Perkins 4.154 - Workshop Manual

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Contents4
Unified Threads and Engine Number Location5
Engine Views6
View of Front Left Hand Side of 4.154 Engine6
View of Rear Right Hand Side of 4.154 Engine7
Exploded View of Cylinder Head Assembly8
Exploded View of Crankshaft, Connecting Rod and Piston Assemblies10
Exploded View of Timing Case, Drive and Camshaft Assembly11
Exploded View of Water Pump Assembly12
General Information13
Engine Data13
Rating Details13
Approximate Engine Weights Dry14
De-Rating for Altitude14
Service Wear Limits15
Recommended Torque Tensions15
Operating Instructions16
Starting the Engine16
To Stop the Engine16
Cold Starting16
Preventive Maintenance17
Preservation of Laid-Up Engine18
Batteries18
Starters and Generators18
Fuel Injection Pump18
Recommended Oils for Inhibiting the Fuel System19
Preparing the Engine for Return to Service19
Starters and Dynamos19
D.P.A. Distributor Pump20
Front Precautions20
Fault Finding Chart21
Key to Fault Finding Chart21
Cylinder Head22
Cylinder Head Dimensions22
To Remove the Cylinder Head24
Valves24
Valve Guides24
Cylinder Head B425
Valve Springs25
Rocker Shaft Assembly25
Rocker Levers25
Refitment of Cylinder Head26
Valve Clearances26
Atomisers26
Engine Running Check26
Pistons and Connecting Rods27
Piston and Rod Dimensions27
Connecting Rod Alignment28
Removal of Piston and Rods29
Sump29
Big End Bearings29
Gudgeon Pins29
Pistons and Connecting Rods C430
Cylinder Block and Liners32
Cylinder Block and Liner Dimensions32
Cylinder Block and Liners D233
To Renew Cylinder Liners33
Crankshaft and Main Bearings34
Crankshaft and Main Bearing Dimensions34
Crankshaft End Float35
Removal of Crankshaft35
Overhaul of Standard Size Crankshaft35
Crankshaft Rear Oil Seal and Housing35
Main Bearing Caps36
Oil Thrower Flange37
Crankshaft Pulley37
Crankshaft Regrind Data38
Timing Case and Drive39
Camshaft and Timing Gear Dimensions39
To Remove the Timing Case41
To Refit the Timing Case41
To Renew the Front Oil Seal42
To Remove Idler Gear and Hub42
To Refit the Idler Gear and Hub42
To Remove the Camshaft Gear43
To Refit the Camshaft Gear43
To Remove the Fuel Pump Gear43
To Refit the Fuel Pump Gear43
To Fit New Fuel Pump Gear44
To Remove the Fuel Pump Drive Hub44
To Refit the Fuel Pump Drive Hub45
To Remove the Fuel Pump Adaptor Housing45
To Refit the Fuel Pump Adaptor Housing45
Crankshaft Gear46
To Remove the Camshaft and Tappets46
To Refit the Camshaft and Tappets47
To Remove the Flywheel48
Flywheel Ring Gear48
To Refit the Flywheel48
Flywheel Run-Out48
To Remove the Flywheel Housing49
To Refit the Flywheel Housing49
Timing50
Timing Marks50
Timing Pin50
To Re-Set to the Original Timing50
Checking Valve Timing51
Fuel Pump Timing Marks51
Checking Fuel Pump Timing52
Lubricating System54
Lubricating Oil System Data and Pump Dimensions55
Removal of Oil Sump56
To Refit the Oil Sump56
To Remove the Oil Pump56
To Dismantle the Oil Pump and Relief Valve56
Examination and Re-Assembly of Oil Pump and Relief Valve57
To Refit the Oil Pump57
Oil Filters58
To Renew Spin-On Type Oil Filter Canister58
Oil Filter Headcasting58
By-Pass Valve58
Cooling System Data and Water Pump Dimensions59
Fan Belt - to Adjust60
To Remove the Water Pump60
Disconnect the Water Pump By-Pass Hose60
To Refit the Water Pump61
To Remove the Thermostat61
To Test the Thermostat62
To Replace the Thermostat62
Fuel System Data63
Starting Aid64
Fuel Filter - to Remove and Replace the Filter Element64
Fuel Lift Pump64
Testing the Lift Pump Fitted to the Engine65
To Remove the Lift Pump65
To Dismantle the Lift Pump65
To Re-Assemble the Lift Pump65
To Refit the Fuel Lift Pump66
To Remove the Fuel Pump Mechanically66
To Refit the Fuel Injection Pump67
Maximum Speed Setting67
Fuel System Maintenance68
Fuel Pipes68
Priming the Fuel System69
Air Cleaner71
Dry Type Air Cleaners71
Air Cleaner Element Renewal71
Restriction Indicator72
Optional Service Method72
Two-Stage Dry Type Air Cleaners with Multiple Filter Elements73
Electrical System75
Checking or Adjusting the Voltage Setting78
Adjustment of Voltage Setting78
Check of Alternator Output78
Check Warning Light Control78
Routine Maintenance79
Inspection of Brush Gear79
Belt Adjustment79
Brush Gear and Commutator Maintenance81
Exhauster Description82
Exhauster Mounting82
Exhauster Lubrication82
Servicing the Exhauster Unit83
To Reassemble Exhauster83
4.154 Marine Engine85
General Data85
Dimensions86
Gearboxes89
Cooling System89
To Dismantle the Sea Water Pump90
To Reassemble the Sea Water Pump90
Fresh Water Pump90
To Remove the Fresh Water Pump90
Fresh Water System91
Sea Water Circuit91
Heat Exchanger92
To Remove the Tube Stack92
Water Pump Belt Adjustment92
New Belts92
To Remove the Engine/Gearbox Oil Cooler93
To Clean the Oil Cooler93
Lubricating Oils94
Glossary of Terms95
Approved Service Tools96
Valve Seat Cutters102
Examples of Service Facilities105
Service Publications105
Index106

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