NOTE: If the injector was removed along with the fuel connector, the installation steps must be followed. Refer to Procedure 006-026 in Section 6. Lubricate the fuel connector a-ring and the threads on the fuel connector retaining nut with clean engine oil. Carefully insert the fuel connector, aligning the guide ball with the slot in… Read More »
Inspect the fuel connector. Look for burrs or deformation around the inlet and outlet sides of the connector. Check the edge filter for signs of plugging or material contamination. Do not reuse a high-pressure fuel connector if debris is present. Check the a-ring for tearing or deterioration. Replace as needed. Inspect the outlet sealing surface… Read More »
Remove the fuel connector retaining nut. Install the fuel connector remover, Part Number 3164025. NOTE: When removing the fuel connector from the cylinder head, care must be taken to make sure the connector o-ring is not damaged. Remove the fuel connector from the cylinder head.
An internal leak from either the high-pressure connector or the fuel injector will result in increased fuel return flow from the cylinder head.A single cylinder cut-out test will not be able to isolate this leak because it occurs before it reaches the control needle inside the injector. Because all injectors share the same pressurized fuel… Read More »
Loosen the fuel rail mounting capscrews. Do not remove the fuel rail. The capscrews are loosened to allow proper alignment of the fuel rail after installing the new fuel line. NOTE: When a high-pressure injector supply line is removed from the engine, the fuel connector nut at the cylinder head must always be torqued. Tighten… Read More »
Inspect the high-pressure fuel supply line ferrules for any signs of burrs, or foreign material, rounding, or cracking; replace if necessary. Check the fuel supply lines for cracks, wear, or pinched areas. Replace if necessary. Inspect the ends of the high-pressure lines for damaged sealing surfaces.
To remove the number 6 injector line on front gear train engines, remove the protective bracket at the rear of the cylinder head. NOTE: A craw’s foot and socket extension will be required to remove and install the fuel line to the fuel connector. Note the location of the high-pressure injector supply lines before removal.… Read More »
Inspect the injector high-pressure supply lines for cracks, chafing, leaks, and loose or broken brackets.
Verify that the new injector sealing washer is the correct thickness. NOTE: Sealing washers are configured in a flat (1) or saucer (2) shape. When replacing the injector sealing washer, only the saucer style washer must be used; not the flat style washer. Verify a new and correct sealing washer has been installed on the… Read More »
Clean the injector tip and body with solvent and a soft, clean cloth. Use an injector bore brush, Part Number 3822510, or equivalent, to clean the carbon from the injector seat. Use chip removal tool, Part Number 3823461, to remove any debris from the injector and fuel connector bore. Inspect the injector tip for carbon… Read More »