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SISU Diesel 320 420 620 634 Engines Service Repair Manual
Manuals Includes info on:
TO THE USER ......................................................................... 0 ---1
ENGINE TYPE DESIGNATIONS 0 ---1 ...........................................................
SAFETY INSTRUCTIONS ................................................................ 0 ---2
ENGINE SPECIFICATION ................................................................ 0 ---3
LIFTING THE ENGINE ................................................................... 0 ---3
LOCATION OF THE ENGINE SERIAL NO. ................................................. 0 ---3
SPECIAL TOOLS ....................................................................... 0 ---4
TECHNICAL DATA ...................................................................... 0 ---6
Cylinder block ................................................................... 0---6
Cylinder liner..................................................................... 0 ---6
Cylinder head .................................................................... 0 ---6
Valves, rocker arms and tappets .................................................... 0 ---7
Camshaft ....................................................................... 0 ---7
Crankshaft ....................................................................... 0 ---8
Flywheel ........................................................................ 0---8
Balancing unit .................................................................... 0 ---9
Timing gears ..................................................................... 0 ---9
Connecting rod .................................................................. 0 ---9
Piston, piston rings and pin ....................................................... 0 ---10
Lubricating system ................................................................ 0 ---10
Oil pump (320, 420) ............................................................... 0 ---10
Oil pump (620, 634) ............................................................... 0 ---11
Coolant pump (320, 420) .......................................................... 0 ---11
Coolant pump (320, 420 separate ball bearings) ....................................... 0 ---11
Coolant pump (620, 634) .......................................................... 0 ---12
Thermostat ...................................................................... 0 ---12
Turbocharger ................................................................... 0 ---12
TIGHTENING TORQUES ............................................................... 0 ---13
CONSTRUCTION ....................................................................... 0 ---14
General ......................................................................... 0 ---14
Cylinder block ................................................................... 0 ---14
Flywheel housing ................................................................ 0 ---14
Cylinder head .................................................................... 0 ---15
Valve mechanism ................................................................. 0 ---15
Crank mechanism ................................................................ 0 ---15
Timing gears .................................................................... 0 ---16
Lubricating system ................................................................ 0 ---17
Cooling system .................................................................. 0 ---18
Inlet and exhaust system .......................................................... 0 ---19
Electronic Engine Management system (EEM) ....................................... 0 ---20
WORK INSTRUCTIONS
1. CYLINDER BLOCK
A. Measuring cylinder liner wear 1 ---1
B. Removing cylinder liner 1 ---1
C. Checking cylinder block 1 ---1
D. Changing camshaft bushing 1 ---1
E. Oversize bushings for camshaft 1 ---2
F. Fitting plug at camshaft rear end 1 ---3
G. Fitting pipe for oil dipstick 1 ---4
H. Fitting cylinder liner 1 ---4
2. FLYWHEEL HOUSING
A. Fitting flywheel housing 2 ---1
B. Changing crankshaft rear oil seal 2 ---1
3. CYLINDER HEAD
A. Removing cylinder head 3 ---1
B. Removing valves 3 ---1
C. Checking cylinder head 3 ---1
D. Changing valve guides 3 ---2
E. Machining valve seat 3 ---2
F. Changing valve seat ring 3 ---3
G. Grinding valves 3 ---3
H. Fitting valves 3 ---3
Fitting cylinder head 3 ---4
4. VALVE MECHANISM
A. Reconditioning valve mechanism 4 ---1
B. Changing camshaft/camshaft gear 4 ---2
C. Adjusting valves 4 ---3
5. CRANKSHAFT
A. Removing crankshaft 5 ---1
B. Checking crankshaft 5 ---1
C. Changing crankshaft gears 5 ---1
D. Changing crankshaft gear rim (420) 5 ---2
E. Fitting crankshaft 5 ---2
F. Crankshaft hub piece 5 ---3
G. Changing crankshaft pulley/vibration damper 5 ---3
H. Checking element of the rubber damper 5 ---4
I. Viscose type vibration damper 5 ---4
6. CONNECTING RODS AND PISTONS
A. Removing pistons together with connecting rods 6 ---1
B. Changing connecting rod bearings 6 ---1
C. Checking connecting rod 6 ---1
D. Changing piston rings 6 ---3
E. Checking pistons 6 ---3
F. Fitting piston pin 6 ---4
G. Fitting piston together with connecting rod 6 ---4
7. COUNTERBALANCE (420)
A. Removing and disassembling counterbalance unit 7 ---1
B. Reconditioning counterbalance unit 7 ---1
C. Fitting counterbalance unit 7 ---1
8. FLYWHEEL
A. Changing starter ring gear on flywheel 8 ---1
B. Fitting flywheel 8 ---1
9. TIMING GEAR ASSEMBLY
A. Removing timing gear casing 9 ---1
B. Reconditioning idler gear 9 ---1
C. Fitting timing gear casing 9 ---2
D. Idler gear with bevelled ball bearings 9 ---4
E. Power take ---off 9 ---5
10. LUBRICATION SYSTEM
A. Reconditioning of oil relief valve for lubricatin oil pressure 10 ---1
B. Removing and dismantling lubricating oil pump 10 ---1
C. Assembling and fitting lubricating oil pump 10 ---2
D. Fitting oil sump gasket 10 ---3
E. Lubricating oil cooler 10 ---3
F. Piston cooling nozzles (620, 634) 10 ---3
G. Lubrication oil quality requirements 10 ---4
11. COOLING SYSTEM
A. Thermostat 11 ---1
B. Reconditioning coolant pump (320, 420) 11 ---1
C Reconditioning coolant pump (320, 420, 620, 634 separate ball bearings) 11 ---2
D. Coolant pumps with heavy ---duty bearings (620, 634) 11 ---4
E. Quality requirements of coolant 11 ---4
12. INLET --- AND EXHAUST SYSTEM
A. Checking air cleaner 12 ---1
B. Checking inlet and exhaust pipes 12 ---1
C. Checking turbocharger 12 ---1
D. Fitting turbocharger 12 ---2
13. FUEL SYSTEM
IN ---LINE FUEL INJECTION PUMP
Technical data 13 ---1
A. Bleeding fuel system 13 ---6
B. Bleeding Thermostart system 13 ---6
C. Measuring fuel feed pressure 13 ---7
D. Checking overflow valve 13 ---7
E. Changing fuel feed pump valves 13 ---7
F. Checking injection timing 13 ---8
G. Adjusting fuel injection timing 13 ---9
H. Removing fuel injection pump 13 ---10
I. Fitting fuel injection pump 13 ---10
J. Checking and changing pressure valve 13 ---12
K. Adjusting idling speed 13 ---12
L. Removing injectors 13 ---13
M. Inspecting injectors 13 ---13
N. Reconditioning injectors 13 ---14
O. Fitting injector in engine 13 ---15
P. Fitting delivery pipes 13 ---15
CAV DISTRIBUTOR PUMP
Technical data 13 ---16
A. Dismounting and mounting injection pump 13 ---17
B. Injection pump gear 13 ---17
C. Bleeding fuel system 13 ---17
D. Feed pump 13 ---18
E. Injector 13 ---18
STANADYNE DISTRIBUTOR PUMP
Technical data 13 ---19
A. Removing pump 13 ---24
B. Fitting injection pump and adjusting injection timing 13 ---24
C. Bleeding fuel system 13 ---25
D. Fuel feed pump 13 ---25
E. Injectors 13 ---25
F. Adjusting low idling speed 13 ---26
G. Bleeding Thermostart system 13 ---26
H. Wiring diagram of electrical advance (CCA) 13 ---26
I. Checking injection timing (dynamic) 13 ---27
Fuel quality requirement 13 ---29
14. EQUIPMENT AND FEEDING TABLES
15. ELECTRICAL SYSTEM
A. Alternators 15 ---1
B. Starters 15 ---4
C. Electric stop device 15 ---7
D. Installation of magnetic pick up 15 ---9
E. Temperature sensor 15 ---9
16. OPTIONAL EQUIPMENT
A. Compressor (Bendix) 16 ---1
B. Compressor (Knorr) 16 ---2
C. Industrial clutch (A.P. Borg & Beck) 16 ---3
Index
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