BS VI SERVICE MANUAL
Developed by: Technical Literature Cell. Release Date : Feb 2020 / First Edition. The information provided in this manual is based on the latest product information available at the time of publication. . C Copyright 2020 TATA MOTORS All rights reserved. The information in this manual shall not be reproduced or copied, in whole or in part, in any form without written permission from TATA MOTORS. Vehicles are subject to modification in design, specification and equipment. Also refer the Service Circulars released by Customer Support about product & procedures.
INTRODUCTION This Service manual provides information pertaining to technical Specifications, repair, maintenance and overhaul of different exclusive aggregates fitted on TATA HARRIER BSVI. All the data contained in this manual is based on the latest product information available at the time of publication and with the assumption that the person is well aware of general Automobile practices. This manual emphasizes the special features of the vehicle and thus benefits our workman, who is conversant with general Automobile practices. The contents which are not covered in this supplement service manual have to be read in conjunction with “TATA HARRIER BSIV” Service manual. For ease of use, this service manual is divided into 3 volumes, comprising several sections. Each aggregate has a separate section. THE BOOK– 1 CONTAINS KRYOTEC ENGINE (2L) C635 TRANSAXLE DRIVESHAFT MT 6F33 TRANSAXLE DRIVESHAFT AT CLUTCH CLTUCH RELEASE SYSTEM SUSPENSION BRAKE HVAC FATC BODY ELECTRICAL THE BOOK– 2 CONTAINS Diagnostic Trouble Shooting Codes (DTC) List of ECU’s THE BOOK– 3 CONTAINS Circuit Schematics
INDEX SR. NO GROUP 1 KRYOTEC ENGINE (2L) 2 C635 TRANSAXLE 3 DRIVESHAFT MT 4 6F33 TRANSAXLE 5 DRIVESHAFT AT 6 CLUTCH 7 CLUTCH RELEASE SYSTEM 8 SUSPENSION 9 BRAKE 10 HVAC 11 FATC 12 BODY 13 ELECTRICAL ***The contents which are not covered in this supplement service manual have to be read in conjunction with “TATA HARRIER BSIV” Service manual. Refer Owner’s manual for latest Oil / Lubrication / Coolant details & Service schedule.
KRYOTEC ENGINE KRYOTEC ENGINE
KRYOTEC ENGINE TABLE OF CONTENTS 1 GENERAL INFORMATION ...................................................................................................................... 1 A ENGINE INTRODUCTION................................................................................................................ 1 B TECHNICAL SPECIFICATION......................................................................................................... 2 C ASSEMBLY CLEARANCES ............................................................................................................. 3 D LEAKAGE RATES ............................................................................................................................ 6 E SPECIAL TOOLS.............................................................................................................................. 6 F RECOMMENDED LUBRICANTS AND COOLANTS........................................................................ 9 2 TROUBLESHOOTING............................................................................................................................ 10 3 CONSTRUCTIONAL AND SERVICE DETAILS .................................................................................... 18 4 EXPLODED VIEW .................................................................................................................................. 23 5 ENGINE TESTS AND DIAGNOSIS........................................................................................................ 63 A ENGINE TESTS.............................................................................................................................. 63 B REGULAR MAINTENANCE ........................................................................................................... 67 i ENGINE OIL AND FILTER CHANGE ............................................................................................ 67 ii ENGINE COOLANT REPLACEMENT........................................................................................... 68 iii AIR FILTER ELEMENT REPLACEMENT...................................................................................... 69 iv FUEL FILTER REPLACEMENT .................................................................................................... 70 v DRAINING WATER FROM FUEL FILTER .................................................................................... 71 vi AC COMPRESSOR, ALTERNATOR BELT REPLACEMENT....................................................... 72 vii DPF REGENERATION / CLEANING............................................................................................. 73 viii HYDROSTATIC LOCKED ENGINE............................................................................................... 73 viii CHECKING ENGINE OIL PRESSURE.......................................................................................... 74 6 REPAIR AND INSPECTION DETAILS .................................................................................................. 75 A TIMING BELT...................................................................................................................................... 75 B FUEL TANK ........................................................................................................................................ 76 C CYLINDER HEAD ............................................................................................................................... 77 D CYLINDER HEAD GASKET ............................................................................................................... 78 E VALVE SPRING.................................................................................................................................. 79 F CYLINDER BORE DEGLAZING......................................................................................................... 80
KRYOTEC ENGINE G MEASURING BEARING CLEARANCE USING PLASTIGAGE ......................................................... 81 H EXHAUST PIPE .................................................................................................................................. 82 7 ENGINE ON VEHICLE SERVICE........................................................................................................... 83 A ENGINE REMOVAL............................................................................................................................ 83 B ENGINE FITMENT.............................................................................................................................. 88 C CYLINDER HEAD ............................................................................................................................... 90 D CYLINDER HEAD COVER ................................................................................................................. 95 E BALANCE SHAFT............................................................................................................................... 98 F VIBRATION DAMPER ...................................................................................................................... 100 G OIL COOLER .................................................................................................................................... 101 H ENGINE OIL FILTER ........................................................................................................................ 103 I OIL PAN ............................................................................................................................................ 104 J DIESEL WARNING LIGHT ............................................................................................................... 106 K DIESEL HIGH PRESSURE ............................................................................................................ 108 L ENGINE OIL PUMP .......................................................................................................................... 109 M OIL PRESSURE REGULATOR........................................................................................................ 110 N EXHAUST MANIFOLD...................................................................................................................... 111 O INTAKE MANIFOLD.......................................................................................................................... 112 P EXHAUST SYSTEM ......................................................................................................................... 117 Q FUEL SYSTEM ................................................................................................................................. 129 8 ENGINE ON STAND............................................................................................................................. 138 A CLUTCH............................................................................................................................................ 138 B ENGINE - POSITION ON STAND AND REMOVE........................................................................... 140 C ENGINE (MANUAL TRANSMISSION) SEPARATION AND REASSEMBLY................................... 141 D DISASSEMBLY AND REASSEMBLY FOLLOWING INSPECTION................................................. 146 E CYLINDER HEAD AND OIL PAN FOR INSPECTION ..................................................................... 161 F CYLINDER HEAD ............................................................................................................................. 169 G CAMSHAFT ...................................................................................................................................... 173 H PISTON............................................................................................................................................. 176
KRYOTEC ENGINE 1 1. GENERAL INFORMATION A. ENGINE INTRODUCTION DESCRIPTION The “2.0L KRYOTEC” is a new generation 4 Cylinder 2.0L Direct injection Common-Rail Turbocharger Intercooled Diesel Engine. This Engine is fitted with common rail system with higher injection pressure (1600 bar) which is controlled by a Electronic Control Unit (ECU).The Engine performance is optimized for various engine speed, load and operating conditions depending upon the various sensor’s inputs. The turbocharger used on this engine is electronically actuated having low inertia of turbine and compressor wheels which reduce the turbo lag at low engine speeds and improves the transient response of the vehicle. This turbocharger incorporates many movable vanes in the turbine housing to control the exhaust flow against the turbine blades which enables higher power, torque, lower fuel consumption and emissions of the engine. The fuel economy and emission has been optimized at source by means of low engine friction, faster engine warm up, fully electronic controlled fuel injection system, EGR (exhaust gas recirculation) and Diesel particulate filter with oxidation catalyst. Hydraulic Lash Adjusters and Roller Finger Followers are used for maintenance free quiet operation and reduced friction. Toothed belt drive with automatic belt tensioner is used for quiet engine operation for longer period. The engine NVH is optimized by means of power train stiffeners and aluminum alloy pan. The engine weight has been optimized by using Aluminum cylinder head, gallery cooled piston.
KRYOTEC ENGINE 2 B. TECHNICAL SPECIFICATION Model FIAT FAM B 2.0 Litre Type Direct Injection Common Rail Turbocharged intercooled Diesel engine No. Of Cylinders 4 Inline Bore / Stroke 83 mm x 90.4mm Engine Capacity 1956 cc Compression Ratio 16.5 : 1 Max. Engine Power Output 170 ps @ 4000 rpm Max. Engine Torque Output 350 Nm @ 1750-2500 rpm Firing Order 1-3-4-2 Engine Oil Capacity 7.0 litres Capacity Of Cooling System 6.5 litres Air Filter Engine Mounted, Dry Paper Cartridge Type Oil Filter Ecological paper cartridge oil filter element Timing Belt Drive Special Items / Features Direct injection, common rail 16 valves, centralized injector. Fully electronic controlled fuel injection system. Higher injection pressure (1600bar) for better performance. Fixed geometry turbo charger with electric actuator EGR cooler with bypass option Single serpentine auxiliary belt drive with automatic tensioner. Emission Norms Bharat Stage VI
KRYOTEC ENGINE 3 C. ASSEMBLY CLEARANCES ENGINE DATA Bore (mm) 83 Stroke (mm) 90.4 Total displacement (cm3) 1956 Maximum power (kW EEC) 103 Maximum power (CV EEC) 140 Max. power (rpm) 3750 Maximum torque (Nm EEC) 350 Maximum torque (kgm EEC) 35.7 Maximum torque (rpm) 1500 Idle speed (rpm) 850 ± 30 Compression ratio 16.5 : 1 CRANKSHAFT Measure Value Crankshaft End Play (mm) 0.049 - 0.211 Journal diameter (mm) 63.705 - 63.718 Journal diameter - Class A (mm) 59.995 - 60.002 Journal diameter - Class B (mm) 59.988 - 59.995 Journal diameter - Class C (mm) 59.981 - 59.988 Connecting rod pin diameter - Class A (mm) 50.800 - 50.807 Connecting rod pin diameter - Class B (mm) 50.793 - 50.800 Connecting rod pin diameter - Class C (mm) 50.786 - 50.793 Journal out of round diameter (mm) 0.127 Diameter connecting rod pins 0.127 MAIN BEARINGS/CRANKSHAFT CONNECTING ROD Measure Value Thickness of bearing shells - Class To (Red) (mm) 1.832 - 1.836 Thickness of bearing shells - Class B (Blue) (mm) 1.835 - 1.839 Thickness of bearing shells - Class C (Yellow) (mm) 1.838 - 1.842 Oversize bearing shells / connecting rod - Class A (Brown) (mm) 0.127 Oversize bearing shells / connecting rod - Class B (Green) (mm) 0.254 Oversize bearing shells / connecting rod - Class C (Black) (mm) 0.508 Thickness of connecting rod bearing - Class A (Red) (mm) 1.528 - 1.532 Thickness of connecting rod bearing - Class B (Blue) (mm) 1.532 - 1.536 Thickness of connecting rod bearing - Class C (Yellow) (mm) 1.535 - 1.539 Clearance of main bearings - crankshaft bearing journals (mm) 0.031 - 0.051 Clearance of rod bearings - crankshaft rod bearings (mm) 0.030 - 0.056
KRYOTEC ENGINE 4 TIMING ANGLES Operation control clearance (mm) Intake ( • ) Exhaust ( • ) Control timing clearance (mm) Intake - Exhaust - Intake Opening (BTDC) 10ᵒ Opening (ATDC) - Closed (after BDC) 2ᵒ Exhaust Opening (before BDC) 40ᵒ Opening (BTDC) - Closed (ATDC) 9ᵒ ( • ) Hydraulic Tappets CYLINDER BORE Measure Value Internal diameter cylinder Bore - Class A (mm) 83.000 - 83.010 Internal diameter cylinder Bore - Class B (mm) 83.010 - 83.020 Internal diameter cylinder Bore - Class C (mm) 83.020 - 83.030 Cylinder Bore Out of Round (mm) < 0.05 Cylinder Bore Taper < 0.005 Oversize inner diameter cylinder bore (mm) 0.1 CYLINDER HEAD Measure Value Cylinder head gasket thickness with maximum protrusion piston (mm) protrusion -0.110 - + 0.230 thickness (no hole) 0.95 +/- 0.05 Cylinder head gasket thickness with maximum protrusion piston (mm) protrusion -0.231 - + 0.330 thickness (one hole) 0.95 +/- 0.05 Cylinder head gasket thickness with maximum protrusion piston (mm) protrusion + 0.331 - + 0.425 thickness (two holes) 1.15 +/- 0.05 Nominal cylinder head height (mm) 107 +/- 0.05 Flatness Cylinder Head Surface (mm) < 0.1 VALVES Valvestemdiameter - Exhaust (mm) 4.972 ÷ 4.990 Valvestemdiameter- Intake (mm) 4.982 ÷ 5.000 VALVE GUIDES Valvestemdiameter- Intake (mm) 4.982 ÷ 5.000 Valvestemdiameter - Exhaust (mm) 4.972 ÷ 4.990 Outer diameter valve guides (mm) 010 ÷ 10.030 Increase outer diameter valve guides (mm) 05 / 0.10 / 0.25 Internal diameter valve guides (mm) 015 ÷ 5.033 VALVE SPRINGS Valvespring free length (mm) 44.1 Valvespring lengthunder loadof 22.80÷25.20daN (mm) 34 Valvespring lengthunder loadof 43.90÷48.10daN (mm) 25.5
KRYOTEC ENGINE 5 VALVE SEATS Outer diameter-intake valve seats (mm) 29.600 ÷ 29.611 Outer diameter-exhaust valve seats (mm) 26.100 ÷ 26.111 Valve seat angle in contact with valve 45° 30’ +/- 1° PINS Diameter of seat pin (mm) 29.985 ÷ 29.990 Pin outer diameter (mm) 29.975 ÷ 29.980 PISTON RINGS Light 1^ seal ring compression cylinders (mm) 0.20 ÷ 0.35 Light 2^ seal ring compression cylinders (mm) 0.60 ÷ 0.80 Light scraper ring piston engine (mm) 0.25 ÷ 0.50 Clearance of axial engine piston scraper ring (mm) 0.030 ÷ 0.070 Thickness 1^ seal ring compression cylinders (mm) 1.470 ÷ 1.495 Thickness 2^ seal ring compression cylinders (mm) 1.470 ÷ 1.495 Thickness 3^ seal ring compression cylinders (mm) 1.970 ÷ 1.990 Seat seal on the piston - 1st slot (mm) 1.620 ÷ 1.640 Seat seal on the piston - 2nd slot (mm) 1.550 ÷ 1.570 Seat seal on the piston - 3rd slot (mm) 2.020 ÷ 2.040 Axial 1^ seal ring compression cylinders (mm) 0.125 ÷ 0.170 Axial 2^ seal ring compression cylinders (mm) 0.055 ÷ 0.100 PISTONS Outside diameter pistons - Class A (mm) 82.930 ÷ 82.940 Outside diameter pistons - Class B (mm) 82.940 ÷ 82.950 Outside diameter pistons - Class C (mm) 82.950 ÷ 82.960 Difference of weight allowed between pistons (g) +/- 5 Increase piston outer diameter (mm) 0.1 CONNECTING RODS Difference of weight allowed between the complete connecting rods (g) +/- 2.5 Inner Diameter small end of bushings (mm) 30.006 ÷ 30.014 Inner Diameter big end of bushings (mm) 53.897 ÷ 53.909 CAMSHAFTS Nominal intake camshaft lift (mm) 8.5 Nominal exhaust camshaft lift (mm) 8 Diameter First pin timing shaft (mm) 43.600 ÷ 43.615 Diameter Second pin timing shaft (mm) 43.400 ÷ 43.415 Diameter Third pin timing shaft (mm) 43.200 ÷ 43.215 Diameter Fourth pin timing shaft (mm) 43.000 ÷ 43.015 Diameter Fifth pin timing shaft (mm) 30.000 ÷ 30.015 Diameter first timing shaft support (mm) 43.646 ÷ 43.671 Diameter second timing shaft support (mm) 43.446 ÷ 43.471 Diameter third timing shaft support (mm) 43.246 ÷ 43.271 Diameter fourth timing shaft support (mm) 43.046 ÷ 43.071 Diameter fifth timing shaft support (mm) 30.045 ÷ 30.070
KRYOTEC ENGINE 6 D. LEAKAGE RATES Region Pressure Leakage (Max.) Air Side 0.125 bar < 200 cc/min Water Side 0.7 bar < 20 cc/min E. SPECIAL TOOL SR. NO. PART NUMBER DESCRIPTION IMAGE 1 541258902402 Support stand 2 5412 5890 0618 Support stand 3 541258900604 locking tool 4 541258900605 Auto tensioner locking tool 5 541258900701 Injector puller 6 541258900628 Adaptor
KRYOTEC ENGINE 7 SR. NO. PART NUMBER DESCRIPTION IMAGE 7 541258902401 Engine support bracket LH 8 5412 5890 0608 Rib socket bolt removal & Fitment 9 541258900602 Engine support bracket RH 10 541258903301 Driveshaft Puller 11 541258904701 Fuel Tank Fitment & Removal 12 5412 5890 0617 Pin 13 553058900101 compressor tool 14 270458903316 Camshaft Oil Seal
KRYOTEC ENGINE 8 SR. NO. PART NUMBER DESCRIPTION IMAGE 15 265458903511 Installer, Differential Oil Seal 16 8855 TOOL 0001 Fuel pump pulley 17 1870896900 locking tool 18 1860898000 Flywheel locking tool @ car 19 541258900631 Flywheel locking tool @ car 20 1860846001 Flywheel locking tool @ standalone 21 2000003000 Locking tool 22 1871003100 Clutch alignment locking tool
KRYOTEC ENGINE 9 SR. NO. PART NUMBER DESCRIPTION IMAGE 23 541258900607 compressor support rail 24 541258900616 Fitment tool 25 541258902501 Mandrel 26 542558900605 Fixture (Stand) Assembly Aggregate Repair
KRYOTEC ENGINE 10 2 TROUBLESHOOTING ENGINE DIAGNOSIS MECHANICAL CONDITION POSSIBLE CAUSES CORRECTION LUBRICATING OIL PRESSURE LOW 1. Low oil level. 1. (a) Check and fill with clean engine oil. (b) Check for a severe oil leak, worn rings (burning oil), oil leaking from the turbocharger to the intake, or other root causes for low Oil level. 2. Oil viscosity thin, diluted or wrong specification. 2. (a) Verify the correct engine oil is being used. (b) Look for reduced viscosity from fuel dilution. 3. Improperly operating pressure switch/gauge. 3. Verify the pressure switch is functioning correctly. If not, replace switch/gauge. 4. Relief valve stuck open. 4. Check/replace valve. 5. If cooler was replaced, shipping plugs may have been left in cooler 5. Check/remove shipping plugs. 6. Worn oil pump. 6. Check and replace oil pump. 7. Suction tube loose or seal leaking. 7. Check and replace seal. 8. Loose main bearing cap. 8. Check and install new bearing. Tighten cap to proper torque. 9. Worn bearings or wrong bearings installed. 9. Inspect and replace connecting rod or main bearings. Check and replace directed piston cooling nozzles. 10. Directed piston cooling nozzles under piston, bad fit into main carrier. 10. Check directed piston cooling nozzles position. 11. Loose directed piston cooling nozzle. 11. Tighten directed piston cooling nozzle. LUBRICATING OIL PRESSURE TOO HIGH 1. Pressure switch/gauge not operating properly. 1. Verify pressure switch is functioning correctly. If not, replace switch/gauge. 2. Engine running too cold. 2. Coolant Temperature Below Normal 3. Oil viscosity too thick. 3. Make sure the correct oil is being used. 4. Oil pressure relief valve stuck closed or binding 4. Check and replace valve. LUBRICATING OIL LOSS 1. External leaks. 1. Visually inspect for oil leaks. Repair as required. 2. Crankcase overfilled. 2. Verify that the correct dipstick is being used. 3. Incorrect oil specification or viscosity. 3. (a) Make sure the correct oil is being used (b) Look for reduced viscosity from dilution with fuel. (c) Review / reduce oil change intervals. 4. Oil cooler leak 4. Check and replace the oil cooler. 5. High blow-by forcing oil out the breather. 5. Check the breather tube area for signs of oil loss. Perform the required repairs.
KRYOTEC ENGINE 11 CONDITION POSSIBLE CAUSES CORRECTION 6. Turbocharger leaking oil to the air intake. 6. Inspect the air ducts for evidence of oil transfer. Repair as required (slight oil residue is normal). COMPRESSION KNOCKS 1. Air in the fuel system. 1. Identify location of air leak and repair. Do not bleed high pressure fuel system. 2. Poor quality fuel or water/gasoline contaminated fuel. 2. Verify by operating from a temporary tank with good fuel. Clean and flush the fuel tank. Replace fuel/water separator filter. Replace fuel/water separator filter. 3. Engine overloaded. 3. Verify the engine load rating is not being exceeded. 4. Improperly operating injectors. 4. Check and replace misfiring/inoperative injectors. EXCESSIVE VIBRATION 1. Loose or broken engine mounts. 1. Replace engine mounts. 2. Damaged fan or improperly operating accessories. 2. Check and replace the vibrating components. 3. Improperly operating vibration damper. 3. Inspect/replace vibration damper. 4. Improperly operating balance shaft. 4. Inspect/replace balance shaft. 5. Improperly operating electronically controlled viscous fan drive. 5. Inspect/replace fan drive. 6. Worn or damaged generator bearing. 6. Check/replace generator. 7. Flywheel housing misaligned. 7. Check/correct flywheel alignment. 8. Loose or broken power component. 8. Inspect the crankshaft and rods for damage that causes an unbalance condition. Repair/ replace as required. 9. Worn or unbalanced driveline components. 9. Check/repair driveline components. EXCESSIVE ENGINE NOISES 1. Drive belt squeal, insufficient tension or abnormally high loading 1. Check the automatic tensioner and inspect the drive belt. Make sure water pump, tensioner pulley, fan hub, generator and power steering pump turn freely. 2. Intake air or exhaust leaks. 2. Refer to Excessive Exhaust Smoke (Refer to Engine - Diagnosis and Testing). 3. Excessive valve lash. 3. Adjust valves. Make sure the rocker arms are not bent. Replace bent or severely worn components. 4. Turbocharger noise. 4. Check turbocharger impeller and turbine wheel for housing contact. Repair/replace as required. 5. Gear train noise. 5. Visually inspect and measure gear back- lash. Replace gears as required. 6. Power function knock. 6. Check/replace rod and main bearings.
KRYOTEC ENGINE 12 ENGINE LUBRICATION DIAGNOSTIC TABLE CONDITION POSSIBLE CAUSES CORRECTION OIL LEAKS 1. (a) Gaskets and O-rings. Misaligned or damaged. 1. (a) Replace as necessary. (b) Loose fasteners, broken or porous metal parts. (b) Tighten fasteners, Repair or replace metal parts. 2. Crankshaft rear Oil seal. 2. Replace rear crankshaft Oil seal (Refer to Engine/ Engine Block,' Seal, Crankshaft Oil, Rear/ Removal) 3. Crankshaft seal flange. Scratched, nicked or grooved. 3. Polish or replace crankshaft. 4. Oil pan flange cracked. 4. Replace Oil pan (Refer to Engine/ Lubrication/ Pan, Oil Removal) 5. Damaged or misaligned crank- shaft front oil seal. 5. Replace crankshaft front oil seal (Refer to Engine/ Engine Block/ Seal, Crankshaft Oil, Front/ Removal) 6. Scratched or damaged vibration damper hub. 6. Polish or replace vibration damper. OIL PRESSURE DROP 1. Low oil level 1. Check and correct oil level. 2. Faulty Oil pressure sensor. 2. Replace Oil pressure sensor (Refer to Engine/ lubrication/ Sensor, Oil Pressure - Removal) 3. Low oil pressure. 3. (a) Check main bearing clearance (Refer to Engine/Engine block - Standard Procedure) . (b) Check rod bearing clearance (Refer to Engine/Engine Block/ Bearings, Connecting Rod - Standard Procedure) 4. Clogged oil filter. 4. Replace oil filter (Refer to Engine/Lubrication/ Filter, Engine Oil - Removal) 5. Worn Oil pump. 5. Replace Oil pump (Refer to Engine/ Lubrication/ Pump, Engine Oil - Removal) 6. Thin or diluted oil. 6. Change oil and filter (Refer to Engine/Lubrication/ Oil Standard Procedure) 7. Excessive bearing clearance. 7. (a) Replace crankshaft bearings (Refer to Engine/ Engine Block/ Bearings, Crankshaft - Standard Procedure) . (b) Replace rod bearings (Refer to Engine/Engine Block/Bearing, Connecting Rod - Standard Procedure). 8. Oil pump relief valve stuck - 9. Oil pump pick-up loose, damaged or clogged 9. Replace oil pump pick-up (Refer to Engine/ Lubrication/, Oil pump - Removal).
KRYOTEC ENGINE 13 CONDITION POSSIBLE CAUSES CORRECTION OIL PUMPING AT RINGS 1. Worn or damaged rings. 1. Hone cylinder bores and replace rings (Refer to Engine/ Engine Block/Bearings, Piston- Standard Procedure). 2. Carbon in Oil ring slots. 2. Replace rings (Refer to Engine/ Engine Block/ Rod, Piston and Connecting - Removal). 3. Worn valve guides. 3. Replace cylinder heads (Refer to Engine/ Cylinder Head Removal). 4. Leaking valve guide seals. 4. Replace valve guide seals (Refer to Engine/ Cylinder Head/ Seal, Valve Guide - Removal).
KRYOTEC ENGINE 14 ENGINE PERFORMANCE DIAGNOSTIC TABLE CONDITION POSSIBLE CAUSE CORRECTION ENGINE WILL NOT START 1. Weak battery. 1. Charge or replace as necessary. 2. Corroded Or loose battery connections. 2. Clean and tighten battery connections. Apply a coat of light mineral grease to the terminals. 3. Faulty starter. 3. (Refer to Electrical/ Engine Systems/ Starting - Diagnosis and Testing). 4. Faulty camshaft position sensor. 4. Replace the camshaft position sensor (Refer to Electrical/ Ignition Control/ Sensor Camshaft Position/ Removal). 5. Faulty crankshaft position sensor. 5. Replace crank position sensor (Refer to Fuel System/ Fuel Injection/Sensor, Crankshaft Position/ Removal). 6. Faulty fuel pump, relay or winding. 6. Repair or replace as necessary. 7. Dirt or water in fuel system. 7. Clean system and replace fuel filter. ENGINE STALLS OR ROUGH IDLE 1. Vacuum leak. 1. Inspect intake manifold and vacuum hoses, repair or replace as necessary. 2. Faulty crank position sensor. 2. Replace crank position sensor (Refer to Fuel System/ Fuel Injection/ Sensor, Crankshaft Position/ Removal) 3. Incorrect camshaft timing. 3. (Refer to Engine/ Valve Timing - Standard Procedure) ENGINE LOSS OF POWER 1. Dirt or water in fuel system. 1. Clean system and replace fuel filter. 2. Faulty fuel pump. 2. Replace the fuel pump 3. Blown cylinder head gasket. 3. Replace the cylinder head gasket. 4. Low compression 4. (Refer to Engine - Diagnosis and Testing) , repair as necessary 5. Burned, warped or pitted valves 5. Replace as necessary 6. Plugged or restricted exhaust system. 6. Inspect and replace as necessary. 7. Incorrect camshaft timing. 7. (Refer to Engine/ Valve Timing - Standard Procedure) ENGINE MISSES ON ACCELERATION 1. Dirt in fuel system. 1. Clean fuel system. 2. Burned, warped or pitted valves. 2. Replace as necessary. ENGINE MISSES AT HIGH SPEED Dirt or water in fuel system. Clean system and replace fuel filter.
KRYOTEC ENGINE 15 SMOKE DIAGNOSIS CHARTS The following charts include possible causes and corrections for excess or abnormal exhaust smoke.Small amounts of exhaust smoke (at certain times) are to be considered normal for a diesel powered engine. EXCESSIVE BLACK SMOKE POSSIBLE CAUSE CORRECTION Air filter dirty or plugged. Check and replace the filter if necessary. Air intake system restricted. Check entire air intake system including all hoses and tubes for restrictions, collapsed parts or damage. Repair/replace as necessary. Air Leak in Intake System. Check entire air intake system including all hoses and tubes for collapse, cracks, loose clamps, or holes in rubber ducts. Also check intake manifold for loose mounting hardware. Diagnostic Trouble Codes (DTC's) active or multiple, intermittent DTC's. (Refer to DTC-Based Diagnostics/ Module, Powertrain Control (PCM) - Diagnosis and Testing) Powertrain Control Module (PCM) has incorrect calibration. (Refer to DTC-Based Diagnostics/ Module, Powertrain Control (PCM) - Diagnosis and Testing) Exhaust system restriction is above specifications. Check exhaust pipes for damage/restrictions. Repair as necessary. Fuel grade is not correct or fuel quality is poor. Temporarily change fuel brands and note condition. Change brand if necessary. Fuel injection pump malfunctioning. A DTC may have been set. If so, (Refer to DTC- Based Diagnostics/Module, Powertrain Control (PCM) - Diagnosis and Testing) Fuel injector malfunctioning. A DTC may have been set. Perform "Injector Classification Programming" using scan tool. Also (Refer to DTC-Based Diagnostics/ Module, Powertrain Control (PCM) - Diagnosis and Testing) and, Return Fuel Quantity Test Fuel injector lower washer doubled or missing. Remove and inspect injector washer. Fuel return system restricted. Check fuel return lines for restriction. Intake manifold restricted. Remove the restriction. Manifold Air Pressure (Boost) Sensor or sensor circuit malfunctioning. A DTC should have been set. (Refer to DTC-Based Diagnostics/ Module, Powertrain Control (PCM) - Diagnosis and Testing). Turbocharger air intake restriction. Remove the restriction. Turbocharger damaged. Replace the turbocharger. Turbocharger has excess build up on compressor wheel or diffuser vanes. Clean or replace the turbocharger. Turbocharger wheel clearance out of specification. Replace the turbocharger.
KRYOTEC ENGINE 16 EXCESSIVE WHITE SMOKE POSSIBLE CAUSE CORRECTION Air in fuel supply: Possible leak in fuel supply side. Inspect fuel system Coolant leaking into combustion chamber. Perform pressure test of cooling system. Diagnostic Trouble Codes (DTC's) active or multiple, intermittent DTC's. (Refer to DTC-Based Diagnostics/Module, powertrain Control (PCM) - Diagnosis and Testing) In very cold ambient temperatures, engine block heater is malfunctioning (if equipped). (Refer to Cooling/Engine/Heater, Engine Block - Diagnosis and Testing) Engine coolant temperature sensor malfunctioning. A DTC should have been set. (Refer to DTC-based Diagnostics/ Module, powertrain Control (PCM) - Diagnosis and Testing). Also check thermostat operation. Powertrain Control Module (PCM) has incorrect calibration. A DTC should have been set. (Refer to DTC-Based Diagnostics/Module, Powertrain Control (PCM) - Diagnosis and Testing). Fuel filter plugged. (Refer to Non-DTC Diagnostics/Drivability - Diesel - Diagnosis and Testing). Fuel grade not correct or fuel quality is poor. Temporarily change fuel brands and note condition. Change brand if necessary. Fuel injector malfunctioning. A DTC should have been set. Perform "Injector Identification Programming" or "Cylinder Cutout Test" using scan tool to isolate individual cylinders. Also (Refer to DTC-Based Diagnostics/ Module, Powertrain Control (PCM) - Diagnosis and Testing) Fuel injector hold-down(s) loose. Replace the copper washer(s) (shim) and tighten to specifications. Fuel injector protrusion not correct. Check washer (shim) at bottom Of fuel injector for correct thickness. Fuel injection pump malfunctioning. A DTC should have been set. (Refer to DTC-Based Diagnostics/ Module, Powertrain Control (PCM) - Diagnosis and Testing). Fuel supply side restriction. (Refer to Non-DTC Diagnostics/Drivability - Diesel - Diagnosis and Testing) for fuel system testing. Intake manifold air temperature sensor malfunctioning A DTC should have been set. (Refer to DTC-Based Diagnostics/ Module, Powertrain Control (PCM) - Diagnosis and Testing). Intake manifold heater circuit not functioning correctly in cold weather. A DTC should have been set. (Refer to DTC-Based Diagnostics/ Module, powertrain Control (PCM) - Diagnosis and Testing). Also check heater elements for correct operation. Intake manifold heater elements not functioning correctly in cold weather. A DTC should have been set if heater elements are malfunctioning. (Refer to DTC-Based Diagnostics/ Module, Powertrain Control (PCM) - Diagnosis and Testing)
KRYOTEC ENGINE 17 EXCESSIVE WHITE SMOKE POSSIBLE CAUSE CORRECTION Internal engine damage (scuffed cylinder). Analyze engine oil and inspect oil filter to locate area of probable damage. Restriction in fuel supply side of fuel system. (Refer to Non-DTC Diagnostics/Drivability - Diesel - Diagnosis and Testing) for fuel system testing. EXCESSIVE BLUE SMOKE POSSIBLE CAUSE CORRECTION Dirty air cleaner or restricted turbocharger intake duct. Check Air Cleaner Housing for debris and replace filter as necessary Air leak in boost system between turbocharger compressor outlet and intake manifold. Service charge air system. Obstruction in exhaust manifold. Remove exhaust manifold and inspect for blockage. Restricted turbocharger drain tube. Remove turbocharger drain tube and remove obstruction. Crankcase ventilation system plugged. Inspect oil separator system for function and clear drain back hole in cylinder head cover/intake manifold Valve seals are worn, brittle, or improperly installed. Replace valve stem Oil seals Valve stems or guides are worn. Remove valves and inspect valves and guides. Broken or Improperly installed piston rings. Tear down engine and Inspect piston rings. Excessive piston ring end gap. Remove pistons and measure piston ring end gap Excessive cylinder liner wear and taper. Remove pistons and measure cylinder liner wear and taper. Cylinder damage. Remove pistons and inspect cylinder liner for cracks or porosity. Repair with new cylinder liner if necessary. Piston damage. Remove pistons and inspect for cracks, holes. Measure piston for out-of-round and taper. Turbocharger failure. Replace the turbocharger.
KRYOTEC ENGINE 18 3. CONSTRUCTIONAL AND SERVICE DETAILS ENGINE MOUNTS DESCRIPTION TIGHTENING TORQUE (N·m) NO REUSE Left Mount Bolt 120 Left Mount to Frame Rail Bolts 90 + 45° Left Mount Bracket Bolts 40 + 45° Right Mount to Frame Rail Bolts 60 + 45° Right Mount Bolt 90 + 45° Rear Mount to Bracket Bolt 90 + 45° Rear Mount Bracket to Transmission Bolts 90 + 45° Rear Mount to Crossmember Bolt 90 + 45° * New Fastener: Do not reuse these fasteners. If removed, a NEW fastener must be installed and tightened to specifications. CYLINDER HEAD DESCRIPTION TIGHTENING TORQUE (N·m) NO REUSE Upper Head Engine 25 Cylinder Head Bolts 65 + 90° + 90° + 90° Glow Plugs 8 Upper Engine Cylinder Head Caps 14 * New Fastener: Do not reuse these fasteners. If removed, a NEW fastener must be installed and tightened to specifications. ENGINE COVERS DESCRIPTION TIGHTENING TORQUE (N·m) NO REUSE Engine Oil Drain Plug 20 Crankcase Bolts 9 Front Cover Oil Seal Bolts 25 Front Cover Oil Seal Bolts 9 Rear Oil Seal Bolts 9 * New Fastener: Do not reuse these fasteners. If removed, a NEW fastener must be installed and tightened to specifications. CRANKSHAFT AND FLYWHEEL DESCRIPTION TIGHTENING TORQUE (N·m) NO REUSE Crankshaft Bearing Caps Bolts 25 + 100° * New Fastener: Do not reuse these fasteners. If removed, a NEW fastener must be installed and tightened to specifications.
KRYOTEC ENGINE 19 PISTONS AND CONNECTING RODS DESCRIPTION TIGHTENING TORQUE (N·m) NO REUSE Connecting Rod Caps Bolts 25 + 60° * New Fastener: Do not reuse these fasteners. If removed, a NEW fastener must be installed and tightened to specifications. TIMING CONTROL DESCRIPTION TIGHTENING TORQUE (N·m) NO REUSE Mobile Tensioner 25 Fixed tensioner Bolts 25 Crankshaft Pulley Bolts 340 Camshaft Pulley Bolt 30 + 40° Protection cover of timing control 9 Tensioners Support of Timing Belt Bolt 25 * New Fastener: Do not reuse these fasteners. If removed, a NEW fastener must be installed and tightened to specifications. ENGINE TURBOCHARGER SYSTEM DESCRIPTION TIGHTENING TORQUE (N·m) NO REUSE Charge Air Cooler Tube Bolts 10 Turbocharger Nuts 25 Turbocharger Oil Feed Line Banjo Bolt (Turbocharger Side) 27 Turbocharger Oil Feed Line Banjo Bolt (Cylinder Head Side) 20 Turbocharger Oil Return Line Bolt (Turbocharger Side) 25 Turbocharger Oil Return Line Bolt (Engine Block Side) 50 * New Fastener: Do not reuse these fasteners. If removed, a NEW fastener must be installed and tightened to specifications. INTAKE AND EXHAUST MANIFOLDS DESCRIPTION TIGHTENING TORQUE (N·m) NO REUSE Intake Manifold Nuts 25 Exhaust Manifold Nuts 20 * New Fastener: Do not reuse these fasteners. If removed, a NEW fastener must be installed and tightened to specifications.
KRYOTEC ENGINE 20 LUBRICATION SYSTEM DESCRIPTION TIGHTENING TORQUE (N·m) NO REUSE Engine Oil Filter Cover 25 Output Pipe From Turbocharger Engine Oil Bolt 50 Oil Pressure Pipe to Turbocharger Bolt 15 Turbocharger to Cylinder Head Oil Pressure Pipe Bolt 25 Oil Pressure Warning Light Switch 25 Oil Pressure Switch 20 Introducing Engine Oil Nozzle 9 Displacement Control Valve Oil Pump motor 7 * New Fastener: Do not reuse these fasteners. If removed, a NEW fastener must be installed and tightened to specifications. MISCELLANEOUS ENGINE PARTS DESCRIPTION TIGHTENING TORQUE (N·m) NO REUSE Vibration Damper Bolt 30 Accessory Drive Fixed Tensioner Bolt 50 Accessory Drive Mobile Tensioner Bolt 28 * New Fastener: Do not reuse these fasteners. If removed, a NEW fastener must be installed and tightened to specifications. SPECIAL TOOLS Engine Diagnosis and Testing Tool (EMEA) Tool (NAFTA) Description Function 1806338000 * Transducers Examiner Kit 2 Test compression cylinders 1860969000 * Fitting Check the engine lubrication system pressure 1870811001 * Fitting Cylinder compression 1870897400 * Incorrect injector Check cylinder compression 2000015600 * Connection tube manometer Check the engine lubrication system pressure 2000018801 * Tee Check the engine lubrication system pressure 2000024300 * Fitting Check the engine lubrication system pressure * Tool not available for NAFTA. Use a commercially available tool or contact Mopar Essential Tools to order the custom EMEA tool.
KRYOTEC ENGINE 21 Engine Procedures Tool (EMEA) Tool (NAFTA) Description Function 1823015000 C-4829A Pry retainer 1860470000 * Cylinder head overhaul 1860815000 * Rotating crankshaft 1860816000 * Introduction oil pump sealing ring 2.0L Turbo Diesel 1860833000 * Loosen/tighten screws side stand Cup distribution and Exchange side 2.0L Turbo Diesel 1860834000 * Loosen/tighten screws on the side sump 2.0L Turbo Diesel 1860846000 * Fly-wheel retainer 1860854001 * Pulley extraction pressure pump control 2.0L Turbo Diesel 1860898000 10272 Fly-wheel retainer Transmission 948TE 1860898000 10272 Fly-wheel retainer 1870718000 * Cut sealing 1870739000 * Electro injectors removal 2.0L Turbo Diesel 10497 Compression Test Adapter 2.0L Turbo Diesel 1870815000 6847 Loosen/tighten fixing screw pulley distribution policy 2.0L Turbo Diesel 1870836000 * Loosen/tighten fixing screw pulley distribution policy 2.0L Turbo Diesel 1870896800 20131 Introduction front oil seal camshaft exhaust 2.0L Turbo Diesel 1870896900 20132 Engine timing 2.0L Turbo Diesel 1870897100 * Introduction oil seals valve guides 2.0L Turbo Diesel 1870897300 * Electro injectors removal 2.0L Turbo Diesel 1871000000 * Engine placement on tripod for review 1871000600 * Extracting/Introduction tappets 2.0L Turbo Diesel 1871001700 * Removing/installing the power plant 1871003100 * Clutch disassembly/ reassembly mechanism 2.0L Turbo Diesel 1871008501 * Extracting/Introduction tappets 2.0L Turbo Diesel 1871008601 * Removing/installing dismissal gears shafts distribution 2.0L Turbo Diesel 2019500031 * Removing rear drive shaft 2000024900 * Clutch disassembly/ reassembly mechanism 2.0L Turbo Diesel 2000026900 20150 Removing/Installing pressure pump 2.0L Turbo Diesel 2000032400 * Tappets extraction/ Introduction oil seal 2.0L Turbo Diesel 2000038602 * Clutch disassembly/ reassembly mechanism 2.0L Turbo Diesel
KRYOTEC ENGINE 22 Tool (EMEA) Tool (NAFTA) Description Function 2000039800 * Capless fuel inlet pipe fastening 2.0L Turbo Diesel 2000040436 8534B Shaft supporting power plant 2000042900 * Capless fuel inlet pipe fastening 2.0L Turbo Diesel 2000043000 * Front suspension cross positioning 2000043300 * Front suspension cross positioning 2000043500 * Front suspension cross positioning 2000043600 * Front suspension cross positioning 2000001400 * Brake/clutch system depression 2000002100 9340 Loosen / tighten the fuel pump mounting ring 2000003000 * Engine timing 2.0L Turbo Diesel 2000004100 20145 Introduction front oil seal crankshaft 2.0L Turbo Diesel 2016000090 * Balancing shaft lock motor 2.0L Turbo Diesel 2019600090 * Control engine balancing shafts 2.0L Turbo Diesel 2000040488 * Extraction drive shafts 2.0L Turbo Diesel * Tool not available for NAFTA. Use a commercially available tool or contact Mopar Essential Tools to order the custom EMEA tool.
KRYOTEC ENGINE 23 4. EXPLODED VIEW 1.ENGINE SUPPORT No. Part Number Description Qty. Notes 1 46336875 SUPPORT 1 2 55274541 BUSH 1 3 16287434 SCREW (With flange M8x35) 1 3 16289434 SCREW (WITH FLANGE M10X1.25X80) 1 FAST. CENTRAL MOTOR SUPPORT TO CYL BLOCK 3 55201021 SCREW 2 FAST. CENTRAL MOTOR SUPPORT TO CYL BLOCK FLANGE M10X1.25X110) 3 55262695 SCREW 1 SPECIAL WITH WASHER INCORPORATED - M10X1.25) ENGINE CENTRE OF GRAVITY SUPPORT TO INJECTION PUMP MOUNTING FASTENING 3 55262695 SCREW (SPECIAL M10 X 1.25) 1 3 16288034 SCREW (WITH FLANGE M8 X 1.25 X 65) FAST. CENTRAL MOTOR SUPPORT TO CYL BLOCK 1 FAST. CENTRAL MOTOR SUPPORT TO
KRYOTEC ENGINE 24 2.CRANKCASE No. Part Number Description Qty. Notes 1 55274879 HEAD GASKET 1 GASKET BET LOWER CYL HEAD & BEDPLATE (Thickness 0.95mm) 1 55274880 HEAD GASKET 1 (Thickness 1.05mm ) 1 55274881 HEAD GASKET 1 (Thickness 1.15mm) 2 55265045 DOWEL 2 GUIDE PIN 3 55265046 DOWEL 4 GUIDE PIN 4 55265047/ 55275655 DOWEL 2 GEAR BOX CENTRAL CAP FOR CYL BLOCK 5 14328501 PLUG (Ø16) 2 BLOCK CUP PLUG DIAM.16 5 14328701 PLUG (Ø20) 1 5 55189943 PLUG (Ø25) 1 5 14329101 PLUG (Ø30) 5 6 55218941 SCREW (Special with flange M 12x98) 10 7 55274701 PROTECTION 1 UPPER DUST COVER
KRYOTEC ENGINE 25 No. Part Number Description Qty. Notes 8 55279036 BUTTON 2 9 51799915 PROTECTION 1 LOWER DUST COVER 10 16296921 SCREW 1 11 55273766 CRANKCASE 1 CYLINDER BLOCK
KRYOTEC ENGINE 26 3.CYLINDER HEAD AND GASKETS No. Part Number Description Qty. Notes 1 55275447 CYLINDER HEAD WITH VALVES (For production) 1 LOWER CYL HEAD ASSLY 2 55262289 CYLINDER HEAD 1 LOWER 3 55253937 STUD (M8X18) 9 STUD M8X18 STEM 46 4 55248941 HEAD GASKET (CAM CARRIER) 1 GASKET BETWEEN UPPER CYL HEAD & LOWER CYL HEAD 5 55214216 SCREW (Special M12x220) 10 BOLT FOR LOWER CYLINDER HEAD TO CYLINDER BLOCK 6 55265044 DOWEL (14X16) 2 7 PIPE 1 8 55280452 CYLINDER HEAD (Upper) 1 CYLINDER HEAD MACHINED 9 SEAL GASKET 1 10 55189807 PLUG 1 FILLER PLUG 11 55249565 PLUG (M16X1.5) 2 12 18752824 SCREW (M8X35) 5 12 55187178 SCREW (Special with flange M8x71) 12
KRYOTEC ENGINE 27 No. Part Number Description Qty. Notes 12 18754021 SCREW (With flange M8X125) 1 13 SCREW 1
KRYOTEC ENGINE 28 4.OIL CAP AND FLOOR PANEL COVER No. Part Number Description Qty. Notes 1 55274872 OIL SUMP 1 PAN ASSY ENGINE OIL 2 55196309 SEAL GASKET 1 3 55274877 PLUG 1 4 55199580 SCREW AND WASHERASSY (Special with washer incorporated M6X16) 5 5 55272147 COVER 1 CRANKSHAFT COVER, FLYWHEEL SIDE 6 14943224 SCREW AND WASHER ASSY (with washer incorporated M8x28) 10 6 14942224 SCREW AND WASHER ASSY (Special with washer incorp. M6x30) 4 FOR OIL SUMP STUD TO OIL PUMP & COVER (5)FASTENING 7 SEALER 1
KRYOTEC ENGINE 29 5.ENGINE SHAFT AND HALF BEARING No. Part Number Description Qty. Notes 1 55277488 CRANKSHAFT 1 2 7761034 / 55189542 SCREW 3 3 46471843 TOOTHED WHEEL 1 4 5978916 / 55266005 DOWEL 1 5 55230264 HALF RING (40,000) 2 STD U 5 46470459 HALF RING (+0, 127) 2 6 55217062 BIG END SHELLS (ANI RED sp. 1,832-1,836) 5 CR.CAP SIDE CLASS A 6 55217063 BIG END SHELLS (BN2 BLUE sp.1,835-1 ,839) 5 CLASS B 6 55217064 BIG END SHELLS (CN3 YELLOW sp.l ,838-1 ,842) 5 CLASS C 6 55227350 BIG END SHELLS (AM6 BROWN sp.1,896 - 1.900) 5 CLASS A 6 55227351 BIG END SHELLS (BM7 GREEN sp. 1,899 - 1.903) 5 CLASS B 6 55227352 BIG END SHELLS (CM8 BLACK SP. 1 ,902 - 1.906) 5 CLASS C 6 55227353 BIG END SHELLS (+0,254 sp. 1 ,959- 1,963) 5
KRYOTEC ENGINE 30 No. Part Number Description Qty. Notes 7 55217055 BIG END SHELLS (ANI RED sp.1,832-1,836) 5 CLASS A 7 55217056 BIG END SHELLS (BN2 BLUE SP. 1,835-1 ,839) 5 CLASS B 7 55217057 BIG END SHELLS (CN3 YELLOW sp.1,838-1 ,842) 5 CLASS C 7 55227346 BIG END SHELLS (AM6 BROWN SP.1,896 - 1.900) 5 CLASS A 7 55227347 BIG END SHELLS (BM7 GREEN SP.1,899 - 1.903) 5 CLASS B 7 55227348 BIG END SHELLS (CM8 BLACK SP.1,902 - 1.906) 5 CLASS C 7 55227349 BIG END SHELLS (+0,254 SP. 1,959 - 1,963) 5
KRYOTEC ENGINE 31 6.FLYWHEEL No. Part Number Description Qty. Notes 1 55261169 FLYWHEEL 1 2 55282093 SCREW (SPECIAL M12X1.25) 3 552820936 VITE(SPECIAL)
KRYOTEC ENGINE 32 7.COUPLING RODS AND HALF BEARINGS No. Part Number Description Qty. Notes 1 55226965 CONNECTING ROD (COMPLETA) 4 2 55200303 BUSH 4 3 55198190 BOLT 8 4 55274456 LOCKRING 8 5 55274519 PISTON PIN 4 6 55217048 BIG END SHELLS (Upper - color) 4 Thickness (1,528-1,532) CL.1 6 55217049 BIG END SHELLS (Upper - Blue color) 4 Thickness (1,532-1,536) CL.2 6 55217050 BIG END SHELLS (Upper - Yellow color) 4 Thickness (1,535-1,539) CL.2 6 55227361 BIG END SHELLS (Upper - Brown color - Oversize O, 127mm) 4 Thickness (1,592-1,596) 6 55227362 BIG END SHELLS (Upper - Green color Oversize O, 127mm) 4 Thickness (1,596-1,600) 6 55227363 BIG END SHELLS (Upper - Black color Oversize O, 127mm) 4 Thickness (1,599-1,603) 6 55227364 BIG END SHELLS (Upper - No color - Oversize O,254mm) 4 Thickness (1,655 - 1,659) 7 55217041 BIG END SHELLS (Lower - Red color) 4 Thickness (1,528-1,532)
KRYOTEC ENGINE 33 No. Part Number Description Qty. Notes 7 55217042 BIG END SHELLS (Lower - Blue color) 4 Thickness (1,532-1,536) 7 55217043 BIG END SHELLS (Lower - Yellow color) 4 Thickness (1,535-1,539) 7 55227357 BIG END SHELLS (Lower - Brow co or - Oversize O, 127mm) 4 Thickness (1,592-1,596) 7 55227358 BIG END SHELLS (Lower - Green color - Oversize 0,127mm) 4 Thickness (1,596-1,600) 7 55227359 BIG END SHELLS (Lower - Black color - Oversize 0,127mm) 4 Thickness (1,599-1,603) 7 55227360 BIG END SHELLS (Lower - No color - Oversize 0,254mm) 4 Thickness (1,655 - 1,659)
KRYOTEC ENGINE 34 8.PISTONS AND RINGS No. Part Number Description Qty. Notes 1 PISTON RINGS SET (+0,0) 4 2 RING SET +0.10 (+0, 1) 4 3 RING SET 40.4 (+0,4) 4 4 55275296 PISTON, RINGS A 4 5 55275301 PISTON, RINGS B 4 6 55275305 PISTON, RINGS C 4 6 55275298 PISTON +0.1 (CLASSE A) 4 6 55275315 PISTON +0.1 (CLASSE B) 4 6 55275309 PISTON +0.1 (CLASSE C) 4 6 55275300 PISTON PIVOT RING +0.4 4
KRYOTEC ENGINE 35 9.CAMSHAFT DRIVE No. Part Number Description Qty. Notes 1 55275559 DRIVEN GEAR 1 GEAR FOR CAMSHAFT 2 46441027 SCREW (Special with flange M12X33) 1 3 55187100 / 55200441 FIXED TIGHTENER 1 FIXED TENSIONER ON CYL BLOCK 4 46463567 SCREW (Special with flange M8x25) 1 5 16289234 SCREW (WITH FLANGE M10X1.25X65) 1 6 46338344 TENSIONER KIT ASSAY 1 SUPPORT 7 55275560 DRIVEN GEAR 1 GEAR FUEL INJECTION PUMP 8 73500821 NUT (Special M14) 1 9 7743197 spACER 1 10 7686765 SCREW (Special with flange M16x70) 1 11 55275558 DRIVING GEAR 1 12 73504017 BELT 1 13 55274553 SUPPORT 1
KRYOTEC ENGINE 36 No. Part Number Description Qty. Notes 14 55274561 BUSH 1 15 55274554 SCREW 1 16 73500265 NUT 1 17 55238027 ADJUSTABLE TIGHTENER 1 18 73501847 SCREW 1
KRYOTEC ENGINE 37 10.CAMSHAFT COVER No. Part Number Description Qty. Notes 1 55258488 COVER 1 2 14942224 SCREW AND WASHERASSY (M6X30) 7 3 55284805 COVER 1 4 55257623 COVER 1 5 55199580 SCREW AND WASHERASSY (M6X1) 4 6 55229836 SCREW 1 7 55258488 SCREW AND WASHERASSY 1
KRYOTEC ENGINE 38 11.CRANKSHAFT AND GEAR TIMING SYSTEM No. Part Number Description Qty. Notes 1 55274568 CAMSHAFT (Exhaust) 1 2 55274435 CAMSHAFT (Intake) 1 3 55234683 DRIVEN GEAR (Exhaust) 1 GEAR EXHAUST CAMSHAFT 4 55234684 DRIVEN GEAR (Intake) 1 GEAR FOR INLET CAMSHAFT 5 46441027 SCREW (Special with flange M12X33) 2 6 46802577 SEAL GASKET (30X45X7) 1 EXHAUST CAMSHAFT
KRYOTEC ENGINE 39 12.VALVE INTAKE AND RELEASE No. Part Number Description Qty. Notes 1 65261261 INTAKE VALVE 8 2 55222934 EXHAUST VALVE 8 3 55274436 ROCKER 16 4 55183812 SEAL 16 OIL RETAINER 5 55220483 TAPPET 16 6 55274434 SPRING 16 7 55183811 CUP 16 8 10592470 SEMI-CONE TAPPETS 32 9 55210015 VALVE GUIDE (+0,05) 16 9 55210016 VALVE GUIDE (+0, 10) 16 9 55210017 VALVE GUIDE (+0,25) 16 10 71752906 SPRING 16
KRYOTEC ENGINE 40 13.BELTS AND PULLEYS No. Part Number Description Qty. Notes 1 55274978 DRIVING PULLEY 1 2 55261930 SCREW (M8X12) 8 M8 X 1.25
KRYOTEC ENGINE 41 14.INJECTION PUMP No. Part Number Description Qty. Notes 1 55274708 DUCTING 1 2 55274710 SLEEVE 1 3 55274711 HOSE 1 4 13125470 COLLAR (Ø 13-14) 3 5 16286024 SCREW (With flange M6x16) 2 6 55274521 INJECTION PUMP 1 7 71754999 SEAL GASKET 1 8 71754620 SEAL GASKET 1 9 71754621 SCREW 3 10 71772309 PRESSURE REGULATOR 1 11 71755000 SEAL GASKET 1 12 13125070 COLLAR 1
KRYOTEC ENGINE 42 15.ENGINE PUMP SUPPORTS No. Part Number Description Qty. Notes 1 55285023 SUPPORT 1 2 55207720 BUSH 1 3 14060011 NUT (MB) 3 4 55237542 SPACER 1 5 46522794 STUD (M8 X 12 X 30) 3 6 18752824 SCREW (M8X35) 3 6 55283551 SCREW (With flange M10x40) 1 6 55207946 SCREW (Special M8x110) 2 7 46469163 PLANE WASHER 10X28X4 1 8 55270197 PROTECTION 1 9 16286021 SCREW 3
KRYOTEC ENGINE 43 16.HYDRAULIC COUNTER AND INJECTORS No. Part Number Description Qty. Notes 1 55284036 HYDRAULIC ACCUMULATOR 1 2 55280822 SENSOR 1 3 55274580 DAMPER 4 4 55274573 PIPE 5 55274579 PIPE 6 16287224 SCREW (With flange M8x25) 2 7 55263233 INJECTOR 4 8 55221016 SEAL GASKET 4 9 55270467 BRACKET 1 10 55189554 PLANE WASHER 4 11 46796662 STUD (M8X16-57) 4 12 14060011 NUT (MB) 4 13 55269856 PIPE 1
KRYOTEC ENGINE 44 17.ENGINE HARNESS AND SUPPORTS No. Part Number Description Qty. Notes 1 46344924 CABLE HARNESS MT 1 Manual Transmission 1 46343815 CABLE HARNESS AT 1 Auto Transmission. 2 55216242 SENDING UNIT (Phase sensor) 1 3 55246559 SCREW AND WASHERASSY 1 4 46798345 SENDING UNIT (Sensor RPM) 1 5 16297024 SCREW (With flange M6x18) 1 6 16285924 SCREW 7 7 BRACKET 1 8 SCREW (M6X16) 2 9 55274703 BRACKET 1 10 16285924 SCREW 1
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