項目   零配件號碼    最近的部分號碼    描述      

    1   CV12651    1      燃料過濾器冒口          

    4   ST43514    3   ST43514    螺拴         

    5   2134 A008  3   2134 A008  墊圈         

    6   2131 A008  3   2131 A008  墊圈         

    7   ST46077    1   ST46077    栓塞         

    8   ST49852    1   ST49852    墊圈         

    9   CV5594 1   CV5594 HEATSHIELD       

    10  ST43506    3   ST43506    螺拴         

    11  2134 A008  3   2134 A008  墊圈         

    12  CV7039 3   CV7039 距離塊       

    13  OD19596    2   OD19596    燃料過濾器       

    14  OD19444    1   OD19444    密封O型圈

    項目   零配件號碼    最近的部分號碼    描述      

    1   OD19525    1   OE52601    燃料過濾器組合             

    項目   零配件號碼    最近的部分號碼    描述      

    2   OD19718    1   OD19718    體        

    3   OD19723    1   OE52601    圈        

    4   OD19720    1   OD19720    錐形         

    5      1      接合         

    6   OD19724    3   OD19724    螺旋         

    7   OD19719    1   OE52601    手提澆斗         

    8   OD19724    3   OD19724    螺旋         

    9      1      密封         

    10  OD19722    1   26560134   栓塞         

    11  KRP1244    1   KRP1244    修理裝備 - 燃料的過濾器 

How to renew the element s of the air

Restriction indicator

Each air filter is fitted with an indicator (A) which gives

a visual warning when the filter needs a service.

When the red warning indicator is seen through the

clear panel after the engine has  stopped, the air filter

element must be renewed.

After a clean element has been fitted, press the reset

button on the res triction indicator.

filters

The two air filters (B) contain paper elements. These

must not be washed. Renew the paper elements as

follows:

1 Loosen the clamp and remove the end cover (B1).

Remove the wing nut (B2), withdraw and discard the

filter element (B3).

2 Clean, thoroughly, the inside of the casing of the air

filter. Fit a new filter element and fit the end cover.

3  Reset the restriction indicator.

Repeat this procedure for the other air filter.

How to drain the primary fuel filter

1  Remove the drain plug from the base of the filter

bowl and allow any water or sediment to drain from

the unit.

2  Fit the drain plug and tighten it securely.

A

3

2

37

1

B

21

19

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4

How to check the drive belts

Check all drive belts and renew a belt if it is worn or

damaged. Where more than one belt is used between

two pulley s, all of the belts must be renewed together.

Maximum belt life will be obtained only if the belts are

kept at the correct tensions.

Check the belt tension at the centre of the longest free

length, for ex ample, position (A5) to check the fan

drive belts.

Use a ‘Gates  "Krikit" V-belt tension gauge’ or similar

tool to check the tension of the belts.

The correct tension for all belts  is 400 to 489 N (90 to

100 lbf). Where more than one belt is used between

two pulleys, check/adjust the tension on the tightest

belt.

Note: When new belts are fitted they must be

checked again after the engine has been run for 15

minutes and, if necessary, adjus ted to the correct

tension.

How to adjust the tension of the fan belts

1  To adjust the tension of the fan belts, loosen the

nuts on the adjustment bolt. Loosen the large loc k nut

(B1) on the belt tensioner and turn the adjustment bolt

(B2) until the correct tension is obtained.

2  Tighten the lock nut and check the tension of the

A

B

1

2

4

1

3

2

5

59

60

belts again.

3  Run the engine for 15 minutes and then check the

belt tension again.

Check the tension of new belts every week for four

weeks and then at the intervals specified in the

service schedule

How to adjust the tension of the alternator belt

1  Loosen the alternator pivot bolt (A1), the

adjustment link bolt (A3) and the adjustment bolt (A2).

Move the alternator to obtain the correct belt tension

and tighten the bolts.

2  Run the engine for 15 minutes and then check the

belt tension again.

Check the tension of new belts every week for four

weeks and then at the intervals specified in the

service schedule.

How to renew the fan belts

1  To renew the fan belts, remove the six bolts whic h

fasten the fan to the pulley and push the fan forward

into the radiator cowl.

2  Release the tension on the belts and remove the

old belts. Ensure that the pulley grooves are free from

grease and dirt. Fit a new set of belts.

3 Fit the fan and tighten the bolts s ecurely. Adjust the

fan belts to the correct tension.

20

How t o renew the alternator belt

1 Remove the fan belts from the crankshaft pulley as

given on this page.

2 Loosen the adjustment bolts to release the tension

on the alternator belt and remove the old belt. Check

that the pulley grooves are clean and fit a new belt.

Adjust the belt to the correct tension. Fit the fan belts

as given on this page.

This document has been printed from SPI². Not for Resale

4

How to check the specific gravity of the

coolant

Drain some coolant from the cooling sy stem after the

engine has been stopped and before the formation of

sediment. Proceed as follows:

1  For mixtures which contain inhibited ethylene

glycol:

(a)  Put a hydrometer, and a reliable thermometer,

into the antifreeze mixture and check the readings

on both instruments.

(b)  Compare the readings obtained with the chart

and adjust the strength of the mixture as

necessary.

C

60

50

40

30

20

10

0

40

45

50 55 60

A

140

122

104

86

68

50

D

2  For mixtures which contain inhibited propylene

glycol:

(a) Open the cover of the refractometer, check that

the clear panel is  clean and use a small syringe to

apply three or four drops of the coolant mix ture to

1.04

1.05

1.06

1.07

B

1.08

1.09

1.10

1.11

the clear panel.

(b)  Spread the coolant over the full area of the

clear panel and close the cover. Hold the

refractometer horizontally with the clear panel at

the top and inspect the sample through the viewer.

(c)  Compare the reading with the chart in the

instructions; adjust the strength of the mixture as

necessary.

Specific gravity chart

A = Percentage anti-freeze by volume

B = Specific gravity

C = Mixture temperature in Centigrade

D = Mixture temperature in Fahrenheit

Caution: The clear panel must be cleaned

thoroughly before use. Some of the fluid which was

tested earlier can remain on the clear panel and this

will affect the reading of the sample.

Protection against frost is as follows:

Antifreeze/water       Protection down to

(% by volume)               (°C)

50/50                    -35

60/40                    -40

How to check the pH value of the coolant

The pH value of the coolant must not be less than pH7

or more than pH9.5. The pH value can be found by

the use of a pH meter or test papers, which are

available from pharmaceutical manufacturers.

If these limits are exceeded the pH value may be

adjusted by the addition of a corrosion inhibitor to the

same specification as that already in use. If this is not

possible, the system must be drained, flushed and

filled with new coolant.

21

This document has been printed from SPI². Not for Resale

4

How to renew the engine lubricating oil

1  Operate the engine until it is warm.

2  Stop the engine, remove the sump drain plug and

drain the lubricating oil from the sump. Fit the drain

plug, complete with a new sealing washer, and tighten

the plug to a torque of 47 Nm (35 lbf ft). If the plug is

fitted to a steel insert, tighten the plug to a torque of

115 Nm (85 lbf ft).

3  Renew the three oil filter canisters as given below.

4  Clean the area around the oil filler cap (A2) and

remove the c ap. Fill the sump to the H mark on the

dipstick (A1) with clean new lubricating oil of an

approved grade as given on page 32. Do NOT overfill.

5 Operate the engine and check for leakage from the

filter canisters. When the engine has cooled, check

the oil level on the dips tick  and put more oil into the

sump, if necessary.

How to renew the canisters of the oil filter

Three screw-on type canisters are fitted to the filter

head which is integral with the bottom of the engine oil

cooler.

1  Put a tray under the canisters to retain the spilt

lubricating oil. Use a s trap wrench to remove each

canister.

A

B

1

2

1

61

64

1

2 Check that the sealing rings (B1) are correctly fitted

to the new canisters and clean the contact faces of

the filter head.

3  Lubricate the top of each canister seal with clean

engine lubric ating oil and fill each canister with the

approved grade of lubricating oil.

4  Fit the new canisters to their adaptors and tighten

each canister until its sealing ring is jus t in contact

with the face of the filter head. Continue to tighten

4

overtighten.

22

This document has been printed from SPI². Not for Resale

4

How to renew the canister of the main fuel

1

How to clean the primary fuel filter

1  Remove the three bolts (A1) and remove the filter

bowl (A2).

2  Clean all of the components  with paraffin and dry

them with a compressed air jet.

3  Fit the bowl to the filter head, together with a new

sealing ring. Align the clamp ring (A3) and fasten it

with the three bolts.

Early engines can be fitted with filters that have

elements which can be cleaned. These elements

should be removed, cleaned with fuel oil and dried

with a compressed air jet.

filter

The main fuel filter is at the rear of the engine on the

‘B’ bank side and has two canisters. Both canisters

must be renewed at the same time.

1 Clean the area around the filter and remove the fuel

filter canisters. If necessary, use a strap wrench.

Discard the canisters.

2 Check that the sealing ring (B1) is fitted correctly to

each new canister and clean the contact faces of the

filter head.

3 Lubricate the top of the canister seal (B1) with clean

fuel oil and renew the sealing ring (B2) on the adaptor.

4 Fit the new canisters to their threaded adaptors and

tighten each canister until the sealing ring just comes

into contact with the filter head. Continue to tighten

4

overtighten.

After the fuel filter canisters have been renewed,

eliminate air from the low pressure fuel system as

given on page 27.

A

1

2

2

1

3

65

B

66

23

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4

How to check/adjust the timing of the fuel

injection pump

If it becomes necessary to check and adjust the timing

of the fuel injection pump, the procedure which

follows is recommended:

1  Ensure that the stop control is in the ‘STOP’

position.

2  Remov e the high-pressure fuel pipes and the

rocker cover from the cylinder head for A4, A5 and A6

cylinders.

3  Remov e the cover from the flywheel housing as

shown (A).

4 Turn the crankshaft by hand, in the normal direction

of rotation, until the relevant number for injection

timing (s ee the engine data plate) aligns with the

timing pointer at the same time as the valves of A6

cylinder are closed, ie. ‘A6’ piston at TDC on its

compression stroke.

5  Check that the timing mark (B1), on the hub of the

fuel injection pump, aligns with the pointer (B2).

6  If the timing mark (B1) does not align with the

pointer, check that the fuel pump drive shaft and the

coupling are secure and are not damaged, then

proceed as follows :

7  Set the timing position as in paragraph 4 above,

and loosen the four cap screws (C1), or for later

engines s pecial bolts, on the injection pump

adjustable coupling.

8 Turn the hub in the normal direction of rotation by  

hand, to just past the timing position. Then turn the

hub back until the timing mark  and pointer align;

For  earlier engines tighten the four cap s crews

(C1) to 69 Nm (51 lbf ft). For later engines tighten

the four special bolts to 46 Nm (34 lbf ft).

9 Turn the engine in reverse direction for a quarter of

a turn (90°) and then forward, in the normal direction

of rotation, until the flywheel timing pointer is again

aligned with the correct timing point (stamped on the

engine data plate). Check that the timing marks of the

fuel injection pump are correctly aligned.

A

B

1

2

67

68

C

1

69

24

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4

Fuel injector fault

A fuel injector fault c an cause an engine misfire.

In order to find which injector is defective, operate the

engine at a fast idle speed. Loosen and tighten the

union nut of the high-pressure fuel pipe at each

injector. When the union nut of the defective injector

is loosened, it has little or no effect on the engine

speed.

Warning!  Ensure that the fuel does not spray onto

your skin.

How to remove the fuel injectors

1  Disconnect and remove the high-pressure pipes

and the spill pipes. For early engines, remove the

relevant rocker box cover. Release the connection for

the leak-off fuel from the fuel injector and remove it

through the wall of the rocker box. For later engines,

remove the relevant pedestal rocker cover.

2  Release the relevant clamp and withdraw the fuel

injector. To remove a tight fuel injector, use the Slide

Hammer, 21825 849 (A1) and the relevant Adaptor

(A2): 21825 854 for M18 threads or 21825 860 for

M14 threads.

Caution: Ensure that the copper fuel injector sleeve

is not loosened in the cylinder head during the use of

A

2

1

93

the slide hammer.

How to correct the fuel injector sleeves

To improve the condition of the injector sleeves, us e

the Reamer/facer tool for the injector sleeve. Grease

must be applied to both of the cutters before use, to

retain carbon and metal particles. Do not remove

more metal than is absolutely necessary to correct the

seat face. The max imum permissible depth of the

seat face, measured from the top face of the cylinder

head, is 104,25 mm (4.104 in).

Note: The Reamer/facer tool is assembled from

these tools: 21825 765, 21825 767 and 21825 768.

How to fit the fuel injectors

1  Check that the new injector is fitted with a new ‘O’

ring seal in the machined groove near to the top of the

stem and check  that the sleeve for each fuel injector

is c lean.

2  If relevant, remove the connection for the leak-off

fuel from each fuel injector and fit carefully each fuel

injector into its sleeve, with the threaded hole for the

leak-off fuel toward the outer wall of the rocker box.

DO NOT use a sealing washer between the injector

and the seating face of the injector sleeve.

3  Fit the assembly of the metal cup and rubber seal

against the head of each connection for leak-off fuel

and fit a new copper washer onto the thread. For

early engines, insert each connection through the

openings in the outer walls of the rocker boxes and fit

the connection into its fuel injector, finger-tight.

4  Fit the clamps to the relevant fuel injectors,

complete with a spherical washer for each clamp. Fit

the cap screws through the washers and the clamps

and tighten them to 60 Nm (44 lbf ft). For early

engines, when all the cap screws of the clamps are

tight, tighten the connections for leak-off fuel to 27 Nm

(20 lbf ft).

5  Check that the joint face of each rocker box is

c lean. Fit a new joint for each rocker box cover and

align correctly the bolt holes.

Continued

25

This document has been printed from SPI². Not for Resale

4

6  Fit c arefully  each roc ker box  cover and fit the

eight bolts , complete with plain and spring was hers.

Tighten the bolts to 27 Nm (20 lbf ft). For later  

engines, fit a new ‘O’ ring around the groove near

the top of each fuel injector. Fit the pedes tal roc ker

cover and tighten lightly all of the bolts . Tighten

ev enly all of the bolts, in the s equence shown (A),

to a torque of 11 Nm (8 lbf ft).

7  For all engines, fit new copper sealing washer to

the connections for leak-off fuel and fit the pipes

between the fuel injectors and the connection block

for the leak-off fuel. Tighten securely each banjo bolt

connection and each union nut.

8  Fit each high-pressure fuel pipe between its

delivery valve and its fuel injector. Tighten by hand

each nut. DO NOT bend a pipe to make it fit between

its connections. Tighten securely each nut to 45 Nm

(33 lbf ft).

Note: The identification of each high-pressure fuel

pipe is made by the cylinder number which is stamped

on the union nut which is fitted to the fuel injector.

9 Fit new rubber dampers around each high-pressure

fuel pipe. Fit the shrouds over the rubber dampers

and retain securely each s hroud to its induction

manifold with bolts and spring washers.

10  Eliminate air from the high-pressure fuel system

as given on page 27.

11  Run the engine and check for leaks.

4

6

1

2

A

7

3

5

70

26

This document has been printed from SPI². Not for Resale

4

How to eliminate air from the fuel system

If air enters the fuel system, the injection pump

pressure may become insufficient to operate the

injector valves and the engine may stop, misfire or fail

to start.

To eliminate air from the system, use the relevant

procedure which follows:

Low pressure system

1  Loosen the low pressure relief valves (A1) on the

fuel injection pump and operate the priming plunger

(B1) of the fuel lift pump. When fuel, free from air,

flows from the relief valves, tighten the unions.

2  Clean away fuel that has been spilled.

High pressure system

Air in the high pressure system must be released at

the injectors.

1  Mov e the s top control to the RUN position and

operate the starter motor.

2 Loosen the nut of the high-pressure fuel pipe at one

of the injectors. When fuel, free from air, is released,

tighten the nut to a torque of 45 Nm (33 lbf ft). DO

NOT OVERTIGHTEN.

Warning!  Ensure that fuel does not spray onto your

skin.

A

B

1

1

71

72

3 Repeat the procedure for the remainder of the fuel

injectors.

4  If the engine starts during this operation but runs

erratically, continue to eliminate air from each injector

until the high pressure system is free from air or until

the engine runs correctly.

5  Return the stop control to the STOP position.

6  Clean away any fuel that has been spilled.