Perkins UA - Piston and Connecting Rod Assembly; Big and Bearing and Cap - to Remove and to Fit; Notes on Connecting Rods

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How to Use this Manual2
Contents6
General Safety Precautions10
Engine Lift Equipment11
Viton Seals12
Consumable Products13
Engine Identification - Location15
Engine Views16
Compression Test Data18
How to Do a Compression Test18
Specifications19
Recommended Torque Tensions20
Data and Dimensions22
Cylinder Head Assembly Data25
Crankshaft Data29
Timing Case and Drive Assembly30
Lubrication Oil Pump Data31
Pistons Data32
Big-End Bearings Data33
Gudgeon Pins Data33
Fuel Injection Pump Data34
Electrical Equipment Data35
Auxiliary Equipment35
Cylinder Head Assembly36
Rocker Cover - to Remove and to Fit36
Rocker Assembly - to Remove and to Fit37
Rocker Shaft - to Dismantle, to Inspect and to Assemble39
Valve Tip Clearance - to Check41
Valve Springs (with Cylinder Head Fitted) - to Remove and to Fit42
Exhaust/Induction Manifolds and Gaskets - to Remove and to Fit43
Cylinder Head Setscrews - to Remove and to Fit44
Cylinder Head Gasket - to Remove and to Fit45
Valve and Valve Springs - to Remove and to Fit46
Valve Stem - to Inspect47
Valve Depth - to Check48
Valve Guides - to Check49
Valve Guides - to Remove and to Fit50
Valve Seats - to Correct51
Valve Seat Insert - to Fit52
Piston and Connecting Rod Assembly53
Big and Bearing and Cap - to Remove and to Fit53
Notes on Connecting Rods53
Cylinder Head - to Check the Distortion of the Lower Face54
Piston and Connecting Rod - to Dismantle and Assemble55
Piston and Piston Ring - Inspection56
Piston and Connecting Rod - to Fit59
Connecting Rod - to Check for Bend and to Inspect60
Connecting Rod - to Check the Length and to Inspect61
Small End Bush - to Remove and to Fit62
To Check the Piston Height above the Cylinder Block63
Connecting Rod Assembly64
Piston Cooling Jets (UC Engines) - to Remove, to Fit and to Align64
Crankshaft Pulley - to Remove and to Fit65
Crankshaft Pulley - to Fit a Wear Sleeve66
Rear Oil Seal - to Remove67
Rear Oil Seal - to Fit68
Thrust Washers and Crankshaft End-Float - to Inspect69
Thrust Washers - to Remove and to Fit70
Main Bearing Caps (with Crankshaft in Position) - to Remove and to Fit71
Main Bearings - to Inspect72
Main Bearing Caps (Front and Rear) - to Remove73
Main Bearing Caps (Front and Rear) - to Fit74
Crankshaft - to Remove75
Crankshaft - to Fit76
Crankshaft - to Inspect and to Overhaul77
Wearsleeve - to Fit78
Timing Case - to Remove and to Fit79
Tamper Proof Screws80
Timing Case - to Fit82
Timing Case - to Renew83
Front Oil Seal - to Remove and to Fit84
Idler Gear - to Remove85
Idler Gear Bushes - to Remove and to Fit86
Idler Gear Hub - to Remove and to Fit87
Camshaft Assembly for the Fuel Injection Pump - to Remove and to Fit88
Camshaft Assembly and Tappets for the Valves - to Remove and to Fit89
Camshaft Assembly for the Valves - to Remove and to Fit90
Backplate - to Remove and to Fit91
Crankshaft Gear - to Remove and to Fit92
Cylinder Block Assembly93
Cylinder Block Bores - to Inspect93
Camshaft Bush - to Renew94
Engine Timing95
To Set Approximately Number 1 Piston to TDC on the Compression Stroke95
Fuel Injection Pump Timing97
To Check Valve Timing98
Turbocharger - to Remove and to Fill101
To Clean the Impeller and Compressor Casing103
Engine Breather Assembly - to Renew104
Lubrication System105
Oil Filter Canister - to Renew105
Engine Lubricating Oil - to Renew106
Filter Head and Oil Cooler - to Remove and Fit107
Sump - to Remove and to Fit108
Oil Strainer and Suction Pipe - to Remove and Fit109
Lubricating Oil Pump - to Renew110
Lubricating Oil Pump - to Inspect111
Relief Valve - to Remove, to Fit and to Renew112
Fuel System113
Fuel Filter Element - to Renew113
Atomiser Fault - to Inspect114
High Pressure Fuel Pipes - to Remove and to Fit115
Leak off Rail - to Remove and to Fit116
Atomisers - to Remove and to Fit117
Fuel Lift Pump - to Remove and to Fit118
Fuel Lift Pump - to Test119
Fuel Injection Pump - to Remove and to Fit120
To Eliminate Air from Fuel System122
Governor Weight Assembly - to Remove and to Fit123
Speed Control Lever Assembly - to Remove and to Fit124
Speed Control Lever Assembly - to Renew125
To Change a Plain Bush to a Threaded Bush126
Fuel Injection Pump Linkage - to Remove and to Fit127
Fuel Injection Pump Linkage - to Renew128
To Record the Maximum Fuel Position of the Fuel Control Rack129
How to Use the Reference Setting for Maximum Fuel134
Cooling System136
To Drain and Fill the Cooling System136
Thermostat - to Remove and to Fit137
Thermostat - to Test138
Fan - to Remove and to Fit139
Coolant Pump - to Remove and to Fit140
Oil Cooler - to Remove and to Fit141
Flywheel and Flywheel Housing142
Flywheel - to Remove and to Fit142
Flywheel - to Inspect143
Starter Ring - to Remove and to Fit144
Flywheel Housing - to Remove and to Fit145
Electrical Equipment146
Drive Belt - to Remove and to Fit146
Alternator - to Remove and to Fit147
Glowplugs (Starting Aid) - to Remove and to Fit148
Glowplugs (Starting Aid) - to Check149
Starter Motor - to Remove, to Fit and to Test150
Electrical Stop Solenoid - to Remove and to Fit151
Power Take-Off Assembly - to Remove and to Fit152
Power Take-Off Assembly - to Dismantle and to Assemble153
Special Equipment154
List of Special Tools154

Perkins UA - Piston and Connecting Rod Assembly; Big and Bearing and Cap - to Remove and to Fit; Notes on Connecting Rods

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