@Perkins

Service Bulletin
Please remove 1100 Series Service Bulletin 65 issue 1 and put Service Bulletin 65 issue 2 in its place as new information has been added.

1100 Series
Fuel Injection Pump Timing - Check

65 Issue 2
February 2008

This service bulletin applies to the 1100 Series three cylinder engines models DC, DD and some DJ and DK.
There have been isolated instances of the incorrect timing of the DP210 and DPG fuel injection pumps. This
issue affects engines from serial number D------U151459P to engine serial number D------U154416P inclusive.
For DJ and some DK engine models that are not shown in Table 1 require to be reworked only if there is a
noise legislation need. The incorrectly set timing may in some cases cause an increase in noise output.
Consultation with the customer and/or engineering teams is required to understand if there is any noise
legislative need or not. Preference is to rework only those units that are sold into an application where noise
level is a key concern. Technical support can be supplied by Perkins Engines Co, Peterborough - attention
Craig Clamp and/or Steve Rickard if you have further questions.
All DC and DD engine models must be reworked using the following instruction. The DK engine build lists that
are listed in Table 1 must be reworked using the following instruction.
Table 1
DK51280
DK51315
DK51327
DK51329
DK51436

Fuel Injection Pump - Remove

1 Stop the engine and allow the engine to cool. Loosen the cooling system filler cap slowly in order to relieve
any pressure. Remove the cooling system filler cap.
2 Open the drain cock or remove the drain plug on the engine. Open the drain cock or remove the drain plug
on the radiator.
3 Allow the coolant to drain into a suitable container.
4 If necessary, remove the radiator.
5 If necessary, remove the setscrews from the fuel injector cover.
6 If necessary, remove the fuel injector cover.
7 If necessary, remove the fan and the fan drive pulley.
8 If necessary, loosen the clamps and remove the hose from the water pump inlet.
9 Remove the setscrews that fasten the water pump to the front housing.
10 If necessary, gently tap the water pump with a soft hammer in order to loosen the water pump.
11 Remove the water pump. Remove the joint from the front housing and the water pump.
12 Remove the setscrews from the front cover.
13 Remove the front cover from the front housing.
14 Remove the joint from the front cover.

Service Bulletin - 1100 Series 65 Issue 2

February 2008

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15 Carefully rotate the crankshaft in the normal direction of the engine in order to align the camshaft gear so
that the Camshaft Timing Pin (Perkins part number 27610212) can be installed through the hole in the
camshaft gear (A2) and into the timing case.
Note: The camshaft gear can rotate a small amount when the pin is installed.
16 Align the hole in the crankshaft with the hole in the timing case (A1). Insert the Crankshaft Timing Pin
(Perkins part number 27610211) fully into the hole in the crankshaft web. The engine is set at the top centre
position for No. 1 piston.
17 Disconnect the fuel injection lines at the fuel injectors.
18 Disconnect the fuel injection lines at the fuel injection pump.
Note: Ensure that connections do not turn on the fuel injection pump.
19 If it is necessary remove the clamps for the fuel injection lines or loosen the clamps for the fuel injection
lines. Remove the fuel injection lines.
20 Install dust caps onto the ports of the fuel injectors and onto the ports of the fuel injection pump. Install dust
caps onto both ends of the fuel injection lines.
Note: Put identification marks on all fuel hose assemblies and on all tube assemblies for installation purposes.
After being disconnected, plug all fuel hose assemblies and all tube assemblies with suitable plastic plugs. Also
install dust caps on all of the connectors on the fuel injection pump. This helps prevent fluid loss, and this helps
to keep contaminants from entering the system.
21 Disconnect the fuel feed and return lines. Disconnect the tube assembly from the fuel injection pump.
Disconnect the throttle.

Service Bulletin - 1100 Series 65 Issue 2

February 2008

22 If necessary, disconnect the OEM harness assembly from the stop solenoid. Disconnect the harness
assembly for the cold start advance.

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23 Apply sufficient pressure to fuel injection pump gear (D1) in a counterclockwise direction in order to remove
the backlash. Loosen the locking screw (B1). Rotate the spacer (B2) in order to allow the locking screw (B1)
to tighten against the shaft of the fuel injection pump. Tighten the locking screw (B1) to a torque of 15 Nm (11
lbf/ft) for the DP210 fuel injection pump. For the DPG fuel injection pump loosen the locking screw (C1). Rotate
the spacer (C2) in order to allow the locking screw (C1) to tighten against the shaft of the fuel injection
pump.Tighten the locking screw (C1) to a torque of 13 Nm (10 lbf/ft).
Note: The locking screw must be tightened in order to prevent the shaft of the fuel injection pump from rotating.
The shaft of the fuel injection pump must not be rotated after the fuel injection pump has been removed from
the engine.

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24 Remove the nut (D3) and the washer (D2) from the shaft of the fuel injection pump.
25 Use a three legged puller in order to remove the fuel injection pump gear (D1).
Note: Do not pry the fuel injection pump gear from the shaft of the fuel injection pump.
26 Remove support bracket assembly.
27 Remove the setscrews in order to remove the fuel injection pump.
Note: The fuel injection pump should be supported by hand as the setscrews are removed.
28 Remove the fuel injection pump from the front housing. Remove the O-ring and discard the O-ring from the
fuel injection pump.
Note: Ensure that the serial number for the fuel injection pump and the serial number for the engine are
recorded so that the fuel injection pump can be installed onto the correct engine. Ensure that the warranty
claim has the fuel injection pump serial number in the justification box.
Note: The Delphi DP210 fuel injection pump must be re-timed and locked by an authorised Delphi technician.
To re-time the DPG fuel injection pump, use the procedure that is described in the rework instructions attached.
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Service Bulletin - 1100 Series 65 Issue 2

February 2008

Fuel Injection Pump - Install

1 Install the new O-ring onto the fuel injection pump. Install new sealing washers to the setscrews.
2 Align the holes in the fuel injection pump with the holes in the front housing. Install the fuel injection pump
to the housing.
Note: The fuel injection pump should be supported by hand until the setscrews are installed.
3 Install setscrews. Tighten the setscrews to a torque of 25 Nm (18 lb ft).
Note: The shaft of the fuel injection pump must remain locked until the timing gear has been installed and
tightened onto the shaft of the fuel injection pump. The locking screw must remain locked until you are
instructed to loosen the locking screw.
4 Position support bracket onto the cylinder block. Install the setscrew finger tight. Install the bolt and the nut
finger tight.
5 Tighten the setscrew to a torque of 44 Nm (32 lbf/ft). Tighten the bolt and the nut for the bracket to a torque
of 22 Nm (16lbf/ft).
Note: Ensure that the fuel injection pump is not stressed as the bolts and the setscrew for the bracket are
tightened.
6 Ensure that shaft on the fuel injection pump is clean, dry and free from damage.
7 Position the fuel injection pump gear (D1) onto the shaft of the fuel injection pump. Ensure that the timing
marks on the gears are in alignment and that the mesh of the gears is correct. Install a new washer (D2) and
the nut (D3). Rotate the fuel injection pump gear in a counterclockwise direction in order to remove the
backlash.
8 Tighten the nut to a torque of 24 Nm (17 lbf/ft).
9 Loosen the locking screw (B1) or (C1). Move the spacer (B2) or (C2) in order to prevent the locking screw
(B1) or (C1) from tightening against the shaft of the fuel injection pump. Tighten the locking screw (B1) or (C1)
to a torque of 12 Nm (8.8 lbf/ft).
Note: The spacer must be correctly positioned and locking screw must be tightened in order to prevent the
locking screw from contacting the shaft of the fuel injection pump.
10 Remove the timing pins from the crankshaft and the camshaft gear.
11 Tighten the nut (D3) that secures the fuel injection pump gear (D1) to a torque of 90 Nm (66 lbf/ft).
12 Thoroughly clean all the surfaces of the front cover and clean the joint face of the housing (front).
13 Install two guide studs into the appropriate holes within the housing (front).
14 Check the joint for damage, if necessary, replace the joint. Position the joint onto the front cover.
Note: The joint is located by the three locating dowels on the front cover.
15 Position the front cover and the joint on the front housing. Install setscrews finger tight.
16 Remove the two guide studs. Install the remainder of the setscrews finger tight.
17 Inspect the drive gear for the water pump for wear or other damage. If necessary, replace the water pump.
18 Clean the joint faces of the water pump and the front cover.
19 Check the joint for damage, if necessary, replace the joint. Install the water pump assembly onto the front
housing.
20 Install the setscrews that fasten the water pump to the front housing finger tight.
21 Tighten the setscrews for the front housing and the water pump to a torque of 22 Nm (16 lbf/ft).
22 Install the hose for the water pump inlet. Tighten the clamps securely.
23 If necessary, install the fan drive pulley and the fan.
24 Inspect the fuel injection lines for wear and for damage. Replace any fuel injection line that are worn or
damaged.
25 Remove the dust caps from the fuel injection pump and from the fuel injectors. Remove the dust caps from
the fuel injection lines. Loosely connect the nuts at both ends of the fuel injection lines.
26 Tighten the fuel injection lines to a torque of 30 Nm (22 lbf/ft).
Note: Ensure that connections do not turn on the fuel injection pump.
27 Ensure that each fuel injection lines does not contact any other fuel injection line or any other engine
component.

Service Bulletin - 1100 Series 65 Issue 2

February 2008

28 Remove all of the dust caps from the low pressure connections on the fuel injection pump. Remove all of
the dust caps from the low pressure tube assemblies.
29 Connect the low pressure tube assemblies to the fuel injection pump.
30 If necessary, connect the OEM harness assembly onto the stop solenoid. Connect the harness assembly
for the cold start advance. Connect the throttle.
31 Close the drain cock or install the drain plug on the engine.
32 Close the drain cock or install the drain plug on the radiator.
33 Fill the cooling system with the required coolant.
34 Turn the key switch to the run position. Leave the key switch in the run position for three minutes.
35 Turn the key switch to the off position.
Note: Damage to the fuel injection pump, to the battery and to the starter motor can occur if the starter motor
is used excessively to purge the air from the fuel system.
36 Loosen the nuts for the high pressure fuel lines on all of the fuel injectors.
37 Operate the starting motor and crank the engine until the fuel is free of air.
38 Tighten the nuts to a torque of 30 Nm (22 lbf/ft).
39 Ensure that each fuel injection lines does not contact any other fuel injection line or any other engine
component.
40 The engine is now ready to start. Operate the engine at low idle for a minimum of five minutes immediately
after air has been removed from the fuel system.
41 If necessary, install the fuel injector cover. Install the setscrews. Tighten the setscrews to a torque of 9 Nm
(80 lbf/in).
42 Start and run the engine at low idle. Increase the engine rpm to high idle. Run the engine at high idle for
one minute in order to purge the air from the cavities of the engine block. For fixed speed engines, run the
engine at no load for five minutes. Stop the engine.
43 Check the coolant level. Maintain the coolant level within 13 mm (0.5 inch) below the bottom of the pipe for
filling. Maintain the coolant level in the expansion bottle (if equipped) at the correct level.
Note: If the engine is to be installed in an application at a later date, install the fuel injector cover and ensure
that the engine is inspected at the time of the application test and careful inspection is made around the areas
of the engine where re-work has been carried out. Check for leaks.
End
Issued by Perkins Engines Company Ltd, Peterborough PE1 5NA, England. Proprietary information of Perkins Engines
Company Ltd 2008, all rights reserved. The information is correct at the time of print. This bulletin is for technical information
only and cannot be used as a basis for any claim including but not limited to warranty.
To enable the distribution lists for service bulletins to be maintained, If you currently receive service bulletins, but
no longer require them, please contact Michael Lowrey via Email [email protected]

Diesel Information
SPECIAL

JAN 2008

SERVOPS 1

COMMERCIALLY CONFIDENTIAL

Pump Timing Issues for Perkins

EQUIPMENT:

DPG and DP210

SUBJECT:

Pump timing setting request

1. INTRODUCTION
Perkins has requested the Delphi Network to assist in a pump timing resetting exercise on
DPG and DP210 3 cylinder applications, specifically 1103A and 1103C variants
2. PROCEDURE
DPG pumps
The Perkins or Perkins OEM distributor has responsibility to remove the fuel pump from the
engine.
On Receipt of the pump the Delphi Workshop will reset and relock the pump drive shaft in the correct
timing position. The Table below gives the timing value to be applied by pump reference number
Set the Static timing value stated in the table on the timing device 7244-27 found in the DPA tool kit
and fit the appropriate drive shaft adaptor. Ensure the pump drive shaft is unlocked. Fit the tool to the
pump drive shaft and rotate the shaft until the indicator tang on the tool aligns with the line scribed on
the pump housing flange. Relock the pump drive shaft in this position.
Return the pump to the Perkins or Perkins OEM distributor.
Note:- It is unnecessary to hydraulically lock the head and rotor as per normal DPA timing procedure.
It is unnecessary to bench test the pump for this exercise.

Delphi Pump reference

Perkins reference

Timing value in degrees

3239F591T

2643B315

330

3230F571T

2643B317

329

3230F581T

2643B319

331

DELPHI Diesel Systems Ltd, Aftermarket Operations, Stratford Road, Shirley, Solihull, West Midlands, B90 4DT, England.
Delphi Diesel Systems UK Ltd
Tel: [44] [0] 121.746.6000 Fax: [44] [0] 121.746.6001

DWXXX - Jan 08 - 2 of 2

DP210 Pumps
The Perkins or Perkins OEM Distributor has the responsibility to remove the pump from the
engine
Only accredited DP210 workshops are able to conduct this exercise.
On receipt of the pump the Delphi workshop must ensure that the drive shaft is in the unlocked
condition. Mount the pump to the test stand with the appropriate DP210 dynamic timing kit. It will be
necessary to use the correct DP210 test pipes and injectors as stated in the appropriate test plan on
Direct Evolution.
It is unnecessary to apply any of the presets stated in the test plan as fuel delivery and advance
checks will not be checked, Transfer pressure advance and carriage position adaptors will not be
required. This is purely a dynamic timing setting exercise. Run the pump to operating temperature
and perform the dynamic timing procedure using the data stated on the appropriate test plan. Lock
the drive shaft in the correct position, drain any test oil from the unit, cap inlets and outlets and return
to the Perkins or Perkins OEM distributor.
Caution:- It is imperative that the dynamic timing procedure is utilised in order to maintain emissions
compliance. It is likely that more than one witness mark will be visible on the timing ring as the pumps
will be re moved from the engine in the incorrect position; It is the Delphi workshops responsibility to
ensure the pump is correctly timed for reassembly to the engine. .
3. RESPONSIBILTY
All costs incurred will be the responsibility of the Perkins distributor. Delphi has agreed the service
time for both types of fuel pump with Perkins. It is envisaged that more than one pump at a time will
be presented for this exercise in order to minimise set up time. The labour rate should not exceed
50.00 per hour or the equivalent value in other currency.
For DPG maximum time should not exceed 0.33 of an hour.
For DP210 the maximum time should not exceed 1.25 hours.