DIESEL ENGINE

4CTi90-1BE6 ... 4CTi90-1BE ...

EURO 3 (66 kW) EURO 3 (75 kW)

SERVICE MANUAL

A/4CTi90-1BE/I/c - EURO 3

1.9.9260

Issue date: February 2002 Revision date: December 2005

ANDORIA-Mot Sp. z o.o. ul. Krakowska 140, 34-120 ANDRYCHW tel.: +48 33 876 27 24 fax: +48 33 875 35 60 http://www.andoria-mot.com.pl, e-mail: sales@andoria-mot.com.pl

Contents Page Precautions during operation and servicing 1. Introduction and technical data 1.1. Technical data 1.2. Engine structure description of major elements 1.3. Wiring diagram 1.4. Tightening torque of the main screw connections 1.5. Operating materials (fuel, oil) 2. Engine operation 2.1. Preparation for first start-up of the engine in the vehicle 2.2. Start-up of the engine in the vehicle 2.3. Running-in 2.4. Stopping the engine 3. Engine servicing 3.1. Table of routine maintenance operations 3.2. Basic servicing operations 3.3. Description of routine maintenance operations 4. Troubleshooting 1 5 6 8 9 10 11 12 12 12 13 13 14 14 15 15 22 5. Storage and preservation after taking the engine out of service for longer period 5.1. Storage of a new engine 5.2. Engine preservation for longer standstill

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Service Manual 4CTi90-1BE - Euro 3

Precautions during operation and servicing

! Daily checks Let the daily checking of engine and engine compartment before operation (start up) and after operation (stopping) become your habit. It will help you to detect fuel, coolant and oil leaks quickly and to locate any abnormal things, which just happened or are going to happen.

Servicing and operation

Stop the engine Before opening or removing engine covers, stop the engine. If otherwise not specified, all operation and servicing operations must be performed with engine immobilized. To avoid accidental engine start up, before beginning any works on engine remove ignition key. At the engine control location, place warning sign that works are performed on the engine. Approaching or performing works on running engine is dangerous. Loose clothing, hair, fingers or dropped tools may catch rotating engine components and cause serious personal injury. Lifting the engine When lifting the engine use lifting eyes fitted on it. Always make sure that lifting equipment is in good condition and of sufficient lifting capacity (engine weight plus all accessories). Never perform any works on engine hanging on lift. Before starting the engine Before starting the engine refit all the covers removed during servicing operations. Check if no tools or other objects are left on the engine. Never start up turbocharged engine without air filter installed. Rotating compressor in turbocharger may cause serious personal injuries. Also foreign objects may be sucked in and cause mechanical engine damage.

Refueling There is a danger of fire or explosion during refueling. Smoking is prohibited, and engine must be shut down. Never overfill the fuel tank. Retighten fuel tank filler tank well. Use only fuels recommended in this manual. Improper fuel grade may cause operation problems or cause engine stopping. On diesel engines, poor fuel quality may cause injection pump control rod sizing and engine overrunning, what in turn may cause engine damage and personal injury. Carbon monoxide poisoning Run the engine only in well ventilated areas. When the engine works in closed space, make sure there is sufficient ventilation to remove exhaust gases and crankcase vapors out of the work area. Operation The engine can not operate in areas where explosive materials or gases are present. Not all the electrical and mechanical engine components are non-sparking. Approaching the running engine is dangerous. Loose clothing, hair, fingers or dropped tools may catch rotating engine components and cause serious personal injury. After installing the engine, all rotating and hot engine components must be protected.
! !

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Service manual - 4CTi90-1BE - Euro 3

Fire and explosion Fuels and lubrication oils All the fuels, most of lubrication oils and many chemicals are flammable. Read instructions on packaging and follow them.
!

Lubrication system Hot oil may cause burning. Avoid skin contact with hot oils. Before commencing work on lubrication system, make sure it is not under pressure. Never start up or run the engine with oil filler cap open because oil may be spread out.
! Cooling system Avoid opening radiator cap when engine is hot. Steam or hot coolant may be spread out causing burning.

When working on fuel system, make sure the engine is cold. Fuel spilled on hot surface or electrical components may cause fire. Do not smoke during refueling or adding oil, near fuel station or engine house.

Batteries Batteries contain and educe hydroxide gas, especially during charging. This gas is inflammable and very flammable. Do not smoke, do not use open flame and do not allow any sparking near the batteries or in battery compartment, under no circumstances. Incorrect cable connection to battery clamps or jumper cables to external batteries may cause sparking, what in turn may cause explosion.
! Hot surfaces and fluids There is always a threat of burning when working on hot engine. Be careful with hot surfaces, e.g. exhaust pipes, turbocharger, oil pan, charge air pipes, hot coolant and hot oil in oil pipes and hoses.

If the works must be performed on engine at operating temperature and with radiator cap open, or hose disconnected, then unscrew radiator cap carefully and slowly to release the pressure before removing the cap. Note that still coolant may be hot and cause burning.
! Fuel injection system

Always wear protective gloves when seeking leaks. Fluids ejected under pressure may puncture body tissues and cause serious personal injuries. There is a threat of blood poisoning.

! Electrical system

! Chemicals

Power supply breaking Always before commencing works on electrical system, stop the engine and cut off power supply. Batteries Batteries contain extremely corrosive electrolyte. Protect skin and clothing when charging or servicing batteries. Always wear protective goggles and gloves. In case of contact of uncover skin with electrolyte immediately wash the skin with plenty of water with soap. If electrolyte comes into eye, immediately wash eyes with plenty of water and right away get medical aid.

Most of chemicals, as antifreeze, anticorrosion agents, preservation oil, degreasing agents, etc. are hazardous for health. Read recommendations on packaging and follow them. Some chemicals, such as preservation oils, are flammable and dangerous when inhaled. Ensure good ventilation and use protective masks when applying by spraying. Read instructions on packaging and follow them.

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Service manual - 4CTi90-1BE - Euro 3

4CTi90-1BE6 engine - EURO 3 of 66 kW and 4CTi90-1BE engine - EURO 3 (meet R49.03 requirements without EGR system)
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Service manual - 4CT90-1BE - EURO 3

of 75 kW

4CTi90-1BE6 engine - EURO 3 of 66 kW and 4CTi90-1BE engine - EURO 3 (meet R 83.05 ECE requirements with EGR system)

of 75 kW

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Service manual - 4CTi90-1BE - Euro 3

1. INTRODUCTION AND TECHNICAL DATA

4CTi90-1BE6 ... (66 kW) and 4CTi90-1BE ... (75 kW) engines (with Bosch injection equipment) meet the requirements of Euro 3 standard (R49.03 without EGR and R83.05 - with EGR system) in a vehicle with charged air cooler installed.

The engines are mainly designed for delivery vehicles of total weight up to 3.5 tons, off-road vehicles and big passenger cars. They can be used for mobile machinery, generating sets, small boats and hydraulic power systems. It is necessary to obey the engine service manual. In a case of operating non-consistently with this manual the customer will lose his rights for the warranty.

The difference of performance parameters between 4CTi90-1BE6 ... (66 kW) and 4CTi90-1BE ... (75 kW) engines results only from the settings of injection pump.
Design of these engines has been based on the experience gained during long-term production and operation of 4C90 and 4CT90-1 engines.
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Service manual - 4CTi90-1BE - Euro 3

Note: Andoria-Mot reserves the rights to introduce design and process modification without previous notification of Customers.

1.1. Technical data

Engine type Engine kind Fuel injection Number and arrangement of cylinders Cylinder diameter Piston stroke Displacement Compression ratio Rated power after complete run-in (operational) Rated speed Peak torque after complete run-in (operational) Peak torque speed Minimum idle speed Specific fuel consumption after complete runin (operational) Crankshaft rotation Power take-off Timing gear system Engine starting Engine oil consumption after complete run-in (operational) 4CTi90-1BE6 (66 kW) 4CTi90-1BE (75 kW)

diesel, four stroke, turbocharged with charged air cooler (intercooler) indirect into swirl chamber 4, vertical 90 mm 95 mm 2417 cm3 20.6 66 kW according to ISO 1585 4100 RPM 205 Nm according to ISO 1585 2000 - 2500 RPM 800 RPM 270 g/kWh according to ISO 1585 255 g/kWh according to ISO 1585 230 Nm according to ISO 1585 75 kW according to ISO 1585

counterclockwise (seen from the flywheel side) from the flywheel through the clutch overhead valves with overhead camshaft electrical, assisted with glow plugs max. 0.033 kg/h

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Service manual - 4CTi90-1BE - Euro 3

Engine type Engine oil pressure with warm engine (within 1500 - 4100 RPM) Engine oil pressure with warm engine at minimum idle speed Maximum permissible oil temperature in the oil gallery Oil capacity for oil change ("max" mark) Coolant capacity (without radiator) Maximum permissible coolant temperature in pressurized circuit (1.2 bar) Recommended optimum coolant temperature Intake and exhaust valve clearance Injection order Injection pressure Minimum injection pressure in-service Beginning of injection (static) Dry engine weight (approximate) Permissible engine inclination: - lengthwise - crosswise

4CTi90-1BE6 (66 kW) 0.25 0.50 MPa min. 0.1 MPa

4CTi90-1BE

(75 kW)

120C (momentarily 130C) about 7 dm3 6.8 dm3 105 C 80 - 90C 0.2 mm (with cold engine) 1-3-4-2 15 MPa 14 MPa 0.8 0,05 mm BTDC 230 kg 30 20

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Service manual - 4CTi90-1BE - Euro 3

1.2 Engine structure - description of major elements

linerless, cast iron with five main bearings, of which the fifth one (the one closest to the flywheel) is a thrust bearing; the crankcase is closed from the bottom with an aluminum oil pan. Main and connecting thin-wall, three-layer, replaceable rod bearing shells cast iron, inlet and exhaust ducts on one side, valve seats Cylinder head and guides are replaceable of controlled thermal expansion made of aluminum alloy Piston die-casting with a cast iron "ALFIN" insert near the upper compression ring forged of alloy steel, toughened and nitrided Crankshaft cast iron, working faces of the cams chilled in casting Camshaft process, driven by crankshaft via timing belt driven by the camshaft cams via second-order rocker Valves arms made of cast iron forged of alloy steel, toughened Connecting rod type VE4, distributor pump equipped with boost pressure Injection pump (Bosch) compensator (LDA), lubricated with fuel Injector (Bosch) with replaceable pintlenozzle bar-type, two heating coils Glow plug Cylinder block Alternator Starter motor (Bosch) Turbocharger Vacuum pump Oil pump Oil filter Oil cooler Fuel filter (Bosch ) Fan Power assisted steering pump (option) EGR valve Electric system Driven by the crankshaft via V-belt; 12V, 70A electrical, 12V; 2 kW Radial with wastegate for brake boost; sliding-vane pump driven by camshaft internal gear pump, (gerotor); located on the crankshaft front end full-flow cartridge of Modine; located in-line under the oil filter cartridge with integrated water separator and manual priming pump with viscosity clutch fixed to water pump hub for steering system assistance, driven by crankshaft via V-belt electronically controlled pneumatic valve a part of exhaust gas recirculation system 12V, "minus to ground"

1.3. Wiring diagram

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Service manual - 4CTi90-1BE - Euro 3

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

Solenoid valve Electronic control unit Coolant temperature sensor Oil pressure sensor Oil pressure control lamp Fuse 10A Battery charging control lamp Ignition switch Alternator LDA solenoid valve Starter motor Fuse 70A Glow plug controller Glow plug control lamp Glow plug control sensor Battery Glow plug Injection pump, Bosch Coolant temperature gauge Coolant temperature sensor

Notes: 1. Alternator terminal W is used to connect tachometer. 2. Alternators are with build-on voltage regulator 3. Rating of battery charging control lamp (item 7) shall be 5W Items 1, 2, 3, 10 exist only on engines with EGR system to meet the requirements of R83.05 Items: 2, 5, 6, 7, 8, 12, 14, 16 are not a part of delivery

Engine identification
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Service manual - 4CTi90-1BE - Euro 3

103583/04

Engine type (e.g.. 4CTi90-1BE) and version (e.g. A0511) are imprinted in rear side of cylinder block over the flywheel housing in two lines (see figure below) Meaning of engine designation:: 4CTi90-1 4-cylider, 4-stroke, turbocharged engine with interccooler, bore diameter 90 mm B BOSCH injection pump; or M MOTORPAL injection pump

4CTi90-1BE A0511

E meets the requirements of EURO 6 - 66 kW (or without number following letter E 75 kW /only engines with intercooler)/ A automotive application G gen-set application 0511 version (0511 destined for Lublin 3 vehicle)

1.4. Tightening torque of the main screw connections

Torque
Injector fixing nuts: Nuts fixing injection pipes to: - injection pump - injectors Glow plugs: 15 - 20 Nm 25 - 30 Nm 20 - 25 Nm 20 - 25 Nm

49B

02 808 03 827

E20

241,17

Homologation symbols are imprinted in cylinder block behind oil filter (see example above) Engine number it is imprinted at the side of cylinder block at its rear part behind injection pump, and it consists of two elements divided with slash mark (see figure at left), e.g. 103583 =sequence number, 04 = 2004 manufacture year Note: Manufacture year not imprinted on engine versions A0511 and A0513.

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Service manual - 4CTi90-1BE - Euro 3

1.5. Operating materials (fuel, oil) Diesel oil (fuel)

Diesel fuels consistent with PN-EN 590 shall be used for the engines. Three periods (summer, transition and winter) and fuel grades required for these periods are defined (according to PN-EN 590) properly to climate conditions. In Poland (temperate climate), three grades of fuels are to be used (according to PN-EN 590): B - for summer season D - for transition season F - for winter season Polski Koncern Naftowy has named its diesel fuels Ekodiesel Plus Range of use of diesel fuel: Summer season: (May 1 September 15) - Ekodiesel Plus B (of cold filter clogging temperature: 00C) Transition season: (March 16 April 30 and September 16 November 15) - Ekodiesel Plus D (of cold filter clogging temperature: -100C) Winter season: (November 16 March 15) - Ekodiesel Plus F (of cold filter clogging temperature: -200C) For arctic climate or other special applications, use diesel fuel grades: 0; 1; 2; 3; 4 (consistent with PN-EN 590) of cold filter clogging temperature: from -200 to 440C. Also the following may be used: - municipal diesel fuel ONM Standard (according to ZN-94/MPiH/NF-213), with sulfur content up to 0.02% and cold filter clogging temperature: -300C

Engine oil (lubricating oil)

Use engine oil of: a) quality grade according to API: CD or better b) viscosity grade according to SAE, appropriate to operation conditions, but not worse than: - for temperate climate: 10W/40 - for tropical climate : 20W/50 Ambient temperature [oC] -30 -20 -10

10

20

30

40

50

60

0W/60 0W/50 0W/40 5W/60 5W/50 5W/40 10W/60 10W/50 10W/40 0W/60 0W/50 5W/60 5W/50 10W/60 10W/50 15W/60 15W/50 20W/60 20W/50

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Service manual - 4CTi90-1BE - Euro 3

2. ENGINE OPERATION

2.1. Preparation for first start-up of the engine in the vehicle (after individual assembly or repair) Prior to first start-up of the engine in the vehicle: 2.1.1. Charge the battery and connect electric system according to wiring diagram. 2.1.2. Fill up the fuel tank with diesel fuel. 2.1.3. Pour in proper amount of engine oil through oil filler in the camshaft housing. (Oil level should reach the upper mark on dipstick). 2.1.4. Fill up the radiator and engine jacket with coolant to the level above min mark on surge tank installed in the vehicle or to the edge of overflow pipe located in the radiator filler, depending on the kind of cooling system. (The use of water is not recommended, but antifreeze).

2.1.5. Check leaktightness of inlet system. Leaking inlet system makes the dirt comes into the engine what leads to accelerated wearing of pistons, piston rings and cylinder bores and reduces engine power and increases exhaust smoke. Leaking inlet system may also be a cause of turbocharger failure.

Note: Bosch injection pump is equipped with cold start device, which facilitate significantly cold engine start. It also has a device, which increases cold engine idle speed at low ambient temperature. Note: Fuel system of the engine with Bosch injection pump is self-bleeding. In case of difficult engine start-up, check the operation of cut-off valve of the injection pump. Do not unscrew any bolt of the injection pump! 2.2.2. Warm engine start-up When starting up warm engine, turn ignition switch key directly into engine start-up position. CAUTION: After starting-up the engine let it run at idle or maximum at 1500 RPM within 10 seconds to allow engine oil to reach turbocharger bearings. It is especially important at winter time and when the engine was not operated for longer time.

2.2. Start-up of the engine in the vehicle 2.2.1. Cold engine start-up Check if the gear lever is in neutral. Turn ignition switch key into glow plug heating position and wait until glow plug control lamp goes off, and then within 6 seconds turn on starter motor the entire cycle may be repeated. Hold the starter motor on for maximum 10 seconds. If the engine does not start within this period, repeat start-up operations after waiting at least 15 seconds. If the engine does not start after several consecutive attempts turn off the ignition switch and seek the cause.

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Service manual - 4CTi90-1BE - Euro 3

2.2.3. Engine start-up at winter Start-up procedure is same as for cold engine start-up. However if the vehicle is parked at open air and ambient temperature drops below -15C, additionally obey the following: strictly use winter diesel fuel Ekodiesel Plus F use engine oil of the following viscosity: 5W/40, 10W/30 or 10W/40 2.2.4. Emergency start-up of the engine by vehicle towing. CAUTION: Because timing gear is driven via timing belt, engine start-up by vehicle towing should be avoided. It is related to high resistance to motion (especially at low ambient temperature) and high inertia of systems driven via timing belt (timing gear, injection pump). With sudden clutch engaging the timing belt is momentarily imposed with high load, which may cause its teeth to be cutoff. If, however, engine start-up with starting motor is impossible, smoothly engage the clutch of towed vehicle (with transmission on II or III gear) in order to avoid timing belt overloading and damaging. For emergency engine start-up tow the vehicle with a speed of 15 - 20 km/h.

2.4. Stopping the engine To stop the engine, move the gear lever into neutral position and turn ignition switch key into STOP position. Remove the key from ignition switch.

2.3. Engine run-in NOTE: Within first 1000 km it is recommended to not load the engine above 3/4 of nominal loading. Obeying the above recommendation extends the interval to first major overhaul. The above recommendation applies also to engine after repair, which involve piston and piston rings or crankshaft dismantling.

CAUTION: After severe and long drive when coolant temperature indicator is close to red zone, before stopping the engine let it still run at idle for minimum 30 seconds. CAUTION: Stop the engine immediately in case of any disturbance to its operation or occurrence of any noise indicating failure.

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Service manual - 4CTi90-1BE - Euro 3

3. ENGINE SERVICING
3.1. Table of routine maintenance operations
Performing the routine maintenance operations listed below is necessary to ensure proper and long engine operation and achieving the required parameters. Meaning of the symbols in the table:

W: - replace S: - check, adjust, clean, fill-up, repair or replace if necessary Engine mileage
No. Operations 1,5
1. 2. 3. 4. 5.

Mileage in kilometers x 1000

10 20 (with tolerance 500 km) 30 40 50 60 70 80 90 100

Engine oil W W W W W W W W W W W Oil filter W W W W W W W W W W W Lubrication system, leaktightness S S S S S S S S S S V-belt, water pump and alternator drive S S S S S S S S S S V-belt, power assisted steering pump and air conditioning According to VEHICLE service manual compressor drive (if applicable) 6. Cooling system, leaktightness According to VEHICLE service manual 7. Coolant S S S 8. Intake system, leaktightness According to VEHICLE service manual 9. Air filter element ** According to VEHICLE service manual 10. Fuel system, leaktightness According to VEHICLE service manual 11. Fuel filter element** W W W W W 12. Valve clearance S S S 13. Injectors, nozzles S* S* 14. Electric system (alternator, starter motor, ) S S 15. Timing belt S S W 16. Glow plugs S W 17. Turbocharger S* * only if there is a reason ** replacing frequency and method of servicing depend on operation conditions in case of excessive dust contamination or low quality fuel even double the frequency

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Service manual - 4CTi90-1BE - Euro 3

3.2 Basic servicing operations DAILY servicing: Inspect visually for any leaks of lubrication, cooling, fuel and intake systems.

3.3. Description of routine maintenance operations 3.3.1. Checking, filling-up and changing engine oil (figures)

WEEKLY (or before longer journey) check the following: Engine oil level Coolant level Leaktightness of lubrication, cooling, fuel and intake systems.

When checking engine oil level, the vehicle should be parked on horizontal surface. Oil level should be checked with cold engine, or about 10 minutes after stopping the engine to let the oil to drip down to oil pan. Remove and clean the dipstick, re-insert it home and remove again. Engine level should be between "MIN" and "MAX" marks. To fill-up the oil, remove oil filler cap and add clean oil, then check the level again and add oil again if necessary, until achieving proper level. Do not add too much of oil. Remember to refit oil filler cap. When changing oil, it should be drained from warm engine when the vehicle is parked
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Service manual - 4CTi90-1BE - Euro 3

on horizontal surface. To facilitate oil draining (via oil draining hole in oil pan) remove oil dipstick or oil filler cap from camshaft housing. After complete engine draining of the old oil, refit the oil draining plug (screwin the plug with fingers to at least 3/4 of the thread length; it prevents incorrect screwingin and damaging the thread). Wash the plug before refitting.

3.3.2. Replacing oil filter (figures) Always replace oil filter together with changing oil. Unscrew old filter manually or by means of special wrench. Before refitting new filter apply engine oil to rubber seal in bottom side of the filter. Tight the filter manually without wrench.

3.3.3. Checking coolant level This operation shall be done according to recommendations and in the manner described in the vehicle service manual. Coolant level should reach the mark on surge tank installed in the vehicle. 3.3.4. Replacing fuel cartridge filter

Be careful when draining old oil while it may be hot.

To replace fuel filter, unscrew old one and refit new one. Fuel filter is integrated with water separator. 3.3.5. Cleaning the water separator To clean the water separator (between fuel filter replacements) unscrew draining plug in the bottom of fuel filter and drain fuel with water and contamination to empty container.

Always replace oil filter when changing oil.

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Service manual - 4CTi90-1BE - Euro 3

3.3.6. Checking leaktightness and proper operation of water pump. In case of lower cooling efficiency resulting in engine overheating during operation with normal load or in case of leaking, give the vehicle over to service station to find out the reason and possibly clean the radiator or repair the water pump. Also the thermostat should be checked. 3.3.7. Replacing injector Remove injectors from the engine, unscrewing before the leak off pipe, injection pipes and injector fixing yoke. Each time before refitting the injector removed or fitting new injector replace the steel washer under the nozzle with new one. When installing the steel washer, take care to install it in proper position (figure).

A steel washer 3.3.8. Checking and adjusting valve clearance (figure) Check and adjust valve clearance with cold engine using feeler gauge of 0.2-mm thickness both for intake as well as exhaust valves.

To check and adjust valve clearance: remove valve cover and set first cylinder piston to TDC position (when both valves are closed) check intake and exhaust valve clearance by inserting feeler gauge between rocker arm and cam if the clearance is improper, loosen the locknut of valve clearance adjusting bolt and screwing the bolt in or out adjust proper clearance (use special wrenches provided with the engine) holding the bolt in position tight-up the lock-nut and recheck valve clearance with feeler gauge. If valve clearance is changed, repeat the above operations. in the same manner adjust clearance of the other valve of first cylinder. then turning crankshaft by 180 adjust clearance of both valves of third, fourth and second cylinder, each time turning crankshaft by another 180 Check the condition of valve cover gasket and replace if defective. It is recommended to replace valve cover gasket each time the cover is removed.

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Service manual - 4CTi90-1BE - Euro 3

3.3.9. Checking, adjusting and replacing drive belts (figures) Water pump and alternator drive Poly-Vbelt (Fig. 1)
2 4 1 P

belt tension adjusting bolt (4) loosen and remove the belt. Install new belt and screwing in the adjusting bolt (4) tension the belt properly. Then tighten the previously slackened nuts and bolt.

Power assisted steering pump V-belt (Fig. 2) (if applicable)

To replace V-belt loosen bolt and nut fixing the pump with front and rear hanger to bracket and bolt and nut fixing front hanger to bracket. Pivoting front hanger with pump down towards the engine loosen and remove old V-belt. Install new V-belt and pulling out the pump properly tension the V-belt. Tighten up previously loosened bolts and nuts.

3.3.10. Replacing timing belt

3

Fig. 3 Alternator and water pump are driven with Poly-V belt. The belt is tensioned properly if under force P = 60 N (Rys.5), deflects about 7 mm. If defective or excessive stretching (impossible to adjust its tension any more) replace the belt with new one. To replace the belt, slacken nut (1) fixing the upper alternator support to tensioner (2) and bolt and nut (3) fixing the bottom alternator support to alternator bracket. Unscrewing the
Service manual - 4CTi90-1BE - Euro 3

CAUTION: This operation can be done only by experienced mechanic, and the best solution is to order performing this operation by the service station. Timing belt is tensioned properly if under force of 11.8 12.7 N (1.2 1.3 kG) applied in the middle between camshaft sprocket and timing advancer sprocket it deflects by 5 mm.

Fig. 2 Power assisted steering pump V-belt is tensioned properly if under force of finger (about 10 kG) applied in the middle between pulley axes it deflects by about 10 mm.

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3.3.11. Inspection of alternator, starter motor and turbocharger Order inspection and repair of these devices by specialized workshops. 3.3.12. Checking and adjusting the injection

rotate flywheel by certain angle counterclockwise (until dial gauge pointer stops moving) set the dial gauge to zero turn flywheel clockwise after the marks of TDC match, check reading of the dial gauge if reading of the dial gauge is 0.8 0.05 mm injection pump is adjusted properly if reading of the dial gauge is different, loosen 3 bolts fixing injection pump drive gear to hub (3 bolts M8 accessible only after removing the timing belt cover) rotate the hub with loosen M8 bolts until reading of the dial gauge is 0.8 0.05 mm moving (rotating) the hub counterclockwise increases the dial gauge reading moving (rotating) the hub clockwise decreases the dial gauge reading Another method: loosen 3 nuts fixing injection pump flange to bracket and rotate injection pump towards the engine or the opposite side until achieving the dial gauge reading of 0.8 0.05 mm; retighten the nuts. retighten the bolts fixing the gear to hub

repeat the measurement (to check proper adjustment) Note: When reinstalling injection pipe do not change their position.

Measuring, adjusting and replacing injection pump shall be done only by specialized workshops! To check and properly adjust the beginning of injection: set first cylinder piston at TDC remove (for convenience) two injection pipes remove the bolt located between injection pipe adapters in the injection pump screw in this hole dial gauge with special adapter enabling this operation. (Preset the dial gauge to value higher than 0.8 0.05 mm). Measurement with dial gauge on a stand or fixed the other way than screwing into injection pump will not ensure proper readings (adjustment).

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Service manual - 4CTi90-1BE - Euro 3

3.3.14. Workshop method to check proper operation EGR System. Procedure to check EGR system of 4CT901BE engines with Bosch injection equipment. 1. connect vacuum meter (16) between EGR valve (6) and electro-pneumatic valve (5), connect manometer (17) between LDA boost pressure compensator (14) and solenoid valve (13) controlling LDA. 2. warm up the engine to normal operating temperature (about 75oC) 3. at idle speed - vacuum pressure at EGR /vacuum meter (16)/ should be 0.50 bar - pressure at LDA /manometer (17)/ should be 0 4. depress accelerator pedal home until the engine reaches maximum speed - vacuum pressure at EGR valve /vacuum meter (16)/ should drop to 0 - pressure at LDA /manometer (17)/ should go up to about 0.5 bar 5. if the system behave differently than described in points 3 and 4, check coolant temperature sensor, electro-pneumatic valve, solenoid valve controlling LDA and potentiometer on injection pump control lever. Kind of failure and its symptom : no signal from coolant temperature sensor (e.g. disconnected connector) - EGR does not operate, the vacuum pressure at EGR valve is zero within entire engine speed range - LDA boost pressure compensator does not operate, pressure at LDA is zero within entire engine speed range no signal from the potentiometer - EGR does not operate, the vacuum pressure at EGR valve is zero within entire engine speed range - LDA boost pressure compensator operates properly Each time the error occurs in coolant temperature sensor circuit the system switches to emergency mode EGR and LDA do not operate. To reset the system to normal operation it is necessary to turn off the ignition switch. After restarting the engine, the system operates properly and the errors are canceled.

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Service manual - 4CTi90-1BE - Euro 3

3.3.14 Connection diagram of EGR system on engine with Bosch injection equipment

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1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.

14 16 15 17

Vacuum pump T-connector Servo Coolant temperature sensor Electro-pneumatic valve EGR valve Check valve Vacuum tank Injection pump, BOSCH Speed signal (impulses picked up from alternator) Electronic control unit Intake manifold Solenoid valve controlling LDA LDA - boost pressure compensator Potentiometer Vacuum meter Manometer

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Service manual - 4CTi90-1BE - Euro 3

4. TROUBLESHOOTING
Causes of failure Fault correction

7. Improper operation of glow plugs or glow plug controller

Call ASS

D. Engine smokes with black smoke

1. Nozzle dirty or sprays incorrectly 2. Air filter dirty 3. Beginning of injection set incorrectly (too late) 4. Valve clearance incorrect 5. Maximum fuel dosage too big 6. Intake and exhaust valves leaking 7. Leaks between cylinder head and block 8. Exhaust or intake valve jammed Call ASS Clean or replace air filter element Check and adjust beginning of injection Adjust valve clearance

A. Low compression pressure

1. Insufficient valve clearance 2. Leaks between cylinder head and cylinder block 3. Leaking valves 4. Broken valve springs 5. Intake or exhaust valve jammed 6. Excessive leaks at pistons Call Authorized Service Station (ASS) Adjust valve clearance with cold engine to 0.2 mm

Call ASS

E. Engine smokes with blue smoke

1. Too much of engine oil 2. Piston rings baked 3. Piston rings broken or worn out 4. Too long engine operation at idle speed 5. Piston ring groves worn out Drain some of engine oil Call ASS Load the engine (avoid too long engine operation at idle) Call ASS

B. Improper operation of supply system

1. No fuel in fuel tank or air trapped in fuel supply system 2. Injection pump shut down 3. Nozzle jammed or worn out 4. Fuel filter, supply pump or fuel pipes dirty 5. Injection pump failure 6. Leaking fuel pipes Fill up fuel tank and bleed the system Turn on injection pump Call ASS Clean out fuel filter, supply pump and fuel pipes. Call ASS Retighten or replace fuel pipes

F. Too hot engine operation

1. No coolant or too low level of coolant 2. Too low engine oil level 3. Nozzle defective 4. Water pump V-belt insufficiently tensioned 5. Viscosity clutch failure 6. Too late injection 7. Maximum fuel dosage too big 8. Radiator pipes dirty Stop the engine and after cooling down fill up cooling system. Fill up engine oil level to max mark on dipstick Replace nozzle Tension properly V-belt Replace viscosity clutch Adjust beginning of injection Call ASS Clean radiator

C. Improper operation of electric system

1. Loosen wire connectors 2. Broken wire 3. Battery discharged 4. Starter motor failure 5. Ignition switch failure 6. Glow plug failure Clean out and tighten wire connectors Replace wire with new one Charge battery Repair or replace starter motor Replace ignition switch Replace glow plug

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Instrukcja obsugi silnika 4CTi90-1BE - Euro 3

9. Cooling system with boiler scale 10. Oil in cooling system 11. Thermostat defective 12. Engine overloaded 15. Water pump failure

Remove boiler scale Call ASS Release engine load Call ASS

3. Incorrect beginning of injection 4. Valve timing shifted 5. Valves jammed 6. Injectors in poor condition

Replace injectors

J. Low turbocharger efficiency

1. Air filter dirty 2. Leaks between turbocharger and intake manifold 3. Turbine outlet duct dirty Replace air filter element Call ASS

G. Too low engine oil pressure

1. Too low engine oil level 2. Old engine oil (not changed for long time) 4. Oil filter dirty 5. 4. Oil pump strainer dirty 5. Leaking lubrication system 6. Fuel or water in lubrication system Fill up engine oil to max mark on dipstick Change oil Replace oil filter Call ASS Find and eliminate the cause of water or fuel leaks to lubrication system. Change oil. Replace manometer Call ASS

K. Turbocharger heats excessively

1. Oil supply pipes leaking 2. Resistance at air inlet and exhaust outlet Call ASS

7. Oil pressure manometer failure 8. Crankshaft bearings worn out

Correction of shortcomings not listed in the above table is a part of engine repair and should be performed by specialized workshop.

H. Engine stops suddenly

1. No fuel supply 2. Fuel filter dirty 3. Air filter dirty 4. Injection pump failure 5. Piston seizure 6. Valves jammed 7. Timing belt broken or incorrectly tensioned Check fuel level and condition of fuel pipes Replace fuel filter Replace air filter element Call ASS Call ASS

I. Knocking noise during engine operation

1. Rocker arms broken 2. Connecting rod bolts loose Call ASS

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Instrukcja obsugi silnika 4CTi90-1BE - Euro 3

5. STORAGE AND PRESERVATION AFTER TAKING THE ENGINE OUT OF SERVICE FOR LONGER PERIOD
5.1. Storage of a new engine Engine delivered by the maker is preserved. Engine can be stored, preserved like that, in dry, closed and dustless room of ambient temperature of about 15C for approximately 6 months. After storing for such period, remove the preservation, prepare the engine for starting-up and start it up. After 15-minute idle run, stop the engine and preserve according to the following instructions. 5.2. Engine preservation for longer standstill Before longer break in operation, preserve each engine against corrosion and other harmful factors. In order to do so, perform the following operations: 1. Carefully clean entire engine. 2. Remove valve cover and wash timing gear with plenty of engine oil. 3. Drain lubrication system of engine oil. 4. Drain supply system of fuel and clean fuel tank. 5. Drain cooling system. 6. Apply anticorrosion grease to all the external not painted parts. 7. Disconnect battery and, if necessary, fill up the electrolyte by adding distilled water. 8. Every month check and possibly charge-up the battery.
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Instrukcja obsugi silnika 4CTi90-1BE - Euro 3

9. Close and protect fuel and coolant fillers as well as inlets and outlets of intake and exhaust systems, and then wrap up injection pump, alternator and starter motor with paraffin paper. The above preservation method protects the engine against corrosion for about 6 months provided that the engine is stored in dry, closed and dustless room of ambient temperature of about 15C. In case of storing the engine longer than 6 months, every such period remove engine preservation, prepare it for starting up and start it up. After 15-minute idle run, stop the engine and preserve according to the above instructions.

NOTE: Obeying the above-mentioned instructions would ensure proper condition of the engine and longer operation until first overhaul. It would also ensure engine startability after storage.