Perkins 4.135 - To Remove and Fit Flywheel; Flywheel Ring Gear; Flywheel Fastener Hole Positions; Flywheel Run-Out Check

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Contents2
General Information Contents3
Introduction4
Safety Precautions5
Engine Identification6
Running-In Procedure6
Engine Number Position6
Powerpart Consumable Products7
Engine Views9
Front/Left Side of 4.135 Engine10
Rear/Right Side of 4.135 Engine10
Front/Left Side of 4.154 Engine11
Rear/Right Side of 4.154 Engine11
Front/Left Side of 4.182 Engine12
Rear/Right Side of 4.182 Engine12
Technical Data13
Emngine Data14
Approximate Installed Dry Engine Weights14
Rating Details15
Component Data and Dimensions16
Cylinder Block16
Cylinder Liners16
Pistons - 4.13516
Pistons - 4.15417
Pistons - 4.18217
Piston Rings17
Gudgeon Pin17
Connecting Rods18
Connecting Rod Alignment18
Connect Rod Bearings18
Crankshaft18
Camshaft19
Cylinder Head19
Valve Guides19
Inlet Valves19
Exhaust Valaves20
Outer Valve Springs20
Inner Valve Springs20
Tappets20
Idler Gear and Hub21
Timing Gears21
Lubricating Oil Recommendations21
Lubricating Oil Pump Clearances21
Thermostat22
Fuel Recommendations22
Fuel Injection Pump22
Atomisers22
Maintenance23
Preventive Maintenance24
Post Delivery Service25
Engine Coolant25
Protection of an Engine Not in Service26
Fault Diagnosis27
Fault Diagnosis Chart28
Code List of Possible Causes28
To Remove Cylinder Head30
Rocker Assembly Removal30
To Remove Valves31
Valve and Valve Seat Overhaul31
Standard Valve Stem Height31
Maximum Permissible Valve Stem Height31
Valve Springs32
Rocker Assembly32
Valve Guide Protrusion Check32
Valve Spring Distortion Check32
To Renew Rocker Lever Bush33
Cylinder Head Inspection33
Combustion Chamber Inserts33
Rocker Lever Assembly33
To Fit Valves34
To Fit Cylinder Head34
Expansion Plug Location34
Cylinder Head Location Thimbles34
To Adjust Valve Tip Clearances35
Exhaust Manifold Installation35
Inlet Manifold Installation35
Valve Tip Clearance Adjustment35
Pistons and Connecting Rods36
To Remove Pistons and Connecting Rods37
To Remove Pistons from Connecting Rods37
Inspection37
Piston and Connecting Rod Assembly37
To Renew Small End Bush38
To Check Piston Ring Gaps38
To Assemble Piston and Connecting Rod38
Piston Ring Gap Check38
To Fit Piston Rings39
To Fit Piston and Connecting Rod39
Oil Control Ring Spring Installation39
Piston Ring Compression Tool39
Connecting Rod Bearing Location40
Connecting Rod and Cap Assembly Numbers40
Cylinder Blocks and Liners41
Cylinder Block Inspection42
Cylinder Liner Check42
Cylinder Liner Check Positions42
Liner Flange Height Check42
Crankshaft and Main Bearing43
Crankshaft End Clearance44
To Renew Thrust Washers44
Crankshaft End Clearance Check44
Centre Main Bearing Cap Removal44
To Remove Crankshaft45
Crankshaft Pulley Removal45
Crankshaft Oil Thrower, Wavy Washer and Friction Gear Removal45
Crankshaft Removal45
Crankshaft Overhaul46
Finished Dimensions for Undersize Crankshafts46
To Fit Crankshaft47
Crankshaft Main Bearings - 4.182 (Centre Lower Half Bearing)47
Main Bearing Cap Position Marks - 4.135 and 4.15447
Main Bearing Cap Position Marks - 4.18247
Crankshaft Rear End Oil Seal48
Crankshaft Rear End Oil Sea Service Positions48
Crankshaft Rear End Oil Seal Housing (Location Dowels)48
Timing Case and Drive49
To Remove Timing Case Cover50
To Renew Crankshaft Front Oil Seal50
To Fit Timing Case Cover50
Timing Case Cover Removal50
To Remove and Fit Idler Gear(S)51
Idler Gear Removal51
Idler Gear Hub Removal (Lubricating Oil Holes)51
To Remove Camshaft Gear52
To Fit Camshaft Gear52
Idler Gear End Clearance Check52
Camshaft Gear Removal52
To Remove Fuel Pump Gear53
Fuel Pump Friction Gear Removal - 4.135 and 4.18253
Fuel Pump Gear Removal - 4.135 and 4.18253
Fuel Pump Gear Removal - 4.15453
To Fit Fuel Pump Gear54
To Remove Camshaft and Tappets54
Camshaft Removal54
Tappet Removal54
To Fit Camshaft and Tappets55
To Remove Timing Case55
Camshaft Thrust Plate55
Timing Case Removal - 4.182 (Location Thimble)55
To Fit Timing Case56
Timing Case Installation - 4.135 and 4.15456
Timing57
Gear Timing Marks58
Crankshaft Timing Arrangement58
To Check Valve Timing58
Flywheel Timing Marks58
Fuel Pump Timing Marks59
To Check Fuel Pump Timing59
Crankshaft Pulley Timing Marks59
Piston TDC Check59
Pump Plunger Measurement Device in Position60
Lubrication System61
Lubrication Circuit62
Lubrication Diagram62
To Renew Lubricating Oil Filter Canister63
Lubricating Oil Flow through Cooler and Filter63
Lubricating Oil Filter Canister Removal63
To Remove Lubricating Oil Sump - 4.135 and 4.15464
To Remove Lubricating Oil Sump - 4.18264
To Fit Lubricating Oil Sump - 4.135 and 4.15464
Lubricating Oil Sump - 4.135 and 4.15464
To Fit Lubricating Oil Sump - 4.18265
To Remove and Fit Lubricating Oil Relief Valve - 4.135 and 4.15465
To Remove and Fit Lubricating Oil Relief Valve - 4.18266
To Remove and Fit Lubricating Oil Dump Valve - 4.18266
To Remove and Fit Lubricating Oil Pump - 4.135 and 4.15466
Lubricating Oil Relief Valve Removal - 4.18266
To Remove and Fit Lubricating Oil Pump - 4.18267
Lubricating Oil Pump Inspection67
Lubricating Oil Pump Removal - 4.18267
Lubricating Oil Pump67
To Remove and Fit Lubricating Oil Cooler - 4.18268
Lubricating Oil Cooler By-Pass Valve - 4.18268
Inner Rotor to Outer Rotor Clearance Check68
Rotor End Clearance Check68
To Remove and Fit Piston Cooling Jets - 4.18269
Lubricating Oil Cooler Removal - 4.18269
Cooler By-Pass Valve Removal - 4.18269
Piston Cooling Jet Removal - 4.18269
Cooling System70
To Check and Adjust Fan Belt Tension71
To Drain Cooling System71
Fan Belt Tension Check71
Coolant Drain Position - 4.13571
To Remove and Fit Water Pump - 4.13572
To Remove and Fit Water Pump - 4.154 and 4.18272
Thermostatic Fan Removal72
Water Pump Removal - 4.13572
To Dismantle Water Pump73
Water Pump Removal - 4.15473
Water Pump Removal - 4.18273
To Assemble Water Pump74
To Remove and Fit Thermostat74
To Check Thermostat75
Fuel System76
Release of Fuel Pump Gear - 4.15477
Release of Fuel Pump Gear - 4.135 and 4.18277
Removal of Fuel Pump Gear Fasteners77
Fuel Pump Removal77
To Fit Fuel Injection Pump78
To Adjust Idle Speed78
Fuel Pump Position Marks78
Pump Speed Adjustment Screws78
Maximum no Load Speed Adjustment79
To Remove and Fit Atomisers - 4.135 and 4.18279
Fuel Leak off Pipe Removal - 4.135 and 4.18279
Atomiser Removal - 4.135 and 4.18279
To Remove and Fit Atomisers - 4.15480
Atomiser Removal - 4.15480
Atomiser Assembly - 4.135 and 4.18280
Atomiser Assembly - 4.15480
To Remove Air from the Fuel System81
Removal of Air from Fuel Pump81
Flywheel and Backplate82
To Remove and Fit Flywheel83
Flywheel Ring Gear83
Flywheel Fastener Hole Positions83
Flywheel Run-Out Check83
To Remove and Fit Flywheel Backplate84
Backplate Face Alignment Check84
Backplate Flange Concentricity Check84
Electrical Equipment85
Alternator86
To Test Voltage86
Output Test86
Alternator Voltage Check86
Starter Motor87
Glow Plugs87
Checks in Service87
To Check Glow Plug Inside Circuit87
To Check Glow Plug Electrical Supply88
Glow Plug Removal88
Exhauster89
To Remove Exhauster90
To Fit Exhauster90
Exhauster Body Removal90
Exhauster Rotor Removal90
Index91

Perkins 4.135 - To Remove and Fit Flywheel; Flywheel Ring Gear; Flywheel Fastener Hole Positions; Flywheel Run-Out Check

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