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Notes Specified value Measured value

Vehicle identification
No. of cylinders Type 4/OHV
Capacity cc 2358
Compression ratio :1 21,5
Injection system
Fuel/injection pump assembly Make Bosch
Fuel/injection pump assembly Type VE 4/10
Fuel/injection pump assembly Part No. 0 460 404 005
Injection sequence 1-2-4-3
Injector nozzle Make Bosch
Nozzle and holder assembly Part No. 0 432 287 049
Nozzle opening pressure - new/used bar 153/145
Back leak (pressure loss) bar/secs 100-75/6-22
Leak rate (dribble) bar/secs 153/20
Tuning and emissions
Crankshaft position (n = ATDC) °BTDC 0
Adjusting method Engine/Pump Special Tool/ Pointer
Dynamic timing v = BTDC, n = ATDC v
- Time Trac Stanadyne, Snap-on °/rpm 10,5/800
Idle speed rpm 650±25
Rated no load speed rpm 4000±30
Oil temperature °C 80
Idle speed - for smoke test rpm 700-850
Governed speed range - for smoke test rpm 3850-4050
Maximum time at governed speed secs 2,0
Test mode A/B B
Probe type 1/2 1
Smoke opacity - EU limit m-1 (%) 2,50 (66)
Starting and charging
Battery V/RC(Ah) 12/110 (68)
Starter motor Make Bosch
Starter motor Type 0 001 358 202
Maximum cranking amps A 184-224
Alternator Make Lucas
Alternator Type 14TR
Alternator output A/V/rpm 35/14,6/4000
Regulated voltage V 14,2-14,6
Glow plugs
Glow plug nominal rating V/A 11/8,5
Glow plug activation time secs 20 Max
Glow plug - part no. Beru 604 MJ
Glow plug - part no. Bosch 0 250 200 066
Glow plug - part no. Champion CH63

Manufacturer: Ford Model: Transit ('78/'82) 2,4D © Autodata Limited 2007

Engine code: 4AA Output: 46 (62) 3600 25.09.2009
Tuned for: Bosch Year: 1978-83 V6.410-
 Glow plug - part no. Lucas/CAV HDS222
Service checks and adjustments
Valve clearance - INLET mm 0,35 cold
Valve clearance - EXHAUST mm 0,35 cold
Compression pressure bar 28
Radiator cap bar 0,9
Thermostat (primary/secondary) open °C 82-92
Drive belt size - alternator mm 9,5x1250
Drive belt tension - alternator/PAS/AC mm 10
Lubricants and capacities
Engine oil grade - moderate climate SAE 10W/30
Engine oil classification API/ACEA CD/B2-96
Engine with filter(s) litres 6,3
Manual gearbox oil grade SAE 80W
Manual gearbox 4/5 speed litres 1,5
Differential oil grade - rear SAE 90W
Differential rear litres 1,7
Cooling system litres 10,6
Tightening torques
Cylinder head instructions
Cylinder head
Renew bolts No
Stage 1 Tighten 70-75 Nm
Stage 2 Tighten 142-152 Nm
Other tightening torques
Main bearings Renew bolts/nuts No
40 Main bearings Stage 1
Big end bearings Renew bolts/nuts No
Big end bearings Stage 1 48-62 Nm
Big end bearings Stage 2 62-73 Nm
Flywheel/driveplate 60-65 Nm
Crankshaft pulley/damper centre bolt 318-346 Nm
Camshaft sprocket/gear 76-96 Nm
Injector/clamp 15-20 Nm
Injector pipe unions 17-20 Nm
Fuel/injection pump sprocket/gear 55 Nm
Fuel/injection pump flange 25 Nm
Injector nozzle to holder 15-20 Nm
Glow plugs 40 Nm
Brake disc and drum dimensions
Minimum disc thickness - solid Front 12,2 mm
45 Maximum drum diameter Rear 230,5 mm
Parking brake travel No. of notches 3-5

Autodata Note 40

Vertical bolts = 120-130 Nm

Horizontal bolts = 130-140 Nm

Autodata Note 45

Twin wheel axle = 256 mm

Manufacturer: Ford Model: Transit ('78/'82) 2,4D © Autodata Limited 2007

Engine code: 4AA Output: 46 (62) 3600 25.09.2009
Tuned for: Bosch Year: 1978-83 V6.410-
Cylinder layout

Idle speed adjustment (A)

Tightening sequence

Manufacturer: Ford Model: Transit ('78/'82) 2,4D © Autodata Limited 2007

Engine code: 4AA Output: 46 (62) 3600 25.09.2009
Tuned for: Bosch Year: 1978-83 V6.410-
 Telephone:
Fax:
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Dimensions
Notes Specified value Measured value
Wheelbase mm 2690\nLWB=3000
Track - front/rear mm 1638/1588
Tightening torques
Notes Specified value Measured value
Tightening torque - steel wheels 75-95 Nm\n6 Stud=170 Nm
Checking range - Front wheels
Notes Specified value Measured value
Load positioning Unladen
Fuel tank - percentage full % 100
Toe-in (N = negative, toe-out) mm 0 - 1,60
Toe-in deg 0° - 16'
Toe-in deg-1/100 0 - 0,27
Camber deg 0° - 1°
Camber deg-1/100 0 - 1
Castor deg 3°15' - 5°45'
Castor deg-1/100 3,25 - 5,75
Setting data - Four wheels
Notes Specified value Measured value
Load positioning Unladen
Fuel tank - percentage full % 100
Toe-in (N = negative, toe-out) mm 0,80±0,80
Toe-in deg 0°8'±8'
Toe-in deg-1/100 0,13±0,13
Camber deg 0°30'±30'
Camber deg-1/100 0,50±0,50
Camber adjustment Not adjustable
Castor deg 4°30'±1°15'
Castor deg-1/100 4,50±1,25
Castor adjustment Not adjustable
KPI (SAI) deg 5°±10'
KPI (SAI) deg-1/100 5±0,17
Included angle deg 5°30'
Included angle deg-1/100 5,50
Lock angles - max. inner deg 42°40'
Lock angles - max. inner deg-1/100 42,67
Lock angles - max. outer deg 33°
Lock angles - max. outer deg-1/100 33

Manufacturer: Ford Model: Transit ('78/'82) 2,4D © Autodata Limited 2007

Engine code: 4AA Output: 46 (62) 3600 25.09.2009
Tuned for: Bosch Year: 1978-83 V6.410-
 Telephone:
Fax:
VAT Registration No.:

Manual gearbox Manual gearbox

Rear axle

Manufacturer: Ford Model: Transit ('78/'82) 2,4D © Autodata Limited 2007

Engine code: 4AA Output: 46 (62) 3600 25.09.2009
Tuned for: Bosch Year: 1978-83 V6.410-