Ade 422 423 424 Workshop Manual Abby PDF

ADE 422 , 423 , 424
Workshop Manual
lX IfllTingto., Diesel dub Workshop Manual for ADE 422, 423,424 S * o Hl o i* * : B e g in thru to section 11
ENGINE REPAIR MANUAL

ADE 420 SERIES
ATLANTIS DIESEL ENGINES (PTY) LTD

AMENDMENT 7/90
Part No. 80530257

Published by the Parts and Service Department of Atlantis Diesel Engines (Pty) Ltd.
W IfllTingto., Diesel dub Workshop Manual for ADE 422, 423,424 S e e Ho ie e : B e g in thru to section 11
FOREW ORD
T h is m anual is d e sig ne d to be o f a s s is ta n c e to a ll personnel co n ce rn e d w ith th e m a in te n a n c e and

overhaul o f th e ADE D iesel Engine. It p re se n ts a c o m p le te and d e ta ile d d e s c rip tio n of th e Engine,
to g e th e r w ith p recise in s tru c tio n s on the s e rv ic in g and overhaul procedure, a lso a sch e d u le co ve r
ing te c h n ic a l d a ta and d im e n s io n s w h ic h s h o u ld be c lo s e ly fo llo w e d w hen o ve rh a u lin g any part
o f th e Engine, to th e M a n u fa c tu re rs s ta n d a rd s.
ADE 420 S eries E ngin es have a le ft hand ro ta tio n w hen view ed fro m th e rear. T h ro u g h o u t th is
m an ua l, w henever L e ft o r R igh t hand sid e o f th e engine is referred to, it is th e side o f th e e ngine
w hen view ed fro m th e fly w h e e l end.
E ffe c tiv e m a in te n a n c e can o n ly be ca rrie d o u t if th e personne l co n ce rn e d are fu lly co n ve rsa n t
w ith the v a rio u s c o m p o n e n ts o f th e engine. Before m a in te n a n ce o p e ra tio n s are co m m e n ce d ,
th e re fo re , th is m a nu al s h o u ld be c a re fu lly s tu d ie d , and sh o u ld at all tim e s be kept w here it w ill
be needed in th e w o rksh o p .
C e rtain o p e ra tio n s d e s c rib e d in th is m anual require th e use o f s p e c ia l to o ls . These to o ls are
o b ta in a b le fro m G ru n d y-T e ch n ifo rm , fu ll d e ta ils are given in S e ctio n 21.
A S ch o o l o f In s tru c tio n is m a in ta in e d at ADE A tla n tis w here s ta ff e m ployed by D is trib u to rs and
O p e ra to rs o f ADE pow ered a p p lic a tio n s are given in s tru c tio n s on diesel engine m ain te n a n ce , w ith
p a rtic u la r regard to the s p e c ia l c h a ra c te ris tic s of ADE Engines.
ENGINE PARTS
W henever p a rts are ordered fo r ADE E ngines it is e s s e n tia l th a t th e fu lle s t in fo rm a tio n p o s s ib le
is given, a lw a y s q u o te th e e n g in e num ber, typ e o f a p p lic a tio n , part n u m b e r and w here p o s s ib le
th e d e s c rip tio n .
Running in Procedure
It is n o t n e ce ssary to g ra d u a lly run-in a new e n gine and any pro lo n g e d lig h t load ru n n in g during
th e early life o f th e e n g in e can in fa c t prove h a rm fu l to th e b e ddin g in o f p is to n rin g s and liners.
CONTENTS
TECHNICAL DATA ................................................................................................................................................ 08
OPERATING AND MAINTENANCE SCHEDULE ............................................................................................09
FAULT FINDING .................................................................................................................................................... 10
CYLINDER BLOCK AND LINERS ......................................................................................................................11
CYLINDER HEAD .................................................................................................................................................. 12
PISTONS AND CONNECTING RODS ............................................................................................................... 13
CRANKSHAFT AND MAIN BEARINGS ............................................................................................................14
CAMSHAFT, TIMING CASE AND DRIVE-TIMING .............................................................. ;................ 15
LUBRICATING SYSTEM AND SUMP ................................................................................................................ 16
FUEL SYSTEM ........................................................................................................................................................17
A N C ILLA R Y EQUIPMENT: COMPRESSOR, FLYW HEEL, TURBOCHARGER, EXHAUST BRAKE

ALTERNATOR AN D STARTER MOTOR, FAN BELT, POWER STEERING PUMP ........................... 18
COOLING SYSTEM ............................................................................................................................................... 19
LUBRICATING OILS ..............................................................................................................................................20
APPROVED SERVICE TOOLS ............................................................................................................................21

__________________________SECTION 08-1
Technical Data
422N 422T 422TI 423N 423T 423TI 424N 424T 424TI
Ratings to SABS 013-1977
O utput kW /r/min ................................ 202/2300243/2300 276/2300 256/2300 300/2300 368/2300 289/2300 412/2300 452/2300
Torque N.m/r/min ............................. 1022/12001402/12001550/12001278/12001687/1200 2000/1200 1388/1200 2236/1200 2400/1400
C ubic cap acity ................................... 14,627 14,627 14,627 18,277 18.277 18.277 21,937 21,937 21,937
Bore mm ................................................ 128 128 128 128 128 128 128 128 128
Stroke mm ............................................. 142 142 142 142 142 142 142 142 142
No. of c y lin d e rs .................................... 8 8 8 10 10 10 12 12 12
Com pression ratio ..................... 16,9:116,25:116,25:1 16,9:1 16,25:1 16,25:1 16,9:1 16,25:1 16.25:1
Com pression test pressure MPa 2,8 2,6 2,6 2,8 2,6 2,6 2,8 2,6 2,6
Engine at operating temperature, readings taken at 180-200 r/min. M inim um pressure 2,0 MPa. Difference between cylinders
should not exceed 0,4 MPa.
S tart of d e liv e ry __________________ 13°±0.515°±0,5 15°±0,5 13°±0,5 15°±0.5 15°±0.5 13°±0,5 15°±0,5 15°±0,5
Firing order ................................... 1.5.7.2.6.3 4.8. 1.6.5.10.2.7.3.8.4.9. 1 . 12.5.8.3.10.6.7.2.11 .4 9
Engine Mass Kg .................................. 815 865 865 965 1020 1020 1115 1165 1215
(approxim ate figu res depending
on application)
Idling s p e e d ............................. 600 r/min
^ “ fcapfing»»» W««l Club

A I ) K Sc M e r c e d e s lirin i» o r d e r » a n d v a lv e se t
Cylinder Arrangement
Le LEp j
Firing Orders:
5 1 6 1 7 1 V S = 1,5,7,2,6,3,4,8
6 2 7 2 8 2
7 3 8 3 9 3 V10= 1,6,5,10,2,7,3,8,4,9
8 4 4 10
9 4
10 5 11 5 V I2 = 1,12,5,8,3,10,6,7,2,11,4,9
| F ly w h e e l | 12 6
F ly w h e e l
Valve Set
V alves Rockiny, 1 2 3 4 5 6 7 8 9 If) 11 12
Set VK I'mnp 6 8 5 7 3 1 4 2
Set V 10 linn}? 7 9 6 10 8 3 1 5 2 4
Set V 12 firing 6 5 4 3 2 ] 12 11 10 9 8 7
Throughout the W orkshop Manual, SI (International Metric Systems) units as

approved by the South A frican Bureau of Standards (SABS) are used. All
measurements are in mm unless otherw ise indicated.
7/90
4 W lo rrin gtc Diesel Club Workshop Manual for ADE 422, 423,424 B e g in thru to section 11
_______________SECTION 09-1
O perating and M aintenance
OPERATING AND MAINTENANCE repeat cranking. When oil pressure is noted on the gauge, or the
low-pressure light goes off, release the rack from the "no fuel"
position to allow engine to start.
Preparation before starting Do not rev-up the engine immediately.
Check the radiator coolant level. -If vehicle is fitted with key-operated stop:
Start engine and run at idling speed. Keep a check on engine oil
Check the engine sump oil level. (See "Oil specification for pressure gauge. Pressure must be indicated after approx. 10
running-in after a major overhaul" below) seconds.
(Refer to "Approved consumables & service intervals" bulletin for

list of approved running-in oils) incorporated in section 9.
ENGINE MAINTENANCE CATEGORIES
Ensure that there is fuel in the tank.
Check that the battery is fully charged and that all electrical Category 1
connections are properly made and all circuits are in order.
Units operating under normal conditions, more than 100 000 km or
2000 hours annually, e.g. long haul operations.
Starting and stopping the engine
Category 2
Starting:
Units operating under normal conditions, up to 100 000 km or
Set accelerator half open and turn the starter switch. When the 2000 hours annually, e.g. medium to long haul operations.
engine starts bring the accelerator to idle position and check the oil
pressure. Do not engage the starter continuously for longer than
15 seconds. Category 3
After an unsatisfactory starting attempt, allow the battery a 15-30 Units subject to severe operating conditions, e.g. extremely poor
seconds recovery time. road conditions, heavy dust conditions, extreme climatic conditions
(temperature and humidity), very short distances in traffic or
Points to note construction operation. Units operating up to 10 000 km or 200
hours annually, e.g. units operating under light loads or intermittent
Always ensure that the starter pinion has stopped rotating before operating conditions, such as stand-by generator sets and emer
re-engaging the starter, as the ring gear or pinion may be gency vehicles. However, when operating less than the
damaged. recommended service intervals, the oil and oil filter should be
changed once or twice a year, depending on the lubricating oil
Check the oil pressure gauge immediately after starting. used. We recommend that maintenance and service be carried out
Should no oil pressure be registered, stop the engine according to hours of operation rather than mileage covered.
immediately and investigate.
NORMAL SERVICE INTERVALS

Stopping:
Recommended oil and filter change intervals
Relieve the load from the engine and gradually cut down engine
speed to idle. Let it run for one minute then stop the engine. It is critical that the correct quality of oil is used when prescribing
service intervals to ensure maximum life from your engine.
Stopping (Turbocharged Engine) While the quality of commercially available oils and the design of
engines are being continually upgraded, the demands placed on
The stopping procedure is more critical for a turbocharged engine, them have also increased.
due to the operational speeds reached by the turbocharger rotor
assembly. Turning the engine off without allowing the engine to Extensive testing has proved it necessary to specify different
idle for at least three minutes after full load operation may damage service intervals for the various quality oils.
the turbocharger bearings which rely on the engine oil pressure for
positive lubrication.
APPROVED CONSUMABLES AND SERVICE INTERVALS
Oil specification for running-in after a m ajor engine overhaul. Details of approved lubricating oils, antifreeze/coolant inhibitors
and powersteering oils are to be found in the latest issue of the
Running-in oil must be used after either: ADE Approved Consumables and Service Intervals bulletin.
a. Fitting new block assembly
b. Fitting new piston-rings and liners
c. Fitting new crankshaft bearings to a reground crankshaft. Service intervals based on fuel usage
Start-up procedure after m ajor engine overhaul Because of the high sulphur levels (>0,3%) in the fuels that are
commercially available in South Africa and its degrading effects on
Ensure that the oil filter bowl is primed with oil prior to cranking. the oils, It is necessary to limit the service intervals based on fuel
Engine start-up after fitting a new short-block or major overhaul throughput. For example a 366N engine having Multi-Series Super
should be in such a way that oil pressure is noted before actual Plus Series 3 Quality oil as listed on page 9 of our bulletin
engine start (i.e. crank engine with starter-motor and hold injection operating in long haul operations (i.e. Operating Category I) should
pump rack in "no fuel" position). However, crank only for 10 be serviced at either 22 500 km, 450 hours or after 5 200 litres of
seconds then allow starter motor to cool for 60 seconds before fuel usage, whichever occurs first.
4 W la rrin g tc Diesel Club Workshop Manual for ADE 422, 423,424 B e g in thru to section 11
OPERATING AND MAINTENANCE 09-2

TABLE 1 - Service & calibration intervals o f F.I.E.
Maintenance function Engine type Service interval

300/360 Series 400/440 incl.
152,236 & 354 420/440V max. km max. hrs Fuel lb-
Service injectors ★ 60 000 1 200 21 000

*
90 000 1 800 34 500
Renew injector * 120 000 2 400 42 000

nozzle * 180 000 3 600 69 000
Service and calibrate * 180 000 3 600 63 000

injection pump
* 270 000 5 400 103 000
Recommended Service & Calibration intervals for injection 2. Check coolant level in the radiator
pumps and injectors.
3. Service air cleaner dust bowl and pre-filter if applicable.
As a general rule normal operating conditions apply to usages of
100 000 km or 2 000 hours per annum.
4. Check air cleaner restriction indicator, service filters If re
For severe operating conditions such as forest, quarry, off-road quired.
mining, around town delivery, etc. the usages should be halved.
5. Ensure there is ample fuel in the tank.
Injectors should be serviced at least once per annum, and fuel
injection pumps at least once every second year. 6. Ensure that the fuel tank cap/breather is unobstructed.
Service calibrations must be performed by authorised diesel
equipment agencies, and pump test-reports should be requested. 7. Ensure that the exterior of the sump is clean with an
unobstructed airflow over the surface.
Pre-delivery Service
8. Ensure radiator fins have an unobstructed airflow.
1. Check general engine installation, i.e all pipes and hoses for
tight sealing, condition and routing. 9. Check oil pressure indicator.
2. Open air cleaner and ensure that the element is positioned

correctly and bolted down. Recommended Service/Maintenance Schedule
3. Check for fuel and oil leaks. 1. Change engine oil, drain oil while still hot. Dependent on oil
change interval in accordance with chosen operating category.
4. Check oil level.
2. Renew oil filter. Dependent on oil change interval in
5. Check coolant level. accordance with chosen operating category.
6. Check coolant for correct mixture, i.e anti-freeze/anti-corro 3. Renew fuel filters every 2nd oil change/service..
sion agent and corrosion inhibitor.
4. Check air cleaner indicator, service filters if required.
7. Check V-belt tension.
5. Check all air cleaner intake ducts, hoses and clips etc. for
8. Check electrical equipment and connections. serviceability and tightness.
9. Check injection pump linkage for total movement. 6. Check that the intercooler is free from obstructions.
10. Check exhaust brake linkage and adjustment if fitted. 7. Check coolant hoses and hose clips for serviceabity and tight
ness.
11. Check that the fan has been fitted correctly.
8. Pressure test cooling system.
12. Start up, then check the oil pressure and coolant temperature
gauges. 9. Ensure that the recommended corrosion inhibitor has been
added to the cooling system.
13. Check for any unusual noises.
10. Ensure that the radiator fins have an unobstructed airflow
14. While the engine is warming up check for oil and water leaks.
11. Tension all V-belts and check for ageing. Replace defective
15. Check operation of visco fan (if fitted). V-belts, Twin V-belts must only be replaced in pairs. New
belts must be re-tensioned after 10-15 minutes of operation.
16. Run to operating temperature and check maximum r/min
12. Check exhaust system for damage or leaks.
Daily Before Starting and after 8-10 Hours Operation 13. Cpeck control linkage on injection pump and exhaust brake for
correct function and adjustment, lubricate all joints.
1. Check engine oil level and pressure upon start-up (ensure
machine is standing level). 14. Check all lines and hoses for tight sealing, chafing and leaks
15. Adjust valve clearance every second service. ENGINE PRESERVATION
16. Re-tighten all visible nuts and bolts on the engine and in par
ticular at: When an engine is laid-up for a prolonged period, it should be
a. Inlet and exhaust manifolds and ducts properly protected against corrosion. Preservation measures
b. Exhaust flange should be carried out in accordance with the different categories
c. Starter motor and alternator fitting listed in the following sections.
d. nozzle holders
e. Engine mount on cross member and engine support
f. Bell housing bolts and nuts. 1.0 General
17. Check for fuel and oil leaks. 2.0 Installed Engines
2.1 Laid up for up to 12 months
18. Check operation of oil pressure and temperature gauges. 2.2 Laid up for 12 to 36 months
2.3 Laid up for more than 36 months
19. Check battery electrolyte level. In summer and hot regions
once a week. 3.0 Non-installed Engines
3.1 Laid up for up to 12 months
20. Check battery terminals for tightness and condition. 3.2 Laid up for 12 to 36 months
3.3 Laid up for more than 36 months
21. Check operation of visco fan (if fitted).
22. Check oil filler cap and dipstick for proper sealing
Preparing Engine for operation
23. Inspect turbocharger turbine and compressor blades for
damage, free rotation, end and side play. 1.0 General
An engine is classified as "laid up" when it has not operated

Note: for over one month. Laid up vehicles or engines should be
stored in dry, well ventilated rooms, and must always be
- Renew coolant every 2nd year protected against direct moisture, e.g. rain or splash water. If
-Attention: Satisfactory longterm operation of the air compres this is not possible, laying up conditions are classified as
sor depends on many varying factors. Therefore a specific ser extreme and the treatment specified for a given period should
vice interval cannot be recommended. Dealers and Fleet-owners be increased, e.g. if an engine is to be laid up for up to 12
should adopt service intervals which will suit their individual ope months it must receive the same treatment as an engine
rating conditions. which is to be laid up for 12 to 36 months.
- Renew breather every 2nd year
1.1 On any laid up engine all machined external unprotec
ted surfaces, e.g. flywheels, V-belt pulley grooves, etc.
Specification o f fresh water should be coated with a preserving agent or grease.
Sum of alkaline earth 89,5 - 358 mg/litre V-belts must be slackened off and removed.
(water hardness)
pH value at 20°C 6 ,5 -8 ,5 All openings must be sealed airtight. This includes ex
Contents of chlorine ions: max. 100 mg/litre haust and air inlet ducts/cleaners on installed engines.
Total contents of
chlorides and sulphates max. 200 mg/litre Batteries must be disconnected in laid up vehicles and
should be recharged outside the vehicle as required.
Full information on the quality of drinking water should be obtained
from local departments of Water Affairs or local authorities. It is
essential to protect your engine at all times against corrosion by 2.0 Installed Engines
the addition of anti-corrosion/anti-freeze additives (ethylene glycol
with corrosion inhibitors) which among others, will meet the These measures apply to all engines in vehicles, tractors and
following demands: industrial engines.
- adequate anti-corrosion and cavitation protection for all
components in the cooling system 2.1 Laid up for up to 12 m onths
- lowering the freezing point
- raising the boiling point. 2.1.1 NEW ENGINES (distance covered up to 300 km or 6
hours of operation):
At no time should the coolant mixture exceed 55% by volume anti
freeze/anti-corrosion agent, as a higher percentage will reduce the The engines must be fitted to the maximum level with
anti-freeze protection as well as lessen the heat dissipation. As approved service products. Ambient temperatures must
corrosion inhibitors decompose during operation and the anti be taken into consideration when selecting SAE grades
corrosion concentration is being reduced by topping up the cooling No further preservation measures are required.
system with water, the frost protection must be checked regularly.
Frost protection of -30°C corersponds with 40 to 45% (by volume) 2.1.2 USED ENGINES (distance covered more than 300 km
anti-freeze/anti-corrosion content in the coolant which may be or 6 hours of operation):
determined by an optical or mechanical hydrometer, (-30°C).
Run engine until warm and drain engine oil. (Running-
The anti-corrosion oil content in the coolant, i.e. 1% by volume, in oil may remain in the engine). Renew oil filter car
may be determined by a refractometer. tridge. Fill with an approved running-in oil (anti-corro
sion engine oil). Fill or top up cooling system with the
specified coolant mixture. Run the engine at medium
O nly use approved products for m ixture w ith the coolant as speed for approx. 5 to 10 minutes until operating tempe
specified in the ADE Approved Consumables and Service rature is reached (coolant temperature 75-79°C). Switch
Intervals bulletin (incorporated in this section) and at all off the engine, fill the sump and the oil bath air filter (if
tim es stric tly adhere to the m ixture specifications. fitted) to maximum level.
2.2 Laid up fo r 12 to 36 m onths 3.1 Laid up for up to 12 m onths:
All the measures set out in sections 1.0 "General" and NEW ENGINES which have only been subjected to the
2.1 "Installed engines, laid up for up to 12 months",
must be carried out.
In addition, the fuel system, the combustion chambers running-in period at ADE do not require any additional
and the air compressor must be preserved in accor preservation measures.
dance with the following instructions.
Running-in oil may be left in the engines. Coolant must
Note: The procedure in this section should also be followed be completely drained. Remove the thermostats and in
after less than 12 months in the case of sea shipments and in sert one Chadpack Tablet (ADE part no. 3617 0072)
tropical areas. into the housing. Refit the thermostats, close cover/out
let and ensure that the joints form a good seal. All en
2.2.1 Preservation o f Fuel System: gine openings must be sealed airtight.
Add approximately 10% running-in oil to diesel fuel and Note: Follow the instructions for sea shipments or tropical
operate the engine with this mixture for approximately areas.
5 to 10 minutes.
USED ENGINES must be treated in accordance with
If a number of vehicle-, tractor- or industrial-engines the measures set out in items 2.1.2 and 2.2.1 before
are to be preserved at the same time, the fuel and the being laid up or dismounted.
running-in oil may be mixed in a separate container be
fore feeding the solution into the fuel system via a three Coolant must be drained completely and a Chadpack
way or four-way cock valve. This enables the concen Tablet must be inserted in the thermostat housing.
tration of oil in diesel fuel to be increased to 15-20%.
RE-MANUFACTURED ENGINES must in all cases
2.2.2 Preservation o f C om bustion Chambers: be preserved in accordance with section 2.2 in full.
Oil may be sprayed into the combustion chambers via 3.2 Laid up for 12 to 36 m onths:
the injector ports after removal of the injectors, which
may be immersed in oil for added protection. The preservation measures set out in section 2.2 must
be carried out in full.
For best results the metered amount of oil must be in
jected into the combustion chamber under pressure to 3.3 Laid up for more than 36 m onths:
ensure complete spraying of all areas. Upon completion
of each cylinder (piston down), rotate the engine at least If the laying up period is extended for more than 36
one full turn by hand. months, preservation must be repeated every J36
months (3 years) or 18 months in accordance with sec
Note: During the above operation the injection pump/governor tion 2.2 in full.
control must be in the shut-off position.
If there is oil in the engine, this may be drained off at
Oil per cylinder 8-10ml room temperature (approx. 20°C).
Note: Do not exceed the above amounts as this may lead to It is not necessary to renew the oil filter cartridge.
hydraulic lock and possible engine damage.
Refit all parts removed and ensure that seals and gaskets are 4.0 PREPARING THE ENGINE FOR OPERATION
in place. Re-position the injection pump governor controls to
the operating position. 4.1 Remove sealing from all openings.
Note: Engines must not be started after the combustion 4.2 Remove preserving agent or grease from the grooves of
chamber preservation has been carried out. V-belt pulleys, flywheel and other unprotected surfaces.
2.2.3 Preservation o f A ir Com pressors: 4.3 Reposition and tension V-belts in accordance with ins
tructions.
Air compressor preservation should be done in con
junction with the combustion chambers. A maximum of 4.4 If not already installed, fit engine to machine.
5 cubic centimetres of running-in oil should be injected
or poured into each cylinder via the compressor air in 4.5 Fill with approved lubricating and coolant service pro
take after which ths engine must be rotated at least one ducts or top up to maximum level.
half turn.
Note: Engines which have not received their first service
2.3 Laid up fo r m ore than 36 m onths must be filled with running-in oil, all others should be filled
with approved operating oils.
If the laying up period is extended for more than 36
months, preservation measures must be repeated every 4.6 Recharge and reconnect batteries.
3 years or 18 months in accordance with section 2.2 in
full. 4.7 Run engine to operating temperature (coolant tempera
ture 75-79°C) while monitoring pressures and tempera
tures.
3.D NON INSTALLED ENGINES
These measures cover new non-installed engines, as well as

remanufactured engines.
W IfllTingto., Diesel dub Workshop Manual for ADE 422, 423,424 S e e H nM ‘ B e g in th ru to se c tio n 11
__________________________SECTION 10-1
Fault Finding
Fault Finding Chart
FAULT . POSSIBLE CAUSE
S tarter m otor turns engine too slow ly 1. 2, 3. 4.

W ill not start 5, 6, 7. 8. 9, 10, 12, 13, 14. 15, 16, 17, 18. 19, 20, 22, 31, 32, 33.
D ifficu lt starting 5, 7, 8. 9. 10, 11, 12, 13, 14, 15, 16. 18, 19, 20, 21, 22, 24. 29, 31, 32, 33.
Lack of power 8 ,9 ,1 0 ,1 1 ,1 2 , 1 3 ,1 4 ,1 8 .1 9 ,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 .
M isfiring 8, 9, 10, 12, 13, 14, 16. 18, 19, 20, 25, 26, 28, 29, 30, 32.
Excessive fuel consum ption 11, 13, 14, 16, 18, 19, 20, 22, 23, 24, 25, 27, 28, 29, 31, 32, 33, 63.
Black exhaust 11, 13, 14, 16, 18, 19. 20, 22, 24, 2 5 ,2 7 ,2 8 ,2 9 ,3 1 ,3 2 , 3 3 ,6 0 .
B lu e/W h ite exhaust 4, 16. 18. 19. 20. 25, 27, 31, 33, 34. 35, 45. 56, 61.
Low oil pressure 4, 36, 37, 38. 39, 40, 42. 43, 44, 58.
Knocking 9, 14, 16, 18, 19, 22. 26, 28, 29, 31, 33, 35, 36, 45, 46, 59.
Erratic running 7, 8, 9, 10, 11. 12, 13, 14, 16, 20, 21, 23, 26, 28, 29, 30, 33, 35, 45, 59.
Vibration 13, 14, 20, 23, 25, 26, 29, 30, 33, 45. 47. 48, 49.
High oil pressure 4 .3 8 .4 1 .
O verheating 11, 13. 14. 16. 18, 19, 24, 25, 45, 50, 51, 52, 53, 54, 57.
Excessive crankcase pressure 2 5 .3 1 ,3 3 , 3 4 ,4 5 , 55.
Poor com pression 11. 19. 25, 28. 29. 31. 32, 33, 34, 46, 59.
Starts and stops 10. 11. 12.
Key to Fault Finding Chart 32. Pitted valves and seats.

1. B attery capacity low. 33. Broken, worn o r sticking piston ring(s).
2. Bad electrical connections. 34. W orn valve stems and guides.
3. Faulty starter motor. 35. O verfull air cleaner or use of incorrect grade of oil
4 Incorrect grade of lubricating oil. 36. Worn or damaged bearings.
5 S tarter m otor turns engine too slow ly 37. Insufficient oil in sump.
6. Fuel tank em pty 38. Inaccurate gauge.
7. Faulty stop con tro l operation. 39. O il pump worn.
8 Blocked fuel feed pipe. 40. Pressure relief valve sticking open.
9 Faulty fuel lift pump. 41. Pressure relief valve sticking closed.
10. Choked fuel filter. 42. Broken re lie f valve spring.
11 R estriction in induction system. 43 Faulty suction pipe.
12 A ir in fuel system. 44. Choked oil filter.
13 Faulty fuel injection pump. 45. Piston seizure /p ick up.
14. Faulty atom isers o r incorrect type. 46. Incorrect piston height.
15. Incorrect use of cold start equipm ent. 47. Damaged fan.
16. Faulty cold starting equipm ent. 48. Faulty engine m ounting (housing).
17. Broken fuel injection pump drive. 49. Incorrectly aligned flyw heel housing or flywheel.
18. Incorrect fuel pump timing. 50. Faulty therm ostat.
19. Incorrect valve tim ing. 51. R estriction in water jacket.
20. Poor com pression. 52. Loose water pum p drive belts.
21. Blocked fuel tank vent 53. Choked radiator.
22. Incorrect type o r grade of fuel. 54. Faulty w ater pump.
23. S ticking throttle or restricted m ovem ent. 55. Choked breather pipe
24. Exhaust pipe restriction 56. Damaged valve stem oil de flectors (if fitted).
25. C ylinder head gasket leaking. 57. Coolant level too low.
26 O verheating. 58. Blocked sump strainer.
27. Cold running. 59 Broken valve spring.
28. Incorrect tappet adjustment. 60. Damaged o r d irty turbocharger impeller.
29. S ticking valves 61. Leaking turbocharger oil seals.
30. Incorrect high pressure pipes. 62. Leaking boost con tro l pipe.
31. W orn cylin d e r bores. 63. Leaking induction system.
W IfllTingto., Diesel dub Workshop Manual for ADE 422, 423,424 S e c H nM ‘ B e g in th ru to se c tio n 11
__________________________ SECTION 11-1

Cylinder Block
Tombak Seal
Cylinder Block
1 C ylinder block 21 H ollow pin 41 Seal
2 Dowel pin 22 H ollo w pin 42 Seal
3 H ollow pin 23 Pin 43 Gasket
4 Bolt 24 Ball 44 Spring washer
5 Bolt 25 Tube 45 Bolt
6 C am shaft bearing 26 C onnector 46 “ O” Ring seals (bottom )
7 Plug C am shaft 27 Seal 47 “ O ” Ring seal (top)
8 Plug 28 Plug 48 Tombak seal
9 Seal 29 Seal 49 Oil jet
10 Plug 30 Plug 50 Seal
11 Seal 31 Seal 51 Connector
12 Plug 32 Plug 52 Transmitter
13 Seal 33 Seal 53 Seal
14 Plug 34 Plug nut 54 Transmitter
15 Seal 35 Seal 55 Seal
16 Plug 36 Plug 56 Breather
17 Plug 37 Seal 57 Breather
18 Plug 38 Adapter 58 Seal
19 Plug 39 Seal 59 Vent tube
20 Seal 40 Cover 60 Hose
61 Vent tube
62 Clamp
7/90
B eg in th ru to sectio n 11
4 l|' JdMMhgton Diesel dub Workshop Manual for ADE 422, 423,424
C Y L I N D E R B L O C K — 11-2
154,0
B o re fo r c y lin d e r lin e r fla n g e “A”
153,9
9.99
F la n g e d e p th “ B”
9.97
145.840
B o re fo r c y lin d e r lin e r f it u p p e r“ C”
145.800
144.540
lo w e r “ D ”
144.500
U p p e r fit/lo w e r f it o v a lity m ax. 0.01
O v a lity fo r re p a ir m ax. 0.08
D e v ia tio n o f fla n g e fa c e t o b lo c k fa c e m a x . 0.02
C y lin d e r b lo c k le a k a g e te s t u n d e r w a te r w ith c o m p re s s e d a ir 150 kPa
111.022
C ra n k s h a ft b e a rin g b a s ic b o re new
111.000
111.040
fo r re p a ir
110.970
P e rm is s ib le o v a lity 0.01
P e rm is s ib le ta p e r o f b o re 0.01
76.030
C a m s h a ft b e a rin g b a s ic b o re
76.000
R oughness o f upper jo in t surfaces Rz 10^m — Rmax 16^m
7/90
CYLINDER BLOCK — 11-3
-— -c- —-
u
/ ' /
0 r
CD| < /
/ /
1
A
/
/
/
/
/
■
/
I
- A ■■■
-
------------- F
)
128,010
L in e r in s id e d ia m e te r “ A ”
127,990
153,757
F la n g e o u ts id e Dia. “ B ”
153,657
145,800
U p pe r f it d ia . “ C ”
145,778
142.0
Dia. o f ste p on lin e r s e a lin g fa ce “ D ”
141.8
145.0
O u ts id e d ia . “ E”
144.7
144.475
L o w e r f it d ia . “ F ”
144.451
10.07
F la n g e th ic k n e s s “ G ”
10.05
1.10
H e ig h t o f ste p above s e a lin g fa ce “ H ”
1.00
253.5
O v e ra ll le n g th " K ” 252.5
M ax. la te ra l ru n -o u t o f lin e r fla n g e “ a ” to c e n te rlin e 0.02
M ax. ru n -o u t be tw ee n lo w e r and u p p e r f it “ c ” 0.025
O v a lity o r ta p e r a t lo w e r f it “ F” B e fo re fitm e n t m ax. 0.06

Installed m ax. 0.04
P ro tru s io n above b lo c k fa c e new 0.05 - 0.09

fo r re p a ir 0.03 - 0.09
F la n g e s h im th ic k n e s s fo r re p a ir 0.8/1.0/1.5
L in e r w e a r a t u p p e r re tu rn 0.06
S u rfa c e ro u g h n e s s o f ho n e d lin e r R3z 3 - 5/ifn

TORQUE SPECIFICATIONS
Main bearing cap bolts (see section 14)............................ M18 x 2 Initia l torque 300 N.m
Final torque 90° — 100°
Max, stretch length 156 mm
Main bearing cap side b o lt s ................................................ M12 x 1,5 80 N.m
Note: Tighten stretch bolts prior to bearing cap side bolts
Blankoff Plugs ........................................................................ M 14x 1,5 50 N.m
M 18x 1,5 80 N.m
M 26x 1,5 120 N.m
M 30x 1,5 150 N.m
Piston cooling nozzles/cam shaft spray nozzles M 14x 1,5 47 N.m
Front oil seal cover bolts to cylinder block M8 25 N.m
Tachograph cable nut to a d a p to r............. M22 x 1,5 35 N.m
Blanking nut to rev. counter d r iv e ............ M 22x 1,5 100 N.m
Crankcase breather to cylinder b lo c k ..... M6 8 N.m
Engine m ounting-front to cylinder block . M12 110 N.m
Adaptor for cooling system vent l i n e ..... M14 x 1,5 50 Nm
Tightening torques for Standard bolts and nuts (normal

and fine pitch) in N.m
(Valid only if no other torque is specified).
C lassifica tion of Strength

Thread 8,8 10,9 12,9
M6 8,6 11,8 14,5

M8 21 29 35,5
M8 x 1 23 32 38
M10 42 58 70
M10 x 1 46,5 65 78
M12 73 100 123
M12 x 1,5 76 105 128
M14 114 165 195
M14 x 1,5 128 178 215
M16 178 250 300
M16 x 1,5 190 270 320
M18 245 355 415
M18 x 1,5 280 390 465
M20 350 490 590
M 2 0 x 1,5 390 550 660
M22 465 660 800
M22 x 1,5 520 730 875
M24 600 850 1000
M24 x 2 660 910 1100
B e g in thru to section 11
4 l|' JdNMhgton Diesel dub Workshop Manual for ADE 422, 423,424
CYLINDER BLO CK — 11-5
In tro d u c tio n
The cylin d e r blocks of the ADE 420 Series Engines are
made of grey cast iron w ith the sides extending below the
cran ksha ft centre line. Interchangeable (Wet) cylinder
liners are fitted, w hich once the cylinder head and pistons
have been removed can ea sily be extracted. On replace
m ent con sid erab le care should be exercised to ensure
th a t the cylin d e r liners are corre ctly seated and sealed.
REM OVING AN D REPLACING CYLINDER

LINERS
R em oving
1. Mark cylin d e r liners and cylinde r block w ith paint, to
ensure tha t the liners are returned to the o rigin al
position.
2. Fit puller studs opposite to each o th er in to bolt holes

in cylin d e r block.
3. Insert puller. Part num ber 40200433, in to cylinde r

lin e r (fig. 1-11).
4. Open jaw s of puller to inner diam eter o f cylinder liner.
5. Fit support of pu lle r on to studs, tig h te n nuts and

screw dow n centre nut on pu lle r shaft.
6. Hold centre sh a ft o f p u lle r w ith a ring spanner and

con tinu e tu rning centre nut p u llin g out liner from
cylin d e r block (fig. 2-11).
7. Retract ja w s of puller. Unscrew support stud s from

cylin d e r block, and remove to g e th e r w ith puller.
8. L ift out cylin d e r liner from cylin d e r blo ck (fig. 3-11).
9. Remove O -rings from cylin d e r block and liner.
10. It is esse ntia l th a t the ou ter surface of the cylin d e r

liner, together w ith the bores in the cylinder block are
th o ro u g h ly cleaned before replacem ent.
Fig. 3-11
7/90
REMOVING AND REPLACING CYLINDER

LINERS
Replacing
1. Insert new O-rings in to cylinde r liner bores in
crankcase (dry).
2. Fit new O-ring in to upper recess of cleaned cylinder

liner.
3. Apply approxim ately a 3mm dia bead of sealing com

pound onto seal (fig. 4-11).
Fig. 4-11
4. Apply a light coating of grease to the bottom o f the

cylinder liner, outer surface.
5. Insert cylin d e r liner w hile rotating it 90° from the

original fitte d po sitio n (fig. 5-11).
Fig. 5-11
6. Fit puller studs opposite to each other in to bolt holes

in cylinder block (fig. 6-11).
7. Place steel disc on top of cylinder liner.
8. Fit support of pu lle r onto studs, tig h te n nuts. Screw

up nut on centre sha ft to back of puller support.
Fig. 6-11
9. Using a ring spanner screw down centre shaft of

puller, in sertin g cylin d e r liner. Tighten w ith torque
wrench to 120 N.m and leave pressure applied for five
m inutes (fig. 7-11).
10. Using a suita ble p la s tic knife, remove excess seal

ing com pound forced out between cylinder block and
liner.
11. Remove puller from cylinde r block.
Fig. 7-11
W IfllTingto., Diesel dub Workshop Manual for ADE 422, 423,424 S e e H nM ‘ B e g in th ru to s e c t i ° n 11
CYLINDER BLOCK - 11-7
12. Measure the inside diam eter o f the cylinder liner at

the bottom , using a suitable internal measuring
instrum ent, at three points o ffset 60° to each other
(fig. 8-11).
Note: If more than 0,04 mm deviation is measured, check
seating of lower O-ring seal.
13. To prevent the cylinder liner moving w h ile fittin g the

pistons, keep the liner under pre-load w ith tw o fa b ri
cated sleeves (approx. 30 N.m). (fig. 9-11).
Im portant
If used pistons are replaced, it is essential to replace the
top piston ring on all pistons removed.
Fig. 9-11
4 W lo rrin gtc Diesel Club Workshop Manual for ADE 422, 423,424 B e g in thru to section 11
Note
It is essential th a t when the cylin d e r liners have been

removed or replaced, the liner protrusion is measured, to
ensure correct sealing o f the cylin d e r liners. The correct
s p e cifica tio n o f liner protrusion m ust be adhered to. The
cylin d e r liner protrusion can be altered by the ad dition
or sub tra ction o f shim s, w h ich can be obtained at your
nearest ADE parts sto ckist.
MEASURING PROTRUSION OF CYLINDER

LINER
1. Remove cylin d e r heads (See sectio n 12).
2. Place gauge plate Part num ber 40201953 on cylin d e r

liner. Insert sho rt cylinde r head b o lts fitte d w ith
spacers, and tig h te n to 50 N.m (fig. 10-11).
Note: Check inside diam eter o f gauge plate prior to f it

m ent and if necessary m achine to 144 mm.
3. Place dial gauge holder on gauge plate and insert dial

gauge, so tha t sensor probe rests on the cylinde r
block w ith pre-load. Tighten dial gauge.
Set dial gauge to “ O” on cylin d e r block, at each m easur

ing point. M axim um tole ran ce between fo u r points, for
each lin e r is 0,02 mm (fig. 11-11).
MACHINING CYLINDER LINER SHOULDER

DEPTH
1. Remove pisto ns and cylin d e r liners.
2. Preparations
Pack the bores in the cylin d e r block w ith clean rag
or a su ita b le m aterial, as far up as possible in the
m achining area, to pro te ct the cran ksha ft and bear
ings against fa llin g sw arf and d irt. Cover all oil
galleries p a rticularly the neighbouring cylinders, e.g.
w ith a p la stic sheet.
3. Clean surface of cylinder block and bores for cylinder

liners.
4. Determining liner shoulder depth: Shoulder o f cylinder

liner dista nce (measured at 4 points, max. difference
o f 4 m easuring po in ts per lin e r 0,02 mm).
+ T hickn ess o f shim
- S pecified liner protrusion
= S houlder depth.
Example
(0.8 mm th ic k shim )
Liner sho ulder mean dista n ce 10,05 mm
+ m easured th ickn e ss of shim 0,80 mm
10,85 mm
- S pecified liner protrusion 0,09 m m
= Shoulder depth 10,76 mm
a = shoulder depth (fig. 12-11)
5. Clean m ach in ing and c u ttin g tool (w ith com pressed

air), prior to inserting tool. Give cutting tool and insert
a lig h t coa ting o f o il (fig. 13-11).
Fig. 13-11
Pull up q u ick-a dju sting ring and guide c u ttin g tool in to

holder. Insert c u ttin g tool so th a t centring ro lle r is on
the side o f c u ttin g too l holder m arked w ith “ R” , and feed'
threads on c u ttin g to o l face away from qu ick-a dju sting
ring (fig. 15-11).
Note 1: Remove protective pa in t on solenoid flange w ith

thinners, p rio r to in itia l use (fig. 14-11).
N ote 2: C e ntralise m achine on cylin d e r bore.
Fig. 14-11
6. C onnect pow er supply. Place m achine on cylin d e r

bore to be m achined and sw itch on solenoid.
Fig. 15-11
7. Pull up qu ick-a dju sting ring w ith tw o fing ers of each

hand. Hold qu ick-a dju sting ring w ith tw o fing ers of
one hand, and push cu ttin g to o l w ith oth er hand un
til cen tring ro lle r is on side w all o f lin e r recess in
cylin d e r block (fig. 16-11).
Note: C orrect he ig ht o f ce n trin g roller is adjusted w ith

feed nut.
8. Move sw itch to position 2. This energises the solenoid

ring and holds the m achine on the cylin d e r block.
Fig. 16-11
4 W la rrin g tc Diesel dub Workshop Manual for ADE 422, 423,424 B e g in thru to section 11
9. Turn crank slo w ly clo ckw ise and check to see if the
centring roller rests on surface around the entire c ir
cum ference o f the liner recess, and the m achine
has not moved (w ith sw itch in centre position). If the
m achine has moved, turn crank clockw ise, and at the
same tim e hold feed ring w ith tw o fingers. If centring-
roller loses co n ta ct w ith shoulder recess, turn crank
anti-clockwise while at the same tim e holding the feed
ring, u n til roller has co n ta ct on the entire c ir
cum ference of sho ulder recess (fig. 17-11).
Note: When centred correctly, the centring roller w ill have

uniform contact all round and m achine w ill not move when
s w itc h in g to “ O ".
Fig. 17-11
10. A fte r cen tring correctly, move sw itch to po sitio n 1.

Pull up quick-a dju sting ring and push in cu ttin g tool
un til cu tte r con tacts liner recess to be m achined, but
not ag ainst side w all (fig. 18-11).
11. Turn crank and feed nut together clockw ise, until cut
tin g to o l makes co n ta ct w ith liner recess seat.
12. L ift qu ick-a dju sting ring and push back cu ttin g tool,
to po sitio n above the liner recess seat.
13. Unscrew alien cap screw s fo r vernier adjustm ent.

Set vernier ring to " O " and tig h te n alien cap screw s
(fig. 19-11).
14. A d ju st cu ttin g depth to 0,05 mm w ith feed nut.
Note: G raduation of vernier = 0,01 mm.
15. Turn crank clockw ise, holding the feed ring w ith the
other hand (fig. 20-11).
W Iflfpingtoi, Diesel dub Workshop Manual for ADE 422, 423,424 S e e H nM ‘ B e g in th ru to se c tio n 11
N ote 1 M easure sh o u ld e r recess depth from surface of

c u ttin g m ach in e a fte r each cut (0,05 mm) (fig. 21-11).
N ote 2: The c u ttin g to o l is ground in such a w ay as to pre

vent the desired diam eter being exceeded. In other words,
the face o f the c u ttin g to o l runs on the lin e r recess
diam eter, if there is resistance, release feed ring
im m e d ia te ly and tu rn crank several tim es.
O nly grind c u ttin g to o ls acco rding to d ra w in g s sup plied

w ith m achine.
Fig. 21-11
Im portant
The feed nut m ust not move w h ile tu rn in g the crank, as
th is w ould change the depth settin g o f the c u ttin g too l.
If necessary tig h te n screw located in feed nut (fig. 22-11).
Fig. 22-11
16. Pull back quick-adjusting ring w ith 2 fingers, and push

back c u ttin g tool to sta rtin g p o sitio n ; set 0,05 mm
c u ttin g depth w ith feed nut and co n tin u e c u ttin g
procedure u n til desired depth is ob tain ed (fig. 23-11).
Fig. 23-11
N ote 1: Remove m achine a p p ro xim a te ly 0,3 mm before

reaching desired sh o ulder recess depth, and recheck
depth w ith a dial gauge. Recheck depth once again before
fin a l m ach in ing , to make sure th a t the desired depth has
been reached (fig. 24-11). Centre m ach in e a fte r each
m easurem ent, (fig. 17-11).
Fig. 24-11
k d r r i n g t o n D iesel t lu b ADE 422, 423,424 Workshop Manual
S E C TIO N 12-1
Cylinder Head
C y lin d e r H ead 8 Valve seat in se rt exhaust 17 Sealing ring

9 G asket a sse m bly-cylin der head 18 G asket
1 C ylind er head w ith valve guides 10 Hex b o lt 19 Spring w asher
2 Core plug 11 Hex bo lt 20 B olt
3 Core plug 12 Hex bo lt 21 Nozzle ho ld er w ith nozzle
4 S ealing ring 13 C ylin d e r head gasket 22 Nozzle hold er
5 B la nking plug 14 Rocker cover 23 In je cto r
6 Valve gu id e 15 R ocker cover (w ith o il fille r) 24 Sealing ring
7 Valve seat in se rt-in le t 16 O il fille r cap 25 In je cto r secu rin g nut
BK ( a p H n g t o n D iesel Club ADE 422, 423,424 Workshop Manual
C Y L IN D E R H E A D — 12-2
O verall h e ig h t o f c y lin d e r head 114.0

113.9
M in im u m c y lin d e r head h e ig h t a fte r m a c h in in g 1) 113.4
P e a k -to -v a lle y s u rfa c e fin is h o f m a tin g s u rfa c e in ^ m 0 -1 6
M ax. u n e v e n n e s s o f m a tin g s u rfa c e 0.015
M ax. p a ra lle l d e v ia tio n be tw ee n u p p e r and lo w e r s u rfa c e 0.1
In je c to r p ro tru s io n 1 .6—2.4
V alve head rece ss b e lo w m a tin g s u rfa c e 0 .7 -1 .1
1) C heck in je c to r p ro tru s io n a fte r m a c h in in g c y lin d e r head m a tin g s u rfa c e and, if necessary, c o rre c t w ith in je c to r washers.
M a c h in in g o f c y lin d e r head m a tin g su rfa ce
In o rd e r to a tta in th e s p e c ifie d s u rfa c e fin is h a d h e re to th e fo llo w in g s p e c ific a tio n s w h en g rin d in g :
S peed: n = 1400 r/m in

Feed: u = 9 2 0 m m /m in .
C u ttin g v e lo c ity : Vs = 27 m /s e c .
The s p e c ifie d c u ttin g v e lo c ity is given by u s in g a se g m e n t g rin d in g w h e e l w ith a d ia m e te r o f 370 m m . W hen u sin g
a d iffe re n t d ia m e te r (d e p e n d in g on m a c h in e type), th e speed m u s t be ch a n g e d so th a t th e re is no g re a te r v a ria tio n
th a n ± 1 0 % fro m V s = 4 ? = 2 7 m /sec.
“ 1000 60
Im p o rta n t: S lo w e r fe e d o r m a n u a l fe e d w ill c h a n g e th e g r in d in g p a tte rn c o n s id e ra b ly a n d th e re w ill be no

g u a ra n te e o f re a c h in g a s u rfa c e fin is h o f Rz = O to 16/u m.
L e aka ge te s t u n d e r w a te r w ith c o m p re s s e d a ir 250 kPa

B a r r i n g t o n D iesel Club ADE 422, 423,424 Workshop Manual
C Y L I N D E R H E A D — 12-3
Inlet Valve Seat Insert Exhaust Valve Seat Insert

Standard Repair 1 Repair 2 Standard Repair 1 Repair 2
Basic bore “ a ” in 60.030 60.230 60.430 53.030 53.230 53.430

cylinder head 60.00 60.200 60.400 53.000 53.200 53.400
Valve seat insert 60.11 60.31 60.51 53.11 53.31 53.51
outside dia. “ a1 " 60.10 60.30 60.50 53.10 53.30 53.50
Valve seat insert interference
fit in cylinder head 0 .0 7 -0 .1 1 0 .0 7 -0 .1 1
Bore depth “ b” in 12.6 12.8 13.0 12.6 12.8 13.0

cylinder head 12.5 12.7 12.9 12.5 12.7 12.9
Valve seat insert previous level 8.9 9.1 9.3 9.7 9.9 10.1
height “ e” 8.8 9.0 9.2 9.6 9.8 10.0
new level- * 8.4 8.6 8.8 9.2 9.4 9.6
8.3 8.5 8.7 9.1 9.3 9.5
Dimension between previous level 3.8 3.0
cyl. head mating 3.6 2.8
surface and valve
4.3 3.5
seat insert face new level *
4.1 3.3
Chamfer “ c ” 45° 45°
Chamfer depth “ d ” — 1.8

1.6
Max. run-out of valve seat measured at O 57 mm measured at O 49 mm
to valve guide 0.01 0.01
" F o r new level Turbo Head with “ T” stamp
7/90
BK ( a p H n g t o n D iesel Club ADE 422, 423,424 Workshop Manual
Inlet Valve Exhaust Valve

Seat Insert Seat Insert
previous level 57.01 49.01

Diameter ‘‘a "
56.99 48.99
new level** 55.01 48.01

54.99 47.99
previous level 4.05 3.55

Distance “ b”
3.90 3.40
new le vel** 4.65 4.05

4.50 3.90
Valve seat angle “ c ” 30° 45°
Distance between cylinder head mating
0 . 7 - 1,1 0 .7 -1 ,1
surface and valve head face
Max. out-of-round measured at O 57 mm measured at O 49 mm
of valve seat to valve guide 0.01 0.01
**F o r new level Turbo Head with “ T” stamp
O ld Level V alves
B re a kp o in ts
ADE 420N — up t o ........ SA002748 N
ADE 420T/TI — up to SA002902 N
Dimen “ A" •B " “ C” •■D" “ E” “ F"

sions Seat Dia Seat Valve Height Width Stem Stem
(mm) Angle Centre Head Dia New Min New Max Dia Hardness
57,01 59,0 3,2 4,3 11,950

Inle t 30° 2,7 7 HRC
56,99 58,8 3,0 3.3 11,932 54
Exhaust 45°
49,01
48,99
51.1
50,9
2,7
2,5
2,2
4,5
3,5
5,5
11,940
11,922
IS
54
HRC
N ew Level V alves
B re a kp o in ts
ADE 420N — SA002749 N and UP
ADE 420T/TI — SA002903 N and UP
Dimen "A " “ C” "D " “ E" “ F”

sions Seat Dia Seat Valve Height Width Stem Stem
(mm) Angle Centre Head Dia New Min New Max Dia Hardness
55,01 59,0 3.8 5,5 11,950

Inle t 30° 3,3 6,5 i54 HRC
54,99 58,8 3,6 4,5 11,932
48,01 51,1 3,2 5,5 11,940

E xhaust 45° 2,7 6,5 t54i HRC
47,99 50,9 3,0 4,5 11,922
M ax. ru n o u t between valve seat and stem 0 .0 3
M ax. run ou t between valve head and stem 0 .2 0
M ax. v a lv e s e a t o v a lity 0.01
7/90
Valve Springs
Engine M odel/ Inside W ire Relaxed Pre-lc>aded Final .oaded

Spring A llo ca tio n Spring Dia. Dia. Length Length Load Length Load
N N
420N in let and 32 ± 0.3 4.7 ± 0.03 64 46.8 345 ± 15 32.8 740 ± 30
Exhaust valves O u te r'
and 32 ± 0 .3 4.8 + 0.05 59 46.8 345 ± 1 5 33.1 720 ± 50
420T/TI
Inner 22.8 + 0.2 3.0 ±0,025 65.5 46.3 143± 12 32.3 280 ± 20
in let valves
420T/TI exhaust O uter 33 ± 0.3 4.5 ± 0.03 68 46.8 355 ± 15 32.8 670 ± 30
valves only
Inner 22.8 ± 0 .2 3.2 ± 0.025 70 46.3 195 ± 1 2 32.3 350 ± 20
'O p tio n a l due to d iffe re n t suppliers
V alve g u id e p ro tru s io n . D im e n s io n “ D ” 17.1 - 17.4

M ax. d e v ia tio n o f valve se a t to valve g u id e ce n tre 0.03
M ax. m is a lig n m e n t o f valve sea t to va lve g u id e
57 m m d ia . fo r in le t 0.01
m e a s u re d at
49 m m dia. fo r e x h a u s t
7/90
V alve C le a ra nce (m m ) — C old Engine
MODEL BREAKPOINTS INLET VALVE EXHAUST VALVE
Up to SA 002762 M 0,25 0,35

ADE 422N SA 002763 M and up 0,40 0,60
Up to SA 003441 P 0,30 0,50
ADE 422T/TI SA 003442 P and up 0,40 0,60
—
ADE 423N 0,40 0,60
S till in e ffe ct 0,30 0,50
ADE 423T/TI To be advised 0,40 0,60
* *
ADE 424N 0,40 0,60
S till in e ffe ct 0,30 0,50
ADE 424T/TI To be advised 0,40 0,60
** At new level since the firs t day o f m anufacture.
Valve T im in g Degrees
ENGINE PRODUCTION INLET VALVE EXHAUST VALVE

MODEL BREAKPOINTS Opens BTDC Closes ABDC Opens BBDC Closes ATDC
Up to SA 002762 M 21,4° 57,4° 52,8° 14,8°

ADE 422N SA 002763 M and up 16° 42° 57° 13°
Up to SA 003441 P 13° 27° 55° 13°
ADE 422T/TI SA 003442 P and up 17° 29° 71° 13°
-
ADE 423N 16° 42° 57° 13°
S till in e ffe ct 13° 27° 55° 13°
ADE 423T/TI To be advised 17° 29° 71° 13°
—
ADE 424N 16° 42° 57° 13°
S till in e ffe ct 13° 27° 55° 13°
ADE 424T/TI To be advised 17° 29° 71° 13
** A t new level sin ce th e firs t day o f m anufacture.
7/90
( d r H n g t o n D iesel Club ADE 422, 423,424 Workshop Manual
TORQUE SPEC IFIC ATIO N S
C ylinder head to cylin d e r block: Single hexagon bo lts M15 x 2 1st stage 10 N.m
2nd stage 50 N.m
3rd stage 100 N.m
4th stage 140 N.m
Final Torque 90° -1 0 0 °
Duo hexagon bolts 1st stage 10 N.m
2nd stage 60 N.m
3rd stage 120 N.m
4th stage 180 N.m
Final Torque 9 0 °-1 0 0 °
Max. stretch length: short 111 mm
m edium 146 mm
170 mm
I 7 -c, iong
Rocker sh a ft pedestal to cylin d e r h e a d ...........................
Valve ad ju sting screw lo c k n u t .............................................
Rocker cover to cylin d e r h e a d .............................................
M10_- > C
M12 x 1
M8
/
X 75 N.m
50 N.m
25 N.m
Inlet m an ifold to cylin d e r h e a d ........................................... M8 25 N.m
Exhaust m an ifold to cylin d e r h e a d .................................... M10 Check during each service 50 N.m
In je cto r securing nut to cylin d e r head (see sectio n 17)
T urbocharger to exhaust m an ifold (see sectio n 18)
B lanking plug to cylin d e r head ........................................... M22 x 1,5 100 N.m
7 /on
CYLINDER HEAD — 12-8
Introduction
The ADE 420 Series Engines are fitte d w ith an in dividu al

cylinde r head fo r each cylinder. As th is type of cylinde r
head is the sam e throu gh ou t the 420 series o f engines,
it makes for greater s tan dard isatio n and ease of service.
REMOVING AND REPLACING ROCKER

COVER
Removing
1. Unscrew and remove b o lts from rocker cover. L ift o ff

cover (fig. 1-12).
2. Remove cover gasket.
Fig. 1-12
Replacing
1. F it new rocker cover gasket.
2. Replace rocker cover and tigh ten b o lts to 25 N.m

(fig. 2 -12).
Fig. 2-12
C Y L IN D E R H E A D - 12-9
REMOVING CYLINDER HEAD
Preparation
1. Drain engine coolant.
2. D isconnect in let pipe.
3. Remove exhaust m anifold
1. Using special ring spanner Part num ber 40200705,

remove in je cto r pipes (fig. 3-12).
2. Remove rocker covers (see fig. 1-12).
3. Unscrew in je cto r pipes from in je ctio n pump, using

special ring spanners 40200970 & 40200705 (fig. 4-12).
4. Pull fuel leak o ff pipes from injector.
5. Unscrew and remove rocker arm brackets (fig. 5-12).
6. Remove push rods.
Fig. 5-12
CYLINDER HEAD — 12-10
7. Unscrew and rem ove c y lin d e r head b o lts (fig. 6-12).
Fig. 6-12
N o t e : C ylin d e r head b o lt underneath in je cto r, can be

loosened w ith special spanner 40200530, but it c an no t be
rem oved from the c y lin d e r head (fig. 7-12).
8. Remove c y lin d e r head.
N o t e : U nless the in je c to r has been rem oved, alw ays lay

th e c y lin d e r head on its side to avoid dam age.
k d r r i n g t o n D iesel Club ADE 422, 423,424 Workshop Manual
C Y L I N D E R H E A D — 12-11
REMOVING AND REPLACING VALVES ,

Removing
1. Place c y lin d e r head in to cla m p and secure.
2. A d ju st fo rk to diam e te r o f valve spring retainer.
3. Fit push rod in to eye o f lever and push down on valve

spring retainer. Remove c o lle ts from valve stem (fig.
8 - 12).
4. Release push rod. Remove valve spring retainer and

valve springs.
5. Pull valve stem seals from valve guides.
6. Remove c ylin d e r head from clam p and remove valves.
7. Remove spacers fo r valve springs (fig. 9-12).
R eplacing
1. L u bricate valve stem w ith engine o il and in sert in to
valve guide.
2. Place c y lin d e r head in to cla m p and secure.
3. Fit spacers fo r valve springs.
4. Replace valve stem seals using special to o l Part

num ber 40201555 (fig. 10-12).
5. F it inner and o u te r valve springs w ith clo se c o ils

to w a rd s the c y lin d e r head. F it valve spring retainer.
6. F it push rod in to eye of lever and push down on valve

spring retainer. Insert c ollets in grooves o f valve stem.
Ensure th e c o lle ts are co rre ctly lo cated (fig. 11-12).
FITTING VALVE STEM SEALS

1. Lubricate valve stem s with engine oil and insert valves
in to guides.
2. Place cylin d e r head in to clam p, and secure.
3. Using special to o l Part num ber 40201555, fit valve

stem seal over valve (fig. 12-12).
4. Press valve stem seal onto valve guide.
5. Remove special too l and repeat procedure on second

valve (fig. 13-12).
REMOVING AND REPLACING

VALVE GUIDES
1. Clam p cylin d e r head.
2. Knock valve guides out o f cylinde r head, from the

co m b u stio n side using special tool Part num ber
40200815.
3. M easure bore fo r valve guide in cylin d e r head and

ream to next repair stage if required.
4. Coat new valve guide w ith graphite o il and knock in

using special too l and spacer (fig. 14-12).
5. Use special reamer Part number 40200831 and ream

valve guide inner diam eter to spe cifie d dim ension.
Fig. 14-12
ftd t't'in gto r. D iesel Club ADE 422, 423,424 Workshop Manual

VALVE SPRINGS
Removing
1. Place cylin d e r head in to clam p and secure.
2. A d ju st fork to diam eter of valve spring retainer.
3. Fit push rod in to eye of lever and push down on valve

spring retainer. Remove c o lle ts from valve stem
(fig. 15-12).
Fig. 15-12
Replacing
1. Clean valve springs, and check spe cific values using
a suita ble spring tester (fig. 16-12).
Fig. 16-12
2. Insert inner and outer valve springs w ith close co ils

tow ards the cylin d e r head. F it valve spring retainer.
3. Fit push rod in to eye of lever and push down on valve

spring retainer. Insert c o lle ts in to grooves of valve
stem . Ensure the c o lle ts are corre ctly located
(fig. 17-12).
Fig. 17-12
C Y L IN D E R H E A D - 12-1 4
G RINDING VALVES
1. Clean carb on d e p o s its from valve.
2. Check to see if valves can be re-used. Valve ends m ust

not have surface dam age. C ollet grooves m ust not be
w orn and chro m e c o a tin g on valve ste m s m u st be
w ith o u t fla w s. A lw a ys replace bu rnt valves.
3. C h eck d im e n s io n s and run out of valves. Do not

a tte m p t to stra ig h te n bent valve stem s.
4. S lig h t run o u t o f valve stem s can be corrected by g rin

din g the valve face.
5. Insert and cla m p the valve im m e d ia te ly behind the

valve head to avoid vib ratio n when grind ing (fig 18-12).
6. Set co rre c t g rin d in g an g le on scale.
7. Move valve to w a rd s ro ta tin g grin d in g wheel at a s lo w

feed rate u n til valve m akes c o n ta c t w ith g rin d in g
w heel face. (fig. 19-12).
8. G rind fa ce o f valve w ith a lig h t feed u n til it is ground

on its e n tire c ircu m fe re n ce .
Fig. 19-12
N o t e : A fte r grinding valve height “ D” m ust not be less than

o u tlin e d in th e s p e c ific a tio n .
9. S ho uld it be necessary the valve stem face can be

gro un d on a V -block m ounted on th e valve g rin d in g
m ach in e (fig. 20-12).
Fig. 20-12

ROCKER ARM
Removing
1. C lam p ro cke r arm b ra cke t in a vice fitte d w ith s o ft
jaw s.
2. U nscrew and rem ove lo c k n u t and valve a d ju s tin g

screw (fig. 21-12).
3. Remove rocke r arm c irc lip (fig. 22-12).
4. Rem ove th ru s t w asher and rocke r arm (fig. 23-12).
5. Clean all p a rts th o ro u g h ly and ch e ck fo r wear.
REPLACEMENT OF ROCKER ARMS
1. F it rocke r arm s and th ru s t w asher to ro cke r arm

bra cke t (fig. 24-12).
Fig. 24-12
B5C
B d t't'in g to »! D iesel Club ADE 422, 423,424 Workshop Manual
CYLINDER HEAD - 12-16
2. Insert c irc lip on rocker arm shaft (fig. 25-12).
3. Screw valve adjusting screw and locknut into rocker

arm (fig. 26-12).
Fig. 26-12
REPLACING CYLINDER HEAD
1. Clean cylin d e r head b o lt holes in cylin d e r block

tho ro ug hly prior to replacing cylin d e r heads. It is par
tic u la rly im portant to remove any w ater trapped in the
b o lt holes.
2. Clean c y lin d e r head and cylin d e r blo ck faces.
3. Place new c y lin d e r head gasket over dow el sleeves

in cylin d e r block face (fig. 27-12).
Fig. 27-12
4. Place c y lin d e r head ca re fu lly o n to cylin d e r head 1

gasket.
5. M easure bo lts to ensure stretch lim it is not exceeded.
6. Give cylinde r head bo lts a light coating o f engine oil,

insert b o lts and tig h te n in the sequence shown (fig.
28-12), acco rding to torque steps liste d under
sp e c ific a tio n s .
N o t e : The stre tch b o lts do not need to be re-torqued.
N o t e 1 : Use spe cia l spanner fo r b o lt underneath the fuel

in jecto r.
N o t e 2: If one of the bo lts has been tightened excessively,

unscrew all 6 bo lts of the cylinde r head, check for stretch
and tig h te n again beginning w ith step 1 (fig. 29-12).
Fig. 29-12
C Y LIN D E R H EAD — 12-18
6. Insert pushrods.
7. F it rocker arm bra cket and tig h te n b o lts o n ly fin g e r

tig h t. A lig n rocke r arm s w ith valves and pushrods.
8. Tighten rocker arm bracket bo lts to 75 N.m (fig. 30-12).
9. A d ju s t valve clearance.
10. R eplace rocker covers and tig h te n b o lts to sp e cifie d

torque.
11. Fit fuel in je c to r pipes and tig h te n co n n e c tio n s on in

je c to r holder to 25 N.m (fig. 31-12).
Note: Hold in je ctio n pum p nuts w ith special spanner Part

num ber 40200970. Tighten con ne ction s o f in je ctio n pum p
td*25 N.m using c ro w fo o t socke t Part No 4020 0721.
(fig. 32-12).
12. C onnect fuel leak o ff pipe to in je cto rs.
N ote: C ylin d e r head b o lts need no lo ng er be retightened.
Fig. 32-12
BK f t d r r in g t o n D iesel Club ADE 422, 423,424 Workshop Manual
C Y L I N D E R H E A D — 12-19
A D JU S T IN G V A LV E C LE A R A N C E (M e th o d ,1)
Note: A d ju stm e n t o f valve clearance can be carried out

w ith the engine Cold.
1. Remove rocker covers and gasket. (See page 12-2)
2. Fit special engine turning to o l Part num ber 40200093

(fig. 33-12), to tim in g case 8 x 20 mm b o lts, and turn
engine in d irectio n o f rotation, until pisto n o f cylinder
to be adjusted is at firin g TDC. Valves should be c lo s
ed, rocker arm s com pletely relaxed and push rods free
to turn, (see fig. 34-12 to identify valves rocking in rela
tio n to c y lin d e r firing).
Fig. 33-12
L o c a tio n o f c y lin d e rs
ADE 420 S eries E n gine s Valves rocking no: 1 2 3 4 5 6 7 8 9 10 11 12
C ylin d e r Firing
V12 V12
422 se t no: 6 8 5 7 3 1 4 2
V10 © © V10 423 set no: 7 9 6 10 8 3 1 5 2 4
424 set no: 6 5 4 3 2 1 12 11 10 9 8 7
VB © © © © V8 F irin g Order: ADE 422 1-5-7-2-6-3-4-8
© © © © © © ADE 423 1-6-5-10-2-7-3-8-4-9
ADE 424 1-12-5-8-3-10-6-7-2-11-4-9
© © © © © © Valve C learance cold
© © © © © ©
Refer to s p e c ific a tio n s in acco rda nce w ith breakpoints.
© © © © © ©
X Fig. 34-12
X — F lyw hee l end
3. Insert fee ler gauge between rocker arm o f in let or ex

haust valve. Valve cle ara nce is co rre ct when feeler
blade can be pulled th ro u g h w ith s lig h t resistance.
4. If the cle ara nce requires ad ju stm e n t, in se rt screw

driver and ring spanner and adjust in the norm al m an
ner (fig. 35-12).
Fig. 35-12
5. Turn the engine to the next cylin d e r TDC firin g p o s i

tio n each tim e, and set a ll the valves in firin g order
sequence.
6. Replace rocke r covers, renew dam aged gaskets,

tig h te n rocke r cover b o lts to 25 N.m (fig. 36-12).
7. Remove spe cia l turning to o l from tim in g case.

EK f t d r r in g t o n D iesel Club ADE 422, 423,424 Workshop Manual
A D J U S T IN G V A LV E C L E A R A N C E (M e th o d 2)
1. R em ove ro cke r cove rs and g a ske ts. (See page 12-2)
2. F it sp e cia l e n gine tu rn in g to o l Part nu m be r 40200093

(fig. 33-12). to tim in g ca se 8 x 20 m m b o lts, and tu rn
e n gine in d ire c tio n o f ro ta tio n , u n til th e No. 1 c y lin d e r
TDC m ark is a lig n e d w ith the edge o f th e in s p e c tio n
hole.
3. C h eck to see if No. 1 c y lin d e r is at TDC, ro c k in g or

firin g . (At TDC firin g bo th valves w ill be c lo se d and
th e push rods w ill tu rn easily).
The fo llo w in g valves can the n be a d ju ste d a t No. 1 firin g

TDC:
L o c a tio n o f c y lin d e rs
A D E 420 S e rie s E n g in e s
E ngine In le t valve E xh a u st valve
V12 V12
422 & 422T 1, 3, 4, 8 1, 2, 5, 7
V10 © © V10 423 1;% 8, 9 1, 2, 5, 6, 9, 10
424 1, 2S4, 7, 9, 11 ** 1, 3, 5, 8, 9, 12
V8 © © © © V8
© © © © © © The fo llo w in g valves can be a d ju s te d at No. 1 R o cking

TDC:
© © © © © ©
Engine In le t valve E xha ust valve

© © © © © ©
422 & 422T 2, 5, 6, 7 3, 4, 6, 8

© © © © © ©
423 2, 3, 5, 6, 7, 10 3, 4, 7, 8
424 3, 5, 6, 8, 10, 12 2, 4, 6, 7, 10, 11
X
X — F ly w h e e l end Fig. 37-12
4. In se rt fe e le r gauge betw een ro c k e r arm o f in le t o r

e xh a u st valve. Valve cle ara nce is c o rre c t w hen fe e le r
b la d e can be pu lle d th ro u g h w ith s lig h t re sista n ce .
5. If th e cle a ra n ce re q u ire s a d ju s tm e n t, in s e rt scre w

d riv e r and ring s p a n n e r and a d ju s t in the norm al
m an ne r (fig. 38-12).
Fig. 38-12
6. R eplace ro cke r covers, renew dam ag ed g a ske ts,

tig h te n ro c k e r co ve r b o lts to 25 N.m (fig. 39-12).
7. R em ove s p e c ia l tu rn in g to o l fro m tim in g case.

- B a r r i n g * » * Diesel Club ADE 422, 4 23 ,4 24 Workshop Manual
<*»
CHECKING COMPRESSION PRESSURE •
Preparation
1. Check Valve Clearance (see fig. 38-12).
2. Run engine u n til norm al operating tem perature is

reached (70-95°C).
3. Remove in je c to r holder and injector.
Testing
1. Insert in je c to r sealing ring (fig. 40-12).
2. Insert ad ap to r in cylin d e r head and tig h te n lo catin g

nut for in je c to r holder (fig. 41-12).
3. Screw com pression tester w ith extension on adaptor

(fig. 42-12).
4. Check com pression pressure at an engine speed of

ap pro xim ately 120 r/m in. (starter speed) w ith the
th ro ttle in clo sed po sitio n. Turn engine un til te st
in d ica to r stop s rising.
Note: If com pression pressure is less than 2,0 MPa, or

when the pressure d iffe re n ce between the cylinde rs are
greater than 0,4 MPa, remove the cylinder heads to inspect
valve seats and cylinde r bores.
5. Remove com pression te ste r and adapter.
6. Replace in jecto r, and sea lin g ring.
Fig. 42-12
CYLIN D ER HEAD — 12-22
In le t M a n ifo ld
1. In le t m a n ifo ld 11. B ra c k e t
2. In le t m a n ifo ld 12. B ra c k e t
3. T h re a d e d in s e rt 13. B ra c k e t
4. G a ske t 14. B ra c k e t
5. S p rin g w a s h e r 15. B ra c k e t
6. B o lt 16. B ra c k e t
7. Cap 17. T ra n sve rse m a n ifo ld
8. H o se c lip 18. G asket
9. Plug 19. S p rin g w a s h e r
10. B ra cke t 20. B o lt
C Y L I N D E R H E A D — 12-2 3
REMOVING AND REPLACING INLET

M ANIFO LD
Removing
1. Unscrew and rem ove in je c to r pipes from ap pro pria te
c y lin d e r head (fig. 43-12).
2. Rem ove transve rse in le t m a n ifo ld .
3. D etach and rem ove hose fro m a ir com p resso r.
4. U nscrew and rem ove in le t m a n ifo ld .
Replacing
1. F it in le t m a n ifo ld w ith new gasket and tig h te n to a
to rq u e o f 25 N.m (fig. 44-12).
2. R eplace transve rse in le t m a n ifo ld .
3. Replace in je c to r pipe s and tig h te n to 25 N.m.
REMOVING AND REPLACING EXHAUST

M ANIFO LD
Rem oving
1. U nscrew and rem ove exh au st pipe from m a n ifo ld .
2. D isco n n e ct e xh a u st brake cylinde r.
3. Remove g a ske ts (fig. 45-12).
Replacing
1. R eplace e xh a u st m a n ifo ld fitte d w ith new gaskets.
2. R eplace m o u n tin g b o lts w ith sleeves and tig h te n to

50 N.m (fig. 46-12).
3. F it e xh a u st brake c y lin d e r and tig h te n b o lts to

s p e c ifie d torque.
4. F it e xh a u st pipe to exh au st m a n ifo ld , and tig h te n

b o lts to s p e c ifie d torque.
Fig. 46-12
■
_________S E C T IO N 13-1
P istons & C o n n ectin g Rods
P iston & C o n ne ctin g Rod
1 B earing s h e lls 7 P isto n

2 C o n n e c tin g rod 8 Sleeve
3 G udgeon pin bush 9 O il c o n tro l ring
4 C irc lip 10 2nd co m p re s s io n ring
5 G ud geo n pin 11 Top co m p re s s io n ring
6 B ig end b o lt
ftd t't'in gto r. D iesel t lu b ADE 422, 423,424 Workshop Manual
PISTONS AND CONNECTING RODS - 13-2
Piston
46.009
G u d g e o n p in bore dia.
46.003
46.000
G u d geo n p in dia.
45.995
D is ta n c e b e tw e e n p is to n c ro w n and c y lin d e r b lo c k + 0,43

m a tin g s u rfa c e w ith p is to n a t TDC + 0,07
G u d g e o n p in /c o n ro d bu sh c le a ra n c e 0 .0 5 5 -0 .0 7 0
G u d g e o n p in /p is to n c le a ra n c e 0 .0 0 3 -0 .0 1 4
P is to n : N o m in a l d ia m e te r 128,0
Piston Rings
E n g in e G ro o v e P is to n Ring S id e C le a ra n c e G ap
C la s s ific a tio n
K e y s to n e M olybodenym - 0 .3 5 - 0 .5 0
1
’ coated
T , M olybodenym
2 T a p e rfa c e cQated 0 .0 6 0 -0 .0 9 5 0 .3 5 - 0 .5 0
420N
B e v e lle d w ith ru b b e r-
3 0 .0 3 0 - 0 .0 6 5 0 .2 5 - 0 .4 0
lin e d s p rin g
.. . M olybodenym
1 K e y s to n e ’ . - 0 .3 5 - 0 .5 0
coated
2 T
Taan
pee rfa
rfa cc e M olybodenym
e cQate(J 0 .0 6 0 -0 .0 9 5 0 .3 5 - 0 .5 0
420T/TI
B eve lled w ith rub be r-

3 0 .0 3 0 - 0 .0 6 5 0 .2 5 - 0 .4 0
lin e d s p rin g
C onrod Bush
46.065
In n e r dia. 46.055
50.700
O u te r dia. 50.670
3 8 .700
W id th 3 8 .200
LC B a r r i n g t o n Diesel Club ADE 422, 4 2 3 ,4 2 4 Workshop Manual
t
PISTONS AN D C O N N EC TIN G RODS - 13-3
Conrod and Conrod Bearing
Repair Size Conrod Bearing Dia. Conrod Bearing Width

Installed
90.106
Standard
90.064
90.006 , 0
Standard 1
89.964
89 856 ( - 0,25) 31.0

Standard 2
89.814 30.8
89.606 , 0 g.
Rep. size 1
8 9 .5 6 4 ' '
89.356 , g 7g,
Rep. size 2
89.314
89.106 ( _ 1 00)
Rep. size 3
89.064 ' ’
95,022
Conrod bearing basic bore dia.
95.000
50.630
Conrod bush basic bore dia.
50.600
Length of connecting rod between 256.05

centre of big and small end 255.98
33.0
Big end
32.6
Connecting rod width at
39.0
Small end
38.7
0.126
Big end bearing clearance radial
0.064
0.500
axial
0.240
Basic bore big/small end cylindrical tolerance 0.01
Max. permissible mass variation within one engine 60 gr
Permissible deviation within 50 mm between centreline

big end bore and centreline gudgeon pin 0.025
TORQUE S P EC IFIC ATIO N S
C onnecting rod b o lt s ...................... M16 x 1,5 In itia l torque 100 N.m

Final torque 9 0 ° - 100°
Max. stretch length 68,5 mm
PISTONS AN D C O N N EC TIN G RODS - 13-4
In tro d u c tio n
The 420 Series of Engines are fitte d w ith lig h t alloy p is
tons. In all cases the top com pression ring is m ounted
in a reinforced groove. The num ber o f pisto n rings fitte d
depends on application. Pistons and connecting rods are
rem ovable from the top of the cylin d e r block.
REM OVING PISTONS — C YLINDER HEAD

AN D SUM P REMOVED
R em oving
1. To avoid damage to the pisto n rings, remove carbon
w ith a scraper from the top of the cylin d e r liner.
2. Unscrew and remove con ne cting rod bearing cap

(fig. 1-13).
Note: Ensure that connecting rod bearing caps are marked

for replacem ent to the same con ne cting rod (fig. 2-13).
3. Push out connecting rod and pisto n from below.
4. Clamp connecting rod and piston in a vice (fitted w ith

so ft jaws), remove gudgeon pin circlip , and press out
gudgeon pin, lift o ff pisto n (fig. 3-13).
Fig. 3-13
PISTO N S A N D C O N N E C T IN G RODS — 13-5
R e p la c e m e n t
1. C lam p co n n e c tin g rod in a v ice (use p ro te ctive ja w s)
so th a t the lo n g e st side o f the co n n e c tin g rod face s
to w a rd s th e rig ht. Place the heated p isto n over the
c o n n e c tin g rod w ith the arrow on th e p isto n crow n
p o in tin g to w a rd th e rig ht.
2. Lubricate and insert gudgeon pin and replace c irc lip s

(fig. 4-13).
3. Coat piston w ith engine oil. O ffset piston rings in rela

tio n to each other. F it relaxed p is to n ring cla m p over
p isto n , and co m p re ss to o u ts id e d ia m e te r o f pisto n,
so th a t th e cla m p can s till move (fig. 5-13).
4. Inse rt bearing she ll in to co n n e c tin g rod. Ensure th a t

the lo c a tin g ta b is fitte d c o rre c tly in th e co n n e c tin g
rod. C oat bearing w ith engine o il (fig. 6-13).
5. L u b rica te bearing su rfa ce s o f c o n n e c tin g rod w ith

en gine o il.
6. Insert p isto n in to c y lin d e r lin e r w ith arrow fa cin g in

to w a rd s th e ce n tre (fig. 7-13) o f the engine.
7. Push p is to n in u n til c o n n e c tin g rod bearing rests on

cra n k s h a ft jo u rn a l.
PISTONS A N D C O N N EC TIN G RODS - 13-6
8. Insert bearing shell in to con ne cting rod cap. Ensure

th a t the locating tab is fitte d corre ctly in the
connecting rod cap. Coat bearing w ith engine oil (fig.
8-13).
9. Measure length o f big end bo lts (fig. 9-13).
Note: Big end b o lts can s till be used as long as stretch

does not exceed 68,5 mm.
10. Fit bearing cap and screw in bearing bolts finger tight.
Note: Ensure th a t marks on bearing cap and connecting

rod align (fig 10-13).
11. T ighten big end bo lts alte rna te ly in tw o steps to 100

N.m, using a torque wrench and then a fu th e r 90°.
Fig. 10-13
ftd t't'in gto r. D iesel Club ADE 422, 423,424 Workshop Manual
PISTO NS A N D C O N N E C T IN G RODS - 13-7
M E A SU R IN G C O N N E C T IN G ROD
BE AR IN G S
N ote Bearing sh e lls fo r c o n n e ctin g rod bearings are

delivered ready fo r in s ta lla tio n . No m a ch in in g o r s cra p
ing sho uld be perform ed on the bearings.
1. Clean bearing surface in con ne cting rod and bearing

cap w ith clean rag.
2. Inse rt bearing she ll in to c o n n e ctin g rod cap. Ensure

th a t the lo c a tin g ta b is fitte d c o rre c tly in the
c o n n e ctin g rod cap (fig. 11-13).
3. Place bearing cap w ith shell in to c o n n e ctin g rod.

Id e n tific a tio n num bers m ust be on the sam e side.
4. T igh te n big end b o lts to an in itia l torqu e o f 100 N.m

in 2 steps and then to a final torque of 90° + 1 0 ° angle
o f rotatio n.
Note: H old co n n e ctin g rod in a vice (fitte d w ith so ft jaws,

as clo se as po ssib le to the c o n n e ctin g rod bearing
(fig. 12-13).
Fig. 12-13
( d r H n g to n Diesel Club ADE 422, 423,424 Workshop Manual
PISTONS AND CONNECTING RODS — 13-8
5. Set a 50-100 mm internal measuring instrum ent to

diameter of connecting rod big end bore using an out
side m icrom eter (fig. 13-13).
6. Measure connecting rod big end bearing bore at three

points (vertically and approxim ately 30° away from
m atin g po in ts, using set 50-100 mm in te rna l
m icrom eter (fig. 14-13).
Note: M easurements specified in table m ust be adhered

to.
7. Unscrew and remove bearing cap.
REPLACING PISTON RINGS

1. Set piston ring pliers Part number 40200307 to 128 mm
diam eter w ith the adjusting screw (fig. 15-13).
2. Piston rings can be removed and replaced at th is

setting.
Fig. 15-13
ir r in g io n Diesel Club ADE 422, 423,424 Workshop Manual S e c tio n s: 14 a n d 15
_________________________ SECTION 14-1

Crankshaft & Main Bearings
C ra n ksh aft & M ain Bearings
1 Hub bolt 8 Bolt

2 V-belt pulley 9 Locating pin
3 Hub 10 Crankshaft gear
4 Dust cover * 11 Spacer
5 Wear ring 12 Spigot bearing
6 Crankshaft w ith counter balances 13 Crankshaft bearing shells
7 Counter balance
B d r r in g t o n D iesel Club A D E 422, 423,424 W orkshop Manual S e c tio n s: 14 an d 15
C R A N K S H A FT AN D M AIN BEAR IN G S - 14-2
C ran k sh a ft
Repair Size Main Bearing Width of Thrust Conrod Bearing Width of Conrod
Journal Dia. Bearing Journal Journal Dia. Bearing journal
Standard 104000 90.000 , q, j ,

103.980 38.062 /gj 89.980 (S,d)
38.000 ( 1
Standard 1 103.900 ( 0,1) 89 900 ( 0,1)
103.880 89.880 '
Standard 2 103.750 , 0 25) 89 750 ( 0,25) 71.120

103.730 38.562 , 0 ,, 89.730 ' ' 71.000
Rep size 1 103.500 ^ Q 5^ 38.500 ( + ° ’5)

89 500 ( - 0 ,5 )
103.480 ' ' 89.480 ' '
ReP s iz e 2 ^ H ^ (-° ,7 5 ) 89 250 ( 0,75)

103.230 39.062 , i q. 89.230 ' 1
39.000 ( ’ '
Rep size 3 103 000 ( _ i,o) § 9 ^2 9 (- 1 ,0 )
102.980 88.980 ' '
C ra n k s h a ft jo u rn a l h a rd n e s s HRC 53 ± 3
F or R e pa ir o n ly: C ra n k s h a ft jo u rn a l h a rd n e ss a t tw o th ird s o f c irc u m fe re n c e M in .: HRC 46
M ax. c ra n k s h a ft jo u rn a l/c o n ro d jo u rn a l ta p e r 0.01
M ax. c ra n k s h a ft jo u rn a l/c o n ro d jo u rn a l o v a lity 0.01
M ax. c ra n k s h a ft ru n o u t w ith c ra n k s h a ft
0.06
ru n n in g o n o u te r c ra n k s h a ft b e a rin g jo u rn a ls
M ax. ra d ia l ru n o u t o f fly w h e e l s p ig o t w ith

0.02
c ra n k s h a ft ru n n in g on o u te r c ra n k s h a ft b e a rin g jo u rn a ls
M ax. la te ra l ru n o u t o f fly w h e e l m o u n tin g s u rfa c e .

0.02
c ra n k s h a ft ru n n in g on o u te r c ra n k s h a ft b e a rin g jo u rn a ls
M ax. la te ra l ru n o u t o f th ru s t b e a rin g s u rfa c e 0.02
M ax. im b a la n c e o f c ra n k s h a ft w ith c o u n te rb a la n c e
60 cm g
w ith o u t fly w h e e l, ru n n in g on o u te r m a in b e a rin g s
R a dii on c ra n k s h a ft and c o n ro d b e a rin g jo u rn a ls 3 .5 -4 .0
R a d ii on th ru s t b e a rin g jo u rn a l 4.0
M ax. m is a lig n m e n t o f c o n ro d b e a rin g s to c ra n k s h a ft

0.01
b e a rin g s in re fe re n c e to b e a rin g le n g th
61.959
S p ig o t d ia . fo r fly w h e e l
61.940
40 * *
BDC fcdriM hgton Diesel Club ADE 422, 423,424 Workshop Manual S e c tio n s! 14 a n d 15
C R A N K S H A FT AND M AIN BEAR IN G S — 14-3
. C ra n k s h a ft Bearing
Crankshaft Bearing Thrust Bearing
Repair Size
Dia. Installed Width
104.112
Standard
104.066
37 -81 (Std)
104.012 , 37.74
Standard 1 -0 ,1 )
103.966 '
103.862 ,
Standard 2 - 0,25)
103.816 3831 , + 0 5 )
103.612 , 38.24^ '
Rep size 1 -0 ,5 )
103.566
103.362 ,
Rep size 2 -0 ,7 5 )
103.316 38.81 / ,
103.112 , 38.74 (
Rep size 3 -1 ,0 )
103.066 1
Max. bearing journal ovality 0.02
for repair 111.040

Basic bore dia. in crankcase for crankshaft bearing
110.970
111.022
new
111.000
Crankshaft end play (thrust bearing) 0.1 9 0 -0 .3 2 2
Radial clearance of crankshaft (Thrust Bearing) 0.0 8 7 -0 .1 5 3
(Other Bearings) 0.0 8 0 -0 .1 4 6
Ra 0.2/im
Main and Bigend journal surface finish (Lapped)
Rmax 2^m
TORQUE SPEC IFIC ATIO N S
Counter balance bo lts to cran ksha ft ................................. M16 x 1,5 In itia l torque 100 N.m
Max. stretch length 84,5 mm
Pulley to hub/vibration d a m p e r........................................... M8 25 N.m
Pulley hub/vibration dam per to c r a n k s h a ft...................... M 1 6 x 1,5 200 N.m
Main bearing cap bo lts (see sectio n 11) .............. M18 X 2 In itia l torque 300 N.m
Max. stretch length 156 mm
Main bearing cap side b o lt s ................................................. M12 x 1,5 80 N.m
Note: Tighten stretch b o lts prior to bearing cap side bolts.
7/90
BDC fcdriM hgton D iesel Club A D E 422, 423,424 W orkshop Manual S e c tio n s: 14 an d 15
CRANKSHAFT AND MAIN BEARINGS — 14-4
Introduction
The crankshaft is forged, precision ground and supported
by steel backed shell bearings, with thrust washers at the
flywheel end. Counterbalances are bolted to the
crankshaft webs.

CRANKSHAl-T AND BEARINGS
Removing
Vibration Damper, Hub and Pistons removed, (see Sec
tion 13).
1. Remove front oil seal housing (fig. 1- ■4).
Fig. 1-14
2. Unscrew and remove side bolts of crankshaft main

bearing caps.
3. Unscrew and remove Main Bearing Bolts, lift off bear
ing caps using bearing bolts (fig. 2-14).
N o te : Mark bearing caps and bearing shells In correct
sequence.
4. Screw guide mandrels Part number 40200077 Into
front and rear of crankshaft.
Fig. 2-14
5. Place a rope around mandrels and lift crankshaft from

crankcase using a suitable hoist (fig. 3-14).
6. Remove main bearing shells from crankcase, check
all parts for damage and wear.
N o te : All main bearing shells are delivered ready for instal

lation. No machining or scraping should be performed on
the bearing shells. Thrust washers are supplied in various
oversizes, the crankshaft must then be reground to the
appropriate bearing shell width to maintain the specified
crankshaft end-float.
REPLACING AND CHECKING SHELL

BEARINGS
1. Clean bearing surface in crankcase and bearing caps

with clean rag.
2. Insert bearing shells into crankcase and bearing caps
in correct order. Ensure that the locking tabs of the
bearing shells are correctly located in cap and
crankcase. Lubricate bearing shells with engine oil.
N o te : Bearing shells in crankcase have an oil deliveiy
hole which must be aligned with the adjacent hole in the
crankcase (fig. 4-14).
( d r H n g t o n D iesel Club A D E 422, 423,424 workshop Manual Sections: 14 and 15
C R A N K S H A F T A N D M A I N B E A R I N G S — 14-5
3. Replace bearing caps fitte d w ith bearing s h e lls .‘En

sure m arks on bearing caps correspond.
4. M easure m ain bearing b o lts for stre tch (fig. 5-14).
N o t e : M ain bearing b o lts may be reused w ith a stre tch

o f up to 156 mm.
5. T igh te n m ain bearing cap b o lts to an in itia l torque of ■ ■ " ' “ ................
300 N.m in 3 stages and then to a fin a l torqu e of I
9 0 ° + 10°.
6. Insert and tig h te n m ain bearing side b o lts to 80 N.m

(fig. 6-14).
© © X I
I
I I W /X F L
< V I
A
/ /
Fig. 6-14
7. Set a 100-160 mm in te rna l m easuring in stru m e n t to

standard diam e te r o f cran ksha ft bearing bore using
an o u tsid e m icro m eter (fig. 7-14).
8. Measure crankshaft bearing bores at three points (ver

tic a lly and a p p ro xim a te ly 30° away from the m atin g
po in ts w ith the set 100-160 mm dial gauge (fig. 8-14).
N o t e : S pe cifie d values m ust be adhered to.
9. Unscrew b o lts and remove bearing caps.

C R A N K S H A F T AN D M AIN BEARING S — 14-6
REPLACING BEARING SH ELLS AND

CRANKSHAFT
1. Clean o il ga lle rie s in crankcase w ith com pressed air

applied from the oil pum p side.
2. Clean crankshaft, bearings and bearing lo catio ns

thoroughly w ith clean rag. Clean oil galleries in crank
sh a ft w ith a w ire brush and blow out w ith com pres
sed air.
3. Check cran ksha ft bearing jo u rn a ls w ith a hardness

te ste r (fig. 9-14).
N o t e : A conversion table is supplied w ith the hardness

tester.
4. Insert bearing shells in to crankcase and bearing caps

in correct order. Ensure th a t the locking tabs are cor
re ctly located in cap and crankcase.
N o t e : Align holes in bearing shells, w ith drilling s in crank

case (fig. 10-14).
5. Lubricate bearing surfaces w ith engine oil.
Fig. 10-14
6. Screw guide m andrels Part num ber 40200077 in to

front and rear of crankshaft. Place rope around
m andrels and lift crankshaft. Lower cran ksha ft in to
crankcase (fig. 11-14).
Fig. 11-14
N o t e : Ensure th a t tim in g m arks are lined up corre ctly

(fig 12-14).
Fig. 12-14
BDC B a r r i n g t o n D iesel Club A D E 422, 423,424 W orkshop Manual S e c tio n s: 14 an d 15
7. Fit main bearing caps ensuring that marks on cap and

crankcase align (fig. 13-14).
8. Measure main bearing bolts for stretch (see fig. 5-14).
N o t e : Main bearing bo lts may be reused w ith a stretch

of up to 156 mm (see fig. 5-14).
Fig. 13-14
9. Tighten m ain bearing cap bolts to an in itia l torque of

300 N.m in 3 stages and then to a final torque of
9 0 ° + 10°.
10. Insert and tig h te n m ain bearing side b o lts to 80 N.m

(fig. 14-14).
11. Fit suita ble dial gauge to crankcase and check end
floa t o f cran ksha ft (fig. 15-14).
Fig. 15-14
C R A N K S H A FT AND M AIN BEARINGS — 14-8
C R AN K SH A FT GRINDING
1. Remove counter balance weights. Check to see if coun

ter balances are marked prior to removal. If not, mark
counter balance using a suitable punch to ensure cor
rect installation.
2. Remove crankshaft tim in g gear.
3. Clean crankshaft and check for m isalignm ent, jo u r

nal run out, hardness using special tool Part number
40200501 and cracks. C rankshafts show ing signs of
cracking should be replaced. S traighten or if
necessary replace bent crankshafts. If bearing jo u r
nals do not meet sp e cifica tio n s or are found to be
scored, the crankshaft should be ground to the next
repair stage (see fig. 16-14).
4. It is essential to keep to the specified radii for the

main bearing and crankpin journals.
5. Lap surface of journals after grinding.

6. Measure length of crankshaft counter balance bolts
(fig. 17-14).
N o t e : Counter balance bolts may be re-used if the stretch
limits are within specification.
Remove counter balance weights.
7. Replace counter balances and tigh ten to an in itial

torque of 100 N.m and a final torque of 90 + 10.
N o t e : Marks on counter balances m ust be aligned w ith

marks on crankshaft.
8. Clean oil galleries in crankshaft w ith a wire brush and

blow out w ith com pressed air.
7/90
i r r i n g i o n D iesel Club A D E 422, 423,424 W orkshop Manual S e c tio n s: 14 an d 15
f t d f H n g t o n Diesel Club ADE 422, 423,424 Workshop Manual S e C t iO f lS ! 14 a n d 15
C R AN KSH AFT AND MAIN BEARINGS — 14-10
R eplacing O il Seal
1. Coat outer surface of oil seal w ith a suitable sealing
com pound.
N o t e : Do not allow sealing com pound to com e in c ontact

w ith the lip of the oil seal or the sealing surface o f the
crankshaft.
2. Insert new oil seal in to housing and press or knock

in so that the seal face is flush w ith the inside of the
housing. Pack (fill) the area between the seal lip and
dust lip w ith m ultipurpose grease.
N o t e : Support cover w hile inserting o il seal in housing.
3. Fit new housing gasket over dow els in crankcase.
4. Lubricate wear sleeve for oil seal w ith engine oil.
5. Replace housing and housing bolts and tigh ten to a _____

torque of 25 N.m (fig. 22-14).
Fig. 22-14
6. Replace sump fitted with new gasket, insert bolts and

tigh ten to a torque of 30 N.m (fig. 23-14).
7. Insert dust cover, fit pulley hub and vibration damper

and tigh ten to a torque of 200 N.m (fig. 24-14).
8. Replace pulley and fan.
Fig. 24-14
B a r r i n g t o n Diesel Club ADE 422, 423,424 workshop Manual Sections: 14 and 15
C R AN KSH AFT AN D M AIN BEARINGS — 14-11
REPLACING W EAR RING ON C R A N KS H AFT
R em oving
1. Fit special tool Part num ber 40249737 over wear ring
on front of crankshaft, and push down adapter sleeve
(fig. 25-14).
2. Pull o ff wear ring.
R eplacing
3. Heat new wear ring to approx 100°C.
4. Fit wear ring in to special tool Part num ber 40201801

and knock onto crankshaft (fig 26-14).
5. Coat surface of wear ring w ith engine oil.
REMOVING AN D REPLACING VIBR ATIO N

DAMPER
R em oving
1. Remove V-belts.
2. Remove fan w ith hub and pulley.
3. Unscrew and remove vib ratio n dam per or pulley hub

(fig. 27-14).
R eplacin g
1. Fit vib ratio n dam per or hub, and tig h te n bo lts to a
torque o f 200 N.m (fig. 28-14).
2. Replace engine fan w ith hub and pulley.
3. Fit and tension V-belts.
Fig. 28-14
BDC B a r r i n g t o n D iesel Club A D E 422, 423,424 W orkshop Manual S e c tio n s! 14 an d 15
__________________________ SE C TIO N 151

C am shaft, Tim ing Case and Drive Timing
C a m s h a ft
1 C am shaft 11 Rocker sha ft and pedestal

2 Inlet valve 12 Ball
3 Exhaust valve 13 Rocker arm
4 Valve spring inner 14 A d ju stin g screw
5 Valve spring outer 15 Locking nut
6 Spacer inner 16 T hrust washer
7 Spacer outer 17 C irclip
8 Spring retainer 18 Rocker sh a ft bolt
9 C o lle t 19 Tappet
10 Stem seal 20 Push rod
B a r r i n g t o n Diesel Club ADE 422, 423,424 Workshop Manual S e c tio n s! 14 a n d 15
C A M SH AFT, TIM IN G CASE AND DRIVE-TIM ING - 15-2
C a m s h a ft
69.940
J o u rn a l Dia. (in cl. th ru s t be a rin g )
69.910
H a rd n e ss jo u rn a l
58-62 HRC
cam
C a m s h a ft/b e a rin g c le a ra n c e ra d ia l 0 .0 6 - 0 .1 5 6
a xia l 0 .2 -0 .9
C a m s h a ft/th ru s t b e a rin g c le a ra n c e ra d ia l 0 .1 3 - 0 .1 8
B a c k la s h c ra n k s h a ft/c a m s h a ft g e ar 0 .1 1 8 -0 .2 4 2
B a c k la s h In je c tio n p u m p /in te rm e d ia te /c a m g e a r 0 .1 0 2 -0 .3 3 8
P e rm is s ib le ru n o u t c a m s h a ft jo u rn a ls (c a m s h a ft s u p p o rte d at o u te r jo u rn a ls ) 0.05
P a ra lle l c a m /c a m s h a ft c e n tre lin e 0.005
C am and jo u rn a l s u rfa c e fin is h Rz 3^m
C a m s h a ft Bearing
70 .090
C o lla r (th ru s t) b e a rin g
7 0 .070
B e a rin g in s id e dia.
70 .066
O th e rb e a rin g s
70 .000
76.030
B a s ic b o re fo r c a m s h a ft be a rin g
76.000
76.100
C a m s h a ft b e a rin g o u te r Dia.
76.070
M axim um Valve L ift w ith S p e c ifie d Valve C learance (mm)
Up to SA 002762 M 13,76 13,66

ADE 422N SA 002763 M and up 1 1 ,9 5 -1 2 ,3 5 1 1 ,9 0 -1 2 ,3 0
Up to SA 003441 P 11 ,5 0 -1 1 ,9 0 1 3 ,1 0 -1 3 ,5 0
ADE 422T/TI SA 003442 P and up 1 1 ,9 0 -1 2 ,3 0 1 1 ,8 5 -1 2 ,2 5
ADE 423N ** 11 ,9 5 -1 2 ,3 5 1 1 ,9 0 -1 2 ,3 0
S till in e ffe ct 11 ,5 0 -1 1 ,9 0 1 3 ,1 0 -1 3 ,5 0
ADE 423T/TI To be advised 1 1 ,9 0 -1 2 ,3 0 1 1 ,8 5 -1 2 ,2 5
ADE 424N ** 1 1 ,9 5 -1 2 ,3 5 1 1 ,9 0 -1 2 ,3 0
S till in e ffe ct 11 ,5 0 -1 1 ,9 0 13 ,1 0 -1 3 ,5 0
ADE 424T/TI To be advised f l ,90 -1 2 ,3 0 11 ,8 5 -1 2 ,2 5
* At new level since the firs t day o f m anufacture.
BDC B a rrin g to n Dicscl Club A D E 422, 423,424 W orkshop Manual S e c tio n s! 14 an d 15
CAM SHAFT, TIM ING CASE AND DRIVE-TIMING — 15-3
Valve Travel at TDC w ith zero valve s e ttin g (mm)
Up to SA 002762 M 0 ,5 0 -0 ,6 5 0,47 - 0,62

ADE 422N SA 002763 M and up 0,60 - 0,80 0 ,6 5 -0 ,8 5
Up to SA 003441 P 0 ,4 0 -0 ,6 0 0 ,5 5 -0 ,7 5
ADE 422T/TI SA 003442 P and up 0 ,5 5 -0 ,7 5 0,65 - 0,85
—
ADE 423N 0 ,6 0 -0 ,8 0 0,65 - 0,85
S till in e ffect 0 ,4 0 -0 ,6 0 0 ,5 5 -0 ,7 5
ADE 423T/TI To be advised 0 ,5 5 -0 ,7 5 0,65 - 0,85
—
ADE 424N 0,60 - 0,80 0 ,6 5 -0 ,8 5
S till in e ffect 0 ,4 0 -0 ,6 0 0 ,5 5 -0 ,7 5
ADE 424T/TI To be advised 0 ,5 5 -0 ,7 5 0,65 - 0,85
** At new level since the firs t day o f m anufacture.
C am follow er
O u te r S h a ft Dia. Bore in C ra nkca se
19.965 20.021
S tan dard
19.944 20.000
20.215 20.271
R epair 1 + 0.25
20.194 20.250
20.465 20.521
Repair 2 + 0.50
20.444 20.500
C le a ra n ce s h a ft/b o re 0 .0 3 5 -0 .0 7 7
Rockershaft/Rockerarm
28.052
B a sic bore rocke rarm
28.000
R ockerarm bush O u te r Dia. 28 090
lnner Dia
24.980
R o cke rsh a ft Dia.
24.967
C le a ra n c e s h a ft/b o re 0 .0 2 0 - 0 .0 5 4
Tim ing device weights to cam shaft g e a r .................... M10 50 N.m
Max. stretch length 25,3 N.m
Injector pump drive gear to tim in g d e v ic e .................. M10 50 N.m
Max. stretch length 25,3 N.m
Injector pump driven gear to flange (see section 17)
Tim ing/Flywheel Housing to cylinder block ................ M10 (Short) 70 N.m
M10 (Long Bolts) 60 N.m
M 1 2 x 1,5 100 N.m
Cover to tim ing housing (top), tightening sequence p. 15-6 M8 25 N.m
Steering pump to tim in g housing (see section 18)
Cam shaft thrust plate to tim ing housing ......................... M8 -v 25 N.m
Check plug for in jecto r pump tim in g m a rk s ................... M 2 6 x 1,5 80 N.m
M38 x 1,5 100 N.m
Cover air com pressor opening to tim ing housing ......... M8 25 N.m
Inspection cover for T.D.C. m a r k ....................................... M8 25 N.m
7/90
A D E 422, 423,424 W orkshop M anual S e c tio n s: 14 an d 15
C AM S H A FT, TIM IN G CASE AN D DRIVE-TIM ING - 15-4
In tro d u c tio n
The cam shaft is forged and precision ground. It is sup

ported by bearings, and driven by gears at the flyw heel
end o f the engine. To gain access to the cam shaft, and
tim in g gears it w ill be necessary to remove the flyw heel
and tim in g case housing.
REM OVING AN D REPLACING

TIM IN G CASE
R em oving
1. D isconnect exhaust brake cylinde r from exhaust
m anifold.
2. Remove oil pressure and return pipe from power steer

ing pump.
3. Unscrew and remove coo la nt feed pipes to co m

pressor, (fig. 1-15).
4. Remove air intake hose and air pressure pipes from

com pressor, (fig. 2-15).
5. Unscrew and remove fuel filte r from tim in g case.
Fig. 3-15
' B a r rin g to n »•«*«! Club A D E 422, 423,424 W orkshop Manual S e c tio n s: 14 an d 15
C A M S H A F T , T IM IN G CASE A N D DRIVE-TIM ING — 15-5
7. Remove all sum p b o lts and lift o ff sum p, (fig. 4; 15)
Fig. 4-15
8. Remove flyw h ee l (See sectio n 18).
9. Unscrew and remove tim in g case m ounting bolts and

lift o ff tim in g case (fig. 5-15).
R e p la c in g
1. F it new gaskets (Right and Left) over do w e ll pins on
tim in g case and trim ends to correct length, (fig. 6-15).
Fig. 6-15
2. F it tim in g case over do w e ll pins replace b o lts and

tig h te n to 70 N.m, (fig. 7-15).
Fig. 7-15
A D E 422, 423,424 W orkshop M anual S e c tio n s: 14 an d 15
CAMSHAFT, TIM ING CASE AND DRIVE-TIMING - 15-6
3. Replace sump and tighten bolts to 25 N.m.
4. Fit tim in g cover w ith new gasket and insert into

correct position using special tool Part number
40200103 (fig. 8-15).
Fig. 8-15
5. Tighten tim ing cover bolts to 25 N.m in the sequence

shown in (fig. 9-15).
6. Fit fuel filte r to tim in g cover and tighten bolts to 80

N.m.
Fig. 9-15
7. Replace air intake hose and air pressure pipe on com

8. Replace and tighten engine brake cylinder on exhaust

manifold.
Fig. 10-15
9. Connect and tighten coolant feed pipes to com

10. Connect and tighten oil pressure and return pipes to

power steering pump.
Fig. 11-15
fta r r in g to n Diesel Club A D E 422, 423,424 W orkshop Manual S e c tio n s: 14 an d 15
C A M S H A F T , T IM IN G CASE A N D DRIVE-TIM ING — 15-7
R EM O VIN G A N D REPLAC IN G C A M S H A F T
In itia l P re p a ra tio n
Remove engine.
Remove rocke r cover, arm s and brackets, lift out push-
rods (see S ectio n 12).
Turn engine over and rem ove sump.
Remove flyw h e e l (see S ection 18).
Remove tim in g case (see page 15-2).
Remove cra n ksh a ft (see S ection 14).
R em oving
1. Turn cran kcase up sid e down.
2. Ensure th a t the ca m fo llo w e rs are moved aw ay from
the ca m s h a ft lobes.
3. Pull ca m sh a ft from drive gear end and slid e out, ta k
ing care not to dam age the bearings.
4. If w ork is to be perform ed on the ca m sh a ft bearings,
it w ill be necessary to pu ll o ff the end blan king plug,
using spe cia l to o l Part num ber 40202004 (fig. 12-15).
Fig. 12-15
R e p la cin g
1. Insert c a m sh a ft and slide in, ta kin g care not to
dam age th e bearings (fig. 13-15).
Fig. 13-15
2. Ensure th a t the tim in g m arks on the c a m sh a ft and

c ra n ksh a ft gears are corre ctly a lign ed (fig. 14-15).
3. Coat edges o f c am sh aft blanking plug w ith a suitable

sealing com pound, and insert. Knock ca re fu lly home
using a cop pe r or hide faced hammer.
Fig. 14-15
C A M S H A FT, TIM IN G CASE AN D DRIVE-TIMING — 15-8
1 Handle 7 C entering tube

2 Sem i-shell 8 Spindle tube
3 Slot 9 Bearing holder
4 Lockpin 10 Locks
5 Bearing flange 11 Locating ring
6 Bolt 12 C o lla r bearing
Fig. 15-15
REM OVING AN D REPLACING C A M S H A FT

BEAR IN G S
In itia l p re p a ra tio n
Remove engine.
Remove rocker covers, arms and brackets, lift out push
rods (see Section 12).
Turn engine over and remove sump.
Remove flyw heel, and tim in g housing.
Remove cam sh aft blanking plug.
Remove cam sh aft and crankshaft.
R em oving
1. B olt bearing flan ge (5) and cen tra lizing tube (7) onto
crankcase using tw o M 1 0 x 25 mm bo lts (6) (fig. 15-15
and 16-15).
2. G uide spind le tube (8) in to crankcase and insert tw o

bearing holders (9) behind appropriate bearing.
N o t e : Insert bearing holder (9) in a reversed po sitio n to

each other (fig. 17-15).
Fig. 17-15
i r r i n g i o n D iesel Club A D E 422, 423,424 W orkshop Manual S e c tio n s: 14 an d 15
C A M S H A F T , T IM IN G CASE AN D D R IVE-TIM ING - 15-9
3. Turn sp in d le tube u n til lo ckpin (4) engages in s lo t (3)

o f sp in d le tube.
4. F it handle (1) on threa ds o f spind le tube (fig. 18-15).
Fig. 18-15
5. Insert bearing holder (9) in to cam sh aft bearing. Insert

locks (10) in grooves behind bearing holder (9). Pull
out ca m sh a ft bearing by tu rn in g handle (fig. 19-15).
N o t e : To reset bearing hold er (9) the sp in d le tu b e (8) f it

ted w ith a handle m ust be pulled o u t o f the crankcase.
Fig. 19-15
6. The co lla r bearing (12) w ill be pressed o u t tow ards the

rear. T his w ill require co n n e ctin g the handle (1) w ith
the bearing flan ge (5) throu gh the sem i-shell (2)
(fig. 20-15).
7. Unscrew handle (1) and remove sp in d le tube (8) w ith

bearing holders (9) and ca m sh a ft bearing bushes.
U nscrew bearing fla n g e (5).
Fig. 20-15
R e p la ce m e n t
1. B olt bearing flan ge (5) and ce n tra lizin g tub e (7) on to
crankcase, using tw o M10 x 25 mm bo lts (6) (fig. 15-15
and 16-15).
2. Insert cam shaft bearing bushes onto bearing holders

(9) and lo ck (fig. 21-15).
3. G uide sp in d le tube (8) in to c a m sh a ft gallery and in

sert bearing ho ld er (9) w ith bearing bush in to
a p p ro p ria te housing. Turn sp in d le tube (8) u n til
lo ckpin (4) in bearing holder engages in groove (3) o f
sp in d le tube.
Fig. 21-15
C f t a r r in g t o n D iesel Club A D E 422, 423,424 W orkshop Manual S e c tio n s: 14 an d 15
C A M S H A F T , T IM IN G C A S E A N D D R IV E -T IM IN G - 15-1 0
N o t e : Locking the bearing holders on the spindle tube also

lo ca te s the o il d rillin g in the ca m sh a ft bush w ith the o il
g a lle ry in th e crankcase.
4. Insert lo ck (10) o n to sp in d le tub e (8), fit handle and

pull in bearing so th a t the oil d rillin g in the ca m s h a ft
bush a lig n s w ith the o il g a lle ry in the cran kcase
(fig. 22-15).
N o t e : L u b rica te the o u tsid e o f the ca m s h a ft bushes w ith

en gine o il p rio r to in sta lla tio n .
5. Insert lo c a tin g ring (1) (fig. 23-15) in th ru s t p o in t o f

c o lla r bearing (12) when pulling in the inner c a m sh a ft
bushes.
N o t e : Because o f the considerable force required, no more

than tw o bearings should be pulled in at once. To reset
the bearing ho ld ers (9) th e sp in d le tube (8) w ith ha nd le
m u st be pu lle d o u t o f the crankcase.
6. W hen lo ckin g c o lla r bearing on bearing hold er (12)

ensure th a t the lower bore of the cam shaft bush faces
to the rig h t o f the ce n tre line (fig. 24-15).
7. Rem ove bearing p u lle r and m easure ca m s h a ft

bushes.
8. C heck th a t o il g a lle rie s and d rillin g s are clear.
Fig. 24-15
B
DC
B a r r i n g t o n D iesel Club A D E 422, 423,424 W orkshop Manual S e c tio n s: 14 an d 15
C A M S H A F T , T IM IN G CASE A N D D R IVE-TIM IN G - 15-11
C H E C K IN G C A M S H A F T E N D -PLAY
In itia l P re p a ra tio n s
Rem ove T im in g case cover.
Remove in je c tio n pum p.
C A M S H A F T EN D -P LAY
1. Push ca m s h a ft a g a in st the tim in g case.
2. A tta c h d ia l gauge to crankcase. Place d ia l gauge

probe pin w ith pre-load on c a m s h a ft gear and set
sca le to 0 (fig. 25-15).
F ig. 25-15
3. Press cam sh aft gear against the dial gauge probe and
read ca m s h a ft end play (fig. 26-15).
Fig. 26-15
R d f r in y t o n Diesel CCftjjIb ADE 422, 423,424 workshop Manual Sections: 14 and 15
C A M SH AFT, TIM IN G CASE AN D DRIVE-TIMING — 15-12
C H EC KIN G VALVE LIFT
1. Remove rocker covers, (fig. 27-15).
2. A tta ch engine turning tool.
3. A djust valve clearances.
4. Turn engine and set to TDC No 1 cylinder rocking.
5. Turn engine in reverse direction of rotation for approxi

mately 90°, and note that the inlet valve is closing fully
during this operation.
6. Attach a dial gauge to the cylinder head, with the probe

placed on the inlet valve, and set gauge to “ O ", (fig,
28-15).
N o t e : Adjust dial gauge to give sufficient pre-load to allow for

valve lift.
7. Turn engine in the normal direction of rotation, and note

reading on dial gauge when the needle stops, i.e. before
it returns to "O ” .
8. Read off INLET valve lift.
9. Re-position dial gauge, and place probe of dial gauge onto

exhaust valve, and set to “ O” , (fig. 29-15).
10. Turn engine in reverse direction of rotation and note read

ing on dial gauge, when the needle stops, i.e. before it
returns to " O ” .
11. Read off measured EXHAUST valve lift.
Fig. 29-15
12. Remove dial gauge, unscrew engine turning tool, and

replace rocker cover and tighten to 25 N.m, (fig. 30-15).
BDC B a r r i n g t o n D iesel Club A D E 422, 423,424 W orkshop Manual S e c tio n s: 14 an d 15
CAMSHAFT, TIMING AND DRIVE TIMING — 15-13
CHECKING VALVE TRAVEL AT ,

ZERO V ALVE CLEARANCE
1. Remove rocker cover of No 1 cylinder, (fig. 31-15).
2. Fit engine turning tool to flywhell housing, (fig. 32-15).
3. Turn engine in normal direction of rotation until TDC No

1 (OT1) mark on flywheel is reached.
Attention! Check valve movement to ensure that No 1 cylinder

is in firing position and n o t in rocking position.
4. Set both vlaves of No 1 cylinder to “ O ” clearance.

5. Turn engine 360° in normal direction of rotation until TDC
No 1 (OT1) mark on flywheel is reached.
A tte n tio n ! Valves of No 1 cylinder should be in rocking posi

tion, i.e. inlet valve starts opening and exhaust closing.
6. Mount dial indicator gauge on No 1 cylinder head.
7. Place dial gauge probe pre-loaded onto inlet valve spring

retainer and set gauge to " O ” , (fig. 33-15).
8. Turn engine back slowly until needle of dial gauge stop.
9. Note reading of inlet valve travel.
10. Remove dial gauge indicator from cylinder head.

11. Turn engine slowly in normal direction of rotation until
piston of No 1 cylinder is once more at TDC, valves
rocking.
12. Mount dial gauge indicator on No 1 Cylinder head.
13. Place dial gauge probe, pre-loaded onto exhaust valve

spring retainer and set gauge to "O ” , (fig. 34-15).
14. Turn engine in normal direction of rotation until needle
of dial gauge stops.
15. Note reading of exhaust valve travel.
16. Compare both readings with the specifications.

17. Remove dial gauge from cylinder head.
18. Continue turning engine in normal direction of rotation

until TDC No 1 (OT1) mark on flywheel is reached.
Attention! No 1 cylinder and valves should be in firing position.
7/90 ^
i r r i n g t o n D iesel Club A D E 422, 423,424 W orkshop Manual S e c tio n s: 14 an d 15
CAM SHAFT, TIM ING AND DRIVE TIM ING — 15-14
20. Replace rocker cover and tighten bolts to specified tor

que, (fig. 36-15).
19. Adjust clearances of both vlaves of No 1 cylinder, (fig.

35-15).
Fig 15-36
: 7/90
BDC B a r r i n g t o n D iesel Club A D E 422, 423,424 W orkshop Manual S e c tio n s! 14 an d 15
C A M S H A F T , T IM IN G C A S E A N D D R IV E -T IM IN G — 1 5-1 5
25
24
r 3
14
Z 05-6015
T im in g C a se
1 TIM IN G C A S E 14 SPR IN G W A SH ER
2 OIL S E A L 15 PLUG
3 STUD 16 GASKET
4 TH RU ST PLATE 17 GASKET
5 SCREW 18 SPR IN G W ATER
6 SPR IN G W A SH ER 19 BOLT
7 TH REA D ED IN SER T 20 BOLT
8 TH REA D ED IN SER T 21 C O V E R TIM IN G H O U S IN G
9 TH REA D ED IN SER T 22 T H REA D ED IN SE R T
10 COVER 23 SEAL
11 COVER 24 BRACKET
12 GASKET 25 BRACKET
13 BOLT
7/90
Bcc B a r r i n g t o n D iesel Club) ADE 422, 423,424 Workshop Manual Section 16 - Lubrication System
_________________ S E C T IO N 16-1
Lubricating S ystem and S um p
O il Pump
1 O il pum p a sse m b ly 12 In te rm e d ia te gear 23 C irc lip
2 G ear 13 B olt 24 B o lt
3 G ear 14 O il pipe 25 Flange
4 Driven G ear 15 F lan ge 26 B olt
5 O il pum p a sse m b ly 16 F lan ge 27 B olt
6 G ear 17 H o lde r 28 S u c tio n pipe
7 G ear 18 B olt 29 G asket
8 Cover 19 H o lde r 30 B olt
9 Shim 20 B olt 31 F ilte r pipe
10 C irc lip 21 C o n n e c tin g sh a ft 32 W asher
11 In te rm e d ia te Gear 22 Sleeve 33 B olt
B a rrin g to n Diesel Club ADE 422, 423,424 Workshop Manual Section 16 - Lubrication System
L U B R I C A T I N G S Y S T E M A N D S U M P — 16-2
O il P u m p s
Engine 422N 422T/TI423N 423T/TI 424N 424T
1st pump J34 43 28 28 34

Width of oil pump gears (nominal dim.)
2nd pump ~ 28 28
Actual width o f gears eg. 1st pump 33.950 42.950 27.960 27.960 33.950
33.911 42.911 27.927 27.927 33.911
34 and 43 mm pump 0.128

0.050
End play between
face and housing
28 mm pump 0.106
0.040
Clearance between 0.122

teeth and housing 0.030
>■ 56.770
Outside dia. of oil pump gears
56.724
Inside dia. of oil pum p gears 21.915

21.900
Dia. of oil pump shafts 21.940

21.930
Inside dia. of oil 21.915

pump drive sprocket 21.900
Min. delivery rate f/m in at 600 r/min 29.4 37.0 51 50.0 54.4
with SAE 10 oil at at 1 700 r/min 155
— — — —
50°C and 400 kPa
at 2 400 r/min 138 175.0 — 227 251.5
O il P re s s u re R e lie f V a lv e
E n g in e 42 2N /T /T I; 4 2 3 N * 423T/TI; 4 2 4 N /T * *
O p e n in g p re s s u re kPa: B e lo w b re a k p o in t 550 kP a 750 kP a
A b o v e b re a k p o in t 650 kPa 650 kPa
* — SA 0 0 2 2 6 5 M
* * _ SA 002424M
C a m s h a ft/P is to n C o o lin g
F low C o n trol
N a tu ra l a s p ira te d 2.0
P is to n o il s p ra y je t in n e r d ia . -------------------------------------------------------
T u rb o c h a rg e d 2.3
C a m s h a ft o il s p ra y h o le s in n e r d ia . 1.0
7/90
BCC B ^ f r i n g t o n D iesel Club) ADE 422, 423,424 Workshop Manual Section 16 - Lubrication System
LU BR IC ATIN G SYSTEM AND SUMP - 16-3
Oil Filter By-pass Valve
Spring for Inside Wire Relaxed Length when Length w ith Opening
Bypass Dia. Gauge Length Pre-loaded Final Load Pressure
Valve (valve open) of By-Pass
Valve
13.5 2.25 53.6 42.1 77 N 31 153 N 230 - 300 kPa
Oil Pressure
M in im u m o il pre ssu re — (s to p e n g in e im m e d ia te ly !) 600 r/m in b e lo w 50 kPa

2.300 r/m in 250 kPa
Oil C a p a c ity
D e p e n d in g on a p p lic a tio n Model range 422N — 424T a p p ro x. 23.0 - 32.5 (
TORQUE SPEC IFIC ATIO N S SECTION 16
Oil pressure relief valve to f la n g e ...................................... M8 35 N.m

O il pump to cylinde r b lo c k ................................................... M8 35 N.m
O il pump cover to pump b o d y ............................................ M8 25 N.m
S uctio n pipe to o il pump ...................................................... M8 35 N.m
S uctio n pipe bracket to cylin d e r b lo c k ............................. M8 35 N.m
Sump to cylinde r b lo c k ......................................... ................ M8 30 N.m
O il pump support to block (L H /R H ).................................... M8 35 N.m
Sump drain plug ...................................................................... M26 X 1,5 80 N.m
O il fille r neck to s u m p ............................................................ M8 25 N.m
O il filte r bowl to filte r h e a d .................................................. M12 x 1,5 50 N.m
O il coo le r to cooler h o u s in g ................................................. M8 25 N.m
O il c o o le r/filte r head to cylinde r b lo c k ............................. M10 50 N.m
Screw plug fo r filte r bypass v a lv e ...................................... M 26x 1,5 60 N.m
O il fille r plug to filte r h e a d ................................................... M26 x 1,5 80 N.m
O il drain plug filte r h e a d ....................................................... M18 x 1,5 50 N.m
D ip stick tube adapter to sum p ........................................... M14 x 1,5 50 N.m
D ip stick tube to a d a p to r ....................................................... M16 x 1,5 35 N.m
Piston coo lin g/cam sh aft spray nozzles (see sectio n 11)
B a r r i n g t o n D iesel Club ADE 422, 423,424 Workshop Manual Section 16 - Lubrication System
LU B R IC A T IN G SYSTEM A N D SUM P — 16-4
IN TR O D U C TIO N L u b ric a tin g S yste m

The ADE 420 series engines are sup plied w ith lu b rica tio n
oil by a gear driven o il pum p, and th e o il is filte re d by a
paper fu ll flo w elem ent. The oil cooler, c ra n ksh a ft, c o n
n e ctin g rods, ca m sh a ft, and rockers are ail pressure fed.
The in je c tio n pum p, and a ir c om p resso r are also d ire c tly
fed with engine oil. Relief and by -pass valves protect the sys
tem against overload.
REMOVING AND REPLACING BREATHER
R em oving
1. Unscrew clamp and pull off hose from breather.
2. Unscrew and remove breather from crankcase (fig. 1-16).
R e p la cin g
1. Insert new O-ring into breather, (fig. 2-16).
2. Fit breather over connection on crankcase (fig. 3-16).
Note: Do not damage the breather while servicing or repair

ing. Even slight damage e.g. dents in cover, could cause a
faulure of the breather. A damaged breather should always
be replaced.
7/90
LU BRICATING SYSTEM AND SUMP — 16-5
3. Tighten clamp of breather to approximately 8 N.m,* (fig.

4-16).
4. Connect hose to breather and tighten clamp.
N o t e : The vacuum in the crankcase is regulated by a spring-

loaded rubber diaphragm fitted integrally with the breather.
Ozone can cause cracks in the rubber diaphragm, through
which the engine can take in unfiltered air. This will lead to
premature engine wear. Always replace the breather when
oil vapour is expelled through the vent on the top of the
breather.

O IL PRESSURE SENDER UNIT
R em oving
1. Unscrew wire connection to oil pressure sender unit.
2. Using a open spanner remove oil pressure sender unit,

(fig. 5-16).
R e p lacin g
1. Screw in oil pressure sender unit fitted with a new seal
ing washer, tighten and attach electrical connection (fig.
6-16).
R EM O VING AN D REPLACING SUMP
R em oving
1. Drain engine oil.
2. Unscrew and remove o il fille r neck and d ip stick guide

tube from sump.
3. Remove b o lts and sum p (fig. 7-16).

4. Clean sum p in te rio r and exterior.
t 7/90
LUBRICATING SYSTEM AND SUMP - 16-6
Replacement
1. F it new gasket to sump.
2. Replace sum p on crankcase and tig h te n bo its to 30

N.m (fig. 8-16).
3. Replace o il fille r neck and d ip s tic k guide tube.
4. Screw in and tig h te n o il drain plug to 80 N.m.
5. F ill sum p w ith oil.
REMOVING AND REPLACING OIL FILTER

BYPASS VALVE
Removing
1. Unscrew drain plug on o il filte r bowl and drain oil.
2. Remove plug for bypass valve, lift out valve and

spring, (fig. 9-16).
3. Check length and tension using a su ita b le spring

tester.
Fig. 9-16
Replacing
1. Insert valve, spring, and plug in to o il filte r body, (fig.
10-16).
Note: Use new sea lin g washer.
2. T ighten filte r plug to 60 N.m.
3. Replace oil filte r drain plug on filte r bowl, and tighten

to 50 N.m
4. Ensure th a t the engine is in stop po sitio n. Turn the

engine several tim es w ith the starter until oil pressure
is registered on the gauge. Release stop c o n tro l and
start the engine.
5. Check fo r oil leaks.

( a r H n g t o n D iesel ( l u b ADE 422, 423,424 Workshop Manual Section 16 - Lubrication System
LU B R IC A T IN G SYSTEM A N D SUMP - 16-7
REM O VIN G A N D REPLAC IN G O IL FILTER

ELEM EN T
R em oving
1. Unscrew drain plug on oil filte r bowl and drain oil.
2 . Remove cen tre bolt from oil filte r bowl, and remove
to g e th e r w ith filte r ca rtrid g e , (fig. 11-16).
3. Remove filte r cartridge from bowl, and take off 0-ring.
R e p la cin g
1. F it new O-ring to filte r housing, (fig. 12-16).
2. Insert new o il filte r ca rtrid g e in to filte r bow l w ith co il

spring to w a rd s the b o tto m o f the bowl.
3. Centre o il filte r bowl on filte r housing, o il drain plug

fa cin g dow n, in sert cen tre b o lt and tig h te n to a to r
que of 50 N.m (fig. 13-16)
4. Ensure th a t the engine is in sto p p o sitio n . Turn the

engine several tim es w ith the starter u n til oil pressure
is registered on the gauge. Release sto p co n tro l and
s ta rt the engine.
5. Check fo r o il leaks.
LU BR IC ATIN G SYSTEM AN D SUM P — 16-8
R EM O VING AN D R EPLAC IN G O IL PUMP
R em oving
1. Drain engine oil.
2. Remove sum p (fig. 14-16).
3 Unscrew o il su ctio n pipe and o il pum p from c ra n k

case.
R ep la cing
1. Replace o il pum p and su ctio n pipe, tig h te n b o lts to
35 N.m (fig 15-16).
2. F it sum p o n to crankcase (Fit new sum p gasket if

necessary), and tig h te n b o lts to 25 N.m.
3. Replace o il drain plug, and tig h te n to 80 N.m. F ill

sum p w ith oil.
D IS M A N T LIN G PR IM AR Y O IL PUMP
D is m a n tlin g
1. Unscrew and remove suctio n pipe (fig. 16-16).
N o t e : ADE 423T/TI engines have pumps with 3 x 2 8 mm

gears. The following operations will in addition, also apply to
this type of three gear oil pump.
2. Remove b o lts from oil pum p cover (fig. 17-16).
7/90
Bcc B a rrin g to n Diesel Club) ADE 422, 423,424 Workshop Manual Section 16 - Lubrication System
LU B R IC A TIN G SYSTEM AN D SUMP - 16-9
3. L ift out oil pum p driven gear from o il pum p Body

(fig. 18-16).
Fig. 18-16
4. Using a s u ita b le puller, rem o ved rive g e a r(fig . 19-16).
5. Remove drive gear from oil pum p body (fig. 20-16).

LU BR IC ATIN G SYSTEM AN D SUMP — 16-10
A S S E M B LIN G PRIM ARY O IL PUMP

1. Insert driving gear w ith sha ft in to o il pum p body
(fig. 21-16).
2. Heat drive gear and drive or press on to drive sha ft

(fig. 22-16).
Note: The gear should be fitte d so th a t the drive sha ft

projects from the gear hub face by 0,5 mm.
3. Insert driven gear and sha ft in to oil pump body, (see

fig . 23-16).
4. Replace cover and bolts in oil pump body and tighten

to 25 N.m (fig 24-16).
5. A tta ch a dial gauge to the o il pump body.
6. Place probe pin o t dial gauge on to end of o il pump

sh a ft w ith pre-load.
7. Push oil pump sha ft down and set dial gauge to “ O” .
8. Push sh a ft or o il pump up, ag ainst dial gauge probe

pin and read end play.
Note: End play o f o il pump drive shaft should be

0,089 ± 0,039 mm.
Fig. 24-16
BCC B a r r i n g t o n D iesel Club ADE 422, 423,424 Workshop Manual Section 16 - Lubrication System
B d P r in g to n D iesel Club ADE 422, 423,424 Workshop Manual Section 16 - Lubrication System
LU BR IC ATIN G SYSTEM A N D SUMP - 16-12
6. Using a su ita b le puller, remove drive gear (fig. 29-16).
7. Remove drive gear and sha ft from o il pum p body

(fig. 30-16).
A S S E M B LIN G SECO NDARY O IL PUMP
1. Insert driving gear o f o il pum p in to pum p body

(fig. 31-16).
2. Heat drive gear fo r o il pump, and press on flush w ith

end o f drive sh a ft (fig. 32-16).
Fig. 32-16
BCC B a rrin g to n Diesel Club ADE 422, 423,424 Workshop Manual Section 16 - Lubrication System
LU B R IC A TIN G SYSTEM AN D SUM P - 16-13
3. Insert driven gear and sha ft in to o il pum p ,body

(fig. 33-16).
Fig. 33-16
4. Replace cover and b o lts in pum p body, and tig h te n

to 25 N.m (fig. 34-16).
5. A tta c h a d ia l gauge to o il pum p body.
6. Place probe pin o f dial gauge o n to end o f o il pum p

sha ft, w ith pre-load.
7. Push sh a ft o f o il pum p down, and set dial gauge to

■• 0" .
8. Push sh a ft o f o il pum p up, a g a in st dial gauge probe

and read end play.
9. Fit o il in ta ke pipe w ith new gasket, and tig h te n b o lts

to 25 N.m (fig. 35-16).
10. R eplace in te rm ed iate gear in oil pum p, and lock w ith

c irc lip (fig. 36-16).
Fig. 36-16
LU B R IC A T IN G SYSTEM A N D SU M P — 16-14
R E M O V IN G A N D R E P LA C IN G PRESSURE
R ELIEF VALVE
R em oving
1. Drain en gine oil.
2. Remove sum p (see fig. 7-16).
3. U nscrew pre ssure re lie f valve from cra n kca se

(fig. 37-16).
R e p la c in g
1. Fit pressure re lie f valve o n to cran kcase and tig h te n
b o lts to 35 N.m (fig. 38-16).
2. Replace sum p fitte d w ith new gasket, and tig h te n

b o lts to 25 N.m.
3. F ill sum p w ith oil.
R EM O VING AN D REPLAC IN G O IL SPRAY JET
R em o vin g
1. U nscrew ce n tre b o lt o f spray je t, and rem ove from
cra n kca se (fig. 39-16).
R e p la c in g
1. Check align m en t o f o il spray je t w ith special to o l part
num ber 40201937 (fig. 40-16).
2. Ensure th a t c a m s h a ft spray holes at spray je t base
are free from o b s tru c tio n .
3. Check tha t fu ll m ovem ent o f the spray je t valve w ith in
the cen tre b o lt is not re stricte d .
7/90
LU B R IC A TIN G SYSTEM A N D SUMP — 16-15
2. Insert o il spray je t so th a t dow el pin engages w ith

de tent in cra n kca se (arrow), and tig h te n to 47 N.m
(fig. 41-16).
R E M O VIN G A N D R EP LAC IN G O IL COOLER
R em oving
1. Unscrew c o o la n t drain plug from o il cooler, and drain
co o la n t (fig. 42-16).
2. Remove b o lts holding oil cooler to c ylin d e r block, and

rem ove c o o le r (fig. 43-16).
R e p la c in g
1. F it new ga sket to o il cooler.
2. Place oil coo le r on crankcase, insert bolts and tigh ten

to 50 N.m (fig. 44-16).
3. Insert coolant drain plug in cooler housing and tigh ten

to 50 N.m.
Fig. 44-16
LU B R IC A TIN G SYSTEM AN D SUM P - 16-16
D IS M A N T LIN G A N D A S S E M B LIN G OIL

COOLER
D ism antling
1. Unscrew and remove filte r bowl and cartridge.
2. Remove o il filte r plug (fig. 45-16).
Fig. 45-16
3. Remove o il drain plug.
4. Remove o il coo le r m ou ntin g b o lts, and remove oil

coo le r from housing (fig. 46-16).
5. Remove o il filte r bypass valve.
Fig. 46-16
A ssem bling
m
1. S tick gasket for oil cooler on housing using a suitable
sea la nt (fig. 47-16).
M ' -
N ote: F it gasket w ith g ra ph ite surface fa cin g oil cooler.
I
^ V ---------------------------------
r- \_ / — ^ X
Fig. 47-16
2. Replace o il co o le r and tig h te n b o lt to 25 N.m

(fig. 48-16).
3. Insert co o la n t drain plug and tig h te n to 50 N.m.
Fig. 48-16
BCC B a r r i n g t o n D iesel Club ADE 422, 423,424 Workshop Manual Section 16 - Lubrication System
LU BR IC ATIN G SYSTEM AN D SUMP — 16-17
4. Insert and tig h te n o il filte r plug to 60 N.m (fig. 49-,16).
5. Replace oil filte r bypass valve and tig h te n to 60 N.m

(fig. 50-16).
6. Fit o il filte r bowl w ith o il filte r c artridge to filte r body,

and tig h te n to 50 N.m.
Note: Remote mounted oil filters must be primed during filter

changes, i.e. fill filter bowl with clean engine oil before fitting
to the fitter head.
Fig. 50-16
7/90
LUBRICATING SYSTEM AND SUMP - 16-18
L U B R IC A T IO N CHART
1. Sump. 9. Injection pump.

2. Oil strainer. 10. Oil pressure switch.
3. Oil pump. 11. Crankshaft.
4. O il pressure relief valve. 12. Rocker arm.
5. Oil cooler. 13. Camshaft.
6. Oil filter. 14. Cam shaft spray and piston cooling jets.
7. F ilter bypass valve. . 15. Combined in each bank of cylinders.
8. Main oil gallery.
Bcc B a rrin g to n Diesel Club) ADE 422, 423,424 Workshop Manual Section 16 - Lubrication System
L U B R IC A T IN G SYSTEM A N D SU M P - 16-19
Oil C o o le r
1 Cover 14 W asher
2 H e lico il insert 15 Plug
3 H e lico il insert 16 O-Ring
4 F ilte r bow l 17 W asher
5 Seal 18 B olt
6 Plug 19 O il co o le r
7 F ilte r ca rtrid g e 20 G asket
8 Valve 21 S pring W asher
9 Spring 22 B olt ~
10 Plug 23 B olt
11 W asher 24 G asket
12 W asher 25 S pring w asher
13 Plug 26 B olt ~
Bcc B a r r i n g t o n D iesel Club) ADE 422, 423,424 Workshop Manual Section 16 - Lubrication System
L U B R IC A T IN G S Y S T E M A N D S U M P - 16-20
Double Oil Cooler

1 Housing 10 Bolt
2 Seal 11 Bolt
3 Plug 12 Bolt
4 Seal 13 Cover
5 Plug 14 Gasket
6 O il cooler 15 Spring washer
7 O il cooler 16 Bolt
a Gasket 17 Bolt
9 Gasket
BbC
ftdrrincjtoh Diesel Cltlb M e r c e d e s a n d A D E 4 2 2 , 4 2 3 ,4 2 4 W o rk sh o p M a n u al
S e c t i o n : F u e l S y s t e m
“ ( a r r i n g t o n D ie s e l C lu b M e r c e d e s a n d A D E 4 2 2 , 4 2 3 ,4 2 4 W o r k s l' ° P M a m la l
F U E L S Y S T E M — 17-2
Fuel System
In je c tio n p u m p a n d Q o v e r n o r B O S C H P r e v io u s C u rre n t
In ie c to r p r e s s u r e new 17 5 M P a 2 0 .0 — 2 0 .8 M P a
used m in 16 5 M P a m in . 1 7 .5 M P a
P r e s s u r e d if f e r e n c e s b e t w e e n in je c to r s 1 .0 M P a
T O R Q U E S P E C IF IC A T IO N S
D r i v e n g e a r to* i n j e c t i o n p u m p f l a n g e ................................ M8 35 N m
I n j e c t i o n p u m p t o c y l i n d e r b l o c k ....................................................... M 10 50 N m
I n j e c t o r s e c u r i n g n u t t o c y l i n d e r h e a d ....................................... M 2 8 x 1 .5 70 N m
I n j e c t o r p i p e n u t s ................................................................................................ M 1 4 x 1 .5 25 N m
F u e l f i l t e r b o w l t o f i l t e r h e a d ................................................................ M8 20 N m
F u e l filte r h e a d to s u p p o rt b r a c k e t .................. ......................... M 1 2 x 1 .5 80 N .m
F u e l f i l t e r s u p p o r t b r a c k e t to : C o v e r o f t i m i n g h o u s in g *
I n l e t m a n i f o l d ....................... M 12 x 1 .5 80 N .m
F u e l p ip e s to lif t p u m p , fu e l f ilte r a n d in je c tio n p u m p M 14 x 1 .5 30 N .m
F u e l r e t u r n p i p e t o i n j e c t i o n p u m p ................................................ M 14 x 1 .5 30 N m
F u e l r e t u r n p i p e t o f u e l f i l t e r b r a c k e t ............................................ M 16 x 1 .5 40 N .m
F u e l s y s t e m b l e e d s c r e w ......................................................... M8 15 N .m
I n j e c t o r n o z z l e t o n o z z l e h o l d e r ...................................................... M 22 x 1 .5 75 N .m
in s p e c tio n h o le p lu g (t im in g c o v e r) s e e s e c tio n 1 5
7/90
“ ( a r r i n g t o n D ie s e l C lu b M e r c e d e s a n d A D E 4 2 2 , 4 2 3 ,4 2 4 W o r k s l' ° P M a m la l
FUEL SYSTEM - 17-3
3 4
LAYOUT OF FUEL INJECTOR PIPES

Etc
Bdfpihcjton Diesel Cltlb M e r c e d e s a n d A D E 4 2 2 , 4 2 3 ,4 2 4 W o rk sh o p M a n u al
Etc
Etc
Etc
Etc
BdPPihcjton Diesel C ltlb M e r c e d e s a n d A D E 4 2 2 , 4 2 3 ,4 2 4 W o rk sh o p M a n u al
Etc
Etc
Etc
F ig 2 5 -1 7
F ig 2 6 -1 7
3 T u r n e n g in e to N o 1 c y lin d e r c o m p r e s s io n s tro k e to s ta rt
o f d e liv e r y ( 1 3 ° o r 1 5 ° B T D C ) u s in g tu rn in g to o l T h e e n
g in e m u s t n o t b e tu r n e d b a c k . V a lv e s o f N o t c y lin d e r
a r e c lo s e d a n d v a lv e s o f N o 6 c y lin d e r (A D E 4 2 2 ) a r e
ro c k in g (fig . 2 7 -1 7 )
N o t e : C e r ta in in d u s tria l a p p lic a tio n s m a y b e fitte d w ith

a p o in te r a n d m a r k o n th e v ib ra tio n d a m p e r , th is w ill o n ly
b e fitte d s h o u ld th e n o r m a l m a r k in g o n th e fly w h e e l b e
in a c c e s s ib le
4 T u r n c a m s h a f t o f m i e c t i o n p u m p u n t il m a r k o n d r iv e
f a n g e s a u g n e d w i t h m a r k o n m ie c t i o n p u m p b o d y .
5 in s e t n e * 0 'm g m t o b o r e o f o il f e e d in i n je c t i o n
pump DOO> if'5 28-’7'
F,g 28-17
7/90
Etc
Etc
Etc
Etc
^13® & ar*H ngt°n Diesel Club A D E 422, 423,424 W orkshop Manual S e c tio n : 18 - V a rio u s
S E C T IO N 18-1
A ir C om pressor
1 DRIVE GEAR 29 GASKET
2 CRANKSHAFT 30 SCREW
5 BOLT 31 SPRING WASHER
6 BEARING 32 CYLINDER HEAD
7 BEARING RETAINING PLATE 33 GASKET
8 SCREW 34 VALVE
9 FLANGE 35 VALVE PLATE
10 BUSH 36 VALVE PLATE HOLDER
11 SEALING RING 37 BOLT
12 CONNECTING ROD 38 GASKET
13 DOWEL 39 BOLT
14 BOLT 40 SPRING WASHER
15 BEARING SHELL 41 SCREW PLUG
17 CYLINDER LINER WITH PISTON 42 SEALING WASHER
18 CYLINDER LINER WITH PISTON 43 SCREW PLUG
21 PISTON RING 44 CONNECTION
22 PISTON RING 45 SEALING RING
23 PISTON RING 46 INTAKE PIPE
24 GUDGEON PIN 47 NUT
25 CIRCLIP 48 HOSE CLIP
26 PLUG
27 SCREW CONNECTOR
28 SEALING RING
^ a r r i n g t o n D iesel H u b A D E 422, 423,424 W orkshop Manual S e c tio n : 18 - V a rio u s
COMPRESSOR - 18-2
Air Com pressor
C ylin d e r 1
Bore 90
S tro ke 46
D is p la c e m e n t 292 cm 3
P ressure 810 kP a /1000 kPa
D elivery c a p a c ity 100 kPa 470 f/m in

a g a in s t
(en gine a t 2.300 r/m in) 810 kPa 400 f/m in
90.030
B o re d ia m e te r
90.000
89.950
P is to n d ia m e te r
89.910
0.08
P isto n cle a ra n ce
0 .1 0
P is to n re tru s io n fro m u p p e r 0.4

e d g e o f c y lin d e r lin e r 1 .2
2 0 .0 0 0
G u d geo n p in d ia m e te r
19.996
0 .0 2 0
G ud geo n pin c le a ra n c e in c o n ro d bush
0.037
0.003
G u d geo n pin c le a ra n c e in p is to n
0 .0 1 2
31.975
C ra n k s h a ft jo u rn a l d ia m e te r
31.959
P isto n ring gap G roove 1

0.35
G roove 2
0.55
G roove 3
0.25
G roove 4
0.40
P is to n rin g s id e c le a ra n c e G roove 1
G roove 2 0.520
G roove 3 0.052
G roove 4
Note: C y lin d e r lin e rs and p is to n w ill be s u p p lie d m a tc h in g th e given to le ra n c e u n d e r one part num ber.
f t d r r i n g t o n D iesel Club A D E 422, 423,424 W orkshop M anual S e c tio n : 18 - V a rio u s
* COMPRESSOR — 18-3
Air C o m p re s s o r (contd.)
36.016
C o n ro d b ig end bore
36.000
32.008
C o n ro d b e a rin g
31.994
105.00
L e n g th o f c o n ro d fro m C L big e n d /s m a ll end b o re
104.95
s m a ll end 20.060
W id th o f c o n ro d
20.000
19.935
b ig end
19.883
TORQUE SP E C IFIC A TIO N S
AIR COMPRESSOR
F ittin g s — suctio n /p re ssu re pipe to c y lin d e r head ....... M 2 6 x 1,5 80 N.m

C om pressor drive gear to c a m s h a ft................................... M10 65 N.m
Driven gear to a ir com p resso r cra n ksh a ft ....................... M18 x 1,5 without special tool 360 N.m
with special tool 270 N.m
A ir com p resso r cylin d e r barrel to tim in g housing ......... M8 30 N.m
C o nn ecting rod to cran ksha ft .............................................. M8 30 N.m
Pressure valve to in te rm ed iate plate ................................. M6 14 N.m
Interm e dia te plate to cylin d e r head ................................... M8 30 N.m
C ylind er head to c y lin d e r barrel .......................................... M8 30 N.m
Inner bearing cage to tim in g housing ............................... M8 25 N.m
Inner bearing re taining plate to cage ............................... M8 50 N.m
Steering pum p o r cover to tim in g housing ...................... M10 60 N.m
B lanking plug s air com pressor c y lin d e r head ................ M22 x 1,5 80 N,m
M 26x 1,5 80 N.m
F ittin g — C o ola nt sup ply to cylin d e r barrel .................... M14 x 1,5 50 N.m
F ittin g — C o ola nt return to cylin d e r head ....................... M 22x 1,5 80 N.m
C o ola nt pipes to fittin g s ........................................................ M 16x 1,5 35 N.m
A ir com p resso r blanking plate (tim in g h o u s in g )............ M8 25 N.m
A ir com p resso r blan king plate c ra n k c a s e ........................ M8 30 N.m
ALTE R N ATO R A N D STARTER MOTOR
A lte rn a to r su p p o rt bracket to cylin d e r b lo c k ................... M14 160 N.m

S upport bracket to a lte r n a to r ............................................... M10 50 N.m
A lte rn a to r a d ju stin g b o lt to sum p ...................................... M10 50 N.m
A d ju stin g b o lt cla m p to a lte rn a to r ..................................... M 12x 1,5 35 N.m
A lte rn a to r pu lle y re taining n u t ............................................. M 14x 1,5 55 N.m
M24 x 1,5 140 N.m
S tarter m otor to tim in g housing .......................................... M 12x 1,5 80 N.m
7/90
+m D iesel Club A D E 422, 423,424 W orkshop Manual S e c tio n : 18 - V a rio u s
COMPRESSOR - 18-4
In tro d u ctio n
The ADE 420 S eries Engines are fitte d w ith a sin g le c y

lin d e r w a te r cooled W estin g h o u se air com pressor,
m ounted on the tim in g housing and driven by gears. The
com p resso r provides a ir fo r the use in the veh icle brak
ing system , and the o p era tion of a n c illa ry air devices.
REMOVING, DISMANTLING, ASSEMBLING,

AND REPLACING AIR COMPRESSOR
D ism antling
1. U nscrew c o o la n t feed pipe from c y lin d e r head
(fig. 1-18).
Fig. 2-18
4. Remove tim in g case to p cover.
5. Remove end cover from tim in g case.
6 . Unscrew and remove cylinder head, w ith suction valve

(fig. 3-18).
Fig. 3-18
COMPRESSOR - 18-5
7. Unscrew and remove cylinder barrel (fig. 4-18).
8 . Remove c irc lip s and push out gudgeon pin from

pisto n (fig. 5-18).
9. Remove connecting rod bearing bolts. L ift o ff bear

ing cap, w ith bearing shells, and pull out connecting
rod (fig. 6-18).
10. Unscrew and remove power steering pump, from end

o f com pressor, and take o ff drive plate (fig. 7-18).
Fig. 7-18
COMPRESSOR — 18-6
11. Turn cran ksha ft toT D C , and insert lo cking tool, Part
num ber 40201238 and b o lt down (fig. 8-18).
Fig. 8-18
12. Unscrew and remove drive gear using special tool,

Part num ber 40201225.
13. Unscrew and remove cran ksha ft lo cking tool.
14. Lever out crankshaft from bearings, so that rear bear

ing flange can be removed. Lift crankshaft out through
top o f housing (fig. 9-18).
15. Remove bearing retaining plate (fig. 10-18).

16. Unscrew inner bearing cage bo lts from tim in g case.
Fig. 10-18
17. Using a suitable puller remove bearing and cage from

tim in g case (fig. 11-18).
Fig. 11-18 *
^l3® & ar*H ngt°n Diesel Club A D E 422, 423,424 W orkshop Manual S e c tio n : 18 - V a rio u s
COMPRESSOR — 18-7
18. Using a special puller Part number 40201160 and sup

port, Part num ber 40200585, pull bearing from cage
(fig. 12-18).
Fig. 12-18
19. Knock or press bush from bearing flan ge using a

suita ble d rift (fig. 13-18).
20. Unscrew and remove valve plate from cylin d e r head.
21. Remove exhaust valve retaining b o lts and remove

valve.
Fig. 13-18
Assem bling
1. Check co n d itio n of exhaust valve and renew if
necessary, the valve m ust not be scored or d isto rte d
(fig. 14-18).
Fig. 14-18
2. Place exhaust valve on valve plate, curved surface

facin g upwards. Insert bo lts and tig h te n to 14 N.m
(fig. 15-18).
F it valve plate to cylinder head, and tig h te n bo lts to

30 N.m.
Fig. 15-18
COMPRESSOR — 18-8
3. K no ck bush in to bearing fla n g e w ith a s u ita b le d rift

and ream to size 30,020 to 30,041 m m (fig. 16-18).
Note: Ensure th a t o il d rillin g s in bush and fla n g e are in

a lign m en t.
4. Using a s u ita b le d rift kno ck bearing in to fro n t fla n g e

(fig. 17-18).
5. Insert bearing flange in to tim in g case and locate w ith

2 b o lts (fig. 18-18).
6. K nock in bearing fla n g e w ith a s u ita b le d rift replace

all b o lts and tig h te n to 25 N.m (fig. 19-18).
Fig. 19-18
COMPRESSOR — 18-9
7. Insert bearing retaining plate, and bolts, tigh ten to 50

N.m (fig. 19-18).
8. Insert crankshaft, w ith balance w e igh ts facing

upwards in to crankcase and knock in to bearing w ith
a so ft hammer.
Fig. 20-18
9. Lubricate rear bearing bush, fit new O-ring to flange

and insert in to crankcase ensuring th a t o il d rillin g s
are in a llig nm e nt (arrowed) (fig. 21-18).
Fig. 21-18
10. Insert bolts in to bearing flange and tigh ten progres

sively (fig. 22-18).
Fig. 22-18
11. Remove bolts from flange.
12. Insert locking tool, and bolt down.
13. Replace drive gear for com pressor (fig. 23-18).

COMPRESSOR — 18-10
14. T igh te n drive gear b o lt to 270 N.m using spe cia l too l
Part num ber 40201225 (fig. 24-18).
Note: The fig u re o f 270 N.m is equal to 360 N.m w ith o u t

using the spe cia l tool.
Fig. 24-18
15. Remove lo ckin g to o l (fig. 25-18).
16. Replace pow er steering pump and tig h te n b o lts to 60

N.m.
17. Insert c o n n e ctin g rod, beairings, bearing cap and

bo lts. T igh te n b o lts to 30 f'i.m.
Fig. 25-18
18. Place pisto n over con ne cting rod and in sert gudgeon
pin.
19. Insert c irc lip s and lo ck gudgeon pin (fig. 26-18).
Fig. 26-18
20. O ffset piston rings by 180° to each other. Using piston

ring cla m p Part num ber 40201212, com p ress rin gs to
o u te r dia m e te r o f pisto n, a llo w in g s lig h t m ovem ent
o f clam p.
21. Insert p is to n in to c y lin d e r barrel, fitte d w ith new

gasket, and push in. Remove ring cla m p (fig. 27-18).
Fig. 27-18
80C fta r r in g to n Diesel Club A D E 422, 423,424 W orkshop Manual S e c tio n : 18 - V a rio u s
COMPRESSOR - 18-11
22. B olt on cylinde r barrel to tim in g case, and tig h te n to

25 N.m.
23. Place inlet valve plate over lo catin g pins on cylinder

head (fig. 28-18).
24. Fit cylinde r head gasket, w ith the word “ TOP” fa c

ing in le t valve, over lo catin g pins on cylinde r head.
25. Replace cylinde r head and tigh ten b o lts to 30 N.m.
26. Replace and tig h te n b o lts o f tim in g case top cover

to 25 N.m in sequence shown in (fig. 29-18).
27. Fit end cover of tim in g case and tigh ten bo lts to 25
N.m.
28. Reconnect a ir pressure feed pipe and in d u ctio n feed

hose to cylinde r head (fig. 30-18).
Fig. 30-18
29. Reconnect co o la n t feed pipe to cylin d e r head

(fig. 31-18).
Fig. 31-18
SEC TIO N 18-13

Flywheel
Flywheel
1 RING GEAR
2 WEAR RING
3 FLYWHEEL
4 FLYWHEEL BOLT
^ a r r i n g t o n Diesel H u b A D E 422, 423,424 Workshop Manual S e c tio n : 18 - V a r io u s
FLYW HEEL — 18-14
Flywheel
432.645
D ia m e te r fo r s ta rte r rin g gear
432.490
115.015
D ia m e te r fo r w e ar sle eve (Rear seal)
114.980
M a xim u m m a te ria l rem oval from c lu tc h su rfa ce 2.0
M ax. rad ia l ru n o u t m easured on w e ar sleeve lo c a tin g su rfa c e 0.05
M ax. ra d ia l ru n o u t m easured on s ta rte r rin g gear lo c a tin g su rfa ce 0.1
M ax. ra d ia l ru n o u t on c lu tc h lo c a tin g fla n g e 0.05
Max. la te ra l ru n o u t on c lu tc h fric tio n su rfa ce 0.1
TORQUE SPECIFICATION
FLYW HEEL AND HOUSING
Flywheel to crankshaft ................................................................. M16 x 1,5 Initial torque 100 N.m

Final torque 9 0 °— 100°
New dual hexagon bolts Initial torque 200— 220 N.m
Final torque 9 0 °— 100°
Max. stretch length Bolt length 74 mm — max. 75 mm
80 mm — max. 81 mm
Flywheel (timing) housing to cylinder block (see section 15) 85 mm — Max. 86 mm
Top cover to tim ing housing (see section 15)
7/90
80C ^ a rrin g to t» Diesel Club A D E 422, 423,424 W orkshop Manual S e c tio n : 18 - V a rio u s
FLYWHEEL — 18-15
S tarter Ring Gear
432.155
R ing g e ar in s id e d ia m e te r
432.000
R ing gear c le a ra n ce 0 .3 3 5 -0 .6 4 5
In s ta lla tio n te m p e ra tu re fo r fittin g 2 0 0 -2 3 0 ° C

s ta rte r rin g gear (yellow colour)
M ax. la te ra l ru n o u t o f m o u n te d s ta rte r rin g gear 0.5
18.6
Ring gear w id th
18.4
* 3 ® B a rrin g to n Diesel Club A D E 422, 423,424 W orkshop Manual S e c tio n : 18 - V a rio u s
FLYW HEEL — 18-16
REMOVING AND REPLACING FLYWHEEL
Removing
1. Loosen m ou ntin g b o lts on flyw heel. Unscrew tw o o p
po site b o lts, screw in guide m an dre ls Part num ber
40200077 (fig. 32-18).
2. Remove re m a in in g flyw h e e l b o lts, scre w in F lyw heel

P o sitio n in g H andles Part num ber 40201982 and slide
o ff flyw h e e l (fig. 33-18).
3. Remove g u id e m an dre ls and flyw h e e l p o s itio n in g

handles. Clean and che ck flyw h e e l fo r dam age.
Replacing
1. Screw g u id e m an dre ls in to end o f cra n k s h a ft and

flyw heel p o sitio n in g handles in to flyw heel (fig. 34-18).
2. Place flyw h e e l on m an dre ls and push in a g a in st end

o f cra n ksh a ft.
Note: Ensure that locating dowel in crankshaft is aligned with

hole in flywheel.
3. M easure le n g th o f flyw h ee l b o lts (fig. 35-18).
Note: Flyw heel b o lts m ay s till be used if stre tch does not
exceed 75 mm.
7/90
FLYWHEEL — 18-17
4. L ig h tly o il threads o f flyw heel bolts, screw in tw o

bolts, remove guide m andrels and flyw heel p o s itio n
ing handles. Replace rem aining flyw heel bolts.
5. Tighten flywheel bolts crossw ise to 100 N.m and then

to a fu rth e r torque angle of 90° + 1 0 ° (fig. 36-18).
REMOVING AND REPLACING WEAR RING

ON FLYWHEEL
Removing and Replacing

1. Using a suitable puller and support pad, pull wear ring
from flyw heel (fig. 37-18).
2. Heat new wear ring to approxim ately 150°C.
3. Insert new wear ring in to m andrel Part num ber

40200268 (rounder edge o f outside diam e te r facin g
forward). Place m andrel on flyw heel and knock in to
po sitio n (fig. 38-18).
REMOVING AND REPLACING SPIGOT

BEARING
Replacing spigot bearing

1. Using su ita b le d rift, kno ck out spigo t bearing from
flyw h ee l (fig. 39-18).
Fig. 39-18
FLYW HEEL - 18-18
2. Turn over flyw h ee l, insert new s p ig o t bearing and

kno ck in to flyw h ee l (fig. 40-18).
Fig. 40-18
N ote: The s p ig o t bearing can be removed and replaced

w ith the flyw h e e l in p o s itio n using p u lle r Part num ber
40200064. This requires rem oving the flyw h e e l m ou ntin g
bo lts, and in se rtin g both guide m andrels. R eplace and
tig h te n flyw h ee l b o lts to s p e c ific a tio n (fig. 41-18).
Fig. 41-18
M ACHINING FLYWHEEL
O peration
N ote I: To de te rm in e if the flyw h ee l can s till be m a ch in
ed, m easure the th ickn e ss o f the flyw h e e l and com pare
the figures w ith spe cifica tion. If the m easurem ent is lower
tha n the s p e c ifie d value, m inus m aterial rem oved, the
flyw h e e l can no long er be used, and m u st be replaced.
1. To m achine, cla m p flyw h ee l in to a s u ita b le lathe,

m ach in e and su rfa ce grind face (fig. 42-18).
2. Remove flyw h ee l and che ck once m ore for surface

heat cracks.
N ote II: If the flyw h e e l is s till cracked a fte r m ach in ing ,

and the cracks cannot be removed to retain spe cifica tions
fo r flyw h ee l th ickn e ss, renew flyw h ee l.
3. Using com pressed air, clean sw arf from tapped holes

fo r c lu tc h pressure plate atta ch m e n t.
4. R eplace flyw h ee l, and tig h te n b o lts to s p e c ific a tio n .
Fig. 42-18
FLYWHEEL - 18-19
RENEWAL OF STARTER RING GEAR '
Operation
1. Remove flyw heel (see page 18-16).
2. Place flywheel under a press. Support starter ring gear

at several points, using supports o f uniform height.
3. Rapidly heat starter ring gear w ith a w e lding torch,

and press flyw heel from ring gear.
4. Check seating of ring gear on flywheel for score marks

m achine if necessary to sp e cifica tio n s.
Note I: Renew flyw heel if score m arks are excessive.
5. Heat new ring gear to spe cifie d tem perature (see Fig. 43-18
spe cifica tions), and press on to flyw heel.
N ote II: When fittin g new starter ring gear to flyw heel,
make sure th a t the ring gear is pressed on squarely. Ring
gears on w hich teeth are damaged, can be turned around
and used again.
Note III: In some instances where no drillings are provided

for the bo lts holding the clu tch pressure plate, it w ill be
necessary to d rill and tap the ring gear M 1 0 x1 5 m m
(fig. 43-18).
6. When cooled, check flywheel and ring gear for run-out.
7. Replace flyw heel, (see page 18-16).

SECTIO N 18-21
Turbocharger
Turbocharger
1 Bearing housing 21 Bolt

2 C irclip 22 Turbine housing
3 Bearing 23 Nut & bolt
4 O-ring 24 S pringw asher and turbine
5 Turbine wheel and shaft side cla m pin g segm ent
6 Piston type seal rings
7 Heat shield
8 T hrust washer
9 Spacer
10 Bearing (Thrust)
11 Seal carrier/Thrust washer
12 O il d e fle cto r
13 Rivet
14 Data plate
15 End plate
16 Allan cap screw
17 C om pressor wheel
18 S haft nut
19 C om pressor housing
20 Springw asher and com pressor
side clam ping segm ent
T U R B O C H A R G E R — 1 8 -2 2
T u rb o ch a rg e r and M a n ifo ld
1 Turbocharger 14 Air intake pipe

2 Turbocharger 15 Hose
3 Nut 16 Hose
4 A ir intake manifold 17 Bracket
5 Air intake manifold 18 Bolt
6 Threaded insert 19 Adapter
7 Spring washer 20 Seal
8 Gasket 21 A ir transverse pipe
9 Bolt 22 Gasket
10 Bolt 23 Bolt
11 Plug 24 Seal
12 Seal 25 PLug
13 Plug 26 Shield
27 Bolt
7/90
TURBOCHARGER — 18-23
T urbocharger C ross-section
TORQUE S PEC IFIC ATIO N
TURBO CHARG ER
O il return m anifold to tu rb o c h a rg e r................................... M8 25 N.m

Securing nut fo r o il return fittin g to tim in g housing (side) M 2 6 x 1,5 30 N.m
O il return tube fittin g to tim in g housing ( to p ) ................ M 2 6 x 1.5 120 N.m
Inlet m an ifold to cylin d e r h e a d s ......................................... M8 25 N.m
Turbocharger to exhaust m an ifold ..................................... M10 50 N.m
O il supply pipe to tu rb o c h a rg e r.......................................... M8 25 N.m
O il supply pipe to cylin d e r b lo c k ........................................ M 1 4 x 1,5 25 N.m
Heat shield to tim in g housing (42 2T )................................. M16 150 N.m
Heat shield to oil return m an ifold (424T )......................... M8 25 N.m
C onnecting m anifold to in let m an ifold LH-RH ............... M10 50 N.m
Air transverse pipe ..................................................................... M8 25 N.m
7/on
TURBOCHARGER - 18-24
Introduction
The G arrett/AiR esearch Turbocharger for internal co m

bustion engine application com prises of a gas turbine and
radial compressor, which utilize a com mon shaft. The tur
bine and com pressor w heels are m ounted at opposite
ends o f the shaft, w hich is enclosed and supported by
the centre housing.
The turbine and com pressor wheels are enclosed by cast

housings attached to the centre housing.
A fte r the engine is started, the flo w o f exhaused gases

from the engine pass throu gh t the tu rbine housing and
cause the sha ft assem bly to rotate. The com pressor
wheel mounted at the opposite end of the shaft draws am
bien t air in to the com pressor housing, com presses the
air and delivers it to the engine.
During operation, the turbocharger responds to the engine

load dem ands by reacting to the flo w of exhaust gasses.
As the power o f the engine increases, the flo w o f the
exhaust also increases and the speed and ou tput of the
ro ta tin g assem bly increases proportionately.

TURBOCHARGER
Removing
1. Unscrew exhaust pipe from turbo cha rge r m anifold.
2. Unscrew air pipe from exhaust brake cylinder.
3. Remove o il feed and return pipes to turbocharger, (fig.

44-18).
4. Unscrew a ir intake hose clips (fig. 45-18).
Fig. 45-18
5. Remove m an ifold between turbo cha rge r a n d 'co o le r

(fig. 46-18).
6 . Unscrew turbo cha rge r from exhaust m an ifold and

remove.
Replacing
Note: Prior to replacing turbocharger, the intake m anifold,

and m an ifold flange ahead o f the com pressor, exhaust
m anifold, and exhaust pipe, as w ell as oil feed and return
pipes, m ust be inspected thoroughly fo r foreign particles,
d irt and dam age. B lanking plugs on openings o f tu rb o
charger sho uld be removed sh o rtly before replacem ent.
F ill bearing housing w ith clean engine oil throu gh o il in
let, before con ne cting o il feed pipes. Turn ro ta tin g parts
by hand to give bearings a co a tin g o f oil.
1. Fit turbocharger w ith new gasket to exhaust manifold,

and tig h te n bo lts to 50 N.m.
2. Replace and tig h te n m an ifold between turbo cha rge r

and a ir coo le r (fig. 47-18).
3. C onnect o il feed and return pipes to turbocharger.
4. Replace a ir inlet hose clam ps and tigh ten (fig. 48-18).
5. Replace a ir in le t pipe to exhaust brake.
6 . A tta ch exhaust pipe to m an ifold and tig h te n b o lts to

sp e cifica tio n .
Fig. 48-18
B0C ^ a r r in g to n Diesel Club A D E 422, 423,424 W orkshop Manual S e c tio n : 18 - V a rio u s
TURBOCHARGER TROUBLESHOOTING
C o n d itio n Possible Cause C o rrection
U nusual exhaust gas d e n sity and In s u ffic ie n t a ir and charge C heck fla n g e and hose co n
pow er loss. pressure to low. n e ctio n s o f tu rbo cha rge r air pipe
fo r leaks.
D irt on in sid e o f com p resso r Remove and clean com p resso r

housing. housing.
C logged a ir cleaner (excessive Clean a ir cle an er o r replace

vacuum ahead o f com pressor, filte r ca rtrid g e . Check intake.
a lso o il leak on com p resso r Check pipe behind tu rbo cha rge r
side.) fo r leaks.
Exhaust pipe behind tu rb o Clean or repair. Check opening

charger, o r sile n ce r d irty o f engine brake valve.
o r damaged.
Unusual noise (e.g. w h istle) Leaks at c o n n e ctio n s and Check flan ge and hose con ne c
fla n g e s o f air and exhaust tio n s, rep la cing gaskets if
pipes. necessary.
R otor scrap in g due to Remove pipes and che ck housing

excessive bearing play. on tu rb in e and com pressor
sides fo r sig n s o f scraping.
Repair o r replace turbo cha rge r
in case o f wear.
C hecking Turbocharger in vehicle
D isco n n e ct a ir in ta ke m an ifold. Turn rotor, che ckin g fo r easy and u n ifo rm running. If necessary turn back and fo rth several
tim e s u n til ro to r is freed o f o il carbon deposits.
The turb o ch a rg e r ro to r has g yro sco p ic s ta b iliz a tio n , and runs in fixe d bearings. To check, move ro to r.in and out. If there
is no c o n ta c t on the tu rb in e or charger sides, th is m eans th a t the end play is corre ct. Move and turn th e ro to r up and down,
if no scrap in g occurs, th e side play is a lso correct.
T urbocharger o il leaks
The bearing ho using on all types o f tu rb o ch a rg e rs used If o il covered in le t po rts are found when servicing,
on ADE engines are fitte d w ith oil c o n tro llin g piston type there is no reason to remove the turb o ch a rg e r as long as
rings, to provide a seal between the oil and the air/exhaust an in sp e ctio n o f the turb o ch a rg e r did not show defects.
gas. The fu n c tio n o f these seals is based on the pressure A n o th e r cause fo r o il leaks cou ld be a dam aged
b u ilt up in th e com pressor housing. However there could (deform ed) or clo g g e d o il return pipe. The reduced cross
be a vacuum at fa s t idle speed of w h ile co a stin g , w h ich s e ctio n size o f th e pipe w o u ld lead to an increase in flo w
would favour oil leakage and coating o f the inlet ports with resistance, causing the oil level in the turbocharger to rise
o il. The am o un t o f o il lo st in th is way is extrem e ly low and o il to leak past the seals on the turbine and co m
and has no, m easurable in flue nce on th e engines oil pre ssor sides. In th is case clean o r replace the oil return
c o n su m p tio n . pipe. '
F ittin g a R econditioned Turbocharger
Prior to fittin g th e turbo cha rge r, the in le t and flanged

m an ifold ahead o f the com pressor, the exhaust m an ifold
and the exhaust pipe, as w e ll as the o il feed and return
pipes, m ust be in spe cte d very th o ro u g h ly fo r d irt and
dam age. Plugs on the op en ing s of th e turb o ch a rg e r
should be removed only shortly before fitting . F ill the bear
ing housing w ith clean engine oil through the o il inlet port
before co n n e ctin g th e o il feed pipe. In d o in g so, turn the
ro ta tin g parts by hand to give the bearings a coa t of oil.
& ar*H ngt°n Diesel Club A D E 422, 423,424 W orkshop Manual S e c tio n : 18 - V a rio u s
CHECKING TURBOCHARGER
M easuring Shaft End Play

1. Clamp turbocharger in a vice fitte d w ith soft jaw s (tur
bine side facin g up).
2. Fit dial gauge in holder.
3. Place dial gauge m easuring tip on sh a ft end o f tu r

bine wheel (fig. 49-18).
4. Push down turbine sha ft and set dial gauge to “ 0” .
5. Push turbine shaft up against dial gauge and read end

play. M axim um perm itted end play = 0 ,1 6 mm.
M easuring Side Play

Note: Side play is m easured only on tu rb in e side.
1. Push turbine wheel to one side, measure gap between

turbine wheel and housing w ith a feeler gauge, note
m easurem ent (fig. 50-18).
2. Push tu rb in e wheel in op po site directio n, measure

gap at the sam e point w ith a feeler gauge, note
m easurem ent.
3. The diffe re nce between the tw o m easurem ents is the

clearance = 0,45 mm.
Note: Measure at least tw o d iffe re n t points.
Fabricated Tool
A K n u rle d s u rfa c e
Fig. 51-18 B A d a p te d to a v a ila b le ro to r
TURBOCHARGER — 1828
DISMANTLING AND ASSEMBLING

TURBOCHARGER
D ism antling
N ote: Clam p is self-m ade to draw ing on page 18-27.
1. M ark po sitio n of tu rb in e housing in relation to bear

ing housing.
2. U nlock lo cking plates on cla m pin g segm ents of tu r

bine housing (fig. 52-18).
Fig. 52-18
3. Unscrew b o lts from turbine housing and remove w ith

cla m pin g segm ents and lock plates.
4. Using a soft faced hammer knock turbine housing and

bearing housing apart (fig. 53-18).
Note: Ensure th a t blades o f turbo cha rge r are not da m ag

ed when rem oving housing.
Fig. 53-18
5. M ark p o s itio n o f bearing housing in relatio n to co m

pressor back plate and com pressor housing (fig.
54-18).
Fig. 54-18
6 . Unscrew com p resso r housing from back plate (fig.

55-18).
7. Loosen and remove com pressor housing from bear

ing housing, w ith lig h t knocks from a so ft faced
ham m er.
Note: Ensure th a t blades of com p resso r are not dam ag

ed when rem oving com p resso r housing.
Fig. 55-18
8. Insert bearing housing in to clam p (self made), and

unscrew com pressor sh a ft nut (fig. 56-18).
Note: When unscrew ing sha ft nut, do not damage the

sh a ft by tw is tin g . Alw ays use a T-socket spanner to
unscrew sha ft nut, to avoid bending shaft.
9. Heat com pressor wheel w ith suita ble hot air blower
(fig. 57-18).
10. Press sha ft from com pressor wheel (fig. 58-18).
Note: The heat shield should be centred to avoid damage

to piston ring seals and shielding.
11. Remove bearing housing and heat shield from shaft.
12. Unscrew com pressor back plate and remove with seal
and O-ring (fig. 59-18).
Fig. 59-18
13. Remove o il d e flector (4), spacer (3), thrust bearing (2),

and th ru st washer (1) (fig. 60-18).
14. Remove com pressor bearing from housing (fig. 61-18).
15. Remove c irc lip s and turbine bearings from bearing

housing (fig. 62-18).
ASSEMBLING
Note: Clean and check all parts fo r damage. Check hous

ing and blades of tu rbine and com pressor w heels for
cracks, signs of foreign p a rticle s and scraping. Check
pisto n ring type seals and grooves fo r wear.
1. Check turbocharger rotor shaft for run out. Place shaft

on tw o V-blocks at height of bearings and measure
run-out 20 mm from end o f rotor shaft, using a dial
gauge. M axim um perm issible run-out = 0,007 mm,
(fig. 63-18).
Fig. 63-18
J f lrH n g to n D iesel Club A D E 422, 423,424 W orkshop M anual S e c tio n : 18 - V a rio u s
2. Insert c irc lip in bearing housing, lu b rica te turbine

end bearing w ith engine oil, and insert w ith 2nd circlip
(fig. 64-18).
N ote: Insert c irc lip s so th a t the rounded side faces

bearing.
3. Turn bearing housing around and insert com pressor

end bearing w ith circlip s.
4. Insert seal rings on to shaft, w ith gaps set at 180° in

relation to each oth er (fig. 65-18).
5. Place heat shield over seal rings on rotor sha ft (fig.

66-18).
6. Fit bearing housing over seal rings, so th a t the seal

ring gap is at 90°, in relation to the o il in let and ou tlet
flan ge s (fig. 67-18).
Note: The heat shield should s till turn easily a fte r fittin g
the bearing housing.
Fig. 67-18
7. Insert th ru st washer (1) and spacer (3). F it th ru st bear

ing (2) w ith oil groove facin g bearing housing, and
dowel pin holes in alignm ent w ith dowel pins in bear
ing housing. Fit o il d e fle cto r (4) (fig. 68-18).
Fig. 68-18
8. Lubricate O-ring w ith brake c y lin d e r grease, and in

sert in to com pressor end plate (fig. 69-18).
9. Insert seal rings on to seal carrier w ith gaps set at 180°

in re la tio n to each other.
10. F it seal ca rrier w ith seal rings in to com p resso r end
plate, so th a t the pisto n ring gap is at 90°, in relatio n
to the o il in let and o u tle t flanges.
Fig. 69-18
11. C oat sea lin g surface between bearing housing and

com p resso r end plate, w ith a su ita b le sealing
com pound.
12. F it com p resso r end plate, lin in g up m arks on bear

ing housing. Coat bolts w ith Loctite, insert and tighten
to 8 N.m (fig. 70-18).
Fig. 70-18
13. Fit O-ring to com pressor end plate (fig. 71-18).
Fig. 71-18
14. Heat com pressor wheel to a maximum of 130°, and

fit onto rotor shaft (fig. 72-18).
15. Coat rotor sha ft nut w ith Loctite, and fit to shaft,
tigh ten nut to 12 N.m (fig. 73-18).
16. Fit com pressor housing, lining up marks on com

pressor end plate. Fit clam ping segments, insert
bolts, and tigh ten to 7 N.m (fig. 74-18).
17. Attach turbine housing, lining up w ith marks on bear

ing housing. Fit clam ping segm ents, and lockplates.
Insert bolts with high temperature grease, and tighten
crossw ise to 20 N.m.
18. Lock m ounting bolts (fig. 75-18).
19. Check turbocharger shaft for free running.
Note: F ill bearing housing through oil in le t port w ith

engine oil prior to operating turbocharger.
Fig. 75-18
EXHAUST BRAKE - 18-34
Introd u ction
Depending on application the ADE 420 Series Engines are

fitte d w ith an exhaust brake consisting of a butterfly valve,
w h ich pivots on a spind le w ith in the exhaust m anifolds.
The b u tte rfly valves are situated at the flywheel end of
each m anifold. The bu tte rfly valves are actuated by a
pneum atically operated lever, which is secured to the but
terfly valve spindles, where the spindles protrudes through
the housing.
When the foot-operated exhaust brake valve (located
on the flo o r o f the cab, drivers side) is pressed, co m
pressed air flow s past the valve and enters an air operated
cylinder. A piston, inside the cylinder and attached to the
spind le levers, pushes the levers tow ards the rear o f the
vehicle and thus closes the b u tte rfly valves. At the same
tim e, the fuel supply to the injectors is cut o ff (ie the speed
con tro l lever moves to the stop position). The back
pressure build up in the exhaust m anifold exerts a brak
ing e ffe ct via the transm ission, to the wheels o f the
vehicle.
CHECKING EXHAUST BRAKE
Checking exhaust brake adjustm ent

1. Unscrew and remove exhaust pipe from m anifold.
2. Check to see if the engine brake retarder valve is wide

open, and marks on engine brake shaft, and valve are
in align m en t (fig. 76-18).
3. Operate engine brake and check to see if retarder flap

is closed com p le te ly (fig. 77-18).
REMOVING AND REPLACING EXHAUST

BRAKE VALVE AND SHAFT
Removing
1. Unscrew and remove exhaust pipe from m anifold.
2. D isconnect engine brake cylinder.
3. Unscrew and remove lever operating brake valve.
4. Remove spacer and bracket (fig. 78-18).
Fig. 78-18
EXHAUST BRAKE — 18-35
5. Knock out engine brake shaft, and remove valve

(fig. 79-18).
Fig. 79-18
6. Gently knock out shaft bushes from exhaust manifold,

(fig. 80-18).
Fig. 80-18
R eplacing
1. Knock new shaft bushes in to exhaust m anifold, so
that the engine brake valve has an end play of 0,2 to
0,5 mm (fig. 81-18).
Fig. 81-18
2. Insert engine brake shaft through valve, so that mark

ing on shaft is in alignm ent w ith engine brake valve,
(fig. 82-18).
Fig. 82-18
B a rr in g to n Diesel Club A D E 422, 423,424 W orkshop Manual S e c tio n : 18 - V a rio u s
EXHAUST BRAKE — 18-36
3. Fit stop bracket over valve operating sha ft and insert

spacer.
4. F it brake op era ting lever onto shaft, so th a t w ith the

valve fu lly open the brake cylin d e r can be fitte d
w ith o u t te n sio n (fig. 83-18).
Fig. 83-18
Note: Fine adjustm ent can be made on the brake cylinder.

On turbocharged engines the stop o f the valve operating
lever m ust rest against the bracket, when the engine brake
valve is fu lly open (fig. 84-18).
5. T ighten cla m p bolt o f engine brake cylin d e r so th a t

the sh a ft has an end play of 0,2 to 0,5 mm.
6. F it engine brake cylinder.
7. O perate engine brake and check to see if the engine

brake valve is fu lly closed.
8. Replace exhaust pipe, fitted with a new gasket, and

securely tighten nuts.
R EM O VING AN D REPLACING
STARTER MOTOR
R em oving
1. D isconnect battery.
2. D isconnect cables to starter m otor.
3. Unscrew and remove m ounting nuts (fig. 85-18).
4. Remove s ta rte r m otor from below.
R eplacin g
1. Fit starter m o to r on to stud s from below (fig. 86-18).
2. Replace nuts and tig h te n to 80 N.m.
3. C onnect cab le s to s ta rte r m otor.
4. C onnect battery.
7/90
SEC TIO N 18-37

A lternator and Starter M otor
SECTIONAL VIEW OF THE K 1 CLAW-POLE ALTERNATOR

B0C ^ d r r i n g io n Diesel Club A D E 422, 423,424 W orkshop Manual S e c tio n : 18 - V a rio u s
ALTERNATOR AND STARTER MOTOR — 18-38
ALTERNATOR (a) Regularly inspect the driving belts for wear and cor
rect tension. It is im portant to ensure that all belts on
Precautions a m ultiple belt drive have equal tension and are each
carrying the ir share of the load. Slack belts w ill wear
The diodes in the alternator fun ction as one-way valves
rapidly and cause slip w hich w ill not drive the alter
and the transisto rs in the regulator/control box operate
nator at the required speed. Drive belts w hich are too
as fast sw itches. Both are accurate and sensitive.
tigh t impose severe side thrust on the alternator bear
They do not wear out and seldom require adjustm ent, but ings and shorten their life. Periodically ensure that the
because they are sensitive to voltage changes and high alternator is correctly aligned to the drive.
temperature, the fo llo w in g precautions are vital to pre
(b) Do not replace fa u lty belts individually in a m ulti-belt
vent them from being destroyed.
system. A com plete matched set of drive belts must
(a) DO NOT disconnect the battery w hile the engine is always be used.
running. This w ill cause a voltage surge in the alte r
(c) Keep the alternator clean w ith a cloth m oistened in
nator charging system that w ill im m ediately ruin the
a suitable cleaning fluid. Ensure that ventilation slots
diodes or transistors.
and air spaces are clear and unobstructed.
(b) DO NOT disconnect lead w ith o u t firs t stopping the
(d) Remove any dirt accum ulated on the regulator/con
engine and turning all electrical sw itches to the off
trol box housing, and ensure that cooling air can pass
position.
freely over the casing.
(c) DO NOT cause a short circu it by connecting leads to
incorrect term inals. Always id e n tify a lead to its cor
rect term inal. A short circu it or wrong connection giv
ing reverse polarity w ill im m ediately and permanently
ruin transisto rs or diodes.
Testing the A lternator in Position
(d) DO NOT connect a battery in to the system w ithout
checking for correct polarity and voltage. First check the driving belt for condition and tension. The
nom inal hot outputs 6 000 r/min (alternator speed) are as
(e) DO NOT “ flash” connections to check for current flow.
fo llo w s :—
No m atter how brief the con tact the transisto rs may
14V — 35A
be ruined.
28V — 28A
28V — 55A
Maintenance
These figures may be exceeded slig h tly when the a lte r
The alternator charging system w ill norm ally require very
nator is running cold.
little atten tion. It should be kept free from build-up
of dirt, and a check made if it fa ils to keep the battery A dust proofed alternator can be fitte d as an option,
charged. depending on application.
Trouble Shooting
If a m alfunction should develop in the current generating
system, it m ust be kept in mind that trouble sources may
exist in the battery, cables or other locations besides the
alternator or regulator. The most common fault symptoms
are listed in the chart below w ith probable causes and
appropriate corrective measures:
Cause Correction
Battery is dead or in su fficie n tly charged:
1. Open circ u it or con tact resistance in charging
circu it 1. Remove open circ u it or contact resistance
2. Defective battery 2. Replace battery
3. Defective alternator ■3. Have alte rna to r repaired in authorized workshop
4. Defective regulator 4. Replace regulator
5. V-Belt too loose 5. Tighten V-Belt

B0C B a rrin g to n Club A D E 422, 423,424 W orkshop Manual S e c tio n : 18 - V a rio u s
Charge indicator lamp does not burn w ith engine stopped

and ig n itio n on:
1. In d ica to r bu lb is burned out 1. Replace w ith new bulb
2. Dead battery 2. Remove battery fo r charging
3. Defective battery 3. Replace battery
4. Loose or dam aged cables 4. Replace or tig h te n cables
6. Shorted positive diode in the a lte rna to r 6. Have a lte rna to r repaired in authorized w orkshop
7. W orn carbon brushes 7. Replace brushes
8. O xide layer on slip-rings, or broken w ire in rotor 8. Have a lte rn a to r repaired
w inding
Charge in d ica to r lam p con tinu es to burn b rig h tly during

higher engine speeds:
1. Cable D + /61 is shorted to ground 1. Repair or replace cable
3. Over-voltage p ro te ction device defective 3. Replace over-voltage pro te ction device
4. Defective rectifier, d irty slip-rings, short in cable “ DF" 4. Have a lte rna to r repaired in authorized w orkshop.
or in rotor w inding
Charge in d ica to r lamp burns b rig h tly w ith engine sto p

ped, but on dim s or glim m ers w ith engine running:
1. Poor con n e ctio n s (contact) resistance) in the charg 1. Remove co n ta ct resistance

ing circu it or in the cable to the charge indicator lamp
3. Defective a lte rna to r 3. Have a lte rna to r repaired
Charge in d ica to r lam p flickers:

1. Replace regulator
1. C o ntact reg ulator may be in correctly adjusted or
regulating re sisto r is burned out
STARTER MOTOR
General
S liding Gear S tarter M otor Type KB

This starter motor, designed for large internal com bustion
engines, operates in tw o stages in order to protect the oil, d irt, or dust penetrating in to the inside o f the starter
pinion and ring gear. m otor, a radial lop-type oil seal is fitte d on the drive end
The arm ature is fixed-m ounted in the drive-end bearing bearing plate. The com m u ta tor end shield and the
plate and in the com m u ta to r end shield; the arm ature solenoid sw itch are enclosed by an end cover or a cover
sha ft is ho llo w and is designed to serve as the housing band.
for a m ulti-disc c lu tch on its drive end. T his c lu tc h hous The drive spindle, on the spiral splines of w hich the m ulti
ing is sealed on the end face by a cover on w hich a ro l disc c lu tc h is m ounted, is supported in a ro lle r bearing
ling or plain bearing is m ounted to support the arm ature in the drive-end bearing plate and in a needle roller bear
in the drive-end bearing plate. On the com m utator end the ing in the armature shaft. The pinion is joined in a positive
arm ature is supported in a plain bearing. A solenoid m echanical con ne ction w ith the spind le by means of a
sw itch for the pinion and a con tro l relay for the tw o s w it fea th er key.
ching stages are flanged to the com m u ta tor end shield.
In th is type o f s ta rte r m otor the pinion is sh ifte d forward The solenoid sw itch is designed to drive the pinion for
(sliding gear) by the solenoid sw itch actin g through an ward in tw o stages. For this purpose it is fitted with a lock
engagem ent rod leading through the hollow arm ature ing device, w ith a trigger, a stop plate, and a release lever.
shaft. The resistance, or opposing, winding located in the This type o f starter m otor is also fitte d w ith a m ulti-disc
solenoid sw itch o f the starter m o to r serves to ad ju st the clu tch between the arm ature and pinion, but in th is case
starter m otor torqu e when m eshing. In order to prevent the clu tch does not have an in itia l m eshing stage.
* 9 ! B a rrin g to n Diesel Club A D E 422, 423,424 W orkshop Manual S e c tio n : 18 - V a rio u s
ALTERNATO R A N D STARTER MOTOR - 18-40
M a in te n a n ce
B asic P oints
W hen w o rk is p e rfo rm e d on th e e le c tric a l p a rts o f th e in
s ta lle d s ta rte r m o to r th e d a n g e r o f s h o rt-c irc u its e x is ts .
F o r th is reason it is s tro n g ly re co m m e n d e d th a t b e fore
such w o rk is s ta rte d th e ground c a b le be d is c o n n e c te d
fro m th e b a tte ry. Do n o t lay to o ls on th e b a tte ry !
B rushes
In th o s e ca se s w h ere th e bru sh e s are e a s ily a c c e s s ib le ,
the y sh o u ld be checked from tim e to tim e to see th a t they
are in g o o d c o n d itio n . A fte r rem oval o f th e end co ve r or
th e co ve r band, th e be st pro ce d u re is to use a ho ok to
lift the s p rin g w h ich presses th e carbon brush a g a in st the
c o m m u ta to r (do not bend th e s p rin g to th e sid e w h en d o
ing th is, and d o not lift th e spring fa rth e r th a n necessary);
a ch e c k can th e n be m ade to see if th e b ru sh can m ove
fre e ly in its holder.
The brushes and the brush holders m ust be free from dust,
o il, and grease. If th e s e pa rts are d irty o r if th e y te n d to
s tic k , th e y sh o u ld be cleaned w ith a cle an c lo th (because
the threads ca tch easily, do not use co tto n w a ste o r w aste
rag). Do n o t w o rk on th e b rig h t ru b b in g s u rfa c e s o f the
bru sh e s w ith em ery paper, file , o r kn ife . C lean th e brush
h o ld e r o u t w e ll w ith d ry co m p re sse d air.
If a brush is broken, if th e so lde red c o n n e c tio n has com e

open, o r if th e bru sh has becom e so w o rn th a t a d a n g e r
e x is ts th a t th e s p rin g o r the s h u n t (p ig ta il) le a d in g to th e
bru sh can c o n ta c t th e brush holder, th e bru sh m u s t be
replaced. W hen in s ta llin g the brush be sure tha t the spring
is sea ted c o rre c tly on it.
W hen th e e n g in e is given a m a jo r o ve rha ul, th e bru she s

s h o u ld be re p la ce d in an y event. Every tim e th e bru she s
are re p la ced th e c o m m u ta to r s h o u ld be tu rn e d dow n.
C o m m u ta to r
T he c o m m u ta to r s h o u ld have a s m o o th u n ifo rm s u rfa c e
and m u s t be fre e fro m o il and grease. D irty c o m m u ta to rs
s h o u ld be cle a n e d w ith a cle a n c lo th (n o t w ith c o tto n
w aste). C o m m u ta to rs th a t have be co m e sco re d and o u t
o f rou nd th ro u g h use m u s t be ro u g h -tu rn e d , th e m ica in
s u la tio n un d e rcu t, and the n p re c is io n tu rn e d in a s u ita b ly
e q u ip p e d w o rksh o p . In no case s h o u ld o n ly em ery pa pe r
o r a file be used to w o rk on a c o m m u ta to r.
REMOVING AND REPLACING ALTERNATOR
Removing
1. D isconnect battery connections.
2. D isconnect e le ctrica l con ne ction s to alternator.
3. Unscrew lock nut of V-belt adjuster and release ten

sion (fig. 87-18).
4. Unscrew and remove alte rn a to r m ounting b o lts and

lift o ff a lte rn a to r (fig. 88-18).
R ep la cing
1. Fit alternator to m ounting brackets and tigth en bolts
to 50 N.m (fig. 89-18).
2. Insert b o lt in V-belt adjuster, on alternator.
3. F it V-belt and tension, using special to o l (fig. 90-18).

Should th is too l not be available, the V-belt tension
can be adjusted as fo llo w s: W ith o u t using undue
pressure it should be possible to depress the V-belt
ap pro xim ately 10 mm, w ith the th u m b applying
pressure at a po in t m idw ay between the w ater pum p
and a lte rna to r pulley.
4. Tighten V-belt te n sio n e r lock nut.
Fig. 90-18
REPLACING V-BELT - 18-42
1. Unscrew lock nut of V-belt adjuster, and release te n

sion (fig. 91-18).
2. L ift V-belt from pulleys.
Fig. 91-18
3. Fit new V-belt and tighten.
Note: See fig. 89-18 fo r m ounting b o lt torqu e ten sion s.
4. Check V-belt for correct tension using special tool (fig.

92-18). Should this tool not be available, the V-belt ten
sion can be adjusted as fo llo w s: W ith o u t using un
due pressure it should be possible to depress the V-
belt ap p ro xim a te ly 10 mm, w ith the thu m b applying
pressure at a point m idw ay between the w a te r pum p
and alte rn a to r pulley.
_________________ SECTION 18-43

Power Steering Pump
Introduction
The ADE 420 Series Engines are fitted w ith two types of
Rotary, Power Steering Pumps, both of which operates
as follows:
When the drive shaft and its rotor are turned, the vanes
are guided in slots and being radially m obile are pressed
against the guide path of the cam ring by the action of
centrifugal force and oil pressure. Two successive vanes
are classed as a cell (a total o f 10), which are laterally
restricted by the pressure plates. Each cell delivers the
maximum effective cell volume tw ice per revolution. The
suction and pressure chambers are arranged so that the
hydraulic and radial forces acting on the rotor, w ill
neutralize each other. The cover-end front plate, and the
drive end front plate are provided with 4 grooves so that
the pressurized oil reaches the internal face of the pump
vanes, which w ill then be supported by the centrifugal
force. From the pressure chamber the oil travels through
holes to the flow restricting valve, and by the way of a
throttle restriction to the pressure line. The reduced
pressure behind the throttle restriction is transm itted via
holes to the springloaded end o f the flow restricting
piston, and therefore to the relief valve.
Increasing speed or pump delivery w ill produce a grow

ing pressure drop behind the throttle restricter and also
against the spring end of the valve piston. As soon as the
hydraulic power (pressure differential tim es piston area)
exceeds the spring force, the piston w ill move towards
the spring, and the oil delivered in excess will flow through
the now exposed ejection hole into the suction duct of
the pump. As a result, an almost constant oil flow for the
steering gear is provided throughout the entire speed
range.
DISMANTLING
Removal of Rotor and Cam Ring

ZF High Pressure Vane Pump 7673
1. Loosen nut on drive shaft and pull off V-belt pulley.
2. Pull out spring clip from groove in pump housing (fig.

93-18).
Fig. 93-18
B a rr in g to n Diesel Club A D E 422, 423,424 W orkshop Manual S e c tio n : 18 - V a rio u s
P O W E R S T E E R I N G P U M P — 18-44
3. Remove cover, com pression spring and face plate

from housing (fig. 94-18).
4. T ilt pum p body and remove cam ring and rotor (fig.
95-18).
Removal of Drive Shaft

5. Remove c irc lip (fig. 96-18).
6. Knock drive sh a ft from housing (fig 97-18).
Fig. 97-18
POWER STEERING PUMP — 18-45
7. Using a hide faced ham mer knock drive end face plate
from housing. '
8. rem ove volum e co n tro l valve.
9. Using a s u ita b le punch knock needle bearing and

sh a ft seal from ho using (see fig. 98-18).
10. Remove O-rings from housing, remove fitte d pin. Take

O-ring from drive end face plate.
11. The bearing can be pressed from drive sh a ft a fte r

rem oving c irc lip (fig. 99-18).
Fig. 99-18
Removal o f Flow and Pressure R e strictio n

Valve Z.F. High Pressure Vane Pump 7637
1. Remove b lan king plug from housing (fig. 100-18).
2. Remove com p ressio n spring and valve co m p le te ly

from ho using bore.
Dism antle, Insp e ction and A ssem bly of Flow

and Pressure R estriction Valve
1. Check pressure and flo w re s tric tio n valve fo r score

m arks and wear. The flo w co n tro l pisto n sho uld not
bind in housing bore. C heck to le ra n ce num ber on
housing (on face end o f valve bore) and on piston (Item
1) (fig. 101-18).
Fig. 101-18
P O W E R S T E E R IN G P U M P - 18-46
2. U nscrew valve seat screw from pressure re s tric tio n

valve (do not cla m p in vice). Ensure th a t none o f the
w ashers, the ball, the spring gu id e and the com p res
sion sp rin g s are lost. The th ickn e ss o f the w asher is
c ritic a l fo r the response range o f the pressure relief
valve. To prevent the p o s s ib ility o f dam age, the
w a she rs a va ila ble p rio r to d is m a n tlin g m ust be re
placed (fig. 102-18).
3. Clean control valve and valve screw and blow out w ith
com pressed air. R einsert com p ressio n spring, guide
pin and ba ll. S crew valve seat screw in to c o n tro l
piston tog ether w ith previously in sta lle d washers and
tig h te n .
1 VALVE PISTON
2 COMPRESSION SPRING PRESSURE RELIEF VALVE
3 SPRING GUIDE PIN
4 VALVE BALL
5 ADJUSTING WASHERS
6 VALVE SEAT SCREW
7 COMPRESSION SPRING VOLUME CONTROL VALVE
8 BLANKING SCREW WITH SEALING RING
Installation of Flow and Pressure Restriction

Valve
4. First insert assem bled valve piston w ith thin shaft into
bore. C heck fo r co rre ct to le ra n ce (fig. 103-18).
5. S lide co m p re ssio n sp rin g on valve p is to n and in sert

blanking plug in to thread hole placin g sealing washer
unde rnea th (fig. 104-18).
POWER STEERING PUMP - 18-47
Pre-assem bly o f Pump H ousing ,
Note: Prior to assem bly, clean all parts, m oiste n s lig h tly
w ith ATF o il and replace all sea lin g rin gs and O -rings.
1. Using a s u ita b le m andrel, press needle bearing in to

h o using (fig. 105-18).....
. . . u n til face end o f needle bearing is 37,0 to 37,2 mm

from fa ce end o f housing (fig. 106-18).
Note: The needle bearing is in s ta lle d o n ly in pum ps w ith

V-belt drive.
2. Press s h a ft seal in to housing w ith a m andrel. In sta ll

seal w ith bearing grease between sea lin g lip s (fig.
107-18).
3. Using a so cke t spanner, screw bla n kin g plug in to

pum p ho using and tig h te n .
4. Place O -ring in to bo tto m groove in housing.
5. Insert fitte d pin in to hole provided (fig. 108-18).
Fig. 108-18
A ssem bly and In sta lla tio n of Drive Shaft
6. Press ball bearing on drive sh a ft and replace c irc lip .

F it key (fig. 109-18).
7. Insert preassembled drive shaft in to housing until ball

bearing rests a g a in st housing flan ge (fig. 110-18).
8. Insert c irc lip lo ca tin g ball bearing (fig. 111-18).
Replacem ent o f Drive End Face Plate
9. Insert O-ring in to groove in neck o f fa ce plate.
10. S lide face plate on pin as shown and press w ith neck
in to ho using (fig. 112-18).
Insta lla tio n of Cam Ring and Rotor
11. Insert O-ring (1) in to groove in housing (fig. 113-18).
12. Insert cam ring. The sm aller hole holds the hollow pin
and the tw o larger ones are above the du cts of the
face plate. The cast, half arrow po in ts tow ards driv
ing d irectio n of pum p (see fig. 114-18).
Fig. 114-18
13. Fit rotor w ith sm ooth bore on drive sha ft (fig. 115-18).
14. Insert the ten vanes w ith the rounded-off ou ter sur
faces facin g the cam ring, in to slo ts of rotor (fig.
116-18).
Fig. 116-18
POW ER STEERING PUMP — 18-50
R e p la ce m e n t o f End Face P late and C over
15. F it face plate on cam ring as shown. The pin is in one

o f the tw o sm a lle r holes (fig. 117-18).
16. Insert O -ring (1) (fig. 118-18).
17. Insert com p ressio n spring in to bore of face plate.

P osition cover w ith recess inw ards and push in to
housing u n til the c irc lip can be inserted (fig. 119-18).
18. Insert flo w and pressure re strictio n valve.
V ic k e rs H igh P ressure O il P um p VT27

D ism a n tlin g -R e m o v a l o f R o to r and Cam Ring
1. Remove screw s on pum p housing to w h ich housing

cover is connected, and remove pum p housing.
2. Remove com p ressio n spring from th ru s t plate. Mark

th ru s t plate, cam ring and housing cover tog e th e r
(refer to arrow) (fig. 120-18).
1 O -R IN G 4 CAM RING
2 TH R U ST PLATE 5 O -R IN G
3 C O M PR ESSIO N SPR IN G 6 HO USIN G COV ER
3. Rem oving th ru s t plate from fitte d pins and take o ff

cam ring (fig. 121-18). •
Fig. 121-18
2 TH RUST PLATE 6 H O U SIN G COVER

4 CAM RING 7 M A R K IN G LINE
4. Remove rotor w ith pump vanes from drive-shaft spline

(fig. 122-18).
Fig. 122-18
4 CAM RING a. O IL INFLO W FR OM S U P P L Y

6 H O U SIN G C O V ER C ONTAIN ER
7 M A RKIN G LINE b. H Y D R A U L I C O IL O U T F L O W
3 F I T T E D PIN O N C A M RI NG
9 ROTOR c. INTAKE B O R E S
10 VANES
5. Remove O-ring from housing cover (Item 1 & 5) (fig

123-18).
6. Remove volum e con tro l valve.
7. Clean all pa rts th o ro u g h ly and rinse.
1 O -R IN G 4 CAM RING
2 TH RU ST PLATE 5 O -R IN G
3 C O M PR E SSIO N SPR IN G 6 HO USIN G C OV ER
R em oval and D is m a n tlin g o f V o lum e C o n tro l

a nd P ressure R elief Valve
1. Knock locking pin from pum p housing.
2. Remove blanking cover o f volum e con tro l valve, and

com pression spring from pum p housing (fig. 124-18).
N o t e : C aution! The com pression spring may push o ff the

blanking cover and the c olum e c on tro l valve after rem ov
ing the locking pin. If the blanking cover rem ains in hous
ing, loosen by applying light hammer blows against cover.
Be sure not to dam age the volum e c o n tro l valve.
1 B LA N K IN G C O V ER 4 V O L U M E C O N T R O L VA LV E
2 L O C K I N G PIN 5 COM PRESSION SPR IN G S
3 O -R IN G 6 PUMP HOUSIN G
3. Clam p volum e con tro l valve at its unground end in a

vice and unscrew valve screw o f pressure relief valve.
Ensure th a t no a d ju sting screw s are lost. Remove
valve cone and com pression spring from volume con
tro l valve (fig. 125-18).
4. Prior to replacement, check ground surface of volume

c on tro l valve and bore in pum p housing fo r wear and
damage. If the surfaces are show ing score marks,
replace complete o il pump. Never replace volume con Fig. 125-18
tro l valve only.
• - *ODj
1 B L A N K I N G C O V E R WITH O -R IN G
2 VO LUM E C O N T R O L VALVE
3 C O M P R E S S I O N S P R I N G F O R P R E S S U R E R E L I E F VA LV E
4 VALVE C O N E
5 A D JU STIN G W A SH ER
6 VALVE S C R E W
7 C O M P R E S S I O N S P R I N G F O R V O L U M E C O N T R O L V A LV E
S pe cia l Tool
Self-m ade (fig. 126-18).
A INSTALLATION TOOL
B INSTALLATION TOOL
C INSTALLATION SLEEVE
POWER STEERING PUMP - 18-53
R e p la ce m e n t o f Drive S h a ft and S e a lin g Ring

w /M m t
1. Press drive from housing cover, paying a tte n tio n to 14-------------- R
shell halves (Item 10) (fig. 127-18).
2. L ift oil seal from housing cover using a screw driver.

i \\/
- — ty
13 12 tl 10 9 8 7 6 8
Fig 127-18
1 O-RING 8 O-RING
2 PUMP HOUSING 9 BEARING BUSH
3 THRUST PLATE 10 SHELL HALF
4 OIL GUIDE PLATE 11 DRIVE SHAFT
5 COMPRESSION SPRING 12 BEARING BUSH
6 CAM RING 13 OIL SEAL
7 ROTOR WITH PUMP VANE 14 HOUSING COVER
3. Place both shell halves on drive shaft, then press drive

sh a ft in to housing cover (fig. 128-18).
N o t e : The shell halves determ ine the end play of the drive
sha ft, w h ich is m axim um 0,7 mm for new high pressure
o il pum ps and should not be more than 1 mm fo r used
pum ps. Replace high pressure o il pump, if end play is
higher.
Fig. 128-18
10 S H E L L HALF
11 DRIVE S H A F T
14 HO USIN G C OV ER
4. Press bearing bush w ith in s ta lla tio n to o l in to hous

ing cover (fig. 129-18).
Fig. 120-18
12 BEA RING BU SH
14 HO USIN G CO V ER
B INSTALLATION TO O L
5. Replace assem bly sleeve on drive shaft and press o il

seal in to housing cover w ith in sta lla tio n too l (fig.
130-18).
13 O IL S E A L A INST ALLAT IO N TO O L
14 H O U SIN G C O V ER
In s ta lla tio n o f R o to r and Cam Ring
1. M oisten all parts w ith ATF oil.
2. Install volum e con tro l valve.
3. Place rotor on drive shaft so that the countersunk end

of the spline d bore faces housing cover.
4. Place cam ring on fitte d pins so th a t the respective

m arkings on the housing cover and on the cam ring
are in alig n m e n t (fig. 131-18).
11 DRIVE S H A F T 16 M A R K I N G LI NE
14 H O USIN G C O V ER
a
Note: When a new cam ring is installed, position it so that
the hyd rau lic o il bores are located accurately above the
recesses in the housing cover (Item 4 & 5, fig. 132-18).
5. Insert pump vanes into slots of rotor so that the round

ed ends are facin g ou tw ard s tow ard the cam ring.
6. P osition th ru s t plate on cam ring and fitte d pins lin

ing up m arkings (fig. 132-18).
N o t e : The o u tle t holes for the hyd rau lic oil should be
above the hydraulic o il bores o f the cam ring (Item 5).
a O IL I N F L O W F R O M S U P P L Y C O N T A I N E R
b H Y D R A U L I C O IL O U T F L O W O N C A M RI NG
1 ROTOR
2 PUMP VANE
3 H Y D R A U L I C O IL U N D E R P U M P V A N E
4 R E C E S S O N H O U S I N G F O R I N L E T O F H Y D R A U L I C O IL
IN T O H Y D R A U L I C O IL B O R E
5 H Y D R A U L I C O IL B O R E 7 INTAKE B O R E S
6 CAM RING 8 DRIVE S H A F T
TORQUE S PEC IFIC ATIO N S
POWER STEERING PUMP
Steering pump to tim in g housing . M10 60 N.m

1^5$ B a r r i n g t o n D iesel Club ADE 422, 423,424 Workshop Manual S e c tio n s: 1 9 th ru 2 1 ( E N D )
S E C TIO N 19-1
C ooling System
W ater Pump
1 W ater pump 20 Pipe
2 S haft 21 Pipe
3 Carbon ring seal 22 C oup lin g nut
4 Im peller 23 Ferrule
5 Sleeve 24 Clam p
6 C eram ic ring 25 Nut
7 C irclip 26 Lockw asher
8 Hub 27 B olt
9 Gasket 28 W ater o u tle t
10 Spring w asher 29 W ater in let
11 B olt 30 B olt
12 Repair k it 31 Gasket
13 Repair kit 32 B olt
14 Therm ostat 33 B olt
15 Seal 34 Spring washer
16 Pulley 35 O utlet adapter
17 Pulley 36 G asket
18 Bolt 37 Spring w asher
19 Spring washer 38 Bolt
COOLING SYSTEM - 19-2
Cooling System
T h e rm o s ta t S ta n d a rd V e rs io n S p e c ia l a p p lic a tio n
S ta rts to o p en at °C 79 + 2 71 ± 2
S tro k e in mm m in 8 m in 8
F u lly o p en a t °C 94 85
Coolant Pump
S p e cifica tio n s and pum p illu s tra tio n can alte r depending on a p p lica tio n
15,039
S h a ft dia.
15,028
Dim. „ A '!
15,018
Im p e lle r bore
15,000
54,994
B e a rin g dia.
54,981
Dim. ,,B’
54,970
H o u s in g bore
54,940
25,061
P ulle y s h a ft dia.
25,048
Dim. „ C ”
25,021
P ulle y fla n g e bore
25,000
Dim. „ D " D is ta n c e im p e lle r to h o u sin g 1 ,0 - 1,4
55.970
Dim. ,,E" Flange dia. fo r pulley location
55.940
M ax. ru n o u t b e tw e e n “ C ” and “ E” 0.03
L a te ra l ru n o u t o f p u lle y fla n g e a t ra d iu s 52 0.02

W ater pum p to c y lin d e r b lo c k ............................................... M8 25 N.m

P ulley to w a te r p u m p ................................................................ M8 25 N.m
C o o la n t d ra in plug on o p tio n a l oil c o o le r ........................ M12 X 1,5 50 N.m
C o o lin g fan to hub (solid f a n ) ............................................... M8 30 N.m
V is c o fan to h u b /vib ra tio n d a m p e r ...................................... M8 30 N.m
C o o la n t o u tle t to w a te r p u m p ............................................... M8 25 N.m
Fan guard to e n gine m o u n tin g /s u m p ................................. M10 50 N.m
Fan guard to b r a c k e t ............................................................... M10 50 N.m
Inle t to w a te r pum p (Depending on a p p lic a tio n ) ............ ( M10 50 N.m
[ M8 25 N.m
FAN RETAINING BOLTS (DIN933) —

TIGHTENING TORQUE
BOLT DIA QUALITY TORQUE
M8 8,8 23 N.m
M8 10,9 30 N.m
M10 8,8 42 N.m
M10 10,9 58 N.m
COOLING SYSTEM — 19-4
Introd u ction
The c irc u la tio n o f the co o la n t is assisted by an im peller

type w ater pum p m ounted on the fro n t o f the cylin d e r
block, and driven by a V-belt from the crankshaft. C ool
ing by a finn ed rad ia to r (water/air) or heat exchange
(water/water). A utom atic tem perature control by tw o ther
m o sta ts connected in parallel.
REMOVING AND REPLACING THERMOSTAT
Removing
1. D isconnect coo la nt hose from th e rm o sta t housing,
and remove.
2. Unscrew and remove the rm o stat cover (fig. 1-19).
Fig. 1-19
3. Remove th e rm o sta t from housing (fig. 2-19).
Replacing
1. Insert th e rm o sta t in housing.
2. Fit new O-ring to the rm o stat housing (fig. 3-19).
3. Fit new gasket to the rm o stat cover and replace,

tig h te n b o lts to 25 N.m.
4. Replace and tig h te n c lip s of co o la n t hose.
Fig. 3-19
B0C B a r r i n g t o n D iesel Club ADE 422, 423,424 Workshop Manual S e c tio n s: 1 9 th ru 2 1 ( E N D )
CHECKING THERMOSTAT
A ttach therm ostat to a piece of wire and hang In a tank

filled with boiling water. The main valve of the therm ostat
must be fully open after six to eight minutes (approximate
ly 8 m m ).
Checking for start of opening.
1. A ttach therm ostat to a piece of wire and hang in a

tank fille d w ith water.
2. Using a suitable source, heat water.
IMPORTANT! From approxim ately 8°C below start of

opening temperature (depending on version), the heating
speed m ust not exceed 10 to 2° per m inute. S tir w ater so
as to produce a uniform temperature.
Note: Never use a welding torch or soldering iron to heat

the therm ostat.
REMOVAL AND REPLACEMENT OF WATER

PUMP
Removal
1. If fille d w ith anti-freeze or an inhibitor, drain coolant
into a clean container. Disconnect and remove water
pump hoses.
2. Loosen lock nut on V-belt adjuster and release

tension.
3. Remove V-belt.
4. Unscrew and remove mounting bolts for water pump,

lift o ff water pump.
5. Remove old gasket, and clean surface of water pump

and cylinder block.
Replacing
1. Replace water pump, fitte d w ith new gasket, insert
bolts and tighten to specified torque.
2. Check V-belt for correct tension using special tool (fig.

4-19). Should th is tool not be available, the V-belt ten
sion can be adjusted as follow s: W ithou t using un
due pressure it should be possible to depress the V-
belt approxim ately 10 mm, with the thum b applying
pressure at a point midway between the water pump
and alternator pulley.
3. Replace water pump hoses and tighten hose clamps.
4. F ill radiator w ith coolant.
Note: Add 1% radiator in hib itor (anti-corrosion oil)

throughout the year.
Fig. 4-19
DISMANTLING AND ASSEMBLING

WATER PUMP
D ism antling
1. Unscrew and remove the rm o stat housing cover,
rem ove th e rm o sta ts (fig. 5-19).
Fig. 6-19
3. Using a suitable puller, remove drive flange from water

pum p sh a ft (fig. 7-19).
Fig. 7-19
4. Remove c irc lip from w ater pum p sh a ft housing

(fig. 8-19).
Fig. 8-19
5. Press water pum p shaft and bearing from water pump

housing (fig. 9-19).
6. Knock carbon ring seal from w ater pump body.
7. Remove ceram ic ring and rubber sleeve from impeller,

(fig. 10-19).
Assem bling
1. Fit new carbon ring seal in w ater pump body, using
special too l, Part num ber 40202020 (fig. 11-19).
2. Press new w ater pump bearing into water pump hous

ing (fig. 12-19).
3. Insert c irc lip in to water pump bearing housing

(tig. 13-19).
4. Press drive flange onto w ater pump shaft (fig. 14-19). —^ //x
P --------
1 '
Fig. 14-19
5. Insert new ceram ic ring and rubber sleeve in to im

peller (fig. 15-19).
6. Press w ater pump im peller on to w ater pump bearing

shaft, leaving a clearance of 1 + 0,4 mm between im
peller and w ater pump body (fig. 16-19).
Fig. 16-19
BDC
B d r r in g t o n D iesel Club ADE 422, 423,424 Workshop Manual S e c tio n s: 1 9 th ru 2 1 ( E N D )
7. Replace pulley and tigh ten bolts to 25 N.m (fig. 17-19).
8. Insert th e rm o sta ts, w ith new seals in to w a te r pum p

housing, and replace th e rm o sta t cover (fig. 18-19).
Fig. 18-19
Page 19-10 blank

» » c sc l Club ADE 422, 423,424 Workshop Manual S e c tio n s: 1 9 th ru 2 1 ( E N D )
Page 19-10 blank
SECTION 19-11
Visco Fan
R e p r e se n ta tio n o f B a s ic F an M o d el
1 A LLEN C A P SC R E W
2 C O V ER , C O M P L E T E
3 C O V ER G A S K E T
4 A LLEN C A P SC R E W
5 PRIM ARY D ISC
6 S P A C E R RING
7 BEA R IN G
8 S E A L IN G RIN G
9 BO DY WITH BLA D E
10 LO C K IN G D EVICE
11 C O U N T E R S U N K SC R E W
12 FLA NGED SH A FT
Page 19-12blank
BDC
B d r r in g t o n D iesel Club ADE 422, 423,424 Workshop Manual S e c tio n s: 1 9 th ru 2 1 ( E N D )
Page 19-12 blank SECTION 19-13

V isco Fan
In tro d u ctio n Filling Capacities
Some ADE 420 Series Engines are fitte d w ith a th e rm o

s ta tic a lly c o n tro lle d v isco u s drive fan, w h ich is m ounted S ilicon Oil
on th e w ater pum p hub, and driven by the V -belt from the Fan V iscosity + ) Qty.
cran ksha ft. M odel cS t cm 3
The visco u s drive fan does not have a rig id co n n e ctio n T 18 I 12.500 35
o f the w a te r pum p pulley. A driven m em ber w h ich is f it 12.500 35
ted to the pu lle y can move w ith in a cham ber o f the fan 12.500 30
w ith a sm all clearance. On reaching a predeterm ined 12.500 42
tem pe rature th e th e rm o sta t opens a llo w in g o il to enter 12.500 42
the cham ber, as a resu lt o f the fric tio n created by th e oil 12.500 42
w ith in the fan cham ber, the non driven body o f the fan 12.500 42
w ill turn thus driving the fan.
T 18 II 12.500 42
T 18 II KW 12.500 45
12.500 40
C hecking and lo c k in g visco us drive fan
T 21 II 12.500 42
If there is an abnorm al rise in co o la n t tem perature, the T 21 II KW 16.500 45
fo llo w in g check should be carried out. 12.500 45
16.500 45
W hen the engine is cold, th e visco us s ilic o n flu id flo w s
12.500 45
back in to the th e rm o sta t cham ber. W ith the engine at
16.500 45
o p era ting tem perature, it sho uld the re fore be d iffic u lt
16.500 45
to turn the fan by hand.
T 21 II D 16.500 42
Start up the cold engine, and allow it to run for 1-2 m inutes
12.500 42
at m edium speed, then sw itch o ff the engine. The fan m ust
12.500 42
now rotate e a sily when m oved by hand, th is is due to the
fa c t th a t the s ilic o n flu id has been throw n to the ou tside
o f the cham ber, and sin ce it is co n tro lle d by the th e r
m ostat, it ca n n o t flo w back when the engine is s till cold.
C heck w h ethe r the visco us drive fan engages properly

when the engine is warm . W ith the veh icle statio nery,
cover the radiator, start engine and a llo w it to run at
m edium speed u n til the w a te r tem perature has risen to
90-95°C. Remove the ra d ia to r covering. The th e rm o sta t
is now heated by the hot air from the ra d ia to r a llo w in g
s ilic o n flu id to flo w in to the fan cham ber.
The fan speed should increase w ith in a few m in utes

(in creasing fan noise), and the w a te r tem pe rature s hould
return to norm al op era ting tem perature. If the engine is
now sw itch e d off, it should be d iffic u lt to turn the fan by
hand as the o il is s till in the fan cham ber.
In the event of fa ilu re o f the visco us fan drive, the device

can be locked. The lo cking device at the rear end o f the
fan serves to cou ple the fan rig id ly to th e pulley.
To do th is, unscrew the lo ckin g nut (fig. 18-19) up to the

lo ck stop, then tu rn the fan slo w ly by hand u n til th e pin
o f the lo cking device is fe lt to snap in to place, aided by
the spring pressure.
The visco us drive fan can be used fo r a lim ite d period

when in the locked co n d itio n . Prolonged operation in th is
c o n d itio n is not advisable, the fan should be exchanged
as soon as possible at your nearest A tla n tis Diesel Engine,
parts sto ckist.
Note:
The visco u s drive fan should alw ays be transp orted and
stored in a vertical position (as fitte d to the engine) to pre
vent the s ilic o n o il from running out. Fig. 18-19
SECTION 20-1
Lubricating O ils
VISCOSITY GRADES
A m b ie n t A ir
SAE G rades
T e m p e ra tu re
30
20
o
o i
0 I
10 O $
CM o o
5
I 1 CO in CM
£ o I
0 o CM
$
CM o
5
10 I
15 o
CM
20
in
*A t prolonged am b ie n t tem pe rature above 20°C SAE 40 can be used.
DUE TO CONTINUOUS DEVELOPMENT, ATLANTIS DIESEL ENGINES ARE CONSTANTLY

REVISING THEIR OIL RECOMMENDATIONS.
TO OBTAIN THE LATEST OIL RECOMMENDATIONS, PLEASE REFER TO OUR SERVICE

BULLETINS, OR CONSULT YOUR NEAREST OIL COMPANY FOR THEIR ADVICE.
SECTIO N 21-1
Approved Service Tools
D istributed by: G rundy-Techniform (Pty) Ltd,
Bruman Road, Deal Party Estate,
Port Elizabeth 6001
Tool Tool No.
Engine turning
tool
4020 0093
Crow foo t socket

for cylinder head 4020 0530
bolts 17 mm
Ring spanner
for in je ctio n pump 4020 0970
pipe connections
Ring spanner
for in jecto r 4020 0705
pipes
Castleated socket for

removal and replacem ent
4020 1047
o f in je cto r securing
nut (pipes in place)
Castleated socket for

removal and replacem ent 4020 1050
o f in jecto r (pipes removed) I &V/
Inje ctor dism an tling

socket
T 4020 0938
A P P R O V E D S E R V IC E T O O L S — 21-2
Tool Tool No.
Valve stem
seal in sta lle r 4024 0778
Drive tool
Flywheel wear 4020 0268
ring
Drive tool
Crankshaft front 4020 1801
wear ring
Drive tool
removal/replacem ent 4020 0116
tim in g case o il seal
Drive tool
Flywheel spigo t 4020 0064
bearing
/ T'\
Drive tool ll '
Crankshaft front
cover o il seal
RBHBV» 4020 0129
Puller for
4020 1160 & 4020 0585
4020 1652
Puller for
4020 1665 4020 0598
Valve guide 4020 0831

reamer 11.99 mm
1^5$ ( d r H n g t o n D iesel d u b ADE 422, 423,424 Workshop Manual S e c tio n s: 1 9 th ru 2 1 ( E N D )
APPROVED SERVICE TOOLS — 21-3
Tool ’ Tool No.
C rankshaft hardness
tester 4020 0501
Drive tool for compressor roller bearing 4020 1199

in timing gear case
Drive tool for bush 7'<\ '<•'*('<r<\ T<Wr<r<'<'<rJ

4020 1209
in compressor bearing flange. i l l l i
Cam shaft blanking

plug puller 4020 2004
O il spray je t alignm ent

4020 1937
tool
(illustration of old type jet)
7 (^T D
Flywheel positioning
4020 1982
handles
7/on
Bt*r*r*'n 3 t o n » » c sc l Club ADE 422, 423,424 Workshop Manual S e c tio n s: 1 9 th ru 2 1 ( E N D )
Tool Tool No.
C onnecting rod
4020 1995
pull through handle
C rankshaft front
w ear ring remover 4024 9737
M easuring tool for cylinder

Liner p ro tru tion 4020 1953
T im ing case cover

assem bly tool 4020 0103
Locking tool for

com pressor 4020 1238
Check too l fo r in jectio n C r~ 1 ]

pum p . 4020 1186
* .....
W rench fo r com pressor

drive gear b o lt 4020 1225
Valve stem seal guide u .i ..... - 4020 1555
7/90
APPROVED SERVICE TO O LS — 21-5
Tool Tool No.
C ro w fo o t socke t for
4020 0721
in je c to r pipes
S upport fo r in je c to r nozzle 4020 0912

holder
C o nn ection for
com p ressio n tester n i | to 4020 0792
C ylind er liner
4020 0433
rem oval/replacer
Universal
4020 0446
Dial guage holder
P iston ring remover/

rep la cing pliers 4020 0307
P ilot m andrels for (iuuiL... I ...ZB

rem oval and replacem ent 4020 0077
of flyw h ee l
buul--------- . (..J I B )
Piston ring com pressor

cla m p 4020 1212
Tool Tool No.
Fuel lift pum p tester 4020 1115
E xtractor for p ilo t bearing

25,5 - 30 mm 4020 1652
E xtractor fo r com pressor bearing 4020 1160
E xtractor for valve seat insert 4020 1665

47 —56 mm
In je cto r im pact
4020 1076
extracto r
c5 1S ?
•a n
Water pump tool 5 MB» 4020 2295
I ^ fydppihgton Diesel Club
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ADE 422 , 423 , 424

ENGINE REPAIR MANUAL

ATLANTIS DIESEL ENGINES (PTY) LTD

Part No. 80530257

T h is m anual is d e sig ne d to be o f a s s is ta n c e to a ll personnel co n ce rn e d w ith th e m a in te n a n c e and

TECHNICAL DATA ................................................................................................................................................ 08

OPERATING AND MAINTENANCE SCHEDULE ............................................................................................09

FAULT FINDING .................................................................................................................................................... 10

CYLINDER BLOCK AND LINERS ......................................................................................................................11

CYLINDER HEAD .................................................................................................................................................. 12

PISTONS AND CONNECTING RODS ............................................................................................................... 13

CRANKSHAFT AND MAIN BEARINGS ............................................................................................................14

CAMSHAFT, TIMING CASE AND DRIVE-TIMING .............................................................. ;................ 15

LUBRICATING SYSTEM AND SUMP ................................................................................................................ 16

FUEL SYSTEM ........................................................................................................................................................17

A N C ILLA R Y EQUIPMENT: COMPRESSOR, FLYW HEEL, TURBOCHARGER, EXHAUST BRAKE

COOLING SYSTEM ............................................................................................................................................... 19

LUBRICATING OILS ..............................................................................................................................................20

APPROVED SERVICE TOOLS ............................................................................................................................21

Ratings to SABS 013-1977

Torque N.m/r/min ............................. 1022/12001402/12001550/12001278/12001687/1200 2000/1200 1388/1200 2236/1200 2400/1400

No. of c y lin d e rs .................................... 8 8 8 10 10 10 12 12 12

Firing order ................................... 1.5.7.2.6.3 4.8. 1.6.5.10.2.7.3.8.4.9. 1 . 12.5.8.3.10.6.7.2.11 .4 9

Idling s p e e d ............................. 600 r/min

^ “ fcapfing»»» W««l Club

Throughout the W orkshop Manual, SI (International Metric Systems) units as

(Refer to "Approved consumables & service intervals" bulletin for

NORMAL SERVICE INTERVALS

OPERATING AND MAINTENANCE 09-2

Maintenance function Engine type Service interval

Service injectors ★ 60 000 1 200 21 000

Renew injector * 120 000 2 400 42 000

Service and calibrate * 180 000 3 600 63 000

2. Open air cleaner and ensure that the element is positioned

OPERATING AND MAINTENANCE 09-3

15. Adjust valve clearance every second service. ENGINE PRESERVATION

An engine is classified as "laid up" when it has not operated

OPERATING AND MAINTENANCE 09-4

2.2 Laid up fo r 12 to 36 m onths 3.1 Laid up for up to 12 m onths:

These measures cover new non-installed engines, as well as

S tarter m otor turns engine too slow ly 1. 2, 3. 4.

Key to Fault Finding Chart 32. Pitted valves and seats.

__________________________ SECTION 11-1

U p p e r fit/lo w e r f it o v a lity m ax. 0.01

O v a lity fo r re p a ir m ax. 0.08

D e v ia tio n o f fla n g e fa c e t o b lo c k fa c e m a x . 0.02

C y lin d e r b lo c k le a k a g e te s t u n d e r w a te r w ith c o m p re s s e d a ir 150 kPa

R oughness o f upper jo in t surfaces Rz 10^m — Rmax 16^m

CYLINDER BLOCK — 11-3

M ax. la te ra l ru n -o u t o f lin e r fla n g e “ a ” to c e n te rlin e 0.02

M ax. ru n -o u t be tw ee n lo w e r and u p p e r f it “ c ” 0.025

O v a lity o r ta p e r a t lo w e r f it “ F” B e fo re fitm e n t m ax. 0.06

P ro tru s io n above b lo c k fa c e new 0.05 - 0.09

S u rfa c e ro u g h n e s s o f ho n e d lin e r R3z 3 - 5/ifn

CYLINDER BLOCK — 11-4

Tightening torques for Standard bolts and nuts (normal

C lassifica tion of Strength

M6 8,6 11,8 14,5

CYLINDER BLO CK — 11-5

REM OVING AN D REPLACING CYLINDER

2. Fit puller studs opposite to each o th er in to bolt holes

3. Insert puller. Part num ber 40200433, in to cylinde r

5. Fit support of pu lle r on to studs, tig h te n nuts and

3. Apply approxim ately a 3mm dia bead of sealing com

10. Using a suita ble p la s tic knife, remove excess seal

Note: Check inside diam eter o f gauge plate prior to f it

Set dial gauge to “ O” on cylin d e r block, at each m easur

N ote 2: The c u ttin g to o l is ground in such a w ay as to pre