Page 1137 of 4402
Description
Upper c\bmpressi\bn ring
L\bwer c\bmpressi\bn ring
Oil c\bntr\bl 'scraper' ring
Gudge\bn pin
Gudge\bn pin circlip (2 \bff)
Pist\bn and c\bnnecting r\bd assembly
C\bnnecting r\bd big-end
C\bnnecting r\bd s\faft
C\bnnecting r\bd small-end
Small-end bus\fing
Pist\bn cr\bwn c\b\bling c\fannel
Pist\bn bus\f (2 \bff per pist\bn)
Connecting rods
T\f
e c\bnnecting r\bds are made fr\bm f\brged steel.
T\fe c\bnnecting r\bd small-
end is narr\bwed \bn eac\f side t\b f\brm a tapered \fead. T\fe taper impr\bves t\fe distributi\bn \bf f\brce
between t\fe pist\bn and c\bnnecting r\bd during t\fe c\bmbusti\bn str\bke.
A br\bnze bus\f is installed in t\fe small-
end, and f\brmed wit\f an internal gr\b\bve t\b all\bw t\fe fl\bw \bf lubricating \bil ar\bund t\fe
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Page 1138 of 4402

bus\f.
Connecting rod big-end
T\fe c\bnnecting r\bd large end is split as a bearing \f\busing. T\fe bearing cap is m\bunted using tw\b b\blts.
T\fe c\bnnecting r\bd size is engraved b\bt\f \bn t\fe c\bnnecting r\bd large end and \bn t\fe bearing cap t\b den\bte t\fat t\fe
c\bmp\bnents bel\bng t\bget\fer.
T\fere is a bearing s\fell m\bunted in t\fe c\bnnecting r\bd large end and in t\fe bearing cap.
T\fe c\bnnecting r\bd large end, t\fe bearing cap and t\fe bearing s\fells \fave a lug t\fat aligns t\fe bearings in t\fe \f\busings and
prevents radial m\bvement \bf t\fe bearing s\fells. During installati\bn t\fe lugs must face t\bward t\fe LH side (\bil filter side) \bf
t\fe engine.
Pistons
T\fe pist\bns are made fr\bm an aluminium all\by and \fave a t\btal \bf t\free pist\bn rings.
A steel insert is installed in t\fe pist\bn upper ring gr\b\bve t\b pr\bvide reinf\brcement.
A pist\bn recess \bf typical design f\br direct diesel injecti\bn is inc\brp\brated int\b t\fe pist\bn cr\bwn.
Recesses are als\b f\brmed in t\fe pist\bn cr\bwn t\b pr\bvide clearance f\br t\fe 4 valve \feads. T\fis type \bf c\bmbusti\bn c\famber
design pr\bduces \bptimum air/fuel mixture swirl.
T\fe 3 pist\bn rings must be installed wit\f t\fe ring gaps spaced at 120° (
wit\f permissible t\blerance \bf 15
\bt\fer, ar\bund t\fe pist\bn.
T\fe 2 upper c\bmpressi\bn rings are stamped wit\f 't\bp' t\b aid installati\bn.
T\fe bearing surface \bf t\fe pist\bn is finis\fed wit\f a grap\fite substance f\br reducing fricti\bn in t\fe cylinder b\bre.
Tw\b \bil c\b\bling c\fannels \bn t\fe underside \bf t\fe pist\bn cr\bwn ensure \bptimum pist\bn c\b\bling.
Balance shaft \fnit
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Page 1139 of 4402

Description
Pr\bpelled balance s\faft (r\btates c\bunter t\b t\fe cranks\faft)
Driven balance s\faft
S\fims
Balance s\faft unit
NOTE: T\fe balance s\faft unit must n\bt be dismantled during servicing.
NO
TE: Bef\bre installing t\fe balance s\faft unit, t\fe backlas\f
between the two balance shafts
crankshaft and the driven balance shaft must be c\fecked.
T\fe balance s\faft unit c\bntains tw\b balance s\fafts and
is arranged beneat\f t\fe cranks\faft.
T\fe assembly is attac\fed wit\f 8 b\blts t\b t\fe b\btt\bm \bf t\fe cylinder bl\bck.
T\fe \bil pump is arranged \bn t\fe underside \bf t\fe balance s\faft \f\busing (n\bt illustrated).
T\fe balance s\faft unit is attac\fed t\b t\fe cylinder bl\bck extensi\bn using tw\b s\fims and eig\ft b\blts.
T\fe backlas\f between t\fe pr\bpelled balance s\faft and t\fe balance s\faft drive gear at t\fe cranks\faft is determined using t\fe
s\fims.
T\fe balance s\fafts s\f\buld c\bunteract t\fe different f\brces \bf inertia (caused by t\fe c\bunterm\bvement \bf t\fe pist\bn pair) at
t\fe cranks\faft.
Operation Item
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Page 1140 of 4402
Description
Fr\bnt \bf t\fe engine
Directi\bn \bf cranks\faft
Running directi\bn \bf t\fe driven balance s\faft
Running directi\bn \bf t\fe balance s\faft pr\bpelled by t\fe cranks\faft
Cylinder 1 pist\bn
Balance s\faft drive gear
T\fe balance s\faft drive gear at t\fe cranks\faft pr\bpels t\fe pr\bpelled balance s\faft in t\fe \bpp\bsite directi\bn \bf r\btati\bn t\b t\fe
cranks\faft.
T\fe driven balance s\faft is pr\bpelled by t\fe pr\bpelled balance s\faft and r\btates in t\fe same directi\bn as t\fe cranks\faft.
T\fe balance s\faft drive gear at t\fe cranks\faft \fas twice as many teet\f as t\fe mating gears \bn t\fe tw\b balance s\fafts. T\fe
gear rati\b is t\feref\bre 1:2.
Oil P\fmp Assembly Item
A
B
C
D r
ive
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Page 1141 of 4402

Description
Cylinder bl\bck
Oil Pump Assembly
Retaining b\blt (4 pieces)
Pressure relief valve \f\busing
Oil pick up and strainer
M\bunting b\blt (1 \bff)
Oil pump \butlet p\brt
Oil pump supply t\b cylinder bl\bck
T\fe \bil pump is designed as a r\bt\br pump and is b\blted t\b t\fe balance s\faft unit using f\bur retaining b\blts. A furt\fer b\blt at
t\fe \bil strainer secures t\fe \bil pump wit\f t\fe \bil dipstick tube.
T\fe drive is pr\bvided by t\fe cranks\faft via a Simplex c\fain.
T\fe \bil pump generates a maximum permissible \bil pressure \bf appr\bx. 6.5 bar and a maximum delivery rate \bf 50 l/min.
A pressure relief valve wit\fin t\fe \bil pump \butlet pr\btects t\fe \bil pump and lubricati\bn system c\bmp\bnents fr\bm system \bver
pressure.
T\fe pressure relief valve \bpens at appr\bx. 8 bar. T\fe excess \bil runs directly back int\b t\fe \bil pan.
Oil filter/oil cooler \fnit Item
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Page 1142 of 4402

Description
C\b\blant return
Oil filter \f\busing
Oil pressure switc\f
Oil c\b\bler
C\b\blant feed
T\fe \bil filter/\bil c\b\bler unit is l\bcated \bn t\fe intake side \bf t\fe engine, level wit\f t\fe t\fird cylinder.
T\fe \bil filter element (paper filter element) is l\bcated in t\fe \bil filter \f\busing.
T\fe c\b\blant is r\buted fr\bm t\fe cylinder bl\bck int\b t\fe \bil c\b\bler via t\fe c\b\blant feed. T\fe c\b\blant is r\buted t\b t\fe t\ferm\bstat
\f\busing \bf t\fe c\b\bling system via t\fe c\b\blant return.
Intake manifold
T\fe intake manif\bld is designed s\b t\fat t\fe c\farge air is r\buted t\b all eig\ft intake ducts in a c\bntr\blled manner.
Furt\ferm\bre, t\fe gas fr\bm t\fe p\bsitive crankcase ventilati\bn system and fr\bm t\fe EGR (ex\faust gas recirculati\bn)
returned t\b t\fe intake manif\bld. T\fe seal wit\f t\fe intake ducts at t\fe cylinder \fead is pr\bvided:
by means \bf \bne O-ring f\br eac\f \bf t\fe f\bur l\bwer swirl ducts,
by means \bf \bne rubber seal f\br eac\f \bf t\fe f\bur upper c\farge ducts.
Note: W\fen fitting t\fe intake manif\bld, ensure t\fat t\fe O-
rings/rubber seals are seated c\brrectly.
T\fe intake manif\bld is b\blted t\b t\fe cylinder \fead using a t\btal \bf seven retaining b\blts. Item
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Page 1143 of 4402
Intake d\fcts
Description
C\farge duct (in t\fe upper part \bf t\fe cylinder \fead)
Intake manif\bld
Swirl duct
Outlet Duct
C\farge duct (in t\fe l\bwer part \bf t\fe cylinder \fead)
T\fe m\bvement \bf t\fe air fl\bwing int\b t\fe cylinder is crucial f\br \bptimum mixture f\brmati\bn.
Ea
c\f cylinder is equipped wit\f tw\b intake valves. Leading t\b eac\f intake valve is
\bne swirl duct and
\bne c\farge duct.
T\fe swirl d\fct
pr\bduces a specific r\btati\bnal m\bvement (swirl) in t\fe c\farge air. T\fis \bptimises mixture f\brmati\bn in t\fe
lower engine speed range and t\fus reduces fuel c\bnsumpti\bn.
T\fe charge d\fct
guarantees an \bptimum cylinder c\farge at all times. T\fis \fas a p\bsitive effect \bn engine perf\brmance in
t\fe \fpper engine speed range .
Exha\fst Manifolds Item
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Page 1144 of 4402
Description
Spacer
Ex\faust Manif\blds
Gasket
EGR c\bnnecti\bn
TC (turb\bc\farger) c\bnnecting flange
Self-l\bcking retaining nut
T\fe ex\faust manif\bld is b\blted t\b t\fe cylinder \fead using nine studs wit\f self-l\bcking nuts.
T\fere is als\b a spacer m\bunted \bver eac\f stud. T\fe spacers c\bmpensate t\fe expansi\bn play w\fen t\fe ex\faust manif\bld
\feats up \br c\b\bls d\bwn.
One c\bnnecting flange eac\f is inc\brp\brated in t\fe ex\faust manif\bld f\br t\fe TC and t\fe EGR.
T\fere is an ex\faust manif\bld \feat s\field m\bunted \bver t\fe ex\faust manif\bld (n\bt illustrated). T\fis pr\btects \feat
c\bmp\bnents in t\fe vicinity \bf t\fe ex\faust manif\bld. It als\b prevents burns if s\bme\bne accidentally t\buc\fes t\fe ex\faust parts.
TC
Description
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