Service Training

MALAGA

301.5 MHEX

II. ENGINE & FUEL SYSTEM

Thorben
MAY 1998
 301.5 MHEX
CHAPTER : Engine & Fuel System

Number of cylinders 3
Cylinder arrangement Vertical in-line
Cycle 4-Stroke
Induction system Naturally aspirated
Combustion system Indirect injection (PC)
Bore 75.0 mm
Stroke 72.0 mm
Compression ratio 23 : 1
Cubic capacity 0.954 liters
Firing order 1, 2, 3
Rotation CCW viewed
from rear
Rating 13.7kW (18.4HP) @ 2300 RPM

Perkins Designation 103-10

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 301.5 MHEX
CHAPTER : Engine & Fuel System

1
6

2 4

1. Air Filter

2. Fuel Filter

3. Oil Filter

4. Fuel Transfer Pump

5. Fuel System Vent Screw

6. Oil Dipstick

7. Oil Fill Cap

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 301.5 MHEX
CHAPTER : Engine & Fuel System

1
2

1. Radiator

2. Alternator

3. Starter

4. Battery

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 301.5 MHEX
CHAPTER : Engine & Fuel System

Fuel Injection Pump

6
5

1. Fuel Pipe (between pump & leak-off connection

2. Rollers

3. Rack

4. Vent Plug

5. Fuel Pipe (between pump & filter)

6. High-Pressure Fuel Pipe Connection

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 301.5 MHEX
CHAPTER : Engine & Fuel System

FUEL INJECTION PUMP ASSEMBLY

(3003 - 103-10)
After having removed the fuel lift pump and the stop
solenoid remove bolts and nuts securing fuel injection
pump to cylinder block.

Slowly lift and position fuel injection pump until access to

link snap pin is gained.

Remove snap pin and remove link from control rack.

Remove fuel injection pump and shim pack.

NOTE:

Injection timing is determined by the shim pack between

fuel injection pump flange and cylinder block mounting
face. The thickness and number of shims should be
checked and recorded to aid re-assembly.

For 3034 (704-30) see additional handouts.

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 301.5 MHEX
CHAPTER : Engine & Fuel System

Wire

Injection Pump
Delivery Holder
Delivery Valve
OUT

Injection timing should be adjusted when a new.....

injection pump

camshaft assembly

cylinder block .....is used.

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 301.5 MHEX
CHAPTER : Engine & Fuel System

FUEL INJECTION TIMING ADJUSTMENT

(3003 - 103-10)

Reassemble the injection pump according to the procedure

in the Workshop Manual. Use a shim of 0.5 mm thickness
between the pump and the block.

Remove the delivery valve holder at the front side (radiator

side) of the injection pump.

Pull out the delivery valve (IN), and reinstall the spring and
delivery valve holder.

When re-assembling the delivery holder, adjust the

location of the delivery valve (OUT) to correct position
using a wire.

Move the governor control lever to “Maximum Fuel”

position, and send fuel with No 1 piston at around 23
degrees BTDC in its compression stroke. At this time, fuel
flows from the delivery holder.

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 301.5 MHEX
CHAPTER : Engine & Fuel System

Then slowly turn the crankshaft clockwise until flowing

fuel from delivery holder is stopped. Check the piston
position at this point. If the position is later than 19
degrees BTDC, use thinner shim. If the position exceeds 21
degrees BTDC, use thicker shim.

Changing the shims thickness by 0.1 mm will change the

timing approximately one degree. Adding shims decreases
the angle while subtracting shims increases the angle.

When the shim is not needed, assemble by coating using

liquid sealant.

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 301.5 MHEX
CHAPTER : Engine & Fuel System

FINDING TOP DEAD CENTER

(3003 - 103-10)

- Align the mark on the crankshaft pulley with the mark on

the timing case.

- Drop the valve on top of the piston (#1) and use a dial
indicator to find Top Dead Center (see additional
handouts).

BLEEDING AIR FROM THE FUEL SYSTEM

(3003 - 103-10)

- Cylinder #2 has to be on Top Dead Center so that the fuel

transer pump can make a full stroke.

- Loosen bleed screw on top of fuel inlet line (lift pump -

fuel injection pump).

- Operate the priming lever of the fuel lift pump (very time
consuming !).

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 301.5 MHEX
CHAPTER : Engine & Fuel System

ROCKER COVER SEALING

(3003 - 103-10)

- Rocker Cover and Air Inlet Manifold is in one piece.

- Make shure to fill the gab between the rocker cover

sealing and the air inlet manifold sealing with liquid
sealant.

LEAK-OFF LINE ASSEMBLY

(3003 - 103-10 with screwed-in injectors)

- Install the leak-off line with the groove down towards the
injectors.

- Use the same washers as the originals (with holes).

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 301.5 MHEX
CHAPTER : Engine & Fuel System

FILLING UP OIL (BEWARE)

(3003 103-10)

- Be careful when ol fill is on rocker cover.

- It takes a long time for the oil to drip down the engine.

- Wait about 3-5 minutes before checking.

WHAT CAN HAPPEN (closed breather system):

- Oil goes through breather

- ...into inlet manifold

- ...into closest cylinder (#1 or #2)

- ...fills combustion chamber

-...creates a hydraulic lock

- Result : Conrod bents and comes

out of the side of the engine

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 301.5 MHEX
CHAPTER : Engine & Fuel System

RELIEF VALVE
(3003 103-10)

- If oil pressure is low below 1000 RPM but normal above

1000RPM, check relief valve.

- Indication for that relief valve is stock open.

See additional handouts.

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