This service manual provides instructions for servicing the loader 455ZX. It details removing and installing the crankshaft, which involves removing many other engine components first. The crankshaft removal process includes removing the main bearing caps and lifting out the crankshaft and bearing shells. Proper cleaning and installation of new bearing shells is emphasized.
Jcb 3 cx backhoe loader service repair manual sn from 2509500 and upfdjjsekksemxs
This service manual provides instructions for servicing backhoe loaders models 3CX, 4CX, and 5CX. It contains sections covering the entire machine including the engine, fuel system, cooling system, brakes, steering, hydraulics, electrical system, and other components. The document provides detailed procedures, diagrams, and specifications for maintenance, repair, and removal/installation of parts. Safety warnings are included throughout advising technicians to read and understand instructions before working on the machine.
Jcb jcb116 roller service repair manual sn from 2492271 to 2492450dfujsjjekme
This service manual provides instructions for servicing the roller components of JCB machines models JCB116, JCB116D, JCB116DD, and VM116. It contains sections on removing and installing various parts including the crankshaft, main bearings, and connecting rods. Detailed steps and diagrams are provided, as well as torque specifications and lists of required consumables. Proper cleaning and inspection of parts is emphasized to avoid damage from blocked oil passages.
Daewoo doosan dx160 w 3 (dieu exp) wheel excavator parts catalogue manualfjjskedmmemm
The document contains diagrams and part lists for components of an engine. It includes diagrams and parts for the cylinder block, timing gear case, flywheel housing, oil seal, oil spray nozzle, breather system, crankshaft, vibration damper, flywheel, connecting rod, and piston. Each diagram lists the part numbers, descriptions, and quantities of components for that assembly.
Daewoo doosan dx160 lc 3 crawler excavator parts catalogue manualfjjskedmmemm
This document contains parts lists and diagrams for components of a DX160LC-3 engine. It includes 11 figures listing over 150 individual parts that make up the cylinder block, timing gear case, flywheel housing, oil seal, oil spray nozzle, breather system, crankshaft, vibration damper, flywheel, connecting rod, and piston. Each part is identified by a unique key number, part number, description, and quantity.
Daewoo doosan dx140 w 3 (dieu exp) wheel excavator parts catalogue manualfjjskedmmemm
The document contains diagrams and part lists for components of an engine. It includes diagrams and parts for the cylinder block, timing gear case, flywheel housing, oil seal, oil spray nozzle, breather system, crankshaft, vibration damper, flywheel, connecting rod, and piston. Each diagram lists the part numbers, descriptions, and quantities of components for that assembly. Serial numbers are included for some parts.
Daewoo doosan solar 030 plus mini crawler excavator parts catalogue manual (s...fjjskedmmemm
This document provides a repair kit parts list and descriptions for a Solar 030Plus engine with serial numbers between 20001 and 20575. The repair kit part number is 587814-0710 and includes seals, gaskets, packings and other parts to repair the cylinder head, cylinder block, timing gear case, flywheel housing, oil pan, oil pump, piston and crankshaft assembly.
Daewoo doosan solar 015 plus mini crawler excavator parts catalogue manual (s...fjjskedmmemm
This document provides a parts list for the crank case of a Solar 015Plus engine. It includes 3 pages listing over 50 individual parts that make up the crank case assembly, including covers, gaskets, cylinders, bolts, pins, bushings, seals, and more. Each part is given a key number, part number, description, and quantity. Serial numbers and whether the part is replaceable are also provided for each item.
Daewoo doosan solar 015 plus mini crawler excavator parts catalogue manualfjjskedmmemm
The document provides a parts list for a crank case assembly with 33 parts. It lists the part numbers, descriptions, quantities, and whether the parts are replaceable for each component. It also includes keys for three piston sizes and their ring sets.
The document contains a parts list for an oil pan and gear case assembly with 14 parts. It lists the part numbers, descriptions, quantities, and whether the parts are replaceable for each component.
The document provides an exploded diagram and parts list for a fuel injection pump with 24 parts. It lists the part numbers, descriptions, quantities, and whether the parts are replaceable for each component.
Jcb 3 cx backhoe loader service repair manual sn from 2509500 and upfdjjsekksemxs
This service manual provides instructions for servicing backhoe loaders models 3CX, 4CX, and 5CX. It contains sections covering the entire machine including the engine, fuel system, cooling system, brakes, steering, hydraulics, electrical system, and other components. The document provides detailed procedures, diagrams, and specifications for maintenance, repair, and removal/installation of parts. Safety warnings are included throughout advising technicians to read and understand instructions before working on the machine.
Jcb jcb116 roller service repair manual sn from 2492271 to 2492450dfujsjjekme
This service manual provides instructions for servicing the roller components of JCB machines models JCB116, JCB116D, JCB116DD, and VM116. It contains sections on removing and installing various parts including the crankshaft, main bearings, and connecting rods. Detailed steps and diagrams are provided, as well as torque specifications and lists of required consumables. Proper cleaning and inspection of parts is emphasized to avoid damage from blocked oil passages.
Daewoo doosan dx160 w 3 (dieu exp) wheel excavator parts catalogue manualfjjskedmmemm
The document contains diagrams and part lists for components of an engine. It includes diagrams and parts for the cylinder block, timing gear case, flywheel housing, oil seal, oil spray nozzle, breather system, crankshaft, vibration damper, flywheel, connecting rod, and piston. Each diagram lists the part numbers, descriptions, and quantities of components for that assembly.
Daewoo doosan dx160 lc 3 crawler excavator parts catalogue manualfjjskedmmemm
This document contains parts lists and diagrams for components of a DX160LC-3 engine. It includes 11 figures listing over 150 individual parts that make up the cylinder block, timing gear case, flywheel housing, oil seal, oil spray nozzle, breather system, crankshaft, vibration damper, flywheel, connecting rod, and piston. Each part is identified by a unique key number, part number, description, and quantity.
Daewoo doosan dx140 w 3 (dieu exp) wheel excavator parts catalogue manualfjjskedmmemm
The document contains diagrams and part lists for components of an engine. It includes diagrams and parts for the cylinder block, timing gear case, flywheel housing, oil seal, oil spray nozzle, breather system, crankshaft, vibration damper, flywheel, connecting rod, and piston. Each diagram lists the part numbers, descriptions, and quantities of components for that assembly. Serial numbers are included for some parts.
Daewoo doosan solar 030 plus mini crawler excavator parts catalogue manual (s...fjjskedmmemm
This document provides a repair kit parts list and descriptions for a Solar 030Plus engine with serial numbers between 20001 and 20575. The repair kit part number is 587814-0710 and includes seals, gaskets, packings and other parts to repair the cylinder head, cylinder block, timing gear case, flywheel housing, oil pan, oil pump, piston and crankshaft assembly.
Daewoo doosan solar 015 plus mini crawler excavator parts catalogue manual (s...fjjskedmmemm
This document provides a parts list for the crank case of a Solar 015Plus engine. It includes 3 pages listing over 50 individual parts that make up the crank case assembly, including covers, gaskets, cylinders, bolts, pins, bushings, seals, and more. Each part is given a key number, part number, description, and quantity. Serial numbers and whether the part is replaceable are also provided for each item.
Daewoo doosan solar 015 plus mini crawler excavator parts catalogue manualfjjskedmmemm
The document provides a parts list for a crank case assembly with 33 parts. It lists the part numbers, descriptions, quantities, and whether the parts are replaceable for each component. It also includes keys for three piston sizes and their ring sets.
The document contains a parts list for an oil pan and gear case assembly with 14 parts. It lists the part numbers, descriptions, quantities, and whether the parts are replaceable for each component.
The document provides an exploded diagram and parts list for a fuel injection pump with 24 parts. It lists the part numbers, descriptions, quantities, and whether the parts are replaceable for each component.
Daewoo doosan solar 015 plus s018 vt mini crawler excavator parts catalogue ...fjjskedmmemm
This document provides a parts list and diagrams for various engine components of a Solar 015PLUS / S018-VT engine. It includes over 30 figures listing over 200 individual part numbers, descriptions, quantities and other specifications for components such as the cylinder block, oil pan, cylinder head, crankshaft, timing parts, fuel supply parts, fuel injection pump, nozzles, and fuel filter.
Daewoo doosan solar 015 mini crawler excavator parts catalogue manualfjjskedmmemm
This document contains 18 figures describing parts related to an engine. Each figure includes a diagram, part numbers, descriptions and quantities of components. Key information includes cylinders, pistons, crankshaft, camshaft, oil pan, filters and various gaskets and seals. Replacement part numbers are provided for some items.
Daewoo doosan solar 010 mini crawler excavator parts catalogue manual (sn 200...fjjskedmmemm
The document provides a list of parts for various components of a solar engine, including the cylinder block, timing gear housing, flywheel housing, cylinder head, suction manifold, and camshaft. It includes the part numbers, descriptions, quantities, and other identifying information for 25 different parts per component. The parts are for a Solar 010 engine with a serial number starting with 20001 or higher.
Daewoo doosan solar 010 mini crawler excavator parts catalogue manualfjjskedmmemm
This document contains diagrams and part numbers for various engine components of a cylinder block, including:
- The cylinder block assembly and individual parts like the cylinder block, cylinder head, bolts, gaskets, etc.
- A timing gear housing showing related parts like the gear case cover, seals, pipes, bolts, and fuel pump assembly.
- A flywheel housing and oil pump diagramming the housing, pins, bolts, oil seal case, and sump assembly.
- A cylinder head and cover labeling the head assembly, valves, springs, rocker arms, bonnet assembly, filler cap, and more.
Daewoo doosan mt41 moxy articulated dump truck parts catalogue manualfjjskedmmemm
This document contains parts lists and diagrams for various engine components of an MT36/41 engine with serial numbers 810001-810108. It includes lists and diagrams for the cylinder head, rocker cover, cylinder block, flywheel housing, oil sump, front casing, crankcase ventilation, crank mechanism, piston, timing gear, and oil pump. The parts are identified by key number, part number, description, and quantity.
Daewoo doosan mt40 b moxy articulated dump truck parts catalogue manualfjjskedmmemm
This document contains parts listings and diagrams for various engine components of an MT40B engine with serial numbers 513001-513140. It includes lists and diagrams for the cylinder head, rocker cover, cylinder block, timing gear housing, flywheel housing, oil sump, crankcase ventilation, and crank mechanism. Each section lists the part numbers, descriptions, and quantities of components.
Daewoo doosan mt36 moxy articulated dump truck parts catalogue manual sn 41...fjjskedmmemm
This document provides parts information for the cylinder head, rocker cover, cylinder block, flywheel housing, oil sump, crankcase ventilation, housing, crank mechanism, piston, and timing gear of an MT36 engine with serial numbers 410001-410309. It includes diagrams of each assembly or component along with a table listing part numbers, descriptions, quantities, and other identifying information for each numbered part.
Daewoo doosan mt36 moxy articulated dump truck parts catalogue manualfjjskedmmemm
This document contains parts lists and diagrams for various engine components of an MT36/41 engine with serial numbers 810001-810108. It includes lists and diagrams for the cylinder head, rocker cover, cylinder block, flywheel housing, oil sump, front casing, crankcase ventilation, crank mechanism, piston, timing gear, and oil pump. The parts are identified by key number, part number, description, and quantity.
Daewoo doosan mt31 moxy articulated dump truck parts catalogue manual sn 71...fjjskedmmemm
This document provides parts information for the crankcase ventilation, engine suspension, charge air pipes, cylinder head, rocker cover, cylinder block, flywheel housing, oil sump, crankshaft mechanism, and piston of an engine. It includes diagrams of these systems and lists the part numbers, descriptions, quantities, and serial number ranges for each component. The parts are identified by key number in the diagrams and parts lists.
Daewoo doosan mt31 moxy articulated dump truck parts catalogue manual sn 71...fjjskedmmemm
This document provides an exploded diagram and parts list for the engine suspension of a marine diesel engine. It includes over 320 individual part numbers, descriptions, quantities, and other identifying information for components of the engine block, cylinder head, valve train, crankshaft, pistons, bearings, and other internal engine parts. The parts list is organized into 18 sections covering the major engine assemblies and sub-assemblies.
Daewoo doosan mt26 moxy articulated dump truck parts catalogue manual sn 71...fjjskedmmemm
This document provides parts information for the crankcase ventilation, engine suspension, charge air pipes, cylinder head, rocker cover, cylinder block, flywheel housing, oil sump, crankshaft mechanism, and piston of an engine. It includes diagrams of these systems and lists the part numbers, descriptions, quantities, and serial number ranges for each component. The parts are identified by key number in the diagrams and parts lists.
Daewoo doosan mt26 moxy articulated dump truck parts catalogue manual sn 71...fjjskedmmemm
This document provides an exploded diagram and parts list for the engine suspension of a marine diesel engine. It includes over 320 individual part numbers, descriptions, quantities, and other identifying information for components of the engine block, cylinder head, valve train, crankshaft, pistons, bearings, and other internal engine parts. The parts list is organized into 18 sections covering the major engine assemblies and sub-assemblies.
Daewoo doosan mt25 moxy articulated dump truck parts catalogue manual sn 71...fjjskedmmemm
This document provides parts information for the crankcase ventilation, engine suspension, charge air pipes, cylinder head, rocker cover, cylinder block, flywheel housing, oil sump, crankshaft mechanism, and piston of an engine. It includes diagrams of these systems and lists the part numbers, descriptions, quantities, and serial number ranges for each component. The parts are identified by key number in the diagrams and parts lists.
Daewoo doosan mt25 moxy articulated dump truck parts catalogue manual sn 71...fjjskedmmemm
This document provides a parts list for engine suspension components for a MT25/26/31 engine with serial numbers between 710001-710654. It includes 3 pages listing over 300 individual part numbers, descriptions, quantities, and other identifying information for components related to the engine suspension, pipes for charge air, cylinder head, rocker cover, cylinder block, timing gear housing, flywheel housing, and crank mechanism.
Daewoo doosan mega 300 v 300 v wheel loader parts catalogue manual (sn 3001-)fjjskedmmemm
This document provides a parts list and exploded diagram for the frame of a MEGA 300-V machine (serial numbers 3001 and up). It lists 46 parts that make up the frame including the rear frame, front frame, caps, bolts, bearings, shims, pins, seals, plates, and cylinders. Serial numbers and replacement part numbers are provided for parts that have changed over time.
Daewoo doosan mega 300 v 300 v wheel loader parts catalogue manual (sn 2001-)fjjskedmmemm
This document provides a parts list for a MEGA 300-V machine, including the frame, engine mounting, air cleaner, oil tank, and fuel tank assemblies. It lists over 50 individual parts that make up these assemblies, including descriptions, part numbers, quantities, and replacement part information. The parts listed include frames, brackets, hoses, filters, seals, bolts, and other structural and functional components of the machine. Serial number ranges are provided to indicate applicable part number revisions over time.
Daewoo doosan mega 300 v 300 v wheel loader parts catalogue manual (sn 1001-)fjjskedmmemm
This document provides a parts list and diagram for the frame of a MEGA 300-V machine. It lists 26 different frame parts in the diagram and key, including various rear and front frame parts that have changed part numbers over different serial number ranges. Fasteners like bolts, nuts, washers that are used on the frame are also detailed.
Daewoo doosan mega 250 v 250 v wheel loader parts catalogue manual (sn 4001 a...fjjskedmmemm
This document provides a parts list and diagram for the cylinder head of a MEGA 250-V engine. It includes 20 key items that make up the cylinder head assembly, their part numbers, descriptions, and quantities. Serial numbers and replacement part numbers are also provided for some items. The diagram labels each part and its corresponding key number.
Daewoo doosan mega 250 v 250 v wheel loader parts catalogue manual (sn 3001-)fjjskedmmemm
This document provides a parts list and specifications for components related to the cylinder block, crank shaft, piston, and cylinder head of a MEGA 250-V engine. It includes the part numbers, descriptions, quantities, serial numbers, and whether parts are replaceable for over 50 individual components. The highest level assemblies listed are the cylinder block assembly, crankshaft assembly, piston assembly, and cylinder head assembly.
Daewoo doosan mega 250 v 250 v wheel loader parts catalogue manualfjjskedmmemm
The document provides a parts list and diagrams for components of an engine, including the cylinder block, timing gear case, flywheel housing, crank shaft, piston, and cylinder head. It lists part numbers, descriptions, quantities, serial numbers and other specifications for each component part. Replacement part numbers are also provided for some items.
Daewoo doosan solar 015 plus s018 vt mini crawler excavator parts catalogue ...fjjskedmmemm
This document provides a parts list and diagrams for various engine components of a Solar 015PLUS / S018-VT engine. It includes over 30 figures listing over 200 individual part numbers, descriptions, quantities and other specifications for components such as the cylinder block, oil pan, cylinder head, crankshaft, timing parts, fuel supply parts, fuel injection pump, nozzles, and fuel filter.
Daewoo doosan solar 015 mini crawler excavator parts catalogue manualfjjskedmmemm
This document contains 18 figures describing parts related to an engine. Each figure includes a diagram, part numbers, descriptions and quantities of components. Key information includes cylinders, pistons, crankshaft, camshaft, oil pan, filters and various gaskets and seals. Replacement part numbers are provided for some items.
Daewoo doosan solar 010 mini crawler excavator parts catalogue manual (sn 200...fjjskedmmemm
The document provides a list of parts for various components of a solar engine, including the cylinder block, timing gear housing, flywheel housing, cylinder head, suction manifold, and camshaft. It includes the part numbers, descriptions, quantities, and other identifying information for 25 different parts per component. The parts are for a Solar 010 engine with a serial number starting with 20001 or higher.
Daewoo doosan solar 010 mini crawler excavator parts catalogue manualfjjskedmmemm
This document contains diagrams and part numbers for various engine components of a cylinder block, including:
- The cylinder block assembly and individual parts like the cylinder block, cylinder head, bolts, gaskets, etc.
- A timing gear housing showing related parts like the gear case cover, seals, pipes, bolts, and fuel pump assembly.
- A flywheel housing and oil pump diagramming the housing, pins, bolts, oil seal case, and sump assembly.
- A cylinder head and cover labeling the head assembly, valves, springs, rocker arms, bonnet assembly, filler cap, and more.
Daewoo doosan mt41 moxy articulated dump truck parts catalogue manualfjjskedmmemm
This document contains parts lists and diagrams for various engine components of an MT36/41 engine with serial numbers 810001-810108. It includes lists and diagrams for the cylinder head, rocker cover, cylinder block, flywheel housing, oil sump, front casing, crankcase ventilation, crank mechanism, piston, timing gear, and oil pump. The parts are identified by key number, part number, description, and quantity.
Daewoo doosan mt40 b moxy articulated dump truck parts catalogue manualfjjskedmmemm
This document contains parts listings and diagrams for various engine components of an MT40B engine with serial numbers 513001-513140. It includes lists and diagrams for the cylinder head, rocker cover, cylinder block, timing gear housing, flywheel housing, oil sump, crankcase ventilation, and crank mechanism. Each section lists the part numbers, descriptions, and quantities of components.
Daewoo doosan mt36 moxy articulated dump truck parts catalogue manual sn 41...fjjskedmmemm
This document provides parts information for the cylinder head, rocker cover, cylinder block, flywheel housing, oil sump, crankcase ventilation, housing, crank mechanism, piston, and timing gear of an MT36 engine with serial numbers 410001-410309. It includes diagrams of each assembly or component along with a table listing part numbers, descriptions, quantities, and other identifying information for each numbered part.
Daewoo doosan mt36 moxy articulated dump truck parts catalogue manualfjjskedmmemm
This document contains parts lists and diagrams for various engine components of an MT36/41 engine with serial numbers 810001-810108. It includes lists and diagrams for the cylinder head, rocker cover, cylinder block, flywheel housing, oil sump, front casing, crankcase ventilation, crank mechanism, piston, timing gear, and oil pump. The parts are identified by key number, part number, description, and quantity.
Daewoo doosan mt31 moxy articulated dump truck parts catalogue manual sn 71...fjjskedmmemm
This document provides parts information for the crankcase ventilation, engine suspension, charge air pipes, cylinder head, rocker cover, cylinder block, flywheel housing, oil sump, crankshaft mechanism, and piston of an engine. It includes diagrams of these systems and lists the part numbers, descriptions, quantities, and serial number ranges for each component. The parts are identified by key number in the diagrams and parts lists.
Daewoo doosan mt31 moxy articulated dump truck parts catalogue manual sn 71...fjjskedmmemm
This document provides an exploded diagram and parts list for the engine suspension of a marine diesel engine. It includes over 320 individual part numbers, descriptions, quantities, and other identifying information for components of the engine block, cylinder head, valve train, crankshaft, pistons, bearings, and other internal engine parts. The parts list is organized into 18 sections covering the major engine assemblies and sub-assemblies.
Daewoo doosan mt26 moxy articulated dump truck parts catalogue manual sn 71...fjjskedmmemm
This document provides parts information for the crankcase ventilation, engine suspension, charge air pipes, cylinder head, rocker cover, cylinder block, flywheel housing, oil sump, crankshaft mechanism, and piston of an engine. It includes diagrams of these systems and lists the part numbers, descriptions, quantities, and serial number ranges for each component. The parts are identified by key number in the diagrams and parts lists.
Daewoo doosan mt26 moxy articulated dump truck parts catalogue manual sn 71...fjjskedmmemm
This document provides an exploded diagram and parts list for the engine suspension of a marine diesel engine. It includes over 320 individual part numbers, descriptions, quantities, and other identifying information for components of the engine block, cylinder head, valve train, crankshaft, pistons, bearings, and other internal engine parts. The parts list is organized into 18 sections covering the major engine assemblies and sub-assemblies.
Daewoo doosan mt25 moxy articulated dump truck parts catalogue manual sn 71...fjjskedmmemm
This document provides parts information for the crankcase ventilation, engine suspension, charge air pipes, cylinder head, rocker cover, cylinder block, flywheel housing, oil sump, crankshaft mechanism, and piston of an engine. It includes diagrams of these systems and lists the part numbers, descriptions, quantities, and serial number ranges for each component. The parts are identified by key number in the diagrams and parts lists.
Daewoo doosan mt25 moxy articulated dump truck parts catalogue manual sn 71...fjjskedmmemm
This document provides a parts list for engine suspension components for a MT25/26/31 engine with serial numbers between 710001-710654. It includes 3 pages listing over 300 individual part numbers, descriptions, quantities, and other identifying information for components related to the engine suspension, pipes for charge air, cylinder head, rocker cover, cylinder block, timing gear housing, flywheel housing, and crank mechanism.
Daewoo doosan mega 300 v 300 v wheel loader parts catalogue manual (sn 3001-)fjjskedmmemm
This document provides a parts list and exploded diagram for the frame of a MEGA 300-V machine (serial numbers 3001 and up). It lists 46 parts that make up the frame including the rear frame, front frame, caps, bolts, bearings, shims, pins, seals, plates, and cylinders. Serial numbers and replacement part numbers are provided for parts that have changed over time.
Daewoo doosan mega 300 v 300 v wheel loader parts catalogue manual (sn 2001-)fjjskedmmemm
This document provides a parts list for a MEGA 300-V machine, including the frame, engine mounting, air cleaner, oil tank, and fuel tank assemblies. It lists over 50 individual parts that make up these assemblies, including descriptions, part numbers, quantities, and replacement part information. The parts listed include frames, brackets, hoses, filters, seals, bolts, and other structural and functional components of the machine. Serial number ranges are provided to indicate applicable part number revisions over time.
Daewoo doosan mega 300 v 300 v wheel loader parts catalogue manual (sn 1001-)fjjskedmmemm
This document provides a parts list and diagram for the frame of a MEGA 300-V machine. It lists 26 different frame parts in the diagram and key, including various rear and front frame parts that have changed part numbers over different serial number ranges. Fasteners like bolts, nuts, washers that are used on the frame are also detailed.
Daewoo doosan mega 250 v 250 v wheel loader parts catalogue manual (sn 4001 a...fjjskedmmemm
This document provides a parts list and diagram for the cylinder head of a MEGA 250-V engine. It includes 20 key items that make up the cylinder head assembly, their part numbers, descriptions, and quantities. Serial numbers and replacement part numbers are also provided for some items. The diagram labels each part and its corresponding key number.
Daewoo doosan mega 250 v 250 v wheel loader parts catalogue manual (sn 3001-)fjjskedmmemm
This document provides a parts list and specifications for components related to the cylinder block, crank shaft, piston, and cylinder head of a MEGA 250-V engine. It includes the part numbers, descriptions, quantities, serial numbers, and whether parts are replaceable for over 50 individual components. The highest level assemblies listed are the cylinder block assembly, crankshaft assembly, piston assembly, and cylinder head assembly.
Daewoo doosan mega 250 v 250 v wheel loader parts catalogue manualfjjskedmmemm
The document provides a parts list and diagrams for components of an engine, including the cylinder block, timing gear case, flywheel housing, crank shaft, piston, and cylinder head. It lists part numbers, descriptions, quantities, serial numbers and other specifications for each component part. Replacement part numbers are also provided for some items.
Ever been troubled by the blinking sign and didn’t know what to do?
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Fleet management these days is next to impossible without connected vehicle solutions. Why? Well, fleet trackers and accompanying connected vehicle management solutions tend to offer quite a few hard-to-ignore benefits to fleet managers and businesses alike. Let’s check them out!
The Octavia range embodies the design trend of the Škoda brand: a fusion of
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Implementing ELDs or Electronic Logging Devices is slowly but surely becoming the norm in fleet management. Why? Well, integrating ELDs and associated connected vehicle solutions like fleet tracking devices lets businesses and their in-house fleet managers reap several benefits. Check out the post below to learn more.
What Could Be Behind Your Mercedes Sprinter's Power Loss on Uphill RoadsSprinter Gurus
Unlock the secrets behind your Mercedes Sprinter's uphill power loss with our comprehensive presentation. From fuel filter blockages to turbocharger troubles, we uncover the culprits and empower you to reclaim your vehicle's peak performance. Conquer every ascent with confidence and ensure a thrilling journey every time.
2. 15 - Engine
12 - Crankshaft
00 - General
15 - 61 9813/4800-3 15 - 61
Component Identification
Figure 152.
A
B
A Crankshaft
B Crankcase
3. 15 - Engine
12 - Crankshaft
00 - General
15 - 62 9813/4800-3 15 - 62
Operation
Refer to Camshaft - Introduction. Refer to: PIL
15-15-00.
Lubrication
Oil is fed from the main gallery via seven drillings,
one to each of the main bearings. A groove around
the diameter of the upper main bearing shell allows
oil transfer to cross drillings in the crankshaft to feed
each of the big end bearings. Crankshaft gear is
'splash' lubricated. Front and rear crankshaft oil seals
prevent oil leakage from, and dirt ingress to, the
engine.
Figure 153.
222
2222
2
2
2
2
2
1
5
5
5
5
5
2
7
6
2
5
3
4
3
4
3
4
3
4
3
4
3
4
3
4
3
4
3
4
3
3
4
3
4
3
4
3
1 Main gallery 2 Drillings (x7)
3 Main bearings 4 Big end bearings
5 Cross drillings 6 Crankshaft gear
7 Crankshaft oil seal
4. 15 - Engine
12 - Crankshaft
00 - General
15 - 63 9813/4800-3 15 - 63
Check (Condition)
1. Check the main bearing surfaces for damage and
excessive wear.
Figure 154.
A
A Main bearing shells
2. Measure the crankshaft diameters to confirm
they are within service limits, refer to Technical
Data (PIL 15-12).
Figure 155.
A
B Crankshaft
3. Check that the oil-way cross drillings in the
crankshaft are clear and free from debris.
Blocked or restricted oil-ways will cause oil
starvation at the big end bearings.
4. Check that the piston cooling J-jets are clear. If
the J-jets cannot be cleared remove the fixing
screws. Remove the J-jets and discard them.
5. Install new J-jets.
Figure 156.
D
C
C J-jets
D Fixing screws
5. 15 - Engine
12 - Crankshaft
00 - General
15 - 64 9813/4800-3 15 - 64
Remove and Install
Consumables
Description Part No. Size
Cleaner/Degreaser
- General purpose
solvent based parts
cleaner
4104/1557 0.4L
CAUTION This component is heavy. It must only
be removed or handled using a suitable lifting
method and device.
Before Removal
1. This procedure requires service parts. Make
sure you have obtained the correct service parts
before you start, refer to Parts Catalogue.
2. Make sure that the engine is safe to work on. If
the engine has been running, let it cool before
you start the service work.
3. Remove the engine, refer to (PIL 15-00).
4. Remove the drive belt, refer to (PIL 15-18).
5. Remove the crankshaft pulley, refer to (PIL
15-12).
6. Remove the oil sump, refer to (PIL 15-45).
7. Disconnect and remove the fuel pipes from the
injectors, refer to (PIL 18-96).
8. Remove the rocker cover, refer to (PIL 15-42).
9. Remove the fuel injectors, refer to (PIL 18-18).
10. Remove the rocker assembly including the push
rods, refer to (PIL 15-42).
11. It is not necessary to remove the cylinder head
assembly to remove the crankshaft. If however
the cylinder head needs to be removed for other
reasons (for piston and connecting rod removal
for example) remove it now, refer to (PIL 15-06).
12. Remove the fuel injection pump, refer to (PIL
18-18).
13. Remove the starter motor, refer to (PIL 15-75).
14. Remove the high duty PTO device (if installed).
15. Position the engine upside down in a suitable jig
or fixture, supported at the front of the cylinder
block.
16. Remove the flywheel, refer to (PIL 15-54).
17. Remove the flywheel housing, refer to (PIL
15-54).
18. Remove the fuel injection pump drive gear, refer
to (PIL 15-51).
19. Remove the oil pump, refer to (PIL 15-60).
20. Remove the high duty PTO idler drive gear (if
installed), refer to (PIL 15-51).
21. Remove the crankshaft drive gear, refer to (PIL
15-51).
22. Remove the camshaft, refer to (PIL 15-15).
23. Remove the rear timing case, refer to (PIL
15-51).
24. If the pistons and connecting rods have not been
removed, undo and remove the main bearing
caps, refer to (PIL 15-12).
25. Remove the bedplate, refer to (PIL 15-09).
Remove
1. Remove the thrust washers between the
crankshaft and crankcase rear main bearing.
Figure 157.
B
A
C
A
A Thrust Washers
B Crankshaft
C Rear main bearing
2. Put labels on the thrust washers to make sure
that they are installed in the correct positions
during assembly.
3. Use suitable lifting equipment to carefully lift the
crankshaft from the crankcase (if the crankshaft
is lifted manually, two people will be required).
4. Carefully lift out the bearing shells.
6. 15 - Engine
12 - Crankshaft
00 - General
15 - 65 9813/4800-3 15 - 65
Figure 158.
A
A Main bearing shells
5. It is recommended that the bearing shells are
replaced. If however they are to be used again,
put label on the shells to make sure that they
are installed in their original positions during
assembly.
6. Inspect the crankshaft and main bearings etc.
for damage and excessive wear. Refer to Check
Condition (PIL 15-12).
Before Installation
1. Clean off all traces of the old sealant compound
from the crankcase and bedplate mating faces.
2. Use a suitable degreasing agent to carefully
clean the main bearing saddles in the bedplate
and crankcase. Take care not to block the oil
ways or the piston cooling jets.
Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner
Important: Cleanliness is of the utmost importance.
Blocked oil-ways or oil jets will cause engine failure.
Before you install the crankshaft make sure that ALL
oil-ways and jets are clear and free from debris.
Install
1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
steps.
2. Make sure that all items are clean and free from
damage and corrosion.
3. If removed or a new crankcase is being installed
then install cooling J jets as follows:
Figure 159.
D
C
C J jets (x4)
D Fixing screws
3.1. Insert the cooling jets into the crankcase.
3.2. Note: There are different types of cooling
jets installed depending on the engine
application. The jets are colour coded.
3.3. Be sure to install the correct jets. Refer to
the relevant parts catalogue for the correct
cooling jet identification.
3.4. Tighten the retaining screws to the correct
torque value.
4. Install the upper bearing shells as follows:
4.1. Use a suitable degreasing agent to make
sure that the surface of the upper bearing
shells are clean.
Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner
4.2. Assemble the bearing shells into the
crankcase bearing saddles. Make sure that
the location tab engages into the slot as
shown.
4.3. Important: Make sure that the oil-way holes
in the bearing saddles align with the holes
in the bearing shell. If the holes are even
partially misaligned the piston cooling oil jet
will be restricted, causing the engine to fail.
4.4. Lubricate the upper bearing shells with
clean engine oil.
5. Use suitable lifting equipment (if the crankshaft
is lifted manually, two people will be required), to
carefully lower the crankshaft into the crankcase.
DO NOT rotate the crankshaft, the bearing shells
can become dislodged, refer to step 4.
6. Install the thrust washers as follows:
7. 15 - Engine
12 - Crankshaft
00 - General
15 - 66 9813/4800-3 15 - 66
Figure 160.
B
A
C
A A
H
A Thrust washers
B Crankshaft
C Rear main bearing
H Oil slot - thrust washers
6.1. Slide the thrust washers between the
crankshaft and the crankcase rear main
bearing.
6.2. Make sure that they are installed in the
correct positions, with the two slots facing
outwards from the bearing saddle.
6.3. If necessary, push the crankshaft forward
and then backwards to obtain clearance to
install the thrust washers.
6.4. DO NOT rotate the crankshaft, the bearing
shells can become dislodged, refer to step
4.
7. Check that the crankshaft end float is within
service limits, refer to Technical Data (PIL 15-12).
Table 62. Torque Values
Item Nm
F 24
8. 15 - Engine
12 - Crankshaft
03 - Main Bearing
15 - 67 9813/4800-3 15 - 67
03 - Main Bearing
Introduction .................................................... 15-67
Check (Condition) .......................................... 15-68
Remove and Install ....................................... 15-68
Introduction
In a piston engine, the main bearings are the
bearings on which the crankshaft rotates.
The bearings hold the crankshaft in place and
prevent the forces created by the piston and
transmitted to the crankshaft by the connecting rods
from dislodging the crankshaft, instead forcing the
crank to convert the reciprocating movement into
rotation.
Figure 161.
A
B
A Main bearing
B Crankshaft
9. 15 - Engine
12 - Crankshaft
03 - Main Bearing
15 - 68 9813/4800-3 15 - 68
Check (Condition)
1. Check the bearing shell surfaces for signs of
damage and excessive wear.
2. Measure the crank pin diameters to confirm they
are within service limits.
Refer to: PIL 15-12-00.
3. Renew any parts that are worn or not within the
specified tolerances.
Remove and Install
Refer to: PIL 15-12-00.
10. 15 - Engine
12 - Crankshaft
06 - Front Oil Seal
15 - 69 9813/4800-3 15 - 69
06 - Front Oil Seal
Remove and Install
Special Tools
Description Part No. Qty.
Crankshaft Front Oil
Seal Installation Tool
892/01157 1
Before Removal
1. This procedure requires service parts. Make
sure you have obtained the correct service parts
before you start, refer to Parts Catalogue.
2. Make sure that the engine is safe to work on. If
the engine has been running, let it cool before
you start the service work.
3. Get access to the engine.
4. Remove the drive belt, refer to (PIL 15-18).
5. Remove the crankshaft pulley, refer to (PIL
15-12-12).
Remove
1. Use a suitable lever behind the lip of the
seal, carefully prise out the oil seal from the
counterbore in the crankcase. Take care not
to scratch or damage the counterbore or the
crankshaft hub. Damaged or dirty sealing faces
will cause the oil seal to fail.
Figure 162.
C
A
B
A Crankshaft oil seal
B Crankcase
C Crankshaft hub
Install
1. Make sure that the counterbore and the
crankshaft hub are clean and free from damage
and corrosion. Use a suitable degreasing agent
to clean all traces of oil and grease from the
counterbore. Important: The oil seal has a special
coating and MUST be installed dry without
lubricant.
2. Dismantle the seal installation tool. Bolt the
centre body to the crankshaft hub, using the
bolts. Refer to Figure 163.
Special Tool: Crankshaft Front Oil Seal
Installation Tool (Qty.: 1)
3. Install the oil seal on to the centre body. Make
sure that the seal is installed the correct way
around. Assemble the outer sleeve on to the
centre body and install the screw. Refer to Figure
163.
11. 15 - Engine
12 - Crankshaft
06 - Front Oil Seal
15 - 70 9813/4800-3 15 - 70
Figure 163.
F D
G
H
B
G
F
C
A
E
A Crankshaft oil seal B Crankcase
C Crankshaft hub D Seal installation tool
E Fixing bolts (x3) F Centre body
G Outer sleeve H Screw
4. Turn the screw to push the seal squarely into
the counterbore until the outer sleeve comes
up against the front edge of the counterbore.
When correctly installed, the front face of the seal
should be flush with the edge of the counterbore
within the specified tolerance. Refer to Figure
164.
Dimension: -0.5 -0/+0.5mm
Figure 164.
B
G
F
C
A
A Crankshaft oil seal
B Crankcase
C Crankshaft hub
F Centre body
G Outer sleeve
5. Remove the seal installation tool.
12. 15 - Engine
12 - Crankshaft
06 - Front Oil Seal
15 - 71 9813/4800-3 15 - 71
After Installation
1. Install the crankshaft pulley, refer to (PIL
15-12-12).
2. Install the drive belt, refer to (PIL 15-18).
13. 15 - Engine
12 - Crankshaft
09 - Rear Oil Seal
15 - 72 9813/4800-3 15 - 72
09 - Rear Oil Seal
Remove and Install
Special Tools
Description Part No. Qty.
Crankshaft Rear Oil
Seal Installation Tool
892/01156 1
Crankshaft Rear Oil
Seal Alignment Tool
892/01158 1
Note: The flywheel hub and crankshaft rear oil seal
need to be replaced as a pair.
Before Removal
1. This procedure requires service parts. Make
sure you have obtained the correct service parts
before you start, refer to Parts Catalogue.
2. Make sure that the engine is safe to work on. If
the engine has been running, let it cool before
you start the service work.
3. Get access to the engine.
4. Remove the flywheel, refer to (PIL 15-54).
Remove
1. Use a suitable lever behind the lip of the seal
to carefully prise out the rear oil seal from the
counterbore in the flywheel housing. Take care
not to scratch or damage the counterbore or the
flywheel hub. Damaged or dirty sealing faces will
cause the oil seal to fail.
Figure 165. 24mm Hub
A
C B
A Crankshaft rear oil seal
B Flywheel housing
C Flywheel hub
Figure 166. 15mm Hub
A
C E
B
A Crankshaft rear oil seal
B Flywheel housing
C Flywheel hub
E Fixing bolt
Install (24mm Hub)
1. Make sure that the counterbore and the flywheel
hub are clean and free from damage and
corrosion.
14. 15 - Engine
12 - Crankshaft
09 - Rear Oil Seal
15 - 73 9813/4800-3 15 - 73
Figure 167.
B
A
D
D
C
A Crankshaft rear oil seal B Flywheel housing
C Flywheel hub D Oil seal alignment tool
2. To prevent the seal lip rolling over and becoming
damaged, make sure that you use the oil seal
alignment tool to initially install the oil seal on to
the flywheel hub. Locate the alignment tool over
the end of the hub, then carefully push the oil seal
over the alignment tool and on to the crankshaft
diameter. Make sure that the oil seal is installed
the correct way around.
Special Tool: Crankshaft Rear Oil Seal
Installation Tool (Qty.: 1)
Special Tool: Crankshaft Rear Oil Seal Alignment
Tool (Qty.: 1)
3. Apply lubricant P80 around the seal outer rubber
diameter.
4. Dismantle the oil seal installation tool. Bolt the
centre body to the flywheel hub, using the two
flywheel bolts. Assemble the outer sleeve on to
the centre body and install the screw.
Figure 168.
A
B
C
F
E
F
H
G
J
H
G
A Crankshaft rear oil seal B Flywheel housing
C Outer sleeve E Oil seal installation tool
F Flywheel bolts G Centre body
H Flywheel hub J Screw
5. Turn the screw to push the seal squarely into
the counterbore until the outer sleeve comes
up against the front edge of the counterbore.
When correctly installed, the front face of the seal
should be flush with the edge of the counterbore
within the tolerance specified.
Length/Dimension/Distance: 0.5mm
6. Remove the oil seal installation tool.
Install (15mm Hub)
1. Make sure that the counterbore and the hub are
clean and free from damage.
15. 15 - Engine
12 - Crankshaft
09 - Rear Oil Seal
15 - 74 9813/4800-3 15 - 74
Figure 169.
B
A
D
D
C
A Crankshaft rear oil seal B Flywheel housing
C Flywheel hub D Oil seal alignment tool
2. Install the new hub on to the crankshaft gear and
install the old hub on the outside of the new hub
to create a double thickness flywheel hub, install
the fixing bolt as shown at A. Do not touch the
PTFE seal lips of the crankshaft oil seal.
3. Make sure that you use the oil seal alignment tool
to initially install the oil seal on to the flywheel
hub to prevent damage to the seal lip. Locate the
alignment tool over the end of the hub, carefully
push the oil seal over the alignment tool as far
on to the crankshaft hub as possible. Make sure
that the seal is installed the correct way around.
Special Tool: Crankshaft Rear Oil Seal
Installation Tool (Qty.: 1)
Special Tool: Crankshaft Rear Oil Seal Alignment
Tool (Qty.: 1)
4. Apply the lubricant P80 around the seal outer
rubber diameter.
5. Dismantle the oil seal installation tool. Use the
two flywheel bolts to attach the centre body on to
the flywheel hub. Assemble the outer sleeve on
to the centre body include the extension ring and
install the screw.
Figure 170.
A
B
C1 C2
F
G
H
J
K
L
K
J
A Crankshaft rear oil seal B Flywheel housing
C1 New hub C2 Old hub
F Flywheel bolts G Oil seal installation tool
H Extension ring J Centre body
K Outer sleeve L Screw
6. Turn the screw to push the seal into position in
the counterbore so that the screw will not turn.
16. 15 - Engine
12 - Crankshaft
09 - Rear Oil Seal
15 - 75 9813/4800-3 15 - 75
7. Remove the oil seal installation tool, remove the
old hub and install the fixing bolt. Repeat steps 5
and 6 to fully install the rear oil seal.
8. Remove the oil seal installation tool.
After Installation
1. Install the flywheel, refer to (PIL 15-54).
Table 63. Torque Values
Item Nm
E 47
17. 15 - Engine
12 - Crankshaft
12 - Pulley
15 - 76 9813/4800-3 15 - 76
12 - Pulley
Remove and Install
Special Tools
Description Part No. Qty.
Torque Wrench
(10-100Nm)
993/70111 1
Before Removal
1. This procedure requires service parts. Make
sure you have obtained the correct service parts
before you start, refer to Parts Catalogue.
2. Make sure that the engine is safe to work on. If
the engine has been running, let it cool before
you start the service work.
3. Get access to the engine.
4. Remove the drive belt. Refer to (PIL 15-18).
Remove
1. Remove the fixing bolts and withdraw the pulley
from the crankshaft.
Figure 171.
A
B
A
A Crankshaft pulley
B Fixing bolts (x3)
2. The bolts must not be reused. Discard the bolts.
Install
1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
steps.
2. Make sure that all items are clean and free from
damage and corrosion.
3. Renew the fixing bolts. Tighten the new bolts in
three stages to the correct torque value.
Special Tool: Torque Wrench (10-100Nm) (Qty.:
1)
4. The bolts are tightened using a torque and
angle method. Refer to Fasteners and Fixings,
General, Introduction (PIL 72-00).
Figure 172.
C
C Angle gauge (obtain locally)
After Replacement
1. Install the drive belt. Refer to (PIL 15-18).
Table 64.
Item Torque Value
(Nm)
Torque Angle
(Degrees)
2 (1st stage) 30N·m
2 (2nd stage) 75N·m
2 (Final stage) 180°
18. 15 - Engine
15 - Camshaft
00 - General
15 - 85 9813/4800-3 15 - 85
Remove and Install
Before Removal
1. Drain the oil from the engine. Refer to (PIL
15-21-00).
2. Disconnect and remove the fuel pipes from the
injectors. Refer to (PIL 18-96-03).
3. Remove the rocker cover. Refer to (PIL
15-42-06).
4. Remove the fuel injection pump.
5. Remove the rocker assembly and push rods.
6. Remove the starter motor. Refer to (PIL
15-75-00).
7. Remove the oil sump. Refer to (PIL 15-45-00).
8. Remove the flywheel. Refer to (PIL 15-54-00).
9. Remove the flywheel housing. Refer to (PIL
15-54-03).
10. Rotate the crankshaft until the camshaft timing
pin can be inserted through the gear and into the
aligning hole in the rear gear case.
Figure 175.
A
A Timing pin - camshaft
11. Remove the taper blanking plug and insert
the crankshaft locking pin. The camshaft and
crankshaft locking pins must be in position to lock
the crankshaft and camshaft before removing the
camshaft assembly.
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20. 15 - Engine
15 - Camshaft
00 - General
15 - 86 9813/4800-3 15 - 86
Figure 176.
C
B
B Timing pin - crankshaft
C Blanking plug
12. Remove the fuel injection pump drive gear. Refer
to (PIL 15-51-09).
Remove
The engine must be inverted. DO NOT attempt
to remove the camshaft and its drive gears with
the engine upright. The tappets and push rods will
fall into the engine and further dismantling will be
required to retrieve them.
1. Remove the camshaft timing pin.
2. Carefully withdraw the camshaft and gear
assembly from the crankcase. Make sure you
fully support the camshaft to prevent the lobes
contacting the bearing surfaces in the crankcase.
The bearing surfaces can easily be damaged by
the sharp hard edges on the cam lobes.
Figure 177.
A
DD
A
A Timing pin - camshaft D Camshaft and drive gear
3. Access the tappets through the apertures in
the crankcase bedplate next to the crankshaft.
Lift out the tappets from the crankcase using a
suitable magnetic probe. Label the tappets for
replacement in their original positions.
21. 15 - Engine
15 - Camshaft
00 - General
15 - 87 9813/4800-3 15 - 87
Figure 178.
E
F
E
E Tappet (8 off)
F Magnetic probe
Inspection
1. Refer to Camshaft- Check Condition (PIL 15-15).
Install
1. Lubricate the tappets and tappet bores inside the
crankcase with clean engine oil.
2. Insert the tappets in their original positions in the
crankcase using a suitable magnetic probe.
3. Lubricate the camshaft bearing journals inside
the crankcase with clean engine oil.
4. Carefully insert the camshaft assembly into the
crankcase as shown. Support the camshaft
preventing the lobes contacting the bearing
surfaces in the crankcase. Before meshing the
camshaft gear with the crankshaft gear, rotate
the camshaft until the timing hole in the gear
aligns with the dowel hole in the gear case. Insert
the timing pin T1 to lock the camshaft in this
position.
After Installation
1. The after installation procedure is the opposite
of the before removal procedure. Additionally do
the following step.
2. Note that the fuel injection pump drive gear
fixing nut is torque tightened as part of the fuel
injection pump replacement procedure. Refer to
(PIL 18-18-15).