Perkins Engine 1000 New, YG to YK Service Manual

Perkins New 1000 Series

This document has been printed from SPI². Not for Resale

Models AJ to AS and YG to YK

WORKSHOP MANUAL

4 and 6 cylinder diesel engines for industrial and
agricultural applications

Publication TPD 1350E, Issue 4.
© Proprietary information of Perkins Engines Company Limited, all rights reserved.
The information is correct at the time of print.
Published in December 2001 by Technical Publications.

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This document has been printed from SPI². Not for Resale

This publication is written in
Perkins Approved Clear English

Chapters
1 General information
2 Specifications
3 Cylinder head assembly
4 Piston and connecting rod assemblies
5 Crankshaft assembly
6 Timing case and drive assembly
7 Cylinder block assembly
8 Engine timing
9 Aspiration system
10 Lubrication system
11 Fuel system
12 Cooling system
13 Flywheel and housing
14 Electrical equipment
15 Auxiliary equipment
16 Special tools

The following pages contain a detailed table of contents

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Contents

1 General information

Introduction ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...1

Engine views . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...2

Engine identification . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...3

Safety precautions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...5

Viton seals . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...6

Engine lift equipment ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...7

POWERPART recommended consumable products . ... ... ... ... ... ... ... ... ... ... ... ... ...8

2 Specifications

Basic engine data . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .11

Data and dimensions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .12

Thread sealant ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .35

Standard torque tensions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .36

Specific torque tensions .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .37

Compression test data . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .40

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3 Cylinder head assembly

General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 41

Rocker cover

Operation 3-1 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 42

Operation 3-2 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 43

Rocker ass embly

Operation 3-3 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 44

Operation 3-4 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 45

Operation 3-5 To inspect and to correct ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 45

Valve tip clearances

Operation 3-6 To check and to adjust (four cylinder engines) ... ... ... ... ... ... ... ... ... ... 46

Operation 3-7 To check and to adjust (six cylinder engines) . ... ... ... ... ... ... ... ... ... ... 47

Valve springs

Operation 3-8 To change the valve springs (with cylinder head fitted) .. ... ... ... ... ... ... 48

Manifolds ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 50

Operation 3-9 To remove and to fit an intake manifold .. ... ... ... ... ... ... ... ... ... ... ... ... 50

Operation 3-10 To remove and to fit an exhaust manifold (one-piece) .. ... ... ... ... ... ... 52

Operation 3-11 To remove and to fit an exhaust manifold (three-piece) ... ... ... ... ... ... 54

Cylinder head assembly

Operation 3-12 To remove . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 56

Operation 3-13 To fit (engine types AJ to AQ and YG to YK) ... ... ... ... ... ... ... ... ... ... 58

Operation 3-14 To fit (engine types AR and AS) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 61

Valves and valve springs

Operation 3-15 To remove . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 64

Operation 3-16 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 65

Operation 3-17 To inspect and to correct .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 66

Valve guides ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 67

Operation 3-18 To inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 67

Operation 3-19 To remove . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 68

Operation 3-20 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 69

Cylinder head

Operation 3-21 To inspect and to correct .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 70

Operation 3-22 To correct a valve seat with a valve seat cutter ... ... ... ... ... ... ... ... ... 71

Operation 3-23 To fit valve seat inserts . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 73

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4 Piston and connecting rod assemblies

General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .75

Big end bearing

Operation 4-1 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .77

Operation 4-2 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .78

Operation 4-3 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .78

Piston and connecting rod

Operation 4-4 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .79

Operation 4-5 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .80

Operation 4-6 To check the piston height above the cylinder block .. ... ... ... ... ... ... ... .82

Piston rings

Operation 4-7 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .83

Operation 4-8 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .84

Piston and connecting rod assembly

Operation 4-9 To dismantle ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .85

Operation 4-10 To assemble . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .86

Operation 4-11 To check the length of a connecting rod .. ... ... ... ... ... ... ... ... ... ... ... .87

Piston and piston rings

Operation 4-12 To inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .88

Connecting rod

Operation 4-13 To inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .89

Partially finished small end bush

Operation 4-14 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .90

Piston cooling jets

Operation 4-15 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .91

Operation 4-16 To check the jet alignment ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .92

5 Crankshaft assembly

General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .93

Crankshaft pulley

Operation 5-1 To remove and to fit (four cylinder engines) ... ... ... ... ... ... ... ... ... ... ... .95

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Crankshaft pulley and damper

Operation 5-2 To remove (six cylinder engines) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 96

Operation 5-3 To fit (six cylinder engines) . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 97

Operation 5-4 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 98

Rear oil seal assembly .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 99

Operation 5-5 To remove and to fit (one-piece assembly) . ... ... ... ... ... ... ... ... ... ... ... 99

Operation 5-6 To remove and to fit (two-piece assembly) . ... ... ... ... ... ... ... ... ... ... .. 102

Operation 5-7 To renew the rear end oil seal (two-piece assembly) ... ... ... ... ... ... .. 103

Operation 5-8 To remove and to fit a wear sleeve . ... ... ... ... ... ... ... ... ... ... ... ... ... .. 104

Thrust washers

Operation 5-9 To check crankshaft end-float . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..105

Operation 5-10 To remove . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 106

Operation 5-11 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 107

Main bearings

Operation 5-12 To remove (with the crankshaft in position) .. ... ... ... ... ... ... ... ... ... .. 108

Operation 5-13 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 109

Operation 5-14 To inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 109

Crankshaft

Operation 5-15 To remove . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 110

Operation 5-16 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 111

Operation 5-17 To inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 113

Balancer unit

Operation 5-18 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 114

Operation 5-19 To dismantle . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 115

Operation 5-20 To assemble . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 117

Operation 5-21 To inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 120

Operation 5-22 To remove and to fit the needle roller bearings for the drive shaft ... .. 121

Operation 5-23 To remove and to fit the bushes for the balance weights . ... ... ... ... .. 122

6 Timing case and drive assembly

General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 123

Timing case cover

Operation 6-1 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 124

Operation 6-2 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 125

Front oil seal

Operation 6-3 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 127

Operation 6-4 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 128

Operation 6-5 To remove and to fit a wear sleeve . ... ... ... ... ... ... ... ... ... ... ... ... ... .. 130

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Idler gear and hub

Operation 6-6 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...131

Operation 6-7 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...133

Idler gear and hub for the compressor

Operation 6-8 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...135

Operation 6-9 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...136

Fuel pump gear . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...137

Operation 6-10 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...137

Operation 6-11 To fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...139

Camshaft gear

Operation 6-12 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...141

Crankshaft gear

Operation 6-13 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...142

Timing case

Operation 6-14 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...143

Operation 6-15 To fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...144

Camshaft and tappets

Operation 6-16 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...146

Operation 6-17 To fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...147

7 Cylinder block assembly

General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...149

Cylinder block

Operation 7-1 To dismantle ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...150

Operation 7-2 To assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...151

Operation 7-3 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...152

Operation 7-4 To remove and to fit a new type ‘D’ plug to the tappet chamber ... ... ...153

Cylinder liner

Operation 7-5 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...155

Operation 7-6 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...156

Operation 7-7 To fit a service liner ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...158

Operation 7-8 To fit a partially finished liner .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...161

Cylinder bore, engine types AR and AS

Operation 7-9 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...164

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8 Engine timing

General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 165

Engine timing

Operation 8-1 To set number 1 piston to TDC on the compression stroke ... ... ... ... .. 167

Operation 8-2 Another method to set number 1 piston to TDC . ... ... ... ... ... ... ... ... .. 168

Operation 8-3 To check the valve timing ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 169

Operation 8-4 To check the timing of the fuel injection pump ... ... ... ... ... ... ... ... ... .. 170

9 Aspiration system

General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 171

Turbocharger

Operation 9-1 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 173

Operation 9-2 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 174

Operation 9-3 To clean the impeller and the compressor casing .. ... ... ... ... ... ... ... .. 176

Operation 9-4 To remove and to fit the actuator assembly of the waste-gate unit ... .. 177

Operation 9-5 To check and adjust the operation of the waste-gate . ... ... ... ... ... ... .. 178

Turbocharger faults ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 179

List of possible causes . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 180

Open engine breather ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 181

Operation 9-6 To clean and to renew ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..181

Operation 9-7 To Inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 183

Closed engine breather . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 184

Operation 9-8 To renew the breather valve assembly ... ... ... ... ... ... ... ... ... ... ... ... .. 185

10 Lubrication system

General description - four cylinder engine lubrication system ... ... ... ... ... ... ... ..187

General description - Six cylinder engine lubrication system . ... ... ... ... ... ... ... .. 188

Filter canister

Operation 10-1 To renew ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 191

Filter head

Operation 10-2 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 192

Sump

Operation 10-3 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 193

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Oil strainer and suction pipe

Operation 10-4 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...194

Operation 10-5 To inspect and to correct .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...195

Lubricating oil pump ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...196

Operation 10-6 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...196

Operation 10-7 To fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...197

Operation 10-8 To inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...198

Lubricating oil pump idler gear shaft .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...199

Operation 10-9 To remove (six cylinder engines) . ... ... ... ... ... ... ... ... ... ... ... ... ... ...199

Operation 10-10 To fit (six cylinder engines) . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...201

Operation 10-11 To remove and to fit (four cylinder engines) ... ... ... ... ... ... ... ... ... ...202

Relief valve

Operation 10-12 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...203

Operation 10-13 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...204

Operation 10-14 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...204

Flexible oil pipes ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...205

Operation 10-15 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...205

Operation 10-16 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...206

Operation 10-17 To Inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...207

11 Fuel system

General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...209

Cold start advance unit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...212

Typical fuel system ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...215

Fuel filters .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...216

Fuel filter element

Operation 11-1 To renew - separate element type ... ... ... ... ... ... ... ... ... ... ... ... ... ...217

Operation 11-2 To renew - canister type ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...218

Operation 11-3 To renew - quick release canister type . ... ... ... ... ... ... ... ... ... ... ... ...219

Atomisers .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...220

Operation 11-4 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...221

Operation 11-5 To fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...222

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Fuel lift pump

Operation 11-6 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 224

Operation 11-7 To dismantle . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..225

Operation 11-8 To assemble . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 226

Operation 11-9 To test ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 227

Bosch fuel injection pump ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..228

Operation 11-10 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 230

Operation 11-11 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 232

Operation 11-12 To adjust . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..234

Lucas/Delphi DP 200 Series fuel injection pump ... ... ... ... ... ... ... ... ... ... ... ... ... .. 235

Operation 11-13 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 237

Operation 11-14 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 239

Operation 11-15 To adjust . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..242

Operation 11-16 Electrical shut off solenoid (ESOS) . ... ... ... ... ... ... ... ... ... ... ... ... .. 243

Stanadyne fuel injection pump ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 245

Operation 11-17 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 248

Operation 11-18 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 249

Operation 11-19 To adjust . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..251

Air in the fuel system ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..254

Operation 11-20 To eliminate air from the fuel system .. ... ... ... ... ... ... ... ... ... ... ... ..254

12 Cooling system

General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 257

Thermostats

Operation 12-1 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 258

Operation 12-2 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 259

Operation 12-3 To test .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 260

Coolant pump - early gear driven pumps ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 261

Operation 12-4 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 261

Operation 12-5 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 262

Operation 12-6 To dismantle . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..263

Operation 12-7 To assemble . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 264

Operation 12-8 To remove and to fit a pressed steel cover (early coolant pumps) ... .. 267

Coolant pump - latest gear driven pumps ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..268

Operation 12-9 To remove . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 268

Operation 12-10 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 269

Operation 12-11 To dismantle ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 270

Operation 12-12 To assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..273

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Coolant pump - belt driven .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...277

Operation 12-13 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...277

Operation 12-14 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...279

Operation 12-15 To remove high position pump ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...281

Operation 12-16 To fit high position pump ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...283

Operation 12-17 To dismantle ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...285

Operation 12-18 To assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...286

Fan

Operation 12-19 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...289

Fan drive (engines with gear driven coolant pumps)

Operation 12-20 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...290

Lubricating oil cooler

Operation 12-21 To remove (four cylinder turbocharged engines) ... ... ... ... ... ... ... ...291

Operation 12-22 To fit (four cylinder turbocharged engines) . ... ... ... ... ... ... ... ... ... ...292

Operation 12-23 To dismantle and to assemble (four cylinder engines) ... ... ... ... ... ...293

Operation 12-24 To remove (six cylinder turbocharged engines) . ... ... ... ... ... ... ... ...294

Operation 12-25 To fit (six cylinder turbocharged engines) .. ... ... ... ... ... ... ... ... ... ...296

Operation 12-26 To dismantle and to assemble (six cylinder engines) . ... ... ... ... ... ...298

Operation 12-27 To remove and to fit (canister type) ... ... ... ... ... ... ... ... ... ... ... ... ...300

Operation 12-28 To remove and to fit cooler bypass valve ... ... ... ... ... ... ... ... ... ... ...300

Intercoolers ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...301

Horizontally mounted intercooler

Operation 12-29 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...302

Operation 12-30 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...304

Vertically mounted intercooler

Operation 12-31 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...306

Operation 12-32 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...307

Operation 12-33 To clean and to inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...309

13 Flywheel and housing

General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...311

Flywheel

Operation 13-1 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...311

Ring gear

Operation 13-2 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...312

Flywheel housing

Operation 13-3 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...313

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14 Electrical equipment

Alternators . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 315

Operation 14-1 To check the drive belts ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 316

Operation 14-2 To adjust drive belt tension ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 317

Operation 14-3 To remove and to fit the drive belts ... ... ... ... ... ... ... ... ... ... ... ... ... .. 318

Operation 14-4 To remove and to fit the alternator ... ... ... ... ... ... ... ... ... ... ... ... ... .. 319

Operation 14-5 To maintain ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 319

Operation 14-6 Fault diagnosis .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 320

Starter motors ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 322

Operation 14-7 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 323

Operation 14-8 To maintain the brush gear and the commutator .. ... ... ... ... ... ... ... ..324

Operation 14-9 To test on the engine ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 324

Operation 14-10 Fault diagnosis ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 325

Starting aids ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 326

Operation 14-11 To remove and to fit a fuelled starting aid ... ... ... ... ... ... ... ... ... ... .. 326

Operation 14-12 To remove and to fit a twin-fuelled starting aid ... ... ... ... ... ... ... ... ..327

Operation 14-13 To check the fuelled starting aid . ... ... ... ... ... ... ... ... ... ... ... ... ... .. 328

Operation 14-14 To remove and to fit a port heater ... ... ... ... ... ... ... ... ... ... ... ... ... .. 328

15 Auxiliary equipment

Bendix Compressor

Operation 15-1 To remove . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 330

Operation 15-2 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 331

Knorr-Bremse compressor

Operation 15-3 To remove . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 333

Operation 15-4 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 334

Operation 15-5 To remove the reed valves ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 336

Operation 15-6 To fit the reed valves . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..337

Operation 15-7 To remove the top unloader valve ... ... ... ... ... ... ... ... ... ... ... ... ... .. 338

Operation 15-8 To fit the top unloader valve .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 339

Operation 15-9 To remove the crankshaft / connecting rod / piston / piston rings . ... .. 340

Operation 15-10 To fit the crankshaft / connecting rod / piston / piston rings ... ... ... .. 341

Power steering pump

Operation 15-11 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 343

Adaptor for a hydraulic pump or a steering pump with a splined drive

Operation 15-12 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 344

Operation 15-13 To dismantle ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 345

Operation 15-14 To assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..346

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Exhauster

Operation 15-15 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...347

16 Special tools

List of special tools . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...350

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New 1000 Series

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General information 1

Introduction

This Workshop Manual has been written to provide assistance in the service and overhaul of Perkins New
1000 Series engines. For overhaul procedures the assumption is made that the engine is removed from the
application. The engine conforms with USA (EPA/CARB) stage 1 and EEC stage 1 emissions legislation for
agricultural and industrial applications.

Most of the general information which is included in the relevant User’s Handbook has not been repeated in
this workshop manual and the two publications should be used together.

Where the information applies only to certain engine types, this is indicated in the text.
The details of some operations will be different according to the type of fuel injection pump which is fitted. The

specific pump type used can be found by reference to the manufacturer’s identification plate on the pump body.
Generally, the type of pump fitted is as shown below.

l Lucas/Delphi - DP200 Series
l Bosch - EPVE
l Stanadyne - DB4.

When reference is made to the "left" or "right" side of the engine, this is as seen from the flywheel end of the
engine.

Special tools have been made available, for a list of these, see Chapter 16, Special tools. Reference to the
relevant special tools is also made at the beginning of each operation, where relevant.

POWERPART recommended consumable products are listed on page 8. Reference to the relevant
consumable products is also made at the beginning of each operation, where relevant.

Data and dimensions are included in Chapter 2, Specifications.
Read and remember the "Safety precautions" on page 5. They are given for your protection and must be used

at all times.
Danger is indicated in the text by two methods:

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

Note: Is used where the information is important, but there is not a danger.

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Engine views

New 1000 Series

A0378N

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Engine identification

The Perkins New 1000 Series engines have been designed for industrial and agricultural applications. There
are both four and six cylinder engines, each of which will have three basic engine types, naturally aspirated,
turbocharged and turbocharged with an intercooler.

In this workshop manual, the different engine types are indicated by their code letters. These are the first two
letters of the engine number as indicated below:

AJ Four cylinder, naturally aspirated
AK Four cylinder, turbocharged
AM Four cylinder, turbocharged and intercooled
AP Four cylinder, naturally aspirated, belt driven coolant pump
AQ Four cylinder, turbocharged, belt driven coolant pump
AR Four cylinder, naturally aspirated, 103 mm cylinder bore
AS Four cylinder, naturally aspirated, belt driven coolant pump, 103 mm cylinder bore
YG Six cylinder, naturally aspirated
YH Six cyli nde r , turbo ch ar ged
YJ Six cylinder, charge cooled, air to air
YK Six cylinder, turbocharged and intercooled

The correct identification of the engine is by the full engine number.
The engine number is stamped on a label which is fastened to the left side (A2) of the cylinder block. An

example of an engine number is:

AK80920*U510256B*

The components of the engine number are as follows:
AK80920*U510256B*
AK Model code number

80920 Build list number

U Built in the UK

510256 Engine serial number

B Year of manufacture

Continued

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Date letters for engines start from the 1st of January each year. To comply with the new emissions legislation
that engines built before 1st April 1999 can be clearly identified from those built after this date, a new letter has
been used from the 1st of April 1999. The date letters used are as follows:

From the 1st of January 1999 to the 31st of March 1999 the date letter is E.
From the 1st of April 1999 to the 31st of January 1999 the date letter is F.
If you need parts, service or information for your engine, you must give the complete engine number to your

Perkins distributor. If there is a number in the area of the label marked TPL No, then this number must also be
given to your Perkins distributor.

Other identification labels fitted to the engine include:
An emissions legislation label (A3) fitted to the side of the cylinder block.
A label (A1) with the fuel injection pum p part numbers.
If a short engine has been fitted in service two engine serial numbers and a TPL number are stamped on the

engine serial number pad (B3).
Examples of the serial numbers are shown in (B).
If parts for the short engine are needed in service, use the serial number (B4). If parts which were moved from

the original engine to the short engine are needed, use the serial number (B1) and the TPL number (B2).

New 1000 Series

AK80920*U510256B*

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AJ39770 TPL No 212

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Safety precautions

These safety precautions are important . You must refer also to the local regulations in the country of use.

Some items only refer to specifi c appl ic ati on s.

l Only use these engines in the type of application for which they have been designed.
l Do not change the specification of the engine.
l Do not smoke when you put fuel in the tank.
l Clean away fuel which has been spilt. Material which has been contaminated by fuel must be moved to a

safe place.

l Do not put fuel in the tank while the engine runs (unless it is absolutely necessary).
l Do not clean, add lubricating oil, or adjust the engine while it runs (unless you have had the correct training;

even then extreme care must be used to prevent injury).

l Do not make adjustments that you do not understand.
l Ensure that the engine does not run in a location where it can cause a concentration of toxic emissions.
l Other persons must be kept at a safe distance while the engine or auxiliary equipment is in operation.
l Do not permit loose clothing or long hair near moving parts.
l Keep away from moving parts during engine operation.

Warning! Some moving parts cannot be seen clearly while the engine runs.

l Do not operate the engine if a safety guard has been removed.
l Do not remove the filler cap or any component of the cooling system while the engine is hot and while the

coolant is under pressure, because dangerous hot coolant can be discharged.

l 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.

l Disconnect the battery terminals before a repair is made to the electrical system.
l Only one person must control the engine.
l Ensure that the engine is operated only from the control panel or from the operators position.
l If your skin comes into contact with high-pressure fuel, obtain medical assistance immediately.
l 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.

l Do not wear clothing which is contaminated by lubricating oil. Do not put material which is contaminated

with oil into the pockets of clothing.

l Discard used lubricating oil in a safe place to prevent contamination.
l Ensure that the control lever of the transmission drive is in the "out-of-drive" position before the engine is

started.

l Use extreme care if emergency repairs must be made in adverse conditions.
l 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, see "Viton seals" on page 6 for safety precautions.

l Read and use the instructions relevant to lift equipment, see "Engine lift equipment" on page 7.

Continued

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l Always use a safety cage to protect the operator when a component is to be pressure tested in a container

of water. Fit safety wires to secure the plugs which seal the hose connections of a component which is to
be pressure tested.

l Do not allow compressed air to contact your skin. If compressed air enters your skin, obtain medical help

immediately.

l Turbochargers operate at high speed and at high temperatures. Keep fingers, tools and items away from

the inlet and outlet ports of the turbocharger and prevent contact with hot surfaces.

l Do not clean an engine while it runs. If cold cleaning fluids are applied to a hot engine, certain components

on the engine may be damaged.

l Fit only genuine Perkins parts.

New 1000 Series

Viton seals

Some seals used in engines and in components fitted to engines are made of Viton.
Viton is used by many manufacturers and is a safe material under normal conditions of operation.
If Viton is burned, a product of this burnt material is an acid which is extremely dangerous. Never allow this

burnt material to come into contact with the skin or with the eyes.
If it is necessary to come into contact with components which have been burnt, ensure that the precautions

which follow are used:

l Ensure that the components have cooled
l Use neoprene gloves and discard the gloves safely after use
l Wash the area with calcium hydroxide solution and then with clean water
l Disposal of components and gloves which are contaminated must be in accordance with local regulations.

If there is contamination of the skin or eyes, wash the affected area with a continuous supply of clean water or
with calcium hydroxide solution for 15-60 minutes. Obtain immediate medical attention.

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Engine lift equipment

The maximum weight of the engine without coolant, lubricant or a gearbox fitted will vary for different
applications. It is recommended that lift equipment of the minimum capacity listed below is used:

Four cylinder engine s 500 kg (1100 lbs)
Six cylinder engines 600 kg (1320 lbs)

Before the engine is lifted:
l Always use lift equipment of the approved type and of the correct capacity to lift the engine. It is

recommended that lift equipment of the type shown in (A) is used, to provide a vertical lift directly above
the engine lift brackets (A1). Never use a single lift bracket to raise an engine

l Check the engine lift brackets for damage and that they are secure before the engine is lifted. The torque

for the setscrews for the engine lift brackets is 44 Nm (33 lbf ft) 4,5 kgf m

l To prevent damage to the rocker cover, ensure that there is clearance between the hooks and the rocker

cover

l Use lift equipment or obtain assistance to lift heavy engine components such as the cylinder block, cylinder

head, balancer unit, flywheel housing, crankshaft and flywheel.

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New 1000 Series

POWERPART recommended consumable products

Perkins have made available the products recommended below in order to assist in the correct operation,
service and maintenance of your engine and your machine. The instructions for the use of each product are
given on the outside of each container. These products are available from your Perkins distributor.

POWERPART Antifreeze

Protects the cooling system against frost and corrosion. Part number 21825166.

POWERPART Easy Flush

Cleans the cooling system. Part number 21825001.

POWERPART Gasket and flange sealant

To seal flat faces of components where no joint is used. Especially suitable for aluminium components. Part
number 21820518.

POWERPART Gasket remover

An aerosol for the removal of sealants and adhesives. Part number 21820116.

POWERPART Griptite

To improve the grip of worn tools and fasteners. Part number 21820129.

POWERPART Hydraulic threadseal

To retain and seal pipe connections with fine threads. Especially suitable for hydraulic and pneumatic systems.
Part number 21820121.

POWERPART Industrial grade super glue

Instant adhesive designed for metals, plastics and rubbers. Part number 21820125.

POWERPART Lay-Up 1

A diesel fuel additive for protection against corrosion. Part number 1772204.

POWERPART Lay-Up 2

Protects the inside of the engine and of other closed systems. Part number 1762811.

POWERPART Lay-Up 3

Protects outside metal parts. Part number 1734115.

POWERPART Metal repair putty

Designed for external repair of metal and plastic. Part number 21820126.

POWERPART Pipe sealant and sealant primer

To retain and seal pipe connections with coarse threads. Pressure systems can be used immediately. Part
number 21820122.

Continued

8 Workshop Manual, TPD 1350E, Issue 4

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POWERPART Radiator stop leak

For the repair of radiator leaks. Part number 21820127.

POWERPART Retainer (high strength)

To retain components that have an interference fit. Part number 21820638.

POWERPART Retainer (oil tolerant)

To retain components that have an interference fit, but is in contact with oil. Part number 21820603.

POWERPART Safety cleaner

General cleaner in an aerosol container. Part number 21820128.

POWERPART Silicone adhesive

An RTV silicone adhesive for application where low pressure tests occur before the adhesive sets. Used for
sealing flange where oil resistance is needed and movement of the joint occurs. Part number 21826038.

POWERPART Silicone RTV sealing and jointing compound

Silicone rubber sealant that prevents leakage through gaps. Part number 1861108.

POWERPART Stud and bearing lock

To provide a heavy duty seal to components that have a light interference fit. Part number 21820119 or

21820120.

1

POWERPART Threadlock and nutlock

To retain small fasteners where easy removal is necessary. Part number 21820117 or 21820118.

POWERPART Universal jointing compound

Universal jointing compound that seals joints. Part number 1861117.

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Specifications 2

Basic engine data

Number of cylinders:

AJ, AK, AM, AP, AQ, AR, AS .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 4

YG, YH, YJ, YK ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 6

Cylinder arrangement.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .In line

Cycle ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Four stroke

Direction of rotation . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Clockwise from the front

Induction system:

AJ, AP, AR, AS, YG. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Naturally aspirated

AK, AQ, YH.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Turbocharged

AM, YJ, YK .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Turbocha rg ed, int er co ole d

Combustion system. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...Direct injection

Nominal bore:

AJ, AK, AM, AP, AQ, YG, YH, YJ, YK. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .100 mm (3.937 in)

AR, AS. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .103 mm (4.055 in)

Stroke.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...127 mm (5.00 in)

Compression ratio:

AJ, AK, AM, AP, AQ, YG, YH, YJ, YK. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..17.25:1

AR, AS. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 18.5:1

Cubic capacity:

AJ, AK, AM, AP, AQ ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .4 litres (243 in

AR, AS. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 4,23 litres (258 in

YG, YH, YJ, YK ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .6 litres (365 in

Firing o rder:

AJ, AK, AM, AP, AQ, AR, AS .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1, 3, 4, 2

YG, YH, YJ, YK ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1, 5, 3, 6, 2, 4

Valve tip clearances (hot or cold):

- Inlet ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,20 mm (0.008 in)

- Exhaust . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,45 mm (0.018 in)

Lubricating oil pressure

AJ, AK, AM, AP, AQ, YG, YH, YJ, YK. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 280 kPa (40 lbf/in2) 2,5 kgf/cm

AR, AS. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 207 kPa (30 lbf/in2) 2,1 kgf/cm

(1) minimum at maximum engine speed and normal engine temperature

(1)

3

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3

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3

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New 1000 Series

Data and dimensions

Note: This information is given as a guide for personnel engaged on engine overhauls. The dimensions which

are shown are those which are mainly used in the factory. The information applies to all engines, unless an
engine type code is shown.

Cylinder head

Angle of valve seat:

- Inlet.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 46° (88° included angle) or 31° (1 1 8° included angle)

- Exhaust ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 46° (88° included angle) or 31° (118° included angle)

2

Leak test pressure . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 200 kPa (29 lbf/in

Head thickness .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 102,79/103,59 mm (4.047/4.078 in)

Finish grade of head face for cylinder head joint ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1,10/3,20 micrometers

Diameter of parent bore for valve guide:

- Inlet.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..13,00/13,027 mm (0.511 8/0. 512 8 in)

- Exhaust ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..14,00/14,027 mm (0.5512/0.5522 in)

Minimum permissible thickness after head face has been machined ... ... ... ... ... ... ... ..102,48 mm (4.035 in)

Maximum permissible distortion of cylinder head
Four cylinder engines

) 2,04 kgf/cm

2

A1... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,08 mm (0.003 in)

A2... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,15 mm (0.006 in)

A3... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,15 mm (0.006 in)

Six cylinder engines

A1... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,13 mm (0.005 in)

A2... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,25 mm (0.010 in)

A3... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,25 mm (0.010 in)

1111111

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Inlet and exhaust valves

Inlet valves

Diameter of valve stem ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..8,953/8,975 mm (0.3525/0.3533 in)

Clearance in valve guide . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,025/0,069 mm (0.001/0.0027 in)

Maximum permissible clearance in valve guide:

- Production limit.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,089 mm (0.0035 in)

- Service limit... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,100 mm (0.008 in)

Diameter of valve head:

- Engine types AJ, AK, AM, AP, AQ, YG, YH, YJ, YK. ... ... ... ... ... ... ... ... ..42,88/43,12 mm (1.688/1.698 in)

- Engine types AR and AS... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..44,88/45,12 mm (1.776/1.767 in)

Angle of valve face .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..45° or 30°

Full length, engine types AJ, AK, AM, AP, AQ, YG, YH, YJ, YK. ... ... ... ..122,65/123,30 mm (4.829/4.854 in)

Full length, engine types AR and AS... ... ... ... ... ... ... ... ... ... ... ... ... ... ..123,75/124,40 mm (4.872/4.897 in)

Seal arrangement ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .Rubber seal fitted to valve guide, colour green

Depth of valve head below the face of cylinder head:

- Production limits, engine types AJ, AK, AM, AP, AQ, YG, YH, YJ, YK. ... ... ..1,40/1,70 mm (0.055/0.067 in)

- Service limit, engine types AJ, AK, AM, AP, AQ, YG, YH, YJ, YK ... ... ... ... ... ... ... ... ... 1,95 mm (0.077 in)

- Production limits, engine types AR and AS... ... ... ... ... ... ... ... ... ... ... ... ... ..0,40/0,60 mm (0.016/0.024 in)

- Service limit, engine types AR and AS.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,805 mm (0.032 in)

Exhaust valves

Diameter of valve stem ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..8,938/8,960 mm (0.3519/0.3528 in)

Clearance in valve guide . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,040/0,84 mm (0.0016/0.0033 in)

Maximum permissible clearance in valve guide:

- Production limits ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,104 mm (0.0041 in)

- Service limit... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,121 mm (0.011 in)

Diameter of valve head:

- Engine types, AJ, AK, AM, AP, AQ, YG, YH, YJ, YK ... ... ... ... ... ... ... ... ..40,88/41,12 mm (1.609/1.619 in)

- Engine types AR and AS... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..41,88/42,12 mm (1.649/1.658 in)

Angle of valve face .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..45° or 30°

Full length, engine types, AJ, AK, AM, AP, AQ, YG, YH, YJ, YK ... ... ... ..122,65/123,30 mm (4.829/4.854 in)

Full length, engine types AR and AS... ... ... ... ... ... ... ... ... ... ... ... ... ... ..123,75/124,40 mm (4.872/4.897 in)

Seal arrangement ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Rubber seal fitted to valve guide, colour brown

Depth of valve head below face of cylinder head:

- Production limits, engine types, AJ, AK, AM, AP, AQ, YG, YH, YJ, YK ... ... ..1,50/1,80 mm (0.059/0.071 in)

- Service limit, engine types, AJ, AK, AM, AP, AQ, YG, YH, YJ, YK... ... ... ... ... ... ... ... ... 2,05 mm (0.081 in)

- Production limits, engine types AR and AS... ... ... ... ... ... ... ... ... ... ... ... ... ..0,40/0,60 mm (0.016/0.024 in)

- Service limit, engine types AR and AS.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,805 mm (0.032 in)

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New 1000 Series

Dimensions of recesses for valve seat inserts

Engine types AJ to AQ and YG to YK
Inlet

A1... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 10,585/10,715 mm (0.4167/0.4219 in)

A2... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 45,535/45,560 mm (1.7927/1.7937 in)

A3... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .Radius 0,38 mm (0.015 in) maximum

Exhaust

A1... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 10,585/10,715 mm (0.4167/0.4219 in)

A2... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 43,535/43,560 mm (1.7139/1.7149 in)

A3... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .Radius 0,38 mm (0.015 in) maximum

Engine types AR and AS
Inlet

A1... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 10,585/10,715 mm (0.4167/0.4219 in)

A2... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 48,035/48,060 mm (1.8911/1.8921 in)

A3... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .Radius 0,38 mm (0.015 in) maximum

Exhaust

A1... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 10,585/10,715 mm (0.4167/0.4219 in)

A2... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 44,035/44,060 mm (1.7336/1.7346 in)

A3... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .Radius 0,38 mm (0.015 in) maximum

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Valve seat insert tool

Inlet (for 45° valves and 30° valves), engine types AJ to AQ and YG to YK

A1 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1,5 mm (0.06 in)

A2 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...20 mm (0.800 in)

A3 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 7,0 mm (0.28 in)

A4 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...100 mm (4.00 in)

A.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..37,25/37,45 mm (1.467/1.474 in)

A6 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..44,75/45,00 mm (1.772/1.762 in)

A7 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .Radius 1,4 mm (0.055) maximum

A8 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Radiu s 1,5 mm (0.06)

A9 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1,5 mm (0.06 in)

A10.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..8,54/8,57 mm (0.336/0.337 in)

Exhaust (for 45° valves and 30° valves), engine types AJ to AQ and YG to YK

A1 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1,5 mm (0.06 in)

A2 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .20 mm (0.80 in)

A3 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 7,0 mm (0.28 in) maximum

A4 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...100 mm (4.00 in)

A5 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..34,38/34,58 mm (1.354/1.361 in)

A6 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..42,75/43,00 mm (1,683/1.693 in)

A7 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . Radius 1,4 mm (0.055 in) maximum

A8 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Radius 1,5 mm (0.06 in)

A9 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1,5 mm (0.06 in)

A10.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..8,54/8,57 mm (0.336/0.337 in)

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Inlet (45° valves), engine types AR and AS

A1... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..1,5 mm (0.06 in)

A2... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .20 mm (0.800 in)

A3... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..7,0 mm (0.28 in)

A4... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .100 mm (4.00 in)

A5... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 37,82/38,02 mm (1.488/1.496 in)

A6... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 47,25/47,50 mm (1.860/1.870 in)

A7... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...Radius 1,4 mm (0.055) maximum

A8... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . Radius 1,5 mm (0.06)

A9... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..1,5 mm (0.06 in)

A10. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 8,54/8,57 mm (0.336/0.337)

Exhaust (45° valves), engine types AR and AS

A1... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..1,5 mm (0.06 in)

A2... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...20 mm (0.80 in)

A3... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .7,0 mm (0.28 in) maximum

A4... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .100 mm (4.00 in)

A5... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 36,62/36,82 mm (1.441/1.449 in)

A6... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 43,25/43,50 mm (1,702/1.712 in)

A7... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...Radius 1,4 mm (0.055 in) maximum

A8... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . Radius 1,5 mm (0.06 in)

A9... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..1,5 mm (0.06 in)

A10. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 8,54/8,57 mm (0.336/0.337 in)

New 1000 Series

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Valve guides and valve springs

Valve guides

Inside diameter of partially finished guide ... ... ... ... ... ... ... ... ... ... ... ... ..8,600/8,700 mm (0.3386/0.3425 in)

Inside diameter of finished guide. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..9,000/9,022 mm (0.3543/0.3552 in)

Outside diameter:

Inlet.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..13,034/13,047 mm (0.5131/0.5137 in)

Exhaust ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..14,034/14,047 mm (0.5525/0.5530 in)

Interference fit of valve guide in cylinder head ... ... ... ... ... ... ... ... ... ... ..0,047/0,007 mm (0.0003/0.0019 in)

Full length ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..51,25 mm (2.018 in)

Protrusion from bottom of recess for valve spring ... ... ... ... ... ... ... ... ... ... ..14,85/15,15 mm (0.585/0.596 in)

Valve springs

Fitted length. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..39,0 mm (1.54 in)

Load at fitted length:

- Engine types, AJ, AK, AM, AP, AQ, YG, YH, YJ, YK ... ... ... ... ... ..246/277,5 N (55.3/62.4 lbf) 25,1/28,3 kgf

- Engine types AR and AS... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...136,3/153,7 N (30.6/34.5 lbf) 13,9/15,7 kgf

Number of active coils . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .3.3

Number of damper coils .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0

Direction of coils .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...Left hand

Tappets, rocker shaft, rocker levers and bushes

Tappets

Diameter of tappet stem .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..18,99/19,01 mm (0.7475/0.7485 in)

Diameter of tappet bore in cylinder block ... ... ... ... ... ... ... ... ... ... ... ... ..19,05/19,08 mm (0.7500/0.7512 in)

Clearance of tappet in cylinder block... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,04/0,09 mm (0.0015/0.0037 in)

Rocker shaft

Outside diameter . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..19,01/19,04 mm (0.7485/0.7495 in)

Rocker levers and bushes

Diameter of parent bore for bush. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 22,23/22,26 mm (0.8750/0.8762 in)

Outside diameter of bush ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..22,28/22,31 mm (0.8770/0.8785 in)

Interference fit of bush in rocker lever . ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,020/0,089 mm (0.0008/0.0035 in)

Internal diameter of fitted bush when reamed . ... ... ... ... ... ... ... ... ... ... ..19,06/19,10 mm (0.7505/0.7520 in)

Clearance between rocker lever bush and rocker shaft.. ... ... ... ... ... ... ... ... 0,03/0,09 mm (0.001/0.0035 in)

Maximum permissible clearance between rocker lever bush and rocker shaft ... ... ... ... ... 0,13 mm (0.005 in)

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New 1000 Series

Pistons and piston cooling jets

Pistons

Type... ... ... ... ... ... ... ... ... ... ... ... ... ... ..."Fastram" combustion bowl inserted top ring groove, graphite skirt

Diameter of bore for gudgeon pin.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... 39,703/39,709 mm (1.5631/1.5633 in)

Height of piston above top face of cylinder block... ... ... ... ... ... ... ... ... ... ... ... 0,38/0,50 mm (0.015/0.020 in)

Width of groove for top ring:

- Engine types AJ, AK, AM, AP, AQ, YG, YH, YJ, YK ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . Tapered

- Engine types AR and AS. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 2,60/2,62 mm (0.1023/0.1031)

Width of groove for second ring. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 2,56/2,58 mm (0.1008/0.1016 in)

Width of groove for third ring:

- Engine types, AJ, AK, AM, AP, AQ, YG, YH, YJ, YK .. ... ... ... ... ... ... ... ... 3,54/3,56 mm (0.1393/0.1401 in)

- Engine types, AR and AS ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 3,53/3,55 mm (0.1389/0.1397 in)

Piston cooling jets

Valve open pressure.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 178/250 kPa (26/36 lbf/in

2

) 1,8/2,6 kgf/cm

Piston rings

Top compression ring:

2

- Engine types, AJ, AK, AM, AP, AQ, YG, YH, YJ, YK .. ... ... ... ... ... . Barrel face, molybdenum insert, wedge

- Engine types AR and AS. ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. Barrel face, molybdenum insert, rectangular

Second compression ring .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..Taper face, cast iron, outside bottom step

Oil scraper ring... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Coil spring loaded, chromium faced

Width of top ring:

- Engine types, AJ, AK, AM, AP, AQ, YG, YH, YJ, YK .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. Tapered

- Engine types AR and AS. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..2,475/2,49 mm (0.097/0.098 in)

Width of second ring .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 2,48/2,49 mm (0.097/0.098 in)

Width of third ring... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 3,47/3,49 mm (0.1366/0.1374 in)

Clearance of top ring in groove:

- Engine types, AJ, AK, AM, AP, AQ, YG, YH, YJ, YK .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Wedge

- Engine types AR and AS only.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,110/0,145 mm (0.004/0.006 in)

Clearance of second ring in groove... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,07/0,1 mm (0.003/0.004 in)

Clearance of third ring in groove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,05/0,09 mm (0.002/0.003 in)

Gap of top ring:

- Engine types, AJ, AK, AM, AP, AQ, YG, YH, YJ, YK .. ... ... ... ... ... ... ... ... ... 0,28/0,63 mm (0.011/0.025 in)

- Engine types AR and AS. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,28/0,51 mm (0.011/0.020 in)

Gap of second ring:

- Engine types, AJ, AK, AM, AP, AQ, YG, YH, YJ, YK .. ... ... ... ... ... ... ... ... ... 0,40/0,85 mm (0.016/0.034 in)

- Engine types AR and AS. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,30/0,63 mm (0.012/0.025 in)

Gap of third ring:

- Engine types, AJ, AK, AM, AP, AQ, YG, YH, YJ, YK .. ... ... ... ... ... ... ... ... ... 0,25/0,75 mm (0.010/0.031 in)

- Engine types AR and AS. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,30/0,63 mm (0.012/0.025 in)

18 Workshop Manual, TPD 1350E, Issue 4

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Connecting rods and big end bearings

Connecting rods

Type. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..‘H' section, wedge shape small end

Location of cap to connecting rod ... ... ... ... ... ... ... ... ... ... ... ... ... ... Flat joint face with dowels or serrations

Diameter of parent bore for big end. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..67,21/67,22 mm (2.6460/2.6465 in)

Diameter of parent bore for small end. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..43,01/43,04 mm (1.693/1.694 in)

Length grades.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. F, G, H, J, K, L

Length between centres .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..219,05/219,10 mm (8.624/8.626 in)

Big end bearings

Type:

- Naturally aspirated engines... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Steel back, aluminium/tin bearing material

- Turbocharged engines .. ... ... ... ... ... ... ... ... ... ... . Steel back, lead bronze bearing material with lead finish

Width:

- Naturally aspirated engines... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 31,62/31,88 mm (1.245/1.255 in)

- Turbocharged engines .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..31,55/31,88 mm (1.240/1.255 in)

Thickness at centre of bearings:

- Naturally aspirated engines... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..1,835/1,842 mm (0.0723/0.0725 in)

- Turbocharged engines .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..1,835/1,844 mm (0.0723/0.0726 in)

Bearing clearance:

- Naturally aspirated engines... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,035/0,081 mm (0.0014/0.0032 in)

- Turbocharged engines .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,030/0,081 mm (0.0012/0.0032 in)

Available undersize bearings... ... ... ... ... ... ..0,25 mm (-0.010 in); -0,51 mm (-0.020 in); -0,76 mm (-0.030 in)

Gudgeon pins and small end bushes

Gudgeon pins

Production:

Type. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..Fully floating

Outside diameter . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..39,694/39,700 mm (1.5628/1.5630 in)

Clearance fit in piston boss . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,003/0,015 mm (0.0001/0.0006 in)

Small end bushes

Type. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Steel back, lead bronze tin bearing materials

Outside diameter . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..43,11/43,15 mm (1.6972/1.6988 in)

Inside diameter ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..39,723/39,738 mm (1.5638/1.5645 in)

Surface finish grade. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...Ra 0,8 micrometers

Clearance between bush in small end and gudgeon pin. ... ... ... ... ... ... ..0,023/0,044 mm (0.0009/0.0017 in)

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New 1000 Series

Crankshaft

Diameter of main journals:

- Four cylinder engines .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 76,16/76,18 mm (2.998/2.999 in)

- Six cylinder engines. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 76,159/76,190 mm (2.9984/2.9996 in)

Maximum wear and ovality on journals and crank pins . ... ... ... ... ... ... ... ... ... ... ... ... ... 0,04 mm (0.0016 in)

Width of front journal.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 36,93/37,69 mm (1.454/1.484 in)

Width of centre journal... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 44,15/44,22 mm (1.738/1.741 in)

Width of all other journals .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 39,24/39,35 mm (1.545/1.549 in)

Diameter of crank pins... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 63,47/63,49 mm (2.499/2.500 in)

Width of crank pins ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 40,35/40,42 mm (1.589/1.591 in)

Diameter of flange.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 133,27/133,37 mm (5.247/5.251 in)

Depth of recess for spigot bearing:

- Four cylinder engines .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 20,22/20,98 mm (0.796/0.826 in)

- Six cylinder engines. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 14,72/15,48 mm (0.579/0.609 in)

Bore of recess for spigot bearing:

- Four cylinder engines .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 46,96/46,99 mm (1.849/1.850 in)

- Six cylinder engines. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 51,97/51,99 mm (2.046/2.047 in)

Crankshaft end-float... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,05/0,38 mm (0.002/0.015 in)

Maximum permissible end-float. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,51 mm (0.020 in)

Fillet radii of journals and crank pins.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 3,68/3,96 mm (0.145/0.156 in)

Undersize journals and crank pins. ... ... ... .. -0,25 mm (-0.010 in); -0,51 mm (-0.020 in); -0,76 mm (-0.030 in)

Crankshaft heat treatment

Induction hardened ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .Part numbers 3131H024

Nitrocarburised... ... ... ... ... ... ... ... ... ... ... ... ... ...Part numbers 3131H022, 31315991, 31315995, 31315681

60 hour Nitride ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .Part numbers 3131H021

Nitreg . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .Part numbers 3131H031

Crankshaft overhaul

Cautions:

l The “Nitreg” process is a special factory process that needs specialist equipment and personnel with the

correct training. Do not use any other heat treatment process on these crankshafts.

l In service it is not possible to regrind the “Nitreg” crankshaft for overhaul purposes. A “new for old”

crankshaft is available.

Notes:

l Induction hardened crank shafts need not be hardened after they have been machined undersize.
l Nitrocarburised crankshafts must be hardened again each time they are machined. These crankshafts

must be nitrocarburised or, if this process is not available, they can be nitrided for 20 hours. If neither
process is available a new crankshaft, or a “new for old” crankshaft, must be fitted.

l Crankshafts which have been nitrided for 60 hours can be reground 0,25 mm (0.010 in) without the need

to harden them again.

l Check the crankshaft for cracks before and after it is ground. Demagnetise the crankshaft after it has been

checked for cracks.

l After the crankshaft has been machined remove any sharp corners from the lubricating oil holes.
l Surface finish and fillet radii must be maintained.

Continued

20 Workshop Manual, TPD 1350E, Issue 4

New 1000 Series

This document has been printed from SPI². Not for Resale

The finished sizes for crankshaft journals (A) which have been ground undersize are given in the table below:

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1

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3 39,47 mm (1.554 in) maximum - -

4 37,82 mm (1.489 in) maximum - ­5 44,68 mm (1.759 in) maximum - ­6 40,55 mm (1.596 in) maximum - ­7 133,17 mm (5.243 in) minimum - ­8 Do not machine this diameter - ­9 3,68/3,96 mm (0.145/0.156 in) - -

Surface finish for journals, crank pins and fillet radii must be 0,4 microns (16 micro inches). Surface finish for
seal area of crankshaft palm must be 0,4/1,1 microns (16/43 micro inches).

0,25 mm

(0.010 in)

75,905/75,926 mm

(2.9884/2.9892 in)

63,216/63,236 mm

(2.4888/2.4896 in)

0,51 mm

(0.020 in)

75,651/75,672 mm

(2.9784/2.9792 in)

62,962/62,982 mm

(2.4788/2.4796 in)

0,76 mm

0.030 in)

75,397/75,418 mm

(2.9684/2.9692 in)

62,708/62,728 mm

(2.4688/2.4696 in)

6666

9

2

9

111117

22

43533

666666

9

2

1111111

9

99999

2222

9

9999

2

9

8

4,8mm

0.189in

2

7

8

9999

3333334

A

Workshop Manual, TPD 1350E, Issue 4 21

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This document has been printed from SPI². Not for Resale

With the crankshaft on mountings at the front and rear journals, the maximum run-out (total indicator reading)
at the journals must not be more than shown below:

Journal 4 cylinder crankshafts 6 cylinder crankshafts

1 Mounting Mounting
2 0,08 mm (0.003 in) 0,10 mm (0.004 in)
3 0,15 mm (0.006 in) 0,20 mm (0.008 in)
4 0,08 mm (0.003 in) 0,25 mm (0.010 in)
5 Mounting 0,20 mm (0.008 in)
6 - 0,10 mm (0.004 in)
7 - Mounting

Run-out must not be opposite. The difference in run-out between one journal and the next must not be more
than 0,10 mm (0.004 in).

Run-out on the crankshaft pulley diameter, rear oil seal diameter and the rear flange diameter must not be
more than 0,05 mm (0.002 in) total indicator reading.

New 1000 Series

Main bearings

Type

Four cylinder engines. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .Steel back, 20% tin-aluminium bearing material

Six cylinder engines... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .Steel back, 20% tin-aluminium bearing material

Bearin g wi dt h

Four cylinder engines:

Centre bearing ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 36,32/36,70 mm (1.430/1.445 in)

All other bearings... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 31,62/31,88 mm (1.245/1.255 in)

Six cylinder engines:

Centre bearing ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 36,32/36,70 mm (1.430/1.445 in)

All other bearings... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 30,86/31,12 mm (1.215/1.225 in)

Bearing thickness at centre

Four cylinder engines. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 2,083/2,089 mm (0.0820/0.0823 in)

Six cylinder engines... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 2,083/2,089 mm (0.0820/0.0823 in)

Bearing clearance

Four cylinder engines:

All bearings ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,057/0,117 mm (0.0022/0.0046 in)

Six cylinder engines:

All other bearings... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,047/0,117 mm (0.0018/0.0046 in)

Available undersize bearings. ... ... ... ... ... ... 0,25 mm (-0.010 in); -0,51 mm (-0.020 in); -0,76 mm (-0.030 in)

22 Workshop Manual, TPD 1350E, Issue 4

New 1000 Series

This document has been printed from SPI². Not for Resale

2

Crankshaft thrust washers

Type. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..Steel back, lead bronze bearing material

Position ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..Each side of centre main bearing

Thickness:

- Standard ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..2,26/2,31 mm (0.089/0.091 in)

- Oversize ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..2,45/2,50 mm (0.096/0.098 in)

Balancer unit

Diameter of drive shaft for front bearing.. ... ... ... ... ... ... ... ... ... ... ... ..28,562/28,575 mm (1.1245/1.1250 in)

Diameter of drive shaft for rear bearing... ... ... ... ... ... ... ... ... ... ... ... ..23,787/23,800 mm (0.9365/0.9370 in)

Number of teeth on gear of drive shaft ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 21

Backlash from gear of drive shaft to idler gear ... ... ... ... ... ... ... ... ... ... ... ... ..0,17/0,29 mm (0.007/0.011 in)

End-float of drive shaft. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,13/0,30 mm (0.005/0.012 in)

Diameter of bore for front bearing of drive shaft.. ... ... ... ... ... ... ... ... ..34,912/34,937 mm (1.3745/1.3755 in)

Diameter of bore for rear bearing of drive shaft... ... ... ... ... ... ... ... ... ..29,972/29,993 mm (1.1800/1.1808 in)

Diameter of bore for idler gear. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..47,64/47,65 mm (1.8755/1.8760 in)

Diameter of hub of idler gear... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..38,09/38,10 mm (1.4996/1.5000 in)

End-float of idler gear .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,07/0,23 mm (0.003/0.009 in)

Thickness of thrust washer for idler gear. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..4,14/4,29 mm (0.163/0.169 in)

Number of teeth on idler gear.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 37

Inside diameter of bushes in balancer frame and end cover (fitted) ... ..38,133/38,174 mm (1.5013/1.5029 in)

Diameter of spigots for balance weights.. ... ... ... ... ... ... ... ... ... ... ... ..38,054/38,069 mm (1.4982/1.4988 in)

Fit of spigot in bush . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,064/0,120 mm (0.0025/0.0047 in)

End-float of balance weights ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,19/0,40 mm (0.007/0.016 in)

Backlash of gears on balance weights ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,10/0,27 mm (0.004/0.011 in)

Backlash of drive gear to spline on balance weight. ... ... ... ... ... ... ... ... ... ... ..0,05/0,20 mm (0.002/0.008 in)

Number of teeth on drive gear. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 24

Number of teeth on spline on balance weight . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..16

Workshop Manual, TPD 1350E, Issue 4 23

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This document has been printed from SPI². Not for Resale

New 1000 Series

Timing case and drive assembly

Camshaft

Diameter of number 1 journal ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 50,71/50,74 mm (1.9965/1.9975 in)

Diameter of number 2 journal ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 50,46/50,48 mm (1.9865.1.9875 in)

Diameter of number 3 journal:

- Four cylinder engines .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 49,95/49,98 mm (1.9665/1.9675 in)

- Six cylinder engines. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 50,20/50,23 mm (1.9765/1.9775 in)

Diameter of number 4 journal:

- Six cylinder .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 49,95/49,98 mm (1.9665/1.9675 in)

Clearance of all journals ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,06/0,14 mm (0.0025/0.0055 in)

Cam lift:

- Inlet, engine types AJ, AK, AM, AP, AQ, YG, YH, YJ, YK... ... ... ... ... ... ... 7,62/7,69 mm (0.2999/0.3029 in)

- Inlet, engine types AR and AS. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 8,58 mm (0.3378 in)

- Exhaust, engine types AJ, AK, AM, AP, AQ, YG, YH, YJ, YK. ... ... ... ... ... 7,71/7,79 mm (0.3036/0.3066 in)

- Exhaust, engine types AR and AS... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 8,80 mm (0.3464 in)

Maximum permissible ovality and wear on journals... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,05 mm (0.021 in)

End-float:

- Production limits .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,10/0,41 mm (0.004/0.016 in)

- Service limits ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,53 mm (0.021 in)

Width of spigot for thrust washer ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 5,64/5,89 mm (0.222/0.232 in)

Camshaft thrust washer

Type... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 360°

Depth of recess in cylinder block for thrust washer ... ... ... ... ... ... ... ... ... ... ... 5,46/5,54 mm (0.215/0.218 in)

Thickness of thrust washer ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 5,49/5,54 mm (0.216/0.218 in)

Relationship of thrust washer to front face of cylinder block.. ... ... ... ... ... .-0,05/+0,08 mm (-0.002/+0.003 in)

Camshaft gear

Number of teeth . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 56

Diameter of bore ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 34,93/34,95 mm (1.3750/1.3760 in)

Outside diameter of hub of camshaft. ... ... ... ... ... ... ... ... ... ... ... ... ... ... 34,90/34,92 mm (1.3741/1.3747 in)

Clearance fit of gear on hub... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,008/0,048 mm (0.0003/0.0019 in)

Fuel pump gear

Number of teeth . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 56

Bore ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 36,00/36,06 mm (1.417/1.419 in)

Clearance fit on hub... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,003/0,075 mm (0.0001/0.0030 in)

Crankshaft gear

Number of teeth . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 28

Diameter of bore ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 47,625/47,650 mm (1.8750/1.8760 in)

Diameter of hub for gear on crankshaft . ... ... ... ... ... ... ... ... ... ... ... ... 47,625/47,645 mm (1.8750/1.8758 in)

Transition fit of gear on crankshaft. ... ... ... ... ... ... ... ... ... ... ... ... ... . -0,020/+0,048 mm (-0.0008/+0.0010 in)

24 Workshop Manual, TPD 1350E, Issue 4

New 1000 Series

This document has been printed from SPI². Not for Resale

Idler gear and hub

Number of teeth... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..63

Diameter of bore of gear.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..57,14/57,18 mm (2.2495/2.2512 in)

- with needle roller bearings ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..69,01/69,03 mm (2.717/2.718 in)

Width of gear and split bush assembly (fitted in position) ... ... ... ... ... ... ... ..30,14/30,16 mm (1.186/1.187 in)

Inside diameter of flanged bushes (fitted in position).. ... ... ... ... ... ... ... ... 50,78/50,80 mm (1.9999/2.000 in)

Outside diameter of hub .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..50,70/50,74 mm (1.9960/1.9975 in)

-with needle roller bearing ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..54,987/55,000 mm (2.1648/2.1654 in)

Clearance of bushes on hub ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,04/0,10 mm (0.0016/0.0039 in)

End float of gear:

- Production limits ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,10/0,20 mm (0.004/0.008 in)

- with needle roller bearings ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,24/0,33 mm (0.009/0.013 in)

- Service limit... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,38 mm (0.015 in)

Backlash for all gears.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,08 mm (0.003 in) minimum

Idler gear and hub for the compressor

Number of teeth... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..32

Diameter of bore of gear.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..55,010/55,025 mm (2.1657/2.1663 in)

Outside diameter of hub .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..50,000/49,990 mm (1.9960/1.9975 in)

End float of gear with needle roller bearing fitted: ... ... ... ... ... ... ... ... ... ... ... ..0,12/0,16 mm (0.005/0.006 in)

Backlash gear.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,07 mm (0.003 in) mini mu m

2

Timing case front cover

Front cover oil seal depth ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..10,20/10,70 mm (0.402/0.421 in)

Cylinder block assembly

Cylinder block

Height between top and bottom faces. ... ... ... ... ... ... ... ... ... ... ... ... ..441,12/441,33 mm (17.367/17.375 in)

Diameter of parent bore for cylinder liner ... ... ... ... ... ... ... ... ... ... ... ... ..104,20/104,23 mm (4.103/4.104 in)

Depth of recess for flange of cylinder liner .. ... ... ... ... ... ... ... ... ... ... ... ... ... ..3,81/3,91 mm (0.150/0.154 in)

Diameter of recess for flange of cylinder liner. ... ... ... ... ... ... ... ... ... ... ..107,82/107,95 mm (4.245/4.250 in)

Diameter of cylinder bore, engine types AR and AS only ... ... ... ... ..103,000/103,025 mm (4.0551/4.0561 in)

Maximum permissible bore wear, engine types AR and AS only ... ... ... ... ... ... ... ... ... ... 0,15 mm (0.006 in)

Diameter of first oversize cylinder bore,

engine types AR and AS only.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..103,500/103,525 mm (4.0748/4.0757 in)

Diameter of second oversize cylinder bore,

engine types AR and AS only.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..104,000/104,025 mm (4.0944/4.0954 in)

Diameter of parent bore for main bearing ... ... ... ... ... ... ... ... ... ... ... ..80,416/80,442 mm (3.1660/3.1670 in)

Camshaft bore diameter

Four cylinder engines:

- Number 1 (for bush) .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..55,56/55,59 mm (2.188/2.189 in)

- Number 2... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..50,55/50,60 mm (1.990/1.992 in)

- Number 3... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..50,04/50,09 mm (1.970/1.972 in)

Six cylinder engine s:

- Number 1 (for bush) .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..55,56/55,59 mm (2.188/2.189 in)

- Number 2... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..50,55/50,60 mm (1.990/1.992 in)

- Number 3... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..50,29/50,34 mm (1.980.1.982 in)

- Number 4... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..50,04/50,09 mm (1.970/1.972 in)

Bore of bush for number 1 camshaft journal ... ... ... ... ... ... ... ... ... ... ... ... ..50,79/50,85 mm (2.000/2.002 in)

Workshop Manual, TPD 1350E, Issue 4 25

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This document has been printed from SPI². Not for Resale

Cylinder liners

Type:

- Production ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. Dry, interference fit, flanged, with flame ring

- Service. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...Dry, transition fit, flanged, with flame ring

- Partially finished liner... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. Dry, interference fit, flanged, with flame ring

Outside diameter of production liner.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... 104,25/104,28 mm (4.105/4.106 in)

Interference fit of production liner .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,03/0,08 mm (0.001/0.003 in)

Inside diameter of production liner. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..100,00/100,025 mm (3.937/3.938 in)

Transition fit of service liner... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...+/- 0,03 mm (+/- 0.001 in)

Inside diameter of service liner with a flame ring (fitted) ... ... ... ... ... ... ..100,00/100,063 mm (3.937/3.939 in)

Maximum permissible wear of liner bore ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,25 mm (0.010 in)

Thickness of flange ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 3,81/3,86 mm (0.150/0.152 in)

Relative position of top of liner flange to top face of cylinder block ... ... ... ... ... ... ...0,10 mm (0.004 in) above

Relative position of top of liner flange to top face of cylinder block ... ... ... ... ... ... ... 0,10 mm (0.004 in) below

New 1000 Series

Cylinder liner specifications

Caution: Specialist training and equipment is needed to machine the finish of a partially finished liner. For
further information contact your nearest Perkins Distributor.

Partially finished liner

Interference fit of liner in parent bore. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,025/0,076 mm (0.003/0.001 in)

Inside diameter of partially machined liner. ... ... ... ... ... ... ... ... ... ... ... 99,162/99,415 mm (3.9040/3.9139 in)

Preliminary bore

Final size of liner before it is honed ... ... ... ... ... ... ... ... ... ... ... ... ... ... 99,873/99,924 mm (3.9320/3.9340 in)

Surface finish . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. Ra 3,2 to 4,0 micrometers

Maximum ovality and taper ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,02 mm (0.0008 in)

Diamond hone

Hone angle (cross hatch)... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 35°

Finish size, diamond honed... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..99,95 mm (3.9350 in)

Surface finish . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. Ra 2,2 to 3,0 micrometers

Maximum ovality and taper ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,012 mm (0.0005 in)

Silicone carbide base hone

Hone angle (cross hatch)... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 35°

Finish size, silicon carbide base hone ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..100,012 mm (3.9374 in)

Surface finish . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. Ra 1,3 to 1,6 micrometers

Maximum ovality and taper ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,010 mm (0.0004 in)

Silicone carbide plateau hone

Final finish size, silicon carbide (plateau hone) . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..100,017 mm (3.9376 in)

Final surface finish grade... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,65/1,3 micrometers

26 Workshop Manual, TPD 1350E, Issue 4

New 1000 Series

This document has been printed from SPI². Not for Resale

2

Cylinder bore specifications (engine types AR and AS)

Note: Two oversize pistons are available in service:- 0,5 mm (0.020 in) and 1,0 mm (0.040 in).

Caution: Specialist training and equipment is needed to machine the cylinder bore. For further information
contact your nearest Perkins Distributor.

Preliminary bore

Final size of standard bore before it is honed.. ... ... ... ... ... ... ... ... ..102,873/102,924 mm (4.0501/4.0521 in)

First oversize of bore before it is honed .. ... ... ... ... ... ... ... ... ... ... ..103,373/103,424 mm (4.0698/4.0718 in)

Second oversize of bore before it is honed . ... ... ... ... ... ... ... ... ... ..103,873/103,924 mm (4.0894/4.0914 in)

Surface finish... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .Ra 3,2 to 4,0 micrometers

Maximum ovality and taper.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,02 mm (0.0008 in)

Diamond hone

Hone angle (cross hatch) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .35°

Finish size of standard bore, diamond honed.. ... ... ... ... ... ... ... ... ..102,949/102,961 mm (4.0531/4.0536 in)

Finish size of first oversize of bore, diamond honed ... ... ... ... ... ... ..103,449/103,461 mm (4.0727/4.0732 in)

Finish size of second oversize of bore, diamond honed.. ... ... ... ... ..103,949/103,961 mm (4.0924/4.0929 in)

Surface finish... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .Ra 2,2 to 3,0 micrometers

Maximum ovality and taper.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,012 mm (0.0005 in)

Silicone carbide base hone

Hone angle (cross hatch) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .35°

Finish size of standard bore, silicon carbide base hone.. ... ... ... ... ..103,000/103,025 mm (4.0551/4.0561 in)

Finish size of first oversize of bore, silicon carbide honed .. ... ... ... ..103,500/103,525 mm (4.0748/4.0757 in)

Finish size of second oversize of bore, silicon carbide honed. ... ... ..104,000/104,025 mm (4.0944/4.0954 in)

Surface finish... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .Ra 1,3 to 1,6 micrometers

Maximum ovality and taper.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,010 mm (0.0004 in)

Silicone carbide plateau hone

Final finish size of standard bore,

silicon carbide (plateau hone).. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..103,000/103,025 mm (4.0551/4.0561 in)

Final finish size of first oversize of bore,

silicon carbide (plateau hone).. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..103,500/103,525 mm (4.0748/4.0757 in)

Final finish size of second oversize of bore,

silicon carbide (plateau hone).. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..104,000/104,025 mm (4.0944/4.0954 in)

Final surface finish grade ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...Ra 0,65/1,3 micrometers

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This document has been printed from SPI². Not for Resale

New 1000 Series

Turbocharger

The make and type of turbocharger fitted is marked on the turbocharger identification plate; as a general guide
the make and type of turbocharger fitted are as follows:

4 Cylinder engines . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . Garrett T20

6 Cylinder engines . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . Garrett T32

Waste-gate test pressure for rod movement of 1,00 mm (0.039 in)
The turbocharger part number is on the turbocharger identification plate, which is fitted to the body of the

turbocharger.

Turbocharger

part number

2674A089 150 21.8 1,53
2674A092 150 21.8 1,53
2674A093 110 15.9 1,11
2674A094 105 15.2 1,07
2674A095 145 21.0 1,48
2674A096 150 21.8 1,53
2674A097 138 20.0 1,40
2674A098 96 13.9 0,97
2674A099 107 15.5 1,09
2674A304 105 15.2 1,07
2674A305 105 15.2 1,07
2674A306 138 20.0 1,40
2674A307 150 21.8 1,53
2674A308 96 13.9 0,97
2674A311 145 21.0 1,48
2674A313 96 13.9 0.97
2674A314 145 21.0 1,48
2674A315 150 21.8 1,53
2674A316 96 13.9 0,97
2674A318 110 15.9 1,11
2674A319 96 13.9 0,97
2674A326 105 15.2 1,07
2674A327 145 21.0 1,48
2674A328 96 13.9 0,97

(kPa)
(+/-5)

Waste-gate pressure

2

(lbf/in

(+/-0.72)

)

(kgf/cm2)

(+/-0,05)

28 Workshop Manual, TPD 1350E, Issue 4

New 1000 Series

This document has been printed from SPI². Not for Resale

2

Lubrication system

Oil filter

Type. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...Full flow, screw-on type canister

Pressure to open by-pass valve in filter... ... ... ... ... ... ... ... ... ... ... ... 55/83 kPa (8/12 lbf/in2) 0,6/0,8 kgf/cm

Pressure to open by-pass valve in oil cooler... ... ... ... ... ... ... ... ... ... ... ... ... 172 kPa (25 lbf/in2) 1,8 kgf/cm

Lubricating oil pump - four cylinder engines

Type. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .Differential rotor, gear driven

Number of lobes .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .Inner rotor 6, outer rotor 7

Clearance of outer rotor to body:

- Without balancer unit. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,15/0,34 mm (0.006/0.013 in)

- With balancer unit.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,31/0,45 mm (0.012/0.017 in)

Clearance of inner rotor to outer rotor . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,04/0,13 mm (0.0015/0.0050 in)

End-float of rotor assembly.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,03/0,10 mm (0.001/0.004 in)

Lubricating oil pump - six cylinder engines

Type. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .Differential rotor, gear driven

Number of lobes:

- Inner rotor.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 4

- Outer rotor. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 5

Clearance of outer rotor to body.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,15/0,34 mm (0.006/0.013 in)

Clearance of inner rotor to outer rotor . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,04/0,13 mm (0.0015/0.0050 in)

End clearance (naturally aspirated engines)

2
2

- Inner rotor.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,05/0,12 mm (0.002/0.005 in)

- Outer rotor. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,04/0,11 mm (0.0015/0.0044 in)

End clearance (turbocharged engines)

- Inner rotor.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,043/0,118 mm (0.0017/0.0046 in)

- Outer rotor. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,031/0,106 mm (0.0012/0.0042 in)

Idler gear for lubricating oil pump

End float:

- Four cylinder engines ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,012/0,643 mm (0.0005/0.0253 in)

- Six cylinder engines .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,020/0,650 mm (0.0008/0.0256 in)

Inside diameter of bush (fitted) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..22,23/22,26 mm (0.875/0.866 in)

Outside diameter of idler shaft. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..22,19/22,21 mm (0.873/0.874 in)

Clearance of bush of idler gear on shaft.. ... ... ... ... ... ... ... ... ... ... ... ... ..0,020/0,066 mm (0.0008/0.0026 in)

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Oil pressure relief valve (standa rd)

Diameter of bore for plunger.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 18,24/18,27 mm (0.718/0.719 in)

Outside diameter of plunger... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 18,16/18,18 mm (0.715/0.716 in)

Clearance of plunger in bore.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,06/0,11 mm (0.002/0.004 in)

Length of spring (fitted):

- Four cylinder engines .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..59,8 mm (2.4 in)

- Six cylinder engines. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..55,6 mm (2.2 in)

Load on spring (fitted):

- Four cylinder engines .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 15,9/23,1 N (3.6/5.2 lbf) 1,6/2,4 kgf

- Six cylinder engines. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 12,9/18,6 N (2.9/4.2 lbf) 1,3/1,9 kgf

Pressure to open valve (Four cylinder engines):

- Without piston cooling jets... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 340/395 kPa (49/57 lbf/in

- With piston cooling jets ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 415/470 kPa (60/68 lbf/in2) 4,2/4,8 kgf/cm

- Six cylinder engines. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 345/414 kPa (50/60 lbf/in2) 3,5/4,2 kgf/cm

Oil pressure relief valve (with balancer)

Diameter of bore for plunger.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 16,00/16,03 mm (0.630/0.631 in)

Outside diameter of plunger... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 15,95/15,98 mm (0.628/0.629 in)

Clearance of plunger in bore.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,02/0,08 mm (0.0008/0.003 in)

Length of spring (fitted).. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..42,7 mm (1.7 in)

Load on spring (fitted) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 34/38 N (7.6/8.5 lbf) 3,5/3,9 kgf

Pressure to open valve .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..523 kPa (76 lbf/in

New 1000 Series

2

) 3,4/4,0 kgf/cm

2

) 5,3 kgf/cm

2
2
2

2

Fuel system

Bosch fuel injection pump

Type... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... EPVE, pin timed, with a locking screw

Direction of rotation from drive end ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Clockwise from drive end

Lucas/Delphi fuel injection pump

Make.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . Lucas/Delphi DP200 Series, pin timed, with a locking screw

Direction of rotation ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Clockwise from drive end

Stanadyne fuel injection pump

Type... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..Stanadyne DB2 or DB4, pin timed

Direction of rotation from drive end ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Clockwise from drive end

Fuel lift pump - four cylinder engines

Type... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . Diaphragm, A.C.Delco, type XD

Method of drive .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .Eccentric on camshaft of engine

Static pressure (no delivery).. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..42/70 kPa (6/10 lbf/in

Test pressure (75% of minimum static pressure) .. ... ... ... ... ... ... ... ... ... ... .31 kPa (4.5 lbf/in2) 0,32 kgf/cm

Fuel lift pump - Six cylinder engines

Type... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..Diaphragm, A.C.Delco, type LU

Method of drive .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .Eccentric on camshaft of engine

Static pressure (no delivery).. ... ... ... ... ... ... ... ... ... ... ... ... ... ..34,5/55,2 kPa (5/8 lbf/in

Test pressure (75% of minimum static pressure) .. ... ... ... ... ... ... ... ... ... ...26 kPa (3.75 lbf/in2) 0,26 kgf/cm

2

) 0,4/0,7 kgf/cm

2

) 0,35/0,56 kgf/cm

2
2

2
2

Fuel filter

Type... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Twin parallel flow or single element

30 Workshop Manual, TPD 1350E, Issue 4

New 1000 Series

This document has been printed from SPI². Not for Resale

2

Atomiser service setting

The code letters are stamped on the side of the atomiser body just below the connection for the nut of the high
pressure pipe.

Code Holder Nozzle

KB 2645A308 2645A624 300 4410 30,4
KC 2645A309 2645A625 290 4263 29,4
KD 2645A310 2645A626 290 4263 29,4
KE 2645A311 2645A627 290 4337 29,9
KF 2645A311 2645A628 295 4337 29,9
KG 2645A314 2645A629 300 4410 30,4
KH 2645A314 2645A630 290 4263 29,4

KJ 2645A315 2645A631 250 3675 25,3
KK 2645A312 2645A632 300 4410 30,4
KL 2645A312 2645A633 300 4410 30,4

KM 2645A313 2645A634 300 4410 30,4
KN 2645A315 2645A635 290 4263 29,4

KP 2645A311 2645A636 290 4410 30,4

KR 2645A311 2645A608 290 4263 29,4

KT 2645A311 2645A638 290 4263 29,4
KS 2645A316 2645A637 290 4263 29,4

KU 2645A317 2645A627 290 4322 29,8

KV 2645A304 2645L615 250 3675 25,3

KW 2645A311 2645K609 290 4263 29,4
NX 2645L306 2645L617 290 4263 29,4
NY 2645L308 2645L618 290 4263 29,4

NZ 2645L307 2645L619 290 4263 29,4
PA 2645L309 2645L620 290 4263 29,4
PB 2645L310 2645L621 290 4263 29,4

PC 2645L310 2645L622 290 4263 29,4
PD 2645L310 2645L622 275 4043 27,9

RZ 0430 133 005 DSLA140P707 250 3675 25,3
SA 2645F316 2645F620 250 3675 25,3
SB 2645F316 2645F621 250 3675 25,3

SC 043013306 DSLA150PV3378123 250 3675 25,3

Set and reset pressure

atm (lbf/in

2

)MP

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New 1000 Series

Cooling system

Coolant pump, early gear driven pump

Type... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. Centrifugal

Outside diameter of shaft... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 18,95/18,96 mm (0.7460/0.7465 in)

Diameter of bore of drive gear... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 18,90/18,92 mm (0.7441/0.7449 in)

Interference fit of drive gear on shaft. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,03/0,06 mm (0.0012/0.0024 in)

Diameter of bore of impeller... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 15,87/15,89 mm (0.6249/0.6257 in)

Outside diameter of shaft for impeller ... ... ... ... ... ... ... ... ... ... ... ... ... ... 15,91/15,92 mm (0.6264/0.6268 in)

Interference fit of impeller on shaft. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,02/0,05 mm (0.0007/0.0020 in)

Diameter of bore for bearing.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 38,06/38,08 mm (1.4983/1.4993 in)

Diameter of bearing ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 38,09/38,10 mm (1.4995/1.5000 in)

Interference fit of bearing in pump body ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,01/0,04 mm (0.0004/0.0016 in)

Dimension of impeller boss to front face of pump body (fitted).. ... ... ... ... ... ... ...7,7/8,0 mm (0.303./0.315 in)

Dimension of gear from rear flat face of pump body (fitted)... ... ... ... ... ... ... ... 21,0/21,5 mm (0.827/0.846 in)

Dimension of gear from rear face of bearing (fitted).. ... ... ... ... ... ... ... ... ... ... 0,47/1,53 mm (0.018/0.060 in)

Coolant pump, latest gear driven pump

Type... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. Centrifugal

Coolant pump, belt driven

Type... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. Centrifugal

Outside diameter of shaft for pulley ... ... ... ... ... ... ... ... ... ... ... ... ... ... 24,587/24,600 mm (0.9679/0.9685 in)

Inside diameter of bore of pulley ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 24,628/24,648 mm (0.9696/0.9704 in)

Clearance fit of pulley on shaft... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,03/0,06 mm (0.001/0.002 in)

Diameter of bore of impeller... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 15,872/15,893 mm (0.6248/0.6257 in)

Outside diameter of shaft for impeller ... ... ... ... ... ... ... ... ... ... ... ... 15,9055/15,9182 mm (0.6263/0.6267 in)

Interference fit of impeller on shaft. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,01/0,04 mm (0.0004/0.0016 in)

Impeller to body clearance. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,69/0,89 mm (0.027/0.035 in)

Impeller to body clearance, engine type AS .. ... ... ... ... ... ... ... ... ... ... ... ... ... 0,20/0,60 mm (0.008/0.024 in)

Diameter of bearing ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..62,000 mm (2.440 in)

Diameter of bore for bearing.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..62,019/62,000 mm (2.441/24.000 in)

Interference fit of bearing in pump body ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,01/0,04 mm (0.0004/0.0016 in)

Fan drive housing

Bore of housing for bearing ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 41,9655/41,9785 mm (1.6529/1.6522 in)

Outside diameter of bearing... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..41,987/42,00 mm (1.6535/1.6530 in)

Interference fit of bearing in housing.. ... ... ... ... ... ... ... ... ... ... ... ... 0,0085/0,0345 mm (0.00136/0.00033 in)

Bore of hub ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 21,938/21,958 mm (0.8637/0.8645 in)

Outside diameter of shaft... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 21,987/22,000 mm (0.8656/0.8661 in)

Interference fit of shaft in hub ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,029/0,062 mm (0.0011/0.0024 in)

Maximum permissible end-float of shaft ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,200 mm (0.0079 in)

32 Workshop Manual, TPD 1350E, Issue 4

New 1000 Series

This document has been printed from SPI². Not for Resale

2

Thermostat

Type:

- Single ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Wax element, by-pass blanking

- Twin... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Wax element, by-pass blanking

Part number

2485613

2485604

2485C023

2485C025

Nominal temperature

stamped on thermostat

by-pass valve

82 °C

(180 °F)

82 °C

(180 °F)

82 °C

(180 °F)

82 °C

(180 °F)

"Start to open"

temperature

77/85 °C

(170/185 °F)

77/85 °C

(170 /185 °F)

80/84 °C

(176/183 °F)

80/84 °C

(176/183 °F)

"Fully open"

temperature

92/98 °C

(198/208 °F)

92/98 °C

(198/208 °F)

96 °C

(205 °F)

96 °C

(205 °F)

Flywheel and housing

Limits for flywheel housing run-out and alignment (total indicator reading)

Diameter of housing flange bore Maximum limit (total indicator reading)

mm in mm in

362 14.25 0,23 0.009
410 16.14 0,25 0.010
448 17.63 0,28 0.011
511 20.11 0,30 0.012
584 22.99 0,36 0.014
648 25.51 0,41 0.016
787 30.98 0,48 0.019

Minimum valve

lift, fully open

9 mm

(0.35 in)

9 mm

(0.35 in)

9 mm

(0.35 in)

9 mm

(0.35 in)

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New 1000 Series

Electrical equipmen t

Alternators
Note: The information which follows is general and can change with specific applications.

Make and type ... ... ... ... ... ... ... ... ... Lucas/Delphi, AC5RS / Magneti Marelli, A127 / Bosch KI and Bosch NI

Rating:

- Lucas/Delphi AC5RS... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..24V/55A

- Magneti Marelli A127... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 12V/55A or 12V/65A or 12V/72A

- Bosch KI .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..12V/55A

- Bosch NI.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..24V/55A

Rotation.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Clockwise from drive end

Starter motors
Note: The information which follows is general and can change with specific applications.

Make and type ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..Lucas/Delphi S115 or Magneti Marelli M127 or Bosch JF

Voltage:

- Lucas/Delphi S115... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..12V or 24V

- Magneti Marelli M127 .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 12V

- Bosch JF.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..12V or 24V

Number of teeth on pinion.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 10

Maximum starter cable resistance at 200 °C (680 °F):

- 12. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...0.0017 ohms

- 24V .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...0.0034 ohms

Starting aids

The information which follows is general and can change with specific applications.

Type... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...Electrically operated heater, with a fuel supply

Voltage... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..12V (dropping resistor used on 24V system)

Flow rate of fuel through starting aid.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 3,5/5,9 ml/min

Auxiliary equipment

Compressor

Type... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...Bendix 1W150R or 1W250R

Number of teeth on compressor drive gear ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 28

Taper of compressor drive shaft ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...1 in 8

34 Workshop Manual, TPD 1350E, Issue 4

New 1000 Series

This document has been printed from SPI². Not for Resale

2

Thread sealant

When setscrews or studs are fitted into holes which are tapped through the cylinder block, a suitable sealant
must be used to prevent leakage.

Micro encapsulated anaerobic sealant (M.E.A.S) fasteners have been introduced instead of jointing
compounds or other sealants when the fasteners are fitted in through holes into oil or coolant passages. The
identification of these fasteners, as supplied, is by a red, blue, or other colour sealant around the fastener
threads.

With M.E.A.S. sealed studs, the sealed end must be fitted into the cylinder head / cylinder block etc. Ensure
that the threaded holes have a 1,59 mm (0.0625 in) 45° chamfer, to ensure that when the new fasteners are
fitted the M.E.A.S. sealant is not removed. If the fasteners have to be removed and fitted again, the threads
must be cleaned and a suitable sealant used.

Note: New setscrews have sealant applied by the manufacturer to the first 13,0 mm (0.50 in) of the threads.
If the setscrews are to be used again, clean the old sealant from the male and female threads and apply new
sealant to the setscrews.

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New 1000 Series

Standard torque tensions

Most of the torque tensions on the engine are standard. Special torque tensions are listed in the separate
special torque tables. The standard torque tensions listed in the tables below can be used when a special
torque is not necessary.

The torque tensions below apply to components lubricated lightly with clean engine oil before they are fitted.

Standard torques for setscrews and nuts

Thread size

M6 x 1,00 9 7 0,9

M8 x 1,25 22 16 2,2
M10 x 1,50 44 33 4,5
M12 x 1,75 78 58 8,0
M14 x 2,00 124 91 12,6
M16 x 2,00 190 140 19,3

Standard torques for studs (metal end)

Thread size

M6 x 1,00 5 4 0,5

M8 x 1,25 11 9 1,1
M10 x 1,50 18 14 1,8
M12 x 1,75 25 19 2,5

Standard torques for pipe unions, plugs, and adaptors

Thread size

(Inches)

1/8 PTF 9 7 0,9
1/4 PTF 17 13 1,7
3/8 PTF 30 23 3,0
3/4 PTF 45 35 4,5

Nm lbf ft kgf m

Nm lbf ft kgf m

Nm lbf ft kgf m

Torque

Torque

Torque

36 Workshop Manual, TPD 1350E, Issue 4

New 1000 Series

This document has been printed from SPI². Not for Resale

2

Specific torque tensions

The torque tensions below apply to components lubricated lightly with clean engine oil before they are fitted.

Special torques for setscrews and nuts

Description

Cylinder head assembly

Setscrews, cylinder head 1/2 UNF see Operation 3-13
Setscrews, cylinder head (Engine types AR and AS)
Fasteners, rocker shaft brackets:

- Aluminium brackets M12 40 30 4,1

- Cast iron and sintered steel brackets M12 75 55 7,6
Cap nuts, composite plastic rocker cover M12 20 15 2,1
Cap nuts, aluminium rocker cover M12 30 22 3,0
Setscrews, inlet manifold to cylinder head M10 44 33 4,5
Setscrews, inlet manifold to cylinder head M8 22 16 2,2
Setscrews, exhaust manifold to cylinder head M10 33 24 3,4
Setscrews, engine lift bracket M10 44 33 4,5

Piston and connecting rod assemblies

Nuts, connecting rods 1/2 UNF 125 92 12,7
Setscrews, connecti ng rods 1/2 UNF 152 114 15,8
Banjo bolts, piston cooling jets 3/8 UNF 27 21 2,7

Crankshaft assembly

Setscrews, main bearings 5/8 UNF 265 196 27,0
Setscrews, crankshaft pulley 7/16 UNF 115 85 11,8
Setscrews, viscous damper to crankshaft pulley M12 75 55 7,6
Cap screws, viscous damper to crankshaft pulley M8 35 26 3,6
Cap screws, crankshaft bonded damper to crankshaft

pulley
Setscrews, rear oil seal housing to cylinder block M8 22 16 2,2
Cap screws, bridge piece to cylinder block M6 16 12 1,6
Cap screws, rear oil seal housing to bridge piece M6 13 10 1,3
Torxscrew, rear oil seal housing to bridge piece M8 22 16 2,2
Setscrew, idler gear hub of balancer unit M12 93 68 9,5
Nut, drive gear of balance weight 1/2 UNF 82 60 8,4
Setscrews, rear cover of balancer frame M10 54 40 5,5
Setscrews, oil transfe r pla te (ba lancer unit) M10 30 22 3,1
Setscrews, oil pump to balancer frame M8 27 20 2,8
Setscrews, balancer to cylinder block M10 54 40 5,5

Timing case and drive assembly

Setscrews, tim ing case to cylinder blo ck M8 22 16 2,2
Setscrews, timing case to cyli nde r block M10 44 33 4,5
Setscrews, hub of idler gear M10 44 33 4,5
Setscrew, camshaft gear M12 95 74 9,5
Setscrews, timing case cover to timing case M8 22 16 2,2
Nuts, timing case cover to timing case M8 22 16 2,2

Thread

size

M10

1/2 UNF

M8 35 26 3,6

Nm lbf ft kgf m

Torque

see Operation 3-14

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New 1000 Series

Description

Cylinder block

Setscrews, fitted instead of piston cooling jet(s) 3/8 UNF 27 21 2,7

Fuel system

Nuts, high-pressure fuel pipes M12 22 16 2,2
Bolt banjo, leak-off connection M8 9 7 0,9
Gland nut, atomiser body - 40 30 4,1
Setscrews, for the gear of the fuel injection pump M10 28 20 2,8
Torxscrew, for the gear of the fuel injection pump M10 28 20 2,8
Setscrews, fuel lift pump M8 22 16 2,2
Nuts for flange of fuel injection pump M8 22 16 2,2
Locking screw of Bosch VE fuel injection pump M10 27 20 2,8
Locking screw of DP 200 fuel injection pump 10 A/F 10 7 1

Lubrication system

Plug, lubricating oil sump 3/4 UNF 34 25 3,5
Setscrews, oil pump to front bearing cap M8 22 16 2,2
Setscrews, cover for oil pump M8 28 21 2,9
Fasteners, lubricating oil sump M8 22 16 2,2

Cooling system

Nut, drive pulley for coolant pump
(Engine types AP, AQ, AS)

Nut, water pump pulley 5/8 UNF 77 56 7.9
Setscrews, fan drive housing to timing case M10 44 33 4,5
Setscrews, fan drive pulley to hub M8 22 16 2,2
Setscrews, fan drive pulley to hub M10 44 33 4,5
Setscrews, fan M8 22 16 2,2
Connector, oil cooler to oil filter head 3/4 UNF 57 42 5,8
Setscrews, coolant pump to body of pump

(Engine type AS)
Screw, cassette type cooler to oil filter head 3/4 UNF 37 29 3,7
Temperature switch (plastic thermostat housing) - 4 3 0,4
Plug (plastic thermostat housing) 1/2 NPSI 4 3 0,4
Plug (plastic thermostat housing) 3/4 NPSI 4 3 0,4

Flywheel and housing

Setscrews, flywheel to crankshaft 1/2 UNF 105 77 10,7
Setscrews, cast iron flywheel housing to cylinder block: M10 44 33 4,5

- Head stamped 8.8 M12 75 55 7,6

- Head stamped 10.9 M10 63 46 6,4

- Head stamped 10.9 M12 115 85 11,7
Setscrews, aluminium flywheel housing to cylinder block M10 70 52 7,1
Setscrews, flywheel housing to cylinder block (paper joint) M10 70 52 7,1

Aspiration system

Nuts, turbocharger to manifold M10 44 33 4,5

Thread

size

M8 22 16 2,2

M8 29 21 2,9

Nm lbf ft k g f m

Torque

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New 1000 Series

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2

Description

Electrical equipment

Nut, alternator pulley:

- CAV AC5RA and AC5RS 5/8 UNF 55 40 5,6

- Thin nut A127, and motorola pulley, 22 mm A/F M17 80 59 8,2

- Thick nut A127, and motorola pulley, 24 mm A/F M17 80 59 8,2

- Bosch 55A M14 50 37 5,1

- Bosch 55A M16 50 37 5,1

- Butec 5524 5/8 UNF 55 40 5,6
Setscrew, adjusting lever to alternator M8 11 8 1,1
Setscrew, adjusting lever to bracket M8 11 8 1,1
Nut, adjusting lever retaining 3/8 UNF 37 29 3,7
Setscrew, adjusting lever alternator 3/8 UNF 37 29 3,7
Bolt, alternator to bracket 7/16 UNF 60 44 6,1
Nut, alternator retaining 7/16 UNF 60 44 6,1
Fuelled start aid to induction manifold 7/8 UNF 31 23 3,1
Port heater to induction manifold M22 60 44 6,1
Nut/screw, starter motor 3/8 UNF 30 23 3,0

Auxiliary equipment

Nut, compressor drive gear to compressor crankshaft 5/8 UNF 120 93 12,0
Nut, (30 A/F) Compressor gears M20 130 101 13,0
Cap screw, bracket to idler hub M10 60 47 6,0
Cap screw, bracket to timing case M8 35 27 3,5
Setscrew, RHS power take off blanking plate (composite) M10 16 12 1,6

Thread

size

Nm lbf ft kgf m

Torque

Workshop Manual, TPD 1350E, Issue 4 39

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New 1000 Series

Compression test data

Tests have shown that many factors affect compression pressures. Battery and starter motor condition,
ambient conditions and the type of gauge used can give a wide variation of results for a given engine.

It is not possible to give accurate data for compression pressure, but tests have shown that the results should
be within 2000/3500 kPa (300/500 lbf/in

Compression tests should only be used to compare between the cylinders of an engine. If one or more
cylinders vary by more than 350 kPa (50 lbf/in

Compression tests should not be the only method used to show the condition of an engine, but they should be
used together with other symptoms and tests.

How to do a compression test

Caution: Before the compression test, ensure that the battery is in good condition and that it is fully charged.
Also ensure that the starter motor is in good condition.

1 Ensure that the valve tip clearances are set correctly, see Operation 3-6 for four cylinder engines or
Operation 3-7 for six cylinder engines.

2 Remove the atomisers.
3 Fit a suitable gauge into the atomiser hole of the cylinder to be tested.

Caution: Ensure that the engine cannot start:

4 Disconnect the stop solenoid or put the stop control in the no-fuel position.
5 Operate the starter motor and note the pressure indicated on the gauge.
6 Repeat for each cylinder.

2

) 21,0/35,0 kgf/cm2 for diesel engines.

2

) 3,5 kgf/cm2, then those cylinders may be faulty.

40 Workshop Manual, TPD 1350E, Issue 4

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3

Cylinder head assembly 3

General description

In a diesel engine there is little carbon deposit and for this reason the number of hours run is no indication of
when to overhaul a cylinder head assembly. The factors which indicate when an overhaul is necessary are
how easily the engine starts and its general performance.

The cylinder head assembly has two valves fitted for each cylinder, each fitted with single valve springs.
The ports for the inlet and exhaust are on the right side of the cylinder head.
The face angle of the valves is either 45° or 30°. The angle of the valve seats in the cylinder head is either 46°

or 31°.
The valves move in phosphated steel guides which can be renewed. The exhaust valve guide has a

counterbore to prevent seizure of the valve stem caused by a build up of carbon under the head of the valve.
Both valve stems are fitted with oil seals that fit over the top of the valve guides.
The engines have steel valve seat inserts fitted in the cylinder head for both inlet and exhaust valves.

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New 1000 Series

Rocker cover

To remove Operation 3-1

Note: Engines are supplied with rocker covers (A or B) made of a plastic material or aluminum.
1 Disconnect the breather pipe.

2 Remove the cap nuts and rubber seal (A1 or B1) from the top of the rocker cover and remove the heat shield,

if one is fitted.
3 Lift off the rocker cover and the joint.

Caution: When the rocker cover is fitted, the cap nuts are tightened onto the nuts of the rocker brackets.
During removal of the cap nuts, it is possible to loosen the nuts of the rocker brackets. The nuts of the rocker
brackets should be tightened to the correct torque every time the cover is removed.

1

A

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To fit Operation 3-2

Note: Reflective heat shields fitted to plastic rocker covers must be kept clean and free from dust, oil or paint.

If the surface of the heat shield is not shiny, the rocker cover protected by the heat shield could be damaged.
1 Check the seal of the oil filler cap (A1 or B4) and the sealing washers (A3 or B3) for the cap nuts (A2 or B1).

Warning! The rocker cover joint may be made from viton, see "Viton seals" on page 6 for safety precautions.

2 Check the condition of the rocker cover joint (A4). If necessary, the joint can be removed and renewed.
3 Clean the joint face of the cylinder head and fit the rocker cover.
4 Fit the sealing washers, the heat shield, if one is fitted, and the cap nuts.

Caution: Damage to the sealing washer can occur if the cap nut is not tightened centrally through the sealing
washer and the rocker cover. If the sealing washer is damaged, it must be renewed.

5 Tighten the rocker cover cap nuts to:

l 20 Nm (15 lbf ft) 2,1 kgf m for plastic covers
l 30 Nm (22 lbf ft) 3,0 kgf m for aluminium covers.

6 Fit the breather pipe.

1

5

4

A

Workshop Manual, TPD 1350E, Issue 4 43

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3

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B

4

1
2

3

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New 1000 Series

Rocker ass embly

To remove and to fit Operation 3-3

To remove
1 Remove the rocker cover, see Operation 3-1.

2 Release evenly and gradually the fasteners of the rocker shaft brackets; begin with the end brackets and

move toward the centre. Remove the fasteners and lift off the rocker assembly.

3 Remove the rubber oil seal (A) from the oil supply connection or from the oil supply hole in the cylinder head.

To fit
1 Fit a new rubber oil seal in the oil supply hole in the cylinder head.

2 Check that the push rods fit correctly in the sockets of the tappets. Fit the rocker assembly; ensure that the

oil supply connection is fitted correctly into the oil seal. Check that the ends of the adjustment screws fit
correctly in the sockets of the push rods.

3 Fit the fasteners of the rocker shaft brackets and tighten the fasteners evenly and gradually; begin with the
inner fasteners and work towards the end fasteners. Tighten the fasteners evenly to the correct torque
according to the material of the rocker shaft brackets:

Type

Aluminium 40 30 4,1
Cast iron 75 55 7,6
Sintered steel 75 55 7,6

4 Check and adjust the valve tip clearances, see Operation 3-6 for four cylinder engines or Operation 3-7 for
six cylinder engines.

Nm lbf ft kgf m

Torque

A

44 Workshop Manual, TPD 1350E, Issue 4

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3

To dismantle and to assemble Operation 3-4

To dismantle
1 Remove the clips from both ends of the rocker shaft. Ensure that the ends of the rocker shaft are not

damaged. Release the location screw (A1) for the oil supply connection.
2 Dismantle the assembly and make a note of the position of each component to ensure that they can be

assembled more easily.

To assemble
1 Ensure that the oil holes in the rocker shaft and in the rocker levers are not restricted.

2 Lubricate the components with clean engine lubricating oil before assembly. Assemble the components in

the correct order with the arrows (A2) on the pedestals in the position shown. Ensure that the location screw
(A1) for the oil supply connection is fitted correctly in the rocker shaft. Fit the clips to the ends of the rocker
shaft.

To inspect and to correct Operation 3-5

To inspect
1 Clean and inspect all the components for wear and any other damage. Check the clearance of the rocker

levers on the rocker shaft. If the clearance is larger than 0,13 mm (0.005 in), renew the rocker lever bush and/
or the rocker shaft.

To correct
1 To renew the rocker lever bush, press out the old bush with a suitable mandrel.

2 Align the lubrication hole of the new bush on the same side as the rocker lever lubrication hole and press

the bush into position.
3 Ream the bush in the rocker lever to give a clearance on the rocker shaft of 0,03/0,09 mm (0.001/0.004 in).

Clean thoroughly the bush and check that the oil hole is free from debris.

2

1

A

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New 1000 Series

Valve tip clearances

To check and to adjust (four cylinder engines) Operation 3-6

Notes:

l The valve tip clearance is measured between the top of the valve stem and the rocker lever (A). With the

engine hot or cold, the correct clearances are 0,20 mm (0.008 in) for the inlet valves and 0,45 mm (0.018 in)
for the exhaust valves. The valve positions are shown at (B).

l The sequence of valves from number 1 cylinder is shown in the table below. Number 1 cylinder is at the

front of the engine.

l The adjusting screws on early engines have a screwdriver slot, later engines have a female Torx drive. Both

types are interchangea ble .

1 Rotate the crankshaft in the normal direction of rotation until the inlet valve (B7) of number 4 cylinder has
just opened and the exhaust valve (B8) of the same cylinder has not closed completely. Check the clearances
of the valves (B1 and B2) of number 1 cylinder and adjust them, if necessary.

2 Set the valves (B3 and B4) of number 2 cylinder as indicated above for number 4 cylinder. Then check /
adjust the clearances of the valves (B5 and B6) of number 3 cylinder.

3 Set the valves (B1 and B2) of number 1 cylinder. Then check / adjust the clearances of the valves (B7 and
B8) of number 4 cylinder.

4 Set the valves (B5 and B6) of number 3 cylinder. Then check / adjust the clearances of the valves (B3 and
B4) of number 2 cylinder.

Cylinder

and

Valve number

Valve

I = Inlet

E = Exhaust

1234

12345678

IEIEIEIE

12 34 56 78

A

46 Workshop Manual, TPD 1350E, Issue 4

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New 1000 Series

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3

To check and to adjust (six cylinder engines) Operation 3-7

Notes:

l The valve tip clearance is measured between the top of the valve stem and the rocker lever (A). With the

engine hot or cold, the correct clearances are 0,20 mm (0.008 in) for the inlet valves and 0,45 mm (0.018 in)
for the exhaust valves. The valve positions are shown at (B).

l The sequence of valves from number 1 cylinder is shown in the table below. Number 1 cylinder is at the

front of the engine.

l The adjusting screws on early engines have a screwdriver slot, later engines have a female Torx drive. Both

types are interchangeable.

1 Rotate the crankshaft in the normal direction of rotation until the inlet valve (B11) of number 6 cylinder has
just opened and the exhaust valve (B12) of the same cylinder has not closed completely. Check the clearances
of the valves (B1 and B2) of number 1 cylinder and adjust them, if necessary.

2 Set the valves (B3 and B4) of number 2 cylinder as indicated above for number 6 cylinder. Then check /
adjust the clearances of the valves (B9 and B10) of number 5 cylinder.

3 Set the valves (B7 and B8) of number 4 cylinder. Then check / adjust the clearances of the valves (B5 and
B6) of number 3 cylinder.

4 Set the valves (B1 and B2) of number 1 cylinder. Then check / adjust the clearances of the valves (B11 and
B12) of number 6 cylinder.

5 Set the valves (B9 and B10) of number 5 cylinder. Then check / adjust the clearances of the valves (B3 and
B4) of number 2 cylinder.

6 Set the valves (B5 and B6) of number 3 cylinder. Then check / adjust the clearances of the valves (B7 and
B8) of number 4 cylinder.

Cylinder

and

Valve number

Valve

I = Inlet

E = Exhaust

123456

123456789101112

IEIEIEIEIEIE

12 34 56 78 9101112

A

Workshop Manual, TPD 1350E, Issue 4 47

A0049A

B

A0028

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New 1000 Series

Valve springs

To change the valve springs (with cylinder head fitted) Operation 3-8

Special requirements

Special tools

Descript i o n Part numb e r Desc r i p tion Part number

Valve spring compressor 21825666
Stud adaptor used with 21825666 21825931

Note: Steps 1 to 12 refer to a change of valve springs for a single cylinder.

Warning! Wear eye protection during this operation.

1 Remove the rocker cover, see Operation 3-1.
2 Rotate the crankshaft in the normal direction of rotation until the inlet valve of the relevant cylinder has just

opened and the exhaust valve has not fully closed. In this position the piston will be at approximately top dead
centre (TDC).

3 Remove the rocker assembly, see Operation 3-3.
4 Fit the valve spring compressor (A1) and the relevant adaptor (A2 or A3).
5 Compress the valve spring and remove the collets. Ensure that the valve spring is compressed squarely or

damage to the valve stem can occur.

Caution: Do not rotate the crankshaft while the valve springs are removed.

Setscrew adaptor used with 21825666 21825932

6 Release the valve spring compressor and remove the valve spring caps and valve spring.

Caution: The outer diameter of the exhaust valve guide is 1 mm larger than the inlet valve guide. To prevent
leakage past the inlet valve stem it is important that the larger exhaust valve seal is not fitted onto the inlet
guide. The seals have a colour code for identification.

7 Fit new valve stem seals on the valve guides. Ensure that the brown seal is fitted to the exhaust valve and
the green seal is fitted to the inlet valves.

8 Put the new valve springs in position.

Continued

1

3

2

A

48 Workshop Manual, TPD 1350E, Issue 4

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9 Fit the valve spring caps.

Caution: Ensure that the valve spring is compressed squarely or damage can occur to the valve stem.

10 Fit the valve spring compressor, compress the valve spring and fit the collets. Remove the valve spring
compressor.

11 Fit the rocker assembly, see Operation 3-3.
12 Check the valve tip clearances, see Operation 3-6 for four cylinder engines or Operation 3-7 for six cylinder

engines.

13 Fit the rocker cover, see Operation 3-2.
Note: If other or all of the valve springs are to be changed, they can be changed two cylinders at a time. The

sets of cylinders are:

l For 4 cylinder engines: 1 and 4, 2 and 3
l For 6 cylinder engines: 1 and 6, 2 and 5, 3 and 4.

If the rocker assembly has been removed, piston TDC can be found as follows:

1 Fit the valve spring compressor and compress the valve springs to open the valve.
2 Rotate the crankshaft, by hand, in the normal direction of rotation until the piston touches the valve.
3 Continue to rotate the crankshaft, and at the same time, release pressure on the valve spring compressor

until the piston is at TDC (B).

3

B

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New 1000 Series

Manifolds

Introduction

The exhaust manifolds fitted to these engines have large clearance holes for the setscrews. It is important that
these manifolds are fitted correctly.

A new three-piece exhaust manifold has been introduced for some turbocharged six cylinder engines with side
mounted turbochargers. The exhaust manifold is in three pieces to allow for expansion.

Intake manifolds fitted to engine types AR and AS, are in two pieces sealed together with a liquid joint. The
two pieces are joined together with setscrews. In service the liquid joint is replaced with a paper joint.

Caution: If a setscrew for the exhaust manifold has become loose or has to be loosened, all of the setscrews
must be loosened and then tightened. If this is not done the manifold could be damaged when it becomes hot.

To remove and to fit an intake manifold Operation 3-9

Special requirements

Consumable products

Description Part number

POWERPART Threadlock and
nutlock

21820117

To remove
1 Loosen the securing clips and remove the air intake hose.

2 Remove the pipe which is fitted between the fuelled starting aid in the intake manifold and the fuel filter.

Disconnect the electrical connection.
3 For engines fitted with a boost control device: Remove the boost control pipe which is fitted between the

intake manifold and the top of the fuel injection pump.
4 Release the intake manifold fasteners and remove the manifold from the cylinder head.
For intake manifolds fitted to engine types AR and AS: The top half of the intake manifold (A1) in production is

sealed to the bottom half (A2) with a liquid joint and fastened together by setscrews. In service the liquid joint
is replaced with a paper joint.

The top half of the manifold must be removed to obtain access to the manifold fasteners (A3), fitted inside the
manifold. These fasteners retain the bottom half of the manifold to the cylinder head.

21

3

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To fit

Caution: Do not scratch or damage the flange faces of the intake manifold.

Notes:

l New setscrews have sealant applied by the manufacturer to the first 13,0 mm (0.50 in) of the threads. If the

setscrews are to be used again, clean the old sealant from the male and female threads and apply new

sealant POWERPART Threadlock and nutlock to the setscrews.
l The manifold joint is fitted without jointing compound.
1 Fit a new intake and exhaust joint to the cylinder head (if required).
The latest joints for both four and six cylinder engines are supplied as one-piece.

2 Fit the intake manifold and tighten the setscrews.
For engine types AR and AS: Remove any sealant from the top and bottom sections of the intake manifold. Fit

the bottom half (B2) to the cylinder head and tighten the setscrews. Fit a new paper joint (B5) to the bottom
half of the intake manifold the paper joint is fitted dry. Fit the top half of the intake manifold (B1) and tighten the
setscrews.

3 For engines fitted with a boost control device: Fit the boost control pipe which is fitted between the intake
manifold and the top of the fuel injection pump.

4 Fit the pipe which is fitted between the fuelled starting aid in the intake manifold and the fuel filter. Connect
the electrical connection.

5 Fit the air intake hose and tighten the securing clips.

3

21

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4

5

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New 1000 Series

To remove and to fit an exhaust manifold (one-piece) Operation 3-10

Special requirements

Consumable products

Description Part number

POWERPART Retainer high
strength

To remove
1 For engines fitted with turbochargers: Disconnect all connections to the turbocharger and remove the

turbocharger, see Operation 9-1.

2 Remove the intake manifold, see Operation 3-9.
3 Release the exhaust manifold fasteners and remove the manifold from the cylinder head.

To fit

Cautions:

l Only use the approved setscrews as they are made of a material to withstand high temperatures.
l Do not fasten brackets, that are not approved by Perkins, to the exhaust manifold as the manifold could be

damaged when it becomes hot.

21820638

Notes:

l New setscrews have sealant applied by the manufacturer to the first 13,0 mm (0.50 in) of the threads. If the

setscrews are to be used again, clean the old sealant from the male and female threads and apply new
sealant POWERPART Retainer high strength to the setscrews.

l New exhaust manifolds are supplied with plastic ferrules fitted to ensure correct alignment. The position of

the ferrules varies according to the exhaust exit port in the manifold. The ferrules are only necessary to
align a new exhaust manifold. If the manifold is to be removed and then fitted again, the manifold can be
aligned by eye.

Continued

52 Workshop Manual, TPD 1350E, Issue 4

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3

1 If fitting a new manifold, ensure that the ferrules are fitted correctly.

On four cylinder engines with a top exit port (A1), the ferrules are in positions 3 and 6. Those with a side exit
port (A2), the ferrules are in positions 2 and 5.

On six cylinder engines with a top exit port (B1), the ferrules are in positions 9 and 12. Those with a side exit
port (B2), the ferrules are in positions 8 and 11.

2 Fit a new intake and exhaust manifold joint.
Note: The manifold joint is fitted without jointing compound.

The latest joints for both four and six cylinder engines are supplied as one-piece.
3 Fit the manifold to the cylinder head, use two of the setscrews through the ferrules to align the manifold

correctly to the cylinder head. Fit the remaining setscrews and tighten to finger tight.

Caution: Damage to the exhaust manifold can occur if it is not aligned correctly.

4 Tighten the manifold setscrews gradually and evenly to 33 Nm (24 lbf ft) 3,4 kgf m, in the sequences shown
in (A and B). Use the same sequences to tighten the setscrews again to the same torque tension.

5 Fit the intake manifold, see Operation 3-9.
6 If removed fit the turbocharger, see Operation 9-2.

1

1191

8

5

6

7

2

14

11

10 12

3

5817

1 3 10 12 13 1518 16 9 7 6 4

2

A

8542

9

3

167

10

11

12

2

A1046

B

17

18

16 9

85 21114

76 3101213

Workshop Manual, TPD 1350E, Issue 4 53

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New 1000 Series

To remove and to fit an exhaust manifold (three-piece) Operation 3-11

Special requirements

Consumable products

Description Part number

POWERPART Retainer high
strength

To remove
1 For engines fitted with turbochargers: Disconnect all connections to the turbocharger and remove the

turbocharger, see Operation 9-1.

2 Remove the intake manifold, see Operation 3-9.
3 Release the exhaust manifold fasteners and remove the manifold from the cylinder head.

To fit

Cautions:

l Only use the approved setscrews as they are made of a material to withstand high temperatures.
l Do not fasten brackets, that are not approved by Perkins, to the exhaust manifold as the manifold could be

damaged when it becomes hot.

21820638

Notes:

l New setscrews have sealant applied by the manufacturer to the first 13,0 mm (0.50 in) of the threads. If the

setscrews are to be used again, clean the old sealant from the male and female threads and apply new
sealant POWERPART Retainer high strength to the setscrews.

l New three-piece manifolds are not supplied with ferrules. The manifold is aligned by the use of guide studs.

1 Make four guide studs that have an M10 x 1,5 mm thread and are 65 mm (2.5 in) long.
2 Fit the guide studs to the cylinder head in the positions shown (A1).
3 Fit a new intake and exhaust manifold joint on to the guide studs.
Note: The manifold joint is fitted without jointing compound.

4 Assemble the three-piece exhaust manifold as shown in (A). Fit the assembly on to the guide studs.

Continued

1 1 1

1

A

54 Workshop Manual, TPD 1350E, Issue 4

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Note: If a side mounted turbocharger support bracket (B2) is fitted, fit the two longer setscrews (B1).
5 Fit the remaining setscrews and tighten them finger tight.

6 Remove the guide studs and fit the remaining setscrews.
7 Tighten all of the setscrews gradually and evenly to 33 Nm (24 lbf ft) 3,4 kgf m.
8 Fit the intake manifold, see Operation 3-9.
9 If removed fit the turbocharger, see Operation 9-2.

3

1

2

B

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New 1000 Series

Cylinder head assembly

To remove Operation 3-12

1 Drain the cooling system.
2 Disconnect the battery terminals.
3 For engines fitted with turbochargers: Disconnect all connections to the turbocharger and remove the

turbocharger, see Operation 9-1.

4 Remove the intake manifold, see Operation 3-9.
5 Remove the exhaust manifold, see Operation 3-10 or Operation 3-11.
6 Remove the low-pressure fuel pipes which are fitted between the fuel injection pump and the fuel filter.
Note: Where a Bosch fuel injection pump is fitted, keep the fuel outlet banjo bolt with the fuel injection pump.

Remove the fuel pipe fitted between the fuel lift pump and the fuel filter. Remove the fuel filter bracket together
with the fuel filter.

Caution: Where access to the fuel injection pump outlet unions is possible, ensure that a separate spanner
is used to prevent movement of the fuel injection pump outlets when the connections of the high-pressure
pipes are released. Fit suitable covers to all open connections on the fuel injection pump.

7 Remove the high-pressure fuel pipes.
8 Remove the atomiser leak-off pipe.
9 Remove the atomisers, see Operation 11-4. Fit suitable covers to the nozzles and the open connections.
10 If a compressor is fitted: Remove the coolant pipe which is fitted between the cylinder head and the

compressor. Then remove the coolant pipe which is fitted between the by-pass connection and the
compressor.

Continued

56 Workshop Manual, TPD 1350E, Issue 4

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3

11 Release the clip of the coolant by-pass hose at the cylinder head. Release the setscrews and remove the

coolant by-pass connection and the hose.

12 Disconnect the coolant temperature sender unit.
13 Four cylinder engines: Remove the oil cooler if it is integral with the cylinder block, see Operation 12-21.
14 Remove the rocker cover, see Operation 3-1.
15 Remove the rocker assembly, see Operation 3-3.
16 Remove the push rods.
17 Release the cylinder head setscrews evenly and gradually in the reverse sequence to that shown in (A

or B).
18 Check the setscrews for distortion with a straight edge (C1) held along the setscrew (C2). If there is a visual

reduction in the diameter of the thread (C3) that has not been in engagement with the cylinder block, the
setscrew must be discarded.

Caution: Do not use a lever to separate the cylinder head from the cylinder block.

19 Remove the cylinder head and put it on a surface that will not damage the face of the cylinder head.

MM M MMM28 18 8 2 13 23

M30

19L9131424M29

M20 M10 M7 M4 M15 25M

MMMML

A

MMMM

18

19 14

M

20

S

ML L

M

21

S

22 11 12 6 5

8

9

10

S

MM

2

M

S

3

S

17 16

1

74

SS

S26S27S16S17S5S6S12S11S22S21S32S31

A0055

12

M

13

M

15

S

3

B

A0053

C

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New 1000 Series

To fit (engine types AJ to AQ and YG to YK) Operation 3-13

Special requirements

Special tools

Description Part number

Angle gauge, to tighten cylinder head
setscrews

Note: See Operation 3-14 for AR and AS engine types
1 Clean the bottom face of the cylinder head and the top face of the cylinder block. Ensure that there is no

debris in the cylinder bores.
Note: The engines have two location pins (A3), one at each end of the cylinder head, pressed into the cylinder

block to hold the cylinder head and cylinder head joint in the correct position when the cylinder head is fitted.

Cautions:

l To prevent damage to the cylin der head joint, e nsure tha t the loc ation pins are pres sed in th e cylind er block

before the cylinder head is fitted.

l The cylinder head joint must be fitted without jointing compound.

2 Put the cylinder head joint in position; It is stamped "FRONT TOP" (A2) for correct assembly.
3 To ensure the cylinder head is fitted into the correct position, fit two suitable 1/2 UNF guide studs (A1) or

(B1) in positions 16 and 21 (Operation 3-12 illustration B) or positions 25 and 30 (Operation 3-12 illustration
A). Put the cylinder head in position. Ensure that the two location pins are fully engaged in the cylinder head.

4 Lightly lubricate the threads of the cylinder head setscrews and the thrust faces of the setscrew heads.
Engage some of the setscrews in their correct positions and remove the guide studs. Engage the remainder
of the setscrews in their correct positions.

5 Gradually and evenly tighten the setscrews to 110 Nm (80 lbf ft) 11,1 kgf m in the sequence shown in
Operation 3-12, illustrations A or B.

6 Repeat step 5 to ensure that all the setscrews are tightened to the correct torque.

21825607

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7 Tighten the setscrews, in the correct sequence, a further part of a turn according to the length of the
setscrews (refer to Operation 3-12 illustrations A or B). Short setscrews (S) must be turned a further 150° (2.5
flats). Medium length setscrews (M) must be turned a further 180° (3 flats). Long setscrews (L) must be turned
a further 210° (3.5 flats). A special tool (C) can be used for this operation.

Fit the tool between the socket and the handle. Position the stop (C1) against a suitable protrusion on the
cylinder head to prevent movement of the degree dial in a clockwise direction. Rotate the pointer to align with
the relevant angle on the degree dial for the length of setscrew. Tighten the setscrew until the pointer on the
tool is aligned with the zero position on the degree dial.

If no tool is available, make a suitable mark on the cylinder head in line with a corner of each setscrew (D).
Make another mark, at the correct angle (counter-clockwise), on the edge of the flange of each fastener
according to the length of the setscrew. Tighten each setscrew in the correct sequence until the marks on the
flange are next to, and in line with, the marks on the cylinder head.

8 Put the push rods in position. Ensure that the end of each push rod fits correctly in the tappet socket.
9 Fit the rocker assembly, see Operation 3-3.
10 Set the valve tip clearances, see Operation 3-6 for four cylinder engines or Operation 3-7 for six cylinder

engines.

11 Fit the atomisers, see Operation 11-5.
12 Fit the high-pressure fuel pipes; tighten the connection nuts to 22 Nm (16 lbf ft) 2,2 kgf m.

Caution: Where access to the fuel injection pump outlet unions is possible, ensure that a separate spanner
is used to prevent movement of the fuel injection pump outlets when the connections of the high pressure pipes
are tightened.

3

13 Fit the fuel filter and the bracket. Fit the low-pressure fuel pipes between the fuel injection pump and the

fuel filter.

14 Fit the coolant by-pass connection; tighten the setscrews and hose clip.
15 Fit the coolant temperature sender unit.
16 If a compressor is fitted: Fit the coolant pipe between the cylinder head and the compressor. Then fit the

pipe between the coolant by-pass and compressor.

17 Four cylinder engines: Fit the oil cooler if it is integral with the cylinder block, see Operation 12-22.
18 Fit the exhaust manifold, see Operation 3-10 or Operation 3-11.
19 Fit the intake manifold, see Operation 3-9.

Continued

1

150° 180° 210°

SML

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20 For engines fitted with turbochargers: Fit the turbocharger, see Operation 9-2.
21 Fit the fuel pipe between the fuel filter and the fuel lift pump.
22 Fill the cooling system.
23 Connect the battery.
24 Eliminate air from the fuel system, see Operation 11-20.
25 Start the engine and run it at low speed. Check that oil flows from the holes in the rocker levers. If the oil

flow is correct, fit the rocker cover, see Operation 3-2.
Note: It is not necessary to tighten the cylinder head setscrews again with the engine hot or after a limited

period in service.

New 1000 Series

60 Workshop Manual, TPD 1350E, Issue 4

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To fit (engine types AR and AS) Operation 3-14

Special requirements

Special tools

Description Part number

Angle gauge, to tighten cylinder head
setscrews

Note: See Operation 3-13 for AJ to AQ and YG to YK engine types.
1 Clean the bottom face of the cylinder head and the top face of the cylinder block. Ensure that there is no

debris in the cylinder bores.
Note: The engines have two location pins (A3), one at each end of the cylinder head, pressed into the cylinder

block to hold the cylinder head and cylinder head joint in the correct position when the cylinder head is fitted.

Cautions:

l To prevent damage to the cylinder head joint, ensure that the location pins are pressed in the cylinder block

before the cylinder head is fitted.
l The cylinder head joint must be fitted without jointing compound.

2 Put the cylinder head joint in position; it is stamped "FRONT TOP" (A2) for correct assembly.
3 To ensure the cylinder head is fitted into the correct position, fit two suitable M10 guide studs (A1) in

positions 16 and 21 (B). Put the cylinder head in position. Ensure that the two location pins are fully engaged
in the cylinder head.

4 Lightly lubricate the threads of the cylinder head setscrews and the thrust faces of the setscrew heads.
Engage some of the setscrews in their correct positions and remove the guide studs. Engage the remainder
of the setscrews in their correct positions. The four 1/2 UNF setscrews are fitted in positions 2, 8, 13 and 18,
refer to (B).

5 Gradually and evenly tighten all of the setscrews to 45 Nm (33 lbf ft) 4,5 kgf m in the sequence shown in (B).
6 Repeat step 5 to ensure that all the setscrews are tightened to the correct torque.
7 Gradually and evenly tighten the four 1/2 UNF setscrews, to 110 Nm (80 lbf ft) 11,1 kgf m in the sequence

2, 8, 13 and 18, shown in (B).
8 Repeat step 7 to ensure that these setscrews are tightened to the correct torque.

21825607

Continued

1

3

A

2

MMMM

A0404

18

19 14

M

20

S

ML L

M

21

S

22 11 12 6 5

B

8

9

10

S

MM

2

M

S

3

S

17 16

1

74

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New 1000 Series

9 Tighten the M10 setscrews, in the correct sequence, a further part of a turn according to the length of the
setscrews, see (C) and (D). Short setscrews (S) must be turned a further 120° (2 flats). Medium length
setscrews (M) must be turned a further 120 ° (2 flats). Long setscrews (L) must be turned a further 150°
(2.5 flats). The four 1/2 UNF setscrews in positions 2, 8, 13 and 18 must be turned 180° (3 flats ).

A special tool (E) can be used to tighten all of the setscrews, instead of the method described in step 9. Fit the
tool between the socket and the handle. Position the stop (E1) against a suitable protrusion on the cylinder
head to prevent movement of the degree dial in a clockwise direction. Rotate the pointer to align with the
relevant angle on the degree dial for the length of setscrew. Tighten the setscrew until the pointer on the tool
is aligned with the zero position on the degree dial.

If no tool is available, make a suitable mark on the cylinder head in line with a corner of each setscrew (D).
Make another mark, at the correct angle (counter-clockwise), on the edge of the flange of each fastener
according to the length of the setscrew. Tighten each setscrew in the correct sequence until the marks on the
flange are next to, and in line with, the marks on the cylinder head.

Continued

MMMM

18

19 14

M

20

21

S

ML L

M

S

22 11 12 6 5

8

9

10

S

MM

2

M

S

3

S

17 16

1

74

SS

C

1

S 1/2 UNF S and M

M

13

M

15

S

A0053

150° 180° 210°

D

A0059

E

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10 Put the push rods in position. Ensure that the end of each push rod fits correctly in the tappet socket.
11 Fit the rocker assembly, see Operation 3-3.
12 Set the valve tip clearances, see Operation 3-6 for four cylinder engines or Operation 3-7 for six cylinder

engines.

13 Fit the atomisers, see Operation 11-5.
14 Fit the high-pressure fuel pipes; tighten the connection nuts to 22 Nm (16 lbf ft) 2,2 kgf m.

Caution: Where access to the fuel injection pump outlet unions is possible, ensure that a separate spanner
is used to prevent movement of the fuel injection pump outlets when the connections of the high pressure pipes
are tightened.

15 Fit the fuel filter and the bracket. Fit the low-pressure fuel pipes between the fuel injection pump and the
fuel filter.

16 Fit the coolant by-pass connection; tighten the setscrews and hose clip.
17 If a compressor is fitted: Fit the coolant pipe between the cylinder head and the compressor. Then fit the

pipe between the coolant by-pass and compressor.

18 Fit the coolant temperature sender unit.
19 Fit the oil cooler if it is integral with the cylinder block, see Operation 12-22.
20 Fit the exhaust manifold, see Operation 3-10 or Operation 3-11.
21 Fit the intake manifold, see Operation 3-9.
22 Fit the fuel pipe between the fuel filter and the fuel lift pump.
23 Fit the fuel pipe between the fuel filter and the fuelled starting aid in the intake manifold. Connect the

electrical connection to the cold start device.

24 Fit the electrical connection to the coolant temperature sender unit.
25 Fill the cooling system.
26 Connect the battery.
27 Eliminate air from the fuel system, see Operation 11-20.
28 Start the engine and run it at low speed. Check that oil flows from the holes in the rocker levers. If the oil

flow is correct, fit the rocker cover, see Operation 3-2.
Note: It is not necessary to tighten the cylinder head setscrews again with the engine hot or after a limited

period in service.

3

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New 1000 Series

Valves and valve springs

To remove Operation 3-15

Special requirements

Special tools

Descript i o n Part numb e r Desc r i p tion Part number

Valve spring compressor 21825666
Stud adaptor used with 21825666 21825931

Warning! Wear eye protection during this operation.

1 Remove the cylinder head, see Operation 3-12.
2 Clean the bottom face of the cylinder head and check the depth of the heads of the valves below the face

of the cylinder head, see Operation 3-17.
3 Make a suitable mark on the heads of the valves to ensure that the valves can be fitted in their original

positions, if they are to be used again.

Caution: Ensure that the valve springs are compressed squarely or the valve stem can be damaged.

4 Use the valve spring compressor and the relevant adaptor to compress the valve spring (A3) and remove
the collets (A2).

5 Release the valve spring compressor and remove the valve spring cap (A1), valve spring and valve stem
seal (A4).

6 Repeat steps 4 and 5 for the other valves.

Setscrew adaptor used with 21825666 21825932

1

2

3

4

5

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To fit Operation 3-16

Special requirements

Special tools

Description Part number Description Part number

Valve spring compres so r 21825666
Stud adaptor used with 21825666 21825931

Warning! Wear eye protection during this operation.

Note: The components of the valve assembly are shown in (A).
1 Lubricate the valve stem (A5) with clean engine oil and fit the valves in their respective guides.

Caution: The outer diameter of the exhaust valve guide is 1 mm larger than the inlet valve guide. To prevent
leakage past the inlet valve stem it is important that the larger exhaust valve seal is not fitted onto the inlet
guide. The seals in the service kit have different colours for identification.

2 Fit new valve stem seals on the valve guides. It is important that all lubricant is removed from the outer
diameter of inlet and exhaust valve guides before the valve seal is fitted. Ensure that the brown seal is fitted
to the exhaust valve and the green seal is fitted to the inlet valves.

3 Put the valve springs in position, they can be fitted with either end to the cylinder head. Fit the valve spring
caps.

Caution: Ensure that the valve spring is compressed squarely or damage can occur to the valve stem.

Setscrew adaptor used with 21825666 21825932

4 Use the valve spring compressor and the relevant adaptor to compress the valve spring and fit the collets.

1

2

3

4

5

A

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New 1000 Series

To inspect and to correct Operation 3-17

Special requirements

Special tools

Descript i o n Part numb e r Desc r i p tion Part number

Gauge, valve depth 21825496 Dial gauge for use with 21825496 21825617

1 Check the depth of the valves below the face of the cylinder head before the valve springs are removed.
2 Ensure that the heads of the valves and the bottom face of the cylinder head are clean.
3 Put the valve depth gauge on the face of the cylinder head and zero the dial gauge.
4 Carefully put the valve depth gauge in position over the head of each valve (A) and make a note of the

measurement. For the maximum depth, in service, refer to the Data and dimensions for "Inlet and exhaust
valves" on page 13.

5 If a valve is below the depth limit, check the valve depth with a new valve in position. If the valve depth is
still below the limit and a valve seat insert is fitted, the insert must be renewed.

6 Check the valves for cracks. Check the stems of the valves for wear and for correct fit in their valve guides.

Caution: Renew damaged valves, the special heat resistant layer on the face of the valve will be destroyed
if valves are lapped.

7 Check that the seat faces of the valves are not badly burnt or damaged. Seat faces of valves which are
damaged can be ground on a special machine. When new valves are fitted, the valve depths must be checked
after the valve springs are fitted.

8 Check that the load on the valve springs is correct at their fitted length, see "Valve guides and valve springs"
on page 17. Fit new valve springs at every complete engine overhaul.

A

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Valve guides

Note: Later engines have an improved exhaust valve guide (B1), with a groove (B2) to retain the valve seal

(B3).

To inspect Operation 3-18

To check the valve guides for wear: The maximum permissible clearance (A5) with a valve lift of 15,0 mm
(0.6 in), between the valve stem and the bore of the guide is 0,100 mm (0.008 in) for inlet valves and 0,121 mm
(0.011 in) for exhaust valves. If the clearance, with a new valve fitted, is more than the limit, then a new valve
guide (A4) must be fitted.

It is recommended that the procedure given below is used to check the valve guide clearance:

1 Put a new valve in the valve guide.
2 Put a dial test indicator with a magnetic base (A1) onto the face of the cylinder head.
3 With the valve lifted 15,0 mm (0.6 in) and the gauge (A2) in contact with the edge of the valve head (A3),

move the valve radially away from the gauge. With the valve held in this position, set the gauge to zero.
4 Move the valve radially across the axis of the cylinder head towards the gauge. Make a note of the reading

on the gauge. If the reading is equal to or greater than the data given above, a new valve guide (A4) must be
fitted.

Note: The partially finished valve guides are reamed and the valve seats are cut in one operation with a
special tool. The valve seat and the guide are cut in one operation to ensure the concentricity of the valve seat
to the valve guide. This will ensure a good seal between the guide and its seat. New valves and new valve seat
inserts must be fitted each time a new valve guide is fitted. Valves must not be lapped, see Operation 3-22. If
all or most of the original valve guides need to be renewed it may be cost effective to overhaul or exchange
the cylinder head.

4

1

2

5

2

3

1

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New 1000 Series

To remove Operation 3-19

Special requirements

Special tools

Description Part number Description Part number

Valve guide remover and replacer 21825478 Adaptor used with 21825478 27610019

1 Fit the adaptor (A4) into the remover/replacer tool (A3).
2 With the adaptor fitted to the tool, put the spacer (A5) in position on the tool. Pass the adaptor through the

valve guide (A6) and put the spacer and tool in position on the valve seat.

3 Fit the attachment (A7) to secure the adaptor to the valve guide.
4 Hold the top handle (A1) and turn the bottom handle (A2) clockwise to pull the valve guide out of the cylinder

head.

1

2

3

4

5

6

7

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To fit Operation 3-20

Special requirements

Special tools

Description Part number Description Part number

Valve guide remover and replacer 21825478
Adaptor used with 21825478,

21825482 and 27610029

1 Clean the parent bore in the cylinder head for the valve guide.
2 Lubricate the outer surface of the new valve guide (A6) with clean engine lubricating oil.
3 Fit the adaptor (A5) into the remover/replacer tool (A3).
4 With the adaptor fitted to the tool, put the spacer (A4) in position on the tool. Pass the adaptor through the

cylinder head and put the spacer and tool assembly in position on the valve seat.
5 Put the valve guide in position on the adaptor and fit the distance piece (A7), 21825482 for inlet valve guides

and 27610029 for exhaust valve guides. Fit the attachment (A8) to secure the valve guide to the adaptor.

Note: The internal recess in the valve guide must be towards the tool.
6 Hold the top handle (A1) and turn the bottom handle (A2) clockwise to pull the valve guide until the distance

piece contacts the cylinder head.
7 When the valve guide is fitted correctly, the top of the valve guide will have a protrusion (A9) of 14,85/

15,15 mm (0.585/0.596 in) above the valve spring seat.
8 Ream the valve guide to the finished size, see Operation 3-22.

27610019

Distance piece, inlet guide, used with
21825478, and 27610019

Distance piece, exhaust guide, used
with 21825478 and 27610019

21825482

27610029

1

2

3

4

5

6
7

9

8

A

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New 1000 Series

Cylinder head

To inspect and to correct Operation 3-21

1 Remove the cylinder head assembly, see Operation 3-12.
2 Remove the thermostat housing.
3 Inspect the cylinder head for signs of gas or coolant leakage.
4 Remove the valve springs and the valves, see Operation 3-15.
5 Clean the face of the cylinder head and the passages for coolant and for lubricating oil. The water jacket can

be cleaned with a special solvent which must be used in accordance with the manufacturer’s instructions.

6 Test the cylinder head for leaks, refer to the Data and dimensions for "Cylinder head" on page 12.
7 When the cylinder head is thoroughly clean, check it for cracks. Inspect carefully the areas around the valve

seats and around the holes for the atomiser nozzles.
8 Use a straight edge and feeler gauges to check the cylinder head for distortion across and along its bottom

face. If the distortion is more than the permissible limit, the bottom face can be machined, refer to the Data and
dimensions for "Maximum permissible distortion of cylinder head" on page 12.

Cautions:

l Remove only the minimum material and ensure that the thickness of the cylinder head will not be less than

102,48 mm (4.035 in) after the cylinder head has been machined.

l After the cylinder head has been machined the valve seats must be corrected to give the correct valve head

depth. Work to the minimum limit to allow for later wear.

9 Check the valve seats for wear and for damage.
10 Before any work is done on the valve seats, new valve guides must be fitted, see Operation 3-19 and

Operation 3-20.
11 More badly damaged valve seats can be corrected by use of the cutter tool, see Operation 3-22, or new

inserts can be fitted, see Operation 3-23.

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3

To correct a valve seat with a valve seat cutter Operation 3-22

Special requirements

Special tools

Description Part number

Cutter (31° or 46°) for inlet and exhaust
valve seats and valve guide reamer

Caution: Valves must not be lapped.

The valve seats are cut and the valve guides are reamed in one operation with a special tool (A). The valve
seat and the guide are cut in one operation to ensure the concentricity of the valve seat to the valve guide. This
will ensure a good seal between the guide and its seat. New valves and new guides must be fitted each time
a new seat insert is fitted. Valves must not be lapped.

1 Before any work is done on the valve seats, new valve guides must be fitted, see Operation 3-19 and
Operation 3-20.

Caution: Ensure that the correct cutter is fitted, 31° or 46° valve seats may be fitted.

2 Select the relevant valve seat cutter, 31° or 46°, (A2) and the valve gui de reamer (A3). Set the blade s of the
cutters to the diameter of the valve seat to be cut. Fit the cutter onto the reamer and push the handle fully onto
the reamer. Ensure that the flat part of the reamer shank is towards the grub screw (A1) and tighten the grub
screw to secure the reamer to the handle. The blades of the reamer must not cut the valve guide when the
seat is cut.

27610030

Continued

1

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3

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Caution: Ensure that the valve seat cutter is not allowed to fall on to the seat as this can damage the blades.

3 Fit the reamer/cutter assembly into the valve guide. Carefully turn the handle in a clockwise direction (B4)
and gradually move the reamer into the valve guide until the valve guide is reamed to the finished size. A
lubricant is not necessary.

4 Continue to turn the handle in a clockwise direction to cut the valve seat. Remove only the minimum material
to ensure a good valve seat. Keep the seat as narrow as possible.

5 When the seat is cut, remove the reamer/cutter assembly. Remove any debris from the area of the valve
guide, valve seat and the port.

6 Fit the valve.
7 Check that the valve depth is within limits, refer to the Data and dimensions for "Inlet and exhaust valves"

on page 13.
Note: If a valve seat has become too damaged or too worn to correct, a valve seat insert can be fitted, see

Operation 3-23. If all or most of the original valve seat inserts need to be renewed, it may be cost effective to
overhaul or exchange the cylinder head.

New 1000 Series

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To fit valve seat inserts Operation 3-23

1 Remove the valve guide and clean the bore into which the guide is to be fitted.
2 Fit new partially finished valve guides, see Operation 3-19.
3 With the bore of the new partially finished valve guide used as a pilot, machine the recess in the cylinder

head to the correct dimensions, refer to the Data and dimensions for "Dimensions of recesses for valve seat
inserts" on page 14, or machine out the old insert. Remove all debris and clean the insert recess.

4 If the bottom face of the cylinder head has been machined, the insert will have to be surface ground on the
back face to ensure that there is no protrusion of the insert above the bottom face of the cylinder head. After
the back of the insert has been ground, ensure that the outer edge of the back face has a 0,9/1,3 mm (0.035/

0.051 in) chamfer at 30° to the vertical.
5 With the bore of the new, partially finished, valve guide used as a pilot, and with the rear face of the insert

towards the cylinder head, press in the insert with the valve seat insert tool. For the dimensions of the valve
seat insert tool, refer to the Data and dimensions "Valve seat insert tool" on page 15. Do not use a hammer on
the insert and do not use lubrication. Use a hydraulic press or a hand press in one continuous movement.
Ensure that the bottom of the insert is in contact with the bottom of the recess.

6 Ream the valve guide and cut the valve seat at an included angle of 88° for 46° valve seats or 118° for 31°
valve seats, see Operation 3-22. Ensure that the depth of the valve head below the face of the cylinder head
is within the production limits, refer to the Data and dimensions "Inlet and exhaust valves" on page 13 for the
production limits. Work as near as possible to the minimum figure to allow for future wear on the valve seat.

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New 1000 Series

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4

Piston and connecting rod assemblies 4

General description

The pistons used in the New 1000 Series engines have a "Fastram" combustion chamber in the top of the
piston (A). The piston (B) for engine types AR and AS has two recesses in the top face for the valves. The
combustion chamber is designed to give an efficient mix of fuel and air.

The pistons and connecting rods are matched to the relevant cylinder.
The pistons have two compression rings and an oil control ring. The groove for the top ring has a hard metal

insert to reduce wear of the groove. The piston skirt has a layer of graphite to improve the wear characteristics.
Axial location of the fully floating gudgeon pin is by circlips. The gudgeon pin is off-centre to reduce the noise

level.
Piston cooling jets are fitted in the cylinder block to spray lubricating oil onto the inner surface of the pistons.
Note: Engine types AR and AS have only one cooling jet fitted to spray the number one piston.
The correct piston height is important to ensure that the piston does not contact the cylinder head and to

ensure the efficient combustion of fuel.
The piston height is controlled by the length of the connecting rod. In production, there are six grades of

connecting rods that can be fitted to the engines. In service for engines fitted with serrated connecting rods,
there are four grades of connecting rod and one piston available to obtain the correct piston height. For engines
fitted with flat faced connecting rods there are two grades of connecting rod and one piston available to obtain
the correct piston height.

To obtain the different grades, the small-end bush is machined off-centre. The amount that the bush is off­centre gives the different length grades.

Continued

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In service, a partially finished small-end bush is available, which can be fitted to the original connecting rod
and machined to obtain the correct length grade, see Operation 4-14. Specialist equipment and personnel with
the correct training are needed to machine the partially finished small-end bush. Connecting rod parts kits are
also available with the small end bush fitted and machined to obtain the correct connecting rod grade. For
further information refer to your nearest Perkins distributor.

Notes:

l If the crankshaft or the cylinder block is to be renewed, it may be necessary to change the grade of the

connecting rods, see Operation 4-11. This will occur if the correct piston height above the cylinder block
face cannot be maintained with the original connecting rod assemblies, see Operation 4-6.

l Engine types AR and AS do not have cylinder liners fitted and the cylinder bores must be machined

oversize to correct a worn cylinder bore. Two oversize pistons and piston rings are available in service

0,5 mm (0.020 in) and 1,00 mm (0.040 in).
l Always use the engine identification number to order new parts.
The connecting rods are machined from "H" section forgings of molybdenum steel. They have wedge shaped

small ends.
Location of the bearing cap to the connecting rod is made by dowels (C1) fitted in the bearing cap. The faces

of the connecting rods and caps are flat and the caps are retained by two setscrews.
Some engines have bearing caps with serrations (D1) which are used to ensure the correct location of the

bearing caps to the connecting rods. These caps are retained by two nuts and bolts.

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Big end bearing

To remove Operation 4-1

Notes:

l There are location thimbles (B1) fitted to the latest bolts used with connecting rods that have serrated faces.
l The location thimbles are used in the factory to prevent movement of the bolts when the nuts for the big

end cap are tightened by automatic equipment.

l When the connecting rods are fitted in service it is not necessary to use the location thimbles and they can

be discarded.

1 Drain the engine lubricating oil .
2 Remove the lubricating oil sump, see Operation 10-3.
3 Remove the lubricating oil strainer and suction pipe, see Operation 10-4 or remove the balancer unit, see

Operation 5-18.

4 Rotate the crankshaft until the relevant connecting rod is at its lowest position.
5 Release the nuts (B4) and remove the bearing cap (B3). Remove the bolts from the connecting rod (B2). If

the bearing cap is retained by setscrews (A4), the location of the bearing cap (A3) will be by two dowels (A2).
To remove these bearing caps, release the setscrews by approximately four turns. Lightly hit the heads of the
setscrews with a soft face hammer to separate the connecting rod (A1) from the bearing cap. Remove the
setscrews and the bearing cap.

6 Remove the lower half of the shell bearing from the cap, but keep it with its relevant cap.
7 Carefully push the connecting rod up the cylinder bore just enough to allow access to the upper half of the

shell bearing. Remove the bearing from the connecting rod. Keep the bearings from the connecting rod and
cap together.

Caution: Do not allow the connecting rod to hit the piston cooling jet, if fitted.

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New 1000 Series

To fit Operation 4-2

1 Clean the bearing faces of the connecting rod and the crank pin.
2 Ensure that the protrusion for the location dowels is 3,0/4,5 mm (0.12/0.18 in) above the cap faces. Clean

the complete bearing and lubricate the bearing surface and the crank pin with clean engine lubricating oil.
Fit the upper half of the shell bearing to the connecting rod; ensure that the location tag is fitted correctly in its

recess (A1). Fit the connecting rod to the crank pin; ensure that the assembly number on the connecting rod
is on the same side as the other connecting rods.

Note: If the bearing cap is secured by nuts and bolts, new nuts must be fitted.
3 Clean, lubricate and fit the lower half of the shell bearings into the cap; ensure that the location tag is fitted

correctly in its recess (A1). Fit the cap to the connecting rod. Ensure that the assembly number on the cap is
the same as that on the connecting rod and that both of the assembly numbers are on the same side (B1).

4 Tighten the fasteners gradually and evenly to the recommended torque of 155 Nm (114 lbf ft) 15,8 kgf m for
setscrews, or 125 Nm (92 lbf ft) 12,7 kgf m for nuts.

5 Ensure that the crankshaft rotates freely.
6 Fit the lubricating oil strainer and suction pipe, see Operation 10-4 or fit the balancer unit, see Operation 5-

18.
7 Fit the lubricating oil sump, see Operation 10-3 and fill the sump to the correct level with lubricating oil of an

approved grade.

To inspect Operation 4-3

Check the bearings and the crank pin for wear or other damage, renew if necessary.

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Piston and connecting rod

To remove Operation 4-4

1 Drain the lubricating oil and the cooli ng sys tem.
2 Remove the cylinder head assembly, see Operation 3-12.
3 Remove all carbon from the top of the bores of the cylinder liners.
4 Remove the lubricating oil sump, see Operation 10-3.
5 Remove the lubricating oil strainer and suction pipe, see Operation 10-4, or the balancer unit, see Operation

5-18.

Caution: The pistons and connecting rods are matched to the relevant cylinder. Note the position of each
connecting rod and piston for correct assembly.

6 Remove the big end caps and the big end bearings from the connecting rods, see Operation 4-1.

Caution: Do not allow the connecting rods to hit the piston cooling jets. If a cooling jet is hit, check its
alignment, see Operation 4-16, and renew it, if necessary.

7 Rotate the connecting rods 90° to prevent contact with the piston cooling jets. Push the pistons and the
connecting rods out through the top of the cylinder block. Keep the bearings and caps together to ensure that
they can be fitted in their original positions.

8 Inspect the crank pins for damage.

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New 1000 Series

To fit Operation 4-5

Special requirements

Special tools

Description Part number

Piston replacer tool 21855615

1 Ensure that the piston, the cylinder bore, the crank pin and the big end of the connecting rod are clean.
Lubricate the piston and the cylinder liner with clean engine lubricating oil.

2 Rotate the crankshaft until the relevant crank pin is at its lowest position. Lubricate the crank pin with clean
engine lubricating oil.

3 Fit the upper half of the shell bearing to the connecting rod. Ensure that the location tag is fitted correctly in
its recess. Lubricate the bearing with clean engine lubricating oil.

4 Put the piston replacer tool in position at the top of the relevant cylinder. The tool has a tapered bore to
compress the piston rings when the piston and connecting rod assembly is fitted. Ensure that the smaller end
of the tapered bore is towards the face of the cylinder block.

5 Put the piston ring gaps 120° apart. Pass the connecting rod through the piston replacer tool and allow the
piston to enter the tool. The arrow mark on the top of the piston (B) must be towards the front of the engine.

Caution: Ensure that the connecting rod will not hit the piston cooling jet as the connecting rod assembly is
fitted.

6 Push the piston and connecting rod assembly through the piston replacer tool (A) and onto the crank pin.
The piston and connecting rod assembly must be rotated to ensure that the connecting rod will not hit the
piston cooling jet as the assembly is fitted. When the connecting rod has passed the piston cooling jet, rotate
the connecting rod until the arrow mark on top of the piston is towards the front of the engine.

Note: If the bearing cap is secured by nuts and bolts, new nuts must be fitted.
7 Clean the connecting rod cap and the lower half of the shell bearings. Fit the bearing to the cap, ensure that

the location tag is fitted correctly in its recess. Lubricate the bearing with clean engine lubricating oil. Fit the
cap and ensure that the assembly number is the same as that on the connecting rod and that the numbers are
on the same side. Tighten the fasteners gradually and evenly to the recommended torque of 155 Nm (114 lbf ft)
15,8 kgf m for setscrews, or 125 Nm (92 lbf ft) 12,7 kgf m for nuts.

8 Check that the crankshaft will rotate freely.

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9 Check the piston height above the top face of the cylinder block, see Operation 4-6.
10 Fit the lubricating oil strainer and suction pipe, see Operation 10-4, or the balancer unit, see Operation 5-

18.

11 Fit the lubricating oil sump, see Operation 10-3.
12 Fit the cylinder head assembly, see Operation 3-13 or Operation 3-14.
13 Fill the sump to the correct level with lubricating oil of an approved grade.
14 Fill the cooling system.

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New 1000 Series

To check the pis ton height above the cylinder block Operation 4-6

Special requirements

Special tools

Description Part number Description Part number

Piston height and valve depth gauge 21825496 Dial gauge for use with 21825496 21825617

Caution: If the correct piston height above the cylinder block is not obtained, damage to the engine can occur.

Put the piston height tool (A) on the face of the cylinder block and rotate the gauge dial to the zero position.
Rotate the crankshaft until the piston crown is approximately at top dead centre (TDC). Carefully put the tool
over the top of the piston with the plunger of the gauge in contact with the piston above the axis of the gudgeon
pin. Rotate the crankshaft to ensure that the piston is at the highest position and make a note of the gauge
indication.

The piston height above the top face of the cylinder block should be 0,36/0,50 mm (0.014/0.020 in).

Notes:

l The top of the piston should not be machined.
l If the original piston is used, ensure that it is assembled to the correct connecting rod and is used in the

original cylinder.
If any of the components listed below are renewed, refer to the relevant operation:

l The connecting rod, see Operation 4-11.
l The small end bush, see Operation 4-14.

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Piston rings

To remove Operation 4-7

Note: The pistons have two compression rings and an oil control ring. All the piston rings are above the

gudgeon pin. To ensure that the correct type is obtained always use the engine identification number to order
new parts.

Caution: Only expand the ring gaps enough to ensure that the ends of the rings do not damage the piston
when the ring is removed.

1 Remove the piston rings with a suitable ring expander. Keep the rings with their relevant piston.

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New 1000 Series

To fit Operation 4-8

Use a suitable piston ring expander to fit the piston rings.

Caution: Only expand the ring gaps enough to ensure that the ends of the rings do not damage the piston
when the ring is put into position.

1 Fit the spring of the oil control ring in the bottom groove with the latch pin (A1) inside both ends of the spring
(A). Fit the oil control ring over the spring (B3) or (C3). Ensure that the ring gap is at 180° to the latch pin.

Note: A small taper has been added to the oil control rings for engine types AR and AS. This is to reduce the
oil consumption during the early life of the engine. When new oil control rings are fitted, the blue mark must be
fitted to the left of the piston ring gap. The word ‘TOP’ will then be toward the top of the piston.

2 Fit the cast iron ring with the taper face into the second groove, with the word "TOP" towards the top of the
piston.

New second rings have a green identification mark which must be on the left of the ring gap when the ring is
fitted and the piston is upright.

The second ring has a step (B2) or (C2) at the bottom of the tapered face.

3 Fit the tapered, top ring (B1) or (C1) with the word 'TOP' towards the top of the piston.
Note: The top ring (C1) of engine types AR and AS is parallel.

New top rings have a red identification mark which must be on the left of the ring gap when the ring is fitted
and the piston is upright.

4 Ensure that the ring gaps are 120° apart.

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Piston and connecting rod assembly

To dismantle Operation 4-9

Caution: The pistons and connecting rods are matched to the relevant cylinder. Note the position of each
connecting rod and piston for correct assembly.

1 Remove the piston rings, see Operation 4-7.
2 Remove the circlips which retain the gudgeon pin.

Caution: Make a temporary mark on the piston. Do not scratch, etch or stamp the piston surface.

3 Put a temporary mark on the piston to indicate the cylinder number as shown on the connecting rod. Put the
temporary mark on the piston on the same side as the mark on the big end to ensure that they are assembled
correctly (A).

4 Push the gudgeon pin out by hand. If the gudgeon pin is tight, heat the piston to 40/50 °C (100/120 °F) for
easy removal of the gudgeon pin.

5 Inspect the piston and connecting rod assembly, see Operation 4-12 and Operation 4-13.

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New 1000 Series

To assemble Operation 4-10

1 Clean the bore of the small end bush and lubricate it with clean engine lubricating oil.
2 Fit a new circlip in the circlip groove of one of the gudgeon pin bosses. Ensure that it fits correctly in the

groove.
3 With the piston upside down, put the connecting rod in position with the recess for the location of the big end

bearing (B1) on the same side as the recess in the gudgeon pin boss (B2). If the original piston is used, ensure
that it is assembled to the correct connecting rod and is used in the original cylinder. If a new connecting rod
is fitted, ensure that it is of the correct length grade, see Operation 4-11.

4 Lubricate the gudgeon pin bosses with clean engine lubricating oil and push in the gudgeon pin towards the
circlip. If the gudgeon pin is a tight fit in the piston, heat the piston to 40/50 °C (100/120 °F) before the gudgeon
pin is fitted.

5 Fit a new circlip in the groove in the other gudgeon pin boss. Ensure that it fits correctly in the groove.
6 Fit the piston rings, see Operation 4-8.

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