维修详情

3012/CV12
12 cylinder diesel engines for industrial
applications
The contents of this manual are applicable to both
CV12 and 3000 Series - 3012 engines.
Publication TSD 3420, Issue 3
© Perkins Group Limited 2000, all rights reserved.
Published in September 2000 by Technical Publications.
Perkins Engines Company Limited, Lancaster Road,
Shrewsbury SY1 3NX, England
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10 General information
Introduction ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  ... ... ... ... ... ... ... ... ... ... .13
Bank and cylinder bore identification . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .13
Engine identification . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .13
General safety precautions .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .14
Safety .  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .15
Useful information   ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .16
Approved lubricants and fluids ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  ... ... ... ... .21
11 Specifications
Basic engine data  . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .23
Recommended specific applied torques  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .26
Recommended nominal applied torques  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .28
12 Cylinder head assembly
General description  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 29
Pedestal rocker cover
12-1 To remove and to fit  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .31
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Pedestal rocker assembly
12-2 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  ... 32
12-3 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  33
Rocker box cover
12-4 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  ... 34
Rocker box
12-5 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  ... 34
12-6 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  35
12-7 To inspect and to correct  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  36
Tappet clearances
12-8 To check and to adjust ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  38
Cylinder head assembly
12-9 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  ... 40
12-10 To dismantle and to assemble . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  44
12-11 To clean and to inspect the cylinder head  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  45
12-12 To correct a valve seat   ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  46
12-13 To remove a valve seat insert .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  47
12-14 To fit a valve seat insert ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  48
12-15 To inspect the valve guides  . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  49
12-16 To renew a valve guide  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  50
12-17 To inspect the bridge pieces and guides  . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  51
12-18 To renew a bridge piece guide   ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  51
12-19 To recondition a fuel injector sleeve   ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  52
12-20 To renew a fuel injector sleeve  ... ...  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  53
Valves, valve springs and valve rotators
12-21 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  57
12-22 To inspect and to correct  . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  57
Push rods
12-23 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  ... 58
12-24 To inspect   ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  58
Fits and clearances - Cylinder heads, rocker assemblies and valves  . ... ... ... ... ...  59
Cylinder heads, rocker assemblies and valves (continued)  . ... ... ... ... ... ... ... ... ...  60
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13 Pistons and connecting rods
General description  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 61
Big end bearings
13-1 To remove and to fit  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .63
13-2 To inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .64
Piston and connecting rod assembly
13-3 To remove and to fit  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .65
13-4 To dismantle and to assemble  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .68
Piston rings
13-5 To remove and to fit  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .70
Piston and rings
13-6 To inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .71
Connecting rod
13-7 To inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .71
Fits and clearances - Pistons and connecting rods
Pistons - 4 rings  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  ... ... ... ... ... ... ... ... ... ... ... .72
Piston rings  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .72
Pistons - 3 rings  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  ... ... ... ... ... ... ... ... ... ... ... .74
Piston rings  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .74
Connecting rods  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 76
14 Crankshaft assembly
General description  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 77
Crankshaft pulley, damper and alternator pulley
14-1 To remove and to fit  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .78
Front oil seal
14-2 To renew  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .79
Rear oil seal
14-3 To renew  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .81
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Crankshaft
14-4 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  ... 83
14-5 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  88
14-6 To clean and inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  88
Main bearings and thrust washers
14-7 To inspect  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  88
Fits and clearances  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  89
15 Timing gears and timing case
General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  91
Timing gears and auxiliary drive shaft
15-1 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  ... 92
15-2 To clean and to inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  98
Double idler gear
15-3 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  98
Auxiliary drive gear
15-4 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  98
Timing case
15-5 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  ... 99
15-6 To clean and to inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 100
Fits and clearances  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 101
16 Crankcase and cylinder liners
General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 105
Crankcase
16-1 To fit to and to remove from a build stand  . ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 107
16-2 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 110
16-3 To clean, to inspect and to correct . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 114
16-4 To test under pressure ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 115
Cylinder liner
16-5 To clean and inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 115
Fits and clearances  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 116
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17 Camshafts and engine timing
General description  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...119
Camshafts
17-1 To remove and to fit  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...121
17-2 To clean and inspect . ... ... ... ... ... ... ... ... ... ... ... ...  ... ... ... ... ... ... ... ... ... ... ...125
Engine timing
17-3 To check the valve timing .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...126
17-4 To check/adjust the timing of the fuel injection pump  ... ... ... ... ... ... ... ... ... ... ...127
Fits and clearances ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...128
18 Induction and exhaust system
General description  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...129
Turbocharger
18-1 To remove and to fit  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...129
18-2 To dismantle and to assemble  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...131
18-3 To clean and to inspect . ... ... ... ... ... ... ... ... ...  ... ... ... ... ... ... ... ... ... ... ... ... ...134
Exhaust manifold
18-4 To remove and to fit  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...135
Induction manifold
18-5 To remove and to fit  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...135
Fits and clearances ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...136
19 Lubrication system
General description  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...137
Lubricating oil sump - early engines
19-1 To remove and to fit  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...139
19-2 To clean and inspect . ... ... ... ... ... ... ... ... ... ... ... ...  ... ... ... ... ... ... ... ... ... ... ...139
Sump adaptor - early engines
19-3 To remove and to fit  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...139
19-4 To clean and inspect . ... ... ... ... ... ... ... ... ... ... ... ...  ... ... ... ... ... ... ... ... ... ... ...140
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Single piece lubricating oil sump
19-5 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 140
19-6 To clean and inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 141
Lubricating oil pump
19-7 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 142
19-8 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 143
19-9 To clean and inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 144
Heat exchanger (oil to coolant) - early engines
19-10 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  .. 145
19-11 To dismantle and to assemble . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 146
19-12 To clean and to inspect  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 146
Mounting adaptor for the heat exchanger - early engines
19-13 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  .. 147
Heat exchanger (oil to coolant)
19-14 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  .. 148
19-15 To dismantle and to assemble . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 149
19-16 To clean and to inspect  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 150
Relief valve
19-17 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  .. 151
20 Fuel system
General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 153
Primary fuel filter
20-1 How to clean the primary fuel filter   ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 156
Fuel filter canisters
20-2 How to renew the canisters of the main fuel filter  .. ... ... ... ... ... ... ... ... ... ... ... .. 156
Fuel filter head
20-3 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 157
Mechanical fuel lift pump
20-4 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 158
20-5 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 159
20-6 To test  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 160
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Fuel injectors
20-7 To remove and to fit  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...161
20-8 To dismantle and to assemble  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...162
20-9 To clean and to inspect . ... ... ... ... ... ... ... ... ...  ... ... ... ... ... ... ... ... ... ... ... ... ...163
20-10 To set and to test   ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...165
Fuel injection pump and governor
20-11 To remove and to fit   ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...166
20-12 To dismantle and to assemble   ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...171
20-13 To inspect  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...187
20-14 To calibrate the fuel injection pump   ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...189
20-15 To test the fuel injection pump   ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...190
Sizes of spacers (A) available for the tappets  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 192
Sizes of lower spring plates (A) available  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...193
Fuel system
20-16 How to eliminate air from the fuel system  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...194
21 Cooling system
General description  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...195
Radiator
21-1 To remove and to fit  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...197
21-2 To clean and to inspect . ... ... ... ... ... ... ... ... ...  ... ... ... ... ... ... ... ... ... ... ... ... ...197
Thermostats
21-3 To remove and to fit  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...198
21-4 To clean and to inspect . ... ... ... ... ... ... ... ... ...  ... ... ... ... ... ... ... ... ... ... ... ... ...198
Coolant pump
21-5 To remove and to fit  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...199
21-6 To dismantle and to assemble  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...200
21-7 To clean and to inspect . ... ... ... ... ... ... ... ... ...  ... ... ... ... ... ... ... ... ... ... ... ... ...202
Fan
21-8 To remove and to fit  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...203
Fan belts and tensioner pulley
21-9 To remove and to fit  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...204
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Fan adaptor
21-10 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  .. 205
21-11 To dismantle and to assemble . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 207
21-12 To clean and to inspect  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 210
22 Flywheel and flywheel housing
General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 211
Flywheel
22-1 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 211
22-2 To inspect  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 211
Starter ring
22-3 To renew  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  .. 212
Flywheel housing
22-4 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 212
23 Electrical equipment
General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 215
Alternator
23-1 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 218
23-2 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 220
23-3 To clean . ... ... ... ... ... ... ... ... ... ... ...  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 221
23-4 To inspect and to correct the rotor . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 221
23-5 To remove and to fit the rectifier  ... ...  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 222
23-6 To test the main diodes with an ohmmeter or a test lamp . ... ... ... ... ... ...  ... ... .. 222
23-7 To test the auxiliary diodes  ... ... ... ... ... ... ... ... ... ...  ... ... ... ... ... ... ... ... ... ... .. 223
23-8 To remove and to fit the D+ and F- wires  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 223
23-9 To check and to renew the carbon brushes ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 223
23-10 To inspect the stator and the housing .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 223
23-11 To inspect the bearings  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 224
23-12 To renew the bearing at the slip ring end   ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 224
23-13 To renew the bearing at the drive end .  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 224
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Starter motor
23-14 To remove and to fit   ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...225
23-15 To dismantle and to assemble the solenoid switch . ... ... ... ... ... ... ... ... ... ... ...226
23-16 To dismantle and to assemble the starter motor . ... ... ... ... ... ... ... ... ... ... ... ...228
23-17 To clean  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...230
23-18 To inspect and to correct . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...230
23-19 To test  . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...231
23-20 To fit the main starter cables ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...232
Electrical switches
23-21 To test  . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...233
Engine stop solenoid (energised to run)
23-22 To adjust the linkage ... ... ... ... ... ...  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...234
Early 3012 engines  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...235
24 Auxiliary equipment
General description  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...237
25 Running-in and test
General information .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...239
Running-in and test
25-1 To run the engine .. ... ... ... ...  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...239
25-2 To check the consumption rate of the engine lubricating oil  . ... ... ... ... ... ... ... ...240
26 Special tools
List of special tools  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...241
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10
General information
10
Introduction
This workshop manual has been designed to provide    Engine identification
assistance in the service and the overhaul of Perkins
3012 (CV12) engines.  Most of the general
information, which is included in the User’s Handbook
(Sections 1 to 9), has not been repeated in this
Workshop Manual and the two publications should be
used together.
The engine number is stamped on the data plate
which is fastened to the right side of the crankcase.
For early engines, a typical engine number is
6A27487U 59426V, which consists of these codes:
6A
=
Engine family
Read the ’Safety precautions’ and remember them.
They are given for your protection and must be
applied at all times.
27487   =
Engine number
U
=
Country of manufacture
Build line number
Year of manufacture
Danger is indicated in the text by two methods:
59426   =
Warning!  This indicates that there is a possible
V
=
danger to the person.
Engines produced after August 1994, have a new
engine number system.  For these engines, a typical
number is: SGD 12 0012 U 1572 Y, which consists of
these codes:
Caution:  This indicates that there is a possible
danger to the engine.
Note:  Is used where the information is important, but
there is not a danger.
SG
D
=
=
=
=
=
=
=
Engine application
Engine type
Bank and cylinder bore identification
12
0012
U
Number of engine cylinders
Engine specification number
The country of manufacture
Build line number
The left and right sides of the engine are as seen from
the rear (flywheel) end.  Where reference is made to
’A’ and ’B’ banks of cylinders: ’A’ bank is to the left and
’B’ bank to the right when viewed from the front end.
1572
Y
The cylinders are numbered from the front of the
crankcase, A1 to A6 and B1 to B6.
Year of manufacture
Units such as the fuel injection pump and
turbochargers have their own data plates.
To ensure that you use the correct information for
your specific engine type, refer to ’Engine
identification’ below.
If you need parts, service or information for your
engine, you must give the complete engine number to
your Perkins distributor.
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10
General safety precautions
Read and use the instructions relevant to lift
equipment which are given on page 15.
These safety precautions are important.
Reference must also be made to the local regulations
in the country of operation.
Always use a safety cage to protect the operator
when a component is to be pressure tested in a
tank of water. Fit safety wires to secure the plugs
which seal the hose connections of a component
which is to be pressure tested.
Only use these engines in the type of application
for which they have been designed.
Do not allow compressed air to contact your skin.
If compressed air enters your skin, obtain medical
help immediately.
Do not change the specification of the engine.
Do not smoke when you put fuel in the tank.
Clean away fuel which has been spilt. Material
which has been contaminated by fuel must be
moved to a safe place.
Turbochargers operate at a high speed and at
high temperatures. Keep fingers, tools and other
items away from the inlet and outlet ports of the
turbocharger and prevent contact with hot
surfaces.
Do not put fuel in the tank while the engine runs
(unless it is absolutely necessary).
Do not clean, add lubricating oil, or adjust the
engine while it runs (unless you have had the
correct training; even then extreme caution must
be used to prevent injury).
Diesel fuel and lubricating oil (especially used
lubricating oil) can damage the skin of certain
persons. Protect your hands with gloves or a
special solution to protect the skin.
Do not make adjustments that you do not
understand.
Do not wear clothing which is contaminated by
lubricating oil. Do not put material which is
contaminated with oil into the pockets.
Ensure that the engine does not run in a location
where it can cause a concentration of toxic
emissions.
Discard used lubricating oil in a safe place to
prevent contamination.
Other persons must be kept at a safe distance
while the engine or equipment is in operation.
Ensure that the control lever of the transmission
drive is in the ‘out-of-drive’ position before the
engine is started.
Do not permit loose clothing or long hair near
moving parts.
The combustible material of some components of
the engine (for example certain seals) can
become extremely dangerous if it is burned. Never
allow this burnt material to come into contact with
the skin or with the eyes.
Keep away from moving parts during engine
operation. Warning! The fan cannot be seen
clearly while the engine runs.
Do not operate the engine if a safety guard has
been removed.
Fit only genuine Perkins parts.
Do not remove the filler cap of the cooling system
while the engine is hot and while the coolant is
under pressure as dangerous hot coolant can be
discharged.
Fuel and oil pipes MUST be inspected for cracks
or damage before they are fitted to the engine.
Do not allow sparks or fire near the batteries
(especially when the batteries are on charge),
because the gases from the electrolyte are highly
flammable. The battery fluid is dangerous to the
skin and especially to the eyes.
Disconnect the battery terminals before a repair is
made to the electrical system.
Only one person must control the engine.
Ensure that the engine is operated only from the
control panel or from the operator’s position.
Be extremely careful if emergency repairs must be
made in adverse conditions.
If your skin comes into contact with high pressure
fuel, obtain medical assistance immediately.
14
Perkins Engines Company Limited
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10
Safety
.
Engine lift equipment
Use only the lift equipment which is designed for the
engine.  The part number for the lift adaptor to use for
the 3012 engine is: 21825 822.
Use lift equipment or obtain assistance to lift heavy
engine components such as the cylinder block,
cylinder head, flywheel housing, crankshaft and
flywheel.
Check the engine lift brackets for security before the
engine is lifted.
A
Asbestos joints
Viton seals
Some joints and gaskets contain compressed
asbestos fibres in a rubber compound or in a metal
outer cover.  The ’white’ asbestos (Chrysotile) which
is used is a safer type of asbestos and the danger of
damage to health is extremely small.
Some seals used in engines and in components fitted
to engines are made from Viton.
Viton is used by many manufacturers and is a safe
material under normal conditions of operation.
If Viton is burned, a product of this burnt material is an
acid which is extremely dangerous.  Never allow this
burnt material to come into contact with the skin or
with the eyes.
Contact with asbestos particles normally occurs at
joint edges or where a joint is damaged during
removal, or where a joint is removed by an abrasive
method.
If it is necessary to come into contact with
components which have been burnt, ensure that the
precautions which follow are used:
To ensure that the risk is kept to a minimum, the
procedures given below must be followed when an
engine which has asbestos joints is dismantled or
assembled.
Ensure that the components have cooled.
Work in an area with good ventilation.
Do NOT smoke.
Use Neoprene gloves and discard the gloves
safely after use.
Wash the area with a calcium hydroxide solution
and then with clean water.
Use a hand scraper to remove the joints - do NOT
use a rotary wire brush.
Disposal of gloves and components which are
contaminated, must be in accordance with local
regulations.
Ensure that the joint to be removed is wet with oil
or water to contain any loose particles.
Spray all asbestos debris with water and place it in
a closed container which can be sealed for safe
disposal.
If there is contamination of the skin or eyes, wash the
affected area with a continuous supply of clean water
or with a calcium hydroxide solution for 15-60
minutes.  Obtain immediate medical attention.
Environmental protection
There is legislation to protect the environment from
the incorrect disposal of used lubricating oil.  To
ensure that the environment is protected, consult your
Local Authority who can give advice.
Perkins Engines Company Limited
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10
Useful information
To clean components
It is important that the work area is kept clean and that
the components are protected from dirt and other
debris.  Ensure that dirt does not contaminate the fuel
system.
Before a component is removed from the engine,
clean around the component and ensure that all
openings, disconnected hoses and pipes are sealed.
Remove, clean and inspect each component
carefully.  If it is usable, put it in a clean dry place until
needed.  Ball and roller bearings must be cleaned
thoroughly and inspected.  If the bearings are usable,
they must be flushed in low viscosity oil and protected
with clean paper until needed.
Before the components are assembled, ensure that
the area is as free from dust and dirt as possible.
Inspect each component immediately before it is
fitted, wash all pipes and ports and pass dry
compressed air through them before connections are
made.
Use suitable gloves for protection when components
are degreased or cleaned with trichloroethylene,
white spirit, etc.  Degreasing solutions which are
basically trichloroethane are not recommended.
16
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10
Leave to soak until all contamination has been
Suitable fluids to clean and to protect
components
removed.
Warning!  Full information for the use of all the
products listed below and for their safe disposal, and
especially for the health and safety of the personnel
who use them, will be found in the Manufacturer’s
data.
Subsequently, the components must be thoroughly
flushed in clean water.  If necessary, a suitable
corrosion inhibitor can be added to the last quantity of
water.
Warning!  Protection for the eyes and for the skin
Ardrox 667: Ardrox Limited, Brentford, Middlesex.
must be used always during the use of this product.
Maxan 774:Henkel Chemicals Limited, Edgeware
Crodafluid CR2: Croda Chemicals Limited, Goole,
Road, London.
Yorkshire.
These products are basically methylene chloride and
are safe to use on most metals for the removal of
carbon and to remove paint.  They can damage
rubber and most plastic materials.
This product is basically an acid solution with a
corrosion inhibitor.  It is used to remove corrosion
from components that are made of ferrous metals.
Method of use
Method of use
Crodafluid CR2 must be contained in a tank that is
made from a material which is not affected by acid.
Before the process begins, the components must be
degreased before they are lowered completely into
the Crodafluid solution.  For medium to heavy
deposits of corrosion, the solution can be heated to
70°C.  Inspect the components now and then to check
the results of the process.  Surface corrosion can be
removed in a short period of time.  The last operation
is to wash thoroughly the components in clean water.
The components to be degreased must be lowered
completely into the degreasing solution.  Allow
enough time to elapse for the components to be
thoroughly cleaned.  Subsequently, the components
must be thoroughly flushed in clean water.  In use,
maintain a layer of water at least 76 mm (3 inches)
deep above the cleaning fluid to ensure that vapour
and toxic gases are not released.
Warning!  Do NOT smoke near the container.
Protection for the eyes and for the skin must be used
always during the use of these fluids, and the
container must be in a place with good ventilation.
Warning!  Protection for the eyes and for the skin
must be used always during the use of this product.
Diverspray 30:  Diversey Limited, Northampton.
Duroclean 150 powder: Diversey Limited,
Northampton.
This product is a moderate and basically alkaline
compound with corrosion inhibitors.  It is either
sprayed over the components to clean them, or is
contained in a tank, for the immersion and agitation of
the components.
This product is basically an alkaline degreasing
solution and is safe to use on brass, copper and
ferrous metals.  It must not be used on aluminium,
lead, tin or zinc.
Diverspray 30 may be added to water to wash
components if a corrosion inhibitor is necessary.  It is
used after other processes, such as corrosion
removal, are finished.
Method of use
It is recommended that Duroclean 150 is used with a
maximum concentration of 50 grams for each litre of
water.  The components to be degreased must be
lowered completely into the degreasing solution
which is heated to 65°C.
Perkins Engines Company Limited
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10
NALCO 2568 Powder: NALCO Limited, PO Box 11,
Hose connections
Winnington Avenue, Northwich  CW8 4DX
Do not use a screwdriver to remove hoses by force
because adaptors or pipe connections can be
damaged.  Cut through the hose and then cut the
ends of the hose from the adaptor or pipe connection.
This product (which is supplied only in quantities of 25
kg) is an inhibited sulphamic acid and can be used for
the removal of hard deposits from the tube stack of
the oil cooler.
When a new hose is fitted, a suitable rubber lubricant
can be used instead of antifreeze, water or french
chalk.  Never lubricate a hose with oil or grease.
Warning!  The solution must be made and used in
accordance with the manufacturer’s instructions.
The NALCO 2568 powder should be mixed with clean
fresh water in the ratio which follows:
Gaskets, joints and ’O’ rings
Discard all used items if an engine or a component is
dismantled and fit only new and correct parts.
15 - 40 kg/Tonne of water
(15 - 40 lb/100 UK gallons of water)
If a jointing compound is needed, ’Hylomar PL 32’
jointing compound is recommended for use, but on
metal joints ONLY.  Only a thin application is needed,
an excessive quantity of compound can restrict the
flow of fluids in pipes and passages.
When the action of the solution is finished, dip the
tube stack in a solution made from: 0,5 kg (1 lb) of
sodium carbonate to 25 litres (5 UK gallons) of hot
water.  The final operation is to dry the inside of the
tubes with compressed air.
Caution:  ’Hylomar’ jointing compound must NOT be
used in contact with any fibre joints as the solvent
contained in ’Hylomar’ can damage the joint material.
Oil seals
Apply petroleum jelly to oil seals before they are fitted,
and do not damage the lip of the seal on sharp edges.
Unless other specifications apply, fit the seal with the
edge of the lip toward the bearing.
Apply a small amount of a suitable lubricant to ’O’ ring
seals to prevent damage during assembly.
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10
Locking devices
Split pins, lock plates and tab washers which have
been used must be discarded.  Various methods to
retain securely the nuts of an engine are shown (A).
Stiffnuts can be used again only if they have not lost
their grip and the original torque is needed to turn
them.
There must be a minimum protrusion of one full
thread of the bolt or stud through the stiffnut when it is
tightened fully. Discard all stiffnuts which have nylon
or fibre inserts.
Application of thread locking compounds
Remove all oil, grease and dirt from engine parts
before thread locking compounds are applied to
them.  Most thread locking compounds have a date by
which they must be used, ensure that the compounds
used are within those dates.
Fits and clearances
The dimensions given in section 11C are acceptable
limits.  The components which have measurements
within these limits are acceptable for a complete
period of service.
Certain components which are worn by more than
these limits can be corrected in accordance with a
Service Reclamation Scheme (SRS).  Information
about the Service Reclamation Schemes is available
from the Service Department at Perkins Engines
(Shrewsbury) Limited.
A
122
Applied torques
The specifications for applied torques, which are
given in section 11B, apply to some bolts and nuts
where damage or failure can occur if they are
incorrectly tightened.  Where joints are fitted, for
example, between the cylinder head and the
crankcase, it is also important that bolts and nuts are
tightened evenly and gradually as instructed in the
assembly sequence. The torque wrenches, listed
below, are suitable for the torque load requirements of
the 3012/CV12 engine, and are available from
Perkins Distributors.
8 to 54 Nm (6 to 40 lbf ft), 21825 846
30 to 150 Nm (20 to 110 lbf ft), 21825 991
70 to 310 Nm (50 to 230 lbf ft), 21825 992
Perkins Engines Company Limited
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10
Checks for cracks
When possible, it is recommended that components
which are affected by high stresses such as the
crankshaft, the connecting rods, the gears and the
cylinder liners are tested for cracks during overhaul.
They should also be checked for cracks when they
have been affected by an excessive load or impact. It
is recommended that ferrous components are tested
by the electro-magnetic method if possible. Portable
electro-magnetic test equipment is available from
Radalloyd Limited, Oadby, Leicester. Non-ferrous
components can be tested by the use of a dye
penetrant process such as ’Ardrox 996’, available
from Ardrox Limited, Brentford, Middlesex. The dye
penetrant must conform to one of the standards listed
below:
MIL-STD 271-E
MIL-L 25135
B.S. 5750
D.T.D. 929
Exchange units
It is recommended that unserviceable units are
returned, as complete as the new exchange unit, with
covers fitted to all openings and the joint faces
protected.  When necessary, protect the unit, both
inside and outside, from corrosion.
Parts
To ensure maximum reliability, fit only genuine
PERKINS parts supplied by a PERKINS distributor.
These parts are made to the latest specification and
have a guarantee for 12 months.  The use of parts,
such as filter elements, which do not conform to
PERKINS standards, may reduce the life of the
engine and can affect the warranty.
If you need parts, spares or information for your
engine, give the complete engine number to your
Perkins distributor.  This will ensure that the correct
parts can be obtained.
20
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10
Approved lubricants and fluids
Equivalent lubricants and fluids of other manufacturers are acceptable
Product or specification
Manufacturer
Alternator
Cleaning fluid for diodes
Grease for diodes
Fluid grade 8-23
Applied Chemicals Limited
Applied Chemicals Limited
Silicon MS200, MS4 and MS5
Camshafts
Anti-seize compound
Anti-scuffing paste
Rocol J166
Rocol
Rocol Limited
Cooling system
Lips of oil seal in coolant pump
Hose and ‘O’ rings
Shell Alvania R3 Grease
Liner lubricant
Shell Oils
Morris’s Shrewsbury
I.C.I Limited
Compound for cleaning the system
Lissapol ‘N’, 1%
(10 cc/ltr - 45 cc/Imp. gallon)
Lissapol ‘NDB’, 2%
(20 cc/ltr - 90 cc/Imp. gallon)
To remove hard deposits from the oil
cooler
NALCO 2568 powder
(in 25 kg drums only)
NALCO Limited
Exhaust system
Anti-seize compound for threads
Copaslip
Slip Group Rocol Limited
Rocol J166
Joints
Jointing compound
Hylomar Silicone Sealant
Marston Bentley Limited
Adhesive and Sealants
Division, Wigan
Sealant and thread locking
Loctite AVV, 241, 270, 290,
542 and 601
Douglas Kane Sealants
Morris’s Shrewsbury Shell
Oils Various
Lubrication system
‘O’ rings and relevant bores
Liner lubricant
Morris’s Shrewsbury
Starter motor
Cleaning fluid for commutators
Lubricant for splines
‘O’ ring lubricant
White spirit
Aeroshell DID5598
Glycerine
Shells Oils
Various
Lubricator wick
Mineral oil
SAE 5W/20
Perkins Engines Company Limited
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10
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11
Specifications
11
Basic engine data
Engine
Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  12
Cylinder arrangement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 degree included angle ‘V’
Cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four stroke
Induction system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharged and charge cooled
Combustion system   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Direct injection
Nominal bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135 mm (5.315 in)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152 mm (5.984 in)
Compression ratio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26,11 litres (1593.24 in3)
Cubic capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  14.5:1
Firing order  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6, B1, A3, B4, A5, B2, A1, B6, A4, B3, A2, B5
Tappet clearances (hot or cold)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engines before ‘build line number’ 8281
(6C27437/29):
Inlet valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,4 mm (0.016 in)
Exhaust valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,5 mm (0.020 in)
Engines from ‘build line number’ 8281
(6C27437/29):
Inlet valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,2 mm (0.008 in)
Exhaust valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,5 mm (0.020 in)
Direction of rotation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Anti-clockwise from the rear of the engine
Injection timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . As stamped on engine data plate
Rated power output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .400 to 740 kW
Maximum rated speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1800 rev/min
Dry weight of engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2120 kg (4674 lb)
(Approximate)
Dry weight of electropak
(Approximate)
3012 TG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2365 kg (5214 lb)
3012 TAG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2315 kg (5103 lb)
Perkins Engines Company Limited
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11
Cooling system
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Liquid cooled
Coolant pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centrifugal unit, gear-driven
Capacities for coolant
Engine and pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 litres (15 UK gallons)
Engine/radiator pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  122,7 litres (27 UK gallons)
Coolant system pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  Up to 69 kN/m2 (10 lbf/in2)
Temperature (normal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70° to 100°C
Thermostats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  Two, single element, wax capsule type
Cooling fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  1220 mm (48 in) diameter, 8 blades, belt driven
Approved coolant  . . . . . . . . . . . . . . . . . . .See section 5 - ‘Engine fluids’ in the User’s Handbook TSD 3138
Fuel system
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  Low-pressure supply to injection pump
with return of spill fuel to the tank
Fuel injection pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 element in-line unit
Governor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  Mechanical, servo assisted, integral with fuel injection
pump, constant speed for operation of generators
(for other applications, variations are fitted)
Fuel lift pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mechanical, operated by camshaft
Fuel supply pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  140 to 210 kN/m2 (20 to 30 lbf/in2)
Fuel injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Axial supply, low spring type, six spray holes
Injection pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 bar (early engines 240 bar)
Main fuel filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  Two screw-on type canisters
Approved fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Centrifugal type
Approved fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See section 5 - ‘Engine fluids’ in the User’s
Handbook TSD 3138
24
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11
Lubrication system
Type  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wet sump
Capacities
Sump maximum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 litres (12 UK gallons)
Sump minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 litres (7.3 UK gallons)
System total. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.8 litres (16.2 UK gallons)
Pressure
Normal load conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  448 kN/m2 (65 lbf/in2)
Minimum at rated speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  345 kN/m2 (50 lbf/in2)
Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Spur gear type, gear driven
Pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Spring loaded plunger, not adjustable
Opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  488 kN/m2 (71 lbf/in2)
Oil-to-coolant heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tube stack and body, with baffle plates
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Three screw-on type canisters
Maximum recommended temperature
of oil in sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  125°C
Approved lubricating oil . . . . . . . . . . . . . . See section 5 - ‘Engine fluids’ in the User’s Handbook TSD 3138
Induction and exhaust systems
Aspiration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure charged by two turbochargers
Air charge coolers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  Two, air to air type, integral with radiator
Air filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Two, paper element type
Electrical equipment
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 volt 40 ampere
Starter motor . . . . . . . . . . . . . . . . . . . . . . . . . 24 volt - flange fitted (certain engines have two starter motors)
Stop control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 volt, energised-to-run
Engine protection switches . . . . . . . . . . . . . . . . . . . . . . 24 volt instrument sender/switches for oil pressure,
coolant temperature and coolant level
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Recommended specific applied torques
Caution:  The torque loads listed below apply to threads in an oil wet condition, unless the use of thread
locking compound is recommended.
Application of a torque specification is NOT enough to ensure that the relevant components are retained
securely as an assembly.  It is important to conform also to the recommendations for assembly and, if given,
the sequence in which the bolts or nuts must be tightened.  This information is given in the relevant section of
this publication.
If a bolt or nut is retained with a locking washer, lock plate or split pin, the specification for a torque load can
be exceeded, if necessary, by the MINIMUM amount that is needed for correct assembly.
Nm
lbf ft
Alternator
Nut, pulley
95
70
Auxiliary drive shaft
Nut, flange
(18 mm  27 A/F)
(22 mm  32 A/F)
200
300
300
221
Camshafts
200 to 250
217
148 to 184
160
Bolts, camshaft gear
‘A’ bank
‘B’ bank
Screws, countersunk head, thrust plate
24
18
Connecting rods
Nuts, big end bearing
60
44
(Caution - refer to operation 13-1)
Crankcase
Bolts, main bearing cap
Front, centre and rear
Others
177
488
131
360
Side bolts, main bearing cap
Front, centre and rear
Others
114
177
315
84
131
232
Studs, cylinder head
Crankshaft
Bolts, damper and pulley
Cap screws, flywheel
80
59
315
232
Cylinder heads
Bolts, cylinder head to crankcase
Bolts in induction ports only
All other long bolts
200
240
148
148
(plus a further 90°)
(plus a further 90°)
Nuts, cylinder head to crankcase (earlier engines)
200
148
Bolts, rocker box to cylinder head
46
35
23
40
34
26
17
30
Cap screws, rocker box to cylinder head
Bolts, rocker box cover to rocker box
Lock nut, adjustment screw, bridge piece
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Nm
40
lbf ft
30
Lock nut, adjustment screw, tappet
Bolt, location, rocker shaft
15
11
Coolant Gallery
Bolts and nuts
23
17
Coolant pump
Lock nut, bearing
Nut, drive gear
100
88
74
65
Exhaust manifolds
Bolts
46
34
Fan adaptor
Nuts, bearing
280
207
Flywheel housing
Bolts, flywheel housing to timing case
Bolts, (2) flywheel housing to crankcase
(later engines with steel crankcase/timing case joints)
80
95
59
70
Fuel filter head
Bolts, bracket to crankcase
Fuel injection pump
Cap screws, adjustable coupling (earlier engines)
Special bolts, adjustable coupling (later engines)
Nut, hub, camshaft
70
46
52
34
149
122
46
110
90
Holders, delivery valve
Bolts, pump to mounting
34
Nuts, coupling, plate, spring
120
88
Fuel injectors
Cap screws, clamp
60
80
27
17
80
59
20
12
Cap nut, nozzle
Connection, spill pipe, new type (directly onto fuel injector)
Connection, spill pipe, new type (directly onto fuel injector)
Fuel lift pump (mechanical)
Nut, cam to auxiliary drive shaft
54
45
40
33
High pressure fuel pipes
Nuts, high pressure fuel pipes
Gears
Bolts, auxiliary drive gear
Bolts, compound idler gear
Bolts, axle, double idler gear
Bolts, axle, idler gear, main
Bolt, axle, idler gear, coolant pump
Bolt, axle, idler gear, oil pump
58
43
30
40
135
135
135
135
100
100
100
100
Induction manifolds
Bolts, induction manifolds
46
34
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Nm
lbf ft
Lubricating oil pump
Bolts, casing
23
17
89
Nut, drive gear
120
Lubricating oil sump
Bolts
55
325
115
47
41
240
85
Insert, drain plug
Drain plug (sump with insert - early engines only)
Drain plug (single piece sump without insert)
35
Timing case
Bolts, timing case to crankcase
Bolts and nut (early engines)
Bolts and cap screws (later engines)
Bolts, timing case to sump
Bolts (early engines)
95
70
135
100
55
75
40
55
Bolts (later engines with steel joints)
Recommended nominal applied torques
Where instructions are not given for the correct torque to be applied to nuts and bolts, the figures which follow
should be used.
Bolt size
M5
Nm
6
lbf ft
4.5
7
M6
9.5
23
M8
17
M10
M12
M14
M16
M18
M20
M22
M24
46
34
80
59
127
198
273
387
526
669
94‘
146
201
285
388
493
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Cylinder head assembly
12
General description
The four cylinder heads, which are all the same, are
made from high quality cast iron and are retained by
bolts or by studs on early engines. They are machined
on the top and bottom faces for the rocker box and the
cylinder head gaskets respectively.  Joint faces are
machined on the inner and outer sides for the
induction and the exhaust manifolds.  There are
passages for coolant in the cylinder head around the
valve guides and the pockets for the fuel injectors.
The valve guides (A6) are made from an alloy of high
quality nickel chromium and are a press fit in the
cylinder head.  The valve seat inserts (A7) are cooled
and pressed into recesses which are machined in the
cylinder heads.
A
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The inlet valves (A9) are made from steel forgings.
The exhaust valves (A8) are made from solid
’Nimonic’ material.  The valves are retained with
collets, springs and spring seat washers.  Exhaust
valves are fitted with valve rotators instead of upper
spring seat washers.  Each set of two valves is
actuated by a bridge piece (A5) which moves on a
guide.  There is an adjustment screw and a lock nut
on the outer arm of each bridge piece.  A nitrided
button is inserted in the top face of each bridge piece
and connects with its rocker lever (A4).  Each rocker
lever is operated by the camshaft through a push rod
(A2) and a tappet (A1).
Three fuel injectors in each cylinder head are retained
by clamps and cap screws.  The connections for the
fuel supply and the surplus fuel are sealed at the
rocker box covers and the walls of the rocker boxes
respectively, to prevent leakage of oil and the entry of
dirt.
Note:   For the illustration (A), inlet and exhaust valves
are shown under the same bridge piece.
The rocker levers (A4) have adjustment screws and
lock nuts for the tappet clearances.  For early
engines, they are assembled on a rocker shaft in
each rocker box and are separated by the springs.
The rocker boxes are held in the correct positions on
the cylinder heads by spring dowels and are retained
with socket head cap screws and bolts, tightened to a
specific torque.  The rocker box covers are made from
castings of aluminium and are retained by bolts.  The
new rocker box covers of these engines are retained
with an extra bolt at each end.
A
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New engines, from engine number 6A28293, do not     1  Ensure that the seal is fitted correctly into the
have rocker boxes and each rocker shaft is mounted
on three pedestals which are bolted to the relevant
cylinder head.  A rocker cover, formed in Vynalester,
encloses the rocker assembly.  Bolt holes are sealed
with rubber washers and the interface with the
cylinder head is sealed with a special rubber sealing
ring.
groove around the pedestal rocker cover, put the
pedestal rocker cover on the cylinder head and fasten
it to two of the pedestals by the two short bolts with
sealing washers.  Do not tighten the bolts.
2  Fit the five long bolts, with sealing washers, through
the pedestal rocker cover into the cylinder head.
Tighten lightly all of the bolts.
For these engines, a new type of fuel injector is used.
These fuel injectors are longer and have the
connections for the leak-off fuel above the rocker
covers.
3  Tighten evenly all the bolts in the sequence shown
(A) to a torque of 11 Nm (8 lbf ft).
4  Fit all other components which were removed, in
reverse sequence to their removal.
A single cylinder head may be removed from the
engine and given an overhaul while the engine is still
connected to its relevant driven unit.  In this situation,
ensure that the batteries are disconnected.
Pedestal rocker cover
To remove and to fit
12-1
To remove
1  Disconnect the batteries.
2  Release the banjo connection bolts from the fuel
injectors and remove the relevant high pressure pipes
for the fuel supply from the fuel injection pump to the
fuel injectors.
3  Remove the two short and five long special bolts
which retain the pedestal rocker cover and then
remove carefully the pedestal rocker cover.
To fit
New sealing washers should be fitted to the special
bolts and a new seal fitted to the pedestal rocker
cover.
A
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Pedestal rocker assembly
3  Fit a new ’O’ ring seal to each end of the lubricating
oil tube (A5) and lubricate the seals with engine
lubricating oil.
To remove and to fit
12-2
4  Turn the coils of the relevant spring (A6) to ensure
that there is clearance around the oil hole in the
rocker shaft and insert one end of the lubricating oil
tube into the hole.  Ensure that the ’O’ ring seal is fitted
correctly and is not damaged. Hold the lubricating oil
tube in its position.
To remove
1  Remove the pedestal rocker cover, operation 12-1.
2  Loosen fully the adjustable screws of the rocker
levers.  Loosen the three bolts, each of which retains
one of the three pedestals, and lift vertically away the
complete rocker assembly while holding the
5  Lower the rocker assembly onto its cylinder head
and fit carefully the lubricating oil tube into its hole in
the cylinder head.  Ensure that the ’O’ ring seal is fitted
correctly and is not damaged
lubricating oil tube which supplies the rocker shaft.
3  Remove the lubricating oil tube from the rocker
shaft and ensure that the ’O’ ring seal at each end of
the tube is removed and discarded carefully.
6  Fit and tighten lightly the three bolts (A3) which
retain the pedestals.  If not already fitted, fit a spring
washer to the screw (A4) and fit the screw to the
tapped hole at the right of the central pedestal. Do not
tighten the screw.  This screw controls the position of
the rocker shaft.
4  Remove the bridge pieces and the push rods, if
relevant.
5  If relevant to the job, remove the fuel injectors,
operation 20-7.
7  Check the end-float of each outer rocker lever (A1
and A8) with feeler gauges.  Loosen the bolt which
retains each outer pedestal as necessary and adjust
its position to obtain the correct minimum clearance
of 0,12 mm (0.005 in).  Tighten again the bolt and also
tighten the two smaller bolts (A7) which retain the
rocker shaft.  It may be necessary to adjust also the
position of the central pedestal to obtain the correct
clearance at each end of the rocker shaft.
To fit
Note:  After the pedestal rocker assembly has been
fitted, it is not possible to remove the bridge pieces
from either end of the cylinder head to tighten the
adjustment to the correct torque.  If relevant to the job,
therefore, the bridge pieces must be set as instructed
in paragraphs 3 and 5 of operation 12-8 before this
operation is started.
8  When the end-float at each end is correct, tighten
the three bolts to a torque of 80 Nm (59 lbf ft).  Check
again the end float and tighten the two smaller bolts
on each pedestal to a torque of 23 Nm (17 lbf ft).
1  If relevant, insert the extreme left hand push rod
through its opening in the cylinder head.  If relevant,
give a full application of oil to the bridge pieces and
their guides and fit the bridge pieces onto their guides.
9  Tighten fully the screw (A4) in the central pedestal
which controls the position of the rocker shaft.
The other push rods may be fitted after the rocker
assembly is installed.
2  Ensure that the adjustment screws (A2) of the
rocker levers and the bridge pieces are loosened fully.
A
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10  Turn the remainder of the bridge pieces 90°, lower
them between the valve assemblies and tilt each
rocker lever to insert the push rods through the
openings in the cylinder head.  Fit the adjustment
screw of each rocker lever into the socket of its push
rod and return the bridge piece to its original position
to retain the push rod.
To assemble
Before the setscrews are fitted to the ends of the
rocker shaft, ensure that all deposits of old locking
agent have been removed and that the internal/
external threads have been degreased.
1  Apply lightly 'Loctite 542' to the threads of one
setscrew and fit the setscrew to one end of the rocker
shaft.
11  Turn clockwise the adjustment screws until they
are nearly at their normal position.
2  Refer to the notes already made and assemble the
components onto the rocker shaft in the correct
sequence with the hole for the lubricating oil tube in
the correct position.  Apply lightly 'Loctite 542' to the
threads of the second setscrew and fit the setscrew to
the other end of the rocker shaft.
12  Adjust the tappet clearances, paragraphs 5 to 20
of operation 12-8.
13  If relevant to the job, fit the fuel injectors, operation
12-7.
14  Fit the pedestal rocker cover, operation 12-1.
3  Hold the assembly by the hexagon of one setscrew
in a vice with soft covers and tighten the other
setscrew to a torque of 24 Nm (17.7 lbf ft) to ensure
that both setscrews are tightened equally.
To dismantle and to assemble
12-3
To dismantle
Caution:  During this operation, prevent damage to
the hexagon flats of the setscrews because the end-
float of the rocker levers next to them may be
affected.  The hexagons are 36,00/35,75 mm A/F.
Before the assembly is dismantled, identify each
component with a temporary mark.  Make a note of
the sequence of the assembly of the components to
ensure that they can be assembled again in the
same sequence and with the hole for the lubricating
oil tube in the correct position.
1  Remove the screw in the central pedestal which
controls the position of the rocker shaft.
4  To move the components along the rocker shaft,
compress the springs and apply clean engine
lubricating oil to the contact faces.  Turn the rocker
shaft until the direction of the oil hole in the rocker
shaft is downward (toward the cylinder head).
2  Remove the setscrews from each end of the rocker
shaft.
5  Fit a spring washer to the screw which has a
screwdriver slot and fit the screw fully into the tapped
hole at the right of the central pedestal. This screw
controls the position of the rocker shaft.
Caution:  During this operation, prevent damage to
the hexagon flats of the setscrews because the end-
float of the rocker levers next to them may be
affected.  The hexagons are 36,00/35,75 mm A/F.
3  Loosen the two small screws which retain the
rocker shaft in each pedestal and slide off each
pedestal, each rocker lever and each spring as it
becomes free.
4  To inspect and to correct the components, refer to
operation 12-7.
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Rocker box cover
6  Check that the socket of each push rod and the
adjustment screw of its relevant rocker lever are
aligned correctly.  Tighten, gradually and evenly,
each bolt to 46 Nm (34 lbf ft) and each cap screw to
35 Nm (26 lbf ft).
To remove and to fit
12-4
7  Adjust the tappet clearances, operation 12-8.
8  Fit the rocker box covers, operation 12-4.
To remove
1  Disconnect the batteries.
2  Disconnect and remove the relevant high pressure
pipes for the fuel supply from the fuel injection pump
to the fuel injectors and then remove the rocker cover.
To fit
1  Fit all components which were removed, in reverse
sequence to their removal.
Rocker box
To remove and to fit
12-5
To remove
1  Remove the rocker box covers, operation 12-4.
2  If relevant, release the connections for the leak-off
fuel from the fuel injectors and remove them through
the wall of the rocker box.
3  Loosen fully the adjustable screws of the rocker
levers.  Loosen evenly and gradually the bolts and the
cap screws which retain the rocker boxes.
4  When the pressure of the valve springs is released,
lift away each rocker box.
5  Remove the bridge pieces and the push rods, if
relevant.
To fit
1  Make locally some suitable guide studs and fit four
guide studs for each rocker box in their relevant
cylinder heads.  Check that the two dowels which
provide the location for each rocker box are fitted into
the cylinder heads.
2  Ensure that the adjustment screws of the rocker
levers and the bridge pieces are loosened  fully.
3  Insert the 6 push rods through the apertures of
each cylinder head.  Give a full application of oil to the
push rods, the guides of the bridge pieces and the
bridge pieces, and fit the bridge pieces into their
guides.
4  Remove all the oil from the joint face of each
cylinder head and fit carefully the new joints in their
correct positions.
5  Fit each rocker box assembly onto its cylinder head
and fit the spherical foot of each rod in its tappet.  Fit
the 8 bolts, with the plain washers and the spring
washers, followed by the 8 cap screws which retain
each rocker box.
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To dismantle and to assemble
12-6
To assemble
1  If relevant, check that the bore for the cup plug in
the end of the rocker box is clean.  Apply ’Loctite 542’
to a new cup plug and press it into the bore until it is
aligned with the wall of the rocker box.
To dismantle
1  If relevant, remove the cup plug (A9) from the bore
for the shaft (A2) in the rocker box (A10).
2  Apply clean engine lubricating oil to the rocker shaft
and insert the end which has the opening into the bore
of the rocker box.  Ensure that the oil hole in the
rocker shaft is facing directly downward (toward the
cylinder head).
2  Remove the bolt (A3) which retains the rocker shaft
and push the rocker shaft to the left, as seen from the
outer edge of the rocker box, until the ’O’ ring (A1) can
be removed from around the rocker shaft.
3  Continue to withdraw the rocker shaft and remove
each rocker lever (A8) and each spring (A6) as it
becomes free.
3  Push the rocker shaft through the end, enough to fit
the first rocker lever onto the rocker shaft. Continue to
push the rocker shaft through the rocker box and fit
the spring and the second rocker lever before the
rocker shaft enters the first pedestal.  Fit the
remainder of the arms and springs in the correct
sequence.
4  If a cup plug is not fitted in the bore of the rocker
box, push the rocker shaft enough in either direction
to remove one ’O’ ring and then push the rocker shaft
in the reverse direction to remove the second ’O’ ring.
5  Continue to withdraw the shaft and remove the
rocker levers and the springs as they become free.
4  Before the rocker shaft is pushed fully into its
correct position, fit the ’O’ ring in its groove around the
rocker shaft.  Push further the rocker shaft until the
bolt hole in the rocker shaft is aligned with the
threaded hole in the pedestal.  Fit the bolt that holds
the rocker shaft, with a plain washer (A5) and a spring
washer (A4), and tighten it securely.
A
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5  If relevant, check that the bore for the cup plug in
the end of the rocker box is clean.  Apply ’Loctite 542’
to a new cup plug and press the cup plug into the
rocker box until it is aligned precisely with the wall.
6  For rocker boxes which do not have a cup plug in
the bore, insert the shaft into the bore from either end.
Ensure that the oil hole in the rocker shaft is facing
directly downward (toward the cylinder head). Fit the
rocker levers and the springs in the correct sequence
and, before the rocker shaft is fully into its correct
position, fit a new ’O’ ring in the groove around the
outer end of the rocker shaft.
7  Push carefully the rocker shaft through the bore
until the groove at the opposite end is just away from
the wall at the end of the rocker box.  Fit the second
’O’ ring and press backward the shaft until the bolt
hole in the rocker shaft is aligned with the threaded
hole in the pedestal.  Fit the bolt that holds the rocker
shaft, with a plain washer and a spring washer, and
tighten it securely.
To inspect and to correct
12-7
1  Remove all of the grease and dirt from the
components by the use of an emulsifiable fluid, such
as ’Pavan’.  Wash and dry each item before
inspection.
A
217
2  Inspect the rocker shaft for wear or damage around
the locations of the rocker levers.  If wear is seen,
renew the shaft.
3  Fit each rocker lever onto the shaft and check the
clearance in the bush (page 35/A7) of the rocker
lever.  If the clearance is excessive, make locally a
suitable tool as shown in figure (A) to press out the
bush.  Make an accurate, temporary, mark on the
rocker lever to indicate the position of the small cutout
in the end of the bush and then press out the bush.
4  Check the bore of the rocker lever for deep
scratches or other damage.
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5  If relevant, check that the bore for the cup plug in
the end of the rocker box is clean.  Apply ’Loctite 542’
to a new cup plug and press the cup plug into the
rocker box until it is aligned precisely with the wall.
6  For rocker boxes which do not have a cup plug in
the bore, insert the shaft into the bore from either end.
Ensure that the oil hole in the rocker shaft is facing
directly downward (toward the cylinder head). Fit the
rocker levers and the springs in the correct sequence
and, before the rocker shaft is fully into its correct
position, fit a new ’O’ ring in the groove around the
outer end of the rocker shaft.
B
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Tappet clearances
To check and to adjust
12-8
1  Remove the four rocker box covers, operation 12-4
or, if relevant, the four pedestal rocker covers,
operation 12-1.
Set the clearances for the bridge pieces and the
tappets as follows:
2  Turn the crankshaft in its normal direction of
rotation, anti-clockwise from the flywheel end, until
the A1 piston is at TDC on its compression stroke.
When the A1 piston is in this position, the exhaust
valves over the A6 cylinder are almost closed and the
inlet valves are just open.  The valves for the A6
cylinder are then ’set’.
A
74
5  If relevant for new engines, remove the bridge
piece from its guide.  Retain securely the bridge piece
in a vice fitted with soft covers.  Hold the adjustment
screw in its position with a screwdriver and tighten the
lock nut  to 40 Nm (30 lbf ft).  Fit the bridge piece to its
guide.  Similarly, set the bridge piece of the A1
exhaust valves.
Caution:  Ensure that no side load is put onto the
valve stems
Caution:  When tappet clearances are checked and
adjusted on new engines, which have pedestal rocker
assemblies, it is necessary to check and adjust the
bridge pieces BEFORE the rocker assembly is fitted.
Caution:  Use a torque wrench and an adaptor with a
ring spanner.  The reading on the torque wrench must
be adjusted to compensate for the extra length which
is caused by the adaptor with the ring spanner.
3  Turn anti-clockwise the adjustment screw and the
lock nut of each bridge piece to ensure that there is no
contact with the valve stem before it is adjusted.  Start
with the number A1 inlet valves; apply pressure to the
tip of the rocker lever in contact with the button on the
bridge piece, or to the button itself if relevant, and turn
clockwise the adjustment screw until it is just in
contact with the tip of the valve stem (A).  Hold the
adjustment screw in this position with a screwdriver
and tighten lightly the lock nut.
4  For early engines, disengage the rocker lever from
its push rod and slide the rocker lever along the rocker
shaft to compress its spring.  Tilt the rocker lever to
remove the bridge piece from its guide.  Retain
securely the bridge piece in a vice fitted with soft
covers.  Hold the adjustment screw in its position with
a screwdriver and tighten the lock nut to 40 Nm (30 lbf
ft).  Replace the bridge piece on its guide.  Similarly,
set the bridge piece of the A1 exhaust valves.
Caution:  Use a torque wrench and an adaptor with a
ring spanner.  The reading on the torque wrench must
be adjusted to compensate for the extra length which
is caused by the adaptor with the ring spanner.
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6  For early engines, use the relevant feeler gauge
between the button of the bridge piece and the pad of
the rocker lever (A), to set the tappet clearance for the
A1 inlet valves to 0,40 mm (0.016 in).  Tighten the lock
nut of the adjustment screw to 40 Nm (30 lbf ft).  For
new engines, from engine 8281 (6C27437/29), set
the tappet clearance for the A1 inlet valves to 0,20
mm (0.008 in).
7  For all engines, set also the tappet clearance of
the A1 exhaust valves to 0,50 mm (0.020 in) and
tighten the lock nut of the adjustment screw to 40 Nm
(30 lbf ft).  After the lock nuts have been tightened,
check again both tappet clearances and reset them, if
necessary, before the next set of tappets is adjusted.
To set the other tappet clearances in the correct
sequence, turn the crankshaft through 60° in its
normal direction of rotation for each set of valves. The
complete sequence is as follows:
8  'Set' the valves of the A6 cylinder.  Then adjust/
check the tappet clearances for the A1 cylinder.
9  'Set' the valves of the B1 cylinder as for the A6
cylinder.  Then adjust/check the tappet clearances for
the B6 cylinder.
10  'Set' the valves of the A3 cylinder.  Then adjust/
check the tappet clearances for the A4 cylinder.
11  'Set' the valves of the B4 cylinder.  Then adjust/
check the tappet clearances for the B3 cylinder.
A
73
12  'Set' the valves of the A5 cylinder.  Then adjust/
check the tappet clearances for the A2 cylinder.
19  'Set' the valves of the B5 cylinder.  Then adjust/
check the tappet clearances for the B2 cylinder.
13  'Set' the valves of the B2 cylinder.  Then adjust/
check the tappet clearances for the B5 cylinder.
20  Fit the rocker box cover, operation 12-4 or, if
relevant, fit the pedestal rocker cover, operation 12-1.
14  'Set' the valves of the A1 cylinder.  Then adjust/
check the tappet clearances for the A6 cylinder.
15  'Set' the valves of the B6 cylinder.  Then adjust/
check the tappet clearances for the B1 cylinder.
16  'Set' the valves of the A4 cylinder.  Then adjust/
check the tappet clearances for the A3 cylinder.
17  'Set' the valves of the B3 cylinder.  Then adjust/
check the tappet clearances for the B4 cylinder.
18  'Set' the valves of the A2 cylinder.  Then adjust/
check the tappet clearances for the A5 cylinder
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12
Cylinder head assembly
To remove and to fit
12-9
Special tools:
Lift adaptor, vertical - cylinder head, 21825 816
Slide hammer, 21825 849
Adaptor, blanking plugs, 21825 859
Lift adaptor - fuel injection pump, 21825 876
Guide studs - cylinder head, 21825 891
Guide studs, M15, cylinder head, 21825 921
To remove
A single cylinder head may be removed from the
engine and given an overhaul while the engine is still
connected to its relevant driven unit.  In this situation,
ensure that the batteries are disconnected.
1  Disconnect the batteries.
2  Drain the coolant from the engine.  Keep the
coolant in a clean container for subsequent use.
3  Disconnect the exhaust pipe from the elbow and
remove the elbow, and the exhaust bellows if one is
fitted.
4  Remove the air ducts between the radiator, the air
filter and the turbocharger where necessary.
Disconnect and remove the air filter.
5  Disconnect and remove the coolant pipes from the
discharge side and the by-pass of the thermostat
housings.
6  Remove the turbocharger from the engine,
operation 18-1.
7  Remove the assembly of the exhaust manifold,
operation 18-4.
8  Remove the high pressure fuel pipes of the fuel
injectors, the linkages to the governor for the engine
stop control and the engine speed control, the
assembly of the cross shaft and the engine stop
solenoid.
9  Disconnect, from the fuel injection pump and the
governor, all the pipes for the fuel supply, the spill fuel
and the lubricating oil.
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12
10  Remove the guard of the auxiliary drive coupling     18  For new engines, release two bolts, one at each
and remove the fuel injection pump, operation 20-11.
end of the three groups of four long bolts and fit two
guide studs, 21825 921.  Release the remainder of
the 22 long bolts and the three short bolts in the
induction port, and remove the lift bracket if relevant.
11  Remove the induction manifold, operation 18-5.
12  For early engines,  remove the pipes for the
surplus fuel from the relevant cylinder head and then
remove the rocker box cover, operation 12-4.
Caution:  The nuts or the bolts should be loosened
evenly and gradually from the centre to prevent local
stresses in the cylinder head.
13  Release the connections for surplus fuel from the
fuel injectors, release the clamps and remove the fuel
injectors, operation 20-7.
19  Use the lift adaptor (A3), 21825 816, to lift away
the cylinder head from the engine.  Fit the lift adaptor
with the point of attachment for the hoist
approximately above the centre of gravity of the
cylinder head.
14  For new engines, disconnect the leak-off banjo
connections from the fuel injectors and remove the
pedestal rocker cover, operation 12-1. Release the
clamps and remove the fuel injectors, operation 20-7.
Caution:  The lift adaptor, 21825 816, is designed for
use when the engine is in a build stand and the
cylinder heads are horizontal.
15  For early engines, remove the rocker box,
operation 12-5.  If relevant for new engines, remove
the pedestal rocker assembly, operation 12-2.
Remove and keep the six bridge pieces of the valves
and withdraw the six push rods.
20  For early engines, remove the bobbin from its
location; for new engines, remove the sleeve (A1)
and the sealing ring (A2).  Discard the cylinder head
gasket.
16  Use the slide hammer, 21825 849, and the
adaptor, 21825 859, to withdraw the three blanking
plugs from the induction ports of the cylinder head.
21  Put the cylinder head on a bench with a soft
17  For early engines, release the 22 nuts and the
three short bolts in the induction port, which retain the
cylinder head and remove the lift bracket if relevant.
surface, to avoid damage to the flame face.
A
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To fit
1  If relevant, remove the four retainers which hold the
cylinder liners in the bank of cylinders.  Check all the
joint faces for cleanliness and ensure that the location
dowels in the top face of the crankcase are
serviceable.
Caution:  Use a brush and some clean engine
lubricating oil to lightly lubricate the threads and the
contact faces of the nuts, the bolts and, where
relevant, the studs which retain the cylinder heads.
Do not dip the fasteners in the lubricating oil.
2  For a cylinder head which is retained by studs
on an early engine, fit the bobbin, with a new ’O’ ring,
into its recess in the top face of the crankcase.  Fit
carefully the new cylinder head gasket.  Fit the
relevant lift adaptor to the cylinder head with the point
of attachment for the hoist approximately above the
centre of gravity of the cylinder head and lower the
cylinder head past the studs.  Fit the lift bracket if
relevant, the plain washers and the nuts.  Insert the
three short bolts which have shoulders through the
openings in the induction ports of the cylinder head
and into the threaded holes in the top face of the
cylinder bank.
A
3  Tighten evenly all the bolts and nuts in the
sequence shown (A) to a torque of 80 Nm (59 lbf ft).
Tighten all the bolts and nuts again, in the same
sequence, to a torque of 160 Nm (118 lbf ft), and then
to a final torque of 200 Nm (148 lbf ft). Do NOT tighten
the bolts in the induction ports (A21, A22 and A23)
beyond 200 Nm (148 lbf ft). Make a temporary mark
to mark the relationship of each nut to the cylinder
head.  Tighten each nut, in the same sequence,
another quarter of a turn (90°). Do NOT turn the bolts
in the induction ports but check again that they are
tightened to a final torque of 200 Nm (148 lbf ft).
4  For a cylinder head which is retained by bolts
on a new engine, apply a small amount of locking
agent 'Loctite 601' to the outer surface of the sleeve
for the lubricating oil, where it will be in contact with
the crankcase, and fit it in its hole in the top face of the
bank of cylinders.  Do not allow the locking agent to
enter the passage for the oil and remove all the
surplus.
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5  Put the sealing ring around the sleeve and push the
sealing ring down to the flame face.  Fit carefully the
new cylinder head gasket.
Caution:  When there are exhaust bellows fitted to a
new engine, the support brackets of the exhaust
bellows must be fitted with the 156 mm long bolts.
6  Fit two guide studs, 21825 921, in the top face of
the crankcase.  Use the relevant lift adaptor to lower
the cylinder head past the guide studs on to the flame
face.  Fit the lift bracket if relevant, and the bolts in
their correct positions according to their lengths.
Remove the guide studs during this operation.  Insert
the three bolts which have shoulders through the
openings in the induction ports of the cylinder head
and into the threaded holes in the top face of the
cylinder bank.
7  Tighten evenly all the bolts in the sequence shown
(page 42/A) to a torque of 80 Nm (59 lbf ft). Tighten all
the bolts again, in the same sequence, to a torque of
160 Nm (118 lbf ft), then again to 200 Nm (148 lbf ft).
Tighten only the long bolts to a final torque of 240 Nm
(177 lbf ft).  Use a marker pen to mark the relationship
of each long bolt to the cylinder head.  Tighten each
bolt, in the same sequence, another quarter of a turn
(90°).  Do NOT turn the bolts in the induction ports but
check again that they are tightened to a final torque of
200 Nm (148 lbf ft).
8  Fit new 'O' rings to the three blanking plugs of the
cylinder head and press each blanking plug into its
location in the induction ports.
9  In sequence, loosen the adjustment screw and the
lock nut of each bridge piece before it is fitted. Apply
engine lubricating oil to the guides of the bridge
pieces and fit the bridge pieces onto their guides with
the adjustment screws toward the outer edge of the
cylinder head.
10  Fit the rocker box, with a new joint, to the cylinder
head, operation 12-5.
11  Set the adjustments for the bridge pieces and the
tappet clearances, operation 12-8.
Caution:  Ensure that no side load is put onto the
valve stems.
12  Fit the rocker box cover, operation 12-4.
13  Fit all components which were removed, in
reverse sequence to their removal.  Check fits and
clearances where relevant.
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12
To dismantle and to assemble
12-10
Special tools:
Drive handle, 21825 861
Replacer kit for cup plugs, 21825 866
Valve spring compressor, 21825 739
Adaptor, 21825 740
Stirrup, 21825 741
To dismantle
Check all cup plugs for signs of coolant leakage.
Plugs that are in doubt can be renewed by use of the
replacer kit, 21825 866, and the drive handle, 21825
861.  Apply ’Loctite 575’ to new cup plugs before they
A
215
To assemble
Apply engine oil to the valve stems, fit each valve into
its correct guide, according to the marking which is
etched on the stem.  Lower carefully the assembly of
the cylinder head on to the bench with the flame face
downward, then fit the lower spring seat, spring and
spring retainer or valve rotator, as relevant, over the
valve stem.
1
are fitted to the cylinder head. If the  /   BSP plug has
8
been removed because of leakage, clean the plug,
apply ’Loctite 270’ to its threads, fit the plug and
tighten it to a torque of 28 Nm (21 lbf ft).
Put the cylinder head, flame face downward, on a
bench with a soft surface and remove the valves by
use of the valve spring compressor, 21825 739, with
adaptors 21825 740 and 21825 741.  Use the
procedure which follows:
Compress each spring assembly and fit the collets
into the collet grooves in the valve stems. Release,
carefully, the valve spring compressor, check that the
collets remain in their correct location, and then
proceed to the next unit.
1  Fit the adaptor, 21825 740, into a suitable bolt hole
for the rocker box.
2  Fit the compressor tool stud into the adaptor, finger-
tight, and tighten the lock nut.
3  Set the arm of the valve spring compressor at a
suitable height on the stud by use of the two lock nuts.
4  Set the stirrup, 21825 741, on the arm, directly over
one of the valve assemblies (A).
5  Compress the valve spring and lift out the collets
followed by the upper spring seat or rotator, then the
spring and the lower spring seat.
6  Move the compressor tool, as necessary, and
repeat the operation until all the valve assemblies
have been removed.  To ensure that the valves are
fitted to the correct positions during the assembly of
the cylinder head, the number of the cylinder and the
position of each valve should be etched above the
collet groove on the valve stem.  Valves must not be
stamped or marked with a centre punch because
cracks may occur.
7  Turn the cylinder head onto its side and withdraw
all of the valves
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To clean and to inspect the
cylinder head
12-11
Clean all of the components; use a cleaning fluid
which can be diluted with water and refer to section 10
for relevant information.  To remove heavy carbon
deposits from most components: soak them in
solutions of ’Maxan’ or ’Ardrox 667’.
Caution:  Do not use the ’Maxan’ or ’Ardrox’
processes on the valve springs or the surface finish
will be damaged.
If cup plugs were removed, before the cylinder head
was cleaned, they must be renewed before the
cylinder head is given a test under pressure. Apply
’Loctite 575’ to the new cup plugs and insert them into
their correct locations in the cylinder head.  Use the
relevant kit of removal/replacer tools for the cup
plugs.
Make, locally, enough seals to close all of the
openings for coolant and fit them to the cylinder head.
Connect a pipe from a supply of air to the coolant
galleries.  Apply air at a pressure of 207 kN/m2 (30 lbf/
in2).
Caution:  Do NOT exceed 207 kN/m2 (30 lbf/in2) as
damage may be caused.
Put the cylinder head in a tank of water which is at a
temperature of 60°C (140°F) and inspect for bubbles
from around all the cup plugs and injector sleeves.
Renew plugs or sleeves which are not fully sealed.
Remove the seals from the openings for coolant.
Inspect the flame face for signs of damage.  If
necessary, the face may be reconditioned by surface
grinding, in four stages, to a maximum of 0,51 mm
(0.020 in).  Information about work done must be
etched on an area of the flame face which is not under
the gasket of the cylinder head.
Caution:  When a cylinder head flame face has been
machined, the valve seats must be re-cut to maintain
the correct distance between the valve faces and the
flame face of the cylinder head.  See fits and
clearances on page 60.
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12
To correct a valve seat
12-12
Special tools:
Valve seat tool, 21825 841
Valve seat cutter, 21825 842
It is recommended that all the valve guides are
inspected, and renewed as necessary, before the
work is begun on the valve seat inserts.  Ensure that
the bores of the guides are within the limits given at
the end of this section.
A
1  Inspect the inserts for erosion and cracks. If it is
necessary to correct the inserts, lightly lap the faces
of the valve seats and their relevant valves. To correct
the faces of more badly damaged valve seats, use the
valve seat tool, 21825 841, and the cutter, 21825 842,
together with the relevant pilot. To use the tool, fit the
guide (A) and proceed as shown (B).  Ensure that the
cutter is correct for the angle of the valve seat, which
is given on page 60.  The surface finish of the valve
seat will be improved if a compressed air supply is
used to remove debris during this operation.
222
Warning!  Ensure that eye protection is used during
the above operation.
Caution:  During the correction of a valve seat it is
important to remove only the minimum amount of
material.
2  After the inspection and correction of a valve seat
and the relevant valve, fit the valve into the guide and
check the depth of the head of the valve below the
flame face.  If the depth is more than the limits given
on page 60 use a new valve to check again.  If the
depth is then within acceptable limits, the new valve
must be fitted to the valve seat when the cylinder
head is assembled.
3  To ensure that the valve is fitted in its correct
position, the number of the cylinder and the position
of the valve must be etched above the collet groove
on the valve stem.  Valves must not be stamped or
marked with a centre punch, because cracks may
occur.
B
223
If the depth still exceeds the acceptable limits, a new
valve seat insert must be fitted.
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To remove a valve seat insert
12-13
Special tools:
Holder, 21825 892
Cutter for the removal of valve seats, 21825 893
Expendable extractor, 21825 896
Caution:  Before a valve seat insert for an exhaust
valve can be removed, the edge of the casting of the
cylinder head, which is rolled over the insert, must be
cut away (A).  A special cutter, 21825 893, and holder,
21825 892, are available for this purpose.
1  If the relevant valve guide has not been removed,
and its bore is within the acceptable limits, turn the
cylinder head onto its side and slide the expendable
extractor, 21825 896, into the valve guide, until the
head is in contact with the valve seat insert.
2  Weld electrically, at two or three equally spaced
positions around the circumference, the expendable
extractor to the valve seat insert.  Make the welds no
larger than is necessary in order to prevent damage
to the cylinder head.
3  Use a soft faced hammer on the end of the stem of
the expendable extractor to remove the old valve seat
insert from its recess (B).
A
224
The expendable extractor may be used again if the
welds and the old valve seat insert are removed and
the head is ground lightly to eliminate the protrusions.
B
225
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Another method for removal of a valve seat insert (A1)
is given below:
1  Fasten securely the cylinder head on a milling
machine, and use a slot drill of approximately 10 mm
3
(  /  in) diameter to machine two slots into the valve
8
seat insert (A3).  The depth of the slots should be 0,50
mm (0.020 in) less than the depth of the valve seat
insert.  The minimum depth of the insert is 7,95 mm
(0.313 in).  The slots should be apart by
1
approximately 13 mm (  /  in) between their centres.
2
Machine the slot to within 0,5 mm (0.020 in) of the
outside diameter of the insert.
2  Use a flat chisel, at the point which is indicated by
the arrow (A2) and in the direction of the opening in
the insert, to break the insert.  Do not damage the
recess during this operation.
A
34
3  Remove the insert and check that the recess is
clean and that there is no damage.
To fit a valve seat insert
12-14
Special tools:
Valve seat tool, 21825 841
Valve seat cutter, 21825 842
Drive handle, 21825 861
Tool to insert valve seat, 21825 867
Holder for rolling tool, 21825 892
Rolling tool, 21825 894
1  Valve seat inserts are available in two sizes,
oversize and standard.  The oversize inserts are 0,05
mm (0.002 in) larger on the outer diameter.  If an
oversize insert is to be fitted, ensure that it has the
correct part number: CV 14128 for an inlet seat or OE
47574 for an exhaust seat.  Check also that the wall
of the recess in the cylinder head will maintain the
correct interference fit, as given on page 60.
2  Cool the valve seat insert in liquid nitrogen to -35°C
(-31°F).  Use the special tool, 21825 867, (B1) and the
handle, 21825 861 (B2), to fit the relevant insert into
its recess as rapidly as possible.
B
226
3  Use a 0,04 mm (0.0015 in) feeler gauge to check
that the bottom of the new insert is in full contact with
the bottom of the recess.
If a new valve seat insert has been fitted for an
exhaust valve, the edge of the casting of the cylinder
head must be rolled over the chamfer which is around
the circumference of the insert. Proceed as follows:
4  Fasten securely the cylinder head on a suitable drill
machine with the flame face in the upper position and
fit the rolling tool, 21825 894, and holder, 21825 892,
to the machine.
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5  Apply clean engine lubricating oil to the rollers, to
the face at the end of the tool and to the counterbore
in the cylinder head.
6  Insert the rolling tool in the valve guide and turn
slowly the rolling tool.  Apply enough pressure to
spread the material of the cylinder head over the
chamfer of the valve seat insert.  Ensure that the face
at the end of the tool is suitably lubricated before the
face at the end of the tool is in contact with the top
face of the insert (A).  When this occurs, the cylinder
head is fully rolled over the insert, and the tool can be
removed.
7  Use the valve seat cutter, 21825 842, and the
relevant pilot, to machine to the correct angle, the
seats which have been renewed.  Ensure that the
cutter is correct for the angle of the valve seat, which
is given on page 60.  Lap the valves to the seats.
Clean thoroughly the area around the valves and the
seats and use engineer’s blue to check that the faces
of the valves are in full contact across and around the
faces of the valve seats.
8  Fit the valves in their relevant seats and use a
straight edge and a feeler gauge to check that the
clearances between the heads of the valves and the
flame face are within the limits given on page 60.  If a
clearance is excessive, a new valve must be fitted.
The number of the cylinder and the position of the
valve should be etched above the collet groove on the
valve stem.  Valves must not be stamped or marked
with a centre punch, because cracks may occur.
A
227
To inspect the valve guides
12-15
Check the clearance of each valve stem in its guide.
This must be within the limits given on page 59.  If the
clearance is excessive, use a new valve to check
again.  If the clearance is still excessive, a new valve
guide must be fitted.
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To renew a valve guide
12-16
Special tools:
Reamer for exhaust valve guides, 21825 755
Reamer for inlet valve guides, 21825 756
Valve seat tool, 21825 841
Valve seat cutter, 21825 842
Remover for inlet valve guides, 21825 885
Remover for exhaust valve guides, 21825 886
Replacer for inlet valve guides, 21825 887
Replacer for exhaust valve guides, 21825 888
Use the extractors: 21825 885 (inlet valves) or 21825
886 (exhaust valves), and the replacer tools 21825
887 (inlet valves) or 21825 888 (exhaust valves),
together with a suitable press.
1  Use the relevant extractors to press out the valve
guides that need to be renewed.  Check the bores in
the cylinder head for wear or damage. See SRS 135
for instructions to correct worn bores.
2  Apply clean lubricating oil to the new guide before
it is inserted in the top end of the bore.
Caution:  The guides for the inlet valves must be
inserted with the tapered end downward.  The guides
for the exhaust valves must be inserted with the
internal chamfer, which is at one end of the bore, at
the top.
A
230
3  Fit the relevant replacer tool onto the guide and
press the guide in until the replacer tool is in contact
with the cylinder head (A).  This will give the correct
protrusions of 12,8 mm (0.50 in) for the guides of the
inlet valves and 17,85 mm (0.70 in) for the guides of
the exhaust valves.
Caution:  If liquid air is available, it may be help if the
new valve guide is cooled immediately before it is
fitted.
4  Use the correct reamer to ream the new valve guide
(B) and check the bore with the relevant plug gauge.
Use the reamer 21825 756 for inlet valve guides and
21825 755 for exhaust valve guides.
If new valve guides have been fitted, the relevant
valve seat insert must be corrected.  Use the special
tool, 21825 842, to ensure concentricity.
B
231
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To inspect the bridge pieces
and guides
12-17
Inspect the bridge pieces and the adjustment screws
for wear.  Use a new guide as a gauge to check the
bores in the bridge pieces.  Similarly, use a new
bridge piece to check the guides.  Renew
components which have excessive wear.
To renew a bridge
piece guide
12-18
Special tools:
Extractor for valve bridge guides, 21825 889
Depth plate for valve bridge guides, 21825 890
Use the extractor, 21825 889, to withdraw a worn
guide from its bore in the cylinder head (A).  Clean
thoroughly the bore.
Apply ’Loctite 648’ to the area of the new guide which
is an interference fit in the cylinder head and use a
press to insert the guide into the cylinder head.  To
obtain the correct protrusion, fit the depth plate,
21825 890, over the guide and press the guide into its
bore until the top face is aligned precisely with the top
face of the depth plate (B).
A
232
B
233
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12
To recondition a fuel injector sleeve
12-19
Special tools:
Tool holder for face cutter and reamer, 21825 765
Face cutter, 21825 767
Reamer, 21825 768
Service kit for fuel injector sleeves, 21825 915
Caution:  The fuel injector sleeves may be renewed
without the removal of the cylinder head from the
engine.  In this situation, the coolant must be drained
until the level is below the cylinder head and the
piston, which is below the faulty fuel injector sleeve,
must be moved to BDC.
1  Use the integral face cutter and reamer to remove
deposits of carbon and to correct the face of the seat,
or the bore at the smaller internal diameter of the
injector sleeve (A).  If the work is done without the
removal of the cylinder head from the engine, the
cutter and the reamer must be given a full application
of grease to retain the particles of the carbon and the
debris.
Caution:  When the face cutter is used, remove only
the minimum material that is necessary to correct the
seat.  The maximum permissible depth of the seat
from the top face of the cylinder head is 104,25 mm
(4.104 in).
A
237
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To renew a fuel injector sleeve
12-20
Special tools:
Remover tool for fuel injector sleeves, 21825 771
Tap, 21825 773
Expander tool for fuel injector sleeves, 21825 776
Ball type expander tool, 21825 883
A fuel injector sleeve which is outside the limit, or has
been damaged, or which leaks from the expanded
joints and cannot be corrected by further expansion of
the ends of the fuel injector sleeves, must be renewed
in accordance with the instructions given below.
A
238
Caution:  The fuel injector sleeves may be renewed
without the removal of the cylinder head from the
engine.  In this situation, the coolant must be drained
until the level is below the cylinder head, and the
piston which is below the faulty fuel injector sleeve
must be moved to BDC.
1  Use the tap, 21825 773, to make a thread in the fuel
injector sleeve to a minimum depth of 25 mm (one
inch)(A).  If the work is done without the removal of the
cylinder head from the engine, push some clean rag
down the larger bore to prevent the possible entry of
debris into the cylinder of the engine.  The tap should
be given a full application of grease to retain the
particles of copper debris.
2  Move up the nut of the remover tool, 21825 771, to
the top of its thread and fit fully the stud into the thread
in the fuel injector sleeve (B).
B
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12
3  Tighten down the nut against the thrust face of the
tool and withdraw the fuel injector sleeve (A). Extra
force is necessary to break the top seal where the
sleeve has been rolled into the groove in the cylinder
head.
4  Clean thoroughly the bores in the cylinder head and
also the groove for the expansion of the fuel injector
sleeve.
A
240
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If the cylinder head has been removed from the
engine, put it on parallel supports under a press, with
the flame face downward.  The supports must be
deep enough to ensure that there is a clearance of
approximately 150 mm (6 in).
5  Dismantle the tool, 21825 883, and insert the
section with the ball type expander through the fuel
injector sleeve as shown (A).  Assemble the tool and
lubricate with grease the end with the ball type
expander.  Install the fuel injector sleeve in the bores
of the cylinder, use the clamp of a fuel injector (B1) to
fasten the assembly to the cylinder head and tighten
the cap screw to 60 Nm (44 lbf ft) to ensure that the
fuel injector sleeve is pressed fully into its correct
location.
A
241
6  Turn the nut (B2) at the top of the tool and pull up
the ball type expander through the fuel injector
sleeve.  This action causes the expansion of the bore
at the smaller internal diameter.
B
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When the expansion of the smaller bore is complete,
the expansion at the top of the fuel injector sleeve
should be done by use of the expander tool, 21825
776, which rolls the copper of the fuel injector sleeve
into the groove in the cylinder head.
7  Insert the housing for the expander rollers into the
injector sleeve until the shoulder of the housing is in
contact with the top face of the cylinder head.
8  Slide the tapered shaft through the housing of the
rollers and use a suitable socket type spanner and a
tee handle to turn the shaft while a constant pressure
is applied downward to the end of the shaft.
9  Continue the operation until the shaft is difficult to
turn when it is approximately at the position shown
(A).  The tool can then be removed; there is not
usually a requirement for the shaft to go deeper.
A
243
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Use engineer’s blue to check that the face of the valve
is in full contact across and around the face of the
valve seat.  Lap the valve to the valve seat if
Valves, valve springs and valve rotators
necessary.  Clean thoroughly the area around the
valves and the seats and again use engineer’s blue to
check that the faces of the valves are in full contact
across and around the faces of the valve seats.
To remove and to fit
12-21
Special tools:
Valve spring compressor, 21825 739
Adaptor, 21825 740
4  Use a straight edge and a feeler gauge to check
that the clearance between the head of the valve and
the flame face is within the limits given on page 60.  If
the clearance is excessive, a new valve must be
fitted.  If, after a new valve has been fitted, the
clearance is still excessive, a new valve seat insert
must be fitted.
Stirrup, 21825 741
To remove
1  Remove the cylinder head, operation 12-9.
5  Insufficient clearance can be corrected by the use of
the valve seat cutter, 21825 841, and its relevant pilot,
to machine the seat of the insert, operation 12-12.
Ensure that the cutter is correct for the angle of the
valve seat, which is given on page 60.  Lap the valves
to the seats.  Clean thoroughly the area around the
valves and the seats and use engineer’s blue to check
that the faces of the valves are in full contact across
and around the faces of the valve seats.
2  Dismantle the cylinder head, operation 12-10 and
keep together the components of each assembly of
the valves.
3  Ensure that the identification of the position of each
valve is maintained, paragraph 5 of operation 12-10.
To fit
1  Ensure that each valve is fitted into its correct guide
according to its identification.
6  If new valves are fitted, the number of the cylinder
and the position of the valve should be etched above
the collet groove on the valve stem.
2  Assemble the valves, valve springs, seats for the
springs and the valve rotators in the cylinder head,
operation 12-10.
7  Fit the new valve in the valve seat and check that
the face of the valve is in full contact across and
around the face of the valve seat.  Check also the
clearance between the head of the valve and the
flame face as given above.
The valve rotators are fitted only on the exhaust
valves.  The valve spring caps are fitted only on the
inlet valves.
3  Fit the cylinder head, operation 12-9.
8  Check each valve spring for wear, damage and
corrosion.  Measure the free length and the length
under a load, as given on page 60.  Discard all springs
which are unserviceable.
To inspect and to correct
12-22
1  Clean thoroughly each valve and inspect visually
for cracks, for pitting or for other damage on the head
of the valve.  Check for wear on the valve stems, the
collet grooves and the valve tips. The heads of the
valves should also be checked for cracks by the use
of the dye penetrant process.
9  Renew the springs as a set of two below their
relevant bridge piece. Old and new springs must not
be mixed on a set of two valves as this can cause
wear to the valve bridge and the valve guide.
Caution:  Fit new valve springs at every complete
engine overhaul.  Ensure that the new valve springs
are correct for the engine before they are fitted.
2  Use a straight edge and a feeler gauge to check
that the top face of the head of the valve is not dished.
Discard the valve if the clearance exceeds 0,13 mm
(0.005 in) at the centre of the valve.
10  Check the valve rotators for cracks and other
damage, and ensure that each component can rotate
freely within the assembly.
3  Clean thoroughly the area around the valve seat
and fit, one at a time, each valve to its correct position
in the cylinder head according to the number of the
cylinder and the position of the valve, which is etched
above the collet groove on the valve stem.
11  Inspect the tips of the exhaust valve stems.  If the
type of wear indicates that a valve has not rotated
correctly, the valve rotator of the relevant valve must
be renewed.
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Push rods
To remove and to fit
12-23
To remove
1  Remove the relevant rocker box cover, operation
12-1 or operation 12-4.
2  Rotate the engine until the tappet of the relevant
push rod is on the heel of its cam, loosen fully the
adjustment screw of the rocker lever. Disengage the
rocker lever from the push rod and slide the rocker
lever along the rocker shaft to compress its spring.
Hold the rocker lever in its new position and lift out the
push rod.
3  If some, or all, of the push rods are to be removed
when the engine is overhauled, remove the rocker
boxes, operation 12-5, or pedestal rocker assemblies,
operation 12-2.
To fit
1  Fit each push rod in the reverse sequence to the
removal.
2  Set the tappets, operation 12-8.
3  Fit the relevant rocker box cover, operation 12-1 or
operation 12-4.
To inspect
12-24
1  Inspect the ends of each push rod for wear and
damage, and check each rod for deflection.  A push
rod which has a run-out of more than 0,2 mm (0.008
in) along its overall length must be renewed.
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Fits and clearances - Cylinder heads, rocker assemblies and valves
Bridge pieces on guides (A3)
Bore of bridge piece  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12,755 to 12,780 mm (0.5021 to 0.5031 in)
Diameter of guide  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12,728 to 12,739 mm (0.5011 to 0.5015 in)
Clearance (new)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,016 to 0,052 mm (0.0006 to 0.0020 in)
Permissible worn clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,10 mm (0.004 in)
Valve springs (A4)
Free length (nominal)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47,066 mm (1.853 in)
Permissible worn length  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44,713 mm (1.76 in)
Load when compressed to 26,87 mm (1.058 in) . . . . . . . . . . . . . . . . . . . .0,5071 to 0,5605 kN (114 to 126 lbf)
Valve guides (A5)
Bore in cylinder head for valve guide  . . . . . . . . . . . . . . . . . . . . . . . .18,00 to 18,02 mm (0.7087  to 0.7094 in)
Outside diameter of valve guide (inlet and exhaust) . . . . . . . . . . . 18,028 to 18,041 mm (0.7097 to 0.7103 in)
Interference fit (new) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,008 to 0,041 mm (0.0003 to 0.0016 in)
Permissible interference fit (worn). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,008 mm (0.0003 in)
Inlet valves in guides (A11)
Diameter of valve stem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  9,464 to 9,482 mm (0.3726 to 0.3733 in)
Bore of valve guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  9,525 to 9,550 mm (0.3750 to 0.3760 in)
Clearance (new)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,043 to 0,086 mm (0.0017 to 0.0034 in)
Permissible worn clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,137 mm (0.0054)
A
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Cylinder heads, rocker assemblies and valves (continued)
Refer to the illustration (A) on page 59.
Exhaust valves in guides (A6)
Diameter of valve stem  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10,930 to 10,947 mm (0.4303 to 0.4310 in)
Bore of valve guide  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10,998 to 11.023 mm (0.4330 to 0.4340 in)
Clearance (new). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,051 to 0,093 mm (0.002 to 0.0037 in)
Permissible worn clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,145 mm (0.0057 in)
Inlet valves in valve seats (A9)
Engines before ’build line number’ 8281 (6C27437/29):
Clearance below flame face (new). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,00 to 1,32 mm (0.039 to 0.052 in)
Permissible worn clearance below flame face. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,03 mm (0.080 in)
Engines from ’build line number’ 8281 (6C27437/29):
Clearance below flame face (new). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,25 to 1,57 mm (0.049 to 0.062 in)
Permissible worn clearance below flame face. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,03 mm (0.080 in)
Exhaust valves in valve seats (A8)
Clearance below flame face. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,00 to 1,38 mm (0.039 to 0.054 in)
Valve seat inserts (A10)
Angle (inlet valve)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  30°
Angle (exhaust valve)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  45°
Bore in cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48,000 to 48,016 mm (1.8898 to 1.8904 in)
Outside diameter of valve seat insert. . . . . . . . . . . . . . . . . . . . . . . 48,054 to 48,065 mm (1.8919 to 1.8923 in)
Interference fit (new) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,038 to 0,065 mm (0.0015 to 0.0026 in)
Rocker levers
Bore in rocker lever for bush (A1) . . . . . . . . . . . . . . . . . . . . . . . . . 26,193 to 26,224 mm (1.0312 to 1.0324 in)
Diameter of bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26,264 to 26,289 mm (1.0340 to 1.0350 in)
Interference fit (new) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,040 to 0,096 mm (0.0016 to 0.0038 in)
Bore of bush (A2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22,212 to 22,238 mm (0.8745 to 0.8755 in)
Diameter of shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22,174 to 22,187 mm (0.8730 to 0.8735 in)
Clearance (new). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,025 to 0,064 mm (0.0010 to 0.0025 in)
Permissible worn clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,08 mm (0.003 in)
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13
Pistons and connecting rods
13
General description
The connecting rods (A) are made from chromium
molybdenum steel forgings and are machined to
receive bearings at the small end, which are bushes
of the split type.  The bushes are rolled and have steel
backs with bearing surfaces of lead bronze.  They are
pressed into the eye of the small end with the split in
the upper half at 45 degrees to align the oil hole of the
bush with the oil hole of the connecting rod.  The
position of the oil hole is 135 degrees from the split.
The small end of each connecting rod is wedge
shaped to conform with the pressure on the small end
and the piston.  An oil hole is drilled axially through the
centre of the connecting rod to provide an intermittent
supply of oil under pressure from the crank pin to
lubricate the small end and the gudgeon pin.
A
200
Four special bolts and nuts, are used to retain each
bearing cap to its relevant connecting rod.  There are
marks on the assembly of each connecting rod which
give the weight, the relationship of the cap to the rod,
and, if relevant, the number of the cylinder bore.
The big end bearings are similar to the main bearings,
but they do not have grooves in the bearing surfaces.
It is important that the larger chamfer in the bore of
each big end is to the outside of the two connecting
rods which are fitted on each crank pin.
The half bearings are held in their positions by the big
end bolts.  The shoulders around the centres of the
bolts fit in the grooves which are machined in the
outer face at each end of a half bearing.  The grooves
are off-centre to the bearing and, therefore, the half
bearing must be fitted correctly.
The weight of each connecting rod, together with the
small end bush, the bearing cap, the big end bolts and
the nuts, is measured during its manufacture, and it is
stamped with a letter (or for new engines, a letter and
a number) which indicates its group according to its
weight.
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All rods which have the same letter have weights
which vary by less than 0,10 kg (0.22 lb) and rods
which have the same letter and number have weights
which vary by less than 0,025 kg (0.055 lb).  If a
connecting rod is to be renewed, it important that the
new connecting rod is of the same group as the
original connecting rod.
The groups for the weights are as follows:
Y1 4,150 kg  to  4,175 kg (9.149  to  9.204 lb)
Y2 4,175 kg  to  4,200 kg (9.204  to  9.259 lb)
Y3 4,200 kg  to  4,225 kg (9.259  to  9.315 lb)
Y4 4,225 kg  to  4,250 kg (9.315  to  9.370 lb)
Z1 4.250 kg  to  4,275 kg (9.370  to  9.425 lb)
Z2 4.275 kg  to  4,300 kg (9.425  to  9.480 lb)
Z3 4.300 kg  to  4,325 kg (9.480  to  9.535 lb)
Z4 4.325 kg  to  4,350 kg (9.535  to  9.590 lb)
A1 4,350 kg  to  4.375 kg (9.590  to  9.645 lb)
A2 4,375 kg  to  4.400 kg (9.645  to  9.700 lb)
A3 4,400 kg  to  4.425 kg (9.700  to  9.755 lb)
A4 4,425 kg  to  4.450 kg (9.755  to  9.811 lb)
B1 4,450 kg  to  4,475 kg (9.811  to  9.866 lb)
B2 4,475 kg  to  4,500 kg (9.866  to  9.921 lb)
B3 4,500 kg  to  4,525 kg (9.921  to  9.976 lb)
B4 4,525 kg  to  4,550 kg (9.976  to 10.031 lb)
A
139
The grades of the connecting rods fitted within a bank
of cylinders must all be the same; for example, ’A’
bank - all grade B1.  A different grade of connecting
rod may be fitted in the other bank of cylinders, but
they must also be all the same within the bank; for
example, ’B’ bank - all C3.
C1 4,550 kg  to  4,575 kg (10.031  to 10.086 lb)
C2 4,575 kg  to  4,600 kg (10.086  to 10.141 lb)
C3 4,600 kg  to  4,625 kg (10.141  to 10.196 lb)
C4 4,625 kg  to  4,650 kg (10.196  to 10.252 lb)
The pistons are made of an aluminium alloy which
contains a high percentage of silicon.  The tops of the
pistons have special toroidal combustion chambers to
give an efficient mix of fuel and air. Each of the early
pistons (A) has three compression rings and one oil
control ring.  The new pistons have two compression
rings and one oil control ring.  The top compression
rings of both types of pistons are wedge shaped and
their grooves are machined in hard metal inserts to
reduce the wear of the grooves.
D1 4,650 kg  to  4,675 kg (10.252  to 10.307 lb)
D2 4,675 kg  to  4,700 kg (10.307  to 10.362 lb)
D3 4,700 kg  to  4,725 kg (10.362  to 10.417 lb)
D4 4,725 kg  to  4,750 kg (10.417  to 10.472 lb)
E1 4,750 kg  to  4,775 kg (10.472  to 10.527 lb)
E2 4,775 kg  to  4,800 kg (10.527  to 10.582 lb)
E3 4,800 kg  to  4,825 kg (10.582  to 10.637 lb)
E4 4,825 kg  to  4,850 kg (10.637  to 10.692)
Each 4-ring piston is tin plated on all the surfaces after
it has been manufactured, except the bore for the
gudgeon pin.
A 3-ring piston is tin plated below the top ring, except
the bore for the gudgeon pin, and the toroidal
combustion chamber is hard anodised. The axial
location of the fully floating gudgeon pin is controlled
by the circlips in the bore.
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Big end bearings
To remove and to fit
13-1
Special tools:
Guide pin, 21825 843
To remove
1  Disconnect the batteries, stop the supply of the fuel
and drain the engine lubricating oil from the sump.
2  Remove the lubricating oil sump, operation 19-1 or,
for new engines, operation 19-5.
3  For early engines, remove the sump adaptor,
operation 19-3.
4  If necessary, release the bolts which retain the
lubricating oil pump and remove the lubricating oil
pump, operation 19-7.
5  Turn the crankshaft until the selected assembly of
the piston and connecting rod is at the bottom of its
stroke and remove the nuts of the big end bolts.
Remove the bearing cap and fit the guide pin, 21825
843, on to one of the big end bolts.  Push carefully the
assembly up the cylinder bore just enough to allow
access to the upper half bearing.
Caution:  There is a danger that the connecting rod
could fall against the cylinder liner and break it. The
use of the guide pin, 21825 843, ensures that this
damage cannot occur.
6  Remove the two half bearings from the connecting
rod and keep them together.  Ensure that they can be
fitted in their original positions, if necessary.
To fit
1  Clean the connecting rod and the cap.
Caution:  Renew the half bearings as a set of two if
there is doubt that they are acceptable for a complete
period of service.  If it is not necessary to renew the
half bearings, ensure that they are fitted in their
original positions.
2  Clean the upper half bearing and lubricate the
bearing surface, the crank pin and the bolts and nuts
with clean engine lubricating oil.  It is recommended
that new bolts and nuts are used. When the bolts are
fitted, press carefully each bolt into the connecting rod
until the bolt head is fully against the machined face
of the connecting rod.
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3  Fit the off-centre upper half bearing to the
connecting rod.  Ensure that the edges of the half
bearing are aligned with the edges of the parent bore
of the connecting rod.  When it is fitted correctly, the
half bearing does not protrude over the chamfer on
the edge of the bore.
4  Use the guide pin, 21825 843, to pull the assembly
of the connecting rod and the piston down the bore
until the big end bearing is fitted on the crank pin.
Remove the guide pin from the connecting rod.
5  Clean the off-centre lower half bearing and fit it to
the cap.  Ensure that the edges of the half bearing are
aligned with the edges of the parent bore of the
connecting rod.  When it is fitted correctly, the half
bearing does not protrude over the chamfer on the
edge of the bore.  Lubricate the bearing surface and
the crank pin.  Ensure that the letters/numbers, which
are stamped on each bearing cap to give its
relationship, match the letters/numbers which are
stamped on the connecting rod, and fit the bearing
cap onto the bolts of the big end.  Ensure that the
connecting rod does not fall from the crank pin.
A
114
10  Fit the lubricating oil sump, operation 19-1 or, for
new engines, operation 19-5.
11  Fill the sump to the correct level with engine
lubricating oil and connect the supply of the  fuel.
12  Connect the batteries.
To inspect
13-2
6  For engines fitted with connecting rod bolts which
have a ’D’ or square-shaped head, fit and tighten the
four nuts of the connecting rod, in the sequence
shown (B), to 20 Nm (15 lbf ft) and then to 45 Nm (33
lbf ft).  The final operation is to tighten them to 70 Nm
(52 lbf ft). During the operation to tighten the bolts, if
the tension on the torque wrench reduces suddenly,
remove the bolt and fit a new bolt and nut.
1  Check the bearings and the crank pin for wear or
other damage.
For early engines, those with round headed
connecting rod bolts, proceed as follows: fit and
tighten the four nuts of the connecting rod, in the
sequence shown (B) to 20 Nm (14 lbf ft) and then to
40 Nm (28 lbf ft).  The final operation is to tighten them
to 60 Nm (42 lbf ft).  During the operation to tighten the
bolts, if the tension on the torque wrench reduces
suddenly, remove the bolt and renew the bolt and its
nut.
Caution:  Round headed connecting rod bolts are
NOT interchangeable with the later types. Connecting
rods must be fitted with only the type of bolts which
were originally used.
7  Ensure that the crankshaft turns freely.
8  Fit the lubricating oil pump if relevant, operation 19-
7.
9  For early engines, fit the sump adaptor, operation
19-3.
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13
Piston and connecting rod assembly
To remove and to fit
13-3
Special tools:
Guide pin, 21825 843
Retainers, 21825 844
To remove
1  Disconnect the batteries, stop the supply of the fuel
and drain the engine lubricating oil from the sump
2  Drain the cooling system.
3  Remove the relevant cylinder head, operation 12-9.
4  Remove the lubricating oil sump, operation 19-1 or,
for new engines, operation 19-5.
5  For early engines, remove the sump adaptor,
operation 19-3.
6  If necessary, release the bolts which retain the
lubricating oil pump and remove the lubricating oil
pump, operation 19-7.
7  Hold the relevant cylinder liner with the retainers,
21825 844, as necessary.
8  Turn the crankshaft until the selected assembly of
the piston and connecting rod is at the bottom of its
stroke and remove the nuts of the big end bolts.
Remove the bearing cap and fit the guide pin, 21825
843, on to one of the big end bolts.  Push carefully the
assembly out through the top of the cylinder.
Caution:  There is a danger that the connecting rod
could fall against the cylinder liner and break it. The
use of the guide pin, 21825 843, ensures that this
damage cannot occur.
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13
To fit
Special tools:
Height gauge, 21825 782
Guide pin, 21825 843
Retainer, 21825 844
Piston ring compressor, 21825 845
1  Turn the crankshaft until the relevant crank pin is at
BDC.  Check that the upper half bearing of the big end
is in its position on the connecting rod.  Set the gaps
of the piston rings in the positions shown (A) if the
pistons have four rings.  If the pistons have three
rings, set the gaps as shown (B).  Apply oil to the
crank pin, the upper half bearing and the piston, and
slide the piston ring compressor, 21825 845, over the
lower end of the piston with the tapered section
against the piston rings.  Fit the guide pin, 21825 843,
onto one of the bolts of the big end bearing (C).  It is
recommended that new bolts and nuts are used.
When the bolts are fitted, press carefully each bolt
into the connecting rod until the bolt head is fully
against the machined face of the connecting rod.
A
12
Caution:  There is a danger that the connecting rod
could fall against the cylinder liner and break it. The
use of the guide pin, 21825 843, ensures that this
damage cannot occur.
B
13
Caution:  If the old bolts and nuts have been used for
the connecting rod, they must first be inspected, for
signs of distortion of the threads, for stress, or for
indications of stretch, etc.  Renew all bolts and nuts
that could be defective.
2  Fit carefully the assembly of the piston and the
connecting rod into its liner.  Ensure that the cutout in
the lower wall of the piston is in the correct
relationship to the piston cooling jet assembly.  Use
the guide pin to pull the assembly through the piston
ring compressor and into the cylinder liner. Ensure
that the piston ring compressor is held, and does not
fall when it becomes free.  Continue to pull the
assembly until the big end bearing is fitted on the
crank pin.  If the piston and the connecting rod are
assembled correctly, the chamfer on the edge of the
bore in the big end is toward the crankshaft web.
Ensure that there is clearance between the piston and
the cooling jet.
Caution:  During this operation, do not damage the
bearing surfaces of the crank pin and the half
bearings of the big end.
A
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Caution:  If a retainer, 21825 844, is removed to give
a clearance for the piston ring compressor, it must be
fitted again for each operation before the crankshaft is
turned.
3  Fit and tighten the four nuts of the connecting rod,
in the sequence shown (A) to 20 Nm (15 lbf ft) and
then to 40 Nm (30 lbf ft).  The final operation is to
tighten them to 60 Nm (44 lbf ft).  It is recommended
that the new bolts and nuts are used.  Lubricate lightly
the threads and the contact faces before they are
fitted to the connecting rods.
Caution:  The nuts of the connecting rod should be
tightened gradually and evenly.  During this operation
avoid rapid or sudden movements of the torque
wrench.
A
114
4  Ensure that the crankshaft turns freely.
5  Check the end-float of the connecting rods with a
dial test indicator, as shown (B).  The clearance for
each set of two connecting rods, between the big
ends and their relevant crankshaft webs, must be
0,20 mm to 0,40 mm (0.008 to 0.016 in).
6  Repeat the procedure for each assembly of a piston
and a connecting rod.
Check the clearance between the top face of the
piston and the top face of the cylinder bank as follows:
7  Put the setting plate of the height gauge, 21825
782, on a clean surface which is machined and put
the base of the tool over the setting plate.  Align the
button of the dial gauge to make contact with the
centre of the plate.  Set the dial gauge to zero and
tighten the locking screw.
B
197
8  Turn the crankshaft until one of the pistons is
almost at the top of its cylinder and move the setting
plate to the top face of the piston.  Put the base of the
tool on the top face of the cylinder block, as shown
(C).
9  Continue to turn slowly the crankshaft, to allow the
piston to pass TDC.  As the piston passes TDC, make
a note of the reading on the dial gauge; the maximum
deflection of the pointer gives a minimum reading to
indicate the clearance between the top face of the
piston and the top face of the cylinder bank.  The
permissible clearance is from 0,31 to 0,38 mm (0.012
to 0.015 in).  For engines manufactured from July
1998, fitted with piston number CV66887, the
permissible clearance is from 0,31 to 0,75 mm (0.012
to 0.029 in).
B
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13
10  Check the clearance of each piston in the
cylinders of ’A’ bank, then turn the crankcase until the
cylinders of ’B’ bank are vertical.  Repeat the
procedure to check the clearance of each piston in the
cylinders of ’B’ bank.
Caution:  If not enough clearance is shown on the
dial gauge, the top face of the piston must be
machined to remove the minimum amount of material
which is necessary to give the correct clearance.  This
will not be necessary for engines manufactured after
July 1998 fitted with the piston XCV66887.
11  Fit the cylinder head, operation 12-9.
12  Fit the lubricating oil pump if relevant, operation
19-7.
13  For early engines, fit the sump adaptor, operation
19-3.
14  Fit the lubricating oil sump, operation 19-1 or, for
new engines, operation 19-5.
15  Fill the sump to the correct level with engine
lubricating oil and connect the supply of the fuel.
16  Fill the cooling system.
17  Connect the batteries.
To dismantle and to assemble
13-4
To dismantle
1  Remove the circlips which retain the gudgeon pin.
2  Push the gudgeon pin out by hand to release the
connecting rod.  If the gudgeon pin is tight, heat the
piston in a tank of warm water.  Keep together each
assembly.
To assemble
Before the connecting rod is assembled, check for
dirt and debris in the passage for the lubricating oil
and clean the passage with compressed air.
1  The gudgeon pin should be a push fit at 20°C
(68°F).  If it is tight in its bore in the piston, heat the
piston in a tank of warm water.  Remove the piston
from the water and use a clean and suitable rag to dry
the bore for the gudgeon pin.  Fit one of the circlips
into its groove in the bore.
2  Give an application of clean engine lubricating oil to
the small end bush, the gudgeon pin and the bore for
the gudgeon pin.
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3  Insert the small end of the connecting rod into the
piston, and ensure that the cut-out in the lower wall of
the piston is on the opposite side to the larger chamfer
in the bore of the big end.
4  Slide the gudgeon pin into the piston through the
small end bush and fit the second circlip into its
groove.
Caution:  When the big-end bolts are to be fitted, the
flat surface, which is machined on the shoulder at the
centre of each bolt, must be away from the bore of the
big end.  The half bearings will then engage correctly
in the bore of the connecting rod. The shoulders of
new bolts do not have the flat surfaces and special
fitting instructions are not needed for them.
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13
Piston rings
To remove and to fit
13-5
Special tools:
Ring expander, 21825 793
To remove
1  Put the top face of the piston on the bench and use
the ring expander, 21825 793, with the location ring,
21825 874, to remove carefully each piston ring.  Only
increase the ring gaps enough to ensure that the ends
of the rings do not damage the piston. Lift out the coil
spring from the groove for the oil control ring.  Keep
the rings with their relevant piston.
To fit
1  Put the top face of the piston on the bench and
lubricate the grooves for the piston rings.  Use the ring
expander, 21825 793, to fit carefully each piston ring
in the sequence given below.  Only increase the ring
gaps enough to ensure that the ends of the rings do
not damage the piston.
2  Remove the coil spring from its oil control ring and
fit it around the bottom piston ring groove, with the
latch pin inside both ends of the spring, before the oil
control ring is fitted to the piston.  Ensure that the
piston ring gap is at 180° to the latch pin.
The sequence of the assembly of the rings is:
Top
-
Barrel faced molybdenum
surface
Second
-
Chromium plated surface,
counterbore toward top of
piston
Third
-
-
'Ferrox' treated surface,
counterbore toward top of
piston
Bottom
Composite chromium plated
oil control ring
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Piston and rings
Connecting rod
To inspect
13-6    To inspect
13-7
1  Soak the components in a solvent, such as ’Maxan’     1  Clean the assembly of each connecting rod in
or ’Ardrox 667’, to remove the carbon. Wash the
components in clean water and dry them with
compressed air.
kerosene or a degreasing solution, and then check for
cracks in the rod, the big end cap and the big end
bolts.
2  Inspect the piston for wear, deep scratches, cracks     Caution:  It is recommended that the old bolts and
and further damage.  Check that the wear in each
piston ring groove does not exceed the permissible
limits.  If necessary, check the grooves by the use of
new piston rings.
the old nuts of the assemblies of the connecting rods
should be discarded.  Fit always new nuts to new
bolts and lubricate lightly the threads and the contact
faces before they are fitted to the connecting rods.
3  Inspect the piston rings for wear, deep scratches
and signs of leakage.  Discard the top ring if the
surface has large holes or cavities, or if there are
signs that the surface finish has started to break.
Compare the surface with the surface of a new ring if
necessary.
2  The bolts and the nuts of the assemblies of the
connecting rods must be inspected for signs of
distortion of the threads, for stress or for stretch, etc.
Renew all bolts which could be defective.
3  Check the small end bush for wear, for roughness
and for deep scratches.  If a bush is damaged, it must
be renewed.
4  Inspect the spring which is behind the oil control
ring.  If the circumference of the spring is excessively
decreased, the spring and the oil control ring must be
renewed as a complete unit.
4  Inspect the half bearings of the big end for cracks,
for scratches and for contamination in the bearing
surfaces.
5  Check the gap of each piston ring in a new cylinder
liner, or in a portion of the original cylinder liner which
is not worn.  Discard a piston ring with a gap which
exceeds the limits given on page 73 or page 75.
5  Check the alignment of the big end and of the small
end of the connecting rod.  Do not try to correct a
connecting rod which is bent or twisted.
Caution:  When a new cylinder liner has been fitted,
the piston rings must also be renewed. When a new
piston ring is fitted into an original cylinder liner, the
bore of the cylinder liner must be honed or lapped to
break the glazed surface.
6  Check for cracks in the gudgeon pin and check also
its fit in the piston.  The gudgeon pin should be a push
fit at 20°C (68°F).  If the gudgeon pin is loose in its
bore, the assembly must be renewed.
Caution:  An assembly of a piston and its gudgeon
pin must be renewed if the components do not
conform to the limits given in Fits and clearances at
the end of this section.  If it is necessary to renew a
piston, it is also necessary to ensure that the
clearance is correct between the top of the new piston
and the top face of the cylinder bank by the use of the
height gauge, 21825 782, operation 13-3.
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Fits and clearances - Pistons and connecting rods
Pistons - 4 rings
Gudgeon pin in piston (A1)
(Gudgeon pin to be push fit at 20°C)
Bore in piston (new). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54,999 to 55,004 mm (2.1653 to 2.1655 in)
Gudgeon pin diameter (new) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54,995 to 55,000 mm (2.1652 to 2.1654 in)
Gudgeon pin in piston - clearance (new) . . . . . . . . . . . . . . . . .-0,001 to +0,009 mm (-0.00004 to +0.00036 in)
Top groove in piston
(wedge shaped for top ring CV 5907)
Diameter over 3,302 mm (0.1300 in) dia. Rollers  . . . . . . . . . . . 136,073 to 135,855 mm (5.3572 to 5.3486 in)
Piston clearance at TDC (A2)
Top of piston below top face of crankcase. . . . . . . . . . . . . . . . . . . . . . . 0,310 to 0,380 mm (0.012 to 0.015 in)
(Machine top face of piston to obtain correct clearance)
Piston rings
Clearances of piston rings in grooves (A3)
Top ring CV 5907 (wedge shaped - new)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to ring gap dimensions
Second ring OE41689 (new) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,0635 to 0,1016 mm (0.0025 to 0.0040 in)
Maximum permissible worn clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,152 mm (0.006 in)
A
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Clearances of piston rings in grooves (continued)
Refer to the illustration (A) on page 72.
Third ring OE 42641 (new)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,0635 to 0,1143 mm (0.0025 to 0.0045 in)
Maximum permissible worn clearance  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,152 mm (0.006 in)
Oil control ring CV 5908 (new)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,049 to 0,086 mm (0.0019 to 0.0034 in)
Maximum permissible worn clearance  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,152 mm (0.006 in)
Free length of coil spring (new) . . . . . . . . . . . . . . . . . . . . . . . . . . . 423,96 to 426,34 mm (16.691 to 16.785 in)
Piston ring gaps measured with ring in new liner (A4)
Top ring CV 5907 (new)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,50 to 0,70 mm (0.0196 to 0.0275 in)
Maximum permissible worn gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,397 mm (0.055 in)
Second ring OE 41689 (new)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,432 to 0,686 mm (0.017 to 0.027 in)
Maximum permissible worn gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,524 mm (0.060 in)
Third ring OE 42641 (new)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,432 to 0,686 mm (0.017 to 0.027 in)
Maximum permissible worn gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,524 mm (0.060 in)
Oil control ring CV 5908 (new)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,430 to 0,810 mm (0.0169 to 0.0319 in)
Maximum permissible worn gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,016 mm (0.040 in)
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Pistons - 3 rings
Gudgeon pin in piston (A1)
(Gudgeon pin to be push fit at 20°C)
Bore in piston (new). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54,999 to 55,009 mm (2.1653 to 2.1657 in)
Gudgeon pin diameter (new) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54,995 to 55,000 mm (2.1652 to 2.1654 in)
Gudgeon pin in piston - clearance (new) . . . . . . . . . . . . . . . . .-0,001 to +0,014 mm (-0.00004 to +0.00055 in)
Top groove in piston
(wedge shaped for top ring CV 19329)
Diameter over 3,666 mm (0.1443 in) dia. rollers . . . . . . . . . . . . 135,155 to 135,405 mm (5.3211 to 5.3309 in)
Piston clearance at TDC (A2)
Top of piston below top face of crankcase. . . . . . . . . . . . . . . . . . . . . . . 0,310 to 0,380 mm (0.012 to 0.015 in)
(Machine top face of piston to obtain correct clearance)
Piston rings
Clearances of piston rings in grooves (A3)
Top ring CV 19329 (wedge shaped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to ring gap dimensions
Second ring CV 18638 (new). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,067 to 0,090 mm (0.0026 to 0.0035 in)
Maximum permissible worn clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,152 mm (0.006 in)
A
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Clearances of piston rings in grooves (continued)
Refer to the illustration (A) on page 74.
Oil control ring CV 18639 (new)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,048 to 0,085 mm (0.0019 to 0.0034 in)
Maximum permissible worn clearance  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,152 mm (0.006 in)
Free length of coil spring (new) . . . . . . . . . . . . . . . . . . . . . . . . . . . 423,96 to 426,34 mm (16.691 to 16.785 in)
Piston ring gaps measured with ring in new liner (A4)
Top ring CV 18637 (wedge shaped - new) . . . . . . . . . . . . . . . . . . . . . .  0,35 to 0,55 mm (0.0138 to 0.0217 in)
Maximum permissible worn gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,397 mm (0.055 in)
Second ring CV 18638 (new)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,43 to 0,68 mm (0.017 to 0.027 in)
Maximum permissible worn gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,524 mm (0.060 in)
Oil control ring CV 18639 (new)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,40 to 0,78 mm (0.016 to 0.031 in)
Maximum permissible worn gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,016 mm (0.040 in)
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13
Connecting rods
Gudgeon pin in bush (A1)
Bore of bush. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55,035 to 55,050 mm (2.1667 to 2.1673 in)
(Bush pressed into position and bored to size)
Diameter of gudgeon pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54,995 to 55,000 mm (2.1652 to 2.1653 in)
Clearance (new). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,035 to 0,055 mm (0.0014 to 0.0022 in)
Permissible worn clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,067 mm (0.0026 in)
Bush in small end (A2)
Bore in connecting rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60,00 to 60,03 mm (2.3622 to 2.3633 in)
Diameter of bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60,072 to 60,097 mm (2.365 to 2.366 in)
Interference fit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,042 to 0,097 mm (0.0017 to 0.0038 in)
Alignment of connecting rod (A3)
Parallel alignment  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,025 mm (0.001 in)
(Measured between big end and small end, for each 25,40 mm (1.000 in) of test mandrel)
Distance between centres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273,05 to 272,95 mm (10.750 to 10.746 in)
End-float of big end (A4)
End-float. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,20 to 0,40 mm (0.008 to 0.016 in)
Permissible worn end-float. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,558 mm (0.022 in)
(End-float of each set of two big ends on common crank pin)
Clearance on diameter of big end (A5)
Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,026 to 0,086 mm (0.001 to 0.003 in)
(Check that crank pin is within limits of ovality)
A
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