2.4.2 Removal of the Injector Tube and O-ring

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1 SERIES 60 SERVICE MANUAL Removal of the Injector Tube and O-ring When removing an injector tube, use J , part of J and J Remove, disassemble, and clean the cylinder head. Refer to section. 2. Place J , in the injector tube. Insert J , through the small opening of the injector tube and thread the pilot into the tapped hole in the end of the installation/removal tool. See Figure Figure 2-14 Removal of Injector Tube 3. Tap on the end of the pilot using a brass hammer or fiber mallet. Carefully drive and lift the injector tube, J and J from the cylinder head. If the injector tube O-ring is not removed with the injector tube, remove the O-ring from the cylinder head casting at the upper end of the injector tube bore. Discard O-ring. All information subject to change without notice. (Rev. 01/02) 6SE Copyright 2002 DETROIT DIESEL CORPORATION From Bulletin

2 2.4 FUEL INJECTOR TUBE AND O-RING 2.4.2a Injector Tube Crevice Volume Removal Tool Instructions Detroit Diesel has made a machining improvement on the Series 60 cylinder head injector tube bore. This machining improvement removes cast iron material from the head at the crevice area, located just above the injector tube to cylinder head sealing land. See Figure 2-14a Figure 2-14a Crevice Area (Rev. 01/02) All information subject to change without notice. 2-31a From Bulletin SE Copyright 2002 DETROIT DIESEL CORPORATION

3 SERIES 60 SERVICE MANUAL This process was implemented on new engines beginning with engine serial number 06R A crevice volume removal service tool J is now available to perform this machining process to engines built before engine serial number 06R This tool includes two replacement bits. Additional bits J are also available. See Figure 2-14b. Figure 2-14b Crevice Column Removal Tool J All information subject to change without notice. (Rev. 01/02) 6SE Copyright 2002 DETROIT DIESEL CORPORATION From Bulletin b

4 2.4 FUEL INJECTOR TUBE AND O-RING This procedure is required whenever the injector tubes are removed and only on engines built before engine serial number 06R Apply cutting oil to cutting bit. 2. Ensure injector tubes and O-rings are removed from injector bores. NOTE: Do not drop tool in bore, doing so would cause the cutting bit to chip. 3. Gently guide Crevice Volume Removal Tool J in injector tube bore taking caution not to score injector O-ring sealing surfaces. NOTE: Do not rotate tool in the counterclockwise direction as damage to the cutting bit will occur. 4. Using a speed handle and socket, turn cutter approximately 10 clockwise rotations at one turn every two seconds using moderate downward force. 5. Remove tool and inspect bit after each cut. If bit is chipped remove allen bolt and rotate bit 90 degrees. Replacement bits J are available 6. Thoroughly flush metal shavings from injector tube bores Cleaning of Injector Tube Thoroughly clean the injector tube hole in the cylinder head to remove any dirt, burrs, or foreign material that may prevent the new tube from seating at the lower end or sealing at the upper end. Excess material in the form of a small copper ring may be left at the lower end of the injector tube counterbore after the injector tube has been removed. This copper ring will have to be removed using a suitable sharp-pointed tool. (Rev. 01/02) All information subject to change without notice. 2-31c From Bulletin SE Copyright 2002 DETROIT DIESEL CORPORATION

6 2.4 FUEL INJECTOR TUBE AND O-RING Installation of Auxiliary Injector Seal Perform the following for installation of auxiliary injector seal. NOTICE: If a cylinder head has a damaged injector hole tube seal, coolant may seep past the seal after injector removal. Drain down the injector tube hole, and fill the combustion chamber. If this condition goes undiscovered and the coolant is not removed from the cylinder before the injector is replaced, the engine may be damaged at startup. Always check cylinders for possible coolant seepage before replacing injectors and use care to prevent coolant or fuel from contaminating the engine lubricating oil. NOTICE: Do not use a metal dowel to install the auxiliary injector seal, as this may damage the seal. 1. Place the auxiliary seal in the injector hole. 2. Seat it against the top of the injector tube with a 1-5/8 in. diameter wood or plastic dowel. See Figure Figure 2-15 Auxiliary Injector Seal Location (Rev. 01/02) All information subject to change without notice From Bulletin SE Copyright 2002 DETROIT DIESEL CORPORATION

NUMBER: 08 MBE REV S.M. REF.: 1.4 ENGINE: EPA07 MBE 4000 DATE: February 2008 SUBJECT: CYLINDER BLOCK LINER SERVICE PROCEDURE

NUMBER: 08 MBE REV S.M. REF.: 1.4 ENGINE: EPA07 MBE 4000 DATE: February 2008 SUBJECT: CYLINDER BLOCK LINER SERVICE PROCEDURE NUMBER: 08 MBE 4000-1 REV S.M. REF.: 1.4 ENGINE: EPA07 MBE 4000 DATE: February 2008 SUBJECT: CYLINDER BLOCK LINER SERVICE PROCEDURE PUBLICATION: DDC-SVC-MAN-0026 (6SE420) Amended tool number J-46180. New