Aurora — Fuel Injection Pump Setting and Front Housing Installation

A Aurora service procedure — check it applies to your exact model before use.

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Procedure

1. Install Tooling (B) into Tooling (C).
2. Assemble Tooling (A).
3. Install Tooling (A) into Tooling (B) until the extension on Tooling (A) touches the rack of the fuel injection pump.
4. Push Tooling (A) into Tooling (B) for a further 2 mm. Lock Tooling (B) in order to retain Tooling (A) in position.
5. Set Tooling (A) to read 2.00 ± 0.01 mm (0.0787 ± 0.0004 inch).
6. Push plunger (12) of Tooling (A) several times in order to seat the rack of the fuel injection pump.
7. When the plunger is gently released, check that Tooling (A) reads 2.00 ± 0.01 mm.
8. Pull plunger (12) of Tooling (A) until the plunger has reached the fully out position. Use a suitable clip to retain the plunger.
9. Remove the fuel injection pump.
10. Remove the original front housing.
11. Disassemble the original front housing.
12. Assemble the replacement front housing with the parts that were removed from the original front housing.
13. Remove Tooling (E) from the original front housing. Install Tooling (E) to the lever assembly of the replacement front housing. Tighten to 0.4 N·m.
14. Remove Tooling (D) from the original front housing. Install Tooling (D) into the replacement front housing.
15. Install the replacement front housing.
16. Install the fuel injection pump to the cylinder block. Install the original shim.
17. Remove the clip from plunger (12) of Tooling (A).
18. Release the plunger on Tooling (A).
19. Use a ring spanner to retain the locknut of the fuel screw in position.
20. Use an allen wrench to rotate the allen head screw. Adjust the allen head screw until the indicator reads 2.00 ± 0.01 mm.
21. Tighten the locknut to 6 N·m to retain the allen head screw in position.

Source: manual:perkins_m0081120_testing_adjusting.pdf. Figures and steps are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.