PERKINS 4.135 WORKSHOP MANUAL Pdf Download

Contents

General Information Contents

Introduction

Safety Precautions

Engine Identification

Running-In Procedure

Engine Number Position

Powerpart Consumable Products

Engine Views

Front/Left Side of 4.135 Engine

Rear/Right Side of 4.135 Engine

Front/Left Side of 4.154 Engine

Rear/Right Side of 4.154 Engine

Front/Left Side of 4.182 Engine

Rear/Right Side of 4.182 Engine

Technical Data

Emngine Data

Approximate Installed Dry Engine Weights

Rating Details

Component Data and Dimensions

Cylinder Block

Cylinder Liners

Pistons - 4.135

Pistons - 4.154

Pistons - 4.182

Piston Rings

Gudgeon Pin

Connecting Rods

Connecting Rod Alignment

Connect Rod Bearings

Crankshaft

Camshaft

Cylinder Head

Valve Guides

Inlet Valves

Exhaust Valaves

Outer Valve Springs

Inner Valve Springs

Tappets

Idler Gear and Hub

Timing Gears

Lubricating Oil Recommendations

Lubricating Oil Pump Clearances

Thermostat

Fuel Recommendations

Fuel Injection Pump

Atomisers

Maintenance

Preventive Maintenance

Post Delivery Service

Engine Coolant

Protection of an Engine Not in Service

Fault Diagnosis

Fault Diagnosis Chart

Code List of Possible Causes

To Remove Cylinder Head

Rocker Assembly Removal

To Remove Valves

Valve and Valve Seat Overhaul

Standard Valve Stem Height

Maximum Permissible Valve Stem Height

Valve Springs

Rocker Assembly

Valve Guide Protrusion Check

Valve Spring Distortion Check

To Renew Rocker Lever Bush

Cylinder Head Inspection

Combustion Chamber Inserts

Rocker Lever Assembly

To Fit Valves

To Fit Cylinder Head

Expansion Plug Location

Cylinder Head Location Thimbles

To Adjust Valve Tip Clearances

Exhaust Manifold Installation

Inlet Manifold Installation

Valve Tip Clearance Adjustment

Pistons and Connecting Rods

To Remove Pistons and Connecting Rods

To Remove Pistons from Connecting Rods

Inspection

Piston and Connecting Rod Assembly

To Renew Small End Bush

To Check Piston Ring Gaps

To Assemble Piston and Connecting Rod

Piston Ring Gap Check

To Fit Piston Rings

To Fit Piston and Connecting Rod

Oil Control Ring Spring Installation

Piston Ring Compression Tool

Connecting Rod Bearing Location

Connecting Rod and Cap Assembly Numbers

Cylinder Blocks and Liners

Cylinder Block Inspection

Cylinder Liner Check

Cylinder Liner Check Positions

Liner Flange Height Check

Crankshaft and Main Bearing

Crankshaft End Clearance

To Renew Thrust Washers

Crankshaft End Clearance Check

Centre Main Bearing Cap Removal

To Remove Crankshaft

Crankshaft Pulley Removal

Crankshaft Oil Thrower, Wavy Washer and Friction Gear Removal

Crankshaft Removal

Crankshaft Overhaul

Finished Dimensions for Undersize Crankshafts

To Fit Crankshaft

Crankshaft Main Bearings - 4.182 (Centre Lower Half Bearing)

Main Bearing Cap Position Marks - 4.135 and 4.154

Main Bearing Cap Position Marks - 4.182

Crankshaft Rear End Oil Seal

Crankshaft Rear End Oil Sea Service Positions

Crankshaft Rear End Oil Seal Housing (Location Dowels)

Timing Case and Drive

To Remove Timing Case Cover

To Renew Crankshaft Front Oil Seal

To Fit Timing Case Cover

Timing Case Cover Removal

To Remove and Fit Idler Gear(S)

Idler Gear Removal

Idler Gear Hub Removal (Lubricating Oil Holes)

To Remove Camshaft Gear

To Fit Camshaft Gear

Idler Gear End Clearance Check

Camshaft Gear Removal

To Remove Fuel Pump Gear

Fuel Pump Friction Gear Removal - 4.135 and 4.182

Fuel Pump Gear Removal - 4.135 and 4.182

Fuel Pump Gear Removal - 4.154

To Fit Fuel Pump Gear

To Remove Camshaft and Tappets

Camshaft Removal

Tappet Removal

To Fit Camshaft and Tappets

To Remove Timing Case

Camshaft Thrust Plate

Timing Case Removal - 4.182 (Location Thimble)

To Fit Timing Case

Timing Case Installation - 4.135 and 4.154

Timing

Gear Timing Marks

Crankshaft Timing Arrangement

To Check Valve Timing

Flywheel Timing Marks

Fuel Pump Timing Marks

To Check Fuel Pump Timing

Crankshaft Pulley Timing Marks

Piston TDC Check

Pump Plunger Measurement Device in Position

Lubrication System

Lubrication Circuit

Lubrication Diagram

To Renew Lubricating Oil Filter Canister

Lubricating Oil Flow through Cooler and Filter

Lubricating Oil Filter Canister Removal

To Remove Lubricating Oil Sump - 4.135 and 4.154

To Remove Lubricating Oil Sump - 4.182

To Fit Lubricating Oil Sump - 4.135 and 4.154

Lubricating Oil Sump - 4.135 and 4.154

To Fit Lubricating Oil Sump - 4.182

To Remove and Fit Lubricating Oil Relief Valve - 4.135 and 4.154

To Remove and Fit Lubricating Oil Relief Valve - 4.182

To Remove and Fit Lubricating Oil Dump Valve - 4.182

To Remove and Fit Lubricating Oil Pump - 4.135 and 4.154

Lubricating Oil Relief Valve Removal - 4.182

To Remove and Fit Lubricating Oil Pump - 4.182

Lubricating Oil Pump Inspection

Lubricating Oil Pump Removal - 4.182

Lubricating Oil Pump

To Remove and Fit Lubricating Oil Cooler - 4.182

Lubricating Oil Cooler By-Pass Valve - 4.182

Inner Rotor to Outer Rotor Clearance Check

Rotor End Clearance Check

To Remove and Fit Piston Cooling Jets - 4.182

Lubricating Oil Cooler Removal - 4.182

Cooler By-Pass Valve Removal - 4.182

Piston Cooling Jet Removal - 4.182

Cooling System

To Check and Adjust Fan Belt Tension

To Drain Cooling System

Fan Belt Tension Check

Coolant Drain Position - 4.135

To Remove and Fit Water Pump - 4.135

To Remove and Fit Water Pump - 4.154 and 4.182

Thermostatic Fan Removal

Water Pump Removal - 4.135

To Dismantle Water Pump

Water Pump Removal - 4.154

Water Pump Removal - 4.182

To Assemble Water Pump

To Remove and Fit Thermostat

To Check Thermostat

Fuel System

Release of Fuel Pump Gear - 4.154

Release of Fuel Pump Gear - 4.135 and 4.182

Removal of Fuel Pump Gear Fasteners

Fuel Pump Removal

To Fit Fuel Injection Pump

To Adjust Idle Speed

Fuel Pump Position Marks

Pump Speed Adjustment Screws

Maximum no Load Speed Adjustment

To Remove and Fit Atomisers - 4.135 and 4.182

Fuel Leak off Pipe Removal - 4.135 and 4.182

Atomiser Removal - 4.135 and 4.182

To Remove and Fit Atomisers - 4.154

Atomiser Removal - 4.154

Atomiser Assembly - 4.135 and 4.182

Atomiser Assembly - 4.154

To Remove Air from the Fuel System

Removal of Air from Fuel Pump

Flywheel and Backplate

To Remove and Fit Flywheel

Flywheel Ring Gear

Flywheel Fastener Hole Positions

Flywheel Run-Out Check

To Remove and Fit Flywheel Backplate

Backplate Face Alignment Check

Backplate Flange Concentricity Check

Electrical Equipment

Alternator

To Test Voltage

Output Test

Alternator Voltage Check

Starter Motor

Glow Plugs

Checks in Service

To Check Glow Plug Inside Circuit

To Check Glow Plug Electrical Supply

Glow Plug Removal

Exhauster

To Remove Exhauster

To Fit Exhauster

Exhauster Body Removal

Exhauster Rotor Removal

Index

Perkins 4.135 Workshop Manual

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Perkins 4.135 Workshop Manual

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