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General Specification Data

 

300 TDI Engine

 

Type ................................................................................. Direct injection, turbocharged, intercooled

Number of cylinders ......................................................... 4

Bore ................................................................................. 90,47 mm

Stroke ............................................................................... 97,00 mm

Capacity ........................................................................... 2495 cc

Compression ratio ............................................................ 19.5:1 ± 0.5:1

Valve operation ................................................................ O.H.V. pushrod operated

 

Crankshaft

 

Main bearing journal diameter .......................................... 63,475 - 63,487 mm

Regrind dimensions ......................................................... 63,2333 - 63,246 mm

                                                                                           Use 0.010 in U/S bearings

Crankpin journal diameter ................................................ 58,725 - 58,744 mm

Regrind dimensions ......................................................... 58,4708 - 58,48985 mm

                                                                                           Use 0.010 in U/S bearings

Crankshaft end thrust ....................................................... Taken on thrust washers at centre main bearing

Crankshaft end float ......................................................... 0,05 - 0,15 mm

 

Main bearings

 

Number and type.............................................................. 5 halved shells with oil grooves

Diametrical clearance ....................................................... 0,0792 - 0,0307 mm

 

Connecting rods

 

Length between centres ................................................... 175,38 - 175,43 mm

Diametrical clearance (big-end bearings) ........................ 0,025 - 0,075 mm

End float on crankpin ....................................................... 0,15 - 0,356 mm

 

Pistons

 

Type ................................................................................. Aluminium alloy, combustion chamber in crown.

                                                                                          Graphite coating on sidewalls.

Skirt diametrical clearance

(at right angle to gudgeon pin) ......................................... 0,025 - 0,05 mm

Maximum height above combustion face ......................... 0,8 mm

 

Gudgeon pins

 

Type ................................................................................. Floating

Fit in piston ....................................................................... Hand push fit

Diameter .......................................................................... 30,1564 - 30,1625 mm

Clearance in connecting rod ............................................ 0,0025 - 0,0163 mmGENERAL 

 

Piston rings

 

Type:

         - Top ........................................................................ Barrel edge, chrome plated

         - Second .................................................................. Taper faced

         - Oil control .............................................................. Expander and rails

Gap in bore:

         - Top ........................................................................ 0,40 - 0,60 mm

         - Second .................................................................. 0,30 - 0,50 mm

         - Oil control .............................................................. 0,3 - 0,6 mm

Clearance in piston grooves:

         - Second .................................................................. 0,050 - 0,085 mm

         - Oil control .............................................................. 0,050 - 0,085 mm

 

Camshaft

 

Drive ................................................................................. 30 mm wide dry toothed belt

Location ........................................................................... Right hand side (thrust side)

End float ........................................................................... 0,1 - 0,2 mm

Number of bearings .......................................................... 4

Material ............................................................................ Steel shell, white metal lined

 

Valves

 

Tappet clearance:

       - Inlet and exhaust ................................................... 0,20 mm

Seat angle:

       - Inlet ....................................................................... 30°

       - Exhaust ................................................................. 45°

Head diameter:

       - Inlet ....................................................................... 38,75 - 39,05 mm

       - Exhaust ................................................................. 36,35 - 36,65 mm

Stem diameter:

       - Inlet ....................................................................... 7,960 - 7,975 mm

       - Exhaust ................................................................. 7,940 - 7,960 mm

Valve lift

      :- Inlet ....................................................................... 9,67 mm

       - Exhaust ................................................................. 9,97 mm

Cam lift:

       - Inlet ....................................................................... 6,81 mm

       - Exhaust ................................................................. 7,06 mm

Valve head stand down:

       - Inlet ....................................................................... 0,81 - 1,09 mm

       - Exhaust ................................................................. 0,86 - 1,14 mm

 

Valve springs

 

Type ................................................................................. Single coil

Length, free ...................................................................... 46,28 mm

Length, under 21 kg load ................................................. 40,30 mm

 

Lubrication

 

System ............................................................................. Wet sump, pressure fed

Pressure, engine warm at normal operating speeds ........ 25 - 55lbf/in2 = 1,76 - 3,87Kgf cm 2

Oil pump:

       - Type ...................................................................... G-rotor integral with front cover.

       - Drive ..................................................................... off crankshaft nose

Oil pressure relief valve .................................................... Non-adjustable

Relief valve spring:

      - Full length ...................................................................... 51,6mm

      - Compressed length at 7.71Kg load ................................ 31mm

Oil filter ............................................................................. Screw-on disposable canister

Engine oil cooler ............................................................... Combined with coolant radiator and intercooler

 

Fuel System - 300 TDI

 

Fuel lift pump type ............................................................ Mechanical with hand primer

Fuel lift pump pressure ..................................................... 42 - 55 kpa at 1800 rpm

Fuel filter .......................................................................... Paper element in disposable canister

Air cleaner ........................................................................ Paper element type

 

Cooling System - 300 TDI

 

System type ..................................................................... Pressurised, spill return, thermostatically controlled

                                                                                           water and anti freeze mixture. Pump assisted thermo

                                                                                           syphon. Coolant radiator combined with oil cooler and

                                                                                           turbo intercooler.

Cooling fan ....................................................................... 11 blade axial flow 433 mm diameter. 1.29:1 drive

                                                                                           ratio. Viscous coupling.

Pump type ........................................................................ Centrifugal, impellor, belt driven.

Thermostat opening ......................................................... 88°

Expansion tank cap pressure ........................................... 15lbf/in2 = 1,06Kgf cm 2 (system pressure)

Engine 300TDI - General Specification Data

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10 November 2019

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