Peugeot 404 Engine Information

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The following technical bulletins were published by AERA.

HEAD GASKET SELECTION FOR 1.9L DIESEL

Head Gasket Selection For
1982-99 Peugeot 1.9L XUD9 Diesel Engines

The AERA Technical Committee offers the following information for the head gasket selection for the 1982-99 Peugeot XUD9 diesel engines. This information should be considered anytime head gasket replacement is occurring.

Four different head gasket thickness options are currently available and they replace all previous head gasket selections. These gaskets provide a greater variety of gasket thickness options to choose from. Selecting the correct replacement head gasket will ensure proper engine specifications are maintained during engine repairs.

Selecting a replacement head gasket requires measuring the amount of piston protrusion above the deck of the block. After determining the piston height, select the appropriate replacement gasket from the chart below. The gaskets are further identified by a different number of notches on one end of each gasket.

Note: The charts in the original service manuals are no longer valid.

Part # Piston Protrusion Gasket thickness Notches
94-8132 .56mm-.0220/ .71mm-.0279 1.48mm-.0580 2
94-8133 .71mm-.0279/ .75mm-.0295 1.52mm-.0600 3
94-8134 .75mm-.0295/ .79mm-.0311 1.58mm-.0620 4
94-8135 .79mm-.0311/ .83mm-.0326 1.62mm-.0637 5

Add this chart to older Peugeot service and overhaul manuals (if applicable) and this information should also be used on Toro Reelmaster® 335-D/3500-D and Groundsmaster® 455-D units.

The AERA Technical Committee

CONNECTING ROD CAUTION

Connecting Rod Caution For
John Deere 6-404 Diesel Engines

The AERA Technical Committee offers the following information on a connecting rod caution for 1970-80 John Deere 6-404 diesel engines. The information contained in this bulletin should be considered any time connecting rod bolts for this engine are being torqued. Several different torque values have been used for this engine during manufacturing, depending upon when the engine was manufactured. It is important to determine which value to use as bore distortion or inadequate clamping force may occur if the wrong torque value is used.

Early engines (no serial number break) used a torque value that ranged from 100-140 ft/lbs for the connecting rod bolts. Later engines were built using a connecting rod bolt torque of 55 ft/lbs plus a 90° turn. As much as .003 bore distortion has been reported if the later torque is used where the lower value was originally applied.

It is important to note on any engine rebuild which torque applies or engine damage will result. It is therefore suggested that all connecting rods be torqued and checked for size before reusing as many early rods have been reconditioned while using the later torque value. It is also recommended to use the later torque value of 55 ft/lbs plus a 90° turn, any time the rods are reconditioned. Those reconditioned rods should then be labeled with a tag indicating the 55 ft/lbs plus a 90° turn to prevent possible confusion during assembly.

The AERA Technical Committee

CRANKSHAFT IDENTIFICATION & APPLICATION

          Crankshaft Identification And Application On
                    GM 3.0L (181 CID) Engines


AERA member machine shops have reported some confusion about
which crankshaft fits certain GM 3.0L (181 CID) cylinder blocks.

All of the high deck cylinder block engines manufactured from
1982 through 1985 use crankshafts with the casting numbers 257 or
404.

Low deck cylinder blocks manufactured as of 1985 use crankshaft
casting 732.  This crankshaft features additional counterweights
when compared to the 257 and 404 castings.  However, these
counterweights are smaller, permitting the crankshaft to operate
in the more confined crankcase of the low deck cylinder block.

AERA member machine shops have reported success in using the 732
casting in high deck cylinder blocks.  Apparently there are no
balance differences between the two styles of crankshafts.  Even
GM has been known to install the 732 casting in high deck
cylinder blocks.

The reverse is not true.  You may not use a 257 or 404 casting in
a low deck cylinder block.  The larger counterweights interfere
with the cylinder block.


                                     The AERA Technical Committee


October 1990 - TB 701

##END##

CYLINDER HEAD SPECIFICATIONS

                                        Cylinder Head Specifications on
                                          John Deere 4020 Diesel Engines
            
AERA members should consider the following specifications when remanufacturing John Deere 4020 cylinder heads.  This engine may also be classified as a John Deere 404 and is available with or without a turbocharger.

The new cylinder head thickness is 6.125 +/-.005 measured from the deck surface to the rocker cover area.  The minimum cylinder head thickness has been established at 6.090

Intake valve recession on the naturally aspirated (non-turbo) engine should be .038-.050 below the cylinder head deck.  The exhaust valve recession specification for the same engine is .054-.068 below the cylinder head deck.

On turbo charged engines, the intake and exhaust valve recession is from .038 above to .024 above the cylinder head deck.  

                                                                                The AERA Technical Committee

FLYWHEEL SPECIFICATION FOR CASE/IHC TRACTORS

                            Flywheel Specifications for Case/IH Tractors

The following chart of new flywheel specifications may be used when surfacing or machining flywheels on Case/IH agricultural and industrial tractors.

Engine    Machine Application       Dim. A                 Dim. B

C-60      Cub, Lo-Boy                         1.625                 0.013
C-123     200, 230, 240 Tractors        1.182                 1.188
C-123     Flywheel #372436R11         1.375                 1.188
C-123     Flywheel #635094R11         1.425                 1.125
C-135     330, 340 Tractors                 1.115                 1.188
C-135     404 Tractor                           1.182                 1.188
C-135     T & TC5 w/CRPTCO             1.425                1.125
BC-144    B-414, 3414 Tractors          1.156                 1.334
BC-144    Flywheel #3047594             2.075                  N/A
BD-144    B-275 Tractor                      1.188                 1.313
C-146     660, 770, 780 Sprayer           0.872                0.800
C-146     424 Tractor                            1.293                1.344
C-146     500 Crawler, single plate     2.050                 N/A
C-146     500 Crawler, dual plate        1.425                 1.125
C-153     504, 2504, 3514 Tractors      1.115                 1.188
C-153     444, 2444, 4000 Forklift         1.293                 1.344
BD-154    B-414 Tractor                       1.156                 1.344
D-155     500C Crawler                        3.216                  N/A
C-157     454, 2400 Tractors               2.000                  1.443
D-166     330, 340 Tractors                 1.115                  1.188
C-169     300 Tractor                           1.187                  1.187
C-175     300, 350 Tractors                 1,187                  1.187
C-175     3514 Tractor                        2.719                   1.188
C-175     454, 464, 2400 Tractors      2.000                   1.443
D-179     454, 484 Tractors                2.494                   1.443
D-188     504, 2504, 3514 Tractors    1.115                   1.188
C-200     544, 2544, 8000 Forklift       2.719                   1.188
C-200     3500 Series A                      2.000                   1.443
          S/N 28344 & above
C-200     574, 674, 2500, 3500 Series A   2.808            1.443
          S/N 28343 & below
C-221     460, 606, 2606, 3616 Tractors   2.719            1.188

C-221     3616 Tractor S/N 49943 & above 2.470        1.437
D-236     460, 606, 2606,                      2.719                 1.188
          3616 S/N 1772 & below
D-236     3616 S/N 1773 & above       2.470                 1.437
D-239     574, 2544, 3544 Tractors      2.460                 1.181
D-239     574, 674, 2500, 3500 Tractors 2.494              1.443
D-239     Flywheel #3144211R91        2.204                  1.437
C-248     M, 6 Series Tractors            1.374                  1.406
C-263     506, 560, 606 Tractors          3.032                  1.406
C-263     706, 2706 Tractors                1.624                  1.406
C-263     656 Tractor                            2.470                  1.437
C-264     Super M, 400 Tractors          1.374                  1.406
D-264     Super MD, 400 Tractors       1.374                  1.406
C-281     400, 450, Super M, Super 6  1.374                  1.406
D-282     560 Tractor                            3.031                  1.406
D-282     660, 706, 2706 Tractors        1.729                  1.406
D-282     656 Tractor                            2.470                  1.437
C-291     666 Tractor                            2.470                  1.437
C-291     9000 Forklift                           1.694                  0.120
C-301     806, 826, 856 Tractors          1.624                  1.406
D-310     706, 756 Tractors                  2.362                  1.406
D-312     666 Gradall                           3.063                   1.437
C-335     W-9, WR-9, WR-9S               1.625                   .500 above
          S/N 501-1439                                                   backplate mounting
C-335     W-9, WR-9, WR-9S               1.625                   1.438
          S/N 1440 & up                       
D-335     WD-9                                      1.625                  .500 above
          S/N 501-1439                                                   backplate mounting
D-335     WD-9                                     1.655                    1.438
          S/N 1440 & up 
C-350     W-9, WR-9, WR-9S,              1.655                    1.438
          600, 650 Tractors
D-350     Super WD9, 600, 650 Tractors 1.655               1.438
D-358     826, 2826 Tractors             2.362                       1.406
D-360     766 Tractor                         1.594                       1.406
D-361     806, 2806 Tractors             1.594                       1.406
DT-361    1206, 21206 Tractors       1.562                        1.938
DT-407    1256, 456, Tractors          1.562                        1.938
                 21256, 21456
DT-407    856, 2856 Tractors           1.594                       1.406
DT-414    966 Tractor                        1.594                      1.406
DT-414    1096 Tractor                      1.562                      1.938
DT-414    815, 915 Tractors              1.562                      1.406
DT-429    4100, 4156                         1.562                       1.938
DT-436    1466 Tractor                      1.562                      1.938                                   
DT-466    4366 Tractor                      1.627                       1.938
DV-550    1468, 1568 Tractors          1.792                       1.938
DV-800    4568, max. stock removal .063 1.437             2.938

Specification `A' is measured from the crankshaft mounting flange surface to the clutch friction surface.  Specification `B' is measured from the pressure plate mounting surface to the clutch friction surface.

                                                                      The AERA Technical Committee

VALVE CROSSHEAD CLEARANCE

Valve Crosshead To Rocker Lever Clearance On
NH, NT & V-1710 Series Cummins Engines

Valve crosshead nose to rocker lever clearance on the subject engines must be checked during engine rebuild and at any time valve crossheads are replaced on engines using crossheads No. 123416 & 3000326. A minimum of .020 (.51 mm) clearance must be present as illustrated in Fig. 1, on the cylinder being checked with valves completely closed and crosshead in the upmost position. After installing rocker lever assemblies, check crosshead to rocker lever clearance as follows:

1. Turn crankshaft slowly in direction of rotation until the valves are closed on the cylinder being checked. With rocker lever held firmly against the stellite pad of the crosshead, a .020 (.51 mm) wire type feeler gauge must pass between the crosshead nose and the lower beam section of the rocker lever.

2. If the feeler gauge does not pass through:

a. Remove the rocker lever and/or crosshead and grind the nose of the crosshead or rocker lever beam in the area circled in Fig. 1 until enough clearance is obtained.

b. If the rocker is ground, grinding should cover the complete area illustrated in Fig. 2 in a continuous arc. Do NOT grind just the contact area.

Caution: A sharp depression in this area will cause a stress riser and eventual failure of the lever. Grind only enough material to achieve the required clearance. If grinding enters the oil passage, the rocker lever must be junked.

c. Grind sharp edges smooth.

The AERA Technical Committee

CRANKSHAFTS INDUSTRIAL

Crankshafts Used In Industrial Applications On
GM (Chevrolet) 5.7L (350 CID) Engines

When the GM (Chevrolet) 5.7L (350 CID) industrial engine is used in some applications such as lift trucks, the only crankshaft that is applicable has the forging number 1182.  Dimension A of the rear flange is slightly smaller than that of other crankshafts used in General Motors 5.7L (350 CID) engines.

The larger flange crankshafts will not pass through the center hole of the bell housing.  This is very critical when an oil clutch system is used.

                                                                     The AERA Technical Committee