5. Mount the injector through the large hole and insert
follower reaches the top of its travel. If the rack does
the injector pin in the proper locating pin hole (Fig. II 1).
not fall freely, loosen the injector nut, turn the tip, then
6. Swing the mounted injector and adaptor plate inward
retighten the nut. Loosen and retighten the nut a couple
until they contact the stop pin at the rear of the support
of times if necessary. Generally this will free the rack.
Then, if the rack isn't free, change the injector nut. In
some cases it may be necessary to disassemble the
injector to eliminate the cause of the misaligned parts.
Clamping the Fuel Injector
Visual Inspection of Plunger
13 and position the injector tester
An injector which passes all of the previous tests should
Lever 2 up and to the rear
have the plunger checked visually, under a magnifying
Lever 3 in the rear detent
glass, for excessive wear or a possible chip on the
Lever 4 up (horizontal)
bottom helix. There is a small area on the bottom helix
Lever 5 up (horizontal)
and lower portion of the upper helix, if chipped, that will
not be indicated in any of the tests.
2. Align the clamping head nylon seals over the injector
Remove the plunger from the injector as follows:
3. Back off the Thru-Flow valve about half-way to allow
1. Support the injector, right side up, in holding fixture J
the self-aligning nylon seals to seat properly during the
2. Compress the follower spring. Then raise the spring
4. Hold the clamping head in position over the filter
above the stop pin with a screw driver and withdraw the
caps and, with the left hand, operate pump lever 1
pin (Fig. 9). Allow the spring to rise gradually.
evenly to move the clamping head down to seal the
filter caps. The Thru-Flow valve should still turn freely.
3. Remove the injector from the holding fixture. Turn
If it does not, turn the valve counterclockwise until it
the injector upside down, to prevent the entry of dirt, and
rotates freely and reapply clamping pressure.
catch the spring and plunger as they drop out.
4. Inspect the plunger. If the plunger is chipped (Fig.
10), replace the plunger and bushing assembly.
Excessive force on lever 1 during
clamping can damage the seals in
5. Reinstall the plunger, follower and spring.
the valves operated by levers 4 and
Installing Fuel Injector in Tester J 23010
1. Select the proper clamping head (Fig. 11). Position
it on the clamping post and tighten the thumb screw into
Move lever 4 down and operate pump lever I to produce
a test oil flow through the injector. When air bubbles no
longer pass through the clear discharge tubing, the
2. Connect the test oil delivery piping into the clamping
system is free of air and is now ready for testing.
Injector Volvo Opening and Spray Pattern Test
3. Connect the test oil clear discharge tubing onto the
pipe on the clamping head.
This test determines spray pattern uniformity and the
relative pressure at which the injector valve opens and
4. Locate the adaptor plate on top of the support
fuel injection begins.
bracket by positioning the 3/8 " diameter hole at the far
right of the adaptor plate onto the 3/8 " diameter dowel
1. Clamp the injector properly and purge the air from
pin. This allows the adaptor plate to swing out for
mounting the fuel injector.
2. Move lever 4 down.