Sylvie Willis
Perkins fuel injectors are integral to the engine's performance and emissions. To clean them, you must first isolate the problem by gravity-feeding fuel directly to the injector pump. This can be done by siphoning clean fuel from a bucket through a hose into the hard pipe leading to the injector pump. Then, bleed the Perkins by loosening the vent plug on the fuel filter, the head locking nut, the air vent screw, and the pipe union coupling. Next, pump fuel until no air bubbles emerge. Repeat this process for each injector. Finally, tighten the first injector when clean fuel exits, and the engine should run smoother.
Characteristics and Values of Cleaning Perkins Fuel Injectors
| Characteristics | Values |
|---|---|
| Frequency of inspection | Every 700 hours |
| Replacement parts | Fuel injectors, gaskets, injector nozzles |
| Tools required | Bucket, clear hose, curved pick, shop vac, fuel pump |
| Steps | Isolate the problem, disassemble and reassemble parts, bleed the injectors, lubricate pistons, test for successful bleeding |
| Common issues | Air bubbles, fuel restriction, bad mechanical lift pump, bad injector pump, poor spraying, leaking fuel |
| Tips | Use a diesel fuel system cleaner, ensure everything is super clean, use a torque wrench to tighten, add sulphur to fuel |
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What You'll Learn
Cleaning products
The Perkins manual states that the injectors on the 4108 should be inspected every 700 hours. It is important to keep the fuel injectors clean to ensure the engine is running smoothly.
To clean the fuel injectors, you will need to bleed the Perkins. This process can be complicated and messy, so it is important to have plenty of "oil diapers" or "oil absorbent pads" to catch any spills. The top of the filters will need to be opened to release trapped air, and the line connecting to the injection pump should be loosened. You will then need to pump fuel through the system until no air bubbles come out.
One user on a forum recommends using a diesel fuel system cleaner in the tank before attempting to bleed the injectors. They suggest using a product called Forte, which can be purchased from a local garage for around £10.
Another user recommends adding a quart of automatic transmission fluid (ATF) to the fuel tank, as many antique injectors relied on the lubricants in old high-sulfur diesel fuel. While modern diesel fuel meets lubricity standards, the addition of 2-cycle oil or ATF can help protect older injectors.
It is also possible to remove the injectors and have them professionally rebuilt or serviced. This option may be more expensive but can ensure that the injectors are thoroughly cleaned and functioning correctly.
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Step-by-step process
Step 1: Inspect the injectors
The Perkins manual recommends inspecting the injectors every 700 hours. If you are unsure when the injectors were last inspected or replaced, it may be a good idea to replace them.
Step 2: Prepare the work area
Before beginning any work, ensure you have a clean work area and the necessary tools and safety equipment. Place oil absorbent pads or "oil diapers" underneath the engine to catch any spills or leaks.
Step 3: Loosen the fuel injectors
Loosen the connector at one injector by turning it about a quarter turn. With the engine cranking, fuel and bubbles will start to come out, followed by just fuel. Tighten the fitting once clean fuel exits the union, and the engine should run smoother. Repeat this process for all injectors.
Step 4: Bleed the fuel injectors
Bleed points 1 and 2 may release a significant amount of clean fuel before any bubbles appear, so be patient and do not move on too quickly. If necessary, remove the fitting completely to allow for better flow. Each time you turn the fitting, a little bleeding will occur, so adjust it back and forth until only clean fuel comes out.
Step 5: Test the engine
Once all the injectors have been bled and tightened, start the engine and let it run for a few minutes. If the engine runs smoothly, the cleaning process is complete. If not, you may need to repeat the bleeding process or inspect the fuel injectors for any other issues.
Step 6: Address other issues
If the engine still does not run smoothly after cleaning the fuel injectors, there may be other issues at play. Check for fuel restrictions, such as algae, erroneous gaskets, or crimped lines, or problems with the mechanical lift pump or injector pump. You may need to consult a mechanic or the Perkins manual for further troubleshooting.
Note: Some sources suggest using a diesel fuel system cleaner or adding lubricants to the fuel to help with injector performance. Always refer to the Perkins manual or a qualified mechanic for specific advice pertaining to your engine.
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Troubleshooting
Battery and Electrical System: Inspect the battery, starter, and wiring for any signs of wear, corrosion, or loose connections. Replace or repair these components as needed to ensure proper current flow and starting capacity.
Fuel Delivery: Ensure that your fuel system is effectively delivering fuel to the engine. Clean or replace clogged fuel filters and check fuel lines for any leaks or obstructions. If your engine is hard to start, try loosening the injector fuel tube nuts at the injector and letting a small amount of clean fuel flow through. This can help dislodge trapped air in the injection pump and verify fuel delivery to the injector.
Glow Plugs: Faulty glow plugs can impact the engine's ability to start, especially in cold conditions. Examine the glow plugs for signs of damage or wear, and replace them if necessary to restore starting efficiency.
Air Intake: Keep your air intake system clear of blockages and ensure the air filter is clean and properly installed. A restricted air intake can lead to reduced engine performance.
Fuel Injectors: Inspect the fuel injectors for signs of wear or damage and clean or replace them as necessary. If your engine is "lumpy" at idle, consider inspecting and servicing the injectors. Before attempting to clean or replace fuel injectors, it is important to consult the Perkins manual for specific instructions and safety precautions.
Drive Belt: A worn or damaged drive belt can lead to reduced engine power. Inspect the drive belt for any signs of wear and replace it if necessary.
Exhaust System: Examine your engine's exhaust system for any blockages or leaks. Ensure that the system is properly maintained to prevent backpressure issues, which can hinder engine performance.
Regular Maintenance: Adhere to the recommended maintenance schedule, including timely oil changes, air and fuel filter replacements, and proper tuning. Regular maintenance can help prevent issues with fuel injectors and other engine components.
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Safety precautions
Safety should be a top priority when cleaning your Perkins fuel injectors. Here are some detailed safety precautions to follow:
Work in a Well-Ventilated Area: Engine cleaning and maintenance can produce toxic fumes. It is crucial to work in a well-ventilated area to avoid inhaling these fumes. If possible, perform the cleaning outdoors or in a space with adequate ventilation and air circulation.
Wear Personal Protective Equipment (PPE): Before starting the cleaning process, put on appropriate PPE, including safety goggles to protect your eyes from any chemical splashes or debris, and gloves to safeguard your hands from chemicals and sharp edges. Consider wearing long sleeves and pants to prevent skin exposure to chemicals and dirt.
Prevent Fire Hazards: As you will be working with fuel and flammable liquids, take extra precautions to avoid fire hazards. Have a fire extinguisher nearby in case of any accidents or fires. Avoid using open flames or creating sparks during the cleaning process. Ensure there are no sources of ignition nearby, such as lit cigarettes or open flames. If working on a boat, be extremely cautious when handling flammable liquids, as mentioned by a user who warned against using a rag saturated with gasoline in an engine room where nothing is spark-arrested.
Disconnect the Battery: Disconnect the battery terminal before beginning any work on the fuel injectors. This precaution will prevent short circuits and accidental activation of electrical components during the cleaning process.
Handle Chemicals with Care: When using chemical cleaning solutions, always read and follow the manufacturer's instructions and safety guidelines. Some chemical cleaners may contain toxic or corrosive substances. Avoid skin contact and inhalation of these chemicals. Properly dispose of any used cleaning solutions and contaminated materials in accordance with local regulations.
Manage Spills and Mess: Place a drip pan or absorbent pads underneath the work area to catch any fuel or cleaning solution spills. Have plenty of absorbent materials, such as rags or "oil diapers," readily available to wipe up any messes immediately. Dispose of these materials responsibly to prevent environmental contamination.
Follow Manufacturer's Guidelines: Refer to the Perkins manual or seek advice from authorized dealers or mechanics if you are unsure about any steps in the cleaning process. Adhering to the manufacturer's guidelines will help ensure your safety and prevent accidental damage to the fuel injectors or engine.
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Replacement parts
When it comes to replacement parts for Perkins fuel injectors, there are a few key components that you may need to consider. Firstly, washers are an important part that sometimes needs to be replaced. It is recommended to use a curved pick to carefully remove old washers, ensuring that nothing breaks off and falls into the cylinder. New washers should then be installed, with one washer per injector being the correct amount.
Another replacement part to consider is the injector itself. In some cases, it may be necessary to rebuild or replace the entire injector. This can be done by sending the injectors to a specialist company for rebuilding, or by purchasing new injectors if they are beyond repair.
Additionally, fuel injection lines may need to be replaced to ensure a proper seal and prevent leaks. It is important to refer to the correct procedures for your specific Perkins engine model when installing new injection lines.
For older Perkins engines, it is worth noting that some antique injectors were designed to work with the lubricants found in old high-sulfur diesel fuel. As sulfur is no longer present in modern diesel fuel, additional lubrication may be required. This can be achieved by adding a small amount of automatic transmission fluid (ATF) or two-stroke outboard oil to the fuel tank.
Finally, other replacement parts may include fuel filters, injection pumps, and flare fittings, all of which are essential components of the fuel system and may need to be replaced if damaged or faulty.
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