Detroit Diesel — Procedure (55 steps)

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Procedure

1. 0. -08 Receipt Amendment No. M020084/00E Publication number: j Update as (PDF) file by E--mail j Update as (PDF) file as CD--ROM j Update in hardcopy form General – Designation of engine sides – Settings – Dangers in the work place – Data sheets – Publication summary – Threaded bore repair – Abbreviations – Keyword index Operation Schedules – Check engine condition – W5 Maintenance Operations – Engine removal – Engine disassembly – Engine assembly – Engine run-in – Engine installation – Engine drawings Task Descriptions – Group survey – Materials and consumables – Component removal – Component disassembly – Inspection and repair – Component assembly – Component installation Page 1 Section A General 20084/0 E 97–07 Contents A001 A002 Designation of Engine Sides and Cylinders A003 A004 Settings A005 Hazards in the Work Area A006 Data Sheets A007 A008 Publication Summary A009 Repairing Threaded Bores A080 Abbreviations A090 Keyword Index Page 2 Section A General 20084/0 E 97–07 *URXS  3DJH  ,PSRUWDQW ,QIRUPDWLRQ 6HFWLRQ $ *HQHUDO  (  $ ,PSRUWDQW ,QIRUPDWLRQ 7KLV PDQXDO LV LQWHQGHG IRU XVH E\ WHFKQLFDO SHUVRQQHO UHVSRQVLEOH IRU WKH PDLQWHQDQFH DQG VHUYLFLQJ RI WKH  VHULHV GLHVHO HQJLQH 7KLV PDQXDO GHVFULEHV - 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Cylinders are designated (to DIN ISO 1204) A on the left engine side and B on the right engine side. The cylinders of each bank are numbered in consecutive order, beginning at No. 1 at the driving end. The consecutive numbering of other components, too, always begins with No. 1 at the driving end of the engine. Designations and Abbreviations Driving end = KS Free end = KGS Left side Right side Top end Bottom end General Group 002 Page 2 Section A Designation of Engine Sides and Cylinder Designations 20084/0 E 97–07 Group 003 Page 1 Section A General Screws and Nuts 20084/00 E 99–08 Designation Tightening Lubricant See Crankcase Centre hex screws for crankshaft bearing cap * Max. shaft length: 176 mm – – Angle of further rotation: 90° + 10° Engine oil C 011.05 C 031.05 Side double-hex screws for crankshaft bearing cap * Engine oil C 011.05 Plugs for main oil ducts (M 30 1.5) Engine oil C 011.05 Plug, driving end, for auxiliary PTO lubrication (M 18 1.5) Engine oil C 011.05 Plug for centre coolant duct, driving end (M 60 2) Engine oil C 011.05 Plugs for coolant ducts to tappet chamber (M 26 1.5) Engine oil C 011.05 Gear Train Double-hex screws for flywheel housing Engine oil C 021.05 Hex screws for belt pulley Engine oil C 028.05 Running Gear Screws for counterweights Max. shaft length: 84 mm – – Angle of further rotation: 90° + 10° Engine oil C 031.05 Double-hex screws for flywheel Max. shaft length: 75 mm Engine oil C 032.05 Hex screws for vibration damper Engine oil C 035.05 Conrod cap screws ** Max. shaft length: 74.5 mm – – Angle of further rotation: 90° + 10° Engine oil C 037.05 * Tightening sequence: Hex screws before double-hex screws ** Replace conrod cap screws with cracked mating faces during each engine disassembly Group 003 Page 2 Section A General Screws and Nuts 20084/0 E 97–07 Designation Tightening Lubricant See Cylinder Head Double-hex screws for cylinder head Max. shaft length: 212 mm – 1st stage – 2nd stage – 3rd stage – 4th stage Angle of further rotation, in stages: – 1st stage – 2nd stage 90° + 10° 90° + 10° Engine oil C 041.05 Cylinder head tightening diagram Protective sleeve for injector Engine oil C 041.05 Valve Gear Locknut on adjusting screw for rocker arm Engine oil C 055.05 Locknut on adjusting screw for valve bridge Engine oil C 055.05 Hex screws for rocker shaft support Max. shaft length: 91 mm – – Angle of further rotation: 90° Engine oil C 055.05 Collar screw for cylinder head cover Engine oil C 055.10 Screws for plug-in clips on injection pump Engine oil C 073.05 Double-hex screws for injection pump Engine oil C 073.05 Hex screw for clamping element on injector Engine oil C 075.05 Union nut of nozzle on nozzle holder Engine oil Oper. Instr. Union nut of injection line on injection pump Engine oil C 075.05 Adapter of injection line in cylinder head Engine oil C 075.05 Group 003 Page 3 Section A General Screws and Nuts 20084/0 E 99–08 Designation Tightening Lubricant See Screw for driver of fuel pump on WP shaft Engine oil C 081.05 Fuel distribution housing: Hex screws for cover on housing Union (M 8 x 1) Union (M 18 x 1.5) Union (M 16 x 1.5) Engine oil Engine oil Engine oil Engine oil C 084.05 Exhaust System Hex screws for exhaust manifold Ultra Therm MTU C 142.05 Starting System Hex nuts for starter on flywheel housing Engine oil C 172.05 Lube Oil System Engine oil C 181.05 Hex screws for oil suction line on oil pump Engine oil C 181.05 Hex screws for cover on oil pump housing Engine oil C 181.05 Non-return valve in crankcase Engine oil C 181.05 Nuts for oil cooling element and stud on cover of oil heat ex- changer Engine oil C 183.05 Hex screws for cover on oil cooler housing Engine oil C 183.05 Screws for oil spray nozzle Engine oil C 184.10 Cooling System Nut for impeller (coolant pump) – Interference fit of impeller – Special lubricating paste DDC 7Y2 C 202.05 Power Supply, Engine Side Hex screw for generator on bracket Engine oil C 213.05 Screw for stress bolt on bracket Engine oil C 213.05 Screw for link on generator Engine oil C 213.05 Nut for belt pulley on generator Engine oil C 213.05 Cooling Air System Hex screws for bracket of bearing unit on retainer Engine oil C 221.05 Nut for bearing on bracket Engine oil C 221.05 Hex screw for ball bearing in belt tensioner Engine oil C 221.05 Mounting Double-hex screws for cover on carrier, free end Engine oil C 231.05 Monitoring, Control and Regulation Devices Engine oil – Group 003 Page 4 Section A General Screws and Nuts 20084/0 E 97–07 This works standard applies to set screws subjected to little dynamic load as per MMN 384, DIN 912, EN 24014 (DIN 931–1), EN 24017 (DIN 933), EN 28765 (DIN 960), EN 28676 (DIN 961), DIN 6912 and to studs as per DIN 833, DIN 835, DIN 836, DIN 938, DIN 939 and associated nuts. It does not apply to heat-proof screws in the hot component area.
2. 10. 9 (bright surface or with phosphate coating). screws and nuts must be coated in engine oil prior to assembly. resulting from inaccurate readings and overtightening during assembly. When tightening mechanically, the permitted assembly tolerance is + 15% Thread Hand-tightened Machine-tightened
3. 8. 8
4. 10. 9
5. 8. 8
6. 10. 9 M 6 9 12 8 11 M 8 21 31 20 28 M 8 x 1 23 32 21 30 M 10 42 60 40 57 M 10 x 1.25 45 63 42 60 M 12 74 100 70 92 M 12 x 1.25 80 110 75 105 M 12 x 1.5 76 105 72 100 M 14 115 160 110 150 M 14 x 1.5 125 180 120 170 M 16 180 250 170 235 M 16 x 1.5 190 270 180 255 M 18 250 350 240 330 M 18 x 1.5 280 400 270 380 M 20 350 500 330 475 M 20 x 1.5 390 550 350 520 M 22 480 680 450 650 M 22 x 1.5 520 730 490 700 M 24 600 850 570 810 M 24 x 1.5 680 950 640 900 M 24 x 2 660 900 620 850 M 27 900 1250 850 1175 M 27 x 2 960 1350 900 1275 M 30 1200 1700 1100 1600 M 30 x 2 1350 1900 1250 1800 Group 004 Page 1 Settings Section A General 20084/0 E 97–07 A004 Settings Firing order A1 – B4 – A4 – A2 – B3 – A3 –B2 – B1 Direction of rotation as viewed from driving end Crankshaft counterclockwise Camshaft clockwise Fuel delivery pump counterclockwise Oil pump clockwise Engine coolant pump counterclockwise Valve clearance, engine cold (20 °C) Inlet
7. 0. 40 mm
8. 0. 60 mm
9. 12. 4° before TDC . . . . . . . . . . . . . 2 Inlet valve closes
10. 18. 4° after BDC . . . . . . . . . . . . . . 3 Exhaust valve opens
11. 55. 6° before BDC

Source: manual:8V2000 Maintenance Manual M020084_00E.pdf. Figures and steps are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.