d5d fuel system

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Service Information

Document Title: Function Group: Information Type: Date:Mechanical injectionD5D, checking andadjusting

236 Service Information 12/07/2011

Profile:Engine, D5D [GB]

Mechanical injection D5D, checking and adjustingDetermining 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 arecharacterized by the EP-codes on the engine ID-plate having a value between 700–799.

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.

ShimHydraulic roller tappet for reduction of white smoke

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9998678 Measuring tool9998679 Timing tool11668408 Setting tool9998685 Setting tool

Indicator

Magnetic base



NOTICE 9998685 Setting tool is used for engines with conventional roller tappets. 11668408 Setting tool is used for engines withhydraulic 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 29998679

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 forwhich 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.



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 againstthe gauge pointer.



Figure 9

1.2.3.4.5.

9998685Dial test indicatorPointerMillimetre graduationGraduated 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 tappetsfor 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 = 6.0Camshaft type = A Vhnom = The value obtained on the timing tool (protractor) when the crankshaft has been turned so far that thecamshaft 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 6.11mm (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 inCalculation 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 whitesmoke)

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.

11668408Dial test indicatorPointerMillimetre graduationGraduated 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 - 5mm = 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 inCalculation 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

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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 ormodification 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 D5D

Cylinder number Cyl. 1 Cyl. 2 Cyl. 3 Cyl. 4

Unit pump serial number[ 1]

EP code (see Value table 3) EP 751

Corrected installation measurement(se Value table 3)

Ek143.275

Basic measurements of unit pump(see Value table 1)

L - 136.8

Manufacturing tolerance (se markingon unit pump)

A/100 - 0,86

Theoretical thickness of shim Ts= 5.62

True thickness of shim (seeCalculation table 2.2)

Ss≈ 5,60

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

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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 andso on.

Figure 26Engine 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 27Manufacturing 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 intable 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

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9998679 Timing tool9998681 Rotation tool



9998684 Installation tool

1. Position the roller tappets together with associated shims.

Figure 28

1. Control arm

CAUTIONTurn 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 enginewith 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 rodShims for pump elementRoller tappet for pump element

CAUTIONCheck 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 by1Nm (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'sbolt 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 toallow a correct, future replacement of the pump.

Calculation table 2.1 Factor Ex. Engine D5D

Cylinder number 3 Cyl. 1 Cyl. 2 Cyl. 3 Cyl. 4

Unit pump serial number[ 2]

Injection angle, measured on timing tool(protractor)

Fbakt5,5

Injection angle (see engine type polate) Fbnom- 6.0

Sum 1, (S1 = Fbakt - Fbnom) S1 = —0,5

Presetting, correction factor (see Value table 1) Vhkorrx 0,14

Sum 2 (S2 = S1 x Vhkorr) S2 = 0,07

Camshaft lift (see Value table 1) Vhnom + 6,11

Basic measurement on unit pump (see Value table1)

L + 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. Cyl. 1 Cyl. 2 Cyl. 3 Cyl. 4

Length between cylinder block and roller tappet L 151,43

Sum 3 (S3 = S2 + Vhnom + L + A / 100) S3 - 149,67

Theoretical thickness of shim Ts = 1,76True thickness of shim (see Value table 2) Ss

≈ 1.8

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 determinedagain 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 Ex. Engine D5D

Cylinder number - - - Cyl. 1 Cyl. 2 Cyl. 3 Cyl. 4

Unit pump serial number[ 3] - -

Injection angle, measured on timing tool(protractor)

Fbakt5,5

Injection angle (see engine type polate) Fbnom- 6.0

Sum 1, (S1 = Fbakt - Fbnom) S1 = –0,5

Correction factor (see Value table1) Vhkorrx 0,14

Sum 2, (S2 = S1 x Vhkorr) S2 = –0,07

Camshaft lift (see Value table 1) Vhnom+ 6.11

Sum 3, (S3 = S2 + Vhnom) S3 = 6.04



Calculation table 3.2 Code Ex. Engine D5D

Cylinder number: - Cyl. 1 Cyl. 2 Cyl. 3 Cyl. 4

Length between cylinder block and roller tappet L - 151.43

Sum 3, (S3 = S2 + Vhnom) S3 - 6.04

Ek (Ek = L - S3) Ek= 145.39

Ek, rounded to the nearest value in Value table 3 Ek ≈ 145,40

EP code (Ek results in EP code in Value table 3) EP = 337

Unit explanations

Unit explanations

Code Factor Explanation

Fbakt°FÖD (°BTDC)

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

Fbnom°FÖD (°BTDC)

Injection angle, can be found on engine type plate

Vhkorr

mm/°FÖD(in/°BTDC)

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

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

L mm Measured between cylinder block and roller tappet according to method

L mm Basic measurement on unit pump

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

A/100 mm Manufacturing tolerance, written on the unit pump

Tsmm Theoretical thickness of shim

Ssmm True thickness of shim

S1, S2 andS3

- Total (sum) of calculations

EP - Code value that can be found in Value table 3 or on engine type plateEk

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

Value table 1, information about camshafts


Injection angle,

Fbnom

°FÖD (°BTDC)

Camshaft type camshaft lift,

Vhnommm (in)Preload, correction

factor, Vhcorrmm/°BTDC(in/°BTDC)

Unit pump's length,basic measurement,

Lmm (in)

5.0 A 6.32 mm (0.2488 in) 0.14 143 mm (5.630 in)

6.0 A 6.11 mm (0.2406 in) 0.14 143 mm (5.630 in)

7.0 A 5.90 mm (0.2323 in) 0.14 143 mm (5.630 in)8.0 A 5.70 mm (0.2244 in) 0.14 143 mm (5.630 in)

9.0 A 5.50 mm (0.2165 in) 0.14 143 mm (5.630 in)

4.0 A 5.31 mm (0.2091 in) 0.14 143 mm (5.630 in)

4.5 B 5.70 mm (0.2244 in) 0.14 143 mm (5.630 in)

5.0 B 5.60 mm (0.2205 in) 0.14 143 mm (5.630 in)

5,5 B 5.50 mm (0.2165 in) 0.14 143 mm (5.630 in)

6.0 B 5.31 mm (0.2091 in) 0.14 143 mm (5.630 in)

7.0 B 5.10 mm (0.2008 in) 0.14 143 mm (5.630 in)

2.0 M 6.06 mm (0.2386 in) - 143 mm (5.630 in)

2.5 M 5.97 mm (0.2350 in) - 143 mm (5.630 in)

3.0 M 5.88 mm (0.2315 in) - 143 mm (5.630 in)

3.5 M 5.79 mm (0.2280 in) - 143 mm (5.630 in)

4.0 M 5.70 mm (0.2244 in) - 143 mm (5.630 in)



4.5 M 5.61 mm (0.2209 in) - 143 mm (5.630 in)

5.0 M 5.52 mm (0.2173 in) - 143 mm (5.630 in)

5,5 M 5.43 mm (0.2138 in) - 143 mm (5.630 in)

6.0 M 5.35 mm (0.2106 in) - 143 mm (5.630 in)

6,5 M 5.26 mm (0.2079 in) - 143 mm (5.630 in)

7.0 M 5.17 mm (0.2035 in) - 143 mm (5.630 in)

7.5 M 5.08 mm (0.2000 in) - 143 mm (5.630 in)

8.0 M 4.99 mm (0.1965 in) - 143 mm (5.630 in)

2.0 S 6.198 mm (0.2440 in) - 143 mm (5.630 in)

2.5 S 6.110 mm (0.2406 in) - 143 mm (5.630 in)

3.0 S 6.020 mm (0.2370 in) - 143 mm (5.630 in)

3.5 S 5.930 mm (0.2335 in) - 143 mm (5.630 in)

4.0 S 5.842 mm (0.2300 in) - 143 mm (5.630 in)

4.5 S 5.75 mm (0.2264 in) - 143 mm (5.630 in)

5.0 S 5.66 mm (0.2228 in) - 143 mm (5.630 in)

5,5 S 5.58 mm (0.2197 in) - 143 mm (5.630 in)

6.0 S 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 whitesmoke)


Injection angle,

Fbnom

°FÖD (°BTDC)

Camshaft type camshaft lift,

Vhnommm (in)Preload, correction

factor, Vhcorrmm/°BTDC(in/°BTDC)

Unit pump's length,basic measurement,

Lmm (in)

2.0 S 6.198 mm (0.2440 in) - 136.8 mm (5.386 in)

2.5 S 6.110 mm (0.2406 in) - 136.8 mm (5.386 in)

3.0 S 6.020 mm (0.2370 in) - 136.8 mm (5.386 in)

3.5 S 5.930 mm (0.2335 in) - 136.8 mm (5.386 in)4.0 S 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 Thickness of shim, Ss Theoretical thickness, Ts Thickness of shim, Ss

0,95 - 1,049 mm(0.03740 - 0.0430 in)

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 Shim thickness, Ss Theoretical thickness, Ts Shim thickness, Ss

4.625 - 4.6749 mm(0.1831 - 0.18697 in)

4.65 mm(0.1831 in)

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) (0.2510 - 0.25295 in) (0.252 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)

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

Value table 3, information about EP codes

EkEP code Ek

EP code EkEP code Ek

EP code

145.35 mm(5.7224 in)

335

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



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 whitesmoke), L0= 136.8 mm

Value table 3, information about EP codes

EkEP code Ek

EP code EkEP code Ek

EP code

142.0 mm(5.5905 in)

700 142.7 mm(5.6181 in)

728 143.4 mm(5.6457 in)

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



(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.



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