This is the Perkins workshop manual for the Prima, Prima Marine, and 500 Series four cylinder diesel engines, publication TPD 01921273. It covers Prima units built for vehicle use, Prima Marine engines for boats, and 500 Series engines for agricultural and industrial machines, both naturally aspirated and turbocharged.The 130 page manual runs through the full engine: cylinder head and valve gear, pistons and connecting rods, crankshaft, timing case and belt, cylinder block, aspiration and turbocharger, lubrication, fuel system, cooling with its raw water circuit, flywheel housing and the marine reverse gearbox, plus electrical equipment with wiring diagrams.Use it to trace a fault, set tappet clearances, renew oil seals and the timing belt, or carry out a full rebuild. Specifications and recommended torque tensions are gathered up front so the wear limits and settings are easy to find.
What's Inside This Perkins Prima, Prima Marine Manual
| System | Pages | Key Topics |
|---|---|---|
| Perkins Workshop Manual | 1 | - |
| Amendment Status | 2-3 | Number, Date |
| General Information | 4-8 | Introduction, Engine Identification, Safety Precautions, Asbestos Joints |
| Specifications | 9-25 | Basic Engine Data, Recommended Torque Tensions |
| Cylinder Head Assembly | 26-38 | General Description, Camshaft Cover, Tappet Clearances, Front Oil Seal of Camshaft, Camshaft, Valves and Valve Springs, Valve Guides |
| Piston and Connecting Rod Assemblies | 39-47 | Big End Bearing (Remove and to Fit, Inspect), Piston and Connecting Rod Assembly (to Remove and to Fit), Piston Rings (to Remove and to Fit), Piston and Rings (to Inspect) |
| Crankshaft Assembly | 48-57 | Crankshaft Pulley (to Remove and to Fit), Front Oil Seal (to Renew), Rear Oil Seal (Renew, Remove and to Fit the Separate Oil Seal Housing) |
| Timing Case and Drive Assembly | 58-66 | Timing Case Cover (to Remove and to Fit), Timing Belt (Check the Belt Condition and Tension, Adjust the Belt Tension, Remove and to Fit) |
| Cylinder Block Assembly | 67-70 | Cylinder Block (Dismantle and to Assemble, Inspect, Correct a Glazed Bore), To Dismantle and to Assemble, To Inspect, To Correct a Glazed Bore |
| Engine Timing | 71-74 | General Description |
| Aspiration System | 75-78 | Induction and Exhaust Manifolds (to Remove and to Fit), Turbocharger (to Remove and to Fit, Waste-Gate Unit) |
| Lubrication System | 79-85 | Filter Canister (to Renew), Filter Head (to Remove and to Fit), Lubricating Oil Sump (to Remove and to Fit) |
| Fuel System | 86-94 | General Description, Fuel Filter Canister, Lift Pump, Fuel Injection Pump |
| Cooling System | 95-105 | Coolant Circuit (Drain, Fill), Raw Water Circuit (to Drain), Thermostat (Remove and to Fit, Test), Water Pump (to Remove and to Fit) |
| Flywheel, Flywheel Housing and Marine Reverse Gearbox | 106-110 | Flywheel (to Remove and to Fit), Ring Gear (to Remove and to Fit), Flywheel Housing or Backplate (to Remove and to Fit), Reverse Gearbox for Marine Engines (to Remove and to Fit) |
| Electrical Equipment | 111-122 | Alternators, Starter Motors, Starting Aid, Wiring Diagrams (Precautions, Drive Belt, Alternator, Starter Motor, Glow Plugs, Marine Engines) |
| Auxiliary Equipment | 123-124 | Exhauster (Remove and to Fit, Test), To Remove and to Fit, To Test |
| List of Special Tools | 125-130 | Tension Gauge, Drive Belt, Alternator, Valve Seat Cutters, Adjustable Pilot, Remover/replacer, Oil Seals, Camshaft |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Cylinder head setscrews torque (first stage) | 50 Nm (37 Ibf ft) 5,1 kgf m | p. 34 |
| Cylinder head setscrews torque (second stage) | 100 Nm (74 Ibf ft) 10,2 kgf m | p. 34 |
| Valve guide inside diameter (reamed in position) | 7,450/7,463 mm (0.2933/0.2938 in) | p. 16 |
| Valve guide interference fit in cylinder head | 0,04/0,08 mm (0.0016/0.0031 in) | p. 16 |
| Top ring width | 1,978/1,990 mm (0.0778/0.0783 in) | p. 18 |
| Second ring width | 1,73/1,74 mm (0.068/0.069 in) | p. 18 |
| Cylinder bore diameter | 84,442/84,469 mm (3.3245/3.3256 in) | p. 21 |
| Maximum permissible wear in bore | 0,15 mm (0.006 in) | p. 21 |
| Maximum resistance of battery cables 1 and 2 | 0.0017 ohms | p. 121 |
| Cylinder bore maximum wear before rebuild | 0,15 mm (0.006 in) | p. 70 |
| Cylinder bore oversize machining diameter | 0,50 mm (0.0197 in) | p. 70 |
| Nominal bore | 84,5 mm (3.33 in) | p. 11 |
Perkins Prima, Prima Marine Common Problems This Manual Covers
Blue smoke on startup
Blue smoke after the engine has been sitting, together with oil use, usually means oil is passing worn valve guides or stem seals. The cylinder head section covers inspecting the valve guides and renewing valves and valve springs.
Manual Section: Cylinder Head Assembly p. 26High oil consumption
Heavy oil burn on an aging Prima or 500 Series engine often traces to worn piston rings. This section covers removing, inspecting, and refitting the pistons and rings.
Manual Section: Piston and Connecting Rod Assemblies p. 39Glazed cylinder bores
Bores that have glazed cause high oil consumption and poor ring sealing. The cylinder block section explains how to inspect the block and correct a glazed bore.
Manual Section: Cylinder Block Assembly p. 67Hard starting or fuel faults
Air intrusion or fuel delivery faults make these engines hard to start. The fuel system section covers the filter canister, lift pump, and fuel injection pump.
Manual Section: Fuel System p. 86Electrical and charging faults
Worn wiring, corrosion, and charging problems are common on older marine installs. The electrical section covers alternators, starter motors, and the wiring diagrams.
Manual Section: Electrical Equipment p. 111Overheating on marine engines
Overheating can come from the thermostat or the raw water circuit on marine units. The cooling section covers testing the thermostat and servicing the water pump and coolant circuits.
Manual Section: Cooling System p. 95Frequently Asked Questions
Which engines and applications are covered?
The manual covers Perkins Prima four cylinder engines for vehicles, Prima Marine engines for marine use, and 500 Series engines for agricultural and industrial machines, in both naturally aspirated and turbocharged forms. It is publication TPD 01921273.
How is it delivered?
It is delivered as an instant PDF download after purchase, with no physical shipping.
What is the cylinder head bolt torque?
The head setscrews are torqued in stages, 50 Nm first, then 100 Nm, then a further quarter turn of 90 degrees. The tightening procedure is in the Cylinder Head Assembly section. p. 26
Does it cover the marine reverse gearbox?
Yes. The Flywheel, Flywheel Housing and Marine Reverse Gearbox section covers removing and refitting the reverse gearbox fitted to the marine engines. p. 106
How quickly can I access this manual?
A 130-page Workshop Manual in searchable PDF format, available the moment you complete checkout. View on computer, tablet, or phone — no shipping wait.
Can I print specific sections of this Perkins Prima, Prima Marine, 500 Series?
The PDF is DRM-free. Print whatever sections you need to take out to the shop. Standard letter or A4 paper works.
Are there wiring harness diagrams in this Perkins Prima, Prima Marine, 500?
Yes — full electrical schematics are included with wire colors, connector locations, and circuit descriptions.
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