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