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300TDI Torque Settings and Engine Spec

Discussion in 'Common Faults and Questions' started by adrian hollister, Feb 19, 2009.

By adrian hollister on Feb 19, 2009 at 12:04 PM
  1. adrian hollister

    adrian hollister Active Member

    Joined:
    May 30, 2007
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    Location:
    Bodmin Moor
    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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60°00’ to 60°30’
    Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°00’ to 45°30’
    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
    [​IMG] [​IMG]
     
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Discussion in 'Common Faults and Questions' started by adrian hollister, Feb 19, 2009.