4.236 & T4.236 DIESEL ENGINES Section B: Technical data Caterpillar


Section B: Technical data
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1.1. Details of Maximum Gross Ratings
2.2. 4.2482 Engines
3.2. 4.248 Engines
4.2. T4.236 Engines
5.2. 4.236 Engines
6.2. 4.212 Engines
7.2. Engine Weights
8.2. De-Rating for Altitude
9.1. Recommended Torque Tensions
10.1. Service Wear Limits
11.1. Manufacturing Data & Dimensions
12.2. Cylinder Block
13.2. Cylinder Liners Cast Iron (4.2482, 4.248, T4.236, 4.236 and 4.212 engines)
14.2. Cylinder Liners Chrome - Thin Wall (4.236 engines)
15.2. Cylinder Liners Chrome - Thick Wall (4.236 engines)
16.2. Pistons (4.2482 Engines)
17.2. Pistons (4.248 engines)-4 Ring
18.2. Pistons (4.248 Engines) - 3 Ring
19.2. Pistons (T4.236 Engines)
20.2. Pistons (4.236 engines) - 5 Ring
21.2. Pistons (4.236 engines) - 3 Ring
22.2. Pistons (4.212 engines)-
23.2. Piston Rings (4.2482 Engines)
24.2. Piston Rings (4.248 Engines) - 4 Ring
25.2. Piston Rings (4.248 Engines) - 3 Ring
26.2. Piston Rings (T4.236 Engines)
27.2. Piston Rings (4.236 engines) - 5 Ring
28.2. Piston Rings (4.236 engines) - 3 Ring
29.2. Piston Rings (4.212 engines)
30.2. Gudgeon Pin (4.2482, 4.248, 4.236 and 4.212 Engines)
31.2. Gudgeon Pin (T4.236 Engines)
32.2. Small End Bush (4.2482, 4.248, 4.236 and 4.212 Engines)
33.2. Small End Bush (T4.236 Engines)
34.2. Connecting Rod (4.2482, 4.248, 4.236 and 4.212 Engines)
35.2. Connecting Rod (T4.236 Engines)
36.2. Connecting Rod Alignment
37.2. Crankshaft
38.2. Crankshaft Thrust Washers
39.2. Main Bearings
40.2. Connecting Rod Bearings
41.2. Camshaft
42.2. Camshaft Thrust Washer
43.2. Cylinder Head
44.2. Valve Guides (if fitted)
45.2. Exhaust Valves
46.2. Inlet Valves
47.2. Inner Valve Springs
48.2. Outer Valve Springs
49.2. Single Valve Springs (Fork Lift Trucks 4.236/4.2482)
50.2. Tappets
51.2. Rocker Shaft
52.2. Rocker Levers
53.2. Rocker Levers with Replaceable Bushes
54.2. Valve Clearances
55.2. Valve Timing
56.2. Camshaft Gear
57.2. Fuel Pump Gear (Hydraulically Governed Pumps)
58.2. Fuel Pump Gear (Mechanically Governed Pumps)
59.2. Idler Gear and Hub
60.2. Idler Gear and Hub - Heavy Duty
61.2. Crankshaft Gear
62.2. Timing Gear Backlash
63.2. Sump
64.2. Oil Pump
65.2. Pump Clearances
66.2. Pump Part No. 4132F014 (Concentric) Centre mounted Balancer
67.2. Oil Pump Drive Gear
68.2. Oil Pump Idler Gear
69.2. Relief Valve
70.2. Relief Valve, Centre Mounted Balancer
71.2. Lubricating Oil Filter - Element or Canister Type
72.2. Type of Cooling System
73.2. Thermostat
74.2. Thermostat - By Pass Blanking (fitted to T4.236 and some 4.248 engines)
75.2. Water Pump
76.2. Balancer Unit - Front Mounted
77.2. Balancer Unit - Centre Mounted
78.2. Approved Fuel Oil Specifications
79.2. Fuel Lift Pump
80.2. Fuel Filter (Final)
81.2. Fuel Injection Pump
82.2. Engine Checking and Fuel Pump Marking Angles, Static Timing
83.2. Atomisers
84.2. Electrical System

Nominal Bore (4.2482 and 4.248) ... 3.975 in(100,96 mm) *

Nominal Bore (T4.236, 4.236 and 4.212) ... 3.875 in(98,43 mm) *

Stroke (4.2482, 4.248, T4.236 and 4.236) ... 5 in(127 mm)

Stroke (4.212) ... 4.5 in(114,3 mm)

No. of Cylinders ... Four

Cubic Capacity (4.2482 and 4.248) ... 248 in3(4,06 litres)

Cubic Capacity (T4.236 and 4.236) ... 236 in3(3,86 litres)

Cubic Capacity (4.212) ... 212 in3(3,47 litres)

Compression Ratio (4.2482) ... 18:1

Compression Ratio (4.236 - LC Piston with 5 rings) ... 16:1

Compression Ratio (4.236 - HC Piston with 3 rings) ... 18:1

Compression Ratio (T4.236) ... 15.5:1

Compression Ratio (4.248) ... 16:1

Compression Ratio (4.212 - HC Piston with 3 rings) ... 17.5:1

Compression Ratio (A4.212 - LC Piston with 4 rings) ... 15.5:1

Direction of Engine Rotation ... Clockwise from the Front

Firing Order ... 1, 3, 4, 2

Cycle ... Four-Stroke

Combustion System ... Direct Injection

Lubricating Oil Pressure ... 30/60 lbf/in2 (2,1/4,2 kgf/cm2) or 207/414 kN/m2 at max engine speed and normal working temperature.


*Nominal -for actual bore size, see pages B.3 and B.4

On A4.212 engines, the HC piston with 3 rings was fitted to MF engines from Nos. 212UA87001 to 212UA147672.

Details of Maximum Gross Ratings

4.2482 Engines

General ... 60 kW (80 bhp) at 2,600 rev/min

Maximum Torque ... 265 Nm (195 lbf ft) at 1,400 rev/min

Heavy Duty ... 54 kW (72.5 bhp) at 2,600 rev/min

Maximum Torque ... 238 Nm (176 lbf ft) at 1,400 rev/min

4.248 Engines

General Agricultural and Industrial ... 62 kW (84 bhp) at 2500 rev/min

Maximum Torque ... 263 Nm (194 lbf ft) at 1400 rev/min

Heavy Duty Agricultural and Industrial ... 58 kW (78.5 bhp) at 2200 rev/min

Maximum Torque ... 279 Nm (206 lbf ft) at 1400 rev/min

T4.236 Engines

General ... 76 kw (102 bhp) at 2,600 rev/min

Maximum Torque ... 337 Nm (250 lbf ft) at 1,600 rev/min

Heavy Duty ... 67 kW (90 bhp) at 2,500 rev/min

Maximum Torque ... 324 Nm (240 lbf ft) at 1,400 rev/min

4.236 Engines

Vehicle ... 61 kW (82 bhp) at 2800 rev/min

Maximum Torque ... 256 Nm (194 lbf ft) at 1450 rev/min

General Agricultural and Industrial ... 60 kW 81 bhp at 2600 rev/min

Maximum Torque ... 267 Nm (197 lbf ft) at 1350 rev/min

Heavy Duty Agricultural and Industrial ... 54 kW (72 bhp) at 2200 rev/min

Maximum Torque ... 272 Nm (201 lbf ft) at 1400 rev/min

4.212 Engines

Agricultural ... 46 kW (62 bhp) at 2200 rev/min

Maximum Torque ... 229 Nm (169 lbf ft) at 1350 rev/min

Engine Weights

Typical dry weight ... 590 lb(269 kg)

Typical installed weight ... 750/900 lb(340/409 kg)

All the above ratings are maximum and can vary according to application. For details of individual ratings, apply to your nearest Perkins Distributor.

De-Rating for Altitude

Where engines operate at high altitudes they should be de-rated. The following table is given as a general guide for naturally aspirated engines to be applied on a percentage basis, where specific figures for a particular engine rating are not available.

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

For turbocharged engines and any further information apply to Perkins Engines Ltd., Peterborough, or to Overseas Companies listed on Page 2.

Recommended Torque Tensions

The following figures will apply with the components lightly oiled before assembly.

Service Wear Limits

The following "wear limits" indicate the condition when it is recommended that the respective items should be serviced or replaced.

Cylinder Head Bow

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

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

Maximum Bore Wear (when reboring or new liners are necessary) ... 0.008 in(0,2 mm)

Crankshaft Main and Big End Journal Wear, Ovality ... 0.0015 in(0,04 mm)

Maximum Crankshaft End Float ... 0.015 in(0,38 mm)

Valve Stem to Bore/Guide Clearance

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

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

Valve Head Thickness between run-out of valve seat and face of valve ... 1/32 in(0,79 mm)

Rocker Clearance on Rocker Shaft ... 0.005 in(0,13 mm)

Camshaft Journals-Ovality and Wear ... 0.002 in(0,05 mm)

Camshaft End Float ... 0.020 in(0,51 mm)

Idler Gear End Float ... 0.010 in(0,25 mm)

*Valve Head Depth below Cylinder Head Face exhaust (Earlier) ... 0.055 in(1,40 mm) maximum

*Valve Head Depth below Cylinder Head Face (Current) ... 0.073 in(1,85 mm) maximum

*Valve Head Depth below Cylinder Head Face inlet ... 0.061 in(1,55 mm) maximum


*Where it is necessary to conform with the smoke density regulation B.S.AU 141a: 1971, then the valve depths must not exceed production limits as given on Page B.10.

Manufacturing Data & Dimensions

All threads used, except perhaps on proprietary equipment are Unified Series and American Pipe Series. The crankshaft and pulley retaining setscrew threaded 7/8 in U.N.F. of 14 T.P.I.

The following data of clearances and tolerances are given as a guide for personnel engaged upon major overhauls and the figures are those used in the factory for production purposes.

Cylinder Block

Total Height of Cylinder Block between Top and Bottom Faces ... 17.367/17.375 in(441,12/441,33 mm)

Parent Bore Dia. for Cylinder Liner (Chrome Thin Wall) ... 3.9625/3.9635 in(100,65/100,67 mm)

Parent Bore Dia. for Cylinder Liner (Chrome Thick Wall) ... 4.0625/4.0635 in(103,19/103,22 mm)

Parent Bore Dia. for Flangeless Cylinder Liner (Cast Iron) ... 4.0615/4.0625 in(103,16/103,19 mm)

Parent Bore Dia. for Flanged Cylinder Liner (Cast Iron) (T4.236, 4.236 and 4.212) ... 4.0625/4.0635 in(103,19/103,22 mm)

Parent Bore Dia. for Flanged Cylinder Liner (Cast Iron) (4.2482 and 4.248) ... 4.1025/4.1035 in(104,20/104,23 mm)

Depth of Recess for Liner Flange (Cast Iron) ... 0.150/0.154 in(3,81/3,91 mm)

Depth of Recess for Liner Flange (Chrome Thin Wall) early type ... 0.046/0.049 in(1,17/1,25 mm)

Depth of Recess for Liner Flange (Chrome Thin Wall) later type ... 0.049/0.051 in(1,25/1,30 mm)

Depth of Recess for Liner Flange (Chrome) Thick Wall ... 0.150/0.152 in(3,81/3,86 mm)

Main Bearing Parent Bore Dia. ... 3.166/3.167 in(80,42/80,44 mm)

Camshaft Bore Dia. No. 1 for Bush (where fitted) ... 2.1875/2.1887 in(55,56/55,59 mm)

Camshaft Bearing Bush Internal Dia. fitted ... 2.0000/2.0017 in(50,8/50,84 mm)

Camshaft Bore Dia. No. 1 ... 2.000/2.001 in(50,80/50,83 mm)

Camshaft Bore Dia. No. 2 ... 1.990/1.9918 in(50,55/50,59 mm)

Camshaft Bore Dia. No. 3 ... 1.970/1.9718 in(50,04/50,08 mm)

Cylinder Liners Cast Iron (4.2482, 4.248, T4.236, 4.236 and 4.212 engines)

Types ... Dry-Interference Fit (Production); Dry-Transition Fit (Pre-finished Service)

Outside Dia. of Production Liner

Flangeless-4.248, 4.236 and 4.212 engines ... 4.0655/4.0665 in(103,26/103,29 mm)

Flanged-4.2482 and 4.248 engines ... 4.1045/4.1055 in(104,25/104,28)

Flanged-T4.236, 4.236 and 4.212 engines ... 4.0645/4.0655 in(103,24/103,26 mm)

Outside Dia of Flanged Pre-Finished Service Liner

4.2482 and 4.248 engines ... 4.1025/4.1035 in(104,20/104,23 mm)

4.236 and 4.212 engines ... 4.0625/4.0635 in(103,19/103,21 mm)

Interference Fit of Production Liner in Cylinder Block

Flangeless-4.248, 4.236 and 4.212 engines ... 0.003/0.005 in(0,08/0,13 mm)

Flanged-4.2482 nd 4.248 engines ... 0.001/0.003 in(0,03/0,08 mm)

Flanged-T4.236, 4.236 and 4.212 engines ... 0.002/0.004 in(0,05/0,10 mm)

Transition Fit of Pre-Finished Service Liner ... ±0.001 in(±0,03 mm)

Finished Bore Dia. of Production Liners

4.2482 and 4.248 engines ... 3.9785/3.9795 in(101,05/101,07 mm)

T4.236, 4.236 and 4.212 engines ... 3.877/3.878 in(98,48/98,50 mm)

Bore Dia. of Pre-Finished Service Liner in Block

4.2482 and 4.248 engines ... 3.980/3.981 in(101,09/101,12 mm)

T4.236, 4.236 and 4.212 engines ... 3.878/3.879 in(98,50/98,52 mm)

Height of Top of Liners above Cylinder Block Face ... 0.028/0.037 in(0,71/0,94 mm)

Flange Thickness of Liner

Earlier 4.236 and 4.212 engines ... 0.144/0.146 in(3,66/3,71 mm)

4.2482, 4.248, T4.236 and current 4.236 and 4.212 engines ... 0.150/0.152 in(3,81/3,86 mm)

Relationship of Liner Flange to Cylinder Block Face

Earlier 4.236 and 4.212 engines ... 0.004/0.010 in(0,10/0,25 mm) Below

4.2482, 4.248, T4.236 and current 4.236 and 4.212 engines ... 0.004 in(0,10 mm) Above to ... 0.004 in(0,10 mm) Below

Maximum Oversize (Rebore) Flangelss Liner (4.236 and 4.212 engines only) ... +0.030 in(+0,76 mm)

Overall Length of Liner (Flangeless - 4.212 and 4.236) ... 9.005/9.015 in(228,7/229 mm)

Overall Length of Liner (Flangeless - 4.248) ... 8.805/8.815 in(223,65/223,90 mm)

Overall Length of Liner (Flanged) ... 8.941/8.954 in(227,10/227,43 mm)

Cylinder Liners Chrome - Thin Wall (4.236 engines)

Type ... Dry-Transition Fit

Outside Dia. of Liner ... 3.9625/3.9635 in(100,65/100,67 mm)

Depth of Liner below Cylinder Block Top Face (Early Type) ... 0.001/0.009 in(0,025/0,23 mm)

Depth of Liner below Cylinder Block Top Face (Later Type) ... 0.004/0.008 in(0,102/0,203 mm)

Flange Thickness (Early Type) ... 0.040/0.045 in(1,016/1,143 mm)

Flange Thickness (Later Type) ... 0.043/0.045 in(1,092/1,143 mm)

Inside Dia. of Liner after fitting ... 3.8765/3.879 in(98,47/98,53 mm)

Overall Length of Liner ... 8.9212/8.8912 in(226,6/225,8 mm)

Cylinder Liners Chrome - Thick Wall (4.236 engines)

Type ... Dry-Transition Fit

Outside Dia. of Liner ... 4.0625/4.0635 in(103,19/103,21 mm)

Depth of Liner Flange below Cylinder Block Top Face ... 0.004/0.008 in(0,102/0,203 mm)

Height of Liner above Cylinder Block Top Face ... 0.028/0.035 in(0,71/0,89 mm)

Flange Thickness ... 0.144/0.146 in(3,66/3,71 mm)

Inside Dia. of Liner after fitting ... 3.877/3.875 in(98,48/98,54 mm

Overall Length of Liner ... 8.939/8.954 in(227,05/227,43 mm)

Pistons (4.2482 Engines)

Type ... Squish Lip - Re-entrant Bowl

Piston Height in relation to Cylinder Block Top Face ... 0.016/0.023 in(0,41/0,59 mm) above

Bore Dia. for Gudgeon Pin ... 1.37485/1.37505 in(34,92/34,93 mm)

Compression Ring Groove Width, Number 1 ... 0.1015/0.1024 in(2,58/2,60 mm)

Compression Ring Groove Width, Number 2 ... 0.1008/0.1015 in(2,56/2,58 mm)

Scraper Ring Groove Width, Number 3 ... 0.1984/0.1992 in(5,04/5,06 mm)

(Pistons have hard anodised crowns and must not be topped).

Pistons (4.248 engines)-4 Ring

Type ... Cavity in Crown

Piston Height in relation to Cylinder Block ... 0.003/0.010 in(0,08/0,25 mm) above

Bore Dia. for Gudgeon Pin ... 1.37485/1.37505 in(34,92/34,93 mm)

Compression Ring Groove Width, Numbers 1, 2 & 3 ... 0.0957/0.0967 in(2,43/2,46 mm)

Scraper Ring Groove Width, Number 4 (plain piston) ... 0.2525/0.2535 in(6,41/6,44 mm)

Scraper Ring Groove Width - No. 4 (inserted piston) ... 0.189/0.190 in(4,80/4,83 mm)

Pistons (4.248 Engines) - 3 Ring

Type ... Cavity in Crown

Piston Height in relation to Cylinder Block Top Face ... 0.003/0.010 in(0,08/0,25 mm) above

Bore Dia. for Gudgeon Pin ... 1.37485/1.37505 in(34,92/34,93mm)

Compression Ring Groove Width, Numbers 1 and 2 ... 0.1015/0.1024 in(2,58/2,60 mm)

Scraper Ring Groove Width, No. 3 ... 0.1984/0.1992 in(5,04/5,06 mm)

Pistons (T4.236 Engines)

Type ... Cavity in Crown

Piston Height in relation to Cylinder Block Top Face ... 0.016/0.024 in(0,41/0,61 mm) above

Bore Dia. for Gudgeon Pin ... 1.5000/1.50002 in(38,10/38,106 mm)

Compression Ring Groove Width, Number 1 ... Tapered

Compression Ring Groove Width, Number 2 ... 0.0955/0.0963 in(2,43/2,45 mm)

Scraper Ring Groove Width, Number 3 ... 0.1885/0.1893 in(4,79/4,81 mm)

Pistons (4.236 engines) - 5 Ring

Type ... Cavity in Crown

Piston Height in Relation to Cylinder Block (standard) ... 0.003/0.010 in(0,08/0,25 mm) above

Piston Height in relation to Cylinder Block (B.S. AU 141a:1971) ... 0.016/0.024 in(0,41/0,61 mm) above

Bore Dia. for Gudgeon Pin ... 1.37485/1.37505 in(34,92/34,93 mm)

Compression Ring Groove Width-Numbers 1, 2, 3 ... 0.0957/0.0967 in(2,43/2,46 mm)

Scraper Ring Groove Width-Numbers 4 and 5 ... 0.2525/0.2535 in(6,41/6,44 mm)

Pistons (4.236 engines) - 3 Ring

Type ... Cavity in Crown - Controlled Expansion - Inserted Top Groove

Piston Height in relation to Cylinder Block Face ... 0.011/0.019 in(0,28/0,48 mm) above

Bore Dia. for Gudgeon Pin ... 1.37485/1.37505 in(34,928/35,934 mm)

Compression Ring Groove Width, No. 1 ... 0.097/0.098 in(2,47/2,49 mm)

Compression Ring Groove Width, No. 2 ... 0.096/0.097 in(2,45/2,47 mm)

Scraper Ring Groove Width, No. 3 ... 0.1885/0.1892 in(4,79/4,81 mm)

Pistons (4.212 engines)-

Type ... Cavity in Crown

Piston Height in Relation to Cylinder Block ... 0.015/0.021 in(0,38/0,53 mm) above

Bore Dia. for Gudgeon Pin ... 1.37485/1.37505 in(34,92/34,93 mm)

Compression Ring Groove Width, Numbers 1, 2 & 3 ... 0.0957/0.0967 in(2,43/2,46 mm)

Scraper Ring Groove Width, Number 4 ... 0.2525/0.2535 in(6,41/6,44 mm)

Piston Rings (4.2482 Engines)

Top Compression ... Molybdenum Faced-Internally Stepped-Barrel Faced

Second Compression ... Internally Stepped-Taper Faced

Third Scraper ... Chrome Faced-Spring Loaded Conformable

Compression Ring Width ... 0.097/0.098 in(2,46/2,49 mm)

No. 1 Clearance in Groove ... 0.0035/0.0054 in(0,09/0,14 mm)

No. 2 Clearance in Groove ... 0.0028/0.0045 in(0,07/0,11 mm)

No. 3 Scraper Ring Width ... 0.1954/0.1964 in(4,96/4,99 mm)

No. 3 Clearance in Groove ... 0.002/0.0042 in(0,05/0,11 mm)

Ring Gap, No. 1 ... 0.016/0.034 in(0,41/0,86 mm)

Ring Gap, No. 2 ... 0.012/0.030 in(0,30/0,76 mm)

Ring Gap, No. 3 ... 0.012/0.036 in(0,30/0,91 mm)

Piston Rings (4.248 Engines) - 4 Ring

Top Compression ... Chrome Insert - Parallel Face/Barrel Face

*2nd and 3rd Compression ... Internally Stepped

**4th Scraper ... Spring Loaded Conformable.

Compression Ring Width, ... 0.0928/0.0938 in(2,36/2,38 mm)

Ring Clearance in Groove, Numbers 1, 2 & 3 ... 0.0019/0.0039 in(0,05/0,10 mm)

Ring Gap - Chrome ... 0.016/0.034 in(0,41/0,86 mm)

Ring Gap - Cast Iron ... 0.012/0.030 in(0,30/0,76 mm)

Ring Gap - Scraper ... 0.012/0.036 in(0,30/0,91 mm) varies according to type of ring.


*On A4.248 engines rated up to 2,000 rev/min, the 2nd compression ring is plain cast iron.


**On some earlier A4.248 engines, the 4th ring was a sealed power scraper.

On some later engines, the 2nd and 3rd compression rings, internally stepped, are chrome plated.

Piston Rings (4.248 Engines) - 3 Ring

Top Compression ... Molybdenum Faced-Internally Stepped-Barrel Faced

Second Compression ... Internally Stepped-Taper Faced

Third Scraper ... Chrome Faced-Spring Loaded Conformable

Compression Ring Width ... 0.097/0.098 in(2,46/2,49 mm)

Nos. 1 and 2 Compression Ring Clearance in Groove ... 0.0017/0.0027 in(0,04/0,07 mm)

No. 3 Scraper Ring Width ... 0.1954/0.1964 in(4,96/4,99 mm)

No. 3 Clearance in Groove ... 0.002/0.0038 in(0,05/0,10 mm)

Ring Gap, No. 1 ... 0.016/0.034 in(0,41/0,86 mm)

Ring Gap, No. 2 ... 0.016/0.034 in(0,41/0,86 mm)

Ring Gap, No. 3 ... 0.016/0.034 in(0,41/0,86 mm)

Piston Rings (T4.236 Engines)

No. 1 Compression ... Molybdenum Faced Wedge

No. 2 Compression ... Cast Iron Taper Faced

No. 3 Scraper ... Chrome Faced Spring Loaded Conformable

No. 1 Compression Width ... Wedge Shaped

No. 2 Compression Width ... 0.093/0.0935 in(2,36/2,37 mm)

No. 2 Clearance in Groove ... 0.002/0.0033 in(0,05/0,08 mm)

No. 3 Scraper Width ... 0.186/0.1875 in(4,72/4,76 mm)

No. 3 Clearance in Groove ... 0.001/0.0033 in(0,03/0,08 mm)

Ring Gap, No. 1 ... 0.010/0.024 in(0,25/0,61 mm)

Ring Gap, No. 2 ... 0.010/0.027 in(0,25/0,66 mm)

Ring Gap, No. 3 ... 0.010/0.031 in(0,25/0,79 mm)

Piston Rings (4.236 engines) - 5 Ring

*Top Compression ... Chrome Faced-Parallel Face

Second and Third - Compression ... Internally Stepped

**Fourth - Scraper ... Spring Loaded Conformable

Fifth - Scraper ... Maxigroove


*A cast iron compression ring is fitted when a chrome liner is used or on certain Agricultural applications.


**With earlier engines, the fourth ring was a maxigroove and where combine harvester engines used a four ring kit in a five groove piston, a maxigroove has been added to the fifth groove.

Compression Ring Width Numbers 1, 2 and 3 ... 0.0928/0.0938 in(2,36/2,38 mm)

Ring Clearance in Groove ... 0.0019/0.0039 in(0,05/0,10 mm)

Scraper Ring Width - Fourth and Fifth ... 0.249/0.250 in(6,33/6,35 mm)

Ring Clearance in Groove ... 0.0025/0.0045 in(0,06/0,11 mm)

Ring Gap - Chrome Compression ... 0.016/0.034 in(0,41/0,86 mm)

Ring Gap - Internally Stepped Compression ... 0.012/0.030 in(0,30/0,76 mm)

Ring Gap - Maxigroove Scraper ... 0.012/0.030 in(0,30/0,76 mm)

Piston Rings (4.236 engines) - 3 Ring

Top Compression ... Chrome Barrel Face, Internal Chamfer

Second Compression ... Chrome Taper Face

Third Scraper ... Chrome Face - Spring Loaded Conformable

Top Compression Ring Width ... 0.0930/0.0935 in(2,36/2,37 mm)

Clearance in Groove ... 0.0035/0.005 in(0,09/0,13 mm)

Second Compression Ring Width ... 0.0930/0.0935 in(2,36/2,37 mm)

Clearance in Groove ... 0.0025/0.004 in(0,06/0,11 mm)

Scraper Ring Width ... 0.1860/0.1865 in(4,73/4,74 mm)

Clearance in Groove ... 0.0020/0.0032 in(0,06/0,08 mm)

Ring Gap, No. 1 ... 0.010/0.022 in(0,25/0,55 mm)

Ring Gap, No. 2 ... 0.008/0.022 in(0,20/0,55 mm)

Ring Gap, No. 3 ... 0.010/0.021 in(0,25/0,53 mm)

Piston Rings (4.212 engines)

High Compression Piston

Top Compression ... Chrome Faced

Second Compression ... Chrome Faced Internally Stepped

Third Scraper ... Spring Loaded Conformable

Low Compression Piston

Top Compression ... Chrome Plated

Second Compression ... Cast Iron-Plain

Third Compression ... Internally Stepped

*Fourth Scraper ... Spring Loaded Conformable

Compression Ring Width-Number 1 ... 0.0927/0.0937 in(2,35/2,38 mm)

Compression Ring Widths-Numbers 2 and 3 ... 0.0928/0.0938 in(2,36/2,38 mm)

Ring Clearance in Groove-Number 1 ... 0.002/0.004 in(0,05/0,10 mm)

Ring Clearance in Groove-Numbers 2 and 3 ... 0.0019/0.0039 in(0,05/0,10 mm)

Ring Gap - Chromed ... 0.016/0.034 in(0,41/0,86 mm)

Ring Gap - Cast Iron ... 0.012/0.030 in(0,30/0,76 mm)


*On some earlier 4.212 engines, the 4th ring was a sealed power scraper.

Gudgeon Pin (4.2482, 4.248, 4.236 and 4.212 Engines)

Type ... Fully Floating

Outside Dia. of Gudgeon Pin ... 1.3748/1.375 in(34,92/34,93 mm)

Length of Gudgeon Pin ... 3.297/3.312 in(83,74/84,12 mm)

Fit in Piston Boss ... Transition

Gudgeon Pin (T4.236 Engines)

Type ... Fully Floating

Outside Dia. of Gudgeon Pin ... 1.4998/1.5000 in(38,095/38,100 mm)

Length of Gudgeon Pin ... 3.244/3.260 in(82,40/82,80 mm)

Clearance Fit in Piston Boss ... 0.000/0.0004 in(0,000/0,010 mm)

Small End Bush (4.2482, 4.248, 4.236 and 4.212 Engines)

Type ... Steel Backed, Lead Bronze Lined

Outside Dia. of Small End Bush ... 1.535/1.5365 in(38,99/39,03 mm)

Length of Small End Bush ... 1.316/1.336 in(33,43/33,93 mm)

Inside Dia. before Reaming ... 1.359/1.363 in(34,52/34,62 mm)

Inside Dia. after Reaming ... 1.37575/1.3765 in(34,94/34,96 mm)

Clearance between Small End Bush and Gudgeon Pin ... 0.00075/0.0017 in(0,019/0,043 mm)

Small End Bush (T4.236 Engines)

Type ... Steel Backed, Lead Bronze Lined

Outside Dia. of Small End Bush ... 1.65975/1.66125 in(42,16/42,20 mm)

Inside Dia. after Reaming ... 1.50075/1.5015 in(38,12/38,14 mm)

Clearance between Small End Bush and Gudgeon Pin ... 0.00075/0.0017 in(0,019/0,043 mm)

Connecting Rod (4.2482, 4.248, 4.236 and 4.212 Engines)

Type ... "H" Section

Cap Location to Connecting Rod ... Serrations

Big End Parent Bore Dia. ... 2.6460/2.6465 in(67,21/67,22 mm)

Small End Parent Bore Dia. ... 1.53125/1.53225 in(38,90/38,92 mm)

Length from Centre Line of Big End to Centre Line of Small End ... 8.624/8.626 in(219,05/219,10 mm)

Big End, Width ... 1.577/1.580 in(40,06/40,13 mm)

Connecting Rod End Float on Crankpin ... 0.0085/0.0145 in(0,21/0,37 mm)

Connecting Rod (T4.236 Engines)

Type ... "H" Section - Wedge Shaped Small End

Cap Location to Connecting Rod ... Serrations

Big End Parent Bore Dia. ... 2.6460/2.6465 in(67,21/67,22 mm)

Small End Parent Bore Dia. ... 1.65625/1,65725 in(42,07/42,09 mm)

Length from Centre Line of Big End to Centre Line of Small End ... 8.624/8.626 in(219,05/219,10 mm)

Big End Width ... 1.577/1.580 in(40,06/40,13 mm)

Connecting Rod End Float on Crankpin ... 0.0085/0.0145 in(0,21/0,37 mm)

Connecting Rod Alignment

Large and small end bores must be square and parallel with each other within the limits of ± 0.010 in (0,25 mm) measured 5 in (127 mm) each side of the axis of the rod on test mandrel as shown in Fig. B.1. With the small end bush fitted, the limit of ± 0.010 in (0,25 mm) is reduced to ± 0.0025 in (0,06 mm)

Crankshaft

Overall Length ... 24.01/24.04 in(609,85/610,62 mm)

Main Journal Dia. ... 2.9984/2.9992 in(76,16/76,18 mm)

Main Journal Length-No. 1 ... 1.453/1.473 in(36,91/37,41 mm)

Main Journal Length Nos. 2, 4 and 5 ... 1.545/1.549 in(39,24/39,34 mm)

*Main Journal Length-No. 3 ... 1.738/1.741 in(44,15/44,22 mm)

*Main Journal Fillet Radii ... 0.145/0.156 in(3,68/3,96 mm)

Crankpin Dia. ... 2.4988/2.4996 in(63,47/63,49 mm)

Crankpin Length ... 1.5885/1.5915 in(40,35/40,42 mm)

*Crankpin Fillet Radii ... 0.145/0.156 in(3,68/3,96 mm)

*Surface Finish-All Journals ... 16 micro inches (0,4 microns) maximum

Main Journal and Crankpin Regrind Undersizes ... -0.010, 0.020 and 0.030 in(-0,25, 0,51 and 0,76 mm)

Oil Seal Helix Dia. (rope seals only) ... 3.124/3.125 in(79,35/79,38 mm)

Oil Seal Helix Width ... 0.050/0.080 in(1,27/2,03 mm)

Oil Seal Helix Depth ... 0.004/0.008 in(0,10/0,20 mm)

Flange Dia. ... 5.247/5.249 in(133,27/133,32 mm)

Spigot Bearing Recess Depth ... 0.781 in(19,84 mm)

Spigot Bearing Recess Bore ... 1.8497/1.8502 in(46,98/47,00 mm)

Crankshaft End Float ... 0.004/0.015 in(0,10/0,38 mm)


*Fillet radii and surface finish must be maintained during crankshaft regrinding. Length of No. 3 main journal not to exceed 1.759 in (44,68 mm) after regrinding. Width of crankpins must not exceed 1.5965 in (40,55 mm) after regrinding. Where necessary use oversize thrust washers to suit.

Crankshafts Part No. 31315542, 31315872, 31315884, 31315984, 31315986, 31316204, 31316224, 31316235, 31316237 and 31316241 are tufftrided and must be re-tuffrided after any regrinding has taken place (see Page H.2). Where facilities for re-tufftriding are not available, then a factory replacement crankshaft should be obtained.

Crankshaft Thrust Washers

Type ... Steel Backed, Aluminium Tin or Lead Bronze Faced

Position in Engine ... Centre Main Bearing

Thrust Washer Thickness (STD) ... 0.089/0.091 in(2,26/2,31 mm)

Thrust Washer Thickness (O/S) ... 0.096/0.099 in(2,44/2,51 mm)

Thrust Washer Outside Dia. ... 4.088/4.098 in(103,84/104,90 mm)

Thrust Washer Inside Dia. ... 3.420/3.430 in(86,87/87,12 mm)

Main Bearings

Type ... Pre-Finished, Steel Backed, Aluminium Tin Faced

Shell Width-Nos. 1, 2, 4, and 5 ... 1.245/1.255 in(31,62/31,88 mm)

Shell Width-No. 3 ... 1.435/1.445 in(36,45/36,70 mm)

Outside Dia. of Main Bearing ... 3.167 in(80,41 mm)

Inside Dia. of Main Bearing ... 3.0010/3.0026 in(76,23/76,27 mm)

Main Bearing Running Clearance ... 0.0018/0.0042 in(0,05/0,11 mm)

Shell Thickness ... 0.0822/0.0825 in(2,088/2,098 mm)

Connecting Rod Bearings

Type ... Pre-Finished, Steel Backed, Aluminium Tin Faced

Shell Width ... 1.245/1.255 in(31,62/31,88 mm)

Outside Dia. of Con. Rod Bearing ... 2.6465 in(67,22 mm)

Inside Dia. of Con. Rod Bearing ... 2.5008/2.5019 in(63,52/63,55 mm)

Con. Rod Bearing Running Clearance ... 0.0012/0.0031 in(0,03/0,08 mm)

Shell Thickness ... 0.0723/0.0726 in(1,836/1,844 mm)

Camshaft

No. 1 Journal Length ... 1.2105 in(30,75 mm)

No. 1 Journal Dia. ... 1.9965/1.9975 in(50,71/50,74 mm)

No. 1 Cylinder Block Camshaft Bore Dia. ... 2.000/2.001 in(50,8/50,83 mm)

No. 1 Journal Running Clearance ... 0.0025/0.0045 in(0,06/0,11 mm)

No. 2 Journal Length ... 1.625 in(41,27 mm)

No. 2 Journal Dia. ... 1.9865/1.9875 in(50,46/50,48 mm)

No. 2 Cylinder Block Camshaft Bore Dia. ... 1.990/1.992 in(50,55/50,60 mm)

No. 2 Journal Running Clearance ... 0.0025/0.0053 in(0,06/0,14 mm)

No. 3 Journal Length ... 1.156 in(29,4 mm)

No. 3 Journal Dia. ... 1.9665/1.9675 in(49,95/49,98 mm)

No. 3 Cylinder Block Camshaft Bore Dia. ... 1.970/1.972 in(50,04/50,09 mm)

No. 3 Journal Running Clearance ... 0.0025/0.0053 in(0,06/0,14 mm)

Cam Lift ... 0.300/0.303 in(7,62/7,70 mm)

Oilways for Rocker Shaft Lubrication ... No. 2 Journal

Camshaft Thrust Washer

Type ... 360°

Thrust Washer Outside Dia. ... 2.872/2.874 in(72,95/73,00 mm)

Cylinder Block Recess Dia. for Thrust Washer ... 2.875/2.885 in(73,03/73,28 mm)

Clearance Fit of Washer in Recess ... 0.001/0.013 in(0,03/0,33 mm)

Thrust Washer Inside Dia. ... 1.75 in(44,45 mm)

Thrust Washer Thickness ... 0.216/0.218 in(5,47/5,54 mm)

Cylinder Block Recess Depth for Thrust Washer (Earlier Type) ... 0.152/0.154 in(3,86/3,91 mm)

Thrust Washer Protrusion beyond Cylinder Block Front Face (Earlier Type) ... 0.062/0.066 in(1,53/1,68 mm)

Cylinder Block Recess Depth for Thrust Washer (Later Type) ... 0.187/0.190 in(4,75/4,83 mm)

Thrust Washer Protrusion beyond Cylinder Block Front Face (Later Type) ... 0.026/0.031 in(0,66/0,79 mm)

Camshaft End Float ... 0.004/0.016 in(0,10/0,41 mm)

Cylinder Head

Cylinder Head Length ... 19.875 in(504,82 mm)

Cylinder Head Depth ... 4.0625 in ± 0.015 in(103,20 mm ± 0,38 mm)

Skimming allowance on Cylinder Head Face ... 0.012 in(0,30 mm)

Min. Cylinder Head Depth after Skimming ... 4.0355 in(102,51 mm)*

Max. Nozzle Protrusion after Skimming ... 0.175 in(4,44 mm)

Leak Test Pressure ... 30 lbf/in2(2,11 kgf/cm2) - 404 kN/m2

Valve Seat Angle ... 45°

Valve Seat Angle (inlet-T4.236 engines only) ... 30°

Valve Bore in Cylinder Head ... 0.37425/0.37525 in(9,51/9,53 mm)


*Minimum Cylinder Head Depth quoted is nominal and Skimming Allowance must be governed by the Maximum Nozzle Protrusion Permissible.

Valve Guides (if fitted)

Inside Dia.-Inlet and Exhaust ... 0.375/0.376 in(9,53/9,55 mm)

Outside Dia. ... 0.6260/0.6265 in(15,90/15,91 mm)

Bore in Cylinder Head for Guide ... 0.625/0.6255 in(15,87/15,88 mm)

Interference Fit of Guide in Cylinder Head Bore ... 0.0005/0.0015 in(0,02/0,04 mm)

Depth of Counterbore-Exhaust Guide ... 0.4062 in(10,32 mm)

Overall Length of Guide ... 2.4375 in(61,92 mm)

Guide Protrusion Above Cylinder Head Top Face ... 0.625 in(15,87 mm)

Exhaust Valves

Valve Stem Dia. ... 0.372/0.3728 in(9,45/9,47 mm)

Clearance Fit of Valve in Guide (if fitted) ... 0.00225/0.004 in(0,06/0,10 mm)

Clearance Fit of Valve in Head ... 0.00145/0.00325 in(0,04/0,08 mm)

Valve Head Dia. ... 1.435/1.445 in(36,45/36,70 mm)

Valve Face Angle ... 45°

Valve Head Depth below Cylinder Head Face (earlier) ... 0.029/0.039 in(0,74/0,99 mm)

Valve Head Depth Below Cylinder Head Face (current) ... 0.047/0.057 in(1,19/1,45 mm)

Overall Length of Valve ... 4.847/4.863 in(123,11/123,52 mm)

Service Valve Stem Oversizes ... 0.003, 0.015 and 0.030 in(0,08, 0,38 and 0,76 mm)

Inlet Valves

Valve Stem Dia. ... 0.3725/0.3735 in(9,46/9,48 mm)

Clearance Fit of Valve in Guide (if fitted) ... 0.0015/0.0035 in(0,04/0,09 mm)

Clearance Fit of Valve in Head ... 0.00075/0.00275 in(0,02/0,07 mm)

Valve Head Dia. ... 1.736/1.746 in(44,09/44,36 mm)

Valve Face Angle ... 45°

Valve Face Angle (T4.236 engines only) ... 30°

Valve Head Depth Below Cylinder Head Face ... 0.035/0.045 in(0,89/1,14 mm)

Overall Length of Valve ... 4.831/4.847 in(122,71/123,11 mm)

Service Valve Stem Oversizes ... 0.003, 0.015 and 0.030 in(0,08, 0,38 and 0,76 mm)

Inner Valve Springs

Fitted Length ... 1.5625 in(39,7 mm)

Load at Fitted Length ... 15.4 lb ± 1 lb(7 kg ± 0,45 kg)

Fitted Position ... Damper Coils to Cylinder Head

Outer Valve Springs

Fitted Length ... 1.780 in (45.22 mm)

Load at Fitted Length ... 40 lb ± 2 lb(18,1 kg ± 0.91 kg)

Fitted Position ... Damper Coils to Cylinder Head

Single Valve Springs (Fork Lift Trucks 4.236/4.2482)

Fitted Length ... 1.6300 in(41,40 mm)

Load at Fitted Length ... 56.4 lb ± 3 lb(25,5 kg ± 1,36 kg)

Fitted Position ... No Damper Coils

Tappets

Overall Length ... 2.96875 in(75,41 mm)

Outside Dia. Tappet Shank ... 0.7475/0.7485 in(18,99/19,01 mm)

Cylinder Block Tappet Bore Dia. ... 0.750/0.7513 in(19,05/19,08 mm)

Tappet Running Clearance in Bore ... 0.0015/0.0038 in(0,04/0,10 mm)

Outside Dia. of Tappet Foot ... 1.1875 in30,16 mm)

Rocker Shaft

Overall Length of Shaft ... 16.796 in(426,62 mm)

Outside Dia. of Shaft ... 0.7485/0.7495 in(19,01/19,04 mm)

Rocker Levers

Inside Dia. of Lever Bore ... 0.7505/0.7520 in(19,06/19,10 mm)

Lever Clearance on Rocker Shaft ... 0.001/0.0035 in(0,03/0,09 mm)

Rocker Levers with Replaceable Bushes

Lever Parent Bore ... 0.875/0.8762 in(22,23/22,26 mm)

Outside Diameter of Bush ... 0.877/0.8785 in(22,28/22,31 mm)

Interference Fit of Bush in Bore ... 0.0008/0.0035 in(0,02/0,09 mm)

Finish Machine Bush Bore ... 0.7505/0.752 in(19,06/19,10 mm)

Clearance of Bush on Shaft ... 0.001/0.0035 in(0,03/0,09 mm)

Valve Clearances

Clearances between Valve Stem and Rocker Lever ... 0.012 in(0,30 mm) Cold

Valve Timing

Refer to Page K.8.

Camshaft Gear

Number of Teeth ... 56

Inside Dia. of Gear Boss ... 1.375/1.376 in(34,93/34,96 mm)

Outside Dia. of Camshaft Hub ... 1.3741/1.3747 in(34,90/34,91 mm)

Fit of Gear on Camshaft Hub ... -0.0009/+0.0013 in(-0,02/+0,03 mm)

Fuel Pump Gear (Hydraulically Governed Pumps)

Number of Teeth ... 56

Inside Dia. of Fuel Pump Gear Bore ... 1.6250/1.6262 in(41,28/41,30 mm)

Outside Dia. of Gear Carrier ... 1.6225/1.6238 in(41,19/41,24 mm)

Running Clearance of Gear on Carrier ... 0.0012/0.0037 in(0,03/0,09 mm)

Fuel Pump Gear (Mechanically Governed Pumps)

Number of Teeth ... 56

Inside Dia. of Gear Bore ... 1.750/1.751 in(44,45/44,47 mm)

Fuel Pump Hub Dia. ... 1.748/1.7488 in(44,40/44,42 mm)

Idler Gear and Hub

Number of Teeth ... 63

Bore Dia. of Gear Bush (requires boring in situ) ... 1.9998/2.0007 in(50,79/50,82 mm)

Outside Dia. of Gear Hub ... 1.996/1.9975 in(50,70/50,74 mm)

Running Clearance of Gear on Hub ... 0.0023/0.0047 in(0,06/0,12 mm)

Idler Gear Width Including Bushes ... 1.1865/1.1875 in(30,14/30,16 mm)

Hub Width ... 1.1915/1.1945 in(30,26/30,33 mm)

Idler Gear End Float ... 0.004/0.008 in(0,10/0,20 mm)

Idler Gear and Hub - Heavy Duty

No. of Teeth ... 63

Bore Dia. of Gear Bush (requires boring in situ) ... 1.9998/2.0007 in(50,79/50,82 mm)

Outside Dia. of Gear Hub ... 1.996/1.997 in(50,70/50,72 mm)

Running Clearance of Gear on Hub ... 0.0028/0.0047 in(0,07/0,12 mm)

Idler Gear Width ... 0.9375/0.9425 in(23,81/23,94 mm)

Idler Gear Thrust Washer Thickness ... 0.119/0.122 in(3,02/3,10 mm)

Hub Width ... 1.1915/1.1945 in(30,26/30,33 mm)

Idler Gear End Float ... 0.008/0.016 in(0,20/0,41 mm)

Crankshaft Gear

Number of Teeth ... 28

Gear Bore ... 1.875/1.876 in(47,63/47,65 mm)

Crankshaft Dia. for Gear ... 1.8750/1.8755 in(47,63/47,64 mm)

Timing Gear Backlash

All gears ... 0.003 in(0,08 mm) minimum

Sump

Sump Capacity (Standard) ... 14 pts(8 litres)

Dipstick Position ... Left or Right Hand Side

Strainer Location ... On Suction Pipe of Lubricating Oil Pump

Oil Pump

Type of Pump ... Rotor Type

No. of Lobes-Inner Rotor Concentric ... Three or Five (centre mounted Balancer, six)

No. of Lobes-Outer Rotor Concentric ... Four or Six (centre mounted Balancer, seven)

No. of Lobes-Inner Rotor Habourn Eaton ... Four

No. of Lobes-Outer Rotor Hobourn Eaton ... Five

Drive Position on Engine ... By Idler Gear from Crankshaft Gear (centre mounted Balancer, off Balancer drive shaft)

Pump Clearances

Pump Part No. 41314054 (Concentric)

Inner Rotor to Outer Rotor ... 0.001/0.003 in(0,025/0,076 mm)

Inner Rotor End Clearance ... 0.0015/0.003 in(0,038/0,076 mm)

Outer Rotor End Clearance ... 0.0005/0.0025 in(0,013/0,063 mm)

Outer Rotor to Pump Body ... 0.011/0.013 in(0,28/0,33 mm)

Pump Part No. 41314061 (Hobourn Eaton)

Inner Rotor to Outer Rotor ... 0.001/0.006 in(0,025/0,152 mm)

Inner and Outer Rotor End Clearance ... 0.001/0.005 in(0,025/0,127 mm)

Outer Rotor to Pump Body ... 0.0055/0.010 in(0,139/0,254 mm)

Pump Part No. 4132F014 (Concentric) Centre mounted Balancer

Inner and Outer Rotor End Clearance ... 0.001/0.003 in(0,025/0,076 mm)

Outer Rotor to Pump Body ... 0.012/0.017 in(0,304/0,44 mm)

Oil Pump Drive Gear

Number of Teeth ... 19

Inside Dia. of Gear Bore ... 0.497/0.4978 in(12,62/12,64 mm)

Outside Dia. of Oil Pump Shaft ... 0.4990/0.4995 in(12,67/12,69 mm)

Interference Fit of Gear on Shaft ... 0.0012/0.0025 in(0,03/0,06 mm)

Clearance between Drive and Pump Body ... 0.003/0.007 in(0,08/0,18 mm)

Oil Pump Idler Gear

Number of Teeth ... 20

Inside Dia. of Gear Bore ... 1.000/1.0012 in(25,40/25,43 mm)

Outside Dia. of Gear Bush ... 1.000/1.0008 in(25,40/25,42 mm)

Inside Dia. of Gear Bush ... 0.8750/0.8763 in(22,23/22,26 mm)

Outside Dia. of Idler Gear Shaft ... 0.8737/0.8742 in(22,19/22,20 mm)

Running Clearance of Gear on Shaft ... 0.0008/0.0026 in(0,02/0,07 mm)

Idler Gear End Float ... 0.002/0.016 in(0,05/0,41 mm)

Relief Valve

Type ... Spring Loaded Plunger

Pressure Setting ... 50/60 lbf/in2(3,52/4,22 kgf/cm2) - 345/414 kN/m2

Length of Plunger ... 0.826 in(20,98 mm)

Outside Dia. of Plunger ... 0.5585/0.5595 in(14,19/14,21 mm)

Inside Dia. of Valve Housing Bore ... 0.5605/0.5625 in(14,23/14,30 mm)

Clearance of Plunger in Bore ... 0.001/0.004 in(0,03/0,10 mm)

Outside Dia. of Spring ... 0.368/0.377 in(9,35/9,58 mm)

Spring - Fitted Length ... 1.28 in(32,51 mm)

Spring - Load at Fitted Length ... 7.76/8.24 lbf(3,52/3,74 kgf) - 34,5/36,7 N

Relief Valve, Centre Mounted Balancer

Type ... Spring loaded plunger

Pressure setting:

Turbocharged engine ... 76 lbf in2(5,34 kgf cm2) 523 kN/m2

Naturally Apirated Engine ... 60 lbf in2(4,22 kgf cm2) 414 kN/m2

Length of Plunger ... 1.476 in(37,48 mm)

Outside Dia. of Plunger ... 0.6279/0.6291 in(15,95/15,98 mm)

Inside Dia. of Valve Housing Bore ... 0.62/0.63 in(16,00/16,03 mm)

Clearance of Plunger in Bore ... 0.003/0.0007 in(0,02/0,08 mm)

Spring Fitted Length ... 1.67 in(42,40 mm)

Spring Load at Fitted Length (T4.236) ... 7.76/8.24 lbf(3,25/3,74 kgf) 34,5/36,7 N

Spring Load at Fitted Length (4.236) ... 5.62/6.50 lbf(2,54/2,94 kgf) 25,0/29,0 N

Lubricating Oil Filter - Element or Canister Type

Type of Filter ... Full Flow

By-Pass Valve Setting ... Opens between 8/17 lbf/in2(0,56/1,2 kgf/cm2) - 55/117 kN/m2

Torque Tension for Filter Bowl Retaining Screw (Element Type) ... 15.0 lbf ft(2,07 kgf m) - 20 Nm

Type of Cooling System

Cylinder Head and Block ... Thermo - Syphon - Impeller Assisted

Engine Water Capacity (Less Radiator) ... 16.5 pints(9,36 litres)

Thermostat

Type ... Bellows or Wax

Opening Temperature ... 170-180°F(77-83°C)

Fully Open at ... 202°F(94°C)

Valve Lift ... 0.312/0.469 in(7,94/11,91 mm)

Thermostat - By Pass Blanking (fitted to T4.236 and some 4.248 engines)

Type ... Wax

Opening Temperature ... 177° - 183°F(80° - 84°C)

Fully Open at ... 208°F(98°C)

Valve and By-Pass Travel ... 0.350 in(8,89 mm)

Water Pump

Type ... Centrifugal

Outside Dia. of Shaft for Pulley ... 0.7492/0.7497 in(19,03/19,04 mm)

Inside Dia. of Pulley Bore ... 0.7508/0.7516 in(19,07/19,09 mm)

Clearance Fit of Pulley on Shaft ... 0.0011/0.0024 in(0,03/0,06 mm)

Outside Dia. of Shaft for Impeller ... 0.6262/0.6267 in(15,90/15,92 mm)

Inside Dia. of Impeller Bore ... 0.6249/0.6257 in(15,87/15,89 mm)

Interference Fit of Impeller on Shaft ... 0.0005/0.0018 in(0,01/0,05 mm)

Outside Dia. of Impeller ... 3.094/3.096 in(78,58/78,63 mm)

Impeller Blade to Body Clearance ... 0.012/0.032 in(0,30/0,81 mm)

Water Pump Seal Type ... Synthetic Rubber, Carbon Faced

Balancer Unit - Front Mounted

NOTE: Later units have needle roller bearings and all current balancer units have reversed weights.

Front Dia. of Shafts (Driving and Driven) ... 1.2484/1.2490 in(31,71/31,73 mm)

Inside Dia. of Front Balance Frame Bushes ... 1.2510/1.2526 in(31,78/31,82 mm)

Running Clearance of Shafts in Bushes ... 0.002/0.0042 in(0,05/0,11 mm)

Rear Dia. of Shafts (Driving and Driven) ... 0.9987/0.9992 in(25,37/25,38 mm)

Inside Dia. of Rear Balance Frame Bushes ... 1.001/1.0022 in(25,43/25,46 mm)

Running Clearance of Shafts in Bushes ... 0.0018/0.0035 in(0,05/0,09 mm)

Shaft Dia. for Balance Weights ... 1.0622/1.0630 in(26,98/27,00 mm)

Bore Dia. of Balance Weights ... 1.0625/1.0637 in(26,99/27,02 mm)

Fit of Balance Weights on Shafts ... -0.0005/+0.0015 in(-0,01/+0,04 mm)

Spigot Dia. of Earlier Balance Weights ... 2.499/2.500 in(63,47/63,50 mm)

Recess Dia. in Earlier Balance Weights ... 2.500/2.501 in(63,50/63,53 mm)

Spigot Dia. for Reversed Balance Weights ... 1.374/1.375 in(34,90/34,93 mm)

Recess Dia. in Reversed Balance Weight Gears ... 1.375/1.376 in(34,93/34,95 mm)

Fit of Gear on Balance Weight ... -0.000/+0.002 in(-0,00/+0,05 mm)

Dia. of Earlier Shaft for Lub. Oil Pump Gear ... 0.4215/0.4235 in(10,71/10,76 mm)

Bore Dia. of Earlier Lub. Oil Pump Drive Gear ... 0.425/0.426 in(10,79/10,82 mm)

Clearance Fit of Earlier Gear on Shaft ... 0.0015/0.0045 in(0,04/0,11 mm)

Dia. of Shaft for Later Lub. Oil Pump Gear ... 0.6500/0.6508 in(16,51/16,53 mm)

Bore Dia. of Later Lub. Oil Pump Drive Gear ... 0.6513/0.6533 in(16,54/16,59 mm)

Clearance Fit of Later Gear on Shaft ... 0.0005/0.0033 in(0,01/0,08 mm)

Depth of Earlier Lub. Oil Pump Body ... 0.999/1.002 in(25,38/25,45 mm)

Depth of Later Lub. Oil Pump Body ... 1.002/1.005 in(25,45/25,53 mm)

Width of Lub. Oil Pump Drive Gears ... 0.998/1.000 in(25,35/25,40 mm)

End Float of Earlier Oil Pump Gears (with joint) ... 0.003/0.008 in(0,08/0,20 mm)

End Float of Later Oil Pump Gears ... 0.002/0.007 in(0,05/0,18 mm)

Shaft Dia. for Lub. Oil Pump Driven Gear ... 0.4382/0.4386 in(11,13/11,14 mm)

Bore Dia. of Lub. Oil Pump Driven Gear ... 0.4394/0.4404 in(11,16/11,19 mm)

Running Clearance of Oil Pump Driven Gear ... 0.0008/0.0022 in(0,02/0,06 mm)

Hub Dia. for Idler Gear ... 1.4984/1.4990 in(38,06/38,08 mm)

Bore Dia. of Idler Gear Bush ... 1.500/1.5016 in(38,10/38,14 mm)

Running Clearance of Idler Gear on Hub ... 0.001/0.0032 in(0,03/0,08 mm)

Idler Gear End Float ... 0.008/0.014 in(0,20/0,36 mm)

Balancer Unit - Centre Mounted

No. of Teeth on Driveshaft Gear ... 21

Dia. of Driveshaft (at Front Bearing) ... 1.124/1.125 in(28,562/28,575 mm)

Dia. of Driveshaft (at Rear Bearing) ... 0.936/0.937 in(23,787/23,800 mm)

Dia. of Oil Pump Drive Splines ... 1.124/1.125 in(28,562/28,575 mm)

No. of Splines ... 6

Dia. of Balance Weight Drive Gear Splines ... 0.650/0.651 in(15,51/15,53 mm)

No. of Splines ... 6

Dia. of Front Bearing Bore (Driveshaft) ... 1.374/1.375 in(34,912/34,937 mm)

Outside Dia. of Front Bearing (Driveshaft) ... 1.3748 in(34,92 mm)

Inside Dia. of Front Bearing (Driveshaft) ... 1.125 in(28,58 mm)

Dia. of Rear Bearing Bore (Driveshaft) ... 1.800/1.805 in(29,972/29,993 mm)

Outside Dia. of Rear Bearing (Driveshaft) ... 1.181 in(30,00 mm)

Inside Dia. of Rear Bearing (Driveshaft) ... 0.937 in(23,8 mm)

Dia. of Balance Frame and End Frame Bush Bores ... 1.656/1.657 in(42,070/42,095 mm)

Outside Dia. of Balance Frame and End Frame Bushes ... 1.66 in(42,164 mm)

Inside Dia. of Balance Frame and End Frame Bushes ... 1.501/1.503 in(38,133/38,174 mm)

Clearance of Balance Weight Shafts in Bushes ... 0.0025/0.0047 in(0,064/0,120 mm)

Shaft Dia. of Balance Weights ... 1.498/1.499 in(38,054/38,069 mm)

No. of Teeth on Weights ... 38

Minimum and Maximum Backlash ... 0.002/0.007 in(0.051/0.185 mm)

No. of Teeth on Driveshaft Balance Weight Drive Gear ... 24

End Float of Balance Weight ... 0.0073/0.0148 in(0,186/0,377 mm)

End Float of Driveshaft ... 0.0067/0.0137 in(0,17/0,35 mm)

No. of Teeth on Idler Gear ... 37

Inside Dia. of Gear Bore ... 1.8754/1.8760 in(47,635/47,650 mm)

Outside Dia. of Gear Bearing ... 1.875 in(47,62 mm)

Inside Dia. of Gear Bearing ... 1.5 in(38,1 mm)

Outside Dia. of Idler Gear Hub ... 1.4996/1.500 in(38,090/38,100 mm)

Idler Gear Hub Thread, or Setscrew ... 7/16 - 20 UNF

Idler Gear End Float ... 0.003/0.009 in(0,08/0,23 mm)

Thrust Washer Thickness ... 0.163/1.169 in(4,14/4,29 mm)

Outside Dia. of Thrust Washer ... 2.323 in(59 mm)

Inside Dia. of Thrust Washer ... 0.787 in(20 mm

Approved Fuel Oil Specifications

France ... AFNOR NF M 15/007 (1078)

Germany ... DIN 51601: 1968

India ... IS: 1460/1974 Grade Special or Grade A

Italy ... CUNA Gas Oil NC 630 01 (1971)

Sweden ... SIS: 15 54 32 (1981)

Switzerland ... Federal Military Specification 9140 335 1404 (1965)

United Kingdom ... BS 2869: 1970 Class A1 or A2

United States ... Federal W F 800a DF-A, DF-1 or DF-2 ... ASTM D 975 66T Numbers 1D or 2D

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

Fuel Lift Pump

Type of Pump ... A.C. Delco. V.P. Series

Method of Drive ... Eccentric on Camshaft

Delivery Pressure - Two Bolt Fixing ... 23/4 to 41/4 lbf/in2(0,19/0,30 kgf/cm2) - 19 to 29 kN/m2

Delivery Pressure - Four Bolt Fixing ... 6 to 10 lbf/in2(0,42/0,70 kgf/cm2) - 41 to 69 kN/m2

Spring Colour Code - Two Bolt Fixing ... Green

Spring Colour Code - Four Bolt Fixing ... Red

Fuel Filter (Final)

Element Type ... Paper

Valve Type ... Gravity Vent Valve

Fuel Injection Pump

Make ... C.A.V.

Type ... D.P.A.

Pump Rotation ... Clockwise

Plunger Dia. ... 8,5 mm

Timing Letter (Hydraulic) ... "A"

Timing Letter (Mechanical) ... "C"

No. 1 Cylinder Outlet ... "W"

Engine Checking and Fuel Pump Marking Angles, Static Timing

The correct marking angles and static timing can be found by reference to the prefix letters and figures of the setting code adjacent to the word "Set" on the fuel pump identification plate. Engine checking and fuel pump marking angles are for use with timing tool MS67B and in some cases, adaptor PD67B-1.

Atomisers

Electrical System

Alternator

Make ... C.A.V., Lucas or Perkins

Type ... AC5, 11AC, 15ACR, 17ACR, 18ACR, 23ACR, A115/45 A133/55, LR135-11, LR135-113, LR135-114 or LR150-160.

Maximum Output AC5 12 volt (hot) ... 55A at 13.5 volts

Maximum Output AC5 24 volt (hot) ... 31A at 27.5 volts

Maximum Output 11AC 12 volt (hot) ... 43A at 13.5 volts

Maximum Output 11AC 24 volt (hot) ... 28A at 27.5 volts

Maximum Output 15 ACR (hot) ... 28A

Maximum Output 17 ACR (hot) ... 36A

Maximum Output De-rated 17ACR (hot) ... 25A

Maximum Output 18ACR (hot) ... 45A

Maximum Output 23ACR (hot) ... 55A

Maximum Output A115/45 (hot) ... 45A

Maximum Output A133/55 (hot) ... 55A

Maximum Output LR135-111, LR135-113, LR135-114 (Hot) ... 35A

Maximum Output LR150-160 (Hot) ... 50A

Dynamo

Make ... Lucas

Type ... C40A. 2 Pole, 2 Brush ... Shunt Wound. Voltage Control

Rotation ... Clockwise

Output ... 11 A maximum

Dynamo Cut-in Speed ... 525-625 rev/min

Alternative Dynamo

Type ... C40L. 2 Pole. 2 Brush. Shunt Wound Voltage Control

Rotation ... Clockwise

Output ... 25 A maximum

Dynamo Cut-in Speed ... 600-680 rev/min

Starter Motor

Make ... Lucas, C.A.V. or Perkins

Type ... 2M113, M45G, CA45, M50, S12-84, S12-85.

Max. Current ... 900 amps

Starter Cable Resistance ... 0.0017 ohms

No. of Teeth on Pinion ... 10

NOTE: The above data is general and can vary with individual applications.

Cold Starting Aid

Make ... C.A.V. C.A.V.

Voltage ... 12 Volt 24 Volt

Maximum Current Consumption ... 18 A 7.5 A

Flow Rate through Thermostart ... 9 cm3/min 9 cm3/min