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Service Service
Manual Manual
Perkins Perkins
700 700
Series All Binders
Series
Engine 4.75 in Engine
I~
9-54880 9-54880
L _ _ _ _ _ _ _ _ .J _ _ _ _ _ L _ _ _ _ .J
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.......
1 - -_ _ Large Binder _ _---1.~ ..... Small Binder - - .
2.85 in 1.63 in
SERVICE MANUAL
PERKINS NEW 700 SERIES
ENGINES
Copyright  2003 CNH France S.A.

Printed in France
CNH Cre 9-54880 May 2003
Cre 9-54880 Issued 05-03
Template Name: SM_2_col Alt= to hide template information
Template Date: 1994_04_05 Alt+ to display template information
Contents
General information ..................................................................................... 10

Specifications .............................................................................................. 11
Service operations
Cylinder head assembly .............................................................................. 12
Piston and connecting rod assembly............................................................ 13
Crankshaft assembly ................................................................................... 14
Timing case and drive assembly .................................................................. 15
Cylinder block assembly .............................................................................. 16
Engine timing............................................................................................... 17
Aspiration system ........................................................................................ 18
Lubrication system....................................................................................... 19
Fuel system ................................................................................................. 20
Cooling system ............................................................................................ 21
Flywheel and flywheel housing .................................................................... 22
List of special tools ...................................................................................... 25
Cre 9-54880 Issued 05-03

GENERAL INFORMATION 10-01
General information 10
Introduction ................................................................................................................. 10.02

Engine views............................................................................................................... 10.03
Engine identification .................................................................................................... 10.04
Safety
General safety precautions ......................................................................................... 10.05
Engine lift equipment................................................................................................... 10.06
Viton seals .................................................................................................................. 10.07
Cre 9-54880 Issued 05-03

10-02 GENERAL INFORMATION
Introduction
This workshop manual has been designed to provide

assistance in the service and overhaul of Perkins 700
Series engines.
Warning! Read and remember the "Safety

precautions". They are given for your protection
and must be used at all times.
The engines that are referred to in this manual are the

UA (3,0 litre - direct injection), and the UB (2,6 litre -
indirect injection). Both engines conform to Stage 1
off-highway emissions to Cl -8 mode cycle ref. ISO
8178 part. 4.
Where the information applies only to one engine

type, this will be indicated in the text.
When reference is made to the "left" or "right" side of

the engine, this is as seen from the flywheel end of the
engine.
Special tools have been made available and a list of

these tools is given in section 25. Reference to the
relevant special tools is also made at the beginning of
each operation.
Loctite recommended consumable products are listed

in section 10. Reference to the relevant consumable
products is made at the beginning of operation.
Data and dimensions are included at the end of each

section.
Danger is indicated in the text by two methods:
Warning! This indicates that there is a possible

danger to the person.
Caution: This indicates that there is a possible

danger to the engine.
Note: Is used where the information is

important, but there is not a danger.
Cre 9-54890 Issued 05-03

Cre 9-54880 Issued 05-03

Engine identification
The 3,0 litre version, is a water cooled, naturally

aspirated, four cylinder diesel engine with direct
injection. It has been specifically designed for
industrial and agricultural applications and is
identified with the letters UA.
The 2,6 litre version, is a water cooled, naturally

aspirated, four cylinder diesel engine with indirect
injection. It has been specifically designed for forklift
truck applications and is identified with the letters UB.
The engine number is stamped on a label (A) which is

fastened to the right, rear side of the cylinder block.
An example of an engine number is:
UA80862Ul23456A
The components of the engine number are as follows:
UA80862Ul23456A
UA Type code letters
80862 Build list number
U Built in the UK
123456 Engine serial number
A Year of manufacture
If you need parts, service or information for your

engine, you must give the complete engine number to
your Case distributor.
Cre 9-54890 Issued 05-03

Safety • Make sure that the engine is operated only from

the control panel or from the operator's position.
General safety precautions • If your skin comes into contact with highpressure
fuel, obtain medical assistance immediately.
These safety precautions are important. You • Diesel fuel and lubricating oil (especially used
must refer also to the local regulations in the lubricating oil) can damage the skin of certain
country of use. Some items only refer to specific persons. Protect your hands with gloves or a
applications. special solution to protect the skin.
• Only use these engines in the type of application • Do not wear clothing which is contaminated by
for which they have been designed. lubricating oil. Do not put material which is
• Do not change the specification of the engine. contaminated with oil into the pockets.
• Do not smoke when you put fuel in the tank. • Discard used lubricating oil in accordance with
local regulations to prevent contamination.
• Clean away fuel which has been spilt. Material
which has been contaminated by fuel must be • Make sure that the control lever of the
moved to a safe place. transmission drive is in the "out-of-drive" position
before the engine is started.
• Do not put fuel in the tank while the engine runs
(unless it is absolutely necessary). • The combustible material of some components of
the engine (for example certain seals) can
• Do not clean, add lubricating oil, or adjust the become extremely dangerous if it is burned.
engine while it runs (unless you have had the Never allow this burnt material to come into
correct training; even then extreme caution must contact with the skin or with the eyes.
be used to prevent injury).
• Always use a safety cage to protect the operator
• Do not make adjustments that you do not when a component is to be pressure tested in a
understand. container of water. Install safety wires to secure
• Make sure that the engine does not run in a the plugs which seal the hose connections of a
location where it can cause a concentration of component which is to be pressure tested.
toxic emissions. • Do not allow compressed air to contact your skin.
• Other persons must be kept at a safe distance If compressed air enters your skin, obtain medical
while the engine, auxiliary equipment is in help immediately.
operation. • Do not clean an engine while it runs. If cold
• Do not permit loose clothing or long hair near cleaning fluids are applied to a hot engine, certain
moving parts. components on the engine may be damaged.
• Keep away from moving parts during engine • Install only genuine Case parts.
operation. Warning! Some moving parts cannot
be seen clearly white the engine runs.
• Do not operate the engine if a safety guard has
been removed.
• Do not remove the filler cap or any component of
the cooling system while the engine is hot and
while the coolant is under pressure, because
dangerous hot coolant can be discharged.
• Do not allow sparks or fire near the batteries
(especially when the batteries are on charge)
because the gases from the electrolyte are highly
flammable. The battery fluid is dangerous to the
skin and especially to the eyes.
• Disconnect the battery terminals before a repair is
made to the electrical system.
• Only one person must control the engine.
Cre 9-54880 Issued 05-03

Safety
Engine lift equipment
Caution: If the sump contains engine lubricating oil

and the engine is tilted to an extreme angle or
turned onto its side or end faces, lubricating oil can
enter the closed breather system, pass into the
induction manifold and the cylinder bores. If this
occurs, it will cause an hydraulic lock in the engine
and the engine may be damaged. If it is necessary
to move an engine in this way, the lubricating oil
must first be drained.
The maximum weight of the engine without coolant,

lubricant or a gearbox installed will vary for different
applications. It is recommended that lift equipment of
300 kg (662 lbs) minimum capacity is used.
Before the engine is lifted:

• Always use engine lift equipment of the approved
type and of the correct capacity to lift the engine.
It is recommended that lift equipment of the type
shown in (A) is used to provide a vertical lift,
directly above the engine lift brackets (A1). Never
use a single lift bracket to raise an engine.
• Check the engine lift brackets for damage and PA044
that they are secure before the engine is lifted.
The torque for the setscrews for the engine lift
brackets is 22 N m (16 lbf ft) 2,2 kgf m.
• To prevent damage to the rocker cover, make
sure that there is clearance between the hooks
and the rocker cover.
• Use lift equipment or obtain assistance to lift
heavy engine components such as the cylinder
block, the cylinder head, the flywheel housing, the
crankshaft and the flywheel.
Cre 9-54890 Issued 05-03

Viton seals
Some seals used in engines and in components

installed to engines are made of Viton.
Viton is used by many manufacturers and is a safe

material under normal conditions of operation.
If Viton is burned, a product of this burnt material is

an acid which is extremely dangerous. Never allow
this burnt material to come into contact with the skin
or with the eyes.
If it is necessary to come into contact with

components which have been burnt, make sure that
the precautions which follow are used:
• Make sure that the components have cooled.

• Use Neoprene gloves and discard the gloves
safely after use.
• Wash the area with calcium hydroxide solution
and then with clean water.
• Disposal of components and gloves which are
contaminated must be in accordance with local
regulations.
If there is contamination of the skin or eyes, wash

the affected area with a continuous supply of clean
water or with calcium hydroxide solution for 15-60
minutes. Obtain immediate medical attention.
Cre 9-54880 Issued 05-03

Cre 9-54890 Issued 05-03

Specifications 11
Basic engine data ......................................................................................11A
Recommended torque tensions ..................................................................11B
Compression test data ...............................................................................11C
Cre 9-54880 Issued 05-03

BASIC ENGINE DATA 11A-01
Basic engine data 11A
Basic engine data...................................................................................................... 11A.02
Cre 9-54880 Issued 05-03

11A-02 BASIC ENGINE DATA
Basic engine data
Cycle..........................................................................................................................................................Four stroke
Number of cylinders................................................................................................................................................... 4
Cylinder arrangement ........................................................................................................................................ In line
Firing order .......................................................................................................................................................1,3,4,2
Direction of rotation .............................................................................................................. Clockwise from the front
Induction system............................................................................................................................ Naturally aspirated
Cubic capacity:
UA engines............................................................................................................................. 2,956 litres (183 in3)
UB engines............................................................................................................................. 2,602 litres (159 in3)
Compression ratio:
UA engines.................................................................................................................................................... 17.5:1
UB engines.................................................................................................................................................... 22.0:1
Combustion system:
UA engines...................................................................................................................................... Direct injection
UB engines....................................................................................................................................Indirect injection
Nominal bore:
UA engines..................................................................................................................................97,0 mm (3.82 in)
UB engines..................................................................................................................................91,0 mm (3.58 in)
Stroke........................................................................................................................................100,0 mm (3.94 in)
Valve tip clearances (cold):

- Inlet and exhaust .........................................................................................................................0,35 mm (0.014 in)
Lubricating oil pressure (at normal engine temperature):

- Minimum pressure at maximum engine speed.....................................................280 kPa (41 lbf/ in2) 2,86 kgf/cm2
Typical dry installed engine weight (1) ................................................................................................ 200 kg (440 lb)
(1) Engine weight may alter with final specification
Cre 9-54880 Issued 05-03

RECOMMENDED TORQUES 11B-01
Recommended torques tensions 11B
General information
Thread sealant .......................................................................................................... 11B.02
Recommended torques tensions

Standard torque tensions .......................................................................................... 11B.03
Special torque tensions ............................................................................................. 11B.03
Cylinder head assembly ............................................................................................ 11B.03

Pistons and connecting rod assembly ....................................................................... 11B.03
Crankshaft assembly................................................................................................. 11B.04
Timing case and drive assembly ............................................................................... 11B.04
Aspiration system...................................................................................................... 11B.04
Fuel system .............................................................................................................. 11B.04
Lubrication system .................................................................................................... 11B.04
Cooling system ......................................................................................................... 11B.05
Flywheel and housing ............................................................................................... 11B.05
Auxiliary equipment ................................................................................................... 11B.05
Cre 9-54880 Issued 05-03

11B-02 RECOMMENDED TORQUES
General information
Thread sealant
When setscrews or studs are installed into holes which are tapped into the inside of the engine, a suitable sealant
should be used.
M.E.A.S. (Micro encapsulated anaerobic sealant) fasteners are installed into the holes that are open to the inside of
the engine. A thin layer of sealant is applied to the threads of the fasteners when they are manufactured. The colour
of the sealant can be red, yellow or blue.
With M.E.A.S. sealed studs, the sealed end must be installed into the cylinder head / cylinder block etc. Make sure
that the threaded holes have a 1,59 mm (0.0625 in) 45° chamfer, such that when the new fasteners are installed the
M.E.A.S. sealant is not removed. If the fasteners have to be removed and installed again, the threads must be
cleaned and a suitable sealant applied.
Cre 9-54880 Issued 05-03

Recommended torque tensions
Most of the fasteners referred to in this manual have standard torque tensions which are shown in the table below.
Those fasteners that need special torque tensions are listed in separate tables together with some standard torque
tensions most frequently used.
Procedures referred to in this manual will have the torque tensions (standard or special) shown in the text and also
listed in the tables for special torque tensions.
The torque tensions that are shown in this manual apply to fasteners with dry threads.
Standard torques tension for setscrews, studs and nuts
Torque tension - setscrews and nuts Torque tension - studs (metal end)
Thread size
Nm lbf ft kgf m Nm lbf ft kgf m
M6 x 1,00 9 7 0,9 5 4 0,5

M8 x 1,25 22 16 2,2 11 8 1,1
M10 x 1,50 44 33 4,5 18 13 1,8
M12 x 1,75 78 58 8,0 25 18 2,5
M14 x 2,00 124 91 12,6 - - -
M16 x 2,00 190 140 19,3 - - -
Special torque tensions for setscrews and nuts
Thread Torque tension

Description size Nm lbf ft kgf m
Cylinder head assembly See page 12A.10

Setscrews, cylinder head to cylinder block M6 9 7 0,9
Setscrews, rocker shaft bracket M8 22 16 2,2
Nuts, rocker shaft bracket M8 11 8 1,1
Cap nuts, rocker cover M8 22 16 2,2
Setscrews, inlet manifold to cylinder head M8 18 13 1,8
Setscrews, engine lift brackets M8 22 18 2,2
Piston and connecting rod assembly

Nuts, connecting rod big end caps M9 54 40 5,5
Cre 9-54880 Issued 05-03


Crankshaft assembly
Setscrews, main bearing caps M14 147 108 15,0
Setscrews, crankshaft pulley to crankshaft M16 185 136 19,0
Timing case and drive assembly

Setscrews, timing case to cylinder block M8 22 16 2,2
Setscrews, timing case to cylinder block M10 44 33 4,5
Setscrews, retainer plate - camshaft for fuel injection
pump M6 9 7 0,9
Setscrews, thrust washer - camshaft for the engine M6 9 7 0,9
Setscrews, timing case to blanking plate M8 22 16 2,2
Nuts, timing case to blanking plate M8 22 16 4,5
Setscrews, timing case to blanking plate M10 44 32 4,5
Aspiration system
Setscrews, breather cover M6 9 7 0,9
Fuel system
Nuts, high-pressure fuel pipes M12 22 16 2,2
Setscrews, atomiser clamps M8 12 9 1,2
Injector - 704.26 (UB) engines M20 39 29 4,0
Nuts, low-pressure fuel pipes M12 20 15 2,0
Setscrews, fuel lift pump to cylinder block M8 22 16 2,2
Setscrews, cassette pump to cylinder block M8 22 16 2,2
Nuts, cassette pump to cylinder block M8 22 16 2,2
Screw, fuel leak-off M6 12 9 2,2
Nuts, maximum fuel adjustment screw M8 14 10 1,4
Angleich unit M16 18 13 1,8
Governor assembly to camshaft gear M5 7 5 0,7
Lubrication system
Plug, lubricating oil sump 3/4 UNF 34 25 3,5
Cap screws, oil pump to timing case M6 9 7 0,9
Setscrews, lubricating oil sump M8 22 16 2,2
Relief valve assembly to timing case M18 20 15 2,0
Cre 9-54880 Issued 05-03


Cooling system
Nuts / screws, coolant pump to cylinder block M8 22 16 2,2
Setscrews, fan and pulley to coolant pump hub M8 22 16 2,2
Setscrews, fan and pulley to coolant pump hub M6 9 7 0,9
Flywheel and housing

Setscrews, flywheel to crankshaft M12 100 77 10,7
Electrical equipment
Nuts, alternator pulley M17 60 44 6,1
Bolt / nut, alternator to timing case M10 24 18 2,4
Setscrew, adjusting lever to alternator M8 12 9 1,2
Glow plugs M10 17 13 1,7
Glow plug connections M4 1,5 1 0,2
Cre 9-54880 Issued 05-03

Cre 9-54880 Issued 05-03

COMPRESSION TEST DATA 11C-01
Compression test data 11C
Compression test data ..............................................................................................11C.02

How to do a compression test ...................................................................................11C.02
Cre 9-54880 Issued 05-03

11C-02 COMPRESSION TEST DATA
Compression test data
Tests have shown that many factors affect

compression pressures. Battery and starter motor
condition, ambient conditions and the type of gauge
used can give a wide variation of results for a given
engine. It is not possible to give accurate data for
compression pressure, but tests have shown that the
results should be within 2000/3500 kPa (300/500 lbf/
in2) 21,0/35,0 kgf/CM2 for diesel engines.
Compression tests should only be used to compare

between the cylinders of an engine. If one or more
cylinders vary by more than 350 kPa (50 lbf/in2) 3,5
kgf/cM2, then those cylinders may be faulty.
Compression tests should not be the only method

used to show the condition of an engine, but they
should be used together with other symptoms and
tests.
How to do a compression test

Caution: Before the compression test, make sure
that the battery is in good condition and that it is
fully charged. Also make sure that the starter motor
is in good condition.
1 Make sure that the valve tip clearances are set

correctly.
2 Remove the atomisers.
3 Install a suitable gauge into the hole in the

cylinder for the atomiser.
4 Make sure that the engine cannot start:

• Disconnect the stop solenoid or put the stop
control in the no-fuel position.
• Operate the starter motor and note the pressure
indicated on the gauge.
5 Repeat for each cylinder.
Cre 9-54880 Issued 05-03

CYLINDER HEAD ASSEMBLY 12A-01
Cylinder head assembly 12
General description ................................................................................................12A.02

Rocker cover
12A-01 To remove and to install...............................................................................12A.03
Rocker assembly
12A-03 To disassemble and to assemble .................................................................12A.05
12A-04 To inspect ....................................................................................................12A.05
Valve tip clearances
12A-05 To check and to adjust .................................................................................12A.06
Valve springs
12A-06 To change the valve springs (with cylinder head installed) ...........................12A.07
Cylinder head assembly
Valves and valve springs
12A-09 To inspect and to correct .............................................................................12A.15
Valve guides
12A-10 To inspect ....................................................................................................12A.16
Cylinder head
12A-12 To inspect and to correct .............................................................................12A.19
12A-13 To correct a valve seat with a valve seat cutter ...........................................12A.20
12A-14 To install valve seat inserts .......................................................................... 12A.11
Data and dimensions ..............................................................................................12A.22
Cre 9-54880 Issued 05-03

12A-02 CYLINDER HEAD ASSEMBLY
General description
Notes:
• The front of the engine is when seen from the end
with the timing case assembly.
• Number one cylinder is at the front of the engine.
In a diesel engine, there is little carbon deposit and for

this reason, the number of hours run is no indication
of when to overhaul a cylinder head assembly. The
factors which indicate when an overhaul is necessary
are how easily the engine starts and its general
performance.
The cylinder head assemblies for both the UA and UB

engines contain two valves for each cylinder. From
the front of the engine, the sequence for valves is first
inlet and then exhaust.
The cylinder head for the UB engine contains a

precombustion chamber (A1) that is made from a
hardened manganese alloy. It will not be possible to,
renew this chamber or to machine the bottom face of
the cylinder head.
Included in the cylinder head assembly for UA and UB

engines, there is a valve guide and a valve seat insert
for each valve. The inserts and guides can be
renewed if necessary. The new valve guides are
pre-finished.
The face angle for all of the valves is 45° and the
angle for all of the valve seats is 45°.
The Inlet and the exhaust valves are each installed to

the cylinder head with a single valve spring and an oil
seal that is installed over the top of the valve guide.
The valve and valve spring are held in position with a
hardened steel cap and two collets.
The glow plugs and the atomisers are both installed

into the top of the cylinder head. The tip of the glow
plug and the atomiser protrude through the bottorn
face of the cylinder head (A2) on UA engines, and into
the pre-combustion chamber (A3) on UB engines.
Caution: The amount of protrusion for both

atomiser and glow plug is important for the
performance of the engine, therefore only Case
parts should be used in service.
Cre 9-54880 Issued 05-03

Rocker cover
To remove and to install 12A-01
The engine is installed with an aluminium rocker

cover which includes a closed breather assembly and
a connection for the breather pipe. A composite
rubber seal is installed into a machined groove (B2) in
the flange face of the cover.
To remove
1 Disconnect the breather pipe (B1).
2 Remove the cap nuts (A1), the steel washers

(A2) and the rubber seals (A3).
3 Lift off the rocker cover (B).
To install
1 Check the condition of the rubber seals (A3) and

the steel washers (A2) for the cap nuts (A1). If
necessary, the seals for the cap nuts can be
renewed.
2 If necessary, check, clean and renew the

components of the breather system, operation
18A-02.
3 Check the condition of the rocker cover seal

(B2) and renew the seal if necessary.
4 Clean the seal face of the cylinder head and

install the rocker cover. When the cover is put
on the cylinder head, make sure that the seal
remains in the groove.
Caution: If the cap nut (A1) is overtightened, the

stud and plate assembly (B3), for the rocker
pedestal may be damaged.
5 Install the rocker cover. Make sure that the cap

nuts, washers and the rubber seals are installed
correctly. Tighten the cap nuts to 11 Nm (8 lbf ft)
1,1 kgf m.). Install the breather pipe.
Cre 9-54880 Issued 05-03

Rocker assembly
To remove
1 Remove the rocker cover, operation 12A-01.
2 Release the eight setscrews (A1) for the

brackets of the rocker shaft. Release gradually
and evenly the nuts (A3) and then the nuts (A4)
for the brackets of the rocker shaft.
Note: The rocker assembly contains three

plates (A2) which include the studs for the
rocker cover. The plates must be installed to
the correct rocker brackets (A).
3 Remove the nuts and lift off the rocker assembly

(B).
Note: A hardened steel pin (B1) is installed in

the lower part of the front bracket. The purpose
of this pin, is to make sure that the bracket is in
the correct position on the rocker shaft. The
hole in the bracket will align with the oil hole
(B2) in the cylinder head and make sure correct
lubrication of the rocker assembly. Protect
these holes to make sure that dirt cannot enter.
To install 5 Tighten gradually and evenly, the eight

setscrews (A1) to, 9 Nm (7 M ft) 0,9 kgf m.
Cautions: Tighten the inner setscrews first and then the
outer setscrews.
• Before the rocker assembly is installed, make
sure that the oit holes (B1) and (B2) are free of 6 Adjust the valve tip clearances, 12A-05.
dirt.
• Check that the push rods (B3) install correctly in 7 Install the rocker cover, operation 12A-01.
thesockets of the tappets.
1 Put the rocker assembly (B) onto the cylinder

head.
2 Install the plates (A2) to the correct brackets for

the rocker shaft.
3 Install the fasteners (A1), (A3) and (A4) finger

tight.
Caution: As the fasteners are gradually tightened,

make sure that the ends of the adjustment screws
(B4) install correctly in the sockets (B3) of the push
rods.
4 Tighten gradually and evenly, the nuts (A4) and

then the nuts (A3) to 22 Nm (1 6 lbt ft) 2,2 kgf m.
Cre 9-54880 Issued 05-03

Rocker assembly
To disassemble and to assemble 12A-03
To assemble
1 Remove the clips (A5) from both ends of the

rocker shaft. Make sure that the ends of the
rocker shaft are not damaged.
2 Remove the spacer (A4), the rocker levers (A2),

the brackets (A3) and the springs (A1).
Note: The bracket (A6), is installed to the

rocker shaft with a hardened steel pin (B1)
which aligns the oil holes. If either the rocker
shaft or the bracket have to be renewed, a new
pin must also be used.
To assemble
1 Make sure that the oil holes in the rocker shaft

and in the rocker levers are not restricted.
2 Before assembly, lubricate the components with

clean engine lubricating oil. Assemble the
components in the correct sequence; the rocker
levers should be installed in the original sequence.
Install the spacers and clips to the ends of the
rocker shaft.
To inspect 12A-04
1 Clean and inspect all the components for wear

and any other damage. Check the clearance
between the rocker levers and the rocker shaft. If
the clearance is more than 0, 124 mm (0.0048 in),
either renew the rocker lever or the rocker shaft, or
both if necessary.
Cre 9-54880 Issued 05-03

Valve tip clearances
To check and to adjust 12A-05
Notes:
• The valve tip clearance is checked with a feeler
gauge between the top of the valve stem and the
rocker lever (A), with the engine cold. The correct
clearance for both the inlet and the exhaust
valves is 0,35 mm (0.014 in).
• The arrangement of the valves is shown in (B).
Valve numbers (B1) and (B2) are for number one
cylinder which is at the front of the engine. A PU012
• Clockwise rotation is when seen from the front of

the engine.
1 Rotate the crankshaft in a clockwise direction

until the valve (B7) has just opened and the
valve (B8) has not closed completely. Check the
clearances of the valves (B1) and (B2) and
adjust them, if necessary.



Cre 9-54880 Issued 05-03

Valve springs
To change the valve springs
(with cylinder head installed) 12A-06
Special Tools:
Valve spring compressor, PD.6118B
Stud adaptor , PD.244
Warning! Wear eye protection when the valve
spring is compressed.
Note: Paragraphs 1 to 12 refer to a change of

valve springs for a single cylinder.
11 Check the valve tip clearances, operation
12A05.
2 Turn the crankshaft in the normal direction of
12 Install the rocker cover, operation 12A-01.
rotation until the inlet valve of the relevant
cylinder has just opened and the exhaust valve
Note: If other or all of the valve springs are to
has not fully closed. In this position the piston
be changed, they can be changed one cylinder
will be at approximately top dead centre (TDC).
at a time in the sequence of cylinders 1 and 4, 2
and 3.
3 Remove the rocker assembly, operation
12A-02.
4 Install the valve spring compressor (A1) and the

adaptor (A2).
5 Compress the valve spring and remove the

collets. Make sure that the valve spring is
compressed squarely or damage to the valve
stem can occur.
Caution: Do not rotate the crankshaft while the

valve springs are removed.
6 Release the valve spring compressor and

remove the valve spring caps and the valve
spring.
7 Put the new valve spring in position.
8 Install the valve spring cap.
Caution: Make sure that the valve spring is

compressed squarely or damage can occur to the
valve stem.
9 Install the valve spring compressor, compress

the valve spring and install the collets. Remove
the valve spring compressor.
10 Install the rocker assembly, operation 12A-02.
Cre 9-54880 Issued 05-03

If the rocker assembly has been rernoved, piston
TDC can be found as follows:
1 Install the valve spring compressor and

compress the valve spring to open the valve.
2 Turn the crankshaft, by hand, in the normal

direction of rotation until the piston touches the
valve.
3 Continue to turn the crankshaft, and at the same

time, release pressure on the valve spring
compressor until the piston is at TDC (A).
Cre 9-54880 Issued 05-03

Special tools:
14 mm extended socket spanner
To remove
Warning! Do not remove the filler cap or any

component of the cooling system while the engine
is hot and while the coolant is under pressure,
because dangerous hot coolant can be discharged.
Caution: Some coolant may enter the cylinder

bores and the threaded holes for the cylinder head
setscrews when the cylinder head is removed.
Make sure that any coolant is removed immediately
to prevent corrosion.
1 Drain the cooling system, operation 21A-04.
2 Disconnect the battery.
Caution: Use a separate spanner to prevent

movement of the ouliet connections of the fuel
injection pump when the high-pressure pipes are 12 Remove the rocker cover, operation 12A-01.
reteased or tightened.
13 Remove the rocker assembly, operation 12A02.
4 Remove the high-pressure fuel pipes. Install
suitable covers to all open connections on the 14 Remove the push rods and note their relative
fuel injection pump and the atomisers. positions.
5 Remove the exhaust manifold and gasket (A).

Continued
6 Remove the induction manifold and gasket (B).
7 Remove the pipe which is installed between the

fuel filter and the connections for the atomiser
leak-off.
8 Remove the atomisers, see operation 20A02A/

B. Install suitable covers to the nozzles and to
the open connections.
9 Remove the glow plugs, operation 23C-01.
10 Release the clips on the hose which is installed

between the water pump and the thermostat
housing and remove the hose.
11 Disconnect the sender unit for the coolant

temperature.
Cre 9-54880 Issued 05-03

15 Release the cylinder head setscrews evenly
and gradually in the reverse sequence to that
shown in (A). To release the four setscrews
(A1), It will be necessary to use a 14 mm
extended socket spanner. Check the setscrews
for damage and renew them if necessary.
Caution: Do not use a lever to separate the

cylinder head from the cytinder block.
16 Remove the cylinder head and put it on a

surface that will not damage the face of the
cylinder head.
To install
1 Clean the bottom face of the cylinder head and

top face of the cylinder block. Make sure that
there is no debris in the cylinder bores or
pre-combustion chambers.
Note: Two dowels (B1) are installed to the

cylinder block to make sure that the cylinder
head gasket and the cylinder head remain in
the correct position when the setscrews are
tightened.
Cautions:
• There is a rubber grommet (B2) installed in the
cytinder head gasket for UB engines. 7 Repeat paragraph 6 to make sure that all of the
setscrews are tightened to the correct torque.
• To prevent damage to the cylinder head gasket,
make sure that the dowels are installed in the
8 Put the push rods into the sockets of the tappets
cylinder block before the gasket and head are
from which they were removed.
installed.
• Jointing compound must not be used with the 9 Install the rocker shaft assembly, see operation
cylinder head gasket. 12A-02.
2 Put the cylinder head gasket in position; it is 10 Set the valve tip clearances, see operation
stamped "top" (B3) and "front" (B4) for correct 12A-05.
assembly.
11 Install the rocker cover, operation 12A-01 and
3 Put the cylinder head in position. tighten the fasteners finger tight only.
4 Lightly lubricate the threads of the cylinder head 12 Connect the sender unit for the coolant
setscrews and the thrust faces of the setscrew temperature.
heads. Engage all the setscrews finger tight.
13 Install the hose between the water pump and
5 Gradually and evenly tighten the setscrews to the thermostat housing and tighten the clips.
70 Nm (52 lbf ft) 7,1 kgf m in the sequence
shown in (A). To tighten the four setscrews 14 Install the glow plugs,operation 23C-01.
(A1l), It will be necessary to use a 14 mm
extended socket spanner.
Continued
6 Gradually and evenly tighten the setscrews to
100 Nm (74 lbf ft) 10,2 kgf m in the same
sequence.
Cre 9-54880 Issued 05-03
15 Install the atomisers, see operation 20A-02A/B.
16 Install the pipe which is installed between the

fuel oil filter and the connections for the
atomiser leak-off.
Note: To retain the exhaust manifold, earlier

engines were installed with two studs and six
setscrews. If these are found to be loose,
remove them and install the manifold with eight
of the latest type setscrews (A3). The threaded
part of the new setscrew is machined to a three
lobe shape.
The new setscrew was introduced from engine

number U#####-801620. The threaded part of the old
setscrew (A5) is the standard shape.
Caution: If the fatest setscrews are installed

instead of the old fasteners, and the bosses on the
manifold have been machined, a plain washer, part
number 0920003, 1,83 mm (0, 072 in) thick must be
installed under the head of each new setscrew. This
is to prevent contact of the new setscrew, which is
longer, with the bottom of the tapped hole in the
cylinder head. If the manifold bosses have not been
machined, it is not necessary to use the plain
washer.
17 To make sure correct alignment of the exhaust

manifold (A1), install two guide studs (A2) and a • Do not tighten the union nuts of the highpressure
new gasket without jointing compound. The pipes more than the recommended torque tension
gasket can be installed two ways, make sure the as this can cause a restriction at the end of the
gasket is installed the correct way up (A4). pipe. This can affect the fuel delivery.
Install the exhaust manifold.
20 Install the high-pressure fuel pipes and tighten
18 Install the setscrews and remove the guide the connection nuts to 22 Nm (16 lbf ft) 2,2 kgf
studs. Tighten first the inner setscrews, and m.
then the outer setscrews, to 18 Nm (13 lbf ft) 1,8
kgf m. The torque for the earlier fasteners is 22 21 Install the breather hose to the connections of
Nm (16 lbf ft) 2,2 kgf m. the cylinder head cover and the induction
manifold.
19 To make sure correct alignment of the inlet
manifold, install two guide studs (B2) and a new 22 Fill the coolingsystem, operation 21A-05.
gasket without jointing compound. The gasket
may be installed either way around. Install the 23 Connect the terminals of the battery.
setscrews and remove the guide studs Tighten
the setscrews to 22 Nm (16 lbf ft) 2,2 kgf m. 24 Connect the air filter.
Cautions: 25 Eliminate air from the fuel system, operation

20A-07.
• If there is a leakage from the union nut, make
sure that the pipe is correctly aligned with the
Continued
atomiser inlet.
Cre 9-54880 Issued 05-03

26 Remove the rocker cover.
27 Start the engine, run it at low speed and check

that oil flows from all the rocker levers,
28 If the oil flow from the rockers is correct, stop the

engine and install the rocker cover, see
operation 12A-01. If the oil flow is not correct,
find the fault.
Cre 9-54880 Issued 05-03

Valves and valve springs
Special tools:
Valve spring compressor, MS.1519A
To remove
Warning! Wear eye protection during this

operation.
1 Remove the cylinder head, see operation 12A-

07.
2 Clean the bottom face of the cylinder head and

check the depth of the valve heads below the
face of the cylinder head, operation 12A-09.
3 Make a suitable mark on the head of each valve

to make sure that the valves can be installed in
their original positions.
Caution: Make sure that the valve springs are

compressed squarely or the valve stem can be
damaged.
4 Use the valve spring compressor (A) to

compress the valve spring (B3) and remove the
collets (B2).
5 Release the valve spring compressor and

remove the valve spring cap (B1), valve spring
(B3), valve stem seal (B4) and the valve (B5).
6 Repeat paragraphs 3 and 4 to remove the

remainder of the valves.
Continued
Cre 9-54880 Issued 05-03

To install

operation.
Cautions:
• Genuine Case valve stem seals must be used. If
they are not, damage can occur to the valve
stems and valve seats.
• Make sure that the valve springs are compressed
squarely or damage can occur to the valve stem.
1 Lubricate the valve stem (A5) with clean engine

oil and install the valve into the valve guide.
2 Install a new valve stem seal (A4) onto the valve

guide. Install the valve spring (A3) and the valve
spring cap (A1). The valve spring can be
installed with either end toward the cylinder
head.
3 Use the valve spring compressor to compress

the valve spring. Install the collets (A2).
4 Repeat paragraphs 1, 2 and 3 to install the

remainder of the valves.
A PC039
Cre 9-54880 Issued 05-03

To inspect and to correct 12A-09
Special tool:
Gauge, valve depth, PD.41D
Dial gauge for use with PD.41D, PD.208
1 Check the depth of the valves below the face of

the cylinder head before the valve springs are
removed. Make sure that the heads of the
valves and the bottom face of the cylinder head
are clean. Put the valve depth gauge on the face
of the cylinder head and set the dial gauge to
zero. Carefully put the valve depth gauge in
position over the head of each valve (A) and
make a note of the measurement. The
maximum depth in service, is given in Data and
dimensions at the end of this section.
2 If a valve is below the depth limit, check the

valve depth with a new valve in position. If the
valve depth is still below the limit, the valve seat
insert(s) must be renewed, see operation
12A-14.
3 Check the valves for cracks. Check the stems of

the valves for wear and for correct install in their
valve guides.
4 Check that the seat faces of the valves are not

burnt or damaged. Seat faces which are
damaged can be ground on a special machine.
Valves which have only a little damage can be
lapped to their valve seats. When new valves
are installed, the valve depths must be checked,
see paragraph 1.
5 Check that the load on the valve springs is

correct at their installed length, see Data and
dimensions. Install new valve springs at every
complete engine overhaul.
Cre 9-54880 Issued 05-03

Valve guides
To inspect 12A-10
To check the valve guides for wear: The maximum

clearance (A5), between the valve stem and the bore
of the guide is 0,107 mm (0.042 in) for inlet valves and
0,14 mm (0.006 in) for exhaust valves. If the
clearance, with a new valve installed, is more than the
limit, then a new valve guide (A4) must be installed.
It is recommended that the procedure given below is

used to check the valve guide clearance:
1 Put a new valve in the valve guide.
2 Put a dial test indicator with a magnetic base

(A1) onto the face of the cylinder head
3 With the valve lifted 15,0 mm (0.6 in) and the

gauge (A2) in contact with the edge of the valve
head (A3), move the valve radially away from
the gauge. With the valve held in this position,
set the gauge zero.
4 Move the valve radially across the axis of the

cylinder head towards the gauge. Make a note
of the reading on the gauge. If the reading is
equal to or greater than the data given below, a
new valve guide (A4) must be installed.
Maximum permissible clearance with a valve lift of

15,0 mm (0.6 in):
• Inlet guide 0,24 mm (0.009 in)
• Exhaust guide 0,28 mm (0.011 in)
Cre 9-54880 Issued 05-03

Special tools:
Remover/replacer for valve guides (main tool),

PD.1D/1
Spacer PD.1D/2, used with main tool PD.1D/1
Adaptor PD.249 used with PD.1D-13
Adaptor PD.1D-13 used with main tool PD.1D/1
To remove
1 Install the adaptor PDI D-13 (A4) into the

remover/ replacer tool (A3).
2 With the adaptor installed to the tool, put the

spacer PD.1D/2 (A5) in position on the tool.
Pass the adaptor through the valve guide (A6)
and put the spacer and tool in position on the
valve seat.
3 Install the attachment (A7) to secure the adaptor

to the valve guide.
4 Hold the top handle (A1) and turn the bottom

handle (A2) clockwise to pull the valve guide out
of the cylinder head.
Continued
Cre 9-54880 Issued 05-03

To install
1 Clean the parent bore in the cylinder head for

the valve guide.
2 Lubricate the outer surface of the new valve

guide (A6) with clean engine lubricating oil.
3 Install the adaptor (A5) into the remover/

replacer tool (A3).
4 With the adaptor installed to the tool, put the

spacer (A4) in position on the tool. Pass the
adaptor through the cylinder head and put the
spacer and tool assembly in position on the
valve seat.
5 Put the new valve guide in position on the

adaptor and install the distance piece PD.249
(A7). Install the attachment (A8) to secure the
valve guide to the adaptor.
Note: The internal recess in the valve guide

must be towards the tool.
6 Hold the top handle (A1) and turn the bottom

handle (A2) clockwise to pull in the valve guide
until the distance piece touches the cylinder
head. A PA065-1
7 When the valve guide is installed correctly, the

top of the valve guide will have a protrusion of
7,7/7,9 mm (0.30/0.31 in) above the valve
spring seat (B9).
Cre 9-54880 Issued 05-03

Cylinder head
To inspect and to correct 12A-12
Caution: The bottom face of the cylinder head for

the UB engine should not be machined. If it is, the
edge of the pre-combustion chamber will be too thin
and could break off during the combustion process.
If the bottom face of the cylinder head is damaged
or the distortion exceeds the service limits, the
cylinder head assembly must be renewed.
1 Remove the cylinder head assembly, operation

12A-07.
Cautions:
2 Inspect the cylinder head for signs of gas or
coolant leakage. • If the cylinder head of a UA engine has been
machined, the maximum nozzie protrusion must
3 Remove the valve springs and the valves, not exceed 2,7 mm (0.11 in), when measured with
operation 12A-08. the nozzle seat washer installed.
• If the cylinder head has been machined, check
4 Clean the face of the cylinder head and the the depth of each valve head, below the bottom,
passages for coolant and for lubricating oil. The face of the cylinder head. If necessary, cut the
water jacket can be cleaned with a special valve seat to obtain the correct dimension, see
solvent which must be used in accordance with Data and dimensions at the end of section 12. It is
the manufacturer's instructions. better to work to the minimum limit to allow for
later wear.
5 Test the cylinder head for leaks at the pressure
given in data and dimensions at the end of the • Before any work is done on the valve seats, new
section. valve guides must be installed, operation 12A-11.
• If a new valve seat insert is to be installed, the
6 When the cylinder head is thoroughly clean, back face must be surface ground to make sure
check it for cracks. Check carefully the areas that there is no protrusion above the bottom, face
around the valve seats, the holes for the of the cylinder head, operation 12A-14.
atomiser nozzles and glow plugs (A2), and the
port (A1) in the pre-combustion chambers. If 9 Check the valve seats for wear and for damage.
there are cracks in these areas, the cylinder
head assembly should be renewed. 10 Where there is little damage, the valve and
valve seat can be lapped. When the valve seats
7 The bottom face of the cylinder head for UA are lapped, keep the seat as narrow as possible
engines (only) can be machined if, there is and make sure that all the compound used to
distortion, deep scratches or the valve depths lap the valve and the seat is removed.
are below the service limit.
11 More badly damaged valve seats can be
8 Use a straight edge and feeler gauges to check corrected by use of the cutter tool, operation
the cylinder head for distortion as shown in Data 12A-13, or new inserts can be installed,
and dimensions at the end of section 12. operation 12A-14.
Cre 9-54880 Issued 05-03

To correct a valve seat
with a valve seat cutter 12A-13
Special tools:
Valve seat cutting tool - kit, MS.76A.
1 Before any work is done on the valve seats, new

valve guides must be installed, operation
12A-11.
2 Install the pilot (A3) in the valve guide and

tighten the pilot.
3 Select the relevant cutter (A2). Set the blades of

the cutters to the diameter of the valve seat to
be cut. Install the cutter on the pilot and install
the handle (A1). Make sure that the cutter is not
allowed to fall on to the seat as this can damage
the blades.
4 Carefully rotate the cutter in a clockwise

direction (A4). Remove only the minimum
material to make sure a good seat. Keep the
seat as narrow as possible.
5 When the seat is cut, remove the cutter and the

pilot. Remove any debris from the area of the
valve seat and the port.
6 Install the valve and lightly lap the valve and the
seat.
7 Check that the valve depth is within limits, see

Data and dimensions at the end of this section.
Note: If a valve seat has become too damaged

or too worn to correct, a valve seat insert can
be installed, operation 12A-14.
Cre 9-54880 Issued 05-03

To install valve seat inserts 12A-14 8 Make sure that when installed, the bottom face
of the insert is in contact with the bottom of the
Caution: A new valve guide must be installed to the recess in the cylinder head. When installed
cylinder head before a new valve seat insert is correctly, the depth of the insert, below the
installed. This is necessary to maintain bottom face of the cylinder head should be:
concentricity between the valve guide and the seat - UA engines: 2,15/2,45 mm (0.085/0.096 in)
for the valve. - UB engines: 2,40/2,70 mm (0.090/0.110 in)
Note: Cylinder heads that are installed with new The depth of the insert should be measured in two
valve seat inserts and new valve guides places, at 90°0 to each other.
(pre-finished) are available.
9 Cut the valve seat at 45° (an included angle of
1 Remove the valve guide and clean the bore into 90°) for the inlet and the exhaust valves (UA and
which the guide is to be installed. UB engines), operation 12A-13. Make sure that
the depth of the valve head below the face of the
2 Install new valve guides, operation 12A-11. cylinder head is within the production limits, see
Data and dimensions. Work as near as possible
3 With the bore of the new valve guide used as a to the minimum figure to allow for future wear on
pilot, machine out the old valve seat insert. the valve seat.
Remove ail debris and clean the recess for the
insert.
Caution: If the bottom face of the cylinder head has

been machined, the depth of the recess for the
valve seat may have changed.
4 Measure the depth of the recess in two places

90° apart. The correct depths are:
- UA engines: 8,35/8,55 mm (0.329/0.337 in)
- UB engines: 8,20/8,40 mm (0.320/0.330 in)
5 If the depth of the recess has been reduced,

surface grind the bottom face of the insert by an
equivalent amount. Check the depth of the
insert and make sure that it is installed correctly.
6 If the insert has been surface ground, make

sure that the outer edge of the back face of the
insert has a 0,7/1,2 mm (0.03/0.05 in) chamfer
at 30°±1° to the vertical.
7 With the bore of the valve guide used as a pilot,

and with the rear face of the insert towards the
cylinder head, press the insert into the recess
with the valve seat insert tool, see Data and
dimensions.
Caution: Do not use a hammer or use lubrication

to install the insert. Use a hydraulic press or a hand
press in one continuous movement.
Cre 9-54880 Issued 05-03

Data and dimensions
Note: This information is given as a guide for personnel engaged on engine overhauls. The dimensions
which are shown are those which are mainly used in the factory. Unless it is indicated to be different,
the data shown below is the same for both UA and UB engines.
Angle of valve seat:

- Inlet ......................................................................................................................... 45° (90° included angle)
- Exhaust.................................................................................................................... 45° (90° included angle)
Diameter of parent bores for valve guides ............................................. 12,000/12,027 mm (0.4724/0.4735 in)
Leak test pressure........................................................................................... 200 kPa (29 lbf/in2) 2,0 kgf/cm2
Cylinder head thickness ................................................................................ 79,85/80,05 mm (3.148/3.151 in)
Minimum permissible thickness after head face has been machined:
- UA engines ...................................................................................................................... 79,8 mm (3.142 in)
- UB engines ................ The cylinder head for this engine must not be machined, see caution on page 12A.17
Maximum protusion of the atomiser nozzle..............................................................................2,7 mm (0.11 in)
Valves guides
Inside diameter ........................................................................................ 7,027/7,052 mm (0.2767/0.2776 in)
Outside diameter ................................................................................... 12,034/12,047 mm (0.4738/0.4743 in)
Interference install of guide in cylinder head.................................... - 0,007/- 0,047 mm ( - 0.0003/- 0.0019 in)
Length ................................................................................................................... 45,2/45,7 mm (1.78/1.80 in)
Protusion above the valve spring seat ................................................................... 7,70/7,85 mm (0.30/0.31 in)
Inlet valves
Diameter of valve stem.............................................................................. 8,970/8,985 mm (0.2704/0.2750 in)
Clearance install of valve guide ................................................................. 0,042/0,082 mm (0.0017/0.0032 in)
Maximum permissible clearance in valve guide: ..............................................................0,107 mm (0.0042 in)
Diameter of valve head
- UA engine ........................................................................................................... 43,9/44,1 mm (1.73/1.74 in)
- UB engine ........................................................................................................... 41,9/42,1 mm (1.65/1.66 in)
Angle of valve face ......................................................................................................................................45°
Depth of valve head below cylinder head face:
- UA engine ............................................................................................... 0,306/0,806 mm (0.0120/0.0137 in)
- UB engine ............................................................................................... 0,325/0,675 mm (0.0128/0.0266 in)
Service limit:
- UA engine ........................................................................................................................ 0,93 mm (0.037 in)
- UB engine ........................................................................................................................ 0,72 mm (0.028 in)
Overall length of valve........................................................................... 106,275/106,625 mm (4.184/4.197 in)
Seal arrangement..................................................................................... Rubber seal installed to valve guide
Cre 9-54880 Issued 05-03
Exhaust valves
Diameter of valve stem ............................................................................ 6,945/6,960 mm (0.2734/0.2740 in)
Clearance install of valve in guide ............................................................ 0,067/0,107 mm (0.0026/0.0042 in)
Maximum permissible clearance in valve guide .................................................................0,15 mm (0.0059 in)
Diameter of valve head:
- UA engine ......................................................................................................... 37,1/37,3 mm (1.46/1.47 in)
- UB engine .......................................................................................................... 33,9/34,1 mm (1.33/1.34 in)
Angle of valve face......................................................................................................................................45°
Depth of valve head below cylinder head face:
- UA engine ............................................................................................. 0,317/0,817 mm (0.0125/0.0322 in)
- UB engine .............................................................................................. 0,425/0,775 mm (0.0165/0.0305 in)
Service limit:
- UA engine ....................................................................................................................... 0,94 mm (0.037 in)
- UB engine ........................................................................................................................ 0,72 mm (0.028 in)
Overall length of valve:
- UA engine ...................................................................................... 106,125/106,475 mm (4.1781/4.1919 in)
- UB engine ....................................................................................... 106,275/106,625 mm (4.1841/4.1978 in)
Seal arrangement......................................................................................Rubber seal installed to valve guide
Valve springs
Installed length.................................................................................................................... 32,0 mm (1.26 in)
Load at installed length ........................................................................ 375/415 N (84,4/93,2 lbf) 38,3/42,3 kgf
Number of active coils ................................................................................................................................. 3,9
Direction of coils ............................................................................................................................... Left hand
Tappets
Diameter of tappet stem ....................................................................... 26,959/26,980 mm (1.0613/1.0622 in)
Diameter of tappet bore in cylinder block............................................... 27,000/27,021 mm (1.0631/1.0641 in)
Clearance of tappet in cylinder block ......................................................... 0,020/0,062 mm (0.0008/0.0024 in)
Rocker shaft
Outside diameter .................................................................................. 21,962/21,987 mm (0.8646/0.8656 in)
Rocker levers
Bore diameter ...................................................................................... 22,013/22,051 mm (0.8667/0.8681 in)
Clearance install on rocker shaft ............................................................... 0,026/0,084 mm (0.0010/0.0033 in)
Maximum permissible clearance .....................................................................................0,124 mm (0.0048 in)
Valve tip clearances (cold) ..................................................................................................0,35 mm (0.014 in)
Cre 9-54880 Issued 05-03

Maximum permissible distortion of cylinder head
(A)
A1 . . . . . . . . . . . . . . . . . . . . . . 0,08 mm (0.003 in)

A2 . . . . . . . . . . . . . . . . . . . . . . 0,15 mm (0.006 in)
A3 . . . . . . . . . . . . . . . . . . . . . . 0,15 mm (0.006 in)
AX . . . . . . . . . . . . . . . . . . . . . . . . . 40 mm (1.6 in)
AY . . . . . . . . . . . . . . . . . . . . . . . . 106 mm (4.2 in)
AZ . . . . . . . . . . . . . . . . . . . . . . . . 106 mm (4.2 in)
Dimensions of a recess for valve seat inserts (B)
Inlet - UA engines
B1 . . . . . . . Radius 0,38 mm (0.015 in) maximum)
B2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° chamfer
B3 . . . . . . . . . . . . . . . 49,0/49,2 mm (1.93/1.94 in)
B4 . . . . . . . 45,175/45,200 mm (1.7785/1.7795 in)
B5 . . . . . . . . . . . . . 8,35/8,55 mm (0.329/0.337 in)
Exhaust - UA engines
B2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° chamfer
B3 . . . . . . . . . . . . . . . 42,5/42,3 mm (1.67/1.79 in)
B4 . . . . . . . 38,475/38,500 mm (1.5148/1.5157 in)
B5 . . . . . . . . . . . . . 8,35/8,55 mm (0.329/0.337 in)
Inlet - UB engines
B2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° chamfer
B3 . . . . . . . . . . . . . . . 46,9/47,1 mm (1.84/1.85 in)
B4 . . . . . . . 43,325/43,350 mm (1.7057/1.7067 in)
B5 . . . . . . . . . . . . . . . . . 8,2/8,4 mm (0.32/0.33 in)
Exhaust - UB engines
B2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° chamfer
B3 . . . . . . . . . . . . . . . 38,7/38,9 mm (1.52/1.53 in)
B4 . . . . . . . 35,125/35,150 mm (1.3828/1.3838 in)
B5 . . . . . . . . . . . . . . . . . 8,2/8,4 mm (0.32/0.33 in)
Continued
Cre 9-54880 Issued 05-03

Dimensions for a valve seat insert tool (A)
Inlet - UA engines
A1 . . . . . . . . . . . . . . . . . . . . . . . .1,5 mm (0.06 in)

A2 . . . . . . . . . . . . . . . . . . . . . . . .19,0 mm (0.7 in)
A3 . . . . . . . . . . . . . . . . . . . . . . . .6,5 mm (0.26 in)
A4 . . . . . . . . . . . . . . . . . . . . . . . . . 60 mm (2.4 in)
A5 . . . . . . . . . . . 38,82/38,85 mm (1.528/1.529 in)
A6 . . . . . . . . . . . . . . . 44,6/45,1 mm (1.76/1.78 in)
A7 . . . . . . . . . . . . . . . . . . . . . . . .0,8 mm (0.03 in) A PA069
A8 . . . . . . . . . . . . . . . . . . . . . . . .1,5 mm (0.06 in)

A9 . . . . . . . . . . . . . . . . . . . . . . . .1,5 mm (0.06 in)
Exhaust - UB engines
A10 . . . . . . . . . . . . 6,95/6,97 mm (0.273/0.274 in)
A1 . . . . . . . . . . . . . . . . . . . . . . . . 1,5 mm (0.06 in)
Exhaust - UA engines
A2 . . . . . . . . . . . . . . . . . . . . . . . . 19,0 mm (0.7 in)
A1 . . . . . . . . . . . . . . . . . . . . . . . .1,5 mm (0.06 in) A3 . . . . . . . . . . . . . . . . . . . . . . . . 6,1 mm (0.26 in)
A2 . . . . . . . . . . . . . . . . . . . . . . . .19,0 mm (0.7 in) A4 . . . . . . . . . . . . . . . . . . . . . . . . . 60 mm (2.4 in)
A3 . . . . . . . . . . . . . . . . . . . . . . . .6,5 mm (0.26 in) A5 . . . . . . . . . . . 28,95/29,02 mm (1.139/1.143 in)
A4 . . . . . . . . . . . . . . . . . . . . . . . . . 60 mm (2.4 in) A6 . . . . . . . . . . . . . 35,08/35,10 mm (1.38/1.88 in)
A5 . . . . . . . . . . . 31,42/31,45 mm (1.237/1.238 in) A7 . . . . . . . . . . . . . . . . . . . . . . . 0,8 mm (0.031 in)
A6 . . . . . . . . . . . 38,43/38,45 mm (1.513/1.514 in) A8 . . . . . . . . . . . . . . . . . . . . . . . . 1,5 mm (0.06 in)
A7 . . . . . . . . . . . . . . . . . . . . . . . 0,8 mm (0.031 in) A9 . . . . . . . . . . . . . . . . . . . . . . . . 1,5 mm (0.06 in)
A8 . . . . . . . . . . . . . . . . . . . . . . . .1,5 mm (0.06 in) A10 . . . . . . . . . . . . 6,95/6,97 mm (0.273/0.274 in)
A9 . . . . . . . . . . . . . . . . . . . . . . . .1,5 mm (0.06 in)
A10 . . . . . . . . . . . . 6,95/6,97 mm (0.273/0.274 in)
Inlet - UB engines
A1 . . . . . . . . . . . . . . . . . . . . . . . .1,5 mm (0.06 in)

A2 . . . . . . . . . . . . . . . . . . . . . . . .19,0 mm (0.7 in)
A3 . . . . . . . . . . . . . . . . . . . . . . . .6,1 mm (0.26 in)
A4 . . . . . . . . . . . . . . . . . . . . . . . . . 60 mm (2.4 in)
A5 . . . . . . . . . . . . . 37,15/37,22 mm (146/1.47 in)
A6 . . . . . . . . . . . 42,75/43,25 mm (1.683/1.703 in)
A7 . . . . . . . . . . . . . . . . . . . . . . . .0,8 mm (0.03 in)
A8 . . . . . . . . . . . . . . . . . . . . . . . .1,5 mm (0.06 in)
A9 . . . . . . . . . . . . . . . . . . . . . . . .1,5 mm (0.06 in)
A10 . . . . . . . . . . . . 6,95/6,97 mm (0.273/0.274 in)
Cre 9-54880 Issued 05-03

Cre 9-54880 Issued 05-03

PISTON AND CONNECTING ROD ASSEMBLY 13A-01
Piston and connecting rod assembly 13
Big end bearing

13A-01 To remove and to install ............................................................................13A.03
13A-02 To inspect .................................................................................................13A.04

13A-03A To check the piston height above the cylinder block ..................................13A.08
Piston rings

13A-05 To disassemble and to assemble .............................................................13A.10
13A-05A To renew ................................................................................................... 13A.11
13A-05B To check the length of a connecting rod ....................................................13A.12
Piston and piston rings

13A-06 To inspect .................................................................................................13A.13
Connecting rod
13A-07 To inspect .................................................................................................13A.14
Small end bush

Cre 9-54880 Issued 05-03

13A-02 PISTON AND CONNECTING ROD ASSEMBLY
General description
There are two types of piston used in the 700 Series

engines. The UA engine, which has direct injection,
has a combustion chamber (A1) in the top of the
piston. This chamber is designed to give an efficient
mix of fuel and air.
The UB engine, which has indirect injection, has a

piston with a different design (B1). This works with the
pre-combustion chamber in the cylinder head to give
an efficient mix of fuel and air.
Both piston types have two compression rings and an

oil control ring.
The pistons and connecting rods are matched to the

relevant cylinder.
Axial location of the fully floating gudgeon pin is by

two circlips.
Caution: The big end bolts are installed to the

connecting by a special process and must not be
removed. If the bolts are removed, the connecting
rod, and the bolts will be damaged.
The connecting rods (C) are machined from "H"

section forgings of molybdenum steel. The bearing
cap is retained by two special bolts and flange face
nuts. The big end bearings have a steel back and an
aluminium / tin face. The small end bearings are a
lead-bronze bush.
In the factory, the correct piston height is obtained by

the use of six lengths of connecting rod and one
piston. The small end bush is machined eccentrically
to obtain the different connecting rod lengths.
In service, three pistons of different heights are

supplied and one connecting rod. The small end bush
is machined concentrically. Pistons with a larger
diameter are also supplied, to be installed if the
cylinder bores are bored oversize. See Data and
dimensions at the end of this section, and section 16,
Cylinder block assembly.
Note: Always use the full engine number to

order new parts.
Cre 9-54880 Issued 05-03

Big end bearing
Notes on connecting rods:
• The left side refers to the side of the engine when

seen from the flywheel end.
• The cylinder number (B1) is etched on the left
side of the connecting rod and cap.
• The letter that indicates the length grade for the
connecting rod is also etched on the left side (B2).
• The letter (B3) which is etched on the right side of
the connecting rod is the manufacturers reference
number.
• The part number shown on the connecting rod
should always be towards the front of the engine.
• Location tags (A1) for the shell bearings will
always be towards the right side of the engine.
To remove
Cautions:
• Make sure that the bolts (A1) for the connecting
rod do not damage the crank pin when the
connecting rod is moved. If necessary, install a
temporary plastic sleeve to the big end bolts. 7 Carefully push the connecting rod up the
cylinder bore just enough to allow access to the
• The big end bolts are installed to the connecting upper half of the shell bearing. Remove the
by a special process and must not be removed. If bearing from the connecting rod. Keep the
the bolts are removed, the connecting rod, and bearings from the connecting rod and cap
the bolts will be damaged. together.
1 Drain the engine lubricating oil.
Continued
2 Remove the lubricating oil sump, operation
19A-03.
3 Remove the lubricating oil strainer and suction

pipe, operation 19A-04.
4 Rotate the crankshaft until the relevant

connecting rod is at its lowest position.
5 Release the nuts and remove the bearing cap.
6 Remove the lower half of the shell bearing from

the cap, but keep it with its relevant cap.
Cre 9-54880 Issued 05-03

To install
1 Clean the bearing faces of the connecting rod

and the crank pin.
2 Clean the upper half of the shell bearing and

install it to the connecting rod; make sure that
the location tag is installed correctly in its recess
(A2). Lubricate the bearing surfaces with clean
engine lubricating oil. Install the connecting rod
to the crank pin; make sure that the assembly
number (B1) and the letter for the length grade
(B2) are on the correct side of the engine.
3 Clean the bearing face of the cap and the lower

half of the shell bearing and install it into the
cap; make sure that the location tag is installed
correctly in its recess (A1). Lubricate the
threads of the bolts.
4 Lubricate the bearing surfaces with clean

engine lubricating oil and install the cap to the
connecting rod. Make sure that the assembly
number on the cap is the same as that on the
connecting rod and that both of the assembly
numbers are on the same side (B). Install the
nuts and tighten them finger tight.
5 Tighten the nuts gradually and evenly to the

recommended torque of 54 Nm (40 lbf ft) 5,5 kgf
m.
6 After each connecting rod is tightened, make

sure that the crankshaft rotates freely.
7 Install the lubricating oil strainer and suction

8 Install the lubricating oil sump, operation

19A-03 and fill the sump to the correct level with
lubricating oil of an approved grade.
To inspect 13A-02
Check the bearings and the crank pin for wear or

other damage.
Cre 9-54880 Issued 05-03

Special tools:
Piston ring compressor, N°. 8
Notes on connecting rods:

• The left side refers to the side of the engine when
seen from the flywheel end.
• The cylinder number (B1) is etched on the left
side of the connecting rod and cap.
• The letter that indicates the length grade for the
connecting rod is also etched on the left side (B2).
Some early engines had the length grade etched
on the right side of the connecting rod and cap.
• The letter (B3) which is etched on the right side of
the connecting rod is the manufacturers reference
number.
• The part number shown on the connecting rod
should always be towards the front of the engine.
• Location tags (A1) for the shell bearings will
always be on the right side of the engine.
To remove
Cautions:
1 Drain the lubricating oil.
• The big end bolts are installed to the connecting
2 Drain the cooling system, operation 21A-04. rod by a special process and must not be
removed. If the bolts are removed, the connecting
3 Remove the cylinder head assembly, operation rod, and the bolts will be damaged.
12A-07. • Make sure that the bolts (A1) for the connecting
rod do not damage the crank pin when the
4 Remove all carbon from the top of the cylinder connecting rod is removed or installed. If
bores. necessary, install a temporary plastic sleeve to
the big end bolts.
19A-03. • The pistons and connecting rods are matched to
the relevant cylinder. Note the position of each
6 Remove the lubricating oil strainer and suction connecting rod and piston for correct assembly.
8 Push the piston and the connecting rod out
7 Remove the big end caps and the big end through the top of the cylinder. Keep the
bearings from the connecting rods, operation bearings and caps together to make sure that
13A-01. they can be installed in their original positions.
9 Inspect the crank pins for damage.
Continued
Cre 9-54880 Issued 05-03

To install
Caution: The correct piston height must be

maintained in service to prevent damage to the
pistons and valves, and make sure that the engine
conforms to emissions legisiation.
1 Make sure that the piston, the cylinder bore, the

crank pin and the big end of the connecting rod
are clean. Lubricate the piston and the cylinder
liner with clean engine lubricating oil.
Note: Rotate the crankshaft counter-clockwise

to make sure that the shell bearing in the big
end remains in position.
2 Rotate the crankshaft until the relevant crank

pin is at its highest position. Lubricate the crank
pin with clean engine lubricating oil.
3 Install the upper half of the shell bearing to the

connecting rod. Make sure that the location tag
is installed correctly in its recess. Lubricate the
bearing with clean engine lubricating oil.
Lubricate the threads of the two bolts for the big
end.
4 Put the piston ring gaps 120° apart. Lubricate

the piston rings with clean engine lubricating oil.
Install the tool (A1) to compress the piston rings.
Cautions:
• Make sure that the bolts for the connecting rod do
not damage the crank pin when the connecting
rod is rernoved or installed. If necessary, install a
temporary plastic sleeve to the big end bolts.
• Make sure that the piston and connecting rod
assembly is installed to the same cylinder bore
from which it was rernoved.
5 The arrows (B1/C1) must be towards the front of

the engine. Install the piston and connecting rod
assembly into the correct cylinder bore. In this
position the combustion bowl / recess (B2/C2) 7 Rotate the crankshaft counter-clockwise, when
will be towards the right side of the engine when seen from the front, until the crank pin is at its
seen from the rear. lowest position. At the same time carefully apply
pressure to the top of the piston with a suitable
6 Carefully push the piston through the piston ring piece of wood or plastic. This will keep the big
compressor and check that the connecting rod end in contact with the crank pin.
is onto the crank pin.
Continued
Cre 9-54880 Issued 05-03

8 Clean the connecting rod cap and the lower half
of the shell bearings. Install the bearing to the
cap; make sure that the location tag is installed
correctly in its recess (A1). Lubricate the
bearing with clean engine lubricating oil.
9 Install the cap and make sure that the assembly

number and length grade letters are in the
correct position, see notes, page 13A.05. Install
the nuts and tighten the them gradually and
evenly to the recommended torque of 54 Nm (40
lbf ft) 5,5 kgf.
10 Check that the crankshaft will rotate freely.
11 Check the piston height above the top face of

the cylinder block, operation 13A-03A.
12 Install the lubricating oil strainer and suction


19A-03.
14 Install the cylinder head assembly, operation

12A-07.
15 Fill the sump to the correct level with lubricating

oil of an approved grade.
16 Fill the cooling system, operation 21A-05.
Cre 9-54880 Issued 05-03

To check the piston height
above the cylinder block 13A-03A
Special tools:
Piston height tool, PD.41D
Dial gauge for use with PD.41D, PD.208
Caution: The correct piston height must be

maintained in service to prevent damage to the
pistons and valves and make sure that the engine
conforms to emissions legislation.
1 Put the piston height tool (A) on the face of the

cylinder block and rotate the dial of the gauge to
the zero position.
2 Rotate the crankshaft until the piston is just

before top dead centre (TDC).
3 Carefully put the tool (A) over the top of the

piston with the plunger of the gauge in contact
with the piston above the axis of the gudgeon
pin. Rotate the crankshaft to make sure that the
piston is at the highest position and make a note
of the gauge indication.
The piston height above the top face of the cylinder

block should be 0,38/0,51 mm (0.015/0.020).
Cre 9-54880 Issued 05-03

Piston rings
The pistons used in the 700 Series engines have two

compression rings and an oil control ring. All the
piston rings are above the gudgeon pin. To make sure
that the correct piston rings are obtained, always use
the full engine number to order new parts.
Note: The piston shown in (A) and (B) is for UA

engines.
Caution: Only expand the ring gaps enough to .

make sure that the ends of the rings do not damage
the piston when the ring is removed or put into
position.
To remove
Remove the piston rings with a suitable ring

expander. Keep the rings with their relevant piston.
To install
Use a suitable piston ring expander to install the

piston rings.
1 Install the spring (A3) of the oil control ring in the

bottom groove of the piston, with the latch pin
(B1) inside both ends of the spring. Install the oil 4 Make sure that the ring gaps are 120° apart.
control ring over the spring. Make sure that the
ring gap is at 1800 to the latch pin. The
manufacturers symbol or the word'TOP', must
be towards the top of the piston.
2 Install the cast iron ring with the taper face (A2)
into the second groove of the piston. The
manufacturers symbol or the word'TOP', must
be towards the top of the piston.
New rings for the second groove have a green

identification mark which must be on the left of the
ring gap when the ring is installed and the piston is
upright.
The second ring has a chamfer (A4) on the inner,

bottom face.
3 Install the top ring, the manufacturers symbol or

the word 'TOP', must be towards the top of the
piston. New rings for the top groove have a red
identification mark on the outer edge. This mark
must be on the left of the ring gap when the ring
is installed and the piston is upright. The top ring
has a small curve on the outer face (A1).
Cre 9-54880 Issued 05-03


connecting rod by a special process and must not
be removed. If the bolts are removed, the
connecting rod, and the bolts will be damaged.
Note: The pistons and connecting rods are

matched to the relevant cylinder. Note the
position of each connecting rod and piston for
correct assembly.
To disassemble
1 Remove the piston rings, operation 13A-04.
2 Remove the circlips which retain the gudgeon

pin.
3 Put a mark on the piston to indicate the cylinder

number as shown on the connecting rod. Put the
mark on the piston on the same side as the mark
on the big end (A3) to make sure that they are
assembled correctly.
4 Push the gudgeon pin out by hand. If the

gudgeon pin is tight, heat the piston to 40/50 °C
(100/120 °F) for easy removal of the gudgeon 5 Install a new circlip in the groove in the other
pin. gudgeon pin boss. Make sure that it fits correctly
in the groove.
To assemble
6 Install the piston rings, operation 13A-04.
1 Clean the bore of the small end bush and
lubricate it with clean engine lubricating oil.
2 Install a new circlip in the circlip groove of one

of the gudgeon pin bosses. Make sure that it fits
correctly in the groove.
3 Install the connecting rod to the piston. The

piston and connecting rod are correctly
assembled when: the arrow (A4) is towards the
front of the engine; the bowl / recess (A1) and
the reference number (A2) are on the right side
of the engine; the assembly number number
(A3) is on the left side of the engine (right side
on some early engines).
4 Lubricate the gudgeon pin bosses with clean

engine lubricating oil and push in the gudgeon
pin towards the circlip. If the gudgeon pin is a
tight install in the piston, heat the piston to 40/
50°C (100/120°F) before the gudgeon pin is
installed.
Cre 9-54880 Issued 05-03

To renew 13A-05A

In service, pistons are supplied in three height grades,

high, nominal and low. Identification is by a letter
shown on the piston crown (A). H is for high and L is
for low. The nominal grade (same as used in
production) is not marked.
Oversize pistons are identified in the same way. For

details of oversize pistons, see Technical data.
In service, only one length of connecting rod is

supplied. They are identified by an X etched onto the
side of the big end (B2). The manufacturers reference
number will be on the right side (B3). These
connecting rods are installed with a concentric small
end bush. Small end bushes supplied loose also have
a concentric bore.
Note: If any of the components listed below are

renewed and the correct piston height cannot
be obtained, it may be necessary to install a
new piston and / or new small end bush:
- The connecting rod Caution: The top of the piston must not be
- The small end bush machined to oblain the correct height.
- The cylinder block
- The crankshaft 6 Check the piston height above the cylinder
block, operation 13A-03A.
1 Check the length grade of the original
connecting rod and select the correct piston,
operation 13A-05B.
Caution: Do not use a letter stamp to mark the

connecting rod.
Note: If it is necessary, install a new small end

bush, operation 13A-08.
3 Put the correct cylinder number (B1) onto the

connecting rod.
Caution: If the original piston is used, make sure

that it is assembled to the correct connecting rod
and is used in the original cylinder.
4 Assemble the piston and connecting rod,

operation 13A-05.
5 Install the piston and connecting rod assembly,

operation 13A-03.
Cre 9-54880 Issued 05-03
To check the length of a
connecting rod 13A-05B

Note: To make sure that the piston height

above the cylinder block is correct in
production, one of six different length grades of
connecting rod is installed, see table opposite.
If a connecting rod is renewed in service, an 'X’
grade (similar to grade 'D') is supplied and is
installed with a concentric small end bush. Connecting rod dimensions
Production grades are identified by a letter, etched

onto the left side of the rod (right side on some early Grade Length minimum / maximum mm (in)
engines). A 132,08/132,11 (5.200/5.201)
If the grade letter on the side of the connecting rod B 132,05/132,08 (5.199/5.200)
cannot be seen, the length can be checked by the
measurement of the dimension shown in (A). The C 132,02/132,05 (5.198/5.199)
dimensions for each grade are shown in the table D 131,99/132,02 (5.196/5.198)
opposite.
E 131,96/131,99 (5.195/5.196)
Note:
F 131,93/131,96 (5.194/5.195)
• Before the length of the connecting rod is
measured, make sure that the large and small X 131,99/132,02 (5.196/5.198)
end bores are square and parallel, operation
13A-07. Piston selection data
• The dimension (A1) is measured from the inside
face of the big end parent bore, to, the centre line Grade Original connecting rod grades
of the small end bush. For accuracy, measure the
dimension (A1) as close as possible to the H (high) A and B
connecting rod. Nominal C and D
To select the correct piston L (low) E and F
• If a new connecting rod or small end bush is fitted,
use the table opposite to, select the correct Piston dimensions
piston.
• If the piston is the only component to be renewed, Grade Heigth (1) minimum / maximum
the nominal grade must always be used. H 53,545/53,500 mm
Caution: All small end bushes supplied for service H 2.1080/2.1063 in
are concentric.
Nominal (2) 53,455/53,500 mm
Nominal (2) 2.1045/2.1063 in
L 53,410/53,455 mm
(1) Measured from centre line of gudgeon pin to piston L 2.1027/2.1045 in

crown
(2) The nominal grade piston and the production grade
X 131,99/132,02 (5.196/5.198)
piston have the same dimensions.
Cre 9-54880 Issued 05-03
Piston and piston ring
To inspect 13A-06
1 Check the piston for wear and other damage.
2 Check that the piston rings are free to move in

their grooves and that they are not broken.
3 Remove the piston rings, operation 13A-04, and

clean the piston ring grooves and the piston
rings.
4 Install new piston rings in the grooves in the

piston and check for wear of the grooves with
feeler gauges (A). Compare the piston ring
clearance in the groove to that given for new
components in Data and dimensions. Renew
the piston, if the grooves are worn too much.
5 Clean all carbon from the top of the cylinder

bores. Install each of the piston rings in the top
part of the cylinder bore and measure the ring
gap with feeler gauges (B).
6 The coil spring must be installed to the oil

control ring when the gap of this piston ring is
measured. The piston ring gaps for new and
oversize components are given in Data and
dimensions.
Cre 9-54880 Issued 05-03

Connecting rod
To inspect 13A-07

1 Check the connecting rod for distortion (A).
Note: The large and small end bores must be

square and parallel with each other within the
limits of +/- 0,20 mm (0.0007 in) measured 130
mm (5.1 in) each side of the connecting rod axis 4 Ream the bush to get the correct clearance
on a test mandrel. between the gudgeon pin and the bush, see the
Data and dimensions.
2 Check the small end bush for wear or for other
damage and renew it, if necessary. Caution: Do not use a letter stamp to mark the
connecting rod.
3 Check the install of the gudgeon pin in the small
end bush and check the gudgeon pin for wear, 5 Remove the original grade mark for the
see the Data and dimensions. connecting rod and etch an "X" instead to show
that a service small end bush has been installed
If necessary, renew the connecting rod, operation to the connecting rod.
13A-05A.
.
Small end bush
Notes :
• The small end bush that is supplied for service
has been machined concentrically. When it is
installed to the connecting rod, the new length will
become X, which is similar to production grade
'D'.
• Correct piston height must be maintained in
service to prevent damage to the piston and the
valves, and to make sure that the engine will
conform to emissions legisiation.
1 Press out the old bush with a suitable adaptor.
2 Clean the connecting rod bore and remove any

sharp edges.
3 Press in the new bush. Make sure that the

lubrication holes in the bush are aligned with the
holes in the connecting rod.
Cre 9-54880 Issued 05-03

Data and dimensions
which are shown are those which are mainly used in the factory. The information applies to all engines,
unless an engine type code is shown.
Pistons
Type
- UA engines ........................................................................................................ Re-entrant combustion bowl
- UB engines ......................................................................................................Flat top with recess for valves
Height of piston above top face of cylinder block ........................................0,386/0,511 mm (0.0152/0.0201 in)
Diameter of bore for gudgeon pin .......................................................... 30,003/30,009 mm (1.1812/1.1814 in)
Width of groove for top ring
- UA engines ..................................................................................................... 2,06/2,08 mm (0.081/0.082 in)
- UB engines ..................................................................................................... 2,08/2,10 mm (0.082/0.083 in)
Width of groove for second ring......................................................................... 2,06/2,08 mm (0.081/0.082 in)
Width of groove for third ring ............................................................................. 4,04/4,06 mm (0.159/0.160 in)
Service height grades ..................................................................... H, Nominal / Production (no marks) and L
Oversize piston ........................................................................................... 0,5 mm (0.020 in) on the diameter
Piston rings
Top compression ring ................................................................................................. Chromium / barrel faced
Second compression ring ............................................................................................ Taper face, barrel faced
Oil control ring........................................................................................... Coil spring loaded, chromium faced
Width of top ring ................................................................................................ 1,97/1,99 mm (0.077/0.078 in)
Width of second ring ......................................................................................... 1,97/1,99 mm (0.077/0.078 in)
Width of third ring .............................................................................................. 3,97/3,99 mm (0.156/0.157 in)
Clearance of top ring in groove
- UA engines ..................................................................................................... 0,07/0,11 mm (0.003/0.004 in)
- UB engines ..................................................................................................... 0,003/0,005 mm (0.09/0.13 in)
Clearance of second ring in groove ................................................................... 0,07/0,11 mm (0.003/0.004 in)
Clearance of third ring in groove ....................................................................... 0,05/0,09 mm (0.002/0.004 in)
Gap of top ring ................................................................................................... 0,20/0,48 mm(0.008/0.019 in)
Gap of second ring............................................................................................ 0,30/0,63 mm (0.012/0.025 in)
Gap of third ring ................................................................................................ 0,20/0,48 mm (0.008/0.019 in)
Continued
Cre 9-54880 Issued 05-03

Connecting rods
Type................................................................................................................................................. 'H' section
Diameter of parent bore for big end........................................................56,000/56,015 mm (2.2047/2.2053 in)
Diameter of parent bore for small end ....................................................32,930/32,955 mm (1.2964/1.2974 in)
Length between centres (parent bores) ..............................................159,975/160,025 mm (6.2982/6.3002 in)
Length grades .............................................................................................................. see operation 13A-05B
Big end bearings

Type.................................................................................................................Steel back, aluminium / tin face
Width .............................................................................................................22,87/23,13 mm (0.900/0.911 in)
Clearance on big end ................................................................................ 0,018/0,064 mm (0.0007/0.0025 in)
Thickness at centre of bearings ................................................................ 1,500/1,506 mm (0.0591/0.0593 in)
Available undersize bearings ........................................................................................... -0,25 mm (-0.010 in)
........................................................................................................................................ -0,51 mm (-0.020 in)
........................................................................................................................................ -0,76 mm (-0.030 in)
Gudgeon pins
Type............................................................................................................................................. Fully floating
Outside diameter.................................................................................... 29,995/30,000 mm (1.1809/1.1811 in)
Clearance install in piston boss ................................................................. 0,003/0,014 mm (0.0001/0.0006 in)
Small end bushes

Type..................................................................................................................... Steel back, lead bronze face
Inside diameter (reamed) .......................................................................30,012/30,025 mm (1.1816/1.1821 in)
Clearance install on gudgeon pin ...........................................................0,008/0,023 mm (0.00031/0.00091 in)
Cre 9-54880 Issued 05-03

Piston pins
Production:
Type ............................................................................................................................................. Fully floating
Outside diameter ................................................................................... 39,694/39,700 mm (1.5628/1.5630 in)
Clearance install in piston boss ................................................................. 0,003/0,015 mm (0.0001/0.0006 in)
Piston end bushings

Type ............................................................................................ Steel back, lead bronze tin bearing materials
Outside diameter ........................................................................................43,11/43,15 mm (1.6972/1.6988 in)
Inside diameter (reamed) ...................................................................... 39,723/39,738 mm (1.5638/1.5645 in)
Surface finish grade .......................................................................................................... Ra 0,8 micrometers
Clearance between bushing in piston end and piston pin .......................... 0,023/0,044 mm (0.0009/0.0017 in)
Cre 9-54880 Issued 05-03

Cre 9-54880 Issued 05-03

CRANKSHAFT ASSEMBLY 14A-01
Crankshaft assembly 14
Crankshaft pulley
14A-01A To install a wear sleeve .............................................................................14A.04
Rear oil seal
14A-02 To remove and to install ...........................................................................14A.05
Thrust washers
14A-04 To check crankshaft end-float ....................................................................14A.06
Main bearings
14A-06 To remove and to install (with the crankshaft in position) ...........................14A.08
14A-07 To inspect..................................................................................................14A.09
Crankshaft
14A-09 To inspect..................................................................................................14A.14
14A-14 To install a wear sleeve .............................................................................14A.14
14A-10A To overhaul ...............................................................................................14A.14
Cre 9-54880 Issued 05-03

14A-02 CRANKSHAFT ASSEMBLY
General description
The induction hardened crankshaft is a forging of

alloy steel and has five main bearing journals.
The crankshaft rotates in five pre-finished shell

bearings which have a steel back and an aluminium /
tin face. The shell bearings are held in position by
tags which install into recesses machined in the
bearing housings and the bearing caps.
The end-float of the crankshaft is controlled by two

half thrust washers, installed into the cylinder block,
either side of number four main bearing housing.
The crankshaft webs are drilled to give full rotation

balance.
To seal the crankshaft pulley and the palm of

crankshaft, Viton seals are installed in the timing case
and in the rear faces of the cylinder block / housing for
the rear main bearing. The seals include a dust lip to
the outside of the main lip and oil return grooves on
the face of the main lip.
Warning! Read the safety precautions for "Viton"

seals on page 10A.07.
For location, the crankshaft pulley is installed to the

nose of the crankshaft with a single key and is
retained by a plain washer and setscrew.
Cre 9-54880 Issued 05-03

Crankshaft pulley
To remove
1 Remove the drive belt, operation 23A-03.
2 Lock the crankshaft to prevent its

counterclockwise movement.
3 Release the setscrew (A2) which retains the

pulley and remove the setscrew and the thick
washer (A1). Remove the pulley.
Caution: Remove the device used to lock the

crankshaft.
4 Clean the components and check for damage.

Renew damaged components.
Note: If the surface for the oil seal is damaged

or there is a deep groove that has been caused
by the seal, it may be possible to install a wear
sleeve to the pulley, operation 14A-01A.
To install
1 Lubricate the main lip of the seal with clean

engine oil.
2 Install the pulley onto the key (B1) in the

crankshaft nose.
3 Lubricate lightly the threads of the setscrews

with engine lubricating oil. Install the thick
washer (A1) to the setscrew (A2) and install the
setscrew finger tight.
4 Lock the crankshaft to prevent its clockwise

movement.
5 Tighten the setscrew to 185 Nm (l 36 lbf ft) 19,0

kgf m
Caution: Remove the device used to lock the

crankshaft.
6 Install the drive belt, operation 23A-03.
Cre 9-54880 Issued 05-03

To install a wear sleeve 14A-01A
Note: It is not possible to install a wear sleeve

to the type of pulley shown (A). If the surface on
this pulley is damaged or there is a deep groove
that has been caused by the oil seal, the pulley
will have to be renewed. If the pulley installed
to the engine is the type shown in (B), then a
wear sleeve can be installed.
To install
With the pulley removed, carefully install the wear

sleeve (C1) in accordance with the manufacturers
instructions (supplied with the sleeve).
Make sure that the sleeve (C1) is installed correctly

(D1) to the pulley.
Cre 9-54880 Issued 05-03

Rear oil seal
Special tools:
Replacer tool for the rear oil seal, PD.255
To remove:
1 Remove the drive components from the rear
end of the engine.
2 Remove the starter motor
3 Remove the flywheel and the flywheel housing,

see section 22.
Caution: When the screws are installed to the seal,

do not damage the crankshaft palm or the recess
for the oil seal.
4 Install two small self-tapping screws and flat

washers (A3) into the front face of the oil seal
(A1).
Note: Install the screws 180° apart.
5 Use suitable levers (A2) and remove the seal.
To install Note: The seal will be installed correctly when it

protrudes 1,5 mm (0.06 in) (132) from the rear
1 Clean the crank palm and the recess for the oil face of the cylinder block / bearing cap.
seal and inspect them both for damage and
wear. If there is a deep groove in the crankshaft 4 Remove any excess oil from the seal and crank
palm that has been caused by the oil seal, it may palm.
be necessary to install a wear sleeve to the palm
of the crankshaft, operation 14A-10A.
2 Lubricate the lip of the oil seal with clean engine

lubricating oil. Carefully install the seal over the
crank palm and up to the rear face of the recess.
Note: Lubrication of the seal is necessary to

prevent damage to the lip of the seal when the
engine is first started.
Caution: Do not damage the crank palm when the

seal is installed.
3 With tool number PD.255 (A1), install the new

oil seal into the recess.
Cre 9-54880 Issued 05-03

Thrust washers
To check crankshaft end-float 14A-04
The end-float of the crankshaft is controlled by two

half thrust washers, installed into the cylinder block
(A1), either side of number four main bearing housing.
The end-float can be checked with a feeler gauge
(A2) between a thrust washer and the crankshaft or
by the use of a dial test indicator (B1) on one end of
the crankshaft.
If the end-float is more than the tolerance allowed,

oversize thrust washers are available to, reduce the
end float.
To remove
The thrust washers install in recesses machined into

the cylinder block (A1) each side of number four main
bearing cap. Make sure that the correct size thrust
washers are installed.
1 Remove the flywheel and flywheel housing, see

section 22.
2 Drain the lubricating oil and remove the

lubricating oil sump, operation 19A-03.
3 Release the two setscrews which retain number

four main bearing cap. Remove the setscrews
and carefully remove the bearing cap. Make
sure that the shell bearing remains installed
correctly to the cap and is kept clean.
Caution: If the crankshaft is rotated, the shell

bearing in the cylinder block may be pulled into an
incorrect position.
4 Remove the two thrust washers (A1). Use of a

suitable piece of plastic (A2) to push them out.
continued
Cre 9-54880 Issued 05-03

To install
1 Lightly lubricate the two thrust washers with

clean lubricating oil. Push (A2) each thrust
washer into position in the recess (A1) on each
side of the main bearing housing. The oil
grooves (B1) in the thrust washers must be
towards the crankshaft web.
2 Inspect the main bearing setscrews for damage

or distortion, renew them if necessary.
3 Make sure that the shell bearing is installed

correctly in the cylinder block.
4 Lubricate the bearing in the cap with clean

engine lubricating oil and put the bearing cap
into position.
5 Lightly lubricate the setscrew threads with clean

engine lubricating oil. Install the setscrews and
tighten them gradually and evenly to 147 Nm
(108 lbf ft) 15,0 kgf m. Rotate the crankshaft and
check the end-float, see operation 14A-04.
6 Install the sump, operation 19A-03. Fill the

sump to the correct level with an approved
lubricating oil.
7 Install the flywheel housing and the flywheel,

see section 22.
Cre 9-54880 Issued 05-03

Main bearings
To remove and to install

(with the crankshaft in position) 14A-06
Special tool:
Seal replacer tool, PD.243
Consumable products:
Produit Loctite Silicone adhesive
Note: The front and rear, bearing caps are

installed to the cylinder block with special
seals, see page 14A.13. 5 To remove the second or third bearing cap,
remove the suction pipe from the cylinder block,
To remove operation 19A-04. Release the setscrews of the
bearing cap and remove the bearing cap.
1 Drain the lubricating oil and remove the sump, Remove the lower half of the shell bearing from
operation 19A-03. the cap.
2 If the front main bearing cap is to be removed, 6 Use a suitable tool (A1) to push the upper half
proceed as follows: of the shell bearing from the side opposite to the
location tag. Carefully rotate the crankshaft to
- Remove the timing case and backplate, section release the bearing from its housing. Keep the
15. bearing halves in their relevant positions.
3 Release the setscrews of the front bearing cap continued

and remove the bearing cap. Remove the lower
half of the shell bearing from the cap.
4 If the rear main bearing cap is to be removed,

proceed as follows:
- Remove the flywheel and the flywheel housing,

see section 22.
- Release the setscrews of the bearing cap and

remove the bearing cap. Remove the lower half
of the shell bearing from the cap.
Notes:
• The rear bearing cap provides half of the reces for
the rear oil seal. When the cap is removed,
remove the seal and check for wear, renew if
necessary, operation 14A-02.
• The procedure to remove number four cap is the

same as for numbers two and three except that It
will not be necessary to remove the suction pipe.
Make sure also that the thrust washers remain in
position.
Cre 9-54880 Issued 05-03

To install
Caution: The shell bearings (A1) which do not

have an oil hole must only be installed to the cap. If
they are fitted to the cylinder block, the bearing will
not receive lubricating oil and cause a seizure of
crankshaft and bearings
1 Clean the upper half of the shell bearing and

lubricate the bearing surface with clean engine
lubricating oil.
2 Put the bearing (with the oil hole) onto the

journal and slide the plain end around between
the journal and the cylinder block until the tag is
installed correctly into the recess (A3). 10 Install the flywheel housing and the flywheel,
see section 22.
3 Clean the lower half of the bearing and the
bearing cap, lubricate the bearing surface with To inspect 14A-07
clean engine lubricating oil.
Inspect the bearings for wear and for other damage.
4 Install the bearing into the cap with the tag of the If a bearing is worn or damaged, replace both half of
bearing installed correctly in the recess (A2) in the shell bearings and check the condition of the other
the cap. bearings.
5 Install the bearing cap with the location tags of

both bearings on the same side.
6 Inspect the setscrews for damage and for

distortion and renew them if necessary. Lightly
lubricate the setscrew threads with clean engine
lubricating oil. Install the setscrews and tighten
them gradually and evenly to 147 Nm (108 lbf ft)
15,0 kgf m.
7 After each cap is tightened, make sure that the

crankshaft turns freely. If the thrust washers
have been removed and installed, check the
crankshaft endfloat, operation 14A-04.
8 If the front or rear main bearings were removed:

• Install the special seals to the front and rear
bearing caps, see page 14A.13
• Install the rear oil seal, operation 14A-02
• Check the alignment of the bearing caps with the
faces of the block, page 14A.12
• Install the backplate for the timing case assembly,
operation 15A-09
• Install the timing case assembly, operation
15A-01

19A-03. Fill the sump to the correct level with an
approved lubricating oil.
Cre 9-54880 Issued 05-03

Crankshaft
Produit Loctite Silicone adhesive
Special tools:
Seal replacer tool, PD.243
Warning! Use lift equipment or oblain assistance to

lift heavy engine components such as the flywheel,
the flywheel housing and the crankshaft.
To remove
Note: Numbers two, three and four main
Note: Case recommend, for safety reasons, bearing caps have an arrow and number (A2)
that this operation is done with the engine on the top to indicate front and sequence. The
upside down. This will ensure that the front and rear caps because of their shape, are
crankshaft can be lifted out and that the pistons easy to identify. The rear cap (A1) has no marks
will be retained in the cylinder bores. and the front cap (A3) has a number only.
1 Drain the lubricating oil. 12 Release and remove the setscrews for the main
bearing caps. Remove the main bearing caps
2 Drain the cooling system, operation 21A-04. together with the lower halves of the shell
bearings. Keep the bearings with the relevant
3 Remove the fan, operation 23A-03 and the drive caps.
belt.
Note: When the rear cap is removed, the rear
4 Remove the crankshaft pulley, operation oil seal will be exposed and should be removed.
14A-01.
13 Remove the thrust washers.
5 Remove the timing case, operation 15A-01.
14 Lift out the crankshaft. Remove the upper
6 Remove the idler gear, operation 15A-03. halves of the bearings and keep them with the
relevant caps.
7 Remove the starter motor, operation 23B-01.
Note: If the main bearings are to be used again,
8 Remove the flywheel and the flywheel housing, they must be installed in the same positions
see section 22. from which they were removed. The rear oil
seal should be renewed.
19A-03.
continued
10 Remove the lubricating oil suction pipe,
operation 19A-04.
11 Release and remove the nuts of the connecting

rods. Remove the big end bearing caps and
keep the bearings with the relevant caps,
operation 13A-01.
Cre 9-54880 Issued 05-03

To Install
Caution: The shell bearings (A1) which do not

have an oil hole must only be installed to the
bearing cap. If they are installed to the cylinder
block, the bearing will not receive lubricating oil
which will cause a seizure of crankshaft and
bearings
1 Make sure that all lubricating oil passages in the

crankshaft and cylinder block are clean and free
from restriction.
2 Clean the main bearing housings and the upper

halves of the shell bearings. Install the bearings
to the cylinder block. Make sure that the location
tags are correctly installed into, the recesses
(A3). Lubricate the bearings with clean engine
lubricating oil.
3 Make sure that the main journals of the

crankshaft are clean. Carefully put the
crankshaft into position on the upper bearings.
4 Clean and lubricate the thrust washers. Slide

them into the recesses in the the cylinder block
either side of number four journal. The grooves
in the thrust washers must be towards the
crankshaft (B1).
5 Clean the bearing caps and the lower half of the

bearings. Install the bearings to the caps with
the location tags installed correctly in their
recesses (A2). Lubricate the bearings with clean
engine lubricating oil.
6 Apply a small amount of silicone adhesive to the

corners of the cylinder block (C) for the rear
main bearing cap.
continued
Cre 9-54880 Issued 05-03

Note: Numbers two, three and four main
bearing caps have an arrow and number (A2)
on the top to indicate front and sequence. The
front and rear caps because of their shape, are
easy to identify. The rear cap (A1) has no marks
and the front cap (A3) has a number only.
7 Put the bearing caps in their correct positions.
8 Check the main bearing setscrews for distortion

and thread damage and renew them as
necessary. Make sure that only the correct
setscrews are used.
Note: Before the front and rear bearing caps

are fully tightened, use a straight edge (B) to
check their alignment with the front / rear faces
of the cylinder block.
9 Install the setscrews to the main bearing caps

and tighten them gradually and evenly to 147
Nm (108 1 lbf ft) 15, 0 kgf m.

crankshaft is free to rotate.
Caution: After the rear cap has been tightened, it

is important to remove any sealant from inside the
recess for the rear oil seal. If this is not done, the oil
seal will not install correctly and will cause oil
leakage.
11 Install the connecting rods and caps, operation

13A-01.

crankshaft is free to rotate.
continued
Cre 9-54880 Issued 05-03

Cautions:
• The seals for the front and rear bearing caps have
a curve at one end (A1) which must be installed
towards the side of the engine (A2,) and with the
curve inserted first into the hole.
• The seals have a soft metal insert. Be careful not
to bend the seal when it is first inserted into the
hole.
13 Inject a small quantity of sealant (A4) into the

holes for the seals, each side of the front and
rear main bearing caps.
14 Install the seals initially by hand (A3) and push,

approximately 30% of the seal into the hole.
15 Slide the tool PD.243, over each seal (B2) and

press the seals fully into their holes (B1).
16 Use a small drift (C1) to push the seal below the

surface of the cap until a resistance is felt; the
seal is now installed to the bottom of the hole.
Remove any excess sealant from around the
holes.
17 Install the two smaller seals to the holes (D), in

the front main bearing cap.
18 Install the lubricating oil suction pipe and

strainer, see section 19. Install the lubricating oil
sump, operation 19A-03.
19 Install the rear oil seal, operation 14A-02.
20 Install the flywheel housing and the flywheel,

see section 22.
21 Install the starter motor, operation 23B-01.
22 Install the backpIate for the timing case

assembly, operation 15A-09.
23 Install the timing case assembly, operation

15A-01.
24 Install the crankshaft pulley, operation 14A-01.
25 Install the drive belt, operation 23A-03 and the

fan,operation 21A-04.
26 Fill the lubricating oil sump to the correct level

with an approved oil.
Cre 9-54880 Issued 05-03

To inspect 14A-09
Check the crankshaft for wear and other damage. The

maximum permissible wear and ovality on the
crankshaft journals and crank pins is 0,04 mm
(0.0016 in).
The main journals and the crank pins of standard size

crankshafts can be machined to 0,25mm (0.010 in),
0,50mm (0.020 in) or 0,75 mm (0.030 in) undersize on
diameter, see data and dimensions at the end of this
section. Special undersize bearings are available.
If the seal position on the crankshaft palm is worn, a

wear sleeve can be installed to the palm, operation
The heat treatment is induction hardened
14A-10A.
To install a wear sleeve 14A-10

Note: Induction hardened crankshafts need not
To install be hardened after they have been machined
undersize.
1 Remove the crankshaft, operation 14A-08.
continued
2 Install the wear sleeve (A2), in accordance with
the manufacturer's instructions, supplied with
the sleeve. Make sure that the sleeve (A2) is
installed to the crank palm (A4) to a dimension
(A3) of 12,0 mm (0,47 in).
Caution: After the sleeve has been installed, the

curved part (A1) which is used to install the sleeve,
must be removed. If this is not done, when the
crankshaft is installed, the sleeve will be in contact
with the cylinder block. When the engine is started,
the sleeve, the cylinder block and the oil seal will be
damaged.
Crankshaft overhaul 14A-10A
Notes:
• Check the crankshaft for cracks before and after it
is ground. Demagnetise the crankshaft after it has
been checked for cracks.
• After the crankshaft has been machined, remove
any sharp corners from the lubricating oil holes.
• Surface finish and fillet radii must be maintained.
• Further information can be found in data and
dimensions at the end of this section.
Caution: After the crankshaft has been

overhauled, it must be thoroughly cleaned and the
oil holes inspected for débris.
Crankshaft heat treatment:
Cre 9-54880 Issued 05-03

Crankshaft overhaul
The finished sizes for crankshaft journals (A) which have been ground undersize are given in the table below:
item 0,25 mm (0.010 in) 0,50 mm (0.020 in) 0,75 mm (0.030 in)
1 64,70/64,72 mm 64,45/64,47 mm 64,20/64,22 mm

(2.547/2.548 in) (2.537/2.538 in) (2.527/2.528 in)
2 52,70/52,72 mm 52,45/52,47 mm 52,20/52,22 mm

(2.075/2.076 in) (2.065/2.066 in) (2.055/2.056 in)
3 33,00/33,04 mm (1.299/1.300 in) - -
4 32,80/34,20 mm (1.290/1.350 in) - -
5 32,95/33,05 mm (1.297/1.301 in) - -
6 30,05/32,95 mm (1.183/1.297 in) - -
7 94,965/95,000 mm (3.7837/3.7401 in) - -
8 3,30/3,70 mm (0.30/0.14 in) - -
Note: The surface finish for the journals, the crank pins and the fillet radii must be 0,4 microns (16
micro inches). The surface finish for the seal area of crankshaft palm must be 0,4/1,1 microns (16/43
micro inches).
Continued
Cre 9-54880 Issued 05-03

Data and dimensions
Introduction
which are shown are those which are mainly used in the factory.
Crankshaft
Diameter of main journals...............................................................................64,951,/64,970 mm (2.5571/2.5578 in)
Maximum wear and ovality on journals and crank pins ...............................................................0,04 mm (0.0016 in)
Width of front journal ...................................................................................................32,80/34,20 mm (1.29/1.35 in)
Width of number four journal ...................................................................................32,95/33,05 mm (1.299/1.300 in)
Width of all other journals ........................................................................................32,95/33,05 mm (1.297/1.301 in)
Diameter of crank pins.............................................................................................52,95/52,97 mm (2.085/2.085 in)
Width of crank pins ..................................................................................................30,05/32,95 mm (1.183/1.297 in)
Diameter of crankshaft palm............................................................................94,965/95,000 mm (3.7837/3.7401 in)
Depth of recess for spigot bearing...................................................................................11,6/12,6 mm (0.46/0.50 in)
Bore of recess for spigot bearing.....................................................................40,000/40,025 mm (1.5748/1.5757 in)
Crankshaft end-float ............................................................................................0,040/0,275 mm (0.0015/0.0108 in)
Maximum permissible end-float.................................................................................................0,405 mm (0.0159 in)
Fillet radii of journals and crank pins ...................................................................................3,3/3,7 mm (0.13/0.14 in)
Undersize journals and crank pins ............................................................................................. - 0,25 mm (0.010 in)
.................................................................................................................................................... - 0,50 mm (0.020 in)
.................................................................................................................................................... - 0,70 mm (0.030 in)
Crankshaft heat treatment

...................................................................................................................................................... Induction hardened
Crankshaft run-out
With the crankshaft on mountings at the front and rear journals, the maximum run-out (total indicator reading) at the
journals must not be more than shown below. Run-out must not be opposite. The difference in run-out between one
journal and the next, must not be more than 0,10 mm (0.004 in).
Journal Crankshaft
1 Mounting
2 0,08 mm (0.003 in)
3 0,15 mm (0.006 in)
4 0,08 mm (0.003 in)
5 Mounting
Cre 9-54880 Issued 05-03

Main bearings
Type........................................................................................................................... Steel back, aluminium / tin face
Width of bearing ..........................................................................................................25,70/26,00 mm (1.01/1.02 in)
Thickness at centre of bearing ............................................................................1,993/1,999 mm (0.0784/0.0787 in)
Clearance between bearing and journal..............................................................0,032/0,092 mm (0.0013/0.0036 in)
Available undersizes bearings.................................................................................................... - 0,25 mm (0.010 in)
.................................................................................................................................................... - 0,50 mm (0.020 in)
.................................................................................................................................................... - 0,75 mm (0.030 in)
Main bearings
Type.......................................................................................................... Steel back, lead / bronze bearing material
Position.......................................................................In cylinder block only, each side of number four main bearing
Thickness ....................................................................................................................................................................
- Standard..................................................................................................................................2,38/2,44 mm (0.0 in)
- Oversize ....................................................................................................................2,58/2,64 mm (0.102/0.104 in)
Cre 9-54880 Issued 05-03

Cre 9-54880 Issued 05-03

TIMING CASE AND DRIVE ASSEMBLY 15A-01
Timing case and drive assembly 15
Timing case
15A-01A to renew ...................................................................................................15A.05
Front oil seal
Idler gear
15A-04 To renew the bushes for the idler gear......................................................15A.08
Idler gear hub
Camshaft assembly for the fuel injection pump

Camshaft assembly and tappets for the valves

Crankshaft gear
Backplate for the timing case

Cre 9-54880 Issued 05-03

15A-02 TIMING CASE AND DRIVE ASSEMBLY
General description
The aluminium timing case assembly contains: the oil

seal (A2) for the crankshaft pulley; the support bush
(A1) for the camshaft gear; the lubricating oil pump
assembly (A5); the lubricating oil relief valve
assembly (A6); the adjustment screw (A4) to set the
maximum fuel position; and the fuel injection pump
linkage (A3). The governor weight assembly (B5) is
installed to the front of the gear for the fuel injection
pump.
The timing case assembly also covers the hardened

steel timing gears that have helical teeth to reduce
noise.
The drive from the crankshaft gear (B4), passes

through the idler gear (B2) to the gear (B3) for the
camshaft for the valves and the gear (B1) for the
camshaft for the fuel injection pump. It also passes to
the gear that drives the lubricating oil pump (A5). A
gear for a power take-off can be driven from the gear
(B3). The camshafts for the valves and the fuel
injection pump both rotate at half the speed of the
crankshaft gear.
The camshaft for the fuel injection pump is made from

steel with induction hardened cams.
Generally, the camshaft for the valves is made of cast

iron with chill-hardened cams. If the engine is installed
with a high-rated power take-off, a camshaft is used
that has a steel nose.
The oil seal (A2) which is made of Viton, operates on

the spigot of the crankshaft pulley. The seal has a
dust lip which protrudes from the front of the seal. This
lip protects the main lip of the oil seal.
Warning! Read the safety precautions for "Viton"

seals in section 10
Cre 9-54880 Issued 05-03

Timing case
To remove
2 Release the fasteners and remove the drive belt

and the alternator, section 23A.
3 If one is installed, remove the fan, operation

21A-03.
4 Remove the crankshaft pulley, operation

14A-01.
5 If one is installed, remove the auxiliary drive

6 Record the maximum fuel position of the fuel

control rack, 20A-11.
7 Disconnect the link (A1) for the governor

control, operation 20A-06.
8 Clean around the edge of the joint face of the

timing case assembly. If this is not done, dirt
may fall onto the timing gears when the timing
case assembly is removed.
Caution: The maximum fuel setting will be affected

if: a sealant is used on the joint faces of the timing
case or backplate; the joint faces are damaged
when the old joint is removed.
9 Remove the setscrews for the timing case

assembly. Note the position of the setscrews as
they are of different lengths and thread sizes. To
prevent damage to the threads, they must be
installed to the correct holes.
10 Hold the control link (A1) and carefully remove

the timing case assembly.
To install
1 If a new gear has been installed, check the

backlash (B). The backlash between the
crankshaft gear and the other gears that are in
mesh with it is 0,076 mm (0.003 in). The
backlash between the idler gear and the gears
for the camshafts is 0,05 (0.002).
continued
Cre 9-54880 Issued 05-03

if: a sealant is used on the joint faces of the timing
case or back plate; the joint faces are damaged
when the old joint is removed.
2 Clean the faces of the timing case assembly

and the backplate (B1). Install a new joint (B2),
without sealant, to the timing case assembly.
3 Make sure that the joint between the cylinder

block and the backplate is not damaged. Install
a new 'O' ring (B8) into the front of the idler gear
hub.
4 Make sure that the oil hole (B5) is not restricted

and lubricate the bush (B4) with clean engine.
Lubricate the teeth on all the gears with clean
engine oil.
Note: Before the timing case is installed, install

the adjustment screw for the maximum fuel to
its original setting and then release by two full
turns. Install the sealing washer and the lock
nut.
5 Hold the control link (B3), and put the timing

case assembly together with the new joint into
position on the studs (B6/B10), the dowels (B9),
and the spigot (B7) on the camshaft gear. At the
same time, it may be necessary to align the
teeth on the gear for the oil pump with teeth on 11 If one is installed, install the auxiliary drive
the crankshaft gear. assembly, operation 24A-01.
6 Install, finger tight, the fasteners to retain the 12 Install the crankshaft pulley, operation 14A-01.
timing case assembly.
13 Install the alternator and the drive belt, section
7 Install the governor control link (A1) and the 23A.
cover plate, operation 20A-06.
14 If one is installed, install the fan, operation
Caution: To make sure that there will be no side 21A-03.
loads on the camshaft gear, tighten the fasteners
for the timing case gradually and evenly, except for 15 Set the adjustment screw for the maximum fuel
the setscrew in the centre, which must be tightened setting.
last.
8 Tighten gradually and evenly, the M8 fasteners

for the timing case assembly to 22 Nm (16 lbf ft)
2,2 kgf m.
9 Tighten the M8 setscrew in the centre of the

timing case assembly to, 22 Nm (16 M ft) 2,2
kgf/m.
10 Check that the camshaft gear has a minimum

backlash of 0,05 mm (0.002 in).
Cre 9-54880 Issued 05-03

To renew 15A-01A
Caution: When the fuel injection pump linkage is

removed / renewed, or a new timing case is
installed, the setting for the maximum fuel may be
affected.
1 Remove the timing case assembly, operation

15A-01
2 Remove from the timing case assembly, the com-

ponents listed below:
• Lubricating oil pump assembly (A4), operation
19A-06
• Lubricating oil relief valve assembly (A5), opera-
tion 19A-08
• Engine speed control lever assembly (A3), opera-
tion 20A-09
• The fuel injection pump linkage (A1), operation
20A-10
• The adjustment screws for the maximum fuel set-
ting(B1), and the high idle (B2) and the low idle
(B3).
3 Install these components to the new timing case

assembly. Install the adjustment screw for the
maximum fuel setting to its original position.
Install the adjustment screws for the high and
low idle.

15A-01.
Cre 9-54880 Issued 05-03

Front oil seal
Special tools:
Replacer tool for front oil seal (main tool), PD.170
Adaptator for use with PD.170, PD.259
Adaptor plate for use with PD.170, PD260-4
To remove
2 Remove the drive belts, operation 23A-03. 7 Remove the replacer tool and lightly lubricate
the seal location area of the crankshaft pulley
3 Remove the crankshaft pulley, operation with clean engine lubricating oil. Install the
14A-01. crankshaft pulley, operation 14A-01.
4 Remove the oil seal with a suitable lever behind 8 Install the drive belt, operation 23A-03.
the main lip of the oil seal. Do not damage the
edge of the oil seal housing. 9 Connect the battery and start the engine. When
it has reached its normal temperature of
To install operation, stop the engine and check for oil
leakage around the seal.
1 Clean the oil seal housing. Inspect the new seal
for damage. If a scratch can be seen across the
lip of the seal, do not install the seal.
2 Lubricate the outer circumference of the oil seal

with clean engine lubricating oil and enter the
seal into the housing. Make sure that the spring
loaded lip of the oil seal is towards the inside of
the timing case assembly and that the oil seal is
square to the bore of the seal housing.
3 Install the adaptor, PD.259, (A8) to the nose of

the crankshaft (A7) and tighten the nut (A6). Put
the adaptor, PD.260-4, (A3) over the nose of the
crankshaft and against the seal (A4). Make sure
that the adaptor has the side stamped 700,
towards the seal.
4 Install the threaded bar, PD. 170, (A9) onto the

adaptor (A8).
5 Install a rod through the hole (A1) in the end of

the threaded bar to prevent movement of the bar
when the nut is tightened.
6 Tighten the nut with the washer (A2) against the

adaptor (A3) to push the seal into the housing.
Note: When the seal is installed correctly, the

rear face of the seal will be against the back
face of the recess (A5) in the seal housing.
Cre 9-54880 Issued 05-03

Idler gear
To remove
Note: When the timing marks on the gears are

aligned and the idler gear is removed, do not
rotate the crankshaft. If the crankshaft is
rotated, top dead centre (TDC) will have to be
set on number 1 cylinder, operation 17A-01.

15A-01.
2 Rotate the crankshaft until the marked teeth of

the crankshaft gear, the gear for the camshaft
for the valves, and the gear for the camshaft for
the fuel injection pump, are aligned with the
marked teeth of idler gear (A).
3 Remove the idler gear assembly (B2) from its

hub (B1).
4 Inspect the gear, the hub, the bushes (B3), and

the thrust washers (B4) for wear and other
damage. If necessary, renew the bushes,
operation 15A-04. If necessary, renew the idler
gear hub, operation 15A-05.
To Install
1 Make sure that the oil hole (B6) is not restricted

and that the hub is clean.
2 Make sure that the bushes (B3) are clean and

apply a small amount of clean engine lubricating
oil to their surfaces.
3 Install the two thrust washers (B4) correctly to

the idier gear with the oil grooves (B5), away
from the gear.
4 Slide the idler gear (B2) onto the hub (B11) with
the marked teeth of the idler gear, aligned with
the marked teeth of the crankshaft gear, the
camshaft gear and the gear for the fuel pump
camshaft (A).

15A-01.
Cre 9-54880 Issued 05-03

To remove and to install the
bushes for the idler gear 15A-04
To remove
Caution: When the bushes for the idler gear are

removed and installed, make sure that the teeth on
the gear are not damaged.
1 With the idler gear removed, use a suitable tool

to press out the old bushes (A2).
To install
Notes:
• The new bushes are supplied with an internal
diameter of 27,425/27,610 mm (1.0797/1.0870
in). After the new bushes have been installed,
they must be reamed to a finished size (131) of
28,077/28,098 mm (1.1054/1.1062 in).
• The installed position of the cut-outs (A1/B3) is
not important.
1 Make sure that the bore of the gear is clean and

is not damaged. Press a new bush into each
side of the gear until the edges with the cut-outs
(A1/B3), protrude (B2) 1,5/2,0 mm (0.06/0.08)
above the side face of the gear.
2 Ream the bushes to the correct size, see note

above.
Cre 9-54880 Issued 05-03

Idler hub
Special tools:
Remover tool (slide hammer) PD.184

Adaptator for use with PD.184, PD.258
Replacer tool for use with MS550, PD.256
Universal drive handle, MS.550
To remove

15A-01.
2 Remove the idler gear, operation 15A-03.
3 Install the adaptor PD.258 (A2), and the slide

hammer PD.184 (A1), to the hub (A4) for the
idler gear. Note the position of the oil hole (A3)
in the hub.
4 Use the slide hammer to remove the old hub

from the cylinder block.
To install
1 Before the new hub is installed, make sure that:

the oil hole (B4) is not restricted; the bore for the
hub is clean and free of debris; the edges (B5)
of the bore are smooth such that they will not
damage the new hub when it is installed.
2 With the oil hole (B2) towards the top, install the
new hub (B3) initially, with a soft hammer (B1)
until the edge of the hub is just inside the bore.
Make sure that it is square to the front face of
the cylinder block.
Caution: Make sure that the replacer tool is clean

and smooth, and does not damage the new hub
when it is installed.
3 Install the replacer tool (C2) onto the hub (C1),

and continue to install the hub to the cylinder
block. The new hub will be installed correctly
when the front face of the tool (D1) is in contact
with the cylinder block.
4 Make sure that the new hub is not damaged.

Install the idler gear, operation 15A-03.

15A-01.
Cre 9-54880 Issued 05-03

Camshaft assembly for the fuel
injection pump
To remove

15A-01.
2 Check that the camshaft end-float (A) is within

the limits shown in Data and dimensions.
Note: When the gear and the fuel pump

camshaft are removed, do not rotate the
crankshaft. If the crankshaft is rotated, top dead
centre (TDC) will have to be set on number one
cylinder, operation 17A-01.

marked teeth of idler gear (B).
4 Remove the lift pump, operation 20A-03.
5 Remove the fuel injection pump, operation 20A- B

06.
6 Remove the governor weight assembly, 20A-08.
7 Release the setscrew (C1) for the plate (C2)

that retains the camshaft bearing. Rotate the
plate 180° and tighten the setscrew. This will
hold the plate away from the bearing.
8 Remove the camshaft assembly (D), make sure

that the cams on the camshaft are not damaged.
Note: If the bearings, the cams or the gear is

worn, a new camshaft assembly will have to be
installed. If this occurs, the fuel injection timing
will have to be set, operation 17A-03.
continued
Cre 9-54880 Issued 05-03

To install
1 Make sure that ail bearing surfaces are clean.
2 Install the camshaft assembly (B). When the

camshaft gear and the idler gear are in mesh,
make sure that the marks on the gears are
aligned (A).
3 Release the setscrew (C1) for the plate that

retains the camshaft bearing. Rotate the plate
(C2) 180° and tighten the setscrew. The plate
will now be across the edge of the bearing and
prevent it from moving.
4 Install the governor assembly, operation

20A-08.
5 Install the fuel injection pump, operation

20A-06.
6 Install the lift pump, operation 20A-03.

15A-01.
Cre 9-54880 Issued 05-03

Camshaft assembly and tappets for the
valves
To remove
1 Remove the cylinder head assembly, operation

12A-07.

15A-01.
Note: When the timing marks on the gears are

aligned and the gear and the camshaft are
removed, do not rotate the crankshaft. If the
crankshaft is rotated, top dead centre (TDC) will
have to be set on number 1 cylinder, operation
17A-01.

4 Check that the camshaft end float (B) is within

5 Remove the tappets (C1) and note their correct

position for assembly.
6 Remove the two setscrews (D1) that retain the

thrust plate for the camshaft.
7 Remove the camshaft assembly (D3) from the

cylinder block, make sure that the cams (D2)
are not damaged.
8 Inspect the camshaft and the tappets for wear,

also inspect the gear and the camshaft bush.
Renew these components as necessary.
continued
Cre 9-54880 Issued 05-03

To install
1 Make sure that all the oil holes in the cylinder

block and on the camshaft (A4) are not
restricied. Clean the camshaft and lubricate the
journals, the cams and the teeth of the gears
with clean engine oil.
2 With the marked teeth on the camshaft gear

aligned with the marked teeth on the idler gear
(B), install the camshaft assembly (A3) to the
cylinder block, make sure that the cams (A2) are
not damaged during this operation.
3 Install the two setscrews (A1) that retain the

thrust plate for the camshaft.
4 Check that the camshaft end float (C) is within

5 Ensure that tappets are clean and that the oil

drain holes (D2) are not restricted. Lubricate the
tappets with clean engine oil and install them in
the correct positions and with the flat face (D1)
towards the cams.

15A-01.
B
12A07.
Cre 9-54880 Issued 05-03

Crankshaft gear
To remove

15A-01.

4 The crankshaft gear is an interference install on

the crankshaft. It may be removed with a
suitable puller. If this is not possible, it will be
necessary to remove the crankshaft, operation
14A-08, and press the gear off.
To install
Warning! Heat is used to install the gear, make sure

that suitable leather gloves are wom to protect the
hands.
1 To install the gear, it will be necessary to heat

the gear before it will install onto the crankshaft.
Heat the gear gradually to not more than 300°C
(572 °F). Do not use a flame as this can cause
local damage. Install the gear with the timing
marks towards the front.
2 Install the idler gear, operation 15A-03 and

make sure that all the timing marks are correctly
aligned.

15A-01.
Cre 9-54880 Issued 05-03

Backplate for the timing case
Caution: The setting for the maximum fuel position

may be affected when the timing case is removed.
To remove

15A-01.
3 Remove the camshaft assembly for the fuel

injection pump, operation 15A-06.
4 Remove the tappets and the camshaft assembly

for the valves, operation 15A-07.
5 Remove the backplate from the engine.

if: sealant is used on the joint faces of the timing
case or back plate; the joint faces are damaged
when the old joint is removed
To install
1 Remove the old joint from the faces of the

cylinder block (A5), and the backplate (A2).
2 Make sure that the joint faces are completely

free of the old joint. Install the backplate with a
new joint (A3), of the correct specification and
without sealant, onto the studs (A1/A4) and the
dowels (A6).
3 Install the tappets and the camshaft assembly

for the valves, operation 15A-07.
4 Install the the camshaft assembly for the fuel

injection pump, operation 15A-06.
5 Install the idler gear, operation 15A-03.

15A-01.
Cre 9-54880 Issued 05-03

Data and dimensions
Introduction
Timing case and drive assembly
Camshaft
Diameter of camshaft journals.........................................................................47,945/47,975 mm (1.8876/1.8887 in)
Clearance of journals in cylinder block:
- number one .......................................................................................................0,025/0,155 mm (0.0010/0.0060 in)
- number two, three, four and five........................................................................0,050/0,115 mm (0.0020/0.0040 in)
maximum permissible camshaft journal wear................................................................................0,05 mm (0.002 in)
Cam lift:
- Inlet............................................................................................................................7,06/7,16 mm (0.278/0.282 in)
- Exhaust .....................................................................................................................7,71/7,79 mm (0.289/0.293 in)
End-float:
- Production limit..........................................................................................................0,10/0,25 mm (0.004/0.010 in)
- Service limit .................................................................................................................................0,35 mm (0.014 in)
Camshaft thrust washer:
- Type .................................................................................................................................................................. 360°
- Thickness ..................................................................................................................2,30/2,40 mm (0.091/0.095 in)
Camshaft gear
Number of teeth.......................................................................................................................................................60
Fuel pump gear

Number of teeth.......................................................................................................................................................60
End float for fuel pump camshaft.............................................................................0,00/0,02 mm (0.0000/0.0008 in)
Crankshaft gear
Number of teeth.......................................................................................................................................................30
Diameter of bore..............................................................................................31,936/31,961 mm (1.2573/1.2583 in)
Diameter of crankshaft nose............................................................................31,979/32,000 mm (1.2590/1.2600 in)
Interference install of gear on crankshaft ................................................. - 0,018/ - 0,064 mm (- 0.0007/ - 0.0025 in)
Continued
Cre 9-54880 Issued 05-03

Idler gear and hub
Number of teeth.......................................................................................................................................................59
Diameter of bore of bushes in gear .....................................................................28,077/28,098 mm (1.054/1.062 in)
Diameter of hub installed to cylinder block ......................................................28,048/28,061 mm (1.1043/1.1048 in)
Clearance install of gear on hub..........................................................................0,016/0,050 mm (0.0006/0.0020 in)
Backlash for gears:
- Crankshaft to oil pump anf idler gears......................................................................... 0,76 mm (0.003 in) minimum
- Gears other than those referred to above ................................................................... 0,05 mm (0.002 in) minimum
Cre 9-54880 Issued 05-03

Cre 9-54880 Issued 05-03

CYLINDER BLOCK ASSEMBLY 16A-01
Cylinder block assembly 16
Cylinder block
16A-01 To disassemble and to assemble ..............................................................16A.03
16A-02 To inspect .................................................................................................16A.05
Cre 9-54880 Issued 05-03

16A-02 CYLINDER BLOCK ASSEMBLY
General description
The cast iron cylinder block is made without cylinder

liners. The cylinder bores are plateau honed with
silicon carbide tools to a controlled finish to make sure
long life and low oil consumption.
A bush is installed in the cylinder block for the

camshaft front journal, the other journals run directly
in the cylinder block.
Cylinder blocks that are supplied for service, are

installed with a steel back, copper / lead bush for the
camshaft front journal, and a new hub for the idler
gear.
Cre 9-54880 Issued 05-03

Cylinder block 12 Remove the cylinder head assembly, operation
12A-07.
13 Remove the auxiliary drive assembly, operation
24A-01.
14 Remove the crankshaft pulley, operation
Loctite 242e Nutlock 14A-01
Loctite Hylosil
Note: 15A-01.
• If the cylinder block is to be renewed, it may be
necessary to install new pistons and small end 16 Remove the backplate for the timing case
bushes, operation 13A-05A. This will occur if the assembly, operation 15A-09.
correct piston height above the block face cannot
be maintained with the original piston and 17 Remove the lubricating oil filter assembly, the
connecting rod assemblies, operation 13A-03A. If dipstick tube, the lubricating oil sump and the
all or most of the original pistons and connecting lubricating oil suction pipe, section 19.
rod assemblies cannot be used it may be cost
effective to install a short engine. 18 Remove the piston and connecting rod
• If the cylinder block is renewed, it will be neces- assemblies, operation 13A-03.
sary to check the timing of the fuel injection pump.
19 Remove the flywheel and the flywheel housing,
To disassemble section 22.
1 Disconnect the battery. 20 Remove the crankshaft and the rear oil seal,
section 14.
21 Inspect the cylinder block, operation 16A-02.
3 Drain the lubricating oil.
4 Disconnect as necessary, any electrical cables,

control wires, hoses and note where they are
installed.
5 Remove the engine from the vehicle or

machine.
6 Remove the alternator drive belt, the alternator

and the mounting brackets, section 23.
7 Remove the fan, the water pump and the

thermostat housing, section 21.
8 Remove the starter motor, operation 23B-01.
9 Remove the electrical stop solenoid, operation

23D-01.
10 Remove the high-pressure and the lowpressure

fuel pipes, the fuel filter, the fuel lift pump, the
atomisers and the fuel injection cassette pump,
section 20.
11 Remove the glow plugs, operation 23C-01.
Cre 9-54880 Issued 05-03

To assemble 18 Install the engine into the vehicle or machine.
1 Clean thoroughly the cylinder block. Make sure 19 Connect electrical cables, control wires and
that all the oil and all the coolant passages are hoses.
clean and free from debris.
2 If a new cylinder block is to be installed, remove
the threaded plugs from the old cylinder block 21 Fill the lubricating oil sump to the correct level
and clean the threads. Seal the threads with with an approved lubricating oil.
Loctite Nutlock, or a similar sealant, and install
the threaded plugs into the new cylinder block. 22 Connect the battery.
3 Install the crankshaft and the rear oil seal, 23 Eliminate air from the fuel system, section 20.
section 14.
24 Start the engine and check for fuel, lubricating
4 Install the flywheel housing and the flywheel, oil and coolant leaks. Allow the engine to reach
section 22. the normal temperature of operation before it is
stopped.
5 Install the piston and connecting rod
assemblies, operation 13A-03.
6 Install the lubricating oil suction pipe, the

lubricating oil sump and the lubricating oil filter
assembly, section 19.
7 Install the backplate for the timing case


15A-01.
9 Install the crankshaft pulley, operation 14A-01.
10 Install the auxiliary drive assembly, operation

24A01.

12A-07.
12 Install the glow plugs, operation 23C-01.
13 Install the fuel injection pump, the atomisers,

the fuel lift pump, the fuel filter, and the high and
the low pressure fuel pipes, section 20.
14 Install the electrical stop solenoid, operation

23D01.
15 Install the starter motor, operation 23B-01.
16 Install the thermostat housing, the water pump

and the fan, section 21.
17 Install the alternator, its mounting brackets and

the alternator drive belt, section 23.
Cre 9-54880 Issued 05-03

To inspect 16A-02
1 Clean the passages for the coolant and for the

oil.
2 Check the cylinder block for cracks and for other

damage.
3 The top face of the cylinder block must not be

machined as this will affect the piston height
above the top face of the cylinder block.
4 Check the condition of the cylinder bores.

The condition of a cylinder bore is decided by:
• The amount and location of any polished areas.
3 Check the cylinder bores for wear and other
• The amount of wear.
damage. The bores should be checked at the
• Damage to the cylinder wall.
top, the centre, the bottom and in two directions,
across the engine and along the centre line.
5 Check the camshaft bush for wear. If the bush is
If the cylinder bores are worn by more than 0,25
to be renewed, use a suitable adaptor to remove
mm (0.01 in), the bores can be bored and honed
the old bush. Do not damage the bore in the
0,5 mm (0.020 in) oversize in diameter and
cylinder block.
oversize pistons installed. To make sure that the
engine will conform to emissions legislation
Caution: Make sure that the oil holes in the bush
after it has been bored, the bores must bored
are aligned with the oil holes (A1) in the cytinder
and then diamond honed, silicon carbide base
block.
honed and then silicon carbide plateau honed to
the surface finish shown in Data and
6 When the new bush is installed, check in six
dimensions.
places, that the diameter (A2) of the bush is
correct.
Caution: If the cylinder block is to be bored, all
cytinders must be bored and new pistons installed
To check the condition of a cylinder bore
as a complete set.
1 Inspect the surface for cracks and deep
Specialist training and equipment is needed to
scratches.
machine the cylinder bores. For further
information contact your nearest Case Distributor.
2 Check for areas where the honed finish has
been polished away. Check especially the area
around the top of the bore just below the carbon
ring. In this area, there is maximum thrust from
the top piston ring.
Caution: An engine can have high oil consumption

with very little wear of the bores, if the surfaces of
the bores are glazed.
Cre 9-54880 Issued 05-03

Data and dimensions
Cylinder block assembly
Cylinder block
Height between top and bottom faces ....................................................360,95/361,05 mm (14.211/14.214 in)
Diameter of parent bore for main bearing........................................................69,000/69,019 mm (2.7165/2.7173 in)
Diameter of bores for camshaft:
- Number one (for bush) ................................................................................ 51,84/51,87 mm (2.041/2.042 in)
- Number two, three, four and five ......................................................... 48,025/48,500 mm (1.8904/1.9094 in)
Diameter of cylinder bores:
- UA engines ......................................................................................... 97,000/97,025 mm (3.8189/3.8199 in)
- UB engines ......................................................................................... 91,000/91,025 mm (3.5827/3.5837 in)
Maximum permissible wear in cylinder bore ......................................................................... 0,25 mm (0.01 in)
Oversize bores
Diameter of oversize cylinder bores before they are honed:
- UA engines ................................................................................................. 97,35/97,42 mm (3.833/3.835 in)
- UB engines ................................................................................................. 91,35/91,42 mm (3.596/3.599 in)
Surface finish ............................................................................................................. RA 3.0/5.0 micro-meters
Surface finish of the diamond hone

Hone angle (cross hatch) ..................................................................................................................... 30°/35°
Surface finish size, diamond honed:
- UA engines ......................................................................................... 97,467/97,472 mm (3.8373/3.8374 in)
- UB engines ..........................................................................................91,467/91,472 mm (3.6011/3.6012 in)
Grade of surface finish ............................................................................................... RA 2,2/3,0 micro-meters
Maximum ovality and taper..............................................................................................0,012 mm (0.0005 in)
Surface finish of the silicone carbide base hone

Hone angle (cross hatch) ..................................................................................................................... 30°/35°
Surface finish size, silicon carbide (base hone):
- UA engines .................................................................................................................97,507 mm (3.8388 in)
- UB engines .................................................................................................................91,507 mm (3.6026 in)
Grade of surface finish ............................................................................................... RA 1,3/1,6 micro-meters
Maximum ovality and taper..............................................................................................0,020 mm (0.0008 in)
Continued
Cre 9-54880 Issued 05-03

Surface finish of the silicone carbide plateau hone
Final surface finish size, silicon carbide (plateau hone):
- UA engines ......................................................................................... 97,500/97,525 mm (3.8386/3.8396 in)
- UB engines ......................................................................................... 91,500/91,525 mm (3.6024/3.6033 in)
Final surface finish grade, silicon carbide (plateau hone) ............................................... 0,65/1,3 micro-meters
Cre 9-54880 Issued 05-03

Cre 9-54880 Issued 05-03

ENGINE TIMING 17A-01
Engine timing 17
17A-01 To set accurately number 1 piston to TDC on the compression stroke ......17A.03
17A-02 To check the valve timing .........................................................................17A.04
17A-03 To check the timing of the fuel injection pump ..........................................17A.05
Cre 9-54880 Issued 05-03

17A-02 ENGINE TIMING
General description
Notes:
• The front of the engine is when seen from the
end with the timing case assembly.
• Number one cylinder is at the front of the engine.
The timing gears for the engine are stamped with

timing marks to make sure that they are assembled
correctly (A).
When the engine is set at top dead centre (TDC) on

the compression stroke for number one cylinder,
operation 17A-01, the timing marks on the fuel pump,
the camshaft and the crankshaft gears may not
necessarily be aligned. This may occur because the
gears rotate at different speeds.
The mark on the crankshaft pulley will be aligned with

the mark on the timing case when the piston for
number one cylinder is at TDC, see operation 17A-01.
The fuel injection pump installed to this engine is of

the in-line cassette type.
The gear for the fuel pump, the roller bearings and the
camshaft for the fuel pump, are supplied as an
assembly.
To adjust the timing of the fuel injection pump, a shim

(B1) of a specific size is installed between the flange
of the pump and the flange on the cylinder block. Six
different size shims are available. Included within the
thickness dimension of each shim, is an amount of
sealant that is necessary to prevent oil leakage from
the flange.
When the timing for the fuel pump has been set, it
should only alter if the camshaft for the fuel pump, or
the cylinder block are renewed. If this occurs, it will be
necessary to check the timing.
If the original fuel injection pump is removed and

installed for any other purpose, and a shim of the
same size is installed, the injection timing should not
alter.
The part number and code letters for the pump are
shown on the plate (B2). For timing details, see Data
and dimensions.
Cre 9-54880 Issued 05-03

To set accurately number 1 piston
to TDC on the compression stroke 17A-01
Special Tools:
Valve spring compressor, PD.6118B
Stud adaptor for use with PD.6118B, PD.244

operation.
Note: Clockwise / counter-clockwise direction is

when seen from the front of the engine.
2 Rotate the crankshaft, clockwise, until the push

rod for the inlet valve of the rear cylinder just
tightens. The piston for number one cylinder will
be near to TDC and the mark on the crankshaft
pulley should be near to the mark on the timing
case (A1).
3 Remove the spring clip and the spacer from the

front of the rocker shaft. Release the fasteners
of the first two pedestals of the rocker shaft.
Release the tappet adjustment screw and
remove the front rocker lever. Tighten the B
fasteners of the rocker shaft pedestals.
Caution: When the valve spring is removed, make

sure that the collets do not fall into the holes for the
push rods.
4 Remove the valve spring and the cap from the

front valve with the valve spring compressor
PD.6118B (B1) and the adaptor PD.244 (B2), for
the pedestal studs. Allow the valve to be held by
the top of the piston.
5 Fasten a dial test indicator with its plunger in

contact with the top of the valve stem (C1) and
with a reading shown on the gauge. Rotate
slowly, the crankshaft counter-clockwise 45°.
Then rotate slowly, the crankshaft clockwise
until the clockwise movement of the dial gauge
pointer stops.
6 With the pointer in the maximum clockwise

position, the piston for number one cylinder will
be at TDC on the compression stroke,
Cre 9-54880 Issued 05-03

To check the valve timing 17A-02
1 Check and, if necessary, adjust the valve tip

clearances, operation 12A-05.
2 Rotate the crankshaft, clockwise from the front,

until the valve (B7) is fully open. The piston for
number one cylinder is now on the compression
stroke.
3 Set the valve tip clearance for valve (B1) to 0,59

mm (0.023 in).

until the push rod for valve (B1) just tightens. In
this position, check if the mark (A1) on the
crankshaft pulley is within ±2.5° of the mark on
the timing case. If it is, the valve timing is
correct.
5 If the timing is more than 2.50 out of position,

the timing gears are probably not in correct
mesh.
Note: Use the formula below to find the

measurement on the pulley which is equal to 2.5°.
CxP
360
Where:
- C = the circumference of pulley
- P = 2.5°

valve (B8) has not closed completely. Set the
valve tip clearance of the valves (B1) and (B2)
to 0,35 mm (0.014 in).
7 Install the rocker cover, operation 12A-01.
Cre 9-54880 Issued 05-03

To check the timing of the
fuel injection pump 17A-03
The method used to check the timing of the fuel

injection pump is spill timing.
Notes:
• The timing marks on the crankshaft pulley and on
the timing case (A1) are not accurate enough
when the engine is spill timed.
• Clockwise / counter-clockwise direction is when
seen from the front of the engine.
2 Set the piston for number one cylinder to top

dead centre (TDC) on the compression stroke,
operation 17A-01.
3 With the dial gauge still on the first valve, rotate

the crankshaft counter-clockwise until the dial
gauge pointer moves counter-clockwise 5,08
mm (0.20 in).

23D-01.
5 Disconnect from the fuel injection pump, the fuel

inlet pipe (B3).
6 Disconnect the high-pressure fuel pipe (B1) for

number one outlet (B2).
Cautions:
• When the delivery valve holder (B2) is removed
from the pump, the crankshaft must not be rotated.
If this does occur, the injection pump will be
permanently damaged.
• Extreme care must be used with the components
(C) when the delivery valve assembly is removed
and installed during the spill timing procedure.
• The area inside the delivery valve chamber must
remain completely clean at all times.
7 Remove the delivery valve holder (B2/C1) for

number 1 cylinder and remove the delivery valve 8 To make sure that the valve seat will remain
(C4), the spring (C3) and the location pin (C2). centred, dry thoroughly the bottom face of the
Keep these components in clean diesel fuel. valve seat and the top face of the plunger
assembly. Put the valve seat onto the top face
Note: Because the pump is installed at an of the plunger and slowly rotate the seat. The
angle, when the delivery valve, spring and seat should then remain centred when the
location pin are removed, the delivery valve delivery valve holder is installed.
seat (C6) will slide to the side of the delivery
valve chamber. This will make it difficult to
install the holder (C1) to the pump. continued
Cre 9-54880 Issued 05-03

Caution: Do not tighten the delivery valve holder
uniess the components are aligned. If they are not,
the injection pump will be permanently damaged.
9 Install in the correct sequence, the holder (B1),

the washer (B5,) and the seat (B6) to the pump.
10 Connect a suitable clean tank, with a capacity of

approximately 0,75 litres (1.32 pints) and a
valve, to the inlet (A4) of the fuel pump.
11 Connect a swan neck pipe (A1) to the delivery

valve holder for number one cylinder. Put a
suitable container below the swan neck pipe to
retain the spilt fuel.
Note: The outlet from the tank should be

approximately 152 mm (6 in) above the pump.
This will make sure that the fuel is supplied to
the pump at a constant pressure.
12 Add 0,5 litres (0.9 pints) of clean fuel to the

container.
13 Open the valve.
14 Make sure that the lever (A3) is held in the

maximum fuel position during this procedure.
B
15 Turn the crankshaft slowly in a clockwise
direction, until the flow of fuel from the swan
18 Assemble the components of the delivery valve
neck pipe, is reduced to one drop every 7-10
assembly in the correct sequence (B) and install
seconds.
the assembly to the pump. Tighten the holder to
43 Nm (32 lbf ft) 4,3 kgf m.
16 Note the reading on the dial test indicator (A2).
Notes: the union nuts to 22 Nm (16 lbf ft) 2,2 kgf m.
• The reading on the indicator shows piston dis-
placement. For the correct displacement static
20 Install the low-pressure fuel pipe and tighten the
timing angles, see Data and dimensions.
banjo bolt to 22 Nm (16 lbf ft) 2,2 kgf m and the
• If it is necessary to adjust the timing, remove the
nut to 12 Nm (9 lbf ft) 1,2 kgf m.
pump and install a shim of the correct thickness,
operation 20A-06.
21 Remove the dial test indicator.
• To retard the timing; install a thicker shim. To
advance the timing; install a thinner shim.
22 Install the valve spring and cap, the rocker lever,
• The timing will change approximately 1° for each
the washer and the circlip and set the valve
0, 10 mm (0.004 in) of shim thickness.
clearance for number one inlet valve to 0,35 mm
• If the shim has to be changed, it will be necessary (0.014 in).
to repeat paragraphs 14 to 20.
• When the timing is correct, remove the swan neck
pipe and the tank assembly. 23 Install the rocker cover.
17 Remove the delivery valve holder from the
pump. 24 Install the electrical stop solenoid, operation
23D-01.
25 Connect the battery and start the engine. Check

for fuel and lubricating oil leaks.
Cre 9-54880 Issued 05-03

Data and dimensions
Introduction
which are shown are those which are mainly used in production.
Timing data
Fuel injection pump

Make ........................................................................................................ Zexel PFR-KX, in-line cassette type
Direction of rotation ...................................................................................................Clockwise from drive end
Fuel pump code letters ............................................................................................................ See table below
For identification purposes, a plate which shows the part number of the pump and the rating code letters is
installed to the side of the pump (17A.02/B2). An example of this is:
- Pump part number ......................................................................................................................... 2644D051
- Pump code letters ...................................................................................................................................... AJ
Timing details for fuel injection ................................................................................................ See table below
Timing data for 700 Series engines
Fuel pump Static timing position in Piston displacement

Engine type
code letters degrees before TDC mm in
UA AJ 16 2,54 0.100
UA BJ 16 2,54 0.100
UB CJ 14 1,93 0.076
UB DJ 10 1,004 0.040
Timing shims
Thickness mm (in)
0,1 (0.004)
0,2 (0.008)
0,3 (0.012)
0,4 (0.016)
0,5 (0.020)
Cre 9-54880 Issued 05-03

Cre 9-54880 Issued 05-03

ASPIRATION SYSTEM 18A-01
Aspiration system 18
Closed breather system

18A-01 To renew the engine breather assembly ...................................................18A.02
Cre 9-54880 Issued 05-03

18A-02 ASPIRATION SYSTEM
Closed breather system
The engine breather assembly is installed to the top

of the rocker cover and consists of: the breather cover
(A3); four setscrews (A2) to retain the cover; the
diaphragm and location ring assembly (A6) and the
spring (A5). The crankcase gases pass from the
breather assembly, through a pipe (Al) and into the
induction manifold.
To renew the engine breather

assembly 18A-01
Cautions:
• It is important that the area around the vent hole
(A7) is kept clean and the vent hole is not
restricied.
• Make sure that the pipe (A1), when installed, does
not contact other components as this may cause
the failure of the pipe.
• Make sure that the components of the breather
assembly are installed in their correct positions (A).
If they are installed incorrectly, the engine can be
damaged.
1 Release the four setscrews and remove the

breather cover.
2 Remove the diaphragm and location ring

Notes:
assembly (A6). Remove the spring (A5).
• The breather assembly (component numbers A5
3 Release the clips that retain the breather pipe and A6) should be renewed every 2000 hours.
and remove the breather pipe. • The breather pipe should be removed and
cleaned every 1000 hours.
4 Clean the breather cavity (A4) in the rocker
cover, the breather pipe (A1) and the vent hole
(A7). Make sure that the vent hole is not
restricted.
5 Install a new spring (A5) into the cavity in the

rocker cover.
6 Install a new location ring (B2) onto the new

diaphragm (B1) and install this assembly onto
the spring. Make sure that the location ring is on
the spring (A5).
7 Install the breather cover, Install and tighten the

four setscrews.
8 Install the breather pipe and tighten the clips.
Cre 9-54880 Issued 05-03

LUBRICATION SYSTEM 19A-01
Lubrication system 19
Filter canister
19A-01 To renew ...................................................................................................19A.03
Filter head
Sump
Oil strainer and suction pipe assembly

19A-05 To inspect ................................................................................................19A.06
Lubricating oil pump
19A-07 To inspect .................................................................................................19A.08
Relief valve
19A-09 To disassemble and to assemble ..............................................................19A.09
19A-10 To inspect .................................................................................................19A.09
Cre 9-54880 Issued 05.03

19A-02 LUBRICATION SYSTEM
General description An extra hole in the bore for each main bearing,
allows oil to pass through passages to lubricate the
Pressure lubrication is supplied by a rotor type pump
journals of the camshaft for the valves. The bush for
contained within the timing case. The pump is driven
the front journal has an oil supply from the front main
by the crankshaft gear.
journal of the crankshaft. The camshaft for the fuel
injection pump is lubricated by splash and oil mist.
Lubricating oil from the sump passes through a
strainer and pipe to the suction side of the pump.
Lubricating oil also passes from the upper pressure
rail through a hole drilled across the front of the
The pump has an inner rotor and an outer rotor which
cylinder block, which connects with a vertical passage
are off-centre to each other. The inner rotor has four
to the front of the cylinder head.
lobes which mesh with the five lobes of the outer
rotor. When the inner rotor rotates, the space
Oil passes through a passage from the front of the
between the lobes of the inner and outer rotors
cylinder head to a restriction in the first pedestal of the
increases to cause a suction as it passes the inlet
rocker shaft. The restriction reduces the oil pressure
chamber. The space between the lobes is then filled
to lubricate the rocker assembly. The oil passes
with oil. As the rotors pass the outlet chamber, the
through the rocker shaft to the bore of each of the
space decreases which causes a pressure increase.
rocker levers and leaves the bores through holes in
This forces the oil into the outlet chamber and into the
the top of the rocker levers. Oil passes along
relief valve.
channels in the top of the rocker levers to the valve
stems, the valve springs and the tappets which are
The lubricating oil, at increased pressure, passes
lubricated by splash and oil mist.
from the outlet of the pump to the relief valve, which is
contained within the timing case. As engine speed
The hub of the idler gear is lubricated by oil from the
increases the output of the oil pump increases, and
pressure rail and the timing gears are splash
more oil flows into the system. The increase in flow
lubricated. Lubricating oil from the timing case returns
causes an increase in pressure in the system. When
to the sump.
the oil pressure on the plunger of the relief valve is
greater than the spring pressure, the valve will open.
.
When the valve opens, surplus oil is returned to, the
sump. This action will reduce the oil pressure and the
valve will close.
Lubricating oil, at pressure, passes from the relief

valve chamber, along an oil pressure rail, which is
drilled the full length of the right side of the cylinder
block, and into the full flow oil filter. The oil passes
through the filter and up the centre tube into another
pressure rail, parallel to, but above the other pressure
rail. The oil filter can be installed in one of two
positions on the right side of the engine. The filter
canister is either installed to the cylinder block or is
installed to, a filter head, which is installed to the
cylinder block.
Lubricating oil passes through drilled holes in the

upper pressure rail, through passages in the main
journals of the crankshaft, to the main bearings.
Lubricating oil also passes through passages in the
crankshaft to the big end bearings. The small end
bearings, the pistons and the cylinder bores are
lubricated by splash and oil mist.
Cre 9-54880 Issued 05.03

Filter canister
To renew 19A-01
Warning! Discard the used canister and lubricating

oil in a sale place and in accordance with local
regulations.
Cautions:
• Make sure that the application is on a level
surface to make sure an accurate reading on the
dipstick.
• When the sump is filled with lubricating oil, make
sure that the level of the oil is not above the notch
(B2) on the dipstick. If the engine operates with
too much oil in the sump, the engine will be
damaged.
Note: Some applications have a separate filter

head that is installed to the cylinder block,
directly onto the filter mounting face, The filter
canister is then installed to the filter head. Use
the same procedure given below to change this
type of filter.
1 Put a tray under the filter to retain spilt

lubricating oil. Clean thoroughly the outside
surfaces of the filter assembly.
2 Use a strap wrench or similar tool to loosen the

filter canister. Remove and discard the canister.
Make sure that the adaptor (A1) is secure in the
filter head.
3 Clean inside the filter head, or the mounting

face.
4 Lubricate the seal (A2) on top of the canister

with clean engine lubricating oil.
5 Install the new canister and tighten by hand until

the seal contacts the filter head, or the mounting
face. Tighten the canister a further 1/2 to 3/4 of
a turn by hand only. Do not use a strap wrench.
Caution: Do not fill the sump past the notch (B2) on
6 Make sure that there is lubricating oil in the the dipstick.
sump. Make sure that the engine will not start
and operate the starter motor until oil pressure 7 Start the engine and check for leakage from the
is obtained. To make sure that the engine will filter. Stop the engine. After 15 minutes, check
not start, disconnect the electrical stop control the oil level on the dipstick and, if necessary, put
of the fuel injection pump. Oil pressure is more lubricating oil into the sump. Fill the sump
indicated when the warning light is extinguished to the notch (B2) on the dipstick (B1) with an
or by a reading on the gauge. approved lubricating oil.
Cre 9-54880 Issued 05.03

Filter head
1 Put a tray under the filter head to contain spilt

lubricating oil.
2 Remove the filter canister, operation 19A-01.
3 Release the setscrew (A1) and remove the filter

head (A3) from the cylinder block. Discard the
"0" rings (A2) on the setscrew. Discard the "0"
ring (A4) on the filter head.
4 Thoroughly clean the flange face of the filter

head and the flange face of the cylinder block.
Install the filter head together with a new "0"
ring. Install new "0" rings to the setscrew tighten
the setscrew to 80 Nm (59 M ft) 8,2 kgf m.
5 Install a new filter canister, operation 19A-01.
Cre 9-54880 Issued 05.03

Sump
Loctite Silicone adhesive
Warnings!
• Discard the used lubricating oil in a safe place
and in accordance, with local regulations.
• If a cast iron sump is used, it will be heavy, make
sure that there is enough support for the sump or
obtain assistance when it is removed or installed.
Cautions:
• Make sure that the application is on a level
surface to make sure an accurate reading on the
dipstick.
damaged.
Note: Some agricultural applications have an

engine with a divided sump to allow for a drive
shaft. If this sump is used, both drain plugs 6 Tighten all the fasteners to 22 Nm (16 lbf ft) 2,2
must be removed to make sure that all of the kgf m. Install the drain plug(s) together with a
lubricating oil is drained from the sump. new "0" ring and tighten the plug(s) to 34 Nm (25
lbf ft) 3,5 kgf m. Where necessary, install the
1 Remove the sump drain plug(s) and the "0" dipstick tube and the dipstick. Fill the sump to
ring(s) and drain the oil. If necessary, remove the notch (B2) on the dipstick (B11) with an
the dipstick and the dipstick tube. approved lubricating oil.
2 Provide a support for the sump. Remove the

setscrews and the two nuts which fasten the
sump to the cylinder block and to the timing
case. Lower the sump.
3 Wash the sump with an approved cleaning fluid,

make sure that all of the cleaning fluid is
removed. Thoroughly clean the flange faces of
the sump and the cylinder block and make sure
that they are free of oil or grease.
4 Put a bead of Loctite Silicone adhesive (A1)

along the flange of the sump.
5 Carefully install the sump onto the cylinder

block. Install a setscrew on each side of the
sump to make sure that it is in the correct
position. Loosely install the remainder of the
setscrews.
Cre 9-54880 Issued 05.03

Oil strainer and suction pipe assembly
The oil strainer (A1) is an integral part of the suction

pipe (A2). No regular service is necessary, but wash
the strainer assembly when it is removed.
1 Remove the sump, operation 19A-03.
2 Release the setscrew (A4) which holds the

bracket (A3) to the cylinder block. Remove the
suction pipe and strainer.
3 Remove the "0" ring (A5) from the hole in the

cylinder block for the suction pipe.
Caution: When the setscrew for the suction pipe

bracket is tightened, make sure that a downward
load (towards the block), is applied to the pipe (A2).
When installed, it should not be possible to move
the pipe by hand.
4 Install a new "0" ring into the groove (A6) in the

hole in the cylinder block for the suction tube.
Lubricate the "0" ring with clean engine
lubrication and install the suction tube. Put the
bracket in position and tighten the setscrew to
22 Nm (16 lbf ft ) 2,2 kgf m. Make sure that there
is no stress on the suction pipe.
To inspect 19A-05
5 Some engines have a different suction pipe to
that shown in (A). The other type has two 1 Wash the assembly in an approved cleaning
support brackets, one as in (A4), and a second fluid and dry it thoroughly.
one that is installed to the centre main bearing
cap. Tighten both setscrews to 22 Nm (16 lbf ft) 2 Check the pipe, the strainer and the welded
2,2 kgf m. joints for cracks and other damage. Check that
the mounting bracket is secure.
Cautions:
• Make sure that the application is on a level 3 If the strainer assembly is cracked or damaged,
surface to ensure an accurate reading on the it must be renewed.
dipstick.
damaged.
6 Install the sump, operation 19A-03, and fill the

sump to the notch (B2) on the dipstick (B1) with
an approved lubricating oil.
Cre 9-54880 Issued 05.03

To remove
1 Remove the timing case, operation 15A-01.
2 Release the three cap screws (A1) and remove

the oil pump (A2).
To install
1 Make sure that the flange face of the oil pump and
the flange face of the timing case for the oil pump
are clean. Align the two dowels (A3) and put the
oil pump in position. Install and tighten the cap
screws (A1) to 22 Nm (16 lbf ft) 2,2 kgf m.
2 Install the timing case, operation 15A-01.
Cre 9-54880 Issued 05.03

To inspect 19A-07
If any part is worn enough to have an effect on the

performance of the oil pump, the complete oil pump
must be renewed.
1 Remove the oil pump, operation 19A-06.
2 Remove the outer rotor and clean thoroughly all

the parts. Check for cracks and any other
damage.
3 Install the outer rotor and check the outer rotor

to body clearance with a feeler gauge (A).
4 Check the inner rotor to outer rotor clearance

(B).
5 Check the rotor end-float with a straight edge

and a feeler gauge (C). For all the above
clearances, see data and dimensions at the end
of this section.
6 Install the oil pump, operation 19A-06.
Cre 9-54880 Issued 05.03

Relief valve
The relief valve (A) is installed in the timing case and

prevents too much pressure in the lubricating oil
system. As engine speed increases the output of the
oil pump increases, and more oil flows into the
system. The increase in flow causes an increase in
pressure in the system. When the oil pressure on the
plunger of the relief valve is greater than the spring
pressure, the valve will open. When the valve opens,
surplus oil is returned to the sump. This action will
reduce the oil pressure and the valve will close. Oil
which passes the relief valve reaches the oil filter.
1 Release the relief valve (A2) from the timing case

(A1) and discard the "0" ring (A3).
2 Install a new "0" ring to the relief valve and install

the relief valve into the timing case. Tighten the
relief valve to 20 Nm (15 lbf ft) 2,0 kgf m.
1 Apply pressure to the end of the plunger (B2),

release and discard the circlip (B1). Carefully
release the pressure to remove the plunger and
2 Check the plunger for wear and other damage
the spring (B3) from the valve body (B4).
and make sure that it slides easily in the bore of
Remove the "0" ring (B5).
the relief valve.
2 Make sure that all the components are cleaned
3 Check the body for wear and other damage.
and then lubricated lightly with clean engine
lubricating oil.
4 Renew worn or damaged components.
3 Install the spring into the plunger and install the
plunger into the bore of the valve body. Apply
pressure to the end of the plunger and install the
circlip into its groove in the valve body. Release
the plunger. Install a new "0" ring.
To inspect 19A-10
Do not try to change the operation pressure of the

relief valve. If necessary, install new components.
1 Check the spring for wear and other damage

and, if possible, check the load necessary to
compress the spring to its installed length, see
data and dimensions at the end of this section.
Cre 9-54880 Issued 05.03

Data and dimensions
Introduction
Lubrication system

Type.....................................................................................................................Differential rotor, gear driven
Number of lobes ......................................................................................................Inner rotor 4, outer rotor 5
Maximum permissible clearance of outer rotor pump body ..................................................0,19 mm (0.007 in)
Inner rotor to outer rotor ......................................................................................................0,25 mm (0.010 in)
Inner and outer rotor end clearance ....................................................................................0,15 mm (0.006 in)
Lubricating oil relief valve

Diameter of bore in pump body .............................................................. 11,000/11,018 mm (0.5605/0.5625 in)
Outside diameter of plunger ...................................................................10,970/10,982 mm (0.5585/0.5595 in)
Clearance install of plunger in bore ........................................................... 0,018/0,048 mm (0.0007/0.0019 in)
Length of spring (installed) ..................................................................................................25,5 mm (1.004 in)
Load on spring (installed) ...........................................................................26,2/27,7 N (5.9/6.2 lbf) 2,7/2,8 kgf
Pressure to open valve ..............................................................240/290 kPa (34.8/42.1 lbf/in2) 2,4/3,0 kgf m2
Lubricating oil filter

Type............................................................................................................... Full flow, screw-on type canister
Pressure to open by-pass valve ............................................................ 55/83 kPa (8/12 lbf/in2) 2,4/3,0 kgf m2
Cre 9-54880 Issued 05.03

FUEL SYSTEM 20A-01
Fuel system 20

Fuel filter element
20A-01 To renew...................................................................................................20A.03
Atomisers
Atomiser fault ..........................................................................................20A.04
20A-02A To remove and to install - UA engines.......................................................20A.05
20A-02B To remove and to install - UB engines.......................................................20A.06
Fuel lift pump

20A-04 To disassemble and to assemble .............................................................20A.08
20A-05 To test .....................................................................................................20A.09
Fuel injection pump

20A-07 To eliminate air from the fuel system ........................................................20A.13
Fuel injection pump controls

20A-08 To remove and to install the governor weight assembly ............................20A.14
20A-09 To remove and to install the engine speed control lever assembly ............20A.15
20A-09A To renew the components of the engine speed control lever assembly .....20A.16
20A-10 To remove and to install the fuel injection pump linkage............................20A.17
20A-10A To renew the fuel injection pump linkage ..................................................20A.19
20A-11 To record the maximum fuel position of the fuel control rack .....................20A.21
20A-11A To set the adjustment screw for the maximum fuel setting ........................20A.22
Cre 9-54880 Issued 05-03

20A-02 FUEL SYSTEM
General description
Caution:
• The fuel injection equipment must only be
checked and adjusted by personnel who have
had the correct training.
• Do not allow dirt to enter the fuel system. Clean
thoroughly the area around all of the components
before they are removed and install suitable
covers to ail open connections.
The fuel injection pump used on the 700 Series

A
engine is a Zexel PFR cassette type pump (A) which
is installed directly into the cylinder block. The
The atomisers are set in the factory and must be
cassette, contains the delivery valves, the pump
checked in accordance with the preventive
elements and the fuel control rack.
maintenance schedules shown in the users's
handbook. The pressure at which the atomisers
The pump elements are operated by a separate
operate can be adjusted by a change of shim,
camshaft that is part of an assembly that is installed
installed above the spring. The setting pressures for
into the front of the cylinder block. The drive gear is
both types of atomiser are listed in Data and
driven by the idler gear.
dimensions.
The governor weight assembly is installed to, the front
The fuel lift pump is a diaphragm type and is
of the gear for the camshaft for the fuel injection
mechanically driven from an eccentric on the
pump. The linkage that operates the fuel injection
camshaft for the fuel injection pump. The pump is
pump is contained within the timing case assembly.
installed to the right side of the cylinder block and has
a priming lever.
The fuel injection timing, is set at the factory and
should only alter if the cylinder block or the camshaft
The fuel filter is a separate element type that is held
for the fuel injection pump are renewed. If this occurs,
between the filter head and a bottom cover. The filter
the timing will have to be checked and if necessary,
head is installed to the right, rear side of the cylinder
set to the correct figure. The timing is controlled by the
block.
use of a specific size shim (A1) that is installed
between the flange of the fuel injection pump and the
cylinder block. If the injection pump is removed, it can
be installed with a new shim, of the same size, and
the timing will not alter.
To assist cold starts, the rack of the fuel injection

pump is returned automatically to the excess fuel
position when the engine stops.
A data plate (A2) is installed Io the side of the pump

flange. The plate shows the part number and the code
letters of the pump. An example of this is:
2644DO51AJ
For full details of all pump codes, see Data and

dimensions.
The two stage atomiser for the UA engine is installed

to, the cylinder head with a clamp assembly. The
single stage atomiser for the UB engine has a
threaded body and fits directly into the cylinder head.
Cre 9-54880 Issued 05-03

FUEL SYSTEM 20A-03
Fuel filter element
To rerenew 20A-01
Cautions:
• It is important that only the genuine Case fuel filter
element is used. The use of a wrong efement can
damage the fuel injection pump.
• Do not allow dirt to enter the fuel system. Clean
thoroughly the area around all of the components
before they are removed and install suitable
covers to ail open connections.
1 Clean the outside surfaces of the fuel filter

assembly.
2 Hold the bottom cover of the filter element and

release the setscrew (A1) which is installed
through the filter head above the centre of the
element.
3 Lower the bottom cover (A6) of the filter.
4 Remove the element (A4) and discard it.
Warning! Discard the used canister and fuel in a

safe place and in accordance with local regulations.
5 Clean the inside surfaces of the filter head and

of the cover.
6 Renew the seals (A2 and A5) and the '0' ring (A3)
and lightly lubricate thern with clean fuel. The
larger seal is installed to the filter head and the
smaller seal is installer to the bottorn cover.
7 Put the bottom cover under the new element

and hold the element squarely to the filter head.
Make sure that the element is installed in the
centre against the '0' ring in the filter head. With
the assembly in this position, engage and tighten
the setscrew.
8 Eliminate the air from the fuel filter, see

operation 20A-07.
Cre 9-54880 Issued 05-03

20A-04 FUEL SYSTEM
Atomisers
Atomiser fault 20A-01
Warnings!
• If your skin comes into contact with high pressure
fuel, obtain medical assistance immediately.
• Keep a way from moving parts during engine
operation. Some moving parts cannot be seen
clearly white the engine runs.
An atomiser fault can cause an engine misfire.
In order to find which atomiser is defective, operate

the engine at a fast idle speed. Loosen and tighten the
union nut (A1/B1) of the high-pressure fuel pipe at
each atomiser. Do not loosen the union nut more than
half a turn. When the union nut of the defective
atomiser is loosened, it will have little or no effect on
the engine speed.
Cre 9-54880 Issued 05-03

FUEL SYSTEM 20A-05
To remove and to install:
- UA engines 20A-02A
Note: Identification letters for the atomiser are

shown on the nozzle holder (A2).
Caution: Do not allow dirt to enter the fuel system.

Before a connection is disconnected, clean
thoroughly the area around the connection. After a
component has been disconnected, install a
suitable cover to ait open connections.
To remove
1 Remove the fuel leak-off pipe. 2 Install the high-pressure fuel pipe and tighten
the union nuts to 22 Nm (16 lbf ft) 2,2 kgf m. If
Caution: Use a separate spanner to prevent necessary, install the pipe clamps.
movement of the outlets of the fuel injection pump
when the high-pressure pipes are released or 3 Renew the sealing washers and install the
tightened. leak-off pipe. Tighten the banjo bolts to 9 Nm (7
lbf ft) 0,9 kgf m.
2 Remove the union nuts of the high-pressure
pipe from the atomiser and from the fuel 4 Eliminate air from the fuel system, operation
injection pump. Do not bend the pipe. If 20A-07.
necessary, remove the pipe clamps.
5 Operate the engine and check for leakage of
3 Remove the setscrew (A7) of the atomiser fuel and air.
clamp and remove the clamp (A6), the spacer
(A5), the atomiser (A2) and its seat washer (A3).
To install
Caution: A new clamp (A5) must be used every

time the atomiser is installed to the engine.
1 Put the new atomiser in position together with a

new seat washer and a new 'O' ring (A1), make
sure that the sharp edges (A4) do not damage
the new "0" ring. Install the atomiser into the
cylinder head with a new clamp (A6) and spacer
(A5). Engage the screw, make sure that the
atomiser is not tilted and tighten the setscrew to,
22 Nm (16 lbf ft) 2,2 kgf m.
Cautions:
• If there is a leakage from, the union nut, make
atomiser inlet.
• Do not tighten the union nuts of the highpressure
pipes more than the recommended torque tension
as this can cause a restriction at the end of the
pipe. This can affect the fuel delivery.
Cre 9-54880 Issued 05-03

20A-06 FUEL SYSTEM
To remove and to install:
- UB engines 20A-02B
Loctite Atomiser thread sealant
Note: Identification marks for the atomiser are

stamped onto the side face of the nut (A4).
Caution: Do not allow dirt to enter the fuel system.

Before a connection is disconnected, cléan
thoroughly the area around the connection. After a
component has been disconnected, install a suitable
cover to all open connections.
Cautions:
To remove
1 Remove the fuel leak-off pipe.
atomiser inlet.
Caution: Use a separate spanner to prevent • Do not tighten the union nuts of the highpressure
movement of the outlets of the fuel injection pump pipes more than the recommended torque tension
when the high-pressure pipes are released or as this can cause a restriction at the end of the
tightened. pipe. This can affect the fuel delivery.
2 Remove the union nuts of the high-pressure pipe 3 Remove the plastic caps and install the
from the atomiser and from the fuel injection highpressure fuel pipes, Tighten the union nuts
pump. Do not bend the pipe. If necessary, remove to 22 Nm (l16 lbf ft) 2,2 kgf m. If necessary,
the pipe clamps. install the pipe clamps.
Caution: The atomiser must be loosened and 4 Renew the sealing washers and fil the leak-off
tightened with the nut (A4). Do not use the nut (A3) as pipe. Tighten the banjo bolts to 9 Nm (7 lbf ft) 0,9
this will split the body of the atomiser assembly. kgf m.
3 Use a 22 mm extended socket spanner to 5 Operate the engine and check for leakage of
remove the atomiser from the cylinder head. fuel and air.
4 Clean thoroughly the threads on the body of the 6 Eliminate air from the fuel system, operation
atomiser. 20A-07.
To install
1 Apply a 2 mm bead of Loctite atomiser thread

sealant to extend 6 mm around each of the first
two thread (A6). Make sure that the sealant does
not contact the body (A2) of the atomiser
Caution: Do not move the atomiser alter it has been

tightened, the seal that is made when torque has
been applied will be broken and corrosion of the
threads may occur.
2 Install a new flame shield washer (A1) with the red

identification mark to the top. Put the atomiser in
position together with a new seat washer (A5).
Tighten the nut (A4) of the atomiser to 39 Nm (29
lbf ft) 4,0 kgf m.
Cre 9-54880 Issued 05-03
FUEL SYSTEM 20A-07
Fuel lift pump
1 Disconnect the fuel pipes from the fuel lift pump.
2 Release the setscrews and remove the fuel lif

pump (A).
3 Make sure that the camshaft eccentric is in the

minimum lift position before the lift pump is
installed. Clean the joint face of the lift pump
and the cylinder block and install the lift pump
together with a new joint. Install the setscrews
and tighten them gradually and evenly to 22 Nm
(16 lbf ft) 2,2 kgf m.
4 Connect the fuel pipes.
5 Release the banjo bolt on the fuel filter head

and operate the priming lever of the fuel lift
pump to eliminate any air between the lift pump
and the fuel filter. Operate the lift pump until
fuel, free of air, comes from the banjo
connection. Tighten the banjo bolt.
6 Operate the engine and check for any fuel or air

leakage.
Cre 9-54880 Issued 05-03

20A-08 FUEL SYSTEM
Note: The only components that can be

renewed are: the inlet and the outlet valves and
seals; the diaphragm; the joint to install the
pump to the cylinder block
To disassemble
1 Clean the outside surfaces of the fuel lift pump.
2 Make a mark across the flanges of the two

halves of the pump to make sure correct
relationship when the pump is assembled.
3 Release the setscrews and separate the two

halves of the pump.
4 Turn the diaphragm assembly (A3) 90° to,

release the pull rod from the link arm (A6) and
remove the diaphragm assembly. Carefully
remove the stem seal (A4), the spring seat
washer (A5) and the spring (A7) from the pull
rod. The diaphragm and pull rod are renewed as
an assembly.
5 The valves (A2/A9) are peened into the upper

part of the pump body and can be removed with
a suitable lever. Some of the peened metal will
have to, be removed before the valves can be 3 Put the diaphragm assembly in position over the
removed. lower half of the body with the blade of the pull
rod aligned with the slot in the link arm. Press
6 Check the components for wear and other lightly on the diaphragm until the notch in the
damage. If components other than the valves pull rod is in the slot in the link arm and rotate
and the diaphragm are worn, the complete the diaphragm 90° in either direction. This
pump will have to be renewed action will engage and retain the pull rod in the
slot of the link arm.
To assemble
4 Push the rocker arm towards the pump body until
1 Thoroughly clean the valve housings. Intall new the diaphragm is level with the body flange and
seat washers (A1 /A8) and push the new valves install the top half of the body in position with the
(A2/A9) into position. As the valves are the marks on the flanges aligned. Keep the pressure
same, but one valve is installed in reverse of the on the rocker arm; install the spring washers and
other, it is possible to install the valves upside the screws and tighten them evenly
down. To make sure that the valves are installed
correctly, install them as shown in A. When the .
valves are correctly installed, peen the edge of
the valve housings in six places, evenly divided,
to keep the valves in position. Make sure that no
metal debris remains in the pump body.
2 Carefully install the diaphragm spring (A7) into

its location under the diaphragm (A3) and put
the spring seat washer (A5) and the stem seal
(A4) into position on the pull rod. Make sure that
the small diameter at the top of the seal is on the
round section of the pull rod.
Cre 9-54880 Issued 05-03
FUEL SYSTEM 20A-09
To test 20A-05
1 Disconnect the fuel outlet tube from the fuel lift

pump. Install a 0-70 kPa (0-10 lbf/in2) 0-0,7 kgf/
cm2 pressure gauge to the outlet of the lift
pump. Release the connection at the gauge and
operate the priming lever of the lift pump to
eliminate air from the tube. When fuel, free of
air, flows from the tube tighten the connection.
Make sure that there are no leaks at the
connections between the pump and the gauge.
2 Operate the starter motor for 10 seconds with

the engine stop control in the stop position or
with the stop solenoid disconnected.
3 Note the maximum pressure indicated on the

gauge. If the pressure indicated is less than the
test pressure of 31 kPa (4,5 lbf/in2) 0,32 kgf/m2,
repair or renew the pump. Also check the rate at
which the pressure reduces to half the
maximum pressure obtained. If this is less than
30 seconds, repair or renew the pump.
4 Remove the gauge and connect the outlet pipe

to the lift pump. Release the vent screw on the
fuel filter head and operate the priming lever
until fuel, free of air, flows from the vent screw.
Tighten the vent screw.
5 Connect the engine stop solenoid.
Cre 9-54880 Issued 05-03

20A-10 FUEL SYSTEM
Fuel injection pump
To remove to install 20A-06
The fuel injection pump is installed directly into the

cylinder block and is retained in position by two
dowels, four flanged setscrews and two flanged nuts.
The fuel injection timing is set at the factory and

should only alter if the cylinder block or the camshaft
for the fuel injection pump are renewed. If this occurs,
the timing will have to be checked and if necessary
set to the correct figure. The timing is controlled by the
use of a specific size shim that is installed between
the flange of the fuel injection pump and the cylinder
block.
If the fuel injection pump is removed for any other

reason, it can be installed again with a new shim, of
the same size, and the timing will not have altered.
For this operation, the position of the crankshaft is not
important.
Cautions:
• Clean around the edges of the fuel injection pump
before it is removed. Dirt may enter the inside of
the engine if this is not done.
• Use a separate spanner to prevent movement of
the outlets of the fuel injection pump, when the
high-pressure pipes are released or tightened. 6 Remove the support bracket / blanking plate
(B1) from the side of the cylinder block. Record
To remove the position of the four setscrews because on
some earlier engines, they are of different
1 Disconnect the battery. lengths.
2 Remove the fuel pipe (A3) that is installed

between the fuel injection pump and the fuel Continued
filter.
3 Remove the fuel pipe (A1) that is installed

between the fuel pump and the leak-off
connection on top of the fuel filter.
Caution: Use a separate spanner to prevent

movement of the outlets of the fuel injection pump
when the high-pressure pipes are released or
tightened.
4 Release the union nuts (A2) of the

high-pressure pipes from the atomisers and
from the fuel injection pump and remove the
pipes. Do not bend the pipes.

23D-01.
Cre 9-54880 Issued 05-03

FUEL SYSTEM 20A-11
7 Disconnect the spring (A1) from the groove in
the peg (A2) on the.
Caution: When the spring (A3) is disconnected

from, the peg (A2), it is possible for the spring to
become disconnected from the pin (A4). If this
occurs, the spring can fall into the sumpl
8 Disconnect the spring (A3) from the groove in

the peg on the rack.
9 Disconnect the governor control link (A5) from

the peg on the rack.
10 Remove the four flanged setscrews (A6), the

two flanged nuts (A7) and lift the pump from the
cylinder block.
To install
Cautions:
• Debris may fait into the engine if the hole in the
cylinder block for the pump is not protecied.
• When the pump is installed, new shim of the
correct size must be installed, without sealant. A
thin layer of sealant is included within the final
thickness of each new shim. Extra sealant will
affect the timing of the fuel injection.
1 Clean the surface of the flanges for both the 6 Install the spring (A1) into the groove on the
pump and the cylinder block. Install a new shim peg.
(B1) of the the correct size (see table opposite)
to the flange on the cylinder block.
Timing shims
2 Make sure that the peg (B2) is aligned with the
Part number Thickness mm (in)
cutout (B3) and that the shim is installed onto
the two dowels (B4). Carefully install the pump 3621F011 0,1 (0.004)
onto the studs and the dowels and make sure
that the link (A5) is not damaged. 3621F012 0,2 (0.008)
3621F013 0,3 (0.012)

3 Install the nuts (A7) and setscrews (A6) and
tighten thern evenly to 22 N m (16 lbf ft) 2,2 kgf 3621F014 0,4 (0.016)
m.
3621F015 0,5 (0.020)
4 Install the governor control link (A5) onto the
peg (A2) on the rack.
Continued
5 Install the spring (A3) to the groove in the peg
(A2) on the rack.
Caution: The spring (A1) must retain at all times,

the spring (A3) and the governor control link (A5)
onto the peg (A2). If the governor control link
becomes separated from the peg, control of the
engine speed will be lost!
Cre 9-54880 Issued 05-03

20A-12 FUEL SYSTEM
7 Clean the surfaces for the joint for the blanking
plate (A1). Install a new joint and the blanking
plate to the side of the cylinder block.
8 Install the stop solenoid, operation 23D-01.

the union nuts (B2) to 22 Nm (16 lbf ft ) 2,2 kgf
m.
Cautions:
atomiser inlet.
• Do not tighten the union nuts of the highpressure
pipes more than the recommended torque tension
as this can cause a restriction at the end of the
pipe. This can affect the fuel delivery.
10 Install the fuel pipe (B1) that is installed

between the pump and the leak-off connection
on the top of the fuel filter, and tighten the union
nuts to 20 Nm (15 lbf ft) 2,0 kgf m.
11 Install the fuel pipe (B3) that is installed

between the pump and the fuel filter and tighten
the union nuts to 20 Nm (15 lbf ft ) 2,0 kgf m.
12 Eliminate air frorn the systern, operation 20A-

07.
13 Connect the battery.
14 Operate the engine and check for leakage of

fuel and air.
Cre 9-54880 Issued 05-03

FUEL SYSTEM 20A-13
To eliminate air from the
fuel system 20A-07
If air enters the fuel system, it must be eliminated

before the engine can be started.
Air can enter the system if:

• The fuel tank is drained during normal operation.
• The low-pressure fuel pipes are disconnected.
• A part of the low-pressure fuel system leaks
during engine operation.
In order to eliminate air from the fuel system, proceed

as follows:
1 Loosen the vent plug (A1) on the side of the fuel

injection pump.
2 Operate the priming lever of the fuel lift pump

(A2) until fuel, free from air, comes from the vent
point. Tighten the vent plug.
3 Turn the start key to the "ON" position.
4 Operate the starter motor for intervals of 15

seconds until the engine starts. If the engine
runs correctly for a short time and then stops or
runs roughly, check for air in the fuel system. If
there is air in the fuel system, there is probably
a leakage in the low pressure system. Stop the
engine and turn the start key to the "OFF"
position.
Cre 9-54880 Issued 05-03

20A-14 FUEL SYSTEM
Fuel injection pump controls
The components listed below are part of the timing

case assembly and are used to control the engine
speed, performance and emissions: the governor
control lever (A1); the Angleich (torque control) unit
(A2); the adjustment screw for the maximum fuel
setting (A3); the engine speed control lever (A4); the
fuel control lever (A5); the governor control link (A6).
Items (A1), (A2), (A5) and (A6) are referred to as "the
fuel pump linkage" in operation 20A-10A. The
governor weight assembly (A7), is installed to the
front of the gear for the camshaft for the fuel injection
pump.
To remove and to install the

governor weight assembly 20A-08
To remove

15A-01.
2 Remove the thrust sleeve (B2) from the spigot

on the gear.
3 Remove the four flange face setscrews (B1) and

withdraw the weight assembly (B4) from the
front of the gear.
4 Check the components for wear and renew

them as necessary.
To install
1 Install the weight assembly (B4) with the four

flange face setscrews (B1) to the the front of the
gear and tighten the setscrews (B1) to 7 Nm (5
lbf ft) 0,7 kgf m.
2 Lubricate with clean engine lubricating oil, the

spigot on the gear and install the thrust sleeve
(B2). Make sure that the flange of the sleeve is
installed into the recess (B3) in each weight.
3 Move the thrust sleeve backwards and forwards

along the shaft, to make sure that the four
weights (B5) operate correctly.
Cre 9-54880 Issued 05-03

FUEL SYSTEM 20A-15
To remove and to install the engine
speed control lever assembly 20A-09
Consumable products
Loctite platelock
To remove

15A-01.
2 Remove the nut, the spring washer and the

plain washer from the shaft (A4) and withdraw
the lever (A1) from the shaft. Unless the lever or
the spring (A5) are to renewed, it will not be
necessary to disconnect the spring from the
lever.
3 Withdraw the lever assembly (B4) from the bush

(B3). Check the components for wear or
damage.
Caution: The bush (B3) is installed to the timing

case with a special adhesive and must not be
removed. If the bush is removed, the threads in the
timing case will be damaged.
To install
1 Clean and lubricate the shaft (B1) and the 'O'

rings (B2) with a smail quantity of grease. Install
the lever assembly (B4) into the bush (B3).
2 Make sure that both ends of the spring (A5) are

installed securely to both levers.
3 Install the lever (A1) with the spring onto the flat
section (A3) of the shaft.
Caution: Make sure that Loctite does not enter the

bush (A2).
4 Apply a small quantity of Loctite Platelock to the

threads of the shaft (A4). Install the plain
washer, the spring washer and the nut and
tighten the nut to 10,5 Nm (8 lbf ft) 1,1 kgf m.
Cre 9-54880 Issued 05-03

20A-16 FUEL SYSTEM
To renew components of the engine
speed control lever assembly 20A-09A
To renew
1 Remove the engine speed control lever

2 Remove the nut (A3).
3 Remove the lever (A2) from the shaft (A1).
4 Remove the '0' rings (A6) from the shaft.
5 Renew the components as necessary.
6 Install the '0' rings to the shaft.
7 Install the lever to the shaft. Make sure that the

lever is installed correctly to the key (A5) on the
shaft.
8 Make sure that the slot (A4) is clean. Install the

nut and tighten to a torque of 45 Nm (33 lbf ft)
4,6 kgf m.
9 Install the engine speed control lever assembly,

operation 20A-09.
Cre 9-54880 Issued 05-03

FUEL SYSTEM 20A-17
To remove and to install the fuel
injection pump linkage 20A-10
Consumable products
Loctite platelock
Note: The fuel injection pump linkage is

contained within the timing case assembly. The
linkage contains two lever assemblies, one for
the governor control and one for the fuel
control.

remove / renewed, or a new timing case is installed,
the setting for the maximum fuel may be affected.
To remove

15A-01.
2 Remove the nut, the spring washer and the flat

washer from the shaft (A4) and remove the lever
(A1) from the shaft.
3 Remove the brass plug (B1) from the side of the

timing case (B2).
4 Remove the two spring clips (C5) that hold the

levers (C3) and (C4) in position. Remove the
outer shaft (C1) that retains the inner shaft (C2).
Remove the inner shaft.
5 Remove the governor control lever assembly

(C3) and the fuel control lever assembly (C4).
Check the components for wear and renew as
necessary, operation 20A-10A.
Continued
Cre 9-54880 Issued 05-03

20A-18 FUEL SYSTEM
To install
1 Clean and lubricate the shafts (A1) and (A2)

with clean engine lubricating oil.
2 Install the inner shaft (A1) and then the outer

shaft (A2) into, the timing case assembly until
the inner shaft has just entered the lever
assembly (A3).
3 Align the holes in the lever (B1) with the holes in

the lever (B3). Continue to push the outer shaft
into the timing case assembly until the inner
shaft has passed through both the levers and
into the boss (B2). Install the clips (B4).
4 Install the plug (C1) with the sealing washer to

the timing case (C2). Tighten the plug to 13 Nm
5 Move the levers in both directions to make sure

that there is no restriction to their movement.
6 Make sure that both ends of the spring (D5) are

installed securely to the levers and install the
lever (D1) onto the flat section (A3) of the shaft
(D4).
Caution: Make sure that Loctite does not enter the

bush (D2).
7 Apply a small quantity of loctite Platelock to the

threads of the shaft (B4). Install the plain
washer, the spring washer and the nut and
tighten the nut to, 10,5 Nm (8 lbf ft) 1,1 kgf m.
8 Operate the lever for the engine speed control

to make sure that there is no restriction to
movement.

15A-01.
Cre 9-54880 Issued 05-03

FUEL SYSTEM 20A-19
To renew the fuel injection
pump linkage 20A-10A
Consumable products
Loctite platelock
Note: The fuel injection pump linkage is

contained within the timing case assembly. The
linkage contains two lever assemblies, one for
the fuel control (A) and one for the governor
control (20A.20/A).

remove / renewed, or a new timing case is installed,
the setting for the maximum fuel may be affected.
To disassemble the fuel control lever assembly
1 Remove the fuel injection pump linkage,

operation 20A-10.
2 Disconnect the spring (A3) from the pegs (A1/

A2).
3 Remove carefully, the spring (B3) from the

Angleich (torque control) unit (B1).
4 Remove the the Angleich unit.
5 Inspect the components for wear and renew as

necessary.
To assemble the fuel control lever assembly
Caution: Make sure that adhesive does not enter

the joint line (C2).
1 Apply a small amount of Loctite Platelock to the

first two threads (C1) and install the Angleich
unit to the lever. Tighten the Angleich unit to 18
Nm (13 lbf ft) 1,3 kgf m.
2 Install carefully, the spring to the Angleich unit.

Make sure that the closed coils (B3) are towards
the arm (B2).
3 Install the spring (A3) to the pegs (A1/A2).
Continued
Cre 9-54880 Issued 05-03

20A-20 FUEL SYSTEM
To disassemblele the governor control lever
assembly
1 Remove the circlip (B2) from the end of the pin

(A3).
2 Compress the spring (A4) and rernove, the pin

from the lever (A2).
3 Release the spring and remove it from the link

(A1).
4 Rernove the spring (A5) from the link.
5 Inspect the components for wear and renew as

necessary.
To assemble the governor control lever assembly
1 Install the spring (B6) to the link (B11). Make

sure the large hook is furthest from the lever
(B3).
Note: The purpose of the large hook is to retain

the governor link to the peg on the fuel control
rack.
2 Install the spring (B5) to the link.
3 Compress the spring and hold the link against

the outside of the lever (B3) and insert the pin
(B4).
4 Install the circlip (B2). To check that it is

installed correctly in the groove, rotate the
circlip.
5 Install the fuel injection pump linkage, operation

20A-10.
Cre 9-54880 Issued 05-03

FUEL SYSTEM 20A-21
To record the maximum fuel
position of the fuel control rack 20A-11
Special tool:
Lever clamp and rack setting tool, PD.254
The two lever assemblies of the fuel pump linkage

operate together to control the fuel settings and the
governor control of the engine.
The maximum fuel position of the fuel lever (and fuel

control rack) is controlled by the adjustment screw
installed to the top of the timing case. The position of
this screw is set at the factory and under normal
conditions of operation, it must not be altered. If the
timing case and fuel pump linkage are removed /
renewed, the adjustment screw must be set to give
the correct setting for maximum fuel.
1 Disconnect and remove the return spring from

the engine speed control lever.
Caution: Make sure that the components behind

the 'D' plug are not damaged.
2 Remove the 'D' plug (A4) from the timing case

(A1).
3 Remove the access plate (B1) from the cylinder

block.
4 Put the tool into the timing case such that the
end of the tool (C1) points downwards.
5 When the end of the tool (C2) is entered far into

the timing case, rotate the tool
counter-clockwise 90° (C5) to engage the lever
(C3). The end of the tool (C6) should now be
behind the lever (C8).
6 Tighten the adjustment screw (C4), finger tight,

to compress the Angleich unit between the two
levers. Make sure that the sides of the tool do
not touch the bore (A1) for the 'D' plug.
Continued
Notes:
• The Angleich, is a spring loaded component.
• The levers (C7/C8) should be compressed
between the end of the tool (A2/3).
• To Make sure that the tool has compressed both
the levers, move the tool backwards and
forwards. The peg should move with the tool.
7 Remove the low-pressure fuel pipes and the

fuel filter assembly.
Cre 9-54880 Issued 05-03
20A-22 FUEL SYSTEM
23D-01. Make sure that the joint is removed.
9 Install the setting tool (A3) to the flange for the

electrical stop solenoid.
Caution: During the setting procedure, make sure

that the fuel control rack (B2) is held in the
maximum fuel position.
10 Push (towards the rear of the engine) the tool

(B3) and the rack (B2) to the maximum (excess)
fuel position. With the rack held in this position,
turn carefully the adjustment screw (B1) of the
setting tool until the tip (A2) is felt to just touch
the end of the rack (A1). Tighten the nut (B5) to
lock the tool in this position.
11 Remove the clamp tool from the levers in the

timing case.
12 Disconnect the governor link from the peg (B2)

operation 20A-06, paragraphs 7, 8 and 9.
13 Remove the cap nut and record the setting

position for the screws for the maximum fuel
(C1), the high idle (C2) and the low idle (C3).
To set the adjustment screw

for the maximum fuel setting 20A-11A
Special tool:
Lever clamp and rack setting tool, PD.254
Loctite Platelock
Loctite 518 Liquid gasket

15A-01.
2 Install carefully, the clamp tool and tighten finger

tight only, the screw to compress the two levers
(D).
Continued
Cre 9-54880 Issued 05-03

FUEL SYSTEM 20A-23
Caution: During the setting procedure, make sure
that the fuel control rack (B2) is heid in the
maximum fuel position (towards the rear of the
engine).
3 Push the tool (B3) and the rack (B2) such that it
just touches the tip of the setting tool (A2). The
rack will now be in the maximum (excess) fuel
position. With the rack and tool held in this
position (C2) turn carefully the adjustment
screw (C1) for the maximum fuel setting until it
just touches the lever (D1).
4 Use a screwdriver (C3) to hold the adjustment

screw (C5) in this position, and tighten the lock
nut (C4) to 12 Nm (9 lbf ft) 1,2 kgf m.
5 Check that the rack and tool are still in the

maximum fuel position (B).
6 Install the sealing washer and the cap nut (C6)

and tighten the cap nut to 12 Nm (9 lbf ft) 1,2 kgf
m.
7 Set to their original settings, the adjustment

screws for the high and the low idle speeds.
8 Carefully remove the clamp tool for the levers.
9 Apply Loctite Liquid gasket to, the side faces of

the 'D' plug and fit the plug to the timing case.
10 Remove the setting tool and install the electrical

stop solenoid, operation 23D-01.
11 Install the fuel filter assembly and the low

pressure fuel pipes.
12 Check again that the governor link and springs

are installed securely and install the access
plate and joint.
13 Install the return spring to the engine speed

controi lever.
14 Eliminate air from the fuel system, operation

20A-07.
15 Connect the battery and control cables. Start

the engine and check for oil leakage, the
maximum no-load and idle speeds.
16 When the speeds are correct, seal against

interference, the adjustment screws for the
maximum no-load speed and the maximum fuel
setting.
Cre 9-54880 Issued 05-03

20A-24 FUEL SYSTEM
Data and dimensions
Introduction
Fuel injection pump

Make.................................................................................................................... Zexel PFR-KX in-line cassette type
Direction of rotation .............................................................................................................Clockwise from drive end
Fuel pump code letters:
- UA engines..................................................................................................................................................... AJ, BJ
- UB engines..................................................................................................................................................... CJ, DJ
Code letters, see table below :
Fuel lift pump

Type........................................................................................................................................................... Diaphragm
Method of drive.................................................................................... Eccentric on camshaft for fuel injection pump
Static pressure - no delivery ..........................................................................42/70 kPa (6/10 lbf/in2) 0,4/0,7 kgf/cm2
Test pressure 75% of minimum static pressure ....................................................... 31 kPa (4.5 lbf/in2) 0,32 kgf/cm2
Atomisers
Atomisers code letters:
- UA engines (two stage injection).......................................................................................................................... UA
- UB engines (single stage injection) ...................................................................................................................... UB
Setting pressures for atomisers
Set pressure (1) Re-set pressure (2)

Engine Code Bar (lbf/in2) Mpa Bar (lbf/in2) Mpa
type letter
Stage one Stage two Stage one Stage two
UA UA 190 (2793) 19,25 230 (3381) 23,3 200 (2940) 20,3 243 (3572) 24,6
UB UB 120 (1764) 12,2 --- 130 (1911) 13,2 ---
(1) For original atomisers

(2) For atomisers which have been overhauled (for example, installed with new springs)
Cre 9-54880 Issued 05-03

Cooling system 21
Thermostats
21A-01 To remove, to install and to test .............................................................. 21A.03
Coolant pump
21A-02 To remove and to install ..........................................................................21A.04
Fan
Cooling system
21A-04 To drain ...................................................................................................21A.06
21A-05 To fill .......................................................................................................21A.06
Cre 9-54880 Issued 05-03

21A-02 COOLING SYSTEM
General description
Coolant from the bottom of the radiator passes

through the centrifugal coolant pump, which is
installed onto the front of the cylinder block to assist
the flow of the coolant through the system.
The pump is driven by a 'V' belt from the crankshaft

pulley.
From the pump, the coolant passes into the front of

the cylinder block.
The coolant then passes around the cylinders and up

into the cylinder head.
The coolant leaves the cylinder head at the front and

passes into the thermostat housing.
When the engine is cold the thermostat is fully closed

and the coolant goes directly through a bypass valve
in the thermostat to the inlet side of the coolant pump.
As the engine warms the thermostat begins to open
and some of the coolant flows to the top of the
radiator. The thermostat will open fully when the
engine reaches the normal temperature of operation.
When the thermostat is open, the by-pass valve is
closed and the coolant passes to the top of the
radiator.
The thermostat maintains the correct engine

temperature by a balance of by-pass flow and full flow
to the top of the radiator.
Air passes over the radiator fins and heat is removed

from the coolant as it passes through the radiator. The
coolant leaves the radiator through the bottom hose
and returns to the coolant pump.
Cre 9-54880 Issued 05-03

COOLING SYSTEM 21A-03
Thermostats
To remove, to install and to test 21A-01
To remove
2 Release the clip (A1) from the outlet connection

and remove the hose.
3 Release the two setscrews (A2) and remove the

cap (A3) from the thermostat housing. Remove
the thermostat (A4).
To install
1 Make sure that the seat in the thermostat

housing for the thermostat is clean. Put the
thermostat (A4) into position in the housing.
Make sure that the jiggle pin (A5) is at the top,
see the arrow in A, and is free to move.
2 Make sure that the joint faces of the housing

and the cap are clean. Install a new joint to the
cap and install the cap to the housing. Tighten
the two setscrews to 22 Nm (16 lbf ft ) 2,2 kgf m.
Make sure that the outlet connection is clean and

install the hose. Tighten the hose clip. Fill the cooling
system, operation 21A-05.
.To test
1 Hang the thermostat unit in a suitable container

filled with coolant.
2 Heat the coolant gradually. Use a thermometer

to check the temperature at which the valve
starts to open and at which it is fully open. The
correct temperature is given in the Data and
dimensions.
Caution: If the thermostat does not operate

correctly, it must be renewed. Do not try to adjust
the settings.
Cre 9-54880 Issued 05-03

Coolant pump
To remove
2 Remove the drive belt, operation 23A-03.
3 Remove the fan, operation 21A-03, the fan

extension and the pulley.
4 Release the hose clips (A1). Remove the hoses

from the coolant pump.
5 Remove the four nuts (A2) that fasten the pump

to the cylinder block and remove the pump (B1)
from the engine.
6 Remove the spacer (B2).
To install
1 Thoroughly clean the mounting faces of the

cylinder block, the spacer (C1) and the rear
plate for the coolant pump.
2 Renew the "0" ring (C2) on each side of the

spacer and install the spacer.
3 Install the coolant pump to the timing case and

tighten the four nuts to 22 Nm (16 lbf ft) 2,2 kgf
m.
4 Connect the hoses to the coolant pump and

tighten the clips.
5 Put the pulley onto the hub and the fan

extension onto the pulley and install the fan,
operation 21A-03.
6 Install the drive belt, operation 23A-03.
7 Install the cooling system, operation 21A-05.
Cre 9-54880 Issued 05-03

Fan
To remove
Release the four setscrews and remove the fan. If

necessary, install the setscrews to retain the fan
extension and the pulley to the hub.
To install
Clean thoroughly the rear of the fan where it fits onto

the fan extension. Also make sure that all paint is
removed from this area. Put the pulley into position on
the hub and the fan extension onto the pulley. Clean
the front face of the fan extension. Install the fan and
tighten the setscrews to 22 Nm (16 lbf ft) 2,2 kgf m.
Cre 9-54880 Issued 05-03

Cooling system
To drain 21A-04
Warnings!
• Do not drain the coolant while the engine is still
hot and the system is under pressure because
dangerous hot coolant can be discharged.
• Discard used coolant in a safe place and in
accordance with local regulations.
1 Make sure that the machine is on a horizontal

surface.
2 Remove the filler cap of the cooling system. • Air will remain in the system if coolant is added
too quickly, or if coolant is added when the
3 Remove the drain plug (A1) from the side of the machine is not on a horizontal surface.
cylinder block in order to drain the engine. Make • If the engine is operated with air in the system,
sure that the drain hole is not restricted. the temperature of operation will be too high and
the engine will be damaged.
4 Open the tap or remove the drain plug at the
bottom of the radiator in order to drain the 1 Make sure that the machine is on a horizontal
radiator. If the radiator does not have a tap or surface.
drain plug, disconnect the hose at the bottom of
the radiator. 2 Slowly remove the filler cap of the header tank.
5 Flush the system with Loctite Easy Flush. 3 Slowly fill the cooling system to the correct level
as shown in the manufacturers handbook for the
6 Install the drain plugs and the filler cap. Close application. Allow time for air bubbles to be
the radiator tap or connect the radiator hose. released from the system and install the cap.
4 Start the engine. When it has reached its normal

To drain 21A-05 temperature of operation, stop the engine and
allow it cool.
Warnings!
5 Slowly remove the filler cap of the header tank
• If coolant is to be added to the system during and if necessary, add coolant to the correct level
service, allow the engine to cool before the as shown in the Operator’s Manual for the
coolant is added. Remove the filler cap slowly, machine. Install the filler cap.
dangerous hot coolant could be discharged if the
coofing system is still under pressure.
• Do not put too much coolant in the coofing
system. There is a relief valve in the filler cap
which will open and release hot coolant if too
much coolantis added.
Cautions:
• If coolant is added to the system during service, it
must be of the same specification as the original
that was used to fill the system. See "Coolant
specification" in section 5 of the users's
handbook.
Cre 9-54880 Issued 05-03

Data and dimensions
Introduction
Cooling system
Type............................................................................................................ Thermostat controlled - pump assistance
Water pump
Type.........................................................................................................................................Centrifugal, belt driven
Thermostat
Type.............................................................................................................................................Single, wax element
Nominal temperature stamped on the base "Start to open" "Fully open" tem- Minimum valve lift,
of the by-pass valve temperature perature fully open
82,0 °C 77/85 °C 92/98 °C 9 mm

(179.6 °F) (170.6/185.0 °F) (197.6/208.4 °F) (0.35 in)
76,0 °C 67/75 °C 85/88 °C 9 mm

(159.8 °F) (152.6/167.0 °F) (185.0/190.4 °F) (0.35 in)
Cre 9-54880 Issued 05-03

Cre 9-54880 Issued 05-03

FLYWHEEL AND FLYWHEEL HOUSING 22A-01
Flywheel and flywheel housing 22
Flywheel
Ring gear
Flywheel housing
Cre 9-54880 Issued 05-03

22A-02 FLYWHEEL AND FLYWHEEL HOUSING
General description
The flywheel is installed with a hardened starter ring.
The flyweel housing is normally made of cast iron.
Cre 9-54880 Issued 05-03

FLYWHEEL AND FLYWHEEL HOUSING 22A-03
Flywheel
Loctite 603 (oil tolerant)
Warning! The flywheel is heavy, use lift equipment

or get help to assist with the lift operation before
removal of the flywheel fasteners.
To remove
1 Remove two opposite setscrews from the

flywheel and install temporarily two guide studs
to make sure of safety when the flywheel is
removed and installed.
2 Remove the remainder of the setscrews and

washers and remove the flywheel.
3 Check the flywheel and ring gear for damage

and renew, if necessary.
To install
1 Make sure that the location faces of the

crankshaft and the flywheel are clean and free
from damage.
2 Install temporarily two guide studs in opposite

holes in the crankshaft palm to make sure safety
when the flywheel is installed. Install the
flywheel over the guide studs. Apply Loctite
Retainer (oil tolerant) to the first three threads of
the setscrews and Install four setscrews and
their washers. Remove the guide studs and
install the remainder of the setscrews and the
washers. Tighten the setscrews to 100 Nm (74
lbf ft) 10,2 kgf m.
3 Check the flywheel run-out with a dial test

indicator (A). This must be less than 0,30 mm
(0.012 in) total indicator reading.
4 Check the alignment of the flywheel face (B).

The error in alignment must not be more than
0,03 mm (0.001 in) total indicator reading for
every 25 mm (1.0 in) of the flywheel radius from
the crankshaft axis to the indicator plunger.
During this operation, keep the crankshaft
pressed toward the front to remove the effect of
crankshaft end-float.
Cre 9-54880 Issued 05-03

22A-04 FLYWHEEL AND FLYWHEEL HOUSING
Ring gear 2 Install the housing onto the dowels and tighten
the setscrews and the two cap screws to 44 Nm
3 Install the flywheel, operation 22A-01 and the
To remove starter motor, operation 23B-01.
Warning! wear eye protection during this operation.
Note: To make sure that the new ring gear is

installed correctly, record the direction of the
chamfer of the gear teeth. Install the new gear
with the chamfer in the saine direction.
To remove the ring gear use a hammer and a chisel

to break the ring. Make sure that the flywheel is not
damaged during this operation.
To install
The ring gear is heated onto the flywheel. When a

new gear is to be installed, make sure that it is not
heated to more than 250°C (480 °F). Make sure
that the chamfer on the teeth of the gear is in the
correct direction.
Flywheel housing
Warning! The flywheel housing is heavy, use lift

equipment or get help to assist with the lift
operation before removal of the flywheel housing
fasteners.
To remove
1 Remove the starter and the flywheel, operation

22A-01.
2 Release the six setscrews and the two cap

screws. Carefully hit the housing, with a soft face
hammer, to remove it from the dowels.
To install
1 Make sure that the rear face of the cylinder

block and the faces of the housing are clean and
free from damage. Make sure that the location
dowels are installed correctly. If a felt seal is
installed to the rear flange of the sump, replace
the seal.
Cre 9-54880 Issued 05-03

25-01
List of Special Tools 25
List of special Tools ...................................................................................................25A.02
These tools are available through your local Case Dealer
Cre 9-54880 Issued 0503

25-02
SPECIAL TOOLS
Number Description Illustration
PD.1D Remover/replacer for valve guides

(main tool)
PD.1D/2 Spacer used with main tool PD.1D
PD.1D-13 Adaptator for use with PD.1D
PD.41D Gauge for piston height, valve depth,

cylinder liner potrusion, for use with PD.208
PD.170
Replacer tool for seal of timing case cover

(main tool)
Cre 9-54880 Issued 0503

25-03
PD.184 Slide hammer
PD.208 Dial gauge for use with PD.41D
PD.243 Rubber plug replacer tool
PD.244 Adaptator for PD.6118B
PD.249 Adaptator for valve guide depth, used with

PD1D.13
Cre 9-54880 Issued 0503

25-04
PD.254 Kit, governor arm lock consists of tools to

measure rack movement
PD.255 Replacer tool for rear oil seal, use with

MS.550
PD256 Replacer tool for idler gear hub, use with

MS.550
PD.258 Adaptator / remover idler hub for use with

PD.184
PD.259 Adaptator / main tool to crankshaft nose, for

use with PD.170
PD.260 Adaptator for front seal, for use with PD.170
Cre 9-54880 Issued 0503

25-05
PD.6118B Valve spring compressor
MS.76A Set of adjustable cutters for valve seats
MS.550 Universal drive handle
MS.1519A Valve spring compressor
No.8 Piston ring compressor
Cre 9-54880 Issued 0503

25-06
Cre 9-54880 Issued 0503

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PERKINS NEW 700 SERIES

Copyright  2003 CNH France S.A.

General information ..................................................................................... 10

Cre 9-54880 Issued 05-03

Introduction ................................................................................................................. 10.02

Cre 9-54880 Issued 05-03

This workshop manual has been designed to provide

Warning! Read and remember the "Safety

The engines that are referred to in this manual are the

Where the information applies only to one engine

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

Special tools have been made available and a list of

Loctite recommended consumable products are listed

Data and dimensions are included at the end of each

Danger is indicated in the text by two methods:

Warning! This indicates that there is a possible

Caution: This indicates that there is a possible

Note: Is used where the information is

Cre 9-54890 Issued 05-03

Cre 9-54880 Issued 05-03

The 3,0 litre version, is a water cooled, naturally

The 2,6 litre version, is a water cooled, naturally

The engine number is stamped on a label (A) which is

An example of an engine number is:

The components of the engine number are as follows:

If you need parts, service or information for your

Cre 9-54890 Issued 05-03

Safety • Make sure that the engine is operated only from

Cre 9-54880 Issued 05-03

Engine lift equipment

Caution: If the sump contains engine lubricating oil

The maximum weight of the engine without coolant,

Before the engine is lifted:

Cre 9-54890 Issued 05-03

Some seals used in engines and in components

Viton is used by many manufacturers and is a safe

If Viton is burned, a product of this burnt material is

If it is necessary to come into contact with

• Make sure that the components have cooled.

If there is contamination of the skin or eyes, wash

Cre 9-54880 Issued 05-03

Cre 9-54890 Issued 05-03

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

Recommended torque tensions ..................................................................11B

Compression test data ...............................................................................11C

Cre 9-54880 Issued 05-03

Basic engine data 11A

Basic engine data...................................................................................................... 11A.02

Cre 9-54880 Issued 05-03

Induction system............................................................................................................................ Naturally aspirated

Valve tip clearances (cold):

Lubricating oil pressure (at normal engine temperature):

Cre 9-54880 Issued 05-03

Recommended torques tensions 11B

Recommended torques tensions

Special torque tensions ............................................................................................. 11B.03

Cylinder head assembly ............................................................................................ 11B.03

Cre 9-54880 Issued 05-03

Cre 9-54880 Issued 05-03

Standard torques tension for setscrews, studs and nuts

M6 x 1,00 9 7 0,9 5 4 0,5

Special torque tensions for setscrews and nuts