - 1 8
8. W it h a B osch h o t a ir b lo w e r o r s im ila r h e a t s o u rc e ,
h e a t t h e c o m p r e s s o r ro to r w h e e l, (F ig . 1 8 A - 1 9 ) .
A tte n tio n ! D o n o t h e a t t h e c o m p r e s s o r ro to r w h e e l w ith a

w e ld in g to rc h .
Fig. 18A-19
April '96
Turbocharger 18A-11
9. L ift o ff th e c o m p r e s s o r ro to r w h e e l fr o m th e tu rb o ro to r
s h a ft.
R e m o v e r e ta in in g a lie n c a p s c re w s fr o m c o p r e s s o r e n d
p la te , (F ig . 1 8 a - 2 0 ) .R e m o v e c o m p r e s s o r e n d p la te fro m
c e n tr e h o u s in g
U n iq u e t o KKK tu r b o c h a r a e r s :
10. L ift o u t th e seal c a r r ie r /th r u s t w a s h e r fr o m th e c o m

p r e s s o r e n d p la te , (F ig . 1 8 A - 2 1 ) .
11. R e m o v e th e in n e r O -r in g fr o m th e end p la te , (F ig .
1 8 A -2 2 ).
F ig . 1 8 A - 2 2
12. R em ove t h e o il d e fle c to r fr o m t h e c e n tr e h o u s in g , (F ig .

1 8 A -2 3 ).
Fig. 18A-23
April '96
Turbocharger 18A-12
13. R e m o v e th e th r u s t b e a r in g , (F ig . 1 8 A - 2 4 ) .
F ig . 1 8 A - 2 4
14. R e m o v e t h e s p a c e r s le e v e , (F ig . 1 8 A - 2 5 ) .
F ig . 1 8 A - 2 5
15. R e m o v e th e th r u s t w a s h e r , (F ig . 1 8 A - 2 6 ) .
■III ASS
F ig . 1 8 A - 2 6
U n iq u e t o GARRETT tu r b o c h a r a e r s :
16. R e m o v e t h e O -r in g fr o m t h e c e n tr e h o u s in g ,
( F ig .1 8 A - 2 7 ) .
Fig. 18A-27
April '96
Turbocharger 18A-13
17. L ift o u t t h e th r u s t b e a r in g a n d th ru s t w a s h e r fr o m th e
c e n tr e h o u s in g , (F ig . 1 9 - 2 8 ) .
F ig . 1 8 A - 2 8
18. R e m o v e t h e s e a l c a r r ie r /th r u s t w a s h e r fr o m th e th ru s t
b e a r in g , (F ig . 1 8 A - 2 9 )
19. R e m o v e t h e s e a lin g rin g fr o m th e s e a l c a rr ie r /th ru s t

w a s h e r , ( F ig .1 8 A - 3 0 )
All T u r b o c h a r a e r s:
20. L ift o f f t h e c e n tr e h o u s in g fr o m th e tu rb o ro to r s h a ft,

(F ig . 1 8 A - 3 1 ).
Fig. 18A-31
April '96
Turbocharger 18A-14
21. R e m o v e th e h e a t s h ie ld fr o m th e tu rb o ro to r s h a ft,
(F ig . 1 8 A - 3 2 ) .
2 2 . R e m o v e t h e b o tto m s e a lin g rin g s fr o m th e tu rb o ro to r

s h a ft, (F ig . 1 8 A - 3 3 ) .
2 3 . R e m o v e t h e tu r b o -r o t o r s h a ft a s s e m b ly a n d th e h o ld in g
to o l c la m p fr o m t h e v ic e .
24. R e m o v e t h e s e a lin g rin g s fr o m th e s e a l c a rr ie r , (F ig .

1 8 A -3 4 ).
25. Rem ove th e c irc lip s r e ta in in g th e tu rb o ro to r b e a r in g s

fr o m th e c e n tr e h o u s in g , (F ig . 1 8 A - 3 5 ) .
Fig. 18A-35
April '96
Turbocharger 18A-15
26. L ift o u t t h e b e a r in g s and re m o v e th e in n e r circlip s,

(F ig . 1 8 A - 3 6 ) .
A tte n tio n ! A ll'p a r t s s h o u ld n o w b e w a s h e d in a s u ita b le

c le a n in g flu id . Do not use a b r a s iv e c le a n in g m e th o d s
w h ic h m a y d a m a g e o r d e s tr o y m a c h in e d s u rfa c e s .
T h o r o u g h ly c le a n t h e tu r b in e e n d oil c a v ity in th e c e n tre
h o u s in g . R e m o v e a ll c a r b o n is e d oil.
C h e c k th e tu r b in e h o u s in g and ro to r b la d e s fo r c ra c k s ,
s c o r e m a r k s a n d fo re ig n p a rtic le s . C h e c k b o th ro to rs fo r
b e n t o r d a m a g e d b la d e s a n d s e a l rin g s fo r w e a r . R e p la c e
a ll w o rn p a rts . E x a m in e m a tin g s u rfa c e s fo r th e s e a l rin g s
in th e c e n tr e h o u s in g a n d b a c k p la te . E x a m in e th e s e a l
g r o o v e s in t h e s h a ft a n d s e a l c a rr ie r fo r w e a r .
ASSEMBLY
1. P la c e tu r b o ro to r s h a ft o n a s u ita b le V -b lo c k , le v e l w ith
th e b e a r in g p o in ts and check th e s h a ft fo r p a ra lle l
r u n n in g 10 m m fr o m th e end o f t h e th r e a d s . R e fe r to
th e s p e c ific a tio n s fo r m a x im u m p e r m is s ib le run out,
(F ig . 1 8 A - 3 7 ) .
2. F it t h e in n e r c irc lip s a n d b e a r in g s to th e c e n tr e h o u s in g ,
(F ig . 1 8 A - 3 8 ) .
3. In s e r t th e o u te r b e a r in g c ir c lip s in th e c e n tr e h o u s in g ,
(F ig . 1 8 A - 3 9 ) .
A t t e n t i o n ! A lw a y s u s e n e w c irc lip s a f te r a n o v e r h a u l.
Fig. 18A-39
April ‘96
Turbocharger 18A-16
4. C la m p th e ro to r s h a ft in a v ic e .
5. F it th e s e a lin g rin g s to th e b o tto m o f th e ro to r s h a ft a n d

lu b r ic a te , (F ig . 1 8 A - 4 0 ) .
F ig . 1 8 A - 4 0
6. F it th e h e a t s h ie ld o v e r th e tu r b o ro to r s h a ft,
(F ig . 1 8 A - 4 1 ).
Ill: /© =
F ig .1 8 A -4 1
7. F it th e c e n tr e h o u s in g o v e r t h e tu r b o ro to r s h a ft. D o no t
d a m a g e t h e s e a lin g rin g s , (F ig . 1 8 A - 4 2 ) .
F ig . 1 8 A - 4 2
U n iq u e t o KKK tu r b o c h a r a e r s :
8. F it th e in n e r th r u s t w a s h e r , (F ig . 1 8 A - 4 3 ) .
Fig. 18A-43
April '96
Turbocharger 18A-T7
9. R e p la c e th e s p a c e r, (F ig . 1 8 A - 4 4 ) .
10. F it th e th r u s t b e a r in g o v e r th e r e ta in in g p in s , (F ig
1 8 A -4 5 ).
11. In s e r t t h e o il d e fle c to r , (F ig . 1 8 A - 4 6 ) .
12. F it a n e w in n e r O -r in g to th e e n d p la te , ( F ig .1 8 A - 4 7 ) .
Fig. 18A-47
April '96
Turbocharger 18A-18
13. R e p la c e a n d lu b ric a te th e s e a lin g rin g s on th e se a l

c a rr ie r a n d fit in to th e e n d p la te , (F ig . 1 8 A -4 8 ).
F ig . 1 8 A - 4 8
14. F it th e e n d p la te to t h e c e n tr e h o u s in g , (F ig . 1 8 A - 4 9 ) .
■wi'
F ig . 1 8 A - 4 9
15. In s e r t th e cap s c re w s r e ta in in g th e e n d p la te to th e
c e n tr e h o u s in g a n d tig h te n to t h e s p e c ifie d to rq u e , (F ig .
1 8 A -5 0 ).
A3=
F ig . 1 8 A - 5 0
U n iq u e t o GARRETT T u r b o c h a r a e r s:
16. L u b r ic a te a n d r e p la c e t h e s e a lin g rin g s o n t h e s e a l

c a r r ie r /th r u s t w a s h e r (F ig . 1 8 A - 5 1 ).
Fig. 18A-51
April '96
Turbocharger 18A-19
17. F it th e th ru s t b e a r in g to th e s e a l c a r r ie r /th ru s t w a s h e r
a n d s lid e o v e r th e tu r b o ro to r s h a ft. A lig n th e th ru s t
b e a r in g w ith th e r e ta in in g p in s , (F ig . 1 8 A - 5 2 ) .
F ig . 1 8 A - 5 2
18. R e p la c e th e O -r in g a t th e to p o f t h e c e n tr e h o u s in g ,
( F ig . 1 8 A - 5 3 ) .
F ig . 1 8 A - 5 3
19. L in e u p t h e s e a lin g rin g o n th e s e a l c a r r ie r /th ru s t

w a s h e r a n d fit th e e n d p la te , (F ig . 1 8 A - 5 4 )
F ig . 1 8 A - 5 4
20. In s e r t th e b o lts fitte d w ith t h e lo c k p la te s in to th e e n d

p la te , (F ig . 1 8 A - 5 5 ) .
Fig. 18A-55
April '96
Turbocharger 18A-20
21. T ig h te n th e b o lts to th e s p e c ifie d to r q u e a n d s e c u r e th e

lo c k p la te s , (F ig . 1 8 A - 5 6 ) .
AH tu rb o c h a ra e rs
22. H e a t th e c o m p r e s s o r w h e e l w ith a B o s c h h o t a ir b lo w e r
o r a lt e r n a t iv e h e a t s o u r c e , (F ig . 1 8 A - 5 7 ) .
A tte n tio n ! Do not heat th e c o m p re s s o r w heel w ith a

w e ld in g to rc h .
F ig . 1 8 A - 5 7
23. F it th e c o m p r e s s o r w h e e l to t h e tu rb o ro to r s h a ft, (F ig .
1 8 A -5 8 ).
F ig . 1 8 A - 5 8
24. R e p la c e th e o u te r O -r in g o n t h e e n d p la te , a p p ly p e tro
le u m je lly to a s s is t, (F ig . 1 8 A - 5 9 ) .
Fig. 18A-59
Turbocharger 18A-21
25. R e p la c e th e c o m p r e s s o r w h e e l r e ta in in g lo c k n u t a n d
tig h te n to th e s p e c ifie d to rq u e . D o n o t b e n d th e s h a ft,
(F ig . 1 8 A - 6 0 ) .
A tte n tio n ! A lw a y s u s e a n e w lo c k n u t
26. M o u n t th e c e n tr e h o u s in g in a v ic e a n d tu rn th e ro to r
s h a ft b y h a n d to c h e c k fo r fr e e r u n n in g , (F ig . 1 8 A - 6 1 ) .
27. F it th e c o m p r e s s o r h o u s in g to th e c e n tr e h o u s in g , (n o te
s c rib e d a s s e m b ly m a r k s ). R e p la c e th e b o lts a n d r e ta i
n in g c la m p s a n d tig h te n to t h e s p e c ifie d to rq u e , (F ig .
1 8 A -6 2 ).
28. F it t h e tu r b in e h o u s in g to t h e c e n tr e h o u s in g (n o te
s c rib e d a s s e m b ly m a r k s ), (F ig . 1 8 A - 6 3 ) .
N o te : O n G a r r e t t tu r b o c h a r g e r s e n s u r e t h a t a n e w O -r in g is
fitte d in t h e c o m p r e s s o r h o u s in g .
April ‘96
Turbocharger 18A-22
2 9 . R e p la c e th e b o lts a n d c la m p s , tig h te n to th e s p e c ifie d

to r q u e a n d b e n d o v e r th e lo c k in g p la te s , (F ig . 1 8 A - 6 4 ) .
A tte n tio n ! A lw a y s fit n e w lo c k in g p la te s .
3 0 . T u rn th e tu rb o ro to r s h a ft b y h a n d a n d c h e c k fo r fr e e
ru n n in g .
F ig . 1 8 A - 6 4
31. L u b r ic a te b e a r in g s in th e c e n tr e h o u s in g w ith e n g in e oil,

(F ig . 1 8 A - 6 5 ) .
■III /B s
F ig . 1 8 A - 6 5
R e p la c in g t h e tu r b o c h a r g e r
1. M o u n t th e tu r b o c h a r g e r o n to th e exhaust m a n ifo ld .
E n s u re th a t th e m a tin g s u r f a c e s o f fla n g e d a r e a s a r e
c le a n a n d f r e e o f b u rrs o r h ig h s p o ts , (F ig . 1 8 A - 6 6 ) .
III U s
F ig . 1 8 A - 6 6
2. F it th e e x h a u s t p ip e e lb o w to t h e tu r b o c h a r g e r (n o te
s c rib e d a s s e m b ly m a r k s ), (F ig . 1 8 A - 6 7 ) .
(Fig. 18A-67
April '96
Turbocharger 18A-23
M o u n t th e heat s h ie ld , if fitte d , to th e tu rb o s tu d s
a n d s e c u r e w ith n e w s e lf lo c k in g n u ts , (F ig . 1 8 A - 6 8 ) .
F ig . 1 8 A - 6 8
4. In s e r t t h e b a n jo b o lt c o n n e c tin g th e tu rb o fe e d p ip e to
th e oil p r e s s u r e g a lle r y on th e c y lin d e r b lo c k a n d tig h
te n t h e b o lt to th e s p e c ifie d to r q u e , (F ig . 1 8 A - 6 9 )
F ig . 1 8 A - 6 9
5. T ig h t e n t h e tu rb o oil fe e d p ip e re ta in in g b r a c k e t to th e
s p e c ifie d to rq u e , (F ig . 1 8 A - 7 0 ) .
F ig . 1 8 A - 7 0
6. U se a new gasket and r e p la c e th e to p o il fe e d p ip e ,

in s e r t t h e b o lts a n d tig h te n to th e s p e c ifie d to rq u e , (F ig .
1 8 A -7 1 ).
Fig. 18A-71
April '96
Turbocharger 18A-24
April '96
Turbocharger 18A-25
INTERCOOLER
D e p e n d in g on a p p lic a tio n a n d /o r r e q u ir e m e n t th e A D E 360 s e rie s e n g in e s a re b u ilt to accept a c h a rg e a ir c o o le r

(In te r c o o le r ), m o u n te d b e tw e e n th e tu r b o c h a r g e r c o m p re s s o r h o u s in g a n d in le t m a n ifo ld .
T h e in te r c o o le r r e s e m b le s a c o o la n t r a d ia to r c o re (s e e fig 1 8 A - 1 1 8 ) . U n d e r lo a d , a ir is c o m p r e s s e d a n d fo rc e d v ia th e
in te r c o o le r in to th e c o m b u s tio n a r e a b y th e tu r b o c h a r g e r . D u rin g c o m p re s s io n b y th e t u r b o c h a r g e r th e a ir h e a ts up an d
e x p a n d s , c o n s e q u e n tly b e c o m in g le s s d e n s e . B y d ire c tin g th e h o t a ir th ro u g h a n in te r c o o le r s o m e h e a t is r e m o v e d . T h e
e x p a n s io n o f th e c h a r g e d a ir is th e r e fo r e r e d u c e d , w h ic h m e a n s m o r e a ir w ill b e fo rc e d in to th e c o m b u s tio n a r e a , th e
in c r e a s e d d e n s ity o f t h e c h a r g e d a ir (o x y g e n ) a llo w s fo r m o r e fu e l to b e in je c te d , a n d c o n s e q u e n tly m o r e p o w e r w ill be
d e v e lo p e d .
1m m Exhaust
2 E S S jifl C h a rg e air
M a in te n a n c e
1. K e e p t h e c o o le r e x te r n a lly c le a n a n d fr e e fr o m o b s tru c tio n w h ic h m a y a f fe c t th e a ir flo w .

2. C h a r g e a ir le a k s w ill re s u lt in lo s s o f p o w e r, th e re fo re :
A ll in d u c tio n tu b in g a n d h o s e jo in ts m u s t b e k e p t tig h t.
E n s u r e t h a t a ll m o u n tin g s a r e s e c u r e to p r e v e n t v ib ra tio n s w h ic h m a y c r a c k th e in te r c o o le r tu b e s .
P e r io d ic a lly in s p e c t t h e in te r c o o ie r t u b e s fo r h o le s d u e to c o rro s io n o r im p a c t b y d e b ris .
3. In t h e e v e n t o f d u s t o r fo re ig n o b je c ts e n te r in g th e in d u c tio n s y s te m a n d /o r tu r b o c h a r g e r c o m p r e s s o r w h e e l fa ilu re ,
c le a n t h e in d u c tio n tu b in g /h o s e s to a n d fr o m th e in te rc o o ie r. D is m a n tle a n d c le a n th e in te r c o o ie r . S e a le d u n its th a t
c a n n o t b e c le a n e d p r o p e r ly s h o u ld b e re p la c e d .
April '96
SECTION 18B
Power Steering Pump
CONTENTS OF SECTION 18B
Page
I L L U S T R A T I O N ........................................................................................................................................................................................................................................1 8 B
I N T R O D U C T I O N ................................................................................................................................................................................................................................ 1 8 B -3
S P E C I F I C A T I O N S ............................................................................................................................................................................................................................. 1 8 B -3
F A U L T F I N D I N G ..................................................................................................................................................................................................................................1 8 B -4
R E M O V A L O F T H E P O W E R S T E E R IN G P U M P :..........................................................................................................................................1 8 B -5
Z . F . H IG H P R E S S U R E P U M P
D IS M A N T L IN G O F T H E R O T O R A N D C A M R I N G .......................................................................................................................................................1 8 B -6
R E M O V A L O F T H E D R IV E S H A F T ........................................................................................................................................................................................ 1 8 B -7
R E M O V A L O F F L O W A N D P R E S S U R E R E S T R IC T IO N V A L V E ........................................................................................................................ 1 8 B -8
D IS M A N T L IN G , I N S P E C T I O N A N D A S S E M B L Y O F
F L O W A N D P R E S S U R E R E S T R I C T I O N V A L V E ..........................................................................................................................................................1 8 B -8
R E P L A C E M E N T O F F L O W A N D P R E S S U R E R E S T R IC T IO N V A L V E ...........................................................................................................1 8 B -9
P R E - A S S E M B L Y O F P U M P H O U S I N G .............................................................................................................................................................................. 1 8 B -9
A S S E M B L Y A N D R E P L A C E M E N T O F D R IV E S H A F T ........................................................................................................................................... 1 8 B - 1 0
R E P L A C E M E N T O F D R IV E E N D F A C E P L A T E ..........................................................................................................................................................1 8 B -1 1
R E P L A C E M E N T O F C A M R IN G A N D R O T O R .............................................................................................................................................................1 8 B -1 1
R E P L A C E M E N T O F E N D F A C E P L A T E A N D C O V E R ........................................................................................................................................... 1 8 B - 1 2
V I C K E R S H IG H P R E S S U R E P U M P
D IS M A N T L IN G A N D R E M O V A L O F R O T O R A N D C A M R I N G ..........................................................................................................................1 8 B - 1 3
R E M O V A L A N D D IS M A N T L IN G O F V O L U M E C O N T R O L
A N D P R E S S U R E R E L IE F V A L V E ........................................................................................................................................................................................ 1 8 B - 1 4
R E P L A C E M E N T O F D R IV E S H A F T A N D S E A L ..........................................................................................................................................................1 8 B - 1 6
R E P L A C E M E N T O F R O T O R A N D C A M R I N G .............................................................................................................................................................1 8 B - 1 7
R E P L A C I N G T H E P U M P .......................................... 1 8 B -1 8
SPECIAL TOOLS................................................................................................................................................................................. 18B-20
April '96
SECTION 18B
Power Steering Pump
Z F -R O T A R Y P U M P T Y P E 7 6 7 3
1 NUT 1 7 O -R IN G
2 S P R IN G W A S H E R 18 F R O N T P L A T E , D R IV E - E N D
3 D R IV E S H A F T 19 ROTO R
4 W O O D R U FF KEY 20 VANE
5 C IR C L IP 21 C A M R IN G
6 B A L L B E A R IN G 22 O - R IN G
7 C IR C L IP 23 F R O N T P L A T E C O V E R -E N D
8 SHAFT SEAL 24 S P R IN G
9 N E E D L E B E A R IN G 25 O - R IN G
10 H O U S IN G 26 COVER
11 B L A N K IN G P L U G 27 H O O K E D C IR C L IP
12 S E A L IN G R I N G 28 T H R O T T L E IN S E R T
13 P H IL L IP S S C R E W 29 V A L V E P IS T O N C O M P L E T E
14 ID E N T I F I C A T I O N P L A T E 30 P R E S S U R E R IN G
15 F I T T E D P IN 31 S E A L IN G R IN G
16 O -R IN G 32 B L A N K IN G P L U G
April '96
Power Steering Pump 18B-3
IN T R O D U C T IO N
D e p e n d in g o n a p p lic a tio n th e A D E 3 6 0 s e rie s e n g in e s c a n b e fitte d w ith e ith e r o f tw o ty p e s o f ro ta ry p o w e r s te e rin g

p u m p s , b o th o f w h ic h o p e r a te a s fo llo w s :
W h e n th e d r iv e s h a ft a n d its ro to r a r e tu rn e d , th e v a n e s a r e g u id e d in s lo ts a n d b e in g r a d ia lly m o b ile , a r e p r e s s e d a g a in s t

th e g u id e p a r t o f t h e c a m rin g b y th e a c tio n o f c e n trifu g a l fo rc e a n d oil p re s s u re . T w o s u c c e s s iv e v a n e s a r e c la s s e d a s a
ce ll ( a to ta l o f 1 0 ). T h e ir la te r a l m o v e m e n t is re s tric te d b y th e p r e s s u r e p la te s . E a c h c e ll d e liv e rs th e m a x im u m e ffe c tiv e
v o lu m e t w ic e p e r r e v o lu tio n . T h e s u c tio n a n d p r e s s u r e c h a m b e r s a r e a r r a n g e d s o t h a t th e h y d r a u lic a n d r a d ia l fo rc e s
a c tin g o n th e ro to r w ill n e u tr a lis e e a c h o th e r. T h e c o v e r e n d fro n t p la te a n d th e d r iv e e n d fr o n t p la te a r e p ro v id e d w ith fo u r
g r o o v e s s o t h a t t h e p r e s s u r is e d oil r e a c h e s th e in te rn a l fa c e o f th e p u m p v a n e s , w h ic h w ill th e n b e s u p p o r te d b y th e c e n tr i
fu g a l fo rc e . F r o m th e p r e s s u r e c h a m b e r th e oil tr a v e ls th ro u g h h o le s to th e flo w re s tric tin g v a lv e , a n d b y w a y o f a th ro ttle
r e s tr ic tio n to th e p r e s s u r e lin e. T h e re d u c e d p r e s s u r e b e h in d th e th ro ttle re s tric tio n is t r a n s m itte d v ia h o le s to th e s p rin g -
lo a d e d e n d o f th e flo w r e s tric tin g p is to n a n d th e r e fo r e o n to th e r e lie f v a lv e .
In c r e a s in g t h e s p e e d o r p u m p d e liv e r y w ill p r o d u c e a g ro w in g p r e s s u r e d ro p b e h in d th e th ro ttle r e s tr ic to r a n d a ls o a g a in s t

th e s p rin g e n d o f t h e v a lv e p is to n . W h e n th e h y d r a u lic p o w e r (p r e s s u r e d iffe r e n tia l tim e s p is to n a r e a ) e x c e e d s th e sp rin g
fo rc e , t h e p is to n w ill m o v e to w a r d s th e s p rin g a n d th e oil d e liv e re d in e x c e s s w ill flo w th ro u g h th e n o w e x p o s e d e je c tio n
h o le in to t h e s u c tio n d u c t o f t h e p u m p . A s a re s u lt, a n a lm o s t c o n s ta n t oil flo w fo r th e s te e r in g g e a r is p r o v id e d th ro u g h o u t
th e e n tir e s p e e d r a n g e .
P u lle y to p u m p s h a f t .................................................................................................... M 1 4 x 1 , 5 ................................................. 8 0 N m

C o v e r to p u m p h o u s in g 3 5 to 4 0 N m
P u m p b r a c k e t to fu e l filte r b r a c k e t ....................................................................... M 1 0 .............................................................. 4 0 N m
A d ju s tin g b o lt to w a t e r p u m p .................................................................................. M 1 0 ...............................................................4 0 N m
A d ju s tin g b o lt to b r a c k e t .............................................................................................M 1 2 x 1 , 5 ................................................. 5 0 N m
V -b elt t e n s io n fo r 1 2 ,5 m m w id e b e lts
N e w V - b e l t ..................... »..................................................................................... ..................................................................................... 4 0 to 4 5 k.q

A fte r ru n -in p e r io d ...... *.................................................................................... ..................................................................................... 3 0 to 4 0 kg
U s e d V - b e l t ........................................................................................................... ..................................................................................... 3 0 to 4 0 kg
April ‘96
V i c k e r s H ig h P r e s s u r e O il P u m p V T 2 7
F a u lt f i n d i n g
Problem Possible Cause Remedy

P u m p is n o t d e l i v e r i n g P u m p r u n n in g in w ro n g d ire c tio n C h a n g e d ire c tio n o f r o ta tio n
P u m p d r iv e s h a ft s h e a r e d R e m o v e th e p u m p to d e te r m in e th e e x te n t o f th e
V - b e lt s lip s o r is to rn d a m a g e a n d R e p la c e d a m a g e d p a rts
F lo w r e s tric tio n , v a lv e b in d s D is m a n tle t h e pum p and c le a n th e v a lv e . R e

in s ta ll v a lv e p is to n and check fo r ease of
o p e r a tio n . S lig h t ro u g h s p o ts c a n b e r e m o v e d by
la p p in g . D o n o t g rin d o r c h a m f e r c o n tro l e d g e s
No re fin is h in g is p e r m itte d on v a lv e b o re . A ll
p a rts m u s t b e c le a n e d p r io r to a s s e m b ly . The
s y s te m s h o u ld b e th o r o u g h ly flu s h e d and fille d
w ith c le a n oil.
V a n e s b in d in ro to r s lo ts R e m o v e th e p u m p a n d c h e c k th e ro to r s lo ts fo r
d irt, a b r a s iv e s a n d s w a rf. C le a n ro to r a n d v a n e s .
D u rin g a s s e m b ly c h e c k th e v a n e s fo r e a s e of
o p e ra tio n .
O il v is c o s ity to o high. U s e oil o f c o rr e c t v is c o s ity .

P u m p can n o t suck
In le t p ip e s p a r tia lly b lo c k e d . D ra in th e oil fr o m th e s y s te m . F lu s h a ll p ip e s . Fill

t h e s y s te m w ith fr e s h oil in a c c o r d a n c e w ith re
c o m m e n d a tio n s .
T a n k v e n t c lo g g e d . R e m o v e ta n k c o v e r a n d c le a n . C h e c k t h e s y s te m
In le t filte r c o n ta m in a te d . filte r o r in ta k e filte r fo r c lo g g in g . If t h e in ta k e filte r
is c lo g g e d , d r a in th e s y s te m , flu s h a n d refill.
E x c e s s iv e p u m p n o is e In ta k e p ip e p a rtia lly or c o m p le te ly T h e p u m p s h o u ld b e a b le to s u c k w ith o u t re s

c lo g g e d . F ilte r c lo g g e d . tric tio n to p r e v e n t c a v ita tio n . D r a in t h e s y s te m ,
c le a n th e in ta k e p ip e and filte r. F ill up w ith
r e c o m m e n d e d oil.
L e a k in g in le t p ip e c o n n e c tio n s . C h e c k b y p o u rin g oil o n c o n n e c tio n s . N o t e th e

c h a n g e in p u m p n o is e , tig h te n c o n n e c tio n s .
L e a k in g s h a ft s e a ls . R e p la c e in a c c o r d a n c e w ith in s tru c tio n s
M is a lig n m e n t o f s h a ft c o u p lin g . In s p e c t th e s h a ft b e a r in g a n d o il s e a l fo r p o s s ib le
fa u lts , r e p la c e a s n e c e s s a r y . R e a lig n s h a ft.
C o n ta in e r s e a l le a k in g . R e p la c e th e c o n ta in e r c o v e r s e a l, tig h te n p ip e to
ta n k c o n n e c tio n s
April '96
REMOVING AND REPLACING THE STEERING PUMP
R e m o v in g th e p u m p
1. L o o s e n th e c la m p b o lt o f th e V -b e lt a d ju s te r, (F ig 1 8 B - 1 ).
Fig 18B-1
2. S la c k e n o ff t h e V - b e lt a d ju s te r fr o m th e p u lle y , (F ig . 1 8 B -2 ).
F ig . 1 8 B - 2
3. U n s c r e w a n d r e m o v e t h e b o tto m p u m p m o u n tin g re ta in in g
b o lt, (F ig . 1 8 B - 3 ).
F ig . 1 8 B - 3
4. C la m p t h e p u m p d r iv e p u lle y in a v ic e , fitte d w ith s o ft ja w s ,

u n s c r e w t h e p u lle y r e ta in in g n u t a n d r e m o v e th e p u lle y ,
(F ig . 1 8 B - 4 )
Fig. 18B-4
April '96
5. U n s c r e w t h e b o lts r e ta in in g th e m o u n tin g b r a c k e t to th e
p u m p a n d r e m o v e th e b r a c k e t, (F ig . 1 8 B - 5 ).
F ig . 1 8 B - 5
DISMANTLING
R em o v a l o f R o to r an d C am R in g
ZF H igh P r e s s u r e V a n e P u m p
1. R e m o v e t h e c irc lip fr o m th e g r o o v e in th e p u m p h o u s in g
(F ig . 1 8 B - 6 ) .
2. R e m o v e th e c o v e r, s p rin g a n d c o v e r e n d p la te fr o m th e
h o u s in g , (F ig . 1 8 B - 7 ) .
F ig . 1 8 B - 7
3. T ilt th e p u m p b o d y a n d r e m o v e c a m rin g a n d ro to r,
(F ig . 1 8 B - 8 ) .
Fig. 18B-8
April '96
R e m o v in g t h e d riv e s h a ft
4. R e m o v e th e c irc lip , (F ig . 1 8 B - 9 ).
F ig . 1 8 B - 9
5. W it h a R u b b e r o r p la s tic h a m m e r k n o c k th e d riv e s h a ft fr o m
th e h o u s in g , (F ig . 1 8 B - 1 0 ) .
■in ra~
F ig . 1 8 B - 1 0
6. K n o c k th e d r iv e e n d fa c e p la te fr o m th e h o u s in g .
7. R e m o v e t h e v o lu m e c o n tro l v a lv e .
8 . W it h a s u ita b le p u n c h k n o c k th e n e e d le b e a r in g a n d d riv e
s h a ft s e a l fr o m t h e h o u s in g , (F ig . 1 8 B - 1 1 ) .
9. R e m o v e th e O -r in g s fr o m t h e h o u s in g , th e h o llo w p in a n d
d r iv e e n d fa c e p la te .
II M B S
Fig . 1 8 B -1 1
10. A fte r r e m o v in g th e c irc lip t h e b e a r in g c a n b e p re s s e d fr o m

th e d r iv e s h a ft, (F ig . 1 8 B - 1 2 ) .
Fig. 18B-12
April '96
R e m o v i n g t h e F l o w a n d P r e s s u r e R e s t r i c t i o n V a lv e
o f t h e Z . F . H ig h P r e s s u r e V a n e P u m p
1. R e m o v e th e s c r e w p lu g fr o m th e h o u s in g , (F ig . 1 8 B - 1 3 ) .
2. R e m o v e th e s p rin g a n d v a lv e p is to n fr o m th e h o u s in g
b o re
F ig . 1 8 B - 1 3
D ism a n tlin g , I n s p e c tio n a n d A s s e m b ly o f

th e F lo w an d P r e s s u r e R e str ic tio n V a lv e
1. C h e c k th e p r e s s u r e a n d flo w re s tric tio n v a lv e fo r s c o r e m a rk s

a n d w e a r . T h e f lo w c o n tr o l p is to n s h o u ld n o t b in d in th e
h o u s in g b o re . C h e c k th e ite m n u m b e r s o n t h e h o u s in g fa c e
a n d th e p is to n to e n s u r e m a tc h in g p a rts a r e u s e d ,
(F ig . 1 8 B - 1 4 ) .
2. U n s c r e w t h e v a lv e s e a t s c r e w fr o m th e p r e s s u r e re s tric tio n
v a lv e (d o n o t u s e a v ic e ). E n s u r e t h a t n o n e o f th e w a s h e r s ,
th e b a ll, th e s p rin g g u id e a n d c o m p re s s io n s p rin g s a r e lo st.
T h e th ic k n e s s o f t h e w a s h e r is c ritic a l fo r t h e r e s p o n s e r a n g e
o f t h e p r e s s u r e r e lie f v a lv e . N e w w a s h e r s m u s t b e fitte d
to p r e v e n t t h e p o s s ib ility o f d a m a g e , (F ig . 1 8 B - 1 5 ) .
3. C le a n t h e c o n tro l v a lv e a n d th e v a lv e s c r e w a n d b lo w o u t w ith
c o m p r e s s e d a ir. R e in s e r t t h e c o m p re s s io n s p rin g , g u id e pin
a n d b a ll. S c r e w t h e v a lv e ,s e a t s c r e w in to th e c o n tro l p is to n ,
to g e t h e r w ith t h e p r e v io u s ly in s ta lle d w a s h e r s .
F ig . 1 8 B - 1 5 ______________________________________________
1 VALVE PISTON
2 COMPRESSION SPRING PRESSURE RELIEF VALVE
3 SPRING GUIDE PIN
4 VALVE BALL
5 ADJUSTING W ASHERS
6 VALVE SEAT S C R EW
7 SPRING VOLUME CO NTRO L VALVE
8 S C R EW PLUG W IT H SEALING W ASHER
April '96
R e p l a c e m e n t o f F l o w a n d P r e s s u r e R e s t r ic t io n V a lv e
4. In s e r t a s s e m b le d v a lv e p is to n in to th e b o re . C h e c k fo r
c o rr e c t to le r a n c e , (F ig . 1 8 B - 1 6 ) .
5. S lid e t h e c o m p r e s s io n s p rin g o n to th e v a lv e p is to n a n d
s c r e w t h e b la n k in g p lu g in to th e th r e a d h o le w ith th e s e a lin g
w a s h e r p la c e d u n d e r n e a th , (F ig . 1 8 B - 1 7 ) .
P r e - a s s e m b l y o f P u m p H o u s in g
N o te : P r io r to a s s e m b ly c le a n a ll p a rts , m o is te n s lig h tly w ith

A T F o il a n d r e p la c e a ll s e a ls a n d O -r in g s .
1. W it h s u ita b le m a n d r e l p re s s th e n e e d le b e a r in g in to th e
h o u s in g , (F ig . 1 8 B - 1 8 ) .
T h e f a c e e n d o f th e n e e d le b e a r in g m u s t b e 3 7 ,0 to 3 7 ,2 m m
fr o m t h e f a c e e n d o f t h e h o u s in g , (F ig . 1 8 B - 1 9 ) .
N o te : T h e n e e d le b e a r in g is in s ta lle d o n ly in p u m p s w ith
V - b e lt d riv e .
Fig. 18B-19
2. W ith a m a n d r e l p re s s th e s h a ft s e a l in to th e h o u s in g .
F it th e s e a l w ith b e a r in g g r e a s e b e tw e e n th e s e a lin g
lip s, (F ig . 1 8 B - 2 0 ) .
3. S c r e w th e p lu g in to t h e h o u s in g a n d tig h te n .
4. F it a n O -r in g in to th e b o tto m g r o o v e o f t h e h o u s in g .
5. In s e r t a h o llo w p in in to th e h o le p ro v id e d , (F ig . 1 8 B - 2 1 ) .
A s s e m b ly a n d R e p la c e m e n t o f t h e D rive S h a ft
6. P re s s th e b a ll b e a r in g o n th e d r iv e s h a ft a n d r e p la c e th e
c irc lip . F it th e w o o d r u f f k e y , (F ig . 1 8 B - 2 2 ) .
LL|
ig. 1 8 B - 2 2
7. In s e r t t h e p r e - a s s e m b le d d r iv e s h a ft in to t h e h o u s in g u n til
th e b a ll b e a r in g r e s ts a g a in s t t h e h o u s in g fla n g e ,
(F ig . 1 8 B - 2 3 ) .
Fig. 18B-23
April '96
8. In s e r t th e c irc lip r e ta in in g th e b a ll b e a rin g , (F ig . 1 8 B - 2 4 )
R e p la c e m e n t o f th e D rive End F a c e P la te
9. In s e r t th e O -r in g in to t h e g r o o v e in th e n e c k o f t h e
f a c e p la te .
1 0 . S lid e t h e d r iv e e n d p la te o n to th e h o llo w p in a n d p re s s
w ith th e n e c k in to t h e h o u s in g , (F ig . 1 8 B - 2 5 ) .
R e p la c e m e n t o f th e C am R in g a n d R otor
11. In s e r t O -r in g ( 1 ) in to th e g r o o v e in th e h o u s in g ,
(F ig . 1 8 B - 2 6 ) .
12. In s e r t t h e c a m rin g . T h e s m a lle r h o le lo c a te s th e h o llo w

p in . T h e c a s t h a lf a r r o w in d ic a te s th e d riv in g d ire c tio n o f
t h e p u m p , (F ig . 1 8 B - 2 7 ) .
April '96
13. F it th e ro to r w ith th e s m o o th b o re o n th e d r iv e s h a ft,

(F ig . 1 8 B - 2 8 )
F ig . 1 8 B - 2 8
14. In s e r t th e te n v a n e s w ith t h e r o u n d e d -o ff o u te r
s u r fa c e s fa c in g t h e c a m rin g in to th e s lo ts o f th e
ro to r, (F ig . 1 8 B - 2 9 ) .
F ig . 1 8 B - 2 9
R e p la c e m e n t o f th e E nd F a c e P la te an d C o v er
15. F it th e c o v e r e n d o n to t h e c a m rin g , a s s h o w n . T h e
h o llo w p in fits in o n e o f th e s m a lle r h o le s ,
(F ig . 1 8 B - 3 0 ) .
ii » =
F ig . 1 8 B - 3 0
16. In s e r t t h e O -r in g , (F ig . 1 8 B - 3 1 ) .
Fig. 18B-31
April '96
1 7 . In s e r t t h e s p rin g in to th e b o re o f th e c o v e r e n d p la te .
P o s itio n th e c o v e r w ith th e re c e s s in w a r d s a n d p u sh
in to th e h o u s in g u n til th e c irc lip c a n b e in s e rte d ,
(F ig . 1 8 B - 3 2 ) .
1 8 . In s e r t t h e flo w a n d p r e s s u r e re s tric tio n v a lv e .
V ic k e r s H igh P r e s s u r e Oil P u m p VT27

D ism a n tlin g -R e m o v a l o f R otor a n d C am R ing
1. R e m o v e t h e s c r e w s o n th e p u m p h o u s in g to w h ic h th e
h o u s in g c o v e r is c o n n e c te d ; r e m o v e th e p u m p h o u s in g .
2. R e m o v e t h e s p rin g fr o m th e th r u s t p la te . M a r k th e th ru s t
p la te , c a m rin g a n d h o u s in g c o v e r to e n s u r e th e p a rts a r e
c o rr e c tly a lig n e d o n a s s e m b ly (r e fe r to a r ro w s ),
( F ig . 1 8 B - 3 3 )
F ig . 1 8 B - 3 3
1 O -R IN G 4 C A M R IN G
2 T H R U S T PLATE 5 O -R IN G
3 S P R IN G 6 H O U S IN G C O V E R
3. R e m o v e t h e th r u s t p la te fr o m th e lo c a tin g p in s a n d
t a k e o ff th e c a m rin g , (F ig . 1 8 B - 3 4 ) .
2 TH R U S T PLATE 6 H O U S IN G C O V E R
4 C A M R IN G 7 M A R K IN G L IN E
April ‘96
4. R e m o v e ro to r w ith p u m p v a n e s fr o m th e d r iv e s h a ft
s p lin e s , (F ig . 1 8 B - 3 5 ) .
Fig . 1 8 B - 3 5
4 C A M R IN G A O IL I N F L O W F R O M
6 H O U S IN G C O V E R S U P P L Y C O N T A IN E R
7 M A R K IN G L IN E B H Y D R A U L IC O IL O U T
8 L O C A T IN G P IN F L O W O N C A M R IN G
9 ROTO R C IN T A K E B O R E S
10 V A N E S
5. R e m o v e O -r in g s ite m s 1 & 5 , (F ig . 1 8 B - 3 6 ) .
6. R e m o v e th e v o lu m e c o n tr o l v a lv e .
7. C le a n a ll p a rts th o r o u g h ly a n d rin s e .
F ig . 1 8 B - 3 6
1 O -R IN G 4 C A M R IN G
2 TH R U ST PLATE 5 O -R IN G
3 S P R IN G 6 H O U S IN G C O V E R
R e m o v a l a n d D is m a n tlin g o f V o lu m e C o n tr o l
a n d P re s s u r e R e lie f V a lv e
1. K n o c k h o llo w p in fr o m t h e p u m p h o u s in g .
2. R e m o v e th e b la n k in g c o v e r o f t h e v o lu m e c o n tro l
v a lv e a n d th e c o m p r e s s io n s p rin g fr o m t h e p u m p
h o u s in g , (F ig . 1 8 B - 3 7 ) .
N o te : C a u tio n ! T h e c o m p r e s s io n s p rin g m a y p u s h o f f th e
b la n k in g c o v e r a n d t h e v o lu m e c o n tro l v a lv e a f te r r e m o v in g
th e h o llo w p in . L o o s e n th e b la n k in g c o v e r w ith lig h t h a m m e r
b lo w s if it s h o u ld r e m a in in t h e h o u s in g . D o n o t d a m a g e th e
v o lu m e c o n tro l v a lv e .
F ig . 1 8 B - 3 7
1 B L A N K IN G C O V E R 4 V O LU M E C O N TR . VALVE
2 H O L L O W P IN 5 S P R IN G S
3 O -R IN G 6 P U M P H O U S IN G
April '96
3. C la m p th e v o lu m e c o n tro l v a lv e a t Its u n g ro u n d en d
in a v ic e a n d u n s c r e w th e v a lv e s c r e w o f th e p re s s u re
r e lie f v a lv e . E n s u r e t h a t n o a d ju s tin g s c re w s a r e lost.
R e m o v e th e v a lv e a n d s p rin g fr o m th e v o lu m e c o n tro l
v a lv e . (F ig . 1 8 B - 3 8 ) .
4. P rio r to r e p la c e m e n t c h e c k th e g ro u n d s u rfa c e o f th e
v o lu m e c o n tro l v a lv e a n d th e b o re in th e p u m p h o u s in g
fo r w e a r a n d d a m a g e . If t h e s u r fa c e s a r e s h o w in g s c o re
m a r k s r e p la c e th e c o m p le te oil p u m p . N e v e r r e p la c e th e
v o lu m e c o n tro l v a lv e o n ly .
F ig . 1 8 B - 3 8
1 B L A N K IN G C O V E R W I T H O - R I N G
2 V O LU M E C O N TR O L VALVE
3 S P R IN G F O R P R E S S U R E R E L IE F V A L V E
4 VALVE C O N E
5 A D J U S T IN G W A S H E R
6 VALVE S C R E W
7 S P R IN G F O R V O L U M E C O N T R O L V A L V E
S p e c ia l T ool
T o b e m a n u fa c tu r e d , (F ig . 1 8 B - 3 9 ) .
A IN S T A L L A T IO N T O O L
B IN S T A L L A T IO N T O O L
C IN S T A L L A T IO N S L E E V E
Fig.18B-39
R e p l a c e m e n t o f D r i v e S h a f t a n d S e a l i n g R in g
1. R e m o v e t h e p u m p h o u s in g a n d p re s s th e d r iv e s h a ft
fr o m th e h o u s in g c o v e r. P a y a tte n tio n to th e s h e ll
h a lv e s ( it e m 1 0 ), (F ig . 1 8 B - 4 0 ) .
2. W it h a s c r e w d r iv e r lift th e o il s e a l fr o m th e h o u s in g
c o v e r.
Fig . 1 8 B - 4 0
1 O - R IN G 8 O -R IN G
2 P U M P H O U S IN G 9 B E A R IN G B U S H
3 TH R U S T PLATE 10 S H ELL HALF
4 O IL G U I D E P L A T E 11 D R IV E S H A F T
5 S P R IN G 12 BUSH
6 C A M R IN G 13 O IL S E A L
7 R O T O R W IT H P U M P V A N E S 14 H O U S IN G C O V E R
3. P la c e b o th s h e ll h a lv e s o n t h e d r iv e s h a ft, th e n p re s s th e
d r iv e s h a ft in to t h e h o u s in g c o v e r, (F ig . 1 8 B - 4 1 ) .
N o te : T h e s h e ll h a lv e s d e te r m in e t h e e n d p la y o f t h e d riv e
s h a ft w h ic h is 0 ,7 m m m a x . fo r n e w h ig h p r e s s u r e o il p u m p s
a n d s h o u ld n o t b e m o r e th a n 1 m m fo r u s e d p u m p s .
R e p la c e t h e h ig h p r e s s u r e oil p u m p if t h e e n d p la y is h ig h e r.
10 S H E L L H A LF
11 D R IV E S H A F T
14 H O U S IN G C O V E R
4. U s e t h e in s ta lla tio n to o l to p r e s s t h e b u s h in to th e h o u s in g ,
(F ig . 1 8 B - 4 2 )
F ig . 1 8 B - 4 2
12 B E A R IN G B U S H
B IN S T A L L A T IO N T O O L
.April '96
R e p la c e th e a s s e m b ly s le e v e o n th e d riv e s h a ft a n d
w ith th e in s ta lla tio n to o l p re s s th e oil s e a l in to th e
h o u s in g , (F ig . 1 8 B - 4 3 ) .
F ig . 1 8 B - 4 3
11 D R IV E S H A F T C ASSEM BLY SLEEVE
13 O IL S E A L A IN S T A L L A T IO N T O O L
R e p la c e m e n t o f R o to r a n d C am R ing
1. M o is te n a ll p a rts w ith A T F oil.
2. In s ta ll v o lu m e c o n tro l v a lv e .
3. P la c e t h e ro to r o n t h e d r iv e s h a ft so t h a t th e c o u n te r
s u n k e n d o f t h e s p lin e d b o re fa c e s th e h o u s in g c o v e r.
4. P la c e t h e c a m rin g o n th e fitte d p in s so t h a t th e
r e s p e c tiv e m a r k in g s o n th e h o u s in g c o v e r a n d o n th e
c a m rin g a r e a lig n e d , (F ig . 1 8 B - 4 4 ) .
F ig . 1 8 B - 4 4
6 C A M R IN G 15 F I T T E D P IN
11 D R IV E S H A F T 16 M A R K IN G L IN E
N o te : W h e n a n e w c a m rin g is in s ta lle d , it m u s t b e
p o s itio n e d s o t h a t t h e h y d r a u lic o il b o re s a r e a c c u r a te ly
lo c a te d a b o v e th e r e c e s s e s in t h e h o u s in g c o v e r,
(ite m 4 & 5 F ig . 1 8 B - 4 5 ) .
5. In s e r t p u m p v a n e s in to s lo ts o r ro to r so t h a t th e
ro u n d e d e n d s a r e fa c in g o u tw a rd s to w a r d th e c a m
rin g .
6. P o s itio n t h e th r u s t p la te o v e r th e c a m rin g , e n s u rin g

m a r k in g s a r e a lig n e d ,
N o te : T h e o u tle t h o le s fo r th e h y d r a u lic oil s h o u ld b e a b o v e

t h e h y d r a u lic o il b o re s ( it e m 5 ) o f th e c a m rin g .
F ig 1 8 B - 4 5
A O IL I N F L O W F R O M S U P P L Y C O N T A IN E R
B H Y D R A U L IC O IL O U T F L O W F R O M C A M R I N G
ROTO R
PUMP VANE
H Y D R A U L IC O IL U N D E R P U M P V A N E
R E C E S S O N H O U S I N G F O R IN L E T O F H Y D R . O IL
IN T O B O R E
O IL B O R E 7 IN T A K E B O R E S
C A M R IN G 8 D R IV E S H A F T
April ‘96
R e p la c in g t h e P u m p
1. F it th e m o u n tin g b r a c k e t to th e p u m p , in s e r t b o lts a n d
tig h te n to th e s p e c ifie d to r q u e , (F ig . 1 8 B - 4 6 ) .
F ig . 1 8 B - 4 6
2. F it t h e p u lle y to t h e p u m p , c la m p t h e p u lle y in a v ic e
fitte d w ith s o ft ja w s , r e p la c e t h e re ta in in g n u t a n d
tig h te n to t h e s p e c ifie d to r q u e , (F ig . 1 8 B - 4 7 ) .
mi
F ig . 1 8 B - 4 7
3. F it th e p u m p to th e m o u n tin g in t h e c y lin d e r b lo c k ,
in s e rt th e b o tto m r e ta in in g b o lt. D o n o t tig h te n ,
(F ig . 1 8 B - 4 8 ) .
III!
F ig . 1 8 B - 4 8
4. F it t h e V - b e lt to t h e p u lle y , (F ig . 1 8 B - 4 9 ) .
\ r ■im ras
Fig. 18B-49
April '96
5. In s e r t th e V - b e lt a d ju s te r c la m p b o lt. D o n o t tig h te n ,
(F ig . 1 8 B - 5 0 ) .
6. U s e s p e c ia l to o l 4 0 2 0 2 3 2 1 a n d a d ju s t th e V -b e lt te n s io n
to 4 0 - 5 0 kg (n e w b e lts ), ru n th e e n g in e fo r 1 0 - 1 5 m in .
a n d r e -c h e c k t h e te n s io n , w h ic h s h o u ld b e 3 0 - 4 0 kg.
A d ju s t to 3 0 - 4 0 kg if t h is fig u r e is n o t re a c h e d .
P o s itio n t h e te n s io n g a u g e o n t h e b e lt w ith th e fla n g e
p a r a lle l a g a in s t t h e b e lt e d g e . G r a d u a lly a p p ly p re s s u re
to t h e p r e s s u r e p a d . W h e n a “c lic k ” is h e a r d o r fe lt, s to p
a n d r e m o v e th e g a u g e . T u rn t h e g a u g e s id e w a y s a n d
t a k e a r e a d in g a t t h e s p o t w h e r e th e in d ic a to r a r m
in te r s e c ts t h e s c a le , (F ig . 1 8 B - 5 1 ) .
7. T ig h t e n th e lo c k n u t o n th e V - b e lt a d ju s te r,
(F ig . 1 8 B - 5 2 ) .
8. T ig h t e n t h e c la m p b o lt o n th e V - b e lt a d ju s te r,
(F ig . 1 8 B - 5 3 ) .
April '96
9. T ig h te n th e b o tto m p u m p r e ta in in g b o lt, (F ig . 1 8 B - 5 4 ) .
SPECIAL T O O LS FO R SECTION 18B
O B T A IN A B L E F R O M : G R U N D Y T E C H N I F O R M , B U R M A N R O A D , D E A L P A R K , P O R T E L IZ A B E T H 6 0 0 1
TEL: (0 4 1 ) 4 3 -2 2 9 9 , FA X : (0 4 1 ) 4 3 -2 2 2 4
. April ‘96
SECTION 18C-1
Exhaust Brake
CONTENTS OF SECTION 18C
Page
I L L U S T R A T I O N ...................................................................................................................................................................................................................................1 8 C - 2
I N T R O D U C T I O N ................................................................................................................................................................................................................................ 1 8 C - 3
S P E C I F I C A T I O N S ............................................................................................................................................................................................................................. 1 8 C - 3
R E M O V I N G T H E E X H A U S T B R A K E ..................................................................................................................................................................................... 1 8 C - 4
R E P L A C I N G T H E E X H A U S T B R A K E .................................................................................................................................................................................. 1 8 C - 5
C H E C K I N G E X H A U S T B R A K E S E T T I N G ......................................................................................................................................................................... 1 8 C - 7
April '96
Exhaust Brake 18C-2
1 SHAFT A ND BUSH 7 N U T AND BOLT

2 EXH A U ST BRAKE VALVE 8 NUT AND W ASHER
3 V A L V E R E T A IN IN G N U T A N D B O L T 9 O P E R A T IN G C Y L IN D E R
4 B R A C K E T R E T A IN IN G B O L T 10 E X H A U S T B R A K E IN P O S I T I O N
5 SHAFT BUSH 11 BRACKET
6 O P E R A T IN G A R M 12 EXHAUST BRAKE BO DY
April '96
Exhaust Brake 18C-3
D e p e n d in g o n a p p lic a tio n , s o m e A D E 3 6 0 s e rie s e n g in e s a r e fitte d w ith a n e x h a u s t b r a k e c o n s is tin g o f a b u tte rfly v a lv e

p iv o tin g o n a s p in d le w ith in a s e p a r a te h o u s in g , s itu a te d in th e e x h a u s t s y s te m . T h e b u tte rfly v a lv e is a c tu a te d b y a
p n e u m a t ic a lly o p e r a te d le v e r, w h ic h is s e c u r e d to th e b u tte rfly v a lv e s p in d le , w h e r e th e s p in d le p r o tru d e s th ro u g h th e
h o u s in g .
W h e n a fo o t o p e r a te d e x h a u s t b r a k e v a lv e , lo c a te d on th e flo o r o f th e c a b (d riv e r s s id e ), is p r e s s e d , c o m p r e s s e d a ir flo w s

p a s t a v a lv e a n d e n te r s a n a ir o p e r a te d c y lin d e r. A p is to n in s id e th e c y lin d e r a tta c h e d to th e v a lv e s p in d le p u s h e s th e le v e r
fo rw a rd a n d th u s c lo s e s th e v a lv e . A t th e s a m e t im e th e fu e l s u p p ly to th e in je c to rs is c u t o ff (i.e . t h e s p e e d c o n tro l le v e r
m o v e s to t h e s to p p o s itio n ).
T h e p r e s s u r e b u ilt-u p in th e e x h a u s t m a n ifo ld a n d c o m b u s tio n c h a m b e r s e x e rts a b r a k in g e ffe c t v ia th e tr a n s m is s io n to th e

w h e e ls o f t h e v e h ic le .
C o n tr o l le v e r c la m p b o l t ..................................... M 6 .............................................................. 8 ,5 N m
C o n tr o l le v e r s e c u r in g b o lt................................ M 1 0 ........................................................... 4 2 N m
C le a r a n c e b e tw e e n v a lv e a n d v a lv e b o d y .......................................................................0 , 2 - 0 ,5 mm
April '96
Exhaust Brake 18C-4
R E M O V IN G A N D R E P L A C IN G T H E E X H A U S T B R A K E
VALVE, BUSHES AN D SH AFT
R e m o v in g
1. D is c o n n e c t th e in n e r a n d o u te r c o n tro l lin k a g e .
2. D is c o n n e c t a n d r e m o v e t h e e x h a u s t b r a k e b o d y fr o m th e
e x h a u s t d o w n p ip e .
3. M o u n t th e e x h a u s t b r a k e b o d y in a v ic e fitte d w ith s o ft
ja w s . M a r k th e lo c a tio n o f th e e x h a u s t b r a k e v a lv e to th e
c o n tro l le v e r, (F ig . 1 8 C - 1 ) .
4. R e m o v e t h e e x h a u s t b r a k e c y lin d e r b a ll jo in t re ta in in g
c lip a n d le v e r o f f t h e o p e r a tin g a r m , (F ig . 1 8 C - 2 ) .
5. R e m o v e th e c la m p b o lt fr o m t h e o p e r a tin g a r m , (F ig .
1 8 C -3 ).
6. R e m o v e t h e o p e r a tin g a r m fr o m t h e s h a ft, (F ig . 1 8 C - 4 ) .
Fig. 18C-4
Exhaust Brake 18C-5
April '96
Exhaust Brake 18C-6
2. In s e r t th e b o lt r e ta in in g th e b r a k e v a lv e to th e s h a ft a n d
tig h te n to th e s p e c ifie d to r q u e , (F ig . 1 8 C - 9 ) .
3. M e a s u r e t h e c le a r a n c e b e tw e e n th e h o u s in g a n d th e
b r a k e v a lv e w ith a fe e le r g a u g e , r e fe r to s p e c ific a tio n .
T h e c le a r a n c e c a n b e a lt e r e d b y m o v in g th e b r a k e v a lv e
s h a ft in o r o u t, (F ig . 1 8 C - 1 0 ) .
4. L in e u p t h e m a r k s a n d r e p la c e th e c o n tro l le v e r to th e b r a k e
v a lv e s h a ft, (F ig . 1 8 C - 1 1 ) .
5. In s e r t th e c o n tro l le v e r r e ta in in g b o lt a n d tig h te n to th e
s p e c ifie d to r q u e , (F ig . 1 8 C - 1 2 ) .
Exhaust Brake 18C-7
6. R e p la c e th e e x h a u s t b r a k e c y lin d e r b a ll jo in t to th e o p e ra tin g
a r m a n d in s e r t th e re ta in in g c lip , (F ig . 1 8 C - 1 3 ) .
F ig . 1 8 C - 1 3
C h e c k in g t h e E x h a u s t B ra k e S e ttin g
1. D is c o n n e c t t h e e x h a u s t p ip e fr o m th e e x h a u s t b r a k e b o d y .
2. E n s u r e t h a t t h e e x h a u s t b r a k e v a lv e is in t h e fu lly o p e n
p o s itio n , (F ig . 1 8 C - 1 4 ) .
3. O p e r a t e t h e e x h a u s t b r a k e a n d e n s u r e t h a t th e v a lv e fu lly
c lo s e s .
F ig . 1 8 C - 1 4
A d ju stin g t h e E x h a u s t B ra k e C y lin d er L en gth

----------------- 170mm-----------------
1. R e m o v e t h e o p e r a tin g le v e r.
r
is
... ,
2. A d ju s t t h e e x h a u s t b r a k e c y lin d e r le n g th to 1 7 0 m m fr o m th e
c e n tr e o f t h e m o u n tin g b o lt to th e c e n tr e o f th e b a ll jo in t
h e a d , (F ig . 1 8 C - 1 5
n=
F ig . 1 8 C - 1 5
3. O p e n th e e x h a u s t b r a k e v a lv e fu lly a n d r e p la c e th e o p e ra tin g
le v e r. P r e -te n s io n t h e c y lin d e r b y 2 to 4 m m a n d fit th e b a ll
jo in t, (F ig . 1 8 C - 1 6 ) .
4. In s e r t t h e b o lt in to t h e o p e r a tin g le v e r a n d tig h te n to th e s p e
c ifie d to rq u e .
5. In s e r t t h e lo c k in g c lip to th e b a ll jo in t.
6. C o n n e c t t h e e x h a u s t p ip e to t h e e x h a u s t b r a k e b o d y .
Fig. 18C-16
April '96
^ (aph itigioit Diesel Club
ADE 364 and ADE 366
Workshop Manual
Section 18D - Flywheel
B a rrin g to n D iesel C lu b
______________________ SECTION 18D
Flywheel
CONTENTS OF SECTION 18D
Page
I L L U S T R A T I O N ...................................................................................................................................................................................................................................1 8 D - 2
I N T R O D U C T I O N ................................................................................................................................................................................................................................1 8 D - 3
S P E C I F I C A T I O N S ............................................................................................................................................................................................................................. 1 8 D - 3
R E M O V I N G T H E F L Y W H E E L ..................................................................................................................................................................... 1 8 D -4
R E P L A C I N G T H E F L Y W H E E L .................................................................................................................................................................................................1 8 D - 5
R E M O V I N G A N D R E P L A C I N G T H E R IN G G E A R ........................................................................................................................................................1 8 D - 6
R E M O V I N G A N D R E P L A C I N G T H E S P I G O T B E A R IN G ......................................................................................................................................... 1 8 D - 8
S P E C IA L T O O L S ................................................................................................................................................................................................................................1 8 D - 8
April '96
Flywheel 18D-2
1 S T A R T E R R IN G G E A R 4 B E A R IN G R E T A IN E R
2 FLYW HEEL 5 F L Y W H E E L R E T A IN IN G B O L T
3 S P I G O T B E A R IN G
April '96
Flywheel 18D-3
M a n u f a c t u r e d fr o m h ig h g r a d e g r e y c a s t iron th e fly w h e e l is p re c is io n m a c h in e d a n d b a la n c e d to fin e lim its T h e s ta rte r

rin g g e a r is h e a t tr e a t e d a n d s h ru n k o n to th e fly w h e e l. E ig h t s tre tc h b o lts re ta in th e fly w h e e l to th e c r a n k s h a ft W hen
re m o v in g it is n o t n e c e s s a r y to m a r k th e r e la tiv e p o s itio n o f th e fly w h e e l a s th e e ig h t b o lt h o le s a r e d rille d e c c e n tric a lly ,
m a k in g in c o r re c t fittin g im p o s s ib le .
T h e fly w h e e l is t h e s to r e h o u s e o f e n e r g y a n d is re q u ire d to
a. p r o v id e e n e r g y fo r o p e r a tin g th e e n g in e b e tw e e n p o w e r s tro k e s , a n d
b. to r e d u c e t h e v a r ia tio n in th e r o ta tio n a l s p e e d o f th e c r a n k s h a ft d u rin g th e e n g in e c y c le
a s it tr a n s m its p o w e r to th e d riv e n m a c h in e .
FLYW HEEL
D ia m e t e r fo r s t a r t e r rin g g e a r 3 3 5 , 3 9 0 to 3 3 5 ,5 3 0
D ia m e t e r fo r m o u n tin g c r a n k s h a ft fla n g e 1 3 0 , 0 0 0 to 1 3 0 ,0 4 0
A x ia l r u n -o u t c r a n k s h a ft fla n g e 0 ,1
F ly w h e e l r u n -o u t m o u n te d to c r a n k s h a ft ra d ia l 0 ,1
la te r a l 0 ,1
Im b a la n c e o f fly w h e e l w ith rin g g e a r 2 0 gem
M a x im u m c lu tc h s u r f a c e m a te r ia l r e m o v a l 2 mm
C lu tc h s u r f a c e fin is h R z 1 6 |jm
S T A R T E R R IN G G E A R
ID o f rin g g e a r 3 3 4 , 6 9 0 to 3 3 4 , 8 3 0
R in g g e a r in te r fe r e n c e fit 0 , 5 6 to 0 ,8 4
L a te r a l r u n - o u t o f m o u n te d s ta r te r rin g g e a r 0 ,5 m m m a x .
S ta r te r rin g g e a r m o u n te d a t a te m p e r a t u r e o f 2 5 0 ° to 2 8 0 °
F ly w h e e l to c r a n k s h a f t M 1 2 x 1 ,5 ... In itia l.............................. 30 - 40 Nm

................................................................................................................F i n a l ................................ 90°-110°
B o lt le n g th 2 5 , 8 m m .................................................................. M a x . s tre tc h le n g th 2 6 .3 m m
o r B o lt le n g th 4 3 , 8 m m ............................................................ M a x . s tre tc h le n g th 4 4 .3 m m
B e ll h o u s in g t o r q u e ....................................................................................................................................................... 110 Nm
April '96
Flywheel 18D-4
REMOVAL AND REPLACEM ENT

O F F L Y W H E E L A N D H O U S IN G
R em oval
1. U n s c r e w a n d r e m o v e th e b o lts re ta in in g th e fly w h e e l,
(F ig . 1 8 D - 1 ).
Fig . 1 8 D -1
2. L ift o ff t h e fly w h e e l, (F ig . 1 8 D - 2 ) .
F ig . 1 8 D - 2
3. U n s c r e w t h e fo u r b o lts r e ta in in g t h e fly w h e e l h o u s in g to th e
c y lin d e r b lo c k , (F ig . 1 8 D - 3 ) .
F ig . 1 8 D - 3
4. U n s c r e w t h e tw o o u te r b o lts , (F ig . 1 8 D - 4 ) .
Fig. 18D-4
. April '96
Flywheel 18D-5
5. L ift o ff th e h o u s in g , (F ig . 1 8 D - 5 ).
F ig . 1 8 D - 5
1. F it t h e fly w h e e l h o u s in g to t h e c y lin d e r b lo c k . R e p la c e
a n d tig h te n th e o u te r b o lts , F ig . 1 8 D - 6 ) .
F ig . 1 8 D - 6
2. In s e r t t h e fo u r in n e r b o lts , (F ig . 1 8 D - 7 ) .
F ig . 1 8 D - 7
3. In s e r t th e tw o to p b o lts a n d tig h te n a ll b o lts to th e s p e c ifie d

to rq u e , (F ig . 1 8 D - 8 ) .
Fig. 18D-8
April '96
Flywheel 18D-6
4. R e p la c e th e fly w h e e l, in s e r t th e b o lts a n d tig h te n to th e

s p e c ifie d to rq u e , (F ig . 1 8 D - 9 ) .
F ig . 1 8 D - 9
REMOVAL AND REPLACEM ENT OF

S T A R T E R R IN G G E A R
Rem oval
1. R e m o v e t h e fly w h e e l, (F ig . 1 8 D - 1 0 ) .
F ig . 1 8 D - 1 0
2. P u n c h m a r k th e rin g g e a r a n d d rill tw o h o le s in to th e s id e o f
th e g e a r . D o n o t d rill th r o u g h t h e rin g g e a r a s th is w ill d a m a g e
th e fly w h e e l, (F ig . 1 8 D - 1 1 ) .
F'<r I 8 D - I I
3. W it h a s h a r p c h is e l s p lit t h e rin g g e a r b e tw e e n th e d rille d
h o le s a n d r e m o v e t h e g e a r fr o m th e fly w h e e l, (F ig . 1 8 D - 1 2 ) .
A t t e n t i o n ! T h o r o u g h ly c le a n t h e fly w h e e l a n d fla n g e p rio r to

re p la c in g .
Fig. 18D-12
April '96
Flywheel 18D-7
R e p la c in g
1. P la c e t h e fly w h e e l o n a fla t s u rfa c e .
2. H e a t th e n e w rin g g e a r to a p p r o x im a te ly 2 5 0 ° C w ith a
w e ld in g to rc h o r o th e r s u ita b le h e a t s o u rc e , (fig . 1 8 D - 1 3 ) .
F ig . 1 8 D - 1 3
3. P la c e th e h e a te d rin g o n to t h e fly w h e e l, (F ig . 1 8 D - 1 4 ) .
F ig . 1 8 D - 1 4
4. If n e c e s s a r y u s e a c o p p e r o r a lu m in iu m h a m m e r to fu lly
lo c a te th e rin g g e a r o n th e fly w h e e l s o t h a t it s e a ts a g a in s t
th e f la n g e s h o u ld e r , (F ig . 1 8 D - 1 5 ) .
F ig . 1 8 D - 1 5
5. R e p la c e t h e fly w h e e l a n d tig h te n th e b o lts to th e s p e c ifie d

to r q u e , (F ig . 1 8 D - 1 6 ) .
Fig. 18D-16
April ‘96
Flywheel 18D-8
R E M O V IN G A N D R E P L A C IN G
T H E S P IG O T B E A R IN G
T h e fly w h e e l s p ig o t b e a r in g c a n b e e x tra c te d w ith th e

fly w h e e l in p o s itio n o r r e m o v e d fr o m t h e e n g in e .
1. W ith s p e c ia l to o l 4 0 2 0 0 3 8 1 pu ll th e s p ig o t b e a r in g fr o m
th e h o u s in g , (F ig . 1 8 D - 1 7 ) .
2. In s e r t th e b e a r in g in to t h e h o u s in g a n d d r iv e in to p la c e
w ith a s u ita b le d rift, (F ig . 1 8 D - 1 8 ) .
A tte n tio n ! T h e s p ig o t b e a r in g is s e a le d a n d d o e s n o t
r e q u ire g r e a s in g .
S P E C IA L T O O L S F O R S E C T IO N 1 8 D
O B T A IN A B L E F R O M : G R U N D Y T E C H N I F O R M , B U R M A N R O A D , D E A L P A R K , P O R T E L IZ A B E T H 6 0 0 1
TEL: (0 4 1 ) 4 3 -2 2 9 9 , FA X : (0 4 1 ) 4 3 -2 2 2 4
April ‘96
SECTION 18E-1
Alternator and Starter Motor
CONTENTS OF SECTION 18E
Page
I N T R O D U C T I O N ................................................................................................................................................................................................................................ 1 8 E - 2
T O R Q U E S P E C I F I C A T I O N S ..................................................................................................................................................................................................... 1 8 E - 2
ALTERNATO R - S E C T I O N A L V I E W ..................................................................................................................................................................................... 1 8 -3
P R E C A U T I O N S ................................................................................................................................................................................................................................... 1 8 E - 4
M A I N T E N A N C E ................................................................................................................................................................................................................................... 1 8 E - 4
T E S T I N G T H E A L T E R N A T O R IN P O S I T I O N .................................................................................................................................................................. 1 8 E - 4
T R O U B L E S H O O T I N G ...................................................................................................................................................................................................................1 8 E - 4
STARTER M OTOR
G E N E R A L ............................................................................................................................................................................................................................................... 1 8 E - 5
R O U T I N E M A I N T E N A N C E ..........................................................................................................................................................................................................1 8 E - 5
S E R V IC IN G - T E S T I N G IN P O S I T I O N ..............................................................................................................................................................................1 8 E - 6
April '96
Alternator and Starter Motor 18E-2
INTRODUCTION
A ltern ator
A lte r n a to r s u s e d o n th e 3 6 0 s e rie s e n g in e s a r e o f th e c la w p o le ty p e w h ic h ra n g e fr o m 1 4 V - 5 5 A to 1 4 V - 9 0 A a n d 2 8 V - 2 8 A
to 2 8 V - 5 5 A . T h e s e a lt e r n a t o r s a r e fitte d w ith e ith e r o n e o r tw o d riv e p u lle y s , d e p e n d in g o n a p p lic a tio n .
S ta rter M otor
S ta r te r m o to r s fitte d to t h e 3 6 0 s e rie s e n g in e s a r e o f th e fo u r p o le , fo u r b ru s h e a rth re tu rn ty p e w ith s e rie s p a ra lle l

c o n n e c te d fie ld c o ils . T h e s e s t a r t e r m o to rs r a n g e fr o m 1 2 V - 3 k W to 1 2 V - 3 ,5 k W a n d 2 4 V ~ 4 k W to 2 4 V - 4 , 5 k W d e p e n d in g
o n a p p lic a tio n .
TORQUE SPECIFICATIO NS
ALTERNATOR AND STAR TER MOTOR
S ta r te r to fly w h e e l h o u s in g ........ . M 1 0 ............................................................ 6 0 N m

A lte r n a to r to b r a c k e t ..................... , M 1 2 x 1 , 5 ...............................................6 0 N m
A d ju s tin g b o lt to c y lin d e r b lo c k . M 1 0 ............................................................ 4 0 N m
A d ju s tin g b o lt c l a m p ..................... . M 1 2 ............................................................ 3 5 N m
P u lle y to a lt e r n a t o r ......................... . M 1 4 x 1 , 5 ...............................................6 0 N m
P u lle y to a lt e r n a t o r ......................... . M 1 6 x 1 , 5 ............................................... 8 0 N m
April ‘96
S E C T IO N A L V IE W O F T H E K 1 C L A W -P O L E A L T E R N A T O R
April '96
ALTERNATO R
P r e c a u tio n s
T h e d io d e s in th e a lt e r n a t o r fu n c tio n a s o n e -w a y v a lv e s . a. In s p e c t th e V -b e lts r e g u la r ly fo r w e a r a n d c o rr e c t te n
T h e tr a n s is to r s in th e r e g u la to r /c o n tr o l b o x o p e r a te a s fa s t sio n . It is im p o rta n t to e n s u r e th a t all V -b e lts o n a m u l
s w itc h e s . B o th a r e a c c u r a te a n d s e n s itiv e . tip le d riv e have e q u a l te n s io n a n d a r e e a c h c a rry in g
th e ir s h a r e of th e lo a d . S la c k d r iv e b e lts w ill w e a r r a
T h e y d o n o t w e a r o u t a n d s e ld o m r e q u ire a d ju s tm e n t, b u t p id ly a n d c a u s e s lip w h ic h w ill n o t d riv e th e a lte r n a to r
b e c a u s e th e y a r e s e n s itiv e to v o lta g e c h a n g e s a n d high a t th e re q u ire d s p e e d . V -b e lts w h ic h a r e to o tig h t im
te m p e r a tu r e th e fo llo w in g p r e c a u tio n s a r e v ita l to p re v e n t p o s e s e v e r e s id e th ru s t on th e a lt e r n a t o r b e a r in g s a n d
th e m fr o m b e in g d e s tro y e d : s h o rte n th e ir life. E n s u r e p e rio d ic a lly t h a t th e a lte r n a to r
is c o rre c tly a lig n e d to th e d riv e .
a. DO NOT d is c o n n e c t th e b a tte r y w h ile th e e n g in e is
ru n n in g . T h is w ill c a u s e a v o lta g e s u rg e in th e a lt e r n a b. D o n o t r e p la c e fa u lty V -b e lts in d iv id u a lly in a m u lti b e lt
to r c h a r g in g s y s te m w h ic h w ill im m e d ia t e ly ru in th e s y s te m . A c o m p le te m a tc h e d s e t o f V -b e lts m u s t a l
d io d e s o r tr a n s is to r s . w a y s be used.
b. DO NO T d is c o n n e c t th e le a d w ith o u t firs t s to p p in g th e c. K e e p th e a lt e r n a t o r c le a n w ith a c lo th m o is te n e d w ith a

e n g in e a n d tu rn in g a ll e le c tr ic a l s w itc h e s to th e o ff s u ita b le c le a n in g flu id . E n s u re th a t v e n tila tio n slo ts
p o s itio n . a n d a ir s p a c e s a r e c le a r a n d u n o b s tr u c te d .
c. DO NOT c a u s e a s h o r t c irc u it b y c o n n e c tin g le a d s to d. R e m o v e a n y d irt a c c u m u la te d on th e r e g u la to r/c o n tr o l

in c o rre c t te r m in a ls . A lw a y s fir s t id e n tify a le a d to its b o x h o u s in g . E n s u re th a t c o o lin g a ir c a n p a s s fre e ly
c o rr e c t t e r m in a l. A s h o r t c irc u it o r w r o n g c o n n e c tio n o v e r th e c a s in g .
g iv in g re v e rs e p o la r ity w ill im m e d ia t e ly and p e rm a

n e n tly ru in tr a n s is t o r s o r d io d e s .
T e stin g th e a ltern a to r in p o s itio n
d. DO NOT c o n n e c t a b a tte r y to th e s y s te m w ith o u t p rio r
c h e c k in g fo r c o r r e c t p o la r ity a n d v o lta g e . F irs t c h e c k th e V -b e lts fo r c o n d itio n and te n s io n . The
n o m in a l h o t o u tp u ts a t 6 0 0 0 r /m in ( a lte r n a to r s p e e d ) a r e
e. DO NOT “fla s h " c o n n e c tio n s to c h e c k fo r c u rr e n t flo w . a s fo llo w s :
No m a tte r h o w b r ie f t h e c o n ta c t, th e tr a n s is to r s m a y 14V - 35A
b e r u in e d .
28V - 28A
M a in ten a n ce
These fig u re s m ay be exceeded s lig h tly w hen th e
T h e a lt e r n a t o r c h a r g in g s y s te m w ill n o r m a lly r e q u ire v e ry a lte r n a to r is ru n n in g co ld .
little a tte n tio n , b u t it s h o u ld b e k e p t fr e e fr o m d irt a n d

c h e c k s s h o u ld b e m a d e if th e a lt e r n a t o r fa ils to k e e p th e A d u s t p r o o fe d a lt e r n a t o r c a n b e fitte d a s a n o p tio n ,
b a tte ry c h a r g e d . d e p e n d in g o n a p p lic a tio n .
T ro u b le S h o o tin g
If a m a lfu n c tio n s h o u ld d e v e lo p in t h e c u rr e n t g e n e r a tin g s y s te m it m u s t b e k e p t in m in d t h a t tr o u b le s o u r c e s m a y e x is t in

th e b a tte ry , c a b le s o r o t h e r lo c a tio n s b e s id e s th e a lte r n a t o r o r re g u la to r. T h e m o s t c o m m o n fa u lt s y m p to m s a r e lis te d in
th e c h a r t b e lo w w ith p r o b a b le c a u s e s a n d a p p r o p r ia te c o rr e c tiv e m e a s u re s :
P r o b lem - C a u s e C o rrectio n
B a ttery is d e a d o r in s u ffic ie n tly c h a r g e d ; R e c h a r g e b a tte ry
1. O p e n c ir c u it o r c o n ta c t r e s is ta n c e in c h a r g in g c irc u it R e m o v e o p e n c irc u it o r c o n ta c t r e s is ta n c e
2. D e fe c tiv e b a tte r y R e p la c e b a tte ry
3. D e fe c tiv e a lt e r n a t o r H a v e a lt e r n a t o r r e p a ire d in a u th o r is e d w o rk s h o p
4. D e fe c tiv e r e g u la to r R e p la c e r e g u la to r
5. V - b e lt lo o s e T ig h te n V -b e lt
April '96
P r o b le m - C a u s e ________________________________________ Correction
C h a rg e in d ic a to r la m p d o e s n o t burn w ith th e e n g in e
s t o p p e d an d t h e ig n itio n o n .
1. In d ic a to r b u lb is b u rn e d o u t R e p la c e w ith a n e w b u lb
2. D e a d b a tte ry C h a r g e b a tte ry
3. D e fe c tiv e b a tte ry R e p la c e b a tte ry
4. L o o s e o r d a m a g e d c a b le s R e p la c e o f tig h te n c a b le s
5. D e fe c tiv e r e g u la to r R e p la c e re g u la to r
6. S h o r te d p o s itiv e d io d e in th e a lte r n a to r H a v e a lte r n a to r r e p a ire d b y a u th o ris e d w o rk s h o p
7. W o r n c a rb o n b r u s h e s R e p la c e b ru s h e s
8. O x id e la y e r o n s lip rin g s o r b ro k e n w ir e in ro to r H a v e a lte r n a to r r e p a ire d

w in d in g
C h a rg e in d ic a to r la m p c o n t in u e s t o burn b righ tly

d u rin g h ig h e r e n g in e s p e e d s
1. C a b le D + /6 1 is s h o r te d to g ro u n d R e p a ir o r r e p la c e c a b le
3. O v e r v o lta g e p r o te c tio n d e v ic e d e fe c tiv e R e p la c e o v e r v o lta g e p ro te c tio n d e v ic e
4. D e fe c tiv e re c tifie r, d irty s lip rin g s , s h o rt in c a b le “D F ” H a v e a lte r n a to r r e p a ire d b y a u th o ris e d w o rk s h o p

o r in ro to r w in d in g
C h a rg e in d ic a to r la m p b u rn s b rig h tly w ith e n g in e

s t o p p e d , b u t o n ly d im s o r g lim m e r s w ith e n g in e
ru n n in g:
1. P o o r c o n n e c tio n s (c o n t a c t r e s is ta n c e ) in th e c h a r R e m o v e c o n ta c t r e s is ta n c e
g in g c irc u it o r in t h e c a b le to th e c h a r g e in d ic a to r la m p
3. D e fe c tiv e a lte r n a t o r H a v e a lte r n a to r r e p a ire d
C h a r g e in d ic a to r la m p flic k e r s
1. C o n ta c t r e g u la to r m a y b e in c o r re c tly a d ju s te d o r R e p la c e r e g u la to r
r e g u la tin g r e s is to r is b u rn e d o u t
STARTER MOTOR
c. S e lf-in d e x in g p in io n to e n s u re s m o o th engagem ent
G en era l b e tw e e n th e p in io n a n d t h e rin g g e a r te e th b e fo re th e
s ta rte r m o to r b e g in s to ro ta te .
T h is s t a r t e r m o to r is a fo u r p o le , fo u r b ru s h e a rth re tu rn
m a c h in e w ith s e rie s p a r a lle l c o n n e c te d fie ld co ils. d. A r m a t u r e b ra k in g s y s te m to e n s u r e r a p id re tu rn to re s t
w h e n th e s ta rte r b u tto n is re le a s e d .
A s o le n o id o p e r a te d p re -e n g a g e d d riv e a s s e m b ly is
c a rr ie d o n a n e x te n s io n o f th e a r m a tu r e s h a ft. T h e m a in
f e a tu r e s o f t h is ty p e o f d r iv e a r e a s fo llo w s :
a. P o s itiv e p in io n e n g a g e m e n t p re v e n tin g th e p in io n b e Routine Maintenance

in g th r o w n o u t o f m e s h w h ile s ta rtin g .
a. The s ta rte r m o to r re q u ire s n o r o u tin e m a in t e n a n c e b e
b. An o v e r ru n n in g c lu tc h is in c o r p o ra te d in th e d riv e a s y o n d th e o c c a s io n a l in s p e c tio n o f th e e le c tr ic a l c o n
s e m b ly g iv in g o v e r s p e e d a n d o v e r lo a d p ro te c tio n . n e c tio n s , b ru s h g e a r a n d th e c o m m u t a to r , w h ic h m u s t
b e c le a n a n d tig h t.
April ‘96
b. A fte r th e s ta r te r m o to r h a s been in s e rv ic e fo r s o m e m in a ls b e fo re p ro c e e d in g . O p e r a te th e s ta rte r c o n tro l a n d

tim e , r e m o v e th e s ta r te r m o to r fr o m th e e n g in e , s u b m it w a tc h fo r th e fo llo w in g s y m p to m s :
it to a th o r o u g h b e n c h in s p e c tio n .
1. The la m p s d im (o r th e v o ltm e te r r e a d in g d ro p s to
a b o u t 6 v o its ) a n d th e m o to r d o e s n o t tu rn th e e n g in e .
1. B ru s h w e a r (th is is a fa ir in d ic a tio n o f th e a m o u n t o f C h e c k th e b a tte ry (m u s t b e a t le a s t h a lf-c h a r g e d ) a n d
w o rk d o n e ), re n e w b ru s h e s w o rn to or a p p r o a c h in g b a tte ry p o s ts (c le a n a n d g o o d e a r th c o n n e c tio n )
7 ,9 m m le n g th .
2. Lam ps do n o t d im , th e v o ltm e te r re a d in g r e m a in s
2. B ru s h s p rin g te n s io n : C o r r e c t te n s io n is 0 ,8 5 - 1 ,1 3 N , s te a d y a t a b o u t 1 2 v o lts , and th e m o to r d o e s n o t tu rn
r e n e w s p rin g s if te n s io n h a s d r o p p e d b e lo w 0 , 7 1 N. th e e n g in e . Connect v o ltm e te r b e tw e e n s o le n o id te r
m in a l a n d s ta rte r y o k e , th e n o p e r a te s ta rte r. No v o lts
3. S k im c o m m u t a t o r if it is p itte d o r b a d ly w o rn . in d ic a te d
4. C heck b e a r in g s fo r e x c e s s iv e s id e p la y on a r m a tu r e C a u ses:
s h a ft.
a. P o o r p o s t c o n n e c tio n a t b a tte ry .
5. C h e c k p in io n m o v e m e n t.
b. B a d e a rth c o n n e c tio n .
6. C le a n a n d lu b r ic a t e p in io n s le e v e b e a rin g .
c. B ro k e n s ta rte r le a d , b a tte ry to s ta r te r
7. C le a n a n d lu b r ic a te d r iv e e n d b r a c k e t b u s h .
F u ll v o lts , i.e . 1 2 /1 4 v o lts in d ic a te d :
S e r v ic in g - T e s tin g in P o s it io n - S y m p t o m s a. F a u lty s o le n o id s w itc h .
S w itc h o n th e lig h ts . If th e v e h ic le is n o t e q u ip p e d w ith b. O p e n c irc u it in s t a r te r - c h e c k b ru s h e s ,

lig h tin g c o n n e c t a 0 / 2 0 v o ltm e te r a c r o s s th e b a tte r y te r -
C u t-a w a y v ie w o f p re e n g a g e d d riv e sta r tin g m o to r

w ith o u te r -w e d g e roller ty p e o v err u n n in g c lu tc h .
April '96
Diesel Club
ADE 364 and ADE 366
Workshop Manual
Section 18 F - Compressor and Vacuum Pump
B a rrin g to n D iesel C h ib
SECTION 18F-1
Compressor/Vacuum Pump
CONTENTS OF SECTION 18F
Page
IL L U S T R A T IO N - C A M S H A F T D R IV E N C O M P R E S S O R ..........................................................................................................................................1 8 F - 2
I N T R O D U C T I O N ................................................................................................................................................................................................................................ 1 8 F -3
S P E C I F I C A T I O N S ............................................................................................................................................................................................................................. 1 8 F - 3
T O R Q U E S P E C I F I C A T I O N S ......................................................................................................................................................................................................1 8 F - 4
M E A S U R IN G T H E B E A R IN G C L E A R A N C E ..................................................................................................................................................................... 1 8 F - 5
D IS M A N T L IN G T H E C Y L IN D E R H E A D ................................................................................................................................................................................1 8 F -7
R E - A S S E M B L Y O F T H E C Y L IN D E R H E A D ..................................................................................................................................................................... 1 8 F - 8
S P E C IA L T O O L S F O R T H I S S E C T I O N .............................................................................................................................................................................. 1 8 F - 9
B E L T - D R I V E N C O M P R E S S O R ............................................................................................................................................................................................. 1 8 F - 1 0
B E L T D R IV E N C O M P R E S S O R - D I S A S S E M B L Y .................................................................................................................................................... 1 8 F -1 1
B E L T D R I V E N C O M P R E S S O R - A S S E M B L Y ............................................................................................................................................................. 1 8 F -1 3
S P E C IA L T O O L S ............................................................................................................................................................................................................................. 1 8 F - 1 7
April '96
Compressor/Vacuum Pump 18F-2
(C a m sh a ft d riv en )
N o te : W h e n b e lt d riv e n c o m p re s s o rs a r e u s e d th e oil h o le in th e lo b e o f th e
c a m s h a ft, u s e d fo r d riv in g th e c o m p re s s o r, is c lo s e d w ith a J u b ile e
c la m p . T o p re v e n t oil lo ss d u rin g e n g in e r e -c o n d itio n in g e n s u re
th a t th e c la m p is in p o s itio n .
AIR COMPRESSOR
1 C Y L IN D E R B A R R E L 12 P IS T O N
2 B E A R IN G S H E L L 13 S C R A P E R R IN G
3 B E A R IN G S H E L L 14 P IS T O N R IN G
4 C O N N E C T IN G R O D 15 V A LV E
5 C O N N E C T IN G R O D B O L T 16 VALVE
6 NUT 17 GASKET
7 BO LT 18 S E A L IN G W A S H E R
8 C IR C L IP 19 IN L E T P IP E
.9 G U D G E O N P IN 20 U N IO N
10 P IS T O N R IN G 21 S E A L IN G W A S H E R
11 SM ALL EN D BUSH 22 C Y L IN D E R H E A D
April ‘96
A ir c o m p r e s s o r s a r e u s e d in v e h ic le s y s te m s to p ro v id e c o m p re s s e d a ir u s e d fo r b r a k in g a n d th e o p e r a tio n o f a n c illa ry air

e q u ip m e n t. T h e s e c o m p r e s s o r s h a v e a s in g le r e c ip ro c a tin g p is to n a n d a r e a ir c o o le d . T h e c o m p r e s s o r s h a v e a o n e -p ie c e
c y lin d e r h e a d , w ith th e in le t v a lv e p a rts s c re w e d in to th e h e a d a n d th e d e liv e ry v a lv e s r e ta in e d b y a lo c k n u t. T h e p isto n
ru n s in a r e p la c e a b le c y lin d e r b a rr e l w h ic h is m o u n te d d ire c tly o n to th e e n g in e c r a n k c a s e a n d s e a le d w ith a g a s k e t a t th e
c y lin d e r h e a d .
D u r in g th e d o w n s tro k e o f th e p is to n a p a rtia l v a c u u m is c r e a te d a b o v e th e p is to n , w h ic h u n s e a ts th e in le t v a lv e a llo w in g

a ir to e n te r t h e c y lin d e r a b o v e th e p is to n . O n th e u p s tro k e , th e a ir p r e s s u r e u n d e r th e v a lv e , p lu s th e e ffo rt o f th e in let
v a lv e s p rin g c lo s e s th e in le t v a lv e a n d th e n o p e n s th e d e liv e ry v a lv e , th e a ir u n d e r c o m p re s s io n is th e n d is c h a rg e d into a
re s e rv o ir. A t t h e s ta rt o f t h e d o w n s tro k e th e d e liv e ry v a lv e c lo s e s a n d th e c y c le is r e p e a te d . T h e c o m p r e s s o r fe e d s a ir into
a r e s e r v o ir fitte d w ith a n u n lo a d e r v a lv e to m a in ta in c o n s ta n t p re s s u re .
T h e a ir c o m p r e s s o r a s s e m b ly c a n b e c h a n g e d to a v a c u u m p u m p b y s im p ly tu rn in g th e c y lin d e r h e a d .
A IR C O M P R E S S O R /V A C U U M P U M P
C y lin d e r ........................................................................................................................................................................................ 1
B o r e .................................................................................................................................................................................................9 4 m m
S t r o k e ............................................................................................................................................................................................ 3 0 m m
D is p la c e m e n t ............................................................................................................................................................................ 2 0 8 c m 3
B o r e d i a m e t e r .......................................................................................................................................................................... 9 3 , 9 8 5 - 9 4 , 0 1 5 m m
P is to n d i a m e t e r ........................................................................................................................................................................9 3 , 8 5 0 - 9 3 , 8 8 0 m m
P is to n c le a r a n c e .....................................................................................................................................................................0 ,0 6 8 - 0 , 0 9 2 m m
P is to n p r o tr u s io n .....................................................................................................................................................................0 ,2 5 0 - 0 , 7 0 0 m m
G u d g e o n p in d ia m e t e r ................................................................................................................................. 1 6 ,0 1 2 - 1 6 , 0 1 5 m m
B o r e in p is to n ....................................................................................................................1 6 ,0 1 8 - 1 6 ,0 2 2 m m
C le a r a n c e in p is to n ........................................................................................................ + 0 ,0 0 3 to + 0 , 0 1 0 m m
C le a r a n c e in s m a ll e n d b u s h ....................................................................................0 ,0 1 0 - 0 , 0 2 3 m m
C o n n e c tin g ro d B ig e n d b a s ic b o r e ........................................................................................................... 3 5 , 0 0 0 - 3 5 , 0 1 6 m m
S m a ll e n d b a s ic b o r e ....................................................................................................1 9 ,0 0 0 - 1 9 ,0 2 1 m m
S m a ll e n d b u s h o u te r d ia ........................................................................................... 1 9 ,0 3 5 - 1 9 ,0 4 8 m m
S m a ll e n d b u s h in n e r d i a ...........................................................................................1 6 ,0 2 5 - 1 6 ,0 3 5 m m
S m a ll e n d b u s h in te r fe r e n c e f i t ............................................................................. 0 ,0 1 4 - 0 , 0 4 8 m m
B ig e n d b e a r in g c le a r a n c e r a d ia i.........................................................0 ,0 2 0 - 0 , 0 6 6 m m
a x i a l ......................................................... 0 ,0 6 5 - 0 , 3 1 7 m m
W id t h o f s m a ll e n d ........................................................................................................ 2 7 , 8 8 3 - 2 7 , 9 3 5 m m
W id t h o f b ig e n d ..............................................................................................................2 7 , 8 8 3 - 2 7 , 9 3 5 m m
L e n g th o f c o n n e c tin g ro d (c e n tr e to c e n t r e ) ....................................................9 6 , 9 5 0 - 9 7 , 0 0 0 m m
B ig e n d b e a r in g /s m a ll e n d b u s h , p a ra lle l w ith in .............................................0 ,0 1 m m
P is to n rin g s ( a ll) G a p ........................................................................................................................................... 0 ,2 5 - 0 ,4 0 m m

S id e c l e a r a n c e ................................................................................................................ 0 , 0 2 0 - 0 , 0 5 5 m m
April '96
C O N N E C T I N G R O D B E A R I N G A N D C R A N K P IN D IA M E T E R S
S ta g e s C a m s h a f t j o u r n a l d ia . B e a r in g i n n e r d i a .
S ta n d a r d 3 1 ,9 8 4 to 3 2 ,0 0 0 3 2 ,0 2 0 to 3 2 ,0 5 0
S ta n d a r d 1 ( - 0 , 1 ) 3 1 ,8 8 4 to 3 1 ,9 0 0 3 1 , 9 2 0 to 3 1 ,9 5 0
R e p a ir s t a g e 1 ( - 0 , 2 5 ) 3 1 ,7 3 4 to 3 1 ,7 5 0 3 1 , 7 7 0 to 3 1 ,8 0 0
R e p a ir s t a g e 2 ( - 0 ,5 ) 3 1 ,4 8 4 to 3 1 ,5 0 0 3 1 , 5 2 0 to 3 1 ,5 5 0
R e p a ir s t a g e 3 ( - 0 ,7 5 3 1 ,2 3 4 to 3 1 ,2 5 0 3 1 , 2 7 0 to 3 1 ,3 0 0
C A P A C IT Y
A ir c o m p r e s s o r a t 2 8 0 0 r /m in . .D e liv e r y a g a in s t. 100 kPa - 1 4 0 £ /m in

810 kPa - 1 3 0 ¿ /m in
M a x im u m o p e r a tin g p r e s s u r e .. 810 kPa
VACUUM PUMP
T a n k c a p a c ity E n g in e s p e e d T im e (s e c ) V a c u u m (m m H g )
61 6 0 0 r /m in 30 625
2 8 0 0 r /m in 30 700
201 6 0 0 r /m in 30 450
2 8 0 0 r/m in 30 675
A IR C O M P R E S S O R /V A C U U M P U M P
C a p to c o n n e c tin g r o d ................................................................................................. M 6 ................................................................. 1 5 N m

E x h a u s t v a lv e to c y lin d e r h e a d .............................................................................. M 6 ................................................................. 1 0 N m
In le t v a lv e to c y lin d e r h e a d ....................................................................................... M 4 0 x 1 , 5 ................................................. 1 8 0 N m
C y lin d e r h e a d b a rr e l to c r a n k c a s e .......................................................................M 8 ................................................................. 3 5 N m
B E L T -D R IV E N C O M P R E S S O R
C y lin d e r lin e r to c r a n k c a s e .............................................................................................................................................................. 2 2 N m

C y lin d e r h e a d to c y lin d e r lin e r ....................................................................................................................................................... 3 0 N m
P u lle y n u t ....................................................................................................................................................................................................1 0 0 N m
April ‘96
M e a s u r in g b e a r in g c le a r a n c e s
A tte n tio n ! S e e p a g e 1 5 - 8 fo r r e m o v a l o f th e c o m p re s s o r fro m

th e e n g in e
1. C la m p th e c o n n e c tin g ro d in a v ic e fitte d w ith s o ft ja w s

a n d r e m o v e t h e b e a r in g c a p , (F ig . 1 8 F - 1 ) .
F ig . 1 8 F -1
2. R e m o v e t h e b e a r in g s h e lls fr o m th e c o n n e c tin g rod a n d c a p ,

(F ig . 1 8 F - 2 ) .
3. F it th e b e a r in g c a p to th e c o n n e c tin g ro d , in s e rt th e b o lts a n d
tig h te n to th e s p e c ifie d to rq u e , (F ig . 1 8 F - 3 ) .
4. S e t a n in te r n a l m e a s u r in g in s tr u m e n t, (F ig . 1 8 F - 4 ) .
April ‘96
5. M e a s u r e th e b ig -e n d b a s ic b o re in th e v e rtic a l p o s itio n ,
(F ig . 1 8 F - 5 ) .
F ig . 1 8 F - 5
6. M e a s u r e th e b o r e o f t h e c o n n e c tin g ro d s m a ll e n d b u sh ,
(F ig . 1 8 F - 6 ) .
Fi.q. 1 8 F - 6
7. U n s c r e w t h e b e a r in g b o lts a n d r e m o v e th e b ig -e n d b e a rin g
c a p , (F ig . 1 8 F - 7 ) .
F ig . 1 8 F - 7
8. In s e r t t h e b ig -e n d b e a r in g s h e lls , fit th e c a p to th e c o n n e c tin g

ro d , in s e r t th e b o lts a n d tig h te n to th e s p e c ifie d to rq u e ,
(F ig . 1 8 F - 8 ) .
Fig. 18F-8
April '96
9. M e a s u r e th e b ig -e n d b e a r in g in s id e d ia m e te r in th re e
p la c e s , (F ig . 1 8 F - 9 ) .
1 0 . R e m o v e t h e b ig -e n d b e a r in g c a p a n d c o n n e c tin g rod
fr o m th e v ic e .
M e a s u r e th e c a m s h a f t e c c e n tric lo b e to d e te r m in e th e
c le a r a n c e a f te r o b ta in in g th e b e a r in g I.D .
D ism a n tlin g t h e c y lin d e r h ea d
1. R e m o v e t h e n u t r e ta in in g th e c y lin d e r h e a d ,
(F ig . 1 8 F - 1 0 ) .
F ig . 1 8 F - 1 0
2. R e m o v e a n d d is m a n tle th e d e liv e ry v a lv e , (F ig . 1 8 F - 1 1 )
F ig . 1 8 F -1 1
3. U n s c r e w th e in le t v a lv e fr o m th e c y lin d e r h e a d , u s in g
s p e c ia l to o l 4 0 2 0 1 7 3 3 , (F ig . 1 8 F - 1 2 ) .
Fig. 18F-12
R e a s s e m b ly o f t h e c y lin d e r h e a d
1 M o u n t th e c y lin d e r h e a d in a v ic e , in s e rt th e d e liv e ry
v a lv e in to th e c y lin d e r h e a d a n d tig h te n th e re ta in in g
n u t to t h e s p e c ifie d to r q u e , (F ig . 1 8 F - 1 3 ) .
2. T u rn o v e r t h e c y lin d e r h e a d a n d in s e r t th e s u c tio n v a lv e a s
fo llo w s : 1 v a lv e s e a t, 2 v a lv e d is k , 3 s p rin g w a s h e r s ,
4 s u c tio n v a lv e n u t, (F ig . 1 8 F - 1 4 ) .
N o te : T h e s u c tio n v a lv e n u ts 4 A a n d 4 B a r e a lt e r n a t e fittin g s
re q u irin g th e u s e o f tw o d iffe r e n t s p e c ia l to o ls fo r r e m o v a l a n d
r e p la c e m e n t. R e fe r to s p e c ia l to o ls lis t p a g e 1 8 F -9 .
3. T ig h te n t h e s u c tio n v a lv e n u t to t h e s p e c ifie d to rq u e , u s in g
s p e c ia l to o ls 4 0 2 0 1 7 3 3 o r 4 0 2 0 2 3 3 4 , (F ig . 1 8 F - 1 5 ) .
A tte n tio n ! S e e p a g e 1 5 - 1 2 fo r r e p la c e m e n t o f c o m p r e s s o r to
e n g in e
4. In s e r t a n e w g a s k e t, r e p la c e t h e c y lin d e r h e a d , in s e rt th e
re ta in in g b o lts a n d tig h te n to th e s p e c ifie d to rq u e ,
(F ig . 1 8 F - 1 6 ) .
N o te : 0 , 6 5 a n d 0 , 9 m m g a s k e t d e p e n d in g o n p is to n p ro tru s io n .
Fig. 18F-16
April '96
5. C o n n e c t th e a ir in le t a n d d e liv e ry p ip e s , (F ig . 1 8 F -1 7 ).
SPEC IA L T O O LS
O B T A IN A B L E F R O M : G R U N D Y - T E C H N I F O R M , B U R M A N R O A D , D E A L P A R T Y E S T A T E , P O R T E L IZ A B E T H 6 0 0 1
\v
0 ( V
■‘Z
J ¡L
S o c k e t fo r r e m o v a l/r e p la c e m e n t
o f c o m p r e s s o r v a lv e . ( T y p e A ).
( S e e F ig . 1 8 F - 1 2 , I8 F - 1 5 )
P a rt n u m b er 4 0 2 0 17 33.
€>
S o c k e t fo r r e m o v a l/r e p la c e m e n t
o f c o m p r e s s o r v a lv e , ( T y p e B ).
( S e e F ig . 1 8 F - 1 2 , I8 F - 1 5 )
/ j L0 ^
fs r* P a rt n u m b er 4 0 2 0 2 3 3 4 .
\//
April '96
Belt-driven Compressor 18F-10
11
BELT-DRIVEN C O M P R E SSO R
1 C O M P R E S S O R P U L L E Y R E T A IN IN G N U T A N D W A S H E R 16 C Y L IN D E R H E A D R E T A IN IN G B O L T S
2 C O M PR ESSO R PULLEY 17 C Y L IN D E R H E A D B O L T F L A T W A S H E R S
3 P IS T O N W IT H C O N N E C T IN G R O D 18 C Y L IN D E R H E A D G A S K E T
4 C O N N E C T IN G R O D C A P 19 VA LVE PLATE
5 C O N N E C T IN G R O D C A P B O L T S 20 V A L V E P L A T E R E T A IN IN G S C R E W
6 C R A N K S H A F T B U S H H O U S IN G 21 IN L E T V A L V E
7 S T E E R I N G P U M P D R IV E W A S H E R 22 E X H A U S T V A L V E R E T A IN E R
8 CRANKSHAFT 23 EXHAUST VALVE
9 CRANKCASE 24 E X H A U S T V A L V E R E T A IN IN G S C R E W S A N D
10 C R A N K C A S E M O U N T IN G B O L T S W IT H F L A T W A S H E R S W ASHERS
11 O IL IN L E T B A N J O B O L T A N D H O U S I N G 25 C Y L IN D E R S L E E V E
12 C R A N K S H A F T B E A R IN G 26 C Y L IN D E R S L E E V E R E T A IN IN G S C R E W S
13 C R A N K S H A F T B E A R IN G R E T A I N I N G C L IP AND W ASHERS
14 C R A N K S H A F T S E A L H O U S IN G 27 C O M P R E S S O R M O U N T C A S T IN G B R A C K E T
15 C Y L IN D E R H E A D W I T H O IL D R A IN A N D ID L E R P U L L E Y
April '96
D IS A S S E M B L Y
1. L o o s e n th e p u lle y fa s te n in g n u t, (F ig . 1 8 F -1 8 ).
2. P u ll o ff th e p u lle y , (F ig 1 8 F - 1 9 ) .
3. U n s c r e w a n d r e m o v e th e c y lin d e r h e a d , (F ig . 1 8 F -2 0 ).
4. R e m o v e t h e v a lv e p la te w ith s u c tio n v a lv e a n d
d e liv e r y v a lv e , (F ig . 1 8 F - 2 1 ) .
Fig. 18F-21
April '96
5. R e m o v e t h e c y lin d e r lin e r re ta in in g n u ts a n d pu ll th e lin er

fr o m th e p is to n , (F ig . 1 8 F - 2 2 ) .
6. R e m o v e t h e lo c k in g rin g fo r t h e p is to n pin, (F ig . 1 8 F - 2 3 ) .
7. P u s h o u t t h e p is to n a n d d e ta c h fr o m th e c o n n e c tin g rod,
(F ig . 1 8 F - 2 4 ) .
8. U n s c r e w th e h o u s in g c o v e r b o lts a n d r e m o v e th e h o u s in g
c o v e r, (F ig . 1 8 F - 2 5 ) .
Fig. 18F-25
April '96
9. D e ta c h th e c o n ro d fr o m th e c r a n k s h a ft a n d r e m o v e th e
c r a n k s h a ft, (F ig . 1 8 F - 2 6 ) .
F ig . 1 8 F - 2 6
10. R e m o v e th e s h a ft s e a lin g rin g fr o m th e b e a r in g c a p ,

(F ig . 1 8 F - 2 7 ) .
F ig . 1 8 F - 2 7
11. R e m o v e th e p is to n rin g s w ith s p e c ia l to o l 4 0 2 0 0 3 0 7

(p is to n rin g p lie r s ), (F ig . 1 8 - 2 8 ) .
F ig . 1 8 F - 2 8
A SSEM B L Y
1. In s e r t s h a ft s e a lin g rin g in to th e b e a r in g c a p ,
(F ig . 1 8 F - 2 9 ) .
mW i
Fig. 18F-29
April ‘96
2. M o u n t O -r in g o n b e a r in g c a p . (F ig . 1 8 F - 3 0 ) .
F ig . 1 8 F - 3 0
3. A s s e m b le c o n n e c tin g ro d to th e c r a n k s h a ft a n d in s ta ll th e
c r a n k s h a ft, (F ig . 1 8 F - 3 1 ) .
F ig . 1 8 F -3 1
4. M o u n t t h e b e a r in g c a p , (F ig . 1 8 F - 3 2 )
N o te : R e c e s s in m o u n tin g b o s s in u p w a r d p o s itio n .
F ig . 1 8 F - 3 2
5. M o u n t p is to n rin g s , (F ig . 1 8 F - 3 3 ) . U s e p is to n rin g p lie rs

p a rt no . 4 0 2 0 0 3 0 7 .
,— ii fas
Fig. 18F-33
April '96
6. P o s itio n t h e p is to n w ith rin g s o v e r th e c o n n e c tin g rod

a n d in s e r t th e p is to n p in , (F ig . 1 8 F - 3 4 ) .
F ig . 1 8 F - 3 4
7. M o u n t t h e r e ta in in g rin g s fo r th e p is to n pin,
(F ig . 1 8 F - 3 5 ) .
F ig . 1 8 F - 3 5
8. M o u n t t h e g a s k e t fo r t h e c y lin d e r lin er.
9. U s e t h e p is to n rin g s q u e e z e r to b rin g th e p is to n ring

d ia m e t e r to p is to n d ia m e t e r a n d m o u n t th e c y lin d e r
lin e r, (F ig . 1 8 F - 3 6 ) .
U s e c o m p r e s s o r p is to n rin g s q u e e z e r 4 0 2 0 1 1 3 1 to g e th e r w ith
p lie rs 4 0 2 0 1 1 4 4 .
ill'A M
F ig . 1 8 F - 3 6
10. F it t h e c y lin d e r lin e r o v e r t h e m o u n tin g s tu d s a n d tig h te n

t h e n u ts to 2 2 N m , (F ig . 1 8 F - 3 7 ) .
Fig. 18F-37
April '96
11. P la c e th e g a s k e t a n d h e a d a s s e m b ly o n th e c y lin d e r lin er,

(F ig . 1 8 F - 3 8 ) .
N o te : G u id e pin o f t h e v a lv e p la te m u s t lo c a te in to a p p r o p ria te
h o le s a t th e to p o f th e c y lin d e r lin e r.
Fig . 1 8 F - 3 8
12. M o u n t c y lin d e r h e a d w ith g a s k e t a n d tig h te n th e b o lts to

3 0 N m , (F ig . 1 8 F - 3 9 ) .
F ig . 1 8 F - 3 9
13. M o u n t p u lle y to t h e c o m p r e s s o r a n d tig h te n th e n u t to

1 0 0 N m , F ig . 1 8 F - 4 0 ) .
F ig . 1 8 F - 4 0
April '96
S P E C IA L T O O L S
TE L : (0 4 1 ) 4 3 -2 2 9 9 , FA X: (0 4 1 ) 4 3 -2 2 2 4
P is to n ring p lie rs
p a rt n u m b e r 4 0 2 0 0 3 0 7
:> *
C o m p r e s s o r p is to n rin g s q u e e z e r
u s e w ith p lie rs b e lo w
p a rt n u m b e r 4 0 2 0 1131
A P lie r s fo r c o m p r e s s o r p is to n ring
squeezer
p a rt n u m b e r 4 0 2 0 1 1 4 4
April '96
Diesel Club
ADE 364 and ADE 366
Workshop Manual
Section 19 - Cooling System
B a rrin g to n D iesel C lu b
_______________________ SECTION 19
Cooling System
Page
I L L U S T R A T I O N ...................................................................................................................................................................................................................................... 1 9 -2
I N T R O D U C T I O N ....................................................................................................................................................................................................................................1 9 -3
S P E C I F I C A T I O N S .................................................................................................................................................................................................................................1 9 -3
R E M O V I N G T H E W A T E R P U M P ................................................................................................................................................................................................ 1 9 -5
D I S M A N T L I N G ........................................................................................................................................................................................................................................ 1 9 -6
A S S E M B L Y ............................................................................................................................................................................................................................................... 1 9 -9
T H E R M O S T A T A N D H O U S I N G ................................................................................................................................................................................................ 1 9 - 1 5
R E M O V I N G / R E P L A C I N G T H E T H E R M O S T A T H O U S I N G ...................................................................................................................................1 9 -1 6
T H E R M O S T A T T E S T ................................................................................................................................................................................................ 1 9 -1 9
V I S C O F A N ..................................................................................................... : ..................................................................................................................................... 1 9 -2 1
I N T R O D U C T I O N ............................................................................................................................................................................................ 1 9 -2 2
S P E C I F I C A T I O N S ............................................................................................ 1 9 -2 2
O V E R H A U L I N G V I S C O F A N ...................................................................................................................................................................................................... 1 9 - 2 3
D I S M A N T L I N G ..................................................................................................................................................................................................................................... 1 9 - 2 3
A S S E M B L Y ............................................................................................................................................................................................................................................ 1 9 - 2 5
S P E C IA L F A B R IC A T E D T O O L S ...............................................................................................................................................................................................1 9 - 2 9
S P E C IA L T O O L S .................................................................................................................................................................................................................................1 9 -3 1
April '96
Cooling System 19-2
360 SERIES WATER PUMP
1. IM P E L L E R
2. CARBON SEAL ASSEM BLY
3. W A T E R P U M P H O U S IN G
4. S E A L
5. B E A R IN G
6. SHAFT
7. B E A R IN G
8. O -R IN G
9. SEAL
10. B E A R IN G C A R R IE R
11. C O U P L IN G F L A N G E /P U L L E Y C O U P L IN G F L A N G E
April '96
Cooling System 19-3
T h e w a t e r p u m p is o f t h e im p e lle r ty p e a n d d riv e n b y V -b e lts fr o m th e c r a n k s h a ft. It is a s e a le d u n it, fille d w ith a s p e c ia l

h ig h m e ltin g p o in t g r e a s e d u rin g a s s e m b ly a n d re q u ire s n o fu r th e r a tte n tio n d u rin g its life tim e .
A t h e r m o s ta t h o u s in g is m o u n te d to t h e c y lin d e r b lo c k w h ic h is jo in e d to th e w a t e r p u m p b y a c o n n e c tin g tu b e a n d s e a le d
b y O -r in g s .
C O O L IN G S Y S T E M
T h e rm o s ta t S ta n d a rd O p tio n a l
S ta r ts o p e n in g a t 7 9 ± 2 °C 71 + 2 °C
M a in v a lv e S tr o k e m m 8 mm 8 mm
F u lly o p e n a t 9 4 °C 85 °C
B y p a s s v a lv e c lo s e d a t 9 1 °C 8 2 °C
M a x . o p e r a tin g t e m p e r a t u r e 9 5 °C 95 °C
C o o la n t c a p a c ity ( e n g in e o n ly ) 11< 11^
W ATER PUMP
Im p e lle r s h a f t d ia m e t e r 1 5 ,0 2 8 to 1 5 ,0 3 9
F o r la r g e b e a r in g 2 9 , 9 9 6 to 3 0 , 0 0 9
F o r s m a ll b e a r in g 1 6 , 9 9 7 to 1 7 ,0 0 8
Fo r hub 2 9 ,0 4 1 to 2 9 , 0 5 4
B o r e in h u b d ia 2 9 , 0 0 0 to 2 9 ,0 2 1
H u b d ia . fo r fr o n t s e a l 4 1 , 8 4 0 to 4 2 , 0 0 0
B o r e d ia . in im p e lle r 1 5 ,0 0 0 to 1 5 ,0 1 8
P re s s in g im p e lle r o n w a t e r p u m p s h a ft Im p e lle r fla n g e flu s h w ith h o u s in g

M a x . ± 0 ,1 m m
L u b r ic a tio n o f w a t e r p u m p G re a s e ap p ro x . 8 0 gr
April ‘96
Cooling System 19-4
A t t e n t i o n : W h e n in s ta llin g a n e x c h a n g e e n g in e , e n s u r e th a t W ATER PUMP

th e s p a c e r rin g fitte d b e tw e e n t h e w a t e r p u m p a n d th e fa n is
o f th e s a m e th ic k n e s s a s in t h e r e m o v e d e n g in e . I f n e c e s s a r y A W a t e r p u m p s h a ft
r e p la c e th e s p a c e r rin g s o t h a t t h e d is ta n c e o f 2 5 to 3 0 m m B Hub
b e tw e e n th e r a d ia to r a n d t h e fa n is re ta in e d . C B e a r in g c a r r ie r
D O -r in g
E L a r g e b a ll b e a r in g
F S m a ll b a ll b e a r in g
G R ear seal
H C a rb o n seal
J Im p e lle r
K D is t a n c e im p e lle r a n d h o u s in g : 0 , 5 + 0 / ^ 0 3
.1 1 9 ± 0 , 5
364N/C/T
T O R Q U E S P E C IF IC A T IO N
W a t e r p u m p to c y lin d e r b l o c k ................................................................................. M 1 0 ............................................................ 5 0 N m

C o o la n t d r a in p lu g to c y lin d e r b l o c k ...................................................................M 1 8 x 1 , 5 ................................................ 5 0 - 6 0 N m
T e m p e r a t u r e g a u g e p r o b e ......................................................................................... M 1 4 x 1 , 5 ................................................2 0 N m
T h e r m o s ta t h o u s in g c o v e r ........................................................................................M 6 ................................................................ 2 5 N m
W a t e r ja c k e t c o v e r to c y lin d e r b lo c k ( 3 6 4 N / C / T ) ......................................... M 8 ............................................................... 3 5 N m
W a t e r p u m p b e a r in g c a r r i e r .................................................................................... M 6 x 3 0 .................................................... 1 5 N m
C a p s c r e w /s p a c e r t o w a t e r p u m p s h a f t ............................................................... M 1 4 x 1 , 5 ............................................... 1 4 0 N m
(L u b r ic a te th r e a d s w ith e n g in e o il)
F A N R E T A IN IN G B O L T S (D IN 9 3 3 ) - T IG H T E N IN G T O R Q U E
B o lt d i a . Q u a l i t y _________________________T o r q u e
M8 8 .8 25 Nm
M8 1 0 .9 35 Nm
M 10 8 .8 50 Nm
M 10 1 0 .9 60 Nm
April ‘96
Cooling System 19-5
Removing the water pump
1. D r a in r a d ia to r .
2. D is c o n n e c t u p p e r r a d ia to r h o s e .
3. D is c o n n e c t lo w e r r a d ia to r h o s e .
4. L o o s e n b o tto m a lt e r n a t o r r e ta in in g b o lt, (F ig . 1 9 - 1 ) .
5. S la c k e n o f f a d ju s te r a n d r e m o v e t h e V -b e lt.
6. R e m o v e t h e th e r m o s t a t h o u s in g .
F ig . 1 9 -1
7. If a p o w e r s te e r in g p u m p is fitte d , lo o s e n th e a d ju s te r
c la m p in g b o lt, ( F ig . 1 9 - 2 ) .
F ig . 1 9 - 2
8. S la c k e n o f f t h e a d ju s te r a n d r e m o v e th e V -b e lt, (F ig . 1 9 -3 ).
F ig . 1 9 - 3
9. U n s c r e w a n d r e m o v e t h e b o lts re ta in in g t h e V - b e lt p u lle y
o r t h e c a p b o lt r e ta in in g th e fa n to th e w a t e r p u m p s h a ft.
R e m o v e p u lle y o r fa n , (F ig . 1 9 - 4 ) .
Fig. 19-4
April '96
Cooling System 19-6
10. S la c k e n t h e t h e r m o s t a t h o u s in g r e ta in in g b o lts .
U n s c r e w a n d r e m o v e t h e b o lts r e ta in in g t h e w a t e r
p u m p to t h e c y lin d e r b lo c k . R e m o v e w a t e r p u m p a n d
g a s k e t, (F ig . 1 9 - 5 ) .
F ig . 1 9 -5
Dismantling
1. W it h a s u ita b le p u lle r r e m o v e t h e h u b fr o m t h e w a t e r
p u m p s h a ft, (F ig . 1 9 - 6 ) .
F ig . 1 9 -6
2. U n s c r e w t h e b o lts r e ta in in g t h e fr o n t b e a r in g c a rrie r,
(F ig . 1 9 - 7 ) . .
F ig . 1 9 - 7
3. L ift o f f t h e b e a r in g c a r r ie r , ( F ig . 1 9 - 8 ) .
Fig. 19-8
April ‘96
Cooling System 19-7
4. W it h s p e c ia l to o l 4 0 2 0 2 3 0 5 t a p th e o ld s e a l fr o m th e s e a l
c a rr ie r , (F ig . 1 9 - 9 )
F ig . 1 9 - 9
5. R e m o v e t h e O -r in g fr o m t h e to p o f t h e fr o n t b e a rin g ,
(F ig . 1 9 - 1 0 )
F ig . 1 9 - 1 0
6. R e m o v e t h e b o lts fr o m t h e fro n t, (F ig . 1 9 - 1 1 ) .
F ig . 1 9 -1 1
7. R e m o v e t h e b o lts fr o m t h e b a c k p la te a n d d e ta c h th e b a c k
p la te fr o m t h e p u m p b o d y , (F ig . 1 9 - 1 2 ) .
Fig. 19-12
April ‘96
Cooling System 19-8
8. M o u n t t h e w a t e r p u m p b o d y u n d e r a p re s s a n d w ith a s u ita b le
m a n d r e l r e m o v e t h e s h a ft c o m p le te w ith b e a r in g s fr o m th e
w a t e r p u m p b o d y , (F ig . 1 9 - 1 3 ) .
F ig . 1 9 - 1 3
9. L ift o u t t h e im p e lle r fr o m t h e r e a r o f t h e w a t e r p u m p b o d y ,
(F ig . 1 9 - 1 4 ) .
F ig . 1 9 - 1 4
10. G e n tly k n o c k o u t t h e r e a r s e a l fr o m th e w a t e r p u m p b o d y ,
(F ig . 1 9 - 1 5 ) .
F ig . 1 9 - 1 5
1 1 . P r e s s t h e la r g e b e a r in g f r o m t h e s h a ft, (F ig . 1 9 - 1 6 ) ,
Fig. 19-16
April '96
Cooling System 19-9
12. R e m o v e t h e s m a ll b e a r in g s fr o m th e w a t e r p u m p s h a ft,
(F ig . 1 9 - 1 7 ) .
F ig . 1 9 - 1 7
Assembly
1. T h o r o u g h ly c le a n t h e w a t e r p u m p . E x a m in e th e b o d y fo r
c o rr o s io n , c r a c k s a n d w e a r . R e p la c e t h e w a t e r p u m p
c o m p le te ly if a n y p a r t s h o w s e x c e s s iv e w e a r .
2. U s e s p e c ia l to o l 4 0 2 0 2 3 5 0 to in s e r t t h e r e a r s e a l in to th e
w a t e r p u m p b o d y , ( F ig . 1 9 - 1 8 ) .
F: ig. 1 9 - 1 8
3. U s e s p e c ia l to o l 4 0 2 0 2 2 9 5 a n d in s e r t t h e c a rb o n s e a l . V ■ V / m ----------------------------------
a s s e m b ly in to t h e h o u s in g , (F ig . 1 9 - 1 9 ) .
: ig. 1 9 - 1 9
4. P a c k b o th b e a r in g s w it h m u lti-p u r p o s e g r e a s e .
5. P r e s s t h e s m a ll b e a r in g o n to th e w a t e r p u m p s h a ft,
(F ig . 1 9 - 2 0 ) .
Fig. 19-20
Aoril '96
Cooling System 19-10
6. P r e s s th e la r g e b e a r in g o n to t h e w a t e r p u m p s h a ft,
(F ig . 1 9 - 2 1 ) .
F ig . 1 9 -2 1
7. U s e s p e c ia l to o l 4 0 2 0 2 3 1 8 a n d r e p la c e t h e s e a l in th e s e a l
c a rr ie r , (F ig . 1 9 - 2 2 )
F ig . 1 9 - 2 2
8. P la c e t h e s e a l c a r r ie r o v e r t h e w a t e r p u m p s h a ft a n d p re s s
th e h u b o n to t h e s h a ft a s f a r a s it w ill g o , (F ig . 1 9 - 2 3 )
F ig . 1 9 - 2 3
9. F ill t h e s p a c e b e tw e e n t h e b e a r in g s w ith m u lti-p u rp o s e

g r e a s e , (F ig . 1 9 - 2 4 ) .
Fig. 19-24
April '96
10. F it O -r in g o v e r t h e la r g e b e a r in g , (F ig . 1 9 - 2 5 ) .
F ig . 1 9 - 2 5
11. P r e s s t h e w a t e r p u m p s h a ft w ith b e a r in g s in to th e
w a t e r p u m p b o d y , (F ig . 1 9 - 2 6 ) .
F ig . 1 9 - 2 6
12. In s e r t t h e b o lts in to t h e s e a l c a r r ie r a n d tig h te n to

t h e s p e c ifie d to r q u e , (F ig . 1 9 - 2 7 ) .
F ig . 1 9 - 2 7
13. P r e s s t h e im p e lle r o n to th e w a t e r p u m p s h a ft a s f a r a s
t h e s p e c ifie d c le a r a n c e b e tw e e n t h e im p e lle r a n d th e
w a t e r p u m p b o d y . U s e a fe e le r g a u g e to c h e c k th e
c le a r a n c e , (F ig . 1 9 - 2 8 ) .
Fig. 19-28
April '96
14. R e p la c e t h e w a t e r p u m p b a c k p la te w ith a n e w g a s k e t
a n d in s e r t t h e fr o n t a n d r e a r b o lts , (F ig . 1 9 - 2 9 ) .
F ig . 1 9 - 2 9
15. T ig h t e n a ll b o lts to t h e s p e c ifie d to rq u e , F ig . 1 9 3 0 ).
F ig . 1 9 - 3 0
16. R e p la c e t h e w a t e r p u m p a n d in s e r t th e b o lts re ta in in g
t h e p u m p t o t h e c y lin d e r b lo c k a n d tig h te n to th e s p e c ifie d
to rq u e . F it t h e t h e r m o s t a t h o u s in g to t h e c y lin d e r b lo c k
w ith a n e w g a s k e t a n d tig h te n t h e b o lts to t h e s p e c ifie d
to rq u e , ( F ig . 1 9 - 3 1 ) .
F ig . 1 9 -3 1
17. In s e r t a lie n c a p b o lt in to t h e c e n tr e h u b a n d tig h te n to th e

s p e c ifie d to r q u e . If fitte d w ith a fa n , in s e r t t h e b o lts re ta in in g
th e fa n to t h e h u b a n d tig h te n to t h e s p e c ifie d to rq u e ,
(F ig . 1 9 - 3 2 ) .
Fig. 19-32
April '96
18. W it h te n s io n g a u g e (s p e c ia l to o l) 4 0 2 0 2 3 2 1 a d ju s t th e V -b e lt
te n s io n to 4 0 - 4 5 k g ( n e w b e lts ), ru n t h e e n g in e fo r 1 0 - 1 5
m in u te s a n d r e -c h e c k t h e te n s io n , w h ic h s h o u ld b e 3 0 - 4 0 kg.
If th is is n o t r e a c h e d a d ju s t t h e te n s io n to 3 0 - 4 0 kg . P o s itio n
t h e te n s io n g a u g e o n t h e b e lt w ith t h e fla n g e p a ra lle l to th e
b e lt e d g e . G r a d u a lly a p p ly p r e s s u r e to th e p r e s s u r e p a d .
W h e n a c lic k is h e a r d o r fe lt, s to p a n d r e m o v e th e g a u g e .
T a k e a n a c c u r a te r e a d in g a t th e s p o t w h e r e th e in d ic a to r a r m
in te r s e c ts th e s c a le , (F ig . 1 9 - 3 3 ) .
19. W h e n t h e c o r r e c t V - b e lt te n s io n s h a v e b e e n o b ta in e d , lo c k
th e s te e r in g p u m p V - b e lt a d ju s te r b o lt ( if fitte d ), (F ig . 1 9 - 3 4 ) .
20. T ig h te n t h e a lt e r n a t o r V - b e lt a d ju s te r n u ts , (F ig . 1 9 -3 5 ) .
21. T ig h t e n t h e b o tto m a lt e r n a t o r m o u n tin g b o lt, (F ig . 1 9 - 3 6 ) .
April '96
2 2 . T ig h t e n t h e s te e r in g p u m p m o u n tin g b o lt, (F ig . 1 9 - 3 7 ) .
2 3 . C o n n e c t t h e u p p e r a n d lo w e r r a d ia tio n h o s e s , fill th e
r a d ia to r w ith c o o la n t t o w h ic h t h e c o r r e c t a m o u n t o f
a p p r o v e d c o rr o s io n in h ib ito r h a s b e e n a d d e d .
2 4 . S t a r t t h e e n g in e , a llo w to r e a c h n o r m a l r u n n in g te m p e r a tu r e
a n d c h e c k fo r c o o la n t le a k s .
A tte n tio n t N e v e r fo r c e a V - b e lt o n to t h e p u lle y b y u s in g a le v e r.

T h e V - b e lt m a y b e d a m a g e d a n d th u s c a u s in g a n e a r ly fa ilu re .
T h e a d ju s te r s h o u ld b e fu lly r e le a s e d a n d t h e V - b e lt tu rn e d
o n to th e p u lle y b y h a n d . I f o n e b e lt in a s e t r e q u ire s r e p la c e m e n t
a lw a y s in s ta ll a m a tc h e d p a ir. If o n ly o n e b e lt is r e p la c e d it w ill
b e c a rr y in g a ll t h e lo a d , w h ic h w ill le a d to e a r ly fa ilu r e .
F ig . 1 9 - 3 7
April '96
Cooling System - Thermostat and Housing 19-15
CAMSHAFT AND TIMING GEARS
1 BOLTS 6 O -R IN G S
2 CO O LANT OUTLET 7 C O N N E C T IN G T U B E
3 O -R IN G 8 GASKET
4 THERM OSTAT 9 W ASHER
5 T H E R M O S T A T H O U S IN G 1 0 T E M P E R A T U R E S E N D E R U N IT
Aprii '96
REMOVING/REPLACING THERMOSTAT
AND HOUSING
Removing
1. U n s c r e w t h e b o lts r e ta in in g t h e c o o la n t o u tle t to th e
t h e r m o s ta t h o u s in g , ( F ig . 1 9 - 3 8 ) .
F ig . 1 9 - 3 8
2. L ift o f f t h e c o o la n t o u tle t, (F ig . 1 9 - 3 9 ) .
F ig . 1 9 - 3 9
3. W it h a s u ita b le s c r e w d r iv e r lift t h e t h e r m o s ta t fr o m
th e h o u s in g .
F ig . 1 9 - 4 0
4. R e m o v e t h e O -r in g fr o m t h e th e r m o s t a t b o d y , (F ig . 1 9 - 4 1 ) .
Fig. 19-41
April ‘96
5. U n s c r e w a n d r e m o v e t h e b o lts r e ta in in g th e th e r m o s ta t
h o u s in g to t h e c y lin d e r h e a d , (F ig . 1 9 - 4 2 ) .
F ig . 1 9 - 4 2
6. R e m o v e t h e t h e r m o s t a t h o u s in g a n d g a s k e t fr o m th e c y lin d e r
head
F ig . 1 9 - 4 3
7. P u ll o u t t h e c o n n e c tin g tu b e fr o m t h e th e r m o s ta t h o u s in g ,
(F ig . 1 9 - 4 4 ) .
-ig . 1 9 - 4 4
8. R e m o v e a n d d is c a r d t h e O -r in g s fr o m th e c o n n e c tin g tu b e ,
(F ig . 1 9 - 4 5 ) .
N o te : P r io r to r e p la c in g th e t h e r m o s ta t c a rr y o u t th e th e r m o s ta t
t e s t a s d e s c r ib e d o n p a g e 1 9 - 1 9 .
Fig. 19-45
April ‘96
Replacing
1. F it n e w O -r in g s to t h e c o n n e c tin g tu b e , (F ig . 1 9 - 4 6 ) .
F ig . 1 9 - 4 6
2. A p p ly a lig h t c o a t o f s ilic o n g r e a s e to th e O -r in g s a n d
in s e r t t h e c o n n e c tin g t u b e in to t h e to p o f t h e w a t e r p u m p
h o u s in g , (F ig . 1 9 - 4 7 ) .
F ig . 1 9 - 4 7
3. F it t h e th e r m o s t a t h o u s in g to t h e c o n n e c tin g tu b e , in s e rt
a n e w g a s k e t b e tw e e n t h e h o u s in g a n d t h e c y lin d e r h e a d
a n d in s e r t r e ta in in g b o lts , ( F ig . 1 9 - 4 8 ) .
F ig . 1 9 - 4 8
4. T ig h t e n t h e r e ta in in g b o lts to t h e s p e c ifie d to rq u e ,
(F ig . 1 9 - 4 9 ) .
Fig. 19-49
April '96
5. In s e r t t h e th e r m o s t a t w ith a n e w O -r in g in to th e h o u s in g ,
(F ig . 1 9 - 5 0 ) .
F ig . 1 9 - 5 0
6. R e p la c e th e c o o la n t o u tle t, in s e r t b o lts a n d tig h te n to th e

s p e c ifie d to r q u e , (F ig . 1 9 -5 1
F ig . 1 9 -5 1
THERMOSTAT TEST
Preparation
1. R e m o v e t h e t h e r m o s t a t fr o m t h e h o u s in g , ( S e e p a g e
1 9 -1 6 ).
2. In s e r t a le n g th o f c o tto n th r e a d b e tw e e n t h e v a lv e a n d
th e t h e r m o s t a t b o d y , s u ita b le to s u s p e n d th e th e r m o s ta t
in t h e c o n ta in e r , ( F ig . 1 9 - 5 2 ) .
F ig . 1 9 - 5 2
3. S u s p e n d t h e t h e r m o s t a t in a c o n ta in e r fille d w ith w a t e r
a n d in s e r t a th e r m o m e t e r . E n s u r e t h a t th e r m o s ta t a n d
th e r m o m e t e r a r e s u s p e n d e d a t t h e s a m e le v e l, (F ig .
1 9 -5 3 ).
Fig. 19-53
April '96
Check for Thermostat Opening Temperature
1. H e a t t h e c o n ta in e r to a t e m p e r a t u r e o f 7 1 ° C . A t th is
t e m p e r a t u r e t h e th e r m o s t a t s h o u ld d ro p o ff t h e c o tto n
th r e a d , (F ig . 1 9 - 5 4 ) .
Full Open Check
2. C o n tin u e t o h e a t t h e c o n ta in e r , w ith th e th e r m o s ta t
re s tin g a t t h e b o tto m , to a t e m p e r a t u r e o f 8 2 ° C . T h e
T h e r m o s t a t s h o u ld n o w b e fu lly o p e n , (F ig . 1 9 - 5 5 ) .
Checking for Length of Travel
3. R e m o v e t h e t h e r m o s t a t fr o m t h e c o n ta in e r. M e a s u r e th e
d is ta n c e b e tw e e n t h e b y -p a s s v a lv e a n d th e lo w e r s u p p o rt
b r a c k e t o f t h e t h e r m o s t a t b o d y . A llo w t h e th e r m o s ta t to
c o o l a n d r e tu rn to its c lo s e d p o s itio n . A g a in m e a s u r e th e
d is ta n c e a n d s u b tr a c t fr o m t h e p r e v io u s ly o b ta in e d d im e n
s io n . T h e r e s u lt is t h e le n g th o f tr a v e l, (F ig . 1 9 - 5 6 ) .
A tte n tio n ! If t h e t h e r m o s t a t fa ils to r e a c h m e a s u r e m e n ts

a s p e r s p e c ific a tio n s o r a n y o f t h e o th e r c h e c k s , it m u s t b e
r e p la c e d .
April '96
Cooling System - Visco Fan 19-21
B A S IC V IS C O F A N
1 COVER 8 SEAL
2 GASKET 9 B E A R IN G
3 D IS K D R IV E 1 0 C IR C L IP
4 FAN B O D Y 11 S P A C E R
5 FLANG ED SHAFT 12 S P A C E R
6 SCREW 13 C A P S C R E W
7 L O C K I N G D E V IC E
Visco Fan 19-22
D e p e n d in g o n a p p lic a tio n 3 6 0 s e r ie s e n g in e s a r e fitte d w ith a th e r m o s ta tic a lly c o n tr o lle d v is c o u s d r iv e fa n , w h ic h is

m o u n te d o n t h e w a t e r p u m p h u b a n d d riv e n b y V -b e lts fr o m th e c r a n k s h a ft.
T h e v is c o u s d r iv e fa n d o e s n o t h a v e a rig id c o n n e c tio n to t h e w a t e r p u m p p u lle y . A d r iv e c o n n e c tio n , fitte d to t h e p u lle y ,
c a n m o v e w ith in a c h a m b e r o f t h e fa n w ith a s m a ll c le a r a n c e . O n r e a c h in g a p r e d e te r m in e d t e m p e r a t u r e t h e th e r m o s ta t
o p e n s , a llo w in g o il to e n te r t h e c h a m b e r . A s a re s u lt o f t h e fric tio n c r e a te d b y th e oil w ith in t h e fa n c h a m b e r , t h e n o n
d riv e n b o d y o f t h e fa n w ill tu rn th u s d r iv in g th e fa n .
C h e c k i n g a n d lo c k i n g v i s c o u s d r i v e f a n V IS C O F A N
If th e r e is a n a b n o r m a l r is e in c o o la n t te m p e r a tu r e c h e c k A D E No. C a p a c ity S ilic o n N o .

w h e th e r t h e v is c o u s d r iv e fa n e n g a g e s p r o p e r ly w h e n th e 7620 0504 3 9 cm 3 3808 0720
e n g in e is w a r m . W it h t h e v e h ic le s ta tio n a r y , c o v e r th e
r a d ia to r . S t a r t t h e e n g in e a n d a llo w to ru n a t m e d iu m
s p e e d u n til t h e w a t e r t e m p e r a t u r e is 9 0 - 9 5 ° C . R e m o v e V i s c o s i t y o f O il
t h e r a d ia to r c o v e r . T h e t h e r m o s t a t is n o w h e a te d b y th e
h o t a ir fr o m t h e r a d ia to r a n d o p e n , a llo w in g s ilic o n flu id to S ilic o n V is c o s ity
flo w in to t h e fa n c h a m b e r , th e r e b y d riv in g t h e fa n . 3808 0720 1 2 ,5 0 c S t
In th e e v e n t o f a fa ilu r e o f t h e v is c o u s f a n d r iv e th e d e v ic e
c a n b e lo c k e d . T h e lo c k in g d e v ic e a t th e r e a r e n d o f th e T o rq u e s
fa n s e rv e s to c o u p le t h e f a n r ig id ly to t h e p u lle y .
D r iv e d is c b o lt s ..........................M 6 ...................... 1 0 - 1 3 N m
T o c o u p le t h e fa n u n s c r e w t h e lo c k in g n u t (F ig . 1 9 - 2 6 ) u p
............................................................. M 8 ...................... 2 8 , 5 - 3 3 N m
to th e lo c k s to p , th e n tu rn t h e f a n s lo w ly b y h a n d u n til th e
T h e r m o s ta t c o v e r ..................................................... 1 0 - 1 3 N m
p in o f h e lo c k in g d e v ic e is fe lt t o s n a p in to p la c e a id e d b y
th e s p rin g p r e s s u r e .
T h e v is c o u s d r iv e fa n c a n b e u s e d fo r a lim ite d p e rio d o n ly

in th e lo c k e d c o n d itio n . E x te n d e d o p e r a tio n in th is
c o n d itio n is n o t a d v is a b le . T h e fa n s h o u ld b e o v e r h a u le d
a s s o o n a s p o s s ib le .
N o te : T h e v is c o u s fa n d r iv e s h o u ld a lw a y s b e tr a n s p o rte d
a n d s to r e d in a v e r tic a l p o s itio n ( a s fitte d to t h e e n g in e ) to
p rev en t th e s ilic o n flu id fr o m r u n n in g o u t. W hen
o v e r h a u lin g t h e fa n it is e s s e n tia l to e n s u r e t h a t o n ly th e
r e c o m m e n d e d s ilic o n flu id is u s e d . D o n o t u s e m in e r a l
b a s e d o il. T h e fa n w ill n o t o p e r a t e c o rr e c tly , c a u s in g o v e r
h e a tin g a n d s e rio u s d a m a g e to t h e e n g in e .
Fig. 19-57
O V E R H A U L IN G T H E V IS C O F A N
D is m a n tlin g
P rio r t o d is m a n tlin g t h e v is c o f a n th o r o u g h ly c le a n th e o u ts id e
w ith a s u ita b le c le a n in g flu id .
1. S e c u r e t h e fa n in a v ic e fitte d w ith s o ft ja w s ,
(F ig . 1 9 - 5 8 ) .
F ig . 1 9 - 5 8
2. R e m o v e t h e t h e r m o s t a t c o v e r re ta in in g s c re w s w ith a
5 m m A lle n k e y , (F ig . 1 9 - 5 9 ) .
F ig . 1 9 - 5 9
3. in s e r t tw o M 8 b o lts in t h e th r e a d e d h o le s in t h e th e r m o
s t a t c o v e r , (F ig . 1 9 - 6 0 ) .
4. S c r e w d o w n t h e b o lts t o lift o f f t h e t h e r m o s ta t c o v e r. T h e
t h e r m o s t a t is p r e - s e t a n d m u s t n o t b e d is m a n tle d .
F ig . 1 9 - 6 0
5. L o o s e n a n d r e m o v e t h e d r iv e d is k r e ta in in g s c re w s w ith
a n in h e x s o c k e t, (F ig . 1 9 - 6 1 ) .
A tte n tio n ! T h e s e s c r e w s a r e s e c u r e d w ith L o c tite a n d m a y b e

d iffic u lt to lo o s e n . T h e s c r e w s c a n b e lo o s e n e d b y lig h tly ta p p in g
th e e n d o f th e s o c k e t w re n c h .
Fig. 19-61
April '96
Visco Fan 19-24
6. L ift o u t t h e d r iv e d is k fr o m t h e fa n b o d y , (F ig . 1 9 - 6 2 ) .
F ig . 1 9 - 6 2
7. C a r e fu lly r e m o v e t h e t h e r m o s t a t c o v e r g a s k e t fr o m th e
fa n b o d y , (F ig . 1 9 - 6 3 ) .
F ig . 1 9 - 6 3
8. P la c e s u p p o r t ( i t e m i p a g e 1 9 - 3 0 ) u n d e r t h e fa n b o d y
a n d u s e a m a n d r e l ( it e m 2 p a g e 1 9 - 3 0 ) to p re s s o u t th e
d r iv e s h a ft, (F ig . 1 9 - 6 4 ) .
F ig . 1 9 - 6 4
9. R e m o v e t h e s p a c e r rin g , (F ig . 1 9 - 6 5 ) .
Fig. 19-65
April ‘96
10. L ift o u t t h e s e a l, (F ig . 1 9 - 6 6 ) .
F ig . 1 9 - 6 6
11. R e m o v e th e c irc lip , (F ig . 1 9 - 6 7 ) .
F ig . 1 9 - 6 7
1 2 . T u r n t h e fa n b o d y o v e r a n d u s in g a s le e v e (it e m 4
p a g e 1 9 - 3 0 ) p r e s s o u t t h e b e a r in g , (F ig . 1 9 - 6 8 ) .
1 3 . T h o r o u g h ly c le a n t h e h o u s in g w ith a s u ita b le
c le a n in g flu id .
1 4 . In s p e c t t h e fa n b o d y fo r a n y d a m a g e .
F ig . 1 9 - 6 8
A s s e m b ly
1. U s e t h e s le e v e a n d s u p p o r t (it e m s 3 a n d 1 p a g e 1 9 - 2 9 )
a n d fit t h e b e a r in g s , (F ig . 1 9 - 6 9 ) .
A tte n tio n ! N e w b e a r in g s a n d fa n m u s t b e u s e d w h e n re

a s s e m b lin g t h e fa n .
2. R e m o v e t h e s u p p o r t fr o m u n d e r t h e fa n a n d fit th e d riv e
s h a ft in to p la c e .
3. U s in g t h e s le e v e p r e s s th e d r iv e s h a ft in to th e h o u s in g ,
(F ig . 1 9 - 6 9 ) .
Fig. 19 69
April '96
Visco Fan 19-26
4. S e c u r e t h e fa n in a v ic e fitte d w ith s o ft ja w s ,
(F ig . 1 9 - 7 0 ) .
F ig . 1 9 - 7 0
5. F it t h e c irc lip , (F ig . 1 9 - 7 1 ) .
F ig . 1 9 -7 1
6. G r e a s e t h e s e a l lip s w ith a s u ita b le g r e a s e a n d r e p la c e th e

s e a l, (F ig . 1 9 - 7 2 ) .
F ig . 1 9 - 7 2
7. W it h a p la s tic o r r u b b e r h a m m e r r e p la c e t h e s p a c e r rin g ,
(F ig . 1 9 - 7 3 ) . .
A tte n tio n ! T a p e r o f s p a c e r to p o in t to w a r d s d r iv e d is k .
Fig. 19-73
April ‘96
8. C a r e fu lly r e p la c e t h e d r iv e d is k in to t h e fa n b o d y ,
(F ig . 1 9 - 7 4 ) .
F ig . 1 9 - 7 4
9. C le a n t h e d r iv e d is k s c r e w th r e a d s a n d in s e r t t h e s c re w s
w ith L o c tite , (F ig . 1 9 - 7 5 ) .
F ig . 1 9 - 7 5
10. T o r q u e t h e s c r e w s u s in g a n In h e x s o c k e t, (F ig . 1 9 -7 6 ) .
F ig . 1 9 - 7 6
11. U s e a s y r in g e fille d w ith s ilic o n o il ( s e e s p e c ific a tio n s

fo r q u a n tity a n d b r a n d ) to fill t h e c e n tr e o f t h e h o u s in g ,
(F ig . 1 9 - 7 7 ) .
Fig. 19-77
April '96
Visco Fan 19-28
12. T h o r o u g h ly c le a n t h e t h e r m o s t a t c o v e r w ith a s u ita b le

c le a n in g flu id , (F ig . 1 9 - 7 8 ) .
F ig . 1 9 - 7 8
13. F it a n e w g a s k e t in to t h e fa n h o u s in g , (F ig . 1 9 - 7 9 ) .
F ig . 1 9 - 7 9
14. R e p la c e t h e t h e r m o s t a t c o v e r w ith tw o M 8 b o lts in th e

t h r e a d e d h o le s , ( F ig . 1 9 - 8 0 ) .
F ig . 1 9 - 8 0
15. T ig h t e n t h e A lle n c a p s c r e w s w ith a 5 m m A lle n k e y

s o c k e t, (F ig . 1 9 - 8 1 ) .
A t t e n t i o n ! A lw a y s s t o r e t h e fa n in a n u p rig h t p o s itio n .
Fig. 19-81
April '96
Special tools for Visco Fan
These tools must be self fabricated
( It e m 1 )
S u p p o r t fo r r e m o v in g b e a r in g s a n d d r iv e fla n g e .
35
~L
( It e m 2 )
M a n d r e l f o r r e m o v in g fla n g e d s h a ft.
100
( It e m 3 )
S le e v e fo r in s ta llin g t h e d r iv e fla n g e .
April '96
Visco Fan 19-30
( It e m 4 )
S le e v e fo r r e m o v in g t h e b e a r in g s .
(It e m 5 )
S le e v e fo r in s ta llin g t h e d r iv e fla n g e .
(It e m 6 )
S u p p o r t fo r t h e fa n b o d y , fo r in s ta lla tio n o f b e a r in g s .
( It e m 7 )
S u p p o r t fo r t h e fa n b o d y , fo r in s ta lla tio n o f b e a r in g s .
April '96
SPEC IA L T O O LS FO R SECTION 19
T E L : (0 4 1 ) 4 3 -2 2 9 9 , FA X : (0 4 1 ) 4 3 -2 2 2 4
W a t e r p u m p fr o n t s e a l
R e m o v e m a n d r e l,
P a rt N o. 4 0 2 0 2 3 0 5
W a t e r p u m p fr o n t s e a l
r e p la c in g m a n d r e l,
P a rt N o. 4 0 2 0 2 3 1 8
C a r b o n a s s e m b ly s e a l
r e p la c in g to o l,
P a rt N o. 4 0 2 0 2 2 9 5
W a t e r p u m p In n e r lip
ty p e s e a l r e p la c in g m a n d r e l
P a rt N o. 4 0 2 0 2 3 5 0
V - b e lt te n s io n in g g a u g e ,
P a rt N o. 4 0 2 0 2 3 21
April ‘96
D iesel C lu b
ADE 364 and ADE 366

End of
Workshop Manual
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■ » 1 1 1 1 1 /® = “

BDC From the Library of Barrington Diesel Club

ENGINE REPAIR MANUAL

ATLANTIS DIESEL ENGINES (PTY) LTD

Part No. 805*&S4i

© C O P Y R IG H T 1988 A T L A N T IS DIESEL E N G IN E S (PTY) LTD.

TECHNICAL DATA .......................................................................................................................................... 08

OPERATING MAINTENANCE SCHEDULE AND LUBRICATING OILS ..............................................09

FAULT FINDING ...............................................................................................................................................10

CYLINDER BLOCK AND LINERS .................................................................................................................11

CYLINDER HEAD .............................................................................................................................................12

PISTONS AND CONNECTING RODS .......................................................................................................... 13

CRANKSHAFT AND MAIN BEARINGS ....................................................................................................... 14

CAMSHAFT, TIMING CASE AND DRIVE-TIMING ................................... ...................................................15

LUBRICATING SYSTEM AND SUMP ............................................................................................................16

FUEL SYSTEM .................................................... ............................................................................................ 17

TURBOCHARGER ........................................................................................................................................... 18A

POWER STEERING ....................................................................................................................................... 18B

EXHAUST BRAKE ........... ....18C

FLYWHEEL ...................................................................................................................................................... 18D

ALTERNATOR AND STARTER MOTOR .................................................................................................... 18E

COMPRESSOR/VACUUM PUMP ..................................................................................................................18F

COOLING SYSTEM ........................................................................................................................................ 19

APPROVED SERVICE TOOLS ......................................................................REFER TO EACH SECTION

ADE 364N AD E 364C A D E 364T A D E 364TI

B o r e ........................................................................... 97,5 m m ..................97,5 m m .................. 97,5 m m .................. 97,5 m m

F irin g o rd e r ............................................................ 1 -3 -4 -2 ..................... 1-3-4-2 ....................... 1-3-4-2 .......................1-3-4-2

DETAIL OF RATINGS (AUTOMOTIVE) TO SABS 013-1977

T y p ic a l d ry m a s s .................................................. 335 kg ..................... 343 kg ..................... 343 kg ..................... 370 kg

A D E 366N A D E 366C A D E 366T A D E 36831

B o r e ............................................................................ 97,5 m m ..................97,5 m m ..................97,5 m m .........97,5 m m

F irin g o rd e r ............................................................ 1-5-3-6-2-4 ............... 1-5-3-6-2-4................1-5-3-6-2-4.................1-5-3-6-2-4

DETAIL OF RATINGS (AUTOMOTIVE) TO SABS 013-1977

T y p ic a l d ry m a s s .................................................. 445 kg ..................... 460 kg ..................... 460 kg ......................495 kg

T h ro u g h o u t th is E n g in e R e p a ir M a n u a l, S1 (In te rn a tio n a l M e tric S yste m ) u n its a s a p p ro ve d by th e S o u th A fric a n B ureau

TORQUE SPECIFICATIONS FOR BOLTS UNDER DIFFERENT GRADE CLASSIFICATIONS

Q uality grade 8.8 10.9 12.9

M6 8.6 11.8 14.5

M 12x1,5 76 105 128

M 14 114 165 195

M 14x1,5 128 178 215

M 16 178 250 300

M 16x1,5 190 270 320

M 18 245 355 415

M 18x1,5 280 390 465

M20 350 490 590

M 20x1,5 390 550 660

M22 465 660 800

M 22x1,5 520 730 875

M24 600 850 1000

M 24x2 660 910 1100

IDENTIFICATION NUMBER POSITIONS

W hen o rd e rin g spare p a rts a llw a ys q u o te th e eng in e

ATLANTIS DIESEL ENGINES (PTY) LTD

ADE M J 01002 SA 046315 T

ENGINE SERIAL NUMBER

C h e c k th e e n g in e s u m p o il le ve l. . C ategory 1 C ategory 2 C ategory 3

E n su re th a t th e re is fu e l in th e ta n k. 7 500 km /150 h rs 5 000 km /100 h rs 2 500 km /50 hrs

C h e c k th a t th e b a tte ry is fu lly ch a rg e d and th a t a ll e le c ­ A t le a s t tw ic e a ye a r w h e n s e rv ic e in te rv a l is n o t re a ch e d

C ateg ory 1 C ategory 2 C ategory 3

U n its o p e ra tin g u n d e r n o rm a l c o n d itio n s , m ore th a n

U n its o p e ra tin g u n d e r n o rm a l c o n d itio n s , up to 100 000

1. C h e ck g e n e ra l e n g in e in s ta lla tio n i.e. A ll p ip e s and

C h e c k th a t th e b a tte ry is fu lly ch a rg e d and th a t a ll e le c A t le a s t tw ic e a ye a r w h e n s e rv ic e in te rv a l is n o t re a ch e d

A d d itio n a l ite m s re q u irin g s e rv ic in g a t 50 000 km in te r ENGINE PRESERVATION

Run e n g in e u n til w a rm a n d d ra in e n g in e o il. c y lin d e r via th e c o m p re s s o r a ir in ta k e w h e re

REBORING CYLINDER BLOCK FOR OVER

3. In s e rt to o l in to b o rin g b a r head and a d ju s t to th e re