Description

Perkins 700 Series UA, 700 Series UB, 700 Series UC 2002 Workshop Manual

I’ve been turning wrenches for 28 years. I’ll tell you straight: if you’re working on a Perkins 700 Series UA, 700 Series UB, 700 Series UC 2002 Workshop Manual and you don’t have the OEM workshop manual, you’re guessing. This 2002 factory manual from Perkins Engines Company Limited is 206 pages of the actual procedures engineers wrote. Not some aftermarket reprint that leaves out the critical steps. This is the document that tells you the exact torque sequence for the cylinder head setscrews, the correct way to measure piston height above the cylinder block, and what to do if the fuel injection pump timing is off. I’ve seen too many guys slap a head on using a generic torque chart—then wonder why the gasket leaks. You want factory data? This is it.

What Does the Perkins 700 Series UA, UB, UC 2002 Workshop Manual Cover?

Sixteen chapters that walk you through the entire four-cylinder diesel engine—both naturally aspirated and turbocharged versions. Chapter 1 has safety precautions (read them, Viton seals are nasty stuff). Chapter 2 has all the specs: basic engine data, data and dimensions, recommended torque tensions on page 31, and compression test data on page 34. Chapters 3 through 7 are the meat: cylinder head assembly, piston and connecting rod assemblies, crankshaft assembly, timing case and drive assembly, and cylinder block assembly. You get every sub-procedure—rocker arm removal, valve spring replacement, main bearing cap torque steps. Chapter 8 covers engine timing, both valve and fuel injection pump. Chapters 9–12 handle aspiration, lubrication, fuel, and cooling systems. Then electrical, auxiliary equipment, and special tools in chapters 13–16.

Cylinder Head and Valve Train Procedures

Chapter 3 is where most rebuilds start. You get rocker assembly procedures for both latest and earlier engines, valve tip clearance adjustment, valve spring removal with cylinder head fitted, cylinder head gasket installation, and valve seat insert dimensions. Page 31 has the recommended torque tensions for the cylinder head setscrews—listed in lb-ft, not some conversion. Don’t trust aftermarket specs on this. I’ve had three engines come into my shop this year alone with blown head gaskets because somebody used a generic bolt torque. Perkins gives you the exact sequence and values. Also covered: valve depth, valve stem dimensions, and valve guide reaming specs.

Get the Crankshaft End-Float Right with Factory Specs

Chapter 5 is crankshaft assembly. You’ll find crankshaft pulley removal, rear oil seal replacement, thrust washers and crankshaft end-float measurement, main bearing cap removal and installation with crankshaft in position, and main bearing torque. If you don’t check end-float with the crankshaft in position, you’ll cook the bearings. The manual specifies the allowable end-float range. Also included: wear sleeve removal and installation. For the timing case (chapter 6), you get gear teeth meshing specs, idler gear bush dimensions, and camshaft assembly for both valves and fuel injection pump.

16 Chapters for Complete Engine Overhaul

You’re not paying for a table of contents. Every system has its own section with step-by-step instructions. Need to rebuild the fuel injection pump? Chapter 11 covers atomiser fault diagnosis, high pressure fuel pipes, leak off rail, atomisers, fuel lift pump, fuel injection pump linkage, and governor weight assembly. Cooling system? Chapter 12 includes thermostat, fan, coolant pump, and oil cooler. Lubrication? Chapter 10 gives oil filter canister, filter head and oil cooler, sump (aluminium and steel), oil strainer, lubricating oil pump, relief valve. The electrical equipment in chapter 14 covers drive belt, alternator, glowplugs (starting aid), starter motor, and electrical stop solenoid. There’s even a special tools chapter (16) listing part numbers for Perkins-specific tools.

Cooling System: Thermostat, Coolant Pump, and Fan Data

Chapter 12 is short but critical. Perkins specifies coolant type and maintenance intervals. Ignore it and you’ll crack the cylinder block. The manual shows thermostat removal and testing, fan removal and belt tension, coolant pump disassembly, and oil cooler replacement. If you’re doing a full rebuild, you need the cooling system data to avoid overheating the new engine. The specs section (chapter 2) includes cooling system capacities and pressure test values.

Is this manual for both naturally aspirated and turbocharged versions?

Yes, covers both. The engine views and specs differentiate them.

Does the manual include wiring diagrams for the electrical equipment?

Chapter 14 covers electrical equipment including alternator, starter motor, glowplugs, and the electrical stop solenoid. It doesn’t include full vehicle wiring diagrams—it’s an engine workshop manual, not a chassis manual. For engine-specific electrical connections, you’ll find the data you need. If you need the vehicle’s wiring, that’s a separate document. The manual does provide component testing procedures, such as checking glowplug resistance and starter motor solenoid continuity. For a basic understanding of manual transmission operation, see Manual Transmission and Manual Transmission.

If you’re serious about rebuilding a Perkins 700 Series engine without wasted time or broken parts, get the factory documentation. Perkins 1100 Series 2002 Workshop Manual – Specs, Torque & Repair is another good reference for other Perkins models. Perkins Peregrine, Serie 1300 1997 Workshop Manual – OEM Specs & Repair covers the 1300 series. And Perkins 110T, 180TI, 210TI Workshop Manual – 174 Pages for the older inline engines. Access the Factory Manual.