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Perkins D3.152 engine

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David UK

11-17-2002 12:59:40




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Would anyone care to offer advice/thoughtsa on an engine problem we have with a Perkins D3.152 engine. This is the industrial variant of the 3.152 (indirect injection) and AD3.152 (agricultural direct injection) used in MF35 and MF135s. Ours is fitted in a JCB406 and is regularly blowing cylinder head gaskets despite a head skim. We've fitted three ourselves and dealer has done one but the problem remains. We suspect a problem with the block which is a JCB recon unit. This problem has extended over a few years. Sometimes it has gone 2 years between "blows", other times onlt 2 weeks. Its been properly torqued and retorqued and other obvious things. However, this time we have noticed two small cracks at the top of two cylinder liners. It looks very like these have led to the most recent blowout. What might cause this cracking? Should the liners project above the block? If so, how is the liner height controlled? Are they shimmed? What's the best way to get the old liners out?

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Hawk

11-17-2002 16:44:27




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 Re: Perkins D3.152 engine in reply to David UK, 11-17-2002 12:59:40  
When correctly installed, top of liner must be located flush to .004" below top face of cylinder block. Got that line from the book. Hope this helps. There are no shims. If you freeze the liner to get it into the block, when it expands and all other sizes being equal it's suppose to stay there.

I haven't had to wrench one yet and hope I don't have to soon. I like going out in the mornin when it's 25 degrees F. and having them start without ether in two turns.

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Ricky in NC

11-20-2002 16:58:26




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 Re: Re: Perkins D3.152 engine in reply to Hawk, 11-17-2002 16:44:27  
Just finished rebuilding my Dads MF-35. It has a Perkins A3-152 3 cylinder diesel. I took the block to a machine shop where they turned the crank and chizeled the old liners out. At the bottom the liners rest on a lip which is part of the engine block. The new liners just slid right in. After installing the pistons I could slide the new liners up and down by turning the crank, friction from the piston rings raised the liners without the head on. The shop manual leads me to beleive the liners will seat and stay in place after engine break in. Hawk is right my book also says the liners should be .004 below the lip not above. The liners are held in compression by torquing the head. I checked the clearance below the head surface by the shop manual. Installed and torqued the head...It has been fine so far. Hasn't done much hard pulling yet though. Good luck.

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David UK

11-18-2002 04:16:02




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 Re: Re: Perkins D3.152 engine in reply to Hawk, 11-17-2002 16:44:27  
That is useful to know. That's about where our liners are sitting. Don't know why there's cracks though, unless someone has been hammering them in it to fit! Looks like we'll be pulling ours at some stage - I have been told that bashing them out from below with a hammer and chisel is one method but the proper way is use a liner puller (special tool!) - if I had a "special tool" I probably would be in Hawaii with half a dozen women so it may be the hammer and chisel option for me. The 135 engine generally does start dead easy, without ether and no heater either but I can testify that it doesn't when one cylinder gets directly connected to the other. The machine is needed to feed 100 cattle so its gettign stuck together again and maybe it will get through this winter without another failure. Or maybe not.

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richard

11-23-2002 14:04:51




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 Re: Re: Re: Perkins D3.152 engine in reply to David UK, 11-18-2002 04:16:02  
The m-f 35 uses different liners to a D3.152 the later engine has a lip at the top this should stand flush to 4 thou above bloc face if it is below you will not keep it in gaskets



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Scott from Pa.

11-18-2002 15:22:18




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 Re: Re: Re: Perkins D3.152 engine in reply to David UK, 11-18-2002 04:16:02  
Removing the liners with the proper tool is the only way to do it right. Not everyone has one of these tools but you may be able to borrow one from a friend or even rent it.



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Paul

11-19-2002 23:15:40




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 Re: Re: Re: Re: Perkins D3.152 engine in reply to Scott from Pa., 11-18-2002 15:22:18  
We had a similar problem with a 135 constantly blowing the head gaskets. After several changes it was found that a cylinder sleeve had slipped ever so slightly & that was the root of the problem. A copper based substance ( cant remember the name of it ) was used under the head gasket the last time in an attempt to remedy the problem. All went well until the father inlaw ran it out of oil ( he replaced the engine oil & didnt tighten the sump plug ) but just assumed it was only the oil pressure gauge that had given up the ghost. Now the old girl has had the head shaved & the block planed as well as new mains, liners & piston & rings. So providing the father inlaw doesnt attempt any more servicing, the old girl should be right for another 8000 hours.

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David

11-20-2002 13:47:18




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 Re: Re: Re: Re: Re: Perkins D3.152 engine in reply to Paul, 11-19-2002 23:15:40  
Our liners look ok as regard position but I suppose its hard to say by eye. They seem about flush or at least not below the 4 thou mentioned. The cracks are definetly bad news though. If anyone knows the name of the copper based substance it might be worth a try. I've heard of a 135 engine "drawing a liner" when put under heavy load but don't really know how it can happen as I'd assumed they seated on metal at the bottom and were held by the head at the top. We have an old block so I'll have a look at that and see how they are located. All may become clear.

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Thyge

11-23-2002 02:39:06




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 Re: Re: Re: Re: Re: Re: Perkins D3.152 engine in reply to David, 11-20-2002 13:47:18  
The liners aren't seated at the bottom, only by the collar at the top. that's why they can be pulled down. I actually had cylinder 1 pulled down and crunched in the crankcase, and the other two just cracked right under the collar. Used the proper removal tool and froze three new ones in.
If you get them as a set with pistons and all it's like getting a new engine. (if bearings are OK)



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twopop

11-20-2002 18:36:14




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 Re: Re: Re: Re: Re: Re: Perkins D3.152 engine in reply to David, 11-20-2002 13:47:18  
the sobstance you are looking fot is COPPERCOAT available at most auto parts stores.the 152 engines that i have worked on do not have a lip at the bottom of the block.there is a counterbore at the top of the block that the top lip of the sleeve fits into,a lip is added to the bottom of the block by machie shops when it is neccessary to install a oversize sleeve.drawing a sleeve is when the piston sticks to the sleeve and the piston pulls the sleeve down into the crankcase.you can use a dull chisel,and from the bottom of the sleeve force the chisel in between the bore and the sleeve,and split the sleeve,or heat the sleeve with a torch up and down in a straight line,the sleeve will shrink and loosen in the bore.if you have shaved the block then the pistons should be shaved so that they sit .002 below the top of the block.the sleeve should not just slip in,the sleeves are .001 smaller to .001 larger than the bore in the block

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