Section

2000
BASIC ENGINE
D-155, D-179, D-206, D-239, D-246, D-268,
D-31 0, D-358, DT-239, DT-358, DT402 Engines

u
J I Case
A Tenneco Company e Don 8 -59030
Pnnted 1n England
November. 1987
 INTRODUCTION

Table of Contents

This Manual covers the following major sections:

{
Page .
1
1. INTRODUCTION 4

2. SERVICE DIAGNOSIS 6

3. SPECIFICATIONS 12

4. LONGITUDINAL AND CROSS SECTION 16

5. VALVE LEVER ASSY 18

6. CAMSHAFT AND IDLER GEAR 21

7. CYLINDER HEAD VALVES AND VALVE GUIDES 27

8. MANIFOLDS 39

9. FAN- V-BELTS 40

10. CRANKSHAFT PULLEY AND VIBRATION DAMPER 41

11. CRANKCASE FRONT COVER AND PLATE 43

(
12. CRANKCASE 45

13. CRANKSHAFT 49

14. PISTONS CYLINDER SLEEVES - CONNECTING RODS 63

15. BALANCER (4-cyl. only) 72

16. FLYWHEEL 77

17. LUBRICATING SYSTEM 80

18. OIL PUMP 81

19. WATER PUMP 86

20. THERMOSTAT AND COOLANT MANIFOLD 89

21 . INJECTION PUMP EP/VA- VE 91

22. INJECT ION NOZZLE HOLDER 96

23. TIMING GEAR TRAIN 97

24. VALVE LASH ADJUSTMENT 99

25. ENGINE TESTING 101

 INTRODUCTION

INDEX

A Page M Page

A ngle Tightening Procedure, Manifold , Coolant 89

Connecting Rod Nuts 70 Manifold , Exhaust 39
Manif old, Intake 39
Main Bearing Caps 61
B
N
Balancer 72
Balancer Drive Gear 57 Nozzles and Holders 96
Balancer We ights 75 Nozzle Holder Sleeves 35
Bearing Inserts 55
Blow-by Values 14 0
Bolt and N ut Identification 15
Oil Pump 81
Oi l Seal , Front 44
c Oi l Seal , Rear 55

Camshaf t and Id ler Gear 21

Connecti ng Rods and Pistons 63 p
Crankcase Front Cover 43
Crankcase 45 Pistons and Connect ing Rods 63
Crankcase Cou nterbore Resur faci ng 47 Pump, Injection 91
Crankcase Pressure 14 Pump, Oi l 81
Crankshaft 49 Pump, Water 86
Crankshaft Pulley 41
Cyli nder Head 27
Cylinder Sleeves 63 R

( Regrinding Crankshaft 53
Running-In 6
D

Data, Engines 12 s
Dat a, Special Nut and Bolt Torque 15
Safety Rules 5
Service Diagnosis 6
Special Nut and Bolt Torque Data 15
E Static Timing 13

Engine, Da ta 12
Engine, Longitud inal and Cross Secti on 16 T
Engine, Handing over 6
Engine Run-in Schedule 6 Technica l Data, Engines 12
Engine Testing 101 Thermostat 89
T iming Gear Train 97

F V

Fan 40 Valve Lever Assembly 18

Flywheel 77 Valves and Valve Guides 28
Fuel Feed Pump 95 Valve Lash 91
Valve Timing 24, 101
V-Belt Pulley 40
Vibration Damper 41

u
r

Idler Gear 21
Injection Nozzles 96 w
Injection Pump 91
Introduction 4 Water Pump 86

-3 -
 INTRODUCT ION

General this manual gives complete service information for the

above engine series and replaces instructions given in
T his Service Manual covers the basic engine of all Neuss previous publ icat ions.
bu il d direct injection engine versions, both natural ly
aspirated and turbocharged.
I H - Diagnostic Center
Together with the manuals
T he engi ne is provided wi th adaptors f or the .. Diagnost ic
- "Electrical Equipment" No. 1091 630 R2 Center". We recommend therefore, t hat all test s be per·
formed wi t h the " I H -Diagnostic Cen ter ".
and

"Fuel System and Turbocharger" No . 1 09 1 627 R2

(t o be issued at a later dat e)

SI -Measurements

A standard of measurement known as Internat ional System of Units (S I) has been adopted for world-wide use. These
units are used throughout th is manual.

. .
SI Unit English Equivalent

mm - millimeter 0.039 inches

cm - centi meter . .. . ... . . . . . .... . .... . . .. . . 0.39 inches
cm3 - cubic centimeter .. .. .. .. . . ........ . .. . 0.06 cubic inches
3
m - cubic meter .. .. ... . . .. .. . ... . · · · · · · · · 35.31 cu bic feet
I - li ter . .. . .... . .. ... . .. . ........ . ..... . 1.057 quarts (
kg- ki logram . . .. . . . .. . .. . . .. . . ......... . 2.205 pounds weight
kPa - ki lopascal ... . .. . . .. ... . ... .. . .. ... . . 0. 145 psi
MPa - Megapascal . . . . . . . . . . . . . . ... . ... . .. . 145 psi
N- Newton ... . . . .. . . .......... . ..... . . . 0.225 pounds force
daN - dekanew ton . . .. .. . .. . . . . . .... . . .... . 2.25 pounds f orce
Nm - Newton meter . . . . . . . . . . . . . . . . . . . . . . . . 0. 738 foot pounds force
daNm - dekanewton meter ... . ... . ... ... .... . 7.38 foot pounds force
°C degrees - Celsius . . ... ... . . . ....... . .... . ° Fahrenheit = 1.8 x °C + 32
kW- kil owatt .. . ....... . ... .. . . . . . . . . . . . . 1.34 horepower
1/m in - !i ter/m inute . . ... .. ... .. . ... . . .... . . 0.2 19 gallons per minute
km/h - ki lometer I hour . . . . . . . . ..... ... .... . 0.621 miles per hour
1/mi n ........... .. .. .. . ... . . .......... . rpm

'
1

- 4-
 INTRODUCTION
Work Safely - Follow these Rules
A
This symbol is used to call your attention to
instructions concern ing your personal safety. Be
sure to observe and follow these instructions.
1. Always wear safety glasses when using a hammer,
chisel or other tools that may cause chips to fly.
2. Keep work area organized and clean. Wipe up oil or
spills of any kind. Keep tools and parts off of the
floor. Eliminate the possibility of a fall which could
result in a serious injury.
3. Be sure to reinstall safety devices, guards or shields
after adjusting and/or servicing the machine.
4. After servicing, be sure all tools, parts, or servicing
equipment are removed from the machine.
5. Use a safety catch on all hoist hooks. Do not take a
chance, the load could slip off of the hook.
6. Electrical storage batteries give off highly inflamm-
able hydrogen gas when charging and conti nue to do
so for some time after receiving a steady charge. Do
not under any circumstances allow an electric spark
or an open flame near the battery. Always dis-
connect a battery cable before working on the
electrical system.
7. Use pullers to remove bearings, bushings, gears,
cylinder sleeves, etc. when applicable. Use hammers,
punches and chisels only when absolutely necessary.
Then, be sure to wear safety glasses.
8. Be careful when usi ng comp ressed air to dry parts.
Use approved air blow guns, do not exceed 30 psi,
wear safety glasses or cloggles.and use proper shield-
ing to protect everyone in the work area.
9. Do nc:>t wear rings, wrist watches or loose fitting
clothing when working on machinery , they could
catch on moving parts causing serious injury. Wear
sturdy, rough-soled work shoes. Never adjust and/or
service a machine in bare feet, sandals or sneakers.
10. Exhaust gases are highly poisonous! Therefore, do
not start the engine in closed rooms unless adequate
ventilation is ensured, or an exhaust decontamination
device is being used.
Lubrication
Instructions on the lubrication of each assembly are
given in the Lubrication Guide in the Operator's Manual.
When assembling any parts, always coat all wearing sur-
faces with the lubricant specified in the guide. Use
sufficient quantities of lubricant to prevent any danger
of seizing, scoring or excessive wear when the assembly
is first operated. Failure to provide "starting lubrica-
tion" may result in serious damage. (Refer to "Priming
Lubricating System" in this Section.)
- 5-
Gaskets and Seals
A lways use new gaskets and seals. Be extremely careful
not to damage the seals in any way during installation.
Service Tools
Internati onal diesel engines are designed so that few
service tools are required other than those in the me-
chanic's tool kit. Wherever the application of inex-
pensive special service equipment will f acilitate work, it
is shown. Otherwise, it is assumed that servicemen will
select from their tool kits such tools as are required.
Information regarding special tool equipment is given in
the " Parts Catalog".
Service Parts
Always use genuine I. H. service parts. The best material
obtainable, and experience gathered through many years
of power equipment manufacturing, enable International
Harvester to produce quality that will not be found in
imitation or "just as good" repai r parts. No serviceman
can afford to guarantee a repair job that is not serviced
with genuine I. H. parts. No owner should be satisfied
with other than genuine I. H. parts.
For the correct service parts to be used on a machine,
always refer to the parts catalog for the particular
machine. The loose-leaf parts catalogs are accurate and
are continually being brought up to date by the issuance
of new pages covering any changes in part numbers.
Serial Numbers
Depending on engien application the engine serial num-
ber is stamped on a pad on the right side of the engine
either near the center below the tappet side cover or to-
wards the rear above the side cover.
Priming Lubricating System
Note: Diesel engines must not be rotated when priming
with oil; otherwise, they are likely to start running.
When assembling the overhauled engine, it is necessary
to thoroughly lubricate the various running parts with
clean engine oil to assure initial lubrication when engine
is first started. However, to further make certain that
complete initial lubrication is available, the engine
lubricating system should be pressure primed M charged
with oil. Attach the line from a priming device to a
suitable fitting located in the main oil gallery, filter
header or oil cooler of the engine and inject sufficient
oil into the engine to fill the oil filters and charge the
entire system. Use only clean engine oil in accordance
with Operator's Manual. New or overhauled engines that
have been in storage over an extended period should also
be pri med in a similar manner.
 INTRODUCTION

After the priming procedure is completed, make certain with Dynamometer

that the oil level is checked before the engine is put into
service. Do not overfill the engine; neither should the Engine Load Ti me
engi ne be short of oil as a resu lt of using the pressure
RPM % mi nutes
priming procedure.
1000 40 5
Priming the engine wil l minim ize the possibility of 2000 50 5
scuffing or heat build-up in the running components ra ted speed 80 10
which cou ld lead to immediate or low mileage failures. 100 below rated speed 50 10

without Dynamometer
(In-Vehicle Run -in Procedure)

Engine Load Time

RPM minutes
3/4 of rated l ight 5
3/4 of rated medium 15
Engine Run-in Schedule ·
rated speed full 20
Note: Do not run the engine at low or high idle speeds
f or long periods after instal ling new rings or sleeves, as After Running-in
ri ngs will not seat during idle operation.
Retighten manifold bolts and/or stud nuts.

Check valve clearance and readjust as necessary.

Handing over the Engine

Start
Prior to starting make sure, that
a) all bearings are pre-lu bricated
b) the crankcase is filled with specified engine oil
c) the coo ling system is filled to correct level
d) Precautions for al ternator operation are observed.
In the presence of the operator check engine oi l level
and coolant level. Test run the engine. Point out to the
operator that the overhau led engine is t o be treated in (
the same way as a new one.
Note: Re-torquing of cylinder head bolt s in t he field is
not necessary when the new "Maintenance-free" cylinder
head gasket has been installed. This new gasket can
easily be identified by its red plastic borders around the
oi l and water sealing faces; refer to lllust. 53.

Run-in SERVICE DIAGNOSIS

1. Start and run the engine at 3/4 rated engine speed
with no load. until operating temperature (80 - 850C)
is reached, cover the radiator if necessary. DO NOT
run for over 10 Minutes.
2. Retorque cylinder head bolts.
Important: DO NOT run the engine longer than 15
Minutes, before retorquing cy linder head bolts.
3. Continue according to the following chart.
Much can be learned about the condition of an engine if
a good visual inspection is performed before the actual
cleaning operations begin.
After cleaning, the exterior of the engine should once
more be inspected carefully and a note made of any
parts such as brackets, covers. bolts. etc .• that are bent,
broken, rusted or missing completely. The crankcase or
cy linder block should be checked for evidence of f reezing
around core plugs or for actual breaks in the water
jacket.

.6·
 SERVICE DIAGNOSIS

Probable Cause Remedy

Engine Fails to Turn

1. Batteries too low to turn engi ne Charge batteries or install new ones.

2. Starting switch inoperative ......... .... ... . Inspect for faulty cables and terminals. Replace starting
switch if necessary.

3. Cranking motor inoperative . . . . . . . . . . . . . . . . Refer to Service Manual "Electrical Equipment".

4. Engine oil too heavy ...... . ... ...... . . . . . Use correct grade of l ubricating oil.

5. Internal seizure ... . ... . ... ... ....... .. . Hand crank the engine. If the engine does not turn easily ,
seizure due to internal damage; including gear train,
pistons, sleeves, connecting rods or main bearings, is in-
dicated.

6. Hydrostatic lock . . . . . . . . . . . . . . . . . . . . . . . . Remove all the injection nozzles and crank the engine.
Check for fuel or coolant in the cylinder.

Engine Does Not Develop Full Power

1. Lo w or no fuel pressure
a. Insufficient fuel . ....... ...... .......
b. Fuel oil filter clogged .. .. .. ..... .. ....
c. Fuel filter gaskets defective
(air being drawn into fuel) . . . . . . . . . . . . . .
d. Moisture in fuel tank ......... . .. .. . ...
. Check fuel tank.
. Disassemble and clean each unit.
. Rep lace gaskets.
. Drain entire system including water trap and filter. Re-
fill with clean fuel , and vent the air from the system.

2. Poor fuel .. . ......... . .. ..... ........ . Use good grade of fuel.

3. Air cleaner clogged . .. .. . . . . . .. . . .. ..... . Remove and service air cleaner as described in operator's
manual.

4. Injection pump not properly timed

to the engine ........ . ......... . ...... . Check timing. (Refer to Section " INJECTION PUMP.")

5. Injection pump not operating properly ........ . Remove injection pump and test it. Refer to Service
Manual "Fuel System and Turbocharger" for test
specifications.

6. One or more fuel injection nozz les

not operating properly ....... . . ... . ...... . Replace the injection nozzles.

7. Loose or broken fuel lines or fittings be-

tween injection pump and injection nozzles . . ... . Tighten or repair.

8. Loose or broken connections or leaking gaskets

at intake manifold or exhaust manifold ........ . Tighten or repair.

9. I m proper va lve settings . . . . . . . . . . . . . . . . . . . Reset as necessary. If out of adjustment an excessive

u
amount, check for bent push rods.

10. If equipped with ether priming system with

butterfly valve, check the valve posit ion ... .... . Correct.

11. Lack of compression . . . . . . . . . . . . . . . . . . . . . Refer to "Poor Compression".

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 SERVICE DIAGNOSIS

Engine Turns But Will Not Start

1. No fuel del ivery t o injection nozzles ....... . .. . Check fuel suppl y, air in system, plugged fi lter elements
and injection pump.

2. Intake or exhaust system clogged .. . . ..... . .. . Rem ove air f low restriction and clean exhaust system.
Service the air cleaner.

3. Improper adjustment on pump linkage

and controls . . .. .. .... . ... . ... . .... . . . Readjust as necessary.

Poor Compression

1. Piston rings worn, broken or cracked Install new rings.

2. Cylinder sleeve worn . . . . . . . . . . . . . .. ..... . Install new sleeves.

3. Valves damaged or worn .... . . . . . . . . . . . . . . Instal l new valves.

4. Broken valve spring .. . .. . .... .. . . . . . .. .. . Install new springs.

5. Worn cy linder head gasket . . ... ... ........ . Install new gasket.

6. Valve seats worn or cracked ..... ... ....... . Grind valve seats. If cracked, install new valves.

7. Worn pistons ........... . . . . . ... .. .... . Install new pistons.

8. Excessive valve guide wear . . . . . . . . . . . . . . . . . Install new valve guides.

9. Stick ing valves or bent valve stems . .......... . Free stem and correct cause. Rep lace valves with bent
stems. (
10. Faulty valve action . .. . .... . ... . . . .... .. . Adjust valve clearance.

Engine Overheats

1. Water pump air bound ...... ... .. . ....... . Vent air from water pump and thermostat housing.

2. Insufficient coolant in cool ing system . .... . .. . . Check level and add if necessary. Check hose connections
for leaks.

3. Cooling system clogged . . ... . ... . .... .. .. . Drain and f l ush cooling system.

4. Insufficient oil ...... . . .... .. . ... . .. .. . . Maintain proper oil level.

5. Engine oil di luted with fuel ... .. ... . .. . ... . Change oil. Inspect for loose fuel line con nections on the
injection nozzles. Check for defective inject ion pump.

6. Defective thermostat . . ...... . .......... . . Remove an d test thermostat. Replace if necessary.

7. Water pump defective . . ... . .. ... .. .. .... . Repai r pump.

8. Defective torque converter (if equ ipped) . ... Repai r.

9. Engine oil cooler or torque conveter oil

cooler (if equipped) clogged . . . .. . ....... . . . Remove coolers and clean.

10. Fan belt sli pping ........ .. .. ... ........ . Adjust belt tension.

11 . Engine overloaded ...... .. ... . . .. . .. ... . Reduce load.

-8-
 SERVICE DIAGNOSIS

Engine Misses on One or More Cylinders

1. Insufficient air to engine Remove and clean air cleaner and ai r cleaner pipe.

2. Defective injection nozzles . . . . . . . . . . . . . . . . . Replace with servi ceable unit .

3. Air lock in the injection pump or fuel filter ..... . Vent air from system and check all fuel lines and con-
nections for leaks.

4. Poor fuel ..... .. ... . . . ........ .. ..... . Use good grade of fuel.

5. Air leaks around intake manifold . ........... . Remove and install new manifold gasket.

6. Injection pump not operating properly . .... ... . Remove injection pump and test it.

7. Injection pump not properly timed to

the engine .... .. .. ...... . ... . ........ . Check and adjust timing if necessary.

Excessive Oil Consumption

1. Piston rings wo rn or broken Install new rings.

2. Oil level in crankcase too high ..... .. . .... . . . Maintain proper oil level.

3. Crankcase oil pan gasket leaking ............ . Install new gasket.

4. Worn valve guides ... . .. .... . .... . ..... . . Install new valve guides.

5. Cylinder sleeves worn . . .... _ .. . .. . . . .... . Install new sleeves.

( 6. Front and rear crankshaft oil seal leaking ...... . Install new oil seals.

7. Piston rings not seati ng ..... .. ........... . Install new rings.

8. Cl ogged oil ring .. .. .... .. . .... . .. .. . .. . Remove and inspect and, if necessary, replace.

9. Oil pan drain plug loose or worn . ........ . .. . Install new drain plug and gasket and t ighten plug.

10. Overheating . . . . . . . . . . . . _ .· . . . . . . . . . . . . . Refer to "Engine Overheats" on preceding page.

Engine Does Not Idle Properly

1. Dirt in governor circuit Clean hydraulic head assembly.

2. Restriction to fuel delivery or leaking

fuel lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspect fuel lines and valves; inspect for proper level in
fuel tank.

3. Improper adjustment of injection pump

l inkage and controls ........ . ... ... . .... . Readjust .

- 9-
 SERVICE DIAGNOSIS

Engine Knocks

1. One or more cylinders misfiring .. . .... . ..... . Locate and correct cause. Disconnect t he injection lines
at the va lve housing one at a time and check for rpm
drop of each cyl inder.

2. Loose co nnecting rod ..... . . . . . . . . . . . . . . . Tighten connecting rod.

3. Poor grade of fuel, or water in f uel . .. .. ... . .. . Use good grade of fuel and check for water in f uel.

4. Incorrect engine temperature ... . . . .. . ..... . Keep temperature in work range of heat indicator.
Check thermostat f or proper operation.

5. Injection pump not operating properly . . .. . ... . Remove injection pump and test it.

Excessive Smoke

1. Ai r cleaner clogged Service air cleaner as described in the operat or's manual.

2. Engine overloaded Reduce load.

3. I m proper f uel .. .. . ... . .. .. ...... . . ... . Use good grade of fuel .

4. Defective injection nozzle . . . . . . . . . . . . . . . . . Install new injection nozzle.

5. Worn pistons, rings and sleeves . . . . ... . . ... . . Install new parts.

6. Incorrect valve adjustmen t . ... .. ..... . .. . Adjust va lves properly .

7. Ether primi ng system bu tterfly valve

cl osed (if equi pped) . ... . . . . . . . . . . . . . . . . . Readjust.

8. Leaking manifold gaskets . . . . . . . . . . . . . . . . . . Install new gaskets.

Bearing Failure

1. Low oil level Mai ntai n proper oil level.

2. Lack of oi l . ... .. .. .. . . .... .. ..... . . . . Maintai n proper oil level.

3. Engine runs too hot ........ . .......... . . Keep engine at normal operating temperature.

4. Loose bearings . . . . . . . . . . . . . . ... .. ... . . . Instal l new bearings.

5. Use of improper lubricating oil .... ... .. .... . Use a suitable oil, of noncorrosive type, correct grade
and viscosity. ·

6. Foreign materials entering engine ......... . .. . Use clean oil containers wh en fi ll ing engi ne with oil and
see that all gaskets on engine ar in good cond it ion.

7. Oil l ines clogged . .. ... . . . . . .... ........ . Clean all oil passages.

8. Connecting rod bent . . . . . . . . . . . . . . . . . . . . . Align rod or install new.

9. Crankshaft out of alignment .... .. .. . .. ... . . Install and shaft.

- 10 - .
 SERVICE DIAGNOSIS

Valves Sticking

1. Valve springs weak . Instal l new springs.

2. Valve springs broken Instal l new springs.

3. Gummy deposits from inferior fuel or oil ...... . Clean and use proper fuel or oil.

4. Valve stems scored or carboned . . . . . . . . . . . . . . Clean. If necessary, install new valves.

5. Insufficient clearance between valve

stem and guide . . . . . . . . . . . . . . . . . . . .. ... . Ream va lve guides for proper clearance.

Piston and Cylinder Sleeve Wear

1. Oil of unsuitable grade of viscosity . ... .... . .. . Change to oil of suitable specifications.

2. Piston rings stu ck or broken . . .. .. . ........ . Install new rings.

3. Lack of oil . ......... . ............ . .. . Keep oil at proper level.

4. Foreign materials entering engine ... . . . ...... . Inspect and service air cleaner. Proper care of air cleaner
is very important.

5. Piston rings not fitted properly to cyl inder ... .. . Install new rings and fit properly.

6. Dirty containers used for lu bricating oil ....... . Lubri cat ing oi l must be kept in a clean place and clean
containers used when filling engines.

( Improper Fuel Pressure

1. Fluctuating fuel pressure Inspect fuel injection pump.

2. Fuel pressure too low . . . . . . . . . . . . . . . . . . . . Check for clogged f uel fi l ter, lines or defective fuel in-
jection pump.

3. A ir leaks on suction side of injecti on pump ..... . Tighten fuel lines. Check for defective fuel fil ter case
gaskets.

Low Engine RPM

1. Governor control linkage bindin g or damaged Repair and install new parts needed.

2. Governor control rod improperly adjusted ...... . Adjust rod t o proper length.

Low Fuel Pressure

1. Dirty fuel fi lters Replace filters.

2. Broken fuel lines .. . . . . . . . . . . . . . . . . . . .. . Repair or i nstal l new line.

3. Clogged line . .... .. . ... . ........ . ..... . Clean or install new line.

u
4. Improper grade of fuel .... ... ..... . ... .. . . Use co rrect fuel.

5. Air leaks on suction side of injecti on pump .. . . . . Tighten fuel li nes. Check for defective fuel filter case
gaskets.

. 11 .
 SE RVICE D IAG NOS IS

High Fuel Pressure ·

1. Clogged fuel return l ine or el bow ...... . .. ... . Remove and clean.

Engine Runs Unevenly and V ibrates

1. Valve and spri ng assembly inopera tive ........ . Repair or install parts needed.

SPEC I FICATIONS

Number Bore Stroke Piston

Engine of Displacement
Cylinders mm (inch) mm (inch) cm 3 (cu. inch)
D-155 111.1 (4.375} 2536 (155 }
3
D-179 128.5 (5.06} 2934 (179)
D-206 98.4 111.1 (4.375) 3382 (206)
D-239 (3.875}
DT-239 128.5 (5.06} 3911 (239)
4
D-246 100.0 128.5 (5.06) 4034 (246)
D-268 (3.937) 139.7 (5.5) 4389 (268)
D-310
98.4
11 1.1 (4.375) 5073 (310) (
D-358 6
(3.875) 128.5 (5.06) 5867 (358)
DT-358
100.0
139.7 (5.5) 6587 (402)
DT -402 (3.937)

Type 4- Cycle-Diesei-E ngines OLD NEW

at rated speed MPa (PSI) 0.25 (36) 0.30 (44)
Direction of rotation, at low idle speed MPa (PSI) *) 0.09 (1 3)
facing f lywheel L. H. *) observe oil pressure warni ng light.

Compression rat io 16 : 1 (except D-268 and DT-402 Oil consumption at rated speed and ful l load, less than
15: 1) 1.5 g/kWh (overhauled engine).

Compression at starting speed,

MPa (PSI ) 2.2-2.4 (3 13- 34 1)

Firing order
3 Cyl. 1- 3- 2
4 Cyl. 1- 3- 4-2 Cooling System
6 Cyl. 1-5- 3 - 6- 2- 4
Valve clearance, engine hot, mm (inch) Most favourable operating
0.30 (.012)
temperature 90° - 95 °C (1 94°- 203 °F )

Lubricating System A ir System

Min. oil pressure at main oil gallery and 90 - 100 °C oil Max. permissible restri ction before
temperature servicing the air cleaner 635 mm (25 inch) of water

- 12 -
 SPEC I FICAT IONS

Static T iming (Degrees BTDC) *

..
0 - 155 VAlVE/PS 0 -239 0 - 246 VAlVE/ PS • 0 - 358 *
OT- 239 VAlVE/ PS 824 18
-- OT - 358 VAlVE
423. E - 423 10
383 10 724. 734 14 834 18 1055. 955 19

500 C/E 12 I 824. 744. s.u. 16 844 18 1056. 956 14/ 8/2.2

453 10 824. 834. 744 Crane 16 784/785 16/ 4/2.5 1630A, 1730A.
18
V/E - 433, VIE - 533 10 TD - 7E. 100 E P.S. 12 84 Hydr. 16 1830A

VIE 433 Series 11 8/ 8/2.5 TD- 8 C. P.S. 12 268 IT 16 531.541 . (8 - 111) 18

VIE 533 Series 11 10/ 8/2.5 125 G.D./P.S. 14 278 IT 16 Acco 1820 with
18
s.u. 533 10 H - 30 B. Galion Gr. 16 AT - 540

5033 12 H - 30 BNico 16 1730 B - 1930 8 18

433 8/ 8/2.5 l 32 1. 431 12 0 -268 VAlVE/PS Galion 102 Grader 16 I

533/385 10/ 8/2.5 lngersoll· Rand 16 844 s 8/ 8/2.5 DU - 2 D 16
5000/5500 W.R. 16/ 8/2.8 845 8/ 8/2.5 H - 60 16

0 - 179 VAlVE/ PS
1130/1230 TOE
743. 745 S/833
12
16/ 8/2.8
620 8
51 0
8
18
l Series 200 ATk. M.T.
1046
18
16

553 14 574 H.S. 16 TD - 8CA 8 1521 s 18

633/633 V + E Sll 14/ 8/2.2 574 G.D. 12 884/885 16/ 8/2.5 725 SP 14

4500 8 T.C. 14 3654. 3654 s.u. 14 270 A 16 H 65 8 17

454 G.D./454 H.S. 14 3500 A G.D./H.S. 14 I 866 - HS (Austr.) 16

464 G.D./H. S. 14 674 G.D. 14 3964/3965 18

3654 s.u. 14 · 2500 A G.D. 12 0-310 VA 3980 16

484. 248 IT 485 14/ 8/2.2 125 B u. TO - BB 946 (2100 RPM) 16 515 16
12
SU·644·LD 14 Ser. 11 946 (2200 RPM) 10 976. 986. 886 (U.S.) 16
2454 G.D./H.S. 14 S.U. 644 - H.D. 686 14 S - BA. S - 10 16
--· 14/ 8/2.8
( 240A S. M/ H.S./T.C.
3400 A G.D./H.S.
14
14
4 - WD.
3400 8 S.M.
766
955
10
12
H - 60 - B. 520 A
H - 65 C
16
16
18
H.S./T.C. 431 . 531 16 530 A 16
2400 A G.D./H.S.
Irrigation - Unit
14
14 684/685 16/ 8/2.8 H - 50 8 I 12 943
I

18
16
506 14 2574 G.D.
250 A. S.M.
12
12
DU - 20
0 - 1500C
16
18
I 953
923 16
260 ATC SM./H.S. 18 616/622 H.S. 16 933 18
0 -206 VAlVE/ PS Irrigation Unit 18 711 S.P Header Harv. 10 1420/782 - / 10
554. 654. 644 12 2500 AH.S. 14 165C 8 3990 16
22 1 14 2574 H.S. 14 696 14 650 16
TD - 7 C G.D. 12 250 A H.S./T.C. 14 1 - 3820 A 14 3980 B/3984 B 20
100 G.D. 12 856 XL -1 8 9000 F.L. 14 630 18
733/733 V + E Sll 12/ 8/2.8 833 V+ E -1 8 715 Comb. 12 280 PH 20
474 G.D./H.S. 14 782 Colt on Picker 16 1246 16
100 8 Series 11 10 786 10 1255 -1 8
584/585 12/ 8/2.8 86 Hydr. 8 786 18
TD - 6 8 10 1400 - 1 12
100 8. 624 10 Irrigation - Unit 16
258 IT 12 640 (D - 358) 16
624 (Mexico) 12 640 (OT - 358) 20
VA = Mac hines with VA lnjec tion Pump 520 8 - 1 10
VE = M achines w ith VE lnjec tio n Pump 858 F -1 8
PS = Plunge r S tro ke - total stroke of InJeCtion p lunger 1n mm w1th a
tolerance of 0.02 mm (pumps w ithout timing window only). OT - 402 VE
3994. 650 HO 16

u 953 HS. 953 GO

1455
530 AS 11
16
11
16

. 13 .
 SPECIFICATIONS

Crankcase Pressure and Blow-by Chart

Max. Crankcase
Engine Pressure Max. permissible Blow-By
(High Idle, No Load)
at Engine Idling at Rated Load
mm H 2 0 in H 2 0 RPM
cu. m/hr (cu. ft./hr) cu. m./hr (cu. ft. /hr)
1500 1.0 ( 35.3) 2.0 ( 70.6)
D-155 38 1.5
2500 1.5 ( 53.0) 2.5 ( 88.0)
2100 1.5 ( 53.0) 2.0 ( 70.6)
D-179 38 1.5
2500 1.5 ( 53.0) 2.5 ( 88.0)
2100 1.5 ( 53.0) 2.5 ( 88.0)
D-206 51 2.0
2500 1.5 ( 53.0) 3.0 (106.0)
2100 1.5 ( 53.0) 2.5 ( 88.0)
D-239 51 2.0
2200 1.5 ( 53.0) 2.5 ( 88.0)
DT-239 152 6.0 2500 2.0 ( 70.6) 3.5 (123.0)
2500 2.0 ( 70.6) 3.0 (106.0)
D-246 51 2.0
2400 2.0 ( 70.6) 3.5 (123.0)
2500 2.0 ( 70.6) 3.0 (106.0)
D-268 51 2.0
2200 1.5 ( 53.0) 3.5 (123.0)
2300 2.0 ( 70.6) 3.5 (123.0)
D-310 64 2.5 2400 2.0 ( 70.6) 3.5 (123.0)
3000 2.0 ( 70.6) 4.0 (141.0)
2200 1.5 ( ,53.0) 3.0 (106.0)
D-358 127 5.0
3000 2.0 ( 70.6) 4.0 (141.0)
2200 4.0 (141.0) 6.0 (212.0)
DT-358 165 6.5
2500 4.0 (141.0) 6.0 (2 12.0)
2200 2.0 ( 70.6) 3.0 (106.0)
DT-402 165 6.5
2500 2.0 ( 70.6) 3.0 (106.0) (

Crankcase Pressure 4. MACHINES WITH HAT-TYPE BREATHER: Remove

the breather. Install the adapter tool (l llust. 225)
Note: For measuring crankcase pressure use orifice re- using the 0-ring and clamp to insu re that all blow-by
strictor tool No. PLT 556 according to lllust. 224. gas passes t hrough the adapter.

Follow the procedure below to check crankcase pressure, 5. Attach crankcase breather restrictor to breather
then refer to Chart above to interpret readings. outlet or adapter.

Note: Refer to Operator's Manual for proper servi cing 6. Connect one leg of water manometer to pressure tap
intervals of breather element. of restrictor assembly with other end open to at-
mosphere.

Operating Instructions 7. Operate engine to establ ish normal coolant operating

1. Park vehicle on level ground.
2. Breather tube must be free of obstructions and ele-
ment free of sludge.
3. Engine oil level must not be above full mark.
temperat ure.
8. Operate engine at HIGH IDLE SPEED, NO LOAD.
9. Observe manometer reading for approximately two
minutes and record average reading (manometer read-
ing will fluctuate).

- 14 -
 SPECI FICATI ON S

daNm Lbf-ft
Special Nut and Bolt T orque Data 1st 2nd final 1st 2nd final
step step step step step step
* Balance weight necked-down bolts (obsolete) 3 5.57 6.0 2 1.7 40 43.5
* Balance weight pitch diameter bolts 6 10.07 10.5 44 72.37 76
* Main bearing cap necked down bolts (obsolete) 10.9 4 8 10.57 11 .5 29 58 76 83
* Main bearing cap necked down bolts (obsolete) 12.9 4 8 13 . 7 14 29 58 94 7 10 1
* Main beari ng cap pitch diameter bolts 12.9 4 8 19 7 20 29 58 137.57 145
* Main bearing cap pitch diameter bolts 10.9 4 8 14 7 15 29 58 10 1 7 109
* Connecti ng rod nuts "Angle" tightening procedure, refer to lllust. 144
* Annu lar spring t ightener element or clamping ring 3 6 6 6.5 21.7 43.5 43.57 47
* Capscrew-clamping ri ng f ront pto 1.5 2.7 3.0 10.8 19.5 22
** Idler gear necked down bol t (obsolete) 9 9.5 65 69
* * Idler gear pitch diameter bolt 10 7 10.5 72 76
* Flywheel bolts 4 8 14 715 30 60 103 7 110
Bolts, seal ring retainer , rear 1.5 1.8 7 2 10.8 13 14.5
* Cyli nder-head nuts (obsolete) 4 8 11 .5 7 12.5 29 58 83 90
* Cyl inder-head studs (obsolete) 5 6 36 44
* Cylinder-head cap screws with round washer (obsolete) 4 8 11 7 12 29 58 80 87
* Cyl inder-head cap screws with collar 4 8 14 7 15 29 58 101 7 109
Valve lever bracket studs 3.57 4 25 29
* Valve lever bracket stud nuts 6 7 44 51
Valve lever bracket clamping screw 1.2 7 8.6
Side cover screws 1.6 7 1.8 12 13
Oil pressure gauge max . 1 max. 7.2
Temperature sender unit max . 2 max. 14.5
Exhaust manifold stud nuts 3.5 7 4.0 26 30
( Nozzle holder stud
Nozzle holder stud nuts flange mounted 0.5
1.3 7 1.8
1.2 3.6
9.4 7 13
7.2 7 8.7
Nozzle union nut nozzle holder 6 8 44 58
* Bolt crab mounted 2.37 2.7 16.6 7 19.5
Nozzle union nut nozzle holder 5 7 36.2 7 50.7
Nozzle holder leak oil connection hollow screw 0.27 0.8 1.5 7 5.8
Injection l ine un ion nuts 2 2.5 15 18
Valve cover adapter stud 1.67 1.8 11 .6 7 13
Valve cover stud nut 0.57 0.7 3.6 7 5
Valve cover screws (sheet metal) 0.57 0.7 3.67 5
Valve cover screws (gray iron) 1.5 7 1.7 11 12.3
Oi l pan drain plug (when asbesto-filled packing
ri ng is used) 5 6 36 43
Oi l pan drain plug (when coppe r ring is used) 13.8 7 15 100 7 118
Plug with socket head (oi l gal lery-crankcase) max. 1.2 max. 8.7
Injection pump gear bolt (3 rad ial li nes) 1.5 2.2 7 2.5 11 16 18
Injection pump gear bolt (6 radial lines) 1.5 2.5 7 2.8 11 19 21
Injection pump cover bolt (tighten crosswise) 0.4 0.87 3 5.8 7 7.2
Injection pu mp f lange nut 1.5 2.27 2.5 11 16 18
Injection pump p lunger end plug (AF 17) 4.5 .-;-- 5.5 33 .-;-- 40
Injection pump plunger end plug (AF 12) 1 .4 .-;-- 2.0 10 .-;-- 15
Injection pump drive shaft nut M 1 2 (AF 1 9) 6 7 44 .-;-- 50
Injection pump drive shaft nut M 14 (AF 22) 8.5 .-;-- 10 63 .-;-- 72
Hol low screws 2 2.5 15 18
Bolts, sheet metal oil pan 1.2 7 1.4 8.7 7 10
Engine breather screw 0.87 1.0 5.87 7.2
Valve set screw clamping torque 1.7 7 4.5 12.3 7 32.6
Exhaust manifold, coolant f ilter mounting stud 3.5 7 4.0 26 29
VE Injection pump support angle mounting bolt M 6 0.7 7 0.9 5.2 7 6.6
* Oiled
** Use liq uid locking compound while mounting
- 15 -
 Identification of Different Bolts

ll lust. 1
A- Shaft diameter
B - Stamping on bolt head

A - Different shaft diameter mm (inch)

Main beari ng bolts, necked down 10.4 (0.4094)
Main bear ing bolts, pitch diameter 12.7 (0.4999)
Balance weight bolts, necked-down 8.6 (0.3385)
Balance weight bolts, pitch diameter 10.2 (0.4015) (
Idler gear bolt , necked-down 9.6 (0.3779)
Idler gear bolt. pitch diameter 11 .3 (0.4449)

B - Different stamping on bolt head, e. g. 10K, 12K ,

10.9, 12.9 or a circular stamping on idler gear pitch
diameter bolt

lllust. 2
Special bolt for injection
pump gear, 6 radial lines.
Observe i ncreased torque va lue.

-15a-
 Longitudinal Section of Engine

1- Oil pump
2- Idler gear (Oil pump)
3- Crankshaft oil seal, front
4 - Crankshaft
5 - Crankshaft pinion
6 -Idler gear
7- Camshaft r-
8 - Camshaft gear 0
9 -Water pump z
G')
10- Valve seat insert
11 - Exhaust valve -1
12 - Coolant jet for injection nozzle c
13 - Valve lever shaft c
14 -Exhaust valve lever z
15 - Intake valve lever )>
16- Intake valve r-
17 - Valve stem guide (/)
18- Turbocharger m
0> 19 - Inject ion nozzle holder 0
20 - Flywheel and crankshaft oil
-1
seal, torque converter version 0
21 -Main bearing, rear z
22 - Main bearing
23 - Balance weight
.,
0
24 -Balance weight bol ts m
25- Fuel feed pump drive z
G')
26 - Oi I suction screen
27 - Flywheel and crankshaft oi l seal, z
early torque converter version m
28- Flywheel housing
29 - Flywheel and crankshaft oil seal .
dry type disk clutch version

lllust. 3
Typical DT·358 engine
 CROSS SECTION OF ENGINE
1 -Valve lever
2 - Valve housing cover
3 -Valve push rod
4 - Valve t appet
5- Fuel feed pump
6 - Camshaft
7 -Oil fil ter
8 - Oil cooler
9 - 0-ring, Cylinder sleeve
lllust. 4
Typical DT-358 engine
10 - Balance weight
11 - Oil filter
12 -Valve spring
13 - Valve stem guide
14 - Injection nozzle holder
15 - Nozzle holder insert
16 - Protect ion sleeve
17 - Injection nozzle
18- Pre-heating plug
- 17-
19 - Piston ring
20- Piston
21 -Cylinder sleeve
22 - Connecting rod
23 - Connecti ng rod bolt
24 - Main bearing bolt
25- Oil suct ion screen
26 - Tu rbocharger
27 - Oil lines
 VALVE LEVER ASSEMBLY

Valve Lever Springs

Free length , mm (inch) . ...... ..... .. 37.7 (1.48)

T est length , mm (inch) ... . .......... 25.0 (1.00)
Test load, N (lbf) . . .... . ... . ..... . .. . 29 (6.6)

Removal and Disassembly

11 ..s>--25 Thoroughly clean the engine externall y.

,."~~ Remove valve housing cover.

~
~14
~17 f;i13 a-:16

~,·'~ 19

~20
~--21

lllust. 5

General lllust. 6

The valve lever assembly receives its lubrication through 1 - Studs

the hollow valve lever shaft. Oil holes are provided in the
valve lever shaft (5) lllust. 5 to lubricate individual va lve
levers.
An oil port is provided in the shaft which must line up
with th e respective oil-way in the bracket. The mark (3)
lllust. 8 must be in line with the clamping slot of the
front bracket. Replaceable oil plugs (24) lllust. 5 are
used to close up both ends of the shaft .
Valve levers for intake and exhaust valves differ in length
but are provided wi th the same replaceable bushings
which must be reamed to size after installation .
Replacement levers are suppl ied with bushings in place.
2 - Clamping bolts
3 - Valve lever shaft bracket, front
4 - Valve lever shaft bracket, rear
5- Pressure spring
6 - Valve push!od
Remove nuts from studs ( 1) I I lust . 6and lift the complete
va lve lever assembly clear of the cylinder head. Loosen
clamping bolts (2) and press in brackets slightly towards
the center, taking care that they do not sl ide off the
shaft , resulting in levers and springs etc. being scattered
all over th e fl oor. Slide all parts off the shaft and place
them on a table in removal order to facilitate correct
reassembly.

Cleaning, Inspection, and Repair

Specifications
Clean all parts in kerosene or Diesel fuel and blow dry
(refer to lllust. 5)
with compressed air. Be sure all oil passages are free
from sludge and sediment.

Valve Lever and Shaft Check valve lever shaft, lever bushings, thrust washers,
and spacer rings. Check bushings and valve lever shaft for
Valve lever shaft diameter, scoring and out-of-round wear and replace, if necessary .
mm (inch) . . . . . . . . . . . . 21.56-21 .59 (0.849-0.850) Use a suitable drift punch and press plate and drive
bushings out of valve levers.
Valve lever clearance on
shaft, mm (inch) ....... 0.023-0.064 (0.0009-0.0025) Instal l new bushings. The new bushing must be flush
with the two side faces (5) lllust. 7. Use a 3 mm= 1/8"
Valve lever bushing reamed drill to open the oil passage (4) in the bushing and re-
to size (inner diameter), move chips and burrs. Ream the bushing to size, see
mm (inch) . . . . . . . . . . . . 21.62-21.64 (0.851-0.852) "Specifications".

- 18 -
 VALVE LEVER ASSEMBL V

Regrin d valve levers that show excessive wear or hammer-

ing at the ends (3) which contact the valves. Remove
only enough material to give an even face on the end of
th e valve lever and take care that the rounding is main-
tained lengthways to assu re perfect gliding action on the
valve stem. Be sure that the surface is not ground out of
line with the valve lever shaft in the lateral plane as this
would place si de thrust on the valve stem, thereby
causing out-of-round wear on the valve guides.

ll lust. S

1 - Valve lever shaft

2- Valve lever shaft bracket, front
3 - Punch mark
4 - Clamping slot
5 - Clamping bolt
6- Expansion plug

Tighten clamping bolt (5) l ightly t o secure th is adjust-

lllust. 7 ment.

1 - Exhaust valve lever Slide all remaining parts on the shaft, observing the
2 - Lever bushing order given in lll ust. Sa.
3- Va lve contact end
4 - Oil passage, 3 mm f/J = 1/S" f/J
5 - Side face
6 -Valve adjusting screw
(
7 - Lock nut

Where appropriate grinding facilities for valve levers are

not available it is advisable to inst all new valve levers.

Inspect contact face of the valve adjusting screw (6) for

hammering.

Replace worn screws with new ones.

Check expansion plugs on both ends of the lever shaft

for leakage and replace plugs, if necessary, using liquid
sealer. Check valve lever springs against specifications
and replace with new ones if signs of corros ion, chafing
or fatigue begin to show.

Inspect valve housing cover for cracks and dist ortion.

Reassembly and Installation

I !lust. 8a
Reassemble the va lve lever shaft in accordance with
lllust. Sa; commencing wi th front bracket (1 ). Oil all 1 - Valve lever shaft bracket, front
parts slight ly before reassem bly. 2 - Valve lever shaft bracket, rear
3 - Exhaust valve lever
Punch mark (3) lllust. S of the shaft end must be in Iine 4- Intake valve lever
with clamping slot (4). This will ensure that oil passages 5- Clamping bolt
in brackets and shaft correspon d. 6- Spring

- 19 -
 VALVE LEVER ASSEMBLY

2 3 5 4 2 lll ust. 9
1 - Bracket, front
2- Spacer
3- Exhaust valve lever (short)

d 4- Intake valve lever (long)

5- Washer
~, 6- Spring
~ A- Max. 1.2 mm (0.047 in.) deviation of center line
FRONT I between lever and valve stem

r=-
~· J
...J..__ __.__

I 6

On reassembly observe the following:
Spacer ri ngs are installed on either side of every inner
valve lever shaft bracket and on the inner side of the
front bracket (1) Ill ust. 8a. There is no spacer ring
between th e rear bracket (2) and the adjacent valve
lever.
Springs (6). located between each valve lever pair, have
thrust washers on both sides. Take ca re to alternate
intake and exhaust valve levers. Slide the assembly on
studs (1) lllust. 6. Install stud nuts and tighten.
Check (A) lllust. 9. Adjust valve clearance.

- 20-
 CAMSHAFT AND IDLER GEAR

General

The camshaft ( 19) l llust. 10 is driven from the front end

of the crankshaft through a train of gears. A ll gears are
punch-marked to ensure correct tuning.

The camshaft is supported in bushings.

End float is con trolled by thrust plate (20). The drive

gear (21) is keyed and shrunk to the camshaft end.

The camshaft bushings are pressure lubricated from the

oil gallery and have drilled holes.

I Ilust. 10

Specifications
(refer to I Ilust. 10)

Camshaft (19)

Cam lobe lift 8.10 (0.318)

(
Journals, OD, mm (inch) 58.00 - 57.97 (2.2835-2.2823)
Bushings, ID, mm (inch) 58.054 -58.024 (2.856-2.844)
Camshaft running clearance in bushings, mm (inch) 0.24 - 0.084 (0.001 0 - 0.0033)
Camshaft end float, mm (inch) 0.10 - 0.45 (0.004-0.018)

Thrust Plate (20)

Thickness, mm (inch) 7.01 - 6.96 (0.276- 0.274)

Gear (21)
Backlash, Drive Gear (21 I Idler Gear (30), mm (inch) 0.09 - 0.27 (0.0035- 0.0106)

Idler Gear (30)

Running, clearance, mm (inch) 0.010- 0.040 (0.0004- 0.0016)
End float, mm (inch) 0.20 - 0.33 (0.008-0.013)
Idler gear carrier (29), OD, mm (i nch) 35.000-34.989 (1.3779-1.3775)

Removal and Disassembly Note 2: Cam lobe lift may be checked by means of a dial
indicator gauge.
Note 1: Before camshaft removal check :
a) Backlash of camshaft drive gear
b) Camshaft end fl oat
c) Cam lobe lift
Rest the stylus of the dial indicator on one of the push
rods.
Rotate th e engine one revolution and note dial indicator
reading.
u
Compare reading with "Specifi cati ons" .

- 21 -
 CAMSHAFT AND IDLER GEAR

lllust. 13
lllust. 11 1 - Idler gear carrier 2 - Aperture

Remove valve housing cover, valve lever shaf t assembly Remove idler gear carrier (1) 111ust. 13.
and crankcase front cover. Refer to respective secti ons.
Lift out push rods. (Arrows, I Ilust. 11.) Remove camshaft th rust plate retainer bol ts. These can
be reached through apert ures (2).

--
eftU!'M(~Ui~ll· A
ll l ust. 12 lllust. 14
1- Camshaft drive gear 1 - Camshaft 2 - Valve tappet
2- Aperture
3- Idler gear Remove crankcase side cover.
4 - Idler gear bolt, LH thread
Hold tappets in their t op-position, using a rubber band
or tu rn engine on its side or pan side up.

Check backlash, running clearance and end float of idler Carefully pull out camshaf t (1) lllust. 14 and remove
gear (3) lll ust. 12 before removing it. tappets (2) .

Remove bolt (4) (LH thread) with washer. Take off idler If necessary press off camshaft drive gear, taki ng care
gear with needle bearings and thrust ring. not to damage the drive slot for the tachometer.

- 22-
 CAMSHAFT AND IDLER GEAR

Cleaning, Inspection and Repair

A

5 Section A- A

(
Front View

Procedure for Line Boring Camshaft Bushings If the camshaft bushings need to be replaced, steam
clean the engine block and replace the ol d bush ings with
lll ust. 15 semi -finished bushings as shown i n lllust. 15 using FES
Install and I i ne-bore bushings as shown 101 camshaft Bearing-Driver.

mm (inch)
58.054 2.2856 after line-boring The foll owing line boring equipment or its equivalent is
58.024 2.2844 required to I ine bore the camshaft bushings.

Kwik-Way or Model LB 2000

146.787 5.7789 Lempco or LB 2600
2 - radius
146.858 5.7818 AMC Danish Mfg.
BERCO Italian Mfg.
3 - Camshaft bushings must be flush with these sur-
faces

4 - Oil holes in all camshaft bushings must line up

with oil holes in crankcase

5 - Idler gear bolt hole

-23-
 CAMSHAFT AND IDLER GEAR

Note: The idler gear carrier (2) with retaining bolt (1)
must be fu rni shed as shown in lllust. 16 to the machine
shop for locating the radius (2) l llust. 15.

lllust. 16
Idler gear carrier with reta ining bolt

1 - Idler gear carrier reta ining bolt

2- Idler gear carrier

With the engine block positioned on the table of the

machine, indicate to the semifinished bush ing on both
ends of the boring bar and position the block so as not
to exceed 0.025 mm = .001 " run out from front to rear.
lllust. 17.
(

lllust. 17
Establ ishing minimum run -out.

Check for the specified radius (2) lll ust. 15 as follows:

a. Add one half of the outside diamet er of the idler gear

car rier and one half of the boring bar diamter to the
speci fied radius. Using an outside micrometer, check
as shown in lllust. 18.

b. If the radius does not fall within specifications, the

boring bar must be moved accordingly t o f all within
specifications on both heads (1). See lllust. 19.

u lllust . 18
Checking radius

- 24-
 CAMSHAFT AND IDLER GEAR

lll ust. 19
- Boring bar heads
With the camshaf t gear and idler gear installed check for proper gear backlash, see "Specif ications".

Camshaft

Camshaft Gear, Thrust Plate and Idler Gear

Replace t he camshaft gear and the idler gear if gear back-

lash (as checked prior t o removal) is not within specified
limits.

Inspect the teeth of these gears also for ch ipping, cracks

and burrs. Replace damaged gears.

Check the condition of t he t hrust plate. Refer to "Speci -

f ications".

If wear is excessive, replace the thrust plate.

Replace camshaft gear as follows :

lllust. 20
Points of measurement to determine
cam lobe wear
Inspect cam lobes for wear. Compare with a new cam-
shaft. If a new camshaft is not avai lable, use a microme-
ter and take a readi ng across "A- C" ll l ust. 20 and
deduct dia "8-0". Th is wil l give the cam lobe lift. Refer
to "Specif ications".
Install the t hrust plate on the end of the camshaft and
insert the Woodruff-key. Heat the camshaft gear to
approximately 400 °F (200 °C), install it on the shaft
with the timing marks pointing outwards and press f lush
with camshaf t front end.
Important: Use FES 11 5-1 Thermomel t St ick to deter-
mine the temperat ure. Mark the surface to be heat ed.

Inspect camshaft journals for wear , refer to "Specifica-

tions".
The mark will appear dul l and cha lky. When the desired
temperature is reached, the mark w ill melt and become
a glossy liquid. Do not be concerned wi th a change in
u
Replace the camshaft if wear is excessive. col or.

- 25 -
 CAMSHAFT AND IDLER GEAR

lllust. 23
lllust. 21 1 - Idler gear carrier I 2 - Needle bearings 3 - Spacer
Pressing drive gear onto camshaft
1 - Supporting plate 2 - Bearing journai 3 - Drift punch

lt may be necessary to press the gear into its proper

position on the shaft.

Idler Gear Carrier and Needle Bearings

lllust. 24
Arrows - Timing marks aligned
When installing the idler gear make sure the timing
marks of the gear train are in li ne, lllust. 24 .
Coat the threads of the idler gear bolt with loctite
No. 41.
Install the thrust washer and tighten to specified torque.
Check idler gear end play.
lll ust. 22
1 - Idler gear carrier 4 - Thrust washer
2 - Idler gear 5 - Necked-down bolt (displaced )
3 - Needle beari ngs 6 - Spacer ring

Replace parts (1-4) I Ilust. 22, if runn ing clearance and/

or end float of the gear (as checked prior to remova l) is
excessive.

Replace needle bearings (3) as a set only. Replace

necked-down bolt (5) with the new pitch diameter bolt
(LH thread).

Reassembly and Installation

Turn the engine on its side or bottom side up.
Lubricate valve tappets and camshaft with SAE 30 and
install into the crankcase.
Tighten thrust plate retainer bolts alternately. Check
camshaft end play.
Install parts (1-3) as shown in lllust. 23 Lubricat"!
needle bearings (2).
ll lust. 25
Gear t rain and timing marks
If the injection pump is installed the foll owing must be
observed:
The injection pump drive gear is used for more than one
engine and carries a serie of timing marks, numbered
from 1 to 6, lllust. 25.
For detail s refer to lllust. 212 and respective chart.

- 26-
 CYLINDER HEAD- VALV ES AND VALVE GUIDES

General

Cylinder heads of naturally aspirated engines (NA engines)

are fitted wi t h va lve seat insert for exhaust valves.

Cylinder heads of turbocharged engines are fitted with

valve seat inserts for both, intake and exhaust valves.

The valve seat inserts can be replaced if necessary.

For this purpose valve seat inserts of two oversizes and a

respective cutting tool assembly are available.

Specifications

(refer to l ll ust. 26)

11~
Cylinder head (1)
ll lust. 26
Cyl inder head for turbocharged engines
mm (inch)
1- Cylinder head 98.81 (3.8902)
2- Gasket , refer to I Ilust. 53
Thickness, new, ---
99.31 (3.9098)
3- Nozzle holder sleeve
4- * Adapter Min. permissible
5- Stud , valve lever shaft bracket thickness when
6- Stud, exhaust manifold sealing face has (
7- Stud , coolant manifold been reworked, 98.54 (3.8795)
8- * Seat insert , intake valve
9- U-plug Warpage on sealing
10 - U-plug surface, max. 0. 12 (0.0047)
11 - * Coolant jet
12 - Va lvespri ng lock
13 - Valve spring retainer cap
14 - " Valve spring Valve spring (1 4) 3 136 000 R1 3 055 060 R1
15 - Valve stem seal (yellow spot) * (red or green spot) *
16 -* Rotocap Free length, mm 52.5-55.5 55.3
17 - Valve stem guide inch 2.06-2. 19 2. 18
18 - lntakevalve
Test length, mm 34.2 34.2
19 - * Exhaust valve
inch 1.34 1.34
20 - Seat insert, exhaust va lve
21 - Seal ring Test load kg 69-76 66-72
22 - Plug lbs 152-168 145.5-158.7
23/24 - Lifting eyes * For appl ication see parts cata log.

* Equipment of cy linder head depends on application Note: Before testing a new valve spring, load it all the
refer to Parts Catal og . way to b locki ng height.

- 27 -
 CYLINDER HEAD- VALVES AND VALVE GUIDES

f- I ____,... _

lllust. 27
Oversize valve seat insert counterbore chart

Exhaust Counterbore Dia

Insert Size
mm (inch) (1) lllust. 27
0.15 (0.006) 42. 15 ( 1.659) 42.22 ( 1.6622)
oversize
--
42. 17 (1.6602)
- -
42.24 (1.6630)
0.40 (0.016) 42.40 ( 1.6692) 42.47 (1.6720)
-- (1.6700)
- - (1 .6728}
oversize 42.42 42.49
Counterbore Dia
Intake
(2} I I lust. 27
0.15 (0.006) 44.183 (1.7395) 44.22 (1.7409}
oversize 44.204 ( 1.7406}
- -
44.24 (1.74 17}
0.40 (0.016} 44.433 (1.7493) 44.47 (1.7509)
- -
oversize 44.454 ( 1.7502) 44.49 (1 .7516)

_ 12.24 mm (0.482)
3
12.29 mm (0.484)

0.5mm (0.020) (R )
4-
0.7 mm (0.028)

Counterbore dia (1) and (2) lllust. 27 must be at righ t

angles and concentric to the va lve guide bore within
0. 10 mm (0.004 inch) T. I. R.

u
-28-
 CYLINDER HEAD- VALVES AND VALVE GUIDES

lllust. 27a
1- Intake valve 6- Rotocap
2- Exhaust va lve 7 -Valve spring retainer cup ·
3- Valve spring 8 -Valve spring locks
4- Valve stem guide 9 - Valve stem seal
5- Valve seat insert 10 - Coolant jet
exhaust
5 A - Valve seat insert, intake
(turbocharged engines only)

Valve Timing

Intake opens - degrees before TDC ..... .. .... 13

Intake closes- degrees after BDC . . . . . . .. . .. . 43
Exhaust opens- degrees before BDC . . . . . . . ... 46
Exhaust closes -degrees after TDC . . . . . .. . ... 10

Valve Dimensional Chart, //lust. 27a (

Intake Ex haust
mm inch mm inch
A/B. Distance from the face of the cy linder head to the 1.0 - 3.0 0.04 - 0.12 1.2 -3.0 0.047-
face of the va lve 0.12
C. Distance from top of valve quide to bottom of the
spring recess 28 1.102 28 1.102
D. Valve stem diameter 9.955 - 0.3920- 9.935- 0.3912-
9.965 0.3924 9.945 0.39 15
E. Valve head diameter 42.8 - 1.685 - 40.8- 1.606 -
43.0 1.693 41.0 1.614
G. Valve guide OD 16.060- 0.6323 - 16.060- 0.6323-
16.078 0.6330 16.078 0.6330
H. Valve guide ID (after reaming) 10.00- 0.3940- 10.00- 0.3940 -
10.02 0.3945 10.02 0.3945
Minimum valve seat contact width 1.5 0.059 1.5 0.059
Maximum al lowabl e stem clearance in guide
before reconditioning 0.15 0.006 0.15 0.006
Valve face angle, between seat and bottom of
valve head, degrees 45 + 15'
Valve seat angle in cylinder head, degrees 45
Maximum allowable eccen tricity :
- valve seat bore to valve guide bore 0.10 0.004 0.10 0.004
- valve face to valve guide bore 0.02 0.0008 0.02 0.0008
Minimum valve face width 1.2 0.047 1.2 0.0047
Valve lash (engine warm) 0.30 0.012 0.30 0.012

-29-
 CYLINDER HEAD- VALVES AND VALVE GUIDES

Removal and Disassembly Take off valve lever shaft assembly and valve push rods.

Clean the engine externally. Mark disassembled parts,
such as valves, valve stem guides and springs and place
them on a table in remova l order to facil itate reassembly.
To avoid warpage do not remove cylinder head screws
unless the engine has cooled down.
Remove cylinder head. T o faci litate lifting the cyli nder
head , lifting plates lllust. 30 are provided.

lllust. 28
1 - I ntake elbow
2- Injection lines lllust. 30
3- Intake manifold

lllust .3 1
Measuring va lve recession
lllust . 29 (refer to " Specifications" for maximum
permissible recession)
1 - Exhaust elbow 5 - Exhaust manifold
2- Turbocharger 6 - Coolant manifold
3- Oil return line 7 - Valve housing cover Inspect valves for wear, I ll ust. 31.
4 -Oil Pressure line 8 - Cylinder head
Excessive wear w ill make for hard starting and impair
engine efficiency.
Note: Illustrations (28 and 29) show a typica l turbo-
charged engine. Remedy:

Remove parts according to I I lust. 28 and 29 . a) Install new va lves

Plug all openings of injecti on pump, injecti on pipes, fuel
line and nozz le holder to prevent entry of dirt into t he
fuel system.
Note: Cylinder head and manifolds can also be removed
as a uni t, how ever, disassembly is necessary wh en
clean ing intake and exhaust bores.
Remove valve housing cover (7) lllust. 29.
b) Install new valve seat inserts
(NA engines, exhaust only)
c) Rework cyli nder head sealing face.
Before rework :
a) Check wh ether the cylinder head height permits
reworking.
b) Check to see, if nozzle tip protrusion will remain
w ithin specified l imit s after rework.

- 30 -
 CYLINDER HEAD- VALVES AND VALVE GUIDES

Cleaning, Inspection and Repair

Clean cy linder head th oroughly.

Remove carbon deposits from the bottom of the cylin-

der head and out of exhaust valve ports.

Flush out water jacket to remove scale and dirt.

Note: Make sure water passages are free of obstructions.

rust or scale.

lll ust. 32
Removing valves

To remove valves compress valve springs with compres-

sor tool and take out spring retainer locks, I I lust. 32.

lll ust. 35
Crack check (
Inspect cylinder head f or hair cracks, using modern
spraying methodes , lllust. 35.

lllust . 33
Removing valve seat inserts

To remove valve seat inserts, first weld two opposite lugs

(2) lllust. 34 to provide puller grip.

lllust. 36

lllust. 34

1- Exhaust valve seat insert

Inspect th e cylinder head (and the crankcase) f or war-
page if engine has been run with a blown head gasket.
lllust. 36.
u
2 - Welded lugs Observe checking pattern, lllust. 37 , see "Specif ication".

- 31 -
 CYLINDER HEAD- VALVES AND VALVE GUIDES

inhi bitor. Check for leakage at lower 0-rings of cyl inder

sleeves, coolant pipes, nozzle bushings, etc. Eliminate
any possible leakage.

Where testing facili ties are available, this test can more
easily be made on a block as shown in lllust. 37b. The
cyl inder head must be mounted on the block in the same
. manner as on the crankcase. For th is purpose the block
lllust. 37 must be level within 0.05 mm = .002".
Checking pattern, cylinder head
and crankcase

If more than a. 0.12 mm (.0047 inch) feeler gauge can

be entered under the strainghtedge, the head (not the
crankcase) may be reworked to true up on possible
warpage or distortion.

Note: Check the cyl inder head height before reworking.

Do not reface the head, if its min imum allowable

reconditioned height is below specified limits.

Replace distorted head.

If leakage is suspected in the water jacket of the cy linder

head and crankcase, make the following test : lllust . 37b
1 -Connecting hose
Mount cylinder head with valves and nozzle bushings on 2 - Coolant manifold
cran kcase. Remove oil pan, crankcase front cover, intake 3- Hose
and exhaust manifolds and thermostat.
( 4 -Shut-off valve
5 - Studs
6 - Testing block

Oversize Valve Seat Inserts

Rework counterbore in th e cyl inder head, refer to
"Specifications".

Before enlarging the counterbore , be certain valve guides

and th e pil ot of the special cutting tool are in order.

Chill th e new valve seat inserts to at least -60 °C = -76 °F

in dry ice before installat ion . This prevents metal scrap-
lllust. 37a ing from th e side of the counterbore, ensuring fu ll con-
tact of the insert on the bottom and sides of the coun-
1 - Water intake port terbore.
2 - Tapped hole
Install new insert using an insert driver provided for this
Seal water intake port (1) ll lust. 37a properly with a purpose, see Parts Catalog.
gasket and a suitable cover plate. Connect the hose of a

A
suitable pump to the coolant manifold in place of the When using carbon dioxide strictly adhere to
connecting hose (3) lllust. 37b. Pump in water at a instructions to avoid injuries. Do not touch
pressure of 2 bar = 28.4 PSI preferably adding a corrosion deep frozen parts with bare hands.

u
- 32 -
 . ~

CYLINDER HEAD- VALV ES AND VALVE GUIDES

Note: Before instal ling the pilot, be sure that the valve
guides are perfectly clean and meet the engine specific-
ations. This is important; otherwise, an eccentric seat
C will be cut.

2. Dress the wheel to the correct angle. L ightly lubricate

and install the p ilot of the correct size into the valve
guide bore.
[IJ A
3. Lower the grinder head over the pilot shank until
the wheel just clears the valve seat. Turn on the power
and very gently allow the wheel to con tact the valve
lll ust. 38 seat. Very little pressure other t han the normal weight
Valve seat insert of the wheel should be used. Sudden hard pressure can
cause cocking of the pilot in the guide and result in
A Intake valve, mm (inch) eccentric grinding. Raise the wheel frequently from the
42.7 ± 0.2 (1.68 ± 0.008) valve seat to prevent overheating and to clear away
A Exhaust valve, mm (inch) grinding dust. Grind the seat sufficiently to provide an
40.7 ± 0.2 ( 1.60 ± 0.008) even, smooth surface. Valve seat angles for intake and
B refer to lllust. 27 exhaust valves are identical lllust. 39.
C Early design: 10 mm (0.39 inch)
C Late design: intake valve, 9.0 mm 4. Check the seat concentricity, roundness and valve
(0.35 inch) face contact using Prussian b lue. Spread an extremely
exhaust va lve, 8.75 mm (0.34 inch) thin fi l m of this blue on the valve face and insert the
D Early design: 30° valve into its gu ide. With pressure on the exact center of
D Late design: 15° the valve head , make a quarter turn rotation in the seat.
Remove the valve and inspect the impression made upon
the seat by the transfer of bluing, and upon the valve
face by the removal of bluing. The valve seat should
center on the valve face and must be concentric with
A the bore of the valve guide within 0.000 - 0.10 mm
B (0.000 - 0.004 inch). Check several ti mes to guarantee (
that no error was made. If a full seat-width contact
around the entire circle of seated valve is not shown, the
angles do not match. lt will then be necessary to redress
the valve seat grinding wheels, changing the angle suffi-
ciently to correct the error.

The correction should be made on the valve seat, not on

c the valve.

lllust. 38a
Insert Ring Properly Installed
A Valve insert ring
'SEB/i-V~
B Insert must be tight fit in counterbore
c Bottom of insert ring must seat squarely on
bottom of counterbore

Note: Do not install inserts by hammering or stirking

insert driver.

Th e following procedure applies for refaci ng seat inserts

or facing new inserts.

1. Remove all carbon, scale and oil before attempting

to reface valve seats. The grinding wheel, when placed
against an oily seat, wi ll become fouled, and uneven lllust. 39
grinding wi ll occur. Va lve Seat Angles

-33-
 CYLINDER HEAD- VALVES AND VALVE GUIDES

Wear Parts

3
1
~
l ll ust. 42
Installing valve guides
l ll ust. 40
1 -Valve
2 -Valve guide
3- Valve stem seal
4 - Rotocap or spring retainer cup
5 -Valve spring
6 -Valve spring retainer
7 -Valve spri ng retainer locks

On major engine overhaul it is recommended to replace

the wear parts (1) to (7) I I lust. 40.

Occasional ly, when the cylinder head has been stripped

down inspect above parts and replace them as necessary. A
Renew valve stem seal (3) whenever valves have been
removed. lll ust. 43
Valve gu ide installi ng tool

A - 120 mm (4.72 inch) B- 28 mm (1.102 inch)

Use special tool, lll ust. 42 and 43 to ensure correct

depth of guides in the cylinder head. Be sure the stepped
end of the guide is up. Check the tool for dimension "B"
and grind down if necessary.

lllust.41

Use a steel spiral brush to re move carbon deposits in the

guide bore. lllust. 41. Wash down guides, using cleaning
solvent. Blow out all carbon with compressed air.
Position a light at the bottom of the guide bore, and
examine the wa lls for burning, cracking and signs of
excessive wear. Check the inside diameter of the guide
lllust. 44
bore at several points around its circumference and
along its length. Specifications for th e guides are given
New valve guides must be reamed to size, lllust. 44, see
in "Specifications". Replace any guides considered "Specifications".
unserviceable or that appear close to a serviceable
borderline. Clean guides after reaming.

-34-
 CYLINDER HEAD - VALV ES AND VALVE GUIDES

Inspect valves f or wear against "Specificat ions". Scrap
excessively worn valves.
If reconditioning valves make sure head margin and
concentricity are within specifications.
To remove the nozzle sleeve use special bolt (7 /8 x
4 inch) PL T-509-11 (F ES-25-12) and turn it into the
sleeve. The bolt wi ll cut its own threads into the brass
sleeve. Then screw si ide hammer adapter OTC-12M
(7/16 in. x 14 NC) into the end of the bolt and use the
sl ide hammer to remove the nozzle sleeve lllust. 47.
Remove the sleeve from the tool and discard.

lllust. 45
Grinding valve face w ith refacing machine

A fter refacing each valve, inspect the end of the stem. If

wear is noticeable, reface the end of the stem. Grind
sufficientl y to true-up the end of the stem.

Lapping
lllust. 47 (
Removing Nozzle Sleeve

1 - Adapter (0TC-12M) 2 - Special bolt

Inspect the nozzle sleeve bore i n the cy linger head and

be sure it is clean and free of grease, oil, scale or rust.

l ll ust. 46
Lapping valves into their sea ts

After lapping, valve faces and seats must be perfect ly

smooth and show even markings. Be sure to clean away
all remnants of grinding compound.

11
Again check the valve recession. See "A" and "8 ,

ll lust. 27a.

ll lust. 48
Nozzle Holder Sleeves
1 - Nozzle-holder sleeve
The injecti on nozzle sleeve can be replaced without 2 - Sealing areas ( Loctite grade B)
removing or disassembling the cylinder head. If done this
way, be sure engine coolant is drained below the cy li n- Coat the sealing areas of the new nozzle sleeve with
der head level before removing the sleeves. Loci te, lllust. 48.

- 35 -
 CYLINDER HEAD - VALVES AND VALVE GUIDES

U-Piugs
Cl990

I I lust. 49
Installing nozzle holder sleeve with special t ool
lllust . 51
Use the tool provided to drive the new sleeve into posi-
If leakage is apparent at the plugs, replace t he plugs.
ti on, l llust. 49. Be sure that the sleeve is completely
Install new plugs with a suitable drift punch using heat
bott omed in t he cyl inder head .
resistant liquid sealer. Plugs must not protrude from
sealing su rface of the cylinder head.

Reassembly and Installation

Valves

Coolant Jets

Installi ng valve stem seals

1 - Plastic jumper
2 -Valve stem seal

•
3- Rotocap or spring retainer cup

When install ing valve stem seal (2) l llust. 52 first place
the rotocap (3) on the valve guide, insert the valve and
l llust. 50 slide jumper (1) over the valve stem end. Instal l the seal
Coolant jet, if so equipped so that it wi ll bottom on t he valve guide.

To remove the coolant jets it is good practice to t ap the After the new seal is installed d o not remove the valve.
inside, see arrow, lllust. 50 and pull out the jet with a
suitabl e screw. To fit valve springs proceed as f ollows:

When install ing new jets, take care that sealing faces With jumper (1) lllust. 52 on the valve stem fit valve
(arrow) are flush with the cyl inder head. springs (3) lll ust. 27a with retainer cups (7).

- 36-
 CYLINDER HEAD - VALV ES AND VALV E GUIDES
' llSO
Using a spring compression tool depress spri ngs only far
enough t o insert spring locks (8). Remove jumper f rom 9 5 7
valve stem and fi t spring locks (8) .

Check valve recession "A" and "B" against "Specifica-

tions".
gOO 600600g
012 0 04 0 02 0 014
8 6 10

Cylinder Head
l llust. 54
1. Clean the carbon f rom the pistons and be sure the
gasket surfaces of the crankcase and cylinder head are
clean and dry .
'£QSO
2. Be sure there is no oi l in the bottom cy linder head 14 6 4 12

~0
0 ~0
0 bOO ~0
0 ~
bolt holes to prevent hydrau lic lock when the bolts are
torqued.

3. Before install ing th e cylinder head, check cyl inder

sleeve prot rusion, refer to lllust . 79. If the sleeve pro-
trusion is not w ithin specif ications. remove the sleeve
FRONT
~

0
15 0
11
000
7 0
3
2 0
5
9 0
13
0
17

and fol low the complete procedu re under l ll ust. 79.

lllust. 55
4. Install a new cy linder head gasket lll ust. 53 to the
crankcase. Using a hoist and sling, move the cylinder
head into place on the crankcase.

'Sl66
22 14 6 4 12 20
~Do~Oo~O
0
o 6
0 0 0
0o~Oo]fOO~
0 0 0
4

23 0 15 0 7 0 2 0 9 0 17 0 25
19 11 3 5 13 21
lllust. 56
Torque sequence f or cyl inder head

6. Foll ow the reassembly procedure as below, referring

to the respective sections of thi s manual where necessary.

Install valve lever shaft assembl y.

ll lust. 53
" Maintenance-free" Cylinder head gasket Adjust valve clearance.
A - lndentificat ion characteristic; red plastic borders
around the water and oi l sealing faces Replace valve housing cover, using a new gasket.

5. Foll owing the sequence given in diagram lll ust. Replace manifolds and thermostat.
54, 55 or 56 t ighten t he cy linder head bolts in three
steps. Strictly observe torque load of the cylinder head Install turbocharger.
bolts. Refer to "Special nut and bolt torque data".
Never use bolts with damaged or marred threads as these Install injection nozzles and nozzle holders.
trend to show a high torque reading.
Reconnect fuel lines.
Note: Cylinder head is mounted either with studs, bolts
with washers or with f lange bolts, depending on year of Fil l the f uel tank and vent the fuel system.
manufacture.
Fill in engine oil.
Note: If bolts or studs must be replaced, do not mi x up
parts, replace complete sets. Fill the cooling system.

- 37 -
 CYLINDER HEAD - VALVES AND VALV E GUIDES

Retighten cy linder head bol ts to speci f ied t orque, to

I I lust . 54, 55 or 56 for sequence.

8. Check valve clearance, and readjust as necessary.

Note: When retorqu ing cy linder head nuts or bolts,

only th ose below proper torque are to be retorqued to
specificat ions. The remaining nuts or bolts, complyi ng
wit h or above torque specifica tions must not be loosened.

lllust . 57 Retorquing cylinder head nuts or bolts using torque

7. Start and rund the engi ne at 3/4 rated engine speed
with no load , until operating temperature (80 - 850C)
is reached, cover t he radiator if necessary. DO NOT
run for over 10 Minutes.
wrench and special wrench lllust. 57.
Note: Re-t orquing of cyl inder head bolts or nuts in the
f ield is not necessary when the new " Maintenance-f ree"
cy linder head gasket l llust . 53 has been inst alled.

-38 -
 MANI FOLDS

General Cleaning, Inspect ion and Repair

Manifolds are used in various designs, depending on
engine type and applications, see Parts Ca talog.
Inspect manifolds for tight sealing, whenever the engine
is overhauled.
Clean the manifold and inspect for cracks and distortion.
Replace the manifold with a new one, whenever dis-
tortion is more than 0.4 mm (.016 inch) per 250 mm
(1 0 inch) length.
Inspect air hose and hose clamps.

Inspect retai ner bolts and their washers. Replace damaged

parts.

Installation

Install the intake and exhaust manifolds and secure,

using capscrews or stud nuts. Always use new gaskets
when installing the manifolds.

l llust. 58
1 - Intake manifold 4 - support
2 - Heating pi pe 5 - Turbocharger
3- Exhaust man ifold

lll ust. 60
Turbocharger installation on a Tractor engine

1 - Compressor housing 5 - Supply oil line

2- Center housing 6- Return oil line
3 - Turbine housing 7- Support
4 - Exhaust elbow 8- Hose

Note: Retighten manifold bol ts after the engine is hot

and again (not later than 250 operating hours).

Reconnect the fuel lines to the inject ion nozzles and

lll ust. 59 pump. Secure the fuel line clamps to the intake mani-
fold. Install fuel fi lter and supply line if removed.
1 - Intake manifold
2- Heati ng plug Note: For turbocharger mounting instructions refer to
3 - Air line to aneroid Service Manual "Fuel System and T urbocharger" .

. 39 .
 FAN- V -BE LT

General Tilt the generator towards the engine and remove th e

V-bel t. When removing fan retainer bolts, spacer ring and
V-belt pulley wi ll come off together with the fan.

If spacer ring (2) lllust. 62 cannot be removed by hand,

tap it lightly with a mallet, taking care not do damage
the seat on t he water pump.

Cleaning, Inspection and Repair

lllust. 61

The fan (1) lllust. 6 1 is mounted on the water pump. A

spacer ring (3) is used to provide the required clearance.

Fans differ in shape of fan blades, effective diameter, lllust. 63

number of blades and direction of air f low; see resp. Checking height of blade edges
Parts Catalog. Clean the fan.

Inspect fan for cracks and distortion. Check to see th at

Removal and Disassembly al l blade lead ing edges are in line, as shown in I I lust. 63.

Clean the engine externally. Check for loosen ri vets.

If blades are cracked or distorted, replace the fan with

new one.

Max. permissible run-out at the fan blade t ip (instal led).

1.5-2.0 mm (0.06 - 0.08 inch) .

Installation

Sealing fa ces on pump and engine front cover must be

clean and even.

Torque bol ts equal ly and in a crosswise sequence.

lllust. 62 Install V-belt pulley, spacer and fan.

1 - Fan
2 - Spacer Adjust V-belt according to "Operator's Manual".
3 - Clamping bolt
4 - Mounting bolt When using new V -belt inform customer to readjust in
5 - V-belts t ime.

-40 -
 CRANKSHA FT PULLEY AND VIBRATION DAMPER

2 Removal

a) Remove the cap screws, retainer plate and thrust

ring, ll lust. 65a.

b) Tap the pulley with a hammer to loosen it and it

wi ll sl ide off the wedge rings.

Note: l.t should not be necessary to use a puller to

remove the crankshaft front pulley.

0-~4
lll ust. 64
0-
1 -Crankshaft pulley 3 - Wedge rings
2- Crankshaft pulley 4 - Thrust ri ngs ll lust. 65a
with vibration damper 5 - Retainer plate Pulley removed
1- Pulley 5 - Crankshaft front end
2- Retainer plate 6 - Dowel pin
3- Thrust ri ngs 7 -Timing slot (
4- Wedge ri ngs

Cleaning, Inspection and Rapair

Thoroughly clean all parts. Inspect pulley for cracks,

wear, burrs on the belt grooves and damage to the bore.

Si nce a repair is unpracti cable, a damaged pulley must be

replaced with a new one.

Inspect wedge rings for cracks and rust and replace as

necessary.

ll lust. 65
1 - Vibration damper 2- Pulley

General

The crankshaft pulley acts as a vibration damper.

3
On DT-358 and DT -402 engines an additi onal vibration
/
damper, version (2) lllust. 64 is installed.

Note: V ibration damper and pulley (2) are balanced as

once unit. Therefore, it is not recommended to separat e
Q
them; otherwise the unit has to be rebalanced to a
max imum residual imbalance of 20 cmg (0.275 oz-inch)
after reassemb ly) . lll ust. 66
1 - Pairs of wedge type rings
The pulleys are fastened either with wedge rims, I! lust. 67 2 - Thrust rings
or with clamping ring, lllust. 68. 3 - Clamping ring, see (2) I! lust. 68

-4 1 -
 CRANKSHAFT PULLEY AND VIBRATION DAMP ER

Reassembly and Installation Insert outer thrust ring (4). Replace ret ainer plate (5)
and secure wi th retainer bolts. Oil bolts (10) before
Reassemble all parts as shown in lllust. 67 or 68. inst alling, but do not use "Molykote" or "Lubricate".
Tighten bolts in three steps, refer to "Special Nut and
3A Bol t Torque Data".

Replace and tighten V -belt.

lllust. 68
V-bel t pulley, fastened wi th clamp ing ring
1 - V-belt pulley 3 - Retainer plate
2 -Clamping ring 4 - Retainer bolts
1
lllust. 67
Crankshaft pulley, fastened with wedge rings

1 - Vibration damper 8 - Crankshaft pinion

2- Pulley 9- Roll pin
3 or 3A- Wedge rings 10- Bolts
4 - Thrust rings 11 - Timing slot
5- Retainer plate 12 - Oil seal
6 - Dowel pin 13 - 0-ring
7 - Spacer ring 14 - Bolts

Be sure that wedge rings (3) lllust . 67 as well as the

pulley bore are completely clean and dry, i. e., free
from oil and grease. First slide one inner wedge ring (3)
on the crankshaft front end. lllust. 69
1 - Contact face 2 - T iming slot
Insert the outer wedge rings and one thrust ring (2) into
the belt pulley bore. T o obtain necessary static fri ction all contact faces (1)
Ill u~. t. 69 crankshaft front end must be free of oi I, rust
Slide th e belt pulley on the crankshaft front end, and dirt.
engaging timing slot (11) over dowel pin (6). Fit the
remaining inner wedge ring. Slots of wedge rings should Be sure dowel pin (6) lllust. 65a engages into timing
be evenly distributed over the entire circumference. slot (2) lllust. 69.

-42 -
 CRANKCASE FRONT COVER AND PLATE

Remove al l retainer bolts after taking off water pump.

Note: On engines equipped with water channel (13)

ll lust. 70 th e crankcase front cover is also secured by
stu d ( 1) ll lust. 72 located behind the water pump,
above the idler gear.

lll ust. 70
General

The crankcase front cover (6) lllust. 70 is a light metal

al l oy casting. lt seals the timing gear tra in and carries the l llust. 72
crankshaft front oil seal and the timing pointer.
1 -Stud
Repairs to the front cover and plate are normally re· 2 - Plug
stricted t o replacement of seals and gaskets. However, 3 - Water channel
the cover must always be removed, whenever removal 4 - Access, injection pump hub
of crankshaft, ca mshaft or idler gear become necessary.
A lways use new gaskets on reassembly. Remove the stu d nut before attempting to take off the
front cover. lt is also advisable to loosen the first 2 or 3
front bolts on both sides of the o il pan. This w ill help t o
Removal and Disassembly release tension from the oil pan gasket, thus protecting it
f rom damage.
Clean engi ne externall y . Drain coolant and engine oil.
If necessary, also remove water cha nnel (3) l llust . 72.
Remove fan, V-belt pulley, generator , thermostat
connecting hose, flange (2) I Ilust. 70 and water pump, as
described under the respective sections.

ll lust. 7 1
lllust. 73
1- Thermostat connecting hose
2- V-belt 1- Retainer bolts
3- V-belt pulley 2- Injection pump drive gear
4- Generator 3- Idler gear
5- Retainer bolts 4- Camshaft drive gear
6- Fan 5 - Dowel pin

. 43-
 CRANKCASE FRONT COVER AND PLATE
To remove the front plate it is necessary t o remove th e
camshaft , the idler gear (3 ) I Ilust . 73, t he injecti on pump
gear (2) and the injection pump f irst. For details refer to
t he respective secti ons of this manual.
l llust . 74/75
1 - Retainer bolts 3- Injecti on pump studs
2- Front plate
Remove retai ner bolts (1) I I lust. 74 and lift off t he front
plate.
Cleaning, Inspection and Repair
Clean all rarts in a suitable solvent. Remove any possible
deposits f rom water channel, water pump carrier, and
f ront cover.
Inspect th e front cover f or cracks and dist ort ion. Re-
place the crankshaft front oil seal (3) ll lust. 76, 0-ring
(9) and spacer ring (6) whenever the f ront cover is
removed.
Note: Install the new oil seal, spacer ri ng and 0-ri ng
w ith the f ront cover in place, refer to I Ilust. 76.
Inspect front plate for distortion and warpage. Install
a new f ront plate, if necessary .
Check the two studs (3) l llust. 74 f or t ight f it. When
install ing studs use liquid sealer and tighten t o 1.0- 1.2
daNm = 7.2- 8.8 f t. lbs. T ighten lock nuts and secure in
place by punching in threads.
When i nstalling the t i mi ng pointer (10) l l lust. 70 use
liquid sealer.
Reassembly and Installation
Use new seals and gaskets through out.
( Replace front plate on crankcase dowels.
Install inject ion pump, camshaft and idler gear.
Refer to "Tuning" f or correct meshing of timing gears.
- 44 -
Replace crankcase front cover on dowel pins, using a
new gasket t o assure tight sealing.
Installation of the front oil seal, crankcase front
cover in place
l ll ust. 76/77
1 - Crankshaft 1
6 - Spacer ring
2- Pinion 7- Dowel pin
3- Oil seal 8 - Pin protrusion
4 - Cran kscase f ront cover 9- 0-R ing
5 -Special tool 3 136 331 R 1
1. Handle oil seals wit h care and prot ect against conta-
mination and/or damage.
2. Prior t o assembly, apply some engine oil t o the
sealing I ips (3) lllust . 76/77. The outer cage of the
seal must be dry when bei ng pressed in.
3. The sealing lip (3) must be installed towards t he oil
side as shown. Use tool (5) to ensure correct depth
cont rol and a perpendicu lar seat to the crankshaft.
4. Place 0-Ring (9) onto crankshaft against pinion (2).
5. Install dowel pin (7) (same length as removed pin)
i nto spacer ring (6). observing di mension (8).
6. Install spacer rin g on crankshaft , t aking care to engage
its roll pin in the ti ming slot of t he crankshaft pinion.
Careful: Do not damage sealing face. Never attempt to
remove minor damage by polishing. Leakage wi ll result.
Instal l V-belt pulley, generator, V-belt and fan.
Fill in engine oil and f ill t he cooling syst em.
Vent t he fuel syst em.
Make a test run and check for leakage, check engine
t iming, etc. and rectify, if necessary.
 CRANKCASE

Note: To provi de the correct cylinder sleeve protrusion

(5) l llust . 79, shims (4) may be used between the sleeve
f lange and crankcase counterbore.

Important: Before install ing the shims it is necessary to

check the counterbore depth (A ) ll lust . 81 at f our points
equally spaced around t he counterbore, using a depth
gauge. Max imum vari ati on bet ween points of measure-
ment must not exceed 0.04 mm (0.001 6 inch). If
variation exceeds 0.04 mm (0.001 6 inch) th e counter-
bore must be refaced. Refer to "Crankcase Counterbore
Refacing" in th is section.

Observe maximum permissible salvage depth (A2).

Removal and Disassembly

Remove the engine and mount it on a suitable stand to

facilitate repair work.

To have free access t o the crankcase, t he f ol lowi ng parts

should be removed :
ll lust. 78
1 - Main bearing cap front Cylinder head, oil pan , ca mshaft , crankshaft, connecting
2 - Main beari ng caps center rods, pi stons, cyl inder sleeves; refer t o th e respective
3 - Main bearing cap rear sections.
4 - Main bearing bolts
5 - Dowel pin
6 - Studs Cleaning, Inspection and Repair
7- Bushing
8 - Plug T horoughly clean the crankcase and the oil pan. The
9 - Expansion plugs most effective way of doing th is is to boi l t hese parts in
10 - Seal ing bar water to wh ich a cleaning solvent is added. Flush out as
11 -Seal stri p much scale and other sediment as possible.
12 - Shim
Clean oilways with comp ressed air or a w ire rifle brush.

General Examine the crankcase for possible warpage and cracks.

T he crankcase and the main bearing caps (1 t o 3) lll ust.
78 are drill ed i n one operation. Main bearing caps are
numbered from 1 to 7, beginning at engine f ro nt end, so
that they can be reinstal led in proper posi tion and
sequence.
Individual bearing caps are not suppl ied separately.
However, for repair purposes. f ield packages are avai l-
able contai ning beari ng cap with bolts and an instruction
leaflet.
Note: Repairs are rest ricted to every second bearing
cap. The front bearing cap is not available f or service.
Check crankcase sealing face f or distortion, if engine has
been run wi th a blown cyl in9er head gasket or evidence
of water leakage is present. Refer to lllust . 37.
If cracks of f issures are detected, do not attempt welding
or braz ing; replace th e cran kcase wi th a new one.
Check for proper seat of sealing parts, such as U-pl ugs
and expansion plugs and replace wi th new ones, if neces-
cary.
To install U-plugs and expansion plugs use special tools
provided f or th is purpose.

Repairs on crankcase are generally restricted to replace- Checking Sleeve Protrusion

ment of sealing parts and cleaning of oil and water
passages.
As a general rul e, machined faces of the cran kcase
should always be exam ined f or damage prior to re-
assembly of the engine.
1. Check counterbore depth (A) lllust . 8 1 and reface
counterbore if necessary.
2. Place the sleeve to be checked in the cran kcase
without the "0" ring.

- 45 -
 CRANKCASE

3. Clamp the sleeve down using four holding adapters 4. Place a dial indicator, with block, across the cylin-
shown in lllust. 80. Make sleeve holding adapters der sleeve.
locally. Space the bolts to obtain uniform pressure
on the sleeve flange as shown in I I lust. 80. Torque the
a) With the dial indicator pointer set on the flange of
bolts to 41 Nm (30 lbf-ft) in three stages at 14 (10).
the cyl inder sleeve, adjust the indicator to zero.
27 (20) and 41 Nm (30 lbf-ft) see Note) .
Move the indicator block until the pointer drops
to the crankcase deck and t ake a reading.
Note: If the crankcase is equipped with studs use suit-
able spacer pipes over four studs and secure the holding
b) If the sleeve flange is below the crankcase deck,
adapters in place using hardened washers and stud nuts.
rest the indicator pointer on the cran kcase deck
and set the indicator at zero. Move the indicator
3
block until the pointer drops to th e sleeve flange
and take a reading.
~~~~~A==============;.~
c) Take readings at th ree or four points around the
,...
C')
sleeve and use the average reading to determine
I
~ which shim, if any, is needed to make protrusion
(!)
(5) lllust. 79.

1 d) Mark each sleeve before removing so that it can be

reinstalled in the same bore and in the same
position as it was while making the protrusion
check.

Note: Shims of following thi ckness are available :

lllus. 79 mm (inch)
Cyl inder Sleeve Protrusion 0.05 (.002)
1 Crankcase 0.10 (.004)
2 Sleeve 0.25 (.010)
3 Outer flange 0.50 (.020)
4 Shim (use only if necessary) 0.80 (.03 1)
5 Protrusion, 0.08-0.12 mm (0.0031 -0.0047 inch)

use shi ms (4) if necessary .

---
Important: Protrusion (5) must not f all below 0.08 mm , 5. Check each sleeve that is to be install ed for pro-
trusion in the same manner as above.

a) Remove the clamping bolts and washers. Clean the

top deck of the crankcase and the cylinder sleeve
counterbore. Clean the sleeve.

b) Install th e shim (if necessary) in the counterbore.

c) Coat the sealing "0" ring with specified clean en-

gine oil and install into the groove (without twist).

Note: Refer to lllust. 120 for correct 0-ring

selection and installation.

d) Brush the sealing ring contacting surface in the

crankcase with clean engine oil.

e) Install the sleeve carefully into the same bore as

removed from and press into place by hand.
lllust. 80
Cylinder Sleeve Clamped Down for Note: After installing a cylinder sleeve in the
Protrusion Check crankcase, check the clearance between the deck
of th e crankcase and the top surface of the outer
1 - Sleeve 3 - Capscrew
sleeve flange. This amount must not exceed the
2 - Holding adapter
maximum dimension (5) lllust. 79.

-46 -
 CRANKCASE

Crankcase Counterbore Resurfacing 2. If one of the four measurements differs more than
0.04 mm (0.0016 inch) the ledge of the counterbore
General must be resurfaced .

The coun terbore cutting tool lllust. 82 is used for Note: If all counterbore ledges of one particular
resurfacing crankcase cy linder counterbores for all wet engine are to be cu t to the same depth, measure all
sleeve engines as mentioned in this manual. counterbores and set up cu tting tool on the lowest

u
counterbore ledge to ensure clean-up of all counter-
bores.

Note: The depth of the cou nterbores is limited.

Never exceed maximum counterbore salvage depth.
See (A2) lllust. 81.

Operating of Cutting Tool

3. Remove all carbon deposits and water sediments

from counterbores.

4. Clean and smooth the crankcase deck as necessary.

· ~89L-~

lllust. 80a
1 - lndica tor
2 - Ledge of counterbore (
1. Using an indicator or a depth micrometer measure
count erbore dimension from top of the crankcase
to the counterbore ledge.
lllust. 80a.
Measure at four points, at right angles.

1 2

3---=~~~~

:=-~~~~~~~~
7--~~~~
lllust. 82
Cutting tool
lllust. 81 A - Max. permissible inclinat ion when regrinding:
30 minutes
1 - Crankcase deck 2- Ledge X- Cutting depth, adjustable

A 1- Counterbore dimension, new 7.595 - 7.620 mm 1 ~ Sp indl e 7- Ring nut

(.2990 - .3000 inch) 2 - Stop-bell 8 - Handle
A 2- Maximum permissible salvage depth 9.020 mm 3 - Cutter 9 - Set screw
(.3551 inch) 4 - Guide 10 - Set screw
A 3- Maximum perm issible warpage of surface (2) 5 - Key 11 - Adjusti ng nut
0.04 mm (0.0016 inch) 6- Washer

- 47 -
 CRANKCASE
5. Slowly and gently rest the tool onto the lowest
counterbore ledge of the crankcase.
6. Back-out set screw (10) lllust. 82
Back off adjusting nut ( 11) by rotating it in counter-
clockwise direction.
7. Place a feeler gauge of 0.10 mm (.004 inch) thick-
ness between crankcase deck and stop-bell (2).
8. Screw down adjusting nut ( 11) until it contacts stop-
bell (2) .
Tighten set screw ( 10).
Remove feeler gauge.
9. The gap between crankcase and stop-bell coincides
wi th the amount of material to be removed f rom the
counterbore ledge.
10. Rotate the cutter in a clockwise direction until the
stop-bell contacts the crankcase.
11. While rotating in clockwise direction lift off the
tool and check to make sure that ledge of the
counterbore is properly cleaned-up.
Note: Adjusti ng nut (11) lllust. 82 has graduated
markings to estimate the amount of cut. Each mark
is 0.10 mm (.004 inch).
Crankcase Salvage
1-
lllust. 82a
1 - Rework area
2 - Counterbore
M - Side view of 1
Note: Do not fill in reworked area and use normal
head gasket.
(Gasket seals on sleeve collars).
- 48-
If a second cut is needed , rotate the adjusting nut
counter-clockwise to the next mar king only and
repeat step 10 and 11.
12. Repeat resu rfacing procedure until the ledge of the
counterbore is properly cleaned up and exactly
parallel to the crankcase deck.
Do not exceed salvage depth.
13. Resurface the remaining counterbores as necessary.
Note: To obtain specified cylinder sleeve protrusion
place shims between counterbore ledge and sleeve.
See lllust. 79.
DO NOT exceed maximum protrusion.
Grinding the Cutter
The cutter is of a select grade of carbide to give maxi-
mum tool-life and is accurately ground with precise
angles on the cutting edges. Never attempt to grind the
tool without special equipment.
After regrinding cutting edges must be square, per-
mitting a tolerance (A) ll lust. 82.
The crankcase may be salvaged by the following rework if
cracks in the top deck area between cylinders are
noted.
1 . Use suitable grinding equipment. Strictly adhere to
rework dimensions. Reworking depth may be less but
not more than shown. Keep rework parallel with top
deck of crankcase.
2 . Protect crankcase top against damage during the
machining process.
3. Remove all burrs.
Important: If the crack is still visible after machining to
max. depth. replace the crankcase.
 CRANKSHAFT

lllust. 83
General
Crankshafts for 3, 4 and 6 cy linder engines are designed
in such a way that basic dimensions of crankp ins and
journals are th e same on all shafts, see "Specifications".
Note 1: If cran kshaft regrinding to the second or third
undersize (lllust. 86) becomes necessary, it is important
to determine the process by which the crankshaft has
been hardened at the factory.
(
Note 2: Tufftrided and induction hardened crankshafts
are without identification marks. These crankshafts may
be identified by a hardness check on a crankshaft web.
Do not check on journals
While on tuffrided crankshafts journals and webs are
hardened, induction hardened crankshafts have a limited
hardness area (A) lllust. 84 on crankpins and journals
only.

Hardening processes:
c A c
a) "Deep Nitroc" (gas nitriding process) present crank-
shaft hardening.

Deep-Nitroc hardened crankshafts have an "N" stamp-

ed on the f ront face of the first web for identification.
These crankshafts require re-hardening after re-
grinding to second or third undersize, see I Il ust. 86.
lllust. 84
b) "Tufftriding" (bath nitriding process). These crank - A Hardness area on journals and crankpins of in-
hafts can be ground to a fi rst or a second undersize duction hardened crankshafts.
only. Re-hardening is necessary after regrinding to B 2 - 3 mm (0.079 - 0.12 inch)
second undersize. (Refer to Note 2.)

c) " Induction" hardened crankshafts can be recondi -

c 5.5 ± 0.5 mm (0.216 ± 0.02 inch)

It is recommended that reconditioning be done at

u
tion ed to a first , second or third undersize without Renewal Stations where equipment and experience can
rehardening. (R efer to Note 2.) produce quality standards as outlined in "Specifications".

-49 -
 CRANKSHAFT

Handle the crankshaft with ca re and protect it against 2

dropping, striking etc. to prevent damage.

Straightening

Inducti on hardened crankshafts can be straightened. A

However, "Oeep-Nitroc" and "Tufftrided" crankshafts
MUST NOT be straightened. Even slight straightening
with compl ete absence of cracks will endanger the high
strength built into th e shaft.

Refer to Parts Catalog for availability of undersize in-

serts for main and connecting rod bearings.

When installing a reground crankshaft be sure to use the

respective undersize bearing inserts. lllust. 85

1 Flywheel seat
2 Permi ssible working range of oil seal lip.

Crankshaft rear end sealing flange A 110.00 - 109.9 mm

(4.3307 - 4.3299 inch)
The rear oil seal , running on the sealing flange can be B 6.5 mm (.25 inch)
offset twice in the oil seal retainer or in the flywheel C - 9.5 mm (.37 inch)
housing, see lllust . 96 and 99 respectively. 0 - 6.2 mm (.24 inch)

If the sealing f ace of the flange is worn, it may be re- Note: Finish sealing f ace t o DIA (A) lllust. 85 by
condit ioned by hard ch.romium plating. plunge-cut grinding.

- 50 -
 CRANKSHAFT

Specifications

lll ust. 86
Limits for Undersize Crankshaft Grinding

Undersize Crankshaft, A B c 0 E
lll ust. 86 mm inch mm inch mm inch mm inch mm inch
1st undersi ze 79.740 3.1393 63.740 2.5094 36.90 1.4528
0.25 mm (0.01 0 inch) 79.72 1 3.1386 63.721 2.5087 36.94 1.4543 25.875 1.01 87
2nd undersize 79.490 3.1 295 63.490 2.4996 37.15
0.50 mm (0.020 inch) 79.47 1 3.1 287 63.471 2.4988 37. 19
1.4626
1.4642 25.750 1.0137 110.00 4.3307
(
3rd undersize 79.240 3. 1197 63.240 2.4898 37.40 1.4724 109.98 4.3299 -
0.75 mm (0.030 inch) 79.221 3. 11 89 63.221 2.4890 37 .44 1.4740 25.625 1.0088

05 0 020
Radii : RF (J·ournals) rrim {inch) 5 ± · {0 200 ± · )
0.1 ° 0.004

RG {crankpins) mm {inch) 5.7 ± ~-

6
(0.224 ± ~- 23 )

Surface finish : journals and crankpins {A , B) Ra 0.2 pm {8 Micro-inch)

flange {E) Ra 0.25- 0.5 pm ( 10 - 20 Micro-i nch)

Rt max. 5 pm {200 Micro-inch)

Re-hardening processes for nitrided crankshafts:

I = short ti me gas nitriding {4h)

11 = bath nitriding, tufftriding process {4h)
Ill = induction harden ing

Surface hardness : " I and 11 " HV 10 400

" I l l " 50 HR c Rockwell

Undersize Factory Process

gas nitrided bath nitrided {tufftrided)
U1, re-hardening not necessary not necessary
U2, re-hardening I or Ill 11
U3, re-hardening U3 not permissible

- 51 -
 CRANKSHAFT

Note: Remove balancer drive gear (10) ll l ust. 84 (4 cyl.) Run out on every one of the journals, with ends of the
and pinion (6) before nitriding the crankshaft. crankshaft places in V-blocks:

Induction hardened crankshafts: 3-cyl. 0.20 mm (.0078 inch)

4-cyl. 0.40 mm (.0156 i nch)
Hardness HAc 50 -55 minimum hardness for undersize 6-cyl. 0.60 mm (.0234 inch)
shafts H Re 40.

Parallelism crankpins to journals, permissible deviation

Journal s and Crankpins
0.010 mm (.00039 inch)
Max . permissible
out-of-round 0.004 mm (.00015 inch) Permissible eccentricity of balancer gear seat to the
adjacent journals
Permissible taper
per 1 inch length 0.004 mm (.00015 inch) 0.020 mm (.00078 i nch)

Crankshaft Rear Sealing Flange mm (inch)

Permissible run-out 0.050 (.0020)

Permissible out-for-true 0.020 (.00078)

Crankshaft Running Clearance and End Play

Running clearance in the main bearings (new) 0.070-0.140 (.00275- .00551)

End play 0. 15 - 0.23 (.006 - .009)

Connecting Rod

Running clerance on crankpins (new) 0.060 -0.120 (.0023 - .0047)

Side clearance 0.15 - 0.25 (.006 - .0 10)

Crankshaft

Max . permissible imbalance, measured at the front and rear journal

3 and 4 cyl. 45 cmg (.62 oz. inch)
6 cyl. (with counterweights) 60 cmg (.83 oz. inch)

Balancer Drive Gear ( 10) /1/ust. 84

Engine Number ID Run-out * Out of True Shrinking Temperature

of teeth mm (inch) mm (inch) mm (i nch) oc (F)
D-206 up to 150.000 (5.9055)
80 0.08 (.0031) 0.10 (.0039) 100 (212)
2200/min 150.025 (5.9064)
D-239
D-246 150.035 (5.9069)
80 0.06 (.0024) 0.04 (.0016) 180 - 200 (356 - 392)
D-206 above 150.075 (5.9085)
2200/min
160.035 (6.3006)
D-268 90 0.06 (.0024) 0.04 (.0016) 180 - 200 (356 - 392)
160.075 (6.3022)

* Installed and in relation to journals No. 2 + 4

- 52-
 CRANKSHAFT

Instructions for Regrinding Crankshafts
The most important considerat ion is t o avoid any burns
in the regrinding operat ion. Refer t o lllust. 86 for re·
gri nding di mensions.
Remove oil pan, crankcase front cover, flywh eel and rear
oil seal retainer.
Note: lt is good practi ce to check end play of the crank-
shaft before removing it.

The crankshaf ts are reground similar t o any precision A lso check the backlash of every gear of t he ti ming gear
cran kshaft wi th the f ollowing precaut ions: train , I Ilust . 87. See " Camshaft" for gear backlash
"Specifications".
1. A mechanical or an automatic wheel dresser is manda·
tory to prevent chatter, burnin g and poor surface
fi nish. A hand stone should NEVE R be used t o rough
or fine dress the face or radii of th e wheel. The radii
shoul d blend evenly into the jou rna l.

2. The selecti on of the grinding wheel is important

because t oo hard a wheel will i ncrease th e possibil ity
of burning. An aluminium ox ide wheel w ith a grit si ze
of approximately 50 and a maximum hardness of
" M" w ill produce sati sfactory results, with other
conditi ons being suitabl e.

3. Carefully check cran kshaft f or hair line cracks before

starting rework .

If cracks are present, do not grind .

lllust. 89
4. Do not grind journals and crankpins beyond the
limits specified in I Ilust . 86. 1 -Sealing bar
2 - Oil suction and pressure pipe
5. Do not change th e radii of journals and crankpins and 3 - Seal strip
strictly observe their cyl indricity.
Turn the engine bot t om side up and remove sealing bar
6. Break all sharp edges. (1) lllust. 89, pipes (2) and the balancer (4-cyl-engines).

7. Highly polish journals and cra nkpins.

Note: Bef ore regrinding "N itr ided" crankshafts al ign

journals individually to a T .I.R. of max . 0.05 mm
(.002 inch) with the shaf t in the machining t ool.

Removal and Dissassembly

lllust . 90
Cran kshaft (6-cyl -engine shown)

1- Connecting rod bearing cap

2- Connecting rod
3- Main bearing caps
4 - Cast dimples (on injection pump side)

Note:

1. Main bearing caps (3) lllust. 90 are numbered con-

lllust . 87/88 secutively so they can be reinstalled to t heir original
Checking gear backl ash positi ons.

- 53 -
 CRANKSHAFT
2. Connecting rods are not numbered. However, it is
recommended to mark these accordingly so that they
can be reassembled to their original positions. On
DT-402 engines bearing cap of connecting rod No. 1
is marked with figure 1.
3. Also main bearing and con necting rod bearing inserts
are without any markings. On removal carefully st ore
them so they can be reassembled to their original
positions when reused.
lllust. 91
Removing or installing oi l pump
The oil pump may be removed as illustrated or as a unit
with main bearing cap No. one.
6-cyl. -engines:
To remove the crankshaft. pistons must be t aken out of
their sleeves individually towards the cylinder head side.
As soon as a pair of connecting rod caps, lllust. 90 is
lifted off, turn the crankshaft until respective pistons
can be pushed out of their sleeves.
3 and 4-cy/. -engines:
lllust . 92
Removing main bearing caps
- 54-
To remove the crankshaft only the connecting rod bear-
ing caps must be removed.
Remove bearing cap bolts and use a locally made lever
tool (lllust. 92) to lift out bearing caps.
Note: Two full length straight pins enter the bearing cap.
The clamping effect resulting from the lever arrangement
will grip the cap for removal.
Remove the crankshaf t taking care not to damage machin-
ed areas by the lifting tackle.
Cleaning, Inspection and Repair
Clean all parts th orough ly with kerosene or D iesel fuel.
Blow through oilways with compressed air.
lllust. 93
Crankshaft (4-cyl.-engines)
1 -Sealing face
2 - Balancer drive gear
3 - Crankshaf t pinion
Journals and Crankpins
Check the cran kshaft for wear on journals and crankpins.
Due to intermittent load characteristics of engine opera-
tion wear becomes usually apparent as out-of-round
wear. Measure at right angles, see "A" and "B" I Ilust. 94.
lllust . 94
Measurung points, cran kshaft
 CRANKSHAFT

Main and Connecting Rod Bearing Inserts

lllust. 95
Visual inspecti on of Inserts A

1 - Even bearing pattern , insert o. k. lllust . 96

2 - Bearing mat eri al partl y worn , replace Oil seal installed in seal retainer

A - First locati on 1 = 1.5 mm ( .059 inch}

Main Thrust Bearing Insert (8) //lust. 83 B- Second location 2 = 0 -0.1 mm (0-.004 inch}
C - T hird location 3 = 1.5 mm ( .059 inch }
Inspect actual beari ng material of t his i nsert simi lar to
main beari ng i nserts. Special tool for proper installation is shown in lllust . 97.

Replace the Lnsert if:

a} actual bearing materi al wear is evident,

(
b ) crankshaft end play (as checked before removal}
is excessive or nearing its wear li mit.

Note: When i nstalli ng a new crankshaft always use

new bearing inserts too.

Crankshaft Rear Sealing Flange

Check cond it ion of th e sealing face for the rear oil seal.
lllust. 97
Offset the new oil seal in the oil seal retainer, if t he seal- 1 - Oil seal retainer
ing lip has worked into t he sealing face . 2 - Oil seal
3- Installing tool
Note: Depending on application oil seals may be installed 4- Spacer ring f or offsetting, section"B"
as shown in I I lust. 96 or 99. 5 - Spacer ring for offsetti ng, section "C"

- 55 -
 CRANKSHAFT
If the sealing face is undamaged use special tool (3)
lllust . 97 to install the oil seal. To offset the oil seal as
shown in section "8" lllust. 96 place the thinner ring
(4) lllust. 97 on the tool and press the oil seal in. For
offsetting as sh own in section "C" place the thicker ring
(5) on t he tool (3) and press t he oil seal in.
Note: When offsetting always use a new seal.
Install the seal with its open side toward the engine.
Keep the outer case of the seal dry wh en the seal is
pressed in .
When in place the seal must be at right angles to the
crankshaft otherwise oil leakage may develop.
ll lust. 98
1 -Flywheel housing, displaced design
2- Oil seal , outer DIA 130 mm (5.118 inch)
ll lust. 99
Oi l seal installed in flywheel housi ng
A First location = 1.5 mm (.059 in.)
B Second location =3.5 mm (.138 in.)
c Third location = 5.5 mm (.217 in .)
1 Flywheel housing present design
2 Double lip oil seal, outer
OIA 140 mm (5.512 in.)
3 Flywheel
- 56 -
Installation tools, and offsetti ng st ages of the oi l seal (2)
lllust. 98 are the same as for the oil seal shown in
lllust . 96.
When renewing th e seal be certai n its main l ip is toward
the engine, i. e. the dust li p must be install ed toward t he
f lywheel.
For installation and offsetting the oil seal (2) lllust. 99
use the respective tool and spacer rings avail able f or this
purpose.
Install the seal with its open side toward the engine.
Keep the ou ter case of the seal dry when the seal is
pressed in.
Crankshaft Pinion
Check crankshaft pinion for wear and chipping. If dama-
ged replace the pinion as follows:
Remove spacer ring (12) lllust . 83 and 0 -ring (11 ) from
crankshaft front end.
l llust. 100
1 - Crankshaft pinion
2- Finished surface
3- Main bearing journal
Place the crankshaft pinion on an anvil and holdt it in
positi on, lllust. 100. The bearing journal (3) must not
touch the anvil edge.
Slide a metal sleeve over t he fi nished surface (2) to pro-
tect it from damage. Wrap a rag around t he chisel to
catch an y possible chippings.
 CRANKSHAFT

lllust . 103
ll lust . 101
1 -Wel ded joint 3 - Bearing journal
2 - Thrust face 4 - Meshing marks
Split the pinion w ith a few fi rm hammer blows at its
weakest point, i.e., at the timing slot , see arrow l llust.
Deburr and remove nicks and scratches f rom the mating
101.
surfaces of the crankshaft and bal ancer drive gear.

A Caution:
~gloves
Beware of chippings ! Use prot ective
and safety goggles.
Install a new rol l pin in the crankshaft and slip the drive
gear on th e crankshaft with the two marked teeth to the
fl ywheel side.

Note: On later producti on engines th e gear must be

heated bef ore i nstall ation . See " Specifi cati ons".

Weld the gear in four places as shown in I I lust. 104 or

105.

lllust. 102

1 - Timin g slot 2- Roll pin

Smooth the pinion seat bef ore inst alling t he new pini on.
Heat replacement pinion to approx. 200 °C = 400 °F.

Do n ot overheat!

Slide the pinion on the shaft wi th the chamfered side

towards the bearing journal and make sure that roll
pin (2) engages i n ti ming slot (1) l llust . 102.

Balancer Drive Gear

(welded)

Check the balancer drive gear for wear and replace wi th I Ilust. 104
a new one, if necessary . Installi ng diagram for bal ancer drive gear on

Grind o ff welded joint ( 1) lllust. 103, and drive the gear

from the crankshaft.
early production engines (D-206)

T he weld must not project above t he finished bearing

u
t hrust surface of crankshaft . Weld 4 places 20 mm
Remove all t races of the broken or damaged drive gear. (3/4 in.) wi de.

- 57 -
 CRANKSHAFT

Use low hydrogen electrodes t o prevent under weld
cracking.
While welding, protect journals against damage caused
by molten electrode particles.
Note: Drill balancing h oles in web areas provided for this
purpose. Observe dia, depth and spacing of the existing
balancing holes.

On later production engi nes replace the balancer drive

gear as described above. Balancer Drive Gear
(shrink-fit)
However, weld the gear as shown in I I lust. 105.

....
/
/
/

/
-....... ...... ' '
II
I
I
I
/
"\ \' \ \
I I \ \
I I I I
\ I I I
\ \ I I
\
\
'' I I
/
'

lllust. 105
lllust. 107
1+3 Welded joints over full contact 1 - Mark on tooth
length on both sides of gear. 2 - Notch on crankshaft
2+4 Welded joints
5 - Marked teet h on flywheel side
6 - Roll pin The balancer drive gear, lllust. 107 is a shrin k-fit on the
7 - 45 mm (1 3/4 in.) cran kshaft.

Before removing a worn gear be certain the crankshaft

is marked with notch (2). If there is no notch (2) on the
crankshaft flange, mark the cran kshaft in a suitable way.

When replacing the gear, it must be split similary as t he

crankshaft pinion is split, see lllust. 100.

Deburr and remove nicks and scratches from th e mating

surfaces of the crankshaft and balancer drive gear.

lllust. 106 Heat th e drive gear (see Specifications). A li gn the single

mark (1) with the notch (2), on the crankshaft flange
After Welding: (lllust. 107).

1. Check th e balancer drive gear for run-out and out- Do not weld the shrink-fit gear.
of-true, lllust. 106. See "Specifications".

2. Rebalance crankshaft. See " Specif ications". After installation check for run-out , lllust. 106.

-58 -
 CRANKSHA FT

Balance Weigh ts (6-cyl. only) 3

5
t

lll ust . 108

lllust. 108a
1 -Sealing f ace
2 - Cran kshaft pinion 1 - Crankshaft web
3 - Balance weight 2- Balance weight
4 - Balance weight bolts 3 - Balance bores
4 - 60°
5- Cran kpin
6 - Mai n bearing journal 5 - 19 mm (.75 inch)
6- 0 -310 = 20 mm (.79 i nch)
0 -358, DT-402 = 25 mm (.98 inch)
Check balance weight bolts (4) ll lust. 108 for proper
torque load. Retighten, if necessary. Reassembly and Installation

Important: Bolts (4) may not be loosened as a change i n

posit ion of the screws would disturb the crankshaft
balance.
If, for some reason or other, balance weights have to be
removed this should be done only if a proper balancing
machine is available to rebalance the crankshaft.
Note: When installing new main bearing caps refer t o
instructions f urn ished with the caps for assembly pro- (
cedure.
Clean crankscase and bearing cap surfaces.
Place upper beari ng insert halves (free of oil) in the
crankcase.

Be certain the inserts are ful ly seated, oil hol tes are in
Proceed as follows:

Balance weights lll ust. 108a are numbered consecutively

.......
line and locking tangs on the inserts f it into recesses.

f rom 1 - 12, beginning at the front end, correspondi ng

to crankshaft webs. This order may not be altered.

The two mounting holes are drilled slightly of fcenter.

When mounting the weight make sure that its protrud·
ing f lank is on th e crankpin side. Balance weights must
be at ri ght angles t o the crankshaft center line. Contact
faces of balance weights and crankshaft webs must be
absulutely clean, dry, level and free from burrs.

Tighten bal ance we ight bol ts in two steps to specified

torque, see " Special Nut and Bolt T orque Data". Re-
balance crankshaft , see "Specifications" and ll lust .
108a.
lllust. 109
Figures (5) and (6) lllust. 108a represent the permi ssible
max imum dimensions and posit ions of the balancing 1 - Guide pins (for alignment )
holes. Observe details (lllust. 108a) whenever holes must 2 - Main bearing cap (lateral alignment)
be drilled. 3 - Cast dimples (on injection pump side)

- 59 -
 CRANKSHAFT

Spread a film of SAE 30 engine oil on the bearing inserts

and place the crankshaft in the crankcase bearings.

Bearing caps {2) lllust. 109 are numbered from front to

rear with consecutive numbers. Be certain to install the
caps in their correct positions with the cast dimples {3)
pointing to the injection pump side of the engine.

----""'+"'11--- 2 ---t
lllust. 112
lllust.110 Checking thrust flange alignment
Guide pin {two required)
1 - Feeler gauge
2 -Screwdriver or lever
mm {inch)
1- 125 {4.92)
2- 55 (2.17)
3 - 12.2 ( .480)
4 - 14.9 ( .587)

Whenever installing main bearing caps without dowel

bushings use guide pins ( 1) I Ilust. 109 to facilitate in-
stallation. See also lllust. 110.

lllust. 111
Main thrust bearing
(shown without crankshaft to permit unobstructed view)
lllust. 11 3
1 - Lateral alignment faces in crankcase Torquing main bearing bolts
2- Bearing cap {without dowel bushings)
3 - Thrust bearing flanges
Torque main bearing bolts in three steps. Refer to
"Special nut and bolt torque data".
When installing the main thrust bearing cap (without
dowel bushings) be certain the thrust flanges {3) lllust. When torquing main bearing bolts, observe the follow-
111 of the upper and lower bearing insert are absolutely ing sequence:
in line.
3-2-4-1 (3-cy l inder engines)
Check thrust flange alignment with feeler gauge ( 1) 3-4-2-5-1 (4-cy linder engines)
lllust. 11 2 on top and bottom. 4-5-3-6-2-7-1 (6-cy linder engines)

- 60-
 CRANKSHAFT
lllust.114
1 - Special wrench
2- Oil pump
The oil pump is mounted on bearing cap number 1.
These two parts can be installed as a unit. A special
wrench (1) I Ilust. 114 is required t o tighten the RH main
bearing cap screw. After main bearing cap screws are
tightened, the crankshaft must rotate freely when turn ed
by hand.
Take care, that main bearing bolts of th e same material
designation are used.
ll lust. 11 5
Checking crankshaft end play
Check end play of cran kshaft. See "Specifications".
Note 1: Pitch d iameter bolts and correspondingly higher
torque values may be used in pla ce of necked-down bolts,
provided the bearing caps are chamfered t o clear the
radius on the underside of the bolt head. See (2) lllust.
11 6.
Note 2: Whenever a reground crankshaft is instal led, be
sure running clearance of th e journals is with in "Spe-
cifications" . Proceed as foll ows:
- 61 -
lllust. 11 6
Main bearing cap
1 - Squer corner
2 - Reworked cap w ith chamfered corner 0.8 - 1.2 mm
X 45° (.03- .05" X 45°)
Remove the center main bearing cap and the lower bear-
ing, and insert a suitable length of 0.20 mm (.008")
virgin , lead wire across the bearing surface of the lower
beari ng and the cra nkshaft journal. Instal l the bearing
cap and tighten the cap bolts to specified torque.
Do not turn the cran kshaft wh il e the wire is in place.
Remove the bearing cap, and carefully remove the wire,
which wi ll have been crushed to the amount of clearan -
ce present . Measure the wire, using a micrometer. The
clearance desired is given in "Specifications".
Installing Rear Oil Seal
a. Seal must be clean and lubricated as follows:
Single Lip-Coat lip with clean engine oil.
Double Lip-Fill cavity between lips approx. 2/3 with
"Molykote BR2" or "Shell A lvania 3".
b. Apply some engine o il onto crankshaft seali ng face.
·saz!:l..,
lllust. 11 7
1 - Seal ju mper 2 - Stud
 CRANKSHAFT

Install stud (2) l llust. 11 7 using liquid sealer. Install t he w ith a straight edge before t ightening cap screws and
rear oi l seal retainer w ith new gasket. Take care not t o reali gn, if necessary .
damage the oil seal.

Use seal jumper (1) for protection.

Note: Seal jumper (1) must be made locally as follows :

Cone angle of the j umper 130 - 150°. The smaller taper Tim ing Gear Train
diameter must be 5.50 mm = .217" less than the seal li p
diameter. The taper f ace must be pol ished.

lllust . 119
lllust. 11 8
Timing gear train adjust ment
1 - Sealing bar 1 -Single punch marks
2 - Seal strip 2 - Double punch marks

Replace sealing bar ( 1) I Ilust. 11 8 and insert the two seal When meshing t iming gears be sure single punch marks
strips (2). using liqu id sealer. The sealing bar must be ex - (1) lll ust. 119 are in line. Double punch marks (2) line-
actly in line with the adjacent crankcase f lange. Check up with th e camshaft gear.

-62-
 PISTONS- CYLINDER SLEEVES - CONNECTING RODS

Four ring pistons , are no longer availabl e for service.

Pi stons, fitted with three rings and their cylinder sleeves

are not classified in groups, however, they should be
10
replaced as a set.

Whenever individual four ring type pistons fail, it is re-

commended to replace all piston sleeve assemblies of the
respecti ve engine to avoid imbalance.

Piston dia and "FRONT" arrow are stamped on the

piston crown.
4
For cyli nder sleeve identification see " Specifi cations".

Note: Pist ons and cylinder sleeves must be handled with

care. Any fall or knock might result in out-of-round.

Note: Tightening procedure for connecting rod nuts has

been changed.

·-D A new "angle" tightening procedure for connecti ng rod

nuts must now be used replacing the old " torque"
tightening method.

Whenever the oil pan is removed, slightly loosen the

lllust. 120
connecting rod nuts and retighten them using the
"angle" tightening procedure according to lllust. 144.
1- Piston ring (first compression)
2- Piston ring (second compression)
3- Oi l control ring Important: Diameter of cylinder sleeve 0 -ring groove in
4-
5-
Piston and sleeve pac kage
Retai11cr ri ll[)
the crankcase has been reduced by 0.22 mm (.0086 inch)
in the f all 1979.
(
6- Piston pin
7- Sleeve
8- Cylinder sleeve o-ring Groove Diameter :
9- Bushing
10- Rod assambly A - NEW = 11 8.32 - 11 8.58 mm Serial no. up
11 - Bearing (4.658 - 4.668 inch)
12 - Bolt
13 - Nut B - OLD = 118.54 - 11 8.80 mm
(4.667 - 4.677 inch) up to Serial No.

Together with this change two new 0-rings (8) have been
General introduced which must be used as follows:

Neuss-build IH-engines have been changed from four A - for NEW groove D IA, 0-ring with golden tracers.
to three ring type pistons. B - for OLD groove DIA, 0 -ring with red tracers.

- 63 -
 PISTONS- CYLINDER SLEEVES- CONNECTING RODS

Specifications

lllust. 122
5 Protrusion of pistons mm (inch)

0.32 (.0126)
A - (4 3/8" stroke engines)
0.70 (.0275)

0.36 (.0141)
lllust. 121 A - (5.06" and 5 1/2"
0.74 (.0291)
Piston versions: stroke engines)

A - with top ring insert (I I lust. 141 a) 1 -Crankcase

8 -without top ring insert (I Ilust. 141 ) 2 - Cylinder sleeve
3 - Piston
- Piston clearance in sleeve measrued 90 degrees f rom
pin hole, mm (inch) ·ous 9
at DIA . (1 ): 0.09-0.13 (.0035 - .0050) V) ' / / / .

at DI A. (2) : 0. 15-0.20 (.0059- .0079) ~.

b
3 - NA-engines: mm (inch)
35.997- 36.002 ( 1.41 72 - 1.41 74)
3 - DT-engines : 4 1

4 -
37.997 - 38.002 ( 1.4959 - 1.4961)
Height of DIA (1) mm (inch)
Version A: 9.5 (.374) •I
,.
8: 4.0 (.157)
5 - Height of DIA (2) mm (inch)
Version A: 59 (2.32) ~ ~3

Piston ring gap

8: 50 (1.968)

Compression rings:
mm

0.35
(inch)

(.014)
-- 2

lll ust. 123/124

---
Cylinder sleeve, mm (inch)
0.55 (.022)
1 - 98.425 (3.8750)
98.449 (3.8759)
Bottom ring : 0.25 (.010)
0.40 (.016) or

1 - 100.000 (3.9370)
100.024 (3.9379)
Pistonpin DIA mm (inch)
2 - 200 (7.874) (4 3/8" stroke engines)
NA-engines: 35.99 1 (1.4170) 2 -215 (8.464) (5.06" and 5 1/2" stroke engines)
35.987 (1.41 68)
7.700 (.3031)
3 -
7.715 (.3037)
DT-engines: 37.99 1 (1.4957)
37.987 ( 1.4955) 4 -11 9 (4.685)

- 64 -
 PISTONS- CYLINDER SLEEVES - CONNECTING RODS

Carefully st ore connecting rod bearing inserts, so that

they can be reinstalled in their original positions when
reused.

Check cy linder sleeve wear before removal, I Ilust. 126.

See Ill ust. 127.
c

l ll ust. 125
Connecti ng rod mm (i nch)

Note: For OT-358 and DT-402 refer to lllust. 137 f or

additional Information.

187.96 (7 .400)
1 - (4 3/8" stroke engines)
188.01 (7.402)

213.84 (8.419) (5.06 and 5 1/2"

1 -
2 13.89 (8.421) stroke engines)

36.012 (1.4178)
2 NA-engines
36.022 ( 1.41 82)

38.026 ( 1.4970)
2 OT-engines
38.036 (1.4974)

3 4.0 (.16) NA and OT-239 engines

Fro nt
3 1.5 (.06) DT-358 I DT-402 (
lllust. 127
Measuring points, cylinder sleeve
Removal and Disassembly

Remove cylinder head and oil pan. See respective sections If excessively worn, remove the cyli nder sleeves, using
the removing tool as shown in lllust. 128, see parts
of this manual.
catalog.
Turn the engi ne bottom side up and remove connect ing
rods individually.

Mark the connecting rods from front to rear with con ·

secutive f igures.

lllust. 128
Removing cylinder sleeves

Mark pistons from front to rear with consecut ive fi gures

before they are re moved.
u
lllust. 126
Checking cylinder sleeve wear Continue as shown i n lll usts. 129 to 13 1.

- 65-
 PISTONS- CYLINDER SLEEVES- CONNECTING RODS

Piston Clearance to Cylinder Sleeve

Check the piston clearance in the sleeves using a 0.10 mm

(0.004 inch) ribbon gauge 12 mm (0.5 inch) wide with a
tension scale (FES-108) lllust. 132 in the following
manner:

a. Position the ribbon in the cylinder bore so that it

extends the entire length of the piston, 90 degrees
from the piston pin location.

b. Invert the piston and install it in the bore so that the

end of the piston is about 38 mm (1.5 inch) below
the top of the cylinder block and the piston pin is
parallel to the crankshaft axis.
lllust. 129
Removing or installing piston rings with ring expander c. Hold the piston and slowly pull the scale in a straight
line with the ribbon, noting the pull required to
remove the feeler ribbon. Do not bend or kink the
9CS S 9
ribbon gauge.

d. Measure and check the clearance with the piston pin

at right angles to the crankshaft axis. (Refer to
"Specifications".)

lt should require 2 to 6 lbs. pull to remove the ribbon

gauge.

lllust,130
Removing or installing piston pin circlips

~)
\. I FES 108
Ribbon gauge

FESM- 1 107
lllust. 131
Removing or installing piston pin lllust 132
Checking p iston clearance with ribbon gauge
Cleaning, Inspection and Repair

Remove carbon deposits from the piston, cleaning also Note: Replace cy linder sleeves and pistons as a set .
ring grooves and lubricating holes.
To aviod imbalance do not mix up three and four ring
Wash all parts in Di esel fuel and dry with compressed air. type pistons in one engine.

- 66 -
 PISTONS- CYLINDER SLEEVES - CONNECTING RODS

Piston Rings

01eck pist on ring gap using a feeler gauge.

Compare the resul t w ith " Specifica ti ons" .

ll lust . 133
Checking connecting rod f or squareness

5. Strictly observe di mensi ons (1) and (2) lllust. 125,

when fine-boring the bushing, lllust . 134, t o ensure
correct piston to head clearan ce.

lllust. 132a 6. Never attempt to replace piston pin bushings unless

Pist on ring gap the necessary t ools and machines are available. Use
a new connecting rod with bushing if necessary .
To check piston rin g gap th e ring must be placed squarely
in a new cy linder sleeve, I Ilust . 132a.

Replace piston rings as a set onl y .

Smooth th e <;:ylinder sleeve in the top dead center to

prevent t op pist on rin g damage. (
Do not replace piston rings with new ones, if ring gap
and/or ring clearance in the pist on grooves has been
badly increased or th e cy linder sleeve is scored, scuffed
or excessively out-of -round.

lllust. 134
Connecting Rods Fine-boring piston pin bushing

To determine the piston pin clearance to piston pin 7. After f ine-boring install the pist on and check for
bushing subtract th e diameter of a new pin (see " Speci- crank pin to pist on pin alignment, lllust . 135.
fications") from the inner diameter of the used bushi ng.

To replace pist on pin bushings , proceed as follows:

A) NA and DT-239 Engines

1. Remove the ol d bushing and clean the eye.

2. Lu bri cate and press in the new bushing taking care

its split is t owards the side and the bushing clears
the edges of the connecting rod eye evenly on both
sides.

3. Drill the lu bricatin g hole. See (3) lll ust. 125.

4. Before f ine-boring the new pist on pin bushing, check lllust . 135
t he connectin g rod for squareness and dist ort ion. Checking alignment
lllust. 133. 1 - Stop 2 - Dial indicat or, stylus wit h bellcrank

- 67 -
 PISTONS- CYLINDER SLEEVES- CONNECTING RODS

8. If necessary realign by straightening the connect-
ing rod, lllust. 136.
A misalignment of max. 0.04 mm (.00 16 in.) is per-
missible.
not damage the connecting rod bore. Remove burrs and
clean the bore thoroughly . Press in the new bushings
from both sides in the connecting rod bore with a
hydraulic precision press.
Make sure the gap between the bushings is within the
speci fications , see (4) I I lust. 137. Chamfer both bushings,
see (5).

Continue according to steps 4 to 8 under A)

Important: On DT-402 engines the No. 1 connecti ng

rod is of controlled length so as not to interfere with
the oil pump. To prevent mixing up of connecting rods
the first rod is marked with a " 1" at t he bottom of the
rod cap, see (1) ll lust. 137. For service pruposes only
connecting rods with control led length are used.

Reassembly and Installation

lllust. 136
Cylinder Sleeves
Straightening the connecting rod
Note: Observe instru ctions bel ow I Ilust. 120 f or correct
0-ring selection in relation t o 0-ring groove diameter.
B) DT-358 and DT-402 Engines
Use new 0-ring when reinstalli ng cylinder sleeves. Make
sure crankcase grooves are clean and dry.

Coat the 0-ring with engine oil and carefully install the
0 -ring i nto the crankcase groove. Be sure th e 0 -ring is
properly seated in its groove.

Apply a light f il m of engine oil to sealing face of each

cylinder sleeve to ensure 0 -rings are not twisted in their
grooves as the sleeve is installed.

lllust . 137
mm (i nch)

(DT -402 only) marking on No. 1 rod

213.84 (8.419)
2
213.89 (8.421)

38.026 (1.4970)
3
38.036 (1.4974)

4 DT-358: 3.5 (. 14)

4 DT-402: 1.5 (.06)

5 0.5 mm x 45° (.02 x 45°) lllust. 138

Checking cyl inder sleeves for out-of-round
6 Evenly on both sides

7 Oil-passage
Check the cylinder sleeves for possible out -of-round
To replace piston pin bushings, proceed as follows: especially in their sealing areas, Ill ust. 138.

With a support plate and a properly fitting adapter press If out-of-round exceeds 0.02 mm (.0008 in .) check for
the old piston pin bushings from the connecting rod. Do twisted 0 -rings, dirt, etc and remedy the fault.

- 68 -
 PISTONS- CYLINDER SLEEVES - CONNECTING RODS

Note: Check cyl inder sleeve protrusion according to

t ust. 79 and 80.

ll lust. 141
Arrangement of pist on rings
(Piston without insert for " 1")

1 - 1~ ~ co mpression ring
2 - 2nd compression ring
3 - Oi l control ring
lllust. 139
Cylinder sleeves locked

,efore turning the engine bottom si de up lock the cylin ·

rler sleeves as shown in lll ust. 139, to protect them
.tgainst dropping out.

Pistons

When installing the piston, be certain the arrow on the

pist on crown points to the front of the engine and the
hoss of the upper con necting rod end is on the camshaft
side.
8 (

lllust. 141a
Arrangement of piston rings
(Piston w ith insert (4)

1 - 1st compression ri ng
2 -2nd compression ring
3 - Oil control ring
4 - Insert
A - Piston pin bore nominal
D IA: N. A. engines :
36 mm (1.4 in.)
DT-engines :
38 mm (1.5 in.)

l llust. 140 Note: lll ust. 141 a shows piston ring equ ipment of
Instal li ng the piston DT-402 engine. On this version ring (2) is marked with
"TOP 3" for identifi cation.
1 - Piston pin
2- Special pliers Use a ri ng expander (ll lust. 129 ) and inst al l pist on rings
3- Connecting rod clamped in vice as shown in I Ilust. 141

Take care the word TOP on the rings point s to the

Heat the piston to approx. 75 °C (1 70°F) before install · cylinder head. Start by installing th e oil control ring and
ing it. lllust. 140. work upwards toward the piston crown.

Insert piston pin circlips. Caution: Do not overspread rings.

- 69 -
 PISTONS - CYLINDER SLEEVES - CONNECTING RODS
lllust. 142
1 - Boss of the upper connecting rod end
2 - Identical mating figures on connecti ng rod and bear-
ing cap
Observe the following when installing the piston and
connecting rod assembly.
a) Boss ( 1) I Ilust. 142 must be on the camshaft side.
b) Mating figures (2) must be in line.
c) Reused pistons and/or reused bearing inserts must be
reinstalled in thei r original positions.
d) On DT -402 observe No. 1 marking on first connecting
rod.
e) Be su re to install bearing inserts wi th oil bores in the
correct position.
f) Lubri cate pistons and cylinder sleeves with engine oil
SAE 30 before install ation. A lso lubricate crankpins
and bearing inserts.
"Angle" Tightening Procedure for Connecting Rod Nu ts
lllust. 143
First st ep of tightening connecting rod nuts
- 70 -
Proceed as follows:
1. Pre-tighten con necting rod nuts to a torque load of
25 Nm (18.5 1b/ftl. lllust. 143.
2. Tighten the nuts further by turning them through an
angle of 120° wh ich corresponds to 2 fl ats of the nut,
l llust. 144.
Note: The 1200 angle can be easily controlled by mark-
ing the connecting rod nuts (socket) in relation to the
bearing cap .
12<f
lllust. 144
"Angle" tighten ing procedure for connecting rod nuts
After connecting rod bearing caps are installed, check
for proper side clearance 0. 16 - 0.30 mm (.006 - 0 12") ,
see lllust. 145.
lllust. 145
Checking connecting rod side clearance
1 -Connecting rod nut
2 - Feeler gauge
Note 1: Whenever th e crankshaft is reground to any un-
dersize the crankpin running clearance should be check-
ed.
Use the virgin lead wire method for this purpose as out-
lined in "Main bearing fitting procedure". See "Specifi-
cations".
Note 2: Check the protrusion of every piston whenever
th e piston pin bushings have been replaced , see il lusts.
122 and 145a.
PISTONS- CYLINDER SLEEVES- CONNECTING RODS

l ll ust. 145a
Checking piston prot rusion

- 71 -
 BALANCER
(4-cyl. -engines only)

General

The function of the balancer is to reduce engine vibra- half of their stroke than they do during the lower half of
tions. Engine vibrations result from pistons travel ling the stroke. See lllusts. 146 and 147.
faster and having higher accelerations during th e upper

tl
I
/1
.
A
_1
I
I
I
I
I
I
I

I
-·-+·I - · C enter line of
.T cranksh aft

A Increased piston travel lllust. 146 B Reduced piston travel

in the upper half of the Diagram of piston travel in in the lower half of the
stroke relation to stroke stroke

r - Without balancer
Vibrating
force
L_ With balancer -o-----""'~------c>------'-J-------0--

I
A 8 c D E

• No. 1 & No. 4 pistons No. 2 & No. 3 pistons · · • Balancer weights 0Inertia Force
ffA- 64471A

lllust. 147
Engine balancer operati on

. 72.
 BALANCER
(4-cy/.-engines only)

The engine balancer is mounted to the underside of the of timing marks stamped on the gears. They are also
engine. Lubrication is provided by a dri lled oil passage in ti med to the engine by means of a marked tooth on the
the crankcase from the engine main oil gallery that lines balancer drive gear wh ich is indexed between two mark-
up with a passage in the balancer when it is installed. ed teeth on the ring gear.

The balancer consists of two eccentric weights located
bel ow the crankshaft in the exact center of the engine.
The weights are driven by a ring gear , which is shrunk on
to the crankshaft.
The ring gear drives the weights in opposite directions at
twice crankshaft speed because the vert ical shaking for-
ces occur at twice engine speed. The balancer gears are
matched and timed t o each other (lllust. 152) by means
Important: The engine balancer has been changed t o
accommodate the higher rpm for use in other applica-
tions. The balancer weights and balancer housing have
been made heavier (lllust. 148). The crankshaft gear
which drives the balancer has been made wider and has a
full back-up surface on the crankshaft. The crankshaft
gears and balancers must be serviced with the same
design parts as originally equipped unless all parts are
changed.

Housing differences

Roll pins driven Roll pins driven

from top dow n Gear width from bottom up
differs
OLD NEW
FESM-3024

lllust. 148
Balancer comparison

Specifications Remove the two cap screws holding the oi l suction tube
in pl ace and remove the oil suction tube assembly and
mm (inch) 0-ring.
Weight assembly running 0.069 (.0027)
clearance on shaf t 0.108 (.0042)
Locate No. 2 piston at top dead center. Check to see
Weight assembly end 0.20 (.008) that the marked teeth on the crankshaft gear and the
clearance in housing 0.40 (.016) balancer drive gear are aligned. A lso, check to see that
the timing marks on the balancer idler gear and balancer
Backlash-between· crankshaft drive gear l ine up. A lso check the backlash between
ring gear and drivi ng weigh t crankshaft ring gear and balancer before removing the
gear (except, 0-268) 0.25 - 0.40 (.01 - .016) balancer. See "Specifications".

on D-268 0.23 - 0.50 (.009 - .020)

Remove the two remaining ca p screws holding the balan-
Backlash-between mating cer in place and remove the balancer from the crankcase.
weight gears 0. 18 - 0.23 (.007 - .009)

Wash assembly in cl ean solvent and blow dry with com-

pressed air.
Removal and Disassembly

Drain the engine lubricating oil. Remove the oil pan, and Check the backlash of the balancer gears to determine
oi I level gauge. their condit ion bef ore disassembly, lllust. 154.

- 73-
 BALANCER
(4-cy/. -engines only)

Clean all parts thoroughly in solvent and blow dry with

compressed air.

Check the weight shaft bearing surfaces f or signs o f ex-

cessive wear.

Check the weight shaft housing bores, shaf t diameters

and shaft f it in housing. Replace shaf t or housing, which-
ever is necessary for proper f it.

Check and , if necessary, clean out the lubricati ng oil

passages in t he housing.

Inspect the gear t eeth for chipping or other signs of ex-

lllust. 149 cessive wear. Replace the weight assembly if necessary.
Weight shaft partiall y removed

Drive the roll pins out of the housing and into th e shaft.
(Refer to l ll ust. 153.)

Press the shafts out of the housing and weights by press-

ing against the plug end (opposite the roll pin end) .

Note: The diameter of the weight shaft is slightly larger

on the pin end. Theref ore the shafts can only be driven
out of the housing towards this end.

Remove the weights from t he housing and remove t he

pins from the shafts.

Inspection and Repair

lllust. 151

Present connecting rod (change on bearing cap)

(D-239)
2 Former connecting rod (D-239 )
3 Milled face (clearance f or balancer)

Where a new balancer assembly has replaced the old

assembly, NEW connecting rod assemblies (ll lust. 151)
wi t h manufactured clearances in the bearing caps must
be installed. Refer to " Installation".

Note: Present connecting rods (wit h milled face (3)) are

installed f rom 1973 and up.

Reassembly

When installing t he balancer weigh ts make sure that the

single punch mark "B", l llust . 152, of the drive weigh t
(1) is in l ine with the double punch mark "C" of t he
driven weight (2) and the t iming mark " A" is on the top ..

A pply lubricating oil to t he weight shafts and t he bush-

lllust. 150 ings in th e weights.
Inspecti on points of a typical balancer

1 - 0 iI passages 3 - Shaft Install the drive weight in t he weight housing by driving

2 - Bushings 4 - Roll pins the weight shaft (plug end first) into place wit h a brass

- 74-
 BALANCER
(4-cy/. -engines only)

hammer, taking care the roll pin bores of the shafts are
in l ine wi th the pin bores of the housing.
Drive new double roll pins {one driven inside the other)
into the housing and weight shafts as shown in l llust.
153. Note that the roll pin installation differs between
housings.
A
Check the backlash of the balancer gears {lllust. 154) to
determine thei r condition before instal l ing the balancer.
Refer to "Specifications".
Apply engi ne oil to the thrust faces of the weight {both
sides) while turn ing the weigh ts a few times.

FESM-3028
ll lust. 152
Balance weight assembly timing marks on the gears
(
1 - Drive weight 2 - D riven weight A, B, C - Punch marks

r
1~i ·
!_ _~m=~~

lllust. 153
Location of installed rol l pin { 1)

-75 -
 BALANCER
(4-cy/.-engines only)

After balance r installation proceed as follows :

1. With the engine up-side down check the backlash

between cran kshaft ring gear and balancer drive gear.
See "Specifications".

2. Turn the crankshaft and check for su fficient clearance

between balancer housing and connecting rods,
lllust. 156.

l llust. 154
Checking backlash

lllust. 156/157
Arrow - Check connect ing rod clearance here

If connecting rod clearance is less than 2 mm (.078")

Installation install new con necti ng rods ( 1) Ill ust. 151.

Position No. 2 piston at TDC.

Position a new 0-ring ( (4) lllust. 158) in th e recessed

seat on the mounting face of the balancer housing.

Instal l the balancer. Be certain punch mark "A" lllust.

152 matches with the punch marked teeth on the crank-
shaft ri ng gear.

Chalk markings (arrow lllust. 155) will faci litate proper

balancer installation.

lllust. 158

1 - 0-rings, pipe sealing

2 + 3- 0-rings, flange sealing
4- 0-ring, housing sealing

Final ly installlub. manifold , lllust. 158.

lllust. 155
Marked teeth in mesh Be certa in all 0 -ring ( 1 to 4) are properly seated.

- 76-
 FLYWHE EL

Removal and Disassembly

Remove clutch assembly or torque converter, lllust. 159.

lll ust. 162

A ngular lifting hook
lllust,159
Flywheel for tractor engine wi th single clutch
Tool s as shown in lllust. 161 and 162 faci litate removal
1- Clutch assembly and installation of the f lywheel. lt is recommended to
2- Clutch assembly retainer bolts make them locally.
3- Flywheel
4- Flywheel ring gear Cleaning, Inspection and Repair
5- Flywheel housing
6- Starter pinion protective cap Clean th e f lywheel th oroughly and inspect the friction
7- Cl utch housing dowel pins surface for ri dges, scores, grooves, heat cracks, and
burned spots.

If the friction surface is in bad condi tio n, replace the

flywheel wi th a new one.
(

lllust. 163
lllust. 160 Flywheel, dual clutch version (6:cy l.-engine)
Remove flywheel bolts
Support the f lywheel before removing the last bolt . 1- Ball bearing life-time lubri ca ted
2- Ring gear (shrink-fit)
3- Recess f or dual clutch cover
4- Friction surface

lllust. 164
Fl ywheel, torque converter version
1 - Surface, f lush with ring gear
2 - Starter side of ring gear

If only slightly damaged, reface by surface grinding or

lllust. 161 tru eing-up in a lathe and pol ish over with a f ine grade of
Guide pins in place emery cloth.

- 77 -
 FLYWHEEL

Take care to remove only as much material as is neces- Installation

sary to true up the friction surface, otherwise clearance
between flywheel bolts heads and clutch disk is reduced
to a dangerous degree.

Care sh ould be taken to rework the flywheel recess (3)

l llust. 163 for the clutch cover by the same amount as
the fricti on surface to maintain sufficient spring tension.

Caution: Be sure the f lywheel is exactly centered when

rotatin g it. T he fri ction surface must be parallel with the
seati ng face (3) lllust. 165. Deviations of more than
0.05 mm (.002 in .) are not perm issible.

Check condi ti on of ball bearing (1) lllust. 163 and re-

place, if necessary . Use a su itable dri f t punch for re-
moval. Inspect bearing seat against specificati ons. Press
in new beari ng, making sure that it is flush with t he
lllust. 165
seatin g face.

The ring gear (5) for the starter is a shrink-fit on the 1 - Rear oil seal retainer
flywheel. Replace th is gear if teeth are badly wo rn or 2 - Oil seal
chipped or if the gear has worked loose on its seat. Use 3 - Cran kshaft flange, rear
a blunt cold chisel to remove the ring gear. 4 - Dowel pin
5 - Stud
Check the seating face on flywheel for damage. Remove 6 -Starter p ini on
burrs etc., if necessary .

Heat the new ring gear to 200°-270 °C (400°- 520 ° F),

place on flywheel and allow to cool down. Be sure the
ri ng gear is t igh t against the shoulder of the flywheel.
The camfered sides of the teeth (clash sides) must be
toward the crankshaft (starter side). Permissible out-of-
true of ring gear = 0.3 mm (.012 in.).
Caution: If a ring gear has worked l oose on the flywheel ,
do not attempt to secure by welding. Remove the loose
gear and replace wi th a new one or replace flywheel with
ring gear.
Replace flywheel w ith ring gear on cran kshaft f lange (3)
I I lust. 165 taking care that dowel pin (4) seats properly
in the flywheel bore. Use guide pins (lllust. 161) and
li fting hook (lllust. 162).
Be sure all seating faces are clean and dry.
T ighten f lywheel bolts i n crosswise sequence in two
passes. Refer to "Special Bolt and Nut Torque Specifi ca-
tions".

- 78 -
NOTES

- 79-
 LUBRICATING SYSTEM

1 - Screen
2- Suct ion l ine
3 - Pressure line
to oil filter
and cooler
4 - 0 i I passages
t o cran kshaf t
main bearings
and crankpins
5 - 0 i I passages
to camshaft
6 - Oil passage
to valve
lever shaf t
7 - Lubrication
bore in
connecti ng rod
f or piston pin
and piston cooling

lllust . 166
Longi tudinal section o f
typical t urbocharged engine

!1111 Oil under - Oil sump and

pressure suction line

u
- 80 -
 OIL PUMP

1 - Oil pump with

relief va lve
2- Sucti on line
with screen
3- Oil pressure
line, pump to
oil filter and
oil cooler
4 - Oil fi lter
5 - Oil cooler
6 - Mai n oil
galler y
7 - Lubri cation
passages to
crankshaft
main bearings
and cran kpins
8 - Oil passage
to camshaft
9- Oil passage
to valve
lever shaft
10 - Lubri cati on
bore to pist on
pin and for
piston cool ing
(in connecti ng rods)
11 - Oil pressure
line, oil
(
filter t o
turbocharger
12- Oil return
to crankcase

lllust. 167/ 168

Cross section of
t ypical turbocharged engine

~ Pressure- 1l11lllll Moving parts - Return oil ,

lubri cated lubricated by Turbocharger
bearings oil splash to crankcase

- 81 -
 OI L PUMP

lllust. 169
Oil pump, present design

General Specifications
ll lust. 169 mm (inch)
Body gears (9) l llust. 169 for 3, 4 and 6 cyl. engines
differ in effective width, result ing in a different pump
Body gears (9). widt h 3-cyl. -engines : 16.708 ( .6578)
capacity to meet the lubricating oil demand of the
various engines. See "Specif ications". 16.726 ( .6585)

4-cyl.-engines: 29.974 ( 1.1801)

30.000 (1.1811)

A relief valve (8) is provided in the pump body to main- 6-cyl. -engines: 38.494 (1.5155)
tain the specified circulating pressure by returning oil in 38.520 (1.5165)
excess of requirements direct to t he oil sump.
End play
Idler gear (10) 0.0 -0.05 (.0 - .002)
Drive gear ( 15) 0.10 (.004)
No te: Self-locki ng nut (14) l llust. 169 replaces the
former fastening method with shaft nut, lock washer and Backlash
tab washer. Crankshaft pinion I
idler gear (10) 0. 15 - 0.38 (.006- .015)
Idler gear I

u
drive gear ( 15) 0.20 - 0.36 (.008 - .014)
Importan t: The new self-locking nut (14) must not be
used on idler gear shafts wit h milled slots for the old tab Spring (7 )
washers. When using the new locking nut, remove the Free length 72.4 (2.850) or 85.8 (3.378)
slotted shaft and install the new idler gear shaft (20) Test length 47.2 (1.858) or 47.2 (1.858)
without a slot, see ll lust. 180a. Test load 15 kg (33 lbs) or22.7 kg (50 lbs)

- 82-
 OIL PUMP

Removal and Disassembly

Removal of the oil pump, see lllust. 91.

lllust.1 72

1- Cover
2- Housing
l llust. 170
3- Idler body gear
Checking gear backlash
4 - Idler gear
lt is a good practice to check oil pump gear backlash and 5 - Carrier
end play before removing (and dissassembling) the pump.
See "Specificat ions". Remove cover (1 ), housing (2), and idler gear (3), lllust.
172.

lllust. 171
Removing the relief valve
l l lust. 173
1 - Retainer washer Spl it off and remove driving body gear , I Ilust. 173.
2- Spring
3 - Valve

Remove the rel ief valve, I I lust. 171. using tool ll lust. 177. A Use protective gloves and goggles.

- 83 -
 OIL PUMP

Slide the hot gear onto shaft (1). making certain , t hat a
gap of 0. 10 mm (.004 in.) is obt ained between gear and
pump carrier (5). Check with a feeler gauge (4).

lll ust. 174

1 - Oil pump drive gear

2 - Idler gear

If necessary, remove t he idler gear (2) l llust . 174.

lllust. 176

Install gear (3) lllust. 172 and reassemble the oil pump
Cleaning, Inspection and Repair as shown in I I lust. 176.

Wash all parts and check them against "Specif ications". Tighten the housing bolts evenly, observing a crosswise
sequence.
Rep lace worn parts or the comp lete pump if worn ex·
cessively. Be sure the pump rotates without binding.

lll ust. 175

1- Drive gear shaft

2- Driving body gear (shri nk-fi t)
3- Housing bolts
4- Feeler gauge (0.0 10 mm = .004 in.)
5- Pump carrier lllust. 177

u Note: Insert bolts (3) before i nstalli ng the gear (2) I Ilust.
175.
Instal l the rel ief va lve, using special too l, I Ilust. 177. See
also lll ust. 171.

Heat body gear (2) to 200- 400 °C (390 - 750 °F). Inst all the idler gear as foll ows:

-84 -
 OIL PUMP

lllust. 178
lllust. 180
1 - Long hub end 4 - Outer race Adjusting idler gear end play
2- Circlip 5 - Inner roller bearing
3- Washer Idler Gear Fastening with Self-locking Nut

Note: The self-locking nut must have a minimum

Insert circl ip (2) I I lust. 178 in its groove. Replace wash er
(3) facing the long hub end side (1) of the gear. Install
'the two outer races (4) with their small diameter f acing
the inside of the gear.
(thread-resistance) torque of 4.5 Nm (3.3 lbf - ft) on
the total thread area bef ore the specified end play of
idler gear (lllust. 180) ist obt ained. Nuts not reaching
this torque have to be replaced. Do not reuse. Replace
the self-locking nut after every dismantling.

Important: Do not use t he self-locking nut on slotted

idler gear shafts. Replace these shafts as follows:

(
Idler Gear Shaft Replacement

lllust . 179

1 - Inner roller bearing 2 - Drift punch

Use the drift punch provided for this purpose and drive
th e inner roller bearing on th e shaft, see lllust. 179.

Lubricate roller bearings w ith engine oil SAE 30.

lllust. 180a
Place idler gear on shaft w ith short hub end f acing t he
oil pump. 1. Press out id ler gear shaft (A), I I lust. 180a, t aking care
not to damage th e shaft bore.
Install the second roller bearing, tab washer, lock washer
and shaft nut in this sequence.

Tighten the shaft nut unt il an idler gear end play of

0 - 0.05 mm ( 0 - .002 in.) is obtained, I Il ust. 180.
2. Measure the shaft bore diamet er. If the diameter ex-
ceeds 19.95 mm, use a new oil pump carrier and shaft
without slot. u
3. App ly liquid loctite into the bore and press in the
Lock the shaft nut . new shaft, observing dimension ( B), I I lust. 180a.

- 85 -
 WATER PUMP

lll ust . 181

1 - Spacer 6- Gasket
2 - Pulley 7 -Spring l oaded packing
3- Hub 8 -lmpeller
4- Bearing 9 - Plastic plug
5- Housing

General

Depending on application, components of the water

pump may vary in design. Refer to Parts Catalog for
detailed information. 2

Removal and Disassembly

l l lust. 183
Removing i mpeller

1 - Jack screw 1/2" - 13 2- lmpeller

Cleaning, Inspection and Repair

u l llust. 182
Oean all parts and dry with compressed ai r.

Replace bearing assembly (1) l llust . 186 with a new one,

Removal or installation of water pump if pump has been running rough and/or noisy.

. 86 .
 WATER PUMP

Note: When servicing the water pump always replace Reassembly

parts (4, 5, 6 and 7) ll lust. 186.

R<:!place V-belt pulley when inside of "V" is worn and

belt is riding low.

lllust. 184
Removal of packing

1 -Spring loaded packing lllust. 186

2 - Rear shaft end A - Gap 0.3-0.5 mm (.012 - .020 in.)
3 - Hub B - Hub must be flush with shaft end

1- Bearing .6- 0-ring, on early pump

2-
3-
Hub
Body
versions only
7 - 0-ring
(
4- Sprin gloaded packing 8 - lmpeller
5- Bearing face ring 9- Plastic plug

Reassemble pump as shown in lllust . 186.

For details se lllust. 187 - 189.

Remove bearing face ring and 0 -ring out of impeller,

lllust. 185.

;!
.._
M

lllust. 187
Pump bearing flush with front
face of pump body

Use an arbor press and suitable mandrel and support

slefNe for bearing installation .
lllust. 185
Removing bearing face r ing Bearing must be flush with body (see arrow lllust. 187).

- 87-
 WATER PUMP

lllust. 188 ll lust. 189

Installing packing Pressing on impeller

1 - Installing sleeve, packing

2 -Support sleeve, body front

When installing spring-loaded packing (4) l llust. 186 and

bearing face ring (5) make sure that Installation

a) 0-ri ng (6 and 7) are installed,
b) packing and face ring are properly seated,
c) seali ng faces of packing and face ring are not damaged.
Clerance "A" lllust. 186 must be maintained when
pressing on i mpeller.
Sealing faces on pump and engine front cover must be
clean and even.
T orque bol ts equally and in a crosswise sequence.
Install V -bel t pulley, spacer and fan.

To correct clearance, use a 1/2" jack screw as shown in Adjust V -belt according t o "Operator's Manual ".
lllust. 183.
When using new V-bel t inform customer to readjust in
Press on hub flush, see " 8" lllust. 186. time.

(J

-88 -
 THERMOSTAT AND COOLANT MANI FOLD

A ,~
9 10

5
3

7
~11 <(
~3 -
L{)
N
15 I
u
14
}j t9

ll lust. 190
A - Long coolant manifold
B - Short coolant manifold

General Specifications

The th ermostat controls the coolant f low wi thin the

engine.
T hermostat (5) lllust. 190
When the thermostat is closed , coolant is circulated by
Opening temperatu re 78 - 82°C ( 172 - 180°F )
the water pump through the crankcase into the cyl inder
Fully open at 88 - 92°C ( 190-198°F )
head and to the water manifold and back to the water
Full stroke 8-9 mm (.31 5 - .355 in.)
pump.

When the thermostat opens, the coolant leaves the cy-

linder head and water manifold and enters the radiator. Thermostat ( 13)

Coolant temperature is monitored by temperature sen- Openi ng temperature 80 - 84°C ( 176 - 183°F)
der unit (10) ll lust . 190 and a temperature gauge on the Ful ly open at 95 °C ( 203 °F )
instrument panel. Ful l stroke 9 mm (.355 in. )

- 89 -
 THERMOSTAT AND COOLANT MANIFOLD

Removal and Disassembly Drain the cooling system. Remove exhaust manifold and
coolant manifold.

To remove thermostat (1) lllust. 191 loosen hose clamps

of connections (3) and (4).

To remove the thermostat of the short coolant manifold,

lllust. 192, remove thermostat housing (4) and li ft out
the insert.

Inspection and Repair

J/
--
'- "'-
Pl ace the thermostat in water. Heat the water and obser-
~
ve opening begin and check if the full stroke of the ther-
mostat is within "Specifications".
ll lust. 191
Make a similar test wi th the temperature sender unit.
1 - Thermostat Check the registered temperat ure on the heat indicator
2 - Connection to radiator against a reading taken with a reliable thermometer.
3- Hose
4 - Hose Repairs on temperature sender unit and thermostat
5- Temperature sender unit should not be attempted. In case of f ai lure, unsatisfact-
6 - Coolant manifold ory servi ce or damage, rep lace defect ive parts with new
7 -Water channel (by-pass) ones.

Check the coolant manifold for cracks and/or distortion

of connecting flanges.

Check all hose connections for cracks and replace brittle

parts with new ones.

Installation

Use new gaskets (2) and (12) lllust . 190 for manif old
and themostat.

To obtain a positive earth connection a copper washer

lllust. 192 (instead of a lockwasher) must be placed under one of
the lower stud nuts.
1 -Cover 5 - Connecting hose
2 -Coolant manifold 6 - Hose clamps Tighten the temperature sender unit to specified torque.
3- Retainer bolts 7- By-pass
4 - Housing, thermostat 8- Tempera ture sender unit See "Special Nut and Bolt Torque Data".

u
-90 -
 INJECTION PUMP EP/VA- VE
General:
This section consists of the following subsections:
Checking Static Timing
Removal
Installing and Timing the Pump to the Engine
Checking Timing with Dial Indicator
For all other seNice instructions refer to seNice Manual
"Fuel System. Injection Pump and Turbocharger".
Checking Static Timing:
B. Timing Window Method
lt is good practice to check static timing of the injection
pump before removing it from the engine.
Note: The dial indicator method A) may be used with all
injection pumps. whereas Method B) is restricted to
pumps with timing window; lllust. 193b.
A. Dial lnidicator Method
1 . Shut off fuel supply.
2. Position the engine on the compression stroke num-
ber one cylinder (intake and exhaust valves are
closed).
1 . Remove central plug from distributor head and mount
dial indica tor with extension (2). lllust. 193 a. Rest
stylus of the indicator on the face of the distributor
plunger and pre-load approx. 3 mm.
lllust. 193 a.
1 - Dial indica tor
2 - Extension (special tool 1329 159C1)
3 - Packing ring
4. Slightly turn the crankshaft to and fro to find the bot-
tom dead centre of the distributor plunger.
5. With the distributor plunger in BDC. zero the dial
indicator.
-91-
6. Slowly turn the crankshaft in direction of the rotation
until the dial indicator shows 1 .0 mm travel of the
distributor plunger.
7. Read actual degrees of static timing on crankshaft
pulley. see lllust. 194 and 195. and compare with
'Technical Data".
8. (Pumps without timing window only). Turn the engine
to check the tota l plunger stroke and compare with
timing specifications. If out by more than 0.02 mm
repeat steps 4 - 8.
1 . Shut off fuel supply.
2. Remove lower cover plate of the pump. lllust.
193 b.
3. Position the engine on the compression stroke num-
ber one cylinder (intake and exhaust valves are
closed).
4. Turn the crankshaft in direction of rotation until the
timing pointer (1) lllust. 194 is in line with the
specified timing mark (2) on the graduation.
For static degrees of the engine. see 'Technical
Data".
5. Read the graduation on the front pulley as outlined in
lllust. 195.
lllust. 193b
1 - Pointer on roller ring
2 - Scribe line on face cam
6. With sta tic timing correct. both pointers (lllust. 193b
and 194) must be in line with their respective
timing marks.
Note: On EPNA pumps the face cam has a second
scribe line marked with letter "L''. Do not use this scribe line
for adjustment.
 INJECTION PUMP EP/VA- VE

Removal

Thoroughly clean th e left side of the engine to prevent

dirt from entering the pump. Cap or plug al l l ines and
ports as they are opened.

Remove the injection pipes. Disconnect all l ines from

the pump.

lllust. 194

1 - Pointer 2- Graduation on the front pulley

lllust . 196
1 - Drive shaft nut
1 2 3
2 - Hub
lllust. 195 3 - Hub cap screws (three)
One graduation mark = 2°

1 - TDC mark 2- 10° BTDC 3 - 20v BTDC

-91a-
 INJECTION PUMP EP/VA- VE
Remove rectangular cover plate from th e crankcase front
cover.
Remove nut (1) lllust. 196 and hub capscrews (3).
Note: Turn engine if necessary to place keyway in "up
Position" (eleven o'clock) to prevent the Woodruff-key
from dropping into the oil pan, when t he hub is removed.
lllust. 197
Pulling hub from drive shaft
Remove gear with hub from the shaft, lllust . 197.
Remove injection pump retainer nuts, using a special
wrench extension for loosening the inner nut, see I I lust.
198.
Note: When removing the injection pump be sure mati ng
gears (pump drive gear - idler gear) are not disengaged
to maintain the ori ginal timing.
lllust. 198
1 - Stud nuts (two)
2 - Washers (two)
3- Wrench. with extension (special tool 3055 700RT)
-92 -
Installing and Timing the Pump to the Engine
The engine must be in static timing position (first cylinder
on compression stroke ?nd timin.g pointer lined up).
Proceed as follows:
1 . Remove cover plates of the injection pump (lllust.
193b) or mount dial indicator (lllust. 193a). Remove
cover plate of the front cover (lllust. 196).
lllust. 199
1 - Engine front plate 2 - Gasket
2. App ly liquid sealer t o both sides of new gasket (2)
l llust. 199.
3. Place woodruff-key into keyway of injection pump
drive shaf t.
4. Turn keyway in 11 o'clock position and install the
pump.
Note: The following step 5 A. does not apply for DT-
402 engines equipped with water channel version ( 1)
lllust. 200. On these engines position the pump as
shown in lllust. 20 1, step 5 B.
lllust. 200
DT-402 engines
Water channel , pump position according t o
step 58
2 Water pump carrier, injection pump postition
accordi ng to step 5 A
 INJECTION PUMP EP/VA - VE

5 A. Positioning the pump so that washers (2) lllust. If the engine is on number one compression at the
198 cover slotted holes of pump flange evenly, i. e. specified static timing and the injection pump is installed
the pump is level. with 1.0 mm plunger stroke the pump will be '"timed'".

5 B. On DT-402 engines with water channel ( 1) l llust.

200 take care to tilt the injection pump toward the However, if the complete timing gear train has been re-
engine all the way within the play of the flange slots moved, the timing of the gear train must be reset as
(2) lllust. 201 before tightening. shown in lllust. 212.

lllust. 203
1- Hub
2 - Hub retainer bolts, with washers
3- Keyway (in 11 o'clock position)

7. Install hub (1) lllust. 203, use quality bolts (six lines
lllust. 204) and steel washers.
( lllust. 20 1
VE -Injection pump position on Tighten bolts (2) I I lust. 203 slightly.
DT402with (1) lllust. 200
·r6eo- v9
1 -Stud 3- Engine
2- Slot 4 - Injection pump, VE

6. Tighten stud nuts ( 1) l llust. 198 to specified torque.

-~
------------
lllust. 204

\1
I

lllust. 202

1 -Injection pump drive gear

2 - Timing marks lllust. 205
1- Hub
Note: Since the idler gear is a walking gear , proper t iming 2 - Hub retai ner nut, with lock washer
alignment (2) lllust. 202 wi ll not always be noted. 3- Bolts, hub to gear

-93-
 INJECTION PUMP EP/VA- VE

8. Install lock washer and nut (2) lllust. 205. Checking Injection Pump Timing with Dial Indicator
(pumps with timing window)
Block the engine and tighten nut (2). observe the dif-
ferent special torques for the respective nut size:
M - 12 = (19 mm spanner) 6 - 7 daNm
M- 14 = (22 mm spanner) 8.5 - 10 daNm

9. Loosen bolts (3).

lllust. 208

1 - Graduation marks. pulley

2 - Pointer shows degrees of timing as specified
3 - Pointer on roller ring
4 - Scribe line on face cam
5 - Extension (special tool)
lllust. 206 6 - Dial indicator. shows 1 .0 mm plunger stroke
Adjusting the injection pump
If the position of timing pointer (1 ) ll lust. 207 is in doubt or
1 0. Turn the injection pump drive shah until the pointer on if scribe mark on face cam cannot be clearly seen check
the roller ring is in line w ith the scribe mark on the face pump timing with dial indicator. following method A. See
cam lllust. 207 or the dial indicator shows 1.0 mm also lllust. 193a
plunger stroke. lllust. 193a.

At this point tighten the retainer bolts to specified tor-

que. See "Special Bolt and Nut Torque Da ta".

Finally turn the engine through a complete cycle and

check to make sure that the timing o f the front pulley
at compression stroke coincides with that of the face
cam lllust. 207 or with the 1.0 mm plunger stroke
shown on the indicator lllust. 193a.

lllust. 207

1 - Pointer on roller ring 2 - Scribe line on face cam ·

-94-
 INJECTION PUMP EP/ VA- V E

Note: (VE-pumps only). When connecting the fuel lines,
make sure to use the fuel return valve (5) lllust . 211 on
th e pump return port.
Fuel Feed Pump
The feed pumps is a diaphragm-type pump driven by the
engine camshaft. lt can also be operated manually on
hand lever (6) lllust. 209 to fill the fuel syst em or for
venting purposes.

A filter screen is instal led in the feed pump to primarily

fi lter the fuel from th e fuel tank. When servicing the
1- engine it is good practice to remove the filter screen. Use
a soft brush and carefu lly clean in Diesel fuel. On reas-
3 sembly make sure all parts seat properly to avoid leaka-
ge. Install a new f eed pump if the diaphragm is damaged
or the operating mechanism is defective.

Install plug ( 11) using liquid sealer.

5 Note: The fuel feed pump is attached to the crankcase

side cover by means of an additional fl ange with two
studs. To prevent dropping the flange into t he crankcase
on removal or instal lati on, stud nuts shou ld be cauti -
ously removed and instal led respectively.
8

lllust. 209
(

u
- 95-
 INJECT ION NOZZLE HOLDER

Installation

A. Flange Mounted Hol der

Pl ace the sealing 0 -ring approx. 6 mm (.24 in. ) above the

nozzle holder nut, them install the nozzle holder. ..
Make sure the 0-ring is not twisted.

T ighten stud nuts or necked-down bolts in two steps to

specified torque.

~I
I
lllust. 211

1 - Nozzle holder 4 - Fuel return l ine

2 - Crab 5 - Return valve
3 - Bolt 6 - Return line

Make sure hollow screws, show to the valve cover,

lllust. 211 .

lllust. 210
1 - Nozz le holder seat capped up
B. Crab Mounted Holder
Clean sleeves in cylinder head and install nozzle holders
using new 0 -rings.
Place the nozzle crabs into position and install the dish-
ed washers and crab bolts.
Ti gh ten the bolts (3) to specified torque.
2 - Nozzle holder
Connect the fuel supply pipes and the fuel return l ine
to the nozzle holders. (
Tigh ten pipe union nuts and fuel return hollow screws to
specified torque, refer to "Special Nut and Bolt Torque
Data".

~I
 TIMING GEAR TRAIN

Adjustment
7 8

1
A-A B-B
lllust 212

1 - Crankshaft pinion 6- End play of camshaft =

2- Idler gear 0.09-0.44 mm (.0035- .0173 in.)
3- Injection pump drive gear 7- Scribe mark on pump f lange (displaced)
4- Camshaft drive gear 8- Front plate
5- End play of idler gear= 9- Injection pump hub
· 0.20-0.33 mm (.0078- .0130 in.) 10 - Idler gear carrier

lllust. 212 shows the gear train of a 6-cyl.-engine with Note: Marks on injection drive gear are fo r easy assem-
piston number one on compression TDC. bly. lt is not essential that the timing mar ks of i njection
pump drive gear be aligned for proper timing.

On all engines the timing marks of gears (1) and (4) must If the engine is on number one compression at the
be in line with the timing marks of the idler gear (2). specified static timing and the injection pump is installed
with the injection plunger at 1 .0 mm stroke. the pump will
be "timed".

The injection pump drive gear (3) is marked wi th num- However. the following timing instructions should be used
bers 1 up t o 6. to facilitate gear installation.

- 97-
 TIMING GEAR TRAIN

Timing Instructions for Injection Pump Gear (3) lllust. 212

(Part Numbers 3055 066 R3, 3056 885 R3, 3218 450 R1)

lllust. 2 12 a.

3 - Cylinder Engines
Engines w ith water channel A. use timing. mark 1 .

Engines with water pump carrier B. use timing mark 3.

4 - Cylinder Engines
Engines w ith water channel A. use timing mark 2.

Engines with wa ter pump carrier B. use timing mark 4 .

(
6 - Cylinder Engines
Engines w ith water channel A. use timing mark 5.

Engines with wa ter pump carrier B. use timing mark 6 .

- 98 -
 VALVE LASH ADJUSTMENT

To adjust valve lash, use the simplified procedure as out- A ll val ves can be adjusted by cran king the engine on ly
lined in the f oll owing lllusts. 2 13 t o 21 5. twice.

3-Cy/inder Engines

With Adjust Valves (Engine Warm)*

No. 1 Pi ston at T .D.C. (Compression ) 1 2 4 5
No. 1 Pist on at T .D .C. (Exhaust) 3

•
FRONT 1 2

lllust 2 13
3 4 5 6

Nu mbering sequence of the va lves which correspond

to the chart

4-Cy/inder Engines

Wi th Adjust Valves (Engine Wa rm) *

No. 1 Piston at T.D.C. (Compressio n) 1 2 4 5
No. 4 Pist on at T.D.C. (Compressio n) 3 6 7 8
(

r;~;s
-
FRONT 1 2 3
l llust.2 14
4 5 6 7 8

6-Cy/inder Engines

With Ad just Valves (Engi ne Warm )*

No. 1 Piston at T.D.C . (Compression ) 1 2 4 5 8 9
No. 6 Piston at T .D.C . (Compression) 3 6 7 10 11 12

L
-
FRONT 1 2 3 4 5
lllust. 215
6 7 8 9 10 11 12

Note: Even numbers are i ntake valves , uneven numbers are exhaust va lves.

* Operating temperatu re

-99 -
 VALVE LASH ADJUSTMENT

Note: If valve lever adjusting screws (4) lllust. 216 are

self-clamping and do not have lock nuts, t hey must t urn
with more th an 16 N.m ( 12 lbf-ft) or a new screw, or
new valve lever or bot h should be instal led since it is
possible that the screw wil l work loose.

lllust. 216
A djusting valve lash
(engine at standstill)

1 -Valve lever, exhaust 3 - Feeler gauge

2 -Valve lever, intake 4 - Adjusting screw and
lock nut ll lust. 217
Adjusting valve lash
The valve lash should be adjusted with t he engi ne warm. (engine running)

Loosen the adjusting screw lock nuts and turn the Using a special tool , the valve lash may be readjusted
rocker arm adjusting screws (see Note) in or out until while the engine is running, I Ilust. 217.
the correct feeler gauge clearance is obtained (Refer to
''Specifications"). The tool is avail able on t he market .

- 100 -
 ENGINE T ESTING
Valve Timing
/alve timi ng is taken care of by the markings on timing
gears of the engi ne, lllust. 212.
If in doubt check the timing with a dial indicator as fol -
lows:
lllust. 218
1. Check valve clearance.
2. Adjust intake valve number 1 to correspond with
T DC, of number 1 piston exhaust stroke.
3. Position dial indicator on cylinder head and set
stylus against spring seat of number 1 intake valve,
lllust. 218.
4. Adjust dial indicator to zero.
5. Rotate the engine to obtain maximum valve opening.
6. Read valve opening TDC-maximum on dial indicato r.
7. Timing is correct when reading is 10.10 to 10.25 mm.
8. With 1 tooth out of time a reading of either 9.00 mm
{earl y) or 10.60 mm {late) wi ll be obtai ned.
Compression
ll lust.219
Checking compression
. 101 .
It is good practice to check compression before and after
a repair to obtain comparative values.
Run engine to warm up {operating temperature). Be sure
battery is f ully charged.
Disconnect fuel supply and return lines.
Remove a nozzle with holder.
Connect-up compression gauge with adapter as shown in
lllust. 2 19.
Crank the engine with the starting motor and take a
compression reading.
An engi ne repair is recommended if :
a) Compression readings of individual cylinders differ
by more than 0.25 MPa {36 PSI).
b) Compression readi ngs are below 1.8 MPa {255 PSI).
Lubricating Oil Pressure
ll l ust. 220
Connect a test pressure gauge {0 - 15 bar = 0 - 250 PS I
range) to the main oi l gallery, ll lust. 220.
Check engine oil pressure against specifications.
Probable causes for insufficient oil pressure:
Bearings excessively worn
Oil pump worn
Relief valve or rel ief valve spring damaged
Suction li ne leaking
Suction screen clogged, insufficient oil level.
Diluted engine oil
Air Cleaner Restriction
Connect a vacuum gauge to the i ntake manifold, lllust.
221 or to the Air Cleaner ll lust . 222 .
 ENGINE TESTING

'~>&s o Boost Pressure

(Tu rbocharged Engines)

Connect a pressure gauge to the intake manifold. lllust.

223.

Check boost pressure agai nst specifications, refer to •'

Servi ce Manual "Fuel System and Turbocharger".

Causes f or insufficient boost pressure :

Excessive air cleaner restri cti on.

Intake and/or exhaust manifold leakages.

lllust. 221

1 - Intake mainfold 2 - Test connecti on Damaged turbocharger.

Crankcase Pressure Orificed Restrictor

(PL T-556 w/7 .04 mm (0.277 in.) Orifice)
Description

The restri ctor is used to measure combustion gas flow

ou t of the engine breather and is used with water mano-
meter PLT-302-8.

lllust.' 222 lllust. 224

Orificed Restri ctor
With the engine at operating temperature take a reading
at rated speed. 1 -Orifice 2 - Adapter for manometer

If max imum restriction values are exceeded replace the For breather pipes wi th 19 mm (.75 in.) 0.0. use an
air cleaner element. adapter hose, 19 x 3 x 60 mm (.75 x .1 2 x 2.4 in .).

Check service indicator , refer to "Chassis Manual ". Note: On engines having a hat-type breather, some
method of attaching th e restrictor tool must be fabri cat-
ed. The tool shown in lllust . 225 may be made local ly.

I
r- {Hfi1r0~.I 1I
lllust. 225
lllust. 223 Orificed Restri ctor Adapter

- 102 -
 ENGINE T EST ING

Note: Refer t o "Crankcase Pressure and Blow-by Chart"
for appl ication and crankcase pressure requirements.
Pressure readings obtained with this restrictor must not
be used as the main source of engine condition . Oil son -
sumption trend 'data must also be used if the pressure
readings are beyond t he specified limi ts. Neither changes
in oi l consumption trends nor crankcase diagnostic
pressures trends can establish a specific component
problem but are on ly indicators that some problem
ex ists.

u
- 103 -
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