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Perkins — Gear Group (Front) - Installation Procedure

For these Perkins models: 1103, 1103 Engine, 1104, 1104 Engine, 1104 Turbocharged Engine, SEBU7833-01.

Applies to: Perkins 1104

Before you start

  • NOTICE: Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
  • Note: The fuel injection pump shaft must remain locked until this procedure instructs you to unlock the fuel injection pump shaft.
  • Note: The three cylinder engine can be equipped with either the Delphi DP210 or the Delphi DPG fuel injection pump.
  • Note: The four cylinder engine can be equipped with the Delphi DP210, the Delphi DPA or the Bosch EPVE fuel injection pump. The various types of fuel injection pump have a different procedure for locking the fuel injection pump shaft.

Procedure

  1. 1. If necessary, install the crankshaft gear. Refer to this Disassembly and Assembly Manual, "Crankshaft Gear - Remove and Install".
  2. 2. Thoroughly clean the housing (front).
  3. 3. Thoroughly clean all of the components and inspect all of the components of the front gear group. If necessary, replace any worn components and/or any damaged components of the front gear group.
  4. 4. Ensure that no. 1 piston is still at top dead center. Refer to the Testing and Adjusting Manual, "Finding Top Center for No. 1 Piston".
  5. 5. Install the camshaft gear (1). Refer to this Disassembly and Assembly Manual, "Camshaft Gear - Remove and Install".
  6. 6. Install the idler gear (2). Refer to this Disassembly and Assembly Manual, "Idler Gear - Remove and Install".
  7. 7. Ensure that the mesh of the idler gear (2) is correct with the camshaft gear (1).
  8. 8. Install the fuel injection pump gear (3) onto the fuel injection pump shaft. Ensure that the mesh of the fuel injection pump gear (3) is correct with the idler gear (2). Install the washer and the nut (6) finger tight.
  9. 9. Apply hand pressure to the fuel injection pump gear (3) in a counterclockwise direction in order to remove the backlash in the gears (1), (2), and (3). Tighten the nut (6) to a torque of 24 N-m (18 lb ft).
  10. 10. Ensure that all of the timing marks on the gears (1), (2), and (3) are in alignment.
  11. 11. Release the locked fuel injection pump shaft. In order to unlock the Bosch EPVE fuel injection pump shaft, loosen the locking screw (7) and install the washer (8). Tighten the locking screw (7) onto the washer (8) to a torque of 12 N-m (9 lb ft).
  12. 12. In order to unlock the Delphi DP210 fuel injection pump shaft, loosen the locking screw (9) and move the washer (10). Tighten the locking screw (9) onto the washer (10) to a torque of 12 N-m (9 lb ft).
  13. 13. Tighten the nut (6) to an increased torque of 90 N-m (66 lb ft). Refer to illustration 160.
  14. 14. Remove the timing pins (4) and (5). Refer to illustration 159.
  15. 15. Check the backlash value for the fuel injection pump gear (3). Refer to the Specifications Manual, "Gear Group (Front)" for further information.
  16. 16. Check the end play of the idler gear (2). Refer to this Disassembly and Assembly Manual, "Idler Gear - Remove and Install" and refer to the Specifications Manual, "Gear Group (Front)" for further information.
  17. 17. Check the backlash value for the idler gear (2). Refer to this Disassembly and Assembly Manual, "Idler Gear - Remove and Install" and refer to the Specifications Manual, "Gear Group (Front)" for further information.
  18. 18. Check the end play of the camshaft gear (1). Refer to this Disassembly and Assembly Manual, "Camshaft Gear - Remove and Install".
  19. 19. Check the backlash value for the camshaft gear (1). Refer to this Disassembly and Assembly Manual, "Camshaft Gear - Remove and Install" and refer to the Specifications Manual, "Gear Group (Front)" for further information.
  20. 20. Lightly lubricate each gear with clean engine lubricating oil.
  21. End By: a. Install the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and Install". b. Install the glow plugs. Refer to this Disassembly and Assembly Manual, "Glow Plugs - Remove and Install". c. Install the rocker shaft. Refer to this Disassembly and Assembly Manual, "Rocker Shaft and Pushrod - Install".

Tools required

  • Camshaft timing pin, Part No. 27610212
  • Crankshaft timing pin, Part No. 27610211

Specs & torque values

  • Fuel injection pump gear nut (6) torque: 24 N-m (18 lb ft) initial, then increased to 90 N-m (66 lb ft)
  • Bosch EPVE locking screw (7) torque: 12 N-m (9 lb ft)
  • Delphi DP210 locking screw (9) torque: 12 N-m (9 lb ft)

Source: manual:Perkins 1100 A-B-C- Series.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.