8 1100 Series, 4 cylinder engines

To check the timing of the Bosch EPVE fuel injection pump Operation 8-3

Special requirements
Special tools
Description Part number
Bosch EPVE fuel pump timing adaptor 27610248

Caution: This procedure must only be carried out by a person with the correct training.
1 Rotate the crankshaft to obtain TDC, see Operation 8-1.
2 Remove the high pressure fuel pipes from the fuel injection pump.
3 Remove the plug (A1) and washer from the rear of the fuel pump and fit the Bosch EPVE fuel pump timing
adaptor (B1), and a suitable dial gauge (B2). Set the dial gauge to indicate approximately 3,0 mm.
4 Slowly rotate the crankshaft, counter-clockwise from the front of the engine, until the dial gauge indicates
that the plunger of the fuel injection pump is at the bottom of its stroke. Set the dial to zero.
5 Slowly rotate the crankshaft clockwise, until the crankshaft timing pin can be pushed into the crankshaft web.
With the engine set at TDC, check the reading on the dial gauge.
Fuel injection pump with the code ER has a plunger lift of 1,55 mm (0.061in).
6 If the fuel pump timing is correct, remove the dial gauge and the Bosch EPVE fuel pump timing adaptor. Fit
a new washer and the plug. Tighten the plug to 29 Nm (21 lbft) 2,9 kgf m.
7 If the fuel injection pump timing is to be adjusted, see Operation 8-4.
8 Fit the high pressure fuel pipes to the fuel injection pump.
9 Eliminate the air from the fuel system, see Operation 11-8.

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1100 Series, 4 cylinder engines 8
To adjust the timing of the Bosch EPVE fuel injection pump Operation 8-4

Special requirements
Special tools
Description Part number
Bosch EPVE fuel pump timing adaptor 27610248

Cautions:
l This procedure must only be carried out by a person with the correct training.
l Do not turn the fuel injection pump with the pump shaft locked.
1 Rotate the crankshaft to obtain TDC, see Operation 8-1.
2 Remove the rocker assembly, see Operation 3-4.
3 Remove the high-pressure fuel pipes from the fuel injection pump.
4 Remove the plug and washer from the rear of the fuel pump and fit the Bosch EPVE fuel pump timing adaptor
(A1) and a suitable dial gauge (A2). Set the dial gauge to indicate approximately 3,0 mm.
5 Remove the timing pins.
6 Rotate the crankshaft slowly counter-clockwise and then clockwise, until the needle of the dial gauge
indicates that the plunger of the fuel injection pump is at the bottom of its stroke. Set the dial to zero.
7 Rotate the crankshaft slowly clockwise, until the needle of the dial gauge indicates the required plunger lift,
see Operation 8-3.
8 To lock the Bosch EPVE pump shaft, loosen the locking screw (B2) and remove the washer (B1). Tighten
the locking screw (B2) to 31 Nm (23 lbf ft) 3,1 kgf m. Ensure that the needle of the dial gauge has not moved.

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Continued

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8 1100 Series, 4 cylinder engines
9 Remove the Bosch mechanical fuel pump gear, see Operation 6-3.

Notes:
l There no key fitted into the keyway (C1).
l If the fuel injection pump is on the correct stroke, the keyway (C1) is towards the outlet (D1).
10 Rotate the crankshaft to obtain TDC, see Operation 8-1.
11 Fit the fuel pump gear, see Operation 6-4.
12 Ensure that the needle of the dial gauge has not moved. Remove the dial gauge and the Bosch EPVE fuel
pump timing adaptor (A1). Fit a new washer and tighten the plug (E1) to 29 Nm (21 lbf ft) 2,9 kgf m.
13 Fit the glow plugs, see Operation 14-10.
14 Fit the high pressure fuel pipes.
15 Fit the timing case cover, see Operation 6-2.
16 Fit the rocker assembly, see Operation 3-4.
17 Fit the rocker cover, see Operation 3-3.

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1100 Series, 4 cylinder engines 8
To check the timing of the Delphi DP210 fuel injection pump Operation 8-5

Caution: The fuel pump timing of the Delphi DP210 fuel injection pump most not be checked or adjusted. If
the fuel pump timing is lost, the pump must be removed and sent to your nearest Perkins Dealer/Distributor to
be reset.
Note: To remove the Delphi DP210 fuel injection pump, see Operation 11-13.

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8 1100 Series, 4 cylinder engines

To check the valve timing Operation 8-6

Note: Do not fit the timing case cover, the glow plugs or the rocker cover at this stage.
1 Set the piston of number 1 cylinder to TDC on the compression stroke, see Operation 8-1.
2 Mark the pulley at TDC, set a temporary pointer to the mark.
3 For naturally aspirated engines:
l Set the valve tip clearance of number 1 cylinder intake valve to 0,589 mm (0,023 in) and No 1 exhaust valve
to 0,698 mm (0.027 in).
4 For turbocharged engines:
l Set the valve tip clearance of number 1 cylinder intake valve to 1,220 mm (0.048 in) and No 1 exhaust valve
to 1,302 mm (0.051 in).
5 Rotate the crankshaft, clockwise from the front, until the push rod of number 1 cylinder intake valve is just
loose and the push rod for number 1 exhaust valve is equally loose. In this position, check if the mark on the
crankshaft pulley or damper is within +/- 2.5° of the temporary pointer. Use the formula below to find the
measurement which is equal to 2.5° on the pulley or damper.
CxP
360

C = circumference of pulley or damper

P = 2.5 degrees
6 If the timing is more than 2.5° out of position, the timing gears are likely not to be in correct mesh.

Notes:
l One tooth on the camshaft gear is equivalent to 18 mm (0.62in) at the circumference of a pulley of 200 mm
(7.87 in) diameter.
l One tooth on the camshaft gear is equivalent to 16 mm (0.70 in) at the circumference of a pulley of 170 mm
(6.69 in) diameter.
7 Rotate the crankshaft, clockwise from the front, until the intake valve of the rear cylinder has just opened,
and the exhaust valve has just closed. Set the valve tip clearance of the intake valve of No 1 cylinder to 0,20
mm (0.008 in). Set the valve tip clearance of the exhaust valve of No 1 cylinder to 0,45 mm (0.018 in).
8 Fit the timing case front cover, see Operation 6-2.
9 Fit the glow plugs, see Operation 14-10.
10 Fit the rocker cover, see Operation 3-3.
11 Remove the temporary pointer from the timing case and the timing mark from the pulley.

142 Workshop Manual, TPD 1487E, Issue 1