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General| Engine Model | 4.99 |
|---|---|
| Fuel Type | Diesel |
| Fuel System | Direct injection |
| Bore | 91.44 mm |
| Stroke | 127 mm |
| Cooling System | Liquid-cooled |
| Aspiration | Naturally aspirated |
Information on engine service, repairs, and warranty extensions.
Availability of service publications and training programs.
Introduction to engine component identification.
Engine data, ratings, weights, and altitude derating.
Torque values for engine assembly.
Criteria for worn parts replacement.
Key dimensions for cylinder block and related parts.
Specifications for 4.108 and 4.107/4.99 cylinder liners.
Details on 4.108 and 4.107/4.99 pistons.
Standard and controlled expansion ring details for 4.108.
Ring specifications for 4.99 vehicle and industrial engines.
Specifications for gudgeon pins and small end bushes.
Details for 4.108 and 4.107/4.99 connecting rods.
Rod alignment requirements and crankshaft dimensions.
Specifications for main bearings and thrust washers.
Details on rod bearings, camshaft journals and thrust plates.
Cylinder head dimensions and face details.
Dimensions for valve guides and springs.
Inlet/exhaust valve details and rocker shaft components.
Specifications for tappets, timing gears, and sump.
General information on the lubrication system.
Specifications for the oil pump and its components.
Overview of cooling system and thermostat details.
Details on water pump types and components.
Approved fuel oils, lift pump, and filters.
Details on hydraulically and mechanically governed injection pumps.
Specifications for atomisers and starting aids.
Details on dynamo and alternator outputs and types.
Details on starter motor types and current ratings.
Steps for starting the engine, including cold start.
Using glow plugs and stopping the engine.
Engine running-in and general maintenance guidelines.
Daily, 4000, 12000, 24000, 72000 mile checks.
Initial checks and engine protection for storage.
Coolant recommendations and system draining.
Table listing common faults and their possible causes.
Steps before dismantling the cylinder head.
Instructions for removing the cylinder head assembly.
Steps for removing valves from the cylinder head.
Servicing combustion inserts, head cleaning, and springs.
Instructions for valve guide removal and fitting.
Checking valves for wear and reconditioning seats.
Technique for grinding valves to their seats.
Procedure for fitting valve seat inserts.
Dismantling, re-assembly, and push rod checks.
Correct fitting of cylinder head gaskets.
Steps for installing the cylinder head onto the block.
Initial engine checks after cylinder head reassembly.
Importance and procedure for retorquing head nuts.
Steps for removing piston/rod assemblies from the block.
Procedure for removing pistons from connecting rods.
Inspecting pistons, rings, and gudgeon pins.
Procedure for reassembling pistons and rods.
Procedure for fitting laminated segment piston rings.
How to fit spring-loaded scraper piston rings.
Installing piston/rod assemblies into cylinder bores.
Considerations for fitting new pistons and height adjustment.
Details for 4.108 liners and renewal procedures.
Information on using and fitting oversize cylinder liners.
Overview of crankshaft and main bearing types.
Procedures for refitting the crankshaft after service.
Data and procedures for crankshaft regrinding.
Removing, renewing, and refitting the timing case cover and seal.
Removing and refitting the idler gear and hub.
Steps for refitting the idler gear and hub assembly.
Procedure for refitting the camshaft gear.
Removing, refitting, and fitting new fuel pump gears.
Checking and setting fuel injection pump timing.
Removing and refitting the fuel pump drive hub.
Removing and refitting the timing case back plate.
Overview of timing gears, marks, and resetting procedures.
Using the timing pin and checking valve timing.
Steps for removing the engine oil sump and pump.
Steps for dismantling and inspecting the oil pump.
Procedures for oil pump assembly and refitting.
Procedure for replacing the oil filter paper element.
Steps for replacing the oil filter canister.
Filter head fitting and by-pass valve information.
Adjusting, removing, and refitting the fan belt.
General information on water pumps and removal steps.
Procedures for dismantling different water pump types.
Inspecting pump parts for wear and damage.
Steps to re-assemble separate and combined shaft water pumps.
Refitting the water pump and information on seals.
Removing, testing, and replacing the thermostat.
General guidelines for servicing air cleaners.
Servicing instructions for Cyclopac and Cyclone air cleaners.
Servicing instructions for Rotopamic and oil bath cleaners.
Information on fuel oil filters and replacing elements.
Procedure for testing the fuel lift pump's operation.
Checking pump pressure and dismantling procedures.
Procedures for re-assembling and refitting the lift pump.
Overview and removal of the fuel injection pump.
Steps for refitting the fuel injection pump.
Checking and setting fuel injection pump timing.
Using a tool to check the fuel pump timing angle.
Method for checking timing without special tools.
Setting maximum speed and idling adjustments.
Procedure for adjusting the anti-stall device.
Atomiser installation, torque, testing, and identification.
Fuel pipe notes and procedure for priming the fuel system.
Steps for removing the flywheel and renewing the ring gear.
Procedures for refitting the flywheel to the crankshaft.
Steps for removing and refitting the flywheel housing.
Alternator precautions, maintenance, and AC5 fault finding.
Procedures for checking 11 AC alternator output and components.
How to check and adjust alternator voltage settings.
Testing output and adjusting voltage settings.
Troubleshooting warning lights and common faults.
Testing alternator output and regulator function.
Details on dynamo construction and output control.
Dynamo maintenance, performance data, and testing.
Description and routine maintenance for M45G starter motor.
Steps for bench inspecting a starter motor.
Testing starter operation and 'S' type drive function.
Routine maintenance for the 'S' Type starter drive.
Description and maintenance for pre-engaged starter motors.
Testing the pre-engaged starter motor in position.
Checking glow plug continuity, supply, and using a voltmeter.
Key differences in cold start, lubrication, and fuel systems.
Specific details for refrigeration unit engines' timing cover, pistons, and rings.
Tools for valve guides, liners, and piston height.
Tools for fuel pump screws and general use.
Tools for pulleys, water pumps, connecting rods, and arbors.
Tools for valve springs and adaptors.
Tool for checking fuel injection pump timing.
Tools for valve seats and timing case centralisation.
Products for cooling, fuel system, and internal protection.
Products for lubrication, cleaning, sealing, and locking.
