1983 Perkins 4.108, 4.107 and 4.99 Diesel Engine OEM Workshop Manual (P/N 601 SER 0383 1072)

This Perkins Engines Limited workshop manual covers the 1983 and later 4.108, 4.107, and 4.99 diesel engines in vehicle, agricultural, industrial, and refrigeration applications. Publication No. 601 SER 0383 1072 supersedes 601 SER 12771072.

• Internal engine repair: Cylinder head overhaul, piston and connecting rod inspection, liner replacement, crankshaft removal, and main bearing renewal.

• Timing case and drive: Camshaft and tappet removal, gear installation, backlash checks, valve timing, and fuel-pump drive-hub service.

• Lubrication: Oil-pump disassembly and clearance checks, pressure-relief valve service, sump sealing, and oil-filter maintenance.

• Cooling system: Water-pump overhaul, fan-belt adjustment, thermostat testing, and application-specific bypass arrangements.

• Air cleaners and fuel system: Air-cleaner servicing, lift-pump pressure testing and overhaul, D.P.A. injection-pump timing, injector checks, and fuel-system bleeding.

• Electrical equipment: Alternator fault finding, Lucas C40-1 generator testing, starter-drive inspection, glow-plug checks, and electrical test-circuit diagrams.

This manual assumes normal workshop practice and suits mechanics familiar with engine disassembly, precision measurement, and the specialized equipment required for overhaul.

Cylinder Head, Liners and Crankshaft

You get a direct breakdown of cylinder head overhauls, piston and connecting rod alignment, and crankshaft assemblies. Valve-seat insert drawings, service wear limits and crankshaft regrinding data help determine when components require machining or replacement. The cylinder-head data explicitly prohibit skimming the head face.

The block section distinguishes dry 4.108 liners from the wet liners used in the 4.107 and 4.99. It also explains the refrigeration-engine exception to the normal 4.108 rebore restriction.

Crankshaft coverage separates Tufftrided and induction-hardened shafts and their different requirements after regrinding. Flywheel ring-gear replacement and flywheel-housing alignment checks are also covered. The safety section expressly excludes marine applications.

D.P.A. Fuel-Pump Timing and Diagnosis

Static timing tables use the pump setting code to identify the applicable timing data. Procedures cover the MS67B timing tool and an alternative drop-valve method, with distinctions between hydraulic and mechanical governors. The timing-drive chapter covers helical and spur gears.

D.P.A. coverage includes removal, installation, timing, idle and anti-stall adjustment; it does not provide a full internal injection-pump overhaul procedure. An exploded injector view supports component identification, while the fault-finding chart links starting, smoke and running complaints to possible causes.

Air-cleaner coverage includes Cyclopac, Cyclone, Rotopamic and oil-bath types, with different cleaning and replacement requirements. The priming section warns that operating an unprimed injection pump can damage it through loss of lubrication.

Oil Circulation and Water-Pump Variants

The lubricating-oil flow diagram traces supply to the bearings and valve gear, alongside an exploded pressure-relief valve view and oil-pump inspection procedures.

Water-pump instructions distinguish separate bearings from combined shaft-and-bearing assemblies, plus earlier and later sealing arrangements. The manual warns that running a ceramic-counterface pump without coolant can crack its seal face.

Charging, Starting and Refrigeration Engines

Electrical diagnosis covers AC5, 11AC, 15ACR and 17ACR alternators, with an alternator output-test circuit and glow-plug test wiring. Starter coverage distinguishes the M45G run-off-helix drive from M45G/2M113 pre-engaged units.

Refrigeration builds: The dedicated 4.108 section compares these engines with standard vehicle versions, including piston rings, crankshaft treatment, glow plugs and lubrication changes. It identifies interim controlled-expansion pistons from 108U113592 and the final design from 108U119423, helping buyers check piston and ring compatibility before ordering parts.

Follow the manual's safety precautions for rotating engine parts, hot coolant and high-pressure fuel.

A Preview of Valve Clearances and Fastener Torques

These examples are a small selection of the manual's adjustment and assembly data.

For all three engine models, the specified inlet and exhaust valve clearance is 0.012 in (0.30 mm), measured cold.

With components lightly oiled, the torque table lists 42 lbf ft (5.81 kgf m) for 4.107/4.99 cylinder-head nuts and 85 lbf ft (11.5 kgf m) for 4.108 main-bearing setscrews. The cylinder-head specification is accompanied by a staged tightening sequence and subsequent torque-check requirements.

PDF Navigation and Page Breakdown

Bookmarks and circuit detail: Text search is not available. Embedded bookmarks link to the main sections, appendices and index. Small labels in the alternator and glow-plug test circuits are legible when enlarged.

One printable, English-language 114-page PDF contains 99 pages of workshop and reference content, one title/publication page, four additional publisher information pages and ten blank pages. All are included in the stated total.