o remove and to fit

Operation 3-8

Special requirements

Torque Nm (lbf ft) kgf m

102-05, 103-07, 103-10

11 (8) 1,1

12 (9) 1,2

103-13, 103-15, 104-19, 104-22

Notes:

Be aware of the oil restriction in the banjo bolts (A1).

The diagram below shows a typical arrangement only.

1

32

Workshop Manual, TPD 1377E, issue 4

This document has been printed from SPI². Not for Resale

3

100 Series

Atomisers

To remove and to fit

Operation 3-9

Special requirements

Torque Nm (lbf ft) kgf m

Test Pressure kgf/cm² (lbf/in²) ats

102-05, 103-07

64 (47) 6,5

81 (60) 8,2

64 (47) 6,5

102-05, 103-07

120 (1707) 116

120 (1707) 116

150 (2133) 145

103-10

103-10

103-13, 103-15, 104-19, 104-22

103-13, 103-15, 104-19, 104-22

Cautions:

Deep sockets should always be used during this procedure.

Connections should be blanked off until assembly.

Notes:

Item (A1) is used on 103-10 engines only.

For emissions approved engines. It is essential that the fuel adjustment screw is not altered from the

original setting.

For emissions approved engines. The maximum No Load Speed must be checked after assembly.

103-13

103-15

104-19

104-22

102-05

103-07

103-10

1

Workshop Manual, TPD 1377E, issue 4

33

This document has been printed from SPI². Not for Resale

3

100 Series

Busbar / glowplugs

To remove and to fit

Operation 3-10

Special requirements

Torque Nm (lbf ft) kgf m

Glowplugs

Contacts

17 (12) 1,7

17 (12) 1,7

Note:   The diagram below shows a typical arrangement only.

34

Workshop Manual, TPD 1377E, issue 4

This document has been printed from SPI². Not for Resale

3

100 Series

Head bolts

To remove and to fit

Operation 3-11

For recommended torques and tightening sequences refer to Operation 3-14.

Notes:

Lubricate bolts with engine lubricating oil.

For emissions approved engines. It is essential that the fuel adjustment screw is not altered from the

original setting.

For emissions approved engines. The maximum No Load Speed must be checked after assembly.

Workshop Manual, TPD 1377E, issue 4

35

This document has been printed from SPI². Not for Resale

3

100 Series

Cylinder head gasket

To remove and to fit

Operation 3-12

Align gasket on dowels, gasket must only be assembled with markings (A1) facing up.

Notes:

Always fit dry.

For emissions approved engines. If the cylinder block, crankshaft, connecting rods or pistons are changed,

the piston height must be checked and the correct thickness gasket used, refer to operation 3-13.

1

36

Workshop Manual, TPD 1377E, issue 4

This document has been printed from SPI². Not for Resale

3

100 Series

To select the correct thickness of cylinder head gasket

Operation 3-13

Caution:  If the correct piston height above or below the cylinder block is not obtained, damage to the engine

can occur. The difference between the highest and the lowest piston height must not exceed 0.1 mm.

1  Put the piston height tool (A) on the face of the cylinder block and rotate the gauge dial to the zero position.

2  Rotate the crankshaft until the piston crown is approximately at top dead centre (TDC).

3  Carefully put the tool over the top of the piston with the plunger of the gauge in contact with the piston above

the axis of the gudgeon pin.

4  Rotate the crankshaft to ensure that the piston is at the highest position and make a note of the gauge

indication.

Notes:

If the cylinder block, crankshaft, connecting rods or pistons are changed the piston height will have to be

checked and the correct thickness gasket used.

If the original piston is used, ensure that it is assembled to the correct connecting rod and is used in the

original cylinder.

Cylinder head gasket selection

Engine

Protrusion above cylinder block top face

0,45 to 0,55 mm

Gasket thickness

1,1 mm

103-10

0,56 to 0,65 mm

1,2 mm

0,66 to 0,75 mm

1,3 mm

103-13

103-15

0,60 to 0,70 mm

1,3 mm

0,71 to 0,80 mm

1,4 mm

0,50 to 0,60 mm

1,2 mm

104-19

Engine

102-05

0,61 to 0,70 mm

1,3 mm

Protrusion below cylinder block top face

-0,30 to -0,15 mm

Gasket thickness

0,5 mm

-0,16 to +0,05 mm

0,6 mm

-0,40 to -0,25 mm

0,4 mm

103-07

104-22

-0,26 to -0,15 mm

0,5 mm

-0,45 to -0,30 mm

0,4 mm

-0,29 to -0,20 mm

0,5 mm

A

H1044

Workshop Manual, TPD 1377E, issue 4

37

This document has been printed from SPI². Not for Resale