Perkins Engine 4.108, 4.107, 4.99 Service Manual

workshop manual for

4.108 4.107 and 4.99 diesel engines

©

Perkins Engines Limited

Peterborough England

1983

All Rights Reserved

Publication No. 601 SER 0383 1072

This publication supersedes the previous edition numbered 601 SER 12771072

This publication is written for world wide use. In territories where legal requirements govern smoke emission, noise, safety factors etc., then all instructions, data and dimensions given must be applied in such a way that, after servicing (preventive maintenance) or repairing an engine, it does not contravene the local regulations in use.

Published by the Technical Publications Department of Perkins Engines Ltd. and Printed in England by Warners (Midlands) pic

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Page 2

I PERKINS COMPANIES

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AUSTRALIA

FRANCE

GERMANY

ITALY

JAPAN

SINGAPORE

UNITED KINGDOM

U.S.A.

Perkins Engines Australia Pty. Ltd.

Suite 2, 364 Main Street, Mornington 3931, Victoria, Australia. Telephone: [phone]. Telex: Perkoil AA30816. Fax: [phone].

Moteurs Perkins S.A.

9-11 Avenue Michelet, 93583 Saint Ouen, Cedex, France. Telephone: [phone]. Telex: 642924F. Fax: [phone].

Perkins Motoren G.m.b.H.

8752 Kleinostheim, Postfach 1180, West Germany.

Telephone: Kleinostheim 6027 5010. Telex: 4188869A PER D.

Fax: [phone].

Motori Perkins S.p.A.

Via Socrate 8, 22070 Casnate con Bernate (Como), Italy.

Telephon: [phone]. Telex: 380658 Perkit I. Fax: [phone].

Massey Ferguson Perkins Engines K.K.

Reinanzaka Building, 6th Floor, 14-2 Akasaka, 1-chome, Minato-ku, Tokyo 107, Japan. Telephone: [phone]. Telex: Perkoil J2424823. Fax: [phone].

Perkins Engines Asia Pacific,

4 Kian Teck Drive, Singapore 2262.

Telephone: [phone]. Telex Perkoil RS37729. Fax: [phone].

Perkins Engines Limited,

Eastfield, Peterborough, PE1 5NA, England.

Telephone: [phone]. Telex 32501 Perken G. Fax: [phone].

Perkins Engines (Shrewsbury) Limited,

Sentinel Works, Shrewsbury SY1 4DP, England.

Telephone: [phone]. Telex: 35171/2 PESL G. Fax: [phone].

Perkins Engines Inc.,

1700 Bellemeade Court, Lawrenceville, Georgia 30245, U.S.A.

Telephone: [phone]. Telex: 544141 Perken Law. Fax: [phone].

Perkins Engines Latin America Inc.,

Suite 620,999 Ponce de Leon Boulevard, Coral Gables, Florida 33134, U.S.A. Telephone: [phone]. Telex: 32501 Perken G. Fax: [phone].

In addition to the above, there are Perkins distributors in most countries. Perkins Engines Ltd., Peterborough or one of the above companies can give details.

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Page 3

FOREWORD

This workshop manual has been compiled for use in conjunction with normal workshop practice. Mention of certain accepted practices therefore, has been purposely omitted in order to avoid repetition.

Reference to renewing joints and cleaning off joint faces has to a great extent been omitted from the text, it being understood that this will be carried out where applicable.

Similarly, it is understood that in reassembly	and inspection, all parts are to be thoroughly
cleaned and where present, burrs and scale are to be removed.
It follows that any open ports of high precision components,		e.g.,	fuel injection equipment, ex-
posed by dismantling, will be blanked off until	reassembled, to prevent the			ingress	of foreign
matter.
: When setscrews or studs are fitted into holes	which are	tapped	through	into the	inside of
: the engine, a suitable sealant must be used on	the threads.

Throughout this manual, whenever the "left" or "right" hand side of the engine is referred to, it is that side of the engine as viewed from the flywheel end.

The engine number is stamped on the fuel pump mounting flange as shown in the above illustration.

Three systems of engine numbering have been used.

On very early engines the serial number consisted of seven digits as follows : -

Engine Type	Typical Engine Number
4.108	7300269
4.107	7100399
4.99	7000251

Identification on these engines can be identified by cbserving the first two figures of the engine number which remain constant depending on engine type.

With later engines, the number consisted of figures and letters

Engine Type	Typical Engine Number
4.108	108U251
4.107	107U251
4.99	99U251

The first figures represent the capacity of the engine in cubic inches, the letter "U" signifies that the engine was built in the United Kingdom and the last group of figures comprises the engine serial number.

On current engines, the number can consist of up to fifteen letters and figures, a typical number being ED21512U510256D

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Page4 ~ Safety precautions

THESE SAFETY PRECAUTIONS ARE IMPORTANT. Reference must also be made to the local regulations in the country of operation.

Do not use these engines in marine applications.

Do not change the specification of the engine.

Do not smoke when you put fuel in the tank.

Clean away any fuel which has fallen and move material which has fuel contamination to a safe place.

Do not put fuel in the tank during engine operation (unless really necessary).

Never clean, lubricate or adjust the engine during operation (unless you have had the correct training when extreme caution must be used to prevent injury).

Do not make any adjustments you do not understand.

Ensure the engine is not in a position to cause a concentration of toxic emissions.

Persons in the area must be kept clear during engine and equipment or vehicle operation.

Do not permit loose clothing or long hair near parts which move.

Keep away from parts which turn during operation. Note that fans can not be seen clearly while the engine is run.

Do not run the engine with any safety guards removed.

Do not remove the radiator cap while the engine is hot and the coolant is under pressure as dangerous hot coolant can be discharged.

Do not use salt water in the cooling system or any other coolant which can cause corrosion.

Keep sparks or fire away from batteries (especially during charge) or combustion can occur. The battery fluid can burn and is also dangerous to the skin and especially the eyes.

Disconnect the battery terminals before you make a repair to the electrical system.
Only one person must be in control of the engine.
Ensure the engine is only operated from the control panel or operators position.
If your skin comes into contact with high pressure fuel, get medical assistance immediately.
Diesel fuel can cause skin damage to some persons.		Use protection on	the hands	(gloves	or
special skin protection solutions).
Do not move equipment unless the brakes are in	good condition.
Ensure that the transmission drive control is in	"Out	of Drive" position	before the	engine	is
started.

Fit only correct Perkins Parts.

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Page 5

CONTENTS

ENGINE VIEWS	A
TECHNICAL DATA	B
OPERATING AND MAINTENANCE	C
FAULT FINDING	D
CYLINDER HEAD	E
PISTONS AND CONNECTING RODS	F
CYLINDER BLOCK AND LINERS	G
CRANKSHAFT AND MAIN BEARINGS	H
TIMING CASE AND DRIVE	J
TIMING	K
LUBRICATING SYSTEM	L
COOLING SYSTEM	M
AIR CLEANERS AND FUEL SYSTEM	N
FLYWHEEL AND HOUSING	P
ELECTRICAL EQUIPMENT	Q
ENGINES FOR REFRIGERATION UNITS	R
APPROVED LUBRICATING OILS	Appendix
APPROVED SERVICE TOOLS
INDEX

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Page 6

EXAMPLES OF SERVICE FACILITIES

Service

If any problems occur with your engine or the components fitted to it, your Perkins distributor can make the necessary repairs and will ensure that only the correct parts are fitted and that the work is done correctly.

Certain components can be supplied by your Perkins distributor through the Perkins Power exchange system. These will enable you to red uce the cost of some repairs.

Extended Warranty

The engine warranty period can be extended to two years. For details, get in contact with your nearest Perkins distributor.

Service Literature

Users handbooks and other service publications are available from your Perkins distributor at a nominal cost.

Training

Local training on correct engine operation, overhaul and service is available at some Perkins distributors. If special training is needed, your Perkins distributor can give details on how to get this at the Product Education Department, Peterborough, or other main centres.

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SECTION A

Engine Views

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ENGINE VIEWS-A.2

Index to Engine Views

Dynamo Pulley

2Water Pump Pulley

3Water Outlet

4Exhaust Manifold

5Breather

6Atomiser

7Thermostat Housing

8Fuel Injection Pump

9Starter Motor

10Lubricating Oil Filter 11 Timing Pin

12 Crankshaft Pulley

13Timing Case

14Fan Belt

15Water Pump

16Cylinder Head Cover

17Fuel Oil Filter

18Starting Aid

19Induction Manifold

20	Oil Filter

21Dipstick

22Dynamo

23W?ter Inlet

24Lubricating Oil Pump Locating Setscrew 25 Lubricating Oil

26 Sump Drain Plug

27 Flywheel Housing

28 Cylinder Block Drain Tap

29 Fuel Lift Pump

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ENGINE VIEWS-A.3

2

3

4

5

----- 7

9

VIEW OF FUEL PUMP SIDE OF ENGINE

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ENGINE VIEWS-A.4

1

17

1

20

VIEW OF CAMSHAFT SIDE OF ENGINE

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SECTION B

Technical Data

Engine Data

			4.108 and 4.107		4.99
Bore (nominalSee Page B.3) ...			3.125 in (79,37	mm)	3.00	in	(76,2 mm)
Stroke ...			3.5 in (88,9 mm)		3.5	in	(88,9	mm)
No. of Cylinders			Four		Four
Cubic	Capacity ...		107.4 in 3 (1,760	litre)	99 in 3		(1,621	litre)
Compression		Ratio	22:1		20:1
Firing Order			1,3,4,2.		1, 3, 4,		2.
Cycle	'"		Four-Stroke		Four-Stroke
Combustion		System	Indirect Injection		Indirect Injection
Engine Rotation ...			Clockwise viewed from		Clockwise viewed from
			front		front

Rating Details

				4.99		4.107		4.108
Maximum	Gross	Rated	Output	48 bhp	(37 kW)	41 bhp	(30,6 kW)	55 bhp		(41 kW)
				at 4000	rev/min	at 3000	rev/min	at	4000	rev/min
Maximum	Gross	Torque	Output	73 Ibf ft	(10,1 kgf m)	79 Ibf ft (10,9 kgf m)		83 Ibf ft (11,5 kgf m)
				at 2250	rev/min	at 1900	rev/min	at	2200	rev/min

Engine Weights, Dry

Approx. dry weight, bare engine, i.e. complete with fuel injection equipment, pressed steel oil sump, dynamo, water pump, but not including starter motor, air cleaner, fan, flywheel or flywheel housing: 330 Ib (150 kg).

Typical dry weight, engine with all accessories: 450 Ib (204 kg).

Where engines are called upon to operate in rarefied	atmospheres occasioned by altitude, such engines should be
de-rated.
The following table is given as a general guide, which	may be applied on a percentage basis, where specific figures
for a particular engine rating are not available.

Altitude				Maximum fuel delivery de-rating*
0- 2,000 feet		( 600 metre)		No change
2,000- 4,000	feet	(1,200	metre)	6%
4,000- 6,000	feet	(1,800	metre)	12%
6,000- 8,000	feet	(2,400	metre)	18%
8,000-10,000	feet	(3,000	metre)	24%
10,000-12,000 feet		(3,600	metre)	30%
* Measured at setting speed given				in pump setting code.

Any necessary adjustments in this respect to the fuel pump should be carried 01.11 by the C.A.V. dealer or Perkins Distributor for the territory concerned.

For any further information apply to Technical Services Department, Perkins Engines Limited, Peterborough or to one of the Perkins Companies listed on Page 2.

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TECHNICAL DATA-B.2

Recommended Torque Tensions

The following torque figures will apply with the components lightly oiled before assembly:-

					4.107 and	4.99		4.108
				Ibf ft	kgf m	Nm	Ibf ft	kgf m	Nm
Cylinder Head Nuts				42	5,81	57	60	8,3	81
Connecting Rod Setscrews				42	5,81	57	42	5,81	57
* Main Bearing Setscrews				85	11,5	115	85	11,5	115
Flywheel Setscrews				60	8,3	81	60	8,3	81
Idler Gear Hub Setscrews				36	4,98	49	36	4,98	49
Crankshaft Pulley Setscrew-1.56 in (39,6 mm) long				150	20,7	203	150	20,7	203
with 1.875 in (47,6 mm) dia. washer
Crankshaft Pulley Setscrew -1.68 in (42,7 mm) long							190	26,3	250
with 1.75 in		(44,6 mm) dia. washer (Cadmium Plated)
Crankshaft Pulley Setscrew (Phosphated)							230	31,5	310
Atomiser Securing Nuts . , .				12	1,7	16	12	1,7	16
High Pressure Fuel Pipe Nuts				15	2,1	20	15	2,1	20
Dynamo Pulley Retaining			Nut	20	2,8	27	20	2,8	27
Alternator Pulley Retaining			Nut	30	4,1	41	30	4,1	41
Thermostart Unit				10	1,38	13	10	1,38	13
Thermostart Insulating Adaptor				10	1,38	13	10	1,38	13
*The	tab and	shim washers may be discarded where		used	on earlier	engines,	but the setscrews must		be tightened
to the	torque	loading indicated.

Service Wear

Limits

The following "wear limits" indicate the condition when it is recommended

that

the respective items should

be servicec

or replaced.

Cylinder

Head

Bow

Longitud inal

0.006

in

(0,15 mm)

Cylinder

Head

Bow

Transverse

0.003 in (0,08 mm) concave

0.005 in (0,13

mm) convex

Maximum Bore Wear (when new liners are necessary)

0.006 in (0,15mm)

Crankshaft

Main

and

Big

End

Journal

Wear

0.001 in

(0,03 mm)

Crankshaft

Main

and

Big

End

Journal

Ovality

0.0005 in (0,01 mm)

Maximum

Crankshaft

End

Float

0.020 in

(0,51 mm)

Valve

Stem

to

Guide

Clearance

inlet

0.005

in

(0,13

mm)

Valve

Stem

to

Guide

Clearance

exhaust

0.006

in (0,15

mm)

Valve Head Thickness at outer edge

0.025 in (0,64 mm)

Rocker Clearance on

Shaft

0.005 in (0,13mm)

Camshaft

Journals

Ovality

and Wear

0.002 in (0,05 mm)

Camshaft

End Float

0.020

in

(0,51 mm)

Idler

Gear

End

Float

0.010

in

(0,25

mm)

*Valve Head Depth below Head Face-inlet and exhaust

0.048 in (1,22 mm)

*Where vehicle engines have to conform with the smoke

density regulation

B.S.AU 141 a: 1971, then the

valve depths

must

not

exceed

production limits as

given on page B.8.

Manufacturing Data and Dimensions

The data regarding clearances and tolerances are given for personnel engaged upon major overhauls.

Further information can be obtained on request from the Technical Services Department, Perkins Engines Ltd., Peterborough.

CYLINDER BLOCK

Total Height of Cylinder Block
between Top & Bottom Faces	4.108,4.107,4.99
Parent Bore Dia. for Cylinder Liner	4.108
Parent Bore Dia. for Cylinder Liner	4.107,4.99
Main Bearing Parent Bore	4.108,4.107,4.99
Camshaft Bore Dia. No.1	4.108,4.107,4.99
Camshaft Bore Dia. No.2	4.108,4.107,4.99
Camshaft Bore Dia. No.3	4.108,4.107,4.99
Tappet Bore Dia.	4.108,4.107,4.99
Fuel Pump Drive Hub Bearing
Bore Dia.	4.108,4.107,4.99

9.936/9.939 in	(252,374/252,451			mm)
3.249/3.250 in	(82,525/82,550 mm)
Wet Liners
2.3950/2.3955	in	(60,833/60,846		mm)
1.794/1.7955 in		(45,568/45,606	mm)
1.78411.787 in	(45,314/45,390		mm)
1.776/1.778 in	(45,110/45,161		mm)
0.562/0.56325	in	(14,275/14,307		mm)
1.812511.8141	in	(46,037/46,078		mm)

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TECHNICAL DATA-B.3

Cylinder Liner	4.108
Type		Cast Iron -	Dry - Interference Fit
Interference Fit of	Liners	0,003/0.005	in	(0,076/0.127	mm)
Inside Dia. of Liner after Finish Boring and Honing		3.12513.126	in	(79,375179,40	mm)
Height of Liner in relation to Cylinder Block Top Face		0.023/0.027 in (0,584/0,686 mm) above
Overall Length of	Liner	6.495/6.505	in	(164,973/165,227 mm)

Cylinder Liner	4.107 and 4.99
Type
Inside Dia. of Liner Pre-Finished				4.99
Inside Dia. of Liner Pre-Finished				4.107
Thickness of Top Flange.				4.99
Depth of Recess in Block for Liner Flange.				4.99
Thickness of Top	Flange..			4,107
Depth of Recess in Block for Liner Flange				4,107
Height of Liner in relation to
Cylinder Block	Top	Face	4,107	and 4.99
Liner Flange Outside		Dia.		4.99
Cylinder Block Top Bore for Liner Flange				4.99
Clearance Fit of Liner Flange
to Block Bore			4.107 and 4.99

Cast Iron -	Wet		Push Fit
3,00/3.001	in	(7620176.225		mm)
3.125/3,126	in	(79,374179.4		mm)
0.312510.3145		in	(7,93717,988		mm)
0.3115/0.3135		in	(7,91217,963		mm)
0.25010,252	in	(6.35/6,4 mm)
0.249/0,251	in	(6.325/6,375		mm)

0.003 in (0,076 mm) Above. 0.001 in (0.025 mm) Below

3.61813.621 in (91.898/91,973 mm) 3.625/3,627 in (92,075/92,125 mm)

0,00410.009 in (0,102/0.229 mm)

Pistons 4.108

Type

Piston Height in relation to Cylinder B!ock Top Face. Bore Dia. for Gudgeon Pin

Compression Ring Groove Width-Top

Compression Ring Groove Width-2nd

Compression Ring Groove Width-3rd Oil Control Ring Groove Width-4th Oil Control Ring Groove Width-5th

Flat Topped

0.00210.006 in (0,051/0.152 mm) Above 1.06255/1.06275 in (26,989/26.994 mm) 0.080510.0815 in (2,045/2,070 mm)

0.0645/0.0655 in (1,638/1,664 mm) 0.0645/0.0655 in (1,638/1,664 mm) 0.126/0.127 in (3.200/3,225 mm)

0.19010.191 in (4,826/4.851 mm)

i With engines rated at 3.000 rev/min or below, the fourth ring groove is the same as the fifth ring groove.

Note: There is a Steel Insert fitted above the Top Groove.

I Pistons 4.108 (Controlled Expansion)

I

IType ...

I Piston Height above Top Face of Cylinder Block I Bore Dia. for Gudgeon Pin

I Compression Ring Groove Width, Top

1Compression Ring Groove Width, Second and Third .. .

I Oil Control Ring Groove Width ... ... .. .

Flat Topped - Four Ring

0.002/0.006 in (0,05/0,15 mm) 1.062711.0629 in (26,992/26,999 mm)

0.080110.0821 in (2,035/2,086 mm)

0.06410.065 in (1,64/1,65 mm) 0.1887/0.1895 in (4,7914,81 mm)

: Pistons 4.108 (Controlled Expansion)

: Type ...

I Piston Height above Top Face of Cylinder Block : Bore Dia. for Gudgeon Pin

I CompreSSion Ring Groove Width, Top

: Compression Ring Groove Width, Second I Oil Control Ring Groove Width

Flat Topped - Three Ring

0.002/0.006 in (0,05/0,15 mm) 1.062711.0629 in (26,992/26,999 mm) 0.080/0.082 in (2,035/2,086 mm) 0.09910.1005 in (2,53/2,55 mm) 0.1890/0.1900 in (4,8014,826 mm)

Pistons 4.107 and 4.99

Type

Piston Height in relation to Cylinder Block Top Face .. Bore Dia. for Gudgeon Pin

later 4.99 and all 4.107 engines ...

Early 4.99 engines

Compression Ring Groove Width-Top Compression Ring Grooves Width 2nd and 3rd Oil Control Ring Grooves 4th and 5th

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Flat Topped

0.0085/0.012 in (0,2210,30 mm) Above

0.93755/0.93775 in (23,81/23,82 mm) 0.87505/0.87525 in (22,22122,23 mm)

0.0801/0.0811 in (2,034/2,06 mm) 0.0645/0.0655 in (1,638/1,664 mm) 0.190/0.191 in (4,826/4,851 mm)

TECHNICAL DATA-B.4

Piston Rings

4.108

Top-Compression

Parallel Faced

Second and Third

Compression

Internally Stepped

Fourth-Oil Control

Laminated Segment '*

Fifth-Oil

Control

Slotted Scraper

Top Compression Ring Width

0.0771/0.0781

in

(1,958/1,984

mm)

Ring Clearance in Grove ...

0.0024/0.0044 in

(0,061/0,112

mm)

Second and Third Compression Ring Width

0.0615/0.0625

in

(1,562/1,587

mm)

Ring

Clearance in Groove

0.00210.004

in

(0,051/0,102

mm)

Fifth Scraper Ring Width ...

0.1865/0.1875

in

(4,737/4,762

mm)

Ring

Clearance in Groove

0.0025/0.0045 in

(0,063/0,114

mm)

Ring Gap-Top Compression

0.00910.017

in

(0,229/0,432

mm)

Ring Gap-Second and Third Compression .

0.00910.017

in

(0,229/0,432

mm)

Ring Gap-Fifth Scraper ...

0.00910.017

in

(0,229/0,432

mm)

:* Engines rated at 3,000 revlmin

and below have a slotted scraper fitted

in

the

fourth groove which has the same

I width, clearance and gap as the fifth ring.

: Piston

Rings

4.108(Controlied

Expansion -

Four Ring)

, Top

Compression

Chrome

Insert -

Parallel

Faced

I Second

and Third

Compression

Internally Stepped

I

Fourth

Oil

Control

Spring Loaded

Scraper

I Top Compression Ring Width

0.077/0.078

in

(1,96/1,98

mm)

I

Ring

Clearance

in

Groove

...

0.002/0.005

in

(0,05/0,13

mm)

: Second and Third Compression Ring Width

0.0615/0.0625 in

(1,5611,59 mm)

Ring Clearance in Groove

0.0015/0.0035

in

(0,0410,09

mm)

IOil Control

Ring

Width ...

0.186/0.1865 in (4,72/4,74 mm)

I Ring Clearance in Groove

0.0022/0.0035

in

(0,0510.09

mm)

J

Ring

Gap,

Top ...

. ..

0.012/0.023

in

(0,30/0,58

mm)

I

Ring Gap, Second and Third

0.009/0.020

in

(0,23/0,50

mm)

I

Ring

Gap,

Oil Control

0.010/0.021

in

(0,25/0,53

mm)

: Piston

Rings

4.108

(Controlled

Expansion -

Three Ring)

I

Top Compression

Chrome, Taper Faced

: Second Compression

Internally Stepped, Taper

Faced

I

Third

Oil Control

Spring Loaded

Scraper

I Top Compression Ring Width

0.0765/0.0775 in

(1,943/1,969

mm)

I

Clearance in Groove

...

0.0025/0.0055

in

(0,063/0,140

mm)

: Second Compression Ring Width

0.097/0.098

in

(2,46/2,49

mm)

I

Clearance

in

Groove

0.0015/0.0035 in

(0,039/0,089

mm)

I

Oil Control

Ring

Width

0.1865/0.1875

in

(4,737/4,763

mm)

: Clearance

in

Groove

0.0015/0.0035 in

(0,039/0,089

mm

I

Ring

Gap,

Top ...

0.01210.023

in

(0,31/0,59 mm)

I Ring

Gap, Second

0.009/0.020

in

(0,23/0,51

mm

I Ring

Gap,

Oil Control

0.012/0.023

in

(0,31/0,59

mm

Piston Rings

4.99 Vehicle

Top Compression

Parallel Faced Chrome Plated

Second

and

Third

Compression

Internally Stepped

Fourth and Fifth Oil Control

Slotted Scraper

Piston

Rings

4.107

and 4.99

and Industrial

Top Compression

Parellel Cast Iron

'Secondand Third Compression

Internally Stepped

Fourth-Oil Control

Chrome Plated Spring Loaded Scraper

Fifth-Oil Control

Slotted Scraper

• 4.99 Agricultural engines have taper faced cast iron compression rings fitted in the second and third ring grooves.

Top Compression Ring Width	0.0771/0.0781		in	(1,96/1,984		mm)
Ring Clearance in Groove	0.002/0.004	in	(0,051/0,102			mm)
Second and Third Compression Ring Width.	0.0615/0.0625 in			(1,562/1,587 mm)
Ring Clearance in Groove	0.00210.004	in	(0,051/0,102			mm)
Fourth and Fifth Scraper Ring Width	0.1865/0.1875		in	(4,73714,762 mm)
Ring Clearance in Groove	0.0025/0.0045 in			(0,064/0.114 mm)
Ring Gap-Compression Rings Chrome Vehicle	0.01210.020	in	(0,30/0,50 mm)
Ring Gap-Oil Control Rings Cast Iron Vehicle	0.009/0.017	in	(0,30/0,432		mm)
Ring Gap-Compression Rings Cast Iron
Agricultural and Industrial	0.009/0.017	in	(0,30/0,432		mm)

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		TECHNICAL DATA-B.S
Gudgeon Pin 4.108
Type	Fully Floating
Outside Dia. of Gudgeon Pin	1.0625/1.0627	in (26,987/26,993 mm)
Length of Gudgeon Pin	2,673/2,687 in	(67,894/68,250 mm)
Fit in Piston Boss	Transition

Gudgeon Pin 4.107 and 4.99

Type	Fully Floating
Outside Dia. of Gudgeon Pin (Later Engines)	0.9375 in/0.9377 in (23,812/23,817 mm)
Outside Dia. of Gudgeon Pin (Earlier Engines)	0.875/0.8752 in (22,225/22,23 mm)
Fit in Piston Boss	Transition

Small End Bush 4.108

Type

Length of Small End Bush

Outside Dia. of Small End Bush

Inside Dia. before Reaming

Inside Dia. after Reaming

Clearance between Small End Bush and Gudgeon Pin

Steel Backed, Lead Bronze Lined

0.935/0.955 in (23,749/24,257 mm) 1.221/1.222 in (31,013/31,039 mm) 1.0495/1.0545 in (26,657/26,784 mm)

1.06315/1.0632 in (27,004/27,005 mm) 0.00045/0.0007 in (0,0114/0,0178 mm)

Small End Bush 4.107 and 4.99

Type	Steel Backed, Lead Bronze Lined
Length of Small End Bush	0.865/0.885	in	(22,00/22,48 mm)
Outside Dia. of Small End Bush
on later 4.99 and all 4.107 engines	1.06511.066	in	(27,05/27,08 mm)
Early 4.99 engines	1.0025/1.0035 in			(25,46125,49 mm)
Inside Dia. after Reaming on later
4.99 and a/l 4.107 engines	0.9382/0.93875		in	(23,83/23,84 mm)
Early 4.99 engines	0.8757/0.87625		in	(22,24/22,26 mm)
Clearance between Small End Bush and Gudgeon Pin	0.0005/0.00125		in	(0,0110,03 mm)

Note. Bushes to be reamed to suit respective Gudgeon Pins, and are provided with a reaming allowance.

nSI::ti§11n Rod 4.108

Type

Cap Location to Connecting Rod

Big End Parent Bore Dia.

Small End Parent Bore Dia.

Length from Centre Line of Big End

to Centre Line of Small End

Big End Setscrew

Connecting Rod End Float

'H'Section

Serrations, Offset 45 to the Horizontal 2.146/2.1465 in (54,508/54,521 mm) 1.21875/1.21975 in (30,956/30,981 mm)

6.217/6.219 in (157,912/157,963 mm) 0.375 in (i in) U.N.F.

0.006510.0105 in (0,165/0,267 mm)

Connecting Rod 4.107 and 4.99

Type		'H'Section
Cap Location to Connecting Rod		Serrations, Offset 45'to the Horizontal
Big End Parent Bore Dia.		2. i 46/2.1465 in (54,508/54,521					mm)
Small End Parent Bore Dia.
on later 4.99 and all 4.107 engines		1.0625/1.0635		in	(26,99/27,01		mm)
Early 4.99 engines		1.00/1.001	in	(25,4/25,43mm)
Length from Centre Line of Big End to Centre Line of
Small	End	6.405/6.407	in	(162,69/162,74 mm)
Big End	Setscrew	0.375 in (i	in) U.N.F.
Connecting Rod End Float
on later 4.99 and all 4.107 engines		0.0065/0.0105		in	(0,1610,27	mm)
Early 4.99 engines		0.0075/0.0105		in	(0,19/0,27	mm)

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TECHNICAL DATA-B.G

Connecting Road Alignment 4.108,4.107,4.99

Large and small end bores must be square and parallel with each other within the limits of ::'::0.010in (0,25 mm) measured 5 in (127 mm) each side of the axis of the rod on test mandrel as shown in Fig. B.1. With the small end bush fitted, the limit of ::'::0.010in (0,25 mm) is reduced to ::'::0.0025in (0,60 mm).

				....
		Ej~	-- -		~	-	c: E
				I
		.= E	Sin ..				.- E
		=.-			Sin	..	=-.::t
		-.::t	~
		It')					' - It')
			-127mm
		=N				- C?N
		00			-- 127mm		=0
		+1 +.					+1+.
			,;		t-.		...J
		...J
		"			-		'f
		B1	i..- :..,...
Crankshaft	4.108,4.107,4.99
Overall Length					21.125 in (536,575 mm)
Main Journal Dia. Nos. 1 and 2					2.248/2.2485 in		(57,099/57,112	mm)
Main Journal Dia. No.3					2.2475/2.248 in		(57,086/57,099 mm)
Main Journal	Length	No.			1.40625 in	(35,719 mm)
Main Journal Length No.2					1.496/1.504	in	(37,998/38,202	mm)
Main Journal	Length	NO.3			1.499/1.502	in	(38.075/38,151	mm)
Main Journal	Fillet Radii				0.12510.141	in	(3,175/3,581 mm)

Crankpin	Dia.	1.9993/2.0001 in	(50,78/50,80 mm)
Crankpin	Length	1.1875/1.1895 in	(30.162/30,213 mm)
Crankpin	Fillet Radii	0.15625/0.17187	in (5/32/11/64 in)

				(3,969/4,366		mm)
Surface Finish-All Journals				8-16 micro-in (0,2 - 0,4 micron)
Main Journal and Crankpin Regrind Undersizes				0.010.0.020,0.030 in (0,25, 0.51.0.76 mm)
Oil	Seal	Helix	Dia.	2.21075/2.21175			in (56,153/56.178	mm)
Oil	Seal	Helix Width		0.050/0.080 in		(1,270/2,032 mm)
Oil	Seal	Helix Depth		0.004/0.008 in		(0,102/0.203 mm)
Flange Dia.				3.9985/3.9995		in	(101,562/101,587	mm)
Flange Width				0.500 in	(12,700 mm)
Spigot Bearing Recess Depth				0.875 in	(22,225		mm)
Spigot Bearing			Recess Bore	1.250 in	(31,750		mm)
Crankshaft End			Float	0.002/0.015 in		(0.0508/0.381 mm)

Crankshaft Thrust Washers 4.108, 4.1

4.99

Type

Position in Engine

Thrust Washer Thickness (STD)

Thrust Washer Thickness (O/S)

Thrust Washer Outside Dia.

Thrust Washer Inside Dia.

Main Bearings 4.108, 4.101, 4.99

Type

Shell Width

Outside Dia. of Main Bearing

Inside Dia. of Main Bearing

Running Clearance-Nos. 1 and 2 .

Running Clearance-No. 3

Steel Thickness

Aluminium Thickness

Steel BaCked-Lead Bronze Faced Rear Main Bearing

0.089/0.091 in (2,261/2,311 mm) 0.0965/0.1005 in (2,451/2,553 mm)

3.24513.255 in (82,423/82.677 mm) 2.590/2.600 in (65.786/66,040 mm)

Pre-finished, Steel Backed. Aluminium Tin Lined

1.245/1.255 in (31.623/31.877 mm) 2.3955 in (60,846 mm)

2.2505/2.2515 in (57,163/57,188 mm)

0.002/0.0035 in (0.051/0,089 mm) 0.0025/0.004 in (0,063/0.102 mm) 0.060 in (1,524 mm) Max.

0.01210.01225 in (0.305/0,311 mm)

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Connecting Rod Bearings 4.108, 4.107, 4.99

Type

Shell Width

Outside Dia. of Can. Rod Bearing .

Inside Dia. of Can. Rod Bearing

Running Clearance

Steel Thickness .

Aluminium Thickness

Camshaft 4.108,4.107,4.99

No. 1 Journal Length

No.1 Journal Dia.

No.1 Cylinder Block Camshaft Bore Dia.

No. 1 Journal Running Clearance

No. 2 Journal Length

No. 2 Journal Dia.

No.2 Cylinder Block Camshaft Bore Dia.

No.2 Journal Running Clearance

No. 3 Journal Length

No. 3 Journal Dia

NO.3 Cylinder Block Camshaft Bore Dia.

NO.3 Journal Running Clearance ...

Cam Lift

Oilways for Rocker Shaft Lubrication

Camshaft Thrust Plates 4.108, 4.107, 4.99

Type

Thrust Plate Outside Dia.

Cylinder Block Recess Dia. for Thrust Plate

Clearance Fit of Thrust Plate in Recess

Thrust Plate Inside Dia.

Thrust Plate Thickness

Cylinder Block Recess Depth for Thrust Plate

Thrust Plate Height in relation to Cylinder Block Face

Camshaft End Float

Valve and Fuel Pump Timing

Refer to later section on timing (page K.1 ) .

CYLINDER HEAD 4.1 4.1 4.99

Overall Length of Cylinder Head

Overall Depth of Cylinder Head

Skimming Allowance on Cylinder Head Face

Pressure for Water Leakage Test

Valve Seat Angle

Bore in Cylinder Head for Guide

Bore in Cylinder Head for Combustion Chamber Inserts

Depth of Bore in Cylinder Head for

Combustion Chamber Inserts

Combustion Chamber Inserts 4.108, 4.101,4.99

Outside Dia. of Insert

Depth of Insert ...

Height of Insert in relation to Cylinder Head Face

Clerance Fit of Insert in Cylinder Head Bore

Method of Location in Cylinder Head

Valve Guides (inlet) 4.108,4.107,4.99

Inside Dia.

Outside Dia.

Interference fit of Guide in Cylinder Head Bore

Overall length of Guide ."

Guide Protrusion Above Top

Face of Cylinder Head

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TECHNICAL DATA-B.7

Pre-finished, Steel Backed, Aluminium Tin Lined 0.870/0.880 in (22,098/22,325 mm)

2.1465 in (54,521 mm)

2.0015/2.0025 in (50,838/50,863 mm) 0.0014/0.0032 in (0,036/0,081 mm) 0.060 in (1,524 mm) Max_ 0.012/0.01225 in (0,305/0,311 mm)

1.347/1.351 in (34,214/34,315 mm) 1.791/1.792 in (45,491/45,517 mm) 1.794/1.7955 in (45,568/45,606 mm) 0.002/0.0045 in (0,051/0,114 mm) 1,250 in (31,750 mm)

1.781/1.782 in (45,237/45,26'3mm) 1,784/1,787 in (45:314/45,390 mm) 0.002/0.006 in (0,051/0,152 mm)

1.000 in (25,400 mm)

1.773/1.774 in (45,034/45,060 mm) 1.776/1.778 in (45,110/45,161 mm) 0.002/0.005 in (0,051/0,127 mm)

0.2592/0.2622 in (6,58/6,66 mm) No. 2 Journal

180'Oil Impregnated Sintered Iron 2.555/2.557 in (64,897/64,948 mm) 2.5585/2.5685 in (64,986/65,240 mm) 0.0015/0.013 in (0,038/0,330 mm) 1.500 in (38,100 mm)

0.160/0.162 in (4,060/4,115 mm) 0.158/0.164 in (4,009/4,166 mm) 0.004 in (0,102 mm) above or below 0.003/0.009 in (0,076/0,228 mm)

20.000 in (508,000 mm)

2.617/2.633 in (66,472/66,878 mm)

NIL-On no account can the cylinder head face be skimmed

20 Ibflin2 (1,4 kgflcm2) -138 kN/m 2 45°

0.4995/0.5005 in (12,687/12,713 mm) 1.250/1.252 in (31,750/31,801 mm)

0.373/0.376 in (9,474/9,550 mm)

1.248/1.249 in (31,699/31,724 mm) 0.374/0.375 in (9,499/9,525 mm) 0.002 in (0,051 mm) above or below 0.001/0.004 in (0,025/0,102 mm)

By Cylinder Block Face and Expansion Washer

0.3141/0.3155 in (7,978/8,014 mm) 0.5021/0.5026 in (12,753/12,766 mm) 0.0016/0.0031 in (0,041/0,079 mm) 2.130 in (54,102 mm)

6.800/0.815 in (20,320/20,701 mm)

TECHNICAL DATA-B.B

Valve Guides (Exhaust) 4.10B, 4.107, 4.99

Inside Dia.	0.3141/0.3155 in				(7,978/8,014 mm)
Outside Dia.	0.5021/0.5026			in	(12,753/12,766 mm)
Interference fit of Guide in Cylinder Head Bore	0.001610.0031			in	(0,041/0,079	mm)
Depth of Counterbore	0.380	in	(9,650 mm)
Overall Length of Guide '"	2.440	in	(61,980 mm)
Guide Protrusion above Top Face of Cylinder Head	0.80010.815 in			(20,320/20,701		mm)

Valves (Inlet) 4.10B, 4,107, 4.99
Valve Stem Dia.	0.312/0.313 in	(7,92511,950 mm)
Clearance fit of Valve Stem in Guide	0.0011/0.0035 in (0,028/0,089 mm)
Valve Head Dia.	1.410/1.414 in	(35,814/35,916 mm)
Valve Face Angle	45'
Valve Head Depth Below Cylinder Head Face	0.028/0.039 in	(0,711/0,991 mm)
Overall Length of Valve	4.592/4.608 in	(116,637/117,043 mm)
Sealing Arrangement	Rubber Oil Seal

Valve (Exhaust)		4.108,4.107,4.99
Valve	Stem Dia.				0.3115/0.3125			in	(7,91217,937 mm)
Clearance Fit of Valve Stem in Guide					0.0016/0.004 in (0,041/0,102 mm)
Valve	Head Dia.				1.19111.195 in			(30,251/30,353 mm)
Valve	Face Angle				45°
Valve Head Depth Below Cylinder Head Face					0.021/0.032		in	(0,53'3/0,813 mm)
Overall Length of Valve					4.60014.616		in	(116,840/117,246		mm)
Sealing Arrangement					No Seal	fitted		to Exhaust Valve
Inner Valve Springs (where fitted)
Fitted	Length				1.530 in	(38,862 mm)
Load	at Fitted Length				28.6 Ibf::':::2 Ibf (13,0 kgf::':::0,91					kgf)
Fitted	Position				Damper Coil to Cylinder Head
Outer Valve Springs			4.10B,	4.107, 4.99
Fitted	Length				1.780 in	(45,212 mm)
Load	at Fitted Length				56.0 Ibf::':::2.8Ibf (25,4 kgf::':::1,27kg!)
Fitted	Position				Damper Coil to Cylinder Head
Rockel' level's		4.108,	4.107,	4.99
Length between Centre Line of Adjusting Screw and
Centre Line of Rocker Shaft					1.042/1.058 in			(26,467/26,873 mm)
Length between Centre Line of Rocker Lever Pad and
Centre Line of Rocker Shaft					1.567/1.583 in			(39,802/40,208 mm)
Inside Dia. of Rocker Lever Bore					0.71825/0.71950 in (18,243/18,275 mm)
Outside Dia. of Rocker Lever Bush					0.720510.7215			in	(18,301/18,326 mm)
Interference Fit of Bush in Rocker Lever					0.00110.00325			in	(0,025/0,082 mm)
Finished Inside Dia. of Rocker Lever Bush					0.6245/0.62575			in	(15,862/15,894 mm)
Clearance of Rocker Lever Bush on Rocker Shaft					0.00075/0.0035			in	(0,01910,089	mm)

Valve Clearances 4.108, 4.107, 4.99

Clearance between Valve Stem Tip and Rocker Lever

Rocker Shaft 4.108, 4.107, 4.99

Overall Length of Shaft

Outside Dia. of Shaft

Lubrication

0.012 in (0,30 mm) Cold

14.5625 in (369,887 mm)

0.62225/0.62375 in (15,805/15,843 mm)

Oil Feed from Cylinder Head through Central Passage to Individual Rocker Levers

Push Rods	4.108, 4.107, 4.99
Overall Length	8.527/8.560 in	(216,58/217,42 mm)
Outside Dia.	0.250 in (6,350	mm)

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			TECHNICAL DATA-B.9
Tappets 4.108, 4.107, 4.99
Overall Length	2.250 in (57,150		mm)
Outside Dia: of Tappet Shank	0.560/0.561 in	(14,224/14,249 mll'l)
Cylinder Block Tappet Bore Dia.	0.56210.56325	in	(14,275/14,307 mm)
Tappet Running Clearance in Cylinder Block Bore	0.001/0.00"325 in		(0,025/0,082 mm)
Outside Dia. of Tappet Foot	1.245/1.255 in	(31,623/31,877 mm)
TIMING GEARS 4.108, 4.107, 4.99

Note: Some engines are fitted with spur gears instead of helical gears, in which case the number of teeth on each gear are given in brackets.

Camshaft Gear

Number of Teeth	48 (50)
Inside Dia. of Gear Boss ...	1.750/1.7514 in	(44,450/44,486 mm)
Outside Dia. of Camshaft Hub	1.7496/1.7509 in	(44,430/44,473 mm)
Transition Fit of Gear and Hub	0.000910.0018 in	(0,023/0,046 mm)

Fuel Pump Gear

Number of Teeth	48 (50)
Inside Dia. of Cylinder Block Bore for Fuel	Pump
Drive Hub Bearing	1.8125/1.8141	in	(46,037/46,078	mm)
Outside Dia. of Fuel Pump Drive Hub Bearing	1.814511.8152 in		(46,088/46,106	mm)
Interference Fit of Drive Hub
Bearing in Cylinder Block Bore ...	0.0004/0.0027 in		(0,010/0,069 mm)
Inside Dia. of Fuel Pump Drive Hub Bearing	1.3125/1.3135 in		(33,34/33,78 mm)
Outside Dia. of Fuel Pump Gear Drive Hub ...	1.3105/1.3115 in		(33,287/33,312	mm)
Running Clearance of Drive Hub in Bearing	0.0031/0.0051	in	(0,079/0,129 mm)
Drive Hub End Float	0.00210.010 in	(0,051/0,254 mm)

Idler Gear and Hub

Number of Teeth	57 (42)
Inside Dia. of Gear Boss ...	1.7187/1.7197	in	(43,655/43,680	mm)
Inside Dia. of Gear Boss with Bush Fitted ...	1.562511.5641	in	(39,687139,728	mm)
Outside Dia. of Gear Hub	1.5612/1.5619 in		(39,654/39,668	mm)
Running Clearance of Gear on Hub	0.0003/0.0016	in	(0,008/0,041 mm)
Idler Gear Width	1.3105/1.3135	in	(33,287/33,363	mm)
Hub Width	1.316511.3195	in	(33,439/33,52	mm)
Idler Gear End Float	0.00310.008 in	(0,076/0,208 mm)

Crankshaft Gear

Number of Teeth	24 (25)
Inside Dia. of Gear	1.25011.2512 in	(31,750/31,780 mm)
Crankshaft Dia. for Gear ...	1.250/1.2506 in	(31,750/31,756 mm)
Transition Fit of Gear on Crankshaft	0.000610.0012 in	(0,015/0,030 mm)

Timing Gear Backlash

Clearance between Crankshaft!ldler and Camshaft!

Idler Gear 0.0015/0.0025 in (0,038/0,064 mm)

LUBRICATING SYSTEM 4.108,4.107,4.99

Lubricating Oil Pressure ...	30/60 Ibflin2 (2,1/4,2 kgflcm2) -2071414 kN/m 2 at
	maximum engine speed and normal working tempera-
	ture.

Sump

Dipstick Position	Camshaft side of engine opposite No.2 cylinder
Strainer Location	End of suction pipe to lubricating oil pump.

Typical Sump Capacities

Refill Capacities-Engine Level	Imp. pt	U.S. pt	Litre
Standard Sump ...	7.0	8.4	4.0
Vauxhall Motors	9.0	10.8	5.1
Chrysler Cars	8.6	10.3	4.9
Ford Motor Co....	8.75	10.5	5.0
Note: The above sump capacities are intended to be used	as a gUide and	actual capaCities should	be governed by
the level indicated on the dipstick.

When refilling the engine after an overhaul has been carried out a further 2 imp. pints, 2! U.S. pints or 1 litre approximately should be added to the capacities quoted, to allow for filling the pipes, oilways, filter assembly, etc.

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TECHNICAL DATA-B.10

Lubricating Oil Pump

Type

Number of Lobes-Inner Rotor

Number of Lobes-Outer Rotor

Method of Drive

Pump Clearances

Inner Rotor to Outer Rotor

Outer Rotor to Pump Body

Inner Rotor End Clearance

Outer Rotor End Clearance

Inside Dia. of ~ore for Pump Shaft

Outside Dia. of Pump Shaft

Running Clearance, Shaft in Bore ...

Lubricating Oil Pump Drive Gear

Number of Teeth

Inside Dia. of Gear Bore ...

Outside Dia. of Oil Pump Drive Shaft

Interference Fit of Gear on Shaft ...

Lubricating Oil Pump Drive Gear Backlash ...

Relief Valve

Type

Pressure Setting

Length of Plunger

Outside Dia. of Plunger ...

Inside Dia. of Valve Housing Bore ...

Clearance of Plunger in Bore

Outside Dia. of Spring

Spring-Free Length

Lubricating Oil Filter

Type

Element Type

By-Pass Valve Setting

COOLING SYSTEM 4.108, 4.101, 4.99

Type

Cylinder Block and Head

Engine Water Capacity (Less Radiator)

Thermostat

Type

Opening Temperature

Fully open at

Minimum Travel at Fully Open Temp.

Water Pump

Type

Outside Dia. of Shaft for Pulley (Separate Bearing Pump)

Inside Dia. of Pulley Bore (Separate Bearing Pump) Outside Dia. of Shaft for Pulley (Combined Bearing

and Shaft)

Inside Dia. of Pulley Bore (Combined Bearing and Shaft Pump) ...

Interference Fit of Pulley on Shaft .. .

Outside Dia. of Shaft for Impeller .. .

Inside Dia. of Impeller Bore Interference Fit of Impeller on Shaft

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Rotor Type

Three or Four

Four or Five

By Spiral Gears from the Camshaft

0.0005/0.0025	in	(0,013/0,063 mm)
0.01110.013 in	(0,28/0,33 mm)
0.0015/0.003 in		(0,038/0,076 mm)
0.0005/0.0025 in (0,013/0,063 mm)
0.50010.501 in	(12,700/12,725 mm)
0.4983/0.4986 in		(12,655/12,664 mm)
0.0014/0.0027 in		(0,036/0,069 mm)
12
0.496510.4970	in	(12,611/12,624	mm)
0.4983/0.4986	in	(12,655/12,664	mm)
0.001310.0021	in	(0,033/0,053 mm)

0.0155/0.019 in (0,394/0,483 mm)

Spring Loaded Plunger

50/65 Ibflin2 (3,5/4,6 kgflcm2) - 344/448 kN/m2 0.9375 in (23,813 mm)

0.5585/0.5595 in (14,19/14,21 mm) 0.5605/0.5625 in (14,24/14,29 mm) 0.001/0.004 in (0,025/0,102 mm)

0.368/0.377 in (9,347/9,576 mm) 1.5 in (38,10 mm)

Full Flow

Paper or Canister

Open between 13-17 Ibflin2

(0,91-1,2 kgflcm2) 90-117 kN/m2 pressure differential

Water Cooled

Thermo-Syphon Impeller Assisted

6 Imp. pt (7.2 U.S. pt or 3,4 Litre)

Wax Capsule

175-182°F (79,5-83,5°C)

200-205°F (93,5-96°C)

0.3125 in (7,94 mm)

Centrifugal-Belt driven from Crankshaft

0.5905/0.5908 in (14,999/15,006 mm) 0.588/0.589 in (14,935/14,961 mm)

0.6262/0.6267 in (15,808/15,920 mm)

0.6239/0.6247 in (15,849/15,869 mm) 0.0015/0.0028 in (0,038/0,071 mm) 0.498/0.499 in (12,649/12,675 mm) 0.497/0.4975 in (12,624/12,636 mm) 0.0005/0.002 in (0,013/0,051 mm)

TECHNICAL DATA-B.11

Outside Dia.	of Impeller	3.094/3.125 in (78,588179,375 mm)
Water Pump	Seal Type	Synthetic Rubber-Carbon Faced

FUEL SYSTEM	4.108,4.107,4.99
Approved Fuel Oil Specification
United Kingdom	8S.2869:1967
United States	VV-F-800a
	AS.T.M.lD975-66T
France	(J.O. 14/9/57)
India	IS: 1460/1968
Germany	DIN-51601 (1967)
Italy	CUNA-Gas Oil NC-630-01 (1957)
Sweden	SIS. 155432 (1969)
Switzerland	Federal Military Spec.
	9140-335-1404 (1965)

Class A1 or A2 Grades OF-A, or DF-2. Nos. 1-0 or 2-D.

Gas Oil or Fuel Domestique Grade Special or Grade A

Fuel oils available in territories other than those listed above which are to an equivalent specification may be used.

Fuel Lift Pump

Type	AC Delco Diaphragm 'YJ'Series
Spring Colour Code	Green
Method of Drive	From Eccentric on Camshaft via Push rod
Total Stroke of Operating Lever	0.192 in (4,877	mm)
Static Pressure-No Delivery	4-7 Ibflin2 (0,28-0,49 kgflcm2) - 28-48 kN/m2
Pump to Distance Piece Gasket Thickness ...	0.018/0.022 in	(0,457/0,559 mm)
Distance Piece-Lift Pump to Tappet Inspection Cover	0.256 in (6,502	mm)

Final Fuel Filter

Element	Type	Paper
Overflow Valve Type		Gravity 8all Check Valve
Valve in	Fuel Pump Drain Connection	Spring Loaded Non-Return Valve set at 0.71-1.25
		Ibflin2 (0,0522-0,0875 kgflcm2) - 5-9 kN/m2

Fuel Injection Pump

Make	CAV.
Type	D.P.A.
Rotation	Clockwise (Viewed from Drive End)
Plunger Dia.	6 mm
Hydraulically Governed	4.108	4.107	4.99
Timing Letter	A		A
No. 1 Cylinder Outlet	W		W
Mechanically Governed		c
Timing Letter	C		C
No. 1 Cylinder Outlet	W	W	W

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TECHNICAL DATA-B.12

Static Timing Position

The static timing position varies according to application, but can be obtained by referring to the first group of letters and digits of the fuel pump setting code (stamped on the fuel pump identification plate).

IOn the latest 4.108 engines the setting codes start with the fuel pump part number followed by the two code letters. Only the Itwo code letters are used in the table for identification purposes.

				(USING TIMING TOOL MS67B)			ALTERNATIVE DROP VALVE METHOD
	First Group of			Engine Checking		Fuel Pump Marking	Static Timing	Piston Displacement
	Fuel Pump Code			Angle (Degrees)		Angle (Degrees)	(Degrees) BTDC	in (mm) BTDC
					4.99
	AH28				282	29S	26	0.226 (5,74)
	BH26				287	300	26	0.226 (5,74)
	CH3S				280~	290	19	0.120 (3,05)
	DH19				287	300	26	0.226 (5,74)
	LH20 }				282	292	20	0.134 (3,40)
	LH26
	LH29				281	292	22	0.160 (4,06)
	MH26				281	290	18	0.110 (2,79)
					4.107
	CH3S				280~	290	19	0.120 (3,05)
	LH23}
	LH28				282	292	20
	LH29							0.134 (3,40)
	LH31		(exceptions
			below)
	LH31 1900/2/2770 }
	LH31 1900/2/3130				281	292	22	0.160 (4,06)
	LH31 1900/9/1880
	MH27}
	PH28				281	290	18	0.110 (2,79)
	PH30
	PH34				280	290	20	0.134 (3,40)
	iEH				4.108			0.11 °(2,79)
	EH34E				281	290	18
	EH39
	LH30				281	292	22	0.160 (4,06)
	IpH				281	290	18	0.1	0 (2,79)
	PH23E		(exceptions		281	290	18	0.110 (2,79)
	PH25E		below)
	PH2SESOO/S/24S0}
	PH2SESOO/9/1990				279~	290	21	0.150 (3,81)
	PH2SESOO/9/2090
	PH27 ~			-	281	290	18	'0.110(2,79)
	i PH28		(exceptions
	PH30		be/ow)
	PH30/S00/5/24SO }
	PH30/S00/6/1S70				279t	290	21	0.150 (3,81)
	PH30/S00/9/1990
	PH30/S00/9/2090
	:RH	1			279~	290	21	0.150 (3,81)
	RH30E
	SH33E
	ITH	}			281	291	20	0.134 (3,40)
	ITH23E .
	Note: For 4.107 and 4.99			mechanically governed engines r aled above 3,000 and 2,SOO rev I min respectively, the static
	timing is altered to		22' B.T.C.D.' piston displacement 0.160 in				(4,06 mmJ. For 4.108 engines prior to engine numbers

108U15973 and 108UD20214, the static timing was 19' B.T.D.C.·, piston displacement 0.120 in (3,05 mm). When re, setting these pumps, it is advisable to set at the figures quoted in above table.

For 4.107 industrial engines having a fuel pump coding of PH30 and an idling speed at 1,000 rev/min, the static timing is 21'B.T.D.C. and a piston displacement of 0.147 in (3,73 mm).

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TECHNICAL DATA-B.13

Atomisers

4.108 Veh., M., Ind., Comb.

4.107 M., Ind., TA

Make ...	CAV.
Holder Type	BKB40S05224
Nozzle Type	BON 12S06236
Code Letter	BG
Min. Working Pressure	135	atm (2000 Ibflin2 or 140 kgf/cm2)
Setting Pressure	150	atm (2200 Ibf/in2 or 155 k9f1cm2)

4.108M, Ind., Comb.

	Make ...	CAV.
	Holder Type	BKB40S05224
	Nozzle Type	BDN4SD6769
	Code Letter	GY			Ibflin2 or 140 kgflcm2)
!	Min. Working Pressure	135	atm	(2000
I	Setting Pressure	150	atm	(2200	Ibflin2 or 155 kgflcm2)

Note: Earlier atomisers bearing the identification code letter 'J'had a setting pressure of 140 atm. When servicing of these atomisers is carried out, they should be reset in accordance with the settings quoted above.

Make

Holder Type

Nozzle Type

Code Letter

Min. Working Pressure

Setting Pressure

Starting Aid

Make

Type Voltage

Maximum Current Consumption Fuel Flow Rate through Unit

Height of Reservoir (where fitted) above Centre of Thermostart ...

Make ...

Type ...

Max. Output

Alternator

Make

	Type ...
	Max. Output		(hot)
	AC5 (12V)
	AC5 (24V)
	11AC	(12V) ..
	11AC	(24V)
	15ACR
	17ACR
I	Starter	Motor
I	Make ...
I	Type ...
	Max. Current
",-(I!I'"	Starter Cable Resistance ...
I	No. of Teeth		on Pinion ...

4.99 Veh	4.99 Veh	4.99 Ind. & 4.107 Ind.
CAV.	CAV.	CAV.
BKB40S5223	BKB40S5224	BKB40S5224
BON12SD6236	BDN12SD6236 BDN4S6157
BK	BL	BE
120	125	130
130	130	135

CAV. Thermostart 12 Volt

12.9 Amperes at 11.5 Volts

4.3-4.9 cm 3 min at 70"F (21'C)

4.5-10 in (11,4-25,4 cm)

Lucas C40 11A

Lucas or C.A.V.

AC5 (12Vor24V), 11AC (12Vor24Vj, 15ACR (12V) and 17ACR (12V)

53A

30A

43A

23A

28A

36A

Lucas

MG45 or 2M113 900A

0.0017 ohms (Max.)

10

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SECTION C

Operating and Maintenance

Starting the Engine

If the weather is warm or the engine has only been stopped for a little while, place the accelerator in the fully open position and engage the starter motor by turning the starter switch in a clockwise direction to the "HS" position (See Fig. C.1).

If the battery is well up, enough to turn the starter motor quickly, the engine should start.

Always be sure that the starter pinion and flywheel have stopped revolving before re-engaging the starter, otherwise the ring or pinion may be damaged.

C1

1.Off Position

2.Run Position

3.Heat Position

4.Heat and Start Position

As soon as the engine starts, the switch should be returned to the "R" position, and the tap on the starting reservoir, when fitted, turned off.

NOTE: The above procedure is not necessary when the engine is hot. To re-start, turn the switch in a clockwise direction to the "HS" position which will engage the starter motor.

Earlier Heat Start Switch

The cold start switch fitted to earlier engines is shown in Fig. C.2.

With this switch, starting a warm engine is effected by turning the switch in a clockwise direction to the "S" position.

In cold weather, the switch should be turned to the "H" position for fifteen to twenty seconds and then to the "HS" position in order to engage the starter motor. As soon as the engine starts, the switch should be returned to the "0" position.

Where this type of switch is used, it was customary to have a separate switch for the electrical circuits and this should be turned on before starting the engine and turned off after stopping the engine.

To

Aid

In cold weather the procedure for the use of this equipment is as follows:-

Ensure that the engine stop control is in the "run" position.

Turn on the fuel supply tap of the starting aid reser- voir, where fitted.

Tum start switch in direction to "H" position for fifteen to twenty seconds.

With accelerator in the fully open position, turn the switch a further clockwise movement to the "HS" position thereby engaging the starter motor.

If the engine does not start after fifteen seconds, return switch to "H" position for ten seconds and then reengage the starter motor.

C2

1.Off Position

2.Start Position

3.Heat Position

4.Heat and Start Position

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OPERATING AND MAINTENANCE-C.2

Alternative Method

With some engines, a different starter switch is provided and the cold start aid is operated by means of a separate push button switch.

The cold starting procedure is the same i.e.

Switch on by turning the starter switch in a clockwise direction to the first position.

Press the heater button for fifteen to twenty seconds and then, with the heater button still pressed, turn the starter switch in a further clockwise direction to engage the starter motor. As soon as the engine starts, release switch and heater button.

I Glow Plugs

Glow plugs are sometimes fitted to engines in applications such as refrigeration units, fork lift trucks and other certain 4.108 mechanically governed engines rated at 3,000 rev/min and below. As the buss bar connecting these glow plugs may not be insulated, extreme care must be exercised to keep pipes, clips or other metal objects well clear as the consequences of a direct short of this buss bar to earth when energised are obvious.

It must be noted that in no circumstances should either or any other unauthorised starting aids be used at the same time as glow plugs.

To operate, use the following procedure : -

Before operating the starter motor, press the "Heat"

button	for 20 to 30 seconds.
I With	the "Heat" button still pressed, engage the

I starter motor until the engine starts.

IContinue to press the "Heat" button for a few seconds

I after the engine		has	started	until even	running has
: been	obtained.
Ilf the	engine does not start,			disengage	the	starter
I motor,	but keep	the	"Heat"	button pressed		for a

I further 10 to 15 seconds, when a further attempt should I be made to start the engine, keeping the glow plugs Ienergised whilst starting and for a few seconds after ithe engine has fired until even running is obtained.

Points to Note

Ensure that the electrical connection to the starting aid is correctly made.

Always ensure that the reservoir feeding fuel to the starting aid is fully primed and is not leaking. With some later engines, this fuel reservoir has been deleted, the cold start aid being fed direct from the fuel filter through a non-return valve.

Extended use of the cold starting equipment above the time periods already stated should be avoided, otherwise the starting aid in the induction manifold may be damaged also continuous flaming will starve the engine of oxygen.

In the event of difficult starting, check that fuel is reaching the starting aid in the induction manifold by unscrewing the inlet fuel connection. If fuel is reaching it satisfactorily, then it may be that the starting aid itself is not working correctly. This can be checked by removing the air cleaner and watching the starting aid whilst the equipment is used. When the starting switch

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is turned to the "heat" position, the element should become red hot, and upon engagement of the starter motor ignition of the fuel should take place.

4.108, 4.107 and 4.99 engines are fitted with efficient starting equipment and no responsibility can be accepted for any damage caused by unauthorised starting aids.

To prevent thermostart damage, it is essential that the thermostart is not operated DRY. After any operation which allows fuel to drain from the the thermostart feed pipe, the pipe must be disconnected at the thermostart and all air bled from the pipe before the thermostart is operated.

Where a thermostart starting aid has to be replaced, care must be taken not to exceed the torque figure quoted on Page B.2. Excessive torque loading can crack the insulator adaptor causing an electrical short and hard starting characteristics.

Stopping the Engine

A spring loaded stop control is located near the normal engine controls and functions by cutting off the fuel at the fuel injection pump.

To operate, pull the knob and hold in mis position until the engine ceases to rotate. Ensure that the control returns to the "run" position, otherwise difficutly may be experienced in re-starting the engine.

Return latest cold start switch to the "0" position.

Some engines may have an electric solenoid stop control on the fuel injection pump operated by a switch on the control panel.

Running In Procedure

It is not necessary to gradually run-in a new or factory rebuilt engine and any prolonged light load running during the early life of the engine can in fact prove harmful to the bedding in of piston rings and liners.

Full load can be applied On a new or factory rebuilt engine as soon as the engine is used, provided that the engine is first allowed to reach a temperature of at least 140°F (60°C).

PREVENTIVE MAINTENANCE

I These preventive		maintenance periods		are	general	in
I application.	Check the periods		given	by	the manu-
I facturer of	the	equipment in	which	the	engine	is

1 installed and, where necessary, use the shorter periods.

I	These		periods		and	procedures must also be adapted
I	to	ensure		correct		operation	for	any	local machine
I regulations.
I It is good				maintenance to check for leakage and loose
I fasteners at each service interval.
I 1 hese			maintenance			periods are only for engines that
I are		operated			with	fuel and	lubricating oil			to	the
I specifications given						in this manual.
I	The	schedules			which follow		must	be	applied	at	the
I interval			(miles,		kilometres, hours			or	months)	which
I	occurs		first.

IOn stop start low mileage work, the hours run are more applicable than the mileage covered.

Daily or every 8 hours

Check coolant level. Check sump oil level.

Check oil pressure (where gauge is fitted).

In extreme dust conditions, clean oil bath air cleaner and empty dust bowl on dry type air cleaner.

Every 4,000 miles (6,000 km), 150 hours or 3 months

t Drain and renew lubricating oil (see list of approved lubricating oils Appendix).

t Renew lubricating oil filter element or canister. Clean oil bath air cleaner.

Empty dust bowl on dry type air cleaner. 'Checkdrive belt tension.

Clean water trap.

Lubricate dynamo rear bush (where applicable).

Every 12,000 miles (18,000 km) 450 hours or 12 months

t Renew final fuel filter element - agricultural and industrial applications.

Clean element of dry type air cleaner or renew (if not indicated earlier).

Every 24,000 miles (36,000 km) or 900 hours

Renew final fuel filter element - vehicle applications.

miles (108,000 or hours

Arrange for examination and service of proprietary equipment, i.e., compressor, exhauster, starter, dynamo etc.

Service atomisers.

Check and adjust valve clearance.

t I	Refrigeration	unit engines have a larger capacity
I	sump and	larger lubricating oil filter canister,

therefore the lubricating oil and filter change can be extended to 1000 hours. Also with a primary fuel oil filter fitted, the main fuel filter element change period can be extended to 1000 hours.

'Thedrive belt tension should be checked monthly on engines rated above 3,000 rev/min.

POST DELIVERY CHECKOVER

After a customer has taken delivery of his Perkins Diesel engine, it is advisable, in his own interest, that a general checkover of the engine be carried out after

4.108 Series Workshop Manual, June 1986

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OPERATING AND MAINTENANCE-C.3

the first 500/1000 miles (800/1600 km) or 25/50 hours in service.

It is also recommended that the following procedure be adopted where an engine has been laid up for a considerable period before it is again put into service. With the engine thoroughly warmed through, this checkover should comprise the following points.

1.Drain lubricating oil sump. Renew lubricating oil filter element or canister. (Refer to Page L.5 or L.6) .

2.Remove the rocker assembly, check that the cylinder head nuts are to the correct torque. (Refer to Page B.2).

3.Refit rocker assembly and set valve clearances. (Refer to Page B.8).

4. Refill lubricating	oil sump with clean new oil to
the correct level.	(Do not overfill).

5.Check fan belt tension. (Refer to Page M.1).

6.Check coolant level in radiator, inspect for any coolant leaks.

7.Check security of all external nuts, setscrews, hose clips, mountings, etc.

8.Start engine and check for any fuel or lubricating oil leaks.

9.Carry out test to check general performance of engine.

Thereafter routine maintenance should be in accordance with Periodical Attentions which are given on previous Page.

NOTE: If the cylinder head is removed for any reason e.g. top overhaul, then it is recommended that the cylinder head nuts are retorqued as shown in Fig. E.23 after 500/1000 miles (800/1600 km) or 25/50 hours with the engine hot, to the setting given on Page B.2.

It is assumed that electrical equipment will have already been checked for such points as dynamo rate of charge, effectiveness of connections and circuits, etc.

ProtecUon of an engine not in service

The recommendations given below are to ensure that damage is prevented when an engine is removed from service for an extended period. Use these procedures immediately the engine is removed from service. The instructions for the use of POWERPART products are given on the outside of each container.

1. Thoroughly clean the outside of the engine.

2.Where a preservative fuel is to be used, drain the fuel system and fill with the preservative fuel. POWERPART lay-Up 1 can be added to the normal fuel to change it to a preservative fuel. If

preservative fuel is not used, the system can be Kept charged with normal fuel but this will have to be drained and discharged at the end of the period together with the fuel filter.

3.Run the engine until it is warm. Correct any fuel,

lubricating oil or air leakage. Stop the engine and drain the lubricating oil sump.

4.	Renew the lubricating oil filter canister.
5.	Fill the sump to the tull mark on the dipstick with
	c,ean new lubricating oil or with a correct
	preservative fluid. POWERPART lay-Up 2 can be
	added to the lubricating oil to give protection
	against corrosion	curing the period in storage.
	If a preservative	fluid is used, this must be
	drained and normal lubricating oil used when the
	engine is returned	to service.

OPERATING AND MAINTENANCE-C.4

6.Drain the cooling system, see below. To give

protection against corrosion, it is better to fill the cooling system with a coolant that has a corrosion

inhibitor, see		'Engine Coolant' below.		If frost
protection	is	needed,	use an antifreeze	mixture.
If no frost	protection		is needed, use water with
an approved corrosion			inhibitor mixture.

7.Run the engine for a short period to send the lubricating oil and coolant around the engine.

8.Clean out the engine breather pipe and seal the end of the pipe.

9.Remove the atomisers and spray POWERPART Lay-Up 2 into each cylinder bore. If this is not available, clean engine lubricating oil will give a degree of protection. Spray into the cylinder bores 140 ml L1- pint) of lubricating oil divided evenly between the four cylinders.

10.Slowly turn the crankshaft one revolution and then install the atomisers complete with new seat washers.

11.Remove the air filter and any pipe installed between the air filter and induction manifold. Spray POWERPART Lay-Up 2 into the induction manioold. Seal the manifold with waterproof tape.

12.Remove the exhaust pipe. Spray POWERPART Lay-Up 2 into the exhaust manifold. Seal the manifold with waterproof tape.

13.Remove the lubricating oil filler cap. Spray POWERPART Lay-Up 2 around tne rocker shaft

assembly. Fit the filler cap. Where the oil filler cap is not on the cylinder head cover, remove the cover to spray the rocker shaft assembly.

14.Disconnect the battery and put it into safe storage in a fully charged condition. Before the battery is put into storage, give the battery terminals a protection against corrosion. POWERPART Lay-Up 3

can be used on the terminals.

15. Seal	the	vent pipe of the fuel tank or the fuel
filler	cap	with waterproof tape.

16.Remove the fan belt and put it into storage.

17.To prevent corrosion, spray the engine with POWERPART Lay-Up 3. Do not spray inside the alternator cooling fan area.

NOTE: Before the	engine is started after a period
in storage,	operate the starter motor with the

engine stop control in the 'off'position until oil pressure shows on the oil pressure gauge or the oil warning light goes out. If a solenoid stop control is used, this will have to be disconnected for this operation.

If the engine protection is done correctly accoding to the above recommendations, no corrosion damage will normally occur. Perkins Engines Ltd. are not responsible for any damage that occurs in relation to a service storage period.

Engine Coolant

1he quality of the coolant used can have a large effect on the efficiency and life of the cooling system. The recommendations given below can be of assistance in the maintenance of a good cooling system with frost and/or corrosion protection.

1.Where possible, use clean soft water.

I 2. If an antifreeze mixture, other than Perkins POWERPART, is used to prevent frost damage,

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it must have an ethanediol (ethylene glycol) base with a corrosion inhibitor. It is recommended that the corrosion inhibitor is of the sodium nitrate/benzoate type. The antifreeze mixture must provide cooling/corrosion protection at least as good as the requirements of the standards below:

UK: 8S.6580: 1985: "Specification for corrosion inhibiting, engine coolant concentrate (antifreeze)". U.S.A. ASTM 03306-74 'EthyleneGlycol Base Engine

Coolant'.

Australia AS 2108-1977 'Antifreeze Compounds and Corrosion Inhibitors for Engine Cooling Systems'.

When Perkins POWER PART antifreeze is used, the correct mixtures of antifreeze and water are as given below. Perkins POWERPART Antifreeze fully passes the above standards.

			Mixture Ratio by
Lowest Temperature		%Volume	Volume
of		of	POWERPART
Protection Needed		POWERPART Antilreeze	Antifreeze:Water
-12°C (	10°F)	25	1:3
-18°C (	O°F)	33	1:2
25°C (	13°F)	40	1:1.5
-37°C (-34°F)		50	1:1

The quality of the antifreeze coolant must be

checked at least	once	a year, for example, at
the start of the cold period.
3. When frost protection is		not necessary, it is still
an advantage to	use	an approved antifreeze

mixture as this gives a protection against corrosion and also raises the boiling point of the coolant. A minimum concentration of 25% by volume of antifreeze is necessary, but it is our recommendation that 33% concentration by volume is used.

If an antifreeze is not used, add a correct corrosion inhibitor mixture to the water.

Change the water/corrosion inhibitor mixture every six months or check according to the inhibitors manufacturer'srecommendations.

Note: Some corrosion inhibitor mixtures contain soluble oil which can have an adverse effect on some types of water hose.

If the correct procedures are not used, Perkins Engines Ltd., can not be held responsible for any frost or corrosion damage.

To Drain the Cooling System

1.Ensure that the vehicle or machine is on level ground.

2.Remove the radiator filler cap.

3.Remove the drain plug from the side of the cylinder block (see engine views) to drain the

engine.	Ensure that the drain hole does not
have any	restriction.

4.Open the tap or remove the drain plug at the bottom to drain the radiator. If a tap or plug is not fitted to the radiator, disconnect the bottom radiator hose.

5.Where necessary, flush the system with clean water.

6.Fit the drain plugs and radiator cap. Where necessary, close the radiator tap or connect the radiator hose.

SECTION D

Fault Diagnosis

Fault																			Possible Cause
Low cranking speed	1, 2, 3, 4.
Will not start	5, 6, 7, 8, 9, 10, 12, 13, 14, 15, 16, 17, 18, 19, 20, 22, 31, 32, 33.
Difficult starting	5,7,8,9,10,11,12,13,14,15,16,18,19,20,21,22,24,29, 31, 32, 33.
Lack of power	8,9, 10, 11, 12, 13, 14, 18,															19,		20,		21,		22,		23, 24, 25, 26, 27,31, 32, 33.
Misfirjng	8,	9,		10,		12,		13,		14,		16,		18,		19,		20,		25,		26,		28,		29,		30, '32.
Excessive fuel consumption	11, 13, 14, 16, 18, 19, 20, 22, 23, 24, 25, 27, 28, 29, 31, 32, 33.
Black exhaust	11,13,14,16,18, 19,20,22,24,25,27,28,29,31,32,33.
Blue/white exhaust	4,	16, 18, 19, 20, 25, 27, 31, 33, 34, 35,																				45,		56.
Low oil pressure	4, '36,37, 38, 39, 40, 42, 43, 44, 58.
Knocking	9,	14,		16,		18,		19,		22,		26,		28,		29,		31,		33,		35,		36,		45,		46,	59.
Erratic running	7,	8, 9, 10, 11, 12, 13, 14, 16, 20, 21, 23, 26,																							28, 29, 30, 33, 35, 45, 59.
Vibration	13,		14,		20,		23,		25,		26,		29,		30,		33,		45,		47,		48,		49.
High oil pressure	4,	38, 41.
Overheating	11,		13,		14,		16,		18,		19,		24,		25,		45,		50,		51,		52,		53,		54,57.
Excessive crankcase pressure	25, 31, 33, 34, 45, 55, 60.
Poor compression	11,19,25,28,29,31,32,33,34,46,59.
Starts and stops	10, 11, 12.

Key to Fault Finding Chart

1.	Battery capacity low.			31.	Worn cylinder bores.
2.	Bad electrical connections.			32.	Pitted valves and seats.
3.	Faulty starter motor.			33.	Broken, worn or sticking piston ring/so
4.	Incorrect grade of lubricating oil.			34.	Worn valve stems and guides.
5.	low cranking speed.			'35.	Overfull air cleaner or use of incorrect grade of
6.	Fuel tank empty.				oil.
7.	Faulty stop control		operation.	36.	Worn or damaged bearings.
8.	Blocked fuel feed		pipe.	37.	Insufficient oil in sump.
9.	Faulty fuel	lift pump.		38.	Inaccurate gauge.
10.	Choked fuel filter.			39.	Oil pump worn.
11.	Restriction in air cleaner or induction system.			40.	Pressure relief valve sticking open.
12.	Air in fuel	system.		41.	Pressure relief valve sticking closed.
13.	Faulty fuel	injection pump.		42.	Broken relief valve spring.
14.	Faulty atomisers or incorrect type.			43.	Faulty suction pipe.
15.	Incorrect use of cold start equipment.			44.	Choked oil	filter.
16.	Faulty cold starting equipment.			45.	Piston seizure/pick up.
17.	Broken fuel injection pump drive.			46.	Incorrect piston height.
18.	Incorrect fuel pump timing.			47.	Damaged fan.
19.	Incorrect valve timing.			48.	Faulty engine mounting (Housing).
20.	Poor compression.			49.	Incorrectly aligned flywheel housing, or flywheel.
21.	Blocked fuel tank vent.			50.	Faulty thermostat.
22.	Incorrect type or grade of fuel.			51.	Restriction	in water jacket.
23.	Sticking throttle or restricted movement.			52.	Loose fan	belt.
24.	Exhaust pipe restriction.			53.	Choked radiator.
25.	Cylinder head gasket leaking.			54.	Faulty water pump.
26.	Overheating.			55.	Choked breather pipe.
27.	Cold running.			56.	Damaged valve stem oil deflectors (if fitted).
28.	Incorrect tappet adjustment.			57.	Coolant level too low.
29.	Sticking valves.			58.	Blocked sump strainer.
30.	Incorrect high pressure pipes.			59.	Broken valve spring.
				60.	Defective exhauster/leaking vacuum pipe.

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