Perkins — Fuel Injection Pump - Remove and Install

Repair & overhaul

From a Perkins service manual covering: 402D-05, 403D-07, 403D-11, 403D-15, 404D-22, 404D-22T, 404D-22TA. 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, Perkins 404D-22TA

Procedure

1. Remove fuel shutoff solenoid.
2. Remove fuel injection lines.
3. Disconnect flexible fuel hose from inlet connection (for 402D-05, 403D-07, 403D-11, 404D-15).
4. Gradually loosen bolts (4) and nuts (2) fastening pump to cylinder block.
5. Raise pump (1) and remove clip (7) connecting link (6) to fuel rack control (5).
6. Remove pump (1) from cylinder block.
7. Remove shims (3) from mounting face; record thickness and number.
8. Clean mating surfaces of cylinder block and pump.
9. Install correct thickness and number of new shims (3).
10. Position pump near mounting face; connect link (6) and fuel rack control (5) with clip (7).
11. Align pump with studs; install to cylinder block.
12. Install bolts (4) and nuts (2); tighten to specified torque.
13. Install fuel injection lines.
14. Connect flexible fuel hose to inlet (for applicable engines).
15. Install fuel shutoff solenoid.

Full service-parts list: Perkins 402D-05 →, Perkins 403D-07 →, Perkins 403D-11 →, Perkins 403D-15 →, Perkins 404D-22 →, Perkins 404D-22T →, Perkins 404D-22TA →

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.

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