All 158 pages of this Perkins 2806C-E16, 2800 shop manual PDF (OEM #TSD3450E) go to one job: rebuilding the 6 cylinder turbocharged diesel engine, with the companion 2306 covered side by side. Inside: a full recommended torque section, factory tolerances for valves, guides, liners, and bearings, and step-by-step disassembly work from the rocker cover down to the flywheel housing. You also get turbocharger, fuel system, cooling, and starter and alternator procedures, plus the complete special tools list Perkins technicians pull from. Measure the inlet valve head at 47,00 mm, the exhaust at 41,81 mm, and fill the 2806 cooling system to 50 litres. No more chasing tolerances through forum threads at midnight. Bookmarked with a live text layer; type the spec you need, jump straight to the page, and get your engine back together.
What's Inside This Perkins 2806C-E16, 2800 Manual
| System | Pages | Key Topics |
|---|---|---|
| General Information | 1-7 | Safety Precautions, Engine Identification |
| Specifications | 8-27 | Basic Engine Data - 2306 Engine, Basic Engine Data - 2806 Engine, Rocker Assemblies, Valves, Valve Guides, Valve Springs, Valve Seat Inserts, Cylinder Head |
| Cylinder Head Assembly | 28-57 | Rocker Cover, Rocker Lever and Rocker Shaft Assemblies, Valve Springs, Valves, Camshaft |
| Pistons and Connecting Rod Assemblies | 58-63 | Piston Ring Gaps, Piston Crown Bearing, Piston Skirt Bearing, Gudgeon Pin, Connecting Rod Small End Bearing, Connecting Rod Big End Bearing |
| Crankshaft Assembly | 64-73 | Crankshaft, Crankshaft Front Seal and Wear Sleeve, Crankshaft Rear Seal and Wear Sleeve, Crankshaft Vibration Damper |
| Gear Case and Drive Assembly | 74-81 | Gear Case Cover, Timing Gears, Gear Case |
| Crankcase and Cylinder Liners | 82-87 | Front Engine Support, Cylinder Liners |
| Engine Timing and Electronic Controls | 88-91 | Electronic Control Module, Engine Timing |
| Aspiration System | 92-95 | Exhaust Manifold, Turbocharger |
| Lubrication System | 96-103 | Oil Filter and Oil Filter Header, Oil Filter Header, Sump, Oil Pump |
| Fuel System | 104-111 | Fuel Priming Pump, Fuel Transfer Pump, Drive for the Fuel Transfer Pump, Fuel Filter Header, Low Pressure Fuel System |
| Cooling System | 112-129 | Radiator, Fan Drive Assembly, Thermostats and Thermostat Housing, Coolant Pump |
| Flywheel and Housing | 130-133 | Flywheel, Flywheel Housing |
| Electrical Equipment | 134-139 | Starter Motor, Alternator |
| Auxiliary Equipment | 140-141 | Oil Sample Valve |
| Special Tools | 142-158 | List of Special Tools |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Torque for nut which retains the earth strap to the starter motor | 30,5 +/- 3,5 Nm (22.5 +/- 2.5 lbf ft) | p. 144 |
| Typical coolant capacity (2806 engine and radiator) | 50 litres | p. 17 |
| Valve rocker lever bore (A1) | 40,065 +/- 0,015 mm | p. 18 |
| Inlet valve head diameter (B3) | 47,00 +/- 0,13 mm | p. 19 |
| Exhaust valve head diameter (B3) | 41,81 +/- 0,13 mm | p. 19 |
| Cylinder head thickness (new) | 120,00 +/- 0,15 mm | p. 22 |
| Crankshaft main bearing journal diameter (G2) | 120,650 +/- 0,020 mm | p. 25 |
| Crankshaft end-float | 0,15 to 0,55 mm | p. 25 |
| Cylinder head bolt torque (final stage) | 450 +/- 20 Nm | p. 48 |
| Dry engine weight | 1551 kg | p. 16 |
Perkins 2806C-E16, 2800 Common Problems This Manual Covers
Perkins 2806C-E16 cranks but will not start, batteries charged and fuel tank full
Load-test both batteries and clean every ground connection back to the block. Torque the nut retaining the earth strap to the starter motor to 30,5 +/- 3,5 Nm; starter procedures begin on page 134. If cranking speed is good, bleed the low pressure fuel system, then check the speed-timing sensor wiring at the ECM.
Manual Section: Electrical Equipment p. 134White smoke at operating temperature, coolant level dropping with no external leaks
Pressure-test the cooling system first to confirm internal leakage. Remove the cylinder head using the procedures starting on page 28, then crack-check it and measure thickness against the 120,00 +/- 0,15 mm new spec on page 22. Fit a new gasket and torque the head bolts to a final stage of 450 +/- 20 Nm per page 48.
Manual Section: Cylinder Head Assembly p. 48Low oil pressure warning at hot idle, pressure recovers at higher RPM
Verify oil level and grade first, then cut open the filter and check for bearing material. Inspect the oil pump using the Lubrication System procedures starting on page 96. If you find metal, pull the sump and measure the crankshaft main journals; page 25 gives 120,650 +/- 0,020 mm for a serviceable journal.
Manual Section: Lubrication System p. 96Coolant temperature climbing under load, engine overheating with radiator full and cap sealing
Test the thermostats in heated water and inspect the coolant pump impeller; both procedures are in the Cooling System section starting on page 112. Check fan drive condition and belt tension while the system is drained. On 2806 engines, refill slowly to the full 50 litre capacity listed on page 17 and bleed air before load-testing.
Manual Section: Cooling System p. 112Frequently Asked Questions
What are the replacement specifications for the starter motor?
The starter motor weighs 32 kg (70 lb). When fitting, the nut retaining the earth strap must be tightened to a torque of 30,5 +/- 3,5 Nm (22.5 +/- 2.5 lbf ft). p. 144
What is the correct torque for the cylinder head bolts?
The cylinder head bolts must be tightened in the specified sequence in three stages: first to 270 +/- 15 Nm (200 +/- 11 lbf ft), then to 450 +/- 20 Nm (333 +/- 15 lbf ft), and finally a second time to 450 +/- 20 Nm (333 +/- 15 lbf ft). p. 48
What are the tappet clearance specifications for the engine?
The inlet valve tappet clearance is 0,38 mm (0.015 in) and the exhaust valve tappet clearance is 0,76 mm (0.030 in). This adjustment must be performed with the engine cold and stopped. p. 42
What is the lubricating oil capacity for the 2806 engine?
The total lubricating oil capacity for the 2806 engine is 68 litres (120 UK pints). The sump maximum capacity is 60 litres (106 UK pints) and the minimum is 45 litres (79 UK pints). p. 17
How do I eliminate air from the fuel system?
Loosen the fuel return pipe union, then operate the hand priming pump until fuel flows free from air. Tighten the union and continue operating the pump until strong pressure is felt, then start the engine and run it with no load until it runs smoothly. p. 119
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