Perkins 1000 Series, Phaser Series Workshop Manual

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Page 1

Perkins Phaser and 1000 Series

Contents

EXIT

Contents

EXIT

Contents

WORKSHOP MANUAL

Phaser 4 and 6 cylinder diesel engines for

automotive applications

1000 Series 4 and 6 cylinder diesel engines for

agricultural and industrial application

Perkins Phaser/1000 Series, April 1995 00.01

Page 2

Amendment status

Issue

number

scription Date

This issue, number TPD 1312E, includes information from earlier issue TPD 0191 1301 and TPD 0391 1266 and new information about:

The Fastram piston, composite rocker cover, dampers, belt driven coolant pumps and different timing case, flame ring and partially finished liners, KSB cold starting aid, Stanadyne and Lucas DP200 fuel injection pumps, turbocharger and faults, closed engine breather, quick release fuel filters, the idler gear of the lubricating oil pump, intercoolers, twin fuelled starting aids, Bendix compressor and lift equipment.

Also new information about: The Bosch EPVE locked fuel injection pump, atomisers and fuel

injection pump codes, data and dimensions

April 1995

00.02 Perkins Phaser/1000 Series, April 1995

Page 3

General information. . . . . . . . . . . . . . . . . . . . . . . . . . 10

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

SERVICE OPERATIONS

Cylinder head assembly. . . . . . . . . . . . . . . . . . . . . . 12

Piston and connecting rod assemblies. . . . . . . . . . . . 13

Crankshaft assembly. . . . . . . . . . . . . . . . . . . . . . . . . 14

Timing case and drive assembly. . . . . . . . . . . . . . . . 15

Cylinder block assembly. . . . . . . . . . . . . . . . . . . . . . 16

Engine timing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Aspiration system. . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Lubrication system. . . . . . . . . . . . . . . . . . . . . . . . . . 19

Fuel system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Cooling system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Flywheel and housing. . . . . . . . . . . . . . . . . . . . . . . . 22

Electrical equipment. . . . . . . . . . . . . . . . . . . . . . . . . 23

Auxiliary equipment. . . . . . . . . . . . . . . . . . . . . . . . . . 24

List of special tools. . . . . . . . . . . . . . . . . . . . . . . . . . 25

Perkins Phaser/1000 Series, April 1995 00.03

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General information10

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.02

Engine views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.03

Engine identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.04

Safety precautions

Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.05

Engine lift equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.06

Asbestos joints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.07

Viton seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.08

Powerpart consumable products. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.09

Perkins Phaser/1000 Series, April 1995 10.01

Page 5

10 GENERAL INFORMATION

Introduction

This workshop manual has been designed to provide assistance in the service and overhaul of Perkins Phaser and 1000 Series engines.

Most of the general information which is included in the relevant User's Handbook (sections 1 to 9) has not been repeated in this workshop manual and the two publications should be used together.

Where the information applies only to certain engine types, this is indicated in the text.

The details of some operations will be different according to the type of fuel injection pump which is fitted. The specific pump type used can be found by reference to the manufacturer's identification plate on the pump body but, generally, the type of pump fitted is as shown below.

Lucas DPA, DPS and DP200 Series Bosch EPVE and MW Stanadyne DB2 and DB4 When reference is made to the "left" or "right" side

of the engine, this is as seen from the flywheel end of the engine.

Special tools have been made available and a list of these is given in section 25. Reference to the relevant special tools is also made at the beginning of each operation.

Data and dimensions are included at the end of each section.

Read and remember the "Safety precautions". They are given for your protection and must be used at all times.

Danger is indicated in the text by two methods:

Warning! This indicates that there is a possible danger to the person.

Caution: This indicates that there is a possible danger to the engine.

Note: Is used where the information is important, but there is not a danger.

10.02 Perkins Phaser/1000 Series, April 1995

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GENERAL INFORMATION 10

PA314

PA315

Perkins Phaser/1000 Series, April 1995 10.03

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10 GENERAL INFORMATION

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Engine identification

The Perkins Phaser and 1000 Series engines have been designed for specific applications, as shown below:

• Phaser for automotive applications.

• 1000 Series for agricultural and industrial applications

Each series consists of both four and six cylinder engines, each of which will have four basic engine types - naturally aspirated, compensated, turbocharged and turbocharged/intercooled.

There are different models in each series. Phaser engines are named according to their

approximate power output, for example: Phaser\110T - four cylinder engine rated at 106 bhp "T" indicates that the engine is turbocharged. Phaser\210Ti - six cylinder engine rated at 210 bhp "Ti" indicates that the engine is turbocharged and

intercooled. 1000 Series engines are identified by a system of

numbers and letters, for example: 1006-6TW - six cylinder engine of six litres "TW" indicates that the engine is turbocharged and

intercooled. In this workshop manual, the different engine types

are indicated by their code letters. These are the first two letters of the engine number as indicated below:

PA043

The engine number is stamped on a label which is fastened to the left side (A1) or rear (A2) of the cylinder block. An example of an engine number is AB30126U510256N.

Further information about the engine number system can be found in the relevant user's handbook.

Note: If you need parts, service or information for your engine, you must give the complete engine number to your Perkins distributor.

Code letters Engine type

AA Four cylinder, naturally aspirated AB Four cylinder, turbocharged AC Four cylinder, compensated AD Four cylinder,

turbocharged/intercooled

AE Four cylinder,

turbocharged/intercooled designed to conform to the USA emission legislation

AG Four cylinder, naturally aspirated

with belt driven water pump.

AH Four cylinder, turbocharged with

belt driven water pump. YA Six cylinder, naturally aspirated. YB Six cylinder, turbocharged. YC Six cylinder, compensated. YD Six cylinder,

turbocharged/intercooled. YE Six cylinder,

turbocharged/intercooled designed

to conform to the USA emission

legislation

10.04 Perkins Phaser/1000 Series, April 1995

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GENERAL INFORMATION 10

General safety precautions

These safety precautions are important. You

must refer also to the local regulations in the country of use. Some items only refer to specific applications.

• Only use these engines in the type of application

for which they have been designed.

• Do not change the specification of the engine.

• Do not smoke when you put fuel in the tank.

• Clean away fuel which has been spilt. Material

which has been contaminated by fuel must be moved to a safe place.

• Do not put fuel in the tank while the engine runs

(unless it is absolutely necessary).

• Do not clean, add lubricating oil, or adjust the

engine while it runs (unless you have had the correct training; even then extreme care must be used to prevent injury).

• Do not make adjustments that you do not

understand.

• Ensure that the engine does not run in a location

where it can cause a concentration of toxic emissions.

• Other persons must be kept at a safe distance

while the engine or auxiliary equipment is in operation.

• Do not permit loose clothing or long hair near

moving parts.

• Keep away from moving parts during engine

operation

be seen clearly while the engine runs.

• Do not operate the engine if a safety guard has

been removed.

• Do not remove the filler cap of the cooling

system while the engine is hot and while the coolant is under pressure, because dangerous hot coolant can be discharged.

• Do not use salt water or any other coolant which

can cause corrosion in the closed circuit of the cooling system.

• Do not allow sparks or fire near the batteries

(especially when the batteries are on charge) because the gases from the electrolyte are highly flammable. The battery fluid is dangerous to the skin and especially to the eyes.

• Disconnect the battery terminals before a repair

is made to the electrical system.

• Only one person must control the engine.

• Ensure that the engine is operated only from the

control panel or from the operators position.

• If your skin comes into contact with high-

pressure fuel, obtain medical assistance immediately.

. Warning! Some moving parts cannot

• Diesel fuel and lubricating oil (especially used lubricating oil) can damage the skin of certain persons. Protect your hands with gloves or a special solution to protect the skin.

• Do not wear clothing which is contaminated by lubricating oil. Do not put material which is contaminated with oil into the pockets of clothing.

• Discard used lubricating oil in a safe place to prevent contamination.

• Ensure that the control lever of the transmission drive is in the "out-of-drive" position before the engine is started.

• Use extreme care if emergency repairs must be made in adverse conditions.

• The combustible material of some components of the engine (for example certain seals) can become extremely dangerous if it is burned. Never allow this burnt material to come into contact with the skin or with the eyes.

• Read and use the instructions relevant to lift equipment which are given on page 10.06.

• Always use a safety cage to protect the operator when a component is to be pressure tested in a container of water. Fit safety wires to secure the plugs which seal the hose connections of a component which is to be pressure tested.

• Do not allow compressed air to contact your skin. If compressed air enters your skin, obtain medical help immediately.

• Turbochargers operate at high speed and at high temperatures. Keep fingers, tools and debris away from the inlet and outlet ports of the turbocharger and prevent contact with hot surfaces.

• Fit only genuine Perkins parts.

Perkins Phaser/1000 Series, April 1995 10.05

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10 GENERAL INFORMATION

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Safety Engine lift equipment

The maximum weight of the engine without coolant, lubricant or a gearbox fitted will vary for different applications. It is recommended that lift equipment of the minimum capacity listed below is used:

Four cylinder engines . . . . . . 500 Kg (1100 lbs)

Six cylinder engines . . . . . . . 600 Kg (1320 lbs)

Before the engine is lifted:

• Always use lift equipment of the approved type and of the correct capacity to lift the engine. It is recommended that lift equipment of the type shown in (A) is used, to provide a vertical lift directly above the engine lift brackets (A1). Never use a single lift bracket to raise an engine.

• Check the engine lift brackets for damage and that they are secure before the engine is lifted. The torque for the setscrews for the engine lift brackets is 44 Nm (33 lbf ft) 4,5 kgf m.

• To Prevent damage to the rocker cover, ensure that there is clearance between the hooks and the rocker cover.

• Use lift equipment or obtain assistance to lift heavy engine components such as the cylinder block, cylinder head, balancer unit, flywheel housing, crankshaft and flywheel.

PA044

10.06 Perkins Phaser/1000 Series, April 1995

Page 10

Safety

Asbestos joints

Some joints and gaskets contain compressed asbestos fibres in a rubber compound or in a metal outer cover. The "white" asbestos (Chrysotile) which is used is a safer type of asbestos and the risk of damage to health is extremely small.

• The risk of asbestos from joints occurs at their edges or if a joint is damaged when a component is removed or if a joint is removed by abrasives.

• To ensure that the risk is kept to a minimum, the precautions given below must be applied when an engine which has asbestos joints is dismantled or assembled.

• Work in an area with good ventilation.

• Do not smoke.

• Use a hand scraper to remove the joints - do not use a rotary wire brush.

• Ensure that the joint to be removed is wet with oil or water to contain loose particles.

• Spray all asbestos debris with water and put it in a closed container which can be sealed for safe disposal.

GENERAL INFORMATION 10

PG008

Perkins Phaser/1000 Series, April 1995 10.07

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10 GENERAL INFORMATION

Safety

Viton seals

Some seals used in engines and in components fitted to engines are made of Viton.

Viton is used by many manufacturers and is a safe material under normal conditions of operation.

If Viton is burned, a product of this burnt material is an acid which is extremely dangerous. Never allow this burnt material to come into contact with the skin or with the eyes.

If it is necessary to come into contact with components which have been burnt, ensure that the precautions which follow are used:

• Ensure that the components have cooled.

• Use Neoprene gloves and discard the gloves safely after use.

• Wash the area with calcium hydroxide solution and then with clean water.

• Disposal of components and gloves which are contaminated must be in accordance with local regulations.

If there is contamination of the skin or eyes, wash the affected area with a continuous supply of clean water or with calcium hydroxide solution for 15-60 minutes. Obtain immediate medical attention.

10.08 Perkins Phaser/1000 Series, April 1995

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GENERAL INFORMATION 10

POWERPART consumable products

Perkins have made available the products recommended below in order to assist in the correct operation, service and maintenance of your engine and your machine. The instructions for the use of each product are given on the outside of each container. These products are available from your Perkins distributor.

POWERPART Antifreeze

Protects the cooling system against frost and corrosion. Part number 1 litre 21825166 or 5 litres 21825167, see the User's Handbook.

POWERPART Easy Flush

Cleans the cooling system. Part number 2182501

POWERPART Jointing compound

Universal jointing compound which seals joints. Currently Hylomar. Part number 1861155 or

1861117.

POWERPART Silicone rubber sealant

Silicone rubber sealant which prevents leakage through gaps. Currently Hylosil. Part number

1861108.

POWERPART Lay-Up 1

A diesel fuel additive for protection against corrosion. Part number 1772204, see the User's Handbook.

POWERPART Studlock

To permanently retain large fasteners and studs. Currently Loctite 270. Part number 21820270.

POWERPART Liquid gasket

To seal flat faces of components where no joint is used. Especially suitable for aluminium components. Currently Loctite 518. Part number 21820518

POWERPART Threadlock (hydraulic/pneumatic)

To retain and seal pipe connections with fine threads. Especially suitable for hydraulic and pneumatic systems. Currently Loctite 542. Part number 2180542

POWERPART Threadlock (pipe)

To retain and seal pipe connections with coarse threads. Pressure systems can be used immediately. Currently Loctite 575. Part number

21820575.

POWERPART Retainer (oil tolerant)

To retain components which have a transition fit. Currently Loctite 603. Part number 21820603.

POWERPART Retainer (high strength)

To retain components which have an interference fit. Currently Loctite 638. Part number 21820638.

POWERPART Lay-Up 2

Protects the inside of the engine and of other closed systems. Part number 1762811, see the User's Handbook.

POWERPART Lay-Up 3

Protects outside metal parts. Part number 1734115, see the User's Handbook.

POWERPART Chisel

Allows easy removal of old gaskets and joints. Currently Loctite Chisel. Part number 21825163.

POWERPART Repel

Dries damp equipment and gives protection against corrosion. Passes through dirt and corrosion to lubricate and to assist removal of components. Currently Loctite Repel. Part number 21825164.

POWERPART Threadlock

To retain small fasteners where easy removal is necessary. Currently Loctite 222e. Part number

21820222.

POWERPART Nutlock

To retain and seal threaded fasteners and cup plugs where easy removal is necessary. Currently Loctite 242e. Part number 21820242

Perkins Phaser/1000 Series, April 1995 10.09

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Specifications11

Basic engine data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11A

Recommended torque tensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . .11B

Perkins Phaser/1000 Series, April 1995 11.01

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Basic engine data11A

Basic engine data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A.02

Perkins Phaser/1000 Series, April 1995 11A.01

Page 15

11A BASIC ENGINE DATA

Basic engine data

Number of cylinders:

- AA, AB, AC, AD, AE, AG, AH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

- YA, YB, YC, YD, YE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Cylinder arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . In-line

Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four stroke

Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise from the front

Induction system:

- AA, AG, YA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Naturally aspirated

- AB, AH, YB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharged

- AC, YC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Altitude compensated

- AD, AE, YD, YE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharged/intercooled

Combustion system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct injection

Nominal bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm (3.937 in)

Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 mm (5.000 in)

Compression ratio:

- AA, AG, YA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.5:1

- Certain YA engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.5:1

- AB, AC, AD, AH, YB, YC, YD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.0:1

- AE, YE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.5:1

- Certain AD engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.25:1 or 17.5:1

Cubic capacity:

Four cylinder engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 litres (243 in

Six cylinder engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 litres (365 in

Firing order:

Four cylinder engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1, 3, 4, 2

Six cylinder engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1, 5, 3, 6, 2, 4

Valve tip clearance (cold):

- Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,20 mm (0.008 in)

- Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,45 mm (0.018 in)

Lubricating oil pressure (minimum at maximum engine speed and normal engine temperature):

- Engines without piston cooling jets . . . . . . . . . . . . . . . . . . . . . . . . . 207 kpa (30 lbf/in

- Engines with piston cooling jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280 kpa (40 lbf/in2) 2,8 kgf/cm

) 2,1 kgf/cm

)

2 2

11A.02 Perkins Phaser/1000 Series, April 1995

Page 16

Recommended torque tensions11B

Cylinder head assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11B.02

Pistons and connecting rod assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . 11B.02

Crankshaft assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11B.02

Timing case and drive assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11B.03

Cylinder block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11B.03

Aspiration system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11B.03

Fuel system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11B.03

Lubrication system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11B.04

Cooling system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11B.04

Flywheel and housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11B.04

Electrical equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11B.04

Auxiliary equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11B.05

Perkins Phaser/1000 Series, April 1995 11B.01

Page 17

11B RECOMMENDED TORQUE TENSIONS

Recommended torque tensions

The torque tensions below apply to components lubricated lightly with clean engine oil before they are fitted.

Torque

Description

Cylinder head assembly

Setscrews, cylinder head 1/2 UNF (see section 12) Fasteners, rocker shaft brackets:

- Aluminium brackets M12 40 30 4,1

- Cast iron and sintered steel brackets M12 75 55 7,6 Cap nuts, rocker cover M12 20 15 2,1 Cap nuts, aluminium rocker cover (with shim washer) M12 30 22 3,0 Setscrews, inlet manifold to cylinder head M10 44 33 4,5 Nuts (plated), exhaust manifold to cylinder head M10 44 33 4,5 Nuts (non-plated), exhaust manifold to cylinder head M10 50 37 5,1 Setscrews, engine lift bracket M10 44 33 4,5

Piston and connecting rod assemblies

Nuts, connecting rods 1/2 UNF 125 92 12,7 Setscrews, connecting rods 1/2UNF 155 114 15,8

Thread

size

Nm lbf ft kgf m

Banjo bolts, piston cooling jets. 3/4 UNF 20 15 2,0

Crankshaft assembly

Setscrews, main bearings (4 cylinder engines) 5/8 UNF 250 185 26,0 Setscrews, main bearings (6 cylinder engines) 5/8 UNF 265 196 27,0 Setscrews, crankshaft pulley 7/16 UNF 115 85 11,8 Setscrews, viscous damper to crankshaft pulley M12 75 55 7,6 Cap screws, viscous damper to crankshaft pulley M8 35 26 3,6 Cap screws, rubber bonded damper to crankshaft pulley M8 35 26 3,6 Setscrews, rear oil seal housing to cylinder block M8 22 16 2,2 Torxscrew, rear oil seal housing to cylinder block M8 22 16 2,2 Cap screws, bridge piece to cylinder block M6 16 12 1,6 Cap screws, rear oil seal housing to bridge piece M8 18 13 1,9 Cap screws, rear oil seal housing to bridge piece M6 13 10 1,3 Torxscrew, rear oil seal housing to bridge piece M8 18 13 1,9

11B.02 Perkins Phaser/1000 Series, April 1995

Page 18

RECOMMENDED TORQUE TENSIONS 11B

Torque

Description

Setscrew, idler gear hub of balancer unit M12 93 68 9,5 Nut, drive gear of balance weight 1/2 UNF 82 60 8,4 Setscrews, rear cover of balancer frame M10 54 40 5,5 Setscrews, oil transfer plate (balancer unit) M10 30 22 3,1 Setscrews, oil pump to balancer frame M8 27 20 2,8 Setscrews, balancer to cylinder block M10 54 40 5,5

Timing case and drive assembly

Setscrews, timing case to cylinder block M8 22 16 2,2 Setscrews, timing case to cylinder block M10 44 33 4,5 Setscrews, hub of idler gear M10 44 33 4,5 Setscrew, camshaft gear M12 78 58 8,0 Setscrew, camshaft gear (for engines, with 45 mm long

setscrew) Setscrews, timing case cover to timing case M8 22 16 2,2 Nuts, timing case cover to timing case M8 22 16 2,2

Thread

size

M12 100 74 10,0

Nm lbf ft kgf m

Cylinder block

Setscrews, fitted instead of piston cooling jets 3/8 UNF 27 20 2,8

Aspiration system

Nuts, turbocharger to manifold M10 44 33 4,5 Setscrew, breather cover M6 9 7 0,9

Fuel system

Nuts, high-pressure fuel pipes M12 22 16 2,2 Setscrews, atomiser M8 12 9 1,2 Setscrews, fuel lift pump M8 22 16 2,2 Nut for gear of fuel injection pump M14 80 59 8,2 Cap screw for gear of in-line fuel injection pump: AE, YE

engines Nut for hub of in-line fuel injection pump: AE, YE engines M18 115 84 11,8 Nuts for adaptor plate of in-line fuel injection pump: AE, YE

engines Nuts for flange of fuel injection pump M8 22 16 2,2 Locking screw for Bosch VE fuel injection pump shaft M10 27 20 2,8

M8 44 33 4,5

M10 44 33 4,5

Locking screw for DP 200 fuel injection pump shaft 10 A/F 10 7 1

Perkins Phaser/1000 Series, April 1995 11B.03

Page 19

11B RECOMMENDED TORQUE TENSIONS

Torque

Description

Lubrication system

Plug, lubricating oil sump 3/4 UNF 34 25 3,5 Setscrews, oil pump to front bearing cap M8 22 16 2,2 Setscrews, cover for oil pump M8 28 21 2,9 Fasteners, lubricating oil sump M8 22 16 2,2

Cooling system

Setscrews, fan drive housing to timing case M10 44 33 4,5 Setscrews, fan drive pulley to hub M8 22 16 2,2 Setscrews, fan drive pulley to hub M10 44 33 4,5 Setscrews, fan M8 22 16 2,2 Connector, oil cooler to oil filter head 3/4 UNF 58 42 5.8 Setscrews, coolant pump to timing case M8 22 16 2,2 Nut, auxiliary coolant pump pulley 1/2 UNF 70 52 7,1 Setscrew, intercooler flange to inlet manifold M6 7 5 0,7 Setscrew, intercooler body to inlet manifold M8 22 16 2,2

Thread

size

Nm lbf ft kgf m

Flywheel and housing

Setscrews, flywheel to crankshaft 1/2 UNF 105 77 10,7 Setscrews, cast iron flywheel housing to cylinder block M10 44 33 4,5

- Stamped 8.8 M12 75 55 7,6

- Stamped 10.9 M10 63 46 6,4

- Stamped 10.9 M12 115 85 11,7 Setscrews, aluminium flywheel housing to cylinder block M10 70 52 7,1 Setscrews, flywheel housing to cylinder block (paper joint) M10 70 52 7,1

Electrical equipment

Nut, alternator pulley:

- CAV AC5RA and AC5RS 5/8 UNF 55 40 5,6

- Lucas A127, and motorola, 22mm A/F M17 60 44 6,1

- Lucas A127, and motorola, 24mm A/F M17 80 59 8,2

- Bosch 55A M14 45 33 4,5

- Bosch 55A M16 50 37 5,1

- Butec 5524 5/8 UNF 78 58 8,0 Fuelled start aid to induction manifold 7/8 UNF 31 23 3,1 Port heater aid to induction manifold M22 60 44 6,1

11B.04 Perkins Phaser/1000 Series, April 1995

Page 20

RECOMMENDED TORQUE TENSIONS 11B

Torque

Description

Auxiliary equipment

Nut, compressor drive gear:

- 6,4 mm (0.25 in) thick 3/4 UNF 80 59 8,2

- 10 mm (0.4 in) thick 3/4 UNF 130 95 13,3 Nuts for gears of auxiliary drive assembly:

- 6,4 mm (0.25 in) thick 3/4 UNF 80 59 8,2

- 10 mm (0.4 in) thick 3/4 UNF 130 95 13,3 Nut for gears of auxiliary drive assembly M20 130 95 13,3

Thread

size

Nm lbf ft kgf m

Perkins Phaser/1000 Series, April 1995 11B.05

Page 21

CYLINDER HEAD ASSEMBLY 12

Cylinder head assembly12

General description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12A.02

Rocker cover

12A-01To remove and to fit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12A.03

Rocker assembly

12A-02To remove and to fit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12A.05

12A-03To dismantle and to assemble. . . . . . . . . . . . . . . . . . . . . . . . . . 12A.06

12A-04To inspect and to correct. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12A.06

Valve tip clearances

12A-05To check and to adjust. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12A.07

Valve springs

12A-06To change the valve springs (with cylinder head fitted). . . . . . . . 12A.09

Cylinder head assembly

12A-07To remove and to fit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12A.11

Valves and valve springs

12A-08To remove and to fit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12A.16

12A-09To inspect and to correct. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12A.17

Valve guides

12A-10To inspect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12A.18

12A-11To remove and to fit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12A.19

Cylinder head

12A-12To inspect and to correct. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12A.20

12A-13To correct a valve seat with a valve seat cutter. . . . . . . . . . . . . 12A.21

12A-14To fit valve seat inserts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12A.22

Data and dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12A.23

Perkins Phaser/1000 Series, April 1995 12A.01

Page 22

12 CYLINDER HEAD ASSEMBLY

General description

In a diesel engine there is little carbon deposit and for this reason the number of hours run is no indication of when to overhaul a cylinder head assembly. The factors which indicate when an overhaul is necessary are how easily the engine starts and its general performance.

The cylinder head assembly has two valves fitted for each cylinder, each fitted with double or single valve springs, according to the engine application. The double springs have damper coils which are fitted towards the top face of the cylinder head.

In most engines the face angle of the valves is 45°, but some engines have inlet valves with a face angle of 30°. The angle of the valve seats in the cylinder head are either 46° or 31°.

The valves move in phosphated guides which can be renewed. The exhaust valve guide has a counterbore at the bottom and is a little longer than the inlet valve guide.

Both valve stems are fitted with oil seals which fit over the top of the valve guides.

Turbocharged engines and some naturally aspirated engines have valve seat inserts fitted in the cylinder head for both inlet and exhaust valves. Engines which do not have valve seat inserts fitted as standard, in production, can have them fitted in service.

12A.02 Perkins Phaser/1000 Series, April 1995

Page 23

CYLINDER HEAD ASSEMBLY 12

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Rocker cover

To remove and to fit12A-01

Engines are supplied with either an aluminium rocker cover (A) or with rocker covers made of a composite material (12A.04/A). The aluminium cover on some engines, has a dust seal which is fitted between the rocker cover and the induction manifold. The dust seal of the composite rocker cover is fitted permanently to the side of the rocker cover with adhesive.

To remove 1 Disconnect the breather pipe.

2 Remove the cap nuts (A2) together with the steel

washers and the shim washers (12A-04/A) from the top of the rocker cover.

3 Lift off the rocker cover and the joint. For aluminium covers, remove the rocker cover dust seal (A1).

Caution: When the rocker cover is fitted, the cap nuts are tightened onto the nuts of the rocker brackets. During removal of the cap nuts, it is possible to loosen the nuts of the rocker brackets. The nuts of the rocker brackets should be tightened to the correct torque every time the cover is removed.

PA045

Perkins Phaser/1000 Series, April 1995 12A.03

Page 24

12 CYLINDER HEAD ASSEMBLY

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To fit 1 Check the seal of the oil filler cap (A1), the

sealing washers (A5), the steel washer (A3) and, if fitted, the shim washer (A4) for the cap nuts (A2).

2 Check the condition of the rocker cover joint (A6) and of the dust seal (A7). If necessary, the joint and the seal can be removed and renewed.

3 Clean the joint face of the cylinder head and fit the rocker cover together with the dust seal.

4 Fit the sealing washers, the steel washers, the shims (if fitted) and the cap nuts.

Caution: Damage to the sealing washer can occur if the cap nut is not tightened centrally through the sealing washer and the rocker cover. If the sealing washer is damaged it must be renewed.

5 Tighten the cap nuts to 20 Nm (15 lbf ft) 2,1 kgf m.

Notes:

• The latest engines have an extra shim washer

(A4) fitted between the cap nut sealing washer and the steel washer for the cap nut. If shim washers are fitted to aluminium rocker covers, tighten the cap nuts to 30 Nm (22 lbf ft) 3,0 kgf m. If shim washers are fitted to composite rocker covers, tighten the cap nuts to 20 Nm (15 lbf ft) 2,1 kgf m.

• Some earlier 1000 Series engines have a rocker

cover joint that has a ribbed bottom face. When this joint is fitted, ensure that the flat face of the joint is towards the rocker cover.

2 3

4 5

PA046

12A.04 Perkins Phaser/1000 Series, April 1995

Page 25

Rocker assembly

To remove and to fit12A-02

To remove 1Remove the rocker cover, operation 12A-01.

2 Release evenly and gradually the fasteners of

the rocker shaft brackets; begin with the end brackets and move toward the centre. Remove the fasteners and the washers and lift off the rocker assembly.

Note: The washers between the fasteners and the rocker brackets have been removed on the latest engines and new flange faced nuts and setscrews have been fitted.

3 Remove the rubber oil seal (A) from the oil supply connection or from the oil supply hole in the cylinder head.

CYLINDER HEAD ASSEMBLY 12

PA047

To fit 1 Fit a new rubber oil seal in the oil supply hole in

the cylinder head. 2 Check that the push rods fit correctly in the

sockets of the tappets. Fit the rocker assembly; ensure that the oil supply connection is fitted correctly into the oil seal. Check that the ends of the adjustment screws fit correctly in the sockets of the push rods.

3 Fit the washers (if fitted) and fasteners of the rocker shaft brackets and tighten the fasteners evenly and gradually; begin with the inner fasteners and work towards the end fasteners. Tighten the fasteners evenly to the correct torque according to the material of the rocker shaft brackets:

Aluminium 40 Nm (30 lbf ft ) 4,1 Kgf m. Cast iron 75 Nm (55 lbf ft) 7,6 Kgf m. Sintered steel 75 Nm (55 lbf ft) 7,6 Kgf m.

Perkins Phaser/1000 Series, April 1995 12A.05

Page 26

12 CYLINDER HEAD ASSEMBLY

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PA048

Rocker assembly

To dismantle and to assemble12A-03

To dismantle 1 Remove the clips from both ends of the rocker

shaft. Ensure that the ends of the rocker shaft are not damaged. Release the location screw (A1) for the oil supply connection.

2 Dismantle the assembly and make a note of the position of each component to ensure that they can be assembled more easily.

To assemble 1 Ensure that the oil holes in the rocker shaft and

in the rocker levers are not restricted. 2 Lubricate the components with clean engine

lubricating oil before assembly. Assemble the components in the correct order (A) and ensure that the location screw (A1) for the oil supply connection is fitted correctly in the rocker shaft. Fit the clips to the ends of the rocker shaft.

3 Ream the bush in the rocker lever to give a clearance on the rocker shaft of 0,03/0,09 mm (0.001/0.004 in). Clean thoroughly the bush and check that the oil hole is free from debris.

Note: The rocker levers used on some low rated engines do not have bushes.

To inspect and to correct12A-04

To inspect 1 Clean and inspect all the components for wear

and any other damage. Check the clearance of the rocker levers on the rocker shaft. If the clearance is larger than 0,13 mm (0.005 in), renew the rocker lever bush and/or the rocker shaft.

To correct 1 To renew the rocker lever bush, press out the

old bush with a suitable mandrel. 2 Align the lubrication hole of the new bush on the

same side as the rocker lever lubrication hole and press the bush into position.

12A.06 Perkins Phaser/1000 Series, April 1995

Page 27

Valve tip clearances

To check and to adjust12A-05

Notes:

• The valve tip clearance is measured between the top of the valve stem and the rocker lever (A). With the engine hot or cold, the correct clearances are 0,20 mm (0.008 in) for the inlet valves and 0,45 mm (0.018 in) for the exhaust valves. The valve positions are shown at (B).

• The sequence of valves from number 1 cylinder is shown in the table below. Number 1 cylinder is at the front of the engine.

Four cylinder engines 1 Rotate the crankshaft in the normal direction of

rotation until the inlet valve (B8) of number 4 cylinder has just opened and the exhaust valve (B7) of the same cylinder has not closed completely. Check the clearances of the valves (B1 and B2) of number 1 cylinder and adjust them, if necessary.

2 Set the valves (B3 and B4) of number 2 cylinder as indicated above for number 4 cylinder. Then check / adjust the clearances of the valves (B5 and B6) of number 3 cylinder.

3 Set the valves (B1 and B2) of number 1 cylinder. Then check / adjust the clearances of the valves (B7 and B8) of number 4 cylinder.

4 Set the valves (B5 and B6) of number 3 cylinder. Then check / adjust the clearances of the valves (B3 and B4) of number 2 cylinder.

CYLINDER HEAD ASSEMBLY 12

PA049

1 2 3 4 5 6 7 8

PA050

Cylinder

and

Valve number

12234356478

Valve

I = Inlet

IEEI IEEI

E = Exhaust

Perkins Phaser/1000 Series, April 1995 12A.07

Page 28

12 CYLINDER HEAD ASSEMBLY

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Six cylinder engines 1 Rotate the crankshaft in the normal direction of

rotation until the inlet valve (A12) of number 6 cylinder has just opened and the exhaust valve (A11) of the same cylinder has not closed completely. Check the clearances of the valves (A1 and A2) of number 1 cylinder and adjust them, if necessary.

2 Set the valves (A4 and A3) of number 2 cylinder as indicated above for number 6 cylinder. Then check / adjust the clearances of the valves (A9 and A10) of number 5 cylinder.

3 Set the valves (A8 and A7) of number 4 cylinder. Then check / adjust the clearances of the valves (A5 and A6) of number 3 cylinder.

4 Set the valves (A1 and A2) of number 1 cylinder. Then check / adjust the clearances of the valves (A11 and A12) of number 6 cylinder.

5 Set the valves (A9 and A10) of number 5 cylinder. Then check / adjust the clearances of the valves (A3 and A4) of number 2 cylinder.

6 Set the valves (A5 and A6) of number 3 cylinder. Then check / adjust the clearances of the valves (A7 and A8) of number 4 cylinder.

PA028

Cylinder

and

Valve number

122343564785910611 12

Valve

I = Inlet

IEEI IEEI IEEI

E = Exhaust

12A.08 Perkins Phaser/1000 Series, April 1995

Page 29

Valve springs

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To change the valve springs (with cylinder head fitted)12A-06

Special tools:

Valve spring compressor, PD.6118B Stud adaptor used with PD.6118B, PD.6118-7 Setscrew adaptor used with PD.6118B, PD.6118-8

Note: Paragraphs 1 to 12 refer to a change of valve springs for a single cylinder.

Warning! Wear eye protection during this operation.

1Remove the rocker cover, operation 12A-01. 2 Rotate the crankshaft in the normal direction of

rotation until the inlet valve of the relevant cylinder has just opened and the exhaust valve has not fully closed. In this position the piston will be at approximately top dead centre (TDC).

3Remove the rocker assembly, operation 12A-02. 4 Fit the valve spring compressor (A1) and the

relevant adaptor (A2 or A3). 5 Compress the valve spring(s) and remove the

collets. Ensure that the valve springs are compressed squarely or damage to the valve stem can occur.

Caution: Do not rotate the crankshaft while the valve springs are removed.

6 Release the valve spring compressor and remove the valve spring caps and valve spring(s).

7 Put the new valve springs in position. If double valve springs are fitted, ensure that the closed damper coils are towards the cylinder head (12A.16/A4).

CYLINDER HEAD ASSEMBLY 12

PA051

Perkins Phaser/1000 Series, April 1995 12A.09

Page 30

12 CYLINDER HEAD ASSEMBLY

8 Fit the valve spring caps. Caution:

compressed squarely or damage can occur to the valve stem.

9 Fit the valve spring compressor, compress the valve springs and fit the collets. Remove the valve spring compressor.

10Fit the rocker assembly, operation 12A-02. 11Check the valve tip clearances, operation

12A-05.

12Fit the rocker cover, operation 12A-01. Note: If other or all of the valve springs are to be

changed, they can be changed two cylinders at a time. The sets of cylinders are:

For 4 cylinder engines: 1 and 4, 2 and 3 For 6 cylinder engines: 1 and 6, 2 and 5, 3 and 4

If the rocker assembly has been removed, piston TDC can be found as follows:

1 Fit the valve spring compressor and compress the valve springs to open the valve.

2 Rotate the crankshaft, by hand, in the normal direction of rotation until the piston touches the valve.

3 Continue to rotate the crankshaft, and at the same time, release pressure on the valve spring compressor until the piston is at TDC (A).

Ensure that the valve springs are

PA052

12A.10 Perkins Phaser/1000 Series, April 1995

Page 31

CYLINDER HEAD ASSEMBLY 12

Cylinder head assembly

To remove and to fit12A-07

To remove 1 Drain the cooling system.

2 Disconnect the battery terminals. 3 Remove the air filter/cleaner hose at the

induction manifold. 4 For engines fitted with turbochargers: Remove

the air filter/cleaner hose at the compressor inlet of the turbocharger.

5 Remove the pipe which is fitted between the fuelled starting aid in the induction manifold and the fuel filter. Disconnect the electrical connection.

6 For engines fitted with a boost control device: Remove the boost control pipe which is fitted between the induction manifold and the top of the fuel injection pump.

7 Remove the induction manifold. 8 For engines fitted with turbochargers: Disconnect

all connections to the turbocharger and remove the turbocharger, operation 18A-01.

9 Remove the exhaust manifold. 10 Remove the low-pressure fuel pipes which are

fitted between the fuel injection pump and the fuel filter.

Note: Where a Bosch fuel injection pump is fitted, keep the fuel outlet banjo bolt with the fuel injection pump.

Remove the fuel pipe fitted between the fuel lift pump and the fuel filter. Remove the fuel filter bracket together with the fuel filter.

11 Remove the high-pressure fuel pipes.

Caution: Where access to the fuel injection pump

outlet unions is possible, ensure that a separate spanner is used to prevent movement of the fuel injection pump outlets when the connections of the high-pressure pipes are released. Fit suitable covers to all open connections on the fuel injection pump.

12 Remove the atomiser leak-off pipe. 13Remove the atomisers, operation 20A-02. Fit

suitable covers to the nozzles and the open connections.

14 If a compressor is fitted: Remove the coolant pipe which is fitted between the cylinder head and the compressor. Then remove the coolant pipe which is fitted between the by-pass connection and the compressor.

15 Release the clip of the coolant by-pass hose at the cylinder head. Release the setscrews and

remove the coolant by-pass connection and the hose.

16 Disconnect the coolant temperature sender unit.

17 For turbocharged and some naturally aspirated four cylinder engines: Remove the oil cooler,

operation 21A-07A.

18Remove the rocker cover, operation 12A-01. 19Remove the rocker assembly, operation

12A-02.

20 Remove the push rods.

Perkins Phaser/1000 Series, April 1995 12A.11

Page 32

12 CYLINDER HEAD ASSEMBLY

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PA055

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21 Release the cylinder head setscrews evenly and gradually in the reverse sequence to that shown in (A or B). Check the setscrews for distortion with a straight edge (C1) held along the setscrew (C2). If there is a visual reduction in the diameter of the thread (C3) that has not been in engagement with the cylinder block, the setscrew must be discarded.

Caution: Do not use a lever to separate the cylinder head from the cylinder block.

22 Remove the cylinder head and put it on a surface that will not damage the face of the cylinder head.

PA053

PA054

12A.12 Perkins Phaser/1000 Series, April 1995

Page 33

To fit

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Special tools:

Angle gauge, to tighten cylinder head setscrews, MS.1531

1 Clean the bottom face of the cylinder head and top face of the cylinder block. Ensure that there is no debris in the cylinder bores.

Note: Certain engines have two location pins (A1), one at each end of the cylinder head, pressed into the cylinder block to hold the cylinder head gasket in the correct position before the cylinder head is fitted.

Caution:

•

To prevent damage to the cylinder head gasket,

ensure that the location pins are

pressed

in the

cylinder block before the cylinder head is fitted.

•

The cylinder head gasket must be fitted without

jointing compound.

2 Put the cylinder head gasket in position; It is stamped "FRONT TOP" for correct assembly (A).

3 To ensure the cylinder head is fitted into the correct position, fit two suitable 1/2 UNF guide studs (B1) in positions 15 and 20 (12A.12/B) or positions 25 and 30 (12A.12/A). Put the cylinder head in position.

4 Lightly lubricate the threads of the cylinder head setscrews and the thrust faces of the setscrew heads. Engage some of the setscrews in their correct positions and remove the guide studs. Engage the remainder of the setscrews in their correct positions.

5 Gradually and evenly tighten the setscrews to 110 Nm (80 lbf ft) 11,1 kgf m in the sequence shown in (12A.12/A or B).

6 Repeat paragraph 5 to ensure that all the setscrews are tightened to the correct torque.

CYLINDER HEAD ASSEMBLY 12

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PA056

PA057

FRONT TOP

Perkins Phaser/1000 Series, April 1995 12A.13

Page 34

12 CYLINDER HEAD ASSEMBLY

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7 Tighten the setscrews, in the correct sequence, a further part of a turn according to the length of the setscrews, see (12A.12/A or B). Short setscrews (S) must be turned a further 150° (2.5 flats). Medium length setscrews (M) must be turned a further 180° (3 flats). Long setscrews (L) must be turned a further 210° (3.5 flats). A special tool (A) can be used for this operation.

Fit the tool between the socket and the handle. Position the stop (A1) against a suitable protrusion on the cylinder head to prevent movement of the degree dial in a clockwise direction. Rotate the pointer to align with the relevant angle on the degree dial for the length of setscrew. Tighten the setscrew until the pointer on the tool is aligned with the zero position on the degree dial.

If no tool is available, make a suitable mark on the cylinder head in line with a corner of each setscrew (B). Make another mark, at the correct angle (counter-clockwise), on the edge of the flange of each fastener according to the length of the setscrew. Tighten each setscrew in the correct sequence until the marks on the flange are next to, and in line with, the marks on the cylinder head.

8 Put the push rods in position. Ensure that the end of each push rod fits correctly in the tappet socket.

9Fit the rocker assembly, operation 12A-01. 10Set the valve tip clearances, operation 12A-05. 11Fit the atomisers, operation 20A-02. 12 Fit the high-pressure fuel pipes; tighten the

connection nuts to 22 Nm (16 lbf ft) 2,2 kgf m.

Caution: Where access to the fuel injection pump outlet unions is possible, ensure that a separate spanner is used to prevent movement of the fuel injection pump outlets when the connections of the high pressure pipes are tightened.

13 Fit the fuel filter and the bracket. Fit the lowpressure fuel pipes between the fuel injection pump and the fuel filter.

14 Fit the coolant by-pass connection; tighten the setscrews and hose clip.

15 If a compressor is fitted: Fit the coolant pipe between the cylinder head and the compressor. Then fit the pipe between the coolant by-pass and compressor.

16 For turbocharged and some naturally aspirated four cylinder engines: Fit the oil cooler, operation

21A-07A.

150°

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180°

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210°

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PA059

12A.14 Perkins Phaser/1000 Series, April 1995

Page 35

17 Fit the exhaust manifold. The manifold joints are

fitted without jointing compound. 18 For engines fitted with turbochargers: Fit the

turbocharger, operation 18A-01. 19 For four cylinder engines: Fit the induction

manifold. Ensure that the manifold joints for the front and rear positions are fitted with the notch at the top left when the manifold is fitted to the cylinder head (A). The manifold joint for the centre position can be fitted either way. Fit the joints without jointing compound.

For six cylinder engines: Fit the induction manifold. Ensure that the joints are fitted with the notch at the top and the straight edge towards the centre (B). Fit the joints without jointing compound. Some of the latest six cylinder engines are fitted with a one piece induction manifold joint.

20 Fit the fuel pipe between the fuel filter and the fuel lift pump.

21 Fit the fuel pipe between the fuel filter and the fuelled starting aid in the induction manifold. Connect the electrical connection to the cold start device.

22 For engines fitted with boost control devices: Fit the boost control pipe between the induction manifold and the top of the fuel injection pump.

23 Fit the electrical connection to the coolant temperature sender unit.

24 Connect the coolant outlet and the hoses for the cab heater. Tighten the clips.

25 Fill the cooling system. 26 Connect the air filter/cleaner. 27 Connect the battery. 28Eliminate air from the fuel system, see section

20.

29 Start the engine and run it at low speed. Check that oil flows from the holes in the rocker levers. If the oil flow is correct, fit the rocker cover, operation

12A-01.

Note: It is not necessary to tighten the cylinder head setscrews again with the engine hot or after a limited period in service.

CYLINDER HEAD ASSEMBLY 12

PA060

PA061

Perkins Phaser/1000 Series, April 1995 12A.15

Page 36

12 CYLINDER HEAD ASSEMBLY

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Valves and valve springs To remove and to fit12A-08

Special tools:

Valve spring compressor, PD.6118B Stud adaptor, PD.6118-7 Setscrew adaptor, PD.6118-8

To remove 1Remove the cylinder head, operation 12A-07.

2 Clean the bottom face of the cylinder head and

check the depth of the heads of the valves below the face of the cylinder head, see operation 12A-09.

3 Make a suitable mark on the heads of the valves to ensure that the valves can be fitted in their original positions, if they are to be used again.

Warning! Wear eye protection during this operation. Caution: Ensure that the valve springs are

compressed squarely or the valve stem can be damaged.

4 Use the valve spring compressor and the relevant adaptor to compress the valve spring(s) and remove the collets.

5 Release the valve spring compressor and remove the valve spring cap, valve spring(s), valve stem seal and the valve seat washer.

6 Repeat items 4 and 5 for the other valves.

4 5

PA062

To fit Note: The components of the valve assembly are

shown in A. Certain engines are fitted with single valve springs.

1 Lubricate the valve stems (A7 and A8) with clean engine oil and fit the valves in their respective guides.

2 Fit the spring seat washers (A6). Fit new valve stem seals (A5) on the valve guides. If double valve springs are used, fit the inner and outer valve springs (A3 and A4) on the spring seat washers with their damper coils toward the cylinder head. If single valve springs are used, the spring does not have a damper coil and it can be fitted with either end to the cylinder head. Fit the valve spring caps (A2).

Warning! Wear eye protection during this operation. Caution: Ensure that the valve springs are

compressed squarely or damage can occur to the valve stem

3 Use the valve spring compressor and the relevant adaptor to compress the valve spring(s) and fit the collets (A1).

12A.16 Perkins Phaser/1000 Series, April 1995

Page 37

To inspect and to correct12A-09

Special tool:

Gauge, valve depth, PD.41D Dial gauge for use with PD.41D, PD.208

1 Check the depth of the valves below the face of the cylinder head before the valve springs are removed.

2 Ensure that the heads of the valves and the bottom face of the cylinder head are clean.

3 Put the valve depth gauge on the face of the cylinder head and zero the dial gauge.

4 Carefully put the valve depth gauge in position over the head of each valve (A) and make a note of the measurement. The maximum depth, in service, is given in the data and dimensions.

5 If a valve is below the depth limit, check the valve depth with a new valve in position. If the valve depth is still below the limit and a valve seat insert is fitted, the insert must be renewed.

6 Where a valve seat insert is not fitted, the bottom face of the cylinder head can be machined to reduce the valve depth, or an insert can be fitted,

operation 12A-14.

Caution: If the bottom face of the cylinder head is to be machined, ensure that the thickness, of the cylinder head will not be less than 102,48 mm (4.035 in) after the cylinder head has been machined.

7 Check the valves for cracks. Check the stems of the valves for wear and for correct fit in their valve guides.

8 Check that the seat faces of the valves are not badly burnt or damaged. Seat faces of valves which are damaged can be ground on a special machine. Valves which have only a little damage can be lapped to their valve seats. When new valves are fitted, the valve depths must be checked, see paragraph 1.

9 Check that the load on the valve springs is correct at their fitted length, see the data and dimensions. Fit new valve springs at every complete engine overhaul.

CYLINDER HEAD ASSEMBLY 12

PA063

Perkins Phaser/1000 Series, April 1995 12A.17

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12 CYLINDER HEAD ASSEMBLY

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Valve guides

To inspect12A-10

To check the valve guides for wear: The maximum clearance (A5), between the valve stem and the bore of the guide is 0,13 mm (0.005 in) for inlet valves and 0,15 mm (0.006 in) for exhaust valves. If the clearance, with a new valve fitted, is more than the limit, then a new valve guide (A4) must be fitted.

It is recommended that the procedure given below is used to check the valve guide clearance:

1 Put a new valve in the valve guide. 2 Put a dial test indicator with a magnetic base

(A1) onto the face of the cylinder head 3 With the valve lifted 15,0 mm (0.6 in) and the

gauge (A2) in contact with the edge of the valve head (A3), move the valve radially away from the gauge. With the valve held in this position, set the gauge zero.

4 Move the valve radially across the axis of the cylinder head towards the gauge. Make a note of the reading on the gauge. If the reading is equal to or greater than the data given below, a new valve guide (A4) must be fitted.

Maximum permissible clearance with a valve lift of 15,0 mm (0.6 in) :

• Inlet guide 0,24 mm (0.009 in)

• Exhaust guide 0,32 mm (0.013)

PA298

12A.18 Perkins Phaser/1000 Series, April 1995

Page 39

CYLINDER HEAD ASSEMBLY 12

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To remove and to fit12A-11

Special tools:

Remover/replacer for valve guides (main tool), PD.1D

Adaptor used with PD.1D, PD.1D-1A Adaptor used with PD.1D and PD.1D-1A, PD.1C-6

To remove 1 Fit the adaptor (A4), PD.1D-1A, into the

remover/replacer tool (A3), PD.1D. 2 With the adaptor fitted to the tool, put the spacer

(A5) in position on the tool. Pass the adaptor through the valve guide and put the spacer and tool in position on the valve seat.

3 Fit the attachment (A7) to secure the adaptor to the valve guide.

4 Hold the top handle (A1) and turn the bottom handle (A2) clockwise to pull the valve guide out of the cylinder head.

To fit 1 Clean the parent bore in the cylinder head for the

valve guide. 2 Lubricate the outer surface of the new valve

guide (B6) with clean engine lubricating oil. 3 Fit the adaptor (B5), PD.1D-1A, into the

remover/replacer tool (B3), PD.1D. 4 With the adaptor fitted to the tool, put the spacer

(B4) in position on the tool. Pass the adaptor through the cylinder head and put the spacer and tool assembly in position on the valve seat.

5 Put the valve guide in position on the adaptor and fit the distance piece (B7), PD.1C-6. Fit the attachment (B8) to secure the valve guide to the adaptor.

6 Hold the top handle (B1) and turn the bottom handle (B2) clockwise to pull the valve guide until the distance piece contacts the cylinder head.

7 When the valve guide is fitted correctly, the top of the valve guide will have a protrusion of 15,10 mm (0.594 in) above the valve spring seat.

PA064

6 7

PA065

Perkins Phaser/1000 Series, April 1995 12A.19

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12 CYLINDER HEAD ASSEMBLY

Cylinder head To inspect and to correct12A-12

1Remove the cylinder head assembly, operation

12A-07.

2 Remove the thermostat housing. 3 Inspect the cylinder head for signs of gas or

coolant leakage. 4 Remove the valve springs and the valves,

operation 12A-08.

5 Clean the face of the cylinder head and the passages for coolant and for lubricating oil. The water jacket can be cleaned with a special solvent which must be used in accordance with the manufacturer's instructions.

6 Test the cylinder head for leaks at the pressure given in the data and dimensions.

7 When the cylinder head is thoroughly clean, check it for cracks. Inspect carefully the areas around the valve seats and around the holes for the atomiser nozzles.

8 The bottom face of the cylinder head can be machined if: there is distortion, see paragraph 9; there are deep scratches; or, for engines without valve seat inserts, the valve depths are below the service limit.

9 Use a straight edge and feeler gauges to check the cylinder head for distortion across and along its bottom face, see the data and dimensions. If the distortion is more than the limit given in the data and dimensions, the bottom face can be machined.

Caution: Remove only the minimum material and ensure that the thickness of the cylinder head will not be less than 102,48 mm (4.035 in) after the cylinder head has been machined.

Notes:

• On AE and YE engines the protrusion of the atomiser nozzle below the bottom face of the cylinder head must not be more than 4,82 mm (0.190 in).

• The nozzle protrusion must be measured with the nozzle seat washer fitted.

Caution: After the cylinder head has been machined the valve seats must be corrected to give the correct valve head depth.Work to the minimum limit to allow for later wear.

10 Check the valve seats for wear and for damage. 11 Before any work is done on the valve seats,

new valve guides must be fitted, operation 12A-11. 12 Where there is little damage, the valve and

valve seat can be lapped. When the valve seats are lapped keep the seat as narrow as possible and ensure that all the compound used to lap the valve and the seat is removed.

13 More badly damaged valve seats can be corrected by use of the cutter tool, operation

12A-13, or new inserts can be fitted, operation 12A-14.

12A.20 Perkins Phaser/1000 Series, April 1995

Page 41

To correct a valve seat with a valve seat cutter12A-13

Special tools:

Cutter for 46° inlet valve seats, MS.281* Cutter for 31° inlet valve seats, MS.642 Cutter for exhaust valve seats, MS.275* Pilot for use with valve seat cutters, MS.150-9.5* Handle set for use with valve seat cutters, MS.67B* *Included in set of adjustable cutters for valve seats,

MS.73

1 Before any work is done on the valve seats, new valve guides must be fitted, operation 12A-11.

2 Fit the pilot in the valve guide and tighten the pilot.

3 Select the relevant cutter. Set the blades of the cutters to the diameter of the valve seat to be cut. Fit the cutter on the pilot and fit the handle (A). Ensure that the cutter is not allowed to fall on to the seat as this can damage the blades.

4 Carefully turn the cutter in a clockwise direction. Remove only the minimum material to ensure a good seat. Keep the seat as narrow as possible.

5 When the seat is cut, remove the cutter and the pilot. Remove any debris from the area of the valve seat and the port.

6 Fit the valve and lightly lap the valve and the seat.

7 Check that the valve depth is within limits, see data and dimensions.

Note: If a valve seat has become too damaged or too worn to correct, a valve seat insert can be fitted, operation 12A-14. Turbocharged engines and some naturally aspirated engines have valve seat inserts fitted as standard and these inserts can be renewed.

CYLINDER HEAD ASSEMBLY 12

PA066

Perkins Phaser/1000 Series, April 1995 12A.21

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12 CYLINDER HEAD ASSEMBLY

To fit valve seat inserts12A-14

1 Remove the valve guide and clean the bore into

which the guide is to be fitted.

2Fit new valve guides, operation 12A-11. 3 With the bore of the new valve guide used as a

pilot, machine the recess in the cylinder head to the dimensions shown in data and dimensions at the end of this section, or machine out the old insert. Remove all debris and clean the insert recess.

4 If the bottom face of the cylinder head has been machined, the insert will have to be surface ground on the back face to ensure that there is no protrusion of the insert above the bottom face of the cylinder head. After the back of the insert has been ground, ensure that the outer edge of the back face has a 0,9/1,3 mm (0.035/0.051 in) chamfer at 30° to the vertical.

5 With the bore of the valve guide used as a pilot, and with the rear face of the insert towards the cylinder head, press in the insert with the valve seat insert tool, see data and dimensions. Do not use a hammer on the insert and do not use lubrication. Use a hydraulic press or a hand press in one continuous movement. Ensure that the bottom of the insert is in contact with the bottom of the recess.

6 Cut the valve seat at an included angle of 88° for 46° valve seats or 118° for 31° valve seats,

operation 12A-13, and lap the valve on to the valve

seat. Ensure that the depth of the valve head below the face of the cylinder head is within the production limits, see data and dimensions. Work as near as possible to the minimum figure to allow for future wear on the valve seat.

12A.22 Perkins Phaser/1000 Series, April 1995

Page 43

CYLINDER HEAD ASSEMBLY 12

Data and dimensions

Note: This information is given as a guide for personnel engaged on engine overhauls. The dimensions

which are shown are those which are mainly used in the factory. The information applies to all engines, unless an engine type code is shown.

Cylinder head

Angle of valve seat:

- Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46° (88° included angle)

- Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46° (88° included angle) or 31° (118° included angle)

Diameter of parent bore for valve guide . . . . . . . . . . . . . . . . . . . . 15,87/15,89 mm (0.6247/0.6257 in)

Leak test pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 kPa (29 lbf/in

Head thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102,79/103,59 mm (4.047/4.078 in)

Minimum permissible thickness after head face has been machined . . . . . . . . . . 102,48 mm (4.035 in)

- AE, YE engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .See operation 12A-12

Inlet valves

Diameter of valve stem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9,46/9,49 mm (0.3725/0.3735 in)

Clearance in valve guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,02/0,10 mm (0.0008/0.0039 in)

Maximum clearance in valve guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,13 mm (0.005 in)

Diameter of valve head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44,86/45,11 mm (1.766/1.776 in)

Angle of valve face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° or 30°

Full length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122,66/123,07 mm (4.829/4.845 in)

Seal arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rubber seal fitted to valve guide

) 2,04 kgf/cm

Depth of valve head below the face of cylinder head AA, AB, AC, AD(1), AG, AH, YA(2), YB, YC: Note: The inlet valve depth for certain engine types fitted with valve seat inserts can vary. The complete

engine number must be given to the distributor when parts are needed.

- Production limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,27/1,60 mm (0.050/0.063 in)

- Service limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,85 mm (0.073 in)

(1) AD vehicle applications fitted with an intercooler . . . . . . . . . . . . . . 1,37/1,68 mm (0.054/0.066 in)

(2) YA engines fitted with original valve seat inserts . . . . . . . . . . . . . . . 1,37/1,68 mm (0.054/0.066 in)

Depth of valve head below the face of cylinder head YD(1):

- Production limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,37/1,68 mm (0.054/0.066 in)

(1) Engine build list YD 80571 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,27/1,60 mm (0.050/0.063 in)

- AE, YE engines:

- Production limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,37/1,62 mm (0.054/0.064 in)

- Production limits (for 30° valves) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,27/1,76 mm (0.050/0.069 in)

- Service limit (for 30° valves) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,01 mm (0.079 in)

Perkins Phaser/1000 Series, April 1995 12A.23

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12 CYLINDER HEAD ASSEMBLY

Exhaust valves

Diameter of valve stem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9,43/9,46 mm (0.371/0.372 in)

Clearance in valve guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,05/0,13 mm (0.002/0.005 in)

Maximum clearance in valve guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,15 mm (0.006 in)

Diameter of valve head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37,26/37,52 mm (1.467/1.477 in)

Angle of valve face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°

Full length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123,07/123,57 mm (4.845/4.865 in)

Seal arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rubber seal fitted to valve guide

Depth of valve head below face of cylinder head AA, AB, AC, AD(1), AG, AH, YA(2), YB, YC: Note: The exhaust valve depth for certain engine types fitted with valve seat inserts can vary. The

complete engine number must be given to the distributor when parts are needed.

- Production limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,28/1,60 mm (0.050/0.063 in)

- Service limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,85 mm (0.073 in)

(1) AD vehicle applications fitted with an intercooler . . . . . . . . . . . . . . . 1,47/1,79 mm (0.058/0.070 in)

(2) YA engines fitted with original valve seat inserts . . . . . . . . . . . . . . . 1,47/1,79 mm (0.058/0.070 in)

Depth of valve head below face of cylinder head AE, YD(1), YE:

- Production limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,47/1,79 mm (0.058/0.070 in)

(1) Engine build list YD 80571 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,28/1,60 mm (0.050/0.063 in)

12A.24 Perkins Phaser/1000 Series, April 1995

Page 45

Maximum permissible distortion of cylinder

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head (A)

CYLINDER HEAD ASSEMBLY 12

Four cylinder engines

A1 . . . . 0,08 mm (0.003 in)

A2 . . . . 0,15 mm (0.006 in)

A3 . . . . 0,15 mm (0.006 in)

Six cylinder engines

A1 . . . . 0,13 mm (0.005 in)

A2 . . . . 0,25 mm (0.010 in)

A3 . . . . 0,25 mm (0.010 in)

Dimensions of recesses for valve seat inserts (B)

Inlet

B1 . . . . 7,19/7,32 mm (0.283/0.288 in)

B2 . . . . 51,22/51,24 mm (2.0165/2.0175 in)

B3 . . . . Radius 0,38 mm (0.015 in) maximum

Exhaust

B1 . . . . 9,52/9,65 mm (0.375/0.380 in)

B2 . . . . 42,62/42,65 mm (1.6780/1.6790 in)

B3 . . . . Radius 0,38 mm (0.015 in) maximum

3 2

2 3

PA067

PA068

Perkins Phaser/1000 Series, April 1995 12A.25

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12 CYLINDER HEAD ASSEMBLY

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Valve seat insert tool (A)

Inlet (for 45° valves)

A1 . . . . . 1,59 mm (0.063 in)

A2 . . . . . 19,05 mm (0.750 in)

A3 . . . . . 6,35 mm (0.250 in)

A4 . . . . . 76,20 mm (3.00 in)

A5 . . . . . 37,26/37,28 mm (1.467/1.468 in)

A6 . . . . . 51,00/51,23 mm (2.008/2.017 in)

A7 . . . . . 0,79 mm (0.031 in)

A8 . . . . . 1,59 mm (0.063 in)

A9 . . . . . 1,59 mm (0.063 in)

A10 . . . . 9,45/9,47 mm (0.372/0.373 in)

Inlet (for 31° valves)

A1 . . . . . 1,59 mm (0.063 in)

A2 . . . . . 19,05 mm (0.750 in)

A3 . . . . . 3,00 mm (0.118 in)

A4 . . . . . 76,20 mm (3.00 in)

A5 . . . . . 35,30/35,60 mm (1.390/1.402 in)

A6 . . . . . 43,94/43,99 mm (1.730/1.732 in)

A7 . . . . . 0,79 mm (0.031 in)

A8 . . . . . 1,59 mm (0.063 in)

A9 . . . . . 1,59 mm (0.063 in)

A10 . . . . 9,45/9,47 mm (0.372/0.373 in)

6 5

PA069

Exhaust (for 45° valves)

A1 . . . . . 1,59 mm (0.063 in)

A2 . . . . . 19,05 mm (0.750 in)

A3 . . . . . 7,92 mm (0.312 in)

A4 . . . . . 76,20 mm (3.00 in)

A5 . . . . . 32,58/32,84 mm (1.283/1.293 in)

A6 . . . . . 42,39/42,62 mm (1,669/1.678 in)

A7 . . . . . 0,79 mm (0.031 in)

A8 . . . . . 1,59 mm (0.063 in)

A9 . . . . . 1,59 mm (0.063 in)

A10 . . . . 9,45/9,47 mm (0.372/0.373 in)

12A.26 Perkins Phaser/1000 Series, April 1995

Page 47

CYLINDER HEAD ASSEMBLY 12

Valve guides

Inside diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9,51/9,56 mm (0.3744/0.3764 in)

Outside diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15,90/15,91 mm (0.6260/0.6265 in)

Interference fit of valve guide in cylinder head . . . . . . . . . . . . . . . . . . 0,03/0,07 mm (0.0012/0.0027 in)

Full length:

- Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57,94 mm (2.281 in)

- Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61,10 mm (2.406 in)

Protrusion from bottom of recess for valve spring . . . . . . . . . . . . . . . . . . . . . . . . 15,10 mm (0.594 in)

Double valve springs - outer

Fitted length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35,8 mm (1.41 in)

Load at fitted length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176/195 N (39.5/43.7 lbf) 18/20 kgf

Number of active coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6

Number of damper coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Direction of coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Left hand - damper coil to cylinder head

Double valve springs - inner

Fitted length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34,0 mm (1.34 in)

Load at fitted length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89/104 N (20/23 lbf) 9/11 kgf

Number of active coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9

Number of damper coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Direction of coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Right hand - damper coil to cylinder head

Single valve springs

Fitted length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40,0 mm (1.57 in)

Load at fitted length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312/344 N (70.1/77.3 lbf) 31,8/35,1 kgf

Number of active coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5

Number of damper coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0

Direction of coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Left hand

Perkins Phaser/1000 Series, April 1995 12A.27

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12 CYLINDER HEAD ASSEMBLY

Tappets

Diameter of tappet stem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18,99/19,01 mm (0.7475/0.7485 in)

Diameter of tappet bore in cylinder block . . . . . . . . . . . . . . . . . . . 19,05/19,08 mm (0.7500/0.7512 in)

Clearance of tappet in cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . 0,04/0,09 mm (0.0015/0.0037 in

Rocker shaft

Outside diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19,01/19,04 mm (0.7485/0.7495 in)

Rocker levers and bushes

Diameter of parent bore for bush . . . . . . . . . . . . . . . . . . . . . . . . . 22,23/22,26 mm (0.8750/0.8762 in)

Outside diameter of bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22,28/22,31 mm (0.8770/0.8785 in)

Interference fit of bush in rocker lever . . . . . . . . . . . . . . . . . . . . . 0,020/0,089 mm (0.0008/0.0035 in)

Internal diameter of fitted bush when reamed . . . . . . . . . . . . . . . . 19,06/19,10 mm (0.7505/0.7520 in)

Clearance between rocker lever bush and rocker shaft . . . . . . . . . . . . 0,03/0,09 mm (0.001/0.0035 in)

Maximum permissible clearance between

rocker lever bush and rocker shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,13 mm (0.005 in)

12A.28 Perkins Phaser/1000 Series, April 1995

Page 49

PISTON AND CONNECTING ROD ASSEMBLIES 13

Piston and connecting rod assemblies13

General description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A.02

Big end bearing

13A-01To remove and to fit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A.03

13A-02To inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A.04

Piston and connecting rod assembly

13A-03To remove and to fit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A.05

13A-03ATo check the piston height above the cylinder block. . . . . . . . . . 13A.08

13A-03BTo check the height grade of a Fastram piston. . . . . . . . . . . . . . 13A.09

Piston rings

13A-04To remove and to fit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A.10

Piston and connecting rod assembly

13A-05To dismantle and to assemble. . . . . . . . . . . . . . . . . . . . . . . . . . 13A.11

Piston and piston rings

13A-06To inspect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A.12

Connecting rod

13A-07To inspect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A.13

Small end bush

13A-08To remove and to fit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A.13

Piston cooling jets

13A-09To remove and to fit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A.14

13A-10To check the jet alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A.14

Data and dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A.15

Perkins Phaser/1000 Series, April 1995 13A.01

Page 50

13 PISTON AND CONNECTING ROD ASSEMBLIES

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PA072

General description

The pistons used in Phaser and 1000 Series engines have either a "Quadram" (A) or a "Fastram" (B) combustion chamber in the top of the piston. These combustion chambers are designed to give an efficient mix of fuel and air.

The latest engines have pistons, with a "Fastram" combustion chamber and are available with different height grades.

The pistons have two compression rings and an oil control ring. The groove for the top ring has a hard metal insert to reduce wear of the groove. Axial location of the fully floating gudgeon pin is by circlips.

Expansion controlled pistons have a steel insert in the piston skirt.

Turbocharged engines which are rated higher than 2300 rev/min have an anodised area on the top face of the piston.

Turbocharged engines have cooling jets fitted in the cylinder block to spray lubricating oil onto the inner surface of the pistons.

The connecting rods are machined from "H" section forgings of molybdenum steel. The connecting rods of turbocharged engines have wedge shaped small ends. Generally, the location of the bearing caps to the connecting rods is made by serrations (C1) and the cap is retained by two nuts and bolts (C).

On some turbocharged engines, used in vehicle applications, the location of the bearing cap to the connecting rod is made by dowels (D1) fitted in the bearing cap (D). The faces of these connecting rods and caps are flat and the caps are retained by two setscrews.

Note: Always use the engine identification number to order new parts.

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FRONT

PA070

PA071

13A.02 Perkins Phaser/1000 Series, April 1995

PA073

Page 51

PISTON AND CONNECTING ROD ASSEMBLIES 13

Big end bearing To remove and to fit13A-01

To remove 1 Drain the engine lubricating oil.

2Remove the lubricating oil sump, operation

19A-03.

3 Remove the lubricating oil strainer and suction pipe, operation 19A-04 or remove the balancer unit,

operation 14A-10.

4 Rotate the crankshaft until the relevant connecting rod is at its lowest position.

5 Release the nuts and remove the bearing cap. Remove the bolts from the connecting rod. If the bearing cap is retained by setscrews, the location of the bearing cap will be by two dowels. To remove these bearing caps, release the setscrews by approximately four rotates. Lightly hit the heads of the setscrews with a soft face hammer to separate the connecting rod from the bearing cap. Remove the setscrews and the bearing cap.

6 Remove the lower half of the shell bearing from the cap, but keep it with its relevant cap.

7 Carefully push the connecting rod up the cylinder bore just enough to allow access to the upper half of the shell bearing. Remove the bearing from the connecting rod. Keep the bearings from the connecting rod and cap together.

Caution: Do not allow the connecting rod to hit the piston cooling jet, if fitted.

Perkins Phaser/1000 Series, April 1995 13A.03

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13 PISTON AND CONNECTING ROD ASSEMBLIES

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To fit 1 Clean the bearing faces of the connecting rod

and the crank pin. 2 If the cap has dowels for location on the

connecting rod, ensure that the dowel protrusion is 3,0/4,5 mm (0.12/0.18 in) above the cap faces. Clean the complete bearing and lubricate the bearing surface and the crank pin with clean engine lubricating oil. Fit the upper half of the shell bearing to the connecting rod; ensure that the location tag is fitted correctly in its recess (A1). Fit the connecting rod to the crank pin; ensure that the assembly number on the connecting rod is on the same side as the other connecting rods.

3 Clean, lubricate and fit the lower half of the shell bearings into the cap; ensure that the location tag is fitted correctly in its recess (A1). Fit the connecting rod bolts with the flat side of the head of the bolts towards the connecting rod. Fit the cap to the connecting rod. Ensure that the assembly number on the cap is the same as that on the connecting rod and that both of the assembly numbers are on the same side (B).

4 Tighten the fasteners gradually and evenly to the recommended torque of 155 Nm (114 lbf ft) 15,8 kgf m for setscrews, or 125 Nm (92 lbf ft) 12,7 kgf m for nuts.

5 Ensure that the crankshaft rotates freely. 6 Fit the lubricating oil strainer and suction pipe,

operation 19A-04 or fit the balancer unit, operation 14A-10.

7Fit the lubricating oil sump, operation 19A-03 and fill the sump to the correct level with lubricating oil of an approved grade.

PA074

PA075

To inspect13A-02

Check the bearings and the crank pin for wear or other damage.

13A.04 Perkins Phaser/1000 Series, April 1995

Page 53

PISTON AND CONNECTING ROD ASSEMBLIES 13

Piston and connecting rod To remove and to fit13A-03

To remove 1 Drain the lubricating oil and the cooling system.

2Remove the cylinder head assembly, operation

12A-07.

3 Remove all carbon from the top of the bores of the cylinder liners.

4Remove the lubricating oil sump, operation

19A-03.

5 Remove the lubricating oil strainer and suction pipe, operation 19A-04, or remove the balancer unit, operation 14A-10.

6 Remove the big end caps and the big end bearings from the connecting rods, operation

13A-01.

Caution: Do not allow the connecting rods to hit the piston cooling jets, if fitted. If a cooling jet is hit, check its alignment, operation 13A-10, and renew it, if necessary.

7 Turn the connecting rods 90° to prevent contact with the piston cooling jets. Push the pistons and the connecting rods out through the top of the cylinder liners. Keep the bearings and caps together to ensure that they can be fitted in their original positions.

8 Inspect the crank pins for damage.

Perkins Phaser/1000 Series, April 1995 13A.05

Page 54

13 PISTON AND CONNECTING ROD ASSEMBLIES

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To fit

Special tools:

Piston replacer tool, PD.206

1 Ensure that the piston, the cylinder bore, the crank pin and the big end of the connecting rod are clean. Lubricate the piston and the cylinder liner with clean engine lubricating oil.

2 Rotate the crankshaft until the relevant crank pin is at its lowest position. Lubricate the crank pin with clean engine lubricating oil.

3 Fit the upper half of the shell bearings to the connecting rod. Ensure that the location tag is fitted correctly in its recess. Lubricate the bearing with clean engine lubricating oil.

4 Put the piston replacer tool in position at the top of the relevant cylinder. The tool has a tapered bore to compress the piston rings when the piston and connecting rod assembly is fitted. Ensure that the smaller end of the tapered bore is towards the face of the cylinder block.

5 Put the piston ring gaps 120° apart. Pass the connecting rod through the piston replacer tool and allow the piston to enter the tool. The arrow or "FRONT" mark on the top of the piston must be towards the front of the engine. In this position the combustion bowl in the top of the piston will be towards the fuel injection pump side of the engine.

6 Push the piston and connecting rod assembly through the piston replacer tool (A) and onto the crank pin. If piston cooling jets are fitted, the piston and connecting rod assembly must be rotated to ensure that the connecting rod will not hit the piston cooling jet as the assembly is fitted. When the connecting rod has passed the piston cooling jet, rotate the connecting rod until the arrow or "FRONT" mark on top of the piston is towards the front of the engine (B).

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FRONT

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PA076

PA077

13A.06 Perkins Phaser/1000 Series, April 1995

Page 55

PISTON AND CONNECTING ROD ASSEMBLIES 13

7 Clean the connecting rod cap and the lower half of the shell bearings. Fit the bearing to the cap; ensure that the location tag is fitted correctly in its recess. Lubricate the bearing with clean engine lubricating oil. Fit the cap and ensure that the assembly number is the same as that on the connecting rod and that the numbers are on the same side. Fit the fasteners; ensure that the flat side of the head of the bolts is towards the connecting rod. When the fasteners are nuts, new nuts must be fitted. Tighten the fasteners gradually and evenly to the recommended torque of 155 Nm (114 lbf ft) 15,8 kgf m for setscrews, or 125 Nm (92 lbf ft) 12,7 kgf m for nuts.

8 Check that the crankshaft will rotate freely. 9 Check the piston height above the top face of

the cylinder block, operation 13A-05. 10 Fit the lubricating oil strainer and suction pipe,

operation 19A-04 or fit the balancer unit, operation 14A-10.

11Fit the lubricating oil sump, operation 19A-03. 12Fit the cylinder head assembly, operation

12A-07.

13 Fill the sump to the correct level with lubricating oil of an approved grade.

14 Fill the cooling system.

Perkins Phaser/1000 Series, April 1995 13A.07

Page 56

13 PISTON AND CONNECTING ROD ASSEMBLIES

To check the piston height above the cylinder block13A-03A

Special tools:

Piston height tool, PD.41D Dial gauge for use with PD.41D, PD.208

Put the piston height tool on the face of the cylinder block and rotate the gauge dial to the zero position. Rotate the crankshaft until the piston is approximately at top dead centre (TDC). Carefully put the tool over the top of the piston with the plunger of the gauge in contact with the piston above the axis of the gudgeon pin (A). Rotate the crankshaft to ensure that the piston is at the highest position and make a note of the gauge indication.

For engines fitted with "Quadram" pistons, the piston height above the face of the cylinder block should be 0,14/0,36 mm (0.005/0.014 in).

For engines fitted with "Fastram" pistons, grades A to L, the piston height above the top face of the cylinder block should be 0,38/0,50 mm (0.015/0.020 in)

Notes:

• Two "Quadram" piston heights can be used in

the factory: "H" - high, "L" - low. In service only "L" pistons are supplied. If an "L" piston is used instead of an "H" piston, the height may be up to 0,19 mm (0.0075 in) below the bottom limit.

• The top of the piston should not be machined.

• If the original piston is used, ensure that it is

assembled to the correct connecting rod and is used in the original cylinder.

PA078

13A.08 Perkins Phaser/1000 Series, April 1995

Page 57

PISTON AND CONNECTING ROD ASSEMBLIES 13

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To check the height grade of a "Fastram" piston13A-03B

For engines fitted with earlier "Fastram "pistons there are five height grades (A to E) of piston in production and in service.

The latest "Fastram" pistons are supplied in six height grades (F to L) in production and in service. Identification of the height grade is by the letter for each piston which is stamped on the top of the piston (A). The letter A or F is the highest grade and letter E or L is the lowest grade. The difference between the grades is 0,045 mm (0.0018 in).

If a new piston is fitted, ensure that it is of the correct height grade. The height grade can be checked by measurement, from the centre of the gudgeon pin to the top of the piston (B1). The dimensions for each grade are listed in the table below:

Piston grade

letter

Piston height

dimension

(mm)

Latest

equivalent

grade

A B C D

E F G H J K L

PA079

A* 70,334 G B* 70,289 H C* 70,244 J D* 70,199 K E* 70,154 L

F 70,391 G 70,345 H 70,299

J 70,253

K 70,207

L 70,161

* Earlier engines Note: The earlier piston grades A to E are now not

supplied as a part. The latest equivalent grades G to L shown in the table above are to be used instead.

Piston rings

To remove and to fit13A-04

PA080

The piston used in the Phaser and 1000 Series engines have two compression rings and an oil control ring. All the piston rings are above the gudgeon pin. Piston rings have different design features. To ensure that the correct type is obtained always use the engine identification number to order new parts.

Perkins Phaser/1000 Series, April 1995 13A.09

Page 58

13 PISTON AND CONNECTING ROD ASSEMBLIES

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PA084

Caution: Only expand the ring gaps enough to ensure that the ends of the rings do not damage the piston when the ring is removed or put into position.

To remove

Remove the piston rings with a suitable ring expander. Keep the rings with their relevant piston.

To fit

Use a suitable piston ring expander to fit the piston rings.

1 Fit the spring of the oil control ring in the bottom groove with the latch pin inside both ends of the spring (A). Fit the oil control ring over the spring (B2, C2 or D3). Ensure that the ring gap is at 180° to the latch pin.

2 Fit the cast iron ring with the taper face (B1 or C1) to the second groove with the word "TOP", or the manufacturer's symbol, towards the top of the piston.

New second rings have a green identification mark which must be on the left of the ring gap when the ring is fitted and the piston is upright.

The second ring on some engines has an outside step (D2) at the bottom of the tapered face.

3 Fit the chromium plated top ring, the manufacturer's symbol or the word 'TOP' must be towards the top of the piston.

New top rings have a red or blue identification mark which must be on the left of the ring gap when the ring is fitted and the piston is upright.

The top ring on some engines has an internal step (D1) on the top face.

4 Ensure that the ring gaps are 120° apart.

PA081

PA082

PA083

13A.10 Perkins Phaser/1000 Series, April 1995

Page 59

PISTON AND CONNECTING ROD ASSEMBLIES 13

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Piston and connecting rod assembly To dismantle and to assemble13A-05

To dismantle 1Remove the piston rings, operation 13A-04.

2 Remove the circlips which retain the gudgeon

pin. 3 Put a mark on the piston to indicate the cylinder

number as shown on the connecting rod. Put the mark on the piston on the same side as the mark on the big end to ensure that they are assembled correctly (A).

4 Push the gudgeon pin out by hand. If the gudgeon pin is tight, heat the piston to 40/50°C (100/120°F) for easy removal of the gudgeon pin.

To assemble 1 Clean the bore of the small end bush and

lubricate it with clean engine lubricating oil. 2 Fit a new circlip in the circlip groove of one of

the gudgeon pin bosses. Ensure that it fits correctly in the groove.

3 With the piston upside down, put the connecting rod in position with the recess for the location of the big end bearing (B1) on the same side as the lug on the gudgeon pin boss (B2). If the original piston is used, ensure that it is assembled to the correct connecting rod and is used in the original cylinder. Engines with "Fastram" pistons have six piston height grades, if a new piston is fitted, ensure that it is of the correct height grade, see

operation 13A-03.

4 Lubricate the gudgeon pin bosses with clean engine lubricating oil and push in the gudgeon pin towards the circlip. If the gudgeon pin is a tight fit in the piston, heat the piston to 40/50°C (100/120°F) before the gudgeon pin is fitted.

5 Fit a new circlip in the groove in the other gudgeon pin boss. Ensure that it fits correctly in the groove.

6Fit the piston rings, operation 13A-04.

PA085

PA086

Perkins Phaser/1000 Series, April 1995 13A.11

Page 60

13 PISTON AND CONNECTING ROD ASSEMBLIES

Piston and piston rings

To inspect13A-06

1 Check the piston for wear and other damage. 2 Check that the piston rings are free to move in

their grooves and that the the rings are not broken. 3Remove the piston rings, operation 13A-04, and

clean the piston ring grooves and the piston rings. 4 Fit new piston rings in the grooves and check for

wear of the grooves with feeler gauges (A). Compare the piston ring clearance in the groove to that given for new components in the data and dimensions and renew the piston, if necessary.

Note: Some pistons have a tapered top groove and the piston ring is wedge shaped (13A.10 C/D); when this occurs the top piston ring clearance cannot be checked by this method.

5 Clean all carbon from the top of the cylinder liners. Fit the piston rings in the top part of the cylinder liner and measure the ring gap with feeler gauges (B). The coil spring must be fitted to the oil control ring when the gap of this piston ring is measured. The piston ring gaps for new components are given in the data and dimensions.

PA087

PA088

13A.12 Perkins Phaser/1000 Series, April 1995

Page 61

PISTON AND CONNECTING ROD ASSEMBLIES 13

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Connecting rod To inspect13A-07

1 Check the connecting rod for distortion (A). Note: The large and small end bores must be

square and parallel with each other within the limits of +/- 0,25 mm (0.010 in) measured 127 mm (5.0 in) each side of the connecting rod axis on a test mandrel. With the small end bush fitted, the limits are reduced to +/- 0,06 mm (0.0025 in).

2 Check the small end bush for wear or for other damage and renew it, if necessary.

3 Check the fit of the gudgeon pin in the small end bush and check the gudgeon pin for wear, see the data and dimensions.

Small end bush To remove and to fit13A-08

1 Press out the old bush with a suitable adaptor. 2 Clean the connecting rod bore and remove any

sharp edges. 3 Press in the new bush. Ensure that the

lubrication hole in the bush is on the same side as, and is aligned with, the hole in the top of the connecting rod.

4 Ream the bush to get the correct clearance between the gudgeon pin and the bush, see the data and dimensions.

Note: On turbocharged engines the small end is wedge shaped. After the small end bush has been fitted, machine the bush to the shape of the small end and remove any sharp edges.

L ±0,25mm

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127mm

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(5in)

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127mm

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(5in)

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L ±0,25mm

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(0.010in)

PG009

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Perkins Phaser/1000 Series, April 1995 13A.13

Page 62

13 PISTON AND CONNECTING ROD ASSEMBLIES

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Piston cooling jets

To remove and to fit13A-09

To remove

Release the valve assembly and remove the piston cooling jet assembly (A).

Note: The crankshaft is removed in A to show clearly the piston cooling jet.

To fit 1 Check that the ball moves freely against spring

pressure in the valve assembly and that the jet tube is not damaged. Renew the valve assembly and/or the body as necessary.

2 Fit the piston cooling jet; ensure that the assembly is fitted correctly on the dowel in the cylinder block. Tighten the valve assembly to 20 Nm (15 lbf ft) 2,0 kgf m.

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14mm

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(0.5in)

33mm

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(1.3in)

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PA089

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21mm

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(0.8in)

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To check the jet alignment13A-10

Insert a 1,70 mm (0.067 in) diameter rod, of suitable length, into the jet. If a suitable rod is not available, reduce the end of a thicker rod to 1,70 mm (0.067 in) diameter for a length of 16,00 mm (0.630 in). When the rod is inserted into the jet it must extend out of the top of the cylinder within the area shown in B.

PA090

13A.14 Perkins Phaser/1000 Series, April 1995

Page 63

PISTON AND CONNECTING ROD ASSEMBLIES 13

Data and dimensions

Note: This information is given as a guide for personnel engaged on engine overhauls. The dimensions

which are shown are those which are mainly used in the factory. The information applies to all engines, unless an engine type code is shown.

Pistons - Naturally aspirated engines:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . "Quadram" combustion bowl, controlled

expansion, inserted top ring groove

Diameter of bore for gudgeon pin . . . . . . . . . . . . . . . . . . . . . . 34,928/34,934 mm (1.3751/1.3754 in)

Height of piston above top face of cylinder block . . . . . . . . . . . . . . . . . . 0,14/0,36 mm (0.005/0.014 in)

Width of groove for top ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,57/2,59 mm (0.101/0.102 in)

Width of groove for second ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,55/2,57 mm (0.100/0.101 in)

Width of groove for third ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,03/4,06 mm (0.1587/0.1598 in)

Pistons - Turbocharged engines:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . "Quadram" combustion bowl, controlled expansion,

inserted top ring groove, reduced diameter top land

Diameter of bore for gudgeon pin . . . . . . . . . . . . . . . . . . . . . . . 38,103/38,109 mm (1.500/1.5004 in)

Height of piston above top face of cylinder block . . . . . . . . . . . . . . . . . . 0,14/0,36 mm (0.005/0.014 in)

Width of groove for top ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tapered

Width of groove for second ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,56/2,58 mm (0.1008/0.1016 in)

Width of groove for third ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,04/4,06 mm (0.1591/0.1598 in)

Pistons - Turbocharged AE, YE, AD* engines:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . "Fastram" combustion bowl, controlled expansion,

inserted top ring groove, high top ring groove

Diameter of bore for gudgeon pin . . . . . . . . . . . . . . . . . . . . . 39,7003/39,7009 mm (1.5355/1.5358 in)

Difference between height grades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,046 mm (0.0018 in)

Height of piston above top face of cylinder block . . . . . . . . . . . . . . . . . 0,38/0,50 mm (0.015/0.020 in)

Width of groove for top ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tapered

Width of groove for second ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,56/2,58 mm (0.1008/0.1016 in)

Width of groove for third ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,04/4,06 mm (0.1591/0.1598 in)

Piston cooling jets - Turbocharged engines:

Valve open pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178/250 kPa (26/36 lbf/in

) 1,8/2,6 kgf/cm

* 110 Ti and 135 Ti AD lists are fitted with pistons which are designed for use in emission controlled areas. Some of these pistons are non-expansion controlled.

Perkins Phaser/1000 Series, April 1995 13A.15

Page 64

13 PISTON AND CONNECTING ROD ASSEMBLIES

Piston rings - Naturally aspirated engines:

Top compression ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Barrel face, molybdenum insert, with

a chamfer at the top of the inner face

Second compression ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Taper face, cast iron

Oil scraper ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coil spring loaded, chromium faced

Width of top ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,48/2,49 mm (0.097/0.098 in)

Width of second ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,48/2,49 mm (0.097/0.098 in)

Width of third ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,98/3,99 mm (0.1566/0.1571 in)

Clearance of top ring in groove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,08/0,11 mm (0.003/0.004 in)

Clearance of second ring in groove . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,06/0,09 mm (0.002/0.003 in)

Clearance of third ring in groove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,04/0,08 mm (0.002/0.003 in)

Gap of top ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,40/0,85 mm (0.016/0.033 in)

Gap of second ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,30/0,76 mm (0.012/0.030 in)

Gap of third ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,38/0,84 mm (0.015/0.033 in)

Piston rings - Turbocharged engines:

Top compression ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Barrel face, molybdenum insert, wedge

Second compression ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Taper face, cast iron

Oil scraper ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coil spring loaded, chromium face

Width of top ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wedge

Width of second ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,48/2,49 mm (0.097/0.098 in)

Width of third ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,98/3,99 mm (0.156/0.157 in)

Clearance of top ring in groove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wedge

Clearance of second ring in groove . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,07/0,11 mm (0.003/0.004 in)

Clearance of third ring in groove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,05/0,08 mm (0.002/0.003 in)

Gap of top ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,35/0,80 mm (0.014/0.031 in)

Gap of top ring with internal step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,35/0,70 mm (0.014/0.028 in)

Gap of second ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,30/0,76 mm (0.012/0.030 in)

For second rings with outside step . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,40/0,85 mm (0.016/0.033 in)

Gap of third ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,38/0,84 mm (0.015/0.033 in)

13A.16 Perkins Phaser/1000 Series, April 1995

Page 65

PISTON AND CONNECTING ROD ASSEMBLIES 13

Connecting rods - Naturally aspirated engines:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 'H' section, square shape small end

Location of cap to connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Serrations

Diameter of parent bore for big end . . . . . . . . . . . . . . . . . . . . . . . 67,21/67,22 mm (2.6460/2.6465 in)

Diameter of parent bore for small end . . . . . . . . . . . . . . . . . . . . . . . 38,89/38,92 mm (1.531/1.532 in)

Length between centres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219,05/219,10 mm (8.624/8.626 in)

Connecting rods - Turbocharged engines:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 'H' section, wedge shape small end

Location of cap to connecting rod:

- Vehicle applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flat joint face with dowels

- Non-vehicle applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Serrations

Diameter of parent bore for big end . . . . . . . . . . . . . . . . . . . . . . . 67,21/67,22 mm (2.6460/2.6465 in)

Diameter of parent bore for small end . . . . . . . . . . . . . . . . . . . . . . . 42,07/42,09 mm (1.656/1.657 in)

Length between centres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219,05/219,10 mm (8.624/8.626 in)

Connecting rod bearings

Type:

- Naturally aspirated engines: . . . . . . . . . . . . . . . . . . . . . . . Steel back, aluminium/tin bearing material

- Turbocharged engines: . . . . . . . . . . . . . . . . Steel back, lead bronze bearing material with lead finish

Width:

- Naturally aspirated engines: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31,62/31,88 mm (1.245/1.255 in)

- Turbocharged engines: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31,55/31,88 mm (1.240/1.255 in)

Thickness at centre of bearings:

- Naturally aspirated engines: . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,835/1,842 mm (0.0723/0.0725 in)

- Turbocharged engines: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,835/1,844 mm (0.0723/0.0726 in)

Bearing clearance:

- Naturally aspirated engines: . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,035/0,081 mm (0.0014/0.0032 in)

- Turbocharged engines: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,030/0,081 mm (0.0012/0.0032 in)

Available undersize bearings . . . . . . . -0,25 mm (-0.010 in); -0,51 mm (-0.020 in); -0,76 mm (-0.030 in)

Perkins Phaser/1000 Series, April 1995 13A.17

Page 66

13 PISTON AND CONNECTING ROD ASSEMBLIES

Gudgeon pins - Naturally aspirated engines:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fully floating

Outside diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34,920/34,925 mm (1.3748/1.3750 in)

Clearance fit in piston boss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,003/0,014 mm (0.0001/0.0006 in)

Gudgeon pins - Turbocharged engines:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fully floating

Outside diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38,095/38,100 mm (1.4998/1.5000 in)

- AE, YE and 110 Ti and 135 Ti AD lists . . . . . . . . . . . . . . . . . . 39,694/39,700 mm (1.5628/1.5630 in)

Clearance fit in piston boss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,003/0,014 mm (0.0001/0.0006 in)

Small end bushes - Naturally aspirated engines:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steel back, lead-bronze or lead-bronze tin bearing material

Outside diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38,94/39,03 mm (1.535/1.536 in)

Inside diameter (reamed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34,94/34,96 mm (1.3758/1.3765 in)

Clearance between bush in small end and gudgeon pin . . . . . . . . . 0,020/0,043 mm (0.0008/0.0017 in)

Small end bushes - Turbocharged engines:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steel back, lead bronze bearing material

- AE, YE, and certain AD lists* . . . . . . . . . . . . . . . . . . . . . Steel back, lead bronze tin bearing materials

Outside diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42,16/42,19 mm (1.6600/1.6613 in)

Inside diameter (reamed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38,12/38,14 mm (1.5008/1.5015 in)

- AE, YE and certain AD lists* . . . . . . . . . . . . . . . . . . . . . . . . . . 39,719/39,738 mm (1.5637/1.5645 in)

Clearance between bush in small end and gudgeon pin . . . . . . . . . 0,020/0,043 mm (0.0008/0.0017 in)

- AE, YE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,010/0,035 mm (0.0004/0.0014 in)

Certain AD lists * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,023/0,044 mm (0.0009/0.0017 in)

*AD lists which are subject to emission legislation

13A.18 Perkins Phaser/1000 Series, April 1995

Page 67

CRANKSHAFT ASSEMBLY 14

Crankshaft assembly14

General description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14A.03

Crankshaft pulley

14A-01ATo remove and to fit - four cylinder engine types. . . . . . . . . . . . 14A.04

Crankshaft pulley and damper

14A-01BTo remove and to fit - six cylinder engine types . . . . . . . . . . . . . 14A.05

14A-01CTo inspect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14A.07

Rear oil seal assembly

14A-02ATo remove and to fit - engines which have the standard seal. . . 14A.08 14A-02BTo remove and to fit - engines which have a flywheel housing

that is oil filled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14A.09

14A-03ATo renew the rear oil seal - engines which have the standard seal14A.11 14A-03BTo renew the rear oil seals - engines which have a flywheel housing

that is oil filled. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14A.12

Thrust washers

14A-04To check crankshaft end-float. . . . . . . . . . . . . . . . . . . . . . . . . . 14A.14

14A-05To remove and to fit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14A.15

Main bearings

14A-06To remove and to fit (with the crankshaft in position). . . . . . . . . 14A.16

14A-07To inspect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14A.17

Crankshaft

14A-08To remove and to fit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14A.18

14A-09To inspect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14A.21

Continued

Perkins Phaser/1000 Series, April 1995 14A.01

Page 68

14 CRANKSHAFT ASSEMBLY

Balancer unit

14A-10To remove and to fit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14A.22

14A-11To dismantle and to assemble. . . . . . . . . . . . . . . . . . . . . . . . . . 14A.23

14A-12To inspect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14A.28

14A-13To remove and to fit the needle roller bearings for the drive shaft14A.29

14A-14To remove and to fit the bushes for the balance weights. . . . . . . 14A.30

Data and dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14A.31

14A.02 Perkins Phaser/1000 Series, April 1995

Page 69

General description

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CRANKSHAFT ASSEMBLY 14

The crankshaft is a chrome-molybdenum forging which has five main journals for four cylinder engines and seven main journals for six cylinder engines.

End-float is controlled by two half thrust washers on both sides of the centre main bearing.

The main bearings have steel backs with a aluminium/tin bearing material except the centre main bearing of six cylinder engines, which has a bearing material of lead bronze with a lead finish. The main bearing caps are made of cast iron or spheroidal graphite (SG) iron.

Note: The bearing material of all the main bearings used on Phaser 210Ti engines is lead bronze with a lead finish.

The front and the rear oil seals are Viton lip seals with a dust lip to the outside of the main lip and with oil return grooves on the face of the main lip. Engines which have a flywheel housing that is oil filled have an arrangement which uses two "Viton" lip seals. These seals are narrower than the standard seal and are fitted back to back on the crankshaft palm. They do not have a dust lip.

Warning! Read the safety precautions for "Viton" seals on page 10A.08.

The crankshaft pulley of the four cylinder engine, usually fitted without a damper, is held in position by a plain thrust block and three setscrews. The nose of the crankshaft is serrated for location.

The location of the front pulley of six cylinder engines is by a key in the crankshaft nose and the pulley is held in position by a tapered rings arrangement (A).

An integral damper, with a rubber insert (A6) is built into the pulley of early six cylinder engines and some four cylinder engines. Later six cylinder vehicle engines have a separate plate damper which has an outer plate (B2), bonded by a rubber insert (B1) to an inner plate (B3) and fastened to the rear face of the crankshaft pulley. The latest six cylinder engines have a viscous damper (C2) which is fastened to the front or rear face of the pulley (C1). All of the dampers are designed for the suppression of torsional vibrations in the engine crankshaft.

A balancer unit is fitted to certain four cylinder engines which have rigid mountings or which are part of the chassis or frame. The purpose of the balancer unit is to reduce the effect of the out-of-balance forces to an acceptable condition.

PA093

PA094

PA165

Perkins Phaser/1000 Series, April 1995 14A.03

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14 CRANKSHAFT ASSEMBLY

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Crankshaft pulley

To remove and to fit - four cylinder engines14A-01A

On certain engines a water immersion seal (A) is fitted to the timing case cover, see operation

15A-02. The water immersion seal has a flexible

front lip that protrudes onto the boss of the crankshaft pulley. The plastic mandrel (A1) supplied with the seal must be fitted to the seal immediately the crankshaft pulley is removed. This will ensure that the front lip of the seal will retain its correct shape. If the mandrel is not available, use the seal adaptor PD.170-8 which is part of the seal replacer tool PD.170.

To remove 1Remove the drive belt(s), operation 23A-04.

2 Release the three setscrews which hold the

pulley and remove the setscrews, the thrust block and the pulley.

3 Clean the components and check for damage. Renew damaged components.

To fit 1 Put the pulley in position on the crankshaft.

Lubricate lightly the threads of the setscrews with engine lubricating oil. Lubricate the main lip of the seal with clean engine oil. Fit the hub and the setscrews and tighten the setscrews gradually and evenly to 115 Nm (85 lbf ft) 11,8 kgf m.

2 Check each setscrew again to ensure that they are still to the correct torque.

3Fit the drive belt(s), operation 23A-04.

PA128

14A.04 Perkins Phaser/1000 Series, April 1995

Page 71

Crankshaft pulley and damper

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To remove and to fit - six cylinder engines 14A-01B

Consumable products: POWERPART Retainer (oil tolerant)

Caution: A viscous damper (C2) should be renewed if there is impact damage to the outer casing or if there is leakage of the viscous fluid from the cover plate. Check the area around the holes for the damper fasteners for damage.

To remove

CRANKSHAFT ASSEMBLY 14

PA097

1Remove the drive belts, operation 23A-04.

Warning! The crankshaft pulley and damper

assembly is heavy and must be given support before removal.

2 Release the fasteners which secure the clamp ring (C3) for the damper to the pulley, if one is fitted, and remove the damper.

3 Remove the three setscrews and the thrust block (B4). If the pulley is not free, do not use an extractor to remove the pulley. Hold a wooden block against the inner hub of the pulley and with a hammer, lightly hit the wooden block towards the rear (A) to loosen the tapered rings.

To fit 1 If the damper is fitted to the rear face of the

pulley, fit the damper to the pulley with its inner flange against the rear face of the pulley. If a viscous damper is fitted, put the damper in position on the face of the pulley (C1). Fit the clamp ring (C3) or the washers.

Notes:

• On some engines the viscous damper is fitted to the rear of the pulley.

• If a clamp ring with a chamfer on the outside edge of the ring is used, ensure that the chamfer is towards the damper when the ring is fitted. Clamp rings may be fitted to viscous or plate dampers.

Apply POWERPART Retainer (oil tolerant) to the cap screws (A4) for the clamp ring and tighten the cap screws gradually and evenly to 35 Nm (26 lbf ft) 3,6 kgf m. For viscous dampers fitted with M12 setscrews tighten the fasteners to 75 Nm (55 lb ft) 7,6 kgf m.

PA093

PA165

Perkins Phaser/1000 Series, April 1995 14A.05

Page 72

14 CRANKSHAFT ASSEMBLY

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Caution: Do not use a degreasing solution.

2 Clean thoroughly the nose of the crankshaft, the

bore of the pulley and the tapered rings components. Do not expand the tapered rings.

3 Put the pulley on the crankshaft with the key engaged and push the pulley towards the rear.

4 Fit the spacer (B1), then the inner ring (B2) and then the outer ring (B3). Ensure that the ring gaps are not aligned.

Caution: It can be very difficult to remove the pulley if the tapered rings are not fitted correctly.

5 Lubricate lightly the "O" ring (B5) and the threads and the thrust faces of the setscrews with clean engine oil. Put the thrust block (B4) and setscrews in position.

6 While the pulley is pressed to the rear, tighten the setscrews gradually and evenly to 115 Nm (85 lbf ft) 11,8 kgf m. Apply the torque again to ensure the pulley is fully tightened.

7Fit the drive belts, operation 23A-04.

PA165

PA093

14A.06 Perkins Phaser/1000 Series, April 1995

Page 73

To Inspect14A-01C

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1 When an integral pulley and damper (A) or a separate plate damper (B) is fitted. The assembly should be renewed if:,

• The rubber insert (A6) or (B1) between the hub

and the outer ring is split.

• The rubber insert is damaged by oil or solvents

• There is movement of the pulley or outer ring on

the hub.

Check the area around the holes for the damper fasteners for cracks or wear.

Caution: Do not use excessive force to lever the damper away from the engine.

2 Remove any paint or dirt in four positions 90° apart on the face (A7) or (B2) of the damper, above the rubber insert. Use a lever to move the damper forward and eliminate the crankshaft end-float. Fit a dial test indicator on the front cover of the timing case. Measure the alignment of the damper face at four locations, 90° apart. The maximum permissible difference between the maximum and minimum figures obtained is:

• Integral pulley and damper 0,18 mm (0.007 in).

• Separate plate damper 0,60 mm (0.024 in). 3 Remove any paint or dirt from the circumference

of the damper. Fit a dial test indicator on the front cover of the timing case.

4 Rotate the crankshaft slowly one complete revolution and measure for run-out on the circumference of the damper with the dial test indicator. The maximum permissible difference between the maximum and minimum figures obtained is:

• Integral pulley and damper 0,12 mm (0.005 in).

• Separate plate damper 0,80 mm (0.032 in). 5 A viscous damper (C1) must be renewed if there

is impact damage to the outer casing or if there is leakage of the viscous fluid from the cover plate. Check the area around the holes for the damper fasteners for damage.

CRANKSHAFT ASSEMBLY 14

PA093

PA094

PA165

Perkins Phaser/1000 Series, April 1995 14A.07

Page 74

14 CRANKSHAFT ASSEMBLY

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Rear oil seal assembly - engines which have the standard seal

To remove and to fit14A-02A

Special tools:

Replacer tool for rear oil seal, PD.145D

Consumable products:

POWERPART Threadlock POWERPART Silicone rubber sealant

1 Remove the drive components from the rear end of the engine.

2 Remove the flywheel and the flywheel housing, see section 22.

3 Remove the setscrews and the cap screws from the housing and remove the housing and seal assembly.

4 Inspect the seal for wear or for damage to the main lip and renew the seal, if necessary. If there is only a small scratch across the lip, renew the seal.

5 Clean the faces of the cylinder block, the oil seal housing and the crankshaft flange. 6 Check that the seal and the outer circumference

of the crankshaft flange are not damaged. Where a new seal has been fitted, check that it is in the correct position in the housing.

7 Ensure that the two dowels (A4) are fitted in the cylinder block. Put a new joint (A3) in position on the dowels, no jointing compound is necessary.

8 Put the seal replacer tool on the crankshaft flange. Lubricate the crankshaft flange, the main lip of the seal and the seal replacer tool with clean engine lubricating oil. The lubrication of the seal is necessary to prevent damage to the seal when the engine is first started.

9 Put the seal and housing (A2) on the replacer tool (A1) and carefully push the assembly into position on the crankshaft flange and onto the dowels. Remove the tool, fit the setscrews and the cap screws. Tighten the setscrews to 22 Nm (16 lbf ft) 2,2 kgf m and tighten the cap screws to 18 Nm (13 lbf ft) 1,9 kgf m.

Note: On the latest engines two torx screws (B2) are fitted instead of cap screws. Tighten the torx screws to 22 Nm (16 lbf ft) 2,2 kgf m. Two extra setscrews (B1 and B3) have also been fitted to later engines.

PA098

PA099

14A.08 Perkins Phaser/1000 Series, April 1995

Page 75

Rear oil seal assembly - engines which

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have a flywheel housing that is oil filled

CRANKSHAFT ASSEMBLY 14

To remove and to fit14A-02B

Special tools:

Replacer tool for rear oil seal, PD.145D

Consumable products:

POWERPART Threadlock POWERPART Silicone rubber sealant

This arrangement for the crankshaft rear oil seal is for engines which have a flywheel housing that is filled with oil. This arrangement uses two lip seals which are narrower than the standard seal and are fitted back to back on the crankshaft palm. The front seal (A9) prevents leakage of oil from the engine and the rear seal (A7) prevents leakage of oil from the flywheel housing. A cover (A4) and joint (A2) are used to prevent leakage of oil past the setscrews which retain the flywheel housing (A1) to the rear face of the cylinder block. An "O" ring (A6) is used to seal between the cover and the seal housing. Oil leakage past the "O" ring or one of the oil seals will pass through a hole in the seal housing between the two seals. The oil will then pass through two cast grooves in the front face of the flywheel housing. These grooves are in the 4 o'clock and 8 o'clock positions.

2 3

PA100

To remove 1 Release the setscrews which retain the flywheel

and remove the flywheel (A3). 2 Release the setscrews (A5) which retain the

cover (A4) and remove the cover. On later covers their are two integral lugs to enable the use of a lever to remove the cover. Remove the joint (A2) and clean the joint faces of the cover and flywheel housing.

3 Release the setscrews and the cap screws and washers which retain the housing (A11) for the rear oil seals and remove the housing. Clean the joint faces of the seal housing and cylinder block.

Perkins Phaser/1000 Series, April 1995 14A.09

Page 76

14 CRANKSHAFT ASSEMBLY

To fit 1 Clean the crankshaft palm (14A.09/A8) and

check for wear in the seal location areas. If there is wear, a "Speedi-Sleeve" (14A.13/A1), part number 21825188, can be fitted, see "To fit and remove a "Speedi-Sleeve". If a "Speedi-Sleeve" is not available the crankshaft palm can be machined to give a minimum diameter of 133,17 mm (5.243 in). Do not machine the last 2,5 mm (0.10 in) of the crankshaft palm as this is necessary for flywheel location. A "Speedi-Sleeve" must not be fitted if the crankshaft palm has been machined undersize.

2 Ensure that the dowels for the oil seal housing are fitted in the cylinder block. Put a new joint (14A.09/A10) in position on the dowels, no jointing compound is necessary.

3 Put the seal replacer tool, which is used for standard seals, on the crankshaft palm. Lubricate lightly the crankshaft palm, the seal replacer tool and the lip of the seals with clean engine lubricating oil.

4 Put the seal and housing assembly onto the seal replacer tool and carefully push the assembly onto the dowels. Remove the seal replacer tool, fit the setscrews and the cap screws together with their washers. Tighten the setscrews to 22 Nm (16 lbf ft) 2,2 kgf m and the cap screws to 13 Nm (10 lbf ft) 1,3 kgf m.

5 Fit a new "O" ring (14A.09/A6) in its recess in the seal housing and lightly lubricate it with clean engine oil.

6 Apply a suitable jointing compound to one side of a new cover joint to hold the joint in position. Put the joint in position on the flywheel housing. Put the cover into position on the joint and fit the setscrews. New setscrews have a sealant applied by the manufacturer. If these setscrews are to be used again, the threads of the setscrews and the threads in the flywheel housing must be cleaned. A suitable sealant, for example POWERPART Threadlock, must then be applied to the setscrew threads. Tighten the setscrews to 22 Nm (16 lbf ft) 2,2 kgf. m.

7 Ensure that the location faces of the flywheel and crankshaft are clean and free from damage. Fit the flywheel and the setscrews together with their washers. Tighten the setscrews to 105 Nm (77 lbf ft) 10,7 kgf m.

8 If the starter motor is removed from the engine, clean the flange face of the starter motor and the face of the flywheel housing. Apply a 2,0 mm (0.080 in) continuous bead of POWERPART Silicone rubber sealant to the flange face of the starter motor near to the spigot before the starter motor is fitted.

Caution: If the engine is to be operated before oil is added to the flywheel housing, the rear oil seal must not be fitted until after the engine has run.

14A.10 Perkins Phaser/1000 Series, April 1995

Page 77

To renew the rear oil seal - engines which

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have the standard seal14A-03A

Special tools:

Replacer tool for rear oil seal, PD.145D

There are four positions in which the seal can be fitted in the housing (A).

Position "1" is used in the factory or if a new seal is fitted on a new or reground crankshaft in service.

Position "2" is used when a new seal is fitted in service and the crankshaft flange is worn in position "1".

Position "3" is used when a new seal is fitted in service and the crankshaft flange is worn in positions "1" and "2".

Position "4" can also be used with a new seal in service, if a wet clutch is not used and the crankshaft is new or the crankshaft palm area has been corrected. Ensure that the seal is fitted square in the housing.

If all positions have been used it is permissible to grind the crankshaft flange, see the data and dimensions.

1 Remove the seal and housing assembly,

operation 14A-02.

2 Put the engine side of the housing on a suitable support and press out the seal with a suitable adaptor.

3 Lubricate the outer circumference of the seal and the bore of the seal housing with clean engine lubricating oil.

4 Put the engine side of the housing on a suitable support and put the seal into position on the flywheel end of the bore with the spring of the seal towards the housing.

5 Press the seal into the housing to the correct position with the relevant side of the tool

CRANKSHAFT ASSEMBLY 14

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2,2mm (0.09in)

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PA101

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Perkins Phaser/1000 Series, April 1995 14A.11

Page 78

14 CRANKSHAFT ASSEMBLY

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To renew the rear oil seals - engines

which have a flywheel housing that is oil filled14A-03B

Consumable products:

POWERPART Threadlock POWERPART Liquid gasket POWERPART Silicone rubber sealant

1 Remove the seals from the housing with a suitable lever. Ensure that the seal housing is not damaged. Do not try to press the seals out of the housing as there is a shoulder in the housing (A).

2 Clean thoroughly the oil seal housing. Inspect the oil seals for damage. If only a small scratch can be seen across the lip of the seal, do not fit the seal.

3 Before the oil seals are fitted into the housing ensure that the correct seal is fitted to the correct side of the housing. Each of the seals has an arrow (A2) and (A3) on the flat face of the seal. This arrow indicates the correct direction of shaft rotation for the seal.

4 Lubricate lightly the outer circumference of the front oil seal and the bore of the housing for the front seal with clean engine oil.

5 With the flywheel side of the seal housing on a suitable support, press the new front seal into the housing. Use a suitable tool which will apply pressure only to the flat inside face of the seal. Use only enough pressure to ensure that the flat face of the seal is against the shoulder in the housing. Too much pressure could damage the shoulder.

6 Lubricate lightly the outer circumference of the rear oil seal and the bore of the housing with clean engine oil.

7 With the engine side of the seal housing on a suitable support, carefully press the rear oil seal onto the shoulder in the housing with the same tool as for the front seal. Ensure that the seal is against the shoulder in the housing.

Caution: The rear oil seal must not be fitted if the engine is to be operated before the oil is added to the flywheel housing. The seal must be fitted to the seal housing after the engine has been run.

PA102

14A.12 Perkins Phaser/1000 Series, April 1995

Page 79

To fit and remove a "Speedi-Sleeve"

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1 Clean the crankshaft palm and remove sharp edges or rough areas from the crankshaft palm.

2 Ensure that the sleeve (A1) is clean. Apply a narrow bead of POWERPART Liquid gasket around the bore of the sleeve 5 mm (0.2 in) from the front face of the flange. The sleeve must be fitted not more than five minutes after the Liquid gasket has been applied.

3 Ensure that the crankshaft is fully forward. Use a suitable adaptor and a hammer to carefully drive the sleeve onto the crankshaft palm. The sleeve must be fitted with a clearance of 0,4/0,6 mm (0.016/0.024 in) between the rear face of the cylinder block and the front face of the sleeve flange (A4). Ensure that this clearance is equal all around the flange of the sleeve. Do not try to pull the sleeve backwards as damage could occur to the sleeve.

4 Fit a new joint for the oil seal assembly. Lubricate lightly the sleeve and the lip of the oil seals with clean engine oil and fit the assembly. Fit a new joint to the flywheel housing and fit the cover. Fit the flywheel.

5 To remove a sleeve, make a deep scratch with a sharp scriber along the full length of the sleeve. Insert the edge of a thin blade at the end of the scratch mark. Turn the blade to make a split along the scratch mark and pull the sleeve apart. If only the flange is removed, a recommendation of the sleeve manufacturer is to spread the sleeve. To do this use a small hammer and a suitable punch with a round end. Make one or more lines of small distortions across the full width of the sleeve. This should increase the diameter of the sleeve enough to enable its removal.

CRANKSHAFT ASSEMBLY 14

PA102

Perkins Phaser/1000 Series, April 1995 14A.13

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14 CRANKSHAFT ASSEMBLY

Thrust washers

To check crankshaft end-float14A-04

The axial movement of the crankshaft is controlled by two half thrust washers fitted both sides of the centre main bearing (A). The end-float can be checked with a feeler gauge between a thrust washer and the crankshaft (B), or with a dial test indicator on one end of the crankshaft to check the movement (C).

If the end-float is more than the tolerance given in data and dimensions, thrust washers which are 0,019 mm (0.0075 in) oversize can be fitted.

The oversize thrust washers can be fitted to one or to both sides of the main bearing. They are fitted instead of the standard size washer, to reduce the end-float to the factory tolerances.

PA103

PA104

PA105

14A.14 Perkins Phaser/1000 Series, April 1995

Page 81

To remove and to fit14A-05

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To remove 1 Drain the lubricating oil and remove the

lubricating oil sump, operation 19A-03. 2If necessary, remove the balancer unit, operation

14A-10.

3 If necessary, remove the lubricating oil strainer and suction pipe, operation 19A-04.

4 Release the setscrews of the centre main bearing and remove the main bearing cap complete with the lower half thrust washers.

5 Press down one end of each upper half thrust washer, with a suitable tool made of a soft material (A1), to slide the washer from its recess. Where necessary, move the crankshaft to the front or to the rear to loosen a tight washer.

To fit

CRANKSHAFT ASSEMBLY 14

PA106

1 Lubricate the thrust washers with clean engine lubricating oil.

2 Slide the upper half thrust washers into their recesses in the cylinder block. Ensure that the sides of the thrust washers which have the grooves are against the crankshaft.

3 Fit the lower half thrust washers to the main bearing cap with the location tags in their recesses.

4 Ensure that the location thimbles are fitted correctly in the main bearing cap or in the cylinder block.

5 Ensure that the bearing is fitted correctly in the cap and that the the bearing and the crankshaft journal are clean. Lubricate the bearing with clean engine lubricating oil.

6 Fit the cap with the location tags of both half of the shell bearings to the same side (B1). Tighten the main bearing setscrews gradually and evenly to 265 Nm (196 lbf ft) 27,0 kgf m for six cylinder engines. 250 Nm (185 lbf ft) 26,0 kgf m for four cylinder engines.

7Check the crankshaft end-float, operation

14A-04.

8If necessary, fit the balancer unit, operation

14A-10.

9 If necessary, fit the lubricating oil strainer and the suction pipe, operation 19A-04.

10Fit the lubricating oil sump, operation 19A-03, and fill it to the correct level with an approved lubricating oil.

PA107

Perkins Phaser/1000 Series, April 1995 14A.15

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14 CRANKSHAFT ASSEMBLY

Main bearings

To remove and to fit (with the crankshaft in position)14A-06

If the rear main bearing is to be removed with the crankshaft in position, the flywheel, the flywheel housing, the rear oil seal housing and the bridge piece will have to be removed.

Except for engines with a balancer unit fitted, the front main bearing can only be removed if a suitable spanner is available that will enable the torque to be applied correctly to the setscrews of the main bearing cap. If a suitable spanner is available, the front main bearing cap can be removed together with the oil pump. For six cylinder engines, it will be necessary to remove the suction pipe and strainer and the delivery pipe. For four cylinder engines, either the balancer unit or the suction pipe and strainer, the delivery pipe and the relief valve will have to be removed.

To remove 1 Drain the lubricating oil and remove the sump,

operation 19A-03.

2 Remove all necessary components to get access to the specific bearing cap.

3 Release the setscrews of the bearing cap and remove the bearing cap. Remove the lower half of the shell bearing from the cap.

4 With a suitable tool, push the upper half of the shell bearing from the side opposite to the location tag to remove the bearing tag from its recess in the bearing housing. Carefully rotate the crankshaft to release the bearing from its housing. Keep the bearing halves in their relevant positions.

14A.16 Perkins Phaser/1000 Series, April 1995

Page 83

To fit

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1 Clean the upper half of the shell bearing and lubricate the bearing surface with clean engine lubricating oil.

Caution: Only the upper half of the bearing has lubrication holes and must be fitted to the side of the cylinder block.

2 Fit the plain end of the upper half of the bearing between the crankshaft journal and the side of the bearing housing which has the recess for the location tag. Slide the bearing into its housing until the tag on the bearing is fitted correctly in its recess in the housing.

3 Clean the lower half of the bearing and cap, lubricate the bearing surface with clean engine lubricating oil.

4 Fit the bearing into the cap with the tag of the bearing fitted correctly in the recess in the cap.

5 Ensure that the location thimbles are fitted correctly to the cap or to the cylinder block. Fit the bearing cap with the location tags of both bearings on the same side (A1).

6 Inspect the setscrews for damage and for distortion and renew them if necessary. Lightly lubricate the setscrew threads with clean engine lubricating oil. Fit the setscrews and the washers and tighten the setscrews gradually and evenly to 265 Nm (196 lbf ft) 27,0 kgf m for six cylinder engines and 250 Nm (185 lb ft) 26,0 Kgf m for four cylinder engines.

Note: Washers are not fitted between the setscrews and the bearing caps on the latest engines.

7 Ensure that the crankshaft turns freely. If the thrust washers have been removed and fitted, check the crankshaft end-float, operation 14A-03.

8 Fit all the components which were removed for access to the main bearing cap.

9Fit the lubricating oil sump, operation 19A-03 and fill it to the correct level with an approved lubricating oil.

CRANKSHAFT ASSEMBLY 14

PA107

To inspect14A-07

Inspect the bearings for wear and for other damage. If a bearing is worn or damaged, renew both half of the shell bearings and check the condition of the other bearings.

Perkins Phaser/1000 Series, April 1995 14A.17

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14 CRANKSHAFT ASSEMBLY

Crankshaft

To remove and to fit14A-08

Consumable products:

POWERPART Silicone rubber sealant POWERPART liquid gasket

Warning! Use lift equipment or obtain assistance to lift heavy engine components such as the balancer unit, flywheel housing, crankshaft and flywheel.

To remove 1 Before the engine is removed from the vehicle or

from the machine, drain the lubricating oil and the coolant.

2Remove the lubricating oil sump, operation

19A-03.

3 Remove the fan, the drive belts, the fan drive pulley and housing and the coolant pump, see

section 21.

4Remove the crankshaft pulley, operation

14A-01A or 14A.01B.

5 Remove the alternator and its mounting bracket, see section 23.

6 Remove the compressor and its drive assembly or remove the exhauster, see section 24.

7Remove the timing case cover, operation

15A-01.

8Remove the fuel injection pump, see section 20. 9 Remove the timing gears and the timing case,

see section 15. 10 Remove the flywheel and the flywheel housing,

see section 22. 11Remove the rear oil seal housing, operation

14A-02A or 14A.02B.

12If a balancer unit is fitted, remove it, operation

14A-10. If a balancer unit is not fitted, remove the

lubricating oil suction pipe and strainer, the lubricating oil pump, the delivery pipe and the relief valve (four cylinder engines) and the lubricating oil crossover pipe, if fitted, see section 19.

13 Remove the bridge piece and the rubber seals. Later engines may not have rubber seals fitted.

14 Remove the caps of the connecting rods. Keep the bearings and caps together. Remove the bolts of the connecting rods and carefully push the pistons into their bores.

14A.18 Perkins Phaser/1000 Series, April 1995

Page 85

15 Ensure that the tops of the main bearing caps

are stamped with their relevant position number. Remove the main bearing caps, the lower half of the shell bearings and the upper and lower thrust washers. Keep the bearings with their relevant caps.

16 Lift out the crankshaft. Remove the upper half of the bearings and keep each bearing with its relevant lower half and cap.

To fit 1 Ensure that all lubricating oil passages are clean

and free from restriction. 2 Clean the main bearing housings and the upper

half of the bearings. Fit the shell bearings with the location tags fitted correctly in their recesses. Lubricate the bearings with clean engine lubricating oil.

3 Ensure that the main journals of the crankshaft are clean. Put the crankshaft in position on the upper bearings.

4 Clean and lubricate the upper half thrust washers and slide them into their recesses on both sides of the bearing housing. Ensure that the slotted sides of the thrust washers are towards the crankshaft.

5 Clean the bearing caps and the lower half of the bearings. Fit the bearings to the caps with the location tags fitted correctly in their recesses. Lubricate the bearings with clean engine lubricating oil.

6 Clean the lower half thrust washers and lubricate them with clean engine lubricating oil. Fit the thrust washers on both sides of the bearing cap for the centre main bearing.

7 Check that the location thimbles for the main bearing caps are fitted correctly in the caps or in the cylinder block. Fit the bearing caps in their correct positions (as shown by the position number stamped on the top of the cap) with the location tags of the bearings on the same side. In this position the serial numbers stamped on the bearing caps will be in line. The serial number stamped on the bearing caps must be the same as the number stamped on the bottom face of the cylinder block. The third and fifth bearing caps of six cylinder engines are not stamped with a serial number.

CRANKSHAFT ASSEMBLY 14

Perkins Phaser/1000 Series, April 1995 14A.19

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14 CRANKSHAFT ASSEMBLY

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8 Fit the setscrews and the washers to the main bearing caps and tighten the setscrews gradually and evenly to 265 Nm (196 lbf ft) 27,0 kgf m for six cylinder engines and 250 Nm (185 lb ft) 26,0 kgf m for four cylinder engines.

Note: Washers are not fitted between the setscrews and the bearing caps on the latest engines.

9 For early engines fitted with rubber seals: Clean the bridge piece and the location areas for the bridge piece in the cylinder block. Apply a narrow strip of POWERPART silicone rubber sealant in the corners and around the thread holes of the bridge piece seat in the cylinder block. Fit the bridge piece and the two rubber seals (A). The rubber seals will be a little higher than the bridge piece when they are fitted correctly. Use a straight edge (B2) to ensure that the bridge piece is in line with the rear face of the cylinder block. Tighten the bridge piece cap screws (B1) to 16 Nm (12 lbf ft) 1,6 kgf m.

For later engines fitted with POWERPART liquid gasket: A bridge piece has been introduced which uses POWERPART liquid gasket instead of the rubber seal in the groove at each end of the bridge piece. The groove at each end of the new bridge piece is cast and is off-centre. The procedure to fit the new bridge piece is the same as for the earlier bridge piece, except for the instructions given below. Apply a 1/8 in (3.0 mm) bead of POWERPART liquid gasket along the corner in the top of the recess in the cylinder block for the bridge piece.

When the bridge piece is in position and the cap screws have been tightened, inject POWERPART liquid gasket into the groove (C2) at each end of the bridge piece. Continue to inject sealant until the groove is completely full and the sealant leaves the lower groove (C1) at the front and rear of the bridge piece.

It may be necessary to stop the sealant at one side of the lower groove in order to ensure it will flow from the opposite side of the groove.

PA108

PA109

PA110

14A.20 Perkins Phaser/1000 Series, April 1995

Page 87

CRANKSHAFT ASSEMBLY 14

Caution: When the sump joint is removed, damage can occur to the seal in the grooves of the bridge piece. If the seal is damaged, apply enough sealant to completely fill the grooves.

Note: Most of the latest engines have setscrews in place of studs to fasten the sump to the bridge piece. The threads of the setscrews have a sealant applied by the manufacturer. When the setscrews are to be used again, ensure that the threads of the setscrews and of the bridge piece are clean and a sealant is applied to the threads of the setscrews. These instructions also apply to studs.

10 Fit the connecting rod caps, operation 13A-01. Rotate the crankshaft two turns to ensure free movement.

11If necessary, fit the balancer unit, operation

14A-10. If a balancer unit is not used, fit the

lubricating oil pump, the lubricating oil suction pipe and strainer, the delivery pipe and the relief valve (four cylinder engines) and if necessary, the lubricating oil crossover pipe, see section 19.

12Fit the rear oil seal housing, operation 14A-02A

or 14A-02B.

13 Fit the flywheel housing and the flywheel, see

section 22.

14 Fit the timing case and the timing gears, see

section 15.

15Fit the fuel injection pump, see section 20. 16Fit the timing case cover, operation 15A-01. 17 Fit the compressor and its drive assembly or fit

the exhauster, see section 24. 18 Fit the alternator and its mounting bracket, see

section 23.

19Fit the crankshaft pulley, operation 14A-01A or

14A-01B.

20 Fit the coolant pump, the fan drive pulley and housing, the drive belts and the fan , see section

21.

21Fit the lubricating oil sump, operation 19A-03. 22 After the engine has been installed, fill the

lubricating oil sump to the correct level with an approved oil. Fill the cooling system.

To inspect14A-09

Check the crankshaft for wear and other damage. The maximum permissible wear and ovality on the crankshaft journals and crank pins is 0,04 mm (0.0016 in).

The main journals and the crank pins of standard size crank shafts can be machined to 0,25mm (0.010 in), 0,50mm (0.020 in) or 0,75 mm (0.030 in) undersize on diameter, see the data and dimensions. Special undersize bearings are available.

If the seal has been used in all of the service positions, the crankshaft palm can be machined to remove the wear marks. Further information can be found in the data and dimensions.

Perkins Phaser/1000 Series, April 1995 14A.21

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14 CRANKSHAFT ASSEMBLY

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Balancer unit To remove and to fit14A-10

To remove 1 Drain the lubricating oil from the sump and

remove the sump, operation 19A-03.

Warning! The weight of the unit is approximately 25 kg (55 lb).

2 Provide a support for the balancer unit before release of the setscrews from the engine.

3 Release the setscrews and lower carefully the balancer unit. Make a note of the positions of the setscrews of different lengths.

To fit 1 Ensure that the contact faces of the cylinder

block and of the balancer unit are clean and that the two thimbles (A1) are fitted correctly to the cylinder block.

2 Set the piston of number 1 cylinder to TDC,

operation 17A-01.

3 Before the balancer unit is fitted, ensure that the flat faces of the balance weights are level with each other (B1) and the weights hang down away from the cylinder block (B2). The timing of the balance weights to the drive shaft is correct when the large hole and small hole in the front of the drive shaft gear are in the positions shown in the illustration (B).

Note: If the gear position shown in (B) cannot be obtained, then the balancer must be partially dismantled and the timing corrected (14A.26/A).

4 Fit the balancer unit to the cylinder block with the correct screws in the centre positions of the balancer frame. Ensure, when the idler and crankshaft gears are in mesh, that the flat faces of the balance weight are level with each other and that they are towards the cylinder block. Check that the balancer unit is fitted correctly on the thimbles and fit the remainder of the setscrews in their correct position. Tighten the setscrews to 54 Nm (40 lbf ft) 5,5 kgf m.

5 Rotate the crankshaft through two turns to ensure that it is free to rotate.

6Fit the lubricating oil sump, operation 19A-03 and fill the sump to the correct level with an approved oil.

PA111

PA112

14A.22 Perkins Phaser/1000 Series, April 1995

Page 89

CRANKSHAFT ASSEMBLY 14

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To dismantle and to assemble14A-11

Consumable products:

POWERPART Nutlock

To dismantle 1 Remove the balance weight cover (A8).

2 Release the setscrew and remove the idler gear

assembly (A1). Keep the components together as an assembly to protect the needle roller bearing.

3 Prevent movement of the drive shaft (A2) and loosen the nut (A4) of the drive gear for the balance weights (A3). Put a suitable flat distance piece in position between the nut and the balancer frame. Turn the nut until it is against the face of the distance piece. Continue to turn the nut with a suitable spanner until the Loctite seal on the splines of the drive shaft is broken and the gear is loose on the shaft. Remove the nut and the drive gear and remove the drive shaft. Ensure that the needle roller bearings are not damaged when the drive shaft is removed.

4 Release the setscrews which hold the lubricating oil pump and the suction pipe (A10 and A9) to the balancer frame and remove the lubricating oil pump and the suction pipe.

5 Release the setscrews and remove the transfer plate and joint for the lubricating oil (A7) from the rear of the balancer unit. Make a note of the position of the direction arrows on the outside of the transfer plate (14A.26/B or C) to ensure that it can be assembled correctly .

PA113

Perkins Phaser/1000 Series, April 1995 14A.23

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14 CRANKSHAFT ASSEMBLY

Notes:

• The latest oil transfer plate is fitted without a joint or sealant; always give the correct engine number when parts are needed.

• There are two plugs in the balancer frame, a short tapered plug with a hexagonal socket head and a long plug with a square socket head. These plugs control the flow of oil through the balancer frame. The position of the plugs is decided by which side of the engine the filter is fitted. When the filter is fitted on the left side, the short plug is fitted in the side of the balancer and the long plug is fitted in the bottom (14A.26/B). When the filter is fitted on the right side of the engine, the short plug is fitted in the bottom of the balancer and the long plug is fitted in the side (14A.26/C).

Caution: Removal of these plugs can cause damage to the threads in the balancer frame and a new balancer frame will be needed. When a balancer unit is to be fitted, ensure that the lubricating oil flow through the balancer frame is correct for the position of the lubricating oil filter.

6 Release the setscrews and remove the rear cover of the balancer frame (14A.23/A6). A hammer and a suitable drift will be necessary to remove the rear cover from the dowels.

7 Remove the balance weights (14A.23/A5). Ensure that the gear of the driven weight does not damage the bush in the balancer frame.

8 Dismantle the lubricating oil relief valve,

operation 19A-09.

9 Clean the lubricating oil passages with an approved kerosene cleaning solution and dry them with low pressure compressed air.

14A.24 Perkins Phaser/1000 Series, April 1995

Page 91

CRANKSHAFT ASSEMBLY 14

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To assemble 1 Ensure that the location thimble (A8) in the rear

of the lubricating oil pump is 5,6/6,4 mm (0.220/0.252 in) above the rear face of the pump. Clean the contact faces of the lubricating oil pump and the balancer frame. Fit the lubricating oil pump (A16) to the balancer frame and tighten the setscrews to 27 Nm (20 lbf ft) 2,8 kgf m.

Note: The latest balancers do not have a thimble for the oil pump location. The location of the latest oil pump is by a spigot on the rear face of the pump.

2Assemble the lubricating oil relief valve, operation

19A-09.

3 Lubricate the needle roller bearings (A7 and A10) with clean engine lubricating oil. Fit the drive shaft (A9) and engage the splines for the lubricating oil pump with the pump rotor. Ensure that the needle roller bearing at the front of the balancer frame is not damaged by the splines on the drive shaft.

4 Clean and dry the splines (A6) and the thread on the end of the drive shaft. Apply a small amount of Loctite Nutlock to the splines and to the thread. Fit the drive gear of the balance weights (A1) with the flat face of the gear towards the rear of the balancer unit. Fit and tighten the nut (A2) to 82 Nm (60 lbf ft) 8,4 kgf m. To tighten the nut, a peg spanner must be made to fit into the two holes in the front of the drive shaft and be suitable for use with a torque wrench. Fit the peg spanner to the front of the drive shaft. Hold the nut with a suitable spanner and apply the torque to the peg spanner.

5 Ensure that the drive shaft turns freely. Check the end-float of the drive shaft with feeler gauges between the front face of the drive gear for the balance weights and the frame (A).

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PA114

Perkins Phaser/1000 Series, April 1995 14A.25

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14 CRANKSHAFT ASSEMBLY

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6 Put the balancer frame upside down on the bench (A1). Turn the gear of the drive shaft (A3) until the larger of the two outer holes (A2) - in the front face of the drive gear - is in the position shown in (A). Ensure that the drive shaft will not move from this position. Lubricate the bushes in the rear of the balancer frame with clean engine lubricating oil and fit the balance weights in the position shown in figure A. Ensure that the flats on the balance weights are level with each other (A4). With the balance weights in the correct position, check that the drive shaft is still in the correct position.

7 Fit the two dowels to the rear face of the balancer frame. Lubricate the bushes in the rear cover of the balance frame with clean engine lubricating oil. Put the rear cover (14A.24/A4) in position with the rear spigots of the balance weights in the bushes of the cover. Hit lightly the rear cover with a soft face hammer to fit the cover onto the dowels. Fit the cover setscrews and tighten them to 54 Nm (40 lbf ft) 5,5 kgf m. Check the end-float of the balance weights with feeler gauges between the rear face of the balance weights and the front face of the rear cover (14A.30/B). The correct end-float is given in the data and dimensions. Check the backlash between the drive gear of the balance weights and the driven gear on the balance weight. The correct backlash is given in the data and dimensions.

8 Fit the oil transfer plate and the joint, if fitted, to the rear of the rear cover and tighten the setscrews to 30 Nm (22 lbf ft) 3,1 kgf m. Ensure that the plate is fitted correctly for the oil filter position. The direction arrow (B or C) indicates the direction of lubricating oil flow for left side (B) and right side (C) oil filter positions. The symbols and arrows (B or C) indicate the position of the plugs in the balancer frame and the shape of their socket heads. Ensure that the plug on the bottom face of the frame is just below the face. If a new frame and plugs are used, ensure that the plugs are fitted correctly for the oil filter position and the symbols on the oil transfer plate.

PA115

PA116

PA117

14A.26 Perkins Phaser/1000 Series, April 1995

Page 93

9 If necessary, press a new bearing (A14) into the

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idler gear (A12). Lubricate the bearing with clean engine lubricating oil. Fit the hub (A13) into the bearing and fit the thrust washer (A15) onto the rear of the hub. Ensure that the threads of the setscrew are clean and dry. Fit the setscrew through the assembly and apply a small amount of Loctite Nutlock to the thread. Fit the assembly to the front of the balancer unit with the idler gear in mesh with the gear of the drive shaft (A11). Tighten the setscrew to 93 Nm (68 lbf ft) 9,5 kgf m. Check the end-float of the idler gear with a feeler gauge between the front face of the idler gear and the hub (A). Check the backlash between the idler gear and the drive shaft gear. The correct backlash is given in the data and dimensions.

10 Fit the balance weight cover and tighten the setscrews.

11 Fit the suction tube and the joint and tighten the setscrews.

CRANKSHAFT ASSEMBLY 14

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PA114

Perkins Phaser/1000 Series, April 1995 14A.27

Page 94

14 CRANKSHAFT ASSEMBLY

To inspect14A-12

1 Clean all the components before inspection. 2 Check the gear teeth and the splines of the drive

shaft for wear or other damage. Renew the drive shaft if necessary.

3 Check the idler gear, needle roller bearing, hub and thrust washer for wear or other damage. Renew the components if necessary.

4 Check the drive gear for the balance weights for wear or other damage. Renew the gear if necessary.

5 Check the balance weights for wear or other damage. If either balance weight is worn or damaged, both balance weights must be renewed.

6 Check the needle roller bearings for the drive shaft for wear or other damage. Renew the bearings, operation 14A-13, if necessary.

7 Check the bushes for the balance weights for wear or other damage. Renew the bushes,

operation 14A-14, if necessary.

8To inspect the lubricating oil pump, see operation

19A-07.

14A.28 Perkins Phaser/1000 Series, April 1995

Page 95

CRANKSHAFT ASSEMBLY 14

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To remove and to fit the needle roller bearings for the drive shaft14A-13

1 Press out the bearings with a suitable adaptor. 2 Clean the parent bores and lubricate them with

clean engine lubricating oil. 3 Make a suitable adaptor to the dimensions given

in (A2). Fit the rear bearing (14A.24/A7) onto the adaptor with the stamped face of the bearing towards the shoulder of the adaptor. Press the bearing into the parent bore in a continuous movement until the shoulder of the adaptor is against the front face of the balancer frame. In this position the front face of the bearing should be 130,0/131,0 mm (5.12/5.16 in) from the front face of the balancer frame (14A.24/A).

4 Make a suitable adaptor to the dimensions given in (A1). Fit the front bearing (14A.24/A10) onto the adaptor with the stamped face of the bearing toward the shoulder. Press the bearing into the parent bore in a continuous movement until the shoulder of the adaptor is against the front face of the balancer frame. In this position the front face of the bearing should be 2,5/3,0 mm (0.01/0.12 in) from the front face of the balancer frame (14A.24/A).

3,25/ 3,30

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MILLIMETRES

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Perkins Phaser/1000 Series, April 1995 14A.29

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14 CRANKSHAFT ASSEMBLY

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To remove and to fit the bushes for the balance weights14A-14

1 Press the bushes out of the balancer frame and the rear cover with a suitable adaptor.

2 Clean the parent bores and lubricate them with clean engine lubricating oil.

3 Make a suitable adaptor to the dimensions given in (A3). Fit a bush onto the adaptor. Press the bush (B4) into the parent bore in the rear of the balancer frame (B3), in a continuous movement, until the shoulder of the adaptor is against the rear face of the balancer frame. In this position the rear face of the bush should be 3,25/3,30 mm (0.128/0.130 in) from the rear face of the balancer frame (B). Repeat this operation for the other bush.

4 Fit a bush (B1) onto the adaptor and put it into position at the front end of one of the parent bores in the rear cover (B2). Press in the bush, in a continuous movement, until the shoulder of the adaptor is against the front face of the rear cover. In this position the front face of the bush should be 3,25/3,30 mm (0.128/0.130 in) from the front face of the rear cover (B). Repeat this operation for the other bush.

3,25/ 3,30

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MILLIMETRES

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14A.30 Perkins Phaser/1000 Series, April 1995

Page 97

CRANKSHAFT ASSEMBLY 14

Data and dimensions

Note: This information is given as a guide for personnel engaged on engine overhauls. The dimensions

which are shown are those which are mainly used in the factory. The information applies to all engines, unless an engine type code is shown.

Crankshaft

Diameter of main journals:

- Four cylinder engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76,16/76,18 mm (2.998/2.999 in)

- Six cylinder engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76,159/76,190 mm (2.9984/2.9996 in)

Maximum wear and ovality on journals and crank pins . . . . . . . . . . . . . . . . . . . . . 0,04 mm (0.0016 in)

Width of front journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36,93/37,69 mm (1.454/1.484 in)

Width of centre journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44,15/44,22 mm (1.738/1.741 in)

Width of all other journals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39,24/39,35 mm (1.545/1.549 in)

Diameter of crank pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63,47/63,49 mm (2.499/2.500 in)

Width of crank pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40,35/40,42 mm (1.589/1.591 in)

Diameter of flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133,27/133,37 mm (5.247/5.251 in)

Depth of recess for spigot bearing:

- Four cylinder engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20,22/20,98 mm (0.796/0.826 in)

- Six cylinder engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14,72/15,48 mm (0.579/0.609 in)

Bore of recess for spigot bearing:

- Four cylinder engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46,96/46,99 mm (1.849/1.850 in)

- Six cylinder engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51,97/51,99 mm (2.046/2.047 in)

Crankshaft end-float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,05/0,38 mm (0.002/0.015 in)

Maximum permissible end-float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,51 mm (0.020 in)

Fillet radii of journals and crank pins . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,68/3,96 mm (0.145/0.156 in)

Undersize journals and crank pins . . . . . . . . . . . . . . . . . . -0,25 mm (-0.010 in); -0,51 mm (-0.020 in);

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -0,76 mm (-0.030 in).

Crankshaft heat treatment:

- Induction hardened . . . . . . . . . . . . . . . Part numbers 31315662, 31315992, 31315993 and 3131H024

- Nitrocarburised . . . . . . . . . . . . . . . . . . . . . . . . . Part numbers 31315661, 31315991 and 3131H022

- 60 hour Nitride . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Part number 3131H021

Crankshaft overhaul

Notes:

• Induction hardened crank shafts need not be hardened after they have been machined undersize.

• Nitrocarburised crankshafts must be hardened again each time they are machined. These crankshafts must be nitrocarburised or, if this process is not available, they can be nitrided for 20 hours. If neither process is available a new crankshaft, or Power Exchange crankshaft, must be fitted.

• Crankshafts which have been nitrided for 60 hours can be reground 0,25 mm (0.010 in) without the need to harden them again.

• Check the crankshaft for cracks before and after it is ground. Demagnetise the crankshaft after it has been checked for cracks.

• After the crankshaft has been machined remove any sharp corners from the lubricating oil holes.

• Surface finish and fillet radii must be maintained.

Perkins Phaser/1000 Series, April 1995 14A.31

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14 CRANKSHAFT ASSEMBLY

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The finished sizes for crankshaft journals (A) which have been ground undersize are given in the table below:

item 0,25 mm (0.010 in) 0,51 mm (0.020 in) 0,76 mm (0.030 in)

1 75,905/75,926 mm

(2.9884/2.9892 in)

2 63,216/63,236 mm

(2.4888/2.4896 in) 3 39,47 mm (1.554 in) maximum 4 37,82 mm (1.489 in) maximum 5 44,68 mm (1.759 in) maximum 6 40,55 mm (1.596 in) maximum 7 133,17 mm (5.243 in) minimum 8 Do not machine this diameter 9 3,68/3,96 mm (0.145/0.156 in)

75,651/75,672 mm

(2.9784/2.9792 in)

62,962/62,982 mm

(2.4788/2.4796 in)

75,397/75,418 mm

(2.9684/2.9692 in)

62,708/62,728 mm

(2.4688/2.4696 in)

Surface finish for journals, crank pins and fillet radii must be 0,4 microns (16 micro inches). Surface finish for seal area of crankshaft palm must be 0,4/1,1 microns (16/43 micro inches).

14A.32 Perkins Phaser/1000 Series, April 1995

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PA120

Page 99

CRANKSHAFT ASSEMBLY 14

With the crankshaft on mountings at the front and rear journals, the maximum run-out (total indicator reading) at the journals must not be more than shown below:

Journal 4 cylinder crankshafts 6 cylinder crankshafts

1 Mounting Mounting 2 0,08 mm (0.003 in) 0,10 mm (0.004 in) 3 0,15 mm (0.006 in) 0,20 mm (0.008 in) 4 0,08 mm (0.003 in) 0,25 mm (0.010 in) 5 Mounting 0,20 mm (0.008 in) 6 7 - Mounting

Run-out must not be opposite. The difference in run-out between one journal and the next must not be more than 0,10 mm (0.004 in).

Run-out on the crankshaft pulley diameter, rear oil seal diameter and the rear flange diameter must not be more than 0,05 mm (0.002 in) total indicator reading.

Main bearings

Four cylinder engines:

Type (All bearings) . . . . . . . . . . . . . . . . . . . . . . . . . . . Steel back, 20% tin-aluminium bearing material

Six cylinder engines:

Centre bearing and all Phaser 210Ti bearings . . . . . . . . . . . . . . . . . . Steel back, lead bronze bearing

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . material with lead finish

All other bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steel back, 20% tin-aluminium bearing material

Bearing width

Four cylinder engines:

Centre bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36,32/36,70 mm (1.430/1.445 in)

All other bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31,62/31,88 mm (1.245/1.255 in)

Six cylinder engines:

Centre bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36,32/36,70 mm (1.430/1.445 in)

All other bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30,86/31,12 mm (1.215/1.225 in)

0,10 mm (0.004 in)

Bearing thickness at centre

Four cylinder engines:

All bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,083/2,089 mm (0.0820/0.0823 in)

Six cylinder engines:

Centre bearing and all Phaser 210Ti bearings . . . . . . . . . . . . . . . . 2,087/2,096 mm (0.0822/0.0825 in)

All other bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,083/2,089 mm (0.0820/0.0823 in)

Perkins Phaser/1000 Series, April 1995 14A.33

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14 CRANKSHAFT ASSEMBLY

Bearing clearance

Four cylinder engines:

All bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,057/0,117 mm (0.0022/0.0046 in)

Six cylinder engines:

Centre bearing and all Phaser 210Ti bearings . . . . . . . . . . . . . . . . 0,035/0,110 mm (0.0014/0.0043 in)

All other bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,047/0,117 mm (0.0018/0.0046 in)

Available undersize bearings . . . . . . . -0,25 mm (-0.010 in); -0,51 mm (-0.020 in); -0,76 mm (-0.030 in).

Crankshaft thrust washers

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steel back, lead bronze bearing material

Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Each side of centre main bearing

Thickness:

- Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,26/2,31 mm (0.089/0.091 in)

- Oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,45/2,50 mm (0.096/0.098 in)

Balancer unit

Diameter of drive shaft for front bearing . . . . . . . . . . . . . . . . . . . 28,562/28,575 mm (1.1245/1.1250 in)

Diameter of drive shaft for rear bearing . . . . . . . . . . . . . . . . . . . 23,787/23,800 mm (0.9365/0.9370 in)

Number of teeth on gear of drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Backlash from gear of drive shaft to idler gear . . . . . . . . . . . . . . . . . . . 0,17/0,29 mm (0.007/0.011 in)

End-float of drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,13/0,30 mm (0.005/0.012 in)

Diameter of bore for front bearing of drive shaft . . . . . . . . . . . . . 34,912/34,937 mm (1.3745/1.3755 in)

Diameter of bore for rear bearing of drive shaft . . . . . . . . . . . . . . 29,972/29,993 mm (1.1800/1.1808 in)

Diameter of bore for idler gear . . . . . . . . . . . . . . . . . . . . . . . . . . 47,64/47,65 mm (1.8755/1.8760 in)

Diameter of hub of idler gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38,09/38,10 mm (1.4996/1.5000 in)

End-float of idler gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,07/0,23 mm (0.003/0.009 in)

Thickness of thrust washer for idler gear . . . . . . . . . . . . . . . . . . . . . . . 4,14/4,29 mm (0.163/0.169 in)

Number of teeth on idler gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Inside diameter of bushes in balancer frame and end cover (fitted) . . . . . . . . . . . . . 38,133/38,174 mm

(1.5013/1.5029 in)

Diameter of spigots for balance weights . . . . . . . . . . . . . . . . . . . 38,054/38,069 mm (1.4982/1.4988 in)

Fit of spigot in bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,064/0,120 mm (0.0025/0.0047 in)

End-float of balance weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,19/0,40 mm (0.007/0.016 in)

Backlash of gears on balance weights . . . . . . . . . . . . . . . . . . . . . . . . . 0,10/0,27 mm (0.004/0.011 in)

Backlash of drive gear to spline on balance weight . . . . . . . . . . . . . . . . 0,05/0,20 mm (0.002/0.008 in)

Number of teeth on drive gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Number of teeth on spline on balance weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

14A.34 Perkins Phaser/1000 Series, April 1995