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Old 19th-February-2009, 13:04
adrian hollister's Avatar
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Default 300TDI Torque Settings and Engine Spec

TORQUE FIGURES 300TDI
Timing belt tensioner bolt . . . . . . . . . . . . . . . . . . . . . . 45 Nm
Timing belt idler pulley nut . . . . . . . . . . . . . . . . . . . . . 45 Nm
Flywheel/drive plate housing plug . . . . . . . . . . . . . . . 12 Nm
Timing belt front cover bolts . . . . . . . . . . . . . . . . . . . . 25 Nm
Crankshaft pulley bolt . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm then further 90
Rocker shaft nuts and bolts . . . . . . . . . . . . . . . . . . . . 5 Nm then further 50
Rocker cover nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm
Crankcase breather cyclone unit bolt . . . . . . . . . . . . 9 Nm
Rear timing cover bolts . . . . . . . . . . . . . . . . . . . . . . . 25 Nm
Oil pressure relief valve plug . . . . . . . . . . . . . . . . . . . 17 Nm
Flywheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 Nm
Drive plate bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 Nm
Drive plate to starter ring gear bolts . . . . . . . . . . . . . . 25 Nm
Flywheel/drive plate housing bolts . . . . . . . . . . . . . . . 45 Nm
Coolant outlet elbow bolts . . . . . . . . . . . . . . . . . . . . . 9 Nm
Thermostat housing bolts . . . . . . . . . . . . . . . . . . . . . 25 Nm
Oil filter head bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm
Cylinder head bolts:
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Nm
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Further 60
Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Further 60
Stage 4 - Bolts 1, 2, 7, 8, 9, 10, 15, 16, 17 and 18
only
Further 20
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sump drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Nm
Oil sump bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm
Oil pick-up pipe bolts:
To main bearing cap . . . . . . . . . . . . . . . . . . . . . . . . . 9 Nm
To timing belt rear cover . . . . . . . . . . . . . . . . . . . . . . 25 Nm
Oil drain pipe bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm
Fuel pump timing gear to hub plate bolts . . . . . . . . . . 25 Nm
Injector clamp nut . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm
Spill return pipe banjo bolts . . . . . . . . . . . . . . . . . . . . 10 Nm
Glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm
Brake servo vacuum pump bolts . . . . . . . . . . . . . . . . 25 Nm
Camshaft gear bolt . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm
Spill return pipe to injection pump banjo bolts . . . . . . 25 Nm
Mounting bracket to fuel injection pump bolts . . . . . . 25 Nm
Fuel injection pump and baffle plate to cylinder
block bolts
25 Nm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft rear oil seal housing bolts . . . . . . . . . . . . 25 Nm
Camshaft thrust plate bolts . . . . . . . . . . . . . . . . . . . . 9 Nm
Camshaft oil jet tube . . . . . . . . . . . . . . . . . . . . . . . . . 17 Nm
Piston oil jet banjo bolts . . . . . . . . . . . . . . . . . . . . . . . 17 Nm
Cam follower guide bolts . . . . . . . . . . . . . . . . . . . . . . 14 Nm
Big-end bearing cap nuts . . . . . . . . . . . . . . . . . . . . . . 59 Nm
Main bearing cap bolts . . . . . . . . . . . . . . . . . . . . . . . 133 Nm


ENGINE DATA 300TDI
Rocker shaft
Rocker shaft wear - maximum . . . . . . . . . . . . . . . . . . 0.025 mm
Rocker arm shaft to bush clearance - maximum . . . . 0.12 mm
Valve clearance - inlet and exhaust . . . . . . . . . . . . . . 0.20 mm
Oil pump
Outer rotor to housing clearance . . . . . . . . . . . . . . . . 0.025 to 0.075 mm
Inner to outer rotor clearance . . . . . . . . . . . . . . . . . . 0.025 to 0.075 mm
Outer rotor end-float . . . . . . . . . . . . . . . . . . . . . . . . . 0.026 to 0.135 mm
Relief valve spring free length . . . . . . . . . . . . . . . . . . 68.0 mm
Cylinder head
Cylinder head maximum warpage . . . . . . . . . . . . . . . 0.08 mm
Maximum movement of valve to guide . . . . . . . . . . . 0.15 mm
Valve stem diameter:
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.96 mm
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.94 mm
Valve head stand down:
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.81 to 1.09 mm
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.86 to 1.14 mm
Valve seat insert face angle:
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Valve face angle:
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6000 to 6030
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4500 to 4530
Valve spring free length . . . . . . . . . . . . . . . . . . . . . . . 46.28 mm
Timing belt tension on torque wrench
Used belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Nm
New belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Nm
Drive plate - automatic gearbox
Setting height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.4 mm

Crankshaft
Maximum bearing journal ovality . . . . . . . . . . . . . . . . 0.040 mm
Maximum bearing journal run-out . . . . . . . . . . . . . . . 0.076 mm
Main bearing journal diameter . . . . . . . . . . . . . . . . . . 63.475 to 63.487 mm
Service limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63.36 mm
Regrind diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63.225 to 63.237 mm
Big-end journal diameter . . . . . . . . . . . . . . . . . . . . . . 58.725 to 58.744 mm
Service limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58.637 mm
Regrind diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58.475 to 58.494 mm
Main and big-end bearing oversizes available . . . . . . 0.25 mm
Main bearing clearance . . . . . . . . . . . . . . . . . . . . . . . 0.031 to 0.079 mm
Crankshaft end-float . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 to 0.15 mm
Thrust washer oversizes available:
1st oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.063
2nd oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.127 mm
Big-end bearing clearance . . . . . . . . . . . . . . . . . . . . . 0.025 to 0.075 mm
Connecting rod end-float . . . . . . . . . . . . . . . . . . . . . . 0.15 to 0.35 mm
Camshaft
End-float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 to 0.2 mm
Pistons and connecting rods
Piston diameter:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.395 mm
1st oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.649 mm
2nd oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.903 mm
Piston to cylinder bore clearance . . . . . . . . . . . . . . . . 0.075 mm
Connecting rod misalignment - maximum . . . . . . . . . 0.075 mm per 25.4 mm
Piston rings
Fitted gap in cylinder bore:
Top compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 to 0.65 mm
2nd compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 to 0.50 mm
Oil control rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 to 0.60 mm
Ring to groove clearance:
Top compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.167 to 0.232 mm
2nd compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 to 0.08 mm
Oil control ring assembly . . . . . . . . . . . . . . . . . . . . . . 0.05 to 0.08 mm
Cylinder block
Cylinder bore maximum ovality . . . . . . . . . . . . . . . . . 0.127 mm
Cylinder bore maximum taper . . . . . . . . . . . . . . . . . . 0.254 mm
Cylinder bore maximum wear . . . . . . . . . . . . . . . . . . 0.177 mm
Cylinder bore size:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.47 mm
For 1st oversize piston . . . . . . . . . . . . . . . . . . . . . . . 90.73 mm
For 2nd oversize piston . . . . . . . . . . . . . . . . . . . . . . . 90.98 mm
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