Perkins — Fuel Injection Pump Front Housing Removal and Setup

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

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Procedure

1. 1. Remove fuel injection pump (refer to Disassembly and Assembly section).
2. 2. Remove crankshaft pulley (refer to Disassembly and Assembly section).
3. 3. Remove front housing. Ensure that the face of the front plate is clean.
4. 4. Remove the gasket.
5. 5. Install Tooling (E) to lever assembly. Tighten tooling (E) to 0.4 N·m (3.5 lb in).
6. 6. Remove start spring and replace with Tooling (D).
7. 7. Install Tooling (C) into cylinder block.
8. 8. Install Tooling (B) into Tooling (C).
9. 9. Assemble Tooling (A).
10. 10. Install Tooling (A) into Tooling (B) until the extension on Tooling (A) touches the rack of the fuel injection pump.
11. 11. Push Tooling (A) into Tooling (B) for a further 2 mm (0.0787 inch). Lock Tooling (B) to retain Tooling (A) in position. Set Tooling (A) to read 2.00 ± 0.01 mm (0.0787 ± 0.0004 inch).
12. 12. Push plunger of Tooling (A) several times to seat the rack of the fuel injection pump. When plunger is gently released, check that Tooling (A) reads 2.00 ± 0.01 mm (0.0787 ± 0.0004 inch).

Source: manual:Perkins_402D-05G_Engine_System_Operations_Testing_and_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.