Perkins — Fuel Injection Lines - Remove and Install
Repair & overhaul
From a Perkins service manual covering: 402D-05, 403D-07, 403D-11, 403D-15, 404D-22, 404D-22T, KENR6226-10. Check it applies to your exact model before use.
Applies to: Perkins 402D-05, Perkins 403D-07, Perkins 403D-11, Perkins 403D-15, Perkins 404D-22, Perkins 404D-22T
Before you start
- Do not let tops of fuel injectors turn.
- Keep all parts clean from contaminants.
Procedure
- Turn fuel supply OFF.
- Disconnect tube nuts from injectors and pump using Tool A.
- Remove fuel injection lines as a unit.
- Cap open ports immediately.
- For rigid return line, remove banjo bolt and washers.
- For flexible return hose, disconnect hose from pump.
- Remove nuts and fuel return line from injectors.
- Cap injectors immediately.
- Install new washers and fuel return line.
- Tighten nuts to 27 N·m.
- Install fuel injection lines.
- Tighten union nuts at pump and injectors to specified torque.
- Turn fuel supply ON.
- Prime fuel system.
Tools required
- 27610294 Injector Pipe Nut Tool Amazon
Tool links are Amazon searches (affiliate links); manufacturer special tools may only be available from a dealer.
Specs & values
- Fuel return line banjo bolt: 7 N·m
- Nuts at injectors: 27 N·m
- Union nuts: 20 N·m or 23 N·m depending on model
Full service-parts list: Perkins 402D-05 →, Perkins 403D-07 →, Perkins 403D-11 →, Perkins 403D-15 →, Perkins 404D-22 →, Perkins 404D-22T →
Source: Perkins service manual. Steps and values are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.