Removal and Installation of the Fuel Injector Cup February Removal of the Fuel Injector Cup Three-Filter System and Two-Filter System

Transcription

1 SUBJECT DATE Removal and Installation of the Fuel Injector Cup February 2014 Additions, Revisions, or Updates Publication Number / Title Platform Section Title Change Removal of the Fuel Injector Cup Three-Filter and Two-Filter DDC-SVC-MAN-0082 DD Platform Installation of the Fuel Injector Cup Three-Filter and Two-Filter Updating procedures with correct tool numbers. Removal of the Fuel Injector Cup - Two-Filter DDC-SVC-MAN-0182 Euro IV Installation of the Fuel Injector Cup - Two-Filter All information subject to change without notice. 3

2 2 Removal of the Fuel Injector Cup - Three-Filter 2 Removal of the Fuel Injector Cup - Three-Filter Remove as follows: NOTICE: Take extra precautions when cleaning the fuel injector bores to ensure that debris does not enter the fuel system. Do not use power tools to clean the fuel injector bores. Do not use compressed air to blowout debris in the bores. NOTICE: Engine coolant must be drained prior to fuel injector tube removal. 1. Drain the engine coolant. Refer to section "Cooling Drain Procedure". 2. Remove fuel injector harness. Refer to section "Removal of the One-Piece Fuel Injector Wiring Harness - Three-Filter ". Refer to section "Removal of the Two-Piece Fuel Injector Wiring Harness - Three-Filter ". 3. Remove the fuel injectors. Refer to section "Removal of the Fuel Injector - Three-Filter ". NOTE: Tool J-47388A or W must be fully engaged with the fuel injector cup to prevent damage to the tool and the cup. 4. Install tool J-47388A or W into fuel injector cup and align tool with slots in tube and turn counter clockwise to remove. 5. Remove fuel injector cup; discard fuel injector cup O-ring in cylinder head. 6. Inspect the fuel injector cup for cracks or defects. If defective replace fuel injector cup. 7. Clean fuel injector cup threads with a fine wire brush, being careful not to abrade the cylinder head to fuel injector cup sealing surface. 8. Clean the fuel injector cup interior sealing surface, a chemical solvent maybe used for cleaning interior sealing surface. 4 All information subject to change without notice. Copyright 2014 DETROIT DIESEL CORPORATION

3 3 Installation of the Fuel Injector Cup - Three-Filter Install as follows: NOTE: Take extra precautions when cleaning fuel injector bores to ensure debris does not enter fuel system. Do not use power tools to clean fuel injector bores, use J hand brush and a rag. Do not use compressed air to blow out debris in the bores. 1. Clean fuel injector bore. Use J hand brush to remove debris. NOTE: Replace fuel injector cup O-ring with a new O-ring when fuel injector cup is removed or replaced. 2. Install O-ring in cylinder head. A small amount of silicone based O-ring lubrication will aid in the installation. 3. Coat threads of fuel injector cup and cup sealing surface with a high temperature nickel-based anti-seize lubricant. 4. Install fuel injector cup onto tool J-47388A or W and install into cylinder head bore. 5. Torque fuel injector cup to 50 N m (37 lb ft). 6. Release torque by rotating injector cup counter clockwise. 7. Re-torque fuel injector cup to 50 N m (37 lb ft). If cylinder head has been removed, ensure edge cup is flush with fire deck. 8. Install fuel injector. Refer to section "Installation of the Fuel Injector - Three-Filter ". 9. Install fuel injector harness. Refer to section "Installation of the One-Piece Fuel Injector Wiring Harness - Three-Filter ". Refer to section "Installation of the Two-Piece Fuel Injector Wiring Harness - Three-Filter ". 10. Install rocker cover. Refer to section "Installation of the Rocker Cover". 11. Fill and pressure test the cooling system; check for leaks. Refer to section "Cooling Fill Procedure". All information subject to change without notice. 5

4 4 Removal of the Fuel Injector Cup - Two-Filter 4 Removal of the Fuel Injector Cup - Two-Filter Remove as follows: NOTICE: Take extra precautions when cleaning the fuel injector bores to ensure that debris does not enter the fuel system. Do not use power tools to clean the fuel injector bores. Do not use compressed air to blowout debris in the bores. NOTICE: Engine coolant must be drained prior to fuel injector tube removal. 1. Drain the engine coolant. Refer to section "Cooling Drain Procedure". 2. Remove fuel injector harness. Refer to section "Removal of the Two-Piece Fuel Injector Wiring Harness - Two-Filter ". 3. Remove the fuel injectors. Refer to section "Removal of the Fuel Injector - Two-Filter ". NOTE: Tool J-47388A or W must be fully engaged with the fuel injector cup to prevent damage to the tool and the cup. 4. Install tool J-47388A or W into fuel injector cup and align tool with slots in tube and turn counter clockwise to remove. 5. Remove fuel injector cup; discard fuel injector cup O-ring in cylinder head. 6. Inspect the fuel injector cup for cracks or defects. If defective replace fuel injector cup. 7. Clean fuel injector cup threads with a fine wire brush, being careful not to abrade the cylinder head to fuel injector cup sealing surface. 8. Clean the fuel injector cup interior sealing surface, a chemical solvent maybe used for cleaning interior sealing surface. 6 All information subject to change without notice. Copyright 2014 DETROIT DIESEL CORPORATION

5 5 Installation of the Fuel Injector Cup - Two-Filter Install as follows: NOTE: Take extra precautions when cleaning fuel injector bores to ensure debris does not enter fuel system. Do not use power tools to clean fuel injector bores, use J hand brush and a rag. Do not use compressed air to blow out debris in the bores. 1. Clean fuel injector bore. Use J hand brush to remove debris. NOTE: Replace fuel injector cup O-ring with a new O-ring when fuel injector cup is removed or replaced. 2. Install O-ring in cylinder head. A small amount of silicone based O-ring lubrication will aid in the installation. 3. Coat threads of fuel injector cup and cup sealing surface with a high temperature nickel-based anti-seize lubricant. 4. Install fuel injector cup onto tool J-47388A or W and install into cylinder head bore. 5. Torque fuel injector cup to 50 N m (37 lb ft). 6. Release torque by rotating injector cup counter clockwise. 7. Torque fuel injector cup to 50 N m (37 lb ft). If cylinder head has been removed, ensure edge cup is flush with fire deck. 8. Install fuel injector. Refer to section "Installation of the Fuel Injector - Two-Filter ". 9. Install fuel injector harness. Refer to section "Installation of the Two-Piece Fuel Injector Wiring Harness - Two-Filter ". 10. Install rocker cover. Refer to section "Installation of the Rocker Cover". 11. Fill and pressure test the cooling system; check for leaks. Refer to section "Cooling Fill Procedure". All information subject to change without notice. 7