1 9 9260 Instr Obs 4CTi90 BE Euro 3 Ang

DIESEL ENGINE

4CTi90-1BE6 ... EURO 3 (66 kW)

4CTi90-1BE ... EURO 3 (75 kW)

SERVICE MANUAL

A/4CTi90-1BE/I/c - EURO 3 1.9.9260 Issue date: February 2002

Revision date: December 2005

ANDORIA-Mot Sp. z o.o. ul. Krakowska 140, 34-120 ANDRYCHÓW tel.: +48 33 876 27 24 fax: +48 33 875 35 60 http://www.andoria-mot.com.pl, e-mail: [email protected]

Service Manual 4CTi90-1BE - Euro 3

Contents

Page Precautions during operation and servicing 1

1. Introduction and technical data 5 1.1. Technical data 6 1.2. Engine structure – description of major elements 8 1.3. Wiring diagram 9 1.4. Tightening torque of the main screw connections 10 1.5. Operating materials (fuel, oil) 11

2. Engine operation 12

2.1. Preparation for first start-up of the engine in the vehicle 12 2.2. Start-up of the engine in the vehicle 12 2.3. Running-in 13 2.4. Stopping the engine 13 3. Engine servicing 14

3.1. Table of routine maintenance operations 14 3.2. Basic servicing operations 15 3.3. Description of routine maintenance operations 15 4. Troubleshooting 22

5. Storage and preservation after taking the engine

out of service for longer period 24 5.1. Storage of a new engine 24 5.2. Engine preservation for longer standstill 24

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Service manual - 4CTi90-1BE - Euro 3

Precautions during operation and servicing

Daily checks

Let the daily checking of engine and engine compartment before operation (start up) and after operation (stopping) become your habit. It will help you to detect fuel, coolant and oil leaks quickly and to locate any abnormal things, which just happened or are going to happen. Refueling

There is a danger of fire or explosion during refueling. Smoking is prohibited, and engine must be shut down. Never overfill the fuel tank. Retighten fuel tank filler tank well. Use only fuels recommended in this manual. Improper fuel grade may cause operation prob-lems or cause engine stopping. On diesel engines, poor fuel quality may cause injection pump control rod sizing and engine overrunning, what in turn may cause engine damage and personal injury. Carbon monoxide poisoning Run the engine only in well ventilated areas. When the engine works in closed space, make sure there is sufficient ventilation to remove exhaust gases and crankcase vapors out of the work area. Operation

The engine can not operate in areas where explosive materials or gases are pre-sent. Not all the electrical and mechanical engine components are non-sparking. Approaching the running engine is dangerous. Loose clothing, hair, fingers or dropped tools may catch rotating engine components and cause serious personal injury. After installing the engine, all rotating and hot engine components must be pro-tected.

Servicing and operation

Stop the engine

Before opening or removing engine covers, stop the engine. If otherwise not specified, all operation and servicing operations must be performed with engine immobilized. To avoid accidental engine start up, before beginning any works on engine re-move ignition key. At the engine control location, place warning sign that works are performed on the engine. Approaching or performing works on running engine is dangerous. Loose cloth-ing, hair, fingers or dropped tools may catch rotating engine components and cause serious personal injury.

Lifting the engine

When lifting the engine use lifting eyes fitted on it. Always make sure that lift-ing equipment is in good condition and of sufficient lifting capacity (engine weight plus all accessories). Never perform any works on engine hanging on lift.

Before starting the engine

Before starting the engine refit all the covers removed during servicing opera-tions. Check if no tools or other objects are left on the engine. Never start up turbocharged engine without air filter installed. Rotating com-pressor in turbocharger may cause serious personal injuries. Also foreign objects may be sucked in and cause mechanical engine damage.

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Fire and explosion

Fuels and lubrication oils

All the fuels, most of lubrication oils and many chemicals are flammable. Read instructions on packaging and follow them. When working on fuel system, make sure the engine is cold. Fuel spilled on hot surface or electrical components may cause fire. Do not smoke during refueling or adding oil, near fuel station or engine house.

Batteries

Batteries contain and educe hydroxide gas, especially during charging. This gas is inflammable and very flammable. Do not smoke, do not use open flame and do not allow any sparking near the batteries or in battery compartment, under no circumstances. Incorrect cable connection to battery clamps or jumper cables to external batter-ies may cause sparking, what in turn may cause explosion. Hot surfaces and fluids

There is always a threat of burning when working on hot engine. Be careful with hot surfaces, e.g. exhaust pipes, turbocharger, oil pan, charge air pipes, hot cool-ant and hot oil in oil pipes and hoses. Chemicals

Most of chemicals, as antifreeze, anticorrosion agents, preservation oil, degreas-ing agents, etc. are hazardous for health. Read recommendations on packaging and follow them. Some chemicals, such as preservation oils, are flammable and dangerous when inhaled. Ensure good ventilation and use protective masks when applying by spraying. Read instructions on packaging and follow them.

Lubrication system

Hot oil may cause burning. Avoid skin contact with hot oils. Before commenc-ing work on lubrication system, make sure it is not under pressure. Never start up or run the engine with oil filler cap open because oil may be spread out. Cooling system

Avoid opening radiator cap when engine is hot. Steam or hot coolant may be spread out causing burning. If the works must be performed on engine at operating temperature and with radiator cap open, or hose disconnected, then unscrew radiator cap carefully and slowly to release the pressure before removing the cap. Note that still coolant may be hot and cause burning. Fuel injection system Always wear protective gloves when seeking leaks. Fluids ejected under pres-sure may puncture body tissues and cause serious personal injuries. There is a threat of blood poisoning. Electrical system

Power supply breaking

Always before commencing works on electrical system, stop the engine and cut off power supply.

Batteries

Batteries contain extremely corrosive electrolyte. Protect skin and clothing when charging or servicing batteries. Always wear protective goggles and gloves. In case of contact of uncover skin with electrolyte immediately wash the skin with plenty of water with soap. If electrolyte comes into eye, immediately wash eyes with plenty of water and right away get medical aid.

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Service manual - 4CT90-1BE - EURO 3

4CTi90-1BE6 engine - EURO 3 of 66 kW and 4CTi90-1BE engine - EURO 3 of 75 kW

(meet R49.03 requirements without EGR system)

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4CTi90-1BE6 engine - EURO 3 of 66 kW and 4CTi90-1BE engine - EURO 3 of 75 kW

(meet R 83.05 ECE requirements with EGR system)

5


1. INTRODUCTION AND TECHNICAL DATA

4CTi90-1BE6 ... (66 kW) and 4CTi90-1BE ... (75

kW) engines (with Bosch injection equipment)

meet the requirements of Euro 3 standard

(R49.03 – without EGR and R83.05 - with EGR

system) in a vehicle with charged air cooler in-

stalled.

The difference of performance parameters be-

tween 4CTi90-1BE6 ... (66 kW) and 4CTi90-1BE

... (75 kW) engines results only from the settings

of injection pump.

Design of these engines has been based on the experience

gained during long-term production and operation of 4C90 and

4CT90-1 engines.

The engines are mainly designed for delivery vehi-

cles of total weight up to 3.5 tons, off-road vehicles and

big passenger cars.

They can be used for mobile machinery, generating sets,

small boats and hydraulic power systems.

It is necessary to obey the engine service manual. In a case

of operating non-consistently with this manual the cus-

tomer will lose his rights for the warranty.

Note: Andoria-Mot reserves the rights to introduce design and proc-

ess modification without previous notification of Customers.

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1.1. Technical data

Engine type 4CTi90-1BE6 (66 kW) 4CTi90-1BE (75 kW)

Engine kind diesel, four stroke, turbocharged with charged air cooler (intercooler)

Fuel injection indirect into swirl chamber Number and arrangement of cylinders 4, vertical Cylinder diameter 90 mm Piston stroke 95 mm Displacement 2417 cm3 Compression ratio 20.6 Rated power after complete run-in (operational)

66 kW according to ISO 1585 75 kW according to ISO 1585

Rated speed

4100 RPM

Peak torque after complete run-in (operational)

205 Nm according to ISO 1585 230 Nm according to ISO 1585

Peak torque speed

2000 - 2500 RPM

Minimum idle speed 800 RPM Specific fuel consumption after complete run-in (operational)

270 g/kWh according to ISO 1585 255 g/kWh according to ISO 1585

Crankshaft rotation counterclockwise (seen from the flywheel side) Power take-off from the flywheel through the clutch Timing gear system overhead valves with overhead camshaft Engine starting electrical, assisted with glow plugs Engine oil consumption after complete run-in (operational)

max. 0.033 kg/h

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Engine type 4CTi90-1BE6 (66 kW) 4CTi90-1BE (75 kW)

Engine oil pressure with warm engine (within 1500 - 4100 RPM)

0.25 – 0.50 MPa

Engine oil pressure with warm engine at minimum idle speed

min. 0.1 MPa

Maximum permissible oil temperature in the oil gallery

120°C (momentarily 130°C)

Oil capacity for oil change ("max" mark) about 7 dm3 Coolant capacity (without radiator)

6.8 dm3

Maximum permissible coolant temperature in pressurized circuit (1.2 bar)

105°C

Recommended optimum coolant temperature

80° - 90°C

Intake and exhaust valve clearance

0.2 mm (with cold engine)

Injection order 1-3-4-2 Injection pressure 15 MPa Minimum injection pressure in-service 14 MPa Beginning of injection (static) 0.8 ±0,05 mm BTDC Dry engine weight (approximate) 230 kg Permissible engine inclination: - lengthwise - crosswise

30° 20°

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1.2 Engine structure - description of major elements

Cylinder block linerless, cast iron with five main bearings, of which the fifth one (the one closest to the flywheel) is a thrust bear-ing; the crankcase is closed from the bottom with an aluminum oil pan.

Main and connecting

rod bearing shells

thin-wall, three-layer, replaceable

Cylinder head cast iron, inlet and exhaust ducts on one side, valve seats and guides are replaceable

Piston of controlled thermal expansion made of aluminum alloy die-casting with a cast iron "ALFIN" insert near the up-per compression ring

Crankshaft forged of alloy steel, toughened and nitrided Camshaft cast iron, working faces of the cams chilled in casting

process, driven by crankshaft via timing belt Valves driven by the camshaft cams via second-order rocker

arms made of cast iron Connecting rod forged of alloy steel, toughened Injection pump

(Bosch)

type VE4, distributor pump equipped with boost pressure compensator (LDA), lubricated with fuel

Injector (Bosch) with replaceable pintlenozzle Glow plug bar-type, two heating coils

Alternator Driven by the crankshaft via V-belt; 12V, 70A Starter motor

(Bosch) electrical, 12V; 2 kW

Turbocharger Radial with wastegate Vacuum pump for brake boost; sliding-vane pump driven by camshaft Oil pump internal gear pump, (gerotor); located on the crankshaft

front end Oil filter full-flow cartridge Oil cooler of Modine; located in-line under the oil filter Fuel filter

(Bosch ) cartridge with integrated water separator and manual priming pump

Fan

with viscosity clutch fixed to water pump hub

Power assisted steer-

ing pump (option)

for steering system assistance, driven by crankshaft via V-belt

EGR valve electronically controlled pneumatic valve a part of ex-haust gas recirculation system

Electric system

12V, "minus to ground"

1.3. Wiring diagram

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1. Solenoid valve 2. Electronic control unit 3. Coolant temperature sensor 4. Oil pressure sensor 5. Oil pressure control lamp 6. Fuse 10A 7. Battery charging control lamp 8. Ignition switch 9. Alternator 10. LDA solenoid valve 11. Starter motor 12. Fuse 70A 13. Glow plug controller 14. Glow plug control lamp 15. Glow plug control sensor 16. Battery 17. Glow plug 18. Injection pump, Bosch 19. Coolant temperature gauge 20. Coolant temperature sensor

Notes:

1. Alternator terminal “W’ is used to

connect tachometer. 2. Alternators are with build-on voltage

regulator 3. Rating of battery charging control

lamp (item 7) shall be 5W Items 1, 2, 3, 10 exist only on engines

with EGR system to meet the require-

ments of R83.05

Items: 2, 5, 6, 7, 8, 12, 14, 16 – are not a part of delivery

Engine identification

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Engine type (e.g.. 4CTi90-1BE) and version (e.g. A0511) are imprinted in rear side of cylinder block over the flywheel housing in two lines (see figure below)

Meaning of engine designation:: 4CTi90-1 – 4-cylider, 4-stroke, turbocharged engine with interccooler, bore diameter 90 mm B –BOSCH injection pump; or M –MOTORPAL injection pump

E – meets the requirements of EURO 6 - 66 kW (or without number following letter E – 75 kW /only engines with inter-cooler)/ A – automotive application G – gen-set application 0511 – version (0511 – destined for Lublin 3 vehicle)

Homologation symbols are imprinted in cylinder block behind oil filter (see example above) Engine number –it is imprinted at the side of cylinder block at its rear part be-hind injection pump, and it consists of two elements divided with slash mark (see figure at left), e.g. 103583 =sequence number, 04 = 2004 manufacture year

Note: Manufacture year not imprinted on engine versions A0511 and A0513.

1.4. Tightening torque of the main screw connections

Torque

Injector fixing nuts: 15 - 20 Nm Nuts fixing injection pipes to:

- injection pump

- injectors

25 - 30 Nm

20 - 25 Nm

Glow plugs: 20 - 25 Nm

E20 241,17

02 808

03 827

49B

103583/04

4CTi90-1BE

A0511

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1.5. Operating materials (fuel, oil) Diesel oil (fuel) Diesel fuels consistent with PN-EN 590 shall be used for the engines.

Three periods (summer, transition and winter) and fuel grades required for these periods are defined (according to PN-EN 590) properly to climate conditions. In Poland (temperate climate), three grades of fuels are to be used (according to PN-EN 590): „B” - for summer season „D” - for transition season „F” - for winter season Polski Koncern Naftowy has named its diesel fuels „Ekodiesel Plus” Range of use of diesel fuel: Summer season: (May 1 – September 15) - „Ekodiesel Plus B” (of cold filter clogging temperature: 00C) Transition season: (March 16 – April 30 and September 16 – November 15) - „Ekodiesel Plus D” (of cold filter clogging temperature: -100C) Winter season: (November 16 – March 15) - „Ekodiesel Plus F” (of cold filter clogging temperature: -200C) For arctic climate or other special applications, use diesel fuel grades: 0; 1; 2; 3; 4 (consistent with PN-EN 590) of cold filter clogging temperature: from -200 to -440C. Also the following may be used:

- municipal diesel fuel „ONM Standard” (according to ZN-94/MPiH/NF-213), with sulfur content up to 0.02% and cold filter clogging temperature: -300C

Engine oil (lubricating oil)

Use engine oil of:

a) quality grade according to API: CD or better

b) viscosity grade according to SAE, appropriate to operation condi-

tions, but not worse than:

- for temperate climate: 10W/40

- for tropical climate : 20W/50

Ambient temperature [o

C]

-30 -20 -10 0 10 20 30 40 50 60

0W/60 0W/50 0W/40

5W/60 5W/50 5W/40 10W/60 10W/50 10W/40

0W/60 0W/50

5W/60 5W/50 10W/60 10W/50 15W/60 15W/50 20W/60 20W/50

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2. ENGINE OPERATION 2.1. Preparation for first start-up of the

engine in the vehicle

(after individual assembly or repair) Prior to first start-up of the engine in the ve-hicle: 2.1.1. Charge the battery and connect electric system according to wiring diagram. 2.1.2. Fill up the fuel tank with diesel fuel. 2.1.3. Pour in proper amount of engine oil through oil filler in the camshaft housing. (Oil level should reach the upper mark on

dipstick). 2.1.4. Fill up the radiator and engine jacket with coolant to the level above “min” mark on surge tank installed in the vehicle or to the edge of overflow pipe located in the radiator filler, depending on the kind of cooling sys-tem. (The use of water is not recommended, but antifreeze).

2.1.5. Check leaktightness of inlet system. Leaking inlet system makes the dirt comes into the engine what leads to accelerated wearing of pistons, piston rings and cylinder bores and reduces engine power and increases exhaust smoke. Leaking inlet system may also be a cause of turbocharger failure. 2.2. Start-up of the engine in the vehicle

2.2.1. Cold engine start-up

Check if the gear lever is in neutral. Turn ignition switch key into glow plug heat-ing position and wait until glow plug control lamp goes off, and then within 6 seconds turn on starter motor – the entire cycle may be repeated. Hold the starter motor on for maximum 10 seconds. If the engine does not start within this period, repeat start-up operations after waiting at least 15 seconds. If the engine does not start after several consecutive attempts turn off the ignition switch and seek the cause.

Note: Bosch injection pump is equipped with

cold start device, which facilitate significantly

cold engine start. It also has a device, which

increases cold engine idle speed at low ambi-

ent temperature.

Note: Fuel system of the engine with Bosch injection pump is self-bleeding. In case of difficult engine start-up, check the operation of cut-off valve of the injection pump. Do not unscrew any bolt of the injec-

tion pump!

2.2.2. Warm engine start-up

When starting up warm engine, turn ignition switch key directly into engine start-up posi-tion.

CAUTION: After starting-up the engine

let it run at idle or maximum at 1500 RPM

within 10 seconds to allow engine oil to

reach turbocharger bearings. It is espe-

cially important at winter time and when

the engine was not operated for longer

time.

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2.2.3. Engine start-up at winter Start-up procedure is same as for cold engine start-up. However if the vehicle is parked at open air and ambient temperature drops below -15°°°°C, additionally obey the following: • strictly use winter diesel fuel „Ekodiesel

Plus F” • use engine oil of the following viscosity:

5W/40, 10W/30 or 10W/40

2.2.4. Emergency start-up of the engine by vehicle towing.

CAUTION: Because timing gear is driven

via timing belt, engine start-up by vehicle

towing should be avoided. It is related to

high resistance to motion (especially at low

ambient temperature) and high inertia of

systems driven via timing belt (timing gear,

injection pump).

With sudden clutch engaging the timing

belt is momentarily imposed with high

load, which may cause its teeth to be cut-

off.

If, however, engine start-up with starting

motor is impossible, smoothly engage the

clutch of towed vehicle (with transmission

on “II” or “III” gear) in order to avoid

timing belt overloading and damaging.

For emergency engine start-up tow the ve-

hicle with a speed of 15 - 20 km/h.

2.3. Engine run-in

NOTE: Within first 1000 km it is recom-

mended to not load the engine above 3/4 of

nominal loading.

Obeying the above recommendation extends the interval to first major overhaul. The above recommendation applies also to engine after repair, which involve piston and piston rings or crankshaft dismantling.

2.4. Stopping the engine

To stop the engine, move the gear lever into neutral position and turn ignition switch key into “STOP” position. Remove the key from ignition switch.

CAUTION: After severe and long drive

when coolant temperature indicator is

close to red zone, before stopping the en-

gine let it still run at idle for minimum 30

seconds.

CAUTION: Stop the engine immediately in

case of any disturbance to its operation or

occurrence of any noise indicating failure.

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3. ENGINE SERVICING

3.1. Table of routine maintenance operations Performing the routine maintenance operations listed below is necessary to ensure proper and long engine operation and achieving the required parameters. Meaning of the symbols in the table:

W: - replace S: - check, adjust, clean, fill-up, repair or replace if necessary

No. Engine mileage

Operations

Mileage in kilometers x 1000 (with tolerance ±±±± 500 km)

1,5 10 20 30 40 50 60 70 80 90 100

1. Engine oil W W W W W W W W W W W 2. Oil filter W W W W W W W W W W W 3. Lubrication system, leaktightness S S S S S S S S S S 4. V-belt, water pump and alternator drive S S S S S S S S S S 5. V-belt, power assisted steering pump and air conditioning

compressor drive (if applicable) According to VEHICLE service manual

6. Cooling system, leaktightness According to VEHICLE service manual 7. Coolant S S S 8. Intake system, leaktightness According to VEHICLE service manual 9. Air filter element ** According to VEHICLE service manual

10. Fuel system, leaktightness According to VEHICLE service manual 11. Fuel filter element** W W W W W 12. Valve clearance S S S 13. Injectors, nozzles S* S* 14. Electric system (alternator, starter motor, ) S S 15. Timing belt S S W 16. Glow plugs S W 17. Turbocharger S*

* only if there is a reason ** replacing frequency and method of servicing depend on operation conditions – in case of excessive dust contamination or low quality fuel – even double the frequency

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3.2 Basic servicing operations

DAILY servicing:

• Inspect visually for any leaks of lubrica-tion, cooling, fuel and intake systems.

WEEKLY (or before longer journey)

check the following:

• Engine oil level • Coolant level • Leaktightness of lubrication, cooling, fuel

and intake systems.

3.3. Description of routine maintenance

operations

3.3.1. Checking, filling-up and changing en-gine oil (figures)

When checking engine oil level, the vehicle should be parked on horizontal surface. Oil level should be checked with cold engine, or about 10 minutes after stopping the engine to let the oil to drip down to oil pan. Remove and clean the dipstick, re-insert it home and remove again. Engine level should be be-tween "MIN" and "MAX" marks. To fill-up the oil, remove oil filler cap and add clean oil, then check the level again and add oil again if necessary, until achieving proper level. Do not add too much of oil.

Remember to refit oil filler cap. When changing oil, it should be drained from warm engine when the vehicle is parked

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on horizontal surface. To facilitate oil drain-ing (via oil draining hole in oil pan) remove oil dipstick or oil filler cap from camshaft housing. After complete engine draining of the old oil, refit the oil draining plug (screw-in the plug with fingers to at least 3/4 of the thread length; it prevents incorrect screwing-in and damaging the thread). Wash the plug before refitting. Be careful when draining old oil while it

may be hot.

Always replace oil filter when changing oil.

3.3.2. Replacing oil filter (figures) Always replace oil filter together with

changing oil.

Unscrew old filter manually or by means of special wrench. Before refitting new filter apply engine oil to rubber seal in bottom side of the filter. Tight the filter manually with-

out wrench.

3.3.3. Checking coolant level This operation shall be done according to recommendations and in the manner de-scribed in the vehicle service manual. Coolant level should reach the mark on surge tank installed in the vehicle. 3.3.4. Replacing fuel cartridge filter

To replace fuel filter, unscrew old one and refit new one. Fuel filter is integrated with water separator. 3.3.5. Cleaning the water separator

To clean the water separator (between fuel filter replacements) unscrew draining plug in the bottom of fuel filter and drain fuel with water and contamination to empty container.

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3.3.6. Checking leaktightness and proper op-eration of water pump.

In case of lower cooling efficiency resulting in engine overheating during operation with normal load or in case of leaking, give the vehicle over to service station to find out the reason and possibly clean the radiator or re-pair the water pump. Also the thermostat should be checked. 3.3.7. Replacing injector Remove injectors from the engine, unscrew-ing before the leak off pipe, injection pipes and injector fixing yoke. Each time before refitting the injector removed or fitting new injector replace the steel washer under the nozzle with new one. When installing the steel washer, take care to install it in proper position (figure).

A – steel washer 3.3.8. Checking and adjusting valve clearance (figure)

Check and adjust valve clearance with cold engine using feeler gauge of 0.2-mm thick-

ness both for intake as well as exhaust

valves.

To check and adjust valve clearance: • remove valve cover and set first cylinder piston to TDC position (when both valves are closed) • check intake and exhaust valve clearance by inserting feeler gauge between rocker arm and cam • if the clearance is improper, loosen the lock-nut of valve clearance adjusting bolt and screwing the bolt in or out adjust proper clearance (use special wrenches provided with the engine) • holding the bolt in position tight-up the lock-nut and recheck valve clearance with feeler gauge. If valve clearance is changed, repeat the

above operations.

• in the same manner adjust clearance of the other valve of first cylinder. • then turning crankshaft by 180° adjust clearance of both valves of third, fourth and

second cylinder, each time turning crankshaft by another 180° Check the condition of valve cover gasket and replace if defective. It is recommended to replace valve cover gasket each time the cover is removed.

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3.3.9. Checking, adjusting and replacing drive belts (figures) Water pump and alternator drive Poly-V-

belt (Fig. 1)

Fig. 3 Alternator and water pump are driven with Poly-V belt. The belt is tensioned properly if under force P = 60 N (Rys.5), deflects about 7 mm.

If defective or excessive stretching (impossi-ble to adjust its tension any more) replace the belt with new one. To replace the belt, slacken nut (1) fixing the upper alternator support to tensioner (2) and bolt and nut (3) fixing the bottom alternator support to alternator bracket. Unscrewing the

belt tension adjusting bolt (4) loosen and re-move the belt. Install new belt and screwing in the adjusting bolt (4) tension the belt prop-erly. Then tighten the previously slackened nuts and bolt.

Power assisted steering pump V-belt (Fig.

2) (if applicable)

Fig. 2

Power assisted steering pump V-belt is ten-sioned properly if under force of finger (about 10 kG) applied in the middle between pulley axes it deflects by about 10 mm.

To replace V-belt loosen bolt and nut fixing the pump with front and rear hanger to bracket and bolt and nut fixing front hanger to bracket. Pivoting front hanger with pump down towards the engine loosen and remove old V-belt. Install new V-belt and pulling out the pump properly tension the V-belt. Tighten up previously loosened bolts and nuts.

3.3.10. Replacing timing belt CAUTION: This operation can be done only by experienced mechanic, and the best solu-tion is to order performing this operation by the service station. Timing belt is tensioned properly if under force of 11.8 – 12.7 N (1.2 – 1.3 kG) applied in the middle between camshaft sprocket and timing advancer sprocket it deflects by 5 mm.

4

2 P

1

3

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3.3.11. Inspection of alternator, starter motor and turbocharger

Order inspection and repair of these devices by specialized workshops. 3.3.12. Checking and adjusting the injection

Measuring, adjusting and replacing injec-

tion pump shall be done only by specialized

workshops!

To check and properly adjust the beginning of injection: • set first cylinder piston at TDC • remove (for convenience) two injection

pipes • remove the bolt located between injection

pipe adapters in the injection pump • screw in this hole dial gauge with special

adapter enabling this operation. (Preset the dial gauge to value higher than 0.8 ±0.05 mm). Measurement with dial gauge on a

stand or fixed the other way than screwing

into injection pump will not ensure proper

readings (adjustment).

• rotate flywheel by certain angle counter-clockwise (until dial gauge pointer stops moving)

• set the dial gauge to zero • turn flywheel clockwise • after the marks of TDC match, check read-

ing of the dial gauge • if reading of the dial gauge is 0.8 ±0.05

mm – injection pump is adjusted properly • if reading of the dial gauge is different,

loosen 3 bolts fixing injection pump drive gear to hub (3 bolts M8 – accessible only after removing the timing belt cover)

• rotate the hub with loosen M8 bolts until reading of the dial gauge is 0.8 ±0.05 mm

• moving (rotating) the hub counterclock-wise increases the dial gauge reading

• moving (rotating) the hub clockwise de-creases the dial gauge reading

• Another method: loosen 3 nuts fixing in-

jection pump flange to bracket and rotate injection pump towards the engine or the opposite side until achieving the dial gauge reading of 0.8 ±0.05 mm; retighten the nuts.

• retighten the bolts fixing the gear to hub

• repeat the measurement (to check proper adjustment)

Note: When reinstalling injection pipe do

not change their position.

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3.3.14. Workshop method to check proper operation EGR System. Procedure to check EGR system of 4CT90-1BE engines with Bosch injection equipment. 1. connect vacuum meter (16) between EGR

valve (6) and electro-pneumatic valve (5), connect manometer (17) between LDA boost pressure compensator (14) and sole-noid valve (13) controlling LDA.

2. warm up the engine to normal operating temperature (about 75oC)

3. at idle speed - vacuum pressure at EGR /vacuum me-

ter (16)/ should be 0.50 bar - pressure at LDA /manometer (17)/

should be 0 4. depress accelerator pedal home until the

engine reaches maximum speed - vacuum pressure at EGR valve

/vacuum meter (16)/ should drop to 0 - pressure at LDA /manometer (17)/

should go up to about 0.5 bar 5. if the system behave differently than de-

scribed in points 3 and 4, check coolant temperature sensor, electro-pneumatic valve, solenoid valve controlling LDA and potentiometer on injection pump control lever.

Kind of failure and its symptom : • no signal from coolant temperature sensor

(e.g. disconnected connector) - EGR does not operate, the vacuum

pressure at EGR valve is zero within entire engine speed range

- LDA boost pressure compensator does not operate, pressure at LDA is zero within entire engine speed range

• no signal from the potentiometer

- EGR does not operate, the vacuum pressure at EGR valve is zero within entire engine speed range

- LDA boost pressure compensator op-erates properly

Each time the error occurs in coolant tem-perature sensor circuit the system switches to emergency mode – EGR and LDA do not operate. To reset the system to normal opera-tion it is necessary to turn off the ignition switch. After restarting the engine, the system operates properly and the errors are canceled.

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3.3.14 Connection diagram of EGR system on engine with Bosch injection equipment

1. Vacuum pump 2. T-connector 3. Servo 4. Coolant temperature sensor 5. Electro-pneumatic valve 6. EGR valve 7. Check valve 8. Vacuum tank 9. Injection pump, BOSCH 10. Speed signal (impulses picked up

from alternator) 11. Electronic control unit 12. Intake manifold 13. Solenoid valve controlling LDA 14. LDA - boost pressure compensator 15. Potentiometer 16. Vacuum meter 17. Manometer

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15 16 17

13

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Instrukcja obsługi silnika 4CTi90-1BE - Euro 3

4. TROUBLESHOOTING

Causes of failure Fault correction

A. Low compression pressure

1. Insufficient valve clearance Adjust valve clearance with cold en-gine to 0.2 mm

2. Leaks between cylinder head and cylinder block 3. Leaking valves 4. Broken valve springs 5. Intake or exhaust valve jammed 6. Excessive leaks at pistons

Call Authorized Service Station (ASS)

B. Improper operation of supply system

1. No fuel in fuel tank or air trapped in fuel supply system

Fill up fuel tank and bleed the system

2. Injection pump shut down Turn on injection pump 3. Nozzle jammed or worn out Call ASS 4. Fuel filter, supply pump or fuel pipes dirty

Clean out fuel filter, supply pump and fuel pipes.

5. Injection pump failure Call ASS 6. Leaking fuel pipes Retighten or replace fuel pipes

C. Improper operation of electric system

1. Loosen wire connectors Clean out and tighten wire connectors 2. Broken wire Replace wire with new one 3. Battery discharged Charge battery 4. Starter motor failure Repair or replace starter motor 5. Ignition switch failure Replace ignition switch 6. Glow plug failure Replace glow plug

7. Improper operation of glow plugs or glow plug controller

Call ASS

D. Engine smokes with black smoke

1. Nozzle dirty or sprays incorrectly Call ASS 2. Air filter dirty Clean or replace air filter element 3. Beginning of injection set incor-rectly (too late)

Check and adjust beginning of injec-tion

4. Valve clearance incorrect Adjust valve clearance 5. Maximum fuel dosage too big 6. Intake and exhaust valves leaking 7. Leaks between cylinder head and block 8. Exhaust or intake valve jammed

Call ASS

E. Engine smokes with blue smoke

1. Too much of engine oil Drain some of engine oil 2. Piston rings baked 3. Piston rings broken or worn out

Call ASS

4. Too long engine operation at idle speed

Load the engine (avoid too long en-gine operation at idle)

5. Piston ring groves worn out Call ASS

F. Too hot engine operation

1. No coolant or too low level of coolant

Stop the engine and after cooling down fill up cooling system.

2. Too low engine oil level Fill up engine oil level to “max” mark on dipstick

3. Nozzle defective Replace nozzle 4. Water pump V-belt insufficiently tensioned

Tension properly V-belt

5. Viscosity clutch failure Replace viscosity clutch 6. Too late injection Adjust beginning of injection 7. Maximum fuel dosage too big Call ASS 8. Radiator pipes dirty Clean radiator

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9. Cooling system with boiler scale Remove boiler scale 10. Oil in cooling system 11. Thermostat defective

Call ASS

12. Engine overloaded Release engine load 15. Water pump failure Call ASS

G. Too low engine oil pressure

1. Too low engine oil level Fill up engine oil to “max” mark on dipstick

2. Old engine oil (not changed for long time)

Change oil

4. Oil filter dirty 5.

Replace oil filter

4. Oil pump strainer dirty 5. Leaking lubrication system

Call ASS

6. Fuel or water in lubrication system Find and eliminate the cause of water or fuel leaks to lubrication system. Change oil.

7. Oil pressure manometer failure Replace manometer 8. Crankshaft bearings worn out Call ASS

H. Engine stops suddenly

1. No fuel supply Check fuel level and condition of fuel pipes

2. Fuel filter dirty Replace fuel filter 3. Air filter dirty Replace air filter element 4. Injection pump failure 5. Piston seizure 6. Valves jammed

Call ASS

7. Timing belt broken or incorrectly tensioned

Call ASS

I. Knocking noise during engine operation

1. Rocker arms broken 2. Connecting rod bolts loose

Call ASS

3. Incorrect beginning of injection 4. Valve timing shifted 5. Valves jammed

6. Injectors in poor condition Replace injectors

J. Low turbocharger efficiency

1. Air filter dirty Replace air filter element 2. Leaks between turbocharger and intake manifold 3. Turbine outlet duct dirty

Call ASS

K. Turbocharger heats excessively

1. Oil supply pipes leaking 2. Resistance at air inlet and exhaust outlet

Call ASS

Correction of shortcomings not listed in the above table is a part

of engine repair and should be performed by specialized work-

shop.

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5. STORAGE AND PRESERVATION AFTER

TAKING THE ENGINE OUT OF SERVICE FOR

LONGER PERIOD 5.1. Storage of a new engine

Engine delivered by the maker is preserved. Engine can be stored, preserved like that, in dry, closed and dustless room of ambient temperature of about 15°C for approximately 6 months. After storing for such period, remove the preservation, pre-pare the engine for starting-up and start it up. After 15-minute idle run, stop the engine and preserve according to the following instructions. 5.2. Engine preservation for longer standstill

Before longer break in operation, preserve each engine against corro-sion and other harmful factors. In order to do so, perform the following operations: 1. Carefully clean entire engine. 2. Remove valve cover and wash timing gear with plenty of engine oil. 3. Drain lubrication system of engine oil. 4. Drain supply system of fuel and clean fuel tank. 5. Drain cooling system. 6. Apply anticorrosion grease to all the external not painted parts. 7. Disconnect battery and, if necessary, fill up the electrolyte by adding distilled water. 8. Every month check and possibly charge-up the battery.

9. Close and protect fuel and coolant fillers as well as inlets and outlets of intake and exhaust systems, and then wrap up injection pump, alter-nator and starter motor with paraffin paper. The above preservation method protects the engine against corrosion for about 6 months provided that the engine is stored in dry, closed and dustless room of ambient temperature of about 15°C. In case of storing the engine longer than 6 months, every such period remove engine preservation, prepare it for starting up and start it up. After 15-minute idle run, stop the engine and preserve according to the above instruc-tions. NOTE: Obeying the above-mentioned instructions would ensure

proper condition of the engine and longer operation until first

overhaul. It would also ensure engine startability after storage.

1 9 9260 Instr Obs 4CTi90 BE Euro 3 Ang

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