PDF Workshop Service Repair Manual Perkins 1000 Series Engines - 2 MB
This comprehensive workshop manual covers the Perkins 1000 Series engines, providing all the information needed for service and repair.
It includes detailed instructions for disassembly, inspection, and reassembly, along with specifications and torque settings.
This manual is an essential tool for any mechanic or technician working on these reliable engines.
Ensure every repair is done to factory standards with this in-depth guide.
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--- Page 1 ---
New 1000 Series
Perkins New 1000 Series
Models AJ to AS and YG to YK
WORKSHOP MANUAL
4 and 6 cylinder diesel engines for industrial and
agricultural applications
Publication TPD 1350E issue 3
© Proprietary information of Perkins Engines Company Limited, all rights reserved.
The information is correct at the time of print.
Published in March 2000 by Technical Publications.
Workshop Manual, TPD 1350, issue 3 1
--- Page 3 ---
New 1000 Series
21 Cooling system
General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 219
Thermostats
21-1 To remove, to fit and to test .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 220
Coolant pump - early gear driven pumps
21-2 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 221
Coolant pump - latest gear driven pumps
21-3 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 222
Coolant pump - belt driven
21-4 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 224
Coolant pump - belt driven high position
21- 5 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 226
Coolant pump - early gear driven pumps
21-6 To dismantle and to assemble .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 229
Coolant pump - latest gear driven pumps
21-7 To dismantle and to assemble .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 232
Coolant pump - belt driven
21-8 To dismantle and to assemble .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 237
Fan
21-9 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 240
Fan drive (engines with gear driven coolant pumps)
21-10 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 240
Lubricating oil cooler
21-11 To remove and to fit - four cylinder turbocharged engines .. ... ... ... ... ... ... ... ... 241
21-12 To remove and to fit - six cylinder engines .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... 242
21-13 To remove and to fit - pressed steel cover type .. ... ... ... ... ... ... ... ... ... ... ... ... 243
21-14 To remove and to fit - canister type.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 245
21-15 To dismantle and to assemble - four cylinder turbocharged engines .. ... ... ... ... 246
21-16 To dismantle and to assemble - six cylinder turbocharged engines ... ... ... ... ... 247
Cooler by-pass valve
21-17 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 247
21-18 To dismantle and to assemble pressed steel cooler type . ... ... ... ... ... ... ... ... ... 248
Workshop Manual, TPD 1350, issue 3 11
--- Page 4 ---
New 1000 Series 10
POWERPART recommended POWERPART Studlock
consumable products To permanently retain large fasteners and studs.
Currently Loctite 270. Part number 21820270.
Perkins have made available the products
recommended below in order to assist in the correct POWERPART Nutlock
operation, service and maintenance of your engine
To retain and seal threaded fasteners and cup plugs
and your machine. The instructions for the use of
where easy removal is necessary. Currently Loctite
each product are given on the outside of each
242e. Part number 21820242
container. These products are available from your
Perkins distributor. POWERPART Liquid gasket
POWERPART Antifreeze To seal flat faces of components where no joint is
used. Especially suitable for aluminium components.
Protects the cooling system against frost and
Currently Loctite 518. Part number 21820518
corrosion. Part number 1 litre 21825166 or 5 litres
21825167, refer to the User's Handbook. POWERPART Threadlock (hydraulic/pnuematic)
POWERPART Easy Flush To retain and seal pipe connections with fine threads.
Especially suitable for hydraulic and pneumatic
Cleans the cooling system. Part number 2182501
systems. Currently Loctite 542. Part number
POWERPART Jointing compound 21820542
Universal jointing compound which seals joints. POWERPART Threadlock (pipe)
Currently Hylomar. Part number 1861155 or
To retain and seal pipe connections with coarse
1861117.
threads. Pressure systems can be used immediately.
POWERPART Silicone rubber sealant Currently Loctite 575. Part number 21820575.
Silicone rubber sealant which prevents leakage POWERPART Retainer (oil tolerant)
through gaps.Currently Hylosil. Part number
To retain components which have a transition fit.
1861108.
Currently Loctite 603. Part number 21820603.
POWERPART Lay-Up 1
POWERPART Retainer (high strength)
A diesel fuel additive for protection against corrosion.
To retain components which have an interference fit.
Part number 1772204, refer to the User's Handbook.
Currently Loctite 638. Part number 21820638.
POWERPART Lay-Up 2
POWERPART Atomiser thread sealant
Protects the inside of the engine and of other closed
To seal the threads of the atomiser into the cylinder
systems. Part number 1762811, refer to the User's
head. Currently Hylomar Advance Formulation. Part
Handbook.
number 21825474.
POWERPART Lay-Up 3
Continued
Protects outside metal parts. Part number 1734115,
refer to the User's Handbook.
POWERPART Chisel
Allows easy removal of old gaskets and joints.
Currently Loctite chisel. Part number 21825163.
POWERPART Repel
Dries damp equipment and gives protection against
corrosion. Passes through dirt and corrosion to
lubricate and to assist removal of components.
Currently Loctite repel. Part number 21825164.
POWERPART Threadlock
To retain small fasteners where easy removal is
necessary. Currently Loctite 222e. Part number
21820222.
Workshop Manual, TPD 1350, issue 3 21
--- Page 5 ---
New 1000 Series
12
Cylinder head assembly 12
General description
In a diesel engine there is little carbon deposit and for
this reason the number of hours run is no indication of
when to overhaul a cylinder head assembly. The
factors which indicate when an overhaul is necessary
are how easily the engine starts and its general
performance.
The cylinder head assembly has two valves fitted for
each cylinder, each fitted with single valve springs.
The ports for the inlet and exhaust are on the right
side of the cylinder head.
The face angle of the valves is either 45° or 30°. The
angle of the valve seats in the cylinder head is either
46° or 31°.
The valves move in phosphated steel guides which
can be renewed. The exhaust valve guide has a
counterbore to prevent seizure of the valve stem
caused by a build up of carbon under the head of the
valve.
Both valve stems are fitted with oil seals that fit over
the top of the valve guides.
The engines have steel valve seat inserts fitted in the
cylinder head for both inlet and exhaust valves.
Workshop Manual, TPD 1350, issue 3 31
--- Page 6 ---
New 1000 Series 12
To fit
(Engine types AJ to AQ and YG to YK) 1
2
See page 45 for AR and AS engine types
Special tools: 3
Angle gauge, to tighten cylinder head setscrews,
MS.1531
1 Clean the bottom face of the cylinder head and the
top face of the cylinder block. Ensure that there is no
debris in the cylinder bores. A A0404
Note: The engines have two location pins (A3), one
at each end of the cylinder head, pressed into the
cylinder block to hold the cylinder head and cylinder
head gasket in the correct position when the cylinder
head is fitted.
Cautions:
! To prevent damage to the cylinder head gasket, 1
ensure that the location pins are pressed in the
cylinder block before the cylinder head is fitted.
! The cylinder head gasket must be fitted without
jointing compound.
2 Put the cylinder head gasket in position; It is
stamped "FRONT TOP" (A2) for correct assembly. B A0057
3 To ensure the cylinder head is fitted into the correct
position, fit two suitable 1/2 UNF guide studs (A1) or
(B1) in positions 16 and 21 (page 40/B) or positions
25 and 30 (page 40/A). Put the cylinder head in
position. Ensure that the two location pins are fully
engaged in the cylinder head.
4 Lightly lubricate the threads of the cylinder head
setscrews and the thrust faces of the setscrew heads.
Engage some of the setscrews in their correct
positions and remove the guide studs. Engage the
remainder of the setscrews in their correct positions.
5 Gradually and evenly tighten the setscrews to 110
Nm (80 lbf ft) 11,1 kgf m in the sequence shown in
(page 40/A or B).
6 Repeat paragraph 5 to ensure that all the setscrews
are tightened to the correct torque.
Continued
Workshop Manual, TPD 1350, issue 3 41
--- Page 7 ---
New 1000 Series 12
Valve guides
4
To inspect 12-10 1 2
5
To check the valve guides for wear: The maximum
permissible clearance (A5) with a valve lift of 15,0 mm
(0.6 in), between the valve stem and the bore of the
guide is 0,100 mm (0.008 in) for inlet valves and 0,121
mm (0.011 in) for exhaust valves. If the clearance,
with a new valve fitted, is more than the limit, then a
new valve guide (A4) must be fitted.
3
It is recommended that the procedure given below is A A0298
used to check the valve guide clearance:
1 Put a new valve in the valve guide.
2 Put a dial test indicator with a magnetic base (A1)
onto the face of the cylinder head.
3 With the valve lifted 15,0 mm (0.6 in) and the gauge
(A2) in contact with the edge of the valve head (A3),
move the valve radially away from the gauge. With the
valve held in this position, set the gauge to zero.
4 Move the valve radially across the axis of the
cylinder head towards the gauge. Make a note of the
reading on the gauge. If the reading is equal to or
greater than the data given below, a new valve guide
(A4) must be fitted.
Note: The partially finished valve guides are reamed
and the valve seats are cut in one operation with a
special tool. The valve seat and the guide are cut in
one operation to ensure the concentricity of the valve
seat to the valve guide. This will ensure a good seal
between the guide and its seat. New valves and new
valve seat inserts must be fitted each time a new
valve guide is fitted. Valves must not be lapped, see
operation 12-13. If all or most of the original valve
guides need to be renewed it may be cost effective to
overhaul or exchange the cylinder head.
Workshop Manual, TPD 1350, issue 3 51
--- Page 8 ---
New 1000 Series 12
Valve guides
Inside diameter of partially finished guide . . . . . . . . . . . . . . . . . . . . . . . . . 8,600/8,700 mm (0.3386/0.3425 in)
Inside diameter of finished guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9,000/9,022 mm (0.3543/0.3552 in)
Outside diameter:
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13,034/13,047 mm (0.5131/0.5137 in)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14,034/14,047 mm (0.5525/0.5530 in)
Interference fit of valve guide in cylinder head . . . . . . . . . . . . . . . . . . . . . 0,047/0,007 mm (0.0003/0.0019 in)
Full length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51,25 mm (2.018 in)
Protrusion from bottom of recess for valve spring . . . . . . . . . . . . . . . . . . . . . 14,85/15,15 mm (0.585/0.596 in)
Valve springs
Fitted length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39,0 mm (1.54 in)
Load at fitted length:
- Engine types, AJ, AK, AM, AP, AQ, YG, YH, YK . . . . . . . . . . . . . . 246/277,5 N (55.3/62.4 lbf) 25,1/28,3 kgf
- Engine types AR and AS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136,3/153,7 N (30.6/34.5 lbf) 13,9/15,7 kgf
Number of active coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
Number of damper coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Direction of coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Left hand
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)
Workshop Manual, TPD 1350, issue 3 61
--- Page 9 ---
New 1000 Series 13
Piston rings
To remove and to fit 13-5
The pistons have two compression rings and an oil
control ring. All the piston rings are above the
gudgeon pin. To ensure that the correct type is
obtained always use the engine identification number
to order new parts.
Caution: Only expand the ring gaps enough to
ensure that the ends of the rings do not damage the 1
piston when the ring is removed or put into position. A A0353
To remove
Remove the piston rings with a suitable ring
expander. Keep the rings with their relevant piston. 1
To fit
Use a suitable piston ring expander to fit the piston
rings.
2
1 Fit the spring of the oil control ring in the bottom
groove with the latch pin (A1) inside both ends of the
spring (A). Fit the oil control ring over the spring (B3) 3
or (C3). Ensure that the ring gap is at 180° to the latch
pin.
2 Fit the cast iron ring with the taper face into the B A1447/1
second groove, with the word "TOP" towards the top
of the piston.
New second rings have a green identification mark
which must be on the left of the ring gap when the ring 1
is fitted and the piston is upright.
The second ring has a step (B2) or (C2) at the bottom
of the tapered face.
2
3 Fit the tapered, top ring (B1) or (C1) with the word
'TOP' towards the top of the piston.
Note: The top ring (C1) of engine types AR and AS is 3
parallel.
New top rings have a red identification mark which
C A1447
must be on the left of the ring gap when the ring is
fitted and the piston is upright.
4 Ensure that the ring gaps are 120° apart.
Workshop Manual, TPD 1350, issue 3 71
--- Page 10 ---
New 1000 Series 14
Crankshaft pulley and damper
To remove and to fit - six cylinder
engines 14-2
Consumable products:
POWERPART Retainer (oil tolerant)
Caution: A viscous damper (C1) should be renewed
if there is impact damage to the outer casing or if
there is leakage of the viscous fluid from the cover A A0097
plate. Check the area around the holes for the damper
fasteners for damage.
To remove 1 2 3 4
1 Remove the drive belts, see operation 23-3.
Warning! The crankshaft pulley and damper
assembly is heavy and must be given support before
removal.
2 Release the fasteners which secure the clamp ring
(C2) for the damper to the pulley, if one is fitted, and
remove the damper.
6 5
Caution: Do not use an extractor to remove the
pulley.
B A0093
3 Remove the three setscrews and the thrust block
(B4). If the pulley is not free. Hold a wooden block
against the inner hub of the pulley and with a hammer,
lightly hit the wooden block towards the rear (A) to
loosen the tapered rings (B2 and B3).
2
1
C A0165
Workshop Manual, TPD 1350, issue 3 81
--- Page 11 ---
New 1000 Series 14
Crankshaft 13 Remove the bridge piece.
Warning! The engine should be upside down before
the fasteners for the crankshaft are removed. If the
To remove and to fit 14-10 engine cannot be turned upside down support the
crankshaft before the fasteners are removed.
Consumable products: 14 Remove the caps of the connecting rods. Keep
POWERPART Silicone rubber sealant the bearings and caps together. Remove the bolts of
the connecting rods and carefully push the pistons
POWERPART liquid gasket towards the top their bores.
15 Ensure that the tops of the main bearing caps are
Note: If the crankshaft is to be renewed, it may be stamped with their relevant position number. Remove
necessary to change the grade of the connecting the main bearing caps, the lower half of the shell
rods, see operation 13-7. This will occur if the correct bearings and the upper and lower thrust washers.
piston height above the block face cannot be Keep the bearings with their relevant caps.
maintained with the original piston and connecting rod 16 Lift out the crankshaft. Remove the upper half of
assemblies, see operation 13-4. the bearings and keep each bearing with its relevant
lower half and cap.
Warning! Use lift equipment or obtain assistance to
lift heavy engine components such as the flywheel,
flywheel housing and the crankshaft.
To remove
1 Before the engine is removed from the vehicle or
from the machine, drain the lubricating oil and the
coolant.
2 Remove the lubricating oil sump, see operation 19-
3.
3 Remove the fan, the drive belts, the fan drive pulley
and housing and the coolant pump, see section 21.
4 Remove the fuel injection pump, see section 20.
5 Remove the crankshaft pulley, see operation 14-1
or operation 14-2.
6 Remove the alternator and its mounting bracket,
see section 23.
7 Remove the compressor and its drive assembly or
remove the exhauster, see section 24.
8 Remove the timing case cover, see operation 15-1.
9 Remove the timing gears and the timing case, see
section 15.
10 Remove the flywheel and the flywheel housing,
see section 22.
11 Remove the rear oil seal housing, see operation
14-4.
12 If a balancer unit is fitted, remove it, see operation
14-12. If a balancer unit is not fitted, remove the
lubricating oil suction pipe and strainer, the lubricating
oil pump, the delivery pipe and the relief valve (four
cylinder engines) and the lubricating oil crossover
pipe, if fitted, see section 19.
Workshop Manual, TPD 1350, issue 3 91
--- Page 12 ---
New 1000 Series 14
To inspect 14-14
1 Clean all the components before inspection.
2 Check the gear teeth and the splines of the drive
shaft for wear or other damage. Renew the drive shaft
if necessary.
3 Check the idler gear, needle roller bearing, hub and
thrust washer for wear or other damage. Renew the
components if necessary.
4 Check the drive gear for the balance weights for
wear or other damage. Renew the gear if necessary.
5 Check the balance weights for wear or other
damage. If either balance weight is worn or damaged,
both balance weights must be renewed.
6 Check the needle roller bearings for the drive shaft
for wear or other damage. Renew the bearings, see
operation 14-15, if necessary.
7 Check the bushes for the balance weights for wear
or other damage. Renew the bushes, see operation
14-16, if necessary.
8 To inspect the lubricating oil pump, see operation
19-8.
Workshop Manual, TPD 1350, issue 3 101
--- Page 13 ---
New 1000 Series 15
Front oil seal
To remove and to fit 15-2
Special tools:
Replacer tool for front oil seal (main tool), PD170
Pressure plate for use with PD.170, PD.170-1
Sleeve for use with PD.170, PD.170-2
Fastener plate for use with PD.170, PD.170-3
Adaptor for use with PD.170 (1) A 1 2 3 4 5 A 0 12 7
(1) Refer to your nearest Perkins distributor. Fit a rod through the hole in the end of the threaded
bar to prevent movement of the bar when the nut is
To remove tightened. Tighten the nut to push the seal into the
housing to the correct depth.
1 Remove the fan, see operation 21-9. and the drive
belts, see operation 23-3. 4 Remove the replacer tool and lightly lubricate the
2 Remove the crankshaft pulley, see operation 14-1 seal location area of the crankshaft pulley with clean
or operation 14-2. engine lubricating oil. Fit the crankshaft pulley, see
operation 14-1 or operation 14-2.
3 Remove the oil seal with a suitable lever behind the
main lip of the oil seal. Do not damage the edge of the 5 Fit the drive belts, see operation 23-3 and adjust
oil seal housing. the belt tension, see operation 23-2.
6 Fit the fan, see operation 21-12.
To fit
Note: The seal is fitted to a depth of 10,20/10,70 mm
(0.402/0.421 in) from the front face of the oil seal
housing to the flat front face of the oil seal. If, in
service, there is wear in the seal location area of the
crankshaft pulley, oil will continue to leak after a new
oil seal is fitted. To renew a worn crankshaft pulley,
see operation 15-3.
1 Clean the oil seal housing. Inspect the new seal for
damage. If a scratch can be seen across the lip of the
seal, do not fit the seal.
2 Lubricate the outer circumference of the oil seal
with clean engine lubricating oil and enter the seal into
the housing. Ensure that the spring loaded lip of the
oil seal is towards the inside of the timing case cover
and that the oil seal is square to the bore of the seal
housing.
3 Assemble the oil seal replacer tool (A). Fit the
fastener plate, PD.170-3, (A3) to the front of the
crankshaft. Put the adaptor, (A5) on the nose of the
crankshaft and against the seal. Ensure that the
adaptor has the side stamped 10,5 mm towards the
seal.
Assemble the pressure plate, PD.170-1, (A2)
together with the sleeve, PD.170-2, (A4) onto the
threaded bar, PD.170, (A1). Put the tool assembly in
position on the adaptor, and tighten the threaded bar
onto the stud of PD.170-3 (A3).
Workshop Manual, TPD 1350, issue 3 111
--- Page 14 ---
New 1000 Series 15
Crankshaft gear
To remove and to fit 15-8
To remove
1 Remove the timing case cover, see operation 15-1.
2 Rotate the crankshaft until the marked teeth of the
crankshaft gear and the camshaft gear are in mesh
with the idler gear. The marked teeth of the idler gear
will not necessarily be in mesh with the marked teeth
of the other gears because of the different speed of
rotation of the idler gear.
3 Remove the idler gear, see operation 15-4.
4 The crankshaft gear is a transition fit on the
crankshaft. It may slide off easily or, if it is a tight fit
and the gear is to be renewed, it may be necessary to
remove the crankshaft, see operation 14-10, to
remove the gear safely.
To fit
1 The gear can fit easily, or it may be necessary to
heat the gear before it will fit onto the crankshaft. If the
gear is to be heated, heat it in an oven to not more
than 180 °C (226 °F). If an oven is not available, heat
it in coolant which is at its boiling point. Do not use a
flame as this can cause local damage. Fit the gear
with the timing marks to the front.
2 Fit the idler gear, see operation 15-4 and ensure
that all the timing marks are correctly aligned.
3 Fit the timing case cover, see operation 15-1.
Workshop Manual, TPD 1350, issue 3 121
--- Page 15 ---
New 1000 Series 16
To remove and to fit 16-4
2
Special tools:
Remover/replacer for cylinder liner (main tool), 1
PD.150B
3
Adaptors for use with PD.150B, PD.150B-17A
Depth gauge, liner flange, PD.41D
Dial gauge for use with PD.41D, PD.208
4
Consumable products: (See Section 10)
POWERPART Retainer (oil tolerant)
Loctite Safety Solvent or a similar product
5
Where several liners are to be removed or a very tight
production liner is fitted, a press should be used.
Where a single liner is to be removed or the
crankshaft is to remain in position, a tool for hand
operation is available.
To remove
1 Drain the lubricating oil and remove the lubricating 6
oil sump, see operation 19-3.
2 Remove the cylinder head assembly, see operation
12-7.
3 Remove the piston and connecting rod assembly, A A0212
see operation 13-3.
4 Carefully remove the piston cooling jet, where
fitted, see operation 13-11.
5 Rotate the crankshaft to give access to the cylinder
liner. Protect the crank pin.
6 Put the tool (A4) on the top face of the cylinder
block and over the centre of the liner (A5). Ensure that
the base of the tool is not on top of the liner flange of
the next cylinder.
7 Put the bearing (A3) in the recess in the top of the
tool with the flat face of the bearing to the bottom of
the recess.
8 Fit the threaded rod (A2) through the bearing and
the top of the tool until the handle (A1) is in the recess
in the top of the bearing. In this position adjust the
threaded rod until the end is below the bottom of the
cylinder liner. Fit the adaptor PD.150B-17/1 (A6) onto
the threaded rod and against the bottom of the
cylinder liner. Ensure that the two lugs on the top of
the adaptor engage with the flats on the threaded rod.
Fit the washer and nut and tighten the nut onto the
adaptor.
9 Lubricate the ratchet of the handle and the
threaded rod with Shell Spirax oil or an equivalent oil.
Operate the handle and pull the cylinder liner out of
the top of the cylinder block.
Workshop Manual, TPD 1350, issue 3 131
--- Page 17 ---
New 1000 Series
17
Engine timing 17
General description
To reach the accurate fuel injection needed for
engines to conform to emissions legislation, the latest
fuel injection pumps operate at a static timing very
close to TDC.
The timing gears are stamped with timing marks to
ensure that they are assembled correctly (A). The
marked teeth of the crankshaft, the camshaft and the
fuel pump gears will be in mesh with the idler gear
when number 1 piston is close to top dead centre
(TDC) on the compression stroke. The marked teeth
of the idler gear may not necessarily be in mesh in this
position, because of the different speeds at which the
gears rotate.
A A0129
The fuel injection pump is timed at TDC on the
compression stroke of number 1 cylinder. It is
important that fuel injection timing is accurate to
conform to emissions legislation. Always use
operation 17-1 or operation 17-2 to obtain TDC on the
1
compression stroke of number 1 cylinder accurately.
Caution: The fuel injection pump has a lock screw
(B1) which locks the shaft. It is important that the
lock screw is released and the pump shaft is free to 2
turn. The drive shaft of the pump must not be rotated
without the spacer (B2) in position under the locking
screw. If the drive shaft is rotated with the locking
screw tightened on to the shaft, the drive shaft will be
damaged. B A0256
Continued
Workshop Manual, TPD 1350, issue 3 141
--- Page 18 ---
New 1000 Series 18
To clean the impeller and the
compressor casing 18-2
Generally, it is not necessary to remove the
turbocharger to remove the compressor casing,
except on some engines where the compressor
casing is held by a circlip and access to the circlip is
not always possible. This type of turbocharger is 1
usually fitted to engines used in vehicle applications.
1 Release the clip and remove the hose from the
compressor inlet. Release the clips and push the
hose on the compressor outlet up the elbow of the
induction manifold. A A0183
2 Make a reference mark on the compressor casing
(A1) and on the bearing housing to ensure correct
assembly later.
3 Release the setscrews and remove the lock plates.
If the compressor casing is retained by a circlip,
remove the circlip. It may be necessary to remove the
turbocharger if access to the circlip is not possible. If
the turbocharger has a waste-gate unit, remove the
actuator and bracket assembly, see operation 18-3.