Volvo D6D Shop Armed [PDF]

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Service Information Document Title: Engine, assembling



Function Group: 210



Information Type: Service Information



Date: 28/08/2021



Profile: D6D



Engine, assembling Showing Selected Profile Valid for serial numbers Model



Production site



Serial number start



D6D Op nbr 11667220 Drift plate 11668401 Installation tool (crankshaft oil seal) 11668402 Installation tool (camshaft bushings) 6999004 Handle 6999030 Drift plate 6999038 Drift plate 9990144 Drift plate 9990145 Piston ring compressor 9992634 Counterhold 9993713 Puller bolt 9993717 Quick nut 9993722 Support 9996400 Impact puller 9998007 Adapter 9998547 Lifting tool, engine 9998671 Fixture 9998676 Rotation (cranking) tool, crankshaft 9998678 Measuring tool



Socket or spanner Torx E10 Socket Torx E12 Socket Torx E18 Socket Torx E20 Lifting eyes M10 and M12 Lifting sling Dial test indicator with magnetic base Dial test indicator with angled base Dial test indicator for inside measurements Depth gauge



Serial number stop



Piston ring pliers Feeler gauge Screw micrometer Connecting rod testing device Steel ruler Torque wrench, open end Stand for checking crankshaft



Front cover with oil pump, assembling 1. Assemble the pump parts. Tighten down the cover to 8–9 Nm (6–6.5 lbf ft).



Figure 1



Cylinder liner D6D, installing 2. Make sure that the cylinder liner and the cylinder liner location in the cylinder block are clean. 3. Install the cylinder liner and tools according to the figure.



Figure 2



1. 2. 3. 4.



9990144 Cylinder liners 11667220 9993713



4. Turn the nut and press down the liner. Check that the cylinder liner collar bottoms in the collar location.



Figure 3



Camshaft and valve tappets, checking



Figure 4



1.



Steel ruler



Check that the contact surface against the camshaft on the valve tappets is convex or flat. If the surface is concave, replace the valve tappets. If the valve tappet is worn across the contact surface, the tappet must be discarded. The "ditch" shows that the tappet has not been rotating. A dark line outermost on the contact surface however, indicates that the surface is not worn down. It is the condition of the valve tappets that determines whether a check of the camshaft wear is necessary. Check that the contact surfaces on the camshaft and the valve tappets do not have severe pitting damage. Pitting damage may arise for varying reasons. The damage is caused by small bits of metal loosening from the hardened surface. Tappets and camshaft with minor pitting damage may be used. Damage such as pitting usually does not get any worse. Check that the camshaft bearing races and cam profiles are not abnormally worn. The cams may, for example, be worn



obliquely in an axial direction. This can, if the damage is light, be adjusted by honing. Replace the camshaft if major damage and wear are present. When replacing the camshaft, the valve tappets must also be replaced.



Camshaft, installing 5. Replace bearing bushings when required. NOTE! The wider bushing (23.5 mm) (0.925 in) should be placed on the flywheel side.



Replace bearing bushings when required. NOTE! The lubricating oil holes must be positioned according to the figure.



Figure 5



Figure 6



1.



Lubricating oil holes 6. Press the bushing into the correct position, from the inside and out using the tool 11668402.



Figure 7



1.



11668402



Figure 8



1. 2. 3.



Press sleeve Bearing bushing Guide sleeve 7. Lightly lubricate the valve tappets with oil and install them



Figure 9



8. Install the camshaft. NOTE! Take care not to damage the bearing bushings.



Check that the camshaft can rotate freely.



Figure 10



Crankshaft, installing 9. Install the piston cooling nozzles. Press them in as far as possible.



Figure 11



10. Install the bearing shells in the cylinder block and lubricate them with oil.



Figure 12



1.



Bearing shell



11. Install the bearing shells in the bearing caps and lubricate them with oil.



Figure 13



12. Clean by wiping the bearing cap together with thrust bearing, thrust washers and bearing journal. Install the thrust washers and measure the width.



Figure 14



13. Determine the end float. The width of the crankshaft bearing journal less the measured width of the bearing cap and the thrust washers gives as a result the actual clearance. Permissible end float: 0.1–0.3 mm (0.004–0.012 in) 14. Lift the crankshaft into position. Make sure that the marking in relation to the camshaft gear will be correctly positioned.



Figure 15



1.



Marking



15. Lubricate and install the thrust washer halves which have no lug. Insert them into position under the crankshaft. Turn the surfaces with oil grooves toward the thrust bearing surfaces on the crankshaft.



Figure 16



16. Attach the other thrust washers onto the bearing cap with a little grease. Turn the washers so that the surfaces with oil grooves are facing toward the thrust bearing surfaces on the crankshaft



Figure 17



17. Lubricate the bearing caps with oil and install them according to the marking. No. 1 nearest to the flywheel end. Initial tightening torque:50 Nm (37 lbf ft). 1st tightening angle: 90° 2nd tightening angle: 90°



NOTICE The bolts should be changed after the engine is dismantled for the third time.



Figure 18



18. Make sure that the thrust washers on the cap fit correctly against the washers in the block.



Figure 19



19. Install the dial test indicator together with magnetic base. Prize with a pinch-bar and check the crankshaft end float. Permissible end float:0.1–0.3 mm (0.004–0.012 in)



Figure 20



1. 2. 3.



Pinch-bar Magnetic base Dial test indicator



Piston and connecting rod, assembling 20. Install one of the lock rings in the groove in the piston.



NOTICE The ring gap on the spring ring should face the piston crown.



Figure 21



21. Install the connecting rod in the piston with the guide pins turned toward the side on the piston, which has a flywheel symbol. Push in the piston pin. Check that the connecting rod can be pushed sideways on the piston pin.



Figure 22 5 1.



Guide pin



Pistons and connecting rods, installing 22. Install the bearing shells in the connecting rods and lubricate them with oil.



Figure 23



23. Install the piston rings. Arrange the piston ring gaps staggered 120° in relation to each other.



Figure 24



24. Remove the guide sleeve and the guide pin and install 9998676 on the crankshaft.



Figure 25



1. 2.



9998676 Spacer washers, 15 mm (0.590 in)



25. Use piston ring compressor 11668407 for D4D and 9990145 for D6D and install the pistons together with connecting rods from the cylinder head end. The flywheel symbol must be turned toward the flywheel end.



Figure 26



1.



9990145



Figure 27



26. Lubricate the big-end bearing journals on the crankshaft with oil. Push the connecting rod against the bearing journal and install the caps according to markings. Install new bolts and tighten them down. Initial tightening torque:30 Nm (22 lbf ft)



1st tightening angle: 60° 2nd tightening angle: 30°



Figure 28



27. Remove the rotation (cranking) tool from the crankshaft. Check that the crankshaft can rotate freely. Regarding checking and adjusting mechanical injection on D4D, see Mechanical injection D4D, checking and adjusting



Timing gear casing, installing 28. Remove any gasket remnants from the timing gear casing and the cylinder block. 29. Apply sealing compound (1161231-4) to the timing gear casing sealing surface.



Figure 29



30. Lightly oil the crankshaft oil seal. 31. Install the timing gear casing without tightening down the bolts. Position the casing aligned with the sealing surface on the oil sump.



Figure 30



32. Apply sealing compound in the groove for the cover.



Figure 31



33. Install the cover and the attaching plate for the connector to the ECU.



Figure 32



1. 2.



Cover Attaching plate



34. Tighten down the bolts. Tightening torque: 21 Nm (15.5 lbf ft) 35. Check the position of the wear groove on the crankshaft.



Figure 33



1.



Wear groove



36. Install the guide (the inner part of installation tool 11668401). Oil and install the crankshaft oil seal with the felt side outward.



Figure 34



1. 2.



Crankshaft oil seal Guide



37. Install any washers, press sleeve, the bearing and the nut. Use the number of washers required to prevent the new crankshaft oil seal from ending up in the same position as the old one.



Figure 35



1. 2. 3. 4.



Washers Press sleeve Bearings Nut



38. Screw the nut until stop. Check that the seal ends up in the correct position.



Front cover with oil pump, installing 39. Turn the engine in the adjustable stand so that the front end comes upward. 40. Clean the cover and the cylinder block from any gasket remnants. 41. Lightly oil the oil pump rotors.



Figure 36



42. Place the gasket on the cylinder block. Align it with the guide sleeves.



Figure 37



43. Install the cover together with the oil pump. Make sure that the oil pump drive aligns with the crankshaft.



NOTE! Only fits in one position.



Install the bolts without tightening them down.



Figure 38



44. Align the cover with the sealing surface on the oil sump.



Figure 39



45. Install the retainer for the revolution sensor. Use the two long bolts.



Figure 40



46. Tighten down the bolts. Tightening torque: 21 Nm (15.5 lbf ft) 47. Check the position of the wear groove on the crankshaft.



Figure 41



1.



Wear groove



48. Install the guide (the inner part of installation tool 11668400). Oil and install the crankshaft oil seal with the felt side outward.



Figure 42



1. 2.



Crankshaft oil seal Guide



49. Install any washers, press sleeve, the bearing and the nut. Use the number of washers required to prevent the new crankshaft oil seal from ending up in the same position as the old one.



Figure 43



1. 2. 3. 4.



Washers Press sleeve Bearings Nut



50. Screw the nut until stop. Check that the seal ends up in the correct position. 51. Install the guide sleeve and the guide pin on the crankshaft.



Figure 44



1. 2.



Guide pin Guide sleeve



52. Install the tooth wheel and the V-belt pulley and align the guide sleeve and the guide pin.



Figure 45



1. 2.



Guide sleeve Guide pin



53. Tighten down the bolts (Torx E20). Initial tightening torque:45 Nm (33 lbf ft) 1st tightening angle: 60° 2nd tightening angle: 60°



Figure 46



1. 2. 3. 4.



Torx E20 9992634 V-belt pulley Toothed wheel



54. Check that the oscillation damper is free from external damage. Turn the engine so that the end with the V-belt pulley comes upward. Install the oscillation damper. Make sure that the bolt holes align with the holes in the belt pulley. Tighten down the bolts. Tightening torque: 70 Nm (52 lbf ft)



Figure 47



55. Install a new gasket at the connection in the front cover for the oil suction pipe.



Figure 48



1.



Gasket



56. Install the oil suction pipe.



Figure 49



1.



Oil suction pipe



57. Fill the joints between the covers and the cylinder block with sealing compound.



Figure 50



58. Apply sealing compound to the oil sump sealing surface. Fill recesses.



Figure 51



59. Install the oil sump and tighten down the bolts. NOTE! Longer bolts at the short sides.



Tightening torque: 21 Nm (15.5 lbf ft)



Figure 52



1.



Longer bolts



Power take-off housing, installing 60. Install the power take-off housing. Apply locking fluid and tighten down the bolts (sockets Torx E10 and E12). 61. Install the oil pipe.



Figure 53



1. 2.



Attaching bolts Oil pipe



Flywheel and flywheel housing, installing 62. Turn the engine in the adjustable stand so that the flywheel end comes upward. 63. Fix the O-ring in the groove in the flywheel housing with a little grease.



Figure 54



1.



O-ring



64. Lift the flywheel housing into position, align the guide pins. Tighten down the bolts. Tightening torque, M12: 100 Nm (74 lbf ft) Tightening torque, M16: 240 Nm (177 lbf ft)



Figure 55



65. Lift the flywheel into position. If there are assembling marks, align the flywheel marking with the marking on the crankshaft.



Figure 56



66. Install the bolts and tighten them. Use 9998676 as a counterhold by the vibration damper. Initial tightening torque, 30–45 mm (1.82–1.77 in) long bolts: 20–30 Nm (15–22 lbf ft). Initial tightening torque, 50–85 mm (1.97–3.35 in) long bolts: 30–40 Nm (22–30 lbf ft). . 1st tightening angle: 60° 2nd tightening angle: 30 mm (1.18 in) bolts: 30°. 2nd tightening angle: 35–85 mm (1.38–3.35 in) bolts: 60°.



Figure 57



67. Install cover washer and tighten down the bolts.



Figure 58



68. Install the camshaft revolution sensor.



Figure 59



1.



Revolution sensor, camshaft



Determining thickness of cylinder head gasket Cylinder head gaskets are marked with one, two or three holes in one of the corners. The gaskets should be used for different piston heights above the cylinder block face. The piston height above the cylinder block face must be measured at two points on all pistons



Figure 60



1.



Marking of cylinder head gasket 69. Install the measuring tool 9998678 together with spacer washers and dial test indicator on the cylinder block. Set the dial test indicator to zero. NOTE! Place the spacer washers on the block, not on the liner edge.



Figure 61



1. 2. 3.



9998678 Dial test indicator Spacer washers



70. Position the dial test indicator at checking points. Turn the crankshaft to find the highest position of the piston. Read off the piston height on the dial test indicator.



Figure 62



71. Measure all pistons in the same way. Make a note of the highest value and use a cylinder head gasket according to the table.



Piston height



Number of holes in cylinder head gasket



0.33 up to 0.55 mm (0.0123 up to 0.0217 in)



1



0.56 up to 0.65 mm (0.0220 up to 0.0256 in)



2



0.66 up to 0.76 mm (0.0260 up to 0.0299 in)



3



Figure 63 Checking points



Cylinder head, installing 72. Place the cylinder head gasket on the cylinder block with the digits upward. Place the guide sleeves in the holes.



Figure 64



1.



Guide sleeves



73. Lift the cylinder head into position. Pay attention to the guide sleeves. Weight D6D: 80 kg (176 lb) Weight D4D: 60 kg (132 lb).



Figure 65



74. Install the push rods.



Figure 66



1.



Push rods



75. Oil the cylinder head bolts (M12) which run through the rocker arm retainers. Install the rocker arm retainers together with the bolts according to the markings. Align them with the push rods and the valves and tighten down the M10 bolts. Tightening torque: 21 Nm (15.5 lbf ft)



Figure 67



1.



Cylinder head bolts



76. Lightly oil the remainder of the cylinder head bolts and install them. Tighten them down in three steps, note the sequence. Initial tightening torque: 30 Nm (22 lbf ft) 2nd step: 80 Nm (59 lbf ft) Final tightening:90°



Figure 68 Tightening diagram for cylinder head 77. Adjust the valve clearance.



Valve adjustment The figures show valve adjustment after assembling the engine, with the fuel system components not yet installed. This method also applies when adjusting with the engine installed in the machine. Position of valves



Figure 69



D6D:1, 3, 5, 7, 9 and 11 are exhaust valves D6D:2, 4, 6, 8, 10 and 12 are inlet valves D4D:1, 3, 5 and 7 are exhaust valves D4D:2, 4, 6 and 8 are inlet valves 78. Crank the engine until the valves for the number 1 cylinder are "overlapping" (rocking). "Overlapping" means that the exhaust valve is about to open and the inlet valve is about to close. In this position it should not be possible to rotate any of the push rods for this cylinder.



Figure 70



79. Adjust the clearance for the valves, which are marked black in the figure. Inlet valve: 0.35 ±0.05 mm (0.0138 ±0.0020 in) Exhaust valve: 0.50 ±0.05 mm (0.01968 ±0.0020 in) NOTE! The valve clearance should be increased by 0.1 mm (0.004 in) when the cylinder head gasket has been replaced. Adjust to the normal valve clearance after 50 hours of operation.



Figure 71



80. Tighten the lock nut to 20 Nm (15 lbf ft). Check the adjustment again with the feeler gauge.



Figure 72



81. Crank the engine one revolution. Adjust the clearance for the valves, which are marked black in the figure



Figure 73



Unit pumps, installing 82. Install the roller tappets. Make sure that the correct tappet is installed in the correct place according to markings on the unit pumps. Make sure that the guide on the tappet engages the groove.



Figure 74



1.



Guide



83. Insert the washer down into the tappet with a screwdriver. The washers are 2.4 mm (0.095 in) thick.



Figure 75



84. Check that the O-rings are free from damage.



Figure 76



1.



O-rings



85. Install the unit pumps according to the marking. Crank the engine so that the camshaft comes in a suitable position for each unit pump before the bolts are tightened. Tightening torque step 1: 5 Nm (4 lbf ft). Step 2: 30 Nm (22 lbf ft). NOTE! When replacing one or more unit pumps, calibration with VCAD-PRO must be carried out.



Unit pump, calibration OP 23691-2.



Figure 77



Injectors and fuel lines, installing 86. Fix a new copper washer to the injector with a little grease.



Figure 78



1.



Washer



87. Install the injectors with the marking/machined surface toward the valve springs.



Figure 79



1.



Marking/machined surface



88. Install the retainers and screw in the bolts loosely. Torx E10.



Figure 80



1. 2.



Bolt, Torx E10 Retainer



89. Install new delivery pipes. Tighten the nuts loosely.



NOTICE The pressure lines may not be bent.



Figure 81



90. Tighten down the retainer attaching bolts. Tightening torque: 16 Nm (12 lbf ft) 91. Tighten down the delivery pipe nuts. Tightening torque:25 Nm (18.4 lbf ft)



Figure 82



92. Connect the fuel pipe to the unit pumps. The thicker gasket must be placed between the pipe and the pump. The thinner between the pipe and the bolt head. Do not install the bolt for unit pump 4. The pipe to the fuel filter is to be installed here later.



Figure 83



Figure 84



1.



Fuel pipe



Manifold, charge air pipe and valve cover, installing 93. Install the manifold together with new gaskets. The gasket flange is to point toward the cylinder head. Lubricate the threads on the screw studs with oil. Install and tighten down the nuts.



Tightening torque: 21 Nm (15.5 lbf ft)



Figure 85



1.



Manifold



94. Install the charge air pipe together with new gaskets and tighten down the bolts. Connect the ground lead. Tightening torque: 9 Nm (6.5 lbf ft)



Figure 86



1. 2.



Ground lead Charge air pipe



95. Place the gasket for the valve cover on the cylinder head. Position the rubber grommets on the fuel pipes.



Figure 87



1. 2.



Gasket Rubber grommets



96. Install the valve cover and tighten down the bolts. Do not tighten the three bolts for the rail. Tightening torque: 9 Nm (6.5 lbf ft)



Figure 88



Figure 89



1.



Bolts for rail



Oil trap, installing 97. Install a new gasket in the groove on the oil trap.



Figure 90



1.



Gasket



98. Align the oil trap connection with the oil line.



Figure 91



1.



Oil line



99. Tighten down the oil trap against the valve cover.



Figure 92



1.



Bolts



Coolant pump and thermostat housing, installing 100. Install the crankshaft revolution sensor.



Figure 93



1.



Speed sensor



101. Check that the coolant pump has no noticeable play. 102. Install the coolant pump together with a new gasket. Tighten the bolts loosely.



Figure 94



103. Lubricate the O-rings on the connecting pipe and install the thermostat housing. Install the bracket for the electrical cable. Tighten down the bolts. Tightening torque, coolant pump: 18 Nm (13 lbf ft) Tightening torque thermostat housing: 30 Nm (22 lbf ft)



Figure 95



104. Install the thermostat with the indicating arrow pointing upward and then install the casing. Tightening torque, coolant pump:18 Nm (13 lbf ft)



Figure 96



1. 2.



Thermostat Casing



Fuel feed pump, installing



105. Install the fuel feed pump Tighten the bolts loosely.



Figure 97



106. Install the V-belt on the belt pulleys. Tension the belt by moving the fuel feed pump. At correct tension it should be possible to depress the belt approx. 10 mm (0.39 in) in the middle between the belt pulleys. Tighten down the bolts.



Figure 98



1. 2.



Attaching bolt Tensioning bolt



Oil filter housing and oil cooler, installing 107. Install the coolant housing together with the connecting pipe.



Figure 99



1. 2.



Coolant housing Connecting pipe



108. Lubricate the O-ring on the connecting pipe with petroleum jelly. Install the filter housing together with a new gasket. Install the bolts and tighten them down. NOTE! Two different bolt lengths.



Tightening torque: 21 Nm (15.5 lbf ft)



Figure 100



109. Install the oil cooler and tighten down the bolts. Leave the upper bolt, as this is where the clamp for the fuel pipe is to be attached. Tightening torque: 21 Nm (15.5 lbf ft)



Figure 101



1.



Bolt for fuel pipe



110. Connect the hose to the fuel feed pump. Install the fuel pipe.



Figure 102



1. 2.



Fuel pipe Hose to fuel feed pump



111. Install the oil filler pipe.



Rail with cable harness, installing 112. Install the rail together with the cable harness. Make sure that none of the leads become pinched.



Figure 103



113. Connect the electrical leads to the unit pumps.



Figure 104



1.



Leads



114. Connect the connectors to the sensors for fuel temperature and oil pressure.



Figure 105



1. 2.



Sensor, fuel temperature Sensor, oil pressure



115. Connect the connector to the sensor for charge air pressure. Join up the connector halves for the camshaft revolution sensor.



Figure 106



1. 2.



Connector for revolution sensor, camshaft Sensor, charge air temperature



116. Connect the connector (3). Assemble the connectors for the crankshaft revolution sensor and the sensor for charge air temperature according to earlier made markings. NOTE! The connectors may be confused.



Connect the connector to the sensor for coolant temperature.



Figure 107



1. 2. 3. 4.



Connector for the sensor for coolant temperature Connector for the sensor for charge air temperature Connector Connector for revolution sensor, crankshaft



Engine, removing from adjustable stand 117. Connect 9998547 to the engine lifting eyes. Weight approx. 500 kg (1102 lb)



Figure 108



1.



9998547



118. Remove the bolts between the adjustable stand and 9998671 and lift away the engine.



Figure 109



1.



9998671



119. Remove the fixture.



Starter motor and turbocharger, installing 120. Install the starter motor.



Figure 110



121. Remove the protective plugs from the connections for the return pipe and the delivery pipe.



Figure 111



1.



Protective plugs



122. Install the turbocharger and tighten down the attaching nuts. Tightening torque M8: 21 Nm (15.5 lbf ft)



Tightening torque M10: 40 Nm (30 lbf ft)



Figure 112



123. Install the oil pressure pipe.



Figure 113



1.



Oil pressure pipe



124. Install a new O-ring on the return pipe. 125. Install the return pipe. Tightening torque: 21 Nm (15.5 lbf ft)



Figure 114



126. Install the retaining yoke.



Figure 115