Injector Replacement

TM 9-2320-363-34-1 · Chapter 3 — Power Package Maintenance

This task covers: a. Removal b. Cleaning c. Inspection d. Installation

Tools and Special Equipment:                          Equipment Condition:
Shop Equipment, SC 4910-95-CL-A31
Tool Kit, SC 5180-90-CL-N05                           Reference               Condition Description
                                                      Page 3-183              Rocker Arm Assemblies
Materials/Parts:                                                              Removed
Ring, Seal                P/N 5234702                 General Safety Precautions:
Ring, Seal                P/N 5234699
Tag, Identification       Appendix B, Item 55                        WARNING
oil, Lubricating          Appendix B, Item 37               Eye protection must be worn to
                                                            prevent fuel from getting in
References:                                                 eyes.
TM 9-2320-363-20

TM page 3-109

Illustration from TM 9-2320-363-34-1 (PDF page 185)

1. DISCONNECT FUEL SUPPLY HOSE (1) FROM FUEL CHECK VALVE FlTTING (2).

2. DISCONNECT FUEL RETURN LINE (3) AT VEHICLE FUEL RETURN LINE CONNECTION (4).

3. PLACE FUEL RETURN LINE (3) IN SUITABLE CONTAINER TO COLLECT DRAINED FUEL.

WARNING Eye protection must be worn to prevent fuel from getting in eyes. **CAUTION** Remove all fuel from cylinder head before removing injector to prevent fuei from entering cylinder. **NOTE**

Do not exceed 20 psi when applying air pressure to fuel supply hose inlet.

4. USING AIR NOZZLE (5), APPLY LOW AIR PRESSURE TO FUEL SUPPLY HOSE TO PURGE REMAINING FUEL FROM CYLINDER HEAD.

CAUTION Use extreme care when handling injector to avoid costly damage from dropping or mishandling. **NOTE** Do not remove screws from injector. Loosen screws enough to allow large opening in harness terminals to be moved under screw head for harness terminai removal. Tag wire terminals prior to removal to aid in installation.

5. LOOSEN TWO SCREWS (5) AND REMOVE INJECTOR HARNESS TERMINALS (7).

TM page 3-110

Illustration from TM 9-2320-363-34-1 (PDF page 186)

6. REMOVE HOLDDOWN BOLT (8), WASHER (9), AND HOLDDOWN CLAMP (10).

CAUTION Use extreme care when handling injector to avoid costly damage by dropping or mishandling. **NOTE** Tag injector prior to removal to aid in installation.

7. LIFT INJECTOR (11) FROM SEAT IN CYLINDER HEAD (12) BY INSERTING PRY BAR UNDER INJECTOR BODY AS SHOWN.

TM page 3-111

Illustration from TM 9-2320-363-34-1 (PDF page 187)

NOTE Replace injector seal rings when replacing injector.

8. REMOVE AND DISCARD THREE INJECTOR SEAL RINGS (13 AND 14) FROM INJECTOR (11), REPEAT STEPS 5 THRU 8 FOR REMAINING INJECTORS.

Use general cleaning methods to clean all parts (page 2-30).

CAUTION

Make sure injector seal rings are not cut or nicked and are installed completely in grooves to prevent damage to equipment.

1. LUBRICATE THREE NEW INJECTOR SEAL RINGS LIGHTLY WITH ENGINE OIL AND INSTALL ON INJECTOR (1).

2. INSTALL TWO LOWER SEAL RINGS (2) IN TWO LOWER GROOVES (3).

3. INSTALL LARGER SEAL RING (4) IN UPPER GROOVE (5).

TM page 3-112

Illustration from TM 9-2320-363-34-1 (PDF page 188)

4. INSERT INJECTOR (1) INTO INJECTOR TUBE (6).

5. PRESS DOWN ON TOP OF INJECTOR FOLLOWER UNTIL INJECTOR IS FULLY SEATED IN INJECTOR TUBE (6).

CAUTION Position holddown clamp carefully so it does not contact or interfere with injector follower spring or intake valve springs. Failure to do so will result in equipment damage. To prevent damage to washer, install washer beveled side down.

6. INSTALL INJECTOR HOLDDOWN CLAMP (7) ON INJECTOR (l).

7. INSTALL WASHER (8) ON HOLDDOWN BOLT (9).

8. INSTALL HOLDDOWN BOLT (9) HAND-TIGHT.

CAUTION Check position of injector and holddown clamp to ensure clearance between intake valve spring and injector follower spring. Failure to do so will result in equipment damage.

9. TIGHTEN HOLDDOWN BOLT (9) TO 43-49 LB-FT (58-66 N.m).

TM page 3-113

Illustration from TM 9-2320-363-34-1 (PDF page 189)

CAUTION Injector harness terminals should be bent upward before installation to avoid contacting surrounding surfaces and causing short circuits. However, do not bend harness terminals after installation to prevent damage to equipment.

The following steps must be performed to provide clearance for engine retarder wiring harness.

10. BEND INJECTOR HARNESS TERMINAL (10) UPWARD, APPROXIMATELY 90 DEGREES.

11. INSTALL INJECTOR HARNESS TERMINAL (10) ON TWO SCREWS (11). TIGHTEN SCREWS TO 12-17 LB-IN. (1.36-1.92 N.m).

12. CONNECT FUEL SUPPLY HOSE (12) TO FUEL CHECK VALVE FlTTlNG (13).

13. CONNECT FUEL RETURN LINE (14) TO VEHICLE FUEL RETURN LINE CONNECTION (15).

14. REPEAT STEPS 11 THRU 13 FOR REMAINING INJECTORS.

NOTE Follow-on Maintenance:

Install rocker arm assemblies (page 3-183). Prime fuel system (TM 9-2320-363-20).

TM page 3-114 Change 1