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Home›Repair guides›Fuel Injection Pump - Remove and Install

Perkins — Fuel Injection Pump - Remove and Install

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

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Before you start

  • Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard.
  • Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.
  • The harness assemblies should be positioned away from fuel injection pump in order to avoid an obstruction.
  • After replacement of the fuel injection pump, the fuel injection pump requires a high-pressure fuel pump calibration procedure.

Procedure

  1. Removal:
  2. 1. Turn the fuel supply to the OFF position.
  3. 2. Turn the battery disconnect switch to the OFF position.
  4. 3. Disconnect harness assembly (1) from the solenoid on fuel injection pump (6).
  5. 4. Place a suitable container below the fuel injection pump to catch any fuel.
  6. 5. Clean the fuel injection pump and the area around it.
  7. 6. Remove fuel injection line (7) that connects fuel injection pump (6) to the fuel manifold.
  8. 7. Use Tooling (A) to cap the open port in the fuel injection pump immediately.
  9. 8. Use Tooling (A) to cap the open port in the fuel manifold immediately.
  10. 9. Make temporary identification marks on all plastic tube assemblies.
  11. 10. Disconnect plastic tube assemblies (2, 3, 4, 5) from fuel injection pump (6).
  12. 11. Use Tooling (A) to cap the open ports in the fuel injection pump immediately.
  13. 12. Use Tooling (A) to plug the plastic tube assemblies immediately.
  14. 13. Remove nuts (8) from fuel injection pump (6).
  15. 14. Carefully remove the fuel injection pump from front housing (10).
  16. 15. Remove O-ring (11) from the fuel injection pump.
  17. Installation:
  18. 1. If necessary, install studs (9) into front cover (10). Tighten to 18 N·m.
  19. 2. Install new O-ring seal (11) onto fuel injection pump (6).
  20. 3. Carefully install fuel injection pump (6) into front housing (10).
  21. 4. Install nuts (8) onto studs (9). Tighten to 25 N·m.
  22. 5. Install new fuel injection line (7).
  23. 6. Connect plastic tube assemblies (2, 3, 4, 5) to fuel injection pump (6).
  24. 7. Connect harness assembly (1) to the solenoid.
  25. 8. Install the fuel injection pump gear.
  26. 9. Replace the filters for primary fuel system.
  27. 10. Replace the filters for secondary fuel system.
  28. 11. Turn the fuel supply to the ON position.
  29. 12. Turn the battery disconnect switch to the ON position.
  30. 13. Remove the air from the fuel system.

Tools required

  • Capping Kit T412504

Specs & torque values

  • Studs torque: 18 N·m (159 lb in)
  • Nuts torque: 25 N·m (221 lb in)

Source: manual:854E-854F Disassebly and Assebly Section UENR0624-02.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.