TPD1357E1

Perkins Service Data Booklet
Part 1: Mature products up to 8,85 litres (540 cu in)
4.108
3.152 Series
4.203 Series
4.236 Series
6.3544 Series
V8.540 Series
Publication TPD 1357E issue 1

Proprietary information of Perkins Group Limited, all rights reserved.
The information is correct at the time of print.
Published in January 1997 by Technical Publications.
Perkins International Limited, Peterborough PE1 5NA, England
i
This document has been printed from SPI. Not for Resale
Service Data Booklet
This publication is written in

Perkins Approved Clear English
Chapters
1
General information
Engine data
General information
The following pages contain a detailed table of contents.
ii
Workshop Manual, TPD 1357E, issue 1
Foreword
The Perkins Service Data Booklet contains the data which is most commonly used by experienced mechanics
and technicians.
The booklet contains information for all Perkins Peterborough engines and is available in two parts:
Part 1: Mature products up to 8,85 litres (540 cu in)
4.108
3.152 Series
4.203 Series
4.236 Series
6.3544 Series
V8.540 Series
Part 2: Current products up to 8,7 litres (530 cu in)
100 Series
4.41
Prima/500 Series
700 Series
900 Series
Phaser/1000 Series
Peregrine/1300 Series
The booklet should be used together with the relevant User's Handbook, Workshop Manual and Service
Bulletins.
Any recommendations for future issues of the booklet should be sent to Technical Publications Department.
iii
This page is intentionally blank
iv
Current product
Contents
1 General information
Perkins companies ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1
List of Perkins service publications ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 2
POWERPART recommended consumable products . ... ... ... ... ... ... ... ... ... ... ... ... ... 3
Basic fault-finding guide .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 7
Turbocharger fault guide . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 9
General safety precautions .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 11
2 Engine data
4.108
Basic technical data . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 13
Preventive maintenance periods . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 14
Maintenance schedules ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 14
Fuel pump codes .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 15
Recommended torque tensions .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 16
Cylinder head torque sequence .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 16
3.152 Series
Service Data Booklet, TPD 1357E, issue 1
Current product
Preventive maintenance periods . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 19
Maintenance schedules ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 19
Fuel pump codes ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 20
Recommended torque tensions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 21
Cylinder head torque sequence ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 22
4.203 Series
Basic technical data .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 24
Maintenance schedule 4.203 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 26
Maintenance schedule 4.2032 .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 27
Fuel pump codes 4.203 and 4.2032 .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 28
Cylinder head torque sequence
4.203 and 4.2032 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 30
4.236 Series
Fuel pump codes ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 33
6.3544 Series
Fuel pump codes 6.3544 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 40
Fuel pump codes T6.3544 . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 41
V8.540 Series
vi
Current product
Preventive maintenance periods . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 46
Maintenance schedules ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 46
Fuel pump codes .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 47
Recommended torque tensions .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 48
Cylinder head torque sequence .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 49
3 General data
Specification of engine fluids .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 51
Standard torque settings . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 52
Conversion tables . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 53
Atomiser information ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 55
Turbocharger waste-gate settings .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 58
Thermostat ratings ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 59
Compression test data . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 59
vii
viii
Current product
1
General information
Perkins companies
Australia
Japan
Perkins Engines Australia Pty. Ltd,

Suite 2, 364 Main Street,
Mornington 3931, Victoria, Australia.
Telephone: 597 51877
Telex: Perkoil AA30816
Fax: 0597 1305
Varity (Japan) K.K.,

Reinanzaka Building, 5th Floor,
14-2 Akasaka, 1-chome, Minato-ku,
Tokyo 107, Japan.
Telephone: 03 586 7377
Telex: Perkoil J2424823
Fax: 03 582 1596
France
Moteurs Perkins S.A.,
9-11 Avenue Michelet,
93583 Saint Ouen, Cedex, France.
Telephone: (1) 40 10 42 70
Telex: 642924F
Fax: (1) 40-10-42-45
Germany
Perkins Motoren GmbH,
Saalaeckerstrasse 4,
63801 Kleinostheim,
Germany.
Fax: 6027 501124
Hong Kong
Perkins International Ltd,
Varity Asia/Pacific,
Suite 3301
Convention Plaza,
1 Harbour road,
Wanchai
Hong Kong.
Telephone: 852 2588 1883
Fax: 852 2827 2311
Italy
Motori Perkins S.p.A.,
Via Socrate 8,
22070 Casnate con Bernate (Como), Italy.
Telephone: 031 564633 or 564625
Telex: 380658 Perkit I
Fax: 031 249092 or 564145
United Kingdom
Perkins International Ltd,
Eastfield, Peterborough PE1 5NA,
England.
Telex: 32501 Perken G
Fax: 01733 582240
United States of America
Perkins International - North America
12025 Tech Center Drive
Livonia
Michigan 48150
USA
Telephone: 313 266 5427
Fax: 313 266 2700
Perkins Engines Latin America Inc,
Suite 620,
999, Ponce de Leon Boulevard,
Coral Gables,
Florida 33134, U.S.A.
Telephone: 305 442 7413
Telex: 32501 Perken G
Fax: 305 442 7419
In addition to the above companies, there are
Perkins distributors in most countries. Perkins
International Ltd, Peterborough or one of the
above companies can provide details.
Current product
List of Perkins service publications

Engine type
4.108
User's Handbook
Workshop Manual
201 TPD 1090 1218
601 SER 0692 1088
TPD 0596 1285 EFG (1)

TPD 0696 1285 EIS (2)
TPD 1091 1208
4.203, D4.203
201 TPD 1090 1216
601 SER 0681 1010
4.2032
201 TPD 1090 1216
601 TPD 0580 1158
4.236, 4.248
TPD 1095 1291 EFG (1)

TPD 0596 1291 EIS (2)
601 TPD 0393 1229
6.3544 Series
TPD 0594 1289 EFG (1)

TPD 0590 1289 EIS (2)
TPD 1089 1146
V8.540 Series
201 TPD 1090 1207
601 TPD 0690 1215
3.152 Series
(1) Printed in English, French and German.

(2) Printed in English, Italian and Spanish.
Current product
POWERPART recommended
consumable products
Perkins have made available the products
recommended below in order to assist in the correct
operation, service and maintenance of your engine
and your machine. The instructions for the use of
each product are given on the outside of each
container. These products are available from your
Perkins distributor.
POWERPART Antifreeze
Protects the cooling system against frost and
corrosion. Part number 1 litre 21825166 or 5 litres
21825167.
POWERPART Atomiser thread sealant
To seal the threads of the atomiser into the cylinder
head. Currently Hylomar Advance Formulation.
POWERPART Chisel
Allows easy removal of old gaskets and joints.
Currently Loctite chisel. Part number 21825163.
POWERPART Compound
To seal the outer diameter of seals. Currently Loctite
Forma Gasket No 2. Part number 1861147.
POWERPART Easy Flush
Cleans the cooling system. Part number 2182501.
POWERPART Gasket eliminator
Improves flange sealing when a gasket is not used. It
provides a seal with temperature resistance that is
flexible in positions where vibration and pressure
occur. Currently Loctite 515. Part number 21826040.
POWERPART Jointing compound
Universal jointing compound which seals joints.
Currently Hylomar. Part number 1861155 or
1861117.
POWERPART Lay-Up 1
1
POWERPART Nutlock
To retain and seal threaded fasteners and cup plugs
where easy removal is necessary. Currently Loctite
242e. Part number 21820242.
POWERPART Platelock
Medium strength anaerobic threadlock for tight fitted
metal surfaces. Suitable for metal plated surfaces and
stainless steel. Currently Loctite 243. Part number
21826039.
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 Retainer (high strength)
To retain components which have an interference fit.
Currently Loctite 638. Part number 21820638.
POWERPART Retainer (oil tolerant)
To retain components which have a transition fit.
POWERPART Silicone adhesive
An RTV silicone adhesive for application where low
pressure tests occur before the adhesive sets. Used
for sealing flange where oil resistance is needed and
movement of the joint occurs. Currently Loctite 5900.
Part number 21826038.
POWERPART Silicone rubber sealant
Silicone rubber sealant which prevents leakage
through gaps. Currently Hylosil. Part number
1861108.
POWERPART Studlock
To permanently retain large fasteners and studs.
Currently Loctite 270. Part number
21820270.POWERPART Threadlock
A diesel fuel additive for protection against corrosion.

Part number 1772204.
To retain small fasteners where easy removal is

necessary. Currently Loctite 222e. Part number
21820222.
POWERPART Lay-Up 2
POWERPART Threadlock (heavy duty)
Protects the inside of the engine and of other closed

systems. Part number 1762811.
To provide a heavy duty seal to components that have

a light interference fit. Currently Loctite 262. Part
number 21820262.
POWERPART Lay-Up 3
Protects outside metal parts. Part number 1734115.
Continued
POWERPART Liquid gasket

To seal flat faces of components where no joint is
used. Especially suitable for aluminium components.
Current product
Engine number location guide

Engine type
Position
4.108
A1
3.152 Series
- up to engine CE31244U906114W
- from engine CE31244U906114W
B3
A4
4.203 Series
B1 or B4
4.236
A2 or B2
4.248
A2
6.3544 Series
A3
V8.540 Series
C1
Notes:
Illustration A shows the left side when looked at
from the flywheel end of the engine.
z
z
Illustration B shows the right side when looked at

from the flywheel end of the engine, and the rear
view of the engine
Illustration C shows the top of the engine.
POWERPART Threadlock (hydraulic/pneumatic)

To retain and seal pipe connections with fine threads.
Especially suitable for hydraulic and pneumatic
systems. Currently Loctite 542. Part number
21820542.
POWERPART Threadlock (pipe)
To retain and seal pipe connections with coarse
threads. Pressure systems can be used immediately.
Current product
Engine number guide For engines made after 1974
Example of an engine number is TU20300U510256F
TU
Engine Family and type code, see Table 1
20300
Parts list number or SOS order reference number
Country of manufacture code, see Table 2
510256 Engine serial number

F
Year of manufacture code, see Table 3
Table 1 - Engine Family and Type Code

A Phaser/1004
AA
Naturally
aspirated
AB
Turbocharged
AC
Compensated
AD
Charge cooled
AE
Fed. Charge
cooled
AG
Narrow front end
naturally aspirated
AH
Narrow front end
turbocharged
New Phaser/1004
AJ
Naturally
aspirated
AK
Turbocharged
AM
Turbocharged
intercooled
AP
Naturally
aspirated
AQ
Turbocharged
BPrima/500
BA
Naturally
aspirated
BB
Turbocharged
BC
Gasolene
C 3.152
CA
P3
CB
3.144
CCP
3.144
CD
3.152
CE
D3.152
CFG
3.152
CGP
3.152
CJ
3.1522
CM
3.1524
CNT
3.1524
C 900 Series
CP
3.27
CRT
3.27
CS
3.25
C
Compensated
CC
Charge cooled
D
Direct injection
E 4.108
EA
4.99
EB
4.107
EC
T4.107
ED
4.108
EE
T4.108
G 4.154/200
GA
4.154
GB
4.135
GC
4.182
GD
4.25
GE
4.30
H 4.165
HA
4.165
J 4.203
JA
P4
JB
4.192
JC
P4.192
JD
4.203
JE
D4.203
JF
G4.203
JG
4.2032
K Perama/100
KA
2 cyl. 0,4 litres
KB
3 cyl. 0,6 litres
KC
3 cyl. 0,9 litres
KD
3 cyl. 1,0 litres
KE
3 cyl. 1,5 litres
KF
4 cyl. 1,9 litres
KG
3 cyl. 1,2 litres
KH
3 cyl. 1,3 litres
KJ
3 cyl. 1,5 litres D
KK
4 cyl. 1,9 litres D
KL
3 cyl. 0,7 litres
KN
2 cyl. 0,5 litres
KR
4 cyl. 2,2 litres
L4.236
LA
4.212
LB
G4.212
LC
4.224
LD
4.236
F
Made in France
Fed.
Federal
G
Gasoline or gas
LE
G4.236
LF
4.248
LG
4.2482
LH
C4.236
LJ
T4.236
LK
D4.236
LL
4.38
LM
4.41
N 4.318
NA
4.270
NB
4.300
NC
4.318
ND
4.3182
P 6.305
PA
P6
PB
6.288
PC
6.305
PD
PF6.305
R 6.247
RA
6.247
SD Sabre CC6.68
T6.354
TA
6.306
TB
6.335
TC
6.354
TD
H6.354
TE
T6.354
TF
H6.354
TG
6.3541
TH
T6.3541
TJ
6.3542
TK
C6.3542
TL
6.3543
TM
C6.3543
TN
H6.3543
TP
T6.3543
TQ
HT6.3543
TR
6.372
TS
6.3723
TT
TC6.3541
TU
T6.3544
H
Horizontal
N
Narrow front end
(Belt driven water pump)
TV
6.3724
TW
6.3544
TX
C6.3544
TY
H6.3544
TZ
HT6.3544
U 700 Series
UA
704-26
UB
704-30
W Peregrine/1300
WA
6.466
WB
T6.466
WC
CC6.466
WD
T6.67
WE
CC6.67
WF
T6.76
WG
CC6.76
WH
T6.87
WJ
CC6.87
X V8.540
XA
V8.510
XB
TV8.510
XC
V8.540
XD
V8.605
XE
TV8.540
Y Phaser/1006
YA
Naturally
aspirated
YB
Turbocharged
YC
Compensated
YD
Charge cooled
YE
Fed. Charge
cooled
New Phaser/1006
YG
Naturally
aspirated
YH
Turbocharged
YK
Turbocharged
intercooled
Z V8.640
ZA
V8.640
ZB
TV8.640
P
Timing chain
T
Turbocharged
V
Vee form
Current product
Table 2 - Country of manufacture code

A
B
C
D
E
F
G
Argentina
Brazil
Australia
Germany
Spain
France
Greece
H
HM
HK
HU
J
K
L
Group
Indonesia
Iraq
Hungary
Japan
Korea
Italy
M
MX
N
P
S
SA
T
Mexico
Mexico
USA
Poland
India
South Africa
Turkey
U
V
W
X
Y
United Kingdom
Pakistan
Iran
Peru
Yugoslavia
1988
1989
1990
1991
1992
1993
1994
A
B
C
D
E
F
G
1995
1996
1997
1998
1999
2000
2001
This code indicates the country of manufacture of the basic engine.

Table 3 - Year of manufacture code
A
B
C
D
E
F
G
1974
1975
1976
1977
1978
1979
1980
H
J
K
L
M
N
P
1981
1982
1983
1984
1985
1986
1987
S
T
U
V
W
X
Y
This code indicates the year of manufacture. The letters I, O, Q, R and Z will not be used.
Current product
Basic fault-finding guide
The chart below is given to assist in the correct diagnosis of basic engine faults.
Problems and possible causes
Problem
Possible causes
The starter motor turns the engine too slowly
1, 2, 3, 4
The engine does not start
5, 6, 7, 8, 9, 10, 12, 13, 14, 15, 17, 34, 35, 36, 37,38, 40,
42, 43, 44
The engine is difficult to start
5, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 19, 34, 36, 37, 38,
40, 42, 43, 44
Not enough power
8, 9, 10, 11, 12, 13, 16, 17, 18, 19, 20, 21, 34, 36, 37, 38,
39, 42, 43, 44, 61, 63, 64
Misfire
8, 9, 10, 12, 13, 15, 20, 22, 34, 36, 37, 38, 39, 40, 41, 43
High fuel consumption
11, 13, 15, 17, 18, 19, 21, 22, 34, 36, 37, 38, 39, 40, 42,
43, 44, 63
Black exhaust smoke
11, 13, 15, 17, 19, 21, 22, 34, 36, 37, 38, 39, 40, 42, 43,
44, 61, 63
Blue or white exhaust smoke
4, 15, 21, 23, 36, 37, 38, 39, 42, 44, 45, 52, 58, 62
The pressure of the lubricating oil is too low
4, 24, 25, 26, 46, 47, 48, 50, 51, 59
The engine knocks
9, 13, 15, 17, 20, 22, 23, 36, 37, 40, 42, 44, 46, 52, 53, 60
The engine runs erratically
7, 8, 9, 10, 11, 12, 13, 15, 16, 18, 20, 22, 23, 34, 38, 40,
41, 44, 52, 60
Vibration
13, 18, 20, 27, 28, 34, 38, 39, 40, 41, 44, 52, 54
The pressure of the lubricating oil is too high
4, 25, 49
The engine temperature is too high
11, 13, 15, 19, 27, 29, 30, 32, 34, 36, 37, 39, 52, 55, 56,
57, 64
Crankcase pressure
31, 33, 39, 42, 44, 45, 52
Bad compression
11, 22, 37, 39, 40, 42, 43, 44, 45, 53, 60
The engine starts and stops
10, 11, 12
1
List of possible causes
Current product
45 Valve stems and/or guides are worn.
1 Battery capacity low.
46 Crankshaft bearings are worn or damaged.
2 Bad electrical connections.
47 Lubricating oil pump is worn.
3 Fault in starter motor.
48 Relief valve does not close.
4 Wrong grade of lubricating oil.
49 Relief valve does not open.
5 Starter motor turns engine too slowly.
50 Relief valve spring is broken.
6 Fuel tank empty.
51 Fault in suction pipe of lubricating oil pump.
7 Fault in stop control.
52 Piston is damaged.
8 Restriction in a fuel pipe.
53 Piston height is incorrect.
9 Fault in fuel lift pump.
54 Flywheel housing or flywheel is not aligned

correctly.
10 Dirty fuel filter element.

11 Restriction in filter/cleaner or air induction system.
12 Air in fuel system.
13 Fault in atomisers or atomisers of an incorrect
type.
14 Cold start system used incorrectly.
15 Fault in cold start system.
16 Restriction in fuel tank vent.
17 Wrong type or grade of fuel used.
18 Restricted movement of engine speed control.
19 Restriction in exhaust pipe.
20 Engine temperature is too high.
21 Engine temperature is too low.
55 Fault in thermostat or thermostat is of an incorrect

type.
56 Restriction in coolant passages.
57 Fault in water pump.
58 Valve stem seal is damaged (if there is one fitted).
59 Restriction in sump strainer.
60 Valve spring is broken.
61 Turbocharger impeller is damaged or dirty.
62 Lubricating oil seal of turbocharger leaks.
63 Induction system leaks (turbocharged engines).
64 Turbocharger waste-gate does not work correctly
(if there is one fitted).
22 Valve tip clearances are incorrect.

23 To much oil or oil of wrong specification used in
wet type oil cleaner.
24 Not enough lubricating oil in sump.
25 Defective gauge.
26 Dirty lubricating oil filter element.
27 Fan damaged.
28 Fault in engine mounting or flywheel housing.
29 Too much lubricating oil in sump.
30 Restriction in air or water passages of radiator.
31 Restriction in breather pipe.
32 Insufficient coolant in system.
33 Vacuum pipe leaks or fault in exhauster.
34 Fault in fuel injection pump.
35 Broken drive on fuel injection pump.
36 Timing of fuel injection pump is incorrect.
37 Valve timing is incorrect.
38 Bad compression.
39 Cylinder head gasket leaks.
40 Valves are not free.
41 Wrong high-pressure pipes.
42 Worn cylinder bores.
43 Leakage between valves and seats.
44 Piston rings are not free or they are worn or
broken.
8
Current product
Turbocharger fault guide
The chart below is given to assist in the correct diagnosis of turbocharger faults.
If the inside of the induction manifold is wet, check that there is not a fuel leak from the fuelled starting aid, if
there is one fitted.
Problems and possible causes
Problem
Possible causes
Not enough power
1, 4, 5, 6, 7, 8, 9, 10, 11, 18, 20, 21, 22, 25, 26, 27, 28, 34,
35, 36
Black smoke
1, 4, 5, 6, 7, 8, 9, 10, 11, 18, 20, 21, 22, 25, 26, 27, 28, 34,
35, 36
Blue smoke
1, 2, 4, 6, 8, 9, 17, 19, 20, 21, 22, 30, 31, 32, 34
High lubricating oil consumption
2, 8, 15, 17, 19, 20, 28, 29, 31, 32, 34
Too much lubricating oil at turbine end
2, 7, 8, 17, 19, 20, 22, 28, 30, 31, 32
Too much lubricating oil at compressor end
1, 2, 4, 5, 6, 8, 19, 20, 21, 28, 31, 32
Not enough lubrication
8, 12, 14, 15, 16, 23, 24, 29, 32, 33, 37, 38
Lubricating oil in the exhaust manifold
2, 7, 17, 18, 19, 20, 22, 28, 31, 32
Inside of the induction manifold wet
1, 2, 3, 4, 5, 6, 8, 10, 11, 17, 18, 19, 20, 21, 28, 32, 34, 39,
40
Damaged compressor impeller
3, 4, 6, 8, 12, 15, 16, 20, 21, 23, 24, 29, 32, 33, 37, 38
Damaged turbine rotor
7, 8, 12, 13, 14, 15, 16, 18, 20, 22, 23, 24, 25, 27, 29, 32,
33, 37, 38
Rotating assembly does not turn freely
3, 6, 7, 8, 12, 13, 14, 15, 16, 18, 20, 21, 22, 23, 24, 29, 32,
33, 37, 38
Worn bearings, bearing bores, journals
6, 7, 8, 12, 13, 14, 15, 16, 23, 24, 29, 33, 37, 38
Noise from turbocharger
1, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 20, 21,
22, 23, 24, 29, 32, 33, 34, 37, 38
Sludge or carbon deposit in bearing housing
2, 11, 13, 14, 15, 17, 18, 24, 29, 33, 37, 38
Current product
List of possible causes

1 Element of the air filter dirty
2 Restricted crankcase breather
3 Element of the air filter not fitted, or not sealing
correctly. Loose connection to turbocharger.
4 Internal distortion or restriction in pipe from air
filter to turbocharger.
5 Damaged/restricted crossover pipe,
turbocharger to induction manifold.
6 Restriction between air filter and turbocharger.
7 Restriction in exhaust system.
8 Turbocharger loose or clamps/setscrews loose.
9 Induction manifold has cracks, is loose, or has
flange distortion.
10 Exhaust manifold has cracks, is loose, or has
flange distortion.
11 Restricted exhaust system.
12 Delay of lubricating oil to turbocharger at engine
start.
13 Insufficient lubrication.
14 Dirty lubricating oil.
15 Incorrect lubricating oil.
16 Restricted lubricating oil supply pipe.
17 Restricted lubricating oil drain pipe.
18 Turbine housing damaged or restricted.
19 Leakage from turbocharger seals.
20 Worn turbocharger bearings.
21 Excessive dirt in compressor housing.
22 Excessive carbon behind turbine rotor.
23 Engine speed raised too rapidly at initial start.
24 Insufficient engine idle period.
25 Faulty fuel injection pump.
26 Worn or damaged atomisers.
27 Valves burned.
28 Worn piston rings.
29 Lubricating oil leakage from supply pipe.
30 Excessive preservation fluid (on initial engine
start).
31 Excessive engine idle period.
32 Restriction in turbocharger bearing housing.
33 Restriction in lubricating oil filter.
34 Wet type air cleaner: Restricted, dirty element,
viscosity of oil to low/high.
35 Waste-gate actuator faulty or damaged.
36 Waste-gate valve not free.
37 Engine stopped too soon from high load.
38 Insufficient lubricating oil.
39 Fuel leakage from fuelled starting aid.
40 Crack in backplate of compressor.
10
Current product
General safety precautions
These safety precautions are important. You must

refer also to the local regulations in the country of use.
Some items only refer to specific applications.
Diesel fuel and lubricating oil (especially used

lubricating oil) can damage the skin of certain
persons. Protect your hands with gloves or a
special solution to protect the skin.
Do not wear clothing which is contaminated by

lubricating oil. Do not put material which is
contaminated with oil into the pockets of clothing.
Discard used lubricating oil in accordance with

local regulations to prevent contamination.
Ensure that the control lever of the transmission

drive is in the "out-of-drive" position before the
engine is started.
The combustible material of some components of

the engine (for example certain seals) can
become extremely dangerous if it is burned. Never
allow this burnt material to come into contact with
the skin or with the eyes.
Read and use the instructions relevant to lift

equipment.
Wear a face mask if the glass fibre cover of the

turbocharger is to be removed or fitted.
Always use a safety cage to protect the operator

when a component is to be pressure tested in a
container of water. Fit safety wires to secure the
plugs which seal the hose connections of a
component which is to be pressure tested.
Do not allow compressed air to contact your skin.

If compressed air enters your skin, obtain medical
help immediately.
Turbochargers operate at high speed and at high

temperatures. Keep fingers, tools and debris away
from the inlet and outlet ports of the turbocharger
and prevent contact with hot surfaces.
Fit only genuine Perkins parts.
Only use these engines in the type of application

for which they have been designed.
Do not change the specification of the engine.
Do not smoke when you put fuel in the tank.
Clean away fuel which has been spilt. Material

which has been contaminated by fuel must be
moved to a safe place.
Do not put fuel in the tank while the engine runs

(unless it is absolutely necessary).
Do not clean, add lubricating oil, or adjust the

engine while it runs (unless you have had the
correct training; even then extreme care must be
used to prevent injury).
Do not make adjustments that you do not

understand.
Ensure that the engine does not run in a location

where it can cause a concentration of toxic
emissions.
Other persons must be kept at a safe distance

while the engine or auxiliary equipment is in
operation.
Do not permit loose clothing or long hair near

moving parts.
Keep away from moving parts during engine

operation. Warning! Some moving parts cannot be
seen clearly while the engine runs.
Do not operate the engine if a safety guard has

been removed.
Do not remove the filler cap or any component of

the cooling system while the engine is hot and
while the coolant is under pressure, because
dangerous hot coolant can be discharged.
Do not use salt water or any other coolant which

can cause corrosion in the closed circuit of the
cooling system.
Do not allow sparks or fire near the batteries

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

made to the electrical system.
Only one person must control the engine.
Ensure that the engine is operated only from the

control panel or from the operators position.
If your skin comes into contact with high-pressure

fuel, obtain medical assistance immediately.
11
12
Current product
2
Engine data
4.108
Basic technical data
Horse power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35,0 kW (47 bhp)
Number of cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four stroke
Induction system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Naturally aspirated
Combustion system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Indirect injection
Nominal bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79,37 mm (3.125 in)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88,90 mm (3.500 in)
Compression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22:1
Cubic capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1,760 litres (107.4 in3)
Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3-4-2
Valve tip clearances
- Inlet (cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,30 mm (0.012 in)
- Exhaust (cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,30 mm (0.012 in)
Lubricating oil pressure
- at maximum engine speed and
normal engine temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . 207/414 kN/m2 (30/60 lbf/in2) 2,1/4,2 kgf/cm2
Coolant temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60C (140F)
Thermostat starts to open
- bellows type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67/75C (152/167F)
- wax type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77/85C (170/185F)
Thermostat fully open
- bellows type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85/88C (185/190F)
- wax type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92/98C (197/208F)
Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise from front
Idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550 rev/min
Location of maximum no-load speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel injection pump data plate
Location of number 1 cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft pulley end
Location of engine timing marks . . . . . . . . . . . . . . . . . . . Scribe lines on fuel injection pump and pump flange
Atomiser codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CAV = BG, GY, OMAP = YB
Fuel pump codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .EH34E, EH39, PH30
Location of fuel pump code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Data plate on fuel pump
Location of fuel pump timing marks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel pump mounting flange
Belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 N (10 lbf) 4,5 kgf
Belt deflection at longest run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 mm (3/8 in)
13
Current product
Preventive maintenance periods

Caution: On short distance operation with frequent starts and stops the hours of operation are more important
than the distance.
These preventive maintenance periods apply to average conditions of operation. Check the periods given by
the manufacturer of the equipment in which the engine is installed. Use the periods which are shortest. When
the operation of the engine must conform to the local regulations these periods and procedures may need to
be adapted to ensure correct operation of the engine.
It is good preventive maintenance to check for leakage and loose fasteners at each service.
Maintenance schedules
A Every day or every 8 hours
B Every 150 hours or 3 months or 6000 km (4000 miles)
C Every 450 hours or 12 months or 18000 km (12000 miles)
D Every 900 hours or 36000 km (24000 miles)
E Every 2700 hours or 108000 km (72000 miles)
The schedules which follow must be applied at the interval (hours or months) which occur first.
A B C D E
z
Operation
Check the amount of coolant (2)
Check the drive belt of the alternator

Lubricate dynamo rear bush (where fitted)
Check for water in the fuel pre-filter and drain as necessary

z
Renew the elements of the fuel-filter
Check the amount of lubricating oil in the sump
Check the lubricating oil pressure at the gauge (1)

z
Renew the engine lubricating oil (4)
Renew the canister of the lubricating oil filter (4)
Clean air compressor filter, if fitted

Clean the air cleaner or empty the dust bowl of the air filter
- extremely dusty conditions

z
- normal conditions
z
Clean or renew the air filter element, if it has not been indicated earlier
z
z
Ensure that the valve tip clearances of the engine are checked and, if necessary, adjusted
(3)
Ensure that the alternator, starter motor etc. are checked (3)
(1) If there is one fitted

(2) Renew the antifreeze every 2 years. If a coolant inhibitor is used instead of antifreeze, it should be renewed every 6 months.
(3) By a person who has had the correct training.
(4) The oil change interval will change with the sulphur content of the fuel (see the table on page 51 and fuel specification). The interval
to change the canister of the lubricating oil filter is not affected.
14
Current product
Fuel pump codes
CAV fuel injection pump
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lucas DPA

Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise from drive end
Outlet for number 1 cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Letter "W"
Fuel injection pump timing
The engine check angle must be used with special tool MS.67B and with the engine set with number 1 piston
at top dead centre (TDC) on the compression stroke. The pump is checked with the pump set at the start of
injection for number 1 cylinder.
The code letters are included in the setting code stamped on the data plate of the fuel injection pump. Some
fuel pumps may have the setting code stamped on a modification plate which is fastened to the flange of the
pump. If a modification plate is fitted, use the code letters stamped on this plate.
Engine check
angle
(degrees)
Pump mark
angle
(degrees)
EH, EH34E, EH39
281
290
LH30
281
292
PH, PH23E, PH27, PH28, PH30
281
290
PH25E500/5/2450
PH25E500/9/1990
PH25E500/9/2090
PH30/500/5/2450
PH30/500/6/1570
PH30/500/9/1990
PH30/500/9/2090
279.5
290
RH, RH30E
279.5
290
SH33E
279.5
290
281
291
Fuel pump code letters
TH, TH23E
15
Current product
Recommended
torque tensions
The torque tensions below apply to components

lubricated lightly with clean engine oil before they are
fitted.
Torque
Thread
size
Nm
lbf ft
kgf m
Nuts, cylinder head
1/2
81
60
8,3
Sump plug
3/4
50
37
5,1
Atomiser clamp
5/16
16
12
1,7
M12 x 1.5
20
15
2,1
Main bearing
1/2
115
85
11,8
Big end bearing
3/8
57
42
5,8
Front pulley
5/8
203
150
20,7
Flywheel
7/16
81
60
8,3
Description
Injector pipe union nut

Caution: This operation must be done by a person
with the correct training. If in doubt, refer to the
workshop manual.
1 Lightly lubricate the threads of the cylinder head
studs and nuts.
2 Gradually and evenly tighten the nuts in three
stages. Tighten the nuts in the final stage to 81 Nm
(60 lbf ft) 8,3 kgf m.
3 Start the engine and run it until the coolant
temperature is 170F (77C). Switch the engine off.
4 Check the tightness of the nuts in the correct
sequence.
z
If a nut moves when checked, tighten it to the

correct torque.
If a nut does not move before the correct torque is

reached, loosen the nut 1/12 to 1/6 (30 to 60) of
a turn and then tighten it to the correct torque.
Caution: It is important that the cylinder head nuts

are tightened again to the correct torque, in the
correct sequence, after 800/ 1600 km (500/1000
miles) 25/50 hours.
16
Current product
3.152 Series
Horse power
- 3.152 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33,6 kW (45 bhp)
- D3.152. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36,5 kW (49 bhp)
- 3.1522 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33,2 kW (44.5 bhp)
- 3.1524 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38,8 kW (52 bhp)
- T3.1524 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44,7 kW (60 bhp)
Induction system
- 3.152, D3.152, 3.1522, 3.1524 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Naturally aspirated
- T3.1524 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharged
Combustion system
- 3.152 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Indirect injection
- D3.152, 3.1522, 3.1524, T3.1524 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Direct injection
Nominal bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91,44 mm (3.60 in)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 mm (5 in)
Compression ratio
- 3.152 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.4:1
- D3.152. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.5:1
- 3.1522 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.0:1
- 3.1524 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.5:1
- T3.1524 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.5:1
Cubic capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5 litres (152.7 in3)
Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-3
- Inlet (cold)
3.152, D3.152 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,30 mm (0.012 in)
3.1522, 3.1524, T3.1524 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,20 mm (0,008 in)
- Exhaust (cold)
3.152, D3.152 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,30 mm (0.012 in)
3.1522, 3.1524, T3.1524 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,32 mm (0,0125 in)
Continued
17
Current product

- bellows type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72/82C (170/179F)
- wax type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81/84C (177/183F)
- bellows type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93C (199F)
- wax type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98C (208F)
Idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750 rev/min
Location of maximum no-load speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel injection pump data plate
Location of engine timing marks . . . . . . . . . . . . . . . . . . . Fuel injection pump flange, rear face of timing case
Atomiser codes
- 3.152 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DD, DE, GC, GW
- D3.152 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BV, CR, CS, DF, DN, EE, FS, GM, ND, UB, XC, XG
- 3.1522 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .GS
- 3.1524 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EE, HN, ND, XG
- T3.1524 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HM, HN, HX
Fuel pump codes
- 3.152 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .LW, PW
- D3.152 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AW, EW, CW, MW, RW, SW, TW, WW
- 3.1522 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XW
- 3.1524 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW, WW, ZW
- T3.1524 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BW, YW, DW
Location of fuel pump code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Left hand side of FIP
Location of fuel pump timing marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel pump mounting flange
Belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 N (10 lbf) 4,5 kgf
Belt deflection at longest run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 mm (3/8 in)
18
Current product
A First service at 25/50 hours (all engines)
F Every 500 hours or 12 months (D3.152)
B Every day or every 8 hours (all engines)
G Every 800 hours or 12 months (3.1524, T3.1524)
C Every 200 hours or 4 months (3.1524, T3.1524)
H Every 2400 hours (3.1524, T3.1524)
D Every 250 hours or 4 months (D3.152)
I Every 2500 hours (D3.152)
E Every 400 hours or 12 months (3.1524, T3.1524)

A B C D E F G H I
z
Check the amount of coolant

Check the drive belt(s)
z
z
z
z
z
z
z
z
Operation
Check for water in the fuel pre-filter (1)

Renew the fuel-filter element(s)
Ensure that the atomisers are checked (2)
Ensure idle speed is checked and adjusted, if necessary (2)
Renew the lubricating oil (3)
Renew the canister(s) of the lubricating oil filter
- normal conditions
z
z
Ensure that the turbocharger impeller and turbocharger compressor casing are
cleaned
z
z
z
z
Clean the compressor air filter (1)

Ensure that the exhauster or compressor (1) is checked (2)
Ensure that the tappet clearances are checked and adjusted, if necessary (2)

(3) The oil change interval will change with the amount of sulphur in the fuel (see the table on page 51 and the fuel specification). The
interval to change the canister of the lubricating oil filter is not affected.
19
Current product
Fuel pump codes

Lucas fuel injection pump
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DPA or DP 200
Direction of rotation from drive end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise
Outlet for number 1 cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Letter "W" or "Z"
Engine
check angle
(degrees)
Pump mark
angle
(degrees)
AW
27
41
PW50
29
38
BW, YW
27
35
RW50, RW52,
RW54
25
37
CW
27
35
SW except below
SW/8/1800,
SW/8/1890
SW48
SW52, SW57, SW58
25
37
22.25
24
25
37
37
37
Fuel pump code

letters
DW
Fuel pump code

letters
Engine
check angle
(degrees)
Pump mark
angle
(degrees)
26.5
35
TW48E
27
37
LW45, LW49
32
40
TW50
26
37
LW51, LW52
29
38
WW except below
WW/3/2470, WW/6/
2200, WW/6/2470,
WW47E, WW48
25 27
35 35
LW58, LW59
29
40
XW50E
29
36
MW47E, MW49,
MW53E, MW57
25
37
ZW
25
37
PW43, PW44
30
38
20
Current product
Stanadyne fuel injection pump
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stanadyne
Outlet for number 1 cylinder . . . . . . . . . . . . . . . . . . . . . 11 o'clock position as seen from the rear of the pump
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Self-vent
Static timing
The engine check angle must be used with special tool MS.67B and with the engine set with the piston of the
number 1 cylinder at top dead centre (TDC) on the compression stroke. The pump is checked with the pump
set at the start of injection for the number one cylinder. To set the pump mark angle, see workshop manual,
publication number TPD 1091 1208E.
Fuel pump code
letters
Engine check angle

(degrees)
Pump mark angle

(degrees)
EW
26
322
Recommended torque tensions

The torque tensions below apply to components lubricated lightly with clean engine oil before they are fitted.
Description
cylinder head (cold)
- fasteners
- nuts
Thread
size
Torque
Nm
lbf ft
kgf m
95
81
70
60
9,7
8,3
7/16 UNF
Sump plug
1/2 PTF
34
25
3,5
Atomiser clamp
3/8 UNF
16
12
1,7
M12 X 1,5
20
15
1,0
Main bearing
9/16 UNF
150
110
15,0
Big end bearing

- cadmium plated
- phosphated
- non-plated
7/16 UNF
61
81
95
45
60
70
6,2
8,3
9,7
Front pulley
- with 4,8 mm (0.19 in) spacer
- with 8,9 mm (0.35 in) spacer
7/8 UNF
142
325
105
240
14,5
33,2
Flywheel
1/2 UNF
106
78
10,8
21
Current product

with the correct training. If in doubt refer to the
workshop manual.
Different cylinder head fasteners have been used on
3.152 and D3.152 engines.
Original cylinder heads were fastened to the cylinder
block by studs and nuts.
As from the engine numbers which follow, cylinder
head studs, nuts and setscrews were fitted:
152U21416L
152UA28411DSL
152U98250D
152UA431805DL
It is important that the studs and the three different

lengths of setscrews be fitted in their correct
positions.
On 3.152 engines, the studs were changed to
setscrews except for those listed below.
Fastener
type
Fastener
length mm (in)
Illustration and
position
Stud
92,0 (3 5/8)
A 2, 3, 6, 7, 12, 13
Setscrew
92,0 (3 5/8)
A 1, 8, 9
Setscrew
98,4 (3 7/8)
A 4, 5, 10, 11, 12,

14, 15, 16, 17
On D3.152 engines, all but two of the original studs

were changed to setscrews.
Fastener
type
Fastener
length mm (in)
Illustration and
position
Stud
92,0 (3 5/8)
B 13, 14
Setscrew
82,5 (3 1/4)
B 2, 3, 7, 8
Setscrew
92,0 (3 5/8)
B 4, 15, 18
Setscrew
98,4 (3 7/8)
B 1, 5, 6, 9, 10, 11,
12, 16, 17
On D3.152 engines from engine number

CE.U597494F another three setscrews were
changed to studs.
Fastener
type
Fastener
length mm (in)
Illustration and
position
Stud
92,0 (3 5/8)
B 4, 13, 14, 15, 18
Setscrew
82,5 (3 1/4)
B 2, 3, 7, 8
Setscrew
98,4 (3 7/8)
B 1, 5, 6, 9, 10, 11,
12, 16, 17
22
Current product
1 Lightly lubricate the threads of the fasteners.
2 Gradually and evenly tighten the fasteners to the
correct torque shown in the table below, in the
sequence shown in (page 22, A or B).
Fastener type
Torque
Nuts only fitted
81 Nm (60 lbf ft) 8,3 kgf m
Nuts and setscrews
3 Start and run the engine until it reaches normal

temperature of operation. Stop the engine.
4 Remove the rocker shaft and remove the
atomisers, then tighten the fasteners again to the
correct torque in the correct sequence.
If a fastener moves when checked, tighten it to the
correct torque.
If a fastener does not move when checked, loosen it
1/12 to 1/6 (30 to 60) of a turn then tighten it to the
correct torque.
5 Check the first 10 positions again, during this check
do not loosen the fasteners.
Caution: Engines fitted with cylinder head gasket,
part number 3681E015 must have the fasteners for
the cylinder head tightened again after the first 25/50
hour of use.
23
Current product
4.203 Series
Horse power
- 4.203
vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47,0 kW (63 bhp)
agriculture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42,5 kW (57 bhp)
- 4.2032 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44,7 kW (60 bhp)
Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Combustion system
- 4.203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Indirect injection
- 4.2032, D4.203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct injection
Nominal bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91,44 mm (3.6 in)
Stroke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 mm (5 in)
Compression ratio
- 4.203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.4:1
- 4.2032 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19:1
Cubic capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,33 litres (203 in3)
Firing order. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-4-2
All 4.192 and 4.203
and D4.203 up to engine number JE....U564083G
- Inlet (cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,30 mm (0.012 in)
D4.203 from engine number JE....U564083G
- Inlet (cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,20 mm (0.008 in)
Coolant temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60C (140F)
Thermostat starts to open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82C (179F)
- bellows type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95C (203F)
- wax type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98C (208F)
Continued
24
Current product
Idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550 - 750 depending on application

Location of engine timing marks . . . . . . . . . . . . . . . . . . . . . . Timing pin on timing case and crankshaft pulley
Atomiser codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . AV, BM, DN, EC, EG, EV, FJ, FM, FR, FS, GB, GC, GM,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .GR, GS, GW, H, HM, HW, HX, J, TC, YA, Z, UA, VA
Fuel pump codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AF, BF, LF, MP, PP, RP, SP, TP,
Location of fuel pump code
- 4.203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel pump mounting flange and fuel pump carrier plate
- 4.2032 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel pump mounting flange and timing case
Location of fuel pump timing marks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel pump mounting flange
25
Current product

Maintenance schedule 4.203

C Every 500 hours or 12 months
B Every 250 hours or 4 months
D Every 2500 hours
A B C D
Operation
Check the concentration of the coolant (2)
Check the drive belt
z
z
z
z
z
z
Lubricate dynamo rear bush (where fitted)

Clean the sediment chamber and the strainer of the fuel lift pump
Check for water in the pre-filter (1)
Renew the element of the fuel-filter
Renew the canister of the lubricating oil filter
z
z
z
z
- normal conditions
z
z
z
z
z
Ensure that the valve tip clearances of the engine are checked and, if necessary, adjusted (3)
(1) if there is one fitted

26
Current product
Maintenance schedule 4.2032
D Every 800 hours
E Every 2400 hours

A B C D E
z
Operation
Check the concentration of the coolant (2)
Check the drive belt
z
z
Renew the element of the fuel-filter
z
z
z

z
z
z
- normal conditions
z
z
z
z
z
Ensure that the valve tip clearances of the engine are checked and, if necessary, adjusted (3)

27
Current product
Fuel pump codes 4.203 and 4.2032

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DPA
Direction of rotation from drive end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Counter-clockwise
Outlet for number 1 cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Letter "W"
4.203 Series
Fuel pump
code letters
Engine check
angle
(degrees)
4.203 Series
Pump mark
angle
(degrees)
Fuel pump
code letters
Engine check
angle
(degrees)
Pump mark
angle
(degrees)
AF37
287
277
LF59
289
279
AF44E
287
277
LP55
287
275
AF46/600/0/
2800
285
277
MP50
290
277
AF46/600/0/
2920
286
277
MP54
293
280
AF49E
287
277
MP55
293
280
AF50
287
277
MP57
293
280
AF53
287
277
PP48E
289.5
281
AF56
289
279
PP53E
289.5
281
BF41E
290
281
PP46E
289.5
281
BF51
290
281
PP50E
289.5
281
LF48
289
279
RP50E
290.0
281
LF51
289
279
SP
289.5
281
LF56
289
279
TP
290.0
281
28
Current product
4.203
Description
Thread
size
Torque
Nm
lbf ft
kgf m
7/16
81
95
95
60
70
70
8,3
9,7
9,7
Sump plug
- with 'washer'
- with 'O' ring
3/4
50
34
34
37
25
25
5,1
3,5
3,5
Atomiser clamp
3/8
16
12
1,6
Fasteners, cylinder head

- nuts only
- nuts and setscrews
- engine numbers JG.U609019S to JG.U609185S
M12 x 1.5
20
15
2,1
Main bearing
9/16
156
115
15,9
Big end bearing

- phosphate
- cadmium
7/16
81
61
60
45
8,3
6,2
Front pulley
7/8
149
110
15,2
Flywheel
1/2
108
80
11,1
Thread
size
Nm
lbf ft
kgf m
Fasteners, cylinder head
7/16
95
70
9,7
Sump plug
- with 'washer'
- with 'O' ring
3/4
3/4
3/4
50
34
34
37
25
25
5,1
3,5
3,5
4.2032
Description
Atomiser clamp
Torque
5/16
15
12
1,6
M12 x 1.5
20
15
2,1
Main bearing
9/16
156
115
15,9
Big end bearing
7/16
60
45
6,2
Front pulley
7/8
149
110
15,2
Flywheel
1/2
110
80
11,1
29
Current product

4.203 and 4.2032
Workshop Manual.
Flame protected engines still have all nuts. All other
engine were changed to nuts and setscrews, from the
engine numbers below.
203U93838CL
203U6963DL
203UA130434DL
On 4.203 engines, all but two of the studs were
changed to setscrews as well as the eight special
studs which also retain the atomisers.
Fastener
type
Illustration
and position
Stud
A 10, 11
Setscrew
A 1 to 9 and 12 to 19
On D4.203 and 4.2032 engines, all but two of the

studs were changed to setscrews.
Fastener
type
Illustration
and position
Stud
B 16, 17
Setscrew
B 1 to 15 and 18 to 23
If these two studs are removed they must be put back

in their correct positions, because they guide the
cylinder head gasket into position.
1 Lightly lubricate the threads of the fasteners.
correct torque in the sequence shown in (A or B).
Repeat to ensure that all the fasteners are tightened
to the correct torque shown in the table below.
Fastener type
Torque
Nuts only fitted
Nuts and setscrews
Caution: Engines fitted with cylinder head gasket,

part number 36812138, must have the fasteners for
the cylinder head tightened again after the first 25/50
hour of use.
Note: Release the cylinder head setscrews evenly
and gradually in the reverse sequence to that shown
in (A).
30
Current product
4.236 Series
Horse power
- 4.236
vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61,1 kW (82 bhp)
industrial/agriculture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60,0 kW (81 bhp)
- 4.248 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62,6 kW (84 bhp)
Combustion system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Direct injection
Nominal bore
- 4.236 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98,43 mm (3.857 in)
- 4.248 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100,96 mm (3.975 in)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 mm (5 in)
Compression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16:1
Cubic capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,86 litres (236 in3)
Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3-4-2
- Inlet (cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,30 mm (0.012 in)
Thermostat starts to open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77/83C (170/180F)
Thermostat fully open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94C (202F)
Idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550 - 750 - 1000 rev/min
Atomiser codes
- 4.236 . . . . . . . . . . . . . . . . . . . . . . CF, UA, AC, DM, CU, AB, EA, FY, XD, FC, FL, HY, NB, NC, ND, XE, YC
- 4.248 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DL, BU, CU, RG, FW
Fuel pump codes . . . . . . . . . . . . . . . . AS, AT, BS, BT, DT, FT, GT, HT, JT, KT, LS, LT, MS, MT, PS, PT, RS,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .RT, SS, ST, TT, TS, VS, VT, WS, XS, XT, YT, ZS, ZT
Location of fuel pump code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Data plate on fuel pump
Location of fuel pump timing marks. . . . . . . . . . . . . . . . . . . . . . . Fuel pump mounting flange and timing case
31
Current product

A First 25/50 hours
D Every 500 hours or 12 months
B Every 8 hours or every day
E Every 2500 hours

A B C D E
Check the drive belt of the alternator
z
z
z
z
z
z
z
z
z
z
z
- normal conditions
Clean or renew the air filter element, if it has not been indicated earlier (4)
Clean the vent valve of the engine breather system (1)
Ensure that the turbocharger impeller and turbocharger compressor casing are cleaned
Ensure that the valve tip clearances are checked and adjusted, if necessary(2)
z
z
z
z
Renew the engine lubricating oil (3) (5)
z
z
Operation
(1) If there is one fitted.

(3) 4.2482 engines, every 500 hours or 12 months.
(4) 4.2482 engines, every 1000 hours.
32
Current product
Fuel pump codes
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DPA and DPS

Outlet for number 1 cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DPA letter "W", DPS letter "X"
Engine
check angle
(degrees)
Pump mark
angle
(degrees)
AS, AT60E, AT67E
279
292
PS61/850/4/3120
PS61/850/7//3100
PS61/850/9/2400
BS44
281
296
PS...62, 66
BS...49, 54, 62, 64
281
292
BT73E
280.5
DT74E
FT70E
Fuel pump code

letters
Engine
check angle
(degrees)
Pump mark
angle
(degrees)
280.5
292
281
292
PT (2643C210)
279.5
291
293
PT (2643C211)
280.5
291
280
289
RS...45, 52, 56, 58
286
297
280
290
Fuel pump code

letters
RT
281
292
SS...64, 66, 68
285
297
279.5
291
TT (build list LJ50272)
280
288
TS...59, 65
281
292
291
TS67 except below
281
292
284
292
TS67/850/2/2380
TS67/850/2/2480
TS67/850/6/2700
285
292
281
296
VS51VS51
284
296
LS...45, 49, 52, 55
284.5
296
VT
280
293
LS...57, 61, 63, 67
284.5
296
WS62, 66
280
292
LS62
283.5
296
XS
280
293
LS66
281
292
XS55E, XS60E
281
293
LT
9.25
17
XT
281
292
MS67
279
292
YS68E
281
289
MT80L
278
285
YT
280
291
PS...45, 48, 51, 54,

55, 57
281
292
ZS51E
278.25
291
PS61 except below
281
292
FT73E
-before U940900L
-from U940900L
286
284
293
293
FT
284
293
ST
278.25
291
281
280
293
293
JT57E
279.5
KT68L
LS44
GT78E
HT87E
-before U028270M
-from U028270M
33
Current product
Fuel pump codes

Stanadyne fuel injection pump
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Stanadyne DB2
Outlet for number 1 cylinder. . . . . . . . . . . . . . . . . . . . . . . 7 o'clock position as seen from the rear of the pump
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Self-vent
set at the start of injection for the number one cylinder. To set the pump mark angle, see workshop manual,
publication number 601 TPD 0393 1229.
Engine check
angle
(degrees)
Pump mark
angle
(degrees)
280
285
67
72
WT
284.5
64
ZT
284.5
64

AU
- before eng. U524012W
- from eng. U524012W

4.236
Torque
Thread
size
Nm
lbf ft
kgf m
Fasteners, cylinder head, refer to head torque sequence
1/2
Sump plug
- with 'washer'
- with 'O' ring
3/4
3/4
3/4
50
34
34
37
25
25
5,1
3,5
3,5
Atomiser clamp
- securing nuts
- clamp nuts
5/16
5/16
18
12
14
9
1,9
1,2
M12 x 1.5
20
15
2,1
5/8
5/8
203
244
150
180
20,7
24,9
Big end bearing

- Cadmium silver finnish
- Phosphated black finnish
1/2
1/2
95
122
70
90
9,7
12,4
Front pulley
- Cadmium
- Phosphated
- 321B6139 (3 Setscrews)
7/8
7/8
7/8
7/16
406
325
390
95
300
240
285
70
42,0
33,0
39,0
9,7
Description

Main bearing
- before
- from
engine numbers 212U582, 212UA119095, 236U82408, 236UA50507,
236UC19949, 236UE4404, 236US12129, 248U6330, 248UA58746
34
Current product
Description
Flywheel
- Setscrews
- Place bolts
Torque
Thread
size
Nm
lbf ft
kgf m
1/2
1/2
108
122
80
90
11,0
12,4
4.248
Torque
Thread
size
Nm
lbf ft
kgf m
1/2 UNF
3/4 UNF
68
34
34
50
25
25
6,8
3,5
3,5
Nuts, atomiser clamp
M8
12
1,2
Nuts, high pressure fuel pipes
M12
20
15
2,1
5/8 UNF
250
184
25,5
Nuts, connecting rods
1/2 UNF
125
92
12,7
Setscrews, crankshaft pulley
7/16 UNF
95
70
9,7
Setscrews, flywheel to crankshaft
1/2 UNF
105
77.5
10,7
Description
Fasteners, cylinder head, refer to head torque sequence
Plug, lubricating oil sump
- engines before DC82D003H, plug only
- engines from DC82D003H, plug and washer
- engines from DC82D003H, plug and O-ring
Set screws, main bearing
35
Current product

workshop manual.
lengths of setscrews are fitted in their correct
positions.
4.236, 4.248 and 4.2482 engines
Fastener
type
Fastener
length mm (in)
Stud
Illustration
and position
A 19, 22
Setscrew
Small
Setscrew
Medium
Setscrew
Large
A 5, 6, 11, 12, 16,

17
A 1, 2, 3, 4, 7, 8, 9,
10, 13, 14, 15, 20
A 18,21
T4.236 engines
Fastener
type
Fastener
length mm (in)
Stud
Illustration
and position
B 16, 21
Setscrew
Small
B 3, 5, 7, 10, 15,
19, 22
Setscrew
Medium
B 1, 2, 4, 6, 8, 9,
11, 12, 13, 14,
17, 20
Setscrew
Large
B 14, 19
Choose the correct method and torque from the table

below.
Engine
type
4.236
engines with nuts
only
up to U550185W
from U550185W
T.4236
up to engine
U027774M
from engine
U027774M
4.248 and 4.2482
up to engine
U573000
from engine
U573000
36
Torque
method Nm
Torque
lbf
ft
kgf m
81
60
8,3
1
2
136 100
120 88
13,8
11,8
136 100
13,8
120
88
11,8
136 100
13,8
120
11,8
88
Current product
Method 1
1 Lightly lubricate the threads of the cylinder head
fasteners.
correct torque and method shown in the table
opposite. Tighten the fasteners in the correct
sequence (page 22, A or B).
temperature of operation. Stop the engine.
4 Remove the rocker shaft and remove the
atomisers, then tighten the fasteners again to the
correct torque in the correct sequence.
If a fastener moves when checked, tighten it to the
correct torque.
If a fastener does not move when checked, loosen it
1/12 to 1/6 (30 to 60) of a turn then tighten it to the
correct torque.
5 Check the first 10 positions again, during this check
do not loosen the fasteners.
6 The fasteners of all engines except the 4.2482 must
be tightened again after the first 25/50 hours use.
Method 2
Follow steps 1 and 2 in method 1, then:
Use the special angle gauge MS 1531 to tighten the
setscrews, in the correct sequence, a further half of a
turn (180).
If the special angle gauge MS 1531 is not available,
make a suitable mark on the cylinder head in line with
a corner of each setscrew (A). Make another mark, at
180 (counter-clockwise), on the edge of the flange of
each setscrew. Tighten each setscrew in the correct
sequence until the marks on the flange are next to,
and in line with, the marks on the cylinder head.
in (A).
37
Current product
6.3544 Series
Horse power
6.3544 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95.5 kW (128 bhp)
T6.3544 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 kW (155 bhp)
Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Induction system
- 6.3544 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Naturally aspirated
- T6.3544 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharged
Combustion system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct injection
Stroke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 mm (5 in)
Compression ratio
- 6.3544 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16:1
- T6.3544 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.5:1
Cubic capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.80 litres (354 in3)
Firing order. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-3-6-2-4
- Inlet (cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,20 mm (0.008 in)
- at max engine speed and normal engine temperature . . . . . . 207/414 kN/m2 (30/60 lbf/in2) 2,1/4,2 kgf/cm2
Coolant temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60C (140F)
- bellows type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67/75C (152/167F)
- wax type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77/85C (170/185F)
- bellows type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85/88C (185/190F)
- wax type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92/98C (197/208F)
Idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel injection pump data plate
Location of maximum no-load speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel injection pump data plate
Location of engine timing marks . . . . . . . . . . . . . . . . . . . . . . . Crankshaft, main idler gear and camshaft gear
Atomiser codes . . . . . FL, FN, GD, GG, GH, GK, GL, GX, HC, HE, HK, HP, HS, HT, HU, RA, RB, VU, XX, Y
Fuel pump codes . . . . . . . . . . . . . . . . . . . . . . AY, BY, CY, DY, EX, EY, FX, FY, GY, HY, JY, KY, LX, LY, MR,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MX, MY, PX, PY, SX, TX, TY, VR, VX, WR, WX, XX, ZX
Location of fuel pump code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel injection pump data plate
Location of fuel pump timing marks . . . . . . . . . . . . . . . . . . . . . . Fuel pump mounting flange and adaptor plate
Belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 N (10 lbf) 4,5 kgf
Belt deflection at longest run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 mm (3/8 in)
38
Current product
Maintenance schedules 6.3544 and T6.3544
A First service at 25/50 hours
D Every 500 hours or 12 months
B Every day or every 8 hours
E Every 1000 hours
F Every 2500 hours
A B C D E F
z
z
z
z
z
z
z
z
z
Clean the vent valve of the engine breather system (1)

- normal conditions
z
z
z
z
z
z

Check the drive belt(s)
Renew the fuel filter element (fuel filter with single element)
Renew the fuel filter element (fuel filter with twin element)
Ensure that the idler speed is checked and adjusted if necessary (2)
Renew the lubricating oil (3)
z
z
Operation
z
z
Ensure that the turbocharger impeller, turbocharger compressor casing and turbocharger
drain pipe for the lubricating oil are cleaned (2)
Ensure that the valve tip clearances are checked and adjusted, if necessary (2)

(3) The oil change interval will change with the amount of sulphur in the fuel (see the table on page 51 and fuel specification). The
interval to change the canister of the lubricating oil filter is not affected.
39
Current product
Fuel pump codes 6.3544

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DPA
Direction of rotation from drive end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Counter-clockwise
Outlet for number 1 cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
Engine
check angle
(degrees)
Pump mark
angle
(degrees)
AY
160
146
BY
160
146
EX
160
146
FX
160
146
PX (except below)
159
146
GY
162
154
PX list TW31012 only
160
146
HY
162
154
SX (6.3724)
159
146
MR (except below)
158
144
TY
153
141.5
MR from engine no.

U780699P
158
147
WR
160
146
MX (except below)
160
146
WX
157
144
Fuel pump code

letters
40
Engine
check angle
(degrees)
Pump mark
angle
(degrees)
MX/4/2640
161
146
MX/5/2420 from
engine no. 728207L
159
146
MX/5/2530
161
146
Fuel pump code

letters
Current product
Fuel pump codes T6.3544
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DPA
Direction of rotation from drive end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Counter-clockwise
Outlet for number 1 cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Letter "X"
Engine
check angle
(degrees)
Pump mark
angle
(degrees)
CY
153
145
DY
160
144
JY
159
LX
Engine
check angle
(degrees)
Pump mark
angle
(degrees)
PY
160
144
TX
159
144
144
VR
159
144
159
144
XX
159
144
LY
153
145
YX
160
144
MY
159
144
ZX
159
144
Fuel pump code

letters
Fuel pump code

letters
Bosch fuel injection pump

Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rotary
Direction of rotation from drive end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Counter-clockwise
Outlet for number 1 cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D
set at the start of injection for the number one cylinder.
Engine check
angle
(degrees)
Pump mark
angle
(degrees)
135
125.5
FY (L21-3)
135
127.5
KY (L107)
123
118
VX (L21 or L73)
135
127

EY (L21-2)
The settings given for Bosch fuel pumps are with the pump set at 1 mm plunger lift. It is important that these
pumps are not fitted at the static timing positions for the CAV pumps. The code given is stamped on the side
of the pump.
41
Current product

6.3544 and T6.3544
Torque
Thread
size
Nm
lbf ft
kgf m
Setscrews, cylinder head, refer to head tightening sequence
1/2 UNF
Sump plug
Description
3/4 UNF
34
25
3,5
Atomiser clamp
5/16
12
1,2
M12
20
15
2,1
Main bearing
- cadmium
- phosphated
5/8 UNF
270
102
200
75
27,7
10,4
Big end bearing

- cadmium
- phosphated
1/2 UNF
129
88
95
65
13,1
9,0
Front pulley
7/16 UNF
125
92
12,7
Flywheel
1/2 UNF
108
80
11,1
42
Current product
workshop manual.
Any cylinder head studs removed from the cylinder
block should be fitted with "Loctite".
The cylinder head gasket fitted to the T6.3544 and
6.3544 engine is not interchangeable with other 6.354
Series engines. It is marked "TOP FRONT". A
different cylinder head gasket is used on 6.3724
engines because of the larger bore size.
The cylinder head gasket must be fitted dry.
There are two methods to tighten the cylinder head
fasteners for service, methods 1 and 2 shown below.
Currently, the factory uses method 2.
Method 1 - hot torque
1 Lightly oil threads of cylinder head studs and
setscrews. See the table below.
correct torque shown in the table below, in the
sequence shown in (A).
temperature of operation. Stop the engine. Tighten
the fasteners again to the correct torque in the correct
sequence.
Fastener type
Plain fasteners
which are fitted
with separate
washers
Position
Torque
Nm lbf ft kgf m
A 1 to 32
130
95
13,1
Flanged fasteners A 1 to 32
fitted with head
gasket, part
number 36812611
156
115
15,9
Small setscrews
38
28
3,9
A 33 to 38
43
Current product
Method 2 - torque and angle

Follow steps 1 and 2 in method 1, then:
Use the special angle gauge MS 1531 to tighten the
setscrews, in the correct sequence (A), a further part
of a turn according to the length of the setscrews, see
the table below.
Fastener
A 5, 6, 11, 12, 16, 17, 21,
22, 26, 27, 31, 32
Further part of a turn

150 or 2 1/2 flats
A 1, 2, 3, 4, 7, 8, 9, 10, 13, 180 or 3 flats

14, 15, 18, 19, 20, 23,
24
A 24, 25, 29, 30
210 or 3 1/2 flats
A 33 to 38
None, check torque
If the special angle gauge MS 1531 is not available,

make a suitable mark on the cylinder head in line with
a corner of each setscrew (B). Make another mark, at
the correct angle (counter-clockwise), on the edge of
the flange of each fastener. Tighten each setscrew in
the correct sequence until the marks on the flange are
next to, and in line with, the marks on the cylinder
head.
44
Current product
V8.540 Series
Horse power
- V8.540 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 kW (180 bhp)
- TV8.540. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 kW (235 bhp)
Induction system
V8.540 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Naturally aspirated
TV8.540 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharged
Combustion system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Direct injection
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120,7 mm (4.75 in)
Compression ratio
V8.540 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.5:1
TV8.540 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15:1
Cubic capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8,85 litres
Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8-7-5-4-3-6-2
- Inlet (cold)
V8.540 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,25 mm (0.10 in)
TV8.540 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,25 mm (0.10 in)
- Exhaust (cold)
V8.540 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,25 mm (0.10 in)
TV8.540 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,50 mm (0.20 in)
normal engine temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280 kN/m2 (40 lbf/in2) 2,8 kgf/cm2
Thermostat starts to open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67/75C (152/167F))
Thermostat fully open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85/88C (185/190F)
Idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel injection pump data plate
Location of number 1 cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front of left bank at crankshaft pulley end
Atomiser codes . . . . . . . . . . . . . . . . . . . . . . . .VA, VB, VJ, VN, WC, FG, GU, VW, WW, WY, WZ, XA, XB, XY
Fuel pump codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TBA
Location of fuel pump code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel injection pump data plate
Location of fuel pump timing marks. . . . . . . . . . . . . . . . . Fuel pump mounting flange and pump adaptor plate
45
Current product

A Every 8 hours or every day
D Every 2000 hours
E Every 2500 hours
C Every 1000 hours
F Every 4000 hours
A B C D E F
Operation
Check the drive belts of the alternator
z
z

z
z
z

z
z
z
z
z
z
z
z
z
z
z
z
z
Clean the engine breather system

- normal conditions
Clean the turbocharger impeller and casing (3)
Check the turbocharger (3)
Ensure that the valve tip clearances are checked and adjusted, if necessary (3)
- V8.540
- TV8.540

46
Current product
Fuel pump codes
Fuel injection pump
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CAV Minimec, DP15 or Bosch MW

Spill timing of CAV Minimec or Bosch MW
Spill timing
position
BTDC
(degrees)
Piston
position
BTDC
mm (in)
MB71/800/A02/1800
MB71/800/A02/1880
MB71/800/C02/1560
MB71/800/C02/1575
RB69/800/41A/2350
RB69/800/41A/2530
RB69/800/44A/2830
RB71/800/41A/2330
RB71/800/41A/2350
RB71/800/41A/2390
RB71/800/41A/2480
RB71/800/41A/2500
RB71/800/41A/2530
RB71/800/41A/2560
RB72/800/41A/2380
RB72/800/41A/2530
2642A210MB/C02/1575
2642A211MB/A02/1890
2642A215RB/41A/2500
2642A215RB/41A/2530
2642A228RB/41A/2330
26
7,62 (0.300)
LB71/800/12/2500
LB71/800/22/2500
MB71/800/D01/2340
MB71/800/D01/2360
MB71/800/D01/2380
MB71/800/D01/2400
MB71/800/D01/2420
MB71/800/D01/2520
MB71/800/E01/2720
LG68E/800/44A/2960
RB71/800/44A/2850**
RB71/800/44A/2910
RB71/800/44A/2960
RB70/800/44A/2910
RB71/800/41A/2550
RB71/800/41A/2660
RB71/800/41A/2730
RB71/800/44A/2630
RB71/800/44A/2770
RB71/800/44A/2830
RB71/800/44A/2850*
2642A213MB/D01/2360
2642A213MB/D01/2420
2642A213MB/D01/2520
2642A214RB/44A/2770
2642A215RB/41A/2550
2642A215RB/41A/2660
2642A223RB/E01/2720
28
8,89 (0.350)
YB68E/800/44A/2960
2642A209RB/44A/2960
2642A214RB/44A/2850
2642A230LG/44A/2960
29
9,53 (0.375)
pb73l/900/d01/2400
pb81e/1100/d01/2520
pb81e/1100/d01/2600
PB81E/1100/D01/2610
PB81E/1100/D01/2620
PB81E/1100/D01/2650
PB81E/1100/E01/2740
2642A243PB/D01/2600
2642A243PB/D01/2520
31
10,85 (0.427)
* Non-vehicle applications
** Vehicle applications
Static timing of CAV DP15
Static timing position BTDC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Timing check angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .312
47
Current product

Torque
Thread
size
Nm
lbf ft
kgf m
Setscrews, cylinder head, see torque sequence
9/16 UNF
Sump plug
3/4 UNF
50
37
5,1
Atomiser clamp
5/16 UNF
16
12
1,7
Description
M12 x 1.5
20
15
2,1
Main bearing
5/8 UNF
285
210
29
Big end bearing
9/16 UNF
142
105
14,5
Front pulley
7/8 UNF
407
300
41,5
Flywheel
1/2 UNF
108
80
11,1
48
Current product
workshop manual.
lengths of setscrews are fitted in their correct
positions.
Fastener
type
Fastener
length mm (in)
Stud
Illustration
and position
A 16, 18
Setscrew
Small
A 2, 4, 6, 8, 12,14,
Setscrew
Medium
A 3, 5, 7, 9, 13, 15,
17, 19
Setscrew
Large
A 1, 10, 11, 20, 21
1 Lightly lubricate the threads of the studs and the

cylinder head setscrews and the thrust faces of the
setscrew.
2 Gradually and evenly tighten the setscrews and
nuts of each bank to the correct torque, in the
sequence (A). Tighten again all the setscrews and
nuts to the correct torque, in the sequence (A).
Engine and
fastener type
V8.540
flanged fasteners
flanged fasteners, scant shank
setscrews with gasket
3681H401
plain fasteners with separate
washers with gasket 3681H401
TV8.540
flanged fasteners
Torque
Nm
lbf
ft
kgf m
169
125
17,3
185
135
18,2
210
155
1,47
210
155
21,4
3 Run the engine until it reaches normal temperature

of operation. Stop the engine. Tighten again all the
setscrews and nuts of each bank to the correct
torque, in the sequence (A).
in (A).
49
50
Current product
3
General data
Specification of engine fluids

4.108, 3.152, 4.203, 4.2032, 4.236, 4.248
6.3544, T6.3544, V8.540
Lubricating oil specification

Minimum lubricating oil specification
- naturally aspirated engines
- turbocharged engines
API CC/SE
API CD/SE or CCMC D4 (1)
Lubricating oil capacity
Dependent on sump fitted, see application user's handbook
Fuel specification
Viscosity
4.236, 4.248, V85402.5/4.5 centistokes at 40C

4.108, 3.152, 4.203, 4.2032,
6.3544, T6.35442.0/4.5 centistokes at 40C
Density
0,835/0,855 kg/litre
Distillation
85% at 350C
Aviation kerosene fuels
JP5 and JP8 only, refer to user's handbook
Cetane number
All 4.236, 4.248

Vehicle only 6.3544, T6.3544, V8.54050 minimum
industrial/ag 6.3544, T6.3544, V8.540
All 4.108, 3.152, 4.203, 4.203245 minimum
Sulphur (2)
4.108, 4.203, 4.2032, 6.3544

T6.3544, V8.5400.5% of mass, maximum
3.152, 4.236, 4.2480.2% of mass, maximum
Coolant specification
Recommended coolant
POWERPART antifreeze
Concentration of antifreeze
50%
Corrosion inhibitor mixture.

Must have a specification at least as good
as BS6580 or MOD AL39
Coolant capacity
Refer to user's handbook
See application user's handbook
(1) Not recommended for naturally aspirated engines during the first 20 to 50 hours or for light load applications.
(2) The oil change interval will change with the amount of sulphur in the fuel (see the table below and the fuel specification)
Amount of sulphur in the fuel % Oil change interval

<0,5
Normal
0,5 - 1,0
3/4 of normal
>1,0
1/2 of normal
51
Current product
Standard torque settings

General notes
1 For 'service', use the nominal torque value. Tolerances to be within 25% of nominal.
2 If there are changes to phosphated surfaces or to thread tolerances, the torque values must change.
3 Torque values in these tables are for 'dry threads'.
These values are not suitable for Merwin C3 type fasteners.
Studs
Thread size
Nominal torque
Nm
lbf ft
kgf m
M6 x 1,00
3.7
0,51
M8 x 1,25
11
8.1
1,12
M10 x 1,50
18
13.3
1,84
M12 x 1,75
25
18.4
2,55
Setscrews and nuts

Thread size
Nominal torque
Nm
lbf ft
kgf m
M6 x 1,00
6.6
0,92
M8 x 1,25
22
16.2
2,24
M10 x 1,50
44
32.5
4,49
M12 x 1,75
78
57.5
7,95
M14 x 2,00
124
91.5
12,64
M16 x 2,00
190
140.0
19,37
Pipe threaded fasteners

Thread size
Nominal torque
Nm
lbf ft
kgf m
1/8" PTF
9,5
7.0
0,97
1/4" PTF
17,0
12.5
1,73
3/8" PTF
30,0
22.1
3,06
3/4" PTF
45,0
33.2
4,59
52
Current product
Conversion tables
Inch
Fraction
Inch
mm
mm
inch
1/4
0.25
6.4
0.04
1/2
0.5
12.7
0.08
3/4
0.75
19.1
0.12
25.4
0.16
50.8
0.20
76.2
0.24
101.6
0.28
127.0
0.31
152.4
0.35
177.8
10
0.39
203.2
20
0.79
228.6
30
1.18
10
10
254.0
40
1.57
20
20
508.0
50
1.97
30
30
762.0
100
3.94
40
40
1016.0
1000
39.37
Miles
Kilometres Kilometres
Miles
1.61
0.62
3.22
1.24
4.83
1.86
6.44
2.49
8.05
3.10
9.66
3.73
11.27
4.35
12.87
4.97
14.48
5.59
10
16.09
10
6.21
20
32.19
20
12.43
30
48.28
30
18.64
40
64.37
40
24.85
50
80.47
50
31.07
100
160.93
100
62.14
0
Feet
Metres
Metres
Feet
0.31
3.28
0.61
6.56
0.91
9.84
1.22
13.12
1.25
16.4
1.83
19.69
2.13
22.97
2.44
26.25
2.74
29.53
10
3.05
10
32.81
20
6.1
20
65.62
30
9.15
30
98.43
40
12.19
40
92.19
50
15.24
50
164.04
53
Current product
Conversion tables, continued

Pounds
54
Kilograms Kilograms
Pounds
Gallons
Litres
Litres
Gallons
0.1
0.05
0.1
0.22
4.55
0.22
0.2
0.09
0.2
0.44
9.09
0.44
0.3
0.14
0.3
0.66
13.64
0.66
0.4
0.18
0.4
0.88
18.18
0.88
0.5
0.23
0.5
1.1
22.73
1.1
0.6
0.27
0.6
1.32
27.28
1.32
0.7
0.32
0.7
1.54
31.82
1.54
0.8
0.36
0.8
1.76
36.37
1.76
0.9
0.41
0.9
1.98
40.92
1.98
0.45
2.2
10
45.46
10
2.2
0.91
4.41
1.36
6.61
Pints
Litres
1.81
8.82
0.5
0.27
2.27
11.02
0.55
2.72
13.23
1.1
3.18
15.43
1.65
3.63
17.64
2.2
4.08
19.84
2.75
10
4.54
10
22.05
20
9.07
20
44.09
30
13.61
30
66.14
40
18.14
40
88.18
50
22.68
50
110.23
Current product
Atomiser information
Code
Holder
Nozzle
AB
BKBL67S5151/
OKLL6752930
AC
2646460
Set and reset pressure

atm
(lbf/in2)
MPa
BDLL150S6435/
OLL150S6705
175
2573
17,7
2646677
175
2573
17,7
AV
BKBL67S5151
BDLL50S6372
170
2499
17,2
BC
BKB35SD5260
BDL110S6133
120
1764
12,2
BG
BKB40SD5224
BDN12SD6236
135
1985
13,7
BM
BKB35SD5260
BDL110S6267
120
1764
12,2
BT
BKBL67SD5151
BDLL150S6310
175
2573
17,7
BU
BKBL67S5151
BDLL150S6435
175
2573
17,7
BV
BKBL67S5151
BDLL150S6513
170
2499
17,2
CR
BKBL67S5151
BDLL150S6513
170
2499
17,2
CF
BKBL67S5299
BDLL150S6507
185
2720
18,7
CS
BKBL67S5151
BDLL150S6554
170
2499
17,2
CT
BKBL67SD5151
BDLL150S6555
175
2573
17,7
CU
BKBL67S5151/
OKLL6752930
BDLL150S6556/
OLL150S6556
175
2573
17,7
CY
OKLL66M11340
OLL150M9302
230
3381
23,3
DD
BKB35S5258
BDL110S6133
120
1764
12,2
DE
BKB35S5258
BDL110S6267
120
1764
12,2
DF
BKBL67S5151
BDLL150S6558
170
2499
17,2
DL
BKBL67S5299
BDLL150SY6545
210
3087
21,3
DM
BKBL67S5151
BDLL150S6561
175
2573
17,7
DN
BKBL67S5299
BDLL150S6554
170
2499
17,2
EA
BKBL67S5299/
OKLL6752930
BDLL150S6591/
OLL150S6649
215
3161
21,8
EC
RKBL67S5268
RDLL150S6554
165
2426
16,7
EE
2646466
2646825
190
2793
19,3
EG
2646466
2646826
210
3087
21,3
EV
BKB35SD5260
BDL110S6267
180
2646
18,2
FC
2646466
2646831
210
3087
21,3
FJ
BKB35SD5259
BDL110S6267
170
2499
17,2
FL
BKBL67S5299
BDLL150S6673
200
2940
20,3
FM
BKB35SD5260
BDL110S6685
170
2499
17,2
FN
BKBL67S5299
BDLL150S6639
195
2867
19,8
FR
BKB35SD5260
BDL110S6267
170
2499
17,2
FS
BKBL67S5299
BDLL150S6674
170
2499
17,2
FW
2646466
2646826
185
2720
18,7
FY
2646460
2646842
175
2573
17,7
GB
BKB35SD5260
BDL110S6709
170
2499
17,2
Continued
55
Current product
Code
Holder
Nozzle
GC
BKB35SD5259
GD
BKBL67S5299

atm
(lbf/in2)
MPa
BDL110S6709
170
2499
17,2
BDLL150S6730
200
2940
20,3
GG
2646466
2646845
210
3087
21,3
GH
BKBL67S5299
BDLL150S6738
210
3087
21,3
GK
2646572
2646782
275
4042
18,7
GL
2646460
2646844
175
2573
17,7
GM
2646466
2646848
185
2720
18,7
GS
2646475
2646850
252
3704
17,1
GW
BKB35SD5258
BDLL150S6709
170
2499
17,2
GX
2645F301
2645F601
250
3675
25,3
GY
2646522
2646724
150
2205
15,2
BKB32S5141
BDL110S6267
120
1764
12,2
HA
2646466
2646854
215
3161
21,8
HB
2646466
2646855
215
3161
21,8
HC
2645A302
2645A602
245
3602
24,8
HD
2645A301
2645A601
260
3822
26,4
HE
2645A302
2645A603
230
3381
23,3
HF
LRB67014
JB6801022
210
3087
21,3
HG
LRB67014
JB6801022
230
3381
23,3
HH
2645A302
2645K603
250
3675
25,3
HK
26456466
2645A605
215
3161
21,8
HL
2645A302
2645K602
230
3381
23,3
HM
2645A301
2645K603
250
3675
25,3
HN
2646467
2646850
240
3528
24,3
HP
2645A302
2645A602
225
3308
22,8
HR
2645A302
2645A605
270
3969
18,4
HS
2646466
26456844
200
2940
20,3
HT
LRB67014
JB6801019
200
2940
20,3
HU
2645A302
2645K604
220
3234
22,3
HX
2645A301
2645K603
210
3087
21,3
HY
2646466
2646845
175
2573
17,7
BKB32SD5141
BDL110S6133
120
1764
12,2
JZ
2645A301
2645A622
230
3381
23,3
NB
2645L301
2645L602
195
2867
19,8
NC
2645L302
2645L603
170
2499
17,2
ND
2645L301
2645L604
175
2573
17,7
NH
2645L304
2645L606
230
3381
23,3
RA
2645F303
2645F602
247
3631
16,8
RB
2645C304
2645F606
250
3675
25,3
Continued
56
Current product
Code
Holder
Nozzle
TC
BKB35SD5259
UA
2645M301

atm
(lbf/in2)
MPa
BDL110S6709
170
2499
17,2
2645M601
TBA
TBA
TBA
UB
2646522
2646724
150
2205
15,2
VA
2645M301
2645M601
TBA
TBA
TBA
VB
HB54S693
NL550
170
2499
17,2
VJ
BKBL54S5312
BDLL150S6573
170
2499
17,2
VN
2646562
2646862
200
2940
20,3
VR
OKLL54S2965
OLL150S3385
195
2867
19,8
VT
OKLL54S5312
OLL150S7777
195
2867
19,8
VU
2645C564
26466866
225
3308
22,8
VW
2646562
2646869
210
3087
21,3
VX
OKLL54S5312
OLL150S7777
195
2867
19,8
VY
OKLL54S2924
OLL150S7777
195
2867
19,8
VZ
OKLL54S2924
OLL150S7788
195
2867
19,8
WA
OKLL54S2924
OLL150S3385
195
2867
19,8
WC
2646568
2646871
195
2867
19,8
WD
OKLL54S2996
OLL150S7604
195
2867
19,8
WJ
OKLL54S3014
OLL150S7788
195
2867
19,8
WK
OKLL54S3014
OLL150S3385
195
2867
19,8
WL
OKLL54S3014
OLL150S7777
195
2867
19,8
WN
2646568
2646872
217
3190
21,9
WP
OKLL54S3052
OLL150S3385
210
3087
21,3
WU
OKLL54M3059
OLL150S8388
235
3455
23,8
WV
OKLL54M3052
OLL150S7788
195
2867
19,8
WW
2645C302
2645C602
240
3528
24,3
WX
2645C303
2645C804
201
2955
20,4
WY
2645C303
2645C605
235
3455
23,8
WZ
2646568
2646869
195
2867
19,8
XA
2645C303
2645K601
230
3381
23,3
XB
2645C303
2645K604
235
3455
23,8
XC
2645C305
2645C608
175
2573
17,7
XD
2645C306
2645C609
170
2499
17,2
XE
2645C305
2645C610
195
2867
19,8
XG
2645C305
2645C615
210
3087
21,3
XJ
2645C305
2645C621
170
2499
17,2
XL
2645C305
2645C619
170
2499
17,2
XX
2645C307
2645C613
245
3602
24,8
XY
2646568
2646864
210
3087
21,3
XZ
2645C308
2645C614
220
3234
22,3
Continued
57
Current product
Code
Holder
Nozzle
2646460
YA

atm
(lbf/in2)
MPa
2646672
175
2573
17,7
2645C308
2645C618
240
3528
24,3
YB
2645C304
2645C616
155
2279
15,7
YC
2645C307
2645C617
230
3381
23,3
YD
2645C310
2645C618
240
3528
24,3
BKBL67SD5151
BDLL50S6355
170
2499
17,2
Turbocharger waste-gate settings

Waste-gate test pressure for rod movement of 1,00 mm (0.039 in)
The turbocharger part number is on the turbocharger identification plate, which is fitted to the body of the
turbocharger.
Waste-gate pressure
Turbocharger
part number
kPa
lbf/in
2674A053
113/120
16.4/17.4
2674A054
110/120
2674A055
120/130
2674A056
58
Waste-gate pressure
Turbocharger
part number
kPa
lbf/in2
kgf/cm2
1,15/1,22
2674A098
96
13.9
0,98
16.0/17.4
1,12/1,22
2674A104
99/106
14.3/15.4
0,99/1,07
17.4/18.9
1,22/1,32
2674A105
99/106
14.3/15.4
0,99/1,07
120/130
17.4/18.9
1,22/1,32
2674A106
99/106
14.3/15.4
0,99/1,07
2674A057
118/126
17.1/18.3
1,20/1,28
2674A108
99/106
14.3/15.4
0,99/1,07
2674A058
118/126
17.1/18.3
1,20/1,28
2674A122
99/106
14.3/15.4
0,99/1,07
2674A059
118/126
17.1/18.3
1,20/1,28
2674A128
101/109
14.6/15.8
1,02/1,11
2674A062
113/120
16.4/17.4
1,15/1,22
2674A129
101/109
14.6/15.8
1,02/1,11
2674A063
92/98
13.3/14.2
0,93/0,99
2674A130
113/120
16.4/17.4
1,15/1,22
2674A064
110/103
15.9/14.9
1,11/1,04
2674A131
101/109
14.6/15.8
1,02/1,11
2674A067
120/130
17.4/18.9
1,22/1,32
2674A138
113/120
16.4/17.4
1,15/1,22
2674A068
110/103
15.9/14.9
1,11/1,04
2674A139
120/130
17.4/18.9
1,22/1,32
2674A072
120/130
17.4/18.9
1,22/1,32
2674A143
99/106
14.3/15.4
0,99/1,07
2674A075
118/126
17.1/18.3
1,20/1,28
2674A144
113/120
16.4/17.4
1,15/1,22
2674A077
113/120
16.4/17.4
1,15/1,22
2674A146
113/120
16.4/17.4
1,15/1,22
2674A079
120/130
17.4/18.9
1,22/1,32
2674A149
133/143
19.3/20.7
1,35/1,45
2674A081
88/98
12.8/14.2
0,90/1.00
2674A150
145/155
21.0/22.5
1,47/1,58
2674A082
88/92
12.8/13.5
0,90/0,93
2674A304
105
15.2
1,04
2674A084
118/128
17.1/18.6
1,20/1,30
2674A305
105
15.2
1,04
2674A085
88/98
12.8/14.2
0,90/1.00
2674A308
96
13.9
0,98
2674A086
118/126
17.1/18.3
1,20/1,28
2674A311
145
21.0
1,47
2674A087
101/109
14.7/15.8
1,03/1,09
2674A313
96
13.9
0,98
2674A089
150
21.8
1,52
2674A314
145
21.0
1,47
2674A093
110
15.9
1,11
2674A315
150
21.8
1,52
2674A094
105
12.5
1,04
2674A316
96
13.9
0,98
2674A095
145
21.0
1,47
2674A701
155
22.5
1,58
2674A096
150
21.8
1,52
kgf/cm
Current product
Thermostat ratings
Nominal temperature
stamped on thermostat by-pass
valve
"Start to open"
temperature
"Fully open"
temperature
Minimum valve lift,

fully open
82C
(180F)
77/85C (170/
185F)
92/98C (198/
208F)
9 mm
(0.35 in)
71C
(160F)
67/75C (153/
167F)
85/88C (185/
190F)
9 mm
(0.35 in)
Compression test data

Tests have shown that many factors affect
compression pressures. Battery and starter motor
condition, ambient conditions and the type of gauge
used can give a wide variation of results for a given
engine.
It is not possible to give accurate data for
compression pressure, but tests have shown that the
results should be within 2000/3500 kPa (300/500 lbf/
in2) 21,0/35,0 kgf/cm2 for diesel engines.
Compression tests should only be used to compare
between the cylinders of an engine. If one or more
cylinders vary by more than 350 kPa (50 lbf/in2) 3,5
kgf/cm2, then those cylinders may be faulty.
Compression tests should not be the only method
used to show the condition of an engine, but they
should be used together with other symptoms and
tests.
How to do a compression test
Caution: Before the compression test, ensure that
the battery is in good condition and that it is fully
charged. Also ensure that the starter motor is in good
condition.
1 Ensure that the valve tip clearances are set
correctly.
2 Remove the atomisers.
3 Fit a suitable gauge into the atomiser hole of the
cylinder to be tested.
4 Ensure that the engine cannot start:
Disconnect the stop solenoid or put the stop control in
the no-fuel position.
Operate the starter motor and note the pressure
indicated on the gauge.
5 Repeat for each cylinder.
59
60

TPD1357E1

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Perkins Service Data Booklet

Part 1: Mature products up to 8,85 litres (540 cu in)

Publication TPD 1357E issue 1

Service Data Booklet

This publication is written in

The following pages contain a detailed table of contents.

Workshop Manual, TPD 1357E, issue 1

This page is intentionally blank

Service Data Booklet, TPD 1357E, issue 1

Service Data Booklet, TPD 1357E, issue 1

This page is intentionally blank

Perkins Engines Australia Pty. Ltd,

Varity (Japan) K.K.,

Service Data Booklet, TPD 1357E, issue 1

List of Perkins service publications

201 TPD 1090 1218

601 SER 0692 1088

TPD 0596 1285 EFG (1)

TPD 1091 1208

201 TPD 1090 1216

601 SER 0681 1010

201 TPD 1090 1216

601 TPD 0580 1158

TPD 1095 1291 EFG (1)

601 TPD 0393 1229

TPD 0594 1289 EFG (1)

TPD 1089 1146

201 TPD 1090 1207

601 TPD 0690 1215

(1) Printed in English, French and German.

Service Data Booklet, TPD 1357E, issue 1

A diesel fuel additive for protection against corrosion.

To retain small fasteners where easy removal is

POWERPART Threadlock (heavy duty)

Protects the inside of the engine and of other closed

To provide a heavy duty seal to components that have

POWERPART Liquid gasket

Service Data Booklet, TPD 1357E, issue 1

Engine number location guide

Illustration B shows the right side when looked at

Illustration C shows the top of the engine.

POWERPART Threadlock (hydraulic/pneumatic)

Service Data Booklet, TPD 1357E, issue 1

Engine Family and type code, see Table 1

Parts list number or SOS order reference number

Country of manufacture code, see Table 2

510256 Engine serial number

Year of manufacture code, see Table 3

Table 1 - Engine Family and Type Code

Service Data Booklet, TPD 1357E, issue 1

Table 2 - Country of manufacture code

This code indicates the country of manufacture of the basic engine.

Service Data Booklet, TPD 1357E, issue 1

The starter motor turns the engine too slowly

The engine does not start

The engine is difficult to start

Not enough power

High fuel consumption

Black exhaust smoke

Blue or white exhaust smoke

The pressure of the lubricating oil is too low

4, 24, 25, 26, 46, 47, 48, 50, 51, 59

The engine knocks

The engine runs erratically