Perkins phaser 135 ti model al (euro 2) diesel engine service repair manual

i
Perkins Phaser 135 Ti
Model AL (Euro 2)
WORKSHOP MANUAL
4 cylinder diesel engines for automotive applications
Publication TPD 1356E, Issue 2.
© Proprietary information of Perkins Engines Company Limited, all rights reserved.
The information is correct at the time of print.
Published in January 1997 by Technical Publications.
Perkins Engines Company Limited, Peterborough, PE1 5NA, England.
This document has been printed from SPI². Not for Resale

ii
Perkins Approved Clear English
This publication is written in
Chapters
1 General information
2 Specifications
3 Cylinder head assembly
4 Piston and connecting rod assemblies
5 Crankshaft assembly
6 Timing case and drive assembly
7 Cylinder block assembly
8 Engine timing
9 Aspiration system
10 Lubrication system
11 Fuel system
12 Cooling system
13 Flywheel and housing
14 Electrical equipment
15 Auxiliary equipment
16 Special tools
The following pages contain a detailed table of contents

Workshop Manual, TPD 1356E, Issue 2 iii
Phaser 135 Ti
Contents
1 General information
Introduction ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1
Engine identification . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 3
Safety precautions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 4
Engine lift equipment ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 6
Viton seals . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 7
POWERPART recommended consumable products . ... ... ... ... ... ... ... ... ... ... ... ... ... 8
2 Specifications
Basic engine data . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 11
Data and dimensions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 12
Thread sealant ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 28
Standard torque tensions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 29
Special torque tensions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 30
Compression test data . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 32

iv Workshop Manual, TPD 1356E, Issue 2
Phaser 135 Ti
3 Cylinder head assembly
General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 33
Rocker cover
Operation 3-1 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 34
Operation 3-2 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 35
Rocker assembly
Operation 3-3 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 36
Operation 3-4 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 37
Operation 3-5 To inspect and to correct ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 38
Valve tip clearances
Operation 3-6 To check and to adjust ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 39
Valve springs
Operation 3-7 To change the valve springs (with cylinder head fitted) .. ... ... ... ... ... ... 40
Cylinder head assembly
Operation 3-9 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 44
Valves and valve springs
Operation 3-10 To remove . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 48
Operation 3-11 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 49
Operation 3-12 To inspect and to correct .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 50
Valve guides
Operation 3-13 To inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 51
Operation 3-15 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 53
Cylinder head
Operation 3-16 To inspect and to correct .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 54
Operation 3-17 To correct a valve seat with a valve seat cutter ... ... ... ... ... ... ... ... ... 55
Operation 3-18 To fit valve seat inserts . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 56

Workshop Manual, TPD 1356E, Issue 2 v
Phaser 135 Ti
4 Piston and connecting rod assemblies
General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 57
Big end bearing
Operation 4-1 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 58
Operation 4-2 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 59
Operation 4-3 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 59
Piston and connecting rod
Operation 4-5 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 61
Operation 4-6 To check the piston height above the cylinder block .. ... ... ... ... ... ... ... . 63
Piston rings
Operation 4-7 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 64
Piston and connecting rod assembly
Operation 4-8 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 65
Operation 4-9 To renew ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 66
Operation 4-10 To check the length of a connecting rod .. ... ... ... ... ... ... ... ... ... ... ... . 67
Piston and piston rings
Operation 4-11 To inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 69
Connecting rod
Operation 4-12 To inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 70
Small end bush
Operation 4-13 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 71
Piston cooling jets
Operation 4-14 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 72
Operation 4-15 To check the jet alignment ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 73

vi Workshop Manual, TPD 1356E, Issue 2
Phaser 135 Ti
5 Crankshaft assembly
Crankshaft pulley and damper
Operation 5-2 To Inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 77
Rear oil seal assembly
Operation 5-4 To renew the rear oil seal ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 79
Thrust washers
Operation 5-5 To check crankshaft end-float . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 80
Main bearings
Operation 5-7 To remove (with the crankshaft in position) ... ... ... ... ... ... ... ... ... ... ... 82
Operation 5-8 To fit (with the crankshaft in position) . ... ... ... ... ... ... ... ... ... ... ... ... ... 83
Operation 5-9 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 83
Crankshaft
Operation 5-11 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 85
Operation 5-12 To inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 87
6 Timing case and drive assembly
Timing case cover
Operation 6-2 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 91
Front oil seal
Operation 6-4 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 93
Idler gear and hub
Operation 6-6 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 95
Idler gear and hub for the Bendix compressor
Operation 6-8 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 97

Workshop Manual, TPD 1356E, Issue 2 vii
Phaser 135 Ti
Fuel pump gear
Operation 6-10 To fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 99
Camshaft gear
Operation 6-11 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 100
Crankshaft gear
Timing case
Operation 6-13 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 102
Operation 6-14 To fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 103
Camshaft and tappets
Operation 6-16 To fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 106
7 Cylinder block assembly
General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 107
Cylinder block
Operation 7-1 To dismantle ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 108
Operation 7-2 To assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 109
Cylinder liner
Operation 7-5 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 112
Operation 7-6 To fit a partially finished liner .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 114
8 Engine timing
Engine timing
Operation 8-1 Flywheel and pin method to set the engine to top dead centre (TDC)
on the compression stroke .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 119
Operation 8-2 Reverse pin timing to set the engine to top dead centre (TDC) on the
compression stroke . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 120
Operation 8-3 Alternative method to set number 1 piston to TDC on the
compression stroke . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 121
Operation 8-4 To check the valve timing ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 122
Operation 8-5 To check the timing of the fuel injection pump ... ... ... ... ... ... ... ... ... ... 123

viii Workshop Manual, TPD 1356E, Issue 2
Phaser 135 Ti
9 Aspiration system
General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 125
Turbocharger
Operation 9-1 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 127
Operation 9-2 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 128
Operation 9-3 To clean the impeller and the compressor casing .. ... ... ... ... ... ... ... .. 130
Operation 9-4 To remove and to fit the actuator assembly of the waste-gate unit ... .. 131
Operation 9-5 To check and adjust the operation of the waste-gate . ... ... ... ... ... ... .. 132
Turbocharger faults ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 133
Open engine breather
Operation 9-6 To clean and to renew ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 135
10 Lubrication system
Engine lubrication system flow diagram . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 138
Filter canister
Operation 10-1 To renew ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 139
Filter head
Operation 10-2 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 140
Sump
Oil strainer and suction pipe
Operation 10-5 To inspect and to correct .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 142
Lubricating oil pump
Operation 10-6 To remove . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 143
Operation 10-7 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 144
Operation 10-8 To renew the shaft for the idler gear . ... ... ... ... ... ... ... ... ... ... ... ... .. 145
Operation 10-9 To inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 146
Relief valve
Operation 10-10 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 147
Operation 10-11 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 148
Operation 10-12 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 148

Workshop Manual, TPD 1356E, Issue 2 ix
Phaser 135 Ti
11 Fuel system
Fuel filter element
Operation 11-1 To renew .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 151
Atomisers
Operation 11-2 Atomiser fault ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 152
Operation 11-4 To fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 154
Fuel lift pump
Operation 11-6 To dismantle . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 157
Operation 11-7 To assemble . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 158
Operation 11-8 To test .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 159
Bosch EPVE fuel injection pump ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 160
Operation 11-10 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 162
Operation 11-11 To adjust - Bosch pump . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 165
Operation 11-12 To eliminate air from the fuel system . ... ... ... ... ... ... ... ... ... ... ... ... 166
12 Cooling system
Thermostats .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 170
Operation 12-2 To test .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 170
Coolant pump ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 171
Operation 12-4 To dismantle . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 172
Operation 12-5 To assemble . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 173
Lubricating oil cooler
Operation 12-7 To dismantle and to assemble . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 176

x Workshop Manual, TPD 1356E, Issue 2
Phaser 135 Ti
13 Flywheel and housing
Flywheel
Ring gear
Flywheel housing
14 Electrical equipment
Operation 14-1 To check the drive belts ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 182
Operation 14-2 To adjust drive belt tension ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 183
Operation 14-3 To remove and to fit the drive belts ... ... ... ... ... ... ... ... ... ... ... ... ... .. 184
Operation 14-4 To remove, to fit and to maintain the alternator ... ... ... ... ... ... ... ... .. 185
Alternator fault diagnosis . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 186
Operation 14-6 To maintain the brush gear and the commutator .. ... ... ... ... ... ... ... .. 189
Operation 14-7 To test on the engine ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 189
Operation 14-8 To remove and to fit a port heater . ... ... ... ... ... ... ... ... ... ... ... ... ... .. 190
15 Auxiliary equipment
Operation 15-1 To remove . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 192
Operation 15-2 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 193
Power steering pump
Exhauster
16 Special tools
List of special tools ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 197

Workshop Manual, TPD 1356E, Issue 2 1
1
Phaser 135 Ti
General information 1
Introduction
This Workshop Manual has been designed to provide assistance in the service and overhaul of Perkins Phaser
(Euro 2) engines. For overhaul procedures the assumption is made that the engine is removed from the
application. The engine conforms with European emissions legislation (Euro 2) for automotive applications.
Most of the general information which is included in the relevant User's Handbook (Chapters 1 to 6) has not
been repeated in this Workshop Manual and the two publications should be used together.
A Bosch EPVE fuel injection pump is fitted.
When reference is made to the "left" or "right" side of the engine, this is as seen from the flywheel end of the
engine.
Special tools have been made available and a list of these is given in Chapter 16, Special tools. Reference to
the relevant special tools is also made at the beginning of each operation.
POWERPART recommended consumable products are under "POWERPART recommended consumable
products" on page 8. Reference to the relevant consumable products is also made at the beginning of each
operation.
Data and dimensions are included in Chapter 2, Specifications.
Read and remember the "Safety precautions" on page 4. They are given for your protection and must be used
at all times.
Danger is indicated in the text by two methods:
Warning! This indicates that there is a possible danger to the person.
Caution: This indicates that there is a possible danger to the engine.
Note: Is used where the information is important, but there is not a danger.

1
2 Workshop Manual, TPD 1356E, Issue 2
Phaser 135 Ti
Engine views
A
B

1
Phaser 135 Ti
Engine identification
The Phaser 135Ti engine is rated at 135 bhp. The letters Ti indicate that the engine is turbocharged and
intercooled.
The latest Phaser 135Ti can be identified by the letters AL at the beginning of the engine number. The correct
identification of the engine is by the full engine number.
The engine number is stamped on a label (A1) which is fastened to the left side of the cylinder block. An
example of the engine number is:
AL30126U510256B
If you need parts, service or information for your engine, you must give the complete engine number to your
Perkins distributor. If there is a number in the area of the label marked TPL No., then this number must also
be given to your Perkins distributor.
Other important identification labels fitted to the engine include:
An emissions legislation label (A3) fitted to the side of the cylinder block.
A label (A2) with the fuel injection pump part numbers.
A 0043
2
3
1

1
Phaser 135 Ti
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.
z Only use these engines in the type of application for which they have been designed.
z Do not change the specification of the engine.
z Do not smoke when you put fuel in the tank.
z Clean away fuel which has been spilt. Material which has been contaminated by fuel must be moved to a
safe place.
z Do not put fuel in the tank while the engine runs (unless it is absolutely necessary).
z 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).
z Do not make adjustments that you do not understand.
z Ensure that the engine does not run in a location where it can cause a concentration of toxic emissions.
z Other persons must be kept at a safe distance while the engine or auxiliary equipment is in operation.
z Do not permit loose clothing or long hair near moving parts.
z Keep away from moving parts during engine operation.
Warning! Some moving parts cannot be seen clearly while the engine runs.
z Do not operate the engine if a safety guard has been removed.
z 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.
z Do not use salt water or any other coolant which can cause corrosion in the closed circuit of the cooling
system.
z 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.
z Disconnect the battery terminals before a repair is made to the electrical system.
z Only one person must control the engine.
z Ensure that the engine is operated only from the control panel or from the operators position.
z If your skin comes into contact with high-pressure fuel, obtain medical assistance immediately.
z 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.
z Do not wear clothing which is contaminated by lubricating oil. Do not put material which is contaminated
with oil into the pockets of clothing.
z Discard used lubricating oil in a safe place to prevent contamination.
z Ensure that the control lever of the transmission drive is in the "out-of-drive" position before the engine is
started.
z Use extreme care if emergency repairs must be made in adverse conditions.
z The combustible material of some components of the engine (for example certain seals) can become
extremely dangerous if it is burned. Never allow this burnt material to come into contact with the skin or with
the eyes. Refer to "Viton seals" on page 7.
z Read and use the instructions relevant to "Engine lift equipment" on page 6.
z 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.
Continued

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1
Phaser 135 Ti
z Do not allow compressed air to contact your skin. If compressed air enters your skin, obtain medical help
immediately.
z Turbochargers operate at high speed and at high temperatures. Keep fingers, tools and items away from
the inlet and outlet ports of the turbocharger and prevent contact with hot surfaces.
z Do not clean an engine while it runs. If cold cleaning fluids are applied to a hot engine, certain components
on the engine may be damaged.
z Fit only genuine Perkins parts.

1
Phaser 135 Ti
Engine lift equipment
The maximum weight of the engine without coolant, lubricant or a gearbox fitted will vary for different
applications. It is recommended that lift equipment of the minimum capacity 500 kg (1100 lbs) is used. Before
the engine is lifted:
z Always use lift equipment of the approved type and of the correct capacity to lift the engine. It is
recommended that lift equipment of the type shown in (A) is used, to provide a vertical lift directly above
the engine lift brackets (A1). Never use a single lift bracket to raise an engine.
z Check the engine lift brackets for damage and that they are secure before the engine is lifted. The torque
for the setscrews for the engine lift brackets is 44 Nm (33 lbf ft) 4,5 kgf m.
z To prevent damage to the rocker cover, ensure that there is clearance between the hooks and the rocker
cover.
z Use lift equipment or obtain assistance to lift heavy engine components such as the cylinder block, cylinder
head, balancer unit, flywheel housing, crankshaft and flywheel.
A
1

1
Phaser 135 Ti
Viton seals
Some seals used in engines and in components fitted to engines are made of Viton.
Viton is used by many manufacturers and is a safe material under normal conditions of operation.
If Viton is burned, a product of this burnt material is an acid which is extremely dangerous. Never allow this
burnt material to come into contact with the skin or with the eyes.
If it is necessary to come into contact with components which have been burnt, ensure that the precautions
which follow are used:
z Ensure that the components have cooled.
z Use Neoprene gloves and discard the gloves safely after use.
z Wash the area with calcium hydroxide solution and then with clean water.
z Disposal of components and gloves which are contaminated must be in accordance with local regulations.
If there is contamination of the skin or eyes, wash the affected area with a continuous supply of clean water or
with calcium hydroxide solution for 15-60 minutes. Obtain immediate medical attention.

Perkins phaser 135 ti model al (euro 2) diesel engine service repair manual

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