Summary PERKINS ENGINE 4 CYLINDER MODEL 1004-4T SERVICE REPAIR SHOP MANUAL

Perkins Phaser and 1000 Series



WORKSHOP MANUAL


Phaser 4 and 6 cylinder diesel engines for
automotive applications

1000 Series 4 and 6 cylinder diesel engines for
agricultural and industrial application




Publication TPD 1312E, Issue 1.
(c) Perkins Group Limited 1995, all rights reserved.
Published 1 April 1995 by Technical Publications,
Perkins International Limited, Peterborough PE1 5NA, England


Perkins Phaser/1000 Series, April 1995 00.01

, Amendment status

Issue
Description Date
number

1 This issue, number TPD 1312E, includes information from earlier
issue TPD 0191 1301 and TPD 0391 1266 and new information
about:
The Fastram piston, composite rocker cover, dampers, belt driven
coolant pumps and different timing case, flame ring and partially
finished liners, KSB cold starting aid, Stanadyne and Lucas DP200
fuel injection pumps, turbocharger and faults, closed engine
breather, quick release fuel filters, the idler gear of the lubricating
oil pump, intercoolers, twin fuelled starting aids, Bendix compressor
and lift equipment.
Also new information about:
The Bosch EPVE locked fuel injection pump, atomisers and fuel
injection pump codes, data and dimensions

April 1995




00.02 Perkins Phaser/1000 Series, April 1995

,Contents
General information . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SERVICE OPERATIONS

Cylinder head assembly ...................... 12
Piston and connecting rod assemblies . . . . . . . . . . . . 13
Crankshaft assembly . . . . . . . . . . . . . . . . . . . . . . . . . 14
Timing case and drive assembly ................ 15
Cylinder block assembly . . . . . . . . . . . . . . . . . . . . . . 16
Engine timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Aspiration system . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Flywheel and housing . . . . . . . . . . . . . . . . . . . . . . . . 22
Electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . 23
Auxiliary equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 24
List of special tools . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Perkins Phaser/1000 Series, April 1995 00.03

, General information 10

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.02
Engine views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.03
Engine identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.04
Safety precautions
Safety .................................................. 10.05
Engine lift equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.06
Asbestos joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.07
Viton seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.08

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




Perkins Phaser/1000 Series, April 1995 10.01