Data and dimensions

Note:  The information in this Workshop Manual is given as a guide for personnel engaged on engine

overhauls. The dimensions which are shown are those which are mainly used in production.

Injection timing

Engine build list

Engine type

102-05

Injection timing

25.5° ± 1°

KN30305, KN30306

KN30308, KN30309

KN30304, KN30327

102-05

27.5° ± 1°

KL30317, KL30318

KL30319, KL30320

KL30323, KL30324

KL30325, KL30326

103-07

17.0° ± 1°

KD30238, KD30239

KD30240

103-10

103-10

103-10

103-13

103-15

103-15

104-19

104-22

104-22

23.0° ± 1°

22.5° ± 1°

18.5° ± 1°

22.5° ± 1°

22.5° ± 1°

16.0° ± 1°

21.5° ± 1°

16.0° ± 1°

20.0° ± 1°

KD30241, KD30242

KD30247, KD30248

KD30245, KD30246

KH30255, KH30256

KH30273

KE30260, KE30261

KE30274

KE30262, KE30263

KF30265, KF30266

KF30276

KR30334, KR30335

KR30331, KR30332

KR30333

Note:  OEM build lists can be found on the relevant service bulletin. If the timing is incorrect refer to "Fuel

injection pump timing" on page 85.

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100 Series

Cylinder bore dimensions

Bore dimension mm (in)

Engine model/Block specification

Standard

Service limit

102-05, 103-07

New Block

67,000 - 67,019 (2.63780 - 2.63854)

67,500 - 67,519 (2.65750 - 2.65822)

68,000 - 68,019 (2.67720 - 2.67791)

67,2 (2.646)

67,7 (2.666)

68,2 (2.685)

1st oversize bore 0,5 mm (0.2 in)

2nd oversize bore 1,0 mm (0.4 in)

103-10

New Block

75,000 - 75,019 (2.95280 - 2.95350)

75,500 - 75,519 (2.97244 - 2.97318)

76,000 - 76,019 (2.99212 - 2.99287)

75,2 (2.961)

75,7 (2.981)

76,2 (2.999)

1st oversize bore 0,5 mm (0.2 in)

2nd oversize bore 1,0 mm (0.4 in)

103-13, 103-15, 104-19, 104-22

New Block

84,000 - 84,019 (3.30710 - 3.30783)

84,500 - 84,519 (3.32677 - 3.32751)

85,000 - 85,019 (3.34650 - 3.34719)

84,2 (3.315)

84,7 (3.335)

85,2 (3.354)

1st oversize bore 0,5 mm (0.2 in)

2nd oversize bore 1,0 mm (0.4 in)

Caution:  When service limits are exceeded following a second oversize bore operation, the block must be

renewed.

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100 Series

Piston and piston ring dimensions

Piston

If the outer surface of the piston is excessively damaged (cracked, scored, or it shows signs of being burnt etc.)

it must be renewed.

Piston skirt

1  Check the larger diameter of the piston skirt (10 mm from bottom) with reference to the following tables.

102-05, 103-07, 103-10, 103-13

Diameter mm (in)

Piston

size

102-05, 103-07

103-10

103-13

66,9375 - 66,9525

(2.6353- 2.6359)

74,9325 - 74,9475

(2.950100 - 2.950690)

83,948 - 83,963

(3.30503 - 3.30562)

Standard

0,5 mm

oversize

67,4375 - 67,4525

(2.6550 - 2.6556)

75,4325 - 75,4475

(2.969780 - 2.970370)

84,448 - 84,463

(3.32472 - 3.32531)

1,0 mm

oversize

75,9325 - 75,9475

(2.989463 - 2.990060)

84,948 - 84,963

(3.34440 - 3.34499)

Not applicable

103-15, 104-19, 104-22

Diameter mm (in)

Piston

size

103-15, 104-19

104-22

83,948 - 83,963

(3.30503 - 3.30567)

83,948 - 83,963

(3.30503 - 3.30562)

Standard

0,5 mm

84,448 - 84,463

84,448 - 84,463

oversize

(3.32472 - 3.32531)

(3.32472 - 3.32531)

1,0 mm

84,948 - 84,963

84,948 - 84,963

oversize

(3.34440 - 3.34499)

(3.34440 - 3.34499)

2  Check inside diameter (thrust direction) of the cylinder.

Diameter mm (in)

Engine model

Standard

Service limit

66,7 (2.626)

74,7 (2.941)

83,7 (3.295)

102-05, 103-07

66,9375 - 66,9525 (2.6353 - 2.6359)

74,9325 - 74,9475 (2.950100 - 2.950690)

83,948 - 83,963 (3.30503 - 3.30562)

103-10

103-13, 103-15, 104-19, 104-22

3  Calculate the clearance between the cylinder and piston. If this clearance is more than standard, or the

piston diameter is less than the service limit, renew the piston.

Clearance mm (in)

Engine model

Standard

Service limit

0,25 (0.010)

0,25 (0.010)

0,25 (0.010)

102-05, 103-07

0,048 - 0,082 (0.00189 - 0.00323)

0,0525 - 0,0865 (0.002070 - 0.003406)

0,038 - 0,072 (0.00150 - 0.00283)

103-10

103-13, 103-15, 104-19, 104-22

Oversized piston

When the cylinder is oversized, ensure that the correct oversized piston and piston ring set is used.

Note:  Ring sets are available for all pistons listed above.

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100 Series

Gudgeon pin

1  Check the outside diameter of the gudgeon pin. If it is less than the service limit, renew the pin.

Diameter mm (in)

Engine model

Standard

Service limit

102-05, 103-07

103-10

18,998 - 19,002 (0.74795 - 0.74811)

20,998 - 21,002 (0.82669 - 0.82685)

24,996 - 25,00 (0.98410 - 0.98425)

27,996 - 28,000 (1.10220 - 1.10240)

27,996 - 28,000 (1.10220 - 1.10240)

27,996 - 28,000 (1.10220 - 1.10240)

18,98 (0.7472)

20,98 (0.8259)

24,98 (0.9835)

27,98 (1.1016)

27,98 (1.1016)

27,98 (1.1016)

103-13

103-15

104-19

104-22

2  Check the clearance between gudgeon pin hole and gudgeon pin. Check the inside diameter of the gudgeon

pin hole and the outside diameter of the gudgeon pin, and calculate the clearance between them. If the

clearance is more than the service limit, renew the piston and gudgeon pin.

Clearance mm (in)

Engine model

Standard

Service limit

0,02 (0.0008)

0,02 (0.0008)

102-05, 103-07, 103-10

-0,004 to +0,004 (-0.00016 to +0.00016)

-0,001 to +0,007 (-0.00040 to +0.00030)

103-13, 103-15, 104-19, 104-22

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100 Series

Crankshaft deflection

1  Support the crankshaft with a V-block.

2  Position a dial gauge on the crankshaft centre journal, and turn the crankshaft gradually by one full turn.

3  If the gauge reading is more than the service limit correction or replacement of the crankshaft is needed.

Deflection mm (in)

Standard

Service limit

0,03 or less (0.011)

0,06 (0.0023)

4  If measured diameter is less than the service limit, correct by grinding and use undersized bearings and bush.

Crankshaft inspection

1  Check the oil seal contact face for damage or wear.

2  Check oil holes for blockage.

3  Check crankshaft journal (A4) and pin (A3) for stepped wear. Take measurements of diameters (A5-A5) and

(A6-A6) at positions (A1) and (A2). If the maximum difference between the measurements (stepped wear) is

more than the service limit of 0,05 mm (0.0019 in) then correction is required.

When grinding the crankshaft, work with the following specifications:

Radius at pin/journal (B1):

Finish precision (B2):

3 mm ± 0,2 mm (0.118 in ± 0.0078 in).

1.6Z

Radius around oil hole (B3):

2 mm (0.0787 in) maximum/5 mm (0.196 in) minimum.

Note:  Use No. 400 emery cloth for final polishing.

1

2

1

2

5

5

6

6

3

4

1

2

3

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100 Series

Crankshaft journal diameters

Diameter mm (in)

Journal

No.

Engine model/Journal type

Standard

Service limit

102-05

1

2

1

2

1

2

42,964 - 42,975 (1.69150 - 1.69193)

45,948 - 45,959 (1.80897 - 1.80941)

42,714 - 42,725 (1.68165 - 1.68210)

45,698 - 45,709 (1.79913 - 1.79960)

42,464 - 42,475 (1.67181 - 1.67224)

45,448 - 45,459 (1.78930 - 1.78972)

42,90 (1.689)

45,90 (1.807)

42,65 (1.679)

45,65 (1.797)

42,40 (1.669) (1)

45,40 (1.787) (1)

Standard

Undersize 0,25 mm (0.01 in)

Undersize 0,50 mm (0.02 in)

103-07

1, 2

3

42,964 - 42,975 (1.69150 - 1.69193)

45,948 - 45,959 (1.80897 - 1.80941)

42,714 - 42,725 (1.68165 - 1.68210)

45,698 - 45,709 (1.79913 - 1.79960)

42,464 - 42,475 (1.67181 - 1.67224)

45,448 - 45,459 (1.78930 - 1.78972)

42,90 (1.689)

45,90 (1.807)

42,65 (1.679)

45,65 (1.797)

42,40 (1.669) (1)

45,40 (1.787) (1)

Standard

1, 2

3

Undersize 0,25 mm (0.01 in)

Undersize 0,50 mm (0.02 in)

1, 2

3

103-10

Standard

1, 2, 3

1, 2, 3

1, 2, 3

45,964 - 45,975 (1.80960 - 1.81004)

45,714 - 45,725 (1.79980 - 1.80020)

45,464 - 45,475 (1.78992 - 1.79035)

45,90 (1.807)

45,65 (1.797)

Undersize 0,25 mm (0.01 in)

Undersize 0,50 mm (0.02 in)

103-13

45,40 (1.787) (1)

Standard

1, 2, 3

1, 2, 3

1, 2, 3

57,957 - 57,970 (2.28177 - 2.28228)

57,707 - 57,720 (2.27192 - 2.27244)

57,457 - 57,470 (2.26210 - 2.26260)

57,9 (2.280)

57,6 (2.268)

Undersize 0,25 mm (0.01 in)

Undersize 0,50 mm (0.02 in)

103-15

57,4 (2.260) (1)

Standard

1, 2, 3

1, 2, 3

1, 2, 3

67,957 - 67,970 (2.67550 - 2.67597)

67,707 - 67,720 (2.66563 - 2.66614)

67,457 - 67,470 (2.65579 - 2.65630)

67,90 (2.6732)

67,65 (2.6634)

67,40 (2.6535) (1)

Undersize 0,25 mm (0.01 in)

Undersize 0,50 mm (0.02 in)

104-19, 104-22

Standard

1, 2, 3, 4

1, 2, 3, 4

1, 2, 3, 4

67,957 - 67,970 (2.67550 - 2.67597)

67,707 - 67,720 (2.66563 - 2.66614)

67,457 - 67,470 (2.65579 - 2.65630)

67,90 (2.6732)

67,65 (2.6634)

67,40 (2.6535) (1)

Undersize 0,25 mm (0.01 in)

Undersize 0,50 mm (0.02 in)

(1) If the diameter is less than this value, the crankshaft must be renewed.

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