Viton seals

Some seals used in engines and in components fitted to engines are made of Viton.

Viton is used by many manufacturers and is a safe material under normal conditions of operation.

If Viton is burned, a product of this burnt material is an acid which is extremely dangerous. Never allow this

burnt material to come into contact with the skin or with the eyes.

If it is necessary to come into contact with components which have been burnt, ensure that the precautions

which follow are used:

Ensure that the components have cooled.

Use neoprene gloves and discard the gloves safely after use.

Wash the area with calcium hydroxide solution and then with clean water.

Disposal of components and gloves which are contaminated must be in accordance with local regulations.

Warning!  If there is contamination of the skin or eyes, wash the affected area with a continuous supply of

clean water or with calcium hydroxide solution for 15-60 minutes. Obtain immediate medical attention.

Safety cautions, when an engine is cleaned

Care should be taken, when an engine is cleaned with the use of a high pressure hose.

Cautions:

Do not wash an engine while the engines runs or if it is hot. If cold cleaning fluids are applied to a hot engine,

certain components on the engine could be damaged.

Leave the engine to cool for at least one hour and disconnect the battery connections before cleaning.

Do not wash any part of the Fuel Injection Pump (FIP), glow plugs, electrical shut off solenoid (ESOS) or

electrical connectors.

Ensure that the alternator, starter motor and any other electrical components are shielded and not directly

cleaned by the high pressure cleaning system.

If these cautions are ignored, the engine or certain components of the engine could be damaged, fail to operate

and also make the manufacturer’s warranty invalid.

Engines that conform to Emissions Levels

Engines that are fitted with an emissions label on the timing case conform to stage 1 emissions legislation and,

for certain service procedures, additional information is included to ensure that the engine remains emissions

approved.

Workshop Manual, TPD 1377E, issue 4

11

This document has been printed from SPI². Not for Resale

1

100 Series

Compression test data

Tests have shown that many factors affect compression pressures. Battery, starter motor condition, ambient

conditions and the type of gauge used can give a wide variation of results for a given engine.

Pressure kPa (lbf/in²)

Engine model

Standard

To be repaired

<2450 (355.5)

<2450 (355.5)

102-05, 103-07, 103-10, 103-13

103-15, 104-19, 104-22

>2940 (426.6) @ 200 rev/min

>2940 (426.6) @ 250 rev/min

A compression test should only be used to compare between cylinders of an engine. If one or more cylinders

vary by more than 350 KPa (50 lbf/in²) then those cylinders may be faulty.

A compression test should not be the only method used to show the condition of an engine, but it should be

used together with other symptoms and tests.

How to do a compression test

Note:   Before the compression test, ensure that the battery is in good condition and that it is fully charged. Also

ensure that the starter motor is in good condition.

1  To ensure that the engine cannot start, disconnect the engine stop solenoid or ensure the engine stop

control is in the ‘stop’ position.

2  Ensure that the valve tip clearances are set correctly.

3  Remove the atomisers.

4  Fit a suitable gauge into the atomiser hole of the cylinder to be tested.

5  Operate the starter motor and record the pressure indicated on the gauge.

6  Repeat for each cylinder.

12

Workshop Manual, TPD 1377E, issue 4

This document has been printed from SPI². Not for Resale

100 Series

2

Specifications

2

Basic engine data

Engine model

Engine build code

Number of cylinders

102-05

KN

103-07

103-10

KD

103-13

KH

103-15

KE

104-19

104-22

KR

KL

3

KF

4

2

3

3

3

4

Cylinder

arrangement and

cycle

Vertical in line, four stroke cycle

Direction of rotation

Induction system

Combustion system

Nominal bore

Clockwise, viewed from front

Naturally aspirated

IDI special swirl

67 mm

(2.6 in)

67 mm

(2.6 in)

75 mm

(2.9 in)

84 mm

(3.3 in)

84 mm

(3.3 in)

84 mm

(3.3 in)

84 mm

(3.3 in)

64 mm

(2.5 in)

64 mm

(2.5 in)

72 mm

(2.8 in)

80 mm

(3.1 in)

90 mm

(3.5 in)

90 mm

(3.5 in)

100 mm

(3.9 in)

Stroke

Compression ratio

24:1

24:1

23:1

22:1

22.5:1

22:1

22:1

0,451 ltrs.

(27.5 in³)

0,676 ltrs.

(41.2 in³)

0,954 ltrs.

(58.2 in³)

1,330 ltrs.

(81.1 in³)

1,496 ltrs.

(91.2 in³)

1,995 ltrs.

(121.7 in³)

2,216 ltrs.

(135.2 in³)

Cubic capacity

Firing order

1, 2

1, 2, 3

1, 2, 3

1, 2, 3

1, 2, 3

1, 3, 4, 2

1, 3, 4, 2

352-448

KPa

Oil pressure relief

Oil pressure switch

262-359 KPa

29,6 KPa

Valve tip clearance

(cold)

0,2 mm

(0.0078 in)

-Inlet

0,2 mm

(0.0078 in)

-Exhaust

Electrical system

Governor

12 volt

Mechanical all speed

Fuel injection

Cassette type fuel injection system

Workshop Manual, TPD 1377E, issue 4

13

This document has been printed from SPI². Not for Resale

2

100 Series

Thread Sealant

When setscrews or studs are fitted into holes which are tapped through the cylinder block, a suitable sealant

must be used to prevent leakage.

Micro encapsulated anaerobic sealant (M.E.A.S) fasteners have been introduced instead of jointing

compounds or other sealants when the fasteners are fitted in through holes into oil or coolant passages. The

identification of these fasteners, as supplied, is by a red, blue, or other colour sealant around the fastener

threads.

With M.E.A.S. sealed studs, the sealed end must be fitted into the cylinder head / cylinder block etc. Ensure

that the threaded holes have a 1,59 mm (0.0625 in) 45° chamfer, to ensure that when the new fasteners are

fitted the M.E.A.S. sealant is not removed. If the fasteners have to be removed and fitted again, the threads

must be cleaned and a suitable sealant used.

Note:   New setscrews have sealant applied by the manufacturer to the first 13,0 mm (0.50 in) of the threads.

If the setscrews are to be used again, clean the old sealant from the male and female threads and apply new

sealant, (Powerpart Threadlock and Nutlock) to the setscrews.

Recommended torque tensions

Most of the torques on the engine are standard. Torques specific to individual operations are listed in the

relevant operation. The standard torques listed in the tables below can be used when a specific torque is not

necessary.

Note:   The torques below apply to components lubricated lightly with clean engine oil before they are fitted.

Standard torques for setscrews, studs and nuts

Coarse Screw Thread

Fine Screw Thread

Thread

size

Bolt

Strength

Pitch

(mm)

Torque

(Nm)

Torque

(lbf ft)

Torque

(kgf m)

Pitch

(mm)

Torque

(Nm)

Torque

(lbf ft)

Torque

(kgf m)

8.8

11T

3

4

2

3

0,3

0,4

M4

M5

0,7

0,8

8.8

11T

6

8

4

6

0,6

0,8

8.8

11T

10

14

7

10

1,0

1,4

M6

1,0

8.8

11T

26

32

19

24

2,7

3,3

30

35

22

26

3,0

3,6

M8

1,25

1,5

1,0

1,25

1,25

1,5

8.8

11T

50

62

37

46

5,1

6,3

56

66

41

49

5,7

6,7

M10

M12

M14

M16

8.8

11T

75

104

55

77

7,6

10,6

84

113

62

83

8,6

11,5

1,75

2,0

8.8

11T

118

157

87

116

12,0

16,0

132

167

97

123

13,5

17,0

8.8

11T

167

230

123

170

17,0

23,4

175

245

129

181

17,8

20,5

2,0

1,5

Examples of applicable material

Bolt

Example

Strength

8.8

S45C

11T

SCM435

14

Workshop Manual, TPD 1377E, issue 4

This document has been printed from SPI². Not for Resale