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Home›Repair guides›Turbocharger Installation

Perkins — Turbocharger Installation

A Perkins service procedure — check it applies to your exact model before use.

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Before you start

  • Do not use the actuator rod of the wastegate to lift the turbocharger.
  • Ensure that tube assembly does not come into contact with any other components.
  • Keep all parts clean from contaminants.

Procedure

  1. Ensure that the turbocharger is clean and free from damage. Inspect the turbocharger for wear.
  2. Test the actuator for correct operation. If the actuator is damaged or does not operate within specified limits, the complete turbocharger must be replaced.
  3. Clean the mating surfaces of the exhaust manifold. If necessary, install studs (15) to the exhaust manifold and tighten to 18 N·m (13 lb ft). Install a new gasket (20) over the studs.
  4. Position turbocharger (4) onto the exhaust manifold. Install nuts (17) and tighten to 25 N·m (18 lb ft).
  5. Ensure that tube assemblies (10) and (13) are clean and free from damage.
  6. If necessary, position a new joint (11) and tube assembly (10) onto the cylinder block. Install bolts (9) finger tight. Position joint (7) on tube assembly (10). Install bolts (8) finger tight. Tighten bolts to 10 N·m (89 lb in).
  7. Lubricate the bearings of turbocharger (4) with clean engine oil through oil inlet port (16). Rotate the shaft to distribute the lubricant.
  8. Install a new O-ring seal (12) to tube assembly (13). Install bolts (14) and tighten to 10 N·m (89 lb in).
  9. Install new washers (3) and banjo bolt (2) to tube assembly (13). Tighten banjo bolt finger tight.
  10. If necessary, install spacer and fasteners to tube clips (6). Torque to 10 N·m (89 lb in).
  11. Tighten banjo bolt (2) to 18 N·m (13 lb ft).
  12. Clean the mating surfaces of exhaust elbow (19). Position new gasket (18) and exhaust elbow (19) on turbocharger (4). Install allen head screws (21) and tighten to 32 N·m (24 lb ft).
  13. Install air inlet hose (1) and tighten hose clamps (5).

Specs & torque values

  • New gasket (20)
  • New gasket (18)
  • New O-ring seal (12)
  • New joint (7, 11)
  • Torque studs (15): 18 N·m (13 lb ft)
  • Torque nuts (17): 25 N·m (18 lb ft)
  • Torque bolts (8, 9): 10 N·m (89 lb in)
  • Torque bolts (14): 10 N·m (89 lb in)
  • Torque banjo bolt (2): 18 N·m (13 lb ft)
  • Torque fasteners to tube clips (6): 10 N·m (89 lb in)
  • Torque allen head screws (21): 32 N·m (24 lb ft)

Source: manual:Disassembly and Assembly-SM-PERKINS 400 SERIES 402D 403D 404D INDUSTRIAL ENGINE.pdf. Figures and steps are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.