Perkins — Fuel Injector - 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
Before you start
- Keep all parts clean from contaminants.
- Do not allow dirt to enter fuel system.
Procedure
- Remove fuel injection lines.
- Use deep socket to remove fuel injector (1) from cylinder head.
- Remove seat washers (2). Note 402D-05 and 403D-07 have two different-diameter seat washers; others have one.
- Cap or plug all openings.
- Clean injector bore and injector threads.
- Install new seat washers (2) into bore.
- Apply bead of Tooling (A) to first two threads of injector: diameter 2 mm, length 6 mm.
- Install fuel injector (1) into cylinder head.
- Use deep socket to tighten injector to 64 N·m (47 lb ft).
- Install fuel injection lines.
Tools required
- 1861117 POWERPART Universal Jointing Compound Amazon
Tool links are Amazon searches (affiliate links); manufacturer special tools may only be available from a dealer.
Specs & values
- 64 N·m (47 lb ft) fuel injector
- 2 mm (0.08 inch) bead diameter
- 6 mm (0.25 inch) bead length
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.