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Sisu Diesel 420DS - User Manual

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WORKSHOP MANUAL
SISUDIESEL 320
420
620
8366 40634 634

Table of Contents

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Summary

SAFETY INSTRUCTIONS

ENGINE SPECIFICATIONS

SPECIAL TOOLS

TECHNICAL DATA

Cylinder liners

Technical data for cylinder liners, including dimensions and tolerances.

Valves, rockers and tappets

Specifications for valves, rocker arms, and tappets, including clearances and dimensions.

Camshaft

Specifications for the camshaft, including bearing journals and clearances.

Crankshaft

Technical data for the crankshaft, including journal diameters and clearances.

Connecting rod

Specifications for connecting rods, including bearing shells and end float.

Piston, rings and pin

Specifications for pistons, rings, and pins, including clearances and gaps.

Turbocharger

Specifications for turbochargers, including end float and radial clearance.

TIGHTENING TORQUES

CONSTRUCTION

Cylinder block

Detailed description of the cylinder block's structure and features.

Crank mechanism

Description of the crankshaft, its support, and related parts.

Cylinder head

Description of the cylinder head design, bolts, and valve guides.

Valve mechanism

Description of the valve mechanism, tappets, and pushrods.

Timing gears

Description of the timing gear train and its components.

Lubricating system

Description of the engine's pressure lubricating system and its components.

Cooling system

Description of the cooling system, coolant pump, and thermostat.

Inlet and exhaust system

Description of the inlet and exhaust systems, including air filters and turbochargers.

Electronic Engine Management system (EEM)

Description of the EEM system, its components, and function.

WORK INSTRUCTIONS

1. CYLINDER BLOCK

Instructions for working on the cylinder block, including measurements.

H. Fitting cylinder liner

Continues fitting instructions for cylinder liners, including checks and markings.

3. CYLINDER HEAD

A. Removing cylinder head

Detailed steps for removing the cylinder head from the engine.

I. Fitting cylinder head

Detailed steps for fitting the cylinder head, including bolt tightening sequence.

4. VALVE MECHANISM

B. Changing camshaft;camshaft gear

Procedure for removing and fitting the camshaft and its gear.

C. Adjusting valves

Instructions for adjusting valve clearances on different engine models.

5. CRANKSHAFT

A. Removing crankshaft

Steps for removing the crankshaft from the engine block.

E. Fitting crankshaft

Steps for fitting the crankshaft, including bearing lubrication and end float checks.

6. CONNECTING RODS AND PISTONS

A. Removing pistons together with connecting rods

Steps for removing pistons and connecting rods from the cylinder liners.

B. Changing connecting rod bearings

Details on changing connecting rod bearings, including weight classes and screw torque.

D. Changing piston rings

Instructions for removing and fitting piston rings, including groove checks.

G. Fitting piston together with connecting rod

Steps for fitting the piston and connecting rod assembly, including bearing lubrication and torque.

9. TIMING GEAR ASSEMBLY

A. Removing timing gear casing

Steps for removing the timing gear casing.

10. LUBRICATION SYSTEM

B. Removing and dismantling lubricating oil pump

Steps for removing and dismantling the lubricating oil pump.

C. Assembling and fitting lubricating oil pump

Instructions for assembling and fitting the lubricating oil pump.

G. Lubricating oil quality requirements

Specifies the quality requirements for lubricating oil and viscosity grades.

11. COOLING SYSTEM

B. Reconditioning coolant pump (320, 420)

Steps for reconditioning the coolant pump in 320 and 420 engines.

C. Reconditioning coolant pump (Separate ball bearings 320, 420, 620, 634)

Procedures for reconditioning coolant pumps with separate ball bearings.

E. Quality requirements of coolant

Specifies the quality standards and mixing proportions for engine coolant.

12. INLET AND EXHAUST SYSTEM

B. Checking inlet and exhaust pipes

Instructions for inspecting inlet and exhaust pipes for leaks and damage.

C. Checking turbocharger

Continues turbocharger checking, including troubleshooting faulty operation.

13. FUEL SYSTEM

IN-LINE FUEL INJECTION PUMP

General instructions for repair and service of the in-line fuel injection pump.

TECHNICAL DATA

Provides technical data for Bosch A/P type injection pumps and fuel feed pumps.

F. Checking injection timing

Continues instructions for adjusting fuel injection timing, including using an electrical device.

G. Adjusting fuel injection timing

Steps for adjusting the fuel injection timing.

I. Checking injection timing (dynamic)

Troubleshooting tips for injection timing checks.

15. ELECTRICAL SYSTEM

Sisu Diesel 420DS Specifications

General IconGeneral
BrandSisu Diesel
Model420DS
CategoryEngine
LanguageEnglish

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