How to Install New water seal/water pump for Perkins 1000 Series Engine

An improved water seal has been introduced for use  on 4 and 6 cylinder engines. The seal was introduced  from engine number AB—–U500690P for 4 cylinder  engines. The new seal has a brass body and is  interchangeable with the earlier rubber seal. This instruction show you guide on how to install new seal/water pump for Perkins 1000 Series Engine.

 

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A new water pump has been introduced for 6 cylinder engines from engine number YB—–U501843P. The  new water pump has the new water seal and a new bearing and shaft assembly which has a larger  bearing and an integral oil seal.

Caution: The new bearing and shaft assembly is not  interchangeable with the earlier assembly.

Identification of the various water pumps is by the  letter and last three digits of the part number stamped on a pad on the front of the water pump body.

 

In the future water pumps for 6 cylinder engines will probably have a 6 on the identification pad.

 

To fit the new water seal

1 It is important that the seal is not contaminated by  oil or grease and, if it is held in the hand, it should be  held by the edge of the flange.

2 Do not damage the ring of green sealant applied to  the body of the water seal just behind the flange.

3 To press the seal onto the shaft, a tool can be made  of any suitable material to the dimensions shown (A).

Note: The tool will not allow axial distortion of the  inner part of the seal while the seal is pressed onto  the shaft. The tool is for use with the new seal, but it can also be used for the earlier seal. If the tool is used with the earlier seal, the tool is a looser fit on the seal so ensure that the hole in the tool is aligned with the shaft as the seal is fitted.

4 With the ring of sealant towards the bearings, use the tool to press the seal onto the shaft until the bottom of the seal flange is in complete contact with the pump body.

 

To dismantle the new water pump

The procedure to dismantle the new water pump is the same as for the earlier pumps, except that the bearing and shaft assembly must be pressed out through the gear end of the pump body.

Caution:This operation can damage the bearing and it is recommended that a new bearing assembly be fitted.

Note: The oil seal is not removed as it is integral with the bearing assembly.

 

To assemble the new water pump

1 Clean thoroughly the inside of the pump body (B4),ensure that the bore for the bearing and the chamfer at the water seal end of the bore are clean and free of corrosion.

2 Apply a thin layer of POWERPART retaining compound to the outer surface of the bearing (B3),

but keep the compound away from the ends of the bearing. Provide a suitable support under the impeller end of the pump body. Put the bearing and shaft assembly in position with the bearing square to the pump body and the longest end of the shaft in the pump body.

 

3 Make a suitable adaptor which will apply force to the outer edge of the bearing and not to the shaft. Use the adaptor to press in the bearing and shaft until the rear face of the bearing is 21,0/21,5 mm (0.83/0.85 in) (dimension ‘B’) above the rear face of the pump body.

4 Press the gear (B1) onto the shaft until the clearance between the front face of the gear and the rear face of the bearing is 0,47/1,53 mm (0.018/0.060 in) (dimension ‘C’).

Note: If the original gear is used again,POWERPART retaining compound must be applied to the bore of the gear and all excess compound removed after the gear is fitted.

5 Turn the pump body over and support the gear end of the body.

 

6 Hold the pump with the gear end of the shaft on a suitable support. With the use of a suitable distance piece and a flat bar, press the impeller (B5) onto the shaft until the front face of the impeller is 7,7/8,0 mm (0.30/0.31 in) (dimension ‘A’) below the front face of the pump body.

7 Remove the adaptor and ensure that the shaft is free to rotate. If the original impeller is to be used again, POWERPART retaining compound must be applied to the bore of the impeller and any excess compound must be removed after the impeller is fitted.

8 Fit a new joint (B8) and the cover (B7) and tighten the fasteners.

9 Fit a new O-ring (B2) to the body of the pump and fit the studs.