Perkins 4.108 Instruction manual

workshop
manual for
4.108 4.107 and 4.99
diesel engines
©
Perkins Engines Limited
Peterborough England
1983
All Rights Reserved
Publication No. 601 SER 0383 1072
This publication supersedes the previous edition numbered 601 SER 12771072
This publication is written for world wide use. In territories where legal requirements govern smoke emission,
noise, safety
factors etc., then all instructions, data and dimensions given must be applied in such a way that,
after
servicing (preventive maintenance) or repairing an engine, it does not contravene the local regulations
in use.
Published by the Technical Publications Department of Perkins Engines Ltd. and Printed in England by Warners (Midlands) pic

Page 2
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PERKINS COMPANIES
I AUSTRALIA Perkins Engines Australia Pty. Ltd.
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FRANCE
GERMANY
ITALY
JAPAN
SINGAPORE
UNITED KINGDOM
U.S.A.
Suite 2,
364 Main Street, Mornington 3931, Victoria, Australia.
Telephone:
597 51877. Telex: Perkoil AA30816. Fax: [phone].
Moteurs Perkins S.A.
9-11 Avenue Michelet,
93583 Saint Ouen, Cedex, France.
Telephone:
(1) 40104200. Telex: 642924F. Fax: [phone].
Perkins Motoren G.m.b.H.
8752 Kleinostheim, Postfach 1180, West Germany.
Telephone: Kleinostheim
6027 5010. Telex: 4188869A PER D.
Fax: [phone].
Motori Perkins S.p.A.
Via Socrate 8,
22070 Casnate con Bernate (Como), Italy.
Telephon: (031)
452332. Telex: 380658 Perkit I. Fax: [phone].
Massey Ferguson Perkins Engines K.K.
Reinanzaka Building,
6th Floor, 14-2 Akasaka, 1-chome, Minato-ku, Tokyo 107, Japan.
Telephone: (03)
5867377. Telex: Perkoil J2424823. Fax: [phone].
Perkins Engines Asia Pacific,
4 Kian Teck Drive, Singapore
2262.
Telephone: [phone]. Telex Perkoil RS37729. Fax: [phone].
Perkins Engines Limited,
Eastfield, Peterborough,
PE1 5NA, England.
Telephone:
(0733) 67474. Telex 32501 Perken G. Fax: [phone].
Perkins Engines (Shrewsbury) Limited,
Sentinel Works, Shrewsbury
SY1 4DP, England.
Telephone:
(0743) 52262. Telex: 35171/2 PESL G. Fax: [phone].
Perkins Engines Inc.,
1700 Bellemeade Court, Lawrenceville, Georgia 30245, U.S.A.
Telephone:
404 822 3000. Telex: 544141 Perken Law. Fax: [phone].
Perkins Engines Latin America Inc.,
Suite
620,999 Ponce de Leon Boulevard, Coral Gables, Florida 33134, U.S.A.
Telephone:
305 442 7413. Telex: 32501 Perken G. Fax: [phone].
In addition to the above, there are Perkins distributors in most countries. Perkins Engines Ltd., Peterborough or one of the above
companies can give details.

Page 3
FOREWORD
This workshop manual has been compiled for use in conjunction with normal workshop practice.
Mention of certain accepted practices therefore, has been purposely omitted in order to avoid
repetition.
Reference to renewing joints and cleaning off joint faces has to a great extent been omitted from
the text, it being understood that this will be carried out where applicable.
Similarly, it is understood that in reassembly and inspection, all parts are to be thoroughly
cleaned and where present, burrs and scale are to be removed.
It follows that any open ports of high precision components, e.g., fuel injection equipment, ex-
posed by dismantling, will be blanked off until reassembled, to prevent the ingress of foreign
matter.
: When setscrews
or studs are fitted into holes which are tapped through into the inside of
: the engine, a suitable sealant must be used on the threads.
Throughout this manual, whenever the "left" or "right" hand side of the engine is referred to, it is
that side of the engine as viewed from the flywheel end.
The
engine number is stamped on the fuel pump mounting flange as shown in the above
illustration.
Three systems of engine numbering have been used.
On very early engines the serial number consisted of seven digits as follows :-
Engine Type Typical Engine Number
4.108 7300269
4.107 7100399
4.99 7000251
Identification on these engines can be identified by cbserving the first two figures of the engine
number which remain constant depending on engine type.
With later engines, the number consisted of figures and letters
Engine Type Typical Engine Number
4.108 108U251
4.107 107U251
4.99 99U251
The first figures represent the capacity of the engine in cubic inches, the letter "U" signifies that
the engine was built in the United Kingdom and the last group of figures comprises the engine
serial number.
On current engines, the number can consist of up to fifteen letters and figures, a typical number
being ED21512U510256D

Page4 ~
Safety precautions
THESE SAFETY PRECAUTIONS ARE IMPORTANT. Reference must also be made to the local
regulations in the country of operation.
Do not use these engines in marine applications.
Do
not change the specification of the engine.
Do
not smoke when you put fuel in the tank.
Clean away any fuel which has fallen and move material which has fuel contamination to a safe
place.
Do
not put fuel in the tank during engine operation (unless really necessary).
Never clean, lubricate
or adjust the engine during operation (unless you have had the correct
training when extreme caution must be used to prevent injury).
Do not make any adjustments you do not understand.
Ensure the engine is not in a position to cause a concentration of toxic emissions.
Persons in the area must be kept clear during
engine and equipment or vehicle operation.
Do not permit loose clothing
or long hair near parts which move.
Keep away from parts which turn during operation. Note that fans can
not be seen clearly while
the engine is run.
Do not run the engine with any safety guards removed.
Do not remove the radiator cap while the
engine is hot and the coolant is under pressure as
dangerous
hot coolant can be discharged.
Do
not use salt water in the cooling system or any other coolant which can cause corrosion.
Keep sparks
or fire away from batteries (especially during charge) or combustion can occur.
The battery fluid can burn and is also dangerous to the skin and especially the eyes.
Disconnect the battery terminals before you make a repair to the electrical system.
Only one person must be in control of the engine.
Ensure the engine is only operated from the
control panel or operators position.
If your skin comes into contact with high pressure fuel, get medical assistance immediately.
Diesel fuel can cause skin damage to some persons. Use protection on the hands (gloves
or
special skin protection solutions).
Do not move equipment unless the brakes are in good condition.
Ensure that the transmission drive control is in "Out of Drive" position before the engine is
started.
Fit only
correct Perkins Parts.

CONTENTS
ENGINE VIEWS
TECHNICAL DATA
OPERATING AND MAINTENANCE
FAULT FINDING
CYLINDER HEAD
PISTONS AND CONNECTING RODS
CYLINDER BLOCK AND LINERS
CRANKSHAFT AND MAIN BEARINGS
TIMING CASE AND DRIVE
TIMING
LUBRICATING SYSTEM
COOLING SYSTEM
AIR CLEANERS AND FUEL SYSTEM
FLYWHEEL AND HOUSING
ELECTRICAL EQUIPMENT
ENGINES
FOR REFRIGERATION UNITS
APPROVED LUBRICATING OILS
APPROVED SERVICE TOOLS
INDEX
A
B
C
D
E
F
G
H
J
K
L
M
N
P
Q
R
Appendix
Page 5

Page 6
EXAMPLES OF SERVICE FACILITIES
Service
If any problems occur with your engine or the components fitted to it, your Perkins distributor
can make the necessary repairs and will ensure that only the correct parts are fitted and that the
work is done correctly.
Certain components can be supplied by your Perkins distributor through the Perkins Power
exchange system. These will enable you to red uce the cost of some repairs.
Extended Warranty
The engine warranty period can be extended to two years. For details, get in contact with your
nearest Perkins distributor.
Service Literature
Users handbooks and other service publications are available from your Perkins distributor at a
nominal cost.
Training
Local training on correct engine operation, overhaul and service is available at some Perkins
distributors. If special training is needed, your Perkins distributor can give details on how to
get this at the Product Education Department, Peterborough, or other main centres.

SECTION A
Engine Views

ENGINE VIEWS-A.2
Index to Engine Views
Dynamo Pulley
2 Water
Pump Pulley
3 Water Outlet
4 Exhaust
Manifold
5 Breather
6
Atomiser
7
Thermostat Housing
8 Fuel Injection
Pump
9 Starter Motor
10 Lubricating Oil Filter
11 Timing Pin
12 Crankshaft Pulley
13 Timing Case
14 Fan Belt
15 Water Pump
16 Cylinder Head Cover
17 Fuel Oil Filter
18 Starting Aid
19 Induction Manifold
20 Oil Filter
21 Dipstick
22 Dynamo
23 W?ter
Inlet
24 Lubricating Oil Pump Locating Setscrew
25 Lubricating Oil
26
Sump Drain Plug
27 Flywheel
Housing
28 Cylinder Block Drain Tap
29 Fuel Lift Pump

ENGINE VIEWS-A.3
2 3 4 5
-----7
9
VIEW OF FUEL PUMP SIDE OF ENGINE

ENGINE VIEWS-A.4
1
17
1
20
VIEW OF CAMSHAFT SIDE OF ENGINE

Engine Data
Bore (nominal- See Page B.3) ...
Stroke ...
No. of Cylinders
Cubic Capacity ...
Compression Ratio
Firing
Order
Cycle '"
Combustion System
Engine Rotation
...
Rating Details
4.99
Maximum Gross Rated Output
Maximum Gross Torque Output
Engine Weights, Dry
48 bhp (37 kW)
at 4000
rev/min
73 Ibf ft (10,1 kgf m)
at 2250 rev/min
SECTION B
Technical Data
4.108 and 4.107
3.125 in (79,37 mm)
3.5 in (88,9 mm)
Four
107.4 in3 (1,760 litre)
22:1
1,3,4,2.
Four-Stroke
Indirect Injection
Clockwise viewed from
front
4.107
41 bhp (30,6 kW)
at 3000 rev/min
79 Ibf ft (10,9 kgf m)
at 1900 rev/min
4.99
3.00 in (76,2 mm)
3.5 in (88,9 mm)
Four
99 in3 (1,621 litre)
20:1
1, 3, 4, 2.
Four-Stroke
Indirect Injection
Clockwise viewed from
front
4.108
55 bhp (41 kW)
at 4000
rev/min
83 Ibf ft (11,5 kgf m)
at 2200 rev/min
Approx. dry weight, bare engine, i.e. complete with fuel injection equipment, pressed steel oil sump, dynamo, water
pump, but not including starter motor, air cleaner, fan, flywheel or flywheel housing: 330 Ib (150 kg).
Typical dry weight, engine with all accessories: 450 Ib (204 kg).
Where engines are called upon to operate in rarefied atmospheres occasioned by altitude, such engines should be
de-rated.
The
following table is given as a general guide, which may be applied on a percentage basis, where specific figures
for a particular engine rating are not available.
Altitude
0- 2,000 feet ( 600 metre)
2,000- 4,000 feet (1,200 metre)
4,000- 6,000 feet (1,800 metre)
6,000- 8,000 feet (2,400 metre)
8,000-10,000 feet (3,000 metre)
10,000-12,000 feet (3,600 metre)
* Measured at setting speed given in pump setting code.
Maximum fuel delivery de-rating*
No change
6%
12%
18%
24%
30%
Any necessary adjustments in this respect to the fuel pump should be carried 01.11 by the C.A.V. dealer or Perkins
Distributor for the territory concerned.
For any further information apply to Technical Services Department, Perkins Engines Limited, Peterborough or to one
of the Perkins Companies listed on Page 2.

TECHNICAL DATA-B.2
Recommended Torque Tensions
The following torque figures will
apply with the components
lightly oiled before assembly:-
4.107 and 4.99 4.108
Ibf ft kgf m Nm Ibf
ft
kgf m Nm
Cylinder Head Nuts
42 5,81 57 60 8,3
81
Connecting Rod Setscrews
42 5,81 57
42 5,81 57
* Main Bearing Setscrews
85 11,5 115 85 11,5
115
Flywheel Setscrews
60 8,3 81 60 8,3
81
Idler Gear Hub Setscrews 36 4,98 49 36 4,98 49
Crankshaft Pulley Setscrew-1.56 in (39,6 mm)
long
150 20,7 203 150 20,7 203
with 1.875 in (47,6 mm) dia. washer
Crankshaft Pulley Setscrew -1.68 in (42,7 mm) long 190 26,3 250
with 1.75 in (44,6 mm) dia. washer (Cadmium Plated)
Crankshaft Pulley Setscrew (Phosphated)
230 31,5
310
Atomiser Securing Nuts
., . 12 1,7
16
12 1,7 16
High Pressure Fuel Pipe Nuts 15 2,1 20 15
2,1
20
Dynamo Pulley Retaining Nut 20 2,8 27 20 2,8 27
Alternator Pulley Retaining Nut
30
4,1
41
30
4,1
41
Thermostart Unit
10 1,38 13 10 1,38 13
Thermostart Insulating Adaptor
10 1,38 13 10 1,38 13
*The tab and shim washers may be discarded where used on earlier engines, but the setscrews must be tightened
to the torque loading indicated.
Service Wear Limits
The following "wear limits" indicate the condition when it is recommended that the respective items should be servicec
or replaced.
Cylinder Head Bow
Cylinder Head Bow
Longitud inal
Transverse
Maximum Bore Wear (when new liners are necessary)
Crankshaft Main and Big End Journal Wear
Crankshaft Main and Big End Journal Ovality
Maximum Crankshaft End Float
Valve Stem to
Guide Clearance inlet
Valve Stem to Guide Clearance
Valve Head Thickness at outer edge
Rocker Clearance on Shaft
Camshaft Journals Ovality and Wear
Camshaft End Float
Idler Gear End Float
exhaust
*Valve Head Depth below Head Face-inlet and exhaust
0.006 in (0,15 mm)
0.003 in (0,08 mm) concave
0.005 in (0,13 mm) convex
0.006 in (0,15mm)
0.001 in (0,03 mm)
0.0005 in (0,01 mm)
0.020 in (0,51 mm)
0.005 in (0,13 mm)
0.006 in (0,15 mm)
0.025 in (0,64 mm)
0.005 in (0,13mm)
0.002 in (0,05 mm)
0.020 in (0,51 mm)
0.010 in (0,25 mm)
0.048 in (1,22 mm)
*Where vehicle engines have to conform with the smoke density regulation B.S.AU 141 a: 1971, then the valve depths
must not exceed production limits as given on page B.8.
Manufacturing Data and Dimensions
The data regarding clearances and tolerances are given for personnel engaged upon major overhauls.
Further information can be obtained on request from the Technical Services Department, Perkins Engines Ltd.,
Peterborough.
CYLINDER BLOCK
Total Height of Cylinder Block
between Top & Bottom Faces
Parent
Bore Dia. for Cylinder Liner
Parent Bore Dia. for Cylinder Liner
Main Bearing Parent Bore
Camshaft Bore Dia. No.1
Camshaft Bore Dia. No.2
Camshaft Bore Dia. No.3
Tappet Bore Dia.
Fuel
Pump Drive Hub Bearing
Bore Dia.
4.108,4.107,4.99
4.108
4.107,4.99
4.108,4.107,4.99
4.108,4.107,4.99
4.108,4.107,4.99
4.108,4.107,4.99
4.108,4.107,4.99
4.108,4.107,4.99
9.936/9.939 in (252,374/252,451 mm)
3.249/3.250 in (82,525/82,550 mm)
Wet Liners
2.3950/2.3955 in (60,833/60,846 mm)
1.794/1.7955 in (45,568/45,606 mm)
1.78411.787 in (45,314/45,390 mm)
1.776/1.778 in (45,110/45,161 mm)
0.562/0.56325 in (14,275/14,307 mm)
1.812511.8141 in (46,037/46,078 mm)

Cylinder Liner 4.108
Type
Interference Fit of Liners
Inside Dia. of Liner after Finish Boring and Honing
Height of Liner in relation to Cylinder Block Top Face
Overall Length
of Liner
Cylinder Liner 4.107 and 4.99
Type
Inside Dia. of Liner Pre-Finished 4.99
Inside Dia. of Liner Pre-Finished 4.107
Thickness of Top Flange. 4.99
Depth of Recess in
Block for Liner Flange. 4.99
Thickness of Top Flange.. 4,107
Depth of Recess in
Block for Liner Flange 4,107
Height of Liner in relation to
Cylinder Block Top Face 4,107 and 4.99
Liner Flange Outside Dia. 4.99
Cylinder
Block Top Bore for Liner Flange 4.99
Clearance Fit of
Liner Flange
to
Block Bore 4.107 and 4.99
Pistons 4.108
Type
Piston Height in relation to Cylinder
B!ock Top Face.
Bore Dia. for Gudgeon Pin
Compression Ring Groove
Width-Top
Compression Ring Groove Width-2nd
Compression Ring Groove Width-3rd
Oil Control Ring Groove Width-4th
Oil Control Ring Groove Width-5th
iWith engines rated at 3.000 rev/min or below, the fourth
Note: There is a Steel Insert fitted above the Top Groove.
IPistons 4.108 (Controlled Expansion)
I
IType ...
I Piston
Height above Top Face of Cylinder Block
IBore Dia. for Gudgeon Pin
I Compression Ring Groove Width, Top
1Compression Ring Groove Width, Second and Third ...
I Oil Control Ring Groove Width ... ... .. .
: Pistons 4.108 (Controlled Expansion)
: Type ...
I Piston Height above Top Face of Cylinder Block
: Bore Dia. for Gudgeon Pin
I CompreSSion Ring Groove Width, Top
: Compression Ring Groove Width, Second
I Oil Control Ring Groove Width
Pistons 4.107 and 4.99
Type
Piston Height in relation to
Cylinder Block Top Face ..
Bore Dia.
for Gudgeon Pin
later 4.99 and all 4.107
engines ...
Early 4.99 engines
Compression Ring Groove Width-Top
Compression Ring Grooves Width 2nd and 3rd
Oil Control Ring Grooves 4th and 5th
TECHNICAL DATA-B.3
Cast Iron -Dry - Interference Fit
0,003/0.005 in (0,076/0.127 mm)
3.12513.126 in (79,375179,40 mm)
0.023/0.027 in (0,584/0,686 mm) above
6.495/6.505 in (164,973/165,227 mm)
Cast Iron -Wet Push Fit
3,00/3.001 in (7620176.225 mm)
3.125/3,126 in (79,374179.4 mm)
0.312510.3145 in (7,93717,988 mm)
0.3115/0.3135 in (7,91217,963 mm)
0.25010,252 in (6.35/6,4 mm)
0.249/0,251 in (6.325/6,375 mm)
0.003 in (0,076 mm) Above. 0.001
in (0.025 mm) Below
3.61813.621 in (91.898/91,973 mm)
3.625/3,627 in (92,075/92,125 mm)
0,00410.009 in (0,102/0.229 mm)
Flat Topped
0.00210.006 in (0,051/0.152 mm) Above
1.06255/1.06275 in (26,989/26.994 mm)
0.080510.0815 in (2,045/2,070 mm)
0.0645/0.0655 in (1,638/1,664 mm)
0.0645/0.0655 in (1,638/1,664 mm)
0.126/0.127 in (3.200/3,225 mm)
0.19010.191 in (4,826/4.851 mm)
ring groove is the same as the fifth ring groove.
Flat Topped -Four Ring
0.002/0.006 in (0,05/0,15 mm)
1.062711.0629 in (26,992/26,999 mm)
0.080110.0821 in (2,035/2,086 mm)
0.06410.065 in (1,64/1,65 mm)
0.1887/0.1895 in (4,7914,81 mm)
Flat Topped - Three Ring
0.002/0.006 in (0,05/0,15 mm)
1.062711.0629 in (26,992/26,999 mm)
0.080/0.082 in (2,035/2,086 mm)
0.09910.1005 in (2,53/2,55 mm)
0.1890/0.1900 in (4,8014,826 mm)
Flat Topped
0.0085/0.012 in (0,2210,30 mm) Above
0.93755/0.93775 in (23,81/23,82 mm)
0.87505/0.87525 in (22,22122,23 mm)
0.0801/0.0811 in (2,034/2,06 mm)
0.0645/0.0655 in (1,638/1,664 mm)
0.190/0.191 in (4,826/4,851 mm)

TECHNICAL DATA-B.4
Piston Rings 4.108
Top-Compression
Second and Third Compression
Fourth-Oil Control
Fifth-Oil Control
Top Compression Ring Width
Ring Clearance in Grove
...
Second and Third Compression Ring Width
Ring Clearance in
Groove
Fifth Scraper Ring Width ...
Ring Clearance in Groove
Ring Gap-Top Compression
Ring
Gap-Second and Third Compression .
Ring
Gap-Fifth Scraper ...
Parallel Faced
Internally Stepped
Laminated Segment
'*
Slotted Scraper
0.0771/0.0781 in (1,958/1,984 mm)
0.0024/0.0044 in (0,061/0,112 mm)
0.0615/0.0625 in (1,562/1,587 mm)
0.00210.004 in (0,051/0,102 mm)
0.1865/0.1875 in (4,737/4,762 mm)
0.0025/0.0045 in (0,063/0,114 mm)
0.00910.017 in (0,229/0,432 mm)
0.00910.017 in (0,229/0,432 mm)
0.00910.017 in (0,229/0,432 mm)
:* Engines rated at 3,000 revlmin and below have a slotted scraper fitted in the fourth groove which has the same
I width, clearance and gap as the fifth ring.
:Piston Rings 4.108(Controlied Expansion - Four Ring)
, Top Compression
I Second and Third Compression
I Fourth Oil Control
I Top Compression Ring Width
I Ring Clearance in Groove ...
: Second and Third Compression Ring Width
Ring Clearance in Groove
IOil Control Ring Width ...
I Ring Clearance in Groove
J Ring Gap, Top ... ...
I Ring Gap, Second and Third
I Ring Gap, Oil Control
Chrome Insert -Parallel Faced
Internally Stepped
Spring Loaded Scraper
0.077/0.078 in (1,96/1,98 mm)
0.002/0.005 in (0,05/0,13 mm)
0.0615/0.0625 in (1,5611,59 mm)
0.0015/0.0035 in (0,0410,09 mm)
0.186/0.1865 in (4,72/4,74 mm)
0.0022/0.0035 in (0,0510.09 mm)
0.012/0.023 in (0,30/0,58 mm)
0.009/0.020 in (0,23/0,50 mm)
0.010/0.021 in (0,25/0,53 mm)
: Piston Rings 4.108 (Controlled Expansion - Three Ring)
I Top Compression
: Second Compression
I Third Oil Control
I Top Compression Ring Width
I Clearance in Groove ...
: Second Compression Ring Width
I Clearance in Groove
I Oil Control Ring Width
: Clearance in
Groove
I Ring Gap, Top ...
I Ring Gap, Second
I Ring Gap, Oil Control
Piston Rings
4.99 Vehicle
Top Compression
Second and Third Compression
Fourth and Fifth Oil Control
Piston Rings 4.107 and 4.99
and Industrial
Top Compression
'Second and Third Compression
Fourth-Oil Control
Fifth-Oil Control
Chrome,
Taper Faced
Internally Stepped, Taper Faced
Spring Loaded Scraper
0.0765/0.0775 in (1,943/1,969 mm)
0.0025/0.0055 in (0,063/0,140 mm)
0.097/0.098 in (2,46/2,49 mm)
0.0015/0.0035 in (0,039/0,089 mm)
0.1865/0.1875 in (4,737/4,763 mm)
0.0015/0.0035 in (0,039/0,089 mm
0.01210.023 in (0,31/0,59 mm)
0.009/0.020 in (0,23/0,51 mm
0.012/0.023 in (0,31/0,59 mm
Parallel Faced Chrome Plated
Internally Stepped
Slotted
Scraper
Parellel Cast Iron
Internally Stepped
Chrome Plated Spring Loaded Scraper
Slotted Scraper
• 4.99 Agricultural engines have taper faced cast iron compression rings fitted in the second and third ring grooves.
Top Compression Ring Width
Ring Clearance in
Groove
Second and Third Compression Ring Width.
Ring Clearance in Groove
Fourth and Fifth Scraper Ring Width
Ring Clearance in Groove
Ring
Gap-Compression Rings Chrome Vehicle
Ring
Gap-Oil Control Rings Cast Iron Vehicle
Ring
Gap-Compression Rings Cast Iron
Agricultural and Industrial
0.0771/0.0781 in (1,96/1,984 mm)
0.002/0.004 in (0,051/0,102 mm)
0.0615/0.0625 in (1,562/1,587 mm)
0.00210.004 in (0,051/0,102 mm)
0.1865/0.1875 in (4,73714,762 mm)
0.0025/0.0045 in (0,064/0.114 mm)
0.01210.020 in (0,30/0,50 mm)
0.009/0.017 in (0,30/0,432 mm)
0.009/0.017 in (0,30/0,432 mm)

Gudgeon Pin 4.108
Type
Outside Dia. of Gudgeon Pin
Length of Gudgeon Pin
Fit in Piston Boss
Gudgeon Pin 4.107 and 4.99
Type
Outside Dia. of Gudgeon Pin (Later Engines)
Outside Dia. of Gudgeon Pin (Earlier Engines)
Fit in Piston Boss
Small End Bush 4.108
Type
Length
of Small End Bush
Outside Dia. of Small End Bush
Inside Dia. before Reaming
Inside Dia. after Reaming
Clearance between Small End Bush and Gudgeon Pin
Small End Bush 4.107 and 4.99
Type
Length
of Small End Bush
Outside Dia.
of Small End Bush
on
later 4.99 and all 4.107 engines
Early 4.99
engines
Inside Dia. after Reaming on later
4.99 and a/l 4.107 engines
Early 4.99 engines
Clearance between Small End Bush and Gudgeon Pin
TECHNICAL DATA-B.S
Fully Floating
1.0625/1.0627 in (26,987/26,993 mm)
2,673/2,687 in (67,894/68,250 mm)
Transition
Fully Floating
0.9375 in/0.9377 in (23,812/23,817 mm)
0.875/0.8752 in (22,225/22,23 mm)
Transition
Steel Backed, Lead Bronze Lined
0.935/0.955 in (23,749/24,257 mm)
1.221/1.222 in (31,013/31,039 mm)
1.0495/1.0545 in (26,657/26,784 mm)
1.06315/1.0632 in (27,004/27,005 mm)
0.00045/0.0007 in (0,0114/0,0178 mm)
Steel Backed, Lead Bronze Lined
0.865/0.885 in (22,00/22,48 mm)
1.06511.066 in (27,05/27,08 mm)
1.0025/1.0035 in (25,46125,49 mm)
0.9382/0.93875 in (23,83/23,84 mm)
0.8757/0.87625 in (22,24/22,26 mm)
0.0005/0.00125 in (0,0110,03 mm)
Note. Bushes to be reamed to suit respective Gudgeon Pins, and are provided with a reaming allowance.
nSI::ti§11n Rod 4.108
Type 'H' Section
Cap Location to Connecting Rod
Big End Parent
Bore Dia.
Small End Parent Bore Dia.
Length from Centre Line
of Big End
to Centre Line of Small End
Big End
Setscrew
Connecting Rod End Float
Connecting Rod 4.107 and 4.99
Type
Cap
Location to Connecting Rod
Big End Parent Bore Dia.
Small End Parent Bore Dia.
on
later 4.99 and all 4.107 engines
Early 4.99
engines
Length from Centre Line of Big End to Centre Line of
Small End
Big End Setscrew
Connecting Rod End Float
on
later 4.99 and all 4.107 engines
Early 4.99 engines
Serrations, Offset 45
to the Horizontal
2.146/2.1465 in (54,508/54,521 mm)
1.21875/1.21975 in (30,956/30,981
mm)
6.217/6.219 in (157,912/157,963 mm)
0.375 in
(i in) U.N.F.
0.006510.0105 in (0,165/0,267 mm)
'H' Section
Serrations, Offset 45' to the Horizontal
2. i 46/2.1465 in (54,508/54,521 mm)
1.0625/1.0635 in (26,99/27,01 mm)
1.00/1.001 in (25,4/25,43mm)
6.405/6.407 in (162,69/162,74 mm)
0.375 in
(i in) U.N.F.
0.0065/0.0105 in (0,1610,27 mm)
0.0075/0.0105 in (0,19/0,27 mm)

TECHNICAL DATA-B.G
Connecting Road Alignment 4.108,4.107,4.99
Large and small end bores must be square and parallel with each other within the limits of ::'::0.010 in (0,25 mm) mea-
sured 5 in (127 mm) each side of the axis of the rod on test mandrel as shown in Fig. B.1. With the small end bush
fitted, the limit of ::'::0.010 in (0,25 mm) is reduced to ::'::0.0025 in (0,60 mm).
-
--
Ej~
.= E
= -.::t
Sin
.-It')
-
..
=N
-
~
00
127mm
+1 +.
...J
"
B1
Crankshaft 4.108,4.107,4.99
Overall Length
Main Journal Dia. Nos. 1 and 2
Main Journal Dia. No.3
Main Journal Length No.
Main Journal Length No.2
Main Journal Length NO.3
Main Journal Fillet Radii
Crankpin Dia.
Crankpin Length
Crankpin Fillet Radii
Surface Finish-All Journals
Main Journal and Crankpin Regrind Undersizes
Oil Seal Helix Dia.
Oil Seal Helix
Width
Oil Seal Helix Depth
Flange Dia.
Flange Width
Spigot Bearing Recess Depth
Spigot Bearing Recess Bore
Crankshaft End Float
Crankshaft Thrust Washers 4.108, 4.1
Type
Position in Engine
Thrust Washer Thickness (STD)
Thrust Washer Thickness (O/S)
Thrust Washer Outside Dia.
Thrust Washer Inside Dia.
Main Bearings 4.108, 4.101, 4.99
Type
Shell Width
Outside Dia. of Main Bearing
Inside Dia. of Main Bearing
Running Clearance-Nos. 1 and 2 .
Running Clearance-No. 3
Steel
Thickness
Aluminium Thickness
,;
i..-
4.99
....
~
-
c: E
I
.- E
Sin
=-.::t
--
-
'-It')
-
..
C?N
127mm
=0
+1+.
t-.
...J
'f
-
:..,...
21.125 in (536,575 mm)
2.248/2.2485 in (57,099/57,112 mm)
2.2475/2.248 in (57,086/57,099 mm)
1.40625 in (35,719 mm)
1.496/1.504 in (37,998/38,202 mm)
1.499/1.502 in (38.075/38,151 mm)
0.12510.141 in (3,175/3,581 mm)
1.9993/2.0001 in (50,78/50,80 mm)
1.1875/1.1895 in (30.162/30,213 mm)
0.15625/0.17187 in (5/32/11/64 in)
(3,969/4,366 mm)
8-16 micro-in (0,2 -0,4 micron)
0.010.0.020,0.030 in (0,25, 0.51.0.76 mm)
2.21075/2.21175 in (56,153/56.178 mm)
0.050/0.080 in (1,270/2,032 mm)
0.004/0.008 in (0,102/0.203 mm)
3.9985/3.9995 in (101,562/101,587 mm)
0.500 in (12,700 mm)
0.875 in (22,225 mm)
1.250 in (31,750 mm)
0.002/0.015 in (0.0508/0.381 mm)
Steel BaCked-Lead Bronze Faced
Rear Main Bearing
0.089/0.091 in (2,261/2,311 mm)
0.0965/0.1005 in (2,451/2,553 mm)
3.24513.255 in (82,423/82.677 mm)
2.590/2.600 in (65.786/66,040 mm)
Pre-finished, Steel Backed. Aluminium Tin Lined
1.245/1.255 in (31.623/31.877 mm)
2.3955 in (60,846 mm)
2.2505/2.2515 in (57,163/57,188 mm)
0.002/0.0035 in (0.051/0,089 mm)
0.0025/0.004 in (0,063/0.102 mm)
0.060 in (1,524 mm) Max.
0.01210.01225 in (0.305/0,311 mm)

Connecting Rod Bearings 4.108, 4.107, 4.99
Type
Shell
Width
Outside Dia. of Can. Rod Bearing .
Inside Dia.
of Can. Rod Bearing
Running Clearance
Steel
Thickness .
Aluminium Thickness
Camshaft 4.108,4.107,4.99
No. 1 Journal Length
No.1 Journal Dia.
No.1 Cylinder Block Camshaft Bore Dia.
No. 1
Journal Running Clearance
No. 2
Journal Length
No. 2
Journal Dia.
No.2 Cylinder Block Camshaft Bore Dia.
No.2 Journal Running Clearance
No. 3
Journal Length
No. 3
Journal Dia
NO.3 Cylinder Block Camshaft Bore Dia.
NO.3 Journal Running Clearance ...
Cam Lift
Oilways for Rocker Shaft Lubrication
Camshaft Thrust Plates 4.108, 4.107, 4.99
Type
Thrust Plate Outside Dia.
Cylinder Block Recess Dia. for Thrust Plate
Clearance Fit of Thrust Plate in Recess
Thrust Plate Inside Dia.
Thrust Plate Thickness
Cylinder Block Recess Depth for Thrust Plate
Thrust Plate
Height in relation to Cylinder Block Face
Camshaft End Float
Valve and Fuel Pump Timing
Refer to later section on timing (page K.1 ).
CYLINDER HEAD 4.1
Overall Length of Cylinder Head
Overall Depth
of Cylinder Head
4.1 4.99
Skimming Allowance on Cylinder Head Face
Pressure
for Water Leakage Test
Valve Seat
Angle
Bore in Cylinder Head for Guide
Bore in
Cylinder Head for Combustion Chamber Inserts
Depth of Bore in
Cylinder Head for
Combustion Chamber Inserts
Combustion Chamber Inserts 4.108, 4.101,4.99
Outside Dia. of Insert
Depth
of Insert ...
Height of Insert in relation to Cylinder Head Face
Clerance Fit
of Insert in Cylinder Head Bore
Method
of Location in Cylinder Head
Valve Guides (inlet) 4.108,4.107,4.99
Inside Dia.
Outside Dia.
Interference fit
of Guide in Cylinder Head Bore
Overall length of Guide ."
Guide Protrusion Above
Top
Face of Cylinder Head
TECHNICAL DATA-B.7
Pre-finished, Steel Backed, Aluminium Tin Lined
0.870/0.880 in (22,098/22,325 mm)
2.1465 in (54,521 mm)
2.0015/2.0025 in (50,838/50,863 mm)
0.0014/0.0032 in (0,036/0,081 mm)
0.060 in (1,524 mm) Max_
0.012/0.01225 in (0,305/0,311 mm)
1.347/1.351 in (34,214/34,315 mm)
1.791/1.792 in (45,491/45,517 mm)
1.794/1.7955 in (45,568/45,606 mm)
0.002/0.0045 in (0,051/0,114 mm)
1,250 in (31,750 mm)
1.781/1.782 in (45,237/45,26'3 mm)
1,784/1,787 in (45:314/45,390 mm)
0.002/0.006 in (0,051/0,152 mm)
1.000 in (25,400 mm)
1.773/1.774 in (45,034/45,060 mm)
1.776/1.778 in (45,110/45,161 mm)
0.002/0.005 in (0,051/0,127 mm)
0.2592/0.2622 in (6,58/6,66 mm)
No. 2 Journal
180' Oil Impregnated Sintered Iron
2.555/2.557 in (64,897/64,948
mm)
2.5585/2.5685 in (64,986/65,240 mm)
0.0015/0.013 in (0,038/0,330 mm)
1.500 in (38,100 mm)
0.160/0.162 in (4,060/4,115 mm)
0.158/0.164 in (4,009/4,166 mm)
0.004 in (0,102 mm) above or below
0.003/0.009 in (0,076/0,228 mm)
20.000 in (508,000
mm)
2.617 /2.633 in (66,472/66,878 mm)
NIL-On no account can the cylinder head face be
skimmed
20 Ibflin
2
(1,4 kgflcm2) -138 kN/m
2
45°
0.4995/0.5005 in (12,687/12,713
mm)
1.250/1.252 in (31,750/31,801 mm)
0.373/0.376 in (9,474/9,550 mm)
1.248/1.249 in (31,699/31,724 mm)
0.374/0.375 in (9,499/9,525 mm)
0.002 in (0,051 mm) above or below
0.001/0.004 in (0,025/0,102 mm)
By Cylinder Block Face and Expansion Washer
0.3141/0.3155 in (7,978/8,014
mm)
0.5021/0.5026 in (12,753/12,766 mm)
0.0016/0.0031 in (0,041/0,079 mm)
2.130 in (54,102 mm)
6.800/0.815 in (20,320/20,701 mm)

TECHNICAL DATA-B.B
Valve Guides (Exhaust) 4.10B, 4.107, 4.99
Inside Dia.
Outside Dia.
Interference fit of Guide in Cylinder Head Bore
Depth of Counterbore
Overall Length
of Guide '"
Guide Protrusion above Top Face of Cylinder Head
Valves (Inlet) 4.10B, 4,107, 4.99
Valve Stem Dia.
Clearance fit of Valve Stem in Guide
Valve Head Dia.
Valve Face Angle
Valve Head Depth
Below Cylinder Head Face
Overall Length of Valve
Sealing Arrangement
Valve (Exhaust) 4.108,4.107,4.99
Valve Stem Dia.
Clearance Fit of Valve Stem in Guide
Valve Head Dia.
Valve Face Angle
Valve Head Depth
Below Cylinder Head Face
Overall Length
of Valve
Sealing Arrangement
Inner Valve Springs (where fitted)
Fitted Length
Load
at Fitted Length
Fitted Position
Outer Valve Springs
Fitted Length
Load
at Fitted Length
Fitted Position
4.10B, 4.107, 4.99
Rockel' level's 4.108, 4.107, 4.99
Length between Centre Line of Adjusting Screw and
Centre Line of Rocker Shaft
Length between Centre Line of Rocker Lever Pad and
Centre Line of Rocker Shaft
Inside Dia. of Rocker Lever Bore
Outside Dia. of Rocker Lever Bush
Interference Fit
of Bush in Rocker Lever
Finished Inside Dia. of Rocker Lever Bush
Clearance of Rocker Lever Bush on
Rocker Shaft
Valve Clearances 4.108, 4.107, 4.99
Clearance between Valve Stem Tip and Rocker Lever
Rocker Shaft 4.108, 4.107, 4.99
Overall Length of Shaft
Outside Dia. of Shaft
Lubrication
Push Rods
Overall Length
Outside Dia.
4.108, 4.107, 4.99
0.3141/0.3155 in (7,978/8,014 mm)
0.5021/0.5026 in (12,753/12,766 mm)
0.001610.0031 in (0,041/0,079 mm)
0.380 in (9,650 mm)
2.440 in (61,980 mm)
0.80010.815 in (20,320/20,701 mm)
0.312/0.313 in (7,92511,950 mm)
0.0011/0.0035 in (0,028/0,089 mm)
1.410/1.414 in (35,814/35,916 mm)
45'
0.028/0.039 in (0,711/0,991 mm)
4.592/4.608 in (116,637/117,043 mm)
Rubber Oil Seal
0.3115/0.3125 in (7,91217,937 mm)
0.0016/0.004 in (0,041/0,102 mm)
1.19111.195 in (30,251/30,353 mm)
45°
0.021/0.032 in (0,53'3/0,813 mm)
4.60014.616 in (116,840/117,246 mm)
No Seal fitted to Exhaust Valve
1.530 in (38,862
mm)
28.6 Ibf::'::: 2 Ibf (13,0 kgf::'::: 0,91 kgf)
Damper Coil to Cylinder Head
1.780 in (45,212
mm)
56.0 Ibf::':::2.8 Ibf (25,4 kgf::':::1,27 kg!)
Damper Coil to Cylinder Head
1.042/1.058 in (26,467/26,873 mm)
1.567/1.583 in (39,802/40,208 mm)
0.71825/0.71950 in (18,243/18,275 mm)
0.720510.7215 in (18,301/18,326 mm)
0.00110.00325 in (0,025/0,082 mm)
0.6245/0.62575 in (15,862/15,894 mm)
0.00075/0.0035 in (0,01910,089 mm)
0.012 in (0,30
mm) Cold
14.5625 in (369,887
mm)
0.62225/0.62375 in (15,805/15,843 mm)
Oil Feed from Cylinder Head through Central
Passage
to Individual Rocker Levers
8.527/8.560 in (216,58/217,42 mm)
0.250 in (6,350
mm)

Tappets 4.108, 4.107, 4.99
Overall Length
Outside Dia: of
Tappet Shank
Cylinder Block Tappet Bore Dia.
Tappet Running Clearance in Cylinder
Block Bore
Outside Dia. of
Tappet Foot
TIMING GEARS 4.108, 4.107, 4.99
TECHNICAL
DATA-B.9
2.250 in (57,150 mm)
0.560/0.561 in (14,224/14,249 mll'l)
0.56210.56325 in (14,275/14,307 mm)
0.001/0.00"325 in (0,025/0,082 mm)
1.245/1.255 in (31,623/31,877 mm)
Note: Some engines are fitted with spur gears instead of helical gears, in which case the number of teeth on each
gear are given in brackets.
Camshaft Gear
Number of Teeth
Inside Dia.
of Gear Boss ...
Outside Dia. of Camshaft Hub
Transition
Fit of Gear and Hub
Fuel Pump Gear
Number of Teeth
Inside Dia.
of Cylinder Block Bore for Fuel Pump
Drive Hub Bearing
Outside Dia.
of Fuel Pump Drive Hub Bearing
Interference Fit
of Drive Hub
Bearing in
Cylinder Block Bore ...
Inside Dia. of Fuel Pump Drive Hub Bearing
Outside Dia.
of Fuel Pump Gear Drive Hub ...
Running Clearance of Drive Hub in Bearing
Drive Hub End
Float
Idler Gear and Hub
Number of Teeth
Inside Dia.
of Gear Boss ...
Inside Dia. of Gear Boss with Bush Fitted ...
Outside Dia. of
Gear Hub
Running Clearance
of Gear on Hub
Idler Gear Width
Hub Width
Idler Gear End Float
Crankshaft Gear
Number of Teeth
Inside Dia.
of Gear
Crankshaft Dia. for Gear ...
Transition Fit of Gear on Crankshaft
Timing Gear Backlash
Clearance between Crankshaft!ldler and Camshaft!
Idler Gear
LUBRICATING SYSTEM 4.108,4.107,4.99
48 (50)
1.750/1.7514 in (44,450/44,486 mm)
1.7496/1.7509 in (44,430/44,473 mm)
0.000910.0018 in (0,023/0,046 mm)
48 (50)
1.8125/1.8141 in (46,037/46,078 mm)
1.814511.8152 in (46,088/46,106 mm)
0.0004/0.0027 in (0,010/0,069 mm)
1.3125/1.3135 in (33,34/33,78 mm)
1.3105/1.3115 in (33,287/33,312 mm)
0.0031/0.0051 in (0,079/0,129 mm)
0.00210.010 in (0,051/0,254 mm)
57 (42)
1.7187/1.7197 in (43,655/43,680 mm)
1.562511.5641 in (39,687139,728 mm)
1.5612/1.5619 in (39,654/39,668 mm)
0.0003/0.0016 in (0,008/0,041 mm)
1.3105/1.3135 in (33,287/33,363 mm)
1.316511.3195 in (33,439/33,52 mm)
0.00310.008 in (0,076/0,208 mm)
24 (25)
1.25011.2512 in (31,750/31,780 mm)
1.250/1.2506 in (31,750/31,756 mm)
0.000610.0012 in (0,015/0,030 mm)
0.0015/0.0025 in (0,038/0,064 mm)
Lubricating Oil Pressure ... 30/60 Ibflin
2
(2,1/4,2 kgflcm2) -2071414 kN/m
2 at
Sump
Dipstick Position
Strainer Location
Typical Sump Capacities
Refill Capacities-Engine Level
Standard Sump
...
Vauxhall Motors
Chrysler Cars
Ford
Motor Co ....
maximum engine speed and normal working tempera-
ture.
Camshaft side
of engine opposite No.2 cylinder
End of suction pipe to lubricating oil pump.
Imp.
pt U.S. pt
Litre
7.0 8.4 4.0
9.0
10.8
5.1
8.6
10.3
4.9
8.75
10.5
5.0
Note: The above sump capacities are intended to be used as a gUide and actual capaCities should be governed by
the level
indicated on the dipstick.
When refilling the engine after an overhaul has been carried out a further 2 imp. pints, 2! U.S. pints or 1 litre approxi-
mately should be added
to the capacities quoted, to allow for filling the pipes, oilways, filter assembly, etc.

TECHNICAL DATA-B.10
Lubricating Oil Pump
Type
Number of Lobes-Inner Rotor
Number of Lobes-Outer Rotor
Method
of Drive
Pump Clearances
Inner Rotor to Outer Rotor
Outer Rotor
to Pump Body
Inner Rotor End Clearance
Outer Rotor End Clearance
Inside Dia.
of ~ore for Pump Shaft
Outside Dia.
of Pump Shaft
Running Clearance, Shaft in Bore ...
Lubricating Oil Pump Drive Gear
Number of Teeth
Inside Dia. of Gear
Bore ...
Outside Dia. of Oil Pump Drive Shaft
Interference Fit of Gear on Shaft ...
Lubricating Oil Pump Drive Gear Backlash
...
Relief Valve
Type
Pressure Setting
Length
of Plunger
Outside Dia.
of Plunger ...
Inside Dia.
of Valve Housing Bore ...
Clearance
of Plunger in Bore
Outside Dia.
of Spring
Spring-Free Length
Lubricating Oil Filter
Type
Element Type
By-Pass Valve Setting
COOLING SYSTEM 4.108, 4.101, 4.99
Type
Cylinder Block and Head
Engine Water Capacity (Less Radiator)
Thermostat
Type
Opening Temperature
Fully open
at
Minimum Travel at Fully Open Temp.
Water Pump
Type
Outside Dia.
of Shaft for Pulley (Separate Bearing
Pump)
Inside Dia.
of Pulley Bore (Separate Bearing Pump)
Outside Dia.
of Shaft for Pulley (Combined Bearing
and
Shaft)
Inside Dia. of Pulley Bore (Combined Bearing and
Shaft Pump)
...
Interference Fit of Pulley on Shaft ...
Outside Dia. of Shaft
for Impeller .. .
Inside Dia.
of Impeller Bore
Interference Fit
of Impeller on Shaft
Rotor Type
Three
or Four
Four
or Five
By Spiral Gears from the Camshaft
0.0005/0.0025 in (0,013/0,063 mm)
0.01110.013 in (0,28/0,33 mm)
0.0015/0.003 in (0,038/0,076 mm)
0.0005/0.0025 in (0,013/0,063 mm)
0.50010.501 in (12,700/12,725 mm)
0.4983/0.4986 in (12,655/12,664 mm)
0.0014/0.0027 in (0,036/0,069 mm)
12
0.496510.4970 in (12,611/12,624 mm)
0.4983/0.4986 in (12,655/12,664 mm)
0.001310.0021 in (0,033/0,053 mm)
0.0155/0.019 in (0,394/0,483 mm)
Spring Loaded Plunger
50/65 Ibflin
2
(3,5/4,6 kgflcm2) - 344/448 kN/m
2
0.9375 in (23,813
mm)
0.5585/0.5595 in (14,19/14,21 mm)
0.5605/0.5625 in (14,24/14,29 mm)
0.001/0.004 in (0,025/0,102 mm)
0.368/0.377 in (9,347/9,576 mm)
1.5 in (38,10 mm)
Full Flow
Paper
or Canister
Open between 13-17
Ibflin
2
(0,91-1,2 kgflcm2) 90-117 kN/m
2 pressure
differential
Water Cooled
Thermo-Syphon
Impeller Assisted
6 Imp.
pt (7.2 U.S. pt or 3,4 Litre)
Wax Capsule
175-182°F (79,5-83,5°C)
200-205°F (93,5-96°C)
0.3125 in (7,94
mm)
Centrifugal-Belt driven from Crankshaft
0.5905/0.5908 in (14,999/15,006 mm)
0.588/0.589 in (14,935/14,961 mm)
0.6262/0.6267 in (15,808/15,920 mm)
0.6239/0.6247 in (15,849/15,869 mm)
0.0015/0.0028 in (0,038/0,071 mm)
0.498/0.499 in (12,649/12,675 mm)
0.497/0.4975 in (12,624/12,636 mm)
0.0005/0.002 in (0,013/0,051 mm)