Identification and Specifications
General Specifications
Item Specification
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Engine Type Peugeot XUD9AI,
4 cycle, water cooled, 4 cylinder, vertical in-line cylinders,
single overhead cam, indirect injection, naturally aspirated.
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Compression ratio 23.5 : 1
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Governor: Mechanical centrifugal type integral with fuel injection pump.
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Governor Adjustment 3000 ± 50 RPM no load
1600 +100/–0 RPM idle speed
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Engine
Engine Rotation Counterclockwise when facing flywheel.
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Crankshaft Forged steel, induction hardened bearing surfaces,
5 main bearing supports.
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Cylinder Block Cast iron with integral cylinder liners.
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Cylinder Head Cast aluminum material with single overhead camshaft.
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Timing Drive The camshaft, water pump and fuel injection pump are
driven from the front end of the crankshaft through belt drive.
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Piston and Piston Rings Pistons are aluminum alloy castings with free-floating wrist pin.
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Lubrication Full pressure feed by gear type pump.
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Oil Filter Full flow, cartridge type, paper element with bypass.
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Oil Capacity 5 liters (5.3 qt.), including oil filter.
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Lubricating Oil API class CD
SAE 15W-40
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Oil Pressure 0.5 Bar (7 PSI) minimum
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Fuel Requirements No. 2 diesel fuel (ASTM No. 2-D).
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Fuel Filter Replaceable paper element.
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Crankcase Ventilation Connected to intake manifold with PCV valve.
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Cooling System Water is circulated through the cylinder block and head by a
centrifugal water pump mounted at the front of the cylinder block.
The water pump operates at 1.05 times engine speed.
Water flow is 92 liters/min. at 2500 engine RPM.
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Firing Order (NO. 1 CYL. IS ON FLYWHEEL END) 1-3-4-2
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Electrical System 12 volt, negative ground, 55 AMP alternator with integral regulator.
12 volt - 1.4 Kw starter motor with integral solenoid, pinion shaft type.
Groundsmaster 455-D Page 3 - 3 Rev. B Engine
Cylinder Head
Cylinder head height h is measured with the camshaft
in place fitted with two bearing caps.
h is measured on the oil seal lip contact diameter (the
largest diameter).
h nominal: 157.40 to 157.75 mm
Maximum permissible bow on bottom of cylinder head:
0.07 mm (camshaft must turn freely).
Maximum permissible gasket face machining: 1.4 mm in rela-
tion to the measured h nominal.
Cylinder heads machined undersize are stamped R in
the area (a):
Figure 2
After machining gasket face, the following operations
must be done:
1. Valve seat machining to re-establish correct
recess (see Valve Recess in this section).
2. Replacement of swirl chambers by repair dimen-
sion and correction of their protrusion (see Swirl
Chambers in this section).
3. Fitting of 0.4 mm thick compensation washers
under the valve springs (to match cylinder head
machining.
Cylinder heads manufactured with oversize camshaft
bearings (+0.5) are stamped 1 in the area (a)
Cylinder Head Gasket
Thickness identification:
Units: mm
Identification (c) Identification (b) Thickness
No notch 2 notches 1.48
3 notches 1.52
4 notches 1.58
5 notches 1.62
Figure 3
Engine Page 3 - 4 Rev. B Groundsmaster 455-D
Camshaft
Camshafts with 0.5 mm oversize bearings* are iden-
tified by a yellow paint ring (d) between the cams of
No. 1 cylinder.
* NOTE: These camshafts are installed only on ex-
change engines, and can be obtained on special order.
Figure 4
Engine
Valves Units: mm
Intake Exhaust
Min. Length l 112.2
+0
øa – 0.015 8.005 7.985
øb ± 0.1 38.5 33
a 90° 90°
Intake: Faces x and y can machined a maximum of 0.2 mm
Exhaust: No machining is permissible.
Figure 5
Valve Recess Units: mm
Intake Exhaust
c 0.5 to 1.05 0.9 to 1.45
Figure 6
Groundsmaster 455-D Page 3 - 5 Rev. B Engine
Valve Springs Units: mm
Spring
ød 29
P1: daN 18
e1 42.4
Figure 7
Valve Guides Units: mm
øf øg h j øk
Tolerance 0 + 0.032 ± 0.25 ± 0.50 0
– 0.011 0 + 0.2
Production 14.02 13.981
14.13 14.051
Repair 1 14.29 14.211 52.00 36.50 8.02
Repair 2 14.59 14.511
øk is obtained by machining after fitting in the cylinder head
Figure 8
Engine Page 3 - 6 Rev. B Groundsmaster 455-D
Valve Seats Units: mm
Intake
øa øb c d
Tolerance 0 ± 0.025 0 ± 0.15
– 0.025 – 0.1
Production 40.161 40 6.25 8.267
40.361 40.2 6.45 8.467
Repair 1 40.461 40.3 6.45 8.467
Repair 2 40.661 40.5 6.45 8.467
Units: mm
Engine
Exhaust
øa øb c d
Tolerance 0 ± 0.025 0 ± 0.15
– 0.025 – 0.1
Production 34.137 34 6.05 8.15
34.337 34.2 6.25 8.35
Repair 1 34.437 34.3 6.25 8.35
Repair 2 34.637 34.5 6.25 8.35
After fitting valve seats into the cylinder head, machine them
according to drawings (Fig. 9).
Figure 9
Swirl Chambers Units: mm
øe øf g h
Tolerance + 0.099 + 0.039 + 0.020 + 0.02
– 0.060 +0 – 0.025 – 0.04
Production 32.05 32 4 3.9
32.25 32.2 4.1 4
Repair 1 32.45 32.4 4.2 4.1
Repair 2 32.65 32.6 4.3 4.2
The protrusion j must be between 0 and 0.03 mm
Dimension j is obtained by machining faces (x) and (y)
Figure 10
Groundsmaster 455-D Page 3 - 7 Rev. B Engine
Cylinder / Piston Matching Units: mm
Identification CYLINDER øa PISTON øb
(x) Tolerance: Tolerance:
+ 0.018 ± 0.009
– 0
Production None 83 82.93
A1 83.03 82.96
Repair 1 R1 83.20 83.13
Repair 2 R2 83.50 83.43
Repair 3 R3 83.80 83.73
NOTE: The piston øb must be measured at dimension c.
C 25.00
NOTE: The repair dimension (x) is stamped on the cylinder block
and pistons.
Figure 11
Piston Pin Units: mm
ø external 24.994 to 25
ø internal 13.8 to 14.1
Engine Page 3 - 8 Rev. B Groundsmaster 455-D
Crankshaft Units: mm
Crank Pins and Journals
øa b øc d
Tolerance –0 ± 0.003 –0 ± 0.003
– 0.016 – 0.019
Production 50.00 1.827 60.00 1.842
Repair 1 49.70 1.977 59.70 1.992
NOTE: Repair 1 size connecting rod and main bearing shells can
be identified by white paint (1) on the edge of the shell.
Units: mm
Engine
End Float
No. 2 Journal Half Shell Thickness
e f
Tolerance + 0.05 ± 0.025
0
Production 26.60 2.305
Repair 1 26.80 2.405
Repair 2 26.90 2.455
Repair 3 27.00 2.505
Units: mm
Oil Seal Contact Surface Figure 13
øg
Tolerance –0
– 0.087
Production 90.00
Repair 1 89.80
Groundsmaster 455-D Page 3 - 9 Rev. B Engine
Tightening Torques
Part Nm Kgm ft-lb
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Connecting rod end caps 50 5 37
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Camshaft bearing caps 17.5 1.8 13
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Camshaft gear 40 4 30
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Coolant pump 15 1.5 11
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* Crankshaft pulley 40 + 60° 4 + 60° 30 + 60°
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Cylinder head bolts
pre-tightening 30 3 22
* tightening 70 +120° 7 + 120° 52 + 120°
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Cylinder head cover 10 1 7
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Flywheel 50 5 36
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Glow plugs 22 2.2 16
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Injector pump gear 47 4.7 33
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Injector into Cylinder Head 90 9 66
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Main bearing caps 70 7 52
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Oil pump 20 2 15
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Oil seal carrier, timing gear end 15 1.5 11
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Sump to block 20 2 15
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Timing belt tensioner 15 1.5 11
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Water drain plug 25 2.5 18
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Oil drain plug 37 3.7 27
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Tension roller pin nut 17 1.7 12
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Manifold screws 22 2.2 16
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Alternator bracket 17 1.7 12
* NOTE: 40 + 60° is tighten to 40 Nm then an additional 60° (60 degrees) of rotation (one flat of bolt head)
Engine Page 3 - 10 Rev. B Groundsmaster 455-D
