VALTRA 39200212 Preview

10 General
20 Engine
30 Electrical
system
205, 255, 305

355, 365, 405 40 Power
transmission
455, 465, 555

565, 665, 865 50 Brakes
600, 700, 800

900, 415M, 60
Front axle and
steering sys-
A75, A85, A95

tem
70 Frame and
wheels
Service Manual
Tractors
80 Cab and
shields
90 Hydraulics
Valtra Inc.
FIN---44200 Suolahti, FINLAND
100
Phone +358 2045501
Telefax +358 204550387 Tools
www.valtra.com
Order no 39 200 212
ENGLISH
Copyright E 2006 by Valtra Inc.
Find manuals at https://best-manuals.com

10. General 11. Layout
12. Maintenance
1
2
To the reader
The Service Manual for the Valtra ---Valmet 205---900 tractors is intended to be a practical reference source to be used in workshop.
The repair instructions in the manual are based on methods which have been worked out in practice during normal workshop
conditions and which are based on the use of special tools from the manufacturer when stated in the instructions. The manual
also contains descriptions of the design and function of the components.
Detailed maintenance instructions can be found in Operator’s Manual.
The Service Manual will be continually updated with new revised pages which should be inserted in the manual. Alterations and
additions will first appear as service bulletins.
Only genuine Valmet spare parts should be used to ensure the best possible function of the machine. Certain operations should
be carried out with the aid of special tools designed by Valmet.
Valtra Inc.
Tractor Service
Note! This Manual also includes tractors 600, 700, 800 and 900 as follows:
--- The build ---up of brakes, cab (not roof), front axles and hydraulic power lifts on 600 ---900 tractors is the
same as on 865 ---tractor. If no separate instructions are given, the instructions for 865 tractor are good for
600 ---900 tractors. Transmission on 600 ---900 tractors is the same as on 865, except that 600 ---900 tractors
have a modified low gear and also an alternative Overdrive is available. These new components require
some minor changes in the main gearbox and for these reasons 600 ---900 tractors have transmission 270
(865 has transmission 250).
--- Electric system on 600 ---900 has been shown in section 31.
--- Engine differences are described in sections 21, 22 and 23. 600 and 700 tractors have a Bosch in ---line
fuel injection pump and 800 ---900 a Stanadyne rotary distribution pump.
3
4
1. 9. 2001 Model Code Page
10. General 205-- 900 110 0
1.4.2006
The following supplements have been published for the Valmet 205---900 Service Manual:
Ordering number Date Content

Service Manual 39 200 211 04/1986 First edition
39 251 211 1.7.1989 --- technical modifications
--- model 455
--- new hydraulic power lift (610312---)
--- fitting instructions for optional equipment
--- models 205, 355, 555 and 415M
--- Autocontrol power lift
--- Agrodata performance monitor
--- models 565 and 665
--- 20---series engines
--- Sige front axle
--- Danfoss steering valve
--- models 255 and 465
--- 2---speed PTO unit
--- hydraulic system with priority valve
--- PTO shaft brake
--- front PTO unit
--- front lift
39 251 216 31.1.1996 --- only for 665---4MOD models
39 251 217 1.5.1996 --- model 865
--- Kontak valves for auxiliary hydraulics
--- technical modifications
39 251 218 1.3.1997 --- AD ---instrument
Supplements --- Control Stop
--- AC power lift on 865
39 251 219 1.1.1998 --- tractors 600, 700, 800, 900
--- modified low gear
--- overdrive
39 259 211 1.6.1998 --- air conditioning
--- HiShift
--- latest fitting instructions for optional equipment
39 259 212 15.4.1999 --- ACB power lift
--- new front PTO
--- new E ---engines for 700 and 800
--- new control valve of ACB power lift
--- pressure ait brakes for trailer
39 259 213 1.9.2001 --- E ---engine on 600 and 900 tractor
--- new coolant pump on 600---900
--- expansion tank for engine coolant
--- Infoline and Agroline instruments
--- PTO HiShift
--- updated fitting instructions for optionl equipment
39 259 214 10.10.2003 --- 12+12R gearbox
--- shuttle
39 259 215 1.4.2004 --- Bosch VE rotary pump
--- wiring diagrams (M21101---)
5
Model Code Page
10. General 205-- 900 110 0
1.4.2006
Ordering number Date Content

Service Manual 39 200 212 04/2006 Second edition
6
Model Code Page
10. General 205-- 865 110 1
1. 12. 1986
Layout of Service Manual

1. Division into groups
The manual is divided into groups (10---100) which are based on the make ---up of the tractor. The groups are listed on the first index
leaf.
Example. 10. General

20. Engine, fuel and cooling systems
30. Electrical system
40. Power transmission
a.s.o.
The number designation for each group is given in the top left box of the respective pages (and the first figure in the code designa-
tion).
Code Page
410 1
50
60
70
80
90
100
2. Division into components or sub ---groups
Each group is further divided into components or sub ---groups. The number and the name of each component is given in the top
left box on each page (and comprise the two first figures in the code designation).
Example. 41. Clutch

42. Gearbox
44. Low gear
45.Final drives etc.
7
Model Code Page
10. General 205-- 865 110 2
1. 12. 1986
3. Tractor model
At the top of each page it is indicated for which tractor the page is valid.
4. Code designation
Three ---digit code designations are used to separate the different document groups for the respective components. The same
code is also used in the Time list as a reference to the text in this manual. The code designation numbers appear in the box at
the top of the page and also in the headings.
Example: Code 410

--- Group: power transmission (4)
--- Component: clutch (41)
--- Document group: general (410)
5. Page numbers
The instructions for all components are numbered in consecutive order in the right---hand box at the top of the page. The page
numbers begin with page 1 for each component.
8. 11. 1990 Model Code Page

41. Clutch 205---665 410 1
15. 5. 1993
6. Date
At the top of each page there are two boxes for dates. In a case of revised issue, the date of the earlier issue is printed in the
crossed ---over box and and the date of the current issue is printed in the proper date box.
7. Additions and amendments of the service manual
New and up ---dated pages will be continuously added to the service manual. The new pages should be inserted as indicated by
the code: the first digit (also the first digit on the index leaf) indicates the group:
--- the two first digits indicate the component or sub ---group.
--- the third digit indicates the document group for the respective components
--- the page number indicates the definite position of the page within the service manual.
If there are two pages with the same code and page number, it is the page with the later date in the date box and the old date
in the crossed ---over box which is valid or which is the current page.
When an entirely new set of repair instructions is issued, it will be accompanied by instructions on where the pages should be
inserted in the file.
8
Model Code Page
1. 12. 1986
10. General 205-- 865 110 3
1. 3. 1997
Code designations in the Service Manual

60. Front axle and steering system
10. General 61. Steering system

110 General, lay out 610 Technical data, description, tools
120 Maintenance 611 Steering valve
612 Priority valve
20 Engine 613 Steering cylinder
21. Engine 62. Non ---powered front axle

210 Technical data, description, tools 620 Technical data, description, tools
211 Cylinder block and flywheel housing 621 Front axle
212 Cylinder head and valve mechanism
213 Crank mechanism 64. Powered front axle
214 Auxiliary drive gears (timing gears) 640 Technical data, description, tools
215 Lubrication system and oil sump 641 Housing and central pivot bearings
216 Induction and exhaust system, turbocharger 642 Drive shafts
219 Removing and fitting engine 643 Hubs
644 Differential
22. Fuel system 645 Adjustments
220 Technical data, description, tools
222 Fuel feed pump and fuel filters 70 Frame and wheels
223 Injection pump and injectors 710 Frame
720 Wheels
23. Cooling system
230 Technical data, description, tools 80 Cab and shields
231 Cooling system 810 Cab
820 Shields
30 Electrical system 830 Air conditioner
310 Tractor electrical system, wiring diagrams
320 Autocontrol hydraulic power lift 90 Working hydraulics, power lift
330 Agrodata performance monitor
331 AD ---instrument 91 Working hydraulics and mechanical power lift
40 Power transmission 911 Pump and pipe system
912 Hydraulic power lift
41. Clutch 913 Adjustments
410 Technical data, description, tools 914 Power lift, 610312---
411 Clutch assembly and pedal rods
92. Electro---hydraulic power lift
42. Gearbox
420 Technical data, description, tools 100 Special tools
421 Selector forks 101 Special tools ETV
422 Gear levers 102 Locally prepared tools ET
423 Shafts and gear wheels in gearbox
424 Differential
43. Torque converter and shuttle on 415 M
44. Low gear

441 Low gear
45 Final drives
451 Final drives
46. Power take off

462 Power take off
50 Brake system
511 Service brakes
512 Parking brake
9
Model Code Page
1. 12. 1986
10. General 205-- 865 110 4
1. 3. 1997
General instructions for repairs
Outer oil seals

The Service Manual contains instructions for changing all outer oil seals, (e.g. oil seals on the PTO shaft end, on the output shaft
to the front wheel drive and on the pinion shaft on the powered front axle, and so on).
Sealing compound and glue

If sealing compounds or glue are required for the repair work, the instructions will specify a sealing compound or glue which is
readily available through specialist dealers. Some seals should be greased before fitting and the space between the lips of the
seal should be filled with universal grease. If the seal is to be pushed over splines or sharp edges the seal should be protected
with for example a thin plastic foil.
Tightening torques and setting values

All necessary tightening torques and setting values for each repair operation are given at the beginning of each repair section
under the heading Technical Data. The most important values can also be found in the repair instructions.
Table 1 later gives the tightening torques in order of dimension, quality and surface treatment. The values given in the table should
be used if the tightening torque is not given in the repair instructions.
Safety
Always bear safety in mind when repairing or servicing the tractor. Use tools and lifting devices in the correct way . When you
are removing tractor components or splitting the tractor, every tractor part must be supported in such a way, that no risk of accident
exists. Avoid working under the supported tractor part if it is not absolutely necessary. When supporting the tractor the centre of
gravity of the frame part must always be checked. For instance the wedges must always be fitted between front axle and engine
to prevent axle oscillation when splitting the front frame of the tractor.
Trouble ---shooting
The following procedure, combined with the information contained in the workshop manual will be helpful in tracing faults accu-
rately. It consists of following a number of logical steps to locate and correct the problem:
a) Determine the problem
b) List possible causes
c) Differentiate the causes
d) Conduct checks in logical order to determine the exact cause
e) Consider approximate remaining service life against cost of parts and labour..
f) Make any necessary repairs.
g) Recheck the parts and functions for correct operation
10
Model Code Page
10. General 205-- 865 110 5
1. 12. 1986
Table
Table 1. Tightening torques, metric standard thread (ISO)
Tightening torques Nm1)

Dim. Quality, surface treatment, material and so on
8.8 8.8 8.8 10.9 12.9
lubr. tol.± Zne2) tol± Znk3) tol. ± lubr. tol. ± lubr tol. ±
M4 --- --- --- --- ---
M5 6,4 0,6 5,7 0,5 --- 9 1 11 1
M6 11 1 10 1 12 1,2 15 1,5 18 2
M8 25 2 23 2 30 3 35 4 45 5
M10 50 5 45 5 60 5 70 7 90 10
M12 90 10 80 8 100 10 125 10 151 15
M14 140 15 125 10 160 15 200 20 240 20
M16 220 20 195 20 250 25 300 30 370 40
M18 300 30 270 30 350 35 430 40 510 50
M20 430 40 380 40 480 50 600 60 720 70
M22 570 60 500 50 650 65 800 80 970 100
M24 740 70 660 70 830 80 1030 100 1250 120
M27 1100 100 950 100 1200 120 1500 150 1800 180
M30 1500 150 1300 130 1600 160 2040 200 2500 250
1) 1 Nm=0,102 kpm
2) Zne=zinc electroplating
3) Znk=hot galvanized
If the bolts differs from the standard range the values in the
table must not be used.
11
Model Code Page
10. General 205-- 865 110 6
1. 7. 1989
Conversion table for common units

Quantities and units Conversion factors
Overall and detail dimensions millimetres (mm) 100 mm=3,94 inches
1 inch=25,4 mm
Short distances e.g. turning circles metres (m) 1 m=3,28 ft

1 ft=0,305 m
Travel distances kilometres 1 km=0,62 mile

1 mile=1,61 km
Tractor weights, axle loadings kilograms (kg) 1 kg=2,2 lbs

1 lb=0,454 kg
Travel speed kilometres per h (km/h) 1 km/h=0,62 mph

1 mph=1,61 km/h
Drawbar pull kilonewtons (kN) 1 kN=224,8 lbs

1 lb=4,448 N
Power (identified by such terms as crankshaft power, 1 kW=1,34 hp

pto power, belt power, drawbar power, indicating 1 hp=0,746 kW
the point at which the measurement was taken)
kilowatts (kW)
Engine torque newton metres (Nm) 1 Nm=0,74 ft lb

1 ft lb=1,356 Nm
Fuel consumption by weight (kilograms per hr, kg/h) 1 kg/h=2,2 lb/hr

(by volume) litres per hr (l/h) 1 lb=0,454 kg
1 l/h=0,22 gal/hr
1 gal=4,54 l
Fuel economy (specific fuel consumption) 304 g/kWh=0,5 lb/hp hr

grams per kilowatt hr (g/kWh)
Engine displacement litres (l) 1 l=61,02 m cu in

100 cu in=1,639 l
Hydraulic pump 1 MPa=145 psi

pressure ---mecapascal (MPa) 1000 psi=6,9 MPa
delivery ---millimetres per sec (ml/s) 100 ml/s=1,32 gpm
1 gpm=75,77 ml/s
Tyre
pressure ---kilopascal (kPa) 100 kPa=14,5 psi
1 psi=6,9 kPa
Area acres---hectare To convert multiply by

0,404686
Volume bushel---litre To convert multiply by

39,3687
Quantity pound per acre ---kilogram per hectare Multiply by 1,12085
Volume Multiply by
superficial foot---cubic metre 0,002360
12
Model Code Page
1. 5. 1996
12. Maintenance 205 -- 900 120 1
1. 1. 1998
Maintenance 205---900
Note! Detailed maintenance procedures are given in the
--- When changing the oil, bear in mind that the oil can be very
Operator”s Manual. hot when it drains from the tractor. Waste oil and oil filters
should be handled carefully and disposed of properly.
--- After completion of the service work always replace all
safety covers etc.
When servicing:
--- Always stop the engine before doing any servicing work.
--- Apply the parking brake to ensure the tractor cannot move.
Lubrication of points provided with grease
If the ground is uneven the wheels should be scotched nipples
--- Always observe the utmost cleanliness in all maintenance
--- Always clean the grease nipples before applying the
work.
grease gun.
---Thoroughly wipe off filler caps and plugs as well as sur- --- Pump in grease to the nipples until clean grease is
rounding parts of the tractor before filling up with fuel or oil. squeezed out (unless otherwise instructed).
--- Inspect the oil and filters when changing. Large amounts of --- Wipe off all surplus grease which has been squeezed out
dirt (e.g. heavily clogged filters) can point to a fault which at the lubricating points.
could cause extensive and costly repairs if not corrected in --- Preferably carry out lubrication with bearing points and
time. joints unloaded and with the bearings in different position (
e.g. lubricate the steering knuckle bearing on the steering axle
--- When carrying out checks the tractor should stand on level
with the wheels at both full left and right lock and with the front
ground. axle lifted up).
--- Levels should be checked in the morning when the oil is
cold and has had time to run down to the bottom of the unit
concerned. Lubrication and maintenance schedule
All intervals are counted from zero on the hour recorder. For
example, 1000---hour service is carried out every 1000 and
2000 hours according to the hour recorder (yearly or every
other year) even if the operates have been carried out at the
guarantee service.
Example:
The 1000---hour service includes all operates listed under
daily/every 10 hours,weekly/every 50 hours,250, 500 and
1000 hours.
13
Model Code Page
1. 5. 1996
12. Maintenance 205 -- 900 120 2
1. 1. 1998
7 6 12 1 9 10 4
7 6 11 4 2 3 5 4 4
Maintenance daily/weekly Weekly/every 50 hours

4. Lubricate front axle and steering nipples
Daily/every 10 hours 2 ---wheel drive
1. Check engine oil level --- axle mountings (2 nipples)
2. Check coolant level --- steering knuckles (2 nipples)
3. Clean the cyclone cleaner (check oil elevel in filter on --- tie ---rod ends (4 nipples: not on later models)
205). 865, 800 and 900 tractors have not a cyclone but 4 ---wheel drive
an ejector pipe. --- universal joints (ZF: 4 nipples, Sige: 2 nipples)
--- front axle mountings (ZF: 6 nipples, Sige: 4 nipples)
--- steering knuckles (on later models 4 nipples)
5. Lubricate propeller shaft, 4WD (3 nipples). On later models
there are no grease nipples for propeller shaft.
6. Lubricate brake and clutch pedals (2 nipples)
7. Lubricate top link and lifting links (5 nipples)
8. Lubricate extra lifting cylinder nipples (if fitted)
9. Check fluid level in windscreen washer
10. Check fan and alternator belt
11. Check electrolyte level in battery
12. Drain water from fuel filter (20---series engines). 865, 800
and 900 tractors also have a separate water trap.
14
Model Code Page
1. 1. 1998
12. Maintenance 205 -- 900 120 3
1. 6. 1998
35 36 32
39 28 33 21 19 15 41 40 15 37 41 14 25 31
29 26
30 23
39 19 17 16 20 13 43 33 42 37 25 24
27 32
3055--- 69
Every 250 hours Every 1000 hours/yearly

13. Clean heating system air filter. 600---900: Clean air filter of 29. Change oil in hydraulic system
roof fan. 30. Change oil in power transmission
14. Clean air filter (change if necessary) (on 255 change oil in 31. Change oil in differential, 4---wheel drive
filter) 32. Change oil in hub reduction gears, 4---wheel drive
15. Change engine oil and oil filter 33. Clean hydraulic pump suction strainer
16. Change hydraulic system pressure filter. First change at 34. Drain fuel tank
100 hours Service inspection. The second change at 250 35. Change fuel filter. 865, 800 and 900 with Stanadyne water
running hours and the third at 500 hours. After that at inter- trap: also change the water trap filter.
vals of 500 running hours. 36. Change safety filter in air cleaner (om 255, clean the filter)
17.Lubricate gear lever joints 37. Check, adjust and lubricate front wheel bearings,
18.Check tyre pressures and wheel nuts 2---wheel drive
38. Check and adjust front wheel toe ---in
Every 500 hours 39. Lubricate drive axle bearings (2 nipples)
19. Clean separate water trap on 865 (not 865, 800 and 900, if 40. Adjust valves
a Stanadyne water trap has been fitted). 40a. 600---900: Change air filter of roof fan.
20. Check brake pedal free travel 40b. 600---900: Change breather filter (in filling cap)
21.Check propulsion clutch pedal free travel
22. Check PTO lever free travel Every 2000 hours/every other year
23. Check oil level in power transmission 41. Clean cooling system
24. Check oil level in differential, 4---wheel drive 42. Check alternator
25.Check oil level in hub reduction gears, 4---wheel drive 43. Check starter motor
26. Check oil level in hydraulic system 44. Check and clean injectors
27.Change pressure filter in hydraulic system
28. Change oil filter in transmission Every 4000 hours (not 205, 355, 365 and 665)
45. Turbo unit checked at authorized workshop
15
Model Code Page
15. 4. 1999
12. Maintenance 205 -- 900 120 4
1. 9. 2001
Recommended fuel and lubricants

(All volumes are incl. of filters)
Part of machine SAE class API grade Volume (litres)

Engine
--- 205, 255, 355, 365, 600 15W/40 (+40... ---10˚C) CE 7
--- 305, 405, 455, 465, 700, 555, 565 10W/30 (+30... ---20˚C) CF/CF ---4 7
--- 665, 800, 865, 900 9
Working hydraulics HT60: ---30˚C...+30˚

HT100: ---10C...+40C ISO VG 32 35 (upper mark)
32: ---30 ˚C...+30˚C ISO VG 46 25 (lower mark)
46: ---10˚C...+40˚C
Power transmission HT60: ---30˚C...+30˚ GL ---4 23 (865, 600---900: 27)
HT100: ---10C...+40C (G2---98)
Powered front axle ZF:
--- differential 4,5
--- hubs 2x0,5
Powered front axle Sige (Dana): 80W/90 GL ---5 (LS)
--- differential 6,5
--- hubs 2x0,8
Fuel tank
--- 205---865 Diesel fuel 73
--- 600---900 79 (extra tank 103)
Cooling system without expansion tank: Anti ---feeze agent+water (stan-
--- 205---565, 600, 700 dard ASTM D3306---86a or BS 10 (600, 700: 11,5)
--- 665, 865, 800, 900 6580:1985) 11,5 (800, 900: 13,5)
Cooling system with expansion tank:

600---700 13,5
800---900 15.5
Windscreen washer Washer fluid 1,5
Front PTO See code 460.
Note! The following Valtra oils are recommended:

Valtra Engine in engine
Valtra transmission in Power Transmission
Valtra Hydraulic in hydraulic system
Valtra Axle in Powered front axles.
Note! Recommended oil in front PTO, see code 460.
415M -- tractor
Oil specification in torque converter/reverse shuttle:

--- automatic transmission fluid (ATF), which meets requirements: Dexron, type A Suffix A
Oil volume:
--- total volume 8,3 litres
--- change volume 6 litres
Other maintenance instructions and filling quantities are the same as on 405 tractor.
16
20. Engine 21. Engine
(309--- and 311---engines)
22. Fuel system

(309--- and 311---engines)
23. Cooling system

(309--- and 311---engines)
21A. Engine
(320,420---engines)
22A. Fuel system

(320,420---engines)
23A. Cooling system

(320,420---engines)
17
18
Model Code Page
21. Engine 205-- 555 210 1
1. 12. 1986
Contents
General (Op. no. 210):
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine, description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Repair instructions
Cylinder block and flywheel housing (Op. no. 211):
1. Cylinder block and cylinder liners:

A. Measuring cylinder liner wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Removing cylinder liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Checking cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
D. Changing camshaft bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
E. Oversize bushings for camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
F. Fitting plug at rear end of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
G. Fitting pipe for oil dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
H. Fitting cylinder liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2. Flywheel housing:
A. Fitting flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
B. Changing crankshaft rear oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cylinder head and valve mechanism (Op. no. 212):
1. Cylinder head:
A. Removing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Removing valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Checking cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
D. Changing valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
E. Changing copper sleeve for injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
F. Machining valve seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
G. Grinding valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
H. Fitting valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
I. Fitting cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.Valve mechanism:
A. Reconditioning rocker arm mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
B. Changing camshaft/camshaft gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
C. Adjusting valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Crank mechanism (Op. no. 213):
1. Crankshaft:
A. Removing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Checking crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Changing crankshaft gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
D. Fitting crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. Connecting rods and pistons:

A. Removing piston together with connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
B. Changing connecting rod bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
C. Checking connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
19
Modell Code Page
1. 7. 1989
21. Engine 205 -- 555 210 2
10. 1. 1992
Engine timing gears (Op. no. 214)

1. Timing gear casing:
A. Removing timing gear casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Fitting timing gear casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Changing crankshaft front oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Lubrication system and oil sump (Op. no. 215)

1. Lubrication system:
A. Reconditioning lubricating oil pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Removing and dismantling lubricating oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C. Assembling and fitting lubricating oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
D. Changing lubricating oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
E. Lubricating oil quality requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inlet and exhaust systems, turbocharger (Op. no. 216)

1. Inlet and exhaust systems:
A. Checking air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Checking inlet and exhaust systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Turbocharger:
A. Checking turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Removing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
C. Reconditioning turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
D. Fitting turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removing and fitting engine (Op. no. 219)

1. Removing and fitting engine by parting tractor:
A. Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
B. Fitting engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. Removing and fitting engine without parting tractor:

A. Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
B. Fitting engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Technical data
Tractor 205 305 355 405 455 555
Designation D27D2 TD27DS3 TD33D TD27DS4 TD33DS4 TD33DS 555
Turbocharger no yes no yes yes yes
No of cylinders 3 3 3 3 3 3
Displ. dm3 2,7 2,7 3,3 2,7 3,3 3,3
Stroke mm 114 114 120 114 120 120
Cyl. bore mm 100 100 108 100 108 108
Compr. ratio 18:1 18:1 17:1 18:1 16:1 16:1
Output kW DIN 36/2350 39/2350 44,5/2350 45/2350 49/2350 53/2350
Torque Nm/rpm 175/1450 195/1400 220/1400 220/1450 240/1450 260/1450
Idling speed rpm 650 650 750 650 750 750
Valve clear. mm 0,30 0,30 0,30 0,30 0,30 0,30
Compr. press. bar24 1) 24 1) 24 1) 24 1) 24 1) 24 1)
1) Minimum value at starter motor speed (warm engine). The greatest allowable difference between cylinders is 0,3 bar.
Note!
From tractor no 656316 tractors 355, 455 and 555 have new 20---series engines. See sections 21A, 22A
and 23 A.
20
Model Code Page
1. 7. 1989
21. Engine 205 -- 555 210 3
10. 1. 1992
Valves, rocker arms and tappets (205---555)

Valve timing
At a valve clearance of 0,30 mm:
--- inlet valve opens at . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10˚ B.T.D.C.
--- inlet valve closes at . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42˚ A.B.D.C.
--- exhaust valve opens at . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42˚ B.B.D.C.
--- exhaust valve closes at . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10˚ A.T.D.C.
Valve clearance, cold or warm engine:
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,30 mm
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,30 mm
Seat angle in cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30˚±5’
Seat width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,0---1,5 mm
Valve seat angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29_30’±5’
Valve head diameter:
--- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 mm (45 mm, 355,455, 555)
--- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 mm (40 mm, 355, 455, 555)
Stem diameter, inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.465---9.480 mm
Stem diameter, exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.445---9.460 mm
Clearance, valve stem ---guide, inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.040---0.070 mm
Clearance, valve stem ---guide, exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.060---0.090 mm
Maximum wear limit, inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 mm
Maximum wear limit, exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.35 mm
Valve guide I.D. (before fitting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.520---9.535 mm
Valve guide O.D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.028---16.039 mm
Bore in cylinder head for valve guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.000---16.018 mm
Height of valve guide above cylinder head face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 mm
Distance between cylinder head and valve head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2---1.4 mm
Valve spring, free length:
--- inner spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 mm
--- outer spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 mm
Loading when valve spring is compressed to:
--- inner spring, 41.5 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70---90 N
--- outer spring, 47 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190---210 N
Rocker arm shaft diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.959---19.980 mm
Rocker arm bushing I.D. (bushing fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.990---20.010 mm
Rocker arm bushing O.D. (before fitting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.035---23.048 mm
Rocker arm hole diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.000---23.021 mm
Pushrod length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231 ---1 (238 ---1, 455)
Pushrods must be straight to within . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4 mm
Rocker arm shaft spring, free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 mm
Loading when rocker arm shaft spring is compressedto 58 mm . . . . . . . . . . . . . . . . . . . . . . . . . 80---100 N
Tappet O.D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.939---29.960 mm
Bore in cylinder block for tappet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.000---30.021 mm
Camshaft (205, 305, 405)
Bearing journal no. 1, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49.925---49.950 mm

Bearing journal nos 2---4, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49.885---49.910 mm
Bearing no. 1, bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.040---50.060 mm
Bearings nos 2---4, bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.000---50.025 mm
Radial clearance no. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.090---0.135 mm
Radial clearance nos. 2---4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.090---0.140 mm
Tolerance, 1st bushing in block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.025---0.080 mm
Camshaft end float (with 0.5 mm gasket betweencylinder block and timing gear
casing and betweentiming gear casing and front cover) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.045---1.550 mm
Cam height (distance between cam lobe top and opposite side).41.44 mm
Cam lift (lobe top height above the “circle”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.44 mm
Max. permissible figure for out---of ---roundness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 mm
21
Model Code Page
1. 7. 1989
21. Engine 205 -- 555 210 4
10. 1. 1992
Camshaft (355, 455, 555)

Bearing journal no. 1, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49.905---49.930 mm
Bearing journal nos 2---4, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49.885---49.910 mm
Bearing bores, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.000---50.025 mm
Radial clearance no. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.070---0.120 mm
Radial clearance nos 2---4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.09---0.140 mm
Tolerance, 1st bushing in block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.023---0.072 mm
Camshaft end float (with 0.5 mm gasket between cylinderblock and timing gear
casing and between timing gearcasing and front cover) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.450---1.550 mm
Cam height (distance between cam lobe top and opposite side) . . . . . . . . . . . . . . . . . . . . . . . . 41.44 mm
Cam lift (lobe top height above the “circle”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.44 mm
Max. permissible figure for out---of ---roundness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 mm
Cylinder liners (205, 305, 405)

Height above block face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.030---0.080 mm
Max. height difference between cylinder liners under thesame cylinder head . . . . . . . . . . . . . . 0.020 mm
Cylinder liner I.D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100.015---100.037 mm
Liner flange height, standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.03---8.05 mm
Liner flange height, 1st oversize, part no 8365 36828 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.08---8.10 mm
Liner flange height, 2nd oversize, part no 8365 36829 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.13---8.15 mm
Liner flange height, 3rd oversize, part no 8365 36830 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.23---8.25 mm
Cylinder liner flange, outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121.90---122.00 mm
Cylinder liners (355, 455, 555)

Height above block face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.030---0.080 mm
Max. height difference between cylinder liners under thesame cylinder head . . . . . . . . . . . . . . 0.020 mm
Cylinder liner I.D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108.000---108.022 mm
Liner flange height, standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.03---9.05 mm
Liner flange height, 1st oversize, part no 8353 29829 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.08---9.10 mm
Liner flange height, 2nd oversize, part no 8353 29830 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13---9.15 mm
Liner flange height, 3rd oversize, part no 8353 29831 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23---9.25 mm
Cylinder liner flange, outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131.700---131.800 mm
Piston, piston rings and piston pin (205, 305, 405)
Minimum distance between piston and cylinder head, measured with a piece of lead
wire through the injector location hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.900---1.150 mm
Piston diameter: --- 26 mm from lower edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99.873---99.887 mm
Piston pin hole, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36.003---36.009 mm
Piston pin diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.995---36.000 mm
Ring groove width:
--- groove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.580---2.600 mm
--- groove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.040---3.060 mm
--- groove 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.040---4.060 mm
Piston ring clearances in grooves:
--- upper compression ring, hard chromed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.09---0.122 mm
--- 2nd compression ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05---0.082 mm
--- oil control ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05---0.082 mm
--- maximum wear limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm
Piston ring widths:
--- ring 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.478---2.490 mm
--- ring 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.978---2.990 mm
--- ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.978---3.990 mm
Piston ring gap:
--- compression rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4---0.6 mm
Max permissible weight difference between pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 g
Heat piston to 100_C before fitting piston pin.
22
Model Code Page
1. 7. 1989
21. Engine 205 -- 555 210 5
10. 1. 1992
Piston, piston rings and piston pin (355, 455, 555)

Piston diameter:
--- 19 mm from lower edge (CS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107.853---107.867 mm
--- 75 mm from lower edge (CS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107.742---107.757 mm
--- 93.5 mm from lower edge (CS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107.580---107.600 mm
--- 108.5 mm from lower edge (CS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107.510---107.530 mm
Piston pin hole, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.000---40.006 mm
Piston pin, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.995---40.000 mm
Ring groove widths:
--- groove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.560---2.580 mm
--- groove 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.030---3.050 mm
--- groove 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.040---5.060 mm
Piston ring clearance in grooves:
--- upper compression ring, hard chromed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.07---0.102 mm
Piston ring width:
--- ring 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.478---2.490 mm
--- ring 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.978---2.990 mm
--- ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.978---4.990 mm
Piston ring gap, new ring kit no. 8363 39201:
--- upper compression ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3---0.55 mm
--- oil control ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3---0.6
--- maximum wear limit, ring 1 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 mm
--- maximum wear limit, ring 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 mm
Max. permissible weight difference between pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 g
Heat piston to 100_C before fitting piston pin.The combustion chamber should be turned towards the injectors.
Connecting rod (205, 305, 405)
Connecting rod bushing I.D. (fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36.025---36.040 mm

Connecting rod bushing O.D. (standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.060---40.076 mm
Connecting rod bushing, (oversize 8360 38605) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.580---40.620 mm
Interference fit: connecting rod bushing/connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.035---0.120 mm
Connecting rod bushing location, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.000---40.025 mm
Connecting rod bushing location, diameter (oversize) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.500---40.525 mm
Big end bearing location, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65.730---65.749 mm
Connecting rod (355, 455, 555)
Connecting rod bushing I.D. (fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.025---40.040 mm

Connecting rod bushing O.D. (standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.082---44.120 mm
Connecting rod bushing O.D. (oversize 8353 28326) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.580---44.620 mm
Interference fit: connecting rod/connecting rod bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.057---0.120 mm
Connecting rod bushing location, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.000---44.025 mm
Big end bearing location, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71.730---71.749 mm
Connecting rod end ---float on crank shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.200---0.312 mm
Weight marking (letter) at lower end.
Max. permissible weight difference between connectingrods in the same engine . . . . . . . . . . 20 g
23
Model Code Page
1. 7. 1989
21. Engine 205 -- 555 210 6
10. 1. 1992
Crankshaft (205, 305, 405)

Big end journals, diameter:
--- standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61.981---62.000 mm
--- 1st undersize, 0.25 mm (bearing 8360 97266) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61.731---61.750 mm
--- 2nd undersize, 0.50 mm (bearing 8360 97267) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61.481---61.500 mm
--- 3rd underside, 1.00 mm (bearing 8360 97269) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60.981---61.000 mm
--- 4th undersize, 1.50 mm (bearing 8360 97271) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60.481---60.500 mm
Big end journals, length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.000---40.160 mm
Big end bearing clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.046---0.098 mm
Main bearing journals, diameter:
--- standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69.988---70.018 mm
--- 1st undersize, 0.25 mm (bearing 8360 97273) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69.738---69.768 mm
--- 2nd undersize, 50 mm (bearing 8360 97274) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69.488---69.518 mm
--- 3rd undersize, 1.00 mm (bearing 8360 97276) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.988---69.018 mm
--- 4th undersize, 1.50 mm (bearing 8360 97278) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.488---68.518 mm
Main bearing clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.051---0.101 mm
Width of thrust bearing journal on crankshaft (nearest flywheel):
--- standard (2 std thrust bearings) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.000---47.080 mm
--- 1st undersize (one std and one 0.2 mm oversize thrust washer) . . . . . . . . . . . . . . . . . . . . . . 47.200---47.280 mm
--- 2nd oversize (two 0.2 mm oversize thrust washers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.400---47.480 mm
Other bearing journals must not be ground so as to make them longer.
Crank shaft end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.100---0.320 mm
Big end and main bearing journals, max. permissible figure for
out---of ---roundness or other deformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 mm
Crankshaft balancing accuracy, max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 Ncm Max
Crankshaft (355, 455, 555)

Big end journals, diameter:
--- standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67.981---68.000 mm
--- 1st undersize, 0.25 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67.731---67.750 mm
--- 2nd undersize, 0.50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67.481---67.500 mm
--- 3rd undersize, 1.00 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.981---67.000 mm
--- 4th undersize, 1.50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.481---66.500 mm
Big end journals, length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.000---40.160 mm
Big end bearing clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.046---0.098 mm
Main bearing journals, diameter:
--- standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.985---85.020 mm
--- 1st undersize, 0.25 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.735---84.770 mm
--- 2nd undersize, 0.50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.485---84.520 mm
--- 3rd undersize, 1.00 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83.985---84.020 mm
--- 4th undersize, 1.50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83.485---83.520 mm
Main bearing location (in block), diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91.000---91.022 mm
Main bearing clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.050---0.127 mm
Width of thrust bearing journal on crankshaft (nearest flywheel):
--- standard (2 std thrust bearings) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.000---45.080 mm
--- 1st oversize (one std and one 0.1 mm oversize thrust washer) . . . . . . . . . . . . . . . . . . . . . . . . 45.100---45.180 mm
--- 2nd oversize (one std and one 0.2 mm oversize thrust washer) . . . . . . . . . . . . . . . . . . . . . . . 45.200---45.280 mm
--- 3rd oversize (one 0.1 mm and one 0.2 mm oversize thrust washer . . . . . . . . . . . . . . . . . . . . . 45.300---45.380 mm
--- 4th oversize (two 0.2 mm oversize thrust washers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.400---45.480 mm
Other bearing journals must not be ground so as to make them longer.Crankshaft end float . 0.100---0.350 mm
Big end and main bearing journals, max. permissible figure
for out---of ---roundness or other deformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 mm
Crankshaft balancing accuracy, maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 Ncm Max
Flywheel (205---555)
Flywheel ring gear, number of teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Interference fit: ring gear ---flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.422---0.600 mm
When fitting the ring gear should be heated to . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150---200_C
Flywheel balancing accuracy, maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 Ncm Max
Permissible throw of flywheel friction surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.06:ø200
24
Model Code Page
1. 7. 1989
21. Engine 205 -- 555 210 6.1
10. 1. 1992
Timing gears (205---555)

Tooth backlash:
--- Crankshaft---idler gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05---0.25 mm
--- Idler gear ---camshaft gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05---0.25 mm
--- Idler gear ---fuel injection pump gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05---0.25 mm
All timing gears, max. radial throw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm
Idler gear shaft, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.951---54.970 mm
Idler gear bushing I.D. (fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.000---55.030 mm
Timing gear markings:
When the timing gear markings are opposite each other the piston in the first
cylinder is at T.D.C. between the compression and power stroke.
On the crankshaft gear wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 punch marks on teeth.
On the idler gear:
--- against the crankshaft gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 on a tooth
--- against the camshaft gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 punch mark on a tooth
--- against the fuel injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 punch mark at a tooth gap
On the camshaft gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 punch mark at a tooth gap
On the fuel injection pump gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 punch mark on a tooth
Crankshaft must be rotated 6 turns before all gear markings fall into line again.
Lubrication (205---555)
Lubricating oil pressure at working temperature:
--- at low idling speed, minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 kPa (1.5 kp/cm@)
--- at rated speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300---500 kPa (3---5 kp/cm@)
Spring for oil relief valve, free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 mm
Spring for oil relief valve, loading when 52 mm long . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54+5 N (5.4+0.5 kp)
Oil relief valve, diameter of valve cone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.602---19.635 mm
Oil relief valve, diameter of hole in insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.700---19.752 mm
Oil filter by ---pass valve opens at a pressure difference of. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.5 bar
Lubrication oil pump (205---555)
Tooth backlash when crankshaft is resting on the main bearings:

--- crankshaft gear ---lubricating oil pump gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05---0.25 mm
--- between the pump gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.16---0.26 mm
Drive shaft clearance in housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.016---0.052 mm
Holes in body and cover, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.000---18.018 mm
Gear wheel I.D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.060---18.078 mm
Gear clearance on fixed drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.021---0.050 mm
Clearance of fixed shaft end ---face of body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5---1.0 mm
Gasket thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.06---0.08 mm
Pump gear O.D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43.486---43.525 mm
Gear clearance in body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.125---0.264 mm
Gear location in body, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43.650---43.750 mm
Width of gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.000---18.027 mm
Gear wheel end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03---0.11 mm
Oil pump body, depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.000---18.043 mm
Number of teeth on gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
25
Model Code Page
1. 7. 1989
21. Engine 205 -- 555 210 6.2
10. 1. 1992
Coolant pump (205---555)

Bearings O.D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.087---38.100 mm
Bearing location, diameter (in pump body) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.058---38.083 mm
Shaft diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.907---15.920 mm
Impeller hole diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.881---15.899 mm
Seal location, diameter (in pump body) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36.450---36.489 mm
The impeller should be mounted on the shaft so thatthe distance between
the rear face of the impeller and therear face of the pump body is . . . . . . . . . . . . . . . . . . . . . . . 1---1.7 mm
The hub should be mounted on the shaft so that the distance
between the contact face for the fan and the rear face of the pump body is . . . . . . . . . . . . . . . 157 mm
Fan guide (shoulder) on hub, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.00---25.20 mm
Fan, max. balancing accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3 Ncm max
Fan, max. throw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3 mm
At correct belt tension it should be possible to deflect the belts . . . . . . . . . . . . . . . . . . . . . . . . . . 15---20 mm
Thermostat (205---555)
Spare part number Diam./Type Opening Fully Max. stroke

commences open mm
8360 15156 ø54/79˚ C 80˚ ---3˚C 94˚ C 7,5
8360 15486 ø54/83˚ C 83˚ ---3˚ C 95˚ C 7,5
Cylinder block (205, 305, 405)
Holes for guide pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.000---13.043 mm

Main bearing location, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76.000---76.019 mm
Cylinder liner location, diameter:
--- at upper end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116.012---116.047 mm
--- at lower end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115.000---115.035 mm
Camshaft bearing bushing, I.D. when fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.040---50.060 mm
Cylinder block (355, 455, 555)
Holes for guide pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.000---13.043 mm

Main bearing location, diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91.000---91.022 mm
Cylinder liner location, diameter:
--- at upper end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123.514---123.554 mm
--- at lower end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122.000---122.040 mm
Camshaft bearing bushing, I.D. when fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.000---50.025 mm
Cylinder head (205---555)
Seat for copper sleeve, diameter:

--- upper end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.000---28.033 mm
--- lower end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.000---27.033 mm
Copper sleeve O.D.:
--- upper end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.979---28.000 mm
--- lower end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.073---27.090 mm
Cylinder head thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104.90---105.10 mm
Cylinder head minimum thickness after machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104.70 mm
Cylinder head bolts, tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Nm
26
Model Code Page
1. 7. 1989
21. Engine 205 -- 555 210 7
10. 1. 1992
Turbocharger Holset H1D (not 205 and 355)

Oil pressure at rated engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . min. 2 bar
Shaft end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10---0.16
Shaft running clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30---0.46
Turbine housing mounting bolts (M8x12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3 Nm
Compressor housing mounting bolts (M6x12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7 Nm
Bearing housing mounting bolts (M6x16) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7 Nm
Nut at end of shaft (LH thread on shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.0 Nm
Turbocharger Schwitzer S2A (not 205 and 355)
Oil pressure at rated engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . min. 2 bar

Shaft end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05---0.12 mm
Shaft running clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max 1.0 mm (dry)
Nut at end of shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 Nm
V ---band nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0 Nm
Partial vacuum and counter pressure

Partial vacuum at air cleaner, maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 kPa (500 mm, water gauge)
Counter pressure at exhaust pipe, maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 kPa (600 mm, water gauge)
Tightening torques
Engine fixing bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm (8 kpm)
Exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm (6 kpm)
Exhaust pipe ---turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm (2.3 kpm)
Big end bearing cap bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Nm (9 kpm)
Main bearing cap bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Nm (16 kpm)
Crankshaft nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600 Nm (60 kpm)
Flywheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Nm (12 kpm)
Idler gear bolts:
---M 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm (6 kpm)
---M 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Nm (14 kpm)
Cylinder head bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Nm (16 kpm)
Flywheel housing bolts:
--- outer ring, M12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Nm (11 kpm)
--- inner ring, M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Nm (6 kpm)
Special tools
21. Engine A
Part number Description

1. 8360 97532 Lever for compressing valve spring (505---905)
2. 8360 97336 Counterhold nut for above (505---905)
3. 8361 97470 Milling tool for injector seat (505---905)
4. 8360 97463 Drift for fitting injector sleeve (505---905)
5. 8360 86085 Extractor for injector sleeve (505---905)
6. 8360 97315 Drift for fitting crankshaft rear seal (505---905)
7. 9030 15200 Drift for fitting crankshaft front seal (505---905)
8. 8360 85499 Puller for coolant pump impeller (505---905)
9. 8360 13091 Puller for coolant pump hub (505---905)
10. 9025 58000 Cylinder head spanner (505---905): earlier number 8360 97328
21. Engine B
Part number Description

11. 8360 97337 Drift for removing valve guide (505---905)
12. 8360 97457 Drift for fitting valve guide (505---905)
13. 8360 97434 T ---handle for valve seat milling cutter (505---905)
27
Model Code Page
1. 7. 1989
21. Engine 205 -- 555 210 8
10. 1. 1992
14. 8360 97435 Milling cutter for facing exhaust and inlet valve seat(505---905)
15. 8360 97436 Milling cutter for exhaust and inlet valve seat (505---905)
16. 8360 97437 Inner milling cutter for exhaust and inlet valve seat (505---905)
17. 8361 97468 Drift for fitting 16 mm cap plug (505---905)
18. 7314 03506 Drift for fitting 36 mm cap plug (505---905)
19. 8360 97327 Puller for crankshaft gear (505---905)
20. 9025 79200 Holder for dial gauge (505---905)
21. 9025 78100 Press tool for cylinder liner (505---905)
22. 9025 98900 Drift for fitting dust cover, crankshaft front seal (505---905)
23. 9051 40200 Drift for fitting coolant pump seal (505---905)
24. 9025 98800 Drift for fitting tubular pin in timing gear casing (505---905)
25. 9025 98700 Drift for fitting tubular pin in timing gear casing (505---905)
26. 9051 73100* Puller for cylinder liner
26A. 8365 39293 Puller flange, 205, 305, 405
26B. 8353 39292 Puller flange, 355, 455, 555
27. 9051 72900* Milling cutter for fitting cylinder liner, 205, 305, 405
27A. 9051 72800 Milling cutter for fitting cylinder liner, 355, 455, 555
28. 9051 71300* Puller for injector
Locally prepared tools

29. 9051 64900 Drift for fitting coolant pump shaft (505---905)
30. ET(893 760) Support between front end and front axle to prevent oscillation
3 4 5
7
6
8
10
28
Model Code Page
21. Engine 205 -- 555 210 9
1. 12. 1986
13 19
14
15
12
11
16
17 18
21
20
22
23
26
25
24
27
26A
28
29
Model Code Page
21. Engine 205 -- 555 210 10
1. 12. 1986
29
30
30
Model Code Page
21. Engine 205 -- 555 210 11
1. 12. 1986
Engine, description
The engine on tractors 305---555 is a liquid ---cooled, four ---
stroke, turbocharged, direct---injection diesel engine. The
peripherals of the engine are shown in Figs. 210 1 and 210---2.
309 left side

1. Turbocharger
2. Injector
3. Fuel filter
4. Water trap
5. Oil pressure gauge sender
6. Oil dipstick
7. Oil filter
8. Oil pressure relief valve
9. Engine heater
10. Timing indicator
11. Fuel feed pump
12. Fuel injection pump
13. Oil filler
14. Thermostat housing
15. Serial number
31
Model Code Page
21. Engine 205 -- 555 210 12
1. 12. 1986
309 right side

1. Thermostart device fuel reservoir
2. Thermostart glow plug
3. Breather hose
4. Temperature gauge sender unit
5. Coolant pump
6. Timing gear casing cover
7. Alternator
8. Starter motor
32
Model Code Page
21. Engine 205 -- 555 210 13
1. 12. 1986
Longitudinal section of engine 309
33
Model Code Page
21. Engine 205 -- 555 210 14
1. 12. 1986
Cylinder block
Figure 210 4
1. Cylinder block
2. Cylinder liner
3. O ---ring
4. Bearing sleeve
5. Bearing cap
6. Bearing cap with thrust bearing
7. Guide sleeve
8. Bolt
9. Plug
10. Threaded plug
11. Guide pin
12. Threaded connection
13. Cylinder head bolt
14. Plug (camshaft end)
15. Pressure sender unit
16. Sealing ring
17. Plug
18. Pipe for oil dipstick
The cylinder block is the main body of the engine, to which

other engine parts are attached. The cylinder liners are so
called wet liners, which means that the coolant is in direct con- The camshaft is located in the cylinder block. The camshaft
tact with the outer surface of the liners. The seal between the front bearing location is provided with a separate bearing
cylinder liner lower part and the cylinder block is achieved by sleeve (4). The remaining bearing locations are machined
two O ---rings (3), which are fitted in grooves in the liner. The directly in the cylinder block. The drilling for the camshaft rear
upper part is sealed by the cylinder head gasket. The distance end is covered with a plug.
between the cylinder liner flange and the face of the cylinder
block plays a major role in sealing the upper part. Bear this in There is space on both sides of the rear main bearing for guide
mind when fitting the cylinder liner. bearing shims (the camshaft thrust bearing).
Flywheel housing
Figure 210 5
1. Flywheel housing
2. Bolt M12x35
3. Socket head bolt M10x30
4. Crankshaft oil seal
5. Rubber plug
6. Tubular pin
7. Screw stud 10x25
8. Washer
9. Nut M10
The flywheel housing is fitted to the rear end of the cylinder

block. The starter motor and the crankshaft rear oil seal are
also fitted in the flywheel housing. There is also a hole in the
flywheel housing for inserting a tool in order to crank the
engine. The return oil flow from the engine lubricating system
is channelled through the flywheel housing. The lower face of the flywheel housing fits up against the oil
sump and its front face against the cylinder block. This has to
be taken into account when fitting the flywheel housing, which
is guided partly by the guide pin (6).
34
Model Code Page
21. Engine 205 -- 555 210 15
1. 12. 1986
Cylinder head
Figure 210 6
1. Cylinder head
2. O ---ring
3. Sleeve for injector
4. Plug
5. Valve guide
6. Plug
7. Valve cover
8. Gasket
9. Nut
10. Washer
11. Rubber seal
12. Breather hose
13. Lifting bracket
14. Screw stud
15. Sealing ring
16. Hose coupling
17. Bolt
18. Cylinder head gasket
The cylinder head is made of cast iron, and each cylinder has
its own inlet port and common exhaust port. The stiffness and The inlet and exhaust valve guides (1) are identical and can
even spread of attaching bolts give a good seal for the cylin- be interchanged. The injectors are surrounded by replace-
der head gasket. The directed flow of the coolant ensures that able copper sleeves (2) which are in contact with the coolant,
the valve seats are effectively. thus the injectors are effectively cooled.
Cross---section of cylinder head
1. Valve guide
2. Injector sleeve
3. O ---ring seals
35
Model Code Page
21. Engine 205 -- 555 210 16
1. 12. 1986
Valve mechanism
1. Circlip
2. Shim
3. Nut
4. Rocker arm
5. Bearing sleeve
6. Adjusting screw
7. Holder
8. Spring
9. Shaft
10. Plug
11. Pushrod
12. Tappet
13. Valve keepers
14. Spring guide
15. Valve spring
16. Valve spring
17. Spring guide
18. Exhaust valve
19. Inlet valve
20. Gear wheel
21. Key
22. Camshaft
23. Threaded plug
The valve mechanism is operated by the camshaft (22) which

is located in the cylinder block. The drive is transferred with
the help of tappets (12) and pushrods (11). The camshaft gear
wheel (20) is fitted with a press fit and fixed with a key (21).
Each bearings is lubricated by the force feed lubrication sys-
tem through drilled oilways in the camshaft.
Crank mechanism
1. Crankshaft
2. Key
3. Cylindrical pin
4. Main bearing
5. Thrust bearing
6. Flywheel
7. Ring gear
8. Bolt
9. Hub
10. Shaft seal boot
11. Deflector ring
12. Gear wheel
13. Gear wheel
14. V ---belt pulley
15. Nut
16. Socket head bolt M8x16
17. Piston
18. Piston rings
19. Piston pin
20. Retaining ring
21. Connecting rod
22. Bearing bushing
23 Bolt
24. Nut
25. Crankshaft bearing
The crankshaft (1) is forged from chrome alloy special steel shaft has splines for the hub (9) of the V ---belt pulley (14). An
and is induction hardened at the bearing and sealing sur- oil deflector ring (11) is fitted between the hub and the gear
faces. Gear wheels (12 and 13) are located at the front end of wheel, and a dust shield (10) is fitted to the hub in order to seal
the crankshaft. They are fitted with a press fit, and drive the the shaft.
idler wheel and oil pump. In addition, the front end of the
crank ---
36
Model Code Page
21. Engine 205 -- 555 210 17
1. 12. 1986
The flywheel (6) is fitted to the rear end of the crankshaft. The
ring gear (7) is fitted to the flywheel with a press fit. The forged
connecting rod has an I ---shaped cross---section. The bear-
ing location at the bottom end of the connecting rod is split,
and the bearing cap is secured by two special bolts (23) and
nuts (24). The upper end of the rod has a fixed bearing loca-
tion, in which the piston pin bearing bushing (22) is fitted with
a press fit.
Piston
1. Combustion chamber
2. Circlip
3. Piston pin
4. Bearing bushing
5. Connecting rod
6. Chromed compression ring
Bearing shell 7. Compression ring
8. Spring loaded oil control ring chromed slide surfaces
1. Indium ---lead alloy The piston is made of an eutectic aluminium alloy. In the upper
2. Lead ---bronze part of the piston there is a combustion chamber (1). The
3. Steel shell shape of the chamber is intended to maximise the mixture of
air and fuel. The number of piston rings is three, of which the
The crankshaft has four main bearings, one on either side of upper (6) has a barrel face, chromed slide surface. The sec-
each cylinder. The thrust bearing is located on either side of ond compression ring (7) is tapered at an angle of 1,5˚, and
the rear main bearing journal. The main and big ---end bear- the third ring is a spring loaded oil control ring (8). The piston
ings are three ---layer bearings, which have a tough lead pin (3) has a close tolerance in the piston and a floating fit in
bronze alloy, with good heat dissipating properties, inside the the connecting rod.
steel shell. The actual sliding surface is covered by a layer of
indium ---lead, which makes the running ---in period easier.
37
Model Code Page
21. Engine 205 -- 555 210 18
1. 12. 1986
Timing gear casing
1. Timing gear casing

2. Bolt
3. Gasket
4. Screw stud
5. Tubular pin
6. Gasket
7. Front cover
8. Sealing ring
9. Protective ring
10. Nut
11. Gasket
12. Filler pipe
13. O ---ring
14. Cap
15. Washer
16. Spacer ring
17. Bearing housing
18. Gasket
19. Bearing
20. Circlip
21. Shaft
22. Plug
23. Sealing washer
24. Timing indicator
25. Attaching plate
26. Rubber plug
The timing gear train consists of hardened, helically cut gear timing gear casing. Sealing ring (8) is fitted to the front end of
wheels. The gears are encased by the timing gear casing (1) the crankshaft and the protective ring (9) is positioned inside
which is fitted to the front of the engine. The fuel injection the location in the front cover. The timing gears drive the cam-
pump, alternator and hydraulic pump with its drive are fitted shaft, fuel injection pump and oil pump.
to the timing gear casing. The front cover (7) is fitted to the
Idler gear with securing parts
1. Bolt M10x55
2. Bolt M14x65
3. Locking flange
4. Bearing bushing
5. Gear wheel
6. Shaft stud
The bearing for the idler gear (5) is a sliding bearing (4) and
is located on the axle (6). It is fitted to the cylinder block with
two bolts (1 and 2). The crankshaft and camshaft gears are
fitted to the shafts with a press fit and key. The fuel injection
pump gear is fitted on the pump shaft, which is tapered, with
a nut and key. In order to ensure the correct timing of the
gears, there are punch marks on each gear.
38
This as a preview PDF file from best-manuals.com
Download full PDF manual at best-manuals.com

VALTRA 39200212 Preview

Uploaded by

Copyright:

Available Formats

VALTRA 39200212 Preview

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

VALTRA 39200212 Preview

Uploaded by

Copyright:

Available Formats

10 General

205, 255, 305

455, 465, 555

600, 700, 800

A75, A85, A95

Find manuals at https://best-manuals.com

Detailed maintenance instructions can be found in Operator’s Manual.

Ordering number Date Content

Ordering number Date Content

Layout of Service Manual

Example. 10. General

2. Division into components or sub ---groups

Example. 41. Clutch

Example: Code 410

8. 11. 1990 Model Code Page

7. Additions and amendments of the service manual

Code designations in the Service Manual

10. General 61. Steering system

21. Engine 62. Non ---powered front axle

43. Torque converter and shuttle on 415 M

44. Low gear

46. Power take off

General instructions for repairs

Outer oil seals

Sealing compound and glue

Tightening torques and setting values

a) Determine the problem

b) List possible causes

c) Differentiate the causes

d) Conduct checks in logical order to determine the exact cause

f) Make any necessary repairs.

g) Recheck the parts and functions for correct operation

Table 1. Tightening torques, metric standard thread (ISO)

Tightening torques Nm1)

Conversion table for common units

Short distances e.g. turning circles metres (m) 1 m=3,28 ft

Travel distances kilometres 1 km=0,62 mile

Tractor weights, axle loadings kilograms (kg) 1 kg=2,2 lbs

Travel speed kilometres per h (km/h) 1 km/h=0,62 mph

Drawbar pull kilonewtons (kN) 1 kN=224,8 lbs

Power (identified by such terms as crankshaft power, 1 kW=1,34 hp

Engine torque newton metres (Nm) 1 Nm=0,74 ft lb

Fuel consumption by weight (kilograms per hr, kg/h) 1 kg/h=2,2 lb/hr

Fuel economy (specific fuel consumption) 304 g/kWh=0,5 lb/hp hr

Engine displacement litres (l) 1 l=61,02 m cu in

Hydraulic pump 1 MPa=145 psi

Area acres---hectare To convert multiply by

Volume bushel---litre To convert multiply by

Quantity pound per acre ---kilogram per hectare Multiply by 1,12085

Maintenance daily/weekly Weekly/every 50 hours

Every 250 hours Every 1000 hours/yearly

Recommended fuel and lubricants

Part of machine SAE class API grade Volume (litres)

Working hydraulics HT60: ---30˚C...+30˚

Cooling system with expansion tank:

Note! The following Valtra oils are recommended:

Note! Recommended oil in front PTO, see code 460.

Oil specification in torque converter/reverse shuttle:

22. Fuel system