POWER

SERVICE

WORKSHOP MANUAL

Prima Four cylinder diesel engines

- for
vehicle applications
Prima Marine Four cylinder diesel engines for
u marine applications
500 Series Four cylinder diesel enginesfor
agricultural and industrial
applications

0
0
In
a Publication TPD 0192 1273.
@ Perkins Group Limited 1992, all rights reserved.
Published by Technical Publications,
.& Perkins Power Sales and Sewice Limited, Peterborough PE1 5NA, England.
s
 Amendment status
Number Description Date

1 To amend and add information January 1992

 Contents
General information ........................
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE OPERATIONS

Cylinder head assembly .....................

Piston and connecting rod assemblies . . . . . . . . . . . .
Crankshaft assembly . . . . . . . . . . . . . . . . . . . . . . . .
Timing case and drive assembly ...............
Cylinder block assembly .....................
Engine timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b Aspiration system . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication system ........................
Fuel system ..............................
Cooling system ...........................
Flywheel. flywheel housing and marine reverse gearbox
Electrical equipment ........................
Auxiliary equipment ........................
(D
.-
........................
L

cn
0
List of special tools
0

w
1
g
General information

lntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.02
Engine identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.03
Safety precautions .................................................... 10.04
Asbestos joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.05
10 GENERAL INFORMATION

Introduction Read and remember the "Safety precautions". They are given
for your protection and must be used at all times.
This workshop manual has been designed to provide assistance in
the service and overhaul of Perkins Prima and 500 Series engines.

Most of the general information which is included in the relevant

User's Handbook (sections 1 to 9) has not been repeated in this
A A hazard symbol in the text indicates that there is a
danger of personal injury if certain operations are
not done correctly.

workshop manual and the two publications should be used

together.

Where the information applies only to certain engine types, this is

indicated in the text.

When reference is made to the "left" or "right" side of the engine,

this is as seen from the flywheel end of the engine.

Special tools have been made available and a list of these is given
in section 25. Reference to relevant special tools is also made at
the beginning of each operation.

All the joints on these engines can be fitted dry unless instructions
are given for the application of sealant. Where fasteners are fitted
into threaded holes which are open to the inside of the engine,
manifolds, etc., a suitable sealant must be applied to the threads.
If necessary, sealant is already applied to new fasteners but, if
these are used more than once, the threads should be cleaned
and new sealant applied.

Prima M60 Prima M80T

504-2 504-2T
 GENERAL INFORMATION 10
Engine identification
The Perkins Prima and 500 Series engines have been designed for
specific applications, as shown below.
Prima for vehicle applications
Prima Marine for marine applications
500 Series for agricuttural and industrialapplications
Each series consists of a range of four cylinder engines which are
either natdrally aspirated or turbocharged.

There are different models in each series.

Prima engines are named according to their approximate power

output, for example:
Prima65 - naturally aspirated vehicle engine rated at 62 bhp
Prima M50 - naturally aspirated marine engine rated at 49 bhp
Prima M80T - turbocharged marine engine rated at 78 bhp
500 Series engines are identified by a system of numbers and
letters, for example:
504-2T - four cylinder turbochargedengine of two litres capacrty
Further information about the engine number system can be found
in the relevant user's handbook.

The information in this workshop manual is relevant to all engine

models, unless specifically indicated.

The engine number is stamped on a label which is fastened to the

left side of the cylinder block (Al). An example of an engine
number is BA50240U523456S.

If you need parts, service or information for your engine, you must
give the complete engine number to your Perkins distributor.
 10 GENERAL INFORMATION

Safety precautions
These safety precautions are important. You must refer also to
the local regulations in the country of use. Some items only apply
to specific applications.
Only use these engines in the type of application for which they
have been designed.
Do not change the specification of the engine.
Do not smoke when you put fuel in the tank.
Clean away fuel which has been spilt. Material which has been
contaminatedby fuel must be moved to a safe place.
Do not put fuel in the tank while the engine runs (unless it is
absolutely necessary).
Do not clean, add lubricating oil, or adjust the engine while it
runs (unless you have had the correct training; even then
extreme caution must be used to prevent injury).
Do not make adjustments that you do not understand.
Ensure that the engine does not run in a location where it can
cause a concentration of toxic emissions.
Other persons must be kept at a safe distance while the engine,
or equipment, is in operation.
Do not permit loose clothing or long hair near moving parts.
Keep away from moving parts during engine operation.
Attention: Some moving parts cannot be seen clearly while the
engine runs.
Do not operate theengine if a safety guard has been removed.
Do not remove the filler cap of the cooling system while the
engine is hot and while the coolant is under pressure, because
dangerous hot coolant can be discharged.
Do not use salt water or any other coolant which can cause
corrosion in the closed coolant circuit.
Do not allow sparks or fire near the batteries (especially when
the batteries are on charge) because the gases from the
electrolyte are highly flammable. The battery fluid is dangerous
to the skin and especially to the eyes.
Disconnect the battery terminals before a repair is made to the
electrical system.
Only one person must control the engine.
Ensure that the engine is operated only from the control panel
or from the operator's position.
If your skin comes into contact with high-pressurefuel, obtain
medical assistance immediately.
Diesel fuel and lubricating oil (especially used lubricat~ngoil)
can damage the skin of certain persons. Protect your hands
with gloves or a special solution to protect the skin.
Do not wear clothing whrch is contaminated by lubricat~ng011.
Do not put material which is contaminated with oil into the
pockets.
Discard used lubricating oil in a safe place to prevent
contamination.
Do not move mobile equipment if the brakes are not in good
condition.
Ensure that the control lever of the transmission dr~veis in the
"out-of-drive" position before the engine is started.
Use extreme care if emergency repairs must be made at sea or
in adverse conditions.
I The combustible material of some components of the engine
I (for example certain seals) can become extremely dangerous if
I it is burned. Never allow this burnt material to come into contact
I with the skin or with the eyes.
Read and use the instructions relevant to asbestos joints.
Fit only genuine Perkins parts.
 GENERAL INFORMATION 10
Asbestos joints
I These engines do not contain asbestos joints and gaskets.
I These instructions may apply to certain joints and gaskets in
I components which have been fitted to the engine after it has left
I the factory.

Some joints and gaskets contain compressed asbestos fibres in a

rubber compound or in a metal outer cover. The "white" asbestos
(Chrysotile) which is used is a safer type of asbestos and the risk
of damage to health is extremely small.

The risk of asbestos from joints occurs at their edges or if a joint is

damaged when a component is removed or if a joint is removed by
abrasion.

To ensure that the risk is kept to a minimum, the procedures given

below must be applied when an engine which has asbestos joints
is dismantled or assembled.
Work in an area with good ventilation
Do not smoke
Use a hand scraper to remove the joints - do not use a rotary
wire brush
Ensure that the joint to be removed is wet with oil or water to
contain loose particles
Spray all asbestos debris with water and put it in a closed
container which can be sealed for safe disposal
Specifications

Basic engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A

Recommended torque tensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 11B
Data and dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11@
Basic engine data 11A

Basic engine data ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1 1 A.02
 11A BASIC ENGINE DATA

Basic engine data

Number of cylinders ................................. 4
Cylinder arrangement ............................... In-line
Cycle .......................................... Four stroke
Inductionsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Naturallyaspirated or turbocharged
Combustion system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct injection
Nominal bore .................................... 84,5 mm (3.33 in)
Stroke .......................................... 88,9 mm (3.50 in)
Compressionratio:
- Naturallyaspirated vehicle and M6O engines ............... 18.1:l
-Turbocharged vehicle and MBOT engines . . . . . . . . . . . . . . . . . . 17.2:l
- 500 and M50 engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.0:l
Cubic capacity .................................... 1,994 litres (122 in3)
Firing order ....................................... 1, 3,4, 2
Tappet clearances (cold):'
I - Inlet (cylinder head fitted to block) ..................... 0,25/0,35 mm (0.010/0.014 in)
(cylinder head not fitted to block) ............... 0,30/0,40 mm (0.01 2/0.016 in)
I - Exhaust (cylinder head fitted to block) .................. 0,35/0,45 mm (0.014/0.'018 in)
(cylinder head not fitted to block) ............... 0,40/0,50 mm (0.016/0.020 in)
I 'Adjust only if clearances are outside limits of:
I - Inlet (cylinder head fitted to block) . . . . . . . . . . . . . . . . . . . . . 0,20/0,40 mm (0.008/0.016 in)
(cylinder head not fitted to block) . . . . . . . . . . . . . . . . . . 0,25/0,45 mm (0.010/0.018 in)
I- Exhaust (cylinder head fitted to block) .................. 0,30/0,50 mm (0.012/0.028 in)
(cylinder head not fitted to block) ............... 0,35/0,55 mm (0.014/0.022 in)
Lubricating oil pressure(minimum at maximum engine speed
and normal engine temperature) . . . . . . . . . . . . . . . . . . . . . . . . 250 kN/m2 (36 Ibfhn2)2,5 kgf/cm2
Direction of rotation ................................. Clockwise from the front
Recommended torque tensions 1lB

Cylinder head assembly ... ... ...

Piston and connecting rod assemblies
Crankshaft assembly ... ... ... ...
Timing case and drive assembly ... ...
Aspiration system ... ... ... ... ...
Lubricationsystem ... ... ... ... ...
Fuel system ... ... ... ... ... ...
Cooling system ... ... ... ... ... ...
Flywheel and housing ... ... ... ...
Electrical equipment ... ... ... ...
Auxiliary equipment ... ... ... ...
 11B RECOMMENDED TORQUE TENSIONS

Recommended torque tensions

The torque tensions below apply to components lubricatedlightly with clean engine oil before they are fitted.

Thread Torque

Description size Nm Ibfft kgfm

Cylinder head assembly

Setscrews, cylinder head ....................................... MI2 See section 12
Setscrews, camshaft cover ....................................... M8 22 16 22

Piston and connecting rod assemblies

Nuts, connecting rod big ends .................................... 11/32 UNF 47 35 43
Banjo bolts, piston cooling jets .................................... M8 11 8 1,1

Crankshaft assembly
Setscrews, main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M I2 112 83 11,4
I Setscrew (gold colour), crankshaft pulleys ........................... MI4 180 133 18,4
I Setscrew (black colour), crankshaft pulleys . . . . . . . . . . . . . . . . . . . . . . . . . . . MI4 200 148 20.4
I Cap screws, crankshaft pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M6 12 9 1.2
M8 27 20 2.7
Setscrews, rear oil seal housing .................................... M8 22 16 22
MI0 43 32 4,4

Timing case and drive assembly

Setscrews, timing case .......................................... M5 3 2 03
M6 6 4 0.6
M8 10 7 1,o
Setscrew, hub of camshaft pulley ................................. MI2 85 63 8,7
Setscrew, camshaft pulley to hub ................................. M8 22 16 22
Cap screw, tensioner pulley .................................... MI0 43 32 4,4
Setscrew, idler pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M I0 43 32 4.4

Aspiration system
Nuts, turbocharger to manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M8 22 16 22
I Nuts, exhaust outlet to turbocharger or to heat exchanger ............... M8 22 16 22
Setscrews, inlet and exhaust manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M8 22 16 22

Lubrication system
Plug, lubricating oil sump ....................................... 1/4 ESP 43 32 4,4
Setscrews, lubricatingoil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M6 9 7 0,9
I MI0 43 32 4,4
Screws, backplateto oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M4 4 3 0,4
Setscrews, filter head to oil pump ................................. M8 22 16 22
Setscrews, lubricatingoil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M6 12 9 1.2

Fuel system
Nuts, high-pressure fuel pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MI2 18 13 1,a
Setscrews, atomiser clamps .................................... MI0 43 32 4.4
Setscrews, fuel lift pump ....................................... M8 22 16 22
Setscrews, mounting bracket for fuel injectionpump . . . . . . . . . . . . . . . . . . .:. M10 43 32 4,4
Nut, pulley to h e l injection pump ................................. M I4 60 44 61
Nuts for flange of fuel injectionpump .............................. M8 22 16 22
 RECOMMENDEDTORQUE TENSIONS 11B
Thread I Torque I
Description size Nm Ibf ft kgf m

Cooling system
Setscrews, water pump ........................... M8 22 16 22
- with engine mounting ............................ MI0 48 35 4,9
- without engine mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . MI0 43 32 4,4
Setscrews, raw water pump (marine only) ............... M6 9 7 0,Q
Cap screws, drive adaptor for raw water pump ............ M6 9 7 0,9
Setscrews, fan and fan extension ..................... M6 9 7 0,9
Cap screw, mounting plate to cylinder head (high level fan drive) M8 39 29 4,O
Setscrews,fan drive mounting (high level fan) ............ M8 22 16 22
MI0 43 32 4,4
Setscrew, tensioner pulley for fan belt .............................. MI0 43 32 4,4

Flywheel and housing

Setscrews, flywheel to crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I 7/16 UNF 65 48 6,6
Setscrews, flywheel housing .................................... M8 22 16 22
M10 43 32 4,4
M12 81 60 83

Electrical equipment
Nut, alternator pulley ..........................................
I M17 60 44 61
Glow plug ................................................
Auxiliary equipment
Setscrew, exhauster .......................................... I
I
Data and dimensions

Introduction ..................
Cylinder head assembly .........
Piston and connecting rod assemblies
Crankshaft assembly ............
Timing case and drive assembly ......
Cylinder block assembly .........
Aspiration system . . . . . . . . . . . . . . .
Lubrication system . . . . . . . . . . . . . . .
Fuel system ..................
Cooling system ...............
Flywheel and housing . . . . . . . . . . . .
Electrical equipment ............
Auxiliary equipment ............
 11C DATA AND DIMENSIONS

Introduction
This information is given as a guide for personnel engaged on engine overhauls. The dimensions which are shown are those which are
mainly used in the factory. The information applies to all engines, unless an engine type is shown.

Cylinder head assembly

Cylinder head
Angle of valve seats ................................. 45"
Diameter of bores for camshaft ........................ 48.018/48,057 mm (1.890/1.892 in)
Diameter of parent bores for valve guides .................. 11,98/12,00 mm (0.4716/0.4724 in)
Diameter of bores for tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . 31,750/31,775 mm (1.25011.251 in)
Leak test pressure ................................. 200 kPa (29 Ibf/in2)2,04 kgf/cm2
Maximum permissible distortion of cylinder head ............ 0,10 mm (0.004 in)
Head thickness .................................... 120,0/120,1 mm (4.724/4.728 in)
Permissible amount to machine from cylinder head face ...... 0,20 mm (0.008 in) -depth of head must not be
less than 119,85 mm (4.718 in)

Valve guides
Inside diameter (reamed in position) ..................... 7,450/7,463 mm (0.2933/0.2938 in)
Outside diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12,04/12,06 mm (0.474/0.475 in)
Interference fit of valve guide in cylinder head . . . . . . . . . . . . . . . 0,04/0,08 mm (0.0016/0.0031 in)
Protrusion above location face for valve spring . . . . . . . . . . . . . . . 10 mm (0.39 in)

Inlet valves
Diameter of valve stem .................. 7,41/7,42 mm (0.2917/0.2922 in)
Clearance in valve guide .................. 0,0310,05 mm (0.001/0.002 in)
Maximum permissible clearance in valve guide ... 0,13 mm (0.005 in)
Diameter of valve head .................. 37,10/37,25 mm (1.461/1.467 in)
Angle of valve face ..................... 44" 30' (91" included angle)
Depth of valve head below face of cylinder head 0,90/1,24 mm (0.03510.049 in)
Overall length ........................ 93,72/93,97 mm (3.690/3.700 in)
Seal arrangement ..................... Rubber seal fitted to valve guide

Exhaust valves
Diameter of valve stem .................. 7,3917,41 mm (0.2909/0.2917 in)
Clearance in valve guide .................. 0,04/0,07 mm (0.0016/0.0028 in)
Maximum permissible clearance in valve guide ... 0,13 mm (0.005 in)
Diameter of valve head .................. 33,55/33,70 mm (1.321/1.327 in)
Valve face angle ........................ 44" 30' (91" included angle)
Depth of valve head below face of cylinder head 1,3011,64 mm (0.051/0.065 in)
Overall length ........................ 93,72/93,97 mm (3.690/3.700 in)
Seal arrangement ..................... Rubber seal fitted to valve guide
 DATA AND DIMENSIONS 11c
-
Valve springs vehicle, M60 and M80T engines
Fitted length ....................................... 34,7 mm (1.37 in)
Load at fitted length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198 N (44.5 Ibf) 20,2 kgf
Number of active coils .............................. 4.5
Number of damper coils .............................. 0
Direction of coils .................................... Left hand
Identification colour ................................. Orange

-
Valve springs 500 and M50 engines
Fitted length ........................................ 34,7 mm (1.37 in)
I Load at fitted length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142/157 N (32/35 Ibt) 14.5/16.0 kgf
Number of active coils .............................. 5.2
Number of damper coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Direction of coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Left hand
Identification colour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . White

Tappets and shims

Material:
- Vehicle, M6O and MBOT engines . . . . . . . . . . . . . . . . . . . . . . . . Steel
- 500 and M50 engines .............................. Cast iron
Outside diameter of tappet ........................... 31,725/31,745 mm (1.2490/1.2498 in)
Clearance of tappet in cylinder head ..................... 0,005/0,050 mm (0.0002/0.0020 in)
Thickness of tappet head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6,85/6,93 mm (0.270/0.273 in)
Overall length:
-Vehicle, M6O and MBOTengines . . . . . . . . . . . . . . . . . . . . . . . . 25,7/26,3 mm (1.01/1.04 in)
- 500 and M50 engines .............................. 29,7/30,3 mm (1.17/1.19 in)
Shim thickness .................................... Range of 45 shims from 2,286 mm (0.090 in) to 3,400 mm
(0.134 in) in grades of 0,025 mm (0.001 in)

Camshaft
Diameter of front and rear journals . . . . . . . . . . . . . . . . . . . . . . . . 47,963/47,975 mm (1.8883/1.8888 in)
Diameter of centre journal ........................... 47,958/47,975 mm (1.8881/1.8888 in)
Clearance of journals in bores:
- Front and rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,043/0,094 mm (0.001710.0037 in)
- Centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,043/0,099 mm (0.001710.0039 in)
Diameter for pulley hub .............................. 36,58/36,61 mm (1.440/1.441 in)
Cam lift - vehicle, M60 and M80T engines:
- Inlet and exhaust ................................. 9,544/9,724 mm (0.3757/0.3828 in)
Cam lift - 500 and M50 engines:
I - Inlet (camshaft part number L141DF11). . . . . . . . . . . . . . . . . . 8,844/9,024 mm (0.3482/0.3553 in)
I - Inlet (camshaft part number L141DF02). . . . . . . . . . . . . . . . . . 9,044/9,224 mm (0.3561/0.3632 in)
- Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9,344/9,524 mm (0.3679/0.3750 in)
0,11/0,27 mm (0.004/0.011 in)
Maximum permissible end-float in service . . . . . . . . . . . . . . . . . . 0,50 mm (0.020 in)
Width of recess for thrust washer . . . . . . . . . . . . . . . . . . . . . . . . 6,06/6,12 mm (0.239/0.241 in)

Camshaft thrust washer

%$'
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180" washer fitted in camshaft cover
5
1
Thickness ....................................... 5,90/5,95 mm 0.232/0.234 in
.-P)
$
(I)
Transition fit of thrust washer in camshaft cover recess . . . . . . . . . + 0,05 mm (+ 0.002 in)
 11C DATA AND DIMENSIONS

u
Piston and connecting rod assemblies
Pistons
Type .............................. "Swirl lip" combustion bowl, controlled expansion, insert for top
ring groove, off centre gudgeon pin
Diameter of bore for gudgeon pin ............ 28,004/28,010 mm (1.102511.1028 in)
Difference between height grades:
- Production grades 1 to 6 ............... 0,051mm (0.002 in)
- Service grades 3 and 6 . . . . . . . . . . . . . . . . . . 0,151 mm (0.006 in)
Height of piston above top face of cylinder block:
- Naturally aspirated vehicle, and M60 engines ... 0,46/0,65 mm (0.018/0.026 in)
-Turbocharged vehicle and M8OTengines ...... 0,41/0,60 mm (0.016/0.024 in)
- 500 and M50 engines . . . . . . . . . . . . . . . . . . 0,52/0,71 mm (0.02010.028 in)
Width of groove for top ring ............... 2,1012,12 mm (0.0827/0.0835 in)
Width of groove for second ring ............ 1,81/1,83 mm (0.071/0.072 in)
Width of groove for third ring . . . . . . . . . . . . . . . 3,03/3,05 mm (0.1 19/0.120 in)
Oversize piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,50 mm (0.020 in) on diameter

Piston rings
Top compression ring .............................. Barrel face, molybdenum insert, internal chamfer in top face
Second compression ring .............................. Taper face, cast iron
Oil scraper ring .................................... Coil spring loaded, chromium faced
Width of top ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,978/1,990 mm (0.0778/0.0783 in)
Width of second ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,7311,74 mm (0.068/0.069 in)
Width of third ring ................................. 2,98/2,99 mm (1.117/0.118 in)
Clearance of top ring in groove ........................ 0,11/0,14 mm (0.004/0.006 in)
Clearance of second ring in groove ..................... 0,0710.10 mm (0.003/0.004 in)
Clearance of third ring in groove ........................ 0,04/0,07 mm (0.002/0.003 in)
Gap of top ring .................................... 0,28/0,56 mm (0.01 1/0.022 in)
Gap of second ring ................................. 0,2810,56 mm (0.011/0.022 in)
Gap of third ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,23/0,56 mm (0.009/0.022 in)

Connecting rods
Type .......................................... "H" section
Diameter of parent bore for big end ..................... 57,683/57,696 mm (2.271012.2715 in)
Diameter of parent bore for small end ..................... 30,93/30,96 mm (1.21811.21 9 in)
Length between centres .............................. 144,98/145,03 mm (5.70815.710in)

Connecting rod alignment (A)

The large and small end bores must be square and parallel with
each other within the limits of +
0,25mm (0.010in) measured
127 mm (5.0 in) each side of the connecting rod axis on a test
mandrel. With the small end bush fitted, the limits are reduced to
+ 0,06 mm (0.0025 in).
 DATA AND DIMENSIONS 11c
u
Gudgeon pins
Type .......................................... Fully floating
Outside diameter .................................... 27,995/28,000 rnrn (1.1022/1 .I024 in)
Clearancefit in piston boss ........................... 0,004/0,015 rnrn (0.0002/0.0006 in)

Small end bushes

Type .......................................... Steel back, lead bronze bearing material
Inside diameter (reamed) .............................. 28,005/28,018 rnrn (1.1026/1.1031 in)
Clearance between small end bush and gudgeon pin ......... 0,005/0,023 rnrn (0.0002/0.0009 in)

Connecting rod bearings

Type .......................................... Steel back, copper lead bearing material
Thickness ....................................... 1,815/1,825 rnrn (0.0715/0.0719 in)
Inside diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54,033/54,066 rnrn (2.127W2.1286 in)
Bearing clearance ................................. 0,023/0,076 rnrn (0.001/0.003 in)
Available undersize bearings ........................... -0,30 rnrn (-0.012 in)
11C DATA AND DIMENSIONS

Crankshaft assembly
Crankshaft
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56,99/57,01mm (2.2437/2.2445in)
Diameter of main journals
Maximum permissiblewear and ovality of main journals ...... 0,03rnrn (0.001in)
Width of front journal ................................. 27,9128.6rnrn (1.10/1.13in)
Width of centre journal .............................. rnrn (1.72411.727in)
32,35/32,43
Width of all other journals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.5/31,1rnrn (1.20/1.22in)
Diameter of crank pins .............................. 53,99/54,01rnrn (2.125612.1264in)
Maximum permissible wear and ovality of crank pins ......... 0,03rnrn (0.001in)
Width of crank pins ................................. rnrn (1.081/1.089
27,45/27,65 in)
Crankshaft end-float ................................. rnrn (0.001/0.010in)
0,03/0,26
Diameter of rear flange .............................. rnrn (3.49813.502in)
88,84/88,95
Minimum permissible diameter of rear flange (service) . . . . . . . . . 88,59rnrn (3.488in)
Diameter for front oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34,965134,995rnrn (1.3766/1.3778
in)
Minimum permissible diameter for front oil seal (service) ...... 34,72rnrn (1.367in)
Diameter for toothed pulley ........................... mm (1.259/1.260
31,98/32,00 in)
Diameter of recess for spigot bearing ..................... mm (1.I2511.I26in)
28,58/28,60
Depth of recess for spigot bearing . . . . . . . . . . . . . . . . . . . . . . . . 20,8rnrn (0.82in)
Undersize journals and crank pins . . . . . . . . . . . . . . . . . . . . . . . . -0,30rnrn (-0.012
in)

Main bearings
Type .......................................... Steel back, aluminium tin bearing material
Bearing width, centre bearing ........................... rnm (0.956/0.965in)
24,27/24,52
Bearing width, all other bearings . . . . . . . . . . . . . . . . . . . . . . . . mm (0.880/0.890
22,35/22,60 in)
Rearingthickness ................................. rnm (0.0720/0.0722
1,828/1,835 in)
Inside diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57,033157,063rnrn (2.245412.2466in)
Bearing clearance ................................. mrn (0.001/0.003
0,023/0,073 in)
Available undersize bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . -0,30rnm (-0.012
in)

Crankshaft thrust washers

Type .......................................... Steel back, aluminium tin bearing material

Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Each side of centre main bearing
Thickness ....................................... rnm (0.091/0.093
2,31/2,36 in)
 DATA AND DIMENSIONS 11c
Timing case and drive assembly
Toothed pulley for crankshaft
Number of teeth .................................... 24
Diameter of bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32,010/32,035 mm (1.2602/1.2612 in)
Clearance fit of pulley on crankshaft ..................... 0,010/0,055 mm (0.0004/0.0022 in)

Toothed pulley and hub for camshaft

Number of teeth .................................... 48
Diameter of bore in hub .............................. 36,62/36,65 mm (1.442A.443 in)
Clearance fit of hub on camshaft . . . . . . . . . . . . . . . . . . . . . . . . 0,01/0,07 rnm (0.0004/0.0028 in)

Toothed pulley for fuel injection pump

Number of teeth .................................... 48
Bore .......................................... Tapered
Timing tooth and keyway letter:
I Where plunger lift of fuel injection pump at
I engine TDC is 1.26 mm (0.050 in) and above . . . . . . . . . . . . . . . "A"
I Where plunger lift of fuel injection pump at
I engine TDC is below 1.26 mm (0.050 in) . . . . . . . . . . . . . . . . . . "B"

Idler pulley for timing belt

Outside diameter .................................... 79,8/80,2 mm (3.14/3.16 in)
Radial internal clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,005/0,025 mrn (0.0002/0.0010 in)

Tensioner pulley for timing belt

Outside diameter .................................... 59,8/60,2 mm (2.35/2.37 in)
Radial internal clearance .............................. 0,005/0,025 mm (0.0002/0.0010 in)
Timing belt tension (gauge):
- New belt ....................................... 95/105 Ibf
- Used belt ....................................... 80 Ibf

Cylinder block assembly

Cylinder block
Height between top face and location face for bearing cap ...... 236,85/236,98 mm (9.325/9.330 in)
Cylinder bore diameter .............................. 84,442/84,469 mm (3.3245/3.3256 in)
Maximum permissible wear in bore ..................... 0,15 mm (0.006 in)
Oversize cylinder bore diameter ........................ 84,942/84,969 mm (3.3442/3.3452 in)
Diameter of parent bore for main bearing . . . . . . . . . . . . . . . . . . 60,703/60,719 rnrn (2.3899/2.3905 in)
11C DATA AND DIMENSIONS

Aspiration system

Tuhocharger
Make and type of turbocharger ........................ Airesearch T2
Boost pressure .................................... 89/96 kPa (12.9/13.9 Ibf/in2)0,91/0,98 kgf/cm2

Lubrication system
Lubricating oil pump

Type .......................................... Differential rotor, fitted around nose of crankshaft

Number of lobes .................................... Inner rotor 10, outer rotor 11
Outer rotor to body clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,30/0,36 mm (0.012/0.014 in)
Inner rotor to outer rotor clearance ..................... 0,025/0,082 m m (0.001/0.003 in)
Inner rotor end clearance . . . . . . . . . . .................... 0,030/0,075 mm (0.001/0.003 in)
Outer rotor end clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,05/0,10 mm (0.002/0.004 in)

Oil pressure relief valve

Valve open pressure ................................. 414 kPa (60 Ibf/in2)4,2 kgf/cm2
Bore diameter of sleeve .............................. 14,21/14,25 mm (0.5594/0.5610 in)
Outside diameter of plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . 14,160/14,186 mm (0.5575/0.5585 in)
Clearance of plunger in sleeve ........................ 0,024/0,090 mm (0.0009/0.0035 in)
Length of spring (fitted) .............................. 30,4 mm (1.2 in)
Load on spring (fitted) .............................. 51,l N (11.5 Ibf) 5,2 kgf
 DATA AND DIMENSIONS 11c
Fuel system
Fuel injection pump
Make .......................................... Bosch
Type .......................................... EPVE
Directionof rotation (from drive end) . . . . . . . . . . . . . . . . . . . . . Clockwise
Outlet for number 1 cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . "A"
Plunger lift at engine TDC:
I - Naturally aspirated vehicle engines
with standard atomisers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,37 mm (0.054 in)
I with two-stage atomisers ........................... 1,00 mm (0.039 in)
- Turbocharged vehicle engines
with standard atomisers ........................... 1.00 mm (0.039 in)
I with two-stage atomisers ........................... 1,20 mm (0.047 in)
I - Naturally aspirated industrial engines .................. 1,42 mm (0.056 in)
I -Turbochargedindustrial engines
I all build lists except BB50325 ........................ 1,24 mm (0.049 in)
I build list BB50325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,42 mm (0.056 in)
I - M50 marine engines .............................. 1,42 mm (0.056 in)
I - M60 marine engines .............................. 1.37 mm (0.054 in)
I - M80T marine engines .............................. 1,17 mm (0.046 in)

Atomisers

Code Holder Nozzle Set and reset pressure

atm Ibf/in2 MPa
JC LRB67030 JB6801061 225 3310 22,8
JD LRB67030 JB6801062 225 3310 22,8
RG KBEL68P40 DLLA150P159 225 3310 22,8

JP 180 2650 18,2

Two stage atomiser - first stage (check pressure only)
RL 200 2975 20,5

Fuel lift pump

Type .......................................... A.C.Delco, typeYD
Method of drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Eccentric on camshaft
Static pressure (no delivery) ........................... 41/69kPa (6/1 Olbf/in2)0,4/0,7 kgf/cm2

Fuel filter
Make .......................................... Bosch
Type .......................................... Screw type canister
11C DATA AND DIMENSIONS

Cooling system
Water pump
Type .......................................... Centrifugal, belt driven

-
Raw water pump marine engines only
Make .......................................... Jabsco
Type .......................................... Rubber impeller
Drive .......................................... From rear end of camshaft

-
Thermostat vehicle engines
Type .......................................... Wax pellet, by-pass blanking
"Start to open" temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . 85"/89"C (185"/192"F)
"Fully open" temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99"/102"C (210"/216"F)
Valve lift, fully open ................................. 9,5 mm (0.374 in) minimum

-
Thermostat 500 and marine engines
Type .......................................... Wax pellet, by-pass blanking
"Start to open" temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . 77"/85"C (171°/185°F)
"Fully open" temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92"/98"C (198"/208"F)
Valve lift, fully open ................................. 9,1 mm (0.358 in) minimum

Flywheel and housing

Flywheel
Maximum permissiblerun-out ........................ 0,30 mm (0.012 in) total indicator reading
Maximum alignment error .............................. 0,03 mm (0.001 in) total indicator reading for every 25 mm (1.0 in)
of flywheel radius from crankshaft axis to indicator plunger

Flywheel housing
Limits for concentricity and alignment ..................... 0,15 mm (0.006 in) total indicator reading
 DATA AND DIMENSIONS 11c
V
Electrical equipment

Alternator
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lucas
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1 27-55 or A1 27-70MT
Rating:
-A127-55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V/55A
-A127-70MT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V/70A
Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise, from drive end

Starter motor
Manufacturer .................................... Lucas
l Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M80R or 2M113
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12v
Number of teeth on pinion ........................... 10
Maximum resistance of starter cable at 20°C (68°F) ............ 0.001 7 ohms
I Brush length:
w M80R 2M113
I - New .......................................... 9,O mm (0.35 in) 22 mm (0.87 in)
I - Minimum permissible, worn . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,5 mm (0.14 in) 8 mm (0,32 in)

Glow plugs
I Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bosch or BERU
I Current:
I - Bosch with 23 mm (0.90 in) probe . . . . . . . . . . . . . . . . . . . . . . . . 12A after 20 seconds
I - Bosch with 28 mm (1.10 in) probe. . . . . . . . . . . . . . . . . . . . . . . . 11A after 20 seconds
I - BERU with 24 mm (0.95 in) probe. . . . . . . . . . . . . . . . . . . . . . . . 16A after 4 seconds

Auxiliary equipment

Exhauster
Make and type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clayton Dewandre REGA 1560, 70 ml piston
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Eccentric on camshaft
Cylinder head assembly

General description ...............

Camshaft cover
To remove and to fit ..................
Tappet clearances
To check ...........................
To adjust ...........................
Front oil seal of camshaft
To remove and to fit ..................
Rear oil seal of camshaft
To remove and to fit ..................
Camshaft
To remove and to fit ..................
Cylinder head assembly
To remove and to fit ..................
Valves and valve springs
To remove and to fit ..................
To inspect and to correct ...............
Valve guides
To inspect ..................
To remove and to fit ..................
Cylinder head
To inspect and to correct ...............
To correct a valve seat with a valve seat cutter
To fit valve seat inserts . . . . . . . . . . . . . . . . . .
12 CYLINDER HEAD ASSEMBLY

General description
In a diesel engine there is little carbon deposit and for this reason
the number of hours run is no indication of when to overhaul a
cylinder head assembly. The factors which indicate when an
overhaul is necessary are how easily the engine starts and its
general performance.

The cylinder head is made of aluminium and the head and the
camshaft cover are bored together to provide bearing locations for
the camshaft. The cams of the camshaft are directly above the
valves and operate them through tappets which are fitted on top
of the valves. Shims are fitted between the tappets and the tops of
the valves to allow for adjustment of tappet clearances.

The cylinder head assembly has two valves fitted for each
cylinder. Each valve is fitted with a single valve spring.

The valves move in cast iron guides which are a press fit in the
cylinder head and can be renewed.

Both valve stems are fitted with oil seals which fit over the top of
the valve guides.

Valve seat inserts are fitted in the cylinder head for both inlet and
exhaust valves.
 CYLINDER HEAD ASSEMBLY 12
Camshaft cover

To remove and to fit 12A-01

To remove
1 Remove the setscrew which fastens the front flange of the
camshaft cover to the timing case (Al).
Some vehicle engines have a setscrew, fitted inside the timing
case, which also fastens the timing case to the camshaft cover
(A2). For these engines the timing case cover will have to be
removed and the setscrew released.
Marine engines: Remove the setscrew which is fitted through the
drive housing of the raw water pump into the rear flange of the
cover (A3). If the cover is too tight for removal, loosen the
mounting bracket for the raw water pump.
2 Remove the setscrew from the timing hole in the top front of
the camshaft cover (A4). Turn the crankshaft until the timing hole
in the front journal of the camshaft aligns with the hole in the
cover. This will ensure easier removal of the fuel lift pump and the
camshaft cover.
3 Remove the engine lift brackets, if fitted. If nothing is driven
from the rear of the camshaft, remove the rear cover and fit the
camshaft retainer PD.181 (61). This will ensure that the camshaft
will not tilt when the camshaft cover is removed.
4 Remove the fuel lift pump, operation 20A-03 and the
exhauster, operation 24A-01, if fitted.
5 Loosen evenly the setscrews of the camshaft cover in the
reverse sequence to that given in figure D. Remove the setscrews
and the cover (6). Ensure that the thrust washer (82) remains in
position in the cover.

To fit
1 Check the cover and the thrust washer for the camshaft for
wear and for other damage. If the cover is worn or damaged, a
new cylinder head assembly will be needed as the bores for the
camshaft journals are machined with the cover and the head
fastened together.
2 Check that the location thimbles (83) and the thrust washer
(82) are correctly fitted. Ensure that the front and the rear seals of
the camshaft are still in their correct positions against the
shoulders in the cylinder head and that they are not tilted.
3 Ensure that the grooves in the camshaft cover and the contact
faces of the cylinder head and the cover are clean. Apply a 2 mm
(0.08 in) diameter bead of POWERPART Hylosil to the outer
grooves of the cover but leave the inner grooves empty, as shown
in figure (C). As soon as the sealant has been applied, fit the cover.
Fit the cover setscrews with the longer setscrews at each end of
the cover. Gradually tighten the setscrews to keep the cover
parallel to the cylinder head as it is pulled down. Finally tighten the
cover setscrews to 22 Nm (16 Ibf ft) 2,2 kgf m in the sequence
shown in figure (D).
4 Where necessary, remove the camshaft retainer and fit the rear
end cover.
Marine engines: Fit and tighten the setscrew which fastens the
drive housing of the raw water pump to the camshaft cover. If the
mounting bracket for the raw water pump has been loosened,
align the bracket before it is fastened, see operation 21A-08.
5 Fit and tighten the setscrew(s) which fasten(s) the timing case
to the camshaft cover. If necessary, fit the timing case cover.
6 Ensilre that the timing hole in the front journal of the camshaft
aligns with the timing hole in the camshaft cover. Fit the fuel lift

- 5:
pump, operation 20A-03 and if necessary, the exhauster,
operation 24A-01. Fit the setscrew in the timing hole in the
camshaft cover. If necessary, fit the engine lift brackets.
 12 CYLINDER HEAD ASSEMBLY

Tappet clearances
-

To check 12A-02
Special tools:
Camshaft retainer, PD.181
Camshaft clamps, PD.180

The tappet clearances are measured between the camshaft and

the top of the tappets (A). With the engine cold, the correct
clearances are 0,25/0,35 mm (0.010/0.014 in) for the inlet valves
and 0,35/0,45 mm (0.014/0.018 in) for the exhaust valves. See B
for the position of the inlet and exhaust cams.

Number 1 cam is at the pulley end of the camshaft.

I Attention: If the cylinder head is not fitted to the engine, see 16,
I operation 12A-12.
I Disconnect the battery.
2 Remove the camshaft cover, operation 12A-01.
Marine engines: Remove the raw water pump, operation 21A-06
and fit the camshaft retainer before the cover is removed.
3 Fit the camshaft clamps PD.180 (Al) to retain the camshaft and
fit the relevant cover setscrews to the clamps. It will be necessary
to move the rear seal on the camshaft to ensure that there is
clearance between the rear clamp and the seal. Ensure that the
spring loaded pads are correctly fitted on the camshaft journals
and tighten evenly the clamp setscrews.
4 Turn the crankshaft until the lobes of numbers 1 and 3 cams
are both near to their top position. Use feeler gauges with bent
blades to measure the tappet clearances of numbers 1 and 3
valves. Make a note of the clearances.
5 Repeat 4 for valves 2 and 5 , 6 and 8, and 4 and 7.
6 Adjustment is only necessary if the clearances are outside the
limits of 0,20/0,40 mm (0.008/0.016 in) for inlet valves or 0,30/0,50
mm (0.012/0.020 in) for exhaust valves. If adjustment is necessary,
see operation 12A-03.
7 When the clearances are correct, remove the camshaft journal
clamps and fit the camshaft cover, operation 12A-01.
8 Connect the battery.

To adjust 12A-03
Special tools:
Camshaft clamps, PD.180
Camshaft retainer, PD.181
Timing pins for camshaft and crankshaft, PD.182
Location pins for the pulley of the fuel injection pump, PD.190
Anti-rotation tool, PD.203

If it is found during a check of the tappet clearances, operation

12A-02, that adjustment is necessary, proceed as follows:
I Attention: If the cylinder head is not fitted to the engine, see 16,
I operation 12A-12.
1 Turn the crankshaft until the timing hole in the front journal of
the camshaft is in the 12 o'clock position. Fit the timing pin PD.182
through the backplate or through the flywheel housing into the
timing hole in the flywheel. Remove the starter motor, operation
238-01 and fit the anti-rotation tool PD.203 to the flywheel.
2 Remove the timing case cover, operation 15A-01.
3 Loosen the setscrews of the camshaft pulley and the setscrew
of the pulley hub.
4 Fit the location pins PD.190 to hold the pulley of the fuel
injection pump.
5 Remove the timing belt, the camshaft pulley and the pulley
hub, see section 15.
6 Remove the camshaft retainer or, for marine engines, remove
the raw water pump, operation 21A-06 and the pump mounting
bracket, operation 21A-08.
 CYI-INDER HEAD ASSEMBLY 12
7 Remove the camshaft clamps and remove the camshaft
(12A.O7/A). Remove the seals from the camshaft.
8 Adjust at each tappet in sequence: Remove the tappet (Al) and
remove the shim (A2) which is fitted in the top of the valve spring
cap (A3). From the notes obtained in operation 12A-02, find the
amount of adjustment needed for this tappet. Measure the
thickness of the shim. If the clearance needs to be increased, put
in a shim which is thinner by the necessary amount. If the
clearance needs to be decreased, put in a thicker shim. For
calculation purposes, use the average clearances of 0,30 mm
(0.012 in) for inlet valves and 0,40 mm (0.016 in) for exhaust valves.
Lubricate the tappet and fit it into its bore. Repeat the operation
for each tappet which needs adjustment.
9 When all the necessary shims have been changed, put the
camshaft in position and temporarily fit the hub for the camshaft
pulley. Remove the timing pin and the anti-rotation tool from the
flywheel. Turn the crankshaft a quarter of a turn in a clockwise
direction. Fit the camshaft clamps PD.180 and check that the
tappet clearances are correct, operation 12A-02.
10 When the clearances are correct, remove the hub for the
camshaft pulley and the camshaft clamps. Turn the crankshaft a
quarter of a turn in a counter-clockwisedirection. Fit the timing pin
and the anti-rotation tool to the flywheel. Lubricate the tappets
and the journals and cams of the camshaft.
11 Fit the camshaft cover, operation 12A-01.
12 Fit new front and rear seals to the camshaft, operations 12A-04
and 12A-05.
13 Fit the camshaft pulley and the timing belt , see section 15.
Remove the location pins from the pulley of the fuel injection
pump and adjust the belt tension, operation 15A-03.
14 Remove the flywheel timing pin and the anti-rotation tool.
Check the timing of the fuel injection pump, operation 17A-03.
15 Fit the timing case cover, operation 15A-01.
16 Fit the setscrew in the timing hole of the camshaft cover. Fit the
rear plate of the camshaft cover.
Marine engines: Fit the bracket for the raw water pump, operation
21A-08 and the raw water pump, operation 21A-06.
17 Turn the crankshaft through two revolutions to ensure that
there is no restrictionto movement.
18 Fit the starter motor, operation 238-01 and connect the
battery.
 12 CYLINDER HEAD ASSEMBLY

Front oil seal of camshaft

To remove and to fit 12A-04

Special tools:
Remover for front seal of camshaft, PD.185
Replacer for front seal of camshaft, PD.186
Timing pins for camshaft and crankshaft, PD.182
Location pins for the pulley of the fuel injection pump, PD.190
Anti-rotation tool, PD.203

1 Disconnect the battery.

2 Remove the setscrew from the timing hole in the top front of
the camshaft cover (12A.O3/A4). Turn the crankshaft until the
timing hole in the front journal of the camshaft aligns with the hole
in the cover.
3 Fit the timing pins PD.182 to the camshaft and to the flywheel.
Remove the starter motor, operation 238-01 and fit the anti-
rotation tool PD.203 to the flywheel.
4 Remove the timing case cover, operation 15A-01.
5 Remove the camshaft pulley, operation 15A-06.
6 Fit the plug of tool PD.185 (Al) into the front end of the
camshaft. Release the centre screw (A2) enough to ensure that it
will not reach the plug and enter the main tool into the seal. Turn
the tool clockwise to ensure that it is tight in the seal and tighten
the centre screw onto the plug to remove the seal.
7 Ensure that the seal housing and the camshaft are clean and
that they are not damaged. Lubricate the new seal with clean
engine lubricating oil and enter it into position with the seal lip to
the inside. Use the seal replacer PD.186 (81) with a soft face
hammer to fit the seal into its final position.
8 Fit the camshaft pulley and the timing belt, see section 15.
Remove the location pins from the pulley of the fuel injection
pump and adjust the tension of the timing belt, operation 15A-03.
9 Remove the anti-rotation tool.
10 Check the timing of the fuel injection pump, operation 17A-03.
11 Remove the timing pins and turn the crankshaft through two
revolutions to ensure that there is no restriction to movement.
12 Fit the setscrew in the timing hole in the camshaft cover. Fit the
starter motor, operation 238-01 and connect the battery.

Rear oil seal of camshaft

To remove and to fit 12A-05

Special tools:
Remover for rear seal of camshaft, PD.187
Replacer for rear seal of camshaft, PD.188
Alignment adaptor for drive housing of raw water pump (marine
engines only), PD.207

1 Remove the rear cover of the camshaft.

Marine engines: Remove the raw water pump and its drive
housing and remove the drive adaptor from the end of the
camshaft, see section 21.
2 Fit the plug of tool PD.187 (Cl) into the rear of the camshaft.
3 Release the centre screw (C2) enough to ensure that it will not
reach the plug and enter the main tool into the seal. Turn the tool
clockwise to ensure that it is tight in the seal and tighten the centre
screw onto the plug to remove the seal.
4 Ensure that the seal housing and the camshaft are clean and
that they are not damaged. Lubricate the new seal with clean
engine lubricating oil and enter it into posit~onwith the seal lip to
the Inside. Use the seal replacer PD.188 (Dl) with a soft face
hammer to fit the seal into its final position.
 CYLINDER HEAD ASSEMBLY 12
5 Fit the rear cover of the camshaft.
Marine engines: Fit the drive housing of the raw water pump with
the bore correctly aligned, operation 21A-08. Fit the drive adaptor
for the raw water pump and tighten the cap screws to 9 Nm (7 Ibf
ft) 0,9 kgf m. Fit the raw water pump, operation 21A-06.

Camshaft

To remove and to fit 12A-06

1 Disconnect the battery.

2 Remove the setscrew from the timing hole in the top front of
the camshaft cover (12A.031A4). Turn the crankshaft until the
timing hole in the front journal of the camshaft aligns with the hole
in the cover.
3 Fit the timing pins PD.182 to the camshaft and to the flywheel.
Remove the starter motor, operation 23B-01 and fit the anti-
rotation tool PD.203 to the flywheel.
4 Remove the timing case cover, operation 15A-01.
5 Remove the camshaft pulley, operation 15A-06.
6 Remove the camshaft cover, operation 12A-01.
Marine engines: Remove the raw water pump and its drive
housing and bracket and, if necessary, the drive adaptor from the
end of the camshaft, see section 21.
7 Remove the camshaft (A) and remove the camshaft seals.
8 Check the camshaft for wear and for damage and renew it, if
necessary.
9 If necessary, fit the drive adaptor for the raw water pump
(marine engines only).
10 Ensure that the camshaft is clean and lubricated with clean
engine oil. Put the camshaft in position and, if necessary, check
the tappet clearances, see operation 12A-02.
11 Fit the camshaft cover, operation 12A-01.
12 Check the end-float of the camshaft with a dial test indicator
(6). The limits are given in section 11C.
13 Fit the camshaft seals, operations 12A-04 and 12A-05.
14 Fit the rear cover of the camshaft.
Marine engines: Fit the drive bracket and the tlousing for the raw
water pump and fit the pump, section 21.
15 Fit the camshaft pulley and the timing belt and adjust the belt
tension, section 15.
16 Check the timing of the fuel injection pump, operation 17A-03.
17 Fit the timing case cover, operation 15A-01. Fit the setscrew in
the timing hole in the top front of the camshaft cover.
18 Ensure that all the timing pins and the anti-rotation tool are
removed. Turn the crankshaft through two revolutions to ensure
that there is no restriction to movement.
19 Fit the starter motor operation 236-01 and connect the battery.
12 CYLINDER HEAD ASSEMBLY

Cylinder head assembly

To remove and to fit

To remove
1 Disconnect the battery.
2 Drain the cooling system.
Marine engines: See operations 21A-01 and 21A.03.
3 Disconnect the coolant hose from the thermostat housing. If
necessary, disconnect the by-pass hose at the bottom of the
thermostat housing. If necessary, disconnect the heater hoses.
4 Disconnect all electrical connections at the cylinder head and
the thermostat housing.
5 Disconnect the air inlet pipe and the exhaust pipe.
6 If the cylinder head is to be dismantled, remove the inlet and
the exhaust manifolds.
Marine engines: Remove the inlet manifold, the turbocharger (if
fitted) and the heat exchanger/manifold/header tank assembly,
operation 21A-12.
7 Disconnect the fuel lift pump and the exhauster, if fitted.
8 Disconnect the fuel filter and remove it from its bracket.
9 Remove the high-pressure pipes from the atomisers and from
the fuel injection pump - d o not bend the pipes. When a pipe nut is
loosened at the pump, hold the outlet connection of the pump with
a spanner to prevent movement of the connection. Fit covers to
the open connections of the atomisers and of the pump.
10 Remove the atomisers, operation 20A-02, and the glow plugs,
operation 23C-01, to prevent possible damage to their tips.
11 Remove the setscrew from the timing hole in the top front of
the camshaft cover 12A.O3/A4. Turn the crankshaft until the timing
hole in the front journal of the camshaft aligns with the hole in the
cover.
12 Remove the starter motor, operation 236-01 and fit the anti-
rotation tool PD.203 to the flywheel.
13 Remove the timing case cover, operation 15A-01 and remove
the camshaft pulley, operation 15A-06.
14 Remove the setscrew which is fitted through the camshaft
cover into the timing case (Al).
Vehicle engines: Remove the setscrew which is fitted through the
timing case into the camshaft cover. Later engines: Remove the
setscrew which fastens the timing case to the cylinder head (A3).
15 Release evenly the setscrews of the cylinder head in the
reverse sequence to that shown in figure 12A.O9/A. Remove the
setscrews and remove the head (6) - ensure that the camshaft
does not hit the timing case. Put the head on a flat surface which
will not damage the bottom face.
16 Check the top face of each cylinder head setscrew for centre
punch marks. If there are four centre punch marks on the setscrew
head, it has been tightened four times in service and it cannot be
used again. Also check the setscrews for distortion with a straight
edge held along the setscrew. If there is a visual reduction in the
diameter of the stem or of the thread that has not been in
engagement with the cylinder head, the setscrew must discarded.
17 Remove the cylinder head gasket.

To fit

Special tools:
Angle gauge, to tighten cylinder head setscrews, MS.1531

1 Clean the bottom face of the cylinder head and the top face of
the cylinder block. Ensure that there is no debris in the cylinder
bores.
 CYLINDER HEAD ASSEMBLY 12
2 Ensure that numbers 1 and 4 pistons are at TDC and that the
timing pin is fitted through the backplate or through the flywheel
housing into the timing hole in the flywheel.
3 Ensure that the two location thimbles (12A.O8/B1) are in
position in the top face of the cylinder block and fit the cylinder
head gasket without jointing compound. The gasket will only fit in
one position over the thimbles.
4 Ensure that the timing pin is fitted through the camshaft cover
into the timing hole in the camshaft. Put the cylinder head in
position over the thimbles. Engage the cylinder head setscrews
with the longer setscrews fitted at the ends of the head. Tighten
evenly all the setscrews in the sequence shown in figure (A) to a
torque of 50 Nm (37 Ibf ft) 5,l kgf m. Tighten all the setscrews
again, in the same sequence, to a torque of 100 Nm (74 Ibf ft) 10,2
kgf m. Finally tighten the setscrews, in the same sequence,
another quarter of a turn (goy. Tool MS.1531 can be used for this
operation (B). Fit the tool between the socket and the handle. Put
the stop (61) against a suitable protrusion on the cylinder head to
prevent movement of the degree dial in a clockwise direction. Turn
the pointer to align with the 90" mark on the degree dial. Tighten
the setscrew until the pointer aligns with the zero position.
If no tool is available, make a suitable mark on the flange of each
setscrew (Cl). Make other marks on the cylinder head (C2) at 90"
clockwise to the marks on the setscrews. Tighten each setscrew
in the correct sequence until the marks on the flange are next to,
and in line with; the marks on the cylinder head (C3). The
setscrews do not need to be tightened again with the engine hot
or after a period in service.
If the original setscrews have been fitted again, mark the top of
each setscrew with a centre punch to indicate that it has been
tightened in service. A maximum of four centre punch marks is
permissible.
5 If necessary, fit the inlet and the exhaust manifolds, section 18.
Marine engines: Fit the heat exchanger/manifold/header tank
assembly, operation 21A-12 and fit the inlet manifold.
6 Connect the air filter and the exhaust pipe.
7 Fit the setscrews which fasten the timing case to the cylinder
head (12A.O8/Al) and to the camshaft cover 12A.O3/Al (and
12A.O3/A2 on some vehicle engines).
8 Fit the camshaft pulley, fit the timing belt and check the belt
tension, see section 15.
9 Check the timing of the fuel injection pump, operation 17A-03
and remove the timing pins. Remove the anti-rotationtool and turn
the crankshaft through two revolutions to ensure that there is no
restrictionto movement.
10 Fit the starter motor, operation 238-01.
11 Fit the glow plugs, operation 23C-01.
12 Fit the atomisers, operation 20A-02.
13 Fit the high-pressure fuel pipes and tighten the pipe nuts to 18
Nm (13 Ibf ft) 1,8 kgf m. Ensure that a separate spanner is used to
prevent movement of the outlets of the fuel injection pump.
14 Fit the fuel filter and the low-pressure fuel pipes between the
fuel injection pump and the fuel filter.
20 Fill the cooling system.
15 If necessary, fit the fuel lift pump, operation 20A-03 and the
exhauster, operation 24A-01. Connect the pipes to the fuel lift marine engines: see 21A-02.
pump and the exhauster. 21 Connect the battery.
16 Fit the timing case cover, operation-15A-01. 22 Eliminate air from the fuel system, operation 20A-10.
17 If necessary,fit the turbocharger, operation 18A-02. 23 Start the engine and check for leaks.
18 Connect the coolant by-pass and the coolant outlet pipe.
v, Marine engines: Connect the raw water pipes to the heat
exchanger and to the raw water pump. If necessary, connect the
heater hoses.
0
5: 19 Connect the electrical connections to the cylinder head and to
the thermostat housing.
12 CYLINDER HEAD ASSEMBLY

Valves and valve springs

To remove and to fit 12A-08

Special tools:
Valve spring compressor, MS.1519A

To remove
1 Removethe cylinder head, operation 12A-07.
2 Remove the rear cover of the camshaft or, for marine engines,
remove the raw water pump, operation 21A-06.
3 Remove the camshaft cover, operation 12A-01.
4 Remove the tappets and the shims and keep the tappet and
shim from each valve together in a marked container to ensure
that they can be fitted in their original positions.
5 Glean the bottom face of the cylinder head and check the
depth of the heads of the valves below the face of the cylinder
head, see operation 12A-09.
6 Make a suitable mark on the heads of the valves to ensure that
the valves can be fitted in their original positions, if they are to be
used again.
7 Use the valve spring compressor to compress the valve spring
(Al). Ensure that the valve spring is compressed squarely or
damage can occur to the valve stem. Remove the split collets (81).
8 Release the valve spring compressor and remove the valve
spring cap (82), the valve spring (B3), the valve stem seal (84) and
the spring seat washer (85). Remove the exhaust valve (86) or the
inlet valve (87).
9 Repeat items 7 and 8 for the other valves.

To fit
The components of the valve assembly are shown in 8.
1 Ensure that all the components are clean.
2 Lubricate the valve stems with clean engine oil and fit the
valves (86167) in their relevant guides. Ensure that the valve head
depth is correct, see operation 12A-09.
3 Fit the spring seat washers (85). Fit new valve stem seals (84)
on the valve guides. Fit the valve springs (83) and the valve spring
caps (82).
4 Use the valve spring compressor to compress the valve spring
and fit the collets (81). Ensure that the valve spring is compressed
squarely or damage can occur to the valve stem.
5 Lubricate the shims and the tappets. Fit each shim in the top of
the spring cap of the relevant valve and fit the tappet on the top of
the shim.
6 Put the camshaft in position and check the tappet clearances
as shown in operation 12A-02. Adjust the clearances as
necessary.
7 Fit the camshaft and the camshaft cover, operation 12A-02.
8 Fit the rear cover of the camshaft or, for marine engines, fit the
raw water pump, operation 21A-06.
9 Fit the cylinder head, operation 12A-07.

To inspect and to correct

Special tools:
Gauge, valve depth, PD.197
Dial gauge for use with PD.197, PD.208

1 Check the depth of the valves below the face of the cylinder
head before the valve springs are removed. Ensure that the heads
of the valves and the bottom face of the cylinder head are clean.
Put the valve depth tool on the face of the cylinder head and set
the dial gauge to zero. Carefully put the valve depth tool in position
 CYLINDER HEAD ASSEMBLY 12
over the head of each valve (A) and make a note of the
measurement. The limits for the valve head depth are given in
section 11C. If a valve is deeper than the maximum limit, check the
valve depth with a new valve in position and, if the valve depth is
still below the limit, a new valve seat insert can be fitted,operation
12A-14.
2 Check the valves for cracks. Check the stems of the valves for
wear and for correct fit in their valve guides.
3 Check that the seat faces of the valves are not badly burnt or
damaged. Seat faces of valves which are damaged can be ground
on a special machine. Valves which have only little damage can be
lapped to their valve seats. When new valves are fitted, the valve
depths must be checked, see 1.
4 Check that the load on the valve springs is correct at their fitted
length, see section 11C.
Fit new valve springs at every complete engine overhaul.

Valve guides

To inspect 12A-10

Check the valve guides for wear. The maximum clearance

between the valve stem and the bore of the guide is 0,13 mm
(0.005 in). If the clearance with a new valve fitted is more than the
limit, then a new valve guide must be fitted.

To remove and to fit 12A-11

Special tools:
Removerlreplacerfor valve guides, PD.189
Reamer for new valve guides, PD.196

To remove
I Ensure that the face of the cylinder head and the base of a
suitable press are clean.
2 Heat the whole cylinder head slowly and evenly to
approximately 100°C (212°F) and put the head on the press, with
the head face downward. Ensure that the head face is not
damaged during this operation.
Attention: Use suitable gloves as a protection against hot metal.
3 Put the narrow shaft of tool PD.189 in the guide and press out
the guide. Repeat as necessary, if other guides need to be
renewed.

To fit
1 Clean the parent bore for the valve guide and ensure that it is
not damaged.
2 Heat the whole cylinder head slowly and evenly to
approximately 100°C (212°F). Put the head on the press, with the
head face downward and with a flat plate underneath the valve
port. Ensure that the head face is not damaged during this
operation.
Attention: Use suitable gloves as a protection against hot metal.
3 Put the guide (Bl) on to the narrow shaft of the tool PD.189 (82)
with the chamfer towards the narrow end of the tool (B). Enter the
chamfer end of the guide into the top of the parent bore and press
in the guide until the end of the tool is in contact with the flat plate.
'c Check that the guide protrusion above the location face for the
valve spring is 10 mrn (0.39 in).
4 Allow the head to cool.
5 Ream the bore of the new guide(s) with reamer PD.196 (C).
i/ '_r
 12 CYLINDER HEAD ASSEMBLY

Cylinder head

To inspect and to correct 12A-12

1 Remove the cylinder head assembly, operation 12A-07.

2 Remove the thermostat hous~ng.
3 Remove the rear cover of the camshaft or, for marine engines,
removethe raw water pump, operation 21A-06.
4 Remove the camshaft cover, operation 12A-01 and the
camshaft.
Remove the tappets and the shims and keep the tappet and shim
from each valve together in a marked container to ensure that they
can befitted in their original positions.
5 Inspectthe cylinder head for signs of gas or coolant leakage.
6 Remove the valve springs and the valves, operation 12A-08.
7 Clean the face of the cylinder head. Clean the passages for
coolant and for lubricating oil. The water jacket can be cleaned
with a special solvent which must be used in accordance with the
manufacturer's instructions.
8 Test the cylinder head for leaks at the pressure given in section
11C.
9 When the cylinder head is thoroughly clean, check it for cracks.
Examine carefully the areas around the valve seats and around the
holes for the atomiser nozzles.
10 Use a straight edge and feeler gauges to check the cylinder
head for distortion across and along its bottom face (A). If the
distortion is more than 0,10 mm (0.004 in), the bottom face can be
machined. Remove only the minimum material and ensure that the
thickness of the cylinder head will not be less than 119,85 mm
(4.718 in) after the cylinder head has been machined.
Attention: After the cylinder head has been machined, the valve
seats must be corrected to give the correct valve head depth. It is
advisable to work to the minimum limit to allow for later wear.
11 Check the valve seats for wear and for damage.
12 Before any work is done on the valve seats, ensure that there is
no wear on the valve guides, see section 11C. If the valve guide
wear is more than the limit, then the valve guide must be renewed,
operation 12A-11.
13 Where there is little damage, the valve and valve seat can be
lapped. When the valve seats are lapped keep the seat as narrow
as possible and ensure that all the compound used to lap the valve
and seat is removed.
14 More badly damaged valve seats can be corrected by use of
the cutter tool, operation 12A-13, or new inserts can be fitted,
operation l2A-14.
15 Fit the valve springs and the valves, operation 12A-08.
1 16 Fit the tappets and the shims in their relevant positions. Put the
I camshaft in position, check the tappet clearances, operation
I 12A-02 and adjust if necessary, operation 12A-03.
I Attention: When the cylinder head is not fitted to the cylinder
I block, the clearances are increased by 0,051 mm (0.002 in) as
I follows:
I Clearance check
-
I lnlet 0,30/0,40 mm (0.012/0.016 in)
I Exhaust - 0,40/0,50 mm (0.016/0.020 in)
I Permissibleclearancelimits
I lnlet - 0,25/0,45 mm (0.010/0.018 in)
I Exhaust - 0,35/0,55 mm (0.014/0.022 in)
I Clearances for shim calculations
I lnlet - 0,351 mm (0.014 in)
I Exhaust - 0,45 mm (0.018 in)
1 17 Fit the camshaft and the camshaft cover, operation 12A-01.
1 18 Fit the rear cover of the camshaft or, for marine engines, fit the
I raw water pump, operation 21A-06.
I 19 Fit the thermostat housing.
1 20 Fit the cylinder head assembly, operation 12A-07.
 CYLINDER HEAD ASSEMBLY 12
L

To correct a valve seat

with a valve seat cutter 12A-13

Special tools:
Pilot for use with valve seat cutters, MS.150-7
Handle set for use with valve seat cutters, MS.76B
Cutter for valve seats, MS.275

1 If the valve guide is worn, renew it, operation 12A-11.

2 Fit the pilot in the valve guide and tighten the pilot.
3 Fit the cutter on the pilot with the 46" side towards the valve
seat and fit the handle (A). Ensure that the cutter is not allowed to
fall on to the seat as this can damage the blades.
4 Carefully turn the cutter in a clockwise direction. Remove only
the minimum material to ensure a good seat. Keep the seat as
narrow as possible.
5 When the seat is correct, remove the cutter and the pilot.
Remove any debris from the area of the valve seat and the port.
6 Fit the valve and lightly lap the valve and the seat.
7 Check that the valve depth is within limits, see section 11C.
If a valve seat has become too damaged or too worn, it can be
renewed, operation 12A-14.

To fit a valve seat insert 12A-14

1 Fit a new valve guide, operation 12A-11.

2 Machine a small segment from the inside of one side of the
insert to a depth of 8,25 mm (0.325 in) from the face of the cylinder
head. Break the insert at its thinnest point and remove it from the
recess. Ensure that the recess is not damaged during this
operation.
3 The valve seat insert must be fitted with the cylinder head hot
and the insert cold. Heat the whole cylinder head slowly and
evenly to approximately 100°C (212°F) and cool .'the insert, if
possible, in liquid nitrogen to -35°C (-31°F). If liquid nitrogen is not
available, reduce the temperature of the insert as far as possible in
a deep freeze unit. Fit the insert in position with the outside
chamfer to the inside of the head. Ensure that the bottom of the
insert is in contact with the bottom of the recess.
Attention: Use suitable gloves as a protection against the hot
cylinder head and the cold insert.
4 Cut the valve seat, operation 12A-09 and lightly lap the valve
and the valve seat. Ensure that the depth of the valve head below
the face of the cylinder head is within the production limits, see
section 11C. Work as near as possible to the minimum figure to
allow for future wear on the valve seat.
 Piston and connecting rod assemblies

General description .......................................... 13A.02

Big end bearing

13A-01 To remove and to fit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A.03
13A-02 To inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A.03
Piston and connecting rod assembly
13A-03 To remove and to fit ................................................ 13A.04
Piston rings
13A-04 To remove and to fit ................................................ 13A.06
Piston and connecting rod assembly
13A-05 To dismantle and to assemble .......................................... 13A.07
Piston and rings
13A-06 To inspect ...................................................... 13A.08
Connecting rod
13A-07 To inspect ...................................................... 13A.08
Small end bush
13A-08 To remove and to fit ................................................ 13A.08
w
Piston cooling jets
13A-09 To remove and to fit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A.09
13A-10 TOcheck the jet alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A.09
 PISTON AND CONNECTING ROD ASSEMBLIES 13
Big end bearing

To remove and to fit 13A-01

To remove
1 Disconnect the battery.
2 Drain the engine lubricatingoil.
3 Remove the lubricating oil sump, operation 19A-03.
4 Remove the lubricating oil strainer and suction pipe, operation
19A-04.
5 Turn the crankshaft until the relevant connecting rod is at its
lowest position.
6 Release the nuts and remove the bearing cap (A). Do not try to
remove the connecting rod bolts.
7 Remove the lower half bearing from the cap but keep it with its
relevant cap.
8 Fit a suitable length of rubber or plastic hose to each
connecting rod bolt to protect the crank pin. Carefully push the
connecting rod up the cylinder bore just enough to allow access to
the upper half bearing. Remove the bearing from the connecting
rod. Keep the bearingsfrom the connecting rod and cap together.
Attention: Do not allow the connecting rod to hit the piston
cooling jet, if fitted.

To fit
1 Clean the bearing faces of the connecting rod and the crank
pin.
2 Clean the complete bearing and lubricate the bearing surface
and the crank pin with clean engine lubricating oil. Fit the upper
half bearing to the connecting rod with the location tag fitted
correctly in its recess (Al). Fit the connecting rod to the crankpin.
Ensure that the assembly number on the connecting - rod (6) is on
the same side as the other connecting rods.
3 Clean, lubricate and fit the lower half bearing into the cap.
Ensure that the location tag is fitted correctly in its recess (A2).
Remove the protection hoses from the connecting rod bolts and
ensure that the bolts have not been moved. Fit the cap to the
connecting rod. Ensure that the assembly number on the cap is
the same as that on the connecting rod (6) and that both of the
assembly numbers are on the same side.
4 Fit new nuts to the connecting rod bolts and tighten them
gradually and evenly to the recommended torque of 47 Nm (35 Ibf
ft) 4,8 kgf m.
5 Ensure that the crankshaft turns freely.
6 Fit the lubricating oil strainer and suction pipe, operation
19A-04.
7 Fit the lubricating oil sump, operation 19A-03 and fill the sump
to the correct level with lubricating oil of an approved grade.
8 Connect the battery.

Check the bearings and the crank pin for wear or other damage.
 PISTON AND CONNECTING ROD ASSEMBLIES 13
6 Push the piston and connecting rod assembly through the bore
and onto the crank pin. If piston cooling jets are fitted, the
assembly must be turned to ensure that the connecting rod will
not hit the jet as the rod is fitted. When the connecting rod has
passed the piston cooling jet, turn the connecting rod until the
arrow on the top of the piston is towards the front of the engine.
7 Remove the protection hoses from the big end bolts. Clean the
connecting rod cap and the lower half bearing. Fit the bearing to
the cap with the location tag fitted correctly in its recess. Lubricate
the bearing with clean engine lubricating oil. Fit the cap and
ensure that the assembly number is the same as that on the
connecting rod and that the numbers are on the same side. Fit
new nuts to the big end bolts and tighten them gradually and
evenly to 47 Nm (35 Ibf ft) 4,8 kgf m.
8 Check that the crankshaft will turn freely.
9 Check the piston height above the top face of the cylinder
block with the piston height tool (A). A 4 mm (0.157 in) plate,
number PD.197-1 is available to allow the piston height to be
measured above the centre of the piston. Put the measurement
tool on a flat surface with the plate under the gauge plunger and
turn the gauge dial to the zero position. Turn the crankshaft until
the piston is approximately at TDC. Put the plate on the top of the
piston. Put the measurement tool over the cylinder bore with the
plunger of the gauge in contact with the centre of the plate. Turn
the crankshaft to bring the piston to its highest position and make
a note of the gauge indication. The correct piston,height is given in
section 11C. If a new lower grade of service piston has been fitted,
see operation 13A-05, the piston height can be 0,10 mm (0.004 in)
below the bottom limit. The piston must not be higher than the top
limit. It is not permissible to remove metal from the top of the
piston.
10 If necessary, fit the lubricating oil strainer and suction pipe,
operation 19A-04.
11 Fit the lubricating oil sump, operation 19A-03.
12 Fit thecylinder head assembly, operation 12A-07.
13 Fill the sump to the correct level with lubricating oil of an
approved grade.
14 Fill the cooling system, see operation 21A-02 for marine
engines.
15 Connect the battery.
 I PISTON AND CONNECTING ROD ASSEMBLIES 13

I Piston and connecting rod assembly

To dismantle and to assemble 13A-05

To dismantle
1 Remove the piston rings, operation 13A-04.
2 Remove the circlips which retain the gudgeon pin.
3 Put a temporary mark on the piston to indicate the cylinder
number as shown on the connecting rod. Put the mark on the
piston on the same side as the mark on the big end to ensure that
they are assembled correctly.
4 Push the gudgeon pin out by hand. If the gudgeon pin is tight,
heat the piston to 4O0/50"C (10O0/12OoF)for easy gudgeon pin
removal.

To assemble
1 Clean the bore of the small end bush and lubricate it with clean
engine lubricating oil.
2 Fit a new circlip in the circlip groove of one of the gudgeon pin
bosses. Ensure that it fits correctly in the groove.
3 If the original piston is used, ensure that it is assembled to the
correct connecting rod and is used in the original cylinder. If a new
piston is to be fitted, ensure that it is of the correct height grade. In
the factory, six different height grades can be used. The grades
are identified by numbers which are stamped on the top of the
piston (A). Number 1 is the highest piston and number 6 is the
lowest piston. In service, only grades 3 and 6 will be available.
Grade 3 must be used if the original piston is stamped 1, 2 or 3.
Grade 6 must be used if the original piston is stamped 4, 5 or 6.
Two different diameter grades "A" and "B" are also used in the
factory. Only the smaller diameter piston "A" will be supplied in
service for the standard size bore. A grade "X" piston will be
available for bores which have been bored 0,50 mm (0.020 in)
oversize in diameter in service. The diameter grades are stamped
on a machined pad at the top rear of the right side of the cylinder
block (16A-04lC). If a bore has been bored oversize in service, the
original grade letter for that bore should be over stamped with a
letter "X".
I Attention: Earlier Prima; M60 and M80T engines had
I pistons with recesses in the top to give clearance for the valves.
I Later engines may be fitted with pistons which do not have these
I recesses.
4 With the piston upside down, put the connecting rod in
position. The location boss on the rod (82) must be on the same
side as the arrow on the bottom of the piston (Bl).
5 Lubricate the gudgeon pin bosses with clean engine lubricating
oil and push in the gudgeon pin towards the circlip. If the gudgeon
pin is a tight fit in the piston, heat the piston to 40"/50"C
(100°/120°F) before the gudgeon pin is fitted.
6 Fit a new circlip in the groove in the other gudgeon pin boss.
Ensure that it fits correctly in the groove.
7 Fit the piston rings, operation 13A-04.
 PISTON AND CONNECTING ROD ASSEMBLIES 13
Piston cooling jets

To remove and to fit 13A-09

To remove
Release the banjo bolt and remove the piston cooling jet assembly
(A). (The crankshaft is removed in A to show clearly the piston
cooling jet.)

To fit
1 Check that the jet tube and the thread of the banjo bolt are not
damaged. Renew the jet assembly or the banjo bolt as necessary.
There are different types of jet assembly for adjacent bores and
the correct assembly must be obtained.
2 Fit the piston cooling jet with the dowel in its location in the
cylinder block. Tighten the banjo bolt to 11 Nm (8 Ibf ft) 1,l kgf m.

To check the iet alianment 13A-10

Insert a 1.5 mm (0.059 in) diameter rod, of suitable length, into the
jet (B). If a suitable rod is not available, reduce the end of a thicker
rod to 1.5 mm (0.059 in) diameter for a length of 10 mm (0.4 in).
When the rod is inserted into the jet, it must extend out of the top
of the cylinder within 5 mm (0.2 in) of the relevant point shown in
C.
 Crankshaft assembly

- General description
Crankshaft pulley
14A-01A To remove and to fit (standard pulley)
14A-01B To remove and to fit (Ringfeder pulley)
.............................................

....................................
....................................
Front oil seal
14A-02 To renew .........................................................
Rear oil seal
14A-03 To renew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14A-04 To remove and to fit the separate oil seal housing ...........................
Thrust washers
14A-05 To check crankshaft end-float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14A-06 To remove and to fit ................................................
Main bearing
14A-07 To remove and to fit ................................................
14A-08 To inspect ......................................................
Crankshaft
b 14A-09 To remove and to fit ................................................
14A-10 To inspect ......................................................
 CRANKSHAFT ASSEMBLY 14
Crankshaft pulley

To remove and to fit (standard pulley) 14A-OIA

Special tool:
Anti-rotation tool, PD.203

I Disconnect the battery.

2 Remove the drive belt of the alternator, operation 23A-03.
3 Remove the starter motor, operation 23B-01 and fit the anti-
rotation tool (Al) to the flywheel.
4 Release and remove the four cap screws which fasten the
pulley to the toothed pulley (B). Release the centre setscrew of the
pulley and remove the pulley (C).
5 Clean the components and check for damage. Renew
damaged components.
6 Put the pulley in position, fit the centre setscrew and tighten it
finger tight. Fit the cap screws which fasten the pulley to the
toothed pulley and tighten them finger tight. Tighten the centre
setscrew to 180 Nm (133 Ibf ft) 18,4 kgf m and then tighten the cap
I screws to 12 Nm (9 Ibf ft) 1,2 kgf m.
7 Remove the anti-rotation tool and fit the starter motor,
operation 238-01.
8 Fit the drive belt of the alternator, operation 23A-03.
9 Connect the battery.

To remove and to fit (Ringfeder pulley) 14A-01B

Special tool:
Anti-rotation tool, PD.203

I Attention: Two types of Ringfeder arrangements (D) are used,

l according to the application. The components are not
I interchangeable between the two arrangements.
I Disconnect the battery.
2 Remove the drive belt of the alternator, operation 23A-03.
3 Remove the starter motor, operation 23B-01 and fit the anti-
rotation tool (Al) to the flywheel.
4 Release and remove the four cap screws which fasten the
pulley to the toothed pulley (B). Release the centre setscrew of the
pulley and remove the pulley (C). Remove the spacer (D2) and the
inner and outer tapered rings (Dl and D3) from the pulley or the
I crankshaft. If necessary, remove the washer (D4).
5 Clean the components and check for damage. Renew
damaged components. Do not use a degreasing solution on the
Ringfeder components and do not open out the tapered rings.
6 Ensure that the toothed pulley for the timing belt is fully
I towards the rear. If necessary, fit the washer (D4) in the recess in
the toothed pulley. Put the inner ring (Dl) on the nose of the
crankshaft with the narrow edge of the ring towards the front end
of the crankshaft. Put the spacer (D2) inside the recess in the rear
of the pulley. Put the outer ring (D3) on the spacer with the narrow
edge of the ring towards the open end of the recess.
7 Ensure that the gap in the outer ring will not align with the gap
in the inner ring when the pulley is fitted and put the pulley
assembly into position on the crankshaft. Fit the centre setscrew
and tighten it finger tight.
a
m 8 Engage the four cap screws which hold the toothed pulley to
m
the crankshaft pulley but do not tighten them.
1 9 Tighten the centre setscrew to the correct torque according to
I its colour. Tighten gold setscrews to 180 Nm (133 Ibf ft) 18.4 kgf m
I or tighten black setscrews to 200 Nm (148 Ibf ft) 2.4 kgf m. Then
I tighten the cap screws to 12 Nm (9 Ibf ft) 1,2 kgf m for M6 cap
I screws or 27 Nm (20 Ibf ft) 2,7 kgf m for M8 cap screws.
2 10 Remove the anti-rotation tool and fit the starter motor
operation 23B-01.
-,
i/ I 1 Fit the drive belt of the alternator, operation 23A-03,
12 Connect the battery.
a
'
 CRANKSHAFT ASSEMBLY 14
Rear oil seal

To renew 14A-03
Special tools:
Protection sleeve, PD.191
Remover tool for rear oil seal, PD.204
Replacer tool for rear oil seal, PD.205

1 Disconnect the battery.

2 Remove the drive components from the rear end of the engine.
3 Remove the flywheel, operation 22A-01.
4 Check the position of the seal in the flywheel housing, in the
separate seal housing or in the backplate. If the rear face of the
seal is level with the rear face of the housing, the new seal can
probably be pressed further into its housing; this will move the seal
location area on the crankshaft flange. This is not possible if a 10
mm (0.39 in) thick backplate is fitted. If the crankshaft flange is
worn and a new seal position is not available, remove the
crankshaft and machine the flange, see section 11C.
5 Release the screw (Al) of the remover tool enough to ensure
that it will not touch the crankshaft. Enter the tool into the seal and
turn it clockwise to ensure that it is tight in the seal. Use a spanner
on the main body of the tool to ensure that the tool is tight in the
seal. Tighten the screw onto the rear of the crankshaft to remove
the seal.
6 Clean the seal housing and the crankshaft flange.
7 Lubricate lightly the seal housing, the crankshaft flange and the
lip of the new seal with clean engine oil.
8 Clean and lubricate the protection sleeve PD.191 (61) and fit it
on the end of the crankshaft flange.
9 Put the seal (82) over the sleeve with the lip towards the engine
and push it along the flange until it enters the seal housing.
Remove the protection sleeve.
10 Put the ring (Cl) of tool PD.205 on the crankshaft flange with
the correct end of the ring towards the seal. If the seal is to be
fitted in the forward position (see paragraph 4), fit the sleeve with
the end which has a reduced diameter towards the seal. Fit the
plate (C2) of tool PD.205 and use the lock nuts to tighten the studs
into the crankshaft flange. Release the lock nuts, ensure that the
plate is fitted squarely to the crankshaft and use the forward nuts
to press the seal into position. The nuts must be tightened
gradually and evenly.
11 Remove the tools and fit the flywheel, operation 22A-01.
12 Fit the drive components to the rear end of the engine and
connect the battery.
 CRAlvKsHAFT ASSEMBLY 14
Thrust washers

To check crankshaft end-float 14A-05

The axial movement of the crankshaft is controlled by two half

thrust washers fitted both sides of the centre main bearing (B). The
end-float can be checked with a feeler gauge between a thrust
washer and the crankshaft. A better method is to use a dial test
indicator on one end of the crankshaft to checkthe movement (A).

To remove and to fit 14A-06

To remove
1 Disconnect the battery.
2 Drain the lubricating oil and remove the lubricating oil sump,
operation 19A-03.
3 Where necessary, remove the lubricating oil strainer and
suction pipe, operation 19A-04.
4 Release the setscrews of the centre main bearing and remove
the main bearing cap complete with the lower half thrust washers
(B).
5 With a suitable tool made of a soft material, press down one
end of each upper half thrust washer in order to slide the washer
from its recess (C). Where necessary, move the crankshaft to the
front or to the rear to loosen a tight washer.

To fit
1 Lubricate the thrust washers with clean engine lubricating oil.
2 Slide the upper half thrust washers into their recesses in the
cylinder block. Ensure that the sides of the thrust washers which
have the grooves are against the crankshaft.
3 Fit the lower half thrust washers to the main bearing cap with
the location tags in their recesses. Ensure that the grooves in the
washers are away from the cap (B).
4 Ensure that the location thimbles are fitted correctly in the main
bearing cap or in the cylinder block.
5 Ensure that the bearing is fitted correctly in the cap and that the
bearing and the crankshaft journal are clean. Lubricate the bearing
with clean engine lubricating oil.
6 Fit the cap with the location tags of both half bearings to the
same side (14A.O8/Bl and 82). Tighten the main bearing
setscrews gradually and evenly to 112 Nm (83 Ibf ft) 11,4 kgf m.
7 Check the crankshaft end-float.
8 If necessary, fit the lubricating oil strainer and the suction pipe,
operation 19A-04.
9 Fit the lubricating oil sump, operation 19A-03, and fill it to the
correct level with an approved lubricating oil.
10 Connect the battery
 CRANKSHAFT ASSEMBLY 14
Crankshaft

To remove and to fit 14A-09

To remove
1 Before the engine is removed from the vehicle or from the
machine, drain the lubricating oil and the coolant.
2 Remove the lubricating oil sump, operation 19A-03. Remove
the lubricating oil suction pipe and strainer, operation 19A-04.
3 Remove the crankshaft pulley, operation 14A-01. If necessary,
remove the fan drive pulleys and the fan drive assembly. Remove
the water pump pulley.
4 Remove the timing case cover, operation 15A-01.
5 Remove the flywheel and the flywheel housing, section 22.
6 Turn the crankshaft until all the pistons are equally up their
bores.
7 Make temporary alignment marks on the timing belt and on
suitable teeth of the crankshaft pulley, the camshaft pulley and the
fuel injection pump pulley. This is to ensure that the belt can be
fitted again in the same position.
8 Remove the timing belt, the toothed pulleys and the timing
case, section 15.
9 Remove the lubricating oil pump, operation 19A-06.
10 Measure the crankshaft end-float to check if new thrust
washers are needed.
11 Ensure that all the connecting rod caps are marked with their
relevant cylinder number. Remove the caps and the lower half big
end bearings, operation 13A-01.
12 The inner main bearing caps are marked 2, 3 and 4 and also
have the word "FRONT" to indicate the correct fitted position (A).
Remove the main bearing caps, the lower half bearings and thrust
washers and keep the bearings with their relevant caps. Slide out
the upper half thrust washers.
13 Remove the crankshaft.
14 Remove the upper half main and big end bearings and keep
them with their relevant caps.

To fit
1 Ensure that all lubricating oil passages are clean and free from
restriction. Clean the sealant grooves in the sides of the front and
the rear main bearing caps.
2 Clean the main bearing housings and the upper half bearings.
Fit the bearings with the location tags fitted correctly in their
recesses. The upper half main bearings have oil holes and grooves
and the centre bearing is wider than the others. Lubricate the
bearings with clean engine lubricating oil.
3 Ensure that the journals of the crankshaft are clean and
lubricate them with clean engine lubricating oil. Carefully lower the
crankshaft into position on the bearings.
4 Clean and lubricate the upper half thrust washers and slide
them into their recesses on both sides of the bearing housing.
Ensure that the lubrication grooves of the thrust washers are
towards the crankshaft.
5 Clean the bearing caps and the lower half bearings. Fit the
bearings to the caps with the location tags fitted correctly in their
recesses. Lubricate the bearings with clean engine lubricatingoil.
6 Ensure that the location thimbles for the main bearing caps are
fitted correctly in the caps or in the cylinder block.
Timing case and drive assembly

General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 15A.02

Timing case cover

To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 15A.03
Timing belt
To check the belt condition and tension ... ... ... ... ... ... ... ... ... ... ... ... 15A.04
To adjust the belt tension ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...15A.04
To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 15A.05
Toothed pulley for fuel injection pump
To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 15A.06
Toothed pulley for camshaft
To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 15A.07
Toothed pulley for crankshaft
To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 15A.08
Timing case
To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 15A.09
 -1-IMING CASE AND DRIVE ASSEMBLY 15
Timing case cover

To remove and to fit 15A-01

To remove
1 Disconnectthe battery.
2 If fitted, remove the fan, operation 21A-09.
3 For applications with a high level fan, remove the fan drive
assembly, operation 21A-10.
4 Removethe alternator drive belt, operation 23A-03.
5 Remove the pulley of the water pump.
6 If a dust seal is fitted, remove the crankshaft pulley, operation
14A-01A or 14A-01B.
1 7 Remove the access panel from the timing case (15A.O4/A).
1 8 The timing case cover of later vehicle engines is in two parts
I (A). Ensure that the screw (Al) is removed before the upper &rt is
I removed (B). Ensure that the setscrew (A2) and screws (A3) are
I removed before the lower part is removed.
1 9 If the water pump has a front inlet and the timing case cover
I is in one piece, drain the coolant and disconnect the inlet pipe.
I 10 Release the clips of the cover and remove the cover (C).
1
To fit
1 Ensure that the cover is clean and that all the spring clips are
fastened to the timong case.
2 If a brush dust seal is fitted to the cover, ensure that it is not
damaged. If a new seal is to be fitted, slide it into the groove in the
cover and ensure that the ends of the seal fit each side of the
I location in the cover(D1).
3 Fit the cover on to the timing case and ensure that all the
I fastener c l i ~ sare messed into ~osition.With two ~ i e c etimina
I covers for iater vehicle engines, fit the bottom part i n d fasten it
I with the setscrew (M), the screws (A3) and the spring clips. Fit the
I top part with the bottom edge of the cover between the front lugs
I (A4) and the rear lug of the bottom part of the cover. Fasten the top
I part with the screw (Al) and the spring clips.
4 Fit the access panel to the timing case and to the cover.
5 If necessary, fit the crankshaft pulley, operation 14A-01.
6 Fit the water pump pulley.
7 Fit the alternator drive belt, operation 23A-03.
8 For applications with a high level fan, fit the fan drive assembly,
operation 21A-10.
9 If necessary, fit the fan, operation 21A-09.
10 If necessary, connect the inlet pipe of the water pump and fill
the cooling system.
11 Connect the battery.
15 TIMING CASE AND DRIVE ASSEMBLY

Timing belt

To check the belt condition and tension 15A-02

Special tool:
Tension gauge, KM.4088P

1 Remove the access panel from the top of the timing case (A).
2 Make a temporary mark on the belt to ensure that the complete
belt will be checked. Check the teeth for wear and damage and
check the belt for cracks and oil contamination. Turn the
crankshaft to check all the teeth and the complete belt. If
necessary, renew the belt, operation 15A-04. Remove the
temporary mark.
3 Press down the ball end of the tension gauge and fit the gauge
over the belt. Ensure that the foot of the gauge is under the belt
and between two of the belt teeth (B). Release the ball end slowly
and check the gauge reading. Move the crankshaft by a small
amount in each direction until a constant reading is obtained. The
correct reading for a new belt is 951105 Ibf and for a used belt the
correct reading is 80 Ibf. If the tension of a used belt has reduced
to 60 Ibf or below, adjust the tension to 80 Ibf, operation 15A-03.
4 When the tension is correct, fit the access panel to the timing
case.

To adiust the belt tension 15A-03

Special tools:
Timing pins, PD.182
Tension gauge, KM.4088P

1 Fit the timing pins to the camshaft and to the flywheel,

operation 17A-01.
2 Remove the timing case cover, operation 15A-01.
3 Fit the tension gauge between the pulleys of the fuel injection
pump and the camshaft.
4 Release the four setscrews of the camshaft pulley to allow the
pulley to turn on its hub. For some early engines, the camshaft
pulley is in one piece and the centre setscrew will need to be
loosened.
5 Loosen the capscrew which fastens the belt tensioner pulley.
Adjust the belt tension with an allen key fitted in the hexagonal
adjustment hole in the pulley (C). The correct tension for a new belt
is 100 Ibf and the correct tension for a used belt is 80 Ibf. When the
tension is correct, tighten the capscrew to 43 Nm (32 Ibf ft) 4,4 kgf
m and check the tension again.
6 Tighten the setscrew(s) of the camshaft pulley to the correct
torque, see section 11B and ensure that the tension is still correct.
7 Remove the timing pins from the camshaft and from the
flywheel.
8 Turn the crankshaft through two revolutions and check the
tension again.
9 Check the timing of the fuel injection pump, operation 17A-03.
10 Fit the cover to the timing case, operation 15A-01.
 TIMING CASE AND DRIVE ASSEMBLY 15
To remove and to fit 15A-04
Special tools:
Timing pins, PD.182
Location pins for fuel pump pulley, PD.190
Anti-rotation tool, PD.203

To remove
I Disconnect the battery.
2 Remove the setscrew from the timing hole in the camshaft
cover. Turn the crankshaft until the timing hole in the camshaft
aligns with the hole in the cover. Fit the timing pins PD.182 into the
camshaft and into the flywheel.
3 Remove the starter motor and fit the anti-rotation tool PD.203
to the flywheel.
4 Remove the timing case cover, operation 15A-01.
5 Fit the location pins PD.190 (Al) through the plain holes in the
pulley of the fuel injection pump and into the pump support
bracket.
6 Remove the belt tensioner pulley and the idler pulley.
7 Remove the timing belt. Do not bend the belt to an acute angle
as this can damage the belt and cause failure. Put the belt on its
edge in a circle on a flat surface. Do not hang it.
8 Inspect the teeth of the belt for wear. Check the complete belt
for oil contamination, cracks and other damage. Renew the belt if
a fault is found.

To fit
I Fit the timing belt over the toothed pulleys of the crankshaft,
the camshaft and the fuel injection pump. Ensurethat the direction
arrows on the belt indicate a clockwise direction from the front
(15A.O4/A).
2 Fit the idler pulley and tighten the pulley setscrew to 43 Nm (32
Ibf ft) 4,4 kgf m.
3 Put the tensioner pulley in position and engage the pulley
capscrew. There are two threaded holes for the capscrew and it
must be fitted in the hole which will allow correct adjustment of the
belt tension. Tighten the capscrew to hold the pulley but do not
tighten it fully.
4 Remove the location pins from the toothed pulley of the fuel
injection pump and adjust the belt tension, operation 15A-03.
5 Tighten the setscrew(s) of the camshaft pulley to the correct
torque, see section 11Band removethe anti-rotationtool.
6 Remove the timing pins from the camshaft and from the
flywheel.
7 Check the timing of the fuel injection pump, operation 17A-03.
8 Turn the crankshaft through two revolutions to check that there
is no restrictionto movement.
9 Fit the timing case cover, operation 15A-01 and fit the access
panel.
10 Fit the setscrew in the timing hole in the camshaft cover.
I 1 Fit the starter motor, operation 23B-01
12 Connect the battery.
 15 TIMING CASE AND DRIVE ASSEMBLY

i/
Toothed pulley for fuel injection pump

To remove and to fit

Special tools:
Timing pins, PD.182
Location pins for fuel pump pulley, PD.190
Pulley remover, PD. 195
Adaptors for use with PD.195, PD.195-1
Anti-rotationtool, PD.203

To remove
1 Disconnect the battery.
2 Remove the setscrew from the timing hole in the camshaft
cover. Turn the crankshaft until the timing hole in the camshaft
aligns with the hole in the cover and fit the timing pins PD.182 into
the camshaft and into the flywheel.
3 Remove the starter motor and fit the anti-rotation tool PD.203
to the flywheel.
4 Remove the timing case cover, operation 15A-01.
5 Release and remove the pulley nut of the fuel injection pump.
Loosen the setscrew@)of the camshaft pulley.
6 Remove the timing belt, operation 15A-04.
7 Remove the pulley with the pulley remover PD.195 and
I adaptors PD.195-1 (A). Ensure that the key is not lost.
8 Check the pulley for wear, cracks and other damage. Renew it
if necessary.

To fit
1 Ensure that the key is correctly fitted in the shaft of the fuel
injection pump.
2 Put the pulley in position on the shaft with the correct keyway in
engagement with the key. There are two keyways and two marked
I teeth "A" and "B" on the pulley. Use the relevant keyway and
I marked tooth according to the plunger lift of the fuel injection
I pump when the engine piston is at TDC (see page 11C.09).
I Where the plunger lift is 1.26 mm and above, use the keyway
I which is on the same side as the tooth marked " A (Bl). Where the
I plunger lift is below 1,26 mm, use the keyway which is on the same
I side as the tooth marked "B" (82). Ensure that the marks on the
I pulley are towards the front of the engine.
3 Fit the spring washer and the pulley nut, hold the pulley to
prevent movement and tighten the nut to press the pulley into
position.
4 Ensure that the relevant marked tooth (see paragraph 2) of the
pulley is near to the arrow on the timing case (A3). Fit the location
pins PD.190 through the plain holes in the pulley and into the
pump support bracket.
5 Fit the timing belt, operation 15A-04. Remove the pulley
location pins and adjust the belt tension, operation 15A-03.
6 Tighten the pump pulley nut to 60 Nm (44 Ibf ft) 6,1 kgf m and
remove the anti-rotation tool.
7 Remove the timing pins from the camshaft and from the
flywheel.
8 Check thetiming of the fuel injection pump, operation 17A-03.
9 Turn the crankshaft through two revolutions to check that there
is no restriction to movement.
10 Fit the timing case cover, operation 15A-01 and fit the access
panel.
11 Fit the setscrew in the timing hole in the camshaft cover.
12 Fit the starter motor, operation 23B-01.
13 Connect the battery.
 TIMING CASE AND DRIVE ASSEMBLY 15
Toothed pulley for camshaft
To remove and to fit 15A-06
Special tools:
Timing pins, PD. 182
Location pins for fuel pump pulley, PD.190
Pulley remover, W.195
Adaptors for use with PD.195, PD.195-1
Anti-rotationtod, PD.203

To rsmove
1 Disconnect the battery.
2 Remove the setscrew from the timing hole in the camshaft
cover. Turn the crankshaft until the timing hole in the camshaft
aligns with the hole in the cover. Fit the timing pins PD.182 into the
camshaft and into the w h e e l .
3 Remove the starter motor and iit the anti-rotation tool PD.203
to the flywheel.
4 Removethe timing case cover, operation 15A-01.
5 Fit the location pins PD.190 through the plain holes in the
pulley of the fuel injection pump and into the pump support
bracket.
6 If the hub of the two piece pulley for the camshaft is to be
removed (or if a one piece pulley is fmed) loosen the centre
setscrew. Loosen the setscrews which fasten the two piece pulley
to the hub.
7 Remove the timing belt, operation 15A-04.
8 Remove the pulley setscrew(s) and remove the pulley (A or B). If
necessary, remove the pulley hub (Cl) and its dowel (C2).
9 Check the pulley for wear, cracks and other damage. Renew it
if necessary.

To fit
1 If a single piece pulley is used, fit the pulley and the setscrew to
the camshaft but do not fully tighten the setscrew.
If a two piece pulley is used and the hub (Cl) has been removed,
ensure that the dowel (C2) is in position in the camshaft. Fit the
hub and its setscrew but do not fully tighten the setscrew. If
necessary, fit the pulley to the hub but do not fully tighten the
setscrews.
2 Fit the timing belt, operation 15A-04. Remove the location pins
from the pulley of the injection pump and adjust the belt tension,
operation 15A-03.
3 Tighten the centre setscrew of the pulley to 85 Nm (63 Ibf ft) 8,7
kgf m and/or tighten the setscrews which fasten the pulley to the
hub to 22 Nm (16 Ibf ft) 2,2 kgf m. Remove the anti-rotationtool.
4 Remove the timing pins from the camshaft and from the
flywheel.
5 Check the timing of the fuel injection pump, operation 17A-03.
6 Turn the crankshaft through two revolutions to check that there
is no restrictionto movement.
7 Fit the timing case cover,operation 15A-01 and fit the access
panel.
8 Fit the setscrew in the timing hole in the camshaft cover.
9 Fit the starter motor, operation 238-01.
10 Connect the battery.
15 TIMING CASE AND DRIVE ASSEMBLY

Toothed pulley for crankshaft

To remove and to fit 15A-07

Special tools:
Timing pins, PD.182
Location pins for fuel pump pulley, PD.190
Pulley remover, PD.195
Adaptors for use with PD.195, PD.195-1
Anti-rotation tool, PD.203

To remove
1 Disconnect the battery.
2 Remove the setscrew from the timing hole in the camshaft
cover. Turn the crankshaft until the timing hole in the camshaft
aligns with the hole in the cover. Fit the timing pins PD.182 into the
camshaft and into the flywheel.
3 Remove the starter motor and fit the anti-rotation tool PD.203
to the flywheel.
4 Remove the crankshaft pulley, operation 14A-01A or 14A-01B.
5 Remove the timing case cover, operation 15A-01
6 Fit the location pins PD.190 through the plain holes in the
pulley of the fuel injection pump and into the pump support
bracket.
7 Remove the timing belt, operation 15A-04.
8 Remove the toothed pulley from the crankshaft. If it is tight, use
remover tool PD.195 and adaptors PD.195-1. Fit the narrow end of
the distance piece (Al) into the crankshaft. Fasten the main tool
(B) to the pulley with the setscrews and tighten the centre screw
onto the distance piece to remove the pulley.
9 Check the pulley for wear, cracks and other damage. Renew it
if necessary.

To fit
1 Ensure that the key is fitted correctly to the crankshaft. Put the
toothed pulley in position on the crankshaft with the tapped holes
towards the front. If a brush type of dust seal is not fitted to the
timing case cover, fit the crankshaft pulley, operation 14A-01A or
14A-01B.
2 Fit the timing belt, operation 15A-04. Remove the location pins
from the pulley of the injection pump and adjust the belt tension,
operation 15A-03. Remove the anti-rotationtool.
3 Remove the timing pins from the camshaft and from the
flywheel.
4 Check the timing of the fuel injection pump, operation 17A-03.
5 Turn the crankshaft through two revolutions to check that there
is no restrictionto movement.
6 Fit the timing case cover, operation 15A-01 and fit the access
panel. If a brush type of dust seal is fitted to the cover, fit the
crankshaft pulley, operation 14A-01A or 14A-01B.
7 Fit the setscrew in the timing hole in the camshaft cover.
8 Fit the starter motor, operation 238-01.
9 Connect the battery.
 TIMING CASE AND DRIVE ASSEMBLY 15
Timing case

To remove and to fit 15A-08

Special tools:
Timing pins, PD.182
Location pins for fuel pump pulley, PD.190
Pulley remover, PD.195
Adaptors for use with PD.195, PD.195-1
Anti-rotationtool, PD.203

To remove
1 Disconnect the battery.
2 Remove the setscrew from the timing hole in the camshaft
cover. Turn the crankshaft until the timing hole in the camshaft
aligns with the hole in the cover. Fit the timing pins PD.182 into the
camshaft and into the flywheel.
3 Remove the starter motor and fit the anti-rotation tool PD.203
to the flywheel.
4 Remove the crankshaft pulley, operation 14A-01A or 14A-01B.
This is not necessary for some vehicle engines.
5 Remove the timing case cover, operation 15A-01.
6 Fit the location pins PD.190 through the plain holes in the
pulley of the fuel injection pump and into the pump support
bracket.
7 Remove the timing belt, operation 15A-04.
8 Remove the toothed pulleys from the fuel injection pump,
operation 15A-05 and from the camshaft, operation 15A-06.
9 Release the setscrews which fasten the timing case to the
cylinder head, the cylinder block, the support bracket for the fuel
injection pump and the lubricating oil pump. On some vehicle
engines, remove the setscrew which fastens the timing case to the
water pump (21A.O5/A2). Remove the timing case (A).
10 Check the timing case for cracks and other damage and renew
the timing case, if necessary. Ensure that all the fastener clips are
fitted correctly to the timing case (Bl). The timing cases of some
industrial engines have dust seals fitted (82). These seals can be
renewed, if necessary. The new seals have adhesive already
applied to one face. Ensure that the seal for the inspection cover
does not protrude past the front edge of the cover.

To fit
1 Ensure that the location faces of the engine and of the timing
case are clean. Put the cover in position and fasten it with the
setscrews. Tighten the setscrews to the correct torque according
to the thread size, see section 11B.
2 Fit the toothed pulleys to the fuel injection pump, operation
15A-05 and to the camshaft, operation 15A-06.
3 If necessary, fit the crankshaft pulley, operation 14A-01A or
14A-01B. If a dust seal is fitted to the timing case cover, fit the
pulley after the timing case cover is fitted.
4 Fit the timing belt, operation 15A-04. Remove the location pins
from the pulley of the injection pump and adjust the belt tension,
operation 15A-03. Remove the anti-rotation tool.
5 Remove the timing pins from the camshaft and from the
flywheel.
6 Check the timing of the fuel injection pump, operation 17A-03.
7 Turn the crankshaft through two revolutions to check that there
is no restrictionto movement.
a,
8 Fit the timing case cover, operation 15A-01 and fit the access

-
cn panel. If a brush type of dust seal is fitted to the cover, fit the
0
o crankshaft pulley, operation 14A-01A or 14A-01B.
9 Fit the setscrew in the timing hole in the camshaft cover.
E
10 Fit the starter motor, operation 238-01.
.- 11 Connect the battery.
Y
Cylinder block assembly

General description ............................................. 16A.02

Cylinder block
16A-01 To dismantle and to assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16A.03
16A-02 To inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16A.04
16A-03 To correct a glazed bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16A.04
General description
The cylinder block is made of cast iron with sides which extend
below the crankshaft for maximum support. The cylinder bores are
machined directly into the block and are specially honed to reduce
wear and oil consumption.
 CYLINDER BLOCK ASSEMBLY 16
Cylinder block

To dismantle and to assemble 16A-01

To dismantle
1 Drain the cooling system and the lubricating oil. For marine
engines, see section 21.
2 Remove the engine from the application.
3 Remove the alternator drive belt and the alternator and its
mounting bracket, see section 23.
4 If necessary, remove the fan and the fan drive, see section 21.
5 Remove the starter motor, operation 238-01 and fit the anti-
rotation tool to the flywheel.
6 Remove the crankshaft pulley, operation 14A-01A or 14A-01 B.
7 Remove the timing case cover, the timing belt, the toothed
pulleys and the timing case, see section 15. Remove the anti-
rotation tool.
8 Remove the lubricating oil pump and filter assembly, operation 9 If necessary, fit the lubricating oil cooler, operation 21A-11.
19A-06. 10 Fit the cylinder head assembly, operation 12A-07.
9 Remove the fuel filter, the atomisers and the fuel injection 11 Fit the fuel filter, the atomisers and the fuel injection pump, see
pump, see section 20. section 20.
10 If necessary, remove the turbocharger and its lubricating oil 12 Fit the lubricating oil pump and filter assembly, operation
supply and drain pipes, see section 18. 19A-06.
11 Remove the reverse gearbox of marine engines. 13 Fit the anti-rotation tool. Fit the timing case, the toothed pulleys
12 Remove the flywheel and the flywheel housing or backplate, and the timing belt, see section 15. If a brush seal is not fitted to
see section 22. For marine engines, remove the gearbox adaptor the timing case cover, fit the crankshaft pulley, operation 14A-01A
housing, the flywheel and the backplate. or 14A-01B. Adjust the tension of the timing belt, operation
13 Remove the cylinder head assembly, operation 12A-07. 15A-03.
14 Remove the lubricating oil cooler, where fitted, operation 14 Remove the timing pins and the anti-rotation tool and turn the
21A-11. crankshaft through two revolutions. Check the timing of the fuel
injection pump, operation 17A-03. Fit the timing case cover,
15 Remove the oil filler/separator assembly.
operation 15A-01.
Marine engines: Remove the oil drain pump and its bracket.
15 If a brush seal is fitted to the timing case cover, fit the
16 Remove the lubricating oil sump, operation 19A-03. anti-rotation tool and fit the crankshaft pulley, operation 14A-01A
17 Remove the piston and connecting rod assemblies, operation or 14A-01B. Remove the anti-rotation tool.
13A-03. 16 Fit the starter motor, operation 23B-01.
18 If necessary, remove the rear oil seal assembly, operation 17 If necessary, fit the fan and the fan drive, see section 21.
14A-04. Remove the crankshaft, operation 14A.09.
18 Fit the alternator and its mounting bracket and the alternator
19 Remove the mounting bracket for the fuel injection pump (A). drive belt, see section 23.
20 Remove the piston cooling jets, operation 13A-09, or the 19 Marine engines: Fit the reverse gearbox, operation 22A-04.
setscrews and washers, if cooling jets are not fitted.
20 If necessary, fit the turbocharger, operation 18A-02.
To assemble 21 Install the engine in the application.

1 Clean thoroughly the new cylinder block. Ensure that all the oil 22 Fill the cooling system. For marine engines, see section 21.
passages are clean and free from debris. Ensure that the plug is 23 Fill the lubricating oil sump to the correct level with an
fitted in the rear end of the pressure rail. approved lubricating oil.
2 If necessary, fit the piston cooling jets, operation 13A-09. If jets 24 Eliminate air from the fuel system, operation 20A-10.
are not used, fit the setscrews and the washers to close the oil
holes and tighten the setscrews to 22 Nm (16 Ibf ft) 2,2 kgf m.
3 Fit the bracket for the fuel injection pump. Ensure that the
dowels (Al) are correctly fitted. Tighten the setscrews to 43 Nm
(32 Ibf ft) 4,4 kgf m.
4 Fit the crankshaft and, if necessary, the separate oil seal
housing, see section 14.
5 Fit the piston and connecting rod assemblies, operation
13A-03.
6 Fit the lubricating oil sump, operation 19A-03.
7 Fit the oil filler/separator assembly.
al
.-
b Marine engines: Fit the oil drain pump and its bracket.
cn
8 Fit the flywheel housing or backplate and the flywheel, see
0
rr, section 22.
Marine engines: Fit the backplate, the flywheel and the gearbox
u &
'-
adaptor housing.
(0
.-C
Y
To inspect 16A-02

1 Clean the passages for the coolant and for the oil.
2 Check the cylinder block for cracks and for other damage.
The top face of the cylinder block cannot normally be machined as
this will affect the piston height above the top face of the cylinder
block. If high pistons (height grade 1) are fitted to all the bores, it
may be possibleto machine up to 0.26 mm (0.010 in) from the top
face of the cylinder block and to fit low pistons (height grade 6). If
the block is machined, the piston height must be checked to
ensure that the pistons are not higher than the top limit as they
could hit the valves and damage the engine.
3 Check the bores for wear (A) and other damage. The bores
should be checked at the top, centre and bottom both along and
across the engine (8). If a bore is damaged or worn by more than
0,15 mm (0.006 in) in diameter, the bores can be bored and honed
0,50 mm (0.0197 in) oversize in diameter and oversize pistons
fitted. For best results bores should be honed at an inclusive angle
of 30" to 35" with silicon carbide hones to give clean cuts. Base
hone to give a roughness average of 1,5/2,0 micrometres and then
plateau hone to give a roughness average of 0,7/1,4 micrometres.
After the bores have been bored oversize, stamp a letter "X" over
the bore grades on the boss at the rear of the right side of the
cylinder block (C).
If the surfaces of the bores are glazed, an engine can have high oil
consumptionwith very little wear of the bores.

To correct a glazed bore 16A-03

A tool, known as a Flex-Hohe, is available to correct the bore

surface.This tool can be used with an electric hand drill at low
speed. The pistons and connecting rods must be removed and the
piston cooling jets, where fitted, must also be removed. Use
covers to protect all engine components from the debris which is
caused during the process.
1 A3 1/2 in grade 80SC Flex-Hone can be used.
2 New Flex-Hones must be operated in an old bore before use in
an engine to remove all loose material and sharp edges.
3 Lubricate lightly the bore and the Flex-Hone with clean engine
lubricating oil.
4 Put the tool in position on top of the bore, but do not press the
tool into the bore until the tool is operated.
5 Operate the tool and move it up and down the bore once a
second for 30-50 seconds.Remove the tool while it rotates.
6 Clean thoroughly the bore to remove all dirt from the operation,
use a hard brush and kerosene.
7 Dry the bores and remove carefully all the covers used to
protect the components. Clean thoroughly all the engine
components which have been affected by debris.
8 If necessary, fit the piston cooling jets. Ensure that new piston
rings are fitted when the engine is assembled.
Attention: After a glazed bore has been corrected, these
recommendations are advised for the first 240 km (150 miles) or 5
hours of operation:
Do not operate the engine at full load.
Do not operate the engine at high speed.
Do not allow the engine to run at low idle speed for extended
periods.
Engine timing

General description ............................................. 17A.02

Engine timing
17A-01 To set number 1 piston to TDC compression stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . 17A.03
17A-02 To check and to adjust the valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17A.03
17A-03 To check and to adjust the timing of the fuel injection pump . . . . . . . . . . . . . . . . . . . . . 17A.04
17 ENGINE TIMING

General description

Location holes for timing pins are provided in the flywheel and in
the front journal of the camshaft. When these holes are aligned
with the timing holes in the flywheel housing or backplate and in
the camshaft cover, number 1 piston is at top dead centre (TDC)
on its compression stroke.

The toothed pulley for the fuel injection pump gear has two timing
marks (A and B) and two keyways. The keyway which is on the
same side as the relevant timing mark must always be used.

The timing of the fuel injection pump must always be checked

afterthe tension of the timing belt has been adjusted.
 ENGINE TIMING 17
Engine timing

To set number 1 piston to

TDC compression stroke 17A-01
Special tools:
Timing pins for camshaft and crankshaft, PD.182

1 Disconnect the battery and remove the setscrew from the

timing hole in the top front of the camshaft cover.
2 Turn the crankshaft (in the normal direction of rotation -
clockwise from the front) until the timing hole in the front journal of
the camshaft aligns with the timing hole in the camshaft cover.
3 Fit the timing pins through the camshaft cover into the
camshaft (Al) and through the flywheel housing or backplate into
the flywheel. The position for the flywheel pin can be on either side
of the engine, according to the engine application (B1). If one of
the pins will not fit, adjust the valve timing, see operation 17A-02.

To check and to adjust the valve timing 17A-02

Special tools:
Timing pins for camshaft and crankshaft, PD.182
Anti-rotation tool, PD.203

Set the piston of number 1 cylinder to TDC compression stroke,

operation 17A-01. If both the timing pins can be fitted, the valve
timing is correct. If only one of the pins can be fitted, adjust the
valve timing as follows;
1 If necessary, remove the timing pin from the flywheel, turn the
crankshaft to align the timing hole in the camshaft with the hole in
the camshaft cover and fit the camshaft timing pin.
2 Remove the timing case cover, operation 15A-01.
3 Two piece camshaft pulley: Loosen the four setscrews which
fasten the camshaft pulley to its hub to allow the pulley to turn on
the hub.
Single piece camshaft pulley: Remove the starter motor, fit the
anti-rotation tool to the flywheel and loosen the centre setscrew of
the pulley. If necessary, remove the anti-rotation tool.
4 Loosen the capscrew of the belt tensioner pulley and reduce
the tension on the timing belt.
5 Turn the crankshaft to align the timing hole in the flywheel with
the hole in the flywheel housing or backplate. Fit the flywheel
timing pin.
1 6 Adjust the tension of the timing belt, operation 15A-03.
7 Tighten the setscrew(s) of the camshaft pulley to the correct
torque, see section 11B. If a single piece pulley is fitted, the
anti-rotation tool must be fitted during this operation.
8 Check the timing of the fuel injection pump, operation 17A-03.
9 Remove the timing pins and turn the engine through two
revolutions to check that there is no restrict~onto movement.
10 Fit the timing case cover, operation 12A-01 and fit the setscrew
in the timing hole in the camshaft cover.
a
11 If necessary, fit the starter motor.
12 Connect the battery.
?!
m
7
17 ENGINE TIMING

ii
To check and to adjust the
timing of the fuel injection pump 17A-03
Special tools:
Gauge to check plunger lift of fuel injection pump, PD.208
Adaptor for plunger lift gauge, MS.107

1 Set the piston of number 1 cylinder to TDC on the compression

stroke, operation 17A-01. Remove the timing pins.
2 Remove the plug and the washer from the centre of the rear
face of the fuel injection pump and fit the adaptor, number MS107
(Al). Fit the dial gauge PD.208 (142)to the adaptor and set the
gauge to indicate approximately 3,O rnrn. Ensure that there is
enough clearance between the gauge and the oil filler tube to
allow for possible radial movement of the pump.
3 Slowly turn the crankshaft (counter-clockwise from the front of
the engine) until the dial gauge indicates that the fuel pump
plunger is at the bottom of its stroke. Set the dial to zero.
4 Slowly turn the crankshaft clockwise until the timing pin will
enter the timing hole in the flywheel. In this position the dial gauge
should indicate the correct plunger lift, see section 11C.
5 If the reading is not within 0,05 mm (0.002 in) of the correct
setting, disconnect the high-pressure fuel pipes from the pump.
Ensure that a spanner is used to prevent movement of the fuel
pump outlets when the high pressure pipes are removed or fitted.
Loosen the nuts for the pump flange and the setscrews for the rear
support bracket.
If the reading is too low, turn the pump clockwise from the rear
until the correct reading is obtained and then tighten the flange
nuts and the bracket setscrews.
If the reading is too high, turn the pump counter-clockwise from
the rear past the correct setting and then clockwise to the correct
position. Tighten the flange nuts and the bracket setscrews.
Remove the timing pin from the flywheel, turn the crankshaft
counter-clockwise approximately 45". Check that the dial gauge is
still set at zero and check the timing again. When the timing is
correct, connect the high-pressure fuel pipes.
6 Remove the dial gauge and the adaptor and fit the plug and the
washerto the pump. Tighten the plug to 10 Nm (71bf ft) 1,O kgf m.
7 Remove the timing pin from the flywheel and fit the setscrew in
the timing hole in the camshaft cover.
8 Connect the battery.
Aspiration system

General description ............................................. 18A.02

Induction and exhaust manifolds

18A-01 To remove and to fit ................................................ 18A.03
Turbocharger
18A-02 Toremoveandtofit ................................................ 18A.03
Waste-gate unit ................................................... 18A.04
 %d

General description

The ports of the inlet manifold are specially designed to match the
combustion characteristics of the engine to ensure the best
engine performance.

For marine engines, the exhaust manifold is an integral part of the

header tanklheat exchanger/manifold assembly. The manifold is
cooled by the coolant in the closed system. The induction air also
passes through passages in this assembly between the induction
manifold and the cylinder head.

The turbocharger, which is fitted between the exhaust and

induction manifolds, is driven by exhaust gases. The turbocharger
supplies air to the engine at more than atmospheric pressure. A
waste-gate unit, which is controlled by boost pressure, is fitted to
the turbocharger. This unit provides a by-pass for some of the
exhaust gases to control the output of the turbocharger. The
turbocharger is lubricated by oil from a connection in the body of
the lubricating oil pump. The oil passes through the bearing
housing of the turbocharger and returns to the lubricating oil
sump.
 AsPtRATloN SYSTEM 18
Induction and exhaust manifolds

To remove and to fit 18A-01

For marine engines, see operation 21A-12.

1 Disconnect the air filter or the pipe
. . from the air filter to the
induction manifold. On turbocharged engines, disconnect the
turbocharger, operation 18A-02.
2 Disconnect the exhaust pipe from the exhaust manifold or from
the turbocharger. If necessary, remove the turbocharger,
operation l8A-02.
3 Loosen the setscrews gradually and evenly in the reverse
sequence to that shown in figure C. The top four setscrews are
common to both of the manifolds and are fitted with washers.
Remove the setscrews and washers and remove the induction
manifold (A) and the exhaust manifold (B). Remove the gasket.
4 Check the manifolds for cracks and other damage. Ensure that
the faces of the manifolds and the cylinder head are clean.
5 Put a new gasket in position with the side of the gasket which is
marked "THIS SIDE OUT" towards the manifolds (B). Do not apply
jointing compound to the gasket.
6 Put the exhaust manifold in position and loosely fit the bottom
setscrews. Fit the induction manifold and its setscrews. Washers
must be fitted to the top four setscrews which fasten the flanges of
both manifolds. Tighten the manifold setscrews gradually and
evenly to 22 Nm (16 Ibf ft) 2,2 kgf m, In the sequence shown in
figure C.
7 Connect the air filter or the pipe from the air filter to the
induction manifold.
8 Connect the exhaust pipe.
Turbocharged engines: Fit the turbocharger, operation 18A-02
and then fit the exhaust pipe.

Turbocharger

To remove and to fit 18A-02

Special tool:
Spanner for oil pipe connection at turbocharger, PD.201

To remove
1 Thoroughly clean the turbocharger.
2 Remove the air filter or the air filter hose at the turbocharger
compressor inlet.
Marine engines: Remove the induction cap, if necessary.
3 Disconnect the exhaust pipe.
4 Release the hose clips and push the hose of the compressor
outlet up the elbow of the induction manifold.
Marine engines: Release the spring clips and remove the heat
shield.
5 Disconnect the oil supply pipe and the oil drain pipe at the
turbocharger. Special spanner PD.201 can be used to disconnect
the supply pipe at the turbocharger. Disconnect the boost
pressure pipe at the turbocharger.
6 Release the nuts at the turbocharger flange and remove the
turbocharger (D) and the gasket. If necessary, remove the exhaust
elbow and its joint from the turbocharger. Fit covers to the
.-3 openings in the turbcharger to ensure that dirt, etc. will not enter.
$ 7 Fit covers to the ends of the pipes and the openings in the
g manifolds or in the header tank / heat exchanger / manifold
assembly.
,
8 Check the air hoses and the oil drain hose for cracks or other
damage and renew them, if necessary.
Ln
.E 9 If necessary, remove and clean the oil drain pipe.
z0
a
18A.03
 V
To fit
1 Remove the covers from the components.
2 Check that the turbocharger inlets and outlets are clean and
free from restriction and that the turbocharger shaft rotates freely.
Also check that the manifold and exhaust pipe openings are clean
and free from restriction.
3 Fit a new gasket to the exhaust manifold to turbocharger
flange. Ensure that the threads of the studs are clean and apply a
suitable compound to the studs to prevent seizure. Fit the
turbocharger, fit the nuts and tighten them to 22 Nm (16 Ibf ft) 2,2
kgf m.
Marine engines: Ensure that the heatshield bracket is fitted
correctly before the flange nuts are fitted and tightened. Fit the
heatshield.
4 If necessary, fit the exhaust elbow to the turbocharger. Ensure
that the faces of the elbow and of the turbocharger are clean and
fit a new joint. Tighten the nuts to 22 Nm (16 Ibf ft) 2,2 kgf m.
5 Connect the oil drain pipe and the boost control pipe to the
turbocharger. 2 Check that the pressure needed to move the rod 0,38 mm
6 Insert 100/140 ml (4/5 fluid ounces) of clean engine lubricating 1 (0.015 in) is within the limits of 89/97 kPa (12.9/14.1 Ibf/in2)
oil through the inlet port in the centre casing of the turbocharger. 1 0,91/0.99 kgf/cm2. Ensure that the dial indicator returns to zero
'd
Turn the rotating assembly by hand to send the oil around the when the air pressure is released. Repeat the test several times to
bearings. ensure that an accurate reading is obtained. It may be necessary
7 Slide the hose on the induction manifold elbow onto the to lightly hit the turbine housing with a soft hammer during the test
compressor outlet and tighten the hose clips. operation.
8 Check that the passages in the air filter and hose or in the 3 If the operation of the waste-gate is not correct, the
induction cap and pipe are clean. Fit the air filter or the induction turbocharger must be renewed. No adjustment is allowed.
cap and tighten the hose clips. 4 Remove the test equipment and connect the boost sensor
9 Put the oil supply pipe in position but leave it disconnected. pipe.
Non-marine engines: Disconnect the stop solenoid at the fuel
injection pump and operate the starter motor until oil flows from
the supply pipe. Connect the stop solenoid.
Marine engines: Operate the starter motor with the stop button
pressed or with the stop control lever in the "stop" position until
oil flows from the supply pipe. Ensure that the stop control lever
returns to the "run" position.
Connect the oil supply pipe. The special spanner PD.201 can be
used to tighten the connection.
Marine engines: Fit the heatshield and its spring clips.
10 Start the engine and check for lubricating oil and air leaks
(especially from the boost sensor pipe that is fitted between the
compressor casing and the waste-gate actuator). The engine
should be operated at low speed for three to four minutes to allow
for oil circulation before the speed is increased.

If the by-pass valve of the waste-gate does not open at the correct
pressure, this will affect the performance of the engine.

A low pressure setting can cause black exhaust smoke at rated

speed and loss of power at 2500 rev/min.

A high pressure setting can cause high cylinder pressures which

can cause failure of the cylinder head gasket and damage to the
bearings and pistons.

The pressure setting can be checked as follows:

1 Disconnect the boost sensor pipe (Al) and connect an air
supply which can be accurately controlled and is fitted with an
accurate gauge. Fasten a dial test indicator to the turbocharger
with the end of the plunger in contact with the end of the actuator
rod to measure axial movement of the rod (A2).
Lubrication system

General description ......

Filter canister
To renew ..................
Filter head
To remove and to fit .........
Lubricating oil sump
To remove and to fit .........
Oil strainer and suction pipe
To remove and to fit .........
To inspect and to correct ......
Lubricating oil pump
To remove and to fit .........
To inspect . . . . . . . . . . . . . . . . . .

Relief valve
To remove and to fit .........
To inspect . . . . . . . . . . . . . . . . . .
 d
General description

The lubricating oil pump is fitted around the forward end of the
crankshaft; the inner rotor of the pump is driven by a key in the
crankshaft. The pump has an inner rotor and an outer rotor which
are offset to each other. The inner rotor has ten lobes which mesh
with the eleven lobes of the outer rotor. When the pump turns, the
space between the lobes which are in mesh increases to cause a
suction or decreases to cause a pressure increase.

Lubricating oil from the sump passes through a strainer and pipe
to a passage in the cylinder block and then to the suction side of
the pump.

A relief valve (which is fitted in the pump body) opens if the

pressure is too high; this allows some of the oil from the outlet side
of the pump to return to the inlet side of the pump.

From the pump the oil passes through a filter which is fitted to the
pump body. After the filter the oil passes to the pressure rail which
is drilled through the length of the block.

From the pressure rail, lubricating oil passes to the crankshaft

main bearings and through passages in the crankshaft to the big
end bearings. The pistons and the cylinder bores are lubricated by
splash and oil mist.

Oil passes (through passages in the block and the cylinder head)
from the rear of the pressure rail in the block to a pressure rail in
the head. From the pressure rail in the head, oil passes to each
camshaft journal. The valves and the tappets are lubricated by
splash and oil mist.

The turbocharger is lubricated by oil which passes through a pipe

from the body of the oil pump or from the filter head. After it has
passed through the turbocharger, the oil returns through a drain
pipe to the sump.

Most turbocharged engines have piston cooling jets fitted. These

jets are connected to the pressure rail in the cylinder block and
spray lubricating oil inside the pistons to keep them cool.

Some engines are fitted with a lubricating oil cooler.This is

connected by pipes to the oil pump and to the filter head. The oil
passes through the cooler before it goes to the filter. For some
applications, most of the oil goes through the cooler but a small
quantity goes through a restricted by-pass direct to the filter.
 LUBRICATION SYSTEM 19
Filter canister

To renew 19A-01

1 Put a tray underthe filter to contain spilt lubricatingoil.

2 Remove the filter canister with a strap wrench or a similar tool.
Ensure that the adaptor (Al) is secure in the filter head and then
discard the canister.
3 Clean the filter head.
4 Add clean engine lubricating oil to the new canister. Allow time
for the oil to fill the canister through the filter element.
5 Lubricate the top of the canister seal with clean engine
lubricating oil.
6 Install the new canister and tighten it by hand only. Do not use
a strap wrench.
7 Ensure that there is lubricatingoil in the sump.
Turbocharged non-marine engines: Disconnect the stop solenoid
at the fuel injection pump and operate the starter until oil pressure
is indicated on the pressure gauge or until the oil warning light is
extinguished. Connect the stop solenoid.
Turbocharged marine engines: Operate the starter motor with the
stop button pressed or with the stop control lever of the fuel pump
in the "stop" position until the oil pressure warning light is
extinguished. Ensure that the stop control lever returns to the
"run" position.
8 Operate the engine and check for leakage from the filter. When
the engine has cooled, check the oil level on the dipstick and add
oil to the sump, as necessary.
Attention: The canister contains a valve and a special tube which
ensure that lubricating oil does not drain from the filter. Therefore,
ensure that the correct Perkins POWERPART canister is used.

Filter head

To remove and to fit 19A-02

1 Put a tray under the filter head to contain spilt lubricatingoil.

2 Remove the filter canister, operation 19A-01.
3 If necessary, disconnect the oil cooler pipe and/or the
turbocharger oil pipe from the filter head.
4 Release the setscrews and remove the filter head from the
lubricating oil pump. Discard the joint.
5 Clean the joint faces of the filter head and of the oil pump.
If an oil cooler is used, ensure that a plug is fitted in the filter head
(Bl). For some applications, the plug will have a small hole in it to
allow some of the oil to pass directly to the filter.
6 Fit the filter head and a new joint to the oil pump and tighten the
setscrews to 22 Nm (16 Ibf ft) 2,2 kgf m.
7 If necessary, connect the oil cooler pipe and/or the
turbocharger oil pipe.
8 Fit a new filter canister, operation 19A-01.
 19 LUBRICATION SYSTEM

Lubricating oil sump

To remove and to fit 19A-03

1 Operate the engine until it is warm.

2 Stop the engine, remove the sump drain plug and its washer
and drain the oil. For marine engines, the sump can be drained by
use of the sump drain pump.
3 Remove the dipstick. Disconnect the drain pipe(s) of the
breather.
Marine engines: Removethe sump drain pump.
Turbocharged engines: Disconnect the drain pipe of the
turbocharger.
4 Where necessary, provide a support for the sump. Remove the
setscrews which fasten the sump to the cylinder block. Lower the
sump and remove the joint.
5 Wash the sump with clean kerosene, ensure that all the
kerosene is removed. Clean the flange faces of the sump and of
the cylinder block.
6 If the front or the rear main bearing cap has been removed,
apply sealant as instructedin item 15 of operation 14A-09.
7 Put a new sump joint in position on the sump or on the cylinder
block. If a two piece joint is to be used, apply POWERPART
Sealant to the ends of each half joint and ensure that the ends are
fitted together correctly. Fit the sump and ensure the correct
location with a setscrew on each side. Fit the remainder of the
I setscrews and tighten all the setscrews to 12 Nm (9 Ibf ft) 1,2 kgf
m. If necessary, fit the drain plug and its washer and tighten the
plug to 43 Nm (32 Ibf ft) 4,4 kgf m.
8 Fit the dipstick. Connect the drain pipe(s) of the breather.
Marine engines: Fit the sump drain pump.
Turbocharged engines: Connect the drain pipe of the
turbocharger.
9 Fill the sump to the "MAX" level on the dipstick with an
approved lubricating oil.

Oil strainer and suction pipe

To remove and to fit 19A-04

The oil strainer is an integral part of the suction pipe. No regular

service is necessary but wash the strainer when it is removed.
I Remove the sump, operation 19A-03.
2 Release the setscrew which holds the bracket to the main
bearing cap.
3 Release the flange setscrews of the suction pipe and remove
the suction pipe and strainer. Remove the "0" ring (Al). Clean the
flange face of the cylinder block and of the suction pipe.
4 Loosely assemble the suction pipe bracket to the correct main
bearing cap. Fit the suction pipe to the oil pump together with a
new "0" ring. Tighten the setscrews. Tighten the setscrew of the
suction pipe bracket; ensure that there is no stress on the suction
pipe.
5 Fit the sump, operation 19A-03 and fill it with an approved oil to
the "MAX" level on the dipstick.

To inspect and to correct 19A-05

1 Wash the assembly in kerosene and dry it thoroughly.

2 Check the pipe, the strainer and the welded joints for cracks
and other damage. Check that the mounting bracket is secure.
3 If the damaged component cannot be welded correctly, renew
the assembly.
 LUBRICATION SYSTEM 19
Lubricating oil pump

To remove and to fit 19A-06

To remove
I Disconnect the battery.
2 Remove the setscrew from the timing hole in the top front of
the camshaft cover. Turn the crankshaft until the timing hole in the
front journal of the camshaft aligns with the hole in the cover.
3 Fit the timing pins to the camshaft and to the flywheel, see
section 17.
4 If necessary, remove the fan. Remove the drive belt of the
alternator, operation 23A-03 and remove the pulley of the water
pump.
5 Remove the crankshaft pulley, operation 14A-01A or 14A-01B.
6 Remove the timing case cover, operation 15A-01.
7 Remove the timing belt, the toothed pulleys and the timing
case, see section 15.
8 Remove the front key of the crankshaft.
9 Release gradually and evenly the setscrews of the oil pump in
the reverse sequence to that shown in figure D.
10 Remove the oil pump (A). If necessary, remove the pulley guard
which is fitted to some vehicle engines.

To fit

Special tool:
Protection sleeve, PD.193

I Ensure that the joint faces of the oil pump, the cylinder block
I and the main bearing cap are clean. Apply POWERPART Sealant
I (Loctite 518) where the main bearing cap meets the cylinder block
I (see 14A.lOA). Ensure that the two dowels (Al) are in position and
put a new joint into position (A2). Where a pulley guard is used
(some vehicle engines), ensure that it is in position at the top of the
pump and is held by the small setscrew in the pump body.
2 Ensure that the rear key is in position and that the chamfered
end of the key is towards-the front (B). If the front key is still in
position, remove it from the crankshaft.
3 Clean the crankshaft and the protection sleeve PD.193 and
lightly lubricate them with clean engine oil. Fit the protection
sleeve (Cl) to the crankshaft.
4 Turn the rotors of the oil pump until the keyway in the inner
rotor will align with the key in the crankshaft. If the seal is fitted in
the front of the pump, lightly lubricate it with clean engine oil.
Carefully put the pump into position with the keyway over the key
and with the dowels fitted into the pump housing. Remove the
protection sleeve.
5 Put the pump setscrews in position with a suitable sealant
applied to the setscrew which fits into the main bearing cap (Dl).
Sealant is already applied to new setscrews. Some vehicle
engines have a pulley guard fitted to the top of the pump. Tighten
the setscrews gradually and evenly to the correct torque, see
I section 11B, in the correct sequence (D).
6 Where necessary, fit the front oil seal into the pump, see
operation 14A-02.
Q)
7 Fit a new front key to the crankshaft.
8 Fit the timing case, operation 15A-08.
9 . Fit the toothed pulleys and the timing belt, see section 15.
m
7 Check the timing of the fuel injection pump, operation 17A-03.
, 10 Fit the timing case cover, operation 15A-01.
&
(I, I 1 Fit the crankshaft pulley, operation 14A-01Aor 14A-01B.
0
o 12 Fit the pulley of the water pump and the drive belt of the
In
alternator, operation 23A-03. Where necessary, fit the fan,
1 operation 21A-09.
%
V)
.-
19 LUBRICATIONSYSTEM

13 Ensure that the timing pins have been removed and fit the
setscrew in the timing hole in the top front of the camshaft cover.
14 Connect the battery.
15 Ensure that the engine will not start and operate the starter
motor until there is a reading on the oil pressure gauge or the oil
warning light is extinguished.
To ensure that a non-marine engine will not start: Disconnect the
stop solenoid at the fuel injection pump.
To ensure that a marine engine will not start: Move the stop control
lever on the fuel injection pump to the "stop" position or press the
stop button while the starter motor is in operation.
16 Start the engine and check for leaks.

To inspect 19A-07

If the rotors are worn enough to have an effect on the performance

of the oil pump, the complete oil pump must be renewed.
1 Release the screws and remove the backplate of the oil pump.
2 Remove the rotors and clean thoroughly all the components.
Check for cracks and other damage.
3 Fit the rotors inside the pump and check the outer rotor to body
clearance (A).
4 Check the inner rotor to outer rotor clearance (B).
5 Check the rotor end-float with a straight edge and a feeler
gauge (C). For all the above clearances, see section 11C.
6 If the oil seal is to be renewed, remove the rotors and press the
seal from the body. The pump is easier to fit to the engine without
the seal in position and the seal can be fitted with the pump on the
engine, see operation 14A-02.
If necessary, the seal can be fitted with the pump off the engine.
Ensure that the lip seal is to the inside of the pump and that the
seal is fitted squarely in the pump. Use a suitable adaptor and
press the seal into the pump until the front face of the seal is 0,5
mm (0.02 in) below the front face of the housing.
7 Lightly lubricate the rotors with clean engine oil and fit them to
the pump. The inner rotor of later pumps has a spigot on one end
and this spigot must be fitted towards the seal housing. Fit the
backplate with the word "TOP" away from the straight edge of the
pump body (D). Fit and tighten the backplate screws to 4 Nm (3 Ibf
ft) 0,4 kgf m.
 LUBRICATION SYSTEM 19
Relief valve

To remove and to fit 19A-08

The relief valve is fitted inside the left side of the pump body and
cannot be removed as an assembly. The pressure setting is not
adjustable except by the installation of new parts.
1 Straighten the open ends of the split pin (Al). Apply pressure to
the end plug (A4) and remove the split pin from the pump body.
2 Release the pressure from the end plug and, if possible,
remove the plug and the spring (A3). If the plug does not come out,
lightly hit it inwards to see if the spring pressure will push it out of
the housing. If the plug will still not come out, drill a small hole in
the centre of the plug; use a self-tapping screw to remove the
plug.
3 Remove the spring and the plunger (A2). A small magnet can
be used to remove the plunger.
4 Renew the split pin, the "0" ring (A5) and the end plug (if the
plug has been drilled).
5 Ensure that all the components are clean and lubricate them
with clean engine oil. Fit the new "0" ring to the end plug.
6 Fit the plunger into the sleeve in the housing with the open end
of the plunger towards the inside. Fit the spring over the boss on
the end of the plunger. Fit the end plug with the end of the spring
fitted inside the recess in the plug.
7 Press in the end plug and fit the split pin through the top hole in
the housing and then through the bottom hole. Bend over the ends
of the split pin.

To inspect 19A-09

1 Check the spring for wear and other damage and, if possible,
check the load necessary to compress the spring to its fitted
length, see section 11C.
2 Check the plunger for wear and other damage and ensure that
it slides easily in the sleeve of the housing.
3 Check the body and the end plug for wear and other damage.
4 Renew worn or damaged components.
Fuel system

General description ............................................. 20A.02

Fuel filter canister

20A-01 To renew ................................................ 20A.03
Atomisers
Atomiser fault ................................................... 20A.03
20A-02 To remove and to fit ................................................ 20A.03

Lift pump
20A-03 To remove and to fit ................................................ 20A.04
20A-04 To dismantle and to assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20A.04
20A-05 To test ......................................................... 20A.05

Fuel injection pump

20A-06 To remove and to fit ................................................ 20A.06
20A-07 To adjust . . . . . . . . . . ............................................... 20A.07
20A-08 To check the cold idle device .......................................... 20A.08
20A-09 To check the cold start advance unit .................................... 20A.08

Fuel system
20A-10 To eliminate air from the fuel system .................................... 20A.09
20 FUEL SYSTEM

General description

All engines are fitted with a Bosch fuel injection pump. These
pumps have mechanicalgovernorsto control the engine speed.

The pumps fitted to vehicle engines and some marine engines

have a cold start advance unit which is fitted to the side of the
pump. This unit alters the timing of the fuel injection when the
engine is cold, to improve the engine start. For some engines the
unit is controlled electrically by a temperature switch which is
fitted in the cylinder head. For other engines the unit is controlled
by the temperature of the pump.

The pumps fitted to some vehicle engines have a device which

increases the idle speed of the engine when it is cold. This device
is controlled by a temperature switch which is fitted into the
thermostat housing.

The pumps which are fitted to most turbocharged engines have a

boost control. The boost control is a device which is affected by
boost pressure (from the turbocharger) and reduces the maximum
fuel delivery at lower engine speeds to match the reduced air
supply to the cylinders.

The atomisers receive high pressure fuel from the fuel injection
pump and inject this fuel into the combustion chambers as a very
fine spray. The pressure at which atomisers operate can be
corrected by a change of shims fitted above the spring.

The fuel injection equipment must only be checked and adjusted

by personnel who have had the correct training.

The lift pump is a diaphragm type pump and is mechanically

driven. It is fitted owthe right side of the camshaft cover and is
driven by an eccentric on the camshaft. The pump is fitted with a
priming lever.

It is very important that dirt does not enter the fuel system. Before
a connection is disconnected, clean thoroughly the area around
the connection. After a component has been disconnected, fit a
suitable cover to all open connections.
 FUEL SYSTEM 20
Fuel filter canister
- -

To renew 20A-01

1 'Thoroughly clean the outside surfaces of the fuel filter

assembly. Loosen, by two or three turns, the vent screw (Al)
which is fitted in the top of the filter. Loosen the drain device (A2)
at the bottom of the danister and drain the fuel into a suitable
container.
2 Use a strap wrench or similar tool to loosen the filter canister
and remove the canister (B).
3 Ensure that the threaded adaptor (Bl) is secure in the filter
I head and that the inside of the head is clean. Ensure that the
I seal (B2) which is supplied with the new canister is in position on
I the top of the canister.
4 Lubricate lightly the top seal of the new canister with clean fuel.
Fit the new canisterto the filter head and tighten, by hand only.
5 Eliminate the air from the fuel filter, see operation 20A-10.
Attention: It is important that only the genuine Perkins fuel filter
canister is used. The use of a wrong canister can damage the fuel
injection pump.

Atomisers

Atomiser fault

An atomiser fault can cause an engine misfire.

To find which atomiser is defective, operate the engine at a fast

idle speed. Loosen and tighten the union nut of the high-pressure
fuel pipe at each atomiser. When the union nut of the defective
atomiser is loosened, it has little or no effect on the engine speed.

A Ensure that the fuel does not spray onto your skin.

To remove and to fit 20A-02

Special tools:
Slide hammer for atomiser removal, PD.184
Adaptor for Bosch atomisersfor use with PD.184, PD.184-1
Adaptor for CAV atomisers for use with PD.184, PD. 184-2

I The two staqe CAV atomisers IC1) . . which are fitted to some
I naturally aspirated vehicle engines are longer than the single stage
I atomisers (C2). The cap nut of these two stage atomisers must not 1
I be loosened as this will cause interferenceto the pressure setting.
I The two stage (Bosch) atomisers which are fitted to some
I turbocharged vehicle engines are approximately the same length
I as the single stage atomisers. The pressures of the two stage
I atomisers cannot be reset in service.
I Single stage atornisers and two stage Bosch atornisers
d Remove the fuel leak-off pipe.

g:
2 Remove the union nuts of the high-pressure pipe from the
atomiser and from the fuel injection pump. Hold the pump outlet
with a spanner to prevent movement while the union is released at
~
the pump. Do not bend the pipe. If necessary, remove the pipe
- clamps.
7
1 3 Release the clamp setscrew of the atomiser. The spacer (D2)
will be either 315 mm (1.2 in) or 7 mm (0.3 in) long, according to the
6
v, type of atomiser used. If a short spacer is used, lift the spring
8
m
assembly during the setscrew removal operation. This will ensure
that the thread of the setscrew does not enter the hole in the
- .E I bottom spring. Remove the clamp assembly (Dl) and the spacer.
I Remove the atomiser (D3) and its seat washer (D4). If the atomiser
2.-
Y
 20 FUEL SYSTEM

I is tight in the cylinder head, use the slide hammer (Al) and the
I relevant adaptor (A2).
4 Check the clamp assembly for damage or distortion and, if
necessary, renew the assembly. Renew the atomiser seat washer.
1 5 Ensure that the atomiser location ring (20A.O3/D5) is in
position in the cylinder head and put the new atomiser and seat
washer into position. Ensure that the atomiser is not tilted. Fit the
clamp assembly and the spacer with the arms of the clamp fitted
squarely on the shoulders of the atomiser. Tighten the clamp
setscrew to 43 Nm (32 Ibf ft) 4,4 kgf m.
6 Fit the high-pressure fuel pipe and tighten the union nuts to 18
Nm (13 Ibf ft) 1,8 kgf m. Hold the pump outlet with a spanner to
prevent movement while the union nut is tightened at the pump. If
necessary, fit the pipe clamps.
7 Fit the leak-off pipe.
8 Operate the engine and check for leakage of fuel and air.

Two stage CAV atomisers

I 1 Remove the fuel leak-off pipe.
1 2 Remove the union nuts of the high-pressure pipe from the
I atomiser and from the fuel injection pump. Hold the pump outlet
I with a spanner to prevent movement while the nut is released at
I the pump. Do not bend the pipe. If necessary, remove the pipe
I clamps.
1 3 Release and remove the nut (87), the special washer (B6), and
I the clamp (85). Remove the atomiser (82) and its seat washer (83).
I If the atomiser is tight in the cylinder head, use the slide hammer
I (Al) and the relevant adaptor (A2).
1 4 Check that the support (B4) for the clamp is secure. If the
I supports are removed, they must be aligned correctly when they
I are fitted, as shown in C and the nuts tightened to 43 Nm (32 Ibf ft)
1 4,4 kgf m.
1 5 Ensure that the location ring (81) is in position in the cylinder
I head and put the atomiser and a new seat washer into position.
I Ensure that the atomiser is not tilted. Fit the clamp over the
I atomiser and the stud with the chamfer at the top. Put the special
I washer in position with its chamfer towards the chamfer in the
I clamp. Fit and tighten the nut to 23 Nm (17 Ibf ft) 2,3 kgf m. It is
I important that the correct torque is used as damage can occur if
I the nut is overtightened.
1 6 Fit the high-pressure fuel pipe and t~ghtenthe union nuts to 18
I Nm (13 Ibf ft) 1,8 kgf m. Hold the pump outlet with a spanner to
I prevent movement while the union nut is tightened at the pump. If
I necessary, fit the pipe clamps.
1 7 Fit the leak-off pipe.
1 8 Operate the engine and check for leakage of fuel and air.

Lift pump

To remove and to fit 20A-03

1 Disconnect the fuel pipes from the lift pump.

2 Remove the setscrew from the timing hole in the top front of
the camshaft cover. Turn the crankshaft until the timing hole in the
front journal of the camshaft aligns with the hole in the cover. This
will ensure that the highest point of the drive eccentric is away fron
the pump lever.
1 3 Release the setscrews and remove the lift pump (D).
4 Clean the joint faces of the lift pump and of the camshaft cover
and fit the lift pump together with a new joint. Fit the setscrews
and tighten them gradually and evenly to 22 Nm (16 Ibf ft) 2,2 kgf
m.
5 Connect the fuel pipes.
6 Release the vent screw on the fuel filter head. Operate the
priming lever of the lift pump to eliminate any air between the lift
pump and the fuel filter. Operate the lever until fuel, free of air,
comes from the vent screw. Tighten the vent screw.
7 Operate the engine and check for any fuel or air leakage.
 FUEL SYSTEM 20
To dismantle and to assemble 20A-04

To dismantle
1 Clean the outside surfaces of the lift pump.
2 Make a mark across the flanges of the two halves of the pump
to ensure correct relationship when the pump is assembled.
1 3 Remove the lift pump cover (Al) and the gauze strainer (A2).
Release the screws and separate the two halves of the pump.
1 4 Turn the diaphragm assembly (A5) 90" to release the
I diaphragm pull rod from the link arm (A9) and remove the
I diaphragm assembly. Remove the stem seal (A7), the spring seat
I washer (A8) and the spring (A13) from the pull rod. The diaphragm
and pull rod assembly is renewed as an assembly and no service
is possible on the diaphragm.
1 5 The valves (A4) are peened in and can be removed with a
suitable lever. Some of the peened metal will have to be removed
before the valves can be removed.
1 6 To remove the link arm: Hold the rocker lever (A12) in a vice and
hit the body of the lift pump with a soft face hammer to release
I the two retainers (A1 1). Be careful not to damage the joint face of
I the pump body. Remove the rocker lever, the pin (AlO), the link
arm and the return spring. Check the components for wear and
other damage.

To assemble
I 1 Thoroughly clean the valve housings. Fit new seat washers (A3)
I and push the new valves (A4) into position. As the valves are the
same, but one valve is fitted in reverse of the other, it is possible to
fit the valves upside down. To ensure that the valves are correctly
I fitted, fit them as shown in A. When the valves are correctly fitted,
peen the edge of the valve housings in six evenly divided places to
keep the valves in position.
1 2 Fit the rocker lever (A12), pin (A10) and link arm assembly (A9)
into the bottom half of the lift pump. Fit the return spring and
ensure that the ends of the spring are in ;heir correct locations.
3 With a light hammer and a suitable adaptor, fit two new
I retainers ( A l l ) in their grooves in the casing until they fasten the
pin. Peen the open ends of the grooves to fasten the retainers in
position.
1 4 Fit the diaphragm spring (A13) into its location under the
I diaphragm (A5). Put the spring seat washer (A8) and a new stem
I seal (A7) into position on the pull rod. Ensure that the small
diameter at the top of the seal is on the round section of the pull
rod.
5 Put the diaphragm assembly in position over the lower half
body with the blade of the pull rod aligned with the slot in the link
arm. Ensure that the small protrusion on the edge of the
I diaphragm (51) is at 90" to the similar protrusion on the body (82).
Press lightly down on the diaphragm until the notch in the pull rod
is in the slot in the link arm. Turn the diaphragm 90" to ensure that
the protrusion on the edge of the diaphragm aligns with the
protrusion on the body. This action will engage and retain the pull
rod in the siot of the link arm.
1 6 Push the rocker lever upwards until the diaphragm is level with
the body flange. Fit the top half of the body in position with the
marks on the flanges aligned. Keep the pressure on the rocker
I lever and fit the spring washers and the screws. Release the
2 I pressure on the rocker lever and tighten the screws evenly.
When fitted, ihe edge of the diaphragm should be approximately
level with the edge of the body.
.-

-
1 7 Fit the gauze strainer (A2) and the cover (Al) with the rubber
o I seal (A14) correctly fitted. Fit the cover screw and its sealing
0
washer and tighten the screw.
m
.E
ii
 20 FUEL SYSTEM

To test 20A-05

If there is a leakage of fuel through the hole in the pump body

1 (20A.05/83), this will indicate that the diaphragm is damaged. If
there is a leakage of lubricating oil, the seal is damaged.
1 Disconnect the fuel outlet pipe from the fuel lift pump. Fit a
0-70 kPa (0-10 Ibf/in2) 0-0,7 kgf/cm2 pressure gauge to the outlet
of the lift pump. Release the connection at the gauge and operate
the priming lever of the lift pump to eliminate air from the pipe.
When fuel, free of air, flows from the pipe tighten the connection.
Ensure that there are no leaks at the connections between the
pump and the gauge.
2 Operate the starter motor for 10 seconds and note the
maximum pressure indicated on the gauge. If the pressure
indicated is less than 75% of the minimum production static
pressure shown in section 11C, correct or renew the pump. Also,
after the crankshaft rotation has stopped, check the rate at which
the pressure reduces to half the maximum pressure obtained. If
this is less than 30 seconds, correct or renew the pump.
3 Remove the gauge and connect the outlet pipe to the lift pump.
Release the vent screw on the fuel filter head and operate the
priming lever until fuel, free of air, flows from the vent screw.
Tighten the vent screw.

Fuel injection pump

To remove and to fit 20A-06

Special tools:
Timing pins, PD.182
Location pins for fuel pump pulley, PD.190
Pulley remover, PD.195
Adaptors for use with PD.195, PD.195-1
Anti-rotation tool, PD.203

1 Disconnect the battery.

2 Set number 1 piston to TDC compression stroke, operation
17A-01 and fit the timing pins PD.182. Remove the starter motor,
operation 238-01 and fit the anti-rotation tool PD.203 to the
flywheel.
3 Remove the timing case cover, the timing belt and the toothed
pulley for the fuel injection pump, see section 15.
4 Disconnect the speed control of the fuel pump and, if
necessary disconnect the stop control. Disconnect the cables
from the stop solenoid on the pump and, if necessary, the cold
start advance unit and the cold idle solenoid. Ensure that the
cables are suitably marked to ensure that they can be connected
correctly.
5 Remove all necessary pipes from the pump. Ensure that a
spanner is used to prevent movement of the fuel pump outlets (A)
when the nuts of the high-pressure pipes are released.
6 Remove the setscrews which fasten the support bracket at the
rear of the pump to the mounting bracket.
7 Remove the flange nuts and remove the pump (B) - ensure that
the key does not fall from the drive shaft.
3 Put the toothed pulley on the shaft with the key engaged in the
To fit correct keyway, see operation 15A-05. Hold the pulley to prevent
Attention: If a new or reconditioned pump is to be fitted, the pump movement, fit the pulley nut and washer and tighten the nut to
shaft may be fastened in the equivalent position to the engine at press the pulley onto the shaft; do not tighten the nut to its final
number 1 piston at TDC compression stroke. If it is, the spacer in torque.
the shape of a pointer (CI) will be removed from under the 4 If the shaft of the pump is fastened in the TDC position (see
setscrew which is fitted to the front left side of the pump. The "Attention" above): Ensure that the correct marked tooth is
spacer will be fastened loosely to the pump by a piece of wire. The towards the arrow on the timing case and fit the timing belt, see
pump can be fitted and the tension of the timing belt adjusted with operation 15A-04. Check the position of the studs within the slots
the pump in this condition but the pump shaft or the crankshaft of the pump mounting flange; ensure that the fuel pump can move
must not be turned without the spacer in position under the in a clockwise direction from the rear while the belt tension is
setscrew. adjusted. If there is not enough movement, change the belt
1 Ensure that the timing pins are fitted into the camshaft and into position on the pulley. Adjust the tension of the timing belt,
the flywheel. Ensure that the anti-rotation tool is fitted. operation 15A-03. Ensure that the studs are not at the ends of the
2 Ensure that the key is correctly fitted to the pump shaft. Put the slots in the mounting flange of the pump and tighten the flange
fuel pump in position with the flange nuts tightened enough to nuts. Loosen the setscrew on the side of the pump and fit the
hold the pump; but not enough to prevent radial movement of the
pump body. Fit the setscrews which fasten the support bracket at
the rear of the pump and tighten them finger tight.
 FUEL SYSTEM 20
spacer underneath. Tighten the setscrew to 12 Nm (9 Ibf ft) 1,2 kgf
m. Tighten the nut of the pump pulley to 60 Nm (44 Ibf ft) 6,l kgf m.
Check the timing of the pump, operation 17A-03.
If the pump shaft is not fastened: Ensure that the correct marked
tooth is towards the arrow on the timing case and fit the location
pins through the plain holes in the pump pulley. Fit the timing belt,
see operation 15A-04 and remove the location pins. Adjust the
belt tension, operation 15A-03. Tighten the nut of the pump pulley
to 60 Nm (44 Ibf ft) 6,l kgf m. Adjust the timing of the pump,
operation 17A-03 and tighten the flange nuts of the pump.
5 Tighten the setscrews which fasten the support bracket at the
rear of the pump to the mounting bracket.
6 Ensure that the timing pins are removed. Remove the
anti-rotation tool and fit the starter motor, operation 23A-01.
7 Fit the timing case cover, operation 15A-01.
8 Fit the low-pressure pipes. Some pumps are fitted with a banjo
connection bolt which is marked "OUT" and this must be fitted at
the fuel return to tank connection.
9 Fit the high-pressure pipes to the pump. Ensure that a spanner
is used to prevent movement of the fuel pump outlets when the
high-pressure pipes are fitted. The relevant cylinders to which the
pump outlets are to be connected are given in figure A. Do not
tighten the connections at the atomisers until the air has been
eliminated from the system.
10 Connect the speed control of the fuel pump and, if necessary,
connect the stop control. Connect the cables from the stop
solenoid on the pump. If necessary, connect the cold start
advance unit and the cold idle solenoid. Connect the battery.
11 Eliminate air from the fuel system, operation 20A-10.
12 Operate the engine and check for leakage. Check that the idle
speed is correct, operation 20A-07.
13 If a new fuel pump has been fitted, check the maximum no load
speed, operation 20A-07.

To adjust 20A-07

I If a cold idle solenoid (B) is fitted and the coolant temperature is

below 30°C (86°F): Start the engine and check the cold idle speed
which should be 1050 rev/min. If necessary, turn the hexagonal
end of the plunger (Bl) to adjust the speed. The idle speed should
decrease automatically when the engine is warm.
2 For all engines: Operate the engine until it reaches its normal
temperature of operation and check the idle speed. If necessary,
adjustment can be made by the inner adjustment screw (Cl).
Release the locknut and turn the screw clockwise to increase or
counter-clockwise to decrease the speed. When the speed is
correct, tighten the locknut. The idle speed setting can change for
different applications. The correct speed will normally be given in
the application manufacturer's handbook. If it is not given, apply
to your nearest Perkins distributor or to Technical Services
I Department, Perkins Power Sales and Service, Peterborough,
England.
3 With the engine at its normal temperature of operation, check
the maximum no load speed. The maximum no load speed is

-$
N
g
",
indicated by the last section of the fuel pump setting code. The
setting code can be found on the data plate on the side of the fuel
pump. A typical setting code is 2643HOOOCW1/3200. In this
2m example, the maximum no load speed is 3200 rev/min. If
necessary, this speed can be adjusted by the outer adjustment
vi
a,
.- screw (C2). Release the locknut and turn the screw counter-
clockwise to increase or clockwise to decrease the speed. When

- o
0
m
.-
V)
c
.-
the speed is correct, tighten the locknut and seal the screw. The
person who fits the pump must ensure that the adjustment screw
is suitably sealed against interferenceafter it has been set initially.
The adjustment screw on original fuel pumps is set and sealed by
the manufacturer. The setting must not be changed as this could
affect the engine warranty.
20 FUEL SYSTEM

To check the cold idle device 20A-08

This device is only fitted to certain vehicle engines.

Turn the electrical control switch to the "on" position.
If the engine coolant is cold - below 30°C (86°F):
The solenoid (Al) should be energised and the solenoid plunger
should push against the control lever of the fuel injection pump. If
the plunger does not move, connect a 12V supply directly to the
solenoid terminal; if the plunger still does not move, renew the
solenoid unit. If the plunger now moves, check the supply current
at the temperature switch (A2) and the cable between the
temperature switch and the solenoid. If these are correct, renew
the temperature switch.
Attention: If the engine has run and is not yet completely cold, the
temperature switch may not reset until the coolant temperature is
at 20°C (58°F).
If the coolant is warm - above 30°C (86°F):
There should be no electrical supply at the solenoid (Al) and the
end of the plunger should be away from the control lever of the
fuel injection pump. If the solenoid is energised, renew the
temperature switch (A2).

To check the cold start advance unit 20A-09

This unit can only be completely checked for correct operation on

a test rig (for fuel injection pumps) or by the use of a dynamic
timing tester (with the engine in operation). The unit can be
renewed by a pump specialist.
If the engine is difficult to start or if there is a lot of white exhaust
smoke when the engine starts: This could indicate that the unit has
not changed the timing position for a cold start.
If the engine is noisy when warm or if the engine power is low: This
could indicate that the unit has not allowed the timing to return to
the normal position after a cold start. Turbocharged marine engines:
TOcheck the electrical supply to the unit, connect a 12V test lamp I These units are not used on later engines.
in the circuit at the advance unit connection (A3 or 81). Turn on the If the engine coolant is cold - below 30°C (86°F):
electrical supply at the control switch. Check the unit as follows: There should be an electrical supply at the advance unit ( ~ ~ ~f1 ,
there is not, check the supply at the temperature switch (B2) and
Vehicle engines: check the cable from the switch to the advance unit. If these are
If the engine coolant is cold - below 30°C (86°F) for turbocharged correct, renew the temperature switch.
engines or below 40°C (104°F) for naturally aspirated engines: Attention: If the engine has run and is not yet completely cold, the
There should be no electrical supply at the unit (A3). If there is a temperature switch may not reset until the coolant temperature is
supply, renew the temperature switch which is fitted at the rear of at 20°C (68°F).
the cylinder head (A4). If the engine coolant is warm - above 30°C (86°F):
Attention: If the engine has run and is not yet completely cold, the There should be no electrical supply at the unit (Bl). If there is a
temperature switch may not reset until the coolant temperature is supply, renew the temperature switch (B2).
10°C (18°F) below the temperatures given above.
If the engine coolant is warm - above 30°C (86°F) for turbocharged Naturally aspirated marine engines:
engines or above 40°C (104°F) for naturally aspirated engines: If an advance unit is fitted, it is controlled by the heat of the fuel
There should be an electrical supply at the advance unit (A3). If injection pump and is not checked electrically.
there is not, check the supply at the temperature switch and the
cable from the switch to the advance unit. If these are correct,
renew the temperature switch (A4).
 FUEL SYSTEM 20
Fuel system

To eliminate air from the fuel system 20A- 10

If air enters the fuel system, it must be eliminated before the

engine can be started.

Air can enter the system if:

The fuel tank is drained during normal operation.
The low-pressure fuel pipes are disconnected.
A part of the low-pressure fuel system leaks during engine
operation.
To eliminate air from the fuel system, proceed as follows:
1 Loosen, by two or three turns, the vent screw (Al) on the top of
the fuel filter.
2 Operate the priming lever (B) on the fuel lift pump until fuel, free
from air, comes from the filter vent point. Tighten the vent screw of
the filter. If the drive cam of the fuel lift pump is at the point of
maximum cam lift, it will not be possible to operate the priming
lever. In this situation, the crankshaft must be turned one
revolution.
3 Loosen the union nuts of the high-pressure pipes at the
atomisers (Cl). According to the type of atomiser fitted, the union
nuts will be connected at the top or at the side of the atomiser.
4 Operate the starter motor until fuel, free from air, comes from
the pipe connections. If a separate starter switch is used, ensure
that the switch for the engine electrical system is in the "on"
position for this operation.
5 Tighten the high-pressure pipe connections.
6 The engine is now ready to start.
If the engine runs correctly for a short time and then stops or runs
roughly, check for air in the fuel system. If there is air in the fuel
system, there is probably a leakage in the low pressure system.
Cooling system

General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
Coolant circuit (marine engines only)
To drain ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
To fill ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
Raw water circuit (marine engines only)
To drain ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
Thermostat
To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
To test ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
Water pump
To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
Raw water pump (marine engines only)
To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ...
Mounting bracket and plate for the raw water pump
... ... ... ... ... ... ... ... ... ... ...
To remove and to fit ... ... ... ... ...
Fan
To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
Fan drive (high position fans only)
To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
Lubricating oil cooler (marine engines only)
To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
Heat exchanger/manifold/header tank assembly
To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
To remove and to fit the tube stack of the heat exchanger ... ... ... ... ... ... ... ...
21 COOLING SYSTEM

General description
Non-marine engines:
Coolant from the bottom of the radiator passes through the
centrifugal water pump which is fitted on the front of the cylinder
block. The pump is belt driven from the crankshaft pulley and
assists the flow of the coolant through the system. From the
pump, the coolant passes directly into the front of the cylinder
block.

The coolant then circulates around the cylinder block and cools
the cylinders. From the cylinder block, the coolant passes to the
cylinder head. Restriction holes in the cylinder head gasket ensure
that the block and head are cooled evenly. The coolant passes out
of the front right side of the head and into the thermostat housing.
If the coolant is cold, it will pass through the by-pass in the
thermostat housing and go directly into the inlet pipe of the water
pump. As the temperature of the coolant increases, the thermostat
valve will open, the by-pass will close and the coolant will pass to
the radiator to be cooled.

Marine engines:
These engines have two cooling circuits. The closed circuit is filled
with coolant which is used to cool the cylinder block and the
cylinder head as for the non-marine engines above. This coolant is
used also to cool the exhaust manifold. The raw water circuit uses
raw water from outside the boat to cool the coolant of the closed
circuit and to cool also the lubricating oil of M60 and M80T
engines.

The heat exchanger, the exhaust manifold and the header tank for
the closed circuit coolant are all together in one assembly. This is
fitted to the right side of the engine.

The coolant in the closed circuit passes from the header tank to
the inlet of the water pump. From the pump the coolant passes
through the cylinder block and the cylinder head to the thermostat
housing. If the coolant is cold, it passes through the by-pass,
directly to the inlet of the water pump. As the temperature of the
coolant increases, the thermostat valve will open, the by-pass will
close and the coolant will pass to the heat exchanger. In the heat
exchanger, the coolant passes around the tubes and is cooled by
the raw water in the tubes. The coolant leaves the exchanger
tubestack and enters the tank assembly where it cools the
exhaust manifold which is an integral part of the assembly. The
coolant then passes to the inlet of the water pump. For M60 and
M80T engines, some coolant passes through an outlet at the rear
of the assembly to an oil cooler and then to the pump inlet.

The raw water is circulated by the raw water pump which is fitted
at the rear of the cylinder head and is driven from the rear end of
the camshaft. From the pump, the raw water passes through the
tubes of the heat exchanger and is then discharged into the
exhaust.
 COOLING SYSTEM 21
C d a n t circuit (marine engines only)
- --

To drain 21A-01

Attention: Do not drain the coolant while the engine is still hot and
the system is under pressure because dangerous hot coolant can
be discharged.
1 Remove the filler cap from the coolant header tank.
2 Remove the drain plug (Al) from the right side of the cylinder
block to drain the engine. Ensure that the drain hole is not
restricted.
3 Remove the drain plug (A2) at the bottom of the heat
exchanger/manifold/headertank assembly to drain the assembly.
Ensure that the drain hole is not restricted.
4 Remove the drain plug (A3) from the inlet of the engine oil
c.ooler (if one is fitted). Ensure that the drain hole is not restricted.
5 Fit the drain plugs and the filler cap.
6 Fasten a suitable label to the engine control panel to indicate
that the coolant has been drained.

To fill 21A-02

See "Coolant specific:!ion" in section 5 of the handbook for

details of the correct coold0~t
to be used in the circuit.
1 Remove the vent plug from the water outlet connection (Bl)or
from the top of the heat exchanger/manifold assembly (82).
2 Remove the filler cap (83) of the header tank and fill the tank
until the coolant level reaches the filler tube.
3 Fit the vent plug and the filler cap.
4 Start the engine and, when it has reached its normal
temperature of operation, stop it and let it cool.
5 Remove the filler cap of the header tank and add coolant until
the level of the coolant reaches the filler tube. Fit the filler cap.
Attention: If coolant is added to the circuit during service, it must
consist of the same original mixture as used to fill the system.

Raw water circuit (marine engines only)

To drain 21A-03

1 Ensure that the seacock is closed.

2 Disconnect both hoses at the raw water pump.
3 Remove the drain plug (A4) from the outlet pipe of the heat
exchanger. Ensure that the drain hole is not restricted.
4 Turn the engine to ensure that the raw water pump is empty.
5 Connect the pipes and fit the drain plug.
21 COOLING SYSTEM

Thermostat

To remove and to fit 21A-04

To remove
1 Drain the cooling system so that the coolant level is below the
thermostat position and disconnect the top hose from the coolant
outlet connection.
2 Release the setscrews and remove the coolant outlet
connection (Al).
3 Remove the thermostat (A2).

To fit
1 Ensure that the joint faces of the housing and the outlet are
clean and that the jiggle pin (A3) in the thermostat is free to move.
2 Put the new thermostat in position in the housing.
3 Fit a new joint and the coolant outlet connection and tighten
the setscrews.
4 Connect the top hose and fill the cooling system with the
correct coolant, see the relevant handbook.

To test

1 Hang the thermostat in a suitable container filled with water.

2 Heat the water gradually. Use a thermometer to check the
temperature at which the valve starts to open and at which it is
fully open. The correct temperatures are given in section 11C.
3 If the thermostat does not operate correctly, it must be
renewed. Do not try to adjust the settings.
 Cool-ING SYSTEM 21
Water pump

To remove and to fit 21A-05

I Attention: the engine mounting is an integral part of the water
I pump for some vehicle engines. A support will have to be provided
I for the engine or the engine will have to be removed before the
I water pump is removed.

To remove
1 Disconnect the battery.
2 Drain the cooling system.
Marine engines: Drain the coolant circuit, operation 21A-01.
3 Disconnect the inlet pipe at the water pump and, if necessary,
disconnect the by-pass connection.
4 Set number 1 piston to TDC compression stroke, operation
17A-01 and fit the timing pins.
5 Remove the timing case cover, operation 15A-01 and the
I timing belt, operation 15A-04. For later vehicle engines it is
I only necessary to hold the toothed pulley for the fuel injection
I pump with the special pins (see operation 15A-04) and remove the
I tensioner pulley and the idler pulley. Disconnect the hose
I connections, remove the pump setscrews and remove the pump (A).
6 For certain vehicle engines, remove the two setscrews which
I fasten the plate for the timing case (61) and remove the plate.
Remove the setscrew which fastens the side of the timing case to
I the pump (82). Remove the pump setscrews and remove the
pump.
For other engines, remove the timing case, operation 15A.08.
Remove the pump setscrews and remove the pump (C).

To fit
1 Check the pump for wear and other damage. If there is a fault,
the pump must be renewed as an assembly.
2 Ensure that the contact faces of the water pump and of the
cylinder block are clean.
3 Apply a 1,0/1,5 mm (0.04/0.06 in) continuous bead of
I POWERPART Sealant (Loctite 518) to the contact face of the
pump, on the impeller side of the fastener holes (Dl). If the old
setscrews are to be used, clean the thread of the setscrew which
will befitted in the 10 o'clock position (Cl) and apply sealant to the
thread. Immediately after the sealant has been applied to the
pump, put the pump in position and fit the setscrews. If necessary,
I also fit the plate for the timing case (Bl). Tighten the setscrews
gradually and evenly to the correct torque, see section 1lB. If
necessary, fit the setscrew which fastens the timing case to the
pump (A2).
I Attention: The threaded holes in the cylinder block for the water
I pump setscrews have been changed from M8 to M10, except for
I hole C1. The latest pump, with the larger holes, will be supplied as
I a spare part for both earlier and later engines. A sleeve is supplied
I with the pump to reduce the diameter of one of the holes for
I location purposes when the pump is used on earlier engines. This
I sleeve should be fitted in the hole opposite to the hole which will
! align with the threaded hole C1.
4 If necessary, fit the timing case and the toothed pulleys, see
section 15. Fit the timing belt, operation 15A-04, and adjust the
belt tension, operation 15A-03. Check the timing of the fuel
injection pump, operation 17A-03.
1 5 Ensure that the timing pins are removed and frt the setscrew
I in the timing hole in the top of the camshaft cover. Fit the timing
I case cover, operation 15A-01.
6 Connect the hose to the pump inlet connection and, if
necessary, connect the by-pass connection. Fill the cooling
system with the correct coolant; see the relevant handbook.
Marine engines: Fill the coolant circuit, operation 21A-02.
7 Connect the battery. Operate the engine and check for
leakage.
21 COOLING SYSTEM

Raw water pump (marine engines only)

To remove and to fit 21A-06

Attention: If the mounting bracket and the mounting plate for the
raw water pump are released, they must be aligned correctly (with
the use of an alignment tool) before the pump is fitted, see
operation 21A-08.
1 Drain the raw water circuit, operation 21A-03.
2 Disconnect the hose connections at the pump.
3 Release the four setscrews which fasten the pump to its drive
housing and remove the pump (A).
4 Clean the contact surfaces of the pump body and the adaptor
plate.
5 Clean and inspect for wear the drive components of the pump.
If necessary, renew the worn components or the pump. If the drive
adaptor is removed from the end of the camshaft, tighten the
adaptor cap screws to 9 Nm (7 Ibf ft) 0,9 kgf m when the adaptor is
fitted.
6 Apply a high melting point grease (for example Shell Alvania
R2) to the drive components and to fill the inside of the drive
housing.
7 Align the slot in the pump shaft (Al) with the projection on the
drive shaft (A2). Fit the pump to the engine with a new joint
between the pump and the adaptor plate. Fit the setscrews and
tighten them to 9 Nm (7 Ibf ft) 0,9 kgf m.
8 Connect the hose connections at the pump.
9 If necessary, open the seacock.

To dismantle and to assemble 21A-07

To dismantle
1 Remove the pump, operation 21A-06.
4 Support the pump on the cover end and press the shaft and
2 Remove the end cover (813) and its joint (814). bearing assembly into the bearing housing. When the assembly
3 Remove the rubber plug (812) from the end of the impeller has been correctly pressed in, the outside bearing will have a
(B11). protrusion of 2,13/2,73 mm (0.08410.107 in) from the mounting
4 Remove carefully the impeller from the shaft (B6) with suitable face.
levers or with long nose pliers. 5 Slide the "0" ring (88) along the shaft until it is in the centre of
5 Press out the shaft and bearing assembly through the drive end the space between the bearing housing and the impeller housing
of the housing with the use of a suitable adaptor. If the bearings 6 Fit the seal spacer (B9) into the seal housing. Lightly lubricate
(85) and their spacers (87) do not come out with the shaft, they the lip of the other seal (83) and press it into position in the
can be pressed out later when the impeller seal (83) has been impeller housing with the lip towards the impeller position.
removad. Do not lose the "0" ring (B8) when the shaft is removed. 7 Put the wear plate (B10) in position in the impeller housing with
6 Release the cam plate screw (Bl) by two or three turns and the dowel in its location. If the plate is worn on one face, fit it with
lightly hit the top of the screw to separate the cam plate (82) from the face which is not worn towards the impeller.
the body. Remove the screw and the cam plate. 8 Apply a suitable jointing compound to the top face and to the
7 Remove the wear ring (BlO), the seal (B3) and the seal spacer front (wear plate) face of the cam plate (B2). Also apply jointing
(B9) from the impeller housing. compound to the thread of the screw (Bl) for the cam plate. Fit the
8 Remove the seal (84) from the bearing housing. cam plate and tighten the screw.
9 Check the components for wear and other damage and renew 9 Apply Marfak 2HD grease to the blades of the impeller (B11)
them, if necessary. Renew the seals and the joint. and fit it on the shaft with the blades bent clockwise (as seen from
the cover end). If the blades are slightly worn, the impeller can be
To assemble fitted with its original front end to the rear. Fit the rubber plug (812)
1 Ensure that all the components are clean. in the end of the impeller.
2 Press one of the bearings (B5) on to the shaft (B6), fit the 10 Apply jointing compound to a new joint (814). Fit the joint, the
spacers (87) and then press on the other bearing. Use an adaptor end cover (B13) and the screws. Tighten the screws gradually and
that will contact the inner flange of the bearing to press on the evenly.
bearings. The bearings are lubricated for life.
3 Press one of the seals (84) into position in the bearing housing
with the lip towards the drive end. Lightly lubricate the lip of the
seal.
 COOLING SYSTEM 21
Mounting bracket and plate for the raw water
Pump
To remove and to fit 21A-08

Special tool:
Alignment adaptor for raw water pump mounting, PD.207

1 Remove the raw water pump, operation 21A-06 and remove

the adaptor plate.
2 Disconnect the fuel pipes at the fuel filter and, if necessary,
remove the filter.
3 Release the four setscrews and remove the mounting plate and
the bracket.
4 Check the bracket and the plate for cracks and other damage.
5 Release the cap screws and remove the drive adaptor from the
end of the camshaft.
6 Put the mounting bracket and plate in position, engage the
setscrews and tighten them finger tight only.
7 Engage the small diameter of the alignment tool (Al) into the
end of the camshaft and the larger diameter into the bore of the
mounting plate. Tighten the setscrews gradually and evenly and
remove the alignment tool.
8 Fit the drive adaptor in the end of the camshaft and tighten the
cap screws to 9 Nm (7 Ibf ft) 0,9 kgf m.
9 Fit the raw water pump, operation 21A-06.
 21 COOLING SYSTEM

--
Fan

To remove and to fit 21A-09

To remove
1 Release the tension of the drive belt, see operation 23A-02.
2 Release the setscrews and remove the fan. If necessary, fit the
setscrews to retain the fan extension and the pulley to the hub.

To fit
1 If necessary, release the setscrews from the hub of the fan
drive. Fit the fan and the setscrews and tighten the setscrews to 9
Nm (7 Ibf ft) 0,9 kgf m.
2 Fit the drive belt for the alternator and adjust the belt tension,
operation 23A-02.

Fan drive (high position fans only)

To remove and to fit 21A-10

Special tool:
Belt tension aauae, J.23600-B

1 Loosen the centre setscrew of the tensioner pulley (A4) and

release the tension on the drive belt for the fan.
2 Remove the fan and its drive belt.
3 Remove the bottom setscrew (A9) and its spacer which fasten
I the fan drive bracket (A10) to the front of the cylinder head. On
I later engines, a cap screw and washer are fitted instead of a
I setscrew.
4 If the assembly is to be removed for access to the front cover:
Remove the three setscrews (A11) which fasten the front bracket
to the top bracket (Al) and remove the fan drive assembly.
If the complete assembly is to be removed: Remove the two
setscrews (A2) which fasten the top bracket to the cylinder head 12 Fit the fan drive belt and the fan. Move the tensioner pulley with
setscrews and remove the drive assembly. a wooden wedge or a wooden lever to get the correct tension and
5 Ensure that all components are clean. Check the components tighten the pulley setscrew to 43 Nm (32 Ibf ft) 4,4 kgf m. Ensure
for wear and for damage and renew them, if necessary. The fan that the tension is still correct. The correct tension is 80 Ibf if the
drive pulley and its bearing and shaft assembly must not be tension gauge is used. If the tension gauge is not available, press
removed from the mounting plate; the complete assembly must be down the belt with the thumb at the centre of the longest free
renewed, if necesssary. length and check the deflection. With moderate thumb pressure,
6 If the extension nuts (A3) have been removed, fit them to the 45 N (10 Ibf) 4,5 kgf, the correct deflection of the belt is 6 mm (1/4 i/

cylinder head setscrews with the counterbores downwards; in).

tighten them to 43 Nm (32 Ibf ft) 4,4 kgf m.
7 If necessary, fit the mounting bracket to the extension nuts and
I tighten the two setscrews to 43 Nm (32 Ibf ft) 4,4 kgf m. On some
I engines, washers are fitted with the two setscrews for the top
I mounting bracket. On these engines the washers must be fitted
I between the extension nuts and the mounting bracket.
8 If necessary, fit the mounting plate to the bracket, fit a setscrew
in the centre hole of the three top holes and tighten it finger tight
1 9 Ensure that the hole in the mounting plate for fastener A9 aligns
I with the threaded hole in the cylinder head. Fit the spacer between
I the mounting plate and the cylinder head and fit the setscrew or
I the cap screw and washer. Tighten the setscrew to 22 Nm (16 Ibf
I ft) 2,2 kgf m or tighten the cap screw to 39 Nm (29 Ibf ft) 4,O kgf m.
10 Fit the other two setscrews in their holes at the top of the plate
and tighten all three setscrews to 43 Nm (32 Ibf ft) 4,4 kgf m.
11 If necessary, fit the tensioner pulley to the mounting plate. Fit
the shoulder nut (A7) inside the slot in the mounting plate and fit
the spacer (A6) over the front of the nut. Assemble the collar (A8)
and the pulley/bearing assembly (A5).Ensure that the flange of the
collar is on the opposite side to the flange in the pulley which
retains the bearing. Fit the assembly to the mounting plate with the
collar flange to the front, engage the setscrew and tighten it finger
tight.
 COOLING SYSTEM 21
Lubricating oil cooler (marine engines only)

To remove and to fit 21A-11

The tubes in the cooler will not normally need to be cleaned as the
coolant which goes through them is from the closed coolant
circuit.
1 Drain the coolant circuit, operation 21A-01.
2 Disconnect the coolant pipes at the cooler
3 Disconnect the lubricating oil pipes at the cooler.
4 Make a suitable mark on the body and on the strap (Al) to
indicate the correct position for the strap.
5 If the cooler only is to be removed: Release the three setscrews
which fasten the strap to the cooler and remove the strap and the
cooler (A) from the bracket.
If the cooler and bracket assembly are to be removed: Remove the
setscrew and the spacer which fasten the bracket for the sump
drain pump. Release the two setscrews which fasten the cooler
bracket to the cylinder block and remove the cooler together with
its bracket and strap.
6 Check the components for damage and renew them, if
necessary.
7 If the cooler and bracket assembly have been removed: Put it
in position and engage the two front setscrews. Engage the rear
setscrew through the bracket of the drain pump and the spacer
and into the cylinder block. Ensure that the cooler body is in the
correct position. Tighten the front setscrews to 22 Nm (16 Ibf ft)
2,2 kgf m and the rear setscrew to 43 Nm (32 Ibf ft) 4,3 kgf m.
If the cooler only has been removed: Put it into its correct position,
fit the strap and tighten the three setscrews for the strap to 22 Nm
(16 Ibf ft) 2,2 kgf m.
8 Connect the coolant hoses and the oil pipes.
9 Fill the coolant system, operation 21A-02.
10 Operate the engine and check for leakage of coolant and
lubricating oil.
 21 COOLING SYSTEM

-
Heat exchanger/manifold/header tank
assembly

To remove and to fit 21A-12

I Attention: For later assemblies, a long stud is fitted at each end of

I the bottom line of fasteners. These studs are used for location
I purposes instead of the dowels (Al) which were fitted to earlier
I engines. A side clearance of at least 135mm (5.3 in) is necessary
I to slide the assembly off these studs. If this clearance is not
I available, it may be possible to slide the assembly along the studs
I and a suitable tool used to get a grip on the studs and to remove
I them. A support must be provided for the assembly while the
I studs are removed. The reverse procedure can be used to fit the
I assembly.
1 Drain the coolant circuit, operation 21A-01 and the raw water
circuit, operation 21A-03.
2 Turbocharged engines: Remove the turbocharger, operation
18A-02 and the oil supply pipe for the turbocharger.
3 Release the support clips which fasten the outlet pipe of the
I heat exchanger to the bottom of the induction manifold. Remove
the induction manifold.
4 Disconnect the inlet and the outlet pipes for the raw water of
the heat exchanger.
5 Release the flange setscrews of the coolant pipe(s) which is/are
fitted to the bottom of the assembly and release the pipe(s) from
the assembly.
6 Remove the support bracket which is fitted between the rear of
the assembly and the adaptor housing for the reverse gearbox.
7 Release evenly and gradually the setscrews which fasten the
assembly to the cylinder head, in the reverse sequence to that
shown in B. Remove the assembly (A).
8 Remove the joints and clean the contact faces of the assembly,
the cylinder head and the flange(s) of the coolant pipe(s). Check
the components for damage and renew them, if necessary. If the
tube stack is to be removed, see operation 21A-13
1 9 Put a new manifold joint in position over the dowels in the
I cylinder head (Al) of earlier engines or over the two location studs
I of later engines. If a new assembly (with no location holes for the
I dowels A l ) is to be fitted to an earlier engine, remove the dowels
I from the cylinder head. It is not necessary to use a jointing
I compound. Ensure that the joint is fitted correctly, as shown in
1 18A.O3/B.
10 Put the assembly in position on the cylinder head and engage
I the setscrews or nuts. Tighten the setscrews or nuts evenly and
gradually to 22 Nm (16 Ibf ft) 2,2 kgf m, in the sequence shown in 6.
11 Fit the support bracket between the rear of the assembly and
the flywheel housing.
12 Fit the coolant pipe(s) to the bottom of the assembly, together
with new joint(s).
13 Connect the inlet and the outlet pipes for the raw water of the
heat exchanger. The end of the outlet pipe should reach the centre
of the end cap.
14 Fit the induction manifold, together with new joints and tighten
the setscrews to 22 Nm (16 Ibf ft) 2,2 kgf rn.
15 Turbocharged engines: Fit the turbocharger, operation 18A-02
and the oil supply pipe for the turbocharger.
16 Fit the support clips which fasten the outlet pipe of the heat
exchanger and the oil supply pipe for the turbocharger to the
I induction manifold.
17 Fill the coolant circuit, operation 21A-02 and open the seacock.
18 Operate the engine and check for leaks.
 COOLING SYSTEM 21
1
To remove and to fit the
tube stack of the heat exchanger 21A-13

The tube stack can be removed (with the heat exchanger in

position) if there is 555 mm (22 in) clearance directly to the front or
the rear of the face of the header tank.
1 Drain the coolant circuit, operation 21A-01 and the raw water
circuit, operation 21A-03.
2 Release the support clips which fasten the outlet pipe of the
heat exchanger to the bottom of the inlet manifold. Disconnectthe
outlet pipe.
3 Loosen the clips of the neoprene end caps and remove the
caps.
4 Press the tube stack out through either end of the heat
exchanger. Ensure that the sleeve (Al) is removed from the body.
5 Ensure that the bores of the tubes are clean. If there are hard
deposits or debris in the tubes, the best method to clean them is
to use a non-caustic solution which is approved by the
manufacturer. If the deposits or the debris are soft, the tubes can
be cleaned with a steel rod of 3 mm (1/8 in) diameter. Push the rod
through the tubes in the opposite direction to the water flow.
Ensure that the rod does not damage the tubes.
6 Check the components for damage and renew them, if
necessary.
7 Slide the sleeve (Al) onto one end of the tube stack until the
end of the tube stack is in contact with the reduced diameter in the
sleeve.
8 Push an end cap (A2) over the other end of the tube stack until
the protrusion on the inside of the cap is in contact with the end of
the tube stack.
9 If a rubber sleeve is used, lubricate it with a little soft soap. Put
the sleeve end of the assembly into the housing and carefully enter
the sleeve into the hole in the baffle plate. Carefully push the tube
stack through the housing and through the opening in the other
end of the housing until the spigot of the housing is correctly fitted
inside the end cap. Do not pull the tube stack backward during the
assembly operation as this will remove the sleeve from the baffle
plate. Check through the filler cap aperture to ensure that the
sleeve is correctly fitted in the baffle plate (B).
10 Fit the other end cap, ensure that the pipe connections of the
end caps are in their correct positions and tighten the clips. If the
assembly has been removed from the engine, put the caps in the
positions shown in C.
11 Fit the inlet and outlet pipes and tighten the hose clips. The end
of the outlet pipe should reach to the centre of the cap. Tighten the
support clips of the outlet pipe.
12 Fill the coolant circuit, operation 21A-02 and open the seacock.
13 Operate the engine and check for leaks.
 Flywheel, flywheel housing and marine reverse gearbox 22

General description ............................................. 22A.02

\d Flywheel
22A-01 To remove and to fit ................................................ 22A.03
Ring gear
22A-02 To remove and to fit ................................................ 22A.03
Flywheel housing or backplate
22A-03 To remove and to fit ................................................ 22A.04
Reverse gearbox for marine engines
22A-04 To remove and to fit ................................................ 22A.05
22 FLYWHEEL, FLYWHEEL HOUSING AND MARINE GEARBOX

General description

The engine may be fitted with an aluminium or mild steel backplate

or a cast iron flywheel housing. Marine engines have an aluminium
adaptor housing fitted between the backplate and the reverse
gearbox.

The steel flywheel has a hardened starter ring which is expansion

fitted. The starter ring fitted to industrial and marine engines has
104 teeth and the ring fitted to vehicle engines has 100 or 115
teeth.

The reverse gearbox which is fitted in the factory for marine

engines is a Hurth HEW10 or HBW250.
 FLYWHEEL, FLYWHEEL HOUSING AND MARINE GEARBOX 22
Flywheel

To remove and to fit 22A-01

To remove
1 Remove the drive components from the rear of the engine.
Marine engines: Remove the gearbox adaptor housing and
remove the flexible drive plate from the flywheel.
2 Remove two opposite setscrews from the flywheel and fit
temporarily two guide studs to ensure safety when the flywheel is
removed and fitted.
3 Remove the remainder of the setscrews and remove the
flywheel.
4 Check the flywheel and the ring gear for damage and renew, if
necessary.

To fit
1 Ensure that the location faces of the crankshaft and of the
flywheel are clean and free from damage.
2 Ensure that the dowel is fitted in the flange of the crankshaft. Fit
the flywheel over the guide studs. Fit four setscrews, remove the
guide studs and fit the other two setscrews. Tighten the setscrews
gradually and evenly to 65 Nm (48 Ibf ft) 6,6 kgf m.
3 Check the flywheel run-out with a dial test indicator (A). This
must be less than 0,30 mm (0.012 in) total indicator reading.
4 Check the alignment of the flywheel face (8). The alignment
error must be not more than 0,03 mm (0.001 in) total indicator
reading for every 25 mrn (1.0 in) of the flywheel radius (from the
crankshaft axis to the indicator plunger). During this check, keep
the crankshaft pressed towards the front to remove the effect of
crankshaft end-float.
5 Marine engines: Fit the flexible plate for the gearbox drive (C).
Apply POWERPART Studlock to the threads of the plate
setscrews. Ensure that the small location diameter of each
setscrew enters the flywheel (Cl). Tighten the setscrews gradually
and evenly to 9 Nm (7 Ibf ft) 0,9 kgf m. Do not start the engine until
the locking agent has had time to harden.
6 Fit the drive components to the rear of the engine.

Ring gear

To remove and to fit 22A-02

To remove

A For this operation eye protection must be used.

Before the ring gear is removed, check the position of the chamfer
on the teeth.
The ring gear can be removed with a hammer and a chisel to break
the ring. Ensure that the flywheel is not damaged during this
operation.

To fit
The ring gear is heated onto the flywheel. When a new gear is to
be fitted, ensure that it is not heated to more than 250°C (480°F).
Ensure that the chamfer on the teeth of the gear is in the correct
v, direction.
.-al
6
V)
0
0
LD
 22 FLYWHEEL, FLYWHEEL HOUSING AND MARINE GEARBOX

Flywheel housing or backplate

To remove and to fit 22A-03

To remove
1 Remove the drive components from the rear of the engine.
2 Remove the starter motor, operation 23B-01.
Marine engines: Remove the adaptor housing for the gearbox.
Before the adaptor housing is removed, the turbocharger drain
pipe (if fitted) must be disconnected and the support plate for the
manifold must be removed.
3 Remove the flywheel, operation 22A-01.
4 Release the setscrews of the flywheel housing or the
backplate. Use a soft face hammer to remove it from the dowels.

To fit

Special tools:
Protection sleeve PD.191
Replacer for crankshaft rear seal PD.550-1

1 Ensure that the rear face of the cylinder block and the faces of
the flywheel housing or backplate are clean and free from damage.
2 Where the rear seal for the crankshaft is fitted in the flywheel
housing or in the backplate, inspect the seal lip for wear and for
damage; renew the seal if necessary, see operation 14A-03. If
there is only a small scratch across the lip, the seal must be
renewed. Tool PD.550-1 can be used to Dress in the seal. The
support ring of the tool is for use with aluminium backplates.
3 Ensure that the location dowels (61) are fitted correctly. Ensure
that the outside diameter of the crankshaft flange is clean. Put the
seal protection sleeve (B2) in position on the crankshaft flange. -
Lubricate lightly, with clean engine lubricating oil, the outside
diameter of the crankshaft flange and the protection sleeve.
4 Apply a 1,5 mm (0.06 in) continuous bead of POWERPART
I Sealant (Loctite 518) to the front face of the housing or backplate
as shown in figure A. This operation is not necessary where a
I separate seal housing or a joint is fitted. Also apply sealant where
I the main bearing cap meets the cylinder block (see 14A.lOA).
5 Fit the housing or the backplate onto the dowels and engage
the setscrews.
If a backplate is used: Tighten the setscrews gradually and evenly
to the relevant torques (given in section 11B) and in the relevant
sequence, shown in figure 22A.O5/A.
If a housing is used: Tighten the setscrews lightly.
6 Check the concentricity of the housing with a dial test indicator.
The maximum permissible total indicator reading is 0,15 mrn
(0.006 in). If any adjustment is necessary, it must be made on the
housing and the concentricitychecked again.
7 Tighten the setscrews gradually and evenly to the relevant
torques given in section 11B, in the relevant sequence shown in
figure 22A.O5/A.
8 Check the alignment of the rear face of the housing. The
maximum permissibletotal indicator reading is 0,15 mm (0.006 in).
All adjustments must be made on the housing and not on the
cylinder block.
9 Marine engines: Fit the flywheel and the gearbox drive adaptor,
operation 22A-01. Ensure that the dowels are correctly fitted in the
backplate. Fit the adaptor housing for the gearbox, tighten the
setscrews to 43 Nm (32 Ibf ft) 4,4 kgf m). Check the housing
concentricity (C) and the alignment (D) as in paragraphs 6 and 8
above. Fit the support plate for the manifold and, if necessary,
connect the drain pipe to the turbocharger.
10 Fit the flywheel, operation 22A-01 and the starter motor,
operation 23B-01. Fit the drive components to the rear of the
engine.
 FLYWHEEL, FLYWHEEL HOUSING AND MARINE GEARBOX 22
Reverse gearbox for marine engines

To remove and to fit 22A-04

1 Disconnect the propeller shaft and the selection control.

2 If a cooler is fitted to the gearbox, disconnect the cooler pipes.
3 Provide a support for the gearbox, release the nuts and remove
the gearbox (B).
4 Ensure that the mounting faces of the gearbox and the adaptor
housing are clean and are not damaged.
5 Align the gearbox shaft with the drive plate, fit the gearbox to
the adaptor housing and tighten the nuts.
6 Connect the propeller shaft. If necessary, connect the coolant
pipes to the gearbox cooler. Ensure that there is a gap of at least
30 mm (1 1/8 in) between the ends of the pipes and the ends of the
cooler connections.
Electrical equipment 23

Alternators .......................................... 23A

Starter motors ........................................ 236
Starting aid .......................................... 23C
Wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23D
Alternators

General description ............................................. 23A.02

Precautions ................................................... 23A.02

Drive belt
23A-01 To check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A.03
23A-02 To adjust tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A.03
23A-03 To remove and to fit ............................................. 23A.03
Alternator
23A-04 To remove and to fit ................................................ 23A.04
To maintain ...................................................... 23A.04
Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23A.04
 -
General description
The Lucas A127 alternator is driven from the crankshaft pulley by a
single drive belt. The rating of the alternator is 55A or 70A
according to the application.

A solid state regulator is fitted in the rear of the alternator and

includes the brush box as a part of the unit. The regulator is sealed
and repair is not possible.

Precautions
To prevent damage to the diodes and to the resistors, the
precautions given below must be followed.
Do not disconnect the battery while the engine is in operation.
This will cause a voltage surge in the alternator charge system
which can cause damage to the diodes or to the transistors.
Do not disconnect an electrical wire before the engine is
stopped and all electrical switches are in the off position.
Do not cause a short circuit by the connection of electrical wires
to the wrong terminals. The correct identification of the
electrical wire to the correct terminal must be made. A short
circuit or wrong connection which gives reverse polarity can
cause permanent damage to the diodes and to the transistors.
Do not connect a battery into the system until it has been
checked for correct polarity and voltage.
Do not check for current flow with a spark contact as damage
can be caused to the transistors.
 ALTERNATORS 23A
Drive belt

To check 23A-01
Special tool:
Tension gauge, 4.23600-8

1 Check the belt for wear and damage and renew the belt, if
necessary.
2 Check the belt tension. To ensure maximum belt life, it is
recommended that a belt tensioner gauge is used. Fit the gauge
(A) at the centre of the free belt length between the crankshaft
pulley and the alternator pulley and check the tension. If a
Burroughs gauge is used, the correct tension is 355 N (80 Ibf) 36
kgf. If the tension is equal to or less than 267 N (60 Ibf) 27 kgf,
adjust it to 355 N (80 Ibf) 36 kgf, operation 23A-02.
If no gauge is available, press down the belt with the thumb at the
centre of the longest free length and check the deflection (B). With
moderate thumb pressure, 45 N (10 Ibf) 4,s kgf, the correct belt
deflection is 10 mm (3/8 in).

To adiust tension 23A-02

1 Loosen the pivot fasteners of the alternator (A1 or B1) and the
adjustment link fasteners (A2 or B2).
2 Change the position of the alternator to give the correct
tension. Tighten the adjustment link fasteners and then the pivot
fasteners of the alternator.
3 Check the belt tension again to ensure that it is still correct.

To remove and to fit 23A-03

1 Loosen the pivot fasteners of the alternator and the adjustment

link fasteners.
2 Release all of the tension from the belt and remove the belt.
3 Fit the belt and adjust the tension as indicated in operation
23A-02. If the belt is new, set the initial tension to 440 N (100 Ibf)
45 kgf or to a 6 mm (1/4 in) deflection. The tension of a new belt
must be checked again after the first 1000 km (500 miles) or 20
hours of operation. At this time, the tension should be at least 355
N (80 Ibf) 36 kgf or the deflection should be 10 mm (3/8 in)
maximum.
Alternator

To remove and to fit 23A-04

To remove
1 Disconnect the electrical connections at the alternator.
2 Loosen the pivot fasteners of the alternator and the adjustment
link fasteners.
3 Release all the belt tension and remove the belt.
4 Remove the adjustment link from the alternator and remove the
pivot bolt. Make a note of the position of the washer to ensure that
it is fitted correctly. Remove the alternator (A).

To fit
1 Put the alternator in position and assemble loosely the pivot
fasteners and the adjustment link and its fasteners. Ensure that
the washer is fitted in its correct position and that the alternator
pulley is aligned to the crankshaft pulley.
5 Start the engine and operate it at a fast idle speed when either:
2 Fit the drive belt and adjust the drive belt tension, operation the warning light should be extinguished or
23A-02. Tighten the adjustment link fasteners and then the pivot
the ammeter indicates a small current charge in relationship to the
fasteners and check the tension again.
engine speed.
3 Connect the electrical connectionsat the alternator.
6 Increase the engine speed for a moment to near maximum
speed; the charge current should be approximately 55 amperes
To maintain for A127-55 alternators or 70 amperes for A127-70MT alternators.
7 Operate the engine at approximately half speed and remove
1 Ensure that the drive belt is not worn and that the belt tension is the electrical load. The voltage should go up to 14 volts for a 12
correct. volt system and then remain constant. At the same time the
2 Keep the alternator clean. To clean the alternator,use a material current reading should show a reduction.
which is damp with kerosene or a special fluid used for this Any change in the above data can indicate a fault and the
purpose. Ensure that the fluid does not enter the alternator. alternator should be removed for test by a specialist.
3 Ensure that air can pass easily over the casing to keep it cool. The regulator is a sealed unit and a repair is not possible. If there is
a regulator fault, the regulator must be renewed.

Fault diagnosis
The alternator is designed so that aflow of current (indicated by no
light at the warning light or by a reading shown on an ammeter)
shows that the system is in correct operation. If the system is in
correct operation, no open circuit, voltage or current output
checks need to be done on the installation unless:
The warning l~ghtdoes not show when the alternator is
stationary and the switch is in the "on" position or it shows a
light when the alternator is in operation.
No charge current is shown on the ammeter.
The battery is discharged.
The battery is hotter than normal which is an indication of loss
of voltage control.
If one or more of the above symptoms occur, the procedure
indicated below should be applied.

1 Ensure that the battery is in afully charged condition.

2 Connect a moving-coil voltmeter of good quality, with a range
of 0-50 volts, across the alternator positive and negative terminals.
If an ammeter is not fitted in the electrical circuit: Fit a moving-coil
ammeter of good quality, with a range of 0-100 ampere, in the wire
between the alternator and the positiveterminal of the battery.
3 Turn the warning light switch to the "on" position (main switch
on instrument panel) when the warning light should be illuminated.
4 Switch on a 10-15 ampere load, for example, lights, fans, etc..
Starter motors

General description ............................................. 238.02

Starter motor
238-01 To remove and to fit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238.02
238-02 To maintain the brush gear and the commutator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238.02
238-03 To test on the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238.02
 General description
I The starter motor is a pre-engaged type. The internal drive of the
I M80R starter motor is through an epicyclic gearbox.

A roller clutch prevents armature rotation at high speed if the

starter is held in the engaged position.

These starters have needle roller bearings to allow higher loads to

be applied.

Starter motor

To remove and to fit

To remove
1 Disconnect the battery.
2 Disconnect the starter motor cables. I For M80R starter motors, the brush assembly and the armature
1 3 Release the fasteners and remove the starter motor (A). assembly can be fitted into the body together but they will be

To fit
pulled into position by the effect of the magnets. Ensure that the
thrust washer remains in position on the front of the armature
.
shaft.
1 Fit the starter motor and tighten the fasteners.
2 Connect the starter motor cables. I When the brush plate assembly is to be fitted on 2M113 starter
3 Connect the battery. I motors, ensure that the slots in the brake segments align with the
I pin in the drive shaft.

To maintain the brush gear If a repair is necessary to the switch gear, etc. the starter must be
sent to a specialist for repair.
and the commutator 238-02

The starter motor must be removed from the engine. TOtest On the engine 238-03
The brush assembly can be removed from the armature assembly
I after the rear plate or the rear cover has been removed.
Ensure that the battery is in a fully charged condition.
Inspect the brushes to ensure that they are free in their guides and
that the wireconnections are free to move. T~ check this, remove Turn on lights and operate the starter switch. If no lights are fitted
the springretainer and the springfrom each brush and pull to the machine, connect a voltmeter across the battery terminals
carefully on the flexible connection. If the brush does not move and Operate the starter switch.
freely, remove it from its holder and clean the sides with a material
which is damp with gasolene. If the starter does not operate but the lights keep their power (or
there is no voltage drop across the battery) check the switch and
Ensure that the brushes are fitted intheir original positionsto keep all the connections and wires. Slow action of the starter can be
the original wear seat. The brushes must have good seats which by faulty
conform to the shape of the commutator. If the length of the
I brushes has been reduced to the service limit (see Section 1lC),
the brushes must be renewed.

The new brushes must be the exact same grade as the original
brushes. To ensure that correct brushes are fitted, use only parts
from the approved manufacturer.

I To remove the earth brushes from M80R starter motors, release

the clips and withdraw the brushes. To remove the field brushes,
remove the insulation plate and remove the bus bar and brush
assembly.

I In 2M113 starter motors, the wires for the brushes are soldered to
I their connections. Before the brushes are inserted in their
hold&, it is advised that the holders are cleaned with
comdressed air or with a material which is damp with gasolene.

The commutator must be completely clean of dirt and oil. Any sign
of dirt or oil must be removed with a piece of clean dry material
(with no loose fibres). If the commutator is dirty (or has a colour
other than its natural colour) it may be possible to clean it with a
fine carborundum paper or similar material. If this is not possible,
send the starter to a specialist for repair.
Starting aid 23C

General description ............................................. 23C.02

Glow plugs
23C-01 To remove and to fit ................................................ 23C.02
To check power supply and continuity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23C.02
To check operation of glow plugs ....................................... 23C.02
General description
The starting aid for these engines consists of a set of glow plugs,
one for each cylinder.

The glow plugs are fitted in the cylinder head near to the
atomisers. The tip of the plug reaches into the combustion cavity
of the piston when the piston is at TDC.

The plugs are operated electrically, usually through the start

switch. When the plugs are energised, their tips become very hot
and improve the combustion process during cold start conditions.

Glow plugs

To remove and to fit 23C-01

1 Disconnectthe electrical connections at the glow plugs.

2 Release and remove the glow plugs (A).
3 Ensure that the threads and the contact faces of the plugs and
the cylinder head are clean. Apply an anti-seize compound, which
is suitable for high temperatures, to the threads and the tapered
seats of the plugs. Fit the plugs and tighten them to 20 Nm (15 Ibf
ft) 2,O kgf m.
4 Connect the electrical connection to the plugs.

To check power supply and continuity

1 Connect a 12 V test lamp between the positive terminal of the

battery and earth to check that the lamp will show a light.
2 Connect the test lamp between the terminal of the glow plug
which is furthest away from the power supply and earth. Operate
the control switch and the test lamp should show a light if the
power supply is correct.
3 Disconnect the cables at the glow plug terminals.
4 Connect the test lamp to the positive terminal of the battery
and to the terminal of each glow plug. The lamp will show a light if
the continuity is correct. If there is no light when a glow plug is
checked, renew the plug.
5 When all the glow plugs have been checked, connect the
cables to the plug terminals.

To check operation of glow plugs

1 Disconnect the power supply cable and the connection cables

from the terminals of the glow plugs.
2 Connect a 50-0-50 ammeter between the power supply cable
and the terminal of a glow plug. Connect a 0-20 voltmeter
between the plug terminal and earth.
3 Engage the control switch and check the readings of the
ammeter and the voltmeter.
With a 12 volt supply, there should be an initial current of
approximately 27 amperes which should be reduced to
approximately 14 amperes after approximately 10 seconds. The
voltmeter reading after this time should be approximately 11 to 12
volts. 8
'C
If the ammeter reading is low or there is no reading, renew the al
(I)

-
glow plug. If there is no voltmeter reading, check the switch and o
0
the power cable.
4 When all the glow plugs have been checked, remove the
B
.E
ammeter and the voltmeter and connect the supply cable. 15
In
c
g
a
Wiring diagrams 23D

Wiring diagrams for marine engines ... ... ... ... ... ... ... ... ... ... ... 23D.02
 -i

Wiring diagrams for marine engines

These wiring diagrams apply only to wiring looms and instrument panels which have been supplied by Perkins.

Notes for wiring diagrams of instrument panel (23D.03fA) and engine (23D.03m)
I *Not used on later engines

Starter motor 12 V Battery (customer supply)

A Alternator Connect earth cable to starter motor fastener

& indicates engine earth

Glow plug relay (33RA)
- ~
Security key switch

Negative earth relay (33RA) Heat switch (push button)

I A Threeltwo 1 amp diodes '11,f2'*L

'3' A Start switch (illuminated push button - 24V11.2W bulb)

Start relay (33RA) Stop switch (illuminated push button - 24Vll.2W bulb)

I A Coolant temperature switch for start advance solenoid Warning lamp for coolant temperature - 12Vll.2W bulb)
I

I A
(open on increase in temperature)'

Start advance solenoid (KSB)'

I A Fourltwo amp diodes r41,15','6f*and'7'.

a Engine stop solenoid (energise to stop)

A Oil pressure switch

Y
Purple

Coolant temperature switch

Coolant temperature sender

A Warning lamp for oil pressure - 12Vll.2W bulb

Warning lamp for alternator - 12Vl2W bulb

Six way connector - t o be sealed with tape to prevent entry
of water A Tachometer - illuminated - 12Vi2W bulb
Eight way connector - to be sealed with tape to prevent
entry of water A Temperature gauge - illuminated - 12Vl2W bulb

A Two fast fuses A Audible alarm

: 12Vl1.2W bulb)
..
G a & i n g device option (includes warning lamp
..A I
1 A Diode panel

/37\
hh Connector - optional illumination switch (customer supply) ,
Connectors 'D1,'W','X','Y' and 'Z'
..
1 ,&! For earlier Prima M80T only' .
-
A
Spare cables

Fit insulation to all spare cables and fasten to wiring loom

1
' WARNING On all other engine models cables must be
fitted with insullion and fastened to wiling loom with tape 1
with tape

Resistanceof battery cables 1 and 2 not to be more than 0.0017 ohms

Maximum Cable Nominal cross Nominal resistance Approx. equivalent sizes
total length size section area in ohms English American
m ft Metric rnm2 in2 perm perft Imperial B &SSAE
2,2 7.3 37/0,9 23,54 0.0365 0.000762 0.0002323 371.036 3
3,7 12.0 6110,9 38,80 0.0601 0.000462 0.0001408 611.036 1
5,6 19.0 61/1,3 61,175 0.0948 0.000293 0.0000890 611.044 00
9,O 28.3 1912,52 95,OO 0.1470 0.000189 0.0000600 5131.018 000
It is recommended that an isolation switch is fitted in the positive battery cable
WIRING DIAGRAMS 23D
Auxiliary equipment

General description ............................................. 24A.02

Exhauster
24A-01 To remove and to fit ................................................ 24A.02
To test ......................................................... 24A.02
 General description
The plunger type exhauster is fmed to the camshaft cover and the
cylinder head and is driven by an eccentric on the engine
camshaft. The exhauster cannot be dismantled and, if it has a
fault, it must be renewed.

Exhauster
To remove and to fit 24C-01

To remove
1 Remove the setscrew from the timing hole in the top front of
the camshaft cover. Turn the crankshaft until the timing hole in the
front journal of the camshaft aligns with the hole in the camshaft
cover. This will make it easier to remove and to fit the exhauster.
2 Disconnect the pipes from the exhauster.
3 Release evenly and gradually the nuts and the setscrews and
remove the exhauster (A).

To tit
1 Ensure that the joint faces of the exhauster, the camshaft wver
and the cylinder head are clean and are not damaged. Renew the
I sealing ring (Al).
2 Ensure that the timing hole in the front journal of the camshaft
aligns with the timing hole in the top front of the camshaft cover.
Fit the exhauster to the camshaft cover and the cylinder head and
engage the setscrews and the nuts and bolts. Gradually and
evenly tighten the fasteners.
3 Connect the pipes to the exhauster.
4 Fit the setscrew to the timing hole in the top front of the
camshaft cover.

To test

1 If a brake assistance reservoir of two litres capacity is used:

Connect a vacuum gauge between the exhauster and the vacuum
pipe. Run the engine at 950 rev/min and check that the time taken
to reach a vacuum of 70 kPa (525 mm Hg) 21 in Hg is not greater
than 12.5 seconds.
If the capacity of the reservoir is not known: Disconnect the
vacuum pipe at the pump and fit a vacuum gauge to the pump
connection. Run the erlgine at 950 rev/min and check that a
vacuum of at least 75 kPa (562 mm Hg) 22 in Hg is obtained.
2 Renew the exhauster, if necessary.
3 If the readings are correct, remove the vacuum gauge and
connect the vacuum pipe to the exhauster.
List of special tools 25

List of special tools ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 25A.02
List of special tools
These tools are available from V.L. Churchill Limited, P.O. Box 3, London Road, Daventry, Northamptonshire, England, NN11 4NF.

Number Description Illustration

5.23600-B Tension gauge for drive belt for alternator.

KM.4088P Tension gauge for timing belt.

MS.76B Handle set for valve seat cutters.

MS.107 Adaptor to check plunger lift of fuel injectionpump; use with PD.208.

MS.150-7 Adjustable pilot for valve seat cutters.

rn

MS.550 Universal drive handle.

@ -I
1-
.-
l i
rn
3
 LIST OF SPECIAL TOOLS 25
Number Description Illustration

MS.1519A Valve spring compressor.

Angle gauge to tighten cylinder head setscrews.

Camshaft clamps (set of three).

PD.181 Camshaft retainer.

PD.182 Timing pins for camshaft and crankshaft.

PD.184 Slide hammer for atomiser removal (main tool).

PD.184-1 Adaptor for Bosch atomisers; use with PD.184.

 Number Description Illustration

PD.185 Remover for front oil seal of camshaft.

PD.186 Replacer for front oil seal of camshaft.

PD.187 Remover for rear oil seal of camshaft.

PD.188 Replacer for rear oil seal of camshaft.

PD.189 Remover/replacer for valve gu~des.

PD.190 Location plns for fuel pump pulley.

PD.192 Remover for front oil seal of crankshaft.

 LIST OF SPECIAL TOOLS 25
L

Protection sleeve for front oil seal of crankshaft.

Replacer for front oil seal of crankshaft.

L
Remover for toothed pulleys of fuel injection pump
and crankshaft (main tool).

Adaptors for use with PD.195.

Reamer for new valve guides.

Gauge for piston height and valve depth.

&
In
.-
0)
PD.197-1 Plate for piston height check; use with PD.197.

r-:
/
V)
0
o PD.201 Spanner for oil pipe connection at turbocharger.

u 2
.-
a'
m
.-
Y,
0)
a
25A.05
 Removerlreplacerwrench for stop solenoid of fuel

Anti-rotation tool.

Remover for rear oil seal of crankshaft.

Replacer for rear oil seal of crankshaft.

Alignment adaptor for mounting of raw water pump.

Dial gauge for use with PD.197 and MS.107.

Replacer for rear oil seal of crankshaft with housing off

engine; use with MS.550.

25A.06
PRINTED IN ENGLAND BY COVENTRY PRINTERS (48184)