This is the factory Perkins Workshop Manual for the G4.236 gasolene, natural gas and LPG engine, published by Perkins Engines Limited under publication number 601TPD06841235. It runs 102 pages and covers the spark-ignition version of the well-known 4.236 four-cylinder engine, including the AG4.236 variant built for Massey Ferguson applications.
Inside you get the full workshop procedures: engine views, general data, periodical attentions, and a fault finding chart, then step by step overhaul of the cylinder head, pistons and connecting rods, cylinder block and liners, crankshaft and main bearings, timing, lubrication, cooling and fuel systems, plus the distributor and electrical system.
With this PDF you can set valve clearances and ignition timing, torque the cylinder head correctly, rebuild the carburettor, renew crankshaft oil seals, and work through starting or running faults using the manual's own diagnostic chart. It is a searchable download you can print or keep on any device in the workshop.
What's Inside This Perkins G4.236 Manual
| System | Pages | Key Topics |
|---|---|---|
| Important Note | 3 | Publication Scope for Gasolene, Natural Gas & Lpg Engines, Obtaining Missing Lpg Engine Information, Perkins Engines Limited Responsibility Disclaimer |
| Engine Views | 7-11 | View of Left Hand Side of Gasolene and Lpg Engine (Lubricating Oil Filler Cap, Spark Plug, Distributor, Breather Pipe, Lubricating Oil Dipstick, Lubricating Oil Filter, Crankshaft Pulley, Drive Belt, Water Pump, Alternator Pulley, Front Lift Bracket, Thermostat Housing) |
| General Information | 12-14 | Data (Type, Bore, Stroke, Compression Ratio, Cubic Capacity, Firing Order, Tappet Clearance, Oil Pressure, Lubricating Oil Sump Capacity, Ignition Timing, Sparking Plug, Sparking Plug Gap, Contact Breaker Points Gap, Reluctor Gap, Fuel Specification) |
| Periodical Attentions | 15-18 | Daily or Every 8 Hours, Every 250 Hours or 4 Months, 5000 Miles, Every 500 Hours or 12 Months, 10, 000 Miles, Every 1, 000 Hours |
| Fault Finding | 19-20 | Fault Finding Chart (Low Cranking Speed, Will Not Start, Stalls, Misfiring at Idling Speed, Misfiring at High Speed, Misfiring on Acceleration, Loss of Power, Overheating, Low Oil Pressure, High Oil Pressure, Excessive Crankcase Pressure, Starts But Stops, Races on No Load Condition, Erratic Performance, Noisy, High Oil Consumption, Knocking) |
| Cylinder Head | 21-26 | To Remove Head, To Remove Valves, Rocker Levers, Valve Bores, Tappets, General, Re-Assembly |
| Pistons and Connecting Rods | 27-31 | To Remove Pistons and Connecting Rods, To Remove Gudgeon Pins, To Fit New Small End Bushes, To Assemble Piston and Connecting Rod, Fitting New Rings |
| Cylinder Block and Liners | 32-34 | Cylinder Block, Liners, Remove, Fitting, Data and Dimensions, Cylinder Liners |
| Crankshaft, Main Bearings and Balancer Unit | 35-44 | Fitting New Main Bearings and Thrust Washers, To Remove Crankshaft, Regrinding the Crankshaft, Replacing Crankshaft, Crankshaft Rear End Oil Seal, To Fit Lip Seal in Its Housing |
| Timing Case and Drive | 45-50 | To Remove Timing Case Cover, To Renew Crankshaft Front Oil Seal, To Replace Timing Case Cover, Timing Gears, To Check Timing Gear Backlash, To Remove Idler Gear and Hub |
| Timing | 51-53 | To Reset Engine Timing, To Check Timing (Valve Timing, Ignition Timing), Ignition Timing, Static Timing (Delco Distributor, Lucas Distributor) |
| Lubrication System | 54-59 | Oil Circulation, Oil Pump, Oil Pressure, Oil Pressure Relief Valve, When to Renew the Oil |
| Cooling System | 60-64 | Data |
| Fuel System | 65-72 | Carburettor (Description, Fuel Supply System, Float Chamber), Idle System, High Speed System, Economiser System, Choke System, Dismantling, Dismantling Throttle Body |
| Flywheel and Flywheel Housing | 73-75 | To Remove Flywheel, To Renew Flywheel Ring Gear, To Refit the Flywheel, To Remove Flywheel Housing, To Refit Flywheel Housing |
| Governor and Distributor Drive | 76-79 | To Remove Governor and Distributor Drive Housing, To Remove Governor and Distributor Drive Shaft, To Replace Governor and Distributor Drive Shaft |
| Distributor | 80-83 | Condenser, Data, Setting Contact Breaker Points |
| Electrical System | 84-94 | Alternator (Models Ac5, 11 AC, 15Acr, 17Acr, 18Acr, 23Acr, A115/45, A133/55, Lr135-111, Lr135-113, Lr135-114, Le15O-160 and 9Ar, General), Maintenance, Precautions |
| Lubricating Oils | 95 | Lubricating Oils for Naturally Aspirated Engines, Lubricating Oils for Turbocharged Engines and Heavy Duty Earthmoving Equipment, Note on Mil-L-2104C Specification |
| Approved Service Tools | 96-97 | Tool Availability, Piston Ring Squeezer, Piston Height and Valve Depth Gauge, Adjustable Valve Seat Cutters, Circlip Pliers, Valve Guide Reamer .015 Inch O/Size |
| Examples of Service Facilities | 98 |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Cylinder head nuts and setscrews torque | 96 Ibf ft (13,2 kgf m, 130 Nm) | p. 13 |
| Valve tip clearances (cold) inlet | 0.012 in (0.30 mm) | p. 23 |
| Valve tip clearances (cold) exhaust | 0.015 in (0.38 mm) | p. 23 |
| Crankshaft Rear End Oil Seal (Rope Type) strip protrusion beyond half housing joint face | 0.010/0.020 in (0,25/0,50 mm) | p. 38 |
| Crankshaft Rear End Oil Seal (Lip Type) installation depth for old type seals (first instance) | 1/8in (3.2 mm) | p. 39 |
| Engine Water Capacity | 16.5 U.K. pints, 19.8 U.S. pints (9.36 litres) | p. 64 |
| Thermostat Opening Temperature | 76/80°C (168.6/176°F) | p. 64 |
| Engine Bore | 3.875 in (98.4 mm) | p. 13 |
| Engine Stroke | 5 in (127 mm) | p. 13 |
| Compression Ratio (Gasolene and LPG engines) | 7.5 : 1 | p. 13 |
| Tappet Clearance (Inlet cold) | 0.012 in (0.30 mm) | p. 13 |
| Lubricating Oil Sump Capacity (less filter) | 7.9 litre (14 U.K. pints, 16.8 U.S. pints) | p. 13 |
