Perkins Engine 4-154 Service Manual

workshop manual

for

diesel

;_

-1

.,

~

engines

~-.

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~-·

• .

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•

4.154

PRINTED IN U.S.A.

workshop
manual

for

4.154

diesel

©

Perkins

32500 Van Born Road
P.O. Box 697 • Wayne, Michigan 48184 • U.S.A.

1976

Engines.

engines

Inc.

Publication No.

This publication supersedes the previous edition
numbered

publication

Tills
territories where

emission, noise, safety factors etc., then

tions, data and dimensions
such a

nance)
the local regulations when in use.

way

or

repairing an engine, it does

Published
of

Perkins Engines Ltd., and printed

Abbey Printers, High Street, Spalding, Lines.

by

601

SEA

1076/1024

601SER1024.

is

written for world-wide

legal

requirements govern smoke

given

that, after servicing, (preventive mainte-

the Service Publications Department

must

use.

all

be

applied

not

contravene

in

England by

instruc-

In

in

PERKINS COMPANIES

AUSTRALIA

BRAZIL

Perkins Engines Division
P.O.

Box 156, Dandenong, Victoria 3175, Australia.

Telephone:
Motores Perkins

Cai.:a Postal 30.028, c Sao Paulo, Estado
Telephone:

792-Q431.

443-1499. TeleK: 23715.

S.A.

Telex:

AA 30816.

Cables:

de

Cables:

'Perkoil'.

Sao Paulo, Brazil.
'Perkoil' Sao Paulo.

FRANCE

GERMANY

GREAT

BRITAIN

Moteurs Perkins S.A.
55 Boulevard Ornano, 93203 Saini-Denis, France.
Telephone.

Perkins

8752 Kleinostheim, Postfach 12. Germany.

Telephone:

Perkins Engines Limited
Peterborough, England

243-04:40.

Motoren G.m.b.H.

Telex.

06027/8081.

PEt

Telex·

SNA.

62251

4188869.

Saint-Denis.

Cables:

'Perkoil' Paris.

Telephone Peterborough 67411. Telex 32501. Cables : 'Perkoil' Peterborough.

ITALY

SOUTH AFRICA

t,I.S.A.

Motori Perkins
22100 Como-Camerlata. Via Pasquale Paoli
Telephone· 504885.

Perkins Engines (Pty,)

P.O. Box 31285.

Telephone Johannesburg 725-5715.

Perkins

32500 Van
P.O.

Box

Tel.. (313)

S.pA

Telex·

ltd.

61h

Floor, Noswal Hall, Braamfonlein. Johannesburg, South Afnca.

Engines,

Born

Road

697 • Wayne,

595-9600

•1elex:

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Inc.

Michigan

23-4002

Telex·

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Italy.

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5430037.

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YUGOSLAVIA

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Simpson & Co. Ltd.
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Telephone:

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6047 Fuchu-Machi, Aki-gun, Hiroshima, Japan.
Telephone:

Hyundai
Telephone.

Motores Perkins S.A.
Tiber No. 68 1er Piso, Me)(ico

Telephone: [phone].

Motor Iberica
Carretera del Aero-Club, Carabanchel Alto, Madrid, Spain.
Telephone:

lndustrija Motora Rakovica
Patrijarha Dimltrija 7-13
Rakovica, Belgrade, Yugoslavia.
Telephone:
Cables:

Madras

Hiroshima 82-1111. Tela)(: 652-333.

Motor

27-5111/9, 27-6111/9.

208

562.043/562-322/562-992.

'lndmotor'

83091

(PABX-10

Co., Bae Jae Building,

SDF.

Telex:

Perkoil Mex 071-71-347.

S.A. (Division Zona

52-40,

208

96-40.

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Telex:

2}

208

2,

lines}.

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Telex:

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Telex:

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2391s.

Cables:

Cables:

Telex:

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11341

YU

IMR.

Cables:

'Toyoko' Hiroshima.

Hyuildaimotor, SeouL

'Simpsons'

'Perkoilmex'.

Cables:

"Perki-e"

Madrid.

In addition to the above, there are Perkins Distributors in the majority
throughout
or

to one

the

world. For further details, apply to Perkins Engines Ltd., Peterborough.

of

the above companies.

of

countries

CONTENTS

General Information

Cylinder Head
Pistons and
Cylinder Block and Uners

Crankshaft and

Timing Case

Connecting Rods

Main

Bearings

and

Drive

Flywheel and Flywheel Housing

Timing

Lubricating System

Cooling System

Fuel System

Air

Cleaner
Electrical System
Exhauster
Marine Engines
Lubricating

Glossary

of

Oils

Terms

Approved Service Tools

Examples

of

Service Facilities

Index

3

SECTION A

SEcnON

SECTION C
SECTION
SECTION E

SECTION

SECTION G
SECTION H
SECTION J
SECTION K
SECTION
SECTION M
SECTION
SECTION P

SECTION

Appendix
Appendix
Appendix
Appendix
Appendix

B

D

F

L

N

Q

FOREWORD

This Workshop Manual has been compiled for use

normal workshop
therefore, have been omitted
removal, dismantling, assembly

it

is

omitted from the text. Similarly, references

cleaning
removal
stood that these procedures will be carried
follows that any open ports
injection equipment, exposed by dismani:ling, will be blanked
re-assembled,
between the minimum and maximum dimensions which are
Manufacturing Data and Dimensions for the relevant component parts
quoted
turing tolerance". This tolerance
and its numerical value
quality

If
corresponding shaft have worn and
place
good workshop practice will ensure that consideration will be given
to
tion

Throughout this manual, whenever the

the

wheel end

joint

of

bum

in each

of

workmanship.

when carrying out a major overhaul it

in

the bush it may be necessary

the advisability

of

life that will involve labour costs at an early date.

engine is referred to, it

of

practice. Mention

faces, cleaning before inspection and re-assembly and

and scale have largely been omitted, it being under-

to

prevent the ingress

of

the sections in this manual

of

returning worn parts

the engine.

in order

or

of

is an expression

is

that

of
to

refitting

high precision components, e.a. fuel

is

side

avoid repetition. Where the

of

foreign matter. The difference

necessary

of

that

the majority

to

renew the bush only, however,

"left"

as

viewed from

in

certain accepted practices

of

out

is

as

the accuracy

is

to

conjunction with

a part

is

straightforward

to

renewing joints,

where applicable.

off

until

given in the

known

as

"the

an aid

found that a bush and

of

service with an expecta-

or

"right"

manufac·

to

manufacture

of

the desired

wear has taken

hand side

the

rear

or

fly-

It

as

of

4

Unified

All
proprietary
American

The

block
number

mation
of
would

Another
where
fuel
engine
for

Threads a

THREADS

ENGINE

immediately

should

or

both

be I 54 U 251.

possible,

injection

when

this

system

equipment

Pipe

ordering

letters

and

later

viewed

nd

used

Series.

NUMBE

he

quoted

parts.

and

system

be

pump

would

Engi

ne Numb

on

the

4.154

arc

R is

behind

standardised

from

located

in full

The

figures,

of

on

the
the

be

GA

13870U500256D.

the

engine

engine

rear. A typical

er

Location

engine

Unified

on

fuel

when

number

an

example

numb<!ring will,

on a pad

left

hand

excepting

Series

the

cylinder

pump.

seeking

of

near

side

and

This

infor-

consists

wh1ch

the

of

the

number

This

manual
Department
endeavour

contained
but

due

turers

reserve

without

noti

is

of

is

made

herein

to

continuous

ce.

produced

Perkins

to

is correct

the

right

by

the

Service

Engines Limited

ensure

that

the

at the

to

alter

date

this

development the

Location

Publications

and

information

of

publication,

manufac-

specification

every

of

Engi

ne

Number

5

ENGINE

VIEWS

View of Front

Perkins engines are built to individu

suit the applications for which they are intended and

the engine views

particular specification.

Left Hand Side

do

not necessarily typify any

of

4.154 Engine

al

requirements to

6

View

of

Rear Right Hand Side

of

4.154 Engine

7

8

----9

10

~

e

-!'

<

.:::

•

'i

i

u

1

Cl>

.ii::

..

Q

i

u

.r

.§

!-<

....

Q

.t

>

1

]

~

~

_;

11

General Information

At

Type
Bore (Nominal, see page
Stroke
Capacity
Compression Ratio
Combustion

Firing Order
Valve

Automotive type Applications

Hydraulic Governor
Maximum Torque

System

Tip Clearance

Section

GENERAL

ENGINE DATA

D.l.)

RATING DETAILS

INFORMATION

'A'

Four

Cylinder,

3.5 in (88,9 mm)

4.0 in (101

153.9 in

21.5:1
Indirect Injection, Ante-Chamber

(Perkins
1-3-4-2

0.012 in (0,30 mm) Cold

70

bhp

113 lbf ft ( 15.6 kgf

Four

Stroke, In-Line

,6

mm)

3

(2,523 litres)

.

"H"

type)

at 3,600 rev/ min

m)

at 2,000 rev/min

Agricultural type Applications

Mechanical Governor
Maximum Torque

Intennittently Operated Industrial Applications

Mechanical Governor

Maximum Torque

Variable Speed Light Duty Industrial Applications

Hydraulic Governor
Maximum Torque

Continuously Operated Industrial Applications

Mechanical Governor
Minimum Governed

Note: The above ratings can vary according

Service Department, Perkins Engines, Ltd., Peterborough.

Speed

to

application.

62

bhp

113 lbf

bhp

62

113 lbf

70

bhp

ll3lbf

55

bhp

1800 rev/min

For

details

at 3,000 rev/min

ft

( 15,6 kgf m) at 2,000 rev/min

at 3000 rev/min

ft

( 15,6 kgf m) at 2,000 rev/min

at 3,600 rev/min

ft

(15,6 kgf

at 3,000 rev/min

of

m)

at 2,000 rev/min

individual ratings, apply

to

General Information

A2

APPROXIMATE ENGINE WEIGHTS DRY

Engines with standard basic components, i.e. fuel injection
electrics.

lb
Automotive
Industrial
Agricultural

of

Installed approximate weight

starter

motor,

air cleaner,

engines including all components, and flywheel, flywheel housing

but

without

Automotive
Industrial
Agricultural

clutch.

DE-RATING

Where engines are called upon
The following table

a particular engine rating are not available.

is

given

to

operate in rarefied atmospheres occasioned

as

a general guide, which may be applied

430
400
430

lb

555
550
565

FOR

pump,

water and lubricating oil pumps, filters and

kg
195
180
195

kg

251

250
255

ALTITUDE

on

a percentage basis, where specific figures for

by

altitude,

or

they

should be de-rated.

backplate, fan,

Altitude

0 -

2,000

ft

(600
2,000 ­4,000 ­6,000
8,000

10,000 -

4,000
6,000

-

8,000

-

10,000 ft
12,000 ft

ft

ft
ft

metre)

( 1200 metre)

(I

800

metre)

(2400

metre)

(3000

metre)

(3600metre)

Any necessary adjustments in this respect
territory concerned. For
or

to

Overseas Companies listed

any

further information apply

on

Page 2.

..................

....................

....................

....................

....................

....................

to

the fuel pump, should

to

Maximum Fuel Delivery

Measured at

,

..

.
.
.
.
.

be

carried

800

rev /min Pump Speed

No change

6%
12%
18%
24%
30%

out

by

De-ratilll

the

C.A.V. dealer for the

Service Department, Perkins Engines Ltd., Peterborough,

The

following wear limits indicate

serviced

or

replaced.

SERVICE WEAR LIMITS

the

condition when it is recommended

that

Generai Information

the

respective items should be

A3

Cylinder Head Bow

Maximum Bore Wear
(when reboring
Crankshaft Main and

Maximum Crankshaft End Float
Valve

Stem

Diametrical Clearance
Valve

H.ead

Rocker Clearance

Camshaft
Camshaft End Float

Idler Gear End Float

Top

Max.

or

new liners are necessary)

to

Guide Bore

Thickness

Journals

Piston Ring

on

Big

End Journals

at

Outer

Shaft

Lift

Edge

RECOMMENDED

The following figures will apply

Component
Cylinder Head Setscrews (also

Secure Rocker

Main Bearing Setscrews .............................................. .

Connecting Rod Nuts
Connecting

Flywheel Setscrews .................................................... ..

Crankshaft Pulley Retaining

Power Take-off Pulley Setscrews ...............................

Camshaft Gear Setscrew .............................................. .

Idler Gear Hub
Dynamo
Alternator Pulley
Atorniser Securing
Lubricating Oil Filter Bowl Securing

Setscrews ......................................................... ..

Pump

Fuel

Shaft bracket) ................................... ...

Rod

Nuts (phosphated) ........................... ..

to

Pulley

Cylinder Block Nuts ....................... .

Nut

.................................................... .

Nut

Nut

Drive Gear Securing Setscrews ................. ..

with

the

components lightly oiled before assembly.

(non

phosphated) ..................... .

Setscrews ...................... ..

................................................

..............................................

Transverse
Longitudinal 0.006 in (0,15 mm)

Ovality 0.0005 in
Wear

Inlet
Exhaust

Ovality and Wear 0.002 in (0,05 mm)

TORQUE

Screw

..

..

..

TENSIONS

Size

1/2 in
1/2 in
7/16 in
7/16 in
1/2

in

5/8

in

3/8 in

1/2 in

5/16 in
7/16 in
7/16 in
5/16 in

1/2 in
5/16

in

0.003 in (0,08 mm) concave

0.005 in (0,13 mm) convex

0.006 in (0,15 mm)

0.001 in (0,03 mm)

0.020 in (0,51 mm)

0.005 in (0,13 mm)

0.006 in (0,15 mm)

0.045 in

0.005 in (0,13 mm)
O.Ql

O.Ql

0.008 in (0,20 mm)

lbfft

85
85

45

60

80

123
32
50
21

20

30
12

10
21

(O,Ql

mm)

(1,14

mm)

5 in (0,38 mm)
5 in (0,38 mm)

kgfm

11,7
11,7

6,2

8,3

11,1

17,0
4,5
6,9
2,9

2,8

4,15

1,7

l ,38

2,9

If

Connecting

Rod

Nuts are removed,

they

should

be

replaced

by

new ones.

•

General Information

A4

OPERATING INSTRUCTIONS

Starting the engine.
If the weather or engine

tion

"R"

run position. Adjust the accelerator

position and engage the starter
starter
"heat
engine starts release the starter switch

position.

Always be sure that the starter pinion and flywheel

have stopped rotating before re-engaging the starter

motor, otherwise the ring

To

A spring loaded

normal engine controls and functions by cutting off

the fuel at the fuel injection pump.

the knob and hold in this position until the engine

ceases
the

experienced

stops
"off"

and ensure the engine stop control

motor

start"

Stop

the engine

to

rotate. Ensure

"run"

rotilting; the switch can then be turned to the

position to switch

is

warm, turn switch

to

switch in a

position, see Fig.

stop

position, otherwise difficulty may be
in

restarting the engine. When the engine

motor

<;lockwise

or

pinion may be damaged.

control

that

off

the electrical auxiliaries.

direction

A.l.

As

is

located near the

To

the control returns to

to

posi-

is

in

the

the
the

to

the

as

the

"run"

the fully open

by turning

soon

to

operate, pull

At

oc.•~+

Cold Starting

stop

Switch on, ensuring the engine
"run"

position. Turn on the fuel supply tap
cold starting aid reservoir where fitted. Turn the
starter switch
for fifteen

With the accelerator
the

starter switch to the
by engaging
start after twenty seconds, return the switch
"heat"
the starter
position.
should be released
on

the
off.

to

the

"heat"

to

twenty seconds.

the

starter motor.

position for

motor

As

cold starting reservoir (where fitted) turned

by switching to

soon.

as

to

position and hold it there

in

the

fully open position,

"heat

ten

seconds and then re-engage

the

engine starts,

the

"run"

control

start"

If

the engine does not

the

position, and

is

in the
of

the

the

turn

to

the

start"

switch

the

tap

position, there-·

"heat

PREVENTIVE MAINTENANCE

General Information

AS

DAILY

level

of

Check
Check level

vehicle or machine
Check lubricating oil pressure (where gauge

In extreme dust conditions, empty dust bowl
type air cleaner.

Under adverse agricultural conditions, clean chaff
screens, radiators and centrifugal pre-filters.

4,000

MONTHS, whichever is the soonest.
Drain and renew lubricating oil - Lubricating oil

meet

must
specification in the appendix.

Renew element in lubricating oil filter.
Empty
Check fan belt tension -

3,000 rev/min the fan belt tension should
monthly.

Clean water trap.

Check engine for oil and water leakage.

Where fitted, lubricate dynamo rear bush.

coolant.

of

lubricating oil in sump (make sure the

is

standing level).

MILES

dry

(6,000

the approved specification. See oil

air cleaner dust bowl.

km)

1~0

HOURS

For

engines rated at above

is

be

checked

fitted).

on

dry

or

The Kilometre conversions
They are periods in Kilometres which should

of

in place

Operators
above

application, therefore he should

maintenance for his engine with the schedule speci­fied
the engine

shorter periods also bearing in mind that on

low mileage work, the hours run are more applicable
than the mileage covered.

Whilst
maintenance,

3

local regulations concerning your vehicle or machine

and ensure that the engine
regulations.

Running-in Procedure
New

at full power
or

20 hours. Neither should they be run without any
load upon them.
To assist in the initial bedding in
such
should be used at
output
after which it may be operated at full power.

Do

for an extended period, nor by running the engine
at idling speeds with no load.

POST DELIVERY CHECKOVER

miles in relevant countries.

of

Preventative Maintenance schedule

by

or

as

not

4.154 engines are reminded that the

the manufacturer

is

fitted, and where necessary adapt the

we

have given specific periods for preventive

you

should have due regard for the

replacement engines should not be operated

output

piston rings, bearings, seals etc., the engine

for the first 500 miles (800 km) or 20 hours,

"run

about

in"

an engine by applying a small load

of

miles are

of

the application

is

operating within those

for the first 500 miles (800 km)

80%

of

not

accurate.

be used

is

c;ompare the routine

of

its maximum power

general in

to

which

stop-start

the moving parts

12,000 MILES (18,000 km)

MONTHS, whichever is
Tractor and Industrial applications, renew the final

fuel filter element;

Check and adjust tappets.

Check hoses and clips.

Clean element
not

indicated earlier)

24,000 MILES (36,000 .Ion)
Vehicle

element.

72,000 MILES (108,000
Arrange for examination

equipment, i.e. Compressor/Exhauste"r, Starter Motor,

Dynamo etc.

Service atomisers.

of

dry type air cleaner,

Applications, renew the final fuel filter

km)

450

the

soonest.

900

HOURS

2,700 HOURS

and

service

HOURS

or

renew, (if

of

proprietary

or

12

After a customer has taken deliveryof his engine, a
general checkover must be carried

500/1,000 miles

service and must include the retightening
cylinder head setscrews in the correct sequence. With
the engine thoroughly warmed through, the check­over comprises the following:-

Drain the lubricating oil sump and refill

1.

correct level with clean new engine oil (Do
overfill).

Renew lubricating oil filter element (canister).

2.

Tighten the cylinder head setscrews in the

3.
correct sequence (see
torque

Reset the valve tip clearances

4.

mm)
Check oil feed

5.

Check the tension

6.
Check the tightness

7.
screws, mountings, etc.

Start the engine and check for any fuel, coolant

8.

or

lubricating oil leaks.

Adjust idling speed

9.

(800/

1,600 km) or

of

80-85

(see page 8.5).

to

rockers.

fig.

lbf

of

the fan belt (see page K.2.)

if

necessary.

out

after the first

20/40

hours m

of

the

to

the

not

8.2)

and to the correct

ft (11,06-11,75 kgf m).

to

0.012 in (0,30

of

all

external nuts, set-

General Information A6

PRESERVATION

OF

LAID-UP ENGINE

Batteries

Where an application which

engine

is

to

able that some measure
engine
intervening period before operations are

menced.

It

is recommended, therefore,

procedure be adopted and applied immediately the

unit

is

I.

2. Run the engine until well warmed through.

3. Discard the paper element in the full flow

4. Clean

5. Fill the lubricating oil sump

be laid-up for several months, it

to

ensure

that

withdrawn from service.

Thoroughly clean all external parts
engine.

Stop

the engine and drain the lubricating oil

sump.

cating oil filter, clean the filter bowl and fit a
new element. Fill the filter bowl (where

sible) with a new oil

list

of

approved lubricating oils appears in the

appendix.

out

the engine breather pipe.

with clean new lubricating oil

as

grade,

referred

is

powered. by a Perkins

of

protectic.n be afforded the

it suffers no

to

in

ill

effect during the

that

the following

of

an approved grade. A

to

the correct level

of

(3)

above.

an approved

is

advis-

recom-

of

lubri-

pos-

the

(a) Remove the

engine and
water, making sure
the separators
cov:ered.

(b) Recharge the

source

(c)

Screw home the vent plugs and clean the
battery
ture.

Clean the terminals and lightly smear

(d)

them with petroleum jelly.

(e)

Store in a cool, dry, dust-free place.
no account should the battery
where there

(f)- Recharge once a

rate

of

battery

top

of

supply.

removing all dust, dirt and mois-

is

charge,

or

up the cells with distilled

or

battery

a risk

batteries from the

that

the

top

separator guards are just

from a separate

of

freezing.

month

to

a state

edges

at

the

of

free gassing.

be

normal

of

On

left

Starters and Generators

Clean the terminals and lightly smear them with
petroleum .ielly
open, the
protected against water falling

If

gener:ttor

the machine
starter

is

and control panel must be

to

dire"ctly

stand in the

onto

them.

6. Carry

7. Drain water by opening all the drain taps

8. Remove the atomisers and spray into the

9. Replace the atomisers (using new

I

0. Remove the air cleaner and any air intake pipe

II.

12. Remove cylinder head cover. lubricate

out

cribed in the appropriate Fuel Pump section.

on the cylinder block and the radiator.
ensure complete draining,
remove the drain taps entirely and check that

the holes are
reasonable drainage period, refit the taps
open position.

cylinder bores
oil, divided between all cylinders.

and slowly
revolution.

which may be fitted between the air cleaner
and air intake.
orifice with waterproofed adhesive tape
other

Remove the exhaust pipe, and seal
orifice with adhesive tape as in

rocker assembly with engine oil and replace

cover.

attention

rotate

suitable medium.

to

the fuel

not

blocked by scale. After a

i pint (70 cm

the crankshaft one complete

Carefully seal the air intake

it

is

3

(I

pump

preferable

)

of

lubricating

joint

the

0) above.

as

both

in

washers)

or

some

manifold

des-

To

to

the

the
the

Fuel Injection Pump

Drain all fuel oil from the fuel tanks and filters.

I.

Put into the fuel tank at least a gallon

the oils listed
Inhibiting
construction
oil

is

inadequate, break the fuel feed line before
the first filter and connect a small capacity
auxiliary tank.

Prime the system as detailed

2.

Start

3.

4.

s.

the engine and run it until the oil has

circulated through the. injection

pipes and injectors, which will be after it has
run light, at
least fifteen minutes.

Stop

the engine.

Seal

the
waterproofed adhesive tape
of

water condensation during the lay-up period.

under

the

Fuel

of

about

air vent in the tank

"Recommended

System".

the

fuel

tank,

half maximum speed, for at

If,

because

this

on

page L.7.

or

filler cap with

to

reduce

of

one

Oils for

of

quantity

pump,

the

of

the

of

feed

risk

13. Remove the fan belt and retain this for refitting
when

the

engine

is

to

be returned

to

service.

The proprietary brands
mended for
panies. They may
world,
to

the

the

purpose

not

but

suitable oils may be obtained

appropriate companies. The specification

of

oils listed are recom-

by

the

be available in all parts

should include the following:-

Viscosity: The viscosity should

centistokes
likely

at

to

the

be experienced

Pour Point: Must be at least

not

lowest ambient temperature

on

l5°F

the lowest ambient temperature likely

on

experienced
be lower
be met during

The oils selected are
calibrating

or

testing pumps.

restarting and should preferably

than

the lowest temperature likely to

the

lay-up period.

not

necessarily suitable for

respective oil com-

of

by

the

reference

be greater than 22

restarting.

(9°C) lower

than

to

be

General Information A 7

PREPARING THE ENGINE FOR RETURN
SERVICE

When

the

engine

is

to

lowing procedure must be

1.

Thoroughly clean all external parts

observed:-

engine.

be returned

2. Carry

3. Ensure

out

cribed in

attention

the

Fuel Pump Section

that

the

cylinder block and rlJdiator

to

drain taps are correctly fitted in the closed
position and fill the system with clean coolant.
Check visually for leaks and remedy where
necessary.

4.

Rotate
freedom

the

water

of

the water pump seals.

pump

to

the

fuel pump

by hand

service,

on

Page A.8.

to

the

of

a!l

TO

fol-

the

des-

ensure

Caution

is

When oil
be allowed

being drained from the system it must not

to

fall on electrical equipment.

RECOMMENDED OILS FOR INHIBITING THE
FUEL SYSTEM

Lowest

Temperature

During

Lay-up

Esso

IL81S
Esso·IL1047
Shell

Calibration

Shell

Calibration

Shell

Fusus

Shell

Fuses

In

Note:
ture likely

........................

..... • .................

Fluid

"C" (U.K.)

Fluid

"B"

"A"

•...................

"A"

R1476

(Overseas)

(Old

Type)

choosing a suitable oil

to

be met

by

the

engine during

.

.

••.•••

...

.....

the

25°F

(-4°C)

0°F

(-l8°C)"

0°F (-l8°C)

-70°F

(-57°C)

-l5°F

(-26°C)

25°F (-l4°C)

lowest tempera-

the

lay-up

period should be estimated, and the oil should be

that

the

such
as,

or

lower

made

to
been at least
table for

temperature given in the table

than

restart

not

this estimate. No

the

en~ne

l5°F

(9 C) above

less

than

24

until

hours; otherwise there may

the

be difficulty in obtaining a free flow

attempt

temperature has

that

.Df

is

as low

should be

shown in the

fuel.

5. Refit the fan belt and adjust

to

the correct

tension.

6. Remove the cylinder head cover, lubricate the

rocker assembly with engine oil and replace the
cover.

7. Remove the adhesive tape from

the

orifice and refit
gauze

is

clean and if

with clean engine oil to

8.

Refit any air intake pipe between the air clean­er and

the

air intake

air cleaner. Ensure that the

it

is the oil bath type, fill
the

whiCh

the

air intake

correct level.

may have been

removed during laying-up procedure.

9. Remove the adhesive tape from the exhaust
the

manifold orifice and refit

exhaust pipe

using new joints.

10. Connect

fully charged and topped

the

battery

or

batteries

up

as

necessary with

into

circuit,

distilled water.

Starters and Dynamos

11. Wipe the grease from
that

all connections are sound.

fitted with a Bendix

the

terminals and check

type

If

of

drive, which proves

the

starter is

sluggish in engagement when operated, the
starter

motor

should be removed and the drive
cleaned thoroughly in a suitable cleaning fluid.
Lubricate with a little light engine oil before
replacement.

12. Check the level and condition
the

sump. Change the oil

the

engine in

the

normal manner checking

13.

oil in
Start

for oil pressure and dynamo charge
ately.

the

14. Whilst

temperature it
running normally and

engine is attaining normal running

is

advisable

that

it is free from water,

fuel and lubricating oil leaks.

to

of

if

check

the

lubricating

necessary.

immedi-

that

it

is

General Information

D.P.A.

Distributor

Remove the adhesive tape from the fuel tank

1.

vent or filler cap.

Drain the fuel tank

2.

and condensed water, and refill the tank with
fuel oil.

3. Fit a new filter element and
oil flows free from air bubbles (see page L.8)

4. Air vent and prime the pump (see page L.7).

Pump

AS

to

remove any remaining oil

vent the filter until

NOTE:

If

the foregoing instructions are observed, the
laying-up and returning to service should be carried
out efficiently and without adverse affect on the
engine. Perkins Engines Ltd., however, cannot accept
liability for direct or consequential damage that
might arise following periods

of

laying-up.

FROST

Precautions against damage
if the engine
weather either by adequately draining the water
system or where this is not convenient, an anti-freeze
of
corrosion inhibitor may be used.

Should it be your policy

When draining a cooiing system, ensure that the

PRECAUTIONS

by

is

to be left exposed to inclement

reputable make and incorporating a suitable

damage by adding anti-freeze to the cooling system,
is

advisable that the manufacturers
mixture be contacted to ascertain whether their
products are suitable for
to ensure that their products will have no harmful
effect on the cooling system generally.
perience that the best results are obtained from
anti-freeze which conforms to British Standard 3151
or has been tested in accordance with

5 to

give

at least

The coolant solution containing
freeze manufactured to BS.3151 in water in a properly
maintained engine should maintain its anti-freeze and
anti-corrosive properties throughout the winter season
and in general, a safe life
ably be expected.

vehicle or machine

as

is

frost should

to

protect engines from frost

use

in Perkins Engines, also

good a result

25

of

12 months may reason-

on level ground.

be

taken

of

the relevant

It

is

our ex-

BS.5ll

7,

Clause

as

BS.315l.

per cent anti-

it

When

the engine

drained, but rotation
by:-

(a) Locking

drain hole being blocked

(b) The locking of the seal through the freezing

globules of moisture between the seal and the

insert.

Operators are therefore advised to-take these
tions when operating in temperatures below freezing
point:

1.

Before starting the engine,
by

hand, this will indicate if freezing has taken

place.

free any ice formation.

If

2.

3.

After an anti-freeze solution has been used, the
cooling system should be thoroughly flushed in
accordance with the anti-freeze manufacturer's
instructions before refilling with normal coolant.

it is impossible

the engine should be filled with warm water.
To

when all water has been drained, run the engine

for a few seconds at
ing any moisture remaining in pump.

is

drained the water

of

the pump may be prevented

of

the impeller

If

freezing has taken place, this should

avoid this trouble. the operator should.

by

by

to

tum

1dung speed, thus

pump

ice due

tum

to

sediment.

the water pump

the

pump

is

also

the pump

precau-

by

hand,

<11Spers-

of

If

the foregoing action
should be experienced,
cannot be held responsible for any frost damage
corrosion which may be incurred.

is

taken, no harmful effects

but

Perkins Engines Ltd.,

or

fault finding chart

General Information

A9

FauH

Low cranking speed

Will not start

Difficult starting
Lack

of

power
Misfiring
Excessive fuel consumption
Black exhaust
Blue/white exhaust
Low oil pressure
Knocking
Erratic running
Vibration
High

oil

pressure

Overheating

Excessive crankcase pressure

Poor compression
Starts, and stops

Poulble

1,

5,
5,
8,
8,

Cause

2,

3,

4.

6,

7,

8,

9.

10.

12. 13, 14,

7.

8,

9,

10, 11, 12. 13,

9,

10,

1~

12, 13. 14. 18, 19,

9,

10. 12, 13, 14, 16. 18. 19.
11, 13, 14, 16, 18, 19,
11,

13,

14,

16.

18, 19,

4,

16.

18. 19,

20,

25, 27.

4,

36.

37, 38,

39,

40,

9,

14, 16. 18, 19,

7,

8,9,

10, 11,

13.

14,

20,

4,

38,

41.

12,

23. 25,

22, 26,

13.
26,

11, 13, 14, 16, 18. 19,

25,

31, 33, 34,

11,

19,

25, 28.

45,

29,

55.
31, 32.

10, 11, 12.

14.

20, 22,
20,f2.

31.

42, 43.

28.

14.

16.

29.

30, 33,

24, 25,

33,

15.

16. 17,

15, 16, 18. 19.

20, 21, 22.
20,

25, 26. 28. 29,

23.

24,

25, 27, 28,

24.

25, 27,

33.

34. 35.

44,

58.

29.

31.

33. 35,

20.

21. 23, 26,

45. 48, 49.

45,

47,

50, 51. 52, 53. 54. 57.

34.

46,

59.

KEY TO FAULT FINDING CHART

1.

Battery capacity low. 31. Worn cylinder bores.

2.

Bad electrical connections.

3.

Faulty starter motor.

4.

Incorrect grade of lubricating oil.

5.

Low cranking speed.

6.

Fuel tank empty.

7.

Faulty stop control operation.

8.

Blocked fuel feed pipe. 38. Inaccurate gauge.

9.

Faulty fuel lift pump.

10.

Choked fuel filter.

11.

Restriction in

12.

Air in fuel system.

13.

Faulty fuel injection pump.

14.

Faulty atomisers

15.

lncor'l-ect use of cold start equipment.

air

cleaner.

or

incorrect type.

16. Faulty cold starting equipment.

17. Broken fuel injection pump drive.

18.

Incorrect fuel pump timing.

19. Incorrect valve timing.

20.

Poor compression.

21.

Blocked fuel tank vent.

22.

Incorrect type or grade

23.

Sticking throttle or-restricted movement.

24.

Exhaust pipe restriction.

25.

Cylinder head gasket leaking. 55. Choked breather pipe.

26.

Overheating.

27.

Cold running. 57. Coolant level too low.

28.

Incorrect tappet adjustment.

29.

Sticking valves.

30.

Incorrect

h_igh

pressure pipes.

of

fuel.

32.

Pitted valves and seats.

33.

Broken, worn

34.

Worn valve stems and guides.

35.

Overfull air cleaner

36.

Worn

or

37.

Insufficient oil in sump.

39.

Oil pump worn.

40.

Pressure relief valve sticking open.

41.

Pressure. relief valve sticking closed.

42.

Broken relief valve spring.

43.

Faulty suction pipe.

44.

Choked oil filter.

45.

Piston seizure/pick up.

46.

Incorrect piston height.

47.

Damaged fan.

48.

Faulty engine mounting (Housing).

49.

Incorrectly aligned flywheel housing,

50.

Faulty thermostat.

51.

Restriction in water jacket.

damaged bearings.

52. Loose fan belt.

53.

Choked radiator.

54.

Faulty water pump.

56.

Damaged valve stem oil deflectors

58.

Blocked sump strainer.
Broken valve spring.

59.

18,

19.

20. 22,

31, 32. 33.

20, 21, 22. 24, 29.

23.

24. 25, 26. 27.
30,

32.

29.

31.32.

28. 29.

31,

32,

45,

56.

36.

45, 46,

28. 29.

30. 33.

or

sticking piston ring/s.

or

use of incorrect grade of oil.

33.

59.

31. 32. 33.

31, 32.

33.

35,

45.

(if

33.

59.

or

flywheel.

fitted).

Section

Cylinder Head B 1

' ,

B

CYLINDER

The cylinder head

of

"cross flow" design with the exhaust and inlet

ing
ports

on
rod operated through the rocker gear mounted
top
cover which
the right hand side
a synthetic rubber oil deflecting seal,
exhaust valves are provided with two springs retained
by a hardened cap and split conical cotters. All valves

Cylinder

opposing sides. The overhead valves are push

of

the cylinder head, covered by a pressed steel

Head

is

a one piece high duty iron cast-

is

provided with a breather pipe fitted

of

the engine. Each inlet

both

CYLINDER HEAD DIMENSIONS

Overall depth
Skimming allowance
Pressure for Water Leak Test
Valve seat angle
Bore for Valve Guide
Bore for
Depth

of

Cylinder Head

Combustion Chamber Inserts

of

bore for Inserts

on

the

to

valve

has

inlet and

HEAD

operate in cast iron guides pressed into the head. The
upper
hemispherical in shape, being formed by an inserted
machined plug containing a throat connecting the
chamber to the cylinder.
cylinder head through jets
fishtail area in the combustion chamber inserts. The

cylinder head
twenty setscrews, seven
rocker shaft

part

of

the combustion chamber

Coolant is delivered

to

the valve bridge and

is

secured

to

the cylinder head.

3.248/3.252 in (82,5/82,6 mm)
Nil
30 lbf/in2 (2.11 kgf/cm
45°

0.500/0.5()1

1.375/1.3766 in (34,92/34,96 mm)

0.425/0.4281 in (10,79/

in (12,7/12,73 mm)

to

the cylinder block by

of

which also secure the

2

)

10,87 mm)

to

is

the

Combustion Chamber Inserts

Outside diameter
Clearance fit
Combustion Chamber Insert thickness
Height

Method

Valve Guides, Inlet

Outside diameter
Interference fit
Overall length
Guide protrusion above
Valve Guide bore diameter

of

of

Insert in relation

of

location

and Exhaust

of

of

Insert

Insert in Bore

to

of

Guide

of

Guide in Bore

Guide

Cylinder Head Top Face

Cylinder Head face

1.3724/1.374 in (34,86/34,9 mm)

0.001/0.0042 in (0,02/0,11 mm)

0.4252/0.426 in

0.001 in (0,02 mm) above,

0.0029 in (0,07 mm) below.
By

Cylinder Block Face and Expansion Washer.

0.50125/0.50175 in (12,73/12,74 mm)

0.00025/0.00175 in (0,01/0,04 mm)

2.13 in (54,10 mm)

0.638/0;662 in ( 16,20/16,81 mm)

0.3145/0.3155 in (7,99/8,01 mm)

(10,80/ 10,82 mm)

Cylinder Head

Valves. Inlet

82

Valve

stem

Clearance

Valve head
Valve face angle

depth

Valve
Overall length

Sealing Arrangement

Valves, Exhaust

Valve stem
C'learance fit
Valve head
Valve face angle

depth

Valve

Overall
Sealing arrangement

Valve Springs Inner

Fitted
Load at fitted length
Free length

Valve Springs Outer

Fitted
Load at
Free length

diameter

fit

of

Valve

diameter

below Cylinder Head face

diameter

of

diameter

below Cylinder Head face

length

length

length

fitted

stem

of

Valve

Valve sten: in Guide

of

Valve

length

in Guide

(Production)
(Service)

(Production)
(Service)

0.312/0.313

0.0015/0.0035

1.591/1.598

45°

0.029/0.041

0.060

in

(1,52

4.503/4.521
Synthetic

0.312/0.313

0.0015/0.0035

1.3937/1,4016

45°

0.027/0.040

0.060

4.503/4.5.21 in

in

Rubber

(I

,52

Nil

1.49 in (

28 ± 1.4

1.74 in

1.59 in

40±

1.8

37,84

lbf

(44,19

(40,38

2.0lbf(l8,1

r in

(45,97

(12,7

in (7

,92/7,95

in

(0,04/0,09

in

(40,41/40,59

in

(0,74/1,04

mm)

in (

114,38/114,83

Deflector

in (7 ,92/7,95

in

(0,04/0,09

in

(35,4/35,6

in

(0,69/1,02

mm)

(114,38/114,83

mm)

± 0,65 kgf)

mm)

mm)

± 0,91 kgf)

mm)

mm)

mm)
mm)

mm)

mm)

mm)

mm)
mm)

mm)

mm)

Rocker Levers

Rocker
Outside
Interference fit
Inside

Rocker Shaft

Outside
C'learance fit
Lubrication

Push Rods

Overall length
Outside

lever bore

diameter

diameter

diameter

of

diameter

diameter

of

Bush

of

Bush in bore

of

Bush

of

Shaft

Rocker

Lever Bush

(fitted)

on

Shaft

0.7188/0.7196

0.7199/0.7207

0.0003/0.0019

0.625/0.6258

0.6234/0.6244

0.0006/0.0024
No.

I Bracket

to

Rocker

8.5102/8.5412

0.247/0.25

Levers

in

in

(18,26/18,28

in

(18,29/18,30

in

(0,01/0,05

in

(15,87/15,89

in

(IS

,83/15,86

in

(0,01/0,06

through

(6,27/6,35

Shaft

in

(216,16/216,94

mm)

mm)

mm)

mm)

mm)

mm)

mm)

mm)

To Remove the Cylinder Head
The following parts are bracketed

head which will have

to

be detached before the

cylinder head can be removed.
Lubricating oil filler tube.
Engine breather pipe.

to

Fuel pipe from lift pump
rear covet plate

of

cylinder head). See Fig.

fuel filter (bracketed

Fuel filter.

to

the cylinder

B.l.

to

Cylinder· Head

BJ

Because the
head
be necessary

ROCKER ASSEMBLY is secured

by

the cylinder head securing setscrews, it will

to

adopt the following procedure.

to

the

Remove the two self-locking nuts from studs locating

in Nos. 1 and 7 rocker support brackets,- counting
from the front. Loosen all the cylinder head setscrews
in the reverse order to

that

shown

on

Fig. B.2.
Remove the seven setscrews securing the rocker
assembly. The rocker assembly can now be removed.

Valves

To remove the valve collets use a valve spring com­pressor and a suitable adaptor.

The valves are numbered
original positions.
the valve depths relative
be contained within the limits quoted
See Fig. B.3. Valve seat and valve angle
both

inlet and exhaust valves.

If

servicing

to

ensure refitment

is

to

necessary, check that ·

the cylinder head face will

As

narrow a seat

on

Page B.2.

is

to

45° for

their

as

possible should be maintained.
When refitting the valve assembly into the cylinder

head, take care
inlet valve only

the rubber oil deflector

is

fitted

onto

the valve stem, open

on

the

that

end facing downwards, under the valve spring cap, see
Fig.B.3.

Bl

82

VALVE SEAT INSERTS cannot be fitted

to

the

4.154 engine.

Valve

Guides

When renewing valve guides, remove the worn guides
by

using a suitable dolly and press.

ment

of
pull in,
in
continued until the guide
of
operation
experienced in restarting.

new guides use a special tool with adaptor

but

of

care must be taken

the guide is commenced, the operation must be

is

fully home.

the guide into its location

is

completed, difficulty

Use

ensure correct guide protrusion

For

the replace-

that

when the pulling

If

is

of

the special stop will

as

quoted

the pulling

halted before the

is

likely

on

Page B 1,

to

to

be

see Fig. B.3.

83

Cylinder Head

84

Valve Springs

84

0

0

0

0

c

Check the
specific lengths against the figures quoted on

8.2,
fatigue.

overhaul

Rocker Shaft Assembly
When

support brackets for re-assembly,

feed to the rockers
cylinder head, and a drilling in the base
support bracket locates with this hole,

Also note that the rocker shaft locating scallop

towards the front

Rocker Levers

If

rocker lever bushes are found
replacement, rocker levers complete with bushes
ready to fit are available.

Rocker level bushes are also available separately.
With early engines, the oil hole in the bush should
align with the oil hole in the rocker lever, but with
later engines, after fitting the bush, it should be
drilled with a 2 mm drill in line with the oil hole in

the rocker lever. With the latter operation, ensure
that all machining swarf
the rocker shaft.

valve

springs for pressures developed at

and for any signs

It

is

advisable to fit new springs when an

is

undertaken.

dismantling, take note

of

is

at the forward end

of

the shaft.

is

8.4.

The oil

of

Page 7.

Page

of
of

No. l

the
the

of

deterioration caused by

of

the order

see

Fig.

see

to

be in need

removed before assembling

is

BS

)

0·001in 0,02

O·OOZiin

n

m•

O,Olmm

above

-

n

DC

14-3

Combustion Chamber Inserts

To

·remove the inserts

through the atomiser bore and tap out.

To replace, locate the inserts

sion washers,
turning whilst the engine

When

cylinder head face should be checked against the
figures quoted on

Cylinder Head Distortion
The limits for cylinder head bow are given in

SERVICE WEAR LIMITS on Page A.3.
tion reveals a dimension in excess
quoted, a replacement cylinder head
as

no

allowance for skimming

Cylinder Head Gasket
Fit a new gasket when replacing the cylinder head.

This

is

the cylinder block top face.

see

fitted, the height

fitted DRY, and

Fig.

Page

use

a short length

by

means

8.5,

to prevent the inserts from

is

in service.

of

the insert in relation

8.1,

see

Fig.

is

provided.

is

located by two dowels in

See Fig.

of

8.6.

If

of

is

recommended,

8.7.

of

bar

the expan-

to

the

examina-

the limits

86

Refitment

Before refitting the cylinder head, ensure that the
oilway in the block
clean. Examine the PUSH
fit into their location.

The rocker assembly

and
through Nos. I and 7 rocker support brackets and
secured by two nuts. The rocker shaft
positioned
securing stud. (Take care that the oilway in the base

of

No. I support bracket
corresponding oilway in the head. After fitting the
cylinder head, replace the seven longest setscrews

through the support brackets into the head and secure
finger tight.

Replace the remaining thirteen setscrews and tighten

them all progressively in the sequence shown in Fig.
B.2, until a final torque
kgf
should

Retighten the two rocker assembly securing nuts.

Valve Oearances

The

cold at

following

(a) With the valves rocking on No. 4 cylinder (the

of

Cylinder Head

top

face and cylinder head is

RODS

for straightness, and

is

is

located by two studs in the cylinder head

by

the scallop which locates on the front

m)

is

achieved. This final torque tightening stage

be

repeated.

valve

tip clearance should be set with the engine

0.012 in (0,3 mm)
procedure:-

period between the opening
and the. closing
clearance on No. 1 cylinder.

fitted before securing the head,

is

is

clean and aligns with the

of

80-851bfft

see

Fig. B.8, using the

of

the exhaust valve), set the

of

the inlet

(II,l-11,7

correctly

valve

Cylinder Head

(b) With the valves rocking on No. 2 cylinder, set

the clearance on No. 3 cylinder.

(c) With the valves rocking on No. I cylinder, set

the clearance on

(d) With the valves rocking on No. 3 cylinder, set

the clearance on No. 2 cylinder.

Atomisers

Refit the atomisers squarely into their locations using
a new sealing washer, and ensure that the securing
nuts are tightened evenly to a torque

(I

,4-1

,7

kgf m).

Engirie.Running Check
Before fitting the top cover, start the engine and run

at a fast idle.
Check for satisfactory oil pressure where a gauge

fitted. Check that lubricant is reaching the rocker
assembly. Check for fuel, oil and coolant leaks.

When

the engine is thoroughly warmed through, shut

down

ap~

re-torque the cylinder head securing set­screws.
clearances

Carry out this check again after

(800/I,600

When

the engine

to

0.012 in (0,30 mm).

km) or 20/40 hours in service.

No.4

is

cylinder.

cold,

re«:t

of I 0-12

the

500/1,000 miles

valve

BS

lbfft

tip

is

B1

B8

0·012in

0,30mm

clld

,,,

• • •

Sect1on

Pistons and Connecting Rods C I

C

PISTONS

The pistons are
aluminium_alJoy, flat
rings, and one scraper ring above the gudgeon
one below

The gudgeon pins which are fully floating are located
axially in

The gudgeon pins are off-set, so ensure

and connecting rods are correctly assembled by means
of

the

rod

it.

the

numbers

big ends

manufactured

topped

pistons by circlips.

on the piston crowns and connecting
as

described later in this section.

with

AND

from high silicon

three compression

that

piR

and

the pistons

PISTON AND ROD DIMENSIONS

Pistons

Pisto!l

Type
Piston Height in relation
Bore Diameter for Gudgeon Pin
Transition fit

Compression Ring Groove Width top, 2nd and

Scraper Ring Groove Width

of

Pin in Bore

Rings

Compression,
Compression, 2nd and
Scraper,
Scraper,

Compression Ring Width,

Ring Clearance in Grooves
Scraper Ring Width,
Ring Clearance in Groove

Scraper Ring Width,

Ring Clearance in Groove
Compression Ring Gap,
Compression Ring Gaps, 2nd and 3rd
Scraper Ring Gap,
Scraper Ring Gap,

top

4th
5th

4th
5th

to

3rd

top,

4th

5th

top

Cylinder Block

4th

and

5th

2nd and

3rd

CONNECTING

The

connecting rods are manufactured from

molybdenum alloy steel stampings with an

section shank. The big ends are split at

the

rod axis, with each cap secured by
bolts. The big end bearing
placeable thin wall aluminium-tin steel backed shell
bearings, and
backed

Top

Face 0.000/0.004/

3rd

bronze

Flat topped

1.2495/1.250

0.00024
interference (0,001/0,01 mm)

0.096/0.097

0.1895/0.1905

Chrome plated

Internally stepped
Chrome plated, slotted
Slotted

0.093/0.0938

0.0022/0.004

0.1868/0.1875

0.002/0.0038

0.1865/0.1875

0.002/0.004

0.014/0.019

0.011/0.016

0.014/0.019

0.011/0.016

in clearance/0.00046

RODS

the

small end bores are fitted

lined bushes.

in

(0,00/0,lO mm) above

in (31 ,74/31,75 mm)

in

(2,44/2,46
in

(4,81/4,84

or

Chrome

in

(2,36/2,38

in

(0,05/0,10

in (

4,74/4,76

in

(0,05/0,10

in

(4,74/4,76

in

(0,05/0,10

in

(0,35/0,48

in

(0,28/0,41

in

(0,35/0,48

in (0,28/0,41 mm)

ri$tht

two

boreS are fitted with re-

in

mm)

mm)

inlay

mm)
mm)

mm)

mm)

mm)

mm)
mm)
mm)

mm)

"H"

an.llles

nuts and

with

steel

to

The Ring Gaps
larger diameter bore.
in diameter above

Gudgeon

Connecting

quoted

3.501

Pins

Type
Outside Diameter
Clearance fit

Rods
Type

Big

End

Small End
Connecting
Length

of

Small End

above are

0.003

in (0.08

in

(88,93 mm).

in Small End Bush

Parent

Bore

Parent

Bore

Rod

Big

from centre line

End

a~

measured in a 3.501 in (88,93 mm) diameter bore.

mm)

should be added to the figures given for every 0.001 in

Fully floating

1.24976/1.24996

0.00054/0.00175

"H"

Section

Width

of

Big End

to

centre line

2.395/2.3955

1.375/1.376

1.361/1.363 in

6.8115/6.8135

in

(60,83/60,84

in

(34,92/34,95
(34,57/34,62

in

If

gaps are measured in a

(0,03

in (31 ,74/31,75
in

(0,01/0,04

(173,01/173,06

mm)

mm)
mm)
mm)

mm)

mm)

mm)

increase

Pistons and Connecting Rods C2

Connecting Rod End

Big

End Bolt Size
Thread
Type

of

of

Big End

Bolt

Float

Nut

0.0095/0.0131
7/16in(ll,ll
U.N.F.

Self Locking

in

(0,24/0,33

mm)

mm)

Note: When

Connecting

Large and small

Big

End nuts are removed, they must be replaced

Rod

alignment

end

Connecting Rod bores must be square and parallel with

in (0,25 mm) measured 5 in ( 127 mm) each side
the small

end

bush fitted, the limit

of±

0.010

II-~

.!:

~

~~

~·

~N

C:>O

+I +I

~

II

Small

End

Bushes

Cl

of

the axis

in (0,25 mm)

5in

127mm

-

by

of

the rod

is

reduced

5in

127mm

new ones.

on

to±

o e

- e

";g

'?N

i'jc:i

~~

each

other

within

the

test mandrel as shown in

0.0025

in

(0,06

mm).

-u

the

limits

Fig.

of±

C.

0.010

I.

With

Type
Length

Out~ide

of

Small End Bush

Diameter

Interference
Inside Diameter (finished bore in position

reaming)

Connecting Rod Bearings

Type
Shell Width
Outside Diameter

Inside Diameter
Connecting Rod Bearing Running Clearance
Steel Thickness
Aluminium

Fit

Tin

Thickness

of

Bush

of

of

Bearings

in

Rod

Bearings

after

Steel Backed, Bronze lined

1.047/1.055 in

1.3785/1.380

0.0025/0.005

1.2505/1.25

Steel

backed,

1.1208/1.1280

2.3955 in (60,85

2.2504/2.2515

0.0014/0.003

0.0467/0.0582

0.0138/0.0256

(26,59/26,80

in

(35,01/35,05

in

(0,06/0,13

15

in

(31,

Aluminium

in

(28,47

mm)

in

(57

,16/57,19

in

(0,04/0,08

in

(I

,19/1,48

in

(0,35/0,65

76/31 ,79

/28.,65

Tin

mm)

mm)

mm)

mm)

lined

mm)
mm)

mm)

mm)
mm)

Remova1

of

Piston and Rods

Sump

On

some applications it will be found necessary

remove the engine from the chassis because the engine

support brackets are fastened
The pistons and connecting rods are removed from

the cylinder block through the
bores, see Fig. C.2.

Big

End Bearings

If

examination reveals
renew big end bearings, they should be suitably
marked

to

ensure ret'itment

to

the sump.

top

of

that

there is no necessity

to

their original positions.

the cylinder

to

to

Pistons and Connecting Rods C3

Gudge«,m
To

the pistons, immerse the pistons in a warm liquid

I00-120°F (40-50°C), when the pins, after removal

of

Pistons and Rings

If

able dependant upon the condition

Production

Service Standard -

Cylinder bore -

Pins

facilitate the removal

the circlips, can

new pistons are to be fitted, three grades are avail-

Standard-

be

of

the gudgeon pins from

easily withdrawn.

of

the

liners.

Piston topping allowance
tive to height above cylinder

top

face

is

block

in

(0,00/0,10 mm).

The piston
and

will

of

limit
Where engines have

conform
regulation B.S.AU14Ia:I971,
then
pistons must
topped
tion limits.

3.5010/3.5020 in

piston height.

to

standard production

to

0.000/0.004

is

minimum topped

not

exceed the top

the smoke density

be

maintain produc-

used and

rela-

to

{88,93/88,95 mm)

Service

Cylinder bore -

(0, 76

0.030 in ­mm)

Oversize

Two pistons are available: one
untapped
the
lation and one with minimum
topping which will
the

3.5310/3.5320 in

B.S.

top

limit

for topping

AU

14la:l971

of

piston height.

not

to

meet
regu-

exceed

(89,69/89,71 mm)

The maximum permissible worn ring lift

piston ring with a new ring fitted
mm).

In a worn cylinder bore, the piston ring gap should be

in

measured
der and checked against the dimensions
Page

C.l.

the unworn, clean portion

is

0.008

of

of

the

in

(0,20

the cylin-

quoted

top

on

C3

Pistons and

Connecting

Rods C4

Connecting Rods
To

renew small
by means
new bushes, making sure

and rod small end align when fitted. Ream
new bush to dimension
squareness with big end bore. See
ing

mnnecting

Assembly

If

H

i~

intended to utilise the existing pistons, ensure
that they are relocated in their original positions
relative to connecting rod and cylinder bores.

Heat the pistons
il)sertwn

end

of

of

the gudgeon pin.

bushes, remove the worn bushes

a suitable press and dolly. Press in the

rod parallelism and twist.

in

liquid

that

the oil holes in the bush

quoted

to

J00-120°F

on

Page

C.2,

Page C.2, for check-

(40-50°C) for

out

the

ensuring

C4

is

given

on

Page

C.l,

they

piston.

beneath

see Fig.

are fitted

number

hom

on

On

It

will be

of

that

the
the

the

the

The piston ring layout

for cross sectional diagram showing layout

C.4

rings, note the position
rings.

Use

piston ring squce1.er when inserting the pistons

into

the cylinder bores.

Where piston rings are
the. marked face
rings

are marked

with the marked face
Each connecting rod

the cylinder to which it belongs counting
forward end
pistons are
camshaft
opposite side
assembly
repeated
assembling the caps
appear
noticed that each connecting rod assembly has its
own assembly

on

is

"TOP",

of

the engine, (1,2,3,4,). When the

in

the bores, these numbers are

side

of

the

of

the connecting rod will be found an

number.

on

the connecting rod cap and when

the same side, see Fig. C'.6.

number.

of

the internally stepped

m>!rked

to the skirt

to

the crown

is

stamped with the

engine, see Fig. C.S.

These assembly numbers are

to

The

'"BTM", ensure
of

ensure

rods, these numbers must

the piston. Where

that

of

the

letter

etched

of

C6