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Home›Repair guides›Perkins›Turbocharger - Remove and Install

Perkins — Turbocharger - 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 use the actuator rod of the wastegate to lift the turbocharger.

Procedure

  1. Loosen hose clamps (5) and remove air inlet hose (1); remove allen head screws (21) and exhaust elbow (19); remove gasket (18).
  2. Remove banjo bolt (2) and washers (3); remove tube clip fasteners; remove bolts (14) and tube assembly (13); remove O-ring seal (12).
  3. Remove bolts (8) and disconnect tube assembly (10) from turbocharger; remove joint (7).
  4. If necessary, remove bolts (9) and tube assembly (10) from cylinder block; remove joint (11).
  5. Remove nuts (17) and turbocharger (4) from exhaust manifold; remove gasket (20).
  6. If necessary, remove studs (15) from exhaust manifold.
  7. Ensure turbocharger clean and free from damage; inspect for wear.
  8. Test actuator; replace complete turbocharger if damaged.
  9. Clean manifold mating surfaces; install studs (15) and tighten to 18 N·m (13 lb ft); install new gasket (20).
  10. Position turbocharger (4) on manifold; install nuts (17) and tighten to 25 N·m (18 lb ft).
  11. Position new joints and tube assemblies; install bolts (9) and (8) finger tight; tighten to 10 N·m (89 lb in).
  12. Lubricate turbocharger bearings with clean engine oil through oil inlet port (16); rotate shaft.
  13. Install new O-ring seal (12) to tube assembly (13); install bolts (14) and tighten to 10 N·m (89 lb in).
  14. Install new washers (3) and banjo bolt (2); tighten banjo bolt to 18 N·m (13 lb ft).
  15. Install new gasket (18) and exhaust elbow (19); install allen head screws (21) and tighten to 32 N·m (24 lb ft); install air inlet hose (1) and tighten hose clamps (5).

Specs & values

  • 18 N·m (13 lb ft) studs (15)
  • 25 N·m (18 lb ft) nuts (17)
  • 10 N·m (89 lb in) bolts (8) and (9)
  • 10 N·m (89 lb in) bolts (14)
  • 10 N·m (89 lb in) tube clip fasteners
  • 18 N·m (13 lb ft) banjo bolt (2)
  • 32 N·m (24 lb ft) allen head screws (21)

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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