Perkins Engine Phaser 4, 6-cylinder Service Manual
Perkins Phaser and 1000 Series
This document has been printed from SPI². Not for Resale
Models AA to AH and YA to YE
WORKSHOP MANUAL
Phaser 4 and 6 cylinder diesel engines for
automotive applications
1000 Series 4 and 6 cylinder diesel engines for
agricultural and industrial applications
Publication TPD 1312E, Issue 2.
© Proprietary information of Perkins Engines Company Limited, all rights reserved.
The information is correct at the time of print.
Published in February 2002 by Technical Publications.
Perkins Engines Company Limited, Peterborough PE1 5NA, England.
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This document has been printed from SPI². Not for Resale
This publication is written in
Perkins Approved Clear English
Chapters
1 General information
2 Specifications
3 Cylinder head assembly
4 Piston and connecting rod assemblies
5 Crankshaft assembly
6 Timing case and drive assembly
7 Cylinder block assembly
8 Engine timing
9 Aspiration system
10 Lubrication system
11 Fuel system
12 C ooling system
13 Flywheel and housing
14 Electrical equipment
15 Auxiliary equipment
16 Sp ec ia l tools
The following pages contain a detailed table of contents
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Contents
1 General information
Introduction ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...1
Engine views . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...2
Engine identification . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...3
Safety precautions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...5
Asbestos joints . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...6
Viton seals . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...7
Engine lift equipment ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...8
POWERPART consumable products .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...9
2 Specifications
Data and dimensions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .28
Thread sealant ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .57
Recommended torque settings ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .58
Compression test data . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .61
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Phaser/1000 Series
This document has been printed from SPI². Not for Resale
3 Cylinder head assembly
General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 63
Rocker cover
Operation 3-1 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 64
Operation 3-2 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 65
Rocker ass embly
Operation 3-3 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 66
Operation 3-4 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 67
Operation 3-5 To inspect and to correct ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 68
Valve tip clearances
Operation 3-6 To check and to adjust (four cylinder engines) ... ... ... ... ... ... ... ... ... ... 69
Operation 3-7 To check and to adjust (six cylinder engines) . ... ... ... ... ... ... ... ... ... ... 70
Valve springs
Operation 3-8 To change the valve springs (with cylinder head fitted) .. ... ... ... ... ... ... 71
Cylinder head assembly
Operation 3-9 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 73
Operation 3-10 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 75
Valves and valve springs
Operation 3-11 To remove . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 78
Operation 3-12 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 79
Operation 3-13 To inspect and to correct .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 80
Valve guides
Operation 3-14 To inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 81
Operation 3-15 To remove . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 82
Operation 3-16 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 83
Cylinder head
Operation 3-17 To inspect and to correct .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 84
Operation 3-18 To correct a valve seat with a valve seat cutter ... ... ... ... ... ... ... ... ... 85
Operation 3-19 To fit valve seat inserts . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 86
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4 Piston and connecting rod assemblies
General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .87
Big end bearing
Operation 4-1 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .89
Operation 4-2 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .90
Operation 4-3 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .90
Piston and connecting rod
Operation 4-4 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .91
Operation 4-5 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .92
Operation 4-6 To check the piston height above the cylinder block .. ... ... ... ... ... ... ... .94
Operation 4-7 To check piston height grade of a “Fastram” piston ... ... ... ... ... ... ... ... .95
Piston rings ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .96
Operation 4-8 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .97
Piston and connecting rod assembly
Operation 4-9 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .98
Piston and piston rings
Operation 4-10 To inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .99
Connecting rod
Operation 4-11 To inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...100
Small end bush
Operation 4-12 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...100
Piston cooling jets
Operation 4-13 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...101
Operation 4-14 To check the jet alignment ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...102
5 Crankshaft assembly
General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...103
Crankshaft pulley
Operation 5-1 To remove and to fit (four cylinder engines) ... ... ... ... ... ... ... ... ... ... ...105
Crankshaft pulley and damper
Operation 5-2 To remove (six cylinder engines) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...106
Operation 5-3 To fit (six cylinder engines) . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...107
Operation 5-4 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...108
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Phaser/1000 Series
This document has been printed from SPI². Not for Resale
Rear oil seal assembly .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 110
Operation 5-5 To remove and to fit (one-piece assembly) . ... ... ... ... ... ... ... ... ... ... .. 111
Operation 5-6 To remove and to fit (two-piece assembly) . ... ... ... ... ... ... ... ... ... ... .. 114
Operation 5-7 To renew the rear end oil seal (two-piece assembly) ... ... ... ... ... ... .. 116
Operation 5-8 To remove and to fit a wear sleeve . ... ... ... ... ... ... ... ... ... ... ... ... ... .. 117
Rear oil seal assembly (engines with a flywheel housing that is oil filled)
Operation 5-9 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 118
Operation 5-10 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 119
Operation 5-11 To renew the rear oil seals ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 121
Operation 5-12 To fit and remove a "Wear-Sleeve" ... ... ... ... ... ... ... ... ... ... ... ... ... .. 123
Thrust washers
Operation 5-13 To check crankshaft end-float ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 124
Operation 5-14 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 125
Main bearings
Operation 5-15 To remove (with the crankshaft in position) .. ... ... ... ... ... ... ... ... ... .. 126
Operation 5-16 To fit (with the crankshaft in position) ... ... ... ... ... ... ... ... ... ... ... ... .. 127
Operation 5-17 To inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 127
Crankshaft
Operation 5-18 To remove . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 128
Operation 5-19 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 129
Operation 5-20 To inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 132
Balancer unit
Operation 5-21 To remove . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 133
Operation 5-22 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 134
Operation 5-23 To dismantle . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 135
Operation 5-24 To assemble . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 137
Operation 5-25 To inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 141
Operation 5-26 To remove and to fit the needle roller bearings ... ... ... ... ... ... ... ... .. 142
Operation 5-27 To remove and to fit the bushes for the balance weights . ... ... ... ... .. 143
6 Timing case and drive assembly
General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 145
Timing case cover
Operation 6-1 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 146
Operation 6-2 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 147
Front oil seal
Operation 6-3 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 148
Operation 6-4 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 149
Operation 6-5 To remove and to fit a wear sleeve . ... ... ... ... ... ... ... ... ... ... ... ... ... .. 151
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Idler gear and hub
Operation 6-6 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...152
Operation 6-7 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...154
Idler gear and hub for the Bendix or Knorr-Bremse compressor ... ... ... ... ... ... ...156
Operation 6-8 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...156
Operation 6-9 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...157
Fuel pump gear
Operation 6-10 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...158
Operation 6-11 To fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...159
Camshaft gear
Operation 6-12 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...160
Operation 6-13 To fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...161
Crankshaft gear
Operation 6-14 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...162
Timing case
Operation 6-15 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...163
Operation 6-16 To fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...164
Camshaft and tappets
Operation 6-17 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...166
Operation 6-18 To fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...167
7 Cylinder block assembly
General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...169
Cylinder block
Operation 7-1 To dismantle ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...170
Operation 7-2 To assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...171
Operation 7-3 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...173
Operation 7-4 To remove and to fit a new type ‘D’ plug to the tappet chamber ... ... ...174
Cylinder liner
Operation 7-5 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...176
Operation 7-6 To recover a glazed liner ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...177
Operation 7-7 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...178
Operation 7-8 To fit a service liner ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...180
Operation 7-9 To fit a partially finished liner .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...183
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Phaser/1000 Series
This document has been printed from SPI². Not for Resale
8 Engine timing
Standard operations
Operation 8-1 To set number 1 piston to TDC on the compression stroke ... ... ... ... .. 187
Operation 8-2 Another method to set number 1 piston to TDC . ... ... ... ... ... ... ... ... .. 188
Operation 8-3 To check the valve timing ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 189
Engines fitted with Bosch EPVE fuel injection pumps .. ... ... ... ... ... ... ... ... ... ... .. 190
Operation 8-4 To check the timing of the fuel injection pump (10° or more, static) ... .. 191
Operation 8-5 To check the timing of the fuel injection pump (9° or less, static) ... ... .. 193
Operation 8-6 To check the timing mark of the fuel injection pump ... ... ... ... ... ... ... .. 194
Operation 8-7 To check the engine timing mark ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 195
Operation 8-8 To check the timing of the pin timed fuel injection pump ... ... ... ... ... .. 196
Engines fitted with Bosch MW in-line fuel injection pumps .. ... ... ... ... ... ... ... ... .. 197
Operation 8-9 To check the timing of the fuel injection pump ... ... ... ... ... ... ... ... ... .. 198
Engines fitted with Lucas/Delphi DPA and DPS fuel injection pumps . ... ... ... ... .. 200
Operation 8-10 To check the timing of the fuel injection pump .. ... ... ... ... ... ... ... ... .. 201
Operation 8-11 To check the timing mark of the fuel injection pump . ... ... ... ... ... ... .. 202
Operation 8-12 To check the engine timing mark .. ... ... ... ... ... ... ... ... ... ... ... ... ... .. 203
Operation 8-13 To check the timing of the pin timed fuel injection pump .. ... ... ... ... .. 204
Engines fitted with a Lucas/Delphi DP200 Series fuel injection pump ... ... ... ... .. 205
Operation 8-14 To check the timing of the fuel injection pump .. ... ... ... ... ... ... ... ... .. 207
Operation 8-15 To check the timing of the pin timed fuel injection pump .. ... ... ... ... .. 209
Engines fitted with Stanadyne fuel injection pumps . ... ... ... ... ... ... ... ... ... ... ... .. 210
Operation 8-16 To check the timing of the fuel injection pump .. ... ... ... ... ... ... ... ... .. 211
Operation 8-17 To check the timing mark of the fuel injection pump . ... ... ... ... ... ... .. 212
Operation 8-18 To check the engine timing mark .. ... ... ... ... ... ... ... ... ... ... ... ... ... .. 214
Operation 8-19 To check the timing of the pin timed fuel injection pump .. ... ... ... ... .. 215
9 Aspiration system
General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 217
Turbocharger
Operation 9-1 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 219
Operation 9-2 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 220
Operation 9-3 To clean the impeller and the compressor casing .. ... ... ... ... ... ... ... .. 222
Operation 9-4 To remove and to fit the actuator assembly of the waste-gate unit ... .. 223
Operation 9-5 To check and adjust the operation of the waste-gate . ... ... ... ... ... ... .. 224
Turbocharger faults ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 225
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Open engine breather ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...227
Operation 9-6 To remove, to fit and to clean (early type) .. ... ... ... ... ... ... ... ... ... ... ...227
Operation 9-7 To clean and to renew (Later type) ... ... ... ... ... ... ... ... ... ... ... ... ... ...228
Operation 9-8 To renew (Latest type) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...229
Operation 9-9 To Inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...230
Closed breather system ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...231
Operation 9-10 To clean the early closed breather system ... ... ... ... ... ... ... ... ... ... ...232
Operation 9-11 To renew latest closed breather system ... ... ... ... ... ... ... ... ... ... ... ...233
Operation 9-12 To repair the connection for the latest breather outlet elbow ... ... ... ...235
10 Lubrication system
General description (four cylinder engine lubrication system) ... ... ... ... ... ... ... ...237
General description (six cylinder engine lubrication system) .. ... ... ... ... ... ... ... ...238
Lubrication system flow diagram ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...239
Lubrication system flow diagram for the relief valve and balancer . ... ... ... ... ... ...240
Filter canister
Operation 10-1 To renew .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...241
Filter head
Operation 10-2 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...242
Sump
Operation 10-3 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...243
Oil strainer and suction pipe
Operation 10-4 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...244
Operation 10-5 To inspect and to correct .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...245
Lubricating oil pump
Operation 10-6 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...246
Operation 10-7 To fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...247
Operation 10-8 To inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...248
Operation 10-9 To remove the idler shaft .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...249
Operation 10-10 Alternative method to remove the idler shaft .. ... ... ... ... ... ... ... ... ...250
Operation 10-11 To fit the idler shaft (Six cylinder engines) . ... ... ... ... ... ... ... ... ... ...251
Operation 10-12 To remove and to fit the idler shaft (four cylinder engines) ... ... ... ...252
Relief valve
Operation 10-13 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...253
Operation 10-14 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...254
Operation 10-15 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...254
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Phaser/1000 Series
This document has been printed from SPI². Not for Resale
Flexible oil pipes
Operation 10-16 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 255
Operation 10-17 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 256
Operation 10-18 To Inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..258
11 Fuel system
General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 259
Cold start advance unit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 262
Fuel filter elements
Operation 11-1 Fuel filter element types ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..264
Operation 11-2 To renew the filter element of the separate element type . ... ... ... ... .. 265
Operation 11-3 To renew the filter element of the canister type ... ... ... ... ... ... ... ... ..266
Operation 11-4 To renew the filter element of the quick release canister type .. ... ... .. 267
Fuel filter canister (Bosch MW fuel injection pump)
Operation 11-5 To renew ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 268
Atomisers
Operation 11-6 Atomiser fault ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 269
Operation 11-7 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 269
Fuel lift pump
Operation 11-8 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 270
Operation 11-9 To dismantle . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..271
Operation 11-10 To assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..272
Operation 11-11 To test . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 273
Fuel lift pump (Bosch MW fuel injection pump)
Operation 11-12 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 274
Operation 11-13 To dismantle and assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 275
Bosch EPVE fuel injection pump (without a locking screw)
Operation 11-14 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 276
Operation 11-15 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 277
Bosch EPVE fuel injection pump (with a locking screw) ... ... ... ... ... ... ... ... ... ... .. 278
Operation 11-16 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 279
Operation 11-17 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 281
Operation 11-18 To set .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 282
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Bosch EPVE fuel injection pump
Operation 11-19 To set the injection advance device (KSB) . ... ... ... ... ... ... ... ... ... ...285
Operation 11-20 To adjust . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...286
Operation 11-21 General description for pin timed fuel injection pump ... ... ... ... ... ...287
Operation 11-22 To remove pin timed fuel injection pump ... ... ... ... ... ... ... ... ... ... ...289
Operation 11-23 To fit pin timed fuel injection pump . ... ... ... ... ... ... ... ... ... ... ... ... ...290
Operation 11-24 To adjust pin timed fuel injection pump .. ... ... ... ... ... ... ... ... ... ... ...292
Operation 11-25 To eliminate air from the fuel system . ... ... ... ... ... ... ... ... ... ... ... ...293
Operation 11-26 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...297
Operation 11-27 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...299
Operation 11-28 To adjust the fuel injection pump ... ... ... ... ... ... ... ... ... ... ... ... ... ...303
Operation 11-29 To remove and fit the adaptor plate for the fuel injection pump . ... ...304
Operation 11-30 To eliminate air from the fuel system . ... ... ... ... ... ... ... ... ... ... ... ...305
Lucas/Delphi DPA and DPS fuel injection pumps
Operation 11-31 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...306
Operation 11-32 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...307
Operation 11-33 To adjust . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...308
Operation 11-34 Electrical shut off solenoid (ESOS) ... ... ... ... ... ... ... ... ... ... ... ... ...309
Operation 11-35 To eliminate air from the fuel system . ... ... ... ... ... ... ... ... ... ... ... ...311
Operation 11-36 Standard method ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...312
Operation 11-37 Self-vent method ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...313
Lucas/Delphi DP 200 Series fuel injection pump ... ... ... ... ... ... ... ... ... ... ... ... ... ...314
Operation 11-38 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...315
Operation 11-39 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...317
Operation 11-40 To adjust . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...318
Operation 11-41 General description for pin timed fuel injection pump ... ... ... ... ... ...319
Operation 11-42 To remove pin timed fuel injection pump ... ... ... ... ... ... ... ... ... ... ...321
Operation 11-43 To fit pin timed fuel injection pump . ... ... ... ... ... ... ... ... ... ... ... ... ...322
Operation 11-44 To adjust pin timed fuel injection pump .. ... ... ... ... ... ... ... ... ... ... ...324
Operation 11-45 Electrical shut off solenoid (ESOS) ... ... ... ... ... ... ... ... ... ... ... ... ...325
Operation 11-46 To eliminate air from the fuel system . ... ... ... ... ... ... ... ... ... ... ... ...327
Stanadyne fuel injection pump ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...329
Operation 11-47 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...331
Operation 11-48 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...332
Operation 11-49 To adjust . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...333
Operation 11-50 General description for pin timed fuel injection pump ... ... ... ... ... ...334
Operation 11-51 To remove pin timed fuel injection pump ... ... ... ... ... ... ... ... ... ... ...335
Operation 11-52 To fit pin timed fuel injection pump . ... ... ... ... ... ... ... ... ... ... ... ... ...336
Operation 11-53 To adjust pin timed fuel injection pump .. ... ... ... ... ... ... ... ... ... ... ...338
Operation 11-54 To eliminate air from the fuel system . ... ... ... ... ... ... ... ... ... ... ... ...341
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Phaser/1000 Series
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12 Cooling system
General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 343
Thermostats
Operation 12-1 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 344
Operation 12-2 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 345
Operation 12-3 To test .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 346
Coolant pump (gear driven) .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 347
Operation 12-4 To remove . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 347
Operation 12-5 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 348
Operation 12-6 To dismantle (early engines) . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 349
Operation 12-7 To assemble (early engines) . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 350
Operation 12-8 To dismantle (later engines) . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 353
Operation 12-9 To assemble (later engines) . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 354
Operation 12-10 To remove and fit pressed steel covers (latest engines) ... ... ... ... .. 358
Coolant pump (belt driven) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 360
Operation 12-11 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 360
Operation 12-12 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 362
Operation 12-13 To dismantle ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 363
Operation 12-14 To assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..364
Coolant pump (auxiliary) .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 366
Operation 12-15 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 366
Operation 12-16 To dismantle ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 367
Operation 12-17 To assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..368
Fan
Operation 12-18 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 370
Fan drive
Operation 12-19 To remove and to fit the early pulley ... ... ... ... ... ... ... ... ... ... ... ... .. 370
Operation 12-20 To remove and to fit the latest pulley .. ... ... ... ... ... ... ... ... ... ... ... .. 371
Lubricating oil cooler
Operation 12-21 To remove and to fit (four cylinder turbocharged engines) . ... ... ... .. 372
Operation 12-22 To remove and to fit (six cylinder engines) . ... ... ... ... ... ... ... ... ... .. 373
Operation 12-23 To remove (six cylinder turbocharged engines) .. ... ... ... ... ... ... ... .. 374
Operation 12-24 To fit (six cylinder turbocharged engines) ... ... ... ... ... ... ... ... ... ... .. 376
Operation 12-25 To dismantle and to assemble - six cylinder engines . ... ... ... ... ... .. 378
Operation 12-26 To dismantle and to assemble (six cylinder turbocharged engines) .. 380
Operation 12-27 To remove and to fit vertical canister type .. ... ... ... ... ... ... ... ... ... .. 381
Operation 12-28 To remove and to fit horizontal canister type .. ... ... ... ... ... ... ... ... .. 382
Cooler by-pass valve
Operation 12-29 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 383
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Intercooler . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...384
Operation 12-30 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...384
Operation 12-31 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...385
Operation 12-32 To clean and to inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...386
13 Flywheel and housing
General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...387
Flywheel
Operation 13-1 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...388
Ring gear
Operation 13-2 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...390
Flywheel housing
Operation 13-3 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...391
14 Electrical equipment
Operation 14-1 To check the drive belts ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...394
Operation 14-2 To adjust belt tension ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...395
Operation 14-3 To remove and to fit the drive belts .. ... ... ... ... ... ... ... ... ... ... ... ... ...396
Operation 14-4 To remove and to fit the alternator ... ... ... ... ... ... ... ... ... ... ... ... ... ...397
Operation 14-5 To maintain the alternator ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...397
Alternator fault diagnosis ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...398
Operation 14-6 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...400
Operation 14-7 To maintain the brush gear and the commutator . ... ... ... ... ... ... ... ...401
Operation 14-8 To test on the engine ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...402
Operation 14-9 To remove and to fit a fuelled starting aid ... ... ... ... ... ... ... ... ... ... ...404
Operation 14-10 To remove and to fit a twin fuelled starting . ... ... ... ... ... ... ... ... ... ...405
Operation 14-11 How to check the fuelled starting aid .. ... ... ... ... ... ... ... ... ... ... ... ...406
Operation 14-12 To remove and to fit a port heater .. ... ... ... ... ... ... ... ... ... ... ... ... ...406
15 Auxiliary equipment
Wabco compressors
Operation 15-1 To remove the earliest compressor and drive assembly .. ... ... ... ... ...408
Operation 15-2 To fit the earliest compressor and drive assembly ... ... ... ... ... ... ... ...409
Operation 15-3 To fit the early compressor and drive assembly ... ... ... ... ... ... ... ... ...410
Operation 15-4 To fit the early compressor only ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...412
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Compressor drive for Wabco compressors
Operation 15-5 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 413
Operation 15-6 To dismantle . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..414
Operation 15-7 To assemble . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 416
Bendix compressors
Operation 15-8 To remove . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 418
Operation 15-9 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 419
Knorr-Bremse compressors
Operation 15-10 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 421
Operation 15-11 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 422
Operation 15-12 To remove the reed valves . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 424
Operation 15-13 To fit the reed valves ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..425
Operation 15-14 To remove the top unloader valve .. ... ... ... ... ... ... ... ... ... ... ... ... .. 426
Operation 15-15 To fit the top unloader valve ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..426
Operation 15-16 To remove the crankshaft / connecting rod / piston / piston rings ... .. 427
Operation 15-17 To fit the crankshaft / connecting rod / piston / piston rings ... ... ... .. 428
Power steering pump
Operation 15-18 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 430
Adaptor for a hydraulic pump or a steering pump with a splined drive
Operation 15-19 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 431
Operation 15-20 To dismantle ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 432
Operation 15-21 To assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..433
Exhauster
Operation 15-22 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 434
16 Special tools
List of special tools .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 435
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General information 1
Introduction
This Workshop Manual has been written to provide assistance in the service and overhaul of Perkins Phaser
and 1000 Series engines. It should be used in conjunction with normal workshop practise and information
contained in current service bulletins. Mention of certain accepted practices therefore, has been purposely
omitted in order to avoid repetition. For overhaul procedures the assumption is made that the engine is
removed from the application.
Most of the general information which is included in the relevant User’s Handbook 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:
l Lucas/Delphi - DPA, DPS and DP200 Series
l Bosch - EPVE and MW
l 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 Chapter 16, Special tools. Reference to
the relevant special tools is also made at the beginning of each operation.
Data and dimensions are included in Chapter 2, Specifications.
Read and remember the "Safety precautions" on page 5. 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.
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Engine views
Phaser/1000 Series
A0314N
A0315
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Engine identification
The Perkins Phaser and 1000 Series engines have been designed for specific applications, as shown below:
l Phaser for automotive applications
l 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:
Code letters Engine type
AA Four cylinder, naturally aspirated
AB Four cylinder, turbocharged
AC Four cylinder, compensated
AD Four cylinder, turbocharged and intercooled
AE Four cylinder, turboch arge d an d i ntercoo led designed to conform to th e USA em is s ion legislation
AG Four cylinder, naturally aspirated with belt driven coolant pump
AH Four cylinder, turbocharged with belt driven coolant pump
YA Six cylinder, naturally aspirated
YB Six cylinder, turbocharged
YC Six cylinder, compensated
YD Six cylinder, turbocharged and intercooled
YE Six cylinder, turbocharged and intercooled designed to conform to the USA emission legislation
Continued
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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.
1 2
Phaser/1000 Series
A
A0043
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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 specifi c appl ic ati on s.
l Only use these engines in the type of application for which they have been designed.
l Do not change the specification of the engine.
l Do not smoke when you put fuel in the tank.
l Clean away fuel which has been spilt. Material which has been contaminated by fuel must be moved to a
safe place.
l Do not put fuel in the tank while the engine runs (unless it is absolutely necessary).
l 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).
l Do not make adjustments that you do not understand.
l Ensure that the engine does not run in a location where it can cause a concentration of toxic emissions.
l Other persons must be kept at a safe distance while the engine or auxiliary equipment is in operation.
l Do not permit loose clothing or long hair near moving parts.
l Keep away from moving parts during engine operation.
Warning! Some moving parts cannot be seen clearly while the engine runs.
l Do not operate the engine if a safety guard has been removed.
l 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.
l Do not use salt water or any other coolant which can cause corrosion in the closed circuit of the cooling
system.
l 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.
l Disconnect the battery terminals before a repair is made to the electrical system.
l Only one person must control the engine.
l Ensure that the engine is operated only from the control panel or from the operators position.
l If your skin comes into contact with high-pressure fuel, obtain medical assistance immediately.
l 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.
l Do not wear clothing which is contaminated by lubricating oil. Do not put material which is contaminated
with oil into the pockets of clothing.
l Discard used lubricating oil in a safe place to prevent contamination.
l Ensure that the control lever of the transmission drive is in the "out-of-drive" position before the engine is
started.
l Use extreme care if emergency repairs must be made in adverse conditions.
l 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. Refer to "Viton seals" on page 7.
l Read and use the instructions relevant to "Engine lift equipment" on page 8.
Continued
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l 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.
l Do not allow compressed air to contact your skin. If compressed air enters your skin, obtain medical help
immediately.
l 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.
l Fit only genuine Perkins parts.
Phaser/1000 Series
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.
l 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 abrasive action.
l 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.
l Work in an area with good ventilation.
l Do not smoke.
l Use a hand scraper to remove the joints - do not use a rotary wire brush.
l Ensure that the joint to be removed is wet with oil or water to contain loose particles.
l Spray all asbestos debris with water and put it in a closed container which can be sealed for safe disposal.
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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:
l Ensure that the components have cooled.
l Use Neoprene gloves and discard the gloves safely after use.
l Wash the area with calcium hydroxide solution and then with clean water.
l 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.
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Phaser/1000 Series
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:
l Four cylinder engines: 500 kg (1100 lbs)
l Six cylinder engines: 600 kg (1320 lbs)
Before the engine is lifted
l 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.
l 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.
l To Prevent damage to the rocker cover, ensure that there is clearance between the hooks and the rocker
cover.
l 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.
A
1
A0044
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1
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 21825166.
POWERPART Easy Flush
Cleans the cooling system. Part number 21825001.
POWERPART Gasket and flange sealant
To seal flat faces of components where no joint is used. Especially for aluminium components. Part number
21820518.
POWERPART Gasket remover
An aerosol for removal of sealants and adhesives. Part number 21820116.
POWERPART Griptite
To improve the grip of worn tools and fasteners. Part number 21820129.
POWERPART Hydraulic threadlock
To retain and seal pipe connections with fine threads. Especially suitable for hydraulic and pneumatic systems.
Part number 21820121.
POWERPART Industrial grade super glue
Instant adhesive designed for metals, plastics and rubbers. Part number 21820125.
POWERPART Lay-Up 1
A diesel fuel additive for protection against corrosion. Part number 1772204.
POWERPART Lay-Up 2
Protects the inside of the engine and of other closed systems. Part number 1762811.
POWERPART Lay-Up 3
Protects outside metal parts. Part number 1734115.
POWERPART Metal repair putty
Designed for external repair of metal and plastics. Part number 21820126.
POWERPART Pipe sealant and sealant primer
To retain and seal pipe connections with coarse threads. Pressure systems can be used immediately. Part
number 21820122.
POWERPART Radiator stop leak
For the repair of radiator leaks. Part number 21820127.
Continued
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POWERPART Retainer (high strength)
To retain components which have an interference fit. Part number 21820638.
POWERPART Retainer (oil tolerant)
To retain components which have a transition fit. Part number 21820603.
POWERPART Safety cleaner
General cleaner in an aerosol container. Part number 21820128.
POWERPART Silicone adhesive
An RTV silicone adhesive for applications where low pressure tests occur before the adhesive sets. Used for
sealing flange where oil resistance is needed and movement of the joint occurs. Part number 21826038.
POWERPART Silicone RTV sealing and jointing compound
Silicone rubber sealant which prevents leakage through gaps. Part number 1861108.
POWERPART Stud and bearing lock
To provide a heavy duty seal to components that have a light interference fit. Part number 21820119.
POWERPART Threadlock and nutlock
To retain small fasteners where easy removal is necessary. Currently Loctite 222e. Part number 21820119 or
21820120.
Phaser/1000 Series
POWERPART Universal jointing compound
Universal jointing compound which seals joints. Part number 1861117.
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Phaser/1000 S eries
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2
Specifications 2
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. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... A ltitude 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 o rder:
- 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
) 2,1 kgf/cm
3
)
3
)
2
2
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Phaser/1000 Series
Data and dimensions
Note: T his 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)
2
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 3-17
Maximum permissible distortion of cylinder head
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
) 2,04 kgf/cm
2
A1... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,13 mm (0.005 in)
A2... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,25 mm (0.010 in)
A3... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,25 mm (0.010 in)
1 1 1 1 1 1 1
3
2
2
3
A
A0067
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Inlet and exhaust valves
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
Depth of valve head below the face of cylinder head AA, AB, AC, AD, AG, AH, YA, YB, YC:
Production limits . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..1,27/1,60 mm (0.050/0.063 in)
Service limit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1,85 mm (0.073 in)
AD vehicle applications fitted with an intercooler ... ... ... ... ... ... ... ... ... ... ... ..1,37/1,68 mm (0.054/0.066 in)
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:
Production limits . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..1,37/1,68 mm (0.054/0.066 in)
Engine build list YD 80571 . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..1,27/1,60 mm (0.050/0.063 in)
AE, YE engines:
Production limits (for 45° valves) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..1,37/1,62 mm (0.054/0.064 in)
Service limit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1,85 mm (0.073 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)
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.
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, AG, AH, YA, YB, YC:
Production limits .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..1,28/1,60 mm (0.050/0.063 in)
Service limit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1,85 mm (0.073 in)
AD vehicle applications fitted with an intercooler ... ... ... ... ... ... ... ... ... ... ... ..1,47/1,79 mm (0.058/0.070 in)
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, YE:
Production limits . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..1,47/1,79 mm (0.058/0.070 in)
Service limit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1,85 mm (0.073 in)
Engine build list YD 80571 . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..1,28/1,60 mm (0.050/0.063 in)
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.
Workshop Manual, TPD 1312, issue 2 29
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This document has been printed from SPI². Not for Resale
Phaser/1000 Series
Dimensions of recesses for valve seat inserts
Inlet
A1... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 7,19/7,32 mm (0.283/0.288 in)
A2... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 51,22/51,24 mm (2.0165/2.0175 in)
A3... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .Radius 0,38 mm (0.015 in) maximum
Exhaust
A1... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 9,52/9,65 mm (0.375/0.380 in)
A2... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 42,62/42,65 mm (1.6780/1.6790 in)
A3... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .Radius 0,38 mm (0.015 in) maximum
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30 Workshop Manual, TPD 1312, issue 2
Phaser/1000 S eries
This document has been printed from SPI². Not for Resale
2
Valve seat insert tool
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)
Exhaust (for 45° valves)
A17.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 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)
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Workshop Manual, TPD 1312, issue 2 31
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This document has been printed from SPI². Not for Resale
Phaser/1000 Series
Valve guides and valve springs
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
Tappets, rocker shaft, rocker levers and bushes
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)
32 Workshop Manual, TPD 1312, issue 2
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