Mercedes Mullins
Bleeding a Perkins diesel engine is a necessary procedure to ensure optimal engine performance. This process involves priming the fuel pump to remove any remaining air inside the injection system. Modern vehicles have systems that allow for easy air extraction without using too many tools. This guide will cover the steps to prime a fuel pump on a Perkins diesel engine, including important considerations for a smooth and safe process.
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What You'll Learn
Ensure the fuel filter is full
To ensure the fuel filter is full, you must first locate the primer. This could be a pump or a bulb and its location can be found in your engine's manual. If you don't have a manual, the primer is likely to have words or symbols that indicate its function. Once located, ensure there is a reasonable amount of fuel in the system before you begin.
The fuel pump needs a sufficient amount of fuel to draw from, so it's important to pour fuel into the tank before executing the task. The system will start drawing fuel and may draw air if there isn't enough fuel in the tank. Modern vehicles have systems that allow for easy air extraction without using too many tools.
To ensure the fuel filter is full, you can follow these steps:
- Unscrew the vent plug on the fuel filter.
- Slacken the vent screw on the hydraulic head locking screw on the side of the fuel injection pump body.
- Slacken the air vent screw near the top of the governor housing on the fuel injection pump.
- Operate the priming lever of the fuel lift pump.
- Operate the priming lever until fuel, free from air bubbles, comes out.
- Tighten the feed pipe union.
Now, the pump and filter should be filled and primed.
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Remove the glow plugs
Removing the glow plugs from a Perkins diesel engine can be a challenging task, especially if the plugs are difficult to turn or have broken off. Here is a step-by-step guide on how to remove the glow plugs:
Locate the glow plugs: Glow plugs are usually found on top of the cylinder head in the engine compartment. They are often located beneath the engine's valve covers. Identify the glow plug wires, which have one end attached to the top of the glow plug and the other end attached to the engine.
Remove the glow plug wires: Use a wrench to remove the small nut that holds the wires to the glow plugs. Detach the wire from the top of the glow plug and set it aside. Repeat this process for each glow plug wire. Ensure all wires are safely moved out of the way.
Extract the glow plugs: To remove the glow plugs, simply screw them out. If they are difficult to turn or stuck, you may need to use a specialized glow plug removal tool. Do not force the plugs, as this can lead to further complications.
Address broken glow plugs: If a glow plug breaks off while turning, you have a few options for removal. One method is to use a left-handed drill bit to carefully drill out the broken piece. Ensure you do not drill all the way through to avoid debris falling into the cylinder. You can also try using a tool called an “easy out” to extract the broken plug. Additionally, compressed air can be used to blow the broken piece out. As a last resort, you may need to remove the cylinder head to access the broken plug.
Replace with new glow plugs: Once all the old glow plugs have been successfully removed, screw in the new glow plugs. Ensure they are securely tightened.
Reconnect the wires: Reattach the electrical wires to the new glow plugs using a wrench to secure the small nut. Ensure all wires are properly connected and secured.
Remember to exercise caution when performing any maintenance on your Perkins diesel engine. If you are unsure or uncomfortable with any steps, it is always best to consult a qualified mechanic or seek professional assistance.
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Crank the engine
Cranking the engine is a crucial step in priming a fuel pump on a Perkins diesel engine. It is important to note that you should not crank the engine for an extended period, or you may end up filling your waterlift. To avoid this, disconnect the raw water cooling line as it enters the exhaust elbow, allowing the water to flow into the bilge during fuel line purging.
Before cranking the engine, you should ensure that the accelerator is in the fully open position and that the stop control is set to "run". These steps are essential for the process to be successful. Once these settings are confirmed, you can turn on the engine using the starter motor.
As the engine turns, pay close attention to the fuel pipes. You should expect to see fuel oil, free from any air bubbles, emerging from all the fuel pipes. The time required for this process can vary, typically ranging from 30 to 60 seconds. Several factors influence this duration, including the speed of rotation and the effectiveness of the previous bleeding operation.
For instance, a fully charged battery in a warm or temperate climate can achieve engine rotation speeds exceeding 280 revolutions per minute. Under these favourable conditions, the trapped air should be completely expelled in less than 30 seconds. However, in colder climates or when using partially discharged batteries, the process may take longer.
Once you observe fuel emerging from the fuel pipes and confirm that it is free of air bubbles, proceed to tighten the unions on the fuel pipes. At this point, your engine is primed and ready for starting.
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Check the banjo bolt
When priming a fuel pump on a Perkins diesel engine, it is important to check the banjo bolt. The banjo bolt is a unique-looking 90-degree bolt that is part of the fuel filter housing. It is located on top of the secondary filter and can interfere with the bolt that removes the filter.
To check the banjo bolt, follow these steps:
- Remove the banjo bolt: This step may require loosening or removing the bolt that removes the filter if it interferes with accessing the banjo bolt. Be careful not to strip the threads of the bolt.
- Inspect and clean the banjo bolt: Look for any debris, corrosion, or blockages in the tiny hole of the banjo bolt. Use a small tool, such as a pin drill, to clear any blockages and ensure the hole is clear. You can also spray the hole with a cleaner, such as brake fluid cleaner, to remove any residue.
- Reinstall the banjo bolt: Once the banjo bolt is clean and clear of any obstructions, carefully reinstall it, ensuring it is securely tightened.
- Check for leaks: After reinstalling the banjo bolt, inspect the area for any fuel leaks. Ensure that all connections are tight and secure, and there is no fuel leakage around the banjo bolt or the fuel filter.
By following these steps, you can ensure that the banjo bolt is in proper condition and functioning correctly. This is an important step in priming the fuel pump and maintaining the overall health of your Perkins diesel engine.
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Bleed the Perkins
Bleeding a Perkins diesel engine is a messy but necessary process to ensure the fuel system is free of air bubbles. The following steps outline a generic procedure for bleeding a Perkins diesel engine:
Firstly, ensure the fuel filter is full and the fuel tank has a reasonable amount of fuel. Locate the primer, which is often a pump or a bulb, and refer to your engine's manual for specific instructions.
Next, disconnect the raw water cooling line from the exhaust elbow to prevent filling the waterlift. Then, follow these steps in order: unscrew the vent plug on the fuel filter, slacken the vent screw on the hydraulic head locking screw, and slacken the air vent screw near the top of the governor housing on the fuel injection pump.
Operate the priming lever of the fuel lift pump, and re-tighten when fuel, free from air bubbles, comes out. Then, slacken the unions at the atomizer ends of the high-pressure fuel pipes. Set the accelerator to the fully open position and ensure the stop control is in the "run" position.
Finally, turn the engine with the starter motor until fuel, free from air bubbles, comes out of all fuel pipes. This may take 30 to 60 seconds. Once complete, tighten the unions on the fuel pipes, and the engine is ready to start.
It is important to note that specific procedures may vary depending on the Perkins diesel model, so it is always recommended to refer to the workshop manual or seek professional guidance for a safe and effective bleeding process.
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