A-PDF Merger DEMO : Purchase from www.A-PDF.

com to remove the watermark

workshop
manualfor
T6.3544,6.3544
and 6.3724
dieselengines

PerkinsEnginesLimited
Peterborough England

1982

PublicationNo. 601SERO1821146

This publicationsupersedesthe previousedition numbered601SEFl0281 1 146

and lncorporatesamendmentPage Sets 1, 2, 3, 4 and 5 issued between 1982 and 1986

This publicationis writtenfor world wide use. In territorieswhere legalrequirementsgovernsmoke emission,noise,safety

factors, etc., then all instructions,data and dimensionsgiven must be applied in such a way that, after servicing
(preventivemaintenance)or repairingan engine,it does not contravenethe local regulationsin use.

Publishedby PerkinsEnginesLimitedand Printedin Englandby c H. Fisher& Sons (Printers)Ltd.,Peterborough

Page2

Perkinscompanies

Australia Singapore
PerkinsEnginesAustraliaPty.Limited, PerkinsEnginesAsiaPacific,
P . O .B o x1 5 6 , 549 UpperThompsonRoad,
22-24 ElliottRoad, Singapore2057.
Dandenong, Telephone:4521841.
Victoria, Telex:RS 37729.,
Australia
Telephone: 794 6555. UnitedKingdom
Telex:AA30B1 6. PerkinsEnginesLimited,
C a b l e : ' P e r k oM
i l 'e l b o u r n e . Eastfield,
Peterborough PEI 5NA,
France England.
MoteursPerkinsS.A., Telephone: (O733) 67474.
9-11AvenueMichelet, Telex:32501PerkenG.
93407SaintOuen, Cable:'Perkoil'Peterborough.
Cedex,
France. PerkinsEngines(Shrewsbury)
Limited,
Telephone:2232000. SentinelWorks,
Telex:642924F. Shrewsbury SY14DP,
Cable:PerkoilParis England
Telephone: (0743) 52262.
Germany Telex:3517112 PESLG.
PerkinsMotorenG.m.b.H.,
8752Kleinostheim, u.s.A.
Postfach1180, PerkinsEnginesInc.,
West Germany. P.O.Box697,
Telephone:060275010. 32500Van Born Road,
Telex:41888694PER D. Wayne,
Michigan48184,
Italy U.S.A.
MotoriPerkinsS p.A., Telephone: (313) 5959600,
Via Gorizia15, T elex: 2340O2PerkenWane.
P . O .B o x 1 2 , Cable:PerkenWane.
22070 Porlichetto/Luisago (Como),
Italy. PerkinsEnginesLatinAmericaInc ,
Telephone: (031) 927364. P.O.Box697,
Telex:380658PerkitI 32500Van Born Road,
Cable:PerkoilPortichetto. Wayne,
M i c h i g a4n8 1 8 4 ,
Japan U.S.A.
MasseyFergusonPerkinsEnginesK.K., Telephone: (313) 5959600,
Reinanzaka Building, f e|exl.234002 PerkenWane.
6th Floor, Cable:PerkenWane.
14-2 Akasaka,1-chome,
Minato-ku,
Tokyo107,
Japan
Telephone: (03)5BO7377.
Telex:PerkoilJ2424823.
Cable:PerkoilTokyo.
Fax:(03)582-1596.

In additionto the above,there are Perkrnsdistributors

ln mostcountries.PerkinsEnginesLtd, Peterborough
or one of the above
companiescan givedetails.

6 3544SeriesWorkshopManual,January1986
 Page3

CONTENTS
Section

E N G I N EP H O T O G R A P H S A

T E C H N I C A LD A T A B

O P E R A T I N GA N D M A I N T E N A N C E C

F A U L TF I N D I N G D

C Y L I N D E RH E A D E

P I S T O N SA N D C O N N E C T I N GR O D S F

C Y L I N D E RB L O C K A N D L I N E R S G

C R A N K S H A F TA N D M A I N B E A R I N G S H

T I M I N GC A S EA N D D R I V E J

TIMING K

L U B R I C A T I N GS Y S T E M L

C O O L I N GS Y S T E M M

A I R C L E A N E R SA N D F U E L S Y S T E M N

F L Y W H E E LA N D F L Y W H E E LH O U S I N G P

TURBOCHARGER o
ALTERNATORAND STARTERMOTOR R

COMPRESSOR S

EXHAUSTER T

LUBRICATING
OILS Appendix

A P P R O V E DS E R V I C ET O O L S

S E R V I C EF A C I L I T I E S

INDEX

'82
6.3544SoriesWorkshopManual,lssu€ 2, Jun€
 T h i s p u b l i c a t i o ni s p u b l i s h e db y t h e T e c h n i c a lP u b l i c a t i o n s
Departmentof PerkinsEnginesLimitedand every endeavour
i s m a d e t o e n s u r e t h a t .t h e i n f o r m a t i o nc o n t a i n e d i n t h i s
Manual is correct at the date of publication but, due to
continuous developments,the manufacturersreserve the
right to make alterationswithout notice.

U S EO N L Y
G E NU I NE
PERKINSPARTS
T O E N S U R EY O U O B T A I N T H E B E S T R E S U L T SF R O M
YOUR ENGINE AND TO SAFEGUARD YOUR OWN
GUARANTEE, FIT ONLY GENUINE PERKINS PARTS.
THESE ARE READILY OBTAINABLE THROUGHOUT
THE WORLD.

6 3544 SeriesWorkshooManual.lssue2. June'82

 Page5

FOREWORD

T h i s W o r k s h o pM a n u a lh a s b e e nc o m p i l e df o r u s e i n c o n j u n c t i o nw i t h n o r m a lw o r k s h o pp r a c t i c e .
Mention of certain accepted practices,therefore,has been purposely omitted in order to avoid
repetition.
Referenceto renewingjoints and cleaningoff joint faces,has to a great extent been omitted from
t h e t e x t ,i t b e i n g u n d e r s t o o dt h a t t h i s w i l l b e c a r r i e do u t w h e r ea p p l i c a b l e .
S i m i l a r l yi,t i s u n d e r s t o o dt h a t i n r e - a s s e m b lay n d i n s p e c t i o na, l l p a r t sa r e t o b e t h o r o u g h l yc l e a n e d ,
and where present,burrs and scale are to be removed.
I t f o l l o w st h a t a n y o p e n p o r t so f h i g h p r e c i s i o nc o m p o n e n t se, . g . f u e l i n j e c t i o ne q u i p m e n te, x p o s e d
b y d i s m a n t l i n gw , i l l b e b l a n k e do f f u n t i l r e - a s s e m b l e dt o, p r e v e n tt h e i n g r e s so f f o r e i g n m a t t e r .
W h e nf i t t i n gs e t s c r e w so r s t u d s i n t o h o l e sw h i c h a r e t a p p e dt h r o u g hi n t o t h e i n t e r i o ro f t h e e n g i n e ,
a s u i t a b l es e a l a n ts h o u l db e u s e d .
New type M.E.A.S.(microencapsulatedanaerobicsealant)fastenersare beingintroducedso that jointing
compoundsor other sealantsneed not be used when the fastenersare fitted in throughholes into oil or
warerways.
The identification
of these fasteners,as supplied,is by a red, blue, or other colour sealantaround the
fastenerthreads.
With M.E.A.S.sealedstuds,the sealedend mustbe fittedintothe cylinderhead/cylinder
blocketc.
Ensurethat the threadedholes have a 1,59mm(1Aain)45" chamfer,so that when the new fastenersare
fittedthe M.E.A.S.sealantis not removed.
lf the fastenershave to be removedand fittedagain,the threadsmust be cleanedand a suitablesealant
used.
Throughoutthis manual,whenever"|eft"or "right"handsideof the engineis referredto, it is that sideof the
enginewhenviewedfromthe flywheelend.

EngineNumberlocation
Withearlierengines,the enginenumberwas stampedon the auxiliary drivehousingimmediately belowthe
fuelinjection pump- see Figs.41 and A3 (item'10).lt consistsof figuresand letters,e.9.,3544U251T. The
firstthreefiguresrepresentthe cubiccapacity,i.e.,354in3:the fourthfiguredenotesthe enginemodeland
the letter"U" signifiesthatthe enginewas builtin the UnitedKingdom.The lastgroupof figurescomprises
the engineserial number. Otherletterswhichmayfollowthe serialnumberdenotespecificinformation, i.e.,
a letter "T" indicatesa turbocharged engine:a letter"L" indicates a lip type seal on the rear end of the
crankshaft.
For currentengines,the enginenumberconsistsof fifteenlettersand figures,a typicalnumberbeing
TW30016U510256D.
In allcases,the enginenumberwhenquoted,shouldbe in full.

Runningin Procedure
I t i s n o t n e c e s s a r tyo g r a d u a l l yr u n - i na n e w o r f a c t o r yr e b u i l te n g i n ea n d a n y p r o l o n g e dl i g h t l o a d
r u n n i n gd u r i n g t h e e a r l y l i f e o f t h e e n g i n ec a n i n f a c t p r o v e h a r m f u lt o t h e b e d d i n gi n o f p i s t o n
r i n g sa n d l i n e r s .
F u l l l o a dc a n b e a p p l i e do n a n e w o r f a c t o r yr e b u i l te n g i n ea s s o o n a s t h e e n g i n ei s u s e d ,p r o v i d e d
that the engine is first allowed to reach a temperatureof at least 140oF (60"C).

6 3544SeriesWorkshopManual,January1986
 SAFETYPRECAUTIONS
T H E S E S A F E T Y P R E C A U T I O N SA R E I M P O R T A N T .R e f e r a l s o t o t h e l o c a t a n d
g o v e r n m e nrte g u l a t i o nasp p l i c a b l e
i n y o u rj u r i s d i c t i o n .
D o n o t u s e t h e s ee n g i n e si n m a r i n ea p p l i c a t i o n s .
D o n o t m o d i f yt h e e n g i n e .
D o n o t s m o k ew h e n r e f u e l l i n g .
Alwaysremovespiltfuel and soakedclothingto a safe place.
D o n o t r e f u e lw h i l s tt h e e n g i n ei s r u n n i n g( u n l e s sa b s o l u t e l ny e c e s s a r y ) .
N e v e rc l e a n ,l u b r i c a t eo r a d j u s tt h e e n g i n ew h i l s ti t i s r u n n i n g( u n l e s sq u a l i f i e dt o d o s o , i n
whichcase,extremecare shouldbe takento avoidinjury).
Do not attemptany adjustmentsyou do not understand.
E n s u r et h e e n g i n ei s p o s i t i o n e sdo a s t o p r e v e n a
t b u i l d - u po f t o x i ce m i s s i o n s .
W a r n p e r s o n s i n t h e a r e a t o k e e p w e l l c l e a r d u r i n g e n g i n e a n d e q u i p m e n to r v e h i c l e
operation.
D o n o t w e a r l o o s ec l o t h i n go r a l l o wl o n gh a i rn e a rm o v i n gm a c h i n e r y .
Keep well clear of rotatingparts or machineryin operation.Note that fans are not clearly
v i s i b l ew h i l s t h e e n g i n ei s r u n n i n g .
Do not run the enginewith any safetyguardsremoved.
Do not removethe radiatorcap whilst the engine is hot and coolantis unoer pressureas
s c a l d i n gc a n r e s u l t .
On no accountshouldsea wateror any otherelectrolytic
or corrosivemediumbe used in the
coolingsystem.
Keep sparks or flames away from batteriesas the gases from the electrolyte(especially
whilstthe batteryis undercharge)are highlyinflammable.
This acid is also dangeiou'sto tn6
s k i n a n d e s p e c i a l l tyh e e y e s .
Always disconnectthe batteryterminalsbefore repairingor interferingwith the electrical
system.
O n l yo n e p e r s o ns h o u l db e i n c o n t r o ol f t h e e n g t n e .
Alwaysoperatethe enginefrom the controlpanelor operator'sseat.
lf your skin comes into contactwith high pressurefuel,seek medicalattentionimmediately.
Dieselfuel can cause skin infectionto some people.Use protectiveglovesor hand cream.
Do not move mobile equipmentwithoutfirst ensuringthat the brakes are in good working
oroer.
Ensure that the transmissiondrive control is in 'Out of Drive' positionbefore startingthe
engine.
F i t o n l yg e n u i n eP e r k i n sP a r t s .

SAFETYIS SENSE.USEIT.
 SECTIONA
EnginePhotographs
P e r k i n sE n g i n e s a r eb u i l t t o i n d i v i d u a rl e q u i r e m e n ttso s u i t t h e a p p l i c a t i o n fso r w h i c h t h e y a r e
i n t e n d e da n d t h e f o l l o w i n ge n g i n ev i e w sd o n o t n e c e s s a r i l tyy p i f y a n y p a r t i c u l a sr p e c i f i c a t i o n .

Index to Engine Photographs

'1.
A l t e r n a t o rP u l l e y
2. ThermostaH t o u s i n ga n d W a t e rO u t l e t
3 . L u b r i c a t i n gO i t F i l l e r
4 . F u e lO i l F i l t e r
5. C y l i n d e rH e a d C o v e r
6. Atomrser
7. B r e a t h e rP i p e
8. F u e l I n j e c t i o nP u m p ( C . A . V . )
9. Dipstick
10. E n g i n eN u m b e rL o c a t i o n
11. LubricatinO g itFilter
12. Sump
13. Fan
14. StarterMotor
15. C r a n k s h a fPt u l l e ya n d V i b r a t i o nD a m p e r
16. FanBelts
17. W a t e rP u m p
18. I n d u c t i o nM a n i f o l d
1 9 . E x h a u s tM a n i f o l d
20. ThermostartUnit
2 1 . F u e lL i f t P u m p
22. FlywheeH l ousing
2 3 . F u e l P i p e f r o m L i f t P u m p t o F i n a lF u e l F i l t e r s
24. Rear Lifting Bracket
2 5 . C y l i n d e rB l o c k D r a i n P o i n t
26. Turbocharger
2 7 . S u m p D r a i nP l u g
28. Oil Feed Pipe to Turbocharger
29. Alternator
30. Oil Drain Pipefrom Turbocharger
31. F u e l I n j e c t i o nP u m p( B o s c h )
32. LubricatingOil Cooler
33. FrontLiftingBracket
34. IntegralAir ChargeCoolerand InductionManifold
E N G I N EP H O T O G R A P H S

%.
9
7

10

A.1 V i e w o f F u e l P u m p S i d e o f 6 . 3 5 4 4E n o i n e

18
*tr
19

29

21

4.2
View of CamshaftSide of 6.3544Engrne

6 3544SeriesWorkshopManual,Aprilg3
 E N G I N EP H O T O G R A P H S A 3

24
4

A.3 V i e w o f F u e l P u m p s i d e o f T 6 . 3 5 4 4E n g i n e

A.4 View of CamshaftSide of T6.3544Engine

ENGINE
PHOTOGRAPHS

33

10

16

A.5 V i e wo f F u e lP u m pS i d eo f T 6 . 3 5 4 4 C C( A i rC h a r g eC o o l e d )E n g i n e

34

19
29

23 26

11
25

A.6 View of CamshaftSide of T6.3544CC(Air ChargeCooled)Engine

 SECTIONB
TechnicalData
B o r e ( T 6 3 5 4 4a n d 6 . 3 5 4 4e n g i n e s ) 3 8 7 5i n ( 9 8 , 4m m ) -
B o r e ( 6 3 7 2 4e n g i n e s ) 3 9 7 5i n ( 1 0 1m m ) -
Stroke 5 i n ( 1 2 7m m )
No of cylinders 6
C u b i c c a p a c i t y( T 6 . 3 5 4 4
a n d 6 . 3 5 4 4e n g i n e s ) 3 5 4i n 3( 5 , 8l i t r e s )
C u b i c c a p a c i t y( 6 . 3 7 2 4e n g i n e s ) 3 7 2i n 3( 6 , 1l i t r e s )
Compressionratio:
T6.3544engines 15.51 :
North America vehicle T6.3544 'l
16:
6 . 3 5 4 4e n g i n e s . . . 16:1
6 . 3 7 2 4e n g i n e s . . . 16:1
F i r i n go r d e r 1,5,3,6,2,4
Combustron system D i r e c ti n j e c t i o n
Cycle 4 stroke
Valve c l e a r a n c e( h o t o r c o l d )
I nl e t 0 . 0 0 8i n ( 0 , 2 0m m )
Exhaust 0 . 0 1 8i n ( 0 , 4 6m m )
L u b r i c a t i n go i l p r e s s u r e m i n i m u ma t
3 0 l b f / i n ' ( 2 , 1k g t / c m ' ?o) r 2 0 7 k N / m ' ?
m a x i m u mw o r k i n g s p e e d a n d n o r m a l o p e r a t i n g
temperature
Turbochargerboost pressures
(measured a t i n d u c t i o nm a n i f o l d ) 1 1 - 1 35 l b f / i n , ( 0 , 8 0 - 0 , 9 5 k 9 f / c m o, )r 7 6 - 9 3 k N / m ' ?
T 6 3 5 4 4e n g i n e so n l y T h e s ep r e s s u r ew s i l l v a r y a c c o r d i n gt o a p p l i c a t i o n ,
e n g i n el o a d s a n ds p e e d sT h e y a r e f o rg u i d a n c e
p u r p o s e so n l y
'Nominal-for
a c t u a lb o r e s r z es e e P a g eB 3 ,
Details of ratings
T6.3544CCVehicle 1 1 9 k W ( 1 5 9 b h p ) a t 2 , 6 0 0r e v l m i n
M a x i m u mt o r q u e 5 0 2 N m ( 3 7 0 l b f f t ) a t 1 , 6 0 0r e v l m i n
T6,3544Vehicle 1 1 5 k W ( 1 5 5 b h p ) a t 2 , 6 0 0r e v l m i n
M a x i m u mt o r q u e 498 Nm (367 lbf ft) at 1,700 revlmin
T6.3544North America vehicle 1 0 4 k W ( 1 a 0 b h p ) a t 2 , 6 0 0r e v l m i n
M a x i m u mt o r q u e 470,5 Nm (347 lbf ft) at 1,700 revlmin
T6.3544Agricultural and I n d u s t r i a l . . 1 0 7 k W ( 1 4 3 b h p ) a t 2 , 5 0 0r e v l m i n
M a x i m u mt o r q u e 469 Nm (346 lbf ft) at 1,600 revlmin
6 . 3 5 4 4P r e m i u mV e h i c l e 9 5 , 5 k W ( 1 2 8 b h p ) a t 2 , 8 0 0r e v l m i n
M a x i m u mt o r q u e 380 Nm (280 lbf ft) at 1,500 rev/min
6 . 3 5 4 4A g r i c u l t u r a al n d I n d u s t r i a l 9 1 k W ( 1 2 2 b h p ) a t 2 , 6 0 0r e v l m i n
M a x i m u mt o r q u e . 384 Nm (283 lbf ft) at 1,400 revlmin
6.3724 Agriculturalengines 9 0 k W ( 1 2 1 b h p ) a t 2 , 5 0 0r e v l m i n
M a x i m u mt o r o u e 396 Nm (292 lbt ft) at 1,450 revlmin
The above ratingi are maximum and can vary according to application.
Engineweights
T y p i c a ld r y w e i g h t 9 4 0 - 9 6 0 1 b( a 2 5 - 4 3 5 k 9 )
T y p i c a li n s t a l l e dw e i g h t 1 1 0 0 - .117 0l b ( 5 0 0 - 5 3 0 k g )
Recommendedtorque tensions
The following figures will apply with the componentslightly lubricatedwith clean engine oil
Screwsize
Cylinder head nuts and setscrews (with formed UNF lbfft kgf m Nm
washer face) - cold * 115 15,9 1EA

Cylinder head nuts and setscrews (with formed

washer face) - hot 1
2 105 14,5 142
Cylinder head nuts and setscrews (with separate
washers) 1
95 13,1 129
C y l i n d e rh e a d s e t s c r e w s ... 5
t 6 28 3,9 38
C o n n e c t i n gR o d N u t s ( C a d m i u mP l a t e d ) . . . + 75 10,4 102
Connecting Rod Nuts (Phosphated) l-
2 95 13,1 129
Main bearing setscrews 5
a 200 27,7 270
ldlergear hub nuts 3
a 36 5,0 49
Fuel lift pump setscrews t 6 20 2,8 27
Sump securing setscrews 5
t 6 15 2,1 20
-
( c o n t i n u e) d
6 3 5 4 4 S e r i e s W o r k s h o p M a n u a l , S e p t e m b e r1 9 8 2
TECHNICAL
DATA 82

Recommendedtorque tensions(continued)
T h e f o l l o w i n gf i g u r e sw i l l a p p l yw i t h t h e c o m p o n e n ttsi g h I y o i l e d
Screwsize
C o mp o n e n t UNF tbf ft kgf m
i;; 64qfiqB'o/za qc
Nm
Flywheelsecuringsetscrews 1/z 't11
80
Flywheelhousingsecuringsetscrews(standard) 3/e 36 49
Flywheelhousingsecuringsetscrews(standard) 7Ae 45 61
Flywheelhousingsecuringsetscrews(Durlok.) "/a o e 91
Flywheelhousingsecuringsetscrews(Durlok.) 7ro(UNC) 1 0 4 1 A A
141
Camshaftgear setscrews 1/z 50 A O 68
Crankshaftpulleysetscrews(cadmiumplated) 7Aa 65 on BB
Crankshaftpulleysetscrews(phosphated) 7Ae 92 Iz , l tz3
Pistoncoolingjet banjobolt (wherefitted) "/a 20 2,8
Rockershaftbracketsetscrewsor nuts 7Aa 55 7,6
O i l c o o i e r t o c y l i n d e rb l o c k ,s e t s c r e w s
(where fitted) 7
6 50 68
L u b r i c a t i n go i l f i l t e r s e t s c r e w s 7
t 6 30 4 1 40
A t o m i s e rS e c u r i n gn u t s / s e t s c r e w s 5
t 6 tz tb
Auxiliary drive shaft gear setscrews 5
t 6 22 ? n 30
H i g h p r e s s u r ef u e l p i p e n u t s 1 2x 1 , 5 t c z, l 20
mm
A l t e r n a t o rp u l l e y n u t 9
l 6 30 4,1 40
Thermostaru t nit '1 '1 A
0 I J

T h e r m o s t a r itn s u l a t i n ga d a p t o r 10 1.4 I J
* Durlok
setscrewshavea formedwasherfacewith radialserrations.

T h e f o l l o w i n gt a b l e i s g i v e na s a g e n e r a lg u i d e ,t o b e a p p l i e do n a p e r c e n t a g eb a s i s ,w h e r e s p e c i f i cf i g u r e sf o r a p a r t i c u l a r
e n g i n er a t i n ga r e n o t a v a i l a b l e

Altitude M a x i m u mf u e l d e l i v e r yd e - r a t i n g
0/2000ft ( 600metre) No change
2000/4000ft (1200metre) 60/o
4000/6000ft (i 800metre) 12o/o
6000/8000ft (2400metre) 18%
8000/10000ft(3000metre) 240/o
10000/12000ft (3600metre) 300/o
*Measured
a t s e t t i n gs p e e dg i v e no n p u m p s e t t i n gc o d e
I t s h o u i db e n o t e dt h a t t h e a b o v ei n f o r m a t i o no n l y a p p l i e st o n a t u r a l l ya s p i r a t e de n g i n e s .F o r t u r b o c h a r g e d
e n g i n e sa p p l y
t o S e r v i c eD e p a r t m e n tP, e r k i n sE n g i n e sL t d , P e t e r b o r o u gohr o n e o f t h e C o m p a n i e sl i s t e do n P a g e2

6 3544SeriesWorkshoplvlanual,
JanuaryI 986
 TECHNICALDATA 83

MANUFACTURINGDATA AND DIMENSIONS

A l l t h r e a d su s e d ,e x c e p tp e r h a p so n p r o p r i e t a r ye q u i p m e n at r e U n i f i e dS e r i e sa n d A m e r i c a nP i p eS e r i e s
T h e f o l l o w i n gd a t a o f c l e a r a n c e sa n d t o l e r a n c e sa r e g i v e n a s a g u i d e f o r p e r s o n n e el n g a g e du p o n m a j o r o v e r h a u l sa n d
thefiguresare those used in the factory for productionpurposes.

CylinderBlock
H e i g h tb e t w e e nT o p a n d B o t t o mF a c e s 1 7 3 6 7 / 1 73 7 s i n ( 4 4 1, 1 2 / 4 4 i , 3 2
mm)
P a r e n tB o r e D i a m e t e fr o r C v l i n d e rL i n e r
J6.3544/6 3544) 4 0 6 2 5 / 40 6 3 5 i n( 1 0 3 , 1 9 / 1 0 3 .m
2 1m )
ParentBore Diameterfor Cylinder Liner (63724) 4j025/4:035in (104,20/104,23mm)
R e c e s sD e p t hf o r C y l i n d e rL i n e r F l a n g e .150/0
O 1 5 4i n ( 3 , 8 1 / 3 , 9m
1m)
R e c e s sD i a m e t e fr o r C y l i n d e rL i n e r F l a n g e
I6.3544/6 3544\ 4 . 2 0 5 / 4 . 2 1i n0 ( 1 0 6 , 8 1 / 1 0 6 ,m
9 4m )
R e c e s sD i a m e t e fro r C y l i n d e rL i n e r F l a n g e
(6 3724\ 4.245/4 25Oin (107,82/ 107,95mm)
Marn BearingParentBore 3 j66/3 167in (8O,42/8O,44mm\
CamshafB t o r e D i a m e t e rN , o. 1 2.OOO/200 i n1( 5 0 , 8 0 / 5 0 , 8 3 m m )
c a m s h a f tB o r e D i a m e t e rN , o.2 1.990/1 992in(50.55/50.60mm)
CamshaftBore Diameter,No. 3 1 gBO/1g82in (50,29150,34 mm)
C a m s h a fB t o r e D i a m e t e rN ,o 4 1 g 7 O / 1 . 9 7i n
2 (50.04l5O.O9mm)

Cyfinder Liners (Cast tron- Ftanged)- T6.g544/6.9544

Type D r y - I n t e r f e r e n cF ei f - P r o d u c t i o n
D r y - T r a n s i t i o nF i t - S e r v i c e
O u t s i d eD i a m e t e or f P r o d u c t i o nL i n e r .. 4 0 6 4 5 i 40 6 5 5i n ( 1 0 3 , 2 4 / j O 3 , m2 6m )
I n t e r f e r e n cFe i t o f P r o d u c t i o nL i n e r 0 0 0 1 / 0 . 0 0i3n ( 0 , 0 3 i 0 , 0m8 m)
I n s i d eD i a m e t e or f P r o d u c t i o nL i n e r a f t e r F i n i s hH o n i n g 3 . 8 7 7 / 38 7 8i n ( 9 8 , 4 8 / 9 8 , 5m0m )
T r a n s i t i o nF i t o f S e r v i c eL i n e r - 0 0 0 1 / + 00 0 1i n ( - 0 0 2 5 / + 00 2 5m m )
I n s i d eD i a m e t e o r f S e r v i c eL i n e ra f t e rf i t t i n q . 3 877/38795in (98,48198,54 mm)
F l a n g eT h i c k n e s s 0 1 5 0 / 01 5 2i n ( 3 8 1 / 38 6 m m )
H e i g h to f L i n e ra b o v eC y l i n d e rB l o c k T o p F a c e 0 0 2 6 / 0O 3 7i n ( 0 , 6 6 / 0 , 9m 4m)
P o s i t i o no f L i n e rF l a n g eR e l a t i v et o T o p F a c eo f
C y l i n d e rB l o c k + 0 O 0 2 / - O0 0 4i n ( + 0 , 0 5 / - 0 , 1m
0m)

CylinderLiners (Cast lron-Flanged)- 6.9724

Type D r y - I n t e r f e r e n cFei t - P r o d u c t i o n
O u t s i d eD i a m e t e r 4 1045/4 1055in (104,25/104,28mm)
I n t e r f e r e n cF
ei t o f L i n e r 0 0 0 1 / 00 0 3i n ( 0 , 0 3 i 0 , 0m 8 m)
I l n s i d eD i a m e t e or f L i n e r a f t e rF i n i s hH o n i n g 3.9785/3.9795 in (101,05/101,08mm)
F l a n g eT h i c k n e s s 0 1 5 0 / 0 1 5 2 i n( 3 , 8 1 / 3 , 8 6 m m )
H e i g h to f L i n e ra b o v eC y l i n d e rB l o c k T o p F a c e 0 . 0 2 8 / 0 . 0 3 5(i0n, 7 1 l 0 , B g m m )
P o s i t i o no f L i n e r F l a n g er e l a t i v et o C y l i n d e rB l o c k
Top Face + 0 0 0 2 /- 0 0 0 4i n ( + 0 , 0 5 / - 0 ,01m m )

Pistons(T6.3544)
Type T o r o i d a lC a v i t yi n C r o w n
P i s t o nH e i g h ti n R e l a t i o nt o C y l i n d e rB l o c kT o p F a c e 0 0 0 0 / 00 0 7 i n ( 0 , 0 0 / 0 , 1 8m m ) a b o v e
B o r e D i a m e t e fro r G u d g e o nP i n 1 S 0 O 0 / i5 O d 2i n ( 3 8 , 1 0 0 / 3 8 , i 0 5m m )
Compression R r n gG r o o v eW i d t h ,N o . 1 Tapered
Compression R r n gG r o o v eW i d t h ,N o 2 0 0 9 5 5 / 0 . 0 9 6 3i n ( 2 , 4 3 / 2 , 4 5m m \
S c r a p e rR i n g G r o o v eW i d t h ,N o 3 0 1 8 8 5 / 0 . 1 8 9 3i n ( 4 , 7 9 / 4 , 8 1m m ] }

Pistons (T6.3544North America vehicles)

Type R e - e n t r a nCt o m b u s t i o nC h a m b e ri n C r o w n
P i s t o nH e i g h ti n R e l a t i o nt o C y l i n d e rB l o c k T o p F a c e 0 . 0 0 0 / 00 0 7 i n ( 0 , 0 0 / 0 , 1 8m m ) a b o v e
B o r e D i a m e t e rf o r G u d g e o nP i n 1 . 5 0 0 0 / 1 . 5 0 0i2n ( 3 8 , 1 0 0 / 3 8 , . 1 0m5m )
C o m p r e s s i o nR i n g G r o o v eW i d t h ,N o . 1 . . Tapered
I CompressionRing Groove Width, No. 2 0 0959/0.0967in (2,4412,46mm)
I Scraper Ring Groove Width, No. 3 0.1900/0.1908in (4,83/4,B5mm)

P i s t o n s( 6 . 3 5 4 4 ) - 3 R i n g
TYPe .. ToroidalCavityin Crown
P i s t o nH e i g h ti n R e l a t r o nt o C y l i n d e rB l o c kT o p F a c e 0 . 0 0 0 / 0 0 7 i n( 0 , 0 0 / 0 , 1 8 m m a b) o v e
Bore Diameterfor Gudgeon Pin 1.375111.3754in (34,928i34,935mm)
I Compression R i n g c r o o v e W i d t h ,N o 1 . . . 0.0g59/O.0978in(2,4412,48mm)
I CompressionRing GrooveWidth, No 2 0.0959/0.0970in(2,4412,46mm)
S c r a p e rR i n g G r o o v eW i d t h ,N o 3 0 . 1 8 8 5 / 0 . 1 8 9 3( i4n, 7 9 / 4 , 8m1m )
'1
6 3544SeriesWorkshopManual,January 986
TECHNICAL
DATA 84

Pistons(6.3544)5 Ring
Type ToroidalCavityin Crown
PistonHeight relativeto Cylinder Block Top Face 0.000/0.007in(0,00/0,1I mm) above
B o r e D i a m e t e fr o r G u d g e o nP i n 1.3748511.37520in(34,921/34,930mm)
Compression R i n g G r o o v eW i d t h ,N o . 1 . . . 0 . 0 9 5 7 / 0 . 0 9 6 i7n ( 2 , 4 3 / 2 , 4 6m m \
Compression R i n g G r o o v eW i d t h ,N o . 2 . . . 0 0 9 5 7 / 0 . 0 9 6 7i n ( 2 , 4 3 / 2 , 4 6m m )
Compression R i n g G r o o v eW i d t h ,N o . 3 .. 0 0957/0.0967in (2,43/2,46 mm)
S c r a p e rR i n g G r o o v eW i d t h ,N o . 4 0.2525/02535 in (6,41/6,44 mm\
S c r a p e rR i n g G r o o v eW i d t h ,N o . 5 . . . 0 2 5 2 5 / 0 . 2 5 3 5i n ( 6 , 4 1/ 6 , 4 4 ' m m )
Pistons (6.3724)
Type Toroid.alCavity in Crown
P i s t o nH e i g h tR e l a t i v et o C y l i n d e rB l o c kT o p F a c e 0 . 0 0 7 / 0 . 0 1 4i n ( 0 , 1 8 . / 0 , 3 m
6 m)
B o r e D i a m e t e fr o r G u d g e o nP i n 1 7 5 0 5i n ( 3 4 , 9 2 1 1 3 4 , 9 2m6m )
1 . 3 7 4 8 5 /.' 3
Compression R i n g G r o o v eW i d t h ,N o . 1 0.0977/0.0987in (2,48/2,51 mm\
Compression R i n g G r o o v eW i d t h ,N o . 2 .. 0.0957/0.0966in (2,43/2,46 mm)
S c r a p e rR i n g G r o o v eW i d t h ,N o . 3 0 . 1 8 9 5 / 0 . 1 9 0 i5n ( 4 , t s 1 / 4 , 8 4
mm)
S c r a p e rR i n g G r o o v eW i d t h ,N o 4 . . 0 . 1 8 9 5 / 01 9 0 5 i n ( 4 , 8 1/ 4 , 8 4 m m )
PistonRings (T6.3544)
No. 1 Cornpression Chromeor MolybdenumFacedWedge
No 2 Compression TaperedFace
No. 3 Scraper ChromeFacedOil ControlConformable
C o m p r e s s i o nR i n g W i d t h , N o . 1 Wedge
C o m p r e s s i o nR i n g W i d t h , N o . 2 0.0930/0.0935 in (2,36/2,37mm)
ScraperRing Width, No. 3 0. 1860/0.1875in (4,72/4,76 mm)
N o 1 C l e a r a n c ei n G r o o v e Wedge
No. 2 Clearance in Groove 0.002/0.0038 in (0,05/0,10 mm)
N o . 3 C l e a r a n c ei n G r o o v e 0.0010/0.0033in (0,03/0,08mm)
P i s t o nR i n g G a p - N o . 1 0.010/0.026in (0,2510,66 mm)
PistonRing Gap - No 2 : 0.012/0.030in (0,30/0,76 mm)
P i s t o nR i n g G a p - N o . 3 0.010/0.033in (0,2510,84 mm)

Piston Rings (T6.3544North America vehicles)

No. 1 Compression Chrome faced wedge
No. 2 Compression Tapered face
No. 3 Scraper C h r o m ef a c e d o i l c o n t r o l c o n f o r m a b l e
C o m p r e s s i o nR i n g W i d t h , N o . I Wedge
C o m p r e s s i o nR i n g W i d t h , N o . z 0.0930/0.0935in (2,36/2,37 mm)
S c r a p e rR i n g W i d t h , N o . 3 0 . 1 8 6 0 / 0 . 1 8 7i5n ( 4 , 7 2 / 4 , 7 6m m )
No. 1 Clearance in Groove Wedge
No. 2 Clearance in Groove O.002410.0037 in (0,061/0,094mm)
No 3 Clearance in Groove 0 . 0 0 2 5 / 0 . 0 0 4 i8n ( 0 , 0 6 / 0 , 1 2 2m m )
P i s t o nR i n g G a p - N o . 1 O . 0 1 2 / 0 . 0 2 i2n ( 0 , 3 0 , u 0 , 5m6 m )
P i s t o nR i n g G a p - N o . 2 0 0 1 2 / 0 . O 2 2i n ( 0 , 3 0 , / 0 , 5 m 6 m)
P i s t o nR i n g G a p - N o . 3 0 . 0 1 0 / 0 . 0 3 3i n ( 0 , 2 5 , / 0 , 8 m
4 m)
PistonRings (6.3544- 3 ring pack)
No l Compression C h r o m e B a r r e l F a c e d I n t e r n a l l yC h a m f e r e d
No. 2 Compression C h r o m eT a p e r F a c e d
No. 3 Scraper C h r o m e F a c e d O i l C o n t r o lC o n f o r m a b l e
C o m p r e s s i o nR i n g W i d t h , N o 1 0 . 0 9 3 0 / 0 . 0 9 3i5n ( 2 , 3 6 / 2 , 3 7m m )
C o m p r e s s i o nR i n g W i d t h , N o . 0 0 9 3 0 / 00 9 3 5 i n ( 2 , 3 6 / 2 , 3 7m m )
ScraperRing Width, No 3 0 1 8 6 0 / 0 . 1 8 7 5i n ( 4 , 7 2 / 4 , 7 6m m )
N o . 1 C l e a r a n c ei n G r o o v e 0.0024/0.0048 in (0,06/0,12 mm)
N o . 2 C l e a r a n c ei n G r o o v e 0.0024/0.0040 in (0,06/0, 10 mm)
N o . 3 C l e a r a n c ei n G r o o v e 0.0010/0.0033 in (0,03/0,08 mm)
P i s t o nR i n g G a p - N o . 1 0.010/0.024in(0,2510,61 mm)
Piston Ring Gap - No. 2 0.016/0.034in (0,41/0,86mm)
P i s t o nR i n g G a p - N o . 3 0.010/0.033in (0,2510,84 mm)
PistonRings (6.3544-5 ring pack)
No. 1 Compression Plain
Nos.2and3Compression Internally
Stepped
I N o . 4S c r a p e r ChromeFacedOil ControlConformable
No. 5 Scraper SlottedOil Control
, Compression RingWidth,Nos.1, 2 and3 0.0928/0,0938 in (2,36/2,38mm)
I ScraperRingWidth,Nos.4 and 5 ... O.249I0.250in (6,3216,35mm)
Nos.1, 2 and3 Clearancein Groove 0.019/0.0039 in (0,05/0,1
0mm)
Nos.4 and 5 Clearancein Groove 0.0025/0.0045 in (0,06/0,11 mm)
I PistonRingGaps- Cast lron 0.012/0.030in (0,30/0,76 mm)
I PistonRingGaps- Chromed 0.016/0.034in(0,41/0,86mm)
6 3544SeriesWorkshopManual,January1986
 TECHNICALDATA B5

Piston Rings (6.3724)

No. 1 Compression P a r a l l eCl h r o m eI n l a y
No 2 Compression C h r o m eP l a t e dI n t e r n a l l yS t e p p e do r
I n t e r n a l l yC h a m f e r e d
No.3 Scraper C h r o m eP l a t e d S , p r i n gE x p a n d e r
No 4 Scraper S l o t t e dO i l C o n t r o l
Compression R i n g W i d t h ,N o s . 1 a n d 2 0 0928/0.0938 in (2,36/2,38 mm)
S c r a p e rR i n g W i d t h N o s .3 a n d 4 ... 0 1865/0.1875 in (4,74/4,76mm)
No. 1 Clearancein Groove 0 . 0 0 3 9 / 0 0 5 9i n ( 0 , 10 / 0 , 1 4m m )
N o . 2 C l e a r a n c ei n G r o o v e 0 0 0 1 9 / 0 . 0 0 3i n9 ( 0 , 0 5 / 0 , 1m
0m )
Nos. 3 and 4 Clearancein Groove 0.O02/O 004in (0,05/0,10 mm)
l P i s t o nR i n g G a p s ,N o s 1 , 2 a n d 3 0.016i0.034in(0,41/0,86mm)
I P i s t o nR i n g G a p , N o . 4 0.012/0.030in (0,30/0,76mm)

GudgeonPin (T6.3544)
Type FullyFloating
O u t s i d eD i a m e t e r 1.4998/1.5000 in (38,095/38,100mm)
Length 3.250/3.2599in (82,55/82,80mm)
C l e a r a n c eF i t i n P i s t o nB o s s 0.0000/0.0004in (0,000/0,0010mm)

Gudgeon Pin (6.3544 and 6.3724)

Type F u l l yF l o a t i n g
O u t s i d eD i a m e t e r 1.3748/3 1 7 5 0i n ( 3 4 , 9 2 0 / 3 4 , 9m
2 5m )
Length 3 297/3.312 in (83,74/ 84,12 mm)
ClearanceFit in PistonBoss 0 00012/0.00055 in (0,003/0,014 mm)

Small End Bush (T6.3544)(includesNorthAmericavehicleengines)

Type Steel Backed,Lead Bronze Lined
O u t s i d eD i a m e t e r 1 65975/166125in (42,16/42,20mm)
r f t e rR e a m i n g
I n s i d eD i a m e t e a 1 . 5 0 0 7 5 /510 1 5i n ( 3 8 , 1 2 1 3 8 , 1 4 m m )
ClearancebetweenSmall End B u s h a n d G u d g e o nP i n 0 0 0 0 7 5 / 00 0 1 7i n ( 0 , 0 1 9 / 0 , 0 4m3m )

Small End Bush (5.3544and 6.3724)

Tvoe Steel Backed,Lead Bronze Lined
O u t s i d eD i a m e t e r 1.535/15365in (38,99/39,03
mm)
I n s i d eD i a m e t e a
r f t e rR e a m i n g in (34,94134,96
1 3758/1.3765 mm)
C l e a r a n c eb e t w e e nS m a l l E n d B u s h a n d G u d g e o n P i n . in (0,020/0,043
0 0008/0.0017 mm)

ConnectingRod
Type H Section
T6.3544-Wedge ShapedSmallEnd
6.3544-ParallelShapeSmallEnd
C a p L o c a t i o nt o C o n n e c t i n gR o d Serrations
B i g E n d P a r e n tB o r e D i a m e t e r 2 646/2 6465in (67,21/67,22mm\
S m a l lE n d P a r e n tB o r e D i a m e t e rf,6 3 5 4 4 1 65625/1 65725in (42,07/ 42,09mm)
6 3544 and 6.3724.. 1 5313/.15323in (38,90/38,92 mm)
L e n g t hf r o m C / L o f B i g E n d t o C / L o f S m a l lE n d 8.624/8626in (219,05/21 9,10 m m)

ConnectingRod Alignment
l i t h e a c h o t h e rw i t h i nt h e l i m i t so f t 0 0 1 0 i n ( 0 , 2 5 m m )m e a s u r e d5 i n
L a r g ea n d s m a l le n d b o r e sm u s t b e s q u a r ea n d p a r a l l ew
( 1 2 7 m m )e a c hs i d e o f t h e a x i s o f t h e r o d o n a t e s t m a n d r e la s s h o w n i n F i g B 1 . W i t h t h e s m a l le n d b u s h f i t t e d ,t h e l i m i t o f
1 0 . 0 1 0i n ( 0 , 2 5m m ) i s r e d u c e dt o t 0 0 0 2 5i n ( 0 , 0 6m m ) .

- C
, = F .EE
o - otr
6 tf,) 6 C
: lf,)
;- o
- o{
+[d
l*, J + l

8.1

6 3544SeriesWorkshopManual,January1986
TECHNICALDATA B6

Crankshaft
O v e r a l lL e n g t h 3 3 . 8 4 4i n ( 8 5 9 , 6 4m m ) - n o m i n a l
M a i n J o u r n a lD i a m e t e r 2 . 9 9 8 4 / 2 . 9 9 9i6n ( 7 6 , 1 6 / 7 6 , 1 9m m )
M a i n J o u r n a lL e n g t h ,N o 1 . 4 5 4 / 1 . 4 8 4i n ( 3 6 , 9 3 / 3 7 , 6 9m m )
M a i nJ o u r n a lL e n g t h N , o s .2 , 3 , 5 , 6 a n d 7 1 . 5 4 5 / 1 . 5 4 9i n ( 3 9 , 2 4 1 3 9 , 3m 5 m)
. M a i n J o u r n a lL e n g t h N , o.4 1 . 7 3 8 / 1 . 7 4 1i n ( 4 4 , 1 5 / 4 4 , 2 2m m )
. F i l l e tR a d i i - M a i n
Journals 0 . 1 4 5 1 0 . 1 5 i6n ( 3 , 6 8 / 3 , 9 6m m )
C r a n k p i nD i a m e t e r 2.4988/2.4998 in (63,47,/63,49mm )
. C r a n k p i nL e n g t h
1 . 5 8 8 5 / 1 . 5 9 1i5n ( 4 0 , 3 5 / 4 O , 4m 2 m\
. F i l l e tR a d i i -
Crankpins 0 1 4 5 l 0 . 1 5 6i n ( 3 , 6 8 , / 3 , 9 m6 m)
S u r f a c eF i n i s h - a l l p i n s a n d j o u r n a l s 1 6 m i c r o - i n c h e s( 0 , 4 m i c r o n s )
R e g r i n dU n d e r s i z e sJ,o u r n a l sa n d P i n s - 0 . 0 1 0 , 0 0 2 0 a n d 0 . 0 3 0i n ( - 0 , 2 5 , 0 , 5 1 a n d 0 , 7 6m m )
F l a n g eD i a m e t e r. . . 5.247/5.249in (133,27/ 133,32mm)
Spigot Bearing Recess- Depth 0 . 5 7 9 / 0 . 6 0 9i n ( 1 4 , 7 1 / 1 5 , 4 7m m )
Spigot Bearing Recess- Bore 2 . 0 4 6 / 2 . 0 4 7i n ( 5 1 , 9 7 , 2 5 1 , 9m9m )
CrankshaftEnd Floai 0 . 0 0 2 / 00 1 5 i n ( 0 , 0 5 , / 0 , 3 m
8 m)

- F i l l e tr a d i i
a n d s u r f a c ef i n i s hm u s tb e m a i n t a i n e d u r i n gc r a n k s h a frte g r i n d i n gL e n g t ho f N o 4 m a i nj o u r n a lm u s t n o t e x c e e d
1 7 5 9 i n ( 4 4 , 6 8 m m )a f t e r r e g r i n d i n gW . h e r e n e c e s s a r yu, s e o v e r s i z et h r u s t w a s h e r st o s u i t L e n g t h o f c r a n k p i n sn o t t o
e x c e e d 1 . 5 9 6 5i n ( 4 0 , 5 5m m ) a f t e r r e g r i n d i n gF . o r c r a n k s h a f jto u r n a lr u n - o u t s, e e P a g e H . 4 .
IMPORTANTNOTE: See remarkson Page H.3 concerningthe regrindingof 60 hour Nitrided crankshafts.

CrankshaftThrust Washers
Type SteelBacked,LeadBronzeFaced
P o s i t i o ni n E n g i n e CentreMainBearing
Thrust WasherThickness- Standard 0.089/0.091 in (2,261 2,31mm)
Thrust WasherThickness- Oversize 0.0965/0.0985 in (2,4512,5O mm)
T h r u s tW a s h e rO u t s i d eD i a m e t e r n ( 1 0 3 , 8 4 / 1 0 4 ,m
4 . 0 8 8 / 4 . 0 9i 8 0 9m )
T h r u s tW a s h e rI n s i d eD i a m e t e r 3 4 2 / 34 3 i n ( 8 6 , 8 7 1 8 7 , m 1 2m )

Main Bearings
Type Pre-finished,SteelBacked,AluminiumSiliconFaced
S h e l lW i d t h ,N o s . 1 , 2 , 3 , 5 , 6 a n d 7 . . . 1.24011255in(31,50/31,88mm)
S h e l lW i d t h ,N o 4 1.43511.445in(36,45136,70 mm)
O u t s i d eD i a m e t e r 3.166/3.167 in (80,42180,44 mm)
I n s i d eD i a m e t e r 3.0010/3.0026in (76,22517 6,266mm)
M a i n B e a r i n gR u n n i n gC l e a r a n c e 0.001B/0.0042 in (0,046/0,
107mm)
S h e l lT h i c k n e s s 0.082210.0825in (2,088/2,096 mm)

ConnectingRod Bearings
Pre-finished,
SteelBacked,AluminiumSiliconor
AluminiumTin Faced
S h e l lW i d t h 1.24511.255in(31,62/31 .88mm)
O u t s i d eD i a m e t e r 2.6461
2.6465in (67,21I 67,22mm)
I n s i d eD i a m e t e r 2.5008/2.501
I in (63,52163,55mm)
t s e a r i n gR u n n i n gC l e a r a n c e 0.0012/0.0031in (0,030/0,08mm)
S h e l lT h i c k n e s s O.072310.0726in (1,836/1,844mm)

Gamshaft
N o . 1 J o u r n a lL e n g t h 1 . 0 8 5 i n( 2 7 , 5 6 m m )
N o . 1 J o u r n a lD i a m e t e r 1.9965/1 .9975in(50,71l50,74mm)
N o 1 J o u r n a lR u n n i n gC l e a r a n c e 0.0025/0.0045in (0,06/0,1
1 mm)
N o 2 J o u r n a lL e n g t h 1 . 4 3 B i (n3 6 , 5 3 m m )
N o . 2 J o u r n a lD i a m e t e r 1.9865/1 .9875in(50,46/50,49 mm)
N o 2 J o u r n a lR u n n i n gC l e a r a n c e 0.0025/0.0055 in (0,06/0,
14 mm)
N o 3 J o u r n a lL e n g t h 1 . 4 3 8 i n( 3 6 , 5 3 m m )
N o . 3 J o u r n a lD i a m e t e r 1 9765/1.977Sin(50,20150,23mm)
N o 3 J o u r n a lR u n n i n gC l e a r a n c e 0.0025/0.0055 in (0,06/0,
14 mm)
N o . 4 J o u r n a lL e n g t h 1 . 1 5 6 i (n2 9 , 3 7 m m )
N o . 4 J o u r n a lD i a m e t e r 1.9665/1 .9675in (49,95/49,98 mm)
N o . 4 J o u r n a lR u n n i n gD i a m e t e r 0.0025/0.0055 in (0,06/0,
14 mm)
Cam Lift- Inlet(non-vehicle) 0 2959/0.2989in (7,516/7,592mm)
Cam Lift- Exhaust(non-vehicle) 0.3025/0.3055 in (7,68417,760 mm)
Cam Lift-lnlet (vehicleonly) 0.2999/0.3029 in (7,617/7,694mm)
Cam Lift-Exhaust (vehicleonly) 0.3036/0.3066 in (7,71117,7BBmm)
CamshaftEnd Float 0.004/0.01 6in (0,10/0,41mm)
Widthof Spigotfor ThrustWasher 0 2221 0.232in(5,64/5,89mm)

6 3544SeriesWorkshopManual,January1986
 TECHNICALDATA 87

CamshaftThrust Washer
Type 360'
O u t s i d eD i a m e t e r 2 . 8 7 2 / 2 . 8i7n4( 7 2 , 9 5 / 7 3 ,m
0m0)
c y l i n d e r B l o c k R e c e s sD i a m e t e rf o r T h r u s tw a s h e r 2 . 8 7 s / 2 . B Bi ns ( 7 3 , 0 3 / 7 3 , 2m8m )
ClearanceFit of Washer in Recess . 0 0 0 1 / 00 1 3i n ( 0 , 0 3 / 0 , 3m 3 m)
InternaD l iameter '1
750in (44,45mm\
Thickness... 0 2 1 6 / 02 i B i n ( 5 , 4 9 1 5 , 5m4m )
C y l i n d e rB l o c k R e c e s sD e p t h f o r T h r u s tW a s h e r 0 2 1 3 / O . 2 j 6 i n( 5 , 4 1 1 5 , 4 9 m m )
P r o t r u s i o no f T h r u s tW a s h e ra b o v eC v l i n d e rB l o c k
Front Face 0 0 0 0 / 00 0 5i n ( 0 . 0 0 / 0 , 1m
3 m)
CylinderHead
C y l i n d e rH e a d D e p t h 3 7 3 5 / 3 7 6 5 i n( 9 4 , 8 7 / 9 5 , 6m3m )
LeakTestPressure 30 lbflin'?(2,11R91/cm'?) -207 kN/m'z
Valve Seat Angle ... 4So
Valve Guide Parent Bore Diameter ... .. 0 6 2 4 7 / 0 . 6 2 5 7i n ( 1 5 , 8 7 1 1 5 , 8 9 m m )
S k i m m i n gA l l o w a n c e 0 0 1 2i n ( 0 , 3 0m m )
P r o v i d i n gt h a t n o z z l ep r o t r u s i o nd o e sn o t e x c e e d0 1 8 4i n
( 4 , 6 7 m mf)o r T 6 3 5 4 4e n g i n e so r 0 1 3 6 i n ( 3 , 4 5 m mf)o r
6 3 5 4 4a n d 6 3 7 2 4e n g i n e sa f t e rs k i m m i n g
Valve Guides
lnside Diameter O.3743t0.3757in (9,51/9,54mm)
I o u t s i d eD i a m e t e r 0.626/0.6265 in (15,90/15,91mm)
I n t e r f e r e n cF
e i t o f G u i d e i n C y l i n d e rH e a d 0 . 0 0 11 / O . O 0 2 6( i0n, 0 3 / 0 , 0 7 m m )
O v e r a l l e n g t h ,I n l e t 2.281in(57,94mm)
O v e r a l l e n g t h ,E x h a u s t 2.406in ( 6 1 , 1m 1 m)
P r o t r u s i o na b o v eV a l v eS p r i n gR e c e s s .. 0 . 5 9 4 i n( 1 5 , 0 9 m m )
lCounterbore,Exhaustonly 0 . 4 2 1 1 } . 4 4 1 i n ( 1 0 , 619, 2/ 10 m md) i a . f o r l e n g t h
Inlet Valve o f 0 . 4 0 6 i n( 1 0 , 3 m m )
ValveStem Diameter (9,46/9,49mm)
OS72SlO.373Sin
I ClearanceFit of Valve in Guide (0,02l0,08mm)
0.000e/O.0032in
M a x i m u mP e r m i s s i b l We orn Servlce
C l e a r a n c eo f V a l v ei n G u i d e 0 005in(0,13mm)
V a l v eH e a d D i a m e t e r 1 736/1746 in (44,09/44,35
mm)
Valve FaceAngle 45"
V a l v eH e a d D e p t h b e l o wC y l i n d e rH e a d F a c e -
P r o d u c t i o nL i m i t s 0 O4O/0 O5 0i n ( 1 , 0 2 1, 1 2 7m m )
O v e r a l lL e n g t h 4 8 3 1 / 48 4 7i n ( 1 2 2 , 7 11/2 3 , '11m m )
S e a l l n gA r r a n g e m e n i R u b b e rs e a lf i t t e dt o v a l v eg u i d e

ExhaustValve
I ValveStemDiameter 2in (9,4219,45
0.3711O.37 mm)
I ClearanceFitto Valvein Guide 0.0O23tO.OO47in(0,06/0,12mm)
M a x i m u mP e r m i s s i b lW e ornService
C l e a r a n c eo f V a l v ei n G u i d e 0 0 0 6 i n( 0 , 1 5 m m )
Valve Head Diameter | 467/1477in (37.26/37.52mm\
V a l v eF a c eA n g l e 45'
V a l v eH e a d D e p t h b e l o wC y l i n d e rH e a d F a c e -
P r o d u c t i o nL i m i t s in (1,021
0.040/0.050 1,27mm)
I O v e r a l lL e n g t h (123,06/1
4.845/4.865in 23,57mm)
S e a l i n gA r r a n g e m e n t Rubbersealfittedto valveguide

Inner Valve Springs (short)

I Fittedlengthand Load . 1.340in(34,04mm)at20.1123.21bf(9,12l10,52kgf)
N u m b e ro f A c t i v e C o i l s 49 (89,4/1
03,2N)
N u m b e ro f D a m p e r C o i l s 1
Coiled , R.H.-Damper Coilto CylinderHead
Inner ValveSprings (long)
I F i t t e dl e n g t h a n d L o a d 1.563in (39,70mm) at 14.63/1
6.67lbf(6,64/7,56kgf)
N u m b e ro f A c t i v e C o i l s 7 (65,1t74,2N)
N u m b e ro f D a m p e rC o i l s z
Coiled R.H.-Damper Coilsto CylinderHead
Outer ValveSprings (short)
I Fittedlengthand Load 1.410in(35,81rnm)at 39.5/43.7|bf
(17,91/19,82kgf)
N u m b e ro f A c t i v e C o i l s . . . 3.6 (175,7t194,4N)
N u m b e ro f D a m p e rC o i l s 1
Coiled L.H.-Damper Coilto CylinderHead

6 3544SenesWorkshoplvlanual,
January1986
TECHNICALDATA B8

Outer Valve Springs ( l o n g )

Fitted length and Load 1.780 in (45,20 mm) aI 38/43 lbf (17,25/19,52kgf)
N u m b e ro f A c t i v e C o i l s 5.8
N u m b e ro f D a m p e rC o i l s
Coiled L . H .- D a m p e rC o i l s t o C y l i n d e rH e a d
Tappets
OverallLength 2.96875in (75,41mm)
T a p p e tS h a n k D i a m e t e r 0 . 7 4 7 5 / 07 4 8 5i n ( 1 8 , 9 1 / 1 9 , 0m1m )
Cylinder Block Tappet Bore Diameter O . 7 5 0 / 0 . 7 5 1i2n5( 1 9 , 0 5 / 1 9 , 0m8m )
R u n n i n gC l e a r a n c eo f T a p p e ti n B o r e 0.0015/0.00375 in (0,0410,09 mm)
Outside Diameterof Tappet Foot 1 . 1 8 7 5 i (n3 0 , 1 6 m m )

Rocker Shaft
OverallLength 2 6 . 0 3 1 2 5 i n( 6 6 1 , 1 9 m m )
Outside Diameter O . 7 4 8 5 / 0 . 7 4i9n5( 1 9 , 0 1 / 1 9 , 0m4m )

Rocker Levers and Bushes

InternalBore Diameterof Rocker Leverfor Bush O.B7 5/ 0.8762 in 122,22 / 22,26mm)
Outside Diameterof Bush O.877 /0.8785in (22,28/22,31 mm)
InterferenceFit of Bush in Rocker Lever 0.0008/0.0035 in (0,0210,09 mm)
InternalDiameterof Bush (after reaming in situ)' 0 . 7 5 0 5 / 0 . 7 5 2i n0 ( 1 9 , 0 6 / 1 9 , 1m0m )
Clearanceof Bush to Rocker Shaft 0.001/0.0035 in (0,03/0,09 mm)

Push Rods
Overall Length of Push Road 1O.456 / 10.540in (265,58/ 267,72 mm)
S h a n kD i a m e t e r 0 3 1 0 / 0 . 3 1i2n ( 7 , 8 7 1 7 , 9m3m )

Camshaft Gear
N u m b e ro f T e e t h . . .
BoreDiameter ... 1 375/1376in (34,93/34,95 mm)
O u t s i d eD i a m e t e ro f C a m s h a f tH u b . . . 1.3751/1.375 i n7( 3 4 , 9 3 / 3 4 , 9m4m )
F i t o f G e a rt o h u b - 0 0 0 0 7 / + 00 0 0 9i n ( - 0 , 0 1 8 / + 0 , 0 2m3m )

Auxiliary Drive Gear

N u m b e ro f T e e t h 28
Bore Diameter 1.000/1.001in (25,4/ 25,43mm)
M a x i m u mA d j u s t m e n it n S l o t t e dH o l e s 10'

Crankshaft Gear
N u m b e ro f T e e t h 28
Bore Diameter 1.875/ 1 876 in (47,63/47,65mm)
CrankshaftDiameterfor Gear 1.875/ 1 8758 in (47,63/47,64mm)
Fit of Gear to Crankshaft - 0 . 0 0 0 8 / + 00 0 1i n ( - 0 , 0 2 0 / + 0 , 0 2m5m )

ldler Gears and Hubs

N u m b e ro f T e e t h 37
Bore Diameter 2 0625/2.0643 in (52,39/52,43 mm)
O u t s i d eD i a m e t e ro f B u s h 2.06625/2 06825i n (52,48/ 52,53mm)
I n s i d eD i a m e t e ro f B u s h ( f i n i s h e di n s i t u ) 1 8750/1.8766 in (47,63/47,67 mm\
O u t s i d eD i a m e t e ro f H u b 1.8714/1873in (47,53/47,57 mm)
C l e a r a n c eo f H u b i n s i d eB u s h O . 0 0 2 / 0 0 5 2i n ( 0 0 5 / 0 , 1 3m m )
End Float of Gears 0.002/0.012 in (0,05/0,30 mm)

Timing Gear Backlash

All Gears 0 . 0 0 3i n ( 0 , 0 8m m ) m i n i m u m

Auxiliary Drive Shaft Assembly

Drive Shaft- OveralI Length 1 0 . 2 5i n ( 2 6 0 , 3 5
mm)
Number of Teeth on S/orm '1
1
Outside Diameterof Worm 1 865/1.870in (47,37/47,5mm)
Diameterof Front Journa 1 9 3 5 5 / 1. 9 3 6 5 i n( 4 9 , 1 6 / 4 9 , 1 9 m m )
Diameterof Rear Journal. 1 . 2 4 8 / 12 4 9i n ( 3 1 , 7 / 3,.712m m )

Drive Shaft Bush-Front

Outside Diameterof Bush 2 1 2 8 3 / 21 3 0 3 i n( 5 4 , 0 6 / 5 4 , 1m1m l
HousingDiameter
for Bush 2.125/2.1262 in (53,98/54,01 mm)
continued . . -
 TECHNICALDATA B9

I n t e r f e r e n cF
eit in Housino 0 0021/0 0053in (0,05/0,13 mm)
Inside Diameterof Fitted Bush 1.9375/ 1.9397irn(49,21/ 49,27mm)
R u n n i n gC l e a r a n c eo f S h a f i i n B u s h 0 . 0 0 1 / 0 . 0 0 4i n2 ( 0 , 0 2 5 / 0 , 1m1 m )
Drive Shalt Bush- Rear
Outside Diameterof Bush 1.4086/1 .4105in (35,78135,83 mm)
H o u s i n gD i a m e t e rf o r B u s h 1.4063/1.4076 in (35,72135,75 mm)
I n t e r f e r e n cF
eit in Housino 0 . 0 0 1 / 0 . 0 0 4i n2 ( 0 , 0 2 5 / 01,1m m )
I n s i d eD i a m e t e ro f F i t t e dB u s h 1 2 5 / 1. 2 5 1 9i n ( 3 1 , 7 5 1 3 1 , m 8 0m )
R u n n i n gC l e a r a n c eo f S h a f t i n B u s h 0 . 0 0 1 / 0 . 0 0 3i n9 ( 0 . 0 2 5 / 0 , 1m0 m )
AuxiliaryDriveThrustWashers
Thickness... 0.1875/0.1905in (4,76/4,84mm)
C y l i n d e rB l o c k R e c e s sD e p t h f o r T h r u s tW a s h e r O.184/O.187 in (4,67/ 4,75 mm\
O u t s i d eD i a m e t e r 2 806/2 812in (71,27/71,42mm)
I n s i d eD i a m e t e ro f C y l i n d e rB l o c k R e c e s s . . 2.8125/2.8225in (71,44/71,69m m )
P r o t r u s i o no f T h r u s tW a s h e ri n C v l i n d e rB l o c k 0 . 0 0 0 5 / 0 . 0 0i n7 ( 0 , 0 1 / 0 , 1m
7 m)
GrooveWidth on Drive Shaft 0 . 1 9 3 / 0 . 1 9 6i n5 ( 4 , 9 / 4 , 9m9 m)
Groove to Thrust Washer Clearance 0.0025/0.009 in (0,064/0,23 mm)
Hydraulically Loaded Wormwheel
B o r e D i a m e t e ri n C y l i n d e rB l o c k f o r F u e l P u m p
A d a p t o rP l a t ea n d U p p e rT h r u s t C o l l a r . . . 3.500/3.5014in (88,90/88,94 mm)
Fuel Pump Adaptor Plate Diameter 3.4986/3.4995 in (88,86/88,89mm)
F i t o f P l a t ei n C y l i n d e rB l o c k . . . 0.0005/0.0028 in (0,01/0,07mm)
O u t e r D i a m e t e ro f U p p e rT h r u s t C o l l a r 3.496/3498 in (88,80/BB,B5 mm)
C l e a r a n c eo f U p p e rT h r u s t C o l l a ri n C y l i n d e rB l o c k 0.002/0.0054in (0,05/0,14 mm)
Bore Diameterin Cylinder Block for Lower Thrust
Washer 2 . 2 4 9 1 / 2 4 9 9i n ( 5 7 , 1 3 / 5 7 , 1m5m )
W i d t h o f G r o o v ei n U p p e rT h r u s t C o l l a r 0 0957/0.0967 in (2,43/2,46mm)
U p p e rT h r u s tC o l l a rS e a l i n gR i n g T h i c k n e s s . . . 0.0928/0.0938 in (2,36/2,38 mm)
Clearanceof SealingRing in Groove 0 . 0 0 1 9 / 0 . 0 0 3i n9 ( 0 , 0 5 / 0 , 1m
0 m)
I n n e r D i a m e t e ro f B u s h i n F u e l P u m p A d a p t o rP l a t e 1.875/ 1.8766 in (47,63/47,67mm)
U p p e r D i a m e t e ro f F u e l P u m p D r i v eS h a f t 1.8714/ 1.873 in (47,53/47,57mm)
Clearanceof Drive Shaft in Adaptor Plate Bush .. 0 002/00052in (0,05/0,13mm)
I n n e r D i a m e t e ro f U p p e rT h r u s t C o l l a r 1 8 8 6 / 1. B g i n ( 4 7 , 9 0 / 4 8 , 0m1m )
Clearanceof Drive Shaft in Upper Thrust Collar 0 . 0 1 3 / 0 . 0 1 8i n6 ( 0 , 3 3 / 0 . 4m7 m)
C u r r e n tE n g i n e s : -
Lower Thrust Collar Bore for Bush . . 1 7 8 1 2 / 17 B 2 B i n(45,24/45,28mm)
Outer Diameterof Bush 1 7843/1.7857 in (45,32/45,36mm)
I n t e r f e r e n cFe i t o f B u s h i n T h r u s tC o l l a r 0.0015/0.0045 in ( 0 , 0 4 1 0 , 1m1m )
I n n e r D i a m e t e or f B u s h ( a f t e rf i n i s h i n gi n s i t u ) 1 6255/1 6266in (41,29/41,32 mm)
Lower Diameterof Fuel Pump Drive Shaft 1 6214/1 6224in (41,18/41,22 mml
C l e a r a n c eo f S h a f ti n B u s h 0.0031/0.005 i n2( 0 , 0 8 / 0 , 1m
3m)
E a r l yE n g i n e s : -
I n n e rD i a m e t e o r f L o w e rT h r u s tC o l l a r 1-625/1 6266in (41,28/41,32mm\
L o w e rD i a m e t e o r f F u e l P u m p D r i v eS h a f t 1.6214/1.6230in (41,18/41,22mm)
C l e a r a n c eo f D r i v eS h a f ti n C o l l a r 0.002/0.0052in (0,05/0,13mm)
Sump
Sump Capacity (typical) 2 6 l m p e r i a lP i n t s ( 1 4 , 8L i t r e s )
M i n i m u mt o M a x i m u mm a r k o n D i p s t i c k 5 l m p e r i a lP i n t s ( 2 , 8 4L i t r e s )
S t r a i n e rP o s i t i o n S u c t i o nP i p e o f L u b r i c a t t n gO i l P u m p
Oil Pump
Type Rotor
Oil Pump Clearance
l n n e r R o t o rt o O u t e r R o t o r 0.003/0.005 in (0,08/0,13 mm)
O u t e r R o t o rt o P u m p B o d y 0 . 0 0 6 / 00 1 3i n ( 0 , 1 5 / 0 , 3m 3 m)
I n n e ra n d O u t e r R o t o r E n d C l e a r a n c e 0 . 0 0 0 5 / 0 . 0 0 2i n5 ( 0 , 0 1 / 0 , 0m
6m)
F o r r e p l a c e m e npt u r p o s e st,h e w h o l e p u m p a s s e m b l ym u s t be replaced.
RelielValve
First Stage PressureSetting (T6 3544 only) 30/ 37 lbt/ in2 (2,11/ 2,6 kgf/ cm,) 2O7/ 255 kN/ m,
Relief Flow PressureSetting 50/60|bf/i n, (3,52/4,22k gf/cm,) 348/ 414 kN/ m,
L e n g t ho f P l u n g e r 0 . 9 3 7 5i n ( 2 3 , 8 1m m )
O u t s i d eD i a m e t e ro f P l u n g e r . . . 0 7 1 5 8 / 07 1 7i n ( 1 8 , 1 8 / 1 8 , 2m1m )
I n s i d eD i a m e t e ro f V a l v eH o u s i n qB o r e 0.718/0.7192 in (18,24/18,27mm)
C l e a r a n c eo f P l u n g e ri n B o r e 0.001/0.0034 in (0,03/0,09 mm)
Free Length of Spring 2.3125in(58,74mm)
Spring Fitted Length and Load 2 . 1 8 7 5 i n( 5 5 , 5 6 m m )a t 3 l b f 8 o z f ( 1 , 5 8 k g f )
TECHNICALDATA 81O

LubricatingOil Filter
Typeof Filter F u l l F l o w R e p l a c e a b lC
e anister
ElementType Paper
By-PassValveSetting B/12lbt/in2(0,56/0,8a kgf/cm'?)55/83kN/m'?

Cooling System
Type T h e r m o - S y p h o nP. u m p a s s i s t e d .
Coolant Capacity 3 8 l m p e r i a lP i n t s ,( 2 . ,16 l i t r e s )

Thermostat
Type T w i n W a x C a p s u l ef i t t e d i n p a r a l l e l
Opening Temperature 177/183"F (80,6/83,9" C)
F u l l yo p e n a t 199 -204" F (93 -96' C)
Valve Lift 0.374/0500 in (9,50/12,70 mm)

WaterPump
Type C e n t r i uf g a l
Outside Diameterof Shaft for Pulley .. 0.8742/0.8747 in (22,20/22,22mm)
lnside Diameterof Pulley Bore 0.8750/0.8758 in (22,23/22,25mm)
ClearanceFit of Pullev on Shaft in (0,01/0,04
0 0003/000.16 mm)
O u t s i d eD i a m e t e r oSf h a f t f o rl m p e l l e r .. 0 . 5 0 1 2 / 05 0 1 8i n ( 1 2 , 7 3 / 1 2 , 7 5 m m \
D i a m e t e ro f l m o e l l e rB o r e . 0 5 0 0 0 / 0 . 5 0 0i n7 (12,7O/12,72mm')
I n t e d e r e n c eF i t o f l m p e l l e ro n S h a f t 0 0 0 0 5 / 0 . 0 0 1i n8 ( 0 , 0 1 3 / 0 , 0 4m6m )
l m p e l l e rB l a d et o P u m p B o d y C l e a r a n c e .. 0 . 0 11 / 0 0 3 5i n ( 0 , 2 8 1 0 , 8m9m )
(including e n dfl o a t )

Approved Fuel Oil Specifications

UnitedKingdom BS.2869:1983 Class41 or A2
UnitedStates VV-F-800C GradesDF-A,DF-1or DF-2
A.S.T.M./D975-817 GradesDF-A,DF-1or DF-2
France AFNORN.F.M.15/007(1978)
India 15:1460/1974 GradeHSD
Germany DIN-51601(1978)
Italy CUNA-GasOil
NC-630-01(1977)
Sweden 515.155432(1981)
Switzerland SN 181 160/1

F u e l o i l s a v a i l a b l ei n t e r r i t o r i e so t h e r t h a n t h o s e l i s t e da b o v ew h i c h a r e t o a n e q u i v a l e nst p e c i f i c a t i o n
may be used

Fuel Lift Pump

Typeof Pump AC DelcoXDSeries
M e t h o do f D r i v e E c c e n t r i co n C a m s h a f t
DeliveryPressure 6/10lbf/in'?(0,43/0,70kgf/cm'?)or 41169kN/m'?
D i a p h r a g mS p r i n gC o l o u r Red

Fuel Filter
Type TwinParallelor single
ElementType Paper

Fuel Injection Pump

Make CAV
Type D , PA
Pump Rotation Anti-clockwise
TimingLetter a

N o . 1 C y l i n d e rO u t l e t "x"
Make Bosch
Type Rotary
Pump Rotation Anti-clockwise
N o . 1 C y l i n d e rO u t l e t D

6 3544SeriesWorkshopl\y'anual, '1
January 986
 TECHNICALDATA 811

Fuellnjection Pump Static Checking Angles

The relevanttiminginformationcan be found by referenceto the prefixlettersor prefixlettersand figuresof the settingcode adjacent
to the word "Set" on the fuel pump identification
plateand the tablebelow.The enginecheckingangleis for use withtimingtool MS67B
and the engineset with No. 1 pistonat TDC compressionstroke.

Prefix EngineChecking FuelPumpMarking StaticTiming Piston

Letters Angle (Degrees) Angle(Degrees) BTDC(Degrees) Displacement
T6.3544
C.A.V.pumps
CY lcJ 145 to 0 . 1 2 4 i n( 3 , 1 5 m m )
DY tou 144 32 0 . 4 8 5 i n( 1 2 , 3 2 m m )
JY 159 144 JU 0 . 4 2 6 i n( 1 0 , 8 2 m m )
LX 144 30 0 . 4 2 6 i n( 1 0 , 8 2 m m )
LY 153 145 to O . 1 2 4 i (n3 , 1 5 m m )
MY t5v 144 30 O . 4 2 6 i (n1 0 , 8 2 m m )
TX 159 144 30 0 . 4 2 6 i n( 1 0 , 8 2 m m )
VR 159 144 30 0 . 4 2 6 i n( 1 0 , 8 2 m m )
XX 159 144 30 0 , 4 2 6 i n( 1 0 , 8 2 m m )
YX 160 144 32 0.483in(12,27mm)
zx 159 144 JU 0 . 4 2 6 i n( 1 0 , 8 2 m m )

Boschpumps
EY (121-2) 135. 1251/2. 10 0 . 1 7 5 i n( 4 , 4 5 m m )
FY (121-3) 135. 1271/2. t3 0 . 110 i n ( 2 , 7 9m m )
KY (1107) 123. 11 8 - 10 0 . 0 4 9 i n( 1 , 2 4 m m )
VX (121or 173) 135- 127- to 0.124in (3,15mm)

6.3544
C.A V. pumps
AY tbu 146 28 0.373in(9,47mm)
BY tou 146 28 0.373in(9,47mm)
EX 160 146 28 0 . 3 7 3 i n( 9 , 4 7 m m )
FX 160 146 28 0.373in(9,47mm)
GY toz 154 to 0.125in (3,18mm)
HY toz 154 to 0.125in (3,18mm)
MR 158 144 zo 0.373in(9,47mm)
MX (exceptbelow) 160 146 28 0.373in(9,47mm)
MXt412640 161 146 30 0 . 4 2 6 i n( 1 0 , 8 2 m m )
MX/512420trom
eng.no.728207L 159 146 zo 0.325in(8,26mm)
MX/5/2530 161 146 30 0 . 4 2 6 i n( 1 0 , 8 2 m m )
PX 160 t+o 28 0 . 3 7 3 i n( 9 , 4 7 m m )
SX 161 146 30 0 . 4 2 6 i n( 1 0 , 8 2 m m )
WR 160 146 28 0 . 3 7 3 i n( 9 , 4 7 m m )
WX 157 144 26 0 . 3 2 5 i n( 8 , 2 6 m m )

6.3724
SX 161 146 30 0 426in (10,82mm)

" The settingsgivenfor the Boschfuel pumpsare withthe pumpset at 1 mm plungerlift.lt is important
thatthesepumpsare not fitted
at the statictimingpositions
givenfor the CAV pumps.The codegivenin bracketsis stampedon the sideof the pump.

6,3544SeriesWorkshopManual,May'85
 TECHNICAL
DATA 812

Atomisers
Code Holder Nozzle Setting Pressure Working Pressure
atm lbilin2 (MN/m'z) atm lbf/in2 (MN/mr)
FL BKBL67S5299 BDLLl5056673 215 3160 (21,8) 20O 2940 (20,3)
FN BKBL6755299 BDLLl50S6639 210 3087 (21,3) 195 2866 (19,8)
GD BKBL67S5299 BDLLl5OS673O 215 3160 (21,8) 200 2940 (20,3)
or or
oKLL67S2931 oLLl 5056730
uu BKBL67S5299 BDLLl5056737 210 3087 (21,3) 21O 3087 (21,3)
GH BKBL67S5299 BDLLl5056738 210 3087 (21,3) 210 3087 (21,3)
GK KBEL62S9/1 3 DLLAl 505741 275 4042 (27,9) 275 4042 (27,9)
GL BKBL67S5151 BDLLl5OS673O 175 2572 (17,7) 170 2500 (17,2)
I G X KBEL64521 DLLAl 40S827 250 3675 (25,3) 25O 3675 (25,3)
HC LR867014. JB6801014 245 3601 (24,8) 245 3600 (24,8)
or or
OKLL66M2884 oLLl 50M8575
HE LR867014. JB6801019 230 3381 (23,3) 230 3381 (23,3)
HK BKBL67S5299 BDLLl35S6834 215 3160 (21,8) 215 3160 (21,8)

I H P LR867014. J86801014 225 3307 (22,8) 225 3307 (22,8)

I or or
I OKLL66M2BB4 oLLl 50M8575
BKBL6735299 BDLLl5OS673O 215 3160 (21,8) 2O0 2940 (20,3)
IHS
or or
I
oKLL6752931 oLLl 5056730
lHr LR867014. J8680101I 200 2940 (20,3) 2o0 2940 (20,3)
or
oKLL66M2884
RA KBEL64116 DLLAl 40P44 250 3675 (25,3) 250 367s (25,3)
RB oKLL62M3136 oLLl 30M9027 250 3675 (25,3) 250 3675 (25,3)
VU oKLL67S2929 oLLl 5057574 250 3675 (25,3) 225 3307 (22,8)
BKBL67S5151 BDLLl5056329 175 2572 (17,7) 170 2500 (17,2)
. In theseatomisersthe pressureis
adjustedby a changeof shims.

ElectricalSystem 12or 24volt

Alternator
I Make Lucas
I TYPe 17ACR 17ACR 18ACR A115 A133/55 25ACR A133/65
I (derated)
I Voltage 12V 12V 12V 12V 12V 12V 12V
Max.output(hot) 284 35A 45A 45A s5A 654 65A
Make c.A.v. ". Perkins
Type ACs&ACsR ACs&ACsR LR135 LR150
Voltage 12V 24V 12V 12V
Max.output(hot) 604 30A 354 50A
I
I Startermotor
I vut"
'Tvpe
LUCaS c.A.v. Perkins
M50 M12712,8 cA45 cA45 s12-84
I vottug" 12V 12V 12V 24V 12V
I Startercableresistance 0.0017f) 0.0017c) 0.0017c) 0.0034c) 0.0017c)
I No. of teethon pinion 10 10 10 10 10

StartingAid
Make C.A.V. - Thermostart
MaximumCurrentConsumption 1 2 . 5 / 1 3 .a
5 tA11 . 5 V
Flow RatesthroughThermostart 3,5/5,0 ml/min

6 3544SeriesWorkshopManual,May'85.
 TECHNICALDATA 813

SERVICEWEAR LIMITS
The following "wear limits" indicatethe condition when it is recommendedthat the respectiveitems should be servicedor
reolaced.
Cylinder Head Bow Transverse 0 . 0 0 5i n ( 0 , 1 3m m )
Longitudinal 0 . 0 1 0i n ( 0 , 2 5m m )
M a x i m u mB o r e W e a r
(when new liners are necessary) 0 . 0 0 8i n ( 0 , 2 0m m )
C r a n k s h a f tM
, a i na n d B i g E n d J o u r n a l ,
Ovalityand Wear 0 . 0 0 1 5i n ( 0 , 0 4 m m )
Maximum CrankshaftEnd Float 0 . 0 2 0i n ( 0 , 5 1m m )
ValveStem to Guide Bore Clearance,Inlet 0 . 0 0 5i n ( 0 , 1 3m m )
Exhaust 0 . 0 0 6i n ( 0 , 1 5r n m )
Valve Head Depth below Cylinder Head Face 0 . 0 6 0i n ( 1 , 5 2m m )
Rocker Clearanceon Rocker Shaft 0 . 0 0 5i n ( 0 , 1 3m m )
CamshaftJournals,Ovality and Wear 0 . 0 0 2i n ( 0 , 0 5 m r n )
CamshaftEnd Float 0 . 0 2 1i n ( 0 , 5 3 m m )
l d l e rG e a r E n d F l o a t 0 . 0 1 5i n ( 0 , 3 8m m )

6 3544 Seriesworkshop Manual,lssue2, June'82

 SECTIONC
Operatingand Maintenance
OPERATING
AND MAINTENANCE C2
To startthe engine
There are several factors which affect engine start, for
example:
The powerof the batteries.
Performanceof the starter motor.
Viscosityof the lubricatingoil.
Installation
of a coldstartsystem.
Diesel engines need a cold startingaid when they are ro
operatein v.erycold conditions.Your vehiclewill riormally
be fitted with the correct equipment for your area of
operation.
Differentsystemsof cold startingaids can be installedon
Perkinsdieselenginesand they are:
Thermostart
An electricallyoperateddevice which heats the induction
air.This deviceburnsa controlledamountof dieselfuel.
Start Pilot
A hand pump discharges the cold start fluid into the
inductionmanifoldthroughan atomiser,The cold startfluid
is heldin a separatereservoir.
KBi
The cold start fluid is held in an aerosol container.lt is
1e]egpe{!y a. push bu.ttonoperated solenoid and sprayed
intothe inductionmanifoldby anozzle.
WARNING
KBi,or.StartPilotequipmentmust not be usedwith heattype
cold startingaidssuch as Thermostart.
Engine start procedure, without cold
startingaids.
1. Adjustthe enginespeed controlto the maximumspeed
oosrlron.
2. Turn the startkey to the'S' (start)position,(see Fig.C1)
to engagethe startermotor.
3. As soon as the enginestarts,releasethe startkey to the
' R ' ( r u n )p o s i t i o n .
4. Adiustthe enginespeedcontrol.
5. lf the enginedoes not start in 15 seconds,releasethe
start key to the 'R' position.Do not enqaqethe starter
motoragainuntil10 to 15 secondshavepassed.
Always ensure that the flywheel and starter motor have
stoppedtheir rotationbeforethe startermotor is engaged
again.
Enginestart procedurewith Thermostart.
1. Wherea separatestop controlis installed,ensureit is in
t h e ' R ' ( r u n )p o s i t i o n .
2. Turn the startkey to_the'H' (Heat)position,(see Fig.C1)
and holdit therefor 20 seconds.
3. Adjustthe enginespeed controlto the maximumsoeeo
position.
'82
6.3544SeriesWorkshopManual,lssue 2, June
4. Turn the start key to the 'HS' (Heat/Start)positionto
engagethe startenmotor.As the enginestarts,retease
the start key to the 'R' (run) position and adjust the
enginespeedcontrolto give a smoothidlespeed.
5. lf the engine does not start in 15 seconds,return the
s t a r t k e y t o t h e ' H ' p o s i t i o n f o r 1 0 s e c o n d sa n d t h e n
engagethe startermotoragatn.
Enginestartprocedurewith StartPilot
The StartPilothand pump must not be used untilthe starter
motoris engaged.
Experiencewill show how much fluid is needed for each
enginestart.
1. Where necessary,chargethe reservoirwith fluid.Raise
the cover of the reservoir,pressthe can, head down on
the.fillerplug and hold squarelyuntilfluidfillsthe bowlup
to the maximummark.
2. Adiustthe enginespeed controlto the maximumspeed
oosrlron.
3. Engagethe startermotorfor a maximumof 30 seconos
and operate the Start Pilot pump during this period.
Adjustthe enginespeedcontrol.
4. lf the enginedoes not start duringthe first 30 seconds,
disengagethe startermotorfor another30 secondsand
then engage the starter motor again and operate the
StartPilothandpump.
The air filterat the outer end of the pump must be inspected
from time to time and if necessaryit must be washed in
Kerosene.
Thin lubricating oil can be appliedto the pumpcylinder.
The nozzle in the inductionmanifoldcan be removedand
washedin kerosene,when necessary.
WARNING
Start Pilotequipmentmust not be used with heat type cold
startingaidssuch as thermostart
Enginestartprocedurewith KBi
1. Where necessary,renew the screw type canister.A
safetyvalveis integralwiththe container.
2. Adiustthe enginespeed controlto the maximumspeed
posrlron.
3. Engagethe startermotor.
4. Pressthe KBi buttonfor a maximumof 2 seconds.As the
enginestarts,adjustthe enginespeed controlto give a
smoothidle soeed.
5. lf the enginedoes not startafterthe first2 secondsallow
5 secondsto pass and then press the KBi buttonfor a
maximum period of 2 seconds with the starter motor
engageo.
WARNING
KBi equipmentmust not be usedwith heattype cold starting
aidssuch as Thermostart.
Stopping the Engine
A spring loaded control is located near the normal
engine controls and functions by cutting off the fuel in
the fuel injectionpump.
To operate, pull the "stop" control and hold until the
engine has completelystopped rotating Ensurethe stop
returns to its "run" position otherwise difficulty may
be experiencedin re-startingthe engine.
Returnswitchto the "O" positron.
W h e r e a n e n g i n e i s f i t t e d w i t h a n e l e c t r i c a l l yo p e r a t e d
s o l e n o i d ,t h e s t o p b u t t o n o r s w i t c h s h o u l d b e o p e r a t e d
u n t i l t h e e n g i n eh a s s t o p p e d .
ThermostartFailure
In the event of difficult starting, check that fuel is
reaching the start aid in the induction manifold by
disconnectingthe fuel pipe.
lf fuel is reaching the start aid satisfactorily, check
that the start aid is functioning by disconnecting the
piping at the induction manifold and watching the
 OPERATINGAND MAINTENANCE C3

cold start aid whilst it is being used. When the switch Checkfor water in the fuel pre-filter(wherefitted)and drainas
i s t u r n e d t o " H " ( h e a t ) p o s i t i o n ,t h e e l e m e n t s h o u l d necessary.
becomered hot, and on engagementof the startermotor, Cleanthe compressorair filter(if fitted).
i t s h o u l db u r s t i n t o f l a m e
Where a thermostartunit has to be replaced,care musr (10,000
Every15000km miles),500
hoursor
be taken not to exceed the torque load as given on 12months
Page B.2. Excessive torque loading can crack the
Cleanthe liftpumpgauzestrainer.
insulatingadaptor causing an electricalshort and hard
startin g characteristics Cleanor renewthe airfilterelement(if not indicated
earlier).
To preventthermostarl damage, it is essentialthat the Renewelementof singleelementfinalfuelfilter.
thermostartis not operateddry After any operationwhich
allows fuel to drain from the thermostarifeed pipe, the Every30000km(20,000miles),1,000hours
pipe must be disconnectedat the thermostartarid all air Renewthe elernentsof doubleelementfinalfuel filter.
bled from the pipe before the thermostart is operated. Cleanthe turbocharger impellerand casing,and the lubricat-
The TO3544 and 6.3544 engine is fitted with efficient i n go i l d r a i np i p e .
c o l d s t a r t i n ge q u i p m e n ta n d n o r e s p o n s i b i l i t yc a n b e
accepted for any damage caused by unauthorised Every90000km(60,000miles)2,500hours
startingaids Have the accessory equipment (starter motor, alternator,
exhauster,etc.)checked.
T6.3544ENGINESONLY Checkand, if necessary,adjustthe valvetip clearances.
Operatingthe Engine-Vehicle Havethe atomiserschecked.
Applications Renew the closed circuit breather element (naturallyaspi-
I t i s e s s e n t i a lt o m a i n t a i n a r e a s o n a b l yh i g h e n g i n e ratedenginesonly).
speed r,vhenclimbing a gradient owing to the power
characteristicsof the turbocharged T6 3544 engine. Air GhargeCooler (remote)
To maintain maximum etficiency,the cooler radiator fins
Do not overload the engine at low engine speed
should be checked periodicallyto ensure that no foreign
Before the engine becomes overloaded, change gear matteris obstructingthe flow of air.
to increaseengine speed
Under no circumstancesshould the radiatorbe "muffed" or
"blanked off" in an attempt to raise the temperaturein the
driver'scab becausethis will impedethe flow of air through
PREVENTIVEMAINTENANCE the chargecooler.
These preventivemaintenanceperiodsare generalin applica-
tion. Check the periods given by the manufacturerof the
Post Delivery Service
equipmentin whichthe engineis installedand,whereneces- The serviceproceduresgiven below must be done at the first
sary, use the shorterperiods.These periodsand procedures 800/1600km(500/1,000miles),25150hoursof operation.
must also be adaptedto ensurecorrectoperationfor any local 1. Runthe engineuntilit is warm.Stopthe engineand drain
vehicleor machineregulations. the lubricating
oil fromthe sump.Fillthe sumpto the "full"
On stop/startshort distanceoperationthe hoursrun are more mark on the dipstickwith clean new lubricatingoil to an
importantthan the distance approvedgrade.

It is good maintenanceto check for leakage and loose 2. Renewthe canisterof the lubricating
oil filter.
fastenersat each serviceinterval. 3. Adjustthe valvetip clearances(see page E.4).
These maintenanceperiodsare only for enginesthat are pumpdrivebelt.
4. Checkthe tensionof the alternator/water
operated with fuel and lubricatingoil to the specifications
givenin thismanual. 5. Checkthat all fastenersare tight.
6. Runthe engineand checkfor fuel,coolantand lubricating
oil leakage.
Schedules
The scheduleswhich follow must be done at the interval 7. lf necessary,get a trainedpersonto adjustthe idlespeed.
(kilometres,
miles,hoursor months)whichoccursfirst.

Daily or every 8 hours

Checkamountof coolant.
Checkamountof lubricating oil in the sump.
Checklubricatingoil pressure(wherea gaugeis installed).
cleandustbowlof airfilter(where
In extremedust conditions,
fitted),

Every7500km(5,000miles),250hoursor 4
months
Renewthe lubricatingoil.
Renewthe lubricatingoil filtercanister/s.
Cleanthe aircleaner,or emptythe dustbowlof the airfilter.
Insoectthe drivebelt.

'1
6 3544SeriesWorkshopManual,January 986
OPERATINGAND MAINTENANCE C4
Protectionof an Enginenot in Service
T h e r e c o m m e n d a t i o n gs i v e n b e l o w a r e t o e n s u r e t h a t
d a m a g e i s p r e v e n t e dw h e n a n e n g i n e i s r e m o v e df r o m
s e r v i c e f o r a n e x t e n d e dp e r i o d . U s e t h e s e p r o c e o u r e s
i m m e d i a t e l yt h e e n g i n e i s r e m o v e d f r o m s e r v i c e T h e
i n s t r u c t i o n sf o r t h e u s e o f P O W E R P A R Tp r o d u c t sa r e
g i v e no n t h e o u t s i d eo f e a c h c o n t a i n e r
1 . T h o r o u g h l yc l e a nt h e o u t s i d eo f t h e e n g i n e
2 . W h e r e a p r e s e r v a t i v ef u e l i s t o b e u s e d , d r a i n t h e
f u e l s y s t e m a n d f i l l w i t h t h e p r e s e r v a t i v ef u e l
POWERPART Lay-Up 1 can be added to the
n o r m a l f u e l t o c h a n g e i t t o a p r e s e r v a t i v ef u e l l f
p r e s e r v a t i v ef u e l i s n o t u s e d , t h e s y s t e m c a n b e
k e p t c h a r g e dw i t h n o r m a lf u e l b u t t h i s w i l l h a v e r o
b e d r a i n e da n d d i s c a r d e da t t h e e n d o f t h e s r o r a o e
p e r i o dt o g e t h e rw i t h t h e f u e l f i l t e r
3 . R u n t h e e n g i n e u n t i l i t i s w a r m C o r r e c ta n y f u e l ,
l u b r i c a t i n go i l o r a i r l e a k a g e .S t o p t h e e n g i n e a n d
d r a i nt h e l u b r i c a t i n goil sump
4 R e n e wt h e l u b r i c a t i n g o i l f i l t e rc a n i s t e r
5 F i l l t h e s u m p t o t h e f u l l m a r k o n t h e d i p s t i c kw i t h
clean new lubricating oil or with a correct
p r e s e r v a t i v ef l u i d . P O W E R P A R TL a y - U p 2 c a n b e
a d d e d t o t h e l u b r i c a t i n go i l t o g i v e p r o t e c t i o n
a g a i n s tc o r r o s i o nd u r i n gt h e p e r i o d i n s t o r a g e .l f a
preservative f l u i d i s u s e d , t h i s m u s t b e d r a i n e da n d
n o r m a l l u b r i c a t i n go i l u s e d w h e n t h e e n g i n e i s
r e t u r n e dt o s e r v i c e .
6 . D r a i n t h e c o o l i n gs y s t e m ,s e e P a g e C 5 . T o g i v e
p r o t e c t i o na g a i n s t c o r r o s i o n ,i t i s b e t t e r t o f i l l t h e
c o o l i n gs y s t e m w i t h a c o o l a n tt h a t h a s a c o r r o s i o n
i n h i b i t o r s, e e ' E n g i n eC o o l a n t 'o n t h i s p a g e l f f r o s t
p r o t e c t i o ni s n e e d e d ,u s e a n a n t i f r e e z em i x t u r e .l f
n o f r o s t p r o t e c t i o ni s n e e d e d , u s e w a t e r w i t h a n
a p p r o v e dc o r r o s i o ni n h i b i t o m r ixture.
7. Run the engine for a short period to send the
l u b r i c a t i n go i l a n d c o o l a n ta r o u n dt h e e n g i n e
8 C l e a n o u t t h e e n g i n e b r e a t h e rp i p e a n d s e a l t h e
end of the pipe.
9 . R e m o v e t h e a t o m i s e r sa n d s p r a y P O W E R P A R T
Lay-Up 2 into each cylinderbore. lf this is not
a v a i l a b l e ,c l e a n e n g i n e l u b r i c a t i n go i l w i l l g i v e a
d e g r e e o f p r o t e c t i o n S p r a y i n t o t h e c y l i n d e rb o r e s
1 4 0 m l ( 1 / 4p i n t ) o f l u b r i c a t i n go i l d i v i d e d e v e n l y
b e t w e e nt h e s i x c y l i n d e r s
10 S I o w l yt u r n t h e c r a n k s h a f o
t n e r e v o l u t i o na n d t h e n
install the atomisers complete with new sear
washers
11 Remove the air filter and any pipe installed
b e t w e e nt h e a i r f i l t e ra n d i n d u c t i o nm a n i f o l d S
. pray
POWERPART Lay-Up 2 into the induction
m a n i f o l dS
. e a l t h e m a n i f o l dw i t h w a t e r p r o otfa p e .
12 R e m o v et h e e x h a u s tp i p e S p r a yP O W E R P A R T Lay-
U p 2 i n t o t h e e x h a u s tm a n i f o l d .S e a l t h e m a n i f o l d
with waterprooftape
13 Remove the lubricating oil filler cap Spray
P O W E R P A R TL a y - U p 2 a r o u n d t h e r o c k e r s h a f t
a s s e m b l y .F i t t h e f i l l e rc a p .
1 4 . D i s c o n n e c t h e b a t t e r ya n d p u l i t i n t o s a f e s t o r a g e
i n a f u l l y c h a r g e d c o n d i t i o n .B e f o r e t h e b a t t e r y i s
put into storage, give the battery terminals a
p r o t e c t i o na g a i n s tc o r r o s i o nP
. O W E R p A R TL a y - U p
3 c a n b e u s e do n t h e t e r m i n a l s .
15. Seal the vent pipe of the fuel tank or the fuel filler
c a p w i t h w a t e r p r o otfa p e .
1 6 . R e m o v et h e f a n b e l t a n d p u t i t i n t o s t o r a g e .
17. To prevent corrosion, spray the engine with
P O W E R P A R TL a y - U p 3 D o n o t s p r a y i n s i d e t h e
a l t e r n a t o cr o o l i n gf a n a r e a .
NOTE:
B e f o r e t h e e n g i n e i s s t a r t e da f t e r a p e r i o d i n s t o r a g e ,
o p e r a t et h e s t a r t e rm o t o r w i t h t h e e n g i n es t o p c o n t r o li n
the 'off' position until oil pressureshows on the oil
p r e s s u r eg a u g e o r t h e o i l w a r n i n g l i g h t g o e s o u t l f a
solenoid stop control is used, this will have to be
d i s c o n n e c t e fdo r t h i s o o e r a t i o n
l f t h e e n g i n ep r o t e c t i o ni s d o n e c o r r e c t l ya c c o r d i n gt o t h e
a b o v e r e c o m m e n d a t i o n s ,n o c o r r o s i o n d a m a g e w i l l
n o r m a l l yo c c u r .P e r k i n sE n g i n e sL t d . a r e n o t r e s p o n s r b l e
f o r a n y d a m a g e t h a t o c c u r s i n r e l a t i o nt o a s e r v i c e
s t o r a g ep e r i o d .
E n g i n eC o o l a n t
T h e q u a l i t yo f t h e c o o l a n t u s e d c a n h a v e a l a r g e e f f e c t
o n t h e e f f i c i e n c ya n d l i f e o f t h e c o o l i n g s y s t e m . T h e
r e c o m m e n d a t i o ngs i v e n b e l o w c a n b e o f a s s i s t a n c ei n
t h e m a i n t e n a n c eo f a g o o d c o o l i n g s y s t e m w i t h f r o s t
a n d / o rc o r r o s i o np r o t e c t i o n
1 W h e r ep o s s i b l e u
, s e c l e a ns o f t w a t e r
2 . W h e r e f r o s t p r o t e c t i o ni s n o t n e c e s s a r y i,t i s s t i l l a n
a d v a n t a g et o u s e a n a p p r o v e d a n t i f r e e z em i x t u r e
( s e e 3 b e l o w ) a s t h i s g i v e s a p r o t e c t i o na g a i n s t
c o r r o s i o na n d a l s o r a i s e s t h e b o i l i n g p o i n t o f t h e
c o o l a n t A m i n i m u mc o n c e n t r a t i o on t 2 5 % b y v o l u m e
of antifreeze is necessary, but it is our
r e c o m m e n d a t i o tnh a t 3 3 % c o n c e n t r a t i o n bv volume
is used.
l f a n a n t i f r e e z ei s n o t u s e d , a d d a c o r r e c tc o r r o s i o n
inhibitor mixture to the water. The mixture of
a d d i t i v e sg i v e n b e l o w h a s b e e n f o u n d t o g i v e g o o d
r e s ul t s .
S o d i u mB e n z o a t e 1 0 - 1 5g r a m m e / l i t r e
S o d i u mN i t r i t e 1 - 2g r a m m e / l l t r e
Benzotriazole 0 . 5g r a m m e / l i t r e
p H ( a c i d / a l k a l i n eC) o n t r o lA d d i t i v e
Change the water/corrosion i n h i b i t o rm i x t u r ee v e r y
six months or check according to the inhibitor
m a n u f a c t u r e r 'rse c o m m e n d a t i o n s
N O T E : S o m e c o r r o s i o n i n h i b i t o rm i x t u r e s c o n t a i n
soluble oil which can have an adverse effect on
s o m e t y p e so f w a t e r h o s e .
3 . l f a n a n t i f r e e z em i x t u r e i s u s e d t o p r e v e n t f r o s t
d a m a g e ,i t m u s t h a v e a n e t h y l e n eg l y c o l( e t h a n e d i o l )
b a s e . A n a n t i f r e e z et h a t i S t o o n e o f t h e s t a n d a r d s
g i v e n b e l o w o r t o a n e q u a l s t a n d a r di s a c c e p t a b l ei f
t h e p H v a l u e i s k e p t w i t h i nt h e r a n g eo f 7 . 0 - 8 5 w h e n
diluted.
U . K . ,8 S 3 1 5 1 : 1 9 5 -9' E t h a n e d i o l A n t i f r e e zTe y p eB
w i t h S o d i u mB e n z o a t ea n d S o d i u mN i t r i t eI n h i b i t o r s '
U . S . A . , A S T M D 3 3 0 6 - 7 4- ' E t h y l e n e G t y c o t B a s e
E n g i n eC o o l a n t ' .
, S 2 1 0 8 - 1 9 7 7- ' A n t i f r e e z e C o m o o u n d s
A u s t r a l i aA
and Corrosion Inhibitors for Engine Cooling
Svstems'.
 O P E R A T I N GA N D M A I N T E N A N C E C 5

W h e n P e r k i n sP O W E R P A R TA n t i f r e e z ei s u s e d ,t h e not fitted to the radiator, disconnect the bottom

correct mixturesof antifreezeand water are as given radiatorhose.
b e l o w .P e r k i n sP O W E R P A R TA n t i f r e e z ef u l l yp a s s e s lf an oil cooler is fitted, drain the coolantfrom it by
the above standards. removingthe drainpluigfrom the end cap of the cooler
MixtureRatio (SectionL).
Lowest by Volume 6 . Wherenecessary,flushthe systemwith cleanwater.
temperature of % V o l u m eo f POWERPART 7 . Fit the drain plugs and radiatorcap. Where necessary,
Protection POWERPART Antifreeze: closethe radiatortap or connectthe radiatorhose.
Needed Antifreeze Water
-12'C ( 10'F) 25 lf the engineis to be left drainedduringfreezingcondi-
1:3
-18'C ( 0"F) 33 tions,removeone of the coolanthoseconnections at the
1:2
-2s'c (- 13'F) 40 cooler and insert 0.5 U.K. pints (250m1)of undiluted
1:1.5
-37'C (-34"F) 50 antifreezeinto the cooler.
1:1
-60'c (-76'F) 66 2:1
T h e q u a l i t y o f t h e a n t i fr e e z e c o o l a n t m u s t o e
checked at least once a year, for example, at the
s t a r to f t h e c o l d p e r i o d .
lf the correct procedures are not used, Perkrns
E n g i n e sL t d . c a n n o tb e h e l d r e s p o n s i b l e
for anyfrost
o r c o r r o s i o nd a m a g e .

To Drainthe CoolingSystem c.2

1. Ensure that the vehicle or machine is on level
ground.
2. R e m o v et h e r a d i a t o rf i l l e rc a o .
3. R e m o v et h e d r a i n p l u g f r o m t h e s i d e o f t h e c y l i n d e r
b l o c k t o d r a i n t h e e n g i n e .E n s u r et h a t t h e d r a i n h o l e
does not have any restriction.
4 . O p e n t h e t a p o r r e m o v et h e d r a i n p l u g a t t h e b o t t o m
o f t h e r a d i a t o rt o d r a i nt h e r a d i a t o r .l f a t a p o r p l u g i s
NOTE:
When drainingor fillingthe coolingsystemof a T6 3544CC
engine(integralinductionmanifoldand air chargecooler)the
vent plug on the outletconnectionof the coolershouldbe
removed (see Fig. C.2) and the plug replacedwhen the
systemhas beenfilled.

6 3544SeriesWorkshopManual,January1986
 SECTIOND
FaultFinding
F A U L TF I N D I N G D2

Fault Finding Chart

FAULT POSSIBLECAUSE

Low cranking speed 1 ,2 , 3 , 4 .

Will not start 5 , 6 , 7 , 8 , 9 , 1 0 ,1 2 ,1 3 ,1 4 ,1 5 ,1 6 ,1 7 ,1 8 , 1 9 , 2 0 , 2 2 , 3 1 , 3 2 , 3 3
D i f f i c u l ts t a r t i n g 5 , 7 , B , 9 , 1 0 ,1 1 ,1 2 ,1 3 , 1 4 ,1 5 ,1 6 ,1 8 , 1 9 ,2 0 , 2 1 ,2 2 , 2 4 ,2 9 ,3 1 , 3 2 , 3 3
Lack of power 8 , 9 , 1 0 ,1 1 ,1 2 ,1 3 ,1 4 ,18 , 19 , 2 0 ,2 1 ,2 2 ,2 3 ,2 4 ,2 5 ,2 6 ,2 7 ,3 1 ,3 2 ,3 3 ,6 0 ,6 2 ,6 3 .
Misfiring 8, 9, 10, 12, 13, 14, 16, 18, 19, 20, 25, 26, 28, 29, 30, 32.
Excessivefuel consumption 1 1 , 1 3 , 1 4 , 1 6 , 1 8 , 1 9 , 2 0 , 2 2 , 2 3 ,2 4 , 2 5 ,2 7 , 2 8 , 2 9 , 3 1 , 3 2 ,3 3 , 6 3
B l a c ke x h a u s t 1 1 ,1 3 , ' 1 41, 6 ,1 8 ,1 9 ,2 0 , 2 2 , 2 4 , 2 5 , 2 7 , 2 8 , 2 9 , 3 1 , 3 2 ,6303 ,
Blue/whiteexhaust 4 , 16 , 1B , 1 9 , 2 0 , 2 5 , 2 7 , 3 1 , 3 3 , 3 4 ,3 5 , 4 5 , 5 6 , 6 1 .
Low oil pressure 4, 36, 37, 38, 39, 40, 42, 43, 44, 58.
Knocking 9 , 1 4 , 1 6 , 1 8 , 1 9 ,2 2 , 2 6 , 2 8 , 2 9 , 3 1 ,3 3 , 3 5 , 3 6 , 4 5 , 4 6 , 5 9 .
E r r a t i cr u n n i n g 7, 8, 9, 10, 11, 12, 13, 14, 16, 20, 21, 23, 26,28, 29, 30, 33, 35, 45, 59
Vibration 13, 14,20, 23,25, 26,29, 30, 33, 45, 47, 48, 49.
Highoil pressure 4 , 3 8 ,4 1
Overheating 11, 13, 14, 16, 18, 19, 24, 25, 45,47, 50, 51, 52, 53, 54,s7.
Excessivecrankcaseoressure 25, 31, 33, 34, 45, 55, 64
Poor compression

Startsand stops 1 0 ,1 1 ,1 2 .

Key to Fault Finding Chart 33. B r o k e n ,w o r n o r s t i c k i n gp i s t o nr i n g ( s ) .

1. Batterycapacity low. 34. Worn valve stems and guides.
2. Bad electricalconnections 35. Overfullair cleaneror use of incorrectgrade of oil
3 Faultystarter motor. 36 Worn or damaged bearings.
4. Incorrecg t r a d eo f l u b r i c a t i n go i l . 37 I n s u f f i c i e not i l i n s u m o .
5. Low cranking speed 38. Inaccurategauge.
6 F u e lt a n k e m p t y . 39. Oil pumpworn
7 Faultystop control operation 40 Pressurerelielfvalve sticking open.
8. Blocked fuel feed pipe. 41. Pressurerelief valve sticking closed.
9. F a u l t yf u e l l i f t p u m p 42. Broken reliefvalve spring.
10. C h o k e df u e l f i l t e r . 43 Faulty suction pipe.
11. R e s t r i c t i o ni n i n d u c t i o ns v s t e m . 44. Choked oil filter.
12. Air in fuel system. 45. Piston seizure/pickup.
13. F a u l t yf u e l i n j e c t i o np u m p . 46 Incorrectpiston height.
14. Faulty atomisersor incorrecttype. 47. Damagedfan.
15. I n c o r r e c tu s e o f c o l d s t a r te q u i p m e n t . 48. F a u l t ye n g i n em o u n t i n g( h o u s i n g ) .
16. F a u l t yc o l d s t a r t i n ge q u i p m e n t . 49. Incorrectlyaligned flywheel housing or flywheel.
17. B r o k e nf u e l i n j e c t i o np u m p d r i v e . 50 Faultythermostat
18. I n c o r r e c ft u e l p u m p t i m i n g . 51 Restrictionin water jacket.
19. I n c o r r e c vt a l v et i m i n g 52 Loose water pump drive belts.
20. Poor compression. 53 Choked radiator
21. Blockedfuel tank vent. 54. Faultywaterpump.
22. Incorrecttype or grade of fuel | 55. Chokedbreatherpipe/Defective breathervent varve
23. Sticking throttle or restrictedmovement. | (wherefitted).
24. Exhaustpipe restriction. 56. Damagedvalve stem oil deflectors(if fitted).
25. C y l i n d e rh e a dg a s k e tl e a k i n g 57. Coolantleveltoo low.
26. Overheating. 58. Blockedsump strainer.
27 Coldrunning. 59. Brokenvalvespring.
28 Incorrecttappet adjustment. 60. Damagedor dirtyturbochargerimpeller.
29 Sticking valves. 61. Leakingturbochargeroil seals.
30. Incorrecthigh pressurepipes. 62. Leakingboostcontrolpipe.
31. W o r n c y l i n d e rb o r e s . 63. Leakinginductionsystem.
32 Pittedvalvesand seats. | 64. Faultin exhauster.

6 3544SeriesWorkshopManual,Aprit83
 SECTIONE
GylinderHead

@e
C Y L I N D E RH E A D E2

To Removethe Cylinder Head

The T6 3544,63544or 6.3724cylinder head is not inter-
c h a n g e a b l ew i t h a n y o t h e r 6 3 5 4 o r T 6 . 3 5 4e n g i n et y p e
c y l i n d e rh e a d s
D r a i nt h e c o o l i n gs y s t e m .
D i s c o n n e c bt a t t e r yt e r m i n a l s .
R e m o v ea i r c l e a n e ra n d t r u n k i n g
Remove exhaust pipe from exhaust manifold (6 3544
e n g i n e so n l y )

D i s c o n n e c ta n d r e m o v e a l l c o n n e c t i o n st o t h e t u r b o -
c h a r g e r a n d r e m o v e t h e t u r b o c h a r g e r ,s e e F i g E 1 .
( T O3 5 4 4e n g i n e so n l y )
Remove electrical connections to the cylinder
. e m o v ef u e l p i p et o t h e r m o -
h e a da n d i n d u c t i o nm a n i f o l d R
s t a r ti n t h e m a n i f o l d
R e m o v et h e w a t e ro u t l e tc o n n e c t i o n .
R e m o v et h e i n d u c t i o na n d e x h a u s tm a n i f o l d s
The fuel pipe from lift pump to fuel filtersshould be
r e m o v e d r, e l e a s i n gt h e c l i p f r o m t h e b a c k o f t h e c y l i n d e r
h e a d .T h e f u e l f i l t e r sm a y a l s o b e r e m o v e d
A l l h i g h p r e s s u r ep i p e sb e t w e e nf u e l i n j e c t i o np u m p a n d
t h e a t o m i s e r ss h o u l d b e r e m o v e d t o g e t h e r w i t h t h e
.9A Oa OA OA a)a 0a
atomisersleak-off pipe assembly.
OB OB OB OB OB OB
R e m o v ea t o m i s e r ss, e e F i g E 2 O D O E @ E O E O E O E D
Disconnect the breather pipe from the rocker cover
a n d c y l i n d e rb l o c k R e m o v et h e b r e a t h e rp i p e O D O E O E O E O E O E D
Removerocker cover and gasket oc oc oc oc oc oc oc oc oc oc oc oc
Release rocker assembly bracket securing setscrews
and lift off rocker assembly.Removethe push rods
n
Remove cylinder head nuts and setscrews in reverse n m l l
o r d e r o f t i g h t e n i n gs e q u e n c es, e e F i g . E . 4 . l l l l n l n
N o t ep o s i t i o no f d i f f e r e nlte n g t hs e t s c r e w ss,e eF i g .E 3 .
A
l ] u u r J l J
B C D E
R e m o v ec v l i n d e rh e a d
E.3

O3o O2o O1o

O31 O32 O21 O22 Ofl

E.4
To Fit the CylinderHead
E n s u r et h e h e a df a c e ,c y l i n d e rb l o c k t o p f a c e a n d b o r e s
a r e c l e a na n d t h a t t h e r o c k e ra s s e m b l yo i l f e e d p a s s a g e
i n t h e c y l i n d e rh e a di s c l e a n
Any cylinderhead studs removedfrom the cylinder
b l o c k s h o u l db e r e fi t t e dw i t h " L o c t i t e "
The cylinderhead gasketfitted to the T6 3544and 6 3544
e n g i n e i s n o t i n t e r c h a n g e a b lw e ith other 6.354series
e n g i n e s l t i s m a r k e d" T O P F R O N T "
A d i f f e r e n tc y l i n d e r h e a d g a s k e t i s u s e d o n 6 3 7 2 4
e n g i n e sd u e t o t h e l a r g e rb o r e s i z e
T h e c y l i n d e rh e a dg a s k e tm u s tb e f i t t e dd r y F i t t h e g a s k e t
e n s u r i n gi t i s c o r r e c t l yl o c a t e do v e r t h e t w o d o w e l s
L o w e rt h e c y l i n d e rh e a di n p o s i t i o nw i t h o u td i s t u r b i n gt h e
gasket
L i g h t l y o i l t h r e a d so f c y l i n d e rh e a d s e c u r i n gs t u d s a n d
E.1 SEISCTEWS
 C Y L I N D E RH E A D E3

See Fig E 3 for correct location of long and short ally aspiratedengines can have a set of steel asbesrosor
setscrews corrugatedstainlesssteel joints fitted. Steel asbestosjoints
P r o g r e s s i v e l yt i g h t e n t h e c y l i n d e r h e a d s e c u r i n g n u t s shouldbe fittedwith jointingcompound,but the corrugated
a n d s e t s c r e w s n, u m b e r s1 t o 3 2 o n l y i n t h e o r d e r s h o w n joints shouldbe fitteddry and so positionedthat the corruga-
i n F i g . E . 4 t o 1 1 5 l b ff t ( 1 5 , 9k g f m ) 15 6 N m w h e n c o t d tionsshouldfacethe manifold.
where the washerface is formedwith the head of the
s e t s c r e wo r n u t o r t o 9 5 l b ff t ( 1 3 , 1k g f m ) i 3 0 N m w h e r e A one pieceexhaust/induction manifoldjointwith an integral
s e p a r a t ew a s h e r sa r e f i t t e d .T h e n p r o g r e s s i v e l tyi g h t e n heat shield is fitted to some engineswhich have the top
t h e s m a l l s e t s c r e w sn u m b e r e d3 3 t o 3 8 i n t h e s e q u e n c e exhaustmanifoldoutlet An improvedrockerassemblycover
s h o w ni n F i g , E . 4 t o 2 8 l b ff t ( 3 , 9k g f m ) 3 8 N m . gasketis alsof ittedto theseengines.
Whenthe gasketsneedto be renewedthe sametype gasket
R e p l a c ep u s h r o d s .
mustbe used,
R e n e w t h e r o c k e r a s s e m b l yf e e d p i p e o i l s e a l , l i g h t l y
o i l i n gi t s i n n e ra n d o u t e rs u r f a c e s a Refit the water outlet connection.
, n d p l a c i n gi t i n t h e o i l
f e e dd r i l l i n g . Connect the electrical lead, fuel feed and return pipes
E x a m i n ea n d r e p l a c et h e r o c k e ra s s e m b l y e t o t h e t h e r m o s t a rut n i t a n d c o n t a i n e r .
, n s u r i n gt h a t
t h e o i l f e e d p i p e , w h i c h h a s a l e a d i n , l o c a t e sc o r r e c t l y Connect any other electricallead (i.e water temperarure
i n t o t h e d r i l l i n g ,w h e n t h e s e a l w i l l b u t t a g a i n s t t h e gauge).
c o n v o l u t i o ns, e e F i g . E , 5 . R e f i t t h e t u r b o c h a r g e r( T 6 . 3 5 4 4e n g i n e s o n l y ) a n d a l l
The rocker assemblysecuringsetscrews,studs and nuts connectionsto it.
should be tighteneddown progressivelyfrom the centre
outwardsto a torque of 55 lbfft (7,60kgfm) or 75Nm. Set R e f i tt r u n k i n ga n d a i r c l e a n e r
v a l v ec l e a r a n c e tso 0 . 0 0 8 i n( 0 , 2 0 m m )f o r i n l e tv a l v e sa n d R e f i te x h a u s tp i p e t o e x h a u s tm a n i f o l d( 6 3 5 4 4o r 6 3 7 2 4
0 . 0 1 8 i n( 0 , 4 5 m m f)o r e x h a u svt a l v e s e
, n g i n eh o to r c o l d ,a s engrneo snly)
detailedon Page E.4.
Refitatomiserswithnewcoppersealingwashers.Ensurethat Reconnectthe battery.
a serviceabledust seal is fitted to the atomiser.Earlierdust R e f i l lt h e c o o l i n gs y s t e m .
seals consisted of a single piece rubber seal, later
arrangements use a two piecedust seal whichconsistsof a B l e e dt h e f u e l s y s t e mo f a i r a s d e t a i l e do n p a g e N . 7 a n d
plasticor aluminiumspacerand a rubberseal. The spacer s t a r tt h e e n g i n e
must be fitteddirectlyunderthe atomiserflangewiththe soft
rubberseal up againstthe spacerat the noizle end of the C h e c kt h e o i l f l o w t o t h e r o c k e rs h a f ta s s e m b l va n d a l l o w
atomiser.Now tighten nuts/setscrewsevenly to a torque of t h e e n g i n et o w a r m u p
l 2 l b f t ( 1, 7k g fm ) o r 16 N m .
S h u t t h e e n g i n e d o w n , a n d r e t i g h t e nt h e c y l i n d e r h e a d
Note: Differentatomiserseatingwashersare usedon natur- securing nuts and setscrewsto the correct torques as
ally aspirated and turbochargedengines. The seating d e t a i l e dp r e v i o u s l y .
washers for naturally aspirated engines are 0.0g0in
(2,03mm) thick and for turbochargedengines, O.02Bin F o r n u t s a n d s e t s c r e w s ,n u m b e r s 1 t o 3 2 w h e r e t h e
(0,71mm) thick. lt is importantthat the correct atomiser w a s h e rf a c e i s f o r m e dw i t h t h e h e a d o f t h e s e t s c r e w t, h e
seatingwashersarefitted. c o r r e c t t o r q u e w h e n h o t i s 1 0 5l b f f t ( 1 4 , 5 k g f m )-
1 4 2N m .
For the T6.3544NorthAmericavehicleenginesthe atomrser
seatingwasheris 0.0B0in(2,03mm)thick W h e n r e t i g h t e n i n gc y l i n d e r h e a d n u t s / s e t s c r e w st,h e
Top entryatomiserswhichare used on some 6.3544serres
enginescan be fittedincorrectly withthe atomiserturned180"
out of positionIn this position,the nozzleholeswill not spray
into the combustionchambercorrectlyand this will causea
powerlossand an increasein smokeemission
These atomisersmust be fittedwith the leak off connection
towardthefuelinjectionpumpside
Refitall high pressurefuel pipes,leak-offpipesand the fuel
filters
T i g h t e n h i g h p r e s s u r ep i p e n u t s t o a t o r q u e o f 1 5 l b ff t
( 2 , 1k g fm ) o r 2 0 N m
R e f i t f u epl i p ef r o m l i f t p u m pt o f i l t e r st,h i s p i p ei s c l i p p e d E.5
o n t o b a c k o f c y l i n d e rh e a d
R e f i ti n d u c t i o na n d e x h a u s tm a n i f o l d s .
I n l e t m a n i f o l d sh a v e c o r r u g a t e dj o i n t s w h i c h a r e c o a t e d
w i t h l a c q u e ra n d s h o u l da l w a y sb e f i t t e d c l r y T h e j o i n t s
a r e n o t s y m m e t r i c aal n d c a n b e f i t t e d i n c o r r e c i l y W . ith
t h e e a r l i e rj o i n t s , t h e l a r g e r j o i n t s h o u l d b e f i t t e d w i t h
0 0 0 8i n ( 0 , 2 0m m ) i n l e t
p a r a l l e le d g e u p p e r m o s ta n d t h e s m a l l e rj o i n t w i t h t h e
0 . 0 1 8i n ( 0 , 4 5m m ) exhaust
w i d e r s p a c e dh o l e a n d t h e w o r d " C O R R O J O I N Tt"o t h e
bottom
Laterjointshavea 1Aain (1,63mm) radiusin the top edgeand
must alwaysbe fittedwith this radrusuppermost.The man-
ifold securingsetscrewsshouldbe tightenedto a torqueof
24lbfft (3,3kgfm) or 32Nm. After at leastten minutesafter
fitting,retorquethe setscrewsto the originalfigure THIS lS
IMPORTANT With exhaust manifoldjoints, turbocharged
engineshavecorrugated stainless steeljoints,whereasnatur- E.6

6 3544SeriesWorkshopManual,January1986
C Y L I N D E RH E A D E4

e n g i n e c o o l a n t t e m p e r a t u r es h o u l d n o t b e l e s s t h a n W i t h t h e v a l v e sr o c k i l n go n N o . 6 c y l i n d e r( i . e .t h e p e r i o d
170"F (77"C\. b e t w e e no p e n i n g o f i n l e t v a l v e a n d c l o s i n g o f e x h a u s t
lf the nut/setscrew moves when retightening, then v a l v e )s e t t h e c l e a r a n c e so n N o . 1 c y l i n d e r
t i g h t e nu p t o t h e t o r q u eq u o t e do n P a g e 8 . 1 .
W i t h v a l v e sr o c k i n gN o 2 - s e t c l e a r a n c e sN o 5
lf the nut/setscrew does not move before the correct W i t h v a l v e sr o c k i n gN o . 4 - s e t c l e a r a n c e sN o 3 .
t o r q u e i s a c h i e v e dt,h e n s l a c k e no f t 1 / 1 2 t o 1 / 6 ( 3 0 ' t o W i t h v a l v e sr o c k i n gN o . 1 - s e t c l e a r a n c e sN o . 6 .
6 0 " ) o f a t u r n a n d r e t i g h t e nt o t h e c o r r e c t f i g u r e .A f t e r W i t h v a l v e sr o c k i n gN o . 5 - s e t c l e a r a n c e sN o 2 .
r e t i g h t e n i n ga l l t h e n u t s / s e t s c r e w s t, h e f i r s t 1 0 p o s i - W i t h v a l v e sr o c k i n gN o . 3 - s e t c l e a r a n c e sN o . 4 .
t i o n s s h o u l d b e r e c h e c k e d ' w i t h o u ft u r t h e r s l a c k e n i n g
To Remove Valves
off, to ascertain they are still tightened to the correct
torque. Fit a suitable stud in one of the rocker assemblysecur-
ing setscrew holes and using Tool No. 61188 and
R e s e t t h e v a l v e c l e a r a n c e st o 0 . 0 0 8 i n ( 0 , 2 0 m m ) f o r a d a p t o r P D . 6 1 1 8 - 4s,e e F l g . E . 7 , d e p r e s sv a l v e s p r i n g s
i n l e t v a l v e sa n d 0 . 0 1 8 i n ( 0 , 4 5 m m ) f o r e x h a u s tv a l v e s and remove split collets.
hot or cold

Refitthe rockercoverjoint, rockercoverand breatherpipe.

To put a rockercoverjoint on correctlyit mustfirst be fittedto
the rocker cover by use of a suitable Bostic type contact
adhesive.The adhesivemust be appliedaccordingto the
manufacturer's instructions.This procedurewill ensurethat
there is a goodseal all roundthe cover.
W h e n r e p l a c i n gt h e c y l i n d e rh e a d c o v e r ,e n s u r et h a t t h e
c o v e r r e t a i n i n gn u t s a r e s c r e w e df u l l y h o m e a g a i n s tt h e
rocker shaft bracketretainingnuts.
Where a washer is fitted under the head of each of the
rocker cover nuts, a washer is also fitted between the
r o c k e r b r a c k e ts e c u r i n gn u t a n d t h e c o v e r n u t . W h e r e a
washer face is formed integral with the cover nut, a
separatewasher must not be fitted under the cover nut
o r b e t w e e nt h e c o v e r n u t a n d t h e r o c k e r b r a c k e tn u t
To Check or Adjust Valve Tip Clearances
T h e v a l v e t i p c l e a r a n c e ss h o u l d b e s e t t o 0 . 0 0 8 i n
( 0 , 2 0 m m ) f o r i n l e t a n d 0 . 0 1 8i n ( 0 , 4 5 m m ) f o r e x h a u s t
by using a feeler gauge between top of valve stem and
r o c k e r l e v e r ,w i t h t h e e n g i n e h o t o r c o l d , s e e F i g . E . 6 .
W h e n s e t t i n gv a l v ec l e a r a n c e st,h e f o l l o w i n g p r o c e d u r e
s h o u l db e a d o o t e d .
E.8
R e m o v e s p r i n g r e t a i n i n gc a p s , s p r i n g s , o i l s e a l s a n d
s p r i n gs e a t i n gw a s h e r s R e m o v ev a l v e s .
l f t h e v a l v e sa r e t o b e u s e da g a i n ,t h e y s h o u l db e s u i t a b l y
marked to ensure they are replacedin their original
positions.

ValveAssembly
T w o s p r i n g sa r e f i t t e dt o e a c hv a l v e ,t h e o u t e rs p r i n g sa r e
l e f th a n dc o i l e da n d t h e i n n e rs p r i n g sr i g h th a n dc o i l e d
A s e c t i o n a vl r e w o f a f i t t e d v a l v e a s s e m b l yi s s h o w n i n
Fig EB

To Fit Valves
L i g h t l y o i l v a l v es t e m s ,a n d p o s i t i o n t h e v a l v e si n t h e r r
rocnontirro nrrirleq

P o s i t i o ns p r i n g s e a t i n g w a s h e r sa n d f i t o i l s e a l s o n t o
v a l v eg u i d e s .
Note: Enginesrated at 149kW (200bhp)or above must be
fitted with exhaust valves which have "Nimonic" heads.
Standardvalvesmustnot be used.
P l a c e i n n e r a n d o u t e r s p r i n g s o n s e a t i n gw a s h e r sw i t h
t h e d a m p e rc o i l s t o w a r d st h e c y l i n d e rh e a d ,s e e F i g E . 8
P o s i t i o nt h e v a l v e s p r i n g r e t a i n i n g c a p s a n d w i t h a
s u i t a b l e c o m p r e s s o r ,d e p r e s s t h e s p r i n g s a n d f i t t h e
s o l i tc o l l e t s
ValveGuides
E.7 Examinevalve guides for wear The maximum per-

6 3544SeriesWorkshoplvlanual,
January1986
 C Y L I N D E RH E A D E5

T h e c y l i n d e rh e a d c a n b e s k i m m e d b y a m a x i m u m o f
0 . 0 1 2 i n( 0 , 3 m m )p r o v i d e dt h a t n o z z l ep r o t r u s i o nd o e sn o t
. 1 8 4 i n( 4 , 6 7 m m )
e x c e e d0 t o r f 6 3 5 4 4e n g i n e so r 0 1 3 6 i n
( 3 , 4 5 m m t)o ( 6 . 3 5 4 4 a n d 6 . 3 7 2e4n g i n e sw i t h t h e a t o m i s e r
s e a t i n gw a s h e r si n p o s i t i o n ,s e e F i g E . 1 1 .T h i s f i g u r e
must not be obtained by the use of additional atomiser
seatingwashers.
W h e n g r i n d i n g i n v a l v e s ,i t i s e s s e n t i a tl h a t n o s i g n s o f
p i t t i n ga r e l e f t o n t h e s e a t i n g s
C a r es h o u l db et a k e nt o a v o i du n n e c e s s a r yg r i n d i n g a w a y
of the seat.
After grinding, check the valve head depths relative to
t h e c y l i n d e rh e a d f a c e , u s i n gt o o l P D 4 1 B .T h e m a x i m u m
permissibledepth for both inlet and exhaustvalves after
s e r v i c i n gi s 0 . 0 6 0i n ( 1 , 5 2m m ) .
After any grinding or machiningoperationhas been
c a r r i e do u t , a l l p a r t ss h o u l db e w a s h e di n c l e a n i n gf l u i d .
Valvesand Valve Seats
Examine valves for cracks. Check wear of valve stems
a n d t h e i r f i ti n t h e v a l v eg u i d e s
When fitting new valves, valve depths relative to the
c y l i n d e rh e a df a c e i s n o t l e s st h a n 0 . 0 4 0 i n( 1 0 2 m m ) .
The valveseats in the cylinderhead should be recon-
ditioned by means of valve seat cutters as listed in
a p p r o v e dt o o l s a t t h e e n d o f t h i s s e c t i o n ,o r s p e c i a l i s e d
g r i n d i n ge q u i p m e n ia t a n a n g l eo f 4 5 o

E.9

m i s s i b l ew o r n c l e a r a n c eo f i n l e t v a l v e s t e m i n g u i d e i s
0 0 0 5 i n ( 0 , 1 3 m m )a, n d e x h a u s tv a l v e s t e m i n g u i d e i s
0 0 0 6 i n ( 0 , 1 5 m m )a n d i f t h e c l e a r a n c ew i t h n e w v a l v e
f i t t e d e x c e e d st h i s f i g u r e t h e g u i d e s h o u l d b e r e p l a c e d .
T h e e x h a u s tv a l v e g u i d e s a r e s l i g h t l y l o n g e r t h a n t h e
inlet guides and the exhaust valve guides used on
c u r r e n t 6 . 3 5 4 4a n d .6 . 3 7 2 4e n g i n e sh a v e a c o u n t e r b o r e
at the bottom of the valve bore.
T o f i t n e w g u i d e s ,p r e s so r d r i v eo u t t h e w o r n g u i d e s ,s e e
Fig E.9
S m e a r t h e o u t e r s u r f a c eo f t h e n e w g u i d e s w i t h c l e a n
o i l a n d u s i n gt o o l N o P D 1 C ,s e eF i g .E 1 0 ,p u l l g u i d ei n t o
t h e c y l i n d e rh e a d u s i n g s t o p N o . P D l C - 6 u n t i l
0 594in (15,08mmo ) f t h e g u i d e i s p r o t r u d i n ga b o v e t h e
v a l v es p r i n g r e c e s s .
CylinderHead Overhaul
l f w a t e r j a c k e t o f c y l i n d e rh e a d s h o w s s i g n o f s c a l e ,a
p r o p r i e t a r yd e s c a l i n gs o l u t i o ns h o u l db e u s e d i n a c c o r d -
a n c e w i t h t h e m a n u f a c t u r e r 'isn s t r u c t i o n s .
A f t e r c l e a n i n gh e a d ,c h e c k f o r c r a c k s o r o t h e r d a m a g e .
M a x i m u mp e r m i s s i b l el o n g i t u d r n abl o w o f c y l i n d e rh e a d
i s 0 . 0 1 0 i n ( 0 , 2 5 m m ) a n d l : r a n s v e r s eb o w i s 0 . 0 0 5 i n
( 0 , 1 3m m ) . E.10

6 3544SeriesWorkshopManual,January1986
C Y L I N D E RH E A D E6

T 6 . 3 5 4 4 - 0 . 1 8 4i n ( 4 , 6 7m m )
6 . 3 5 4 4 - 0 . 1 3 6i n ( 3 , 4 5m m )
6 . 3 7 2 4 - 0 . 1 3 6i n ( 3 , 4 5m m )
E.11
U s i n gt h e v a l v eg u i d e b o r e a s a p i l o t ,m a c h i n et h e " f t a r e "
o n i n l e t v a l v e s e a t i n s e r t st o t h e d i m e n s i o n ss h o w n r n
F i g .E . 1 4 D
. i m e n s i o nA i s0 . 1 0 6 / 0 . 1 1i n
0(2,69/2,79mm).
Cut the valveseat at an included angle of 90o so that the
v a l v eh e a d d e p t h b e l o w t h e c y l i n d e rh e a d f a c e i s w i t h i n
the production Ii mitsof 0.040/0.050 i n (1,02/1,27mm).
3 . 7 3 5i n W o r k a s c l o s e l y a s p o s s i b l et o t h e m j n i m u m f i g u r e t o
( 9 4 , 8 7m m ) allow for re*seatingat a later date.When refacinga valve
MIN. t h e i n c l u d e da n g l eo f t h e c o n t a c tf a c e i s g 0 o .
L i g h t l yg r i n d i n v a l v ea n d v a l v es e a t ,k e e p i n ga s n a r r o wa
seat as possible.
MAX 0.012in MAX. l f t h e c y l i n d e rh e a dh a s b e e ns k i m m e d t, h e i n s e r tw i l l h a v e
(0,30mm)
to be surfaceground on its back face so that, with insert
fitted, faces of insert and cylinder head are level

lnlet
A-o.283 I0.288in (7,19/7,32mm)
g-2.0 16512.0175in (51,22t51,24mm)
C - R a d i u s 0 . 0 1 5 i n( 0 , 3 8 m mM
) ax.
Exhaust
A-0.375/0.380in (9,53/9,65
mm)
.679in(42,62142,65mm)
B-1 .67811
C-Radius 0.015 in (0,38mm) Max.
Afterreconditioning,
valvesand seatsshouldbe lightlyground
in, keepingas narrowa seat as possible,and aftergrinding,
the valveheaddepthshouldbe checked. lnlet
Valve Seat Inserts A-Xain (1,59mm)at 45'
B-3/cin (19,05mm)
Valve seat inserts are fitted as standard on T63544
C-0.250 in (6,35mm)
e n g i n e s b, u t a r e n o t f i t t e do n 6 3 5 4 4o r 6 3 7 2 4p r o d u c t i o n
D - 3 . 0 i n ( 7 6 , 2 0m m )
e n gIn e s
E - 1 . 5 8 2 / 1. 5 8 3i n ( 4 0 , 1 8 / 4 0 , 2m1m )
l f v a l v es e a t sb e c o m ed a m a g e do r u n s e r v i c e a b lteh r o u g h F -2.009/2.019in (51,03/51,28mm)
wear, insertscan be fitted to 6 3544 and 63724 enqines G-%zin (0,79mm)radius
o r t h e i n s e r t sr e p l a c e do n T 6 3 5 4 4e n g i n e s H - h a i n ( 1 , 5 9 m m )r a d i u s
P r e s so u t t h e e x i s t i n gv a l v eg u i d e a n d c l e a n t h e g u i d e J - X e i n ( 1 , 5 9m m ) a t 4 5 '
bore K-0.372/0.373in (9,4519,47 mm)
P r e s si n n e w g u i d e sa s d e t a i l e do n P a g eE 4 Exhaust
U s i n gt h e v a l v eg u i d ea s a p i l o t ,m a c h i n et h e r e c e s si n t h e 4 - l a i n ( 1 , 5 9 m ma) t 4 5 '
c y l i n d e rh e a d t o t h e d i m e n s i o n sg i v e n i n F i g E 1 2 f o r B-3/qin (19,05mm)
6 3 5 4 4 o r 6 3 7 2 4e n g i n e s ;o r m a c h i n eo u t t h e o l d i n s e r t C - 0 . 3 1 2 i n ( 7 , 9 2m m ) .
f o r T 6 3 5 4 4e n g i n e s . D-3.0 in (76,20mm)
R e m o v ea l l m a c h i n i n gs w a r fa n d c l e a nt h e i n s e r tr e c e s s E-1 .248/1.249in(31,70131 ,72mm)
F-1 .670/1.680in(42,42142,67mm)
U s i n g t h e v a l v e g u i d e b o r e a s a p i l o t , p r e s st h e i n s e r t G*%zin (0,79mm)radius
h o m e w i t h t h e i n s e r t i n gt o o l , F i g E . 1 3 .D o n o t h a m m e r H - / * i n ( 1 , 5 9m m ) r a d i u s
t h e i n s e r th o m e o r u s e l u b r i c a t i o nE n s u r et h a t t h e i n s e r t J -%ain (1,59mm) at 45'
i s f u l l y h o m e a n d f l u s h w i t h t h e b o t t o mo f r e c e s s K-0.372/0.373 in (9,4519,47 mm)

6 3544SenesWorkshopN.4anual,
January1986

E.14
ValveSprings
A new set of springs should be fitted at every major
overhaul.
I Examinethe springswith regardto squarenessof ends and
I pressuresdevelopedat fittedlengths.
T w o t y p e s o f v a l v e s p r i n g s c a n b e f o u n d a c c o r d i n gt o
the camshaft fitted. They are of different lengths the
l o n g e r v a l v es p r i n g sh a v i n ga f l a t v a l v e s p r i n g c a p .
The shorter inner valve springs require a load of 20.1/
2 3 3 l b f ( 9 , 1 3 / 1 0 , 5 8k g f) t o c o m p r e s st h e m t o a f i t t d d
l e n g t h o i 1 3 4 0 i n ( 3 4 , 0 4m m ) .
T h e s h o r t e ro u t e r v a l v e s p r i n g s r e q u i r ea l o a d o f 3 9 . 5 /
4 3 7 l b f ( 1 7 , 9 3 / 1 9 , 8 4k g f) t o c o m p r e s st h e m t o a f i t t e d
l e n g t ho f 1 4 1 0 i n ( 3 5 , 8 1m m ) .
T h e l o n g e r i n n e r v a l v e s p r i n g s r e q u i r ea l o a d o f 1 4 6 3 /
1 6 6 7 l b f ( 6 , 6 4 / 7 , 5 7m m ) t o c o m p r e s st h e m t o a f i t t e d
l e n g t ho f 1 . 5 6 3i n ( 3 9 , 7 0m m ) .
T h e l o n g e r o u t e r v a l v e s p r i n g s r e q u i r ea l o a d o f 3 8 / 4 3
lbI (17,25/19,52 kgf) to compress them to a fitted
l e n g t ho f 1 . 7 8 0i n ( 4 5 , 2 0m m )
E.15
E.16
6 3544SeriesWorkshopManual,January1986
C Y L I N D E RH E A D E7
Rocker Shaft Assembly
To dismantle
Removecirclips and washersfrom each end of shaft.
Withdrawrockerlevers,springsand supportbrackets
Remove the locating screw from the rocker oil feed
c o n n e c t i o na n d w i t h d r a wt h e c o n n e c t i o n .
Examinerocker leverbores and shaft for wear.The levers
should be an easy fit on the shaft without excessiveside
p l a ya n d t h e r es h o u l db e n o i n d e n t a t i o nw h e r et h e r o c k e r
taps the valvetip.
To renew the rocker lever bushes, press out the worn
b u s h e sa n d p r e s s i n t h e n e w b u s h e sm a k i n g s u r e t h a t
t h e o i l h o l e s a r e i n l i n e ,s e e F i g . E 1 5 .
Ream out to a diameter of 0 7505/O7520in (19.06/
.19.10
mm)
To assemble.
Fit oil feed connection to rocker shaft and secure with
l o c a t i n gs c r e w ,e n s u r i n gt h a t t h e s c r e we n t e r st h e l o c a t i n g
holein the shaft
F i t t h e s u p p o r t b r a c k e t s ,s p r i n g s a n d r o c k e r l e v e r s i n
t h e c o r r e c to r d e r ,s e e F i g E 1 6 .
F i t s e c u r i n gw a s h e ra n d c i r c l i pt o e a c h e n d o f t h e s h a f t .
Push Rods
Check push rods for straightness lf any are bent, fit
replacements.
BreatherVent Valve
On 6.3544engines,a vent valve is sometimesfittedbetween
the rocker cover and the inlet manifold.This unit can be
cleanedin petrol (gasoline)or paraffin(kerosene)notingthe
followingcriticalpoints:-
1 . B e f o r ec l e a n i n g ,i t i s e s s e n t i a tl o s e a l o f f t h e s m a l l
hole in the top coverof the unit.
2 . l I a n a i r l i n e i s u s e d t o d r y o u t t h e u n i t ,t h i s m u s t
b e a l o w p r e s s u r ea i r b l a s t o r i r r e p a r a b l ed a m a g e
will result.
tt*
 SECTIONF
Pistonsand GonnectingRods
P I S T O N SA N D C O N N E C T I N GR O D S F2

The pistonsfittedto the T6.3544and 6.3544enginehave an

insertin the top ringgrooveand are not commonto the 6.354
engrnesenes. .rtt=-.4,-\\
Nor are T6.3544and 6.3544 pistonsinterchangeable as the
turbocharged pistonhas a largergudgeonpin.
I ForT6.3544NorthAmericavehicleenginespistonsand rings
I see pageF.6.

i4'*

To remove Piston and Rod Assembly

..
S e eF i g .F . 1 .
ri
R e m o v ec y l i n d e rh e a d ,P a g e E 2 .
D r a i n l u b r i c a t i n go i l , r e m o v e s u m p a n d l u b r i c a t i n go i l
s u c t i o np i p e .P a g e L . 3 .
R e m o v ep i p e f r o m t h e r e d u c i n gv a l v e t o p i s t o n c o o l i n g
feed connection (T6.3544engines only)
W h e n p u s h i n gt h e p i s t o n a n d r o d a s s e m b l i e sf r o m o u t
of the top of the cylinders,care must be taken to avoid
damage to the piston cooling jets situated in the
c r a n k c a s e ,s e e F i g . F . 2 . ( T 6 3 5 4 4 e n g i n e s o n l y )

R e m o v et h e n u t s f r o m t h e b i g e n d b o l t s
R e m o v et h e b i g e n d c a p s ,b e a r i n gs h e l l sa n d b o l t s
F.2

T u r n c o n n e c t i n g r o d s i n a n a n t i - c l o c k w i s ed i r e c t i o n
a n d p r e s st h e p i s t o n a s s e m b l i e sf r o m o u t o f t h e t o p o f
t h e c y l i n d e rb o r e s ,s e e F i g F . 3
T h e p i s t o n s ,c o n n e c t i n gr o d s a n d c a p s a r e m a r k e dw i t h
t h e i r r e s p e c t i v ec y l i n d e r n u m b e r a n d s h o u l d b e k e p t
together as an assemblywith the relevantbig end
b e a rni o s .

To RemovePistonsand Rings from

ConnectingRods
An explodedvrew of a piston and connectingrod
a s s e m b l yi s s h o w n i n F i g F 1
N o t e : T h e n u m b e ro f p i s t o n r i n g s p e r p i s t o nc a n v a r y
a c c o r d i n gt o e n g i n et y p e a n d a p p l i c a t i o n( s e e P a g e F 4 ) .
U s i n g a r i n g s c r s s o rt o o J , r e m o v e t h e r i n g s f r o m t h e
pi s t o n s

e9 F.3

'82
6 3 5 4 4S e r i e sW o r k s h o pN / a n u a l ,s s u e2 , J u n e
 PISTONSAND CONNECTING
RODS F3

P r e s si n n e w b u s h e n s u r i n gt h a t o i l h o l e i n b u s h a l i g n s
w i t h d r i l l i n gi n r o d
H o n e o u t b u s h t o f i n i s h e dd i a m e t e ro f 1 5 0 0 7 5 / 15 0 1 5 i n
( 3 8 , 1 2 1 3 8 , 1 4 m mf o) ,r t u r b o c h a r g e de n g i n e s o r 1 . 3 7 5 8 /
'I
3765in (34,94/34,96 mm) for naturallyaspiratedengines
W i t h n a t u r a l l y a s p i r a t e de n g i n e s t h e c o n n e c t i n g r o d
s m a l le n d i s p a r a l l efla c e da n d t h e s m a l le n d b u s hr e q u i r e s
n o f u r t h e rm a c h i n i n g
W i t h t u r b o c h a r g e de n g i n e s , t h e s m a l l e n d o f t h e
c o n n e c t i n gr o d r s w e d g es h a p e da n d t h e s m a l le n d b u s h
s h o u l db e m a c h r n e tdo s u i tt h e c o n t o u r so f t h ew e d o e
R e m o v ea l l b u r r s
C h e c kf o r p a r a l l e l i s m
a n d t w i s tw i t h b i g e n d b o r e
To Check Piston Ring Gaps
I n a w o r n c y l i n d e r ,p i s t o n r i n g g a p s s h o u l d b e c h e c k e d
a t e x t r e m et o p o f c y l i n d e r a f t e r a n y c a r b o n h a s b e e n
r e m o v e ds, e e F i g F 6

F.4
l f t h e p i s t o n sa r e t o b e u s e d a g a i n ,n o t e t h e m a r k i n g so n
t h e p i s t o nc r o w n , s e e F i g F 4 , s o t h a t o n r e - a s s e m b l y ,
t h e y c a n b e f i t t e dt o t h e c o n n e c t i n gr o d s i n t h e i r o r i g i n a l
p o s i t i o n s ,i e t h r u s t s i d e o f p i s t o n t o t h r u s t s i d e o f t h e
engn re
R e m o v et h e c i r c l i p sa n d w i t h d r a wt h e g u d g e o np i n . l f t h e
pin is tight in the piston bore, heat the piston in fluid
to a temperature of 100/120"F (40/50"C), then press
t h e g u d g e o np i n o u t .
Inspection
C h e c k p i s t o n sf o r s c o r i n go r o t h e r d a m a g e
C h e c k p i s t o n r i n g g r o o v e s b y c h e c k i n g c l e a r a n c eo f
n e w r i n g s f i t t e d i n g r o o v e s .l f c l e a r a n c ei s f o u n d t o b e
e e wp i s t o n sm u s tb e f i t t e d .
e x c e s s i vn
E x a m i n eg u d g e o n p i n a n d p i s t o n b o r e s f o r w e a r a n d
c h e c k f i t o f p i n i n s m a l le n d b u s h
C h e c k c o n n e c t i n gr o d a l i g n m e n t T h e l a r g e a n d s m a l l
e n d b o r e s m u s t b e s q u a r e a n d p a r a l l e lt o e a c h o t h e r
w i t h i n t h e l i m i t s o f t 0 0 1 0 i n ( 0 , 2 5 m m ) m e a s u r e d5 i n
( 1 2 7 m m )e a c h s i d e o f a x i s o f r o d o n t e s t m a n d r e l a s
s h o w n i n F i g .F 5 .
With the small end bush fitted, the limit of t0.010in
( 0 , 2 5 m m )i s r e d u c e dt o t 0 0 0 2 5 i n ( 0 , 0 6 m m )
F o r p i s t o nr i n g g a p s ,s e e P a g e8 4
To AssemblePistonsand Connecting
Rods
A s s e m b l et h e p i s t o n ,r o d a n d g u d g e o n p i n , a n d f i t n e w
c i r cl i p s
l f n e c e s s a r yw , a r m t h e p i s t o n t o 1 O 0 / j 2 OF" ( 4 0 1 5 0 . C )
t o f i t t h e g u d g e o np i n
lf the old pistons are being used ensure they are
a s s e m b l e dt o t h e o r i g i n a l c o n n e c t i n gr o d s a n d i n t h e
s a m e p o s i t i o na s o r i g i n a l l ya s s e m b l e d .
T h e t o r o i d a lc a v i t y s h o u l d b e t o t h e s a m e s i d e a s t h e
m a r k i n g so n t h e c o n n e c t i n gr o d a n d c a p .
lf new parts are being fitted, mark piston crown and
a d j a c e n tf a c e s o f r o d a n d c a p w i t h t h e i r c o r r e s p o n d i n g
c y l i n d e rn u m b e r
The big end bearingshelltabs are fittedon the oppositeside
of the rodto the rod/bearing
cap numbers.
On fitmentthe rod/bearing cap numbermust be towardthe
fuelinjectionpumpsideof the engine.

To Renew Small End Bush

U s i n gs u i t a b l ea d a p t o r ,p r e s so u t w o r n b u s h
R e m o v ea n y s h a r p e d g e sf r o m a r o u n d s m a l l e n d p a r e n t
bore

- E
E
6 <r 5in 5in 9+
rn
I c\l
o o 121mm 127mm "o .R
i
+l +l :!;i

F.5 F.6

January1986
6 3544SeriesWorkshopN.4anual,
P I S T O N SA N D C O N N E C T I N GR O D S F4

T6.3544 6.3544

F.7

To Fit PistonRings
6.3544StandardEngines
P i s t o n r i n g l a y o u t sa r e a s f o l l o w s: -
No 1 C h r o m e I n s e r tC o m p r e s s i o n
T6.3s44(Fis. F.7) No 2 i n i e r n a i l yS t e p p e dC o m p r e s s i o n .
No 1 C h r o m e B a r r e lF a c e d W e d g eC o m p r e s s i o n
No 3 I n t e r n a l l yS t e p p e dC o m p r e s s i o n .
No.2 TaoerFaced.
No 4 S l o t t e dO i l C o n t r o l
N o . 3 C h r o m eF a c e d ,S p r i n gL o a d e dC o n f o r m a b l O
e il
No 5 S l o t t e dO i l C o n t r o l
Control.
F i t r i n g s a s f o l l o w s: -
F i t r i n g s a s f o l l o w s: -
Fit No 5 ring in bottomring groove.
Fit spring of No 3 oil control ring in grooveensuring
Fit No 4 ring in fourth ring groove.
that the latch pin enters both ends of the ring, see
F i g .F B Fit Nos 3 and 2 rings in the third and second ring
g r o o v e sw i t h t h e i n t e r n a ls t e p a n d t h e w o r d " T O P " o r
P o s i t i o no i l c o n t r o l r i n g o v e r s p r i n g w i t h s p r i n g c o r r e c t -
s a r k s t o w a r d st h e p i s t o nc r o w n .
m a n u f a c t u r e r 'm
l y l o c a t e di n g r o o v e o f r i n g a n d r i n g g a p d i a m e t r i c a l l y
o p p o s i t et o l a t c h p i n Fit No 1 ring in top ring groove.
F i t t a p e r f a c e d N o . 2 c o m p r e s s i o nr i n g i n t h e s e c o n d Ensurethat the piston ring gaps are equallyspaced
groove with the word "TOP" or the manufacturer's a r o u n dt h e p i s t o n a n d n o t i n l i n e
identification m a r k t o w a r d st h e p i s t o n c r o w n
F i t b a r r e l f a c e d N o . 1 c o m p r e s s i o nr i n g i n t o p g r o o v e
w i t h t h e w o r d " T O P " o r m a n u f a c t u r e r ' si d e n t i f i c a t i o n
towards Distoncrown.
E n s u r e t h a t t h e r i n g g a p s a r e e q u a l l ys p a c e d a r o u n d
t h e p i s t o na n d n o t i n l i n e .

6.3544PremiumEngines(Fig. F.7)
No 1 C h r o m e B a r r e l F a c e d C o m p r e s s i o nI,n t e r n a l
C h a m ef r .
N o .2 C h r o m eT a p e r F a c e d C o m p r e s s i o nP, a r a l l e l .
No 3 C h r o m e F a c e d , S p r i n g L o a d e d C o n f o r m a b l eO i l
Control.
F i t r i n g s a s f o l l o w s: -
F i t N o . 3 a s d e t a i l e df o r T 6 . 3 5 4 4e n g i n e .
F i t t a p e r f a c e d N o . 2 c o m p r e s s i o ni n t h e s e c o n dg r o o v e
w i t h w o r d " T O P " o r m a n u f a c t u r e r ' isd e n t i f i c a t i o nm a r k
t o w a r d sp i s t o n c r o w n .
F i t N o . 1 c o m p r e s s i o nr i n g i n t h e t o p g r o o v e w i t h t h e
internalchamfer and the word "TOP" or the manu-
facturer's mark towards the piston crown
Ensure that the piston ring gaps are equallyspaced
a r o u n dt h e p i s t o na n d n o t i n l i n e . F.9
 P I S T O N SA N D C O N N E C T I N GR O D S F5

T. | |

e n s u r i n gl a t c h p i n e n t e r sb o t h e n d s o f r i n g , s e e F i g . F . B .
Position No. 3 oil control ring over spring correctly
located in groove of ring and ring gap diametrically
o p p o s i t et o l a t c h p i n .
Fit No. 2 compressionring wi'th internalstep of chamfer
F.10 and word "TOP" or manufacturer's mark towards
crown of oiston.
6.3544Combine Engines F i t N o . 1 c o m p r e s s i o nr i n g i n t o p r i n g g r o o v e
No.1 C h r o m e I n s e r tC o m p r e s s i o n . Ensure that the piston ring gaps are equally spaced
N o .2 I n t e r n a l l yS t e p p e dC o m p r e s s i o n . a r o u n dt h e p i s t o n a n d n o t i n l i n e .
N o .3 I n t e r n a l l yS t e p p e dC o m p r e s s i o n . To Fit Pistonand ConnectingRod
No.4 C h r o m e F a c e d ,S p r i n g L o a d e d C o n f o r m a b l eO i l lf necessary,deglazecylinderbore,see SectionG.
Control Clean cylinder bore, piston and bearings and liberallycoat
N o .5 No ring fitted. withcleanengineoil.
Compresspistonringswith ring clamp 38U3 and enterthe
F i t r i n g s a s f o l l o w s: - assembliesin the top of their respectivecylinderbores,see
F i t s p r i n g o f N o . 4 r i n g i n f o u r t h g r o o v e e n s u r i n gt h a t Fig. F.9. The piston and rod number must relate to the
t h e l a t c h p i n e n t e r sb o t h e n d s o f t h e r i n g , s e e F i g F . 8 . cylinderintowhichit is beingfitted,see Fig.F.10,and the rod
identificationnumber must be towardthe fuel injectionpump
Position oil control ring over spring with spring
correctly located in groove of ring and the ring gap sideof the engine.
d i a m e t r i c a l l yo p p o s i t et o t h e l a t c h p i n WithturbocharEed e n g i n e sw, h e n p r e s s i n gt h e a s s e m b l y
through the bore, care mLrstbe taken to avoid damage
F i t N o s . 3 a n d 2 r i n g s i n t h i r d a n d s e c o n dr i n g g r o o v e s
t o t h e p i s t o nc o o l i n g j e t s .
w i t h t h e i n t e r n a ls t e p a n d t h e w o r d " T O P " o r t h e m a n u -
facturer's marks towards the piston crown. Note: Piston cooling jets are not fitted to naturally
Fit No 1 ring in top ring groove. aspiratedengines.
With the respectivecrankpin in B.D.C. position, ensure
Ensurethat the piston ring gaps are equallyspaced
that the big end is turned to avoid contact with the piston
a r o u n dt h e p i s t o n a n d n o t i n l i n e .
cooling jets, see Fig. F.2.
6.3724Engines
W h e n t h e b i g e n d o f t h e c o n n e c t i n gr o d h a s p a s s e d
No 1 C h r o m e I n s e r tP a r a l l e lC o m p r e s s i o n .
t h e p i s t o n c o o l i n g j e t s , t u r n t h e a s s e m b l yb a c k a g a i n
No 2 C h r o m e F a c e d I n t e r n a l l yS t e p p e d o r I n t e r n a l l y to locate on the crankpin ensuring that upper half
C h a m ef r e d C o m p r e s s i o n . bearing is correctly located in big end and tabs fit in
No.3 C h r o m e F a c e d ,S p r i n g L o a d e dC o n f o r m a b l eO i l r e c e s so f r o d , F i g F . 1 1 .A l s o c h e c k t h a t t h e l e t t e r " F "
Control. or arrow on the piston crown is towards the front of
the engine.
No.4 S l o t t e dO i l C o n t r o l
N o t e : W i t h l a t e r C o m b i n e e n g i n e s ,t h e N o : 4 s l o t t e d Fit cap with lower half bearing correctly positioned
c o n t r o lr i n g i s n o t f i t t e d . a n d n u m b e r s o f c a p a n d r o d c o i n c i d i n g ,F i g F . 1 0 .
Refitthe two securing bolts so that the flat on the head of
F i t r i n g s a s f o l l o w s: -
e a c h b o l t i s l o c a t e d a g a i n s t t h e s h o u l d e ro f t h e r o d ,
F i t N o . 4 o i l c o n t r o l r i n g i n b o t t o mg r o o v e . Secure with new nuts and tighten to a torque of 75 lbf ft
Fit springof No 3 oil controlring in third ring groove ( 1 0 , 4 k g fm ) o r 1 0 2 N m f o r c a d m i u m p l a t e d n u t s o r

6 3544SeriesWorkshopManual,January1986
PISTONSAND CONNECTINGRODS F6

9 5 l b ff t ( 1 3 , 1k g f m ) - 1 2 9 N m f o r p h o s p h a t e dn u t s .
C a d m i u mp l a t e d n u t s h a v e a s i l v e r c o l o u r f i n i s h w h i l s t
t h e p h o s p h a t e dh a v e a d u l l b l a c kc o l o u rf i n i s h .

Check that, with piston in T D.C. positionand using

piston height gauge PD 41B, the piston crown is
0 . 0 0 0 / 0 . 0 0 7i n ( 0 , 0 0 / 0 , 1 8m m ) a b o v et h e c y l i n d e rb l o c k
toD face
T h e p i s t o n h e i ' g h tf o r n a t u r a l l ya s p i r a t e de n g i n e s w a s
l o r m e r l y 0 . 0 0 7 3 / 0 . 0 1 5i n ( 0 , 1 9 / 0 , 3 8 m m ) a b o v e t h e
c y l i n d e rb l o c k f a c e a n d , w h e n c h e c k i n ge a r l i e re n g i n e s ,
either of the two heights are acceptable

Where new production pistons are used, then these

must be topped as necessaryto bring them within the
above limits.
Fit the pipe from relief valve to piston cooling jet
connection.(T6.3544only).
F i t l u b r i c a t i n go i l s u c t i o np i p e .
R e f i t t h e l u b r i c a t i n go i l s u m p , P a g e L . 3 , a n d r e f i l l w i t h
lubricatingoil to correct specification.
Refit the cylinder head,see Page E.2.
F.12

The T6.3544 North America vehicle engines are fitted with

aluminiumsilicon alloy pistonswith a re-entrantcombustion
chamberin the crown see Fig. F.12.A steel insertis fitted in
the top ring groove and two compressionand one scraDer
pistonringsare used.
The pistonsare cooledby lubricatingoil pressurelets.
Oversize pistons are not available as the cvlinder liners
cannotbe boredoversize.
The method used to remove and dismantlepiston and ring
assembliesis the same as usedtor otherT6.3544engines.
The height of the piston crown relativeto the top face of the
cylinderblockis 0.000/0.007in (0,000/0,18 mm) abovethe top
face.
The pistons have hard anodised crowns and must not be
topped. In production,three gradesof pre-toppedpistonsare
suppliedfor the high, mediumand low requirementsand the
letters H, M and L are stamped on the piston crown. To
changepistonsin service,the same gradeof pistonMUST be
useo.

6 3 5 4 4 S e r i e s W o r k s h o p M a n u a l , S e p t e m b e r1 9 8 2
A-PDF Merger DEMO : Purchase from www.A-PDF.com to remove the watermark

SECTIONG
GylinderBlockand Liners

;,:\\
\----l :
",(7
- ---7t
)--

Y O )E
C Y L I N D E RB L O C K A N D L I N E R S G2

CylinderBlock in
0.026/0.037
T h e t o p f a c e o f t h e c y l i n d e rb l o c k c a n n o t b e m a c h i n e d (0,66/0,94
mm)
a s t h i s w o u l d i n t e r f e r ew i t h t h e l i n e r f l a n g e r e c e s s
depth
CylinderLiners
P r o d u c t i o nl i n e r sa r e a n i n t e r f e r e n cfei t , o f 0 0 0 1 / 0 . 0 0 3
in +0 002/-0.004in
(0.025/0.076mm i n)t h e c y l i n d e rb l o c k a n d a r e b o r e da n d ( + 0 , 0 5 / - 0 , 1m0 m )
honed to a diameter oI 3.877/3.B7Bin(98,48/98,50mm)
for T6 3544 and 6.3544 engines or 3.9785/39795in
( 1 0 1, 0 5 / 1 0 1 , 0 7 m mf o) r 6 . 3 7 2 4e n g i n e s .
T h e m a x i m u m o e r m i s s i b l ew o r n i n s i d e d i a m e t e r o f
a l i n e r , i n s e r v i c e i s 3 8 8 6 i n ( 9 8 , 7 0 m m f)o r T 6 . 3 5 4 4
a n d 6 . 3 5 4 4e n g i n e so r 3 . 9 8 7 5 i n( 1 0 1 , 2 8 m m f)o r 6 . 3 7 2 4
e ng I n e s
An engine with perfect or little worn cylinderbores can
sometimesconsumean excessiveamountof lubricating oil
due to glazing.When fittingnew piston rings to cure this
problem, it is essentialthat the cylinder bores are first
de-glazed.
A tool is availablefor de-glazing,marketedunderthe trade
name of "Flex-Hone",manufacturedby Brush Research
Manufacturing Co. Inc.,LosAngeles,California,
U.S A. under
the registeredtrade mark U.S. Patent Nos 3384915and
3871139and BritishPatentNos. 1,230503and 18450,which
is idealfor thispurposeas it doesnot removeany appreciable
amount of metal and producesa good quality cross hatch
pattern.
It can oftenbe used with the enginein situ if usedwith a hand lf the liners are found to be worn over the acceptable
held electricpower drill on low speed. Brand new "Flex- l i m i t ,t h e y c a n n o tb e b o r e do v e r s i z e .
Hones" are to be used for one minutein a slave bore to For servicein T6 3544and 6.3544engines,a pre-finished
removeall loosematerialandsharpedges. l i n e ri s a v a i l a b l eh a v i n ga t r a n s i t i o nf i t o f + 0 0 0 1 / - 0 . 0 0 i1n
1. Grade80sc "Flex-Hone"is to be used.The "Flex-Hone" (+0,025/-0,O25mm) The fitted internal bore diameter is
size is to be determinedby measuringthe bore diameter 3 877/3.8795 in (98,48198,54 mm )
and selectingthe "Flex-Hone"of the nearestsize larger The liners can be renewedusing tools PD 150 and
thanthe bore.
PD 150-18.
2. Removethe piston coolingjets as fitted on turbocharged
engines.Guardthe mainjournalsand pinsby tyingclean
dry rags around them. Where possible use cardboard To Renew ServiceCylinder Liners
shields to preventdebris contaminationof adjacentparts
of the engine. Remove all components from the cylinder block,
3. Lubricatethe bore with clean engineoil and also smear including the piston cooling jets. They should be
engineoil on the ballsof the "Flex-Hone" c a r e f u l l yh a n d l e d t o p r e v e n t m i s a l i g n m e n ti n r e f i t t i n g
4. Restthe "Flex-Hone"againstthe cylinderblockandswitch Piston cooling jets are not fitted to naturally aspirated
on whilst pressinginto the bore Do not force the tool into e n g rn e s .
the borewhilstit is noi rotating. T h e l i n e r ss h o u l d b e p r e s s e do u t f r o m t h e b o t t o m .
5 Pass the tool up and down the bore once per secondfor F i tt h en e w l i n e r sa sf o l l o w s :
30-50secondsand removeit whilstit is stillrotating.
It is oointedout that all pre-finished linerscan be a 0.001in
6. Thoroughly wash the boresto removeall the residuefrom (0,03mm)interference fit in the parentbore,i.e. if a lineron
the honingoperation, usinga coarsebrushand paraffin. top limitis fittedin a bottomlimitparentbore.
7. Dry the boresusinga cleanrag and carefullyremovethe
A tight liner should never be hammeredin bui should be
the masking.Thoroughlycleanall partsof the enginethat
pressedor drawn into the bore using a suitabledolly and
have beenaffectedby the honingoperation.
pressor puller.
8. Refit the piston cooling jets on turbochargedengines
(SectionM). Generally clean the parent bore and degrease the
t o p 2 i n ( 5 0 m m )a n d t h e l i n e r f l a n g er e c e s su s i n g" L o c t i t e "
This tool is equallysuccessfulin producinga good quality
Safety Solvent (aerosolcan) as per instructionson can
bedding-infinishon new cylinderbores,after boringout to
finishedsize. Apply engine oil to the cylinder block paretrt bore
e x c e p tf o r t h e t o p 2 i n ( 5 0m m ) .
Enquiries concerning detailsand supplyof the "Flex-Hohe"
in
the U.K. or outside the U.S. where no Brush Research G e n e r a l l yc l e a n t h e o u t s i d e s u r f a c e so f t h e l i n e r a n d
Distributor is available,
shouldbe addressedas follows: degreaseusing "Loctite" Safety Solvent (aerosolcan) as
p e r i n s t r u c t i o n so n c a n
Nicro(Leamington) Ltd.
Unit19A,ChalfordIndustrial Estate, Locate the liner in the bore and press in to within
Chalford.Nr. Stroud.Gloucestershire GL6BNT. a p p r o x i m a t e l 2y i n ( 5 0m m ) o f i t s f i n a l p o s i t i o n
Telephone : (0453)884966 Furthedr e gr e a s et h e f l a n g ea r e ao f t h e l i n e ru s t n g" L o c t i t e "
T e l e x4: 37104 Safety Solvent to remove handling contamination.

6 3544SeriesWorkshopManual,January1986
 CYLINDERBLOCKAND LINERS G3

Apply a band of "Loctite" Retaining Compound, Grade

602, 1in (25mm) wide around the top of the tiner
immediately under the flange. Also liberally apply the
"Loctite" to the base of the flange recess.
Pressthe liner into the fully fitted position and wipe the
top of the cylinder block to remove any surplus
"Loctite". The top of the liner. should protrude
0.026/0.037in(0,66/0,94mm)above ihe top face of the
cylinderblock and the liner flange should be within
0.002in (0,05mm) above the top face of the blocK ro
0.004in (0,10mm) below the top face of the block
It is advisableto allow a setiling period to elapse after
fitting before checking the fitted internal bore diamerer
of the liner.
However, allow at least 15 minutes to elapse before
commencingto fit pistonsas this time lag is requiredto
allow the "Loctite" to reach handling strength. Full cure
strength is achievedafter 3 hours

6 3544SeriesWorkshopManual,January1986
 SECTIONH
Grankshaftand Main Bearings
C R A N K S H A F TA N D M A I N B E A R I N G S H 2

T h e c r a n k s h a f tr u n s i n s e v e n p r e - f i n i s h e dr e p l a c e a b l e
s h e l lb e a r i n g s
E n d f l o a t o f t h e c r a n k s h a f ti s c o n t r o l l e db y f o u r t h r u s t
w a s h e r sw h i c h a r e l o c a t e do n b o t h s i d e s o f t h e c e n t r e
m a i n b e a r i n gh o u s i n g s, e e F i g H 1 O 0 0 7 5 i n( 0 , l 9 m m )
o v e r s i z et h r u s t w a s h e r s a r e a v a i l a b l ew h i c h m a y b e
combined with standard thrust washers to give an
a d j u s t m e not f 0 0 0 7 5 i n( O1 9 m m )o r w h e n u s e do n b o t h
s i d e s o f t h e b e a r i n g h o u s i n g g i v e a n a d j u s t m e n to f
0 0 1 5i n ( 0 , 3 5m m )
T h e m a x i m u m p e r m i s s i b l ec r a n k s h a f te n d f l o a r t s
0 0 2 0r n ( 0 , 5 1
mm)
C r a n k s h a f t sf i t t e d t o t u r b o c h a r g e de n g i n e sa r e 6 0 h o u r
N i t r i d e do r T u f f t r i d e d
C r a n k s h a f t sf i t t e d t o n a t u r a l l y a s p i r a t e de n g i n e s a r e
i n d u c t i o nh a r d e n e d
T h e c r a n k s h a fht a s p r o v i s i o nt o r 1 2 b o l t f l y w h e e lf i x i n g

To Renew Thrust Washers

R e n e w a lo f t h r u s t w a s h e r sc a n b e c a r r i e d o u t w i t h o u t
the removao l f c r a n k s h a fat s f o l l o w s :
D r a i nt h e l u b r i c a t i n go i l a n d r e m o v et h e s u m p ,o i l s u c r r o n
pipe and pipe from reducingvalve to cylinder block
( T 6 . 3 5 4 4e n g i n e so n l y )
R e m o v et h e c e n t r e m a i n b e a r i n gc a p ( N o . 4 )
R e m o v et h e t w o b o t t o m h a l f t h r u s t w a s h e r s
R e m o v et h e t w o t o p h a l v e s o f t h e t h r u s t w a s h e r s b y
s l i d i n gt h e m r o u n dt h e c r a n k s h a fat n d o u t o f t h e r e c e s s e s
m a c h i n e di n t h e c y l i n d e rb l o c k m a r n b e a r i n gh o u s i n g ,
see Fig H 2
L i b e r a l l yo i l t h e t w o u p p e r h a l v e sa n d s l i d e t h e m i n t o
t h e r e c e s s e so n e i t h e r s i d e o f t h e c e n t r e m a r n b e a r i n q
n o u snr o
R e f i tt h e t w o b o t t o m h a l v e so f t h e t h r u s t w a s h e r st o t h e
Deaflngcap
C l e a n a n d o i l c r a n k s h a f tj o u r n a l a n d p l a c e t h e c a p i n
p o s i t i o ne n s u r i n gt h a t t h e b l o c k s e r i a l n u m b e r s t a m p e d
o n t h e c a p r e a d si n l i n e w i t h o t h e r c a p s
T i g h t e n t h e m a i n b e a r i n gc a p s e t s c r e w st o a t o r q u e o I
2 0 0l b f f t ( 2 7 , 7 k g t m )o, r 2 7 O N m
C h e c kt h e c r a n k s h a f e t n d f l o a t b y u s i n g a f e e l e rg a u g e
b e t w e e nt h e t h r u s t w a s h e r a n d c r a n k s h a f tw e b o r b y
u s i n g a d i a l t e s t i n d i c a t o ro n o n e e n d o f t h e c r a n k s h a f t ,
see Fig H 3
R e f i ts u c t i o n p i p e , p i p e f r o m r e d u c i n gv a l v et o c y l i n d e r
b l o c k ( T 63 5 4 4 o n l y ) a n d s u m p R e f i l l t h e s u m p w i t h
l u b r i c a t i n go i l o f a n a p p r o v e dg r a d e .

To RemoveCrankshaft
I t w i l l b e n e c e s s a r yt o r e m o v et h e e n g i n e f r o m v e h i c l e
or machine
D r a i n a n d r e m o v e t h e s u m p , l u b r i c a t i n go i l s u c t i o n
p i p e a n d p i p e f r o m r e d u c i n gv a l v et o t h e c y l i n d e r b l o c k
(T6 3544 only)
R e m o v e t h e c r a n k s h a f t p u l l e y E x t r a c t o r ss h o u l d n o t
b e u s e d a s t h e p u l l e y w i l l p r o b a b l y b e d e s t r o y e da n d
t h e c r a n k s h a f td a m a g e d . R e m o v e t h e t h r e e s e c u r i n g
s c r e w s .l f t h e p u l l e yd o e s n o t i m m e d i a t e l yb e c o m ef r e e
t h e l o c k i n gr i n g sc a n b e r e l e a s e db y h i t t i n gt h e f r o n t f a c e
o f t h e p u l l e yi n n e rh u b , s e e F i g H . 4

R e m o v ec a m s h a f tg e a r , a u x i l i a r yd r i v e g e a r a n d t i m i n g
aAaA cAA P d6 | t

R e m o v ef i y w h e e la n d f l y w h e e lh o u s i n g
H.1 R e m o v er e a r m a i n o i l s e a l h o u s i n o .

H.3
R e m o v ef r o n t a n d r e a r b r i d g e p i e c e sf r o m t h e c y l i n d e r
b l o c k b o t t o mf a c e ,w i t h t h e r u b b e ro i l s e a l s
Removeconnectingrod caps and big end bearings
K e e p b e a r i n g sw i t h a p p r o p r i a t ec a p s T a k e c a r e n o t
t o d a m a g et h e p i s t o nc o o l i n gj e t s
R e m o v et h e m a i n b e a r i n gc a p s a n d h a l f b e a r i n g s
L i f t o u t t h e c r a n k s h aaf tn d r e m o v et h e u p p e rh a l f b e a r i n g s ,
m a k i n gn o t e o f f i t t e d p o s i t i o n s
Crankshaftregrinding
lnduction hardened crankshafts (Pt No. 31323283,
31323288,31323294, 3131H023, 3131H024 or 3 131H025)
f itted to naturallyaspiratedengines can be regroundto
- 0 0 1 0 i n( 0 , 2 5 m m )0, . 0 2 0 i n( 0 , 5 1m m ) o r 0 0 3 0 i n( 0 , 7 6 m m )
withoutany subsequent rehardening.
60 hourNitridedcrankshafts (Pt No. 31323281or 3131H021)
fittedto turbocharged enginesmay be regroundto -0.010in
(0,25mm) without re-Nitriding.Subsequentregrindingto
-0 020in (0,51mm) or 0 030in (0,76mm)callsfor re-Nitriding
for a 60 hourperiodaftereachregrinding
operation
Tufftrided crankshafts (Part No 31323292 or 3j31H022)
mustbe re-Tufftrided
aftereachregrinding
operation
l f a 6 0 h o u r N i t r i d e dc r a n k s h a f its f o u n dt o b e s u i t a b l ef o r
further service, but necessaryto re-grind down to
0 . 0 2 0i n ( 0 , 5 1m m ) o r 0 0 3 0 i n ( 0 , 7 6m m ) u n d e r s i z eg, r i n d
d o w n t o 0 0 0 1 5 / 0 . 0 0 2 i n( 0 , 0 4 / 0 , 0 5 m m )a b o v e f i n i s h e d
size leaving an allowance to grind off the white
c o m p o u n dl a y e r{ o r m e db y t h e 6 0 h o u r N i t r i d i n gp r o c e s s
6 3544 SoriesWorkshopManual,January '1986
C R A N K S H A F TA N D M A I N B E A R I N G S H 3
H.4
A f t e r n i t r i d i n go f t h e c r a n k s h a f tr,e g r i n d i n go f t h e f i l l e l
r a d i ii s n o t p e r m i s s i b l e
W h e n r e - g r i n d i n gt,h e o p e r a t i o nc a l l s f o r s p e c i a l i s e d
equipmena t n d g r e a tc a r e
U s i n g a P r i n c et y p e g r i n d e rw i t h a U n i v e r s aG l rinding
Wheel Company wheel to Grade WA-80 JE (or
e q u i v a l e n t )r,e m o v et h e w h i t e c o m p o u n d l a y e r f o r m e d
b y t h e N i t r i d i n g p r o c e s st o a c h i e v e f i n i s h e d s i z e T h e
c o l l a r f a c e s o f t h e c r a n k s h a f ts h o u l d b e l i g h t l y f l a s h e d
b u t n o t g r o u n da t t h i s o p e r a t i o na n d t h e f i t l e tr a d i is h o u l d
b e m a i n t a i n e da t 0 1 4 5 / 0 1 5 6 i n ( 3 , 6 8 / 3 , 9 6 m m )T h i s
w i l l l e a v et h e c o m p o u n dl a y e r i n t h e r a d i i a n d c o l l a r s
W h e n r e m o v i n gt h e c o m p o u n dl a y e r ,a g r i n d i n gw h e e l
s p e e d o f B B 0 r e v l m i n a n d a c r a n k s h a f tw o r k i n g s p e e d
o f 1 6 r e v l m i n f o r m a i n j o u r n a l sa n d 8 r e v l m i n f o r p i n s
s h o u l d b e o b s e r v e da n d a h a n d f e e d o f a p p r o x i m a t e l y
0 0 0 0 5i n ( 0 , 0 1m m ) p e r r e v o l u t i o n o f c r a n k s h a f t
A n a d e q u a t es u p p l y o f c o o l a n t ( W a l k e rC e n t u r y , 4 3 0 5 )
s h o u l db e u s e d
W h e r ef a c r l i t i e sf o r r e - N i t r i d i n ga r e n o t a v a t l a b l et,h e n a
f a c t o r y r e p l a c e m e n ct r a n k s h a f ts h o u l d b e f i t t e d
N i t r i d e dc r a n k s h a f t cs a n n o tb e s t r a i g h t e n e d
B e f o r e r e g r i n d i n g a c r a n k s h a f t ,i t s h o u l d b e c r a c k
d e t e c t e d D e - m a g n e t i z ea f t e r c r a c k d e t e c t i n g
D a t a f o r c r a n k s h a f tr e - g r i n d i n gi s g i v e n o n P a g e H 4
A f t e rr e g r i n d i n gt,h e s h a r pc o r n e r so n t h e o i l h o l e ss h o u l d
b e r e m o v e d a n d t h e c r a n k s h a f tc r a c k d e t e c t e d a n d
de-magnetized
N o t e :l t i s i m p o r t a n t h a tt h e r a d i io n t h e m a i nj o u r n a l sa n d
c r a n k p i n sa r e m a i n t a i n e d
C R A N K S H A F TA N D M A I N B E A R I N G S H 4

H.5

T h e r e g r i n dd i m e n s i o n sa r e a s f o l l o w s s e e F i g . H 5

0 . 0 1 0i n ( 0 , 2 5m m ) 0 . 0 2 0i n ( 0 , 5 1m m ) 0 . 0 3 0i n ( 0 , 7 6 m m )
A 2.9884/29896 in 2 - 9 7 8 4 / 29 7 9 6 i n 2.9684/2.9696in
( 7 5 , 9 1/ 7 5 , 9 4 m m ) ( 7 5 , 6 5 / 7 5 , 6 8m m) (75,40/75,43mm)
B 2.4888./2.4898i,n 2.4788/2.4798in 2.4688/2.4698in
(63,22/63,24 mm) ( 6 2 , 9 6 / 6 2 , 9 9m m) (62,70/62,73 mln)
(, 1 7 5 9 i n ( 4 4 , 6 8m m ) m a x i m u m
D 1 . 4 8 9i n ( 3 7 , 8 2m m ) m a x i m u m
E 1 5 5 4 i n ( 3 9 . 4 7m m ) m a x i m u m
F 1 . 5 9 6 5i n ( 4 0 , 5 5m m ) m a x i m u m
0 . 1 4 5 1 0 . 1 5i6n ( 3 , 6 8 / 3 , 9 6m m ) r a d i u sa l l p i n s a n d j o u r n a l s
Sudacefinishof 16 microinches(0,4 microns)of the crankpinsand journalsand 50 microinches(1,3microns)of the filletradii(R)
mustbe maintainedduringregrinding.

M a x i m u mr u n - o u tw i t h t h e c r a n k s h a f m
t o u n t e do n t h e e n d m a i n i o u r n a l s .
I n d e p e n d e nrt e a d i n g s .

CrankshaftPulley R e a rO i l S e a l F l y w h e e lF l a n g e
D i a m e t eT r .l.R D i a m e t e rT . l . R . D i a m e t e rT . l R
0 . 0 0 2i n ( 0 , 0 5 m m ) 0 0 0 2 i n ( 0 , 0 5m m ) 0 . 0 0 2i n ( 0 , 0 5 m m )
J o u r n a l sT l . R . - R u n - o u tm u s t n o t b e o p p o s e d:

N u m b e r1 N u mb e r 2 N u m b e r3 N u m b e r4
Mounting 0 0 0 4 i n ( 0 , 1 0m m ) 0 0 0 8 i n ( 0 , 2 0m m ) 0 . 0 1 0i n ( 0 , 2 5m m )
N u m b e r5 N u m b e r6 N u m b e r7
0 . 0 0 8i n ( 0 , 2 0 m m ) 0 . 0 0 4i n ( 0 , 1 0m m ) Mounting
The differencein run-out betweenany two a d j a c e n tb e a r i n g sm u s t n o t b e g r e a t e rt h a n 0 . 0 0 4i n ( 0 , 1 0 m m ) .

To Fit Crankshaft P o s i t i o nt h e c r a n k s h a f t .
Ensure that the oilways in the cylinder block and
Oil the two upper thrust washersand slide into the
crankshaftare free from obstruction
r e c e s s e so n e i t h e r s i d e o f t h e c e n t r e m a i n b e a r i n q
Check the main bearingsetscrewsfor stretch or damage housing
l f t h e y a r e t o b e r e p l a c e d ,o n l y u s e P e r k i n s g e n u i n e
C l e a nt h e m a i n b e a r i n gc a p s a n d p l a c e t h e l o w e r h a l v e s
spare parrs
of the bearings, with the tabs correctly located, into
C l e a nt h e b e a r i n gh o u s i n g s ;p l a c e t h e t o p h a l f b e a r i n g s p o s i t i o n L i b e r a l l yo i l a n d p l a c e t h e c a p s i n p o s i t i o n
i n p o s i t i o na n d l i b e r a l l yo i l . making sure thai the cap to cylinder block locating

6 3544SeriesWorkshopManual,January1986
 C R A N K S H A F TA N D M A I N B E A R I N G S H 5

S,..'
l *

i liitlili

H.6

thimblesare in place and that the caps, whicn are Check the crankshaftend float for a clearanceol 0.O02/
n u m b e r e do n e t o s e v e n a r e f i t t e d t o t h e r e l e v a n tm a t n 0.015 (0,05/0,38mm).Oversize thrust washers may be
b e a r i n gh o u s i n g sC . a r em u s t a l s o b e t a k e nt o e n s u r et h a t f itted.
t h e c a p sa r ef i t t e ds o t h a tt h e c y l i n d e rb l o c ks e r i a ln u m b e r ,
Refit the connecting rod caps and big end bearings.
which is stampedon the cylinder block bottom face
as well as on each cap, read in line,see Fig H 6. Refit the front and rear bridge pieces to the cylinder
block using.lointing compound between the bridge
Beforefitting the centre main bearing cap, place the piecesand the cylinderblock at the setscrewholes.Check
lower halvesof the thrust washers into the recesseson
w i t h a s t r a i g h te d g e t o e n s u r et h a t t h e e n d f a c e s o f t h e
e i t h e rs i d e o f t h e c a D . b r i d g ep i e c e sa r e f l u s h w i t h t h e e n d f a c e so f t h e c y l i n d e r
F i t a n e w s h i m w a s h e rt o e a c h m a i n b e a r i n gc a p s e t s c r e w b l o c k ,s e eF i g .H . 7 .I n s e r tn e wr u b b e ro i l s e a l s s, e e F i g .H . 8 .
a n d l i g h t l yo i l .
T i g h t e nt h e s e t s c r e w st o a t o r q u e o f 2 0 0 l b f t ( 2 7 , 7 k Tm
f )
or 270Nm

H.7 H.8
C R A N K S H A F TA N D M A I N B E A R I N G S H 6

H.10
H.9

F i t n e w s e a l i n t h e r e a r m a i n o i l s e a l h o u s i n ga n d r e f i t c h e c k i n g f o r l u b r i c a t i n go i l a t t h e t u r b o c h a r g e r ,s e e
the housing. P a g eC . 2 .
Refit the pipe from reducingvalve to cylinder block
( T 6 3 5 4 4o n l y ) l u b f l c a t i n go i l s u c t i o np i p e a n d s u m p
CrarrkshaftRear Oil Seal
R e f i tt h e t i m i n g c a s e ,c a m s h a f tg e a r a n d a u x i l i a r yd r i v e
g e a r ,s e e P a g eJ . 2 A circularspringloadedlipseallocateson the periphery
of the
rearflangeof the crankshaft.
Refit the crankshaftpulley employing the following
recommendedorocedure. This seal is easily damaged and exlremecare should be
taken when handlingand fittingit to its housingor to the
(a) Removeoil and greasefrom pulley bore, shaft,
crankshaftAnyvisualdamageacrossthe lipof a newsealwill
l o c k i n g e l e m e n t sa n d s p a c e r , b u t d o n o t u s e a
causeleakageand preventbeddingin of the seal.
d e g r e a s i n gs o l u t i o n . D o n o t e x p a n d t h e r i n g s
beyond their free state.
( b ) F i t p u l l e yt o s h a f t ,l i n i n g u p k e y a n d k e y w a y
To Fit OilSeal in its Housing
( c ) I n s e r tt h e s p a c e r( 1 ) i n t o t h e p u l l e y b o r e o v e r t h e
Earlierseals have a flat rear face, as shown in Fig H.11
s h a f t ,f o l l o w e db y t h e i n n e r ( 2 ) a n d t h e n t h e o u t e r
whereasthe latestseal has a dust lip protruding
fromthe rear
( 3 ) l o c k i n ge l e m e n t se, n s u r i n gt h a t t h e s l o t s d o n o t
f a c e ,a s s h o w ni n F i g .H . 1 2
c o i n c i d e s, e e F i g . H . 9
Note: Where power take-off at the front end of the On production, the old type sealwas fittedflushwithtne rear
c r a n k s h a f ti s c r i t i c a l ,t h e n t w o p a i r s o f l o c k l n ge l e m e n t s face of the housing(Fig.H.11)but the new type sealis fitted
a r e f i t t e d- s e e F i g . H . 9 ( 2 ) a n d ( 3 ) d e e p e irn t ot h eh o u s i n ga t " A " , F i g .H . 1 2 .

( d ) F i t t h e t h r u s tb l o c k ( 5 ) w i t h " O " r i n g ( 4 ) i n t o t h e In service,when a new seal is fitted to a worn crankshaft,it

p u l l e yb o r e . should be pressed further into the housing In the first
instanceit can be pressedin to Tein (3,2mm)for old type
( e ) L i g h t l y o i l s c r e w t h r e a d s a n d u n d e r s i d eo f s c r e w
sealsor position"8" for new typesealsor, if this positionnas
h e a d s b e f o r e fi t t i n g . D o n o t u s e m o l y b d e n u m
beenused,to Tain(6,4mm)for old typesealsor position"C"
disulphide.
for newtypeseals.
(f) P u s h p u l l e y f u l l y h o m e a n d t i g h t e n s e t s c r e w st o
lf a newtypesealis usedin placeof an exisitingoldtypeseal,
e s t a b l i s ha f i r m c o n n e c t i o n
position"C" shouldbe used if the old seal was fittedTein
(g) Tighten screws evenly and in severalstages until a (3,2mm)belowthe housingface.
f i n a l t o r q u e o f 6 5 l b ff t ( 9 , 0 k g m
f ) or BB Nm is
a c h i e v e ds, e e F i g . H . 1 0 . lf all threepositionshavebeenused,it may be permissible
to
machinethe worn sealingarea of the crankshaft flange,but
C h e c kt i g h t e n i n gt o r q u e o n e a c h s c r e w . not the spigotarea on whichthe flywheellocates- See Fig.
Refit and correctly align the flywheel housing and H.13.
flywheel,see Page P.2.
R e b u i l de n g i n e i n t o v e h i c l eo r m a c h i n e F i l l t h e s u m p
t o t h e c o r r e c t d i p s t i c k l e v e l w i t h a r e c o m m e n d e do i l .
W i t h t u r b o c h a r g e de n g i n e sd o n o t f i r e t h e e n g i n e u n t i l
 C R A N K S H A F TA N D M A I N B E A R I N G S H 7

5 . 2 4 3i n
(tss,tzmm)
MIN
-l
I
___l
I
---l I

::+ \ r

Usingclean enginelubricating oil, lubricatethe outsidedia-

meterof the sealandthe insidediameterof the housing.
Pressthe sealintothe housingto the requiredposition, taking
care that the seal is entered and pressed in squarely,
otherwisedamageto the outsidediameterof the seal may
occuror, if not squarein the housingwhenfittedto the engine,
it may leak.

H.11
When a new seal is fittedto a new or reconditioned
crankshaft
in service,it shouldbe fittedin the productionposition,but if
the latestsealis not to be usedin a wet backend application,
it can be fittedflush with the housingrear face (,,D",Fig.
H.12).
Whenpressingin the latesttypeseal,ensurethatthe adaptor
has a suitablerecessto clear the protrudingdust lip Tool
PD145Ccan be usedwithbothtypeseals.
Beforefittingthe seal in the housing,carefullyexaminethe
sealfor damageespecially on the lipand outsidediamerer.
*--A OOgrn(2,2nrni)
T o F i t O i l S e a l a n dH o u s i n g
The seal and Frousingshould be fitted, using seal guide
PD145C,as follows:-
Cleanthe facesof the cylinderblockand the oil seal housing
and the outsidediameterof the crankshaft
flange.
Checkthatthe sealand the outsidediameterof thecrankshaft
flangeare not damaged.Wherea new seal has been fitted,
check that it is in the correct positionin the housing,as
detailedabove
Ensurethat the two dowels are fittedin the cylinderblock.
Coat both sides of the housingjoint with Perkins(Hylomar)
JointingCompoundand positionthe jointover the dowelsin
the block.
Using clean engine lubricatingoil, lubricatethe crankshaft
flange,the sealand the sealguide.The lubrication of the seal
is necessary to preventdamagethat may be causedby initial
d r yr u n n r n g .
Positionthe seal and housingon the seal guide,locatethe
guideon the crankshaftflangeand gentlypressthe sealand
housingintopositionon the flange,locatingthe housingon its
oowets.
Withdrawthe guide and securethe housingwith setscrews
ano wasners.

<--B 01Bin (4.6rrrrrr)

* C O 2 7 i n ( 6 . ! ) n ' rrr)r

H.12

6 3544SeriesWorkshoplvlanual,
January1986
 SECTIONJ
TimingCaseand Drive

-4

\\

)\
\\\
T I M I N G C A S EA N D D R I V E J2

To RemoveTiming Case, Camshaft

Gear and Auxiliary Drive Gear
S l a c k e nt h e g e n e r a t o rm o u n t i n g b o l t s a n d r e m o v e t h e
drive belts
Where necessary,removethe water pump.
R e m o v et h e c r a n k s h a f pt u l l e y ,s e e P a g e H . 2 .
R e m o v e t h ec a m s h a f gt e a ra n d a u x i l i a r yd r i v eg e a rc o v e r s .
The camshaft gear securing setscrew and washers can
now be removed.Extractthe gear from the camshaft,see
F i g .J 2
R e m o v et h e r e t a i n i n gp l a t e s e c u r i n gt h e a u x i l i a r yd r l v e
g e a r t o t h e a u x i l i a r yd r i v e s h a f t h u b a n d w i t h d r a w t h e
g e a r ,s e e F i g .J . 3 .
T h e t i m i n gc a s es e c u r i n gs e t s c r e w sl ,o w e rn u t sa n d t i m i n g
case can now be removed.

To RenewCrankshaltFront Oil Seal

U s i n ga p r e s s ,r e m o v et h e o i l s e a l f r o m t h e t i m i n g c a s e .
A l t e r n a t i v e l yt h, e s e a lm a y b e t a p p e do u t
Early seals were black with a flat front face Later sealswere J.2
red and also had a flat front face. Currentseals are blackand
have a protrudingdust seal lip at the front.An oil throweris To Refit Timing Gase,CamshaftGear
fittedbetweenthe crankshaftgear and pulleywith the early and Auxiliary Drive Gear
blacksealsbut this is removedand a spaceror longerpulley
R e m o v et h e r o c k e rc o v e ra n d s l a c k e nt h e r o c k e ra s s e m b l y
is fittedwiththe laterredand blackseals.
securing setscrews.
lf the latestseal,with a dust seal lip, is used in placeof an
earliertypeseal,a cleanlocatingsurfacefor the dust lip must Turn the crankshaftuntilNos. 1 and 6 oistonsare at T.D C.
be providedon the pulleyboss. Clean paint,etc. from the withthe keywayin the crankshaftgearat T.D.C.
pulleyfor a distanceof 3/ein(9mm) forwardof the lip seal lf the doubledot on the loweridlergear is not in linewiththe
location. single dot on the crankshaftgear, removethe idler gear and
Pressthe seal into positionfrom the front untilthe flat front replacewiththe marksin line.
face of the seal is 0.265/0.285in(6,7317,24mm) belowthe
frontfaceof thetimingcase,see Fig.J.4.

ek&

s
11,,.;
J.1

6 3544SeriesWorkshoplvlanual,
January1986
 T I M I N G C A S EA N D D R I V E J3

J.3 J.5
P o s i t i o nt h e t i m i n g c a s e w i t h a n e w . J o i not n t h e c y l i n d e r R e f i tt h e a u x i l i a r yd r i v eg e a r c o v e rp l a t e
block by nreansof two oppositesetscrewsfitted loosely R e f i tt h e f u e l i n j e c t i o np u m p ,s e e P a g eN 6
C e n t r a l i s et h e c a s e b y l o c a t i n gt h e t i m i n g c a s e c e n t r a l -
i s i n g t o o l P D . 1 6 3 o n t h e c r a n k s h a f ta n d i n t h e s e a l T i g h t e n t h e r o c k e r a s s e m b l y a n d a dj u s t t h e v a l v e
housing and tighten the assemblyby means of the c l e a r a n c e st o 0 0 0 8 i n ( 0 , 2 0 m m ) f o r i n l e t v a l v e s a n d
c r a n k s h a f tp u l l e y s e t s c r e w sa n d t h e w a s h e r p r o v i d e d 0 0 1 8 i n ( 0 , 4 5 m m )f o r e x h a u s tv a l v e s c o l d a n d r e p l a c e
Do not overtightenTighten all the timing case set- the cover.
s c r e w sa n d n u t s a n d r e m o v et h e t o o l . l f t h e c e n t r a l i s i n g
t o o l i s n o t a v a i l a b l et,h e c r a n k s h a f tp u l l e yc a n b e u s e d R e f i tt h e c r a n k s h a f pt u l l e y ,s e e P a g e H 6
t o c e n t r a l i s et h e c a s e , b u t , a s t h i s m e t h o d u t i l i s e st h e
F i t t h e d r i v eb e l t sa n d r e t i g h t e nt h e g e n e r a t o r
i n s i d e d i a m e t e ro f t h e s e a l w h i c h i s s o f t , t h e c a s e m a y
n o t b e t r u l y c e n t r a la n d l e a k s m a y o c c u r .
lf the latesttype of crankshaftoil seal with a protrudingdust To Removeldler Gearsand Hubs
seal lip at the front is fitted,ensurethat the centralising
tool R e m o v et h e t i m i n g c a s e ,s e e P a g eJ 2
hasa suitablerecessin it to clearthe dustseallip
R e m o v et h e s e l f l o c k i n g n u t s s e c u r i n ge a c h i d l e r g e a r
P o s i t i o nt h e c a m s h a f ts o t h a t t h e k e y i s a l i g n e d w i t f r t h r u s tp l a t e .
the keyway in the camshaft gear and at the same time, R e m o v et h e r e t a i n i n gp l a t e s a n d w i t h d r a w t h e g e a r s ,
t h e t i m i n g m a r k s o n t h e c a m s h a f ta n d i d l e r g e a r s a r e seeFig J 5
aligned
W i t h d r a wt h e h u b s
Draw the gear onto the camshaftby fitting the gear
retainingwasher, tabwasher,shimwasherand setscrew
T i g h t e nt h e s e t s c r e wt o a t o r q u eo f 5 0 l b f f t ( 6 , 9 k g fm ) o r
6 8 N m ,a n d l o c k w i t h t h e t a b w a s h e r ,
Refit the camshaftgear cover plate.
B e f o r ef i t t i n g t h e a u x i l i a r yd r i v e g e a r , r e m o v e t h e f u e l
i n j e c t i o np u m p ,s e e P a g eN 6 . a n d t u r n t h e a u x i l i a r yd r i v e
s h a f tu n t i it h es l o t i n t h e v e r t i c afl u e l p u m pd r i v eh u b a l i g n s
w i t h t h e s l o t i n t h e f u e l p u m p a d a p t o rp l a t e ,s e e F i g K 2
W i t h t h e e n g i n e s e t r n t h i s p o s i t i o n ,f i t t h e a u x i l i a r y
d r i v eg e a rs o t h a t t h e t h r e es e t s c r e wh o l e si n t h e s h a f ta r e
w i t h i n t h e t h r e e s l o t so f t h e o e a r
Securethe gear with the retaining plate and setscrews

J.4 J.6

6 3544SeriesWorkshopL4anual,
January1986
T I M I N G C A S EA N D D R I V E J4

J.7 J.8

To Refit ldler Gears and Hubs A d j u s tt h e v a l v ec l e a r a n c e st o 0 . 0 0 B i n( 0 , 2 0 m m )f o r i n l e t

T u r n t h e c r a n k s h a f tu n t i l N o s . 1 a n d 6 p i s t o n s a r e a t
T . D C . w i t h t h e k e y w a yi n t h e c r a n k s h a f tg e a r a t T . D C
R e f i tt h e i d l e r g e a r h u b s ,l o c a t e db y d o w e l s ,s e e F i g .J . 6 .
Ensurethat the oilways are clear
R e f i t t h e i d l e r g e a r s a n d r e t a i n i n gp l a t e s s o t h a t t h e
timing marks on the lower idler gear align with the
t i m i n g m a r k so n t h e c r a n k s h a f gt e a r
Using new self locking nuts, tighten to a torque of
3 6 l b ff t ( 5 , 0k g f m ) o r 4 9 N m .
B e f i t t h e t i m i n g c a s e , c a m s h a f tg e a r a n d a u x i l i a r yd r i v e
gear, see Page J 2
Check the end float which should be 0.004/0016in
( 0 , 1 0 / 0 , 4m
1 m ) , s e e F i g .J . 7
v a l v e sa n d 0 . 0 1 8i n ( 0 , 4 5m m ) f o r e x h a u s vt a l v e sc o l d . R e fi t
the rocker cover.
R e f i l l s u m p w i t h l u b r i c a t i n go i l o f a n a p p r o v e dg r a d e .
To Remove Auxiliary Drive Shaft and
Fuel Pump Drive Shaft
R e m o v et h e t i m i n g c a s e ,s e e P a g eJ . 2 .
R e m o v et h e c o m p r e s s oar n d a u x i l i a r yp u m p ( i f f i t t e d )a n d
cou pilngs.
R e m o v et h e f u e l i n j e c t i o np u m p , s e e P a g e N . 6 l
W i t h a t w i s t i n gm o t i o n ,w i t h d r a wt h e a u x i l i a r ys h a f t a n d
t h e t w o 1 8 0 " h a l f t h r u s tw a s h e r s s. e e F i q J . 1 0 .

To Remove Camshaft and Tappets

R e m o v et h e t i m i n g c a s e ,s e e P a g eJ . 2 .
Removethe rocker cover, rocker assemblvand withdraw
the oushrods.
Removethe fuel lift pump, see Page N.5
T u r n t h e e n g i n eo n i t s s i d e a n d r e m o v et h e s u m p .
Remove the camshaft thrust ring and withdraw the
camshaft,see Fig. J.B.
Removethe tappets.

To ReplaceCamshaft and Tappets

Refit the tappets,camshaftand sump.
Fit the camshaft thrust ring so that it is correcily
p o s i t i o n e do n t h e d o w e l ,s e e F i g J . 9 .
C h e c k t h e p r o t r u s i o no f t h e t h r u s t r i n g b e y o n d t h e
cylinderblock front face which should be within the
l i m i t so f 0 . 0 0 0 / 00 0 5i n ( 0 , 0 0 / 0 , 1m
3 m).
R e f i tt h e f u e l l i f t p u m p a n d c o n n e c t i o n s
F i t t h e t i m i n gc a s ea n d r e fi t t h e t i m i n gg e a r s ,s e ep a g e J 2
R e f i tt h e p u s h r o d sa n d r o c k e ra s s e m b l y
 T I M I N G C A S EA N D D R I V E J5

llt:r
it,r;

{l'

19'
llliiSlrttl{

J.10 J.12

R e m o v et h e f u e l p u m p a d a p t o r p l a t e c o m p l e t e w i t h that these be drawn into the block by means of a

r u b b e rs e a l i n gr i n g a n d b u s h .
W i t h d r a wt h e u p p e r t h r u s t c o l l a r c o m p l e t ew i t h p i s t o n
r i n g s e a l ,s e e F i g J 1 1 .
T h e f u e l i n j e c t i o np u m p a n d l u b r i c a t i n go i l p u m p d r i v e
s h a f t c o m p l e t ew i t h w o r m w h e e lc a n n o w b e p u l l e d u p
a n d r e m o v e ds, e e F i g .J 1 1
T h e w o r m w h e e li s s h r u n k o n a n d p u n c h p e e n e dt o t h e
d r i v e s h a f t I n t h e e v e n t o f t h e g e a r r e q u i r i n gr e n e w a t ,
t h e g e a r a n d s h a f t a s s e m b l ys h o u l d b e r e p l a c e d .T h e
I o w e r t h r u s t c o l l a r a n d b u s h w i l l r e m a i ni n i t s l o c a t i o n
i n t h e c y l i n d e rb l o c k a n d c a n b e r e m o v e db y r e m o v i n g
the sumpand lubricatino gil pump.
W i t h t h e u s e o f a s p e c i a lt o o l P D 1 4 0 w i t h a d a p t o r1 4 0 - 3
t h e t h r u s t c o l l a r a n d b u s h c a n n o w b e w i t h d r a w n ,s e e
Fig J.12 Some earlier enginesdid not have a bush
f itted.
W h e r e n e c e s s a r y ,r e n e w t h e a u x i l i a r yd r i v e s h a f t f r o n t
a n d r e a r b u s h e s i n t h e c y l i n d e r b l o c k . l t ' r sa d v i s a b l e
s u i t a b l et h r e a d e db a r a n d a d a o t o r s
To Refit Auxiliary Drive Shaft and Fuel Pump
Drive Shaft see Fig. J.13.
R e f i i t h e l o w e r t h r u s t c o l l a r a s s e m b l va n d o r e s s i n t o
oosition.
The wormwheeland fuel pump drive assembly can
now be fitted.
Fit the upper thrust collar with the piston ring seal
in its location
R e f i t t h e l u b r i c a t i n go i l p u m p a n d s u m p , f i l t i n g w i t h
o i l t o a n a p p r o v e dg r a d e .
F i t t h e f u e l p u r n pa d a p t o rp l a t ea s s e m b l yc, o m p l e t ew i t h
bush sealing ring and joint, so that the timing mark
s c r i b e d o n f l a n g e i s a d j a c e n tt o t h e o u t s i d e s e c u r i n g
s t ud .
Where oil leaks past the adaptorplate "O" ring occur in
service,the "O" ring shouldbe renewedand a joint (Pt No
36822118)fitted betweenthe adaptorplate and the cytinder
block.

J.11 J.13
T I M I N G C A S EA N D D R I V E J6

PABTSIDE VIEWON AUX.DRIVEHOUSING

J.15

J.14

Fit the auxiliary drive shaft into position with the T h e s p r a yt u b e i s a p u s h f i t i n t h e a u x i l i a r yd r i v e h o u s i n g

t h r u s t w a s h e r h a l v e sf i t t e d a r o q n d t h e g r o o v e i n t h e a n d s e a l e dw i t h a " D " p l u g
s h a f t ,f i n a l l y l o c a t i n gi n t h e c y l i n d e r b l o c k r e c e s sw i t h
D u r i n g e n g i n e o v e r h a u l ,t h i s s p r a y t u b e s h o u l d b e
two oppositebutt faces locatedby a dowel, see Fig. J.14
r e m o v e da n d c l e a n e d .
T h e e n d fl o a t o f t h e d r i v e s h a f t i s c o n t r o l l e d b y
New cylinder blocks suppliedas loose parts are not
the clearance between the thrust washers, (which are
fitted with this spray tube, therefore when renewing a
held in positionby the timing case) and the groove
c y l i n d e rb l o c k , e n s u r et h a t t h e t u b e i s t r a n s f e r r e df r o m
of the drive shaft
t h e o l d b l o c k ,o r a n e w o n e f i t t e d ( s e e F i g . J . 1 5 ) .
T h e e n d f l o a t i s b e t w e e n0 0 0 2 5 i na n d 0 . 0 0 9 i n( 0 . 0 6 4 m m
a n d 0 , 2 3m m ) .
R e p l a c et h e t i m i n g c a s e , t i m i n g g e a r s a n d f u e l p u m p
Checkingthe Timing Gear Backlash
R e m o v e t h e c a m s h a f t g e a r a n d a u x r l i a r yd r i v e g e a r
covers
AuxiliaryDrive Spray Tube C h e c k t h e b a c k l a s hb e t w e e nt h e t i m i n g g e a r s u s i n g a
T h e a u x i l i a r yd r i v e g e a r s a r e l u b r r c a t e db y o i l d i r e c t e o c l o c k g a u g eo r f e e l e rg a u g e s .
onto them by a spray tube T h e b a c k l a s hs h o u l db e 0 . 0 0 3i n ( 0 , 0 8m m ) m i n r m u m .
SECTIONK
Timing
TIMING K2
Timing Marks
W h e n t h e e n g i n e t i m i n g i s s e t a t t h e f a c t o r y ,m a r k i n g s
a r e m a d e o n t h e c r a n k s h a f tg e a r , i d l e r a n d c a m s h a f t
g e a r w i t h t h e e n g i n es e t w i t h N o 1 p i s t o n a t T D . C o n
i t s c o m p r e s s i o sn t r o k e( s e eF i g . K . 1 )
T h e r e m a y b e m a r k i n g so n t h e e n g r n et o e s t a b l i s ht r u e
T D.C but where not, No. 1 piston at T D C on rts
compression stroke can be ascertained by dropping
a v a l v eo n t o N o 1 p i s t o n c r o w n a n d w i t h t h e m e a n so {
a c l o c k g a u g e e s t a b l i s ht h e m a x i m u m l i f t o f t h e v a l v e
w h e n t h e v a l v e so f N o . 6 c y l i n d e r s h o u l d b e r o c k i n g ,
I t s h o u l d b e n o t e d t h a t F i g K . 1 h a s b e e n p r e p a r e dt o
s h o w t h e m a r k i n g so n t h e t i m i n g g e a r s .T h e c a m s h a f t
a n d f u e l p u m p g e a r s a r e n o t n o r m a l l yf i t t e d u n t i l t h e
t i m i n gc a s eh a s b e e n r e p l a c e d .
Fuel Pump Timing
When the fuel pump is removed,a machined slot
will be noted in the top of the fuel pump drive shaft
a n d a s l o t a p p r o x i m a t e l y%i n ( 3 , 2m m ) w i d e i n t h e
a d a p t o rp l a t ew i l l a l s o b e s e e n ( F i g . K . 2 ) .
With No 1 piston set at T D C on its compression
s t r o k e ,t h e s et w o s l o t ss h o u l db e i n l i n e
O n t h e m o u n t i n gf l a n g e o f t h e f u e l p u m p i s a s c r i b e d
Irne and a further line is scribed on the fuel pump
a d a o t o rD l a t e
W h e n t h e f u e l p u m p i s f i t t e d ,t h e s e t w o m a r k s s h o u l d
b e i n a l i g n m e n t( s e eF i g . K 3 )
K.1
To ResetEngine Timing
I t i s a s s u m e dt h a t t h e t i m i n g c a s e a n d a l l t h e t i m i n g
g e a r s h a v e b e e n r e m o v e d a n d r e q u i r e r e p l a c i n gw i t h
t h e k n o w l e d g et h a t t h e v a l v e a n d f u e l p u m p t i m i n g
w i l l b e t o t h e o r i g i n a ls e t t i n g .
T o r e s e t t h e t i m i n g t o t h e o r i g i n a l m a r k i n g s ,p r o c e e d
as follows:
Removethe rocker assembly,push rods and atomisers
T u r n t h e e n g i n ec r a n k s h a fut n t i l N o s 1 a n d 6 p i s t o n sa r e
at T.D.C.
That this has been obtarned may be checked by
observingthat the keyway for the crankshaftgear is at
T D C
P l a c et h e t w o i d l e r g e a r s i n p o s i t i o no n t h e i r r e s p e c t i v e
hubs, making sure that the double line timing mark
o n t h e l e f t h a n d g e a r i s o p p o s i t et h e s i n g l e l i n e t i m i n g
m a r k o n t h e c r a n k s h a f gt e a r ( s e eF i g K 1 ) . T h e n t i g h t e n
t h e s e c u r i n gn u t s t o t h e c o r r e c t t o r q u e ( s e e p a g e 8 . 2 ) .
R e p l a c et h e t r m i n g c a s e a n d s e c u r e i t t o t h e c y l i n d e r
block
F i t c r a n k s h a f pt u l l e ya s d e t a i l e do n P a g e H 6
With the engine still in the T.D C position,refit the
c a m s h a f tg e a r w i t h t h e d o u b l e d o t t i m i n g m a r k o p p o s i t e
t h e s i n g l ed o t t i m i n g m a r k o n t h e i d l e r g e a r .
D r a wg e a ro n t o c a m s h a f at n d f i t w a s h e r ,t a b w a s h e r ,s h i m
w a s h e ra n d r e t a i n i n gs e t s c r e w T i g h t e n s e t s c r e wt o t h e
correcttorque (seepageB 2) and lock with tab washer
 T I M I N GK 3

K.2 K.3 (C.A.v. Pump)

W i t h t h e e n g i n es t i l l a t T . D . C t u r n t h e f u e l p u m p d r i v e
CheckingFuel Pump Timing
s h a f t u n t i l t h e m a c h i n e ds l o t i n t h e f u e l p u m p d r i v i n g
Ensuresthat No. 1 pistonis at T.D.C,on compression.
h u b i s i n l i n e w i t h t h e m a c h i n e ds l o t i n t h e f u e l o u m o
The valveson No, 6 cylindershouldbe rocking.
a d a p t o rp l a t e( s e eF i g K 2 ) .
R e m o v et h e f u e l i n j e c t i o n p u m p a n d e n s u r e t h a t t h e
F i t t h e f u e l p u m p d r i v eg e a r w i t h t h e p a r t n u m b e r t o t h e
s l o t i n t h e f u e l p u m p d r i v i n g h u b i s i n a l i g n m e n tw i t h
f r o n t s o t h a t t h e t h r e e s e t s c r e wh o l e s c o i n c i d e w i t h
t h e s l o t i n t h e f u e l p u m p m o u n t i n gf l a n g e .
the holes in the fuet pump drive shaft when it is in
m e s hw i t h t h e i d l e rg e a r a n d s e c u r ei n t h i s p o s i t i o n . lf these slots are not in line, the necessaryadjustment
E n s u r ew h e n f i t t i n g t h e g e a r , t h a t t h e t w o m a c h i n e d shouldbe made on the fuel pump drive gear,through
s l o t s r e m a i ni n l i n e t h e a p e r t u r ei n t h e t i m i n g c a s e

F i t t i m i n g g e a r c o v e r st o t h e t i m i n g c a s e . T h i s a d j u s t m e n tm a y b e e f f e c t e db y s l a c k e n i n go f f t h e
t h r e e g e a r s e c u r i n gs e t s c r e w sa n d t u r n i n g t h e a u x i l i a r y
R e p l a c et h e f u e l p u m p e n s u r i n g t h a t t h e s c r i b e d l i n e drive shaft by means of the setscrews
o n i t s m o u n t i n gf l a n g e c o i n c i d e sw i t h t h e s c r i b e d l i n e
W h e n t h e t i m i n g i s f o u n d t o b e c o r r e c t ,r e f i t t h e f u e l
o n t h e f u e l p u m p a d a p t o rp l a t e ( s e e F i g . K 3 ) .
p u m p e n s u r i n gt h e s c r i b e dl i n e o n t h e m o u n t i n gf l a n g e
W i t h l a t e r B o s c h f u e l p u m p s ,t h i s s c r i b e d l i n e i s o n t h e c o i n c i d e sw i t h l t h es c r i b e dl i n e o n t h e f u e l p u m p a d a p t o r
t o p o f t h e m o u n t i n gf l a n g e . plate (see Fig. K.3)
R e p l a c ea t o m i s e r sa n d f u e l p i p e s .
R e p l a c e r o c k e r a s s e m b l ya n d a d j u s t v a l v e c l e a r a n c e
CheckingValveTiming CheckingFuel Pump Timing
(AlternativeMethod-C.A.V. Fuel Pumps only)
1 . T u r n t h e c r a n k s h a f ut n t i l t h e v a l v e so n N o . 6 c y l i n d e r
T h e r ei s a r o t o r i n t h e p u m p b e a r i n ga n u m b e ro f s c r i b e d
a r e r o c k i n g . I n t h i s p o s i t i o n ,s e t t h e c l e a r a n c eo n
l i n e s ,e a c h o n e h a v i n ga n i n d i v i d u a l e t t e r( s e e F i g K . 4 )
N o . 1 i n l e t v a l v e t o o n e o f t h e f o l l o w i n gc l e a r a n c e s
A t i m i n g c i r c l i p i s p o s i t i o n e di n s i d e t h e p u m p w h i c h
a c c o r d i n gt o t h e p a r t n u m b e r w h i c h i s s t a m p e do n
has to be set so that when the appropriatescribed line
the rear of the camshaft:
o n t h e f u e l p u m p r o t o ra l i g n sw i t h t h e s t r a i g h te d E eo f t h e
c i r c l i p , i t d e n o t e s c o m m e n c e m e n to f i n j e c t i o n ( s t a t i c
Camshaft Part No. Clearance timing).
31416207 0 . 0 5 1i n ( 1 , 3 0 m m ) T o s e t t h e t i m i n g c i r c l i p ,i t i s n e c e s s a r yt o r e m o v et h e
| 31416222 0 . 0 2 6 i n( 0 , 6 6 m m ) p u m pf r o m t h e e n g i n ea n d f i x t h e p o s i t i o no f t h e c i c c l i pb y
31416302 0 0 5 1i n ( 1 , 3 0 m m ) connectingNo 1 cylinder outlet connection (X) on
31416303 0 0 4 7 i n( 1 , 1 9 m m ) t h e p u m p t o a n a t o m i s e rt e s t e ra n d p u m p u p t o 3 0 a t m
31416304 0 . 0 6 0 i n( 1 , 5 2 m m ) 4 4 0 l b t / i n 2o r ( 3 1k g f / c m r ) T u r n t h e p u m p b y h a n d i n t h e
n o r m a ld i r e c t i o no f r o t a t i o nu n t i l i t l o c k su p . T h e s q u a r e d
2. Turn the crankshaftin the normaldirectionof rotationuntil e n d o f t h e c i r c l i ps h o u l dn o w b e a d j u s t e du n t i l i t l i n e su p
the pushrodof No. 1 inletvalvejusttightens. w i t h t h e l e t t e r" F " o n t h e p u m p r o t o r
3. Checkthat Nos. 1 and 6 pistonsare at T.D.C.The valve E n s u r et h e f u e l p u m p i s c o r r e c t l yf i t t e d w i t h t h e s c r i b e d
timingtoleranceis plusor minus2l/2". l i n e o n t h e m o u n t i n g f l a n g e c o i n c i d i n gw i t h t h e m a r k
4. When the valve timingis foundto be correct,resetvalve o n t h e f u e l p u m p a d a p t o rp l a t e
clearance to 0.008in (0,20mm)cold. Positionthe crankshaftso that No 1 piston is at T.D.C
.lncludes on its compressionstroke.
I6.3544 NorthAmericavehicleengine.
Note: Thereis no adjustmentprovidedfor valvetiming.lf the Removethe rocker cover.
timingis foundto be incorrect,thenthe gearscan onlybe one R e m o v et h e c o l l e t s ,s p r i n g c a p a n d s p r i n g sf r o m N o . 1
or moreteeih out of correctmesh. inletvalveand allowthe valveto reston top of the oisron

6 3544SeriesWorkshopl\y'anual,
January1986
TIMING K4

Repositionthe valve stem seal to the collet groove to CheckingFuel Pump Timing
p r e v e n t h e v a l v ef r o m d r o p p i n gi n t o t h e c y l i n d e r . (AlternativeMethod - Bosch Fuel Pumps only)
With the aid of a clock gauge in contact with the end E n s u r e f u e l p u m p i s c o r r e c t l yf i t t e d t o e n g i n e a s d e s -
of the valve now sitting on No. 1 piston, it will be c r i b e d u n d e r " T o R e s e t E n g i n eT i m i n g " o n P a g e K 2 .
necessaryto position the crankshaft so that the piston
W i t h t h e r o c k e r c o v e r r e m o v e d s, e t t h e e n g i n et o T . D . C .
w i l l b e a t i t s s t a t i ct i m i n g p o i n t ( s e eP a g eB 1 0 ) .
N o . 1 c y l i n d e r c o m p r e s s i o n ,i . e . , t h e v a l v e s o f N o . 6
T o d o t h i s , t u r n t h e c r a n k s h a f it n t h e o p p o s i t ed i r e c t i o n c y l i n d e rr o c k i n g .
t o n o r m a l r o t a t i o n ,a p p r o x i m a t e l ya n e i g h t h o f a t u r n
T h o r o u g h l yc l e a n t h e f u e l p u m p a r o u n d t h e v e n t p l u g
B T . D C a n d t h e n f o r w a r d u n t i l t h e r e q u i r e dp o s i t i o n
i n t h e h v d r a u l i ch e a d .
i s r e g i s t e r e do n t h e c l o c k g a u g e T h i s e n a b l e s t h e
b a c k l a s hi n t h e t i m i n g g e a r st o b e t a k e n u p Removethe centralplug from the end of the pump (C, Fig.
R e m o v e t h e f l a t i n s p e c t i o np l a t e o n t h e f u e l p u m p N.14) andfit one of the timingtoolassemblies
givenbelow:-
e n a b l i n gt h e r o t o r t o b e s e e n . Bosch: Body 1688 130 045, Extension1683 458 019 and
Dial lndicator1687233 012
Churchill:AdaptorMS107and DialIndicator
SM991A.
Ensuredirtdoesnot enterthe pump.
Ensurethat the dial indicatorplungeris depressedat least
0 . 1 1 8 i n( 3 m m ) t o c o v e r t h e p l u n g e rl i f t w h i c h i s 0 . 1 1 0 i n
(2,Bmm).
Turnthe enginein eachdirectionto obtainB.D.C.of the pump
plungerand setthe dialindicator
to zeroat thispoint.

K.4 (C.A.V.Pump)

With No. 1 piston at the static timing point on its

compression s t r o k e ,t h e s c r i b e dl i n e o n t h e r o t o r m a r k e d
'F'should
a l i g nw i t h t h e s t r a i g h et d g eo f t h e t i m i n gc i r c l i p .
S e eF i g .K 4 .
lf the timing marks do not align, releasethe nurs
s e c u r i n gt h e f u e l p u m p a n d t w i s t t h e p u m p b o d y i n
t h e r e q u i r e dd i r e c t i o n u n t i l t h e m a r k s a l i g n F u r t h e r
a d j u s i m e n tc a n b e m a d e b y t u r n i n g t h e a u x i l i a r yd r i v e
s h a f t ,a f t e rt r r s tr e l e a s r n tgn e a u x i l i a r yd r i v eg e a r s e c u r i n g
setscrews
l f a f t e r b o t h t h e s e a d l u s t m e n t s t, h e t i m i n g m a r k s d o
n o t a l i g n , i t c o u l d m e a n t h e a u x i l i a r yd r i v e g e a r h a s
f i t t e di n c o r r e c t l y

K.5

R e p o s i t i o nt h e e n g i n e a t T . D . C .N o 1 c y l i n d e rc o m p r e s -
sion and using tool No. 61188, remove the collets,
spring cap and springs from No. 1 inlet valve (see
F i g . K . 5 ) a n d a l l o w t h e v a l v et o r e s t o n t h e t o p o f t h e
piston. Reposition the valve stem seal to the collet
groove to prevent the valve from dropping into the
cylinder.
P o s i t i o na d i a l i n d i c a t o rw i t h t h e p l u n g e rr e s t i n go n t o p o f
the valve stem, determineexact T D.C. position and zero
the dial indicator.

6 3544SeriesWorkshopManual,January1986

K.6
T u r n t h e c r a n k s h a f it n t h e o p p o s i t ed i r e c t i o nt o n o r m a l
rotation approximately'/eof a turn and therr turn in the
normal direction of rotation until the dial indicator
i n d i c a t e tsh a tt h e p i s t o ni s0 12 5i n ( 3 , 1B m m ) B . T D C .
A t t h i s p o s i t i o n ,t h e d i a l i n d i c a t o r o n t h e f u e l p u m p
s h o u l d r e a d 0 . 0 3 9 4i n ( 1 m m ) - s e e F i g . K . 6 .
Adjust timing as necessaryby releasingthe three screws
s e c u r i n gt h e a u x i l i a r yd r i v e g e a r t o t h e a u x i l i a r yd r i v e
shaft.
l f t h e p l u n g e rl i f t i s i n e x c e s so f 1 m m , t u r n t h e a u x i l i a r y
d r i v es h a f tc l o c k w i s ea n d t h e n a n t i - c l o c k w i s eu n t i l 1m m
l i f ti s o b t a i n e dS e c u r e t h eg e a re n s u r i n gt h e g e a rb a c k l a s h
i s t a k e n u p b y h o l d i n gt h e g e a r a g a i n s tn o r m a l d i r e c t i o n
of rotation
l f t h e p l u n g e lri f ti s l e s st h a n 1 m m , t u r n t h e a u x i l i a r d
yrive
s h a f ta n t i - c l o c k w i suen t i l 1 m m l i f t i s o b t a i n e d S e c u r er n e
g e a r e n s u r i n gt h e g e a r b a c k l a s hi s t a k e n u p b y h o l d i n g
t h e g e a r a g a i n s t h e n o r m a ld i r e c t i o no f r o t a t i o n .
R e c h e c kt i m i n g a s p r e v i o u s l yd e t a i l e d
W h e n t i m r n g i s c o r r e c t ,t u r n t h e e n g i n e i n t h e n o r m a l
d i r e c t i o no f r o t a t i o nu n t i l N o . 1 p i s t o n i s a t T . D . C . R e f i t
valvestem oil seal,valve springs,spring cap and collets.
Resetvalveclearanceto 0 008in (0,20mm).
Removethe specialtiming tool from the fuel pump and refit
the plug,lf the largeinspectionplugwas removed,tightenit to
4Olbfft(54Nm) s,skgfm or if the small vent plug was re-
moved,tightenit to Tlbfft (10Nm) 1,0kgfm. lf ihe lowpressure
fuel pipes have been disturbed,bleed the system as de-
scribedon PageN.7.
CheckingFuel Pump Timing
( U s i n gC h u r c h i l T
l ool MS.67B- See Fig. K.7)
W i t h t h e e n g i n e p o s i t i o n e dw i t h N o 1 p i s t o n a t T . D . C .
compressionstroke, the tool is substitutedfor the fuel
i n j e c t i o np u m p .A s t h e e n g i n ei s a t T . D . C . ,t h e p o i n t e ro n
t h e t o o l i s s e t a t t h e r e l e v a n tf u e l p u m p m a r k i n ga n g l e ,
plus half the static timing angle and then the timing
t r a i n i s s e t t o c o r r e s p o n dt o t h e t i m i n g m a r k o n t h e f u e l
injectionpump adaptor plate.
6 3544SeriesWorkshopl\ilanual,
January1986
TIMING K5
K.7
To Gheck Engine MarkingAngle
Position the engine with No. 1 piston at T D.C.
c o m p r e s s i o an n d u s i n gt o o l N o . 6 11 B B ,r e m o v et h e c o l l e t s ,
s p r i n g c a p a n d s p r i n g sf r o m N o . 1 i n l e t v a l v e a n d a l l o w
the valveto rest on the top of the piston. Repositionthe
inletvalvestemsealto the colletgrooveto preventthe valve
f r o m d r o p p i n gi n t o t h e c y l i n d e r .P o s i t i o na d i a l i n d i c a t o r
with the plungerrestingon top of the valvestem,determine
t h e e x a c tT . D . C .o o s i t i o n
R e m o v et h e f u e l i n j e c t i o np u m p .
R e l e a s es c r e w ( 5 ) - F i g . K . 7 - a n d p o s i t i o ns p l i n e d
s h a f t ( 6 ) s o t h a t i h e l a r g e r s p l i n e d a d a p t o ri s t o t h e
front of the tool
E n s u r et h a t t h e s l o t t e dp o i n t e r( 2 ) i s p o s i t i o n e dw i t h t h e
slot to the f ront of the tool and chamferedsides of the slot
are outwards.At this stage,the slotted,end of the pointer
should be kept well back from the front of the body.
Ensure that the flat in the washer fitted behind Dointer
securingscrew (3) is locatedoverpointer
Releasethe bracket screw (4) and set bracket so that
t h e c h a m f e r e de d g e i s i n l i n e w i t h t h e r e l e v a n te n g i n e
checkingangle.This angle can be obtainedby reference
to the fuel pump setting code and table given on
P a g e8 1 1 .
Fit timingtool to the enginein the fuel pump position
e n s u r i n gf i r s t l yt h a ts p l i n e ds h a f tw i t h m a s t e rs p l in e i s f u l l y
locatedin pump drive shaft and then that the registerof
tool is seated in fuel pump locating aperture Lock
s p l i n e ds h a f t i n t o o l l f p o i n t e ri s 1 B 0 of r o m t i m i n g m a r k ,
e n g i n e i s p r o b a b l yo n i t s w r o n g s t r o k e , i n w h i c h c a s e ,
removethe tool and set the engine on correct stroke
S l i d e t h e s l o t t e dp o i n i e r d o w n w a r d ss o t h a t t h e e n d o f
p o i n t e ra b u t s f l a n g e- s e e F i g . K . 8
T u r n t i m i n g t o o l b y h a n d i n o p p o s i t ed i r e c t i o nt o p u m p
rotation(shown on pump nameplate)to take up backlash
a n d t h e n c h e c kt h a t t i m i n g m a r k o n f u e l p u m p a d a p t o ri s
i n l i n e w i t h s l o t o f p o i n t e r .l f t i m i n g m a r k d o e s n o t a l i g n ,
t h e p o s i t i o no f t h e a u x i l i a r yd r i v es h a f ts h o u l db e a l t e r e d
r e l a t i v et o i t s d r i v e g e a r .T h e h o l e s i n t h e a u x i l i a r yd r i v e
gear are slottedto allow for adjustment
W h e ne n g i n et i m i n gi s c o r r e c t r, e m o v et h et o o l .
W h e r e n e c e s s a r yt,h e f u e l p u m p m a r k i n ga n g l e c a n b e
checked by using timing tool as described later
Refitf uel pump to engineas given on PageN.6.Refit No. 1
inletvalvestem seal,valvesprings,spring cap and collets
Then set valve clearanceto 0 008 in (0,20mm).
TIMING K6
K.9
K.8
Checking Fuel Pump Marking Angle
R e l e a s es c r e w ( 5 ) - F i g . K . 7 - a n d r e m o v es p l i n e d
shaft (6)
Ensureslotted pointer (2) is positionedwith slot to rear
of tool and chamferedside of slot outwards At this stage,
slotted end of pointer should be kept well back towards
b o d y o f t o o l E n s u r et h a t f l a t i n w a s h e r f i t t e d b e h i n d
pointer securingscrew (3) is locatedover side of pointer.
W i t hC . A . V p u m p s ,c o n n e c tN o 1 o u t l e tc o n n e c t i o no f t h e
p u m p ( m a r k e d" X " ) t o a n a t o m i s e rt e s t e ra n d p u m p u p t o
3 0 a t m 4 4 0 l b/fi n 2 o r ( 3 1 k g f l c m r ) l f a p r e s s u r i s i n gv a l v e
is fitted, this must be removed.
Release bracket screw (4) - see Fig. K 7 - and set
b r a c k e t s o t h a t t h e c h a m f e r e de d g e i s i n l i n e w i t h
r e l e v a n tp u m p m a r k i n ga n g l e ( s e e P a g e B 1 1 ) .
P o s i t i o nt i m i n g t o o l o n p u m p d r i v e w i t h m a s t e r s p l i n e s
engaged and tool locatedon spigot - see Fig. K.g.
W i t h C A V p u m p s ,t u r n t h e p u m p i n t h e n o r m a l d i r e c -
t i o n o f r o t a t i o na s s h o w n o n n a m e p l a t e u n t i l i t " l o c k s
up".
6 3544SeriesWorkshoplvlanual,
January1986
With Bosch pumps, ensure that the keyway in the fuel
p u m p d r i v e s h a f t i s i n l i n e w i t h N o 1 o u t l e t m a r k e d" D "
o n t h e h y d r a u l i ch e a d .
Removethe centralplug from the end of the pump (C, Fig.
N.14)and fit one of tli're givenbelow:-
timingtoolassemblies
Bosch: Body 1688 130 045, Extension1683 458 019 and
Dial lndicator1687233O12.
Churchill:AdaptorMS107,and DialIndicator
SM991A
Ensuredirtdoesnot enterthe pump.
Turn the pump againstthe normaldirectionof rotationano
zerothe dialindicatorwhenthe plungeris at B.D.C.Thenturn
pump in normal directionof rotationuntil 0 0394in (1mm) of
liftis obtainedon the pumpplunger.
In thesepositions(forbothC.A.V.and Boschpumps)slidethe
pointer(2) of the timingtool - Fig. K.7 - forwarduntilit is
halfwayover the pump flange and check that timing mark on
the f langeis centralto the slotin the pointer- see Fig.K.9.
lf necessary,removeincorrectlypositionedmark and make a
new markin the correctpositionon the pumpflange.
Removetimingtool from Bosch pumpsand refitthe plug.lf
the large inspectionplus was removed,tighten it to 4olbfft
(54Nm) 5,5kgfm or, if the small vent plug was removed,
tightenit to Tlbfft (10Nm) 1,0kgfm).
 SECTIONL
LubricatingSystem

@
@
g
4
:-44
L U B R I C A T I N GS Y S T E M

- - R O G K E-R
- -_ S H A F T- --_ A S S E M B L-Y -

GOOLI]{GJET GAttERY
AUXITIARY
DRIVE

L.1

Note: Piston cooling is only applicable to mosr

t u r b o c h a r g e de n g i n e s e x c e p t c u r r e n t T 6 . 3 5 4 4 e n g i n e s
f i t t e d t o g e n e r a t i n gs e t s a n d a n o i l c o o l e r i s n o t a l w a y s
f i t t e dt o n a t u r a l l ya s p i r a t e de n g i n e s .B y - p a s sv a l v e sa r e
not incorporated i n o i l c o o l e r sf i t t e dt o n a t u r a l l ya s p i r a t e d
engrnes
 LUBRICATINGSYSTEM L3

Oil Circulation
T h e l u b r i c a t i n go i l p u m p d r a w s o i l t h r o u g h t h e s u c t i o n
pipe and strainerto an oil cooler, cooled by water from
t h e e n g i n e c o o l i n g s y s t e m .O i l c o o l e r sa r e n o t a l w a y s
fitted to naturallyaspiratedengines. From the oil
c o o l e r ,o i l p a s s e st h r o u g h a t u l l f l o w f i l t e r t o t h e m a r n
p r e s s u r er a i l d r i l l e d t h e l e n g t h o f t h e c y l i n d e r b l o c k .
D r i l l i n g si n t h e c r a n k c a s ew e b s f e e d o i l f r o m t h e m a r n
g a l l e r yt o t h e m a i nb e a r i n g sa n d d r i l l i n g si n t h e c r a n k s h a f t
carry oil to the big-end bearings Through drillings
in Nos.1,3,5 and 7 crankcase w e b s ,o i l p a s s e sf r o m
t h e m a i n b e a r i n g st o l u b r i c a t et h e c a m s h a f tb e a r i n g s .
N o 2 c a m s h a f tb e a r i n gs u p p l i e sa c o n t r o l l e df e e d o f o i l
to the rocker shaft assemblywhich escapesthrough a
small bleed hole in each rocker lever to lubricate the
v a l v e sa n d s p r i n g s .
With most turbochargedengines,the pistonsare cooled by
lubricatingoil being sprayed on their undersidesby piston
coolingjets. L.2

Pistons fitted to naturally aspirated engines are not

cooled and cooling jets are not fitted.
The feed for the piston cooling jets is controlled by a Oil Strainer
two stage pressure relief valve situated after the oil T h e o i l s t r a i n e ri s p a r t o f t h e o i l p u m p s u c t i o n p i p e .
cooler and comes into operationat a specifiedpressure T h e r e i s n o p e r i o d i c s e r v i c i n go n t h i s s t r a i n e r b u t i t
after oil is flowing f reelyto the main working parts of the should be cleaned wheneverthe sump is removed.
engrne.
L u b r i c a t i o nf o r t h e t i m i n g g e a r s i s t a k e n f r o m t h e o i l
passagesconnecting the pressure rail with the front To RemoveOil Pump
m a i n b e a r i n ga n d a u x i l i a r yd r i v e
Remove the sump and then the setscrews securing
T h e t w o i d l e r g e a r h u b s i n t e r s e c t h e s ed r i l l i n g sa n d o i l the oil pump to cylinder block and withdraw the oil
i s p a s s e dt h r o u g h t h e h u b s t o r a d i a l d r i l l i n g s i n t h e p u m p ,s e e F i g . L . 2
i d l e r g e a r st o l u b r i c a t et h e t e e t ho f t h e g e a r t r a i n .
T h e a u x i l i a r yd r i v e s h a f t b e a r i n g sa r e l u b r i c a t e db y a
d r i l l i n g f r o m t h e p r e s s u r er a i l t o t h e f r o n t a u x i l i a r y
d r i v es h a f tb e a r i n gT . h e o i l t h e n p a s s e sa r o u n da g r o o v e
To Dismantle Oil Pump, see Fig. L.3
i n t h e b e a r i n gj o u r n a l a n d t h r o u g h a f u r t h e r d r i l l i n g Remove the suction pipe and bottom cover of the oil
a l o n gt h e o u t e r s i d e o f t h e a u x i l i a r yd r i v eh o u s i n gt o t h e pump.
r e a ra u x i l i a r yd r i v es h a f tb e a r i n g
L u b r i c a n tf o r t h e u p p e r f u e l p u m p b e a r i n g i s a l s o
t a k e nf r o m t h i s d r i l l i n g
A l s o c o n n e c t e dw i t h t h e o u t e r d r i l l i n g i s a s m a l l s p r a y
tube, which directs oil onto the wormwheel ano
wormgear
O i l p r e s s u r ei s c o n t r o l l e db y a p r e s s u r er e l i e fv a l v et h a t
r e t u r n se x c e s so i l t o t h e s u m p .
w
T h e f i l t e r i s p r o v i d e dw i t h a b y - p a s sf a c i l i t yi n t h e e v e n t
of blockage.
O i l c o o l e r sf i t t e d t o n a t u r a l l ya s p i r a t e de n g i n e s d o n o t
h a v e b y - p a s sv a l v e s .

To RemoveSump
L o w e r t h e s u m pb y r e l e a s i n g
a l l f l a n g es e t s c r e w a
s ndnuts

To ReplaceSump
P l a c et h e s u m p i n p o s i t i o na n d s e c u r e b y f a s t e n i n gt h e
n u t so n t h e f o u r s t u d s l o c a t e di n t h e b r i d g ep i e c e s .
The securingsetscrewscan now be inserted
Tighten the setscrewsand nuts to a torque of 15lbfft
( 2 , 1 k gm
f ) or 20llm. L.3

6 3544SenesWorkshopi/anual,January1986
L U B R I C A T I N GS Y S T E M L4

L.4 L.6

The shaft, inner and outer rotors can now be removed
Inspectionof Oil Pump
The innerrotormay have4 or 6 lobesand the outerrotor5 or
7lobes
Inspect the rotors for cracks or scores.
I n s t a l lt h e d r i v e a n d d r i v e n r o t o r s i n t h e p u m p b o d y .
The two sections of the outer rotor can be fitted in
any oroer.
Check clearancesgiven on Page 89, between inner
and outer rotors,see Fig. L.4, rotor end float,see Fig. L 5,
and clearancebetweenouter rotor and pump body, see
Fig 1.6
These clearancesare applicableto a new pump and are
t o b e u s e da s a g u i d e .
l f t h e p u m p i s f a u l t y ,i t m u s t b e r e p l a c e da s a c o m p l e t e
u n i t a s p a r t s a r e n o t s u p p l i e di n d i v i d u a l l y .
To Re-assembleand Refit Oil Pump
With the inner and outer rotors fitted into the pump
b o d y , r e f i t t h e e n d c o v e r w i t h t h e l o c a t i n gd o w e l s i n
p o s i t i o na n d w i t h t h e j o i n t f a c e ss m e a r e dw i t h a s u i t a b l e
j o i n t i n gc o m p o u n d .
P r i m et h e p u m p w i t h c l e a nl u b r i c a t i n go i l
T h e o i l p u m p a s s e m b l ya n d j o i n t c a n n o w b e f i t t e d i n t o
i t s l o c a t i o ni n t h e c y l i n d e rb l o c k a n d s e c u r e dw i t h t w o
setscrewsand washers
R e f i tt h e s u c t i o np i p e a n d s t r a i n e r
R e p l a c et h e s u m p , a n d r e f i l l w i t h o i l t o a n a p p r o v e d
g rade.
To Removeand Dismantlethe Pressure
ReliefValveAssemblysee Fig. L.7
R e m o v et h e s u m p a n d t h e n t h e p i p e f r o m v a l v e t o
t h e c y l i n d e rb l o c k ( T 6 3 5 4 4o n l y ) .
Release the two securing setscrews and remove the
valve
R e m o v et h e c i r c l i p w h i c h w i l l e n a b l et h e s p r i n g s e a t ,
s p r i n ga n d p l u n g e rt o b e w i t h d r a w nf r o m t h e v a l v eb o r e .

i%"
ffi &?$&WWS

t :

L,7

To Assembleand Retit the Pressure

Relief Valve Assembly
R e p l a c et h e p l u n g e r ,s p r i n g a n d s p r i n g s e a t i n t h e v a l v e
bore and refit the circlip.

6 3544SeriesWorkshopManual,January1986
 LUBRICATINGSYSTEM L5

Using a new joint, refit the valve assembly to the To RemoveOil Cooler
c y l i n d e rb l o c k .
Drain the cooling system also the coolant from the
R e fi t p i p ef r o m v a l v et o t h e c y l i n d e rb l o c k .( T 6 3 5 4 4o n l y ) . c o o l e rb y r e m o v i n gt h e d r a i n p l u g . D r a i n t h e l u b r i c a t i n g
With turbochargedengines,the f irst blow off stageto feed o i l f r o m t h e c o o l e r b y r e m o v i n gt h e o i l d r a i n p l u g
the piston cooling jets should reach a steady flow at Disionnect the cooler inlet and outlet connections
30/37lbt/in2 12,11/2,60k9t/cm2) or 2O7/255kN/m2, relief Removethe oil filter assembly(wherefitted) or canisters
valve flow should commence at 50/60lbt/in, B.S2/ f r o m t h e c o o l e rc a s t i n g .
4,22kgf/ cmzl ot 343/414 kN/ m,.
Releasethe five setscrewssecuring the cooler to the
W i t h n a t u r a l l ya s p i r a t e de n g i n e s t, h e r e i s o n l y o n e o r o w adaptoror cylinder block and removethe cooler.
off stage, when the relief valve flow should commence
at 50/60|bf/in, (3,52/ 4,22kgI/c m,) o r 343/ 414kN/ mz
R e f i tt h e s u m p a n d f i l l w i t h l u b r i c a t i n go i l t o a n a p p r o v e o To DismantleOil Gooler
g raoe. TurbochargedEngines-Lefl Hand Mounting
( s e eF i g s .L B a n d L . 9 )
Remove three nuts and washers securing the flanged
Oil Coolers tube stack to the cooler bodv
O i l c o o l e r sa r e f i l l e dt o t u r b o c h a r g e de n g i n e sa n d s o m e
n a t u r a l l ya s p i r a t e de n g i n e s
Four different types of cooler are utilised. For turoo-
c h a r g e de n g i n e sh a v i n gt h e c o o l e r o n t h e l e f t h a n d s i d e
o f t h e e n g i n e ,s e e F i g s .L 8 a n d L . 9 .
T h e o i l c o o l e rf i t t e dt o t h e r i g h th a n ds i d eo f t u r b o c h a r g e d
e n g i n e si s s h o w n i n F i g L 1 0 . T h i s c o o l e r h a s t w o f i l t e r
canistersfitted on the top of the cooler and the coorer
i ncorporatesthe oi I pressurereliefvalve.
Where an oil cooler is fitted to the left hand side of
n a t u r a l l ya s p i r a t e d
e n g i n e st,h i s i s s h o w ni n F i g .L 1 1 ,a n d
where fitted to the right hand side of naturallyaspirated
e n g i n e st,h e n t h i s i s s h o w n i n F i g L 1 2 .
Oil passesthrough the cooler and is cooled by water
f lowing through the tubes A valve is incorporated
into the headcastingwhich allows oil to by-pass the
cooler in the event of a restriction,where the oil coorer
is fitted to the left hand side of turbochargedengines
Oil coolers fitted to the right hand of turbocharged
e n g i n e s o r e i t h e r s i d e o f n a t u r a l l ya s p i r a t e de n g i n e s
do not have by-passvalves.

Withdrawthe tube stackf rom out of the coolerbodv.

R e m o v et h e " O " r i n g s
Removeplug and washer from the cooler bypass valve.
W i t h d r a ws p r i n ga n d p i s t o n .

To Re-assembleOil Cooler
TurbochargedEngines- Left Hand Mounting
New "O" rings must always be used.
L i g h t l yo i l t h e r i n g s a n d t h e i r r e s p e c t i v el o c a t i o n s .
T h e f i r s t" O " r i n g s h o u l dt h e n b e f i t t e dt o t h e f l a n g e de n d
o f t h e t u b e s t a c k , b y p l a c i n g i t o v e r t h e o p p o s i t ee n d
and sliding it over the full length of the stack until
its locationis reached.
The second "O" ring may now be fitted into the groove
o n t h e u n p o r t e de n d o f t h e t u b e s t a c k .
Carefully insert the tube stack into the cooler body
until the flange locates onto the studs and secure with
1 spring washersand nuts
L.8 The bypass valve assembly may now be refitted into
1. Coolant Drain Plug the headcasting.
2. LubricatingOil Drain Plug R e f i tt h e w a t e ra n d o i l d r a i np l u g s
 LUBRICATING
SYSTEM L6

1.10
1. Coolant Drain Plug

To DismantleOil Cooler
TurbochargedEngines- RightHand Mounting
( s e eF i g . L . 1 0 )
Removerear clamp plate.
Removerear "O" ring.
Unscrewthree nuts at front of cooler and withdraw ruoe
stack out of front of cooler body complete with front
platewhich is integralwith tube stack
R e m o v ef r o n t " O " r i n g .
To remove oil pressure relief valve, remove end plate 1 . C o o l a n tD r a i nP l u g
and pipe (which relievesoil to crankcase)and witnoraw 2. LubricatingOil Drain Plug
s p r i n ga n d p l u n g e r .
To re-assemblecooler, reverse order of disman|ing,
To DismantleOil Cooler
N e w " O " r i n g ss h o u l d b e u s e d w h i c h s h o u l d b e l i g h f l y NaturallyAspirated Engines- Right Hand Mounting
oiled beforefitting. ( s e eF i g .L . 1 2 )
Removesinglescrew and locking tab at top of cooler.
Remove three screws at bottom of cooler and remove
c l a m pp l a t e
P u s ht u b e s t a c kd o w n a n d r e m o v et o p , , O , r, i n g .
Removetube stack out of top of cooler body and remove
b o t t o m" O " r i n g .
To re-assemblecooler, reversethe order of dismaniling.
N e w " O " r i n g s s h o u l d b e u s e d ,t h e s eb e i n g l i g h i l yo i l e d
beforefitting
With this cooler, where the coolant feed is taken from
the side of the cylinderblock, if it is necessaryto replace
t h e a d a p t o rw h i c h i s a p u s h f i t i n t h e b l o c k ,t h e n i t m u s t
b e f i t t e d u s i n g L o c t i t e R e t a i n i n gC o m p o u n dG r a d e 7 5 .

L.11 To Test an Oil Cooler

1. Coolant Drain Plug Suitable adaptors, incorporating pressure connecttons
2. LubricatingOil Drain Plug must be fabricated to blank off oil ports and water
connectrons
To test water side
To DismantleOil Cooler F i l l w a t e rs i d e w i t h w a t e ra n d i m m e r s et h e u n i t i n w a r e r ,
e n s u r i n ga b s e n c eo f t r a p p e da i r
NaturallyAspirated Engines- Lefi Hand Mounting
( s e eF i g . 1 . 11 ) Pressurisewater side with air at a pressureof 30lbf/in,
( 2 , 1 1 k 7 t / c m zo)r 2 0 7 k N / m ,a n d e x a m i n ef o r l e a k s
Remove screw complete with locking tab at each end
of the cooler. To test oil side
With water side filled with water and unit immersed in
Slidethe tube stackto the left and removethe right hand
water, pressurise oil side at a pressure of 90lbf/in,
s i d e" O " r i n g .
(6,33kgf/cmr)or 620kN/m, for turbochargedengines or
Removethe tube stack to the right and remove the left 60lbf/in, (4,22k9t/cm2) or 414kN/m, for naturally
h a n ds i d e" O " r i n g . aspirated engines.Test for two minutes and examrne
To re-assemblecooler, reverse order of dismanfling. for leaks.
N e w " O " r i n g ss h o u l d b e u s e d w h i c h s h o u l d b e l i g h i l y The tube stack should be reiected if bubbles persist
oiled beforefitting. from the water inlet or outlet connections.
 LUBRICATINGSYSTEM L7

1.13 L.14

Adaptor- GoolertoCylinderBlock To RenewLubricatingOil Filter Element

(wheretitted)
The adaptor may be releasedby removingthe securing
s e t s c r e ws, e e F i g . L . 1 3
W h e n r e f i t t i n gu s e a n e w j o i n t a n d s u i t a b l e s e a l i n g
c o m p o u n da n d s e c u r ew i t h s e t s c r e w p
, l a i n w a s h e ra n d
s p r i n gw a s h e r .
To Refit Oil Cooler
The joint, lubricatingoil cooler to adaptorblock, must be
fastenedto the oil coolerflangewith an approvedadhesive;
"Bostik"clear,"Evostik"or DunlopSN 1901.
There must not be any sealantbetweenthe joint and the
adaptorblock.Thissideof thejointmustbe fitteddry.
Refitthe oil cooler to adaptoror cylinderblock and
secure with five setscrews,plain and spring washers.
R e f i tt h e o i l f i l t e rw i t h f o u r s e t s c r e w sa n d s o r i n ow a s h e r s
or refit f ilter canisters.
R e c o n n e c tt h e c o o l e r i n l e t a n d o u t l e t c o n n e c t i o n s .
E n s u r i n gt h a t t h e w a t e r a n d o i l d r a i n p l u g s a r e f i t t e d ,
refill the cooling system.
S t a r t t h e e n g i n e ,b u t d o n o t s p e e d t h e e n g i n e u n t i l o i l
pressureis achieved
C h e c kf o r o i l a n d w a t e r l e a k s
U n s c r e w f i l t e r c a n i s t e rf r o m f i l t e r h e a d c a s t i n g ( s e e
Fig L 14).
C h e c kt h a tt h r e a d e da d a p t o ri s s e c u r ei n h e a dc a s t i n g
D i s c a r do l d c a n i s t e r
C l e a nf i l t e r h e a d
P r i m et h e n e w c a n i s t e rw i t h l u b r i c a t i n go i l a l l o w i n gt i m e
f o r t h e o i l t o f i l t e rt h r o u g ht h e e l e m e n t
U s i n g c l e a n e n g i n eo i l , l i b e r a l l yo i l t h e t o p s e a l o f t h e
r e p l a c e m e ncta n i s t e r
S c r e w r e p l a c e m e n ct a n i s t e ro n t o f i l t e r h e a d u n t i l t h e
s e a l j u s t t o u c h e st h e h e a d a n d t h e n t i g h t e n b y h a n d
a s p e r t h e i n s t r u c t i o n so n c a n i s t e r .W h e r e a t o o l i s
.15lbf (2,07kgf
a v a i l a b l et,i g h t e nt o ft m) or 20Nm
R u n e n g i n ea n d c h e c kf o r l e a k s
W h e r e t w i n f i l t e r s a r e f i t t e d , b o t h c a n r s t e r ss h o u l d b e
r e p l a c e da t t h e s a m et i m e
N o t e : T h e o i l f i l t e r c a n i s t e r sh a v e i n t e r n a l v a l v e s t o
prevent drain back and a special tube stack, so always
e n s u r et h a t t h e c o r r e c i r e p l a c e m e nits f i t t e d .

6 3544SeriesWorkshooManual.January1986
 SECTIONM
CoolingSystem
C O O L I N GS Y S T E M M2

C i r c u l a t i o no f t h e c o o l a n t i s a s s i s t e d b y a n i m p e l l e r
checkedafter a short period of running to allow for
t y p e w a t e r p u m p m o u n t e do n t h e f r o n t o f t h e c V l i n d e r
t h e i n i t i a ls t r e t c h
b l o c k ,d r i v e nb y t w i n b e l t sf r o mt h e c r a n k s h a fpt u l l e y .
B e l t a d j u s t m e n ti s o b t a i n e db y l o o s e n i n gt h e g e n e r a t o r
From the twin volute water pump, the coolant flows m o u n t i n gb o l t a n d a l t e r i n gt h e p o s i t i o no f t h e q e n e r a r o r
f r o m o n e o u t l e t i n t o t h e c y l i n d e rb l o c k a n d u p i n t o t h e o n i t s m o u n t i n gl i n k .
cylinderhead.Coolantfrom the other ouilet is piped
T h e t e n s i o ns h o u l db e s u c ht h a t a p r e s s u r ea p p l i e db y t h e
i n t o t h e o i l c o o l e rw h e r e i t c i r c u l a t e sa n d i s t h e n p i o e d
thumb on the longest unsupportedstretch of belt
i n t o t h e r e a r o f t h e c y l i n d e rb l o c k . l t t h e n f l o w s u p i n t o
s h o u l d d e p r e s s i t a p p r o x i m a t e l y% i n ( 1 O m m ) , s e e
t h e c y l i n d e rh e a d .
Fig M.1
W h e r et h e o i l c o o l e r i s f i t t e d t o t h e l e f t h a n d s t d e o f
naturally aspirated engines, the coolant feed is To Removeand Refit Thermostats
s o m e t i m e st a k e n f r o m t h e s i d e o f t h e c y l t n d e r b l o c k The water outlet connection forms the top half of the
a n d i n t h i s c a s e ,t h e a d a p t o rw h i c h i s a p u s h f i t i n t h e t h e r m o s t aht o u s i n g
b l o c k m u s t b e f i t t e d w i t h L o c t i t e R e t a i n i n gC o m p o u n d
D r a i nt h e c o o l i n gs y s t e ma n d d i s c o n n e c t h e t o p r a o t a t o r
G r a d e7 5 .
hose, remove three setscrews securing the water
W h e r en o e n g i n eo i l c o o l e r i s f i t t e d ,t h e n a l l t h e c o o t a n t o u t l e tc o n n e c t i o na n d r e m o v e s, e e F i g . M . 2 .
f l o w s i n t o t h e f r o n t o f t h e c y l i n d e rb l o c k
T h e t h e r m o s t a t s c anno w b e w i t h d r a w nf r o m t h e h o u s i n g
The coolantexits from the front of the cylinderhead
W h e n r e p l a c i n g ,e n s u r e t h a t t h e j i g g l e p i n s a r e f r e e
i n t o a t w i n t h e r m o s t act h a m b e r a, n d w h e n t h e t h e r m o s r a r s
IO mOVe
a r e i n t h e o p e n p o s i t i o n ,a l l o w st h e c o o l a n tt o p a s s I n t o
the radiator. Ensurethat only by-passthermostatsare fitted.
U n t i l t h e c o o l a n t r e a c h e s a s p e c i if e d t e m p e r a t u r e , Refit the water outlet connection correcily placrng a
h o w e v e r ,t h e t h e r m o s t a t sw i l l b e i n a c l o s e d p o s i t i o n new joint, connect the top water hose and refill the
d e n y i n g a c c e s s t o t h e r a d i a t o ra n d t h e c o o l a n t w i l j cooling system Check for leaks
flow into a by-passand back into the water pump
A cylinder block drain point is providedon the fuel
p u m p s i d e o f t h e e n g i n ea t t h e r e a r .
W i t h T 6 . 3 5 4 4 C Ce n g i n e s w h i c h i n c o r p o r a t ea n i n t e g r a l
a i r c h a r g e c o o l e r a n d i n d u c t i o nm a n i f o l d ,i t s h o u l d b e
n o t e d t h a t t h e d r a i n p l u g o f t h e c o o l e ro u t l e tc o n n e c t i o n
( s e e F i g . C . 2 ) s h o u l db e r e m o v e dw h e n e i t h e rd r a i n r n qo r
f i l l i n gt h e c o o l i n gs y s t e m .

Fan Belts
Twin belts are used to drive the generator and water
pump.
The fan may be mounted on either the water pump
p u l l e yo r d i r e c tt o t h e c r a n k s h a f p
t ulley
New belts should be fitted in pairs and the tension

M.2

M.3

To Test the Thermostats
S u s p e n dt h e t h e r m o s t a t si n w a t e r a n d h e a t g r a d u a l l y
W i t h a t h e r m o m e t e r c, h e c k t h a t t h e t h e r m o s t a ts t a r t s
t o o p e n a I 1 7 7 / 1 8 3F" ( B i l 8 4 . C ) a n d i s f u l t y o p e n a t
199/205.F (93/96.C)
T h e v a l v e l i f t w h e n f u l l y o p e n i s 0 3 7 4 1 05 0 O i n ( 9 . 5 0 /
12,7Omm)
To RemoveWater pump
R e m o v et h e d r i v e b e l t s .
D r a i n t h e c o o l i n g s y s t e m a n d d i s c o n n e c tt h e n o s e s ,
The water pump securing setscrewsand nut can now
be releasedand the water pump removed,see Fig M.3.
To DismantleWater pump
R e m o v et h e s e l f l o c k i n g n u t a n d p l a i n w a s h e rs e c u r i n g
tne water pump pulley and withdraw the pulley from
t h e s h a f t ,s e e F i g . M . 4 .
P r e s st h e s h a f t ,c o m p l e t ew i t h i m p e l l e r ,o u t o f t h e b o d v
from the front.
i Press the impellerfrom the shaft and removethe rear sear,
I counterfaceand flinger.Latest pumps have one-pieceseats
I with an iniegralcounterfaceand a flingeris not fitted.
Removethe bearingretainingcirclipfrom water pump oooy
and pressout the two bearingsand distancepiece.
M.4
lWhere applicable, the flange,retainerand frontsealcan now
; be withdrawn from the body. The front felt seal assemblyis
; not fittedto latestpumps and can be discardedprovidedthat
Ithe latest one-piecerear seal, shaft and longer bearing
I distancepieceare to be fitted.
lTo Re-assembleWater Pump, Fig. M.5
I lf the latestone-pieceseal with an integralcounterfaceis to
lbe fittedto an earlierpump,the felt seal assemblyand the
lflingercan be discarded.A new shaft and a longerbearing
6 3544SeriesWorkshopl\.4anual,
January1986
C O O L I N GS Y S T E M M 3
I distancepiece (to allow for the removalof the felt seal flange)
I willbe suppliedwiththe newseat.
Pressthe two bearingsonto the shaft with the distancepiece
in between,ensuringthat the shieldedface of each bearino
facesoutwards.
Whereapplicable, fit the frontseal assembly- retainerwith
felt seal inside- into its location,with felt face towardsthe
frontof the pump.
Greasethe bearingsand half fill the space betweenthe two
bearingswith high meltingpointgrease.Whereapplicable, fit
the flangeover the impellerend of the shaftwith the dished
face to the bearingsand pressthe completeshaftand bearinq
assemblyintothe pumpbodyfromthe pulleyend.
Fit the circlipinto its recessin the pump body immediately
forwardof the front bearing.
Where applicable,slide the rubberflingerover the impeller
end of the shaft until the flat face butts againstthe bearing
retainingflange.
lf the rear seal has a brass casing,coat its locatingsurface
withjointingcompound.Fitthe rearsealoverlhe impellerend
of the shaft and press onto its flange locationin the pump
bodywith the contactface outwards.
Rotatethe shaftand checkfor undueresistance.
Where applicable,fit the ceramic counterfaceensuringthat
the ceramicface bears againstthe carbon face of the sprino
loadedseal.
 COOLING SYSTEM M4

Before fitting the pulley, insert the captive setscrew and
washerin its respectivehole,see Fig. M.6.
Fitpulleydrivingkey and presson pulleymakingsurethereis
no rearwardmovementof shaft.
Press impeller onto shaft until a clearanceis obtained be-
tween impellervanes and pump body, includingend float of
0.012/0.035in(0,30/0,89mm) - see Fig.M.5.
Fit plainwasher,springwashersand pulleysecuringnut and
tightento a torqueof 60lbfft (8,30kgfm)or 82Nm. Spin the
pump pulleyto ensurefreedomof movement.
which connects with an auxiliary oil pressure rail
drilled the length of the cylinder block above the
camshaftchamber.
This pressurerail is tapped in six placesto accommodate
the dowelled piston spray iet block.
The removal and retitting of the pressure relief valve
is dealt with in the LubricatingSection L., on Page L.4.
To Remove Piston Cooling Jets
Drain the lubricatingoil and removesump, see Page L.3.

Ceramic Seals
l f a n e n g i n ei s r u n w i t h o u t c o o l a n ti n t h e w a t e r p u m p ,
the heat build-uo between the carbon seal and the
ceramic counter face is very rapid, resulting in the
crackingof the ceramic
T h i s c a n c a u s e a m i s u n d e r s t a n d i n tgh a t t h e l e a k a g e
of water from the pump is due to the incorrectassembly
o f t h e s e a l i n ga r r a n g e m e ni tn t h e w a t e r p u m p .

To Refit Water Pump

Using a new joint, refit the water pump, securing with
setscrews, nuts and spring washers to a torque of
20lbttl (2,77kgf m) or 27 Nm.
Reconnectthe hoses,fill the system with coolant.
Refit the drive belts, start the engine and check for
leaks.

M.8

Remove the banjo holt securing the jet body to the

c y l i n d e rb l o c k .
The piston jet assembly can now be removed, see
F i g .M . 8 .

To Refit Piston Cooling Jet

@ T h e b o d y s h o u l d b e f i t t e dt o t h e c y l i n d e rb l o c k m a k i n g
sure that the dowel locatescorrectly.
Insert the banjo bolt with washer fitted and tighten to
a t o r q u eo f 2 0 l b ff t ( 2 , 7 7 k 7m ' f ) o r 2 7 N m . R e f i tt h e s u m p ,
a n d f i l l w i t h l u b r i c a t i n go i l o f a n a p p r o v e dg r a d e .

M.7
PistonCoolingJets,seeFig.M.7
Piston cooling iets are fitted to most turbochargedengines
I only.They are not fittedto normallyaspiratedengines.
Cooled lubricating oil is directed, by means of spray
lets situatedat the base of each cylinder liner, onto the
underside of each piston crown where it circulates,
dispersing heat from the combustion area. The oil
then drains back into the sump.
Oil is carried to the spray jets by means of a pipe from
the relief valve to an oil gallery in the cylinder block
Nozzle Positioning
In the event of a nozzleof a piston cooling jet becoming
m i s a l i q n e di,t i s i m p o r t a n t h a t t h e c o n d i t i o ni s r e c t i f i e d
a n d t h e i l l u s t r a t i o ni ns F i g s M 9 a n d M 1 0 w i l l s h o w h o w
this maybe accomplished.
W i t h a p i s t o n r e m o v e d ,i n s e r t a p i e c e o f l r i n ( 2 , 3 8
m m ) , r o d ( s u c ha s w e l d i n gr o d ) i n t o t h e j e t n o z z l es o t h a t
it protrudesabove the top of the cylinder bore.
Fig. M.9 shows the dimensions taken on the top face
of the cylinder block and it will be seen that the
measurements of 1 781in (45,24mm) and 0 641in
(16,28mm)are taken from two sides of the liner bore
as illustrated.
The rod should projectat a pointwhere the lines drawnfrom
two measurementsintersect.
Fig. M.10 illustrateshow the correct nozzle angle may be
achievedby the use of rules.

6 3544 SeriesWorkshopManual,January 1986.


0 . 6 4 1i n
1.781in (45,24mm) ( 1 6 , 2m8 m)
Charge cooler (integralairlwater)
No preventive mainlenance is necessary on the intercooler
as
the air passing over the cooling fins is clean. lf the
turbocharger oil sealsleak,this may necessitate the removar
and cleaningof the intercooler.The intercooler
is a sealedunit
and no repairsare possibleexceptperhapsby specialisrs.
The chargecoolershouldbe removedand fittedwiththe Intet
manifoldattachedand the manifold,intercoolerand top cover
treated as a completeassembly.In the case of tractorsthis
assembly will have to be removed before the exhaust
manifoldcan be removed.
The air charge cooler can be removedand dismantreo
as
follows:
1. Draincoolantsystem- removeair bleedscre\r'ion coolant
outletelbowof chargecoolerto ensurethatcoolantdrains
from cooler.
12.Disconnectcoolant,air and fuel pipes.Releasepipeclips
and supoortbrackets.
6 3544SeriesWorkshopManual,January1986
C O O L I N GS Y S T E M M 5
M.10
lJ. Removechargecooler/manifold
assemblyfrom engine.
4. Removecoolantpipe flangesfrom top coverand manifold
Note "O" ringfittedin groovein flangebore.
5. Remove setscrews securing top cover and manifold
flanges.
6. Slide the top cover over the coolantpipe by liftingthe
oppositeend of the coverto clearthe intercooler.
7. Slide the intercoolerout of the manifoldby liftingthe
to clearthe manifold,'
non-pipeend of the intercooler
8. Reassembleand refit in reverseorder. Fit new joints with
Hylomar.Remove air bleed screw when fillingcoolant
system- if top of radiatoris below intercooler,the system
may haveto be toppedup aftera shortperiodof running
The coolantflowfor the chargecooleris fromthe waterpump
outlet- throughthe intercooler- backto the waterpumpinlet
for tractorenginesor the rearof the cylinderheadfor combine
enornes.
 SECTIONN
Air Filtersand FuelSystem
AIR FILTERSAND FUEL SYSTEM N2

Air ChargeCooling *
(T6.3544enginesonly)
T6.3544CC engines have an air charge cooler integral
with the inductionmanifold(see Figs. A.5 and A.6).
Another method of cooling the air between the outlet of
the compressor side of the turbochargerand the
induction manifold is by pushing air through an 'air
cooling radiator'usually mounted in the same air stream
a s t h e e n g i n ew a t e rc o o l i n gr a d i a t o r( s e e F i g . N . 1 ) .

Air Cleaners
Operatingconditions play an important part in deciding
how frequentlyit is necessaryto servicethe air cleaner.
Where the cleaner has a dust bowl fitted, the amounr
of dust present in the bowl when removed, will show
whether it is being emptied at the correct time for the
prevailing conditions. lf the dust bowl is allowed to
become full, it will reduce the life of the element.
lf an automatic dust ejector is fitted, it should be kept
clean and the lips of the rubber ejector checked to see
that they close, but do not adhere together. N.2
Where a restrictionindicatoris fitted,this will give a positive
indicationthat the air cleaner element needs attentionand Release the wing nut and remove filter element.
eliminates haphazard servicing. lf you do not have a Dry dust can be removed from the element by blowing
restrictionindicatorfitted, then you should consider having back from the clean side of the pleats by using air
one fitted on the trunking between the air cleaner and (7 kgf/cm'?)
pressurenot exceeding100lbf/in'? or 689 kN/m'?.
turbochargeriinductionmanifold. A 22in (559mm) water
lf the element is contaminated by oil and/or soot,
gauge indicatortitted on the cleaneroutlet is suitablefor the
it can be cleaned in warm water using a suitable
majorityof cases. lt shouldbe rememberedthat the indicator
non-foaming detergent as recommended by the air
does not showthe amountof dust oresentin the dust bowl.
cleanermanufacturer.
The type of air cleanerfitted to your vehicle or machine
Allow, the element to soak for about ten minutes and
depends upon the manufacturer of your equipment.
then agitate.Spray clean water onto the "clean" side of
Usually, guidance for the servicing is shown on the
the element rinsing thoroughly and allow to dry, do not
body of the air cleaner, but the following advice may
use oven heat
also help.
NEVER FIT a wet element as water may be inducted
Dry Type Two Stage"Cyclopac", by the engine carrying dust with it.
see Fig. N.2
Examine the element for pin holes, thin areas, or
Unclamp the dust bowl, remove the baffle plate and other damage by placing a bright light inside the
clean out the bowl. element.
The dust in the bowl must not be allowed to reach The element should be renewed after six cleanings
within %in (13mm) of the dust entry slot in baffle or once a year, whicheveroccurs first'
DO NOT USE PETROL (GASOLINE) for cleaning any
part of air cleaners. Clean the inside of the filter body and fins, making
sure no dirt entersthe air f ilter outlet.
Check all hoses and joints for condition and security.
Re-assembleair cleaner unit.
lf an automaticdust ejector (vacuator)is fitted, it should
be kept clean and the lips of the rubber ejector
checked to see that they close but do not adhere
together.

Dry Type Two Stage"Cyclone",

see Fig. N.3
Unscrew the clamping screw and remove the element
retaining strip. Remove the seal plate and element.
lf the element is blocked by dry dust, clean by caretully
hand tapping the element or by directing low pressure
comoressed air on to the clean side of the element.
lf the element is contaminatedby oil or soot, it can be
partially restoredby washing in a suitable non foaming
detergentsolution.
A{ter washing, rinse out thoroughly by directing clean
water on to the clean air side of the element and allow
to dry - do not oven dry. Never fit a wet element to the

6 3544SeriesWorkshopManual,January1986

N.3
filter as dust may be carriedthrough the elemenl oy
water.
Inspect the cleaned element by placing a bright
light inside and looking through the element. Any
thin spots,pin holes or other damagewill renderthe
e l e m e n tu n fi t f o r f u r t h e ru s e
The element should be renewed after six detergent
w a s n e so r a n n u a l l y ,w h i c h e v e ro c c u r s f i r s t .
C l e a n t h e i n s i d eo f t h e f i l t e r b o d y a n d d r y t h o r o u g n r y
- d o n o t u s e p e t r o l ( g a s o l i n e )f o r c l e a n i n g
Inspect the joints and hoses and renew where
n ecessary
R e - a s s e m b l et h e f i l t e r e n s u r i n g t h a t a l l j o i n t s a r e
leakproof
uiFTril;;lr ":;
N.4
A I R F I L T E R SA N D F U E L S Y S T E M N3
Dry ].yp9 T-woStage,,Duo-Dry",
seeFig.N.4
DustBowl
U n c l a m pt h e d u s t b o w l , e m p t y o u t t h e d u s t a n d c l e a n
t h e b o w l - d o n o t u s e p e t r o l ( E a s o l i n e )f o r c l e a n i n g .
T h e d u s t i n t h e b o w i m u s t n e v e rb e a l l o w e dt o b u i l d u p t o
1 i n ( 2 5 m m ) o f t h e b o t t o mo f t h e t u b e s .
Element
Clean the top of the cleaner and then unclip and
remove the top cover Unscrew the wrng nut ano
r e m o v et h e i n n e rc o v e ra n d e l e m e n t
C l e a n a n d i n s p e c t t h e e l e m e n t a s d e t a i l e d fo r r n e
"Cyclopac" cleaner, bearing in mind that the ctean
s i d e o f t h e e l e m e n to f t h e " D u o - D r y , 'c l e a n e ri l l u s r r a t e d
i s t h e o u t s i d eo f t h e e l e m e n t
C l e a nt h e i n s i d eo f t h e b o d y - d o n o t u s e p e t r o l l f t h e
t u b e s a r e n o t t o o d i r t y , t h e y c a n b e c l e a n e dw i t h a s t i f f
f i b r e b r u s h b u t , i f h e a v i l y c o n t a m i n a t e d ,t h e r u o e
b o d y s h o u l d b e r e m o v e da n d c l e a n e dw i t h c o m p r e s s e d
a r r o r w a r m w a t e r n o t e x c e e d i n g1 5 0 " F ( 6 5 . C )
I n s p e c ta l l j o i n t s a n d h o s e sa n d r e n e w w h e r e n e c e s s a r y
R e - a s s e m b lteh e c l e a n e re n s u r i n gt h a t a l l p a r t s a r e o r V
a n d a l l j o i n t sa r e l e a k p r o o f .
l f t h e t u b e b o d y h a s b e e n r e m o v e d ,t i g h t e n t h e c r a m p
b e t w e e n i t a n d t h e u p p e r b o d y b e f o r e t i g h t e n i n gl i t e
m o u n t i n gc l a m p
Dry Type, Multi-Element
"Rotopamic",
see Fig. N.5
T h e e l e m e n t so f t h i s t y p e c l e a n e rs h o u l d n o t b e c l e a n e d
but the completefilter cartridge should be renewed
when necessary
R e l e a s et h e c l a m p s a n d r e m o v et h e m o i s t u r ee l i m i n a t o r
o r p r e - c l e a n epr a n e l .C l e a nt h e o p e n i n g si n t h e p a n e l o f
a n y d u s t ,s o o t ,e t c
R e m o v et h e f i l t e r c a r t r i d g ea n d c l e a n t h e i n t e r i o ro f t h e
c l e a n e r h o u s i n g - d o n o t u s e p e t r o l( g a s o l i n e )
Fit the new cartridgeIn position ensunng a positive
s e a l b y p r e s s i n ga r o u n d t h e e d g e s o f t h e c a r t r i d g e_
d o n o t p r e s si n t h e c e n t r e .
Refit the morsture eliminator or pre-cleanerpanel
a n d r e c l a m pi n p o s i t i o n .
N.5
 AIR FILTERSAND FUEL SYSTEM N4

Oil Bath Air Cleaner,see Fig. N.6

T o s e r v i c et h e o i l b a t h t y p e c l e a n e r ,t h e l i d s h o u t d
be
removedand the element lifted out.
Drain the oil from out of the container and crean
t h e d i r t a n d s l u d g ef r o m t h e c o n t a i n e ru s i n g a s u i t a b l e
c l e a n i n gf l u i d .
R e f i l l t h e c o n t a i n e rw i t h f r e s h e n g i n e l u b r i c a t i n go i l ,
SAE40grade,to the indicatedlevel.
The element should be cleaned in a bath of Kerosene.
D o n o t u s e p e t r o l ( g a s o l i n e )f o r c l e a n i n g p u r p o s e s
R e p l a c et h e c l e a n e de l e m e n t i n t h e c o n t a i n e r .
Refit the lid, making sure that the lid seats properly
on the seal.
D o n o t e x c e e dt h e i n d i c a t e dl e v e l m a r k w h e n r e f i l l i n g
t h e o i l c o n t a i n e r ,b e c a u s eo i l c o u l d b e d r a w n i n t o t h e
engine leading to uncontrolled engine speed and
excessiveengine wear.

N.7

n o l e a k sa t t h e c o n n e c t i o n sb e t w e e np u m p a n d g a u g e .
C r a n kt h e e n g i n ef o r 1 0 s e c o n d sa n d n o t e t h e m a x r m u m
p r e s s u r er e c o r d e do n t h e g a u g e l f t h e p r e s s u r er e c o r d e d
FUEL FILTERS i s l e s s t h a n 7 5 o / oo f t h e m i n i m u m p r o d u c t i o n s t a t i c
pressure shown in the table below, then rectify the
Twin bowl, parallel flow fuel filters are situated at the
pump. Also observe the rate at which the pressure
rear of the engine on the left hand side, bracketed to
d r o p s t o h a l f t h e m a x i m u m fi g u r e o b t a i n e d w h e n
t h e c y l i n d e rh e a d , i n m o s t a p p l i c a t i o n s .
c r a n k i n g h a s c e a s e d .l f l e s s t h a n 3 0 s e c o n d s ,r e c t i f y
the oump.
To Renew Fuel Filter Elements. M i n i m u mP r o d u c t i o n
see Fig. N.7 Static Pressure
T h o r o u g h l yc l e a n t h e e x t e r i o r o f t h e f i l t e r a s s e m b l y lbf/in2 kgf/cm2 kN/m,
S u p p o r t i n gt h e b a s eo f o n e o f t h e f i l t e r b o w l s , u n s c r e w 6 0,42 41
the setscrewIn the centre of the cover of each filter Minimum Test Pressure
Lower filter base plate and discardthe dirty element (75% of Min. Productionpressure)
Repeatthe procedurewith the twin filter. lbf/in2 kgf /cm2 kN/m'?
4 5 0,31 31
Thoroughly clean the filter heads and bases in a
s u i t a b l ec l e a n i n gf l u i d
Inspectsealing rings and renew if damaged in any
way
Place a base squarely on bottom of new elemenr ano
offer up assembly squarely to a filter head so that
the top rim of the element locatescentrallyagatnst
the sealing rim in filter head. Hold in this position
whilst securing setscrewis locatedand screwed home.
R e p e a t h e p r o c e d u r ew i t h t h e t w i n f i l t e r
After the fuel filter has been re-assembled,the fuel
s y s t e ms h o u l db e b l e d a s d e t a i l e do n p a g e N 7 .

Fuel Lift Pump

T h e m e c h a n r c adli a p h r a g mt y p ef u e l l i f t p u m p i s o p e r a t e d
b y a n e c c e n t r i co n t h e c a m s h a f ta n d i s m o u n t e d o n
the right hand srde of the cylinder block, below rne
t u r b o c h a r g e rl t i s f i t t e dw i t h a h a n d p r i m i n gl e v e r

PressureCheckingof Fuel Lift pumps

Fit a O-10lbf/in, (0-0,7kgflcm,) or 0-70kN/m, pressure
gauge to the outlet of the pump. Ensure that there are
N.8
 AIR FII.TERSAND FUEL SYSTEM N5

To Remove and Fit Fuel Lilt Pump, The valvesare "staked in" and can be prised out using
see Fig. N.8 a screwdriveror other suitable tool. Clean the casting
D i s c o n n e ct th e i n l e ta n do u t l e tt u e l p i p e s . so that new valvescan be correctlyseated
Removethe setscrewsand retaininq plates and remove Press valves into position using a suitable "dolly".
the pumpand joint. Stake the casting around the valves in six places.
l f d i f f i c u l t yi s e n c o u n t e r e di n r e m o v i n g t h e l i f t p u m p The rocker arm pin can be removed by securing the
from the engine,turn the cranksha{tto rotatethe camshaft rocker arm in a vice and tapping the body with a soft
e c c e n t r i ct o a D o s i t i o nw h i c h w i l l e n a b l e t h e r o c k e r m a l l e tu n t i l t h e r e t a i n e r sa r e d i s l o d g e d
arm to withdraw. The rocker, pin, lever and return spring can now be
F i t p u m p u s i n g a n e w j o i n t , e n s u r i n gt h a t t h e m a t i n g examinedfor wear.
faces are clean.
Damage can be caused to the pump operatinglever if the
pump is fittedto the enginewith the pump drivingeccentricon
To Re-assemblethe Lift Pump,
see Fig. N.9
the camshaft in the maximum lift position.This problem is
most likelyif the four pumpfastenersare not tightenedevenly. Fit the rocker arm assemblyinto the bottom half of the
l i f t p u m p F i t t h e r o c k e ra r m r e t u r ns p r i n g m a k i n g s u r e
Thereforewhen the pump is fitted to an engine (especiallya that it seats properly
four bolt pump) ensure that the camshaft eccentric is on
Tap new retainers into the grooves in the casting and
minimumlift, rotatingthe engine if necessary,and also that
stake over the open end of the grooves.
the pumpfastenersare tightenedevenly.
F i t t h e s p r i n g i n t o i t s l o c a t i o na n d p l a c e t h e d i a p h r a g m
A lossof maximumenginepowercan occurif the liftpumpis
a n d p u l l r o d a s s e m b l yo v e r t h e s p r i n g w i t h t h e p u l l
damagedduringfitment.
r o d d o w n w a r d sl o c a t i n g t h e t o p o f t h e s p r i n g i n t h e
The securing setscrewsshould be tightened to 20lbfft
diaphragmprotectorwasher.
(2,8kgfm) or 27Nm and re-torquedwhen hot.
Position the rod so that the notched blade locates into
R e - c o n n e cpt u m p i n l e ta n d o u t l e t p i p e s .
t h e r o c k e ra r m l i n k .
Bleed the fuel system,Page N 7.
P r e s s d o w n w a r d so n t h e d i a p h r a g ma s s e m b l ys o t h a t
t h e n o t c h e so n t h e p u l l r o d a l i g n w i t h t h e r o c k e r a r m
To Dismantle Fuel Lift Pump l i n k a n d t w i s t i t t h r o u g h g 0 o i n e i t h e r d i r e c t i o n ,t h i s
action will engageand retainthe pull rod in the fork
Clean exterior and file mark the flanges of top and
of the link
bottom bodies for guidance in re-assembly.Removethe
d o m e d e n d c o v e ra n d s e a l . W h e n r e - a s s e m b l i n gt h e t w o p u m p h a l v e s , p u s h t h e
r o c k e r a r m t o w a r d s t h e p u m p u n t i l t h e d i a p h r a g mi s
Thegauze filter may now be lifted off.
l e v e l w i t ht h e b o d yf l a n g e sT h e t o p h a l fc a n n o w b e p l a c e d
Releasethe five setscrews securing the two halves of i n p o s i t i o nw i t h t h ef i l em a r k sa l i g n e d .
the pump and separatethe two halves.
T u r n t h e d i a p h r a g ma s s e m b l yt h r o u g h 9 0 ' a n d l i f t t h e
d i a p h r a g ma n d p u l l r o d a s s e m b l yf r o m t h e b o d y
The diaphragmand pull rod assemblyare servicedas an
assembly and no attempt should be made to separate
t h e l a y e r so f t h e d i a p h r a g m .

N.10 (G.A.V. Pump)

6 3544SeriesWorkshopManual,January'1986
 A I R F I L T E R SA N D F U E L S Y S T E M N6
M a i n t a i n i n gt h e p r e s s u r eo n t h e r o c k e r
arm, fit the
s e c u n n gs c r e w sa n d w a s h e r sa n d t i g h t e n
evenlv
R e f i tt h e g a u z ef i l t e r
The domed cover may now be refitted,
ensuringthat
t h e r u b b e r s e a l i n gr i n g i s c o r r e c i l y l o c a t e d .
Fuel Injectionpump
T h e f u e l i n j e c t i o np u m p i s a C A V , D p A o r B o s c h
d i s t r i b u t o rt y p e , v e r t i c a l l y m o u n t e d o n t h e a u x i l i a r v
d r i v e h o u s i n g a n d i s s p l i n e - c o u p l e dt o t h e a u x i l i a r v
drve wormgear.
The pump is a compact, oil tight unit, lubricated
throughout by fuel oil and requires no separare
l u b r i c a t i o ns y s t e m .
S p e e d c o n t r o l i s m a i n t a i n e db y a m e c h a n i c a g l overnor
a n d a u t o m a t i c v a r i a t i o n o f t h e c o m m e n c e m e n to f
i n j e c t i o n i s o b t a i n e d w i t h a n a u t o m a t i ca d v a n c e u n i t .
With Bosch fuel injection pumps, a boost control is
fitted at the side of the pump. lts function is to vary rne
f u e l i n t o t h e e n g i n e d e p e n d i n go n l o a d . E n s u r et h a t a l l
c o n n e c t i o n so f t h e b o o s t s e n s i n g p i p e a r e i n g o o o
condition
U n l e s s p r o p e r t e s t e q u i p m e n t a n d t h e r e j e v a n tT e s t
D a t a f o r t h e f u e l p u m p i s a v a i l a b l e ,a d j u s t m e n r o r
m a i n t e n a n c eo f t h e f u e l p u m p s h o u l d b e r e f e r r e d t o
t h e P e r k i n s D i s t r i b u t o ro r a n a c c r e d i t e df u e l p u m p
agent.
N.11
(C.A.V.Pump)
To Removethe Fuel Injection pump
D i s c o n n e ctth e s t o p a n d t h r o t i l ec o n t r o l sf r o m t h e p u m p
a n d r e m o v e t h e r e t u r n s p r i n g s ( C . A . V .p u m p s )
The Bosch fuel pump has a combined speed/stop
c o n t r o ll e v e r .U n d e r n o c i r c u m s t a n c essh o u l dt h e s p e e o u
stop control lever be removed when removing a Bosch
fuel pump as it will upset the the settingsmaking it
necessarytoput it on a test machineto resetit.
R e m o v et h e h i g h a n d l o w p r e s s u r ef u e l p i p e s f r o m t h e
pump.
6 3544SeriesWorkshopN,4anual,
January1986
T h e f u e l p u m p c a n n o w b e w i t h d r a w na f t e r t h e s e c u r i n g
n u t s a n d w a s h e r sh a v eb e e n r e m o v e d s, e e F i o . N . 1 0 .
To Fit the Fuel Injectionpump
F i t t h e f u e l p u m p e n s u r i n gt h a t t h e m a s t e r s p l i n e o n
t h e f u e l p u m p s h a f t w i l l e n t e r t h e f e m a l es p l i n e w i t h i n
t h e v e r t i c a ld r i v e s h a f t .
P o s i t i o nt h e f u e l p u m p s o t h a t t h e s c r i b e d l i n e o n t h e
fuel pump mounting flange aligns with the scribed
l i n e o n t h e a d a p t o rp l a t e ,s e e F i g N 1 1 ( 1 ) .S e c u r et h e
p u m p t o t h e a d a p t o rp l a t e
R e f i t t h e h i g h a n d l o w p r e s s u r ef u e l p i p e s t o t h e f u e l
pump
Reconnectthe throtfle and stop lever controls and attach
t h e r e t u r ns p r i n g s .
Bleed the fuel system as detailedon page N 7.
lf necessarya , diust the maximum and idling speeos.
D e t a i l sw i l l b e f o u n d o n t h i s p a g e ,
Maximum Speed Setting
The maximumspeed screw is set and sealed by the
m a n u f a c t u r e r sa n d m u s t n o t b e a l t e r e d i n a n y w a y
u n l e s sf a c t o r ya u t h o r i t yi s f i r s t o b t a i n e d A
. ny adjusrment
should be carried out by experiencedfuel pump
t e c h n i c i a n s .T h e u n a u t h o r i s e dr e m o v a l o f a n y s e a t s
o n t h e p u m p m a y r e n d e rt h e g u a r a n t e ev o i d .
W h e n a f u e l p u m p i s s u p p l i e da s a d i r e c t r e p l a c e m e n r ,
t h e m a x i m u m s p e e d a d j u s t m e n ti s s e t t o a n o m i n a l
f i g u r e o n l y , a n d f i n a l a d j u s t m e n tm u s t b e m a d e a f i e r
the pump is fitted to the engine In order to establish
the correct setting which can vary accorotng ro
a p p l i c a t i o n ,r e f e r e n c em u s t b e m a d e t o t h e s e t t i n g
code symbol, stamped on the plate fastenedto the
pump booy.
F o r t h e p u r p o s eo f s e t t i n gt h e m a x i m u m( n o l o a d )s p e e d
s t o p ,t h e l a s tf o u r f i g u r e ss h o w n o n t h e f u e l p u m p s e t t i n g
code is the maximum no load engine speed. Warm
t h e e n g i n ea n d r u n u p u n t i l t h i s f i g u r e i s r e a c h e d ;t h e
m a x t m u m s p e e d s t o p a d j u s t m e n ts h o u l d t h e n o e s e r
at thisfigure
Under no circumstanceshould the engine be allowed
t o o p e r a t e a t h i g h e r r e v l m i n t h a n s p e c i f i e do r s e v e r e
d a m a g et o t h e e n g i n em a y r e s u l t
ldlinE Speed Setting
With C A.V pumpsthe engineidling speed is adjusted
b y t h e i d l i n gs c r e w ,s e e F i g N i 1 ( 2 ) W i t h B o s c h p u m p s ,
t h e i d l i n g s p e e d a d j u s t i n gs c r e w i s a t t h e r e a r o f t h e
pump
With the engine warm, turn the screw clockwiseto
i n c r e a s et h e s p e e d o r a n t i - c l o c k w i s et o d e c r e a s ei t .
The idling speed will vary, accordingto application
F o r d e t a i l s , a p p l y t o y o u r p e r k i n s D i s t r i b u t o ro r a n
a c c r e d i t e df u e l p u m p D e a l e r a
, l t e r n a t i v e l yS,e r v i c eD e p t ,
P e r k i n sE n g i n e sL t d , P e t e r b o r o u g h
Atomisers
When replacingatomisersit is essentialthat a new, correcr
type copper seatingwasher is fitted betweenthe nozzrecap
andthe cylinderhead.
Note: Different atorrniserseating washers are used on
naturally aspiratedand turbochargedengines The
s e a t i n g w a s h e r s f o r n a t u r a l l y a s p i r a t e de n g i n e s a r e
0 0 B 0 i n ( 2 , 0 3 m m )t h i c k a n d f o r t u r b o c h a r g e de n g i n e s ,
 A I R F I L T E R SA N D F U E L S Y S T E M N 7

makes a "cracking" sound. lt is not until it sounos

"dead" that its condition is likely to affect the runnino
of the engine.

Note: Do not allow the hands or face to come Into

c o n t a c t w i t h t h e a t o m i s e dj e t o f f u e l , a s t h e w o r k i n g
p r e s s u r ew i l l c a u s e t h e f u e l o i l t o p e n e t r a t et h e s k i n .
W h e n c h a n g i n g a n a t o m i s e ra l w a y s r e m o v e t h e p t p e
e n t i r e l y .N e v e rb e n d t h e p i p e

Bleeding the Fuet System

-fhe
air must be vented from the fuel system and the
s y s t e mp r i m e dw i t h f u e l o i l w h e n e v e ra n y d i s c o n n e c t i o n
in the fuel system has taken place, or when the svsrem
h a s b e e ne m p t i e do f f u e l .
N o a t t e m p tm u s t b e m a d e t o s t a r t t h e e n g i n e u n t i l t h e
i n j e c t i o np u m p h a s b e e n v e n t e da n d p r i m e d a s s e n o u s
o a m a g ec a n b e c a u s e db y l a c k o f l u b r i c a t i o n .

N o t e : l f t h e c a m o n t h e e n g i n e c a m s h a f to p e r a t i n gt h e
f u e l l i f t p u m p i s o n m a x i m u ml i f t ,i t w i j l n o t b e p o s s i b l et o
N.12 o p e r a t et h e h a n d p r i m e r l f s u c h a c o n d i t i o na r i s e s ,t h e n
t h e e n g i n es h o u l d b e t u r n e do n e c o m p l e t er e v o l u t t o n .
0 0 2 8 i n ( 0 , 7 1m m ) t h i c k l t i s i m p o r t a n tt h a t t h e c o r r e c t l f , a f t e r b l e e d i n gt h e f u e l s y s t e m ,t h e e n g i n es t a r t s a n d
atomiserseatingwashersare fitted runs satisfactorilyfor a few momentsand then stops, runs
I See page E3 for guidanceon latesttype of atomiserdust seal erratically,or has loss of power and when checked, the
I and alsotop entrytvpe atomisers. systemis found to be full of air, then a leak on tne
E n s u r et h a t t h e a t o m i s e ri s s e a t e dc e n t r a l l ya n d t i g h t e n s u c t i o ns i d e i s i n d i c a t e d .
securing nuts/setscrewsdown evenly to a torque of
l 2 l b f f t ( 1 , 7 k gmf ) o r 1 6 N m
W h e n f i t t i n g t h e h i g h p r e s s u r ep i p e s ,t i g h t e nt h e u n i o n s
t o 1 5 l b f t ( 2 , 1k g fm ) o r 2 0 N m
A faulty atomiser can be determined by releasingthe
f u e l p i p e u n i o n n u t o f e a c h a t o m i s e ri n t u r n , w i t h t h e
e n g i n er u n n i n ga t a f a s t " t i c k - o v e r " l f a f t e r s l a c k e n r n ga
p i p e u n i o n n u t , t h e e n g i n e r e v o l u t i o n sr e m a i n c o n s r a n r ,
t h i s d e n o t e sa f a u l t ya t o m i s e r
No attempt should be made to service or reset the
pressure of an atomiser unless the proper testing
p u m p a n d p r e s s u r eg a u g e i s a v a i l a b l e .
A n a t o m i s e r ,w h e n t e s t e d b y p u m p i n g f u e l t h r o u g h i t
gives a short "plnging" sound as the fuel emerges.
After the atomiser has been in service for some time, it

N.14
To BleedC.A.V.Fuel Pump
1. Removeair from the fuel filterthroughthe filtervent plug,
see FigureN.13.lf a filtervent plug is not fitted,the rerurn
to tank banio connectionin the top of the filter can be
loosenedto reducethe time neededto fill the filterwith
fuel.
Operatethe priminglever of the fuel lift pump untilfuel,
freeof air,issuesfromthe ventingpoint
Tightenthe plugor connection.
2. Loosenthe inletconnection at the fuelpump,see Fig.N.12
N.13 item C and remove the air again by use of the lift pump.

6 3544SeriesWorkshopManual,January'1986
AIR FILTERSAND FUEL SYSTEM N8

When appropriate,tightenthe connectionbut ensurethat it

is notovertightened.
3. Ensurethat the stop controlis in the 'run' position.lf an
electricsolenoidstop controlis used, turn the start switch
to the'R' position.
4. Loosenthe vent screws in the hydraulichead lockingbolt
and the governorhousingof the fuel injectionpump,see
Fig.N12,itemsA and B, and removeair fromthe pumpby
use of the liftpump.
Tighten first the hydraulichead vent screw, item B and
thenthe governorhousingventscrew,itemA.
5. lf the fuel pipe to the Thermostartcold startingaid has
beendrained,loosenthe unionnut at the startingaid and
operatethe priminglever untilfuel, free from air, comes
fromthe connection. Tightenthe unionnut.
6. Slackenthe unions at the atomiserends of two high
pressure pipes. Set the accelerator at the fully open
positionand ensurethat the 'stop' controlis in the 'run'
oosition.
Turnthe engineuntilfueloil,freeof air,issuesfromaround
the threadsandtightenthe unionnuts.
The engineis now readyfor starting.

To BleedBosch Fuel Pump

S l a c k e nt h e v e n t s c r e wo n t h e t o p o f t h e f i n a l f u e l f i l t e r s ,
see Fig N 13
S l a c k e nt h e i n l e t c o n n e c t i o no n t h e f u e l p u m p ( A ) , s e e
Fig N.14
S l a c k e nt h e o u t l e tc o n n e c t i o no n t h e f u e l p u m p ( B ) , s e e
F i g N 1 4 T h i s c o n n e c t i o ni s f i t t e d w i t h a n o n - r e t u r n
v a l v ea n d m u s t n o t b e f i t t e dt o t h e i n l e t p o r t .
O p e r a t et h e p r i m i n g l e v e r o n t h e f . u e l l i f t p u m p u n t i l
f u e l ,f r e e f r o m a i r , i s s u e sf r o m t h e f i n a l f u e l f i l t e r v e n t i n g
p o i n t .T i g h t e nt h e f u e l f i l t e r v e n t s c r e w a n d c o n t i n u et o
o p e r a t et h e l i f t l u m p u n t i l f u e l , f r e e f r o m a i r , i s s u e sf r o m
t h e i n l e t c o n n e c t i o no n t h e f u e l p u m p ( A ) T i g h t e n t h e
i n l e t c o n n e c t i o na n d c o n t i n u e t o o p e r a t et h e l i f t p u m p
u n t i lf u e l ,f r e ef r o m a i r , i s s u e sf r o m t h e o u t l e tc o n n e c t i o n
o n t h e f u e l p u m p ( B ) a n d t i g h t e nt h e c o n n e c t i o n
T h o r o u g h l yc l e a n t h e t o p o f t h e p u m p a r o u n dt h e c e n t r e
p l u g i n t h e h y d r a u l i ch e a d a n d s l a c k e n t h e v e n t p l u g
( C ) . O p e r a t et h e p r i m i n g l e v e r o f t h e l i f t p u m p u n t i l
fuel,free from air, issuesfrom aroundthe plug.Tightenthe
p l u gt o T l b f f t( 1 0 N m )1 , 0 k g f m .
lf the fuel pipeto the Thermostart cold startingaid has been
drained,loosenthe unionnut at the startingaid and operate
the priminglever until fuel, free from air, comes from the
connectron. Tightenthe unionnut
Slackenthe nuts of two of the high pressurepipes at the
a t o m i s e re n d .
W i t h t h e s p e e dc o n t r o l i n t h e m a x i m u ms p e e d p o s i t i o n ,
motor the engine over by means of the starter motor
u n t i l f u e l , f r e e f r o m a i r , i s s u e s f r o m t h - oc o n n e c t i o n s .
T i g h t e n t h e c o n n e c t i o n sT . he engine is now ready for
startin g

6 3544SeriesWorkshopManual,January1986
 SECTIONP
Flywheeland FlywheelHousing
FLYWHEELAND FLYWHEELHOUSING P2

To Removethe Flywheel
Removethe twelvesetscrewsand washerswhich secure
the flywheel to the crankshaft flange.
I t i s a d v i s a b l et o f i t s u i t a b l eg u i d e s t u d s t o p r e v e n tt h e
flywheel from dropping as it clears the crankshaft
flanoe

Flywheel Ring Gear

T h e r i n g g e a r i s s h r u n ko n t o t h e f l y w h e e l .
W h e n r e p l a c i n gt h e r i n g g e a r , t h e a p p l i e d h e a t t o t h e
new ring should not exceed 480. F (250"C)
Attention should be paid to the chamfered lead - rn
edge of the ring gear, and its relative position on the
flvwheel

To Refit the Flywheel

Using suitable guide studs, refit the flywheel to the
crankshaftf langeand securewith setscrewsand wasners.
Tighten setscrewsto a torque of S0lbfft (11,1kgfm) or
1 0 8N m

Flywheel Runout
T h e o u t s i d e d i a m e t e ro f t h e f l y w h e e l s h o u l d b e c o n -
c e n t r i c w i t h i n 0 . 0 1 2 i n( 0 , 3 0 m m )t o t a l i n d i c a t o rr e a d i n g ,
to the crankshaftaxis.
Flywheel Alignment
T h e a l i g n m e n to f t h e f l y w h e e l f a c e s h o u l d b e w i t h i n
t h e l i m i t o f 0 0 0 1i n ( 0 , 0 3 m m ) p e r i n c h ( 2 5 , 4 m m ) o f
flywheel radius from the crankshaft axis to the clock
g a u g e p l u n g e r ,s e e F i g . P 1
When carrying out this check, press the c?ankshaftone
way to take up the end float whilst turning the flywheel

To Removethe Flywheel Housing

Removethe startermotor and flywheel.
Unscrew the securing setscrews and tap the housing
c a r e f u l l yt o d i s l o d g ei t f r o m t h e l o c a t i n gd o w e l s .

To Refit the Flywheel Housing

Ensure that the rear face of the cylinder block and the
matingface of the housing are clean and free from burrs
F i t n e w d o w e l s ,a n d s e c u r e h o u s i n g t o c y l i n d e r b l o c k
to allow for adjustment,if necessary.
With a clock gauge, check that the alignment of the
flywheel housing bore and face, see Figs. P.2 and p.3,
P.1 are within the limits listed on Page P.3,
 FLYWHEELAND FLYWHEELHOUSING P3

A l l a d j u s t m e n t tso b r i n g t h e h o u s i n g w i t h i n t h e s e l i m i t s
*
m u s tb e c a r r i e do u t o n t h e h o u s i n ga n d n o t o n t h e c y l i n d e r ,*
,,
block.
Tightenthe securingsetscrewsto torquegivenon page B.2,

P.3

Diameterof housing Bore Limit-Totallndicator Reading

U p t o 1 4 2 5 i n ( 3 6 2m m ) . . . . . . . . . . 0 . 0 0 6i n ( 0 , 1 5m m )
1 4 2 5 t o 2 0 . 1 2 5i n ( 3 6 2t o 5 11 m m ) . . . . 0 . 0 0 8i n ( 0 , 2 0m m )
2 0 . 1 2 5t o 2 5 5 i n ( 5 1 1t o 6 4 8 m m ) 0 . 0 1 0i n ( 0 , 2 5m m )
2 5 5 t o 3 1 . 0i n ( 6 4 8t o 7 8 7m m ) 0 . 0 1 2 i n( 0 , 3 0 m m )
A l l a d j u s t m e n t tso b r i n g t h e h o u s i n gw i t h i n t h e s e l i m i t s m u s t b e c a r r i e do u t o n t h e h o u s i n ga n d n o t o n t h e
c y l i n d e rb l o c k .

6 3544 SeriesWorkshopManual,January 1986

 SECTIONO
Turbocharger
TURBOCHARGER Q2
T6.3544Enginesonly
The turbochargeris fittedon the exhaustmanifoldoutler,see
Fig.A.4.lt is lubricated
by oiltakenfromthe enginelubricating
system. Oil pressure should never drop below 30lbf/in2
(2,11kgtlcm2)or 2o7kNlm2at normal runningspeed.Check
this pressureregularly.
The maximumboostpressureshouldbe 11- 13.5lbvin2 (0,80
- 0,95kgf/cm2)
or 76 - 93kN/m2whenthe engineis runningat
maximumspeedand fullload.
With some engineswhere it is not possibleto fully load the
engine,the boostpressurewill be somewhatlower.
No attentionneed be paid to the speed of the turbocnarger
since this variesautomaticallywith the speed and load of the
engrne,
Maintenance
Every20,000miles(30,000km)or 1,000hours,cleanthe oil
drain pipe from turbochargerto sump, also turbocnarger
compressorwheeland cover.
The compressorwheel and cover may be cleaned without
removingthe turbocharger
fromthe engine(Fig.e.1).
Removethe air inletduct and compressorhousingand check
for dirtor dustbuilduo.
Removeall foreign matter- determineand correctcause of
b u i l du o .
Use soft brushon compressorwheel as unevendepositscan
affectrotorbalanceand causebearingfailure.
With the compressorhousingremoved,push the compressor
housing wheel towards the turbine wheel and turn rotating
assemblyby hand: check for bindingand rubbing.Listen
carefullyfor unusualnoises.lf bindingor rubbingis evident,
removethe turbochargerfor dismantlingand inspection.
Q.1
6 3544SeriesWorkshopManual,January1986
FaultDiagnosis
lf the performanceof the turbochargeris suspect,check the
installationfor the followingfaults:
Excessive
air inletdeoression.
Lowor highair deliverypressure.
Low oil pressureand/orlow oil flow.
Restrictedexhaustfrom turbine.
Fuelpumpor injectionfaults.
Check and rectify in accordance with the following
paragraphs:
Excessiveair inletdepression:The air depressionat the entry
to the compressor,that is in the ductingafterthe air filterand
immediatelybeforethe compressorcover,shouldnot exceed
a 20 in (500mm) headof water.
lf the depressionis excessive,the cause will be due ro a
restrictionof inletair by a dirtyair filter.
Servicethe air filter.
Low or high air delivery pressure:The pressure will vary
accordingto the enginerating,speedand load.
lf the pressure is low, the probable cause is a dirty or
damagedcompressor,incorrectfuellingof the enginefuel
pump,or leakingmanifoldjoints.
Checkthatthe injectionpumpfuellinghas not beendisturbed
and if satisfactory,removethe turbochargerfrom the engine
for inspection.
A higherreadingmay also indicateincorrectinjectionpump
fuellingor damageto the turbine.
Actionas for low oressure.
Low oil pressure and/or oil flow: The oil delivery pressure
should not be less than 30lbf/in2(2,1kgilcm2)or 207kN/m2
undernormalconditions of load.
lf oil pressureis low, refer to Section L. Clean bores of the
feed and return pipes and check the connections for
obstruction.
Restrictedexhaust from the turbine: A restrictionof the
exhaustfrom the turbinewill affectengineperformance.lf the
back pressureis more than 20in (500mm)head of water,
check the exhaust system for obstructionand rectify as
necessary.
Reconditioning
When a turbocharger is removed from an engine, it is
imperativethat all terminationsof oil connectionsare sealed
immediately,to preventthe entryof dirt.
Duringall stagesof turbochargerdismantling, examination
and rebuilding,care mLlstbe taken to ensurethat no damage
is causedto comoonents
 TURBOCHARGER
Q3

Holset3LD Remove"O" ring(4)frominsert(19).

Dismantling
The individualparts of the thrust assemblycan now
be lifted
Numbersin bracketsreferto numberson Sectional out.
Drawing,
Fig.Q.2.
(a) Spacersleeve(16) which can be gentlypushed
out of the
Clampunituprightin viceon turbineinletflange. insert(19).
Markrelativepositionsof turbinehousing(B),bearinghousing (b) Oil deflector(13)positionedby two groovepins.
(14),compressor cover(21) and ,,V',clamp(7).
(c) Thrustring(12).
Removethe eight bolts (3) and associatedlockwashers
(2), (d) Thrustplare(5).
fasteningcompressorcover(21)to bearinghousing(14)
and
liftoffcover(21). Note: The groove pins are a press fit in the bearinghousrng
(14)and shouldnot be removeo.
Removethe "V" clamp locknutand spring,,V,,clamp (7)
back
onto bearinghousing(14).Liftthe core assemblyciear Removeshaftand turbinewheelassembly(10)together
of the with
turbinehousing(8). its pistonrings(9) and (15).
Holdingthe turbinewheelat the hub,removethe compressor Insertfingertipintoboreof bearing(11)
fnd remove.
locknut(17). Carefullyexpand and remove piston rifrgs(9) and (15) from
Slidecompressor wheel(18)offthe shaft. boththe spacersleeveand turbinewhe$land shaftassembty.
Usingcirclippliers,removethe largeretainingring(20)which Caution: Over expansion of piston ring will cause
a
retainscompressorinsert (19). Two screwdriverishould permanentset or breakthe rino.
be
usedto liftinsert(19)frombearinghousing(14).

Q.2

6 3544SeriesWorkshopManual,January1986
TURBOCHARGER Q4

Gleaning Procedure (18).

Compressorwheel
Use a commerciallyapprovedcleaneronly.Causticsolutions Checkcarefullyfor cracked,bent or damagedbladesbut do
willdamagecertainpartsandshouldnot be used. not attempt to straighten blades.
Soakpartsin cleaneruntilalldepositshavebeenlooseneo. "O" ring(4).
Use a plasticscraperor brisiletype brushon aluminiumoarts. Replaceif sectionthroughring has taken a permanentset;
Vapour blast may also be used providingthe shaft and other indicatedby flatson the sidesof the ring.
bearingsurfacesare protected.
A schedule of tolerances which includes allowaore
Cleanall drilledpassageswith compressedairjet. afterservice,is givenbelow.
dimensions
Make certainthat surfacesadjacentto wheels on stationarv
housingare free of depositsand are cleanand smooth, Re-assembly
When the turbochargerhas been thoroughly cleaned,
lnternal Parts Inspection inspectedand any damaged parts replaced,assemblycan
Shaftandturbinewheelassembly(10). commence.
(a) Inspect bearing journals for excessive scratches ano Assemblyof the unit is the reverseof dismantling,
but the
wear. Minorscratchesmay be tolerated. followingpointsshouldbe noticed.
(b) Inspect piston ring groove walls for scoring. Minor (a) Lubricatebearings,thrust assembly,piston rings and
scratchesare acceotable. rotorshaft,withcleanengineoil.
(c) Checkcarefullyfor cracked,bent or damagedblades,but (b) When replacingturbinewheeland shaft(10)into bearing
do not attempt to straighten blades. housing(4), and spacersleeve(16) into insert(19),do not
force pistonringsinto bore as an off-centredrrngwill fracture,
Bearing(1'1). causingthe shaftto bind.
Replacebearingsif excessivelyscratchedor worn. (c) The large retainingring (20) shouldhave bevelledside
BearingHousing(14). facingoutwards.
Replace housing if bearing or piston ring bores are ( d ) T o r q u el o c k n u(t1 7 )t o l 3 l b f f t( 1 , 8 k g f mo) r 1 7 N m ,b o t t( 3 )
excessively
scratchedor worn. to slbfft (0,7kgfm)or 7Nm and "V" clamp locknut(6) to
1 0 l b f t ( 1 , 4 k gm
f ) o r 1 3N m .
SpacerSleeve(16)
(e) On completion,
spinshaftto ensureit rotatesfreely.
Replaceif pistonringgrooveor spacerare damaged.
Note: lf during the dismantlingof the turbocharger,the
Thrustring(12):thrustplate(5).
lubricatingoil feed and drain pipe adaptorswere removed
(a) Replaceif thrustfacesare damaged.Minorscratchesare from the bearinghousing,these should,on re-assembly,be
acceptable. torqued to 30lbfft (4,15kgfm) or 41 Nm and 65tbfft
(b) Replace thrust plate (5) if faces are worn excessrverv, (8,99kgfm) or89Nm respectively.
unevenly,severelyscratchedor otherwisedamaged. The unit is now ready for fittingto the engine.lf it is not
(c) The small feed groovesin the thrust plate (5) must be intended to mount the turbocharger on the engine
cleanandfreef romobstruction. immediately afterassembly,thenthe gas and oil connections
mustbe sealedoff to preventthe entryof dirt

HOLSET 3LD
SCHEDULEOF TOLERANCES
Manufactured Dimensions Allowable Oimensions after Service RemarKs
T o t a lt u r b i n e w h e e l c l e a r a n c e 0 0 4 7 / 0 O 5 7 i n ( i , 1 9 / 1, 4 S m m ) OO24in(0,61 mm) min
Back turbinewheel clearance 0 01510027 in (0,38/0,68mm) As Manufactured Wheel pushed to compressorend
Frontturbinewheelclearance 0024/003Bin(0,61/0,96mm) OO24in(0,61mm)min
Total compressorwheel clearance 0 049/0 062in (1,2411,57mm) As Manutactured
Back compressorwheel clearance 0 026i0 043 in (0,66/1,09mm) As Manulactured Wheel pushed to turbine end
Thrustclearance 0 0 0 4 / 00 0 8 i n ( 0 , 1 o / O , 2 o m m ) As Manulactured
Radialfloatatcompressorwheh eu l b 0015/0021 in(0,38/O,53mm) O O 2 4 i n ( O , 6 1 m mm ) ax
Bearing outsidediameter 0 8714/0 8719in (22,13t22J4mm) As Manutactured
Bearing insidediameter 0 4815/0 4818 in ( 12,23t1224mm) As Manulactured
Thrustbearingwidth 0 1 0 5 / 01 0 7 i n ( 2 , 6 7 1 2 J 2 m m ) O 1 o 4 i n( 2 , 6 4 m m )m i n
Squarenessofbackfaceofturbinewheel 0002inTlR (O,OsmmTlF) AsL4anutactured OnVeeblockatl3T5inradius
E c c e n t r i c i t ysomf a l ld i a m e t e r o t s h a f t 00006inTlR (O,OimmTlR) AsL4anutacrureo
P i s t o nr i n gg r o o v e so n s h a f t 0 0 6 6 / 00 6 8 i n ( 1 , 6 9 / 1 , 7 3 m m ) O 0 6 6 / 0O T O i n( 1, 6 8 / t , 7 9 m m )
Piston ring groove on spacer sleeve 0 066/0 068 in (1,68/1,73mm) O 066/0 O7Oin (1,68/t ,79mm)
Piston ring width at turbineend 0 062/0 063 in (1,szl 1,60mm) Feplace at each seruice
Piston ring width at compressorend 0 062/0 063 in ( 1,57/1,60mm) Fleplaceat each seruice
B e a r i n gh o u s i n gb o r e f o r p i s t o n r i n g 0 8 7 5 0 / 08 7 5 5 i n ( Z Z , 2 2 t 2 2 , Z 4 m m ) OB77in(2Z,2}mm)max
Compressorinsert bore 0 875/0 876in (22,22t22,25mm) O B77in (22,28mm) max
Bearing housing bore at bearing 0 8750/0 8755 in (22,22t22,24mm) As Manufactured
Turbinewheeloutsidediameter 2977/297,in (75,62/75,56mm) 2 9 8 0 i n ( 7 5 , 6 9 m m )m a x
Shaftdiameteratbearing 0 4 8 0 3 / 04 B O O i n (i2,ZOt12J9mm) O 4 7 9 9 i n( 1 2 , i 9 m m ) m i n

6 3544SeriesWorkshopManual,January1986
 TURBOCHARGER Q5

AiresearchT-048(seeFig.e.3) bearingsuntilclearof centrehousing.

Dismantling
Clean the exterior with a pressure spray of a non_
causticcleaningsolventbeforedismantling. Dismantleonly
as requiredto make necessaryinspectionor repairs.As each
part is removed,place in a clean containerto preventloss or
oamage.
Note: The turbinewheel shroud is not retainedto the centre
housingandwillfallfreewhenthe shaftwheelis removed.
Removelockplatesand boltsfrom back plate.
Tap backplatewith soft malletto removefrom recessin cenrre
housing.

Remove the bolts, clamps and lockplateswhich hold the
compressorand turbine housingsto the centre housrng
group.Tap the housingswith a soft faced hammerif torce ts
neededfor removal.
Note: Exercisecautionwhen removinghousingsto prevent
damageto compressor or turbinewheel,Oncedamaged,they
cannot be repaired. Never attempt to straighten bent
compressor or turbineblades- replacethe faultycomponent,
Placethe centrehousinggroup in a suitableholdingfixture
whichwillpreventthe turbinewheelfromturning.
Use a T-handledwrench when removingthe compressor
wheellocknutto avoidpossiblebendingof the shaft.
Lift the compressorwheel off the shaft. Remove the shaft
wheel from the centre housingkeepingshaft centralwith
Removethrustcollarand thrustbearingfrom centrehousing.
Removebearingsand retainersfrom centrehousinq.Discard
rubbersealingring.
Cleaning
Beforecleaning,inspectall partsfor signsof rubbing,burnrng
or otherdamagewhichmightnot be evidentaftercleanrng.
Soak all parts in clean non-causticcarbon solvent. After
soaking,use a stiff bristlebrush and removeall dirt particles.
Dry partsthoroughly.
Note: Normally,a lightaccumulation
of carbondepositswill
not affectturbineoperation.

A BOLT I S E A LR I N G
B LOCKPLATE J C E N T R EH O U S I N G
ASSEMBLY
C THRUST BEARING K RETAINING RING
D BACKPLATE ASSEMBLY L BEARING
E L O C KN U T M SHROUD
F COMPRESSO WRH E E L N PISTON R I N GT, U R B I N E
G P I S T O NR I N G ' C O M P R E S S O R o S H A F TW H E E LA S S E M B L Y
H THRUSTCOLLAR

Q.3
6 3544SeriesWorkshopManual,January't986
 TURBOCHARGER Q6
Internal Parts lnspection
Parts must not show signs of damage, corrosion or
deterioration.Threads must not be nicked, crossed or
stripped.
The turbinewheelmustshow no signsof rubbingand vanes
must not be torn or worn lo a feather edge. The shaft must
show little signs of scoring,scratchesor seizurewith the
bearings.
The compressormust show no signs of rubbin$or damage
from foreignmatter.The compressorwheel bore must not be
chafed.
Seal parts must show no signs of rubbingor scoringof the
runningfaces Housingsmust show no signsof contactwith
rotatingparts. Oil and air passagesmust be clean and free
from obstructions
Burnishor polish out minor surfacedamage. Use silicon
carbide abrasive cloth for aluminium parts and crocus
abrasivecloth for the steel parts. Thoroughlyclean pa(s
beforere-assembly.
Replaceany partswhichdo not meet requirements
Replacethe followingparts:sealring,lockplates,
pistonrings,
turbine housing bolts, journal bearings,bearing retaining
rings,and compressorwheellocknut.
lf thrustbearingand thrustcollarshowsignsof nicks,scores,
varnishdepositsor foreignmatterembedments- replace.
Also,a closeinspection of bearingboresin the centrehousing
should be made and if any of the above conditionsexist,
replacethe centrehousing.
Re-assembly
Check each part prior to installation
to ensurecleanliness
Exercise care to prevent entry of foreign matter during
assembly.
Checkthrustcollarpistonringgroovefor nicksor burns
Assemblein thefollowingmanner:
Install inboard bearing retainers.Lubricatebearingswith
cleanengineoil Fitbearingsandouterbearingretainers
Place turbine wheel upright Gently guide shaft through
shroud and centre housingbearings Place thrust bearing
overthrustcollar
Fit pistonringon thrustcollar.Placethrustcollarovershaftso
that thrust bearingis flat againstthe centre housingand
engagesthe centrehousinganti-rotating pins.
Installsealringin groovein centrehousing.
Ensure that thrust spring is installedin back plate Align
mountingholesof centrehousingand backplateand install
over shaftand thrustcollar.Use care not to breakpistonring
when engagingseal into backplatebore.Backplateis easily
installedif openend positionis engagedinto backplatebore
first.
Installcompressorbackplateboltsand lockplate.Tightento
79lbfin (104kgfcm)orB,93Nmand securelockplates.
Fit compressorwheel.The largerface of the locknutand the
'1
6 3544SeriesWorkshopManual,January 986
frontfaceof the impellermustbe smoothand clean.Lightlyoil
threads and face of' nut and tightento 20lbfin (23kgfcm)or
2,26Nm, Then continue to tighten until length of shaft
increasesby 0.0055/0.0065in (0,14i0,16mm). Tightennut by
using T-handledwrenohto avoid side load which may cause
shaftto bend.Check axialend play for 0.001/0.004in (0,03/
0,10mm)travel.lf equipmentis not available to measureshaft
stretch,this alternativemethod may be used: after installing
impellernut and tighteningto 20lbfin (23kgfcm)or 2,26Nm
continueto tightenthroughan angleof g0'.
Check for clearancebetween wheel shroud and turbine
wheel.
Orientatecompressorhousingto centre housing.Fit the six
bolts and three lockplates.Tighten bolts to 130lbfin
( 1 5 0 k g f c mo)r 1 4 , 0 9 N m .
Orientateturbine housingto centre housing.Coat bolt heads
with a high temperaturethread lubricant.Installbolts,clamps
and lockplates.Tighten bolts to 130lbfin (150kgfcm)or
14,09Nm.Bendup lockplates.
After assembly,push the rotatingassemblyas far as possible
from the turbineend and check for binding.Repeatcheck,
pushingfromcompressor end.
lf the unit is to be stored, lubricateinternallyand install
protective
coverson all openings.
Note: The turbocharger does not require testing atter
overhaul.
Schwitzer3LM and 5.76
Dismantling
Numbersin parentheses
0 referto key numbersin Fig.Q.4.
Clampthe edge of turbinehousing(22) mountingflangein
vice. Mark the relativepositionsof turbinehousing,bearing
housing(13) and compressor cover(1).
Removethe setscrews(15),lockplates(16)and clampplates
(17). Lift the assemblyfrom the turbinehousing place on
workbenchwithturbinewheel(21)up
Removesetscrews(12) and clampplates(11). Removecore
assemblyfromcompressorcover(1).
Invertcore assemblyand place in turbinehousingwhich is
clampedin vice.
Holdthe end of turbinewheelwith 1%ainAIFsocketwrench,
remove the compressornut (2). Removethe compressor
wheel(3). Use extreme care in handling the compressor
wheel as the bladesbend very easily.
Removethe snap ring (8) using suitablepliers.Note the
positionof bevelon the outeredgeof the snapring;it mustbe
replacedthe sameway on re-assembly
Removethe insert(6) from the bearinghousing,removethe
thrustsleeve(4), pistonring (5) and the oil deflector(7) from
the shaft.
Remove"O" ring(9)fromthe insert.
Removepistonring(19)fromthe thrustsleeve.Both"O" ring
and pistonring must be renewedon re-assemblySeparate
the oil deflectorfromthe thrustsleeve.Liftthrustbearing(10)
out of bearinghousing.The thrustbearingmust be renewed
whenre-assembling.
Remove the shaft and bearing housingfrom the turbine
housing(22)

Separateshaft and wheel assembly (21) from the bearrng
housing. Care must be taken not to damage the
compressor wheel or the shaft.
Remove the bearing (14). Renew the bearingwhen re-
assembling.
Separatethe backplate(18) and gasket(20),if fitted,from the
bearinghousing.Where a gasket is fitted it must be reneweo
whenre-assembling.
Remove the piston ring (19) from the shaft and wheel
assembly The pistonringmust be renewedon re-assemotv.
Do not removethe pinsin the bearinghousing,
Cleaning
Beforecleaning,inspectall partsfor signsof rubbing,burnrng
or otherdamage.
Clean all parts in clean non-causticcarbon solvent. After
soaking,use a stiffbristlebrushto removeall dirtoarticles.
Oil
and air passagesmust be cleanand free from obstructions.
Blowdrywithcleanjet of compressed dry air.
Followingthe cleaning,the partsshouldbe examinedand, if
found to be in satisfactorycondition,re-assembledin the
reverseorderof the strippingsequence.
I5
Q.4
6 3544SeriesWorkshoplvlanual,
January1986
TURBOCHARGER Q7
Parts Inspection
It is suggestedthat all partsto be re-usedshouldbe checked
and measuredafterthe partshave beenthroughlycleaned.
A. BearingHousingand GroovePin Assembly
1. Inspectfor cracks or fractures,pittingof the gasket (from
corrosion or hot gas corrosion) and other machined
surfaces,or distortionof turbine end flange. Renew the
partsif conditionis excessive.
2. Visuallycheck the bearingbore for surfacecracks.Renew
if boreconditionis sub-standard.
Referencemaximumbore diametersare:
Standard - 0.7505in(i 9,06mm)
.010Oversizerebuilt - 0.7605in(19,32mm)
.020Oversizerebuilt - 0.7705in(19,57mm)
Note:The borediameterof a rebuiltturbocharger is coded
by the lastdiEitof the serialnumber
Standard - I
010Over - 0
020 Over - B
B. Compressor Wheel
1 Inspectfor evidenceof bent,burredor erodedvanesand
wear marks on the back. Renew if damaged. Do not
attempt to straighten bent vanes.
TURBOCHARGER Q8
C. TurbineWheeland ShaftAssembly
1. Inspectthe wheelfor evidenceof bent,burredor erooeo
vanes and wear marks on the back face. Renew if
damaged Do not attempt to straighten bent vanes.
2. Checkthe hub for marks (fromhigh speedcontactwith the
bearing housing bore) and for damage of the seal ring
groove.Renewif damagedor wear is excessive.
3. Inspectthe bearingjournalsfor evidenceof anydamageor
wear. Renewthe journalif necessary.
Minimum j o u r n adl i a m e t e r 0 . 4 4 0(i 1n1 , 1 8 m m )
4. Measure the concentricitybetween the large and small
shaft diameterswith a dial indicatorand vee block.Limitof
eccentricityis 0.0006in (0,015mm)T.l.R. Renew if not
withinlimit.
D, ComoressorCover
Check for damage from wheel contact, renew if damage is
excessive.lt is permissible
to polishout any smallnicksin the
coverconlour.
E. TurbineHousingand Backplate
Check for damage from wheel contact and evidence of
excessivetemperaturedamage to internalflangedsurfaces,
such as surface crackingand pitting or distortion.Renew if
cracked.lt is permissibleto polish out small nicks in the
contour.
F. SmallInternalParts
1. Fit new compressorseal ringin the insertbore.Checkfor
full circle of contact and measurering gap with feeler
gauge.Gap range0.002/0.007in (0,05/0,18mm).
Renew
insertif ringfit is out of the limit.
2. Inspect the thrust sleeve for evidence of wear and
scratches.Renewif damaqeis excessive.
Re-assembly
Numbersin parentheses
0 referto key numbersin Fig.e 4.
Check each part before re-assembly.The following items
mustbe renewedwhenthe turbocharger is rebuilt:
Compressor nut (2) Bearing(14)
Pistonring(5) Lockplates(16)
"O" ring(9) Pistonring(19)
Thrustbearing('10) Gasket(20)- whereapplicable
Fix the turbinehousing(22) securelyin vice with the four
threadedholesfacingupwards.
Oil pistonring (19) and fit in ring grooveof shaftand wheel
assembly(21), being carefulnot to over-expandthe ring.
Positionthe bearinghousing(13) with turbineend up. Fit
gasket(20),whereapplicable, and turbinebackplate(18).
The separate backplate has no attachment to the bearing
housing, its position is fixed when the bearing housing
and the turbine housing are clamped together. A few
models do not require a gasket (20).
Oil the pistonring area of the shaftand wheelassembly.Fit
into bearinghousingusing care to avoid damageto piston
nng.
Holdingthe end of the shaftto preventthe shaftwheelfrom
fallingout of the bearinghousing,place sub-assemblyin
turbinehousingwheelend down
Oil the bearing(14)and slip bearingdown overthe shaftinto
the bearinghousingbore
Oil the thrustfaceson bothsidesof thrustbearing(10).place
thrust bearingbronze side up over shaft and groove pins
6 3544SeriesWorkshopManual,January'1986
engagingpins to holesin thrustbearing.Some modelshave
onlyone groovepin
Placeoil deflector(7) on thrustsleeve(4).
Oil the pistonring (5) and fit on thrustsleeveusingcare not to
over expandthe pistonring
Oil the "O" ringand fit intogrooveof insert(6).
Oil the thrustsleeveand fit the smallend in holeof the insert
from the concaveside, taking care not to damagethe piston
flng.
Oil the thrust cavity in bearing housing and fit insert/oil
deflector/thrustsleeve sub-assemblyover the shaft into the
bearinghousing,aligningoil deflectorwith oil draincavityin
bearinghousing.Takecarenotto damage"O" ring.
Usingsuitablepliers,fit snap ring (8) intothe groovewiththe
flatsideagainstthe insert.Ensurethe snapringis securelyin
position.
Mounta dial indicatoron the bearinghousingwiththe stemof
the indicatoron the end of the shaft. Make sure that the
turbineend of the bearinghousingis correctlyseatedin the
turbinehousing.Movethe shaftvertically to determineturbine
wheel contour clearance.The clearancemust be between
0.018in(0,46mm)and 0.049in(1,24mm\.lf clearancers not
within these tolerances,dismanile unit to determinethe
cause. Look for burrs, dirt particlesor incorrectlyassembled
parts. lf after re-assemblyit is still out of the permitted
tolerance,do not use.
Installcompressorwheel (3) on shaft.
Removeany oil from the shaft threadsand apply 2 drops of
"Loctrte 601" (or equivalentlocking agent) to the shaft
threads.Usinga socketwrenchon the turbinewheel lug to
preventthe shafl from turning,tightenthe compressornut to
l 3 l b f f t( 1 7 , 6 N m ) .
Mountthe dial indicatoron the bearinghousingwithstemon
the end of the shaft,measurethe end play.The toleranceis
0.002/0.005in (0,05/0,13mm).This is a dry (no oil) reading.
lf not within tolerance,dismantleand look for burrs, dirt
particlesor incorrectassembly.Re-assembleand if stillout of
tolerance,do not use.
Place compressorcover (1) on the bench with wheel cavity
upwards.Lubricatethe smalldiameterof the shaftwithgrease
or oil and place lhe turbochargercore assembly in
compressorcoverwiththe turbinewheelup.
Check turbine wheel clearance between back face of the
turbine wheel and plate on oppositesides of the shaft.
clearancetolerancemust be 0.017/0.049in (0,4311
,24mm\.lt
clearanceis not withinthe limits,dismantleand inspectas
with previouscomponents,if on re-assemblystill not to
tolerance,
do not use.
Ensure that the location marks previouslymade on the
compressorcover and bearinghousingare in line and fit the
four clamp plates (11) with setscrewsand lockingwasher
(12). Tightensetscrewsto slbfft (6,BNm).Use care not to
overtighten screws as damage can be caused to the
aluminiumcompressor cover.
Turn unit over and place in the turbine housing.Apply
anti-seize
compoundto threadsand setscrews(15).
Ensurethatthe locationmarkspreviously madeon theturbine
housingand bearinghousingare in line.
Fitclampplates(17),lockplates(16)andsetscrews.
Tightenthe setscrewsto l2lbfft (16,3Nm)and lockthetabsto
setscrews.
Removecompletedturbochargerfrom the vice.
 TURBOCHARGER Q9

InstallationCheck List
Inspectthe air intake system and the exhaust
manifoldfor
cleanlinessand foreignmatter.
Inspectthe oil drainlineand makesureit is notclogged.
Inspect the oil supply line for clogging,deterioration
or
possibility
of leakingunderpressure.
Inspect the turbochargermounting pad on the manifold
to
make certainthat all the old gasket has been removed.
On
some applications an adaptor is fitted between
the
turbochargerand exhaustmanifoldassembly.The adaptor
is
securedto the manifoldby four stud nuts and washers
and it
should be ascertainedthat all traces of the old gasket
have
been removedfrom it.
Installa new gasket betweenthe turbochargerand
exnaust
manifold. ln cases where an adaptor is iitteC, it wiil
be

Installturbocharger
and tightenmountingbolts or secunnq
nuts.
Connect the oil supply line but leave the oil drain line
disconnected.
Connectthe compressorinlet and outlet piping.Check
all
joinls for possibleleaks. Make certainthat the piping
rs not
exertinga strainon the compressorcover.
Connectexhaustpipe.
Motorthe enginewithoutfiring(i.e.by operatingstopcontrot),
untila steadyflowof oil comesfromthe oil drainline.
Stop motoringand connectoil drainpipeconnection.
Note: When the turbochargeris put into service, it is not
advisableto run up to maximumspeed or boostdurinqrne
first500 milesor 25 hoursof runnino.

6 3544SeriesWorkshoplvlanual,
January1986
 SECTIONR
Alternatorand starterMotor
ALTERNATORAND STARTERMOTOR R2
ALTERNATOR
M o d e l s A C s , 1T A C R ( d e r a t e d ) , 17 A C R ,
1 8 A C R ,2 5 A C Ro r A 1 3 3 / 6 5 .
1. General
At the time of writing there are five types of alternator
fitted to the T6.3544 and 6.3544 engine,namely the
A C s , 1 7 A C R ,1 8 A C R , 2 5 A C R
a n dA 1 3 3 / 6 5 .
These are driven by the engine in the same manner
a s a D C G e n e r a t o rn, a m e l y b, e l td r i v e nf r o m t h e c r a n k s h a f t
p u l l e y ,b u t t h e a d v a n t a g el i e s i n t h e i r a b i l i t yt o p r o v i d e
h i g h e r m a x i m u m o u t p u t a t l o w e r s p e e d s ,t o c o p e w i t h
i n c r e a s e de l e c t r i c a ll o a d d e m a n d e d b y m o d e r n e q u i p -
ment and decreased road speeds owing to increased
d e n s i t yo f t r a f f i c ,e s p e c i a l l yi n b u i l t u p a r e a s .T h e y a r e
a l s o m u c h l i g h t e ri n w e i g h t ,o u t p u t f o r o u t p u t
A s o p p o s e dt o t h e D C G e n e r a t o ri n w h i c h t h e a r m a t u r e
w i n d i n g s r o t a t e i n s i d e a s t a t i o n a r yf i e l d s y s t e m , t h e
alternatorhas a rotating field system inside a stationary
generatingwinding When the rotor rotates inside
t h e s t a t o r , t h e o u t p u t p r o d u c e d i s a l t e r n a t i n gc u r r e n t
( A C ) T h i s i s u n s u i t a b l ef o r c h a r g i n gt h e b a t t e r y w h i c h
r e q u i r e sd i r e c t c u r r e n t ( D C ) , s o i t i s . r e c t i f i e db y m e a n s
o f d i o d e sw h i c h c o n v e r ti t t o u n i - d i r e c t i o n af l o w t o t h e
battery
The alternatorvoltage output is maintained within
close limits by meansof a control box which is fullv
t r a n s i s t o r i s eadn d f u n c t i o n sa s f a s t s w i t c h e s
2. Precautions
A s p r e v i o u s l yd e s c r i b e dt h e d i o d e s i n t h e a l t e r n a t o r
f u n c t i o n a s o n e - w a y v a l v e sa n d t h e t r a n s i s t o r si n t h e
regulator/control box operate as fast switches. Both
are accurateand sensitive
T h e y d o n o t w e a r o u t a n d s e l d o m r e q u r r ea d j u s t m e n t ,
but because they are sensitive to voltage changes
a n d h i g h t e m p e r a t u r e ,t h e p r e c a u t i o n s a r e v r t a l t o
preventthem from being destroyed
( a ) D O N O T d i s c o n n e c tt h e b a t t e r y w h i l s t t h e e n g i n e
i s r u n n i n g T h i s w i l l c a u s e a v o l t a g es u r g e i n t h e
a l t e r n a t o rc h a r g i n g s y s t e m t h a t w i l l i m m e d i a t e l v
r u i n t h e d i o d e so r t r a n s i s t o r s .
( b ) D O N O T d i s c o n n e c ta l e a d w i t h o u t f i r s t s t o p p i n g
t h e e n g i n ea n d t u r n r n ga l l e l e c t r i c a sl w i t c h e st o t h e
off position
( c ) D O N O T c a u s ea s h o r t c i r c u i t b y c o n n e c t i n gl e a d s
t o i n c o r r e c tt e r m i n a l s A l w a y s i d e n t i f ya l e a d t o i t s
c o r r e c t e r m i n a lA. s h o r tc i r c u i to r w r o n g c o n n e c t i o n
giving reverse polarity will immediately and
p e r m a n e n t l yr u i n t r a n s i s t o r so r d i o d e s
( d ) D O N O T c o n n e c ta b a t t e r yi n t o t h e s y s t e mw i t h o u t
c h e c k i n gf o r c o r r e c t p o l a r i t ya n d v o l t a g e
( e ) D O N O T " f l a s h " c o n n e c t i o n st o c h e c k f o r c u r r e n r
f l o w N o m a t t e rh o w b r i e ft h e c o n t a c tt h e t r a n s i s t o r s
may be ruined
3. Maintenance
T h e a l t e r n a t o rc h a r g i n g s y s t e m w i l l n o r m a l l y r e q u i r e
v e r y l i t t l e a t t e n t i o n ,b u t i t s h o u l d b e k e p t f r e e f r o m
build-upof dirt, and a check made if it fails to kccn
the battery charged
( a ) R e g u l a r l yi n s p e c t t h e d r i v i n g b e l t s f o r w e a r a n d
c o r r e c t t e n s i o n . l t i s t m p o r t a n tt o e n s u r e t h a t a l l
b e l t so n a m u l t i p l eb e l t d r i v e h a v ee q u a lt e n s i o na n d
are each carryingtheir share of the load Slack
beltswill wear rapidlyand cause slip which will
n o t d r i v et h e a l t e r n a t o ra t t h e r e a u i r e ds o e e d .D r i v e
belts which are too tight impose severeside thrust
o n t h e a l t e r n a t o rb e a r i n g sa n d s h o r t e n t h e i r l i f e
P e r i o d i c a l l ye n s u r e t h a t t h e a l t e r n a t o ri s c o r r e c t l y
a l i g n e dt o t h e d r i v e .
( b ) D o n o t r e p l a c ef a u l t y b e l t s i n d i v i d u a l l yi n a m u l t i -
belt system.A complete matched set of drive belts
must always be used.
(c) Keep the alternatorclean with a cloth moistenedin
k e r o s e n eo r c l e a n i n gf l u i d s E n s u r et h a t v e n t i l a t i o n
s l o t s a n d a i r s p a c e sa r e c l e a r a n d u n o b s t r u c t e d
( d ) R e m o v e a n y d i r t a c c u m u l a t e do n t h e r e g u l a t o r /
c o n t r o l b o x h o u s i n g ,a n d e n s u r e t h a t c o o l i n g a i r
can pass freely over the casing
4. Fault Finding on AC5
T h e A C s a l t e r n a t o ri s s o d e s i g n e dt h a t a f l o w o f c u r r e n t
i n d i c a t e de i t h e rb y t h e e x t i n g u i s h i n o
g f t h e w a r n i n gl i g h t ,
o r a ss h o w no n t h e a m m e t e r i,s s u f fi c i e n te v r d e n c e t h a tt h e
system is in proper working order Therefore, no open
circuit, voltage or current output checks should be
p e r f o r m e do n t h e i n s t a l l a t i o nU N L E S S :
(a) The warning light fails to illuminatewhen ihe
g e n e r a t o ri s s t a t i o n a r y ,a n d t h e s w i t c h i s c l o s e d
OR fails to become extinguished when the
a l t e r n a t b irs r u n n i n g .
( b ) N o c h a r g i n gc u r r e n ti s s h o w n o n a m m e t e r .
(c) The battery is flat
( d ) T h e b a t t e r y i s " b o i l i n g " ,i n d i c a t i n gl o s s o f v o l t a g e
control
lf any of the above symptoms occur, the procedure
i n d i c a t e db e l o ws h o u l d b e f o l l o w e d :
(a) Connect a good quality moving coil voltmeter
0-50 volts range across the battery or regulator
n e g a t i v et e r m i n a l , a n d o n e o f t h e t h r e e p o s i t i v e
t e r m i n a l sm a r k e dL O , M E D , H l l f a n a m m e t e ri s n o t
p a r t o f t h e a p p l i c a t i o n sc i r c u i t , f i t a g o o d q u a i i t y
m o v i n gc o i l 0 - 1 0 0 a m p a m m e t e ri n t h e a l t e r n a t o r
to battery positive line The battery should be in a
chargedcondition.
(b) Close the warnrng light switch (niasterelectrrc
switch on dashboard)when the warning lamp
s h o u l dl i g h tu p
( c ) S w i t c h o n a 1 0 - 1 5 a m p e r e sl o a d s u c h a s | i g h t s ,
fans, etc
(d) Start engine and run at fast idle speed when
' 1 T h e w a r n i n El i g h t s h o u l dg o
out
2 The ammeter records a small charoe
d e p e n d e no t n e n g i n es p e e d
( e ) l n c r e a s ee n g i n e s p e e d m o m e n t a r i l yt o m a x i m u m
speed, when the charging current should be
a b o u t 3 0 a m p e r e sf o r 2 4 v o l t s - 5 5 a m p e r e sf o r
' 1 2v o l t
systems
(f) W i t h t h e a l t e r n a t o rr u n n i n g a t a p p r o x i m a t e l yh a l f
s p e e d ( e n g i n es p e e d a b o u t 1 , 5 0 0r e v m i n ) , s w i t c h
o f f e l e c t r i c a ll o a d D e p e n d i n go n t h e c o n n e c t i o n
s e l e c t e df o r t h e p o s i t i v es e n s i n gw i r e L O , M E D , o r
H l , t h e v o l t a g es h o u l d r i s e t o b e t w e e n 2 6 a n d 2 8
v o l t so n 2 4 v o l t s y s t e m sa n d 1 3 - . 1 4 v o l t s o n 1 2 v o l t
s y s t e m sa n d t h e n r e m a i n c o n s t a n t A t t h e s a m e
t r m e t h e c u r r e n t r e a d i n gs h o u l d d r o p a p p r e c i a b l y
 ALTERNATORAND STARTERMOTOR R3

A n y v a r i a n c ei n t h e a b o v e d a t a c o u l d i n d i c a t e a f a u l t
a n d t h e f o l l o w i n gp r o c e d u r es h o u l d b e a d o p t e d b e f o r e
disconnectina gny components
T h e r e g u l a t o ri s a s e a l e d u n i t a n d i s n o n _ r e p a i r a b l e
a n d i f f o u n d t o b e f a u l t yi t m u s t b e r e p l a c e d .

Warning Lamp does not light up when switched ,,On,,.

check the bulb
lf no fault
C h e c k a l l w i r i n g c o n n e c t i o n sa t r e g u l a t o r ,a l t e r n a t o r
and battery
lf no fault
S w i t c ho f f , d i s c o n n e c "t F ' , l e a d a t r e g u l a t o ra n d c o n n e c t
i t t o t h e n e g a t i v et e r m i n a l .
S w i t c h o n l f w a r n i n g l a m p l i g h t s u p , t h e r e g u l a t o ri s
f a u l t y l f l a m p f a i l s t o l i g h t u p t h e a t t e r n a t o ri s f a u t t y

Warning Lamp does not go out and Ammeter shows

no output when running.
C h e c k a l l r e g u l a t o ra
, l t e r n a t o ra n d b a t t e r yc o n n e c t i o n s .
lf no fault
S w i t c ho f f , d i s c o n n e c t ' , F l, e' a d a t r e g u l a t o ra n d c o n n e c r
t o r e g u l a t o rn e g a t i v et e r m i n a l
S w i t c ho n , a n d r u n a t f a s t i d l e
l f n o o u t p u t ,a l t e r n a t o irs f a u l t y .
l f o u t p u t a p p e a r s r, e g u l a t o ri s f a u l t y
Warning Lamp does not go out when running and
Ammeter shows reduced output with full output only
at maximum speed or Warning Lamp goes out but
Alternator delivers reduced output. Full output only at
maximum speed.
A l t e r n a t o rf a u l t y R e m o v e f r o m i n s t a l l a t i o na n d a p p l y
o p e n c i r c u i td i o d e c h e c k
Warning Lamp f lashes intermittenily and Ammeter
needle oscillateswhen Battery is fully charged and no
loads are switched in.
C h e c k f o r e x c e s s i v er e s i s t a n c ei n r e g u l a t o r n e g a t i v e
s e n s i n gl e a d
l f n o f a u l t ,r e g u l a t o ri s f a u l t y
Batteries overcharging and Ammeter indicates high
o r f u l l o u t p u ta l l t h e t i m e .
C h e c kr e g u l a t o p
r o s i t i v es e n s i n gl e a d a n d i t s c o n n e c t i o n
at regulator.
l f n o f a u l t ,r e g u l a t o ri s f a u l t y
5 . T e s t i n g t h e 1 7 A C R , 1 B A C R ,2 5 A C R a n d
A 1 3 3 / 6 5i n P o s i t i o n
F i r s tc h e c kt h e d r i v i n gb e l t f o r c o n d i t i o na n d t e n s i o n T
. he
n o m i n a l h o t o u t p u t sa t 6 , 0 0 0r e v / m i n( a l t e r n a t o sr p e e d )
a r e g i v e n o n P a g e 8 1 2 . T h e s e f i g u r e sm a y b e e x c e e d e d
s l i g h t l y w h e n t h e a l t e r n a t o ri s r u n n i n g c o l d . T o a v o r d
m i s l e a d i n gr e s u l t s ,t h e f o l l o w i n gt e s t p r o c e d u r es h o u l d
t h e r e f o r eb e c a r r i e d o u t w i t h t h e a l t e r n a t o rr u n n t n ga s
n e a r a s p o s s i b l et o i t s n o r m a lo p e r a t i n gt e m p e r a t u r e .
T e s t C i r c u i tf o r 1 7 A C Ra l t e r n a t o r s
Standardterminations,batterv_sensed
R.1
AlternatorOutput Test with Regulator
Inoperative
W i t h d r a w t h e c a b l e c o n n e c t o r ( s )f r o m t h e a l t e r n a t o r ,
r e m o v et h e m o u l d e d c o v e r ( s e c u r e d b y t w o s c r e w s )
a n d e a r t h t h e r e g u l a t o rg r e e n l e a d o r c o n n e c t o rs t r i o
to frame
C o n n e c ta n e x t e r n a lt e s t c i r c u i t t o t h e a l t e r n a t o ro u r p u r
termanaa l ss s h o w ni n F i g R , 1 ,R . 2 o r R 3
V a l u e o f c o m p o n e n t si n F i g s R 1 , R . 2 a n d R 3 a r e a s
follows:
1 '12 volt 2 2 watt butb.
2 0-60 ammeter
3 1 2v o l t b a t t e r y
4 0-20 moving coil voltmeter
5 0 - 1 5 o h m 3 5 a m p v a r i a b l er e s i s t o r
O b s e r v ec a r e f u l l yt h e p o l a r i t yo f b a t t e r y a n d a l t e r n a t o r
t e r m i n a l s- reversedconnectionswill damaoe thc
a l t e r n a t od
r iodes
The variable resistor across the battery teri-ninalsmust
not be left connected for longer than is necessarvro
c a r r yo u t t h e f o l l o w i n gt e s t .
S t a r tt h e e n g i n e A t 1 , 5 0 0r e v l m i n( a l t e r n a t osr p e e d ) ,t h e
t e s t c i r c u i tb u l b s h o u l db e e x t i n g u i s h e dI.n c r e a s ee n g i n e
s p e e d u n t i l t h e a l t e r n a t o ri s r u n n i n g a t 6 , 0 0 0 r e v l m t n
a p p r o x i m a t e l ya,n d a d j L l stth e v a r i a b l er e s i s t a n c eu n t i lt h e
v o l t m e t e rr e a d s 1 3 6 v o l t s T h e a m m e t e rr e a d i n gs h o u l d
t h e n b e a p p r o x i m a t e l ye q u a l t o t h e r a t e d o u t p u r ( s e e
p r e v i o u sh e a d i n g ) .A n y a p p r e c i a b l ed e v i a t i o nf r o m t h i s
f i g u r ew i l l n e c e s s i t a tteh e a l t e r n a t o br e i n g r e m o v e df r o m
t h ee n g i n ef o r f u r t h e re x a m i n a t i o n .
F a i l u r eo f o n e o r m o r eo f t h e d i o d e sw i l l b e i n d i c a t e di n t h e
above test by effect on alternator output, and also in
s o m ei n s t a n c e b s y a b n o r m a l l yh i g h a l t e r n a t otre m p e r a r u r e
a n d n o i s el e v e l
RegulatorTest
The following test assumesthe alternator to have oeen
tested and found satisfactorv.
 ALTERNATORAND STARTERMOTOR R4

Disconnect the variable resistor and remove the earth m e a n st h a t t h e r e g u l a t o ri s n o t f u n c t i o n i n gp r o p e r l ya n d

c o n n e c t i o nf r o m t h e r e g u l a t o rg r e e n l e a d o r c o n n e c r o r must be replaced.
strip to frame.
lf the foregoing tests show the alternatorand regulator
W i t h t h e r e m a i n d e ro f t h e t e s t c i r c u i t c o n n e c t e da s f o r to be satisfactorily performing, disconnect the test
the alternator output test, start the engine and agarn circuit and reconnectthe alternator terminal connector.
run the alternatorup to 6,000 revlmin until the ammeter Now connect a low range voltmeterbetweenthe positive
shows an output current of less than 10 amperes The t e r m i n aol f t h e a l t e r n a t o (r t h em o u l d e dt e r m i n a cl o n n e c r o r
v o l t m e t e sr h o u l dt h e n g i v ea r e a d i n go f 1 3 , 6- 1 4 , 4v o r t s i s o p e n e n d e dt o f a c i l i t a t et h i s ) a n d t h e p o s i t i v et e r m i n a l
A n y a p p r e c i a b l ed e v i a t i o nf r o m t h i s ( r e g u l a t i n g v) o l t a g e of the battery.Switch on battery load (headlightsetc.),
start the engine and increasespeed until the alternator
runs at approximately6,000 revlmin Note the voltmeter
Bo+ -T
? reading.
Transfer the voltmeter connections to the negative
2 I terminalsof the alternatorand batteryand again note the
A meter reading
lf the readingexceeds0 5 volt on the positiveside or 0.25
v o l t o n t h e n e g a t i v es i d e ,t h e r e i s a h i g h r e s i s t a n c ei n t h e
chargingcircuit which must be traced and remedied.
3

STARTERMOTOR
Model M50

e^ \y
General Description
The model M50 startermotor is a four pole machine
o f 5 i n ( 1 2 7 , 0 m m )n o m i n a l y o k e d i a m e t e r ,a n d n a s a
21 slotarmature.
+.nn ^9^r, T h e d r i v e i s o f p r e - e n g a g e d s, o l e n o i d o p e r a t e d ,p u s n
screw type, incorporatinga five roller clutch.
The function of the clutch is to prevent the armarure
T e s t C i r c u i t f o r 1 7 A C R a l t e r n a t o r sw i t h s t a n d a r dt e r m i n a l s a n d
t w o p i e c ec o n n e c t i o np l u g ( m a c h i n e - s e n s e d ) being rotatedat high speeds in the event of the engaged
position being held after the engine has started The
R.2 solenoidincorporatesa two-stageswitchingarrangement
w h i c h e n s u r e st h a t t h e m o t o r d e v e l o p s i t s m a x i m u m
+' e) + IND
t o r q u e o n l y w h e n f u l l p i n i o n - f l y w h e eel n g a g e m e n th a s
been achieved

I 1 Testingon the Application

I Ensurethat the battery is in a charged condition

Switch on the lamps and operate the starter button.
l f t h e s t a r t e rf a i l s t o f u n c t i o n , b u t t h e l i g h t s m a i n t a i n
f u l l b r i l l i a n c ec, h e c k t h e s w i t c h a n d b a t t e r yc o n n e c t r o n s
_J t o t h e s t a d e ra n d a l l e x t e r n a l e a d s .S l u g g i s ha c t i o no f t h e
starter can be caused by a poor or faulty connection.

I Difficulty in smooth engagement between starter ano

engineflywheelis probablydue to dirt on the starter-shaft
-r h e l i c e s p r e v e n t i n gf r e e p i n i o n m o v e m e n t . T h e s h a f t
s h o u l db e t h o r o u g h l yc l e a n e dw i t h c l e a n i n gf l u i d f o l l o w e d
b y t h e a p p l i c a t i o no f a s m a l l q u a n t i t yo f A c r o S h e l l 6 8
or itsequivalent
@^^
\:./
/?\
+- A A A\l nnn -- MAINTENANCE
Brush Gear and Commutator
Inspectthe brushes at intervalsto ensure that they are
free in their guides and that the leads are quite free
T e s t C i r c u i tf o r 1 7 A C R ,1 8 A C R , 2 5 A C Ra n d A 1 3 3 / 6 5a t t e r n a t o r s
w i t h E u r o p e a nt e r m i n a t i o n sa n d s i n g l e3 t e r m i n a lc o n n e c r o rp t u g f o r m o v e m e n t ,b y e a s i n g b a c k t h e b r u s h s p r i n g s a n d
( m a c h i n e - s e n s e d )B. r o k e n l i n e c a b l e c o n n e c t i o na o o l i e s t o p u l l i n gg e n t l y o n t h e f l e x i b l ec o n n e c t i o n s .l f a b r u s h i s
b a t t e r y - s e n s e di,n w h i c h c a s e , t h e c o n n e c t i o n sb e t w e e nt h e t w o i n c l i n e dt o s t i c k , r e m o v e i t f r o m i t s h o l d e r a n d c r e a n
'+'terminals
w i l l n o t a p p l y a n d t h e b r o k e nl i n e t e r m i n a w
l ill be the sides with a petrol moistened cloth
m a r k e d" S " i n s t e a do f " + "
B e s u r e t o r e f i t t h e b r u s h e si n t h e i r o r i g i n a l p o s i t i o n s
R.3 t o r e t a i n t h e " b e d d i n g " .T h e b r u s h e s s h o u l d b e w e l l
 ALTERNATORAND STARTERMOTOR R5

l i k e l yt o r e q u i r ea d j u s t m e n ts, u c h a s t h e s w i t c h g e a r
and
c o m m u t a t o ra s s e m b l i e s .

Testingon the Application

Ensurethat the battery is in a charged condrtron
Switch on the lamps ano operate the starter button.
l f t h e s t a r t e rf a i l st o f u n c t i o n ,b u t t h e l i g h t s m a i n t a i n
full
b r i l l i a n c ec, h e c k t h e s w i t c h a n d b a t t e r y c o n n e c t i o n s
to
t h e s t a r t e ra n d a l l e x t e r n a ll e a d s .S l u g g i s ha c t i o n
of the
startercan be causedby a poor or faulty connection
D i f f i c u l t y i n s m o o t h e n g a g e m e n tb e t w e e n s t a r t e r a n d
e n g i n e f l y w h e e l i s p r o b a b l yd u e t o d i r t o n t h e s r a r r e r _
s h a f th e l i c e sp r e v e n t i n gf r e e p i n i o n m o v e m e n tT n e s h a f t
should be thoroughly cleaned with cleaning fluid
c o n n e c t o rl e a d s ,h e l d b y t w o o f t h e f i x i n g s c r e w s . f o l l o w e db y t h e a p p l i c a t i o no f a s m a l l q u a n t i t yo f A c r o
Before S h e l l6 8 o r i t s e q u i v a l e n t .
i n s e r t i n gb r u s h e s i n t h e i r h o l d e r s , i t i s a d v l s a b l e
to
b l o w t h r o u g h t h e h o l d e r sw i t h c o m p r e s s e da i r o r
clean
t h e mw i t ha c l o t hm o i s t e n e d w i t hp e t r o l .
MAINTENANCE
T h e c o m m u t a t o rs h o u l d b e c l e a n , e n t i r e l y f r e e
from Brush Gear and Commutator
oil or dirt. Any trace of such should be iemoved
by I n s p e c tt h e b r u s h e sa t i n t e r v a l st o e n s u r et h a t t h e y a r e
p r e s s i n ga c l e a n d r y f l u f f l e s sc l o t h a g a i n s t
it, while
armatureis hand rotated. f r e e i n t h e i r g u i d e sa n d t h a t t h e l e a d sa r e q u i t e f r e e f o r
m o v e m e n tb, y e a s i n gb a c k t h e b r u s h s p r i n g sa n d p u l l i n g
l f t h e c o m m u t a t o ri s d i r t y o r d i s c o l o u r e dt,i l t t h e
brushes g e n t l yo n t h e f l e x i b l ec o n n e c t i o n s l.f a b r u s h l s l n c t t n e d
a n d w r a p a s t r i p o f f i n e g l a s s o r c a r b o r u n d u mp a p e r
t o s t i c k , r e m o v ei t f r o m i t s h o l d e r a n d c l e a n t h e s r o e s
(not emery cloth) round the commutator,
with the w i t h a p e t r o lm o i s t e n e dc l o t h
abrasive side inwards. Rotate the armature by
hand B e s u r e t o r e f l t t h e b r u s h e si n t h e i r o r i g i n a l p o s i t i o n s
until the surface is even. Clean with a petrol moistened
cloth. t o r e t a j n t h e " b e d d i n g , ' .T h e b r u s h e s s h o u l d b e w e r r
b e d d e d( i . e .w o r n t o t h e c o m m u t a t o rp e r i p h e r y )b u t i f n o t ,
l f r e p a i ri s n e c e s s a r yt o t h e c o m m u t a t o ro r s w i t c h g e a r
w r a p a s t r i p o f v e r y f i n e g l a s s o r c a r b o r u n d u mp a p e r
etc., the starter must be exchanged or repaired
by an f i r m l y a r o u n d t h e c o m m u t a t o r w i t h t h e a b r a s i v es i d e
a u t h o r i s e da g e n t .
outwards With the brushes ln position, rotate the
armature by hand in the normal working dtrection
o f r o t a t i o n ;u n t i l t h e c o r r e c t b r u s h s h a p e i s o b t a i n e d .
lf the brushes are worn down so that the springs
Model CA45 a r e n o l o n g e r p r o v i d i n ge f f e c t i v ep r e s s u r e ,t h e y s h o u l d
b e r e n e w e dC . h e c kt h e b r u s hs p r i n gp r e s s u r eb y h o o x r n g
General Description
a spring balance under the spring lip. The correct
D e s i g n e df o r f l a n g e m o u n t i n g ,t h e C A 4 5 s t a r t e r m o r o r t e n s i o ni s 3 0 / 4 0 o z f( 0 , 8 5 / 1 , t 3 k g f )
has a uniform cylindrical shape with no surface
p r o t r u s i o n s .T h i s i s b e c a u s e t h e s o l e n o i d a n d I t i s e s s e n t i a tl h a t r e p l a c e m e n tb r u s h e s a r e t h e s a m e
main g r a d e a s t h o s e o r i g i n a l l yf i t t e d .G e n u i n e s p a r e ss h o u l d
s w i t c h a s s e m b l i e sa r e h o u s e d w i t h i n t h e d r i v e
eno_ alwaysbe used.To removethe brushes,unscrewthe four
s h i e l d ,a r o u n d ( i e . , c o - a x i a l l yw i t h ) t h e a r m a t u r es h a f t
f j x i n g s c r e w s ,o n e t o e a c h b r u s h . I n r e _ a s s e m b l i ncga r e
The essentialfeature of the co-axial starter is that, m u s t b e t a k e n t o r e - c o n n e c tt h e f i e l d c o i l a n d i n t e r _
the
P i n i o na l o n em o v e sa x i a l l yt o e n g a g et h e e n g i n ef l y w n e e t . connectorleads,held by two of the f ixing screws Before
T h e r ei s n o I o n g i t u d i n am l o v e m e no t f t h e w h o l eu i r " t r r " i n s e r t i n gb r u s h e s i n t h e i r h o l d e r s ,i t r s a d v i s a b l et o b t o w
a s s e m b l ya, s i n t h e a x i a lt y p e s t h r o u g ht h e h o l d e r sw i t h c o m p r e s s e da i r o r c l e a n t n e m
S m o o t h e n g a g e m e n to f t h e p i n i o n w i t h t h e e n g t n e w i t h a c l o t h m o i s t e n e dw i t h p e t r o l
f lywheel is constantly ensured by using two_stage T h e c o m m u t a t o rs h o u l d b e c l e a n , e n t i r e l yf r e e f r o m o i l
operation of the solenoid and swrtch mechantsms. o r d i r t .A n y t r a c eo f s u c h s h o u l d b e r e m o v e db y p r e s s l n g
T h u s t h e r i s k o f d a m a g et o b o t h p i n i o n a n d f l y w h e e l , a c l e a n d r y f l u f f l e s sc l o t h a g a i n s t i t , w h i l e a r m a t u r ei s
t h r o u g hf a u t t ym e s h i n g ,i s p r a c t i c a l l ye l i m i n a t e d . hand rotated
In construction, the starter consists of three l f t h e c o m m u t a t o ri s d i r t y o r d i s c o l o u r e dt,i l t t h e b r u s n e s
main
s e c t i o n s ,i n t o w h i c h i t c a n b e e a s i l y d i s m a n i l e d . a n d w r a p a s t r i p o f f i n e g l a s s o r c a r b o r u n d u mp a p e r
1 T h e s o l e n o i ds w i t c h - g e aar n d p i n i o na s s e m b l yh o u s e d ( n o t e m e r y c l o t h ) r o u n d t h e c o m m u t a t o r ,w i t h
the
i n t h e d r i v ee n d - s h i e l d a b r a s i v es i d e i n w a r d s .R o t a t et h e a r m a t u r eb y h a n d u n t i l
2 The armature,shaft and commutator assembly. t h e s u r f a c ei s e v e n .C l e a nw i t h a p e t r o l m o i s i e n e dc l o t h .
3 T h e y o k e , p o l e - p i e c ea n d f i e l d - c o i la s s e m b l y l f r e p a i r i s n e c e s s a r yt o t h e c o m m u t a t o r o r s w i t c h
g e a r e t c . t h e s t a r t e r m u s t b e e x c h a n g e do r r e p a t r e d
Ready access is possibletherefore,to those parts mosr
b y a n a u t h o r i s e da g e n t .
SECTIONS
Compressor
COMPRESSOR S2
T h e a i rc o m p r e s s oirs a s i n g l eo r t w i n c y l i n d e rw a t e rc o o l e d
unit which is bracketmounted on the cylinder block
a n d d r i v e nf r o m t h e a u x i l i a r yd r i v e .
S h o u l d i t b e n e c e s s a r yt o d r a i n t h e e n g i n e c o o l i n g
system to prevent damage by frost, the Clayton
D e w a n d r e c o m p r e s s o rm u s t a l s o b e d r a i n e d D r a i n
p l u g s a r e p r o v i d e do n t h e c o m p r e s s o rc y l i n d e r b l o c k .
W i t h t h e B e n d i x W e s t t n g h o u s ec o m p r e s s o r ,o n l y t h e
cylinder head is water cooled and this will be auto-
m a t i c a l l ye m p t i e dw h e n t h e e n g i n e i s d r a i n e d
lf leakage in the braking system is not excessive,
f a i l u r e o f t h e c o m p r e s s o rt o m a i n t a i n a d e q u a t ea i r i n
the system, or to charge the system in a reasonable
t i m e ,u s u a l l yd e n o t e sl o s so f e f f i c i e n c yd u e t o w e a r .T h i s
wear could be in the cylinder head (valvesand seats) or
cylinders (piston assemblies)Another sign of wear
is excessiveoil passing through to the reservoir
PreventiveMaintenance
E v e r y5 , 0 0 0m i l e s ( 7 , 5 0 0 k m ) , 2 5 0 h o u r s o r 4 m o n t h s
( w h i c h e v eor c c u r sf i r s t ) .
R e m o v e ,d i s m a n t l ea n d c l e a n c o m p r e s s o ra i r c l e a n e r
(if fitted).
E v e r y 1 0 , 0 0 0m i l e s ( 1 5 , 0 0 0k m ) , 5 0 0 hours or 12
m o n t h s ( w h i c h e v e ro c c u r s f i r s t ) .
Visually check all unions, pipe fittings,etc., for
l o o s e n e s so r l e a k a g e
C h e c k c y l i n d e rh e a d b o l t s f o r c o r r e c tt i , g h t n e s s
C h e c k e n d c o v e r sf o r o i l l e a k s
C h e c k t h a t c o m p r e s s o rm o u n t i n gi s s e c u r e .
E v e r y2 0 , 0 0 0m i l e s ( 3 0 , 0 0 0k m ) o r 1 , 0 0 0h o u r s
U n c o u p l ed e l i v e r yp o r t a n d c h e c k t h e h e a d p a s s a g e s
f o r e x c e s s i v ec a r b o n d e p o s i t sw h i c h , i f p r e s e n t ,m u s t
b e r e m o v e db y d i s m a n t l i n gt h e c y l i n d e rh e a d .
. C h e c kc o m p r e s s o rd e l i v e r y I i n e f o r c a r b o n d e p o s i t s ,
c l e a n o r r e p l a c eI i n e a s n e c e s s a r y .
Every 60,000miles (90,000km) or 2,500hours
D i s m a n t l ec o m p r e s s o r ,t h o r o u g h l yc l e a n a l l p a r t s a n d
inspect for wear or damage Repair or replace all
worn or damaged parts or replace with Factory
B e c o n d i t i o n e dU n i t
To Removethe Compressor
D r a i n t h e e n g i n e c o o l i n g s y s t e m a n d c o m p r e s s o ro f
coolant
Remove hydraulrc pump which may be fitted to rear
of compressor.
Removesteadyingbracket betweencompressorcylinder
h e a da n d e n g i n ec y l i n d e rh e a d .
Removeall connectionsto and f rom comoressor.
Unscrew compressor mounting bolts and remove
c o m p r e s s o frr o m e n g i n e
To ReplaceCompressor
The replacement of the compressor is a reversal to
removat.
When the compressoris fitted, check that the clearance
between the rubber insert and the forward half-
c o u p l i n g i s 0 . 0 2 0 / 0 . 0 2 5 i n( 0 , 5 1 / 0 , 6 3 m m ) .
S h o u l d t h e c l e a r a n c eb e i n c o r r e c t , t h e h a l f - c o u p l i n g
can be moved on the shaft to obtain the correct
clearance.
CLAYTON DEWANDRESC6 COMPRESSOR
Dismantling
Marking before dismantling
The compressor should have the following items
m a r k e dt o s h o w t h e c o r r e c t r e l a t i o n s h i pt o d i s m a n t l i n g
1 Position of cylinder head in relation to cylinder
and crankcase.
2 Position of end-cover(s) in relation to crankcase
3 Position of crankshaft in relation to crankcase
Removingand DismantlingCylinder
Head and Cylinder
Remove the unloader cap and copper washer and
w i t h d r a w t h e u n l o a d e r p l u n g e r a s s e m b l ya n d s p r i n g .
Removethe deliveryvalve cap and copper washer,
and remove delivery valve spring and seat retaining
spflng
U n s c r e wt h e f o u r n u t s a n d w a s h e r sf r o m c y l i n d e r h e a d
studs and lift off cylinder head Remove the joint.
Removethe deliveryvalve and screw out the valve seat
W i t h d r a wi n l e t v a l v e s p r i n g g u i d e . ( A s i m p l e e x t r a c t o r
can be made from two %in UNF bolts and a strip of
m e t a l f o r m e d t o b r i d g e t h e g u i d e) R e m o v e t h e i n l e t
v a l v es p r i n g ,i n l e tv a l v ea n d v a l v es e a t
W i t h d r a wc y l i n d e ra n d r e m o v et h e j o i n t
Removingand DismantlingPiston and
Connecting Rod Assemblies
R e m o v et h e c o m p r e s s o rm o u n t i n g b r a c k e t a n d j o i n t .
Turn the crankshaftto B D.C position and releasethe
tabs of the locking strap. Unscrew the two bolts and
remove the connecting rod cap Withdraw piston
assembly and replace connecting rod cap
Remove the piston rings from the piston. lf the
piston is to be detached from the connecting rod,
r e l e a s eo n e g u d g e o n p i n r e t a i n i n g c i r c l i p a n d p r e s s
t h e g u d g e o n p i n f r o m t h e p i s t o n a n d c o n n e c t i n gr o d
Removing Crankshaft
Removedrive key f rom crankshaft.
Unscrew the four setscrews or nuts together with
washers securing the rear end-cover to crankcase
W i t h d r a w t h e e n d - c o v e r ,p l a i n b e a r i n g ,t h r u s t w a s h e r
( w h e r ef i t t e d )a n d j o i n t
Unscrew the four setscrewsor nuts securing the drive
end-cover, and withdraw the end-cover complete
with crankshaft and joint. Tap crankshaft with bearing
from drive end-cover
Cleaning
E n s u r et h a t a l l c a r b o n i s r e m o v e d f r o m t h e c y l i n d e r
head. Check that the air passagesin the head and the
oilwaysin the crankcase,where applicable,rearend-cover
and crankshaftare clear and clean.
Clean inlet and discharge valves, not damaged or
worn excessively,by lapping them on a sheet of crocus
cloth held on a f lat surface.
 C O M P R E S S O R S3

Inspection of parts
Cylinder
Check cylinder bore for excessive wear, out_ot_round
o r s c o r i n g .l f s c o r e do r o u t - o f - r o u n dm o r e t h a n 0 . 0 0 2 i n

Wear in bore Remedy

+ 0 0 0 5 i n( 0 , 1 3 m m )
F r t n e w s t a n d a r dr i n E s
+0.005/0 0 1 0i n ( 0 , 1 3 / 0 , 2m
5m ) B o r eo u t t o + 0 0 i 0 i n ( 0 , 2 5 m m a) n d f i t O 0 1 0 i n ( 0 , 2 5m m )
o v e r s i z ep i s t o n r i n g s
+ 0 0 1 5 i n( 0 , 3 8 m m )
F i t n e w 0 0 1 0 i n ( 0 , 2 5 m m )o v e r s i z er i n g s .
+0.015/0 0 2 0 i n ( 0 , 3 8 / 0 , 5m
1m ) . . . . B o r e o u t t o + 0 2 0 i n ( 0 , 5 1m m ) a n d f i t 0 . 0 2 0 i n( 0 , 5 1m m )
o v e r s i z ep i s t o na n d r i n g s
+0025in(0,63mm)
F i t n e w 0 . 0 2 0 i n( 0 , 5 1m m ) o v e r s i z er i n g s

Pistonand ConnectingRod n e a t s l i d i n gf i t i n t h e g u i d e l f i t i s n e c e s s a r yt o r e p l a c e
I n s p e c tp i s t o nf o r s c o r e s ,c r a c k so r d a m a g eo f a n y k i n d . t h e u n l o a d e rp i s t o n g u i d e , t h i s w i l l b e f o u n d t o h a v e
C h e c k f i t o f r i n g s i n r i n g g r o o v e s , c l e a r a n c es h o u l d a n u n d e r s i z e db o r e , a n d w i l l r e q u i r er e a m i n gi n s i t u t o
b e 0 . 0 0 0 5 / 0 . 0 0 2 5 i n( 0 , 0 1 / 0 , 0 6 m m ) .I n s t a i l r i n g s I n 0 . 3 7 4 5 / 0 . 3 7 5i5n ( 9 , 5 1 / 9 , 5 4 m m )E. n s u r e t h a t t h e o o r e
c y l i n d e r a n d c h e c k t h a t g a p s a r e 0 . 0 0 3 / 0 . 0 0 7 i n( 0 , 0 8 / i s m a c h i n e ds q u a r e t o t h e u n d e r s i d eo f t h e c y l i n d e r
0,18mm). Check fit of gudgeon pin in piston and h e a d T h e m a x i m u mf i n i s h o f t h e g u i d e b o r e s h o u t d b e
c o n n e c t i n gr o d . G u d g e o np i n s h o u l d b e a l i g h t p r e s sf i t 2 5 m i c r o i n c h e s( 0 , 6 m i c r o n s )A. c h a m f e ri s a l s o r e q u i r e d
i n p i s t o n a n d c l e a r a n c ei n t h e c o n n e c t i n g r o d b u s h a t t h e t o p o f t h e g u i d e b o r e t o a n a n g l eo f 1 5 o a n d t o a
s h o u l dn o t e x c e e d0 . 0 0 1 5 i n( 0 , 0 4 m m ) . d e p t h o f 0 . 1 0 2 i n ( 2 , 5 9 m m ) .M a k e s u r e t h a t t h e
Inspect connecting rod bearing for correct fit g u i d e a n d c h a r n f e ra n g l e a r e f r e e f r o m b u r r s E x a m i n e
on
crankshaft journal. Clearance between rod u n l o a d e rp l u n g e r s e a l r i n g f o r w e a r I n s p e c t i n l e t a n d
Journal delivery valves and seats. lf valves are grooved oeeper
a n d b e a r i n g m u s t n o t b e l e s s t h a n 0 . 0 0 1i n ( 0 , 0 2 m m )
a n d n o t m o r e t h a n 0 . 0 0 3 i n( 0 , 0 B m m )C . heckconnectrno t h a n 0 . 0 0 3 i n( 0 , 0 8 m m )w h e r et h e y c o n t a c tt h e s e a t .t h e v
rod for cracks or damage. should be replaced lf not badly groovedthey can be
refaced by lapping on crocus cloth Valve seats, if
s h o w i n gs l i g h t s c r a t c h e s m , a y b e r e c l a i m e db y l a p p i n g
Crankshaftand Bearings with fine grinding paste.lf badty pitted or scratched.
E x a m i n eb a l l b e a r i n g sf o r d i s c o l o r a t i o np, i t t i n gw e a r a n d u s e a s e a t i n gr e a m e rb e f o r el a p p i n g .
cracked races. Rotate slowly to check for rougnness. Renew delivery valve spring and check remainino
D e f e c t i v eb e a r i n g ss h o u l d b e r e m o v e d ,u s i n g a w e l l _ s p r i n g sf o r c o r r o s i o n f, a t i g u eo r p e r m a n e n st e t .
f i t t i n ge x t r a c t i n gt o o l .P r e s sn e w b e a r i n go n t o c r a n k s h a f t ,
u s i n ga s u i t a b l el e n g t ho f t u b e , u n t i l i t c o n t a c t ss h o u l d e r .
Inspect crankshaft for wear and check threads, Re-assembly
shaft ends, keyways and drive keys for damage. L u b r i c a t ea l l i n t e r n a l p a r t s w i t h c l e a n e n g i n e o r r t o
The crank pin diametershould be within the timits prevent possible damage until the oil supply is
0 . 8 74/ 0 . 8 73 5i n ( 2 2 , 2 /02 2 , 19 m m \ . f u n c t i o ni n g .
I n s t a l l t h e c r a n k s h a f t ,c o m p l e t e w i t h b e a r i n g , r n t o
the drive end-cover.Insert the crankshaft into tne
Crankshaftand End-covers
c r a n k c a s ea n d s e c u r et h e d r i v e e n d - c o v e r e, n s u r i n gt h a t
I n s p e c t o i l s e a l c a r e f u l l y ,e n s u r i n g t h a t s e a l i n g e d g e the joint is correctly positionedover the oil drain
is intact and sharp. lf an oil leak has been obseiveo at ports.
t h e c r a n k s h a fet n d , a n e w s e a l m u s t b e f i t t e d L i p o f s e a l
s h o u l df a c e i n w a r d s . P o s i t i o nt h e t h r u s t w a s h e r i n t h e r e a r e n d _ c o v e rw i t h
the steel face towards the plain bearingand the tab
Examine crankcase, end-cover and mounting bracket locatedin the slot. Assemblethe rear end-coverwith joint
for damage and cracks. Check bearing bores for and secure.Check the crankshaftto ensure free rotation
wear The ball race should be a ligfrt press fit in a n d t h e n t i g h t e n e n d - c o v e rn u t s o r b o l t s . F i t t h e o r r v e
e n d - c o v e ra n d t h e c r a n k s h a f ts h o u l d b e a n e a t s l i d i n g key to the crankshaft.
fit in the plain bearing. Inspect crankshaft thrust
washer for wear (where f itted). R e fi t t h e p i s t o n r i n g s , e n s u r i n g t h a t s i d e s m a r k e d
"Top" are uppermost, and assemble the piston to the
c o n n e c t i n gr o d . A s s e m b l et h e c o n n e c t i n g r o d o n t h e
CylinderHead c r a n k s h a f t ,t i g h t e n t h e b o l t s t o a t o r q u e o f 4 l b f f t
( 0 , 5 5 k gm
f ) or 5,4Nm, and turn uF the tabs of the
I n s p e c tc y l i n d e rh e a d f o r c r a c k s a n d u n l o a d e rp r u n g e r locking strap. Space the piston ring gaps and assemble
g u i d e b u s h f o r w e a r . C h e c k t h a t u n l o a d e rp l u n g e r i s a the cylinderw , i t h j o i n t ,o v e r t h e p i s t o n .
COMPRESSOR S4
Assemble the cylinder head. Lighily smear the
o u t s i d e d i a m e t e r so f t h e i n l e t v a l v e s e a t a n d s p r r n g
g u i d e w i t h " L o c t i t e " ,o r e q u i v a l e n t s, e a l i n g c o m p o u n d .
I n s e r tt h e i n l e t v a l v e s e a t , i n l e t v a l v e a n d v a l v e s p r i n g
a n d p r e s st h e s p r i n g g u i d e i n t o p o s i t i o n S c r e w i n t h e
deliveryvalve seat, using a wrench inseried in the
hexagonal hole through the centre of the fitting,
a n d t i g h t e n s e c u r e l y P l a c e t h e d e l i v e r yv a l v e o n t h e
s e a t a n d p o s i t i o n t h e s p r i n g s .S c r e w i n t h e v a l v e c a p
togetherwith the copper washer Lightly smear the
unloader plunger with "Dow-Corning" grease, and
insert the spring and plunger complete with the
s p r i n g c i r c l i p S c r e w i n t h e u n l o a d e rc a p t o g e t h e rw i t h
c o p p e rw a s n e r
Placethe joint on the cylinderand correcily position
t h e c y l i n d e rh e a do n t h e s t u d s T i g h t e nn u t s p r o g r e s s i v e l y
t o a t o r q u e o f l 0 l b f f t ( 1 , 3 8 k g f m )o r 1 3 , 6 N m .
Invert the compressorand apply clean engine oil
o v e r t h e c r a n k s h a f ta n d o n t h e c y l i n d e rw a l l A s s e m b l e
t h e m o u n t i n gb r a c k e ta n d j o i n t
B E N D I XW E S T I N G H O U S E
TWIN 9
COMPRESSOR
To DismantleCompressor
R e m o v ef i l t e ra s s e m b l yf,i l t e r e l e m e n ta n d a d a p t o rp l a t e .
Remove top cover and cylinder head/valve plate
a s s e mo r y .
R e m o v ev a l v e p l a t e f r o m c y l i n d e r h e a d M a r k v a l v e s ,
s p r i n g sa n d v a l v ec a g e st o i d e n t i f yp o s i t i o n .
R e m o v em o u n t i n gb r a c k e ta n d g a s k e t
M a r k c o n n e c t i n gr o d s a n d c a p s t o i d e n t i f yp o s i t i o n
R e l e a s eb i g e n d s e c u r i n g b o l t s a n d r e m o v e p i s t o n /
connecting rod assembly (Note it is importanr ro
r e l e a s eb i g e n d b o l t s b e f o r e t h e b o l t s s e c u r i n g t h e
eno cover)
Remove gudgeon pins to release pistons from
c o n n e c t i n gr o d s .
R e m o v ep i s t o nr i n g s .
R e m o v ee n d c o v e r
R e m o v ep l a s t i cc o v e rf r o m n o n - d r i v ee n d o f c o m p r e s s o r
(if fitted)
Removecrankshaftwith thrust washer
B e m o v ea l l s e a l s ," O " r i n g s a n d g a s k e t s
Reconditioning
A l l g a s k e t s ,s e a l s a n d " O " r i n g s s h o u l d b e r e n e w e d
The cylinder head and associated parts, and the
pistons should be cleaned of any carbon present
The valve discs,springs and valve guides should be
renewed. The valve seats may be lapped with a fine
g r i n d i n gp a s t e ,b u t i f t h e r e i s a n y a p p r e c i a b l ew e a r , t h e
v a l v eD l a t es h o u l db e r e n e w e d .
T h e u n l o a d i n gp i s t o n sm u s t b e a n e a t s l i d i n g f i t i n t h e
g u i d e b u s h e s .l f w e a r i s a p p a r e n t ,r e n e w t h e p i s t o n so r
bushesas necessary
T h e m a x i m u mp e r m i s s i b l e w o r n d i a m e t e ro f t h e c y l i n d e r
b o r e si s 2 . 2 5 7 i n( 5 7 , 3 3 m m ) .
T h e c l e a r a n c eo f t h e c o m p r e s s i o nr i n g s i n t h e p i s t o n
grooves is 0.0005/0.002in(0,012/0,051mm) and that of
the scraperrings is 0.0005/00025in (0,012/0,063mm). The
g a p o f t h e c o m p r e s s i o na n d s c r a p e rr i n g s i n t h e c y l i n d e r
7 ( 0 , 0 8 / 0 ,B1m m )
i s 0 , 0 0 3 / 0 . 0 0i n
l f t h e p i s t o n r i n g s a r e b e i n g r e f i t t e da n d a r e b e d d e d
for more than the 300/of the width or if new rings are
being fitted,the glaze on the cylinderbores must be
br o k e n
T h e c l e a r a n c eo f t h e c r a n k s h a f ti n t h e m a i n b e a r i n g s
should not exceed 0 0035in (0,09mm), whilst the
c l e a r a n c eo f t h e c r a n k p i n s i n t h e b i g e n d b e a r i n g s
s h o u l dn o t e x c e e d 0 0 3 i n( O , 0 B m m ) .
The end float of the crankshaft is 0004i0012in
( 0 , 1 0 / 0 , 3m
0m )
The gudgeon pin should be a light press fit in the
p i s t o n a n d t h e c l e a r a n c eo f t h e p i n i n t h e s m a l l e n d
of the connecting rod should not exceed 00015in
( 0 , 0 3 8 m m ) .R e n e w g u d g e o n p i n c i r c l i p s i f n e c e s s a r y
To Re-assembleCompressor
Clean all parts, remove all jointing compound and
gaskets Ensure that all oilways and water passages
are clean and free from obstruction Lightly oil all
b e a r i n g s u r f a c e s , j o u r n a l s a n d t h r u s t w a s h e rf a c e s
F i t o i l s e a l st o c r a n k c a s ea n d e n d c o v e r .
F i t c r a n k s h a f tt o c r a n k c a s ee n s u r i n g t h a t o i l s e a l i s
n o t d a m a g e db y t h e e d g e s o f t h e s l o t i n t h e c r a n k s h a f t
Fit thrust washerto crankshaft
Coat joint face of end cover with sealing compound
a n d f i t e n d c o v e r t o c r a n k c a s es e c u r i n gw i t h s e t s c r e w s
a n d s p r i n gw a s h e r s
T i g h t e ns e t s c r e w tso 9 l b f f t ( 1 , 2 4 k g f m o
) r ' 12 , 2 N m
E n s u r et h a t e n d f l o a t o f c r a n k s h a f ti s c o r r e c t
Fit connectingrod to piston Fit gudgeon pin and
s e c u r ew i t h c i r c l i p
F i t p i s t o n r i n g s t o p i s t o n , e n s u r i n gt h a t t h e r i n g g a p s
a r e e q u a l l ys p a c e d a r o u n d t h e p i s t o n T h e t w o c o m -
p r e s s i o nr i n g s o n e a c h p i s t o n m u s t b e f i t t e d w i t h t h e
i n t e r n asl t e p s o r c h a r n f e r s t o w a r d s t p
h ies t o nc r o w n R i n g s
are usuallymarked with the word "top" or "bottom"
o n t h e a p p r o p r i a t ef a c e t o a i d c o r r e c tf i t t i n g
L u b r i c a t ep r s t o n r i n g s a n d c y l i n d e r b o r e s t h o r o u g h l y
w i t h c l e a n e n g i n e o i l b e f o r e f i t t i n g p i s t o n si n c y l i n d e r s
F i t p i s t o n / c o n n e c t i n gr o d a s s e m b l i e s i n c r a n k c a s e ,
e n s u r i n gt h a t t h e y a r e f i t t e d w i t h t h e t o o l i n g h o l e i n
t h e c o n n e c t i n gr o d f a c i n g i n w a r d s t o w a r d s t h e c e n t r e
lineof the compressor
F i t b i g e n d c a p s a n d s e c u r ew i t h b o l t s a n d t a b w a s h e r s
T i g h t e n b o l t s t o 9 l b f f t ( 1, 2 4 k g t m ) o r 1 2 , 2 N m a n d l o c k
tabwashers
Ensurecompressorhas f ree rotation
F i t " O " r i n g s t o u n l o a d e rp i s t o n s ,l u b r i c a t i n ga s s e m b l i e s
w i t h S i l i c o n eF l u i dM S 2 0 0 .F i t u n l o a d e ro i s t o na s s e m b l i e s
t o c r a n k s h a f tF i t s p r i n ga n d s a d d l e E n s u r et h a t u n l o a d e r
pistons have free movement
F i t i n l e t a n d e x h a u s t v a l v e s ,s p r i n g s a n d v a l v e g u i d e s
t o c y l i n d e rh e a d . F i t v a l v e p l a t e t o c y l i n d e r h e a d w i t h
gasket and secure with countersunkscrew Tighten
s c r e wt o 5 0 l b fi n ( 0 , 5 7k g f m ) o r 5 , 6N m .
Ensure valves have free movement after assembly
F i t c y l i n d e r h e a d / v a l v ep l a t e a s s e m b l yw i t h g a s k e t t o
c r a n k c a s eF i t c o v e rw i t h g a s k e tt o c y l i n d e rh e a d S e c u r e
with nuts and spring washers where studs are fitted
and with bolts and spring washers at tapped hole
 COMPRESSOR 55

p o s i t i o n sT
. i g h t e n n u t s a n d b o l t s t o 1 7 l b ff t ( 2 , 3 5 k gm
f ) s c r e w s t i g h t e n e d t o 5 0 l b f i n ( 0 , 5 B k g f m )o r 5 , 6 N m
or 23Nm progressively
F i t n e w f i l t e r e l e m e n tt o f i l t e r b o d y F i t r e t a i n i n gp r a r e
F i t m o u n t i n gb r a c k e tw i t h g a s k e tt o b a s e o f c o m p r e s s o r a n d r e t a i nw i t h b o l t sa n d s p r i n g w a s h e r s
w i t h b o l t s a n d s p r i n g w a s h e r s .T i g h t e n b o l t s t o 1 7 l b f t
F i t f i l t e r a s s e m b l yt o a d a p t o r p l a t e a n d s e c u r e w i t h
( 2 , 3 5 k 9mf ) or 23Nm progressivety
nuts and spring washers tightening to a torque of
W h e r e r e q u i r e d ,f i t p l a s t i c c o v e r t o n o n d r i v e e n d 9 l b f t( 0 , 1 2 4 k m 9 f) o r 1 2 , 2 N m
o f c o m p r e s s o ar n d c r a n k s h a f t
F i t k e y t o d r i v ee n d o f c r a n k s h a f t
C o a t j o i n t f a c e o f f i l t e r a d a p t o rw i t h s e a l i n gc o m p o u n d
F i n a l l y p r o t e c t a l l p o r t s t o p r e v e n t i n g r e s so f f o r e i g n
and fit plate to crankcase Secure with countersunk
malter

Data and Dimensionsfor Bendix WestinghouseTwin 9 Compressor

C y l i n d e rb o r e d i a m e t e r 2 2 5 0 / 22 5 1i n ( 5 7 , 1
5/57,1 8 mm)
M a x .p e r m i s s i b l eworn borediameter. 2 2 5 7i n ( 5 7 , 3 3m m )
C l e a r a n c eo f p i s t o ns k i r t i n b o r e 0 0 0 2 3 / 00 0 4 3i n ( 0 , 0 6 / 0 , 1m1 m)
C l e a r a n c eo f c o m p r e s s i o nr i n g s I n p i s t o ng r o o v e s 0 0 0 0 5 / 0O O 2i n ( O , 0 1 2 / 0 , 0 m5 1m )
C l e a r a n c eo f s c r a p e rr i n g s i n p i s t o ng r o o v e s . . 0 0 0 0 5 i 00 0 2 5i n ( 0 , 0 1 2 l 0 , 0 6m3m )
C o m p r e s s i o nr i n g g a p i n c y l i n d e r 0 0 0 3 / 00 0 7i n ( 0 , 0 8 / 0 , 1m8 m)
S c r a p e rr i n g g a p i n c y l i n d e r . . . . . 0 0 0 3 / 00 0 7i n ( 0 , 0 8 / 0 , 1m8 m)
C r a n k p i nd i a m e t e r 1 2495/1250 in (31,74/31,75mm)
B i g e n d r u n n i n gc l e a r a n c e 0 0 0 5 / 00 0 1 5i n ( 0 , 0 1 2 l 0 , 0 3m8m )
Max permissibleworn big end bearing running
clearance 0 0 0 3i n ( 0 , 0 7 6m m )
M a i nj o u r n a ld i a m e t e r. 1 2 4 8 2 / 12 4 9 1i n ( 3 1, 7 O / 3 1 ' , 7 3 m m )
M a i n b e a r i n gr u n n i n gc l e a r a n c e 0 0 0 0 9 / 00 0 2 8i n ( 0 , 0 2 1 0 , 0m7m )
M a x p e r m i s s i b l ew o r n m a i n b e a r i n g r u n n r n gc l e a r a n c e 0 0 0 3 5i n ( 0 , 0 9m m )
C r a n k s h a fet n d f I o a t 0 0 0 4 1 00 1 2i n ( 0 , 1 0 / 0 , 3m
0 m)
M a x p e r m i s s i b l e n d f l o a to n w o r n c o m p r e s s o r O 0 1 7i n ( 0 , 4 3m m )

RecommendedTorques
C y l i n d e rh e a d b o l t s / n u t s 1 7 l b f t ( 2 , 3 5k g f m ) o r 2 3N m
E n d c o v e rb o l t s 9 l b ff t ( 1 , 2 4 k g t mo\ r 1 2 , 2 N m
M o u n t i n gb r a c k e tb o l t s 1 7I b ff t ( 2 , 3 5k g f m ) o r 2 3 N m
S t r a i n e rm o u n t i n gn u t s 9 l b f f t( 1 , 2 4 k 9mf ) o r 1 2 , 2 N m
S t r a i n e ra d a p t o rs c r e w s 5 0l b fi n ( 0 , 5 8 k 9mf ) o r 5 , 6 N m
Big End Bolts 9 l b ff t ( 1, 2 4 k g I m )o r 1 2 , 2 N m

Drive Coupling (Holset)

With the compressorfitted to the engineand the coupling
assemblyin place on the auxiliarydrive shaft the distance
betweenthe two halvesof the coupling(see Fig.S 1 dim C)
mustbe adjustedto the valuegivenin the tablebelow When
fitting the coupling,ensure that the scribed lines on rne
outsideof the flangesaretn line

Couplingdiameter DimensionC Diff. between

Cl andC2
3.B75in ( 9 8 , 4 m m ) 0 . 1 4 6 / 02 5 0 i n 0.068in (1,71 mm)
(3,7116,m 3 5m )
3 . 0 0 i n( 7 6 , 2 m m ) 0 . 1 2 5 1 0 . 1 8 7 i n0 . 0 5 2 i n( 1 , 3 2 m m )
(3,18/4,75mm)

The parallelalignmentcan be checkedwith a straightedge

and feelergaugeto dimensionB as shownin Fig S.1
To checkthe angularalignmentfind the differencebetween
C1 and C2 as shownin Fig.S.1 lf this difference is the same
as or less than the dimensiongiven in the chartaboveany
angularmisalignment willbe 1' or lesswhichis satisfactory.
On later enginesthe couplingsetscrewsand separatetab
washers have been replaced by washer-facedsetscrews A. Straightedge C 1 . M a x .g a p
only These setscrews should be tiqhtened to lBlbfft B. M a x 0 . 0 0 6 i n( 0 , 1 5 m m ) C . 2 M i n .g a p
( 2 4 , 4 N m ) , 2 , 5 km
s f. C. Gap betweencouplinghalves

6 3544SeriesWorkshopManual,January1986

DESCRIPTION
The A.350 type exhausteris a rotary sliding vane
pump,
with an eccentricallymountedrotor.
reservoir,and the outlet port formed in the base
of the
exhausteralignswith an aperturein the enginecrankcase.
OPERATION
At all speeds the rotor blades are kept in contactwith
the
bore of the body by centrifugalforce, assisted
by the
hydraulicaction of the oil beneath the blades. When
the
rotor turns,the spaces betweenthe bladesvary, because
of the eccentric mounting of the rotor in the exhauster
body.As a blade passesthe inletport the space between
it
and the followingblade increasesand air is drawnfrom
the
vacuum reservoir. This air is then compressed
and
expelledwith the lubricatingoil through the outlet port
to
the enginecrankcase.
SERVICING
EXHAUSTER
Periodic lnspection and preventive Maintenance
Weekly or every 5,000miles
Examinethe vacuum lines and fittings.Vacuum leaKage
may occur through the line or reservoir mounted non_
return valve, if the valve seat is dirty or pitted. Should
Fig.T.1. Explodedview of an Exhauster.
6 3544 SeriqsWorkshopManual,lssue2, June'92
SECTIONT
Exhausters
leakage occur, the exhausterwill pressurisethe engrne
crankcase,resultingin oil leakageat the crankshaft
seals
and otherjoints. Examinethe exhausterfor evidence
of oil
leakage,particularlyat the end coverjointsand at the
shaft
oil level. Check the oil supply line for leaks at fit$ngsanct
connections.
Every 10,000miles
Check the mounting setscrewsand end cover retainino
screwsfor tightness.
Every 60,000miles
Bemoveand dismantlethe exhauster,thoroughlyclean all
parts and inspect them for wear and damage.
lf the
exhausteris well worn it will be advisableto return it to
Perkins Engines Ltd., in exchange lor a factorv
reconditionedunit.
To Remove the Exhauster
Disconnectthe oil vacuumpipes at the exhausterand plug
qpen unions to prevent the entry of foreign matter.
lhe
Release the driving coupling from the end oi the rotor
shaft. Unscrewthe setscrewswhich securethe exnauster
to the crankcase,and removethe unit from the enqine.
Dismantling
Mark the end covers in relation to the body to ensure
correctlocationon re-assembly.Unscrewthe four socKet-
headed screws and remove the rear end cover with the
rubbersealingring. Mark the bladesin relationto the rotor
and withdrawthe rotorcompletewith bladesfrom the bodv.
Unscrewthe four socket-headedscrews and remove the
driveend coverwith its rubbersealingring.
C L E A N I N GA N D I N S P E C T I O N
Cleaning
Wash all the componentsin cleaningsolventand clearthe
rotorand driveend coveroil ways with compressedair.
Inspection of Parts
Examinethe bushes for excessivewear. To renew them
see "Overhaul" section. Inspect the rotor and shaft for
cracksand damage,check the fit of the fibre bladesin the
rotor slots and replace any worn or damaged blades.
Examinethe seals carefullyto see that the selling edges
are pliable, intact and sharp. Seals rendered ineffective
(usually by dirty oil and grit) should be renewed as
prescribedin the sectionheaded,,Overhaul',.
Examinethe
body for cracks and damage and the bore for longitudinal
EXHAUSTERS_T.2

ripples or lines. lf these are only slight the body is still in the rotor slots, making sure that the marks made during
serviceable,if excessive the body should be renewed. dismantlingcorrespond.
Examine the end covers, and renew them if thev are
crackedor scored. Installthe rearend coverwithits rubber'O'ringon to the body
(ensuringthat the dowelslocatein their respectiveholes)and
tightenthe socket-headedscrews.
OVERHAUL
To renew End Cover Bearings and Seals Turn the rotorby handto makesure that it revolvesfreely.
Drive End Cover Installation
Extractthe seal from the drive end cover and press in the Replacethe joint and remountthe exhaustersecurelyto the
n e w o n e u n t i l t h e s t e e l s e a l h o l d e r a b u t s a g a i n s tt h e engine crankcase,with the couplinghalves fitted looselyon
shoulder in the cover. With the seal removed,press the the shafts.
worn plain bearing out of the cover using a bar or tube
Wherethere are scribedlineson the outsideof the coupling
1%oin diameter.Pressthe new bearinginto the cover until
flanges,thesemustbe in line.
it is 7ein belowthe coverf ace.
Ensure that there is approximately%in (3mm) between
Rear End Cover auxiliaryshaftoil sealand fronthalfcoupling.
Blank end covers are not fitted with seals. The bearing
should be extractedor machined out taking care not to WhereSimmscouplingsarefitted(Fig.T.2),ensurethatthere
damage the housing, or in an emergency it may be is a nominalclearanceol 3/a+in(1,2mm)betweenthe rubber
removed by cutting a groove along the bearing,using a couplingand each halfcoupling.WhereHolsetcouplingsare
narrowhalf round chisel.Inspectthe housing,removeany fitted,checkthe paralleland angularalignmentwitha straight
burrs and press the new bush fully into the cover. Where edgeandfeelergaugesas shownin Fig.T.3.
the rear end has been bored straightthroughand blanked When the alignmentis correcttightenthe couplingsetscrews
off, the circlip should be removedfollowed by the blanking and in the case of earlierHolsetcouplingslock the setscrews
disc and 'O' ring,which acts as a seal.The bush may then be with the tab washers. Later Holset couplingshave washer
pressedout of the cover,usinga baror tube,1%eindiameter. faced setscrews without tabwashers and these setscrews
When replacingthese componentsit is advisableto fit the mustbe tightenedto l Slbfft(24Nm)2,5kgfm.
circlipin its grooveand then refitthe blankingdiscfollowedby
Reconnectthe oil feed and vacuumpipes.
a new 'O' ring. The new bush should be pressed into the
cover until it slightly compressesthe 'O' ring against the
blankingdisc, the resultingreductionin internaldiameterof
the 'O' ring ensuringan effectiveseal on the shaft.The large
rubber 'O' rings which seal the gaps betweenthe exhauster
body and the end covers,shouldbe renewedif they appearto
be in any way compressedor damaged.
Re-assembly
Lubricate
all movingpartswithcleanengineoil.
Carefullyinsert the shaft into the drive end cover, avoiding
damageto the seal.
With the large rubber 'O' ring fitted in its groovein the cover,
assemblethe latterto the body, locatingthe dowels in their
resoectiveholes.
Hold the body,drive end downwards,and replacethe blades

Fig.T.3
A Straightedge C 1 .M a x .g a p
B. M a x .0 . 0 0 6 i n( 0 , 1 5 m m ) C . 2 M i n .g a p
C. G a p0 . 1 2 5 / 0 . 1 8 7 i n Max.difference C1-C2,
( 3 , 1 8 / 4 , 7m5m ) 0 . 0 5 2 i n( 1 , 3 2 m m )

Fig.T.2. RemovingExhauster.
1. Exhauster.
2. ExhausterCoupling(DrivenHalf).
3. ExhausterCoupling(DriveHalf).
4. R u b b e rC o u p l i n g .

6 3544SeriesWorkshopManual,January1986
 LUBRICATINGOILS
L u b r i c a t i n go i l s f o r n a t u r a l l ya s p i r a t e de n g i n e ss h o u l d m e e t t h e r e q u i r e m e n tos f t h e U . S .O r d n a n c e
Specification M I L - L - 4 6 1 5o2r M I L - L - 2 1 0 4 C L .u b r i c a t i n go i l s f o r t u r b o c h a r g e de n g i n e sa n d e n g i n e s
i n s t a l l e di n H e a v y D u t y E a r t h m o v i n gE q u i p m e n ts h o u l d m e e t t h e U . S . O r d n a n c e S p e c i f i c a t i o n
MtL-L-2104C.
S o m e o f t h e s eo i l s a r e l i s t e db e l o w a n d n e x t p a g e .A n y o t h e r o i l s w h i c h m e e tt h e s es p e c i f i c a t i o n s
a r e a l s os u i t a b l e .

M|L-L.46152
otLS

Company Brand S.A.E.Designation

0"F (-18'C) 30'F (-1'C) Over

IO IO 8 0 ' F ( 2 7 "C )
30'F (-1"C) 80'F (27'C)
B . P .L t d . V a n e l l u sM 10w 20w 30
V a n e l l u sM 20w/50 20w/50
CastrolLtd. C a s t r o l / D e u s oCl R X 10w 20 30
C a s t r o l / D e u s oCl R X 10w/30 10w/30 10w/30
C a s t r o l / D e u s oCl R X 20w/50 20w/50
D e u s o lR X S u p e r 20w/40 20w/40
D u c k h a m C o . Ltd. F l e e t o lH D X 10 20 30
Q M o t o rO i l 20w/50 20w/50
F l e e t o lM u l t iV 20w/50 20w/50
F l e e t o lM u l t i l i t e 10w/30 10w/30 10w/30
F a r m a d c oH l DX 20 30
E s s o P e t r o l e u mC o . L t d . E s s o l u b eX D - 3 10w 20w 30
E s s o l u b eX D - 3 15W/40 15W/40
M o b i lO i l C o . L t d . D e l v a c1 2 0 0S e r i e s 1210 1220 1230
D e l v a cS p e c i a l 10w/30 '10w/30
10w/30
Shell R o t e l l aT X 10w 20w/20 30
R o t e l l aT X 20w/40 20w/40
R i m u l aX 10w 20w/20 30
R i m u l aX 10w/30 10w/30 10w/30
R i m u l aX 15W/40 15W/40
R i m u l aX 20w/40 20w/40
T o t a lO i l C o . L t d . T o t a l S u p e rH D 20w/20 30
Total HD2-M 10w/30 20w/40 20w/50
Total HD3-C
( R u b i aS ) 10w 20w/20 30
Total HD3-C
( R u b i aT M ) 15W/40 15W/40
Total Universal
T r a c t o rO i l
(Multagri) 20w/30 20w/30
T o t a l S u p e rU n i v e r s a l
T r a c t o rO i l
( M u l t a g rTi M ) 20w/30 20w/30
 MIL-L-2104CO|LS

Company Brand S.A.E.Designation

0 ' F ( - 1 8 " C ) 3 0 " F( - 1 ' C ) Over

to to 80"F(27'C)
3 0 " F( - 1 ' C ) 8 0 ' F ( 2 7 ' C )
B . P .L t d . V a n e l l u sC 3 10w 20w/20 30
CastrolLtd. CastrolDeusolCRD 10w 20 30
D e u s o lR X S u p e r 20w/40 20w/40
A g r i c a s t r oH
l DD 10w ZU 30
A g r i c a s t r oM
l P 20w/30 20w/30
A g r i c a s t r oM
l P 20w/40 20w /40
A . D u c k h a m& C o . L t d . F l e e t o l3 J/ lu 3/20 3/30
F a r m a d c o3l 3/10 3/20 3/30
E s s o P e t r o l e u mC o . L t d . E s s o l u b eD - 3 H P 10w 20w 30
EssolubeXD-3 20w 20w 30
E s s o l u b eX D - 3 15W/40 15W/40
M o b i lO i l C o . L t d . D e l v a c1 3 0 0S e r i e s 1310 1320 1330
Shell R i m u l aC T 10w 20w/20 30
R i m u l aX 10w 20w/20 30
R i m u l aX 10w/30 10w/30 10w/30
R i m u l aX 15W/40 15W/40
R i m u l aX 20w/40 20w/40
R o t e l l aT X 10w 20w/20 30
R o t e l l aT X 20w/40 20w /40
Total Oil Co. Ltd. Total HD3-C
( R u b i aS ) 10w 20w/20 30
Total HD3-C
( R u b i aT M ) 1sw/40 15W/40
T o t a l S u p e rU n i v e r s a l
Tractor Oil
( M u l t a g rTi M ) 20w/30 20w/30

L u b r i c a t i n go i l s f o r u s e i n P e r k i n sD i e s e le n g i n e ss h o u l d h a v ea m i n i m u mv i s c o s i t yi n d e x o f 8 0 .

6 3544 SeriesWorkshooManual,lssue2, June '82

 APPROVED
S E R V I C ET O O L S
Available
fromV. L. churchill& co. Ltd.,Daventry,
Northamptonshire,England,
NN114NF.
Thenumbers shownin brackets afterthechurchilltoolnumberarethepartnumbers
Perkins
tools.Perkins of equivalent
toolsareavailable yourperkinsDistributor.
through
Tool No. Descriptlon

PD.1D V A L V EG U I D E R E M O V E RA N D R E P L A C E R( M A I N T O O L )
(21825026)

PD.1D-1A ADAPTORFOR PD.1D OR 21825026

(21825027)
@M4 A pairof pullerbarsfittedwith knurlednuts.Suitablelor
sAa"and3" guides.The necessary
distancepiecefromthe
adaptorsbelowshouldalso be used.

PD.1D.6 A D A P T O RF O RP D . 1D O R 2 18 2 5 0 2 6
(2182s030) A 1elgz"(15mm)distancepieceusedto replacevalveguroes
to a set height.

No.8 P I S T O NR I N G S Q U E E Z E R
(2182s018)

PD.41B P I S T O NH E I G H TA N D V A L V ED E P T HG A U G E
(21825019) A simple method of quickly checking piston height.

PD.140 CAMSHAFT BUSH/THRUSTCOLLAR REMOVER

PD.140-3 FUEL PUMP THRUST COLLAR REMOVER/REPLACER

ADAPTORS
 Tool No. Description

PD.145 CRANKSHAFTREAR OIL SEAL REPLACERADAPTOR

( L r PT Y P E S E A L )

s@
PD,15OA C Y L I N D E RL I N E RR E M O V E R / R E P L A C E(R
M A I NT O O L )
(21825052) For Field Servicereplacementof single liners.Not advised
for completeoverhaul.For this work use adaptorswith a
h y d r a u l i cr a m u n i t .

qs
P D . 15 0 -1B ADAPTORS FOR PD.150
(21825054\ Suitablefor cylindersof 3.6" dia. and 3.87,,dia. Removar
and replacement.

PD.150-74 A D A P T O R SF O R P D , 1 5 0
(21825057) S u i t a b l ef o r c y l i n d e r so f 3 9 7 " d i a . R e m o v a l
and reolacement.

1558 BASIC PULLER

(21825006) The cruciform head with multiple holes at differentcentres
is used with adaptors listed below.

PD.155-1 ADAPTORSFOR PD.155B

Used to removewater pump pulleys.Also suitableto remove
CamshattGears.

MF.200-26 WATER PUMP OVERHAULKIT

Used with 370 Taper Base and Press.
A
c2---)
ffi
 Tool No. Description

'JJC C O N R O D J I G & 3 3 6 M A S T E RA R B O R

336-102 ARBOR ADAPTOR

Used with 335

6 11 8 8 - 4 V A L V ES P R I N GC O M P R E S S O R
(21825020)

6 11 B B - 4 A D A P T O RF O R 6 1 1 8 8
(2182502s)

M567B T O O L F O R C H E C K I N GF U E L
INJECTION TIMING

PD163 T I M I N GC A S E C E N T R A L I S I NTGO O L
(21825042)

\
)
.//

MS73 A D J U S T A B L EV A L V E
( 2 18 2 5 0 6 4 ) SEATCUTTERS
 Consumableproducts
POWERPART
To give assistancein the correct operation,service and maintenanceof your
engine and
machine,PerkinsEnginesLtd. have made availablethe productsshown below.
The instructionsfor the use of each productare given on the outsideof each container.
These productsare availablefrom your perkinsdistributor.
POWERPARTAntifreeze
Gives corrosionprotectionand also a more efficientcoolantin hot conditions.See page C.5.
POWERPARTLay-Up 1
A dieselfuel additivefor protectionagainstcorrosion.see page c.4.
POWERPARTLay-Up 2
Gives insideprotectionto the engineand otherclosedsystems.see page c.4.
P O W E R P A R TL a y - U p3
Gives outsideprotectionto any metalparts.See page C.4.
POWERPARTDe-lcer
To remove frost.
P O W E R P A R TS i l e n t S p r a y
S i l i c o n el u b r i c a t i o tno l u b r i c a t ea n d p r e v e n tn o i s ef r o m h i n g e s ,s l i d ed o o r s ,e t c .
POWERPARTDamp Disptacer
To make damp electricalequipmentdry and to give futureprotection.
P O W E R P A R TH y l o m a r
U n i v e r s asl e a l i n gc o m p o u n dt o s e a l j o i n t s .
P O W E R P A R TH y l o s i l
S i l i c o n er u b b e rs e a l a n t o p r e v e n tl e a k a g e .
POWERPARTlmpact Adhesive
T o k e e pj o i n t si n p o s i t i o nd u r i n gi n s t a l l a t i oann d o t h e rg e n e r a a
l t t a c h m e npt u r p o s e s .
P O W E R P A R TS o l v e n t
To thoroughlyclean metalfaces beforeassemblV.
P O W E R P A R TL o c k i n g A g e n t
Used to securelyinstallfasteners,sleeves,erc.
EXAMPLES
OFSERVICE
FACILITIES
ServicePublications
The followingServiceLiteraturemay be purchasedthrough
your localPerkinsDistributor
WorkshopManuals,
OperatorsHandbooks,
Crankshaft
Regrinding,
FaultFindingGuide,
Installation
and MaintenanceGuidefor staticstandbyEngines,
EngineBrakeTestingData,
Etcetera.

ServiceInstruction
P E T ER B OR OU GH

Applyto ProductEducationDepartment
for details.
 INDEX
AlternatorAC5,17ACR,1BACR,25ACR Engine,Operating v,z
and A133/65
Precautions
Engine,Starting c2
n.z Oil Feedpipeto
Engine,StartingafterDisturbing
Maintenance R.2 Turbocharger
FaultFindingACS R.2 Engine,Stopping
Testing17ACR,18ACR,25ACRandA133/65
c.2
R.3 ExhaustSmoky,FaultFinding D.2
Data 812
Altitude,De-rating 8.2 FaultFindingChart D.2
, Atomisers, Filter
I Data 812 Air,DryType N.2
General N.6 Air,General N.2
Preventive
Maintenance c.3 Air,Oil BathType N.4
I PressureSetting 8.12 Fuel,Data 8.10
Fuel,To RenewElemenr N4
Belt,Fan,Adjustment M.2 LubricatingOil,Dataand Dimensions B.10
Belt,Fan,Preventive Maintenance c.3 LubricatingOil,Preventive
Maintenance U.J
Bearing,Main,Dataand Dimensions B6 LubricatingOil,To Flenew l 1

Bearing,Main,To Fit H.4 Foreword P.^a q

Block,Cylinder v,z Flywheel,Alignment P.2
Block,Cylinder,Dataand Dimensions Flywheel,To Remove P.2
Bush,AuxiliaryDriveShaftFront,Dataand Flywheel,To Refit P.2
Dimensions ttd Flywheel,Runout P.2
Bush,AuxiliaryDriveShaftRear,Dataand FuelOil Specification 8.10
Dimensions 8.9 FuelSystem,Bleeding N.7
Bush,Connecting Rod,SmallEnd,Dataand
Dimensions B5 Gauze,FuelLiftPump,Preventive Maintenance a e
Bush,Connecting Rod,to Renew F3 Gasket,CylinderHead E.2
Gear
Case,Timing,To Remove J.2 AuxiliaryDriveShaft,Dataand Dimensions 8.8
Case,Timing,To Refit J.2 AuxiliaryDriveShaft,To Remove J.2
Camshaft,Dataand Dimensions B6 AuxiliaryDriveShaft,To Refit J.2
Camshaft,To Remove J4 Camshaft,Dataand Dimensions B.B
Camshaft,To Replace J4 Camshaft,To Remove J2
ColdStartingAid,Failure c.2 Camshaft, To Refit J2
ColdStartingAid,Operation c.2 Crankshaft,Dataand Dimensions 8.8
Companies, Overseas Page2 FlywheelRing T Z
Compressor HydraulicallyLoadedWormwheel, Dataand
PreventiveMaintenance s.2 Dimensions 8.9
To Remove S2 ldler,Dataand Dimensions B.B
To Replace s.2 ldler,To Remove J3
Compressor SC6 ldler,To Refit J.4
Dismantling s.2 Timing,Backlash B8
Cleaning s.2 Timing,Backlash,Checking J.6
Inspection of Parts S3 Guide,Valve,Dataand Dimensions 8.7
Re-assembly J.J Guides,Valve
Compressor, Twin9
Dataand Dimensions S5 Head,Cylinder
To Dismantle s.4 Dataand Dimensions 8.7
To Re-assemble J.4 To Bemove E,2
To Recondition D.4 To Overhaul
I Cooler,ArrCharge,(remote)Preventive To Fit E2
Maintenance v.o Housing,Flywheel,AlignmentLimits T.J
I Cooler,Air Charge,(integralairlwater) M5 Housing,Flywheel,To Remove P.2
Cooler,Air Charge,Description N2 Housing,Flywheel,To Refit P.2
Cooler,Oil Hub,ldlerGear,Dataand Dimensions BB
To Remove 1.5 Hub,ldlerGear,To Remove J J
To Dismantle L 5 a n d1 . 6 Hub,ldlerGear,To Refit J.4
To Be-assemble L 5 a n d1 , 6
To Test 1,6 Inserts,ValveSeat E.5
To Refit L7
CoolerAdapter, Jets,PistonCooling
Oil Coolerto CylinderBlock L7 Description M4
CoolingSystem,Data B10 NozzlePositioning M.5
CoolingSystem,Description M.2 To Refit M.5
Crankshaft, To Remove tv.4
Dataand Dimensions ttb
Description H.2 I Laying-Up, EnginePreservation C4
To Regrind H3 Liner,Cylinder g z
To Remove H2 Dataand Dimensions 8.3
To Fit H4 To Renew G.2
LubricatingOil
I Data,Engine B 1 ApprovedGrades Appendix
Crrculation 1.3
EngineCoolant c.4 OperatingPressure 6 l

6 3544SeriesWorkshopManual,January1986
 INDEX(Continued)

HighPressure,FaultFinding D,2 Shaft,AuxiliaryDrive,To Refit t q

Level,PreventiveMaintenance c.3 Shaft,AuxiliaryDriveAssembly,Dataand
Low Pressure,FaultFinding D.2 Dimensions D.6
Renewal,PreventiveMaintenance U.J Shaft,Fuel InjectionPumpDrive,To Remove J.4
Shaft,FuelInjectionPumpDrive,To Refit J.C
Misfire,Engine,FaultFinding D,2 Shaft,Rocker,Dataand Dimensions 8.8
Shaft,Rocker,Dismantlingand Assembly =-I
Number,EngineLocation Page5 Spring,InnerValve,Dataand Dimensions 8.7
Spring,OuterValve,Dataand Dimensions 6.1
Overheating,
Engine,FaultFinding D.2 Springs,Valve E.6
StarterMotorM50
Protectionof an Enginenot in Service c.4 GeneralDescription R.4
Pin,Gudgeon,Dataand Dimensions 8.5 Maintenance R.4
Pistonand Rod Testingon Vehicle R.4
To Assemble F.3 StarterMotorCA45
Dataand Dimensions 8 . 3& 8 . 4 GeneralDescription R.5
To Dismantle F,2 Maintenance R.5
Inspection F.3 Testingon Vehicle n.c
To Remove F.2 Starting,Difficulty,FaultFinding D.2
To Fit F.5 Sump,
I Post DeliveryService c.3 Data 8.9
PowerLack,FaultFinding D,2 To Remove 1.3
Pressure, Crankcase, FaultFinding D.2 To Replace 1.3
Pulley,Crankshaft,To Fit Strainer,LubricatingOil 1.3
Pulley,Crankshaft,To Remove H.2
Pump,FuelInjection Tappets,Dataand Dimensions 8.8
ldlingSpeedSetting N.6 Tappets,To Remove J.4
MaximumSpeedSetting N.6 Tappets,To Replace J.4
Data 8.10 Thermostat
Description N.5 Data B.10
Timing K.2 Testing M.2
To CheckTiming K.3 To Removeand Refit M.2
To Remove N.6 Timing,FuelInjection,
Checking K.3
To Fit N.6 Timing,Fuellnjection K.3
Pump,Fuel Lift Timing,FuelInjectionStatic,Position B.11
I Data 8.10 Timing,Valve,Checking K.3
Dismantling N.5 Tools,ApprovedService Appendix
Re-assembly N.5 Torque,Recomrnended Tensions 8.1
To Removeand Fit N.5 TurbochargerT-048
Pump,Lubricating Oil , Cleanino u.5
Clearances B.9 oismaniiins
Data
II Q.5
I 8.9 FaultDiaqnosis Q.2
;I Inspection L.4 I Inspectioi LJ. O
To Dismantle L.J I Installation
CheckList Q,9
I To Re-assembleand Refit L.4 Re-assembly
; \J. O
I To Remove 1.3 j Reconditioning Q.2
Pump,Water ' Turbocharger 3LD
Dataand Dimensions 8,10 I Cleaning Q.4
To Dismantle M.3 I Dismantling \J.*t
To Re-assemble M.3 ; FaultDiagnosis Q.2
To Remove M.3 Inspection
I
To Refit M.4 ;' InstallationCheckList no
PushRod,Dataand Dimensrons 8.8 Re-assembly Q.4
Push Rod E.T I Reconditioning Q.2
; Turbocharger 3LM & S-76
Rating,Details 8.1 Cleaning Q.7
;
Restriction
Indicator N.2 \J.O
I Ring,Piston,Dataand Dimensions u.J- t .5 Q.2
Rings,Piston,To Fit F.4 Q.7
Rings,Piston,To CheckGaps F.3 Q.7
Rockers,Dataand Dimensions 8.8 Q.8
Rod,Connecting Q.2
Alignment F.3
Dataand Dimensions 8.5 Valves
Bearings,Dataand Dimensions 8.6 Assembly
Inspection F.3 Exhaust,Dataand Dimensions 8.7
To Remove F.2 Inlet,Dataand Dimensions 6.1
To Replace F.4 Inspection E.5
Seats,Valve
Seal,CrankshaftFrontEnd Oil,To Renew J.2 I Tip Clearances E.4
Seal,Crankshaft RearEndOil,To Fit H.6 To Fit E.4
Seal, RockerShaftOil FeedConnection,Fitting E.3 To Remove E,4
Service,EngineReturnPreparation c.4 Valve,Oil PressureRelief
ServiceInstruction Appendix Removaland Dismantling L.4
Shaft,AuxiliaryDrive,To Remove J.4 I Re-assemblyand Refitting L.4

6.3544SeriesWorkshopManual,January'1986
INDEX(Continued)

Dataand Dimensions B.9

Washers,AuxiliaryDriveThrust,Dataand
Dimensions B.9
Washer,CamshaftThrust,Data ll-t
Washer,CrankshaftThrust,Dataand Dimensions E.b
Washer.CrankshaftThrust.To Renew H.2
Water Level,PreventiveMaintenance u.\t
Weights,Engine B.1

6.3544SeriesWorkshooManual.Januaru1986