Special requirements

Special tools

Part number

Description

Remover / replacer for valve guides

Adaptor

Description

Part number

21825478

21825479

Adaptor

21825935

1  Clean the parent bore for the valve guide (A6).

2  Lubricate the outer surface of the new guide with clean engine lubricating oil.

3  Fit the adaptor 21825479 (A5) into the remover / replacer tool 21825478 (A3). Pass the tool and adapter

through the spacer (A4) and the cylinder head, from the bottom face. Fully fasten the valve guide, with the large

15° chamfer at the bottom, and the distance piece (A7), 21825935, onto the adapter with the attachment (A8).

4  Turn the top handle (A1) to take up the excess movement in the tool and turn the bottom handle (A2) to pull

the valve guide into the cylinder head.

Caution: Do not ream new valve guides. They are supplied in a finished condition.

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7

8

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Peregrine EDi and 1300 Series EDi

Cylinder head

To inspect and to correct

Operation 3-17

1  Remove the cylinder head assembly, see Operation 3-8.

2  Remove the valve springs and the valves, see Operation 3-10.

3  Remove the thermostat, see Operation 12-2.

4  Inspect the cylinder head for signs of gas or coolant leakage.

5  Clean the face of the cylinder head, the passages for coolant and the passages for the lubricating oil.

6  The water jacket can be cleaned with a special solvent, which must be used in accordance with the

manufacturer’s instructions.

2

2

7  Pressure test the cylinder head to a pressure of 124/138 kPa (18/20 lbf in ) 1,27/1,41 kgf cm   and inspect

the cylinder head for leaks.

Warning! Always use a safety cage to protect the operator when a component is to be pressure tested in a

bath of water. Fit safety wires to secure the plugs that seal the hose connections of a component that is to be

pressure tested.

8  When the cylinder head is thoroughly clean, check it for cracks. Examine carefully the areas around the

valve seats and around the holes for the injector units.

9  The bottom face of the cylinder head can be machined if:

l   There is distortion (see step 10).

l   There are deep scratches.

10  Use a straight edge and feeler gauges to check the cylinder head for distortion (A) across and along its

bottom face, refer to the relevant Data and dimensions for the "Cylinder head" on page 10. If the distortion is

more than the given limit the bottom face can be machined.

Cautions:

l   Remove only the minimum material and ensure that the thickness of the cylinder head will not be less than

106,17 mm (4.180 in) after the cylinder head has been machined.

l   After the cylinder head has been machined the valve seats must be corrected to give the correct valve head

depth, see Operation 3-18.

l   It is advisable to work to the minimum limit to allow for later wear.

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6

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Peregrine EDi and 1300 Series EDi

11  Check the valve seats for wear and for damage.

12  Before any work is done on the valve seats, new valve guides must be fitted, see Operation 3-15 and

Operation 3-16.

13  Where there is little damage, the valve and valve seat can be lapped. When the valve seats are lapped

keep the seat to the measurements given in the relevant Data and dimensions for the "Cylinder head" on page

10. Ensure that all the compound used to lap the valve seat is removed from the valve and the valve seat.

14  Badly damaged valve seats can be corrected with a valve seat cutter, see Operation 3-18.

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Peregrine EDi and 1300 Series EDi

To

To correct a valve seat with a valve seat cutter

Operation 3-18

Special requirements

Special tools

Description

Part number

Set of adjustable cutters for valve seats

21825938

1  Before work is done on the valve seats, new valve guides must be fitted.

2  Fit the pilot in the valve guide and tighten the pilot.

3  Select the relevant cutter. Set the blades of the cutters to the diameter of the valve seat to be cut. Fit the

cutter on the pilot and fit the handle. Ensure that the cutter is not allowed to fall on to the seat as this can

damage the blades.

4  Carefully rotate the cutter in a clockwise direction (A). Remove only the minimum material to ensure a good

seat. Keep the seat as narrow as possible.

5  When the seat is cut, remove the cutter and the pilot. Remove any debris from the area of the valve seat

and the port.

6  Fit the valve and lightly lap the valve and the seat.

7  Check that the valve depth is within limits, see Operation 3-12.

8  If a valve seat has become too damaged or too worn to correct, a new valve seat insert can be fitted, see

Operation 3-19.

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Peregrine EDi and 1300 Series EDi

To fit valve seat inserts

Operation 3-19

1  Fit new valve guides, see Operation 3-15 and Operation 3-16.

2  With the bore of the new valve guide used as a pilot, machine out the old insert. Remove all debris and clean

the insert recess.

3  If the bottom face of the cylinder head has been machined, the insert will have to be surface ground on the

back face to ensure that there is no protrusion of the insert above the bottom face of the cylinder head. After

the back of the insert has been ground, ensure that the outer edge of the back face has a 0,9/1,3 mm (0.035/

0.051 in) chamfer at 30° to the vertical.

Warning! When frozen components are handled, frost proof gloves must be worn. If liquid nitrogen is used to

freeze components, then eye protection must also be worn.

4  Put the valve seat inserts in a deep freeze unit for 30 minutes. This will reduce the size of the valve seat

inserts to allow them to fit more easily into their recesses.

5  With the bore of the valve guide used as a pilot, and with the rear face of the insert towards the cylinder

head, press in the insert (A). Use a hydraulic press or a hand press in one continuous movement. Do not use

a hammer on the insert and do not use lubrication. Ensure that the bottom of the insert is in contact with the

bottom of the recess.

6  Cut the valve seat at an included angle of 90° for 45° valve seats or 120° for 30° valve seats, see Operation

3-18. Lap the valve on to the valve seat. Ensure that the depth of the valve head below the face of the cylinder

head is within the production limits, see Operation 3-12.

Note: Work as near as possible to the minimum figure to allow for future wear on the valve seat.

A

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Peregrine EDi and 1300 Series EDi

To renew injector unit sleeves

Operation 3-20

Special requirements

Special tools

Part number

Description

Description

Part number

27610093

Special tap

27610091

21825960

27610092

Adaptor (for use with 21825960 and

27610092)

Injector unit sleeve remover

Adaptor

Tool to fit the injector unit sleeve

27610094

Consumable products

Description

Part number

21820119 or

21820120

POWERPART Stud and bearing lock

To remove

1  Remove the fuel injector units, see Operation 11-2.

Caution: If the correct procedure is not used, the cylinders of the engine will be filled with fuel and engine

lubricating oil.

2  Put a suitable plug into the bottom of each sleeve to prevent the entry of debris into the cylinder.

3  Put the special tap, 27610091, (A1) into the sleeve for the injector unit and cut a thread into the sleeve (A).

Remove the tap.

4  Fit and tighten the adaptor 27610092 (B1) into the injector unit sleeve.

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Peregrine EDi and 1300 Series EDi

5  Fit the adaptor 27610093 (C2) into the adaptor 27610092 (C1).

6  Fit the injector unit sleeve remover 21825960 (C3) (slide hammer) to the adaptor.

7  Operate the sleeve remover to free the injector unit sleeve (D2) from the contact surfaces (D3) in the cylinder

head (D1).

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C

D

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To fit

Caution: Ensure that the piston is at the bottom of the cylinder or the tool used to fit the injector unit sleeve

might hit the piston. Do not allow debris to fall into the cylinder.

1  Use a wire brush to clean the top and bottom of the bore for the injector unit sleeve.

2  Remove any debris.

3  Put the sleeve onto the tool 27610094. Put POWERPART Stud and bearing lock onto the top and bottom

contact faces (E1) of the injector unit sleeve.

Note: Illustration (F) shows the contact faces (F3) of the injector unit sleeve (F2) in the cylinder head (F1).

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4  Put the sleeve and the tool into the bore for the injector unit in the cylinder head (G).

5  Hit the tool with a hammer to drive the injector unit sleeve into position at the bottom of the bore (H) in the

cylinder head.

6  Remove the tool.

7  Fit the injector units, see Operation 11-3.

G

H

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Peregrine EDi and 1300 Series EDi

To set the valve tip clearance

Operation 3-21

Notes:

l   The valve tip clearance is measured between the top of the valve stem and the rocker lever (B).

l   With the engine hot or cold, the correct clearances are 0,64 mm (0.025 in) for the inlet valves and for the

exhaust valves.

l   The positions of the valves are shown at (A). Number 1 cylinder is at the front of the engine.

l   The arrangement of the valves for each cylinder, in sequence, is inlet valve then exhaust valve.

Method one

1  Remove the rocker cover, see Operation 3-1.

2  Rotate the crankshaft in the normal direction of rotation until valve (A11) has just opened and valve (A12)

has not closed fully. Check / adjust the clearances of valves (A1) and (A2).

3  Set valves (A3) and (A4) as indicated above then check / adjust the clearances of valves (A9) and (A10).

4  Set valves (A7) and (A8) then check / adjust the clearances of valves (A5) and (A6).

5  Set valves (A1) and (A2) then check / adjust the clearances of valves (A11) and (A12).

6  Set valves (A9) and (A10) then check / adjust the clearances of valves (A3) and (A4).

7  Set valves (A5) and (A6) then check / adjust the clearances of valves (A7) and (A8).

8  Fit the rocker cover, see Operation 3-2.

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12

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