Factory-level procedures for the Perkins G4.236 fill these 102 pages (OEM #601TPD06841235), spanning the gasolene, natural gas, and LPG variants from cylinder head assembly down to the flywheel housing. Wiring diagrams cover alternator models from AC5 through 23ACR, and the fault finding chart maps the engine's failure modes, from low cranking speed through knocking. Rebuild procedures cover pistons, crankshaft, timing gears, and distributor, backed by exploded views of every major assembly and a torque tensions table listing big-end, main bearing, and flywheel setscrew values. Cold valve clearances run 0.012 in (0.30 mm) inlet and 0.015 in (0.38 mm) exhaust; cylinder head nuts pull to 130 Nm. Specs that once meant cross-referencing four sources now sit in one bookmarked, keyword-searchable file.
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 |
Perkins G4.236 Common Problems This Manual Covers
Perkins G4.236 compression loss, exhaust smoke, overheating, and coolant pressurization after a top-end problem p. 22
Remove the cylinder head as outlined on page 22 to inspect the head gasket for breaches. Clean the mating surfaces thoroughly. Install the new gasket and torque the cylinder head nuts and setscrews to 96 lbf ft (130 Nm) in the proper sequence.
Manual Section: Cylinder HeadHard starting, poor running, loss of power, and fuel starvation symptoms during cold weather operation p. 65
Inspect the fuel supply system components detailed on page 65 for air ingress or clogged filters. Drain and clean the float chamber. Cross-check the fault finding chart on page 19, and set the inlet valve tappet clearance cold to 0.012 in (0.30 mm).
Manual Section: Fuel SystemRapid coolant loss, engine overheating, and mayonnaise-like oil contamination in the cooling system p. 64
Drain the cooling system and inspect the heat exchanger for internal corrosion. Flush the block and refill with exactly 9.36 litres (16.5 U.K. pints) of fresh coolant mixture. Test the thermostat; it should open at 76/80°C (168.6/176°F) as specified on page 64.
Manual Section: Cooling SystemErratic performance, high oil consumption, and low oil pressure at operating temperature p. 59
Test the oil pump pressure relief valve setting on page 59. Adjust or replace the spring if pressure drops below the required 50/60 lbf/in² (3.52/4.22 kgf/cm²). Confirm the lubricating oil sump holds its full 7.9 litre capacity before running the engine again.
Manual Section: Lubrication SystemExcessive knocking and noisy operation from the front cover area at low idling speeds p. 50
Pull the timing case cover and check the gears for wear. Measure backlash on all gears as shown on page 50. Replace any gear where backlash falls below the 0.003 in (0.08 mm) minimum to quiet the noise.
Manual Section: Timing Case and DriveFrequently Asked Questions
What are the torque specs for Perkins G4.236 head bolts, main bearings, and connecting rods?
On the Perkins G4.236, cylinder head nuts and setscrews torque to 96 lbf ft (130 Nm). Big end nuts (cadmium plated) take 72 lbf ft (98 Nm); phosphated big end nuts need 92 lbf ft (125 Nm). Main bearing setscrews call for 145 lbf ft (196 Nm) on earlier editions and 171 lbf ft (232 Nm) on later ones.
How do I set valve clearance on a Perkins G4.236?
To set valve clearance on the Perkins G4.236, the running clearance between the valve stem tip and the rocker arm should be 0.012 in (0.30 mm) for the inlet valve and 0.015 in (0.38 mm) for the exhaust valve (cold). Adjust clearances by rotating the engine: with valves rocking on No. 4 cylinder, set clearances on No. 1; with No. 2 rocking, set No. 3; with No. 1 rocking, set No. 4; and with No. 3 rocking, set No. 2.
How to torque Perkins G4.236 cylinder head bolts
To torque Perkins G4.236 cylinder head bolts, lower the head onto its studs and torque the nuts and setscrews to the correct value of 96 lbf ft (130 Nm) given in the 'General Information' section, following the sequence in Fig. E7. Fit a new cylinder head gasket DRY, without jointing compound.
What are the replacement specifications for oil seals and gaskets?
For the crankshaft rear oil seal (rope type), each end of the strip should project 0.010/0.020 in (0,25/0,50 mm) beyond the half housing joint face. (Page 38) For the crankshaft front oil seal, press the new seal into the cover until it sits 0.25 in (6.35 mm) below the front face. (Page 46) A new lip type rear seal can be pressed in to 1/8 in (3.2 mm) or 1/4 in (6.4 mm), depending on previous seal usage. (Page 39)
Is this Perkins Engines Limited G4.236 Workshop Manual a digital download?
A 102-page searchable PDF lands in your account the moment checkout clears. Open it on a laptop, tablet, or phone, whatever you keep nearby while working.
Can I print this Perkins Engines Limited G4.236 manual?
Print as many copies as you like; there are no restrictions. Plenty of mechanics just run off the one section they happen to be working from.
Does this Perkins Engines Limited G4.236 manual have electrical diagrams?
Yes. You'll find full electrical schematics with wire routing diagrams, connector identification, and circuit descriptions.
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