Perkins 4108 M injector pump removal and alignment

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I have a 4108 which is a converted van engine fitted in my boat,i also have a 4108 (M) that i have purchased for spares.
I need to remove the marine injection pump from the spare (M)engine and fit it to the engine fitted in the boat.
I cannot see how the pump can be removed as the drive gear appears too big to pass through the back plate on the engine.
I would appreciate any information on pump removal/istallation set up etc.
The reason for changing the pumps is so i can have the correct injector pump driven raw water pump.
Any information appreciated many thanks
 
I once removed the main fuel injection pump of my 4.108 and did not have any problem with the drive gear being too big. The main problem was the timing after reassembly. Do you have the workshop manual? If not, let me know and I will send you a pdf file.
Regards
Daniel
 
You have to remove the gear in situ, need a puller to do it properly. With the greatest of respect are you sure you can do this? If you have to ask the basic questions, do you have the knowledge and skill to time the pump afterwards?
Sorry to appear rude!
Stu
 
Stu,
just curious: which gear has to be removed in situ? If this is so, I am a bit puzzled on how you are supposed to put the injection pump back in its place. My guess is that you are probably talking of the "fuel pump drive hub" which may need a puller. To withdraw the pump you just need to: "remove low and high pressure pipes ... remove securing setscrews ... withdraw pump". That's all!
Daniel
 
[ QUOTE ]
"remove low and high pressure pipes ... remove securing setscrews ... withdraw pump".

[/ QUOTE ]
That's all!
I have done it twice and not had to take any cogs off,
 
Exactly the pump drive has a flat that aloows you to remove and refit without disturbing the timing at all. But you MUST never undo the other screws that appear to hold it in place - they are the guide plate. As poster before says ... remove high and low pressure pipes, disconnect cables and stop ... undo the mount bolts and slide it out.

I do this at odd times as I have 2 inj. pumps. Muy engine is 4-107 but has same set-up.

If you do mistakenly loosen the guide plate ... the manual I have gives instructions how to re-align if you don't have the proper workshop tool.
 
I have done this and you do Not remove the gear ! It has a spline drive with a master spline. I also have a manual for this engine and could copy the relevant pages for you if you decide to attack it.
 
Hello
from the question it would appear that he has undone the pump and it wont come off because the gear wont pass thru the plate, I made an assumption that it fitted on a tapered shaft, the same as a lot of similar engines do, it would now appear from the other info that the gear is stuck on the splines in the gear hub, my mistake in assuming.
Stu
 
One of the mistakes that people make when doing this first time is to assume that water pump needs taking of as well along with guide adaptor plate. That is the matter I refer to earlier in my other post.
The inj. pump should come out straight once disconnected and mount bolts undone. Nothing difficult except that typical engine bolts are tight area to work in !! I had to machine a hex attachment to fit on the inside bolt !!
 
[ QUOTE ]
I have done this and you do Not remove the gear ! It has a spline drive with a master spline. I also have a manual for this engine and could copy the relevant pages for you if you decide to attack it.

[/ QUOTE ]

If you remove the return fuel housing( two screws ) and rotate the engine by hand until two lines (inside the pump) are together before you remove it, then fit the new pump in the same point. it will be spot on!
If you send me a pm with your Email I will send you the whole PDF manual by return.
Rick..
 
It is a very good suggestion but in my case (and unfortunately in most cases) impossible to be followed unless you have a fiber optics remote viewer.
Daniel
 
Apologies to all who replied i have not been on site for a while!
Many thanks for the offers of manual copies,i have had a copy mailed to me but poor quality unfortunately.
My reason for removal of pump gear and pump is to fit the correct raw water pump to my engine.This drives off the front of the injection pump.
I have since found out that there is a drive hub and this is held by a circlip apparently .
I have had previous experience stripping and rebuilding engines in the past and was an M.O.T inspector for a few years so have a little knowledge...
I am just being cautious and asking helpful members on here so i get it right!
Dont believe in gung ho! and hope for the best!
Once again thanks for your consructive help and advice and offers of copy.
I would appreciate a copy if anyone could provide a clear copy of detail for pump/hub removal many thanks
 
Most manuals thrown around are based on the static and industrial versions - Pub. # 601 SER 0383 1072. The one I passed is the later covering marine versions - Pub # 601 SER 0582 1088. Unfortunately when I inherited it with the boat - the previous owner had left it on board and it was damp - so a few pages have lost print, but that's in the data section.

No manual I have seen has enough detail particularly in the area you are working in. I think this is because of the dire warnings of disturbing that alignment plate.

My suggestion is to combine the industrial version quoted here and mine to obtain best possible. Other than contacting Perkins - who I found very helpful ... they ARE still around despite all reports of being long gone. They are just part of a larger organisation that includes Sabre etc. - well they were when I last spoke to the guy ...
 
Thanks to all for your help,i finally attacked it and having established that there is a circlip holding the pump drive hub all s well!
I had previously lined the marks on the gears as per usual but could not draw hub through backplate as circlip inside ,fiddly but easy once you know its there.
 
Hi,
Just being nosey and read that you had a PDF of the 4108m, could you possibly send me 1. That would be very helpful as i have just bought and am fining it difficult to find a manual.

Cheers Dan.
 
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