GENERAL SPECIFICATION DATA
1
INFORMATION REV: 05/99 300Tdi 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 63,233 - 63,246 mm.........................................................
Crankpin journal diameter 58,725 - 58,744 mm................................................
Regrind dimensions 58,471 - 58,490 mm.........................................................
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 r/angle to gudgeon pin) 0,025 - 0,05 mm....
Maximum height above combustion face 0,8 mm.........................
Gudgeon pins
Type Fully floating.................................................................................
Fit in piston Hand push fit.......................................................................
Diameter 30,156 - 30,163 mm..........................................................................
Clearance in connecting rod 0,003 - 0,016 mm............................................
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 0,30 - 0,60 mm..............................................................
Clearance in piston grooves:
- Second 0,050 - 0,085 mm..................................................................
- Oil control 0,050 - 0,085 mm..............................................................
LUBRICANTS, FLUIDS AND CAPACITIES
3
INFORMATION REV: 05/99 CAPACITIES
The following capacity figures are approximate and are provided as a guide only.
Capacities (approx.)* Litres Pints
Engine sump oil 5,8................................................................ 10.20
Extra when refilling after fitting new filter 0,85.......................... 1.50
Manual gearbox 2,67............................................................... 4.70
Transfer gearbox oil 2,30......................................................... 4.00
Front differential 1,70............................................................... 3.00
Rear differential 1,70................................................................ 3.00
Power steering box and reservoir LHD 2,90............................ 5.00
Power steering box and reservoir RHD 3,40............................ 6.00
Swivel pin housing oil/grease (each) 0,35................................ 0.60
Fuel tank usable fuel 79,5........................................................ 17.5 gall
Cooling system 11,50................................................................ 20.20
Washer bottle 3,0................................................................... 5.28
NOTE: * All levels must be checked by dipstick or level plugs as applicable.
ANTI-FREEZE
PERCENTAGE CONCENTRATION - 50%
PROTECTION - LOWER TEMPERATURE LIMIT
Complete protection
Vehicle may be driven away immediately from cold,
-33°C (-36°F).
Safe limit protection
Coolant in semi-frozen state. Engine may be started
and driven away after warm-up period, -41°C (-42°
F).Lower protection
Prevents frost damage to cylinder head, block and
radiator. Thaw out before starting engine, -47°C (-53°
F).
CAUTION: Anti-freeze content must never
be allowed to fall below 25% (pre 99MY) or
50% (99MY on) otherwise damage to the
engine is liable to occur. Anti-freeze content
should not exceed 60% (all models) as this will
greatly reduce cooling efficiency.
