Service Manual Perkins

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workshop
manualfor
T6.3544,6.3544
and 6.3724
dieselengines
@
PerkinsEnginesLimited
Peterborough England
1982
PublicationNo. 601SERO1821146
This publicationsupersedesthe previousedition numbered601SEFl0281
1 146
and lncorporatesamendmentPage Sets 1, 2, 3, 4 and 5 issued between 1982 and 1986
This publicationis writtenfor world wide use. In territorieswhere legalrequirementsgovernsmoke emission,noise,safety

factors, etc., then all instructions,data and dimensionsgiven must be applied in such a way that, after servicing
(preventivemaintenance)or repairingan engine,it does not contravenethe local regulationsin use.
Publishedby PerkinsEnginesLimitedand Printedin Englandby c H. Fisher& Sons (Printers)Ltd.,Peterborough
Page2
Perkinscompanies
Australia
PerkinsEnginesAustraliaPty.Limited,
P . O .B o x1 5 6 ,
22-24 ElliottRoad,
Dandenong,
Victoria,
Australia
Telephone:
794 6555.
Telex:AA30B1
6.
C a b l e : ' P e r k oM
i l 'e l b o u r n e .
France
MoteursPerkinsS.A.,
9-11AvenueMichelet,
93407SaintOuen,
Cedex,
France.
Telephone:2232000.
Telex:642924F.
Cable:PerkoilParis
Germany
PerkinsMotorenG.m.b.H.,
8752Kleinostheim,
Postfach1180,
West Germany.
Telephone:
060275010.
Telex:41888694PER D.
Italy
MotoriPerkinsS p.A.,
Via Gorizia15,
P . O .B o x 1 2 ,
22070 Porlichetto/Luisago
(Como),
Italy.
(031) 927364.
Telephone:
Telex:380658PerkitI
Cable:PerkoilPortichetto.
Japan
MasseyFergusonPerkinsEnginesK.K.,
Reinanzaka
Building,
6th Floor,
14-2 Akasaka,1-chome,
Minato-ku,
Tokyo107,
Japan
Telephone:
(03)5BO7377.
Telex:PerkoilJ2424823.
Cable:PerkoilTokyo.
Fax:(03)582-1596.
Singapore
PerkinsEnginesAsiaPacific,
549 UpperThompsonRoad,
Singapore
2057.
Telephone:4521841.
Telex:RS 37729.,
UnitedKingdom
PerkinsEnginesLimited,
Eastfield,
Peterborough
PEI 5NA,
England.
Telephone: (O733) 67474.
Telex:32501PerkenG.
Cable:'Perkoil'Peterborough.
PerkinsEngines(Shrewsbury)
Limited,
SentinelWorks,
Shrewsbury
SY14DP,
England
Telephone: (0743) 52262.
Telex:3517112
PESLG.
u.s.A.
PerkinsEnginesInc.,
P.O.Box697,
32500Van Born Road,
Wayne,
Michigan48184,
U.S.A.
(313) 5959600,
Telephone:
T elex: 2340O2PerkenWane.
Cable:PerkenWane.
PerkinsEnginesLatinAmericaInc ,
P.O.Box697,
32500Van Born Road,
Wayne,
M i c h i g a4n8 1 8 4 ,
U.S.A.
(313) 5959600,
Telephone:
f e|exl.234002
PerkenWane.
Cable:PerkenWane.
In additionto the above,there are Perkrnsdistributors

ln mostcountries.PerkinsEnginesLtd, Peterborough
or one of the above
companiescan givedetails.
6 3544SeriesWorkshopManual,January1986
Page3
CONTENTS
Section
E N G I N EP H O T O G R A P H S
T E C H N I C A LD A T A
O P E R A T I N GA N D M A I N T E N A N C E
F A U L TF I N D I N G
C Y L I N D E RH E A D
P I S T O N SA N D C O N N E C T I N GR O D S
C Y L I N D E RB L O C K A N D L I N E R S
C R A N K S H A F TA N D M A I N B E A R I N G S
T I M I N GC A S EA N D D R I V E
TIMING
L U B R I C A T I N GS Y S T E M
C O O L I N GS Y S T E M
A I R C L E A N E R SA N D F U E L S Y S T E M
F L Y W H E E LA N D F L Y W H E E LH O U S I N G
TURBOCHARGER
ALTERNATORAND STARTERMOTOR
COMPRESSOR
EXHAUSTER
LUBRICATING
OILS
A P P R O V E DS E R V I C ET O O L S
S E R V I C EF A C I L I T I E S
INDEX
6.3544SoriesWorkshopManual,lssu 2, Jun
'82
Appendix
T h i s p u b l i c a t i o ni s p u b l i s h e db y t h e T e c h n i c a lP u b l i c a t i o n s
Departmentof PerkinsEnginesLimitedand every endeavour
i s m a d e t o e n s u r e t h a t .t h e i n f o r m a t i o nc o n t a i n e d i n t h i s
Manual is correct at the date of publication but, due to
continuous developments,the manufacturersreserve the
right to make alterationswithout notice.
U S EO N L Y
G E NU I NE
PERKINSPARTS
T O E N S U R EY O U O B T A I N T H E B E S T R E S U L T SF R O M
YOUR ENGINE AND TO SAFEGUARD YOUR OWN
GUARANTEE, FIT ONLY GENUINE PERKINS PARTS.
THESE ARE READILY OBTAINABLE THROUGHOUT
THE WORLD.
6 3544 SeriesWorkshooManual.lssue2. June'82
Page5
FOREWORD
T h i s W o r k s h o pM a n u a lh a s b e e nc o m p i l e df o r u s e i n c o n j u n c t i o nw i t h n o r m a lw o r k s h o pp r a c t i c e .
Mention of certain accepted practices,therefore,has been purposely omitted in order to avoid
repetition.
Referenceto renewingjoints and cleaningoff joint faces,has to a great extent been omitted from
t h e t e x t ,i t b e i n g u n d e r s t o o dt h a t t h i s w i l l b e c a r r i e do u t w h e r ea p p l i c a b l e .
S i m i l a r l yi,t i s u n d e r s t o o dt h a t i n r e - a s s e m b lay n d i n s p e c t i o na, l l p a r t sa r e t o b e t h o r o u g h l yc l e a n e d ,
and where present,burrs and scale are to be removed.
I t f o l l o w st h a t a n y o p e n p o r t so f h i g h p r e c i s i o nc o m p o n e n t se, . g . f u e l i n j e c t i o ne q u i p m e n te, x p o s e d
b y d i s m a n t l i n gw
, i l l b e b l a n k e do f f u n t i l r e - a s s e m b l e dt o, p r e v e n tt h e i n g r e s so f f o r e i g n m a t t e r .
W h e nf i t t i n gs e t s c r e w so r s t u d s i n t o h o l e sw h i c h a r e t a p p e dt h r o u g hi n t o t h e i n t e r i o ro f t h e e n g i n e ,
a s u i t a b l es e a l a n ts h o u l db e u s e d .
New type M.E.A.S.(microencapsulatedanaerobicsealant)fastenersare beingintroducedso that jointing
compoundsor other sealantsneed not be used when the fastenersare fitted in throughholes into oil or
warerways.
The identification
of these fasteners,as supplied,is by a red, blue, or other colour sealantaround the
fastenerthreads.
With M.E.A.S.sealedstuds,the sealedend mustbe fittedintothe cylinderhead/cylinder
blocketc.
Ensurethat the threadedholes have a 1,59mm(1Aain)45" chamfer,so that when the new fastenersare
fittedthe M.E.A.S.sealantis not removed.
lf the fastenershave to be removedand fittedagain,the threadsmust be cleanedand a suitablesealant
used.
Throughoutthis manual,whenever"|eft"or "right"handsideof the engineis referredto, it is that sideof the
enginewhenviewedfromthe flywheelend.
EngineNumberlocation
Withearlierengines,the enginenumberwas stampedon the auxiliary
drivehousingimmediately
belowthe
pump- see Figs.41 and A3 (item'10).lt consistsof figuresand letters,e.9.,3544U251T.
fuelinjection
The
firstthreefiguresrepresentthe cubiccapacity,i.e.,354in3:the fourthfiguredenotesthe enginemodeland
the letter"U" signifies
thatthe enginewas builtin the UnitedKingdom.The lastgroupof figurescomprises
number.
i.e.,
the engineserial
Otherletterswhichmayfollowthe serialnumberdenotespecificinformation,
"T"
indicates
letter
a
turbocharged
"L"
indicates
lip
type
seal
on
the
rear
end
of
the
a
engine:a letter
a
crankshaft.
For currentengines,the enginenumberconsistsof fifteenlettersand figures,a typicalnumberbeing
TW30016U510256D.
In allcases,the enginenumberwhenquoted,shouldbe in full.
Runningin Procedure
I t i s n o t n e c e s s a r tyo g r a d u a l l yr u n - i na n e w o r f a c t o r yr e b u i l te n g i n ea n d a n y p r o l o n g e dl i g h t l o a d
r u n n i n gd u r i n g t h e e a r l y l i f e o f t h e e n g i n ec a n i n f a c t p r o v e h a r m f u lt o t h e b e d d i n gi n o f p i s t o n
r i n g sa n d l i n e r s .
F u l l l o a dc a n b e a p p l i e do n a n e w o r f a c t o r yr e b u i l te n g i n ea s s o o n a s t h e e n g i n ei s u s e d ,p r o v i d e d
that the engine is first allowed to reach a temperatureof at least 140oF (60"C).
SAFETYPRECAUTIONS
T H E S E S A F E T Y P R E C A U T I O N SA R E I M P O R T A N T .R e f e r a l s o t o t h e l o c a t a n d
g o v e r n m e nrte g u l a t i o nasp p l i c a b l e
i n y o u rj u r i s d i c t i o n .
D o n o t u s e t h e s ee n g i n e si n m a r i n ea p p l i c a t i o n s .
D o n o t m o d i f yt h e e n g i n e .
D o n o t s m o k ew h e n r e f u e l l i n g .
Alwaysremovespiltfuel and soakedclothingto a safe place.
D o n o t r e f u e lw h i l s tt h e e n g i n ei s r u n n i n g( u n l e s sa b s o l u t e l ny e c e s s a r y ) .
N e v e rc l e a n ,l u b r i c a t eo r a d j u s tt h e e n g i n ew h i l s ti t i s r u n n i n g( u n l e s sq u a l i f i e dt o d o s o , i n
whichcase,extremecare shouldbe takento avoidinjury).
Do not attemptany adjustmentsyou do not understand.
E n s u r et h e e n g i n ei s p o s i t i o n e sdo a s t o p r e v e n a
t b u i l d - u po f t o x i ce m i s s i o n s .
W a r n p e r s o n s i n t h e a r e a t o k e e p w e l l c l e a r d u r i n g e n g i n e a n d e q u i p m e n to r v e h i c l e
operation.
D o n o t w e a r l o o s ec l o t h i n go r a l l o wl o n gh a i rn e a rm o v i n gm a c h i n e r y .
Keep well clear of rotatingparts or machineryin operation.Note that fans are not clearly
v i s i b l ew h i l s t h e e n g i n ei s r u n n i n g .
Do not run the enginewith any safetyguardsremoved.
Do not removethe radiatorcap whilst the engine is hot and coolantis unoer pressureas
s c a l d i n gc a n r e s u l t .
On no accountshouldsea wateror any otherelectrolytic
or corrosivemediumbe used in the
coolingsystem.
Keep sparks or flames away from batteriesas the gases from the electrolyte(especially
whilstthe batteryis undercharge)are highlyinflammable.
This acid is also dangeiou'sto tn6
s k i n a n d e s p e c i a l l tyh e e y e s .
Always disconnectthe batteryterminalsbefore repairingor interferingwith the electrical
system.
O n l yo n e p e r s o ns h o u l db e i n c o n t r o ol f t h e e n g t n e .
Alwaysoperatethe enginefrom the controlpanelor operator'sseat.
lf your skin comes into contactwith high pressurefuel,seek medicalattentionimmediately.
Dieselfuel can cause skin infectionto some people.Use protectiveglovesor hand cream.
Do not move mobile equipmentwithoutfirst ensuringthat the brakes are in good working
oroer.
Ensure that the transmissiondrive control is in 'Out of Drive' positionbefore startingthe
engine.
F i t o n l yg e n u i n eP e r k i n sP a r t s .
SAFETYIS SENSE.USEIT.
SECTIONA
EnginePhotographs
P e r k i n sE n g i n e s a r eb u i l t t o i n d i v i d u a rl e q u i r e m e n ttso s u i t t h e a p p l i c a t i o n fso r w h i c h t h e y a r e
i n t e n d e da n d t h e f o l l o w i n ge n g i n ev i e w sd o n o t n e c e s s a r i l tyy p i f y a n y p a r t i c u l a sr p e c i f i c a t i o n .
Index to Engine Photographs
'1.
A l t e r n a t o rP u l l e y
2. ThermostaH
t o u s i n ga n d W a t e rO u t l e t
3 . L u b r i c a t i n gO i t F i l l e r
4 . F u e lO i l F i l t e r
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
C y l i n d e rH e a d C o v e r
Atomrser
B r e a t h e rP i p e
F u e l I n j e c t i o nP u m p ( C . A . V . )
Dipstick
E n g i n eN u m b e rL o c a t i o n
LubricatinO
g itFilter
Sump
Fan
StarterMotor
C r a n k s h a fP
t u l l e ya n d V i b r a t i o nD a m p e r
FanBelts
W a t e rP u m p
I n d u c t i o nM a n i f o l d
1 9 . E x h a u s tM a n i f o l d
20. ThermostartUnit
2 1 . F u e lL i f t P u m p
22. FlywheeH
l ousing
2 3 . F u e l P i p e f r o m L i f t P u m p t o F i n a lF u e l F i l t e r s
24. Rear Lifting Bracket
2 5 . C y l i n d e rB l o c k D r a i n P o i n t
26. Turbocharger
2 7 . S u m p D r a i nP l u g
28. Oil Feed Pipe to Turbocharger
29. Alternator
30.
31.
32.
33.
34.
Oil Drain Pipefrom Turbocharger

F u e l I n j e c t i o nP u m p( B o s c h )
LubricatingOil Cooler
FrontLiftingBracket
IntegralAir ChargeCoolerand InductionManifold
E N G I N EP H O T O G R A P H S
%.
9
7
I
10
A.1
V i e w o f F u e l P u m p S i d e o f 6 . 3 5 4 4E n o i n e
18
*tr
19
29
21
4.2
6 3544SeriesWorkshopManual,Aprilg3
View of CamshaftSide of 6.3544Engrne
E N G I N EP H O T O G R A P H S A 3
3
24
4
A.3
V i e w o f F u e l P u m p s i d e o f T 6 . 3 5 4 4E n g i n e
A.4
View of CamshaftSide of T6.3544Engine
ENGINE
PHOTOGRAPHS
33
10
16
A.5
V i e wo f F u e lP u m pS i d eo f T 6 . 3 5 4 4 C C( A i rC h a r g eC o o l e d )E n g i n e
34
19
29
23
26
11
25
A.6
View of CamshaftSide of T6.3544CC(Air ChargeCooled)Engine
SECTIONB
TechnicalData
B o r e ( T 6 3 5 4 4a n d 6 . 3 5 4 4e n g i n e s )
B o r e ( 6 3 7 2 4e n g i n e s )
Stroke
No of cylinders
C u b i c c a p a c i t y( T 6 . 3 5 4 4
a n d 6 . 3 5 4 4e n g i n e s )
3 8 7 5i n ( 9 8 , 4m m ) 3 9 7 5i n ( 1 0 1m m ) 5 i n ( 1 2 7m m )
6
3 5 4i n 3( 5 , 8l i t r e s )
3 7 2i n 3( 6 , 1l i t r e s )
C u b i c c a p a c i t y( 6 . 3 7 2 4e n g i n e s )
Compressionratio:
T6.3544engines
North America vehicle T6.3544
6 . 3 5 4 4e n g i n e s . . .
6 . 3 7 2 4e n g i n e s . . .
F i r i n go r d e r
Combustron
system
Cycle
15.51
:
'l
16:
16:1
16:1
1,5,3,6,2,4
D i r e c ti n j e c t i o n
4 stroke
Valve c l e a r a n c e( h o t o r c o l d )
I nl e t
Exhaust
L u b r i c a t i n go i l p r e s s u r e
0 . 0 0 8i n ( 0 , 2 0m m )
0 . 0 1 8i n ( 0 , 4 6m m )
m i n i m u ma t
3 0 l b f / i n ' ( 2 , 1k g t / c m ' ?o) r 2 0 7 k N / m ' ?
m a x i m u mw o r k i n g s p e e d a n d n o r m a l o p e r a t i n g
temperature
Turbochargerboost pressures
(measured
a t i n d u c t i o nm a n i f o l d )
T 6 3 5 4 4e n g i n e so n l y
'Nominal-for
1 1 - 1 35 l b f / i n , ( 0 , 8 0 - 0 , 9 5 k 9 f / c m o, )r 7 6 - 9 3 k N / m ' ?
s i l l v a r y a c c o r d i n gt o a p p l i c a t i o n ,
T h e s ep r e s s u r ew
e n g i n el o a d s a n ds p e e d sT h e y a r e f o rg u i d a n c e
p u r p o s e so n l y
a c t u a lb o r e s r z es e e P a g eB 3 ,
Details of ratings
T6.3544CCVehicle
M a x i m u mt o r q u e
T6,3544Vehicle
T6.3544North America vehicle
T6.3544Agricultural and I n d u s t r i a l . .
6 . 3 5 4 4P r e m i u mV e h i c l e
6 . 3 5 4 4A g r i c u l t u r a al n d I n d u s t r i a l
6.3724 Agriculturalengines
M a x i m u mt o r o u e
1 1 9 k W ( 1 5 9 b h p ) a t 2 , 6 0 0r e v l m i n
5 0 2 N m ( 3 7 0 l b f f t ) a t 1 , 6 0 0r e v l m i n
1 1 5 k W ( 1 5 5 b h p ) a t 2 , 6 0 0r e v l m i n
498 Nm (367 lbf ft) at 1,700 revlmin
1 0 4 k W ( 1 a 0 b h p ) a t 2 , 6 0 0r e v l m i n
470,5 Nm (347 lbf ft) at 1,700 revlmin
1 0 7 k W ( 1 4 3 b h p ) a t 2 , 5 0 0r e v l m i n
9 5 , 5 k W ( 1 2 8 b h p ) a t 2 , 8 0 0r e v l m i n
380 Nm (280 lbf ft) at 1,500 rev/min
9 1 k W ( 1 2 2 b h p ) a t 2 , 6 0 0r e v l m i n
9 0 k W ( 1 2 1 b h p ) a t 2 , 5 0 0r e v l m i n
396 Nm (292 lbt ft) at 1,450 revlmin
The above ratingi are maximum and can vary according to application.
Engineweights
T y p i c a ld r y w e i g h t
T y p i c a li n s t a l l e dw e i g h t
9 4 0 - 9 6 0 1 b( a 2 5 - 4 3 5 k 9 )
1 1 0 0 - .117 0l b ( 5 0 0 - 5 3 0 k g )
Recommendedtorque tensions
The following figures will apply with the componentslightly lubricatedwith clean engine oil
Screwsize
Nm
lbfft
kgf m
UNF
Cylinder head nuts and setscrews (with formed
1EA
washer face) - cold
115
15,9
*
Cylinder head nuts and setscrews (with formed
1
washer face) - hot
105
14,5
142
2
Cylinder head nuts and setscrews (with separate
1
washers)
95
13,1
129
5
C y l i n d e rh e a d s e t s c r e w s
...
28
3,9
38
t 6
C o n n e c t i n gR o d N u t s ( C a d m i u mP l a t e d ) . . .
+
75
10,4
102
lConnecting Rod Nuts (Phosphated)
13,1
129
95
2
5
Main bearing setscrews
200
270
27,7
a
3
ldlergear hub nuts
36
5,0
49
a
Fuel lift pump setscrews
20
2,8
27
t 6
5
20
15
2,1
Sump securing setscrews
t 6
( c o n t i n u e) d
6 3 5 4 4 S e r i e s W o r k s h o p M a n u a l , S e p t e m b e r1 9 8 2
TECHNICAL
DATA
82
Recommendedtorque tensions(continued)
T h e f o l l o w i n gf i g u r e sw i l l a p p l yw i t h t h e c o m p o n e n ttsi g h I y o i l e d
C o mp o n e n t
Flywheelsecuringsetscrews
Flywheelhousingsecuringsetscrews(standard)
Flywheelhousingsecuringsetscrews(standard)
Flywheelhousingsecuringsetscrews(Durlok.)
Flywheelhousingsecuringsetscrews(Durlok.)
Camshaftgear setscrews
Crankshaftpulleysetscrews(cadmiumplated)
Crankshaftpulleysetscrews(phosphated)
Pistoncoolingjet banjobolt (wherefitted)
Rockershaftbracketsetscrewsor nuts
O i l c o o i e r t o c y l i n d e rb l o c k ,s e t s c r e w s
(where fitted)
L u b r i c a t i n go i l f i l t e r s e t s c r e w s
A t o m i s e rS e c u r i n gn u t s / s e t s c r e w s
Auxiliary drive shaft gear setscrews
H i g h p r e s s u r ef u e l p i p e n u t s
Screwsize
UNF
tbf ft
1/z
80
3/e
36
7Ae
45
1 2x 1 , 5
mm
A l t e r n a t o rp u l l e y n u t
Thermostaru
t nit
T h e r m o s t a r itn s u l a t i n ga d a p t o r
* Durlok
setscrewshavea formedwasherfacewith radialserrations.
9
l 6
't11
o e
"/a
7ro(UNC) 1 0 4
1/z
50
7Aa
65
7Ae
92
20
"/a
7Aa
55
7
6
7
t 6
5
t 6
5
t 6
kgf m
50
30
1 A A
A O
on
Iz , l
i;; 64qfiqB'o/za qc
Nm
49
61
91
141
68
BB
tz3
2,8
7,6
4 1
tz
68
40
tb
22
? n
t c
z, l
30
'1
0
10
4,1
'1 A
40
1.4
I J
30
20
I J
T h e f o l l o w i n gt a b l e i s g i v e na s a g e n e r a lg u i d e ,t o b e a p p l i e do n a p e r c e n t a g eb a s i s ,w h e r e s p e c i f i cf i g u r e sf o r a p a r t i c u l a r
e n g i n er a t i n ga r e n o t a v a i l a b l e
Altitude
0/2000ft ( 600metre)
2000/4000ft (1200metre)
4000/6000ft (i 800metre)
6000/8000ft (2400metre)
8000/10000ft(3000metre)
10000/12000ft (3600metre)
*Measured
a t s e t t i n gs p e e dg i v e no n p u m p s e t t i n gc o d e
M a x i m u mf u e l d e l i v e r yd e - r a t i n g
No change
60/o
12o/o
18%
240/o
300/o
I t s h o u i db e n o t e dt h a t t h e a b o v ei n f o r m a t i o no n l y a p p l i e st o n a t u r a l l ya s p i r a t e de n g i n e s .F o r t u r b o c h a r g e d
e n g i n e sa p p l y
t o S e r v i c eD e p a r t m e n tP, e r k i n sE n g i n e sL t d , P e t e r b o r o u gohr o n e o f t h e C o m p a n i e sl i s t e do n P a g e2
6 3544SeriesWorkshoplvlanual,
JanuaryI 986
TECHNICALDATA
83
MANUFACTURINGDATA AND DIMENSIONS

A l l t h r e a d su s e d ,e x c e p tp e r h a p so n p r o p r i e t a r ye q u i p m e n at r e U n i f i e dS e r i e sa n d A m e r i c a nP i p eS e r i e s
T h e f o l l o w i n gd a t a o f c l e a r a n c e sa n d t o l e r a n c e sa r e g i v e n a s a g u i d e f o r p e r s o n n e el n g a g e du p o n m a j o r o v e r h a u l sa n d
thefiguresare those used in the factory for productionpurposes.
CylinderBlock
H e i g h tb e t w e e nT o p a n d B o t t o mF a c e s
P a r e n tB o r e D i a m e t e fr o r C v l i n d e rL i n e r
J6.3544/6 3544)
ParentBore Diameterfor Cylinder Liner (63724)
R e c e s sD e p t hf o r C y l i n d e rL i n e r F l a n g e
R e c e s sD i a m e t e fr o r C y l i n d e rL i n e r F l a n g e
I6.3544/6 3544\
R e c e s sD i a m e t e fro r C y l i n d e rL i n e r F l a n g e
(6 3724\
Marn BearingParentBore
CamshafB
t o r e D i a m e t e rN
, o. 1
c a m s h a f tB o r e D i a m e t e rN
, o.2
CamshaftBore Diameter,No. 3
C a m s h a fB
t o r e D i a m e t e rN
,o 4
1 7 3 6 7 / 1 73 7 s i n ( 4 4 1, 1 2 / 4 4 i , 3 2
mm)
2 1m )
4 0 6 2 5 / 40 6 3 5 i n( 1 0 3 , 1 9 / 1 0 3 .m
4j025/4:035in (104,20/104,23mm)
.150/0
1m)
O
1 5 4i n ( 3 , 8 1 / 3 , 9m
9 4m )
4 . 2 0 5 / 4 . 2 1i n0 ( 1 0 6 , 8 1 / 1 0 6 ,m
4.245/4 25Oin (107,82/
107,95mm)
3 j66/3 167in (8O,42/8O,44mm\
i n1( 5 0 , 8 0 / 5 0 , 8 3 m m )
2.OOO/200
1.990/1
992in(50.55/50.60mm)
1 gBO/1g82in (50,29150,34
mm)
2 (50.04l5O.O9mm)
1 g 7 O / 1 . 9 7i n
Cyfinder Liners (Cast tron- Ftanged)- T6.g544/6.9544

Type
O u t s i d eD i a m e t e or f P r o d u c t i o nL i n e r
..
I n t e r f e r e n cFe i t o f P r o d u c t i o nL i n e r
I n s i d eD i a m e t e or f P r o d u c t i o nL i n e r a f t e r F i n i s hH o n i n g
T r a n s i t i o nF i t o f S e r v i c eL i n e r
I n s i d eD i a m e t e o
r f S e r v i c eL i n e ra f t e rf i t t i n q
.
F l a n g eT h i c k n e s s
H e i g h to f L i n e ra b o v eC y l i n d e rB l o c k T o p F a c e
P o s i t i o no f L i n e rF l a n g eR e l a t i v et o T o p F a c eo f
C y l i n d e rB l o c k
D r y - I n t e r f e r e n cF
ei f - P r o d u c t i o n
D r y - T r a n s i t i o nF i t - S e r v i c e
2 6m )
4 0 6 4 5 i 40 6 5 5i n ( 1 0 3 , 2 4 / j O 3 , m
8 m)
0 0 0 1 / 0 . 0 0i3n ( 0 , 0 3 i 0 , 0m
3 . 8 7 7 / 38 7 8i n ( 9 8 , 4 8 / 9 8 , 5m0m )
- 0 0 0 1 / + 00 0 1i n ( - 0 0 2 5 / + 00 2 5m m )
mm)
3 877/38795in (98,48198,54
0 1 5 0 / 01 5 2i n ( 3 8 1 / 38 6 m m )
4m)
0 0 2 6 / 0O 3 7i n ( 0 , 6 6 / 0 , 9m
+ 0 O 0 2 / - O0 0 4i n ( + 0 , 0 5 / - 0 , 1m
0m)
CylinderLiners (Cast lron-Flanged)- 6.9724

Type
O u t s i d eD i a m e t e r
I n t e r f e r e n cF
ei t o f L i n e r
I l n s i d eD i a m e t e or f L i n e r a f t e rF i n i s hH o n i n g
F l a n g eT h i c k n e s s
H e i g h to f L i n e ra b o v eC y l i n d e rB l o c k T o p F a c e
P o s i t i o no f L i n e r F l a n g er e l a t i v et o C y l i n d e rB l o c k
Top Face
ei t - P r o d u c t i o n
D r y - I n t e r f e r e n cF
4 1045/4 1055in (104,25/104,28mm)
8 m)
0 0 0 1 / 00 0 3i n ( 0 , 0 3 i 0 , 0m
3.9785/3.9795
in (101,05/101,08mm)
0 1 5 0 / 0 1 5 2 i n( 3 , 8 1 / 3 , 8 6 m m )
0 . 0 2 8 / 0 . 0 3 5(i0n, 7 1 l 0 , B g m m )
+ 0 0 0 2 /- 0 0 0 4i n ( + 0 , 0 5 / - 0 ,01m m )
Pistons(T6.3544)
Type
P i s t o nH e i g h ti n R e l a t i o nt o C y l i n d e rB l o c kT o p F a c e
B o r e D i a m e t e fro r G u d g e o nP i n
Compression
R r n gG r o o v eW i d t h ,N o . 1
Compression
R r n gG r o o v eW i d t h ,N o 2
S c r a p e rR i n g G r o o v eW i d t h ,N o 3
T o r o i d a lC a v i t yi n C r o w n
0 0 0 0 / 00 0 7 i n ( 0 , 0 0 / 0 , 1 8m m ) a b o v e
1 S 0 O 0 / i5 O d 2i n ( 3 8 , 1 0 0 / 3 8 , i 0 5m m )
Tapered
0 0 9 5 5 / 0 . 0 9 6 3i n ( 2 , 4 3 / 2 , 4 5m m \
0 1 8 8 5 / 0 . 1 8 9 3i n ( 4 , 7 9 / 4 , 8 1m m ] }
Pistons (T6.3544North America vehicles)

Type
P i s t o nH e i g h ti n R e l a t i o nt o C y l i n d e rB l o c k T o p F a c e
B o r e D i a m e t e rf o r G u d g e o nP i n
C o m p r e s s i o nR i n g G r o o v eW i d t h ,N o . 1 . .
I CompressionRing Groove Width, No. 2
I Scraper Ring Groove Width, No. 3
R e - e n t r a nC
t o m b u s t i o nC h a m b e ri n C r o w n
0 . 0 0 0 / 00 0 7 i n ( 0 , 0 0 / 0 , 1 8m m ) a b o v e
1 . 5 0 0 0 / 1 . 5 0 0i2n ( 3 8 , 1 0 0 / 3 8 , . 1 0m5m )
Tapered
(2,4412,46mm)
0 0959/0.0967in
(4,83/4,B5mm)
0.1900/0.1908in
P i s t o n s( 6 . 3 5 4 4 ) - 3 R i n g
TYPe
..
P i s t o nH e i g h ti n R e l a t r o nt o C y l i n d e rB l o c kT o p F a c e
Bore Diameterfor Gudgeon Pin
I Compression
R i n g c r o o v e W i d t h ,N o 1 . . .
I CompressionRing GrooveWidth, No 2
S c r a p e rR i n g G r o o v eW i d t h ,N o 3
'1
6 3544SeriesWorkshopManual,January 986
ToroidalCavityin Crown
0 . 0 0 0 / 0 0 7 i n( 0 , 0 0 / 0 , 1 8 m m
a b) o v e
(34,928i34,935mm)
1.375111.3754in
0.0g59/O.0978in(2,4412,48mm)
0.0959/0.0970in(2,4412,46mm)
0 . 1 8 8 5 / 0 . 1 8 9 3( i4n, 7 9 / 4 , 8m1m )
TECHNICAL
DATA
84
Pistons(6.3544)5 Ring
Type
PistonHeight relativeto Cylinder Block Top Face
B o r e D i a m e t e fr o r G u d g e o nP i n
Compression
R i n g G r o o v eW i d t h ,N o . 1 . . .
Compression
R i n g G r o o v eW i d t h ,N o . 2 . . .
Compression
R i n g G r o o v eW i d t h ,N o . 3
..
S c r a p e rR i n g G r o o v eW i d t h ,N o . 4
S c r a p e rR i n g G r o o v eW i d t h ,N o . 5 . . .
ToroidalCavityin Crown
0.000/0.007in(0,00/0,1I mm) above
1.3748511.37520in(34,921/34,930mm)
0 . 0 9 5 7 / 0 . 0 9 6 i7n ( 2 , 4 3 / 2 , 4 6m m \
0 0 9 5 7 / 0 . 0 9 6 7i n ( 2 , 4 3 / 2 , 4 6m m )
0 0957/0.0967in (2,43/2,46 mm)
0.2525/02535 in (6,41/6,44 mm\
0 2 5 2 5 / 0 . 2 5 3 5i n ( 6 , 4 1/ 6 , 4 4 ' m m )
Pistons (6.3724)
Type
P i s t o nH e i g h tR e l a t i v et o C y l i n d e rB l o c kT o p F a c e
B o r e D i a m e t e fr o r G u d g e o nP i n
Compression
Compression
..
S c r a p e rR i n g G r o o v eW i d t h ,N o . 3
S c r a p e rR i n g G r o o v eW i d t h ,N o 4 . .
Toroid.alCavity in Crown
6 m)
0 . 0 0 7 / 0 . 0 1 4i n ( 0 , 1 8 . / 0 , 3 m
1 . 3 7 4 8 5 /.' 3
1 7 5 0 5i n ( 3 4 , 9 2 1 1 3 4 , 9 2m6m )
0.0977/0.0987in (2,48/2,51 mm\
0.0957/0.0966in (2,43/2,46 mm)
mm)
0 . 1 8 9 5 / 0 . 1 9 0 i5n ( 4 , t s 1 / 4 , 8 4
0 . 1 8 9 5 / 01 9 0 5 i n ( 4 , 8 1/ 4 , 8 4 m m )
PistonRings (T6.3544)
No. 1 Cornpression
No 2 Compression
No. 3 Scraper
C o m p r e s s i o nR i n g W i d t h , N o . 1
C o m p r e s s i o nR i n g W i d t h , N o . 2
ScraperRing Width, No. 3
N o 1 C l e a r a n c ei n G r o o v e
No. 2 Clearance in Groove
N o . 3 C l e a r a n c ei n G r o o v e
P i s t o nR i n g G a p - N o . 1
PistonRing Gap - No 2
Chromeor MolybdenumFacedWedge
TaperedFace
ChromeFacedOil ControlConformable
Wedge
in (2,36/2,37mm)
0.0930/0.0935
0. 1860/0.1875in (4,72/4,76 mm)
Wedge
in (0,05/0,10 mm)
0.002/0.0038
0.0010/0.0033in (0,03/0,08mm)
0.010/0.026in (0,2510,66
mm)
mm)
0.012/0.030in (0,30/0,76
0.010/0.033in (0,2510,84
mm)
Piston Rings (T6.3544North America vehicles)

No. 1 Compression
No. 2 Compression
No. 3 Scraper
C o m p r e s s i o nR i n g W i d t h , N o . I
C o m p r e s s i o nR i n g W i d t h , N o . z
S c r a p e rR i n g W i d t h , N o . 3
No 3 Clearance in Groove
PistonRings (6.3544-
Chrome faced wedge

Tapered face
C h r o m ef a c e d o i l c o n t r o l c o n f o r m a b l e
Wedge
0.0930/0.0935in (2,36/2,37 mm)
0 . 1 8 6 0 / 0 . 1 8 7i5n ( 4 , 7 2 / 4 , 7 6m m )
Wedge
in (0,061/0,094mm)
O.002410.0037
0 . 0 0 2 5 / 0 . 0 0 4 i8n ( 0 , 0 6 / 0 , 1 2 2m m )
O . 0 1 2 / 0 . 0 2 i2n ( 0 , 3 0 , u 0 , 5m6 m )
6 m)
0 0 1 2 / 0 . O 2 2i n ( 0 , 3 0 , / 0 , 5 m
4 m)
0 . 0 1 0 / 0 . 0 3 3i n ( 0 , 2 5 , / 0 , 8 m
3 ring pack)
No l Compression
No. 2 Compression
No. 3 Scraper
C o m p r e s s i o nR i n g W i d t h , N o 1
C o m p r e s s i o nR i n g W i d t h , N o .
ScraperRing Width, No 3
Piston Ring Gap - No. 2
C h r o m e B a r r e l F a c e d I n t e r n a l l yC h a m f e r e d
C h r o m eT a p e r F a c e d
C h r o m e F a c e d O i l C o n t r o lC o n f o r m a b l e
0 . 0 9 3 0 / 0 . 0 9 3i5n ( 2 , 3 6 / 2 , 3 7m m )
0 0 9 3 0 / 00 9 3 5 i n ( 2 , 3 6 / 2 , 3 7m m )
0 1 8 6 0 / 0 . 1 8 7 5i n ( 4 , 7 2 / 4 , 7 6m m )
0.0024/0.0048
in (0,06/0,12 mm)
in (0,06/0,
0.0024/0.0040
10 mm)
0.0010/0.0033
in (0,03/0,08
mm)
0.010/0.024in(0,2510,61
mm)
0.016/0.034in (0,41/0,86mm)
0.010/0.033in (0,2510,84
mm)
PistonRings (6.3544-5 ring pack)

No. 1 Compression
Nos.2and3Compression
I N o . 4S c r a p e r
No. 5 Scraper
RingWidth,Nos.1, 2 and3
, Compression
...
I ScraperRingWidth,Nos.4 and 5
Nos.1, 2 and3 Clearancein Groove
Nos.4 and 5 Clearancein Groove
I PistonRingGaps- Cast lron
I PistonRingGaps- Chromed
Plain
Internally
Stepped
ChromeFacedOil ControlConformable
SlottedOil Control
in (2,36/2,38
0.0928/0,0938
mm)
mm)
O.249
I0.250in (6,3216,35
in (0,05/0,1
0.019/0.0039
0mm)
in (0,06/0,11 mm)
0.0025/0.0045
mm)
0.012/0.030in (0,30/0,76
0.016/0.034in(0,41/0,86mm)
TECHNICALDATA
B5
Piston Rings (6.3724)

No. 1 Compression
No 2 Compression
No.3 Scraper
No 4 Scraper
Compression
R i n g W i d t h ,N o s . 1 a n d 2
S c r a p e rR i n g W i d t h N o s .3 a n d 4
...
No. 1 Clearancein Groove
Nos. 3 and 4 Clearancein Groove
l P i s t o nR i n g G a p s ,N o s 1 , 2 a n d 3
I P i s t o nR i n g G a p , N o . 4
P a r a l l eC
l h r o m eI n l a y
C h r o m eP l a t e dI n t e r n a l l yS t e p p e do r
I n t e r n a l l yC h a m f e r e d
, p r i n gE x p a n d e r
C h r o m eP l a t e d S
S l o t t e dO i l C o n t r o l
mm)
in (2,36/2,38
0 0928/0.0938
in (4,74/4,76mm)
0 1865/0.1875
0 . 0 0 3 9 / 0 0 5 9i n ( 0 , 10 / 0 , 1 4m m )
0m )
0 0 0 1 9 / 0 . 0 0 3i n9 ( 0 , 0 5 / 0 , 1m
004in (0,05/0,10
mm)
0.O02/O
0.016i0.034in(0,41/0,86mm)
0.012/0.030in (0,30/0,76mm)
GudgeonPin (T6.3544)
FullyFloating
1.4998/1.5000 in (38,095/38,100mm)
3.250/3.2599in (82,55/82,80mm)
0.0000/0.0004in (0,000/0,0010mm)
Type
Length
C l e a r a n c eF i t i n P i s t o nB o s s
Gudgeon Pin (6.3544 and 6.3724)

Type
Length
ClearanceFit in PistonBoss
F u l l yF l o a t i n g
2 5m )
1.3748/3
1 7 5 0i n ( 3 4 , 9 2 0 / 3 4 , 9m
3 297/3.312 in (83,74/ 84,12 mm)
in (0,003/0,014
mm)
0 00012/0.00055
Small End Bush (T6.3544)(includesNorthAmericavehicleengines)

Type
I n s i d eD i a m e t e a
r f t e rR e a m i n g
ClearancebetweenSmall End B u s h a n d G u d g e o nP i n
Steel Backed,Lead Bronze Lined

1 65975/166125in (42,16/42,20mm)
1 . 5 0 0 7 5 /510 1 5i n ( 3 8 , 1 2 1 3 8 , 1 4 m m )
0 0 0 0 7 5 / 00 0 1 7i n ( 0 , 0 1 9 / 0 , 0 4m3m )
Small End Bush (5.3544and 6.3724)

Tvoe
I n s i d eD i a m e t e a
r f t e rR e a m i n g
C l e a r a n c eb e t w e e nS m a l l E n d B u s h a n d G u d g e o n P i n .
Steel Backed,Lead Bronze Lined

mm)
1.535/15365in (38,99/39,03
1 3758/1.3765
in (34,94134,96
mm)
in (0,020/0,043
mm)
0 0008/0.0017
ConnectingRod
Type
C a p L o c a t i o nt o C o n n e c t i n gR o d
B i g E n d P a r e n tB o r e D i a m e t e r
S m a l lE n d P a r e n tB o r e D i a m e t e rf,6 3 5 4 4
6 3544 and 6.3724..
L e n g t hf r o m C / L o f B i g E n d t o C / L o f S m a l lE n d
H Section
T6.3544-Wedge ShapedSmallEnd
6.3544-ParallelShapeSmallEnd
Serrations
2 646/2 6465in (67,21/67,22mm\
1 65625/1 65725in (42,07/ 42,09mm)
mm)
1 5313/.15323in (38,90/38,92
9,10 m m)
8.624/8626in (219,05/21
ConnectingRod Alignment
l i t h e a c h o t h e rw i t h i nt h e l i m i t so f t 0 0 1 0 i n ( 0 , 2 5 m m )m e a s u r e d5 i n
L a r g ea n d s m a l le n d b o r e sm u s t b e s q u a r ea n d p a r a l l ew
( 1 2 7 m m )e a c hs i d e o f t h e a x i s o f t h e r o d o n a t e s t m a n d r e la s s h o w n i n F i g B 1 . W i t h t h e s m a l le n d b u s h f i t t e d ,t h e l i m i t o f
1 0 . 0 1 0i n ( 0 , 2 5m m ) i s r e d u c e dt o t 0 0 0 2 5i n ( 0 , 0 6m m ) .
- C
, = F
o 6
tf,)
;- o
- o{
l*,
8.1
.EE
otr
6
:
C
lf,)
+[d
J + l
TECHNICALDATA
B6
Crankshaft
O v e r a l lL e n g t h
M a i n J o u r n a lD i a m e t e r
M a i n J o u r n a lL e n g t h ,N o
M a i nJ o u r n a lL e n g t h N
, o s .2 , 3 , 5 , 6 a n d 7
. M a i n J o u r n a lL e n g t h N
, o.4
. F i l l e tR a d i i - M a i n
Journals
C r a n k p i nD i a m e t e r
. C r a n k p i nL e n g t h
. F i l l e tR a d i i Crankpins
S u r f a c eF i n i s h - a l l p i n s a n d j o u r n a l s
R e g r i n dU n d e r s i z e sJ,o u r n a l sa n d P i n s
F l a n g eD i a m e t e r. . .
Spigot Bearing Recess- Depth
Spigot Bearing Recess- Bore
CrankshaftEnd Floai
3 3 . 8 4 4i n ( 8 5 9 , 6 4m m ) - n o m i n a l
2 . 9 9 8 4 / 2 . 9 9 9i6n ( 7 6 , 1 6 / 7 6 , 1 9m m )
1 . 4 5 4 / 1 . 4 8 4i n ( 3 6 , 9 3 / 3 7 , 6 9m m )
5 m)
1 . 5 4 5 / 1 . 5 4 9i n ( 3 9 , 2 4 1 3 9 , 3m
1 . 7 3 8 / 1 . 7 4 1i n ( 4 4 , 1 5 / 4 4 , 2 2m m )
0 . 1 4 5 1 0 . 1 5 i6n ( 3 , 6 8 / 3 , 9 6m m )
2.4988/2.4998 in (63,47,/63,49mm )
2 m\
1 . 5 8 8 5 / 1 . 5 9 1i5n ( 4 0 , 3 5 / 4 O , 4m
6 m)
0 1 4 5 l 0 . 1 5 6i n ( 3 , 6 8 , / 3 , 9 m
1 6 m i c r o - i n c h e s( 0 , 4 m i c r o n s )
- 0 . 0 1 0 , 0 0 2 0 a n d 0 . 0 3 0i n ( - 0 , 2 5 , 0 , 5 1 a n d 0 , 7 6m m )
5.247/5.249in (133,27/ 133,32mm)
0 . 5 7 9 / 0 . 6 0 9i n ( 1 4 , 7 1 / 1 5 , 4 7m m )
2 . 0 4 6 / 2 . 0 4 7i n ( 5 1 , 9 7 , 2 5 1 , 9m9m )
8 m)
0 . 0 0 2 / 00 1 5 i n ( 0 , 0 5 , / 0 , 3 m
- F i l l e tr a d i i
a n d s u r f a c ef i n i s hm u s tb e m a i n t a i n e d u r i n gc r a n k s h a frte g r i n d i n gL e n g t ho f N o 4 m a i nj o u r n a lm u s t n o t e x c e e d
1 7 5 9 i n ( 4 4 , 6 8 m m )a f t e r r e g r i n d i n gW
. h e r e n e c e s s a r yu, s e o v e r s i z et h r u s t w a s h e r st o s u i t L e n g t h o f c r a n k p i n sn o t t o
e x c e e d 1 . 5 9 6 5i n ( 4 0 , 5 5m m ) a f t e r r e g r i n d i n gF
. o r c r a n k s h a f jto u r n a lr u n - o u t s, e e P a g e H . 4 .
IMPORTANTNOTE: See remarkson Page H.3 concerningthe regrindingof 60 hour Nitrided crankshafts.
CrankshaftThrust Washers
Type
P o s i t i o ni n E n g i n e
Thrust WasherThickness- Standard
Thrust WasherThickness- Oversize
T h r u s tW a s h e rO u t s i d eD i a m e t e r
T h r u s tW a s h e rI n s i d eD i a m e t e r
SteelBacked,LeadBronzeFaced
CentreMainBearing
0.089/0.091 in (2,261
2,31mm)
0.0965/0.0985
in (2,4512,5O
mm)
0 9m )
n ( 1 0 3 , 8 4 / 1 0 4 ,m
4 . 0 8 8 / 4 . 0 9i 8
1 2m )
3 4 2 / 34 3 i n ( 8 6 , 8 7 1 8 7 , m
Main Bearings
Type
S h e l lW i d t h ,N o s . 1 , 2 , 3 , 5 , 6 a n d 7 . . .
S h e l lW i d t h ,N o 4
I n s i d eD i a m e t e r
M a i n B e a r i n gR u n n i n gC l e a r a n c e
S h e l lT h i c k n e s s
Pre-finished,
SteelBacked,AluminiumSiliconFaced
1.24011255in(31,50/31,88mm)
1.43511
.445in(36,45136,70
mm)
3.166/3.167 in (80,42180,44
mm)
3.0010/3.0026in (76,22517
6,266mm)
0.001B/0.0042
in (0,046/0,
107mm)
0.08221
0.0825in (2,088/2,096
mm)
ConnectingRod Bearings
S h e l lW i d t h
I n s i d eD i a m e t e r
t s e a r i n gR u n n i n gC l e a r a n c e
S h e l lT h i c k n e s s
Pre-finished,
SteelBacked,AluminiumSiliconor
Aluminium
Tin Faced
1.2451
1.255in(31,62/31
.88mm)
2.6461
2.6465in (67,21I 67,22mm)
2.5008/2.501
I in (63,52163,55
mm)
0.0012/0.0031
in (0,030/0,08
mm)
(1,836/1,844
O.072310.0726in
mm)
Gamshaft
N o . 1 J o u r n a lL e n g t h
N o . 1 J o u r n a lD i a m e t e r
N o 1 J o u r n a lR u n n i n gC l e a r a n c e
N o 2 J o u r n a lL e n g t h
N o 3 J o u r n a lL e n g t h
N o . 4 J o u r n a lL e n g t h
N o . 4 J o u r n a lR u n n i n gD i a m e t e r
Cam Lift- Inlet(non-vehicle)
Cam Lift- Exhaust(non-vehicle)
Cam Lift-lnlet (vehicleonly)
Cam Lift-Exhaust (vehicleonly)
CamshaftEnd Float
Widthof Spigotfor ThrustWasher
1 . 0 8 5 i n( 2 7 , 5 6 m m )
1.9965/1
.9975in(50,71l50,74mm)
(0,06/0,1
0.0025/0.0045in
1 mm)
1 . 4 3 B i (n3 6 , 5 3 m m )
1.9865/1
.9875in(50,46/50,49
mm)
0.0025/0.0055
in (0,06/0,
14 mm)
1 . 4 3 8 i n( 3 6 , 5 3 m m )
1 9765/1.977Sin(50,20150,23mm)
0.0025/0.0055
in (0,06/0,
14 mm)
1 . 1 5 6 i (n2 9 , 3 7 m m )
1.9665/1
.9675in (49,95/49,98
mm)
0.0025/0.0055
in (0,06/0,
14 mm)
(7,516/7,592mm)
0 2959/0.2989in
0.3025/0.3055
in (7,68417,760 mm)
in (7,617/7,694mm)
0.2999/0.3029
0.3036/0.3066
in (7,71117,7BBmm)
0.004/0.01
6in (0,10/0,41mm)
0 2221
0.232in(5,64/5,89mm)
TECHNICALDATA
87
CamshaftThrust Washer
Type
c y l i n d e r B l o c k R e c e s sD i a m e t e rf o r T h r u s tw a s h e r
ClearanceFit of Washer in Recess
InternaD
l iameter
Thickness...
C y l i n d e rB l o c k R e c e s sD e p t h f o r T h r u s tW a s h e r
P r o t r u s i o no f T h r u s tW a s h e ra b o v eC v l i n d e rB l o c k
Front Face
360'
0m
0)
2 . 8 7 2 / 2 . 8i7n4( 7 2 , 9 5 / 7 3 ,m
.
2 . 8 7 s / 2 . B Bi ns ( 7 3 , 0 3 / 7 3 , 2m8m )
3 m)
0 0 0 1 / 00 1 3i n ( 0 , 0 3 / 0 , 3m
'1
750in (44,45mm\
0 2 1 6 / 02 i B i n ( 5 , 4 9 1 5 , 5m4m )
0 2 1 3 / O . 2 j 6 i n( 5 , 4 1 1 5 , 4 9 m m )
3 m)
0 0 0 0 / 00 0 5i n ( 0 . 0 0 / 0 , 1m
CylinderHead
C y l i n d e rH e a d D e p t h
3 7 3 5 / 3 7 6 5 i n( 9 4 , 8 7 / 9 5 , 6m3m )
-207 kN/m'z
30 lbflin'?(2,11R91/cm'?)
LeakTestPressure
Valve Seat Angle ...
Valve Guide Parent Bore Diameter ...
..
S k i m m i n gA l l o w a n c e
4So
0 6 2 4 7 / 0 . 6 2 5 7i n ( 1 5 , 8 7 1 1 5 , 8 9 m m )
0 0 1 2i n ( 0 , 3 0m m )
P r o v i d i n gt h a t n o z z l ep r o t r u s i o nd o e sn o t e x c e e d0 1 8 4i n
( 4 , 6 7 m mf)o r T 6 3 5 4 4e n g i n e so r 0 1 3 6 i n ( 3 , 4 5 m mf)o r
6 3 5 4 4a n d 6 3 7 2 4e n g i n e sa f t e rs k i m m i n g
Valve Guides
lnside Diameter
I o u t s i d eD i a m e t e r
e i t o f G u i d e i n C y l i n d e rH e a d
O v e r a l l e n g t h ,I n l e t
O v e r a l l e n g t h ,E x h a u s t
P r o t r u s i o na b o v eV a l v eS p r i n gR e c e s s
lCounterbore,Exhaustonly
..
Inlet Valve
ValveStem Diameter
I ClearanceFit of Valve in Guide
M a x i m u mP e r m i s s i b l W
e orn Servlce
C l e a r a n c eo f V a l v ei n G u i d e
V a l v eH e a d D i a m e t e r
Valve FaceAngle
V a l v eH e a d D e p t h b e l o wC y l i n d e rH e a d F a c e P r o d u c t i o nL i m i t s
O v e r a l lL e n g t h
S e a l l n gA r r a n g e m e n i
(9,51/9,54mm)
O.3743t0.3757in
0.626/0.6265
in (15,90/15,91mm)
0 . 0 0 11 / O . O 0 2 6( i0n, 0 3 / 0 , 0 7 m m )
2.281in(57,94mm)
2.406in
( 6 1 , 1m
1 m)
0 . 5 9 4 i n( 1 5 , 0 9 m m )
0 . 4 2 1 1 } . 4 4 1 i n ( 1 0 , 619, 2/ 10 m md) i a . f o r l e n g t h
o f 0 . 4 0 6 i n( 1 0 , 3 m m )
(9,46/9,49mm)
OS72SlO.373Sin
(0,02l0,08mm)
0.000e/O.0032in
0 005in(0,13mm)
1 736/1746 in (44,09/44,35
mm)
45"
0 O4O/0
O5 0i n ( 1 , 0 2 1, 1
2 7m m )
4 8 3 1 / 48 4 7i n ( 1 2 2 , 7 11/2 3 , '11m m )
R u b b e rs e a lf i t t e dt o v a l v eg u i d e
ExhaustValve
I ValveStemDiameter
I ClearanceFitto Valvein Guide
M a x i m u mP e r m i s s i b lW
e ornService
C l e a r a n c eo f V a l v ei n G u i d e
Valve Head Diameter
V a l v eF a c eA n g l e
V a l v eH e a d D e p t h b e l o wC y l i n d e rH e a d F a c e P r o d u c t i o nL i m i t s
I O v e r a l lL e n g t h
S e a l i n gA r r a n g e m e n t
0.3711O.37
2in (9,4219,45
mm)
(0,06/0,12mm)
0.0O23tO.OO47in
0 0 0 6 i n( 0 , 1 5 m m )
| 467/1477in (37.26/37.52mm\
45'
1,27mm)
in (1,021
0.040/0.050
(123,06/1
23,57mm)
4.845/4.865in
Rubbersealfittedto valveguide
Inner Valve Springs (short)

I Fittedlengthand Load
N u m b e ro f A c t i v e C o i l s
N u m b e ro f D a m p e r C o i l s
Coiled
1.340in(34,04mm)at20.1123.21bf(9,12l10,52kgf)
(89,4/1
49
03,2N)
1
R.H.-Damper Coilto CylinderHead
Inner ValveSprings (long)

I F i t t e dl e n g t h a n d L o a d
N u m b e ro f D a m p e rC o i l s
Coiled
1.563in (39,70mm) at 14.63/1

6.67lbf(6,64/7,56kgf)
(65,1t74,2N)
7
z
R.H.-Damper Coilsto CylinderHead
Outer ValveSprings (short)

I Fittedlengthand Load
N u m b e ro f A c t i v e C o i l s . . .
Coiled
6 3544SenesWorkshoplvlanual,
January1986
(17,91/19,82kgf)
1.410in(35,81rnm)at 39.5/43.7|bf
(175,7t194,4N)
3.6
1
L.H.-Damper Coilto CylinderHead
TECHNICALDATA
B8
Outer Valve Springs ( l o n g )

Fitted length and Load
Coiled
1.780 in (45,20 mm) aI 38/43 lbf (17,25/19,52kgf)

5.8
L . H .-
D a m p e rC o i l s t o C y l i n d e rH e a d
Tappets
OverallLength
T a p p e tS h a n k D i a m e t e r
Cylinder Block Tappet Bore Diameter
R u n n i n gC l e a r a n c eo f T a p p e ti n B o r e
Outside Diameterof Tappet Foot
2.96875in (75,41mm)
0 . 7 4 7 5 / 07 4 8 5i n ( 1 8 , 9 1 / 1 9 , 0m1m )
O . 7 5 0 / 0 . 7 5 1i2n5( 1 9 , 0 5 / 1 9 , 0m8m )
0.0015/0.00375
in (0,0410,09
mm)
1 . 1 8 7 5 i (n3 0 , 1 6 m m )
Rocker Shaft
OverallLength
Outside Diameter
2 6 . 0 3 1 2 5 i n( 6 6 1 , 1 9 m m )
O . 7 4 8 5 / 0 . 7 4i9n5( 1 9 , 0 1 / 1 9 , 0m4m )
Rocker Levers and Bushes

InternalBore Diameterof Rocker Leverfor Bush
Outside Diameterof Bush
InterferenceFit of Bush in Rocker Lever
InternalDiameterof Bush (after reaming in situ)'
Clearanceof Bush to Rocker Shaft
O.B7
5/ 0.8762 in 122,22
/ 22,26mm)
O.877
/0.8785in (22,28/22,31
mm)
0.0008/0.0035
in (0,0210,09
mm)
0 . 7 5 0 5 / 0 . 7 5 2i n0 ( 1 9 , 0 6 / 1 9 , 1m0m )
0.001/0.0035
in (0,03/0,09
mm)
Push Rods
Overall Length of Push Road
S h a n kD i a m e t e r
1O.456
/ 10.540in (265,58/ 267,72 mm)
0 3 1 0 / 0 . 3 1i2n ( 7 , 8 7 1 7 , 9m3m )
Camshaft Gear
N u m b e ro f T e e t h . . .
BoreDiameter ...
O u t s i d eD i a m e t e ro f C a m s h a f tH u b . . .
F i t o f G e a rt o h u b
1 375/1376in (34,93/34,95
mm)
1.3751/1.375
i n7( 3 4 , 9 3 / 3 4 , 9m4m )
- 0 0 0 0 7 / + 00 0 0 9i n ( - 0 , 0 1 8 / + 0 , 0 2m3m )
Auxiliary Drive Gear

N u m b e ro f T e e t h
Bore Diameter
M a x i m u mA d j u s t m e n it n S l o t t e dH o l e s
28
1.000/1.001in (25,4/ 25,43mm)
10'
Crankshaft Gear
Bore Diameter
CrankshaftDiameterfor Gear
Fit of Gear to Crankshaft
28
1.875/ 1 876 in (47,63/47,65mm)
1.875/ 1 8758 in (47,63/47,64mm)
- 0 . 0 0 0 8 / + 00 0 1i n ( - 0 , 0 2 0 / + 0 , 0 2m5m )
ldler Gears and Hubs

Bore Diameter
O u t s i d eD i a m e t e ro f B u s h
I n s i d eD i a m e t e ro f B u s h ( f i n i s h e di n s i t u )
O u t s i d eD i a m e t e ro f H u b
C l e a r a n c eo f H u b i n s i d eB u s h
End Float of Gears
37
in (52,39/52,43
mm)
2 0625/2.0643
2.06625/2 06825i n (52,48/ 52,53mm)
mm\
1 8750/1.8766
in (47,63/47,67
1.8714/1873in (47,53/47,57
mm)
O . 0 0 2 / 0 0 5 2i n ( 0 0 5 / 0 , 1 3m m )
mm)
0.002/0.012
in (0,05/0,30
Timing Gear Backlash

All Gears
0 . 0 0 3i n ( 0 , 0 8m m ) m i n i m u m
Auxiliary Drive Shaft Assembly

Drive Shaft- OveralI Length
Number of Teeth on S/orm
Outside Diameterof Worm
Diameterof Front Journa
Diameterof Rear Journal.
1 0 . 2 5i n ( 2 6 0 , 3 5
mm)
'1
1
1 865/1.870in (47,37/47,5mm)
1 9 3 5 5 / 1. 9 3 6 5 i n( 4 9 , 1 6 / 4 9 , 1 9 m m )
1 . 2 4 8 / 12 4 9i n ( 3 1 , 7 / 3,.712m m )
Drive Shaft Bush-Front

HousingDiameter
for Bush
2 1 2 8 3 / 21 3 0 3 i n( 5 4 , 0 6 / 5 4 , 1m1m l
2.125/2.1262
in (53,98/54,01
mm)
continued . . -
TECHNICALDATA
eit in Housino
Inside Diameterof Fitted Bush
R u n n i n gC l e a r a n c eo f S h a f i i n B u s h
mm)
0 0021/0 0053in (0,05/0,13
1.9375/ 1.9397irn(49,21/ 49,27mm)
0 . 0 0 1 / 0 . 0 0 4i n2 ( 0 , 0 2 5 / 0 , 1m1 m )
Drive Shalt Bush- Rear

H o u s i n gD i a m e t e rf o r B u s h
eit in Housino
I n s i d eD i a m e t e ro f F i t t e dB u s h
R u n n i n gC l e a r a n c eo f S h a f t i n B u s h
mm)
1.4086/1
.4105in (35,78135,83
1.4063/1.4076
in (35,72135,75
mm)
0 . 0 0 1 / 0 . 0 0 4i n2 ( 0 , 0 2 5 / 01,1m m )
8 0m )
1 2 5 / 1. 2 5 1 9i n ( 3 1 , 7 5 1 3 1 , m
0 . 0 0 1 / 0 . 0 0 3i n9 ( 0 . 0 2 5 / 0 , 1m0 m )
AuxiliaryDriveThrustWashers
Thickness...
C y l i n d e rB l o c k R e c e s sD e p t h f o r T h r u s tW a s h e r
I n s i d eD i a m e t e ro f C y l i n d e rB l o c k R e c e s s . .
P r o t r u s i o no f T h r u s tW a s h e ri n C v l i n d e rB l o c k
GrooveWidth on Drive Shaft
Groove to Thrust Washer Clearance
0.1875/0.1905in (4,76/4,84mm)
O.184/O.187 in (4,67/ 4,75 mm\
2 806/2 812in (71,27/71,42mm)
2.8125/2.8225in (71,44/71,69m m )
7 m)
0 . 0 0 0 5 / 0 . 0 0i n7 ( 0 , 0 1 / 0 , 1m
9 m)
0 . 1 9 3 / 0 . 1 9 6i n5 ( 4 , 9 / 4 , 9m
mm)
0.0025/0.009
in (0,064/0,23
Hydraulically Loaded Wormwheel

B o r e D i a m e t e ri n C y l i n d e rB l o c k f o r F u e l P u m p
A d a p t o rP l a t ea n d U p p e rT h r u s t C o l l a r . . .
Fuel Pump Adaptor Plate Diameter
F i t o f P l a t ei n C y l i n d e rB l o c k . . .
O u t e r D i a m e t e ro f U p p e rT h r u s t C o l l a r
C l e a r a n c eo f U p p e rT h r u s t C o l l a ri n C y l i n d e rB l o c k
Bore Diameterin Cylinder Block for Lower Thrust
Washer
W i d t h o f G r o o v ei n U p p e rT h r u s t C o l l a r
U p p e rT h r u s tC o l l a rS e a l i n gR i n g T h i c k n e s s . . .
Clearanceof SealingRing in Groove
I n n e r D i a m e t e ro f B u s h i n F u e l P u m p A d a p t o rP l a t e
U p p e r D i a m e t e ro f F u e l P u m p D r i v eS h a f t
Clearanceof Drive Shaft in Adaptor Plate Bush ..
I n n e r D i a m e t e ro f U p p e rT h r u s t C o l l a r
Clearanceof Drive Shaft in Upper Thrust Collar
C u r r e n tE n g i n e s : Lower Thrust Collar Bore for Bush . .
Outer Diameterof Bush
e i t o f B u s h i n T h r u s tC o l l a r
I n n e r D i a m e t e or f B u s h ( a f t e rf i n i s h i n gi n s i t u )
Lower Diameterof Fuel Pump Drive Shaft
C l e a r a n c eo f S h a f ti n B u s h
E a r l yE n g i n e s : I n n e rD i a m e t e o
r f L o w e rT h r u s tC o l l a r
L o w e rD i a m e t e o
r f F u e l P u m p D r i v eS h a f t
C l e a r a n c eo f D r i v eS h a f ti n C o l l a r
mm)
3.500/3.5014
in (88,90/88,94
in (88,86/88,89
mm)
3.4986/3.4995
in (0,01/0,07
mm)
0.0005/0.0028
mm)
3.496/3498 in (88,80/BB,B5
in (0,05/0,14 mm)
0.002/0.0054
2 . 2 4 9 1 / 2 4 9 9i n ( 5 7 , 1 3 / 5 7 , 1m5m )
in (2,43/2,46mm)
0 0957/0.0967
in (2,36/2,38
mm)
0.0928/0.0938
0 m)
0 . 0 0 1 9 / 0 . 0 0 3i n9 ( 0 , 0 5 / 0 , 1m
1.875/ 1.8766 in (47,63/47,67mm)
1.8714/ 1.873 in (47,53/47,57mm)
0 002/00052in (0,05/0,13mm)
1 8 8 6 / 1. B g i n ( 4 7 , 9 0 / 4 8 , 0m1m )
7 m)
0 . 0 1 3 / 0 . 0 1 8i n6 ( 0 , 3 3 / 0 . 4m
1 7 8 1 2 / 17 B 2 B i n(45,24/45,28mm)
1 7843/1.7857
in (45,32/45,36mm)
0.0015/0.0045
in ( 0 , 0 4 1 0 , 1m1m )
1 6255/1 6266in (41,29/41,32
mm)
mml
1 6214/1 6224in (41,18/41,22
3m)
i n2( 0 , 0 8 / 0 , 1m
0.0031/0.005
1-625/1 6266in (41,28/41,32mm\
1.6214/1.6230
in (41,18/41,22mm)
0.002/0.0052
in (0,05/0,13
mm)
Sump
Sump Capacity (typical)
M i n i m u mt o M a x i m u mm a r k o n D i p s t i c k
S t r a i n e rP o s i t i o n
2 6 l m p e r i a lP i n t s ( 1 4 , 8L i t r e s )
5 l m p e r i a lP i n t s ( 2 , 8 4L i t r e s )
S u c t i o nP i p e o f L u b r i c a t t n gO i l P u m p
Oil Pump
Type
Rotor
Oil Pump Clearance

mm)
l n n e r R o t o rt o O u t e r R o t o r
in (0,08/0,13
0.003/0.005
3 m)
O u t e r R o t o rt o P u m p B o d y
0 . 0 0 6 / 00 1 3i n ( 0 , 1 5 / 0 , 3m
6m)
I n n e ra n d O u t e r R o t o r E n d C l e a r a n c e
0 . 0 0 0 5 / 0 . 0 0 2i n5 ( 0 , 0 1 / 0 , 0m
F o r r e p l a c e m e npt u r p o s e st,h e w h o l e p u m p a s s e m b l ym u s t be replaced.
RelielValve
First Stage PressureSetting (T6 3544 only)
Relief Flow PressureSetting
L e n g t ho f P l u n g e r
O u t s i d eD i a m e t e ro f P l u n g e r . . .
I n s i d eD i a m e t e ro f V a l v eH o u s i n qB o r e
C l e a r a n c eo f P l u n g e ri n B o r e
Free Length of Spring
Spring Fitted Length and Load
30/ 37 lbt/ in2 (2,11/ 2,6 kgf/ cm,) 2O7/ 255 kN/ m,
50/60|bf/i n, (3,52/4,22k gf/cm,) 348/ 414 kN/ m,
0 . 9 3 7 5i n ( 2 3 , 8 1m m )
0 7 1 5 8 / 07 1 7i n ( 1 8 , 1 8 / 1 8 , 2m1m )
0.718/0.7192 in (18,24/18,27mm)
mm)
in (0,03/0,09
0.001/0.0034
2.3125in(58,74mm)
2 . 1 8 7 5 i n( 5 5 , 5 6 m m )a t 3 l b f 8 o z f ( 1 , 5 8 k g f )
B9
TECHNICALDATA
81O
LubricatingOil Filter
Typeof Filter
ElementType
By-PassValveSetting
e anister
F u l l F l o w R e p l a c e a b lC
Paper
kgf/cm'?)55/83kN/m'?
B/12lbt/in2(0,56/0,8a
Cooling System
Type
Coolant Capacity
T h e r m o - S y p h o nP. u m p a s s i s t e d .
3 8 l m p e r i a lP i n t s ,( 2 . ,16 l i t r e s )
Thermostat
Type
Opening Temperature
F u l l yo p e n a t
Valve Lift
T w i n W a x C a p s u l ef i t t e d i n p a r a l l e l
177/183"F (80,6/83,9"
C)
199 -204" F (93 -96' C)
mm)
0.374/0500 in (9,50/12,70
WaterPump
Type
Outside Diameterof Shaft for Pulley
lnside Diameterof Pulley Bore
ClearanceFit of Pullev on Shaft
O u t s i d eD i a m e t e r oSf h a f t f o rl m p e l l e r
D i a m e t e ro f l m o e l l e rB o r e
I n t e d e r e n c eF i t o f l m p e l l e ro n S h a f t
l m p e l l e rB l a d et o P u m p B o d y C l e a r a n c e
..
C e n t r i uf g a l
in (22,20/22,22mm)
0.8742/0.8747
in (22,23/22,25mm)
0.8750/0.8758
mm)
in (0,01/0,04
0 0003/000.16
..
.
..
0 . 5 0 1 2 / 05 0 1 8i n ( 1 2 , 7 3 / 1 2 , 7 5 m m \
0 5 0 0 0 / 0 . 5 0 0i n
7 (12,7O/12,72mm')
0 0 0 0 5 / 0 . 0 0 1i n
8 ( 0 , 0 1 3 / 0 , 0 4m6m )
0 . 0 11 / 0 0 3 5i n ( 0 , 2 8 1 0 , 8m9m )
(including
e n dfl o a t )
Approved Fuel Oil Specifications

UnitedKingdom
UnitedStates
France
India
Germany
Italy
Sweden
Switzerland
BS.2869:1983
VV-F-800C
A.S.T.M./D975-817
AFNORN.F.M.15/007(1978)
15:1460/1974
(1978)
DIN-51601
CUNA-GasOil
(1977)
NC-630-01
515.155432(1981)
SN 181 160/1
Class41 or A2
GradesDF-A,DF-1or DF-2
GradesDF-A,DF-1or DF-2
GradeHSD
F u e l o i l s a v a i l a b l ei n t e r r i t o r i e so t h e r t h a n t h o s e l i s t e da b o v ew h i c h a r e t o a n e q u i v a l e nst p e c i f i c a t i o n
may be used
Fuel Lift Pump

Typeof Pump
M e t h o do f D r i v e
DeliveryPressure
D i a p h r a g mS p r i n gC o l o u r
AC DelcoXDSeries
E c c e n t r i co n C a m s h a f t
6/10lbf/in'?(0,43/0,70kgf/cm'?)or 41169kN/m'?
Red
Fuel Filter
Type
ElementType
TwinParallelor single
Paper
Fuel Injection Pump

Make
Type
Pump Rotation
TimingLetter
N o . 1 C y l i n d e rO u t l e t
Make
Type
Pump Rotation
N o . 1 C y l i n d e rO u t l e t
'1
6 3544SeriesWorkshopl\y'anual,
January 986
CAV
D , PA
Anti-clockwise
a
"x"
Bosch
Rotary
Anti-clockwise
D
TECHNICALDATA
811
Fuellnjection Pump Static Checking Angles

The relevanttiminginformationcan be found by referenceto the prefixlettersor prefixlettersand figuresof the settingcode adjacent
to the word "Set" on the fuel pump identification
plateand the tablebelow.The enginecheckingangleis for use withtimingtool MS67B
and the engineset with No. 1 pistonat TDC compressionstroke.
Prefix
Letters
T6.3544
pumps
C.A.V.
CY
DY
JY
LX
LY
MY
TX
VR
XX
YX
zx
Boschpumps
EY (121-2)
FY (121-3)
KY (1107)
VX (121or 173)
EngineChecking
Angle (Degrees)
FuelPumpMarking
Angle(Degrees)
StaticTiming
BTDC(Degrees)
159
159
159
160
159
145
144
144
144
145
144
144
144
144
144
144
135.
135.
123.
135-
1251/2.
1271/2.
11 8 127-
tbu
146
146
146
146
154
154
144
146
146
28
28
28
28
159
161
160
161
160
157
146
146
zo
161
lcJ
tou
159
153
t5v
to
32
JU
30
to
30
30
30
30
32
JU
10
t3
10
to
Piston
Displacement
0 . 1 2 4 i n( 3 , 1 5 m m )
0 . 4 8 5 i n( 1 2 , 3 2 m m )
0 . 4 2 6 i n( 1 0 , 8 2 m m )
0 . 4 2 6 i n( 1 0 , 8 2 m m )
O . 1 2 4 i (n3 , 1 5 m m )
O . 4 2 6 i (n1 0 , 8 2 m m )
0 . 4 2 6 i n( 1 0 , 8 2 m m )
0 . 4 2 6 i n( 1 0 , 8 2 m m )
0 , 4 2 6 i n( 1 0 , 8 2 m m )
0.483in(12,27mm)
0 . 4 2 6 i n( 1 0 , 8 2 m m )
0 . 1 7 5 i n( 4 , 4 5 m m )
0 . 110 i n ( 2 , 7 9m m )
0 . 0 4 9 i n( 1 , 2 4 m m )
(3,15mm)
0.124in
6.3544
C.A V. pumps
AY
BY
EX
FX
GY
HY
MR
MX (exceptbelow)
MXt412640
MX/512420trom
eng.no.728207L
MX/5/2530
PX
SX
WR
WX
6.3724
SX
tou
160
160
toz
toz
158
160
161
to
to
zo
28
30
0.373in(9,47mm)
0.373in(9,47mm)
0 . 3 7 3 i n( 9 , 4 7 m m )
0.373in(9,47mm)
(3,18mm)
0.125in
(3,18mm)
0.125in
0.373in(9,47mm)
0.373in(9,47mm)
0 . 4 2 6 i n( 1 0 , 8 2 m m )
146
146
144
30
28
30
28
26
0.325in(8,26mm)
0 . 4 2 6 i n( 1 0 , 8 2 m m )
0 . 3 7 3 i n( 9 , 4 7 m m )
0 . 4 2 6 i n( 1 0 , 8 2 m m )
0 . 3 7 3 i n( 9 , 4 7 m m )
0 . 3 2 5 i n( 8 , 2 6 m m )
146
30
0 426in (10,82mm)
t+o
" The settingsgivenfor the Boschfuel pumpsare withthe pumpset at 1 mm plungerlift.lt is important
thatthesepumpsare not fitted
givenfor the CAV pumps.The codegivenin bracketsis stampedon the sideof the pump.
at the statictimingpositions
6,3544SeriesWorkshopManual,May'85
TECHNICAL
DATA
812
Atomisers
Code
FL
FN
GD
uu
GH
GK
GL
I G X
HC
HE
HK
I H P
I
I
IHS
I
lHr
RA
RB
VU
Holder
Nozzle
BKBL67S5299
BKBL6755299
BKBL67S5299
or
oKLL67S2931
BKBL67S5299
BKBL67S5299
KBEL62S9/1
3
BKBL67S51
51
KBEL64521
LR867014.
or
OKLL66M2884
LR867014.
BKBL67S5299
BDLLl5056673
BDLLl50S6639
BDLLl5OS673O
or
oLLl 5056730
BDLLl5056737
BDLLl5056738
DLLAl 505741
BDLLl5OS673O
DLLAl 40S827
JB6801014
or
oLLl 50M8575
JB6801019
BDLLl35S6834
LR867014.
or
OKLL66M2BB4
BKBL6735299
or
oKLL6752931
LR867014.
or
oKLL66M2884
KBEL641
16
oKLL62M3136
oKLL67S2929
BKBL67S51
51
atm
215
210
215
Setting Pressure
(MN/m'z)
lbilin2
(21,8)
3160
(21,3)
3087
(21,8)
3160
Working Pressure
atm
lbf/in2 (MN/mr)
(20,3)
20O
2940
(19,8)
195
2866
(20,3)
200
2940
210
210
275
175
250
245
3087
3087
4042
2572
3675
3601
(21,3)
(21,3)
(27,9)
(17,7)
(25,3)
(24,8)
21O
210
275
170
25O
245
3087
3087
4042
2500
3675
3600
(21,3)
(21,3)
(27,9)
(17,2)
(25,3)
(24,8)
230
215
3381
3160
(23,3)
(21,8)
230
215
3381
3160
(23,3)
(21,8)
J86801014
or
oLLl 50M8575
BDLLl5OS673O
or
oLLl 5056730
J8680101I
225
3307
(22,8)
225
3307
(22,8)
215
3160
(21,8)
2O0
2940
(20,3)
200
2940
(20,3)
2o0
2940
(20,3)
DLLAl 40P44
oLLl 30M9027
oLLl 5057574
BDLLl5056329
250
250
250
175
3675
3675
3675
2572
(25,3)
(25,3)
(25,3)
(17,7)
250
250
225
170
367s
3675
3307
2500
(25,3)
(25,3)
(22,8)
(17,2)
. In theseatomisersthe pressureis
adjustedby a changeof shims.
ElectricalSystem
Alternator
I Make
I TYPe
I
I Voltage
Max.output(hot)
Make
Type
Voltage
Max.output(hot)
12or 24volt
Lucas
17ACR 17ACR
(derated)
12V
12V
284
35A
c.A.v. ".
ACs&ACsR
12V
604
I Startermotor
I vut"
'Tvpe
I vottug"
I Startercableresistance
I No. of teethon pinion
LUCaS
M50
12V
0.0017f)
10
18ACR
A115
A133/55 25ACR
12V
45A
12V
45A
12V
s5A
Perkins
LR135
12V
354
ACs&ACsR
24V
30A
M12712,8
12V
0.0017c)
10
c.A.v.
cA45
12V
0.0017c)
10
cA45
24V
0.0034c)
10
StartingAid
Make
MaximumCurrentConsumption
Flow RatesthroughThermostart
6 3544SeriesWorkshopManual,May'85.
12V
654
- Thermostart
C.A.V.
1 2 . 5 / 1 3 .a
5 tA11 . 5 V
ml/min
3,5/5,0
A133/65
12V
65A
LR150
12V
50A
Perkins
s12-84
12V
0.0017c)
10
TECHNICALDATA
813
SERVICEWEAR LIMITS
The following "wear limits" indicatethe condition when it is recommendedthat the respectiveitems should be servicedor
reolaced.
Cylinder Head Bow Transverse
Longitudinal
M a x i m u mB o r e W e a r
(when new liners are necessary)
C r a n k s h a f tM
, a i na n d B i g E n d J o u r n a l ,
Ovalityand Wear
Maximum CrankshaftEnd Float
ValveStem to Guide Bore Clearance,Inlet
Exhaust
Valve Head Depth below Cylinder Head Face
Rocker Clearanceon Rocker Shaft
CamshaftJournals,Ovality and Wear
CamshaftEnd Float
l d l e rG e a r E n d F l o a t
6 3544 Seriesworkshop Manual,lssue2, June'82
0 . 0 0 5i n ( 0 , 1 3m m )
0 . 0 1 0i n ( 0 , 2 5m m )
0 . 0 0 8i n ( 0 , 2 0m m )
0 . 0 0 1 5i n ( 0 , 0 4 m m )
0 . 0 2 0i n ( 0 , 5 1m m )
0 . 0 0 5i n ( 0 , 1 3m m )
0 . 0 0 6i n ( 0 , 1 5r n m )
0 . 0 6 0i n ( 1 , 5 2m m )
0 . 0 0 5i n ( 0 , 1 3m m )
0 . 0 0 2i n ( 0 , 0 5 m r n )
0 . 0 2 1i n ( 0 , 5 3 m m )
0 . 0 1 5i n ( 0 , 3 8m m )
SECTIONC
Operatingand Maintenance
OPERATING
AND MAINTENANCE C2
To startthe engine
There are several factors which affect engine start, for
example:
The powerof the batteries.
Performanceof the starter motor.
Viscosityof the lubricatingoil.
Installation
of a coldstartsystem.
Diesel engines need a cold startingaid when they are ro
operatein v.erycold conditions.Your vehiclewill riormally
be fitted with the correct equipment for your area of
operation.
Differentsystemsof cold startingaids can be installedon
Perkinsdieselenginesand they are:
Thermostart
An electricallyoperateddevice which heats the induction
air.This deviceburnsa controlledamountof dieselfuel.
Start Pilot
A hand pump discharges the cold start fluid into the
inductionmanifoldthroughan atomiser,The cold startfluid
is heldin a separatereservoir.
KBi
The cold start fluid is held in an aerosol container.lt is
1e]egpe{!y a. push bu.ttonoperated solenoid and sprayed
intothe inductionmanifoldby anozzle.
WARNING
KBi,or.
StartPilotequipmentmust not be usedwith heattype
cold startingaidssuch as Thermostart.
Engine start procedure, without cold

startingaids.
1. Adjustthe enginespeed controlto the maximumspeed
oosrlron.
2. Turn the startkey to the'S' (start)position,(see Fig.C1)
to engagethe startermotor.
3. As soon as the enginestarts,releasethe startkey to the
' R ' ( r u n )p o s i t i o n .
4. Adiustthe enginespeedcontrol.
5. lf the enginedoes not start in 15 seconds,releasethe
start key to the 'R' position.Do not enqaqethe starter
motoragainuntil10 to 15 secondshavepassed.
Always ensure that the flywheel and starter motor have
stoppedtheir rotationbeforethe startermotor is engaged
again.
Enginestart procedurewith Thermostart.

1. Wherea separatestop controlis installed,ensureit is in
t h e ' R ' ( r u n )p o s i t i o n .
2. Turn the startkey to_the'H' (Heat)position,(see Fig.C1)
and holdit therefor 20 seconds.
3. Adjustthe enginespeed controlto the maximumsoeeo
position.
4. Turn the start key to the 'HS' (Heat/Start)positionto

engagethe startenmotor.As the enginestarts,retease
the start key to the 'R' (run) position and adjust the
enginespeedcontrolto give a smoothidlespeed.
5. lf the engine does not start in 15 seconds,return the
s t a r t k e y t o t h e ' H ' p o s i t i o n f o r 1 0 s e c o n d sa n d t h e n
engagethe startermotoragatn.
Enginestartprocedurewith StartPilot
The StartPilothand pump must not be used untilthe starter
motoris engaged.
Experiencewill show how much fluid is needed for each
enginestart.
1. Where necessary,chargethe reservoirwith fluid.Raise
the cover of the reservoir,pressthe can, head down on
the.fillerplug and hold squarelyuntilfluidfillsthe bowlup
to the maximummark.
2. Adiustthe enginespeed controlto the maximumspeed
oosrlron.
3. Engagethe startermotorfor a maximumof 30 seconos
and operate the Start Pilot pump during this period.
Adjustthe enginespeedcontrol.
4. lf the enginedoes not start duringthe first 30 seconds,
disengagethe startermotorfor another30 secondsand
then engage the starter motor again and operate the
StartPilothandpump.
The air filterat the outer end of the pump must be inspected
from time to time and if necessaryit must be washed in
Kerosene.
Thin lubricating
oil can be appliedto the pumpcylinder.
The nozzle in the inductionmanifoldcan be removedand
washedin kerosene,when necessary.
WARNING
Start Pilotequipmentmust not be used with heat type cold
startingaidssuch as thermostart
Enginestartprocedurewith KBi
1. Where necessary,renew the screw type canister.A
safetyvalveis integralwiththe container.
2. Adiustthe enginespeed controlto the maximumspeed
posrlron.
3. Engagethe startermotor.
4. Pressthe KBi buttonfor a maximumof 2 seconds.As the
enginestarts,adjustthe enginespeed controlto give a
smoothidle soeed.
5. lf the enginedoes not startafterthe first2 secondsallow
5 secondsto pass and then press the KBi buttonfor a
maximum period of 2 seconds with the starter motor
engageo.
WARNING
KBi equipmentmust not be usedwith heattype cold starting
aidssuch as Thermostart.
Stopping the Engine

A spring loaded control is located near the normal
engine controls and functions by cutting off the fuel in
the fuel injectionpump.
To operate, pull the "stop" control and hold until the
engine has completelystopped rotating Ensurethe stop
returns to its "run" position otherwise difficulty may
be experiencedin re-startingthe engine.
Returnswitchto the "O" positron.
W h e r e a n e n g i n e i s f i t t e d w i t h a n e l e c t r i c a l l yo p e r a t e d
s o l e n o i d ,t h e s t o p b u t t o n o r s w i t c h s h o u l d b e o p e r a t e d
u n t i l t h e e n g i n eh a s s t o p p e d .
ThermostartFailure
In the event of difficult starting, check that fuel is
reaching the start aid in the induction manifold by
disconnectingthe fuel pipe.
lf fuel is reaching the start aid satisfactorily, check
that the start aid is functioning by disconnecting the
piping at the induction manifold and watching the
6.3544SeriesWorkshopManual,lssue 2, June
'82
OPERATINGAND MAINTENANCE C3
cold start aid whilst it is being used. When the switch
i s t u r n e d t o " H " ( h e a t ) p o s i t i o n ,t h e e l e m e n t s h o u l d
becomered hot, and on engagementof the startermotor,
i t s h o u l db u r s t i n t o f l a m e
Where a thermostartunit has to be replaced,care musr
be taken not to exceed the torque load as given on
Page B.2. Excessive torque loading can crack the
insulatingadaptor causing an electricalshort and hard
startin g characteristics
To preventthermostarl damage, it is essentialthat the
thermostartis not operateddry After any operationwhich
allows fuel to drain from the thermostarifeed pipe, the
pipe must be disconnectedat the thermostartarid all air
bled from the pipe before the thermostart is operated.
The TO3544 and 6.3544 engine is fitted with efficient
c o l d s t a r t i n ge q u i p m e n ta n d n o r e s p o n s i b i l i t yc a n b e
accepted for any damage caused by unauthorised
startingaids
T6.3544ENGINESONLY
Operatingthe Engine-Vehicle
Applications
I t i s e s s e n t i a lt o m a i n t a i n a r e a s o n a b l yh i g h e n g i n e
speed r,vhenclimbing a gradient owing to the power
characteristicsof the turbocharged T6 3544 engine.
Do not overload the engine at low engine speed
Before the engine becomes overloaded, change gear
to increaseengine speed
PREVENTIVEMAINTENANCE
These preventivemaintenanceperiodsare generalin application. Check the periods given by the manufacturerof the
equipmentin whichthe engineis installedand,wherenecessary, use the shorterperiods.These periodsand procedures
must also be adaptedto ensurecorrectoperationfor any local
vehicleor machineregulations.
On stop/startshort distanceoperationthe hoursrun are more
importantthan the distance
Checkfor water in the fuel pre-filter(wherefitted)and drainas

necessary.
Cleanthe compressorair filter(if fitted).
(10,000
Every15000km
miles),500
hoursor
12months
Cleanthe liftpumpgauzestrainer.
Cleanor renewthe airfilterelement(if not indicated
earlier).
Renewelementof singleelementfinalfuelfilter.
Every30000km(20,000miles),1,000hours
Renewthe elernentsof doubleelementfinalfuel filter.
Cleanthe turbocharger
impellerand casing,and the lubricati n go i l d r a i np i p e .
Every90000km(60,000miles)2,500hours
Have the accessory equipment (starter motor, alternator,
exhauster,etc.)checked.
Checkand, if necessary,adjustthe valvetip clearances.
Havethe atomiserschecked.
Renew the closed circuit breather element (naturallyaspiratedenginesonly).
Air GhargeCooler (remote)

To maintain maximum etficiency,the cooler radiator fins
should be checked periodicallyto ensure that no foreign
matteris obstructingthe flow of air.
Under no circumstancesshould the radiatorbe "muffed" or
"blanked off" in an attempt to raise the temperaturein the
driver'scab becausethis will impedethe flow of air through
the chargecooler.
Post Delivery Service

The serviceproceduresgiven below must be done at the first
800/1600km(500/1,000miles),25150hoursof operation.
1. Runthe engineuntilit is warm.Stopthe engineand drain
the lubricating
oil fromthe sump.Fillthe sumpto the "full"
mark on the dipstickwith clean new lubricatingoil to an
approvedgrade.
It is good maintenanceto check for leakage and loose

fastenersat each serviceinterval.
2. Renewthe canisterof the lubricating

oil filter.
These maintenanceperiodsare only for enginesthat are

operated with fuel and lubricatingoil to the specifications
givenin thismanual.
pumpdrivebelt.
4. Checkthe tensionof the alternator/water
Schedules
The scheduleswhich follow must be done at the interval
(kilometres,
miles,hoursor months)whichoccursfirst.
Daily or every 8 hours

Checkamountof coolant.
Checkamountof lubricating
oil in the sump.
Checklubricating
oil pressure(wherea gaugeis installed).
In extremedust conditions,
cleandustbowlof airfilter(where
fitted),
Every7500km(5,000miles),250hoursor 4
months
Renewthe lubricating
oil.
Renewthe lubricatingoil filtercanister/s.
Cleanthe aircleaner,or emptythe dustbowlof the airfilter.
Insoectthe drivebelt.
'1
3. Adjustthe valvetip clearances(see page E.4).

5. Checkthat all fastenersare tight.
6. Runthe engineand checkfor fuel,coolantand lubricating
oil leakage.
7. lf necessary,get a trainedpersonto adjustthe idlespeed.
OPERATINGAND MAINTENANCE C4
Protectionof an Enginenot in Service

T h e r e c o m m e n d a t i o n gs i v e n b e l o w a r e t o e n s u r e t h a t
d a m a g e i s p r e v e n t e dw h e n a n e n g i n e i s r e m o v e df r o m
s e r v i c e f o r a n e x t e n d e dp e r i o d . U s e t h e s e p r o c e o u r e s
i m m e d i a t e l yt h e e n g i n e i s r e m o v e d f r o m s e r v i c e T h e
i n s t r u c t i o n sf o r t h e u s e o f P O W E R P A R Tp r o d u c t sa r e
g i v e no n t h e o u t s i d eo f e a c h c o n t a i n e r
1 . T h o r o u g h l yc l e a nt h e o u t s i d eo f t h e e n g i n e
2 . W h e r e a p r e s e r v a t i v ef u e l i s t o b e u s e d , d r a i n t h e
f u e l s y s t e m a n d f i l l w i t h t h e p r e s e r v a t i v ef u e l
POWERPART Lay-Up 1 can be added to the
n o r m a l f u e l t o c h a n g e i t t o a p r e s e r v a t i v ef u e l l f
p r e s e r v a t i v ef u e l i s n o t u s e d , t h e s y s t e m c a n b e
k e p t c h a r g e dw i t h n o r m a lf u e l b u t t h i s w i l l h a v e r o
b e d r a i n e da n d d i s c a r d e da t t h e e n d o f t h e s r o r a o e
p e r i o dt o g e t h e rw i t h t h e f u e l f i l t e r
3 . R u n t h e e n g i n e u n t i l i t i s w a r m C o r r e c ta n y f u e l ,
l u b r i c a t i n go i l o r a i r l e a k a g e .S t o p t h e e n g i n e a n d
d r a i nt h e l u b r i c a t i n g
oil sump
4 R e n e wt h e l u b r i c a t i n g
o i l f i l t e rc a n i s t e r
5
F i l l t h e s u m p t o t h e f u l l m a r k o n t h e d i p s t i c kw i t h
clean new lubricating oil or with a correct
p r e s e r v a t i v ef l u i d . P O W E R P A R TL a y - U p 2 c a n b e
a d d e d t o t h e l u b r i c a t i n go i l t o g i v e p r o t e c t i o n
a g a i n s tc o r r o s i o nd u r i n gt h e p e r i o d i n s t o r a g e .l f a
preservative
f l u i d i s u s e d , t h i s m u s t b e d r a i n e da n d
n o r m a l l u b r i c a t i n go i l u s e d w h e n t h e e n g i n e i s
r e t u r n e dt o s e r v i c e .
6 . D r a i n t h e c o o l i n gs y s t e m ,s e e P a g e C 5 . T o g i v e
p r o t e c t i o na g a i n s t c o r r o s i o n ,i t i s b e t t e r t o f i l l t h e
c o o l i n gs y s t e m w i t h a c o o l a n tt h a t h a s a c o r r o s i o n
i n h i b i t o r s, e e ' E n g i n eC o o l a n t 'o n t h i s p a g e l f f r o s t
p r o t e c t i o ni s n e e d e d ,u s e a n a n t i f r e e z em i x t u r e .l f
n o f r o s t p r o t e c t i o ni s n e e d e d , u s e w a t e r w i t h a n
a p p r o v e dc o r r o s i o ni n h i b i t o m
r ixture.
7. Run the engine for a short period to send the
l u b r i c a t i n go i l a n d c o o l a n ta r o u n dt h e e n g i n e
8 C l e a n o u t t h e e n g i n e b r e a t h e rp i p e a n d s e a l t h e
end of the pipe.
9 . R e m o v e t h e a t o m i s e r sa n d s p r a y P O W E R P A R T
Lay-Up 2 into each cylinderbore. lf this is not
a v a i l a b l e ,c l e a n e n g i n e l u b r i c a t i n go i l w i l l g i v e a
d e g r e e o f p r o t e c t i o n S p r a y i n t o t h e c y l i n d e rb o r e s
1 4 0 m l ( 1 / 4p i n t ) o f l u b r i c a t i n go i l d i v i d e d e v e n l y
b e t w e e nt h e s i x c y l i n d e r s
10
S I o w l yt u r n t h e c r a n k s h a f o
t n e r e v o l u t i o na n d t h e n
install the atomisers complete with new sear
washers
11
Remove the air filter and any pipe installed

b e t w e e nt h e a i r f i l t e ra n d i n d u c t i o nm a n i f o l d S
. pray
POWERPART Lay-Up 2 into the induction
m a n i f o l dS
. e a l t h e m a n i f o l dw i t h w a t e r p r o otfa p e .
R e m o v et h e e x h a u s tp i p e S p r a yP O W E R P A R T
LayU p 2 i n t o t h e e x h a u s tm a n i f o l d .S e a l t h e m a n i f o l d
with waterprooftape
12
13
Remove the lubricating oil filler cap Spray

P O W E R P A R TL a y - U p 2 a r o u n d t h e r o c k e r s h a f t
a s s e m b l y .F i t t h e f i l l e rc a p .
1 4 . D i s c o n n e c t h e b a t t e r ya n d p u l i t i n t o s a f e s t o r a g e
i n a f u l l y c h a r g e d c o n d i t i o n .B e f o r e t h e b a t t e r y i s
put into storage, give the battery terminals a
p r o t e c t i o na g a i n s tc o r r o s i o nP
. O W E R p A R TL a y - U p
3 c a n b e u s e do n t h e t e r m i n a l s .
15. Seal the vent pipe of the fuel tank or the fuel filler
c a p w i t h w a t e r p r o otfa p e .
1 6 . R e m o v et h e f a n b e l t a n d p u t i t i n t o s t o r a g e .
17. To prevent corrosion, spray the engine with
P O W E R P A R TL a y - U p 3 D o n o t s p r a y i n s i d e t h e
a l t e r n a t o cr o o l i n gf a n a r e a .
NOTE:
B e f o r e t h e e n g i n e i s s t a r t e da f t e r a p e r i o d i n s t o r a g e ,
o p e r a t et h e s t a r t e rm o t o r w i t h t h e e n g i n es t o p c o n t r o li n
the 'off' position until oil pressureshows on the oil
p r e s s u r eg a u g e o r t h e o i l w a r n i n g l i g h t g o e s o u t l f a
solenoid stop control is used, this will have to be
d i s c o n n e c t e fdo r t h i s o o e r a t i o n
l f t h e e n g i n ep r o t e c t i o ni s d o n e c o r r e c t l ya c c o r d i n gt o t h e
a b o v e r e c o m m e n d a t i o n s ,n o c o r r o s i o n d a m a g e w i l l
n o r m a l l yo c c u r .P e r k i n sE n g i n e sL t d . a r e n o t r e s p o n s r b l e
f o r a n y d a m a g e t h a t o c c u r s i n r e l a t i o nt o a s e r v i c e
s t o r a g ep e r i o d .
E n g i n eC o o l a n t
T h e q u a l i t yo f t h e c o o l a n t u s e d c a n h a v e a l a r g e e f f e c t
o n t h e e f f i c i e n c ya n d l i f e o f t h e c o o l i n g s y s t e m . T h e
r e c o m m e n d a t i o ngs i v e n b e l o w c a n b e o f a s s i s t a n c ei n
t h e m a i n t e n a n c eo f a g o o d c o o l i n g s y s t e m w i t h f r o s t
a n d / o rc o r r o s i o np r o t e c t i o n
1
, s e c l e a ns o f t w a t e r
W h e r ep o s s i b l e u
2 . W h e r e f r o s t p r o t e c t i o ni s n o t n e c e s s a r y i,t i s s t i l l a n
a d v a n t a g et o u s e a n a p p r o v e d a n t i f r e e z em i x t u r e
( s e e 3 b e l o w ) a s t h i s g i v e s a p r o t e c t i o na g a i n s t
c o r r o s i o na n d a l s o r a i s e s t h e b o i l i n g p o i n t o f t h e
c o o l a n t A m i n i m u mc o n c e n t r a t i o on t 2 5 % b y v o l u m e
of antifreeze is necessary, but it is our
r e c o m m e n d a t i o tnh a t 3 3 % c o n c e n t r a t i o n
bv volume
is used.
l f a n a n t i f r e e z ei s n o t u s e d , a d d a c o r r e c tc o r r o s i o n
inhibitor mixture to the water. The mixture of
a d d i t i v e sg i v e n b e l o w h a s b e e n f o u n d t o g i v e g o o d
r e s ul t s .
S o d i u mB e n z o a t e
1 0 - 1 5g r a m m e / l i t r e
S o d i u mN i t r i t e
1 - 2g r a m m e / l l t r e
Benzotriazole
0 . 5g r a m m e / l i t r e
p H ( a c i d / a l k a l i n eC) o n t r o lA d d i t i v e
Change the water/corrosion
i n h i b i t o rm i x t u r ee v e r y
six months or check according to the inhibitor
m a n u f a c t u r e r 'rse c o m m e n d a t i o n s
N O T E : S o m e c o r r o s i o n i n h i b i t o rm i x t u r e s c o n t a i n
soluble oil which can have an adverse effect on
s o m e t y p e so f w a t e r h o s e .
3 . l f a n a n t i f r e e z em i x t u r e i s u s e d t o p r e v e n t f r o s t
d a m a g e ,i t m u s t h a v e a n e t h y l e n eg l y c o l( e t h a n e d i o l )
b a s e . A n a n t i f r e e z et h a t i S t o o n e o f t h e s t a n d a r d s
g i v e n b e l o w o r t o a n e q u a l s t a n d a r di s a c c e p t a b l ei f
t h e p H v a l u e i s k e p t w i t h i nt h e r a n g eo f 7 . 0 - 8 5 w h e n
diluted.
U . K . ,8 S 3 1 5 1 : 1 9 5 -9' E t h a n e d i o l A n t i f r e e zTe y p eB
w i t h S o d i u mB e n z o a t ea n d S o d i u mN i t r i t eI n h i b i t o r s '
U . S . A . , A S T M D 3 3 0 6 - 7 4- ' E t h y l e n e G t y c o t B a s e
E n g i n eC o o l a n t ' .
A u s t r a l i aA
, S 2 1 0 8 - 1 9 7 7- ' A n t i f r e e z e C o m o o u n d s
and Corrosion Inhibitors for Engine Cooling
Svstems'.
O P E R A T I N GA N D M A I N T E N A N C E C 5
W h e n P e r k i n sP O W E R P A R TA n t i f r e e z ei s u s e d ,t h e
correct mixturesof antifreezeand water are as given
b e l o w .P e r k i n sP O W E R P A R TA n t i f r e e z ef u l l yp a s s e s
the above standards.
MixtureRatio
by Volume
% V o l u m eo f
POWERPART
POWERPART Antifreeze:
Antifreeze
Water
25
1:3
33
1:2
-2s'c (- 13'F)
40
1:1.5
-37'C (-34"F)
50
1:1
-60'c (-76'F)
66
2:1
Lowest
temperature of
Protection
Needed
-12'C ( 10'F)
-18'C ( 0"F)
not fitted to the radiator, disconnect the bottom

radiatorhose.
lf an oil cooler is fitted, drain the coolantfrom it by
removingthe drainpluigfrom the end cap of the cooler
(SectionL).
6 . Wherenecessary,flushthe systemwith cleanwater.
7 . Fit the drain plugs and radiatorcap. Where necessary,
closethe radiatortap or connectthe radiatorhose.
lf the engineis to be left drainedduringfreezingconditions,removeone of the coolanthoseconnections
at the
cooler and insert 0.5 U.K. pints (250m1)of undiluted
antifreezeinto the cooler.
T h e q u a l i t y o f t h e a n t i fr e e z e c o o l a n t m u s t o e
checked at least once a year, for example, at the
s t a r to f t h e c o l d p e r i o d .
lf the correct procedures are not used, Perkrns
E n g i n e sL t d . c a n n o tb e h e l d r e s p o n s i b l e
for anyfrost
o r c o r r o s i o nd a m a g e .
To Drainthe CoolingSystem
c.2
1. Ensure that the vehicle or machine is on level

ground.
2.
3.
R e m o v et h e r a d i a t o rf i l l e rc a o .
R e m o v et h e d r a i n p l u g f r o m t h e s i d e o f t h e c y l i n d e r
b l o c k t o d r a i n t h e e n g i n e .E n s u r et h a t t h e d r a i n h o l e
does not have any restriction.
4 . O p e n t h e t a p o r r e m o v et h e d r a i n p l u g a t t h e b o t t o m
o f t h e r a d i a t o rt o d r a i nt h e r a d i a t o r .l f a t a p o r p l u g i s
NOTE:
When drainingor fillingthe coolingsystemof a T6 3544CC
engine(integralinductionmanifoldand air chargecooler)the
vent plug on the outletconnectionof the coolershouldbe
removed (see Fig. C.2) and the plug replacedwhen the
systemhas beenfilled.
SECTIOND
FaultFinding
F A U L TF I N D I N G
D2
Fault Finding Chart

FAULT
POSSIBLECAUSE
Low cranking speed
1 ,2 , 3 , 4 .
Will not start
5 , 6 , 7 , 8 , 9 , 1 0 ,1 2 ,1 3 ,1 4 ,1 5 ,1 6 ,1 7 ,1 8 , 1 9 , 2 0 , 2 2 , 3 1 , 3 2 , 3 3
D i f f i c u l ts t a r t i n g
5 , 7 , B , 9 , 1 0 ,1 1 ,1 2 ,1 3 , 1 4 ,1 5 ,1 6 ,1 8 , 1 9 ,2 0 , 2 1 ,2 2 , 2 4 ,2 9 ,3 1 , 3 2 , 3 3
Lack of power
8 , 9 , 1 0 ,1 1 ,1 2 ,1 3 ,1 4 ,18 , 19 , 2 0 ,2 1 ,2 2 ,2 3 ,2 4 ,2 5 ,2 6 ,2 7 ,3 1 ,3 2 ,3 3 ,6 0 ,6 2 ,6 3 .
Misfiring
8, 9, 10, 12, 13, 14, 16, 18, 19, 20, 25, 26, 28, 29, 30, 32.
Excessivefuel consumption
1 1 , 1 3 , 1 4 , 1 6 , 1 8 , 1 9 , 2 0 , 2 2 , 2 3 ,2 4 , 2 5 ,2 7 , 2 8 , 2 9 , 3 1 , 3 2 ,3 3 , 6 3
B l a c ke x h a u s t
1 1 ,1 3 , ' 1 41, 6 ,1 8 ,1 9 ,2 0 , 2 2 , 2 4 , 2 5 , 2 7 , 2 8 , 2 9 , 3 1 , 3 2 ,6303 ,
Blue/whiteexhaust
4 , 16 , 1B , 1 9 , 2 0 , 2 5 , 2 7 , 3 1 , 3 3 , 3 4 ,3 5 , 4 5 , 5 6 , 6 1 .
Low oil pressure
4, 36, 37, 38, 39, 40, 42, 43, 44, 58.
Knocking
9 , 1 4 , 1 6 , 1 8 , 1 9 ,2 2 , 2 6 , 2 8 , 2 9 , 3 1 ,3 3 , 3 5 , 3 6 , 4 5 , 4 6 , 5 9 .
E r r a t i cr u n n i n g
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.
Highoil pressure
4 , 3 8 ,4 1
Overheating
11, 13, 14, 16, 18, 19, 24, 25, 45,47, 50, 51, 52, 53, 54,s7.
Excessivecrankcaseoressure
25, 31, 33, 34, 45, 55, 64
Poor compression
Startsand stops
1 0 ,1 1 ,1 2 .
Key to Fault Finding Chart

1.
2.
3
4.
5.
6
7
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27
28
29
30.
31.
32
Batterycapacity low.
Bad electricalconnections
Faultystarter motor.
Incorrecg
t r a d eo f l u b r i c a t i n go i l .
Low cranking speed
F u e lt a n k e m p t y .
Faultystop control operation
Blocked fuel feed pipe.
F a u l t yf u e l l i f t p u m p
C h o k e df u e l f i l t e r .
R e s t r i c t i o ni n i n d u c t i o ns v s t e m .
Air in fuel system.
F a u l t yf u e l i n j e c t i o np u m p .
Faulty atomisersor incorrecttype.
I n c o r r e c tu s e o f c o l d s t a r te q u i p m e n t .
F a u l t yc o l d s t a r t i n ge q u i p m e n t .
B r o k e nf u e l i n j e c t i o np u m p d r i v e .
I n c o r r e c ft u e l p u m p t i m i n g .
I n c o r r e c vt a l v et i m i n g
Poor compression.
Blockedfuel tank vent.
Incorrecttype or grade of fuel
Sticking throttle or restrictedmovement.
Exhaustpipe restriction.
C y l i n d e rh e a dg a s k e tl e a k i n g
Overheating.
Coldrunning.
Incorrecttappet adjustment.
Sticking valves.
Incorrecthigh pressurepipes.
W o r n c y l i n d e rb o r e s .
Pittedvalvesand seats.
6 3544SeriesWorkshopManual,Aprit83
33.
34.
35.
36
37
38.
39.
40
41.
42.
43
44.
45.
46
47.
48.
49.
50
51
52
53
54.
| 55.
|
56.
57.
58.
59.
60.
61.
62.
63.
| 64.
B r o k e n ,w o r n o r s t i c k i n gp i s t o nr i n g ( s ) .
Worn valve stems and guides.
Overfullair cleaneror use of incorrectgrade of oil
Worn or damaged bearings.
I n s u f f i c i e not i l i n s u m o .
Inaccurategauge.
Oil pumpworn
Pressurerelielfvalve sticking open.
Pressurerelief valve sticking closed.
Broken reliefvalve spring.
Faulty suction pipe.
Choked oil filter.
Piston seizure/pickup.
Incorrectpiston height.
Damagedfan.
F a u l t ye n g i n em o u n t i n g( h o u s i n g ) .
Incorrectlyaligned flywheel housing or flywheel.
Faultythermostat
Restrictionin water jacket.
Loose water pump drive belts.
Choked radiator
Faultywaterpump.
Chokedbreatherpipe/Defective
breathervent varve
(wherefitted).
Damagedvalve stem oil deflectors(if fitted).
Coolantleveltoo low.
Blockedsump strainer.
Brokenvalvespring.
Damagedor dirtyturbochargerimpeller.
Leakingturbochargeroil seals.
Leakingboostcontrolpipe.
Leakinginductionsystem.
Faultin exhauster.
SECTIONE
GylinderHead
@e
E2
To Removethe Cylinder Head

The T6 3544,63544or 6.3724cylinder head is not interc h a n g e a b l ew i t h a n y o t h e r 6 3 5 4 o r T 6 . 3 5 4e n g i n et y p e
c y l i n d e rh e a d s
D r a i nt h e c o o l i n gs y s t e m .
D i s c o n n e c bt a t t e r yt e r m i n a l s .
R e m o v ea i r c l e a n e ra n d t r u n k i n g
Remove exhaust pipe from exhaust manifold (6 3544
e n g i n e so n l y )
D i s c o n n e c ta n d r e m o v e a l l c o n n e c t i o n st o t h e t u r b o c h a r g e r a n d r e m o v e t h e t u r b o c h a r g e r ,s e e F i g E 1 .
( T O3 5 4 4e n g i n e so n l y )
Remove electrical connections to the cylinder
h e a da n d i n d u c t i o nm a n i f o l d R
. e m o v ef u e l p i p et o t h e r m o s t a r ti n t h e m a n i f o l d
R e m o v et h e w a t e ro u t l e tc o n n e c t i o n .
R e m o v et h e i n d u c t i o na n d e x h a u s tm a n i f o l d s
The fuel pipe from lift pump to fuel filtersshould be
r e m o v e d r, e l e a s i n gt h e c l i p f r o m t h e b a c k o f t h e c y l i n d e r
h e a d .T h e f u e l f i l t e r sm a y a l s o b e r e m o v e d
A l l h i g h p r e s s u r ep i p e sb e t w e e nf u e l i n j e c t i o np u m p a n d
t h e a t o m i s e r ss h o u l d b e r e m o v e d t o g e t h e r w i t h t h e
atomisersleak-off pipe assembly.
R e m o v ea t o m i s e r ss, e e F i g E 2
Disconnect the breather pipe from the rocker cover
a n d c y l i n d e rb l o c k R e m o v et h e b r e a t h e rp i p e
.9A
Oa
OA
OA
a)a
0a
OB
OB
OB
OB
OB
OB
Release rocker assembly bracket securing setscrews

and lift off rocker assembly.Removethe push rods
Remove cylinder head nuts and setscrews in reverse
o r d e r o f t i g h t e n i n gs e q u e n c es, e e F i g . E . 4 .
N o t ep o s i t i o no f d i f f e r e nlte n g t hs e t s c r e w ss,e eF i g .E 3 .
R e m o v ec v l i n d e rh e a d
oc oc oc oc oc oc oc oc oc oc
oc oc
Removerocker cover and gasket
n
n
l l l l n l n
l ] u u r J l J
E.3
O1o
O2o
O3o
O31 O32 O21 O22 Ofl
E.4
To Fit the CylinderHead
E n s u r et h e h e a df a c e ,c y l i n d e rb l o c k t o p f a c e a n d b o r e s
a r e c l e a na n d t h a t t h e r o c k e ra s s e m b l yo i l f e e d p a s s a g e
i n t h e c y l i n d e rh e a di s c l e a n
Any cylinderhead studs removedfrom the cylinder
b l o c k s h o u l db e r e fi t t e dw i t h " L o c t i t e "
The cylinderhead gasketfitted to the T6 3544and 6 3544
e ith other 6.354series
e n g i n e i s n o t i n t e r c h a n g e a b lw
e n g i n e s l t i s m a r k e d" T O P F R O N T "
A d i f f e r e n tc y l i n d e r h e a d g a s k e t i s u s e d o n 6 3 7 2 4
e n g i n e sd u e t o t h e l a r g e rb o r e s i z e
T h e c y l i n d e rh e a dg a s k e tm u s tb e f i t t e dd r y F i t t h e g a s k e t
e n s u r i n gi t i s c o r r e c t l yl o c a t e do v e r t h e t w o d o w e l s
L o w e rt h e c y l i n d e rh e a di n p o s i t i o nw i t h o u td i s t u r b i n gt h e
gasket
L i g h t l y o i l t h r e a d so f c y l i n d e rh e a d s e c u r i n gs t u d s a n d
E.1
SEISCTEWS
See Fig E 3 for correct location of long and short
setscrews
P r o g r e s s i v e l yt i g h t e n t h e c y l i n d e r h e a d s e c u r i n g n u t s
a n d s e t s c r e w s n, u m b e r s1 t o 3 2 o n l y i n t h e o r d e r s h o w n
i n F i g . E . 4 t o 1 1 5 l b ff t ( 1 5 , 9k g f m ) 15 6 N m w h e n c o t d
where the washerface is formedwith the head of the
s e t s c r e wo r n u t o r t o 9 5 l b ff t ( 1 3 , 1k g f m ) i 3 0 N m w h e r e
s e p a r a t ew a s h e r sa r e f i t t e d .T h e n p r o g r e s s i v e l tyi g h t e n
t h e s m a l l s e t s c r e w sn u m b e r e d3 3 t o 3 8 i n t h e s e q u e n c e
s h o w ni n F i g , E . 4 t o 2 8 l b ff t ( 3 , 9k g f m ) 3 8 N m .
R e p l a c ep u s h r o d s .
R e n e w t h e r o c k e r a s s e m b l yf e e d p i p e o i l s e a l , l i g h t l y
o i l i n gi t s i n n e ra n d o u t e rs u r f a c e s a
, n d p l a c i n gi t i n t h e o i l
f e e dd r i l l i n g .
E x a m i n ea n d r e p l a c et h e r o c k e ra s s e m b l y e
, n s u r i n gt h a t
t h e o i l f e e d p i p e , w h i c h h a s a l e a d i n , l o c a t e sc o r r e c t l y
i n t o t h e d r i l l i n g ,w h e n t h e s e a l w i l l b u t t a g a i n s t t h e
c o n v o l u t i o ns, e e F i g . E , 5 .
The rocker assemblysecuringsetscrews,studs and nuts
should be tighteneddown progressivelyfrom the centre
outwardsto a torque of 55 lbfft (7,60kgfm) or 75Nm. Set
v a l v ec l e a r a n c e tso 0 . 0 0 8 i n( 0 , 2 0 m m )f o r i n l e tv a l v e sa n d
0 . 0 1 8 i n( 0 , 4 5 m m f)o r e x h a u svt a l v e s e
, n g i n eh o to r c o l d ,a s
detailedon Page E.4.
Refitatomiserswithnewcoppersealingwashers.Ensurethat
a serviceabledust seal is fitted to the atomiser.Earlierdust
seals consisted of a single piece rubber seal, later
arrangements
use a two piecedust seal whichconsistsof a
plasticor aluminiumspacerand a rubberseal. The spacer
must be fitteddirectlyunderthe atomiserflangewiththe soft
rubberseal up againstthe spacerat the noizle end of the
atomiser.Now tighten nuts/setscrewsevenly to a torque of
l 2 l b f t ( 1, 7k g fm ) o r 16 N m .
Note: Differentatomiserseatingwashersare usedon naturally aspirated and turbochargedengines. The seating
washers for naturally aspirated engines are 0.0g0in
(2,03mm) thick and for turbochargedengines, O.02Bin
(0,71mm) thick. lt is importantthat the correct atomiser
seatingwashersarefitted.
For the T6.3544NorthAmericavehicleenginesthe atomrser
seatingwasheris 0.0B0in(2,03mm)thick
Top entryatomiserswhichare used on some 6.3544serres
enginescan be fittedincorrectly
withthe atomiserturned180"
out of positionIn this position,the nozzleholeswill not spray
into the combustionchambercorrectlyand this will causea
powerlossand an increasein smokeemission
These atomisersmust be fittedwith the leak off connection
towardthefuelinjectionpumpside
Refitall high pressurefuel pipes,leak-offpipesand the fuel
filters
T i g h t e n h i g h p r e s s u r ep i p e n u t s t o a t o r q u e o f 1 5 l b ff t
( 2 , 1k g fm ) o r 2 0 N m
ally aspiratedengines can have a set of steel asbesrosor

corrugatedstainlesssteel joints fitted. Steel asbestosjoints
shouldbe fittedwith jointingcompound,but the corrugated
joints shouldbe fitteddry and so positionedthat the corrugationsshouldfacethe manifold.
A one pieceexhaust/induction
manifoldjointwith an integral
heat shield is fitted to some engineswhich have the top
exhaustmanifoldoutlet An improvedrockerassemblycover
gasketis alsof ittedto theseengines.
Whenthe gasketsneedto be renewedthe sametype gasket
mustbe used,
Refit the water outlet connection.
Connect the electrical lead, fuel feed and return pipes
t o t h e t h e r m o s t a rut n i t a n d c o n t a i n e r .
Connect any other electricallead (i.e water temperarure
gauge).
R e f i t t h e t u r b o c h a r g e r( T 6 . 3 5 4 4e n g i n e s o n l y ) a n d a l l
connectionsto it.
R e f i tt r u n k i n ga n d a i r c l e a n e r
R e f i te x h a u s tp i p e t o e x h a u s tm a n i f o l d( 6 3 5 4 4o r 6 3 7 2 4
engrneo
snly)
Reconnectthe battery.
R e f i l lt h e c o o l i n gs y s t e m .
B l e e dt h e f u e l s y s t e mo f a i r a s d e t a i l e do n p a g e N . 7 a n d
s t a r tt h e e n g i n e
C h e c kt h e o i l f l o w t o t h e r o c k e rs h a f ta s s e m b l va n d a l l o w
t h e e n g i n et o w a r m u p
S h u t t h e e n g i n e d o w n , a n d r e t i g h t e nt h e c y l i n d e r h e a d
securing nuts and setscrewsto the correct torques as
d e t a i l e dp r e v i o u s l y .
F o r n u t s a n d s e t s c r e w s ,n u m b e r s 1 t o 3 2 w h e r e t h e
w a s h e rf a c e i s f o r m e dw i t h t h e h e a d o f t h e s e t s c r e w t, h e
c o r r e c t t o r q u e w h e n h o t i s 1 0 5l b f f t ( 1 4 , 5 k g f m )1 4 2N m .
W h e n r e t i g h t e n i n gc y l i n d e r h e a d n u t s / s e t s c r e w st,h e
R e f i t f u epl i p ef r o m l i f t p u m pt o f i l t e r st,h i s p i p ei s c l i p p e d
o n t o b a c k o f c y l i n d e rh e a d
R e f i ti n d u c t i o na n d e x h a u s tm a n i f o l d s .
I n l e t m a n i f o l d sh a v e c o r r u g a t e dj o i n t s w h i c h a r e c o a t e d
w i t h l a c q u e ra n d s h o u l da l w a y sb e f i t t e d c l r y T h e j o i n t s
a r e n o t s y m m e t r i c aal n d c a n b e f i t t e d i n c o r r e c i l y W
. ith
t h e e a r l i e rj o i n t s , t h e l a r g e r j o i n t s h o u l d b e f i t t e d w i t h
p a r a l l e le d g e u p p e r m o s ta n d t h e s m a l l e rj o i n t w i t h t h e
w i d e r s p a c e dh o l e a n d t h e w o r d " C O R R O J O I N Tt"o t h e
bottom
Laterjointshavea 1Aain (1,63mm) radiusin the top edgeand
must alwaysbe fittedwith this radrusuppermost.The manifold securingsetscrewsshouldbe tightenedto a torqueof
24lbfft (3,3kgfm) or 32Nm. After at leastten minutesafter
fitting,retorquethe setscrewsto the originalfigure THIS lS
IMPORTANT With exhaust manifoldjoints, turbocharged
engineshavecorrugated
stainless
steeljoints,whereasnatur-
E3
E.5
0 0 0 8i n ( 0 , 2 0m m ) i n l e t
0 . 0 1 8i n ( 0 , 4 5m m ) exhaust
E.6
E4
e n g i n e c o o l a n t t e m p e r a t u r es h o u l d n o t b e l e s s t h a n
170"F (77"C\.
lf the nut/setscrew moves when retightening, then
t i g h t e nu p t o t h e t o r q u eq u o t e do n P a g e 8 . 1 .
lf the nut/setscrew does not move before the correct
t o r q u e i s a c h i e v e dt,h e n s l a c k e no f t 1 / 1 2 t o 1 / 6 ( 3 0 ' t o
6 0 " ) o f a t u r n a n d r e t i g h t e nt o t h e c o r r e c t f i g u r e .A f t e r
r e t i g h t e n i n ga l l t h e n u t s / s e t s c r e w s t, h e f i r s t 1 0 p o s i t i o n s s h o u l d b e r e c h e c k e d ' w i t h o u ft u r t h e r s l a c k e n i n g
off, to ascertain they are still tightened to the correct
torque.
R e s e t t h e v a l v e c l e a r a n c e st o 0 . 0 0 8 i n ( 0 , 2 0 m m ) f o r
i n l e t v a l v e sa n d 0 . 0 1 8 i n ( 0 , 4 5 m m ) f o r e x h a u s tv a l v e s
hot or cold
W i t h t h e v a l v e sr o c k i l n go n N o . 6 c y l i n d e r( i . e .t h e p e r i o d
b e t w e e no p e n i n g o f i n l e t v a l v e a n d c l o s i n g o f e x h a u s t
v a l v e )s e t t h e c l e a r a n c e so n N o . 1 c y l i n d e r
W i t h v a l v e sr o c k i n gN o 2 - s e t
W i t h v a l v e sr o c k i n gN o . 4 - s e t
c l e a r a n c e sN o 5
c l e a r a n c e sN o 3 .
c l e a r a n c e sN o . 6 .
c l e a r a n c e sN o 2 .
c l e a r a n c e sN o . 4 .
To Remove Valves
Fit a suitable stud in one of the rocker assemblysecuring setscrew holes and using Tool No. 61188 and
a d a p t o r P D . 6 1 1 8 - 4s,e e F l g . E . 7 , d e p r e s sv a l v e s p r i n g s
and remove split collets.
Refitthe rockercoverjoint, rockercoverand breatherpipe.

To put a rockercoverjoint on correctlyit mustfirst be fittedto
the rocker cover by use of a suitable Bostic type contact
adhesive.The adhesivemust be appliedaccordingto the
instructions.
manufacturer's
This procedurewill ensurethat
there is a goodseal all roundthe cover.
W h e n r e p l a c i n gt h e c y l i n d e rh e a d c o v e r ,e n s u r et h a t t h e
c o v e r r e t a i n i n gn u t s a r e s c r e w e df u l l y h o m e a g a i n s tt h e
rocker shaft bracketretainingnuts.
Where a washer is fitted under the head of each of the
rocker cover nuts, a washer is also fitted between the
r o c k e r b r a c k e ts e c u r i n gn u t a n d t h e c o v e r n u t . W h e r e a
washer face is formed integral with the cover nut, a
separatewasher must not be fitted under the cover nut
o r b e t w e e nt h e c o v e r n u t a n d t h e r o c k e r b r a c k e tn u t
To Check or Adjust Valve Tip Clearances

T h e v a l v e t i p c l e a r a n c e ss h o u l d b e s e t t o 0 . 0 0 8 i n
( 0 , 2 0 m m ) f o r i n l e t a n d 0 . 0 1 8i n ( 0 , 4 5 m m ) f o r e x h a u s t
by using a feeler gauge between top of valve stem and
r o c k e r l e v e r ,w i t h t h e e n g i n e h o t o r c o l d , s e e F i g . E . 6 .
W h e n s e t t i n gv a l v ec l e a r a n c e st,h e f o l l o w i n g p r o c e d u r e
s h o u l db e a d o o t e d .
E.8
R e m o v e s p r i n g r e t a i n i n gc a p s , s p r i n g s , o i l s e a l s a n d
s p r i n gs e a t i n gw a s h e r s R e m o v ev a l v e s .
l f t h e v a l v e sa r e t o b e u s e da g a i n ,t h e y s h o u l db e s u i t a b l y
marked to ensure they are replacedin their original
positions.
ValveAssembly
T w o s p r i n g sa r e f i t t e dt o e a c hv a l v e ,t h e o u t e rs p r i n g sa r e
l e f th a n dc o i l e da n d t h e i n n e rs p r i n g sr i g h th a n dc o i l e d
A s e c t i o n a vl r e w o f a f i t t e d v a l v e a s s e m b l yi s s h o w n i n
Fig EB
To Fit Valves
L i g h t l y o i l v a l v es t e m s ,a n d p o s i t i o n t h e v a l v e si n t h e r r
rocnontirro
nrrirleq
P o s i t i o ns p r i n g s e a t i n g w a s h e r sa n d f i t o i l s e a l s o n t o
v a l v eg u i d e s .
Note: Enginesrated at 149kW (200bhp)or above must be
fitted with exhaust valves which have "Nimonic" heads.
Standardvalvesmustnot be used.
P l a c e i n n e r a n d o u t e r s p r i n g s o n s e a t i n gw a s h e r sw i t h
t h e d a m p e rc o i l s t o w a r d st h e c y l i n d e rh e a d ,s e e F i g E . 8
P o s i t i o nt h e v a l v e s p r i n g r e t a i n i n g c a p s a n d w i t h a
s u i t a b l e c o m p r e s s o r ,d e p r e s s t h e s p r i n g s a n d f i t t h e
s o l i tc o l l e t s
ValveGuides
E.7
January1986
Examinevalve guides for wear The maximum per-
E5
T h e c y l i n d e rh e a d c a n b e s k i m m e d b y a m a x i m u m o f
0 . 0 1 2 i n( 0 , 3 m m )p r o v i d e dt h a t n o z z l ep r o t r u s i o nd o e sn o t
. 1 8 4 i n( 4 , 6 7 m m )
t o r f 6 3 5 4 4e n g i n e so r 0 1 3 6 i n
e x c e e d0
( 3 , 4 5 m m t)o ( 6 . 3 5 4 4 a n d 6 . 3 7 2e4n g i n e sw i t h t h e a t o m i s e r
s e a t i n gw a s h e r si n p o s i t i o n ,s e e F i g E . 1 1 .T h i s f i g u r e
must not be obtained by the use of additional atomiser
seatingwashers.
W h e n g r i n d i n g i n v a l v e s ,i t i s e s s e n t i a tl h a t n o s i g n s o f
p i t t i n ga r e l e f t o n t h e s e a t i n g s
C a r es h o u l db et a k e nt o a v o i du n n e c e s s a r yg r i n d i n g a w a y
of the seat.
After grinding, check the valve head depths relative to
t h e c y l i n d e rh e a d f a c e , u s i n gt o o l P D 4 1 B .T h e m a x i m u m
permissibledepth for both inlet and exhaustvalves after
s e r v i c i n gi s 0 . 0 6 0i n ( 1 , 5 2m m ) .
After any grinding or machiningoperationhas been
c a r r i e do u t , a l l p a r t ss h o u l db e w a s h e di n c l e a n i n gf l u i d .
Valvesand Valve Seats

Examine valves for cracks. Check wear of valve stems
a n d t h e i r f i ti n t h e v a l v eg u i d e s
When fitting new valves, valve depths relative to the
c y l i n d e rh e a df a c e i s n o t l e s st h a n 0 . 0 4 0 i n( 1 0 2 m m ) .
The valveseats in the cylinderhead should be reconditioned by means of valve seat cutters as listed in
a p p r o v e dt o o l s a t t h e e n d o f t h i s s e c t i o n ,o r s p e c i a l i s e d
g r i n d i n ge q u i p m e n ia t a n a n g l eo f 4 5 o
E.9
m i s s i b l ew o r n c l e a r a n c eo f i n l e t v a l v e s t e m i n g u i d e i s
0 0 0 5 i n ( 0 , 1 3 m m )a, n d e x h a u s tv a l v e s t e m i n g u i d e i s
0 0 0 6 i n ( 0 , 1 5 m m )a n d i f t h e c l e a r a n c ew i t h n e w v a l v e
f i t t e d e x c e e d st h i s f i g u r e t h e g u i d e s h o u l d b e r e p l a c e d .
T h e e x h a u s tv a l v e g u i d e s a r e s l i g h t l y l o n g e r t h a n t h e
inlet guides and the exhaust valve guides used on
c u r r e n t 6 . 3 5 4 4a n d .6 . 3 7 2 4e n g i n e sh a v e a c o u n t e r b o r e
at the bottom of the valve bore.
T o f i t n e w g u i d e s ,p r e s so r d r i v eo u t t h e w o r n g u i d e s ,s e e
Fig E.9
S m e a r t h e o u t e r s u r f a c eo f t h e n e w g u i d e s w i t h c l e a n
o i l a n d u s i n gt o o l N o P D 1 C ,s e eF i g .E 1 0 ,p u l l g u i d ei n t o
t h e c y l i n d e rh e a d u s i n g s t o p N o . P D l C - 6 u n t i l
) f t h e g u i d e i s p r o t r u d i n ga b o v e t h e
0 594in (15,08mmo
v a l v es p r i n g r e c e s s .
CylinderHead Overhaul
l f w a t e r j a c k e t o f c y l i n d e rh e a d s h o w s s i g n o f s c a l e ,a
p r o p r i e t a r yd e s c a l i n gs o l u t i o ns h o u l db e u s e d i n a c c o r d a n c e w i t h t h e m a n u f a c t u r e r 'isn s t r u c t i o n s .
A f t e r c l e a n i n gh e a d ,c h e c k f o r c r a c k s o r o t h e r d a m a g e .
M a x i m u mp e r m i s s i b l el o n g i t u d r n abl o w o f c y l i n d e rh e a d
i s 0 . 0 1 0 i n ( 0 , 2 5 m m ) a n d l : r a n s v e r s eb o w i s 0 . 0 0 5 i n
( 0 , 1 3m m ) .
E.10
E6
U s i n gt h e v a l v eg u i d e b o r e a s a p i l o t ,m a c h i n et h e " f t a r e "
o n i n l e t v a l v e s e a t i n s e r t st o t h e d i m e n s i o n ss h o w n r n
F i g .E . 1 4 D
. i m e n s i o nA i s0 . 1 0 6 / 0 . 1 1i n
0(2,69/2,79mm).
Cut the valveseat at an included angle of 90o so that the
v a l v eh e a d d e p t h b e l o w t h e c y l i n d e rh e a d f a c e i s w i t h i n
the production Ii mitsof 0.040/0.050
i n (1,02/1,27mm).
3 . 7 3 5i n
( 9 4 , 8 7m m )
MIN.
W o r k a s c l o s e l y a s p o s s i b l et o t h e m j n i m u m f i g u r e t o
allow for re*seatingat a later date.When refacinga valve
t h e i n c l u d e da n g l eo f t h e c o n t a c tf a c e i s g 0 o .
L i g h t l yg r i n d i n v a l v ea n d v a l v es e a t ,k e e p i n ga s n a r r o wa
seat as possible.
T 6 . 3 5 4 4 - 0 . 1 8 4i n ( 4 , 6 7m m )
6 . 3 5 4 4 - 0 . 1 3 6i n ( 3 , 4 5m m )
6 . 3 7 2 4 - 0 . 1 3 6i n ( 3 , 4 5m m )
MAX
0.012in MAX.
(0,30mm)
E.11
l f t h e c y l i n d e rh e a dh a s b e e ns k i m m e d t, h e i n s e r tw i l l h a v e
to be surfaceground on its back face so that, with insert
fitted, faces of insert and cylinder head are level
lnlet
A-o.283 I0.288in (7,19/7,32mm)
g-2.0 16512.0175in (51,22t51,24mm)
) ax.
C - R a d i u s 0 . 0 1 5 i n( 0 , 3 8 m mM
Exhaust
A-0.375/0.380in (9,53/9,65
mm)
B-1 .67811
.679in(42,62142,65mm)
C-Radius 0.015 in (0,38mm) Max.
Afterreconditioning,
valvesand seatsshouldbe lightlyground
in, keepingas narrowa seat as possible,and aftergrinding,
the valveheaddepthshouldbe checked.
lnlet
P r e s so u t t h e e x i s t i n gv a l v eg u i d e a n d c l e a n t h e g u i d e
bore
A-Xain (1,59mm)at 45'

B-3/cin (19,05mm)
C-0.250 in (6,35mm)
D - 3 . 0 i n ( 7 6 , 2 0m m )
E - 1 . 5 8 2 / 1. 5 8 3i n ( 4 0 , 1 8 / 4 0 , 2m1m )
F -2.009/2.019in (51,03/51,28mm)
G-%zin (0,79mm)radius
H - h a i n ( 1 , 5 9 m m )r a d i u s
J - X e i n ( 1 , 5 9m m ) a t 4 5 '
K-0.372/0.373in (9,4519,47
mm)
P r e s si n n e w g u i d e sa s d e t a i l e do n P a g eE 4
Exhaust
U s i n gt h e v a l v eg u i d ea s a p i l o t ,m a c h i n et h e r e c e s si n t h e
c y l i n d e rh e a d t o t h e d i m e n s i o n sg i v e n i n F i g E 1 2 f o r
6 3 5 4 4 o r 6 3 7 2 4e n g i n e s ;o r m a c h i n eo u t t h e o l d i n s e r t
f o r T 6 3 5 4 4e n g i n e s .
4 - l a i n ( 1 , 5 9 m ma) t 4 5 '
B-3/qin (19,05mm)
C - 0 . 3 1 2 i n ( 7 , 9 2m m ) .
D-3.0 in (76,20mm)
E-1 .248/1.249in(31,70131
,72mm)
F-1 .670/1.680in(42,42142,67mm)
G*%zin (0,79mm)radius
H - / * i n ( 1 , 5 9m m ) r a d i u s
J -%ain (1,59mm) at 45'
K-0.372/0.373 in (9,4519,47
mm)
Valve Seat Inserts

Valve seat inserts are fitted as standard on T63544
e n g i n e s b, u t a r e n o t f i t t e do n 6 3 5 4 4o r 6 3 7 2 4p r o d u c t i o n
e n gIn e s
l f v a l v es e a t sb e c o m ed a m a g e do r u n s e r v i c e a b lteh r o u g h
wear, insertscan be fitted to 6 3544 and 63724 enqines
o r t h e i n s e r t sr e p l a c e do n T 6 3 5 4 4e n g i n e s
R e m o v ea l l m a c h i n i n gs w a r fa n d c l e a nt h e i n s e r tr e c e s s
U s i n g t h e v a l v e g u i d e b o r e a s a p i l o t , p r e s st h e i n s e r t
h o m e w i t h t h e i n s e r t i n gt o o l , F i g E . 1 3 .D o n o t h a m m e r
t h e i n s e r th o m e o r u s e l u b r i c a t i o nE n s u r et h a t t h e i n s e r t
i s f u l l y h o m e a n d f l u s h w i t h t h e b o t t o mo f r e c e s s
6 3544SenesWorkshopN.4anual,
January1986
E7
Rocker Shaft Assembly

To dismantle
Removecirclips and washersfrom each end of shaft.
Withdrawrockerlevers,springsand supportbrackets
Remove the locating screw from the rocker oil feed
c o n n e c t i o na n d w i t h d r a wt h e c o n n e c t i o n .
E.14
ValveSprings
A new set of springs should be fitted at every major
overhaul.
I Examinethe springswith regardto squarenessof ends and
I pressuresdevelopedat fittedlengths.
T w o t y p e s o f v a l v e s p r i n g s c a n b e f o u n d a c c o r d i n gt o
the camshaft fitted. They are of different lengths the
l o n g e r v a l v es p r i n g sh a v i n ga f l a t v a l v e s p r i n g c a p .
The shorter inner valve springs require a load of 20.1/
2 3 3 l b f ( 9 , 1 3 / 1 0 , 5 8k g f) t o c o m p r e s st h e m t o a f i t t d d
l e n g t h o i 1 3 4 0 i n ( 3 4 , 0 4m m ) .
T h e s h o r t e ro u t e r v a l v e s p r i n g s r e q u i r ea l o a d o f 3 9 . 5 /
4 3 7 l b f ( 1 7 , 9 3 / 1 9 , 8 4k g f) t o c o m p r e s st h e m t o a f i t t e d
l e n g t ho f 1 4 1 0 i n ( 3 5 , 8 1m m ) .
T h e l o n g e r i n n e r v a l v e s p r i n g s r e q u i r ea l o a d o f 1 4 6 3 /
1 6 6 7 l b f ( 6 , 6 4 / 7 , 5 7m m ) t o c o m p r e s st h e m t o a f i t t e d
l e n g t ho f 1 . 5 6 3i n ( 3 9 , 7 0m m ) .
T h e l o n g e r o u t e r v a l v e s p r i n g s r e q u i r ea l o a d o f 3 8 / 4 3
lbI (17,25/19,52 kgf) to compress them to a fitted
l e n g t ho f 1 . 7 8 0i n ( 4 5 , 2 0m m )
Examinerocker leverbores and shaft for wear.The levers

should be an easy fit on the shaft without excessiveside
p l a ya n d t h e r es h o u l db e n o i n d e n t a t i o n
w h e r et h e r o c k e r
taps the valvetip.
To renew the rocker lever bushes, press out the worn
b u s h e sa n d p r e s s i n t h e n e w b u s h e sm a k i n g s u r e t h a t
t h e o i l h o l e s a r e i n l i n e ,s e e F i g . E 1 5 .
Ream out to a diameter of 0 7505/O7520in (19.06/
.19.10
mm)
To assemble.
Fit oil feed connection to rocker shaft and secure with
l o c a t i n gs c r e w ,e n s u r i n gt h a t t h e s c r e we n t e r st h e l o c a t i n g
holein the shaft
F i t t h e s u p p o r t b r a c k e t s ,s p r i n g s a n d r o c k e r l e v e r s i n
t h e c o r r e c to r d e r ,s e e F i g E 1 6 .
F i t s e c u r i n gw a s h e ra n d c i r c l i pt o e a c h e n d o f t h e s h a f t .
Push Rods
Check push rods for straightness lf any are bent, fit
replacements.
BreatherVent Valve
On 6.3544engines,a vent valve is sometimesfittedbetween
the rocker cover and the inlet manifold.This unit can be
cleanedin petrol (gasoline)or paraffin(kerosene)notingthe
followingcriticalpoints:1 . B e f o r ec l e a n i n g ,i t i s e s s e n t i a tl o s e a l o f f t h e s m a l l
hole in the top coverof the unit.
E.15
2 . l I a n a i r l i n e i s u s e d t o d r y o u t t h e u n i t ,t h i s m u s t
b e a l o w p r e s s u r ea i r b l a s t o r i r r e p a r a b l ed a m a g e
will result.
tt*
E.16
SECTIONF
Pistonsand GonnectingRods
F2
The pistonsfittedto the T6.3544and 6.3544enginehave an

insertin the top ringgrooveand are not commonto the 6.354
engrnesenes.
Nor are T6.3544and 6.3544 pistonsinterchangeable
as the
pistonhas a largergudgeonpin.
turbocharged
I ForT6.3544NorthAmericavehicleenginespistonsand rings
I see pageF.6.
.rtt=-.4,-\\
i4'*
To remove Piston and Rod Assembly

S e eF i g .F . 1 .
..
ri
R e m o v ec y l i n d e rh e a d ,P a g e E 2 .
D r a i n l u b r i c a t i n go i l , r e m o v e s u m p a n d l u b r i c a t i n go i l
s u c t i o np i p e .P a g e L . 3 .
R e m o v ep i p e f r o m t h e r e d u c i n gv a l v e t o p i s t o n c o o l i n g
feed connection (T6.3544engines only)
W h e n p u s h i n gt h e p i s t o n a n d r o d a s s e m b l i e sf r o m o u t
of the top of the cylinders,care must be taken to avoid
damage to the piston cooling jets situated in the
c r a n k c a s e ,s e e F i g . F . 2 . ( T 6 3 5 4 4 e n g i n e s o n l y )
R e m o v et h e n u t s f r o m t h e b i g e n d b o l t s
R e m o v et h e b i g e n d c a p s ,b e a r i n gs h e l l sa n d b o l t s
F.2
T u r n c o n n e c t i n g r o d s i n a n a n t i - c l o c k w i s ed i r e c t i o n
a n d p r e s st h e p i s t o n a s s e m b l i e sf r o m o u t o f t h e t o p o f
t h e c y l i n d e rb o r e s ,s e e F i g F . 3
T h e p i s t o n s ,c o n n e c t i n gr o d s a n d c a p s a r e m a r k e dw i t h
t h e i r r e s p e c t i v ec y l i n d e r n u m b e r a n d s h o u l d b e k e p t
together as an assemblywith the relevantbig end
b e a rni o s .
To RemovePistonsand Rings from

ConnectingRods
An explodedvrew of a piston and connectingrod
a s s e m b l yi s s h o w n i n F i g F 1
N o t e : T h e n u m b e ro f p i s t o n r i n g s p e r p i s t o nc a n v a r y
a c c o r d i n gt o e n g i n et y p e a n d a p p l i c a t i o n( s e e P a g e F 4 ) .
U s i n g a r i n g s c r s s o rt o o J , r e m o v e t h e r i n g s f r o m t h e
pi s t o n s
e9
'82
6 3 5 4 4S e r i e sW o r k s h o pN / a n u a l ,s s u e2 , J u n e
F.3
PISTONSAND CONNECTING
RODS
F3
P r e s si n n e w b u s h e n s u r i n gt h a t o i l h o l e i n b u s h a l i g n s
w i t h d r i l l i n gi n r o d
H o n e o u t b u s h t o f i n i s h e dd i a m e t e ro f 1 5 0 0 7 5 / 15 0 1 5 i n
( 3 8 , 1 2 1 3 8 , 1 4 m mf o) ,r t u r b o c h a r g e de n g i n e s o r 1 . 3 7 5 8 /
'I
3765in (34,94/34,96
mm) for naturallyaspiratedengines
W i t h n a t u r a l l y a s p i r a t e de n g i n e s t h e c o n n e c t i n g r o d
s m a l le n d i s p a r a l l efla c e da n d t h e s m a l le n d b u s hr e q u i r e s
n o f u r t h e rm a c h i n i n g
W i t h t u r b o c h a r g e de n g i n e s , t h e s m a l l e n d o f t h e
c o n n e c t i n gr o d r s w e d g es h a p e da n d t h e s m a l le n d b u s h
s h o u l db e m a c h r n e tdo s u i tt h e c o n t o u r so f t h ew e d o e
R e m o v ea l l b u r r s
C h e c kf o r p a r a l l e l i s m
a n d t w i s tw i t h b i g e n d b o r e
To Check Piston Ring Gaps
I n a w o r n c y l i n d e r ,p i s t o n r i n g g a p s s h o u l d b e c h e c k e d
a t e x t r e m et o p o f c y l i n d e r a f t e r a n y c a r b o n h a s b e e n
r e m o v e ds, e e F i g F 6
F o r p i s t o nr i n g g a p s ,s e e P a g e8 4
F.4
l f t h e p i s t o n sa r e t o b e u s e d a g a i n ,n o t e t h e m a r k i n g so n
t h e p i s t o nc r o w n , s e e F i g F 4 , s o t h a t o n r e - a s s e m b l y ,
t h e y c a n b e f i t t e dt o t h e c o n n e c t i n gr o d s i n t h e i r o r i g i n a l
p o s i t i o n s ,i e t h r u s t s i d e o f p i s t o n t o t h r u s t s i d e o f t h e
engn
re
R e m o v et h e c i r c l i p sa n d w i t h d r a wt h e g u d g e o np i n . l f t h e
pin is tight in the piston bore, heat the piston in fluid
to a temperature of 100/120"F (40/50"C), then press
t h e g u d g e o np i n o u t .
To AssemblePistonsand Connecting
Rods
A s s e m b l et h e p i s t o n ,r o d a n d g u d g e o n p i n , a n d f i t n e w
c i r cl i p s
l f n e c e s s a r yw
, a r m t h e p i s t o n t o 1 O 0 / j 2 OF" ( 4 0 1 5 0 . C )
t o f i t t h e g u d g e o np i n
lf the old pistons are being used ensure they are
a s s e m b l e dt o t h e o r i g i n a l c o n n e c t i n gr o d s a n d i n t h e
s a m e p o s i t i o na s o r i g i n a l l ya s s e m b l e d .
T h e t o r o i d a lc a v i t y s h o u l d b e t o t h e s a m e s i d e a s t h e
m a r k i n g so n t h e c o n n e c t i n gr o d a n d c a p .
Inspection
C h e c k p i s t o n sf o r s c o r i n go r o t h e r d a m a g e
C h e c k p i s t o n r i n g g r o o v e s b y c h e c k i n g c l e a r a n c eo f
n e w r i n g s f i t t e d i n g r o o v e s .l f c l e a r a n c ei s f o u n d t o b e
e x c e s s i vn
e e wp i s t o n sm u s tb e f i t t e d .
E x a m i n eg u d g e o n p i n a n d p i s t o n b o r e s f o r w e a r a n d
c h e c k f i t o f p i n i n s m a l le n d b u s h
C h e c k c o n n e c t i n gr o d a l i g n m e n t T h e l a r g e a n d s m a l l
e n d b o r e s m u s t b e s q u a r e a n d p a r a l l e lt o e a c h o t h e r
w i t h i n t h e l i m i t s o f t 0 0 1 0 i n ( 0 , 2 5 m m ) m e a s u r e d5 i n
( 1 2 7 m m )e a c h s i d e o f a x i s o f r o d o n t e s t m a n d r e l a s
s h o w n i n F i g .F 5 .
lf new parts are being fitted, mark piston crown and

a d j a c e n tf a c e s o f r o d a n d c a p w i t h t h e i r c o r r e s p o n d i n g
c y l i n d e rn u m b e r
The big end bearingshelltabs are fittedon the oppositeside
cap numbers.
of the rodto the rod/bearing
cap numbermust be towardthe
On fitmentthe rod/bearing
fuelinjectionpumpsideof the engine.
With the small end bush fitted, the limit of t0.010in

( 0 , 2 5 m m )i s r e d u c e dt o t 0 0 0 2 5 i n ( 0 , 0 6 m m )
To Renew Small End Bush

U s i n gs u i t a b l ea d a p t o r ,p r e s so u t w o r n b u s h
R e m o v ea n y s h a r p e d g e sf r o m a r o u n d s m a l l e n d p a r e n t
bore
E
E
6 <r
rn
I c\l
o o
+l +l
5in
121mm
9+
5in
i
127mm "o .R
F.5
January1986
6 3544SeriesWorkshopN.4anual,
:!;i
F.6
T6.3544
F4
6.3544
F.7
To Fit PistonRings
P i s t o n r i n g l a y o u t sa r e a s f o l l o w s: -
T6.3s44(Fis. F.7)
No 1
C h r o m e B a r r e lF a c e d W e d g eC o m p r e s s i o n
No.2
TaoerFaced.
N o . 3 C h r o m eF a c e d ,S p r i n gL o a d e dC o n f o r m a b l O
e il
Control.
F i t r i n g s a s f o l l o w s: Fit spring of No 3 oil control ring in grooveensuring
that the latch pin enters both ends of the ring, see
F i g .F B
P o s i t i o no i l c o n t r o l r i n g o v e r s p r i n g w i t h s p r i n g c o r r e c t l y l o c a t e di n g r o o v e o f r i n g a n d r i n g g a p d i a m e t r i c a l l y
o p p o s i t et o l a t c h p i n
F i t t a p e r f a c e d N o . 2 c o m p r e s s i o nr i n g i n t h e s e c o n d
groove with the word "TOP" or the manufacturer's
m a r k t o w a r d st h e p i s t o n c r o w n
identification
F i t b a r r e l f a c e d N o . 1 c o m p r e s s i o nr i n g i n t o p g r o o v e
w i t h t h e w o r d " T O P " o r m a n u f a c t u r e r ' si d e n t i f i c a t i o n
towards Distoncrown.
E n s u r e t h a t t h e r i n g g a p s a r e e q u a l l ys p a c e d a r o u n d
t h e p i s t o na n d n o t i n l i n e .
6.3544StandardEngines
No 1
C h r o m e I n s e r tC o m p r e s s i o n
No 2
i n i e r n a i l yS t e p p e dC o m p r e s s i o n .
No 3
I n t e r n a l l yS t e p p e dC o m p r e s s i o n .
No 4
No 5
F i t r i n g s a s f o l l o w s: Fit No 5 ring in bottomring groove.

Fit No 4 ring in fourth ring groove.
Fit Nos 3 and 2 rings in the third and second ring
g r o o v e sw i t h t h e i n t e r n a ls t e p a n d t h e w o r d " T O P " o r
m a n u f a c t u r e r 'm
s a r k s t o w a r d st h e p i s t o nc r o w n .
Fit No 1 ring in top ring groove.
Ensurethat the piston ring gaps are equallyspaced
a r o u n dt h e p i s t o n a n d n o t i n l i n e
6.3544PremiumEngines(Fig. F.7)
No 1
C h r o m e B a r r e l F a c e d C o m p r e s s i o nI,n t e r n a l
C h a m ef r .
N o .2
C h r o m eT a p e r F a c e d C o m p r e s s i o nP, a r a l l e l .
No 3
C h r o m e F a c e d , S p r i n g L o a d e d C o n f o r m a b l eO i l
Control.
F i t r i n g s a s f o l l o w s: F i t N o . 3 a s d e t a i l e df o r T 6 . 3 5 4 4e n g i n e .
F i t t a p e r f a c e d N o . 2 c o m p r e s s i o ni n t h e s e c o n dg r o o v e
w i t h w o r d " T O P " o r m a n u f a c t u r e r ' isd e n t i f i c a t i o nm a r k
t o w a r d sp i s t o n c r o w n .
F i t N o . 1 c o m p r e s s i o nr i n g i n t h e t o p g r o o v e w i t h t h e
internalchamfer and the word "TOP" or the manufacturer's mark towards the piston crown
Ensure that the piston ring gaps are equallyspaced
a r o u n dt h e p i s t o na n d n o t i n l i n e .
F.9
F5
T. | |
e n s u r i n gl a t c h p i n e n t e r sb o t h e n d s o f r i n g , s e e F i g . F . B .
Position No. 3 oil control ring over spring correctly
located in groove of ring and ring gap diametrically
o p p o s i t et o l a t c h p i n .
F.10
6.3544Combine Engines
Fit No. 2 compressionring wi'th internalstep of chamfer

and word "TOP" or manufacturer's mark towards
crown of oiston.
F i t N o . 1 c o m p r e s s i o nr i n g i n t o p r i n g g r o o v e
N o .2
Ensure that the piston ring gaps are equally spaced

a r o u n dt h e p i s t o n a n d n o t i n l i n e .
N o .3
To Fit Pistonand ConnectingRod
No.4
C h r o m e F a c e d ,S p r i n g L o a d e d C o n f o r m a b l eO i l
Control
N o .5
No ring fitted.
No.1
C h r o m e I n s e r tC o m p r e s s i o n .
F i t r i n g s a s f o l l o w s: F i t s p r i n g o f N o . 4 r i n g i n f o u r t h g r o o v e e n s u r i n gt h a t
t h e l a t c h p i n e n t e r sb o t h e n d s o f t h e r i n g , s e e F i g F . 8 .
Position oil control ring over spring with spring
correctly located in groove of ring and the ring gap
d i a m e t r i c a l l yo p p o s i t et o t h e l a t c h p i n
F i t N o s . 3 a n d 2 r i n g s i n t h i r d a n d s e c o n dr i n g g r o o v e s
w i t h t h e i n t e r n a ls t e p a n d t h e w o r d " T O P " o r t h e m a n u facturer's marks towards the piston crown.
Fit No 1 ring in top ring groove.
Ensurethat the piston ring gaps are equallyspaced
a r o u n dt h e p i s t o n a n d n o t i n l i n e .
6.3724Engines
No 1
C h r o m e I n s e r tP a r a l l e lC o m p r e s s i o n .
No 2
C h r o m e F a c e d I n t e r n a l l yS t e p p e d o r I n t e r n a l l y
C h a m ef r e d C o m p r e s s i o n .
No.3
C h r o m e F a c e d ,S p r i n g L o a d e dC o n f o r m a b l eO i l
Control.
No.4
N o t e : W i t h l a t e r C o m b i n e e n g i n e s ,t h e N o : 4 s l o t t e d
c o n t r o lr i n g i s n o t f i t t e d .
F i t r i n g s a s f o l l o w s: F i t N o . 4 o i l c o n t r o l r i n g i n b o t t o mg r o o v e .
Fit springof No 3 oil controlring in third ring groove
lf necessary,deglazecylinderbore,see SectionG.
Clean cylinder bore, piston and bearings and liberallycoat
withcleanengineoil.
Compresspistonringswith ring clamp 38U3 and enterthe
assembliesin the top of their respectivecylinderbores,see
Fig. F.9. The piston and rod number must relate to the
cylinderintowhichit is beingfitted,see Fig.F.10,and the rod
identificationnumber must be towardthe fuel injectionpump
sideof the engine.
WithturbocharEed
e n g i n e sw
, h e n p r e s s i n gt h e a s s e m b l y
through the bore, care mLrstbe taken to avoid damage
t o t h e p i s t o nc o o l i n g j e t s .
Note: Piston cooling jets are not fitted to naturally
aspiratedengines.
With the respectivecrankpin in B.D.C. position, ensure
that the big end is turned to avoid contact with the piston
cooling jets, see Fig. F.2.
W h e n t h e b i g e n d o f t h e c o n n e c t i n gr o d h a s p a s s e d
t h e p i s t o n c o o l i n g j e t s , t u r n t h e a s s e m b l yb a c k a g a i n
to locate on the crankpin ensuring that upper half
bearing is correctly located in big end and tabs fit in
r e c e s so f r o d , F i g F . 1 1 .A l s o c h e c k t h a t t h e l e t t e r " F "
or arrow on the piston crown is towards the front of
the engine.
Fit cap with lower half bearing correctly positioned
a n d n u m b e r s o f c a p a n d r o d c o i n c i d i n g ,F i g F . 1 0 .
Refitthe two securing bolts so that the flat on the head of
e a c h b o l t i s l o c a t e d a g a i n s t t h e s h o u l d e ro f t h e r o d ,
Secure with new nuts and tighten to a torque of 75 lbf ft
( 1 0 , 4 k g fm ) o r 1 0 2 N m f o r c a d m i u m p l a t e d n u t s o r
PISTONSAND CONNECTINGRODS F6
9 5 l b ff t ( 1 3 , 1k g f m ) -
1 2 9 N m f o r p h o s p h a t e dn u t s .
C a d m i u mp l a t e d n u t s h a v e a s i l v e r c o l o u r f i n i s h w h i l s t
t h e p h o s p h a t e dh a v e a d u l l b l a c kc o l o u rf i n i s h .
Check that, with piston in T D.C. positionand using
piston height gauge PD 41B, the piston crown is
0 . 0 0 0 / 0 . 0 0 7i n ( 0 , 0 0 / 0 , 1 8m m ) a b o v et h e c y l i n d e rb l o c k
toD face
T h e p i s t o n h e i ' g h tf o r n a t u r a l l ya s p i r a t e de n g i n e s w a s
l o r m e r l y 0 . 0 0 7 3 / 0 . 0 1 5i n ( 0 , 1 9 / 0 , 3 8 m m ) a b o v e t h e
c y l i n d e rb l o c k f a c e a n d , w h e n c h e c k i n ge a r l i e re n g i n e s ,
either of the two heights are acceptable
Where new production pistons are used, then these
must be topped as necessaryto bring them within the
above limits.
Fit the pipe from relief valve to piston cooling jet
connection.(T6.3544only).
F i t l u b r i c a t i n go i l s u c t i o np i p e .
R e f i t t h e l u b r i c a t i n go i l s u m p , P a g e L . 3 , a n d r e f i l l w i t h
lubricatingoil to correct specification.
Refit the cylinder head,see Page E.2.
The T6.3544 North America vehicle engines are fitted with

aluminiumsilicon alloy pistonswith a re-entrantcombustion
chamberin the crown see Fig. F.12.A steel insertis fitted in
the top ring groove and two compressionand one scraDer
pistonringsare used.
The pistonsare cooledby lubricatingoil pressurelets.
Oversize pistons are not available as the cvlinder liners
cannotbe boredoversize.
The method used to remove and dismantlepiston and ring
assembliesis the same as usedtor otherT6.3544engines.
The height of the piston crown relativeto the top face of the
cylinderblockis 0.000/0.007in (0,000/0,1
8 mm) abovethe top
face.
The pistons have hard anodised crowns and must not be
topped. In production,three gradesof pre-toppedpistonsare
suppliedfor the high, mediumand low requirementsand the
letters H, M and L are stamped on the piston crown. To
changepistonsin service,the same gradeof pistonMUST be
useo.
6 3 5 4 4 S e r i e s W o r k s h o p M a n u a l , S e p t e m b e r1 9 8 2
F.12
A-PDF Merger DEMO : Purchase from www.A-PDF.com to remove the watermark
SECTIONG
GylinderBlockand Liners
;,:\\
\----l
)--
",(7
- ---7t
Y O )E
C Y L I N D E RB L O C K A N D L I N E R S
G2
CylinderBlock
in
0.026/0.037
(0,66/0,94
mm)
T h e t o p f a c e o f t h e c y l i n d e rb l o c k c a n n o t b e m a c h i n e d
a s t h i s w o u l d i n t e r f e r ew i t h t h e l i n e r f l a n g e r e c e s s
depth
CylinderLiners
P r o d u c t i o nl i n e r sa r e a n i n t e r f e r e n cfei t , o f 0 0 0 1 / 0 . 0 0 3
in
(0.025/0.076mm
i n)t h e c y l i n d e rb l o c k a n d a r e b o r e da n d
honed to a diameter oI 3.877/3.B7Bin(98,48/98,50mm)
for T6 3544 and 6.3544 engines or 3.9785/39795in
( 1 0 1, 0 5 / 1 0 1 , 0 7 m mf o) r 6 . 3 7 2 4e n g i n e s .
+0 002/-0.004in
( + 0 , 0 5 / - 0 , 1m0 m )
T h e m a x i m u m o e r m i s s i b l ew o r n i n s i d e d i a m e t e r o f
a l i n e r , i n s e r v i c e i s 3 8 8 6 i n ( 9 8 , 7 0 m m f)o r T 6 . 3 5 4 4
a n d 6 . 3 5 4 4e n g i n e so r 3 . 9 8 7 5 i n( 1 0 1 , 2 8 m m f)o r 6 . 3 7 2 4
e ng I n e s
An engine with perfect or little worn cylinderbores can
sometimesconsumean excessiveamountof lubricating
oil
due to glazing.When fittingnew piston rings to cure this
problem, it is essentialthat the cylinder bores are first
de-glazed.
A tool is availablefor de-glazing,marketedunderthe trade
name of "Flex-Hone",manufacturedby Brush Research
Manufacturing
Co. Inc.,LosAngeles,California,
U.S A. under
the registeredtrade mark U.S. Patent Nos 3384915and
3871139and BritishPatentNos. 1,230503and 18450,which
is idealfor thispurposeas it doesnot removeany appreciable
amount of metal and producesa good quality cross hatch
pattern.
It can oftenbe used with the enginein situ if usedwith a hand
held electricpower drill on low speed. Brand new "FlexHones" are to be used for one minutein a slave bore to
removeall loosematerialandsharpedges.
1. Grade80sc "Flex-Hone"is to be used.The "Flex-Hone"
size is to be determinedby measuringthe bore diameter
and selectingthe "Flex-Hone"of the nearestsize larger
thanthe bore.
2. Removethe piston coolingjets as fitted on turbocharged
engines.Guardthe mainjournalsand pinsby tyingclean
dry rags around them. Where possible use cardboard
shields to preventdebris contaminationof adjacentparts
of the engine.
3. Lubricatethe bore with clean engineoil and also smear
engineoil on the ballsof the "Flex-Hone"
4. Restthe "Flex-Hone"againstthe cylinderblockandswitch
on whilst pressinginto the bore Do not force the tool into
the borewhilstit is noi rotating.
5 Pass the tool up and down the bore once per secondfor
30-50secondsand removeit whilstit is stillrotating.
wash the boresto removeall the residuefrom
6. Thoroughly
the honingoperation,
usinga coarsebrushand paraffin.
7. Dry the boresusinga cleanrag and carefullyremovethe
the masking.Thoroughlycleanall partsof the enginethat
have beenaffectedby the honingoperation.
8. Refit the piston cooling jets on turbochargedengines
(SectionM).
This tool is equallysuccessfulin producinga good quality
bedding-infinishon new cylinderbores,after boringout to
finishedsize.
Enquiries
detailsand supplyof the "Flex-Hohe"
concerning
in
the U.K. or outside the U.S. where no Brush Research
Distributor
is available,
shouldbe addressedas follows:
Nicro(Leamington)
Ltd.
Estate,
Unit19A,ChalfordIndustrial
GL6BNT.
Chalford.Nr. Stroud.Gloucestershire
: (0453)884966
Telephone
T e l e x4
: 37104
lf the liners are found to be worn over the acceptable

l i m i t ,t h e y c a n n o tb e b o r e do v e r s i z e .
For servicein T6 3544and 6.3544engines,a pre-finished
l i n e ri s a v a i l a b l eh a v i n ga t r a n s i t i o nf i t o f + 0 0 0 1 / - 0 . 0 0 i1n
(+0,025/-0,O25mm)
The fitted internal bore diameter is
mm )
3 877/3.8795 in (98,48198,54
The liners can be renewedusing tools PD 150 and
PD 150-18.
To Renew ServiceCylinder Liners

Remove all components from the cylinder block,
including the piston cooling jets. They should be
c a r e f u l l yh a n d l e d t o p r e v e n t m i s a l i g n m e n ti n r e f i t t i n g
Piston cooling jets are not fitted to naturally aspirated
e n g rn e s .
T h e l i n e r ss h o u l d b e p r e s s e do u t f r o m t h e b o t t o m .
F i tt h en e w l i n e r sa sf o l l o w s :
linerscan be a 0.001in
It is oointedout that all pre-finished
(0,03mm)interference
fit in the parentbore,i.e. if a lineron
top limitis fittedin a bottomlimitparentbore.
A tight liner should never be hammeredin bui should be
pressedor drawn into the bore using a suitabledolly and
pressor puller.
Generally clean the parent bore and degrease the
t o p 2 i n ( 5 0 m m )a n d t h e l i n e r f l a n g er e c e s su s i n g" L o c t i t e "
Safety Solvent (aerosolcan) as per instructionson can
Apply engine oil to the cylinder block paretrt bore
e x c e p tf o r t h e t o p 2 i n ( 5 0m m ) .
G e n e r a l l yc l e a n t h e o u t s i d e s u r f a c e so f t h e l i n e r a n d
degreaseusing "Loctite" Safety Solvent (aerosolcan) as
p e r i n s t r u c t i o n so n c a n
Locate the liner in the bore and press in to within
a p p r o x i m a t e l 2y i n ( 5 0m m ) o f i t s f i n a l p o s i t i o n
Furthed
r e gr e a s et h e f l a n g ea r e ao f t h e l i n e ru s t n g" L o c t i t e "
Safety Solvent to remove handling contamination.
CYLINDERBLOCKAND LINERS
Apply a band of "Loctite" Retaining Compound, Grade

602, 1in (25mm) wide around the top of the tiner
immediately under the flange. Also liberally apply the
"Loctite" to the base of the flange recess.
Pressthe liner into the fully fitted position and wipe the
top of the cylinder block to remove any surplus
"Loctite". The top of the liner. should protrude
0.026/0.037in(0,66/0,94mm)above ihe top face of the
cylinderblock and the liner flange should be within
0.002in (0,05mm) above the top face of the blocK ro
0.004in (0,10mm) below the top face of the block
It is advisableto allow a setiling period to elapse after
fitting before checking the fitted internal bore diamerer
of the liner.
However, allow at least 15 minutes to elapse before
commencingto fit pistonsas this time lag is requiredto
allow the "Loctite" to reach handling strength. Full cure
strength is achievedafter 3 hours
G3
SECTIONH
Grankshaftand Main Bearings
C R A N K S H A F TA N D M A I N B E A R I N G S H 2
T h e c r a n k s h a f tr u n s i n s e v e n p r e - f i n i s h e dr e p l a c e a b l e
s h e l lb e a r i n g s
E n d f l o a t o f t h e c r a n k s h a f ti s c o n t r o l l e db y f o u r t h r u s t
w a s h e r sw h i c h a r e l o c a t e do n b o t h s i d e s o f t h e c e n t r e
m a i n b e a r i n gh o u s i n g s, e e F i g H 1 O 0 0 7 5 i n( 0 , l 9 m m )
o v e r s i z et h r u s t w a s h e r s a r e a v a i l a b l ew h i c h m a y b e
combined with standard thrust washers to give an
a d j u s t m e not f 0 0 0 7 5 i n( O1 9 m m )o r w h e n u s e do n b o t h
s i d e s o f t h e b e a r i n g h o u s i n g g i v e a n a d j u s t m e n to f
0 0 1 5i n ( 0 , 3 5m m )
T h e m a x i m u m p e r m i s s i b l ec r a n k s h a f te n d f l o a r t s
0 0 2 0r n ( 0 , 5 1
mm)
C r a n k s h a f t sf i t t e d t o t u r b o c h a r g e de n g i n e sa r e 6 0 h o u r
N i t r i d e do r T u f f t r i d e d
C r a n k s h a f t sf i t t e d t o n a t u r a l l y a s p i r a t e de n g i n e s a r e
i n d u c t i o nh a r d e n e d
T h e c r a n k s h a fht a s p r o v i s i o nt o r 1 2 b o l t f l y w h e e lf i x i n g
To Renew Thrust Washers

R e n e w a lo f t h r u s t w a s h e r sc a n b e c a r r i e d o u t w i t h o u t
the removao
l f c r a n k s h a fat s f o l l o w s :
D r a i nt h e l u b r i c a t i n go i l a n d r e m o v et h e s u m p ,o i l s u c r r o n
pipe and pipe from reducingvalve to cylinder block
( T 6 . 3 5 4 4e n g i n e so n l y )
R e m o v et h e c e n t r e m a i n b e a r i n gc a p ( N o . 4 )
R e m o v et h e t w o b o t t o m h a l f t h r u s t w a s h e r s
R e m o v et h e t w o t o p h a l v e s o f t h e t h r u s t w a s h e r s b y
s l i d i n gt h e m r o u n dt h e c r a n k s h a fat n d o u t o f t h e r e c e s s e s
m a c h i n e di n t h e c y l i n d e rb l o c k m a r n b e a r i n gh o u s i n g ,
see Fig H 2
L i b e r a l l yo i l t h e t w o u p p e r h a l v e sa n d s l i d e t h e m i n t o
t h e r e c e s s e so n e i t h e r s i d e o f t h e c e n t r e m a r n b e a r i n q
n o u snr o
R e f i tt h e t w o b o t t o m h a l v e so f t h e t h r u s t w a s h e r st o t h e
Deaflngcap
C l e a n a n d o i l c r a n k s h a f tj o u r n a l a n d p l a c e t h e c a p i n
p o s i t i o ne n s u r i n gt h a t t h e b l o c k s e r i a l n u m b e r s t a m p e d
o n t h e c a p r e a d si n l i n e w i t h o t h e r c a p s
T i g h t e n t h e m a i n b e a r i n gc a p s e t s c r e w st o a t o r q u e o I
2 0 0l b f f t ( 2 7 , 7 k g t m )o, r 2 7 O N m
C h e c kt h e c r a n k s h a f e
t n d f l o a t b y u s i n g a f e e l e rg a u g e
b e t w e e nt h e t h r u s t w a s h e r a n d c r a n k s h a f tw e b o r b y
u s i n g a d i a l t e s t i n d i c a t o ro n o n e e n d o f t h e c r a n k s h a f t ,
see Fig H 3
R e f i ts u c t i o n p i p e , p i p e f r o m r e d u c i n gv a l v et o c y l i n d e r
b l o c k ( T 63 5 4 4 o n l y ) a n d s u m p R e f i l l t h e s u m p w i t h
l u b r i c a t i n go i l o f a n a p p r o v e dg r a d e .
To RemoveCrankshaft
I t w i l l b e n e c e s s a r yt o r e m o v et h e e n g i n e f r o m v e h i c l e
or machine
D r a i n a n d r e m o v e t h e s u m p , l u b r i c a t i n go i l s u c t i o n
p i p e a n d p i p e f r o m r e d u c i n gv a l v et o t h e c y l i n d e r b l o c k
(T6 3544 only)
R e m o v e t h e c r a n k s h a f t p u l l e y E x t r a c t o r ss h o u l d n o t
b e u s e d a s t h e p u l l e y w i l l p r o b a b l y b e d e s t r o y e da n d
t h e c r a n k s h a f td a m a g e d . R e m o v e t h e t h r e e s e c u r i n g
s c r e w s .l f t h e p u l l e yd o e s n o t i m m e d i a t e l yb e c o m ef r e e
t h e l o c k i n gr i n g sc a n b e r e l e a s e db y h i t t i n gt h e f r o n t f a c e
o f t h e p u l l e yi n n e rh u b , s e e F i g H . 4
R e m o v ec a m s h a f tg e a r , a u x i l i a r yd r i v e g e a r a n d t i m i n g
aAaA
cAA
d6
| t
R e m o v ef i y w h e e la n d f l y w h e e lh o u s i n g
H.1
R e m o v er e a r m a i n o i l s e a l h o u s i n o .
H.4
H.3
R e m o v ef r o n t a n d r e a r b r i d g e p i e c e sf r o m t h e c y l i n d e r
b l o c k b o t t o mf a c e ,w i t h t h e r u b b e ro i l s e a l s
A f t e r n i t r i d i n go f t h e c r a n k s h a f tr,e g r i n d i n go f t h e f i l l e l
r a d i ii s n o t p e r m i s s i b l e
Removeconnectingrod caps and big end bearings

K e e p b e a r i n g sw i t h a p p r o p r i a t ec a p s T a k e c a r e n o t
t o d a m a g et h e p i s t o nc o o l i n gj e t s
W h e n r e - g r i n d i n gt,h e o p e r a t i o nc a l l s f o r s p e c i a l i s e d
equipmena
t n d g r e a tc a r e
R e m o v et h e m a i n b e a r i n gc a p s a n d h a l f b e a r i n g s
L i f t o u t t h e c r a n k s h aaf tn d r e m o v et h e u p p e rh a l f b e a r i n g s ,
m a k i n gn o t e o f f i t t e d p o s i t i o n s
Crankshaftregrinding
lnduction hardened crankshafts (Pt No. 31323283,
31323288,31323294, 3131H023, 3131H024 or 3 131H025)
f itted to naturallyaspiratedengines can be regroundto
- 0 0 1 0 i n( 0 , 2 5 m m )0, . 0 2 0 i n( 0 , 5 1m m ) o r 0 0 3 0 i n( 0 , 7 6 m m )
withoutany subsequent
rehardening.
60 hourNitridedcrankshafts
(Pt No. 31323281or 3131H021)
fittedto turbocharged
enginesmay be regroundto -0.010in
(0,25mm) without re-Nitriding.Subsequentregrindingto
-0 020in (0,51mm) or 0 030in (0,76mm)callsfor re-Nitriding
for a 60 hourperiodaftereachregrinding
operation
Tufftrided crankshafts (Part No 31323292 or 3j31H022)
mustbe re-Tufftrided
aftereachregrinding
operation
l f a 6 0 h o u r N i t r i d e dc r a n k s h a f its f o u n dt o b e s u i t a b l ef o r
further service, but necessaryto re-grind down to
0 . 0 2 0i n ( 0 , 5 1m m ) o r 0 0 3 0 i n ( 0 , 7 6m m ) u n d e r s i z eg, r i n d
d o w n t o 0 0 0 1 5 / 0 . 0 0 2 i n( 0 , 0 4 / 0 , 0 5 m m )a b o v e f i n i s h e d
size leaving an allowance to grind off the white
c o m p o u n dl a y e r{ o r m e db y t h e 6 0 h o u r N i t r i d i n gp r o c e s s
6 3544 SoriesWorkshopManual,January '1986
U s i n g a P r i n c et y p e g r i n d e rw i t h a U n i v e r s aG
l rinding
Wheel Company wheel to Grade WA-80 JE (or
e q u i v a l e n t )r,e m o v et h e w h i t e c o m p o u n d l a y e r f o r m e d
b y t h e N i t r i d i n g p r o c e s st o a c h i e v e f i n i s h e d s i z e T h e
c o l l a r f a c e s o f t h e c r a n k s h a f ts h o u l d b e l i g h t l y f l a s h e d
b u t n o t g r o u n da t t h i s o p e r a t i o na n d t h e f i t l e tr a d i is h o u l d
b e m a i n t a i n e da t 0 1 4 5 / 0 1 5 6 i n ( 3 , 6 8 / 3 , 9 6 m m )T h i s
w i l l l e a v et h e c o m p o u n dl a y e r i n t h e r a d i i a n d c o l l a r s
W h e n r e m o v i n gt h e c o m p o u n dl a y e r ,a g r i n d i n gw h e e l
s p e e d o f B B 0 r e v l m i n a n d a c r a n k s h a f tw o r k i n g s p e e d
o f 1 6 r e v l m i n f o r m a i n j o u r n a l sa n d 8 r e v l m i n f o r p i n s
s h o u l d b e o b s e r v e da n d a h a n d f e e d o f a p p r o x i m a t e l y
0 0 0 0 5i n ( 0 , 0 1m m ) p e r r e v o l u t i o n o f c r a n k s h a f t
A n a d e q u a t es u p p l y o f c o o l a n t ( W a l k e rC e n t u r y , 4 3 0 5 )
s h o u l db e u s e d
W h e r ef a c r l i t i e sf o r r e - N i t r i d i n ga r e n o t a v a t l a b l et,h e n a
f a c t o r y r e p l a c e m e n ct r a n k s h a f ts h o u l d b e f i t t e d
N i t r i d e dc r a n k s h a f t cs a n n o tb e s t r a i g h t e n e d
B e f o r e r e g r i n d i n g a c r a n k s h a f t ,i t s h o u l d b e c r a c k
d e t e c t e d D e - m a g n e t i z ea f t e r c r a c k d e t e c t i n g
D a t a f o r c r a n k s h a f tr e - g r i n d i n gi s g i v e n o n P a g e H 4
A f t e rr e g r i n d i n gt,h e s h a r pc o r n e r so n t h e o i l h o l e ss h o u l d
b e r e m o v e d a n d t h e c r a n k s h a f tc r a c k d e t e c t e d a n d
de-magnetized
N o t e :l t i s i m p o r t a n t h a tt h e r a d i io n t h e m a i nj o u r n a l sa n d
c r a n k p i n sa r e m a i n t a i n e d
H.5
T h e r e g r i n dd i m e n s i o n sa r e a s f o l l o w s s e e F i g . H 5
0 . 0 1 0i n ( 0 , 2 5m m )
0 . 0 2 0i n ( 0 , 5 1m m )
0 . 0 3 0i n ( 0 , 7 6 m m )
2.9884/29896 in
( 7 5 , 9 1/ 7 5 , 9 4 m m )
2 - 9 7 8 4 / 29 7 9 6 i n
( 7 5 , 6 5 / 7 5 , 6 8m m)
2.9684/2.9696in
(75,40/75,43mm)
2.4888./2.4898
i,n
(63,22/63,24 mm)
2.4788/2.4798in
( 6 2 , 9 6 / 6 2 , 9 9m m)
2.4688/2.4698in
(62,70/62,73 mln)
(,
1 7 5 9 i n ( 4 4 , 6 8m m ) m a x i m u m
1 . 4 8 9i n ( 3 7 , 8 2m m ) m a x i m u m
1 5 5 4 i n ( 3 9 . 4 7m m ) m a x i m u m
1 . 5 9 6 5i n ( 4 0 , 5 5m m ) m a x i m u m
0 . 1 4 5 1 0 . 1 5i6n ( 3 , 6 8 / 3 , 9 6m m ) r a d i u sa l l p i n s a n d j o u r n a l s
Sudacefinishof 16 microinches(0,4 microns)of the crankpinsand journalsand 50 microinches(1,3microns)of the filletradii(R)

mustbe maintained
duringregrinding.
M a x i m u mr u n - o u tw i t h t h e c r a n k s h a f m
t o u n t e do n t h e e n d m a i n i o u r n a l s .
I n d e p e n d e nrt e a d i n g s .
CrankshaftPulley
D i a m e t eT
r .l.R
0 . 0 0 2i n ( 0 , 0 5 m m )
J o u r n a l sT l . R . -
R e a rO i l S e a l
D i a m e t e rT . l . R .
0 0 0 2 i n ( 0 , 0 5m m )
F l y w h e e lF l a n g e
D i a m e t e rT . l R
0 . 0 0 2i n ( 0 , 0 5 m m )
R u n - o u tm u s t n o t b e o p p o s e d:
N u m b e r1
Mounting
N u m b e r5
0 . 0 0 8i n ( 0 , 2 0 m m )
N u mb e r 2
0 0 0 4 i n ( 0 , 1 0m m )
N u m b e r3
0 0 0 8 i n ( 0 , 2 0m m )
N u m b e r6
0 . 0 0 4i n ( 0 , 1 0m m )
N u m b e r4
0 . 0 1 0i n ( 0 , 2 5m m )
N u m b e r7
Mounting
The differencein run-out betweenany two a d j a c e n tb e a r i n g sm u s t n o t b e g r e a t e rt h a n 0 . 0 0 4i n ( 0 , 1 0 m m ) .
To Fit Crankshaft
Ensure that the oilways in the cylinder block and
crankshaftare free from obstruction
Check the main bearingsetscrewsfor stretch or damage
l f t h e y a r e t o b e r e p l a c e d ,o n l y u s e P e r k i n s g e n u i n e
spare parrs
C l e a nt h e b e a r i n gh o u s i n g s ;p l a c e t h e t o p h a l f b e a r i n g s
i n p o s i t i o na n d l i b e r a l l yo i l .
P o s i t i o nt h e c r a n k s h a f t .
Oil the two upper thrust washersand slide into the
r e c e s s e so n e i t h e r s i d e o f t h e c e n t r e m a i n b e a r i n q
housing
C l e a nt h e m a i n b e a r i n gc a p s a n d p l a c e t h e l o w e r h a l v e s
of the bearings, with the tabs correctly located, into
p o s i t i o n L i b e r a l l yo i l a n d p l a c e t h e c a p s i n p o s i t i o n
making sure thai the cap to cylinder block locating
S,..'
l *
liitlili
H.6
thimblesare in place and that the caps, whicn are

n u m b e r e do n e t o s e v e n a r e f i t t e d t o t h e r e l e v a n tm a t n
b e a r i n gh o u s i n g sC
. a r em u s t a l s o b e t a k e nt o e n s u r et h a t
t h e c a p sa r ef i t t e ds o t h a tt h e c y l i n d e rb l o c ks e r i a ln u m b e r ,
which is stampedon the cylinder block bottom face
as well as on each cap, read in line,see Fig H 6.
Beforefitting the centre main bearing cap, place the
lower halvesof the thrust washers into the recesseson
e i t h e rs i d e o f t h e c a D .
F i t a n e w s h i m w a s h e rt o e a c h m a i n b e a r i n gc a p s e t s c r e w
a n d l i g h t l yo i l .
Check the crankshaftend float for a clearanceol 0.O02/

0.015 (0,05/0,38mm).Oversize thrust washers may be
f itted.
Refit the connecting rod caps and big end bearings.
Refit the front and rear bridge pieces to the cylinder
block using.lointing compound between the bridge
piecesand the cylinderblock at the setscrewholes.Check
w i t h a s t r a i g h te d g e t o e n s u r et h a t t h e e n d f a c e s o f t h e
b r i d g ep i e c e sa r e f l u s h w i t h t h e e n d f a c e so f t h e c y l i n d e r
b l o c k ,s e eF i g .H . 7 .I n s e r tn e wr u b b e ro i l s e a l s s, e e F i g .H . 8 .
T i g h t e nt h e s e t s c r e w st o a t o r q u e o f 2 0 0 l b f t ( 2 7 , 7 k Tm
f )
or 270Nm
H.7
H.8
H.10
H.9
F i t n e w s e a l i n t h e r e a r m a i n o i l s e a l h o u s i n ga n d r e f i t
the housing.
Refit the pipe from reducingvalve to cylinder block
( T 6 3 5 4 4o n l y ) l u b f l c a t i n go i l s u c t i o np i p e a n d s u m p
R e f i tt h e t i m i n g c a s e ,c a m s h a f tg e a r a n d a u x i l i a r yd r i v e
g e a r ,s e e P a g eJ . 2
Refit the crankshaftpulley employing the following
recommendedorocedure.
(a) Removeoil and greasefrom pulley bore, shaft,
l o c k i n g e l e m e n t sa n d s p a c e r , b u t d o n o t u s e a
d e g r e a s i n gs o l u t i o n . D o n o t e x p a n d t h e r i n g s
beyond their free state.
( b ) F i t p u l l e yt o s h a f t ,l i n i n g u p k e y a n d k e y w a y
( c ) I n s e r tt h e s p a c e r( 1 ) i n t o t h e p u l l e y b o r e o v e r t h e
s h a f t ,f o l l o w e db y t h e i n n e r ( 2 ) a n d t h e n t h e o u t e r
( 3 ) l o c k i n ge l e m e n t se, n s u r i n gt h a t t h e s l o t s d o n o t
c o i n c i d e s, e e F i g . H . 9
Note: Where power take-off at the front end of the
c r a n k s h a f ti s c r i t i c a l ,t h e n t w o p a i r s o f l o c k l n ge l e m e n t s
a r e f i t t e d- s e e F i g . H . 9 ( 2 ) a n d ( 3 )
( d ) F i t t h e t h r u s tb l o c k ( 5 ) w i t h " O " r i n g ( 4 ) i n t o t h e
p u l l e yb o r e .
( e ) L i g h t l y o i l s c r e w t h r e a d s a n d u n d e r s i d eo f s c r e w
h e a d s b e f o r e fi t t i n g . D o n o t u s e m o l y b d e n u m
disulphide.
(f)
P u s h p u l l e y f u l l y h o m e a n d t i g h t e n s e t s c r e w st o
e s t a b l i s ha f i r m c o n n e c t i o n
(g) Tighten screws evenly and in severalstages until a

f ) or BB Nm is
f i n a l t o r q u e o f 6 5 l b ff t ( 9 , 0 k g m
a c h i e v e ds, e e F i g . H . 1 0 .
C h e c kt i g h t e n i n gt o r q u e o n e a c h s c r e w .
Refit and correctly align the flywheel housing and
flywheel,see Page P.2.
R e b u i l de n g i n e i n t o v e h i c l eo r m a c h i n e F i l l t h e s u m p
t o t h e c o r r e c t d i p s t i c k l e v e l w i t h a r e c o m m e n d e do i l .
W i t h t u r b o c h a r g e de n g i n e sd o n o t f i r e t h e e n g i n e u n t i l
c h e c k i n g f o r l u b r i c a t i n go i l a t t h e t u r b o c h a r g e r ,s e e
P a g eC . 2 .
CrarrkshaftRear Oil Seal

A circularspringloadedlipseallocateson the periphery
of the
rearflangeof the crankshaft.
This seal is easily damaged and exlremecare should be
taken when handlingand fittingit to its housingor to the
crankshaftAnyvisualdamageacrossthe lipof a newsealwill
causeleakageand preventbeddingin of the seal.
To Fit OilSeal in its Housing

Earlierseals have a flat rear face, as shown in Fig H.11
whereasthe latestseal has a dust lip protruding
fromthe rear
f a c e ,a s s h o w ni n F i g .H . 1 2
On production,
the old type sealwas fittedflushwithtne rear
face of the housing(Fig.H.11)but the new type sealis fitted
d e e p e irn t ot h eh o u s i n ga t " A " , F i g .H . 1 2 .
In service,when a new seal is fitted to a worn crankshaft,it
should be pressed further into the housing In the first
instanceit can be pressedin to Tein (3,2mm)for old type
sealsor position"8" for new typesealsor, if this positionnas
beenused,to Tain(6,4mm)for old typesealsor position"C"
for newtypeseals.
lf a newtypesealis usedin placeof an exisitingoldtypeseal,
position"C" shouldbe used if the old seal was fittedTein
(3,2mm)belowthe housingface.
lf all threepositionshavebeenused,it may be permissible
to
machinethe worn sealingarea of the crankshaft
flange,but
not the spigotarea on whichthe flywheellocates- See Fig.
H.13.
5 . 2 4 3i n
(tss,tzmm)
MIN
-l
I
___l
I
---l
I
::+
\
Usingclean enginelubricating
oil, lubricatethe outsidediameterof the sealandthe insidediameterof the housing.
Pressthe sealintothe housingto the requiredposition,
taking
care that the seal is entered and pressed in squarely,
otherwisedamageto the outsidediameterof the seal may
occuror, if not squarein the housingwhenfittedto the engine,
it may leak.
H.11
T o F i t O i l S e a l a n dH o u s i n g
The seal and Frousingshould be fitted, using seal guide
PD145C,as follows:-
When a new seal is fittedto a new or reconditioned

crankshaft
in service,it shouldbe fittedin the productionposition,but if
the latestsealis not to be usedin a wet backend application,
it can be fittedflush with the housingrear face (,,D",Fig.
H.12).
Whenpressingin the latesttypeseal,ensurethatthe adaptor
has a suitablerecessto clear the protrudingdust lip Tool
PD145Ccan be usedwithbothtypeseals.
Beforefittingthe seal in the housing,carefullyexaminethe
sealfor damageespecially
on the lipand outsidediamerer.
Cleanthe facesof the cylinderblockand the oil seal housing

and the outsidediameterof the crankshaft
flange.
Checkthatthe sealand the outsidediameterof thecrankshaft
flangeare not damaged.Wherea new seal has been fitted,
check that it is in the correct positionin the housing,as
detailedabove
Ensurethat the two dowels are fittedin the cylinderblock.
Coat both sides of the housingjoint with Perkins(Hylomar)
JointingCompoundand positionthe jointover the dowelsin
the block.
Using clean engine lubricatingoil, lubricatethe crankshaft
flange,the sealand the sealguide.The lubrication
of the seal
is necessary
to preventdamagethat may be causedby initial
d r yr u n n r n g .
Positionthe seal and housingon the seal guide,locatethe
guideon the crankshaftflangeand gentlypressthe sealand
housingintopositionon the flange,locatingthe housingon its
oowets.
Withdrawthe guide and securethe housingwith setscrews
ano wasners.
*--A
OOgrn(2,2nrni)
<--B
01Bin (4.6rrrrrr)
H.12
January1986
O 2 7 i n ( 6 . ! ) n ' rrr)r
SECTIONJ
TimingCaseand Drive
-4
\\
)\
\\\
T I M I N G C A S EA N D D R I V E
J2
To RemoveTiming Case, Camshaft

Gear and Auxiliary Drive Gear
S l a c k e nt h e g e n e r a t o rm o u n t i n g b o l t s a n d r e m o v e t h e
drive belts
Where necessary,removethe water pump.
R e m o v et h e c r a n k s h a f pt u l l e y ,s e e P a g e H . 2 .
R e m o v e t h ec a m s h a f gt e a ra n d a u x i l i a r yd r i v eg e a rc o v e r s .
The camshaft gear securing setscrew and washers can
now be removed.Extractthe gear from the camshaft,see
F i g .J 2
R e m o v et h e r e t a i n i n gp l a t e s e c u r i n gt h e a u x i l i a r yd r l v e
g e a r t o t h e a u x i l i a r yd r i v e s h a f t h u b a n d w i t h d r a w t h e
g e a r ,s e e F i g .J . 3 .
T h e t i m i n gc a s es e c u r i n gs e t s c r e w sl ,o w e rn u t sa n d t i m i n g
case can now be removed.
To RenewCrankshaltFront Oil Seal

U s i n ga p r e s s ,r e m o v et h e o i l s e a l f r o m t h e t i m i n g c a s e .
A l t e r n a t i v e l yt h, e s e a lm a y b e t a p p e do u t
Early seals were black with a flat front face Later sealswere
red and also had a flat front face. Currentseals are blackand
have a protrudingdust seal lip at the front.An oil throweris
fittedbetweenthe crankshaftgear and pulleywith the early
blacksealsbut this is removedand a spaceror longerpulley
is fittedwiththe laterredand blackseals.
lf the latestseal,with a dust seal lip, is used in placeof an
earliertypeseal,a cleanlocatingsurfacefor the dust lip must
be providedon the pulleyboss. Clean paint,etc. from the
pulleyfor a distanceof 3/ein(9mm) forwardof the lip seal
location.
Pressthe seal into positionfrom the front untilthe flat front
face of the seal is 0.265/0.285in(6,7317,24mm)
belowthe
frontfaceof thetimingcase,see Fig.J.4.
J.2
To Refit Timing Gase,CamshaftGear
and Auxiliary Drive Gear
R e m o v et h e r o c k e rc o v e ra n d s l a c k e nt h e r o c k e ra s s e m b l y
securing setscrews.
Turn the crankshaftuntilNos. 1 and 6 oistonsare at T.D C.
gearat T.D.C.
withthe keywayin the crankshaft
lf the doubledot on the loweridlergear is not in linewiththe
single dot on the crankshaftgear, removethe idler gear and
replacewiththe marksin line.
ek&
11,,.;
J.1
January1986
J.3
J.5
P o s i t i o nt h e t i m i n g c a s e w i t h a n e w . J o i not n t h e c y l i n d e r
block by nreansof two oppositesetscrewsfitted loosely
C e n t r a l i s et h e c a s e b y l o c a t i n gt h e t i m i n g c a s e c e n t r a l i s i n g t o o l P D . 1 6 3 o n t h e c r a n k s h a f ta n d i n t h e s e a l
housing and tighten the assemblyby means of the
c r a n k s h a f tp u l l e y s e t s c r e w sa n d t h e w a s h e r p r o v i d e d
Do not overtightenTighten all the timing case sets c r e w sa n d n u t s a n d r e m o v et h e t o o l . l f t h e c e n t r a l i s i n g
t o o l i s n o t a v a i l a b l et,h e c r a n k s h a f tp u l l e yc a n b e u s e d
t o c e n t r a l i s et h e c a s e , b u t , a s t h i s m e t h o d u t i l i s e st h e
i n s i d e d i a m e t e ro f t h e s e a l w h i c h i s s o f t , t h e c a s e m a y
n o t b e t r u l y c e n t r a la n d l e a k s m a y o c c u r .
R e f i tt h e a u x i l i a r yd r i v eg e a r c o v e rp l a t e
lf the latesttype of crankshaftoil seal with a protruding

dust
tool
seal lip at the front is fitted,ensurethat the centralising
hasa suitablerecessin it to clearthe dustseallip
To Removeldler Gearsand Hubs
P o s i t i o nt h e c a m s h a f ts o t h a t t h e k e y i s a l i g n e d w i t f r
the keyway in the camshaft gear and at the same time,
t h e t i m i n g m a r k s o n t h e c a m s h a f ta n d i d l e r g e a r s a r e
aligned
Draw the gear onto the camshaftby fitting the gear
retainingwasher, tabwasher,shimwasherand setscrew
T i g h t e nt h e s e t s c r e wt o a t o r q u eo f 5 0 l b f f t ( 6 , 9 k g fm ) o r
6 8 N m ,a n d l o c k w i t h t h e t a b w a s h e r ,
R e f i tt h e f u e l i n j e c t i o np u m p ,s e e P a g eN 6
T i g h t e n t h e r o c k e r a s s e m b l y a n d a dj u s t t h e v a l v e
c l e a r a n c e st o 0 0 0 8 i n ( 0 , 2 0 m m ) f o r i n l e t v a l v e s a n d
0 0 1 8 i n ( 0 , 4 5 m m )f o r e x h a u s tv a l v e s c o l d a n d r e p l a c e
the cover.
R e f i tt h e c r a n k s h a f pt u l l e y ,s e e P a g e H 6
F i t t h e d r i v eb e l t sa n d r e t i g h t e nt h e g e n e r a t o r
R e m o v et h e t i m i n g c a s e ,s e e P a g eJ 2
R e m o v et h e s e l f l o c k i n g n u t s s e c u r i n ge a c h i d l e r g e a r
t h r u s tp l a t e .
R e m o v et h e r e t a i n i n gp l a t e s a n d w i t h d r a w t h e g e a r s ,
seeFig J 5
W i t h d r a wt h e h u b s
Refit the camshaftgear cover plate.

B e f o r ef i t t i n g t h e a u x i l i a r yd r i v e g e a r , r e m o v e t h e f u e l
i n j e c t i o np u m p ,s e e P a g eN 6 . a n d t u r n t h e a u x i l i a r yd r i v e
s h a f tu n t i it h es l o t i n t h e v e r t i c afl u e l p u m pd r i v eh u b a l i g n s
w i t h t h e s l o t i n t h e f u e l p u m p a d a p t o rp l a t e ,s e e F i g K 2
W i t h t h e e n g i n e s e t r n t h i s p o s i t i o n ,f i t t h e a u x i l i a r y
d r i v eg e a rs o t h a t t h e t h r e es e t s c r e wh o l e si n t h e s h a f ta r e
w i t h i n t h e t h r e e s l o t so f t h e o e a r
Securethe gear with the retaining plate and setscrews
J.4
January1986
6 3544SeriesWorkshopL4anual,
J3
J.6
J4
J.7
J.8
To Refit ldler Gears and Hubs
A d j u s tt h e v a l v ec l e a r a n c e st o 0 . 0 0 B i n( 0 , 2 0 m m )f o r i n l e t
v a l v e sa n d 0 . 0 1 8i n ( 0 , 4 5m m ) f o r e x h a u s vt a l v e sc o l d . R e fi t
the rocker cover.
T u r n t h e c r a n k s h a f tu n t i l N o s . 1 a n d 6 p i s t o n s a r e a t
T . D C . w i t h t h e k e y w a yi n t h e c r a n k s h a f tg e a r a t T . D C
R e f i tt h e i d l e r g e a r h u b s ,l o c a t e db y d o w e l s ,s e e F i g .J . 6 .
Ensurethat the oilways are clear
R e f i t t h e i d l e r g e a r s a n d r e t a i n i n gp l a t e s s o t h a t t h e
timing marks on the lower idler gear align with the
t i m i n g m a r k so n t h e c r a n k s h a f gt e a r
Using new self locking nuts, tighten to a torque of
3 6 l b ff t ( 5 , 0k g f m ) o r 4 9 N m .
B e f i t t h e t i m i n g c a s e , c a m s h a f tg e a r a n d a u x i l i a r yd r i v e
gear, see Page J 2
Check the end float which should be 0.004/0016in
( 0 , 1 0 / 0 , 4m
1 m ) , s e e F i g .J . 7
To Remove Camshaft and Tappets

R e m o v et h e t i m i n g c a s e ,s e e P a g eJ . 2 .
Removethe rocker cover, rocker assemblvand withdraw
the oushrods.
Removethe fuel lift pump, see Page N.5
T u r n t h e e n g i n eo n i t s s i d e a n d r e m o v et h e s u m p .
Remove the camshaft thrust ring and withdraw the
camshaft,see Fig. J.B.
Removethe tappets.
To ReplaceCamshaft and Tappets

Refit the tappets,camshaftand sump.
Fit the camshaft thrust ring so that it is correcily
p o s i t i o n e do n t h e d o w e l ,s e e F i g J . 9 .
C h e c k t h e p r o t r u s i o no f t h e t h r u s t r i n g b e y o n d t h e
cylinderblock front face which should be within the
l i m i t so f 0 . 0 0 0 / 00 0 5i n ( 0 , 0 0 / 0 , 1m
3 m).
R e f i tt h e f u e l l i f t p u m p a n d c o n n e c t i o n s
F i t t h e t i m i n gc a s ea n d r e fi t t h e t i m i n gg e a r s ,s e ep a g e J 2
R e f i tt h e p u s h r o d sa n d r o c k e ra s s e m b l y
R e f i l l s u m p w i t h l u b r i c a t i n go i l o f a n a p p r o v e dg r a d e .
To Remove Auxiliary Drive Shaft and

Fuel Pump Drive Shaft
R e m o v et h e t i m i n g c a s e ,s e e P a g eJ . 2 .
R e m o v et h e c o m p r e s s oar n d a u x i l i a r yp u m p ( i f f i t t e d )a n d
cou pilngs.
R e m o v et h e f u e l i n j e c t i o np u m p , s e e P a g e N . 6 l
W i t h a t w i s t i n gm o t i o n ,w i t h d r a wt h e a u x i l i a r ys h a f t a n d
t h e t w o 1 8 0 " h a l f t h r u s tw a s h e r s s. e e F i q J . 1 0 .
J5
llt:r
it,r;
{l'
19'
llliiSlrttl{
J.10
J.12
R e m o v et h e f u e l p u m p a d a p t o r p l a t e c o m p l e t e w i t h
r u b b e rs e a l i n gr i n g a n d b u s h .
that these be drawn into the block by means of a

s u i t a b l et h r e a d e db a r a n d a d a o t o r s
W i t h d r a wt h e u p p e r t h r u s t c o l l a r c o m p l e t ew i t h p i s t o n
r i n g s e a l ,s e e F i g J 1 1 .
T h e f u e l i n j e c t i o np u m p a n d l u b r i c a t i n go i l p u m p d r i v e
s h a f t c o m p l e t ew i t h w o r m w h e e lc a n n o w b e p u l l e d u p
a n d r e m o v e ds, e e F i g .J 1 1
T h e w o r m w h e e li s s h r u n k o n a n d p u n c h p e e n e dt o t h e
d r i v e s h a f t I n t h e e v e n t o f t h e g e a r r e q u i r i n gr e n e w a t ,
t h e g e a r a n d s h a f t a s s e m b l ys h o u l d b e r e p l a c e d .T h e
I o w e r t h r u s t c o l l a r a n d b u s h w i l l r e m a i ni n i t s l o c a t i o n
i n t h e c y l i n d e rb l o c k a n d c a n b e r e m o v e db y r e m o v i n g
the sumpand lubricatino
gil pump.
W i t h t h e u s e o f a s p e c i a lt o o l P D 1 4 0 w i t h a d a p t o r1 4 0 - 3
t h e t h r u s t c o l l a r a n d b u s h c a n n o w b e w i t h d r a w n ,s e e
Fig J.12 Some earlier enginesdid not have a bush
f itted.
W h e r e n e c e s s a r y ,r e n e w t h e a u x i l i a r yd r i v e s h a f t f r o n t
a n d r e a r b u s h e s i n t h e c y l i n d e r b l o c k . l t ' r sa d v i s a b l e
J.11
To Refit Auxiliary Drive Shaft and Fuel Pump

Drive Shaft see Fig. J.13.
R e f i i t h e l o w e r t h r u s t c o l l a r a s s e m b l va n d o r e s s i n t o
oosition.
The wormwheeland fuel pump drive assembly can
now be fitted.
Fit the upper thrust collar with the piston ring seal
in its location
R e f i t t h e l u b r i c a t i n go i l p u m p a n d s u m p , f i l t i n g w i t h
o i l t o a n a p p r o v e dg r a d e .
F i t t h e f u e l p u r n pa d a p t o rp l a t ea s s e m b l yc, o m p l e t ew i t h
bush sealing ring and joint, so that the timing mark
s c r i b e d o n f l a n g e i s a d j a c e n tt o t h e o u t s i d e s e c u r i n g
s t ud .
Where oil leaks past the adaptorplate "O" ring occur in
service,the "O" ring shouldbe renewedand a joint (Pt No
36822118)fitted betweenthe adaptorplate and the cytinder
block.
J.13
J6
PABTSIDE VIEWON AUX.DRIVEHOUSING
J.15
J.14
Fit the auxiliary drive shaft into position with the

t h r u s t w a s h e r h a l v e sf i t t e d a r o q n d t h e g r o o v e i n t h e
s h a f t ,f i n a l l y l o c a t i n gi n t h e c y l i n d e r b l o c k r e c e s sw i t h
two oppositebutt faces locatedby a dowel, see Fig. J.14
T h e e n d fl o a t o f t h e d r i v e s h a f t i s c o n t r o l l e d b y
the clearance between the thrust washers, (which are
held in positionby the timing case) and the groove
of the drive shaft
T h e e n d f l o a t i s b e t w e e n0 0 0 2 5 i na n d 0 . 0 0 9 i n( 0 . 0 6 4 m m
a n d 0 , 2 3m m ) .
R e p l a c et h e t i m i n g c a s e , t i m i n g g e a r s a n d f u e l p u m p
T h e s p r a yt u b e i s a p u s h f i t i n t h e a u x i l i a r yd r i v e h o u s i n g
a n d s e a l e dw i t h a " D " p l u g
D u r i n g e n g i n e o v e r h a u l ,t h i s s p r a y t u b e s h o u l d b e
r e m o v e da n d c l e a n e d .
New cylinder blocks suppliedas loose parts are not
fitted with this spray tube, therefore when renewing a
c y l i n d e rb l o c k , e n s u r et h a t t h e t u b e i s t r a n s f e r r e df r o m
t h e o l d b l o c k ,o r a n e w o n e f i t t e d ( s e e F i g . J . 1 5 ) .
Checkingthe Timing Gear Backlash

R e m o v e t h e c a m s h a f t g e a r a n d a u x r l i a r yd r i v e g e a r
covers
AuxiliaryDrive Spray Tube

T h e a u x i l i a r yd r i v e g e a r s a r e l u b r r c a t e db y o i l d i r e c t e o
onto them by a spray tube
C h e c k t h e b a c k l a s hb e t w e e nt h e t i m i n g g e a r s u s i n g a
c l o c k g a u g eo r f e e l e rg a u g e s .
T h e b a c k l a s hs h o u l db e 0 . 0 0 3i n ( 0 , 0 8m m ) m i n r m u m .
SECTIONK
Timing
TIMING
K2
Timing Marks
To ResetEngine Timing
W h e n t h e e n g i n e t i m i n g i s s e t a t t h e f a c t o r y ,m a r k i n g s
a r e m a d e o n t h e c r a n k s h a f tg e a r , i d l e r a n d c a m s h a f t
g e a r w i t h t h e e n g i n es e t w i t h N o 1 p i s t o n a t T D . C o n
i t s c o m p r e s s i o sn t r o k e( s e eF i g . K . 1 )
T h e r e m a y b e m a r k i n g so n t h e e n g r n et o e s t a b l i s ht r u e
T D.C but where not, No. 1 piston at T D C on rts
compression stroke can be ascertained by dropping
a v a l v eo n t o N o 1 p i s t o n c r o w n a n d w i t h t h e m e a n so {
a c l o c k g a u g e e s t a b l i s ht h e m a x i m u m l i f t o f t h e v a l v e
w h e n t h e v a l v e so f N o . 6 c y l i n d e r s h o u l d b e r o c k i n g ,
I t s h o u l d b e n o t e d t h a t F i g K . 1 h a s b e e n p r e p a r e dt o
s h o w t h e m a r k i n g so n t h e t i m i n g g e a r s .T h e c a m s h a f t
a n d f u e l p u m p g e a r s a r e n o t n o r m a l l yf i t t e d u n t i l t h e
t i m i n gc a s eh a s b e e n r e p l a c e d .
I t i s a s s u m e dt h a t t h e t i m i n g c a s e a n d a l l t h e t i m i n g
g e a r s h a v e b e e n r e m o v e d a n d r e q u i r e r e p l a c i n gw i t h
t h e k n o w l e d g et h a t t h e v a l v e a n d f u e l p u m p t i m i n g
w i l l b e t o t h e o r i g i n a ls e t t i n g .
Fuel Pump Timing

When the fuel pump is removed,a machined slot
will be noted in the top of the fuel pump drive shaft
a n d a s l o t a p p r o x i m a t e l y%i n ( 3 , 2m m ) w i d e i n t h e
a d a p t o rp l a t ew i l l a l s o b e s e e n ( F i g . K . 2 ) .
With No 1 piston set at T D C on its compression
s t r o k e ,t h e s et w o s l o t ss h o u l db e i n l i n e
O n t h e m o u n t i n gf l a n g e o f t h e f u e l p u m p i s a s c r i b e d
Irne and a further line is scribed on the fuel pump
a d a o t o rD l a t e
W h e n t h e f u e l p u m p i s f i t t e d ,t h e s e t w o m a r k s s h o u l d
b e i n a l i g n m e n t( s e eF i g . K 3 )
K.1
T o r e s e t t h e t i m i n g t o t h e o r i g i n a l m a r k i n g s ,p r o c e e d
as follows:
Removethe rocker assembly,push rods and atomisers
T u r n t h e e n g i n ec r a n k s h a fut n t i l N o s 1 a n d 6 p i s t o n sa r e
at T.D.C.
That this has been obtarned may be checked by
observingthat the keyway for the crankshaftgear is at
T D C
P l a c et h e t w o i d l e r g e a r s i n p o s i t i o no n t h e i r r e s p e c t i v e
hubs, making sure that the double line timing mark
o n t h e l e f t h a n d g e a r i s o p p o s i t et h e s i n g l e l i n e t i m i n g
m a r k o n t h e c r a n k s h a f gt e a r ( s e eF i g K 1 ) . T h e n t i g h t e n
t h e s e c u r i n gn u t s t o t h e c o r r e c t t o r q u e ( s e e p a g e 8 . 2 ) .
R e p l a c et h e t r m i n g c a s e a n d s e c u r e i t t o t h e c y l i n d e r
block
F i t c r a n k s h a f pt u l l e ya s d e t a i l e do n P a g e H 6
With the engine still in the T.D C position,refit the
c a m s h a f tg e a r w i t h t h e d o u b l e d o t t i m i n g m a r k o p p o s i t e
t h e s i n g l ed o t t i m i n g m a r k o n t h e i d l e r g e a r .
D r a wg e a ro n t o c a m s h a f at n d f i t w a s h e r ,t a b w a s h e r ,s h i m
w a s h e ra n d r e t a i n i n gs e t s c r e w T i g h t e n s e t s c r e wt o t h e
correcttorque (seepageB 2) and lock with tab washer
T I M I N GK 3
K.2
K.3
W i t h t h e e n g i n es t i l l a t T . D . C t u r n t h e f u e l p u m p d r i v e
s h a f t u n t i l t h e m a c h i n e ds l o t i n t h e f u e l p u m p d r i v i n g
h u b i s i n l i n e w i t h t h e m a c h i n e ds l o t i n t h e f u e l o u m o
a d a p t o rp l a t e( s e eF i g K 2 ) .
F i t t h e f u e l p u m p d r i v eg e a r w i t h t h e p a r t n u m b e r t o t h e
f r o n t s o t h a t t h e t h r e e s e t s c r e wh o l e s c o i n c i d e w i t h
the holes in the fuet pump drive shaft when it is in
m e s hw i t h t h e i d l e rg e a r a n d s e c u r ei n t h i s p o s i t i o n .
E n s u r ew h e n f i t t i n g t h e g e a r , t h a t t h e t w o m a c h i n e d
s l o t s r e m a i ni n l i n e
F i t t i m i n g g e a r c o v e r st o t h e t i m i n g c a s e .
R e p l a c et h e f u e l p u m p e n s u r i n g t h a t t h e s c r i b e d l i n e
o n i t s m o u n t i n gf l a n g e c o i n c i d e sw i t h t h e s c r i b e d l i n e
o n t h e f u e l p u m p a d a p t o rp l a t e ( s e e F i g . K 3 ) .
W i t h l a t e r B o s c h f u e l p u m p s ,t h i s s c r i b e d l i n e i s o n t h e
t o p o f t h e m o u n t i n gf l a n g e .
R e p l a c ea t o m i s e r sa n d f u e l p i p e s .
(C.A.v. Pump)
CheckingFuel Pump Timing

Ensuresthat No. 1 pistonis at T.D.C,on compression.
The valveson No, 6 cylindershouldbe rocking.
R e m o v et h e f u e l i n j e c t i o n p u m p a n d e n s u r e t h a t t h e
s l o t i n t h e f u e l p u m p d r i v i n g h u b i s i n a l i g n m e n tw i t h
t h e s l o t i n t h e f u e l p u m p m o u n t i n gf l a n g e .
lf these slots are not in line, the necessaryadjustment
shouldbe made on the fuel pump drive gear,through
t h e a p e r t u r ei n t h e t i m i n g c a s e
T h i s a d j u s t m e n tm a y b e e f f e c t e db y s l a c k e n i n go f f t h e
t h r e e g e a r s e c u r i n gs e t s c r e w sa n d t u r n i n g t h e a u x i l i a r y
drive shaft by means of the setscrews
W h e n t h e t i m i n g i s f o u n d t o b e c o r r e c t ,r e f i t t h e f u e l
p u m p e n s u r i n gt h e s c r i b e dl i n e o n t h e m o u n t i n gf l a n g e
c o i n c i d e sw i t h l t h es c r i b e dl i n e o n t h e f u e l p u m p a d a p t o r
plate (see Fig. K.3)
R e p l a c e r o c k e r a s s e m b l ya n d a d j u s t v a l v e c l e a r a n c e
CheckingValveTiming
1 . T u r n t h e c r a n k s h a f ut n t i l t h e v a l v e so n N o . 6 c y l i n d e r
a r e r o c k i n g . I n t h i s p o s i t i o n ,s e t t h e c l e a r a n c eo n
N o . 1 i n l e t v a l v e t o o n e o f t h e f o l l o w i n gc l e a r a n c e s
a c c o r d i n gt o t h e p a r t n u m b e r w h i c h i s s t a m p e do n
the rear of the camshaft:
Camshaft Part No.
31416207
| 31416222
31416302
31416303
31416304
Clearance
0 . 0 5 1i n ( 1 , 3 0 m m )
0 . 0 2 6 i n( 0 , 6 6 m m )
0 0 5 1i n ( 1 , 3 0 m m )
0 0 4 7 i n( 1 , 1 9 m m )
0 . 0 6 0 i n( 1 , 5 2 m m )
2. Turn the crankshaftin the normaldirectionof rotationuntil

the pushrodof No. 1 inletvalvejusttightens.
3. Checkthat Nos. 1 and 6 pistonsare at T.D.C.The valve
timingtoleranceis plusor minus2l/2".
4. When the valve timingis foundto be correct,resetvalve
clearance
to 0.008in (0,20mm)cold.
.lncludes
I6.3544 NorthAmericavehicleengine.
Note: Thereis no adjustmentprovidedfor valvetiming.lf the
timingis foundto be incorrect,
thenthe gearscan onlybe one
or moreteeih out of correctmesh.
6 3544SeriesWorkshopl\y'anual,
January1986
(AlternativeMethod-C.A.V. Fuel Pumps only)

T h e r ei s a r o t o r i n t h e p u m p b e a r i n ga n u m b e ro f s c r i b e d
l i n e s ,e a c h o n e h a v i n ga n i n d i v i d u a l e t t e r( s e e F i g K . 4 )
A t i m i n g c i r c l i p i s p o s i t i o n e di n s i d e t h e p u m p w h i c h
has to be set so that when the appropriatescribed line
o n t h e f u e l p u m p r o t o ra l i g n sw i t h t h e s t r a i g h te d E eo f t h e
c i r c l i p , i t d e n o t e s c o m m e n c e m e n to f i n j e c t i o n ( s t a t i c
timing).
T o s e t t h e t i m i n g c i r c l i p ,i t i s n e c e s s a r yt o r e m o v et h e
p u m pf r o m t h e e n g i n ea n d f i x t h e p o s i t i o no f t h e c i c c l i pb y
connectingNo 1 cylinder outlet connection (X) on
t h e p u m p t o a n a t o m i s e rt e s t e ra n d p u m p u p t o 3 0 a t m
4 4 0 l b t / i n 2o r ( 3 1k g f / c m r ) T u r n t h e p u m p b y h a n d i n t h e
n o r m a ld i r e c t i o no f r o t a t i o nu n t i l i t l o c k su p . T h e s q u a r e d
e n d o f t h e c i r c l i ps h o u l dn o w b e a d j u s t e du n t i l i t l i n e su p
w i t h t h e l e t t e r" F " o n t h e p u m p r o t o r
E n s u r et h e f u e l p u m p i s c o r r e c t l yf i t t e d w i t h t h e s c r i b e d
l i n e o n t h e m o u n t i n g f l a n g e c o i n c i d i n gw i t h t h e m a r k
o n t h e f u e l p u m p a d a p t o rp l a t e
Positionthe crankshaftso that No 1 piston is at T.D.C
on its compressionstroke.
Removethe rocker cover.
R e m o v et h e c o l l e t s ,s p r i n g c a p a n d s p r i n g sf r o m N o . 1
inletvalveand allowthe valveto reston top of the oisron
TIMING
K4
Repositionthe valve stem seal to the collet groove to

p r e v e n t h e v a l v ef r o m d r o p p i n gi n t o t h e c y l i n d e r .
With the aid of a clock gauge in contact with the end
of the valve now sitting on No. 1 piston, it will be
necessaryto position the crankshaft so that the piston
w i l l b e a t i t s s t a t i ct i m i n g p o i n t ( s e eP a g eB 1 0 ) .
T o d o t h i s , t u r n t h e c r a n k s h a f it n t h e o p p o s i t ed i r e c t i o n
t o n o r m a l r o t a t i o n ,a p p r o x i m a t e l ya n e i g h t h o f a t u r n
B T . D C a n d t h e n f o r w a r d u n t i l t h e r e q u i r e dp o s i t i o n
i s r e g i s t e r e do n t h e c l o c k g a u g e T h i s e n a b l e s t h e
b a c k l a s hi n t h e t i m i n g g e a r st o b e t a k e n u p
R e m o v e t h e f l a t i n s p e c t i o np l a t e o n t h e f u e l p u m p
e n a b l i n gt h e r o t o r t o b e s e e n .

(AlternativeMethod -
Bosch Fuel Pumps only)

E n s u r e f u e l p u m p i s c o r r e c t l yf i t t e d t o e n g i n e a s d e s c r i b e d u n d e r " T o R e s e t E n g i n eT i m i n g " o n P a g e K 2 .
W i t h t h e r o c k e r c o v e r r e m o v e d s, e t t h e e n g i n et o T . D . C .
N o . 1 c y l i n d e r c o m p r e s s i o n ,i . e . , t h e v a l v e s o f N o . 6
c y l i n d e rr o c k i n g .
T h o r o u g h l yc l e a n t h e f u e l p u m p a r o u n d t h e v e n t p l u g
i n t h e h v d r a u l i ch e a d .
Removethe centralplug from the end of the pump (C, Fig.
N.14) andfit one of the timingtoolassemblies
givenbelow:Bosch: Body 1688 130 045, Extension1683 458 019 and
Dial lndicator1687233 012
Churchill:AdaptorMS107and DialIndicator
SM991A.
Ensuredirtdoesnot enterthe pump.
Ensurethat the dial indicatorplungeris depressedat least
0 . 1 1 8 i n( 3 m m ) t o c o v e r t h e p l u n g e rl i f t w h i c h i s 0 . 1 1 0 i n
(2,Bmm).
Turnthe enginein eachdirectionto obtainB.D.C.of the pump
plungerand setthe dialindicator
to zeroat thispoint.
K.4
(C.A.V.Pump)
With No. 1 piston at the static timing point on its

compression
s t r o k e ,t h e s c r i b e dl i n e o n t h e r o t o r m a r k e d
'F'should
a l i g nw i t h t h e s t r a i g h e
t d g eo f t h e t i m i n gc i r c l i p .
S e eF i g .K 4 .
lf the timing marks do not align, releasethe nurs
s e c u r i n gt h e f u e l p u m p a n d t w i s t t h e p u m p b o d y i n
t h e r e q u i r e dd i r e c t i o n u n t i l t h e m a r k s a l i g n F u r t h e r
a d j u s i m e n tc a n b e m a d e b y t u r n i n g t h e a u x i l i a r yd r i v e
s h a f t ,a f t e rt r r s tr e l e a s r n tgn e a u x i l i a r yd r i v eg e a r s e c u r i n g
setscrews
l f a f t e r b o t h t h e s e a d l u s t m e n t s t, h e t i m i n g m a r k s d o
n o t a l i g n , i t c o u l d m e a n t h e a u x i l i a r yd r i v e g e a r h a s
f i t t e di n c o r r e c t l y
K.5
R e p o s i t i o nt h e e n g i n e a t T . D . C .N o 1 c y l i n d e rc o m p r e s sion and using tool No. 61188, remove the collets,

spring cap and springs from No. 1 inlet valve (see
F i g . K . 5 ) a n d a l l o w t h e v a l v et o r e s t o n t h e t o p o f t h e
piston. Reposition the valve stem seal to the collet
groove to prevent the valve from dropping into the
cylinder.
P o s i t i o na d i a l i n d i c a t o rw i t h t h e p l u n g e rr e s t i n go n t o p o f
the valve stem, determineexact T D.C. position and zero
the dial indicator.
TIMING
K5
K.7
K.6
T u r n t h e c r a n k s h a f it n t h e o p p o s i t ed i r e c t i o nt o n o r m a l
rotation approximately'/eof a turn and therr turn in the
normal direction of rotation until the dial indicator
i n d i c a t e tsh a tt h e p i s t o ni s0 12 5i n ( 3 , 1B m m ) B . T D C .
A t t h i s p o s i t i o n ,t h e d i a l i n d i c a t o r o n t h e f u e l p u m p
s h o u l d r e a d 0 . 0 3 9 4i n ( 1 m m ) - s e e F i g . K . 6 .
Adjust timing as necessaryby releasingthe three screws
s e c u r i n gt h e a u x i l i a r yd r i v e g e a r t o t h e a u x i l i a r yd r i v e
shaft.
l f t h e p l u n g e rl i f t i s i n e x c e s so f 1 m m , t u r n t h e a u x i l i a r y
d r i v es h a f tc l o c k w i s ea n d t h e n a n t i - c l o c k w i s e
u n t i l 1m m
l i f ti s o b t a i n e dS e c u r e t h eg e a re n s u r i n gt h e g e a rb a c k l a s h
i s t a k e n u p b y h o l d i n gt h e g e a r a g a i n s tn o r m a l d i r e c t i o n
of rotation
l f t h e p l u n g e lri f ti s l e s st h a n 1 m m , t u r n t h e a u x i l i a r d
yrive
s h a f ta n t i - c l o c k w i suen t i l 1 m m l i f t i s o b t a i n e d S e c u r er n e
g e a r e n s u r i n gt h e g e a r b a c k l a s hi s t a k e n u p b y h o l d i n g
t h e g e a r a g a i n s t h e n o r m a ld i r e c t i o no f r o t a t i o n .
R e c h e c kt i m i n g a s p r e v i o u s l yd e t a i l e d
W h e n t i m r n g i s c o r r e c t ,t u r n t h e e n g i n e i n t h e n o r m a l
d i r e c t i o no f r o t a t i o nu n t i l N o . 1 p i s t o n i s a t T . D . C . R e f i t
valvestem oil seal,valve springs,spring cap and collets.
Resetvalveclearanceto 0 008in (0,20mm).
Removethe specialtiming tool from the fuel pump and refit
the plug,lf the largeinspectionplugwas removed,tightenit to
4Olbfft(54Nm) s,skgfm or if the small vent plug was removed,tightenit to Tlbfft (10Nm) 1,0kgfm. lf ihe lowpressure
fuel pipes have been disturbed,bleed the system as describedon PageN.7.

( U s i n gC h u r c h i l T
l ool MS.67B- See Fig. K.7)
W i t h t h e e n g i n e p o s i t i o n e dw i t h N o 1 p i s t o n a t T . D . C .
compressionstroke, the tool is substitutedfor the fuel
i n j e c t i o np u m p .A s t h e e n g i n ei s a t T . D . C . ,t h e p o i n t e ro n
t h e t o o l i s s e t a t t h e r e l e v a n tf u e l p u m p m a r k i n ga n g l e ,
plus half the static timing angle and then the timing
t r a i n i s s e t t o c o r r e s p o n dt o t h e t i m i n g m a r k o n t h e f u e l
injectionpump adaptor plate.
January1986
6 3544SeriesWorkshopl\ilanual,
To Gheck Engine MarkingAngle

Position the engine with No. 1 piston at T D.C.
c o m p r e s s i o an n d u s i n gt o o l N o . 6 11 B B ,r e m o v et h e c o l l e t s ,
s p r i n g c a p a n d s p r i n g sf r o m N o . 1 i n l e t v a l v e a n d a l l o w
the valveto rest on the top of the piston. Repositionthe
inletvalvestemsealto the colletgrooveto preventthe valve
f r o m d r o p p i n gi n t o t h e c y l i n d e r .P o s i t i o na d i a l i n d i c a t o r
with the plungerrestingon top of the valvestem,determine
t h e e x a c tT . D . C .o o s i t i o n
R e m o v et h e f u e l i n j e c t i o np u m p .
R e l e a s es c r e w ( 5 ) - F i g . K . 7 - a n d p o s i t i o ns p l i n e d
s h a f t ( 6 ) s o t h a t i h e l a r g e r s p l i n e d a d a p t o ri s t o t h e
front of the tool
E n s u r et h a t t h e s l o t t e dp o i n t e r( 2 ) i s p o s i t i o n e dw i t h t h e
slot to the f ront of the tool and chamferedsides of the slot
are outwards.At this stage,the slotted,end of the pointer
should be kept well back from the front of the body.
Ensure that the flat in the washer fitted behind Dointer
securingscrew (3) is locatedoverpointer
Releasethe bracket screw (4) and set bracket so that
t h e c h a m f e r e de d g e i s i n l i n e w i t h t h e r e l e v a n te n g i n e
checkingangle.This angle can be obtainedby reference
to the fuel pump setting code and table given on
P a g e8 1 1 .
Fit timingtool to the enginein the fuel pump position
e n s u r i n gf i r s t l yt h a ts p l i n e ds h a f tw i t h m a s t e rs p l in e i s f u l l y
locatedin pump drive shaft and then that the registerof
tool is seated in fuel pump locating aperture Lock
s p l i n e ds h a f t i n t o o l l f p o i n t e ri s 1 B 0 of r o m t i m i n g m a r k ,
e n g i n e i s p r o b a b l yo n i t s w r o n g s t r o k e , i n w h i c h c a s e ,
removethe tool and set the engine on correct stroke
S l i d e t h e s l o t t e dp o i n i e r d o w n w a r d ss o t h a t t h e e n d o f
p o i n t e ra b u t s f l a n g e- s e e F i g . K . 8
T u r n t i m i n g t o o l b y h a n d i n o p p o s i t ed i r e c t i o nt o p u m p
rotation(shown on pump nameplate)to take up backlash
a n d t h e n c h e c kt h a t t i m i n g m a r k o n f u e l p u m p a d a p t o ri s
i n l i n e w i t h s l o t o f p o i n t e r .l f t i m i n g m a r k d o e s n o t a l i g n ,
t h e p o s i t i o no f t h e a u x i l i a r yd r i v es h a f ts h o u l db e a l t e r e d
r e l a t i v et o i t s d r i v e g e a r .T h e h o l e s i n t h e a u x i l i a r yd r i v e
gear are slottedto allow for adjustment
W h e ne n g i n et i m i n gi s c o r r e c t r, e m o v et h et o o l .
W h e r e n e c e s s a r yt,h e f u e l p u m p m a r k i n ga n g l e c a n b e
checked by using timing tool as described later
Refitf uel pump to engineas given on PageN.6.Refit No. 1
inletvalvestem seal,valvesprings,spring cap and collets
Then set valve clearanceto 0 008 in (0,20mm).
TIMING
K6
K.9
K.8
Checking Fuel Pump Marking Angle

R e l e a s es c r e w ( 5 ) - F i g . K . 7 - a n d r e m o v es p l i n e d
shaft (6)
Ensureslotted pointer (2) is positionedwith slot to rear
of tool and chamferedside of slot outwards At this stage,
slotted end of pointer should be kept well back towards
b o d y o f t o o l E n s u r et h a t f l a t i n w a s h e r f i t t e d b e h i n d
pointer securingscrew (3) is locatedover side of pointer.
W i t hC . A . V p u m p s ,c o n n e c tN o 1 o u t l e tc o n n e c t i o no f t h e
p u m p ( m a r k e d" X " ) t o a n a t o m i s e rt e s t e ra n d p u m p u p t o
3 0 a t m 4 4 0 l b/fi n 2 o r ( 3 1 k g f l c m r ) l f a p r e s s u r i s i n gv a l v e
is fitted, this must be removed.
Release bracket screw (4) - see Fig. K 7 - and set
b r a c k e t s o t h a t t h e c h a m f e r e de d g e i s i n l i n e w i t h
r e l e v a n tp u m p m a r k i n ga n g l e ( s e e P a g e B 1 1 ) .
P o s i t i o nt i m i n g t o o l o n p u m p d r i v e w i t h m a s t e r s p l i n e s
engaged and tool locatedon spigot - see Fig. K.g.
W i t h C A V p u m p s ,t u r n t h e p u m p i n t h e n o r m a l d i r e c t i o n o f r o t a t i o na s s h o w n o n n a m e p l a t e u n t i l i t " l o c k s
up".
With Bosch pumps, ensure that the keyway in the fuel

p u m p d r i v e s h a f t i s i n l i n e w i t h N o 1 o u t l e t m a r k e d" D "
o n t h e h y d r a u l i ch e a d .
Removethe centralplug from the end of the pump (C, Fig.
N.14)and fit one of tli're
givenbelow:timingtoolassemblies
Bosch: Body 1688 130 045, Extension1683 458 019 and
Dial lndicator1687233O12.
Churchill:AdaptorMS107,and DialIndicator
SM991A
Ensuredirtdoesnot enterthe pump.
Turn the pump againstthe normaldirectionof rotationano
zerothe dialindicatorwhenthe plungeris at B.D.C.Thenturn
pump in normal directionof rotationuntil 0 0394in (1mm) of
liftis obtainedon the pumpplunger.
In thesepositions(forbothC.A.V.and Boschpumps)slidethe
pointer(2) of the timingtool - Fig. K.7 - forwarduntilit is
halfwayover the pump flange and check that timing mark on
the f langeis centralto the slotin the pointer- see Fig.K.9.
lf necessary,removeincorrectlypositionedmark and make a
new markin the correctpositionon the pumpflange.
Removetimingtool from Bosch pumpsand refitthe plug.lf
the large inspectionplus was removed,tighten it to 4olbfft
(54Nm) 5,5kgfm or, if the small vent plug was removed,
tightenit to Tlbfft (10Nm) 1,0kgfm).
January1986
SECTIONL
LubricatingSystem
@
g
@
:-44
- - R O G K E-R
- -_ S H A F T- --_ A S S E M B L-Y -
GOOLI]{GJET
AUXITIARY
DRIVE
L.1
Note: Piston cooling is only applicable to mosr

t u r b o c h a r g e de n g i n e s e x c e p t c u r r e n t T 6 . 3 5 4 4 e n g i n e s
f i t t e d t o g e n e r a t i n gs e t s a n d a n o i l c o o l e r i s n o t a l w a y s
f i t t e dt o n a t u r a l l ya s p i r a t e de n g i n e s .B y - p a s sv a l v e sa r e
not incorporated
i n o i l c o o l e r sf i t t e dt o n a t u r a l l ya s p i r a t e d
engrnes
GAttERY
LUBRICATINGSYSTEM
L3
Oil Circulation
T h e l u b r i c a t i n go i l p u m p d r a w s o i l t h r o u g h t h e s u c t i o n
pipe and strainerto an oil cooler, cooled by water from
t h e e n g i n e c o o l i n g s y s t e m .O i l c o o l e r sa r e n o t a l w a y s
fitted to naturallyaspiratedengines. From the oil
c o o l e r ,o i l p a s s e st h r o u g h a t u l l f l o w f i l t e r t o t h e m a r n
p r e s s u r er a i l d r i l l e d t h e l e n g t h o f t h e c y l i n d e r b l o c k .
D r i l l i n g si n t h e c r a n k c a s ew e b s f e e d o i l f r o m t h e m a r n
g a l l e r yt o t h e m a i nb e a r i n g sa n d d r i l l i n g si n t h e c r a n k s h a f t
carry oil to the big-end bearings Through drillings
in Nos.1,3,5 and 7 crankcase
w e b s ,o i l p a s s e sf r o m
t h e m a i n b e a r i n g st o l u b r i c a t et h e c a m s h a f tb e a r i n g s .
N o 2 c a m s h a f tb e a r i n gs u p p l i e sa c o n t r o l l e df e e d o f o i l
to the rocker shaft assemblywhich escapesthrough a
small bleed hole in each rocker lever to lubricate the
v a l v e sa n d s p r i n g s .
With most turbochargedengines,the pistonsare cooled by
lubricatingoil being sprayed on their undersidesby piston
coolingjets.
L.2
Pistons fitted to naturally aspirated engines are not

cooled and cooling jets are not fitted.
The feed for the piston cooling jets is controlled by a
two stage pressure relief valve situated after the oil
cooler and comes into operationat a specifiedpressure
after oil is flowing f reelyto the main working parts of the
engrne.
L u b r i c a t i o nf o r t h e t i m i n g g e a r s i s t a k e n f r o m t h e o i l
passagesconnecting the pressure rail with the front
m a i n b e a r i n ga n d a u x i l i a r yd r i v e
T h e t w o i d l e r g e a r h u b s i n t e r s e c t h e s ed r i l l i n g sa n d o i l
i s p a s s e dt h r o u g h t h e h u b s t o r a d i a l d r i l l i n g s i n t h e
i d l e r g e a r st o l u b r i c a t et h e t e e t ho f t h e g e a r t r a i n .
T h e a u x i l i a r yd r i v e s h a f t b e a r i n g sa r e l u b r i c a t e db y a
d r i l l i n g f r o m t h e p r e s s u r er a i l t o t h e f r o n t a u x i l i a r y
d r i v es h a f tb e a r i n gT
. h e o i l t h e n p a s s e sa r o u n da g r o o v e
i n t h e b e a r i n gj o u r n a l a n d t h r o u g h a f u r t h e r d r i l l i n g
a l o n gt h e o u t e r s i d e o f t h e a u x i l i a r yd r i v eh o u s i n gt o t h e
r e a ra u x i l i a r yd r i v es h a f tb e a r i n g
Oil Strainer
T h e o i l s t r a i n e ri s p a r t o f t h e o i l p u m p s u c t i o n p i p e .
T h e r e i s n o p e r i o d i c s e r v i c i n go n t h i s s t r a i n e r b u t i t
should be cleaned wheneverthe sump is removed.
To RemoveOil Pump
Remove the sump and then the setscrews securing
the oil pump to cylinder block and withdraw the oil
p u m p ,s e e F i g . L . 2
To Dismantle Oil Pump, see Fig. L.3

Remove the suction pipe and bottom cover of the oil
pump.
L u b r i c a n tf o r t h e u p p e r f u e l p u m p b e a r i n g i s a l s o
t a k e nf r o m t h i s d r i l l i n g
A l s o c o n n e c t e dw i t h t h e o u t e r d r i l l i n g i s a s m a l l s p r a y
tube, which directs oil onto the wormwheel ano
wormgear
O i l p r e s s u r ei s c o n t r o l l e db y a p r e s s u r er e l i e fv a l v et h a t
r e t u r n se x c e s so i l t o t h e s u m p .
T h e f i l t e r i s p r o v i d e dw i t h a b y - p a s sf a c i l i t yi n t h e e v e n t
of blockage.
O i l c o o l e r sf i t t e d t o n a t u r a l l ya s p i r a t e de n g i n e s d o n o t
h a v e b y - p a s sv a l v e s .
To RemoveSump
L o w e r t h e s u m pb y r e l e a s i n g
a l l f l a n g es e t s c r e w a
s ndnuts
To ReplaceSump
P l a c et h e s u m p i n p o s i t i o na n d s e c u r e b y f a s t e n i n gt h e
n u t so n t h e f o u r s t u d s l o c a t e di n t h e b r i d g ep i e c e s .
The securingsetscrewscan now be inserted
Tighten the setscrewsand nuts to a torque of 15lbfft
( 2 , 1 k gm
f ) or 20llm.
6 3544SenesWorkshopi/anual,January1986
L.3
L4
L.4
L.6
The shaft, inner and outer rotors can now be removed
To Re-assembleand Refit Oil Pump
Inspectionof Oil Pump
With the inner and outer rotors fitted into the pump
b o d y , r e f i t t h e e n d c o v e r w i t h t h e l o c a t i n gd o w e l s i n
p o s i t i o na n d w i t h t h e j o i n t f a c e ss m e a r e dw i t h a s u i t a b l e
j o i n t i n gc o m p o u n d .
The innerrotormay have4 or 6 lobesand the outerrotor5 or

7lobes
Inspect the rotors for cracks or scores.
I n s t a l lt h e d r i v e a n d d r i v e n r o t o r s i n t h e p u m p b o d y .
The two sections of the outer rotor can be fitted in
any oroer.
Check clearancesgiven on Page 89, between inner
and outer rotors,see Fig. L.4, rotor end float,see Fig. L 5,
and clearancebetweenouter rotor and pump body, see
Fig 1.6
These clearancesare applicableto a new pump and are
t o b e u s e da s a g u i d e .
l f t h e p u m p i s f a u l t y ,i t m u s t b e r e p l a c e da s a c o m p l e t e
u n i t a s p a r t s a r e n o t s u p p l i e di n d i v i d u a l l y .
P r i m et h e p u m p w i t h c l e a nl u b r i c a t i n go i l
T h e o i l p u m p a s s e m b l ya n d j o i n t c a n n o w b e f i t t e d i n t o
i t s l o c a t i o ni n t h e c y l i n d e rb l o c k a n d s e c u r e dw i t h t w o
setscrewsand washers
R e f i tt h e s u c t i o np i p e a n d s t r a i n e r
R e p l a c et h e s u m p , a n d r e f i l l w i t h o i l t o a n a p p r o v e d
g rade.
To Removeand Dismantlethe Pressure

ReliefValveAssemblysee Fig. L.7
R e m o v et h e s u m p a n d t h e n t h e p i p e f r o m v a l v e t o
t h e c y l i n d e rb l o c k ( T 6 3 5 4 4o n l y ) .
Release the two securing setscrews and remove the
valve
R e m o v et h e c i r c l i p w h i c h w i l l e n a b l et h e s p r i n g s e a t ,
s p r i n ga n d p l u n g e rt o b e w i t h d r a w nf r o m t h e v a l v eb o r e .
i%"
ffi &?$&WWS
t :
L,7
To Assembleand Retit the Pressure
Relief Valve Assembly
R e p l a c et h e p l u n g e r ,s p r i n g a n d s p r i n g s e a t i n t h e v a l v e
bore and refit the circlip.
LUBRICATINGSYSTEM
Using a new joint, refit the valve assembly to the

c y l i n d e rb l o c k .
R e fi t p i p ef r o m v a l v et o t h e c y l i n d e rb l o c k .( T 6 3 5 4 4o n l y ) .
With turbochargedengines,the f irst blow off stageto feed
the piston cooling jets should reach a steady flow at
30/37lbt/in2 12,11
/2,60k9t/cm2) or 2O7/255kN/m2, relief
valve flow should commence at 50/60lbt/in, B.S2/
4,22kgf/ cmzl ot 343/414 kN/ m,.
W i t h n a t u r a l l ya s p i r a t e de n g i n e s t, h e r e i s o n l y o n e o r o w
off stage, when the relief valve flow should commence
at 50/60|bf/in, (3,52/ 4,22kgI/c m,) o r 343/ 414kN/ mz
R e f i tt h e s u m p a n d f i l l w i t h l u b r i c a t i n go i l t o a n a p p r o v e o
g raoe.
Oil Coolers
L5
To RemoveOil Cooler
Drain the cooling system also the coolant from the
c o o l e rb y r e m o v i n gt h e d r a i n p l u g . D r a i n t h e l u b r i c a t i n g
o i l f r o m t h e c o o l e r b y r e m o v i n gt h e o i l d r a i n p l u g
Disionnect the cooler inlet and outlet connections
Removethe oil filter assembly(wherefitted) or canisters
f r o m t h e c o o l e rc a s t i n g .
Releasethe five setscrewssecuring the cooler to the
adaptoror cylinder block and removethe cooler.
To DismantleOil Gooler
TurbochargedEngines-Lefl Hand Mounting
( s e eF i g s .L B a n d L . 9 )
Remove three nuts and washers securing the flanged
tube stack to the cooler bodv
O i l c o o l e r sa r e f i l l e dt o t u r b o c h a r g e de n g i n e sa n d s o m e
n a t u r a l l ya s p i r a t e de n g i n e s
Four different types of cooler are utilised. For turooc h a r g e de n g i n e sh a v i n gt h e c o o l e r o n t h e l e f t h a n d s i d e
o f t h e e n g i n e ,s e e F i g s .L 8 a n d L . 9 .
T h e o i l c o o l e rf i t t e dt o t h e r i g h th a n ds i d eo f t u r b o c h a r g e d
e n g i n e si s s h o w n i n F i g L 1 0 . T h i s c o o l e r h a s t w o f i l t e r
canistersfitted on the top of the cooler and the coorer
i ncorporatesthe oi I pressurereliefvalve.
Where an oil cooler is fitted to the left hand side of
n a t u r a l l ya s p i r a t e d
e n g i n e st,h i s i s s h o w ni n F i g .L 1 1 ,a n d
where fitted to the right hand side of naturallyaspirated
e n g i n e st,h e n t h i s i s s h o w n i n F i g L 1 2 .
Oil passesthrough the cooler and is cooled by water
f lowing through the tubes A valve is incorporated
into the headcastingwhich allows oil to by-pass the
cooler in the event of a restriction,where the oil coorer
is fitted to the left hand side of turbochargedengines
Oil coolers fitted to the right hand of turbocharged
e n g i n e s o r e i t h e r s i d e o f n a t u r a l l ya s p i r a t e de n g i n e s
do not have by-passvalves.
Withdrawthe tube stackf rom out of the coolerbodv.

R e m o v et h e " O " r i n g s
Removeplug and washer from the cooler bypass valve.
W i t h d r a ws p r i n ga n d p i s t o n .
To Re-assembleOil Cooler
TurbochargedEngines- Left Hand Mounting
New "O" rings must always be used.
L i g h t l yo i l t h e r i n g s a n d t h e i r r e s p e c t i v el o c a t i o n s .
T h e f i r s t" O " r i n g s h o u l dt h e n b e f i t t e dt o t h e f l a n g e de n d
o f t h e t u b e s t a c k , b y p l a c i n g i t o v e r t h e o p p o s i t ee n d
and sliding it over the full length of the stack until
its locationis reached.
The second "O" ring may now be fitted into the groove
o n t h e u n p o r t e de n d o f t h e t u b e s t a c k .
1
L.8
1. Coolant Drain Plug
2. LubricatingOil Drain Plug
Carefully insert the tube stack into the cooler body

until the flange locates onto the studs and secure with
spring washersand nuts
The bypass valve assembly may now be refitted into
the headcasting.
R e f i tt h e w a t e ra n d o i l d r a i np l u g s
LUBRICATING
SYSTEM L6
1.10
To DismantleOil Cooler
TurbochargedEngines- RightHand Mounting
( s e eF i g . L . 1 0 )
Removerear clamp plate.
Removerear "O" ring.
Unscrewthree nuts at front of cooler and withdraw ruoe
stack out of front of cooler body complete with front
platewhich is integralwith tube stack
R e m o v ef r o n t " O " r i n g .
To remove oil pressure relief valve, remove end plate
and pipe (which relievesoil to crankcase)and witnoraw
s p r i n ga n d p l u n g e r .
To re-assemblecooler, reverse order of disman|ing,
N e w " O " r i n g ss h o u l d b e u s e d w h i c h s h o u l d b e l i g h f l y
oiled beforefitting.
1 . C o o l a n tD r a i nP l u g
NaturallyAspirated Engines( s e eF i g .L . 1 2 )
Right Hand Mounting
Removesinglescrew and locking tab at top of cooler.

Remove three screws at bottom of cooler and remove
c l a m pp l a t e
P u s ht u b e s t a c kd o w n a n d r e m o v et o p , , O , r, i n g .
Removetube stack out of top of cooler body and remove
b o t t o m" O " r i n g .
To re-assemblecooler, reversethe order of dismaniling.
N e w " O " r i n g s s h o u l d b e u s e d ,t h e s eb e i n g l i g h i l yo i l e d
beforefitting
With this cooler, where the coolant feed is taken from
the side of the cylinderblock, if it is necessaryto replace
t h e a d a p t o rw h i c h i s a p u s h f i t i n t h e b l o c k ,t h e n i t m u s t
b e f i t t e d u s i n g L o c t i t e R e t a i n i n gC o m p o u n dG r a d e 7 5 .
L.11
To Test an Oil Cooler

Suitable adaptors, incorporating pressure connecttons

must be fabricated to blank off oil ports and water
connectrons
NaturallyAspirated
Engines- Lefi Hand Mounting
( s e eF i g . 1 . 11 )
Remove screw complete with locking tab at each end
of the cooler.
Slidethe tube stackto the left and removethe right hand
s i d e" O " r i n g .
Removethe tube stack to the right and remove the left
h a n ds i d e" O " r i n g .
To re-assemblecooler, reverse order of dismanfling.
N e w " O " r i n g ss h o u l d b e u s e d w h i c h s h o u l d b e l i g h i l y
oiled beforefitting.
To test water side

F i l l w a t e rs i d e w i t h w a t e ra n d i m m e r s et h e u n i t i n w a r e r ,
e n s u r i n ga b s e n c eo f t r a p p e da i r
Pressurisewater side with air at a pressureof 30lbf/in,
( 2 , 1 1 k 7 t / c m zo)r 2 0 7 k N / m ,a n d e x a m i n ef o r l e a k s
To test oil side
With water side filled with water and unit immersed in
water, pressurise oil side at a pressure of 90lbf/in,
(6,33kgf/cmr)or 620kN/m, for turbochargedengines or
60lbf/in, (4,22k9t/cm2) or 414kN/m, for naturally
aspirated engines.Test for two minutes and examrne
for leaks.
The tube stack should be reiected if bubbles persist
from the water inlet or outlet connections.
LUBRICATINGSYSTEM
1.13
L.14
Adaptor- GoolertoCylinderBlock
To RenewLubricatingOil Filter Element
(wheretitted)
The adaptor may be releasedby removingthe securing
s e t s c r e ws, e e F i g . L . 1 3
W h e n r e f i t t i n gu s e a n e w j o i n t a n d s u i t a b l e s e a l i n g
c o m p o u n da n d s e c u r ew i t h s e t s c r e w p
, l a i n w a s h e ra n d
s p r i n gw a s h e r .
L7
U n s c r e w f i l t e r c a n i s t e rf r o m f i l t e r h e a d c a s t i n g ( s e e
Fig L 14).
C h e c kt h a tt h r e a d e da d a p t o ri s s e c u r ei n h e a dc a s t i n g
D i s c a r do l d c a n i s t e r
C l e a nf i l t e r h e a d
P r i m et h e n e w c a n i s t e rw i t h l u b r i c a t i n go i l a l l o w i n gt i m e
f o r t h e o i l t o f i l t e rt h r o u g ht h e e l e m e n t
To Refit Oil Cooler

The joint, lubricatingoil cooler to adaptorblock, must be
fastenedto the oil coolerflangewith an approvedadhesive;
"Bostik"clear,"Evostik"or DunlopSN 1901.
There must not be any sealantbetweenthe joint and the
adaptorblock.Thissideof thejointmustbe fitteddry.
Refitthe oil cooler to adaptoror cylinderblock and
secure with five setscrews,plain and spring washers.
R e f i tt h e o i l f i l t e rw i t h f o u r s e t s c r e w sa n d s o r i n ow a s h e r s
or refit f ilter canisters.
R e c o n n e c tt h e c o o l e r i n l e t a n d o u t l e t c o n n e c t i o n s .
E n s u r i n gt h a t t h e w a t e r a n d o i l d r a i n p l u g s a r e f i t t e d ,
refill the cooling system.
S t a r t t h e e n g i n e ,b u t d o n o t s p e e d t h e e n g i n e u n t i l o i l
pressureis achieved
C h e c kf o r o i l a n d w a t e r l e a k s
6 3544SeriesWorkshooManual.January1986
U s i n g c l e a n e n g i n eo i l , l i b e r a l l yo i l t h e t o p s e a l o f t h e
r e p l a c e m e ncta n i s t e r
S c r e w r e p l a c e m e n ct a n i s t e ro n t o f i l t e r h e a d u n t i l t h e
s e a l j u s t t o u c h e st h e h e a d a n d t h e n t i g h t e n b y h a n d
a s p e r t h e i n s t r u c t i o n so n c a n i s t e r .W h e r e a t o o l i s
.15lbf (2,07kgf
a v a i l a b l et,i g h t e nt o
ft
m) or 20Nm
R u n e n g i n ea n d c h e c kf o r l e a k s
W h e r e t w i n f i l t e r s a r e f i t t e d , b o t h c a n r s t e r ss h o u l d b e
r e p l a c e da t t h e s a m et i m e
N o t e : T h e o i l f i l t e r c a n i s t e r sh a v e i n t e r n a l v a l v e s t o
prevent drain back and a special tube stack, so always
e n s u r et h a t t h e c o r r e c i r e p l a c e m e nits f i t t e d .
SECTIONM
CoolingSystem
C O O L I N GS Y S T E M
M2
C i r c u l a t i o no f t h e c o o l a n t i s a s s i s t e d b y a n i m p e l l e r
t y p e w a t e r p u m p m o u n t e do n t h e f r o n t o f t h e c V l i n d e r
b l o c k ,d r i v e nb y t w i n b e l t sf r o mt h e c r a n k s h a fpt u l l e y .
From the twin volute water pump, the coolant flows
f r o m o n e o u t l e t i n t o t h e c y l i n d e rb l o c k a n d u p i n t o t h e
cylinderhead.Coolantfrom the other ouilet is piped
i n t o t h e o i l c o o l e rw h e r e i t c i r c u l a t e sa n d i s t h e n p i o e d
i n t o t h e r e a r o f t h e c y l i n d e rb l o c k . l t t h e n f l o w s u p i n t o
t h e c y l i n d e rh e a d .
W h e r et h e o i l c o o l e r i s f i t t e d t o t h e l e f t h a n d s t d e o f
naturally aspirated engines, the coolant feed is
s o m e t i m e st a k e n f r o m t h e s i d e o f t h e c y l t n d e r b l o c k
a n d i n t h i s c a s e ,t h e a d a p t o rw h i c h i s a p u s h f i t i n t h e
b l o c k m u s t b e f i t t e d w i t h L o c t i t e R e t a i n i n gC o m p o u n d
G r a d e7 5 .
W h e r en o e n g i n eo i l c o o l e r i s f i t t e d ,t h e n a l l t h e c o o t a n t
f l o w s i n t o t h e f r o n t o f t h e c y l i n d e rb l o c k
The coolantexits from the front of the cylinderhead
i n t o a t w i n t h e r m o s t act h a m b e r a, n d w h e n t h e t h e r m o s r a r s
a r e i n t h e o p e n p o s i t i o n ,a l l o w st h e c o o l a n tt o p a s s I n t o
the radiator.
U n t i l t h e c o o l a n t r e a c h e s a s p e c i if e d t e m p e r a t u r e ,
h o w e v e r ,t h e t h e r m o s t a t sw i l l b e i n a c l o s e d p o s i t i o n
d e n y i n g a c c e s s t o t h e r a d i a t o ra n d t h e c o o l a n t w i l j
flow into a by-passand back into the water pump
A cylinder block drain point is providedon the fuel
p u m p s i d e o f t h e e n g i n ea t t h e r e a r .
W i t h T 6 . 3 5 4 4 C Ce n g i n e s w h i c h i n c o r p o r a t ea n i n t e g r a l
a i r c h a r g e c o o l e r a n d i n d u c t i o nm a n i f o l d ,i t s h o u l d b e
n o t e d t h a t t h e d r a i n p l u g o f t h e c o o l e ro u t l e tc o n n e c t i o n
( s e e F i g . C . 2 ) s h o u l db e r e m o v e dw h e n e i t h e rd r a i n r n qo r
f i l l i n gt h e c o o l i n gs y s t e m .
checkedafter a short period of running to allow for

t h e i n i t i a ls t r e t c h
B e l t a d j u s t m e n ti s o b t a i n e db y l o o s e n i n gt h e g e n e r a t o r
m o u n t i n gb o l t a n d a l t e r i n gt h e p o s i t i o no f t h e q e n e r a r o r
o n i t s m o u n t i n gl i n k .
T h e t e n s i o ns h o u l db e s u c ht h a t a p r e s s u r ea p p l i e db y t h e
thumb on the longest unsupportedstretch of belt
s h o u l d d e p r e s s i t a p p r o x i m a t e l y% i n ( 1 O m m ) , s e e
Fig M.1
To Removeand Refit Thermostats

The water outlet connection forms the top half of the
t h e r m o s t aht o u s i n g
D r a i nt h e c o o l i n gs y s t e ma n d d i s c o n n e c t h e t o p r a o t a t o r
hose, remove three setscrews securing the water
o u t l e tc o n n e c t i o na n d r e m o v e s, e e F i g . M . 2 .
T h e t h e r m o s t a t s c anno w b e w i t h d r a w nf r o m t h e h o u s i n g
W h e n r e p l a c i n g ,e n s u r e t h a t t h e j i g g l e p i n s a r e f r e e
IO mOVe
Ensurethat only by-passthermostatsare fitted.

Refit the water outlet connection correcily placrng a
new joint, connect the top water hose and refill the
cooling system Check for leaks
Fan Belts
Twin belts are used to drive the generator and water
pump.
The fan may be mounted on either the water pump
p u l l e yo r d i r e c tt o t h e c r a n k s h a f p
t ulley
New belts should be fitted in pairs and the tension
M.2
M.3
C O O L I N GS Y S T E M M 3
To Test the Thermostats
S u s p e n dt h e t h e r m o s t a t si n w a t e r a n d h e a t g r a d u a l l y
W i t h a t h e r m o m e t e r c, h e c k t h a t t h e t h e r m o s t a ts t a r t s
t o o p e n a I 1 7 7 / 1 8 3F" ( B i l 8 4 . C ) a n d i s f u l t y o p e n a t
199/205.F (93/96.C)
T h e v a l v e l i f t w h e n f u l l y o p e n i s 0 3 7 4 1 05 0 O i n ( 9 . 5 0 /
12,7Omm)
To RemoveWater pump
R e m o v et h e d r i v e b e l t s .
D r a i n t h e c o o l i n g s y s t e m a n d d i s c o n n e c tt h e n o s e s ,
The water pump securing setscrewsand nut can now
be releasedand the water pump removed,see Fig M.3.
To DismantleWater pump
I distancepiece (to allow for the removalof the felt seal flange)
I willbe suppliedwiththe newseat.
Pressthe two bearingsonto the shaft with the distancepiece
in between,ensuringthat the shieldedface of each bearino
facesoutwards.
Whereapplicable,
fit the frontseal assembly- retainerwith
felt seal inside- into its location,with felt face towardsthe
frontof the pump.
Greasethe bearingsand half fill the space betweenthe two
bearingswith high meltingpointgrease.Whereapplicable,
fit
the flangeover the impellerend of the shaftwith the dished
face to the bearingsand pressthe completeshaftand bearinq
assemblyintothe pumpbodyfromthe pulleyend.
Fit the circlipinto its recessin the pump body immediately
forwardof the front bearing.
R e m o v et h e s e l f l o c k i n g n u t a n d p l a i n w a s h e rs e c u r i n g
tne water pump pulley and withdraw the pulley from
t h e s h a f t ,s e e F i g . M . 4 .
Where applicable,slide the rubberflingerover the impeller

end of the shaft until the flat face butts againstthe bearing
retaining
flange.
P r e s st h e s h a f t ,c o m p l e t ew i t h i m p e l l e r ,o u t o f t h e b o d v
from the front.
lf the rear seal has a brass casing,coat its locatingsurface

withjointingcompound.Fitthe rearsealoverlhe impellerend
of the shaft and press onto its flange locationin the pump
bodywith the contactface outwards.
i Press the impellerfrom the shaft and removethe rear sear,

I counterfaceand flinger.Latest pumps have one-pieceseats
I with an iniegralcounterfaceand a flingeris not fitted.
Removethe bearingretainingcirclipfrom water pump oooy
and pressout the two bearingsand distancepiece.
M.4
the flange,retainerand frontsealcan now
lWhere applicable,
withdrawn
be
from
the body. The front felt seal assemblyis
;
; not fittedto latestpumps and can be discardedprovidedthat
Ithe latest one-piecerear seal, shaft and longer bearing
I distancepieceare to be fitted.
lTo Re-assembleWater Pump, Fig. M.5

I lf the latestone-pieceseal with an integralcounterfaceis to
lbe fittedto an earlierpump,the felt seal assemblyand the
lflingercan be discarded.A new shaft and a longerbearing
6 3544SeriesWorkshopl\.4anual,
January1986
Rotatethe shaftand checkfor undueresistance.

Where applicable,fit the ceramic counterfaceensuringthat
the ceramicface bears againstthe carbon face of the sprino
loadedseal.
COOLING SYSTEM
M4
Before fitting the pulley, insert the captive setscrew and

washerin its respectivehole,see Fig. M.6.
Fitpulleydrivingkey and presson pulleymakingsurethereis
no rearwardmovementof shaft.
Press impeller onto shaft until a clearanceis obtained between impellervanes and pump body, includingend float of
- see Fig.M.5.
(0,30/0,89mm)
0.012/0.035in
Fit plainwasher,springwashersand pulleysecuringnut and
tightento a torqueof 60lbfft (8,30kgfm)or 82Nm. Spin the
pump pulleyto ensurefreedomof movement.
which connects with an auxiliary oil pressure rail

drilled the length of the cylinder block above the
camshaftchamber.
This pressurerail is tapped in six placesto accommodate
the dowelled piston spray iet block.
The removal and retitting of the pressure relief valve
is dealt with in the LubricatingSection L., on Page L.4.
To Remove Piston Cooling Jets

Drain the lubricatingoil and removesump, see Page L.3.
Ceramic Seals
l f a n e n g i n ei s r u n w i t h o u t c o o l a n ti n t h e w a t e r p u m p ,
the heat build-uo between the carbon seal and the
ceramic counter face is very rapid, resulting in the
crackingof the ceramic
T h i s c a n c a u s e a m i s u n d e r s t a n d i n tgh a t t h e l e a k a g e
of water from the pump is due to the incorrectassembly
o f t h e s e a l i n ga r r a n g e m e ni tn t h e w a t e r p u m p .
To Refit Water Pump

Using a new joint, refit the water pump, securing with
setscrews, nuts and spring washers to a torque of
20lbttl (2,77kgf m) or 27 Nm.
Reconnectthe hoses,fill the system with coolant.
Refit the drive belts, start the engine and check for
leaks.
M.8
Remove the banjo holt securing the jet body to the
The piston jet assembly can now be removed, see
F i g .M . 8 .
To Refit Piston Cooling Jet

T h e b o d y s h o u l d b e f i t t e dt o t h e c y l i n d e rb l o c k m a k i n g
sure that the dowel locatescorrectly.
Insert the banjo bolt with washer fitted and tighten to
' f ) o r 2 7 N m . R e f i tt h e s u m p ,
a t o r q u eo f 2 0 l b ff t ( 2 , 7 7 k 7m
a n d f i l l w i t h l u b r i c a t i n go i l o f a n a p p r o v e dg r a d e .
Nozzle Positioning
M.7
PistonCoolingJets,seeFig.M.7
In the event of a nozzleof a piston cooling jet becoming

m i s a l i q n e di,t i s i m p o r t a n t h a t t h e c o n d i t i o ni s r e c t i f i e d
a n d t h e i l l u s t r a t i o ni ns F i g s M 9 a n d M 1 0 w i l l s h o w h o w
this maybe accomplished.
W i t h a p i s t o n r e m o v e d ,i n s e r t a p i e c e o f l r i n ( 2 , 3 8
m m ) , r o d ( s u c ha s w e l d i n gr o d ) i n t o t h e j e t n o z z l es o t h a t
it protrudesabove the top of the cylinder bore.
Piston cooling iets are fitted to most turbochargedengines

I only.They are not fittedto normallyaspiratedengines.
Cooled lubricating oil is directed, by means of spray
lets situatedat the base of each cylinder liner, onto the
underside of each piston crown where it circulates,
dispersing heat from the combustion area. The oil
then drains back into the sump.
Fig. M.9 shows the dimensions taken on the top face

of the cylinder block and it will be seen that the
measurements of 1 781in (45,24mm) and 0 641in
(16,28mm)are taken from two sides of the liner bore
as illustrated.
The rod should projectat a pointwhere the lines drawnfrom
two measurementsintersect.
Oil is carried to the spray jets by means of a pipe from

the relief valve to an oil gallery in the cylinder block
Fig. M.10 illustrateshow the correct nozzle angle may be

achievedby the use of rules.
6 3544 SeriesWorkshopManual,January 1986.
C O O L I N GS Y S T E M M 5
1.781in (45,24mm)
0 . 6 4 1i n
( 1 6 , 2m
8 m)
M.10
Charge cooler (integralairlwater)

No preventive
mainlenance
is necessary
on the intercooler
as
the air passing over the cooling fins is clean. lf the
turbocharger
oil sealsleak,this may necessitate
the removar
and cleaningof the intercooler.
The intercooler
is a sealedunit
and no repairsare possibleexceptperhapsby specialisrs.
The chargecoolershouldbe removedand fittedwiththe Intet
manifoldattachedand the manifold,intercoolerand top cover
treated as a completeassembly.In the case of tractorsthis
assembly will have to be removed before the exhaust
manifoldcan be removed.
The air charge cooler can be removedand dismantreo
as
follows:
1. Draincoolantsystem- removeair bleedscre\r'ion coolant
outletelbowof chargecoolerto ensurethatcoolantdrains
from cooler.
12.Disconnect
coolant,air and fuel pipes.Releasepipeclips
and supoortbrackets.
lJ. Removechargecooler/manifold
assemblyfrom engine.
4. Removecoolantpipe flangesfrom top coverand manifold
Note "O" ringfittedin groovein flangebore.
5. Remove setscrews securing top cover and manifold
flanges.
6. Slide the top cover over the coolantpipe by liftingthe
oppositeend of the coverto clearthe intercooler.
7. Slide the intercoolerout of the manifoldby liftingthe
non-pipeend of the intercooler
to clearthe manifold,'
8. Reassembleand refit in reverseorder. Fit new joints with
Hylomar.Remove air bleed screw when fillingcoolant
system- if top of radiatoris below intercooler,the system
may haveto be toppedup aftera shortperiodof running
The coolantflowfor the chargecooleris fromthe waterpump
- backto the waterpumpinlet
outlet- throughthe intercooler
for tractorenginesor the rearof the cylinderheadfor combine
enornes.
SECTIONN
Air Filtersand FuelSystem
AIR FILTERSAND FUEL SYSTEM
N2
Air ChargeCooling
(T6.3544
enginesonly)
T6.3544CC engines have an air charge cooler integral

with the inductionmanifold(see Figs. A.5 and A.6).
Another method of cooling the air between the outlet of
the compressor side of the turbochargerand the
induction manifold is by pushing air through an 'air
cooling radiator'usually mounted in the same air stream
a s t h e e n g i n ew a t e rc o o l i n gr a d i a t o r( s e e F i g . N . 1 ) .
Air Cleaners
Operatingconditions play an important part in deciding
how frequentlyit is necessaryto servicethe air cleaner.
Where the cleaner has a dust bowl fitted, the amounr
of dust present in the bowl when removed, will show
whether it is being emptied at the correct time for the
prevailing conditions. lf the dust bowl is allowed to
become full, it will reduce the life of the element.
lf an automatic dust ejector is fitted, it should be kept
clean and the lips of the rubber ejector checked to see
that they close, but do not adhere together.
Where a restrictionindicatoris fitted,this will give a positive
indicationthat the air cleaner element needs attentionand
eliminates haphazard servicing. lf you do not have a
restrictionindicatorfitted, then you should consider having
one fitted on the trunking between the air cleaner and
turbochargeriinductionmanifold. A 22in (559mm) water
gauge indicatortitted on the cleaneroutlet is suitablefor the
majorityof cases. lt shouldbe rememberedthat the indicator
does not showthe amountof dust oresentin the dust bowl.
The type of air cleanerfitted to your vehicle or machine
depends upon the manufacturer of your equipment.
Usually, guidance for the servicing is shown on the
body of the air cleaner, but the following advice may
also help.
Dry Type Two Stage"Cyclopac",

see Fig. N.2
Unclamp the dust bowl, remove the baffle plate and
clean out the bowl.
The dust in the bowl must not be allowed to reach
within %in (13mm) of the dust entry slot in baffle
DO NOT USE PETROL (GASOLINE) for cleaning any
part of air cleaners.
N.2
Release the wing nut and remove filter element.
Dry dust can be removed from the element by blowing
back from the clean side of the pleats by using air
(7 kgf/cm'?)
pressurenot exceeding100lbf/in'?
or 689 kN/m'?.
lf the element is contaminated by oil and/or soot,
it can be cleaned in warm water using a suitable
non-foaming detergent as recommended by the air
cleanermanufacturer.
Allow, the element to soak for about ten minutes and
then agitate.Spray clean water onto the "clean" side of
the element rinsing thoroughly and allow to dry, do not
use oven heat
NEVER FIT a wet element as water may be inducted
by the engine carrying dust with it.
Examine the element for pin holes, thin areas, or
other damage by placing a bright light inside the
element.
The element should be renewed after six cleanings
or once a year, whicheveroccurs first'
Clean the inside of the filter body and fins, making
sure no dirt entersthe air f ilter outlet.
Check all hoses and joints for condition and security.
Re-assembleair cleaner unit.
lf an automaticdust ejector (vacuator)is fitted, it should
be kept clean and the lips of the rubber ejector
checked to see that they close but do not adhere
together.
Dry Type Two Stage"Cyclone",

see Fig. N.3
Unscrew the clamping screw and remove the element
retaining strip. Remove the seal plate and element.
lf the element is blocked by dry dust, clean by caretully
hand tapping the element or by directing low pressure
comoressed air on to the clean side of the element.
lf the element is contaminatedby oil or soot, it can be
partially restoredby washing in a suitable non foaming
detergentsolution.
A{ter washing, rinse out thoroughly by directing clean
water on to the clean air side of the element and allow
to dry - do not oven dry. Never fit a wet element to the
A I R F I L T E R SA N D F U E L S Y S T E M
N3
Dry ].yp9 T-woStage,,Duo-Dry",

seeFig.N.4
DustBowl
U n c l a m pt h e d u s t b o w l , e m p t y o u t t h e d u s t a n d c l e a n
t h e b o w l - d o n o t u s e p e t r o l ( E a s o l i n e )f o r c l e a n i n g .
T h e d u s t i n t h e b o w i m u s t n e v e rb e a l l o w e dt o b u i l d u p t o
1 i n ( 2 5 m m ) o f t h e b o t t o mo f t h e t u b e s .
Element
Clean the top of the cleaner and then unclip and
remove the top cover Unscrew the wrng nut ano
r e m o v et h e i n n e rc o v e ra n d e l e m e n t
N.3
filter as dust may be carriedthrough the elemenl oy
water.
Inspect the cleaned element by placing a bright
light inside and looking through the element. Any
thin spots,pin holes or other damagewill renderthe
e l e m e n tu n fi t f o r f u r t h e ru s e
The element should be renewed after six detergent
w a s n e so r a n n u a l l y ,w h i c h e v e ro c c u r s f i r s t .
C l e a n t h e i n s i d eo f t h e f i l t e r b o d y a n d d r y t h o r o u g n r y
- d o n o t u s e p e t r o l ( g a s o l i n e )f o r c l e a n i n g
Inspect the joints and hoses and renew where
n ecessary
R e - a s s e m b l et h e f i l t e r e n s u r i n g t h a t a l l j o i n t s a r e
leakproof
C l e a n a n d i n s p e c t t h e e l e m e n t a s d e t a i l e d fo r r n e
"Cyclopac" cleaner, bearing in mind that the ctean
s i d e o f t h e e l e m e n to f t h e " D u o - D r y , 'c l e a n e ri l l u s r r a t e d
i s t h e o u t s i d eo f t h e e l e m e n t
C l e a nt h e i n s i d eo f t h e b o d y - d o n o t u s e p e t r o l l f t h e
t u b e s a r e n o t t o o d i r t y , t h e y c a n b e c l e a n e dw i t h a s t i f f
f i b r e b r u s h b u t , i f h e a v i l y c o n t a m i n a t e d ,t h e r u o e
b o d y s h o u l d b e r e m o v e da n d c l e a n e dw i t h c o m p r e s s e d
a r r o r w a r m w a t e r n o t e x c e e d i n g1 5 0 " F ( 6 5 . C )
I n s p e c ta l l j o i n t s a n d h o s e sa n d r e n e w w h e r e n e c e s s a r y
R e - a s s e m b lteh e c l e a n e re n s u r i n gt h a t a l l p a r t s a r e o r V
a n d a l l j o i n t sa r e l e a k p r o o f .
l f t h e t u b e b o d y h a s b e e n r e m o v e d ,t i g h t e n t h e c r a m p
b e t w e e n i t a n d t h e u p p e r b o d y b e f o r e t i g h t e n i n gl i t e
m o u n t i n gc l a m p
Dry Type, Multi-Element

"Rotopamic",
see Fig. N.5
T h e e l e m e n t so f t h i s t y p e c l e a n e rs h o u l d n o t b e c l e a n e d
but the completefilter cartridge should be renewed
when necessary
R e l e a s et h e c l a m p s a n d r e m o v et h e m o i s t u r ee l i m i n a t o r
o r p r e - c l e a n epr a n e l .C l e a nt h e o p e n i n g si n t h e p a n e l o f
a n y d u s t ,s o o t ,e t c
uiFTril;;lr ":;
R e m o v et h e f i l t e r c a r t r i d g ea n d c l e a n t h e i n t e r i o ro f t h e
c l e a n e r h o u s i n g - d o n o t u s e p e t r o l( g a s o l i n e )
Fit the new cartridgeIn position ensunng a positive
s e a l b y p r e s s i n ga r o u n d t h e e d g e s o f t h e c a r t r i d g e_
d o n o t p r e s si n t h e c e n t r e .
Refit the morsture eliminator or
a n d r e c l a m pi n p o s i t i o n .
N.4
N.5
pre-cleanerpanel
N4
Oil Bath Air Cleaner,see Fig. N.6

T o s e r v i c et h e o i l b a t h t y p e c l e a n e r ,t h e l i d s h o u t d
be
removedand the element lifted out.
Drain the oil from out of the container and crean
t h e d i r t a n d s l u d g ef r o m t h e c o n t a i n e ru s i n g a s u i t a b l e
c l e a n i n gf l u i d .
R e f i l l t h e c o n t a i n e rw i t h f r e s h e n g i n e l u b r i c a t i n go i l ,
SAE40grade,to the indicatedlevel.
The element should be cleaned in a bath of Kerosene.
D o n o t u s e p e t r o l ( g a s o l i n e )f o r c l e a n i n g p u r p o s e s
R e p l a c et h e c l e a n e de l e m e n t i n t h e c o n t a i n e r .
Refit the lid, making sure that the lid seats properly
on the seal.
D o n o t e x c e e dt h e i n d i c a t e dl e v e l m a r k w h e n r e f i l l i n g
t h e o i l c o n t a i n e r ,b e c a u s eo i l c o u l d b e d r a w n i n t o t h e
engine leading to uncontrolled engine speed and
excessiveengine wear.
N.7
FUEL FILTERS
Twin bowl, parallel flow fuel filters are situated at the
rear of the engine on the left hand side, bracketed to
t h e c y l i n d e rh e a d , i n m o s t a p p l i c a t i o n s .
n o l e a k sa t t h e c o n n e c t i o n sb e t w e e np u m p a n d g a u g e .
C r a n kt h e e n g i n ef o r 1 0 s e c o n d sa n d n o t e t h e m a x r m u m
p r e s s u r er e c o r d e do n t h e g a u g e l f t h e p r e s s u r er e c o r d e d
i s l e s s t h a n 7 5 o / oo f t h e m i n i m u m p r o d u c t i o n s t a t i c
pressure shown in the table below, then rectify the
pump. Also observe the rate at which the pressure
d r o p s t o h a l f t h e m a x i m u m fi g u r e o b t a i n e d w h e n
c r a n k i n g h a s c e a s e d .l f l e s s t h a n 3 0 s e c o n d s ,r e c t i f y
the oump.
To Renew Fuel Filter Elements.

see Fig. N.7
M i n i m u mP r o d u c t i o n
Static Pressure
lbf/in2
kgf/cm2
6
0,42
T h o r o u g h l yc l e a n t h e e x t e r i o r o f t h e f i l t e r a s s e m b l y
S u p p o r t i n gt h e b a s eo f o n e o f t h e f i l t e r b o w l s , u n s c r e w
the setscrewIn the centre of the cover of each filter
Lower filter base plate and discardthe dirty element
Minimum Test Pressure

(75% of Min. Productionpressure)
lbf/in2
4 5
Repeatthe procedurewith the twin filter.

Thoroughly clean the filter heads and bases in a
s u i t a b l ec l e a n i n gf l u i d
Inspectsealing rings and renew if damaged in any
way
Place a base squarely on bottom of new elemenr ano
offer up assembly squarely to a filter head so that
the top rim of the element locatescentrallyagatnst
the sealing rim in filter head. Hold in this position
whilst securing setscrewis locatedand screwed home.
R e p e a t h e p r o c e d u r ew i t h t h e t w i n f i l t e r
After the fuel filter has been re-assembled,the fuel
s y s t e ms h o u l db e b l e d a s d e t a i l e do n p a g e N 7 .
Fuel Lift Pump

T h e m e c h a n r c adli a p h r a g mt y p ef u e l l i f t p u m p i s o p e r a t e d
b y a n e c c e n t r i co n t h e c a m s h a f ta n d i s m o u n t e d o n
the right hand srde of the cylinder block, below rne
t u r b o c h a r g e rl t i s f i t t e dw i t h a h a n d p r i m i n gl e v e r
PressureCheckingof Fuel Lift pumps

Fit a O-10lbf/in, (0-0,7kgflcm,) or 0-70kN/m, pressure
gauge to the outlet of the pump. Ensure that there are
kN/m,
41
N.8
kgf /cm2
0,31
kN/m'?
31
AIR FII.TERSAND FUEL SYSTEM
To Remove and Fit Fuel Lilt Pump,

see Fig. N.8
D i s c o n n e ct th e i n l e ta n do u t l e tt u e l p i p e s .
Removethe setscrewsand retaininq plates and remove
the pumpand joint.
l f d i f f i c u l t yi s e n c o u n t e r e di n r e m o v i n g t h e l i f t p u m p
from the engine,turn the cranksha{tto rotatethe camshaft
e c c e n t r i ct o a D o s i t i o nw h i c h w i l l e n a b l e t h e r o c k e r
arm to withdraw.
F i t p u m p u s i n g a n e w j o i n t , e n s u r i n gt h a t t h e m a t i n g
faces are clean.
Damage can be caused to the pump operatinglever if the
pump is fittedto the enginewith the pump drivingeccentricon
the camshaft in the maximum lift position.This problem is
most likelyif the four pumpfastenersare not tightenedevenly.
Thereforewhen the pump is fitted to an engine (especiallya
four bolt pump) ensure that the camshaft eccentric is on
minimumlift, rotatingthe engine if necessary,and also that
the pumpfastenersare tightenedevenly.
A lossof maximumenginepowercan occurif the liftpumpis
damagedduringfitment.
The securing setscrewsshould be tightened to 20lbfft
(2,8kgfm) or 27Nm and re-torquedwhen hot.
R e - c o n n e cpt u m p i n l e ta n d o u t l e t p i p e s .
Bleed the fuel system,Page N 7.
To Dismantle Fuel Lift Pump

Clean exterior and file mark the flanges of top and
bottom bodies for guidance in re-assembly.Removethe
d o m e d e n d c o v e ra n d s e a l .
Thegauze filter may now be lifted off.
Releasethe five setscrews securing the two halves of
the pump and separatethe two halves.
The valvesare "staked in" and can be prised out using

a screwdriveror other suitable tool. Clean the casting
so that new valvescan be correctlyseated
Press valves into position using a suitable "dolly".
Stake the casting around the valves in six places.
The rocker arm pin can be removed by securing the
rocker arm in a vice and tapping the body with a soft
m a l l e tu n t i l t h e r e t a i n e r sa r e d i s l o d g e d
The rocker, pin, lever and return spring can now be
examinedfor wear.
To Re-assemblethe Lift Pump,

see Fig. N.9
Fit the rocker arm assemblyinto the bottom half of the
l i f t p u m p F i t t h e r o c k e ra r m r e t u r ns p r i n g m a k i n g s u r e
that it seats properly
Tap new retainers into the grooves in the casting and
stake over the open end of the grooves.
F i t t h e s p r i n g i n t o i t s l o c a t i o na n d p l a c e t h e d i a p h r a g m
a n d p u l l r o d a s s e m b l yo v e r t h e s p r i n g w i t h t h e p u l l
r o d d o w n w a r d sl o c a t i n g t h e t o p o f t h e s p r i n g i n t h e
diaphragmprotectorwasher.
Position the rod so that the notched blade locates into
t h e r o c k e ra r m l i n k .
P r e s s d o w n w a r d so n t h e d i a p h r a g ma s s e m b l ys o t h a t
t h e n o t c h e so n t h e p u l l r o d a l i g n w i t h t h e r o c k e r a r m
l i n k a n d t w i s t i t t h r o u g h g 0 o i n e i t h e r d i r e c t i o n ,t h i s
action will engageand retainthe pull rod in the fork
of the link
W h e n r e - a s s e m b l i n gt h e t w o p u m p h a l v e s , p u s h t h e
r o c k e r a r m t o w a r d s t h e p u m p u n t i l t h e d i a p h r a g mi s
l e v e l w i t ht h e b o d yf l a n g e sT h e t o p h a l fc a n n o w b e p l a c e d
i n p o s i t i o nw i t h t h ef i l em a r k sa l i g n e d .
T u r n t h e d i a p h r a g ma s s e m b l yt h r o u g h 9 0 ' a n d l i f t t h e
d i a p h r a g ma n d p u l l r o d a s s e m b l yf r o m t h e b o d y
The diaphragmand pull rod assemblyare servicedas an
assembly and no attempt should be made to separate
t h e l a y e r so f t h e d i a p h r a g m .
N.10
6 3544SeriesWorkshopManual,January'1986
N5
(G.A.V. Pump)
A I R F I L T E R SA N D F U E L S Y S T E M
N6
M a i n t a i n i n gt h e p r e s s u r eo n t h e r o c k e r
arm, fit the
s e c u n n gs c r e w sa n d w a s h e r sa n d t i g h t e n
evenlv
R e f i tt h e g a u z ef i l t e r
The domed cover may now be refitted,
ensuringthat
t h e r u b b e r s e a l i n gr i n g i s c o r r e c i l y l o c a t e d .
Fuel Injectionpump
T h e f u e l i n j e c t i o np u m p i s a C A V , D p A o r B o s c h
d i s t r i b u t o rt y p e , v e r t i c a l l y m o u n t e d o n t h e a u x i l i a r v
d r i v e h o u s i n g a n d i s s p l i n e - c o u p l e dt o t h e a u x i l i a r v
drve wormgear.
The pump is a compact, oil tight unit, lubricated
throughout by fuel oil and requires no separare
l u b r i c a t i o ns y s t e m .
S p e e d c o n t r o l i s m a i n t a i n e db y a m e c h a n i c a g
l overnor
a n d a u t o m a t i c v a r i a t i o n o f t h e c o m m e n c e m e n to f
i n j e c t i o n i s o b t a i n e d w i t h a n a u t o m a t i ca d v a n c e u n i t .
With Bosch fuel injection pumps, a boost control is
fitted at the side of the pump. lts function is to vary rne
f u e l i n t o t h e e n g i n e d e p e n d i n go n l o a d . E n s u r et h a t a l l
c o n n e c t i o n so f t h e b o o s t s e n s i n g p i p e a r e i n g o o o
condition
U n l e s s p r o p e r t e s t e q u i p m e n t a n d t h e r e j e v a n tT e s t
D a t a f o r t h e f u e l p u m p i s a v a i l a b l e ,a d j u s t m e n r o r
m a i n t e n a n c eo f t h e f u e l p u m p s h o u l d b e r e f e r r e d t o
t h e P e r k i n s D i s t r i b u t o ro r a n a c c r e d i t e df u e l p u m p
agent.
T h e f u e l p u m p c a n n o w b e w i t h d r a w na f t e r t h e s e c u r i n g
n u t s a n d w a s h e r sh a v eb e e n r e m o v e d s, e e F i o . N . 1 0 .
To Fit the Fuel Injectionpump

F i t t h e f u e l p u m p e n s u r i n gt h a t t h e m a s t e r s p l i n e o n
t h e f u e l p u m p s h a f t w i l l e n t e r t h e f e m a l es p l i n e w i t h i n
t h e v e r t i c a ld r i v e s h a f t .
P o s i t i o nt h e f u e l p u m p s o t h a t t h e s c r i b e d l i n e o n t h e
fuel pump mounting flange aligns with the scribed
l i n e o n t h e a d a p t o rp l a t e ,s e e F i g N 1 1 ( 1 ) .S e c u r et h e
p u m p t o t h e a d a p t o rp l a t e
R e f i t t h e h i g h a n d l o w p r e s s u r ef u e l p i p e s t o t h e f u e l
pump
Reconnectthe throtfle and stop lever controls and attach
t h e r e t u r ns p r i n g s .
Bleed the fuel system as detailedon page N 7.
lf necessarya
, diust the maximum and idling speeos.
D e t a i l sw i l l b e f o u n d o n t h i s p a g e ,
Maximum Speed Setting

The maximumspeed screw is set and sealed by the
m a n u f a c t u r e r sa n d m u s t n o t b e a l t e r e d i n a n y w a y
u n l e s sf a c t o r ya u t h o r i t yi s f i r s t o b t a i n e d A
. ny adjusrment
should be carried out by experiencedfuel pump
t e c h n i c i a n s .T h e u n a u t h o r i s e dr e m o v a l o f a n y s e a t s
o n t h e p u m p m a y r e n d e rt h e g u a r a n t e ev o i d .
W h e n a f u e l p u m p i s s u p p l i e da s a d i r e c t r e p l a c e m e n r ,
t h e m a x i m u m s p e e d a d j u s t m e n ti s s e t t o a n o m i n a l
f i g u r e o n l y , a n d f i n a l a d j u s t m e n tm u s t b e m a d e a f i e r
the pump is fitted to the engine In order to establish
the correct setting which can vary accorotng ro
a p p l i c a t i o n ,r e f e r e n c em u s t b e m a d e t o t h e s e t t i n g
code symbol, stamped on the plate fastenedto the
pump booy.
F o r t h e p u r p o s eo f s e t t i n gt h e m a x i m u m( n o l o a d )s p e e d
s t o p ,t h e l a s tf o u r f i g u r e ss h o w n o n t h e f u e l p u m p s e t t i n g
code is the maximum no load engine speed. Warm
t h e e n g i n ea n d r u n u p u n t i l t h i s f i g u r e i s r e a c h e d ;t h e
m a x t m u m s p e e d s t o p a d j u s t m e n ts h o u l d t h e n o e s e r
at thisfigure
Under no circumstanceshould the engine be allowed
t o o p e r a t e a t h i g h e r r e v l m i n t h a n s p e c i f i e do r s e v e r e
d a m a g et o t h e e n g i n em a y r e s u l t
ldlinE Speed Setting

With C A.V pumpsthe engineidling speed is adjusted
b y t h e i d l i n gs c r e w ,s e e F i g N i 1 ( 2 ) W i t h B o s c h p u m p s ,
t h e i d l i n g s p e e d a d j u s t i n gs c r e w i s a t t h e r e a r o f t h e
pump
N.11
(C.A.V.Pump)
To Removethe Fuel Injection pump

D i s c o n n e ctth e s t o p a n d t h r o t i l ec o n t r o l sf r o m t h e p u m p
a n d r e m o v e t h e r e t u r n s p r i n g s ( C . A . V .p u m p s )
The Bosch fuel pump has a combined speed/stop
c o n t r o ll e v e r .U n d e r n o c i r c u m s t a n c essh o u l dt h e s p e e o u
stop control lever be removed when removing a Bosch
fuel pump as it will upset the the settingsmaking it
necessarytoput it on a test machineto resetit.
R e m o v et h e h i g h a n d l o w p r e s s u r ef u e l p i p e s f r o m t h e
pump.
6 3544SeriesWorkshopN,4anual,
January1986
With the engine warm, turn the screw clockwiseto

i n c r e a s et h e s p e e d o r a n t i - c l o c k w i s et o d e c r e a s ei t .
The idling speed will vary, accordingto application
F o r d e t a i l s , a p p l y t o y o u r p e r k i n s D i s t r i b u t o ro r a n
a c c r e d i t e df u e l p u m p D e a l e r a
, l t e r n a t i v e l yS,e r v i c eD e p t ,
P e r k i n sE n g i n e sL t d , P e t e r b o r o u g h
Atomisers
When replacingatomisersit is essentialthat a new, correcr
type copper seatingwasher is fitted betweenthe nozzrecap
andthe cylinderhead.
Note: Different atorrniserseating washers are used on
naturally aspiratedand turbochargedengines The
s e a t i n g w a s h e r s f o r n a t u r a l l y a s p i r a t e de n g i n e s a r e
0 0 B 0 i n ( 2 , 0 3 m m )t h i c k a n d f o r t u r b o c h a r g e de n g i n e s ,
A I R F I L T E R SA N D F U E L S Y S T E M N 7
makes a "cracking" sound. lt is not until it sounos

"dead" that its condition is likely to affect the runnino
of the engine.
Note: Do not allow the hands or face to come Into
c o n t a c t w i t h t h e a t o m i s e dj e t o f f u e l , a s t h e w o r k i n g
p r e s s u r ew i l l c a u s e t h e f u e l o i l t o p e n e t r a t et h e s k i n .
W h e n c h a n g i n g a n a t o m i s e ra l w a y s r e m o v e t h e p t p e
e n t i r e l y .N e v e rb e n d t h e p i p e
Bleeding the Fuet System
-fhe
air must be vented from the fuel system and the

s y s t e mp r i m e dw i t h f u e l o i l w h e n e v e ra n y d i s c o n n e c t i o n
in the fuel system has taken place, or when the svsrem
h a s b e e ne m p t i e do f f u e l .
N o a t t e m p tm u s t b e m a d e t o s t a r t t h e e n g i n e u n t i l t h e
i n j e c t i o np u m p h a s b e e n v e n t e da n d p r i m e d a s s e n o u s
o a m a g ec a n b e c a u s e db y l a c k o f l u b r i c a t i o n .
N.12
0 0 2 8 i n ( 0 , 7 1m m ) t h i c k l t i s i m p o r t a n tt h a t t h e c o r r e c t
atomiserseatingwashersare fitted
I See page E3 for guidanceon latesttype of atomiserdust seal
I and alsotop entrytvpe atomisers.
E n s u r et h a t t h e a t o m i s e ri s s e a t e dc e n t r a l l ya n d t i g h t e n
securing nuts/setscrewsdown evenly to a torque of
l 2 l b f f t ( 1 , 7 k gmf ) o r 1 6 N m
W h e n f i t t i n g t h e h i g h p r e s s u r ep i p e s ,t i g h t e nt h e u n i o n s
t o 1 5 l b f t ( 2 , 1k g fm ) o r 2 0 N m
A faulty atomiser can be determined by releasingthe
f u e l p i p e u n i o n n u t o f e a c h a t o m i s e ri n t u r n , w i t h t h e
e n g i n er u n n i n ga t a f a s t " t i c k - o v e r " l f a f t e r s l a c k e n r n ga
p i p e u n i o n n u t , t h e e n g i n e r e v o l u t i o n sr e m a i n c o n s r a n r ,
t h i s d e n o t e sa f a u l t ya t o m i s e r
No attempt should be made to service or reset the
pressure of an atomiser unless the proper testing
p u m p a n d p r e s s u r eg a u g e i s a v a i l a b l e .
A n a t o m i s e r ,w h e n t e s t e d b y p u m p i n g f u e l t h r o u g h i t
gives a short "plnging" sound as the fuel emerges.
After the atomiser has been in service for some time, it
N o t e : l f t h e c a m o n t h e e n g i n e c a m s h a f to p e r a t i n gt h e
f u e l l i f t p u m p i s o n m a x i m u ml i f t ,i t w i j l n o t b e p o s s i b l et o
o p e r a t et h e h a n d p r i m e r l f s u c h a c o n d i t i o na r i s e s ,t h e n
t h e e n g i n es h o u l d b e t u r n e do n e c o m p l e t er e v o l u t t o n .
l f , a f t e r b l e e d i n gt h e f u e l s y s t e m ,t h e e n g i n es t a r t s a n d
runs satisfactorilyfor a few momentsand then stops, runs
erratically,or has loss of power and when checked, the
systemis found to be full of air, then a leak on tne
s u c t i o ns i d e i s i n d i c a t e d .
N.14
To BleedC.A.V.Fuel Pump
1. Removeair from the fuel filterthroughthe filtervent plug,
see FigureN.13.lf a filtervent plug is not fitted,the rerurn
to tank banio connectionin the top of the filter can be
loosenedto reducethe time neededto fill the filterwith
fuel.
Operatethe priminglever of the fuel lift pump untilfuel,
freeof air,issuesfromthe ventingpoint
Tightenthe plugor connection.
N.13
2. Loosenthe inletconnection
at the fuelpump,see Fig.N.12
item C and remove the air again by use of the lift pump.
N8
When appropriate,tightenthe connectionbut ensurethat it

is notovertightened.
3. Ensurethat the stop controlis in the 'run' position.lf an
electricsolenoidstop controlis used, turn the start switch
to the'R' position.
4. Loosenthe vent screws in the hydraulichead lockingbolt
and the governorhousingof the fuel injectionpump,see
Fig.N12,itemsA and B, and removeair fromthe pumpby
use of the liftpump.
Tighten first the hydraulichead vent screw, item B and
thenthe governorhousingventscrew,itemA.
5. lf the fuel pipe to the Thermostartcold startingaid has
beendrained,loosenthe unionnut at the startingaid and
operatethe priminglever untilfuel, free from air, comes
Tightenthe unionnut.
fromthe connection.
6. Slackenthe unions at the atomiserends of two high
pressure pipes. Set the accelerator at the fully open
positionand ensurethat the 'stop' controlis in the 'run'
oosition.
Turnthe engineuntilfueloil,freeof air,issuesfromaround
the threadsandtightenthe unionnuts.
The engineis now readyfor starting.
To BleedBosch Fuel Pump
S l a c k e nt h e v e n t s c r e wo n t h e t o p o f t h e f i n a l f u e l f i l t e r s ,
see Fig N 13
S l a c k e nt h e i n l e t c o n n e c t i o no n t h e f u e l p u m p ( A ) , s e e
Fig N.14
S l a c k e nt h e o u t l e tc o n n e c t i o no n t h e f u e l p u m p ( B ) , s e e
F i g N 1 4 T h i s c o n n e c t i o ni s f i t t e d w i t h a n o n - r e t u r n
v a l v ea n d m u s t n o t b e f i t t e dt o t h e i n l e t p o r t .
O p e r a t et h e p r i m i n g l e v e r o n t h e f . u e l l i f t p u m p u n t i l
f u e l ,f r e e f r o m a i r , i s s u e sf r o m t h e f i n a l f u e l f i l t e r v e n t i n g
p o i n t .T i g h t e nt h e f u e l f i l t e r v e n t s c r e w a n d c o n t i n u et o
o p e r a t et h e l i f t l u m p u n t i l f u e l , f r e e f r o m a i r , i s s u e sf r o m
t h e i n l e t c o n n e c t i o no n t h e f u e l p u m p ( A ) T i g h t e n t h e
i n l e t c o n n e c t i o na n d c o n t i n u e t o o p e r a t et h e l i f t p u m p
u n t i lf u e l ,f r e ef r o m a i r , i s s u e sf r o m t h e o u t l e tc o n n e c t i o n
o n t h e f u e l p u m p ( B ) a n d t i g h t e nt h e c o n n e c t i o n
T h o r o u g h l yc l e a n t h e t o p o f t h e p u m p a r o u n dt h e c e n t r e
p l u g i n t h e h y d r a u l i ch e a d a n d s l a c k e n t h e v e n t p l u g
( C ) . O p e r a t et h e p r i m i n g l e v e r o f t h e l i f t p u m p u n t i l
fuel,free from air, issuesfrom aroundthe plug.Tightenthe
p l u gt o T l b f f t( 1 0 N m )1 , 0 k g f m .
lf the fuel pipeto the Thermostart
cold startingaid has been
drained,loosenthe unionnut at the startingaid and operate
the priminglever until fuel, free from air, comes from the
Tightenthe unionnut
connectron.
Slackenthe nuts of two of the high pressurepipes at the
a t o m i s e re n d .
W i t h t h e s p e e dc o n t r o l i n t h e m a x i m u ms p e e d p o s i t i o n ,
motor the engine over by means of the starter motor
u n t i l f u e l , f r e e f r o m a i r , i s s u e s f r o m t h - oc o n n e c t i o n s .
T i g h t e n t h e c o n n e c t i o n sT
. he engine is now ready for
startin g
SECTIONP
Flywheeland FlywheelHousing
FLYWHEELAND FLYWHEELHOUSING
P2
To Removethe Flywheel
Removethe twelvesetscrewsand washerswhich secure
the flywheel to the crankshaft flange.
I t i s a d v i s a b l et o f i t s u i t a b l eg u i d e s t u d s t o p r e v e n tt h e
flywheel from dropping as it clears the crankshaft
flanoe
Flywheel Ring Gear

T h e r i n g g e a r i s s h r u n ko n t o t h e f l y w h e e l .
W h e n r e p l a c i n gt h e r i n g g e a r , t h e a p p l i e d h e a t t o t h e
new ring should not exceed 480. F (250"C)
Attention should be paid to the chamfered lead - rn
edge of the ring gear, and its relative position on the
flvwheel
To Refit the Flywheel

Using suitable guide studs, refit the flywheel to the
crankshaftf langeand securewith setscrewsand wasners.
Tighten setscrewsto a torque of S0lbfft (11,1kgfm) or
1 0 8N m
Flywheel Alignment
Flywheel Runout
T h e o u t s i d e d i a m e t e ro f t h e f l y w h e e l s h o u l d b e c o n c e n t r i c w i t h i n 0 . 0 1 2 i n( 0 , 3 0 m m )t o t a l i n d i c a t o rr e a d i n g ,
to the crankshaftaxis.
T h e a l i g n m e n to f t h e f l y w h e e l f a c e s h o u l d b e w i t h i n
t h e l i m i t o f 0 0 0 1i n ( 0 , 0 3 m m ) p e r i n c h ( 2 5 , 4 m m ) o f
flywheel radius from the crankshaft axis to the clock
g a u g e p l u n g e r ,s e e F i g . P 1
When carrying out this check, press the c?ankshaftone
way to take up the end float whilst turning the flywheel
To Removethe Flywheel Housing

Removethe startermotor and flywheel.
Unscrew the securing setscrews and tap the housing
c a r e f u l l yt o d i s l o d g ei t f r o m t h e l o c a t i n gd o w e l s .
To Refit the Flywheel Housing

Ensure that the rear face of the cylinder block and the
matingface of the housing are clean and free from burrs
F i t n e w d o w e l s ,a n d s e c u r e h o u s i n g t o c y l i n d e r b l o c k
to allow for adjustment,if necessary.
P.1
With a clock gauge, check that the alignment of the

flywheel housing bore and face, see Figs. P.2 and p.3,
are within the limits listed on Page P.3,
FLYWHEELAND FLYWHEELHOUSING
A l l a d j u s t m e n t tso b r i n g t h e h o u s i n g w i t h i n t h e s e l i m i t s
m u s tb e c a r r i e do u t o n t h e h o u s i n ga n d n o t o n t h e c y l i n d e r
block.
Tightenthe securingsetscrewsto torquegivenon page B.2,
P.3
Diameterof housing Bore

U p t o 1 4 2 5 i n ( 3 6 2m m ) . . . . . . . . . .
1 4 2 5 t o 2 0 . 1 2 5i n ( 3 6 2t o 5 11 m m ) . . . .
2 0 . 1 2 5t o 2 5 5 i n ( 5 1 1t o 6 4 8 m m )
2 5 5 t o 3 1 . 0i n ( 6 4 8t o 7 8 7m m )
Limit-Totallndicator Reading
0 . 0 0 6i n ( 0 , 1 5m m )
0 . 0 0 8i n ( 0 , 2 0m m )
0 . 0 1 0i n ( 0 , 2 5m m )
0 . 0 1 2 i n( 0 , 3 0 m m )
A l l a d j u s t m e n t tso b r i n g t h e h o u s i n gw i t h i n t h e s e l i m i t s m u s t b e c a r r i e do u t o n t h e h o u s i n ga n d n o t o n t h e
6 3544 SeriesWorkshopManual,January 1986
P3
,*
,,
SECTIONO
Turbocharger
TURBOCHARGER Q2
T6.3544Enginesonly
FaultDiagnosis
The turbochargeris fittedon the exhaustmanifoldoutler,see

Fig.A.4.lt is lubricated
by oiltakenfromthe enginelubricating
system. Oil pressure should never drop below 30lbf/in2
(2,11kgtlcm2)or 2o7kNlm2at normal runningspeed.Check
this pressureregularly.
lf the performanceof the turbochargeris suspect,check the

installationfor the followingfaults:
The maximumboostpressureshouldbe 11- 13.5lbvin2

(0,80
- 0,95kgf/cm2)
or 76 - 93kN/m2whenthe engineis runningat
maximumspeedand fullload.
With some engineswhere it is not possibleto fully load the
engine,the boostpressurewill be somewhatlower.
No attentionneed be paid to the speed of the turbocnarger
since this variesautomaticallywith the speed and load of the
engrne,
Maintenance
Excessive
air inletdeoression.
Lowor highair deliverypressure.
Low oil pressureand/orlow oil flow.
Restrictedexhaustfrom turbine.
Fuelpumpor injectionfaults.
Check and rectify in accordance with the following
paragraphs:
Excessiveair inletdepression:The air depressionat the entry
to the compressor,that is in the ductingafterthe air filterand
immediatelybeforethe compressorcover,shouldnot exceed
a 20 in (500mm) headof water.
Every20,000miles(30,000km)or 1,000hours,cleanthe oil

drain pipe from turbochargerto sump, also turbocnarger
compressorwheeland cover.
lf the depressionis excessive,the cause will be due ro a

restrictionof inletair by a dirtyair filter.
The compressorwheel and cover may be cleaned without

removingthe turbocharger
fromthe engine(Fig.e.1).
Low or high air delivery pressure:The pressure will vary

accordingto the enginerating,speedand load.
Removethe air inletduct and compressorhousingand check

for dirtor dustbuilduo.
lf the pressure is low, the probable cause is a dirty or

damagedcompressor,incorrectfuellingof the enginefuel
pump,or leakingmanifoldjoints.
Removeall foreign matter- determineand correctcause of

b u i l du o .
Use soft brushon compressorwheel as unevendepositscan
affectrotorbalanceand causebearingfailure.
With the compressorhousingremoved,push the compressor
housing wheel towards the turbine wheel and turn rotating
assemblyby hand: check for bindingand rubbing.Listen
carefullyfor unusualnoises.lf bindingor rubbingis evident,
removethe turbochargerfor dismantlingand inspection.
Servicethe air filter.
Checkthatthe injectionpumpfuellinghas not beendisturbed

and if satisfactory,removethe turbochargerfrom the engine
for inspection.
A higherreadingmay also indicateincorrectinjectionpump
fuellingor damageto the turbine.
Actionas for low oressure.
Low oil pressure and/or oil flow: The oil delivery pressure
should not be less than 30lbf/in2(2,1kgilcm2)or 207kN/m2
undernormalconditions
of load.
lf oil pressureis low, refer to Section L. Clean bores of the
feed and return pipes and check the connections for
obstruction.
Restrictedexhaust from the turbine: A restrictionof the
exhaustfrom the turbinewill affectengineperformance.lf the
back pressureis more than 20in (500mm)head of water,
check the exhaust system for obstructionand rectify as
necessary.
Reconditioning
When a turbocharger is removed from an engine, it is
imperativethat all terminationsof oil connectionsare sealed
immediately,to preventthe entryof dirt.
Duringall stagesof turbochargerdismantling,
examination
and rebuilding,care mLlstbe taken to ensurethat no damage
is causedto comoonents
Q.1
TURBOCHARGER
Q3
Holset3LD
Dismantling
Numbersin bracketsreferto numberson Sectional
Drawing,
Fig.Q.2.
Clampunituprightin viceon turbineinletflange.
Markrelativepositionsof turbinehousing(B),bearinghousing
(14),compressor
cover(21) and ,,V',clamp(7).
Removethe eight bolts (3) and associatedlockwashers
(2),
fasteningcompressorcover(21)to bearinghousing(14)
and
liftoffcover(21).
Removethe "V" clamp locknutand spring,,V,,clamp (7)
back
onto bearinghousing(14).Liftthe core assemblyciear
of the
turbinehousing(8).
Holdingthe turbinewheelat the hub,removethe compressor
locknut(17).
Slidecompressor
wheel(18)offthe shaft.
Usingcirclippliers,removethe largeretainingring(20)which
retainscompressorinsert (19). Two screwdriverishould
be
usedto liftinsert(19)frombearinghousing(14).
Q.2
Remove"O" ring(4)frominsert(19).
The individualparts of the thrust assemblycan now
be lifted
out.
(a) Spacersleeve(16) which can be gentlypushed
out of the
insert(19).
(b) Oil deflector(13)positionedby two groovepins.
(c) Thrustring(12).
(d) Thrustplare(5).
Note: The groove pins are a press fit in the bearinghousrng
(14)and shouldnot be removeo.
Removeshaftand turbinewheelassembly(10)together
with
its pistonrings(9) and (15).
Insertfingertipintoboreof bearing(11)
fnd remove.
Carefullyexpand and remove piston rifrgs(9) and (15) from
boththe spacersleeveand turbinewhe$land shaftassembty.
Caution: Over expansion of piston ring will cause
a
permanentset or breakthe rino.
TURBOCHARGER Q4
(18).
Compressorwheel
Gleaning Procedure
Use a commercially
approvedcleaneronly.Causticsolutions
willdamagecertainpartsandshouldnot be used.
Soakpartsin cleaneruntilalldepositshavebeenlooseneo.
Checkcarefullyfor cracked,bent or damagedbladesbut do

not attempt to straighten blades.
Use a plasticscraperor brisiletype brushon aluminiumoarts.

Vapour blast may also be used providingthe shaft and other
bearingsurfacesare protected.
Replaceif sectionthroughring has taken a permanentset;

indicatedby flatson the sidesof the ring.
Cleanall drilledpassageswith compressedairjet.

Make certainthat surfacesadjacentto wheels on stationarv
housingare free of depositsand are cleanand smooth,
"O" ring(4).
A schedule of tolerances which includes allowaore

dimensions
afterservice,is givenbelow.
lnternal Parts Inspection

Shaftandturbinewheelassembly(10).
Re-assembly
When the turbochargerhas been thoroughly cleaned,
inspectedand any damaged parts replaced,assemblycan
commence.
(a) Inspect bearing journals for excessive scratches ano

wear. Minorscratchesmay be tolerated.
Assemblyof the unit is the reverseof dismantling,

but the
followingpointsshouldbe noticed.
(b) Inspect piston ring groove walls for scoring. Minor

scratchesare acceotable.
(a) Lubricatebearings,thrust assembly,piston rings and

rotorshaft,withcleanengineoil.
(c) Checkcarefullyfor cracked,bent or damagedblades,but

do not attempt to straighten blades.
(b) When replacingturbinewheeland shaft(10)into bearing

housing(4), and spacersleeve(16) into insert(19),do not
force pistonringsinto bore as an off-centredrrngwill fracture,
causingthe shaftto bind.
Bearing(1'1).
Replacebearingsif excessivelyscratchedor worn.
BearingHousing(14).
Replace housing if bearing or piston ring bores are
excessively
scratchedor worn.
SpacerSleeve(16)
Replaceif pistonringgrooveor spacerare damaged.
Thrustring(12):thrustplate(5).
(a) Replaceif thrustfacesare damaged.Minorscratchesare
acceptable.
(b) Replace thrust plate (5) if faces are worn excessrverv,
unevenly,
severelyscratchedor otherwisedamaged.
(c) The small feed groovesin the thrust plate (5) must be
cleanandfreef romobstruction.
(c) The large retainingring (20) shouldhave bevelledside

facingoutwards.
( d ) T o r q u el o c k n u(t1 7 )t o l 3 l b f f t( 1 , 8 k g f mo) r 1 7 N m ,b o t t( 3 )
to slbfft (0,7kgfm)or 7Nm and "V" clamp locknut(6) to
f ) o r 1 3N m .
1 0 l b f t ( 1 , 4 k gm
(e) On completion,
spinshaftto ensureit rotatesfreely.
Note: lf during the dismantlingof the turbocharger,the
lubricatingoil feed and drain pipe adaptorswere removed
from the bearinghousing,these should,on re-assembly,
be
torqued to 30lbfft (4,15kgfm) or 41 Nm and 65tbfft
(8,99kgfm) or89Nm respectively.
The unit is now ready for fittingto the engine.lf it is not
intended to mount the turbocharger on the engine
immediately
afterassembly,thenthe gas and oil connections
mustbe sealedoff to preventthe entryof dirt
HOLSET 3LD
SCHEDULEOF TOLERANCES
Manufactured Dimensions
Allowable Oimensions after Service
RemarKs
T o t a lt u r b i n e w h e e l c l e a r a n c e
0 0 4 7 / 0 O 5 7 i n ( i , 1 9 / 1, 4 S m m )
OO24in(0,61
mm) min
Back turbinewheel clearance
0 01510027 in (0,38/0,68mm)
As Manufactured
Wheel pushed to compressorend
Frontturbinewheelclearance
0024/003Bin(0,61/0,96mm)
OO24in(0,61mm)min
Total compressorwheel clearance
0 049/0 062in (1,2411,57mm)
As Manutactured
Back compressorwheel clearance
0 026i0 043 in (0,66/1,09mm)
As Manulactured
Wheel pushed to turbine end
Thrustclearance
0 0 0 4 / 00 0 8 i n ( 0 , 1 o / O , 2 o m m )
As Manulactured
Radialfloatatcompressorwheh
eu
l b
0015/0021 in(0,38/O,53mm)
O O 2 4 i n ( O , 6 1 m mm
) ax
Bearing outsidediameter
0 8714/0 8719in (22,13t22J4mm)
As Manutactured
Bearing insidediameter
0 4815/0 4818 in ( 12,23t1224mm)
As Manulactured
Thrustbearingwidth
0 1 0 5 / 01 0 7 i n ( 2 , 6 7 1 2 J 2 m m )
O 1 o 4 i n( 2 , 6 4 m m )m i n
Squarenessofbackfaceofturbinewheel 0002inTlR (O,OsmmTlF)
AsL4anutactured
OnVeeblockatl3T5inradius
E c c e n t r i c i t ysom
f a l ld i a m e t e r o t s h a f t
00006inTlR (O,OimmTlR)
AsL4anutacrureo
P i s t o nr i n gg r o o v e so n s h a f t
0 0 6 6 / 00 6 8 i n ( 1 , 6 9 / 1 , 7 3 m m )
O 0 6 6 / 0O T O i n( 1, 6 8 / t , 7 9 m m )
Piston ring groove on spacer sleeve
0 066/0 068 in (1,68/1,73mm)
O 066/0 O7Oin (1,68/t ,79mm)
Piston ring width at turbineend
0 062/0 063 in (1,szl 1,60mm)
Feplace at each seruice
Piston ring width at compressorend
0 062/0 063 in ( 1,57/1,60mm)
Fleplaceat each seruice
B e a r i n gh o u s i n gb o r e f o r p i s t o n r i n g
0 8 7 5 0 / 08 7 5 5 i n ( Z Z , 2 2 t 2 2 , Z 4 m m )
OB77in(2Z,2}mm)max
Compressorinsert bore
0 875/0 876in (22,22t22,25mm)
O B77in (22,28mm) max
Bearing housing bore at bearing
0 8750/0 8755 in (22,22t22,24mm)
As Manufactured
Turbinewheeloutsidediameter
2977/297,in (75,62/75,56mm)
2 9 8 0 i n ( 7 5 , 6 9 m m )m a x
Shaftdiameteratbearing
(i2,ZOt12J9mm)
0 4 8 0 3 / 04 B O O i n
O 4 7 9 9 i n( 1 2 , i 9 m m ) m i n
TURBOCHARGER Q5
AiresearchT-048(seeFig.e.3)
Dismantling
Clean the exterior with a pressure spray of a non_
causticcleaningsolventbeforedismantling.
Dismantleonly
as requiredto make necessaryinspectionor repairs.As each
part is removed,place in a clean containerto preventloss or
oamage.
bearingsuntilclearof centrehousing.
Note: The turbinewheel shroud is not retainedto the centre
housingandwillfallfreewhenthe shaftwheelis removed.
Removelockplatesand boltsfrom back plate.
Tap backplatewith soft malletto removefrom recessin cenrre
housing.
Removethrustcollarand thrustbearingfrom centrehousing.
Remove the bolts, clamps and lockplateswhich hold the

compressorand turbine housingsto the centre housrng
group.Tap the housingswith a soft faced hammerif torce ts
neededfor removal.
Removebearingsand retainersfrom centrehousinq.Discard

rubbersealingring.
Note: Exercisecautionwhen removinghousingsto prevent

damageto compressor
or turbinewheel,Oncedamaged,they
cannot be repaired. Never attempt to straighten bent
compressor
or turbineblades- replacethe faultycomponent,
Placethe centrehousinggroup in a suitableholdingfixture
whichwillpreventthe turbinewheelfromturning.
Cleaning
Beforecleaning,inspectall partsfor signsof rubbing,burnrng
or otherdamagewhichmightnot be evidentaftercleanrng.
Soak all parts in clean non-causticcarbon solvent. After
soaking,use a stiff bristlebrush and removeall dirt particles.
Dry partsthoroughly.
Use a T-handledwrench when removingthe compressor

wheellocknutto avoidpossiblebendingof the shaft.
Note: Normally,a lightaccumulation

of carbondepositswill
not affectturbineoperation.
Lift the compressorwheel off the shaft. Remove the shaft

wheel from the centre housingkeepingshaft centralwith
A BOLT
B LOCKPLATE
C THRUST
BEARING
D BACKPLATE
ASSEMBLY
E L O C KN U T
F COMPRESSO
WRH E E L
G P I S T O NR I N G ' C O M P R E S S O R
H THRUSTCOLLAR
Q.3
6 3544SeriesWorkshopManual,January't986
I
J
K
L
M
N
S E A LR I N G
C E N T R EH O U S I N G
ASSEMBLY
RETAINING
RING
BEARING
SHROUD
PISTON
R I N GT, U R B I N E
S H A F TW H E E LA S S E M B L Y
TURBOCHARGER Q6
Internal Parts lnspection

Parts must not show signs of damage, corrosion or
deterioration.Threads must not be nicked, crossed or
stripped.
The turbinewheelmustshow no signsof rubbingand vanes
must not be torn or worn lo a feather edge. The shaft must
show little signs of scoring,scratchesor seizurewith the
bearings.
The compressormust show no signs of rubbin$or damage
from foreignmatter.The compressorwheel bore must not be
chafed.
Seal parts must show no signs of rubbingor scoringof the
runningfaces Housingsmust show no signsof contactwith
rotatingparts. Oil and air passagesmust be clean and free
from obstructions
Burnishor polish out minor surfacedamage. Use silicon
carbide abrasive cloth for aluminium parts and crocus
abrasivecloth for the steel parts. Thoroughlyclean pa(s
beforere-assembly.
Replaceany partswhichdo not meet requirements
frontfaceof the impellermustbe smoothand clean.Lightlyoil

threads and face of' nut and tightento 20lbfin (23kgfcm)or
2,26Nm, Then continue to tighten until length of shaft
increasesby 0.0055/0.0065in
(0,14i0,16mm).
Tightennut by
using T-handledwrenohto avoid side load which may cause
shaftto bend.Check axialend play for 0.001/0.004in
(0,03/
0,10mm)travel.lf equipmentis not available
to measureshaft
stretch,this alternativemethod may be used: after installing
impellernut and tighteningto 20lbfin (23kgfcm)or 2,26Nm
continueto tightenthroughan angleof g0'.
Check for clearancebetween wheel shroud and turbine
wheel.
Orientatecompressorhousingto centre housing.Fit the six
bolts and three lockplates.Tighten bolts to 130lbfin
( 1 5 0 k g f c mo)r 1 4 , 0 9 N m .
Orientateturbine housingto centre housing.Coat bolt heads
with a high temperaturethread lubricant.Installbolts,clamps
and lockplates.Tighten bolts to 130lbfin (150kgfcm)or
14,09Nm.Bendup lockplates.
After assembly,push the rotatingassemblyas far as possible
from the turbineend and check for binding.Repeatcheck,
pushingfromcompressor
end.
lf the unit is to be stored, lubricateinternallyand install
protective
coverson all openings.
Replacethe followingparts:sealring,lockplates,
pistonrings,
turbine housing bolts, journal bearings,bearing retaining
rings,and compressor
wheellocknut.
Note: The turbocharger does not require testing atter

overhaul.
lf thrustbearingand thrustcollarshowsignsof nicks,scores,

varnishdepositsor foreignmatterembedments- replace.
Also,a closeinspection
of bearingboresin the centrehousing
should be made and if any of the above conditionsexist,
replacethe centrehousing.
Schwitzer3LM and 5.76
Re-assembly
Check each part prior to installation
to ensurecleanliness
Exercise care to prevent entry of foreign matter during
assembly.
Checkthrustcollarpistonringgroovefor nicksor burns
Dismantling
Numbersin parentheses
0 referto key numbersin Fig.Q.4.
Clampthe edge of turbinehousing(22) mountingflangein
vice. Mark the relativepositionsof turbinehousing,bearing
housing(13) and compressor
cover(1).
Removethe setscrews(15),lockplates(16)and clampplates
(17). Lift the assemblyfrom the turbinehousing place on
workbenchwithturbinewheel(21)up
Assemblein thefollowingmanner:
Removesetscrews(12) and clampplates(11). Removecore

assemblyfromcompressor
cover(1).
Install inboard bearing retainers.Lubricatebearingswith

cleanengineoil Fitbearingsandouterbearingretainers
Invertcore assemblyand place in turbinehousingwhich is

clampedin vice.
Place turbine wheel upright Gently guide shaft through

shroud and centre housingbearings Place thrust bearing
overthrustcollar
Holdthe end of turbinewheelwith 1%ainAIFsocketwrench,

remove the compressornut (2). Removethe compressor
wheel(3). Use extreme care in handling the compressor
wheel as the bladesbend very easily.
Fit pistonringon thrustcollar.Placethrustcollarovershaftso

that thrust bearingis flat againstthe centre housingand
pins.
engagesthe centrehousinganti-rotating
Removethe snap ring (8) using suitablepliers.Note the

positionof bevelon the outeredgeof the snapring;it mustbe
replacedthe sameway on re-assembly
Installsealringin groovein centrehousing.
Removethe insert(6) from the bearinghousing,removethe

thrustsleeve(4), pistonring (5) and the oil deflector(7) from
the shaft.
Ensure that thrust spring is installedin back plate Align

mountingholesof centrehousingand backplateand install
over shaftand thrustcollar.Use care not to breakpistonring
when engagingseal into backplatebore.Backplateis easily
installedif openend positionis engagedinto backplatebore
first.
Installcompressorbackplateboltsand lockplate.Tightento
79lbfin (104kgfcm)orB,93Nmand securelockplates.
Fit compressorwheel.The largerface of the locknutand the
'1
Remove"O" ring(9)fromthe insert.

Removepistonring(19)fromthe thrustsleeve.Both"O" ring
and pistonring must be renewedon re-assemblySeparate
the oil deflectorfromthe thrustsleeve.Liftthrustbearing(10)
out of bearinghousing.The thrustbearingmust be renewed
whenre-assembling.
Remove the shaft and bearing housingfrom the turbine
housing(22)
TURBOCHARGER Q7
Separateshaft and wheel assembly (21) from the bearrng
housing. Care must be taken not to damage the
compressor wheel or the shaft.
Remove the bearing (14). Renew the bearingwhen reassembling.
Separatethe backplate(18) and gasket(20),if fitted,from the
bearinghousing.Where a gasket is fitted it must be reneweo
whenre-assembling.
Remove the piston ring (19) from the shaft and wheel
assembly The pistonringmust be renewedon re-assemotv.
Do not removethe pinsin the bearinghousing,
Cleaning
Beforecleaning,inspectall partsfor signsof rubbing,burnrng
or otherdamage.
Clean all parts in clean non-causticcarbon solvent. After
soaking,use a stiffbristlebrushto removeall dirtoarticles.
Oil
and air passagesmust be cleanand free from obstructions.
Blowdrywithcleanjet of compressed
dry air.
Followingthe cleaning,the partsshouldbe examinedand, if
found to be in satisfactorycondition,re-assembledin the
reverseorderof the strippingsequence.
I5
Q.4
January1986
Parts Inspection
It is suggestedthat all partsto be re-usedshouldbe checked
and measuredafterthe partshave beenthroughlycleaned.
A.
BearingHousingand GroovePin Assembly

1. Inspectfor cracks or fractures,pittingof the gasket (from
corrosion or hot gas corrosion) and other machined
surfaces,or distortionof turbine end flange. Renew the
partsif conditionis excessive.
2. Visuallycheck the bearingbore for surfacecracks.Renew
if boreconditionis sub-standard.
Referencemaximumbore diametersare:
- 0.7505in(i 9,06mm)
Standard
.010Oversizerebuilt - 0.7605in(19,32mm)
.020Oversizerebuilt - 0.7705in(19,57mm)
Note:The borediameterof a rebuiltturbocharger
is coded
by the lastdiEitof the serialnumber
- I
Standard
- 0
010Over
- B
020 Over
B. Compressor
Wheel
1 Inspectfor evidenceof bent,burredor erodedvanesand
wear marks on the back. Renew if damaged. Do not
attempt to straighten bent vanes.
TURBOCHARGER Q8
C. TurbineWheeland ShaftAssembly
1. Inspectthe wheelfor evidenceof bent,burredor erooeo
vanes and wear marks on the back face. Renew if
damaged Do not attempt to straighten bent vanes.
2. Checkthe hub for marks (fromhigh speedcontactwith the
bearing housing bore) and for damage of the seal ring
groove.Renewif damagedor wear is excessive.
3. Inspectthe bearingjournalsfor evidenceof anydamageor
wear. Renewthe journalif necessary.
j o u r n adl i a m e t e r 0 . 4 4 0(i 1n1 , 1 8 m m )
Minimum
4. Measure the concentricitybetween the large and small
shaft diameterswith a dial indicatorand vee block.Limitof
eccentricityis 0.0006in (0,015mm)T.l.R. Renew if not
withinlimit.
D, ComoressorCover
Check for damage from wheel contact, renew if damage is
excessive.lt is permissible
to polishout any smallnicksin the
coverconlour.
E. TurbineHousingand Backplate
Check for damage from wheel contact and evidence of
excessivetemperaturedamage to internalflangedsurfaces,
such as surface crackingand pitting or distortion.Renew if
cracked.lt is permissibleto polish out small nicks in the
contour.
F. SmallInternalParts
1. Fit new compressorseal ringin the insertbore.Checkfor
full circle of contact and measurering gap with feeler
gauge.Gap range0.002/0.007in
(0,05/0,18mm).
Renew
insertif ringfit is out of the limit.
2. Inspect the thrust sleeve for evidence of wear and
scratches.Renewif damaqeis excessive.
Re-assembly
Numbersin parentheses
0 referto key numbersin Fig.e 4.
Check each part before re-assembly.The following items
mustbe renewedwhenthe turbocharger
is rebuilt:
Compressor
nut (2) Bearing(14)
Pistonring(5)
Lockplates(16)
"O" ring(9)
Pistonring(19)
Thrustbearing('10) Gasket(20)- whereapplicable
Fix the turbinehousing(22) securelyin vice with the four
threadedholesfacingupwards.
Oil pistonring (19) and fit in ring grooveof shaftand wheel
assembly(21), being carefulnot to over-expandthe ring.
Positionthe bearinghousing(13) with turbineend up. Fit
gasket(20),whereapplicable,
and turbinebackplate
(18).
The separate backplate has no attachment to the bearing
housing, its position is fixed when the bearing housing
and the turbine housing are clamped together. A few
models do not require a gasket (20).
Oil the pistonring area of the shaftand wheelassembly.Fit
into bearinghousingusing care to avoid damageto piston
nng.
Holdingthe end of the shaftto preventthe shaftwheelfrom
fallingout of the bearinghousing,place sub-assemblyin
turbinehousingwheelend down
Oil the bearing(14)and slip bearingdown overthe shaftinto
the bearinghousingbore
Oil the thrustfaceson bothsidesof thrustbearing(10).place
thrust bearingbronze side up over shaft and groove pins
engagingpins to holesin thrustbearing.Some modelshave

onlyone groovepin
Placeoil deflector(7) on thrustsleeve(4).
Oil the pistonring (5) and fit on thrustsleeveusingcare not to
over expandthe pistonring
Oil the "O" ringand fit intogrooveof insert(6).
Oil the thrustsleeveand fit the smallend in holeof the insert
from the concaveside, taking care not to damagethe piston
flng.
Oil the thrust cavity in bearing housing and fit insert/oil
deflector/thrustsleeve sub-assemblyover the shaft into the
bearinghousing,aligningoil deflectorwith oil draincavityin
bearinghousing.Takecarenotto damage"O" ring.
Usingsuitablepliers,fit snap ring (8) intothe groovewiththe
flatsideagainstthe insert.Ensurethe snapringis securelyin
position.
Mounta dial indicatoron the bearinghousingwiththe stemof
the indicatoron the end of the shaft. Make sure that the
turbineend of the bearinghousingis correctlyseatedin the
turbinehousing.Movethe shaftvertically
to determine
turbine
wheel contour clearance.The clearancemust be between
0.018in(0,46mm)and 0.049in(1,24mm\.lf clearancers not
within these tolerances,dismanile unit to determinethe
cause. Look for burrs, dirt particlesor incorrectlyassembled
parts. lf after re-assemblyit is still out of the permitted
tolerance,do not use.
Installcompressorwheel (3) on shaft.
Removeany oil from the shaft threadsand apply 2 drops of
"Loctrte 601" (or equivalentlocking agent) to the shaft
threads.Usinga socketwrenchon the turbinewheel lug to
preventthe shafl from turning,tightenthe compressornut to
l 3 l b f f t( 1 7 , 6 N m ) .
Mountthe dial indicatoron the bearinghousingwithstemon
the end of the shaft,measurethe end play.The toleranceis
(0,05/0,13mm).
0.002/0.005in
This is a dry (no oil) reading.
lf not within tolerance,dismantleand look for burrs, dirt
particlesor incorrectassembly.Re-assembleand if stillout of
tolerance,
do not use.
Place compressorcover (1) on the bench with wheel cavity
upwards.Lubricatethe smalldiameterof the shaftwithgrease
or oil and place lhe turbochargercore assembly in
compressor
coverwiththe turbinewheelup.
Check turbine wheel clearance between back face of the
turbine wheel and plate on oppositesides of the shaft.
clearancetolerancemust be 0.017/0.049in (0,4311
,24mm\.lt
clearanceis not withinthe limits,dismantleand inspectas
with previouscomponents,if on re-assemblystill not to
tolerance,
do not use.
Ensure that the location marks previouslymade on the
compressorcover and bearinghousingare in line and fit the
four clamp plates (11) with setscrewsand lockingwasher
(12). Tightensetscrewsto slbfft (6,BNm).Use care not to
overtighten screws as damage can be caused to the
aluminiumcompressor
cover.
Turn unit over and place in the turbine housing.Apply
anti-seize
compoundto threadsand setscrews(15).
Ensurethatthe locationmarkspreviously
madeon theturbine
housingand bearinghousingare in line.
Fitclampplates(17),lockplates(16)andsetscrews.
Tightenthe setscrewsto l2lbfft (16,3Nm)and lockthetabsto
setscrews.
Removecompletedturbochargerfrom the vice.
TURBOCHARGER Q9
InstallationCheck List
Inspectthe air intake system and the exhaust
manifoldfor
cleanlinessand foreignmatter.
Inspectthe oil drainlineand makesureit is notclogged.
Inspect the oil supply line for clogging,deterioration
or
possibility
of leakingunderpressure.
Inspect the turbochargermounting pad on the manifold
to
make certainthat all the old gasket has been removed.
On
some applications an adaptor is fitted between
the
turbochargerand exhaustmanifoldassembly.The adaptor
is
securedto the manifoldby four stud nuts and washers
and it
should be ascertainedthat all traces of the old gasket
have
been removedfrom it.
Installa new gasket betweenthe turbochargerand
exnaust
manifold. ln cases where an adaptor is iitteC, it wiil
be
Installturbocharger
and tightenmountingbolts or secunnq
nuts.
Connect the oil supply line but leave the oil drain line
disconnected.
Connectthe compressorinlet and outlet piping.Check
all
joinls for possibleleaks. Make certainthat the piping
rs not
exertinga strainon the compressorcover.
Connectexhaustpipe.
Motorthe enginewithoutfiring(i.e.by operatingstopcontrot),
untila steadyflowof oil comesfromthe oil drainline.
Stop motoringand connectoil drainpipeconnection.
Note: When the turbochargeris put into service, it is not
advisableto run up to maximumspeed or boostdurinqrne
first500 milesor 25 hoursof runnino.
January1986
SECTIONR
Alternatorand starterMotor
R2
ALTERNATOR
M o d e l s A C s , 1T A C R ( d e r a t e d ) , 17 A C R ,
1 8 A C R ,2 5 A C Ro r A 1 3 3 / 6 5 .
b e l t so n a m u l t i p l eb e l t d r i v e h a v ee q u a lt e n s i o na n d
are each carryingtheir share of the load Slack
beltswill wear rapidlyand cause slip which will
n o t d r i v et h e a l t e r n a t o ra t t h e r e a u i r e ds o e e d .D r i v e
belts which are too tight impose severeside thrust
o n t h e a l t e r n a t o rb e a r i n g sa n d s h o r t e n t h e i r l i f e
P e r i o d i c a l l ye n s u r e t h a t t h e a l t e r n a t o ri s c o r r e c t l y
a l i g n e dt o t h e d r i v e .
1. General
At the time of writing there are five types of alternator
fitted to the T6.3544 and 6.3544 engine,namely the
A C s , 1 7 A C R ,1 8 A C R , 2 5 A C R
a n dA 1 3 3 / 6 5 .
These are driven by the engine in the same manner
a s a D C G e n e r a t o rn, a m e l y b, e l td r i v e nf r o m t h e c r a n k s h a f t
p u l l e y ,b u t t h e a d v a n t a g el i e s i n t h e i r a b i l i t yt o p r o v i d e
h i g h e r m a x i m u m o u t p u t a t l o w e r s p e e d s ,t o c o p e w i t h
i n c r e a s e de l e c t r i c a ll o a d d e m a n d e d b y m o d e r n e q u i p ment and decreased road speeds owing to increased
d e n s i t yo f t r a f f i c ,e s p e c i a l l yi n b u i l t u p a r e a s .T h e y a r e
a l s o m u c h l i g h t e ri n w e i g h t ,o u t p u t f o r o u t p u t
A s o p p o s e dt o t h e D C G e n e r a t o ri n w h i c h t h e a r m a t u r e
w i n d i n g s r o t a t e i n s i d e a s t a t i o n a r yf i e l d s y s t e m , t h e
alternatorhas a rotating field system inside a stationary
generatingwinding When the rotor rotates inside
t h e s t a t o r , t h e o u t p u t p r o d u c e d i s a l t e r n a t i n gc u r r e n t
( A C ) T h i s i s u n s u i t a b l ef o r c h a r g i n gt h e b a t t e r y w h i c h
r e q u i r e sd i r e c t c u r r e n t ( D C ) , s o i t i s . r e c t i f i e db y m e a n s
o f d i o d e sw h i c h c o n v e r ti t t o u n i - d i r e c t i o n af l o w t o t h e
battery
The alternatorvoltage output is maintained within
close limits by meansof a control box which is fullv
t r a n s i s t o r i s eadn d f u n c t i o n sa s f a s t s w i t c h e s
( b ) D o n o t r e p l a c ef a u l t y b e l t s i n d i v i d u a l l yi n a m u l t i belt system.A complete matched set of drive belts

must always be used.
(c) Keep the alternatorclean with a cloth moistenedin
k e r o s e n eo r c l e a n i n gf l u i d s E n s u r et h a t v e n t i l a t i o n
s l o t s a n d a i r s p a c e sa r e c l e a r a n d u n o b s t r u c t e d
( d ) R e m o v e a n y d i r t a c c u m u l a t e do n t h e r e g u l a t o r /
c o n t r o l b o x h o u s i n g ,a n d e n s u r e t h a t c o o l i n g a i r
can pass freely over the casing
4. Fault Finding on AC5

T h e A C s a l t e r n a t o ri s s o d e s i g n e dt h a t a f l o w o f c u r r e n t
i n d i c a t e de i t h e rb y t h e e x t i n g u i s h i n o
g f t h e w a r n i n gl i g h t ,
o r a ss h o w no n t h e a m m e t e r i,s s u f fi c i e n te v r d e n c e
t h a tt h e
system is in proper working order Therefore, no open
circuit, voltage or current output checks should be
p e r f o r m e do n t h e i n s t a l l a t i o nU N L E S S :
(a) The warning light fails to illuminatewhen ihe
g e n e r a t o ri s s t a t i o n a r y ,a n d t h e s w i t c h i s c l o s e d
OR fails to become extinguished when the
a l t e r n a t b irs r u n n i n g .
2. Precautions
( b ) N o c h a r g i n gc u r r e n ti s s h o w n o n a m m e t e r .
A s p r e v i o u s l yd e s c r i b e dt h e d i o d e s i n t h e a l t e r n a t o r
f u n c t i o n a s o n e - w a y v a l v e sa n d t h e t r a n s i s t o r si n t h e
regulator/control box operate as fast switches. Both
are accurateand sensitive
(c) The battery is flat

( d ) T h e b a t t e r y i s " b o i l i n g " ,i n d i c a t i n gl o s s o f v o l t a g e
control
T h e y d o n o t w e a r o u t a n d s e l d o m r e q u r r ea d j u s t m e n t ,
but because they are sensitive to voltage changes
a n d h i g h t e m p e r a t u r e ,t h e p r e c a u t i o n s a r e v r t a l t o
preventthem from being destroyed
( a ) D O N O T d i s c o n n e c tt h e b a t t e r y w h i l s t t h e e n g i n e
i s r u n n i n g T h i s w i l l c a u s e a v o l t a g es u r g e i n t h e
a l t e r n a t o rc h a r g i n g s y s t e m t h a t w i l l i m m e d i a t e l v
r u i n t h e d i o d e so r t r a n s i s t o r s .
( b ) D O N O T d i s c o n n e c ta l e a d w i t h o u t f i r s t s t o p p i n g
t h e e n g i n ea n d t u r n r n ga l l e l e c t r i c a sl w i t c h e st o t h e
off position
( c ) D O N O T c a u s ea s h o r t c i r c u i t b y c o n n e c t i n gl e a d s
t o i n c o r r e c tt e r m i n a l s A l w a y s i d e n t i f ya l e a d t o i t s
c o r r e c t e r m i n a lA
. s h o r tc i r c u i to r w r o n g c o n n e c t i o n
giving reverse polarity will immediately and
p e r m a n e n t l yr u i n t r a n s i s t o r so r d i o d e s
( d ) D O N O T c o n n e c ta b a t t e r yi n t o t h e s y s t e mw i t h o u t
c h e c k i n gf o r c o r r e c t p o l a r i t ya n d v o l t a g e
( e ) D O N O T " f l a s h " c o n n e c t i o n st o c h e c k f o r c u r r e n r
f l o w N o m a t t e rh o w b r i e ft h e c o n t a c tt h e t r a n s i s t o r s
may be ruined
3. Maintenance
T h e a l t e r n a t o rc h a r g i n g s y s t e m w i l l n o r m a l l y r e q u i r e
v e r y l i t t l e a t t e n t i o n ,b u t i t s h o u l d b e k e p t f r e e f r o m
build-upof dirt, and a check made if it fails to kccn
the battery charged
( a ) R e g u l a r l yi n s p e c t t h e d r i v i n g b e l t s f o r w e a r a n d
c o r r e c t t e n s i o n . l t i s t m p o r t a n tt o e n s u r e t h a t a l l
lf any of the above symptoms occur, the procedure

i n d i c a t e db e l o ws h o u l d b e f o l l o w e d :
(a) Connect a good quality moving coil voltmeter
0-50 volts range across the battery or regulator
n e g a t i v et e r m i n a l , a n d o n e o f t h e t h r e e p o s i t i v e
t e r m i n a l sm a r k e dL O , M E D , H l l f a n a m m e t e ri s n o t
p a r t o f t h e a p p l i c a t i o n sc i r c u i t , f i t a g o o d q u a i i t y
m o v i n gc o i l 0 - 1 0 0 a m p a m m e t e ri n t h e a l t e r n a t o r
to battery positive line The battery should be in a
chargedcondition.
(b) Close the warnrng light switch (niasterelectrrc
switch on dashboard)when the warning lamp
s h o u l dl i g h tu p
( c ) S w i t c h o n a 1 0 - 1 5 a m p e r e sl o a d s u c h a s | i g h t s ,
fans, etc
(d) Start engine and run at fast idle speed when
' 1 T h e w a r n i n El i g h t s h o u l dg o
out
2 The ammeter records a small charoe
d e p e n d e no
t n e n g i n es p e e d
( e ) l n c r e a s ee n g i n e s p e e d m o m e n t a r i l yt o m a x i m u m
speed, when the charging current should be
a b o u t 3 0 a m p e r e sf o r 2 4 v o l t s - 5 5 a m p e r e sf o r
' 1 2v o l t
systems
(f)
W i t h t h e a l t e r n a t o rr u n n i n g a t a p p r o x i m a t e l yh a l f
s p e e d ( e n g i n es p e e d a b o u t 1 , 5 0 0r e v m i n ) , s w i t c h
o f f e l e c t r i c a ll o a d D e p e n d i n go n t h e c o n n e c t i o n
s e l e c t e df o r t h e p o s i t i v es e n s i n gw i r e L O , M E D , o r
H l , t h e v o l t a g es h o u l d r i s e t o b e t w e e n 2 6 a n d 2 8
v o l t so n 2 4 v o l t s y s t e m sa n d 1 3 - . 1 4 v o l t s o n 1 2 v o l t
s y s t e m sa n d t h e n r e m a i n c o n s t a n t A t t h e s a m e
t r m e t h e c u r r e n t r e a d i n gs h o u l d d r o p a p p r e c i a b l y
R3
A n y v a r i a n c ei n t h e a b o v e d a t a c o u l d i n d i c a t e a f a u l t
a n d t h e f o l l o w i n gp r o c e d u r es h o u l d b e a d o p t e d b e f o r e
disconnectina
gny components
T h e r e g u l a t o ri s a s e a l e d u n i t a n d i s n o n _ r e p a i r a b l e
a n d i f f o u n d t o b e f a u l t yi t m u s t b e r e p l a c e d .
Warning Lamp does not light up when switched ,,On,,.
check the bulb
lf no fault
C h e c k a l l w i r i n g c o n n e c t i o n sa t r e g u l a t o r ,a l t e r n a t o r
and battery
lf no fault
S w i t c ho f f , d i s c o n n e c "t F ' , l e a d a t r e g u l a t o ra n d c o n n e c t
i t t o t h e n e g a t i v et e r m i n a l .
S w i t c h o n l f w a r n i n g l a m p l i g h t s u p , t h e r e g u l a t o ri s
f a u l t y l f l a m p f a i l s t o l i g h t u p t h e a t t e r n a t o ri s f a u t t y
Warning Lamp does not go out and Ammeter shows
no output when running.
T e s t C i r c u i tf o r 1 7 A C Ra l t e r n a t o r s
Standardterminations,batterv_sensed
C h e c k a l l r e g u l a t o ra
, l t e r n a t o ra n d b a t t e r yc o n n e c t i o n s .
lf no fault
S w i t c ho f f , d i s c o n n e c t ' , F l, e' a d a t r e g u l a t o ra n d c o n n e c r
t o r e g u l a t o rn e g a t i v et e r m i n a l
R.1
S w i t c ho n , a n d r u n a t f a s t i d l e
l f n o o u t p u t ,a l t e r n a t o irs f a u l t y .
l f o u t p u t a p p e a r s r, e g u l a t o ri s f a u l t y
Warning Lamp does not go out when running and
Ammeter shows reduced output with full output only
at maximum speed or Warning Lamp goes out but
Alternator delivers reduced output. Full output only at
maximum speed.
A l t e r n a t o rf a u l t y R e m o v e f r o m i n s t a l l a t i o na n d a p p l y
o p e n c i r c u i td i o d e c h e c k
Warning Lamp f lashes intermittenily and Ammeter
needle oscillateswhen Battery is fully charged and no
loads are switched in.
C h e c k f o r e x c e s s i v er e s i s t a n c ei n r e g u l a t o r n e g a t i v e
s e n s i n gl e a d
l f n o f a u l t ,r e g u l a t o ri s f a u l t y
Batteries overcharging and Ammeter indicates high
o r f u l l o u t p u ta l l t h e t i m e .
C h e c kr e g u l a t o p
r o s i t i v es e n s i n gl e a d a n d i t s c o n n e c t i o n
at regulator.
l f n o f a u l t ,r e g u l a t o ri s f a u l t y
5 . T e s t i n g t h e 1 7 A C R , 1 B A C R ,2 5 A C R a n d
A 1 3 3 / 6 5i n P o s i t i o n
F i r s tc h e c kt h e d r i v i n gb e l t f o r c o n d i t i o na n d t e n s i o n T
. he
n o m i n a l h o t o u t p u t sa t 6 , 0 0 0r e v / m i n( a l t e r n a t o sr p e e d )
a r e g i v e n o n P a g e 8 1 2 . T h e s e f i g u r e sm a y b e e x c e e d e d
s l i g h t l y w h e n t h e a l t e r n a t o ri s r u n n i n g c o l d . T o a v o r d
m i s l e a d i n gr e s u l t s ,t h e f o l l o w i n gt e s t p r o c e d u r es h o u l d
t h e r e f o r eb e c a r r i e d o u t w i t h t h e a l t e r n a t o rr u n n t n ga s
n e a r a s p o s s i b l et o i t s n o r m a lo p e r a t i n gt e m p e r a t u r e .
AlternatorOutput Test with Regulator

Inoperative
W i t h d r a w t h e c a b l e c o n n e c t o r ( s )f r o m t h e a l t e r n a t o r ,
r e m o v et h e m o u l d e d c o v e r ( s e c u r e d b y t w o s c r e w s )
a n d e a r t h t h e r e g u l a t o rg r e e n l e a d o r c o n n e c t o rs t r i o
to frame
C o n n e c ta n e x t e r n a lt e s t c i r c u i t t o t h e a l t e r n a t o ro u r p u r
termanaa
l ss s h o w ni n F i g R , 1 ,R . 2 o r R 3
V a l u e o f c o m p o n e n t si n F i g s R 1 , R . 2 a n d R 3 a r e a s
follows:
1 '12 volt 2 2 watt butb.
2
0-60 ammeter
1 2v o l t b a t t e r y
0-20 moving coil voltmeter
0 - 1 5 o h m 3 5 a m p v a r i a b l er e s i s t o r
O b s e r v ec a r e f u l l yt h e p o l a r i t yo f b a t t e r y a n d a l t e r n a t o r
t e r m i n a l sreversedconnectionswill damaoe thc
a l t e r n a t od
r iodes
The variable resistor across the battery teri-ninalsmust
not be left connected for longer than is necessarvro
c a r r yo u t t h e f o l l o w i n gt e s t .
S t a r tt h e e n g i n e A t 1 , 5 0 0r e v l m i n( a l t e r n a t osr p e e d ) ,t h e
t e s t c i r c u i tb u l b s h o u l db e e x t i n g u i s h e dI.n c r e a s ee n g i n e
s p e e d u n t i l t h e a l t e r n a t o ri s r u n n i n g a t 6 , 0 0 0 r e v l m t n
a p p r o x i m a t e l ya,n d a d j L l stth e v a r i a b l er e s i s t a n c e
u n t i lt h e
v o l t m e t e rr e a d s 1 3 6 v o l t s T h e a m m e t e rr e a d i n gs h o u l d
t h e n b e a p p r o x i m a t e l ye q u a l t o t h e r a t e d o u t p u r ( s e e
p r e v i o u sh e a d i n g ) .A n y a p p r e c i a b l ed e v i a t i o nf r o m t h i s
f i g u r ew i l l n e c e s s i t a tteh e a l t e r n a t o b
r e i n g r e m o v e df r o m
t h ee n g i n ef o r f u r t h e re x a m i n a t i o n .
F a i l u r eo f o n e o r m o r eo f t h e d i o d e sw i l l b e i n d i c a t e di n t h e
above test by effect on alternator output, and also in
s o m ei n s t a n c e b
s y a b n o r m a l l yh i g h a l t e r n a t otre m p e r a r u r e
a n d n o i s el e v e l
RegulatorTest
The following test assumesthe alternator to have oeen
tested and found satisfactorv.
R4
Disconnect the variable resistor and remove the earth

c o n n e c t i o nf r o m t h e r e g u l a t o rg r e e n l e a d o r c o n n e c r o r
strip to frame.
W i t h t h e r e m a i n d e ro f t h e t e s t c i r c u i t c o n n e c t e da s f o r
the alternator output test, start the engine and agarn
run the alternatorup to 6,000 revlmin until the ammeter
shows an output current of less than 10 amperes The
v o l t m e t e sr h o u l dt h e n g i v ea r e a d i n go f 1 3 , 6- 1 4 , 4v o r t s
A n y a p p r e c i a b l ed e v i a t i o nf r o m t h i s ( r e g u l a t i n g v) o l t a g e
Bo+
-T
?
2
m e a n st h a t t h e r e g u l a t o ri s n o t f u n c t i o n i n gp r o p e r l ya n d
must be replaced.
lf the foregoing tests show the alternatorand regulator
to be satisfactorily performing, disconnect the test
circuit and reconnectthe alternator terminal connector.
Now connect a low range voltmeterbetweenthe positive
t e r m i n aol f t h e a l t e r n a t o (r t h em o u l d e dt e r m i n a cl o n n e c r o r
i s o p e n e n d e dt o f a c i l i t a t et h i s ) a n d t h e p o s i t i v et e r m i n a l
of the battery.Switch on battery load (headlightsetc.),
start the engine and increasespeed until the alternator
runs at approximately6,000 revlmin Note the voltmeter
reading.
Transfer the voltmeter connections to the negative
terminalsof the alternatorand batteryand again note the
meter reading
lf the readingexceeds0 5 volt on the positiveside or 0.25
v o l t o n t h e n e g a t i v es i d e ,t h e r e i s a h i g h r e s i s t a n c ei n t h e
chargingcircuit which must be traced and remedied.
STARTERMOTOR
Model M50
e^
General Description
The model M50 startermotor is a four pole machine
o f 5 i n ( 1 2 7 , 0 m m )n o m i n a l y o k e d i a m e t e r ,a n d n a s a
21 slotarmature.
\y
+.nn ^9^r,
T h e d r i v e i s o f p r e - e n g a g e d s, o l e n o i d o p e r a t e d ,p u s n
screw type, incorporatinga five roller clutch.
T e s t C i r c u i t f o r 1 7 A C R a l t e r n a t o r sw i t h s t a n d a r dt e r m i n a l s a n d
t w o p i e c ec o n n e c t i o np l u g ( m a c h i n e - s e n s e d )
R.2
+' e)
IND
I
I
The function of the clutch is to prevent the armarure

being rotatedat high speeds in the event of the engaged
position being held after the engine has started The
solenoidincorporatesa two-stageswitchingarrangement
w h i c h e n s u r e st h a t t h e m o t o r d e v e l o p s i t s m a x i m u m
t o r q u e o n l y w h e n f u l l p i n i o n - f l y w h e eel n g a g e m e n th a s
been achieved
Testingon the Application

Ensurethat the battery is in a charged condition
Switch on the lamps and operate the starter button.
l f t h e s t a r t e rf a i l s t o f u n c t i o n , b u t t h e l i g h t s m a i n t a i n
f u l l b r i l l i a n c ec, h e c k t h e s w i t c h a n d b a t t e r yc o n n e c t r o n s
t o t h e s t a d e ra n d a l l e x t e r n a l e a d s .S l u g g i s ha c t i o no f t h e
starter can be caused by a poor or faulty connection.
Difficulty in smooth engagement between starter ano
engineflywheelis probablydue to dirt on the starter-shaft
h e l i c e s p r e v e n t i n gf r e e p i n i o n m o v e m e n t . T h e s h a f t
s h o u l db e t h o r o u g h l yc l e a n e dw i t h c l e a n i n gf l u i d f o l l o w e d
b y t h e a p p l i c a t i o no f a s m a l l q u a n t i t yo f A c r o S h e l l 6 8
or itsequivalent
_J
I
-r
@^^
\:./
/?\
+- A A A\l nnn
--
MAINTENANCE
Brush Gear and Commutator
T e s t C i r c u i tf o r 1 7 A C R ,1 8 A C R , 2 5 A C Ra n d A 1 3 3 / 6 5a t t e r n a t o r s
w i t h E u r o p e a nt e r m i n a t i o n sa n d s i n g l e3 t e r m i n a lc o n n e c r o rp t u g
( m a c h i n e - s e n s e d )B. r o k e n l i n e c a b l e c o n n e c t i o na o o l i e s t o
b a t t e r y - s e n s e di,n w h i c h c a s e , t h e c o n n e c t i o n sb e t w e e nt h e t w o
'+'terminals
w i l l n o t a p p l y a n d t h e b r o k e nl i n e t e r m i n a w
l ill be
m a r k e d" S " i n s t e a do f " + "
R.3
Inspectthe brushes at intervalsto ensure that they are

free in their guides and that the leads are quite free
f o r m o v e m e n t ,b y e a s i n g b a c k t h e b r u s h s p r i n g s a n d
p u l l i n gg e n t l y o n t h e f l e x i b l ec o n n e c t i o n s .l f a b r u s h i s
i n c l i n e dt o s t i c k , r e m o v e i t f r o m i t s h o l d e r a n d c r e a n
the sides with a petrol moistened cloth
B e s u r e t o r e f i t t h e b r u s h e si n t h e i r o r i g i n a l p o s i t i o n s
t o r e t a i n t h e " b e d d i n g " .T h e b r u s h e s s h o u l d b e w e l l
R5
l i k e l yt o r e q u i r ea d j u s t m e n ts, u c h a s t h e s w i t c h g e a r
and
c o m m u t a t o ra s s e m b l i e s .
Testingon the Application
c o n n e c t o rl e a d s ,h e l d b y t w o o f t h e f i x i n g s c r e w s .
Before
i n s e r t i n gb r u s h e s i n t h e i r h o l d e r s , i t i s a d v l s a b l e
to
b l o w t h r o u g h t h e h o l d e r sw i t h c o m p r e s s e da i r o r
clean
t h e mw i t ha c l o t hm o i s t e n e d
w i t hp e t r o l .
T h e c o m m u t a t o rs h o u l d b e c l e a n , e n t i r e l y f r e e
from
oil or dirt. Any trace of such should be iemoved
by
p r e s s i n ga c l e a n d r y f l u f f l e s sc l o t h a g a i n s t
it, while
armatureis hand rotated.
l f t h e c o m m u t a t o ri s d i r t y o r d i s c o l o u r e dt,i l t t h e
brushes
a n d w r a p a s t r i p o f f i n e g l a s s o r c a r b o r u n d u mp a p e r
(not emery cloth) round the commutator,
with the
abrasive side inwards. Rotate the armature by
hand
until the surface is even. Clean with a petrol moistened
cloth.
l f r e p a i ri s n e c e s s a r yt o t h e c o m m u t a t o ro r s w i t c h g e a r
etc., the starter must be exchanged or repaired
by an
a u t h o r i s e da g e n t .
Model CA45
General Description
D e s i g n e df o r f l a n g e m o u n t i n g ,t h e C A 4 5 s t a r t e r m o r o r
has a uniform cylindrical shape with no surface
p r o t r u s i o n s .T h i s i s b e c a u s e t h e s o l e n o i d a n d
main
s w i t c h a s s e m b l i e sa r e h o u s e d w i t h i n t h e d r i v e
eno_
s h i e l d ,a r o u n d ( i e . , c o - a x i a l l yw i t h ) t h e a r m a t u r es h a f t
The essentialfeature of the co-axial starter is that,
the
P i n i o na l o n em o v e sa x i a l l yt o e n g a g et h e e n g i n ef l y w n e e t .
T h e r ei s n o I o n g i t u d i n am
l o v e m e no
t f t h e w h o l eu i r " t r r "
a s s e m b l ya, s i n t h e a x i a lt y p e s
S m o o t h e n g a g e m e n to f t h e p i n i o n w i t h t h e e n g t n e
f lywheel is constantly ensured by using two_stage
operation of the solenoid and swrtch mechantsms.
T h u s t h e r i s k o f d a m a g et o b o t h p i n i o n a n d f l y w h e e l ,
t h r o u g hf a u t t ym e s h i n g ,i s p r a c t i c a l l ye l i m i n a t e d .
In construction, the starter consists of three
main
s e c t i o n s ,i n t o w h i c h i t c a n b e e a s i l y d i s m a n i l e d .
1 T h e s o l e n o i ds w i t c h - g e aar n d p i n i o na s s e m b l yh o u s e d
i n t h e d r i v ee n d - s h i e l d
2 The armature,shaft and commutator assembly.
3 T h e y o k e , p o l e - p i e c ea n d f i e l d - c o i la s s e m b l y
Ready access is possibletherefore,to those parts mosr
Ensurethat the battery is in a charged condrtron

Switch on the lamps ano operate the starter button.
l f t h e s t a r t e rf a i l st o f u n c t i o n ,b u t t h e l i g h t s m a i n t a i n
full
b r i l l i a n c ec, h e c k t h e s w i t c h a n d b a t t e r y c o n n e c t i o n s
to
t h e s t a r t e ra n d a l l e x t e r n a ll e a d s .S l u g g i s ha c t i o n
of the
startercan be causedby a poor or faulty connection
D i f f i c u l t y i n s m o o t h e n g a g e m e n tb e t w e e n s t a r t e r a n d
e n g i n e f l y w h e e l i s p r o b a b l yd u e t o d i r t o n t h e s r a r r e r _
s h a f th e l i c e sp r e v e n t i n gf r e e p i n i o n m o v e m e n tT n e s h a f t
should be thoroughly cleaned with cleaning fluid
f o l l o w e db y t h e a p p l i c a t i o no f a s m a l l q u a n t i t yo f A c r o
S h e l l6 8 o r i t s e q u i v a l e n t .
MAINTENANCE
Brush Gear and Commutator
I n s p e c tt h e b r u s h e sa t i n t e r v a l st o e n s u r et h a t t h e y a r e
f r e e i n t h e i r g u i d e sa n d t h a t t h e l e a d sa r e q u i t e f r e e f o r
m o v e m e n tb, y e a s i n gb a c k t h e b r u s h s p r i n g sa n d p u l l i n g
g e n t l yo n t h e f l e x i b l ec o n n e c t i o n s l.f a b r u s h l s l n c t t n e d
t o s t i c k , r e m o v ei t f r o m i t s h o l d e r a n d c l e a n t h e s r o e s
w i t h a p e t r o lm o i s t e n e dc l o t h
B e s u r e t o r e f l t t h e b r u s h e si n t h e i r o r i g i n a l p o s i t i o n s
t o r e t a j n t h e " b e d d i n g , ' .T h e b r u s h e s s h o u l d b e w e r r
b e d d e d( i . e .w o r n t o t h e c o m m u t a t o rp e r i p h e r y )b u t i f n o t ,
w r a p a s t r i p o f v e r y f i n e g l a s s o r c a r b o r u n d u mp a p e r
f i r m l y a r o u n d t h e c o m m u t a t o r w i t h t h e a b r a s i v es i d e
outwards With the brushes ln position, rotate the
armature by hand in the normal working dtrection
o f r o t a t i o n ;u n t i l t h e c o r r e c t b r u s h s h a p e i s o b t a i n e d .
lf the brushes are worn down so that the springs
a r e n o l o n g e r p r o v i d i n ge f f e c t i v ep r e s s u r e ,t h e y s h o u l d
b e r e n e w e dC
. h e c kt h e b r u s hs p r i n gp r e s s u r eb y h o o x r n g
a spring balance under the spring lip. The correct
t e n s i o ni s 3 0 / 4 0 o z f( 0 , 8 5 / 1 , t 3 k g f )
I t i s e s s e n t i a tl h a t r e p l a c e m e n tb r u s h e s a r e t h e s a m e
g r a d e a s t h o s e o r i g i n a l l yf i t t e d .G e n u i n e s p a r e ss h o u l d
alwaysbe used.To removethe brushes,unscrewthe four
f j x i n g s c r e w s ,o n e t o e a c h b r u s h . I n r e _ a s s e m b l i ncga r e
m u s t b e t a k e n t o r e - c o n n e c tt h e f i e l d c o i l a n d i n t e r _
connectorleads,held by two of the f ixing screws Before
i n s e r t i n gb r u s h e s i n t h e i r h o l d e r s ,i t r s a d v i s a b l et o b t o w
t h r o u g ht h e h o l d e r sw i t h c o m p r e s s e da i r o r c l e a n t n e m
w i t h a c l o t h m o i s t e n e dw i t h p e t r o l
T h e c o m m u t a t o rs h o u l d b e c l e a n , e n t i r e l yf r e e f r o m o i l
o r d i r t .A n y t r a c eo f s u c h s h o u l d b e r e m o v e db y p r e s s l n g
a c l e a n d r y f l u f f l e s sc l o t h a g a i n s t i t , w h i l e a r m a t u r ei s
hand rotated
l f t h e c o m m u t a t o ri s d i r t y o r d i s c o l o u r e dt,i l t t h e b r u s n e s
a n d w r a p a s t r i p o f f i n e g l a s s o r c a r b o r u n d u mp a p e r
( n o t e m e r y c l o t h ) r o u n d t h e c o m m u t a t o r ,w i t h
the
a b r a s i v es i d e i n w a r d s .R o t a t et h e a r m a t u r eb y h a n d u n t i l
t h e s u r f a c ei s e v e n .C l e a nw i t h a p e t r o l m o i s i e n e dc l o t h .
l f r e p a i r i s n e c e s s a r yt o t h e c o m m u t a t o r o r s w i t c h
g e a r e t c . t h e s t a r t e r m u s t b e e x c h a n g e do r r e p a t r e d
b y a n a u t h o r i s e da g e n t .
SECTIONS
Compressor
COMPRESSOR S2
T h e a i rc o m p r e s s oirs a s i n g l eo r t w i n c y l i n d e rw a t e rc o o l e d
unit which is bracketmounted on the cylinder block
a n d d r i v e nf r o m t h e a u x i l i a r yd r i v e .
can be moved on the shaft to obtain the correct

clearance.
S h o u l d i t b e n e c e s s a r yt o d r a i n t h e e n g i n e c o o l i n g
system to prevent damage by frost, the Clayton
D e w a n d r e c o m p r e s s o rm u s t a l s o b e d r a i n e d D r a i n
p l u g s a r e p r o v i d e do n t h e c o m p r e s s o rc y l i n d e r b l o c k .
W i t h t h e B e n d i x W e s t t n g h o u s ec o m p r e s s o r ,o n l y t h e
cylinder head is water cooled and this will be autom a t i c a l l ye m p t i e dw h e n t h e e n g i n e i s d r a i n e d
CLAYTON DEWANDRESC6 COMPRESSOR
lf leakage in the braking system is not excessive,

f a i l u r e o f t h e c o m p r e s s o rt o m a i n t a i n a d e q u a t ea i r i n
the system, or to charge the system in a reasonable
t i m e ,u s u a l l yd e n o t e sl o s so f e f f i c i e n c yd u e t o w e a r .T h i s
wear could be in the cylinder head (valvesand seats) or
cylinders (piston assemblies)Another sign of wear
is excessiveoil passing through to the reservoir
Marking before dismantling

The compressor should have the following items
m a r k e dt o s h o w t h e c o r r e c t r e l a t i o n s h i pt o d i s m a n t l i n g
1 Position of cylinder head in relation to cylinder
and crankcase.
2 Position of end-cover(s) in relation to crankcase
3 Position of crankshaft in relation to crankcase
Removingand DismantlingCylinder
Head and Cylinder
Remove the unloader cap and copper washer and
w i t h d r a w t h e u n l o a d e r p l u n g e r a s s e m b l ya n d s p r i n g .
PreventiveMaintenance
E v e r y5 , 0 0 0m i l e s ( 7 , 5 0 0 k m ) , 2 5 0 h o u r s o r 4 m o n t h s
( w h i c h e v eor c c u r sf i r s t ) .
R e m o v e ,d i s m a n t l ea n d c l e a n c o m p r e s s o ra i r c l e a n e r
(if fitted).
E v e r y 1 0 , 0 0 0m i l e s ( 1 5 , 0 0 0k m ) , 5 0 0
m o n t h s ( w h i c h e v e ro c c u r s f i r s t ) .
Dismantling
hours or 12
Visually check all unions, pipe fittings,etc., for

l o o s e n e s so r l e a k a g e
C h e c k c y l i n d e rh e a d b o l t s f o r c o r r e c tt i , g h t n e s s
C h e c k e n d c o v e r sf o r o i l l e a k s
Removethe deliveryvalve cap and copper washer,

and remove delivery valve spring and seat retaining
spflng
U n s c r e wt h e f o u r n u t s a n d w a s h e r sf r o m c y l i n d e r h e a d
studs and lift off cylinder head Remove the joint.
Removethe deliveryvalve and screw out the valve seat
W i t h d r a wi n l e t v a l v e s p r i n g g u i d e . ( A s i m p l e e x t r a c t o r
can be made from two %in UNF bolts and a strip of
m e t a l f o r m e d t o b r i d g e t h e g u i d e) R e m o v e t h e i n l e t
v a l v es p r i n g ,i n l e tv a l v ea n d v a l v es e a t
W i t h d r a wc y l i n d e ra n d r e m o v et h e j o i n t
C h e c k t h a t c o m p r e s s o rm o u n t i n gi s s e c u r e .
E v e r y2 0 , 0 0 0m i l e s ( 3 0 , 0 0 0k m ) o r 1 , 0 0 0h o u r s
U n c o u p l ed e l i v e r yp o r t a n d c h e c k t h e h e a d p a s s a g e s
f o r e x c e s s i v ec a r b o n d e p o s i t sw h i c h , i f p r e s e n t ,m u s t
b e r e m o v e db y d i s m a n t l i n gt h e c y l i n d e rh e a d .
. C h e c kc o m p r e s s o rd e l i v e r y I i n e f o r c a r b o n d e p o s i t s ,
c l e a n o r r e p l a c eI i n e a s n e c e s s a r y .
Every 60,000miles (90,000km) or 2,500hours
D i s m a n t l ec o m p r e s s o r ,t h o r o u g h l yc l e a n a l l p a r t s a n d
inspect for wear or damage Repair or replace all
worn or damaged parts or replace with Factory
B e c o n d i t i o n e dU n i t
Removingand DismantlingPiston and

Connecting Rod Assemblies
R e m o v et h e c o m p r e s s o rm o u n t i n g b r a c k e t a n d j o i n t .
Turn the crankshaftto B D.C position and releasethe
tabs of the locking strap. Unscrew the two bolts and
remove the connecting rod cap Withdraw piston
assembly and replace connecting rod cap
Remove the piston rings from the piston. lf the
piston is to be detached from the connecting rod,
r e l e a s eo n e g u d g e o n p i n r e t a i n i n g c i r c l i p a n d p r e s s
t h e g u d g e o n p i n f r o m t h e p i s t o n a n d c o n n e c t i n gr o d
To Removethe Compressor
Removing Crankshaft
D r a i n t h e e n g i n e c o o l i n g s y s t e m a n d c o m p r e s s o ro f
coolant
Removedrive key f rom crankshaft.
Remove hydraulrc pump which may be fitted to rear

of compressor.
Removesteadyingbracket betweencompressorcylinder
h e a da n d e n g i n ec y l i n d e rh e a d .
Removeall connectionsto and f rom comoressor.
Unscrew compressor mounting bolts and remove
c o m p r e s s o frr o m e n g i n e
To ReplaceCompressor
The replacement of the compressor is a reversal to
removat.
When the compressoris fitted, check that the clearance
between the rubber insert and the forward halfc o u p l i n g i s 0 . 0 2 0 / 0 . 0 2 5 i n( 0 , 5 1 / 0 , 6 3 m m ) .
S h o u l d t h e c l e a r a n c eb e i n c o r r e c t , t h e h a l f - c o u p l i n g
Unscrew the four setscrews or nuts together with

washers securing the rear end-cover to crankcase
W i t h d r a w t h e e n d - c o v e r ,p l a i n b e a r i n g ,t h r u s t w a s h e r
( w h e r ef i t t e d )a n d j o i n t
Unscrew the four setscrewsor nuts securing the drive
end-cover, and withdraw the end-cover complete
with crankshaft and joint. Tap crankshaft with bearing
from drive end-cover
Cleaning
E n s u r et h a t a l l c a r b o n i s r e m o v e d f r o m t h e c y l i n d e r
head. Check that the air passagesin the head and the
oilwaysin the crankcase,where applicable,rearend-cover
and crankshaftare clear and clean.
Clean inlet and discharge valves, not damaged or
worn excessively,by lapping them on a sheet of crocus
cloth held on a f lat surface.
C O M P R E S S O R S3
Inspection of parts
Cylinder
Check cylinder bore for excessive wear, out_ot_round
o r s c o r i n g .l f s c o r e do r o u t - o f - r o u n dm o r e t h a n 0 . 0 0 2 i n
Wear in bore
+ 0 0 0 5 i n( 0 , 1 3 m m )
+0.005/0
5m )
0 1 0i n ( 0 , 1 3 / 0 , 2m
+ 0 0 1 5 i n( 0 , 3 8 m m )
+0.015/0
1m ) . . . .
0 2 0 i n ( 0 , 3 8 / 0 , 5m
+0025in(0,63mm)
Pistonand ConnectingRod
I n s p e c tp i s t o nf o r s c o r e s ,c r a c k so r d a m a g eo f a n y k i n d .
C h e c k f i t o f r i n g s i n r i n g g r o o v e s , c l e a r a n c es h o u l d
b e 0 . 0 0 0 5 / 0 . 0 0 2 5 i n( 0 , 0 1 / 0 , 0 6 m m ) .I n s t a i l r i n g s I n
c y l i n d e r a n d c h e c k t h a t g a p s a r e 0 . 0 0 3 / 0 . 0 0 7 i n( 0 , 0 8 /
0,18mm). Check fit of gudgeon pin in piston and
c o n n e c t i n gr o d . G u d g e o np i n s h o u l d b e a l i g h t p r e s sf i t
i n p i s t o n a n d c l e a r a n c ei n t h e c o n n e c t i n g r o d b u s h
s h o u l dn o t e x c e e d0 . 0 0 1 5 i n( 0 , 0 4 m m ) .
Inspect connecting rod bearing for correct fit
on
crankshaft journal. Clearance between rod
Journal
a n d b e a r i n g m u s t n o t b e l e s s t h a n 0 . 0 0 1i n ( 0 , 0 2 m m )
a n d n o t m o r e t h a n 0 . 0 0 3 i n( 0 , 0 B m m )C
. heckconnectrno
rod for cracks or damage.
Crankshaftand Bearings
E x a m i n eb a l l b e a r i n g sf o r d i s c o l o r a t i o np, i t t i n gw e a r a n d
cracked races. Rotate slowly to check for rougnness.
D e f e c t i v eb e a r i n g ss h o u l d b e r e m o v e d ,u s i n g a w e l l _
f i t t i n ge x t r a c t i n gt o o l .P r e s sn e w b e a r i n go n t o c r a n k s h a f t ,
u s i n ga s u i t a b l el e n g t ho f t u b e , u n t i l i t c o n t a c t ss h o u l d e r .
Inspect crankshaft for wear and check threads,
shaft ends, keyways and drive keys for damage.
The crank pin diametershould be within the timits
0 . 8 74/ 0 . 8 73 5i n ( 2 2 , 2 /02 2 , 19 m m \ .
Crankshaftand End-covers
I n s p e c t o i l s e a l c a r e f u l l y ,e n s u r i n g t h a t s e a l i n g e d g e
is intact and sharp. lf an oil leak has been obseiveo at
t h e c r a n k s h a fet n d , a n e w s e a l m u s t b e f i t t e d L i p o f s e a l
s h o u l df a c e i n w a r d s .
Examine crankcase, end-cover and mounting bracket
for damage and cracks. Check bearing bores for
wear The ball race should be a ligfrt press fit in
e n d - c o v e ra n d t h e c r a n k s h a f ts h o u l d b e a n e a t s l i d i n g
fit in the plain bearing. Inspect crankshaft thrust
washer for wear (where f itted).
CylinderHead
I n s p e c tc y l i n d e rh e a d f o r c r a c k s a n d u n l o a d e rp r u n g e r
g u i d e b u s h f o r w e a r . C h e c k t h a t u n l o a d e rp l u n g e r i s a
Remedy
F r t n e w s t a n d a r dr i n E s
B o r eo u t t o + 0 0 i 0 i n ( 0 , 2 5 m m a) n d f i t O 0 1 0 i n ( 0 , 2 5m m )
o v e r s i z ep i s t o n r i n g s
F i t n e w 0 0 1 0 i n ( 0 , 2 5 m m )o v e r s i z er i n g s .
B o r e o u t t o + 0 2 0 i n ( 0 , 5 1m m ) a n d f i t 0 . 0 2 0 i n( 0 , 5 1m m )
o v e r s i z ep i s t o na n d r i n g s
F i t n e w 0 . 0 2 0 i n( 0 , 5 1m m ) o v e r s i z er i n g s
n e a t s l i d i n gf i t i n t h e g u i d e l f i t i s n e c e s s a r yt o r e p l a c e
t h e u n l o a d e rp i s t o n g u i d e , t h i s w i l l b e f o u n d t o h a v e
a n u n d e r s i z e db o r e , a n d w i l l r e q u i r er e a m i n gi n s i t u t o
0 . 3 7 4 5 / 0 . 3 7 5i5n ( 9 , 5 1 / 9 , 5 4 m m )E. n s u r e t h a t t h e o o r e
i s m a c h i n e ds q u a r e t o t h e u n d e r s i d eo f t h e c y l i n d e r
h e a d T h e m a x i m u mf i n i s h o f t h e g u i d e b o r e s h o u t d b e
2 5 m i c r o i n c h e s( 0 , 6 m i c r o n s )A. c h a m f e ri s a l s o r e q u i r e d
a t t h e t o p o f t h e g u i d e b o r e t o a n a n g l eo f 1 5 o a n d t o a
d e p t h o f 0 . 1 0 2 i n ( 2 , 5 9 m m ) .M a k e s u r e t h a t t h e
g u i d e a n d c h a r n f e ra n g l e a r e f r e e f r o m b u r r s E x a m i n e
u n l o a d e rp l u n g e r s e a l r i n g f o r w e a r I n s p e c t i n l e t a n d
delivery valves and seats. lf valves are grooved oeeper
t h a n 0 . 0 0 3 i n( 0 , 0 8 m m )w h e r et h e y c o n t a c tt h e s e a t .t h e v
should be replaced lf not badly groovedthey can be
refaced by lapping on crocus cloth Valve seats, if
s h o w i n gs l i g h t s c r a t c h e s m
, a y b e r e c l a i m e db y l a p p i n g
with fine grinding paste.lf badty pitted or scratched.
u s e a s e a t i n gr e a m e rb e f o r el a p p i n g .
Renew delivery valve spring and check remainino
s p r i n g sf o r c o r r o s i o n f, a t i g u eo r p e r m a n e n st e t .
Re-assembly
L u b r i c a t ea l l i n t e r n a l p a r t s w i t h c l e a n e n g i n e o r r t o
prevent possible damage until the oil supply is
f u n c t i o ni n g .
I n s t a l l t h e c r a n k s h a f t ,c o m p l e t e w i t h b e a r i n g , r n t o
the drive end-cover.Insert the crankshaft into tne
c r a n k c a s ea n d s e c u r et h e d r i v e e n d - c o v e r e, n s u r i n gt h a t
the joint is correctly positionedover the oil drain
ports.
P o s i t i o nt h e t h r u s t w a s h e r i n t h e r e a r e n d _ c o v e rw i t h
the steel face towards the plain bearingand the tab
locatedin the slot. Assemblethe rear end-coverwith joint
and secure.Check the crankshaftto ensure free rotation
a n d t h e n t i g h t e n e n d - c o v e rn u t s o r b o l t s . F i t t h e o r r v e
key to the crankshaft.
R e fi t t h e p i s t o n r i n g s , e n s u r i n g t h a t s i d e s m a r k e d
"Top" are uppermost, and assemble the piston to the
c o n n e c t i n gr o d . A s s e m b l et h e c o n n e c t i n g r o d o n t h e
c r a n k s h a f t ,t i g h t e n t h e b o l t s t o a t o r q u e o f 4 l b f f t
( 0 , 5 5 k gm
f ) or 5,4Nm, and turn uF the tabs of the
locking strap. Space the piston ring gaps and assemble
the cylinderw
, i t h j o i n t ,o v e r t h e p i s t o n .
COMPRESSOR S4
Assemble the cylinder head. Lighily smear the

o u t s i d e d i a m e t e r so f t h e i n l e t v a l v e s e a t a n d s p r r n g
g u i d e w i t h " L o c t i t e " ,o r e q u i v a l e n t s, e a l i n g c o m p o u n d .
I n s e r tt h e i n l e t v a l v e s e a t , i n l e t v a l v e a n d v a l v e s p r i n g
a n d p r e s st h e s p r i n g g u i d e i n t o p o s i t i o n S c r e w i n t h e
deliveryvalve seat, using a wrench inseried in the
hexagonal hole through the centre of the fitting,
a n d t i g h t e n s e c u r e l y P l a c e t h e d e l i v e r yv a l v e o n t h e
s e a t a n d p o s i t i o n t h e s p r i n g s .S c r e w i n t h e v a l v e c a p
togetherwith the copper washer Lightly smear the
unloader plunger with "Dow-Corning" grease, and
insert the spring and plunger complete with the
s p r i n g c i r c l i p S c r e w i n t h e u n l o a d e rc a p t o g e t h e rw i t h
c o p p e rw a s n e r
Placethe joint on the cylinderand correcily position
t h e c y l i n d e rh e a do n t h e s t u d s T i g h t e nn u t s p r o g r e s s i v e l y
t o a t o r q u e o f l 0 l b f f t ( 1 , 3 8 k g f m )o r 1 3 , 6 N m .
Invert the compressorand apply clean engine oil
o v e r t h e c r a n k s h a f ta n d o n t h e c y l i n d e rw a l l A s s e m b l e
t h e m o u n t i n gb r a c k e ta n d j o i n t
B E N D I XW E S T I N G H O U S E
TWIN 9
COMPRESSOR
To DismantleCompressor
R e m o v ef i l t e ra s s e m b l yf,i l t e r e l e m e n ta n d a d a p t o rp l a t e .
Remove top cover and cylinder head/valve plate
a s s e mo r y .
R e m o v ev a l v e p l a t e f r o m c y l i n d e r h e a d M a r k v a l v e s ,
s p r i n g sa n d v a l v ec a g e st o i d e n t i f yp o s i t i o n .
R e m o v em o u n t i n gb r a c k e ta n d g a s k e t
M a r k c o n n e c t i n gr o d s a n d c a p s t o i d e n t i f yp o s i t i o n
R e l e a s eb i g e n d s e c u r i n g b o l t s a n d r e m o v e p i s t o n /
connecting rod assembly (Note it is importanr ro
r e l e a s eb i g e n d b o l t s b e f o r e t h e b o l t s s e c u r i n g t h e
eno cover)
Remove gudgeon pins to
c o n n e c t i n gr o d s .
release pistons from
R e m o v ep i s t o nr i n g s .
R e m o v ee n d c o v e r
R e m o v ep l a s t i cc o v e rf r o m n o n - d r i v ee n d o f c o m p r e s s o r
(if fitted)
g a p o f t h e c o m p r e s s i o na n d s c r a p e rr i n g s i n t h e c y l i n d e r
i s 0 , 0 0 3 / 0 . 0 0i n
7 ( 0 , 0 8 / 0 ,B1m m )
l f t h e p i s t o n r i n g s a r e b e i n g r e f i t t e da n d a r e b e d d e d
for more than the 300/of the width or if new rings are
being fitted,the glaze on the cylinderbores must be
br o k e n
T h e c l e a r a n c eo f t h e c r a n k s h a f ti n t h e m a i n b e a r i n g s
should not exceed 0 0035in (0,09mm), whilst the
c l e a r a n c eo f t h e c r a n k p i n s i n t h e b i g e n d b e a r i n g s
s h o u l dn o t e x c e e d 0 0 3 i n( O , 0 B m m ) .
The end float of the crankshaft is 0004i0012in
( 0 , 1 0 / 0 , 3m
0m )
The gudgeon pin should be a light press fit in the
p i s t o n a n d t h e c l e a r a n c eo f t h e p i n i n t h e s m a l l e n d
of the connecting rod should not exceed 00015in
( 0 , 0 3 8 m m ) .R e n e w g u d g e o n p i n c i r c l i p s i f n e c e s s a r y
To Re-assembleCompressor
Clean all parts, remove all jointing compound and
gaskets Ensure that all oilways and water passages
are clean and free from obstruction Lightly oil all
b e a r i n g s u r f a c e s , j o u r n a l s a n d t h r u s t w a s h e rf a c e s
F i t o i l s e a l st o c r a n k c a s ea n d e n d c o v e r .
F i t c r a n k s h a f tt o c r a n k c a s ee n s u r i n g t h a t o i l s e a l i s
n o t d a m a g e db y t h e e d g e s o f t h e s l o t i n t h e c r a n k s h a f t
Fit thrust washerto crankshaft
Coat joint face of end cover with sealing compound
a n d f i t e n d c o v e r t o c r a n k c a s es e c u r i n gw i t h s e t s c r e w s
a n d s p r i n gw a s h e r s
) r ' 12 , 2 N m
T i g h t e ns e t s c r e w tso 9 l b f f t ( 1 , 2 4 k g f m o
E n s u r et h a t e n d f l o a t o f c r a n k s h a f ti s c o r r e c t
Fit connectingrod to piston Fit gudgeon pin and
s e c u r ew i t h c i r c l i p
F i t p i s t o n r i n g s t o p i s t o n , e n s u r i n gt h a t t h e r i n g g a p s
a r e e q u a l l ys p a c e d a r o u n d t h e p i s t o n T h e t w o c o m p r e s s i o nr i n g s o n e a c h p i s t o n m u s t b e f i t t e d w i t h t h e
i n t e r n asl t e p s o r c h a r n f e r s t o w a r d s t p
h ies t o nc r o w n R i n g s
are usuallymarked with the word "top" or "bottom"
o n t h e a p p r o p r i a t ef a c e t o a i d c o r r e c tf i t t i n g
L u b r i c a t ep r s t o n r i n g s a n d c y l i n d e r b o r e s t h o r o u g h l y
w i t h c l e a n e n g i n e o i l b e f o r e f i t t i n g p i s t o n si n c y l i n d e r s
Removecrankshaftwith thrust washer

B e m o v ea l l s e a l s ," O " r i n g s a n d g a s k e t s
F i t p i s t o n / c o n n e c t i n gr o d a s s e m b l i e s i n c r a n k c a s e ,
e n s u r i n gt h a t t h e y a r e f i t t e d w i t h t h e t o o l i n g h o l e i n
t h e c o n n e c t i n gr o d f a c i n g i n w a r d s t o w a r d s t h e c e n t r e
lineof the compressor
Reconditioning
F i t b i g e n d c a p s a n d s e c u r ew i t h b o l t s a n d t a b w a s h e r s
T i g h t e n b o l t s t o 9 l b f f t ( 1, 2 4 k g t m ) o r 1 2 , 2 N m a n d l o c k
tabwashers
A l l g a s k e t s ,s e a l s a n d " O " r i n g s s h o u l d b e r e n e w e d
The cylinder head and associated parts, and the
pistons should be cleaned of any carbon present
The valve discs,springs and valve guides should be
renewed. The valve seats may be lapped with a fine
g r i n d i n gp a s t e ,b u t i f t h e r e i s a n y a p p r e c i a b l ew e a r , t h e
v a l v eD l a t es h o u l db e r e n e w e d .
T h e u n l o a d i n gp i s t o n sm u s t b e a n e a t s l i d i n g f i t i n t h e
g u i d e b u s h e s .l f w e a r i s a p p a r e n t ,r e n e w t h e p i s t o n so r
bushesas necessary
T h e m a x i m u mp e r m i s s i b l e
w o r n d i a m e t e ro f t h e c y l i n d e r
b o r e si s 2 . 2 5 7 i n( 5 7 , 3 3 m m ) .
T h e c l e a r a n c eo f t h e c o m p r e s s i o nr i n g s i n t h e p i s t o n
grooves is 0.0005/0.002in(0,012/0,051mm) and that of
the scraperrings is 0.0005/00025in (0,012/0,063mm). The
Ensurecompressorhas f ree rotation

F i t " O " r i n g s t o u n l o a d e rp i s t o n s ,l u b r i c a t i n ga s s e m b l i e s
w i t h S i l i c o n eF l u i dM S 2 0 0 .F i t u n l o a d e ro i s t o na s s e m b l i e s
t o c r a n k s h a f tF i t s p r i n ga n d s a d d l e E n s u r et h a t u n l o a d e r
pistons have free movement
F i t i n l e t a n d e x h a u s t v a l v e s ,s p r i n g s a n d v a l v e g u i d e s
t o c y l i n d e rh e a d . F i t v a l v e p l a t e t o c y l i n d e r h e a d w i t h
gasket and secure with countersunkscrew Tighten
s c r e wt o 5 0 l b fi n ( 0 , 5 7k g f m ) o r 5 , 6N m .
Ensure valves have free movement after assembly
F i t c y l i n d e r h e a d / v a l v ep l a t e a s s e m b l yw i t h g a s k e t t o
c r a n k c a s eF i t c o v e rw i t h g a s k e tt o c y l i n d e rh e a d S e c u r e
with nuts and spring washers where studs are fitted
and with bolts and spring washers at tapped hole
COMPRESSOR 55
p o s i t i o n sT
. i g h t e n n u t s a n d b o l t s t o 1 7 l b ff t ( 2 , 3 5 k gm
f )
or 23Nm progressively
F i t m o u n t i n gb r a c k e tw i t h g a s k e tt o b a s e o f c o m p r e s s o r
w i t h b o l t s a n d s p r i n g w a s h e r s .T i g h t e n b o l t s t o 1 7 l b f t
( 2 , 3 5 k 9m
f ) or 23Nm progressivety
W h e r e r e q u i r e d ,f i t p l a s t i c c o v e r t o n o n d r i v e e n d
o f c o m p r e s s o ar n d c r a n k s h a f t
C o a t j o i n t f a c e o f f i l t e r a d a p t o rw i t h s e a l i n gc o m p o u n d
and fit plate to crankcase Secure with countersunk
s c r e w s t i g h t e n e d t o 5 0 l b f i n ( 0 , 5 B k g f m )o r 5 , 6 N m
F i t n e w f i l t e r e l e m e n tt o f i l t e r b o d y F i t r e t a i n i n gp r a r e
a n d r e t a i nw i t h b o l t sa n d s p r i n g w a s h e r s
F i t f i l t e r a s s e m b l yt o a d a p t o r p l a t e a n d s e c u r e w i t h
nuts and spring washers tightening to a torque of
9 f) o r 1 2 , 2 N m
9 l b f t( 0 , 1 2 4 k m
F i t k e y t o d r i v ee n d o f c r a n k s h a f t
F i n a l l y p r o t e c t a l l p o r t s t o p r e v e n t i n g r e s so f f o r e i g n
malter
Data and Dimensionsfor Bendix WestinghouseTwin 9 Compressor

C y l i n d e rb o r e d i a m e t e r
M a x .p e r m i s s i b l e
worn borediameter.
C l e a r a n c eo f p i s t o ns k i r t i n b o r e
C l e a r a n c eo f c o m p r e s s i o nr i n g s I n p i s t o ng r o o v e s
C l e a r a n c eo f s c r a p e rr i n g s i n p i s t o ng r o o v e s . .
C o m p r e s s i o nr i n g g a p i n c y l i n d e r
S c r a p e rr i n g g a p i n c y l i n d e r . . . . .
C r a n k p i nd i a m e t e r
B i g e n d r u n n i n gc l e a r a n c e
Max permissibleworn big end bearing running
clearance
M a i nj o u r n a ld i a m e t e r.
M a i n b e a r i n gr u n n i n gc l e a r a n c e
M a x p e r m i s s i b l ew o r n m a i n b e a r i n g r u n n r n gc l e a r a n c e
C r a n k s h a fet n d f I o a t
M a x p e r m i s s i b l e n d f l o a to n w o r n c o m p r e s s o r
2 2 5 0 / 22 5 1i n ( 5 7 , 1
5/57,1
8 mm)
2 2 5 7i n ( 5 7 , 3 3m m )
1 m)
0 0 0 2 3 / 00 0 4 3i n ( 0 , 0 6 / 0 , 1m
5 1m )
0 0 0 0 5 / 0O O 2i n ( O , 0 1 2 / 0 , 0 m
0 0 0 0 5 i 00 0 2 5i n ( 0 , 0 1 2 l 0 , 0 6m3m )
8 m)
0 0 0 3 / 00 0 7i n ( 0 , 0 8 / 0 , 1m
8 m)
0 0 0 3 / 00 0 7i n ( 0 , 0 8 / 0 , 1m
1 2495/1250 in (31,74/31,75mm)
0 0 0 5 / 00 0 1 5i n ( 0 , 0 1 2 l 0 , 0 3m8m )
0 0 0 3i n ( 0 , 0 7 6m m )
1 2 4 8 2 / 12 4 9 1i n ( 3 1, 7 O / 3 1 ' , 7 3 m m )
0 0 0 0 9 / 00 0 2 8i n ( 0 , 0 2 1 0 , 0m7m )
0 0 0 3 5i n ( 0 , 0 9m m )
0 m)
0 0 0 4 1 00 1 2i n ( 0 , 1 0 / 0 , 3m
O 0 1 7i n ( 0 , 4 3m m )
RecommendedTorques
C y l i n d e rh e a d b o l t s / n u t s
E n d c o v e rb o l t s
M o u n t i n gb r a c k e tb o l t s
S t r a i n e rm o u n t i n gn u t s
S t r a i n e ra d a p t o rs c r e w s
Big End Bolts
1 7 l b f t ( 2 , 3 5k g f m ) o r 2 3N m
9 l b ff t ( 1 , 2 4 k g t mo\ r 1 2 , 2 N m
1 7I b ff t ( 2 , 3 5k g f m ) o r 2 3 N m
9 l b f f t( 1 , 2 4 k 9mf ) o r 1 2 , 2 N m
5 0l b fi n ( 0 , 5 8 k 9mf ) o r 5 , 6 N m
9 l b ff t ( 1, 2 4 k g I m )o r 1 2 , 2 N m
Drive Coupling (Holset)

With the compressorfitted to the engineand the coupling
assemblyin place on the auxiliarydrive shaft the distance
betweenthe two halvesof the coupling(see Fig.S 1 dim C)
mustbe adjustedto the valuegivenin the tablebelow When
fitting the coupling,ensure that the scribed lines on rne
outsideof the flangesaretn line
Couplingdiameter
DimensionC
Diff. between
Cl andC2
3.B75in
( 9 8 , 4 m m ) 0 . 1 4 6 / 02 5 0 i n
(1,71
0.068in
mm)
(3,7116,m
3 5m )
3 . 0 0 i n( 7 6 , 2 m m ) 0 . 1 2 5 1 0 . 1 8 7 i n0 . 0 5 2 i n( 1 , 3 2 m m )
(3,18/4,75mm)
The parallelalignmentcan be checkedwith a straightedge
and feelergaugeto dimensionB as shownin Fig S.1
To checkthe angularalignmentfind the differencebetween
C1 and C2 as shownin Fig.S.1 lf this difference
is the same
as or less than the dimensiongiven in the chartaboveany
angularmisalignment
willbe 1' or lesswhichis satisfactory.
On later enginesthe couplingsetscrewsand separatetab
washers have been replaced by washer-facedsetscrews
only These setscrews should be tiqhtened to lBlbfft
( 2 4 , 4 N m ) , 2 , 5 km
s f.
A.
B.
C.
Straightedge
C 1 . M a x .g a p
M a x 0 . 0 0 6 i n( 0 , 1 5 m m )
C . 2 M i n .g a p
Gap betweencouplinghalves
SECTION
T
Exhausters
DESCRIPTION
The A.350 type exhausteris a rotary sliding vane
pump,
with an eccentricallymountedrotor.
leakage occur, the exhausterwill pressurisethe engrne

crankcase,resultingin oil leakageat the crankshaft
seals
and otherjoints. Examinethe exhausterfor evidence
of oil
leakage,particularlyat the end coverjointsand at the
shaft
oil level. Check the oil supply line for leaks at fit$ngsanct
connections.
Every 10,000miles
Check the mounting setscrewsand end cover retainino
screwsfor tightness.
reservoir,and the outlet port formed in the base

of the
exhausteralignswith an aperturein the enginecrankcase.
OPERATION
At all speeds the rotor blades are kept in contactwith
the
bore of the body by centrifugalforce, assisted
by the
hydraulicaction of the oil beneath the blades. When
the
rotor turns,the spaces betweenthe bladesvary, because
of the eccentric mounting of the rotor in the exhauster
body.As a blade passesthe inletport the space between
it
and the followingblade increasesand air is drawnfrom
the
vacuum reservoir. This air is then compressed
and
expelledwith the lubricatingoil through the outlet port
to
the enginecrankcase.
SERVICING
EXHAUSTER
Periodic lnspection and preventive Maintenance
Weekly or every 5,000miles
Examinethe vacuum lines and fittings.Vacuum leaKage
may occur through the line or reservoir mounted non_
return valve, if the valve seat is dirty or pitted. Should
Every 60,000miles
Bemoveand dismantlethe exhauster,thoroughlyclean all
parts and inspect them for wear and damage.
lf the
exhausteris well worn it will be advisableto return it to
Perkins Engines Ltd., in exchange lor a factorv
reconditionedunit.
To Remove the Exhauster
Disconnectthe oil vacuumpipes at the exhausterand plug
qpen unions to prevent the entry of foreign matter.
lhe
Release the driving coupling from the end oi the rotor
shaft. Unscrewthe setscrewswhich securethe exnauster
to the crankcase,and removethe unit from the enqine.
Dismantling
Mark the end covers in relation to the body to ensure
correctlocationon re-assembly.Unscrewthe four socKetheaded screws and remove the rear end cover with the
rubbersealingring. Mark the bladesin relationto the rotor
and withdrawthe rotorcompletewith bladesfrom the bodv.
Unscrewthe four socket-headedscrews and remove the
driveend coverwith its rubbersealingring.
C L E A N I N GA N D I N S P E C T I O N
Cleaning
Wash all the componentsin cleaningsolventand clearthe
rotorand driveend coveroil ways with compressedair.
Inspection of Parts
Examinethe bushes for excessivewear. To renew them
see "Overhaul" section. Inspect the rotor and shaft for
cracksand damage,check the fit of the fibre bladesin the
rotor slots and replace any worn or damaged blades.
Examinethe seals carefullyto see that the selling edges
are pliable, intact and sharp. Seals rendered ineffective
(usually by dirty oil and grit) should be renewed as
prescribedin the sectionheaded,,Overhaul',.
Examinethe
body for cracks and damage and the bore for longitudinal
Fig.T.1. Explodedview of an Exhauster.

6 3544 SeriqsWorkshopManual,lssue2, June'92
EXHAUSTERS_T.2
ripples or lines. lf these are only slight the body is still
serviceable,if excessive the body should be renewed.
Examine the end covers, and renew them if thev are
crackedor scored.
OVERHAUL
To renew End Cover Bearings and Seals
Drive End Cover
Extractthe seal from the drive end cover and press in the
n e w o n e u n t i l t h e s t e e l s e a l h o l d e r a b u t s a g a i n s tt h e
shoulder in the cover. With the seal removed,press the
worn plain bearing out of the cover using a bar or tube
1%oin diameter.Pressthe new bearinginto the cover until
it is 7ein belowthe coverf ace.
Rear End Cover
Blank end covers are not fitted with seals. The bearing
should be extractedor machined out taking care not to
damage the housing, or in an emergency it may be
removed by cutting a groove along the bearing,using a
narrowhalf round chisel.Inspectthe housing,removeany
burrs and press the new bush fully into the cover. Where
the rear end has been bored straightthroughand blanked
off, the circlip should be removedfollowed by the blanking
disc and 'O' ring,which acts as a seal.The bush may then be
pressedout of the cover,usinga baror tube,1%eindiameter.
When replacingthese componentsit is advisableto fit the
circlipin its grooveand then refitthe blankingdiscfollowedby
a new 'O' ring. The new bush should be pressed into the
cover until it slightly compressesthe 'O' ring against the
blankingdisc, the resultingreductionin internaldiameterof
the 'O' ring ensuringan effectiveseal on the shaft.The large
rubber 'O' rings which seal the gaps betweenthe exhauster
body and the end covers,shouldbe renewedif they appearto
be in any way compressedor damaged.
in the rotor slots, making sure that the marks made during
dismantlingcorrespond.
Installthe rearend coverwithits rubber'O'ringon to the body
(ensuringthat the dowelslocatein their respectiveholes)and
tightenthe socket-headedscrews.
Turn the rotorby handto makesure that it revolvesfreely.
Installation
Replacethe joint and remountthe exhaustersecurelyto the
engine crankcase,with the couplinghalves fitted looselyon
the shafts.
Wherethere are scribedlineson the outsideof the coupling
flanges,thesemustbe in line.
Ensure that there is approximately%in (3mm) between
auxiliaryshaftoil sealand fronthalfcoupling.
WhereSimmscouplingsarefitted(Fig.T.2),ensurethatthere
(1,2mm)betweenthe rubber
is a nominalclearanceol 3/a+in
couplingand each halfcoupling.WhereHolsetcouplingsare
fitted,checkthe paralleland angularalignmentwitha straight
edgeandfeelergaugesas shownin Fig.T.3.
When the alignmentis correcttightenthe couplingsetscrews
and in the case of earlierHolsetcouplingslock the setscrews
with the tab washers. Later Holset couplingshave washer
faced setscrews without tabwashers and these setscrews
mustbe tightenedto l Slbfft(24Nm)2,5kgfm.
Reconnectthe oil feed and vacuumpipes.
Re-assembly
Lubricate
all movingpartswithcleanengineoil.
Carefullyinsert the shaft into the drive end cover, avoiding
damageto the seal.
With the large rubber 'O' ring fitted in its groovein the cover,
assemblethe latterto the body, locatingthe dowels in their
resoectiveholes.
Hold the body,drive end downwards,and replacethe blades
Fig.T.3
A
B.
C.
1.
2.
3.
4.
Fig.T.2. RemovingExhauster.
Exhauster.
ExhausterCoupling(DrivenHalf).
ExhausterCoupling(DriveHalf).
R u b b e rC o u p l i n g .
Straightedge
M a x .0 . 0 0 6 i n( 0 , 1 5 m m )
G a p0 . 1 2 5 / 0 . 1 8 7 i n
( 3 , 1 8 / 4 , 7m5m )
C 1 .M a x .g a p
C . 2 M i n .g a p
Max.difference
C1-C2,
0 . 0 5 2 i n( 1 , 3 2 m m )
LUBRICATINGOILS
L u b r i c a t i n go i l s f o r n a t u r a l l ya s p i r a t e de n g i n e ss h o u l d m e e t t h e r e q u i r e m e n tos f t h e U . S .O r d n a n c e
Specification
M I L - L - 4 6 1 5o2r M I L - L - 2 1 0 4 C
L .u b r i c a t i n go i l s f o r t u r b o c h a r g e de n g i n e sa n d e n g i n e s
i n s t a l l e di n H e a v y D u t y E a r t h m o v i n gE q u i p m e n ts h o u l d m e e t t h e U . S . O r d n a n c e S p e c i f i c a t i o n
MtL-L-2104C.
S o m e o f t h e s eo i l s a r e l i s t e db e l o w a n d n e x t p a g e .A n y o t h e r o i l s w h i c h m e e tt h e s es p e c i f i c a t i o n s
a r e a l s os u i t a b l e .
M|L-L.46152
otLS
Company
Brand
S.A.E.Designation
0"F (-18'C) 30'F (-1'C)
IO
IO
30'F (-1"C) 80'F (27'C)

B . P .L t d .
CastrolLtd.
D u c k h a m C o . Ltd.
E s s o P e t r o l e u mC o . L t d .
M o b i lO i l C o . L t d .
Shell
T o t a lO i l C o . L t d .
V a n e l l u sM
V a n e l l u sM
C a s t r o l / D e u s oCl R X
D e u s o lR X S u p e r
F l e e t o lH D X
Q M o t o rO i l
F l e e t o lM u l t iV
F l e e t o lM u l t i l i t e
F a r m a d c oH
l DX
E s s o l u b eX D - 3
D e l v a c1 2 0 0S e r i e s
D e l v a cS p e c i a l
R o t e l l aT X
R o t e l l aT X
R i m u l aX
R i m u l aX
R i m u l aX
R i m u l aX
T o t a l S u p e rH D
Total HD2-M
Total HD3-C
( R u b i aS )
Total HD3-C
( R u b i aT M )
Total Universal
T r a c t o rO i l
(Multagri)
T o t a l S u p e rU n i v e r s a l
T r a c t o rO i l
( M u l t a g rTi M )
10w
Over
8 0 ' F ( 2 7 "C )
10w/30
20w
20w/50
20
10w/30
20w/50
20w/40
20
20w/50
20w/50
10w/30
20
20w
15W/40
1220
'10w/30
20w/20
20w/40
20w/20
10w/30
15W/40
20w/40
20w/20
20w/40
30
20w/50
30
10w/30
20w/50
20w/40
30
20w/50
20w/50
10w/30
30
30
15W/40
1230
10w/30
30
20w/40
30
10w/30
15W/40
20w/40
30
20w/50
10w
20w/20
30
15W/40
15W/40
20w/30
20w/30
20w/30
20w/30
10w
10w/30
10
10w/30
10w
1210
10w/30
10w
10w
10w/30
MIL-L-2104CO|LS
Company
Brand
S.A.E.Designation
0 ' F ( - 1 8 " C ) 3 0 " F( - 1 ' C )
Over
to
to
80"F(27'C)
3 0 " F( - 1 ' C ) 8 0 ' F ( 2 7 ' C )
B . P .L t d .
CastrolLtd.
A . D u c k h a m& C o . L t d .
E s s o P e t r o l e u mC o . L t d .
M o b i lO i l C o . L t d .
Shell
Total Oil Co. Ltd.
V a n e l l u sC 3
CastrolDeusolCRD
D e u s o lR X S u p e r
A g r i c a s t r oH
l DD
A g r i c a s t r oM
l P
A g r i c a s t r oM
l P
F l e e t o l3
F a r m a d c o3l
E s s o l u b eD - 3 H P
EssolubeXD-3
D e l v a c1 3 0 0S e r i e s
R i m u l aC T
R i m u l aX
R i m u l aX
R i m u l aX
R i m u l aX
R o t e l l aT X
R o t e l l aT X
Total HD3-C
( R u b i aS )
Total HD3-C
( R u b i aT M )
T o t a l S u p e rU n i v e r s a l
Tractor Oil
( M u l t a g rTi M )
10w
10w
10w
J/ lu
3/10
10w
20w
1310
10w
10w
10w/30
10w
10w
20w/20
20
20w/40
20w/30
20w/40
3/20
3/20
20w
20w
15W/40
1320
20w/20
20w/20
10w/30
15W/40
20w/40
20w/20
20w/40
30
30
20w/40
30
20w/30
20w /40
3/30
3/30
30
30
15W/40
1330
30
30
10w/30
15W/40
20w/40
30
20w /40
20w/20
30
1sw/40
15W/40
20w/30
20w/30
ZU
L u b r i c a t i n go i l s f o r u s e i n P e r k i n sD i e s e le n g i n e ss h o u l d h a v ea m i n i m u mv i s c o s i t yi n d e x o f 8 0 .
6 3544 SeriesWorkshooManual,lssue2, June '82
APPROVED
S E R V I C ET O O L S
Available
fromV. L. churchill& co. Ltd.,Daventry,
Northamptonshire,
England,
NN114NF.
Thenumbers
shownin brackets
afterthechurchilltoolnumberarethepartnumbers
of equivalent
Perkins
tools.Perkins
toolsareavailable
through
yourperkinsDistributor.
@M4
Tool No.
Descriptlon
PD.1D
(21825026)
V A L V EG U I D E R E M O V E RA N D R E P L A C E R( M A I N T O O L )
PD.1D-1A
(21825027)
ADAPTORFOR PD.1D OR 21825026

A pairof pullerbarsfittedwith knurlednuts.Suitablelor
sAa"and3" guides.The necessary
distancepiecefromthe
adaptorsbelowshouldalso be used.
PD.1D.6
(2182s030)
A D A P T O RF O RP D . 1D O R 2 18 2 5 0 2 6
A 1elgz"
(15mm)distancepieceusedto replacevalveguroes
to a set height.
No.8
(2182s018)
P I S T O NR I N G S Q U E E Z E R
PD.41B
(21825019)
P I S T O NH E I G H TA N D V A L V ED E P T HG A U G E
A simple method of quickly checking piston height.
PD.140
CAMSHAFT BUSH/THRUSTCOLLAR REMOVER
PD.140-3
FUEL PUMP THRUST COLLAR REMOVER/REPLACER

ADAPTORS
Tool No.
Description
PD.145
CRANKSHAFTREAR OIL SEAL REPLACERADAPTOR

( L r PT Y P E S E A L )
PD,15OA
(21825052)
C Y L I N D E RL I N E RR E M O V E R / R E P L A C E(R
M A I NT O O L )
For Field Servicereplacementof single liners.Not advised
for completeoverhaul.For this work use adaptorswith a
h y d r a u l i cr a m u n i t .
P D . 15 0 -1B
(21825054\
ADAPTORS FOR PD.150

Suitablefor cylindersof 3.6" dia. and 3.87,,dia. Removar
and replacement.
PD.150-74
(21825057)
A D A P T O R SF O R P D , 1 5 0
S u i t a b l ef o r c y l i n d e r so f 3 9 7 " d i a . R e m o v a l
and reolacement.
1558
(21825006)
BASIC PULLER
The cruciform head with multiple holes at differentcentres
is used with adaptors listed below.
PD.155-1
ADAPTORSFOR PD.155B
Used to removewater pump pulleys.Also suitableto remove
CamshattGears.
MF.200-26
WATER PUMP OVERHAULKIT

Used with 370 Taper Base and Press.
s@
qs
c2---)
ffi
Tool No.
Description
'JJC
C O N R O D J I G & 3 3 6 M A S T E RA R B O R
336-102
ARBOR ADAPTOR
Used with 335
6 11 8 8 - 4
(21825020)
V A L V ES P R I N GC O M P R E S S O R
6 11 B B - 4
(2182502s)
A D A P T O RF O R 6 1 1 8 8
M567B
T O O L F O R C H E C K I N GF U E L
INJECTION
TIMING
PD163
(21825042)
T I M I N GC A S E C E N T R A L I S I NTGO O L
\
)
.//
MS73
( 2 18 2 5 0 6 4 )
A D J U S T A B L EV A L V E
SEATCUTTERS
POWERPART
Consumableproducts
To give assistancein the correct operation,service and maintenanceof your
engine and
machine,PerkinsEnginesLtd. have made availablethe productsshown below.
The instructionsfor the use of each productare given on the outsideof each container.
These productsare availablefrom your perkinsdistributor.
POWERPARTAntifreeze
Gives corrosionprotectionand also a more efficientcoolantin hot conditions.See page C.5.
POWERPARTLay-Up 1
A dieselfuel additivefor protectionagainstcorrosion.see page c.4.
POWERPARTLay-Up 2
Gives insideprotectionto the engineand otherclosedsystems.see page c.4.
P O W E R P A R TL a y - U p3
Gives outsideprotectionto any metalparts.See page C.4.
POWERPARTDe-lcer
To remove frost.
P O W E R P A R TS i l e n t S p r a y
S i l i c o n el u b r i c a t i o tno l u b r i c a t ea n d p r e v e n tn o i s ef r o m h i n g e s ,s l i d ed o o r s ,e t c .
POWERPARTDamp Disptacer
To make damp electricalequipmentdry and to give futureprotection.
P O W E R P A R TH y l o m a r
U n i v e r s asl e a l i n gc o m p o u n dt o s e a l j o i n t s .
P O W E R P A R TH y l o s i l
S i l i c o n er u b b e rs e a l a n t o p r e v e n tl e a k a g e .
POWERPARTlmpact Adhesive
T o k e e pj o i n t si n p o s i t i o nd u r i n gi n s t a l l a t i oann d o t h e rg e n e r a a
l t t a c h m e npt u r p o s e s .
P O W E R P A R TS o l v e n t
To thoroughlyclean metalfaces beforeassemblV.
P O W E R P A R TL o c k i n g A g e n t
Used to securelyinstallfasteners,sleeves,erc.
EXAMPLES
OFSERVICE
FACILITIES
ServicePublications
The followingServiceLiteraturemay be purchasedthrough
your localPerkinsDistributor
WorkshopManuals,
OperatorsHandbooks,
Crankshaft
Regrinding,
FaultFindingGuide,
Installation
and MaintenanceGuidefor staticstandbyEngines,
EngineBrakeTestingData,
Etcetera.
ServiceInstruction
P E T ER B OR OU GH
Applyto ProductEducationDepartment
for details.
INDEX
Alternator
AC5,17ACR,1BACR,25ACR
and A133/65
Precautions
Maintenance
FaultFindingACS
Testing17ACR,18ACR,25ACRandA133/65
Data
Altitude,De-rating
, Atomisers,
I
Data
General
Preventive
Maintenance
I
PressureSetting
Belt,Fan,Adjustment
Belt,Fan,Preventive
Maintenance
Bearing,Main,Dataand Dimensions
Bearing,Main,To Fit
Block,Cylinder
Block,Cylinder,Dataand Dimensions
Bush,AuxiliaryDriveShaftFront,Dataand
Dimensions
Bush,AuxiliaryDriveShaftRear,Dataand
Dimensions
Bush,Connecting
Rod,SmallEnd,Dataand
Dimensions
Bush,Connecting
Rod,to Renew
Case,Timing,To Remove
Case,Timing,To Refit
Camshaft,Dataand Dimensions
Camshaft,To Remove
Camshaft,To Replace
ColdStartingAid,Failure
ColdStartingAid,Operation
Companies,
Overseas
Compressor
Preventive
Maintenance
To Remove
To Replace
Compressor
SC6
Dismantling
Cleaning
Inspection
of Parts
Re-assembly
Compressor,
Twin9
Dataand Dimensions
To Dismantle
To Re-assemble
To Recondition
I Cooler,ArrCharge,(remote)Preventive
Maintenance
I Cooler,Air Charge,(integralairlwater)
Cooler,Air Charge,Description
Cooler,Oil
To Remove
To Dismantle
To Be-assemble
To Test
To Refit
CoolerAdapter,
Oil Coolerto CylinderBlock
CoolingSystem,Data
CoolingSystem,Description
Crankshaft,
Dataand Dimensions
Description
To Regrind
To Remove
To Fit
I Data,Engine
EngineCoolant
n.z
R.2
R.2
R.3
812
8.2
812
N.6
c.3
8.12
M.2
c.3
B6
H.4
v,z
ttd
8.9
B5
F3
J.2
J.2
B6
J4
J4
c.2
c.2
Page2
s.2
S2
s.2
s.2
s.2
S3
J.J
S5
s.4
J.4
D.4
v.o
M5
N2
1.5
L 5 a n d1 . 6
L 5 a n d1 , 6
1,6
L7
L7
B10
M.2
Engine,Operating
Engine,Starting
Engine,StartingafterDisturbing
Oil Feedpipeto
Turbocharger
Engine,Stopping
ExhaustSmoky,FaultFinding
FaultFindingChart
Filter
Air,DryType
Air,General
Air,Oil BathType
Fuel,Data
Fuel,To RenewElemenr
Lubricating
Oil,Dataand Dimensions
Lubricating
Oil,Preventive
Maintenance
Lubricating
Oil,To Flenew
Foreword
Flywheel,
Alignment
Flywheel,To Remove
Flywheel,To Refit
Flywheel,
Runout
FuelOil Specification
FuelSystem,Bleeding
Gauze,FuelLiftPump,Preventive
Maintenance
Gasket,CylinderHead
Gear
AuxiliaryDriveShaft,Dataand Dimensions
AuxiliaryDriveShaft,To Remove
AuxiliaryDriveShaft,To Refit
Camshaft,Dataand Dimensions
Camshaft,To Remove
Camshaft,
To Refit
Crankshaft,
Dataand Dimensions
FlywheelRing
Hydraulically
LoadedWormwheel,
Dataand
Dimensions
ldler,Dataand Dimensions
ldler,To Remove
ldler,To Refit
Timing,Backlash
Timing,Backlash,
Checking
Guide,Valve,Dataand Dimensions
Guides,Valve
Head,Cylinder
Dataand Dimensions
To Bemove
To Overhaul
To Fit
Housing,Flywheel,
AlignmentLimits
Housing,Flywheel,
To Remove
Housing,Flywheel,
To Refit
Hub,ldlerGear,Dataand Dimensions
Hub,ldlerGear,To Remove
Hub,ldlerGear,To Refit
v,z
c2
c.2
D.2
D.2
N.2
N.2
N.4
8.10
N4
B.10
U.J
l
P.^a
P.2
P.2
P.2
P.2
8.10
N.7
a e
E.2
8.8
J.2
J.2
B.B
J2
J2
8.8
T Z
8.9
B.B
J3
J.4
B8
J.6
8.7
8.7
E,2
E2
T.J
P.2
P.2
BB
J J
J.4
Inserts,ValveSeat
E.5
Jets,PistonCooling
Description
NozzlePositioning
To Refit
To Remove
M4
M.5
M.5
tv.4
ttb
H.2
H3
H2
H4
B 1
c.4
I Laying-Up,
EnginePreservation
Liner,Cylinder
Dataand Dimensions
To Renew
Lubricating
Oil
ApprovedGrades
Crrculation
OperatingPressure
C4
g z
8.3
G.2
Appendix
1.3
6
INDEX(Continued)
HighPressure,FaultFinding
Level,PreventiveMaintenance
Low Pressure,FaultFinding
Renewal,PreventiveMaintenance
Misfire,Engine,FaultFinding
Number,EngineLocation
I
;I
I
I
D,2
D.2
U.J
D,2
Page5
Overheating,
Engine,FaultFinding
D.2
Protectionof an Enginenot in Service

Pin,Gudgeon,Dataand Dimensions
Pistonand Rod
To Assemble
Dataand Dimensions
To Dismantle
Inspection
To Remove
To Fit
Post DeliveryService
PowerLack,FaultFinding
Pressure,
Crankcase,
FaultFinding
Pulley,Crankshaft,To Fit
Pulley,Crankshaft,To Remove
Pump,FuelInjection
ldlingSpeedSetting
MaximumSpeedSetting
Data
Description
Timing
To CheckTiming
To Remove
To Fit
Pump,Fuel Lift
Data
Dismantling
Re-assembly
To Removeand Fit
Pump,Lubricating
Oil
Clearances
Data
Inspection
To Dismantle
To Re-assembleand Refit
To Remove
Pump,Water
Dataand Dimensions
To Dismantle
To Re-assemble
To Remove
To Refit
PushRod,Dataand Dimensrons
Push Rod
c.4
8.5
Rating,Details
Restriction
Indicator
I Ring,Piston,Dataand Dimensions
Rings,Piston,To Fit
Rings,Piston,To CheckGaps
Rockers,Dataand Dimensions
Rod,Connecting
Alignment
Dataand Dimensions
Bearings,Dataand Dimensions
Inspection
To Remove
To Replace
Seal,CrankshaftFrontEnd Oil,To Renew
Seal,Crankshaft
RearEndOil,To Fit
Seal, RockerShaftOil FeedConnection,Fitting
Service,EngineReturnPreparation
ServiceInstruction
Shaft,AuxiliaryDrive,To Remove
6.3544SeriesWorkshopManual,January'1986
Shaft,AuxiliaryDrive,To Refit
Shaft,AuxiliaryDriveAssembly,Dataand
Dimensions
Shaft,Fuel InjectionPumpDrive,To Remove
Shaft,FuelInjectionPumpDrive,To Refit
Shaft,Rocker,Dataand Dimensions
Shaft,Rocker,Dismantlingand Assembly
Spring,InnerValve,Dataand Dimensions
Spring,OuterValve,Dataand Dimensions
Springs,Valve
StarterMotorM50
GeneralDescription
Maintenance
Testingon Vehicle
StarterMotorCA45
GeneralDescription
Maintenance
Testingon Vehicle
Starting,Difficulty,FaultFinding
Sump,
Data
To Remove
To Replace
Strainer,LubricatingOil
c.3
F.3
8 . 3& 8 . 4
F,2
F.3
F.2
F.5
c.3
D,2
D.2
H.2
N.6
N.6
8.10
N.5
K.2
K.3
N.6
N.6
8.10
N.5
N.5
N.5
B.9
8.9
L.4
L.J
L.4
1.3
8,10
M.3
M.3
M.3
M.4
8.8
E.T
8.1
N.2
u.J- t .5
F.4
F.3
8.8
F.3
8.5
8.6
F.3
F.2
F.4
J.2
H.6
E.3
c.4
Appendix
J.4
Tappets,Dataand Dimensions
Tappets,To Remove
Tappets,To Replace
Thermostat
Data
Testing
To Removeand Refit
Timing,FuelInjection,
Checking
Timing,Fuellnjection
Timing,FuelInjectionStatic,Position
Timing,Valve,Checking
Tools,ApprovedService
Torque,Recomrnended
Tensions
TurbochargerT-048
Cleanino
,
II
oismaniiins
FaultDiaqnosis
I
Inspectioi
Installation
CheckList
I
Re-assembly
;
j
Reconditioning
' Turbocharger
3LD
I
Cleaning
Dismantling
I
FaultDiagnosis
;
Inspection
I
Installation
CheckList
;'
Re-assembly
I
Reconditioning
3LM & S-76
; Turbocharger
Cleaning
;
t q
D.6
J.4
J.C
8.8
=-I
8.7
6.1
E.6
R.4
R.4
R.4
R.5
R.5
n.c
D.2
8.9
1.3
1.3
1.3
8.8
J.4
J.4
B.10
M.2
M.2
K.3
K.3
B.11
K.3
Appendix
8.1
u.5
Q.5
Q.2
LJ. O
Q,9
\J. O
Q.2
Q.4
\J.*t
Q.2
no
Q.4
Q.2
Q.7
\J.O
Q.2
Q.7
Q.7
Q.8
Q.2
Valves
Assembly
Exhaust,Dataand Dimensions
Inlet,Dataand Dimensions
Inspection
Seats,Valve
I
Tip Clearances
To Fit
To Remove
Valve,Oil PressureRelief
Removaland Dismantling
Re-assemblyand Refitting
I
8.7
6.1
E.5
E.4
E.4
E,4
L.4
L.4
INDEX(Continued)
Dataand Dimensions
Washers,AuxiliaryDriveThrust,Dataand
Dimensions
Washer,CamshaftThrust,Data
Washer,CrankshaftThrust,Dataand Dimensions
Washer.CrankshaftThrust.To Renew
Water Level,PreventiveMaintenance
Weights,Engine
6.3544SeriesWorkshooManual.Januaru1986
B.9
B.9
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E.b
H.2
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B.1

Service Manual Perkins

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Service Manual Perkins

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This publicationis writtenfor world wide use. In territorieswhere legalrequirementsgovernsmoke emission,noise,safety

Publishedby PerkinsEnginesLimitedand Printedin Englandby c H. Fisher& Sons (Printers)Ltd.,Peterborough

In additionto the above,there are Perkrnsdistributors

6 3544 SeriesWorkshooManual.lssue2. June'82

Oil Drain Pipefrom Turbocharger

View of CamshaftSide of 6.3544Engrne

View of CamshaftSide of T6.3544Engine

View of CamshaftSide of T6.3544CC(Air ChargeCooled)Engine

MANUFACTURINGDATA AND DIMENSIONS

Cyfinder Liners (Cast tron- Ftanged)- T6.g544/6.9544

CylinderLiners (Cast lron-Flanged)- 6.9724

Pistons (T6.3544North America vehicles)

Piston Rings (T6.3544North America vehicles)

Chrome faced wedge

PistonRings (6.3544-5 ring pack)

Piston Rings (6.3724)

Gudgeon Pin (6.3544 and 6.3724)

Small End Bush (T6.3544)(includesNorthAmericavehicleengines)

Steel Backed,Lead Bronze Lined

Small End Bush (5.3544and 6.3724)

Steel Backed,Lead Bronze Lined

Inner Valve Springs (short)

Inner ValveSprings (long)

1.563in (39,70mm) at 14.63/1

R.H.-Damper Coilsto CylinderHead

Outer ValveSprings (short)

Outer Valve Springs ( l o n g )

1.780 in (45,20 mm) aI 38/43 lbf (17,25/19,52kgf)

Rocker Levers and Bushes

Auxiliary Drive Gear

ldler Gears and Hubs

Timing Gear Backlash

Auxiliary Drive Shaft Assembly

Drive Shaft Bush-Front

Drive Shalt Bush- Rear

Hydraulically Loaded Wormwheel

Oil Pump Clearance

Approved Fuel Oil Specifications

Fuel Lift Pump

Fuel Injection Pump

Fuellnjection Pump Static Checking Angles

6 3544 Seriesworkshop Manual,lssue2, June'82

Engine start procedure, without cold

Enginestart procedurewith Thermostart.

4. Turn the start key to the 'HS' (Heat/Start)positionto

Stopping the Engine

Checkfor water in the fuel pre-filter(wherefitted)and drainas

Air GhargeCooler (remote)

Post Delivery Service

It is good maintenanceto check for leakage and loose

2. Renewthe canisterof the lubricating

These maintenanceperiodsare only for enginesthat are

Daily or every 8 hours

3. Adjustthe valvetip clearances(see page E.4).

Protectionof an Enginenot in Service

Remove the air filter and any pipe installed

Remove the lubricating oil filler cap Spray

not fitted to the radiator, disconnect the bottom

1. Ensure that the vehicle or machine is on level

Fault Finding Chart

Low cranking speed

Will not start