head is maintained. Pack the flutes of the reamer with
Assemble Plunger and Follower
grease to retain the carbon removed from the tube.
1. Refer to Fig. 37 and slide the head of the plunger
Be sure the fuel injector is filled with fuel oil. If
into the follower.
necessary, add clean fuel oil at the inlet filter cap until it
2. Invert the injector in the assembly fixture (filter cap
runs out of the outlet filter cap.
end up) and push the rack all the way in. Then place
Install the injector in the engine as follows:
the follower spring on the injector body.
1. Refer to Fig. 6 and insert the injector into the injector
3. Refer to Fig. 42 and place the stop pin on the
tube with the dowel pin in the injector body registering
injector body so that the follower spring rests on the
with the locating hole in the cylinder head.
narrow flange of the stop pin. Then align the slot in the
follower with the stop pin hole in the injector body. Next
2. Slide the injector rack control lever over so that it
align the flat side of the plunger with the slot in the
registers with the injector rack.
follower. Then insert the free end of the plunger in the
injector body. Press down on the follower and at the
3. Install the injector clamp, special washer (with curved
same time press the stop pin into position. When in
side toward injector clamp) and bolt. Tighten the bolt to
place, the spring will hold the stop pin in position.
20-25 lb-ft (27-34 Nm) torque. Make sure that the
clamp does not interfere with the injector follower spring
Check Spray Tip Concentricity
To assure correct alignment, check the concentricity of
the spray tip as follows:
Check the injector control rack for
1. Place the injector in the concentricity gage J 29584
free movement. Excess torque can
as shown in Fig. 43 and adjust the dial indicator to zero.
cause the control rack to stick or
2. Rotate the injector 360 and note the total runout as
indicated on the dial.
4. Move the rocker arm assembly into position and
secure the rocker arm brackets to the cylinder head by
3. If the total runout exceeds .008", remove the injector
tightening the bolts to the torque specified on Page 10-
from the gage. Loosen the injector nut, center the spray
tip and tighten the nut to 75-85 Ib-ft (102-115 Nm)
torque. Recheck the spray tip concentricity. If, after
5. Remove the shipping caps. Then install the fuel
several attempts, the spray tip cannot be positioned
pipes and connect them to the injector and the fuel
satisfactorily, replace the injector nut.
connectors. Use socket J 8932-01 to tighten the
connections to 12-15 Ib-ft (16-20 Nm) torque. Do not
Test Reconditioned Injector
bend the fuel pipes and do not exceed the specified
torque. Excessive tightening will twist or fracture the
Before placing a reconditioned injector in service,
flared end of the fuel line and result in leaks.
perform all of the tests (except the visual inspection of
Lubricating oil diluted by fuel oil can cause serious
the plunger) previously outlined under Test Injector.
damage to the engine bearings (refer to Pressurize Fuel
The injector is satisfactory if it passes these tests.
Failure to pass any one of the tests indicates that
defective or dirty parts have been assembled. In this
An indication of fuel leakage at the
case, disassemble, clean, inspect, reassemble and test
fittings of the fuel injector supply
the injector again.
lines and connector nut seals could
be either low lubricating oil pressure
(dilution) or fuel odor coming from
Before installing an injector in an engine, remove the
carbon deposits from the beveled seat of the injector
oil filler cap. When any of the above
tube in the cylinder head. This will assure correct
are detected, remove the valve rocker
alignment of the injector and prevent any undue
cover. A close inspection of the
stresses from being exerted against the spray tip.
rocker cover, cylinder head, fuel
lines and connectors will usually
show if there is a fuel leakage
to clean the carbon from the injector tube. Exercise
problem. Under normal
care to remove ONLY the carbon so that the proper
clearance between the injector body and the cylinder