Rebuilding a Perkins diesel? This 94-page Perkins 4.135, 4.154, 4.182 Shop Manual PDF (OEM 601 SER01901176) covers valve seat overhaul, crankshaft and main bearing work, gear timing, and fuel injection service across all three engines. You get a fault diagnosis chart that walks from symptom to cause, a technical data section loaded with clearances and torque figures, and step-by-step teardown procedures for the cylinder head, pistons, liners, timing case, cooling system, and electrical equipment. Torque the atomisers on the 4.135 and 4.182 to 69 Nm, then set injection pressure at 135/140 kgf/cm2 (1920/1990 lbf/in2). No more chasing specs through forum threads at midnight. Bookmarked chapters and a full text layer let you jump straight to the section you need; download it and get wrenching.
What's Inside This Perkins 4.135, 4.154, 4.182 Manual
| System | Pages | Key Topics |
|---|---|---|
| General Information | 1-9 | Introduction, Safety Precautions, Engine Identification, Running-In Procedure, Powerpart Consumable Products, Perkins Companies, Examples of Service Assistance |
| Engine Views | 10-13 | Engine |
| Technical Data | 14-23 | Engine Data, Component Data and Dimensions |
| Maintenance | 24-27 | Preventive Maintenance |
| Fault Diagnosis | 28-29 | Fault Diagnosis Chart |
| Cylinder Head | 30-36 | Valve and Valve Seat Overhaul |
| Pistons and Connecting Rods | 37-41 | Piston Removal, Connecting Rod Removal, Small End Bush, Piston Ring Gaps, Piston Assembly |
| Cylinder Block and Liners | 42-43 | Cylinder Block Inspection, Cylinder Liners, Liner Flange Height |
| Crankshaft and Main Bearings | 44-49 | Crankshaft End Clearance, Thrust Washers, Crankshaft Removal, Crankshaft Overhaul, Main Bearings, Rear End Oil Seal |
| Timing Case and Drive | 50-57 | Timing Case Cover, Crankshaft Front Oil Seal, Timing Gears, Idler Gear, Camshaft Gear, Fuel Pump Gear |
| Timing | 58-61 | Gear Timing Marks, Crankshaft Timing, Valve Timing, Fuel Pump Timing |
| Lubrication System | 62-70 | Lubrication Circuit, Oil Filter Canister, Lubricating Oil Sump, Oil Relief Valve, Oil Pump, Oil Cooler |
| Cooling System | 71-76 | Fan Belt Tension, Cooling System Drain, Water Pump, Thermostat |
| Fuel System | 77-83 | Fuel Filter Canister, Fuel Injection Pump, Idle Speed Adjustment, No Load Speed Adjustment, Atomisers, Fuel System Air Removal |
| Flywheel and Backplate | 84-86 | Flywheel, Flywheel Ring Gear, Flywheel Backplate, Backplate Face Alignment, Location Flange Run-Out |
| Electrical Equipment | 87-90 | Alternator, Starter Motor, Glow Plugs, Voltage Test, Output Test, Glow Plug Electrical Supply |
| Exhauster | 91 | Exhauster Inspection, Exhauster Removal, Exhauster Installation |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| 4.154 | ||
| Atomiser flange nuts | 23 Nm (17 lbf ft) | p. 16 |
| Cylinder head setscrew torque (4.154) | 115 Nm (85 lbf ft) | p. 35 |
| 4.135 and 4.182 | ||
| Atomisers | 69 Nm (50 lbf ft) | p. 16 |
| All Models | ||
| Lubricating oil pressure | 207 kN/m2 (30 lbf/in2) 2,1 kgf/cm2 minimum at maximum engine speed and normal engine temperature | p. 15 |
| Injection pressure | 135/140 kgf/cm2 (130/135 atm) 1920/1990 lbf/in2 | p. 23 |
| Thermostat starts to open | 80.5/83.5°C (177/182°F) | p. 23 |
| Thermostat fully open | 95°C (203°F) | p. 23 |
| Atomiser flange nuts torque | 23 Nm | p. 82 |
| Fan belt movement (4.135) | 10 mm | p. 72 |
| Fan belt movement (4.154 and 4.182) | 13 mm | p. 72 |
| 4.135 | ||
| Cylinder head setscrew torque (4.135) | 115 Nm (85 lbf ft) | p. 35 |
| Lubricating oil sump capacity (4.135) | 5.0 litres | p. 15 |
Perkins 4.135, 4.154, 4.182 Common Problems This Manual Covers
Perkins 4.154 diesel cranks but will not start after fuel filter change, no exhaust smoke
Bleed air from the fuel system using the air removal procedure starting on page 77. Loosen the filter vent screw and operate the lift pump until fuel flows free of bubbles, then bleed at the injection pump. If it still will not fire, test atomiser opening pressure; correct setting is 135/140 kgf/cm2.
Manual Section: Fuel System p. 77Engine overheats and loses coolant under load, temperature gauge climbs within twenty minutes
Check the thermostat first: it should start to open at 80.5/83.5°C per the data on page 23; test it in heated water and replace it if it stays shut. Inspect the air cleaner and exhaust for restriction, then set valve tip clearances to 0.30 mm cold. Water pump procedures start on page 71.
Manual Section: Cooling System p. 71Diesel leaks around injector flanges after fitting new atomisers, fuel smell and wet cylinder head
Remove the leaking atomiser and fit a new seat washer; the old copper washer never seals twice. Lower the atomiser straight into its bore without tilting it, then tighten the flange nuts evenly in small stages, to a final 23 Nm on the 4.154, following the procedure on page 82. Uneven tightening distorts the nozzle.
Manual Section: Fuel System p. 82Oil pressure gauge reads low at operating temperature, warning light flickers at idle
Verify actual pressure against spec: minimum is 207 kN/m2 (30 lbf/in2) at maximum engine speed and normal temperature, listed on page 15. Confirm the oil grade and level are correct, then replace the filter canister. If pressure stays low, inspect the relief valve and oil pump; those procedures begin on page 62.
Manual Section: Lubrication System p. 62Battery discharges overnight, fan belt squeals on cold start, charge light glows at idle
Check belt deflection midway on the longest run; set free movement to 10 mm on the 4.135, using the tension procedure on page 72. Replace any belt that is glazed or cracked down in the grooves. Then run the alternator voltage and output tests in the electrical section starting on page 87.
Manual Section: Cooling System p. 72Frequently Asked Questions
How do I adjust the idle speed on a Perkins 4.135 engine?
To adjust the idle speed, run the engine until it reaches normal operating temperature. Use the idle adjustment screw (marked 1 in fig. P9) and turn it clockwise to increase the idle speed. The target idle speed for the 4.135 engine is 580/630 rev/min. p. 80
What is the torque specification for the Perkins 4.154 atomiser flange nuts?
The atomiser flange nuts for the 4.154 engine should be tightened evenly by small amounts to a torque of 23 Nm (17 lbf ft) or 2,4 kgf m. p. 82
How do I remove air from the fuel system on these engines?
To remove air, loosen the vent screw on the fuel filter and operate the priming pump until fuel flows free of air, then tighten the screw. Next, loosen the return connection on the fuel injection pump, operate the priming pump until fuel is clear of air, and tighten the connection. Finally, loosen the high-pressure pipe connections at the atomisers and operate the starter motor until fuel flows freely before tightening them. p. 83
What is the correct valve tip clearance for these engines?
The correct clearance for both the inlet and exhaust valves is 0,30 mm (0.012 in) when the engine is cold. p. 36
What is the lubricating oil sump capacity for the Perkins 4.135 engine?
The lubricating oil sump capacity for the 4.135 engine is 5,0 litres (8.8 Imp. pints) or 5,3 US quarts. p. 15
Is this Perkins 4.135 Shop Manual a digital download?
Immediate download of the complete 94-page searchable Shop Manual. Access it on any device, from a laptop at your desk to a phone in the field.
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Absolutely. No DRM or copy protection. Print the whole manual or just the pages you need. Any home or office printer works.
