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Service Information

Document Title:
Function Group:
Mechanical
injection 236
D5D,
checking
and
adjusting

Information Type:
Service Information

Date:
12/07/2011

Profile:
Engine, D5D [GB]

Mechanical injection D5D, checking and adjusting


Determining injection angle and thickness of shim

NOTICE
Before determining injection angle, thickness of shim and installing the unit pumps, measure the control rod, see
236 Control rod, measuring.

Injection angle (timing) and type of camshaft are indicated on the ID-plate.
To reduce white smoke at cold start, the later versions of D5D are equipped with hydraulic roller tappets. These engines are
characterized by the EP-codes on the engine ID-plate having a value between 700799.
Since the hydraulic roller tappets' height differs from the earlier, the unit pumps have different installation measurements.
Thus different special tools are used for measuring the distance between roller tappet and the engine block.

Figure 1

1.
2.

Shim
Hydraulic roller tappet for reduction of white smoke

Op nbr
9998678 Measuring tool
9998679 Timing tool
11668408 Setting tool
9998685 Setting tool

Indicator
Magnetic base

NOTICE
9998685 Setting tool is used for engines with conventional roller tappets. 11668408 Setting tool is used for engines with
hydraulic roller tappets to reduce white smoke
The following methods only need to be performed after replacing engine block, camshaft or a roller tappet.
When only replacing a unit pump, see the section "Replacing unit pump".
Determining top dead centre
1. Install timing tool (protractor) 9998679 on the flywheel flange on the crank shaft.

NOTICE
Tighten the bolts thoroughly so that there is no clearance.

Figure 2
9998679
2. Secure the indicator. Use a magnetic base.

Figure 3

3. Position measuring rod 9998678 together with spacer washers above the piston relevant to the unit injector for
which the injection angle is to be determined.
Turn the crankshaft in the direction of rotation of the engine until the pointer has reached its turning point.
Set the graduated ring on the dial test indicator to zero.

Figure 4
9998678
To reduce the risk of obtaining the wrong measurement when determining top dead centre, the
following method must be performed:

4. Turn the crankshaft in the direction of rotation of the engine approx. 350 until there is 8 mm (0.315 in) left to the
top dead centre (the turning point of the test dial indicator).
Set the timing tool (protractor) 9998679 to zero.

Figure 5

5. Turn the crankshaft in the opposite direction until there is 8 mm (0.315 in) left to the top dead centre (the turning
point of the test dial indicator).
Read off the timing tool (protractor) .
Example: 50.

Figure 6

6. Turn the crankshaft a distance equal to half of the obtained reading.


Example: (0 + 50) / 2 = 25 = Actual value. This corresponds to the top dead centre and should agree with the

turning point on the dial indicator.

Figure 7

7. Set the timing tool (protractor) 9998679 to zero.

NOTICE
Leave the timing tool (protractor) in position in preparation for the next stage in determining the injection angle.

Figure 8
Measuring tolerance deviation, engine block (engine without hydraulic roller tappets for reduction of
white smoke)
We suggest copying the Value tables 1, 2 and 3.

8. Install the dial indicator on measuring tool 9998685, with a preload of 5 mm (0.20 in) on the millimetre scale.
The hollow cylinder's measurement, Le, is calibrated to 150 mm (5.905 in). Reset the scale ring to zero against
the gauge pointer.

Figure 9

1.
2.
3.
4.
5.

9998685
Dial test indicator
Pointer
Millimetre graduation
Graduated ring

9. Place the roller tappet without shim for the unit pump for which the timing is to be adjusted, on the base circle of
the camshaft.
Carefully insert 9998685 in the unit pump's hole.

Figure 10

NOTICE
Make sure that the guide on the roller tappet engages the groove in the location.
10. Turn the crankshaft until it is certain that the roller tappet is on the camshaft's base circle.

Figure 11

11. Measure "L" (Le - dial indicator X mm) and enter this in "Calculation table 2.2".
Example:
Measuring tool: Le = 150 mm (5.905 in)
Dial indicator (X mm) = 2.18 mm (0.086 in)
The dial indicator shows 7.18 mm (0.283 in) when it is placed in the unit pump's hole.
The preload was 5 mm.
7.18 mm (0.283 in) - 5 mm (0.197 in) = 2.18 mm (0.086 in)

L= 150 mm (5.905 in) + 2.18 mm (0.086 in) = 152.18 mm (5.991 in)

Figure 12
Measuring tolerance deviation, roller tappets and camshaft (engine without hydraulic roller tappets
for reduction of white smoke)
12. Read off the injection angle, Fbnom on the engine type plate.
Read off the lift of the camshaft, Vhnom i Value table 1.
Enter both values in "Calculation table 2.1".
Example:
Fbnom = injection angle = 6.0
Camshaft type = A
Vhnom = The value obtained on the timing tool (protractor) when the crankshaft has been turned so far that the
camshaft has affected the tappet 6.11 mm (0.241 in).
Turn the crankshaft in the engine's rotational direction until the dial indicator shows - (minus) Vhnom's value of 6.11
mm (0.241 in), which is the camshaft lift.
Example:
7 mm (0.2756 in) - 6.11 mm (0.241 in) = 0.89 mm (0.035 in).
The dial indicator was reset to 5 mm (0.1968 in) preload on the gauge, and when it shows 0.89 mm (0.035 in),
then Vhnom has been obtained.

Figure 13

13. The value shown on the timing tool (protractor) is the number of degrees at which the injection begins (e.g.
354.4).
Example: 360 - 354.4 = 5.5
Enter this value in the Calculation tables 2.1 and 3.1

Figure 14

14. Read off the measurement "A" on the unit pump and enter this in the table Calculation table2.1.
Example: A / 100 = 0.63 mm (0.025 in).

Figure 15

15. Remove the measuring tool and the dial indicator. Conclude the calculations to determine the shim thickness in
Calculation table 2.2

NOTICE
Do not forget to change the EP-code on the engine's ID-plate.

Figure 16

16. Allow the shim to slide into position along, for example, a screwdriver and down into the roller tappet.

NOTICE
Repeat the measuring procedures described in points 12-16 for each unit injector.

Figure 17

Measuring tolerance deviation, engine block (engine with hydraulic tappets for reduction of white
smoke)
We suggest copying the Value tables 1, 2 and 3.
17. Install the dial indicator on 11668408, with a preload of 5 mm (0.20 in) on the millimetre scale.
The hollow cylinder's measurement, Le, is calibrated to 149.25 mm (5.876 in). Reset the scale ring to zero
against the gauge pointer.

Figure 18

1.
2.
3.
4.
5.

11668408
Dial test indicator
Pointer
Millimetre graduation
Graduated ring

18. Place the roller tappet without shim for the unit pump for which the timing is to be adjusted, on the base circle of
the camshaft.
Carefully insert 11668408 in the unit pump's hole.

Figure 19

NOTICE
Make sure that the guide on the roller tappet engages the groove in the location.
19. Turn the crankshaft until it is certain that the roller tappet is on the camshaft's base circle.

Figure 20

20. Measure "L" (Le + Roller tappet's piston lift 1 mm - dial indicator X mm) and enter it in "Calculation table 2.2".
Example:
Measuring tool: Le = 149.25 mm (5.876 in)
The dial indicator shows 5,94 mm when it is positioned in the unit pump's hole. The preload was 5 mm. 5.94 - 5
mm = 0.94 mm
L= 149.25 mm (5.876 in) + 1 mm (0.039 in) - (+0.94 mm) (0.037 in) = 149.31 mm (5.878 in)

Figure 21

21. Read off the measurement "A" on the unit pump and enter this in the table Calculation table2.1.
Example: A / 100 = 0.86 mm (0.034 in).

Figure 22

22. Remove the measuring tool and the dial indicator. Conclude the calculations to determine the shim thickness in
Calculation table 2.2

NOTICE
Do not forget to alter the EP code on the engine type plate.

Figure 23

23. Allow the shim to slide into position along, for example, a screwdriver and down into the roller tappet.

NOTICE
Repeat the measuring procedures described in points 17-25 for each unit injector.

Figure 24

Measuring control rod stroke for adjusting engine revolution governor


Op nbr

1. Measure the control rod's X-measurement from the face of the timing gear casing to the stop position.
Example of the X measurement: 1.1 mm (0.0433 in).

NOTICE
The measured value must be stated for when running in a test bench after completed repairs, alteration or
modification of the governor with regard to the operating speed.

Figure 25

Determining the shim's thickness when changing unit pump

NOTICE
This may be done if no other machining has been carried out.
Mathematical formula for new shim thickness: Ts = Ek - (L + A / 100)
True thickness of shim, Ss, is obtained from Value table 2.

NOTICE
This formula only applies to replacement of unit pump.
Calculation table 1

Factor

Ex

Cylinder number

D5D
Cyl. 1

Cyl. 2

Unit pump serial number[ 1] 


EP code (see Value table 3)

EP

751

Corrected installation measurement Ek


(se Value table 3)

143.275

Basic measurements of unit pump L


(see Value table 1)

136.8

Manufacturing tolerance (se marking A/100


on unit pump)

0,86

Theoretical thickness of shim

Ts

5.62

(see Ss

5,60

True thickness of
Calculation table 2.2)

shim

Example: Change of unit pump for cylinder 3 on a D5D with hydraulic roller tappets
Op nbr

Cyl. 3

Cyl. 4

1. Read off the EP-code for cylinder 3 from the engine type plate in the column "EP", e.g. 751.
Order of readings in the "EP" column on the engine type plate: line 1 = cylinder No. 1, line 2 = cylinder No. 2 and
so on.

Figure 26
Engine type plate
2. Using the EP-code, read off the corrected installation measurement, Ekfor the unit pump from Value table 3.
Example: EP-code = 751 gives Ek = 143.275 mm (5.641 in).
3. Read off the manufacturing tolerance for the unit pump's length A, from the new unit pump.
Example: Tolerance value A / 100 gives 86 / 100 = 0.86 mm (0.0339 in).

Figure 27
Manufacturing tolerance

NOTICE
If the value is not legible, remove any dirt, but not by scraping.

4. Read off the standard measurement for the unit pump, L, from Calculation table 1.
Example: 136.8 mm (5.3858 in)
5. Determine the theoretical shim thickness, Ts, according to the formula: Ts = Ek-(L + A / 100)(also see example in
table Calculation table 1)
Example: Ts=143.275 mm - (136.8 mm + 0.86 mm) = 5.62 mm (0.2213 in)
6. Select thickness of shim, Ss, according to Value table 2.
Example: Ts= 5.62 mm (0.2213 in) gives Ss = 5.6 mm (0.2205 in).
Unit pump, installing
Op nbr
9998679 Timing tool
9998681 Rotation tool

9998684 Installation tool

1. Position the roller tappets together with associated shims.

Figure 28

1.

Control arm

CAUTION
Turn the unit pump's link arm to the middle position.
2. Check that the cam on the unit pump is placed against the base circle for the relevant cylinder. Crank the engine
with the aid of tool 9998681 or timing tool (protractor) 9998679.

NOTICE
The control rod must be locked in stop position with tool 9998684.
3. Coat the O-rings on the unit pump with oil. Carefully enter the unit pump into its location.

Figure 29

1.
2.
3.

Control rod
Shims for pump element
Roller tappet for pump element

CAUTION
Check that the unit pump's link arm is in the control rod's groove before it is pressed down.

4. Position the flange with the chamfer directed toward the body of the unit pump.
Coat the bolts with oil and tighten them evenly.
Tightening torque, see step 1 and 2, 030 Fuel system, tightening torques

Figure 30

5. Carefully turn the unit pump counter-clockwise. Use a torque wrench with gauge and socket 11668403.
Make a note of the reading on the gauge on the torque wrench required to turn the unit pump, e.g. 3.5 Nm (2.6 lbf
ft).
Stop turning the torque wrench when the unit pump has reached its stop position and the torque has increased by1
Nm (0.74 lbf ft).
Example: 3.5 + 1 = 4.5 Nm (2.58 + 0.74 = 3.32 lbf ft)

Figure 31

6. Tighten the bolts alternately according to 030 Fuel system, tightening torques.

NOTICE
Check that the control rod moves easily after installing each unit pump

7. Repeat points 1-6 for the other cylinders.

NOTICE
Check that the control rod moves easily after installing each unit pump

8. Loosen the bolt on measuring tool 9998684 and turn it away from the control rod, and tighten the measuring tool's
bolt on the measuring position.

Figure 32

1.

9998684

9. Measure from the tool to the control rod stop position.


Example: 30.5 mm (1.20 in)

Figure 33

10. Measure from the measuring tool to the starting position for the control rod.
Example: 13.6 mm (0.535 in) The difference between the start and stop positions is the control rod stroke.
Control rod's smallest stroke =16. 8 mm (0.661 in).
Example: Stop position = 30.5 mm (1.20 in)
Starting position = 13.6 mm (0.535 in)
Control rod's stroke: 30.5 - 13.6 = 16.9 mm (1.20 - 0.535 = 0.665 in).
Determining thickness of shim when injector is to open

NOTICE
Determining the thickness of shim shall be done when changing engine block, camshaft or roller tappet.

Use Calculation table 2.1 and Calculation table 2.2below for calculating the shim's thickness.
Mathematical formula for determining new thickness of shim:
Ts = L - ((Fbakt - Fbnom) x Vhkorr + Vhnom + L + A / 100)

The true shim thickness can be found in Calculation table 2.2.Ts

Ss

NOTICE
After the shim thickness has been determined, a new EP-code must alwaysbe retrieved from Value table 3 in order to
allow a correct, future replacement of the pump.

Calculation table 2.1

Factor

Cylinder number

Ex.

Engine D5D

Cyl. 1

Cyl. 2

Cyl. 3

Cyl. 4

Cyl. 1

Cyl. 2

Cyl. 3

Cyl. 4

Unit pump serial number[ 2] 


Injection angle,
(protractor)

measured

on

timing

tool Fbakt

5,5

Injection angle (see engine type polate)

Fbnom

6.0

Sum 1, (S1 = Fbakt - Fbnom)


Presetting, correction factor (see Value table 1)

S1

0,5

Vhkorr

0,14

Sum 2 (S2 = S1 x Vhkorr)


Camshaft lift (see Value table 1)

S2

0,07

Vhnom

6,11

Basic measurement on unit pump (see Value table L


1)

143

Manufacturing tolerance (see Unit pump)

A/100

0,63

Sum 3 (S3 = S2 + Vhnom + L + A / 100)

S3

149,67

Calculation table 2.2

Code

Ex.

Length between cylinder block and roller tappet

151,43

Sum 3 (S3 = S2 + Vhnom + L + A / 100)


Theoretical thickness of shim

S3

149,67

Ts

1,76

Ss

1.8

True thickness of shim (see Value table 2)

Determining corrected installation measurement, Ek, and EP code for unit pump
When replacing cylinder block, camshaft or roller tappet, the corrected installation measurement, Ek, must be determined
again and the EP code and the engine type plate must be altered.
Mathematical formula for the corrected installation measurement, Ek
The following applies to engine without hydraulic roller tappets for reduction of white smoke:
Ek = L - ((Fbakt - Fbnom) x Vhkorr + Vhnom
The following applies to engine with hydraulic roller tappets for reduction of white smoke:
Ek = L - Vhnom
New EP-code can be calculated in Calculation table 3.2 where the Ek - value gives a new EP-code in Value table 3.
Calculation table 3.1

Code

Cylinder number

Unit pump serial number[ 3] 

Injection angle,
(protractor)

measured

on

timing

Injection angle (see engine type polate)


Sum 1, (S1 = Fbakt - Fbnom)
Correction factor (see Value table1)
Sum 2, (S2 = S1 x Vhkorr)
Camshaft lift (see Value table 1)
Sum 3, (S3 = S2 + Vhnom)

Ex.

tool Fbakt

5,5

Fbnom
S1

6.0

Vhkorr
S2

Vhnom
S3

+ 6.11

= 0,5
0,14

= 0,07
= 6.04

Engine D5D
Cyl. 1

Cyl. 2

Cyl. 3

Cyl. 4

Calculation table 3.2

Code

Cylinder number:

Ex.
-

Length between cylinder block and roller tappet

151.43

Sum 3, (S3 = S2 + Vhnom)


Ek (Ek = L - S3)

S3

6.04

Ek
Ek

= 145.39

EP

= 337

Ek, rounded to the nearest value in Value table 3


EP code (Ek results in EP code in Value table 3)

Engine D5D
Cyl. 1

Cyl. 2

Cyl. 3

Cyl. 4

145,40

Unit explanations
Unit explanations
Code

Factor

Explanation

Fbakt

FD
BTDC)

( Injection angle, measured on timing tool (protractor) according to method

Fbnom

FD
BTDC)

( Injection angle, can be found on engine type plate

Vhkorr

mm/FD
(in/BTDC)

Pre-tension, correction factor can be found in Value table 1

Vhnom

mm

Camshaft lift, nominal. Can be found in Value table 1

mm

Measured between cylinder block and roller tappet according to method

mm

Basic measurement on unit pump

Lfb
A/100

mm

The exact point at which the unit pump begins to supply fuel

mm

Manufacturing tolerance, written on the unit pump

Ts
Ss

mm

Theoretical thickness of shim

mm

True thickness of shim

S1, S2 and S3

Total (sum) of calculations

EP

Code value that can be found in Value table 3 or on engine type plate

Ek

mm

The total of one calculation. Only applies when calculating EP code.

Value table 1, information about camshafts


Value table 1, information about camshafts
Injection
angle, Camshaft type
Fbnom
FD (BTDC)

camshaft
Vhnommm (in)

lift, Preload, correction Unit pump's length,


measurement,
factor,
Vhcorrmm/ basic
BTDC
Lmm (in)
(in/BTDC)

5.0

6.32 mm (0.2488 in)

0.14

143 mm (5.630 in)

6.0

6.11 mm (0.2406 in)

0.14

143 mm (5.630 in)

7.0

5.90 mm (0.2323 in)

0.14

143 mm (5.630 in)

8.0

5.70 mm (0.2244 in)

0.14

143 mm (5.630 in)

9.0

5.50 mm (0.2165 in)

0.14

143 mm (5.630 in)

4.0

5.31 mm (0.2091 in)

0.14

143 mm (5.630 in)

4.5

5.70 mm (0.2244 in)

0.14

143 mm (5.630 in)

5.0

5.60 mm (0.2205 in)

0.14

143 mm (5.630 in)

5,5

5.50 mm (0.2165 in)

0.14

143 mm (5.630 in)

6.0

5.31 mm (0.2091 in)

0.14

143 mm (5.630 in)

7.0

5.10 mm (0.2008 in)

0.14

143 mm (5.630 in)

2.0

6.06 mm (0.2386 in)

143 mm (5.630 in)

2.5

5.97 mm (0.2350 in)

143 mm (5.630 in)

3.0

5.88 mm (0.2315 in)

143 mm (5.630 in)

3.5

5.79 mm (0.2280 in)

143 mm (5.630 in)

4.0

5.70 mm (0.2244 in)

143 mm (5.630 in)

4.5

5.61 mm (0.2209 in)

143 mm (5.630 in)

5.0

5.52 mm (0.2173 in)

143 mm (5.630 in)

5,5

5.43 mm (0.2138 in)

143 mm (5.630 in)

6.0

5.35 mm (0.2106 in)

143 mm (5.630 in)

6,5

5.26 mm (0.2079 in)

143 mm (5.630 in)

7.0

5.17 mm (0.2035 in)

143 mm (5.630 in)

7.5

5.08 mm (0.2000 in)

143 mm (5.630 in)

8.0

4.99 mm (0.1965 in)

143 mm (5.630 in)

2.0

6.198 mm (0.2440 in)

143 mm (5.630 in)

2.5

6.110 mm (0.2406 in)

143 mm (5.630 in)

3.0

6.020 mm (0.2370 in)

143 mm (5.630 in)

3.5

5.930 mm (0.2335 in)

143 mm (5.630 in)

4.0

5.842 mm (0.2300 in)

143 mm (5.630 in)

4.5

5.75 mm (0.2264 in)

143 mm (5.630 in)

5.0

5.66 mm (0.2228 in)

143 mm (5.630 in)

5,5

5.58 mm (0.2197 in)

143 mm (5.630 in)

6.0

5.49 mm (0.2161 in)

143 mm (5.630 in)

Value table 1, information about camshafts (engines with hydraulic roller tappets for reduction of white
smoke)
Value table 1, information about camshafts
Injection
angle, Camshaft type
Fbnom
FD (BTDC)

camshaft
Vhnommm (in)

lift, Preload, correction Unit pump's length,


measurement,
factor,
Vhcorrmm/ basic
BTDC
Lmm (in)
(in/BTDC)

2.0

6.198 mm (0.2440 in)

136.8 mm (5.386 in)

2.5

6.110 mm (0.2406 in)

136.8 mm (5.386 in)

3.0

6.020 mm (0.2370 in)

136.8 mm (5.386 in)

3.5

5.930 mm (0.2335 in)

136.8 mm (5.386 in)

4.0

5.842 mm (0.2300 in)

136.8 mm (5.386 in)

Value table 2, information about shim thicknesses, L0=143 mm


Value table 2, information about shim thicknesses
Theoretical thickness, Ts
0,95 - 1,049 mm
(0.03740 - 0.0430 in)

Thickness of shim, Ss

Theoretical thickness, Ts

Thickness of shim, Ss

1,0 mm
(0.039 in)

3,05 - 3,149 mm
(0.1201 - 0.12398 in)

3,1 mm
(0.122 in)

1,05 - 1,149 mm
(0.0413 - 0.04524 in)

1,1 mm
(0.043 in)

3,15 - 3,249 mm
(0.1240 - 0.12791 in)

3,2 mm
(0.126 in)

1,15 - 1,249 mm
(0.0453 - 0.04917 in)

1,2 mm
(0.047 in)

3,25 - 3,349 mm
(0.1280 - 0.13185 in)

3,3 mm
(0.130 in)

1,25 - 1,349 mm
(0.0492 - 0.05311 in)

1,3 mm
(0.051 in)

3,35 - 3,449 mm
(0.1319 - 0.13579 in)

3,4 mm
(0.134 in)

1,35 - 1,449 mm
(0.0531 - 0.05705 in)

1,4 mm
(0.055 in)

3,45 - 3,549 mm
(0.136 - 0.13972 in)

3,5 mm
(0.138 in)

1,45 - 1,549 mm
(0.057 - 0,06098 in)

1,5 mm
(0.059 in)

3,55 - 3,649 mm
(0.1398 - 0.14366 in)

3,6 mm
(0.142 in)

1,55 - 1,649 mm
(0.0610 - 0.06492 in)

1,6 mm
(0.063 in)

3,65 - 3,749 mm
(0.1437 - 0.14760 in)

3,7 mm
(0.146 in)

1,65 - 1,749 mm
(0.0650 - 0.06886 in)

1,7 mm
(0.067 in)

3,75 - 3,850 mm
(0.1476 - 0.15157 in)

3,8 mm
(0.150 in)

1,75 - 1,849 mm
(0.0689 - 0.07280 in)

1,8 mm
(0.071 in)

3,85 - 3,949 mm
(0.1515 - 0.15547 in)

3,9 mm
(0.154 in)

1,85 - 1,949 mm
(0.0730 - 0.07673 in)

1.9 mm
(0.075 in)

3,95 - 4,049 mm
(0.1555 - 0.15941 in)

4,0 mm
(0.158 in)

1,95 - 2,049 mm

2.0 mm

4,05 - 4,149 mm

4,1 mm

(0.0768 - 0.08067 in)

(0.079 in)

(0.1594 - 0.16335 in)

(161 in)

2,05 - 2,149 mm
(0.0807 - 0.0846 in)

2,1 mm
(0.083 in)

4,15 - 4,249 mm
(0.1634 - 0.16728 in)

4,2 mm
(165 in)

2,15 - 2,249 mm
(0.0846 - 0.08854 in)

2.2 mm
(0.087 in)

4,25 - 4,349 mm
(0.1673 - 0.17122 in)

4,3 mm
(0.169 in)

2,25 - 2,349 mm
(0.0886 - 0.9248 in)

2.3 mm
(0.091 in)

4,35 - 4,449 mm
(0.1713 - 0.17516 in)

4,4 mm
(0.173 in)

2,35 - 2,449 mm
(0.0925 - 0.09642 in)

2,4 mm
(0.095 in)

4,45 - 4,549 mm
(0.1752 - 0.17909 in)

4,5 mm
(0.177 in)

2,45 - 2,549 mm
(0.0965 - 0.1004 in)

2,5 mm
(0.098 in)

4,55 - 4,649 mm
(0.1791 - 0.18303 in)

4,6 mm
(0.181 in)

2,55 - 2,649 mm
(0.1004 - 0.10429 in)

2,6 mm
(0.102 in)

4,65 - 4,749 mm
(0.1831 - 0.18697 in)

4,7 mm
(0.185 in)

2,65 - 2,749 mm
(0.1043 - 0.10823 in)

2,7 mm
(0.106 in)

4,75 - 4,849 mm
(0.1870 - 0.19091 in)

4,8 mm
(0.189 in)

2,75 - 2,849 mm
(0.1083 - 0.11217 in)

2,8 mm
(0.110 in)

4,85 - 4,949 mm
(0.1910 - 0.19484 in)

4,9 mm
(0.193 in)

2,84 - 2,949 mm
(0.1118 - 0.11610 in)

2,9 mm
(0.115 in)

4,95 - 5,049 mm
(0.1949 - 0.19878 in)

5,0 mm
(0.197 in)

2,95 - 3,049 mm
(0.1161 - 0.12004 in)

3,0 mm
(0.118 in)

Value table 2, information about shim thicknesses (engines with hydraulic roller tappets for reduction of
white smoke), L0=136.8 mm
Value table 2, information about shim thicknesses
Theoretical thickness, Ts
4.625 - 4.6749 mm
(0.1831 - 0.18697 in)

Shim thickness, Ss
4.65 mm
(0.1831 in)

Theoretical thickness, Ts

Shim thickness, Ss

5.575 - 5.6249 mm
(0.2195 - 0.22145 in)

5.60 mm
(0.220 in)

4.675 - 4.7249 mm
(0.18406 - 0.18602 in)

4.70 mm
(0.1850 in)

5.625 - 5.6749 mm
(0.2215 - 0.22342 in)

5.65 mm
(0.222 in)

4.725-4.7749 mm
(0.18602 - 0.18800 in)

4.75 mm
(0.1870 in)

5.675 - 5.7249 mm
(0.22342 - 0.22539 in)

5.70 mm
(0.224 in)

4.775 - 4.8249 mm
(0.18800 - 0.19000 in)

4.80 mm
(0.1900 in)

5.725 - 5.7749 mm
(0.2254 - 0.22736 in)

5.75 mm
(0.226 in)

4.825 - 4.8749 mm
(0.19000 - 0.19192 in)

4.85 mm
(0.1909 in)

5.775 - 5.8249 mm
(0.2274 - 0.22933 in)

5.80 mm
(0.228 in)

4.875 - 4.9249 mm
(0.19192 - 0.19389 in)

4.90 mm
(0.1929 in)

5.825 - 5.8749 mm
(0.2293 - 0.23129 in)

5.85 mm
(0.230 in)

4.925 - 4.9749 mm
(0.19192 - 0.19586 in)

4.95 mm
(0.1949 in)

5.875 - 5.9249 mm
(0.2313 - 0.23326 in)

5.90 mm
(0.232 in)

4.975 - 5.0249mm
(0.19586 - 0.19783 in)

5.00 mm
(0.1968 in)

5.925 - 5.9749 mm
(0.2333 - 0.23523 in)

5.95 mm
(0.234 in)

5.025 - 5.0749 mm
(0.19783 - 0.19980 in)

5.05 mm
(0.1988 in)

5.975 - 6.0249 mm
(0.2352 - 0.23720 in)

6.00 mm
(0.236 in)

5.075 - 5.1249 mm
(0.19980 - 0.20177 in)

5.10 mm
(0.2008 in)

6.025 - 6.0749 mm
(0.2372 - 0.23917 in)

6.05 mm
(0.238 in)

5.125 - 5.1749 mm
(0.20177 - 0.20374 in)

5.15 mm
(0.2027 in)

6.075 - 6.1249 mm
(0.2392 - 0.24114 in)

6.10 mm
(0.240 in)

5.175 - 5.2249 mm
(0.20374 - 0.20570 in)

5.20 mm
(0.2047 in)

6.125 - 6.1749 mm
(0.2411 - 0.24311 in)

6.15 mm
(0.242 in)

5.225 - 5.2749 mm
(0.20570 - 0.20767 in)

5.25 mm (0.207 in)


(0.2067 in)

6.175 - 6.2249 mm
(0.2431 - 0.24507 in)

6.20 mm
(0.244 in)

5.275 - 5.3249 mm
(0.20768 - 0.20964 in)

5.30 mm
(0.2087 in)

6.225 - 6.2749 mm
(0.2451 - 0.24704 in)

6.25 mm
(0.246 in)

5.325 - 5.3749 mm
(0.20965 - 0.21161 in)

5.35 mm
(0.2106 in)

6.275 - 6.3249 mm
(0.2470 - 0.24901 in)

6.30 mm
(0.248 in)

5.375 - 5.4249 mm
(0.21161 - 0.21358 in)

5.40 mm
(0.2156 in)

6.325 - 6.3749 mm
(0.2490 - 0.25098 in)

6.35 mm
(0.250 in)

5.425 - 5.4749 mm

5.45 mm

6.375 - 6.4249 mm

6.40 mm

(0.21161 - 0.21555 in)

(0.2146 in)

5.475 - 5.5249 mm
(0.21555 - 0.21752 in)

5.50 mm
(0.2165 in)

5.525 - 5.5749 mm
(0.21752 - 0.21948 in)

5.55 mm
(0.2185 in)

(0.2510 - 0.25295 in)

(0.252 in)

Value table 3, information about EP-codes, L0=143 mm


Value table 3, information about EP codes
Ek
145.35 mm
(5.7224 in)

EP code

Ek

EP code

Ek

EP code

Ek

EP code

145.375 mm
(5.7234 in)

336

145.4 mm
(5.7244 in)

337

146.0 mm
(5.7480 in)

361

146.6 mm
(5.7716 in)

385

147.2 mm
(5.7953 in)

409

145.425 mm
(5.7254 in)

338

146.025 mm
(5.7490 in)

362

146.625 mm
(5.7726 in)

386

147.225 mm
(5.7962 in)

410

145.45 mm
(5.7264 in)

339

146.05 mm
(5.7500 in)

363

146.65 mm
(5.7736 in)

387

147.25 mm
(5.7972 in)

411

145.475 mm
(5.7273 in)

340

146.075 mm
(5.7510 in)

364

146.675 mm
(5.7746 in)

388

147.275 mm
(5.7982 in)

412

145.5 mm
(5.7283 in)

341

146.1 mm
(5.7520 in)

365

146.7 mm
(5.7756 in)

389

147.3 mm
(5.7992 in)

413

145.525 mm
(5.7293 in)

342

146.125 mm
(5.7529 in)

366

146.725 mm
(5.7766 in)

390

147.325 mm
(5.8002 in)

414

145.55 mm
(5.7303 in)

343

146.15 mm
(5.7539 in)

367

146.75 mm
(5.7775 in)

391

147.35 mm
(5.8012 in)

415

145.75 mm
(5.7382 in)

344

146.175 mm
(5.7549 in)

368

146.775 mm
(5.7785 in)

392

147.375 mm
(5.8021 in)

416

145.6 mm
(5.7323 in)

345

146.2 mm
(5.7559 in)

369

146.8 mm
(5.7800 in)

393

147.4 mm
(5.8031 in)

417

145.625 mm
(5.7333 in)

346

146.225 mm
(5.7568 in)

370

146.825 mm
(5.7805 in)

394

147.425 mm
(5.8041 in)

418

145.65 mm
(5.7342 in)

347

146.25 mm
(5.7579 in)

371

146.85 mm
(5.7815 in)

395

147.45 mm
(5.8051 in)

419

145.675 mm
(5.7352 in)

348

146.275 mm
(5.7588 in)

372

146.875 mm
(5.7825 in)

396

145.7 mm
(5.7362 in)

349

146.3 mm
(5.7600 in)

373

146.9 mm
(5.7834 in)

397

145.725 mm
(5.7372 in)

350

146.325 mm
(5.7608 in)

374

146.925 mm
(5.7844 in)

398

145.75 mm
(5.7382 in)

351

146.35 mm
(5.7618 in)

375

146.95 mm
(5.7854 in)

399

145.775 mm
(5.7392 in)

352

146.375 mm
(5.7628 in)

376

146.975 mm
(5.7864 in)

400

145.8 mm
(5.7401 in)

353

146.4 mm
(5.7638 in)

377

147.0 mm
(5.7874 in)

401

145.825 mm
(5.7411 in)

354

146.425 mm
(5.7647 in)

378

147.025 mm
(5.7884 in)

402

145.85 mm
(5.7421 in)

355

146.45 mm
(5.7657 in)

379

147.05 mm
(5.7894 in)

403

145.875 mm
(5.7431 in)

356

146.475 mm
(5.7667 in)

380

147.075 mm
(5.7903 in)

404

145.9 mm
(5.7441 in)

357

146.5 mm
(5.7677 in)

381

147.1 mm
(5.7913 in)

405

145.925 mm
(5.7451 in)

358

146.525 mm
(5.7687 in)

382

147.125 mm
(5.7923 in)

406

335

145.95 mm
(5.7460 in)

359

146.55 mm
(5.7697 in)

383

147.15 mm
(5.7933 in)

407

145.975 mm
(5.7470 in)

360

146.575 mm
(5.7707 in)

384

147.175 mm
(5.7943 in)

408

Value table 3, information about EP-codes (engines with hydraulic roller tappets for reduction of white
smoke), L0= 136.8 mm
Value table 3, information about EP codes
Ek
142.0 mm
(5.5905 in)

EP code

Ek
142.7 mm
(5.6181 in)

EP code

Ek
143.4 mm
(5.6457 in)

EP code

Ek

EP code

756

144.1 mm
(5.6732 in)

784

142.025 mm
(5.5915 in)

701

142.725 mm
(5.6191 in)

729

143.425 mm
(5.6466 in)

757

144.125 mm
(5.6742 in)

785

142.05 mm
(5.5925 in)

702

142.75 mm
(5.6201 in)

730

143.45 mm
(5.6476 in)

758

144.15 mm
(5.6752 in)

786

142.075 mm
(5.5935 in)

703

142.775 mm
(5.6210 in)

731

143.475 mm
(5.6486 in)

759

144.175 mm
(5.6762 in)

787

142.1 mm
(5.5945 in)

704

142.8 mm
(5.6220 in)

732

143.5 mm
(5.6496 in)

760

144.2 mm
(5.6771 in)

788

142.125 mm
(5.5955 in)

705

142.825 mm
(5.6230 in)

733

143.525 mm
(5.6506 in)

761

144.225 mm
(5.6781 in)

789

142.15 mm
(5.5964 in)

706

142.85 mm
(5.6240 in)

734

143.55 mm
(5.6516 in)

762

144.25 mm
(5.6791 in)

790

142.175 mm
(5.5974 in)

707

142.875 mm
(5.6250 in)

735

143.575 mm
(5.6525 in)

763

144.275 mm
(5.6801 in)

791

142.2 mm
(5.5984 in)

708

142.9 mm
(5.6260 in)

736

143.6 mm
(5.6535 in)

764

144.3 mm
(5.6811 in)

792

142.225 mm
(5.5994 in)

709

142.925 mm
(5.6270 in)

737

143.625 mm
(5.6545 in)

765

144.325 mm
(5.6821 in)

793

142.25 mm
(5.6004 in)

710

142.95 mm
(5.6280 in)

738

143.65 mm
(5.6555 in)

766

144.35 mm
(5.6831 in)

794

142.275 mm
(5.6014 in)

711

142.975 mm
(5.6289 in)

739

143.675 mm
(5.6565 in)

767

144.375 mm
(5.6840 in)

795

142.3 mm
(5.6023 in)

712

143.0 mm
(5.6299 in)

740

143.7 mm
(5.6575 in)

768

142.325 mm
(5.6033 in)

713

143.025 mm
(5.6309 in)

741

143.725 mm
(5.6584 in)

769

142.35 mm
(5.6043 in)

714

143.05 mm
(5.6319 in)

742

143.75 mm
(5.6594 in)

770

142.375 mm
(5.6053 in)

715

143.075 mm
(5.6329 in)

743

143.775 mm
(5.6604 in)

771

142.4 mm
(5.6063 in)

716

143.1 mm
(5.6338 in)

744

143.8 mm
(5.6614 in)

772

142.425 mm
(5.6073 in)

717

143.125 mm
(5.6348 in)

745

143.825 mm
(5.6624 in)

773

142.45 mm
(5.6083 in)

718

143.15 mm
(5.6358 in)

746

143.85 mm
(5.6634 in)

774

142.475 mm
(5.6092 in)

719

143.175 mm
(5.6368 in)

747

143.875 mm
(5.6644 in)

775

142.5 mm
(5.6102 in)

720

143.2 mm
(5.6378 in)

748

143.9 mm
(5.6653 in)

776

142.525 mm
(5.6112 in)

721

143.225 mm
(5.6388 in)

749

143.925 mm
(5.6663 in)

777

142.55 mm
(5.6122 in)

722

143.25 mm
(5.6397 in)

750

143.95 mm
(5.6673 in)

778

142.575 mm
(5.6132 in)

723

143.275 mm
(5.6407 in)

751

143.975 mm
(5.6683 in)

779

142.6 mm
(5.6142 in)

724

143.3 mm
(5.6417 in)

752

144,0 mm
(5.67 in)

780

700

728

(5.669 in)
142.625 mm
(5.6151 in)

725

143.325 mm
(5.6427 in)

753

144.025 mm
(5.6703 in)

781

142.65 mm
(5.6161 in)

726

143.35 mm
(5.6437 in)

754

144.05 mm
(5.6712 in)

782

142.675 mm
(5.6171 in)

727

143.375 mm
(5.6447 in)

755

144.075 mm
(5.6722 in)

783

[ 1]The unit pump serial number may be used to make it easier to keep the parts together.
[ 2]The unit pump serial number may be used to make it easier to keep the parts together.
[ 3]The unit pump serial number may be used to make it easier to keep the parts together.