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4 B ratings-Automotive Applications
Engine Model
Rating power
Fuel pump
Peak torque
EQB210-20
P7100 /PW2000/VE
EQB190-20
VE
EQB180-20
P7100/PW2000/VE
EQB160-20
VE/PW2000
7 Cylinder block The cylinder block has an integral Oil cooler housing
Water pump housing
Oil pump housing
Coolant intake port
Internal water bypass
8 Main bearing
The thrust bearing is located in the number 4 main bearing journal for four cyli
nder engines, in the number 6 main bearing journal for six cylinder engines.
Oversize service main bearings are available for use with crankshafts that have
been machined undersize.
The main bearing caps are numbered to ensure that they are installed in the corr
ect saddle position. The main caps should be installed with the numbers toward t
he oil cooler side of the engine.
20 Vibration Damper
The vibration damper controls the twisting or torsional vibration of the cranksh
aft.
A vibration damper is engineered for use on a specific engine model.
It is not economical to repair a vibration damper in the field. Install a new or
rebuilt vibration damper if the inspection indicates that a damper is defective
.
The viscous vibration damper has a limited service life. The damper must be repl
aced if worn or damaged.
Viscous damper (A) for engines rated at speeds above 2500 rpm.
Rubber element damper (B) for engines rated at speeds below 2500 rpm.
23 Cylinder Head
The cylinder head is a 2 valve per cylinder design. one intake and one exhaust v
alve.
The cylinder head also includes an integral intake manifold, and integral thermo
stat housing.
The cylinder head has integrally cast valve guides, Valve seats.
24 Valves
The intake and exhaust valves look very similar but are machined at different se
at angles.
intake valve :30
exhaust valve:45
The easiest way to distinguish the intake from the exhaust valves is to look for
the dimple on the exhaust valve face.
25 Valve Seat The cylinder head has integrally cast valve seat.
The valve seats are hardened.
Can be repaired with valve seat inserts.
the size of Intake valve seat bore the size of exhaust valve seat bore
28 Overhead Set
Engine coolant temperature must be less than 60C [140F].
Four-Cylinder Engine Adjustment
Make sure the engine is at top dead center (TDC) for cylinder number 1.
Set number#1?#2?#3?#6 valves
rotate the crankshaft 360 degrees.
Set number#4?#5?#7?#8
Six-Cylinder Engine Adjustment
Set number#1?#2?#3?#6?#7?#10 valves
Set number#4?#5?#8?#9?#11?#12 valves
32 specifications Automotive
Distributor-Type Fuel Injection Pumps B3.9 and B5.9 Engines Maximum In
let Restriction to the Fuel Transfer Pump Must Not Exceed mm Hg [4 in Hg]
Maximum Allowable Return Line Restriction mm Hg [20.4 in Hg] Maxim
um Allowable Pressure Drop across Fuel Filter kPa [5 psi] Maximum Inle
t Pressure to the Injection Pump Must Not Exceed kPa [10 psi]
In-Line-Type Fuel Injection Pumps B3.9 and B5.9 Engine Maximum Inlet R
estriction to the Fuel Transfer Pump Must Not Exceed mm Hg [4 in Hg] F
uel Transfer Pump Minimum Output Pressure kPa [25 psi] at Rated rpm Fu
el Filter Restriction (maximum pressure drop across filters) kPa [5 psi]
Fuel Pressure Gallery Pressure kPa [20 psi] at Rated rpm Fuel Retur
n Maximum Restriction mm Hg [20.4 in Hg]
33 Specifications continued
Industrial Applications
For performance and fuel rate values, refer to the Engine Data Sheet or the fuel
injection pump for the particular model involved.
Distributor-Type and In-Line-Type Fuel Injection Pumps Engine Idle Spe
ed to 1000 rpm Maximum Fuel Inlet Restriction to Lift Pump kPa [4 in H
g] Maximum Allowable Return Line Restriction kPa [20 in Hg]
Fuel Pressure Range at Fuel Filter Outlet (engine cranking) to 28 kPa [3 to 4 ps
i] Fuel Pressure Range at Fuel Filter Inlet (engine running at idle) t
o 48 kPa [5 to 7 psi] Maximum Pressure Drop across Fuel Filter kPa [5
psi] Fuel Drain Line Maximum Restriction kPa [10 psi] Fuel T
ransfer Pump Minimum Output Pressure (low flow) kPa [5.5 psi] Fuel Tra
nsfer Pump Minimum Output Pressure (high flow) kPa [25 psi] Minimum Fu
el Injection Pump Gallery Pressure (low flow fuel transfer pump) kPa [12 psi]
Minimum Fuel Injection Pump Gallery Pressure (high flow fuel transfer pu
mp) kPa [20 psi] Fuel Inlet Maximum Temperature C [158F]
Engine Minimum Cranking Speed rpm
38 vent
Controlled venting is provided at the injection pump through the fuel drain mani
fold. Small amounts of air introduced by changing the filters or injection pump
supply line will be vented automatically if the fuel filter is changed in accord
ance with the instructions.
manual bleeding will be required if one of the following conditions exists:
The fuel filter is not filled prior to installation
The fuel injection pump is replaced
The high-pressure fuel line connections are loosened, or the lines are replaced
It is an initial engine start-up or start-up after an extended period of no engi
ne operation.
64 Flow diagram
65 Flow diagram
66 Flow diagram
67 Fill oil hole There are three locations available:
the top of the rocker lever cover.
a low position on the front gear cover
the left side of the block.
70 specifications
Lubricating Oil Pressure at Idle (minimum allowable) . 69 kPa [10 psi]
Lubricating Oil Pressure at Rated (minimum allowable) kPa [30 psi]
Regulating Valve Opening Pressure kPa [65 psi]
Lubricating Oil Capacity Standard Pan Only
B liters [10 qt] B liters [15 qt] L
ubricating Oil Capacity Total System - Liters [U.S. qt]
B liters [11.6 qt] B liters [17.3 qt]
Lubricating Oil Capacity Low to High B liter
[1 qt] B liters [2 qt]
71 Oil flow The suction tube delivers oil to the lubricating oil pump.
The pump then delivers the lubricating oil through an internal drilling to the o
il cooler cover and the pressure regulator. When the oil pressure exceeds the pr
essure regulator valve opening pressure , the valve opens, allowing some oil to
drain back to the oil sump
Oil also is directed to a cast-in passage in the oil cooler cover leading to the
oil cooler element.
From the outlet of the cooler, the oil continues through another cast passage in
the oil cooler cover to the oil filter, The oil flows up the center of the filt
er and into the filter head.
72 Oil flow
In the event of a plugged filter, the cooler cover incorporates a bypass valve t
o maintain oil flow. If the pressure drop across the oil filter exceeds specific
ation, the bypass valve opens, allowing unfiltered oil to lubricate the engine.
Once the oil is cooled and filtered, oil flow is divided, with a portion of the
oil flowing to the turbocharger and the rest passing through the cooler cover do
wn a cast passage to a cross drilling in the block.
One cross drilling between cylinder number one and cylinder number two carries t
he oil across the block to the main oil rifle, carries oil to the overhead ( lub
ricates the overhead and main bearings( lubricates the bearings)
73 Oil flow
The transfer drillings connected to the main oil rifle supplies oil to a groove
in the upper main bearing shells. Oil is then supplied to the cam bores through
short radial drillings.( lubricates camshaft main journals)
From the main bearings, oil enters the crankshaft and lubricates the connecting
rod bearings through internal cross drillings.
Oil from the main bearings is directed to saddle-jet piston cooling nozzles and
then sprayed onto the pistons.
74 Oil flow
The piston pins are splash lubricated by the piston cooling nozzle spray Oil
To the overhead is carried to the cylinder head deck by individual vertical dril
lings - one per cylinder - intersecting the main oil rifle. The oil then continu
es to flow vertically through drillings in the cylinder head.
From the drillings in the cylinder head, oil flows through a groove in the botto
m of the pedestal plate. The oil then flows around the rocker lever mounting cap
screws to the rocker shafts.
Oil flows through angle drillings in the capscrew bore in the shaft. At each end
of the shaft, a drilling allows oil to flow from the inside
Diameter of the shaft to the rocker lever bore.
75 Oil flow
A lubrication groove in each end of the shaft directs oil to two drillings provi
ding a path for oil flow; one drilling directs oil flow to the foot pad that con
tacts the crosshead. Oil from this drilling then travels down the crosshead and
lubricates the valve stems. The second drilling in the rocker lever directs oil
to the adjusting screw. Oil flow around the adjusting screw lubricates the push
rod sockets.
For a front gear train equipped engine, lubrication is received from oil splash
and oil carryover. The oil pump idler gear is pressure-lubricated. From here the
oil drains back to the pan for recirculation.
79 Water pump
Coolant is circulated by the integrally- mounted water pump.
The pump is belt driven
The pump installs in the integral volute in the engine block
80 Thermostat
The integral thermostat housing, located in the cylinder head
provides a location for mounting the vented thermostat vertically in the cooling
system
Depending on engine application and date of manufacturer the thermostat can be f
ound in either a vertical or horizontal position.
83 Coolant flow
The coolant then exits the oil cooler cavity and circulates into the block to co
ol the cylinders.
The head gasket is orificed to control coolant flow into the cylinder head.
When the engine is below operating temperature, the thermostat is closed, allowi
ng the coolant to pass the radiator and flow back to the water pump inlet throug
h internal drillings in the cylinder head and block.
84 Coolant flow
When operating temperature is reached, the thermostat opens, blocking the bypass
passage to the water pump and opening the outlet to the radiator.
The engine must never by operated without a thermostat. Without a thermostat, th
e coolant recirculates, by-passing the radiator, causing the engine to overheat.
The coolant flow to the air compressor. After cooling the air compressor the coo
lant returns to the engine by way of connection at the rear of the cylinder head
.
85 SPECIFICATIONS
Coolant Capacity (engine only) B liters [11.1 qt]
Standard Modulating Thermostat Range Start to Open C [181F] Fu
lly Open C [203F]
Pressure Cap 104C [220F] Systems KPa [15 psi] 99C [210F] Systems
kPa [7 psi]
Minimum Recommended Operating Temperature C [160F] Minimum Recommended Pressure Ca
p kPa [7 psi] Maximum Recommended Pressure Cap kPa [15 psi]
86 Intake system
A filter minder, installed at the air cleaner, indicates the condition of the fi
lter and whether the restriction is excessive.
The intake manifold is integrated into the cylinder head
A grid heater is required for most applications. It is installed on the intake m
anifold cover and is designed to heat intake air in cold ambient conditions.
The charge air cooler mounted in front of the radiator reduces the temperature o
f the intake air.
90 Exhaust flow
After combustion, the exhaust gases flow from the combustion chambers to the opp
osite side of the cylinder head , the exhaust gas pass through the exhaust manif
old , enter the turbo of the turbocharger, the exhaust energy is used by the tur
bocharger compressor wheel to pump intake air into the engine, from the outlet o
f the turbo, the exhaust gas flow to the silencer
91 specifications
Maximum Allowable Intake Restriction Clean Air Filter Element mm H2O [
10 in H2O] Dirty Air Filter Element mm H2O [25 in H2O
Maximum Allowable Exhaust Restriction at Rated Speed and Loaded 1991 t
o 1993 EPA Certified mm Hg [4.5 in Hg] 1994 to 1998 EPA Certified (wit
h oxidation catalyst) mm Hg
92 troubleshooting
Nearly all engine symptoms concerning the air system are related to Low Power co
mplaints, Black Smoke, or both.
One possible source of a low power or black smoke symptom is a restriction in th
e air cleaner.
If a problem is suspected with the air system, a boost pressure check verifies t
he problem since most air system problems reduce the boost pressure.
A leak test measures how well the Charge Air Cooler retains pressure in the cool
er core.
check the pressure drop across the Charge Air Cooler
93 troubleshooting
Confirm the efficiency of the Charge Air Cooler by measuring the difference betw
een ambient air temperature and intake air temperature in the intake manifold.
If the boost pressure is out of range, whether too high or too low, the waste ga
te may be malfunctioning and should be checked for proper operation
Back pressure in the exhaust system can also cause air