Bore (763844 and 6.9544 engines) Bore (6 3724 engines) Stroke No of eylinders Cubic capacity (T6.9544 and 6.3544 engines) Cubic capacity (6.9724 engines) Compression rato: 76.3548 engines North America vehicle 76.3544 6.2544 engines 6.3724 engines Firing order Combustion system cycle Vane clearance (hot or cold) Tnvet Exhaust Lupneating ot pressure Turbocharger boost pressures {moasures at induction manitold) 6.3544 enginas only *Nominal-—for actual bore size see Page 8 3. Details of ratings T8.2544CC Vehicle Maximum torque 78.3544 Vehicle Maximum torque 8.2544 North America vehicle Maximum torque 76.3544 Agricuitural and Industrial Maximum torque 6.544 Premium Vehicle Maximum torque 6.3544 Agricultural and Industral Maximum torque 6.3724 Agrioultural engines Maximum torque SECTION B Technical Data 3 875in (98,4:mm)" 3.976in (101 mm)" Sin (127 mm) 8 a64in? (6.8 1tres) 372in° (6, tres) as6:1 164 184 164 1,8,9,6,2,4 Direct injection 4 stroke (0.008 in (0,20 mm) 0.018 in (0,48 mm) 20 Iotin® (2.1kaom*!) oF 207kN/m! minimum at maximum working speed and normal operating temperature 11-13 Sibiin? (0,60-0,95kgH/om®) or 76-98kN/m These pressures will engine loads and spe« purposes only ry according to application, 18 They are tor guisance 119 kW (159 bhp) at 2,600 rev/min 502 Nm (970 lot ft) at 1,600 rev/min 415 KW (155 bhp) at 2,600 rev/min 498 Nm (367 [bt ft) at 1,700 rev/min 104 KW (140 bhp) at 2,600 rev/min 470.5 Nem (347 Tot tt) st 1,700 rev/min 107 kW (143 bhp) at 2,600 rev/min 469 Nm (248 Ibt ft) at 3,600 rev/min 95,5 KW (128 bhp) at 2,800 rev/min ‘380 Nm (280 Hof f) at 1,500 rev/min 91 KW (122 bhp) at 2.600 rev/min 384 Nm (289 Ibt ft) at 1,400 rev/min 90 KeW (121 bhp) at 2,600 rev/min 396 Nm (292 lof ft) at 1,450 rev/min The above ratings are maximum and can vary according to application. Engine weights Typical dry weight ‘Typical installed weight Recommended torque tensions (940-960 (425-435 kg} 1100- 11701b (500-5309) ‘The following figures will apply with the components lightly lubsloated with clean engine olf Cylinder head nuts and setscrews (with formed washer face) — cold Ovlinder head nuts and setscrews (with formed washer face) — hot Cylinder head nuts and setscrews (with separate washers) Oytinder head setscrews Connecting Rod Nuts (Cadmium Plated) Connecting Rod Nute (Phosphated) Main bearing setscrews Idler gear hub nuts Fue! litt pump setscrews ‘Sump securing setscraws 159548 Sexes Workshop Manu, Sorter 1082 ‘Seraw size UNF) Ibff kgf New ee) $5145 42 t 91128 he 2% 398 + 7 104 102 + 9 1t129 fee 00 27.t 4 To) i 38504 bm 28 ot a 1% Bt 0 (continued) —TECHNICAL DATA 82 ons (continued) ith the components lightly oiled Screw size UNF fetft —kgtm Nm eat 109 44/ 3880/30.72 s(Standare) % % 5049 s (standard) he 4 62st 5(OurioK) % 67 83k 5 (Owok”) T(QUNC) 1081441 apes 60 aCe es) mpiated) he 6580 rated he 9 BT 185 ted) % 2 28 ts he 37H & 888 Bo 4a ao s a 2 17 8 ows ie 3.0) 30) ris 1210 m0 Aaa 0 a 13 Cn) ssher face with radial sercatons, xeneral guide, to be applied on @ percentage basis, where specific figures for a particular tude Maximum fuel delivery de-rating (£00 metre) No change (1200 metre) 6% (1800 metre) 12% (2400 metre) 18% (2000 metro) 2A (3600 metre) 20% ‘on pump setting code Information only applies to naturally aspirated engines. For turbocharged engines apply Igines Lid Peterborough or ane of the Companies listed on Page 2TECHNICAL DATA B3 MANUFACTURING DATA AND DIMENSIONS All threads used, except pertaps on proprietary equipment are Unified Series and American Pipe Series ‘The following data of clearances and tolerances are given as a guide for personnel engaged upon major overhauls and therigures are those used in the factory for production purposes, Cylinder Block Height between Top and Bottom Faces Parent Bore Diameter for Cylinder Liner (Tes4av6 3548) Parent Bore Diameter for Cylinder Liner (6 3724) Feces Depth for Cylinder Liner Flange Recess Diameter for Cylinder Liner Flange (Te.ssaave 3544) Recess Diameter for Cylinder Liner Flange (63724) Main Bearing Parent Bore ‘Camshatt Bore Diameter, No. 1 Camshat Bore Diameter, No. 2 Camshaft Bore Diameter, No. 3 Camshatt Bore Diameter, No 4 17 967/17 875in (481,12/481,32 mm) 4.0625/4 0635in (103,19/108.21 mm) 4.1085/4.1035 in (104 20/104.23 mm) 0150/0 154in (8,81/3,81 mm) 4.20814.2101n (106,81/106,94 mm) 4.245/4 250in (107,82/107.95 mm) £3166 167 in (80,42/00,44 mm) £2.000/2 001 in (50 80/50,88 mm) 4.99071 992 in (50,55/50,50 mm) 1980/1 982 in (50.29/50,34 mm) 1 970/1.872n ($0,04/80,08mm) Cylinder Liners (Cast iron—Flanged)—T6.3544/6.9544 Type Outside Diameter of Production Liner Interference Fit of Production Liner Inside Diameter of Production Liner atter Finish Honing Transition Fit of Service Liner Inside Diamater of Service Liner attr iting Flange Thickness Height of Liner above Cylinder Block Top Face Position of Liner Flange Relative to Top Face of Cylinder Block Type Outside Diameter Interference Fit of Liner Inside Diameter of Liner after Finish Honing Flange Thickness Height of Liner above Cylinder Block Top Face Position of Liner Flange relative to Cylinder Biock Top Face Pistons (6.3544) Type Piston Height in Relation to Cylinder Block Top Face Bore Diamater for Gudgeon Pin ‘Compression Ring Groove Width, No. + Gompression Ring Groove Width, No 2 Scraper Ring Groove Width, No 3 Pistons (16.3544 North America vehicles) mn Height in Rlation to Cylinder Block Top Face Diameter for Gudgeon Pin Compression Ring Groove With, No. 1 Compression Ring Groove Width, No. 2 Seraper Ring Groove Width, No. 3 Pistons (6.3544)—3 Ring Type Picton Hoight in Relation to Cylinder Block Top Face Bore Diameter for Gudgeon Pin Compression Ring Groove With, No’ 1 Gompression Ring Groove Width, No 2 Scraper Ring Groove Width, No 3 Dry— Interference Fit— Production Dry— Teansition Fit— Service +4. 0845/4 0685 in (108,24/109,26 mm) (0.001/0.003in (0,02/0,08 mm) '3.877/3 878i (88 48/98,50 mm) ~0.001/+0 001 in {-0 026/40 026mm) 3.877/38795in (98,48/98,54 mm) (0150/0 1521n (9.1/9 86mm) (0026/0 037 in (0,68/0,4 mim) +0.002/-0 004 in {+0,05/-0,t0mm) Dry—Interlerence Fit— Production 4 1045/8 1058 in (104,251 104,28 nm) (9001/0 0031 (0,09/0,08 mm) 3.978513 9795in (101,05/101 08mm) 0 15010 152i (3,81/3;86mm) 0.0280.035in(0,71/0,89mm) +0 002/-0 004m (+0.05/-0.10 mm) Toroidal Cavity in Crown (0.00070 007 in (0,000.18 mm) above 15000/1 50d2 in (38,100/88,105 mm) Tapered (00955/0.0083 in (2,43/2.45 mm) (0 1885/0.1893 in (4,79/8,81 mm) Ro-entrant Combustion Chamber in Crown 10,0000 007 In (0,00/0,18 mm) above 1.5000/1.5002 in (38,100/38,105 mm) Tapered (00959/0.0967 in (2,44/2,46mmm) (0.190000. 1908in(4,88/4,85mm) “Toroidal Cavityin Crown (0.000'0:007in (0,00'0,18mm) above 1.3751/1 375Ain (36,928134 935mm) 0.088910 0978n (2,442,48mm) (0.035810 0970in (2,44/2.48mm) (0:1885,0.1883in(4,79/4.81 mm)TECHNICAL DATA B4 Pistons (6.9544) 5 Ring Type Piston Height relative to Cylinder Block Top Face Bore Diameter for Gudgeon Pin ‘Compression Ring Groove Wiath, No.1 Compression Ring Groove With, No. 2 Compression Ring Groove With, No. 3 Scraper Ring Groove Width, No. 4 Seraper Ring Groove Width, No. 5 Type Piston Height Relative to Cylinder Block Top Face Bore Diameter for Gudgeon Pin ‘Compression Ring Groove Width, No. 1 Compression Ring Groove Width, No. 2 Scraper Ring Groove Width, No. 3 Scraper Ring Groove Width, No 4 Piston Rings (6.3544) No, 1 Compression No 2 Compression No. 8 Scraper Compression Fing Width, No. 1 Compression Ring Width, No. 2 Scraper Ring Width, No. 9 No 1 Clearance in Groove No. 2 Clearance in Groove No. 8 Clearance in Groove Piston Ring Gap — No, 1 Piston Ring Gap — No 2 Piston Ring Gap — No. 3 Piston Rings (T6.3544 North America vehicles) No. 1 Compression No. 2 Compression No. 3 Seraper ‘Compression Ring Width, No. 1 Compression Ring Width, No. 2 Soraper Ring Width, No. 3 No. 1 Clearance in Groove No. 2 Clearances in Groove No 3 Clearance in Groove Piston Ring Gap — No. 1 Piston Ring Gap — No. 2 Piston Ring Gap — No. 3 No 1 Compression No. 2 Compression No. 9 Seraper Compression Ring Width, No 1 Compression Ring Width, No. 2 Seraper Ring Wicth, No No. 1 Clearance in Groove No. 2 Clearance in Groove No. 3 Clearance in Groove Piston Fing Gap — No. 1 Piston Ring Gap — No. 2 Piston Fing Gap — No. 3 Piston Rings (6.3544—5 ring pack) No.1 Compression Nos. 2 and 3 Compression No. 4 Scraper No. 5 Scraper Compression Fing Wiath, Nos. 1, 2and33 | Sccaper Ring Width, Nos. 4 and5 Nos. 1, and Clearance in Groove Nos, 4 and 5 Clearance In Groove | Piston Ring Gaps ~ Cast Iron | Piston Ring Gaps-~ Chromed (5544 Sene Worann Maru any 108 “Toroidal Cavity in Crown 0.00010.007n (0,000, 18mm) above 1.37486/1.87520in (94,921/34,880mm) (0.0957/0.0967 in (2,43/2,46 mm! (90957/0.0967 in (2,43/2,46 mm) 0.0957/0.0967 in (2,43/2.48 mm) (0.2525/0 2535 in (6,41/6,44 mm) (0 2525/0,2535 in (6,41/6,44"mm) Toroidal Cavity in Crown 0.007/0.014 in (0,18/0,36 mm) 41.87486/ 1.87508 in (94,921/34,928 mm) (0.0977/0.0987 in (2,48/2,51 mm) 0.0957/0.0866 in (2,43/2.48 mm) (0.1895/0.1905 in (4,8174,84 mm) (01895/0 1905 in (4,81/4.84 mm) (Crome or Molyodenum Faced Wedge ‘Tapered Face Chrome Faced 01 Contvol Conformable Wedge 0.098010 0986in (2,26:2,87rmm) 0.186010.1875in (4,724 76mm) Wedge 0.0020.0038In 0,080,101) 0.0010(0.0039in (0,0310,08mm) 0.01010.026in (0,2510,66mm) 0.01210.020in (0,2010,76mm) 0.01010.033in (0,2610,84mm) Chrome faced wedge Tapered face Chrome faced oll cont Wedge 0.0930/0.0935 in (2,96/2,97 mm) (0.1860/0-1875 in (4,72/4,76 mm) Wedge 0.0024/0.0037in (0,06110,004mm) 0.0025/0.0048 in (0,06/0,122 mm) 0.012/0.022 in (0,30/0,56 mma) (0012/0,022 in (0,30/0,56 mm) 0.010/0.033 in (0,25/0.84 mm) conformable Chrome Barrol Faced Internally Chamfored Chrome Taper Faced Chrome Faced Oil Conteol Conformable 0.0930/0.0985 in (2.96/2,37 mm) (00980/0 0955 in (2.36/2.37 mm) (01860/0.1878 in (4,72/4,76 mm) 0.0024/0.0048in (0,060,12rmm) 0.0024/0.0040in (0,060,10mm) (0.007010.0033in (0,08/0,08mm) 0.01010.024in (0,250,61mm) 0.016°0.034in (0,41/0,88mm) 0.01090.033in(0,25°0,84mm) Pian Internally Stepped ‘Chrome Faced Oil Contol Conformable Slots Ol Control 10,0328/0.0938in (2,36:2,38mm) (0.249/0.250in (6,3216,35™mm) (0.019/0.0038in (0,080,t0mm) (0.0025/0.0045in (0,060.1 1mm) (0.0120.030in (0,900,78mm) 0.01610.034in (0,410,86mm)Piston Rings (6.3724) No. 1 Gompression No 2 Compression No.8 Seraper No 4 Seraper Compression Ring Width, Nos. 1 and 2 Scraper Ring Width Nos. 3 and 4 ‘No. 1 Clearance in Groove ‘No.2 Clearance in Groove ‘Nos. 8 and 4 Goarance in Groove [Piston Ring Gaps, Nos 1, 2ana'3 [Piston Ring Gap, No.4 Gudgeon Pin (76.3544) Type Outside Diameter Length Clearance Fit in Piston Boss Gudgeon Type Outside Diameter Length Clearance Fit in Piston Boss Type. Outside Diameter Inside Diameter ater Reaming Clearance between Small End Bush and Gudgeon Pin ‘Small End Bush (6.3544 and 6.3724) Type Outside Dlameter Incide Diameter after Reaming Clearance between Small End Bush and Gudgeon Pin Type Cap Lacation to Connecting Rod Big Eng Parent Bore Diameter ‘Small End Parent Bore Diameter, 76.3548 63544 and 6.5724 Length from C/L of Big End to CiL of Small End Connecting Rod Alignment TECHNICAL DATA B85 Parallel Chrome inlay Chrome Plated Internally Stepped or Internally Chamfored Chrome Plated, Spring Expander ‘Siotted Oii Control (0. 0926/0.0986in (2,86/2,88 mm) (0 1865/0.1875in (4,74/4.76 mm) (9.0089/0.0059in (0,10/0, 4mm) (9.0019/0.0039in (0,05/0,10 mm) (0.002/0 004i (0,05/0,10 mm) 10.01610.034in (0,41/0,86mm) 0.01210.030i (0,30,76mmm) Fully Floating 41,4998/1.5000 in (38,095/38,100 mm) 8.250/3.2509 in (82,65/82,80 mm) 0.0000/0.0004 in (0,000/0,0010 mm) Fully Floating 1.3748/1 8750in (94,920/84.925 mm) 8.297/3.312in (89,74/84,12mm) (0.00012/0.00055in (0,003/0,014 mm) ‘Stee! Backed, Lead Bronze Lined 1.65975/1 66125. (42,16/42,20 me) 1 50075/1 5015 in (38, 12/38, 14 mm) (909075/0 0017 in (0,019/0,048 mm) ‘Stoo! Backed, Load Bronze Lined 1.836/1 5365 (88,99/39,03 mm) 1 3758/1.3785 in (34,94/34,96 mm) (0.0008/0.0017 in (0,020,043 mm) H Section “T6.3544—Wedge Shaped Small End 6.3544—Parallel Shape Small End Serrations 2 646/2 6465in (67,21/67,22mm) 1 65625/1 65725 in (42.07/42,08mm) + 5312/1 5323 n (98.90/30,92 mm) £62478 6261n (219,05/219,10rmm) Large and small end bores must be square and paralle! with each other within the limits of « 001Din (0,25mm) measured Sin (127 mm) each side of the axis of the rod on a test mand! £0.010in (0,25mm) is reduced to + 000261n (0,08mm, L £00101 0254mm Bt (54 Sersoaatap Mans Jaa 056 a8 shown in Fig B 1, With the small end bush ited, the limit of L:0010in £0254mmTECHNICAL DATA B86 Crankshaft Overall Length Main Journal Diameter Main Journal Length, No Main Journal Length, Nos. 2,3, 5,6 and 7 “Main Journal Length, No. 4 let Racii— Main Journals, Crankpin Diameter “Crankpin Length + Fillet Racii— Crankpins Surface Finish—all pins and journals Regrind Undersizes, Journals and Pins Flange Diameter ‘Spigot Bearing Recoss~-Depth ‘Spigot Bearing Recess Bore rankshatt End Float “Fillet rai and surface finish must be maintained during crankshaf 35.844 in (859,64 mm) — nominal 2.9984/2.9896 in (76,16/76,19 mm) 1.454/1.484 in (86,93/37,69 mm) 11548 /1.549 in (89.24/38,35 mm) 1.738/1.741 in (44,18/44,22 mm) 0.145/0-186 in (3.68/3,98 mm) 2.4988/2.4998 in (63.47/03,49 mm) 1.5885/1,5916 in (40,35/40,42 mm) 0145/0.156 in (3,68/3.98 mm) 16 micto-inches (0,4 microns) =0.010, 0020 and 0.080 in (—0,26, 0,81 and 0,76 mm) |5.24715 249in (133,27/133;32mm) (0579/0608 in (14,71/15,47 mm) 2.046/2.087 jn (51,97/51,99 mm) 0.002/0 018 In (0,08/0,38 mm) regrinding Length of No main journal must not exceed 1 788in (44,68mm) after regrinding. Where necessary, use oversize thrust washers to sult Length of crankpins not to ‘exceed 1.5905 in (40,55 mm) aftor regrinding, For orankshatt journal runout, see Page Hi IMPORTANT NOTE: See remarks on Page H.3 concerning the regrinding of 60 hour Nitrided erankshatts. Crankshaft Thrust Washers Type Position in Engine: ‘Thrust Washor Thickness— Standard ‘Thrust Washer Thickness— Oversize ‘Thrust Washer Outside Diameter ‘Thrust Washer Inside Diameter Main Bearings Type Shell Width, Nos. 1, 2.8, 5.6 and 7 Sno Width, No 4 Outside Diameter Inside Diameter ‘Main Bearing Running Clearance Shell Thickness Type Shell wit Outside Diameter Inside Diameter Bearing Running Clearance Shell Thickness. ‘Camshatt No, 1 Journal Length No. 1 Journal Diameter No 1 Journai Running Clearance No 2 Joumai Length No. 2 Journal Diameter No 2 Journal Running Clearance No 8 Journal Length No. 3 Journal Diameter No 8 Journal Running Clearance No, 4 Journal Length No. 4 Journal Diameter No. 4 Journal Running Diameter Cam Lit—Inet (ron-vohict) Gam Lit— Exhaust (non-vehicle) Cam Lit—Inlot (vehicle only) (Cam Lit Exhaust (vohicle only), Camshatt End Float Wiath of Spigot for Thrust Washer 8 958 See eaten Marl Jarry 806 ‘Stoo! Backed, Lead Bronze Faced ont Main Bearing (0.08910.091 in (2.26231 mm) 0.096510.0988in (2,45'2,80rm) 4,088/4.088 in (105,84/104, 09mm) 8.42/3 48in (86.87/67,12mm) Pre-fnished, Steel Backes, Aluminium Slicon Faced 1.24001 255in (31,50'31 88mm) 1495/1448 (36,45'36,70mm) 3.1663. 167in (60,42180, 44mm) 8.0010°8.0028in (76.298/76,266mmrn) 0.001810.0042n (0,046,107 mm) (0.0822/0.0825in (2,08812,096mm) Pre-inished, Stee! Backed, Aluminium Sticon or ‘Aluminium Tin Faced 1.24811.255in (31,62°31.88mm) 2.646;2.6485in (67,21167,22mm) 2.500812 5019in (63,52163,55mm) '.001210.0081in (0.030:0,08mm) (0.0723/0.0726in (1,896/1,884mm) 4.985in (27,56mm) 1.9968 1.9975in (50,71/50,?4mm) (01002510.0048in (0,660,11 mm) 1.438in (96,5mm) 1 .9865)1.9875in (50,46:50,49mm) (0,002510.0055in (0,080, 14mm) 1.438ia (36,53) 19766)1.9775in (50,20180,2amm) 0,0025:0.0055in (0,080,+4mm) 1.156in (29,37mm) 1 .9665)1.9675in (49,95149,08mm) 0.002510.0055in (0,06:0,14mm) (0295910.2980in (7,5167.582mm) (0.8025'0.3058in (7,6847,760m) 0.299910 3020in (7,617/7.698mm) (0.03610.2066in (7,711/7,788mm) 0.00410.016in (0,101,411) (0. 22210.292in(6,6485,89r%m)Camshaft Thrust Washer Outside Diameter Gylinder Block Recess Diameter for Thrust Washer Clearance Fit of Washer in Recess Internal Diameter Thickness ylincer Block Recess Depth for Thrust Washer Protrusion of Thrust Washer above Cylinder Block Front Face Cylinder Head Cylinder Head Depth Leak Test Pressure Vane Seat Angle Vane Guide Parent Sore Diameter Skimming Allowance Valve Guides Inside Diameter | Outside Diameter Interference Fit of Guide in Cylinder Head Overall length, Inlet, Overall length, Exnaust Protrusion above Valve Spring Recess | Counter bore, Exraust only Valve Stem Diameter | Clearance Fit of Valve in Guide Maximum Permissible Worn Service Clearance of Valve in Guide Valve Head Diameter Valve Face Angle Valve Head Depth below Cylinder Head Face— Production Limits Overall Length Sealing Arrangement Exhaust Valve | Vaive Stem Diameter | Ciearance Fito Valve in Guide Maximum Permissible Worn Service Glearanee of Vaive in Guide Valve Head Diameter Valve Face Angie Valve Head Depth below Cylinder Head Face— Production Limits | overati Langtn Sealing Arrangement Inner Valve Springs (short) [ Fitted tength and Load Number of Active Coils Number of Damper Colts Coiled Inner Valve Springs (long) | Fited length and Load Number of Active Cais Number of Damper Coils Coites Outer Valve Springs (short) | Fitted length and Load Number of Active Coils Number of Damper Coils Coiled TECHNICAL DATA 87 00° 2.872/2.874in (72:98/78,00mm) 2.875/2.885in (73.08/73,28 mm) (0001/0 o13in (0,08/0.38 mm) 1 750in (48,45 mm) 0216/0 2181in (5.49/5,54 mm) 0219/0.216in (5.41/5,49mm) (9000/0 005:n (0,00/0,131mm} 3738/3 785in (94,87/95,63 mm) Bo Kbt/in? (2.11 kgl/em®) =207 kNime a5" (06247/0.6257 in 15,87/15.88ram) 0012In (0.20mm) Providing that nozzle protrusion does not exceed 0 184 in (467 mm) for T3544 engines oF 0 136i (3,45mm) for 68544 and 63724 engines alter skimming 0.374310.3757in (9,51/9.54mm) 0.62610.6265in (15,90115,91 mm) (.0011/0.0026in (0,080.07mm) 2.281n(57,84mm) 2.406in (61,11 me) (.834in(15,09mm) (042110.441 in (10,69/11,20mm) da for length (0f0.406in (10.3mm) (0.372510:3736in (9,469,49mm) (0.0008:0.0032in (0,0220,08mm) 2.005:n (0,13mm) 1796/1 746 in (44,09/44,38 mm) 45° (.040/0 0501 (1,02/1,27 mm) 4831/4 847 in (122,71/123.11 mm) Fubber seal fitted to valve guide 0371/0372In (8.428,48mm) 0.00230.0047in (0,080,t2mm) 0 006in (0,15 mm) 1467/1 477 in (37.26/87,52emm) a (0.04010.050in (1,02/1,27emm) +4.845/4,865in (128,06/123,57rmm) Fubver seal ite to valve guide 4.9401n (94,04mmm) at 20.1/29-21¢(9,12/10,52kgf) 49 (€9.4/108,2N) 1 FLH.—Damper Coll to Oytinder Head 1.583in (89,70mm) at 14.63/16.671b (6,647 56k) 7 (65,174.20) 2 FLH.—Damper Coli to Cyindor Hoad 1.4101n (85,81 mm) 8139.5°43.71t (17,91/19,82k) a6 (175,71194,4N) 1 LH.—Damper Coilto Cylinder HeadTECHNICAL DATA B8 Outer Valve Springs (long) Fiited engin and Load Number of Active Coils Number of Damper Coils Coiled Tappets Overall Length Tappet Shank Diameter Cylinder Block Tappet Bore Diametor Funning Clearance of Tappet in Sore Outside Diameter of Tappat Foot Rocker Shaft Overall Length (Outside Diameter Internal Bore Diameter of Rocker Lever for Bush Outside Diameter of Bush Interference Fit of Bush in Rocker Lever Internal Diameter of Bush (after reaming in situ} Clearance of Bush to Rocker Shatt ‘Overall Length of Push Road ‘Shank Diameter Camshaft Gear Number of Teeth Bore Diameter Outside Diameter of Camshaft Hub Fit of Gear to nub Number of Teeth Bore Diameter Maximum Agjustment in Siotted Holes Number of Teeth Bore Diameter Crankshaft Diameter for Gear Fit of Gear to Crankshatt Number of Teeth Bore Diametor Outside Diameter of Bush Inside Diameter of Bush (finished in situ) Outside Diameter of Hub Clearance of Hub inside Bush End Float of Gears Timing Gear Backlash All Gears Auxiliary Drive Shaft Assembly Drive Shaft— Overall Length Number of Teeth on Worm Outside Diameter of Worm Diameter of Front Jouenal Diameter of Rear Journal. Drive Shaft Bush—Front Outside Diameter of Bush Housing Diameter tor Bush 41.780 in (45,20 mm) at 98/49 tot (17,25/79,50 kat) 58 2 LH. — Damger Coils to Cylinder Head 2.96875in (75,4 mmm) (0.747870 7488 n (18,91/19,01 mm) (0.780/0.75126in (19,05/19,08 mm) £0.0018/0.00875 in (0,04/0,09 mm) 1.4875 in (90,16mm) 26,08125in (661,19mm) (0.7485/0.7495 in (19,01/19.04 mm) 0.875/0.8762in (22,22/22,26rmm) 0,877/0.8788 in (22,28/22.31 mm) 0.0008/0.0085 in (0,02/0,09 mm) 0.7505/0.7520in (19,06/19,10mm) 0.001/0.0038 in (0,08/0,08 mm) 10,456/10.540in (265,58/267,72mm) 0.310/0.3121n (7,87/7,88mm) 56 1375/1 376in (84,9/34,95 mm) 1.3781/1.3757 in (84,88/84,84 mm) =0.0007/+0 a009in (-0,018/4+0,028 mm) 2a 4,000/1.001 in (25 4/25,43mm) 10° 28 1.875/1 676in (47,69/47,65 mm) 1875/1 87581n (47.69/47, 64mm) =0,0008/ +0 001 in (-0,020/0,025mm) sr 2 0625/2.0643 in (52,99/52,48mm) 2.06625/2 06828 in (52.48/52,58 mm) 1 8750/1 8768 in (47,69/47,67 mm) 41.87 14/1 873:n (47.59/47, 57mm) 0.002/0 0052 (0 05/0,13 mm) 0.092/0.012in (0,05/0.30mm) 0.003 in (0,08 mm) minimum 10.25:n (260,35 mm) " 4 885/1.870in (47,37/47.8mm) 1 9355/1.9365 in (49,16/49, 19mm) 1.248/1 24910 (31,7731,72mm) 2 1289/2 190i (54,06/54,11 mm) 2.%25/2.1262 in (58,98/54,01 mm) continuedInterference Fit in Housing Inside Diameter of Fitted Bush Running Clearance of Shaft in Bush Drive Shaft Bush—Rear Outside Diameter of Bush Housing Diameter for Bush Intorterenco Fit in Housing Inside Diameter of Fitted Bush Funning Clearance of Shaft in Bush Auxiliary Drive Thrust Washers Thickness Cylinder Block Recess Depth for Thrust Washer Outside Diameter Inside Diameter of Cylinder Block Recess Protrusion of Thrust Washer in Cylinder Block Groove Width on Dewe Shatt Groove to Thrust Washer Clearance Hydraulically Loaded Wormwheel Bore Diameter in Cylinder Block for Fuel Pump ‘Adaptor Plate and Upper Thrust Collar Fuel Pump Adaptor Plate Diameter Fit of Pato in Cylinder Block Outer Diameter of Upper Thrust Coll Clearance of Upper Thrust Collar in Cylinder Block Bore Diameter in Cylindor Block for Lower Thrust Washer Width of Groove in Upper Thrust Collar Upper Thrust Collar Sealing Ring Thickness Clearance of Sealing ing In Groove Inner Diameter of Bush in Fuel Pump Adaptor Piate Upper Diameter of Fuel Pump Drive Shaft Clearance of Drive Shatt in Adaptor Pate Bush Inner Diameter of Upper Thrust Collar Clearance of Drive Shatin Upper Thrust Collar Current Engines:— Lower Thrust Collar Bore for Bush Outer Diameter of Bush Interference Fit of Bush in Thrust Collar Inner Diameter of Bush (ater finishing in situ) Lower Diameter of Fuel Pump Drive Shatt Clearance of Shatin Bush Early Engines:— Inner Diameter of Lower Thrust Collar Lower Diameter of Fuel Pump Drive Shaft Gleerance of Drive Shatin Collar sump Sump Capacity (typical) Minimum to Maximum mark on Oipstick Strainer Position Oil Pump Type Oil Pump Clearance Inner Rotor to Outer Rotor (Outer Rotor to Pump Body Inner and Outer Rotor End Oiesrance TECHNICAL DATA B9 (00021/0 0088 n (0,05/0,18mm) 41.9375/1,9397 in (49,21/89,27 men) 10.001/0.0042 in (0,025/0,11 mm) 1.4086/1.4105 in (25,78/95,88mm) 1.4083/1.4076 in (35,72/35,75 mm) 0.001/0.0042 in (0,028/0,11 mm) 125/1.2819in (31,75/81,80_mm) 0.001/0.0099 in (0.026/0,10mm) (0.1875/0.1905 in (4.76/4,84 mm) 0.184/0.187 in (4.671/4,7mm) 2806/2 812in (71,27/71,42 mm) 2.8125/28205in (71,44/71,69mm) 0.0005/0.007 in (0,01/0,17 mmm) 0.189/0. 1968 n (4.9/4,99 mm) 0,0025/0.009 in (0,064/0,28 men) 3.5003 5014n (88,90/88,94 mr) £3.4986/3.4995 in (88,86/68,89 mm) 0.0005/0.002Bin (0,01/0,07 mm) 3.496/3.498in (85,80/88,85 mm) 0.002/0.0054 in (0,08/0,14 min) 2.2491/2 24991 (57.19/87,15mm) (0.0987/0.0967 in (2.48/2.46 mm) 0.0928/0.0988in (2,36/2,38 mm) 19.0019/0.00a8in (0,06/0,10 mm) 11.875)1,8768 n (47.63/47 67 mm) 41.8714/1 873 n (47.53/47 57 mm) (9002/0 0052 (0,08/0,13 mm) 1 886/1.09in (47,80/48.01 me) 0.013/0.0186 in (0,39/0.47 mm) 1 7812/1 782Biin (45,24/45,28mm) 1 7843/1.7BST in (45,82/45.36 mm) 0.0018/0,0045 in (0,04/0,11 mm) 1 6255/1 6256 in (41.29/41 32mm) 41 6214/1 6224n (41.18/41.22mm) (0.0081/0,0082 in (0,68/0,13 mm) 1.625/1 6268in (41,28/41.32 mm) 4.6214/1.62301n (41,18/41,22 mm) 0.002/0.0082 n (0,08/0,18mm) 26 Imperial Pints (14.8 Litres) 5 Imperial Pints (2,84Litres) Suction Pipe of Lubricating Oil Pump Rotor 0.004/0.005:n (0,08/0,13mm) (.006/0 073 n (0,18/0.33 mm) 0.0005/0,00251n (0,01/0,08 mm) For replacement purposes, the whole pump assembly must be replaced, Relief Valve First Stage Pressure Setting (T6 3544 only) Alief Flow Pressure Setting Length of Plunger ‘Outside Diameter of Plunger Inside Diameter of Valve Housing Bore ‘Clearance of Plunger in Bore Free Length of Spring Spring Fitted Length and Load 30/37 IbVint(2.11/2,8kg\/em) 207/255 kN/mé 50/60 Ib/in(9,52/4,22kgt/em®) 948/414 kN/m? (0.8375in (28,81 mm) (07188/0 717 in (18,18/18,21 mm) 0.718/0.7192in (18,24/18.27 mm) (0.001/0.0034in (0,03/0,08 mm) 2.3125in (58,74™mm) 2.1875in (55,58mm) at Sibf Bozt (1.5891)TECHNICAL DATA B10 Lubricating Oil Filt ‘Type of Filter Element Type By-Pass Valve Setting Type Coolant Capacity Thermostat Type Opening Temperature Fully opon at Valve Lit Water Pump Type Outside Diamoter of Shatt for Pulley Insige Diameter of Pulley Bore Clearance Fit of Pulley on Shatt (Outside Diameterof Shalt forimpelier Diameter of Impelier Bore Interference Fit of impoller on Shatt Impeler Blade to Pump Body Cie Approved Fuel Oil Specifications United Kingdom United Statos| France India Germany hay Swocen Switzerland BS, 2869:1963 W.F8000 ASTMDO7S-81T Full Flow Replacoable Canistor Paper B/I2Ibt/n* (0,58/0,84KgtVom*) 55/8KN/m* “Thormo-Syphon, Pump assisted. {38 Imperial Pints, (21,61tres) “Twin Wax Capsule fitted in paral {I77/183°F (80.6/83,9°C) 199-204" F (80 96°C) (0.374/0 500i (9,50/12,70 mm} Centrifugal 10.8742/0.8747 in (22,20/22,22mm) 0.8750/0.87881n (22,25/22,25mm) 0 0008/0 001m (0.01/0,04mn) 0.5012/0 5018in (12.73/12.78mm) (0 8000/0,5007 in (12.70/12, 72mm) (0.0005/0.0018in (0,013/0.048 mm) 0.01170 038 in (0,28/0,89 mm) {including ene thoat) Cass At or A2 Grados DF-A, DF-1 or DF-2 (Grades OF-A, DF-1 or OF-2 |AFNOR NFM, 151007 (1978), 1s:146071974 DIN-S1601 (1978) CUNAGas Oil NC-630-01 (1977) SIS, 155432 (1981) SN 181 160/1 Grade HSO Fuel oils avallabie in territories other than those listed above which are to an equivalent specitication may ve used ‘Type of Pump Method of Drive Dolivery Pressure Diaphragm Spring Colour Type Element Type Make Type Pump Rotation Timing Letter No. 1 Cylinder Outlet Make Type Pump Rotation No. 1 Cylinder Outlet AG Deleo X D Series Eccentric on Camshaft 6/0lbtre? (0,43/0,70kgViemt) or 41/69KN/m? Red Twin Paralll or single Paver cay DPA Anti-clockwise adh “x Bosch Rotary Aati-clockwise DTECHNICAL DATA B11 Fuel Injection Pump Static Checking Angles ‘The relevant iming information can be found by reterenceto the prefix ltrs or prfix ltrs and igure ofthe setting cade adjacent {othe word “Set” on the fue! pump identification plate and the table below. The engine checking angles for use with timing tool MS67B and the angine sot with No. T piston at TOC compression stroke. Prefix Engine Checking Fuel Pump Marking Static Timing Piston Letters ‘Angle (Degrees) ‘Angle (Degrees) BTOC (Degrees) Displacoment 6.548 CAN, pumps cy 153 us 6 0.124in @,18mm) by 160 148 32 (0.485in (12.32mm) wy 159 14a 30 (0.426in (10.82mm) x 159 144 30 (0.426in (10.82mm) low 153 145, 6 (0.128in(3,16mm) ny 159 18 20 (0.426in (10,82mm) 1% 159 144 30 (04263 (10,82mm) vA 159 144 30 (0.426n (10,82) xx. 159 148 20 (9426in (10,82mm) yx. 160 144 32 0.483 (12:27 me) a 159 144 30 0.426in (10,82mm) Bosch pumps EY (121-2) 135° 1256" 18 0.175in (4,45) FY (L213) 135° 1a 1 0.110in 2,79mm) Ky (L107) tes" ne 10 (0.049in(1.24mm) Vx (C21 or L73) 135° wr 16 0-12Ain (315mm) 6.3546 CAV. pumps: ay 160 46 2 0.373in (947mm) By 160 146 28 0.373in(9,47mmm) x 160 4, 28 0.373in(9.47 mm) FX 160 46 28 (0.373in (3,47) ey 162 156 16 0.125in (318mm) HY 162 196 16 0.128in(3,18mm) MR 158 waa 28 (0.373in (3.47 mm) | MX(exceptbeiow) 160 46 28 0.373in(3,47!mm) | Mx2640 161 146 20 (0.428in (10,82) | MXI5/2420 from | eng.no. 728207 189 146 26 0.825in (8,26mm) | Mx/52550 161 46 20 (0.426in (10,82mm) Px 160 146 28 (0.373in(9,47mm) | sx 161 146 30 (0.426n (10,82mm) wa 160 146, 28 (0.373in (9,47 mm) wx 187 144 26 (0325in (8,28) 6.2728 sx 61 46 30 0.4261 (10,82mm) | * The settings given forthe Bosch fuel pumps are with the pump set at 1mm plunger lit. tis important that these pumps are not fitted | the static ming positions given for the CAV purnps, The code given in brackets is stamped onthe side ofthe purnpTECHNICAL DATA B12 Atomisers Code Holder AL BKBL67S5209 FN BKBLG7S5299 6D BKBLG755209 (OKLL6752951 co ‘BKBL6755209 GH BKBL6755209 Gk KBELE2S9/13 GL BKBLG7S5151 | Gx KBEL6AS21 He LRBE7O14* OKLLesM2664 HE LRBE7014* HK BKBL6755209 LHP: LRBS7014" 1 or I OKLLesM26e4 14s BKBL6755209 : (OKLL6752951 Sar ‘LRBS7014" OKLLesM2864 RA KBELG4116, RB OKLL6aM3196 wu OKLL6752929 Y BKBL67S5151 Nozzle BDLL15086679 BOLL180$8639 ‘BDLL15088730 ouL15086730 BDLL15086797 BOLL15086738 DLLAIS0S741 'BDLL1508670 DLLAT408827 ‘sB6807014 ‘OLLtsoMs575 ‘JB6801019 BOLL35S604 sB6801014 ‘OLL150Ma575 BDLL15088730 ‘0uL 15086790 ‘486001019 DLLAtaoPaé ‘OLL130Ma027 ‘OL 15087574 BOLL15086329 Setting Pressure Working Pressur aim thin? (MNim?) atm 215 3160 (24,8) 200 210 3087s) 195 215 318018) 200 20 308718) 210 20 3087218) 210 275 4082279) 278 1752572 (17.7), —170 250 (3675 (258) 250 2459601 (28.8) 245 220 gas) 23) 80 215-3160 (218) 215 225 8307 (228) 5 215 31802.) 200 200 2840 (208) 200 250 9675258) 250 250 ©9675 (25,3) 280 250 ©9675 (25,3) 25 1752572 (17.7)—170 * Inthese atomisers the pressure is adjusted by a change of shims. Electrical System Alternator 1 Make Type | Yotage Max. output (hot Make Type Vottage Max ou at) | Starter motor " ake 1 Type " Vottage | starter cable resistance No. of teeth on pinion Starting Aid Make ‘Maximum Current Consumption Flow Rates through Thermostart, iin? (MN) 2040 (20,9) 2866 (198) 2040 (20,3) 9087 1.3) 3087 (21/3) 4082 27.9) 2500 (17.2) 3675 (253) 3600 (24.8) 3381 (23,3) 3160 18) 3807 (22,8) 2000 (20,3) 2010 (20,3) 3675 (25,3) 3675 (25.3) 3907 (22.8) 2500 (17.2) wv 5A, 12024 volt Lucas TTACR 17ACR18ACR— ATI. ATS3ISS._25A0R, (ce0rateo) WwW OW tay 2A «5A ABA SAA CAN. Perkine ACS&ACSR — ACSAACSR LRt35 1aV 20 12v 60a 0A, 35A Lucas CAN. M50 M2728 GAAS cass, wav 12v 12v av 0.00172 9.00172 00172-0034 10 70 10 10 CAV. Thomostant y25/r3.5Aat 11.5 35150 mimin A1a9165 rv 6A, Larso 12v 50a, Perkins si2s4 12V o.oor7 10SERVICE WEAR LIMITS TECHNICAL DATA B13 ‘The following “wear limits” indicate the condition when itis recommended that the respective items should be serviced or replaced. Cylinder Head Bow Transverse Longitudinal Maximum Bore Wear (when new liners are necessary) Crankshatt, Main and Big End Journal, Ovallty and Wear Maximum Crankshaft End Float Valve Stem to Guide Bore Clearance, Inlet Exhaust Valve Head Depth below Cylinder Head Face Rocker Clearance on Rocker Shaft Camshaft Journals, Ovality and Wear Camshatt End Float Idler Gear End Float 0.005 in (0,13) 0.010in (0.25mm) (0.008 in (0,20mm) 0.0015 in (0,04 mm) 0.020 in (0.098 in 10,006 in 0.060 in 0.005 in 0.002 in 0.021 in 0.015 in (0,51 mm) (0,13 mm) (0,15 mm) (1552 mm) (0,13 mm) (0105 mm) (0,53 mm) (038 mm)