Valmet 309 User Manual

UALMET
diesel
3o,9
911
4tl
611
612
Woftshop
Manual
1
General
Cylinder head and
valve mechanism
11
optionat equipment
lnlet- and exhaust
system.
Turbocharger.
1. Edition
15. 1.1986
YAITIT
VALMET CorDorrllon.
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12

Valmet 309 Specifications

General

Brand	Valmet
Model	309
Category	Engine
Language	English

Summary

VALMET diesel Workshop Manual

2 Cylinder block and flywheel housing

Details on the engine's cylinder block and flywheel housing.

3 Cylinder head and valve mechanism

Information on the cylinder head and valve train components.

6 Lubrication system

Details on the engine's lubrication system.

7 Cooling system

Components and operation of the cooling system.

8 Inlet- and exhaust system. Turbocharger.

Covers the engine's intake, exhaust, and turbocharger.

9 Fuel system

Information on the fuel delivery and injection system.

Tightening Torques

Technical Data (Cylinder Block)

Technical Data (Cylinder Liner)

Specifications for cylinder liners, including dimensions and oversizes.

Flywheel Housing

A. INSTALLING THE FLYWHEEL HOUSING

B. REPLACING THE CRANKSHAFT REAR END SEAL

Procedure for replacing the rear crankshaft seal.

Repair Instructions: Cylinder Block and Cylinder Liners

A. MEASURING THE CYLINDER LINER WEAR

Procedure for measuring cylinder liner wear.

B. REMOVING THE CYLINDER LINER

C. CHECKING THE CYLINDER BLOCK

D. REPLACING THE CAMSHAFT BEARING BUSH 309, 311 AND 411

Procedure for replacing camshaft bearing bushes on specific engine models.

Replacing Camshaft Bearing Bushes (611/612)

Camshaft Correction Bearing Bushes (311/411)

Camshaft Correction Bearing Bush (509)

Fitting the Cylinder Liner

Technical Data (Valves, Rocker Arms, and Tappets)

Work Instructions: Cylinder Head

A. REMOVING THE CYLINDER HEAD

B. REMOVING THE VALVES

C. CHECKING THE CYLINDER HEAD

Replacing the Valve Guide

Replacing the Injector Sleeve

Machining the Valve Seat

Replacing the Valve Seat Ring

Grinding the Valves

Fitting the Valves

Fitting the Cylinder Head (309, 311, 411)

Fitting the Cylinder Head (611, 612)

Valve Mechanism

A. RECONDITIONING THE VALVE MECHANISM

Steps for reconditioning valve train components like tappets and rocker arms.

B. REPLACING THE CAMSHAFT / CAMSHAFT GEAR

Procedures for replacing the camshaft and its associated gear.

Technical Data (Piston, Piston Rings, and Piston Pin)

Crankshaft

Repair Instructions: Crankcase

A. REMOVING THE CRANKSHAFT

B. CHECKING THE CRANKSHAFT

REPLACING THE CRANKSHAFT GEAR RIM (411 engines)

Instructions for replacing the crankshaft gear rim on 411 engines.

Replacing Crankshaft Gears

Installing the Crankshaft

Connecting Rods and Pistons

A. REMOVING THE CONNECTING ROD AND PISTON

B. CHECKING AND REPLACING THE CONNECTING ROD BEARINGS

How to check and replace connecting rod bearings.

OVERSIZE PISTON PIN BEARING BUSH

D. INSPECTING THE CONNECTING ROD

Inspecting and Replacing Piston Rings

Fitting the Piston Pin

Fitting the Piston and Connecting Rod

Flywheel

A. REPLACING THE FLYWHEEL STARTER RIM

Steps for replacing the starter rim on the flywheel.

B. FITTING THE FLYWHEEL

Instructions for correctly installing the flywheel onto the crankshaft.

Technical Data (Timing Gear)

Fitting the Gear Housing

Replacing Crankshaft Front End Shaft Seal (309, 311, 411 engines)

Technical Data (Lubrication)

Work Instructions: Lubrication System

A. INSPECTING THE OIL PRESSURE REGULATING VALVE

B. REMOVING AND INSPECTING THE OIL PUMP

C. ASSEMBLING AND INSTALLING THE OIL PUMP

Replacing the Oil Cooler

Technical Data (Coolant Pump)

Work Instructions: Thermostat

A. REMOVING AND INSPECTING THE THERMOSTAT

Work Instructions: Coolant Pump

A. REMOVING THE COOLANT PUMP

B. RECONDITIONING THE COOLANT PUMP (309, 311, 411)

Guide for reconditioning the coolant pump for 309, 311, and 411 engines.

Reconditioning the Coolant Pump (Separate Ball Bearings 611, 611, 612)

Installing the Coolant Pump

Technical Data (Turbocharger)

Work Instructions: Inlet and Exhaust System

A. INSPECTING THE AIR FILTER

B. INSPECTING THE INLET AND EXHAUST PIPES

Reconditioning the Turbocharger (Holset H1B)

Disassembling the Turbo

Checking Turbo Parts

Installing the Turbocharger

Installing the Intercooler

Technical Data (Injection Pump Bosch "A")

Injection Pump Bosch "P" (611, 612)

Instructions for Repairing the Fuel System

1. FEED PUMP

A. BLEEDING THE FUEL SYSTEM

Steps for bleeding air from the fuel system.

B. MEASURING THE FEED PRESSURE

How to measure the fuel feed pressure.

C. CHECKING THE OVERFLOW VALVE

Procedure for checking the overflow valve's operation.

D. DISMOUNTING THE FEED PUMP AND CHECKING THE VALVES

2. INJECTION PUMP BOSCH "A"

A. CHECKING THE INJECTION TIMING

Procedure for checking the injection pump timing.

B. ADJUSTING THE INJECTION TIMING

C. REMOVING THE INJECTION PUMP

D. MOUNTING THE INJECTION PUMP

E. CHECKING AND REPLACING THE PRESSURE VALVE

3. INJECTION PUMP BOSCH "P" 611/612

A. MOUNTING THE INJECTION PUMP

Step-by-step instructions for mounting the injection pump.

B. CHECKING AND ADJUSTING THE INJECTION TIMING

C. ADJUSTING THE IDLING SPEED

Nozzle Needle Tightness Test

C. DISASSEMBLING, CHECKING AND ASSEMBLING THE INJECTOR

5. INJECTION PIPES

A. INSTALLING THE INJECTION PIPES

Steps for correctly installing injection pipes.

Technical Data (Alternators)

Controlling the Operation of Stop Solenoid

Compressor (Bendix - 611/612 Engines)

A. REMOVING AND FIXING THE COMPRESSOR

B. RECONDITIONING THE COMPRESSOR

Guide for reconditioning the compressor using a repair kit.

Reassembly (Compressor)

Servicing and Adjusting the Industrial Clutch

Adjusting Rings of the Clutch

Adjusting the Main Bearing

Clutch Adjustment