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Service Information Document Title: Function Group: Information Type: Date: Mechanical injection 236

Service Information

Document Title:

Function Group:

Information Type:

Date:

Mechanical

injection

236

Service Information

12/07/2011

D5D,

checking

and

adjusting

Profile:

Engine, D5D [GB]

 

Mechanical injection D5D, checking and adjusting

Determining injection angle and thickness of shim

NOTICE

Before determining injection angle, thickness of shim and installing the unit pumps, measure the control rod, see 236 Control rod, measuring

.

Injection angle (timing) and type of camshaft are indicated on the ID-plate.

To reduce white smoke at cold start, the later versions of D5D are equipped with hydraulic roller tappets. These engines are characterized by the EP-codes on the engine ID-plate having a value between 700–799.

Since the hydraulic roller tappets' height differs from the earlier, the unit pumps have different installation measurements. Thus different special tools are used for measuring the distance between roller tappet and the engine block.

the distance between roller tappet and the engine block. Figure 1 1. Shim 2. Hydraulic roller

Figure 1

1. Shim

2. Hydraulic roller tappet for reduction of white smoke

Op nbr

9998678 Measuring tool

9998679 Timing tool

11668408 Setting tool

9998685 Setting tool

Indicator

Magnetic base

NOTICE

9998685 Setting tool is used for engines with conventional roller tappets. 11668408 Setting tool is used for engines with hydraulic roller tappets to reduce white smoke

The following methods only need to be performed after replacing engine block, camshaft or a roller tappet. When only replacing a unit pump, see the section "Replacing unit pump".

Determining top dead centre

1. Install timing tool (protractor) 9998679 on the flywheel flange on the crank shaft.

NOTICE

Tighten the bolts thoroughly so that there is no clearance.

Tighten the bolts thoroughly so that there is no clearance. Figure 2 9998679 2. Secure the

Figure 2

9998679

2. Secure the indicator. Use a magnetic base.

2 9998679 2. Secure the indicator. Use a magnetic base. Figure 3 3. Position measuring rod

Figure 3

3. Position measuring rod 9998678 together with spacer washers above the piston relevant to the unit injector for which the injection angle is to be determined. Turn the crankshaft in the direction of rotation of the engine until the pointer has reached its turning point. Set the graduated ring on the dial test indicator to zero.

Figure 4 9998678 To reduce the risk of obtaining the wrong measurement when determining top

Figure 4

9998678

To reduce the risk of obtaining the wrong measurement when determining top dead centre, the following method must be performed:

4. Turn the crankshaft in the direction of rotation of the engine approx. 350° until there is 8 mm (0.315 in) left to the top dead centre (the turning point of the test dial indicator). Set the timing tool (protractor) 9998679 to zero.

Set the timing tool (protractor) 9998679 to zero. Figure 5 5. Turn the crankshaft in the

Figure 5

5. Turn the crankshaft in the opposite direction until there is 8 mm (0.315 in) left to the top dead centre (the turning point of the test dial indicator). Read off the timing tool (protractor) .

Example: 50°.

Read off the timing tool (protractor) . Example: 50°. Figure 6 6. Turn the crankshaft a

Figure 6

6. Turn the crankshaft a distance equal to half of the obtained reading.

Example: (0º + 50º) / 2 = 25º = Actual value. This corresponds to the top dead centre and should agree with the

turning point on the dial indicator.

turning point on the dial indicator. Figure 7 7. Set the timing tool (protractor) 9998679 to

Figure 7

7. Set the timing tool (protractor) 9998679 to zero.

NOTICE

Leave the timing tool (protractor) in position in preparation for the next stage in determining the injection angle.

for the next stage in determining the injection angle. Figure 8 Measuring tolerance deviation, engine block

Figure 8

Measuring tolerance deviation, engine block (engine without hydraulic roller tappets for reduction of white smoke)

We suggest copying the Value tables 1, 2 and 3.

8. Install the dial indicator on measuring tool 9998685, with a preload of 5 mm (0.20 in) on the millimetre scale.

The hollow cylinder's measurement, L e , is calibrated to 150 mm (5.905 in). Reset the scale ring to zero against the gauge pointer.

measurement, L e , is calibrated to 150 mm (5.905 in) . Reset the scale ring

Figure 9

1.

9998685

2.

Dial test indicator

3.

Pointer

4.

Millimetre graduation

5.

Graduated ring

9. Place the roller tappet without shim for the unit pump for which the timing is to be adjusted, on the base circle of the camshaft. Carefully insert 9998685 in the unit pump's hole.

Carefully insert 9998685 in the unit pump's hole. Figure 10 NOTICE Make sure that the guide

Figure 10

NOTICE

Make sure that the guide on the roller tappet engages the groove in the location.

10. Turn the crankshaft until it is certain that the roller tappet is on the camshaft's base circle.

that the roller tappet is on the camshaft's base circle. Figure 11 11. Measure " L

Figure 11

11. Measure "L" (L e - dial indicator X mm) and enter this in "Calculation table 2.2".

Example:

Measuring tool: L e = 150 mm (5.905 in) Dial indicator (X mm) = 2.18 mm (0.086 in)

The dial indicator shows 7.18 mm (0.283 in) when it is placed in the unit pump's hole. The preload was 5 mm. 7.18 mm (0.283 in) - 5 mm (0.197 in) = 2.18 mm (0.086 in)

L= 150 mm (5.905 in) + 2.18 mm (0.086 in) = 152.18 mm (5.991 in)

mm (5.905 in) + 2.18 mm (0.086 in) = 152.18 mm (5.991 in) Figure 12 Measuring

Figure 12

Measuring tolerance deviation, roller tappets and camshaft (engine without hydraulic roller tappets for reduction of white smoke)

12. Read off the injection angle, Fb nom on the engine type plate. Read off the lift of the camshaft, Vh nom i Value table 1. Enter both values in "Calculation table 2.1".

Example:

Fb nom = injection angle = 6.0 Camshaft type = A Vh nom = The value obtained on the timing tool (protractor) when the crankshaft has been turned so far that the camshaft has affected the tappet 6.11 mm (0.241 in).

Turn the crankshaft in the engine's rotational direction until the dial indicator shows - (minus) Vh nom 's value of 6.11

mm (0.241 in), which is the camshaft lift.

Example:

7 mm (0.2756 in) - 6.11 mm (0.241 in) = 0.89 mm (0.035 in).

The dial indicator was reset to 5 mm (0.1968 in) preload on the gauge, and when it shows 0.89 mm (0.035 in),

then Vh nom has been obtained.

Figure 13 13. The value shown on the timing tool (protractor) is the number of

Figure 13

13. The value shown on the timing tool (protractor) is the number of degrees at which the injection begins (e.g.

354.4°).

Example: 360° - 354.4° = 5.5°

Enter this value in the Calculation tables 2.1 and 3.1

Enter this value in the Calculation tables 2.1 and 3.1 Figure 14 14. Read off the

Figure 14

14. Read off the measurement "A" on the unit pump and enter this in the table Calculation table2.1.

Example: A / 100 = 0.63 mm (0.025 in).

Figure 15 15. Remove the measuring tool and the dial indicator. Conclude the calculations to

Figure 15

15. Remove the measuring tool and the dial indicator. Conclude the calculations to determine the shim thickness in Calculation table 2.2

NOTICE

Do not forget to change the EP-code on the engine's ID-plate.

forget to change the EP-code on the engine's ID-plate. Figure 16 16. Allow the shim to

Figure 16

16. Allow the shim to slide into position along, for example, a screwdriver and down into the roller tappet.

NOTICE

Repeat the measuring procedures described in points 12-16 for each unit injector.

into the roller tappet. NOTICE Repeat the measuring procedures described in points 12-16 for each unit

Measuring tolerance deviation, engine block (engine with hydraulic tappets for reduction of white smoke)

We suggest copying the Value tables 1, 2 and 3.

17. Install the dial indicator on 11668408, with a preload of 5 mm (0.20 in) on the millimetre scale.

The hollow cylinder's measurement, L e , is calibrated to 149.25 mm (5.876 in). Reset the scale ring to zero against the gauge pointer.

. Reset the scale ring to zero against the gauge pointer. Figure 18 1. 11668408 2.

Figure 18

1.

11668408

2.

Dial test indicator

3.

Pointer

4.

Millimetre graduation

5.

Graduated ring

18. Place the roller tappet without shim for the unit pump for which the timing is to be adjusted, on the base circle of the camshaft. Carefully insert 11668408 in the unit pump's hole.

Carefully insert 11668408 in the unit pump's hole. Figure 19 NOTICE Make sure that the guide

Figure 19

NOTICE

Make sure that the guide on the roller tappet engages the groove in the location.

19. Turn the crankshaft until it is certain that the roller tappet is on the camshaft's base circle.

Figure 20 20. Measure " L " (L e + Roller tappet's piston lift 1

Figure 20

20. Measure "L" (L e + Roller tappet's piston lift 1 mm - dial indicator X mm) and enter it in "Calculation table 2.2".

Example:

Measuring tool: L e = 149.25 mm (5.876 in)

The

dial indicator shows 5,94 mm when it is positioned in the unit pump's hole. The preload was 5 mm. 5.94 - 5

mm

= 0.94 mm

L= 149.25 mm (5.876 in) + 1 mm (0.039 in) - (+0.94 mm) (0.037 in) = 149.31 mm (5.878 in)

mm (0.039 in) - (+0.94 mm) (0.037 in) = 149.31 mm (5.878 in) Figure 21 21.

Figure 21

21. Read off the measurement "A" on the unit pump and enter this in the table Calculation table2.1.

Example: A / 100 = 0.86 mm (0.034 in).

Figure 22 22. Remove the measuring tool and the dial indicator. Conclude the calculations to

Figure 22

22. Remove the measuring tool and the dial indicator. Conclude the calculations to determine the shim thickness in Calculation table 2.2

NOTICE

Do not forget to alter the EP code on the engine type plate.

Do not forget to alter the EP code on the engine type plate. Figure 23 23.

Figure 23

23. Allow the shim to slide into position along, for example, a screwdriver and down into the roller tappet.

NOTICE

Repeat the measuring procedures described in points 17-25 for each unit injector.

procedures described in points 17-25 for each unit injector. Figure 24 Measuring control rod stroke for

Figure 24

Measuring control rod stroke for adjusting engine revolution governor

Op nbr

1. Measure the control rod's X-measurement from the face of the timing gear casing to the stop position.

Example of the X measurement: 1.1 mm (0.0433 in).

NOTICE

The measured value must be stated for when running in a test bench after completed repairs, alteration or modification of the governor with regard to the operating speed.

of the governor with regard to the operating speed. Figure 25 Determining the shim's thickness when

Figure 25

Determining the shim's thickness when changing unit pump

NOTICE

This may be done if no other machining has been carried out.

Mathematical formula for new shim thickness: T s = Ek - (L+ A / 100) True thickness of shim, S s , is obtained from Value table 2.

NOTICE

This formula only applies to replacement of unit pump.

Calculation table 1

 

Factor

 

Ex

 

D5D

 

Cylinder number

     

Cyl. 1

Cyl. 2

Cyl. 3

Cyl. 4

Unit pump serial number[ 1]

               

EP code (see Value table 3)

 

EP

 

751

       

Corrected installation measurement (se Value table 3)

E

k

 

143.275

       

Basic measurements of unit pump (see Value table 1)

L

-

136.8

       

Manufacturing tolerance (se marking on unit pump)

A/100

-

0,86

       

Theoretical thickness of shim

 

T

s

=

5.62

       

True thickness

of

shim

(see

S

s

5,60

       

Calculation table 2.2)

   

Example: Change of unit pump for cylinder 3 on a D5D with hydraulic roller tappets

Op nbr

1.

Read off the EP-code for cylinder 3 from the engine type plate in the column "EP", e.g. 751. Order of readings in the "EP" column on the engine type plate: line 1 = cylinder No. 1, line 2 = cylinder No. 2 and so on.

line 1 = cylinder No. 1, line 2 = cylinder No. 2 and so on. Figure

Figure 26 Engine type plate

2. Using the EP-code, read off the corrected installation measurement, E k for the unit pump from Value table 3.

Example: EP-code = 751 gives E k = 143.275 mm (5.641 in).

3. Read off the manufacturing tolerance for the unit pump's length A, from the new unit pump.

Example: Tolerance value A / 100 gives 86 / 100 = 0.86 mm (0.0339 in).

value A / 100 gives 86 / 100 = 0.86 mm (0.0339 in). Figure 27 Manufacturing

Figure 27 Manufacturing tolerance

NOTICE

If the value is not legible, remove any dirt, but not by scraping.

4. Read off the standard measurement for the unit pump, L, from Calculation table 1.

Example: 136.8 mm (5.3858 in)

5. Determine the theoretical shim thickness, T s , according to the formula: T s = E k -(L+ A / 100)(also see example in table Calculation table 1)

Example: T s =143.275 mm - (136.8 mm + 0.86 mm) = 5.62 mm (0.2213 in)

6. Select thickness of shim, S s , according to Value table 2.

Example: T s = 5.62 mm (0.2213 in) gives S s = 5.6 mm (0.2205 in).

Unit pump, installing

Op nbr

9998679 Timing tool

9998681 Rotation tool

9998684 Installation tool

1. Position the roller tappets together with associated shims.

Position the roller tappets together with associated shims. Figure 28 1. Control arm CAUTION Turn the

Figure 28

1. Control arm

CAUTIONtogether with associated shims. Figure 28 1. Control arm Turn the unit pump's link arm to

Turn the unit pump's link arm to the middle position.

2. Check that the cam on the unit pump is placed against the base circle for the relevant cylinder. Crank the engine with the aid of tool 9998681 or timing tool (protractor) 9998679.

NOTICE

The control rod must be locked in stop position with tool 9998684.

3. Coat the O-rings on the unit pump with oil. Carefully enter the unit pump into its location.

with oil. Carefully enter the unit pump into its location. Figure 29 1. Control rod 2.

Figure 29

1. Control rod

2. Shims for pump element

3. Roller tappet for pump element

CAUTION2. Shims for pump element 3. Roller tappet for pump element Check that the unit pump's

Check that the unit pump's link arm is in the control rod's groove before it is pressed down.

4.

Position the flange with the chamfer directed toward the body of the unit pump. Coat the bolts with oil and tighten them evenly. Tightening torque, see step 1 and 2, 030 Fuel system, tightening torques

1 a n d 2 , 030 Fuel system, tightening torques Figure 30 5. Carefully turn

Figure 30

5. Carefully turn the unit pump counter-clockwise. Use a torque wrench with gauge and socket 11668403. Make a note of the reading on the gauge on the torque wrench required to turn the unit pump, e.g. 3.5 Nm (2.6 lbf ft). Stop turning the torque wrench when the unit pump has reached its stop position and the torque has increased by1 Nm (0.74 lbf ft).

Example: 3.5 + 1 = 4.5 Nm (2.58 + 0.74 = 3.32 lbf ft)

ft) . Example: 3.5 + 1 = 4.5 Nm (2.58 + 0.74 = 3.32 lbf ft)

Figure 31

6. Tighten the bolts alternately according to

030 Fuel system, tightening torques

.

NOTICE

Check that the control rod moves easily after installing each unit pump

7. Repeat points 1-6 for the other cylinders.

NOTICE

Check that the control rod moves easily after installing each unit pump

Figure 32 1. 9998684 9. Measure from the tool to the control rod stop position.

Figure 32

1.

9998684

9. Measure from the tool to the control rod stop position.

Example: 30.5 mm (1.20 in)

to the control rod stop position. Example: 30.5 mm (1.20 in) Figure 33 10. Measure from

Figure 33

10. Measure from the measuring tool to the starting position for the control rod.

Example: 13.6 mm (0.535 in) The difference between the start and stop positions is the control rod stroke. Control rod's smallest stroke =16. 8 mm (0.661 in).

Example: Stop position = 30.5 mm (1.20 in) Starting position = 13.6 mm (0.535 in)

Control rod's stroke: 30.5 - 13.6 = 16.9 mm (1.20 - 0.535 = 0.665 in).

Determining thickness of shim when injector is to open

NOTICE

Determining the thickness of shim shall be done when changing engine block, camshaft or roller tappet.

Use Calculation table 2.1 and Calculation table 2.2below for calculating the shim's thickness.

Mathematical formula for determining new thickness of shim:

T s = L - ((Fb akt - Fb nom ) x Vh korr + Vh nom + L+ A / 100)

The true shim thickness can be found in Calculation table 2.2.T s S s

NOTICE

After the shim thickness has been determined, a new EP-code must alwaysbe retrieved from Value table 3 in order to allow a correct, future replacement of the pump.

Calculation table 2.1

 

Factor

 

Ex.

Engine D5D

 

Cylinder number

     

3

Cyl. 1

Cyl. 2

Cyl. 3

Cyl. 4

Unit pump serial number[ 2]

               

Injection

angle,

measured

on

timing

tool

Fb akt

 

5,5

       

(protractor)

Injection angle (see engine type polate)

 

Fb nom

-

6.0

       

Sum 1, (S1 = Fb akt - Fb nom )

 

S1

=

—0,5

       

Presetting, correction factor (see Value table 1)

 

Vh korr

x

0,14

       

Sum 2 (S2 = S1 x Vh korr )

 

S2

=

0,07

       

Camshaft lift (see Value table 1)

 

Vh nom

+

6,11

       

Basic measurement on unit pump (see Value table

L

+

143

       

1)

Manufacturing tolerance (see Unit pump)

 

A/100

+

0,63

       

Sum 3 (S3 = S2 + Vh nom + L+ A / 100)

 

S3

=

149,67

       

Calculation table 2.2

 

Code

 

Ex.

Cyl. 1

Cyl. 2

Cyl. 3

Cyl. 4

Length between cylinder block and roller tappet

 

L

 

151,43

       

Sum 3 (S3 = S2 + Vh nom + L+ A / 100)

 

S3

-

149,67

       

Theoretical thickness of shim

 

T

s

=

1,76

       

True thickness of shim (see Value table 2)

 

S

s

1.8

       

Determining corrected installation measurement, E k , and EP code for unit pump

When replacing cylinder block, camshaft or roller tappet, the corrected installation measurement, E k , must be determined again and the EP code and the engine type plate must be altered.

Mathematical formula for the corrected installation measurement, E k The following applies to engine without hydraulic roller tappets for reduction of white smoke:

E k = L - ((Fb akt - Fb nom ) x Vh korr + Vh nom

The following applies to engine with hydraulic roller tappets for reduction of white smoke:

E k = L - Vh nom

New EP-code can be calculated in Calculation table 3.2 where the E k - value gives a new EP-code in Value table 3.

Calculation table 3.1

 

Code

 

Ex.

 

Engine D5D

 

Cylinder number

 

-

-

-

Cyl. 1

Cyl. 2

Cyl. 3

Cyl. 4

Unit pump serial number[ 3]

 

-

-

         

Injection

angle,

measured

on

timing

tool

Fb akt

 

5,5

       

(protractor)

Injection angle (see engine type polate)

 

Fb nom

-

6.0

       

Sum 1, (S1 = Fb akt - Fb nom )

 

S1

=

–0,5

       

Correction factor (see Value table1)

 

Vh korr

x

0,14

       

Sum 2, (S2 = S1 x Vh korr )

 

S2

=

–0,07

       

Camshaft lift (see Value table 1)

 

Vh nom

+

6.11

       

Sum 3, (S3 = S2 + Vh nom )

 

S3

=

6.04

       

Calculation table 3.2

 

Code

 

Ex.

   

Engine D5D

 

Cylinder number:

   

-

 

Cyl. 1

Cyl. 2

Cyl. 3

Cyl. 4

Length between cylinder block and roller tappet

L

-

151.43

         

Sum 3, (S3 = S2 + Vh nom )

 

S3

-

6.04

         

E k (E k = L - S3)

 

E

k

=

145.39

         

E k , rounded to the nearest value in Value table 3

E

k

145,40

         

EP code (E k results in EP code in Value table 3)

EP

=

337

         

Unit explanations

 

Unit explanations

 

Code

 

Factor

Explanation

Fb akt

 

°FÖD

Injection angle, measured on timing tool (protractor) according to method

 
 

BTDC)

 

Fb nom

 

°FÖD

Injection angle, can be found on engine type plate

 

BTDC)

 

Vh korr

 

mm/°FÖD

Pre-tension, correction factor can be found in Value table 1

 
 

(in/°BTDC)

 

Vh nom

 

mm

Camshaft lift, nominal. Can be found in Value table 1

 

L

mm

Measured between cylinder block and roller tappet according to method

 

L

mm

Basic measurement on unit pump

 

L fb

mm

The exact point at which the unit pump begins to supply fuel

 

A/100

 

mm

Manufacturing tolerance, written on the unit pump

 

T s

mm

Theoretical thickness of shim

 

S s

mm

True thickness of shim

 

S1,

S2

and

-

Total (sum) of calculations

 

S3

 

EP

-

Code value that can be found in Value table 3 or on engine type plate

 

E k

mm

The total of one calculation. Only applies when calculating EP code.

 

Value table 1, information about camshafts

 

Value table 1, information about camshafts

 

Injection

angle,

Camshaft type

camshaft lift, Vh nom mm (in)

Preload, correction

Unit

pump's

length,

Fb nom

 

factor,

Vh corr mm/°

basic measurement,

°FÖD (°BTDC)

   

BTDC

Lmm (in)

 
 

(in/°BTDC)

 

5.0

A

6.32

mm (0.2488 in)

 

0.14

143

mm (5.630 in)

 

6.0

A

6.11

mm (0.2406 in)

 

0.14

143

mm (5.630 in)

 

7.0

A

5.90

mm (0.2323 in)

 

0.14

143

mm (5.630 in)

 

8.0

A

5.70

mm (0.2244 in)

 

0.14

143

mm (5.630 in)

 

9.0

A

5.50

mm (0.2165 in)

 

0.14

143

mm (5.630 in)

 

4.0

A

5.31

mm (0.2091 in)

 

0.14

143

mm (5.630 in)

 

4.5

B

5.70

mm (0.2244 in)

 

0.14

143

mm (5.630 in)

 

5.0

B

5.60

mm (0.2205 in)

 

0.14

143

mm (5.630 in)

 

5,5

B

5.50

mm (0.2165 in)

 

0.14

143

mm (5.630 in)

 

6.0

B

5.31

mm (0.2091 in)

 

0.14

143

mm (5.630 in)

 

7.0

B

5.10

mm (0.2008 in)

 

0.14

143

mm (5.630 in)

 

2.0

M

6.06

mm (0.2386 in)

 

-

143

mm (5.630 in)

 

2.5

M

5.97

mm (0.2350 in)

 

-

143

mm (5.630 in)

 

3.0

M

5.88

mm (0.2315 in)

 

-

143

mm (5.630 in)

 

3.5

M

5.79

mm (0.2280 in)

 

-

143

mm (5.630 in)

 

4.0

M

5.70

mm (0.2244 in)

 

-

143

mm (5.630 in)

 

4.5

M

5.61

mm (0.2209 in)

-

143

mm (5.630 in)

5.0

M

5.52

mm (0.2173 in)

-

143

mm (5.630 in)

5,5

M

5.43

mm (0.2138 in)

-

143

mm (5.630 in)

6.0

M

5.35

mm (0.2106 in)

-

143

mm (5.630 in)

6,5

M

5.26

mm (0.2079 in)

-

143

mm (5.630 in)

7.0

M

5.17

mm (0.2035 in)

-

143

mm (5.630 in)

7.5

M

5.08

mm (0.2000 in)

-

143

mm (5.630 in)

8.0

M

4.99

mm (0.1965 in)

-

143

mm (5.630 in)

2.0

S

6.198

mm (0.2440 in)

-

143

mm (5.630 in)

2.5

S

6.110

mm (0.2406 in)

-

143

mm (5.630 in)

3.0

S

6.020

mm (0.2370 in)

-

143

mm (5.630 in)

3.5

S

5.930

mm (0.2335 in)

-

143

mm (5.630 in)

4.0

S

5.842

mm (0.2300 in)

-

143

mm (5.630 in)

4.5

S

5.75

mm (0.2264 in)

-

143

mm (5.630 in)

5.0

S

5.66

mm (0.2228 in)

-

143

mm (5.630 in)

5,5

S

5.58

mm (0.2197 in)

-

143

mm (5.630 in)

6.0

S

5.49

mm (0.2161 in)

-

143

mm (5.630 in)

Value table 1, information about camshafts (engines with hydraulic roller tappets for reduction of white smoke)

Value table 1, information about camshafts

 

Injection

angle,

Camshaft type

camshaft lift, Vh nom mm (in)

Preload, correction

Unit

pump's

length,

Fb nom

factor,

Vh corr mm/°

basic measurement,

°FÖD (°BTDC)

 

BTDC

Lmm (in)

 

(in/°BTDC)

 

2.0

S

6.198

mm (0.2440 in)

-

136.8

mm (5.386 in)

2.5

S

6.110

mm (0.2406 in)

-

136.8

mm (5.386 in)

3.0

S

6.020

mm (0.2370 in)

-

136.8

mm (5.386 in)

3.5

S

5.930

mm (0.2335 in)

-

136.8

mm (5.386 in)

4.0

S

5.842

mm (0.2300 in)

-

136.8

mm (5.386 in)

Value table 2, information about shim thicknesses, L0=143 mm

Value table 2, information about shim thicknesses

 

Theoretical thickness, T s

Thickness of shim, S s

Theoretical thickness, T s

Thickness of shim, S s

0,95 - 1,049 mm (0.03740 - 0.0430 in)

1,0 mm

3,05 - 3,149 mm (0.1201 - 0.12398 in)

3,1 mm

(0.039 in)

(0.122 in)

1,05 - 1,149 mm (0.0413 - 0.04524 in)

1,1 mm

3,15 - 3,249 mm (0.1240 - 0.12791 in)

3,2 mm

(0.043 in)

(0.126 in)

1,15 - 1,249 mm (0.0453 - 0.04917 in)

1,2 mm

3,25 - 3,349 mm (0.1280 - 0.13185 in)

3,3 mm

(0.047 in)

(0.130 in)

1,25 - 1,349 mm (0.0492 - 0.05311 in)

1,3 mm

3,35 - 3,449 mm (0.1319 - 0.13579 in)

3,4 mm

(0.051 in)

(0.134 in)

1,35 - 1,449 mm (0.0531 - 0.05705 in)

1,4 mm

3,45 - 3,549 mm (0.136 - 0.13972 in)

3,5 mm

(0.055 in)

(0.138 in)

1,45 - 1,549 mm (0.057 - 0,06098 in)

1,5 mm

3,55 - 3,649 mm (0.1398 - 0.14366 in)

3,6 mm

(0.059 in)

(0.142 in)

1,55 - 1,649 mm (0.0610 - 0.06492 in)

1,6 mm

3,65 - 3,749 mm (0.1437 - 0.14760 in)

3,7 mm

(0.063 in)

(0.146 in)

1,65 - 1,749 mm (0.0650 - 0.06886 in)

1,7 mm

3,75 - 3,850 mm (0.1476 - 0.15157 in)

3,8 mm

(0.067 in)

(0.150 in)

1,75 - 1,849 mm (0.0689 - 0.07280 in)

1,8 mm

3,85 - 3,949 mm (0.1515 - 0.15547 in)

3,9 mm

(0.071 in)

(0.154 in)

1,85 - 1,949 mm (0.0730 - 0.07673 in)

1.9

mm

3,95 - 4,049 mm (0.1555 - 0.15941 in)

4,0 mm

(0.075 in)

(0.158 in)

1,95 - 2,049 mm

2.0

mm

4,05 - 4,149 mm

4,1 mm

(0.0768 - 0.08067 in)

(0.079 in)

(0.1594 - 0.16335 in)

(161 in)

2,05 - 2,149 mm (0.0807 - 0.0846 in)

2,1 mm

4,15 - 4,249 mm (0.1634 - 0.16728 in)

4,2 mm

(0.083 in)

(165 in)

2,15 - 2,249 mm (0.0846 - 0.08854 in)

2.2

mm

4,25 - 4,349 mm (0.1673 - 0.17122 in)

4,3 mm

(0.087 in)

(0.169 in)

2,25 - 2,349 mm (0.0886 - 0.9248 in)

2.3

mm

4,35 - 4,449 mm (0.1713 - 0.17516 in)

4,4 mm

(0.091 in)

(0.173 in)

2,35 - 2,449 mm (0.0925 - 0.09642 in)

2,4 mm

4,45 - 4,549 mm (0.1752 - 0.17909 in)

4,5 mm

(0.095 in)

(0.177 in)

2,45 - 2,549 mm (0.0965 - 0.1004 in)

2,5 mm

4,55 - 4,649 mm (0.1791 - 0.18303 in)

4,6 mm

(0.098 in)

(0.181 in)

2,55 - 2,649 mm (0.1004 - 0.10429 in)

2,6 mm

4,65 - 4,749 mm (0.1831 - 0.18697 in)

4,7 mm

(0.102 in)

(0.185 in)

2,65 - 2,749 mm (0.1043 - 0.10823 in)

2,7 mm

4,75 - 4,849 mm (0.1870 - 0.19091 in)

4,8 mm

(0.106 in)

(0.189 in)

2,75 - 2,849 mm (0.1083 - 0.11217 in)

2,8 mm

4,85 - 4,949 mm (0.1910 - 0.19484 in)

4,9 mm

(0.110 in)

(0.193 in)

2,84 - 2,949 mm (0.1118 - 0.11610 in)

2,9 mm

4,95 - 5,049 mm (0.1949 - 0.19878 in)

5,0 mm

(0.115 in)

(0.197 in)

2,95 - 3,049 mm (0.1161 - 0.12004 in)

3,0 mm

   

(0.118 in)

Value table 2, information about shim thicknesses (engines with hydraulic roller tappets for reduction of white smoke), L0=136.8 mm

Value table 2, information about shim thicknesses

 

Theoretical thickness, T s

Shim thickness, S s

Theoretical thickness, T s

Shim thickness, S s

4.625

- 4.6749 mm

4.65

mm

5.575

- 5.6249 mm

5.60

mm

(0.1831 - 0.18697 in)

(0.1831 in)

(0.2195 - 0.22145 in)

(0.220 in)

4.675

- 4.7249 mm

4.70

mm

5.625

- 5.6749 mm

5.65

mm

(0.18406 - 0.18602 in)

(0.1850 in)

(0.2215 - 0.22342 in)

(0.222 in)

4.725-4.7749 mm (0.18602 - 0.18800 in)

4.75

mm

5.675

- 5.7249 mm

5.70

mm

(0.1870 in)

(0.22342 - 0.22539 in)

(0.224 in)

4.775

- 4.8249 mm

4.80

mm

5.725

- 5.7749 mm

5.75

mm

(0.18800 - 0.19000 in)

(0.1900 in)

(0.2254 - 0.22736 in)

(0.226 in)

4.825

- 4.8749 mm

4.85

mm

5.775

- 5.8249 mm

5.80

mm

(0.19000 - 0.19192 in)

(0.1909 in)

(0.2274 - 0.22933 in)

(0.228 in)

4.875

- 4.9249 mm

4.90

mm

5.825

- 5.8749 mm

5.85

mm

(0.19192 - 0.19389 in)

(0.1929 in)

(0.2293 - 0.23129 in)

(0.230 in)

4.925

- 4.9749 mm

4.95

mm

5.875

- 5.9249 mm

5.90

mm

(0.19192 - 0.19586 in)

(0.1949 in)

(0.2313 - 0.23326 in)

(0.232 in)

4.975

- 5.0249mm

5.00

mm

5.925

- 5.9749 mm

5.95

mm

(0.19586 - 0.19783 in)

(0.1968 in)

(0.2333 - 0.23523 in)

(0.234 in)

5.025

- 5.0749 mm

5.05

mm

5.975

- 6.0249 mm

6.00

mm

(0.19783 - 0.19980 in)

(0.1988 in)

(0.2352 - 0.23720 in)

(0.236 in)

5.075

- 5.1249 mm

5.10

mm

6.025

- 6.0749 mm

6.05

mm

(0.19980 - 0.20177 in)

(0.2008 in)

(0.2372 - 0.23917 in)

(0.238 in)

5.125

- 5.1749 mm

5.15

mm

6.075

- 6.1249 mm

6.10

mm

(0.20177 - 0.20374 in)

(0.2027 in)

(0.2392 - 0.24114 in)

(0.240 in)

5.175

- 5.2249 mm

5.20

mm

6.125

- 6.1749 mm

6.15

mm

(0.20374 - 0.20570 in)

(0.2047 in)

(0.2411 - 0.24311 in)

(0.242 in)

5.225

- 5.2749 mm

5.25 mm (0.207 in) (0.2067 in)

6.175

- 6.2249 mm

6.20

mm

(0.20570 - 0.20767 in)

(0.2431 - 0.24507 in)

(0.244 in)

5.275

- 5.3249 mm

5.30

mm

6.225

- 6.2749 mm

6.25

mm

(0.20768 - 0.20964 in)

(0.2087 in)

(0.2451 - 0.24704 in)

(0.246 in)

5.325

- 5.3749 mm

5.35

mm

6.275

- 6.3249 mm

6.30

mm

(0.20965 - 0.21161 in)

(0.2106 in)

(0.2470 - 0.24901 in)

(0.248 in)

5.375

- 5.4249 mm

5.40

mm

6.325

- 6.3749 mm

6.35

mm

(0.21161 - 0.21358 in)

(0.2156 in)

(0.2490 - 0.25098 in)

(0.250 in)

5.425

- 5.4749 mm

5.45

mm

6.375

- 6.4249 mm

6.40

mm

(0.21161 - 0.21555 in)

(0.2146 in)

(0.2510 - 0.25295 in)

(0.252 in)

5.475

- 5.5249 mm

5.50

mm

   

(0.21555 - 0.21752 in)

(0.2165 in)

5.525

- 5.5749 mm

5.55

mm

   

(0.21752 - 0.21948 in)

(0.2185 in)

Value table 3, information about EP-codes, L0=143 mm

Value table 3, information about EP codes

 

E

k

EP code

E

k

EP code

E

k

EP code

E

k

EP code

145.35

mm

335

           

(5.7224 in)

145.375

mm

336

           

(5.7234 in)

145.4

mm

337

146.0

mm

361

146.6

mm

385

147.2

mm

409

(5.7244 in)

(5.7480 in)

(5.7716 in)

(5.7953 in)

145.425

mm

338

146.025

mm

362

146.625

mm

386

147.225

mm

410

(5.7254 in)

(5.7490 in)

(5.7726 in)

(5.7962 in)

145.45

mm

339

146.05

mm

363

146.65

mm

387

147.25

mm

411

(5.7264 in)

(5.7500 in)

(5.7736 in)

(5.7972 in)

145.475

mm

340

146.075

mm

364

146.675

mm

388

147.275

mm

412

(5.7273 in)

(5.7510 in)

(5.7746 in)

(5.7982 in)

145.5

mm

341

146.1

mm

365

146.7

mm

389

147.3

mm

413

(5.7283 in)

(5.7520 in)

(5.7756 in)

(5.7992 in)

145.525

mm

342

146.125

mm

366

146.725

mm

390

147.325

mm

414

(5.7293 in)

(5.7529 in)

(5.7766 in)

(5.8002 in)

145.55

mm

343

146.15

mm

367

146.75

mm

391

147.35

mm

415

(5.7303 in)

(5.7539 in)

(5.7775 in)

(5.8012 in)

145.75

mm

344

146.175

mm

368

146.775

mm

392

147.375

mm

416

(5.7382 in)

(5.7549 in)

(5.7785 in)

(5.8021 in)

145.6

mm

345

146.2

mm

369

146.8

mm

393

147.4

mm

417

(5.7323 in)

(5.7559 in)

(5.7800 in)

(5.8031 in)

145.625

mm

346

146.225

mm

370

146.825

mm

394

147.425

mm

418

(5.7333 in)

(5.7568 in)

(5.7805 in)

(5.8041 in)

145.65

mm

347

146.25

mm

371

146.85

mm

395

147.45

mm

419

(5.7342 in)

(5.7579 in)

(5.7815 in)

(5.8051 in)

145.675

mm

348

146.275

mm

372

146.875

mm

396

   

(5.7352 in)

(5.7588 in)

(5.7825 in)

145.7

mm

349

146.3

mm

373

146.9

mm

397

   

(5.7362 in)

(5.7600 in)

(5.7834 in)

145.725

mm

350

146.325

mm

374

146.925

mm

398

   

(5.7372 in)

(5.7608 in)

(5.7844 in)

145.75

mm

351

146.35

mm

375

146.95

mm

399

   

(5.7382 in)

(5.7618 in)

(5.7854 in)

145.775

mm

352

146.375

mm

376

146.975

mm

400

   

(5.7392 in)

(5.7628 in)

(5.7864 in)

145.8

mm

353

146.4

mm

377

147.0

mm

401

   

(5.7401 in)

(5.7638 in)

(5.7874 in)

145.825

mm

354

146.425

mm

378

147.025

mm

402

   

(5.7411 in)

(5.7647 in)

(5.7884 in)

145.85

mm

355

146.45

mm

379

147.05

mm

403

   

(5.7421 in)

(5.7657 in)

(5.7894 in)

145.875

mm

356

146.475

mm

380

147.075

mm

404

   

(5.7431 in)

(5.7667 in)

(5.7903 in)

145.9

mm

357

146.5

mm

381

147.1

mm

405

   

(5.7441 in)

(5.7677 in)

(5.7913 in)

145.925

mm

358

146.525

mm

382

147.125

mm

406

   

(5.7451 in)

(5.7687 in)

(5.7923 in)

145.95

mm

359

146.55

mm

383

147.15

mm

407

(5.7460 in)

(5.7697 in)

(5.7933 in)

145.975

mm

360

146.575

mm

384

147.175

mm

408

(5.7470 in)

(5.7707 in)

(5.7943 in)

Value table 3, information about EP-codes (engines with hydraulic roller tappets for reduction of white smoke), L0= 136.8 mm

Value table 3, information about EP codes

 

E

k

EP code

E

k

EP code

E

k

EP code

E

k

EP code

142.0

mm

700

142.7

mm

728

143.4

mm

756

144.1

mm

784

(5.5905 in)

(5.6181 in)

(5.6457 in)

(5.6732 in)

142.025

mm

701

142.725

mm

729

143.425

mm

757

144.125

mm

785

(5.5915 in)

(5.6191 in)

(5.6466 in)

(5.6742 in)

142.05

mm

702

142.75

mm

730

143.45

mm

758

144.15

mm

786

(5.5925 in)

(5.6201 in)

(5.6476 in)

(5.6752 in)

142.075

mm

703

142.775

mm

731

143.475

mm

759

144.175

mm

787

(5.5935 in)

(5.6210 in)

(5.6486 in)

(5.6762 in)

142.1

mm

704

142.8

mm

732

143.5

mm

760

144.2

mm

788

(5.5945 in)

(5.6220 in)

(5.6496 in)

(5.6771 in)

142.125

mm

705

142.825

mm

733

143.525

mm

761

144.225

mm

789

(5.5955 in)

(5.6230 in)

(5.6506 in)

(5.6781 in)

142.15

mm

706

142.85

mm

734

143.55

mm

762

144.25

mm

790

(5.5964 in)

(5.6240 in)

(5.6516 in)

(5.6791 in)

142.175

mm

707

142.875

mm

735

143.575

mm

763

144.275

mm

791

(5.5974 in)

(5.6250 in)

(5.6525 in)

(5.6801 in)

142.2

mm

708

142.9

mm

736

143.6

mm

764

144.3

mm

792

(5.5984 in)

(5.6260 in)

(5.6535 in)

(5.6811 in)

142.225

mm

709

142.925

mm

737

143.625

mm

765

144.325

mm

793

(5.5994 in)

(5.6270 in)

(5.6545 in)

(5.6821 in)

142.25

mm

710

142.95

mm

738

143.65

mm

766

144.35

mm

794

(5.6004 in)

(5.6280 in)

(5.6555 in)

(5.6831 in)

142.275

mm

711

142.975

mm

739

143.675

mm

767

144.375

mm

795

(5.6014 in)

(5.6289 in)

(5.6565 in)

(5.6840 in)

142.3

mm

712

143.0

mm

740

143.7

mm

768

   

(5.6023 in)

(5.6299 in)

(5.6575 in)

142.325