Peregrine EDi and 1300 Series EDi

To dismantle and inspect

Operation 3-6

1  Remove the circlip from the end of the rocker shaft.

2  Slide all of the components from the shaft and put them on a bench in the correct sequence.

3  Inspect all of the components for signs of damage.

4  Check the rocker shaft, the rocker levers and the bushes for deep scratches or signs of excessive wear.

5  The bushes of the rocker lever have a groove to assist with lubrication, ensure that the grooves are free from

debris.

6  Measure the internal diameter of the bushes at two places 90° apart and record the readings.

7  Measure the external diameter of the rocker shaft at two places 90° apart where it contacts the bushes of

the rocker levers. Record the readings.

8  If the difference between the measurements is greater than 0,13mm (0.005 in), renew the worn component,

either the shaft or the bushes.

9  Ensure that all the lubricating oil holes and passages of the rocker shaft assembly are free of debris.

10  Check the plugs at the ends of the rocker shaft for leaks or damage.

11  Measure and record the free length of the rocker shaft springs.

12  Measure and record the length of the springs when a load of 31N (7 lbf) 3,2 kgf is applied. Compare both

measurements with those given in the relevant Data and dimensions for the "Rocker shaft springs" on page 12.

13  Renew any springs that are not within the tolerance.

TOP

A

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Peregrine EDi and 1300 Series EDi

To assemble

Operation 3-7

1  Apply clean lubricating oil to the bushes of the rocker levers.

2  Ensure that a circlip is fitted to one end of the rocker shaft.

3  The rocker shaft is marked “TOP“ at the centre of its length. Ensure that this mark is at the top. Slide the

components onto the rocker shaft in the correct sequence, ensure that the lubricating oil holes are aligned

correctly.

4  Ensure that the setscrew holes in the rocker shaft brackets align with the recesses in the shaft.

5  Compress the rocker shaft springs and fit the second circlip to the rocker shaft.

TOP

A

W076

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Peregrine EDi and 1300 Series EDi

Cylinder head assembly

To remove

Operation 3-8

Warning! The cylinder head weighs 77 kg (170 lbs). Use lift equipment or obtain assistance to lift the cylinder

head.

1  Drain the cooling system.

2  Disconnect the high-pressure oil pipe (A1) at the supply manifold (A3).

3  Disconnect the fuel pipe (A2) at the supply manifold (A3).

4  Remove the rocker cover, see Operation 3-1.

5  Remove the rocker shaft assembly, see Operation 3-4.

6  Remove all the push rods and record their relative positions.

7  Remove all the pipes and hoses from the turbocharger.

8  Remove the exhaust manifold setscrews and remove the exhaust manifold and turbocharger as an

assembly. Remove the gasket for the exhaust manifold.

9  Release evenly and gradually then remove the cylinder head setscrews together with their washers.

10  Carefully separate the cylinder head from the cylinder block with a suitable lever (B).

11  Remove the cylinder head.

Caution: Put the cylinder head on blocks of wood to protect the tips of the fuel injector units.

2

1

3

A

B

W211/1

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Peregrine EDi and 1300 Series EDi

To fit

Operation 3-9

Special requirements

Special tools

Description

Part number

Cylinder head setscrew test tool

27610202

Warning! The cylinder head weighs 77 kg (170 lbs). Use lift equipment or obtain assistance to lift the cylinder

head.

1  Clean the bottom face of the cylinder head and the top face of the cylinder block. Ensure that there is no

debris in the cylinder bores. Ensure that the holes for the cylinder head setscrews are dry and free from debris.

2  Fit the thermostat, if it was removed earlier.

3  Check the cylinder liner protrusion, see Operation 7-4.

4  Fit the dowels into the cylinder block (A).

5  Fit a new cylinder head gasket onto the dowels (A).

6  Put the cylinder head in position (A).

7  Fit the rocker shaft assembly, see Operation 3-5.

8  Lightly lubricate with clean engine oil the setscrew threads, the setscrew head seating areas, and the

washers.

A

W208

Continued

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Peregrine EDi and 1300 Series EDi

9  For WK, WL, WM, and WN engines: tighten evenly and gradually all of the cylinder head setscrews as

follows:

l   150 Nm (110 lbf ft) 15 kgf m in the sequence shown in (B)

l   210 Nm (155 lbf ft) 21,5 kgf m in the sequence shown in (B)

l   225 Nm (165 lbf ft) 23,0 kgf m in the sequence shown in (B)

l   Then proceed to step 13.

10  For WP, WQ, WR and WS engines: Position the crankshaft at TDC for number 1 cylinder, and then rotate

the crankshaft 30° past TDC.

Caution: As the cylinder head setscrews are tightened to yield point, the setscrews must be tested for

extension by use of special tool (27610202). Renew any setscrew that fails. If the special tool is not available,

then all of the setscrews must be renewed.

11  The threaded special tool is fitted on to each cylinder head setscrew. The setscrew must be renewed if the

tool becomes tight on the setscrew thread. This tightness indicates that the setscrew thread is extended and

the setscrew must be discarded.

20

19

12

11

4

3

5

6

13

14

21

22

24

23

16

15

8

7

1

2

9

10

17

18

25

26

B

W1382

12  The cylinder head setscrews must be tightened as follows. Tighten evenly all of the setscrews in the

sequence shown in (B) to 135 Nm (100 lbf ft) 13,8 kgf m.

l   Tighten each cylinder head setscrew to 177 Nm (130 lbf ft) 18 kgf m in the sequence shown in (B).

l   Repeat this step to ensure even tightness.

l   Tighten the setscrews in the same sequence by a further 90°. To do this, apply a mark (C1) to each

setscrew head or socket spanner, and another mark (C2) at 90° clockwise on the cylinder head surface as

shown. Tighten each setscrew until the two marks align.

Caution: Chlorinated solvents must not be used on setscrews or crankcase tapped holes. Components should

be clean and dry, and free of any chemical contamination other than engine oil.

1

3

2

C

W1383

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Peregrine EDi and 1300 Series EDi

13  Remove both of the feeler gauges from the rocker shaft, see Operation 3-5.

14  Check the rocker levers for free movement.

15  Set the valve tip clearance, see Operation 3-21.

16  Fit the high-pressure oil pipe at the supply manifold.

17  Fit the fuel pipe at the supply manifold.

18  Fit the rocker cover, see Operation 3-2.

19  Fit the gasket for the exhaust manifold. Fit the exhaust manifold and turbocharger assembly. Fit and tighten

the setscrews for the exhaust manifold to 81 Nm (60 lbf ft) 8,3 kgf m.

20  Fit all of the pipes and hoses removed earlier from the turbocharger.

21  Fill the cooling system.

22  Eliminate air from the fuel system, see Operation 11-9.

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Peregrine EDi and 1300 Series EDi

Valves and valve springs

To remove

Operation 3-10

Warning! Eye protection must be worn during this operation.

1  Remove the cylinder head, see Operation 3-8. Put the cylinder head on a surface that will not damage its

face.

2  Use a valve spring compressor to compress the valve spring.

3  Remove the collets (A1).

4  Release and remove the valve spring compressor.

5  Remove the valve rotator (A2), the valve rotator seal (A3), the valve spring (A4), the valve seal assembly

(A5) and the valve (A6).

6  Separate the inlet valve springs from the exhaust valve springs. They are rated differently.

7  Discard the valve seal assemblies.

1

2

3

4

5

6

A

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Peregrine EDi and 1300 Series EDi

To fit

Operation 3-11

Warning! Eye protection must be worn during this operation.

1  Ensure that the valve guides are clean.

2  Apply clean lubricating oil to the valve stems and fit the valves (A6) into the valve guides.

3  Apply clean lubricating oil to the inside of new valve seal assemblies (A5) and fit them to the valve stems.

Ensure that each valve seal assembly is fitted fully into the valve spring recess in the cylinder head.

4  Put the valve springs (A4) in position on the valve seal assemblies.

Caution: Ensure that the inlet valve springs are fitted to inlet valves and that the exhaust valve springs are

fitted to exhaust valves. They are rated differently.

5  Fit new seals (A3) to the valve rotators (A2) and put the rotators onto the valve springs.

6  Use a valve spring compressor to compress each valve spring.

7  Fit the collets (A1).

8  Release and remove the valve spring compressor.

1

2

3

4

5

6

A

W077

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Peregrine EDi and 1300 Series EDi

To inspect and to correct

Operation 3-12

Special requirements

Special tools

Description

Part number

21825617 and

21825496

Valve depth gauge

1  Remove the cylinder head, see Operation 3-8.

2  Put a small amount of low viscosity oil, for example calibration fluid, into the inlet and exhaust ports then

check for leakage.

3  Wait five minutes, then check again for leakage.

Note: If no oil leaks past the valve seat, it does not need to be reground.

4  Ensure that the heads of the valves and the face of the cylinder head are clean.

5  Check the depth of the valves below the face of the cylinder head before the valve springs are removed. Put

the valve depth gauge on the face of the cylinder head and set the dial gauge to zero. Carefully put the valve

depth gauge in position over the head of each valve (A) and compare the measurement with the relevant Data

and dimensions for the "Inlet and exhaust valves" on page 10.

6  If a valve is below the depth limit, check the valve depth with a new valve in position.

7  If the valve depth is still below the limit, the valve seat insert must be renewed, see Operation 3-19.

8  Remove the valves and valve springs, see Operation 3-10.

9  Visually inspect the condition of the collets.

10  Visually inspect the valve springs for corrosion, for damage or distortion.

11  Check that the end faces of the springs are square and flat.

12  Measure the free length of the valve springs (B) and compare it with the relevant Data and dimensions for

the "Valve guides and springs" on page 11.

A

B

W131

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Peregrine EDi and 1300 Series EDi

13  Measure the springs under a load (C), refer to the relevant Data and dimensions for the "Valve guides and

springs" on page 11.

14  Check the valves for cracks. Check the stems for wear and correct fit in their valve guides.

15  Check that the seat faces of the valves are not badly burnt or damaged. Seat faces of valves that are

damaged can be ground on a special machine. Valves that have only a little damage can be lapped to their

valve seats. When new valves are fitted, the valve depths must be checked.

16  Measure the valve dimensions and compare them with the relevant Data and dimensions for the "Inlet and

exhaust valves" on page 10.

C

W113

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Peregrine EDi and 1300 Series EDi

To inspect a valve rotator

Operation 3-13

1  Visually inspect the valve rotator for corrosion, damage or distortion.

2  To test the operation of the rotator (A4), put a valve spring (A3), the valve rotator and a steel ball bearing

(A5) in a valve spring tester (A1).

3  Mark the rotator with a reference line (A2).

4  Compress the valve spring rapidly several times and check that the rotator rotates.

5  Replace any rotator that does not rotate.

1

5

2

3

4

A

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Peregrine EDi and 1300 Series EDi

Valve guides

To inspect a valve guide

Operation 3-14

Check the valve guides for wear. The maximum clearance between the valve stem and the bore of the guide

is 0,15 mm (0.006 in) for the inlet valves and the exhaust valves.

If the clearance with new valves fitted is more than the limit, then a new valve guide must be fitted.

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Peregrine EDi and 1300 Series EDi

To remove

Operation 3-15

Special requirements

Special tools

Part number

Description

Description

Part number

Remover / replacer for valve guides

21825478

Adaptor

21825479

1  Fit the adaptor 21825479 (A4) into the remover / replacer tool 21825478 (A3). Pass the tool and adapter

through the spacer (A5) and the cylinder head, from the bottom face. Fully fit the attachment (A7) to secure

the adapter in the valve guide (A6).

2  Turn the top handle (A1) to take up the excess movement in the tool and turn the bottom handle (A2) to pull

the valve guide out of the cylinder head.

1

2

3

4

5

6

7

A

W132

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