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1104 Perkins engine - Removing and refitting adjacent components

The injection pumps fitted on 4-cylinder 1104 Perkins engines (5400/6400 Massey Ferguson tractor) are mechanical. Two models are fitted: Bosch VE10, Delphi DP210.

Removing fuel injection channels - Remove the front bonnet body. Clean the injector cover, channels and parts close to the injectors to prevent impurities from entering the system. Remove the injector cover by taking the screws out of the cover plate. Make indelible marks on the channel locations to make reassembly easier. Disconnect the injection channels on the injector side.

Disconnect the injection channels on the injection pump side. Position a container to recover the fuel contained in the channels. Disassemble or loosen the injection channel flanges. Remove the channels. Plug the unions of the injection pump and injectors to keep dust out. Also block the injection channels to keep dust out.

Removing the crankshaft pulley, fan and water pump - Loosen the alternator screws. Release the belts by turning the alternator. Take out the three screws and the spacer. Remove the crankshaft pulley. Remove the fan. Take off the belts. Drain the 1104C Perkins cooling system.

Loosen and remove the hoses attached to the water pump. Remove the screws from the pump. If required, gently tap the pump with a plastic hammer in order to release it. Take off the water pump. Take off and discard the seal.

Removing the front cover plate - Remove the screws (3) (4) and (5) from the cover plate (1) (Fig. 5). The screws are not identical. Mark them in relation to their holes in order to make reassembly easier. Remove the cover plate (1). Take off and discard the seal (2) (Fig. 5).

Refitting fuel injection channels

Check the condition of the channels. Replace those that are defective. Refit the injection channel flanges to hold the channels in place, without tightening. Remove the dustproof plugs from the unions of the pipes and injection pump. Reassemble the unions without tightening on either side of the injection channels. Ensure that the channels fit correctly without being obstructed by other engine parts. Tighten the channel flanges. Check their correct positioning again. Tighten the channel / injector unions to 30 Nm. Tighten the channel / injection pump unions to 30 Nm.

Bleed the system. Delphi DP210 pump: bleeding is automatic. Switch on the ignition for approximately 3 minutes. The air should bleed automatically from thesystem. Bosch VE10 pump: bleeding is not automatic. Switch on the ignition for 3 minutes then switch it off. Loosen the injector unions. Activate the starter until there is no air in the fuel flowing out of the injector unions (no bubbles). Retighten the unions to 30 Nm.

Start the 1104C Perkins engine. Ensure it operates correctly and that there are no leaks. Stop the engine. Clean the internal surfaces of the injector cover. Refit the injector cover. Refit the screws. Tighten to a torque of 9 Nm.

Refitting the front cover plate - Carefully clean all cover plate surfaces and the mating face of the seal on the housing. Position two guide studs in the appropriate holes (6) (Fig. 7). Check for the presence of three dowel pins (7) (Fig. 7) and ensure they are in good condition. Replace them if necessary. Fit the seal on the cover plate. The seal is fitted on the cover plate using the three dowel pins (7).

Position the cover plate (1) and the seal (2) on the engine sump. Fit screws (3) in holes (8) and screws (5) in holes (9). Take the two guide studs out of the holes (6). Fit the remaining screws (4). Tighten the screws by hand. Refit the water pump before tightening the screws to a torque of 22 Nm.

Refitting the crankshaft pulley, fan and water pump

Check the condition of the water pump and its drive mechanism. Clean the mating faces of the seals on the pump (4) and the housing (1) (Fig. 8). Install two guide studs (5) on the housing (1) (Fig. 8). Do not apply sealing product to the new seal (2). Fit the new seal (2) on the housing (1).

Position the water pump (4) on the housing (1) (Fig. 9). Position the water pump tightening screws (3) (Fig. 9). Do not tighten the screws. Remove the guide studs from the housing and refit the last remaining screws (3). Tighten the screws (3) in the order indicated in Fig. 10 to a torque of 22 Nm. Tighten the screws (3) consistently.

Fit the hoses removed from the water pump. Tighten the attachment clips. Fill the cooling system. Clean the crankshaft pulley (3) and the spacer (2). Check their condition. Position the pulley (3) on the crankshaft (4). Lightly oil the threads and heads of the screws (1) with clean engine oil. Refit the spacer (2) and screws (1). Tighten the screws consistently to a torque of 115 Nm.

Check the tightening again for correct torque. Fit the accessory belts. Refit the fan. Correctly tension the belts by adjusting the alternator. Belt tension is measured at the middle of the longest run and should be 535 N for a new belt and 355 N for a used belt. Tighten the alternator screws to a torque of 22 Nm.

Timing the engine at Top Dead Centre on the first cylinder (4-cylinder 1104 engine) - The first cylinder is the cylinder furthest from the engine flywheel. Take out the rocker cover and glow plugs. Turn the crankshaft in the normal engine operating direction until the inlet valve of cylinder 4 is slightly open and the exhaust valve of the same cylinder is nearly closed.

Slowly turn the crankshaft in the normal engine operating direction to align the hole in the crankshaft with the hole in the engine block. Fit the pin ref. 4224730M1 fully in the hole. Fit the pin ref. 4224757M1 into the hole in the camshaft gear. The engine is now timed at Top Dead Centre on the first piston.